Chromalox CTF-025, CTF-040, CTF-050, CTF-060, CTF-075 Quick Start Manual

CTF Single Phase Advanced SCR

Top view

Top view

of line voltage

)

Input control signal (+)

(GND)

5

Power Controller Quick Start Manual

0037-75558 (PK536)

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 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 Pro­gramming 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 equip­ment must be performed by a qualified person and must be effectively
grounded in accordance with the National Electrical Code or local gov­erning 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 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.

2. INSTALLATION

Input & Output Connections: CTF 25 – 120 Amp Models Input & Output Connections: CTF 150 – 250 Amp Models

WITHOUT Modbus Option

Key HB

J2
TTL port for
Port Configuration

Master/Slave connection

Alarm output

(solid state relay - HB option)

Green Led (RUN)

Yellow Led (STATUS)

Red Led (Alarm output HB)

Yellow Led (Status digital input)

Led: Green = SCR ON
Yellow = Te mperature OVER

1/L1

LINE connection

Reference connection

Key HB

Syncronous output for

Key HB

3/L2

WITH Modbus Option

J3, J4
RJ10 connectors
RS485 serial line

Modbus

Potentiometer output power supply (+5Vdc

Digital input (PWM input)

Earth Ground

Switch for
serial line

Power supply terminal 24Vac/Vdc

J1
Power supply /control
connector

Fixing screw
at heatsink

Fixing screw
at heatsink

Address x 10

2/T1

LOAD connection

Address x 1

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.

Top View

Line voltage

reference

connection

Line Voltage

Connector

2/T1 Load

Connection

Bottom View Without

Modbus RS485 Option

Fan
Protection
Grill

1/L1
Line
Connection

J8

3/L2

n.c.

J8

2/T1

Load

Conn.

Fan Protection Grill

Line Connection

1/L1

Front Cover
Fastener (Fuse Access)

Outputs

Supply

Status LEDs

Digital Input

Key HB

Address Rotary
Switch
(Optional)

Analog Control
Input Connector

J5
Config.
TTL Port

J1

J2

J3

J4

Bottom View WITH

Modbus RS485 Option

2/T1

Load

Conn.

HB OUT Switch (Optional)

OUT Master (7 V)
GND

24 Vac/dc
24 Vac/dc
Earth

n.c.
n.c.
+ INDIG (PWM input)
GND

OUT +5V (Potentiometer)
+ IN
SHUNT – mA
GND

RUN ...................................(Green)

STATUS .............................(Yellow)

ALARM HB ......................(Red)

DIGITAL INPUT STATUS (Yellow)

ON SCR............................(Green)

OVER Temperature........... (Yellow)

Recommended Wire Gauges

CTF Current

Level Terminal Cable Wire Wire Terminal Tightening Torque / Tool

25A 1/L1, 2/T1, PE

40A 1/L1, 2/T1, PE

50A 1/L1, 2/T1, PE

60A 1/L1, 2/T1, PE

75A 1/L1, 2/T1, PE

90A 1/L1, 2/T1, PE

120A 1/L1, 2/T1, PE

-

150A 1/L1, 2/T1

200A 1/L1, 2/T1

250A 1/L1, 2/T1

-

NOTE: Cables must be Copper “Stranded Wire” or “Compact-Stranded Wire” type with max. operating temp. 60/75°C

3/L2

(Ref. Vline)

3/L2

(Ref. Vline)

2

4 mm

10 AWG

2

10 mm

7 AWG

2

10 mm

7 AWG

2

16 mm

5 AWG

2

25 mm

3 AWG

2

35 mm

2 AWG

2

50 mm

1/0 AWG

0.25 ...2.5 mm

23...14 AWG

2

70 mm

2/0 AWG

2

95 mm

4/0 AWG

2

120 mm

250 KCMIL

0.25 ...2.5 mm

23...14 AWG

Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3

Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3

Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3

Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3

Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3

Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3

Wire terminal / Eye D. 6mm 2.5 Nm / Phillips screwdriver PH2 - PH3

2

2

Wire terminal tip

Wire stripped for 25 mm or with

crimped pre-insulated terminal tube

Wire stripped for 25 mm or with

crimped pre-insulated terminal tube

Wire stripped for 25 mm 6 Nm / No. 6 hex head wrench

Wire stripped for 8 mm or with tag

terminal

0.5 ...0.6 Nm / Screwdriver blade 0.6 x

3.5 mm

6 Nm / No. 6 hex head wrench

6 Nm / No. 6 hex head wrench

0.5 ...0.6 Nm / Flat-head screwdriver tip

0.6 x 3.5 mm

Dip Switch
serial line

J6, J7
RJ10
connector
serial RS48
Modbus

3. INSTALLATION CONSIDERATIONS: DIMENSIONS & WEIGHTS, MOUNTING & SPACING REQUIREMENTS 4. DERATING CURVES

(104)

Dimensions are in Inches (mm)

W

L

LOAD, FIRING, DIAGNOSTICS & RATINGS

CATEGORY OF USE
(Tab. 2 EN60947-4-3)

AC 51 resistive or low inductance loads
AC 55b infrared lamps
AC 56a: transformer loads

Trigger Mode

PA - Load management by adjusting the firing angle (only
configuration single-phase or delta open)
ZC - Zero Crossing with constant cycle time (settable in range
1-200sec)

BF - Burst Firing, or D.O.T. with variable cycle time optimized min.
HSC - Half Single Cycle corresponds to Burst Firing that includes ON

and OFF half-cycles.
Useful for reducing flicker with short-wave IR loads (applied only to
single-phase resistive or 3-phase 6-wire open delta loads).

Feedback Mode

V, V

2

: Voltage feedback proportional to RMS voltage value on load

(useful to compensate possible variations in line voltage).

I, I

2

:

Current feedback: bound to RMS current value on load to com-

pensate variations in line voltage and/or variations in load impedance.
P: Power feedback: proportional to real power value on load (useful
to keep constant values of electrical power assigned regardless of
load impedance or line voltage variations).

Max rated voltage 480 Vac 600 Vac 690 Vac

Work voltage range 90 - 530 Vac 90 - 660 Vac 90 - 760V ac

Non-repetitive voltage 1200 Vp 1600 Vp 1600 Vp

Rated Frequency 50/60Hz Auto-Synchronization

CTF MODEL CTF-025 CTF-040 CTF-050 CTF-060 CTF-075 CTF-090 CTF-120 CTF-150 CTF-200 CTF-250

Rated Current, AC51 ­AC55b Resistive Load
(@ 40˚C contin. service)

25A 40A 50A 60A 75A 90A 120A 150A 200A 250A

Rated current AC56A
permitted trigger
modes: ZC, BF/DOT
with DT (Delay Trigger),
PA with softstart
(@ Tamb = 40 °C)

20A 32A 40A 50A 60A 75A 100A 125A 160A 200A

Maximum Surge Current
(t = 10 ms) A

400A 520A 520A 1150A 1150A 1500A 1500A 5000A 8000A 8000A

Maximum I

2

t for fusing

(blowout) A

2

s

450 1,800 1,800 6,600 6,600 11,200 11,200 125,000 320,000 320,000

Critical dV/dt Off-state
(minimum)

1,000V/µs

Nom. Impulse Voltage 4KV

Nominal SCCR 5KA

FUNCTION

Diagnostics

Detection of shorted load circuit,
absence of line voltage, HB alarm (partial break of load)

OPTIONS

Options

- Timed Soft-Start firing ramp, with or without peak current control

- Soft-Start firing ramp (specific for infrared lamps)

- Timed shut-off ramp

- Limitation of RMS current in load

- 0-90° Delay-Triggering for firing inductive loads in ZC and BF/DOT modes.

Diagnostic

- SCR in short circuit (presence of current with OFF control)

- Absence of SCR current when under load.

- Overtemperature alarm
Current read

• HB alarm: interrupted or partially interrupted load

• Automatic calibration of HB alarm setpoint starting from current value in load

• Alarm for load in short circuit or overcurrent

Voltage read

• No line voltage

GENERAL DATA

Power Supply

CTF 25-120 A: 24 Vac 50-60 Hz / Vdc ± 25%, max 3 VA
CTF 150-250 A: 24 Vac 50-60 Hz / Vdc ± 25%, max 11 VA

Power supply for external fan
(only for CTF120A model)

24 Vdc ± 10%, max 200mA

Signals

5 leds: RUN: run state of CPU
STATUS: operating state
ALARM: state of alarm output
DIGITAL INPUT: state of digital inputs
ON / OVER-TEMP.: state of SCR power / Alarm for overheating

Load Type and Connection

Single phase load
Independent single-phase load in open delta
3-phase load
3-phase load (star without neutral or closed triangle) with 2-leg control

Protection IP20

Ambient Temperature

0 to 50˚C (32 to 122˚F) (Per EN 60947-4-3 § 7.1.1: Average Temperature over 24
hour period shal not exceed 35˚C (95˚F)

Storage Temperature -20˚C to 70˚C (-4˚F to 158˚F)

Relative Humidity 20…85% RH non-condensing

Ambient Conditions for use Indoor use, altitude up to 2000m

Installation DIN Rail EN50022 or panel with screws

Installation Requirements

Installation category II, pollution level 2, double isolation (only for model >120A):

- Max. temperature of air surrounding device 40°C; for temperature >40°C refer
at derating curves

- Device type: “UL Open Type”

25 25

22.5

20

40

40

35

30

15

20

25

30

35

40

45

0 40 45 50

;7* ;7*

99*

97*97* 97*

:9*

:7*

30

35

40

45

50

55

60

65

70

0 40 45 50

200 200

180

160

250 250

225

200

150 150

135

120

100

125

150

175

200

225

250

275

0 40 45 50

90 90

80

70

120 120

107.5

95

75 75

67.5

60

55

60

65

70

75

80

85

90

95

100

105

110

115

120

125

0 40 45 50

Current (Amps)

Enclosure / Ambient Temperature ˚C

CTF-025 & CTF-040

Current (Amps)

Enclosure / Ambient Temperature ˚C

CTF-050 & CTF-060

Current (Amps)

Enclosure / Ambient Temperature ˚C

CTF-150, CTF-200, CTF-250

Current (Amps)

Enclosure / Ambient Temperature ˚C

CTF-75, CTF-90, CTF-120

CTF 25 A
CTF 40 A

CTF 50 A (Without Fan)
CTF 60 A (Without Fan)

CTF 75 A (Without Fan)
CTF 90 A (Without Fan)

CTF 120 A (With Fan)

2.4 (60.1)

3.1 (80)

0.7 (18.5)

4.1

0.5 (14.0)

Depth: 5.6 (143)

Depth: 5.6 (143)

Weight: 1.8 lbs (810 g)

Weight: 2.1 lbs (970 g)

Weight: 2.9 lbs (1,300 g)
Weight: 3.3 lbs (1,500 g)

Rear Panel Mounting Template

Model

In. (mm)

CTF 25-40-50-60A 4.4 (112) 1.7 (44)

CTF 75-90-120A 4.4 (112) 4.4 (113)

CTF 150-200-250A 11.3 (287) 1.7 (42)

Length

Width

In. (mm)

5 (127)

Depth: 5.6 (143)

1.2 (30)

Fan

3.9

(100)

1.3

(32)

11.9

(302)

CTF 150 A, 200 A, 250 A

11.3

(287.4)

Depth: 6.7 (170.4)

Weight: 5.7 lb. (2,600 g)

Minimum Spacing Requirements

4.3 (108.3)

3.3 (84)

1.7 (42)

5. GENERAL TECHNICAL DATA & SPECIFICATIONS 6. FUSES & FUSE HOLDERS

2

I

CTF Model
480 & 600 Vac
unless otherwise
specified

Fuse

Rating,

Amps I

2

t

t Extra Rapid Fuses Fuse Holder

Power

Dissi-

pation Fuse Size

Manufacturer’s

Model Code Part No. Part No.

Fuse Holder

Rating (UL)

Fuse Holder
Rating (IEC)

CTF-25 25A 390 A²s 6W 10x38 FWC25A10F 0024-07815 0024-12124 30A@600V 32A@690V

CTF-40 50A 1,600 A²s 9.5W 22x58 FWP50A22F 0024-07816 0024-12199 100A@600V 125A@690V

CTF-50 50A 1,600 A²s 9.5W 22x58 FWP50A22F 0024-07816 0024-12199 100A@600V 125A@690V

CTF-60 63A 3,080 A²s 11W 22x58 FWP63A22F 0024-07817 0024-12199 100A@600V 125A@690V

CTF-75 80A 6,600 A²s 14W 22x58 FWP80A22F 0024-07818 0024-12199 100A@600V 125A@690V

CTF-90 125A 6,950 A²s 25W 100x51x30 170M2665 0024-07819 0024-12029 400A@600V *not CE-marked

CTF-120 125A 6,950 A²s 25W 100x51x30 170M2665 0024-07819 0024-12029 400A@600V *not CE-marked

CTF-150 200A 31,500 A²s 19W FUS-200S DN000UB69V200 0024-07820 Fuse is mounted internal to the controller

CTF-200/250 450A 196,000 A²s 17W FUS-450S DN00UB60V450L 0024-07821 Fuse is mounted internal to the controller

CTF-200/250 @690V 400A 150,000 A²s 20W FUS-400S DN00UB69V400L 0024-07822 Fuse is mounted internal to the controller

Instrument Fuse Fuse Holder

Power

Dissi-

2

t

pation

Fuse Size

Manufacturer’s

Model Code Part No. Part No.

Fuse Holder

Rating (UL)

Fuse Holder
Rating (IEC)

CTF Model

Fuse

Rating,

Amps I

All Models 1A N/A N/A 10x38 KTK-1 0024-01113 0024-12124 30A@600V 32A@690V

PK536

0037-75558

August 2015

© 2016 Chromalox, Inc.