Grieve Corporation PC1X-E20 Installation Manual

0600-0039-0000 Rev D Made in the U.S.A.

March 2007 $10.00 Supersedes: 0600-0039-0000 Rev C

User’s 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

3 Year Warranty

CUSTOMER

SATISFACTION

Power Series

Microprocessor-Based

SCR Power Controller

U.S. English

Safety Information in this Manual

Note, caution and warning symbols appear throughout this book to draw your attention to important operational and safety information.

A “NOTE” marks a short message to alert you to an important detail. A “CAUTION” safety alert appears with information that is important for

protecting your equipment and performance. A “WARNING” safety alert appears with information that is important for

protecting you, others and equipment from damage. Pay very close attention to all warnings that apply to your application.

The ç symbol (an exclamation point in a triangle) precedes a general CAUTION or WARNING statement.

The Ó symbol (a lightning bolt in a lightning bolt in a triangle) precedes an

electric shock hazard CAUTION or WARNING safety statement.

Technical Assistance

If you encounter a problem with your Watlow controller, see the Troubleshooting Table in the 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 the

above, you can get technical assistance from your local Watlow representative, or by dialing +1 (507) 454-5300, 7:00 a.m. to 7:00 p.m. Central Standard Time.

An applications engineer will discuss your application with you.

Please have the following information available when you call:

• Complete model number • All configuration information

• User’s Manual • Diagnostic Menu readings

Warranty and return information are on the back cover of this manual.

Your Comments

Your comments or suggestions on this manual are welcome. Please send them to the Technical Literature Team, Watlow Winona, 1241 Bundy Boulevard, P.O. Box 5580, Winona, Minnesota, 55987-5580 U.S.; Telephone: +1 (507) 454-

Safety Alert CAUTION or WARNING

∫

Electrical Shock Hazard

CAUTION or WARNING

Chapter 1: Overview . . . . . . . . . . . . . . . . .1.1

Chapter 2: Installation . . . . . . . . . . . . . . . .2.1

Dimensions . . . . . . . . . . . . . . . . . . . .2.2

Mounting the Power Series . . . . . . . . .2.2

Enclosure Guidelines . . . . . . . . . . . . .2.3

Harsh Environments . . . . . . . . . . . . . .2.3

Removing the Power Series . . . . . . . .2.4

Maintaining the Power Series . . . . . . .2.4

Output Rating Curves . . . . . . . . . . . . .2.5

Chapter 3: Wiring . . . . . . . . . . . . . . . . . . .3.1

Torque Guidelines . . . . . . . . . . . . . . .3.1

Input Wiring . . . . . . . . . . . . . . . . . . . .3.2

Line Power/Output Wiring . . . . . . . . . .3.4

Wiring Example . . . . . . . . . . . . . . . . .3.6

Chapter 4: Navigation and Software . . . . .4.1

Keys and Displays . . . . . . . . . . . . . . .4.1

Navigation . . . . . . . . . . . . . . . . . . . . .4.2

Software Map . . . . . . . . . . . . . . . . . . .4.3

Chapter 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 . . . . . . . . . . . . . . . . . . .6.1

Setup Page . . . . . . . . . . . . . . . . . . . .6.5

Factory Page . . . . . . . . . . . . . . . . . . .6.14

Factory Mode . . . . . . . . . . . . . . . . . . .6.20

Appendix . . . . . . . . . . . . . . . . . . . . . . . . .A.1

Troubleshooting . . . . . . . . . . . . . . . .A.2

Troubleshooting Alarms and Errors . .A.4

Checking and Replacing Fuses . . . . .A.6

Power Series Backup . . . . . . . . . . . . .A.7

Modbus™ Register Numbers . . . . . . .A.8

Product Specifications . . . . . . . . . . . .A.9

Ordering Information . . . . . . . . . . . . .A.10

Index . . . . . . . . . . . . . . . . . . . . . . . . .A.11

Prompt Index . . . . . . . . . . . . . . . . . . .A.13

CE Declaration of Conformity . . . . . . .A.14

Warranty and Returns Policy . . .back cover

Power Series

Table of Contents Watlow Power Series ■ i

ii ■ Watlow Power Series Table of Contents

Overview, Chapter 1 Watlow Power Series ■ 1.1

Chapter One

Overview

Introduction

The Power Series is a state-of-the-art microprocessor-based Silicon Controlled Rectifier (SCR) power controller intended for controlling industrial heaters. This product is based on one package with several configurations that include single phase, three phase, and single phase-multizone capabilities. Each package configuration has a specific current rating depending on the number of phases switched. The switching capabilities include 65 to 250A rms at 50°C from 24 to 600V~ depending on the configuration or model number selected. See page 1.2 for additional information on the Power Series configuration options.

Figure 1.1 — Power Series features.

Removable Mounting Plate

Power Series snaps on a premounted, removable plate.

Terminal Cover

Electrically touch-safe package.

Fuse Cover

Slides up and down for fuse maintenance and covers the high voltage components.

Digital Programmer/Display

For controller configuration, setup, and monitoring features.

Power Series Solid State Power Control

Ground Lug

Built in, designed for easy

ground connections.

I/O Port

Input, retransmit output, communications, and alarms.

On-Board Fan

A fan is integrated into the package on forced air cooled models to eliminate separate power connection for fan.

Allen Wrench

Used to torque terminals 1 to 6 and ground lug.

Single Phase

This configuration can be purchased with any or all the features available on the Power Series. The only limitations are the features selected by the customer upon purchase. It has the highest current rating of all configurations since it is only switching one phase of the ac line. It is intended for resistive heaters, but can also be used on transformer connected loads in the phase angle firing mode.

Three Phase, Two-Leg Configuration

This configuration is intended for zero cross firing into a stable resistive heater, i.e., nichrome element. Typically, a three phase, three-wire delta or ungrounded wye/star connected heater is most often used where only two of the three V~ line phases are switched. The third phase is a direct connection through a bussbar on board the Power Series and is controlled by the previous two phases. For this reason, a two-leg configuration should not be used for three phase grounded wye/star connected heaters. (For heaters that are required to be three phase grounded wye/star connected, see “Three Phase, Three-Leg Configuration” section below.)

Because this configuration does not allow phase angle firing, it should not be used on transformer coupled heaters and less stable resistance heaters such as silicon carbide, molybdenum disilicide, carbon graphite, or tungsten lamp heaters. This may cause premature heater failure or nuisance fuse blowing.

Heater current monitoring and kVA options are available with a three phase, two-leg configuration via the heater diagnostics option. Phase angle firing, including 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 configurations.

The three-leg version is intended for phase angle firing into a transformer connected load or direct connection to heating that requires soft start and/or current limiting.

The four-wire configuration is intended for zero cross firing into a four-wire wye connected nichrome/resistive heater.

Single Phase, Multizone Configuration

This configuration is available in two and three single phase zones. Back-to-back SCRs are used and all of the features of a single phase unit are available. (Note that there is only one alarm relay and all zones in the controller must use the same control method.) This configuration is intended for applications with multiple command signals from independent control zones. The multizone platform offers reduced panel space compared to using multiple single phase power controllers.

Heater Diagnostics

Heater diagnostics is a key feature of the Power Series SCR power controller. Heater diagnostics may include all or only some of the features that require heater current monitoring, depending on the model selected. Heater current monitoring is only available with heater diagnostics installed on the controller. The features dependent on heater current monitoring are heater bakeout, current limiting, heater current and kVA monitoring, retransmit, and heater monitoring alarms such as open heater, heater out of tolerance, load balance, and shorted SCR detection/error. Heater diagnostics must also be installed if you need phase angle control with current limit.

1.2 ■ Watlow Power Series Overview, Chapter 1

Chapter Two

Installation

Installation, Chapter 2 Watlow Power Series ■ 2.1

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 understanding 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 airflow. 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.). 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 semiconductor 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 51 2.0 100 0802-0102-0100 170M1317 80 4 76 3.0 125 0802-0102-0125 170M1318 85 4 76 3.0 125 0802-0102-0125 170M1318

90 4 76 3.0 125 0802-0102-0125 170M1318 100 3 76 3.0 160 0802-0102-0160 170M1319 105 3 76 3.0 160 0802-0102-0160 170M1319 120 2 89 3.5 160 0802-0102-0160 170M1319 125 2 89 3.5 160 0802-0102-0160 170M1319 140 1 114 4.5 200 0802-0102-0200 170M1320 155 1/0 140 5.5 200 0802-0102-0200 170M1320 160 1/0 140 5.5 250 0802-0102-0250 170M1321 165 1/0 140 5.5 250 0802-0102-0250 170M1321 185 2/0 152 6.0 250 0802-0102-0250 170M1321 200 3/0 165 6.5 250 0802-0102-0250 170M1321 250 4/0 178 7.0 315 0802-0102-0315 170M1322

2.2 ■ W atlow Power Series Installation, Chapter 2

Mounting the Power Series Controller

NOTE: The Power Series controller must be mounted vertically. When multiple units are used in one cabinet, it is best that they are mounted side-by-side when possible. If they are mounted one above the other, adequate spacing and airflow must be provided. See Enclosure Guidelines on page 2.3.

1. Determine the panel location for mounting the Power Series controller and punch or drill holes for the

4 mounting screws per the drawing below. The mounting plate can be used as a template.

2. Attach the Power Series mounting plate using 4 screws (customer supplied, #10 screw minimum, 1/4 inch screw maximum).

3. Align the heads of the shoulder screws on the back of the Power Series heat sink with the key slots on the mounting plate. Push the unit in, and then down until it snaps into place. Mounting is complete.

Figure 2.2c — Installing the controller.Figure 2.2b — Mounting plate dimensions.

Figure 2.2a — Power Series dimensions.

Power Series Dimensions

Add a 9-in. clear-

ance dimension to help develop the chimney cooling effect. This should be on the top and bottom of the Power Series mounting.

Power Series Top View

Power Series Front View

200 mm

(7.9 in.)

Power Series Solid State Power Control

354 mm

(14.0 in.)

191 mm

(7.5 in.)

45 6

Power Series Mounting Plate

Mounting Holes (4)

7mm

(0.27 in.)

Key Slots

102mm

(4.00 in.)

151mm

(5.93 in.)

Release Tab

178mm

(7.00 in.)

39mm

(1.53 in.)

25mm (0.97 in.)

Installation, Chapter 2 Watlow Power Series ■ 2.3

Enclosure Guidelines

The Power Series must be mounted in a suitable electrical enclosure. It must have adequate wire bending space and cooling. The maximum ambient temperature in the enclosure must not exceed 50°C (122°F) for name plate rating. For other output ratings and enclosure ambient temperatures, see output rating curves on pages 2.5 and 2.6.

To maintain the proper cooling, the enclosure must be large enough to dissipate the heat generated by the Power Series, or there must be some form of active cooling.

1. Air circulation — fans bring air into the bottom of the enclosure and louver plates to allow the air to exit the top of the enclosure. Filters are not recommended as they can become plugged and block air flow. To maintain 80 percent of the CFM of a fan, the outlet must be four times the area of the fan inlet. Ensure that each Power Series is within an unobstructed airstream.

2. Vortex coolers operate on compressed air and provide good cooling on a sealed enclosure, but are noisy and consume a lot of air.

3. Cabinet air conditioners work well on sealed enclosures.

4. Heat pipe coolers work 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. Multiply the amperage by

1.2 and then by the number of phases controlled. This is the output power dissipated by the SCRs in watts. Add the watts dissipated by the controller’s power supply (21W) and multiply the total power in watts by 3.41 to get BTUs per hour. Vortex coolers, heat pipe coolers, and air conditioner cooling are rated in BTUs removed.

2. Add up the watts generated by other electronics in the enclosure and

multiply by 3.41 to get BTUs per hour.

3. Add up the total BTUs inside the enclosure and pick a cooling device that will

remove that amount of BTUs.

4. For fan cooled enclosures, enclosure and fan manufacturers usually have

free software programs and application notes to help size the fans for enclosures. If necessary, contact the Application Engineers at Watlow Controls for assistance.

Harsh Environment

The Power Series meets standards UL508, Pollution degree 3 for safety which states: “Conductive pollution occurs or non-conductive pollution occurs which becomes conductive due to condensation which is to be expected.” However, Watlow recommends that the Power Series be used in a clean, dry environment to ensure long-term reliability.

2.4 ■ Watlow Power Series Installation, Chapter 2

Removing the Power Series Controller

1. To release the Power Series controller from the mounting plate, press in on

the release tab at the top of the mounting plate.

2. When the release tab is in, push up on the controller from the bottom to

release it from the mounting plate. Beware of sharp edges on the heat

sink when you push upward. This will take some force!

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 condensation.

• Calibration: Not normally necessary. See pages 6.15-6.16 for data restore

and backup.

• Retorquing: See page 3.1 for torque guidelines.

• Software backup and refresh: Not necessary; see page A.7, Power Series

Backup.

NOTE: All Power Series controllers have been 100 percent tested before shipment. The records of these tests are on file for recall if necessary.

Figure 2.4 — Removing the controller.

CAUTION: You may want to use a large screwdriver to press in on the release tab while you are pushing on the controller to avoid potential injury to your hands.

Power Series Output Rating Curves

Fan Cooled

All curves are at 100% on with 90°C rated load wire and line wire connected. Note that each chart is slightly different on the amperage scale. The safe operating region is from 1 amp up to the specific curve for the output amperage code selected. For example: F25 Single Phase is rated up to 200 amps at 50°C; F30 Single Phase is rated for 250 amps at 50°C. See page 2.6 for Natural Convection Cooled output rating curves.

3 Phase, 3-Leg and 3-Zone Multizone

Fan Cooled at 100% On

70 17080

Current (Amps) into a Resistive Load

90 100 110 120 130 140 150 160

F20 F25

F30

Enclosure Internal

Ambient Temperature °C

3 Phase, 2-Leg and 2-Zone Multizone

Fan Cooled at 100% On

100 210110

Current (Amps) into a Resistive Load

120 130 140 150 160 170 180 190 200

F20 F25 F30

Enclosure Internal

Ambient Temperature °C

Single Phase Fan Cooled at 100% On

110 220120

Current (Amps) into a Resistive Load

230130 240140 250150 260160 170 180 190 200 210

Enclosure Internal

Ambient Temperature °C

F20 F25 F30

Watlow Power Series Installation ■ 2.5

Power Series Output Rating Curves

Natural Convection

All curves are at 100% on and with 90°C rated load wire and line wire connected. Note that each chart is slightly different on the amperage scale. The safe operating region is from 1 amp up to the specific curve for the output amperage code selected. For example: N25 Single Phase is rated up to 140 amps at 50°C; N30 Single Phase is rated for 165 amps at 50°C.

3 Phase, 3-Leg and 3-Zone Multizone

Natural Convection at 100% On

Current (Amps) into a Resistive Load

N20 N25 N30

Enclosure Internal

Ambient Temperature °C

60 14070 80 90 100 110 120 13050

3 Phase, 2-Leg and 2-Zone Multizone

Natural Convection at 100% On

Current (Amps) into a Resistive Load

60 14070 80 90 100 110 120 130

N20 N25 N30

Enclosure Internal

Ambient Temperature °C

Single Phase Natural Convection at 100% On

Current (Amps) into a Resistive Load

80 21090 100 110 120 130 140 150 170 180 190 200160

N20 N25 N30

Enclosure Internal

Ambient Temperature °C

2.6 ■ Installation Watlow Power Series

Chapter Three

Wiring

Wiring the Power Series Controller

Wiring options depend on the model number. Check the terminal designation stickers on the right side of the controller and compare your model number to those shown here and with the model number breakdown in the Appendix (page A.10) of this manual.

Chapter 3 illustrates how to wire the inputs and outputs for all options. Refer to Figure 3.1 for terminal torque guidelines.

Torque Guidelines

• Properly torque terminals by holding for 30 seconds to allow for wires to settle and minimize loosening due to cold flow.

• Re-torque all terminals after 48 hours.

• Establish a maintenance program to re-torque line and load terminations every 3-6 months.

Figure 3.1 — Torque and wire stripping.

Wiring, Chapter 3 Watlow Power Series ■ 3.1

Terminals 1 - 6 and Ground Lug

Torque to 180 in.-lbs. (20 Nm.) with 3/8 inch Allen wrench provided.

Fuse

Strip wires 1-1/8 inch (30mm)

#3 Phillips Screws for Fuse Mounting

For models PXX-F20X-XXXX PXX-N20X-XXXX Torque to 26 in.-lbs. (2.93 Nm.)

For models PXX-F25X-XXXX PXX-N25X-XXXX PXX-F30X-XXXX PXX-N30X-XXXX Torque to 44 in.-lbs. (4.95 Nm.)

Fuse

Power Series Solid State Power Control

Fuse

5/16 inch Bolts for Fuse Mounting

Torque to 44 in.-lbs. (4.95 Nm.)

Controller Connectors

Strip wires

0.24 in. (6mm)

Torque to 8 in.-lbs. (0.9 Nm.) using a 1/8 inch (2.5 mm) blade screwdriver. Accepts 12-22 AWG or 2 No. 22-18 AWG wires.

Allen Wrench

(Flat surface must be against the case.)

3.2 ■ Watlow Power Series Wiring, Chapter 3

ç∫

WARNING: To avoid damage to

property and equipment, and/or injury or loss of life, use National Electric Code (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: Input, retransmit and

communications external terminals have been designed for protection in case of direct contact in accordance with Europpean Standard EN50178.

NOTE: Insure ground is wired

with the same size wire as line and load connections to a ground of sufficient current carrying capacity. (Refer to Chapter 2, p. 2.1, Power Series Wire Bending Radius at Base Current and Ambient Temperature Rating.)

NOTE: Torque and wire strip

guidelines:

• Control wiring 1 thru

23.

• Strip wire to 0.24 inch (6mm). 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 3.2a – Control Power and Alarm Wiring

Figure 3.2b – Retransmit Wiring

Figure 3.2c – Communications Wiring

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 Connector

COMMS

7 8

485 T/R +

(Common)

9 10 11

232 TRAN (EIA/TIA-232 Transmit Out)

232 REC (EIA/TIA-232 Receive In)

485 T/R -

RETRANSMIT

DC 10V/20mA

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 Connector

12 13 14

(Current Out, 4 to 20mA)

(Common)

(Voltage Out, 0 to 10V)

Power Series

External Connector

Relay Internal to Power Series

NC C NO

208 or 240V~

(Alarm Common) (Alarm

Normally Open)

(Alarm Normally Closed)

Unused

120V~

6 5 4 3 2 1

11 10

9 8 7

14 13 12

17 16 15

20 19 18

23 22 21

CONTROLLER

POWER SUPPLY

85 to 265V~ 55VA

Neutral

ALARM

250V~ 3A

1 2 3 4 5 6

Wiring, Chapter 3 Watlow Power Series ■ 3.3

Figure 3.3a – Single Zone Input Wiring

Figure 3.3b – 2-Zone Input Wiring

Figure 3.3c – 3-Zone Input Wiring

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 Connectors

21 22 23

INPUT 1

18 19 20

INPUT 2

15 16 17

INPUT 3

(Current In, 4 to 20mA)

(Common)

(Voltage In, 0 to 10V)

(Current In, 4 to 20mA)

(Common)

(Voltage In, 0 to 10V)

(Current In, 4 to 20mA)

(Common)

(Voltage In, 0 to 10V)

NOTE: Successful installation

requires four steps:

• Choose the controller’s hardware configuration and model number (Appendix);

• Install the controller (Chapter Two);

• Wire the controller (Chapter Three); and

• Configure the controller (Chapters Four, Five and Six).

ç∫

WARNING: To avoid damage to

Power Series

External Connector

INPUT 1

(Voltage In, 0 to 10V)

23 22 21

20 19 18

17 16 15

14 13 12

11 10

9 8 7

6 5 4 3 2 1

(Current In, 4 to 20mA)

21 22 23

(Common)

Power Series

External Connectors

INPUT 1

23 22 21

20 19 18

17 16 15

14 13 12

11 10

9 8 7

6 5 4 3 2 1

21 22 23

INPUT 2

18 19 20

(Voltage In, 0 to 10V)

(Current In, 4 to 20mA)

(Common)

(Voltage In, 0 to 10V)

(Current In, 4to 20mA)

(Common)

3.4 ■ Watlow Power Series Wiring, Chapter 3

Line Power/Output Wiring

Figure 3.4a – Single Phase Output Wiring

(Model PC1X-XXXX-XXXX)

Figure 3.4b – 3 Phase, 2-Leg, 4 SCR Output Wiring

(Model PC2X-XXXX-XXXX)

NOTE: Our illustrations illustrate circuit breakers for branch circuit protection. Fuses can also be used.

NOTE: Successful installation

requires four steps:

• Choose the controller’s hardware configuration and model number (Appendix);

• Install the controller (Chapter Two);

• Wire the controller (Chapter Three); and

• Configure the controller (Chapters Four, Five and Six).

ç∫

WARNING: To avoid damage to

NOTE: Torque and wire strip

guidelines:

• Connections 1 thru 6, and ground lug

• Strip wire 1-1/8 in. (30mm). Torque to 180 in.-lbs. (20 Nm).

• Hold torque for 30 seconds to allow for wiring settling and cold flow. Re-torque after 48 hours.

• All load connections should be re-torqued every 3-6 months.

çCAUTION: Figure 3.4a shows the

Watlow-recommended output wiring using the internal bussbar as a return current path and with ref. 2 not connected. Should a user choose a non-recommended wiring scheme, then ref. 2 or the internal bussbar must be connected to the appropriate line or neutral. Failure to follow these guidelines could cause damage to the Power Series.

çCAUTION: Figure 3.4b shows the

Watlow-recommended output wiring using the internal bussbar as a return current path and with ref. 1 and 3 not connected. Should a user choose a non-recommended wiring scheme, then ref. 1 or ref. 3 or the internal bussbar must be connected to the appropriate line. Failure to follow these guidelines could cause damage to the Power Series.

L1 L2

Contacts

Heater

120V~ and 277V~

L1 L2

L1 Neutral

240V~ and above

Limit Control Contacts

(If Required)

1 3

On-board

Semiconductor

Fuse

4 5 6

Heater

Gnd

Internal Bussbar

ref.2

Limit Control

1 3

On-board

Semiconductor

Fuses

Internal Bussbar

4 5 6

ref.1 ref.3

Gnd

(If Required)

Figure 3.5c – **Multizone Output Wiring

(Models PC8X-XXXX-XXXX and PC9X-XXXX-XXXX)

Figure 3.5a – 3 Phase, 3-Leg,

6 SCR, Output Wiring for 4-Wire Wye Application

(Model PC4X-XXXX-XXXX)

Figure 3.5b – 3 Phase, 3-Leg, 6

SCR Output Wiring

(Model PC3X-XXXX-XXXX)

Wiring, Chapter 3 Watlow Power Series ■ 3.5

ç∫

WARNING: To avoid damage to

WARNING: Install high or low

temperature limit control protection in systems where an over temperature fault condition could 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.

NOTE: For reference connections

1 to 3, use QC 0.250 in. wide and 0.032 in. thick compatible connection which is fully insulated with nylon and has a metal grip ring.

For 14-16 AWG: Molex/ETC AA-5261; 3M MNG14250DFIX 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-

neutral, independent of how the other legs are wired.

çCAUTION: Do not connect ref.

connections with PC3 models. Failure to follow this guideline could cause damage to the Power Series.

L1 L2 L3

Limit Control

Contacts

1 3

Gnd On-board

Semiconductor

Fuses

(If Required)

L1 L2 L3

Limit Control

Contacts

1 3

On-board

Semiconductor Fuses

Gnd

(If Required)

4 5 6

ref.1 ref. 2 ref. 3

4 5 6

Heater

L1 L2 L3

Limit Control

Contacts

(If Required)

1 3

Gnd

On-board

Semiconductor

Fuses

Limit Control

Contacts

(If Required)

1 3

Gnd On-board

Semiconductor

Fuses

ref.1 ref. 3

PC8

4 5

ref.1 ref. 2 ref. 3

PC9

Heater

2 Independent,

Single Phase

Heaters

Heater

L2 L3

Heater

3 Independent,

Single Phase

Heaters

3.6 ■ Watlow Power Series Wiring, Chapter 3

Wiring Example

Figure 3.6 - System wiring example.

Recommended fusing options to meet 200KA SCCR. All other untested combinations are defaulted to 5KA per UL508A and NEC guidelines.

ç∫

WARNING: To avoid damage to

WARNING: Install high or low

NOTE: Our wiring example illustrates circuit breakers for branch circuit protection. Fuses can also be used.

Power Series Model Fuse Rating Watlow Fuse P/N Bussmann Fuse P/N

PC1X-N20 160 0808-0102-0160 170M1319 PC1X-N25 200 0808-0102-0200 170M1320 PC1X-N30 250 0808-0102-0250 170M1321 PC1X-F20 160 0808-0102-0160 170M1319 PC1X-N25 250 0808-0102-0250 170M1321 PC1X-N30 315 0808-0102-0315 170M1322 PC2(8)X-N20 125 0808-0102-0125 170M1318 PC2(8)X-N25 160 0808-0102-0160 170M1319 PC2(8)X-N30 160 0808-0102-0160 170M1319 PC2(8)X-F20 160 0808-0102-0160 170M1319 PC2(8)X-F25 250 0808-0102-0250 170M1321 PC2(8)X-F30 250 0808-0102-0250 170M1321 PC3(4,9)X-N20 100 0808-0102-0100 170M1317 PC3(4,9)X-N25 125 0808-0102-0125 170M1318 PC3(4,9)X-N30 160 0808-0102-0160 170M1319 PC3(4,9)X-F20 125 0808-0102-0125 170M1318 PC3(4,9)X-F25 200 0808-0102-0200 170M1320 PC3(4,9)X-F30 200 0808-0102-0200 170M1320

Line

Neutral

Fuse

High Limit Controller

1 3

Semiconductor

Zero Cross Fired

Power Series

4 5 6

On-board

Fuses

3Ø, 2-leg

Gnd

Neutral

Line

High Limit Contactor

Circuit Breakers

Overtemp. Indicator

Fuse

Reset Switch

Line

Fuse

(+)

Series 93 Thermocouple Input Process Output

93BA-1FA0-00RR

4 to 20mA

Retransmit to Monitor Output Operation

Control Power

Neutral

9 +

10 -

Three Phase

Resistive Heater

Chapter Four

Navigation and Software

Keys and Displays

This chapter explains keys, displays and navigation skills. You’ll also find a complete software map.

Navigation and Software, Chapter 4 Watlow Power Series ■ 4.1

Figure 4.1 — Power Series keys and displays.

Alarm Indication LED: Lit when an alarm is active.

Upper Display:

Indicates operating levels - requested current, line voltage or power feedback levels for the parameter in the lower display.

Lower Display:

Indicates the parameter whose value appears in the upper display.

***8

Increment/Decrement Keys: Moves to next or

previous submenu if at the top item of a menu, or increments/decrements

current menu item.

Home Key: Returns to the Display Loop if in any other page or menu, or in the Display Loop, moves between like prompts of different

zones or phases.

Small LED: Blinks with communications activity.

Left/Right Keys: Moves to the next or previous item in a submenu.

Navigating the Power Series

Choose a page (Setup or Factory) and press its key sequence. The page appears in the lower display.

PressÎ or Ó to find a specific menu in a page. The menu appears in the upper display and the page remains in the lower display.

Press ® to enter the list of parameters in the menu displayed. The menu’s parameters appear in the lower display and the values in the upper display. To go backward through the parameter list press ¬ .

PressÎ or Ó to select a value, either alpha or numeric, within a specific parameter.

Setup Page - for setting up the control, alarms, retransmit, and communications.

Factory Page for calibration and diagnostic information.

Display Loop for monitoring parameters and adjusting manual/digital input, and for clearing alarms if they are latched.

4.2 ■ Watlow Power Series Navigation and Software, Chapter 4

NOTE: The Load Activity Indicator in the Display Loop indicates different things, dependent on whether heater diagnostics is installed. With heater diagnostics installed, it indicates load current has been detected. Without heater diagnostics installed, it indicates the SCRs are being gated and line voltage is present.

• Setup Page: From Display Loop, press ± and ¬ keys together for 2 sec.

• Factory Page:

• Display Loop: From Setup or Factory Page, press the ± key.

***8

From Setup Page, press ± and ¬ and ® keys together for 2 sec

***8

algo

SEt

***8

FCty

-–-

load

Navigation

¬®[````]¬®[````]¬®[load]¬®[freq]¬®

Single-Zone Single-Phase

¬®[In``] or [In|c] or [In|u] ¬®[`Out]¬®[`Hbt]¬%%% ®[`UoL]¬®[`Cur]¬®[`HUa]

Multi-Zone [```] Three-Phase [```]

%%%% [2one]

%%%%%%% [PHAS]

Display Loop

Use the Increment/Decrement keys ( Ó Î ) to select a Zone or Phase within the Display Loop. The Zone/Phase appears in the upper display.

Use the Left/Right arrow keys ( ¬ ® ) to select a parameter within a Zone or Phase. The parameter appears in the bottom display.

Use the Increment/Decrement keys (

Ó Î ) to select a value, either alpha or

numeric, within a parameter. The value appears in the upper display.

Use the Home key ( ± ) to toggle between Zones/Phase 1, 2, or 3 sequentially.

(#)

Display Zone Selection

Display Phase Selection

(#)

(code) (code)

Active Alarms

(if any)

[```1] Zone 1 [```1] Phase 1 [2one] % ¬®[In1`] or [In|`c1] or [In|`u1] ¬®[Out1]¬®[Hbt1]¬®[UoL1]¬®[Cur1]¬®[HUa1]¬®% [`ph5] % ¬®[UoL1]¬®[Cur1]¬®

%Î% ±% ±% ±% ±% ±% ±% ±% ±% Î% ±% ±% % Ó%%%%%% Ó%

[```2] Zone 2 [```2] Phase 2 [2one] % ¬®[In2`] or [In|`c2] or [In|`u2] ¬®[Out2]¬®[Hbt2]¬®[UoL2]¬®[Cur2]¬®[HUa2]¬®% [`ph5] % ¬®[UoL2]¬®[Cur2]¬®[`HUa]¬®

% Î% ±% ±% ±% ±% ±% ±% ±% ±%% Î% ±% ±% % Ó%%%%%% Ó

[```3] Zone 3 [```3] Phase 3 [2one] % ¬®[In3`] or [[In|`c3] or [In|`u3] ¬®[Out3]¬®[Hbt3]¬®[UoL3]¬®[Cur3]¬®[HUa3]¬®% [`ph5] % ¬®[UoL3]¬®[Cur3]¬®

%Î% ±% ±% ±% ±% ±% ±% ±% ±% Î% ±% ±% % Ó%%%%%% Ó

Navigation and Software, Chapter 4 Watlow Power Series ■ 4.3

NOTE: For an explanation of the parameters in the Display Loop, range information, Modbus address, and conditions for the parameter to appear, see pp. 6.1-6.4, Chapter Six, Parameters.

NOTES: What you see in each Page and in each Menu are factory set, depending on the options and settings of your controller.

The input signal method indicator will change depending on the input signal method chosen — digital, current, or volts. Current operating parameters may be modified at any time with the use of the keypad or communications port.

The Display Loop is used to monitor parameters and adjust manual/digital input, and to clear alarms if they are latched.

***8

Press Home and Left Keys together for 2 seconds to enter the Setup Menus from the Display Loop.

Setup Page Menus

±¬

Display Loop

±±

Press Home Key from any menu to return to the Display Loop.

% ±¬®

Press Home, Left and Right Keys all together for 2 seconds to enter the Factory Menus from the Setup Menus.

Factory Page Menus

4.4 ■ Watlow Power Series Navigation and Software, Chapter 4

**NOTE: These menus and display prompts are only viewable in the Factory Mode using a password.

NOTE: For an explanation of the parameters in the Setup Page, (range information, Modbus address, and conditions for the parameter to appear), see Chapter Six, Parameters, pp. 6.5-6.14; for information on the Factory Page, see pp. 6.14-6.22.

[dAta] System Data Manipulation

[FctY]% ¬®[baup]¬®[dflt]¬®[rEst]¬®[nUOl]¬® %Î

%Ó

[`Loc] Global/Menu Lockouts

[[FctY]% ¬®[gloc]¬®[`Ctr]¬®[`OPt]¬®[`Alr]¬®[COm]¬®[retr]¬®[`CIn]¬®[C|`rtr]¬®[dAta]¬®[diAg]¬® %Î

%Ó

[InFo] Unit Information

[FctY]% ¬®[`sn–]¬®[`sn_]¬®[date]¬®[HUEr]¬®[SUEr]¬®[sbld]¬®[ratU]¬®[rata]¬®[2onC]¬®[`Opt]¬®[```Ç]¬®

%Ó

%%% ¬®[Hrs_]¬®[Hrs–]¬®[HIÇ`]¬®[sdÇ`]¬®[AlÇ`]

[diAg] Diagnostics

[[FctY]% ¬®[``Ad]¬®[Cnts]¬®[l!A1]¬®[l!A2]¬®[l!A3]¬®[l@A1]¬®[l@A2]¬®[l@A3]¬®[l#A1]¬®[l#A2]¬®[l#A3]¬®

%Ó%

¬®[retr]¬®[`UAL]¬®[``In]¬®[dIsp]

[`pw] Factory Password

[FctY]

% ¬®[`pw]¬®[fcty]¬®

%Ó

[CIn1] Calibrate Analog Input Signal Zone 1**

[FctY] % ¬®[nnA_]¬®[nnA–]¬®[UoL_]¬®[UoL–]¬®[Cala]¬®

%Ó

[CIn2] Calibrate Analog Input Signal Zone 2**

[FctY] % ¬®[nnA_]¬®[nnA–]¬®[UoL_]¬®[UoL–]¬®[Cala]¬®

%Ó

[CIn3] Calibrate Analog Input Signal Zone 3**

[FctY] % ¬®[nnA_]¬®[nnA–]¬®[UoL_]¬®[UoL–]¬®[Cala]¬®

%Ó

[Crtr] Calibrate Retransmit**

[FctY]% ¬®[nnA_]¬®[nnA–]¬®[UoL_]¬®[UoL–]¬®[Calr]¬® %Î

Factory Page Menus

Use the Increment/Decrement keys ( Ó Î ) to select a menu within the Factory Page. The menu appears in the upper display.

Use the Left/Right arrow keys (

¬ ® ) to select a parameter

within a menu. The parameter appears in the bottom display.

Use the Increment/Decrement keys ( Ó Î ) to select a value, either alpha or numeric, within a parameter. The value appears in the upper display.

*NOTE: This prompt will only appear in [Ctr1], and if the controller is 3 phase.

Setup Page Menus

[algo] Control Algorithm

[`set]

% ¬®[algo]¬®[`ftb]¬®[``UC]¬®

%Î% Î %Ó% Óv %

[Ctr1] Setup Control Zone 1

% ¬®[``In]¬®[%dflt]¬®[nna_]¬®[nna–]¬®[Uol_]¬®[Uol–]¬®[lrn|``A]¬®[bl`U]¬®[lrn|``U]¬®[type]¬®[rate]¬®[soft]¬®[rdly]¬®

[`set] %Î

%Ó

[Opt1] Setup Options Zone 1

[`set]

% ¬®[`Hbo]¬®[Min]¬®[`HbC]¬®[`Cli]¬®[`Cla]¬®[tol_]¬®[toL–]¬®[Indf]¬®[1Cur]¬®

%Î %Ó

[Ctr2] Setup Control Zone 2

[`set]

% ¬®[``In]¬®[dflt]¬®[nna_]¬®[nna–]¬®[Uol_]¬®[Uol–]¬®[lrn|``A]¬®[bl`U]¬®[lrn|``U]¬®[rate]¬®[soft]¬®

%Ó

[Opt2] Setup Options Zone 2

[`set]

% ¬®[`Hbo]¬®[Min]¬®[`HbC]¬®[`Cli]¬®[`Cla]¬®[tol_]¬®[toL–]¬®[Indf]¬®[1Cur]¬®

%Î %Ó

[Ctr3] Setup Control Zone 3

[`set]

% ¬®[``In]¬®[dflt]¬®[nna_]¬®[nna–]¬®[Uol_]¬®[Uol–]¬®[lrn|A]¬®[bl`U]¬®[lrn|``U]¬®[rate]¬®[soft]¬®

%Ó

[Opt3] Setup Options Zone 3

[`set]

% ¬®[`Hbo]¬®[Min]¬®[`HbC]¬®[`Cli]¬®[`Cla]¬®[tol_]¬®[toL–]¬®[Indf]¬®[1Cur]¬®

%Î %Ó

[`aLr] Setup Alarms Configuration

[`set]

% ¬ ®[A|``l9c]¬®[glbl]¬®[Open]¬®[`tol]¬®[``Ot]¬®[`aLÇ]¬®[Line]¬®[p|bal]¬®[lbal]¬®[ldif]¬®[freq]¬®

%Î %Ó

% %%% ¬® [C|``wd]¬®[``OU]¬®[``UC] [COm] Setup Comms Configuration

[`set]

% ¬®[addr]¬®[baUd]¬®[`wd]¬®[`seC]¬®[pwr]¬®

%Î %Ó

[retr] Setup Retransmit Configuration

[`set]

% ¬®[`Cfg]¬®[type]¬®[pha5]¬®[2one]¬®[Cur_]¬®[Cur–]¬®[HUa_]¬®[HUa–]¬®[rt|``C_]¬ ®[rt|``C–]¬ ®[rt|``U_]¬ ®[rt|``U–]¬ ®

%Î %Ó

[cont] Î [`OFF] Î [`ftb] Î Urtb] Î [pH2t]

Use the Increment/Decrement keys ( Ó Î ) to select a menu within the Setup Page. The menu appears in the upper display.

Use the Left/Right arrow keys ( menu. The parameter appears in the bottom display.

Use the Increment/Decrement keys ( or numeric, within a parameter. The value appears in the upper display.

¬ ® ) to select a parameter within a

Ó Î ) to select a value, either alpha

+ 50 hidden pages