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Chapter Two

Installation

Installation, Chapter 2

Watlow Power Series

I

2.1

2

The following two chapters will explain how to install the Power Series
controller. Watlow power controllers are thoroughly tested before leaving the
factory, so the Power Series controller is ready to install when you receive it.

Chapters 2 and 3 describe the steps required to install the Power Series
controller. Refer to Chapter 2 for mounting information and Chapter 3 for input,
power, and load wiring of the Power Series.

Before beginning installation, read through these chapters to gain an under-
standing of the entire installation. Consider the installation carefully. Plan the
power, load, and input signal wiring before mounting the Power Series. Also
consider the cabinet space, controller dimensions, wire bending radius, and air-
flow. Use good wiring practices to minimize electrical noise problems.

∫

WARNING:

To avoid potential electric
shock and other hazards,
all mounting and wiring
for the Power Series must
conform to the National
Electric Code (NEC) and
other locally applicable
codes.

Power Series Wire Bending Radius at Base Current and Ambient
Temperature Rating and Replacement Semiconductor Fuses

Minimum recommended wire sizes are based on the NEC 30°C ambient with 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 terminal lug wire range for all Power Series amperages is 350 MCM to 6

AWG. The recommended terminal torque is 180 in.-lbs. (20 Nm.).

Terminal lug

ratings are for

one

wire per lug.

Refer to page

3.1 for torque guidelines.

NOTE: Ground must be
wired with the same size
wire as line and load
connections to a ground
of sufficient current
carrying capacity.

NOTE: Integral semicon-
ductor fuses do not
qualify as branch circuit
protection.

Power Series

Current (Amps)

Minimum

Recommended Wire

Size (90C) (AWG)

Wire Bending

Radius

mm inches

Semiconductor

Fuse Rating

(Amps)

Watlow Replacement

fuse P/N

Bussmann

Replacement Fuse

P/N

65

6 AWG

51

2.0

100

0808-0102-0100

170M1317

80

4

76

3.0

125

0808-0102-0125

170M1318

85

4

76

3.0

125

0808-0102-0125

170M1318

90

4

76

3.0

125

0808-0102-0125

170M1318

100

3

76

3.0

160

0808-0102-0160

170M1319

105

3

76

3.0

160

0808-0102-0160

170M1319

120

2

89

3.5

160

0808-0102-0160

170M1319

125

2

89

3.5

160

0808-0102-0160

170M1319

140

1

114

4.5

200

0808-0102-0200

170M1320

155

1/0

140

5.5

200

0808-0102-0200

170M1320

160

1/0

140

5.5

250

0808-0102-0250

170M1321

165

1/0

140

5.5

250

0808-0102-0250

170M1321

185

2/0

152

6.0

250

0808-0102-0250

170M1321

200

3/0

165

6.5

250

0808-0102-0250

170M1321

250

250 MCM

216

8.5

315

0808-0102-0315

170M1322

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Содержание PC1X-N20

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 72: ......

Страница 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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