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© 2021 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 Stop
•  Compact Size and Construction
•  dv/dt Transient Voltage Protection
•  MOV Protection
•  Automatic 50/60 Hz line sensing

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 Stop System
•  Cycle Resolution 3,5,7,11,13,17,19
•  Shorted SCR Detection (Optional)
•  Soft Start
•  Time Proportional Switching Mode
•  Staged Heating
•  Rotary Swtich Selection of Input, Leg Configuration, Modbus

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.

Summary of Contents for MiniMax 1

Page 1: ...PK565 User s Manual P N 0037 75589 www chromalox com 800 443 2640 2021 Chromalox Inc MiniMax Digital ...

Page 2: ......

Page 3: ...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 Stop System Cycle Resolution 3 5 7 11 13 17 19 Shorted SCR Detection Optional Soft S...

Page 4: ...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 ...

Page 5: ... 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 MiniMax 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 nation...

Page 6: ...hermal shock The power SCR assemblies consist of one two or three pairs of SCRs connected back to back with an op tional semiconductor fuse RC Snubber and MOV protection The firing circuit is based on a common On Off control board with plug and play Shorted SCR and DOT fired plug in boards Diagnostic indicators are included Plug in terminal blocks for easy customer interface are also provided Mini...

Page 7: ...Before choosing a location in which to mount your MaxPac please consider the following 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 tempera...

Page 8: ... 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 figures before mounting your unit Figure Model 1 MiniMax 1 30 50 Amp Mounting Base 1 MiniMax 1P 30 50...

Page 9: ...9 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 55M...

Page 10: ... form electrical wiring for the MiniMax Power Paks LETHALLY HIGH VOLTAGES are associated with this equipment and are dangerous if improperly installed WARNING The following wiring instructions are for the Digital Minimax only If using Analog Minimax contact factory for appropriate wiring schematics Analog Minimax is designated as MMAXI II or III followed by the number 1 2 3 or 4 under the firing m...

Page 11: ...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 I2 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 ...

Page 12: ...n 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 Single Phase transformer Coupled MINIMAX 1P L2 L2 L1 X1 L2 connection to MiniMax is instrument power only ...

Page 13: ...Customer Connection Please refer to the figures on page 12 for illustrations of the 6 8 and 10 pin input terminals 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 Groundi...

Page 14: ...OSED SWNC CONTACT NORMALLY OPEN SWNO SWITCH ASSEMBLY SW PANEL TO BE MOUNTED TO LEGEND PLATE LP AUTO HAND SWITCH KNOB SW AUTO HAND WIRING 1 4 NC NO 1K POTENTIOMETER J2 CW 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...

Page 15: ...n off input is isolated by an opto coupler The dc and contact closure inputs are buffered by the circuitry The drive signal to the SCR trigger boards The temperature alarm The heat sink temperature is derived from a resistive temperature detection RTD 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 all...

Page 16: ...set rotary switch at SW1 to position 0 0 10Vdc Select AUTO mode by jumpering J2 4 J2 5 and then set rotary switch at SW1 to position 2 0 5Vdc Select AUTO mode by jumpering J2 4 J2 5 and then set rotary switch at SW1 to position 3 1 5Vdc Select AUTO mode by jumpering J2 4 J2 5 and then set rotary switch at SW1 to position 4 0 20mA Select AUTO mode by jumpering J2 4 J2 5 and then set rotary switch a...

Page 17: ...apidly 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 de tected 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 de tected in one direction Blinks rapidly if phase voltage is not present...

Page 18: ...ly 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 field calibrated by use of zero and gain potentiometers IMPO...

Page 19: ...ositive 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 v...

Page 20: ...erature 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 Outpu...

Page 21: ...heck 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 particulat...

Page 22: ... 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 ...

Page 23: ...m 26 inch lb 3Nm SCR Replacement 575 Vac Be sure to replace thermstrate interface material and torque as follows MFG Part SCR Part Thermstrate Part Torque inch lb Torque inch lb to Heat Sink to Terminals SKKT42 14E 0002 42519 0029 00700 44 inch lb 5 Nm 26 inch lb 3Nm SKKT92 14E 0002 47561 0029 00700 44 inch lb 5 Nm 26 inch lb 3Nm MiniMax 1 2 and 3 Accessories Part Number Description 0135 20117 Pot...

Page 24: ...instructions Users are responsi ble 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 Instruments and Controls must be accomp...

Page 25: ...e 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 104 F Ambient 01 30 Amp 02 50 Amp 03 75 Amp Code Line Voltage 1 120 480Vac 2 575Vac Code Instrument Power 1 120 to 240Vac 50 60Hz Code Remote Manual Adjust Auto...

Page 26: ...ge 1 120 Vac 2 208 Vac 3 240 Vac 4 277 Vac 5 480 Vac 6 575 Vac Code Remote Manual Adjust Auto Manual Switch3 0 None 1 Pot with 0 100 dial and local Remote Switch Single Turn 1K ohm Potentiometer Requires Proportional Board Mmax 1P 2 01 1 1 Typical Model Number 1 SCR fusing is for semiconductor protection only not wire protection 2 Supplied loose for customer mounting 575V fusing only 3 Supplied lo...

Page 27: ...ghest 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 104 F Ambient 01 30 Amp 02 50 Amp 03 75 Amp Code Line Voltage 1 120 480 Vac 2 575 Vac Code Instrument Power 1 120 to 240Vac 50 60Hz Code Remote Manual A djust Auto Manual Switch3 0 None 1 Pot with 0 1...

Page 28: ...ture Line Frequency Monitoring Third Party Certifications UL cUL CE DEMKO 650 A and below Code Current at 50 C 104 F Ambient 01 30 Amp 02 50 Amp 03 75 Amp Code Line Voltage 1 120 480 Vac 2 575 Vac Code Instrument Power 1 120 to 240 Vac 50 60Hz Code Remote Manual Adjust Auto Manual Switch 0 None 1 Pot with 0 100 dial and local Remote Switch Single Turn 1K ohm Potentiometers Requires Pro portional B...

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