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Metek TWRF1 SCR Series Instruction, Operation And Maintenance Manual

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TWRF1 SCR Series
30-225 Amperes
Single-phase
Phase-fired
SCR POWER CONTROLLER
for RF Applications
Instruction, Operation and
Maintenance Manual
Number: 9100051
Revision 2
530 La keview Pl aza Blvd, Ste C
Worthington, O hio, USA 43085
To l l F r e e : 1 - 8 8 8 - P W R - C N T L ( 7 9 7 - 2 6 8 5 )
P h o n e : 6 1 4 - 3 0 8 - 5 5 0 0
F a x : 6 1 4 - 3 0 8 - 5 5 0 6
We b :
w w w. h d r p o w e r. c o m

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Summary of Contents for Metek TWRF1 SCR Series

  • Page 1 TWRF1 SCR Series 30-225 Amperes Single-phase Phase-fired SCR POWER CONTROLLER for RF Applications Instruction, Operation and Maintenance Manual Number: 9100051 Revision 2 530 La keview Pl aza Blvd, Ste C Worthington, O hio, USA 43085 To l l F r e e : 1 - 8 8 8 - P W R - C N T L ( 7 9 7 - 2 6 8 5 )
  • Page 2 This manual applies to all Model TWRF1 SCR Power Controls. Former TWRF1 manual – 9100026 has been replaced with this manual. For the support representative nearest you, please call Ametek HDR Power Systems main office at (614)-308- 5500. Revision 1 December 2017 Initial Release Revision 2...
  • Page 3 TWRF1 SCR Power Controller Table of Contents TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS ......................1 CHAPTER 1 - DESCRIPTION ..........................3 General Description Application Operation Selecting the Proper Rated Power Controller Specification Option ER (Extended Ramp) Additional Options CHAPTER 2 - INSTALLATION ..........................7 Mounting the TWRF1 Input/Output Wiring Fan Wiring (applicable to models rated 90 A and higher)
  • Page 4 Table of Contents TWRF1 SCR Power Controller Warranty In-house Repair Services Field Service Repairs APPENDIX ................................26 Appendix A – System Schematic Appendix B – 30-60 A Outline Appendix C – 90-225 A Outline Ametek HDR Power Systems Rev 2...

  • Page 5: Table Of Contents

    TWRF1 SCR Power Controller Table of Contents TABLE OF CONTENTS Par. Title Page ILLUSTRATIONS Figure 2.1 Thermostat Connections ........................8 Figure 2.2 Isolated/Non-Isolated Switches ......................8 Figure 2.3 T1 Transformer Connections ......................9 Figure 3.1 Control Panel ............................ 11 Figure 3.2 Remote Control with a Potentiometer ....................12 Figure 3.3 Process Controller Input Connections ....................
  • Page 6 Table of Contents TWRF1 SCR Power Controller Ametek HDR Power Systems Rev 2...
  • Page 7 TWRF1 SCR Power Controller Safety Instructions IMPORTANT SAFETY INSTRUCTIONS WARNING Observe all warnings and cautions in this manual. Failure to do so may result in serious injury or death. Refer all service to properly trained and qualified service personnel. Never work alone. Lethal voltages exist on exposed heat sinks even if the power controller is turned off.
  • Page 8 Safety Instructions TWRF1 SCR Power Controller Ametek HDR Power Systems Rev 2...
  • Page 9 TWRF1 SCR Power Controller Description CHAPTER 1 - Description General Description The TWRF1 is a Single-phase, phase-fired power controller, and can operate with a wide variety of input signals and line voltages up to 575 Vac and currents ranging from 30 through 225 amperes. The TWRF1’s output voltage is proportional to its input signal, with the output voltage regulated to +1% with a +10% line voltage change.

  • Page 10: Table 1.1 Kva Vs. Impedance

    Description TWRF1 SCR Power Controller Table 1.1 kVA vs. Impedance Impedance Current Rating 30 Amps 40 Amps 60 Amps 120 Amps 225 Amps Specification Specifications for the TWRF1 SCR power controller are given in Tables 1.1 and 1.2. Table 1.2 TWRF1 Model Number Breakdown TWRF1 –...

  • Page 11: Table 1.3 General Specifications Of Twrf1 Models

    TWRF1 SCR Power Controller Description Table 1.3 General Specifications of TWRF1 Models Input line voltage: * 120, 240, 400, 480, or 575 Vac, +10%, -15%, Single-phase Line frequency: * 50 or 60 Hz Current rating: * As indicated by model number (refer to Table 1.2) Thermostat contact rating: 120 Vac, 5 A;...
  • Page 12 Description TWRF1 SCR Power Controller Ametek HDR Power Systems Rev 2...

  • Page 13: Table 2.1 Wire Size Information

    TWRF1 SCR Power Controller Installation CHAPTER 2 - Installation Mounting the TWRF1 Determine the voltage and current ratings from the nameplate of the unit (refer to Table 1.2). Then determine space and mounting hole requirements by referring to the outline drawing (at the Appendix) that applies to your model’s current rating.

  • Page 14: Figure 2.1 Thermostat Connections

    Installation TWRF1 SCR Power Controller Wiring Overtemperature Contacts Normally-closed (N.C.) heat sink thermostats are standard on all fan-cooled models (rated 90 A and higher). These thermostats, which close on high heat sink temperature (200 ºF), may be used to initiate an alarm, shunt trip, or other device for SCR protection. Thermostat connections are on terminals 23 and 24 as shown in Figure 2.1.

  • Page 15: Figure 2.3 T1 Transformer Connections

    TWRF1 SCR Power Controller Installation Determining Line Frequency The TWRF1 is designed to operate on either 50 or 60 Hz. Usually the TWRF1 is shipped for 60 Hz operation, unless otherwise ordered. The TWRF1 can be set for either ac line frequency by selecting 50 Hz or 60 Hz on SW3 on the control board on the inside front door.
  • Page 16 Operation TWRF1 SCR Power Controller Ametek HDR Power Systems Rev 2...

  • Page 17: Figure 3.1 Control Panel

    TWRF1 SCR Power Controller Operation CHAPTER 3 - Operation General This Chapter provides information necessary for proper setup and operation of various methods used to control the TWRF1. a. Front Panel indications b. Command input control c. Remote manual control with a potentiometer d.

  • Page 18: Figure 3.2 Remote Control With A Potentiometer

    Operation TWRF1 SCR Power Controller a. With the power to the TWRF1 turned off, connect the potentiometer as shown in Figure 3.3. The CW position is the full power output position. Terminal TB1-5 is internally connected to a positive dc voltage source. Figure 3.2 Remote Control with a Potentiometer b.

  • Page 19: Figure 3.3 Process Controller Input Connections

    TWRF1 SCR Power Controller Operation Figure 3.3 Process Controller Input Connections d. Adjust the ZERO control CW until the output just turns on, then turn the ZERO control CCW just to the point where the output voltage reading is zero. e.

  • Page 20: Figure 3.5 On/Off Control

    Operation TWRF1 SCR Power Controller On/Off Control Some applications require that a simple ON/OFF type control be used. The unit can be used in these simple applications. It can be connected for turn on by a contact closure. WARNING This method of control is not to be used with isolated inputs With the TWRF1 configured for non-isolated inputs and the power to the TWRF1 turned off, connect the system as shown in figure 3.5.

  • Page 21: Figure 3.7 Current Limit/Trip Board

    TWRF1 SCR Power Controller Operation Overcurrent Trip Refer to Chapter 3.3, and adjust the ZERO and SPAN controls. Then adjust Overcurrent Trip as follows: a. Adjust the OC (CUR/PWR) potentiometer fully CW. b. With the power controller at full output, adjust OC (CUR/PWR) potentiometer CCW until the unit shuts off.
  • Page 22 Operation TWRF1 SCR Power Controller Ametek HDR Power Systems Rev 2...

  • Page 23: Figure 4.1 Ac Switch And Scr On-Time

    TWRF1 SCR Power Controller Theory CHAPTER 4 - Theory Functional Description The main function of the TWRF1 is to control the amount of power delivered to a load. The TWRF1 accomplishes this by controlling the portion of each input cycle for which power is delivered. The SCR is either on or off and conducts in one direction when turned on.
  • Page 24 Theory TWRF1 SCR Power Controller SPAN and ZERO Controls The ZERO and SPAN potentiometers are screwdriver adjustable. The center position of the ZERO control corresponds to zero bias and zero power output. The approximate zero setting can be found by rotating the control over its range, stopping near the midpoint of rotation. The precise zero setting can be found by observing the output level while rotating the control near the midpoint of rotation.
  • Page 25 TWRF1 SCR Power Controller Troubleshooting CHAPTER 5 – Troubleshooting Customer-Service Program Although service is seldom necessary, because of the inherent long-term reliability of solid-state components and conservative design, Ametek HDR Power Systems emphasizes customer satisfaction by maintaining a rapid-response and cooperative customer-service. If operational difficulties occur, Ametek HDR Power Systems will provide replacement parts or units quickly, courteously and efficiently.
  • Page 26 Troubleshooting TWRF1 SCR Power Controller d. Transport static sensitive components in static shielding bags or rails. A new printed circuit board should be treated as a static sensitive device. A part completely installed on a board does not make the part static-safe. e.

  • Page 27: Table 5.1 Troubleshooting Chart (Symptoms And Solutions)

    TWRF1 SCR Power Controller Troubleshooting Correcting Troubles in the TWRF1 Itself Table 5.1 provides a comprehensive guide for troubleshooting the TWRF1. Table 5.1 Troubleshooting Chart (Symptoms and Solutions) Cause Solution No output even with manual control (Zero) turned full CW. (1a) Open SCR fuse Disconnect power and check the fuse.
  • Page 28 Service TWRF1 SCR Power Controller CHAPTER 6 - Service Communication Procedures If operational problems arise that cannot be resolved by review of all related procedures given in this manual, please contact “Service” at Ametek HDR Power Systems. Please have your model number and serial number of the unit ready as it is required for our technicians to assist you.

  • Page 29: Table 6.1 Twrf1 Spare Parts List

    TWRF1 SCR Power Controller Service Spare Parts List The following table lists the minimum recommended quantities for spare parts for the TWRF1. As spares are used, replacements should be ordered. Table 6.1 TWRF1 Spare Parts List Item Item No. 30 Ampere Units PCB Assy, PF1 Extended Gate 2099160 PCB Assy, Over current Trip...
  • Page 30 Warranty TWRF1 SCR Power Controller CHAPTER 7 – Warranty Policy This chapter details the warranty policy of Ametek HDR Power Systems products. Ametek HDR Power Systems standard warranty policy is listed below. Note that the warranty policy for a particular job agreement may be different from the standard policy.
  • Page 31 TWRF1 SCR Power Controller Warranty Field Service Repairs Repairs may be performed at your location. Please contact Ametek HDR Power Systems at (614) 308-5500 to discuss terms and conditions, to get the current service rates and to schedule field repairs at your location.
  • Page 32 Warranty TWRF1 SCR Power Controller APPENDIX Appendix A – System Schematic Ametek HDR Power Systems Rev 2...
  • Page 33 TWRF1 SCR Power Controller Appendix Appendix B – 30-60 A Outline Rev 2 Ametek HDR Power Systems...
  • Page 34 Warranty TWRF1 SCR Power Controller Appendix C – 90-225 A Outline Ametek HDR Power Systems Rev 2...
  • Page 35 Notes:...
  • Page 36 530 Lakeview Plaza Blvd, Ste C Worthington, Ohio, 43085 USA...

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