Chromalox MaxPac Manuel utilisateur

PK480-5

0037-75428

June 2018

User’s Manual

MaxPac

Thank you for choosing the Chromalox®MaxPac™ - a complete power control solution with industry-best

price and performance.

For more than 100 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 Stop

• Compact Size and Construction

• Touch-Safe Design (option on 100 - 650 Amp models)

• dv/dt Transient Voltage Protection

• MOV Protection

• Built-In Power Distribution

• Soft Start

• 100KA SCCR Rating

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 - 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 Stop System

• Cycle Resolution 3, 5, 7, 11, 13, 17, 19

• Shorted SCR Detection (Optional)

• Soft Start

• Time proportional switching mode

• Staged Heating

• Rotary wwitch selection of input, leg conﬁguration, modbus

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)

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

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

Before working inside the equipment, conﬁrm that all power has been turned off, locked off, and pref-

erably earthed [grounded] at all points of low and high potential, on both the supply line and load side

circuits, as required / permitted by all codes and standards.

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

symbols 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.

Each safety message is preceded by a safety alert symbol and one of three words: DANGER, WARNING, 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.

Important Safeguards

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.

Key Safety Practices

All personnel working on high voltage electrical equipment must adhere to all national and local regulations,

codes, and standards.

Only suitably qualiﬁed and experienced persons, who are familiar with this equipment, and the work they are

to do, should carry out installation, commissioning, operation, or maintenance of this panel and the associ-

ated heater.

Such persons shall adhere to proper high voltage safety procedures, including the use of appropriate per-

sonal protective equipment (ppe).

Failure to adhere to any of the above may result in equipment damage, operating losses, injury, or death.

Chromalox will not be liable for failure to adhere to all governing regulations, codes, standards, site proce-

dures and information given in this manual.

The MaxPac User Manual uses this symbol to

alert personnel to potential hazards that may

damage the equipment.

The MaxPac User Manual uses this symbol to

alert personnel to potential hazards that may

cause injury or death.

IMPORTANT SAFEGUARDS

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

Description

MaxPac I, II, and III

The Chromalox Model MaxPac IP, I, II and III Series are speciﬁcally designed for the OEM market. The Chro-

malox MaxPac I, II and III controllers are highly versatile SCR Power Paks. Firing modes includes On/Off

and DOT proportional zero voltage switching. Chromalox’s exclusive DOT (Demand Oriented Transfer) ﬁring

switches the fewest number of cycles to provide the most precise zero crossover control. At 50% output the

units 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 one percent. This

DOT ﬁred technique also minimizes temperature overshoot, temperature ﬂuctuations and helps extend the

loads element life due to reduced thermal shock.

The power SCR assemblies consist of one, two or three SCR’s connected back to back with a semiconductor

fuse, RC Snubber and MOV protection. The ﬁring circuit is based on common integrated circuit. Diagnostic

indicators are included as well as plug-in terminal blocks for easy customer interface.

MaxPac IP

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.

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 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, 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 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.

WARNING

Hazardous Voltage: Disconnect and lockout power before in-

stalling or servicing. Failure to comply could result in per-

sonal injury or equipment damage.

READ AND UNDERSTAND BEFORE

CARRYING OUT THE WORK DETAILED BELOW

Installation

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

Phase 1 Phase 3 Fan

or In or In

Configuration Three

Warm Air Out

Out

Phase 3

or In

Out

Phase 1

In or In

Fan

Cool Air In

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 Max-

Pac 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 de-

signs allow incoming and outgoing wiring in either

direction.

Examples of Proper Air Flow

Pagoda Top

Fan

Air

Louvers

MaxPac

Air

Fan MaxPac

Fan

Enclosure

Air

Enclosure

Fan

Filter

Forced Air In

(Recommended)

Forced Air Out

(Not Recommended)

Louvers

Since hot air rises naturally, it is not recommended that cooling air enter from the top and exhaust at the bot-

tom of the enclosure.

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.

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

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

not drawn to the same scale.

READ AND UNDERSTAND BEFORE

CARRYING OUT THE WORK DETAILED BELOW

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