Ametek SCZF1 SSR Series Operation and maintenance manual

SCR POWER CONTROLLER
Instruction, Operation and
Maintenance Manual
Number: 9100043
Revision 2
530 Lakeview Plaza Blvd, Ste C
Worthington, Ohio, USA 43085
Toll Free: 1-888-PWR-CNTL (797-2685)
Phone: [phone]
Fax: [phone]
Web: www.hdrpower.com
SCZF1 SSR Series
15-65 Amperes
Single-phase
Zero-fired

This manual applies to all Model SCZF1 SSR Power Controls. Former SCZF1 manual – 9100021 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 October 2014 Initial Release
Revision 2 July 2015 Revised Address
2014 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.

SCZF1 SSR Power Controller Table of Contents
Rev 2 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 LF (Load Failure Alarm) 3
CHAPTER 2 - INSTALLATION............................................................................................................................5
2.1Mounting the SCZF1 5
2.2Load Wiring 5
2.3Line Wiring 5
2.4Command Signal Input 5
2.5Heatsink Thermostat Contacts 6
CHAPTER 3 - OPERATION.................................................................................................................................7
3.1General 7
3.2Power On Indicator 7
3.3Command Indicator 7
3.4Zero and Span Adjustments 7
3.5Command Input Control 7
3.6Remote Manual Control with a Potentiometer 8
CHAPTER 4 – TROUBLESHOOTING...............................................................................................................10
4.1Customer-Service Program 10
4.2Troubleshooting Typical Symptoms 10
4.3Static Precautions when Servicing 10
4.4Environmental Problems 11
4.5Input Power and Load Connections 11
4.6Correcting Troubles in the SCZF1 Itself 12
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..........................................................................................................................................................16
Appendix A – System Schematic 16
Appendix B –Outline 17
Appendix C – Declaration of Conformity 18

Table of Contents SCZF1 SSR Power Controller
ii Ametek HDR Power Systems Rev 2
TABLES
Table 1.1 SCZF1 Model Number Breakdown................................................................................................... 3
Table 1.2 General Specifications of SCZF1 SSR Models............................................................................... 4
Table 4.1 Troubleshooting Chart (Symptoms and Solutions)..................................................................... 12
Table 5.1 SCZF1 SSR Spare Parts List .......................................................................................................... 14
Table 5.2 SCZF1 SSR Drawing List................................................................................................................ 14

SCZF1 SSR Power Controller Safety Instructions
Rev 2 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 4 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
Made in U.S.A.

Safety Instructions SCZF1 SSR Power Controller
2 Ametek HDR Power Systems Rev 2

SCZF1 SSR Power Controller Description
Rev 2 Ametek HDR Power Systems 3
CHAPTER 1 - Description
1.1 General Description
The SCZF1 is a Single-phase, zero-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 65 amperes. The
SCZF1’s average output voltage is proportional to its input signal. The SCZF1 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 integrated circuit. Terminals are provided to ease installation.
1.2 Application
A variable time base firing circuit is used to provide precise control of power to resistive loads. These
units should never be used on inductive loads. However, they are versatile enough to be used in
place of mechanical contactors and mercury relays on dryers, kilns, ovens, environmental chambers,
extruders, molding equipment, and other types of equipment which use resistive heat.
1.3 Specification
Specifications for the SCZF1 SSR power controller are given in Tables 1.1 and 1.2.
Table 1.1 SCZF1 Model Number Breakdown
SCZF1 – 480 – 25 – NO – LF – 01
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 LF (Load Failure Alarm)
Load Failure Alarm detects changes in the load and should be used when the “Load” is made up of
several parallel paths. The load failure alarm will determine when 5% or more of the load has failed.
A relay output is provided.
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
65 A rms - 65
N.O. Thermostat - NO
N.C. Thermostat - NC
Load Failure Alarm - LF
Can have multiple selections
4-20 mA - 01
0-10 Vdc - 02
0-5 Vdc - 03
Manual Pot input - 05
Others - xx

Description SCZF1 SSR Power Controller
4 Ametek HDR Power Systems Rev 2
Table 1.2 General Specifications of SCZF1 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 k, 1/2 watt (Customer-supplied).
2. Temperature or process controller *
Control signal input impedance:
Voltage input
Current input
1500 
500 Isolation:
From power to ground 1,500 Vac
Power SCRs protection:
Current surge Subcycle I² T semiconductor fuse
Transient voltage spikes (dv/dt)
SCCR Rating
Metal Oxide Varistor (MOV) across each SCR pair
100kA Miscellaneous:
Zero-firing timebase Variable see 3.1
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 50 ºC) 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 65 A lbs 6 kg 2.75
Outline and mounting: See appropriate drawing in Appendix
* Specify with order
NOTE: The SCZF1 should be tested or operated with an adequate load since an open output will have line
voltage at the load connections.

SCZF1 SSR Power Controller Installation
Rev 2 Ametek HDR Power Systems 5
CHAPTER 2 - Installation
2.1 Mounting the SCZF1
Determine space and mounting hole requirements by referring to the outline drawing in the Appendix.
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. Separate mounting brackets are provided.
2.2 Load Wiring
Connect the load to the proper terminals (refer to schematic in Appendix A) using appropriately sized
and insulated conductors. All input/output conductors should be stranded copper wire only; minimum
temperature rating is 75 ºC.
2.3 Line Wiring
Connect input lines from the fused disconnect or circuit breaker to the Line terminal (refer to schematic
in Appendix A) 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 SCZF1 series unit.) Torque Line and Load connection
to 25 in-lbs.
2.4 Command Signal Input
HDR’s SCPF1 SSR Power Controllers have the capability of having a current, voltage or potentiometer
Command Signal input. For current command (4-20 mA) connected the process controller across
terminals 1 and 2, for voltage command remove jumper in Figure 3.1.
Figure 2.1 Process Controller Input Connections
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 SCZF1 SSR Power Controller
6 Ametek HDR Power Systems Rev 2
Some applications only require a manual control input and not a closed loop input from a process
controller. This potentiometer may be located on a remote panel near other controls related to the
process being powered by the SCZF1. Connect a potentiometer rated 500 ohms to 5 k, 1/2 Watt
minimum as in Figure 2.2 or the schematic in Appendix A. Remove jumper in Figure 3.1.
Figure 2.2 Potentiometer Input Connections
2.5 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.