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