Watlow 60A, 210A Operating Manual

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

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 •

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 •

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 •

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 •

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 •

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

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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 •

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 •

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 •

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

+ 112 hidden pages

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