Chromalox MaxPac User Manual
User’s Manual
MaxPac
PK480-5
0037-75428
June 2018
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 solutions 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/process 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)
1
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
2
Important Safeguards
1
IMPORTANT SAFEGUARDS
The MaxPac User Manual uses this symbol to
alert personnel to potential hazards that may
damage the equipment.
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 preferably 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. Contact 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
The MaxPac User Manual uses this symbol to
alert personnel to potential hazards that may
cause injury or death.
CAUTION You CAN be hurt if you do not follow instructions.
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 associated heater.
Such persons shall adhere to proper high voltage safety procedures, including the use of appropriate personal 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 procedures and information given in this manual.
3
Description
2
MaxPac I, II, and III
The Chromalox Model MaxPac IP, I, II and III Series are specifically designed for the OEM market. The Chromalox 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.
† This can be set to three cycles ‘On’ / three cycles ‘Off’ (see section on installation options).
4
Before You Install
3
Immediately after receiving your MaxPac I, II, III or IP Series Controller, visually inspect the shipment packaging and record any damage on the shipping documents. Unpack the controller and carefully inspect for obvious 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 environment. Temperature extremes and excessive moisture can damage the controller.
Before choosing a location in which to mount your MaxPac, please consider the following:
READ AND UNDERSTAND BEFORE
CARRYING OUT THE WORK DETAILED BELOW
Temperature
When mounting the SCR unit in a control panel, attention should be paid to the enclosure temperature. 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 cabinet 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 ensure proper air flow necessary to cool the device.
WARNING
Hazardous Voltage: Disconnect and lockout power before installing or servicing. Failure to comply could result in personal injury or equipment damage.
5
Installation
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 MaxPac allow the input line power to connect from
either of two directions.
Configuration One
In In
Warm Air
Fan
Phase 1
or In Out or In Out
Phase 3
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 designs allow incoming and outgoing wiring in either
direction.
Out
Configuration Three
Warm Air Out
Phase 3
In
Out
or In
Configuration Two
Out Out
Warm Air
Out
Phase 1 Phase 3
or In or In
In In
Fan
Cool Air
In
Out
Phase 1
In or In
Fan
Cool Air In
6
Examples of Proper Air Flow
Louvers
Enclosure
(Not Recommended)
Since hot air rises naturally, it is not recommended that cooling air enter from the top and exhaust at the bottom of the enclosure.
Louvers
Air
Fan MaxPac
Enclosure
Fan
Filter
Forced Air In
(Recommended)
Pagoda Top
Fan
Air
MaxPac
Fan
Air
Louvers
Forced Air Out
7
Installation
4
READ AND UNDERSTAND BEFORE
CARRYING OUT THE WORK DETAILED BELOW
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 various 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
8
not drawn to the same scale.
Figure 1
4.7" [107mm]
0.0" [0mm]
1.0" [25mm]
4.75" [121mm]
8.5" [216mm]
9.5" [241mm]
6.0" [153mm]
7.3" [185mm]
FIRING PACKAGE
FAN END
Ø0.280" [Ø7.11mm]
(6 HOLES)
4.2" [107mm]
0.0" [0mm]
1.0" [25mm]
7.2" [184mm]
13.5" [342mm]
14.5" [368mm]
6.0" [153mm]
7.28" [185mm]
FIRING PACKAGE
FAN END
Ø0.280" [Ø7.11mm]
(6 HOLES)
7.2" [183mm]
0.0" [0mm]
1.3" [33mm]
7.3" [185mm]
13.3" [337mm]
14.6" [371mm]
12.0" [305mm]
13.3" [338mm]
FIRING PACKAGE
FAN END
Ø0.280" [Ø7.11mm]
(6 HOLES)
5.12" [130mm]
0.0" [0mm]
1.3" [33mm]
9.3" [237mm]
13.3" [338mm]
14.6" [371mm]
8.1" [206mm]
9.1" [232mm]
FIRING PACKAGE
FAN END
Ø.3125 [Ø7.94mm]
(8 HOLES)
5.3" [135mm]
8.4" [214mm]
0.0" [0mm]
1.3" [33mm]
9.3" [237mm]
13.3" [338mm]
14.6" [371mm]
14.7" [375mm]
15.75" [400mm]
FIRING PACKAGE
FAN END
Ø.3125" [Ø7.94mm]
(8 HOLES)
5.3" [135mm]
Figure 2
Figure 3
Figure 5
Figure 4
9
13.8" [351mm]
0.0" [0mm]
1.3" [33mm]
26.5" [673mm]
16.3" [414mm]
17.6" [448mm]
11.3" [287mm]
25.5" [648mm]
FIRING PACKAGE
FAN END
Ø.3125" [Ø7.94mm]
(8 HOLES)
6.3" [160mm]
Figure 6 Figure 7
11.7" [298mm]
0.0" [0mm]
1.3" [33mm]
9.3" [237mm]
13.31" [338mm]
14.62" [371mm]
21.4" [543mm]
22.4" [568mm]
FIRING PACKAGE
FAN END
Ø.3125" [Ø7.94mm]
(8 HOLES)
5.3" [135mm]
5.8" [148mm]
0.0" [0mm]
1.3" [33mm]
11.3" [28mm]
16.3" [414mm]
17.6" [448mm]
9.5" [241mm]
10.5" [267mm]
FIRING PACKAGE
FAN END
Ø.3125" [Ø7.94mm]
(8 HOLES)
6.3" [160mm]
9.8" [249mm]
0.0" [0mm]
1.3" [33mm]
11.3" [287mm]
16.3" [414mm]
17.6" [448mm]
17.5" [444mm]
18.5" [470mm]
FIRING PACKAGE
FAN END
Ø.3125" [Ø7.94mm]
(8 HOLES)
6.3" [160mm]
Figure 8
Figure 9
10
4.2 - Step 2: Wiring
COOLING AIR
COOLING AIR
SCR
FUSE
HEATSINK FINS
COVER PROVIDES FOR TOUCH SAFE FEATURE
TOUCH-SAFE COVER PROVIDES WIRE ENTRANCE AND
EXIT THROUGH SEALS COVERING THE WIRE WINDOW.
REMOVAL OF THE TAPE BEHIND THE WINDOWS TO
BE USED ALLOWS WIRES TO PASS. THE TAPE
REMAINS ON UNUSED WINDOWS TO PROVIDE TOUCH
SAFE FEATURE.
BUS BAR DESIGN ALLOWS
FOR WIRING FROM EITHER
DIRECTION AND MULTIPLE
LOAD CIRCUITS
BUS BAR DESIGN ALLOWS
FOR WIRING FROM EITHER
DIRECTION AND MULTIPLE
LOAD CIRCUITS
LONG LIFE, HIGH OUTPUT BALL
BEARING FANS PROVIDE RELIABLE
COOLING
Careful attention must be paid when attaching the wiring to the MaxPac to ensure proper and safe operation. This section contains detailed information on how to connect the power, resistive load, ground, and
command signal wiring.
WARNING
Hazardous Voltage: Only qualified personnel should perform
electrical wiring for the MaxPac Power Paks. LETHALLY HIGH
VOLTAGES are associated with this equipment and are dangerous if improperly installed.
IMPORTANT: Select installation wiring that is in accordance with the National
Electrical Code and any local standards that may be applicable.
4.2.1 - Touch-Safe Design
If the MaxPac model you purchased is of a Touch-Safe design, follow the steps on the following page to
install the electrical wiring. This will ensure the wiring is done properly while maintaining the Touch-Safe
feature. If your MaxPac is of an Open design below 400 Amps, disregard this subsection.
The following is a detailed drawing of a Touch-Safe unit:
11
4.2.2 - Steps for Touch-Safe Design Cover Removal and Installation
MaxPac I
L2
L1
X1
Single Phase
Resistive
Remove Cover:
1. Loosen the thumb screws on both ends of the cover.
2. Lift the cover from the base.
Install Wiring:
3. Attach the wires to the bus bars in accordance with the instructions in the next section.
4. Choose the entrance and exit directions for the wiring as desired.
5. After the wiring is complete, remove the tape from the inside of the wire gaskets of the
windows that the power wiring will enter or exit.
WARNING
Hazardous Voltage: DO NOT remove the tape from the back of
the windows that are not used, as this maintains the TouchSafe feature.
Replace Cover:
6. Angle the end of the cover without screws towards the “fan-end” of the unit.
7. Slip that end into place first while allowing the wiring to pass through the desired windows.
8. Slip the opposite end of the cover into place.
9. Tighten all thumb screws.
4.2.3 - Line/Load Power Wiring
The following illustrations depict how to connect the MaxPac to a resistive load. Make sure you refer to the
correct illustration for the MaxPac series you have purchased.
For the power/load drawings:
On open design units up to 300 Amps, X1, X2, X3, L1, L2, and L3 refer to copper lugs.
On open design units 400 Amps and greater and all Touch-Safe designs, X1, and X2, and X3, L1, L2, and
L3 refer to bus bar connections.
MaxPac I
12
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