Chromalox CS1 Instruction manual

CS1 Single Phase SSR Quick Start Manual
0037-75553 (PK527)
This manual is intended to provide only the basic installation and operation instruc-
tions for the CS1 Single Phase Solid State Relay. Please refer to manual, PK521, for
complete installation & operation details. The most current revision of PK521 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: 0.79” (20 mm)
–Min. vertical distance between adjacent power control units: 11.81” (300 mm)
–Min. horizontal distance between adjacent power control units: 0.79” (20 mm)
3. INSTALLATION – ELECTRICAL
Control Signal Input
Dimensions & Weights
Control Terminal Description – CS1 Models > 40 Amps
Terminal Description
24VDC Input Signal (Type 1)
(6 – 32 VDC)
VAC/DC Input Signal
(Type 2)
(20 – 260 VAC/DC)
1 Not Used
2Control Signal Input
& VDC Power Supply
Control Signal Input (-)
& Optional -24 VDC Power Supply Input VAC/DC INPUT
3 Control Signal Input Control Signal Input (+)
4 VDC Power Supply Optional +24 VDC Power Supply Input Not Used
5 Not Used
6 Alarm Output Alarm Options 1 & 2:
Solid State Switch
Alarm Options 3 & 4:
Internally connected to
Terminal #4 (+VDC Power
Supply)
Alarm Option 1:
Solid State Switch
7 Alarm Output Alarm Options 3 & 4:
PNP Digital Signal Output
8 Not Used
Depth = 5.6” (142)
Weight = 2.9 lb (1300 g)
3.7 lb (1700 g)
Depth = 4.2” (107) 5.6” (142) 5.6” (142) 5.6” (142)
Weight = .71 lb (320 g) 1.2 lb (540 g) 1.9 lb (900 g) 2.6 lb (1200 g)
(without fan)
(without fan)
(with fan)
1.97” (50) max.
1.18” (50)
5” (127)
3.15” (80)
2.36” (60)
1.4” (35)
.95” (24)
3.94” (100)
4.24” (108)
0.5”
(14)
0.7”
(18)
CS1 25 A CS1 40 A CS1 50 A CS1 60 A
CS1 75 A
CS1 90 A
CS1 120 A
CS1 CS1 CS1 CS1 CS1
LED 1
Red: Input Control Signal Present
Yellow: Overtemperature Condition,
Input Control Signal Present
Blank: No Input Control Signal
LED 2 (Optional)
Red: Alarm Output Active
Blank: No Alarm Output
LOAD
2 /T1
LINE
1 /L1
GROUND
1 2 3 4 5 6 7 8
+
Control Signal
Input –
24 Vdc or
20 - 260 Vac/dc
25 & 40 Amp 50 -120 Amp
ON (Red)
OVER TEMP (Yellow)
AL
Optional
External -24 Vdc Power Supply
External +24 Vdc Power Suppl
y
Alarm Output See Wiring
Alarm Output Diagrams
2 3
ON
LOAD
2 /T1
LINE
1 /L1
GROUND
+
–
Control & Power
Connections
LEGACY PRODUCT

4. LOAD WIRING
LED Status Definition
LED Color Condition LED Color Condition LED Color Condition
ON BLANK SCR OFF,
no Alarm
ON RED SCR ON,
No Alarm
ON RED SCR ON, Alarm
Output is Active
AL BLANK AL BLANK AL RED
LED Color Condition LED Color Condition
ON BLANK SCR OFF, Alarm Output is Active
(alarm stored) This condition is only
valid with Type “1” input control sig-
nal and alarm option.
ON YELLOW Control Signal is ON, Over Temperature
Protection Engaged, SCR is OFF, Alarm
Output is Active
AL RED AL RED
Notes:
“ON” LED comes standard with ALL CS1 Models
“AL” LED is only available when optional Alarm Output feature is chosen. See order table.
Derating Curves
Rated Current versus Ambient Temperature for each CS1 Model.
(These curves reflect units tested complete with approved heat sinks and fans, if applicable)
30
25
10
5
10
15
20
25
30
35
40
04080
Current (Amps)
Ambient Temperature ˚C
CS1-025
50
40
15
60
50
18
70
60
20
10
20
30
40
50
60
70
80
04080
Current (Amps)
Ambient Temperature ˚C
CS1-040, CS1-050, CS1-060
75 75
30
90 90
50
120 120
90
20
40
60
80
100
120
140
04
08
0
Current (Amps)
Ambient Temperature ˚C
CS1-075, CS1-090, CS1-120
CS1 with
20-260 VAC/DC
Control Signal
Input
CS1 with
6-32 VDC
Control Signal
Input
Control Signal
Output
Temperature /
Process Controller
+ –
Phase
Neutral
Ground
FuseLoad
Single Phase Load
CS1 with 20- 260 Vac/dc
Control Signal Input
CS1 with 6-32 Vdc
Control Signal Input
Control Signal Output
+ –
Temperature /
Process Controller
Delta Load Wye or
Star Load
RR
R
R
R
R
Fuse
Fuse
Phase L1
Phase L2
Phase L3
Ground
Controlling 2 Phases (Legs) of a Three Phase (no Neutral) Wye (Star) or Delta Load Configuration
LEGACY PRODUCT

5. OPTIONAL ALARM WIRING (ALARMS AVAILABLE ON CS1 MODELS > 40 AMPS
CS1 with 20- 260 VAC/DC
Control Signal Input
CS1 with 6-32 VDC
Control Signal Input
Control Signal
Output
Temperature /
+
Neutral
Phase L1
Phase L2
Phase L3
Ground
Fuse Fuse Fuse
Load
–
F
u
s
e
Process Controller
Three Phase Load in a Wye or Star Connection with Neutral
+
24 VDC Control
Signal Input
Solid State Switch
Alarm Output
24 VDC/AC External Power
Supply Required
Note:
Parallel connection required
for multiple CS1 with
Normally Open Alarm
Switch (Code = 1)
Series connection required
for multiple CS1 with Normally
Closed Alarm Switch (Code = 2)
+
24 VDC External
Power Supply LOAD LOAD
+
24 VDCControl
Signal Input
+
24 VDC External
Power Supply LOAD
Optional Single 24 VDC
Power Supply wiring
method for DC alarms only
Jumper Terminals #4 & #6
–
–
–
–
–
–
Control Signal Input: 24 VDC (6 – 32 VDC)
Alarm Output: Solid State Switch
Alarm Option Code: 1 or 2 (See Order Table)
5. OPTIONAL ALARM WIRING (continued)
+
24 Vdc Control
Signal Input
Digital Logic +24 Vdc
PNP Output
Note:
Parallel connection
required for multiple
CS1 with Normally
Open Alarm Switch
(Code = 3)
Single connection
for CS1 with Normally
Closed Alarm Switch
(Code = 4)
Terminal #6 is internally
connected to Terminal #4
(+Vdc Power Supply)
+ +
20-260 Vac
Control
Signal Input
Solid State Switch
Alarm Output
24 Vdc/AC External
Power Supply
Required
Note:
Parallel connection
required for multiple
CS1 with Normally
Open Alarm Switch
(Code = 1)
24 Vdc External
Power Supply
LOAD LOAD
–
––
–
–
–
–
Control Signal Input: 24 VDC (6 – 32 VDC)
Alarm Output: Digital Logic PNP
Alarm Output Code: 3 or 4 (See Order Table)
Control Signal Input: VAC (20 – 260 VAC)
Alarm Output: Solid State Switch
Alarm Output Code: 1 (See Order Table)
LEGACY PRODUCT

Outputs
Specification CS1-025 CS1-040 CS1-050 CS1-060 CS1-075 CS1-090 CS1-120
Rated Current (@ 40˚C continuous service) 25 A 40 A 50 A 60 A 75 A 90 A 120 A
Max. Surge Current (t=20 ms) 400 A 600 A 1,150 A 1,300 A 1,500 A
Max. I2t for fusing (blowout) 645 A2s 1,010 A2s6,600 A2s 8,000 A2s 11,200 A2s
Critical dV/dt Off-state (min.)
1,000 V/µs
Off-state Leakage Current (@ Rated Voltage)
< 3 mA
6. SPECIFICATIONS
PK527
0037-75553
July 2015
© 2015 Chromalox, Inc.
General
Category of use:...................................................................................................AC1
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
Operational frequency:...............................................................................45 - 65 Hz
Non-repetitive peak voltage
• 480 VAC models: ...................................................................................... 1200 Vp
• 600 VAC models: ...................................................................................... 1400 Vp
Zero Voltage Turn-on:....................................................................................... ≤20 V
Activation time:..........................................................................................= 1/2 cycle
Deactivation time:......................................................................................= 1/2 cycle
Potential drop at rated current: .............................................................. = < 1.4 Vrms
Power factor:......................................................................................................... = 1
Inputs
VDC Input (Type “1”)
Control voltage:.........................................................................................6 - 32 VDC
Maximum input:.................................................................................. < 10 mA @32 V
Maximum reverse voltage: ............................................................................. 36 VDC
Activation voltage:...................................................................................... > 5.1 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
Environment Conditions
Operating Temperature Range: .................................................................0˚C to 80˚C
Maximum Relative Humidity:...................................................................50% @ 40˚C
Max. Installation Altitude: ......................................................2000 m above sea level
Pollution Level: ..........................................................................................................2
Storage Temperature:.......................................................................... -20˚C to +85˚C
Junction Temperature:....................................................................................... 125˚C
This device conforms to European Union Directive 2004/108/CE and 2006/95/CE as
amended with reference to generic standards:
EN 61000-6-2 (immunity in industrial environment)
EN 61000-6-4 (emission in industrial environment)
EN 61010-1 (safety regulations).
Alarm Outputs
The alarms are only available only on models rated at 50 Amps and greater.
There are two types of alarm outputs:
1. Solid State Switch – Controls a connected device for an alarm event, such as a
horn or light.
a. Requires external 24VAC/DC power supply
b. Ratings: Imax = 150 mA
Vmax = 30 VAC/DC
Z close < 15 ȍ(impedance)
Z open > 1 Mȍ(impedance)
2. Digital Logic – PNP output signal for logic gated devices, such as PLCs
a. Requires external 24VDC (6-32 VDC) power supply
b. Ratings: Imax = 150 mA
Vmax = 30 VAC/DC
Alarm Behavior
The functionality of the alarm switching varies depending on the type of gating signal
For Models with 24 VDC Input Control Signal
The alarm output function actuates (opens or closes) the isolated solid state output
switch (or digital output signal) when it detects any of the following fault conditions:
The control signal is active, but:
• There is no current on the load (zero current or interrupted load)
• There is no line voltage power supply
• The internal temperature limit of the SSR has been exceeded
Latching Alarm Function
On the VDC gated CS1 controllers, the alarm state remains latched if the Control Signal
is switched off. The Alarm Output will reset (unlatch) once the current load is restored
or when the CS1 24 VDC power supply is cycled.
For Models with 20 - 260 VAC/DC Input Control Signal
The alarm output function closes the isolated solid state output switch when it de-
tects any of the following fault conditions:
The control signal is active, but:
• There is no current on the load (zero current or interrupted load)
• There is no line voltage power supply
• The internal temperature limit of the SSR has been exceeded
Latching Note:
On the VAC gated CS1 controllers, in the absence of the control signal, the alarm
output is always open. The alarm memory latch function is not possible as with the
CS1 with VDC control signal.
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.
Limited Warranty:
Please refer to the Chromalox limited warranty applicable to this product at
http://www.chromalox.com/customer-service/policies/termsofsale.aspx.
Chromalox, Inc.
1347 Heil Quaker Boulevard
Lavergne, TN 37086
[phone]
www.chromalox.com
LEGACY PRODUCT