Ametek PF1 SSR Series Operation and maintenance manual

SCR POWER CONTROLLER
Instruction, Operation and
Maintenance Manual
Number: 9100031
Revision 3
530 Lakeview Plaza Blvd, Ste C
Worthington, Ohio, USA 43085
Toll F re e : 1 - 8 88- PWR- C NTL (7 9 7 -26 85)
Ph o n e: 61 4 -3 0 8-550 0
Fa x : 614 - 3 08 - 5506
Web: w w w .hd rpow e r. c o m
PF1 SSR Series
15-70 Amperes
Single-phase
Phase-fired

This manual applies to all Model PF1 SSR Power Controls. Former PF1 manual – 9100015 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 September 2014 Initial Release
Revision 2 July 2015 Revised Address
Revision 3 Aug 2022 General Revision
 2022 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.

PF1 SSR Power Controller Table of Contents
Rev 3 Ametek HDR Power Systems i
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS ............................................................................................................. 1
CHAPTER 1 - DESCRIPTION .............................................................................................................................. 3
1.1 General Description 3
1.2 Application 3
1.3 Specification 3
1.4 Option NO/NC (Thermostat) 3
1.5 Option FK (Fuse Kit) 3
1.6 Option TX (24 Vac Transformer) 3
1.7 Option OC (Overcurrent Trip) 4
1.8 Option CL (Current Limit) 4
CHAPTER 2 - INSTALLATION ............................................................................................................................ 5
2.1 Mounting the PF1 5
2.2 Load Wiring 5
2.3 Line Wiring 5
2.4 Wiring Input Fuse 6
2.5 Optional Current Transformer 6
2.6 Command Signal Input 6
2.7 Heatsink Thermostat Contacts 6
CHAPTER 3 - OPERATION ................................................................................................................................. 7
3.1 General 7
3.2 Command Indicator 7
3.3 Command Input Control 7
CHAPTER 4 – TROUBLESHOOTING ................................................................................................................. 9
4.1 Customer-Service Program 9
4.2 Troubleshooting Typical Symptoms 9
4.3 Static Precautions when Servicing 9
4.4 Environmental Problems 10
4.5 Input Power and Load Connections 10
4.6 Correcting Troubles in the PF1 Itself 11
CHAPTER 5 - SERVICE ..................................................................................................................................... 13
5.1 Communication Procedures 13
5.2 Spare Parts Orders – Routine or Emergency 13
5.3 Spare Parts List 14
5.4 Drawing List 14
CHAPTER 6 – WARRANTY POLICY ................................................................................................................ 15
6.1 Warranty 15
6.2 In-house Repair Services 15
APPENDIX .......................................................................................................................................................... 17
Appendix A – System Schematic 17
Appendix B – 15-40 A Outline 18
Appendix C – 70 A Outline 19
Appendix D – Option TX Transformer Outline 20
Appendix E – Option FK Mounting 20
Appendix F – Option CL Outline 21
Appendix G – Option OC Outline 21
Appendix H – Declaration of Conformity 22

Table of Contents PF1 SSR Power Controller
ii Ametek HDR Power Systems Rev 3
TABLES
Table 1.1 PF1 Model Number Breakdown........................................................................................................ 3
Table 1.2 General Specifications of PF1 SSR Models .................................................................................... 4
Table 2.1 Control Transformer Voltage Wiring ............................................................................................... 5
Table 2.2 Current Transformer Turns .............................................................................................................. 6
Table 4.1 Troubleshooting Chart (Symptoms and Solutions) ..................................................................... 11
Table 5.1 PF1 SSR Spare Parts List ............................................................................................................... 14
Table 5.2 PF1 SSR Drawing List ..................................................................................................................... 14

PF1 SSR Power Controller Safety Instructions
Rev 3 Ametek HDR Power Systems 1
SAVE THESE 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. Remove power and lock
out power before attempting any service.
This manual contains important safety instructions that must be followed during the installation and
maintenance of the SCR Power controller. Read this manual thoroughly before attempting to operate this
Power controller.
An appropriate branch circuit fused disconnect or circuit breaker with this Power Controller is required to
ensure the safety of operating personnel.
CAUTION
HAZARDOUS VOLTAGES exist at the Power Controller Line and Load terminals, AT ALL TIMES, when input
voltage is connected. This condition exists even when the Power Controller is set to deliver zero output.
Printed circuit boards contain sensitive components that can be damaged by electrostatic discharge (ESD).
Observe precautions for handling electrostatic sensitive devices. Reference Maintenance and Troubleshooting
Chapter of this manual for details
In case of fire, use a dry chemical fire extinguisher to put out the fire. Using a liquid fire extinguisher may
cause electric shock.
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
100kA SCCR
IEC 947-5-1

Safety Instructions PF1 SSR Power Controller
2 Ametek HDR Power Systems Rev 3

PF1 SSR Power Controller Description
Rev 3 Ametek HDR Power Systems 3
CHAPTER 1 - Description
1.1 General Description
The PF1 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 15 through 70 amperes. The PF1’s
output voltage is proportional to its input signal. The PF1 SSR Series utilizes an isolated base Solid-
State-Relay (SSR) Module which contains two SCRs connected back to back. The firing circuit is
based on a common phase firing integrated circuit which includes soft-start for loads which have a
large resistance change due to temperature or start-up. Terminals are provided to ease installation.
1.2 Application
The PF1 provides infinitely variable firing angles for precise control of single-phase power to resistive
or loads with large resistance change (cold to hot). The PF1 may also be used on straight resistive
loads as well, but the lower power factor and higher harmonics may present a problem to other
equipment mounted nearby. A zero fired model may be a better choice for non-transformer coupled
loads.
1.3 Specification
Specifications for the PF1 SSR power controller are given in Tables 1.1 and 1.2.
Table 1.1 PF1 Model Number Breakdown
PF1 – 480 – 25 – CL – FK – 01
NOTE: * Required for operation.
1.4 Option NO/NC (Thermostat)
Heatsink Thermostats (Option NO or NC) provide a dry contact either Normally Open (NO) or Normally
Closed (NC).
1.5 Option FK (Fuse Kit)
The Fuse Kit (Option FK) consists of a Semi-Conductor Fuse and a fuse block. It is the user's
responsibility to mount this fuse kit and connect in series with the Line of the Power Controller.
1.6 Option TX (24 Vac Transformer)
The PF1 requires 24 Vac @ 3VA control power. Appropriate sized transformer (Option TX) is available
with 120, 240, 400, 480 or 600 V ac primaries.
120 Vac - 120
240 Vac - 240
400 Vac - 400
480 Vac - 480
575 Vac -
575
15 A rms - 15
25 A rms - 25
40 A rms - 40
70 A rms - 70
N.O. Thermostat - NO
N.C. Thermostat - NC
Fuse Kit - FK
24 Vac Transformer* - TX
Current Limit - CL
Over Current Trip - OC
Can have multiple selections
4-20 mA - 01
0-10 Vdc - 02
0-5 Vdc - 03
Manual Pot input - 05
Others
-
xx

Description PF1 SSR Power Controller
4 Ametek HDR Power Systems Rev 3
Table 1.2 General Specifications of PF1 SSR 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 1.1)
Thermostat contact rating: 120 Vac, 5 A; resistive (optional)
Input Signal:
Voltage
Current
0 to 1.5 V (min); 0 to 10 V (max)
0 to 6 mA (min); 0 to 20 mA (max)
Control methods: 1. Potentiometer, 5 kΩ, 1/2 watt (Customer-supplied).
2. Temperature or process controller
*
Control signal input impedance:
Voltage input
Current input
1500 Ω
500 Ω
I
solation:
From power to ground 1,500 Vac
Power SCRs protection:
Current surge Subcycle I² T semiconductor fuse - OPTIONAL
Transient voltage spikes (dv/dt)
SCCR Rating
Metal Oxide Varistor (MOV) across each SCR pair
100kA
Miscellaneous:
Phase-firing timebase 0º to 180º conduction per SCR
Controls: ZERO and SPAN potentiometers; 10-turn, screwdriver-adjustable.
Approvals UL/cUL (E151547), CE
Ambient Temperature range:
Environment 32 ºF to 122 ºF ( 0 ºC to 5 0ºC) surrounding air
Pollution degree 2
Overvoltage Category III
Storage 14 ºF to 158 ºF ( -10 ºC to 70 ºC)
Weight per unit: Current Rating
15 through 40 A
70 A
lbs
1.2
3
kg
0.55
1.36
Outline and mounting: See appropriate drawing in Appendix
* Specify with order
NOTE: The PF1 should be tested or operated with an adequate load since an open output will have line
voltage at the load connections.
1.7 Option OC (Overcurrent Trip)
The Overcurrent Trip Option (OC) provides circuit protection from output current overloads by serving
as a fast-gate shutdown (functions similar to an electronic fuse). Current transformers on the SCR
Power Control’s input lines allow Option OC to monitor instantaneous peak current. When the peak
current level exceeds the preset trip level, SCRs are gated off, and the load current is shut down within
1/2 cycle. Trip point is adjustable from 30% to 200% of the current transformer rating. The RESET
pushbutton on the OC Trip PCB must be manually reset to resume operation.
The Overcurrent Trip Option includes a Form C relay output and provisions for a remote overcurrent
reset push button. Reference Appendix G.
1.8 Option CL (Current Limit)
The Current Limit Option (CL) prevents the output current of an SCR Power Control from exceeding a
preset maximum current level, as determined by the current limit control setting (30% to 125%). The
current limit adjustment is located on the current limit PCB, reference Appendix F.

PF1 SSR Power Controller Installation
Rev 3 Ametek HDR Power Systems 5
CHAPTER 2 - Installation
2.1 Mounting the PF1
Determine space and mounting hole requirements by referring to the outline drawing (in the Appendix)
that applies to your model’s current rating. Mount the unit so the line and load connections are at the
top and ensure that upward airflow over the heat sink fins is unrestricted.
2.2 Load Wiring
Connect the load to the proper terminals (refer to the input/output connections schematic in Appendix
A) using appropriately sized and insulated conductors. All input/output conductors should be stranded
copper wire only; minimum temperature rating is 75ºC.
2.3 Line Wiring
Connect input lines from the fused disconnect or circuit breaker to the Line terminal (refer to the
input/output connections diagram) using appropriately sized and insulated conductors. (NOTE: Input
power should be routed through a fused disconnect or circuit breaker with a fuse or trip rating of 100%
to 125% of the current rating stamped on the nameplate of the PF1 series unit.)
Torque Line and Load connection to 45 in-lbs.
Mount and connect the Control transformer (Option TX) per the schematic in Appendix A. Select the
appropriate Transformer voltage tap as shown in Table 2.1 and solder wires to the primary terminals.
An insulator is also provided to install between the transformer and the mounting plate.
Table 2.1 Control Transformer Voltage Wiring
Desired Voltage Primary Tap
120 120
208 240
220 240
240 240
380 400
400 400
415 400
480 480
575 575
WARNING - ELECTRIC SHOCK CAN KILL
HAZARDOUS VOLTAGES exist at the (LINE and LOAD) terminals when the
input voltage is connected. This condition exists even when the Controller is
set to deliver zero output. Always remove power and properly lock out power to
the unit before attempting any service, including the load.
WARNING
Branch circuit overcurrent protection required is to be provided in accordance
with the national and local codes of the inspecting authority.

Installation PF1 SSR Power Controller
6 Ametek HDR Power Systems Rev 3
2.4 Wiring Input Fuse
An Option (FK) Fuse Kit is available with high speed fuses (I²T) to protect the Solidstate Relays (SSR)
from Load shorts. The fuses are NOT meant for over current protection, separate branch circuit
protection is required. Mount the fuse blocks, reference Appendix E for mounting details.
2.5 Optional Current Transformer
Install the Current transformer for option OC or CL near the Line connection, reference Appendix F &
G for mounting. Run L1 through current transformer the amount of turns shown in Table 2.2. Connect
the cable provided from the CT PCB to the Firing Circuit PCB and adjust pot to desired current or trip
level per 3.3.
Table 2.2 Current Transformer Turns
Current Rating Turns
15 A 3
25 A 2
40 A 1
70 A 1
2.6 Command Signal Input
HDR’s PF1 SSR Power Controllers have the capability of having a current, voltage or potentiometer
Command Signal input. For current command (4-20 mA) a 500 ohm 1/4 W resistor is connected
across terminals 1 and 2, for voltage command and remote potentiometer the 500 ohm resistor is
removed. A potentiometer may be located on a remote panel near other controls related to the
process being powered by the PF1. The potentiometer should be rated 5 kΩ, 1/2 Watt minimum.
Reference the schematic in Appendix A.
The Command Signal is NOT isolated from the Line. An isolated device such as an isolated PLC
output module to drive the command signal is required or damage can occur to the Power Controller.
2.7 Heatsink Thermostat Contacts
Normally-open (N.O.) or normally-closed (N.C.) thermostat is mounted to the heat sink when this
option is purchased. This thermostat, which close or open on high heat sink temperature (200 ºF),
may be used to initiate an alarm, shunt trip, or other device for SCR protection.