Chromalox C4, C4-IR, C4X Series, C4X Hardware Instruction Manual
Hardware Instruction Manual
C4
4-Channel SCR Power Controller
with Independent PID Control
PK544
0037-75573
April 2018
i
Table of Contents
Important Safeguards ............................................................................................................. 1
1. Initial Instructions .............................................................................................................. 2
1.1 General Description ................................................................................................................................. 2
1.2 Features ................................................................................................................................................... 2
1.3 Product Inspection .................................................................................................................................. 2
2. Dimensions & Weights ...................................................................................................... 3
3. Installation - Mounting ...................................................................................................... 4
4. Installation - Wiring ........................................................................................................... 5
5. Emission, Immunity and Safety Standards ..................................................................... 6
6. Controller Overview .......................................................................................................... 7
6.1 Layout ................................................................................................................................................... 7
6.2 Cooling Fan ............................................................................................................................................. 8
6.3 Inserting a New Field Bus Interface Card ................................................................................................ 8
7. Connections and Indication ............................................................................................. 9
7.1 Power Connections ................................................................................................................................. 9
7.2 Power Wiring Considerations .................................................................................................................. 9
7.3 Input & Output Connections .................................................................................................................. 10
7.4 LED Logic .............................................................................................................................................. 10
7.5 Rotary Switches .................................................................................................................................... 11
7.6 Connector Detail .................................................................................................................................... 11
7.6.1 Connector J1/J1a ......................................................................................................................... 11
7.6.2 Connector J2 ................................................................................................................................ 14
7.6.3 Connector J3 ................................................................................................................................ 15
7.6.4 Connector J4 ................................................................................................................................ 16
7.7 DIP-Switch Configuration ...................................................................................................................... 17
7.8 Serial Communication Ports .................................................................................................................. 18
7.8.1 Port1 (Standard Local Bus) ..........................................................................................................18
7.8.2 Port2 (Optional Fieldbus) .............................................................................................................. 19
7.8.3 Connection Example: Communication Port ................................................................................. 25
8. Load Connection Examples ........................................................................................... 29
8.1 4 Single Phase Loads, 3- Phase Line with Neutral ............................................................................... 31
8.1 4 Single Phase Loads, 3- Phase Line without Neutral .......................................................................... 31
8.3 Two 3-Phase Loads, Closed Delta ........................................................................................................32
8.4 Two 3-Phase Loads, Star (Wye) without Neutral ................................................................................... 32
8.5 One 3-phase Load Active, One 3-Phase Load Inactive, Wye without Neutral ...................................... 33
8.6 One 3-Phase Load, Inside Delta ............................................................................................................ 33
9. Inductive and Transformer Coupled Load Guidelines ................................................. 34
10. Communications Port (Modbus RTU/RS485) ............................................................... 34
11. Autobaud Function .......................................................................................................... 35
11.1 Autobaud Port 1 Sequence ................................................................................................................... 35
11.2 11.2 Autonode Sequence for Fieldbus Use ........................................................................................... 35
12. Specifications .................................................................................................................. 36
13. Ordering Information ....................................................................................................... 40
14. Configuration and Programming ................................................................................... 41
15. Accessories ..................................................................................................................... 41
ii
Important Safeguards
HIGH VOLTAGE (up to 480 VAC) 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.
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
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 temperatures, and keeps a
high temperature even after the unit is turned
off due to its high thermal inertia.
Higher voltages may be present. DO NOT work
on the power section without first cutting out
electrical power to the panel. Failure to do so
may cause serious injury or death.
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.
1
1. Initial Instructions
1.1 General Description
The C4 is an extremely compact advanced SCR power
controller that provides a unique combination of performance, reliability, and flexibility. The C4 multiple
zone SCR power controller manages both single phase
and 3-phase industrial heating load applications. Load
management options include: Up to 4 independently
controlled single phase loads or one 3-phase/3-leg
load (with or without an additional single phase load) or
up to two 3-phase/2-Leg loads.
Standard features: Output choices range from 30 kW
to 80 kW per unit or from 16 to 40 Amps per zone at
480 Vac (for higher amperages the C4X can be used);
Four universal main process inputs, two digital inputs,
two configurable alarm outputs, Mod-bus RTU/RS485
digital communications, DIN Rail or panel mountable.
Optional features: One or four Current Transformers (input), four analog inputs, integral fuse holder (30
kW & 60 kW only), four configurable outputs, modular
Fieldbus Communication protocols including Modbus
RTU, Modbus TCP, Ethernet IP, EtherCAT, CANopen,
DeviceNet, Profibus, and Profinet. This new Chromalox
controller is the ideal PID and power control solution
for applications demanding high performance, continuous service, preventative maintenance information,
and increasing need for process data and information
for quality and process improvement analysis. Industry
markets such as, but not limited to:
• Packaging
• Plastics Processing; Extrusion; Thermforming; Injection Molding, Welding & Joining
• Semiconductor
• Material Finishing; Paint Booths;
• Textile
• Multiple zoned furnaces; Tunnel Ovens
• Food Processing
1.2 Features
• 30, 60, 80kW controller size capacity (refer to C4X
for higher amperages)
• Solid state relay control
• One or four current transformers
• Fuses-holder (option)
• 4 universal main inputs
• 4 heat/cool independent PID
• 4 main output internally wired to the SSR
• 4 auxiliary analog inputs (option)
• 4 configurable output (option): relay / logic / analog/
TRIAC
• 2 configurable relay alarm output
• 2 digital inputs
• Standard digital communication: Modbus RTU/
RS485
• Optional Fieldbus communication: Profibus DP,
CANopen, DeviceNet, Modbus RTU, Ethernet Modbus TCP, Ethernet IP, EtherCAT, ProfiNET
• DIN rail mounting
• Integrated heat sink and fan
• cULus, CE
1.3 Product Inspection
Immediately after unpacking the unit and prior to installing, check the order code and the other data on
the label attached to the outside of the container and
write them down. If troubleshooting is necessary, you
will need to provide this data to a Chromalox customer
service representative.
Upon removing package, ensure that there is no physical damage to the controller during shipment, and that
the package also contains the “Configuration and Programming” manual.
If there are signs of damage or if any parts are missing,
notify your Chromalox representative immediately.
Read through all installation sections in detail within
this document before installing the C4 on any piece of
equipment or in a control panel enclosure. Spacing requirements must be honored for proper operation and
safety.
2
2. Dimensions and Weights
(155)
Models without Fuse Holder
3.85
(92.5)
0.75
(19.6)
1.4
(35)
0.75
(19.5)
5.5
(140)
1.4
(35)
5.75
(147)
5.75
(147)
(140)
5.5
(140)
5.5
1.55
(42)
5.5
(140)
4.4
(111.5)
5.5
(140)
0.16
(4)
0.16
(4)
4
(101.5)
4.3
(109.5)
4
(101.5)
0.16
(4)
5.2
(132)
0.16
(4)
5.2
(132)
3.25
(52
)
4.3
(109.5)
3.65
(92.5)
7.7
7.2
(182)
3
3. Installation
ROTATE
To ensure proper performance, maximum safety and
reliability, it is essential to install the unit correctly. This
includes proper mounting, spacing, hardware and wiring. See below:
• Maximum surrounding air temperature is 40°C in
“Open Type Equipment” which is suitable for use in
pollution degree 2. For temperature >40°C refer to
the Derating Curves.
• Install the unit vertically (max 10° inclination from
vertical axis).
Spacing
To ensure maximum reliability, the device must be correctly installed in the panel in such a way as to obtain
adequate heat exchange between the heat sink and
the surrounding air under conditions of natural convec-
Mounting
C4 Models to be installed on a DIN Rail . Rear panel
dimensions are on previous page.
tion. Under no circumstance shall any component, including cable channels, compromise minimum thermal
spacing dimensions. Air must be able to flow vertically
on the heat sink without any obstacles.
Solid state devices dissipate heat which may impact
installation room temperature. Exchange with external
air or an air conditioner may be necessary to transfer
heat outside the panel.
• Minimum vertical distance between unit and panel
wall: 3.9” (100 mm)
• Minimum horizontal distance between unit and panel wall: 0.8” (20 mm)
• Minimum horizontal distance between adjacent
power control units: 0.4” (10 mm)
To install C4 onto a DIN Rail:
1. Depress DIN mounting spring. u
2. Position controller on the DIN Rail at a slight angle.
3. Lower controller on to DIN Rail. v
4. Release the mounting spring.
1
PRESS
2
ROTATE
To remove from DIN Rail:
1. Depress DIN mounting spring. u
2. Rotate bottom of controller off of the DIN Rail. v
3. Remove from DIN Rail.
1
PRESS
2
4
4. Installation – Wiring
This section covers the C4 wiring installation instructions for the power supply, inputs, outputs and interfaces.
CAREFULLY READ THE FOLLOWING WARNINGS
BEFORE INSTALLING THE INSTRUMENT!
Failure to obey these warnings could create
electrical safety and electromagnetic compatibility problems, as well as void the warranty
and cause personal injury or death.
Electrical Power Supply
• The controller DOES NOT have an On/Off switch.
The user must install a switch or isolator that conforms to all codes and electrical safety requirements
(CE mark) to cut off the power supply upstream of
the controller. The switch must be installed in the
immediate vicinity of the controller and with-in
reach of the operator. A single switch can be used
for multiple devices.
• The earth connection must be made with a specific
lead.
• If the product is used in applications with risk of
harm to persons or damage to machines or materials, it MUST be equipped with auxiliary alarm
device(s). It is advisable to provide the ability to
check for tripped alarms during regular operation.
DO NOT install the product in rooms with hazardous (inflammable or explosive) atmosphere; it may
be connected to elements that operate in such atmosphere only by means of appropriate interfaces
that conform to current safety standards..
Notes on Electrical Safety and Electromagnetic
Compatibility
CE MARKING: EMC (electromagnetic compatibility)
conformity in compliance with Directive 2004/108/
CE and following modifications. Series C4 control-
lers are mainly intended for industrial use, installed on
panels or control panels of production process machines or systems. For purposes of electromagnetic
compatibility, the most restrictive generic standards
have been adopted, as shown on the tables.
LV (low voltage) conformity Directive 2006/95/CE.
EMC compliance has been verified with respect to the
information in Tables 1 and 2.
Recommended Installation for purposes of EMC
Instrument power supply
• The power supply for the electronic instrumentation
on the panels must always come directly from a cut/
off device with fuse for the instrument part.
• Electronic instrumentation and electromechanical
power devices such as relays, contactors, solenoids,
etc., MUST ALWAYS be powered by separate lines.
• When the power supply line of electronic instruments is heavily disturbed by switching of SCR power groups or by motors, you should use an isolation
transformer only for the controllers, grounding its
sheathing.
• It is important for the system to be well grounded.
Voltage between neutral and ground must not be > 1
V and resistance must be < 6Ω (Ohms).
• If the grid voltage is highly unstable, use a voltage
stabilizer.
• In proximity of high frequency generators or arc
welders, use adequate grid filters.
• The power supply lines must be separate from instrument input and output lines.
• Supply from Class II or from limited energy sources.
Input and output connections
Before connecting or disconnecting any connection, always check that the power and control cables are isolated from voltage. Appropriate devices must be provided:
fuses or automatic switches to protect power lines.
•
Connected outside circuits must be doubly isolated.
• To connect analog or linear inputs, strain gauges,
TC, RTD, etc., you have to:
• physically separate the input cables from those
of the power supply, outputs, and power connections.
• use braided and shielded cables, with sheath-
ing grounded at a single point.
• To connect the control outputs and alarm outputs
(contactors, solenoids, motors, fans, etc.), install
RC (series of capacitors and resistors) groups parallel to inductive loads that work in AC.
(Note: all condensers must conform to VDE stan-
dards (class X2) and support voltage of at least
220Vac. Resistances must be at least 2W).
• Install a 1N4007 diode parallel to the coil of inductive loads that work in DC.
Installation Notes
Use the extra rapid fuse indicated in Table 15.1 later
in this manual, 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.
5
5. Emission, Immunity and Safety Standards
Table 1: EMC Emission
AC semiconductor motor controllers and conductors
for non-motor loads
Emission enclosure compliant in firing mode single
cycle and phase angle if external filter fitted
Table 2: EMC Immunity
Generic standards, immunity standard for
industrial environments
ESD immunity EN 61000-4-2
RF interference immunity
Conducted disturbance immunity
Burst immunity EN 61000-4-4
Surge immunity EN 61000-4-4/5
EN 60947-4-3
EN 60947-4-3
EN 60947-4-3 CISPR-11
EN 55011
4 kV contact discharge
8 kV air discharge
10 V/m amplitude modulated
80 MHz-1 GHz
10 V/m amplitude modulated
1.4 GHz-2 GHz
10 V/m amplitude modulated
0.15 MHz-80 MHz
2 kV power line
2 kV I/O signal line
PPower line-line 1 kV (level 2)
Power line-earth 2kV (level 3)
Signal line-earth 1kV (level 2)
Class A
Group 2
Magnetic fields immunity EN 61000-4-8 100 A/m (level 5)
Voltage dips, short interruptions and voltage
immunity tests
Table 3: LVD Safety
Safety requirements for electrical equipment for
measurement, control and laboratory use
ATTENTION
This product has been designed for class A equipment. Use of the product in domestic environments may cause
radio interference, in which case the user may be required to employ additional noise mitigation methods.
Per UL, the SCCR (Short Circuit Current Rating) is 100kA for models: C4 - XXXXX - 0 - XX Suitable for use on
a circuit capable of delivering not more than 100RMS kA symmetrical, 480VAC when protected only by listed
cartridge fuses manufactured by BUSSMAN type DFJ200 non renewable (JDDZ) 200A class J current limiting
fuses.
The CE declaration of conformity is available on request.
EN 61000-4-11 100%U, 70%U, 40%U,
EN 61010-1
UL 508
6
6. Controller Overview
6.1 Layout
Front DIN rail mount for the C4-OP programming module.
1.
This mount is only present on models without fuse holders.
2. Screwdriver access to power connection screws.
3. Power supply connection terminals
4. Heat sink ventilation screen: DO NOT OBSTRUCT
5. Spring clamp release for rear DIN rail.
6. Fastening slots for additional mounting security.
7. DIP switches for controller function / load configuration.
8. Communication ports (Port1, Port2).
9. Rotary switches for setting node address or number
Input signal & low voltage power supply terminals
10.
(J1, J2, J3, J4)
11. Fuse holders. (Only available on 30KW and 60KW models).
12. Terminals for fuse holder connection (F1, F2, F3, F4/N)
13. Terminals for load power connection (U1, U2, U3, U4)
14. Air intake / fan protection screen: DO NOT OBSTRUCT
7
6.2 Cooling Fan
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 the fan connector from the board
c. Check the condition of the fan
d. Clean or replace the fan
NOTE: Ensure that the air flow arrow on the fan is
pointing towards the heat sink e Insert the connector into the board
f. Insert the fan support grille until it attaches
g. Power up the device and check fan rotation when at
least one load is on
6.3 Inserting a New Field Bus Interface Card
Before and during the inspection/
maintenance, cut power to the fan
controller and verify that the system
is isolated for operator safety.
14 Support Grill
15 Fan
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)
Before attempting board replacement,
ensure that power to the controller
has been cut and verify that the
system is isolated for operator safety.
8
7. Connections and Indication
Model without fuse holder Model with fuse holder
So
li
Solid Wire
d
d
Solid Wire
Stranded Wire
d
d
Solid Wire
Stranded Wire
Soldered, Pin
Insulated Tube
Torque Force
d
d
7.1 Power Connections
F1,F2,F3,F4/
7.2 Power Wiring Considerations
Model 30kW 60kW 80kW
Max Current 16 Amps 30 Amps 40 Amps
Solid Wire
Stranded Wire
Soldered, Pin
Insulated Tube
0.2 - 6mm2 24 - 10 AWG 0.2 - 6mm2 24 - 10 AWG 0.5 - 16mm2 20 - 6 AWG
0.2 - 4mm2 24 - 10 AWG 0.2 - 4mm2 24 - 10 AWG 0.5 - 10mm2 20 - 7 AWG
0.25 - 4mm2 23 - 10 AWG 0.25 - 4mm2 23 - 10 AWG 0.5 - 10mm2 20 - 7 AWG
0.5 - 0.6Nm 0.5 - 0.6 Nm 1.2 - 1.5Nm
/N
4.4 - 5.3
In-lb
4.4 - 5.3
In-Lb
10.6 - 13.3
In-Lb
9
7.3 Input & Output 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.
TRIAC Logic/Analog Relay
• For 2-wire RTDs, make the connection indicated instead of the third wire.
• Refer to the applicable Connectors Detail starting in
section 7.6
7.4 LED Logic
LED Description Color
RN RUN - Flashes during regular operation Green
ERROR (Fault Condition) - Illuminates when a fault is present
Lo = Process Variable value < Lo.S
ER
HI = Process Variable value > Hi.S
Sbr = Sensor interrupted or input values over maximum limits
Err = RTD third wire interrupted for Pt100 or input values below minimum
ER = (red) flashing: Alarm temperature OVER_HEAT (STATUS.STRUMENTO 4 bit 1)
DI1 State of digital input 1: DI1 Yellow
DI2 State of digital input 2: DI2 Yellow
O1 State of output 1: O1 Yellow
O2 State of output 2: O2 Yellow
O3 State of output 3: O3 Yellow
O4 State of output 4: O4 Yellow
Red
10
7.5 Rotary Switches
0
Switch Drescription
0
1
F
2
E
3
D
4
C
5
B
A
9
8
0
1
F
E
D
C
B
A
9
8
X1
6
7
2
3
4
5
6
7
X1
Defines Address of Controller Module
Available address: 00...99
7.6 Connector Detail
7.6.1 Connector J1 / J1a (Note: If Auxiliary Outputs O5 - O8, are present, connector J1a becomes J1.)
0.2 - 2.5mm2 24-14 AWG
0.25 - 2.5mm2 23-14 AWG
Outputs 5 - 8: Logic or Analog Output Type
Logic outputs: 18 - 36Vdc, max 20mA
Analog outputs: Voltage (default): 0 - 10V, 2 - 10V, max 25mA or Current: 0 - 20mA, 4 - 20mA, max 500Ω
Wiring Schematic for Outputs 5 - 8, both Logic & Analog Outputs
O5
PIN Legend
Polarity
O6
O7
PIN Name Description
1 Com O5-O8 Outputs Common ( – )
(Logic or Analog)
2 O5 Output 5 ( + )
O8
3 O6 Output 6 ( + )
4 O7 Output 7 ( + )
5 O8 Output 8 ( + )
Com O5-O8
11
When the optional Auxiliary Output type “A” (Analog) is selected, one must choose whether the output is Voltagebased (default) or Current-based. This selection is carried out via proper jumper placement on the board as follows:
C4
Output Card
C4
Output Card
12
C4
Output Card
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