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Chromalox MAXPAC PK480 User Manual

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PK480
User's Manual
www.chromalox.com
800-443-2640
© 2002 Chromalox, Inc.
P/N 0037-75428

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Summary of Contents for Chromalox MAXPAC PK480

  • Page 1 PK480 User's Manual www.chromalox.com 800-443-2640 © 2002 Chromalox, Inc. P/N 0037-75428...
  • Page 2 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 solutions for industrial heating applications. Chromalox manufactures the world’s largest and broadest line of electric heat and control products.

  • Page 3: Table Of Contents

    6 ..........Maintenance ....................25 7 ..........Troubleshooting .................... 26 8 ..........Parts and Accessories .................. 27 9 ..........Warranty and Return Information ..............28 10 ..........EC Declaration of Conformity ............... 37 ® - 2 - © 2002 Chromalox , Inc. 1-888-996-9258...

  • Page 4: Important Safeguards

    You will see other IMPORTANT messages that are proceeded by the word 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. ® - 3 - 1-888-996-9258 © 2002 Chromalox , Inc.

  • Page 5: 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 firing and shorted SCR detection boards. Firing modes include On/Off and DOT proportional zero voltage switching.

  • Page 6: Before You Install

    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.

  • Page 7: Installation

    Warm Air Out Cool Air In Phase 1 Phase 3 or In or In Configuration Three Warm Air Out Phase 3 or In Phase 1 or In Cool Air In ® - 6 - © 2002 Chromalox , Inc. 1-888-996-9258...
  • Page 8 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. ® - 7 - 1-888-996-9258 © 2002 Chromalox , Inc.

  • Page 9: Mounting

    9 ....550A & 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 - © 2002 Chromalox , Inc. 1-888-996-9258...
  • Page 10 Figure 4 8.4" [214mm] 0.0" [0mm] 1.3" [33mm] Ø.3125" [Ø7.94mm] (8 HOLES) 5.3" [135mm] FIRING PACKAGE 9.3" [237mm] 13.3" [338mm] 14.6" [371mm] FAN END 14.7" [375mm] 15.75" [400mm] Figure 5 ® - 9 - 1-888-996-9258 © 2002 Chromalox , Inc.
  • Page 11 FIRING PACKAGE 11.3" [287mm] 11.3" [287mm] 16.3" [414mm] 16.3" [414mm] 17.6" [448mm] 17.6" [448mm] FAN END FAN END 25.5" [648mm] 17.5" [444mm] 26.5" [673mm] 18.5" [470mm] Figure 8 Figure 9 ® - 10 - © 2002 Chromalox , Inc. 1-888-996-9258...

  • Page 12: Wiring

    FOR WIRING FROM EITHER DIRECTION AND MULTIPLE DIRECTION AND MULTIPLE LOAD CIRCUITS LOAD CIRCUITS FUSE COOLING AIR HEATSINK FINS COOLING AIR LONG LIFE, HIGH OUTPUT BALL BEARING FANS PROVIDE RELIABLE COOLING ® - 11 - 1-888-996-9258 © 2002 Chromalox , Inc.

  • Page 13: Cover Removal And Installation

    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 Connection is NOT on MaxPac ® - 12 - © 2002 Chromalox , Inc. 1-888-996-9258...
  • Page 14 IMPORTANT: The I t 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. ® - 13 - 1-888-996-9258 © 2002 Chromalox , Inc.
  • Page 15 IMPORTANT: The I t 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 - © 2002 Chromalox , Inc. 1-888-996-9258...
  • Page 16 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-hole crimp lugs per phase. ® - 15 - 1-888-996-9258 © 2002 Chromalox , Inc.

  • Page 17: Instrument Power

    Chasis is provided with hole pattern for standard NEMA two-hole crimp lugs. 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 - © 2002 Chromalox , Inc. 1-888-996-9258...

  • Page 18: Command Signal Wiring

    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 steady “on” and steady “off”. With the DOT Firing option, the indicator will display the rapid firing sequence. ® - 17 - 1-888-996-9258 © 2002 Chromalox , Inc.
  • Page 19 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 the externally connected device output is activated. 2AMP (2AG) CHROMALOX P/N 0024-01097 LITTLEFUSE P/N 225 002 ® - 18 - ©...
  • Page 20 Proportional DOT Firing Board SHORT J3-1 & 2 FOR SHORT J3-2 & 3 FOR Chromalox’s exclusive DOT (De- 1 CYCLE FIRING 3 CYCLE FIRING mand Oriented Transfer) firing technique switches the fewest number of cycles to provide the most precise zero crossover control.
  • Page 21 J1 - 1 & 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 - © 2002 Chromalox , Inc. 1-888-996-9258...
  • Page 22 0 TO +5 VDC PROPORTIONAL INPUT SIG 0 +10 VDC PROPORTIONAL INPUT SIG 120~240 ON/OFF CONTROL FIG 10. FIG 11. FIG 12. COMMON COMMON EXTERNAL +5~32 VDC ON/OFF DRY CONTACT ON/OFF REMOTE SHUTDOWN ® - 21 - 1-888-996-9258 © 2002 Chromalox , Inc.
  • Page 23 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.

  • Page 24: Calibration

    Thus, it effectively cancels positive inputs to the MaxPac Power Pak. EXAMPLE: 0 - 5 mA input à set to 0 mA input 4 - 20 mA input à set to 4 mA input ® - 23 - 1-888-996-9258 © 2002 Chromalox , Inc.

  • Page 25: Specifications

    ± 10% 50/60 Hz output current Load Current Rating ... 100, 150, 200, 300, 400, Soft Start ......25% demand per second 550, 650, 800, 1000, typical reset speed 8.3 milliseconds ® - 24 - © 2002 Chromalox , Inc. 1-888-996-9258...

  • Page 26: Maintenance

    The filters used with these devices should be changed on a periodic basis to insure adequate enclosure cooling is maintained. Dust – Periodically check for dust or other particulate buildup on heatsinks and bus bars. ® - 25 - 1-888-996-9258 © 2002 Chromalox , Inc.

  • Page 27: Troubleshooting

    J10, J11, and J12. If Demand Light is “On” 1. Check the connections to SCR trigger board. 2. Check the power fuses (I 3. Look for damage on the trigger board. ® - 26 - © 2002 Chromalox , Inc. 1-888-996-9258...

  • Page 28: Parts And Accessories

    Parts and Accessories ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Instrument Power Fuse Chromalox Part Number Description 0024-01097 Littlefuse # 225 002 2 AG 2AMP...

  • Page 29: Warranty And Return Information

    This warranty extends for three years from date of shipment from the factory or authorized distributor. Limitations Products must be installed and maintained in accordance with Chromalox instructions. Users are responsible 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.
  • Page 30 For Other Ranges See Crimp Lug Chart None 100 - 150 Amp PAK 1(#2 - 4/0)/connection 200 - 300 Amp PAK 1(1/0 - 500mcm)/connection MXPC I - (Continued on next page) ® - 29 - 1-888-996-9258 © 2002 Chromalox , Inc.
  • Page 31 0135-10009 LCD3/0-12-X #4/0 AWG or #3/0 Weld 0135-10010 LCD4/0-12-X 0135-10007 LCD1/0-12-X #1/0 AWG or #1 Weld Chromalox Part Numbers 0135-10011 LCD250-12-X 250 MCM or #4/0 Weld 0135-10008 LCD2/0-12-X #2/0 AWG or #1/0 Weld 0005-60055 — Line filter, single phase, 230VAC...
  • Page 32 For Other Ranges See Crimp Lug Chart None 100 - 150 Amp PAK 1(#2 - 4/0)/connection 200 - 300 Amp PAK 1(1/0 - 500mcm)/connection MXPC IP - (Continued on next page) ® - 31 - 1-888-996-9258 © 2002 Chromalox , Inc.
  • Page 33 Note: NEMA standard two hole copper crimp lugs only 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. ® - 32 - © 2002 Chromalox , Inc. 1-888-996-9258...
  • Page 34 For Other Ranges See Crimp Lug Chart None 100- 150 Amp PAK 1 (#2 - 4/0)/connection 200-300 Amp PAK 1 (1/0 - 500mcm)/connection MXPC II - (Continued on next page) ® - 33 - 1-888-996-9258 © 2002 Chromalox , Inc.
  • Page 35 #3/0 AWG or #2/0 Weld LCD3/0-12-X 0135-10007 LCD1/0-12-X #1/0 AWG or #1 Weld 0135-10010 #4/0 AWG or #3/0 Weld LCD4/0-12-X Chromalox Part Numbers 0135-10011 250 MCM or #4/0 Weld 0135-10008 LCD2/0-12-X LCD250-12-X #2/0 AWG or #1/0 Weld 0005-60056 — Line filter, three phase, 440VAC...
  • Page 36 100- 150 Amp PAK 1 (#2 - 4/0)/connection 200-300 Amp PAK 1 (1/0 - 500mcm)/connection Note: 550- 1200 Amp and all Touch-Safe Designs: Buss MXPC III - (Continued on next page) ® - 35 - 1-888-996-9258 © 2002 Chromalox , Inc.
  • Page 37 #3/0 AWG or #2/0 Weld LCD3/0-12-X 0135-10006 LCD1-56C-E #1 AWG or #2 Weld 0135-10010 #4/0 AWG or #3/0 Weld LCD4/0-12-X Chromalox Part Numbers 0135-10007 LCD1/0-12-X #1/0 AWG or #1 Weld 0135-10011 LCD250-12-X 250 MCM or #4/0 Weld 0005-60056 — Line filter, three phase, 440VAC...

  • Page 38: Ec Declaration Of Conformity

    EC Declaration of Conformity Chromalox Precision Heat and Control 1382 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...
  • Page 39 Filters Required: Instrument power filter: 10. Surge Immunity Chromalox P/N 0005-60057 EN 61000-6-2:1999 / 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)
  • Page 40 1-888-996-9258 © 2002 Chromalox ® , Inc. - 39 -...

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