Chromalox CS3-025 Instruction manual

CS3 Three Phase SSR Quick Start Manual
0037-75554 (PK528)
This manual is intended to provide only the basic installation and operation instruc-
tions for the CS3 Three Phase Solid State Relay. Please refer to manual PK522, for
complete installation & operation details. The most current revision of PK522 may be
found on the Chromalox website: www.chromalox.com
1. IMPORTANT SAFEGUARDS
ELECTRIC SHOCK HAZARD: Read and understand all instructions before
installing, servicing or operating this controller. Failure to do so could
result in equipment or property damage as well as personal injury and
even death.
HIGH VOLTAGE is used in the operation of this equipment. DEATH ON
CONTACT may result if personnel fail to observe safety precautions.
Learn the areas containing high-voltage connections when installing or
operating this equipment.
Be careful not to contact high-voltage connections when installing or
operating this equipment. Before working inside the equipment, turn
power off and ground all points of high voltage potential before touch-
ing.
ELECTRIC SHOCK HAZARD. Any installation involving control equip-
ment must be performed by a qualified person and must be effectively
grounded in accordance with the National Electrical Code to eliminate
shock hazard.
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 integrity of the controller
and/or cause product failure resulting in a safety risk to operational
service and personnel.
This controller utilizes a heat sink which is designed to cool the unit
during operation. Under no circumstance should air flow around the
controller be compromised in any way. Failure to do so may result in the
overheating of the controller, product failure, product temperatures and
even fire.
During continuous operation, the heat sink can reach a very high tem-
peratures, 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 disconnecting electrical power to the panel. Failure to do
so could result in serious injury or death.
2. INSTALLATION - MECHANICAL
To ensure proper performance, maximum safety and reliability, it is essential to install
the unit correctly. This includes proper mounting, spacing, hardware and wiring. 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:
–Min. vertical distance between unit and panel wall: 3.9” (100 mm)
–Min. horizontal distance between unit and panel wall: 0.8” (20 mm)
–Min. vertical distance between adjacent power control units: 11.8” (300 mm)
–Min. horizontal distance between adjacent power control units: 0.8” (20 mm)
3. INSTALLATION – ELECTRICAL CONTROL, LOAD & LINE CONNECTIONS & LED INDICATION
CS3 with VDC Control Signal Input CS3 with VAC Control Signal Input
Dimensions & Weights
1/L1 3/L2 5/L3
AC51: 25A
AC53a: 5A
CS3-02548-110
On
L1 L2 L3 A1+
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
CS3-04060-221
On
13 5 A1+
24 6A2-
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
1/L1 3/L2 5/L3
AC51: 40A
AC53a: 8A
CS3-04060-111
On
13 5 A1+
24 6 A2-
Alarm B1
B2
A1
A2
2/T1 4/T2 6/T3
5-32 Vdc
600 VAC
50/60 Hz
fan: 230 VAC
Label Connection/Indication Label Connection/Indication
L1, L2, L3 Line 1, Line 2, Line 3 VAC Input B2 Alarm Output (Option)
T1, T2, T3 Load 1, Load 2, Load 3 VAC Input ON Red LED - Command Signal Indication
A1 (+) VDC Control Signal Input Alarm Yellow LED - Over Temp. Indication
A2 (-) VDC Control Signal Input GND Earth Ground (Not shown, varies by model)
B1 Alarm Output (Option)
Label Connection/Indication Label Connection/Indication
L1, L2, L3 Line 1, Line 2, Line 3 VAC Input ON Red LED - Command Signal Indication
T1, T2, T3 Load 1, Load 2, Load 3 VAC Input Alarm Yellow LED - Over Temp. Indication
A1, A2 AC Control Signal Input OUT-AL Red - LED Load/Line Interrupt Alarm
(Alarm Code 2 Only)
B1 Alarm Output (Option) GND
Earth Ground (Not shown, varies by model)
B2 Alarm Output (Option)

4. WIRING - LOAD, LINE, INPUT SIGNAL AND OPTIONAL ALARM
5. SPECIFICATIONS
General
Category of use:...................................................................................AC51, AC53a
Switching Mode: ......................................................................................Zero Cross
Input/Output Isolation Voltage:........................................................ 4,000 VAC RMS
Operational Voltage Range
• 480 VAC models: ............................................................................ 24 - 530 VAC
• 600 VAC models: ............................................................................ 24 - 660 VAC
Nominal Frequency: .................................................................................50 - 60 Hz
Non-repetitive peak voltage
• 480 VAC models: .................................................................................... 1200 Vp
• 600 VAC 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
Protection: ........................................................................................................ IP20
Inputs
VDC Input (Type “1”)
Control voltage: ....................................................................................... 5 - 32 VDC
Maximum input: .................................................< 18 mA @5 VDC 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
Integrated Thermal Protection
The SSR temperature is constantly monitored. If the maximum temperature limit
(230°F/110°C) is exceeded, 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 which actuates a wired device during an
alarm event, such as a horn or light. This output alarm requires an external 24 VAC/
DC power supply.
Alarm Output Ratings: Imax........................................................................150 mA
Vmax................................................................. 32 VAC/DC
Z close (impedance) ................................................ < 15 Ω
For Models with 24 VDC 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 (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 (Code 1)
• There is no current on the 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 including with reference to product standard EN 60947-4-3 (Low-
voltage switchgear and control gear – AC contactors and semiconductor motor
starters). The product is designed for type A environments. Use of the product in
type B environments may cause undesired electromagnetic noise. In this case, the
user should take appropriate steps for improvement.
PK528
0037-75554
July 2015
© 2015 Chromalox, Inc.
RR
RR
RR
F1 F2 F3
5-32 VDC
Control
Signal
Output
RRR
Phase L1
Phase
L2
Phase L3
Neutral
Ground
Load
1/L1 3/L2 5/L3
AC51: 40A
AC53a: 8A
CS3-04060-111
On
13 5A1+
24 6A2-
Alarm
B1
B2
A1
A2
2/T1 4/T2 6/T3
5-32 Vdc
600 VAC
50/60 Hz
fan: 230 VAC
Temperature / Process
Controller
LOADLOAD
Optional Over Temperature
Alarm Output Feature
CS3 Wiring with VDC Control Signal Input CS3 Wiring with VAC/VDC Control Signal Input (Code 2)
RR
RR
RR
F1 F2 F3
20 - 260 VAC/DC
Control Signal Output
RRR
Phase L1
Phase
L2
Phase L3
Neutral
Ground
Load
Temperature / Process
Controller
LOADLOAD
Optional Over Temperature
Alarm Output Feature
1/L1 3/L2 5/L3
AC51: 40A
AC53a: 8A
CS3-04060-221
On
13 5 A1+
24 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
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 A2s1,010 A2s 6,600 A2s
Critical dV/dt Off-state (minimum) 1,000 V/μs
Off-state Leakage Current (@ Rated Voltage) < 3 mA CS3-025, CS3-040 & CS-055 Derating Curves
Rated Current versus Ambient Temperature
Note: Models as tested with approved heat sinks and
fans, if applicable.
25
40
55
0
20
40
60
04
08
0
Current (Amps)
Ambient Temperature ˚C