Chromalox MaxPac series Bedienungsanleitung

PK480-2

P/N 0037-75428

User's Manual

www.chromalox.com

800-443-2640

PK480-2

P/N 0037-75428

User's Manual

www.chromalox.com

800-443-2640

- 1 -

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-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, II, and III include:

• ZeroCrossoverFiring

• 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Vdc

  RemoteManualAdjust(Optional)

  RemoteAuto/ManualSwitch(Optional)

• ElectronicallyProtectedwithTemperatureWarningandShutdownSystem

• Single-orThree-CycleResolution(JumperSelectable)

• ShortedSCRDetection(Optional)

Features for the MaxPac IP include:

• PhaseAngleFiring

• 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&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.

Table of Contents

Section Topic Page

1................................................. ImportantSafeguards..................................................................................... 3

2................................................. Description ..................................................................................................... 4

3................................................. BeforeYouInstall............................................................................................ 5

4................................................. Installation ...................................................................................................... 6

 4.1................................. Mounting......................................................................................................... 8

 4.2................................. Wiring............................................................................................................ 11

 4.2.1 ............. Touch-SafeDesign ....................................................................................... 11

 4.2.2 ............. CoverRemovalandInstallation.................................................................... 12

 4.2.3 ............. Power/LoadWiring ....................................................................................... 12

 4.2.4 ............. InstrumentPower ......................................................................................... 16

 4.2.5 ............. Grounding..................................................................................................... 16

 4.2.6 ............. CommandSignalWiring............................................................................... 17

 4.2.7 ............. Calibration .................................................................................................... 23

5................................................ Speciﬁcations ............................................................................................... 24

6................................................ Maintenance ................................................................................................. 25

7................................................ Troubleshooting ............................................................................................ 26

8................................................ PartsandAccessories.................................................................................. 27

9................................................ WarrantyandReturnInformation ................................................................. 28

10 .............................................. ECDeclarationofConformity....................................................................... 37

-3-

1-888-996-9258

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reandelectricalshockhazards.

SafetyAlertSymbol

InternationalShock/ElectrocutionSymbol

Eachsafetymessageisprecededbyasafetyalertsymbol andoneofthreewords:DANGER,WARN-

ING,orCAUTION.

Thesemean:

Important Safeguards

YouWILLbekilledorseriouslyhurtifyoudonotfollowinstructions.

YouCANbekilledorseriouslyhurtifyoudonotfollowinstructions.

YouCANbehurtifyoudonotfollowinstructions.

DANGER

WARNING

CAUTION

DamagePreventionMessages:

YouwillseeotherIMPORTANTmessagesthatare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.

† Thiscanbesettothreecycles‘On’/threecycles‘Off’(seesectiononinstallationoptions).

Description

MaxPac I, II, and III

TheChromaloxMaxPacI,II,andIIIcontrollersarehighlyversatileSCRPowerPakswithoptionalplug-in

proportionalringandshortedSCRdetectionboards.FiringmodesincludeOn/OffandDOTproportional

zerovoltageswitching.ChromaloxexclusiveDOT(DemandOrientedTransfer)ring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51%,theoutputcontinueswithonecycle“On,”

onecycle“Off,”andgraduallyintegratesoneextra“On”cyclefortheadditional1%.ThisDOTredtech-

niquealsominimizestemperatureovershoot,temperatureuctuations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ringcircuitisbasedonacommon

On/OffcontrolboardwithplugandplayShortedSCRandDOTredplug-inboards.Diagnosticindicators

are included. Plug-in terminal blocks for easy customer interface are also provided.

MaxPac IP

TheChromaloxMaxPacIPutilizesSinglePhase,PhaseAnglering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.

-5-

1-888-996-9258

Before You Install

ImmediatelyafterreceivingyourMaxPacI,II,III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le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,dry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efciency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ownecessarytocoolthedevice.

WARNING

Hazardous Voltage: Disconnectandlockoutpowerbeforeinstall-

ingorservicing.Failuretocomplycouldresultinpersonalinjury

or equipment damage.

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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.

In In

Configuration One

CoolAirIn WarmAirOut

Fan Phase 1 Phase 3

orIn Out orIn Out

Configuration Two

Out Out

In In

WarmAirOut CoolAirIn

Phase 1 Phase 3Fan

orIn orIn

Configuration Three

WarmAirOut

Out

Phase 3

orIn

Out

Phase 1

In orIn

Fan

CoolAirIn

-7-

1-888-996-9258

InstallationSection

(

continuation of

e 5

)

ExamplesofProperAirFlow

Pagoda Top

Fan

Air

Louvers Louvers

MaxPac

Air

FanMaxPac

Fan

Enclosure

AirEnclosure

Fan

Filter

Forced Air In

Forced Air Out

Louvers

Since hot air rises naturally, it is not recommended that cooling air ente

from the top and exhaust at the bottom of the enclosure.

Figure Drawing Number Model

Figure Model

1................100A,150A,&200A2-LegOpenType

1................100A,150A,200A,&300A1-LegOpenType

2................100A,150A,&200A3-LegOpenType

3................300A2-LegOpenType

4................100A,150A,200A,300A&400A1-LegTouch-Safe

4................400A1-LegOpenType

5................100A,150A,200A,300A&400A2-LegTouch-Safe

5................400A2-LegOpenType

6................100A,150A,200A,300A&400A3-LegTouch-Safe

6................300A&400A3-LegOpenType

7................550A&650A1-LegTouch-Safe

7................550A&650A1-LegOpenType

8................550A&650A2-LegTouch-Safe

8................550A&650A2-LegOpenType

9................550A&650A3-LegTouch-Safe

9................550A&650A3-LegOpenType

..................800-1200Ampunits,consultfactory

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’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.

IMPORTANT: Please note that the ﬁgures on the following pages are

not drawn to the same scale.

- 9 -

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]

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