Watlow 35A, 40A Operating Manual

35A to 40A Power Controller

ISO 9001

User’s Guide

1943-2287 Rev C

July 2018

1241 Bundy Boulevard., Winona, Minnesota USA 55987

Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507

http://www.watlow.com

Registered Company

Winona, Minnesota USA

Safety Information

We use note, caution and warning symbols 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. Be especially careful to read and follow all cautions that apply to your application.

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 safety alert symbol, (an exclamation point in a triangle) precedes a general CAUTION or WARNING statement.

The electrical hazard symbol, (a lightning bolt in a triangle) precedes an electric shock hazard CAUTION or WARNING safety statement. Further explanations follow:

Symbol Explanation

CAUTION – Warning or Hazard that needs further explanation than the label on unit can provide. Consult User's Guide for further information.

Electrical Shock Hazard - Symbol (a lightning bolt in a triangle) precedes an electric shock hazard CAUTION or WARNING safety statement.

ESD Sensitive product, use proper grounding and handling techniques when installing or servicing product.

Do not throw in trash, use proper recycling techniques or consult manufacturer for proper disposal.

Unit is a Listed device per Underwriters Laboratories. It has been investigated to ANSI/UL® 508 standards for Industrial Control Switches and equivalent to CSA C22.2 #14. For more detail search for File E73741 on www.ul.com.

Unit is compliant with European Union directives. See Declaration of Conformity for further details on Directives and Standards used for Compliance.

WARNING! To avoid damage to property and equipment, injury and loss of life, adhere to applicable electrical codes and standard wiring practices when installing and operating this product. Failure to do so could result in damage, injury and death.

AVERTISSEMENT! Pour éviter d’endommager la propriété et l’équipement, les blessures et la perte de vie, respecter les codes électriques en vigueur et les pratiques de câblage standard au moment de l’installation et de l’utilisation de ce produit. Dans le cas contraire, cela peut entraîner la mort, des blessures graves ou des dommages.

WARNING! All service including inspection, installation, wiring, maintenance, troubleshooting, fuse or other

user-serviceable component replacement must be performed only by properly qualied personnel. Service personnel must read this manual before proceeding with work. While service is being performed other, unqualied

personnel should not work on the unit or be allowed in the immediate vicinity.

AVERTISSEMENT! Tous les services, y compris l’inspection, l’installation, le câblage, l’entretien, le dépannage, le remplacement de fusibles ou d’autres composants pouvant être réparés par l’utilisateur, doivent être

Watlow - ASPYRE 35A to 40A Power Controller • 2 •

effectués uniquement par un personnel dûment qualié. Le personnel de service doit lire ce manuel avant d’effectuer tout travail. Pendant que l’entretien est exécuté, tout personnel non qualié ne doit effectuer de travail

sur l’appareil ni se trouver à proximité.

WARNING! When in use the power controller is connected to dangerous voltages. Do not remove the protec-

tive covers without rst disconnecting and preventing power from being restored while servicing the unit.

AVERTISSEMENT! Au moment de l’utilisation, le régulateur de puissance est connecté à des tensions dangereuses. Ne retirer aucun couvercle de protection sans d’abord débrancher l’appareil et ainsi empêcher l’alimentation d’être rétablie pendant l’entretien.

WARNING! Do not use in aerospace or nuclear applications.

AVERTISSEMENT! Ne pas utiliser pour les applications aérospatiales ou nucléaires.

WARNING! The power controller’s protection rating is IP20 with all covers installed and closed. It must be

installed in an enclosure that provides all the necessary additional protections appropriate for the environment and application.

AVERTISSEMENT! L’indice de protection du régulateur de puissance est de IP20 lorsque les couvercles sont installés et fermés. L’appareil doit être installé dans une enceinte qui assure toute la protection supplémentaire nécessaire pour l’environnement et l’application.

WARNING! Ground the power controller via the provided protective earth grounding terminal. Verify ground

is within impedance specications. This should be veried periodically.

AVERTISSEMENT! Mise à la terre du régulateur de puissance par le biais de la borne de prise de terre de

protection fournie. Vérier que la prise de terre est conforme aux spécications de l’impédance. Cela doit être vérié périodiquement.

WARNING! Electric Shock Hazard: when the power controller has been energized, after shutting off the power, wait at least one minute for internal capacitors to discharge before commencing work that brings you in to contact with power connections or internal components.

AVERTISSEMENT! Risque de décharges électriques : lorsque le régulateur de puissance est mis sous tension, après avoir été éteint, attendre au moins une minute pour que les condensateurs internes se déchargent avant de commencer tout travail incluant le contact avec les connexions électriques ou les composants internes.

WARNING! The installation must be protected by electromagnetic circuit breakers or by fuses. The semicon-

ductor fuses located inside the power controller are classied for UL® as supplementary protection for semicon-

ductor devices. They are not approved for branch circuit protection.

AVERTISSEMENT! L’installation doit être protégée par des disjoncteurs électromagnétiques ou des fusibles. Les fusibles pour semi-conducteurs situés à l’intérieur du régulateur de puissance sont classés UL® comme protection supplémentaire pour les dispositifs pour semi-conducteurs. Ils ne sont pas approuvés pour la protection des circuits de dérivation.

WARNING! When making live voltage or current measurements, use proper personal protective equipment

for the voltages and arc-ash potentials involved.

Watlow - ASPYRE 35A to 40A Power Controller • 3 •

AVERTISSEMENT! Au moment de relever des mesures de tension ou de courant en direct, utiliser un équipe-

ment de protection individuelle approprié pour les tensions et les potentiels d’arc électrique concernés.

WARNING! Verify the voltage and current ratings of the power controller are correct for the application.

AVERTISSEMENT! Vérier que les valeurs de tension et de courant du régulateur de puissance sont correctes

pour l’application.

CAUTION: To avoid compromising the insulation, do not bend wire or other components beyond their bend

radius specications.

ATTENTION : Pour éviter de compromettre l’isolation, ne pas plier le l ou tout autre composant au-delà de

ses spécications en matière de rayon de courbure.

CAUTION: Protect the power controller from high temperature, humidity and vibrations.

ATTENTION : Protéger le régulateur de puissance contre les températures élevées, l’humidité et les vibra-

tions.

CAUTION: The power controller warranty is void if the tested and approved fuses are not used.

ATTENTION : La garantie du régulateur de puissance est nulle si aucun fusible testé et approuvé n’est util-

isé.

CAUTION: Only trained and authorized personnel should access and handle the internal electronics and they

must follow proper electro-static prevention procedures.

ATTENTION : Seul le personnel formé et autorisé peut accéder aux composants électroniques internes et les

gérer, et il doit se conformer à des procédures de prévention électrostatique appropriées.

CAUTION: Install an appropriately sized RC lter across contactor coils, relays and other inductive loads.

ATTENTION : Installer un ltre RC de dimensions appropriées sur les bobines du contacteur, les relais et

autres charges par induction.

NOTE! Provide a local disconnect to isolate the power controller for servicing.

REMARQUE : Fournir une déconnexion locale an d’isoler le régulateur de puissance pour l’entretien.

NOTE! The nominal current is specied for ambient temperatures at or below 40° C. Ensure the application

design allows for adequate cooling of each power controller. The power controller must be mounted vertically. The cooling design must prevent air heated by one power controller from causing power controllers mounted above to exceed the ambient operating temperature limit. When power controllers are mounted side by side allow a minimum spacing of 15mm between them.

Watlow - ASPYRE 35A to 40A Power Controller • 4 •

REMARQUE : Le courant nominal est précisé pour des températures ambiantes égales ou inférieures à 40

°C. S’assurer que la conception de l’application permette le refroidissement adéquat de chaque régulateur de

puissance. Le régulateur de puissance doit être monté verticalement. La conception de refroidissement doit empêcher l’air chauffé par le régulateur de puissance de dépasser la limite de température de fonctionnement ambiante de la part des régulateurs de puissance montés au-dessus. Lorsque les régulateurs de puissance sont montés côte à côte, il faut conserver un espacement minimal de 15 mm entre les deux.

NOTE! Use only copper cables and wires rated for use at 90°C or greater, unless otherwise noted.

REMARQUE : N’utiliser que des câbles et des ls en cuivre pour l’utilisation à 90 °C ou plus, sauf indication

contraire.

Technical Assistance

If you encounter a problem with your Watlow® controller, review your conguration information to verify that your selections are consistent with your application: inputs, outputs, alarms, limits, etc. If the problem persists, you can get technical assistance from your local Watlow representative (see back cover), by e-mailing your questions to wintechsupport@watlow.com or by dialing +1 (507) 494-5656 between 7 a.m. and 5 p.m. Central

Time USA & Canada. Ask for for an Applications Engineer. Please have the complete model number available when calling.

Return Material Authorization (RMA)

1. Call Watlow Customer Service, (507) 454-5300, for a Return Material Authorization (RMA) number before returning any item for repair. If you do not know why the product failed, contact an Application Engineer or Product Manager. All RMA’s require:

• Ship-to address

• Bill-to address

• Contact name

• Phone number

• Method of return shipment

• Your P.O. number

• Detailed description of the problem

• Any special instructions

• Name and phone number of person returning the product

2. Prior approval and an RMA number from the customer service department is required when returning any product for credit, repair or evaluation. Make sure the RMA number is on the outside of the carton and on all paperwork returned. Ship on a freight prepaid basis.

3. After we receive your return, we will examine it and try to verify the reason for returning it.

4. In cases of manufacturing defect, we will enter a repair order, replacement order or issue credit for material returned. In cases of customer mis-use, we will provide repair costs and request a purchase order to proceed with the repair work.

5. To return products that are not defective, goods must be be in new condition, in the original boxes and they must be returned within 120 days of receipt. A 20 percent restocking charge is applied for all returned stock controls and accessories.

6. If the unit is not repairable, you will receive a letter of explanation and be given the option to have the unit returned to you at your expense or to have us scrap the unit.

7. Watlow reserves the right to charge for no trouble found (NTF) returns.

Watlow - ASPYRE 35A to 40A Power Controller • 5 •

Warranty

The Watlow ASPYRE® power controller is warranted to be free of defects in material and workmanship for 36

months after delivery to the rst purchaser for use, providing that the units have not been misapplied. Since

Watlow has no control over their use, and sometimes misuse, we cannot guarantee against failure. Watlow’s obligations hereunder, at Watlow’s option, are limited to replacement, repair or refund of purchase price, and

parts which upon examination prove to be defective within the warranty period specied. This warranty does

not apply to consumable parts such as fuses or to damage resulting from transportation, alteration, misuse or abuse. The purchaser must use Watlow parts to maintain all listed ratings.

Watlow® and ASPYRE® are registered trademarks of Watlow Electric and Manufacturing Company. Cooper Bussman® is a registered trademark of Cooper Industries Inc. EtherNet/IP™ is a trademark of Open DeviceNet Vendors Association. Kanthal® is a registered trademark of Bulten-Kanthal Aktiebolag Joint Stock Company Microsoft® and Windows® are registered trademarks of Microsoft Corporation. Modbus® is a registered trademark of Schneider Automation Incorporated. UL® is a registered trademarks of Underwriter’s Laboratories, Inc.

Watlow - ASPYRE 35A to 40A Power Controller • 6 •

Contents

Safety Information ......................................................2

Technical Assistance ....................................................5

Return Material Authorization (RMA) .......................................5

Warranty ..............................................................6

Overview ............................................9

Recognizing Product Features .............................................9

Identifying the Product ...................................................9

Product Selection ......................................................10

Features and Benefits ...................................................12

Product Block Diagram .................................................13

Wi-Fi Transmitter Module ................................................14

Installation ..........................................15

Installing the ASPYRE Power Controller ....................................15

Environmental Conditions ...............................................15

Cooling Requirements ..................................................16

Mounting Dimensions ..................................................17

Wiring .............................................19

Wiring the ASPYRE Power Controller ......................................19

Good Wiring Practices ..................................................19

Wiring Overview Diagrams ...............................................20

Wire Selection, Prep and Torque ..........................................21

Opening The Covers ....................................................22

Connecting Control Signals ..............................................22

Connecting the Auxiliary Power ...........................................26

Wiring the Line Power and Load ..........................................26

Initial Setup .........................................29

Using the ASPYRE Configurator Software ...................................29

Configuring the ASPYRE Power Controller ..................................29

Operation ...........................................33

Control Panel .........................................................33

Menu Navigation ......................................................34

Indicators (LEDs) ......................................................35

Alarms and Messages ..................................................36

Using ASPYRE Configurator ..............................37

Overview ............................................................37

How To ..............................................................37

Reference ............................................................42

Parameter Reference ...................................51

Watlow - ASPYRE 35A to 40A Power Controller • 7 •

Features ...........................................69

Closed Loop Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Feedback ............................................................70

Current Limit .........................................................71

Configurable Inputs and Outputs ..........................................72

Firing Types ..........................................................74

Soft Start ............................................................80

Start Ramp (DT1 Models) ...............................................80

Safety Ramp (DT1 Models) ..............................................80

Heater Bakeout Function (Models with Current Limit) ..........................81

Totalizer .............................................................81

Data Logging .........................................................81

Maintenance & Troubleshooting ...........................83

Routine Maintenance ...................................................83

Alarms and Indicators ..................................................83

Opening the SCR Module Covers ..........................................86

Replacement Fuses ....................................................86

Accessing the Control Electronics .........................................86

Replacing the Battery ...................................................88

Calibration Procedures ..................................................88

Updating the Firmware ..................................................90

Troubleshooting .......................................................91

Troubleshooting Schematics .............................................92

Communication .......................................95

Overview ............................................................95

Enabling the Secondary Port .............................................96

Ethernet Network Setup .................................................96

Modbus® TCP .........................................................97

EtherNet/IP™ Setup ....................................................97

Profinet IO Setup .....................................................100

Profibus DP Setup ....................................................105

Holding Registers .....................................................111

Input Registers .......................................................112

Modbus® RTU .......................................................114

Modbus® RTU Holding Registers .........................................115

Specifications .......................................119

Declaration of Conformity ..............................................124

Watlow - ASPYRE 35A to 40A Power Controller • 8 • Chapter

Overview

This chapter describes how to locate the model number of the ASPYRE® power controller, explains how to deter-

mine which ordering options are present, identies its physical features, lists its main functional features and benets and provides a functional overview in the form of a block diagram.

Recognizing Product Features

This illustration indicates the physical features of the product as referenced in this manual.

Line & load power connections

Earth ground connection

Product identification label

USB connector

Control panel

Mounting holes (top and bottom)

Identifying the Product

To identify the power controller, locate the part number on the product identication label, see the illustration.

With the part number and the part number table you can determine important characteristics of the power controller.

Product Identification Label

The product identication label includes not only the part number but also the voltage and current ratings and

auxiliary and fan voltage requirements.

Sample Label Detail

Mod. Ser. NO.

Max. Load Current Max. Load Voltage Auxiliary Voltage Fan Voltage

Second Port

:DT160-0351A-11BAA :12345-123456-123

:35A :600Vac - 50/60Hz :120Vac - 50/60Hz 6VA :110/120Vac - 50/60Hz 1 Phase 1 Leg Control :Modbus TCP

Watlow - ASPYRE 35A to 40A Power Controller • 9 • Chapter 1 Overview

Part Number

NOTE! No UL® on 690V models.

Product Selection

This section describes how to choose the appropriate ordering options.

Digit 3, Phase

Choose the number of switched legs. Ungrounded-wye and delta loads are most economically controlled with two-leg switching. Grounded-wye and open-delta loads require three-leg switching.

Watlow - ASPYRE 35A to 40A Power Controller • 10 • Chapter 1 Overview

Digits 4 and 5, Maximum Line and Load Voltage

Choose the lowest voltage range that is equal to or greater than the nominal voltage supplied to the ASPYRE

power controller. The actual voltage is specied with digit 9.

Digits 6, 7 and 8, Amperage

These digits indicate the maximum current that can be switched. Choose a power controller with adequate current capacity for your load. Use one of the formulas below to determine the nominal load current based on the

load conguration, the line voltage and the load power or resistance.

In the formulas below:

• I is the nominal load current calculated according to the formula

• P is the total power of the load

• R is the resistance of each heating element

• V is the nominal voltage supplied to the ASPYRE power controller (see the 9

digit in the part number)

Single Phase Resistive Load

1.73V

1.73R

2-Leg, 3-Phase Resistive Load in Delta Conguration

3-Leg, 3-Phase Resistive Load in Grounded Wye Cong.

R R R

2-Leg, 3-Phase Resistive Load in Wye Conguration

R R R

3-Leg, 3-Phase Resistive Load in Wye Conguration

R R R

3-Leg, 3-Phase Resistive Load in Delta Conguration

1.73V

1.73R

1.73V R

3-Leg, 3-Phase Resistive Load in Open Delta Cong.

Watlow - ASPYRE 35A to 40A Power Controller • 11 • Chapter 1 Overview

Digit 9, Nominal Voltage Supplied to SCR

Choose the voltage the will be used to power the load. This is also the voltage for the auxiliary power supply input. The voltage chosen here must be less than or equal to the Maximum Line and Load Voltage chosen with digits 4 and 5.

Digit 10, Current Limit Loop and Analog Retransmit Output 1*

Choose if the power controller limits current and/or can retransmit load voltage, current, power or measured input. The current limit option is available only with single phase models.

Digit 11, Cooling Fan Voltage

For power controllers that switch 90A or more, choose the voltage you will supply to power the fans in the ASPYRE power controller. Models that switch less than 90A do not require or include cooling fans.

Digit 12, Additional Wired Communication Option*

If desired, choose an optional communication port in addition to the EIA-485, Modbus® RTU port that comes standard on all models.

Digit 13, Wireless Communication and Data Logging Option

Choose the desired combination of Wi-Fi and data logging options.

Characters 14 and 15, Custom Options

Choose the desired options or use a factory supplied two-character option.

*If using both analog retransmit (digit 10, options A or D) and additional wired communication (digit 12, options 1 to 5) an external power supply is required.

Features and Beneﬁts

This section provides a high-level overview of the features and benets of the ASPYRE power controller.

Heater bakeout

• Protects heater upon start up

• Eliminates labor and time associated with checking for wet heaters

Integrated semiconductor fusing, current transformer and user interface

• Saves installation time and eases setup and commissioning

• Delivers a user-friendly, intuitive interface

Industry-leading design and serviceability

• Offers a robust SCR design to meet a rugged industrial environment’s high quality and reliability needs

• Provides quick and easy access to maintain and service fuses and individual legs in minimal time

• Enables fast troubleshooting by providing helpful thermal system diagnostics

Comprehensive power controller range

• Provides wide range of options from simple single phase to complex three-phase loads to 690V

100KA short circuit current rating (SCCR) (has not been reviewed by UL®)

• Enables greater protection in the event of a short circuit

c-UL® 508 Listed

• Shortens project schedules, agency testing and expenses

Control modes: contactor, voltage, current or power

• Satises a wide range of demanding thermal applications

Watlow - ASPYRE 35A to 40A Power Controller • 12 • Chapter 1 Overview

Load firing modes: zero-cross, burst fire, phase angle, soft start, half-cycle, single-cycle, delayed trig-

Voltage

Sensing

USB Device

• Conﬁguration

Software Connection

• Data Log File Transfer

Analog Retransmit

• User-Selectable

Retransmit

Parameter

DC Power Supply

• Dry Contact

Switches

• Potentiometers

WiFi

• Conﬁguration

• Monitor Operation

2 Analog Inputs

• Set Point

• Feedback

• Current Limit*

2 Digital Inputs

• Enable

• Select Feedback

• Local/Remote

• Set Firing Type

Auxiliary Power

• Controller

Electronics

• Voltage Sensing

• Zero-Cross Sensing

Out to LoadIndustrial Communications

• Modbus

TCP

• EtherNet/IP™

• 2nd Modbus

RTU (485)

Analog

Input

RS-485

Interface

Analog

Input

Analog

Retransmit

(Optional)

Current

Sensing

Mechanical Relay Output

• Alarm Annunciation

NCNO

Data

Logging

(Optional)

•

Proﬁbus DP

• Proﬁnet

(Optional)

Power

Demand

Loop

+10 VDC

Output

Current

Limit

Loop*

(Optional)

Auxiliary

Power

*Single-phase models only

Power Switching

• 1, 2 or 3 Legs

• Back-to-Back SCR Switching

• Replaceable Semiconductor Fuses

Supplemental Power

• Retransmit

• Communications

+24 VDC

Input

gering

• Handles a wide range of load types including nichrome, medium and long waveform infrared lamps, moly, transformers, silicon carbide, UV lamps and tungsten

• Protects and extends the life of connected loads

Wide range of communication protocols

• Enable factory and process automation with connectivity to process and equipment data via Modbus® RTU, Modbus® TCP, EtherNet/IP™ , Wi-Fi, Probus, Pronet, USB device (conguration and data le transfers)

Open heater and shorted SCR indication

• Minimizes production downtime with easy to understand, intelligent, troubleshooting diagnostics

Integrated USB and user interface for configuration

• Easily and safely program conguration settings as the user interface can be powered through USB connection

• Eliminates need to work in a high voltage hazard environment. High voltage to the power controller and

system panel can be shut off and locked out for safety while conguring controller.

Product Block Diagram

This diagram represents the features and functions of the ASPYRE power controller in a graphical format showing the relationships between various functions. Optional features are indicated.

Product Block Diagram for 35A to 40A Models

Watlow - ASPYRE 35A to 40A Power Controller • 13 • Chapter 1 Overview

Wi-Fi Transmitter Module

Models DT_ _ _-_ _ _ _-_ _ _[B or D]_ _ contain a Wi-Fi transmitter module. See the label on the module to determine which of the following modules is installed. The transmitter module is mounted on the top of the microprocessor board. See “Accessing the Control Electronics” on page 86.

Module FCC ID: 2ADUIESP-12-F WiFi module 802.11b/g/n 2412-2462 MHz

Output power:

• 802.11b: 15.58 dBm (Max.)

• 802.11g: 13.72 dBm (Max.)

• 802.11n: 12.53 dBm (Max.)

Antenna gain: 1.0 dBi PCB antenna 11 channels.

Module FCC ID: 2AL3B-ESP-F 802.11b/g/n 2412-2462 MHz

Output power:

• 802.11b: 14.0 dBm (Max.)

• 802.11g: 12.8 dBm (Max.)

• 802.11n: 13.6 dBm (Max.)

Antenna gain: 1.0 dBi PCB antenna 11 channels.

Unit is assembled from tested components, complete system not tested.

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation.

If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

Watlow - ASPYRE 35A to 40A Power Controller • 14 • Chapter 1 Overview

Installation

WARNING: To avoid damage to property and equipment, injury and loss of life, adhere to applicable electrical codes and standard wiring practices when installing and operating this product. Failure to do so could result in damage, injury and death.

Installing the ASPYRE Power Controller

This chapter provides the information necessary to select and prepare a location and to mount one or more ASPYRE power controllers.

Consider the spacing required for power, load, and control signal wiring before mounting the power controller. Take in to account the controller dimensions, wire bending radius, and cooling requirements. Use good wiring practices to minimize electrical noise problems.

Peripheral Components

Allow room for fuses and fuse holders for the auxiliary input power and fans (if present).

Mounting Orientation

Mount power controllers vertically to optimize air cooling.

Bend Radius

Allow adequate space to route cables without requiring bending more than permitted for the type of cable.

Environmental Conditions

Mount ASPYRE power controllers in a suitable electrical enclosure. Allow adequate wire bending space and cool-

ing. The maximum ambient temperature in the enclosure must not exceed 104°F (40°C).

Ambient Temperature

Storage Temperature

Installation Location

Altitude

Humidity

Pollution degree

32° to 104°F (0° to 40°C)

-13° to 158°F (-25°to 70°C)

Install away from direct sun light, conductive dust, corrosive gas, vibration, water and corrosive salts.

Up to 6560 feet (2000m) above sea level At altitudes above 3280 feet (1000m) reduce the nominal current by 2% for

each 328 feet (100m). From 5 to 95% relative humidity, non-condensing and without ice Installation Category III, Pollution degree 2

Watlow - ASPYRE 35A to 40A Power Controller • 15 • Chapter 2 Installation

Cooling Requirements

To maintain the ambient temperature in the enclosure in which the power controller, circuit breakers, fuses and other components are installed, there must be adequate cooling to remove the heat generated by all the devices. The power controllers are designed to be cooled by drawing cool air in from the bottom and expelling heated air at the top. Typically cabinets are designed with one or more fans on the front door or on the top of the enclosure. The designer will need to know the heat generated by the power controller. See the table below.

Total Heat Generated by ASPYRE Power Controller

Model Current (A) Switched Legs Heat Loss (W)

DT1_ _-035... 35 1 44 DT1_ _-040... 40 1 50 DT2_ _-035... 35 2 88 DT2_ _-040... 40 2 100 DT3_ _-035... 35 3 135 DT3_ _-040... 40 3 150

Spacing for Multiple Power Controllers

Maintain the minimum distances as shown in the diagram. When multiple power controllers are mounted side-byside they may be placed as close together as is practical for installation and service.

Power Controller Spacing

30 cm (11.8 in.)

2 cm (0.8 in.)

20 cm (7.9 in.)

Hot Air

Outlet

Cool Air

Intake

Watlow - ASPYRE 35A to 40A Power Controller • 16 • Chapter 2 Installation

Mounting Dimensions

5.22 in. (132.5 mm)

The power controller may be mounted on a DIN rail or with screws. See the tables and illustrations below for the product dimensions, weight and mounting locations and sizes.

Power Controller Dimensions and Weight

Model W H D Weight

DT1...

DT2...

DT3...

Mounting Locations

2.83 in. 72 mm

4.25 in.

108 mm

5.67 in.

144 mm

4.75 in. 121 mm

7.29 in. 185 mm

3.80 in. (96.5 mm)

2.38 in. (60.5 mm)

0.23 in. (5.8 mm)

2.53 lb.

1.15 kg

3.87 lb.

1.75 kg

5.3 lb.

2.4 kg

Dimensions

4.32 in

(109.7 mm)

0.22 in. (5.5 mm)

Mounting Hole Size

Mounting Hole Diameter

Note! The maximum thickness for the DIN rail is 1mm.

0.188 in. (4.78 mm)

2.31 in

(58.8 mm)

2.44 in

(62 mm)

Watlow - ASPYRE 35A to 40A Power Controller • 17 • Chapter 2 Installation

Watlow - ASPYRE 35A to 40A Power Controller • 18 • Chapter 2 Installation

Wiring

WARNING: The installation must be protected by electromagnetic circuit breakers or by fuses. The semicon-

ductor fuses located inside the power controller are classied for UL® as supplementary protection for semicon-

ductor devices. They are not approved for branch circuit protection.

Wiring the ASPYRE Power Controller

This chapter describes how to select, prepare and attach power and signal wires to the power controller.

Good Wiring Practices

Follow good wiring practices to minimize the effects of interference from nearby equipment and the line power on the operation of the power controller:

• Install an appropriately sized RC lter across contactor coils, relays and other inductive loads

• Use shielded twisted-pair cables for input, output and communication signals

• Route control and signal cables away from motors and other sources of electromagnetic interference and not parallel to power cables

• Follow all local regulations applicable to electrical installations

NOTE: Use only copper cables and wires rated for use at 90°C or greater unless otherwise noted.

REMARQUE : N’utiliser que des câbles et des ls en cuivre pour l’utilisation à 90 °C ou plus, sauf indication

contraire.

Watlow - ASPYRE 35A to 40A Power Controller • 19 • Chapter 3 Wiring

Wiring Overview Diagrams

123

The diagrams in this section indicate the locations of the line power, load, earth ground and control signal connections on the power controller.

Single Phase 35A and 40A

Cover Closed

Cover Tipped Forward

L/R F

480V 40 A

L/R F

M3 M2

Three-Phase, Two-Leg 35A and 40A

Covers Closed

T1 L1

480V 40 A

Covers Tipped Forward

T1 L1

T2 L2

L/R F

480V 40 A

L/R F

480V 40 A

M3 M2

Watlow - ASPYRE 35A to 40A Power Controller • 20 • Chapter 3 Wiring

Three-Phase, Three-Leg, 35A and 40A

123

Covers Tipped Forward

T1 L1

480V 40 A

T2 L2

480V 40 A

T3 L3

480V 40 A

L/R F

M3 M2

Covers Closed

480V 40 A

L/R F

Wire Selection, Prep and Torque

This section lists the recommended cable and bus bar sizes for line power, load, earth ground and control signal connections. There are also recommendations for insulation stripping and termination torque.

Line Power and Load Cable Size and Termination

Model Cable Size Bolt Temperature Rating

DT_ _ _-035... DT_ _ _-040...

16 to 6 AWG (1.5 to 16 mm2) M5 90°C or greater

Ground Cable Size

Model Cable Size Bolt Temperature Rating

DT_ _ _-035... DT_ _ _-040...

10 AWG (6 mm2) 3.5 mm 75°C or greater

Control and Signal Cable Size

Range: 22 to 14 AWG (0.50 to 1.5 mm2)

Recommended: 18 AWG (0.75 mm2)

Temperature Rating: 75°C or greater

Insulation Stripping and Torque

To insure proper connections, but minimize hazardous exposure of conductors, strip the correct amount of insulation from each cable.

Insulation Stripping

Load & Line Power

Ground

Control and Signal

Watlow - ASPYRE 35A to 40A Power Controller • 21 • Chapter 3 Wiring

Per crimp lug requirements Per crimp lug requirements

0.24 in. (6mm)

Control Signal and Ground Torque

Control & Signal

Ground

Line Power and Load Torque

Model Connector Type Wire Termination Proper Torque

DT_ _ _-035... DT_ _ _-040...

4 in.-lb. (0.11 Nm) 31 in.-lb. (3.5 Nm)

Bus Bar with M6 bolt

UL Listed (ZMVV) Rigid / Flexible Spade Terminal

26.6 in.-lb. (3.0 Nm)

Opening The Covers

WARNING: To prevent injury and loss of life, shut off power and ensure it cannot be restored while perform-

ing work with the covers open or removed.

AVERTISSEMENT : Pour éviter les blessures et les pertes de vie, couper l’alimentation électrique et s’assurer

qu’elle ne peut être restaurée pendant l’exécution du travail avec les couvercles ouverts ou enlevés.

To open the front cover to access line power, load and other connections:

1. Grip the cover by the handle .

2. Pull the cover rmly toward you and down.

Connecting Control Signals

This section shows how to connect control signals to the M1 and M2 terminal strips.

M1 Terminal Connections

M1 Function Description

10 Analog common - For analog input 2 and retransmit output 11 Factory connection 12 Factory connection 13 Factory connection 14

Alarm output

15 NO (normally open contact) 16 NC (normally closed contact)

M2 Terminal Connections

M2 Function Description

1 10V Power supply common For dry contact digital inputs or potentiometers for analog inputs 2 Digital input common Reference to 10V Aux common if necessary 3 Digital input 2 4 Digital input 1 5 Analog input 1+ Set point signal input 6 Analog common - For analog input 1 7 +10V power supply For digital inputs and potentiometer 8 Not used 9 Not used

C (common)

Watlow - ASPYRE 35A to 40A Power Controller • 22 • Chapter 3 Wiring

M3 Terminal Connections

Bottom View

Analog Input 2

19 18

Top View

M3 Function Description

A+

Port 1 Modbus® RTU RS-485

B- Connect to A- on USB-to-485 adapter

M4 Terminal Connections

M4 Function Description

L1 Auxiliary power input Line 1

- Not used

L2/N Auxiliary power input Line 2 or neutral (DT1 models)

M5 Terminal Connections*

M5 Function Description

A+

Port 2 Modbus® RTU RS-485

B- Connect to A- on USB-to-485 adapter

*Connect 485 signal here only on units with second Modbus® RTU 485 communications port option. Connecting signal here on units with other wired communications options will interfere with the operation of that option.

M6Terminal Connections

M6 Function Description

17 24VDC power input

18 Analog common Common for 24 VDC power input, analog input 2 and retransmit output 19 Analog input 2+ Alternate set point, external feedback or current limit (DT1) 20 Retransmit output+

Connect to B+ on USB-to-485 adapter

Supplemental power for applications that use both analog retransmit and the second communication port (other than Modbus® RTU.)

Set Point (Analog Input 1)

To control the power to the load with a device such as a temperature controller, connect the control signal to analog input 1.

This input accepts current (0 to 20mADC, 4 to 20mADC), voltage (0 to 10VDC) and potentiometer (0 to 10,000Ω)

signals. Congure the power controller to recognize the

signal on the hardware menu; see “Analog In 1 [Signal Type]” on page 51.

Analog Input 1 Wiring on M1 Terminals (Bottom View)

Analog Input 1

Set Point, Feedback or Current Limit (Analog Input 2)

What this input does is user-congurable. Connect an analog signal that indicates:

• An alternate set point signal

• Measured power, voltage or current for use as feedback

• In models with the current limit option: the maximum current to the load (current limit set point)

This input accepts current (0 to 20mADC, 4 to 20mADC), voltage (0 to 10VDC) and potentiometer (0 to 10,000Ω) sig-

nals. Congure the power controller to recognize the signal

and how the power controller uses it on the hardware menu; see “Analog In 2 [Signal Type]” on page 52 and “Analog In 2 Function” on page 52.

Analog Input 2 Wiring on M1 Terminals (Top View)

Analog Input 2

10 11 12 13 14 15 16

19 18

L2/N

17 18 19 20

Watlow - ASPYRE 35A to 40A Power Controller • 23 • Chapter 3 Wiring

Configurable Digital Inputs (Digital Input 1 and Digital Input 2)

Bottom View

External DC Supply

Analog Input 2

19 18

Top View

Bottom View

Analog Input 2

19 18

Top View

What these inputs do is user-congurable. Connect digital

signals to:

• Enable the power controller to output power to the load

• Change the feedback to voltage

• Change whether the local or remote set point is used

• Change the ring type to phase angle

Congure how the power controller uses these signals on

the hardware menu; see “Digital In 1 Function” on page 54 and “Digital In 2 Function” on page 55.

NOTE! If you use the +10VDC power supply to provide the input signal, connect the 10VDC common (M2 terminal 1) to the digital input common (M2 terminal 2).

Digital Input Wiring on M1 Terminals (Bottom Views)

Digital Input 2

Digital Input 1

–

Alarm Outputs

Connect to the relay contacts so that alarms in the power controller can be detected or enunciated by exter-

nal devices. Congure which alarms cause the relay to

energize with the hardware menu; see “Alarm Function” on page 51.

Retransmit Option

Connect the analog output to an external device so it can monitor or record set point, current, voltage, or actual power.

Which data is retransmitted and the scaling of the output are user-congurable on the hardware menu; see “Retransmit (Models with Retransmit)” on page 63, “Retransmit Type (Models with Retransmit)” on page 64 and “Retransmit Scale (Models with Retransmit)” on page

63.

If using the retransmit feature and any Ethernet protocol or Probus, connect an external power to the supplemental 24VDC input.

Digital Input 2

Digital Input 1

Alarm Wiring on M1 Terminals (Top View)

17 18 19 20

L2/N

10 11 12 13 14 15 16

Alarm Output

Retransmit Wiring on M1 Terminals (Top View)

Retransmit Output and Supplemental 24VDC Input

20 18

10 11 12 13 14 15 16

Normally Closed Contact

Normally Open Contact

Common

Retransmit

Common

+24VDC Input

17 18 19 20

L2/N

Watlow - ASPYRE 35A to 40A Power Controller • 24 • Chapter 3 Wiring

Communication Connections

RS-485

Bottom View

Top View

All models include at least one RS-485 communication port. Some models include a second communication port. Connect these ports to allow other equipment to monitor, operate or congure the power controller. The communication protocols have adjustable software settings on the Communication menu see “Menu Listing” on page 35.

Accessing the Optional Second Communication Port

The location of the optional second communication port, if present is dependent on the communication option.

Communication Options

Model Communication Option Connector Type Connector Location

DT_ _ _-_ _ _ _ _-_0_ _ _ No additional port N/A N/A DT_ _ _-_ _ _ _ _-_1_ _ _ Modbus DT_ _ _-_ _ _ _ _-_2_ _ _ Modbus DT_ _ _-_ _ _ _ _-_3_ _ _ Probus DP DB9

DT_ _ _-_ _ _ _ _-_5_ _ _ EtherNet/IP™ RJ-45

TCP (Ethernet) RJ-45 Top, next to M1

RTU (2nd RS485 port) Removable screw terminal Bottom, M5

RS-485, Modbus RTU Wiring on M3 Terminals (Bottom View)

A-

B+

Top, next to M1DT_ _ _-_ _ _ _ _-_4_ _ _ Pronet RJ-45

Port 2 Ethernet (Top View)

RJ-45

10 11 12 13 14 15 16

Port 2 Probus DP (Top View)

DB9

10 11 12 13 14 15 16

Port 2 RS-485, Modbus RTU (Top View)

A-

17 18 19 20

L2/N

RS-485

B+

17 18 19 20

L2/N

Watlow - ASPYRE 35A to 40A Power Controller • 25 • Chapter 3 Wiring

Connecting the Auxiliary Power

123

Top View

123

The auxiliary power input supplies the controller’s electronics. The voltage supplied at M4 terminal L1 must be synchronized with the phase that is connected to the L1 line power terminal. The auxiliary voltage is indicated on

the product identication label and encoded in

the part number as the nominal voltage (character 9).

Auxiliary Power Input on M2 Terminals (Top View)

10 11 12 13 14 15 16

17 18 19 20

L2/N

Install fuses on each hot leg (not required for

Line 1

Fuses

single-phase neutral). Use 2A class CC fuses rated for 600VAC similar to Bussman LP-CC Series.

Line 2 /Neutral

Wiring the Line Power and Load

Line Power Connection Locations

The following illustrations indicate how to connect line power and loads.

Single-Phase Line Power and Load Wiring

Three-Phase. Two-Leg Line Power and Load Wiring

Auxiliary Power

L2 L3

L/R F

480V 40 A

L/R F

480V 40 A

Watlow - ASPYRE 35A to 40A Power Controller • 26 • Chapter 3 Wiring

Three-Phase, Three Leg Line Power and Load Wiring

123

480V 40 A

L/R F

480V 40 A

Three-Phase, Two-Leg Load Wiring Congurations

Delta Wye

Three-Phase, Three-Leg Load Wiring Congurations

Delta Open Delta Wye Grounded Wye

Watlow - ASPYRE 35A to 40A Power Controller • 27 • Chapter 3 Wiring

Watlow - ASPYRE 35A to 40A Power Controller • 28 • Chapter 3 Wiring

Initial Setup

This chapter provides the information necessary to begin using your ASPYRE power controller.

The procedures below call for setting and verifying parameter settings. These parameters can be set via the control panel or using the ASPYRE Congurator software. To learn more about how to use the control panel to access and set parameters on the menus; see “Menu Navigation” on page 34.

Using the ASPYRE Conﬁgurator Software

The power controller can be set up and monitored via the menus using the on-board keypad and display or using

a computer running the ASPYRE Congurator software. The ASPYRE Congurator software is available on the

Watlow website.

To use the software:

1. Download and run the ASPYRE Congurator software instal-

lation le and follow the on-screen instructions.

2. Connect a USB cable (Watlow p/n 0219-0480-0000) between a USB host port on the computer and the micro USB port on the front of the ASPYRE power controller.

3. Wait for the communications port installation to complete.

4. Launch the ASPYRE Congurator software

5. From the Setting menu, choose Serial Port.

6. Choose the communications port and click OK.

7. For a single-phase model select ASPYRE or for a 2-leg or 3-leg model, select ASPYRE 3PH.

8. Click Upload from unit.

9. Click Read.

10. In the Selection list under power controller click the menu to access.

ASPYRE Congurator Software

Conﬁguring the ASPYRE Power Controller

The ASPYRE power controller includes many advanced features. You can learn more about these in the Features chapter of the manual. In order to get the optimum performance in your application, be sure to verify or adjust these settings before beginning operation:

Initial setup:

1. Nominal current and voltage

2. Firing type

3. Feedback type

4. Input for power request / set point

5. Enable input, if used

6. Current limit (DT1 models), if used

Watlow - ASPYRE 35A to 40A Power Controller • 29 • Chapter 4 Initial Setup

Set Nominal Current and Voltage

In order for the power controller to function correctly, set the nominal line voltage and load current. To calculate the nominal load current see “Digits 6, 7 and 8, Amperage” on page 11. Otherwise it can be determined empirically after completing the installation and other setup steps by applying 100% power and measuring the resulting current.

On this menu... set this parameter... to the...

Setup Nominal V nominal line voltage (RMS)

Setup Nominal I nominal current (RMS) in each leg of the load at 100% power

Set the Firing Type

Choose the ring type in order to optimize the performance of the load.

On this menu... set this parameter... to the...

Adv Setup Firing type of power switching appropriate for your load

Also on the Adv Setup menu set the parameters that adjust the behavior of the ring type you chose.

For... set this parameter... to the...

Phase Angle Soft Start Soft Start

Burst Fire Start Ramp Start Ramp number of half cycles over which each burst should ramp Burst Fire

Burst Fire Start Ramp Burst Fire Delay Trigger

Burst Fire Delay Trigger Delay ring delay from zero cross in degrees Zero Crossing Cycle Time duration of each on-off cycle

Min Cycles fewest number of cycles the output should be on or off

amount of time for the output to ramp from zero to the set point

Set the Feedback

Choose the variable to use for feedback to optimize the performance of the application.

On this menu... set this parameter... to the...

Adv Setup Feedback type of measured feedback appropriate for your application

Configure the Input for Power Demand / Set Point

The signal to analog input 1 indicates the desired percent of full output the power control should deliver to the load.

Congure the power request / set point signal:

On this menu... set this parameter... to the type of signal and range...

0-10 V / 10k pot (0 to 10 VDC or potentiometer)

Hardware Analog In 1

NOTE! This procedure assumes the analog input signal wiring, if used has been connected and that the signal

can be set to various values as needed to perform the procedure. See “Set Point” on page 64.

4-20mA (4 to 20 mADC)

0-20mA (0 to 20 mADC)

Configure the Enable Input

By default digital input 1 is used to enable the power controller.

Watlow - ASPYRE 35A to 40A Power Controller • 30 • Chapter 4 Initial Setup

+ 96 hidden pages

Watlow 35A, 40A Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Information

Technical Assistance

Return Material Authorization (RMA)

Warranty

Overview

Recognizing Product Features

Identifying the Product

Product Selection

Product Block Diagram

Wi-Fi Transmitter Module

Installation

Installing the ASPYRE Power Controller

Environmental Conditions

Cooling Requirements

Mounting Dimensions

Wiring

Wiring the ASPYRE Power Controller

Good Wiring Practices

Wiring Overview Diagrams

Wire Selection, Prep and Torque

Opening The Covers

Connecting Control Signals

Connecting the Auxiliary Power

Wiring the Line Power and Load

Initial Setup