Chromalox CTF-025 Quick Start Manual

CTF Single Phase Advanced SCR
Power Controller Quick Start Manual
0037-75558 (PK536)
This manual is intended to be a quick reference guide for basic installation require-
ments and an overview of the connections, wiring considerations, and general spec-
ifications for the CTF Advanced SCR Power Controller. For complete installation,
operation, programming and configuration, please refer to the following manuals:
PK533 CTF Hardware Instruction Manual; PK534 CTF & CTF-XTRA Controller Pro-
gramming Manual; PK537 C-PWR Configuration Software Manual. The most current
revisions may be found on the Chromalox website: www.chromalox.com.
1. IMPORTANT SAFEGUARDS
ELECTRIC SHOCK HAZARD: Read and understand all instructions before
installing, servicing or operating this controller. Failure to do so could
result in equipment or property damage as well as personal injury and
even death.
HIGH VOLTAGE is used in the operation of this equipment; DEATH ON
CONTACT may result if personnel fail to observe safety precautions.
Learn the areas containing high-voltage connections when installing or
operating this equipment.
Be careful not to contact high-voltage connections when installing or
operating this equipment. Before working inside the equipment, turn
power off and ground all points of high potential before touching them.
ELECTRIC SHOCK HAZARD: Any installation involving control equip-
ment must be performed by a qualified person and must be effectively
grounded in accordance with the National Electrical Code or local gov-
erning electrical code/authority, to eliminate shock hazard.
The owner/installer must provide all necessary safety and protection
devices and follow all current electrical wiring standards and regula-
tions. Failure to do so may compromise the integrity of the controller
and/or cause product failure resulting in a safety risk to operational and
service personnel.
This controller utilizes a heat sink which is designed to cool the unit
during operation. Under no circumstance should air flow around the
controller be compromised in any way. Failure to do so may result in the
overheating of the controller, product failure, product temperatures and
even fire.
During continuous operation, the heat sink can reach very high tem-
peratures, and keeps a high temperature even after the unit is turned
off due to its high thermal inertia.
2. INSTALLATION
Input & Output Connections: CTF 25 – 120 Amp Models
Top view
WITHOUT Modbus Option
Key HB
Key HB
J2
TTL port for
Port Configuration
RJ10 connectors
RS485 serial line
(GND)
Syncronous output for
Master/Slave connection
Alarm output
(solid state relay - HB option)
Key HB
Green Led (RUN)
Yellow Led (STATUS)
Red Led (Alarm output HB)
Yellow Led (Status digital input)
Led: Green = SCR ON
Yellow = Temperature OVER
1/L1
LINE connection
3/L2
Reference connection
of line voltage
Installation Wiring Note:
Use the extra rapid fuses as indicated in the CTF Hardware Instruction Manual PK533,
according to the wiring schematic examples and controller rating. Additionally, the
applications with solid state units require a safety automatic switch to disengage the
load power line during certain alarm events.
Input & Output Connections: CTF 150 – 250 Amp Models
Top View
Top view
WITH Modbus Option
Line voltage
reference
Address x 1
connection
Address x 10
J3, J4
J8
Switch for
Line Voltage
serial line
Connector
Modbus
Input control signal (+)
Potentiometer output power supply (+5Vdc)
Digital input (PWM input)
Power supply terminal 24Vac/Vdc
J1
Power supply /control
connector
Fixing screw
at heatsink
2/T1 Load
Connection
Fixing screw
at heatsink
CTF Current
Level Terminal
25A 1/L1, 2/T1, PE
40A 1/L1, 2/T1, PE
2/T1
50A 1/L1, 2/T1, PE
LOAD connection
60A 1/L1, 2/T1, PE
75A 1/L1, 2/T1, PE
90A 1/L1, 2/T1, PE
Earth Ground
120A 1/L1, 2/T1, PE
-
(Ref. Vline)
150A 1/L1, 2/T1
200A 1/L1, 2/T1
250A 1/L1, 2/T1
-
(Ref. Vline)
NOTE: Cables must be Copper "Stranded Wire" or "Compact-Stranded Wire" type with max. operating temp. 60/75°C
Bottom View Without Bottom View WITH
Modbus RS485 Option Modbus RS485 Option
Fan
Protection
Grill
2/T1
2/T1
Load
Load
Conn.
Conn.
1/L1
Line
Connection
J5
Config.
J8 TTL Port
3/L2
Fan Protection Grill
n.c.
Line Connection
1/L1
Front Cover
Fastener (Fuse Access)
J1
HB OUT Switch (Optional)
OUT Master (7 V)
GND
Outputs
J2
24 Vac/dc
24 Vac/dc
Supply RUN ...................................(Green)
Earth
STATUS .............................(Yellow)
Status LEDs
ALARM HB ......................(Red)
DIGITAL INPUT STATUS (Yellow)
J3
ON SCR ............................ (Green)
n.c.
OVER Temperature...........(Yellow)
n.c.
Digital Input
+ INDIG (PWM input)
GND
Key HB
Address Rotary
Switch
J4
(Optional) OUT +5V (Potentiometer)
+ IN
Analog Control SHUNT – mA
Input Connector
GND
Recommended Wire Gauges
Cable Wire Wire Terminal Tightening Torque / Tool
4 mm
2
Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3
10 AWG
10 mm
2
Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3
7 AWG
10 mm
2
Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3
7 AWG
16 mm
2
Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3
5 AWG
25 mm 2
Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3
3 AWG
35 mm 2
Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3
2 AWG
50 mm 2
Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3
1/0 AWG
3/L2 0.25 ...2.5 mm 2 0.5 ...0.6 Nm / Screwdriver blade 0.6 x
Wire terminal tip
23...14 AWG
70 mm 2 Wire stripped for 25 mm or with
6 Nm / No. 6 hex head wrench
2/0 AWG crimped pre-insulated terminal tube
95 mm 2 Wire stripped for 25 mm or with
6 Nm / No. 6 hex head wrench
4/0 AWG crimped pre-insulated terminal tube
120 mm 2
Wire stripped for 25 mm 6 Nm / No. 6 hex head wrench
250 KCMIL
3/L2 0.25 ...2.5 mm 2 Wire stripped for 8 mm or with tag 0.5 ...0.6 Nm / Flat-head screwdriver tip
23...14 AWG terminal
Dip Switch
serial line
J6, J7
RJ10
connector
serial RS485
Modbus
3.5 mm
0.6 x 3.5 mm