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.

ZF2/ZF3 SSR Power Controller Operation
Rev 2 Ametek HDR Power Systems 7
CHAPTER 3 - Operation
3.1 General
The ZF2/ZF3 controls power by the switching action of two SCRs connected in a back to back
configuration in each controlled phase. The zero crossing detector built into the solid-state relay
module synchronizes the gating of these SCRs with the line frequency (either 50 or 60 Hz). The firing
circuit provides timing pulses to the SSR proportional to the command signal. The power controller
regulates the output voltage by proportionally controlling the number of AC cycles “on” versus the
number “off”. Because the voltage is “turned on” at zero crossing, very little radio frequency
interference (RFI) is generated and the power factor (PF) is near unity. The output may be adjusted
by a voltage or current signal from a process controller. Zero and Span controls allow the user to
calibrate the power controller’s output to the process signal.
The firing control circuit of the ZF2/ZF3 operates on a variable rather than fixed time base. Operating
on a fixed-time base of 1/3 second (20 cycles), for example, at 50% power the SCRs would be on for
10 cycles, off for 10 cycles, on for 10 cycles, and so on. Operating on a variable-time-base, at 50%
power, the SCRs are on for one cycle and off for the next. At 75% power, the controller, with a fixed-
time-base of one-third second (20 cycles), would be on for 15 cycles and off for 5. The variable-time-
base, however, would be on for three cycles, off for one, and so on. The time required to describe the
operation of the ZF1 would be the period of four cycles in this case – three cycles on and one cycle off.
For 50% power, the time required to describe the operation of the variable-time-base would be the
period of two cycles – one cycle on and one cycle off. Hence the time-base of the ZF1 would be the
period of two cycles for 50% power and four cycles for 75% power. The time-base varies for other
power levels as well, so its period is always that of a whole number of cycles
Keep in mind that ZF units can only be used on resistive loads. If an inductive load or a load with a
large resistance change (instantaneously or cold to hot) is being used, a phase fired (PF) power
control should be used.
3.2 Command Indicator
The Command Indicator is a green Light Emitting Diode (LED) located on the Firing board. The
brilliance of this LED will change with a Command Signal. The flash rate increases with an increased
Command Signal and decreases with a decreased Command Signal
3.3 Command Input Control
Connect the control signal per the schematic in Appendix A. The ZF2/ZF3 Zero and Span 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. (Note: Adjustments requires a jeweler’s screw driver
for multi-turn bias & gain adjustments.)
The output voltage linearity for any given command is affected by the setting of the Zero and Span
adjustments.
a. Set the ZERO and SPAN controls fully CCW (counterclockwise).
b. Connect a voltmeter across terminals LINE and LOAD of the ZF2/ZF3. Set the voltmeter range to
measure full input voltage.
c. Close the fused disconnect or circuit breaker to apply power to the ZF2/ZF3. Turn the Process
controller on and set to demand zero power output or remote potentiometer fully CCW.
d. Adjust the ZERO control CW until the output just turns on, then turn the ZERO control CCW just to
the point where the output voltage reading is zero.

Operation ZF2/ZF3 SSR Power Controller
8 Ametek HDR Power Systems Rev 2
e. Set the Process controller to demand 100% output or the remote potentiometer fully CW.
Observing the voltmeter, adjust SPAN CW just to the point where the reading is below the
maximum output voltage. Then adjust SPAN CW just to the point where the meter reading is at
maximum.
Note: The output voltage measurement on Zero Fired Power Controllers with a digital voltmeter
will be erratic except at full output. This is due to the variable pulses to regulate the output.
f. Repeat steps 3.3c through 3.3e as necessary, to ensure proper control adjustments have been
made.
g. Turn off the line power to the ZF2/ZF3 and disconnect the test equipment. The ZF2/ZF3 is now
ready for operation.

ZF2/ZF3 SSR Power Controller Troubleshooting
Rev 2 Ametek HDR Power Systems 9
CHAPTER 4 – Troubleshooting
4.1 Customer-Service Program
Although service is seldom necessary, because of the inherent long-term reliability of solid-state
components and conservative design, Ametek HDR Power Systems emphasizes customer satisfaction
by maintaining a rapid-response, 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 5.
4.2 Troubleshooting Typical Symptoms
The ZF2/ZF3 is considered to be operating properly when its output voltage can be satisfactorily varied
from 0% to 97% of the available input voltage by a control signal. Improper operation of the unit is
usually indicated by one of the following symptoms:
a. No output.
b. Full output at all times, with no change resulting from a control signal change.
c. Output variable from some intermediate value to maximum, but cannot be brought to zero.
d. Output variable from zero to some intermediate value, but cannot be brought to maximum.
The symptoms listed may be caused by one or more of the following: an environmental problem,
faulty input-power or load connections, and the ZF2/ZF3 itself. These possible causes should be
investigated as described in Chapters 4.4 through 4.6.
4.3 Static Precautions when Servicing
Servicing should be performed by qualified personnel only, following procedures described herein.
If troubleshooting indicates a need to replace a component on a printed circuit board or possibly the
entire board, measures to prevent electrostatic discharge (ESD) damage must be taken.
a. ALWAYS wear a wrist strap connected to ground through a 1-megohm resistor when working on
printed circuit boards.
b. Use soldering iron with a grounded tip.
c. Use a non-static solder sucker (metallic) or solder removal braid.
WARNING - ELECTRIC SHOCK CAN KILL
HAZARDOUS VOLTAGES exist at the exposed (LINE and LOAD) terminals
unless the line-source fused disconnect or circuit breaker is open or off.
This is true even when the SCR’s are turned off. Always remove power and
properly lock out power to the unit before attempting any service is
performed.
ATTENTION
Printed circuit boards contain sensitive components that can be damaged
by electrostatic discharge (ESD). Observe precautions for handling
electrostatic sensitive devices.

Troubleshooting ZF2/ZF3 SSR Power Controller
10 Ametek HDR Power Systems Rev 2
d. Transport static sensitive components in static shielding bags or rails. A new printed circuit board
should be treated as a static sensitive device. A part completely installed on a board does not
make the part static-safe.
e. If possible, perform printed circuit board maintenance at a work station that has a conductive
covering which is grounded through a 1-megohm resistor. If a conductive table top is unavailable,
a clean steel or aluminum table top is an excellent substitute.
f. Keep plastic, vinyl, Styrofoam or other non-conductive materials away from printed circuit boards.
They are good static generators that do not give up their charge easily.
g. Return goods to Ametek HDR Power Systems in static-safe packaging. This will limit further
component damage from ESD.
h. CAUTION. Do not touch any printed circuit board unless you are wearing a ground wrist strap, as
circuit damage may occur. Grounding kits are also available commercially and can be purchased
through most electronic wholesalers.
4.4 Environmental Problems
Check to see that none of the following environmental problems exist.
Inadequate Cooling. Allow at least 1 inch of air space (in any direction) between the heat sinks and
any item or structure near the ZF2/ZF3 power modules. Heat sink fins should be free of dust or dirt for
proper heat transfer, and free of obstructions which could prevent proper airflow.
Contamination. The unit should be periodically cleaned of all dust and dirt. However, certain kinds of
dust or particles are particularly conductive. A small accumulation of conductive material can cause
component failures from arc-over or complete shorts.
High Ambient Temperature. Lack of a proper ambient-temperature check before installation, or an
increase in ambient temperature, can result in numerous problems. Check the ambient temperature
under existing conditions. If it is 122 ºF (50 ºC) or lower, ambient temperature should not be a
problem. 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. If vibration is isolated as a probable cause of improper operation, standard vibration-
isolation mounting techniques should be employed.
4.5 Input Power and Load Connections
Turn off the power to the ZF2/ZF3 and check all power connections, input and output, to make sure
they are mechanically secure and free of corrosion. Make the same checks at the power source and
load. Visually check insulation on input and load wiring for evidence of damage or overheating.

ZF2/ZF3 SSR Power Controller Troubleshooting
Rev 2 Ametek HDR Power Systems 11
4.6 Correcting Troubles in the ZF2/ZF3 Itself
Table 4.1 provides a comprehensive guide for troubleshooting the ZF2/ZF3.
Table 4.1 Troubleshooting Chart (Symptoms and Solutions)
Cause Solution
No output even with manual control (Zero) turned full CW.
(1a) Open SCR fuse Disconnect power and check the fuse. If it has opened, replace it after
completing (b)
(1b) SCRs not firing Install a good fuse in the circuit, and apply power to the ZF2/ZF3. If the output
is fully controllable using the manual control, then resume normal operation. If
the power output is still zero, contact Ametek HDR Power Systems service.
Maximum power at all times regardless of control setting.
(2a) All SCR networks
shorted
Disconnect power and check the front-to-back SCR pairs by measuring
resistance between terminals L1 (of the SSR) and 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
section defective
Return the power to the unit. If the problem persists, contact Ametek HDR
Power Systems service.
Output is variable but can’t be brought to zero with ZERO control
(3a) SCR network
shorted
Check SSR network per solution 2a.
(3b) Firing control
section defective
Contact Ametek HDR Power Systems service for assistance
Output is variable but can’t be brought to maximum with SPAN control
(4a) Firing control
section defective
Contact service for assistance

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

ZF2/ZF3 SSR Power Controller Service
Rev 2 Ametek HDR Power Systems 13
CHAPTER 5 - Service
5.1 Communication Procedures
If operational problems arise that cannot be resolved by review of all related procedures given in this
manual, please contact “Service” at Ametek HDR Power Systems. Please have your model number
and serial number of the unit ready as it is required for our technicians to assist you.
If you are experiencing downtime or other critical circumstances during our off-hours (see above), and
wish to telephone us, please inform our 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.
When we are reached by phone, our first step will be to give you over-the-phone assistance at no
charge. If the problem cannot be resolved by phone we will arrange for service at your site or by
shipment to Ametek HDR Power System, as you request. We will make every possible attempt to
support your emergency, on-site needs, regardless of how contacted.
5.2 Spare Parts Orders – Routine or Emergency
Requests for spare parts should be directed to “Inside Sales” at Ametek HDR Power Systems during
normal hours, if possible, or via any method shown above for off-hours. Often we can provide same-
day delivery for critical circumstances. When contacting us, please present as much information as
possible – the related equipment Model Number and Serial Number; the required part name and any
identifying part of vendor number(s); and your time needs. An approved Purchase Order Number
should be given with your order.
NORMAL BUSINESS HOURS 8 am to 5 pm, USA EASTERN TIME ZONE, Monday
through Friday.
TELEPHONE [phone]. Our Answering Service will accept your message
during all off-hours, including weekends. We receive those messages at 8 am on
the next normal workday. We will respond at the earliest time possible, within your
time zone and normal work day.
FACSIMILE 614-308-5506. Automatic reception during all hours.

Service ZF2/ZF3 SSR Power Controller
14 Ametek HDR Power Systems Rev 2
5.3 Spare Parts List
The following table lists the minimum recommended quantities for spare parts for the ZF2/ZF3 SSR.
As spares are used, replacements should be ordered.
Table 5.1 ZF2 SSR Spare Parts List
Item Item No. Qty
15 Ampere Units
Fuse, 20 A, 700 V 7520070 1
PCB Assy, ZF2 Firing Circuit (-C Models only) 2081000 1
PCB Assy, ZF2 Firing Circuit 2082000 1
SSR, 50 A 7451110 1
MOV 660 V, 230 J 6600010 1
25 Ampere Units
Fuse, 32 A, 700 V 7530070 1
PCB Assy, ZF2 Firing Circuit (-C Models only) 2081000 1
PCB Assy, ZF2 Firing Circuit 2082000 1
SSR, 50 A 7451110 1
MOV 660 V, 230 J 6600010 1
40 Ampere Units
Fuse, 50 A, 700 V 7550070 1
PCB Assy, ZF2 Firing Circuit (-C Models only) 2081000 1
PCB Assy, ZF2 Firing Circuit 2082000 1
SSR, 90 A 7491110 1
MOV 660 V, 230 J 6600010 1
70 Ampere Units
Fuse, 80 A, 700 V 7580070 1
PCB Assy, ZF2 Firing Circuit (-C Models only) 2081000 1
PCB Assy, ZF2 Firing Circuit 2082000 1
SSR, 90 A 7491110 1
MOV 660 V, 230 J 6600010 1
Table 5.2 ZF3 SSR Spare Parts List
Item Item No. Qty
15 Ampere Units
Fuse, 20 A, 700 V 7520070 1
PCB Assy, ZF1 Firing Circuit 2099148 1
SSR, 50 A 7451110 1
MOV 660 V, 230 J 6600010 1
25 Ampere Units
Fuse, 32 A, 700 V 7530070 1
PCB Assy, ZF1 Firing Circuit 2099148 1
SSR, 50 A 7451110 1
MOV 660 V, 230 J 6600010 1
40 Ampere Units
Fuse, 50 A, 700 V 7520070 1
PCB Assy, ZF1 Firing Circuit 2099148 1
SSR, 90 A 7491110 1
MOV 660 V, 230 J 6600010 1
70 Ampere Units
Fuse, 80 A, 700 V 7580070 1
PCB Assy, ZF1 Firing Circuit 2099148 1
SSR, 90 A 7491110 1
MOV 660 V, 230 J 6600010 1

ZF2/ZF3 SSR Power Controller Service
Rev 2 Ametek HDR Power Systems 15
5.4 Drawing List
This Chapter contains drawings that show outline dimensions, installation wiring, and printed circuit
board component locations, as well as an overall schematic of the ZF2 and ZF3. These drawings are
useful in installing and troubleshooting all ZF2/ZF3 models. Table 5.3 lists the drawings for each
model, Appendix provides simplified drawings in the order of their appearance. Drawings may also be
downloaded from www.hdrpower.com.
Table 5.3 ZF2/ZF3 SSR Drawing List
Drawing Title Drawing No.
Schematic, ZF2 SSR (-C Models) S2710017
Schematic, ZF2 SSR S2710018
Schematic, ZF3 SSR S2710034
Outline & Mounting, ZF2 SSR – 15 - 40 A (-C Models) M2710017
Outline & Mounting, ZF2 SSR – 15 - 40 A M2710018
Outline & Mounting, ZF2 SSR – 70 A (-C Model) M2710081
Outline & Mounting, ZF2 SSR – 70 A M2710082
Outline & Mounting, ZF3 SSR – 15 - 40 A M2710034
Outline & Mounting, ZF3 SSR – 70 A M2710083

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