Chromalox MiniMax 1 Installation guide

Chromalox
Brand
Chromalox
Model
MiniMax 1
Type
Installation guide

This manual is also suitable for

PK481-4
User’s Manual
P/N 0037-75433
www.chromalox.com
800-443-2640
© 2014 Chromalox, Inc.
MiniMax
PK481-4
User’s Manual
P/N 0037-75433
www.chromalox.com
800-443-2640
© 2014 Chromalox, Inc.
MiniMax
- 1 -
© 2014 Chromalox
®
, Inc.
1-888-996-9258
Thank you for choosing the Chromalox
®
MiniMax™ - a complete power control solution with industry-best
price and performance.
For more than 80 years, customers have relied on Chromalox for the utmost in quality and innovative solu-
tions for industrial heating applications. Chromalox manufactures the world’s largest and broadest line of
electric heat and control products.
The MiniMax Series SCR Controllers provide the best control for applications where consistent heater/pro-
cess temperature is critical or where fine resolution of power is required.
Common MiniMax features include:
• 120-575Vac@30-75Amps
• IsolatedControlCircuit
• EasyCustomerInterface
• RemoteShutdown
• CompactSizeandConstruction
• dv/dtTransientVoltageProtection
• MOVProtection
Features for the MiniMax 1, 2, and 3 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,0-5Vdc,1-5Vdc,0-10Vdc
 RemoteManualAdjust(Optional)
RemoteAuto/ManualSwitch(Optional)
• ElectronicallyProtectedwithTemperatureWarningandShutdownSystem
• Single-orThree-CycleResolution(JumperSelectable)
• ShortedSCRDetection(Optional)
Features for the MiniMax 1P 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)
Ifyouhaveapplicationquestions,refertotheEngineeringResourcesectionofourwebsiteat
www.chromalox.com to find the answer you’re looking for, or call one of our application engineers
at1-888-996-9258forpersonalassistance.
-2-
© 2014 Chromalox
®
, Inc.
1-888-996-9258
Table of Contents
Section Topic Page
1................................................. ImportantSafeguards ..................................................................................... 3
2................................................. Description ..................................................................................................... 4
3................................................. BeforeYouInstall ............................................................................................ 5
4................................................. Installation ...................................................................................................... 6
4.1 ................................. Mounting ......................................................................................................... 6
4.2 ................................. Wiring .............................................................................................................. 8
4.2.1 ................. Power/LoadWiring ......................................................................................... 8
4.2.2 ................. InstrumentPower ......................................................................................... 11
4.2.3 ................. Grounding .................................................................................................... 11
4.2.4 ................. CommandSignalWiring ............................................................................... 11
4.2.5 ................. Calibration .................................................................................................... 17
5................................................. Specifications ............................................................................................... 18
6................................................. Maintenance ................................................................................................. 19
7................................................. Troubleshooting ............................................................................................ 20
8................................................. PartsandAccessories .................................................................................. 21
9................................................. WarrantyandReturnInformation ................................................................. 22
10............................................... ECDeclarationofConformity ....................................................................... 27
-3-
© 2014 Chromalox
®
, Inc.
1-888-996-9258
1
PleasereadallinstructionsbeforeinstallingandoperatingyourMiniMax™.
Toavoidelectricalshockorinjury,alwaysremovepowerbeforeservicingacircuit.
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 MiniMax 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reandelectricalshockhazards.
SafetyAlertSymbol
InternationalShock/ElectrocutionSymbol
Eachsafetymessageisprecededbyasafetyalertsymbol andoneofthreewords:DANGER,WARN-
ING,orCAUTION.
Thesemean:
Important Safeguards
YouWILLbekilledorseriouslyhurtifyoudonotfollowinstructions.
YouCANbekilledorseriouslyhurtifyoudonotfollowinstructions.
YouCANbehurtifyoudonotfollowinstructions.
DANGER
WARNING
CAUTION
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 MiniMax™orotherequipment.NotethatDamagePreventionMessagesare
NOTaccompaniedbytheSafetyAlertSymbol.
-4-
© 2014 Chromalox
®
, Inc.
1-888-996-9258
2
† Thiscanbesettothreecycles‘On’/threecycles‘Off’(seesectiononinstallationoptions).
Description
MiniMax 1, 2, and 3
TheChromaloxMiniMax1,2,and3controllersarehighlyversatileSCRPowerPakswithoptionalplug-in
proportionalringandshortedSCRdetectionboards.FiringmodesincludeOn/OffandDOTproportional
zerovoltageswitching.ChromaloxexclusiveDOT(DemandOrientedTransfer)ringtechniqueswitchesthe
fewestnumberofcyclestoprovidethemostprecisezerocrossovercontrol.At50%output,theunit’s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1%.ThisDOTredtech-
niquealsominimizestemperatureovershoot,temperatureuctuationsandhelpsextendtheload’selement
life due to reduced thermal shock.
ThepowerSCRassembliesconsistofone,two,orthreepairsofSCRsconnectedbacktoback(withan
optionalsemiconductorfuse),RCSnubber,andMOVprotection.Theringcircuitisbasedonacommon
On/OffcontrolboardwithplugandplayShortedSCRandDOTredplug-inboards.Diagnosticindicators
areincluded.Plug-interminalblocksforeasycustomerinterfacearealsoprovided.
MiniMax 1P
TheChromaloxMiniMax1PutilizesSinglePhase,PhaseAnglering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MiniMax1P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.
-5-
© 2014 Chromalox
®
, Inc.
1-888-996-9258
3
Before You Install
ImmediatelyafterreceivingyourMiniMax1,2,3,or1P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le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envi-
ronment. Temperature extremes and excessive moisture can damage the controller.
BeforechoosingalocationinwhichtomountyourMiniMax,pleaseconsiderthefollowing:
Temperature
WhenmountingtheSCRunitinacontrolpanel,attentionshouldbepaidtotheenclosuretempera-
ture.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cabi-
net temperature is used.
Cleanliness
Carefulattentionmustbepaidinareassubjectedtoairborneparticles.Theefciency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 en-
sureproperairownecessarytocoolthedevice.
WARNING
Hazardous Voltage: Disconnect and lockout power before install-
ingorservicing.Failuretocomplycouldresultinpersonalinjury
or equipment damage.
- 6 -
© 2014 Chromalox
®
, Inc.
1-888-996-9258
Figure Drawing Number Model
Figure Model
1................MiniMax1–30&50AmpMountingBase
1................MiniMax1P–30&50AmpMountingBase
2................MiniMax1–75AmpMountingBase
2................MiniMax1P–75AmpMountingBase
3................MiniMax2–30&50AmpMountingBase
4................MiniMax2–75AmpMountingBase
5................MiniMax3–30,50&75AmpMountingBase
4
Installation
PleasereadallinformationinthissectionbeforebeginningtheinstallationofyourMiniMax.
InstallationoftheMiniMaxrequiresthreesteps:
1. Mounting
2. Powerwiring
3. 120or 230Vac50/60hzforinstrumentpower.See4.2.4,pg.11.
4.1 - Step 1: Mounting
BeforemountingyourMiniMax,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MiniMax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 vari-
ousMiniMaxPowerPakmodels.Pleaserefertotheseguresbeforemountingyourunit.
IMPORTANT: Pleasenotethattheguresonthefollowingpagesare
not drawn to the same scale.
-7-
© 2014 Chromalox
®
, Inc.
1-888-996-9258
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
MINIMAX1&1P30&50AMP
MOUNTINGBASE
GND
6.50(165.10MM)
7.50(190.50MM)
ø.28(ø7.14MM)
(4PLACES)
4.00
(101.60MM)
3.25
(82.55MM)
.75
(19.05MM)
.00
(0.00MM)
MINIMAX1&1P-75AMP
MOUNTINGBASE
GND
8.50(215.90MM)
9.50(241.30MM)
0.00
(0.00MM)
0.75
(19.05MM)
3.25
(82.55MM)
4.00
(101.60MM)
ø.28(ø7.14MM)
(4PLACES)
MINIMAX2–30&50AMP
MOUNTINGBASE
GND
8.5(215.90MM)
9.50(241.30MM)
0.00
(0.00MM)
0.75
(19.05MM)
3.25
(82.55MM)
4.00
(101.60MM)
ø.28(ø7.14MM)
(4PLACES)
MINIMAX2–75AMP
MOUNTINGBASE
GND
13.00(330.20MM)
14.00(355.60MM)
0.00
(0.00MM)
0.75
(19.05MM)
3.25
(82.55MM)
5.00
(127.00MM)
ø.28(ø7.14MM)
(4PLACES)
13.00(330.20MM)
14.00(335.60MM)
0.00
(0.00MM)
0.75
(19.05MM)
3.25
(82.55MM)
8.25
(209.55MM)
MINIMAX3–30,50&75AMP
MOUNTINGBASE
GND
5.75
(146.05MM)
10.00
(254.00MM)
ø.28(ø7.14MM)
(4PLACES)
- 8 -
© 2014 Chromalox
®
, Inc.
1-888-996-9258
4.2 - Step 2: Wiring
Careful attention must be paid when attaching the wiring to the MiniMax to ensure proper and safe opera-
tion. This section contains detailed information on how to connect the power, resistive load, ground, and
command signal wiring.
IMPORTANT: SelectinstallationwiringthatisinaccordancewiththeNational
ElectricalCodeandanylocalstandardsthatmaybeapplicable.
WARNING
Hazardous Voltage: Onlyqualiedpersonnelshouldperform
electricalwiringfortheMiniMaxPowerPaks.LETHALLYHIGH
VOLTAGESareassociatedwiththisequipmentandaredanger-
ous if improperly installed.
4.2.1 - Power/Load Wiring
The following illustrations depict how to connect the MiniMax to a resistive or inductive load. Make sure you
refer to the correct illustration for the MiniMax series you have purchased.
MINIMAX1
L2
L1
X1
Single Phase
Resistive
L2 Connection is
NOT on MiniMax
- 9 -
© 2014 Chromalox
®
, Inc.
1-888-996-9258
MiniMax 2
MiniMax 3
Three Wire
2 Leg Control
MINIMAX 2
L1
L3
L2
X1
X3
L2 Connection is
NOT on MiniMax
Four Wire
3 Leg Control
MINIMAX 3
L1
L2
L3
X1
X2
X3
N
N Connection is
NOT on MiniMax
IMPORTANT: TheI
2
t 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
- 10 -
© 2014 Chromalox
®
, Inc.
1-888-996-9258
MiniMax 3
MiniMax 1P
IMPORTANT: TheI
2
t 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
Three Wire
3 Leg Control
MINIMAX 3
L1
L2
L3
X1
X2
X3
- 11 -
© 2014 Chromalox
®
, Inc.
1-888-996-9258
4.2.4 - Command Signal Wiring
Pleaserefertotheguresonpage12forillustrationsofthe6-,8-,and10-pininputterminals.
MiniMax 1, 2, and 3
On/Off Control Signals
AC Input–The120thru230VacsignallinesareconnectedtoterminalJ1-7&8(seeFig.9on
page21).Aninputvoltageof120to230VacturnsthepowerOn.TheturnOFFvoltageis0Vac.
DC Input–The5-32VdcsignallinesareconnectedtoterminalJ3-1&4(seeFig.10onpage21).
Aninputvoltageof5to32VdcturnsthepowerOn.TheturnOFFvoltageis0Vdc.
Contact Closure Input–ThedrycontactsignallinesareconnectedtoterminalJ3-1&2(seeFig.
11onpage21).AclosedcontactturnsthepowerOn.TheturnOFFvoltageisanopencontact.
Process Analog Control Signals
MiniMax1,2,and3havebeenfactorycalibrated.Theseunitsaccept0-5,1-5,0-10Vdc,and4-
20mAinputsignalsthatareconnectedtoTerminalBlockJ2.Thefollowingsignalsareconnectedto:
0-5Vdc: TerminalJ2-9(+)&7(-)(seeFig.7onpage21)
1-5Vdc: TerminalJ2-5(+)&7(-)(seeFig.5onpage21)
0-10Vdc:TerminalJ2-10(+)&7(-)(seeFig.8onpage21)
4-20mA: TerminalJ2-6(+)&7(-)(seeFig.6onpage21)
4.2.2 - Instrument Power
MiniMax 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 15).
This supply is fused on the main circuit board.
4.2.3 - Grounding
Chasis is provided with a stud for ground connections.
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.
IMPORTANT
-12-
© 2014 Chromalox
®
, Inc.
1-888-996-9258
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
option, the indicator will display the rapid firing sequence.
Auto/Manual Input
TheMiniMax1,2,and3can
be wired to make it possible
to select an input from either a
temperature process controller
or a manual input potentiom-
eter.Aswitchisusedtoselect
between the input from a 1K
potentiometer and a linear
controlinput(seeFig.4onpage
15).Theunitisshippedwitha
jumperfromterminals2and3
ofterminalblockJ2(seeillustra-
tion3).Removejumpertoinstall
auto/manual input.
IMPORTANT: WhenenablingtheAuto/ManualInput,thejumperfromterminals2
and3ofterminalblockJ2mustberemoved.
CAUTION
Illustration 3
SCR Control Board
TheBasiccontrolboardprovidesthefollowingfunctions:
Thelowvoltagedctooperatethecircuitry:
Aswitchingregulatorcircuitconvertstheinstrumentpowervoltageto+12Vdc.
Thepowerdistributionforthecoolingfans:
The incoming instrument power is fused and then routed to the fan power terminals.
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.Ampliersconverttheanaloginputsandthepotentiometerin-
put to a signal level compatible with the optional proportional firing board. The plug-in recep-
tacle for the optional proportional board allows for an easy upgrade to proportional control.
ThedrivesignaltotheSCRtriggerboards:
Thetemperaturealarm:
The heat sink temperature is derived from a solid state 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:
The plug-in receptacle for the shorted SCR board is located on this board. Signals
fromtheSCRareroutedtotheoptionboard.Whenashortisdetectedtheexternally
connected device output is activated.
N
C
N
O
CO
NTA
CT
N
O
RMALLY
C
L
OS
E
D
(S
WN
C)
CO
NTA
CT
N
O
RMALLY
O
PE
N
(
SWNO
)
S
WIT
CH
A
SS
EMBL
Y
(
SW
)
PANEL T
O
B
E
M
OU
NTED T
O
LE
G
EN
D
PLATE
(
LP
)
AU
T
O
HAND
S
WITCH KNO
B
(
SW
)
AU
T
O
HAND
W
IRIN
G
1
4
N
C
N
O
1K
P
O
TENTI
O
METE
R
J2
CW
-13-
© 2014 Chromalox
®
, Inc.
1-888-996-9258
Proportional DOT Firing Board
Chromalox’sexclusiveDOT(De-
mandOrientedTransfer)ringtech-
nique switches the fewest number
of cycles to provide the most pre-
cisezerocrossovercontrol.At50%
output, the unit’s output alternates
betweenonecycle“On”andone
cycle“Off.”At51%,theoutput
continueswithonecycle“On,”one
cycle“Off,”andgraduallyinte-
gratesoneextra“On”cycleforthe
additional1%.
Remote Shutdown
Whenitisnecessarytodisabletheoutput,connectadrycontactbetweenJ3-3&4(seeFig.12on
page15).Whenitisclosed,thepowercontrolwillshutOFF.
IMPORTANT: Thisshutdownoverridesthecontrolinputonly.ItwillNOTprotect
against faulted or damaged SCRs.
CAUTION
SHORTJ3-1&2FOR
1CYCLEFIRING
SHORTJ3-2&3FOR
3CYCLEFIRING
Unitshippedfor3cycleoperation
2AMP(2AG)
CHROMALOXP/N0024-01097
LITTLEFUSEP/N225002
}
(SEE MODEL NUMBER)
(SEE MODEL NUMBER)
(SEE MODEL NUMBER)
-14-
© 2014 Chromalox
®
, Inc.
1-888-996-9258
Shorted SCR Detection (optional)
Thisoptionprovidesameansofalertinganoperatortoaproblemwiththesystem.Anexternal
indicatinglamporrelaycanbeconnectedtoJ1-5&6(seeFig.2onpage15).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.ShortingJ3-5&6candisabletheoutputatJ1-5&6.Thealarmcanbeselected
as latching or non-latching.
A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switch–customerprovided)ispressed.A
non-latching alarm resets automatically.
SHORTEDSCRDETECTION
DEMAND
123
Shorted SCR Detection (optional), cont’d.
Thelatchingandnon-latchingoptionisjumperselectable;thejumperislocatedontheplug-in
shortedSCRdetectionboard.Latchingandnon-latchingoperationbytheoutputatJ1-5&6is
controlledbyJ3ontheshortedSCRdetectionboard0135-28096.Whenthisjumperisinstalled,
latching operation is achieved. The drawing below shows the Shorted SCR Detection board.
Heat Sink Over-Temperature
AnexternallamporrelaymaybeconnectedtoJ1-3&4(seeFig.2onpage15)(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 is approaching an unsafe temperature level. The unit will enter a shutdown mode if the
temperature continues to rise.
UNIT SHIPPED IN NON-LATCHING MODE.
-15-
© 2014 Chromalox
®
, Inc.
1-888-996-9258
Input Terminals (MiniMax 1, 2, and 3):
120~240 ON/OFF CONTROL
4-20mA PROPORTIONAL INPUT SIG
COMMON
4-20mAPROPORTIONALINPUT
66
0 TO +5 VDC PROPORTIONAL INPUT SIG
0TO+5VDCPROPORTIONALINPUT
5
1
2
4
3
J3
6
COMMON
10
9
7
8
0 +10 VDC PROPORTIONAL INPUT SIG
0+10VDCPROPORTIONALINPUT
J3
5
2
1
3
4
6
COMMON
10
9
7
8
5
2
1
3
4
J3
6
4
5
2
3
J2
1
MANUAL CONTROL INPUT SIG
10
7
8
9
6
5
AUTO
POTREFVOLTAGE
COMMON
J2
2
4
3
1
MANUAL
1-5 VDC PROPORTIONAL INPUT SIG
1-5VDCPROPORTIONALINPUT
4
5
2
3
1
J2
10
COMMON
7
8
9
6
5
J1
10
7
8
9
6
5
1 K
J2
2
4
3
1
J2
2
4
3
1
J1
J3
120~230INSTRUMENTPOWER
REQUIRED ON ALL CONFIGURATIONS
120~230 INSTRUMENT POWER
J1
SHORTED SCR AND
HI TEMP INDICATORS.
SHORTED SCR INDICATOR RESET.
FIG12.
FIG9.
FIG6.
L2
COMMON
REMOTE SHUTDOWN
EXTERNAL +5~32 VDC ON/OFF
COMMON
FIG10.
+
-
DRY CONTACT ON/OFF
FIG11.
+
FIG7.
FIG4.
FIG8.
+
L1
FIG5.
JUMPER
EXTERNAL120~230
FIG2.
FIG3.
FIG1.
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
HITEMPINDICATOR.
SHORTEDSCRINDICATOR.
1
2
3
4
5
6
1
2
3
4
5
6
7
8
JUMPER
JUMPER
JUMPER
ON/OFFCONTROL
TheseareACvoltageoutputsat100mAmax.,
not contact closures. See model number
for voltage rating.
- 16 -
© 2014 Chromalox
®
, Inc.
1-888-996-9258
MiniMax 1P
TheChromaloxMiniMax1Pisasolid-stateproportionalpowercontrollerthatutilizesaPhaseAnglering
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Shutdown,andoptionalRemoteManualBiaswith0 - 100%dial.Allunitshavethermostatpro-
tectionwithN.C.contacts.
Start-up
TheMiniMax1Phasbeenfactorycalibratedfor4-20mAinput.Besuretheoperatingvoltageand
signalinputarecorrectlyapplied.Also,makesuretheEmergencyShutdown,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eldcalibratedbyuseof
zeroandgainpotentiometers.
IMPORTANT: WiththeCurrentLimitoption,thecurrenttransformermustbeter-
minated properly to prevent it from being damaged.
CAUTION
0-5mA, 1-5mA
(0-10Vdc, 0-5Vdc)
4-20mA
0-20mA
10-50mA, 0-50mA
COM
CLOSE FOR
REMOTE
SHUTDOWN
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
Customer Connection
-17-
© 2014 Chromalox
®
, Inc.
1-888-996-9258
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(Cur-
rent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MiniMaxPowerPakintheab-
sence 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MiniMax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out-
put 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Shutdown.
EmergencyShutdowninhibitsallSCRtriggerpulses
regardless of the level of the input signal or manual
potentiometer.ForEmergencyShutdown,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MiniMax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.
4.2.5 - Calibration (MiniMax 1P):
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operat-
ingtemperatures,thecurrentdrawnthroughtheMiniMax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.
- 18 -
© 2014 Chromalox
®
, Inc.
1-888-996-9258
5
Specifications
Control Inputs
Acceptsallofthefollowingasstandards:
On/Off Control
SignalInput
120thru230Vac±10%
5-32Vdc
Contact Closures
Proportional Control
SignalInput InputImpedance
4-20mA ................. 250Ohms
1-5Vdc .................. 10kOhmsorgreater
0-5Vdc .................. 10kOhmsorgreater
0-10Vdc ................ 10kOhmsorgreater
Optional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 ......30,50,75
Ambient Temperature ....0-50°C(32-122°F)
SCR Capability
Dielectric .................Withstandcapability
Surge Rating  1500VRMSmin.
Typicallyfteen(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 ..........VoltageOutput
Indicator Output 100mA@InstrumentPower
Shorted SCR ..................VoltageOutput
Indicator Output 100mA@InstrumentPower
MiniMax 1, 2, and 3
MiniMax 1P
Control Inputs
Acceptsallofthefollowingasstandards:
Phase Angle Control
SignalInput InputImpedance
1-5,0-5mA ......... 1KOhms
4-20,0-20mA ..... 250Ohms
10-50,0-50mA ... 100Ohms
OptionalRemoteManualAdjust
Fan Power ................... 120or230VAC
50/60Hz
Output Voltage ............ 0-99%RMSlinevoltage
Resolution (proportional)Betterthan0.1%
Line Voltage ................ 120,208,240,277,380,
...................................... 480 and575Vac
±10%50/60Hz
Load Current Rating ... 30,50,75
Ambient Temperature .....0-50°C(32-122°F)
SCR Capability ................Withstandcapability
 1500VRMSmin.
Typicallyfteen(15)times
nominal RMS rating for
8.3milliseconds
Surge Rating ...................Typicallyfteen(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
- 19 -
© 2014 Chromalox
®
, Inc.
1-888-996-9258
6
Maintenance
Connections –Looseconnectionsinthepowerwiringwillgeneratehotspots.Thesewillcausedegradation
ofelectronicequipment.Periodicinspectionsshouldbemadetoensurethatconnectionsaresecureand
that there are no signs of excessive heating such as discoloration, and so on.
Corrosion–Ifthepowermoduleisinstalledinanenvironmentwithhighhumidityordampness,electrical
connectionsmaysuffercorrosion.Periodicallycheckthepowermoduleforcorrosion.
Damage–Periodicallycheckforrodentdamagetowiringandothercomponents.
Filters – Many high-powered control enclosures rely on blowers or fans to maintain a safe operating temper-
ature. The filters used with these devices should be changed on a periodic basis to insure adequate enclo-
sure cooling is maintained.
Dust–Periodicallycheckfordustorotherparticulatebuilduponheatsinksandbusbars.
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.
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Chromalox MiniMax 1 Installation guide

Chromalox
Brand
Chromalox
Model
MiniMax 1
Type
Installation guide
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