Chromalox CS3 Installation Instructions Manual

Solid State Relay PK522-2 0037-75550 August 2015 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

equipment; DEATH ON CONTACT may result if personnel fail to observe safety precautions. Learn the areas containing high-voltage con- nections when installing or operating this equipment. Be careful not to contact high-voltage connec- tions when installing or operating this equip- ment. Before working inside the equipment, turn power off and ground all points of high poten- tial before touching them. ELECTRIC SHOCK HAZARD: Any installation in- volving control equipment must be performed by a qualified person and must be effective- ly grounded in accordance with the National Electrical Code to eliminate shock hazard. Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

General The CS3 Series of solid state relays are an ideal, low cost power control solution for switching resistive 3-phase loads found applications in such as furnaces, ovens, heat treating, injection molding, thermoforming, press platens, commercial food equipment, semicon- ductor, lighting and drying, just to name a few. The CS3 Series power controllers feature: • Rugged, industrial design & touch-safe exterior • Conservative, continuous service ratings at 40˚C • Up to 3 x 55 Amps and up to 600 VAC • AC and DC Voltage command signals • Zero cross firing • Easy terminal access via removable covers • Integrated heat sink and fan • SCR thermal protection with LED indication • Optional over temperature alarm • Optional load / line interrupt alarm • USA & Canadian UL component recognition • CE conformity The owner/installer must provide all necessary safety and protection devices and follow all current electrical wiring standards and regula- tions. Failure to do so may compromise the in- tegrity 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 de- signed to cool the unit during operation. Un- der 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 tempera- tures and even fire. During continuous operation, the heat sink can reach very high temperatures, and keeps a high temperature even after the unit is turned off due to its high thermal inertia. Higher voltages may be present. DO NOT work on the power section without first cutting out electrical power to the panel. Failure to do so may cause serious injury or death. To ensure proper performance, maximum safety and reliability, it is essential to install the unit correctly. This includes proper mounting, spacing, hardware and wir- ing. See below: 1. Maximum surrounding air temperature is 40°C in “Open Type Equipment” which is suitable for use in pollution degree 2. 2. Install the unit vertically (max 10° inclination from vertical axis). 3. Spacing: - Minimum vertical distance between unit and panel wall: 3.94” (100 mm) - Minimum horizontal distance between unit and panel wall: .79” (20 mm) - Minimum vertical distance between adjacent power control units: 11.81” (300 mm) - Minimum horizontal distance between adjacent power control units: .79” (20 mm) Installation and Operation Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

T1 T2 T3 A2- Alarm B1 B2 A1 A2 2/T1 4/T2 6/T3 1/L1 3/L2 5/L3 AC51: 40A 600V ac AC53a: 8A 50/60Hz CS3-04060-112 On L1 L2 L3 A1+ T1 T2 T3 A2- Alarm B1 B2 A1 A2 2/T1 4/T2 6/T3 5” (127) 5” (127) 8 1.18” (30) 3.94 (100) 1.97” (50) Max 3.15” (80) 8 CS3 25A CS3 40A / CS3 55A Depth: - Models CS3-xxxxx-1xx: 5.9” (150) - Models CS3-xxxxx-2xx: 6.2” (158) 2.4lb (1100 g) 3.0 lb (1350 g) 1.18” (30) 1/L1 3/L2 5/L3 AC51: 40A AC53a: 8A CS3-04060-111 On 1 3 5 A1+ 2 4 6 A2- Alarm B1 B2 A1 A2 2/T1 4/T2 6/T3 5-32 Vdc 600 VAC 50/60 Hz fan: 230 VAC 1/L1 3/L2 5/L3 AC51: 40A AC53a: 8A CS3-04060-221 On 1 3 5 A1+ 2 4 6 A2- Alarm B1 B2 A1 A2 2/T1 4/T2 6/T3 20-260 VAC/VDC 600 VAC 50/60 Hz fan: 230 VAC nc nc Out AI CS3 with VDV Control Signal Input CS3 with VAC Control Signal Input Label Connection / Indication L1, L2, L3 Line 1, Line 2, Line 3 VAC Input T1, T2, T3 Load 1, Load 2, Load 3 VAC Output A1 (+) VDV Control Signal Input A2 (-) VDV Control Signal Input B1 Alarm Output (option) B2 Alarm Output (option) ON Red LED - Command Signal Indication Alarm Yellow LED - Over Temp. Indication GND Earth Ground (Not shown, varies by model) Label Connection / Indication L1, L2, L3 Line 1, Line 2, Line 3 VAC Input T1, T2, T3 Load 1, Load 2, Load 3 VAC Output A1, A2 AC Control Signal Input B1 Alarm Output (option) B2 Alarm Output (option) ON Red LED - Command Signal Indication Alarm Yellow LED - Over Temp. Indication OUT-AL Red LED - Load/Line Interrupt Alarm (Alarm Code 2 Only) GND Earth Ground (Not shown, varies by model) Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Temperature / Process Controller LOAD LOAD Optional Over Temperature Alarm Output Feature R R R R R R F1 F2 F3 20 - 260 VAC/DC Control Signal Output R R R Phase L1 Phase L2 Phase L3 Neutral Ground Load Temperature / Process Controller LOAD LOAD Optional Over Temperature Alarm Output Feature 1/L1 3/L2 5/L3 AC51: 40A AC53a: 8A CS3-04060-221 On 1 3 5 A1+ 2 4 6 A2- B1 B2 A1 A2 2/T1 4/T2 6/T3 20-260 VAC/VDC 600 VAC 50/60 Hz fan: 230 VAC nc nc Out AI Wiring CS3 with VDC Control Signal Input Wiring CS3 with VAC/VDC Control Signal Input (Code 2) Wiring Diagrams Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

Switching Mode: .........................................Zero Cross Input/Output Isolation Voltage: ............4,000 VAC RMS Operational Voltage Range • 480VAC models: ................................. 24 - 530 VAC • 600VAC models: ................................. 24 - 660 VAC Nominal Frequency: .....................................50 - 60 Hz Non-repetitive peak voltage • 480VAC models: ......................................... 1200 Vp • 600VAC models: ......................................... 1200 Vp Zero Voltage Turn-on: .......................................... ≤ 20V Activation time: ............................................= 1/2 cycle Deactivation time: ........................................= 1/2 cycle Potential drop at rated current: ................ = < 1.4 Vrms Power factor ............................................................ = 1 IP20 Protection Inputs VDV Input (Type “1”) Control voltage: ...........................................5 - 32 VDC Maximum input: ......< 18 mA @5 VDV to 22 mA @ 32 V Maximum reverse voltage: ............................... 36 VDC Activation voltage: ........................................ > 4.5 VDC Deactivation voltage: ....................................... < 3 VDC VAC Input (Type “2”) Control voltage: .................................20 - 260 VAC/DC Activation voltage: ................................... > 15 VAC/DC Deactivation voltage: ................................. < 6 VAC/DC Current draw: ...................≤ 8 mAac/dc @ 260 VAC/DC Specifications Outputs Specification CS3-025 CS3-040 CS3-055 Rated Current (@ 40˚C continuous service) AC51 AC53 AC51 AC53 AC51 AC53 3 X 25A 3 X 5A 3 X 40A 3 X 8A 3 X 55A 3 X 15A Maximum Surge Current (t=20 ms) 400 A 600 A 1,150 A Maximum I2t for fusing (blowout) 645 A2s 1,010 A2s 6,600 A2s Critical dV/dt Off-state (minimum) 1,000 V/μs Off-state Leakage Current (@ Rated Voltage) < 3 mA Integrated Thermal Protection The SSR temperature is constantly monitored. If the maximum temperature limit (230°F/110°C) is exceed- ed, current to the load is interrupted and the YELLOW over-temperature condition LED illuminates. Alarm Output Option The Alarm Output is a Solid State Switch (isolated contact) which controls a connected device during an alarm event, such as a horn or light. • Requires external 24 VAC/DC power supply • Ratings: Imax = 150 mA Vmax = 32 VAC/DC Z close < 15 � (impedance) For Models with 24 VDV Input Control Signal The alarm output function closes the isolated solid state output switch when it detects the following fault condition: The control signal is active, but: • The internal temperature limit of the SSR has been exceeded (Alarm Option Code 1) For Models with 20 - 260 VAC/DC Input Control Signal The alarm output function closes the isolated solid state output switch when it detects any of the following fault conditions: The control signal is active, but: • The internal temperature limit of the SSR has been exceeded (Alarm Option Code 1) • There is no current on the load (zero current or inter- rupted load) (Alarm Option Code 2) • There is no line voltage power supply (Alarm Option Code 2) Environment Conditions Operating Temperature Range: ............... -20˚C to 80˚C Max. Relative Humidity: ............................50% @ 40˚C Max. Installation Altitude: .........2000m above sea level Pollution Level: ............................................................2 Storage Temperature: ............................-20˚C to +85˚C Junction Temperature: ......................................... 125˚C This device conforms to ECC 2004/108/CE and 2006/95/CE and subsequent modifications includ- ing with reference to product standard EN 60947-4-3 (Low-voltage switchgear and control gear – AC contac- tors and semiconductor motor starters). The product is designed for type A environments. Use of the product in type B environments may cause un- desired electromagnetic noise. In this case, the user should take appropriate steps for improvement. Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

(These curves reflect units tested complete with approved heat sinks and fans, if applicable) 25 40 55 0 20 40 60 0 40 80 Current (Amps) Ambient Temperature ˚C CS3-025, CS3-040, CS3-055 Model 3-Phase, 3- Leg Solid State Relay Power Controller - DIN Rail Mount CS3 The CS3 Series are DIN Rail mounted 3-phase, 3-leg solid state relays with integrated heatsink for switching resis- tive loads in industrial applications. Standard features: Zero-voltage turn-on, LED input status indicator, IP20 touch protection, two different input control signal choices, integrated SCR thermal protection with LED signal indication, operating voltage up to 600 VAC. Optional features: Alarms for over temperature protection and load/line interrup- tion* conditions. Approvals: CE, UL, cUL Code Current @ 104˚F (40˚C) Ambient, continuous service 025 25 Amps 040 40 Amps 055 55 Amps Code Voltage 48 480 VAC 60 600 VAC Code Input Control Signal 1 5 - 32 VDV 2 20 - 260 VAC/DC Code Alarm Options 0 None 1 Termal Protection 2* Interrupted Load or Line & Thermal Protection Code Fan (for 40A & 55A Versions Only) 0 No Fan (25 Amp Only) 1 **Fan (230 VAC Power Supply Requirement) 2 **Fan (120 VAC Power Supply Requirement) CS3 - 040 48- 1 1 2 Typical Model Number Notes: * Available ONLY for input control signal code 2 ** Fan requires customer supplied voltage. The following Chromalox Temperature Controllers offer a suitable 24 VDV power supply for the alarm option: 40 Series: 6040 / 8040 / 4040 50 Series: 6050 / 4050 60 Series: 6060 80 Series: 4080 / 4081 / 4082 Ordering Information External 24 V Power Supply is Required to Power the Alarms Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com

http://www.chromalox.com/customer-service/policies/termsofsale.aspx. Chromalox, Inc. 1347 Heil Quaker Boulevard Lavergne, TN 37086 (615) 793-3900 www.chromalox.com © 2014 Chromalox, Inc. Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com