Watlow 60A, 210A Operating Manual

Download

Page 1

60A to 210A Power Controller

ISO 9001

User’s Guide

1917-1409 Rev D

March 2019

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

Page 2

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 60A to 210A Power Controller • 2 •

Page 3

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 60A to 210A Power Controller • 3 •

Page 4

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 60A to 210A Power Controller • 4 •

Page 5

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 75°C or greater.

REMARQUE : N’utiliser que des câbles et des ls en cuivre pour l’utilisation à 75°C ou plus.

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 failed product to Watlow. If you do not know why the product failed, contact an Application Engineer. 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. 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 to verify the reason for the product failure. Unless otherwise agreed to in writing, Watlow’s standard warranty provisions, which can be located at, www.watlow.

com/terms, will apply to any failed product.

4. In the event that the product is not subject to an applicable warranty, we will quote repair costs to you and request a purchase order from you prior to proceeding with the repair work.

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

Warranty

The ASPYRE® power controller is warranted by Watlow for a period of 36 months in accordance with the terms and conditions set forth on Watlow’s website, which may be accessed at www.watlow.com/terms.

Watlow - ASPYRE 60A to 210A Power Controller • 5 •

Page 6

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 Windows® is a registered trademark of Microsoft Corporation. Modbus® is a registered trademark of Schneider Automation Incorporated. Siemens® is a registered trademark of Siemens Aktiengesellschaft Corporation. UL® is a registered trademarks of Underwriter’s Laboratories, Inc.

Watlow - ASPYRE 60A to 210A Power Controller • 6 •

Page 7

Contents

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

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

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

Warranty ..............................................................5

Overview ...........................................11

Recognizing Product Features ............................................11

Identifying the Product ..................................................11

Product Selection ......................................................12

Features and Benefits ...................................................14

Product Block Diagram .................................................15

Installation ..........................................17

Installing the ASPYRE Power Controller ....................................17

Environmental Conditions ...............................................17

Cooling Requirements ..................................................18

Mounting Dimensions 480V and 600V ......................................19

Mounting Dimensions 690V ..............................................20

Wiring 480V and 600V Units ..............................21

Wiring the ASPYRE Power Controller ......................................21

Good Wiring Practices ..................................................21

Wiring Overview 480V and 600V Units .....................................22

Wire Selection, Prep and Torque ..........................................23

Terminal Strip Connections ..............................................24

Connecting Control Signals ..............................................25

Powering the Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Connecting the Auxiliary Power (DT1 and DT2 Only). . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Opening The Covers ....................................................29

Wiring the Line Power and Load ..........................................29

Wiring 690V Units .....................................31

Wiring the ASPYRE Power Controller ......................................31

Good Wiring Practices ..................................................31

Wiring Overview 690V Units .............................................32

Wire Selection, Prep and Torque ..........................................34

Removing the Covers ...................................................35

Connecting Control Signals ..............................................35

Powering the Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Connecting the Auxiliary Power ...........................................40

Wiring the Line Power and Load ..........................................40

Initial Setup .........................................43

Using the ASPYRE Configurator Software ...................................43

Configuring the ASPYRE Power Controller ..................................43

Watlow - ASPYRE 60A to 210A Power Controller • 7 •

Page 8

Operation ...........................................47

Control Panel .........................................................47

Menu Navigation ......................................................48

Indicators (LEDs) ......................................................49

Alarms and Messages ..................................................50

Using ASPYRE Configurator ..............................51

Overview ............................................................51

How To ..............................................................51

Reference ............................................................56

Parameter Reference ...................................65

Alarm Function ........................................................65

Analog In 1 [Signal Type] ................................................65

Analog In 1 [Value] ....................................................66

Analog In 2 [Signal Type] ................................................66

Analog In 2 [Value] ....................................................66

Analog In 2 Function ...................................................66

Aux Voltage ..........................................................66

Bakeout Current (Models with Current Limit) ................................66

Bakeout Off Time (Models with Current Limit) ................................67

Bakeout Ramp Time (Models with Current Limit) .............................67

Command Bits ........................................................67

Cycle Time ...........................................................68

Delay ...............................................................68

Digital In 1 ...........................................................68

Digital In 1 Function ....................................................68

Digital In 2 ...........................................................69

Digital In 2 Function ....................................................69

Enable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Ethernet Address ......................................................69

Ethernet Subnet .......................................................70

Ethernet Gateway ......................................................70

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

Firing ...............................................................70

Frequency ...........................................................71

Half Cycles to Delay ....................................................71

Heater Bakeout (Models with Current Limit) .................................71

HH:MM:SS ...........................................................71

Host Name ...........................................................71

Htr Break Delay .......................................................71

Htr Break Sensitivity ....................................................71

I Limit (Models with Current Limit) ........................................72

I Limit Local / Remote (Models with Current Limit) ............................72

I Output .............................................................72

Integral Current (Models with Current Limit) ................................72

Integral Power ........................................................72

kVA Real Time ........................................................72

kW Real Time .........................................................72

Watlow - ASPYRE 60A to 210A Power Controller • 8 •

Page 9

kW Total .............................................................73

Leg 1 I Output (DT2 and DT3 Models) ......................................73

Leg 2 I Output (DT2 and DT3 Models) ......................................73

Leg 3 I Output (DT2 and DT3 Models) ......................................73

Limit Peak Current (Models with Current Limit) ..............................73

Load Ω ..............................................................73

Logging .............................................................73

Logging Interval .......................................................74

Max Current .........................................................74

Max Voltage ..........................................................74

Min Cycles ...........................................................74

MM/DD/YY ...........................................................74

Neutral Connected (DT2 and DT3 Models) ...................................74

Nominal I ............................................................74

Nominal V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Out Scale ............................................................75

Port 1 Address ........................................................75

Port 1 Baud ..........................................................75

Port 2 ...............................................................75

Port 2 Access .........................................................76

Port 2 Address ........................................................76

Port 2 Baud ..........................................................76

Power ..............................................................76

Power Factor .........................................................76

Prop Band Current (Models with Current Limit) ..............................76

Prop Band Power ......................................................77

Release ..............................................................77

Remote SP ...........................................................77

Retransmit (Models with Retransmit) ......................................77

Retransmit Scale (Models with Retransmit) ..................................78

Retransmit Type (Models with Retransmit) ..................................78

Safety Ramp Duration ..................................................78

Safety Ramp Off Time ..................................................78

SCR Temperature ......................................................79

Serial Number ........................................................79

Set Point ............................................................79

Set Point Source ......................................................79

Soft Start ............................................................79

Start Ramp ...........................................................79

Startup Display ........................................................80

Status Bits ...........................................................80

Thermal Alarm Counter .................................................80

Unit Type ............................................................80

User Access Level .....................................................81

V Input .............................................................81

V Output .............................................................81

Version ..............................................................81

Watchdog ............................................................81

Watlow - ASPYRE 60A to 210A Power Controller • 9 •

Page 10

Watchdog Reset Time ..................................................81

Wi-Fi ................................................................82

Wi-Fi Address .........................................................82

Features ...........................................83

Closed Loop Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Feedback ............................................................84

Current Limit .........................................................86

Configurable Inputs and Outputs ..........................................86

Firing Types ..........................................................88

Soft Start ............................................................94

Start Ramp (DT1 and DT3 Models) ........................................94

Safety Ramp (DT1 and DT3 Models) .......................................95

Heater Bakeout Function (Models with Current Limit) ..........................95

Totalizer .............................................................95

Data Logging .........................................................96

Maintenance & Troubleshooting ...........................97

Routine Maintenance ...................................................97

Alarms and Indicators ..................................................97

Opening The Covers ....................................................99

Replacement Fuses ...................................................100

Replacing the Battery ..................................................100

Calibration Procedures .................................................101

Updating the Firmware .................................................103

Troubleshooting ......................................................104

Troubleshooting Schematics ............................................105

Communication ......................................111

Overview ...........................................................111

Enabling the Secondary Port ............................................112

Ethernet Network Setup ................................................112

Modbus® TCP ........................................................113

EtherNet/IP™ Setup ...................................................113

Profinet IO Setup .....................................................116

Profibus DP Setup ....................................................121

Holding Registers .....................................................127

Input Registers .......................................................128

Modbus® RTU .......................................................130

Modbus® RTU Holding Registers .........................................131

Specifications .......................................135

Declaration of Conformity ..............................................141

Watlow - ASPYRE 60A to 210A Power Controller • 10 •

Page 11

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 power connection

Mounting slots (top and bottom)

Product identification label

Part number label Part number label

Control panel

Load power connection

Cover handle

USB connector

Earth ground connection

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

Max. Load Current Max. Load Voltage Auxiliary Voltage Fan Voltage Second Port

Watlow - ASPYRE 60A to 210A Power Controller • 11 • Chapter 1 Overview

: 120A : 600Vac ~ 50/60Hz : 540-660Vac ~ 50/60Hz 6VA : 120 VAC : Modbus TCP 1 Phase 1 Leg Control

Use Wire rated 75°C, Max Ambient 40°C For use in Pollution Degree 2 Environment User Manual: 1917-1409

Page 12

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 60A to 210A Power Controller • 12 • Chapter 1 Overview

Page 13

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guration

Watlow - ASPYRE 60A to 210A Power Controller • 13 • Chapter 1 Overview

Page 14

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 and three-phase, three-leg 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)

• 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 60A to 210A Power Controller • 14 • Chapter 1 Overview

Page 15

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

Voltage

Sensing

Analog

Input

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

Mechanical Relay Output

• Alarm Annunciation

Fan Power

• 120VAC

• 240VAC

• 24VDC

Out to LoadIndustrial Communications

• Modbus

TCP

• EtherNet/IP™

• 2nd Modbus

RTU (485)

Analog

Input

Data

Logging

RS-485

Interface

NCNO

Analog

Retransmit

Current

Sensing

Power

Demand

Loop

(Optional)

•

Proﬁbus DP

• Proﬁnet

(Optional)

+10 VDC

Output

Current

Limit

Loop*

Fan Power

Input

Auxiliary

Power

Supplemental Power

• Retransmit

• Communications

+24 VDC

Input

* Single-phase and three-phase, three-leg models only

Power Switching

• 1, 2 or 3 Legs

• Back-to-Back SCR Switching

• Replaceable Semiconductor Fuses

(Optional)

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 60A to 210A Models

Watlow - ASPYRE 60A to 210A Power Controller • 15 • Chapter 1 Overview

Page 16

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 visible when the center cover is tipped forward.

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 60A to 210A Power Controller • 16 • Chapter 1 Overview

Page 17

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.

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 60A to 210A Power Controller • 17 • Chapter 2 Installation

Page 18

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

DT1_ _-060... 60 1 102 136 DT1_ _-090... 90 1 145 175 DT1_ _-120... 120 1 200 213 DT1_ _-150... 150 1 205 216 DT1_ _-180... 180 1 235 254 DT1_ _-210... 210 1 304 295 DT2_ _-060... 60 2 205 277 DT2_ _-090... 90 2 290 354 DT2_ _-120... 120 2 398 448 DT2_ _-150... 150 2 409 416 DT2_ _-180... 180 2 486 545 DT2_ _-210... 210 2 598 638 DT3_ _-060... 60 3 290 354 DT3_ _-090... 90 3 580 469 DT3_ _-120... 120 3 598 601 DT3_ _-150... 150 3 594 611 DT3_ _-180... 180 3 740 725 DT3_ _-210... 210 3 898 848

Generated Heat (W)

480V & 600V 690V

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

Hot Air

30 cm (11.8 in.)

2 cm (0.8 in.)

20 cm (7.9 in.)

Watlow - ASPYRE 60A to 210A Power Controller • 18 • Chapter 2 Installation

Outlet

Cool Air

Intake

Page 19

Mounting Dimensions 480V and 600V

See the tables for the product dimensions, weight and keyhole mounting slot locations and size.

Note! 60A units do not have Fans; 90A to 210A units have fans.

Power Controller Dimensions and Weight

Model W H (no fan) H (with fan) D

DT1...

DT2...

DT3...

3.66 in. 93 mm

7.36 in.

187 mm

11.06 in. 281 mm

10.61 in. 270 mm

10.79 in. 274 mm

6.69 in. 170 mm

Weight

(no fans)

7.5 lb.

3.4 kg

15.0 lb.

6.8 kg

22.4 lb.

10.2 kg

Weight

(with fans)

7.9 lb.

3.6 kg

15.4 lb.

7.0 kg

23.3 lb.

10.6 kg

Mounting Slot Locations

Model A B (no fans) B (with fans)

DT1...

DT2...

DT3...

Slot Locations

2.80 in. 71 mm

6.50 in.

165 mm

5.10 in.

129.5 mm 2 pl.

10.06 in. 256 mm

10.24 in.

0.35 in. (9 mm) diameter typical

A A A

Dimensions

260 mm

0.20 in. (5 mm) typical

Watlow - ASPYRE 60A to 210A Power Controller • 19 • Chapter 2 Installation

Page 20

Mounting Dimensions 690V

See the tables for the product dimensions, weight and keyhole mounting slot locations and size.

Power Controller Dimensions and Weight

Model W H D Weight

DT_ _ _-060... DT_ _ _-090... DT1 _ _-120... DT1 _ _-150... DT1 _ _-180... DT1 _ _-210... DT2_ _-120... DT2_ _-150... DT2_ _-180... DT2_ _-210... DT3_ _-120... DT3_ _-150... DT3_ _-180... DT3_ _-210...

Mounting Slot Locations

Model A B

5.39 in. 137 mm

10.32 in. 262 mm

3.82 in. 97 mm

8.74 in.

222 mm

17.32 in. 440 mm

16.14 in. 410 mm

10.63 in. 270 mm

Slot Locations

0.28 in. (7 mm) typical

23.1 lb.

10.5 kg

39.6 lb.

18.0 kg

Dimensions

0.47 in. (12 mm) diameter typical

Watlow - ASPYRE 60A to 210A Power Controller • 20 • Chapter 2 Installation

Page 21

Wiring 480V and 600V Units

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 75°C or greater.

REMARQUE : N’utiliser que des câbles et des ls en cuivre pour l’utilisation à 75 °C ou plus.

Watlow - ASPYRE 60A to 210A Power Controller • 21 • Chapter 3 Wiring 480V and 600V Units

Page 22

Wiring Overview 480V and 600V Units

The diagrams in this section indicate the locations of the line power, load, earth ground and control signal connections on 480V and 600V power controllers.

Single Phase, 60A to 210A

Cover Closed

Cover Tipped Forward

Port

Three-Phase, Two-Leg, 60A to 210A

Covers Closed

Covers Tipped Forward

Port

Watlow - ASPYRE 60A to 210A Power Controller • 22 • Chapter 3 Wiring 480V and 600V Units

Page 23

Three-Phase, Three-Leg, 60A to 210A

Covers Tipped Forward

Port

Covers Closed

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

Cable Termination UL® Listed (ZMVV)

DT_ _ _-060... 6 AWG (16mm2) DT_ _ _-090... 3 AWG (25mm2) DT_ _ _-120... 1 AWG (50mm2) DT_ _ _-150... 1/0 AWG (70mm2)

Terminal Copper Tube Crimp Lug

M8DT_ _ _-180... 2/0 AWG (70mm2)

DT_ _ _-210... 4/0 AWG (120mm2)

Ground Cable Size

Model Wire Size Bolt

DT_ _ _-060... 10 AWG (6mm2) DT_ _ _-090... 8 AWG (10mm2) DT_ _ _-120...

6 AWG (16mm2)DT_ _ _-150...

DT_ _ _-180... DT_ _ _-210... 4 AWG (25mm2)

Control and Signal Cable Size

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

Recommended: 18 AWG (0.75mm2)

Watlow - ASPYRE 60A to 210A Power Controller • 23 • Chapter 3 Wiring 480V and 600V Units

Page 24

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

Control Signal and Ground Torque

Control & Signal

Ground

Line Power and Load Torque

Model Connector Type Wire Termination Proper Torque

DT_ _ _-060...

DT_ _ _-120... DT_ _ _-150...

DT_ _ _-210...

Per crimp lug requirements Per crimp lug requirements

0.24 in. (6mm)

4 in.-lb. (0.11 Nm)

70.8 in.-lb. (8.0 Nm)

Bus Bar with M6 bolt

UL® Listed (ZMVV) Copper Tube Crimp Lug

Bus Bar with M8 bolt 141.6 in.-lb. (16.0 Nm)DT_ _ _-180...

70.8 in.-lb. (8.0 Nm)DT_ _ _-090...

Terminal Strip Connections

This section lists and describes the terminal strip connections.

M1 Terminal Connections (90A to 210A only)

M1 Function Description

Power input for fan

F2 - For DC fans, line or neutral for AC fans

M2 Terminal Connections (DT1 and DT2 only)

M2 Function Description

L1 Auxiliary power input Line 1

- Not used

L2/N Auxiliary power input Line 2 or neutral on single-phase units

M3 Terminal Connections

M3 Function Description

1 10V power supply common For digital inputs and potentiometer 2 Digital input common Reference to 10V power supply common, if necessary 3 Digital input 2 4 Digital input 1 5 Analog input 1+ Set point signal input 6 Analog common - For analog in 1 and 2 7 +10V power supply For dry contact digital inputs or potentiometers for analog inputs 8 Analog input 2+ Alternate set point, external feedback or current limit (DT1 and DT3) 9 Not used

10 Retransmit output+

+ For DC fans, line or neutral for AC fans

See “Congurable Digital Inputs (Digital Input 1 and Digital Input 2)” on page 26

Watlow - ASPYRE 60A to 210A Power Controller • 24 • Chapter 3 Wiring 480V and 600V Units

Page 25

M3 Function Description

Port 1 Modbus® RTU RS-485

12 Connect to A- on USB-to-485 adapter 13 Analog common For retransmit output 14

Alarm output

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

M4 Terminal Connections for Modbus® RTU Secondary Communication Option

M4 Function Description

1 +24VDC input

2 Common For 24VDC input 3 Not used 4

Port 2 Modbus® RTU RS-485*

5 Connect to B+ 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.

Connect to B+ on USB-to-485 adapter

C (common)

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

Connect to A- on USB-to-485 adapter

Connecting Control Signals

This section shows how to connect control signals to the M3 terminals.

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 65.

Analog Input 1 Wiring on M3 Terminals (Top 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)

signals. 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 66 and “Analog In 2 Function” on page 66.

Analog Input 2 Wiring on M3 Terminals (Top View)

Analog Input 2

Watlow - ASPYRE 60A to 210A Power Controller • 25 • Chapter 3 Wiring 480V and 600V Units

Page 26

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

Normally Closed Contact

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 68 and “Digital In 2 Function” on page 69.

Digital Input Wiring on M3 Terminals (Top View)

Digital Input 2

Digital Input 1

External DC Supply

–

Digital Input 2

Digital Input 1

NOTE! If you use the +10VDC power supply to provide the input signal, connect the 10VDC common (M1 ter-

minal 1) to the digital input common (M3 terminal 2).

Alarm Outputs

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

ciated by external devices. Congure which

alarms cause the relay to energize with the hardware menu; see “Alarm Function” on page

65.

Alarm Wiring on M3Terminals (Top View)

Alarm Output

Normally Open Contact

Common

Retransmit Option

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

Retransmit Wiring on M3 Terminals (Top View)

Which data is retransmitted and the scaling of the output are user-congurable on the hardware menu; see “Retransmit (Models with

Retransmit Output

Common

Retransmit)” on page 77, “Retransmit Type

Retransmit

(Models with Retransmit)” on page 78 and

“Retransmit Scale (Models with Retransmit)” on page 78.

If using the retransmit feature and any Ethernet

protocol or Probus, connect an external power

to the supplemental 24VDC input.

Watlow - ASPYRE 60A to 210A Power Controller • 26 • Chapter 3 Wiring 480V and 600V Units

Supplemental Power Wiring on M4 Terminals (Front View)

–

+24VDC Input

Page 27

Communication Connections

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 the “Menu Listing” on page 49.

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

A-

RS-485

B+

Accessing the Optional Second Communication Port

The second communication port, if present is located near the center of the front cover of the module with the user interface.

Communication Options

Model Communication Option Connector Type

DT_ _ _-_ _ _ _ _-_0_ _ _ No additional port N/A DT_ _ _-_ _ _ _ _-_1_ _ _ Modbus® TCP (Ethernet) RJ-45 DT_ _ _-_ _ _ _ _-_2_ _ _ Modbus® RTU (2nd RS485 port)* Removable Screw Terminal (M4) DT_ _ _-_ _ _ _ _-_3_ _ _ Probus DP DB9 DT_ _ _-_ _ _ _ _-_4_ _ _ Pronet RJ-45 DT_ _ _-_ _ _ _ _-_5_ _ _ EtherNet/IP™ RJ-45

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

RJ-45

DB9

Watlow - ASPYRE 60A to 210A Power Controller • 27 • Chapter 3 Wiring 480V and 600V Units

Page 28

Powering the Cooling Fans

Connect power of the appropriate voltage for the cooling fans. For AC fans install fuses on each hot leg (not required for single-phase neutral). Use 2A class CC fuses rated for 600VAC similar to Cooper Bussman® LP-CC Series. Supply power for one fan per switched leg for 90A to 210A models (60A models have no fans).

Cooling Fan Voltage and Power Per Fan

Fan Voltage Option Fan Voltage

DT_ _ _ -_ _ _ _ _-0_ _ _ _ No Fan DT_ _ _ -_ _ _ _ _-1_ _ _ _ 120VAC 15W 30W 45W DT_ _ _ -_ _ _ _ _-2_ _ _ _ 240VAC 16W 32W 48W DT_ _ _ -_ _ _ _ _-3_ _ _ _ 24VDC 12W 24W 36W

Fan Power Wiring on M1 Terminals (Bottom View)

Power Requirement

DT1... DT2... DT3...

–

Fan Power

Fuses (for AC Fans)

Connecting the Auxiliary Power (DT1 and DT2 Only)

The auxiliary power input supplies the controller’s electronics. The voltage supplied at M2 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).

Install fuses on each hot leg (not required for single-phase neutral). Use 2A class CC fuses rated for 600VAC similar to Cooper Bussman® LP-CC Series.

NOTE! DT3 models supply power to the controller’s electronics internally from the line power connections

and the auxiliary power connector is not present.

Auxiliary Power Input on M2 Terminals (Bottom View)

Line 2 /Neutral

Auxiliary Power

Line 1

Watlow - ASPYRE 60A to 210A Power Controller • 28 • Chapter 3 Wiring 480V and 600V Units

Fuses

Page 29

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.

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

L1 L3

Watlow - ASPYRE 60A to 210A Power Controller • 29 • Chapter 3 Wiring 480V and 600V Units

Page 30

Three-Phase, Three Leg Line Power and Load Wiring

T1 T2

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 60A to 210A Power Controller • 30 • Chapter 3 Wiring 480V and 600V Units

Page 31

Wiring 690V Units

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 75°C or greater.

REMARQUE : N’utiliser que des câbles et des ls en cuivre pour l’utilisation à 75 °C ou plus.

Watlow - ASPYRE 60A to 210A Power Controller • 31 • Chapter 4 Wiring 690V Units

Page 32

Wiring Overview 690V Units

The diagrams in this section indicate the locations of the line power, load, earth ground and control signal connections on 690V power controllers.

Single Phase, 60A to 210A

Top & Bottom Covers O

L/R F

Center Cover Tipped Forward

Three-Phase, Two-Leg, 60A and 90A

Top & Bottom Covers O

L1 L2 L3

L/R F

Center Cover Tipped Forward

T1 T2 T3

Watlow - ASPYRE 60A to 210A Power Controller • 32 • Chapter 4 Wiring 690V Units

Page 33

Three-Phase, Three-Leg, 60A and 90A

Top & Bottom Covers O

L1 L2 L3

L/R F

T1 T2 T3

Center Cover Tipped Forward

Three-Phase, Two-Leg, 120A to 210A

Top & Bottom Covers O

T3L3T2

L2T1

L/R F

Center Cover Tipped Forward

Watlow - ASPYRE 60A to 210A Power Controller • 33 • Chapter 4 Wiring 690V Units

Page 34

Three-Phase, Three-Leg, 120A to 210A

Top & Bottom Covers O

Center Cover Tipped Forward

T3L3T2

L2T1

L/R F

Wire Selection, Prep and Torque

Line Power and Load Cable Size and Termination

Model Cable Size Tool Strip Insulation Proper Torque

DT_ _ _-060... 6 AWG (16mm2) DT_ _ _-090... 3 AWG (35mm2) DT_ _ _-120... 1 AWG (50mm2) DT_ _ _-150... 1/0 AWG (70mm2)

6mm Hex Key

Per terminal

block size DT_ _ _-180... 2/0 AWG (70mm2) DT_ _ _-210... 4/0 AWG (120mm2)

Ground Cable Size

Model Cable Size Tool Cable Termination Proper Torque

DT_ _ _-060... 8 AWG (10mm2) DT_ _ _-090...

DT_ _ _-150... DT_ _ _-180... DT_ _ _-210...

6 AWG (16mm2)DT_ _ _-120...

4 AWG (25mm2)

M6 Wrench

UL® Listed (ZMVV)

Tube Crimp Lug

Control and Signal Cables

Size Range Recommended Size Strip Insulation Proper Torque

22 to 14 AWG (0.50 to 1.5mm2) 18 AWG (0.75mm2) 0.24 in. (6mm)

177 in.-lb. (20.0 Nm)

70.8 in.-lb. (8.0 Nm)

4 in.-lb.

(0.11 Nm)

Watlow - ASPYRE 60A to 210A Power Controller • 34 • Chapter 4 Wiring 690V Units

Page 35

Insulation Stripping and Torque

To insure proper connections, but minimize hazardous exposure of conductors, strip the correct amount of insulation from each cable. For ground strip cable insulation per crimp lug requirements. For load, line power and control and signal cables see tables above.

Removing 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 remove the top cover (line power) or bottom cover (load connections):

1. Loosen and remove the fasteners (1 ea. single-phase, 2 ea. three-phase).

2. Tilt the cover toward you and remove it.

To access the M2 connector:

• After removing the top and bottom covers, tilt the center cover forward.

Connecting Control Signals

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

M1 Terminal Connections

M1 Function Description

Alarm output

2 C (common) 3 NC (normally closed contact) 4 Analog input 2+ Alternate set point, external feedback or current limit (DT1 and DT3) 5 Digital input 2 6 Digital input 1 7

Port 1 Modbus® RTU RS-485*

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

Watlow - ASPYRE 60A to 210A Power Controller • 35 • Chapter 4 Wiring 690V Units

NO (normally open contact)

See “Congurable Digital Inputs (Digital Input 1 and Digital Input 2)” on page 26

Connect to B+ on USB-to-485 adapter

Page 36

M1 Function Description

9 +10V power supply 10 10V power supply common 11 Analog common - For analog in 1 and 2 12 Analog input 1+ Set point signal input 13 Digital input common Reference to 10V power supply common, if necessary 14 Not Used 15

Power input for fan

16 - For DC fans, line or neutral for AC fans 17 Not used 18 Auxiliary power input Line 1 19 Not used 20 Auxiliary power input Line 2 or neutral on single phase units

M2 Terminal Connections

M2 Function

+24VDC supplemental power for applications that use both analog retransmit and the sec-

ond communication port (other than Modbus® RTU) 2 Unused 3 Retransmit output+ 4 Common for retransmit and 24VDC input

For dry contact digital inputs or potentiometers for analog inputs

+ For DC fans, line or neutral for AC fans

Secondary Modbus® RTU Terminal Connections*

Function Description

A+

Port 2 Modbus® RTU RS-485

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

Connect to B+ on USB-to-485 adapter

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

65.

Analog Input 1 Wiring on M1 Terminals

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

11 12

–

Analog Input 1

Watlow - ASPYRE 60A to 210A Power Controller • 36 • Chapter 4 Wiring 690V Units

Page 37

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

14 15 16 17 18 19 20

17 18 19 20

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) signals. 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 66 and “Analog In 2 Function” on page 66.

Analog Input 2

Analog Input 2 Wiring on M1 Terminals

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

–

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

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 68 and “Digital In 2 Function” on page 69.

Digital Input Wiring on M1 Terminals

1 2 3 4 5 6 7 8 9 10 11 12 13

10 1396

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

136

–

Digital Input 2

Digital Input 1

Digital Input 2

Digital Input 1

External DC

Power Supply

NOTE! If you use the +10VDC power supply to provide the input signal, connect the 10VDC common (M1 ter-

minal 10) to the digital input common (M1 terminal 13).

Watlow - ASPYRE 60A to 210A Power Controller • 37 • Chapter 4 Wiring 690V Units

Page 38

Alarm Outputs

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

external devices. Congure which alarms cause the

relay to energize with the hardware menu; see “Alarm Function” on page 65.

Alarm Wiring on M1 Terminals

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

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 77, “Retransmit Type (Models with Retransmit)” on page 78 and “Retransmit Scale (Models with Retransmit)” on page

78.

If using the retransmit feature and any of the Ethernet protocols or

Probus, connect an external power to the supplemental 24VDC input.

Alarm Output

Normally Closed Contact

Common

Normally Open Contact

Retransmit Wiring on M2 Terminals

1 2 3 4

Retransmit Output

Common

Retransmit

+24VDC Input

Communication Connections

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 the “Menu Listing” on page 49.

RS-485, Modbus® RTU Wiring on M1 Terminals

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A-

B+

RS-485

Watlow - ASPYRE 60A to 210A Power Controller • 38 • Chapter 4 Wiring 690V Units

Page 39

Accessing the Optional Second Communication Port

The second communication port, if present is located on a daughter card mounted on the back of the main electronics board. Tip the center cover forward and down to access the port.

Communication Options

Model Communication Option Connector Location on Daughter Card

DT_ _ _-_ _ _ _ _-_0_ _ _ No additional port N/A DT_ _ _-_ _ _ _ _-_1_ _ _ Modbus® TCP (Ethernet) RJ-45 on right side DT_ _ _-_ _ _ _ _-_2_ _ _ Modbus® RTU (2nd RS485 port) 2-pin connector on left side* DT_ _ _-_ _ _ _ _-_3_ _ _ Probus DP DB9 connector on right side DT_ _ _-_ _ _ _ _-_4_ _ _ Pronet RJ-45 on right side DT_ _ _-_ _ _ _ _-_5_ _ _ EtherNet/IP™ RJ-45

RJ-45

or DB9

RS-485

Powering the Cooling Fans

Connect power of the appropriate voltage for the cooling fans. Install fuses on each hot leg (not required for single-phase neutral). Use 2A class CC fuses rated for 600VAC similar to Cooper Bussman® LP-CC Series. Supply power for one 17W fan for all single-phase models and all 60A and 90A models and two 17W fans for two- and three-leg 120A to 210A models.

Cooling Fan Voltage

Model Voltage

DT_ _ _-_ _ _ _ _-0_ _ _ _ No Fan DT_ _ _-_ _ _ _ _-1_ _ _ _ 120VAC DT_ _ _-_ _ _ _ _-2_ _ _ _ 240VAC DT_ _ _-_ _ _ _ _-3_ _ _ _ 24VDC

Fan Power

Fan Power Wiring on M1 Terminals

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

15 16

–

Fuses (for AC fans)

Watlow - ASPYRE 60A to 210A Power Controller • 39 • Chapter 4 Wiring 690V Units

Page 40

Connecting the Auxiliary Power

The auxiliary power input supplies the controller’s electronics. The voltage supplied at M1 terminal 18 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).

Install fuses on each hot leg (not required for single-phase neutral). Use 2A class CC fuses rated for 600VAC similar to Cooper Bussman® LP-CC Series.

Auxiliary Power Input on M1 Terminals

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

18 20

Line 1

Line 2 /Neutral

Fuses

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

L/R F

Three-Phase Line Power and Load Wiring 60A and 90A

L/R F

Watlow - ASPYRE 60A to 210A Power Controller • 40 • Chapter 4 Wiring 690V Units

Page 41

Three-Phase Line Power and Load Wiring 120A to 210A

L/R F

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 60A to 210A Power Controller • 41 • Chapter 4 Wiring 690V Units

Page 42

Watlow - ASPYRE 60A to 210A Power Controller • 42 • Chapter 4 Wiring 690V Units

Page 43

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 48.

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

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 and DT3 models), if used

Watlow - ASPYRE 60A to 210A Power Controller • 43 • Chapter 5 Initial Setup

Page 44

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 13. 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), 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 amount of time for the output to ramp to the set point 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 BF Strt Rmp Delay Trigger Burst Fire Delay Trigger BF Strt Rmp Delay Trigger Zero Crossing Cycle Time duration of each on-off cycle

Half Cycle Safety Ramp

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

Delay ring delay from zero cross in degrees Half Cycles to Delay number of half cycles to which to apply the delayed ring

Safety Ramp Duration

Safety Ramp Off Time

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

minimum amount of off-time before ramping is needed

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 79.

Watlow - ASPYRE 60A to 210A Power Controller • 44 • Chapter 5 Initial Setup

4-20mA (4 to 20 mADC)

0-20mA (0 to 20 mADC)

Page 45

Configure the Enable Input

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

To verify that digital input 1 is congured to enable the power controller:

• On the Hardware menu verify that Digital In 1 Function is set to Enable.

NOTE! If the power controller is used to switch power on and off simply following an on-off or time propor-

tioned signal, that signal can be connected to the enable input and the set point can be set to 100%.

Configure the Current Limit

For models with this option the current limit feature prevents the current from exceeding the user-set current limit. As the current approaches the limit, the power controller decreases its output to avoid exceeding the current limit. The current limit set point can be set with the I Limit parameter or by an analog input.

CAUTION: This procedure must be performed only by qualied persons.

ATTENTION : Cette procédure ne doit être effectuée que par le personnel qualié.

CAUTION: This procedure requires turning on full power to the load. This should only be performed once the

installation is complete and when it is safe to provide full power.

ATTENTION : Cette procédure nécessite la mise sous tension totale de la charge. Cela ne doit être effectué

qu’une fois l’installation terminée et lorsque la puissance maximale peut être fournie en toute sécurité.

To limit the current using the parameter setting:

1. On the Hardware menu set I Limit Local / Remote to Local.

2. On the Operator menu set I Limit to 0%.

3. Enable the power controller and set the power demand set point to 100%.

4. Gradually increase the current limit set point until the RMS current is at the maximum desired value.

5. Disable the power controller.

To limit the current using the signal to analog input 2:

1. On the Hardware menu set Analog In 2 for the type of signal and range:

0 to 10 VDC or 10k potentiometer

4 to 20 mADC

0 to 20 mADC

2. On the Hardware menu set the Analog In 2 Function to I Limit.

3. On the Hardware menu set the I Limit Local / Remote to Analog In 2.

4. Set the signal to the analog input to the minimum value (typically 0 V).

5. Enable the power controller and set the power demand / set point to 100%.

6. Gradually increase the signal to the analog input until the RMS current is at the maximum desired value.

7. Disable the power controller.

0-10 V / 10k 4-20mA 0-20mA

Watlow - ASPYRE 60A to 210A Power Controller • 45 • Chapter 5 Initial Setup

Page 46

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, Feedback or Current Limit (Analog Input 2)” on page 25.

Watlow - ASPYRE 60A to 210A Power Controller • 46 • Chapter 5 Initial Setup

Page 47

Operation

This chapter describes how to operate the controller using its control panel interface, how to access and navigate the menus and how to interpret the indicators and alarm messages.

Control Panel

The control panel is located on the front of the power controller. The display indicates the alarms, input and

output signals, and by navigating the menus with the keypad, provides access to the conguration parameters.

Iout0.0A SP 100%

Output Current RMS Output Voltage (RMS)

On the home page the keys are used as follows:

Press... to...

Function Scroll through the parameters on the home page

Local / Remote Switch between local and remote set point for power demand

Up Increment power demand set point when set to local

Down Decrement power demand set point when set to local

Vout0.0V SP 100%

Pout0% SP 100%

Output Power

(Average)

Aux High ALARM

Alarms

To view the status parameters:

• Press function once to advance from one parameter to the next

To set the set point locally:

1. Press local / remote (Note: indicator 1 ashes steadily when set point is set locally.)

2. Use down and/or up to set the local set point.

Watlow - ASPYRE 60A to 210A Power Controller • 47 • Chapter 6 Operation

Press and hold for about two seconds to access the menus

Page 48

Menu Navigation

The menus are accessible using the control panel keypad and display.

Home

Page

Choose

Enter Password Choose Parameter Edit Parameter

(~2 sec.)

(wrong password)

(~2 sec.)

To access a menu and edit a setting:

1. Press and hold local / remote and function together + until the upper display ashes Menu.

2. Press up to choose the menu. (Press down if you overshoot the menu you want.)

3. Press function to advance to the password prompt.

4. Use up and/or down to set the password (see the table).

5. Press function to enter the password and advance to the rst parameter on the menu.

6. Press up to advance to the next parameter and repeat to reach the desired parameter.

7. Press function to start editing the parameter. The parameter name ashes in the upper display.

8. Use up and/or down to change the parameter setting.

9. Press function to stop editing the parameter. The parameter name stops ashing.

10. Press and hold local / remote and function together + for about two seconds to exit the menus.

Menu Password Parameters Used To...

Operator 0 View measured values and basic settings including current, voltage and set point Setup 2 Congure the power controller for the load

Adv Setup 10

Hardware 5

Comm 3 Congure communication parameters

Monitor 0

Congure power switching, closed-loop control of power and adjustable settings for

data logging and heater bakeout Congure the functions of the analog and digital inputs and outputs, and the re-

transmission parameters

View the states of digital inputs, values of analog inputs and information about the power controller such as serial number and software version

Watlow - ASPYRE 60A to 210A Power Controller • 48 • Chapter 6 Operation

Page 49

Menu Listing

Aux High ALARM

The table below lists the parameters found on each menu. See “Parameter Reference” starting on page 65 for descriptions and the other details of each parameter.

Operator Setup Advanced Setup Hardware Communication Monitor

Set Point Out Scale Firing Analog In 1 Port 1 Baud Digital In 1 V Output I Limit I Output Nominal V Soft Start Analog In 2 Function Port 2 Baud Enable Leg 1 I Output1Nominal I Safety Ramp Off Time Digital In 1 Function Port 2 Access Set Point Source Leg 2 I Output1Soft Start Safety Ramp Duration Digital In 2 Function Watchdog Analog In 1 Leg 3 I Output1Remote SP Start Ramp Alarm Function Watchdog Reset Time Analog In 2 Power Delay I Limit Local / Remote2Wi-Fi Address V Input Half Cycles to Delay2Retransmit Frequency Cycle Time Retransmit Scale Power Factor Feedback Retransmit Type Load Ω Prop Band Power Startup Display Host Name Max Current

I Limit Out Scale Prop Band Current Nominal V Integral Current Nominal I Htr Break Sensitivity MM/DD/YY

Shaded items are read only.

DT2 and DT3 models

DT1 and DT3 models with the current limit option

Models with corresponding options (retransmit, Ethernet, Wi-Fi and/or real-time clock)

Min Cycles Analog In 2 Port 1 Address Digital In 2

Integral Power Port 2 Address Aux Voltage

Htr Break Delay HH:MM:SS Logging kW Real Time Logging Interval kW Total Heater Bakeout Bakeout Ramp Time Bakeout Current Bakeout Off Time Neutral Connected

Ethernet Address Ethernet Subnet Ethernet Gateway

Port 2 Serial Number

Wi-Fi

Version Release Unit Type Max Voltage

SCR Temperature

kVA Real Time Thermal Alarm Counter

Indicators (LEDs)

The four indicators on the control panel show the general state of the power controller.

Flashing Power output set locally or via communications

Local/Remote

Off Power output set remotely (via analog input)

On Output enabled

Enable

Off Output disabled

Communication Flashing Active communications

On Active alarm

Alarm

Off No alarm

Watlow - ASPYRE 60A to 210A Power Controller • 49 • Chapter 6 Operation

Page 50

Alarms and Messages

The power controller display indicates certain modes of operation and alarms by ashing a message on the top

display.

Alarm or Message DT1 DT2 DT3 Description

Aux High X X X Aux voltage too high

Aux Line Loss

Aux Low X X X Aux voltage too low Bakeout X X Heater bakeout function is active Heater Break X X X Heater break alarm I Limit X X Output reduced by current limit feature PH Loss X One or more phases of the line power are disconnected SD Card Error X X X SD card error SCR Short X X X Shorted SCR causing output to be on continuously SCR Over Temp X X X Thermal switch over temperature Unbalance Load X X One or more legs of the load are open Watchdog X X X Communication watchdog error

X X X Auxiliary power is not detected

X Line power not detected

Watlow - ASPYRE 60A to 210A Power Controller • 50 • Chapter 6 Operation

Page 51

Using ASPYRE Configurator

This chapter explains how to use the ASPYRE Congurator software as an alternative to using the power controller’s keypad and display for viewing and setting parameters as well as the advanced features not available via the power controller’s onboard user interface.

Overview

This section describes the scope and intent of the ASPYRE Congurator software.

Typical Uses

The software may be used during commissioning to set and make a record of settings that determine how the power controller operates and performs; to copy or clone the setup or one power controller to another; on a day-to-day basis to monitor operation and power usage; if necessary, to examine performance in more detail to determine if any corrective actions are needed; or to restore the setup of the power controller.

Communicating with Power Controllers

ASPYRE Congurator software can communicate with ASPYRE power controllers via USB or RS-485. When initially

commissioning the power controller it is convenient to connect a computer to the power controller via the USB port located below the control panel’s display. The power controller’s electronics are powered by the computer via the USB connection when the auxiliary line power is turned off. This makes it possible to examine and congure the power controller’s settings prior to applying power to the panel.

USB is designed to connect consumer electronics and peripheral devices such as cameras and keyboards to computers in home and ofce environments; it is not an industrial communications protocol. To continue communicating once the panel door is closed and line power is on, connect the computer to the power controller via the RS-485 communications port. See “Communication Connections” on page 27.

Recipes

A recipe is a computer le which contains a setting for each user adjustable parameter in a power controller. A recipe can be used to congure a power controller for a particular application or job. A recipe can be used to

copy the settings of one power controller to another. A recipe can be created by uploading the settings from a

power controller to the ASPYRE Congurator software and saving it as a le on the computer. A power controller can be congured by downloading a saved recipe from the ASPYRE Congurator software to the power controller.

How To

This section provides step-by-step procedures for common tasks.

Communicate For the First Time

These procedures are for installing the software and establishing communications for the rst time.

To install ASPYRE Congurator:

1. Locate the installer:

• On www.watlow.com linked to the ASPYRE power controller product page. Download the installer to your computer

• On the Controls Tools DVD ROM disk.

Watlow - ASPYRE 60A to 210A Power Controller • 51 • Chapter 7 Using ASPYRE Configurator

Page 52

2. Double-click the installer program.

3. Follow the on-screen instructions to complete the installation.

To communicate with a power controller:

1. For the direct USB connection:

• Connect the USB cable (Watlow p/n 0219-0480-0000) between the computer and the micro USB connector between the display and keypad on the ASPYRE power controller’s control panel.

• Wait for the USB driver to install, if necessary.

2. For an RS-485 connection:

• Connect the computer to the ASPYRE power controller. See “Communication Connections” on page 27. For most computers a USB-to-485 converter is required (Watlow p/n 0847-0326-0000).

3. Launch the ASPYRE Congurator software.

4. Select:

• ASPYRE to communicate with a single-phase power controller

• ASPYRE 3PH to communicate with a three-phase power controller (two or three switched legs)

5. From the Setting menu, choose Serial Port.

6. For Port, select the COM port that is connected to the power controller (see the note below).

7. To verify communications, click Test.

8. Click OK.

NOTE! There are several ways to determine which port is connected to the power controller. You can look in

the Windows® Device Manager under Ports (COM & LPT) for the COM port named “LPC USB VCOM Port (COMx)”

where x is the port number. You can also disconnect the USB cable from the computer, run ASPYRE Congurator and note the ports available in the list on the Serial Port dialog, then close ASPYRE Congurator, reconnect the

USB cable and run the program again; the port that did not appear previously is the correct one.

Using ASPYRE Configurator

These procedures are for using the software once communication has been set up. They assume the software has been installed and the COM port and model type (ASPYRE or ASPYRE 3PH) have already been selected.

To view or save a power controller’s settings using the Simple view:

1. Click Simple, if not already on the simple view.

2. Click Upload from unit.

3. Set the address, if necessary.

4. Click READ.

5. Wait for the software to read the parameter settings.

6. Click OK.

Watlow - ASPYRE 60A to 210A Power Controller • 52 • Chapter 7 Using ASPYRE Configurator

Page 53

7. If desired, to save the settings in a recipe le:

• Click Save.

• Name the recipe.

• Click Save.

NOTE! In the simple view, the parameter values are only read from the power controller when the user uploads the settings. Changes to parameter values are only set in the controller when the user downloads the settings.

To edit a setting in a recipe:

1. Click Simple, if not already on the simple view.

2. Click Open existing recipe.

3. Locate and select the recipe le and click Open.

4. Click OK.

5. Click the menu with the setting you want to change (Setup, Advanced setup, Hardware or Communi-

cations).

6. Select the value you want to change.

7. Edit the value with the increment and decrement

buttons in the eld or type the new value and press the Enter key.

8. Repeat steps 5 to 7 for all the changes you want to make.

9. To save the settings in a recipe le:

• Click Save.

• Name the recipe.

• Click Save.

To download a recipe le into a power controller:

1. Click Simple, if not already on the Simple view.

2. Click Open existing recipe.

3. Locate and select the recipe le and click Open.

4. Click OK.

5. Click Download to unit.

6. Set the address, if necessary.

7. Click SEND.

8. Wait for the software to write the parameter settings.

9. Click OK.

To monitor a power controller with the Test view:

1. Click Test, if not already on the test view.

2. Click Connect.

To log in on the test view to change the digital input and analog input functions:

1. Click the Access Level value (zero when logged out).

2. Type the password: 1111.

3. Click OK.

Watlow - ASPYRE 60A to 210A Power Controller • 53 • Chapter 7 Using ASPYRE Configurator

Page 54

To log out the test view:

1. Click the Access Level value.

2. Click Log out.

3. Click OK.

To view data on the scope:

1. Click Test, if not already on the test view.

2. Click Connect.

3. Click Load Analyzer.

4. For each of up to three channels (Ch 1 to Ch 3):

• With PV1 choose the value to monitor

• Select Show.

• Click the color swatch to change the color

• Click the button to turn the channel on.

To reset the power totals:

1. Click Test, if not already on the test view.

2. Click Connect.

3. Click Reset Totals.

4. Click Yes.

Setting Up and Using Data Logging

To set up data logging:

1. Click Test, if not already on the test view.

2. Click Connect.

3. Click Data Log.

4. In the Data Log window ensure the slider is set to Log Enabled.

5. Click Set Time.

6. Set the date and time and close the date/ time window.

7. Set Log Time to the number of seconds between records.

8. Click Connect.

9. Click Cong.

10. For up to ten parameters to log:

• Click + to add a parameter to the list

• In a row in the list either: Type a parameter’s Modbus® address in the Par eld OR Select the parameter from the drop down list in the Name eld

11. Click Save to send the parameter list to the controller

12. Click OK when prompted that the download is complete.

13. Click Close.

Watlow - ASPYRE 60A to 210A Power Controller • 54 • Chapter 7 Using ASPYRE Configurator

Page 55

14. Click Disconnect.

15. Close the Data Log window.

To retrieve a data log le from the power controller:

1. Click Test, if not already on the test view.

2. Click Connect.

3. Click Data Log.

4. Click Connect.

5. Select a le from the list.

6. Click Download.

7. Select a location and click Save.

8. Wait for the le to download. The progress is indicated at the bottom of the Data Log window.

9. Click OK when prompted that the download is complete.

10. To delete the log le from the controller memory, if desired, click Delete File.

11. Click Disconnect.

12. Close the Data Log window.

To view a data log le after downloading it:

1. Click Test, if not already on the test view.

2. Click Data Log.

3. Click Data Explorer.

4. Click Open.

5. Locate and open the data log le.

6. If desired, click Graph to view the data on a graph.

Watlow - ASPYRE 60A to 210A Power Controller • 55 • Chapter 7 Using ASPYRE Configurator

Page 56

Reference

This section provides explanations of the features found in the ASPYRE Congurator Software.

Program Window

Main Menu

Access these menus.

File menu

• Exit—close the program

Setting menu

• Language—open the Settings dialog to the language section

• Serial Port—open the Settings dialog to the serial port section

• Option—open the Settings dialog to the options section

? (Help) menu

• Message Log—opens the message view

• About—displays the About dialog with the program name and version and Watlow contact information

View selector

Select the view to use:

• HOME—the default view

• ASPYRE—access the Simple and Test views for a single-phase power controller

• ASPYRE 3PH—access the Simple and Test views for a three-phase power controller

• MSG—use the tools for monitoring and analyzing serial communication between the computer and the power controller.

Status Bar

Indicates information such as time and date, communications port and baud rate.

Simple view

Use this view to create, save, upload and download recipes, saved sets of parameters settings. You can also use this view to see the settings in a controller.

Access this view by selecting ASPYRE for a single-phase power controller or ASPYRE 3PH for a three-phase power controller and clicking the Simple tab below the main menu, if not already selected.

NOTE! The parameter values are not updated continuously. They

are read only when you upload them from the power controller.

Click one of these options to open or create a recipe:

• Create a New recipe—create a recipe le with the standard default settings

• Open existing recipe—open a previously saved recipe le

• Upload from unit—create a new recipe with the settings of the currently connected power controller

Watlow - ASPYRE 60A to 210A Power Controller • 56 • Chapter 7 Using ASPYRE Configurator

Page 57

Click one of these options to manipulate the recipe:

• Close—close the recipe

• Save—save the recipe in a le

• Save as—save a copy of the recipe in a le

• Download to unit—set the parameters in the currently connected power controller to the values in the recipe

• Print—print the recipe (see sample at left)

• Print report—print the recipe (see sample at left)

• Fast Settings—opens the setup wizard

Click a parameter menu to edit the corresponding parameters:

• Setup

• Advanced setup

• Hardware

• Communications

Click a parameter’s value to alter it.

NOTE! Changes to the values here affect the open recipe only. To apply these changes to the power controller settings, download them to the power controller using the Download to unit option.

Test view

Use this view to monitor and adjust the operation of the power controller while communicating with it in real time.

Access this view by selecting ASPYRE for a single-phase power controller or ASPYRE 3PH for a three-phase power controller and clicking the Test tab below the main menu, if not already selected.

Use these features to communicate with a power controller:

• Communications status indicator—sweeps clockwise when the software is communicating with a power controller and data is updating continuously

• Connect/Disconnect button—click to start or stop communication updates with the power controller

• Address selector—set the address of the power controller

• Access Level—click the value to log in or out. Password is “1111”.

• Fast Tune—when logged in, click to open the Fast Tune window.

• Port 2—set whether the secondary port is used only to read data or to read and write data (does not apply to Modbus® RTU).

Use these features to congure and monitor the digital inputs:

• Digital input states and functions—show whether each input detects an open or closed circuit and the function the input performs

• Digital Input States and Function Selectors—set the function for each digital input. Click DI1 or DI2 to expand the options.

Watlow - ASPYRE 60A to 210A Power Controller • 57 • Chapter 7 Using ASPYRE Configurator

Page 58

View these indicators and elds for an overview or the conguration and status of the power controller.

Status and Setup Indicators:

• Digital input status—illuminated when the input detects a closed circuit

• Enable indicator—illuminated when the power controller is enabled

• Enable/Disable button—click to enable the power

controller if a digital input is not congured for

this function

• ON indicator—illuminated when there is demand for the output to be on

• SC indicator—illuminated when there is a shorted SCR error

• HB indicator—illuminated when there is a heater break error

• TH indicator—illuminated when the heat sink is over temperature

• I Lim indicator—illuminated when the current being called for exceeds the current limit setting

• Unit Size—indicates the maximum rated current of the power controller

• Max Volt—indicates the maximum rated voltage for the power controller

• V Aux—indicates the voltage the auxiliary input is congured to use for powering the electronics

• Input Type1—indicates the type of signal analog input 1 is set to measure

• Input Type2—indicates the type of signal analog input 2 is set to measure

• DI1—indicates digital input 1’s function

• DI2—indicates digital input 2’s function

• Firing—indicates the ring type the power controller is set to use

• Feedback—indicates the type of feedback the power controller is set to use

• Data Log—indicates whether or not data is being logged by the power controller

NOTE! The data log indicator appears whether or not the connected power controller has the data logging

option.

Use these buttons to access the setup options:

• Communication—view and set the options for the communication ports and protocols

• Feedback—view and set what is used for feedback

• Firing—view and set the ring type and the associated parameters

• Load Analyzer—view the graphing utility

• Data Log—click to open the Data Log window.

Watlow - ASPYRE 60A to 210A Power Controller • 58 • Chapter 7 Using ASPYRE Configurator

Page 59

Use these features to congure and monitor the analog inputs:

• Analog Input 1—click Ai 1 to view the signal type

• Input button (Local/Remote set point source selector)—click to toggle between using the signal received at analog input 1 (remote) or the slider (local) to set the set point.

• Set Point—drag the slider, click the increment (+) or decrement (-) buttons or click one of the three percentages (0%, 50% or 100%) to set the set point when the set point source is set to local.

• Analog Input 2—click Ai 2 to view the signal type and function

Use these options to congure and monitor the power controller:

• Power Request—indicates the set point signal received via analog input 1 as a percent of full scale or as set with the reference slider

• Soft Start Time—indicates the time over which set point changes are ramped

• Output Scaling—indicates the scaling applied to the set point signal before it is used by the control loop

• Output Voltage (RMS), Output Power (RMS) and Output

Current (RMS) indicators—indicates the RMS current,

RMS voltage and RMS power output by the power controller

• Current Limit Set Point (RMS)—indicates the current limit set point

• Bakeout button—click to view and set the heater bakeout feature options

• Load Calibration—set or view the nominal line voltage and nominal load current settings for the application.

NOTE! The Load Calibration settings, Load Voltage and

Load Current dene 100% power for the load.

Energy Monitor—indicates power, power factor and energy usage

over time which may be reset with the Reset Totals button.

Data Log—use to congure the data logging feature if present

and retrieve data logs.

Fast Settings—opens the setup wizard.

Save Image—click to save a JPEG le with an image of the test

view.

Watlow - ASPYRE 60A to 210A Power Controller • 59 • Chapter 7 Using ASPYRE Configurator

Page 60

Load Analyzer (ASPYRE Scope)

Click Load Analyzer on the test view to open this window.

For each of up to three channels

(Ch 1, Ch 2 and Ch 3) congure

a pen on the graph:

• On/Off button—click to start trending data

• PV—choose the parameter to trend

• Show—set this option to display the trend

• Show Mark—set this option to display data markers along the trend in the graph area

Live!—click to view a detailed

graph of the current in the Live! window.

Use the History options to control the movement of the chart

• Scroll left—click to move the chart left to view more recent data

• Stop/Play—click to toggle chart movement on and off

• Scroll right—click to move the chart right to view older data

Use the Actions to:

• Clear—click to clear the data from the graph

• Save—click to save a JPEG image of the ASPYRE Scope window with the current trends

• Export—click to open a window and that includes the trend graph and table with the currently displayed

data that can be saved as a JPEG or exported to a CSV le.

Use the X – Scale settings to adjust the horizontal (time) axis:

• Min—set the number of minutes of data displayed

• Sec—set the number of seconds of data displayed

• Filter—set this option to lter the data

Use the Y – Scale settings to adjust the vertical (percent of full scale) axis

• Max—set the maximum value for the vertical axis

• Reset—click to reset the vertical axis scaling

NOTE! Use the increment (up arrow) and decrement (down arrow) buttons to adjust the x and y scales. Nu-

meric entry does not allow the full range of values to be set.

Watlow - ASPYRE 60A to 210A Power Controller • 60 • Chapter 7 Using ASPYRE Configurator

Page 61

Live! Scope

This view provides a detailed graph of instantaneous current over a few sample cycles. The data updates automatically.

Use these options to con-

gure the displayed data:

• Enable—set this option to view the current on the graph

• Save—click to save a JPEG image of the ASPYRE Scope window with the current trend

• Show Data—click to open the Data pane to the right of the graph that shows the data points for the current sample

Y Axis:

• Auto Scale—set this option to have ASPYRE Congurator automatically adjust the vertical and horizontal axis settings

• Max—set the high end of the vertical axis

• Min—set the low end of the vertical axis

• Marks–set this option to display data markers along the trend in the graph area

X Axis (future use):

• Max

• Min

• Reset X

Data Log Window

Use the data log window to set up data logging and manage the memory used for data

log les in the power controller.

• Log Enabled/Log Disabled slider—starts and stops data logging. Must be set to

enabled to congure logging or retrieve les.

• Log Time—the time between data log records in seconds

• Cong—opens the data log conguration window

• File List—lists the data log les available in the power controller

• Connect—displays and allows downloading and deleting data log les in the power controller

• Disconnect—stops displaying data log les in the power controller

• Download—copies the selected le from the power controller to the computer

• Delete File—erases the selected le from the power controller

• Close—closes the Data Log window

• Data Explorer—expands the data explorer

Watlow - ASPYRE 60A to 210A Power Controller • 61 • Chapter 7 Using ASPYRE Configurator

Page 62

Data Log Configuration window

Use the data log conguration window to view and set which parameters are logged.

• Close—closes the window

• Load—reads and displays the list of parameters being logged

• Logged parameters list—the parameters being logged

• Par—view or enter the Modbus® address of the parameter to log

• Name—view or choose the name of a parameter to log

• Tab Name—view or enter the name of the logged parameter dis-

played in the log le

• + button—adds a row to the list

• - button—removes the last row from the list

• Save—sends the list of parameters to be logged to the controller

Data Explorer

Use the data explorer to view data logged in

les that have been downloaded from the power

controller.

• Open—displays the open le dialog. Use this to open and display a data log that has been saved on the computer.

• Data—click to display the data from the log

le in a table

• Graph—click to display the data from the

log le in a graph

• Data table—displays the contents of the

data log le.

Watlow - ASPYRE 60A to 210A Power Controller • 62 • Chapter 7 Using ASPYRE Configurator

Page 63

Data Explorer Graph

Use the data explorer graph view data logged in les that have been downloaded from the power controller.

• Graph series check boxes—select the data to include on the graph.

• Settings (gear icon)—click to open the graph settings dialog to set the range of the graph and other options

• Graph—displays the contents of the data log le.

MSG view

Use the message view to monitor communication activity between the computer and the power controller.

• PORT/COM—view when the COM port is accessed and its settings

• MODBUS/READ Area—view the parameters being polled

• MODBUS/WRITE Area—view what parameters are being set and the values to which they are being set

• MODBUS/Log Msg—view the raw Modbus® messages (in hex) between ASPYRE Congurator and the power controller

• MODBUS/Status—view the status and settings of the COM port

• SYSTEM/Memory—view the memory usage of the ASPYRE Congurator program on the computer

Watlow - ASPYRE 60A to 210A Power Controller • 63 • Chapter 7 Using ASPYRE Configurator

Page 64

Settings window

Use this window to choose user-settable options for the ASPYRE Congurator software. To open the Settings

window, choose any of the items on the Settings menu, then select the tab you want.

Language:

• Available Languages—choose the language used in the program

Serial Port:

• Test—click to test for communication with a power controller via the selected port

• Port—select the computer’s COM port to use to communicate with power controllers

• Baud rate—select Auto to allow ASPYRE Congura- tor to set the baud rate for the COM port or deselect the option to set the baud rate yourself

Options:

• List Options—set whether or not parameter values are displayed in hexadecimal in simple view recipes

• Directory—set the directories in which recipes and images are saved

• Disable Check Type—set to allow communication with power controllers that are not precise matches for the supported types.

View:

• Hide Tool Bar—future use

• Hide Status Bar—select to hide the status bar that appears at the bottom of the program window.

Watlow - ASPYRE 60A to 210A Power Controller • 64 • Chapter 7 Using ASPYRE Configurator

Page 65

Parameter Reference

This chapter describes the parameters accessed via the control panel, ASPYRE Congurator software and serial

communications. To learn how to access the menus described below see “Menu Navigation” on page 48.

Alarm Function

Choose for which conditions the digital output indicates an alarm. The output always indicates an alarm when the heat sink is over temperature. The digital output is energized for normal operating conditions and de-energized when then power controller is off or when there is an alarm.

NOTE! The power controller monitors for heater break or shorted SCR conditions only when included in the

option selected for Alarm Output Function.

Option Description

None SCR over temperature only Heater Break Heater break or SCR over-temperature SCR Short Shorted SCR or SCR over-temperature I Limit* Current limit or SCR over-temperature HB / SC Heater break, shorted SCR or SCR over-temperature HB / IL* Heater break, current limit or SCR over-temperature SC / IL* Shorted SCR, current limit or SCR over-temperature All* Heater break, shorted SCR, current limit or SCR over-temperature

Communication watchdog error or SCR over-temperature Communication watchdog error, heater break or SCR over-temperature Communication watchdog error, shorted SCR or SCR over-temperature

These options may be set via communication only

*Models with current limit

Default: Heater Break Menu: Hardware (read-write)

Communication watchdog error, heater break, shorted SCR or SCR over-temperature Communication watchdog error, SCR over-temperature or current limit* Communication watchdog error, heater break, SCR over-temperature or current limit* Communication watchdog error, shorted SCR, SCR over-temperature or current limit* Communication watchdog error, heater break, shorted SCR, SCR over-temperature or

current limit*

Analog In 1 [Signal Type]

Choose the type of signal to be measured by analog input 1.

Option Description Value 0-10V / 10k Pot 0 to 10 Vdc or 10,000Ω potentiometer 1 4-20mA 4 to 20 mAdc 2 0-20mA 0 to 20 mAdc 3

Default: 0-10V / 10k Pot Menu: Hardware (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 65 • Chapter 8 Parameter Reference

Page 66

Analog In 1 [Value]

Indicates the percent of full scale measured by analog input 1.

Range: 0 to 100.0% Menu: Monitor (read-only)

Analog In 2 [Signal Type]

Choose the type of signal to be measured by analog input 2.

Option Description

0-10V / 10k Pot 0 to 10 Vdc or 10,000Ω potentiometer 4-20mA 4 to 20 mAdc 0-20mA 0 to 20 mAdc

Default: 0-10V / 10k Pot Menu: Hardware (read-write)

Analog In 2 [Value]

Indicates the percent of full scale measured by analog input 2.

Range: 0 to 100.0% Menu: Monitor (read-only)

Analog In 2 Function

Choose how the signal measured by analog input 2 is used.

Option Description

I Limit* Current limit set point Feedback External feedback Set Point Power demand set point

*DT1 and DT3 models

Default: I Limit or Feedback (models without current limit feature) Menu: Hardware (read-write)

Aux Voltage

Indicates the measured line voltage.

Range: 0 to 1023V Menu: Monitor (read-only)

Bakeout Current (Models with Current Limit)

Set the maximum current for the heater bakeout.

Range: 0 to 999.9 A Default: 0 Menu: Advanced Setup (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 66 • Chapter 8 Parameter Reference

Page 67

Bakeout Off Time (Models with Current Limit)

Set the maximum off time before the heater bakeout is required.

Range: 1 to 1,999 minutes Default: 1 Menu: Advanced Setup (read-write)

Bakeout Ramp Time (Models with Current Limit)

Set the total time for the bakeout ramp in minutes.

Range: 1 to 1,999 minutes Default: 1 Menu: Advanced Setup (read-write)

Command Bits

Set the bit corresponding to the option to be enabled or command to be executed.

Bit Description Clear Bit (0) Set Bit (1)

0 Not used 1 Local/remote set point* Remote Local

2 Enable Output (if no digital input is congured as Enable)** Not Enabled Enable output

3 Not used

4 Local/remote current limit

5 to 15 Not used

*When using a power controller with a secondary communication port other than Modbus® RTU, with Port 2 Access set to Read and Write, the local / remote option is determined only by command bit 1 regardless of wheth-

er or not a digital input is congured to set this option.

**When using a power controller with a secondary communication port other than Modbus® RTU, with Port 2 Access set to Read and Write and the power controller congured to be enabled by a digital input, the power controller is enabled only when the digital input and command bit 2 are both on.

Set the value corresponding to the combination of features you want to enable.

Value Set Point

0 Remote Off Remote 2 Local Off Remote 4 Remote On Remote

6 Local On Remote 16 Remote Off Local 18 Local Off Local 20 Remote On Local 22 Local On Local

Enable

Output

Current

Limit

Remote (set via

Analog input 2)

Local (set via keypad

or communications)

Watlow - ASPYRE 60A to 210A Power Controller • 67 • Chapter 8 Parameter Reference

Page 68

Cycle Time

Set the duration of one on-off cycle in increments of 50 ms. Applies to zero crossing; see “Zero-Crossing” on page 88.

Range: 0 to 255 (0 to 12.75 sec) Default: 30 (1.5 sec) Menu: Advanced Setup (read-write)

Delay

Set the ring delay in degrees. Applies to burst re with delay trigger. For more information see “Burst Firing with Delayed Triggering (DT1 and DT3 Models)” on page 91.

Range: 0 to 90° Default: 60° Menu: Advanced Setup (read-write)

Digital In 1

Indicates the state of the signal to digital input 1.

Option

Off On

Menu: Monitor (read-only)

Digital In 1 Function

Choose how the signal detected by digital input 1 is used.

Option Description Enable Voltage Feedback Use voltage feedback when on Local / Remote Phase Angle Set Point Analog In 1 / 2 Select remote set point source: analog input 1 when off or analog input 2 when on Logging Enable logging Heater Bakeout

When using a power controller with a secondary communication port other than Modbus® RTU, with Port 2 Access set to Read and Write and the power controller congured to be enabled by a digital input, the power controller is enabled only when the digital input and command bit 2 are both on.

When using a power controller with a secondary communication port other than Modbus® RTU, with Port 2 Access set to Read and Write, the local / remote option is determined only by command bit 1 regardless of wheth-

er or not a digital input is congured to set this option.

DT1 and DT3 models

Models with current limit

Default: Voltage Feedback Menu: Hardware (read-write)

Enable power output

Local when on / remote when off

Use phase angle ring when on

Enable heater bakeout

Watlow - ASPYRE 60A to 210A Power Controller • 68 • Chapter 8 Parameter Reference

Page 69

Digital In 2

Indicates the state of the signal to digital input 2.

Option

Off On

Menu: Monitor (read-only)

Digital In 2 Function

Choose how the signal detected by digital input 2 is used.

er or not a digital input is congured to set this option.

DT1 and DT3 models

Models with current limit

Default: Enable Menu: Hardware (read-write)

Enable power output

Local when on / remote when off

Use phase angle ring when on

Enable heater bakeout

Enable

Indicates whether or not the power controller is enabled. The enable signal must be on for the unit to output power to the load.

Option

Off On

Menu: Monitor (read-only)

Ethernet Address

Indicates the IP address of the power controller with an Ethernet communication option.

Range: 0 to 255 each part Default: 193.168.0.221 (Modbus® TCP), 193.168.0.220 (EtherNet/IP™) Menu: Communication (read-only)

Watlow - ASPYRE 60A to 210A Power Controller • 69 • Chapter 8 Parameter Reference

Page 70

Ethernet Subnet

Indicates the subnet mask of the power controller with an Ethernet communication option.

Range: 0 to 255 each part Default: 255.255.255.0 Menu: Communication (read-only)

Ethernet Gateway

Indicates the gateway address of the power controller with an Ethernet communication option.

Range: 0 to 255 each part Default: 0.0.0.0 Menu: Communication (read-only)

Feedback

Choose the measured value used as feedback for controlling to the set point. See “Firing Types” on page 88.

Option Description Voltage None No feedback Current Voltage Voltage Current Current Power Power External External signal via analog input 2

Default: Voltage Menu: Advanced Setup (read-write)

Voltage squared

Current squared

Firing

Choose how the output turns on and off to deliver the requested percent power. See “Feedback” on page 84.

Option

Zero Cross Single Cycle* Burst Fire Phase Angle** Burst Fire Start Ramp** Phase Angle Soft Start** Burst Fire Delay Trigger** BF Strt Rmp Delay Trigger** Half Cycle*

Half Cycle Safety Ramp* *DT1 models **DT1 and DT3 models

Default: Burst Fire Menu: Advanced Setup (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 70 • Chapter 8 Parameter Reference

Page 71

Frequency

Indicates the frequency of the power input.

Range: 0 to 655.35 Hz Menu: Operator (read-only)

Half Cycles to Delay

Set the number of half cycles with a delay for burst re delay trigger ring.

Range: 0 to 255 Default: 1 Menu: Advanced Setup (read-write)

Heater Bakeout (Models with Current Limit)

Enable or disable the heater bakeout feature.

Option

Off On

Default: Off Menu: Advanced Setup (read-write)

HH:MM:SS

Indicates the time setting in the real time clock.

Default: 00:00:00 January 1, 2000 Menu: Monitor (read-only), ASPYRE Congurator Test view (read-write)

Host Name

Indicates the name of the power controller.

Default: none Menu: Communication (read-only)

Htr Break Delay

Set a delay between when the resistance drops below the value set for heater break sensitivity and when the heater break alarm is indicated. This is set in increments of 50 ms.

Range: 0 to 255 (0 to 12.75 seconds) Default: 50 (2.5 seconds) Menu: Advanced Setup (read-write)

Htr Break Sensitivity

Set the threshold of resistance that activates the heater break alarm. This setting is in percentage of the nominal load resistance.

Range: 0 to 100% Default: 20% Menu: Advanced Setup (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 71 • Chapter 8 Parameter Reference

Page 72

I Limit (Models with Current Limit)

Set the maximum percent of the nominal current the power control allows. This parameter is in RMS current by default, but can be set to limit peak current. See “Limit Peak Current (Models with Current Limit)” on page

73.

Range: 0 to 100.0% Default: 100.0% Menu: Operator (read-only), Setup (read-write)

I Limit Local / Remote (Models with Current Limit)

Choose how the current limit is set.

Option Description

Analog In 2 Set point set via analog input

Local Set point set via keypad or communications

Default: Local Menu: Hardware (read-write)

I Output

Indicates the average (RMS) current of all phases.

Range: 0 to 999.9A Menu: Operator (read-only)

Integral Current (Models with Current Limit)

Set how aggressively the integral acts in the current loop. A smaller setting yields a larger adjustment to the output for a given deviation over a given time.

Range: 0 to 255 Default: 30 Menu: Advanced Setup (read-write)

Integral Power

Set how aggressively the integral part of the control algorithm acts. A smaller setting yields a larger adjustment for a given deviation over a given time.

Range: 0 to 255 Default: 10 Menu: Advanced Setup (read-write)

kVA Real Time

Indicates the instantaneous apparent power consumption.

Range: : 0 to 655.35 kVA Menu: Monitor (read-only)

kW Real Time

Indicates the instantaneous real power consumption taking power factor into account.

Range: : 0 to 9,999 kW Menu: Monitor (read-only), ASPYRE Congurator Test view (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 72 • Chapter 8 Parameter Reference

Page 73

kW Total

Indicates the totalized energy consumption in kWh. The kW total is stored with tenths resolution in two registers

with the most signicant word in the higher register. Set kW Real Time to zero (0) to reset this total.

Range: 0 to 429,496,729.5 kWh Default: 0 Menu: Monitor (read-only)

Leg 1 I Output (DT2 and DT3 Models)

Indicates the RMS current measured for leg 1.

Range: 0 to maximum current Menu: Operator (read-only)

Leg 2 I Output (DT2 and DT3 Models)

Indicates the RMS current measured for leg 2.

Range: 0 to maximum current Menu: Operator (read-only)

Leg 3 I Output (DT2 and DT3 Models)

Indicates the RMS current measured for leg 3.

Range: 0 to maximum current Menu: Operator (read-only)

Limit Peak Current (Models with Current Limit)

Set whether to limit the peak current or RMS current.

Option

RMS Current Peak Current

Default: 0 Menu: ASPYRE Congurator Test view (read-write)

Load Ω

Indicates the resistance of the load.

Range: 0 to 655.35 Ω Menu: Operator (read-only)

Logging

Enable or disable data logging on the internal SD card.

Option

Off On

Default: Off Menu: Advanced Setup (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 73 • Chapter 8 Parameter Reference

Page 74

Logging Interval

Set how often data is logged.

Range: 0 to 255 seconds Default: 5 seconds Menu: Advanced Setup (read-write)

Max Current

Indicates the maximum current capacity of the power controller.

Range: 0 to 9,999A Menu: Monitor (read-only)

Max Voltage

Indicates the maximum voltage rating of the power controller.

Range: 0 to 1,023V Menu: Monitor (read-only)

Min Cycles

Set the minimum number of on cycles and off cycles for burst ring.

Range: 0 to 255 Default: 8 Menu: Advanced Setup (read-write)

MM/DD/YY

Indicates the date setting in the real time clock.

Default: 00:00:00 January 1, 2000 Menu: Monitor (read-only), ASPYRE Congurator Test view (read-write)

Neutral Connected (DT2 and DT3 Models)

For three-phase loads, set whether or not the AC neutral is connected to the load.

Option Description

No Neutral Delta or ungrounded wye wiring

Neutral Connected Grounded wye wiring Menu: Advanced Setup (read-write)

Nominal I

Set the nominal load current.

Range: 0 to 999.9 A Default: maximum current for power control Menu: Operator (read-only), Setup (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 74 • Chapter 8 Parameter Reference

Page 75

Nominal V

Set the nominal value for the line voltage input.

Range: 0 to 1023V Default: 220V Menu: Operator (read-only), Setup (read-write)

Out Scale

Set the percentage by which the set point is scaled. For example, if a 0 to 10V analog input providing the set point is 5V and Output Scaling is 80%, then the effective set point is 40%.

Range: 0 to 100.0% Default: 100% Menu: Setup (read-write)

Port 1 Address

Set the address for the primary serial port.

Range: 0 to 255 Default: 1 Menu: Communication (read-write)

100

Scaled Set Point

0 20 40 60 80 100

Output Scaling = 100%

Output Scaling = 80%

Output Scaling = 40%

Input

Port 1 Baud

Choose the baud rate for the primary serial port.

Option

9600 19200 38400

115200

Default: 38400 Menu: Communication (read-write)

Port 2

Indicates the type of secondary communication port.

Option Description Disabled No secondary communications port Ethernet Protocols that use Ethernet RS-485 RS-485

Menu: Hardware (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 75 • Chapter 8 Parameter Reference

Page 76

Port 2 Access

Use this parameter to disable writing data via port 2 and disable the secondary communication watchdog. Note for protocols other than Modbus® RTU the output from the power controller will be disabled if data is not written at least as often as the communications watchdog is set to expect communications. See “Communication Watchdog” on page 111.

Option Description

Read and Write Data may be written via port 2 and the watchdog function is enabled. Read Only Data may not be written via port 2 and the watchdog function is disabled.

Default: Read and Write Menu: Communication (read-write)

Port 2 Address

Set the address for the secondary serial port or the Probus address.

Range: 0 to 255 Default: 0 Menu: Communication (read-write)

Port 2 Baud

Choose the baud rate for the secondary serial port.

Option

9600 19200 38400

115200

Default: 9600 Menu: Communication (read-write)

Power

Indicates the average power output as a percent of full power.

Range: 0 to 100% Menu: Operator (read-only)

Power Factor

Indicates the power factor of the output power.

Range: 0 to 1.000 Menu: Operator (read-only)

Prop Band Current (Models with Current Limit)

Set the proportional relationship between the output and the feedback for the current limit control loop. This setting determines how big a correction the proportional part of the control algorithm makes when the feedback deviates from set point. Set the gain for the current loop. A smaller proportional band yields a larger adjustment for a given deviation.

Range: 0 to 255% Default: 15% Menu: Advanced Setup (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 76 • Chapter 8 Parameter Reference

Page 77

Prop Band Power

Set the proportional relationship between the output and the feedback for the power demand control loop. This setting determines how big a correction the proportional part of the control algorithm makes when the feedback deviates from set point. A smaller proportional band yields a larger adjustment for a given deviation.

Range: 0 to 255% Default: 5% Menu: Advanced Setup (read-write)

Release

Indicates the software release date year and week (yyww).

Range: 0 to 65535 Menu: Monitor (read-only)

Remote SP

Choose the source for the remote set point. If a digital input is congured to select between the analog inputs

as the source of the set point, the digital input takes precedence and this parameter indicates the analog input selected with the digital input.

Option

Analog Input 1 Analog Input 2

Default: Analog Input 1 Menu: Setup (read-write)

Retransmit (Models with Retransmit)

Choose which parameter is retransmitted by the analog output.

Option Description

None Do not retransmit a value Set Point Set point V Output RMS voltage output I Output RMS current output Power Average output power

Default: Power Menu: Hardware (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 77 • Chapter 8 Parameter Reference

Page 78

Retransmit Scale (Models with Retransmit)

Set the value of the retransmitted parameter to be represented by the full scale of the analog output. See the table below.

Range: 0 to 9,999 Default: 0 Menu: Hardware (read-write)

Retransmit Settings

Retransmit

Set point 100

V Output

I Output

Power 100

xV where x is the Nominal Line Voltage

xA where x is the Nominal Load Current

Recommended

Retransmit Scaling

Resulting Signal

(4 to 20mADC)

4mADC = 0% 20mADC = 100% 4mADC = 0% 20mADC = xV

4mADC = 0A 20mADC = xA

4mADC = 0% 20mADC = 100%

Resulting Signal

(0 to 20mADC)

0mADC = 0% 20mADC = 100% 0mADC = 0% 20mADC = xV

0mADC = 0A 20mADC = xA

0mADC = 0% 20mADC = 100%

Resulting Signal

(0 to 10VDC)

0VDC = 0% 10VDC = 100% 0VDC = 0% 10VDC = xV

0VDC = 0A 10VDC = xA

0VDC = 0% 10VDC = 100%

Retransmit Type (Models with Retransmit)

Choose the type of signal for the retransmit output.

Option

0-10V 4-20mA 0-20mA

Default: 4-20mA Menu: Hardware (read-write)

Safety Ramp Duration

Enable the safety ramp feature and set how long the ramp takes by setting a value greater than zero in increments of 50ms.

Range: 0 to 65,535 x50ms Default: 10 (500 ms) Menu: Advanced Setup (read-write)

Safety Ramp Off Time

Set the minimum amount of time the power to the load is off before the safety ramp occurs in increments of 50ms.

Range: 0 to 65,535 x50ms Default: 200 (10 seconds) Menu: Advanced Setup (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 78 • Chapter 8 Parameter Reference

Page 79

SCR Temperature

Indicates whether the SCR is below or above the factory-set trip point.

Option Description

Disabled No sensor present / temperature below limit Over Temp Over temperature

Menu: Monitor (read-only)

Serial Number

Indicates the serial number of the power controller.

Range: 1 to 9999 (each part) Menu: Monitor (read-only)

Set Point

View the set point.

Range: 0 to 100% Menu: Operator (read-write)

Set Point Source

Indicates whether the power controller is in local or remote set point mode.

Option Description

Remote Set point set via analog input Local Set point set via keypad or communications

Default: Remote Menu: Monitor (read-only)

Soft Start

Set the duration of the soft start in increments of 50 ms. The power controller ramps set point changes over the time set here. For more information see “Soft Start” on page 94.

Range: 0 to 255 (0 to 12.75 seconds) Default: 8 (400 ms) Menu: Setup (read-write), Advanced Setup (read-write)

Start Ramp

Set the number of half cycles over which the power ramps each time the output turns on. Available on DT1 and DT3 models. For more information see “Start Ramp (DT1 and DT3 Models)” on page 94.

Range: 0 to 1,023 Default: 0 Menu: Advanced Setup (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 79 • Chapter 8 Parameter Reference

Page 80

Startup Display

Choose which parameter is displayed on the home page at power-up.

Option

Current Voltage Power

Default: Current Menu: Hardware (read-write)

Status Bits

Indicates the state of various features.

Bit Description Clear Bit (0) Set Bit (1)

0 Shorted SCR alarm No alarm Alarm 1 Heater Break Alarm No alarm Alarm 2 Output Enabled Disabled Enabled 3 Not used 4 Current Limit Alarm No alarm Alarm 5 Thermal Alarm No alarm Alarm 6 Communication Alarm ( WD) No alarm Alarm 7 Not used 8 Digital input 1 status Off On

9 Digital input 2 status Off On 10 Unbalance load alarm No alarm Alarm 11 Not used 12 Not used 13 Phase Loss (loss of power on one or more legs) No alarm Alarm 14 Heater Bakeout Off On

Latched Thermal Alarm (indicates thermal alarm has oc-

curred since last power cycle)

Access: Read-only

Off On

Thermal Alarm Counter

Indicates the number of times the SCR Over Temp alarm has occurred.

Range: 0 to 65,535 Menu: ASPYRE Congurator Test view (read-only)

Unit Type

Indicates the type of power controller.

Option Description 1 Leg Single phase 2 Leg Two-Leg, three-phase 3 Leg Three-Leg, three-phase (zero cross) 3 Leg PA Three-Leg, three-phase (phase angle)

Menu: Monitor (read-only)

Watlow - ASPYRE 60A to 210A Power Controller • 80 • Chapter 8 Parameter Reference

Page 81

User Access Level

Set this parameter to the code corresponding to the level of access to be granted for writing parameter values via the primary communications port.

Range: 0 to 65,535

Value Allows...

0 Access to monitor and operation parameters 1111 Access to setup parameters

Menu: ASPYRE Congurator Test view (read-write)

V Input

Indicates the average (RMS) voltage input.

Range: 0 to 6,553.5V Menu: Operator (read-only)

V Output

Indicates the average (RMS) voltage of all phases.

Range: 0 to 1,023V Menu: Operator (read-only)

Version

Indicates the software version number (x.xx.x).

Range: 0 to 65535 Menu: Monitor (read-only)

Watchdog

Enable or disable the watchdog on the primary serial port.

Option

Off On

Default: Off Menu: Communication (read-write)

Watchdog Reset Time

Set the amount of time to wait for a message before triggering the watchdog error.

Range: 0 to 255 seconds Default: 5 seconds Menu: Communication (read-write)

Watlow - ASPYRE 60A to 210A Power Controller • 81 • Chapter 8 Parameter Reference

Page 82

Wi-Fi

Enable or disable Wi-Fi communication.

Option

Off On

Default: Off Menu: Communication (read-write)

Wi-Fi Address

Indicates the IP address of the WiFi connection in the power controller.

Range: 0 to 255 (each part) Default: 192.168.4.1 Menu: Communication (read-only)

Watlow - ASPYRE 60A to 210A Power Controller • 82 • Chapter 8 Parameter Reference

Page 83

Features

This chapter describes the programmable features of the ASPYRE power controller.

CAUTION: all parameter settings should be determined only by qualied persons.

ATTENTION : Toutes les congurations de paramètre doivent être déterminées uniquement par le personnel

qualié.

Closed Loop Control

The ASPYRE power controller measures the voltage and current delivered to the load, and depending on how it is

congured, corrects for, among other things, variations in line voltage and load resistance.

DT1 Models and DT3 Models

Single phase and three-phase, three-leg models that include the current limit option, use two control loops to regulate power to the load. One loop attempts to drive the output to match the power demand set point. The other loop attempts to drive the current through the load to match the current limit. By using the lesser of the outputs from the two control loops, the power is controlled to the set point but prevented from exceeding the current limit.

While the current limit loop overrides the power demand loop, the output is phase angle

red and the display

indicates the current limit alarm. If the alarm output function is set to indicate the current limit, the alarm relay is de-energized.

Closed Loop Control (DT1 and DT3 models)

Firing Selection

Burst Fire Start Ramp

Power Demand

Loop

Set Point

Burst Fire Trigger Delay

*Single Phase Only

Current Limit Loop (Option)

Current Limit

Set Point

Feedback Selection

External

Feedback

None

External

Current

Sensing

Voltage

Sensing

Single Cycle*

Zero Cross

Burst Fire

Half Cycle*

Phase Angle

{

LOAD

Each loop adjusts its output based on its measurement of error, the difference between the set point and the measured and calculated feedback. For the current limit loop, the error is the difference between the current

Watlow - ASPYRE 60A to 210A Power Controller • 83 • Chapter 9 Features

Page 84

limit set point and the measured current. For the power demand loop, the error is the difference between the

Firing Selection

set point and the user-selected feedback. See Feedback below.

The two loops use proportional and integral (PI) control which allows them to compensate for both transient and long-term variations in conditions, including line voltage and load resistance. The performance of each loop can be tuned by adjusting the corresponding proportional band and time integral settings. The Prop Band Power and Integral Power parameters determine how the power controller adjusts its output to match the set point. The Prop Band Current and Integral Current parameters determine how the power controller adjusts the output to ensure that the current limit set point is enforced. These parameters are on the advanced setup menu.

The power demand set point can be set with the Set Point parameter on the Operator menu via the keypad or via communications. Alternatively it can be set by an analog voltage or current signal from a potentiometer or another piece of automation equipment such as a temperature controller.

DT2 Models

Three-phase, two-leg models use one control loop to regulate power to the load. The power demand loop attempts to drive the output to match the power demand set point.

The loop adjusts its output based on its measurement of error, the difference between the set point and the measured and calculated feedback. See Feedback below.

The power demand loop uses proportional and integral (PI) control which allows it to compensate for both transient and long term variations in conditions, including line voltage and load resistance. The performance of this loop can be tuned by adjusting the proportional band and time integral settings. The Prop Band Power and Integral Power parameters determine how the power controller adjusts its output to match the set point. These parameters are on the advanced setup menu.

Closed Loop Control (DT2 models)

Power Demand

Loop

Set Point

None

Feedback

Selection

External

Feedback

External

Zero Cross

Burst Fire

Current

Sensing

Voltage

Sensing

{

LOAD

Feedback

The feedback setting determines what the power controller attempts to keep constant and therefore what variations are minimized.

Because closed-loop control reacts to the difference between the user-supplied set point and the measured feedback, the feedback selection also determines the meaning of the set point. For example, if Feedback is set to Voltage, the set point is interpreted as a percentage of the nominal load voltage. In that case, with set point at 50%, the power controller adjusts the output to make the voltage drop across the load half the Nominal V setting.

Watlow - ASPYRE 60A to 210A Power Controller • 84 • Chapter 9 Features

Page 85

These options are available for feedback:

(

)

(

)

1 Phase

2 Leg, 3 Phase

3 Leg, 3 Phase

Set Point is a percentage of V

nominal

1 Phase

2 Leg, 3 Phase

3 Leg, 3 Phase

Set Point is a percentage of I

nominal

1 Phase

2 Leg, 3 Phase

3 Leg, 3 Phase

Set Point is a percentage of I

nominal

• Voltage—the power controller adjusts the output to make the measured load voltage divided by the nominal load voltage equal to the set point. This method of control compensates for line voltage uctuations; the power remains constant as long as the load impedance does not change.

rms

=Feedback 100%

nominal

• Voltage Squared—the power controller adjusts the output to make the square of the measured load voltage divided by the square of the nominal load voltage equal to the set point. The output power responds linearly to changes in the set point for loads with constant resistance. This method of control

compensates for line voltage uctuations; the power remains constant as long as the load impedance does

not change.

Set Point is a percentage of V

nominal

rms

=Feedback 100%

nominal

• Power—the power controller adjusts the output to make the product of the measured load current and voltage divided by the product of the nominal load voltage and nominal load current equal to the set point. With this method of control the power remains constant even when the line voltage or load impedance varies.

=Feedback

• Current Squared—the power controller adjusts the output to make the square of the measured load current divided by the square of the nominal load current equal to the set point. The set point is a percentage of the square of the nominal load current. With this method of control the power remains constant as long as the load impedance does not change.

=Feedback

• Current—the power controller adjusts the output to make the measured load current divided by the nominal load current equal to the set point. This method of control maintains constant current even when the line voltage or load impedance varies.

rmsIrms

(

nominalInominal

rms

(

nominal

2 2 2

100%

)

Set Point is a percentage of V

( )

rms

100%

)

(

rms

nominal

rms

nominalInominal

rms

100%

)

rms

(

100%

)

rms

nominal

( )

rms

nominalInominal

rms

)

(

rms

100%

rms

100%

)

• External—the power controller adjusts the output to make the signal received as eternal feedback on analog input 2 equal to the set point.

• No Feedback—the power controller output is on for a percentage of time equal to the set point. The power demand loop does not adjust the output based on the measured voltage or current.

Keep in mind that in single-phase and 60A to 500A three-phase models, the output is limited by the current limit loop. Therefore, at times the actual output may be less than the power demand loop’s set point calls for. See “Current Limit” on page 86.

Set the feedback on the advanced setup menu see “Firing” on page 70. The feedback can also be set with a digital input. See “Digital Inputs” on page 86.

Watlow - ASPYRE 60A to 210A Power Controller • 85 • Chapter 9 Features

=Feedback

(

rms

)

nominal

100%

(

rms

nominal

rms

100%

)

(

rms

nominal

rms

100%

)

Page 86

Current Limit

For models that include current limiting, this feature is always active. By default it limits the RMS load current by reducing the output whenever the power demand control loop would tend to drive current above the current limit set point.

You can congure the power controller to limit peak rather than RMS current. The controller limits peak current by switching to phase angle ring whenever the peak current would otherwise exceed the limit. When peak

current limiting is enabled, the current limit set point is interpreted as peak rather than RMS current. See “Limit Peak Current (Models with Current Limit)” on page 73.

Set the current limit set point, I Limit, on the setup menu. To determine the current limit set point empirically, see “Congure the Current Limit” on page 45.

Conﬁgurable Inputs and Outputs

The ASPYRE power controller features two digital inputs, up to two analog inputs and a relay output. Some models also include an analog output for retransmitting a measured value to other automation equipment. This section describes the various functions of these inputs and outputs and how they interact with other features of the power controller.

Digital Inputs

The ASPYRE power controller has two optically-isolated, digital inputs that can be connected to control panel switches or other automation equipment such as a temperature controller or programmable logic controller. See “Congurable Digital Inputs (Digital Input 1 and Digital Input 2)” on page 26 for information on connecting to the digital inputs.

Using Digital In 1 Function and Digital In 2 Function on the hardware menu each digital input can be congured to perform one of the following:

• Enable—the power output is off unless this signal is on. If both digital inputs are set to this option, the state of digital input 2 takes precedence.

• Voltage Feedback—this signal overrides the feedback setting. When this signal is on, the control loop uses voltage feedback. When the signal is off, the loop reverts to the feedback parameter setting.

• Local / Remote—this signal selects how the set point is set. When this signal is on, the control loop’s set point is set using the keypad or through communications. When this signal is off, the set point is set by the an analog input. When a digital input is set to this function, the Local/Remote (L/R) button on the front panel cannot be used to choose the source of the set point.

• Phase Angle—this signal overrides the Firing setting. When this signal is on, the power controller uses

phase-angle ring. When the signal is off, the controller uses the method set with the ring parameter on

the advanced setup menu. This option is available with single-phase and 60A to 500A three-phase models.

• SP Analog In 1 / 2—this signal chooses which of the two analog inputs is used as the source of the set point when the remote set point is in effect. When this signal is off, analog input 1 is the source of the remote set point. When the signal is on, analog input 2 is the source of the remote set point.

• Logging—this signal turns data logging on or off. When the signal is on, data is logged. When the signal is off, data is not logged. When this signal is on, it supersedes the setting of the Logging parameter on the advanced setup menu.

• Heater Bakeout—this signal turns the heater bakeout feature on or off. When the signal is on, the heater bakeout feature is enabled. When the signal is off, the heater bakeout feature is disabled. When this signal is on, it supersedes the setting of the Heater Bakeout parameter on the advanced setup menu. This option is available with single-phase and 60A to 500A three-phase models.

To congure how the power controller uses these signals, see “Digital In 1 Function” on page 68 and “Digital In 2 Function” on page 69.

Watlow - ASPYRE 60A to 210A Power Controller • 86 • Chapter 9 Features

Page 87

Analog Input 1: Set Point

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, voltage and potentiometer signals. The signal is interpreted as set point by comparing the measured value to the input’s full scale. For example, the set point is 50% when the analog input detects

5V and the input is congured to receive 0 to 10VDC.

Congure the power controller to recognize the signal with the hardware menu; see “Analog In 1 [Signal Type]”

on page 65. For instructions for wiring this input see “Set Point (Analog Input 1)” on page 25.

Analog Input 2: Set Point, Feedback or Current Limit Set Point

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

• An alternate set point signal

• Measured power, voltage or current from an external device used as feedback

• Maximum current to the load (current limit) in single-phase and 60A to 500A three-phase models

This input accepts current, voltage and potentiometer signals. The signal is interpreted by comparing its measured value to the input’s full scale. For example, the signal is 50% when the analog input detects 12mADC and

the input is congured to receive 4 to 20mADC.

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 66 and “Analog In 2 Function” on page 66. For instructions for wiring this input see “Set Point, Feedback or Current Limit (Analog Input 2)” on page 25.

Alarms and Alarm Relay Output

Choose which conditions determine the alarm relay output with the Alarm Function setting on the hardware menu. See “Alarm Function” on page 65.

NOTE! The alarm relay output indicates an alarm

whenever the temperature of the heat sink is too high even when Alarm Function on the hardware menu is set to None.

NOTE! The power controller monitors for heater

break or short circuit conditions only when included in the option selected for Alarm Function.

Alarm Function Options

Alarm Output Energizes for...

Heater Break

Shorted SCR

Current Limit

Communication

Watchdog Error

None X Heater Break(HB) X X SCR Short (SC) X X

I Limit (IL)* X X

Hb / SC X X X Hb / IL* X X X SC / IL* X X X HB / SC / IL* X X X X Watchdog X X WE / HB X X X WE / SC X X X WE / SC / HB X X X X WE / IL* X X X WE / IL / HB* X X X X WE / IL / HB* X X X X WE / IL or SC / HB* X X X X X

*Models with current limit

Heat Sink Over

Temperature

Watlow - ASPYRE 60A to 210A Power Controller • 87 • Chapter 9 Features

Page 88

Retransmit Output

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

Which parameter is retransmitted and the scaling of the output are user-congurable on the hardware menu;

see “Retransmit (Models with Retransmit)” on page 77, “Retransmit Type (Models with Retransmit)” on page 78 and “Retransmit Scale (Models with Retransmit)” on page 78.

Firing Types

This section describes the options for the Firing parameter. Using the correct ring ensures the optimum perfor- mance of the power controller with a particular type of load. Set Firing on the advanced setup menu.

Zero-Crossing

This ring type is used with relatively slow loads and when

it is desirable to minimizing radio frequency emissions by switching only as the line voltage crosses zero volts. Power

to the load is on for a percentage of the xed time-base

proportional to the required output percentage. The time base is dened by the Cycle Time parameter. For example, if the cycle time is ten seconds and 75% power is called for, the output turns on for 7.5 seconds and off for 2.5 seconds, and repeats.

Zero-Cross Firing Examples

Output to Load

25%

50%

The illustration shows examples of zero-cross ring with a

cycle time of 10 seconds:

• 25%, the output is on for 2.5 out of every 10 seconds

(150 out of 600 cycles at 60Hz)

• 50%, the output is on for 5 out of every 10 seconds

(300 out of 600 cycles at 60Hz)

• 75%, the output is on for 7.5 out of every 10 seconds

(450 out of 600 cycles at 60Hz)

• 100%, the output is on continuously

0 10 20 30

Time (seconds)

Zero-Crossing Settings

In order to operate the power controller with zero-cross ring, set the following parameters as indicated.

Menu Parameter Setting

Adv Setup

Feedback As desired Firing Zero Cross

Set Point:

Hardware Analog In 1 According to the connected signal

Operator Set Point As desired

75%

100%

Watlow - ASPYRE 60A to 210A Power Controller • 88 • Chapter 9 Features

Page 89

Contactor Operation

The power controller can be congured to switch power on

and off following a signal from, for example, a temperature controller’s output. In this case, power to the load is on when the signal from the temperature controller to the power controller’s digital input is high, and off when the signal is low. The power controller is said to operate as a contactor. When controlled by a device such as a temperature controller, any time proportioning is determined by

that device, not the power controller. In this conguration

the power controller’s power demand loop does not adjust the output or use feedback, but in single-phase and 60A to 500A three-phase models the current limiting loop is active and will reduce power delivered to ensure current does not exceed the limit.

Though the output is said to follow the enable input, power to the load is actually switched on or off only at the voltage zero cross in order to minimize radio frequency emissions.

Contactor Operation Settings

In order to operate the power controller as a contactor, set the following parameters as indicated.

Menu Parameter Setting

Adv Setup

Hardware Digital In 1 Function Enable Operator Set Point 100%

Feedback No feedback Firing Zero Cross

Contactor Operation Example

Line Voltage

Off

Enable Signal

Output to Load

Single Cycle (DT1 Models)

Use this ring type when it is desirable for the power to

the load to switch on and off as frequently as every ac line cycle while still minimizing radio frequency emissions by switching only as the line voltage crosses zero volts.

With single-cycle ring, power to the load is on for a number cycles proportional to the required output percentage.

The illustration shows examples of single-cycle ring:

• 25%, the output is on for one out of every four cycles

• 50%, the output is on one out every two cycles

• 75%, the output is on for three out of every four cycles

• 100%, the output is on continuously

Single-Cycle Settings

In order to operate the power controller using single-cycle ring, set the following parameters as indicated.

Menu Parameter Setting

Adv Setup

Feedback As desired Firing Single Cycle

Set Point:

Hardware Analog In 1 According to the connected signal

Single-Cycle Firing Examples

Line Voltage

Output to Load

25%

50%

75%

100%

Operator Set Point As desired

Watlow - ASPYRE 60A to 210A Power Controller • 89 • Chapter 9 Features

Page 90

Burst Firing

100%

75%

50%

25%

100%

75%

50%

25%

Use this ring type when it is desirable for the power to the load to switch on and off frequently but not as frequently as every ac line cycle. Burst ring minimizes radio frequency emissions by switching only as the line

voltage crosses zero.

With burst ring, power to the load is on for a number cycles proportional to the required output percentage.

Burst Firing Examples

Line Voltage

Burst ring is similar to single-cycle ring, but the output is on and off for a minimum number of cycles specied by

the user with the Min Cycles setting on the advanced setup

Output to Load

menu.

The illustration shows examples of burst ring with four

minimum cycles:

• 25%, the output is on for four out of every sixteen cycles

• 50%, the output is on for four out every eight cycles

• 75%, the output is on for twelve out of every sixteen cycles

• 100%, the output is on continuously

Burst Firing Settings

In order to operate the power controller using burst ring, set the following parameters as indicated.

Menu Parameter Setting

Feedback As desired

Adv Setup

Firing Burst Fire Min Cycles As desired

Set Point:

Hardware Analog In 1 According to the connected signal

Operator Set Point As desired

Burst Firing with Start Ramp (DT1 and DT3 Models)

This ring type is similar to burst ring, however, the

addition of the start ramp feature causes the output to be

phase-angle red for a user-specied number of half cycles

at the beginning of each burst. This intermittent phase-an-

gle ring increases radio frequency emissions compared with purely zero-cross switching ring types. This ring

type is recommended for use with small inductive loads to avoid inrush current.

The illustration shows examples of burst ring with four

minimum cycles and a six half-cycle start ramp:

• 25%, the output ramps up for three and is on for one full cycle out of every sixteen

• 50%, the output ramps up for three and is on for one full cycle out of every eight

• 75%, the output ramps up for three and is on for nine full cycles out of every sixteen

• 100%, the output ramps up for three cycles and then is on continuously

Burst Firing with Start Ramp Examples

Line Voltage

Output to Load

Watlow - ASPYRE 60A to 210A Power Controller • 90 • Chapter 9 Features

Page 91

Burst ring is similar to single-cycle ring, the load switches on for a number cycles proportional to the required output percentage, but the output is on and off for a minimum number of cycles specied by the user on the

advanced setup menu with the Minimum Cycles setting.

Burst Firing with Start Ramp Settings

In order to operate the power controller using burst ring with Start Ramp, set the following parameters as

indicated.

Menu Parameter Setting

Feedback As desired

Adv Setup

Firing Burst Fire Start Ramp Min Cycles As desired Start Ramp As desired

Set Point:

Hardware Analog In 1 According connected signal

Operator Set Point As desired

Burst Firing with Delayed Triggering (DT1 and DT3 Models)

This ring type is similar to burst ring except that it turns on at a user-specied ring angle at the beginning of each

burst.

Burst Firing with Delay Triggering Examples

Line Voltage

Delaying the ring angle is recommended when switching

the primary of a transformer coupled to a load with stable resistance on the secondary. Zero-cross switching of induc-

Output to Load

25%

tive loads such as transformer-coupled heaters can generate transient over currents that can blow fuses. By delaying

50%

the point the output is switched on to the point at which the current will be zero rather than when relative to when the voltage crosses zero, minimizes these adverse effects.

The illustration shows examples of burst ring with two

66%

100%

minimum cycles and a delay of 50 degrees applied to one half-cycle:

• 25%, the output turns on at 50° and remains on for the remainder of two out of every eight cycles

• 50%, the output turns on at 50° and remains on for the remainder of two out of every four cycles

• 66%, the output turns on at 50° and remains on for the remainder of two out of every three cycles

• 100%, the output turns on at 50° and remains on continuously

NOTE! Do not use this ring type with transformer-coupled loads that have low resistances when cold, such

as heaters with silicon carbide, molybdenum and tungsten elements. Instead consider using phase-angle ring.

Delayed triggering increases radio frequency emissions compared with purely zero-cross switching ring types.

Other than the programmable delay, this ring method is similar to burst ring. The load switches on for a num-

ber cycles proportional to the required output percentage. The output is on and off for at least the user-speci-

ed number of cycles.

Watlow - ASPYRE 60A to 210A Power Controller • 91 • Chapter 9 Features

Page 92

The illustrations below contrast burst ring with and without the switching delay.

100%

66%

50%

33%

Burst Firing without Delay Burst Firing with Delay

Delay Angle

Current

Voltage

Current

The ideal delay angle is the delay necessary to switch when the current is zero. This angle depends on the power

factor. The delay angle suggested for most applications is 80°.

Burst-Firing-with-Delay Settings

In order to operate the power controller using burst ring with delay, set the following parameters as indicated.

Menu Parameter Setting

Feedback As desired Firing Burst Fire Delay Trigger

Adv Setup

Set Point: Hardware Analog In 1 According to the connected signal

OR Operator Set Point As desired

Min Cycles As desired Delay As desired Half Cycles to Delay As desired

Half Cycle (DT1 Models)

Use this ring type when faster switching than single-cycle ring is desired to reduce power uctuations while main-

taining the minimized radio frequency emissions of zero-cross switching. Rather than switching every line cycle, the power can be switched every half cycle. Positive and

negative cycles are balanced to prevent DC bias. This ring

type is recommended for shortwave infrared lamps.

The load switches on for a number half-cycles proportional to the required output percentage.

The illustration shows examples of half-cycle ring:

• 25%, the output turns on for one half cycle out of every one and a half cycles

• 50%, the output turns on for one half cycle out of every cycle

• 66%, the output turns on for two half cycles out of every one and a half cycles

• 100%, the output is on continuously

Watlow - ASPYRE 60A to 210A Power Controller • 92 • Chapter 9 Features

Half Cycle Firing Examples

Line Voltage

Output to Load

Page 93

Half Cycle Firing Settings

In order to operate the power controller using half-cycle ring, set the following parameters as indicated.

Menu Parameter Setting

Adv Setup

Feedback As desired

Firing Half Cycle Set Point: Hardware Analog In 1 According to the connected signal

OR Operator Set Point As desired

Phase Angle (DT1 and DT3 Models)

This ring type is recommended for controlling inductive loads including the primary of transformer-coupled load and for loads with low resistances when cold such as heaters with silicon carbide, molybdenum and tungsten elements. The disadvantage is increased radio frequency

emissions compared with zero-cross ring types.

The load switches on for a portion of each half line cycle. This limits the voltage applied across the load when the power is less than 50%.

Phase-Angle Firing Examples

Line Voltage

Output to Load

25%

50%

The illustration shows examples of phase-angle ring:

• 25%, the output is on for a quarter of each half cycle

(on at 135°, off at 180°, on at 315°, off at 360°)

• 50%, the output is on for one half of each half cycle

(on at 90°, off at 180°, on at 270°, off at 360°)

• 75%, the output is on for three quarters of each half cycle (on at 45°, off at 180°, on at 225°, off at 360°)

• 100%, the output is on continuously

Phase-Angle Firing Settings

In order to operate the power controller using phase-angle ring, set the following parameters as indicated.

Menu Parameter Setting

Adv Setup

Feedback As desired Firing Phase Angle

Set Point:

Hardware Analog In 1 According to the connected signal

Operator Set Point As desired

NOTE! When the ring type is set to Phase Angle, the soft start feature is ignored. To use soft start with

phase angle, set the ring type to Phase Angle with Soft Start.

75%

100%

Watlow - ASPYRE 60A to 210A Power Controller • 93 • Chapter 9 Features

Page 94

Phase Angle with Soft Start (DT1 and DT3 Models)

This ring type is the same as Phase Angle except it does use the soft start feature. Whenever the set point is

changed, the ring angle is gradually adjusted rather than

being instantaneously changed. The set point is ramped from the previous set point to the new set point over the user-set Soft Start Time which is set in 50ms increments on the advanced setup menu.

The soft start feature also applies when the enable signal turns on. For example if the set point is 60% but the enable signal is off, when the enable signal turns on, the output gradually increases as if the set point was ramped up from 0% to 60% over the soft start time. However, when the enable signal turns off, unlike the case of lowering the set point, the output turns off immediately rather than ramping down.

This ring type is recommended to reduce inrush current with transformers during the cycle of magnetization or with cold resistance loads that are nearly short circuits when they are rst turned on.

Phase Angle with Soft Start Settings

In order to operate the power controller using phase-angle ring with soft start, set the following parameters as

indicated.

Phase-Angle Firing with Soft Start Example

Line Voltage

Set Point

100%

Output Voltage

Load Voltage RMS

100%

Menu Parameter Setting

Feedback As desired

Adv Setup

Firing Phase Angle Soft Start Soft Start Time As desired

Set Point:

Hardware Analog In 1 According to the connected signal

Operator Set Point As desired

Soft Start

The soft start feature can be used with all ring types except Phase Angle. Soft start acts as a lter on the set

point gradually applying changes to the set point over the user-set soft start time. The soft start time is set in 50ms increments on the advanced setup menu.

The soft start feature also applies when the enable signal changes state. For example, if the set point is 60% but the enable signal is off, when the enable signal turns on, the output gradually increases as if the set point was ramped up from 0% to 60% over the soft start time setting.

NOTE! When the ring type is set to Phase Angle, the soft start feature is ignored. To use soft start with

phase angle, set the ring type to Phase Angle Soft Start.

Start Ramp (DT1 and DT3 Models)

Start ramp causes the output to be phase-angle red for a user-specied number of half cycles each time the output is turned on. This intermittent phase-angle ring increases radio frequency emissions compared with purely zero-cross ring types. Set the duration of the ramp using the Start Ramp parameter on the advanced set-

up menu in increments of half cycles.

Watlow - ASPYRE 60A to 210A Power Controller • 94 • Chapter 9 Features

Page 95

Safety Ramp (DT1 and DT3 Models)

Bakeout SP 100%

This feature is the same as start ramp except it is active only if the output is off for longer than a user-set time.

Safety ramp can be used with single-phase and 60A to 500A three-phase models using burst ring with delay or half cycle ring. Use it to ramp up the voltage applied to a heater or other load which has been off for more

than a user set time.

With this option enabled, after power to the load has been off for more than the user-set time, once power is

called for, the ring type is temporarily changed to phase angle and the power is ramped up from zero to the set point over the safety ramp time. Once the ramp is complete, the ring type reverts to the user setting.

Because it uses phase-angle ring, safety ramp increases radio frequency emissions when active compared with

purely zero-cross switching.

Enable the safety ramp feature and set how long the ramp takes by setting the Safety Ramp Duration (#66) to a value greater than zero (in increments of 50ms). Set the minimum amount of time the power to the load is off before the ramp occurs with the Safety Ramp O Time parameter in increments of 50ms (#65).

Heater Bakeout Function (Models with Current Limit)

When a heater insulated with magnesium oxide (MgO) is powered off, not in use or in storage for a long period of time, it can absorb moisture. If full power is applied, excessive current can damage the heater or blow fuses. The heater bakeout feature limits the voltage and current applied as the heater is brought back in to service. This drives moisture out of the heater and prevents blown fuses and damage to the heater.

Using Heater Bakeout

While the heater bakeout feature is active, the ASPYRE power controller ramps the current according to the user-set current and ramp time parameters for the heater bakeout function. The heater bakeout function does not ramp the output above the normal process set point. Once the function has run for the user-set time, the bakeout function terminates and the power controller attempts to perform control to set point normally.

Use Heater Bakeout Ramp Time to set the duration of the bakeout in minutes. Use Heater Bakeout Current to set the current to which the function attempts to ramp in Amperes. Use Heater Bakeout Off Time to set how many minutes the heater can be off before the bakeout fuction runs the next time the heater is used.

While the performing the heater bakeout function, the power controller displays a message.

Totalizer

The ASPYRE power controller includes a power totalizator that sums the power over time in various terms. The total power over time can be viewed on the ASPYRE Con-

gurator PC software’s Test view.

Heater Bakeout Indication

Totalizer Function in ASPYRE Congurator

Watlow - ASPYRE 60A to 210A Power Controller • 95 • Chapter 9 Features

Page 96

Data Logging

The ASPYRE power controller offers an optional data logging feature. Record up to ten parameters as often as

once per second. Use ASPYRE Congurator software to set the real-time clock, to select which parameters to log, to retrieve data log les and to manage the logging memory. See “Setting Up and Using Data Logging” on

page 54. The ASPYRE Congurator software also supports viewing the data in log les after downloading them from the power controller.

Data logging can be turned on and off using:

• ASPYRE Congurator software (see “Setting Up and Using Data Logging” on page 54.)

• The advanced setup menu in the power controller’s user interface (see “Logging” on page 73)

• A digital input (see “Digital In 1 Function” on page 68, “Digital In 2 Function” on page 69 and “Digital

Inputs” on page 86)

Watlow - ASPYRE 60A to 210A Power Controller • 96 • Chapter 9 Features

Page 97

Maintenance & Troubleshooting

This chapter describes the routine maintenance that should be planned, provides information for troubleshooting and includes procedures for corrective actions.

NOTE! To ensure proper and safe operation of the equipment all investigation, adjustments and replacement

procedures must be performed by qualied individuals.

REMARQUE : Pour assurer un fonctionnement approprié et sécuritaire de l’équipement, toutes les recherch-

es, les réglages et les procédures de remplacement doivent être effectués par le personnel qualié.

Routine Maintenance

With very little maintenance you can expect the ASPYRE power controller to provide years of trouble-free operation.

1. To prevent overheating, periodically clean the heat-sink and protective grill on the fans. Depending on the environment, this cleaning may be necessary more or less frequently.

2. Periodically verify the torque on the bolts for the line, power and safety earth ground connections.

Alarms and Indicators

This section describes the alarms that can occur and what can cause them.

Aux High

Alarm Indicator

When an alarm occurs and while the condition persists, the indicator labeled "4" on the display is lit. The indicator is normally off.

ALARM

Alarm Relay Output

When an alarm occurs and while the condition persists, the alarm relay is de-energized. The alarm relay is energized when power is supplied to the controller’s electronics via the auxiliary power input and there are no alarms. The alarm relay can be congured to indicate various combinations of alarms using the hardware menu see “Alarm Function” on page 65.

Watlow - ASPYRE 60A to 210A Power Controller • 97 • Chapter 10 Maintenance & Troubleshooting

480V 600V

690V

No Power No Alarm Alarm

C NC NO

NO C NC

C NC NO

NO C NC

C NC NO

NO C NC

Page 98

Alarms and Messages

The display normally indicates the power demand set point and one of the home page parameters such as output

current. When an alarm or other condition occurs and while the condition persists, the upper display ashes the

corresponding message. See the table below and the following sections for descriptions of each.

Alarms and Messages

Alarm or Message DT1 DT2 DT3 Description

Aux High X X X Aux voltage too high

Aux Line Loss

Aux Low X X X Aux voltage too low Bakeout X X Heater bakeout function is active Heater Break X X X Heater break alarm I Limit X X Output reduced by current limit feature PH Loss X X X One or more phases of the line power are disconnected SD Card Error X X X SD card error SCR Short X X X Shorted SCR (output on continuously) SCR Over Temp X X X Thermal switch over temperature Unbalance Load X X One or more legs of the load are open Watchdog X X X Communication watchdog error

X X Auxiliary power lost

X Line power lost

Aux High

This alarm occurs when the auxiliary voltage is over the maximum required. Verify the auxiliary power requirement per the model number.

Aux Line Loss

This alarm is indicated when the line power is off, but the electronics are powered by another means, such as the USB port or the optional 24VDC input.

Aux Low

This alarm occurs when the auxiliary voltage is below the minimum required. Verify the auxiliary power requirement per the model number.

Bakeout

The heater bakeout feature is controlling the output. See “Heater Bakeout Function (Models with Current Limit)” on page 95.

Heater Break

This alarm occurs when the measured load resistance is higher than expected. See “Heater Break Calibration Procedure” on page 102.

I Limit

In models with the current limit option this alarm indicates when the current loop overrides the power demand loop to prevent the load current from exceeding the current limit set point. In DT3 models this alarm indicates when the current exceeds the user-set current limit. DT1 and DT3 models reduce the output to enforce the limit; DT2 models do not. For more information see “Current Limit” on page 86.

Watlow - ASPYRE 60A to 210A Power Controller • 98 • Chapter 10 Maintenance & Troubleshooting

Page 99

PH Loss

One or more phases of the line power are disconnected. For DT3 models this message appears only with the loss of line power to phase 3; if phase 1 or 2 are lost, because the auxiliary power is connected internally, it also is

lost and the control electronics looses power or if powered by the USB port or the optional 24VDC input the Aux Line Loss error is displayed.

SD Card Error

This error occurs when the SD memory card option is present but does not work properly or when it is impossible to read or write data. Contact your supplier.

SCR Short

This alarm occurs when the SCR is stuck on and the output is on continuously.

SCR Over Temp

This alarm occurs when the temperature sensor on the heat sink indicates it is too hot. The thermal switch alarm triggers the alarm relay output. Until the temperature is reduced, power to the load is turned off. Correct the environmental conditions that caused the over temperature or reduce the load current to resume operation.

Operating the unit at temperatures outside the specied range can void the warranty. For information on proper

cooling see “Cooling Requirements” on page 18.

Unbalanced Load

The resistance of one or more legs of the load has gone outside the tolerance for a balanced load. The alarm indication specifies which leg of the load is outside the tolerance. This likely indicates one or more legs of the

load are open.

Watchdog

This error occurs when the communications watchdog feature is enabled but no transmission has been received for longer than the user-set watchdog reset time. When this error occurs, power to the load is turned off. See “Watchdog” on page 81 and “Watchdog Reset Time” on page 81.

Opening The Covers

WARNING: Before opening the cover, disconnect and lock out the line power and control signals to the unit

and verify that power and control cables are isolated from voltage sources.

AVERTISSEMENT : Avant d’ouvrir le couvercle, débrancher et verrouiller les signaux d’alimentation de ligne

et de commande, puis vérier que les câbles d’alimentation et de commande sont isolés des sources de tension.

CAUTION: Take appropriate precautions to prevent electrostatic discharges from damaging electronic com-

ponents when handling the boards.

ATTENTION : Prendre les précautions appropriées pour empêcher que les décharges électrostatiques n’en-

dommagent les composants électroniques au moment de la manipulation des cartes de circuits.

To open the front cover:

1. Grip the cover by the handle .

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

Watlow - ASPYRE 60A to 210A Power Controller • 99 • Chapter 10 Maintenance & Troubleshooting

Page 100

Replacement Fuses

The ASPYRE power controller contains fast-blow fuses protecting the SCR power switches. These fuses are critical to safe operation of the power controller particularly in preventing catastrophic failure in the event of a shorted load. The agency approvals are contingent upon the use of the same fuses (manufacturer and model) that were tested. The table below lists the tested and approved fuses for the various models.

Replacement Fuses

ASPYRE Model Qty.

DT_ _ _-060...

DT_ _ _-120... 0808-0363-0180 20 559 20.180 DT_ _ _-150... 0808-0363-0200 20 559 20.200 2048-4405 20 282 20.200 DT_ _ _-180... 0808-0363-0250 20 559 20.250 2048-4418 20 282 20.250 DT_ _ _-210... 0808-0363-0315 20 559 20.315 2048-4426 20 282 20.315

*One fuse per switched leg for 480V and 600V models. For 690V models one fuse for single-phase models and three fuses for all three-phase models.

Replacement Fuse Torque

60A to 120A

150A to 210A

1 to 3*

480V and 600V 690V

26.6 in.-lb. (3 Nm)

44.3 in.-lb. (5 Nm)

0808-0363-0160 20 559 20.160

480V and 600V 690V

Watlow Siba Watlow Siba

2048-2760 20 282 20.160DT_ _ _-090...

44.3 in.-lb. (5 Nm)

CAUTION: These fuses protect life and property against catastrophic failure in the event of a shorted load.

They do not provide and are not approved for branch circuit protection.

ATTENTION : Ces fusibles protègent la vie et la propriété contre des pannes catastrophiques en cas de

charge en court-circuit. Ils n’assurent aucune protection des circuits de dérivation et ne sont pas approuvés à

cette n.

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.

WARNING: Before opening the cover, disconnect and lock out the line power and control signals to the unit

and verify that power and control cables are isolated from voltage sources.

AVERTISSEMENT : Avant d’ouvrir le couvercle, débrancher et verrouiller les signaux d’alimentation de ligne

et de commande, puis vérier que les câbles d’alimentation et de commande sont isolés des sources de tension.

Replacing the Battery

The real time clock option includes a battery so that the time and date settings and the clock function persist when line power is shut off. The battery is expected to provide years of service, but must be replace when the clock fails to keep time when the power is off.

WARNING: Before opening the cover, disconnect and lock out the line power and control signals to the unit

and verify that power and control cables are isolated from voltage sources.

Watlow - ASPYRE 60A to 210A Power Controller • 100 • Chapter 10 Maintenance & Troubleshooting

Watlow 60A, 210A 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

Installation

Installing the ASPYRE Power Controller

Environmental Conditions

Cooling Requirements

Mounting Dimensions 480V and 600V

Mounting Dimensions 690V

Wiring 480V and 600V Units

Wiring the ASPYRE Power Controller

Good Wiring Practices

Wiring Overview 480V and 600V Units

Wire Selection, Prep and Torque

Terminal Strip Connections

Connecting Control Signals

Powering the Cooling Fans

Connecting the Auxiliary Power (DT1 and DT2 Only)

Opening The Covers

Wiring the Line Power and Load

Wiring 690V Units

Wiring the ASPYRE Power Controller

Good Wiring Practices

Wiring Overview 690V Units

Wire Selection, Prep and Torque

Removing the Covers

Connecting Control Signals

Powering the Cooling Fans

Connecting the Auxiliary Power

Wiring the Line Power and Load

Initial Setup

Operation

Control Panel

Menu Navigation

Indicators (LEDs)

Alarms and Messages

Using ASPYRE Configurator

Overview

How To

Reference

Parameter Reference

Alarm Function

Analog In 1 [Signal Type]

Analog In 1 [Value]

Analog In 2 [Signal Type]

Analog In 2 [Value]

Analog In 2 Function

Aux Voltage

Bakeout Current (Models with Current Limit)

Bakeout Off Time (Models with Current Limit)

Bakeout Ramp Time (Models with Current Limit)

Command Bits

Cycle Time

Delay

Digital In 1

Digital In 1 Function

Digital In 2

Digital In 2 Function

Enable

Ethernet Address

Ethernet Subnet

Ethernet Gateway

Feedback

Firing

Frequency

Half Cycles to Delay

Heater Bakeout (Models with Current Limit)

HH:MM:SS

Host Name

Htr Break Delay