user's manual · 1-888-99-98 01 chromalox ®, nc. - 1 - thank you for choosing the chromalox®...

PK480-2

P/N 0037-75428

User's Manual

www.chromalox.com 800-443-2640 © 2014 Chromalox, Inc.

PK480-2

P/N 0037-75428

User's Manual

www.chromalox.com 800-443-2640 © 2014 Chromalox, Inc.

- 1 -© 2014 Chromalox®, Inc.1-888-996-9258

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:• 120-575Vac@100-1200Amps• IsolatedControlCircuit• FlexibleI/OPowerWiring• EasyCustomerInterface• RemoteShutdown• CompactSizeandConstruction• Touch-SafeDesign(optionon100-650Ampmodels)• dv/dtTransientVoltageProtection• MOVProtection• Built-InPowerDistribution

Features for the MaxPac I, II, and III include:• ZeroCrossoverFiring• IsolatedControlCircuit

On/OffControlInputs: 120thru240Vac 5-32Vdc DryContactClosure

Proportional(DOTFiring)Inputs: 4-20mA,0-5Vdc,1-5Vdc,0-10Vdc RemoteManualAdjust(Optional) RemoteAuto/ManualSwitch(Optional)• ElectronicallyProtectedwithTemperatureWarningandShutdownSystem• Single-orThree-CycleResolution(JumperSelectable)• ShortedSCRDetection(Optional)

Features for the MaxPac IP include:• PhaseAngleFiring• IsolatedControlCircuitInputs

0-5mA,0-20mA 0-50mA,1-5mA 4-20mA,10-50mA 0-5Vdc,0-10Vdc

• OptionalCurrentLimit• SoftStart• LineVoltageCompensation• Zero&GainAdjustments• Built-InManualAdjustment• CurrentLimitAdjustment(Optional)

Ifyouhaveapplicationquestions,refertotheEngineeringResourcesectionofourwebsiteatwww.chromal-ox.com to find the answer you’re looking for, or call one of our application engineersat1-888-996-9258forpersonalassistance.

-2- © 2014 Chromalox®, Inc. 1-888-996-9258

Table of Contents

Section Topic Page

1................................................. ImportantSafeguards ..................................................................................... 32................................................. Description ..................................................................................................... 43................................................. BeforeYouInstall ............................................................................................ 54................................................. Installation ...................................................................................................... 6 4.1 ................................. Mounting ......................................................................................................... 8 4.2 .................................Wiring ............................................................................................................ 11 4.2.1 ............. Touch-SafeDesign ....................................................................................... 11 4.2.2 ............. CoverRemovalandInstallation .................................................................... 12 4.2.3 ............. Power/LoadWiring ....................................................................................... 12 4.2.4 ............. InstrumentPower ......................................................................................... 16 4.2.5 .............Grounding ..................................................................................................... 16 4.2.6 ............. CommandSignalWiring ............................................................................... 17 4.2.7 ............. Calibration .................................................................................................... 235 ................................................ Specifications ............................................................................................... 246 ................................................ Maintenance ................................................................................................. 257 ................................................ Troubleshooting ............................................................................................ 268 ................................................ PartsandAccessories .................................................................................. 279 ................................................WarrantyandReturnInformation ................................................................. 2810 .............................................. ECDeclarationofConformity ....................................................................... 37

-3-© 2014 Chromalox®, Inc.1-888-996-9258

1Please read all instructions before installing and operating your MaxPac™.

Toavoidelectricalshockorinjury,alwaysremovepowerbeforeservicingacircuit.

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-bolswillalertyoutopotentialhazards.Safetyprecautionsshouldalwaysbefollowedtoreducetheriskofpersonalinjurytopersonsfromfireandelectricalshockhazards.

SafetyAlertSymbol

InternationalShock/ElectrocutionSymbol

Eachsafetymessageisprecededbyasafetyalertsymbol andoneofthreewords:DANGER,WARN-ING,orCAUTION.

Thesemean:

Important Safeguards

YouWILLbekilledorseriouslyhurtifyoudonotfollowinstructions.

YouCANbekilledorseriouslyhurtifyoudonotfollowinstructions.

YouCANbehurtifyoudonotfollowinstructions.

DANGER

WARNING

CAUTION

DamagePreventionMessages:

YouwillseeotherIMPORTANTmessagesthatareproceededbytheword CAUTION that are intended to help prevent damage to the MaxPac™orotherequipment.NotethatDamagePreventionMessagesareNOTaccompaniedbytheSafetyAlertSymbol.

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2

† Thiscanbesettothreecycles‘On’/threecycles‘Off’(seesectiononinstallationoptions).

Description

MaxPac I, II, and IIITheChromaloxMaxPacI,II,andIIIcontrollersarehighlyversatileSCRPowerPakswithoptionalplug-inproportionalfiringandshortedSCRdetectionboards.FiringmodesincludeOn/OffandDOTproportionalzerovoltageswitching.ChromaloxexclusiveDOT(DemandOrientedTransfer)firingtechniqueswitchesthefewestnumberofcyclestoprovidethemostprecisezerocrossovercontrol.At50%output,theunit’soutputalternatesbetweenonecycle“On”andonecycle“Off.”At51%,theoutputcontinueswithonecycle“On,”onecycle“Off,”andgraduallyintegratesoneextra“On”cyclefortheadditional1%.ThisDOTfiredtech-niquealsominimizestemperatureovershoot,temperaturefluctuationsandhelpsextendtheload’selementlife due to reduced thermal shock.

ThepowerSCRassembliesconsistofone,two,orthreepairsofSCRsconnectedbacktoback(withanoptionalsemiconductorfuse),RCSnubber,andMOVprotection.ThefiringcircuitisbasedonacommonOn/OffcontrolboardwithplugandplayShortedSCRandDOTfiredplug-inboards.Diagnosticindicatorsare included. Plug-in terminal blocks for easy customer interface are also provided.

MaxPac IPTheChromaloxMaxPacIPutilizesSinglePhase,PhaseAnglefiringtomodulatepowertoaninductiveorresistiveload.PhaseAnglecontrolhastheadvantageofproportioningeverycycletherebyprovidingveryfine resolution of power. Fast responding loads in which the resistance changes as a function of temperature requirePhaseAnglecontrol.TheMaxPacIPoffersaSoftStartfeaturethatassuresthattheloadpowerisgraduallyincreasedfromzerotothevaluesetbythecommandsignalintheeventofapowerinterruption.Inaddition,optionalCurrentLimitisusedtoprotecttheload,SCRcontrollerandthetotalsystemfromlargesurge currents that could occur at start-up.

-5-© 2014 Chromalox®, Inc.1-888-996-9258

3Before You Install

ImmediatelyafterreceivingyourMaxPacI,II,IIIorIPSeriesController,visuallyinspecttheshipmentpackag-ing and record any damage on the shipping documents. Unpack the controller and carefully inspect for obvi-ousdamageduetoshipment.Ifanydamagehasoccurred,YOUmustfileaclaimwiththecarriercompany,sincethecarriercompanywillnotacceptaclaimfromtheshipper(Chromalox).

BesuretocheckthemodelnumberandverifythatyouhavereceivedthecorrectModelofcontroller.

Ifthecontrollerisnotinstalledandplacedintooperationimmediately,itshouldbestoredinacool,dryenvi-ronment. Temperature extremes and excessive moisture can damage the controller.

BeforechoosingalocationinwhichtomountyourMaxPac,pleaseconsiderthefollowing:

TemperatureWhenmountingtheSCRunitinacontrolpanel,attentionshouldbepaidtotheenclosuretempera-ture.TheSCRisratedtoperformatitsnameplatecurrentratingintemperaturesupto50˚C(122˚F).Ensurethatadequateventilationisprovidedorsomeothermethodofmaintainingthecorrectcabi-net temperature is used.

CleanlinessCarefulattentionmustbepaidinareassubjectedtoairborneparticles.Theefficiencyoftheheatsinksreliesontheirconductingsurfacesbeingmaintainedinacleanmanner.(SeetheMaintenanceSection.)

DampnessHigh humidity or hosing down a unit should be avoided.

ClearanceChoose a location that will provide adequate spacing around the unit when mounted. This will en-sureproperairflownecessarytocoolthedevice.

WARNING

Hazardous Voltage: Disconnectandlockoutpowerbeforeinstall-ingorservicing.Failuretocomplycouldresultinpersonalinjuryor equipment damage.

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InstallationSection(continuationofpage5)

TheforcedairdesignoftheMaxPacseriesallowsmountinginanydirection.Itisessentialthatairflowthrough the enclosure be planned to insure proper cooling.

The100ampthrough300ampopendesignMaxPacallowtheinputlinepowertoconnectfromeitheroftwodirections.The output power can only be connected from one direction. The three mounting configurations

areshownbelow(MaxPacIIThree-PhaseTwo-LegShown).

Opendesignsabove300ampsandallcloseddesignsallowincomingand outgoing wiring in either direction.

In In

Configuration One

CoolAirInWarmAirOut

Fan Phase 1 Phase 3

orIn Out orIn Out

Configuration TwoOut Out

In In

WarmAirOut CoolAirInPhase 1 Phase 3 Fan

orIn orIn

Configuration Three

WarmAirOut

Out

Phase 3

orInIn

Out

Phase 1

In orIn

Fan

CoolAirIn

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InstallationSection(continuation of page 5)

ExamplesofProperAirFlow

Pagoda Top

Fan

Air

Louvers Louvers

MaxPac

AirFan MaxPac

Fan

Enclosure

Air Enclosure

FanFilter

Forced Air In

Forced Air OutLouvers

Since hot air rises naturally, it is not recommended that cooling air enterfrom the top and exhaust at the bottom of the enclosure.

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Figure Drawing Number ModelFigure Model1................100A,150A,&200A2-LegOpenType1................100A,150A,200A,&300A1-LegOpenType2................100A,150A,&200A3-LegOpenType3................300A2-LegOpenType4................100A,150A,200A,300A&400A1-LegTouch-Safe4................400A1-LegOpenType5................100A,150A,200A,300A&400A2-LegTouch-Safe5................400A2-LegOpenType6................100A,150A,200A,300A&400A3-LegTouch-Safe6................300A&400A3-LegOpenType7................550A&650A1-LegTouch-Safe7................550A&650A1-LegOpenType8................550A&650A2-LegTouch-Safe8................550A&650A2-LegOpenType9................550A&650A3-LegTouch-Safe9................550A&650A3-LegOpenType..................800-1200Ampunits,consultfactory

4Installation

Please read all information in this section before beginning the installation of your MaxPac.

InstallationoftheMaxPacrequiresthreesteps:1. Mounting2. Powerwiring3. 120or 230Vac50/60hzforinstrumentpower.See4.2.4,pg.16.

4.1 - Step 1: Mounting

BeforemountingyourMaxPac,pleasereadthesectiontitled“BeforeYouInstall’onpage5foradescriptionof 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.

IMPORTANT: Please note that the figures on the following pages are not drawn to the same scale.

- 9 -© 2014 Chromalox®, Inc.1-888-996-9258

Figure 1 Figure 2

Figure 3 Figure 4

Figure 5

4.7" [107mm]0.0" [0mm]

1.0" [25mm]

4.75" [121mm]

8.5" [216mm]9.5" [241mm]

6.0" [153mm]7.3" [185mm]

FIRING PACKAGE

FAN END

Ø0.280" [Ø7.11mm](6 HOLES)

4.2" [107mm]0.0" [0mm]

1.0" [25mm]

7.2" [184mm]

13.5" [342mm]14.5" [368mm]

6.0" [153mm]

7.28" [185mm]

FIRING PACKAGE

FAN END

Ø0.280" [Ø7.11mm](6 HOLES)

7.2" [183mm]0.0" [0mm]

1.3" [33mm]

7.3" [185mm]

13.3" [337mm]14.6" [371mm]

12.0" [305mm]13.3" [338mm]

FIRING PACKAGE

FAN END

Ø0.280" [Ø7.11mm](6 HOLES)

5.12" [130mm]0.0" [0mm]

1.3" [33mm]

9.3" [237mm]

13.3" [338mm]14.6" [371mm]

8.1" [206mm]9.1" [232mm]

FIRING PACKAGE

FAN END

Ø.3125 [Ø7.94mm](8 HOLES)

5.3" [135mm]

8.4" [214mm]0.0" [0mm]

1.3" [33mm]

9.3" [237mm]

13.3" [338mm]

14.6" [371mm]

14.7" [375mm]

15.75" [400mm]

FIRING PACKAGE

FAN END

Ø.3125" [Ø7.94mm](8 HOLES)

5.3" [135mm]

- 10 - © 2014 Chromalox®, Inc. 1-888-996-9258

Figure 9

13.8" [351mm]0.0" [0mm]

1.3" [33mm]

26.5" [673mm]

16.3" [414mm]17.6" [448mm]

11.3" [287mm]

25.5" [648mm]

FIRING PACKAGE

FAN END

Ø.3125" [Ø7.94mm](8 HOLES)

6.3" [160mm]

Figure 6 Figure 7

Figure 8

11.7" [298mm]0.0" [0mm]

1.3" [33mm]

9.3" [237mm]

13.31" [338mm]

14.62" [371mm]

21.4" [543mm]

22.4" [568mm]

FIRING PACKAGE

FAN END

Ø.3125" [Ø7.94mm](8 HOLES)

5.3" [135mm]

5.8" [148mm]0.0" [0mm]

1.3" [33mm]

11.3" [28mm]

16.3" [414mm]17.6" [448mm]

9.5" [241mm]10.5" [267mm]

FIRING PACKAGE

FAN END

Ø.3125" [Ø7.94mm](8 HOLES)

6.3" [160mm]

9.8" [249mm]0.0" [0mm]

1.3" [33mm]

11.3" [287mm]

16.3" [414mm]17.6" [448mm]

17.5" [444mm]18.5" [470mm]

FIRING PACKAGE

FAN END

Ø.3125" [Ø7.94mm](8 HOLES)

6.3" [160mm]

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4.2 - Step 2: Wiring

4.2.1 - Touch-Safe Design

IftheMaxPacmodelyoupurchasedisofaTouch-Safedesign,followthestepsonthefollowingpagetoinstall the electrical wiring. This will ensure the wiring is done properly while maintaining the Touch-Safe feature.IfyourMaxPacisofanOpendesignbelow400Amps,disregardthissubsection.

ThefollowingisadetaileddrawingofaTouch-Safeunit:

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.

IMPORTANT: SelectinstallationwiringthatisinaccordancewiththeNationalElectricalCodeandanylocalstandardsthatmaybeapplicable.

WARNING

Hazardous Voltage: OnlyqualifiedpersonnelshouldperformelectricalwiringfortheMaxPacPowerPaks.LETHALLYHIGHVOLTAGESareassociatedwiththisequipmentandaredanger-ous if improperly installed.

COOLING AIR

COOLING AIR

SCR

FUSE

HEATSINK FINS

COVER PROVIDES FOR TOUCH SAFE FEATURE

TOUCH-SAFE COVER PROVIDES WIRE ENTRANCE AND EXIT THROUGH SEALS COVERING THE WIRE WINDOW.

REMOVAL OF THE TAPE BEHIND THE WINDOWS TOBE USED ALLOWS WIRES TO PASS. THE TAPE

REMAINS ON UNUSED WINDOWS TO PROVIDE TOUCHSAFE FEATURE.

BUS BAR DESIGN ALLOWSFOR WIRING FROM EITHERDIRECTION AND MULTIPLELOAD CIRCUITS

BUS BAR DESIGN ALLOWSFOR WIRING FROM EITHERDIRECTION AND MULTIPLELOAD CIRCUITS

LONG LIFE, HIGH OUTPUT BALLBEARING FANS PROVIDE RELIABLE

COOLING

-12- © 2014 Chromalox®, Inc. 1-888-996-9258

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.

Forthepower/loaddrawings:

Onopendesignunitsupto300Amps,X1,X2,X3,L1,L2,andL3refertocopperlugs.

Onopendesignunits400AmpsandgreaterandallTouch-Safedesigns,X1,X2,X3,L1,L2,andL3referto bus bar connections.

MaxPac I

4.2.2 - Steps for Touch-Safe Design Cover Removal and Installation

RemoveCover: 1. Loosenthethumbscrewsonbothendsofthecover. 2. Liftthecoverfromthebase.

InstallWiring: 3. Attachthewirestothebusbarsinaccordancewiththeinstructionsinthenextsection. 4. Choosetheentranceandexitdirectionsforthewiringasdesired. 5. Afterthewiringiscomplete,removethetapefromtheinsideofthewiregasketsofthe windows that the power wiring will enter or exit.

ReplaceCover: 6. Angletheendofthecoverwithoutscrewstowardsthe“fan-end”oftheunit. 7. Slipthatendintoplacefirstwhileallowingthewiringtopassthroughthedesiredwindows. 8. Slip the opposite end of the cover into place. 9. Tighten all thumb screws.

WARNING

Hazardous Voltage: DONOTremovethetapefromthebackofthe windows that are not used, as this maintains the Touch-Safe feature.

MAX PAC I

L2

L1 X1

Single PhaseResistive

L2 Connection isNOT on MaxPac

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MaxPac II

MaxPac III

Three Wire2 Leg ControlMAX PAC II

L1

L3

L2

X1

X3

L2 Connection isNOT on MaxPac

Four Wire�3 Leg Control

MAX PAC III

L1

L2

L3

X1

X2

X3

NN Connection is�NOT on MaxPac

IMPORTANT: TheI2t 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.

CAUTION

-14- © 2014 Chromalox®, Inc. 1-888-996-9258

MaxPac III

MaxPac IP

IMPORTANT: TheI2t 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.

CAUTION

Three Wire3 Leg Control

MAX PAC III

L1

L2

L3

X1

X2

X3

Single Phasetransformer

CoupledMAX PAC IP

L2

L2

L1 X1

L2 connection toMaxPac is instrument

power only

-15-© 2014 Chromalox®, Inc.1-888-996-9258

ThebusbarsaredesignedtoacceptNEMAstandardtwo-holecrimplugsinaccordancewiththechartsbelow.

Thefollowingdrawingsshowproperinstallationofthecrimplugsonthebusbars:

Illustration 1:ViewFromRearVentilatedPanel

FUSE

Smaller wire, #1 through #8, often usedfor power distribution, can be connectedtobothsidesoftheloadbus.Wiringmustbe bent slightly to align with the windowsin the top of the touch safe units.

LINEBUSBAR

LOADBUSBAR

FANEND

SCR

1/0through500mcmwire must mount on thefuse side of the busbar as shown tomaintain requiredelectrical clearances

Illustration 2:ViewFromTop

Touch-Safe Units100-400Amps

InputBusUpto(3)1/0-300mcm(70mm2—150mm2)

Upto(2)350-500mcm(185mm2—240mm2)

OutputBusUpto(10)#8-#1(10mm2—50mm2)

Upto(3)1/0-300mcm(70mm2—150mm2)Upto(2)350-500mcm(185mm2—240mm2)

550-650AmpsInputBus

Upto(4)1/0-300mcm(70mm2—150mm2)

Upto(3)350-500mcm(185mm2—240mm2)

OutputBusUpto(12)#8-#1(10mm2—50mm2)

Upto(4)1/0-300mcm(70mm2—150mm2)Upto(3)350-500mcm(185mm2—240mm2)

800-1200AmpsOpenDesign

Inputandoutputbusdrilledtoaccomodateqty(4)1/0-500mcmNEMAstandardtwo-holecrimplugsperphase.

Allboltsmustmountwith excess bolt lengths toward the fuse to main-tain required electrical

clearances.

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The power wiresmustalwaysconnecttothefuseside(refertoillustration1onpage15)ofthebusbar.Thisis essential to maintain the required spacing between the phases and sides, and to align with the openings in thetop.Theonlyexceptiontothisiswhenusingpowerdistributionusingconnectorsofsizes#8to#1.Thereis adequate spacing for these connectors to be mounted on both sides of the bus bar, if necessary.

The bolt headshouldalwaysbeontheoutsideofthebusbar(refertoillustration2onpage15)withtheboltextending 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. Onthe550Ampand650Ampmodels,itisnecessarytomountthewireintheholesthatmaximizethedistanceforthewiretoexittheenclosure.Thismaximizesthedistancefromthecovertothenon-insulatedconnector.

Whenusingthepower distribution feature and mounting terminals on both sides of the bus bar, the wires mountedontheoutsideofthebusbarmustbebentinwardslightlytoalignwiththeopeninginthetop.Allwiring,especiallythelargerwires,shouldbebentpriortomountingtothebusbars.DONOTusethebusbars as an anchor to bend the power cables.

4.2.4 - Instrument Power

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

ChasisisprovidedwithholepatternforstandardNEMAtwo-holecrimplugs.

WARNING

Hazardous Voltage: ThisElectricalEquipmentmustbeinstalledbya qualified person and effectively grounded in accordance to the NationalElectricCodeandlocalcodes.

IMPORTANT

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4.2.6 - Command Signal Wiring

Pleaserefertothefiguresonpage19forillustrationsofthe6-,8-,and10-pininputterminals.

MaxPac I, II, and III

On/Off Control Signals

AC Input–The120thru230VacsignallinesareconnectedtoterminalJ1-7&8(seeFig.9onpage21).Aninputvoltageof120to230VacturnsthepowerOn.TheturnOFFvoltageis0Vac. DC Input–The5-32VdcsignallinesareconnectedtoterminalJ3-1&4(seeFig.10onpage21).Aninputvoltageof5to32VdcturnsthepowerOn.TheturnOFFvoltageis0Vdc.

Contact Closure Input–ThedrycontactsignallinesareconnectedtoterminalJ3-1&2(seeFig.11onpage21).AclosedcontactturnsthepowerOn.TheturnOFFvoltageisanopencontact.

Process Analog Control Signals

MaxPacI,II,andIIIhavebeenfactorycalibrated.Theseunitsaccept0-5,1-5,0-10Vdc,and4-20mAinputsignalsthatareconnectedtoTerminalBlockJ2.Thefollowingsignalsareconnectedto:

0-5Vdc: TerminalJ2-9(+)&7(-)(seeFig.7onpage21)1-5Vdc: TerminalJ2-5(+)&7(-)(seeFig.5onpage21)0-10Vdc:TerminalJ2-10(+)&7(-)(seeFig.8onpage21)4-20mA: TerminalJ2-6(+)&7(-)(seeFig.6onpage21)

Auto/Manual Input

TheMaxPacI,II,andIIIcanbe wired to make it possible to select an input from either a temperature process controller or a manual input potentiom-eter.Aswitchisusedtoselectbetween the input from a 1K potentiometer and a linear controlinput(seeFig.4onpage21).Theunitisshippedwithajumperfromterminals2and3ofterminalblockJ2(seeillustra-tion3).Removejumpertoinstallauto/manual input.

Demand IndicatorTheLEDdemandindicatorislocatedonthemainPCboardandisviewablethroughthecover.WiththeOn/Offcontroloption,theindicatorwilldisplaysteady“on”andsteady“off”.WiththeDOTFiringoption, the indicator will display the rapid firing sequence.

IMPORTANT: WhenenablingtheAuto/ManualInput,thejumperfromterminals2and3ofterminalblockJ2mustberemoved.

CAUTION

Illustration 3

NC NOCONTACTNORMALLY CLOSED

(SWNC)

CONTACTNORMALLY OPEN(SWNO)

SWITCHASSEMBLY(SW)

PANEL TO BEMOUNTED TO

LEGENDPLATE(LP)

AUTO HAND

SWITCH KNOB(SW)

AUTO HAND

WIRING

1

4

NC NO

1KPOTENTIOMETER

��

CW

2

3

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SCR Control Board TheBasiccontrolboardprovidesthefollowingfunctions: Thelowvoltagedctooperatethecircuitry: Aswitchingregulatorcircuitconvertstheinstrumentpowervoltageto+12Vdc.

Thepowerdistributionforthecoolingfans: The incoming instrument power is fused and then routed to the fan power terminals.

Thesignalconditionfortheon/offinputandanaloginputs: The120to240on/offinputisisolatedbyanopto-coupler.Thedcandcontact closureinputsarebufferedbythecircuitry.Amplifiersconverttheanaloginputsand 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.

ThedrivesignaltotheSCRtriggerboards: Thetemperaturealarm: 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. TheShortedSCRAlarm: The plug-in receptacle for the shorted SCR board is located on this board. Signals fromtheSCRareroutedtotheoptionboard.Whenashortisdetectedtheexternally connected device output is activated.

2AMP(2AG)CHROMALOXP/N0024-01097LITTLEFUSEP/N225002

( @ )

( )

( )

( )

- 19 -© 2014 Chromalox®, Inc.1-888-996-9258

Proportional DOT Firing Board

Chromalox’sexclusiveDOT(De-mandOrientedTransfer)firingtech-nique switches the fewest number of cycles to provide the most pre-cisezerocrossovercontrol.At50%output, the unit’s output alternates betweenonecycle“On”andonecycle“Off.”At51%,theoutputcontinueswithonecycle“On,”onecycle“Off,”andgraduallyinte-gratesoneextra“On”cyclefortheadditional1%.

Remote Shutdown

Whenitisnecessarytodisabletheoutput,connectadrycontactbetweenJ3-3&4(seeFig.12onpage21).Whenitisclosed,thepowercontrolwillshutOFF.

Shorted SCR Detection (optional)

Thisoptionprovidesameansofalertinganoperatortoaproblemwiththesystem.AnexternalindicatinglamporrelaycanbeconnectedtoJ1-5&6(seeFig.2onpage21).ThisindicatormustberatedfortheinstrumentpowerappliedtoJ1-1&2.ThreediagnosticLEDsshowwhichSCRpairisfaulted.Theselightsaresynchronizedwiththedemandindicatorandcanonlyindicatewhilethedemandisactive.ShortingJ3-5&6candisabletheoutputatJ1-5&6.Thealarmcanbeselectedas latching or non-latching.

Alatchingalarmmeansthatifthealarmactivatesandthesystemsubsequentlyreturnstonormal,thealarmwillremainlatcheduntilaresetbutton(externalswitch–customerprovided)ispressed.Anon-latching alarm resets automatically.

IMPORTANT: Thisshutdownoverridesthecontrolinputonly.ItwillNOTprotectagainst faulted or damaged SCRs.

CAUTION

SHORTEDSCRDETECTION

DEMAND

1 2 3

SHORTJ3-1&2FOR1CYCLEFIRING

SHORTJ3-2&3FOR3CYCLEFIRING

Unitshippedfor3cycleoperation

-20- © 2014 Chromalox®, Inc. 1-888-996-9258

Shorted SCR Detection (optional), cont’d.

Thelatchingandnon-latchingoptionisjumperselectable;thejumperislocatedontheplug-inshortedSCRdetectionboard.Latchingandnon-latchingoperationbytheoutputatJ1-5&6iscontrolledbyJ3ontheshortedSCRdetectionboard0135-28096.Whenthisjumperisinstalled,latchingoperationisachieved.ThedrawingbelowshowstheShortedSCRDetectionboard.

Heat Sink Over-Temperature

AnexternallamporrelaymaybeconnectedtoJ1-3&4(seeFig.2onpage21)(thismustberatedfortheinstrumentpowerappliedtoJ1-1&2).Thiswillprovideanindicationtotheoperatorthatthe heat sink is approaching an unsafe temperature level. The unit will enter a shutdown mode if the temperature continues to rise.

UNIT SHIPPED IN NON-LATCHING MODE.

-21-© 2014 Chromalox®, Inc.1-888-996-9258

Input Terminals (MaxPac I, II, and III):

120~240 ON/OFF CONTROL

4-20mA PROPORTIONAL INPUT SIG

COMMON4-20mAPROPORTIONALINPUT

66

0 TO +5 VDC PROPORTIONAL INPUT SIG

0TO+5VDCPROPORTIONALINPUT

5

12

43

J3

6

COMMON

109

78

0 +10 VDC PROPORTIONAL INPUT SIG

0+10VDCPROPORTIONALINPUT

J3

5

21

34

6

COMMON

109

78

5

21

34

J3

6

45

23

J21

MANUAL CONTROL INPUT SIG

10

789

65

AUTO

POTREFVOLTAGE

COMMONJ2

2

43

1

MANUAL

1-5 VDC PROPORTIONAL INPUT SIG

1-5VDCPROPORTIONALINPUT

45

23

1J2

10

COMMON789

65

J1

10

789

65

1 K

J2

2

43

1J2

2

43

1

J1 J3

120~230INSTRUMENTPOWER

REQUIRED ON ALL CONFIGURATIONS120~230 INSTRUMENT POWER

J1

SHORTED SCR ANDHI TEMP INDICATORS.

SHORTED SCR INDICATOR RESET.

FIG12.

FIG9.

FIG6.

L2

COMMON

REMOTE SHUTDOWNEXTERNAL +5~32 VDC ON/OFF

COMMON

FIG10.

+ -

DRY CONTACT ON/OFF

FIG11.

+

FIG7.

FIG4.

FIG8.

+

L1

FIG5.

JUMPER

EXTERNAL120~230

FIG2. FIG3.FIG1.

12345678

12345678

HITEMPINDICATOR.

SHORTEDSCRINDICATOR.

123456

12345678

JUMPER

JUMPER JUMPER ON/OFFCONTROL

TheseareACvoltageoutputsat100mAmax.,not contact closures. See model numberfor voltage rating.

-22- © 2014 Chromalox®, Inc. 1-888-996-9258

MaxPac IP

TheChromaloxMaxPacIPisasolid-stateproportionalpowercontrollerthatutilizesaPhaseAnglefiringtechniquetomodulatepowertoaninductiveorresistiveload.SeparateadjustableZero,Gain,ManualBias,andCurrentLimitpotentiometersareprovidedalongwithscrewtypeplug-inconnectorsforinputsignals,EmergencyShutdown,andoptionalRemoteManualBiaswith0 - 100%dial.Allunitshavethermostatpro-tectionwithN.C.contacts.

Start-up

TheMaxPacIPhasbeenfactorycalibratedfor4-20mAinput.Besuretheoperatingvoltageandsignalinputarecorrectlyapplied.Also,makesuretheEmergencyShutdown,ifused,hasN.O.contactsandjumperpins4&5onthe10-pinconnectorifremotemanualbiasarenotused.Pleaseread the information on calibration at the end of this section for current limit settings for loads with extremehottocoldratiosorthosethatareoverrated.Otherrangesmaybefieldcalibratedbyuse ofzeroandgainpotentiometers.

IMPORTANT: WiththeCurrentLimitoption,thecurrenttransformermustbeter-minated properly to prevent it from being damaged.

CAUTION

0-5MA(0-10V)

4-20mA

10-50mACOM

CLOSE FORREMOTE

SHUTDOWN

N/C

N/C

JUMPER 4 TO 5WHEN NOT USINGREMOTE POT

UNIT SHIPPED WITH JUMPER INSTALLED

INSTRUMENTWIRE

LOAD

SCR

FUSE

X1

L2

L1

CT

TB1CON1P

JB1JUMPER JB1 FOR 0-5mAOPEN JB1 FOR 0-10V

Customer Connection

-23-© 2014 Chromalox®, Inc.1-888-996-9258

1.SetCurrentLimit(ILIM)potto0%forfullcurrentoutput(CCW).

CurrentLimitisforlimitingcurrentforloadsthathave

extremehottocoldresistanceratiosorareoverrated.We

recommendforthesetypesofloadstoadjustILIM(Cur-

rentLimit)to50%orless.Thiswillalsodecreasevoltage

aswellascurrent.0%CurrentLimitgives100%current

output(CCW).100%CurrentLimitgives10%current

output(CW).

2.SetManual(MAN)pottozerosounitwillnotbebiasedabove

input(CCW).

Manualcontroladjustmentprovidesameansofsetting

the output level of the MaxPac Power Pak in the absence

of controlling instrumentation. The manual control signal

value“adds”tothecontrollinginstrumenttosetmini-

mum output. The desired output power level may be set

byadjustingthemanualcontrol.Thisvalueofoutputwill

then be present even in the absence of a control signal.

3.SetRemoteManualpottozerooutputsounitwillnotbebiased

aboveinput(CCW).(Jumperpins4&5ifnotused.)

RemoteManualcontroladjustmentprovidesameans

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”tothecontrollinginstrumenttosetminimum

output. The desired output power level may be set by

adjustingtheRemoteManualcontrol.Thisvalueofout-

put will then be present even in the absence of a control

signal.ConnectRemoteManualpotwiretoPin4(CCW),

Pin5(W),andPin6(CW)ofplug-inconnector.

4.CheckforopencontactforEmergencyShutdown.

EmergencyShutdowninhibitsallSCRtriggerpulses

regardless of the level of the input signal or manual

potentiometer.ForEmergencyShutdown,closecontact

Pin7toPin8ofplug-inconnector.Leavecontactsopen

for operation.

5.Checkforpolarityofinputsignal.

6.Adjustinputsignaltolowendofscale.

ZeroAdjustcontrolsetsthepoweroutputstartingpoint

or reference. Thus, it effectively cancels positive inputs

to the MaxPac Power Pak.

EXAMPLE: 0-5mAinputàsetto0mAinput

4-20mAinputàsetto4mAinput

7.Withpoweroff,connectlinevoltageandloadasshown.

8. Connect meter to input and output.

WARNING:Setmetertocorrectscaletoreadproperinput

or output.

9.Applypowertounit.

10.Adjustinputsignaltolowendofscale.

11.UsingtheZeropot,adjusttheoutputvoltagejusttozerovolts.

12.Adjustinputsignaltotopendofscale.

GainAdjustControlsetsthemaximumpoweroutputfor

maximum input signal.

EXAMPLE: 0-5mAinput:setto5mAinput

4-20mAinput:setto20mAinput

13.UsingtheGainpot,adjustoutputvoltagejusttomaximum

volts.

14.Repeatsteps11,12,13,and14untilnoadjustmentis

necessaryofZeroandGainpotsforproperoutputvoltage

indication.Voltageoutputshouldincreaseproportionallytothe

signal input applied.

15.Adjustinputsignaltolowendofscale(zerovoltageoutput).

16.WithManualpotatzeroforzerovoltageoutput,adjust(CW)

to100%forfullvoltageoutput.Voltageoutputshould

increaseproportionally.ReturntoCCWpositionandoutputwill

decreasetozerooutput.

17.WithRemoteManualatzeroforzerovoltageoutput,adjust

(CW)to100%forfullvoltageoutput.Voltageoutputshould

increaseproportionally.ReturntoCCWpositionandoutputwill

decreasetozerooutput.

18.WithManualpot(CW)at100%andILIM(CurrentLimit)at

0%, adjustILIMtowards100%notingthatvoltage

outputde creaseswiththeadjustmentofthe

CurrentLimitpot.Adjust CurrentLimitpotforyour

application, if needed.

19.TurnPOWEROFFandremovemeters.TESTCOMPLETE.

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,andTantalum,tonameafew,drawexcessivecurrentonstart-up.Dependingonthemassoftheelements,

these“highstartingcurrents”mayexistforextendedperiodsoftime.Generally,oncetheelementshaveachievedtheirnormaloperat-

ing temperatures, the current drawn through the MaxPac Power Pak will fall within the rating of the unit. For these types of loads, we

recommendadjustingtheILIM(CurrentLimit)to50%orless.Thiswilldecreasevoltageaswellascurrent.

-24- © 2014 Chromalox®, Inc. 1-888-996-9258

5Specifications

Control InputsAcceptsallofthefollowingasstandards:

On/Off ControlSignalInput120thru230Vac±10%5-32VdcContact Closures

Proportional ControlSignalInput InputImpedance4-20mA ................. 250Ohms1-5Vdc .................. 10kOhmsorgreater0-5Vdc .................. 10kOhmsorgreater0-10Vdc ................ 10kOhmsorgreater

OptionalRemoteManualAdjustAuto/ManualSwitch

Instrument Power ...... 120or230Vac 50/60Hz

Output Voltage ........... 0-99%RMSlinevoltage (Eo=Vsupply-1.5VSCR forwarddrop)

Resolution (proportional)Betterthan0.1%

Line Voltage ...................120-575Vac,60Hz CE400Vac50Hz

Load Current Rating ......100,150,200,300,400, 550,650,800,1000,1200A

Ambient Temperature ....0-50°C(32-122°F)

SCR Capability Dielectric .................Withstandcapability Surge Rating 1500VRMSmin. Typicallyfifteen(15)times nominal RMS rating for 8.3milliseconds

Isolation .....................SCRsisolation2500V Input-outputisolation1500V

Heat Sink ........................Groundpotentialupto 650Amps

High Temperature ..........ACVoltageOutputIndicator Output 100mA@InstrumentPower

Shorted SCR ..................ACVoltageOutputIndicator Output 100mA@InstrumentPower

MaxPac I, II, and III

MaxPac IPControl InputsAcceptsallofthefollowingasstandards:

Phase Angle ControlSignalInput InputImpedance1-5,0-5mA .......... 1KOhms4-20,0-20mA ...... 250Ohms10-50,0-50mA .... 100Ohms

OptionalRemoteManualAdjust

Fan Power .................. 120or230VAC 50/60Hz

Output Voltage ........... 0-99%RMSlinevoltage (Eo=Vsupply-1.5VSCR forwarddrop)

Resolution (proportional)Betterthan0.1%

Line Voltage ............... 120,208,240,277,380,...................................... 480 and575Vac ±10%50/60Hz

Load Current Rating .. 100,150,200,300,400, 550,650,800,1000,1200A

Ambient Temperature ....0-50°C(32-122°F)

SCR Capability ...............Withstandcapability 1500VRMSmin. Typicallyfifteen(15)times nominal RMS rating for 8.3milliseconds

Surge Rating ..................Typicallyfifteen(15)times nominal RMS rating for 8.3milliseconds

Isolation ..........................SCRsisolation2500V Input-outputisolation1500V

Heat Sink ........................Groundpotentialupto 650Amps

Thermostat .....................4Amps@120Vresistive 2Amps@240Vresistive N.C.ContactStandard

Current Limit ..................10-100%ofrated output current

Soft Start ........................25%demandpersecond typical reset speed 8.3milliseconds

-25-© 2014 Chromalox®, Inc.1-888-996-9258

6Maintenance

Connections –Looseconnectionsinthepowerwiringwillgeneratehotspots.Thesewillcausedegradationof 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–Ifthepowermoduleisinstalledinanenvironmentwithhighhumidityordampness,electricalconnections 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.

WARNING

Hazardous Voltage: Disconnectallpowerbeforeperforminganymaintenanceorexaminingthepowermodule.ExposedterminalsmaycarryLETHALLYHIGHVOLTAGESwhenpowerisapplied.

-26- © 2014 Chromalox®, Inc. 1-888-996-9258

7Troubleshooting

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. IfDemandLightis“Off”

1. Check incoming line power.2. Checktheinstrumentpower.3. Checkthefuseonthemainboard.4. Verifytheinputsignal.5. CheckthatremoteshutdownJ3-3to4isopen.6. CheckthattheJ2-2to3isJumpered.7. Verifythatheatsinkisnotinovertemperaturemodebyremovingtemperaturesensor plugsfromJ10,J11,andJ12.

IfDemandLightis“On”1. Check the connections to SCR trigger board.2. Checkthepowerfuses(I2t).3. Lookfordamageonthetriggerboard.

-27-© 2014 Chromalox®, Inc.1-888-996-9258

8Parts and Accessories

Instrument Power Fuse Chromalox Part Number Description 0024-01097 Littlefuse#2250022AG2AMPI2T Fuses for 500 Vac Applications 0024-07634 200AmpI2t Fuse 0024-07630 250AmpI2t Fuse 0024-07632 400AmpI2t Fuse 0024-03116 500AmpI2t Fuse 0024-07633 700AmpI2t Fuse 0024-03118 800AmpI2t Fuse 0024-03200 1000AmpI2t FuseI2T Fuses for 575 Vac Applications 0024-07644 125AmpI2t Fuse 0024-07645 175AmpI2t Fuse 0024-07636 250AmpI2t Fuse 0024-07637 400AmpI2t Fuse 0024-07638 500AmpI2t Fuse 0024-07639 700AmpI2t Fuse 0024-07640 800AmpI2t Fuse 0024-07646 1000AmpI2t Fuse 0024-01191 1200AmpI2t Fuse

Fans Chromalox Part Number Description 0045-00231 120VacratedFan 0045-00235 230VacratedFan

Crimp Lug Chart ForOpenDesign400-1200AmpandallTouch-SafeModels:

Conductor Size Chromalox Part # Panduit Part ##8AWG(10mm2) 0135-10002 LCD8-14A-L#6AWGor#6Weld(16mm2) 0135-10003 LCD6-14A-L#4AWGor#4Weld(25mm2) 0135-10004 LCD4-14A-L#2AWG(35mm2) 0135-10005 LCD2-56B-Q#1AWGor#2Weld(50mm2) 0135-10006 LCD1-56C-E#1/0AWGor#1Weld(70mm2) 0135-10007 LCD1/0-12-X#2/0AWGor#1/0Weld(70mm2) 0135-10008 LCD2/0-12-X#3/0AWGor#2/0Weld(95mm2) 0135-10009 LCD3/0-12-X#4/0AWGor#3/0Weld(120mm2) 0135-10010 LCD4/0-12-X250MCMor#4/0Weld(150mm2) 0135-10011 LCD250-12-X300MCM(150mm2) 0135-10012 LCD300-12-X350MCM(185mm2) 0135-10013 LCD350-12-6400MCM(240mm2) 0135-10014 LCD400-12-6500MCM(240mm2) 0135-10015 LCD500-12-6

SCR ReplacementBesuretoreplacethermstrateinterfacematerialandtorqueasfollows:

MFG Part # SCR Part # Thermstrate Part # Torque inch/lb Torque inch/lb to Heat Sink to TerminalsSKKT92 0002-47560 0029-00700 44inch/lb(5Nm) 26inch/lb(3Nm)SKKT162 0002-47559 0029-00822 44inch/lb(5Nm) 44inch/lb(5Nm)SKKT250 0002-47537 0029-00719 44inch/lb(5Nm) 80inch/lb(9Nm)SKKT500 0002-47557 0029-00814 44inch/lb(5Nm) 106inch/lb(12Nm)

MaxPac I, II, and IIIAccessories:

Part Number Description0135-28096 Plug-InShortedSCRDetectionBoard0135-28095 Plug-InProportionalDOT-FiredControlBoard0135-28093 SCRTriggerBoard0135-28094 On/OffMainFiringBoard0135-20117 Potentiometer&Remote/ManualSwitch

For CE Application, the Following Filters are Required:0005-60055 LineFilterSinglePhase230Vac0005-60057 LineFilter120-230Vac3Amps0005-60056 LineFilterThreePhase440Vac

MaxPac IPAccessories:

Part Number Description0135-28002 FiringCircuit120,240Vac0135-28006 FiringCircuit208,277,480Vac0135-28037 FiringCircuit380Vac

-28- © 2014 Chromalox®, Inc. 1-888-996-9258

9Warranty and Return Information

Warranty NoticeTheWarrantybelowcomplieswiththefederallawapplicabletoproductsmanufacturedafterDecember31,1976.Thiswarrantygivesyouspecificlegalrightsandyoumayalsohaveotherrightswhichvaryfromstateto state.

Chromalox WarrantyChromaloxinstrumentsandcontrolsarewarrantedagainstdefectsinworkmanshipandmaterials.Nootherexpress warranty, written or oral, applies with the exception of a written statement from an officer of Chro-malox®,Inc.

Warranty PeriodThiswarrantyextendsforthreeyearsfromdateofshipmentfromthefactoryorauthorizeddistributor.

LimitationsProducts must be installed and maintained 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.

ReturnsItemsreturnedtoChromaloxmustbeaccompaniedbyaReturnAuthorizationNumber.ThisnumbermaybeobtainedfromChromalox’CustomerServiceDepartmentatthephonenumberlistedbelow.

TheReturnAuthorizationNumbermustappearontheexterioroftheshippingcartonandontheshippingdocuments.

Defectiveitemswillberepairedorreplacedatouroptionandatnocharge.

Returnthedefectivepartorproduct,freightprepaid,tothefollowingaddress:Chromalox,Inc.1347HeilQuakerBlvd.LaVergne,TN37086-3536

Phone:(615)793-3900Fax:(615)793-3563

-29-© 2014 Chromalox®, Inc.1-888-996-9258

Ordering Information for MaxPac IModel SCR Power Pack

MXPC I Single Phase SCR Power Pack

Code Control Configuration

1 On/OffStandard(Accepts:120Vac,240Vac,5-32Vdc,DryContactClosure) 2 On/OffControlwithShortedSCRDetection 3 ProportionalControl,DOTFiring(Accepts:4-20mA,1-5Vdc,0-5Vdc,0-10Vdc) 4 ProportionalControl,DOTFiringwithShortedSCRDetection

Code Current at 50°C (122°F)

01 100Amp OpenDesign 02 100Amp TouchSafeDesign 03 150Amp OpenDesign 04 150Amp TouchSafeDesign



13 650Amp OpenDesign 14 650Amp TouchSafeDesign 15 800Amp OpenDesign 16 1000Amp OpenDesign 17 1200Amp OpenDesign

Code Line Voltage

1 120Vac-480Vac 2 575Vac

Code Instrument Power

1 120Vac50/60Hz 2 230Vac50/60Hz

Code Compression Lug Kits (Open Design up to 300 Amps)

ForOtherRangesSeeCrimpLugChart

L0 None L1 100-150AmpPAK1(#2-4/0)/connection L2 200-300AmpPAK1(1/0-500mcm)/connection

MXPC I - 2 03 1 1 L1 (Continued on next page)

-30- © 2014 Chromalox®, Inc. 1-888-996-9258

Ordering Information for MaxPac I (continued)

Code Fusing Option (1)

For<500VacApplications,SelectOne F00 None F01 100-150AmpPAK (200AmpFuse) F02 200AmpPAK (250AmpFuse) F03 300AmpPAK (400AmpFuse)

F04 400AmpPAK (500AmpFuse) F05 550AmpPAK (700AmpFuse) F06 650AmpPAK (800AmpFuse) F07 800AmpPAK (1000AmpFuse)

F08 1000AmpPAK (1200AmpFuses) F09 1200AmpPAK (Two1000AmpFuses)

For575VacApplications,SelectOne(2) F10 100AmpPAK (125AmpFuse) F11 150AmpPAK (175AmpFuse)


F16 650AmpPAK (800AmpFuse) F17 800AmpPAK (1000AmpFuse) F18 1000AmpPAK (1200AmpFuse) F19 1200AmpPAK (Two1000AmpFuses)

Code Remote Man. Adjust/Auto Man. Switch

0 None 1 Potwith0-100%dialandLocal/Remote Switch(2)SingleTurn1KW Potentiometer

MXPC I - 2 03 1 1 L1 F01 1 Typical Model Number

Crimp Lug Chart

Chromalox # Panduit # Conductor Size

Torque

In-Lb. Nm0135-10002 LCD8-14A-L #8AWG 180 200135-10003 LCD6-14A-L #6AWGor#6Weld 180 200135-10004 LCD4-14A-L #4AWGor#4Weld 180 200135-10005 LCD2-56B-Q #2AWG 180 200135-10006 LCD1-56C-E #1AWGor#2Weld 180 200135-10007 LCD1/0-12-X #1/0AWGor#1Weld 480 540135-10008 LCD2/0-12-X #2/0AWGor#1/0Weld 480 540135-10009 LCD3/0-12-X #3/0AWGor#2/0Weld 480 540135-10010 LCD4/0-12-X #4/0AWGor#3/0Weld 480 540135-10011 LCD250-12-X 250MCMor#4/0Weld 480 540135-10012 LCD300-12-X 300MCM 480 540135-10013 LCD350-12-6 350MCM 480 540135-10014 LCD400-12-6 400MCM 480 540135-10015 LCD500-12-6 500MCM 480 54

Note:NEMAstandardtwoholecoppercrimplugsonly.

1) SCRFusingisforsemiconductor protection only, not wire protection.

2) SuppliedLooseforCustomer Mounting.

Note:StorageTemperature14ºFto158ºF(-10ºCto70ºC).CEapplicationrequiresfilters.

Chromalox Part Numbers0005-60055:Linefilter,singlephase, 230VAC0005-60057:Linefilter,120-230VAC

-31-© 2014 Chromalox®, Inc.1-888-996-9258

Ordering Information for MaxPac IPModel SCR Power Pack

MXPC IP Single Phase SCR Power Pack


1 PhaseAngleControl (Accepts:0-5mA,0-20mA,0-50mA,105mA,4-20mA,10-50mA,0-5Vdc,0-10Vdc) 2 PhaseAngleControlwithCurrentLimit


01 100 AmpOpenDesign 02 100 AmpTouchSafeDesign 03 150 AmpOpenDesign 04 150 AmpTouchSafeDesign



13 650 AmpOpenDesign 14 650 AmpTouchSafeDesign 15 800 AmpOpenDesign 16 1000 AmpOpenDesign 17 1200 AmpOpenDesign

Code Voltage

1 120Vac 2 208Vac 3 240Vac 4 277Vac 5 480Vac 6 575Vac

Code Fan Power

1 120 Vac 50/60 Hz 2 230 Vac 50/60 Hz

Code Compression Lug Kits (OpenDesignupto300Amps)



MXPC IP - 2 03 1 1 L1 (Continued on next page)

-32- © 2014 Chromalox®, Inc. 1-888-996-9258

Ordering Information for MaxPac IP (continued)









0 None 1 Potwith0-100%dialandLocal/Remote Switch(2)SingleTurn1KW Potentiomete

MXPC IP - 2 03 1 1 L1 F01 1 Typical Model Number

Crimp Lug Chart


Torque






Chromalox Part Numbers0005-60055:Linefilter,singlephase, 230VAC0005-60057:Linefilter,120-230VAC

-33-© 2014 Chromalox®, Inc.1-888-996-9258

Ordering Information for MaxPac IIModel SCR Power Pack

MXPC II Three Phase SCR Power Pack








Code Line Voltage

1 120Vac-480Vac 2 575Vac


1 120Vac50/60Hz 2 230Vac50/60Hz




MXPC II - 2 03 1 1 L1 (Continued on next page)

-34- © 2014 Chromalox®, Inc. 1-888-996-9258

Ordering Information for MaxPac II (continued)









0 None 1 Potwith0-100%dialandLocal/Remote Switch(2)SingleTurn1KW Potentiometer (RequiresProportionalBand)

MXPC II - 2 03 1 1 L1 F01 1 Typical Model Number

Crimp Lug Chart


Torque






Chromalox Part Numbers0005-60055:Linefilter,threephase, 440VAC0005-60057:Linefilter,120-230VAC

-35-© 2014 Chromalox®, Inc.1-888-996-9258

Ordering Information for MaxPac IIIModel SCR Power Pack

MXPC III Three Phase Six SCR Power Pack








Code Line Voltage

1 120Vac-480Vac 2 575Vac


1 120Vac50/60Hz 2 230Vac50/60Hz




Note:550-1200AmpandallTouch-SafeDesigns:Buss

MXPC III - 1 04 1 1 L1 (Continued on next page)

-36- © 2014 Chromalox®, Inc. 1-888-996-9258

Ordering Information for MaxPac III (continued)








Code Remote Manual Adjust

0 None 1 Potwith0-100%dialandLocal/Remote Switch(2)SingleTurn1KW Potentiometer (RequiresProportionalBand)

MXPC III - 2 04 1 1 L1 F02 1 Typical Model Number

Crimp Lug Chart


Torque






Chromalox Part Numbers0005-60055:Linefilter,threephase, 440VAC0005-60057:Linefilter,120-230VAC

-37-© 2014 Chromalox®, Inc.1-888-996-9258

EC Declaration of Conformity

We, ChromaloxPrecisionHeatandControl 1347HeilQuakerBoulevard LaVergne,Tennessee37086-3536 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 theappropriatebasicsafetyandhealthrequirementsoftheECLowVoltageDirective(2006/95/EC)andECElectromagneticCompatibilityDirective(2004/108/EC)basedonitsdesignandtype,asbroughtintocircula-tionbyus.Incaseofalterationofthemachine,notagreeduponbyus,thisdeclarationwillloseitsvalidity.

DescriptionoftheElectricalEquipment:MaxPacSCRcontrollers

ModelNumber:MaxPacSeries;MaxPacI,II,III

Applicable Harmonized Standards:

Low Voltage Directive EMC Directive

Specification: EN60947-4-3:2000 1. RadiatedDisturbanceEmissions–30to1000 Low-voltageswitchgearand MHzElectricField controlgear EN61000-6-4:2001/EN55011:2007

Part4-3:Contactorsand 2. ConductedDisturbanceEmissions–Voltage motor-starters EN61000-6-4:2001/EN55011:2007 ACsemiconductorcontrollers andcontactorsfornon-motorloads 3. ConductedDisturbanceImmunityUtilization AC-51Non-inductiveorslightly EN61000-6-2:2005/EN61000-4-6:1996Category: inductiveloads,resistive furnaces 4. RadiatedDisturbanceImmunity EN61000-6-2:2005/EN61000-4-3:1995Pollution Normallyonlynon-conductiveDegree2 pollutionoccurs.Occasionally, 5. ElectricalFastTransients/BurstsImmunity atemporaryconductivity EN61000-6-2:2005/EN61000-4-2:1995 caused by condensation may beexpected. 6. VoltageDipsandInterruptsImmunity EN61000-6-2:2005/EN61000-4-11:1994VoltageRating: 400Vac50HzLine 230Vac50HzInstrumentmax 7. ElectrostaticDischargeImmunity 75watts EN61000-6-2:2005/EN61000-4-2:1995

ImpulseRating: 2.5KVfor5seconds 8. VoltageFluctuations/Flicker EN61000-3-3/A2:2005Overload 140%for1secondCurrentProfile: 9. HarmonicCurrentEmissions EN61000-3-2:2006Fuses: 500Volt,200KARMS symmetrical interrupting rating, I2tfusingprovidedwithallCE units.

-38- © 2014 Chromalox®, Inc. 1-888-996-9258

FiltersRequired: Instrumentpowerfilter: 10. SurgeImmunity ChromaloxP/N0005-60057 EN61000-6-2:2005/EN61000-4-5:1995 LineFilter,singlephase: ChromaloxP/N0005-60055 LineFilter,threephase: ChromaloxP/N0005-60056

TheTechnicaldocumentationrequiredbyAnnexIV(3)oftheLowVoltageDirectiveismaintainedby(Name)of(companyandlocationintheEuropeanUnion)

YearinwhichCEMarkingwasaffixed:2002

AuthorizedSignature/Date:__________________________________________________________________ JimBirnie Date

EngineeringManagerTitleofSignatory:________________________________

Chromalox,InternationalUnit1.22,LombardHouse2PurleyWayCroydonCRO3JPSurreyU.K.

user's manual · 1-888-99-98 01 chromalox ®, nc. - 1 - thank you for choosing the chromalox®...

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