Indeeco 110-Z3 User manual

Indeeco Controls
425 Hanley Industrial Court Telephone: [phone]
St. Louis, Missouri 63144 www.indeeco.com
110 - Z3
OPERATING MANUAL
TABLE OF CONTENTS
Introduction ........................................... p. 2
Features .............................................. p. 2
Description ........................................... p. 3
Theory of Operation............................. p. 3
Installation............................................ p. 4
Electrical Connections.......................... p. 5
Options ................................................. p. 6
Warranty............................................... p. 6
Specifications ........................................ p. 7
Troubleshooting .................................... p. 8
Ordering Codes…………………………. p. 9
Wiring Diagrams .................................... p.
10 - 18
Dimensional Drawings ........................... p . 19 - 28
Declaration of Conformity ..................... p . 29
NRNT FILE # E350716
ENM - 3716 - 00

INTRODUCTION
Congratulations on your purchase of an INDEECO 110-Z3 series power control. This manual
was designed to assist you in installing, operating and maintaining your new power control in a
safe manner. Upon reading and following the instructions in this manual, you will be rewarded
many years of trouble free service from your new 110-Z3. If reading manuals is not for you, it is
essential that you at least read the captions followed by the safety warnings; they are located
throughout the manual and are very easy to identify.
Indicates important installation, operating, servicing instructions
Indicates dangerous voltage present and risk of electric shock
FEATURES
 UL 508, cUL508 listed, CE certified
 compact and light weight
 100 % solid state circuitry
 over-rated SCR power modules
 over-sized heat sink
 full power ratings up to 50ºC (122ºF) ambient temperature
 optically isolated 4-20 mA input standard
 variable time base provides high resolution control
 electrically isolated chassis and heat sinks to 600 Amps
 gold alodined chassis and heat sink
 I²T fusing and MOV protection on all power SCR's
 SanRex, SemiKron, International Rectifier and Fairchild semiconductors
 double sided FR4 VO-94 rated glass epoxy PCB's
Page 2

DESCRIPTION
The 110-Z3 is a proportional, zero voltage switched, two leg controlled, three phase power
controller capable of delivering 0-99% of the applied line voltage to directly connected electric
heaters. It will not control high inrush loads (tungsten lamps), transformers or motors. This is
accomplished by time proportionally switching SCR's on and off. Modular construction allows
for simple and solderless field serviceability. There are four field replaceable items:
printed circuit board
fuses
SCR packages
MOV's (metal oxide varistors)
THEORY OF OPERATION
The standard input signal (4-20mA) is applied to the blue input terminal block, processed and fed to
optical couplers. The output of each opto coupler controls its respective SCR. An I²T fuse connected in
series with the input provides over current protection in the event of external wiring shorts, or too large of
a heater load. Additionally, a MOV (metal oxide varistor) is connected in parallel with each SCR,
providing voltage spike protection to the controller.
Zero voltage switching controls proportionally turn on and off each full cycle of the power line. By
varying the number of AC power line cycles, the SCR provides power to the heaters. With a variable
time base, the optimum number of cycles turned on/off is achieved. This method produces less RFI line
noise than phase angle fired SCRs. Power factor is 100%, while harmonic distortion is limited. Charts
below, left and center show 25% power output using variable time based zero voltage switching. The
chart on the right shows 50% output.
INDEECO 110-Z3 variable time base SCR firing. Note how half cycles can be turned on and off
providing 0.08 second resolution on 60Hz power lines.
Page 3

INSTALLATION
WARNING: FIRE HAZARD!! Even the best electronic components CAN FAIL
SHORTED, KEEPING FULL POWER ON! Provide a completely SEPARATE (redundant) OVER
TEMPERATURE SHUTDOWN MEANS to switch power off if safe temperature is exceeded.
Solid state
devices are never “off” unless you physically disconnect the incoming electrical power to the SCR.
WARNING: HIGH VOLTAGE!! This control must be installed in a GROUNDED
enclosure. Provide a safety interlock on door to remove power before gaining access to device.
The ground/earth connection can be made to the 110-Z3 chassis mounting point on heat sink / side panel.
This controller must be installed by a qualified electrician in accordance with any and all
local and national electric codes including NEC and any other applicable codes.
First things first, do you have the proper controller for your application? Check the INDEECO 110-Z3serial tag and
verify the correct voltage/ ampere ratings and input control signal for your application.
After verifying you have the proper controller, the next most important item is adequate cooling/ ventilation. All
INDEECO power controllers are rated to deliver full power to their respective load(s) at an ambient temperature not
to exceed 50ºC. Use this formula to calculate the minimum size enclosure required.
Heat is the worst enemy to any electrical device, including power controllers. Orient heat sink fins and chassis
channel in a vertical position, providing adequate air flow above and below unit. The cooler the unit operates, the
longer it will provide seamless, reliable service. Fan cooled units should have fans on bottom facing up.
As a quick rule for spacing is take footprint measurement of SCR and use that as ideal spacing distance for SCR and
other components.
Example; if the SCR is 12” x 12”, space other objects 6” above, 6” below & 6” side to side for best heat dissipation.
Plastic wire duct is an insulator and blocks air flow.
The dryer and cleaner, the better! Over time, a combination of moisture and contaminates will lead to failure due to
corrosion and insulation breakdown (arcing and sparking). If the controller absolutely must be installed in a harsh
and corrosive environment, it is recommended that an air conditioned NEMA 4X or similar type of environmentally
sealing enclosure be used during installation.
Number of SCR’s X 1.2 VOLTS X MAXIMUM HEATER CURRENT = TOTAL WATTS
DISSIPATED
Example: 2 x 1.2 x 60 amps = 144 watts that the power controller has to dissipate
Page 4

ELECTRICAL CONNECTIONS
Again, this work must be performed by a qualified electrician and in
accordance with any and all local and national codes that may apply. Please refer to the wiring
diagrams (pgs. 10 - 18).
To reduce the risk of electrocution, TURN ALL POWER OFF to wires that will be
connected to the power control before making any connections. The 110-Z3 controller should be
installed in a metal enclosure for protection against electrocution. Remember, solid state devices
are never “off” unless you physically disconnect the incoming electrical power to the SCR.
1200 amp controller heat sinks are on line voltage!!
AC POWER INPUT:
Power input (AC MAINS) is connected to lugs labeled "LINE 1" and "LINE 2"(see figure 1 for correct wire size and
torque specs.) Line 3 is directly connected to third leg of heater load.
LOAD CONNECTION:
Load connections are equally simple; connect the load/ heater to lugs labeled "HTR 1" and "HTR 2" (see figure 1 for
correct wire size and torque specs).
NOTE: For open delta or 4 wire "wye" connected loads use INDEECO model 110-Z6, 3 phase, 3 leg, 6 SCR
control.
The 110-Z3 is capable of driving unbalanced loads, but it is highly recommended to equally BALANCE LOADS
BETWEEN ALL THREE PHASES (to provide consistent tracking between all three phases).
The I²T Semiconductor fuses that are built into the SCR do NOT qualify as branch
circuit protection. Separate branch circuit overcurrent protection is required. This overcurrent protection needs to be
provided in accordance with both national and local codes of the inspecting authority.
Check heater resistance to insure heater current will not exceed fuse ratings. Controllers DO NOT blow fuses -
excess heater current does. Check for heater wiring shorts, loose connections, shorted load connections which will
instantly blow expensive fuses.
Page 5

INPUT CONTROL SIGNAL:
Connect the control signal to the blue terminal block labeled "4-20mA INPUT" observing proper polarity (positive
to "+" and negative to "-"). Terminal torque is 5 In-Lbs for mA input block.
THERMOSTAT for FAN FAILURE:
On all INDEECO SCR Controls 150 Amps and above, fans are used to cool the SCR heat sinks. INDEECO mounts
a Snap-disc thermostat to the heat sink. If the fan fails, air is blocked or a safe ambient temperature is exceeded, the
thermostat will activate. This thermostat can be used to break I/O relay logic, trigger alarms or shut down a power
contactor. See wiring diagram for thermostat wiring page 16.
OPTIONS
"R" RELAY OPTION: For 10-32 VDC or 120VAC Signal Input to turn 110-Z3 into On/Off controller,
use "R" relay option. Call out as "-R32" or "-R120"
For manual control use INDEECO model MAP. Isolated Potentiometer 4-20mA signal card.
For LINEAR 0-5 or 0-10 VDC Analog Signal use MAI milliamp interface card.
MAI-05V takes a 0-5VDC signal input and outputs 4-20mA.
MAI-10V takes a 0-10VDC signal input and outputs 4-20mA.
For third Leg Fusing add "-3RD" to part number. All fuses come mounted to chassis w/lugs. Higher amp
fuse (over 100A) come with block & lugs.
WARRANTY
All INDEECO 110-Z3 SCRs carry a full five year, warranty from date of purchase, parts and labor
warranty against component failure and defects in workmanship. In the event your controller fails to
perform properly, contact INDEECO to obtain a return authorization number. Controllers sent to
INDEECO for warranty service that have no apparent defect will be treated as a standard repair and a
$50.00 charge will be applied. INDEECO will repair or replace any unit that failed due to defective parts
or assembly. This warranty DOES NOT cover damage due to shipping, abuse, misapplication or
operation beyond specified rating. Furthermore, fuses and improperly fused SCR's are NOT COVERED
by this warranty. INDEECO is not responsible for any subsequent or other damage experienced in use of
this device.
Page 6

SPECIFICATIONS
INPUT VOLTAGE:…………………………… see model description
OUTPUT VOLTAGE:………………………… 0-99% of input voltage
CURRENT CAPACITY:……………………….see model description
CONTROL SIGNAL:…………………………..4-20mA @ 6 volts DC
INPUT IMPEDANCE:………………………….300 ohms
4-20mA INPUT TERMINAL TORQUE RATING 5 In-Lbs
COOLING: 30-100 amp…………………... convection
150-1200 amp……………….. fan(s) 120VAC
THERMOSTAT:………………………………. 190ºF (fan cooled units only)
POWER DISSIPATION (Watts):………………..2.4 x maximum current
draw of heater load
DIMENSIONS:………………………………… see dimensional drawings
WEIGHT: NET SHIPPING
30 amp……………………………….,. 7 lbs. 9 lbs.
40-60 amp……………………………. 8 lbs. 11 lbs.
80-100 amp…………………………... 13 lbs. 14 lbs.
150 amp………………………………. 35 lbs. 53 lbs.
200-350 amp…………………………. 38 lbs. 55 lbs.
600 amp………………………………. 50 lbs. 75 lbs.
1200 amp……………………………... 180 lbs. 250 lbs.
Wire Gauge and Torque Specifications for 90ºC Temp Wire
Power Control
Maximum
Current
Rating/ Circuit
Copper Wire Only
MINIMUM AWG Wire Lug Torque Spec.
(IN-LBS.)
Lug Size
30A 10AWG 35 10 AWG
40A 8AWG 40 1/0 - 14
60A 6AWG 45 1/0 - 14
80A 4AWG 45 1/0 - 14
100A 3AWG 50 1/0 - 14
150A 1AWG 180 250MCM - 6
200A 3/0 AWG 250 250MCM - 6
225A 3/0 AWG 250 250MCM - 6
250A 4/0 AWG 250 250MCM - 6
350A TWO: 4/0 AWG 250 TWO: 250MCM-6
600A TWO: MCM 350 325 TW0: 600MCM-2
1200A FOUR: MCM 350 375 FOUR: 600MCM-2
Figure 1
Ground wire should be mounted to chassis of SCR. The hardware used to mount SCR to back plate/enclosure can be
used for ground lug. Size of the ground wire should be able to supply enough current capacity to match line and load
power levels. Use copper wire only. Follow NEC NFPA 70 National Electrical Code.
Page 7

TROUBLESHOOTING
SYMPTOM
POSSIBLE CAUSE POSSIBLE SOLUTION
Heaters do not heat up no power to 110-Z3 verify correct input voltage between the
three "LINE" lugs on 110-Z3.
blown fuses in 110-Z3 check for heater and wiring shorts, check
current rating on heaters and replace fuses
as necessary. will blow fuses on tungsten
lamps or transformers
no control signal to 110-Z3 verify 4-20mA signal is hooked up
correctly (positive to "+" and negative to
"-") on the source and 110-Z3.
defective heaters check for output voltage between the
three "HTR" lugs. If voltage is present,
check
wiring to the heaters and the actual
heaters
defective source measure the output of the source
(temperature controller, PLC, etc.) by
placing a milliamp meter in SERIES
with the signal wires.
Heaters on one leg are on all
the time, others 25- 50% short to ground, sneak path in between lines Heater or power wires are shorted to ground. Third leg (uncontrolled) is
conducting. Use amp probe to find were
current draw is going. Use meg-ohm
meter to find short to ground or in
between lines.
Heaters are on full all the time incorrect source signal verify 4-20mA signal varies from 4-
20mA
shorted SCR's in controller with power applied, measure voltage drop
across "LINE 1" and "HTR 1", if voltage
reading is less than one volt, the
associated SCR is bad. Perform same
test on "LINE 2" to "HTR 2"
Process will not stabilize,
control signal oscillates incorrect temperature control tuning, slow
temperature sensing
re-tune temperature control, use faster
sensor, place sensor closer to process
Page 8

110 - Z3 SERIES SCR POWER CONTROLLERS
ORDERING CODES
110 - Z3 - _________-__________-__________-_________
Voltage Amperes Options Options
VOLTAGE DESIGNATIONS
240 = 200-240 VAC 50/60Hz
380 = 380 VAC 50/60Hz
480 = 415-480 VAC 50/60Hz
600 = 575-600 VAC 50/60Hz
LOAD IN AMPS:
30, 40, 60, 80, 100, 150
200, 225, 250, 350, 600, 1200
OPTIONS:
Thru-hole Mount (only on 40, 60, 80 & 100 Amp units). Add – TH to part number.
Specify if you need RTV for NEMA 4/4X
R Option
10-32 VDC on-off command signal = R32
120 VAC on-off command signal = R120
Third Leg Fuse Option = 3RD
Example: 110-Z3-480-100 is a zero voltage switched, three phase 2-leg, 480VAC, 100 Ampere SCR
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