Ametek SHPF3 Series Operation and maintenance manual

SCR POWER CONTROLLER

Instruction, Operation and

Maintenance Manual

Number: 9100035

Revision 2

530 Lakeview Plaza Blvd, Ste C

Worthington, Ohio, USA 43085

Toll Free: 1-888-PWR-CNTL (797-2685)

Phone: 614-308-5500

Fax: 614-308-5506

Web: www.hdr

ower.com

SHPF3 SCR Series

15-225 Amperes

Three-phase

Phase-fired

This manual applies to all Model SHPF3 SCR Power Controls. Former SHPF1/SHPF3 manual – 9100022 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.

SHPF3 SCR 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Operation 3

1.4Specification 3

CHAPTER 2 - OPTIONS ......................................................................................................................................5

2.1General 5

2.2Option OC (Three-Phase Overcurrent Trip) 5

2.3Option CL/OC (Current Limit/Overcurrent Trip) 5

2.4Option CR/OC (Current Regulation/Overcurrent Trip) 5

2.5Option PR (Power Regulation with Current Limit) 6

2.6Option ER (Extended Ramp) 6

2.7Additional Options 6

CHAPTER 3 - INSTALLATION............................................................................................................................7

3.1Mounting the SHPF3 7

3.2Input/Output Wiring 7

3.3Fan Wiring (applicable to models rated 90 A and higher) 7

3.4Wiring Overtemperature Contacts 8

3.5Command Signal Input 8

3.6Determining Line Frequency 9

3.7Voltage Changeover 9

3.8Options 10

CHAPTER 4 - OPERATION...............................................................................................................................11

4.1General 11

4.2Front Panel Indicators 11

4.3Command Input Control 11

4.4Remote Manual Control with a Potentiometer 12

4.5Auto/Manual Control with a Controller and Remote Potentiometer 13

4.6On/Off Control 14

4.7Shutdown 15

CHAPTER 5 – OPTIONS SETUP ......................................................................................................................17

5.1Option OC (Overcurrent Trip) 17

5.2Option CL/OC (Current Limit/Over Current Trip) 17

5.3Option CR/OC (Current Regulation/Over Current Trip) 18

5.4Option PR 18

CHAPTER 6 - THEORY......................................................................................................................................19

6.1Functional Description 19

6.2Overview of the SHPF3 19

6.3Digital Firing Control Circuit 19

6.4Pulse-Train Firing 19

6.5Phase-Lock Loop 19

6.6SPAN and ZERO Controls 20

6.7Voltage-Squared Feedback 20

6.8Shut-down 20

6.9Soft-Start Circuit 20

Table of Contents SHPF3 SCR Power Controller

ii Ametek HDR Power Systems Rev 2

CHAPTER 7 – TROUBLESHOOTING...............................................................................................................21

7.1Customer-Service Program 21

7.2Troubleshooting Typical Symptoms 21

7.3Static Precautions when Servicing 21

7.4Environmental Problems 22

7.5Input Power and Load Connections 22

7.6Correcting Troubles in the SHPF3 Itself 23

CHAPTER 8 - SERVICE.....................................................................................................................................24

8.1Communication Procedures 24

8.2Spare Parts Orders – Routine or Emergency 24

8.3Spare Parts List 25

8.4Drawing List 26

CHAPTER 9 – WARRANTY POLICY................................................................................................................27

9.1Warranty 27

9.2In-house Repair Services 27

APPENDIX..........................................................................................................................................................29

Appendix A – System Schematic 29

Appendix B – 15 and 25 A Outline 30

Appendix C – 60-225 A Outline 31

Appendix D – Declaration of Conformity 32

SHPF3 SCR Power Controller Table of Contents

Rev 2 Ametek HDR Power Systems iii

TABLE OF CONTENTS

Par. Title Page

ILLUSTRATIONS

Figure 3.1 Fan and Thermostat Connections.................................................................................................. 8

Figure 3.2 Isolated/Non-Isolated Switches...................................................................................................... 9

Figure 3.3 T1, T2 Transformer Connections.................................................................................................... 9

Figure 4.1 Control Panel.................................................................................................................................. 11

Figure 4.2 Process Controller Input Connections........................................................................................ 12

Figure 4.3 Remote Control with a Potentiometer ......................................................................................... 13

Figure 4.4 Auto/Man Control with Controller and Remote Potentiometer................................................. 14

Figure 4.5 On/Off Control................................................................................................................................ 14

Figure 4.6 Shutdown Control.......................................................................................................................... 15

Figure 5.1 Current Limit/Trip Board............................................................................................................... 17

Figure 6.1 AC Switch and SCR On-time......................................................................................................... 19

TABLES

Table 1.1 SHPF3 Model Number Breakdown .................................................................................................. 3

Table 1.2 General Specifications of SHPF3 Models....................................................................................... 4

Table 3.1 Wire Size Information........................................................................................................................ 7

Table 3.2 Transformer Voltage Wiring........................................................................................................... 10

Table 3.3 Current Transformer Turns ............................................................................................................ 10

Table 7.1 Troubleshooting Chart (Symptoms and Solutions)..................................................................... 23

Table 7.2 Torque Specifications..................................................................................................................... 23

Table 8.1 SHPF3 Spare Parts List................................................................................................................... 25

Table 8.2 SHPF3 Drawing List ........................................................................................................................ 26

Table of Contents SHPF3 SCR Power Controller

iv Ametek HDR Power Systems Rev 2

SHPF3 SCR 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 Load, 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 7) 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 SHPF3 SCR Power Controller

2 Ametek HDR Power Systems Rev 2

SHPF3 SCR Power Controller Description

Rev 2 Ametek HDR Power Systems 3

CHAPTER 1 - Description

1.1 General Description

The SHPF3 is a Three-phase, phase-fired power controller, and can operate with a wide variety of

input signals and line voltages up to 575 Vac and currents ranging from 15 through 225 amperes. The

SHPF3’s output voltage is proportional to its input signal. The SHPF3 features pulse-train firing which

provides high immunity to possible SCR firing disturbances, and phase-lock loop circuitry which

ensures line frequency synchronization. Other features are input isolation from ground, soft-start, and

automatic restart circuitry. Terminals are provided to permit connection of a variety of external control

methods. A more detailed description of the features mentioned above is provided in Chapter 6 of this

manual.

1.2 Application

Phase-Fired SCR Power Controllers provide infinitely variable firing angles for precise control of three-

phase power to resistive or inductive loads. This precise control is essential for transformer coupled

loads or loads with great resistance changes due to temperature or start-up. Phase-Fired units may

also be used on straight resistive loads as well, but the lower power factor and higher harmonics may

present a problem to other equipment mounted nearby. A zero fired model would be a better choice.

1.3 Operation

The SHPF3 accomplishes power control by the switching action of a pair of inverse-parallel power

SCRs. The switching, or gating, of the SCRs is controlled by a digital firing control circuit synchronized

“in phase” with line frequency (either 50 or 60 Hz). A soft-start (approximately a 12 cycle ramp)

feature is standard that allows the Power Controller to fire into the primary of a transformer or to

control power to heating elements which have a large resistance change during start-up. The output

may be adjusted by the on-board multi-turn potentiometers or by a voltage or current signal from a

process controller. ZERO and SPAN controls allow the user to calibrate the SCR unit's output to the

process command signal. Terminals are available for connection of a remote manual potentiometer.

1.4 Specification

Specifications for the SHPF3 SCR power controller are given in Tables 1.1 and 1.2.

Table 1.1 SHPF3 Model Number Breakdown

SHPF3 – 480 – 180 – CR – UB – 01

NOTE: N.O. Thermostat is included in current ratings above 60 A.

120 Vac - 120

240 Vac - 240

400 Vac - 400

480 Vac - 480

575 Vac - 575

15 A rms - 60

25 A rms - 60

30 A rms - 60

60 A rms - 60

90 A rms - 90

120 A rms - 120

180 A rms - 180

225 A rms - 225

N.O. Thermostat - NO

N.C. Thermostat - NC

RMS Current Limit/OC - CL

RMS Current Reg/OC - CR

Over Current Trip - OC

True Power Reg/CL – PR

Load Unbalance Alarm – UB

Extended Ramp - ER

Can have multiple selections

4-20 mA - 01

0-10 Vdc - 02

0-5 Vdc - 03

Auto/Man - 04

Manual Pot input - 05

Others

Description SHPF3 SCR Power Controller

4 Ametek HDR Power Systems Rev 2

Table 1.2 General Specifications of SHPF3 Models

Input line voltage: *120, 240, 400, 480, or 575 Vac,

+10%, -15% , 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

Input Signal:

Non-isolated

Isolated

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. Dry contact closure (customer-supplied).

3. Temperature or process controller**

Control signal input impedance:

Non-isolated input

Isolated input

1500 

500 Control signal isolation:

From SCRs 2,500 Vac

From ac power input lines 2,500 Vac

From chassis 500 Vac Power output:

Power output linearity versus

control signals input

+2% (Non-isolated)

+5% (Isolated)

Power SCRs protection:

Current surge Subcycle I² T semiconductor fuse.

Transient voltage spikes (dv/dt)

SCCR Rating

Metal Oxide Varistor (MOV) and R-C snubber across each SCR pair; all

SCRs have PIV rating of 1,400 V.

100kA Miscellaneous:

Phase-firing timebase 0 º to 180 º conduction per SCR

Controls: ZERO and SPAN potentiometers; 10-turn, screwdriver-adjustable.

Approvals UL/cUL (E151547), CE

Fan-cooling power (as applicable):

For 90 A through 225 A units 0.30 amperes, 35 VA (50 Hz)

0.28 amperes, 46 VA (60 Hz)

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

15 and 25 A

30 through 225 A

lbs

Outline and mounting: See appropriate drawing in Appendix

* Specify with order

** If you will be using temperature/process controller, specify its output; e.g., 4-20 mA, 0-10 Vdc, 2-10 Vdc,

etc. with your order.

NOTE: The SHPF3 should be tested or operated with an adequate load since an open output will have line

voltage at the load connections.

Table of contents

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