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
MaxPac II
Three Wire
2 Leg Control
MAX PAC II
L1
L3
L2
X1
X3
L2 Connection is
NOT on MaxPac
Four Wire
3 Leg Control
MAX PAC III
L1
L2
L3
X1
X2
X3
N
N Connection is
NOT on MaxPac
MaxPac III
IMPORTANT: The I2t fuses installed on the SCR are designed to protect the SCR
from faults on the load connection side. They are NOT intended to provide wire
protection.
CAUTION
13
MaxPac III
Three Wire
3 Leg Control
MAX PAC III
L1
L2
L3
X1
X2
X3
Single Phase
transformer
Coupled
MAX PAC IP
L2
L2
L1
X1
L2 connection to
MaxPac is instrument
power only
MaxPac IP
IMPORTANT: The I2t fuses installed on the SCR are designed to protect the SCR
from faults on the load connection side. They are NOT intended to provide wire
protection.
CAUTION
The bus bars are designed to accept NEMA standard two-hole crimp lugs in accordance with the charts
below.
14
The following drawings show proper installation of the crimp lugs on the bus bars:
FUSE
Smaller wire, #1 through #8, often used
for power distribution, can be connected
to both sides of the load bus. Wiring must
be bent slightly to align with the windows
in the top of the touch safe units.
LINE BUS BAR
LOAD BUS BAR
FAN END
SCR
1/0 through 500 mcm
wire must mount on the
fuse side of the bus
bar as shown to
maintain required
electrical clearances
Illustration 1: View From Rear Ventilated Panel
All bolts must mount
with excess bolt lengths
toward the fuse to main-
tain required electrical
clearances.
Input Bus
Up to (3) 1/0 - 300 mcm (70 mm2 — 150 mm2)
Up to (2) 350 - 500 mcm (185 mm2 — 240 mm2)
Input Bus
Up to (4) 1/0 - 300 mcm (70 mm2 — 150 mm2)
Up to (3) 350 - 500 mcm (185 mm2 — 240 mm2)
Input and output bus drilled to accomodate qty (4) 1/0 - 500 mcm NEMA standard two-hole crimp lugs per phase.
Illustration 2: View From Top
Touch-Safe Units
100 - 400 Amps
Up to (10) #8 - #1 (10 mm2 — 50 mm2)
Up to (3) #1/0 - 300 mcm (70 mm2 — 150 mm2)
Up to (2) 350 - 500 mcm (185 mm2 — 240 mm2)
550 - 650 Amps
Up to (12) #8 - #1 (10 mm2 — 50 mm2)
Up to (4) #1/0 - 300 mcm (70 mm2 — 150 mm2)
Up to (3) 350 - 500 mcm (185 mm2 — 240 mm2)
800 - 1200 Amps Open Design
Output Bus
Output Bus
15
The power wires must always mount on the fuse side of the bus bar. This is essential for maintaining the
required spacing between phases and the sides and to align with the openings in the top. The only exception to this is when using power distribution using connectors of size #8 to #1. There is adequate spacing for
these connectors to mount on both sides of the bus bar if necessary. The bolt head should always be on the
outside of the bus (side away from the fuse) with the bolt extending toward the fuse. Flat washers should be
used on both the bolt head and the nut and a lockwasher should be under the nut. The Touch Safe MaxPac
is designed to allow both input and output wiring to enter/exit in either direction. On the 550 amp and 650
amp models it is necessary to mount the wire in the holes that maximize the distance for the wire to exit
the enclosure. This maximizes the distance from the cover to the un-insulated connector. When using the
power distribution feature and mounting terminals on both sides of the bus bar, the wires mounted on the
outside of the bus bar must be bent inward slightly to align with the opening in the top. All wiring, especially
the larger wires should be bent prior to mounting to the bus bars. Do not use the bus bars as an anchor to
bend the power cables.
4.2.4 - Instrument Power
MaxPac requires 120 or 230 VAC 50/60Hz for instrument power. This voltage supplies power
for the control circuits, fans, high temperature warning indicator, and shorted SCR Indicators
(see Fig. 1 on page 21).
This supply is fused on the main circuit board.
4.2.5 - Grounding
The MaxPac uses electrically isolated SCR’s. The enclosure will therefore be at the potential of the panel to
which it is mounted. Holes are provided on the back of both sides of the MaxPac for NEMA standard two
hole crimp lugs (the same as used on the bus bars) for additional grounding as may be required.
IMPORTANT
Chasis is provided with hole pattern for standard NEMA two-hole crimp lugs.
WARNING
Hazardous Voltage: This Electrical Equipment must be installed by a qualified person and effectively grounded in accordance to the National Electric Code and local codes.
16
4.2.6 - Command Signal Wiring
Connection
Connection
Please refer to the following figure for illustrations of the 6-, 8-, and 10-pin input terminals.
Not a
Customer
Connection
Outputs
for
Customer
Customer
Input
Outputs
for
Customer
**
Not a
Customer
Customer
Inputs*
Modbus
*Only one customer input is allowed, eg. J3 pins 1 & 2 contact control may not be used at the same time as
J2 pins 6 & 7 (4-20 mA)
**Instrument power 4 VA maximum
MaxPac I, II, and III
On/Off Control Signals
AC Input – The 120 – 230 VAC signal lines are connected to terminal J1-7 & 8. An input voltage of
120 to 230 VAC turns the power On. The turn OFF voltage for the power control is 0 VAC.
DC Input – The 5 – 32 VDC signal lines are connected to terminal J3-1&4. An input voltage of 5 to 32
VDC turns the power On. The turn OFF voltage for the power control is 0 VDC.
NOTE: For AC or DC input to be used for ON/OFF control, SWI rotary switch must be set to position 0 and
unit must be jumpered for AUTO
Contact Closure Input – The dry contact signal lines are connected to terminal J3-1&2. A closed
contact turns the power On. The turn OFF is an open contact.
17
Process Analog Control Signals
NC NO
CONTACT
NORMALLY CLOSED
(SWNC)
CONTACT
NORMALLY OPEN
(SWNO)
SWITCH
ASSEMBLY
(SW)
PANEL TO BE
MOUNTED TO
LEGEND
PLATE
(LP)
AUTO
HAND
SWITCH KNOB
(SW)
AUTO
HAND
The MaxPac II accepts 0 –5/1 – 5/0 – 10
VDC and 4 – 20 mA input signals, they
are factory calibrated. The following signals are connected to:
0 - 5 VDC: Terminal J2 9(+) & 7(-)
1 - 5 VDC, 11 - 5 VDC: Terminal J2 5(+) & 7(-)
0 - 10 VDC: Terminal J2 10(+) & 7(-)
4 - 20 mA, 10 - 20 mA: Terminal J2 6(+) & 7(-)
Auto/Manual Input
Illustration 3
The MaxPac I, II and II can be wired to make it possible to select an input from either a temperature/
process controller or a manual input potentiometer. A switch is used to select between the input
from a 1K potentiometer or a linear control input (see input connections).
The unit is shipped with a jumper from terminals 4 and 5 of terminal block J2. This jumper must be
removed when connecting the auto/manual switch and potentiometer.
Demand Indicator
The LED demand indicator is located on the main PC board and is viewable through the cover. With
the On/Off control option, the indicator will display steady “on” and steady “off”. With the DOT Firing
or Time-Proportional options, the indicator will display the firing sequence.
SCR Control Board
The control board provides the following functions:
The low voltage dc to operate the circuitry:
A switching regulator circuit converts the instrument power to +8 VDC.
The power distribution for the cooling fans:
The incoming instrument power is routed to the fan power terminals.
Add fusing as required for fan power requirement.
The signal condition for the on/off input and analog inputs:
The 120 to 240 on/off input is isolated by an opto-coupler. The DC and contact
closure inputs are buffered by the circuitry.
18
The drive signal to the SCR trigger boards:
riggering
LD3-SCR1 LD4-SCR2 LD5-SCR3 LD2-Demand
The temperature alarm:
The heat sink temperature is derived from a resistive temperature detection (RTD)
sensor mounted on the heat sink. This is then compared to two set points.
The first alarm is a warning and activates the externally connected device.
This allows time to correct the problem before the second alarm inhibits the firing circuit.
The Shorted SCR Alarm:
When a short is detected the externally connected device output is activated.
SW3 - Phase/T
Selection
SW1 - Input Selection
19
The method of setting the MaxPac for desired mode of operation is as follows:
Input Command Selection
The unit can be set to drive its output in response to the following command inputs:
• Analog potentiometer
• Analog inputs: 4-20mA (or 0-20mA), 0-5Vdc (or 1-5Vdc), 0-10V
• Digital ON/OFF inputs: AC ON/OFF, DC ON/OFF
To select between any of these inputs, set the MaxPac as indicated in the table below:
Input Command Select Method of Selection
Potentiometer Select MANUAL mode by leaving no connection
between J2.4 & J2.5. The rotary switch selection at
SW1 is ignored when in MANUAL mode
OR
Select AUTO mode by jumpering J2.4 & J2.5, and
then set rotary switch at SW1 to position 1
ON / OFF (will turn output in if either AC or DC ON/
OFF inputs are energized)
0-10Vdc Select AUTO mode by jumpering J2.4 & J2.5, and
0-5Vdc Select AUTO mode by jumpering J2.4 & J2.5, and
1-5Vdc Select AUTO mode by jumpering J2.4 & J2.5, and
0-20mA Select AUTO mode by jumpering J2.4 & J2.5, and
4-20mA Select AUTO mode by jumpering J2.4 & J2.5, and
Select AUTO mode by jumpering J2.4 & J2.5, and
then set rotary switch at SW1 to position 0
then set rotary switch at SW1 to position 2
then set rotary switch at SW1 to position 3
then set rotary switch at SW1 to position 4
then set rotary switch at SW1 to position 5
then set rotary switch at SW1 to position 6
Note: SW1 position 7 is reserved for factory use, and should not be used
Phase Selection and Firing Mode
SW3 selects the phase selection and firing method of the MaxPac.
Normally, this switch should be left in its factory-installed position. If it should become necessary to change it, set only accordance to the table below. Choosing a setting that does not
match your unit’s number of phases and legs will result in the unit entering alarm mode and
turning the output off after an initial attempt to turn outputs on.
20
SW3
Position Selection Note
0 Reserved for factory use Do Not Use this Selection
1 DOT for MXPCI Caution: Do not choose this setting if your unit is a
MXPCII or MXPCII type
2 DOT for MXPCII Caution: Do not choose this setting if your unit is a
MXPCI or MXPCII type
3 DOT for MXPCIII Caution: Do not choose this setting if your unit is a
MXPCI or MXPCII type
4 Time Proportional for MXPCI Caution: Do not choose this setting if your unit is a
MXPCII or MXPCII type
5 Time Proportional for MXPCII Caution: Do not choose this setting if your unit is a
MXPCI or MXPCII type
6 Time Proportional for MXPCIII Caution: Do not choose this setting if your unit is a
MXPCI or MXPCII type
7 Reserved for factory use Do Not Use this Selection
LED Indicators
LEDs and their function are as follows:
Designator Name Description
LD2 Output Demand Indication This LED blinks on according to the switching of output
LD3 Switch SCR1 OFF in normal operation. Turns ON if shorted SCR is detected
in one direction. Blinks rapidly if phase voltage is not present or
if SCR is shorted in both directions.
LD4 Switch SCR2 OFF in normal operation. Turns ON if shorted SCR is detected
in one direction. Blinks rapidly if phase voltage is not present or
if SCR is shorted in both directions.
LD5 Switch SCR3 OFF in normal operation. Turns ON if shorted SCR is detected
in one direction. Blinks rapidly if phase voltage is not present or
if SCR is shorted in both directions.
Alarm Output
The form C contact at J14 will be in the alarmed state in any of the following conditions:
• If any shorted SCR is detected. One or more of the shorted SCR LEDs LD3-LD5 will be lit in this case
• If missing Zero Cross transitions are detected at the SCRs. Typically, this is caused by missing power on
one or more phases, or from incorrect detection of phase sequence. One or more of the shorted SCR
LEDs LD3-LD5 will be blinking in this case
• If sensed temperature of the heat sink at an SCR junction exceeds 200 degrees Fahrenheit or 93 degrees
Celsius. The Overtemp output will also be engaged in this case.
• If sensed phase sequence does not match the setting of selector SW3. (Normally, SW3 should be left in
its factory-set state. See caution in section titled, “Phase Selection and Firing Mode“).
21
Remote Stop
SHORTED SCR DETECTION
DEMAND
123
When it is necessary to disable or enable the output, connect a dry contact between J3 – 3 & 4.
When it is closed, the power control will disable the output.
IMPORTANT: This stop overrides the control input only. It will NOT protect against
faulted or damaged SCRs.
Shorted SCR Detection (optional)
This features provides a means of alerting an operator to a problem with the system. An external
indicated lamp or relay can be connected to J1 – 5 & 6 (See Fig. 2). This indicator must be rated for
the instrument power applied to J1 -1 & 2. Three diagnostic LEDs show which SCR pair is faulted.
These lights are synchronized with the demand indicator and can only indicate while the demand is
active.
The latching alarm means that if the alarm activates and the system subsequently returns to normal,
the alarm will remain latched until a reset button (external – customer provided) is pressed. A nonlatching alarm resets automatically.
CAUTION
Heat Sink Over-Temperature
An external lamp or relay may be connected to J1 – 3 & 4 (see Figure 2) (this must be rated for the instrument power applied to J1 – 1 & 2). This will provide an indication to the operator that the heat sink has approached an unsafe temperature level of 200˚F (93˚C) The unit will enter a stop mode if the temperature rises
to 212˚F (100˚C).
22
Input Terminals (MaxPac I, II, and III):
FIG 1
FIG 2
FIG 3
TIONAL INPUT
FIG
DRY CONTACT ON/OFF
REMOTE SHUTDOWN
J1
8
7
6
5
4
3
2
120-230 INSTRUMENT POWER
1
120-230 INSTRUMENT POWER
REQUIRED ON ALL CONFIGURATIONS
FIG 4
J2
COMMON
1
2
3
4
5
6
7
8
9
10
MANUAL CONTROL INPUT SIG
MANUAL
0-5 / 1-5 VDC INPUT
J1
8
7
6
5
4
3
2
1
SHORTED SCR AND
HI TEMP INDICATORS.
SHORTED SCR INDICATOR
HI TEMP INDICATOR
These are AC voltage outputs at 100 mA max.,
not contact closures. See model number
for voltage rating
FIG 5
J2
1
2
3
4
JUMPER
5
6
COMMON
7
8
0-5 / 1-5 VDC INPUT
9
10
0-5 / 1-5 VDC PROPORTIONAL INPUT SIG
J3
6
5
4
3
2
1
SHORTED SCR INDICATOR RESET
FIG 6
J2
1
2
3
4
JUMPER
5
4-20mA PROPOR
6
7
COMMON
8
9
10
4-20mA PROPORTIONAL INPUT SIG
7
J2
1
2
3
4
JUMPER
5
6
7
COMMON
8
9
0 +10 VDC PROPORTIONAL INPUT
10
0 +10 VDC PROPORTIONAL INPUT SIG
FIG 10
J3
6
5
4
3
2
1
+
FIG 8
J1
8
L1 – EXTERNAL 120-230
7
L2 – ON/OFF CONTROL
6
5
JUMPER
4
3
2
1
120-240 ON/OFF CONTROL
FIG 11
J3
6
5
COMMON
4
3
2
1
FIG 9
J3
6
5
COMMON
4
3
2
1
EXTERNAL +5-32 VDC ON/OFF
+
23
MaxPac IP
0-5MA
(0-10V)
4-20mA
10-50mA
COM
CLOSE FOR
REMOTE
STOP
N/C
N/C
JUMPER 4 TO 5
WHEN NOT USING
REMOTE POT
UNIT SHIPPED WITH JUMPER INSTALLED
INSTRUMENT
WIRE
L
O
A
D
SCR
FUSE
X1
L2
L1
CT
TB1CON1P
JB1
JUMPER JB1 FOR 0-5mA
OPEN JB1 FOR 0-10V
The Chromalox MaxPac IP is a solid-state proportional power controller that utilizes a Phase Angle firing
technique to modulate power to an inductive or resistive load. Separate adjustable Zero, Gain, Manual Bias,
and Current Limit potentiometers are provided along with screw type plug-in connectors for input signals,
Emergency Stop, and optional Remote Manual Bias with 0 - 100% dial. All units have thermostat protection
with N.C. contacts.
Start-up
The MaxPac IP has been factory calibrated for 4 - 20mA input. Be sure the operating voltage and signal
input are correctly applied. Also, make sure the Emergency Stop, if used, has N.O. contacts and jumper
pins 4 & 5 on the 10-pin connector if remote manual bias are not used. Please read the information on
calibration at the end of this section for current limit settings for loads with extreme hot to cold ratios or
those that are overrated. Other ranges may be field calibrated by use
of zero and gain potentiometers.
CAUTION
IMPORTANT: With the Current Limit option, the current transformer must be termi-
nated properly to prevent it from being damaged.
24
Customer Connection
4.2.6 - Calibration (MaxPac IP):
Many high-temperature heating elements exhibit extreme hot to cold resistance ratios. Heating elements composed of Platinum,
Molybdenum, Tungsten, and Tantalum, to name a few, draw excessive current on start-up. Depending on the mass of the elements,
these “high starting currents” may exist for extended periods of time. Generally, once the elements have achieved their normal operating temperatures, the current drawn through the MaxPac Power Pak will fall within the rating of the unit. For these types of loads, we
recommend adjusting the I LIM (Current Limit) to 50% or less. This will decrease voltage as well as current.
1. Set Current Limit (I LIM) pot to 0% for full current output (CCW).
Current Limit is for limiting current for loads that have
extreme hot to cold resistance ratios or are overrated. We
recommend for these types of loads to adjust I LIM (Current Limit) to 50% or less. This will also decrease voltage as
well as current. 0% Current Limit gives 100% current output
(CCW). 100% Current Limit gives 10% current output (CW).
2. Set Manual (MAN) pot to zero so unit will not be biased above
input (CCW).
Manual control adjustment provides a means of setting the
output level of the MaxPac Power Pak in the absence of
controlling instrumentation. The manual control signal value
“adds” to the controlling instrument to set minimum output.
The desired output power level may be set by adjusting the
manual control. This value of output will then be present even
in the absence of a control signal.
3. Set Remote Manual pot to zero output so unit will not be biased
above input (CCW). (Jumper pins 4 & 5 if not used.)
Remote Manual control adjustment provides a means of
setting the output level of the MaxPac Power Pak in the
absence of controlling instrumentation. The Remote Manual
control is also effective when a control signal is connected.
The Remote Manual control signal value “adds” to the
controlling instrument to set minimum output. The desired
output power level may be set by adjusting the Remote
Manual control. This value of output will then be present even
in the absence of a control signal. Connect Remote Manual
pot wire to Pin 4 (CCW), Pin 5 (W), and Pin 6 (CW) of plug-in
connector.
4. Check for open contact for Emergency Stop.
Emergency Stop inhibits all SCR trigger pulses regardless
of the level of the input signal or manual potentiometer. For
Emergency Stop, close contact Pin 7 to Pin 8 of plug-in connector. Leave contacts open for operation.
5. Check for polarity of input signal.
6. Adjust input signal to low end of scale.
Zero Adjust control sets the power output starting point or
reference. Thus, it effectively cancels positive inputs to the
MaxPac Power Pak.
EXAMPLE: 0 - 5 mA input à set to 0 mA input
4 - 20 mA input à set to 4 mA input
7. With power off, connect line voltage and load as shown.
8. Connect meter to input and output.
WARNING: Set meter to correct scale to read proper
input or output.
9. Apply power to unit.
10. Adjust input signal to low end of scale.
11. Using the Zero pot, adjust the output voltage just to zero volts.
12. Adjust input signal to top end of scale.
Gain Adjust Control sets the maximum power output for
maximum input signal.
EXAMPLE: 0 - 5 mA input: set to 5 mA input
4 - 20 mA input: set to 20 mA input
13. Using the Gain pot, adjust output voltage just to maximum
volts.
14. Repeat steps 11, 12, 13, and 14 until no adjustment is
necessary of Zero and Gain pots for proper output voltage
indication. Voltage output should increase proportionally to the
signal input applied.
15. Adjust input signal to low end of scale (zero voltage output).
16. With Manual pot at zero for zero voltage output, adjust (CW)
to 100% for full voltage output. Voltage output should
increase proportionally. Return to CCW position and output will
decrease to zero output.
17. With Remote Manual at zero for zero voltage output, adjust
(CW) to 100% for full voltage output. Voltage output should
increase proportionally. Return to CCW position and output will
decrease to zero output.
18. With Manual pot (CW) at 100% and I LIM (Current Limit)
at 0%, adjust I LIM towards 100% noting that voltage output
decreases with the adjustment of the Current Limit pot. Adjust
Current Limit pot for your application, if needed.
19. Turn POWER OFF and remove meters. TEST COMPLETE.
25
Controller Configuration
5
26
27
Specifications
6
MaxPac I, II, and III
Control Inputs
Accepts all of the following as standards:
On/Off Control
Signal Input
120 thru 230 VAC ± 10% (4 VA Maximum)
5-32 VDC
Contact Closures
Proportional Control
Signal Input Input Impedance
4 - 20 mA ...................... 50 Ohms
1 - 5 VDC ...................... 10k Ohms or greater
0 - 5 VDC ...................... 9k Ohms or greater
Remote Manual Adjust
Auto/Manual Switch
Instrument Power ...... 120 or 230 VAC
50/60 Hz
Output Voltage ........... 0 - 99% RMS line voltage
(Eo-Vsupply - 1.5V SCR
forward drop)
Resolution (proportional) Better than 0.1%
Line Voltage ...................120 - 575 VAC, 60 Hz
CE 400 VAC 50 Hz
Load Current Rating ......100, 150, 200, 300, 400,
550, 650, 800, 1000, 1200A
Ambient Temperature ....0 - 50°C (32 - 122°F)
SCR Capability
Dielectric .................Withstand capability
Surge Rating 1500V RMS min.
Typically fifteen (15) times
nominal RMS rating for
8.3 milliseconds
Isolation .....................SCRs isolation 2500V
Input-output isolation 1500V
Heat Sink ........................Ground potential up to
650 Amps
High Temperature ..........AC Voltage Output
Indicator Output 100 mA @ Instrument Power
Shorted SCR ..................AC Voltage Output
Indicator Output 100 mA @ Instrument Power
MaxPac IP
Control Inputs
Accepts all of the following as standards:
Phase Angle Control
Signal Input Input Impedance
1 - 5, 0 - 5mA 1K Ohms
4 - 20, 0 - 20mA ........ 250 Ohms
10 - 50, 0 - 50mA ...... 100 Ohms
Optional Remote Manual Adjust
Fan Power .................. 120 or 230 VAC
50/60 Hz
Output Voltage ........... 0 - 99% RMS line voltage
(Eo=Vsupply - 1.5V SCR
forward drop)
Resolution (proportional) Better than 0.1%
Line Voltage ............... 120, 208, 240, 277, 380,
...................................... 480 and 575 VAC
± 10% 50/60 Hz
Load Current Rating .. 100, 150, 200, 300, 400,
550, 650, 800, 1000, 1200A
Ambient Temperature ....0 - 50°C (32 - 122°F)
SCR Capability ...............Withstand capability
1500V RMS min.
Typically fifteen (15) times
nominal RMS rating for
8.3 milliseconds
Surge Rating ..................Typically fifteen (15) times
nominal RMS rating for
8.3 milliseconds
Isolation ..........................SCRs isolation 2500V
Input-output isolation 1500V
Heat Sink ........................Ground potential up to
650 Amps
Thermostat .....................4 Amps @ 120V resistive
2 Amps @ 240V resistive
N.C. Contact Standard
Current Limit ..................10 - 100% of rated
output current
Soft Start ........................25% demand per second
typical reset speed
8.3 milliseconds
28
Maintenance
7
Environmental Issues:
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 it’s 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.
READ AND UNDERSTAND BEFORE
CARRYING OUT THE WORK DETAILED BELOW
WARNING
Hazardous Voltage: Disconnect all power before performing
any maintenance or examining the power module. Exposed
terminals may carry LETHALLY HIGH VOLTAGES when power
is applied.
Cleanliness:
Careful attention must be paid in areas subjected to airborne particles The efficiency of the heatsinks rely on
there conducting surfaces being maintained in clean manner. (See Maintenance Section)
Dampness:
High humidity or hosing down should be avoided.
Connections:
Ensure that all electrical connections are secure and tight. (See Maintenance Section)
Fusing:
The I2t fuses installed on the SCR are designed to protect the SCR’s from faults on the load connection side.
They are NOT intended to provide wire protection.
Maintenance
Connections:
Loose connections in the power wiring will generate hot spots, which will cause degradation of electronic
equipment. Periodically inspections should be made to to ensure that connections are secure and that there
are no signs of excessive heating such as discoloration etc.
Filters:
Many high power control enclosures rely on blowers or fans to maintain a safe operating temperature. The
filters used with these devices should be changed on a periodic basis to insure adequate enclosure cooling
is maintained.
29
Troubleshooting
8
READ AND UNDERSTAND BEFORE
CARRYING OUT THE WORK DETAILED BELOW
The following guidelines cover most of the common problems that could occur with the MaxPac. They are
not intended to be, nor can they be, absolutes to cover every possible failure.
Problem
Note: Heater load must be conntected to Test.
No Power or unbalanced power to the load.
If Demand Light is “Off”
1. Check incoming line power. Verify that fans are running
2. Check the instrument power.
3. Check the fuse on the main board.
4. Verify the input signal.
5. Check that remote stop J3 - 3 to 4 is open.
6. Check that the J2 - 4 to 5 is Jumpered.
7. Verify that heat sink is not in over temperature mode.
If Demand Light is “On”
1. Check the connections to SCR trigger board.
2. Check the power fuses (I2t).
3. Look for damage on the trigger board.
Observation Possible Root Cause
LD3 – SCR1 light is ON and Alarm relay engaged Shorted SCR1
LD4 – SCR2 light is ON and Alarm relay engaged Shorted SCR2
LD5 – SCR3 light is ON and Alarm relay engaged Shorted SCR3
LD3 – SCR1 light is blinking and Alarm relay engaged Missing phase or phase error, SCR1
LD4 – SCR2 light is blinking and Alarm relay engaged Missing phase or phase error, SCR2
LD5 – SCR3 light is blinking and Alarm relay engaged Missing phase or phase error, SCR3
Over temp output conducts, Alarm relay engaged,
and heater output still functions
Over temp output conducts, Excessive temperature
of heat sink and Alarm relay engaged, heater output
still functions
Diagnostics with Safety Cover Removed
Observation Possible Root Cause
Heartbeat LED not blinking Loss of electronics AC power. Check fuse.
Heat Sink Temperature greater than 200˚F (93˚C)
detected but all outputs less than 212˚F (100˚C)
Heat Sink Temperature greater than 200 ˚F (93˚C)
detected but all outputs less than 212˚F (100˚C)
30
Parts and Accessories
9
Instrument Power Fuse
Chromalox Part Number Description
0024-01312 Fuse, 0.125A, 2 AG
500 VAC I
0024-07634 200 Amp I
0024-07630 250 Amp I
0024-07632 400 Amp I
0024-03116 500 Amp I
0024-07633 700 Amp I
0024-03118 800 Amp I
0024-03200 1000 Amp I
600 VAC I2T Fuse
0024-07644 125 Amp I
0024-07645 175 Amp I
0024-07636 250 Amp I
0024-07637 400 Amp I
0024-07638 500 Amp I
0024-07639 700 Amp I
0024-07640 800 Amp I
0024-07646 1000 Amp I
0024-01191 1200 Amp I
Fans
Chromalox Part Number Description
0045-00231 120 VAC rated Fan
0045-00235 230 VAC rated Fan
Crimp Lug Chart
For Open Design 400 - 1200 Amp and all Touch-Safe Models:
SCR Replacement
Be sure to replace thermstrate interface material and torque as follows:
MaxPac I, II, and III
Accessories:
2
T Fuse
Conductor Size Chromalox Part # Panduit Part #
#8 AWG (10mm
#6 AWG or #6 Weld (16mm
#4 AWG or #4 Weld (25mm
#2 AWG (35mm
#1 AWG or #2 Weld (50mm
#1/0 AWG or #1 Weld (70mm
#2/0 AWG or #1/0 Weld (70mm
#3/0 AWG or #2/0 Weld (95mm
2
) 0135 - 10002 LCD8 - 14A - L
2
) 0135 - 10005 LCD2 - 56B - Q
2
) 0135 - 10003 LCD6 - 14A - L
2
) 0135 - 10004 LCD4 - 14A - L
2
) 0135 - 10006 LCD1 - 56C - E
2
) 0135 - 10007 LCD1/0 - 12 - X
2
2
#4/0 AWG or #3/0 Weld (120mm
250 MCM or #4/0 Weld (150mm
300 MCM (150mm
350 MCM (185mm
400 MCM (240mm
500 MCM (240mm
2
) 0135 - 10012 LCD300 - 12 - X
2
) 0135 - 10013 LCD350 - 12 - 6
2
) 0135 - 10014 LCD400 - 12 - 6
2
) 0135 - 10015 LCD500 - 12 - 6
MFG Part # SCR Part # Thermstrate Part # Torque inch/lb Torque inch/lb
to Heat Sink to Terminals
SKKT92 0002 - 47560 0029 - 00700 44 inch/lb (5 Nm) 26 inch/lb (3Nm)
SKKT162 0002 - 47559 0029 - 00822 44 inch/lb (5 Nm) 44 inch/lb (5 Nm)
SKKT250 0002 - 47537 0029 - 00719 44 inch/lb (5 Nm) 80 inch/lb (9 Nm)
SKKT500 0002 - 47557 0029 - 00814 44 inch/lb (5 Nm) 106 inch/lb (12 Nm)
Part Number Description
0135 - 28193 SCR Trigger Board
0135 - 28194 On/Off Main Firing Board
0135 - 20117 Potentiometer & Remote/Manual Switch
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
2
t Fuse
) 0135 - 10008 LCD2/0 - 12 - X
) 0135 - 10009 LCD3/0 - 12 - X
2
) 0135 - 10010 LCD4/0 - 12 - X
2
) 0135 - 10011 LCD250 - 12 - X
MaxPac IP
Accessories:
Part Number Description
0135 - 28002 Firing Circuit 120, 240 VAC
0135 - 28006 Firing Circuit 208, 277, 480 VAC
0135 - 28037 Firing Circuit 380 VAC
31
Warranty and Return Information
10
Warranty Notice
The Warranty below complies with the federal law applicable to products manufactured after December 31,
1976. This warranty gives you specific legal rights and you may also have other rights which vary from state
to state.
Chromalox Warranty
Chromalox instruments and controls are warranted against defects in workmanship and materials. No other
express warranty, written or oral, applies with the exception of a written statement from an officer of Chromalox®, Inc.
Warranty Period
This warranty extends for one year from date of shipment from the factory or authorized distributor.
Limitations
Products must be installed and maintained in accordance with Chromalox instructions. Users are responsible for the suitability of the products to their application. There is no warranty against damage resulting from
corrosion, misapplication, improper specification or other operating conditions beyond our control. Claims
against the carrier company for damage in transit must be filed by the buyer.
Returns
Items returned to Chromalox must be accompanied by a Return Authorization Number. This number may be
obtained from Chromalox’ Customer Service Department at the phone number listed below.
The Return Authorization Number must appear on the exterior of the shipping carton and on the shipping
documents.
Defective items will be repaired or replaced at our option and at no charge.
Return the defective part or product, freight prepaid, to the following address:
Chromalox, Inc.
1347 Heil Quaker Blvd.
LaVergne, TN 37086-3536
Phone: (615) 793-3900
Fax: (615) 793-3563
32
Ordering Information for MaxPac I
Model SCR Power Pack
MXPC I Single Phase SCR Power Pack
Code Control Configuration
5 Proportional Control, DOT Zero-Crossover Firing, Command Input Signals: 4-20mA, 0-5
VDC, 1-5 VDC (via Modbus RTU/485 only), 0-10 VDC, Remote 0-1000 OHM Potentiometer
w/Manual Override, Modbus RTU/RS485 Communications. RTD Heat Sink Temperature
Sensor with Two Set-Points, Automatic Line Sensing 50/60HZ, Remote Permissive Stop
Input, Form “C” Dry Contact Alarm Output, Staged Heating w/Digital Calibration Zero /
Span Adjustments(4-8 mA, 8-12 mA,12-16 mA,16-20 mA (via Modbus RTU/RS485 only),
LED Diagnostics: Command Input, Main/Trigger Boards Running, SCR Status per Phase,
Diagnostic Kit via Modbus RTU/RS485: Highest Heat Sink Temperature, Last Heat Sink
Temperature, Highest and Lowest Ambient Temperature, Line Frequency Monitoring, Third
Party Certifications: UL, cUL, CE, DEMKO (650 A and below).
Code Current at 50°C (122°F)
01 100 Amp Open Design
02 100 Amp Touch Safe Design
03 150 Amp Open Design
04 150 Amp Touch Safe Design
05 200 Amp Open Design
06 200 Amp Touch Safe Design
07 300 Amp Open Design
08 300 Amp Touch Safe Design
09 400 Amp Open Design
10 400 Amp Touch Safe Design
11 550 Amp Open Design
12 550 Amp Touch Safe Design
13 650 Amp Open Design
14 650 Amp Touch Safe Design
15 800 Amp Open Design
16 1000 Amp Open Design
17 1200 Amp Open Design
Code Line Voltage
1 120 VAC - 480 VAC
2 575/600 VAC
Code Instrument Power
1 120 VAC 50/60 Hz
2 230 VAC 50/60 Hz
Code Compression Lug Kits (Open Design up to 300 Amps)
For Other Ranges See Crimp Lug Chart
L0 None
L1 100 - 150 Amp PAK 1(#2 - 4/0)/connection
L2 200 - 300 Amp PAK 1(1/0 - 500mcm)/connection
MXPC I - 5 03 1 1 L1 (Continued on next page)
33
Ordering Information for MaxPac I (continued)
Code Fusing Option (1)
For < 500VAC Applications, Select One
F00 None
F01 100 -150 Amp PAK (200 Amp Fuse)
F02 200 Amp PAK (250 Amp Fuse)
F03 300 Amp PAK (400 Amp Fuse)
F04 400 Amp PAK (500 Amp Fuse)
F05 550 Amp PAK (700 Amp Fuse)
F06 650 Amp PAK (800 Amp Fuse)
F07 800 Amp PAK (1000 Amp Fuse)
F08 1000 Amp PAK (1200 Amp Fuses)
F09 1200 Amp PAK (Two 1000 Amp Fuses)
F10 100 Amp PAK (125 Amp Fuse)
F11 150 Amp PAK (175 Amp Fuse)
F12 200 Amp PAK (250 Amp Fuse)
F13 300 Amp PAK (400 Amp Fuse)
F14 400 Amp PAK (500 Amp Fuse)
F15 550 Amp PAK (700 Amp Fuse) W
F16 650 Amp PAK (800 Amp Fuse)
F17 800 Amp PAK (1000 Amp Fuse)
F18 1000 Amp PAK (1200 Amp Fuse)
F19 1200 Amp PAK (Two 1000 Amp Fuses)
Code Remote Man. Adjust/Auto Man. Switch
0 None
1 Pot with 0 - 100% dial and Local/Re-
700 V Fuses for 575/600 V Applications, Select One
mote Single Turn 1K Potentiometer (Proportional Control Only) (Supplied loose
for customer mounting)
MXPC I - 5 03 1 1 L1 F01 1 Typical Model Number
Crimp Lug Chart
1) SCR Fusing is for semiconductor
protection only, not wire protection.
2) Supplied Loose for Customer
Mounting.
Note:
Storage Temperature 14ºF to 158ºF
(-10ºC to 70ºC).
CE application requires filters.
Chromalox # Panduit # Conductor Size
0135-10002 LCD8-14A-L #8 AWG 180 20
0135-10003 LCD6-14A-L #6 AWG or #6 Weld 180 20
0135-10004 LCD4-14A-L #4 AWG or #4 Weld 180 20
0135-10005 LCD2-56B-Q #2 AWG 180 20
0135-10006 LCD1-56C-E #1 AWG or #2 Weld 180 20
0135-10007 LCD1/0-12-X #1/0 AWG or #1 Weld 480 54
0135-10008 LCD2/0-12-X #2/0 AWG or #1/0 Weld 480 54
0135-10009 LCD3/0-12-X #3/0 AWG or #2/0 Weld 480 54
0135-10010 LCD4/0-12-X #4/0 AWG or #3/0 Weld 480 54
0135-10011 LCD250-12-X 250 MCM or #4/0 Weld 480 54
0135-10012 LCD300-12-X 300 MCM 480 54
0135-10013 LCD350-12-6 350 MCM 480 54
0135-10014 LCD400-12-6 400 MCM 480 54
0135-10015 LCD500-12-6 500 MCM 480 54
Note: NEMA standard two hole copper crimp lugs only.
Torque
In-Lb. Nm
34
Ordering Information for MaxPac IP
Model SCR Power Pack
MXPC IP Single Phase SCR Power Pack
Code Control Configuration
1 Phase Angle Control (Accepts: 0-5 mA, 0-20 mA, 0-50 mA, 1-5mA, 4-20 mA, 10-50 mA,
0-5Vdc, 0-10 VDC)
2 Phase Angle Control with Current Limit
Code Current at 50°C (122°F)
01 100 Amp Open Design
02 100 Amp Touch Safe Design
03 150 Amp Open Design
04 150 Amp Touch Safe Design
05 200 Amp Open Design
06 200 Amp Touch Safe Design
07 300 Amp Open Design
08 300 Amp Touch Safe Design
09 400 Amp Open Design
10 400 Amp Touch Safe Design
11 550 Amp Open Design
12 550 Amp Touch Safe Design
13 650 Amp Open Design
14 650 Amp Touch Safe Design
15 800 Amp Open Design
16 1000 Amp Open Design
17 1200 Amp Open Design
Code Voltage
1 120 VAC
2 208 VAC
3 240 VAC
4 277 VAC
5 480 VAC
6 575 VAC
Code Fan Power
1 120 VAC 50/60 Hz
2 230 VAC 50/60 Hz
Code Compression Lug Kits (Open Design up to 300 Amps)
For Other Ranges See Crimp Lug Chart
L0 None (Select for all Touch Safe Designs and for over 30
Amp Open Design)
L1 100 - 150 Amp PAK 1(#2 - 4/0)/connection
L2 200 - 300 Amp PAK 1(1/0 - 500mcm)/connection
MXPC IP - 2 03 1 1 L1 (Continued on next page)
35
Ordering Information for MaxPac IP (continued)
Code Fusing Option (1)
For < 500VAC Applications, Select One
F00 None
F01 100 -150 Amp PAK (200 Amp Fuse)
F02 200 Amp PAK (250 Amp Fuse)
F03 300 Amp PAK (400 Amp Fuse)
F04 400 Amp PAK (500 Amp Fuse)
F05 550 Amp PAK (700 Amp Fuse)
F06 650 Amp PAK (800 Amp Fuse)
F07 800 Amp PAK (1000 Amp Fuse)
F08 1000 Amp PAK (1200 Amp Fuses)
F09 1200 Amp PAK (Two 1000 Amp Fuses)
700 V Fuses for 575 V Applications, Select One
F10 100 Amp PAK (125 Amp Fuse)
F11 150 Amp PAK (175 Amp Fuse)
F12 200 Amp PAK (250 Amp Fuse)
F13 300 Amp PAK (400 Amp Fuse)
F14 400 Amp PAK (500 Amp Fuse)
F15 550 Amp PAK (700 Amp Fuse)
F16 650 Amp PAK (800 Amp Fuse)
F17 800 Amp PAK (1000 Amp Fuse)
F18 1000 Amp PAK (1200 Amp Fuse)
F19 1200 Amp PAK (Two 1000 Amp Fuses)
Code Remote Man. Adjust/Auto Man. Switch
0 None
1 Pot with 0 - 100% dial and Local/Remote
Switch(2) Single Turn 1KW Potentiomete
MXPC IP - 2 03 1 1 L1 F01 1 Typical Model Number
Crimp Lug Chart
1) SCR Fusing is for semiconductor
protection only, not wire protection.
2) Supplied Loose for Customer
Mounting.
Note:
Storage Temperature 14ºF to 158ºF
(-10ºC to 70ºC).
CE application requires filters.
Chromalox # Panduit # Conductor Size
0135-10002 LCD8-14A-L #8 AWG 180 20
0135-10003 LCD6-14A-L #6 AWG or #6 Weld 180 20
0135-10004 LCD4-14A-L #4 AWG or #4 Weld 180 20
0135-10005 LCD2-56B-Q #2 AWG 180 20
0135-10006 LCD1-56C-E #1 AWG or #2 Weld 180 20
0135-10007 LCD1/0-12-X #1/0 AWG or #1 Weld 480 54
0135-10008 LCD2/0-12-X #2/0 AWG or #1/0 Weld 480 54
0135-10009 LCD3/0-12-X #3/0 AWG or #2/0 Weld 480 54
0135-10010 LCD4/0-12-X #4/0 AWG or #3/0 Weld 480 54
0135-10011 LCD250-12-X 250 MCM or #4/0 Weld 480 54
0135-10012 LCD300-12-X 300 MCM 480 54
0135-10013 LCD350-12-6 350 MCM 480 54
0135-10014 LCD400-12-6 400 MCM 480 54
0135-10015 LCD500-12-6 500 MCM 480 54
Note: NEMA standard two hole copper crimp lugs only.
Torque
In-Lb. Nm
36
Ordering Information for MaxPac II
Model SCR Power Pack
MXPC II Three Phase SCR Power Pack
Code Control Configuration
5 Proportional Control, DOT Zero-Crossover Firing, Command Input Signals: 4-20 mA, 0-5
VDC, 1-5 VDC (via Modbus RTU/485 only), 0-10 VDC, Remote 0-1000 OHM Potentiometer
w/Manual Override, Modbus RTU/RS485 Communications. RTD Heat Sink Temperature
Sensor with Two Set-Points, Automatic Line Sensing 50/60HZ, Remote Permissive Stop
Input, Form “C” Dry Contact Alarm Output, Staged Heating w/Digital Calibration Zero /
Span Adjustments(4-8 mA, 8-12 mA,12-16 mA,16-20 mA(via Modbus RTU/RS485 only),
LED Diagnostics: Command Input, Main/Trigger Boards Running, SCR Status per Phase,
Diagnostic Kit via Modbus RTU/RS485: Highest Heat Sink Temperature, Last Heat Sink
Temperature, Highest and Lowest Ambient Temperature, Line Frequency Monitoring, Third
Party Certifications: UL, cUL, CE, DEMKO (650A and below).
Code Current at 50°C (122°F)
01 100 Amp Open Design
02 100 Amp Touch Safe Design
03 150 Amp Open Design
04 150 Amp Touch Safe Design
05 200 Amp Open Design
06 200 Amp Touch Safe Design
07 300 Amp Open Design
08 300 Amp Touch Safe Design
09 400 Amp Open Design
10 400 Amp Touch Safe Design
11 550 Amp Open Design
12 550 Amp Touch Safe Design
13 650 Amp Open Design
14 650 Amp Touch Safe Design
15 800 Amp Open Design
16 1000 Amp Open Design
17 1200 Amp Open Design
Code Line Voltage
1 120 VAC - 480VAC
2 575/600 VAC
Code Instrument Power
1 120 VAC 50/60 Hz
2 230 VAC 50/60 Hz
Code Compression Lug Kits (Open Design up to 300 Amps)
For Other Ranges See Crimp Lug Chart
L0 None
L1 100 - 150 Amp PAK 1(#2 - 4/0)/connection
L2 200 - 300 Amp PAK 1(1/0 - 500mcm)/connection
MXPC II - 5 03 1 1 L1 (Continued on next page)
37
Ordering Information for MaxPac II (continued)
Code Fusing Option (1)
For < 500VAC Applications, Select One
F00 None
F01 100 -150 Amp PAK (200 Amp Fuse)
F02 200 Amp PAK (250 Amp Fuse)
F03 300 Amp PAK (400 Amp Fuse)
F04 400 Amp PAK (500 Amp Fuse)
F05 550 Amp PAK (700 Amp Fuse)
F06 650 Amp PAK (800 Amp Fuse)
F07 800 Amp PAK (1000 Amp Fuse)
F08 1000 Amp PAK (1200 Amp Fuses)
F09 1200 Amp PAK (Two 1000 Amp Fuses)
700 V Fuses for 575 V Applications, Select One
F10 100 Amp PAK (125 Amp Fuse)
F11 150 Amp PAK (175 Amp Fuse)
F12 200 Amp PAK (250 Amp Fuse)
F13 300 Amp PAK (400 Amp Fuse)
F14 400 Amp PAK (500 Amp Fuse)
F15 550 Amp PAK (700 Amp Fuse)
F16 650 Amp PAK (800 Amp Fuse)
F17 800 Amp PAK (1000 Amp Fuse)
F18 1000 Amp PAK (1200 Amp Fuse)
F19 1200 Amp PAK (Two 1000 Amp Fuses)
Code Remote Man. Adjust/Auto Man. Switch
0 None
1 Pot with 0 - 100% dial and Local/Remote
Single Turn 1KW Potentiometer
(Proportional Control Only)
(Supplied loose for customer mounting)
MXPC II - 5 03 1 1 L1 F01 1 Typical Model Number
Crimp Lug Chart
1) SCR Fusing is for semiconductor
protection only, not wire protection.
2) Supplied Loose for Customer
Mounting.
Note:
Storage Temperature 14ºF to 158ºF
(-10ºC to 70ºC).
Chromalox # Panduit # Conductor Size
0135-10002 LCD8-14A-L #8 AWG 180 20
0135-10003 LCD6-14A-L #6 AWG or #6 Weld 180 20
0135-10004 LCD4-14A-L #4 AWG or #4 Weld 180 20
0135-10005 LCD2-56B-Q #2 AWG 180 20
0135-10006 LCD1-56C-E #1 AWG or #2 Weld 180 20
0135-10007 LCD1/0-12-X #1/0 AWG or #1 Weld 480 54
0135-10008 LCD2/0-12-X #2/0 AWG or #1/0 Weld 480 54
0135-10009 LCD3/0-12-X #3/0 AWG or #2/0 Weld 480 54
0135-10010 LCD4/0-12-X #4/0 AWG or #3/0 Weld 480 54
0135-10011 LCD250-12-X 250 MCM or #4/0 Weld 480 54
0135-10012 LCD300-12-X 300 MCM 480 54
0135-10013 LCD350-12-6 350 MCM 480 54
0135-10014 LCD400-12-6 400 MCM 480 54
0135-10015 LCD500-12-6 500 MCM 480 54
Note: NEMA standard two hole copper crimp lugs only.
Torque
In-Lb. Nm
38
Ordering Information for MaxPac III
Model SCR Power Pack
MXPC III Three Phase Six SCR Power Pack
Code Control Configuration
5 Proportional Control, DOT Zero-Crossover Firing, Command Input Signals: 4-20 mA, 0-5
VDC, 1-5 VDC (via Modbus RTU/485 only), 0-10 VDC, Remote 0-1000 OHM Potentiometer
w/Manual Override, Modbus RTU/RS485 Communications. RTD Heat Sink Temperature
Sensor with Two Set-Points, Automatic Line Sensing 50/60HZ, Remote Permissive Stop
Input, Form “C” Dry Contact Alarm Output, Staged Heating w/Digital Calibration Zero /
Span Adjustments(4-8 mA, 8-12 mA,12-16 mA,16-20 mA(via Modbus RTU/RS485 only),
LED Diagnostics: Command Input, Main/Trigger Boards Running, SCR Status per Phase,
Diagnostic Kit via Modbus RTU/RS485: Highest Heat Sink Temperature, Last Heat Sink
Temperature, Highest and Lowest Ambient Temperature, Line Frequency Monitoring, Third
Party Certifications: UL, cUL, CE, DEMKO (650A and below).
Code Current at 50°C (122°F)
01 100 Amp Open Design
02 100 Amp Touch Safe Design
03 150 Amp Open Design
04 150 Amp Touch Safe Design
05 200 Amp Open Design
06 200 Amp Touch Safe Design
07 300 Amp Open Design
08 300 Amp Touch Safe Design
09 400 Amp Open Design
10 400 Amp Touch Safe Design
11 550 Amp Open Design
12 550 Amp Touch Safe Design
13 650 Amp Open Design
14 650 Amp Touch Safe Design
15 800 Amp Open Design
16 1000 Amp Open Design
17 1200 Amp Open Design
Code Line Voltage
1 120 VAC - 480VAC
2 575/600 VAC
Code Instrument Power
1 120 VAC 50/60 Hz
2 230 VAC 50/60 Hz
Code Compression Lug Kits (Open Design up to 300 Amps)
For Other Ranges See Crimp Lug Chart
L0 None
L1 100 - 150 Amp PAK 1(#2 - 4/0)/connection
L2 200 - 300 Amp PAK 1(1/0 - 500mcm)/connection
Note: 550-1200 Amp and all Touch-Safe Designs: Buss
MXPC III - 5 04 1 1 L1 (Continued on next page)
39
Ordering Information for MaxPac III (continued)
Code Fusing Option (1)
For < 500VAC Applications, Select One
F00 None
F01 100 -150 Amp PAK (200 Amp Fuse)
F02 200 Amp PAK (250 Amp Fuse)
F03 300 Amp PAK (400 Amp Fuse)
F04 400 Amp PAK (500 Amp Fuse)
F05 550 Amp PAK (700 Amp Fuse)
F06 650 Amp PAK (800 Amp Fuse)
F07 800 Amp PAK (1000 Amp Fuse)
F08 1000 Amp PAK (1200 Amp Fuses)
F09 1200 Amp PAK (Two 1000 Amp Fuses)
700 V Fuses for 575 V Applications, Select One
F10 100 Amp PAK (125 Amp Fuse)
F11 150 Amp PAK (175 Amp Fuse)
F12 200 Amp PAK (250 Amp Fuse)
F13 300 Amp PAK (400 Amp Fuse)
F14 400 Amp PAK (500 Amp Fuse)
F15 550 Amp PAK (700 Amp Fuse)
F16 650 Amp PAK (800 Amp Fuse)
F17 800 Amp PAK (1000 Amp Fuse)
F18 1000 Amp PAK (1200 Amp Fuse)
F19 1200 Amp PAK (Two 1000 Amp Fuses)
Code Remote Manual Adjust
0 None
1 Pot with 0 - 100% dial and Local/Remote
Single Turn 1KW Potentiometer
(Proportional Control Only)
(Supplied loose for customer mounting)
MXPC III - 5 04 1 1 L1 F02 1 Typical Model Number
Crimp Lug Chart
1) SCR Fusing is for semiconductor
protection only, not wire protection.
2) Supplied Loose for Customer
Mounting.
Note:
Storage Temperature 14ºF to 158ºF
(-10ºC to 70ºC).
Chromalox # Panduit # Conductor Size
0135-10002 LCD8-14A-L #8 AWG 180 20
0135-10003 LCD6-14A-L #6 AWG or #6 Weld 180 20
0135-10004 LCD4-14A-L #4 AWG or #4 Weld 180 20
0135-10005 LCD2-56B-Q #2 AWG 180 20
0135-10006 LCD1-56C-E #1 AWG or #2 Weld 180 20
0135-10007 LCD1/0-12-X #1/0 AWG or #1 Weld 480 54
0135-10008 LCD2/0-12-X #2/0 AWG or #1/0 Weld 480 54
0135-10009 LCD3/0-12-X #3/0 AWG or #2/0 Weld 480 54
0135-10010 LCD4/0-12-X #4/0 AWG or #3/0 Weld 480 54
0135-10011 LCD250-12-X 250 MCM or #4/0 Weld 480 54
0135-10012 LCD300-12-X 300 MCM 480 54
0135-10013 LCD350-12-6 350 MCM 480 54
0135-10014 LCD400-12-6 400 MCM 480 54
0135-10015 LCD500-12-6 500 MCM 480 54
Note: NEMA standard two hole copper crimp lugs only.
Torque
In-Lb. Nm
40
EC Declaration of Conformity
We, Chromalox Precision Heat and Control
1347 Heil Quaker Boulevard
LaVergne, Tennessee 37086-3536
Phone: +1 (615) 793-7561
Fax: +1 (615) 213-8091
declare under sole responsibility that the following described product in our delivered version complies with
the appropriate basic safety and health requirements of the EC Low Voltage Directive (2006/95/EC) and EC
Electromagnetic Compatibility Directive (2004/108/EC) based on its design and type, as brought into circulation by us. In case of alteration of the machine, not agreed upon by us, this declaration will lose its validity.
Description of the Electrical Equipment: MaxPac SCR controllers
Model Number: MaxPac Series; MaxPac I, II, III
Applicable Harmonized Standards:
Low Voltage Directive EMC Directive
Specification: EN60947-4-3:2000 1. Radiated Disturbance Emissions – 30 to 1000
Low-voltage switch gear and MHz Electric Field
control gear EN 61000-6-4:2001 / EN 55011:2007
Part 4-3: Contactors and 2. Conducted Disturbance Emissions – Voltage
motor-starters EN 61000-6-4:2001 / EN 55011:2007
AC semiconductor controllers
and contactors for non-motor loads 3. Conducted Disturbance Immunity
Utilization AC-51 Non-inductive or slightly EN 61000-6-2:2005 / EN 61000-4-6:1996
Category: inductive loads, resistive
furnaces 4. Radiated Disturbance Immunity
EN 61000-6-2:2005 / EN 61000-4-3:1995
Pollution Normally only non-conductive
Degree 2 pollution occurs. Occasionally, 5. Electrical Fast Transients/Bursts Immunity
a temporary conductivity EN 61000-6-2:2005 / EN 61000-4-2:1995
caused by condensation may
be expected. 6. Voltage Dips and Interrupts Immunity
EN 61000-6-2:2005 / EN 61000-4-11:1994
Voltage Rating: 400 VAC 50 Hz Line
230 VAC 50 Hz Instrument max 7. Electrostatic Discharge Immunity
75 watts EN 61000-6-2:2005 / EN 61000-4-2:1995
Impulse Rating: 2.5 KV for 5 seconds 8. Voltage Fluctuations/Flicker
EN 61000-3-3 / A2:2005
Overload 140% for 1 second
Current Profile: 9. Harmonic Current Emissions
EN 61000-3-2:2006
Fuses: 500 Volt, 200KA RMS
symmetrical interrupting rating,
I2t fusing provided with all CE
units.
41
Filters Required: Instrument power filter: 10. Surge Immunity
Chromalox P/N 0005-60057 EN 61000-6-2:2005 / EN 61000-4-5:1995
Line Filter, single phase:
Chromalox P/N 0005-60055
Line Filter, three phase:
Chromalox P/N 0005-60056
The Technical documentation required by Annex IV (3) of the Low Voltage Directive is maintained by (Name)
of (company and location in the European Union)
Year in which CE Marking was affixed: 2002
Authorized Signature/Date: ________________________________________ __________________________
Jim Birnie Date
Engineering Manager
Title of Signatory: ________________________________
Chromalox, International
Unit 1.22, Lombard House
2 Purley Way
Croydon CRO 3JP
Surrey
U.K.
42
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