Compact SCR Power Controller

EPack Lite Two Phase

HA033172 Issue 3
05/2019
 EPack

2
EPack

Legal Information
The information provided in this documentation contains general descriptions and/or
technical characteristics of the performance of the products contained herein. This
documentation is not intended as a substitute for and is not to be used for
determining suitability or reliability of these products for specific user applications. It
is the duty of any such user or integrator to perform the appropriate and complete risk
analysis, evaluation and testing of the products with respect to the relevant specific
application or use thereof. Eurotherm Limited, Schneider Electric or any of its
affiliates or subsidiaries shall not be responsible or liable for misuse of the
information contained herein.

If you have any suggestions for improvements or amendments or have found errors
in this publication, please notify us.

You agree not to reproduce, other than for your own personal, non-commercial use,
all or part of this document on any medium whatsoever without permission of
Eurotherm Limited, given in writing. You also agree not to establish any hypertext
links to this document or its content. Eurotherm Limited does not grant any right or
license for the personal and non-commercial use of the document or its content,
except for a non-exclusive license to consult it on an "as-is" basis, at your own risk.
All other rights are reserved.

All pertinent state, regional, and local safety regulations must be observed when
installing and using this product. For reasons of safety and to help ensure compliance
with documented system data, only the manufacturer should perform repairs to
components.

When devices are used for applications with technical safety requirements, the
relevant instructions must be followed.

Failure to use Eurotherm Limited software or approved software with our hardware
products may result in injury, harm, or improper operating results.

Failure to observe this information can result in injury or equipment damage.

Eurotherm, EurothermSuite, ECAT, EFit, EPack, EPower, Eycon, Eyris, Chessell,

Mini8, nanodac, optivis, piccolo and versadac are trademarks of Eurotherm Limited
SE, its subsidiaries and affiliated companies. All other trademarks are the property of
their respective owners.

© 2019 Eurotherm Limited. All rights reserved.

HA033172 Issue 3 3
Table of Contents EPack

Table of Contents
Table of Contents ...............................................................................4
Safety Information ..............................................................................8
Important Information................................................................................... 8
Safety Notes ......................................................................................9
Reasonable use and responsibility .............................................................11
SELV ................................................................................................................ 12
Symbols Used in the Instrument Labeling........................................................ 13
Hazardous Substances .................................................................................... 13
Cybersecurity ................................................................................................... 14
Introduction ................................................................................................ 14
Cybersecurity Good Practices ................................................................... 14
Introduction ......................................................................................15
Unpacking the Units ......................................................................................... 15
Order Code ...................................................................................................... 16
Software Upgrade Options......................................................................... 18
Installation ........................................................................................20
Mechanical Installation..................................................................................... 20
Mounting details......................................................................................... 20
Mechanical installation requirements......................................................... 22
Mounted clearance dimensions ................................................................. 23
Bulkhead Mounting .............................................................................. 23
DIN Rail Mounting................................................................................ 26
Dimensions ................................................................................................ 27
16A to 32A unit dimensions ................................................................. 27
40A to 63A unit dimensions ................................................................. 28
80A to 100A unit dimensions ............................................................... 29
125A unit dimensions........................................................................... 30
Summary - all units (16A - 125A) ......................................................... 31
Electrical Installation ........................................................................................ 32
Connection Details..................................................................................... 33
Auxiliary supply .......................................................................................... 37
24V ac/dc auxiliary supply ................................................................... 37
85 to 550Vac auxiliary supply .............................................................. 37
Connections (Supply Power and Load) ..................................................... 39
16A to 32A and 40A to 63A Units ......................................................... 41
......................................................................................................................... 41
Load Configurations................................................................................... 43
Delta .................................................................................................... 43
Star ...................................................................................................... 44
Signal wiring............................................................................................... 45
Firing Enable........................................................................................ 45
Alarm Acknowledge ............................................................................. 45
Main Setpoint ....................................................................................... 45
Relay Output ........................................................................................ 45
I/O Input & Output Details .................................................................... 47
Fuse Holders Contact Data (Fuse Ordering Code HSM)..................... 48
Operator Interface ............................................................................51
Display ............................................................................................................. 51
Status area................................................................................................. 51
Softkey icons.............................................................................................. 52
Pushbuttons ..................................................................................................... 53
Pushbutton functions ................................................................................. 53
Menu item value selection ......................................................................... 53

4 HA033172 Issue 3
EPack Table of Contents

Front Panel Event Indication ............................................................................ 54

Instrument events ...................................................................................... 54
Indication alarms........................................................................................ 54
System alarms ........................................................................................... 54
Process alarms .......................................................................................... 54
Quickcode ........................................................................................55
Quickcode Menu Parameters Description........................................................ 56
Firing modes definitions ............................................................................. 57
Logic .................................................................................................... 57
Burst Fixed Firing................................................................................. 57
Burst Variable Firing............................................................................. 58
Feedback type ........................................................................................... 59
Chop Off Definition............................................................................... 59
Configuration from the Front Panel ..................................................61
Menu Pages ..................................................................................................... 62
Meas menu ................................................................................................ 63
Adjust menu ............................................................................................... 64
Examples ................................................................................................... 66
Safety Ramps, Soft Start and Delayed Trigger, firing types................. 66
PLF menu .................................................................................................. 67
Info menu ................................................................................................... 68
Alarms menu.............................................................................................. 69
Alm Disable menu...................................................................................... 70
Alm Latch Menu ......................................................................................... 71
Alm Stop menu .......................................................................................... 72
Alm Relay menu......................................................................................... 73
DI Stat menu .............................................................................................. 74
PLF Adjust menu........................................................................................ 74
Settings menu ............................................................................................ 75
Access menu ............................................................................................. 76
Alarms ..............................................................................................78
Global System Monitoring ................................................................................ 78
System Alarms ................................................................................................. 79
Missing mains ............................................................................................ 79
Thyristor short circuit.................................................................................. 79
Over temperature....................................................................................... 79
Network dips ............................................................................................. 79
Mains frequency fault detected .................................................................. 79
Chop Off alarm........................................................................................... 79
Process Alarms ............................................................................................... 80
Total Load Failure (TLF) ............................................................................ 80
Closed Loop alarm..................................................................................... 80
Alarm input................................................................................................. 80
Over current detection ............................................................................... 80
Over Voltage Alarm .................................................................................... 80
Under Voltage Alarm .................................................................................. 80
Partial Load Failure (PLF).......................................................................... 81
Indication Alarms ............................................................................................. 81
Load Over-Current ..................................................................................... 81
Maintenance ....................................................................................83
Precautions ...................................................................................................... 83
Reasonable use and responsibility ............................................................ 83
Preventive Maintenance................................................................................... 84
Fusing .............................................................................................................. 85
Fuses Holders Contacts Kit ................................................................. 87
Fuse holder dimensions............................................................................. 88
Auxiliary supply fuse protection ........................................................... 91
Instrument upgrade .......................................................................................... 93
Software upgrade....................................................................................... 93

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Table of Contents EPack

Obtaining a Passcode via Telephone................................................... 93

EPack Licence Notice ................................................................................ 94
Technical Specification .....................................................................96
Standards......................................................................................................... 96
Installation Categories ............................................................................... 97
Specification..................................................................................................... 97
Power (at 45°C) ................................................................................... 97
Physical ............................................................................................... 99
Environment......................................................................................... 99
Operator Interface.............................................................................. 102
Inputs/Outputs ................................................................................... 102
Digital Inputs ...................................................................................... 103
Relay Specification ............................................................................ 104
Fuse Holders Contacts Kit Specification............................................ 104
Mains Network Measurements .......................................................... 105

6 HA033172 Issue 3
EPack Table of Contents

HA033172 Issue 3 7
Safety Information EPack

Safety Information

Important Information
Read these instructions carefully and look at the equipment to become familiar with
the device before trying to install, operate, service, or maintain it. The following
special messages may appear throughout this manual or on the equipment to warn of
potential hazards or to call attention to information that clarifies or simplifies a
procedure.

The addition of either symbol to a “Danger” or “Warning” safety label

indicates that an electrical hazard exists which will result in personal
injury if the instructions are not followed.

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

W DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.

W WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

W CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.

NOTICE
NOTICE is used to address practices not related to physical injury.

8 HA033172 Issue 3
EPack Safety Notes

Safety Notes
W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See
applicable national standards e.g. NFPA70E, CSA Z462, BS 7671, NFC 18-510.

• This equipment must only be installed and serviced by qualified electrical personnel.

• Refer to manual for installation and servicing.

• The product is not suitable for isolation applications, within the meaning of EN60947-1. Turn off all power
supplying this equipment before working on the loads of the equipment.

• Turn off all power supplying this equipment before working on equipment.

• Always use a properly rated voltage sensing device to confirm power is off.

• If on receipt, the unit or any part within is damaged, do not install but contact your supplier.

• Do not disassemble, repair or modify the equipment. Contact your supplier for repair.

• This product must be installed, connected and used in compliance with prevailing standards and/or
installation regulations.

• Do not exceed the device's ratings.

• The unit must be installed in an enclosure or cabinet connected to the protective earth ground.

• Electrically conductive pollution must be excluded from the cabinet in which the product is mounted.

• Do not allow anything to fall through the case apertures and ingress the product.

• Before any other connection is made, the protective earth ground terminal must be connected to a protective
conductor.

• Protective conductor must be sized in compliance with local and national regulatory requirements.

• Tighten all connections in conformance with the torque specifications. Periodic inspections are required.

• High speed fuses (supplemental fuses in addition to branch circuit protective device), as listed in fusing
sections, are mandatory to protect EPack Lite against load short circuit.

• If opening of either the branch circuit protective device or the high-speed fuses (supplemental fuses) occurs,
the product must be examined by suitably qualified personnel and replaced if damaged.

• A High-speed fuse (supplemental fuses in addition to branch circuit protective device) or a double protection
fuse as listed in fusing sections is mandatory for 85Vac to 550Vac auxiliary supply.

• If opening of any fuses or branch circuit protection device that supply the 85Vac to 550Vac auxiliary supply
occurs, first check the wiring. If the wiring is not damaged, do not replace the fuse and contact the
manufacturer's local service center.

• The maximum voltage between any pole of the 85Vac to 550Vac auxiliary supply and all other terminals must
be lower than 550Vac.

• The “24V auxiliary supply” is an SELV circuit. The supply Voltage must be derived from a SELV or PELV
circuit.

• The I/O Input & Output, the Communications ports are SELV circuit. They must be connected to SELV or
PELV circuit.
Failure to follow these instructions will result in death or serious injury.

HA033172 Issue 3 9
Safety Notes EPack

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• The relay output and the fuse holders contacts are compliant to the SELV requirements; they can be
connected to SELV, PELV circuit or to voltage up to 230V (maximum value of rated operational voltage to
earth:230V)

• Ensure all cables and wiring harness are secured using a relevant strain relief mechanism.

• Respect electrical installation requirements to ensure optimum IP rating.

• Replace doors and plug-in terminals before turning on power to this equipment.

• Use appropriate safety interlocks where personnel and/or equipment hazards exist.
Failure to follow these instructions will result in death or serious injury.

W DANGER
HAZARD OF FIRE
• Product current rating must be greater than or equal to the maximum current of the load.

• This product does not contain any branch-circuit protection, the installer must add branch-circuit protection
upstream of the unit.

• Branch circuit protection must be selected according to maximum current in each phase and must be rated in
compliance with local and national regulatory requirements.

• Power connections: The cables must be rated 90°C stranded copper only, the cross section must be selected
according to the branch circuit protection rating.

• The cables used to connect the EPack Lite’s auxiliary supply and voltage reference must be protected by
branch-circuit protection. Such branch-circuit protection must comply with local and national regulatory
requirements.

• Connection of two conductors in the same terminal is not permitted, partial or total loss of connection may
create an overheat of the terminals.

• The conductor stripping length must be as stated in electrical installation.

• Respect mechanical installation requirements to allow heatsink to dissipate power.

• At commissioning ensure that under maximum load condition, the ambient temperature of the product will not
exceed the limit stated in that manual.

• Heat-sink must be cleaned regularly. Periodicity depends on the local environment, but should not exceed 1
year.
Failure to follow these instructions will result in death or serious injury.

10 HA033172 Issue 3
EPack Safety Notes

W WARNING
UNINTENDED EQUIPMENT OPERATION
• Do not use the product for critical control or protection applications where
human or equipment safety relies on the operation of the control circuit.

• Signal and power voltage wiring must be kept separate from one another.
Where this is impractical, all wires must be rated to the power voltage &
shielded cables are recommended for signal wiring.

• This product has been designed for environment A (Industrial). Use of this
product in environment B (domestic, commercial and light industrial) may
cause unwanted electromagnetic disturbances in which cases the installer
may be required to take adequate mitigation measures.

• For Electromagnetic Compatibility, panel or DIN rail to which product is

attached must be grounded.

• Observe all electrostatic discharge precautions before handling the unit.

• Nominal current of product must be set between 25% & 100% of maximum
current.

• At commissioning, ensure cybersecurity robustness of the installation.

Failure to follow these instructions can result in death, serious injury or
equipment damage.

W CAUTION
HOT SURFACE RISK OF BURNS
• Allow heatsink to cool before servicing.

• Do not allow flammable or heat-sensitive parts in the immediate vicinity of

heatsink.
Failure to follow these instructions can result in injury or equipment
damage.

Reasonable use and responsibility

The information contained in this manual is subject to change without notice. While
every effort has been made to ensure the accuracy of the information, your supplier
shall not be held liable for errors contained herein.

EPack Lite is an “AC semiconductor controller for non-motor loads” designed

according to IEC60947-4-3 & UL60947-4-1, it meets the requirements of the Low
voltage and EMC European Directives which covers safety and EMC aspects.

Use in other applications, or failure to observe the installation instructions of this

manual may impair safety or EMC.

The safety and EMC of any system incorporating this product is the responsibility of
the assembler/installer of the system.

Failure to use approved software/hardware with our hardware products may result in
injury, harm, or improper operating results

HA033172 Issue 3 11
Safety Notes EPack

Eurotherm shall not be held responsible for any damage, injury, losses or expenses
caused by inappropriate use of the product (EPack Lite), or failure to comply with
these instructions.

SELV
SELV is defined (in IEC60947-1) as an electrical circuit in which the voltage cannot
exceed 'ELV' under normal conditions or under single fault conditions, including earth
ground faults in other circuits. The definition of ELV is complex as it depends on
environment, signal frequency, etc. See IEC 61140 for further details.

The I/O connector (5-way) & auxiliary supply (24V ac/dc, 2-way) are compliant to the
SELV requirements.

The alarm relay output and the fuse holder contacts are compliant with the SELV
requirements; they can be connected to SELV or to voltage up to 230V (Rated
insulation voltage Ui: 230V).

12 HA033172 Issue 3
EPack Safety Notes

Symbols Used in the Instrument Labeling

One or more of the symbols below may appear as a part of the instrument labeling.

Risk of electric shock

Protective conductor terminal

Precautions against static electrical

AC supply only
discharge must be taken when handling this
unit.
Underwriters laboratories listed
!
Refer to the manual for instructions
mark, for Canada and the U.S.

Do not touch heatsink Hot CE Mark. Indicates compliance with the

Surface appropriate European Directives and
Standards
EAC (EurAsian Conformity) Regulatory Compliance Mark (RCM) to
customs union mark of Australian Communication and Media
conformity Authority

Hazardous Substances
This product conforms to European Restriction of Hazardous Substances (RoHS)
(using exemptions) and Registration, Evaluation, Authorisation and Restriction of
Chemicals (REACH) Legislation.

RoHS Exemptions used in this product involve the use of lead. China RoHS legislation
does not include exemptions and so lead is declared as present in the China RoHS
Declaration.

Californian law requires the following notice:

WWARNING: This product can expose you to chemicals including lead and lead
compounds which are known to the State of California to cause cancer and birth
defects or other reproductive harm. For more information go to:
http://www.P65Warnings.ca.gov

HA033172 Issue 3 13
Safety Notes EPack

Cybersecurity

Introduction
When utilizing EPack Lite controllers’ range in an industrial environment, it is
important to take ‘cybersecurity’ into consideration: in other words, the installation’s
design should aim to prevent unauthorized and malicious access. This includes
physical access (for instance via the front fascia).

WARNING
UNINTENDED EQUIPMENT OPERATION
• At commissioning, ensure cybersecurity robustness of the installation.
Failure to follow these instructions can result in death, serious injury or
equipment damage.

To minimize any potential loss of control when communicating across a network via a
third-party device (i.e. controller, PLC or configuration tool), ensure all system
hardware, software and network design are correctly configured and commissioned
for maximum cybersecurity robustness.

Cybersecurity Good Practices

Overall design of a site network is outside the scope of this manual. The
Cybersecurity Good Practices Guide, Part Number HA032968 provides an overview
of principles to consider. This is available from www.eurotherm.co.uk.

14 HA033172 Issue 3
EPack Introduction

Introduction
This document describes the installation, operation and configuration of a 2 phase
EPack Lite Power Controller.The unit includes the following analog and digital inputs
and outputs, fitted as standard:

• Two digital inputs (contact closure or voltage level), of which one of the digital
inputs can be configured as 10V user output.

• One analog input.

• One change-over relay under software control, configurable by the user.

Chapter Installation provides details on connector locations and pinouts.

The operator interface consists of a 1.44 inch square TFT display and four
pushbuttons for navigation and data selection.

The 2 phase EPack Lite comes in four versions with maximum load currents of: 32A,
63A, 100A and 125A.

The supply voltage for the units can be specified as either low voltage (24V ac/dc) or
line voltage (85 to 550V ac). The choice is made at time of order and cannot be
changed in the field.

Unpacking the Units

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• If on receipt, the unit or any part within is damaged, do not install but contact
your supplier.
Failure to follow these instructions will result in death or serious injury.

The units are despatched in a special pack, designed to give adequate protection
during transit. If any of the outer boxes show signs of damage, open them
immediately and examine the instrument. If there is evidence of damage, do not
operate the instrument and contact your local representative for instructions.

After the instrument has been removed from its packing, examine the packing to
ensure that all accessories and documentation have been removed. Then store the
packing for future transport requirements.

HA033172 Issue 3 15
Introduction EPack

Order Code
EPack Lite power controller is ordered using a short code for hardware and
chargeable software options code.

W DANGER
HAZARD OF FIRE
• Product current rating must be greater than or equal to the maximum current
of the load.
Failure to follow these instructions can result in death, serious injury or
equipment damage.

Calculate the maximum current of the load by taking account of load resistive
tolerance (tolerance and variation due to temperature) and voltage tolerance.

16 HA033172 Issue 3
EPack Introduction

Basic Product Coding

HA033172 Issue 3 17
Introduction EPack

Software Upgrade Options

18 HA033172 Issue 3
EPack Introduction

HA033172 Issue 3 19
Installation EPack

Installation
Mechanical Installation

Mounting details

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See applicable national standards e.g. NFPA70E,
CSA Z462, BS 7671, NFC 18-510.

• This equipment must only be installed and serviced by qualified electrical

personnel.

• Turn off all power supplying this equipment before working on equipment.

• Always use a properly rated voltage sensing device to confirm power is off.

• If on receipt, the unit or any part within is damaged, do not install but contact
your supplier.

• Do not disassemble, repair or modify the equipment. Contact your supplier for
repair.

• This product must be installed, connected and used in compliance with

prevailing standards and/or installation regulations.

• Do not exceed the device's ratings.

Failure to follow these instructions will result in death or serious injury.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• The unit must be installed in an enclosure or cabinet connected to the
protective earth ground.
Failure to follow these instructions will result in death or serious injury.

Notes:
1. CE: protective earth ground minimum size must be selected according to IEC
60364-5-54 table 54.2 or IEC61439-1 table 5 or applicable national standards.
2. U.L.: protective earth ground minimum size must be selected according to NEC
table 250.122 or NFPA79 table 8.2.2.3 or applicable national standards.

20 HA033172 Issue 3
EPack Installation

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Electrically conductive pollution must be excluded from the cabinet in which
the product is mounted.
Failure to follow these instructions will result in death or serious injury.

Notes:
1. The product has been designed for pollution degree 2 according to IEC60947-1
definition: Normally, only non-conductive pollution occurs. Occasionally, however,
a temporary conductivity caused by condensation may be expected.
2. Electrically conductive pollution must be excluded from the cabinet in which the
product is mounted. To ensure a suitable atmosphere in conditions of conductive
pollution, fit adequate air conditioning/filtering/cooling equipment to the air intake
of the cabinet, e.g. fitting fan-cooled cabinets with a fan failure detection device
or a thermal safety cut-out.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Do not allow anything to fall through the case apertures and ingress the
product.
Failure to follow these instructions will result in death or serious injury.

Note: Conductive or non-conductive parts which ingress the product may reduce or
short circuit the insulation barriers inside the product.

W WARNING
UNINTENDED EQUIPMENT OPERATION
• Observe all electrostatic discharge precautions before handling the unit.
Failure to follow these instructions can result in death, serious injury or
equipment damage.

HA033172 Issue 3 21
Installation EPack

Mechanical installation requirements

W DANGER
HAZARD OF FIRE
• Respect mechanical installation requirements to allow heatsink to dissipate
power.
Failure to follow these instructions can result in death or serious injury.

Notes:
1. The product is designed to be mounted vertically.
2. There must be no obstructions (above or below) which could reduce or hamper
airflow.
3. If more than one instance of the product is in the same cabinet, they must be
mounted in such a way that air from one unit is not drawn into another.
4. The gap between two EPack Lite devices must be at minimum 10mm.
5. The gap between EPack Lite and cable tray must be at least those defined in the
table in Mounted clearance dimensions.

W DANGER
HAZARD OF FIRE
• At commissioning ensure that under maximum load condition, the ambient
temperature of the product will not exceed the limit stated in that manual.
Failure to follow these instructions can result in death or serious injury.

Notes:
1. EPack Lite has been designed for a maximum temperature of 45°C (113°F) at
1000m (3281ft) altitude at nominal current & 40°C (104°F) at 2000m (6562ft)
altitude at nominal current.
2. At commissioning ensure that the ambient temperature inside the cabinet does
not exceed the limit under maximum load condition.

W DANGER
HAZARD OF FIRE
• Heat-sink must be cleaned regularly. Periodicity depends on the local
environment, but should not exceed 1 year.
Failure to follow these instructions can result in death or serious injury.

W CAUTION
HOT SURFACE RISK OF BURNS
• Do not allow flammable or heat-sensitive parts in the immediate vicinity of
heatsink.
Failure to follow these instructions can result in injury or equipment
damage.

22 HA033172 Issue 3
EPack Installation

Mounted clearance dimensions

Phase: 2 phase

Amps: 16 - 32A 40 - 63A 80 - 100A 125A

EPack Lite clearance

dimensions mm (inches):

between cable tray and 70 (2.76) 100 (3.94) 150 (5.91) 150 (5.91)
EPack Lite

between two cable trays 306 (12.05) 366 (14.41) 530 (20.87) 530 (20.87)

between or side by side 10 (.39) 10 (.39) 10 (.39) 10 (.39)

another EPack Lite

Figures 4 to 7 show dimensions for the various units.

The units are designed for DIN Rail or bulkhead mounting using the mounting fixings
supplied.

Bulkhead Mounting

32A and 63A Units

For Bulkhead mounting, fit the upper bracket ‘A’ to the rear of the unit by removing
screw ‘B’ x2 and associated shakeproof washers, offering the bracket up to the unit,
and then securing it by installing x2 screw ‘B’ ensuring that the bracket is correctly
oriented (as shown) and that the shakeproof washers are fitted between the screw
head and the bracket.

HA033172 Issue 3 23
Installation EPack

Use a screwdriver with a 3mm AF hexagonal bit. The recommended tightening

torque is 1.5 Nm (1.1 lb-ft). To mount, secure using x2 M5 screws and shakeproof
washers using the top and bottom mount points.

Figure 1 Fitting upper bulkhead mounting bracket (32A unit shown; 63A units similar)

24 HA033172 Issue 3
EPack Installation

80A, 100A and 125A Units

For bulkhead mounting, brackets ‘A’ and ‘B’ on the rear of the unit are used to mount
the product. Secure using x3 M6 screws and shakeproof washers using the top and
bottom mount points.

Figure 2 Bulkhead mounting 80A/100A unit shown (125A similar)

HA033172 Issue 3 25
Installation EPack

DIN Rail Mounting

32A and 63A Units

The 32A and 63A units can be mounted using two horizontal, parallel, 7.5mm or
15mm DIN rails. Locate the upper mounting hooks ‘A’ (×2) on the upper DIN rail ‘B’.
To secure the unit against the lower DIN rail ‘C’, slide the lower mounting catches ‘D’
(×2) upwards and tighten the mounting screws ‘E’ (x2) to the recommended
tightening torque of 3Nm (2.2lb ft).

A
A

160mm ±3
(6.29 inches)

125mm ±3
(4.92 inches)

D Slide up
D

Figure 3 DIN rail mounting (32A unit shown; 63A units similar)

80A, 100A and 125A Units

The higher power units cannot be mounted using any type of DIN rail configuration
due to the size and relative mass.

See "Bulkhead Mounting" on page 23 for further details.

26 HA033172 Issue 3
EPack Installation

Dimensions

16A to 32A unit dimensions

EPack (auxiliary) supply power (low Not connected

voltage option shown)

View on
upper face

Power mains line (2 Phases)

Voltage reference
connected to Line3

Front view

View on
right-hand side

Load power outputs

Protective earth
ground connection
(M6 nut).
The protective earth
ground connection
I/O connector must be made using
View on a listed ring type
lower face crimp.

Relay output

Figure 4 Mechanical installation details (16A to 32A units)

HA033172 Issue 3 27
 Installation EPack

40A to 63A unit dimensions

EPack (auxiliary) supply power (low

voltage option shown)
Not connected

90.5 mm
(3.56 in)
(3.15 in)

(3.15 in)
80 mm

80 mm
View on upper

AC/DC
24V
face C
L

N/L2
202.1 mm (7.96 in)
Power mains line (2 phases)
46.7mm (1.84 in)
Voltage reference
connected to Line3

1/L1

Front view
321.23 mm (12.65 in)

231.00 mm (9.09 in)

218.25 mm (8.59 in)

175.46 mm (6.91 in)

197.6 mm (7.78 in)

182 mm (7.17 in)

View on
right-hand side

2/T1

Load power output

Protective earth ground connection

I/O connector (M6 nut).
130.50 mm (5.14 in) The protective earth ground
connection must be made using a
View on Listed ring type crimp.
lower face 1 2 3 4 5
(3.15 in)

Relay output
80 mm

04 01 02

Figure 5 Mechanical installation details (40A to 63A units)

28 HA033172 Issue 3
 EPack Installation

80A to 100A unit dimensions

EPack (auxiliary) supply power (low
voltage option shown)
Not connected

View on
upper face

Voltage reference
Connected to Line3 Power mains line (2 Phases)
Wire guide
Power mains line
(2 places)
terminals screw head

Door
catch

Front View

Right-hand side
View

Door catch

Wire guide
Load power output
(2 places)
terminals screw head

Protective earth ground

connection (M6 nut).

Load power outputs

Note: The Protective earth ground connection
must be made using a listed ring type crimp.

View on lower
face

Wall Bracket

I/O connector
Relay output

Figure 6 Mechanical installation details (80A to 100A units) (doors open).

HA033172 Issue 3 29
Installation EPack

125A unit dimensions

EPack (auxiliary) supply power (low

voltage option shown) Power mains line (2 Phases)
Not connected

View on
upper face
Voltage reference
connected Line3

Wire guide Power mains line

(2 places) terminals screw head

Door catch

Front View

Right-hand side
View

Wire guide Load power output

(2 places) terminals screw head Door catch

Load power outputs Protective earth ground

connection (M6 nut).

View on lower Note: The protective earth ground connection

face must be made using a listed ring type crimp.

Wall bracket

I/O connector

Relay output

Figure 7 Mechanical installation details (125A units) (Doors open).

30 HA033172 Issue 3
EPack Installation

Summary - all units (16A - 125A)

Phase 2 phase

Amps: 16 - 32A 40 - 63A 80 - 100A 125A

Dimensions mm (inches)

Height 166 (6.535) 166 (6.535) 230 (9.055) 230 (9.055)

with Double DIN Rail 213.5 (8.405) 213.5 (8.405) N/A1 N/A1

with Wall back plate 229.5 (9.035) 229.5 (9.035) 291 (11.456) 291 (11.456)

Doors open 290 (11.417) 290 (11.417) 310 (12.204) 310 (12.204)

Depth 185 (7.283) 220 (8.661) 235 (9.251) 235 (9.251)

with Wall back plate 192 (7.559) 227 (8.937) 242 (9.527) 242 (9.527)

with doors open N/A2 N/A2 325 (12.795) 325 (12.795)

Width 117 (4.606) 117 (4.606) 160 (6.299) 240 (9.448)

with doors open 242 (9.527) 242 (9.527) N/A3 N/A3

Wall mount fixings

Distance apart:

Medium mount 219 (8.622) 219 (8.622) - -

Large mount - - 277 (10.905) 277 (10.905)

Double DIN Rails 125 ±3 125 ±3 - -

(4.921 ±0.12) (4.921 ±0.12)

Distance between top, two

mounting fixings:

Large mount - - 60 (2.362) 60 (2.362)

HeatSink Depth 55 (2.165) 90 (3.543) 97 (3.818) 130 (5.118)

1. Not applicable, double DIN rail option not available.

2. Not applicable, doors open sideways increasing only the width.
3. Not applicable, doors open vertically (up or down) towards the center of the product increasing only the depth.

HA033172 Issue 3 31
Installation EPack

Electrical Installation
W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See applicable national standards e.g. NFPA70E,
CSA Z462, BS 7671, NFC 18-510.

• This equipment must only be installed and serviced by qualified electrical

personnel.

• Turn off all power supplying this equipment before working on equipment.

• Always use a properly rated voltage sensing device to confirm power is off.

• If on receipt, the unit or any part within is damaged, do not install but contact
your supplier.

• Do not disassemble, repair or modify the equipment. Contact your supplier for
repair.

• This product must be installed, connected and used in compliance with

prevailing standards and/or installation regulations.

• Do not exceed the device's ratings.

Failure to follow these instructions will result in death or serious injury.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Do not allow anything to fall through the case apertures and ingress the
product.
Failure to follow these instructions will result in death or serious injury.

Note: Conductive or non-conductive parts which ingress product may reduce or

short the insulations barriers inside the product.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Ensure all cables and wiring harness are secured using a relevant strain relief
mechanism.
Failure to follow these instructions will result in death or serious injury.

Note: Wires may slip out of the terminals.

32 HA033172 Issue 3
EPack Installation

W WARNING
UNINTENDED EQUIPMENT OPERATION
• Observe all electrostatic discharge precautions before handling the unit.

• Signal and power voltage wiring must be kept separate from one another.
Where this is impractical, all wires must be rated to the power voltage &
shielded cables are recommended for signal wiring.

• For Electromagnetic Compatibility, panel or DIN rail to which product is

attached must be grounded.
Failure to follow these instructions can result in death, serious injury or
equipment damage.

Connection Details

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Before any other connection is made, the protective earth ground terminal
must be connected to a protective conductor.

• Protective conductor must be sized in compliance with local and national

regulatory requirements.
Failure to follow these instructions will result in death or serious injury.

The earth connection must be made by using a lug terminal of size as given in
Table 1, “Connection Details”. The cables must be rated 90°C stranded copper only.

• CE: The protective earth ground cable minimum size must be selected according
to IEC 60364-5-54 table 54.2 or IEC61439-1 table 5 or applicable national
standards. The protective earth ground connection must be made to the unit with
a ring type crimp terminal, using the nut and shakeproof washer supplied (M6 for
16A to 125A units).

• U.L.: The protective earth ground cable cross sectional area should be selected
according to NEC table 250.122 or NFPA79 table 8.2.2.3 or applicable national
standards. The protective earth ground connection must be made to the unit with
a U.L. listed ring type crimp terminal, using the nut and shakeproof washer
supplied (M6 for 16A to 125A units).

HA033172 Issue 3 33
Installation EPack

W DANGER
HAZARD OF FIRE
• Power connections: The cables must be rated 90°C stranded copper only, the
cross section must be selected according to the branch circuit protection
rating.
Failure to follow these instructions will result in death or serious injury.

CE: Wire conductor cross sections must comply with IEC 60364-5-52 or applicable
national standards

U.L.: Wire conductor cross sections must comply with NEC Table 310.15(B)(16)
(formerly Table 310.16) taking account of table 310.15(B)(2) for the ampacity
correction factors or NFPA79 Table 12.5.1 taking account of Table 12.5.5(a) for the
ampacity correction factors or applicable national standards.

Table 1, “Connection Details” gives details of tightening torques for the various supply
power and signal wiring connections.

34 HA033172 Issue 3
EPack Installation

Table 1: Connection Details

Terminals Terminal Capacity1 Wire Type Torque Comments

Product
Rating
mm2 AWG
Supply voltage 16A to 1.5mm2 to AWG 14 to Stranded 2Nm PZ2 or
(1/L1, 3/L2) 63A AWG 4 copper (18lb in) Flat-bladed
25mm2
and Rated screwdriver
Load supply 90°C 5.5 x 1.0mm
(2/T1, 4/T2) (194°F) (7/32in x 0.039in) or
6.5 x 1.2mm
(1/4in x 0.047in)
80A to 10mm2 to AWG 8 to 5.6Nm Flat-bladed
125A AWG 2/0 (50lb in) screwdriver
50mm2
5.5 x 1mm
(7/32in x 0.039in) or
6.5 x 1.2mm
(1/4in x 0.047in)
Protective earth ground 16A to M6 ring-type crimp 2.5Nm U.L.: Listed ring-type
63A terminal (22lb in) crimp terminal must be
used
80A to M6 ring-type crimp 5.6Nm U.L.: Listed ring-type
125A terminal (50lb in) crimp terminal must be
used
Voltage Reference (Vref) All 0.25mm2 AWG 24 to Stranded 0.56Nm Flat-bladed
(2-way) AWG 12 copper (5lb in) screwdriver
to 2.5mm2
Supply (24Vac/dc) Rated 3.5 x 0.6mm
(2-way) 75°C (1/8in x 0.0236in)
Supply (167°F)
(85V-550Vac)(3-way)
I/O connector (5-way)
Relay connector (3-way)

1. AWG (American Wire Gauge) for USA and Canada (according to cUL standard); section in mm² for IEC countries (according to IEC/EN
standard).

HA033172 Issue 3 35
Installation EPack

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Tighten all connections in conformance with the torque specifications. Periodic
inspections are required.
Failure to follow these instructions will result in death or serious injury.

See Table 1, “Connection Details”.

Wires are not properly retained in terminals with insufficient torque.

Insufficient torque may increase the contact resistance:

• The protective earth ground connection may be too resistive. In case of short
circuit between live parts and heatsink, the heatsink may reach a dangerous
voltage.

• The power terminals will overheat.

Excessive torque may damage the terminal.

W DANGER
HAZARD OF FIRE
• Connection of two conductors in the same terminal is not permitted.
Failure to follow these instructions will result in death or serious injury.

Partial or total loss of connection as a result of attempting to connect two or more

conductors in the same terminal results in an overheat of the terminals.

See Table 1, “Connection Details”.

36 HA033172 Issue 3
EPack Installation

Auxiliary supply
The auxiliary supply connections (to operate the EPack unit) are terminated using a
2-way (24V ac/dc version) or 3-way (85 to 550Vac version) connector, located on the
upper side of the unit, as shown in Figure 8 and Figure 9.

24V ac/dc auxiliary supply

W DANGER
HAZARD OF FIRE
• The cables used to connect the EPack Lite’s auxiliary supply and voltage
reference must be protected by branch-circuit protection. Such branch-circuit
protection must comply with local and national regulatory requirements.
Failure to follow these instructions will result in death or serious injury.

• CE: branch-circuit protection must be selected according to IEC 60364-4-43 or

applicable local regulations.

• UL: branch-circuit protection must be selected according to NEC article 210.20, it

is necessary for compliance with National Electric Code(NEC) requirements.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• The “24V auxiliary supply” is an SELV circuit. The supply Voltage must be
derived from a SELV or PELV circuit.
Failure to follow these instructions will result in death or serious injury.

SELV is defined (in IEC60947-1) as an electrical circuit in which the voltage cannot
exceed 'ELV' under normal conditions or under single fault conditions, including earth
ground faults in other circuits.

The definition of ELV is complex as it depends on environment, signal frequency, etc.

See IEC 61140 for further details.

85 to 550Vac auxiliary supply

W DANGER
HAZARD OF FIRE
• The cables used to connect the EPack Lite’s auxiliary supply and voltage
reference must be protected by branch-circuit protection. Such branch-circuit
protection must comply with local and national regulatory requirements.
Failure to follow these instructions will result in death or serious injury.

Branch circuit protection is mandatory to protect the cable used to connect the
auxiliary supply.

• CE: branch-circuit protection must be selected according to IEC 60364-4-43 or

applicable local regulations.

• UL: branch-circuit protection must be selected according to NEC article 210.20, it

is necessary for compliance with National Electric Code(NEC) requirements.

HA033172 Issue 3 37
Installation EPack

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• A High-speed fuse (supplemental fuses in addition to branch circuit protective
device) or a double protection fuse as listed in "Fusing" on page 85 is
mandatory for 85Vac to 550Vac auxiliary supply.
Failure to follow these instructions will result in death or serious injury.

This fuse is necessary to avoid the 85Vac to 550Vac auxiliary supply to emit flame or
molten element in case of breakdown of a component.

High-speed fuse (supplemental fuse) does not protect the wiring, they must be fitted
(in addition to branch circuit protective device).

Double protection fuse comprises a branch circuit fuse and a high-speed fuse.

Double protection fuses must be selected according to applicable national standards

Branch circuit protection fuses standards in USA/Canada differ from IEC standards
(e.g; Europe (CE)). Therefore:

• A fuse approved as branch circuit protection fuses in USA/Canada is not a

branch circuit in all countries where IEC standards apply (e.g; Europe (CE)).

• A fuse approved as branch circuit protection fuses in all countries where IEC
standards apply (e.g; Europe (CE)) is not a branch circuit in USA/Canada.

See tables in "Fusing" on page 85.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• If opening of any fuses or branch circuit protection device that supply the
85Vac to 550Vac auxiliary supply occurs, first check the wiring. If the wiring is
not damaged, do not replace the fuse and contact the manufacturer’s local
service center.
Failure to follow these instructions will result in death or serious injury.

If the wiring is not damaged a component inside the 85Vac to 550Vac auxiliary supply
is broken and product must go back to service center.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• The maximum voltage between any pole of the 85Vac to 550Vac auxiliary
supply and all other terminals must be lower than 550Vac.
Failure to follow these instructions will result in death or serious injury.

If the 85Vac to 550Vac auxiliary supply is supplied by a dedicated transformer the

phasing must be checked to avoid overvoltage.

38 HA033172 Issue 3
EPack Installation

Connections (Supply Power and Load)

W DANGER
HAZARD OF FIRE
• This product does not contain any branch-circuit protection, therefore the
installer must add branch-circuit protection upstream of the unit.

• Branch circuit protection must be selected according to maximum current in

each phase and must be rated in compliance with local and national regulatory
requirements.
Failure to follow these instructions will result in death or serious injury.

Branch circuit protection is mandatory to protect the wiring.

• CE: branch-circuit protection must be selected according to IEC 60364-4-43 or

applicable local regulations.

• UL: branch-circuit protection must be selected according to NEC article 210.20, it

is necessary for compliance with National Electric Code(NEC) requirements.

W DANGER
HAZARD OF FIRE
• Power connections: The cables must be rated 90°C stranded copper only, the
cross section must be selected according to the branch circuit protection
rating.
Failure to follow these instructions will result in death or serious injury.

CE: Wire conductor cross sections must comply with IEC 60364-5-52 or applicable
national standards

U.L.: Wire conductor cross sections must comply with NEC Table 310.15(B)(16)
(formerly Table 310.16) taking account of table 310.15(B)(2) for the ampacity
correction factors or NFPA79 Table 12.5.1 taking account of Table 12.5.5(a) for the
ampacity correction factors or applicable national standards.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• High speed fuses (supplemental fuses in addition to branch circuit protective
device), as listed in fusing sections, are mandatory to protect EPack Lite
against load short circuit.

• If opening of either the branch circuit protective device or the high-speed fuses
(supplemental fuses) occurs, the product must be examined by suitably
qualified personnel and replaced if damaged.
Failure to follow these instructions will result in death or serious injury.

See tables in "Fusing" on page 85.

HA033172 Issue 3 39
Installation EPack

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Respect electrical installation requirements to ensure optimum IP rating.
Failure to follow these instructions will result in death or serious injury.

Products are rated IP20 according to EN60529.

If the conductor stripping lengths of the power cables are longer than the
requirements, then IP20 is compromised.

If the conductor stripping lengths of the power cables are shorter than the
requirements there is a potential risk of total loss of connection. Wires may slip out of
the terminals.

If the breakaway features are removed for cables with diameter lower than 9mm then
IP20 rating is compromised and the product is rated at IP10.

W DANGER
HAZARD OF FIRE
• The conductor stripping length must be as stated in Electrical Installation.
Failure to follow these instructions will result in death or serious injury.

If the conductor stripping lengths of the power cables are shorter than the
requirements there is a potential risk of partial loss of connection which may create
an overheat of the terminals

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Replace doors and plug-in terminals before turning on power to this equipment
Failure to follow these instructions will result in death or serious injury.

If the upper and/or lower access door are open, then IP20 rating is compromised and
the products are rated at IP10.

40 HA033172 Issue 3
EPack Installation

16A to 32A and 40A to 63A Units

Figure 8 Supply power and Load connection details (16A to 63A units)

Power mains lines (2 phases) 63A units shown; 32A units similar

View on
Lift-up flaps upper face

Access to power mains

line terminals screw head

Pull-down flap
Access to load power output
terminals screw heads

Auxiliary power supply.

Specifiable at time
Protective earth ground of order as 24V
(M6 nut). Must be made Load power or 500V (shown below)
with a listed ring type output Not connected

Voltage reference
connected to Line3

Centre pin not

connected

HA033172 Issue 3 41
Installation EPack

80A, 100A and 125A units

Power mains lines (2 phases)

Pull-down flap
Access to power mains 125A unit shown; 100A & 80A units
line terminals screw head similar

View on
upper face

Lift-up flap

Access to load power output

Protective earth ground terminal screw head
(M6 nut). Must be made
with a listed ring type
crimp Auxiliary power supply.
Specifiable at time
Load power output of order as 24V
or 500V (shown below)
Not connected
Voltage reference
connected to Line3

Centre pin not

connected

Figure 9 Supply power and Load connection details (80A to 125A units)
.
See Figure 9 for basic wiring details.

EPack rating Exposed conductor length Remove terminal housing breakaway part? Cable diameter maximum
(Amps) mm (inch) mm (inch) cable diameter mm (inch)

16A to 63A 20 - 23 (0.79 - 0.91) Yes, for cables greater than 9 (0.35) 10.5 (0.41)

80A to 125A 20 - 23 (0.79 - 0.91) Yes, for cables greater than 9 (0.35) 17.5 (0.69)

Table 2: EPack cable connection specification

42 HA033172 Issue 3
 EPack Installation

Load Configurations

Delta

Closed Delta
High speed thyristor Phase 1
protection fuses
Phase 2
Phase 3

1/L1 2/T1
Phase 1 Isolating
devices

EPack auxiliary
Fuse
supply (low voltage Fuse
V 1/L1 3/L2
V3 option shown)
Vline Vline 3
3

Lo
ad

ad
Lo

Voltage reference
1

connected
to Line3
Load 2
3/L2 4/T2 2/T1 4/T2
Phase 2

Vline 2 V2
Phase 3

Load 3 Load 2 Load 1

Figure 10 2 phase Closed Delta wiring scheme/load configuration

HA033172 Issue 3 43
Installation EPack

Star

Star without Neutral

High speed thyristor Phase 1
protection fuses Phase 2
Phase 3

Isolating
Phase 1 1/L1 2/T1 devices
Fuse
EPack auxiliary
supply

Load 1
(low voltage Fuse
option shown) 1/L1 3/L2
Vline V
V3
Vline 3
Lo Voltage
ad
2

reference
ad

3
Lo

connected to
Phase 2 3/L2 4/T2
Line3 2/T1 4/T2

V2
Vline 2

Phase 3

Load 1 Load 2 Load 3

Figure 11 2 phase Star without neutral wiring scheme/load configuration

44 HA033172 Issue 3
EPack Installation

Signal wiring
Figure 12 shows the connector location, on the underside of the unit, for the digital
and analog inputs, and for the internal relay output.

Firing Enable
For the power module thyristors to operate, the Firing Enable must be enabled.

In the default configuration Digital input 1 is used to enable the firing and is
configured in contact closure type. Therefore, Firing Enable is achieved by shorting
pins 0V and DI1 of the I/O connector located on the underside of the unit (Digital
input 1).

QuickCode menu allows the user to select Digital input 2 to Enable Firing. Digital
input 2 is configured in contact closure type, therefore, Firing Enable is achieved by
shorting pins 0V and DI2 of the I/O connector located on the underside of the unit
(Digital input 2).

If none of them have been selected, firing is enabled internally.

Alarm Acknowledge
In the default configuration, shorting pins 0V and DI2 of the I/O connector located on
the underside of the unit (Digital input 2) acknowledges alarms. This can be done
also using DI1.

DI can be configured as a voltage input (if required), and in this case it requires a high
signal to be applied to DI with the relevant zero voltage connected to 0V.

Main Setpoint
In the default configuration, the analog input sets the main setpoint.

Relay Output
The relay is normally energized (Common and Normally Open pins shorted), and is
de-energized (Common and Normally Closed pins shorted) when active. In the
default configuration, the relay output is operated by the Fault detect ‘Custom Alarm’
becoming active.

By default, the Custom alarm is set up to be equivalent to ‘AnySystemAlarm’ which

becomes active if any ‘stop firing’ conditions, such as those listed below, is detected.

In configuration mode, it is also possible to configure the relay using the Alarm Relay
menu in the Operator Interface ().

1. Missing mains. Supply voltage line is missing.

2. Thyristor short circuita

HA033172 Issue 3 45
Installation EPack

3. Network dips. A reduction in supply voltage exceeding a configurable value

(VdipsThreshold), causes firing to be inhibited until the supply voltage
returns to a suitable value. VdipsThreshold represents a percentage
change in supply voltage between successive half cycles.
4. Freq out of range. The supply frequency is checked every half cycle, and if
the percentage change between successive half cycles exceeds a
threshold value (max. 5%), a Mains Frequency System Alarm is
generated.
5. Supply failure detected to EPack unit.
6. Chop Off (page 59)
7. Analog input over current. For mA inputs this alarm is active if there is too
high a current flowing through the shunt.
8. Line under voltage (of nominal voltage).
9. Line over voltage (of nominal voltage).
10. Over current (of nominal current).
The relay is de-energized temporarily then re-energized at start-up.

a. It is not possible to detect a thyristor short circuit when the unit is delivering
100% output power.

46 HA033172 Issue 3
EPack Installation

I/O Input & Output Details

Analog input 32A unit shown; other units

(Pins 1 and 2) similar
V or mA input
0 to 10V, 1 to 5V (see note 3)
2 to 10V, 0 to 5V
0 to 20 mA
4 to 20 mA

1 (0 V)
Digital inputs
(Pins 3, 4, and 5) Relay output
2 (+) View on
lower face 02
Contact input
3 (0 V)
800Ω to ∞ = open
0Ω to 450Ω = closed
01
4 (DI1)
451Ω to 799Ω = undefined
04
5 (DI2)
Voltage level inputs Pins:
11V to 30V, with >6mA to <30mA = high 02 = Normally connected
-3V to 5V, with >2mA to <30mA= low 01 = Common
or 04 = Normally open
5V to 11V with <2mA Switching characteristics
(resistive loads):
Digital Output (DI2) • Vmax: 264V RMS
User configurable output • Vmin: 5V dc
10.2v, with max. 10mA • Imax: 2A RMS
• Imax: 10mA

Figure 12 I/O details

Notes:

1. Diagram shows DI1 as a contact input and DI2 as a voltage level input.
2. DI1 can be configured as contact inputs or voltage inputs.
3. DI2 can be configured as contact inputs or voltage inputs or 10.2V output
(with max. 10mA).
4. Analog input type (Volts or mA) is selected in I/O Analog IP configuration.
When a mA range is selected, a suitable shunt resistor is automatically
connected into circuit. It is thus unnecessary for the user to fit external
components.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Do not exceed the device's ratings

• The I/O Input & Output, the Communications ports are SELV circuit. They
must be connected to SELV or PELV circuit.

• The relay output and the fuse holders contacts are compliant to the SELV
requirements; they can be connected to SELV, PELV circuit or to voltage up to
230V (maximum value of rated operational voltage to earth:230V).
Failure to follow these instructions will result in death or serious injury.

SELV is defined (in IEC60947-1) as an electrical circuit in which the voltage cannot
exceed 'ELV' under normal conditions or under single fault conditions, including earth
ground faults in other circuits.

The definition of ELV is complex as it depends on environment, signal frequency, etc.

See IEC 61140 for further details.

HA033172 Issue 3 47
Installation EPack

Fuse Holders Contact Data (Fuse Ordering Code HSM)

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Do not exceed the device's ratings.

• The relay output and the fuse holders contacts are compliant to the SELV
requirements; they can be connected to SELV, PELV circuit or to voltage up to
230V (maximum value of rated operational voltage to earth:230V).
Failure to follow these instructions will result in death or serious injury.

SELV is defined (in IEC60947-1) as an electrical circuit in which the voltage cannot
exceed 'ELV' under normal conditions or under single fault conditions, including earth
ground faults in other circuits.

The definition of ELV is complex as it depends on environment, signal frequency, etc.

See IEC 61140 for further details.

If fuse ordering code HSM has been selected, the fuses holder is delivered with a
contact kit which provides indication if the fuse is blown or missing. This is shown
locally on the fuseholder by a red handle which also activates microcontacts. These
contacts may be wired to a digital input on the EPack as shown in the following
diagrams.

Fuses Holders Contacts Kit are delivered with NO, NC contact.

Fuse in fuse Fuse missing or

holder and not fuse blown
blown
The handle is open
The handle and and shown red. The
contacts are in contacts are in open
the closed state state

• Connection: Faston lugs 2.8 x 0.5mm (0.11 x 0.02in)

• Rated insulation voltage: 250VAC

• Rated operational current following IEC 60947-5 & -1

• Utilization category AC15: 4A/24V, 4A/48V, 3A/127V, 2.5A/240V

• Utilization category DC13: 3A/24V, 1A/48V, 0.2A/127V, 0.1A/240V

48 HA033172 Issue 3
EPack Installation

For contact kit reference according to product rating see Table 3 or Table 4.

Contact kit Mersen Y227928A, for fuse size 14x51 or Contact kit Mersen G227959A
for fuse size 22x58.

Minimum operational current and voltage: 1mA/4V AC or DC.

• These contacts are compatible with Digital inputs configured in contact closure
mode.

Recommended wiring:
NC

Fuse holder
contact

For contact kit Mersen E227612A, for fuse size 27x60

Minimum operational current and voltage: 100mA/20V AC or DC

• These contacts are not compatible with Digital inputs configured in contact
closure mode.

• These contacts are compatible with Digital inputs configured in Voltage inputs
with external dc power supply and load 100 mA dc minimum.

Recommended wiring: 24 Vdc Power supply

NC

Fuse holder
contact

HA033172 Issue 3 49
Installation EPack

50 HA033172 Issue 3
EPack Operator Interface

Operator Interface
Located at the front of the Driver Module, the operator interface consists of a square
display, and four pushbutton switches.

Display
The display is divided vertically into three areas, which for the purposes of this
manual are called the status area at the top, the data display, in the center, and the
soft keys at the bottom. This display, together with the four pushbuttons allows full
operation and configuration of the unit.

Status area

Display area

Softkey icons

Figure 13 Operator interface

The figure above shows a typical operator mode screen. The other available screens
are scrolled through using the return (page) pushbutton. The configuration of the unit
defines which parameters actually appear.

The screens are displayed in the following order:

1. EPack Lite Main Screen (as shown in the figure)
2. Meas menu
3. Alarms menu
4. DI Stat
Notes:
1. The Alarms display appears only if there are any active alarms. The up/down
arrow pushbuttons can be used to scroll through the alarm list, if there are more
alarms active than can be displayed on one screen height.
2. The ‘Goto’ item allows the user to enter Configuration mode, providing the
known.

Status area
This area at the top of the screen contains text descriptive of the current operation,
and a number of icons as follows
Configuration key. Displayed when the unit is in configuration mode.
Alarm symbol. Indicates that one or more alarms is active.

HA033172 Issue 3 51
Operator Interface EPack

Softkey icons
A number of icons can appear at the bottom of the display, and each icon represents
the action of the pushbutton immediately below it.
Menu. This appears in the bottom left corner, and operation of the
Return pushbutton causes the top level menu to appear.

Return. This red cross icon appears in the bottom left corner, and
operation of the Return pushbutton causes any configuration changes
on the current page to be ‘undone’ or, if none, causes the display to ‘go
up’ one level.

Plus and minus icons. Operation of the associated scroll up/down

pushbutton causes the displayed value to increment or decrement.

Up/down arrows. Operation of the associated scroll up/down

pushbutton causes the various menu items on display to be scrolled
through.

Right/Left arrow. The right-pointing arrow appears in the bottom

right-hand corner, and operation of the Enter pushbutton causes the
cursor to shift right. Once this has been done, a left-pointing arrow
appears in the bottom left-hand corner, allowing the user to shift the
cursor to the left using the Return pushbutton.

Enter. This green tick appears in the bottom right corner, and operation
of the Enter pushbutton causes any configuration change(s) on the
display page to be confirmed.

Remote/Local. This appears in the bottom right corner, and operation

of the Enter pushbutton toggles the setpoint selection between local
and remote.

52 HA033172 Issue 3
EPack Operator Interface

Pushbuttons
The functions of the four pushbuttons below the display depend on what is displayed
in the softkey area. The leftmost pushbutton (Return) is associated with the leftmost
soft key, the down arrow pushbutton is associated with the next soft key and so on. In
the example above, the ‘Return’ key is used both to enter the Menu, and to return
from it to the initial display.

Return Scroll Scroll Enter

Down Up

Pushbutton functions
Return Returns to previous menu (while menus are displayed), cancels
editing (during parameter editing), and performs screen cycling
(during operator mode).
Scroll down/up Allows the user to scroll through the available menu items or
values.
Enter Goes to next menu item. In parameter edit mode, this button
confirms the changes.

Menu item value selection

Menu items are scrolled through using the up/down pushbuttons. Once the required
item is displayed, the Enter pushbutton is used to select it for editing. Editing of the
item’s value is carried out by scrolling through the available choices, using the up and
down scroll keys. Once the desired value is displayed, the Enter pushbutton is used
to confirm the choice.

Where multiple changes have to be made (as in editing an IP address for example),
the Enter pushbutton acts as a right cursor key, moving from the field just edited to
the next field. (The Return pushbutton moves the cursor left). Once all fields have
been edited, the Enter pushbutton is used a final time to confirm the choice.

HA033172 Issue 3 53
Operator Interface EPack

Front Panel Event Indication

A number of instrument alarms and events can occur, and these are indicated by
icons appearing on the display screen. The events and alarms are listed below. See
Alarms (page 78) for a more details.

Instrument events
Conf Entry The instrument has been placed in configuration mode
(cogwheel symbol).
Conf Exit The instrument has been taken out of configuration mode (no
icon).
GlobalAck A global acknowledgement of all latched alarms has been
performed.
Quick Code Entry The Quick Code menu is active (cogwheel icon + ‘QCode’ in
display area).
The following alarms all cause a red bell icon to appear in the top right hand corner of
the screen.

Indication alarms
LoadOverI An over current alarm has become active in one or more Network
blocks.

System alarms
ChopOff The ‘Chop-off’ alarm has been detected.
FuseBlown There is no internal fuse, but it is possible to use DI2 as a
‘fuse-blown’ input wired to the alarm block in iTools.
MainsFreq Mains Frequency is outside the acceptable range.
Missmains Supply power is missing.
NetwDip The ‘network dip’ alarm has been detected.
Thyr SC Thyristor short circuit. It is not possible to detect a thyristor short
circuit when the unit is delivering 100% output power.

Process alarms
ClosedLp The Control block ‘Closed Loop’ alarm has been detected.
Ana_In Over C Over current in shunt. If this alarm is detected, firing is stopped
by default and Analog Input type is automatically switched to
0-10V mode to avoid damage.
Under Volt Line under voltage
Over Volt Line over voltage (configurable between 2 and 10% of nominal
voltage)
PLF The ‘Partial Load Failure’ alarm has been detected.
TLF The ‘Total Load failure’ alarm has been detected.

54 HA033172 Issue 3
EPack Quickcode

Quickcode
At first switch-on, the EPack unit enters the ‘QuickCode’ menu which allows the user
to configure the major parameters without having to enter the full configuration menu
structure of the unit. Figure 14 shows an overview of a typical QuickCode menu. The
actual displayed menu items will vary according to the number of software features
purchased. When ‘Finish’ is selected to ‘Yes’, the instrument cold starts after
confirmation (Enter key); when set to ‘Cancel’ the instrument discards any changes
and restarts with the previous configuration.

Select Lang. Select display language

V Nominal Enter nominal voltage value
I Nominal Enter nominal load current value
Clone Code Define configuration using 12 digits

Load Coupli Select load coupling configuration

Firing Select firing mode
Burst MinOn Select minimum on time (FC1, C16 or C64)
Control Select control mode (V2, I2 or Open loop)

Transfo. Yes = Load connected via transformer

AnaIn Functi Select analog input function
Analn Type Select analog input type
DigIn1 Funct Select Digital input 1 function

DigIn1 Type Select Digital input 1 type

DigIn2 Funct Select Digital input 2 function
DigIn2 Type Select Digital input 2 type
Finish Select ‘Yes’, ‘No’ or ‘Cancel’. If ‘Yes’, confirm using Enter key. If
‘Cancel’, the instrument discards all changes and restarts with the
previous configuration. If ‘No’ quickcode editing can be
continued.

Figure 14 Typical QuickCode menu

Notes:
1. If the unit has been fully configured at the factory, the Quickcode menu will be
skipped, and the unit will go into operation mode at first switch on.
2. Once quit, the Quickcode menu can be returned to at any time from the Access
menu via the front panel. Returning to the Quickcode menu cold-starts the unit.

HA033172 Issue 3 55
Quickcode EPack

Quickcode Menu Parameters Description

Language Select English, French, German, Italian or Spanish. Once
confirmed all further displays appear in the selected
language.
V Nominal The nominal value of the supply voltage (valid entries are
20V to 500V). Default value appears. Use the up/down
arrow buttons to edit.
I Nominal The current flowing through the load according to the
nominal load power. This current must not exceed the
maximum current the unit has been designed for. Lower
values are not recommended as in such cases, the
resulting accuracy and linearity may not be within
specification. Default value appears. Use up/down arrow
buttons to edit.
Load Coupling Select one of the following; 3D (closed Delta), or 3S (Star
without Neutral). See Load Configurations (page 43) for
more details.
Clone Code Define the configuration of the unit simply by using 12
digits. By setting these 12 digits (copied from another unit,
for example), the product will be fully configured. It is a
quick way to clone a configuration from another unit.
Firing Mode Select from Burst Var (Burst Variable), Burst Fix (Burst
Fixed), Logic. Note that in Burst fixed firing mode, the
modulation period is set to 2 seconds.
Burst MinOn Select the minimum on-time for the burst variable between
1, 16 and 64 mains cycles.
Control Select VSq (V2), Isq (I2), or Open Loop
XFMR (Transfo.) No = Resistive load type; Yes = Transformer primary.
AnaIn Functi Select SP (setpoint) or None (no function) as Analog Input
function
Note: Setpoint is only available for AnaIn Functi if DI1 or DI2 Fct are not set to
'Setpoint' while Firing Mode is set to 'Logic'.
AnaIn Type Select 0 to 10V, 1 to 5V, 2 to 10V, 0 to 5V, 0 to 20mA or 4
to 20 mA as analog input type.
DI1 Fct Select ‘Firing Enable’, Alarm ack(nowledge), RemSP sel
(select remote setpoint), Fuse Blown, Setpoint (in logic
mode) or none.
Notes:
1. The function is available if not set in DI2.
2. Setpoint is only available for DigIn1 Function if AnaIn or DI2 Fct is not set to
’Setpoint’ whilst Firing Mode is set to ’Logic’
DigIn1 Type Select from IpContact (Input contact) and IpVolts (Input
volts)
DI2 Fct Select Firing Enable, Alarm ack(nowledge), RemSP sel
(select remote setpoint), Fuse Blown, Setpoint, 10V user
output, Firing Enable or none.
Notes:
1. Setpoint is only available for DI1 Fct or DI2 Fct if Analn Functi is not set to
'Setpoint' while Firing Mode is set to 'Logic'.
2. DI1 Fct and DI2 Fct are mutually exclusive.
DigIn2 Type Select from IpContact (Input contact) and IpVolts (Input
volts)
Finish If ‘Yes’ is selected (and confirmed using the enter key),
quick code exits and the instrument restarts with the new
configuration. If ‘No’ is selected then no action is taken and

56 HA033172 Issue 3
EPack Quickcode

the user can continue to edit the quick code parameters. If

‘Cancel’ is selected then all changes are discarded, quick
code exits and the instrument restarts with the previous
(i.e. unedited) configuration.

Firing modes definitions

Logic
Power switches on, two or three zero crossings of the supply voltage after the logic
input switches on. Power switches off, two or three zero crossings of current after the
logic input switches off. For resistive loads, voltage and current cross zero
simultaneously. With inductive loads, a phase difference exists between the voltage
and current, meaning that they cross zero at different times. The size of the phase
difference increases with increasing inductance.

Power on-off delay = two or three mains

zero crossings depending on where in the
mains cycle the logic output changes state. Power applied

Logic output from controller

Figure 15 Logic firing mode

Burst Fixed Firing

This means that there is a fixed ‘cycle time’ equal to an integer number of supply
voltage cycles as set up in the Modulator menu. Power is controlled by varying the
ratio between the ON period and the OFF period within this cycle time (Figure 16).

Tcyc

Power applied Power applied

Ton Toff Ton

Tcyc = Ton + Toff

Figure 16 Burst Fixed mode

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Quickcode EPack

Burst Variable Firing

Burst Firing Variable is the preferred mode for temperature control. Between 0 and
50% of setpoint, the ON time is the ‘Min on’ time set in the modulator menu and the
OFF time is varied to achieve control. Between 50% and 100%, the OFF time is the
value set for ‘Min on’ and power is controlled by varying the number of ON cycles.

Power Power
applied applied
Power applied Power applied
Min off Min on Min off Min on
Ton Toff Ton Ton Toff Ton

Toff = 1/2 Min on = 66.7% duty cycle Toff = Min on = 50% duty cycle
Power applied Power applied
Min On = Min Off = 2 Min on
for these examples Ton Toff Ton

Toff = 2 x Min on = 33.3% duty cycle

Figure 17 Burst variable firing

58 HA033172 Issue 3
EPack Quickcode

Feedback type
All feedback types (except ‘Open Loop’) are based on real-time measurement of
electrical parameters that are normalized to their equivalent Nominal values.
V2 Feedback is directly proportional to the square of the RMS
voltage measured across the load.
I2 Feedback is directly proportional to the square of the RMS
current through the load. For two- or three-phase systems,
feedback is proportional to the average of the squares of
the individual RMS load currents.
Open loop No measurement feedback. The thyristor firing angle in
Phase angle mode, or the duty cycle in burst-firing mode,
are proportional to the setpoint.

Chop Off Definition

This is a technique which detects an over-current alarm state and stops further
thyristor firing for the duration of that alarm state.

The conditions that trigger a Chop Off alarm are:

1. When the ChopOff Threshold exceeds the number of times specified in

NumberChop Off parameter. NumberChop Off is set to 10. The ChopOff
Threshold is set to 120%.
When the alarm is triggered the unit stops firing and raises a chop off alarm. Firing is
not resumed until the operator acknowledges the Chop Off alarm, to restart.

HA033172 Issue 3 59
Quickcode EPack

60 HA033172 Issue 3
EPack Configuration from the Front Panel

Configuration from the Front Panel

At power up or after quitting the Quickcode menu, the unit initializes and then enters
the summary page (Figure 18) showing the real-time values of the two parameters
configured, see "Instrument Display configuration" on page 159 for details.

EPackLite2PH

EPackLite2PH
VN.NN = software
75.4 revision level

Return key Enter key

Figure 18 Initialization screens

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Configuration from the Front Panel EPack

Menu Pages
Operating the return key opens the first page of the menu, the content of which
depends on the current access level and on the number of options enabled.

Meas Meas menu

Adjust Adjust menu
Info Info menu
Alarms Alarms menu

Alm Disable Alm Disable menu

Alm Latch Alm Latch Menu
Alm Stop Alm Stop menu
Alarm Relay Alm Relay menu

DI Stat DI Stat menu

Access Access menu

62 HA033172 Issue 3
EPack Configuration from the Front Panel

Meas menu
This menu allows the user to view a number of measured values in real time.

Meas Meas

Vline VlineN Displays a measurement of

the selected supply
Vline2 voltage (Phase 1, 2 or 3)
Vline3
0.0

Meas
Meas
Supply voltage
Frequency
Vline frequency
Frequency
0.00
V
I

Meas Meas

V VN
Displays an RMS
measurement of the
V2 selected load voltage
V3 (load 1, 2, 3, or the
V Average 0.0 average of all three)

Meas
Meas Displays an RMS
I IN measurement of the
selected load current
I2 (load 1, 2, 3, or the
I3 0.0 average of all three)
I Average

0.0
Meas

Energy

0
1 Wh

Meas Meas
Energy Z
Z Z2
Load impedance
Z3
0

Figure 19 Meas menu

HA033172 Issue 3 63
 Configuration from the Front Panel EPack

Adjust menu
This menu allows a number of network and firing output parameters to be set up, as
well as Analog input type.

Enter nominal
Adjust values Adjust
Vline Load
Nominal Adjust Adjust
Coupling Select the rele-
vant Load
I NominalPV configuration
230 Nominal 3S

16.0 52900
Adjust

Vline Nomin. Adjust

I Nominal Enter Value Firing
NominalPV Mode Select
Load Coupli. firing
BurstVar mode

Adjust
Adjust
Firing Mode
Lgc Max Cyc Lgc Max
SP Op Access. Cycle Time Set the
Cycle
Backlight Di. 750 Time

Adjust
Adjust
Ana_in type SP
Safety Ramp
Op Access
Soft Start Select
Soft Stop No Yes or No

Menu

Adjust Adjust
Backlight
PLF Adjust R
Dimming
PLF Adjuste
PLF Sensitiv. Select
Yes Yes or No

Adjust
Ana_In
Adjust
type
PLF 0–10V
Select
analogue
Sensitivity input type
2

Adjust
Safety
Select Adjust Ramp Select
Sensitivity val- Ramp Rate
ue PLF Adjust Adjust Adjust 16
Adjusted Soft
PLF Soft
Adjust Req Stop Start
No
No Off Off

Select Select
Yes or No number of
Select Select number of cycles
Yes or No cycles

Figure 20 Adjust menu

64 HA033172 Issue 3
EPack Configuration from the Front Panel

Vline Nominal Line voltage nominal value (Line to line for all listed config-
urations), see Load Configurations (page 43).
I Nominal Nominal current supplied to the load.
NominalPV Nominal Process Variable. Defines the nominal value for
each control type. For example, for Vsq control, you must
set NominalPV to the nominal value you expect for Vsq—
typically this could be VloadNominal * VloadNominal.
Load Coupling Allows you to specify how the load is configured on your in-
stallation. Select one of the following; 3D (closed Delta), or
3S (Star without Neutral). See Load Configurations
(page 43) for more details.
Lgc Max Cyc Max cycle time for Logic mode. This is set in mains
periods.This is the equivalent to the modulation period and
it is used to compute Network electrical quantities when
there is no modulation shift. It is only available in Logic
Mode.
Firing Mode Firing Mode allows the firing mode to be selected as Burst
Var, Burst Fix, or Logic.
SP Op Access Setpoint Operator Access: Allows the user setpoint access
via the front panel, in operator configuration when enabled.
To enable set to Yes. (The default setting is Yes).
Backlight Di. Backlight Dimming: By default, the backlight on the
EPack’s display dims automatically to save power. Set this
parameter to No if you want the backlight to always remain
on. If set to Yes, the backlight dims 30 seconds after you
last operate the buttons on the front panel.
Ana_in type Select the Analog Input type as 0 to 10V, 1 to 5 V, 2 to 10V,
0 to 5V, 0 to 20mA,4 to 20mA.
‘Safety Ramp’ Displays the startup ramp duration, in supply voltage
cycles (0 to 255), to be applied at startup. The ramp is
either a phase angle ramp from zero to the requested
target phase angle or, for Burst Firing, from 0 to 100%.
‘Safety Ramp’ is not applicable to Half cycle Mode.
Soft Start For Burst Firing only, this is the soft start duration, in supply
voltage cycles, applying a phase angle ramp at the
beginning of each ON period.
Soft Stop In Burst Firing, the soft stop duration, in supply voltage
cycles, applying a phase angle ramp at the end of each ON
period.
Delay Triggering Appears only if Mode is Burst, Soft Start is Off, and Load
Type is TxFormer. Delayed Trigger specifies the triggering
delay, in phase angle, when delivering power into a
transformer load. Used to minimize inrush current, the
value is configurable between 0 and 90 degrees, inclusive.
PLF Adjust R Partial Load Failure Adjustment Request: When the
process has achieved a steady state condition the
operator must set the PLFAdjustReq. This makes a load
impedance measurement to be used as a reference for
detecting a partial load failure. If the load impedance
measurement is successful ‘PLFAdjusted’ is set. The
measurement cannot be made if the load voltage (V) is
below 30% of VNominal or if the current (I) is below 30%
of INominal. The input is edge sensitive, so if the request
is made from external wiring, and the input remains
permanently at a high level, only the first 0 to 1 edge is
taken into account.
PLF Adjusted Partial Load Failure Adjusted: A successful load imped-
ance measurement has been made (see PLF Adjust R
above).

HA033172 Issue 3 65
Configuration from the Front Panel EPack

PLF Sensitivity Partial load failure sensitivity.

This defines how sensitive the partial load failure detection
is to be as the ratio between the load impedance for a
PLFadjusted load and the current impedance
measurement. For example for a load of N parallel,
identical elements, if the PLF Sensitivity (s) is set to 2, then
a PLF alarm will occur if N/2, or more elements are broken
(i.e. open circuit). If PLF Sensitivity is set to 3, then a PLF
alarm occurs if N/3 or more elements are broken. If (N/s) is
non-integer, then the sensitivity is rounded up. E.G. if the
N = 6 and s= 4, then the alarm is triggered if 2 or more
elements are broken.

Examples

Safety Ramps, Soft Start and Delayed Trigger, firing types

Safety (Magnetisation) Ramp
(4 cycles)
Safety Ramp (10 cycles)

Output
voltage

Output
voltage Line
Line supply
Delayed trigger angle
supply
Resistive load Inductive load
Figure 21 Safety ramp (burst firing) examples
Soft start = 2

Output
voltage
Line
supply

Figure 22 Soft start example

High current transient

Load voltage

Load current

Switch at zero volts

Figure 23 Delayed trigger definition

Note: Waveforms have been idealized for clarity.

66 HA033172 Issue 3
EPack Configuration from the Front Panel

PLF menu
The PLF (Partial Load Failure) menu is only available in Engineer mode.

Note: The default Engineer access level code is 2.

PLF

PLF Use the arrow

push-buttons to
Adjust Req toggle between ‘No’
and ‘Request’
No
PLF

PLF Adjust R
PLF Adjuste.
PLF Sensitiv. PLF

PLF
Adjusted
No Read-only

PLF

PLF
Read-only
Sensitivity

Figure 24 PLF menu

HA033172 Issue 3 67
Configuration from the Front Panel EPack

Info menu
This display gives read only information about the unit.

Info
Serial
Num

1234567890
Info
SW
Version
Info E N.NN
Serial Num
Serial Num
SW version
SW version
Passcode1
Info
Clone Code
Passcode1 Passcode1

12345
Clone Code

X3XX00
X0101X

Figure 25 Info menu

68 HA033172 Issue 3
EPack Configuration from the Front Panel

Alarms menu
Allows the user to view Global acknowledgement enable status, and issues with
calibration (if any). Any active alarms appear, and details can be found by highlighting
the relevant alarm and using the Enter pushbutton.

Active alarms can be acknowledged, if applicable, by a further operation of the Enter

button.

Alarms

Alarm

Yes
ACK?

Alarms

Calib
Error
Alarms
1
Alarm Ack
Calib Error Use Enter button to
Miss Mains acknowledge alarms
Alarms
Thyr SC
Miss Mains

Use up/down arrows to P1Latched

scroll through alarm list ACK?
Use Page (Menu) button to
return to the Alarms top level
Alarms
Thyr SC

P1Latched
ACK?

Figure 26 Alarms menu

HA033172 Issue 3 69
Configuration from the Front Panel EPack

Alm Disable menu

This menu allows the user to disable particular alarm types, so that they are no
longer detected or acted upon.

By default all of the alarms are enabled.

To disable or re-enable an alarm, simply scroll through the list and select the alarm
you want, then use the arrow keys to toggle its status between Disable and Enable as
required.

Alm Disab Use the arrow keys to scroll through the list of
Miss Mains alarms, and press the Enter key when the green
cursor is next to the alarm you want.
Thyr SC
Volt Dips
Freq Fault

Alm Disab

Chop Off
Under Volt
Over Volt
Alm Disab
TLF
Alarm
name
Alm Disab Disable
PLF
PLU
Over I Use the arrow keys to toggle
Ana_In Over. between Disable and Enable for the
selected alarm.
You do not need to press the
Enter key for this to take effect.
(Pressing the Enter key here moves
Alm Disab to the next alarm
in the list.)
Closed Loop
Extern In

Figure 27 Alarm Disable menu

70 HA033172 Issue 3
EPack Configuration from the Front Panel

Alm Latch Menu

This menu allows the user to set latching or no latching to particular alarm types.

To select the latching type, simply scroll through the list and select the alarm you
want, then use the arrow keys to toggle its status between Latch and NoLatch as
required.

Alm Latch
Use the arrow keys to scroll through the list of
Miss Mains alarms, and press the Enter key when the green
cursor is next to the alarm you want.
Thyr SC
Volt Dips
Freq Fault

Alm Latch

Chop Off
Under Volt
Over Volt Alm Latch
TLF
Alarm
name
Alm Latch
Latch
PLF
PLU
Over I Use the arrow keys to toggle
Ana_In Over. between Latch and NoLatch for the
selected alarm.
You do not need to press the
Enter key for this to take effect.
(Pressing the Enter key here moves
Alm Latch to the next alarm
in the list.)
Closed Loop
Extern In

Figure 28 Alarm Latch Menu

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Configuration from the Front Panel EPack

Alm Stop menu

This menu allows the user to set which alarms will cause the EPack Lite to stop firing.

By default, none of the alarms are set to stop firing.

To change whether an alarm causes the EPack Lite to stop firing, simply scroll
through the list and select the alarm you want, then use the arrow keys to toggle its
status between Stop and NoStop as required.

Alm Stop Use the arrow keys to scroll through the list of
alarms, and press the Enter key when the green
Miss Mains cursor is next to the alarm you want.
Thyr SC
Volt Dips
Freq Fault

Alm Stop

Chop Off
Under Volt
Over Volt
Alm Stop
TLF
Alarm
name
Alm Stop Stop
PLF
PLU
Over I Use the arrow keys to toggle
between Stop and NoStop for the
Ana_In Over. selected alarm.
You do not need to press the
Enter key for this to take effect.
(Pressing the Enter key here moves
to the next alarm
Alm Stop
in the list.)
Closed Loop
Extern In

Figure 29 Alarm Stop menu

72 HA033172 Issue 3
EPack Configuration from the Front Panel

Alm Relay menu

This menu allows the user to select which alarms are to operate (de-energize) the
EPack Lite’s ‘watchdog’ relay. For each selected alarm, select ‘Yes’ or ‘No’.

Alm Relay

Miss Mains
Thyr SC
Volt Dips
Freq Fault

Alm Relay

Chop Off
Under Volt
Over Volt
Alm Relay
TLF
Alarm
name
Alm Relay Yes
PLF
PLU
Over I
For each alarm selected choose
Ana_In Over. ‘Yes’ if you want the watchdog relay
to operate (de-energise) when the
alarm is raised.
Otherwise, select ‘No’.

Alm Relay
Closed Loop
Extern In

Figure 30 Alarm Relay menu

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Configuration from the Front Panel EPack

DI Stat menu
The DI Stat menu displays the status of the EPack Lite’s two digital inputs, DI1 and
DI2.

‘0’ means a low level logic signal is being received at the input, ‘1’ means a high level
logic signal is being received at the input.

DI Stat

DI1 DI2

0 1

Figure 31 DI Stat menu

PLF Adjust menu

See "Adjust menu" on page 64.

74 HA033172 Issue 3
EPack Configuration from the Front Panel

Settings menu
The Settings menu is only available in Engineer mode. This menu is read-only, and
lets you view the values of the parameters described below.

Settings

Vline
Nominal Settings

I
230
Nominal

16.0
Settings
Vline Nomin. Settings
I Nominal
Load
Load Coupling
Coupling
Firing Mode
3S

Settings

Ana In type Settings

Firing
Mode

Settings BurstVar
Ana_in
type

2–10V

Figure 32 Settings menu

Vline Nominal Line voltage nominal value (Line to neutral) or Line to L2
(phase to phase connection).Line voltage nominal value
(Line to line for all listed configurations), see Load
Configurations (page 43).
I Nominal Nominal current supplied to the load.
Load Coupling Displays the current load configuration type. For diagrams
of these configurations, see Load Configurations
(page 43).
Firing Mode Reports the firing mode: Burst Var, Burst Fix, Logic, Phase
Angle (PA).
Ana_in type Reports the Analog Input type: 0 to 10V, 1 to 5 V, 2 to 10V,
0 to 5V, 0 to 20mA, or 4 to 20mA.

HA033172 Issue 3 75
Configuration from the Front Panel EPack

Access menu
Allows access to the Operator, Engineer, Configuration, and Quick Code menus and
allows passwords to be set up.

Edit Edit

Goto Pass
Code
Select access Select correct
Config level required 3 pass code for
selected access
level

Edit

Config
Code
Edit Config
Menu 3 level code
Goto
Config Code
Engineer Co.
Quick Code Edit
Edit Engineer
Quick Code
Code Edit Engineer
Edit
level code
4 Quick code 2
access code

Figure 33 Access menu

Note: The default access codes are Operator = 0, Engineer = 2, Config = 3,

Quickcode = 4.

76 HA033172 Issue 3
EPack Configuration from the Front Panel

HA033172 Issue 3 77
Alarms EPack

Alarms
W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Use appropriate safety interlocks where personnel and/or equipment hazards
exist.
Failure to follow these instructions will result in death or serious injury.

EPack Lite alarms protect thyristors and loads against abnormal operation, and
provide the user with valuable information regarding the type of fault.

Under no circumstances must these alarms be regarded as a replacement for proper

personnel protection.

Global System Monitoring

At power-up and in running for some functionalities EPack Lite performs a check of
most of electronic parts (power supply, digital memory, and so on). In case of failure,
EPack Lite reports a status in the Global Status Parameters available using
communication and displays a message on its front fascia.

There are four types of message described below:

• The first one is related to a detected failure on displays microcontroller board and
EPack Lite displays ‘CONFIG ERROR’. For this kind of problem it is
recommended to send the unit back to a repair center. EPack Lite also displays a
code in hexadecimal for a technician. This code is also available in decimal
through iTools in Global Status 0.

• The second one reports issues related to a hardware problem detected by the
microcontroller. Issues can be located on the different boards. In this situation
EPack Lite displays ‘HW Problem’. For this kind of problem it is recommended to
send the unit back to a repair center or contact your local representative. EPack
Lite also displays a code in hexadecimal for a technician. This code is also
available in decimal through iTools in Global Status 1.

• The third one is more related to configuration data set on production line, or
during upgrade. In this case EPack Lite displays ‘INVALID DATA’. For this kind of
problem it is recommended to send the unit back to a repair center. EPack Lite
also displays a code in hexadecimal for a technician. This code is also available
in decimal through iTools in Global Status 2.

• The fourth one concerns detection of an internal malfunction mainly on the

display microcontroller board. For this event EPack Lite displays ‘INTERNAL
FAILURE’. For this kind of problem it is recommended to send the unit back to a
repair center. EPack Lite also displays a code in hexadecimal for a technician.
This code is also available in decimal through iTools in Global Status 3.

78 HA033172 Issue 3
EPack Alarms

System Alarms
System alarms are considered to be ‘Major Events’ which help prevent proper
operation of the system, and the unit is placed in standby mode.

The following subsections describe each of the possible system alarms.

Missing mains
Supply power is missing.

Thyristor short circuit

A thyristor short circuit leads to current flow even when not firing.

Over temperature
Reserved for future development.

Network dips
This detects a reduction in supply voltage, and if this reduction exceeds a
configurable measured value (VdipsThreshold), firing will be inhibited until the supply
voltage returns to a suitable value. VdipsThreshold represents a percentage change
in supply voltage between successive half cycles and is set to 20% of Vline Nominal.

Mains frequency fault detected

Triggered if the supply voltage frequency strays out of the range 47 to 63Hz, or if the
mains frequency changes, for one cycle to the next, by more than the threshold
defined in the Network

The threshold value is set to 5%.

Chop Off alarm

Chop-off alarm will be active when a current threshold is exceeded for more than a
pre-defined number of mains periods. This current threshold is set to 120%.

HA033172 Issue 3 79
Alarms EPack

Process Alarms
Process Alarms are related to the application and can be configured either to stop the
unit firing (Standby Mode) or to allow operation to continue. Process alarms can also
be configured to be latched and if so, they have to be acknowledged before the alarm
is considered to be non-active. Alarms cannot be acknowledged until the trigger
source has returned to a non-active state.

Total Load Failure (TLF)

No load is connected.

Closed Loop alarm

Closed loop break alarm is currently active.

Alarm input
The alarm input associated with the alarm block is active.

Over current detection

The analog input over current detection alarm is active.

Over Voltage Alarm

A threshold to monitor an over-voltage is set to 10% of Vline Nominal. If exeeded, the
OverVoltage alarm is set.

Note: This Alarm is returned FALSE if the MissingMains Alarm is set.

Under Voltage Alarm

The threshold to monitor the under-voltage is set to 25% of Vline Nominal. If the
VLine voltage falls below this threshold the UnderVoltage alarm is set.

Note: This Alarm is returned FALSE if the MissingMains Alarm is set.

80 HA033172 Issue 3
EPack Alarms

Partial Load Failure (PLF)

This alarm detects a static increase in load impedance by comparing the reference
load impedance (as configured by the user) with the actual measured load
impedance over a mains cycle (for phase angle firing) and over the burst period (for
burst and logic firing).

Non-inductive loads, for example resistance furnaces, resistive loads with low
temperature coefficient or short wave infrared loads can be monitored using this
function. For other load types, for example AC51 slightly inductive loads or AC56a
primary of transformer, please consult Eurotherm.

The sensitivity of the partial load failure measurement can be set to any value
between 2 to 6 inclusive, where an entry of 2, for example, means that one half of the
elements (or more) must be open circuit in order to trigger the alarm; an entry of 3
means that one third of the elements (or more) must be open circuit in order to trigger
the alarm, and so on down to one sixth. All elements must have identical
characteristics and identical impedance values and must be connected in parallel).

The relevant parameters (PLFAdjustReq, and PLFSensitivity) are both to be found in

the as described in the section "Configuration from the Front Panel" on page 61.

Indication Alarms
Indication Alarms signal events for operator action if required. Indication alarms
cannot be configured to stop power module firing, but they may be latched if required,
and if latched, they must be acknowledged for the Signalling Status to return to the
normal (non-alarm) state.

Load Over-Current
Indicates when a configurable RMS load current threshold (OverIthreshold) is
reached or exceeded. This threshold is set to 120% of he nominal current.

HA033172 Issue 3 81
Alarms EPack

82 HA033172 Issue 3
EPack Maintenance

Maintenance
Precautions
W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See applicable national standards e.g. NFPA70E,
CSA Z462, BS 7671, NFC 18-510.

• This equipment must only be installed and serviced by qualified electrical

personnel.

• Refer to manual for installation and servicing.

• The product is not suitable for isolation applications, within the meaning of
EN60947-1 Turn off all power supplying this equipment before working on the
loads of the equipment.

• Turn off all power supplying this equipment before working on equipment.

• Always use a properly rated voltage sensing device to confirm power is off.

• Do not disassemble, repair or modify the equipment. Contact your supplier for
repair.

• This product must be installed, connected and used in compliance with

prevailing standards and/or installation regulations.
Failure to follow these instructions will result in death or serious injury.

Reasonable use and responsibility

The information contained in this manual is subject to change without notice. While
every effort has been made to ensure the accuracy of the information, your supplier
shall not be held liable for errors contained herein.

EPack Lite is an “AC semiconductor controllers for non-motor loads” designed

according to IEC60947-4-3 & UL60947-4-1, it meets the requirements of the Low
voltage and EMC European Directives which covers safety and EMC aspects.

Use in other applications, or failure to observe the installation instructions of this

manual may impair safety or EMC.

The safety and EMC of any system incorporating this product is the responsibility of
the assembler/installer of the system.

Failure to use approved software/hardware with our hardware products may result in
injury, harm, or improper operating results.

Eurotherm shall not be held responsible for any damage, injury, losses or expenses
caused by inappropriate use of the product (EPack Lite), or failure to comply with
these instructions.

HA033172 Issue 3 83
Maintenance EPack

Under some circumstances, the EPack Lite heatsink temperature may rise by more
than 50°C and it can take up to 15 minutes to cool after the product is shut down.

W CAUTION
HOT SURFACE RISK OF BURNS
• Allow heatsink to cool before servicing.

• Do not allow flammable or heat-sensitive parts in the immediate vicinity of

heatsink.
Failure to follow these instructions can result in injury or equipment
damage.

Preventive Maintenance
W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Tighten all connections in conformance with the torque specifications. Periodic
inspections are required.
Failure to follow these instructions will result in death or serious injury.

See Table 1, “Connection Details” on page 35.

Wires are not properly retained in terminals with insufficient torque.

Insufficient torque may increase the contact resistance:

• The protective earth ground connection may be too resistive. In case of short
circuit between live parts and heatsink, the heatsink may reach a dangerous
voltage.

• The power terminals will overheat.

Excessive torque may damage the terminal.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Do not allow anything to fall through the case apertures and ingress the
product.
Failure to follow these instructions will result in death or serious injury.

Conductive or non-conductive parts which ingress product may reduce or short the
insulations barriers inside the product.

W DANGER
HAZARD OF FIRE
• Heat-sink must be cleaned regularly. Periodicity depends on the local
environment, but should not exceed 1 year.
Failure to follow these instructions will result in death or serious injury.

84 HA033172 Issue 3
EPack Maintenance

Fusing

W DANGER
HAZARD OF FIRE
• This product does not contain any branch-circuit protection, the installer must
add branch-circuit protection upstream of the unit.

• Branch circuit protection must be selected according to maximum current in

each phase and must be rated in compliance with local and national regulatory
requirements.
Failure to follow these instructions will result in death or serious injury.

Branch circuit protection are mandatory to protect the wiring.

• CE: branch-circuit protection must be selected according to IEC 60364-4-43 or

applicable local regulations.

• UL: branch-circuit protection must be selected according to NEC article 210.20, it

is necessary for compliance with National Electric Code(NEC) requirements.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• High speed fuses (supplemental fuses in addition to branch circuit protective
device), as listed in fusing sections, are mandatory to protect EPack Lite
against load short circuit.

• If opening of either the branch circuit protective device or the high-speed fuses
(supplemental fuses) occurs, the product must be examined by suitably
qualified personnel and replaced if damaged.
Failure to follow these instructions will result in death or serious injury.

The power circuit must be protected by a supplementary fuse, which should be used
in conjunction with suitable fuse holders (and contact kits, if required) as shown in
Table 3 or Table 4.

Note: With a supplementary fuse (high speed fuse), EPack is suitable for use on a
circuit capable of delivering not more than 100kA RMS symmetrical amperes, 500
Volts Maximum (coordination Type 2)

Coordination Type 1 and Type 2 explanations

Type 1: Type 1 coordination requires that, under short-circuit conditions, the
device must cause no danger to persons or to the installation but may not be
suitable for further service without repair and replacement of parts.

Type 2: Type 2 coordination requires that, under short-circuit conditions, the

device must cause no danger to persons or to the installation and must be
suitable for further use.

HA033172 Issue 3 85
Maintenance EPack

Table 3: Details of high-speed fuses (WITHOUT microswitch) and fuse holders required for
EPack with order code HSP

EPack Fuse holder Contact kit

Fuse Fuse manufacturer Fuse body
current Qty Manufacturer &
rating & catalog number size (mm) Qty Qty
rating catalog number

Mersen
Mersen
30A US102
FR10GR69V30
≤25A or 10×38 or
Mersen
32A Mersen
FR10GR69V32
CUS102

Mersen
FR14GR69V40
Mersen
32A 40A
FR14GC69V40
Cooper-Bussmann Mersen
FWP-40A14F 14×51
US142
Mersen 2 1 0
FR14UC69V50
40A 50A
Cooper-Bussmann
FWP-50A14F

Mersen
50A 63A
FR22UD69V63
Mersen Mersen
22x58
FR22GC69V80 US222
63A 80A
Cooper Bussmann
FWP-80A22F

80A to Mersen Mersen

200A 27x60
125A FR27UQ69V200T US272

86 HA033172 Issue 3
EPack Maintenance

Table 4: Details of high-speed fuses (WITH microswitch) and fuse holders required for
EPack with order code HSM

Fuse holder Contact kit

EPack Fuse
Fuse Fuse manufacturer Manufacturer Manufacturer
current Qty body size
rating & catalog number & catalog Qty & catalog Qty
rating (mm)
number number

Mersen
FR14GR69V32T
Mersen
≤25A 32A
FR14GC69V32T
Cooper-Bussmann
FWP-32A14FI

Mersen
FR14GR69V40T Mersen Mersen
14×51
Mersen US142 Y227928A
32A 40A
FR14GC69V40T
Cooper-Bussmann
FWP-40A14FI

Mersen 2 1 2
FR14UD69V50T
40A 50A
Cooper-Bussmann
FWP-50A14FI

Mersen
50A 63A
FR22UD69V63T

Mersen Mersen Mersen

22×58
FR22GC69V80T US222 G227959A
63A 80A
Cooper-Bussmann
FWP-80A22FI

80A & Mersen Mersen Mersen

200A 27x60
125A FR27UQ69V200T US272 E227612A

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Tighten all connections in conformance with the torque specifications. Periodic
inspections are required.
Failure to follow these instructions will result in death or serious injury.

Unless otherwise mentioned on the side of the fuse holders, torque fuse holders
terminals at 2Nm.

Wires are not properly retained in terminals with insufficient torque. Insufficient torque
may increase the contact resistance, causing the power terminals to overheat.

Excessive torque may damage the terminal.

Fuses Holders Contacts Kit

For technical specification and recommended wiring, see "Fuse Holders Contact
Data (Fuse Ordering Code HSM)" on page 48.

HA033172 Issue 3 87
Maintenance EPack

Fuse holder dimensions

Figures 34 to 38 show dimensional details for the various fuse holders listed in
Table 3 and Table 4 (not all shown to the same scale).

Figure 34 Fuse holder dimensions: US102 (10x38mm)

56.5 mm
2.22 in
35 mm 20 mm
1.378 in 0.78 in
17.5 mm
.689 in
45 mm
1.8 in

76.5 mm
3.01 in

79.3 mm
3.12 in

4.6 mm
43 mm 0.18 in
1.69 in

76.9 mm
3.03 in

Figure 35 Fuse holder dimensions: CUS102 (10x38mm)

88 HA033172 Issue 3
EPack Maintenance

94mm
3.7 in
70 mm
2.8 in
50.5 mm 53 mm
1.99 in 2.1 in

107 mm 4.21 in

45 mm
1.8 in
50.5 mm 3.8 mm
1.99 in 0.15 in
52 mm
26.5 mm
2.0 in
1.04 in
76.5 mm
3.0 in

Figure 36 Fuse holder dimensions: US142 (14x51mm)

HA033172 Issue 3 89
Maintenance EPack

96.5 mm 3.80 in

70 mm
2.8 in
50.5 mm
1.99 in 70mm 2.76 in

126.5mm 4.98 in
45 mm
1.77 in
1 mm
50.5 mm
0.03 in
1.99 in
35 mm
1.38 in

76.5 mm 3.01 in
Figure 37 Fuse holder dimensions: US222 (22x58mm)
80mm 3.2 in

40mm 1.6in
5.25mm
117mm 4.61in
0.21in 29.5mm
1.16in 57mm 2.2in
4mm
8mm
0.16in
0.3in
63mm 2.48in
80.5mm

37.5mm 1.48in
3.12 in

46mm 1.81in

32mm
1.23in
45mm 1.77in
17.5mm
0.689in

55 7in
35mm 1.38in
130mm 5.12in

2.1
mm
75mm 2.95in

66mm 2.60in
118mm 4.65in

146mm 5.75in

25.5mm
1.00in

6mm
0.24in
6mm
0.24in

3.4mm 6.5mm 87mm

20mm 40mm
0.133in 0.26in 3.4in
0.79in 1.57in

Figure 38 Fuse holder dimensions: US272 (27x60mm)

90 HA033172 Issue 3
EPack Maintenance

Auxiliary supply fuse protection

W DANGER
HAZARD OF FIRE
• The cables used to connect the EPack Lite’s auxiliary supply and voltage
reference must be protected by branch-circuit protection. Such branch-circuit
protection must comply with local and national regulatory requirements.
Failure to follow these instructions will result in death or serious injury.

Branch circuit protection is mandatory to protect the cable used to connect the
auxiliary supply.

• CE: branch-circuit protection must be selected according to IEC 60364-4-43 or

applicable local regulations.

• UL: branch-circuit protection must be selected according to NEC article 210.20, it

is necessary for compliance with National Electric Code(NEC) requirements.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• A High-speed fuse (supplemental fuses in addition to branch circuit protective
device) or a double protection fuse as listed in fusing sections is mandatory for
85Vac to 550Vac auxiliary supply.
Failure to follow these instructions will result in death or serious injury.

This fuse is necessary to avoid the 85Vac to 550Vac auxiliary supply to emit flame or
molten element in case of breakdown of a component.

High-speed fuse (supplemental fuse) does not protect the wiring they must be fitted
in addition to branch circuit protective device).

Double protection fuse combines a branch circuit fuse and a high-speed fuse. Double
protection fuse must be selected according to applicable national standards. Branch
circuit protection fuses Standard in USA/Canada differ from IEC standards (e.g;
Europe (CE)). Therefore:

• A fuse approved as branch circuit protection fuses in USA/Canada is not a

branch circuit in all countries where IEC standards apply (e.g; Europe (CE)).

• A fuse approved as branch circuit protection fuses in all countries where IEC
standards apply (e.g; Europe (CE)) is not a branch circuit in USA/Canada.

HA033172 Issue 3 91
Maintenance EPack

Table 5: Auxiliary supply fuse protection

UL Fuse CE Fuse Fuse (Make and Type)
Category Category
Supplemental Supplemental ATM2-type fuse rated 2A, 600Vac/dc:
Mersen/Ferraz Shawmut (UL file: E33925)
Branch Circuit Supplemental J-type fuse rated 3A/600Vac:
HSJ3 by Mersen/Ferraz Shawmut
(UL file: E2137; CSA class: 1422-02
LR12636)
or
DFJ-3 by Eaton/Cooper Bussman
(UL file: E4273; CSA class: 1422-02
LR53787)
Supplemental Branch Circuit gR-type fuses rated 3A /700V:
FR10GR69V3 (V1014571) by
Mersen/Ferraz Shawmut (UL file: E76491)

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• If opening of any fuses or branch circuit protection device that supply the
85Vac to 550Vac auxiliary supply occurs, first check the wiring. If the wiring is
not damaged, do not replace the fuse and contact the manufacturer's local
service center.
Failure to follow these instructions will result in death or serious injury.

If the wiring is not damaged a component inside the 85Vac to 550Vac auxiliary supply
is broken and product must go back to service center.

92 HA033172 Issue 3
EPack Maintenance

Instrument upgrade
Contact your local representative.

Software upgrade
Software upgrade can be carried out by following the section below.

Obtaining a Passcode via Telephone

1. Telephone the local Eurotherm Sales/Service agent with the serial number of the
instrument to be updated, and the current software version. This information can
be found in the Info sub-menu whilst in Configuration mode from the front panel.
Refer to "Info menu" on page 68.

2. Place an order for the required new functionality.

3. A new passcode will be provided which is to be entered in the Info menu

available from the front panel whilst in Configuration mode.

HA033172 Issue 3 93
Maintenance EPack

EPack Licence Notice

FreeRTOS
EPack is powered by an original FreeRTOS from version v7.1.0.
FreeRTOS is available at http://www.freertos.org

94 HA033172 Issue 3
EPack Maintenance

HA033172 Issue 3 95
Technical Specification EPack

Technical Specification
Standards
The product is designed and produced to comply with:

Standard
Countries Standard details
symbol

EN60947-4-3:2014.
Low-voltage switchgear and controlgear -
Part 4-3:Contactors and motor-starters - AC
European semiconductor controllers and contactors
community for non-motor loads (identical to
IEC60947-4-3:2014).
Declaration of conformity available on
request.

UL60947-4-1 CAN/CSA C22.2

NO.60947-4-1-14
Low-Voltage Switchgear and Controlgear -
USA &
Part 4-1: Contactors and Motor-Starters -
Canada
Electromechanical Contactors and
Motor-Starters
U.L. File N° E86160

Regulatory Compliance Mark (RCM) to

Australian Communication and Media
Australia
Authority.
Based on compliance to EN60947-4-3:2014.

Product not listed in catalog of products

China / subject to
China Compulsory Certification (CCC)

96 HA033172 Issue 3
EPack Technical Specification

Installation Categories
W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Do not exceed the device's ratings.
Failure to follow these instructions will result in death or serious injury.

The insulation barriers of the equipment have been designed for the rating as defined
in the table below at an altitude of 2000m maximum.

Table 6: Installation categories

Installation Rated impulse Rated Maximum value of

Category withstand insulation rated operational
voltage (Uimp) voltage voltage to earth

Communications II 0.5kV 50V 50V

Standard IO II 0.5kV 50V 50V

Relays III 4kV 300V 300V

Power terminals III 6kV 500V 500V

Specification

Power (at 45°C)

Voltage range Load: 100 to 500V (+10% -15%)
Auxiliary: 24V ac/dc (+20% -20%)
or
100 to 500V (+10% -15%)

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• The maximum voltage between any pole of the 85Vac to 550Vac auxiliary
supply and all other terminals must be lower than 550Vac.
Failure to follow these instructions will result in death or serious injury.

If the 85Vac to 550Vac auxiliary supply is supplied by a dedicated transformer the

phasing must be checked to avoid overvoltage.

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• The “24V auxiliary supply” is an SELV circuit. The supply voltage must be
derived from a SELV or PELV circuit.
Failure to follow these instructions will result in death or serious injury.

SELV is defined (in IEC60947-1) as an electrical circuit in which the voltage cannot
exceed 'ELV' under normal conditions or under single fault conditions, including earth
ground faults in other circuits.

The definition of ELV is complex as it depends on environment, signal frequency, etc.

See IEC 61140 for further details.

HA033172 Issue 3 97
Technical Specification EPack

Frequency range 47 to 63Hz for line and ac auxiliary supplies

Power requirement:
24V dc 12W
24V ac 18VA
500V ac 20VA
Installation category See Table 6 above.
Nominal load current 16 to 125 Amps
Power Dissipation 1.3 Watts per amp, per phase
Pollution degree Pollution degree 2

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Electrically conductive pollution must be excluded from the cabinet in which
the product is mounted.
Failure to follow these instructions will result in death or serious injury.

The product has been designed for pollution degree 2 according to IEC60947-1
definition: Normally, only non-conductive pollution occurs. Occasionally, however, a
temporary conductivity caused by condensation may be expected.

Electrically conductive pollution must be excluded from the cabinet in which the
product is mounted. To ensure a suitable atmosphere in conditions of conductive
pollution, fit adequate air conditioning/filtering/cooling equipment to the air intake of
the cabinet, e.g. fitting fan-cooled cabinets with a fan failure detection device or a
thermal safety cut-out.

Duty cycle Uninterrupted duty / continuous operation

Device form designation Form 4 (Semiconductor controller)
Short circuit protection By external supplemental fuses (high speed
fuse) - see "Fusing" on page 85.
Rated conditional short-circuit 100kA (Coordination Type 2)
current
Utilization categories AC51: Non-inductive or slightly inductive loads,
resistance furnaces
AC56a: Transformer Primary
Heater Type Low/high temperature coefficient and
non-aging/aging types: MOSI Molybdenum
Silicide, Silicon Carbide, Carbon.
Overload conditions AC51: 1xIe continuous
Load Power factor 0.85 for Loads from 32A up to 125A

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Do not exceed the device's ratings.
Failure to follow these instructions will result in death or serious injury.

Only SLIGHTLY inductive loads are allowed, contact Eurotherm for advice for Loads
lower than 32A.

98 HA033172 Issue 3
EPack Technical Specification

Physical
Dimensions and mounting See Figure 4, Figure 5, Figure 6 and Figure 7 for
centers details
Weight:
16 to 32A units 2530g + user connectors
40 to 63A units 2970g + user connectors
80A and 100A units 5830g + user connectors
125 A units 7940g + user connectors

Environment
Temperature limits:
Operating: 0°C to 45°C at 1000m
0°C to 40°C at 2000m
Storage: -25°C to +70°C
Altitude: 1000m maximum at 45°C
2000m maximum at 40°C

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Do not exceed the device's ratings.
Failure to follow these instructions will result in death or serious injury.

The insulations barriers of the equipment have been designed for an altitude of
2000m maximum.

W DANGER
HAZARD OF FIRE
• At commissioning ensure that under maximum load condition, the ambient
temperature of the product will not exceed the limit stated in that manual.
Failure to follow these instructions will result in death or serious injury.

Humidity limits 5% to 95% RH (non-condensing)

Degree of Protection (CE)
All units: IP20 (EN60529)

W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• Respect electrical installation requirements to ensure, improve the IP rating.
Failure to follow these instructions will result in death or serious injury.

If the conductor stripping lengths of the power cables are longer than the
requirements IP20 is compromised.

If the conductor stripping lengths of the power cables are shorter than the
requirements there is a potential risk of total loss of connection. Wires may slip out of
the terminals.

If the breakaway features are removed for cables with diameter lower than 9mm the
IP20 is compromised and the product is IP10.

HA033172 Issue 3 99
Technical Specification EPack

Enclosure type ratings (UL)

All units: Open type
Atmosphere Non-explosive, non-corrosive, non-conductive
External wiring
IEC/CE: Must comply with IEC60364-1 and
IEC60364-5-54 and all applicable local
regulations.
UL: Wiring must comply with NEC and all applicable
local regulations. Cross sections must comply
with NEC, Article 310 Table 310-16.(see Table 1
of this manual for temperature ratings)
Shock According to EN60068-2-27 and IEC60947-1
(Annex Q, Category E)
Vibration According to EN60068-2-6 and IEC60947-1
(Annex Q, Category E)
EMC Standard: EN60947-4-3:2014.
See Table 7 and Table 8 for EMC emission and
immunity levels attained.

Table 7: EMC immunity tests

EMC immunity tests (According to EN60947-4-3:2014)
Level Criteria
Requested Achieved Requested Achieved
Electrostatic discharge Air discharge mode 8kV Air discharge mode 8kV 2 2
(test method of IEC 61000-4-2) Contact discharge mode Contact discharge mode
4kV 4kV
Radiated radio-frequency 10V/m from 80MHz to 15V/m from 80MHz to 1 1
electromagnetic field test 1GHz and from 1.4GHz to 3GHz
(test method of EN 61000-4-3) 2GHz
Fast transient/burst test (5/50 Power ports 2kV / 5kHz Power ports 4kV / 5 kHz 2 2
ns) Signal ports 1kV / 5kHz Signal ports 4kV / 5 kHz
(test method of EN 61000-4-4)
Surge Voltage test 2kV line to earth 2kV line to earth 2 2
(1,2/50μs – 8/20μs) 1kV line to line 1kV line to line
(test method of EN 61000-4-5)
Conducted radio-frequency test 10V (140dBμV) 15V (143.5dBμV) 1 1
(test method of EN 61000-4-6) from 0.15MHz to 80 MHz from 0.15MHz to 80 MHz
0% during 0.5 cycle & 1 0% during 0.5 cycle & 1 2 2
Voltage dips test cycle cycle
(test method of EN 61000-4-11) 40% during 10/12 cycles 40% during 10/12 cycles 3 2
70% during 25/30 cycles 70% during 25/30 cycles 3 2
80% during 250/300 cycles 80% during 250/300 3 2
cycles
Short interruptions test 0% during 250/300 cycles 0% during 250/300 3 2
(test method of EN 61000-4-11) cycles

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Table 8: EMC emission tests

EMC emission tests (According to EN60947-4-3:2014)
Test Frequency Limit level for class A Comments
(MHz) industrial
Quasi peak Average
dB (μV) dB (μV)
Radiated radio frequency emission test 30 to 230 40 at 10m N/A Pass
According to EN60947-4-3:2014 230 to 47 at 10m N/A
(test method of CISPR11) 1000
Conducted radio frequency emission test 0.15 to 0.5 79 66 The conducted
According to EN 60947-4-3:2014 for rated 5 to 30 73 60 emissions can meet the
power <20kVA requirement of
(test method of CISPR11) IEC60947-4-3:2014
Conducted radio frequency emission test 0.15 to 0.5 100 90 with an external filter
According to EN 60947-4-3:2014 for rated added on the line
0.5 to 5 86 76 connections.
power >20kVA
(test method of CISPR11) 5 to 30 90 to 731 80 to 601 This is in line with the
rest of the industry2
1. Decrease with log of frequency emissions.
2. Technical note TN1618 (available upon customer request) describes the recommended filter structures which reduce conducted
radio-frequency emissions.

W WARNING
UNINTENDED EQUIPMENT OPERATION
• Do not use the product for critical control or protection applications where
human or equipment safety relies on the operation of the control circuit.

• Signal and power voltage wiring must be kept separate from one another.
Where this is impractical, all wires must be rated to the power voltage &
shielded cables are recommended for signal wiring.

• This product has been designed for environment A (Industrial). Use of this
product in environment B (domestic, commercial and light industrial) may
cause unwanted electromagnetic disturbances in which cases the installer
may be required to take adequate mitigation measures.

• For Electromagnetic Compatibility, the panel or DIN rail to which the product is
attached must be grounded.

• Observe all electrostatic discharge precautions before handling the unit.

• Nominal current of product must be set between 25% & 100% of maximum
current
Failure to follow these instructions can result in death, serious injury or
equipment damage.

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W DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION OR ARC FLASH
• The I/O Input & Output, the Communications ports are SELV circuit. They must
be connected to SELV or PELV circuit.

• The relay output and the fuse holders contacts are compliant to the SELV
requirements; they can be connected to SELV, PELV circuit or to voltage up to
230V (maximum value of rated operational voltage to earth:230V)
Failure to follow these instructions will result in death or serious injury.

SELV is defined (in IEC60947-1) as an electrical circuit in which the voltage cannot
exceed 'ELV' under normal conditions or under single fault conditions, including earth
ground faults in other circuits.

The definition of ELV is complex as it depends on environment, signal frequency, etc.

See IEC 61140 for further details.

Operator Interface
Display 1.44” square TFT colour display allowing
viewing of selected parameter values in real
time, plus configuration of instrument
parameters for users with adequate access
permission.
Push buttons Four push buttons provide page and item entry
and scroll facilities.

Inputs/Outputs
All figures are with respect to 0V, unless otherwise stated.

Number of inputs/outputs 1 Analog input; 2 Digital inputs (DI1 and DI2);

1 Relay output
See I/O Input & Output Details (page 47)
Update rate Twice the mains frequency.
Defaults to 55Hz (18 ms) if the supply frequency
lies outside the range 47 to 63Hz.)
Termination Removable 5-way connector. Located as shown
in Figure 12.
Analog Input
Performance See Table 9 and Table 10
Input type Configurable as one of: 0 to 10V, 1 to 5V,2 to
10V, 0 to 5V, 0 to 20mA, 4 to 20mA
Absolute input maxima -0.6V to +16V and ±40mA

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Table 9: Analog input specification (voltage inputs)

Analog input: Voltage input performance
Parameter Typical Max/Min
Total voltage working input span 0V to +10V
Resolution (electrical noise free) (note 1) 11 bits
Calibration accuracy (notes 2, 3) <0.1% <0.1%
Linearity accuracy (note 2) ±0.1%
Ambient temperature deviation (note 3) <0.01%/°C
Input resistance (terminal to 0V) 142kΩ ±0.2%
Note 1: w.r.t. total working span Note 3: After warm up. Ambient = 25 °C
Note 2: % of effective range (0 to 5V, 0 to 10V)

Table 10: Analog input specification (current inputs)

Analog input: Current input performance

Parameter Typical Max/Min
Total current working input span 0 to +25mA
Resolution (electrical noise free) (note 1) 11 bits
Calibration accuracy (notes 2, 3) <0.2%
Linearity accuracy (note 2) ±0.1%
Ambient temperature deviation (note 2) ±0.01%/°C
Input resistance (terminal to 0v) <102Ω ±1%

Note 1: w.r.t. total working span Note 3: After warm up. Ambient = 25 °C
Note 2: % of effective range (0 to 20mA)

Digital Inputs
Voltage inputs
Active level (high): 11V<Vin<30V with 6mA<input current<30mA
Non-active level (low): -3V<Vin<5V with 2mA<input current<30mA
Or
5V<Vin<11V with input current <2mA
Contact closure inputs
Source current: 10mA min - 15mA max
Open contact (non active)
resistance: >800Ω
Closed contact (active)
resistance: <450Ω
Absolute Maxima: ±30V or ±25mA

Note: Absolute maximum ratings refer to externally applied signals

Digital Output
User configured output (DI2): ±2% 10.2V, 10mA
For example; To supply a potentiometer
between 2kΩ - 10kΩ (±20%) used to drive the
Analog Input when set to Voltage mode - see
Inputs/Outputs (page 102).

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Relay Specification
The relay has gold plated contacts suitable for ‘dry circuit’ (low current) use. See
"I/O Input & Output Details" on page 47.
Contact life
Resistive loads: 100,000 operations
Inductive loads: Derate as per accompanying graph
(Figure 39)
High power use
Current: 2A (resistive loads)
Voltage: <264V RMS (UL: voltage 250Vac.)
Low power use
Current: >10 mA
Voltage: >5V
Contact configuration: Single pole change-over (one set of Common,
Normally Open and Normally Closed
contacts)
Termination Removable 3-way connector. Located as
shown in Figure 12.
Installation Category Installation category III, assuming that nominal
phase to earth ground voltage is ≤ 300V RMS.
Absolute max. switching <2A at 240V RMS (resistive loads)
capability

Note: ‘Normally Closed’ and ‘Normally Open’ refer to the relay when the coil is not
energized.
Reduction factor

Power factor (cos ) φ

Inductive life = resistive life x reduction factor

Figure 39 Relay derating curves

Fuse Holders Contacts Kit Specification

Fuse Holders Contacts Kit are delivered with NO, NC contact
Connection: Faston lugs 2.8 X 0.5 mm
Rated insulation voltage: 250VAC
Rated operational current following IEC 60947-5 & -1
Utilization category AC15: 4A/24V, 4A/48V, 3A/127V, 2.5A/240V
Utilization category DC13: 3A/24V, 1A/48V, 0.2A/127V, 0.1A/240V

Minimum operational current and voltage:

(For contact kit reference according to product rating see Table 4)
Contact kit Mersen Y227928A, for fuse size 14x51, or,
Contact kit Mersen G227959A for fuse size 22x58.
1mA/4V AC or DC
Contact kit Mersen E227612A, for fuse size 27x60
100mA/20V AC or DC

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Mains Network Measurements

All network measurements are calculated over a full mains cycle, but internally
updated every half-cycle. For this reason, power control and alarms all run at the
mains half-cycle rate. The calculations are based on waveform samples taken at a
rate of 20kHz. The phase voltage referred to is the line voltage referenced to input
potential.

The parameters below are directly derived from measurements for each phase.
Accuracy (20 to 25°C)
Line frequency (F): ±0.02Hz
Line RMS voltage (Vline): ±2% of Nominal Vline.
Load RMS voltage (V): ±2% of Nominal V for voltage readings
>1% of Nominal V. Unspecified for
readings lower than 1%Vnom.
Load current (IRMS): ±2% of Nominal IRMS for current readings
>3.3% of Nominal IRMS. Unspecified for
readings ≤ 3.3% of Nominal. IRMS.
Load RMS voltage squared (Vsq): ±2% of (Nominal V)2
Thyristor RMS current squared (Isq): ±2% of (Nominal I)2
Frequency resolution 0.1 Hz
Measurement resolution 11 bits of Nominal value
Measurement drift with ambient <0.02% of reading / °C
temp.

Further parameters (Z, IsqBurst, and Vsq Burst) are derived from the above, for the
network (if relevant).

W WARNING
UNINTENDED EQUIPMENT OPERATION
• Nominal current of product must be set between 25% & 100% of maximum
current.
Failure to follow these instructions can result in death, serious injury or
equipment damage.

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Rear Cover (Master)

Scan for local contents

Eurotherm Ltd
Faraday Close
Durrington
Worthing
West Sussex
BN13 3PL
Phone: +44 (0)1903 268500
www.eurotherm.co.uk

As standards, specifications, and designs change from time to time, please ask for confirmation
of the information given in this publication.

© 2019 Eurotherm Limited. All Rights Reserved.

*HA033172*
HA033172 Issue 3
(CN37358)