Control Concepts Fusion Instruction Manual

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© Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799
FUSION
INSTALLATION &
MAINTENANCE MANUAL
SCR POWER CONTROLLERS
FUSION Installation Manual Revision 350.3
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CONTROL CONCEPTS, INC. 2 YEAR LIMITED WARRANTY
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.
If any CONTROL CONCEPTS, INC. product is found to be defective in material or workmanship during the applicable
warranty period, CONTROL CONCEPTS, INC.’s entire liability, and purchasers sole and exclusive remedy, shall be the
repair or replacement of the defective product at CONTROL CONCEPTS, INC.’s election. CONTROL CONCEPTS,
INC. shall not be liable for any costs or expenses, whether direct or indirect, associated with the installation, removal or
re-installation of any defective product. All shipping and freight costs are the responsibility of the customer. CONTROL
CONCEPTS, INC.’s limited warranty shall not be effective or actionable unless there is compliance with all installation
and operating instructions furnished by CONTROL CONCEPTS, INC., or if the products have been modified or altered
without the written consent of CONTROL CONCEPTS, INC., or if such products have been subject to accident, misuse,
mishandling, tampering, negligence or improper maintenance. Any warranty claim must be submitted to CONTROL
CONCEPTS, INC. in writing within the stated warranty period.
CONTROL CONCEPTS, INC.’s limited warranty is made in lieu of, and CONTROL CONCEPTS, INC. disclaims all other
warranties, whether expressed or implied, including but not limited to any IMPLIED WARRANTY OF MERCHANTABILITY,
ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, any implied warranty arising out of a
course of dealing or of performance, custom or usage of trade.
CONTROL CONCEPTS, INC. SHALL NOT, UNDER ANY CIRCUMSTANCES BE LIABLE FOR ANY DIRECT,
INDIRECT, INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO, LOSS
OF PROFITS, REVENUE OR BUSINESS) OR DAMAGE OR INJURY TO PERSONS OR PROPERTY IN ANY WAY
RELATED TO THE MANUFACTURE OR THE USE OF ITS PRODUCTS. The exclusion applies regardless of whether
such damages are sought based on breach of warranty, breach of contract, negligence, strict in tort, or any other legal
theory, even if CONTROL CONCEPTS, INC. has notice of the possibility of such damages.
By purchasing CONTROL CONCEPTS, INC.’s products, the purchaser agrees to the terms and conditions of this
limited warranty.
WARNING: The Control Concepts, Inc. power controllers use power thyristors to switch voltage to the connected
load. Line voltage must be assumed at the output terminals at all times, even when the control signal has been
removed and the load voltage appears to be off. It has been mandated by the National Electrical Code and the
Occupational Safety and Heath Act of 1970 that a physical disconnect be opened ahead of all remotely actuated
controls before performing any maintenance work on the controller or its connected load.
PROPRIETARY DATA
© Copyright 2009, Control Concepts, Inc. Chanhassen, MN 55317
The information and design disclosed herein are the property of Control Concepts, Inc. and may not be used,
reproduced or disclosed in any form except as granted in writing by:
CONTROL CONCEPTS, INC
18760 LAKE DRIVE EAST
CHANHASSEN, MN 55317
PHONE: [phone]
TOLL FREE: [phone]
FAX: [phone]
www.ccipower.com
© Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799
FUSION Installation Manual Revision 3.50.3

TABLE OF CONTENTS
DECLARATION OF CONFORMITY .............................................................................................ii
CERTIFICATE OF COMPLIANCE ..............................................................................................iv
1. RECOMMENDED FUSING..................................................................................................... 1
2. INSTALLATION ....................................................................................................................... 2
2.1 Mounting Considerations for All AC Controllers ........................................................... 2
2.1.1 Single Phase One Zone (50-400 Amps) .......................................................... 3
2.1.2 Single Phase, Two Zone (50-400 Amps) ......................................................... 4
Three Phase - Two Leg (50-400 Amps).................................................................... 4
2.1.3 Single Phase, Three Zone (50-400 Amps) ...................................................... 5
Three Phase - Three Leg (50-400 Amps) ................................................................. 5
2.1.4 Single Phase, Four Zone (50-400 Amps) ........................................................ 6
2.1.5 Single Phase, One Zone (500-1200 Amps) ..................................................... 7
2.1.6 Single Phase Two Zone (500-1200 Amps) ...................................................... 8
Three Phase - Two Leg (500-1200 Amps)................................................................ 8
2.1.7 Single Phase Three Zone (500-1200 Amps) ................................................... 9
Three Phase - Three Leg (500-1200 Amps) ............................................................. 9
2.1.8 Single Phase, Four Zone (500-1200 Amps) .................................................. 10
2.2 Mounting Considerations for All DC Controllers..........................................................11
2.2.1 Single Phase (45 - 360 Amps) DC................................................................. 12
2.2.2 Single Phase (720 - 1080 Amps) DC............................................................. 13
2.2.3 Three Phase (60 - 490 Amps) DC ................................................................. 14
2.2.4 Three Phase (975-1400 Amps) DC ............................................................... 15
2.3 Remote Display Kit..................................................................................................... 16
2.3.1 Mounting Considerations ............................................................................... 16
2.3.2 Mounting Instructions..................................................................................... 17
3. WIRING ................................................................................................................................. 19
3.1 Torque Specifications ................................................................................................. 19
3.2 Universal Input Power ................................................................................................ 20
3.3 AC Cable Entry Heights / Wire Acceptance ............................................................... 21
3.4 DC Cable Entry Heights / Wire Acceptance ............................................................... 22
3.4.1 Single Phase (45 - 360 Amps) DC................................................................. 22
Three Phase (60 - 490 Amps) DC ......................................................................... 22
3.4.2 Single Phase (720 - 1080 Amps) DC............................................................. 23
Three Phase (975 - 1400 Amps) DC ...................................................................... 23
3.5 AC Line / Load Connections....................................................................................... 24
3.5.1 Single Phase, One Zone................................................................................ 24
3.5.2 Single Phase, Two Zone................................................................................ 25
3.5.3 Single Phase, Three Zone ............................................................................. 26
3.5.4 Single Phase, Four Zone ............................................................................... 27
3.5.5 Three Phase - Two Leg.................................................................................. 28
3.5.6 Three Phase - Three Leg - Delta or Three Wire Wye .................................... 29
3.5.7 Three Phase - Three Leg - Inside Delta......................................................... 30
3.5.8 Three Phase - Three Leg - Four Wire Wye.................................................... 31
3.6 DC Line / Load Connections ...................................................................................... 32
3.6.1 Single Phase - DC ......................................................................................... 32
3.6.2 Three Phase - DC.......................................................................................... 33
3.7 Connectors................................................................................................................. 34
3.7.1 P1-12 Pin Command Connector.................................................................... 34
3.6.2 External Feedback......................................................................................... 34
3.7.4 SYNC-GUARD™ ........................................................................................... 35
3.7.3 P2 - 6 Pin Command Connector.................................................................... 35
4. AUX I/O Card (Optional) ........................................................................................................ 36
4.1 P3 - 10 Pin Aux I/O Connector ................................................................................... 36
APPENDIX A: Changing from Inside Delta to Delta or 3-Wire Wye Load ................................. 37
APPENDIX B: Changing from 4 Wire Wye to Delta or 3-Wire Wye Load ................................. 38

i
© Control Concepts Inc., 2014
www.ccipower.com 1-800-765-2799
FUSION Manual Certications
Listed 3L32 - Industrial Control Equipment
100kA Short Circuit Current Rating*
File Number E136219
*On select models with appropriate fusing.
EN60947-4-3
IP 20
See CE Declaration of Conformity
Part 15 Subpart B
Class A Device
See RoHS Certificate of Compliance

ii
© Control Concepts Inc., 2014
www.ccipower.com 1-800-765-2799
FUSION Manual Certications
FUSION Series SCR Power Controller
Control Concepts, Inc.
18760 Lake Drive East
Chanhassen, MN 55317 USA
Declares that the following product:
Designation: FUSION Series Power Controller
Model Numbers: Model Fusion followed by ZC, PA or DC, followed by 1, 2 or 3, followed by 1 through 9 or A
through E, followed by O, S or E, may be followed by numbers and/or letters, may be followed by
numbers and/or letters, may be followed by NS, may be followed by numbers and/or letters.
Classification: Solid State Power Controller, Class I, Pollution Degree II
Rated Voltage: 24 - 600 Vac
Rated Frequency: 45 - 65 Hz
Meets the essential requirements of the following European Union Directive(s) using the relevant section(s) of the
normalized standards and related documents shown:
EN 60947-4-3: 2000 Low-voltage switchgear and controlgear
EMC Directive 2004/108/EC
-EN 61000-6-2: 2005
-EN61000-4-2: 1995 + Amendments A1:1998 + A2: 2001 ESD Immunity
-EN61000-4-3: 2006 Radiated Immunity
-EN61000-4-4: 2004 + Corrigendum 2004 EFT / Burst Immunity
-EN61000-4-5: 2006 Surge Immunity
-EN61000-4-6: 2007 Conducted Immunity
-EN61000-4-8: 1993 + Amendment A1: 2001 Magnetic Field Immunity
-EN61000-4-11 Second Edition: 2004 Voltage Dips & Interruptions
-EN 61000-6-4: 2007 Conducted & Radiated Emissions
Note 1: All power terminals must be populated as to keep the controller touch safe to comply with EN 60947-4-3.
Note 2: Controller must be mounted in a shielded enclosure to comply with EMC Directive 2004/108/EC.
Note 3: Controller must have appropriate line and control power filter to comply with EN61000-6-2.
_________________________________________________________________________________________________
Third party conformance testing conducted by TÜV America.
TÜV SÜD America Inc.
Suite 104
1774 Old Highway 8 NW
New Brighton, MN 55112-1891
_________________________________________________________________________________________________
Name of Authorized Representative: Cory Watkins
Title of Authorized Representative: President
Place of Issue: Chanhassen, Minnesota, USA
Date of Issue: November 2009
_______________________________ _______________
Signature of Authorized Representative Date
DECLARATION OF CONFORMITYDECLARATION OF CONFORMITY

iii
© Control Concepts Inc., 2014
www.ccipower.com 1-800-765-2799
FUSION Manual Certications
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. The line input
power filter however, will need to be sized accordingly for your load. Please contact Schaffner EMC Inc. for
help finding the appropriate filter. Schaffner EMC Inc.
52 Mayfield Avenue | Edison, New Jersey 08837 / USA
T 1-800-367-5566 | T 732-225-9533 | F 732-225-4789
[e-mail] | http://www.schaffner.com/us
*No filtering is required for emissions.
Wire filters as shown below:
1 Phase Controller 3 Phase Controller
Other wire diagrams are available for models not listed here by contacting Control Concepts, Inc.
ATTENTION
This product has been designed for class A equipment. Use of this product in domestic
environments may cause radio interference, in which case the user may be required to
employ additional mitigation methods.
NOTICE
This product has been designed for environment A. Use of this product in environment
B may cause unwanted electromagnetic disturbances, in which case the user may be
required to take adequate mitigation measures.
100-240Ref
Vac
PEGND
L
O
A
D
Load A
Line A Line BAC/LAC/N PEGND
FN2030
-3-06
LineI nput
Filter
PEGND Line A Line B Line C
100-240
Vac
LineI nput
Filter
AC/LAC/N
FN2030
-3-06
PEGND PEGND
PEGND

iv
© Control Concepts Inc., 2014
www.ccipower.com 1-800-765-2799
FUSION Manual Certications
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.
FUSION FUSION- - - - - - 11/13/2009
FUSION CF CF- - - - - - 12/20/2010
Authorized Signature Date Last Updated
Cory Watkins, President
CONTROL CONCEPTS, INC.
18760 LAKE DRIVE EAST
CHANHASSEN, MN 55317
[phone]
1-800-765-2799
FAX [phone]
www.ccipower.com
CERTIFICATE OF COMPLIANCECERTIFICATE OF COMPLIANCE
PB-FREE/REDUCTION OF HAZARDOUS SUBSTANCE (RoHS)

1
© Control Concepts Inc., 2014
www.ccipower.com 1-800-765-2799
FUSION Installation Manual Revision 3.50.3
It is recommended that the controller be protected by fast acting class ‘J,’ fast acting ‘L’ or ‘T’ fuse(s).
Branch rated fuses are required to meet Short Circuit Current Rating (SCCR) requirements. The
table below shows the controller size with the recommended fuse size.
Frame Size Fuse Size (Amps)
600 V Rated
CCI P/N
for Class T
1Ø OR 3Ø AC 1Ø DC 3Ø DC
1 50A 45A DC 60A DC 60 Fast Acting J or T 0042110-0460-360
280A - - 100 Fast Acting J or T 0042110-0460-410
3 100A 90A DC 120A DC 125 Fast Acting J or T 0042110-0460-412
4 130A - - 175 Fast Acting J or T 0042110-0460-417
5 160A 145A DC 195A DC 200 Fast Acting J or T 0042110-0460-420
6 200A - - 250 Fast Acting J or T 0042110-0460-425
7 240A 220A DC 290A DC 300 Fast Acting J or T 0042110-0460-430
8 320A - - 400 Fast Acting J or T 0042110-0460-440
9 400A 360A DC 490A DC 500 Fast Acting J or T 0042110-0460-450
A500A - - 600 Fast Acting J or T 0042110-0460-460
B 650A - - 800 Fast Acting J or T 0042110-0460-480*
C800A 720 A DC 975A DC 1000 Fast Acting L or T 0042110-0460-510*
D 1000A - - 1200 Fast Acting L or T 0042110-0460-512*
E1200A 1080A DC 1400A DC 1500 Fast Acting L 0042270-0460-515
(Fast Acting L)
* UL listed but not CSA approved. Contact Control Concepts for information on CSA approved fusing.
Control Concepts carries an inventory of branch-rated fuses and fuse blocks for customers to
purchase.
1. RECOMMENDED FUSING

2© Control Concepts Inc., 2014
www.ccipower.com 1-800-765-2799
FUSION Installation Manual Revision 3.50.3
2. INSTALLATION
2.1 Mounting Considerations for All AC Controllers
Mount 50 Amp controllers vertical for convection cooling. All other controllers have forced air cooling
and may be mounted horizontally or vertically.
The keep out area on the top and bottom is for air circulation. The top and bottom of the controller
must have a minimum of 3.00 [76.2] free from obstructions as measured from fan guards.
Dimensions above are measured from the edge of base plate.
Mounting hardware: 50 - 400 Amp 1/4-20 or M6 bolts with flat and lock washers
(Not included) 500 - 1200 Amp 5/16 or M8 bolts with flat and lock washers
P1, P2 and P3 protrude approximately 0.50 [12.7] from the left side of this figure. When using the
remote display, this distance is approximately 2.25 [57.2]. They are required for operation but
may be removed for wiring. 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.
Keep Out Area
Air Flow
Frame Size (Amp)
50 - 400 500 - 1200
A1.82 [46.2] 1.67 [42.4]
B2.31 [58.7] 2.22 [56.4]
Depth9.57 [243.0] 11.21 [284.7]
B
A
P3
Dimensions:
Inches [mm]
Keep out area for top and bottom:
* Depth with DeviceNet adaptor:
50-400 Amp - 9.82 [249.4]
500-1200 Amp - 11.46 [291.1]
*
P1
P2
Remote
Display

3
© Control Concepts Inc., 2014
www.ccipower.com 1-800-765-2799
FUSION Installation Manual Revision 3.50.3
PE GROUND M6 STUD
13.44
[341.4]
14.03
[356.5]
0.487 [12.4]
0.345 [8.8]
0.98 [24.8]
4.09 [103.9]
5.96 [151.4]
Ø0.281 [7.1]
R0.141 [3.6]
R0.313 [8]
0.50 [12.7]
2.1.1 Single Phase One Zone (50-400 Amps)
Height
14.03 [356.5]
Width
5.96 [151.4]
Depth
9.57 [243.0]
Amp Weight (lbs[kg])
50 14 [6.4]
80 14 [6.4]
100 14 [6.4]
130 15 [6.8]
160 15 [6.8]
200 15 [6.8]
240 15 [6.8]
320 17 [7.7]
400 17 [7.7]
Dimensions:
Inches [mm]