Watlow PC1X-N20 User Manual Download

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A p p e n d i x

Wa t l o w P o w e r S e r i e s

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A . 1 1

Index

A to D Failure Error A.4
Accum Hours (0 - 9999) 6.18
Accum Hours (10K - 100M) 6.18
Active Alarms 6.1
Active Relay State 6.10
Adjust High mA Cal Point Zones 1-3

6.21

Adjust High V Cal Point Zones 1-3 6.21
Adjust Low mA Cal Point Zones 1-3

6.21

Adjust Low V Cal Point Zones 1-3 6.21
Alarms 5.7

active relay state 5.7
global 5.7
latched 5.7
latched and silenced 5.7
silencing 5.7
standard 5.7

Alarms Setup Menu Lockout 6.16
Alarms, troubleshooting A.4-A.5

communications watchdog alarm A.4
frequency out of tolerance alarm A.4
heat sink over temperature alarm A.4
heater open alarm A.4
heater tolerance alarm A.4
line compensation alarm A.4
line loss alarm A.4
line over voltage alarm A.4
load balance alarm A.4
phase balance alarm A.4

Ambient Temperature Rating 2.1
Analog (mA) Input 1 Signal 6.2, 6.3
Analog (mA) Input 2 Signal 6.2, 6.3
Analog (mA) Input 3 Signal 6.3
Analog (mA) Input Signal 6.1
Analog (V) Input 1 Signal 6.2, 6.3
Analog (V) Input 2 Signal 6.2, 6.3
Analog (V) Input 3 Signal 6.3
Analog (V) Input Signal 6.1, 6.4
Analog Input Factory Menus Lockout 6.16

Backup A.7
Backup Data Set 6.15
Baseline Voltage 5.6
Baseline Voltage Learn Req. Zones 1-3

6.7

Baseline Voltage Read/Adj. Zones 1-3

6.7

Cal Retransmit Request 6.22
Calibrate Analog Input Req. Zones 1-3

6.21

Calibrate Analog Input Signal Zones 1-3

Menus 6.21

Calibrate Retransmit Menu 6.22
Comms Setup Menu Lockout 6.16
Comms Watchdog Alarm Config. 6.11
Communications 5.8
Communications Watchdog Alarm A.4
Configuration Installed Options 6.18

Control Configurations 1.2

3 phase, 2-leg 1.2
3 phase, 3-leg 1.2
3 phase, multizone 1.2
single phase 1.2

Control Setup Menus Lockout 6.16
Cooling 2.3
Current Limit Select (On/Off) Zones 1-3

6.8

Current Limit Set Point (A) Zones 1-3 6.9
Current Limiting 5.5

DC Contactor - Zero Cross 5.2
Default Data Set 6.15
Default Numeric Input Sig. (%) Zones 1-3

6.6

Diagnostics Factory Menu Lockout 6.17
Diagnostics Menu 6.19-6.20
Dimensions 2.2
Display Loop Errors 6.1, A.4-A.7
Display Loop Menu 4.2, 4.3
Display Phase Selection 1-3 6.4
Display Test 6.20
Display Zone Selection 6.2, 6.3

Enable NVOL Storage 6.16
Enclosure Guidelines 2.3
Errors, troubleshooting A.4-A.5

A to D failure error A.4
half cycle line loss error A.6
heater bakeout overcurrent error A.4
nonvolatile memory checksum error A.6
over temperature error A.6
phase rotation error A.6
RAM error A.6
shorted SCR error A.4
system configuration error A.4

Factory Mode 6.20
Factory Mode Request 6.20
Factory Page Menu 4.2, 4.4
Factory Page Parameters 6.14 - 6.22
Factory Password 6.20
Factory Password Entry 6.20
Factory Safety Shutdown Temp 6.18
Fan Cooled Output Rating Curves 2.5
Fast Start Guide 5.10
Fixed Time Base (Sec) 6.5
Fixed Time Base - Zero Cross 5.1
Frequency Out of Tol. Alarm Config. 6.11
Frequency Out of Tolerance Alarm A.4
Fuse Replacement A.6

Global Alarm Configuration 5.7, 6.10
Global Lockout 5.6, 6.16
Global/Menu Lockouts Menu 6.16-6.17

Half Cycle Line Loss Error A.6
Hardware Version 6.17
Harsh Environment 2.3
Heat Sink Alarm Temp 6.18
Heat Sink Over Temperature Alarm A.4
Heat Sink Over Temperature Alarm

Configuration 6.10

Heat Sink Over Temperature Alarm

Temperature 6.10

Heat Sink Temp (°C) 6.18
Heater Bakeout 5.4
Heater Bakeout Overcurrent Error A.4
Heater Bakeout Overcurrent Trip

Zones 1-3 6.8

Heater Bakeout Select (On/Off) Zones 1-3

6.8

Heater Bakeout Select Time Zones 1-3 6.8
Heater Bakeout Timeout 6.2
Heater Bakeout Timeout Zone 1 6.2, 6.3
Heater Bakeout Timeout Zone 2 6.2, 6.3
Heater Bakeout Timeout Zone 3 6.3
Heater Diagnostics Feature 1.2
Heater Open Alarm A.4
Heater Open Alarm Config. 6.10
Heater Tolerance Alarm A.4
Heater Tolerance Alarm Config. 6.10
Heater Tolerance Detection 5.4
High Tolerance Set Point (A) Zones 1-3

6.9

I J

Inductive Current 6.9
Inductive Load Factor Request 6.9
Input 5.6

signal selection 5.6

Input Signal Method Select (dig, mA, Volt)

Zones 1-3 6.6

Input Wiring 3.2-3.3

2 zone 3.3
3 zone 3.3
communications 3.2
control power and alarm 3.2
retransmit 3.2
single zone 3.3

Installation 2.1-2.6

Keys and Displays 4.1

Learn Input Learn Req. (Hi, Lo) Zones 1-3

6.7

Line Compensation Alarm A.4
Line Frequency (Hz) 6.1
Line Loss Alarms 6.19, A.4
Line Loss Alarm Configuration 6.10
Line Over Voltage Alarm A.4
Line Potential (Volts) rms Zone 1 6.3, 6.4
Line Potential (Volts) rms Zone 2 6.3, 6.4
Line Potential (Volts) rms Zone 3 6.3, 6.4
Line Potential (Volts) rms 6.2
Line Power Wiring 3.4
Line Voltage Compensation 6.6
Load Activity Indicator 6.1
Load Balance Alarm A.4
Load Balance Alarm Config. 6.11
Load Balance Percentage 6.11
Load Current (Amps) rms 6.2
Load Current (Amps) rms Zone 1

6.3, 6.4

Load Current (Amps) rms Zone 2 6.3, 6.4
Load Current (Amps) rms Zone 3 6.4
Load Power (kVA) 6.2, 6.4
Load Power (kVA) Zone 1 6.3, 6.4

Summary of Contents for PC1X-N20

Page 1: ...Manual 1241 Bundy Boulevard P O Box 5580 Winona Minnesota USA 55987 5580 Phone 1 507 454 5300 Fax 1 507 452 4507 http www watlow com Registered Company Winona Minnesota USA ISO 9001 TOTAL 3Y earWarran...

Page 2: ...e Appendix and review all of your configuration information to verify that your selections are consistent with your application inputs outputs alarms limits etc If the problem persists after checking...

Page 3: ...5 Control Methods and Features 5 1 Zero Cross 5 1 Phase Angle 5 2 Other Features 5 6 Input 5 6 Alarms 5 7 Communications 5 8 Retransmit 5 9 Fast Start Guide 5 10 Chapter 6 Parameters 6 1 Display Loop...

Page 4: ...ii Watlow Power Series Table of Contents...

Page 5: ...del number selected See page 1 2 for additional information on the Power Series configuration options Figure 1 1 Power Series features Ground Lug Built in designed for easy ground connections I O Port...

Page 6: ...ng current limiting and heater bakeout is not available Three Phase Three Leg Configuration There are two Power Series configurations that include six SCR control All features are available in these c...

Page 7: ...th not more than three current carrying conductors in raceway or cable while also considering the Power Series 50 C enclosure temperature and semiconductor fuse rating Use copper conductors only The t...

Page 8: ...he key slots on the mounting plate Push the unit in and then down until it snaps into place Mounting is complete For F35 models F35 models are a bolt down package Drill and tap six holes per the above...

Page 9: ...k well on sealed enclosures but do not provide as much cooling as vortex coolers or air conditioners To determine how much cooling is required 1 Determine the amperage load on the Power Series Multipl...

Page 10: ...reverse the mounting operation Maintaining the Power Series Cleaning The heatsink fins must be kept clean for proper cooling and the printed circuit board should be free of conductive residue condens...

Page 11: ...10 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 60 55 50 45 40 35 30 25 Current amps into a Resistive Load Enclosure Internal Ambient Temperature in C 3 Phase 3 Leg and 3 Zone Multizone...

Page 12: ...ne Natural Convection at 100 On 25 30 35 40 45 50 55 60 65 Current Amps into a Resistive Load N20 N25 N30 Enclosure Internal Ambient Temperature C 60 140 70 80 90 100 110 120 130 50 3 Phase 2 Leg and...

Page 13: ...maintenance program to re torque line and load terminations every 3 6 months Figure 3 1 Torque and wire stripping Terminals 1 6 and Ground Lug Torque to 180 in lbs 20 Nm with 3 8 inch Allen wrench pr...

Page 14: ...Torque to 8 in lbs 0 9 Nm Hold torque for 30 seconds to allow for wiring settling and cold flow Re torque after 48 hours All line connections should be re torqued every 3 6 months Input Wiring Figure...

Page 15: ...INPUT 2 I V Current In 4 to 20mA Common Voltage In 0 to 10V I V Current In 4to 20mA Common Voltage In 0 to 10V Power Series 6 5 4 3 2 1 11 10 9 8 7 14 13 12 17 16 15 20 19 18 23 22 21 External Connec...

Page 16: ...NEC standard wiring practices to install and operate the Power Series Failure to do so could result in damage and or injury or death NOTE Torque and wire strip guidelines Connections 1 thru 6 and gro...

Page 17: ...p ring For 14 16 AWG Molex ETC AA 5261 3M MNG14 250DFIX C 54 503X or equivalent NOTE Models PC8 and PC9 control legs are isolated so that they may be wired from phase to phase inside delta or phase to...

Page 18: ...uld present a fire hazard or other hazard Failure to install temperature limit control protection where a potential hazard exists could result in damage to equipment property and injury to personnel N...

Page 19: ...display Upper Display Indicates operating levels requested current line voltage or power feedback levels for the parameter in the lower display Home Key Returns to the Display Loop if in any other pa...

Page 20: ...keys together for 2 sec 8 8 Factory Page From Setup Page press and and keys together for 2 sec 8 8 load Display Loop From Setup or Factory Page press the key Setup Page for setting up the control alar...

Page 21: ...n c3 or In u3 Out3 Hbt3 UoL3 Cur3 HUa3 ph5 UoL3 Cur3 Press Home and Left Keys together for 2 seconds to enter the Setup Menus from the Display Loop Setup Page Menus Factory Page Menus Display Loop Pre...

Page 22: ...eter appears in the bottom display Use the Increment Decrement keys to select a value either alpha or numeric within a parameter The value appears in the upper display NOTE This prompt will only appea...

Page 23: ...zero cross Figure 5 1a Zero cross switching SCR Switch On Off Points 0 Fixed Time Base Zero Cross In the fixed time base control method the selected percentage power level output is generated over a...

Page 24: ...The off on thresholds are 2 0V 3 5V for voltage input 5 0mA 8 0mA for current input This means the unit is off for an input voltage current of 2 0V 5 0mA or lower and 100 on for an input volt age cur...

Page 25: ...t start sequence ends to cause large changes in requested power to be implemented gradually The maximum rate of change of the power is defined as the percentage of power change allowed every 0 1 secon...

Page 26: ...Heater bakeout operates with an over current trip The operator must set the maximum current allowed during heater bakeout using the HbOC prompt This will set the maximum allowable load during heater b...

Page 27: ...rove current measurement when phase angle firing into a transformer or other inductive loads The adjustment should be done with active phase angle control with a requested power of 5 to 50 in the zone...

Page 28: ...n the display reads data press until loc fcty fcty is displayed Press until Unl is displayed glOC Use Global Lockout gLOC to write protect all prompts by choosing locked LOC If set to un locked Unl in...

Page 29: ...dition is over A description of the alarms and errors why they occur and how to troubleshoot them can be found on pages A 4 A 7 Setup Page Enter the Setup Page holding for 2 seconds When the display r...

Page 30: ...need to run software that uses the Modbus RTU protocol to read or write to registers in the controller See Chapter Six Parameters for the Modbus registers These registers contain the parameter values...

Page 31: ...s or zone 2one if it is a multizone unit HUa retransmits the load power of selected zone 2one in all models Select phase phas or zone 2one to choose the phase zone that will represent your retransmit...

Page 32: ...res Watlow Power Series Get Your Power Series Controlling Heat Fast Start Guide load ___ set algo algo cont Off Ftb Urtb PH2t set algo set Ctr1 In nna Uolt dig Off nna_ Uol_ nna Uol dflt bl u lrn U re...

Page 33: ...es Watlow Power Series load ___ set algo algo cont Off Ftb Urtb PH2t set algo set Ctr1 In nna Uolt dig Off nna_ Uol_ nna Uol dflt bl u lrn U req type 2l d 2lod 2luy none 3lid 3l d 3lgy Fast Start Guid...

Page 34: ...utside LEDs operate in 3 phase 3 leg and multizone each zone operates a separate LED ___ or _ per display v LoAd Load Activity Indicator Displays if load has power applied Active Any active error See...

Page 35: ...heater diagnostics option is installed 156 r n a 0 to 9999 0 to 9999 HUa Load Power kVA Displays est calcu lated load power Active if heater diagnostics option is installed 164 r n a 0 to 9999 0 to 99...

Page 36: ...Three Zone Single Phase Active with multizone configuration and heater diag nostics option is installed 156 r 1 166 r 2 n a 0 to 9999 0 to 9999 HUa1 HUa2 Load Power kVA Read calculated est load power...

Page 37: ...on 3 ph 2 leg models do not show 2 Phas n a 1 to 3 1 2 3 Phas Display Phase Selection 1 to 3 Select phase for display Active Always Appears in Display Loop 159 r 0 0 to 10 0 0 to 1000 Out Output Power...

Page 38: ...ill restart the system 55 r w Off non operational 1 cont dc contactor 0 Off non operational 1 Ftb fixed time base zero cross 2 Urtb variable time base zero cross 3 PH2t phase angle 4 ALgo Power Contro...

Page 39: ...t to cont 5101 r w 1 5201 r w 2 5301 r w 3 nna cur rent 1 OFF off 0 nna current 1 Uolt voltage 2 dig keyboard or comms 3 In Input Signal Method Select dig mA Volt Select the input signal method for ch...

Page 40: ...lrn U Baseline Voltage Learn Request Allows software to learn the baseline voltage on line connected to the zone chosen Active Always 5594 r w 1 5595 r w 2 5596 r w 3 Line Voltage rating Minimum to m...

Page 41: ...us is available only if Heater Diagnostics is installed Zone 1 is used if Input Output Configuration is single phase single zone or three phase Zone 1 and Zone 2 are used if Input Output configuration...

Page 42: ...quested power is above 20 5114 r w 1 5214 r w 2 5314 r w 3 0 0 0 to tol 0 amps to High Toler ance Set Point 1 amp increments 0 to Heater High Tolerance Set Point tol_ Low Tolerance Set Point A Set hea...

Page 43: ...Tolerance Alarm Config Selects heater tolerance alarm configuration Active if heater diagnostics is installed Active if glbl is set to Off 860 r w std active 0 std active 0 LaT latched 1 SIl silenced...

Page 44: ...cy tol erance alarm config uration Active if heater diagnostics is installed Active if controller is 3 phase 991 r w 100 100 0 to 100 0 to 100 Ldif Load Balance Percentage Selects the mini mum percent...

Page 45: ...serial communications option is installed and Wd Watchdog is set to On 86 r w 9999 9999 0 to 9999 0 to 9999 seC Watchdog Timeout Sec Selects a timeout in seconds for the communications watchdog Activ...

Page 46: ...tr type is set to Cur 877 r w load current Cur_ to load current Minimum Amps Re transmit to load cur rent Cur Maximum Amps Retransmit Select maximum load current to be retransmitted Active if retransm...

Page 47: ...ay Loop The Factory Page contains nine menus The Factory Mode parameters of the Factory Page are used for calibration of the Power Series Since the Power Series is precalibrated at the factory field c...

Page 48: ...ies Backup information Active Always 951 r w idle no backup re quested 0 idle no backup re quested 0 all all parameters listed in system zone 1 2 and 3 1 sys system related parameters includes locks a...

Page 49: ...Alr Alarms Setup Menu Lockout Sets lock on alarm configuration menu Active if glOC is set to Unl Active if heater diagnostics option is installed 1352 r w Unl 0 Unl Unlocked 0 LOC Locked 1 Opt Options...

Page 50: ...h 00 to 52 date Manufactured Date yymm Reads month and year of manufacture Active Always 2 r n a 0 to 9999 0 to 9999 Sn_ Unit Serial Num ber Low Digits Reads the low digits of the serial number of the...

Page 51: ...over temp alarm Active Always 1590 r n a 0 to 9999 0 to 9999 Heat Sink Temp C Reads the current heat sink temp Active Always 54 r n a nOne none 0 c comms 1 r retransmit 2 rc comms retrans mit 3 h heat...

Page 52: ...n Active Always n a n a 0 to 4095 Cnts Read Selected A D Counts Reads the selected analog to digital channel Active Always 1560 r 1561 r 1562 r 1563 r 1564 r 1565 r 1566 r 1567 r 1568 r 1569 r 1570 r...

Page 53: ...To enter the Factory Mode requires a password Call Watlow at 1 507 454 5300 and ask an applications engineer for this password Once the password is entered the controller is in Factory Mode The contro...

Page 54: ...decimal places because of the resolution of the display The comms registers are set and stored with three decimal places of resolution Active if in factory mode 5412 r w 1 5422 r w 2 5432 r w 3 1 00 1...

Page 55: ...gh voltage value for retransmit cal Active if in factory mode Active if retransmit option is installed 5720 r w 000 1000 0 to UOL 0 to Retransmit Cal Volts High Uol_ Retransmit Cal Volts Low Set the l...

Page 56: ...leshooting Alarms and Errors A 4 Checking and Replacing Fuses A 6 Power Series Backup A 7 Modbus Registration Numbers A 8 Product Specification A 9 Ordering Information A 10 Index A 11 Prompt Index A...

Page 57: ...that line power is connected and is on at the appropriate voltage Return the unit to the factory for repair Heater or load wire is not connected Blown fuse set algo is set to OFF Incorrect input wirin...

Page 58: ...Figure 3 5C Two phases are 180 out of phase of each other No current monitor on the display Reference connections to other lines or neutral must be made appropriately for each zone See page 3 5 for wi...

Page 59: ...ess than the value set in the Setup Page Options Menu toL_ or is greater than the value set in toL This will accomplish both the overcurrent condition alarm and the heater failure low current alarm Th...

Page 60: ...r evaluation Yes if ph2t Yes Insure that the line voltage is the same for each phase If line voltages are the same check line voltages calibrations Yes if ldif Yes Address load balance on heaters No C...

Page 61: ...s err Phase Rotation p rOt Error err Over Temperature Ot Error Error will occur when heat sink temperature is greater than factory shutdown temperature sd err Ram Error ram Error will occur when RAM f...

Page 62: ...m persists return to factory for repair 195 r 8 No Yes Corrective Action Modbus Number Auto Recovery Shut down 195 r No Yes Yes No 195 r 1 It s likely the heater is too wet for heater bakeout time sel...

Page 63: ...80 Select Discrete Input 1581 Read Selected Input Value 1590 Heat Sink Temp C 1591 Record High Heat Sink Temp 1700 Factory Mode Request 1799 Factory Password Entry 1960 Accum Hours 10K 100M 1961 Accum...

Page 64: ...Rs 3 phase 2 leg control 4 SCRs Resistive load only zero cross firing only 3 phase 3 leg control 6 SCRs 3 phase 3 leg control 6 SCRs for 4 wire wye loads Multizone two and three single phase zones Out...

Page 65: ...Must have heater diagnostics selected Custom 00 None AA No Watlow logo with agency approval marks AB ZZ Custom consult factory for options 01 Select for PC8 or PC9 using single phase power supply Wat...

Page 66: ...r A 4 nonvolatile memory checksum error A 6 over temperature error A 6 phase rotation error A 6 RAM error A 6 shorted SCR error A 4 system configuration error A 4 F Factory Mode 6 20 Factory Mode Requ...

Page 67: ...20 Retransmit Setup Menu Lockout 6 16 Retransmit Type Select 6 12 Retransmit Wiring 3 2 Retransmit Zone Select 6 13 S Safety Information inside front cover Select Analog to Digital Channel 6 19 Selec...

Page 68: ...6 18 L l a1 Line Loss Alarm Most Recent 6 19 l a2 l a2 l a2 Line Loss 6 19 l a3 l a3 l a3 Alarm Type 6 19 l a1 Line Loss Alarm Previous 6 19 l a1 Line Loss Alarm Least Recent 6 19 Lbal Load Balance Al...

Page 69: ...ps Short Interruptions and Voltage Variations EN 61000 3 2 2009 Harmonic Current Emissions4 EN 61000 3 3 2013 Voltage Fluctuations and Flicker Unit Supply EN 61000 3 11 2000 Voltage Fluctuations and F...

Page 70: ...m to local and national electrical codes Failure to observe this warning could result in damage to property and or injury to death for personnel In line power filters have been shown to properly suppr...

Page 71: ...Over Temp Alarm Temp _ Line Line Loss Alarm _ _ _ _ _ _ _ _ _ _ p bAl Phase Bal Alarm _ _ _ _ _ _ _ _ _ _ Lbal Load Bal Alarm _ _ _ _ _ _ _ _ _ _ Ldif Load Bal Percent _ _ _ _ _ _ _ _ _ _ Freq Freq Ou...

Page 72: ......

Page 73: ...manship for 36 months after delivery to the first purchaser for use pro viding that the units have not been misapplied Since Watlow has no control over their use and sometimes misuse we cannot guarant...

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