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Summary of Contents for Control Concepts FUSION Series
- Page 1 COMPACT FUSION SCR POWER CONTROLLERS INSTALLATION & MAINTENANCE MANUAL www.ccipower.com 1-800-765-2799 Compact FUSION Installation ManualRevision 3.50.2 © Control Concepts Inc., 2013...
- Page 2 CONTROL CONCEPTS, INC. warrants that the products delivered will be as described in the sales order or contract. CONTROL CONCEPTS, INC. warrants to the original user that CONTROL CONCEPTS, INC. products will be free from defects in materials and workmanship for a period of two (2) years after the date CONTROL CONCEPTS, INC. ships such products.
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Page 3: Table Of Contents
TABLE OF CONTENTS DECLARATION OF CONFORMITY ..............ii CERTIFICATE OF COMPLIANCE ..............iv 1. RECOMMENDED FUSING ................1 2. INSTALLATION ....................2 2.1 Mounting Considerations ..............2 2.2 Mounting Dimensions for Single Module Controllers ......3 2.3 Mounting Dimensions for Two Module Controllers ....... 4 2.4 Remote Display Kit ................ - Page 4 Listed 3L32 - Industrial Control Equipment 100kA Short Circuit Current Rating File Number E136219 EN60947-4-3 IP 20 See CE Declaration of Conformity Part 15 Subpart B Class A Device See RoHS Certificate of Compliance Compact FUSION Manual Certifications www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2013...
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Page 5: Declaration Of Conformity
Name of Authorized Representative: Cory Watkins Title of Authorized Representative: President Place of Issue: Chanhassen, Minnesota, USA Date of Issue: December 2010 _____________________________________ _______________ Signature of Authorized Representative Date www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2013 Compact FUSION Manual Certifications... - Page 6 External EMI filters must be used in conjunction with the FUSION series power controllers to maintain CE immunity* approval. The following filters were used during the immunity testing. Universal input power: Line input power: Schaffner filter Schaffner filter P/N: FN 2030-3-06 P/N: FN 3270H-35-33 The Schaffner filter for universal input power, or it’s equivalent, may be used as listed above.
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Page 7: Certificate Of Compliance
CERTIFICATE OF COMPLIANCE CERTIFICATE OF COMPLIANCE This document certifies that Control Concepts, Inc’s products listed in the table are fully RoHS complient as of Nov 13, 2009 in accordance with EU RoHS Directive 2002/95/EC. The products listed in the table have been identified as RoHS compliant do not exceed the maximum limit for the six substances: Lead, Mercury, Cadmium, Hexavalent chromium, Polybrominated biphenyls and Polybrominated diphenyl ether. -
Page 8: Recommended Fusing
125 Fast Acting T 0042110-0460-412 125A 150 Fast Acting T 0042110-0460-415 160A 200 Fast Acting T 0042110-0460-420 Control Concepts carries an inventory of fuses and fuse blocks for purchase. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 9: Installation
It is important to leave enough room for the removal of the connectors (approximately 1.00 [25.4] - More if using Remote Display) and wiring considerations. CAD Blocks are available for download at www.ccipower.com. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799... -
Page 10: Mounting Dimensions For Single Module Controllers
0.98 [24.8] 4.09 [103.9] 5.96 [151.4] This model includes controllers: • Single Phase • Single Phase with Pass Through • (2x) Single Phase • Three Phase Two Leg © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 11: Mounting Dimensions For Two Module Controllers
• (3x) Single Phase • (4x) Single Phase • Three Phase Two Leg with Pass Through • Three Phase (Delta, Inside Delta, 3 or 4 Wire Wye) © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 12: Remote Display Kit
[92.1] 3.627 [92.1] Must be mounted on enclosure with smooth surface. Follow the mounting instructions on the following pages for proper installation. Maximum panel thickness: 0.25 [6.4]. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 13: Mounting Instructions
(See Number 2, bottom left) STEP Remove the display from the lid. The four tabs holding the display into the lid are marked. (See Number 3 bottom right) © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... - Page 14 Concepts for a replacement. When the controller is supplied with the Universal input power [100-240 Vac] the display shall now operate the same as when mounted on the controller © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2...
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Page 15: Wiring
3. WIRING Control Concepts configures and tests each controller before shipping. Once received, the controller is ready to install. The following sections will describe how to properly wire the unit with the recommended fusing. For line and load connections use copper conductors rated 75°C minimum. In the wiring drawings the wire acceptance is listed with the entry heights. -
Page 16: Universal Input Power
87.4 3Ø - 2 Leg - 1 Zone 28.3 34.3 40.3 58.3 3Ø - 2 Leg w/ Pass 33.4 33.4 57.4 87.4 3Ø 38.3 62.3 62.3 92.3 © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 17: Ac Cable Entry Heights / Wire Acceptance
5.73 [145.5] 5.73 [145.5] LINE & LOAD LUGS WIRE ACCEPTANCE 10-80A Screw 14 AWG - 2 AWG 100-160A 5/16” Hex Drive [8] 6 AWG - 250 MCM © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 18: Line / Load Connections
This figure shows a single phase controller connected Phase A to Phase B. The controller is not phase sensitive and can be connected to any two phases. It can also be connected from Phase to Neutral. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799... -
Page 19: Single Phase, Two Zone
The controller is not phase sensitive and any zone can be connected to any two phases. Any or all zones can be connected from Phase to Neutral. Note: During operation Zone 1 must have line power “ON” in order for other zones to operate. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799... -
Page 20: Single Phase, Three Zone
The controller is not phase sensitive and any zone can be connected to any two phases. Any or all zones can be connected from Phase to Neutral. Note: During operation Zone 1 must have line power “ON” in order for other zones to operate. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799... -
Page 21: Single Phase, Four Zone
The controller is not phase sensitive and any zone can be connected to any two phases. Any or all zones can be connected from Phase to Neutral. Note: During operation Zone 1 must have line power “ON” in order for other zones to operate. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799... -
Page 22: Single Phase With Pass-Through
This figure shows a single phase controller connected Phase A to Phase B. The controller is not phase sensitive and can be connected to any two phases. It can also be connected from Phase to Neutral. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799... -
Page 23: Single Phase Two Zone With Pass-Through
The controller is not phase sensitive and any zone can be connected to any two phases. Any or all zones can be connected from Phase to Neutral. Note: During operation Zone 1 must have line power “ON” in order for other zones to operate. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799... -
Page 24: Three Phase - Two Leg
This figure shows a three phase two leg controller connected to either a Delta or 3 Wire Wye load. Note: An optional current transducer may be ordered for monitoring the current on the third leg that does not run through the controller. Contact Control Concepts for more details. © Control Concepts Inc., 2013 www.ccipower.com... -
Page 25: Three Phase - Two Leg, With Pass-Through
LO AD Delta or 3 Wire Wye Load This figure shows a three phase two leg controller connected to either a Delta or 3 Wire Wye load. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 26: Three Phase Three Leg - Delta Or Three Wire Wye
Lo ad B2 Lo ad C2 LO AD This figure shows a three phase three leg controller connected to either a Delta or 3 Wire Wye load. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 27: Three Phase Three Leg - Inside Delta
There are instructions in Appendix A showing how to change from Inside Delta to a standard configuration (Delta or 3 Wire Wye). Both wire harnesses are necessary to perform this task. For ordering details see Appendix B in the Operator Manual. The model number configuration data is 0001. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799... -
Page 28: Three Phase, Three Leg - Four Wire Wye
There are instructions in Appendix B showing how to change from 4 Wire Wye to a standard configuration (Delta or 3 Wire Wye). Both wire harnesses are necessary to perform this task. For ordering details see Appendix B in the Operator Manual. The model number configuration data is 0002. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799... -
Page 29: Connectors
On a 2 zone controller, SP1 is used to control zone 1 and SP2 is used to control zone 2. On controllers with more than 2 zones, a digital interface must be ordered for communication with all zones. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799... -
Page 30: External Feedback
Three controllers providing 33.3% Three controllers with Sync-Guard™, 33.3% power each, power each, with Sync-Guard™. two providing 33.3% power and one operating synchronously providing 66.6% power. (without Sync-Guard™). © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 31: P2 - 6 Pin Relay Connector
For more details see the Aux I/O Card section in this manual. 3.5.6 P4 - Remote Display Connector This connector is for remote mounting the display. For more details see the Remote Display Kit section in this manual. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 32: Aux I/O Card (Optional)
This shows momentary switches for digital inputs 1 & 2. The digital output 1 is driven by the onboard 4 Vdc power supply. The digital output 2 is driven by the customers own supply. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 33: Appendix A: Changing From Inside Delta To Delta Or 3-Wire Wye Load
NOTE: Delta loads and 3 Wire Wye loads use the same wire harness. After changing wire harness, change the load type in the FUSION Control Panel software. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 34: Appendix B: Changing From 4 Wire Wye To Delta Or 3-Wire Wye Load
NOTE: Delta loads and 3 Wire Wye loads use the same wire harness. After changing wire harness, change the load type in the FUSION Control Panel software. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... -
Page 35: Appendix C: Fuse Replacement
Gate Driver board. Gently lift the Failure to do this may damage the board. board out of the controller. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2... - Page 36 STEP After verifying that all wiring has been connected correctly, the lids can be re-attached. Apply control and line power to the controller. Verify that the blown fuse indicator is NOT present. © Control Concepts Inc., 2013 www.ccipower.com 1-800-765-2799 Compact FUSION Installation Manual Revision 3.50.2...
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