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User`s Manual

1. 4 2 107mm 0 0 Omm 1 0 25mm 4 1 FIRING PACKAGE i 7 2 184mm A l 13 5 342mm 14 5 368mm FAN END 6 0 153mm 7 28 185mm Figure 2 5 12 130mm 0 0 Omm 1 3 23mm 5 3 135mm E FIRING PACKAGE BS i 9 3 237mm 13 3 338mm 14 6 371mm FAN END 8 1 206mm 9 1 232mm Figure 4 0 0 Omm 1 0 25mm N 90 280 7 11mm FIRING PACKAGE 6 HOLES 4 75 121mm 8 5 216mm 9 5 241mm FAN END 6 0 153mm 7 3 185mm Figure 1 7 2 183mm e 0 0 Omm 1 3 33mm T 0 280 07 11mm 6 HOLES FIRING PACKAGE p 7 3 185mm H 13 3 337mm JA 14 6 371mm FAN END 12 0 305mm 13 3 338mm Figure 3 8 4 214mm H 0 0 Omm 1 3 33mm K 9 3125 7 94mm 8 HOLES 5 3 135mm A gt FIRING PACKAGE 9 3 227mm 13 3 338mm 4 gt 14 6 371mm FAN END 14 7 375mm 15 75 400mm Figure 5 0 280 7 11mm 6 HOLES EN T 93125 07 94mm 8 HOLES 1 888 996 9258 O 2014 Chromalox Inc 11 7 298mm a 5 8 148mm 0 0 0mm 0 0 0mm 1 3 33mm n 1 3 33m
2. 24 NE ERISEE Maintenance je 25 r M Beeler e ne DE 26 BS El Elle Ree 27 EE vases Warranty and Return Information reerrsrnnvvnnnnrnnvrrnnnnnnnvrnnnnrrnrrnnnnernnrrennnenn 28 om EC Declaration of Conforimlty cierre aene terree en nianus 37 O 2014 Chromalox Inc 1 888 996 9258 Important Safeguards Please read all instructions before installing and operating your MaxPac To avoid electrical shock or injury always remove power before servicing a circuit Personnel working with or near high voltages should be familiar with modern methods of resuscitation Con tact an area supervisor or safety personnel for more information Throughout the MaxPac User Manual the safety alert and the international electric shock electrocution sym bols will alert you to potential hazards Safety precautions should always be followed to reduce the risk of personal injury to persons from fire and electrical shock hazards AN Safety Alert Symbol International Shock Electrocution Symbol gt Each safety message is preceded by a safety alert symbol AN and one of three words DANGER WARN ING or CAUTION These mean DANGER You WILL be killed or seriously hurt if you do not follow instructions WARNING You CAN be killed or seriously hurt if you do not follow instructions CAUTION You CAN be hurt if you do not follow instructions Damage Prevention Messages You will see other IMPORTANT messages that are
3. 25 Troubleshooting The following guidelines cover most of the common problems that could occur with the MaxPac They are not intended to be nor can they be absolutes to cover every possible failure Problem No Power or unbalanced power to the load If Demand Light is Off Check incoming line power Check the instrument power Check the fuse on the main board Verify the input signal Check that remote shutdown J3 3 to 4 is open Check that the J2 2 to 3 is Jumpered Verify that heat sink is not in over temperature mode by removing temperature sensor plugs from J10 J11 and J12 NOOR GOSA If Demand Light is On 1 Check the connections to SCR trigger board 2 Check the power fuses It 3 Look for damage on the trigger board 26 2014 Chromalox Inc 1 888 996 9258 Parts and Accessories e e e e e e e e e e e e e e e Instrument Power Fuse Chromalox Part Number Description 0024 01097 Littlefuse 225 002 2 AG 2AMP FT Fuses for 500 Vac Applications 0024 07634 200 Amp It Fuse 0024 07630 250 Amp It Fuse 0024 07632 400 Amp It Fuse 0024 03116 500 Amp It Fuse 0024 07633 700 Amp Pt Fuse 0024 03118 800 Amp It Fuse 0024 03200 1000 Amp Dt Fuse FT Fuses for 575 Vac Applications 0024 07644 125 Amp II Fuse 0024 07645 175 Amp t Fuse 0024 07636 250 Amp It Fuse 0024 07637 400 Amp It Fuse 0024 07638 500 Amp It Fuse 0024 07639 700 Amp Pt Fuse 0024 07640 800 Amp It Fuse 0024 07646 1000
4. Conductor Size 8 AWG Torque 0135 10003 LCD6 14A L 6 AWG or 6 Weld 0135 10004 LCD4 14A L 4 AWG or 4 Weld 0135 10005 LCD2 56B Q 2 AWG 0135 10006 LCD1 56C E 1 AWG or 2 Weld 0135 10007 LCD1 0 12 X 1 0 AWG or 1 Weld 0135 10008 LCD2 0 12 X 2 0 AWG or 1 0 Weld 0135 10009 LCD3 0 12 X 3 0 AWG or 2 0 Weld 0135 10010 LCD4 0 12 X 4 0 AWG or 3 0 Weld 0135 10011 LCD250 12 X 250 MCM or 4 0 Weld 0135 10012 LCD300 12 X 300 MCM 0135 10013 LCD350 12 6 350 MCM 0135 10014 LCD400 12 6 400 MCM 0135 10015 LCD500 12 6 500 MCM Note NEMA standard two hole copper crimp lugs only 2014 Chromalox Inc 1 888 996 9258 Chromalox PRECISION HEAT AND CONTROL EC Declaration of Conformity We Chromalox Precision Heat and Control 1347 Heil Quaker Boulevard LaVergne Tennessee 37086 3536 Phone 1 615 793 7561 Fax 1 615 213 8091 declare under sole responsibility that the following described product in our delivered version complies with the appropriate basic safety and health requirements of the EC Low Voltage Directive 2006 95 EC and EC Electromagnetic Compatibility Directive 2004 108 EC based on its design and type as brought into circula tion by us In case of alteration of the machine not agreed upon by us this declaration will lose its validity Description of the
5. 300 MCM 0135 10013 LCD350 12 6 350 MCM 0135 10014 LCD400 12 6 400 MCM 0135 10015 LCD500 12 6 500 MCM Note NEMA standard two hole copper crimp lugs only 2014 Chromalox Inc 1 888 996 9258 Ordering Information for MaxPac IP Model SCR Power Pack MXPC IP Single Phase SCR Power Pack 1 2 MXPC IP 2 1 888 996 9258 Code Control Configuration Phase Angle Control Accepts 0 5mA 0 20mA 0 50mA 105mA 4 20mA 10 50mA 0 5 Vdc 0 10 Vdc Phase Angle Control with Current Limit Current at 50 C 122 F Code 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 03 100 100 150 150 200 200 300 300 400 400 550 550 650 650 800 1000 1200 Amp Open Design Amp Touch Safe Design Amp Open Design Amp Touch Safe Design Amp Open Design Amp Touch Safe Design Amp Open Design Amp Touch Safe Design Amp Open Design Amp Touch Safe Design Amp Open Design Amp Touch Safe Design Amp Open Design Amp Touch Safe Design Amp Open Design Amp Open Design Amp Open Design Code Voltage OO Po 120 Vac 208 Vac 240 Vac 277 Vac 480 Vac 575 Vac Code Fan Power 1 120 Vac 50 60 Hz 2 230 Vac 50 60 Hz Code Compression Lug Kits Open Design up to 300 Amps For Other Ranges See Crimp Lug Chart LO None L1 100 150 Amp PAK 1 2 4 0 connection L2 200 300 Amp PAK 1 1 0 500mcm connection 1 L1 Continued on next
6. The Chromalox MaxPac IP utilizes Single Phase Phase Angle firing to modulate power to an inductive or resistive load Phase Angle control has the advantage of proportioning every cycle thereby providing very fine resolution of power Fast responding loads in which the resistance changes as a function of temperature require Phase Angle control The MaxPac IP offers a Soft Start feature that assures that the load power is gradually increased from zero to the value set by the command signal in the event of a power interruption In addition optional Current Limit is used to protect the load SCR controller and the total system from large surge currents that could occur at start up T This can be set to three cycles On three cycles Off see section on installation options 4 O 2014 Chromalox Inc 1 888 996 9258 Before You Install Immediately after receiving your MaxPac II Ill or IP Series Controller visually inspect the shipment packag ing and record any damage on the shipping documents Unpack the controller and carefully inspect for obvi ous damage due to shipment If any damage has occurred YOU must file a claim with the carrier company since the carrier company will not accept a claim from the shipper Chromalox Be sure to check the model number and verify that you have received the correct Model of controller If the controller is not installed and placed into operation immediately it should be stored in a cool d
7. 10 current output CW 2 Set Manual MAN pot to zero so unit will not be biased above input CCW Manual control adjustment provides a means of setting the output level of the MaxPac Power Pak in the absence of controlling instrumentation The manual control signal value adds to the controlling instrument to set mini mum output The desired output power level may be set by adjusting the manual control This value of output will then be present even in the absence of a control signal 3 Set Remote Manual pot to zero output so unit will not be biased above input CCW Jumper pins 4 amp 5 if not used Remote Manual control adjustment provides a means of setting the output level of the MaxPac Power Pak in the absence of controlling instrumentation The Remote Manual control is also effective when a control signal is connected The Remote Manual control signal value adds to the controlling instrument to set minimum output The desired output power level may be set by adjusting the Remote Manual control This value of out put will then be present even in the absence of a control signal Connect Remote Manual pot wire to Pin 4 CCW Pin 5 W and Pin 6 CW of plug in connector 4 Check for open contact for Emergency Shutdown Emergency Shutdown inhibits all SCR trigger pulses regardless of the level of the input signal or manual potentiometer For Emergency Shutdown close contact Pin 7 to Pin 8 of plug in connector
8. Amp I t Fuse 0024 01191 1200 Amp Ft Fuse Fans Chromalox Part Number Description 0045 00231 120 Vac rated Fan 0045 00235 230 Vac rated Fan Crimp Lug Chart For Open Design 400 1200 Amp and all Touch Safe Models Conductor Size Chromalox Part Panduit Part 8 AWG 10mm 0135 10002 LCD8 14A L 6 AWG or 6 Weld 16mm 0135 10003 LCD6 14A L 4 AWG or 4 Weld 25mm 0135 10004 LCD4 14A L 2 AWG 35mm 0135 10005 LCD2 56B Q 1 AWG or 2 Weld 50mm 0135 10006 LCD1 56C E 1 0 AWG or 1 Weld 70mm 0135 10007 LCD1 0 12 X 2 0 AWG or 1 0 Weld 70mm 0135 10008 LCD2 0 12 X 3 0 AWG or 2 0 Weld 95mm 0135 10009 LCD3 0 12 X 4 0 AWG or 3 0 Weld 120mm 0135 10010 LCD4 0 12 X 250 MOM or 4 0 Weld 150mm 0135 10011 LCD250 12 X 300 MOM 150mm 0135 10012 LCD300 12 X 350 MOM 185mm 0135 10013 LCD350 12 6 400 MCM 240mm 0135 10014 LCD400 12 6 500 MOM 240mm 0135 10015 LCD500 12 6 SCR Replacement Be sure to replace thermstrate interface material and torque as follows MFG Part SCR Part Thermstrate Part Torque inch Ib to Heat Sink to Terminals 44 inch Ib 5 Nm 44 inch Ib 5 Nm 44 inch Ib 5 Nm 44 inch Ib 5 Nm Torque inch Ib SKKT92 SKKT162 SKKT250 SKKT500 0002 47560 0002 47559 0002 47537 0002 47557 0029 00700 0029 00822 0029 00719 0029 00814 26 inch Ib 3Nm 44 inch Ib 5 Nm 80 inch Ib 9 N
9. MaxPac Ill continued MXPC Ill 2 1 SCR Fusing is for semiconductor protection only not wire protection 2 Supplied Loose for Customer Mounting Note Storage Temperature 14 F to 158 F 10 C to 70 C CE application requires filters Chromalox Part Numbers 0005 60055 Line filter three phase 0005 60057 Line filter 120 230VAC 236 Code FOO FO1 F02 F03 F04 F05 F06 F07 F08 F09 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 L1 F02 Fusing Option 1 For lt 500Vac Applications Select One None 100 150 Amp PAK 200 Amp PAK 300 Amp PAK 400 Amp PAK 550 Amp PAK 650 Amp PAK 800 Amp PAK 1000 Amp PAK 1200 Amp PAK 100 Amp PAK 150 Amp PAK 200 Amp PAK 300 Amp PAK 400 Amp PAK 550 Amp PAK 650 Amp PAK 800 Amp PAK 1000 Amp PAK 1200 Amp PAK 0 None 200 Amp Fuse 250 Amp Fuse 400 Amp Fuse 500 Amp Fuse 700 Amp Fuse 800 Amp Fuse 1000 Amp Fuse 1200 Amp Fuses Two 1000 Amp Fuses For 575Vac Applications Select One 2 125 Amp Fuse 175 Amp Fuse 250 Amp Fuse 400 Amp Fuse 500 Amp Fuse 700 Amp Fuse 800 Amp Fuse 1000 Amp Fuse 1200 Amp Fuse Two 1000 Amp Fuses Code Remote Manual Adjust 1 Pot with 0 100 dial and Local Remote Switch 2 Single Turn 1KQ Potentiometer Requires Proportional Band 1 Typical Model Number Crimp Lug Chart Chromalox 0135 10002 Panduit LCD8 14A L
10. must mount on the fuse side of the bus bar as shown to maintain required O electrical clearances l in h o o D Smaller wire 1 through 8 often used TT TT for power distribution can be connected to both sides of the load bus Wiring must be bent slightly to align with the windows in the top of the touch safe units FUSE JO O O Hos FAN END LINE BUS BAR Illustration 2 View From Top The bus bars are designed to accept NEMA standard two hole crimp lugs in accordance with the charts below Touch Safe Units 100 400 Amps Input Bus Output Bus Up to 3 1 0 300 mcm 70 mm 150 mm Up to 10 8 1 10 mm 50 mm Up to 2 350 500 mem 185 mm 240 mm Up to 3 1 0 300 mcm 70 mm 150 mm Up to 2 350 500 mcm 185 mm 240 mm 550 650 Amps Input Bus Output Bus Up to 4 1 0 300 mcm 70 mm 150 mm Up to 12 8 1 10 mm 50 mm Up to 3 350 500 mem 185 mm 240 mm Up to 4 1 0 300 mcm 70 mm 150 mm Up to 3 350 500 mcm 185 mm 240 mm 800 1200 Amps Open Design Input and output bus drilled to accomodate qty 4 1 0 500 mcm NEMA standard two h
11. on page 5 for a description of an ideal environment for the unit s operation The space required for mounting the MaxPac Power Pak depends upon the model The table below refers to the figures on the following pages These figures illustrate the dimensions and mounting holes for the vari ous MaxPac Power Pak models Please refer to these figures before mounting your unit Figure Model prem 100A 150A amp 200A 2 Leg Open Type 14s 100A 150A 200A amp 300A 1 Leg Open Type L 100A 150A amp 200A 3 Leg Open Type E 300A 2 Leg Open Type r 100A 150A 200A 300A amp 400A 1 Leg Touch Safe 400A 1 Leg Open Type Dornan 100A 150A 200A 300A amp 400A 2 Leg Touch Safe 400A 2 Leg Open Type o EE 100A 150A 200A 300A amp 400A 3 Leg Touch Safe Does 300A amp 400A 3 Leg Open Type 550A amp 650A 1 Leg Touch Safe pon 550A amp 650A 1 Leg Open Type e iagr egreegtg 550A amp 650A 2 Leg Touch Safe Gunnil 550A amp 650A 2 Leg Open Type minste 550A amp 650A 3 Leg Touch Safe 9 E 550A amp 650A 3 Leg Open Type 800 1200 Amp units consult factory IMPORTANT Please note that the figures on the following pages are not drawn to the same scale 8 O 2014 Chromalox Inc 1 888 996 9258 4 7 107mm 3
12. page 2014 Chromalox Inc 31 Ordering Information for MaxPac IP continued MXPC IP 2 03 1 1 1 SCR Fusing is for semiconductor protection only not wire protection 2 Supplied Loose for Customer Mounting Note Storage Temperature 14 F to 158 F 10 C to 70 C CE application requires filters Chromalox Part Numbers 0005 60055 Line filter single phase 230VAC 0005 60057 Line filter 120 230VAC 39 Code Fusing Option 1 For 500Vac Applications Select One FOO None F01 100 150 Amp PAK 200 Amp Fuse F02 200 Amp PAK 250 Amp Fuse F03 300 Amp PAK 400 Amp Fuse F04 400 Amp PAK 500 Amp Fuse F05 550 Amp PAK 700 Amp Fuse F06 650 Amp PAK 800 Amp Fuse F07 800 Amp PAK 1000 Amp Fuse F08 1000 Amp PAK 1200 Amp Fuses F09 1200 Amp PAK Two 1000 Amp Fuses For 575Vac Applications Select One 2 F10 100 Amp PAK 125 Amp Fuse F11 150 Amp PAK 175 Amp Fuse F12 200 Amp PAK 250 Amp Fuse F13 300 Amp PAK 400 Amp Fuse F14 400 Amp PAK 500 Amp Fuse F15 550 Amp PAK 700 Amp Fuse F16 650 Amp PAK 800 Amp Fuse F17 800 Amp PAK 1000 Amp Fuse F18 1000 Amp PAK 1200 Amp Fuse F19 1200 Amp PAK Two 1000 Amp Fuses Code Remote Man Adjust Auto Man Switch 0 None 1 Pot with 0 100 dial and Local Remote Switch 2 Single Turn 1KQ Potentiomete L1 F01 1 Typical Model Number Crimp Lug Chart Chromalox 0135 10002 Panduit LCD8 14A L Torque Co
13. the externally connected device output is activated g a S o m bp Bg hg pos DISABLE ENABLE zu 3 CH i bo amp Og 6 P HEATSINK 1 p E 3 Sa d S SHORTED SCR SWITCH TEMPERATURE 2 5 8 2 1 E ux 3 4 gt SENSOR 3 5 uy z az 14 LY n 8 Ne m GE M z 3 7 SHUTDOWN 5 TO 32 VDC ON OFF JH 1 IK CONTROL SIGNAL Co 3 53 ake CONTACT CONTROL HEATSINK 1 8 ggl 33 299 2233 s i TEMPERATURE 2 5 pl f Hi ETO aes Ji SENSOR 3 Ch 1 i B 8 120 to 230 Voc ON OFF CONTROL SIGNAL J12 D Bg S i 8 HEATSINK 1 p BERAREZ Aa O kas 3 S KX SHORTED SCR INSTRUMENT POWER 100mA TEMPERATURE 2 L 8 888 T SENSOR 3 wi 3 2 UD HEATSINK OVERTEMP n 10 e y COMMON 7 r 3 ci 120 or 230 Vac INSTRUMENT POWER INPUT C99 Lid R50 1 2 Le ge SS y O SEE MODEL NUMBER 1K MANUAL NC AUTO 5 LN C n POT REF VOLTAGE e 9 21 Dei 2 1 5 VDC PROP INPUT
14. this jumper is installed latching operation is achieved The drawing below shows the Shorted SCR Detection board R8 K D7 m R10 R7 R25 R29 15 R41 R43 m Y a e f 23 UA EMT E ve a E K A ER C3 E P Ak R27 2 En r gt 2 2 3 P S 3 GE 3 E 2 S Go 3 Sk 3 ERE es Ut C6 i Ge R42 Ko Ri ov 7 g S g e E pr a R35 3 S S E 2 GAME TE R36 ES 5 m za 8 d ge gt r RA J3 9960 11016 REV 2 U3 J3 JUMPERED FOR LATCHING FOR 1 PHASE DETECTION J4 amp J5 ARE INSTALLED FOR 2 PHASE DETECTION REMOVE J4 LEAVE J5 INSTALLED FOR 3 PHASE DETECTION REMOVE J4 amp J5 UNIT SHIPPED IN NON LATCHING MODE Heat Sink Over Temperature An external lamp or relay may be connected to J1 3 amp 4 see Fig 2 on page 21 this must be rated for the instrument power applied to J1 1 amp 2 This will provide an indication to the operator that the heat sink is approaching an unsafe temperature level The unit will enter a shutdown mode if the temperature continues to rise 20 2014 Chromalox Inc 1
15. 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 03 100 Amp 100 Amp 150 Amp 150 Amp 200 Amp 200 Amp 300 Amp 300 Amp 400 Amp 400 Amp 550 Amp 550 Amp 650 Amp 650 Amp 800 Amp 1000 Amp 1200 Amp Open Design Touch Safe Design Open Design Touch Safe Design Open Design Touch Safe Design Open Design Touch Safe Design Open Design Touch Safe Design Open Design Touch Safe Design Open Design Touch Safe Design Open Design Open Design Open Design Code Line Voltage 1 120 Vac 480Vac Compression Lug Kits Open Design up to 300 Amps For Other Ranges See Crimp Lug Chart 100 150 Amp PAK 1 2 4 0 connection 200 300 Amp PAK 1 1 0 500mcm connection 2 575 Vac Code Instrument Power 1 120 Vac 50 60 Hz 2 230 Vac 50 60 Hz Code LO None L1 L2 1 1 L1 Continued on next page O 2014 Chromalox Inc 29 Ordering Information for MaxPac I continued MXPCI 2 03 1 1 1 SCR Fusing is for semiconductor protection only not wire protection 2 Supplied Loose for Customer Mounting Note Storage Temperature 14 F to 158 F 10 C to 70 C CE application requires filters Chromalox Part Numbers 0005 60055 Line filter single phase 230VAC 0005 60057 Line filter 120 230VAC 30 Code FOO FO1 F02 F03 F04 F05 F06 F07 F08 F09 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 L1 F01 Fusing Option 1 For lt 500Va
16. 200 Amp Open Design Touch Safe Design Open Design Touch Safe Design Open Design Touch Safe Design Open Design Touch Safe Design Open Design Touch Safe Design Open Design Touch Safe Design Open Design Touch Safe Design Open Design Open Design Open Design Code Line Voltage 1 120 Vac 480Vac Compression Lug Kits Open Design up to 300 Amps For Other Ranges See Crimp Lug Chart 100 150 Amp PAK 1 2 4 0 connection 200 300 Amp PAK 1 1 0 500mcm connection 2 575 Vac Code Instrument Power 1 120 Vac 50 60 Hz 2 230 Vac 50 60 Hz Code LO None L1 L2 1 1 L1 Continued on next page O 2014 Chromalox Inc 33 Ordering Information for MaxPac II continued MXPC II 2 03 1 1 1 SCR Fusing is for semiconductor protection only not wire protection 2 Supplied Loose for Customer Mounting Note Storage Temperature 14 F to 158 F 10 C to 70 C CE application requires filters Chromalox Part Numbers 0005 60055 Line filter three phase 440VAC 0005 60057 Line filter 120 230VAC BCE a Code FOO FO1 F02 F03 F04 F05 F06 F07 F08 F09 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 L1 F01 Fusing Option 1 For lt 500Vac Applications Select One None 100 150 Amp PAK 200 Amp PAK 300 Amp PAK 400 Amp PAK 550 Amp PAK 650 Amp PAK 800 Amp PAK 1000 Amp PAK 1200 Amp PAK 100 Amp PAK 150 Amp PAK 200 Amp PAK 300 Amp PAK 400 Am
17. 500V Input output isolation 1500V Ground potential up to 650 Amps 4 Amps Q 120V resistive 2 Amps Q 240V resistive N C Contact Standard 4 10 100 of rated output current 2596 demand per second typical reset speed 8 3 milliseconds 1 888 996 9258 Maintenance e e e e e e e A WARNING Hazardous Voltage Disconnect all power before performing any maintenance or examining the power module Exposed terminals may carry LETHALLY HIGH VOLTAGES when power is applied Connections Loose connections in the power wiring will generate hot spots These will cause degradation of electronic equipment Periodic inspections should be made to ensure that connections are secure and that there are no signs of excessive heating such as discoloration and so on Corrosion If the power module is installed in an environment with high humidity or dampness electrical connections may suffer corrosion Periodically check the power module for corrosion Damage Periodically check for rodent damage to wiring and other components Filters Many high powered control enclosures rely on blowers or fans to maintain a safe operating temper ature The filters used with these devices should be changed on a periodic basis to insure adequate enclo sure cooling is maintained Dust Periodically check for dust or other particulate buildup on heatsinks and bus bars 1 888 996 9258 2014 Chromalox Inc
18. 888 996 9258 Input Terminals MaxPac I II and III FIG 1 c NM Q SO OO NO B 120 230 INSTRUMENT POWER 120 230 INSTRUMENT POWER REQUIRED ON ALL CONFIGURATIONS FIG 4 COMMON 2 AUTO e MANUAL 1K POT REF VOLTAGE 5 6 7 8 9 10 MANUAL CONTROL INPUT SIG FIG 7 c NG JUMPER H COMMON oO OO JO Om A O N A 0 TO 5 VDC PROPORTIONAL INPUT c 0 TO 5 VDC PROPORTIONAL INPUT SIG FIG 10 COMMON P Co 4 ND oo EXTERNAL 5 32 VDC ON OFF FIG 2 8 1 SHORTED SCR INDICATOR lt 5 HI TEMP INDICATOR AM oO PO OO OO for voltage rating SHORTED SCR AND HI TEMP INDICATORS FIG 5 e v JUMPER 1 5 VDC PROPORTIONAL INPUT COMMON oO OO JO Om A ON e 1 5 VDC PROPORTIONAL INPUT SIG FIG 8 c vl JUMPER COMMON cO OO 4 On 01 A O N M D 10 VDC PROPORTIONAL INPUT ce 0 10 VDC PROPORTIONAL INPUT SIG FIG 11 P Co HN OO By 1 d DRY CONTACT ON OFF These are AC voltage outputs at 100 mA max not contact closures See model number FIG 3 oo aN WR OOD SHORTED SCR INDICATOR RESET FIG 6 c Ne JUMPER 4 20mA PROPORTIONAL INPUT m COMMON oO OO 4 On On A O N ce 4 20mA PRO
19. Electrical Equipment MaxPac SCR controllers Model Number MaxPac Series MaxPac Il III Applicable Harmonized Standards Specification Utilization Category Pollution Degree 2 Voltage Rating Impulse Rating Overload Current Profile Fuses 1 888 996 9258 Low Voltage Directive EN60947 4 3 2000 Low voltage switch gear and control gear Part 4 3 Contactors and motor starters AC semiconductor controllers and contactors for non motor loads AC 51 Non inductive or slightly inductive loads resistive furnaces Normally only non conductive pollution occurs Occasionally a temporary conductivity caused by condensation may be expected 400 Vac 50 Hz Line 230 Vac 50 Hz Instrument max 75 watts 2 5 KV for 5 seconds 140 for 1 second 500 Volt 200KA RMS symmetrical interrupting rating It fusing provided with all CE units 2014 Chromalox Inc EMC Directive Radiated Disturbance Emissions 30 to 1000 MHz Electric Field EN 61000 6 4 2001 EN 55011 2007 Conducted Disturbance Emissions Voltage EN 61000 6 4 2001 EN 55011 2007 Conducted Disturbance Immunity EN 61000 6 2 2005 EN 61000 4 6 1996 Radiated Disturbance Immunity EN 61000 6 2 2005 EN 61000 4 3 1995 Electrical Fast Transients Bursts Immunity EN 61000 6 2 2005 EN 61000 4 2 1995 Voltage Dips and Interrupts Immunity EN 61000 6 2 2005 EN 61000 4 11 1994 Electrostatic Discharge Immu
20. Leave contacts open for operation 5 Check for polarity of input signal 6 Adjust input signal to low end of scale Zero Adjust control sets the power output starting point or reference Thus it effectively cancels positive inputs to the MaxPac Power Pak EXAMPLE 0 5 mA input a set to 0 mA input 4 20 mA input a set to 4 mA input 7 With power off connect line voltage and load as shown 8 Connect meter to input and output WARNING Set meter to correct scale to read proper input or output 9 Apply power to unit 10 Adjust input signal to low end of scale 11 Using the Zero pot adjust the output voltage just to zero volts 12 Adjust input signal to top end of scale Gain Adjust Control sets the maximum power output for maximum input signal EXAMPLE 0 5 mA input set to 5 mA input 4 20 mA input set to 20 mA input 13 Using the Gain pot adjust output voltage just to maximum volts 14 Repeat steps 11 12 13 and 14 until no adjustment is necessary of Zero and Gain pots for proper output voltage indication Voltage output should increase proportionally to the signal input applied 15 Adjust input signal to low end of scale zero voltage output 16 With Manual pot at zero for zero voltage output adjust CW to 100 for full voltage output Voltage output should increase proportionally Return to CCW position and output will decrease to zero output 17 With Remote Manual at zero for zero voltage outp
21. PK480 2 e CHROMALOX Advanced Thermal Technologies MAXPAC User s Manual www chromalox com 800 443 2640 O 2014 Chromalox Inc P N 0037 75428 Thank you for choosing the Chromalox MaxPac a complete power control solution with industry best price and performance For more than 80 years customers have relied on Chromalox for the utmost in quality and innovative solu tions for industrial heating applications Chromalox manufactures the world s largest and broadest line of electric heat and control products The MaxPac Series SCR Controllers provide the best control for applications where consistent heater pro cess temperature is critical or where fine resolution of power is required Common MaxPac features include 120 575 Vac 100 1200 Amps Isolated Control Circuit Flexible I O Power Wiring Easy Customer Interface Remote Shutdown Compact Size and Construction Touch Safe Design option on 100 650 Amp models dv dt Transient Voltage Protection MOV Protection Built In Power Distribution Features for the MaxPac I Il and Ill include e Zero Crossover Firing e Isolated Control Circuit On Off Control Inputs 120 thru 240 Vac 5 32 Vdc Dry Contact Closure Proportional DOT Firing Inputs 4 20 mA 0 5 Vdc 1 5 Vdc 0 10 Vde Remote Manual Adjust Optional Remote Auto Manual Switch Optional e Electronically Protected with Temperature Warning and Shutdown System e Single or Three Cycle Reso
22. PORTIONAL INPUT SIG FIG 9 Ji L1 L2 EXTERNAL 120 230 ON OFF CONTROL NM oO OO NO 120 240 ON OFF CONTROL FIG 12 J3 COMMON 5 MPO wf ND REMOTE SHUTDOWN 1 888 996 9258 2014 Chromalox Inc 21 MaxPac IP The Chromalox MaxPac IP is a solid state proportional power controller that utilizes a Phase Angle firing technique to modulate power to an inductive or resistive load Separate adjustable Zero Gain Manual Bias and Current Limit potentiometers are provided along with screw type plug in connectors for input signals Emergency Shutdown and optional Remote Manual Bias with 0 100 dial All units have thermostat pro tection with N C contacts Start up The MaxPac IP has been factory calibrated for 4 20mA input Be sure the operating voltage and signal input are correctly applied Also make sure the Emergency Shutdown if used has N O contacts and jumper pins 4 amp 5 on the 10 pin connector if remote manual bias are not used Please read the information on calibration at the end of this section for current limit settings for loads with extreme hot to cold ratios or those that are overrated Other ranges may be field calibrated by use of zero and gain potentiometers CAUTION 0 5MA 0 10V 4 20mA 10 50mA COM CLOSE FOR REMOTE SHUTDOWN IMPORTANT With the Current Limit option the current transformer must be ter minated pro
23. SIG 5 LINE VOLTAGE TO FA ut L Ste MODEL NUMBER 4 20 PROP Bie D COMMO Fi CG 5 COMMON 8 e P gr de EC LINE VOLTAGE TO FAN re ee eo le R SEE MODEL NUMBER 0 10 VDC PROP INPUT SIG 10 2AMP 2AG CHROMALOX P N 0024 01097 LITTLEFUSE P N 225 002 18 O 2014 Chromalox Inc 1 888 996 9258 J3 JS Proportional DOT Firing Board 1 3 TI PE f SHORT J3 1 amp 2 FOR SHORT J3 2 amp 3 FOR Chromalexs exclusiva DOT DE 1 CYCLE FIRING 3 CYCLE FIRING mand Oriented Transfer firing tech nique switches the fewest number aM ep of cycles to provide the most pre UU vi wet as wo vas cise zero crossover control At 50 5 E ws Eser SEG output the unit s output alternates SE mom Se m SE between one cycle On and one co cdm Ha cycle Off At 5196 the output Mn o Ed continues with one cycle On one SS EAR of Er cycle Off and gradually inte a ae Re grates one extra On cycle for the Uia m ris Se additional 1 I ores sca Eg See d Unit shipped for 3 cycle operation Remote Shutdown When it is necessary to disable the output connect a dry co
24. Touch Safe design follow the steps on the following page to install the electrical wiring This will ensure the wiring is done properly while maintaining the Touch Safe feature If your MaxPac is of an Open design below 400 Amps disregard this subsection The following is a detailed drawing of a Touch Safe unit ole o o o kat o o cd e e TOUCH SAFE COVER PROVIDES WIRE ENTRANCE AND Le Wo o o EXIT THROUGH SEALS COVERING THE WIRE WINDOW REMOVAL OF THE TAPE BEHIND THE WINDOWS TO o O CD BE USED ALLOWS WIRES TO PASS THE TAPE RI REMAINS ON UNUSED WINDOWS TO PROVIDE TOUCH o o SAFE FEATURE BUS BAR DESIGN ALLOWS VA FOR WIRING FROM EITHER DIRECTION AND MULTIPLE C A LOAD CIRCUITS COOLING AIR BUS BAR DESIGN ALLOWS FOR WIRING FROM EITHER DIRECTION AND MULTIPLE LOAD CIRCUITS COOLING AIR LONG LIFE HIGH OUTPUT BALL BEARING FANS PROVIDE RELIABLE COOLING 1 888 996 9258 2014 Chromalox Inc 11 4 2 2 Steps for Touch Safe Design Cover Removal and Installation Remove Cover 1 Loosen the thumb screws on both ends of the cover 2 Lift the cover from the base Install Wiring 3 Attach the wires to the bus bars in accordance with the instructions in the next section 4 Choose the entrance and exit directions for the wiring as desire
25. c Applications Select One None 100 150 Amp PAK 200 Amp PAK 300 Amp PAK 400 Amp PAK 550 Amp PAK 650 Amp PAK 800 Amp PAK 1000 Amp PAK 1200 Amp PAK 100 Amp PAK 150 Amp PAK 200 Amp PAK 300 Amp PAK 400 Amp PAK 550 Amp PAK 650 Amp PAK 800 Amp PAK 1000 Amp PAK 1200 Amp PAK Remote Man Adjust Auto Man Switch Code 0 None 200 Amp Fuse 250 Amp Fuse 400 Amp Fuse 500 Amp Fuse 700 Amp Fuse 800 Amp Fuse 1000 Amp Fuse 1200 Amp Fuses Two 1000 Amp Fuses For 575Vac Applications Select One 2 125 Amp Fuse 175 Amp Fuse 250 Amp Fuse 400 Amp Fuse 500 Amp Fuse 700 Amp Fuse 800 Amp Fuse 1000 Amp Fuse 1200 Amp Fuse Two 1000 Amp Fuses 1 Pot with 0 100 dial and Local Remote Switch 2 Single Turn 1KQ Potentiometer 1 Typical Model Number Crimp Lug Chart Chromalox 0135 10002 Panduit LCD8 14A L Conductor Size 8 AWG Torque 0135 10003 LCD6 14A L 6 AWG or 6 Weld 0135 10004 LCD4 14A L 4 AWG or 4 Weld 0135 10005 LCD2 56B Q 2 AWG 0135 10006 LCD1 56C E 1 AWG or 2 Weld 0135 10007 LCD1 0 12 X 1 0 AWG or 1 Weld 0135 10008 LCD2 0 12 X 2 0 AWG or 1 0 Weld 0135 10009 LCD3 0 12 X 3 0 AWG or 2 0 Weld 0135 10010 LCD4 0 12 X 4 0 AWG or 3 0 Weld 0135 10011 LCD250 12 X 250 MCM or 4 0 Weld 0135 10012 LCD300 12 X
26. d 5 After the wiring is complete remove the tape from the inside of the wire gaskets of the windows that the power wiring will enter or exit A WARNING Hazardous Voltage DO NOT remove the tape from the back of the windows that are not used as this maintains the Touch Safe feature Replace Cover 6 Angle the end of the cover without screws towards the fan end of the unit 7 Slip that end into place first while allowing the wiring to pass through the desired windows 8 Slip the opposite end of the cover into place 9 Tighten all thumb screws 4 2 3 Power Load Wiring The following illustrations depict how to connect the MaxPac to a resistive or inductive load Make sure you refer to the correct illustration for the MaxPac series you have purchased For the power load drawings On open design units up to 300 Amps X1 X2 X3 L1 L2 and L3 refer to copper lugs On open design units 400 Amps and greater and all Touch Safe designs X1 X2 X3 L1 L2 and L3 refer to bus bar connections MaxPac I Single Phase Resistive MAX PAC I L2 L2 Connection is NOT on MaxPac 12 O 2014 Chromalox Inc 1 888 996 9258 MaxPac II Three Wire 2 Leg Control MAX PAC II off ER Kl L2 L2 Connection is NOT on MaxPac MaxPac Ill Four Wire 3 Leg Control MAX PAC III te E p
27. input line power to connect from either of two directions The output power can only be connected from one direction The three mounting configurations are shown below MaxPac II Three Phase Two Leg Shown Open designs above 300 amps and all closed designs allow incoming and outgoing wiring in either direction Configuration One Warm Air Out Cool Air In gt Fan or In Out or In Out Configuration Two Warm Air Out Cool Air In Phase 1 Phase 3 Configuration Three Warm Air Out Out Phase 3 or In Out m gt r gt Phase 1 or In Cool Air In 6 2014 Chromalox Inc 1 888 996 9258 Installation Section continuation of page 5 Examples of Proper Air Flow Qa Louvers Louvers Air MaxPac Enclosure Filter Forced Air In Pagoda Top MaxPac Enclosure Louvers Forced Air Out Since hot air rises naturally it is not recommended that cooling air enter from the top and exhaust at the bottom of the enclosure 1 888 996 9258 2014 Chromalox Inc 7 Installation Please read all information in this section before beginning the installation of your MaxPac Installation of the MaxPac requires three steps 1 Mounting 2 Power wiring 3 120 or 230 Vac 50 60hz for instrument power See 4 2 4 pg 16 4 1 Step 1 Mounting Before mounting your MaxPac please read the section titled Before You Install
28. l Inputs Ambient Temperature Accepts all of the following as standards SCR Capability Phase Angle Control Signal Input Input Impedance 1 5 0 5mA 1K Ohms 4 20 0 20mA 250 Ohms 10 50 0 50mA 100 Ohms Surge Rating Optional Remote Manual Adjust Fan Power 120 or 230 VAC 50 60 Hz Isolation Output Voltage 0 9996 RMS line voltage Eo Vsupply 1 5V SCR Heat Sink forward drop Th LE NE Resolution proportional Better than 0 1 er Line Voltage 120 208 240 277 380 480 and 575 Vac Current Limit x 1096 50 60 Hz Load Current Rating 100 150 200 300 400 Soft Start 550 650 800 1000 1200A 24 2014 Chromalox Inc 550 650 800 1000 1200A 0 50 C 32 122 F Withstand capability 1500V RMS min Typically fifteen 15 times nominal RMS rating for 8 3 milliseconds SCRSs isolation 2500V Input output isolation 1500V Ground potential up to 650 Amps AC Voltage Output 100 mA Instrument Power AC Voltage Output 100 mA Instrument Power 0 50 C 32 122 F Withstand capability 1500V RMS min Typically fifteen 15 times nominal RMS rating for 8 3 milliseconds Typically fifteen 15 times nominal RMS rating for 8 3 milliseconds m SCRS isolation 2
29. l have been factory calibrated These units accept 0 5 1 5 0 10 Vdc and 4 20 mA input signals that are connected to Terminal Block J2 The following signals are connected to 0 5Vdc Terminal J2 9 amp 7 see Fig 7 on page 21 1 5Vdc Terminal J2 5 amp 7 see Fig 5 on page 21 0 10 Vdc Terminal J2 10 amp 7 see Fig 8 on page 21 4 20 mA Terminal J2 6 amp 7 see Fig 6 on page 21 Auto Manual Input The MaxPac I Il and III can AUTO HAND CONTACT be wired to make it possible NORMALLY OPEN to select an input from either a NORMEN 0 NC NO re temperature process controller ewe NI Ea or a manual input potentiom L aw eter A switch is used to select PANELTOBE LEGEND between the input from a 1K MSIE a WIRING potentiometer and a linear n 1K control input see Fig 4 on page Eu pe per qur ee 21 The unit is shipped with a AUTO HAND or jumper from terminals 2 and 3 gt of terminal block J2 see illustra ew tion 3 Remove jumper to install auto manual input Illustration 3 CAUTION IMPORTANT When enabling the Auto Manual Input the jumper from terminals 2 and 3 of terminal block J2 must be removed Demand Indicator The LED demand indicator is located on the main PC board and is viewable through the cover With the On Off control option the indicator will display s
30. lution Jumper Selectable e Shorted SCR Detection Optional Features for the MaxPac IP include e Phase Angle Firing e Isolated Control Circuit Inputs 0 5 mA 0 20 mA 0 50 mA 1 5 mA 4 20 mA 10 50 mA 0 5 Vdc 0 10 Vdc Optional Current Limit Soft Start Line Voltage Compensation Zero amp Gain Adjustments Built In Manual Adjustment Current Limit Adjustment Optional If you have application questions refer to the Engineering Resource section of our website at www chromal ox com to find the answer you re looking for or call one of our application engineers at 1 888 996 9258 for personal assistance 1 888 996 9258 2014 Chromalox Inc Table of Contents Section Topic Page W PE EE Important Safeguarcds uie ce oat ete itid ti eere Pert e ERR EUER EUN 3 D IR le de M E S 4 SN Before You Install terr etti heme ee 5 D aces Installation ss 6 D MOUNN T 8 E WANG BEE 11 4 231 2e Bee perio 11 4 2 2 Cover Removal and Installaton un 12 4 2 3 Power liar a MWIFIDOI eicere teen rere eet eessen 12 4 2 4 esee Instrument Power idee enn yere xE ERR AEFR ECKER SEENEN 16 42 5 ieu E 1 6 0 pl lee E 16 4 2 6 Command Signal Wiring deo ee iex emi EE xa ea En Rees 17 LE Calibration rer 23 D stove acide eeeeedee SPECINcatlOhs eec
31. ly 2014 Chromalox Inc 1 888 996 9258 Ordering Information for MaxPac Ill Model SCR Power Pack MXPC Ill Three Phase Six SCR Power Pack P GO ch Code 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 MXPC III 1 04 1 888 996 9258 Code Control Configuration On Off Standard Accepts 120Vac 240Vac 5 32Vdc Dry Contact Closure On Off Control with Shorted SCR Detection Proportional Control DOT Firing Accepts 4 20 mA 1 5 Vdc 0 5 Vdc 0 10 Vdc Proportional Control DOT Firing with Shorted SCR Detection Current at 50 C 122 F 100 Amp Open Design 100 Amp Touch Safe Design 150 Amp Open Design 150 Amp Touch Safe Design 200 Amp Open Design 200 Amp Touch Safe Design 300 Amp Open Design 300 Amp Touch Safe Design 400 Amp Open Design 400 Amp Touch Safe Design 550 Amp Open Design 550 Amp Touch Safe Design 650 Amp Open Design 650 Amp Touch Safe Design 800 Amp Open Design 1000 Amp Open Design 1200 Amp Open Design Code Line Voltage 1 120 Vac 480Vac 2 575 Vac Code Instrument Power 1 120 Vac 50 60 Hz 2 230 Vac 50 60 Hz Code Compression Lug Kits Open Design up to 300 Amps For Other Ranges See Crimp Lug Chart LO None L1 100 150 Amp PAK 1 2 4 0 connection L2 200 300 Amp PAK 1 1 0 500mcm connection Note 550 1200 Amp and all Touch Safe Designs Buss 1 1 L1 Continued on next page O 2014 Chromalox Inc 35 Ordering Information for
32. m seer x J4mM 9 3125 7 94mm 8 HOLES 8 HOLES S3 domm eerte 6 3 160mm H FIRING PACKAGE 9 3 ee FIRING PACKAGE VW 11 3 28mm H 13 31 338mm 14 62 371mm mm 16 3 414mm t Fr Zr 543mm 17 6 448mm DHT 22 4 568mm ar primal 10 5 267mm Figure 6 Figure 7 9 8 249mm 13 8 351mm n 0 0 Omm 0 0 Omm 1 3 33mm 34 1 3 323mm 0 3125 07 94mm 9 3125 07 94mm 8 HOLES 8 HOLES 6 3 160mm 6 3 160mm H A FIRING n RING 11 3 87mm 11 3 287mm H 4 16 3 414mm 4 16 3 414mm La y 17 6 448mm 17 6 448mm FAN END FAN END 175 444mm 25 5 648mm 18 5 470mm 26 5 673mm Figure 8 Figure 9 10 O 2014 Chromalox Inc 1 888 996 9258 4 2 Step 2 Wiring Careful attention must be paid when attaching the wiring to the MaxPac to ensure proper and safe opera tion This section contains detailed information on how to connect the power resistive load ground and command signal wiring A WARNING Hazardous Voltage Only qualified personnel should perform electrical wiring for the MaxPac Power Paks LETHALLY HIGH VOLTAGES are associated with this equipment and are danger ous if improperly installed IMPORTANT Select installation wiring that is in accordance with the National Electrical Code and any local standards that may be applicable 4 2 1 Touch Safe Design If the MaxPac model you purchased is of a
33. m 106 inch Ib 12 Nm MaxPac I Il and Ill Accessories Part Number 0135 28096 0135 28095 0135 28093 0135 28094 0135 20117 Description Plug In Shorted SCR Detection Board Plug In Proportional DOT Fired Control Board SCR Trigger Board On Off Main Firing Board Potentiometer amp Remote Manual Switch For CE Application the Following Filters are Required Line Filter Single Phase 230 Vac Line Filter 120 230 Vac 3 Amps Line Filter Three Phase 440 Vac 0005 60055 0005 60057 0005 60056 MaxPac IP Accessories Part Number Description 0135 28002 0135 28006 0135 28037 1 888 996 9258 Firing Circuit 120 240 Vac Firing Circuit 208 277 480 Vac Firing Circuit 380 Vac 2014 Chromalox Inc Warranty and Return Information Warranty Notice The Warranty below complies with the federal law applicable to products manufactured after December 31 1976 This warranty gives you specific legal rights and you may also have other rights which vary from state to state Chromalox Warranty Chromalox instruments and controls are warranted against defects in workmanship and materials No other express warranty written or oral applies with the exception of a written statement from an officer of Chro malox Inc Warranty Period This warranty extends for three years from date of shipment from the factory or authorized distributor Limitations Products must be installed and mai
34. nductor Size 8 AWG 0135 10003 LCD6 14A L 6 AWG or 6 Weld 0135 10004 LCD4 14A L 4 AWG or 4 Weld 0135 10005 LCD2 56B Q 2 AWG 0135 10006 LCD1 56C E 1 AWG or 2 Weld 0135 10007 LCD1 0 12 X 1 0 AWG or 1 Weld 0135 10008 LCD2 0 12 X 2 0 AWG or 1 0 Weld 0135 10009 LCD3 0 12 X 3 0 AWG or 2 0 Weld 0135 10010 LCD4 0 12 X 4 0 AWG or 3 0 Weld 0135 10011 LCD250 12 X 250 MCM or 4 0 Weld 0135 10012 LCD300 12 X 300 MCM 0135 10013 LCD350 12 6 350 MCM 0135 10014 LCD400 12 6 400 MCM 0135 10015 LCD500 12 6 500 MCM Note NEMA standard two hole copper crimp lugs only 2014 Chromalox Inc 1 888 996 9258 Ordering Information for MaxPac Il Model SCR Power Pack MXPC II Three Phase SCR Power Pack P GO ch MXPC II 2 1 888 996 9258 Code Control Configuration On Off Standard Accepts 120Vac 240Vac 5 32Vdc Dry Contact Closure On Off Control with Shorted SCR Detection Proportional Control DOT Firing Accepts 4 20 mA 1 5 Vdc 0 5 Vdc 0 10 Vdc Proportional Control DOT Firing with Shorted SCR Detection Current at 50 C 122 F Code 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 03 100 Amp 100 Amp 150 Amp 150 Amp 200 Amp 200 Amp 300 Amp 300 Amp 400 Amp 400 Amp 550 Amp 550 Amp 650 Amp 650 Amp 800 Amp 1000 Amp 1
35. nity EN 61000 6 2 2005 EN 61000 4 2 1995 Voltage Fluctuations Flicker EN 61000 3 3 A2 2005 Harmonic Current Emissions EN 61000 3 2 2006 s Filters Required Instrument power filter 10 Surge Immunity Chromalox P N 0005 60057 EN 61000 6 2 2005 EN 61000 4 5 1995 Line Filter single phase Chromalox P N 0005 60055 Line Filter three phase Chromalox P N 0005 60056 The Technical documentation required by Annex IV 3 of the Low Voltage Directive is maintained by Name of company and location in the European Union Year in which CE Marking was affixed 2002 Authorized Signature Date f B Jim Birnie Date Title of Signatory Engineering Manager Chromalox International Unit 1 22 Lombard House 2 Purley Way Croydon CRO 3JP Surrey U K 38 2014 Chromalox Inc 1 888 996 9258
36. ntact between J3 3 amp 4 see Fig 12 on page 21 When it is closed the power control will shut OFF CAUTION IMPORTANT This shutdown overrides the control input only It will NOT protect against faulted or damaged SCRs Shorted SCR Detection optional This option provides a means of alerting an operator to a problem with the system An external indicating lamp or relay can be connected to J1 5 amp 6 see Fig 2 on page 21 This indicator must be rated for the instrument power applied to J1 1 amp 2 Three diagnostic LEDs show which SCR pair is faulted These lights are synchronized with the demand indicator and can only indicate while the demand is active Shorting J3 5 amp 6 can disable the output at J1 5 amp 6 The alarm can be selected as latching or non latching A latching alarm means that if the alarm activates and the system subsequently returns to normal the alarm will remain latched until a reset button external switch customer provided is pressed A non latching alarm resets automatically DEMAND SHORTED SCR DETECTION C 1 2 3 1 888 996 9258 2014 Chromalox Inc 19 Shorted SCR Detection optional cont d The latching and non latching option is jumper selectable the jumper is located on the plug in shorted SCR detection board Latching and non latching operation by the output at J1 5 amp 6 is controlled by J3 on the shorted SCR detection board 0135 28096 When
37. ntained in accordance with Chromalox instructions Users are responsi ble for the suitability of the products to their application There is no warranty against damage resulting from corrosion misapplication improper specification or other operating conditions beyond our control Claims against the carrier company for damage in transit must be filed by the buyer Returns Items returned to Chromalox must be accompanied by a Return Authorization Number This number may be obtained from Chromalox Customer Service Department at the phone number listed below The Return Authorization Number must appear on the exterior of the shipping carton and on the shipping documents Defective items will be repaired or replaced at our option and at no charge Return the defective part or product freight prepaid to the following address Chromalox Inc 1347 Heil Quaker Blvd LaVergne TN 37086 3536 Phone 615 793 3900 Fax 615 793 3563 28 2014 Chromalox Inc 1 888 996 9258 Ordering Information for MaxPac I Model SCR Power Pack MXPC I Single Phase SCR Power Pack RON MXPCI 2 1 888 996 9258 Code Control Configuration On Off Standard Accepts 120Vac 240Vac 5 32Vdc Dry Contact Closure On Off Control with Shorted SCR Detection Proportional Control DOT Firing Accepts 4 20 mA 1 5 Vdc 0 5 Vdc 0 10 Vdc Proportional Control DOT Firing with Shorted SCR Detection Current at 50 C 122 F Code 01 02
38. ole crimp lugs per phase 1 888 996 9258 2014 Chromalox Inc 15 The power wires must always connect to the fuse side refer to illustration 1 on page 15 of the bus bar This is essential to maintain the required spacing between the phases and sides and to align with the openings in the top The only exception to this is when using power distribution using connectors of sizes 8 to 1 There is adequate spacing for these connectors to be mounted on both sides of the bus bar if necessary The bolt head should always be on the outside of the bus bar refer to illustration 2 on page 15 with the bolt extending towards the fuse Flat washers should be used on both the bolt head and the nut and a lock washer should be under the nut The Touch Safe MaxPac is designed to allow both input and output wiring to enter exit in either direction On the 550 Amp and 650 Amp models it is necessary to mount the wire in the holes that maximize the distance for the wire to exit the enclosure This maximizes the distance from the cover to the non insulated connector When using the power distribution feature and mounting terminals on both sides of the bus bar the wires mounted on the outside of the bus bar must be bent inward slightly to align with the opening in the top All wiring especially the larger wires should be bent prior to mounting to the bus bars DO NOT use the bus bars as an anchor to bend the power cables 4 2 4 Instrument P
39. ower IMPORTANT MaxPac requires 120 or 230 Vac 50 60Hz for instrument power This voltage supplies power for the control circuits fans high temperature warning indicator and shorted SCR Indicators see Fig 1 on page 21 This supply is fused on the main circuit board 4 2 5 Grounding Chasis is provided with hole pattern for standard NEMA two hole crimp lugs A WARNING Hazardous Voltage This Electrical Equipment must be installed by a qualified person and effectively grounded in accordance to the National Electric Code and local codes 16 2014 Chromalox Inc 1 888 996 9258 4 2 6 Command Signal Wiring Please refer to the figures on page 19 for illustrations of the 6 8 and 10 pin input terminals MaxPac Il and Ill On Off Control Signals AC Input The 120 thru 230 Vac signal lines are connected to terminal J1 7 amp 8 See Fig 9 on page 21 An input voltage of 120 to 230 Vac turns the power On The turn OFF voltage is 0 Vac DC Input The 5 32 Vdc signal lines are connected to terminal J3 1 amp 4 see Fig 10 on page 21 An input voltage of 5 to 32 Vdc turns the power On The turn OFF voltage is 0 Vdc Contact Closure Input The dry contact signal lines are connected to terminal J3 1 amp 2 see Fig 11 on page 21 A closed contact turns the power On The turn OFF voltage is an open contact Process Analog Control Signals MaxPac I II and Il
40. p PAK 550 Amp PAK 650 Amp PAK 800 Amp PAK 1000 Amp PAK 1200 Amp PAK Remote Man Adjust Auto Man Switch Code 0 None 200 Amp Fuse 250 Amp Fuse 400 Amp Fuse 500 Amp Fuse 700 Amp Fuse 800 Amp Fuse 1000 Amp Fuse 1200 Amp Fuses Two 1000 Amp Fuses For 575Vac Applications Select One 2 125 Amp Fuse 175 Amp Fuse 250 Amp Fuse 400 Amp Fuse 500 Amp Fuse 700 Amp Fuse 800 Amp Fuse 1000 Amp Fuse 1200 Amp Fuse Two 1000 Amp Fuses 1 Pot with 0 100 dial and Local Remote Switch 2 Single Turn 1KQ Potentiometer Requires Proportional Band 1 Typical Model Number Crimp Lug Chart Chromalox 0135 10002 Panduit LCD8 14A L Conductor Size 8 AWG Torque 0135 10003 LCD6 14A L 6 AWG or 6 Weld 0135 10004 LCD4 14A L 4 AWG or 4 Weld 0135 10005 LCD2 56B Q 2 AWG 0135 10006 LCD1 56C E 1 AWG or 2 Weld 0135 10007 LCD1 0 12 X 1 0 AWG or 1 Weld 0135 10008 LCD2 0 12 X 2 0 AWG or 1 0 Weld 0135 10009 LCD3 0 12 X 3 0 AWG or 2 0 Weld 0135 10010 LCD4 0 12 X 4 0 AWG or 3 0 Weld 0135 10011 LCD250 12 X 250 MCM or 4 0 Weld 0135 10012 LCD300 12 X 300 MCM 0135 10013 LCD350 12 6 350 MCM 0135 10014 LCD400 12 6 400 MCM 0135 10015 LCD500 12 6 500 MCM Note NEMA standard two hole copper crimp lugs on
41. perly to prevent it from being damaged CON1P R2 1K c Vier 17 JB1 JUMPER JB1 FOR 0 5mA o OPEN JB1 FOR 0 10V CCW O JUMPER 4 TO5 X WHEN NOT USING REMOTE POT UNIT SHIPPED WITH JUMPER INSTALLED 222 INSTRUMENT WIRE L2 Customer Connection 2014 Chromalox In C 1 888 996 9258 4 2 6 Calibration MaxPac IP Many high temperature heating elements exhibit extreme hot to cold resistance ratios Heating elements composed of Platinum Molybdenum Tungsten and Tantalum to name a few draw excessive current on start up Depending on the mass of the elements these high starting currents may exist for extended periods of time Generally once the elements have achieved their normal operat ing temperatures the current drawn through the MaxPac Power Pak will fall within the rating of the unit For these types of loads we recommend adjusting the LIM Current Limit to 50 or less This will decrease voltage as well as current 1 Set Current Limit I LIM pot to 0 for full current output CCW Current Limit is for limiting current for loads that have extreme hot to cold resistance ratios or are overrated We recommend for these types of loads to adjust LIM Cur rent Limit to 50 or less This will also decrease voltage as well as current 0 Current Limit gives 100 current output CCW 100 Current Limit gives
42. proceeded by the word CAUTION that are intended to help prevent damage to the MaxPac or other equipment Note that Damage Prevention Messages are NOT accompanied by the Safety Alert Symbol 1 888 996 9258 2014 Chromalox Inc 3 Descriptio MaxPac I Il and Ill The Chromalox MaxPac I Il and III controllers are highly versatile SCR Power Paks with optional plug in proportional firing and shorted SCR detection boards Firing modes include On Off and DOT proportional zero voltage switching Chromalox exclusive DOT Demand Oriented Transfer firing technique switches the fewest number of cycles to provide the most precise zero crossover control At 50 output the unit s output alternates between one cycle On and one cycle Off At 5196 the output continues with one cycle On one cycle Off and gradually integrates one extra On cycle for the additional 1 This DOT fired tech nique also minimizes temperature overshoot temperature fluctuations and helps extend the load s element life due to reduced thermal shock The power SCR assemblies consist of one two or three pairs of SCRs connected back to back with an optional semiconductor fuse RC Snubber and MOV protection The firing circuit is based on a common On Off control board with plug and play Shorted SCR and DOT fired plug in boards Diagnostic indicators are included Plug in terminal blocks for easy customer interface are also provided MaxPac IP
43. pt KP O LH N O N Connection iso NOT on MaxPac CAUTION IMPORTANT The Dt fuses installed on the SCR are designed to protect the SCR from faults on the load connection side They are NOT intended to provide wire protection 1 888 996 9258 2014 Chromalox Inc 3 MaxPac lll Three Wire 3 Leg Control MAX PAC III MaxPac IP Single Phase MAX PAC IP transformer Coupled pa S L2 L2 connection to MaxPac is instrument power only CAUTION IMPORTANT The It fuses installed on the SCR are designed to protect the SCR from faults on the load connection side They are NOT intended to provide wire protection 14 2014 Chromalox Inc 1 888 996 9258 The following drawings show proper installation of the crimp lugs on the bus bars CRIMP LUG NUT FLAT WASHER LOCK WASHER LOCK WASHER n FLAT WASHER CRIMP LUG LOAD BUS BAR FLAT WASHER BOLT LINE BUS BAR FLAT WASHER BOLT en CJ nl amm All bolts must mount FLAT WASHER CRIMP LUG with excess bolt lengths Illustration 1 View From Rear Ventilated Panel toward the fuse to main tain required electrical clearances LOAD BUS BAR 1 0 through 500 mcm Ne wire
44. ry envi ronment Temperature extremes and excessive moisture can damage the controller Before choosing a location in which to mount your MaxPac please consider the following Temperature When mounting the SCR unit in a control panel attention should be paid to the enclosure tempera ture The SCR is rated to perform at its nameplate current rating in temperatures up to 50 C 122 F Ensure that adequate ventilation is provided or some other method of maintaining the correct cabi net temperature is used Cleanliness Careful attention must be paid in areas subjected to airborne particles The efficiency of the heat sinks relies on their conducting surfaces being maintained in a clean manner See the Maintenance Section Dampness High humidity or hosing down a unit should be avoided Clearance Choose a location that will provide adequate spacing around the unit when mounted This will en sure proper air flow necessary to cool the device A WARNING Hazardous Voltage Disconnect and lockout power before install ing or servicing Failure to comply could result in personal injury or equipment damage 1 888 996 9258 2014 Chromalox Inc 5 Installation Section continuation of page 5 The forced air design of the MaxPac series allows mounting in any direction It is essential that air flow through the enclosure be planned to insure proper cooling The 100 amp through 300 amp open design MaxPac allow the
45. teady on and steady off With the DOT Firing option the indicator will display the rapid firing sequence 1 888 996 9258 O 2014 Chromalox Inc rd SCR Control Board The Basic control board provides the following functions The low voltage dc to operate the circuitry A switching regulator circuit converts the instrument power voltage to 12Vdc The power distribution for the cooling fans The incoming instrument power is fused and then routed to the fan power terminals The signal condition for the on off input and analog inputs The 120 to 240 on off input is isolated by an opto coupler The dc and contact closure inputs are buffered by the circuitry Amplifiers convert the analog inputs and the potentiometer input to a signal level compatible with the optional proportional firing board The plug in receptacle for the optional proportional board allows for an easy upgrade to proportional control The drive signal to the SCR trigger boards The temperature alarm The heat sink temperature is derived from a solid state sensor mounted on the heat sink This is then compared to two set points The first alarm is a warning and activates the externally connected device This allows time to correct the problem before the second alarm inhibits the firing circuit The Shorted SCR Alarm The plug in receptacle for the shorted SCR board is located on this board Signals from the SCR are routed to the option board When a short is detected
46. ut adjust CW to 100 for full voltage output Voltage output should increase proportionally Return to CCW position and output will decrease to zero output 18 With Manual pot CW at 100 and I LIM Current Limit at 0 adjust LIM towards 100 noting that voltage output de creases with the adjustment of the Current Limit pot Adjust Current Limit pot for your application if needed 19 Turn POWER OFF and remove meters TEST COMPLETE 1 888 996 9258 2014 Chromalox Inc Eoee MaxPac I Il and Ill 120 575 Vac 60 Hz CE 400 Vac 50 Hz 100 150 200 300 400 Control Inputs Resolution proportional Better than 0 1 Accepts all of the following as standards Line Voltage On Off Control Signal Input 120 thru 230 Vac 10 Load Current Rating 5 32 Vdc Contact Closures Ambient Temperature Proportional Control SCR Capability Signal Input Input Impedance 4 4 20 mA 250 Ohms Bu ume 125 We E 10k Ohms or greater urge nating 0 5VdC6uisee 10k Ohms or greater 0 10 Vac 10k Ohms or greater Optional Remote Manual Adjust Isolation Auto Manual Switch Instrument Power 120 or 230 Vac Heat Sink 50 60 Hz Output Voltage 0 99 RMS line voltage High Temperature Eo Vsupply 1 5V SCR Indicator Output forward drop Shorted SCR Indicator Output MaxPac IP Contro

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