INSTALLATION AND OPERATING INSTRUCTIONS

INSTALLATION AND OPERATING INSTRUCTIONS PRODUCTS CCM SERIES NOTE: This document provides the necessary information for the use and operation of Greystone current valves. Greystone Energy Systems Inc. reserves the right to make design modifications without prior notice. 50 English Drive, Moncton, NB EE 4G7 Tel: 506-85-057 Fax: 506-85-604 E-mail: greystone@nbnet.nb.ca Visit our Web Site at: www.greystoneenergy.com

Part Number Designation CCM - X - XX - X - XXX Amperage Version E Electronic P Pneumatic S Slave Wiring 0 Single Phase 0 phase wire 40 phase 4 wire Series Style Open frame/small Enclosed/Small Enclosed/Large INTRODUCTION The CCM Series are solid state current valves that provide time proportioned control for commercial constant-resistance electric heat loads. The CCM-X-0-X-XXX controls up to 80A single phase loads. The CCM-X-0-X-XXX controls up to 55A three-phase, three-wire delta or ungrounded wye connected loads. The CCM-X-40-X-XXX controls up to 40A threephase, four-wire wye connected loads. BEFORE INSTALLATION Carefully read and fully understand the instruction contained in this installation guide. Ensure that power is disconnected prior to installation or if working inside the current valve. All wiring to the current valve must conform to local codes. On models with covers, an integral ground terminal is provided to permit proper grounding of the device and the cover must remain on the unit at all times during operation. If the current valve model may be used on a wide variety of supply voltages, ensure the voltage selection jumper in the current valve is properly positioned. MOUNTING The enclosed CCM current valves may be directly mounted on wall or in cabinets. In all types of installations the heatsink fins must be in a vertical position to permit proper convection cooling. If the current valve is mounted in a cabinet or other enclosure additional ventilation may be. (see table, and figures & ) Spacing for air circulation and access to the internal connections to the current valve should be provided. If several units are to be placed in the same area, care should be taken to ensure heat rising from one unit does not interfere with cooling of other units. The open frame current valves must be mounted in a properly grounded metal panel or cabinet system. Page

INPUT CONNECTIONS (figures and 4). Remove the cover from the device to permit access to the wiring terminals.. If interlock contacts are to be connected, remove the factory installed jumper from terminals and 4 (small units) or 5 and 6 (large units). Connect the interlock between these two terminals.. Refer to the job specifications and drawing to determine the control signal type. 4. Using figures and 4, connect the control signal to the appropriate terminals. 5. If the input signal must be grounded then connect the terminal marked GND to ground. 6. Open frame units require a 4 Vac supply connected to terminals and. NOTES: () The Red LED next to the terminal block indicates the level of input control signal to the firing circuit board. For example if the input level is 0 Vdc of a -0 Vdc input signal, the red LED will be full on. If the input level is 6 Vdc (ie: 50% of -0 Vdc input signal) the red LED will be flashing at 50% on time. If the input signal is Vdc, the red LED will be full off. () If the input the signal is grounded at the input device, disconnect and cap the green ground wire from the CCM case (ie: isolate terminal from the case). PNEUMATIC INPUT (figure 5) If this model is equipped for 8 Kpa ( psi) pressure control signal (CCM-X-XX-P-XXX series), connect the pressure input line to the barbed pressure sensor fitting. All other input connections will be omitted except for the GND terminal, the INTERLOCK terminals and, on some models, the 4 Vac terminals. POWER CONNECTIONS (figures 6, 7, and 8) The power connections to the load use standard L/T and L/T terms. To install a -phase, -wire CCM unit connect A.C. Line to L and A.C. Line to L. A.C. Line is connected directly to the -wire load. Load wire is connected to T and Load wire is connected to T as shown in Figure 7. To install a single phase CCM unit, connect the A.C. Line (HOT Side) to L and the A.C. Line (Neutral) to L. The load is connected to T and T as shown in Figure 6, this configuration L and T are internally connected to permit the Neutral to pass unbroken. Ensure crimp type ring lug terminals are used on all power connections to the device and are properly tightened. On line-powered units, in order for the internal control electronics to function properly, the Line-to-Line service voltage must be determined. Set the voltage selection jumper to this voltage. The jumper comes factory installed at the highest voltage range. Large current valves require transformer tap selection. (figures 9 and 0) WARNING: DO NOT USE VOLTAGES HIGHER THAN THE NAMEPLATE RATING START-UP INSTRUCTIONS. Ensure the service voltages and load currents are within those stated on the nameplate ratings.. Ensure all wiring connections are tight.. Ensure local codes have been complied with in connecting this device. 4. For open frame units, ensure the device is mounted to a properly grounded metal panel or cabinet system and grounded in accordance with the requirements of local electrical codes. Page

MOUNTING DIMENSIONS (Table ) Product Number A Dim. B Dim. C Dim. D Dim. E Dim. Max Height Fig # CCM0E045 CCM0P045 CCM0S045 CCM0E040 CCM0P040 CCM0E070 CCM0P070 5 mm (8 / in.) 05 mm (8 in.) N/A N/A N/A 60 mm (6 /8 in.) # CCM0E05 CCM0P05 CCM0E00 CCM0P00 CCM0E05 CCM0P05 CCM0E00 CCM0P00 65 mm (6 / in.) 55 mm (6 /8 in.) N/A N/A N/A 5 mm (4 / in.) # CCM0E040 CCM0P040 CCM0E070 CCM0P070 5 mm (8 / in.) 05 mm (8 in.) N/A N/A N/A 0 mm (5 /8 in.) # CCM40E40 CCM40P40 CCM0E55 CCM0P55 CCM0E80 CCM0P80 479 mm (8.9 in.) 45 mm (7.8 in.) mm (.5 in.) 7 mm (.8 in.) 50 mm (.8 in.) 5 mm (9.9 in.) # CCM0E05 CCM0P05 4 mm (6.6 in.) 96 mm (5.6 in.) 5 mm (. in) mm (.8 in.) 8 mm (7. in.) 0 mm (8.0 in.) # CCM0E5 CCM0P5 4 mm (6.6 in.) 96 mm (5.6 in.) 5 mm (. in.) mm (.8 in.) 8 mm (7. in.) 5 mm (9.9 in.) # CCM40E040 CCM40P040 50 mm (9.8 in.) 476 mm (8.8 in.) 5 mm (. in.) mm (.8 in.) 5 mm (4.9 in.) 78 mm (7.0 in.) # 65 mm (6 / in.) E 40 mm (5 / in.) A B A B 6.5 mm (/4 in.) D C F I G U R E # NTS. FIGURE # NTS. Page 4

CCM INPUT CONNECTIONS OPTIONAL INPUTS SHOWN Gnd LED C ircuit gro und 4 Vac when 4 Remove jumper when interlock is used 5 Optional 5 ohm potentiometer 6 7 8 Optional setpoint -0Vdc or 4-0ma using a 500 ohm resistor Optional 500 ohm watt resistor 9 0 Optional 700 ohm resistor Small Open Frame & Enclosed Versions Figure # OPTIONAL INPUTS SHOWN Gnd LED Case ground (green wire) Gnd LED Case ground (green wire) 4 Vac when 4 Vac when Interlock Optional 5 ohm potentiometer 4 5 6 7 8 Remove jumper whe n interlock is used 4 5 6 Remove jumper when interlock is used (small version) Remove jumper whe n interlock is used (large version) 9 0-8 kpa (- psi) Pressure transd ucer -0Vdc or 4-0ma using a 500 ohm resistor Optional 500 ohm watt resistor Optional 700 ohm resistor Large- Enclosed Version Pneumatics Inputs Figure #4 Figure #5 Page 5

CCM POWER CONNECTIONS SINGLE PHASE POWER CONNECTIONS LINE LOAD Magnetic contactor where by local codes manual reset auto reset HEATER (load) Fused disconnect Transformer if A.C. Line FIGURE #6 PHASE, WIRE POWER CONNECTIONS PHASE, 4 WIRE POWER CONNECTIONS LINE LOAD LINE LOAD N N Magnetic contactor where by local codes Magnetic contactor where by local codes manual reset manual reset auto reset auto reset Transformer if Transformer if HEATER (load) Fused disconnect Fused disconnect HEATER (load) A.C. Line FIGURE #7 A.C. Line FIGURE #8 Page 6

CCM POWER CONNECTIONS (Con t) LARGE UNITS ONLY In order to provide proper voltage to the control circuit board and/or cooling fan, first determine the Line to Line service voltage and connect the lead(s) to the appropriate terminal(s) as outline below. These units are factory w ired for the highest specified voltage range show n on the device name plate. For pow er connections to loads see figures 6,7 & 8. * Warning: if the s erv ic e v oltage is low er than the voltage show n on the name plate, reconnect selection flylead to the correct terminal as determined from the charts below. Do not use voltages higher than the nameplate rating. Power Terminal Block * Service Range Line to Line 600-46 45-89 88-00 Typical Service Line to Line 480/600 47/80/45 08/40/77 Connect to Tap Prim ary 50/60 Hz Se condary Control Circuit Board com. Transformer Connections Without Fan FIGURE #9 50/60 Hz * Service Range Line to Line Typical Service Line to Line Connect To Tap Prim ary Se condary 600-55 600-6 Power Terminal Block * 55-505 504-457 456-409 408-6 60- - 480 45 80/400 47-5 -4-6 -5-4 4 5 Control Circuit Board and/or Cooling Fan -65 64-7 77 40-6 -5 6 6-98 08-4 Transformer Connections With Cooling Fan FIGURE #0 Page 7

MASTER/SLAVE OPERATION BEFORE INSTALLATION Carefully read and fully understand the installation guide enclosed with all CCM current valves and ensure the power is disconnected before working inside the device. Ensure the service voltages and load currents are within those stated on the device nameplate ratings and mount the current valves following the instructions in the installation guide. OPERATION To control two separate loads with only one control signal the CCM series current valves may be used in conjunction with CCM0S045 slave relay module. Any standard unit from the CCM series can control one slave module which in turn operates a separate load. The CCM0S045 can switch single phase loads up to 45 Amps. The Master unit operates in a time proportioned mode controlled by the input signal ( 0 Vdc, 5 Ohm Potentiometer, or 700 Ohm Thermistor) to switch the load on or off. The Slave unit duplicates the switching operation of the Master, needing only a -wire connection to the Master. This configuration will prove advantageous in both new and retrofit applications because of the reduction in the number of control circuits and wiring needed. WIRING Terminal (+) and (-) on Slave units are connected to the interlock terminals (+) and 4 (-) on the Master unit. Remove the factory installed jumper. AC Line Neutral Single Phase Load AC Line Hot Side AC Line Neutral Single Phase Load AC Line Hot Side T T T L CCM0S045 Slave (-) (+) 4 8 0 L L CCM0E045 Master Slave control signal (remove interlock from master) -0 Vdc Control Signal Page 8