Chromalox C4 Quick Start Manual

C4 4-Channel SCR Power Controller with

Independent PID Control Quick Start

Manual 0037-75569 (PK541)

This manual is intended to be a quick reference guide for basic installation require­ments and an overview of the connections, wiring considerations, and general spec­ifications for the C4 4-Channel SCR Power Controller with Independent PID control.
For complete installation and operation, refer to the PK544 C4 Hardware Instruction
Manual. For complete configuration and programming refer to the PK548 C4 Con­figuration and Programming 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 voltage potential before touch­ing.

ELECTRIC SHOCK HAZARD. Any installation involving control equip­ment must be performed by a qualified person and must be effectively
grounded in accordance with the National Electrical Code to eliminate
shock hazard.

The Owner/Installer must provide all necessary safety and protection
devices and follow all current electrical wiring standards and regula­tions. Failure to do so may compromise the integrity of the controller
and/or cause product failure resulting in a safety risk to operational
service and 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 a very high
temperatures, and keeps a high temperature even after the unit is
turned off due to its high thermal inertia.

2. OVERVIEW & LAYOUT

Use the extra rapid fuses as indicated in the C4 Hardware Instruction Manual PKXXX,
according to the wiring schematic examples and controller rating. Additionally, the
applications with solid state units require safety automatic switch to disengage the
load power line during certain alarm events.

Installation Wiring Note:

Item Description

1. Front DIN Rail Mount For C4-OP

2. Power terminal: screws

3. Power terminal

4. Ventilation screen (DO NOT Obstruct)

5. Spring clamp release for rear DIN rail

6. Screw holes for additional mounting

7. DIP switch for configuration

8. Communication Port

9. Rotary switch for addressing

10. Connectors J1, J2, J3, J4

11.

Fuse holder
(only for 30KW and 60KW models)

12. Fuse holder terminals (F1, F2, F3, F4/N)

13. Power terminals (U1, U2, U3, U4)

14. Ventilation screen (DO NOT Obstruct)

1

2

3

4

5

6

7

8

9

10

8

14

11

12

13

Before and during the inspection/ maintenance cut power to the fan
controller and verify that the system is isolated for operator safety.

COOLING FAN CARE

Periodic Cleaning

Every 6-12 months (depending on the
dust level of the installation) blow a com­pressed air jet downward through the up­per rectangular cooling grilles (on the side
opposite the fan). This will clean the inter­nal heat dissipater and the cooling fan.

In Case of Overheat Alarm

If periodic cleaning does not eliminate the
problem, do as follows:

a. Remove the fan support grille by

detaching the two support tabs
b. Disconnect fan connector from board
c. Check the condition of the fan
d. Clean or replace the fan (*)
e. Insert the connector into the board
f. Insert fan support grille until it attaches
g. Power up the device and check fan

rotation when at least one load is on

15

14

Direction

of air flow

14. Support Grill

15. Fan

Before attempting board replacement, ensure that power to the controller
has been cut and verify that the system is isolated for operator safety.

INSERTING A NEW FIELD BUS INTERFACE CARD

To insert a communication module, the Field Bus Interface Board compartment
must be accessed. Follow these steps:

1. Remove the Fieldbus compartment cover screw 16

2. With a flat screwdriver, gently apply pressure at 18

3. Remove compartment cover 17

4. Insert Fieldbus card 19 into the proper connector 21

5. Remove applicable communication port tab 20 on cover 17

6.

Carefully replace compartment cover 17

7. Tighten compartment cover screw 16

16

17

18

19

20

21

PK541

0037-75569

January 2018

© 2018 Chromalox, Inc.

3. WIRING

Power Wiring Considerations

Model without fuse holder Model with fuse holder

F1,F2,F3,F4/N Line Connection Terminals

U1,U2,U3,U4 Load Connection Terminals

F1,F2,F3,F4/N Line Connection Terminals

U1,U2,U3,U4 Load Connection Terminals

Model 30 kW 60 kW 80 kW

Item 16A 30A 40A

rigid

0.2-6mm2 24-10 AWG 0.2-6mm2 24-10 AWG 0.5-16mm2 20-6 AWG

rigid

flexible

0.2-4mm2 24-10 AWG 0.2-4mm2 24-10 AWG 0.5-10mm2 20-7 AWG

rigid

flexible

0.25-4mm2 23-10 AWG 0.25-4mm2 23-10 AWG 0.5-10mm2 20-7 AWG

rigid

flexible

0.25-4mm2 23-10 AWG 0.25-4mm2 23-10 AWG 0.5-10mm2 20-7 AWG

rigid

flexible

0.5-0.6 Nm 4.4-5.3 In-Lb 0.5-0.6 Nm 4.4-5.3 In-Lb 1.2-1.5 Nm 10.6-13.3 In-Lb

Voltage/Current Considerations

C4

Current (Amp) Voltage (Vac) Power (kW)

Max Per Channel Range Nominal Working Per Channel Controller Total

164

(4x16A)

16 24-530 480

120 1.9 7.7
208 3.3 13.3
240 3.8 15.4
277 4.4 17.7
400 6.4 25.6
480 7.7 30.7

304

(4x30A)

30 24-530 480

120 3.6 14.4
208 6.2 25.0
240 7.2 28.8
277 8.3 33.2

400 12.0 48.0

480 14.4 57.6

404

(4x40A)

40 24-530 480

120 4.8 19.2
208 8.3 33.3
240 9.6 38.4
277 11.1 44.3
400 16.0 64.0
480 19.2 76.8

4. OPTIONS, INPUTS AND OUTPUTS CONNECTIONS

• Use adequately compensated cable for thermocouple inputs. Maintain polarity
by avoiding junctions on the cables

• If using a grounded thermocouple, the connection must be at a single point

• For RTD inputs, use copper extension cables and avoid junctions on the cables.
Resistance must not exceed 20 Ohm

• For 2-wire RTD’s, make the connection indicated instead of the third wire

• Refer to the applicable Connectors Detail

N

L1

Load 1

Load 2

Load 3

Load 4

+

+

+

+

_

c (OUT 5,...8)

(OUT 5 no)

OUT 9

(OUT 6 no)

(OUT 7 no)

(OUT 8 no)

OUT 10

c

c

no

no

+

+

+

+

_

POWER SUPPLY

18...32Vdc

+24Vdc

OUT 1
OUT 2
OUT 3
OUT 4

IN 5

IN 6

IN 7

IN 8

IN 1

IN 2

IN 3

IN 4

C1

O5

O6

O7

O8

C9

O9

C10

O10

O1
O2
O3
O4

O2

O3

O4

J3a

RN

J1a

ER

DI2

DI1

J1

J2

J3

J4

1

9

1

7

1

12

1

12

DI2

DI1

M

M

L+

L+

O1

I5­I5+
I6­I6+
I7­I7+
I8­I8+

I1­I1+
IN1
I2­I2+
IN2
I3­I3+
IN3
I4­I4+
IN4

Triac

Port 1

Port 2

S1

S2

S3

S4

S5

4

3
2

1
4

3
2

1

+VI

Tx/Rx­Tx/Rx+

GNDI
+VI

Tx/Rx­Tx/Rx+

GNDI

6

9

1

4

Relay

Logic/continuous

5. DIP SWITCH CONFIGURATION

Dip Switch Legend

Dip Switch Function Description

1

Load Connection

See Load Configuration

Table Below

2

3

4 No Function

5 Frequency ON: 60 Hz OFF: 50 Hz

6 Factory Default ON: Resets Controller to Factory Settings

7 Simulation ON: Simulation Mode

8 RS-485 Communications

ON: When the device is the ONLY RS485 Device

or when it is the LAST RS485 Device

Load Configuration Table

Dip Switch

Load Connection Type

1 2 3
OFF OFF OFF 4 Independent zones (4 single-phase loads)
ON OFF OFF Zone 1: 3-phase load, star (wye) connection, with neutral
OFF ON OFF Zone 1: 3-phase load, open delta connection
ON ON OFF Zone 1 & 3: Two 3-phase loads, star (wye) connection, without neutral
OFF OFF ON Zone 1 & 3: Two 3-phase loads, closed delta connection
ON OFF ON No Function
OFF ON ON No Function
ON ON ON No Function

6. GENERAL DATA

General Data

Power Supply

24 VDC +/-25%, max 8VA

Indicators

Eight LEDS:
RN CPU in run state , ER Fault Signal
DI1, DI2 state of digital inputs
O1,...O4 state of outputs

Protection

IP20

Work/Storage Temperature

0 - 50˚C (see dissipation curves) / -20˚C...70˚C

Relative Humidity

20 - 85% RH non-condensing

Ambient Work Conditions

Indoor use, altitude up to 2000m

Installation

DIN RAIL EN50022 or panel using screws

Installation Instructions

Installation category II, Pollution level 2, double isolation
Max surrounding air temp. 50˚C (for UL) Open type equipment

Weight
Models 30kW, 60kW, 80kW

1200g

Models 30kW, 60kW, w/fuse holder

1600g

Current [A]

Ambient Temperature [°C]

DERATING

45

40

35

30

25

20

15

10

5

0

0 10 20 30 40 50 60

C4-404

C4-304

C4-164

Power (Solid State Power Units, 4 Units)

Rated Voltage 480 Vac

Work Voltage Range 24....530 Vac

Non-Repetitive Voltage 1200 Vp
Zero Switching Voltage <20 V
Rated Frequency 50/60 Hz Self Testing
Rated Current AC51 30 kW 4x16A 60 kW 4x30 80 kW

4x40A

Non-repetitive Overcurrent (t=1....10msec) 400A 600A 1150A

I

2

T Fusion (t=1....10msec) 645A2S 1010A2S 6600A2S

Critical Dv/dt with Output Deactivated 1000 V/Sec
Rated Isolation Voltage 4000 V

Minimum Clearance
Considerations

Attention: Respect

the min. distances
shown in figure to provide
adequate air circulation.