Ametek ZF2 SCR Series Instruction, Operation And Maintenance Manual
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Ametek ZF2 SCR Series Instruction, Operation And Maintenance Manual

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SCR POWER CONTROLLER
Instruction, Operation and
Maintenance Manual
Number: 9100040
Revision 3
ZF2/ZF3 SCR Series
60-1200 Amperes
Two/Three-phase
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
We b :
w w w. h d r p o w e r. c o m
Zero-fired
F a x : 6 1 4 - 3 0 8 - 5 5 0 6

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  • Page 1 ZF2/ZF3 SCR Series 60-1200 Amperes Two/Three-phase Zero-fired SCR POWER CONTROLLER Instruction, Operation and Maintenance Manual Number: 9100040 Revision 3 530 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 :...
  • Page 2 Revision 2 July 2015 Revised Address Revision 3 August 2022 General Revision  2015 by Ametek HDR Power Systems. No portion of this document may be reproduced either mechanically or electronically without the prior consent of Ametek HDR Power Systems...
  • Page 3 Digital Firing Control Circuit Variable-Time Base Pulse-Train Firing Phase-Lock Loop SPAN and ZERO Controls Voltage-Squared Feedback Shut-down CHAPTER 7 – TROUBLESHOOTING ....................... 23 Customer-Service Program Troubleshooting Typical Symptoms Static Precautions when Servicing Environmental Problems Rev 3 Ametek HDR Power Systems...
  • Page 4 Appendix G – ZF3 60-225 A Outline Appendix H – ZF3 350-500 A Outline Appendix I – ZF3 650 A Outline Appendix J – ZF3 800-1200 A Outline Appendix K – Declaration of Conformity Ametek HDR Power Systems Rev 3...

  • Page 5: Table Of Contents

    Table 7.1 Troubleshooting Chart (Symptoms and Solutions) ..............25 Table 7.2 Torque Specifications ........................25 Table 8.1 ZF2 Spare Parts List ........................28 Table 8.2 ZF3 Spare Parts List ........................29 Table 8.3 ZF2/ZF3 Drawing List ........................31 Rev 3 Ametek HDR Power Systems...
  • Page 6 Table of Contents ZF2/ZF3 SCR Power Controller Ametek HDR Power Systems Rev 3...
  • Page 7 The SCR Power Controller makes use of components dangerous for the environment (electronic printed circuit boards, electronic components). The components removed must be taken to specialized collection and disposal centers. E151547 IEC 947-5-1 100kA SCCR Rev 3 Ametek HDR Power Systems...
  • Page 8 Safety Instructions ZF2/ZF3 SCR Power Controller Ametek HDR Power Systems Rev 3...

  • Page 9: Table 1.1 Zf2 And Zf3 Model Number Breakdown

    500 A rms - 500 650 A rms - 650 800 A rms - 800 1000 A rms - 1000 1200 A rms - 1200 NOTE: N.O. Thermostat is included in current ratings above 60 A. Rev 3 Ametek HDR Power Systems...

  • Page 10: Table 1.2 General Specifications Of Zf2/Zf3 Models

    650 A 87 lbs 39.6 kg 126 lbs 57.3 kg 800, 1000, 1200 A 180 lbs 47.6 kg 231 lbs 104.8 kg Outline and mounting: See appropriate drawing in Appendix * Specify with order Ametek HDR Power Systems Rev 3...
  • Page 11 ** If you will be using temperature/process controller, specify its output; e.g., 4-20 mA, 0-10 Vdc, 2-10 Vdc, etc. with your order. NOTE: The ZF2/ZF3 should be tested or operated with an adequate load since an open output will have line voltage at the load connections. Rev 3 Ametek HDR Power Systems...
  • Page 12 Option LG will provide compression lugs for the 350-1200 A Power Controllers. Additional Options The options described above are the ones most commonly used. Additional options are available. For more information, contact Ametek HDR Power Systems. Ametek HDR Power Systems Rev 3...

  • Page 13: Table 3.1 Wire Size Information

    3.1. Refer to Table 1.2 for fan power requirements by model. The ZF2/ZF3 terminals available for the 120 Vac fan connections are shown Figure 3.1 and in the schematic at the rear of this manual. Optional 220 Vac fans are available. Rev 3 Ametek HDR Power Systems...

  • Page 14: Figure 3.1 Fan And Thermostat Connections

    Command Signals. Zero based Command Signals may have a small amount of non-linearity (input to output) at the low end. This should not be a problem on closed loop systems. Ametek HDR Power Systems Rev 3...

  • Page 15: Figure 3.2 Isolated/Non-Isolated Switches

    1. Open the SCR power controller, and locate transformer T1. The primary side of T1 transformer will contain two wires (one black, the other white and black). Refer to Figure 3.3. Figure 3.3 T1 Transformer Connections Rev 3 Ametek HDR Power Systems...

  • Page 16: Figure 3.4 Typical Zf2/Zf3 Line And Load Connections

    Phase 1 CT connects to terminals 51 and 52; Phase 2 CT connects to terminals 53 and 54, and Phase 3 CT connects to terminals 55 and 56. INPUT LINE LOAD GROUND CONTROL Note: Unit shown with optional CT’s Figure 3.4 Typical ZF2/ZF3 Line and Load Connections Ametek HDR Power Systems Rev 3...

  • Page 17: Figure 4.1 Control Panel

    The ZF2/ZF3 is calibrated at the Factory for the specified input type and normally does NOT need adjustment. However, should a setup be required use the following methods. Refer to chapter 3.5 for the Command signal input configuration. Rev 3 Ametek HDR Power Systems...

  • Page 18: Figure 4.2 Process Controller Input Connections

    Set the SPAN control and remote potentiometer fully CCW. d. Close the fused disconnect or circuit breaker to apply power to the ZF2/ZF3. The unit should be energized, with no output. Ametek HDR Power Systems Rev 3...

  • Page 19: Figure 4.3 Remote Control With A Potentiometer

    Figure 4.4 and remove jumper from terminal TB1-7 and TB1-8. Install the AUTO/MAN switch in the same general location as the remote manual potentiometer. Note that the full CW position of the potentiometer is the full-power-output position. Figure 4.4 Auto/Man Control with Controller and Remote Potentiometer Rev 3 Ametek HDR Power Systems...

  • Page 20: Figure 4.5 On/Off Control

    When it is necessary to shutdown or disable the output, it is a simple matter. Connect a dry contact closure between terminals 3 and 4 of the firing circuit as shown in Figure 4.6. A closed contact will disable the ZF2/ZF3 output. Figure 4.6 Shutdown Control (Output Disabled By Contact Closure) Ametek HDR Power Systems Rev 3...
  • Page 21 LED indicates the alarm condition. Each LED is labeled on the board. The relay output is on terminals 58 (N.O.), 59 (Common) and 60 (N.C.) as shown in figure 4.7. The relay is energized on alarm. Rev 3 Ametek HDR Power Systems...

  • Page 22: Figure 4.7 Unbalance Alarm Board

    Typically the SCR Shorted Alarm board is a piggy-back board on the Unbalance Alarm and does not require any calibration. The Shorted SCR Alarm can be used with or without the Unbalance Alarm Figure 4.8 Shorted SCR Alarm Board Ametek HDR Power Systems Rev 3...

  • Page 23: Figure 4.9 Unbalance Block Diagram

    ZF2/ZF3 SCR Power Controller Operation Figure 4.9 Unbalance Block Diagram Rev 3 Ametek HDR Power Systems...
  • Page 24 Operation ZF2/ZF3 SCR Power Controller Ametek HDR Power Systems Rev 3...

  • Page 25: Table 5.1 Unbalance Dip Switch Settings

    3.01 Vdc. If there is any difference in this voltage, it can be trimmed out by increasing the gain of the two lower signals to match the highest signal. The potentiometers allow an increase of up to 16% on Rev 3 Ametek HDR Power Systems...
  • Page 26 If you are attempting to monitor a large number of heaters using a very sensitive setting, the above factors could either cause a false alarm, or prevent the loss of one heater element from being detected. Ametek HDR Power Systems Rev 3...

  • Page 27: Figure 6.1 Ac Switch

    ZF2/ZF3 would be the period of four cycles in this case – three cycles on and one cycle off. Table 6.1 Variable-Time-Base Relationship (Example) Control signal, % SCR Pair, Complete SCR Pair, Complete Power Demand On Cycles Off Cycles 100% Rev 3 Ametek HDR Power Systems...
  • Page 28 3 and terminal 4. This removes the input signal to the comparator that tells the circuit when to gate the SCRs on. It also instantaneously turns off the SCR gating pulses. Ametek HDR Power Systems Rev 3...
  • Page 29 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. If servicing problems arise that are not within the scope of the following troubleshooting guide, service is readily available, as detailed in Chapter 7.
  • Page 30 If it is above 122 ºF (50 ºC), steps should be taken to provide more cooling, or the ZF2/ZF3 should be moved to a cooler location, or call the Ametek HDR Power Systems service department. Excessive Vibration. A significant degree of pitched or unpitched vibration can cause numerous problems.

  • Page 31: Table 7.1 Troubleshooting Chart (Symptoms And Solutions)

    X1. On the Rx1 scale, the resistance should be infinite in both directions. If a shorted component is indicated in any of these cases, replace it. (2b) Firing control Return the power to the unit. If the problem persists, contact Ametek HDR section defective Power Systems service.
  • Page 32 Troubleshooting ZF2/ZF3 SCR Power Controller Ametek HDR Power Systems Rev 3...
  • Page 33 Answering Service operator of the nature and degree of your problem. In such cases the operator is authorized to call Ametek HDR Power Systems Service. We cannot, however, guarantee that service assistance will be available at any given off-hour time.

  • Page 34: Table 8.1 Zf2 Spare Parts List

    Fan, axial, 115 Vac, 100 CFM 4520001 Fuse, 630 A, 700 V 7500124 Lug Kit, 2/3 Phase 500 A 2710209 PCB Assy, ZF2 2099158 SCR, 800 A, 1400 V 5080114 PCB Assy, DVDT 2071000 Ametek HDR Power Systems Rev 3...

  • Page 35: Table 8.2 Zf3 Spare Parts List

    SCR/dual pkg, 90 A, 1400 V 6791114 180 Ampere Units Fan, axial, 115 Vac, 110 CFM 4520001 Fuse, 225 A, 700 V 7523170I PCB Assy, PF3 2099162 PCB Assy, DVDT 2099000 SCR/dual pkg, 142 A, 1400 V 6712114 Rev 3 Ametek HDR Power Systems...
  • Page 36 Fan, axial, 115 Vac, 350 CFM 4520002 Fuse, 1600 A, 700 V 7500128 Lug Kit, 2/3 Phase 1200 A 2710213 PCB Assy, ZF3 2099162 SCR, 2800 A, 1400 V 5028214 PCB Assy, DVDT 2072000 Ametek HDR Power Systems Rev 3...

  • Page 37: Table 8.3 Zf2/Zf3 Drawing List

    Outline & Mounting, ZF3 – 60 - 225 A M2710038 Outline & Mounting, ZF3 – 350 A, 500 A M2710042 Outline & Mounting, ZF3 – 650 A M2710044 Outline & Mounting, ZF3 – 800, 1000, 1200 A M2710045 Rev 3 Ametek HDR Power Systems...
  • Page 38 AMETEK HDR warrants that the equipment delivered will be free from defects in workmanship and material for a period of five years from the date of shipment. AMETEK HDR will repair or replace, at AMETEK HDR's option, any part found defective during proper and normal use, provided that written notice of the nature of the defect is received by AMETEK HDR within the five year warranty period and that the customer returns the part to AMETEK HDR freight paid both ways.
  • Page 39 ZF2/ZF3 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 40 Appendix ZF2/ZF3 SCR Power Controller APPENDIX Appendix A – ZF2 System Schematic Ametek HDR Power Systems Rev 3...
  • Page 41 ZF2/ZF3 SCR Power Controller Appendix Appendix B – ZF3 System Schematic Rev 3 Ametek HDR Power Systems...
  • Page 42 Appendix ZF2/ZF3 SCR Power Controller Appendix C – ZF2 60-225 A Outline Ametek HDR Power Systems Rev 3...
  • Page 43 ZF2/ZF3 SCR Power Controller Appendix Appendix D – ZF2 350-500 A Outline Rev 3 Ametek HDR Power Systems...
  • Page 44 Appendix ZF2/ZF3 SCR Power Controller Appendix E – ZF2 650 A Outline Ametek HDR Power Systems Rev 3...
  • Page 45 ZF2/ZF3 SCR Power Controller Appendix Appendix F – ZF2 800-1200 A Outline Rev 3 Ametek HDR Power Systems...
  • Page 46 Appendix ZF2/ZF3 SCR Power Controller Appendix G – ZF3 60-225 A Outline Ametek HDR Power Systems Rev 3...
  • Page 47 ZF2/ZF3 SCR Power Controller Appendix Appendix H – ZF3 350-500 A Outline Rev 3 Ametek HDR Power Systems...
  • Page 48 Appendix ZF2/ZF3 SCR Power Controller Appendix I – ZF3 650 A Outline Ametek HDR Power Systems Rev 3...
  • Page 49 ZF2/ZF3 SCR Power Controller Appendix Appendix J – ZF3 800-1200 A Outline Rev 3 Ametek HDR Power Systems...
  • Page 50 ZF2/ZF3 SCR Power Controller Appendix K – Declaration of Conformity EC DECLARATION OF CONFORMITY AMETEK HDR POWER SYSTEMS 503 Lakeview Plaza Blvd, Ste C Worthington, Ohio, 43085 - USA Declare under our sole responsibility that the products listed below and bearing the CE label:...
  • Page 51 Notes:...
  • Page 52 503 Lakeview Plaza Blvd, Ste C Worthington, Ohio, 43085 USA...

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