This document is an installation and maintenance manual for Compact FUSION SCR Power Controllers, manufactured by Control Concepts Inc. It provides comprehensive information for the proper installation, operation, and maintenance of these devices.
Function Description:
The Compact FUSION SCR Power Controllers are designed to regulate power to various loads. SCR (Silicon Controlled Rectifier) power controllers are solid-state devices used for precise control of AC power, typically for resistive heating applications, but can also be used for other types of loads. These controllers are equipped with fast-acting, branch-rated Class T fuses for safety and compliance. They are designed to be mounted vertically for convection cooling, and proper airflow is crucial for their operation. The controllers can be configured for single-phase, two-phase, three-phase (two-leg or three-leg), and four-zone applications, with or without pass-through functionality, and for Delta or Wye load configurations. They offer various input power options and can be integrated with external feedback and auxiliary I/O cards for enhanced control and monitoring.
Important Technical Specifications:
- Certifications:
- cULus Listed: Industrial Control Equipment, 100kA Short Circuit Current Rating (File Number E136219).
- CE Marked: EN60947-4-3, IP 20. Includes compliance with EMC Directive 2004/108/EC and various EN61000 standards for immunity and emissions.
- FCC Compliant: Part 15 Subpart B, Class A Device.
- RoHS Compliant: Pb-Free.
- Power Ratings:
- Rated Voltage: 24 - 600 Vac.
- Rated Frequency: 45 - 65 Hz.
- Ampere Ratings: Available in various current ratings from 10A to 160A.
- Fusing:
- Requires fast-acting, branch-rated Class T fuses.
- Recommended fuse sizes (Amps) for 600V Rated: 15A (10A controller), 30A (25A controller), 60A (50A controller), 100A (80A controller), 125A (100A controller), 150A (125A controller), 200A (160A controller).
- Universal Input Power:
- The universal input power supply is rated for 100 - 240 Vac at 50/60 Hz.
- Internally fused with a 4 Amp fast blow fuse.
- Typical power consumption @ 120 VAC (Watts) varies by amperage and zone configuration (e.g., 10-25A: 23.4W for 1-zone, 28.3W for 2-zone; 160A: 53.4W for 1-zone, 58.3W for 2-zone).
- Mounting Dimensions:
- Single Module Controllers: Height 14.03 inches [356.5 mm], Width 5.96 inches [151.4 mm], Depth 9.57 inches [243.0 mm]. Weight ranges from 14.0 - 15.5 lbs [6.4-7.0 kg] for 10-50A, to 15.5 - 17.5 lbs [7.0-7.9 kg] for 160A.
- Two Module Controllers: Height 14.03 inches [356.5 mm], Width 9.61 inches [244.1 mm], Depth 9.57 inches [243.0 mm]. Weight ranges from 22.5 - 24.5 lbs [10.2-11.1 kg] for 10-50A, to 26.5 - 28.5 lbs [12.0-12.9 kg] for 160A.
- Keep Out Area: Minimum of 3.00 inches [76.2 mm] free from obstructions above and below the base plate for proper air circulation.
- Remote Display Kit:
- IP65 rated for total ingress protection against dust and protected against jets of water.
- UL Type 1 and UL Type 12 enclosure ratings for indoor use.
- Mounting dimensions: 3.627 inches [92.1 mm] x 3.627 inches [92.1 mm] cutout.
- Wiring:
- Line and load connections use copper conductors rated 75°C minimum.
- Wire acceptance is listed with the entry heights.
- Recommended tightening torque for line/load connectors: 35 IN-LBS (14-10 AWG) to 325 IN-LBS (250 MCM).
- Recommended tightening torque for universal input: 5.0 IN-LBS (12-18 GA).
- Recommended tightening torque for green connectors: 5.0 IN-LBS (12-26 GA).
- External EMI Filters: Required to maintain CE immunity approval. Schaffner filters are recommended (e.g., FN 2030-3-06 for universal input, FN 3270H-35-33 for line input).
- Auxiliary I/O Card (Optional):
- Provides (2) digital inputs, (2) digital outputs, and (2) analog outputs (retransmits).
- Analog Retransmit Specifications: Voltage output: 0-10 Vdc, 20 mA max; Current output: 0-20 mA, 15 Vdc compliance.
- Digital Inputs (x2): Dry contact 0.4 mA to circuit common; Open collector TTL to circuit common, pull up to 5 Vdc through a 10KΩ resistor.
- Digital Outputs (x2): Relay Driver (transistor based) 150 mA at up to 48 Vdc; Open collector (transistor based) 100 mA onboard power supply.
Usage Features:
- Mounting: Designed for vertical mounting to ensure proper convection cooling. Keep-out areas must be maintained for adequate airflow.
- Wiring Configurations: Supports a wide range of wiring configurations including:
- Single Phase (1 Zone, 2 Zones, 3 Zones, 4 Zones).
- Single Phase with Pass-Through (1 Zone, 2 Zones).
- Three Phase (Two Leg, Two Leg with Pass-Through, Three Leg - Delta or Three Wire Wye, Three Leg - Inside Delta, Three Leg - Four Wire Wye).
- The controller is not phase sensitive, and any zone can be connected to any two phases or from phase to neutral.
- Remote Display Kit: Allows for remote mounting of the display for easier access and monitoring. The kit includes a gasket, ferrite, display retainer, screws, and a 5 or 25 foot shielded cable.
- P1-12 Pin Command Connector: Used for connecting a 4/20 mA command and SP2 setpoint with a 0/5 Vdc command. Also includes "Run/Reset" functionality, which can be configured as a digital input or through the FUSION Control Panel software.
- External Feedback: Connects to pins 4 and 5 of the P1 (12-pin) connector for external feedback signals.
- SYNC-GUARD™ Feature: Reduces the possibility of synchronous operation of two or more Zero Cross controllers. Up to 10 controllers can be connected, with power distribution depending on the number of controllers (e.g., three controllers provide 33.3% power each).
- P2 - 6 Pin Relay Connector: Provides two Form C contacts for alarms. Default alarms include Digital Enable, Shorted SCR, Heatsink Over Temp, Watchdog Timeout, Voltage Limit, Line Phase Loss, Processor Error Trap, PLL Lock Loss, Current Limit, Heatsink Warning Temp, Communications Error, Memory Error, Power Limit, Current Trip, and Run Enable.
- P3 - 10 Pin Auxiliary I/O Connector: Used for connecting an auxiliary I/O card, which provides additional digital inputs/outputs and analog outputs.
- Universal Input Power: The controller's universal input power supply allows for operation across a broad range of AC voltages (100-240 Vac) without requiring manual configuration changes.
Maintenance Features:
- Fuse Replacement: Detailed instructions are provided for replacing fuses on a three-phase 80 Amp controller. This involves turning off power, removing lids, disconnecting internal wiring, removing the Gate Driver board, replacing the fuse, and reassembling. Specific steps are outlined for different controller sizes (10-50 Amps vs. 80-160 Amps).
- Wiring Harness Changes: Appendices A and B provide step-by-step instructions for changing internal wiring to convert between Inside Delta and 3-Wire Wye Load, or between 4-Wire Wye and 3-Wire Wye Load configurations. This involves removing lids, gently removing wiring harnesses, and connecting new harnesses.
- Troubleshooting: The manual implies that the FUSION Control Panel software can be used for configuration and troubleshooting, particularly for features like SYNC-GUARD™ and Auxiliary I/O Card settings.
- Warranty: Control Concepts Inc. offers a 2-year limited warranty, covering defects in materials and workmanship. The warranty excludes damage from improper installation, misuse, mishandling, tampering, negligence, or improper maintenance.
- Safety Warnings: Emphasizes the importance of proper wiring according to the National Electrical Code (NEC) and/or other local wiring codes. Also warns against touching any circuit board when it is outside of the controller, as failure to do so may damage the board.
- Technical Support: Contact information (phone, fax, email, website) is provided for technical support and inquiries.
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