Ametek ZF2 Series Operation and maintenance manual

SCR POWER CONTROLLER
Instruction, Operation and
Maintenance Manual
Number: 9100039
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
ZF2/ZF3 SSR Series
15-70 Amperes
Two/Three-phase
Zero-fired

This manual applies to all Model ZF2 and ZF3 SSR Power Controls. Former ZF2/ZF3 manual – 9100028 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
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.

ZF2/ZF3 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 FK (Fuse Kit) 3
1.6Option TX (24 Vac Transformer) 3
1.7Option UB (Load Unbalance Alarm) 4
1.8Option SF (SCR Failure Alarm) 4
CHAPTER 2 - INSTALLATION............................................................................................................................5
2.1Mounting the ZF2/ZF3 5
2.2Load Wiring 5
2.3Line Wiring 5
2.4Wiring Input Fuse 6
2.5Command Signal Input 6
2.6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 ZF2/ZF3 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 15
CHAPTER 6 – WARRANTY POLICY................................................................................................................17
6.1Warranty 17
6.2In-house Repair Services 17
APPENDIX..........................................................................................................................................................18
Appendix A – ZF2 System Schematic (-C models only) 18
Appendix B – ZF2 System Schematic 19
Appendix C – ZF3 System Schematic 20
Appendix D – ZF2 15-40 A Outline 21
Appendix E – ZF2 70 A Outline 22
Appendix F – ZF3 15-40 A Outline 23
Appendix G – ZF3 70 A Outline 24
Appendix H – Option Transformer Outline 25
Appendix I – Option FK Mounting 25

Table of Contents ZF2/ZF3 SSR Power Controller
ii Ametek HDR Power Systems Rev 2
Appendix J – Declaration of Conformity 26
TABLES
Table 1.1 ZF2/ZF3 Model Number Breakdown ................................................................................................ 3
Table 1.2 General Specifications of ZF2/ZF3 SSR Models............................................................................. 4
Table 2.1 Control Transformer Voltage Wiring............................................................................................... 5
Table 4.1 Troubleshooting Chart (Symptoms and Solutions)..................................................................... 11
Table 5.1 ZF2 SSR Spare Parts List ............................................................................................................... 14
Table 5.2 ZF3 SSR Spare Parts List ............................................................................................................... 14
Table 5.3 ZF2/ZF3 SSR Drawing List.............................................................................................................. 15

ZF2/ZF3 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 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 ZF2/ZF3 SSR Power Controller
2 Ametek HDR Power Systems Rev 2

ZF2/ZF3 SSR Power Controller Options
Rev 2 Ametek HDR Power Systems 3
CHAPTER 1 - Description
1.1 General Description
The ZF2 is three-phase 2-leg/4 SCR control and the ZF3 is a three-phase, 3-leg/6 zero-fired SCR
Power Controller. Each of these 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 ZF1’s output voltage is
proportional to its input signal. HDR’s zero-fired SCR Power Controls utilize a variable-time-base that
helps maintain constant power to the load. The ZF1 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
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 uses resistive heat.
1.3 Specification
Specifications for the ZF2/ZF3 SSR power controller are given in Tables 1.1 and 1.2.
Table 1.1 ZF2/ZF3 Model Number Breakdown
ZF2 (or ZF3) – 480 – 25 – CL – FK – 01
NOTE: * Requires 24 Vac Transformer Option
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 ZF1 requires 24 Vac @ 3VA control power for Voltage or Pot Command signal. Appropriate sized
transformer (Option TX) is available with 120, 240, 400, 480 or 600 Vac 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
Arms
-
70
N.O. Thermostat - NO
N.C. Thermostat - NC
Fuse Kit - FK
24 Vac Transformer - TX
Load Unbalance Alarm - UB
SCR Failure Alarm - SF
Can have multiple selections
4-20 mA (self powered) - C
4-20 mA - 01
*0-10 Vdc - 02
*0-5 Vdc - 03
*Manual Pot Input - 05
Others - xx

Options ZF2/ZF3 SSR Power Controller
4 Ametek HDR Power Systems Rev 2
Table 1.2 General Specifications of ZF2/ZF3 SSR Models
Input line voltage: *120, 240, 400, 480, or 575 Vac,
+10%, -15% , Two-phase or Three-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 - OPTIONAL
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 lbs kg lbs kg
: 15 through 40 A
70 A
2.5 lbs
5.7 lbs
1.1
2.6
3.6
9
1.63
4.1
Outline and mounting: See appropriate drawing in Appendix
* Specify with 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.
1.7 Option UB (Load Unbalance Alarm)
The Load Unbalance Alarm Option (UB) monitors three phase currents and provides an alarm if the
load currents become unbalanced by more than the preset percentage. The limit is DIP switch
selectable and a form C relay is available for alarm along with diagnostic indicators. This option is
mounted external to ZF2/ZF3 Power Controller, reference 3-phase Load Unbalance & Shorted SCR
Alarm manual.
1.8 Option SF (SCR Failure Alarm)
The SCR Failure Alarm Option (SF) optional circuit monitors each SCR pair’s voltage drop and detects
when an SCR is shorted. Three green LEDs are lit when the SCRs are not shorted. If an SCR shorts,
the respective green LED will go out and the red alarm LED will light and the Form C relay will
energize. Relay output and terminals for connection are provided. This option is mounted external to
ZF2/3 Power Controller, reference 3-phase Load Unbalance & Shorted SCR Alarm manual.

ZF2/ZF3 SSR Power Controller Installation
Rev 2 Ametek HDR Power Systems 5
CHAPTER 2 - Installation
2.1 Mounting the ZF2/ZF3
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 75 ºC.
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 ZF2 or ZF3 series unit.)
Torque Line and Load connection to 45 in-lbs.
If required, 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 ZF2/ZF3 SSR Power Controller
6 Ametek HDR Power Systems Rev 2
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 G for mounting details.
2.5 Command Signal Input
HDR’s ZF2/ZF3 SSR Power Controllers have the capability of having a current, voltage or
potentiometer Command Signal input. On –C models it is current control only. If the Firing board is
capable of both voltage and current there is a 500 ohm 1/4W resistor is connected across terminals 1
and 2, for voltage command and remote potentiometer the 500 ohm resistor is removed. For Remote
control a potentiometer may be located on a remote panel near other controls related to the process
being powered by the ZF2/ZF3. The potentiometer should be rated 5 k, 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.
2.6 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.