Watlow Power Series User Manual

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Page 1

Registered Company

Winona, Minnesota USA

ISO 9001

TOTAL

3Year Warranty

CUSTOMER

SATISFACTION

Power Series

User’s Manual

Microprocessor-Based

SCR Power Controller

U.S. English

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

July 2012 $10.00 Supersedes: 0600-0039-0000 Rev G

1241 Bundy Boulevard, P.O. Box 5580, Winona, Minnesota USA 55987-5580

Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507 http://www.watlow.com

Page 2

Safety Information in this Manual

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

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

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

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

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

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

electric shock hazard CAUTION or WARNING safety statement.

Technical Assistance

If you encounter a problem with your Watlow controller, see the Troubleshooting Table in the Appendix and review all of your configuration information to verify that your selections are consistent with your application: inputs; outputs; alarms; limits; etc. If the problem persists after checking the

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

An applications engineer will discuss your application with you.

Please have the following information available when you call:

• Complete model number • All configuration information

• User’s Manual • Diagnostic Menu readings

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

Your Comments

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

Safety Alert CAUTION or WARNING

∫

Electrical Shock Hazard

CAUTION or WARNING

Page 3

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Chapter 5: Control Methods and Features .5.1

Zero Cross . . . . . . . . . . . . . . . . . . . . .5.1

Phase Angle . . . . . . . . . . . . . . . . . . . .5.2

Other Features . . . . . . . . . . . . . . . . . .5.6

Input . . . . . . . . . . . . . . . . . . . . . . . . .5.6

Alarms . . . . . . . . . . . . . . . . . . . . . . . .5.7

Communications . . . . . . . . . . . . . . . .5.8

Retransmit . . . . . . . . . . . . . . . . . . . . .5.9

Fast Start Guide . . . . . . . . . . . . . . . . .5.10

Chapter 6: Parameters . . . . . . . . . . . . . . 6.1

Display Loop . . . . . . . . . . . . . . . . . . .6.1

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

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

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

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

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

Troubleshooting Alarms and Errors . .A.4

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

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

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

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

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

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

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

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

Warranty and Returns Policy . . .back cover

Power Series

Table of Contents Watlow Power Series ■ i

Page 4

ii ■ Watlow Power Series Table of Contents

Page 5

Overview, Chapter 1 Watlow Power Series ■ 1.1

Chapter One

Overview

Introduction

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

Figure 1.1 — Power Series features.

Removable Mounting Plate

Power Series snaps on a premounted, removable plate.

Terminal Cover

Electrically touch-safe package.

Fuse Cover

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

Digital Programmer/Display

For controller configuration, setup, and monitoring features.

Power Series Solid State Power Control

Ground Lug

Built in, designed for easy

ground connections.

I/O Port

Input, retransmit output, communications, and alarms.

On-Board Fan

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

Allen Wrench

Used to torque terminals 1 to 6 and ground lug.

Page 6

Single Phase

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

Three Phase, Two-Leg Configuration

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

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

Heater current monitoring and kVA options are available with a three phase, two-leg configuration via the heater diagnostics option. Phase angle firing, including current limiting and heater bakeout, is not available.

Three Phase, Three-Leg Configuration

There are two Power Series configurations that include six SCR control. All features are available in these configurations.

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

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

Single Phase, Multizone Configuration

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

Heater Diagnostics

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

1.2 ■ Watlow Power Series Overview, Chapter 1

Page 7

Chapter Two

Installation

Installation, Chapter 2 Watlow Power Series I 2.1

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

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

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

∫

WARNING:

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

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

Minimum recommended wire sizes are based on the NEC 30°C ambient with not more than three current carrying conductors in raceway or cable, while also considering the Power Series 50°C enclosure temperature and semiconductor fuse rating. Use copper conductors only.

The terminal lug wire range for all Power Series amperages is 350 MCM to 6 AWG. The recommended terminal torque is 180 in.-lbs. (20 Nm.). Refer to page

3.1 for torque guidelines.

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

NOTE: Integral semiconductor fuses do not qualify as branch circuit protection.

Power Series

Current (Amps)

Minimum

Recommended Wire

Size (90C) (AWG)

Wire Bending

Radius

mm inches

Semiconductor

Fuse Rating

(Amps)

Watlow Replacement

fuse P/N

Bussmann

Replacement Fuse

P/N

65 6 AWG 51 2.0 100 0808-0102-0100 170M1317 80 4 76 3.0 125 0808-0102-0125 170M1318 85 4 76 3.0 125 0808-0102-0125 170M1318

90 4 76 3.0 125 0808-0102-0125 170M1318 100 3 76 3.0 160 0808-0102-0160 170M1319 105 3 76 3.0 160 0808-0102-0160 170M1319 120 2 89 3.5 160 0808-0102-0160 170M1319 125 2 89 3.5 160 0808-0102-0160 170M1319 140 1 114 4.5 200 0808-0102-0200 170M1320 155 1/0 140 5.5 200 0808-0102-0200 170M1320 160 1/0 140 5.5 250 0808-0102-0250 170M1321 165 1/0 140 5.5 250 0808-0102-0250 170M1321 185 2/0 152 6.0 250 0808-0102-0250 170M1321 200 3/0 165 6.5 250 0808-0102-0250 170M1321 250 250 MCM 216 8.5 315 0808-0102-0315 170M1322

Page 8

2.2 I Watlow Power Series Installation, Chapter 2

Mounting the Power Series Controller

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

For models N20 through F30:

1. Determine the panel location for mounting the Power Series controller and punch or drill holes for the 4 mounting screws per the drawing below. The mounting plate can be used as a template.

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

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

For F35 models:

F35 models are a bolt-down package. Drill and tap six holes per the above drawing for 1/4-inch 20 bolts.

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

Figure 2.2a — Power Series dimensions.

Power Series Dimensions

Add a 9-in. clearance dimension to help develop the chimney cooling effect. This should be on the top and bottom of the Power Series mounting.

Figure 2.2aa — F35 model only.

Power Series Front View

Power Series Solid State Power Control

45 6

Power Series Top View

354 mm

(14.0 in.)

191 mm (7.5 in.)

200 mm (7.9 in.)

337 mm

(13.3 in.)

305 mm

(12.0 in.)

ower Serie

olid State Power Contro

178 mm (7.0 in.)

7.1 mm

(0.28 in.)

356 mm

(14.0 in.)

33 mm

(1.3 in.)

421 mm

(16.6 in.)

191 mm

(7.5 in)

234.1 mm (9.2 in.)

Mounting Holes (4)

Power Series Mounting Plate

7mm

(0.27 in.)

Key Slots

102mm

(4.00 in.)

151mm

(5.93 in.)

Release Tab

178mm

(7.00 in.)

39mm

(1.53 in.)

25mm (0.97 in.)

Page 9

Installation, Chapter 2 Watlow Power Series ■ 2.3

Enclosure Guidelines

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

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

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

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

3. Cabinet air conditioners work well on sealed enclosures.

4. Heat pipe coolers work well on sealed enclosures, but do not provide as much cooling as vortex coolers or air conditioners.

To determine how much cooling is required:

1. Determine the amperage load on the Power Series. Multiply the amperage by

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

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

multiply by 3.41 to get BTUs per hour.

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

remove that amount of BTUs.

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

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

Harsh Environment

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

Page 10

2.4 I Watlow Power Series Installation, Chapter 2

Removing the Power Series Controller

1. To release the Power Series controller from the mounting plate, press in on the release tab at the top of the mounting plate.

2. When the release tab is in, push up on the controller from the bottom to release it from the mounting plate. Beware of sharp edges on the heat

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

3. The F35 model does not use the standard mounting plate. See page 2.2 for mounting instructions. To remove: reverse the mounting operation.

Maintaining the Power Series

• Cleaning: The heatsink fins must be kept clean for proper cooling and the printed circuit board should be free of conductive residue condensation.

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

• Retorquing: See page 3.1 for torque guidelines.

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

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

Figure 2.4 — The F35 Power Series (right) is cooled with larger fans.

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

Page 11

Power Series Output Rating Curves

Fan Cooled

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

Watlow Power Series Installation I 2.5

Single-Phase Fan Cooled at 100% On

Enclosure Internal

Ambient Temperature in °C

8090100

Ambient Temperature in °C

8090100

F20

110

130

120

Current (amps) into a Resistive Load

3-Phase, 2-Leg and 2-Zone Multizone

F20

110

120

Current (amps) into a Resistive Load

3-Phase, 3-Leg and 3-Zone Multizone

150

140

160

Fan Cooled at 100% On

130

150

140

160

Fan Cooled at 100% On

170

180

F25

190

210

200

220

F30F25 F35

210

200

220

230

F30

240

250

260

150

160

F30F25

F35

170

190

210

230

180

200

220

240

250

260

Enclosure Internal

Ambient Temperature in °C

8090100

F20

110

130

120

140

Current (amps) into a Resistive Load

Page 12

Power Series Output Rating Curves

Natural Convection

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

3 Phase, 3-Leg and 3-Zone Multizone

Natural Convection at 100% On

Current (Amps) into a Resistive Load

N20 N25 N30

Enclosure Internal

Ambient Temperature °C

60 14070 80 90 100 110 120 13050

3 Phase, 2-Leg and 2-Zone Multizone

Natural Convection at 100% On

Current (Amps) into a Resistive Load

60 14070 80 90 100 110 120 130

N20 N25 N30

Enclosure Internal

Ambient Temperature °C

Single Phase Natural Convection at 100% On

Current (Amps) into a Resistive Load

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

N20 N25 N30

Enclosure Internal

Ambient Temperature °C

2.6 ■ Installation Watlow Power Series

Page 13

Terminals 1 - 6 and Ground Lug

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

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

#3 Phillips Screws for Fuse Mounting

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

For models PXX-F25X-XXXX PXX-N25X-XXXX PXX-F30X-XXXX PXX-N30X-XXXX PXX-F35X-XXXX Torque to 44 in.-lbs. (4.95 Nm.)

5/16 inch Bolts for Fuse Mounting

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

Strip wires

0.24 in. (6mm)

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

Controller Connectors

Allen Wrench

(Flat surface must be against the case.)

Fuse

Power Series Solid State Power Control

Chapter Three

Wiring

Wiring the Power Series Controller

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

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

Torque Guidelines

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

• Re-torque all terminals after 48 hours.

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

Wi r ing , C h apt e r 3 Wat l ow Pow er S e rie s I 3 .1

Figure 3.1 — Torque and wire stripping.

Page 14

3.2 ■ Watlow Power Series Wiring, Chapter 3

ç∫

WARNING: To avoid damage to

property and equipment, and/or injury or loss of life, use National Electric Code (NEC) standard wiring practices to install and operate the Power Series. Failure to do so could result in damage, and/or injury or death.

NOTE: Input, retransmit and

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

NOTE: Insure ground is wired

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

NOTE: Torque and wire strip

guidelines:

• Control wiring 1 thru

23.

• Strip wire to 0.24 inch (6mm). Torque to 8 in.lbs. ( 0.9 Nm).

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

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

Input Wiring

Figure 3.2a – Control Power and Alarm Wiring

Figure 3.2b – Retransmit Wiring

Figure 3.2c – Communications Wiring

Power Series

6 5 4 3 2 1

11 10

9 8 7

14 13 12

17 16 15

20 19 18

23 22 21

External Connector

COMMS

7 8

485 T/R +

(Common)

9 10 11

232 TRAN (EIA/TIA-232 Transmit Out)

232 REC (EIA/TIA-232 Receive In)

485 T/R -

RETRANSMIT

DC 10V/20mA

Power Series

6 5 4 3 2 1

11 10

9 8 7

14 13 12

17 16 15

20 19 18

23 22 21

External Connector

12 13 14

(Current Out, 4 to 20mA)

(Common)

(Voltage Out, 0 to 10V)

Power Series

External Connector

Relay Internal to Power Series

NC C NO

208 or 240V~

(Alarm Common) (Alarm

Normally Open)

(Alarm Normally Closed)

Unused

120V~

6 5 4 3 2 1

11 10

9 8 7

14 13 12

17 16 15

20 19 18

23 22 21

CONTROLLER

POWER SUPPLY

85 to 265V~ 55VA

Neutral

ALARM

250V~ 3A

1 2 3 4 5 6

Page 15

Wiring, Chapter 3 Watlow Power Series ■ 3.3

Figure 3.3a – Single Zone Input Wiring

Figure 3.3b – 2-Zone Input Wiring

Figure 3.3c – 3-Zone Input Wiring

Power Series

6 5 4 3 2 1

11 10

9 8 7

14 13 12

17 16 15

20 19 18

23 22 21

External Connectors

21 22 23

INPUT 1

18 19 20

INPUT 2

15 16 17

INPUT 3

(Current In, 4 to 20mA)

(Common)

(Voltage In, 0 to 10V)

(Current In, 4 to 20mA)

(Common)

(Voltage In, 0 to 10V)

(Current In, 4 to 20mA)

(Common)

(Voltage In, 0 to 10V)

NOTE: Successful installation

requires four steps:

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

• Install the controller (Chapter Two);

• Wire the controller (Chapter Three); and

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

ç∫

WARNING: To avoid damage to

Power Series

External Connector

INPUT 1

(Voltage In, 0 to 10V)

23 22 21

20 19 18

17 16 15

14 13 12

11 10

9 8 7

6 5 4 3 2 1

(Current In, 4 to 20mA)

21 22 23

(Common)

Power Series

External Connectors

INPUT 1

23 22 21

20 19 18

17 16 15

14 13 12

11 10

9 8 7

6 5 4 3 2 1

21 22 23

INPUT 2

18 19 20

(Voltage In, 0 to 10V)

(Current In, 4 to 20mA)

(Common)

(Voltage In, 0 to 10V)

(Current In, 4to 20mA)

(Common)

Page 16

3.4 ■ Watlow Power Series Wiring, Chapter 3

Line Power/Output Wiring

Figure 3.4a – Single Phase Output Wiring

(Model PC1X-XXXX-XXXX)

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

(Model PC2X-XXXX-XXXX)

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

NOTE: Successful installation

requires four steps:

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

• Install the controller (Chapter Two);

• Wire the controller (Chapter Three); and

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

ç∫

WARNING: To avoid damage to

NOTE: Torque and wire strip

guidelines:

• Connections 1 thru 6, and ground lug

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

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

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

çCAUTION: Figure 3.4a shows the

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

çCAUTION: Figure 3.4b shows the

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

L1 L2

Contacts

Heater

120V~ and 277V~

L1 L2

L1 Neutral

240V~ and above

Limit Control Contacts

(If Required)

1 3

On-board

Semiconductor

Fuse

4 5 6

Heater

Gnd

Internal Bussbar

ref.2

Limit Control

1 3

On-board

Semiconductor

Fuses

Internal Bussbar

4 5 6

ref.1 ref.3

Gnd

(If Required)

Page 17

Limit Control

Contacts

(If Required)

Heater

Gnd

1 3

4 5 6

On-board

Semiconductor Fuses

Limit Control

Contacts

(If Required)

Gnd

On-board

Semiconductor

Fuses

ref.1 ref. 2 ref. 3

PC9

Limit Control

Contacts

(If Required)

Gnd

1 3

4 5 6

On-board

Semiconductor

Fuses

ref.1 ref. 2 ref. 3

ç∫

Limit Control

Contacts

(if required)

Gnd

PC8

On-board

Semi-

conductor

Fuses

2 Independent,

Single-phase Heaters

heater 2

ref.1 ref. 3

heater 1

Limit Control

Contacts

(if required)

Gnd

PC8

On-board

Semi-

conductor

Fuses

2 Independent,

Single-phase Heaters

heater 2

ref.1 ref. 3

heater 1

Gnd

On-board

Semi-

conductor

Fuses

PC9

ref.1 ref. 2 ref. 3

heater

3 Independent,

Single-phase Heaters

Limit Control

Contacts

(if required)

Limit Control

Contacts

(if required)

Gnd

On-board

Semi-

conductor

Fuses

PC9

ref.1 ref. 2 ref. 3

heater

3 Independent,

Single-phase Heaters

WARNING:

To avoid damage to property and equipment, and/or injury or loss of life, use National Electric Code (NEC) standard wiring practices to install and operate the Power Series. Failure to do so could result in damage, and/or injury or death.

WARNING:

Install high or low temperature limit control protection in systems where an over temperature fault condition could present a fire hazard or other hazard. Failure to install temperature limit control protection where a potential hazard exists could result in damage to equipment, property and injury to personnel.

Figure 3.5a – 3-Phase, 3-Leg,

6-SCR Output Wiring for

Figure 3.5b – 3-Phase, 3-Leg,

6-SCR Inside Delta

4-Wire Wye Application (Model PC4X-XXXX-XXXX)

Note: 1. Phasing must be as shown.

2. Do not connect Ref. terminals.

Figure 3.5d – **Multizone Output Wiring

Figure 3.5c – 3 Phase, 3-Leg,

6-SCR Output Wiring (Model PC3X-XXXX-XXXX)

Note: Wiring must be A, B, C rotation.

çCAUTION: Do not connect ref. connections with PC3 models. Failure to follow this guideline could cause damage to the Power Series.

NOTE:

For reference connections 1 to 3, use QC 0.250 in. wide and

0.032 in. thick compatible connection which is fully insulated with nylon and has a metal grip ring.

For 14-16 AWG: Molex/ETC AA-5261; 3M MNG14-250DFIX C-54503X or equivalent.

**NOTE: Models PC8 and PC9 control legs are isolated so that they may be wired from phase-to-phase inside delta or

PC8X-XXXX-XXX1

Molex/ETC AA-5261; 3M MNG14-250DFIX C-54-503X or equivalent.

Figure 3.5e – Fan Wiring for 250A Models

PC8X-XXXX-XXX3 PC9X-XXXX-XXX1

Note: Wiring must be A,

B, C rotation if phase control is selected.

PC9X-XXXX-XXX3

Note: Wiring must be A,

B, C rotation if phase control is selected.

phase-to-neutral, independent of how the other legs are wired.

Wi r ing , Cha p ter 3 Wat l ow P o wer S eri e s I 3. 5

Page 18

3.6 I Watlow Power Series Wiring, Chapter 3

Wiring Example

Figure 3.6 - System wiring example.

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

ç∫

WARNING:

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

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

PC1X-N20 160 0808-0102-0160 170M1319

PC1X-N25 200 0808-0102-0200 170M1320

PC1X-N30 250 0808-0102-0250 170M1321

PC1X-F20 160 0808-0102-0160 170M1319 PC1X-F25 250 0808-0102-0250 170M1321 PC1X-F30 315 0808-0102-0315 170M1322

PC2(8)X-N20 125 0808-0102-0125 170M1318

PC2(8)X-N25 160 0808-0102-0160 170M1319

PC2(8)X-N30 160 0808-0102-0160 170M1319

PC2(8)X-F20 160 0808-0102-0160 170M1319

PC2(8)X-F25 250 0808-0102-0250 170M1321

PC2(8)X-F30 250 0808-0102-0250 170M1321

PC3(4,9)X-F35 315 0808-0102-0315 170M1322

PC2(8)X-F35 315 0808-0102-0315 170M1322

PC3(4,9)X-N20 100 0808-0102-0100 170M1317

PC3(4,9)X-N25 125 0808-0102-0125 170M1318

PC3(4,9)X-N30 160 0808-0102-0160 170M1319

PC3(4,9)X-F20 125 0808-0102-0125 170M1318

PC3(4,9)X-F25 200 0808-0102-0200 170M1320

PC3(4,9)X-F30 200 0808-0102-0200 170M1320

480V~

(ac)

Breaker

480V~ (ac)

120V~ (ac)

CRI Coil

PM6C2FA-ALAJAAA

–

Control Thermocouple

CRI: High

Limit

Contactor

213

On-board

Semiconductor

Fuses

3Ø, 2-leg

Zero Cross Fired

Power Series

456

Gnd

4 to 20mA

–

Retransmit to Monitor Output Operation

Control Power

Three-phase

Resistive Heater

High Limit Thermocouple

AC Common AC High

Page 19

Chapter Four

Navigation and Software

Keys and Displays

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

Navigation and Software, Chapter 4 Watlow Power Series ■ 4.1

Figure 4.1 — Power Series keys and displays.

Alarm Indication LED: Lit when an alarm is active.

Upper Display:

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

Lower Display:

Indicates the parameter whose value appears in the upper display.

***8

Increment/Decrement Keys: Moves to next or

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

Home Key:

Returns to the Display Loop if in any other page or menu, or in the Display Loop, moves between like prompts of different zones or phases.

Small LED: Blinks with communications activity.

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

Page 20

Navigating the Power Series

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

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

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

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

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

Factory Page for calibration and diagnostic information.

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

4.2 ■ Watlow Power Series Navigation and Software, Chapter 4

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

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

• Factory Page:

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

***8

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

***8

algo

SEt

***8

FCty

-–-

load

Page 21

Navigation

¬®[````]¬®[````]¬®[load]¬®[freq]¬®

Single-Zone Single-Phase

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

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

%%%% [2one]

%%%%%%% [PHAS]

Display Loop

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

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

Use the Increment/Decrement keys (

Ó Î ) to select a value, either alpha or

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

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

(#)

Display Zone Selection

Display Phase Selection

(#)

(code) (code)

Active Alarms

(if any)

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

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

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

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

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

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

Navigation and Software, Chapter 4 Watlow Power Series ■ 4.3

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

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

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

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

***8

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

Setup Page Menus

±¬

Display Loop

±±

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

% ±¬®

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

Factory Page Menus

Page 22

4.4 ■ Watlow Power Series Navigation and Software, Chapter 4

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

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

[dAta] System Data Manipulation

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

%Ó

[`Loc] Global/Menu Lockouts

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

%Ó

[InFo] Unit Information

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

%Ó

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

[diAg] Diagnostics

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

%Ó%

¬®[retr]¬®[`UAL]¬®[``In]¬®[dIsp]

[`pw] Factory Password

[FctY]

% ¬®[`pw]¬®[fcty]¬®

%Ó

[CIn1] Calibrate Analog Input Signal Zone 1**

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

%Ó

[CIn2] Calibrate Analog Input Signal Zone 2**

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

%Ó

[CIn3] Calibrate Analog Input Signal Zone 3**

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

%Ó

[Crtr] Calibrate Retransmit**

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

Factory Page Menus

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

Use the Left/Right arrow keys (

¬ ® ) to select a parameter

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

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

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

Setup Page Menus

[algo] Control Algorithm

[`set]

% ¬®[algo]¬®[`ftb]¬®[``UC]¬®

%Î% Î %Ó% Óv %

[Ctr1] Setup Control Zone 1

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

[`set] %Î

%Ó

[Opt1] Setup Options Zone 1

[`set]

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

%Î %Ó

[Ctr2] Setup Control Zone 2

[`set]

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

%Ó

[Opt2] Setup Options Zone 2

[`set]

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

%Î %Ó

[Ctr3] Setup Control Zone 3

[`set]

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

%Ó

[Opt3] Setup Options Zone 3

[`set]

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

%Î %Ó

[`aLr] Setup Alarms Configuration

[`set]

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

%Î %Ó

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

[`set]

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

%Î %Ó

[retr] Setup Retransmit Configuration

[`set]

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

%Î %Ó

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

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

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

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

¬ ® ) to select a parameter within a

Ó Î ) to select a value, either alpha

Page 23

Chapter Five

Control Methods and Features

Features, Chapter 5 Watlow Power Series ■ 5.1

Zero cross (also known as burst firing) provides even output power with the lowest level of noise generation (RFI). Zero cross is the preferred method for controlling a resistive load.

The controller determines when the ac sine wave crosses the 0-volts point, then switches the load, minimizing RFI.

Zero cross control is available for all Power Series configurations.

Soft start and current limiting are not available with zero cross control.

Setup Page:

• Enter the Setup Page by holding ± ¬for 3 seconds.

• When the display reads [algo], press ® until [`Off]

[`set] [Algo]

is displayed. Press Ó Î to select [`ftb] fixed time base, zero cross or [Urtb] variable time base, zero cross.

Figure 5.1a — Zero cross switching.

Fixed Time Base - Zero Cross

In the fixed time base control method, the selected percentage power level output is generated over a fixed time period (i.e. a fixed number of cycles), regardless of power level selected. Resolution of operator selectable power may be more precise than the fixed time base allows. Selected power output level is rounded to the closest possible power output value in full cycles as necessary.

Line voltage compensation is not used in the fixed time base control method.

Setup Page:

• Enter the Setup Page by holding ± ¬for 2 seconds.

• When the display reads [algo], press ® until [`Off]

[`set] [Algo]

is displayed. Press Ó Î to select [`ftb] fixed time base, zero cross.

• Press ® until [1seC] is displayed.

[`Ftb]

Press Ó Î

to select [1seC] or [4seC].

Figure 5.1b — 40% power, fixed time base, 60 Hz, 1 sec time base.

Zero Cross

SCR Switch On/Off Points

24 Cycles ON 36 Cycles OFF

Page 24

5.2 ■ Watlow Power Series Features, Chapter 5

Variable Time Base - Zero Cross

In the variable time base control method, an optimal ratio of cycles on to cycles off is used to generate the desired power output. The number of cycles needed to completely generate a desired power level is variable in single cycle increments. Line voltage compensation algorithms are used to adjust the percentage power output while operating in this mode. Variable time base operation gives the best response time and resolution and provides for the longest heater life.

In single cycle variable time base below 50 percent power, the unit is never on for more than one consecutive full cycle. Above 50 percent power, the unit is not off for more than one consecutive full cycle while maintaining the proper output.

Line voltage compensation is active if selected; however, it can be disabled.

Setup Page:

• Enter the Setup Page by holding ±¬for 2 seconds.

• When the display reads [algo], press ® until [`Off]

[`set] [Algo]

is displayed. Press Ó Î to select [Urtb] variable time base, zero cross.

Figure 5.2a — 50% variable time base

1 cycle on, 1 cycle off.

Figure 5.2b — 40% single cycle variable time base

1 cycle on, 1 cycle off, 1 cycle on, 2 cycles off.

DC Contactor - Zero Cross

DC contactor control mode is a specialized version of zero cross control in which the analog control input is always used and percentage power output is fixed at 100 percent or 0 percent.

The off/on thresholds are 2.0V/3.5V for voltage input; 5.0mA/8.0mA for current input. This means the unit is off for an input voltage (current) of

2.0V(5.0mA) or lower, and 100% on for an input volt-

age (current) of 3.5V(8.0mA) or higher. Maximum input voltage is 10.0V.

In contactor mode use a four second cycle time to improve heater diagnostics operation.

Line voltage compensation is not used under dc contactor control, the output is either 100 percent on or 100 percent off.

Setup Page:

• Enter the Setup Page by holding ±¬for 2 seconds.

• When the display reads [algo], press ® until [`Off]

[`set] {Algo]

is displayed. Press ÓÎto select [cont] dc contactor.

NOTE: Heater Tolerance, Heater Open and Load Balance alarms do not work in DC Contactor control mode.

The phase angle control method gates a limited portion of the line voltage cycle to the load based on percentage power selected. Soft start is always included when phase angle is selected.

Phase angle control may not be selected in a 3 phase, 2-leg system.

Line voltage compensation will be used to adjust the percentage power output while operating in this mode if selected.

Current limiting is a valid option with phase angle if the unit is equipped with heater diagnostics.

Setup Page:

• Enter the Setup Page by holding ±¬for 2 seconds.

• When the display reads [algo], press ® until [`Off]

[`set] [Algo]

is displayed. Press Ó Î to select

[PH2t] phase

angle.

Figure 5.2c— Phase angle firing.

NOTE: The maximum output power is 99%. This is considered full on for the Power Series.

Phase Angle

Page 25

Features, Chapter 5 Watlow Power Series ■ 5.3

Soft Start

Soft start is a variation of phase angle control executed on startup in which there is a gradual increase in power until the final selected power output is reached. If soft start is selected, the system will execute the soft start sequence each time a zone starts active control. This happens at power-on and on recovery from an alarm such as “Line Loss.” The soft start time is the time it takes to achieve 100 percent power after a zone restart. The actual time may be greater than the set time because of the resolution, but the actual time will never be less than the set time. Rate = 100.0 ÷ time. The actual power achieved is set by the temperature control input (see Figure 5.3a and 5.4a).

NOTE: Soft start is intended to be used only

for slowly

increasing power on the initial power request.

Soft start is available in single phase and 3 phase, 3leg models only.

Soft start is always used in systems with phase angle control mode selected unless

[soft] is set to [```0].

Setup Page: Adjustable Soft Start - On Power Up

• Enter the Setup Page by holding ± ¬for 2 seconds.

• When the display reads [algo], press Î until [CTr1]

[`set] [`set]

is displayed. Press ®

until [``$0] is displayed.

[soft]

Use the Ó Î keys to set the desired soft start time in seconds.

NOTE: Repeat this procedure for each zone that you wish to configure.

Figure 5.3a — Soft start.

Maximum Rate of Change

The maximum rate of change is used during normal operation of a phase angle controlled system (after

a soft start sequence ends) to cause large changes in requested power to be implemented gradually. The

maximum rate of change of the power is defined as the percentage of power change allowed every 0.1 second. This prevents a sudden increase or decrease in

current from one phase angle level to another level from one cycle to the next into a nonlinear load that could be damaged or blow a fuse.

Setup Page: Adjustable Maximum Rate of Change On Signal Change

• Enter the Setup Page holding ± ¬for 2 seconds.

• When the display reads [algo], press Î until [CTr1]

[`set] [`set]

is displayed. Press ®

until [`1)0] is displayed.

[rate]

Use the Ó Î keys to set the desired % output change per 0.1 seconds to reach the desired output power level when in phase angle control.

Example:

Time needed for 100% change in power at selected [rate] :

10.0% increase = 1 sec. from 0 to 100% power

10.0% increase = 0.8 sec. from 10 to 90% power

10.0% increase = 0.4 sec. from 10 to 50% power

NOTE: The default for Maximum Rate of Change is set to 10%/0.1 second.

NOTE: Repeat this procedure for each zone that you wish to configure.

Figure 5.3b — Maximum rate of change set to 10%.

100%

Rate of change limited by phase angle maximum rate of change.

Requested power level changed from 10% to 50% at (time) t1. Actual power out has changed from 10% to 50% by t2.

0.4

seconds

t1 t2

50%

10%

Page 26

Heater Bakeout

If a system is shut down for long periods, some heaters can absorb moisture. With a standard power controller, turning the power full “on” when moisture is present, can cause the fuses or the heater to blow. However, with the Power Series you can now “bake out” the moisture in a wet heater before applying full power and destroying the heater.

During heater bakeout, the Power Series slowly increases voltage to the heater while monitoring the output current. If the heater achieves full output before the bakeout time expires, then the heater is dry and can be put into service. At all times, the output will not exceed the temperature controller set point.

If the output current reaches a user-specified trip point during the bakeout (as it would if arcing occurred in the heater), then the Power Series shuts off the output and activates an over-current trip error, [HbOC]. The operator should then lengthen the bakeout time and restart or just restart, depending on how long the initial bakeout ran. To start heater bakeout you must cycle the controller power. After a successful heater bakeout, the Power Series automatically switches to the operator pre-selected control mode (phase angle or zero cross).

NOTE: Heater bakeout is intended for magnesium oxide filled nichrome elements. A nichrome element heater can have a tolerance up to ± 10%. This tolerance could add to the maximum heater current during normal operation. For example, a 50-amp heater could draw 55 amps and still be a good and dry heater.

Heater bakeout may be selected in single phase (phase to neutral) and 3 phase, 6 SCR systems with any pre-selected control mode. You must also have

the heater diagnostics option installed on your Power Series.

Heater bakeout operates with an over-current trip. The operator must set the maximum current allowed during heater bakeout using the [HbOC] prompt. This will set the maximum allowable load during heater bakeout.

Setup Page:

• Enter the Setup Page by holding ± ¬for 2 seconds.

• When the display reads [algo], press Î until [Opt1]

[`set] [`set]

is displayed. Press ®

until [`Off] is displayed.

[`Hbo]

Use the Ó Î keys to turn heater bakeout on.

• Press ®

until [Min] appears in the lower display.

Use the Ó Î keys to set the desired heater bake- out time in minutes.

• Press ®

until [`HbC] appears in the lower display.

Use the Ó Î keys to set the desired maximum load current during the heater bakeout process.

NOTE: Repeat this procedure for each zone that you wish to configure.

Figure 5.4a— Heater bakeout.

100%

60%

Output P

ower

Time

Temperature Control

Command Signal

Process Set Point

5.4 ■ Watlow Power Series Features, Chapter 5

Heater Tolerance Detection

Heater tolerance detection allows you to detect a failed heater or a heater that is beginning to fail. An alarm is triggered if the load current drops below or rises above specific levels.

For example, if you have five heaters that draw 20 amps each, for a total load current of 100 amps at 100 percent power, you could program the heater tolerance alarm to trigger if the load current drops below 80 amps at 100 percent power. This would indicate that one of the heaters has failed (open.)

To monitor for a heater that is beginning to fail or age, you could watch for too little or too much current. For example, in Figure 5.4b the alarm is programmed to trigger if the load current drops below 90 amps, or rises above 110 amps at 100 percent power.

The Power Series automatically adjusts the set points, depending upon the percent power, as shown in the illustration below.

Figure 5.4b— Heater Tolerance Detection.

Heater Tolerance High Set Point

Load Current

Heater Tolerance Low Set Point

Amps

100 75 50 25 0

Percent Power

Page 27

Watlow Power Series Features I 5.5

Current Limiting

The current limit uses the RMS current entered by the user. When a zone goes from 0.0% to a requested power greater than 0.0%, the software increments the output power by 0.1% increments per AC cycle until a current limit is detected. The software will continue to increment and decrement by 0.1% per AC cycle based on the current limit until the goal power is met. During normal operation (after the initial goal power is met), a detected current limit will cause decrements at 0.1% power per AC cycle until the current limit is no longer active. The software will continue to increment and decrement by 0.1% per AC cycle based on the current limit, until the goal power is again met.

Current limiting is available on units equipped with heater diagnostics, (P _ _ 1 - _ _ _ _ - _ _ _ _ ).

Current limiting is not available with 3 phase, 2-leg systems.

Current limiting is available under phase angle control operation.

Setup Page:

• Enter the Setup Page by holding ±¬for 2 seconds.

•

When the display reads [algo], press Î until [Opt1]

[`set] [`set]

is displayed. Pre

ss ® until [`Off] is displayed.

[`Cli]

Use the ÓÎkeys to turn current limit on.

• Press ® until [Cl`a] appears in the lower display. Use the ÓÎkeys to set the desired current limit set point.

NOTE: Repeat this procedure for each zone that you wish to configure.

Figure 5.5 — Current limiting.

Inductive Load Adjustment

The effect of inductive loads on current readings with phase angle control can be factored in by requesting an Inductive Load Factor Adjustment. This feature is used to improve current measurement when phase angle firing into a transformer or other inductive loads.

The adjustment should be done with active phase angle control with a requested power of 5% to 50% in the zone of interest using a true RMS current meter.

NOTE: If an inductive load factor has been requested and the load is no longer inductive, the current reading will not be accurate. Use the [`Clr] parameter in the [Indf] prompt to remove the inductive factor.

Setup Page:

• Enter the Setup Page by holding

±¬

for 2 seconds.

• When the display reads [algo], press Î until [Opt1]

[`set] [`set]

is displayed. Press ® until [idle] is displayed.

[Indf]

Using the ÓÎkeys, select [`req] in the upper display.

• Press ® until [1CuR] appears in the lower dis-

play. The upper display shows the current calculated by the system with no inductive factor. Read the actual current measured by a true RMS meter; use the ÓÎ keys until that value is displayed.

• Press ¬ until [Indf] appears in the lower display. Using the ÓÎ keys, select [`ACt] in the upper display. After 5 seconds, the prompt will

read [idle] if the adjustment was successful, or [`Err] if there was an error.

• To return to using no Inductive Load Factor,

select [`Clr].

NOTE: Using the inductive load factor parameter the Power Series displayed current can only be increased to match the current reading of a true RMS meter. The Power Series displayed current reading cannot be decreased below what it initially calculated and displayed. The maximum inductive load factor increase allowed is 50% of the non-inductive current measured initially by the Power Series. If you exceed the allowable adjustment then the Power Series will display [`Err] in the upper display and [Indf] in the lower display. In the event of an error push the up or down key to [`req] and start the process over.

Page 28

Baseline Voltage and

Voltage Compensation

The baseline voltage is used by the controller to adjust the output so that the system power remains constant. This adjustment is called voltage compensation. The requested power is assumed to occur at the baseline voltage. If there are any deviations of the line voltage from the baseline voltage, the applied output power will be adjusted.

For example, the starting line voltage of the system is 121 volts and the baseline voltage is set to 121 volts. The requested power is set to 50.0 percent. After the system has been controlling, the line voltage drops to 110 volts. During the time that the line voltage is at 110 volts, the applied output power will

be adjusted to (121

/1102) x .50 = 60.5 percent so that

the system power remains constant. The baseline voltage is also used for adjusting oper-

ating parameters in the software. It is important to adjust the baseline voltage to the normal operating voltage of the unit to enable it to operate at maximum accuracy.

Menu Lock

Menu locks allow a user to restrict access to parameters. If a lock is set on a menu, the parameters become read only. The system will not allow parameter to be changed, either from the keypad or through communications.

Factory Page:

• Enter the Factory Page by holding ± ¬ ® for 2 seconds.

• When the display reads [data], press Î until[`loc]

[fcty] [fcty]

is displayed. Press ®

until [`Unl] is displayed.

[glOC]

Use Global Lockout {gLOC} to write protect all prompts by choosing locked [`LOC]. If set to unlocked [`Unl], individual menu locks can be set by selecting each parameter in the Global/Menu Lockouts Menu and individually setting each to locked [`LOC] or unlocked [`Unl].

5.6 ■ Watlow Power Series Features, Chapter 5

Signal Selection

You need to configure the Power Series for current, voltage or digital.

Setup Page:

• Enter the Setup Page by holding ± ¬for 2 seconds.

• When the display reads [algo], press Î until [CTr1]

[`set] [`set]

is displayed. Press ®

until [`nna] is displayed.

[``In]

Use the Ó Î keys to select either current {`nnA], volt {Uolt], or digital [`dig].

NOTE: Repeat this procedure for each zone that you wish to configure.

Analog is typically 0-5VÎ (dc), 1-5VÎ (dc), 0-10VÎ (dc), 4-20mA.

Digital is used for keypad manual control or communications to control the Power Series.

Digital input is entered from the keypad in the Display Loop on the [`1n1], [`1n2] or [`1n3] prompt.

Current inputs are hardware limited to 0 to 20mA, but may be scaled using the {nnA_] and {nnA–] prompts. Note that the power will be fully off at the current specified by prompt {nnA_] +.2mA, and fully on at the current specified by prompt {nnA–]

-.2mA.

Voltage inputs are hardware limited to 0 to 10V, but may be scaled using the {Uol_] and {Uol–] prompts. Note that the power will be fully off at the current specified by prompt {Uol_] +.1V, and fully on at the current specified by prompt {Uol–] -.1V.

Other Features

Input

Page 29

Features, Chapter 5 Watlow Power Series ■ 5.7

Alarm Standard

If an alarm is configured as “standard” [`Std], the alarm indicators only occur while the alarm is active. The alarm indicators are the relay, which state is set in Active Relay State [ALgc] as either energized on alarm or de-energized on alarm, and the display, which has an indicator LED in the upper display and the descriptive prompt for the active alarm. When the alarm becomes inactive (and no other alarms are active) the alarm indicators are turned off.

Alarm Latched & Unlatching an Alarm Indicator

If an alarm is configured as “latched” [`Lat], the alarm indicators remain active until the user deactivates them. For a latched alarm, the descriptive prompt on the display in the Display Loop

will read [`Lat], and the user can switch to [UnLA], if the alarm is cleared, to turn off the alarm indicators. Once alarm indicators have been turned off, the operator does not have to reconfigure an alarm as latched.

Alarms

An alarm takes some action, usually notifying an operator, when a control parameter leaves a defined range. A user can configure how and when an alarm is triggered and whether it turns off automatically when the alarm condition is over. A description of the alarms and errors, why they occur, and how to troubleshoot them can be found on pages A.4 - A.7.

Setup Page:

• Enter the Setup Page holding ± ¬for 2 seconds.

• When the display reads [algo], press Î until [`alr]

[`set] [`set]

is displayed.

Global Alarm Configuration

The Global Alarm Configuration [glbl] is used when all of the alarms in the system are to be configured in the same mode. If individual alarms need to be set to different configurations, the Global Alarm Configuration should be set to [`OFF].

Alarm Silencing

If an alarm is configured as “silenced” [`sIl], the relay does not activate on the active alarm, although the display indicators are still visible. When the alarm becomes inactive (and no other alarms are

active) the display alarm indicators are turned off.

Alarm Latched and Silenced

If an alarm is configured as “latched and silenced” [lasI], only the display alarm indicators are active until the user deactivates them. The alarm displays must be switched off once the alarm has been cleared. See unlatching an alarm indicator above.

Active Relay State

For maximum flexibility, the Power Series controller can generate alarms from the energized or de-energized state of the relay. Creating an alarm from the de-energized state of the relay is the most reliable method of alarm generation since a power loss or any other control malfunction would cause an alarm.

Page 30

5.8 ■ Features Watlow Power Series

Overview

A Power Series controller can also be programmed and monitored by connecting it with a personal computer or programmable logic controller (PLC) via serial communications. To use this communications option, a Power Series must be equipped with an EIA/TIA 232/485 (P_ _ _ - _ _ _ _ - 1 _ _ _) communications board.

To view or change controller settings with a personal computer, you need to run software that uses the Modbus™ RTU protocol to read or write to registers

in the controller. See Chapter Six, Parameters, for the Modbus registers. These registers contain the parameter values that determine how the controller will function and the values that reflect the current input and output values of the system.

Parameters relating to communications appear in the Comms Menu (Setup Page). Match the Baud Rate [baud] to that of the computer and select an Address [Addr] (1 to 247, default is 1).

The Power Series supports a maximum read of up to 32 registers. See appendix A.8 for Modbus registers.

Communications

Page 31

Watlow Power Series Features ■ 5.9

Retransmit

Retransmitting Output Load Current or Load Power

The retransmit feature allows an output to retransmit an analog signal that can serve as an input variable for another device such as a chart recorder to document system performance over time.

To use the retransmit feature a Power Series must be equipped with heater diagnostics and a universal retransmit board (P_ _ 1 - _ _ _ _ - _ 1 _ _).

Setup Page:

• Enter the Setup Page by holding ± ¬for 2 seconds.

• When the display reads [algo], press Î until[retr]

[`set] [`set]

is displayed. Press ® : Select [`Cfg] to choose the type of output

retransmitted, mA [`nna] or volts [UOlt]. Select [type] to choose the type of information

that will be retransmitted.

[nOne] retransmit not active. [`CUr] retransmits the load current of

selected phase [phas] or zone [2one] if it is a multizone unit. [`HUa] retransmits the load power of selected zone [2one] in all models.

Select phase [phas] or zone [2one] to choose the phase/zone that will represent your retransmit signal. A three phase unit can only be single zone.

To scale the retransmit output signal, set the low value load current or kVA to be retransmitted with [Cur_] or [HUa_] and set the high value load current or kVA to be retransmitted with [Cur–] or [HUa–]. For example, if you want 4-20mA to represent a 50A to 250A current, set [Cur_] to 50 and [Cur–] to 250. As the load current varies between 50 and 250A, the retransmit output will vary between 4mA and 20mA.

Current outputs are hardware limited to 0 to 20mA, but may be scaled using the {rt| C_] and {rt| C–] prompts.

Voltage outputs are hardware limited to 0 to 10V, but may be scaled using the {rt| U_] and {rt| U–] prompts.

Figure 5.9a — Retransmitting a remote set point.

Figure 5.9b — Example circuit.

Power Series

Heater

Power Series

Retransmit

Circuit

Recorder

Device

Page 32

Fast Start Guide

Get Your Power Series Controlling Heat

Single Phase Control

Apply power to the line and the electronics power supply. The displays will read [`___]

[load]

• Enter the Setup Page holding ± ¬ for 2 seconds.

• When the display reads [algo] ® to [`Off],

[`set] [algo]

then cycle thru the list of choices using the ÓÎ keys. Choose one*.

[cont] dc contactor [`Off] non-operational [`Ftb] fixed time base, zero cross [Urtb] variable time base, zero cross [PH2t] phase angle

Press ¬.

• At [algo], press Î to [Ctr1].

[`set] [`set]

• **Press ® until [`nna] (default) is displayed. [``In]

Using the Ó Î keys, select input type: [`Off] off, [`nna] current, [Uolt] voltage, or [`dig] keyboard or comms.

• **Press ® until [nna_] or [Uol_] is displayed.

[Ctr1] [Ctr1]

Using the Ó Î keys, set the low end of the input scale to the desired input.

• **Press ® until [nna–] or [Uol–] is displayed.

[Ctr1] [Ctr1]

Using the Ó Î keys, set the high end of the input scale to the desired input.

• **Press ® until [IDLE] is displayed.

[lrn;U]

Using the Ó Î keys, select [`req] , and the Power Series will set the baseline voltage. Line voltage compensation, under voltage alarm, and some internal operating parameters are based on this.

*NOTE: One type of power control algorithm must be

selected for all zones.

**NOTE: Repeat this procedure for each zone in multizone

configurations.

Three Phase Control

Apply power to the line and the electronics power supply. The displays will read [`___]

[load]

• Enter the Setup Page holding ± ¬ for 2 seconds.

• When the display reads [````] ® to [````],

[`set] [algo]

then cycle thru the list of choices using the Ó key. Choose one.

[cont] dc contactor [`Off] non-operational [`Ftb] fixed time base, zero cross [Urtb] variable time base, zero cross [PH2t] phase angle

Press ¬.

• At [algo], press Î to [Ctr1].

[`set] [`set]

• **Press ® until [````] (default) is displayed. [``In]

Using the Ó key, select input type: [`Off] off, [`nna] current, [Uolt] voltage, or [`dig] keyboard

or comms.

• Press ® until [nna_] or [Uol_] is displayed.

[Ctr1] [Ctr1]

Using the Ó or Î key, set the low end of the input scale to the desired input.

• Press ® until [nna–] or [Uol–] is displayed.

[Ctr1] [Ctr1]

Using the Ó or Î key, set the high end of the input scale to the desired input.

• Press ® until [IDLE] is displayed.

[lrn;U]

Using the Ó Î keys, select [`req] , and the Power Series will set the baseline voltage. Line voltage compensation, under voltage alarm, and some internal operating parameters are based on this.

• Press ® until [````] is displayed.

[type]

Select the load type for Zone 1. (Choice is dependent on unit hardware.)

[2l`d] 3 ph, 2-leg delta [2lod] 3 ph, 2-leg open delta [2luy] 3 ph, 2-leg ungrounded wye [none] unconfigured [3lid] 3 ph, 3-leg, 6 SCR inside delta [3l`d] 3 ph, 3-leg, 6 SCR delta [3lgy] 3 ph, 3-leg, 6 SCR grounded wye

• Press ± to start the Power Series.

5 . 1 0 I F e a tu r e s W a t lo w P owe r Se r i es

Page 33

Display Loop

The resting-state display shows one of the following sets of data, depending on controller setup. The first prompt appears in the top display, the second in the bottom display.

Active: Always. Appears in Display Loop.

150 r [mA] 151 r [V] 5102 r/w

[dig]

[``)0][``)0] to [2)00] [mA]

(0 to 2000)

[``)0] to [1)00] [V]

(0 to 1000)

[``)0] to [10)0] [%]

(0 to 1000)

0.1 increments

[``In] Analog (mA or V)

or Numeric (%) Input Signal

Displays mA/V analog input; selects numeric % power.

Single Zone / Single Phase

Active: Always. Appears in Display Loop.

198 rn/a

[``47] to [``63]

[47 to 63]

[frEq] Line Frequency

(Hz)

Displays the AC line.

Active: Always. Appears in display loop. (In single phase, single zone, only

the center LED operates; in single phase, 2-zone, or 3-phase, 2-leg, only the outside LEDs operate; in 3-phase, 3-leg, and multizone, each zone operates a separate LED.)

[`___][``-`] or [``_`]

per display

[LoAd] Load Activity

Indicator

Displays [``-`] if load has power applied.

Active: Any active error. See Appendix, pp. A.4-7.

195 r n/a

[````] Inactive (0) [`err] Active (1)

(See Appendix A.7 for

values)

[```] Display Loop

Errors

[alpha) (if any)

Displays present error conditions.

Active: Any active unmasked

alarm.

Individual Modbus registers may

have [Unla] Unlatched (4) written to them to clear a latched alarm.

NOTE: a latched alarm must be

[[``llaatt]]

Latched Inactive (3) before it can be unlatched.

181 to 190

r/w

[[`alr] Active (1) [`lat] Latched Active

(2)

[`lat] Latched Inac-

tive (3)

[Unla] Unlatched (4)

[```] Active Alarms

[alpha) (if any)

Displays present alarm conditions.

System Information

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Register Parameters to Appear

read/write

Parameters, Chapter 6 Watlow Power Series ■ 6.1

Chapter Six

Parameters

Page 34

Active if heater diagnostics option

is installed and heater bakeout is running in the zone.

157 r [1] 167 r [2]

n/a

[9999] to [```0]

[minutes] (9999 to 0)

[Hbt1], [Hbt2] Heater

Bakeout Timeout

Displays the time left on a heater bakeout.

Active with multizone

configuration.

159 r [1] 169 r [2]

[``)0][``)0] to [10)0]

(0 to 1000)

[Out1], [Out2]

Output Power (%)

Displays present output power.

Active with multizone

configuration.

mA, r [1][2] 150,160 V, r [1][2] 151,161 dig, r/w [1][2] 5102, 5202

[``)0][``)0] to [1)00] [V]

(0 to 1000)

[``)0] to [2)00] [mA]

(0 to 2000)

[``)0] to [10)0] [%]

(0 to 1000)

0.1 increments

[In`1], [In`2]

Analog (mA or V) or Numeric (%) Input Signal

Displays mA/V analog input; selects numeric % power.

Active with multizone

configuration.

n/a1

[```1] to [```2][```1], [```2]

[2one] Display Zone

Selection

Select Zone 1 or 2 for display.

Two Zone, Single Phase

Active if heater diagnostics option

is installed.

156 r n/a

[```0] to [9999]

(0 to 9999)

[`HUa] Load Power

(kVA)

Displays (est.) calculated load power.

Active if heater diagnostics option

is installed.

164 rn/a

[```0] to [9999]

(0 to 9999)

[`Cur] Load Current

(Amps) rms

Displays measured load current.Peak current converted to rms, then multiplied by % power = average rms current measured by the onboard CT.

Active: Always. Appears in Display Loop.

162 rn/a

[```0] to [9999]

(0 to 9999)

[`UoL] Line Potential

(Volts) rms

Displays measured line voltage.

Active if heater diagnostics option

is installed and heater bakeout is running in the zone.

157 r [1]n/a

[9999] to [```0]

[minutes] (9999 to 0)

[`Hbt] Heater Bakeout

Timeout

Displays the time left on a heater bakeout.

Active: Always. Appears in Display Loop.

159 r

[``)0][``)0] to [10)0]

(0 to 1000)

[`Out] Output Power (%)

Displays present output power.

6.2 ■ Watlow Power Series Parameters, Chapter 6

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Page 35

Active with multizone

configuration.

152 r [1] 162 r [2] 172 r [3]

n/a

[```0] to [9999] [V]

(0 to 9999)

[Uol1], [Uol2], [Uol3]

Line Potential (Volts) rms

Read measured line voltage.

Active if heater diagnostics option

is installed and heater bakeout is running in the zone.

157 r [1] 167 r [2] 177 r [3]

n/a

[9999] to [```0]

[minutes] (9999 to 0)

[Hbt1], [Hbt2], [Hbt3]

Heater Bakeout Timeout

Displays the time left on a heater bakeout cycle.

Active with multizone

configuration.

159 r [1] 169 r [2] 179 r [3]

[``)0][``)0] to [10)0] [%]

(0 to 1000)

[Out1], [Out2], [Out3]

Output Power (%)

Displays present output power.

Active with multizone

configuration.

mA, r[1][2][3] 150,160,170 V, r[1][2][3] 151,161,171 dig, r/w

[1][2][3]

5102, 5202,

5302

[``)0][``)0] to [2)00] [mA]

(0 to 2000)

[``)0] to [1)00] [V]

(0 to 1000)

[``)0] to [10)0] [%]

(0 to 1000)

0.1 increments

[In`1], [In`2], [In`3]

Analog (mA or V) or Numeric (%) Input Signal

Displays mA/V analog input; selects numeric % power.

Active with multizone

configuration.

n/a1

[```1] to [```3][```1], [```2] [```3]

[2one] Display Zone

Selection

Select Zone 1, 2 or 3 for display.

Three Zone, Single Phase

Active with multizone

configuration and heater diagnostics option is installed.

156 r [1] 166 r [2]

n/a

[```0] to [9999]

(0 to 9999)

[HUa1], [HUa2]

Load Power (kVA)

Read calculated (est.) load power.

Active with multizone

configuration and heater diagnostics option is installed.

154 r [1] 174 r [2]

n/a

[``00] to [9999]

(0 to 9999)

[Cur1], [Cur2]

Load Current (Amps) rms

Read measured line current.

Active with multizone

configuration.

152 r [1] 172 r [2]

n/a

[```0] to [9999]

(0 to 9999)

[Uol1], [Uol2]

Line Potential (Volts) rms

Read measured line voltage.

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Parameters, Chapter 6 Watlow Power Series ■ 6.3

NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features.

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

Current operating parameters may be modified at any time with the use of a keypad or serial input. The Input Signal Method Indicator will change depending on the Input Signal Method chosen — process, current, or volts.

Page 36

6.4 ■ Watlow Power Series Parameters, Chapter 6

Active with multiphase

configuration and heater diagnostics option is installed.

156 r n/a

[```0] to [9999]

[kVA] (0 to 9999)

[`HUA] Load Power (kVA)

Read calculated (est.) load power.

NOTE: In 3 phase, 2-leg systems,[Cur2] is the current displayed; it is the average of phase 1 and phase 3 ( [Cur1] and

[Cur3] ).

Active with multiphase

configuration and heater diagnostics option is installed.

154 r [1] 164 r [2] 174 r [3]

n/a

[``00] to [9999] [A]

(0 to 9999)

[Cur1], [Cur2], [Cur3]

Load Current (Amps) rms

Read measured load current.

Active with multiphase

configuration.

152 r [1] 162 r [2] 172 r [3]

n/a

[``00] to [9999] [V]

(0 to 9999)

[Uol1], [Uol2], [Uol3]

Line Potential (Volts) rms

Read measured line voltage.

Active with multiphase

configuration.

n/a

[```1] to [```3][```1], [```2], [```3]

[Phas] Display Phase

Selection 1 to 3

Select phase for display.

Active: Always. Appears in Display Loop.

159 r

[``)0][``)0] to [10)0] [%]

(0 to 1000)

[`Out] Output Power (%)

Displays present output power.

Active: Always. Appears in Display Loop.

151 r [V]

150 r [mA]

5102 r/w

[dig]

[``)0][``)0] to [2)00] [mA]

(0 to 2000)

[``)0] to [1)00] [V]

(0 to 1000)

[``)0] to [10)0] [%]

(0 to 1000)

0.1 increments

[``In] Analog (mA or V)

or Numeric (%) Input Signal

Displays mA/V analog input; selects numeric % power.

Multi-Phase

Active with multizone

configuration and heater diagnostics option is installed.

156 r [1] 166 r [2] 176 r [3]

n/a

[```0] to [9999]

[kVA] (0 to 9999)

[HUa1], [HUa2], [HUa3]

Load Power (kVA)

Read calculated (est.) load power.

Active with multizone

configuration and heater diagnostics option is installed.

154 r [1] 164 r [2] 174 r [3]

n/a

[``00] to [9999] [A]

(0 to 9999)

[Cur1], [Cur2], [Cur3]

Load Current (Amps) rms

Read measured line current.

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Page 37

Setup Page

To enter the Setup Page, press the Home and Left keys (± ¬ ) together while in the Display Loop. Each of the following menus in the Factory Page are selected by pressing the

Increment/Decrement keys (Ó Î ). Each press of the button will scroll you up or down through these main menu options.

To select a parameter within a menu, use the Left/Right arrow keys (¬ ® ). The parameter appears in the bottom display.

To select a value for each parameter (either alpha or numeric), use the Increment/Decrement keys (Ó Î ). The value appears in the upper display.

Pressing the Home key (± ) in this menu will return you to the Display Loop. The Setup Page contains ten menus:

Active if [algo] is set to [`ftb].

56 r/w

[1SEC] 1

second (0)

[1SEC] 1 second (0) [4SEC] 4 second (1)

[`FTB] Fixed Time Base

(Sec)

Set the fixed time base in seconds for selected zone.

Active: Always. [cont] is not available if any

input on controller is digital.

[PH2t] phase angle is not

available with 3 phase, 2-leg controllers.

NOTE: Changing this parameter will restart the system.

55 r/w

[`Off] non-

operational (1)

[cont] dc contactor (0) [`Off] non-operational

(1)

[`Ftb] fixed time base,

zero cross (2)

[Urtb] variable time

base, zero cross (3)

[PH2t] phase angle (4)

[ALgo] Power Control

Algorithm Select

Select power control algorithm.

[algo] Setup Control Algorithm

[`Set] Setup Page

This menu is used to set the control algorithm for the system.

NOTE: Changing the algorithm will restart the system.

*NOTE: These menus are dependent on the hardware options that are installed in your controller. Please see the individual menus for the options that must be installed for each of these menus to appear.

[algo][algo] Control

Algorithm

[Ctr1] Control Zone 1 [Opt1] *Options Zone 1 [Ctr2] Control Zone 2 [Opt2] *Options Zone 2 [Ctr3] Control Zone 3 [Opt3] *Options Zone 3 [`ALr] Alarms

Configuration

[COM] *Comms

Configurations

[rEtr] *Retransmit

Configuration

[`Set] Setup Page Select

Go to a setup menu.

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Register Parameters to Appear

read/write

Parameters, Chapter 6 Watlow Power Series ■ 6.5

NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features.

Page 38

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

6.6 ■ Watlow Power Series Parameters, Chapter 6

Active if [``In] is set to [Uolt]

voltage.

5013 r/w [1] 5023 r/w [2] 5033 r/w [3]

[`)00] (0)[`)00] to

[Uol–] [- 2.5V]

(0 to Analog Input High Voltage [-2.5V])

[Uol_] Analog Input Low

Voltage (Volts)

Sets voltage value which will correspond to 0% power if input is voltage type.

Active if [``In] is set to [`nna]

current.

5012 r/w [1] 5022 r/w [2] 5032 r/w [3]

[2)00]

(2000)

[nna_] [+ 5mA] to

[9(99]

(Analog Input Low

Current [+5mA] to

9999)

[nna–] Analog Input High

Current (mA)

Sets current value which will correspond to 100% power if input is current type.

Active if [``In] is set to [`nna]

current.

5011 r/w [1] 5021 r/w [2] 5031 r/w [3]

[`)00] (0)[`)00] to [nna–] [- 5mA] (0 to Analog Input High Current[-5mA])

[nna_] Analog Input Low

Current (mA)

Sets current value which will correspond to 0% power if input is current type.

Active if input signal method is

set to [`dIG].

5103 r/w [1] 5203 r/w [2] 5303 r/w [3]

[``)0] (0)[``)0] 0 percent to [10)0] 100 percent

(0 to 1000)

[dFlt] Default Numeric

Input Signal (%)

Selects the power-on level for chosen zone.

Active: Always.

[`dig] is not available if [Set`]

® [algo] in the Setup Page is

set to [cont].

5101 r/w [1] 5201 r/w [2] 5301 r/w [3]

[`nna] cur-

rent (1)

[`OFF] off (0) [`nna] current (1) [Uolt] voltage (2) [`dig] keyboard or

comms (3)

[``In] Input Signal

Method Select (dig, mA, Volt)

Select the input signal method for chosen zone.

[Ctr1] [Ctr2] [Ctr3] Setup Control Zone 1, 2, and 3 Menus

[`Set] [`Set] [`Set] Setup Page

This menu is used to set up the control for the chosen zone.

Zone 1 is used if Input/Output Configuration is single phase, single zone, or three phase. Zone 1 and 2 are used if Input/Output Configuration is single phase, two zones. All zones are used if Input/Output Configuration is single phase, three zones.

Active: Always.80 r/w

[``ON]] on

(0)

[``ON] on (0) [`Off] off (1)

[``UC] Line Voltage Com-

pensation

Automatically adjusts output duty cycle to compensate for line voltage fluctuations.

Page 39

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Register Parameters to Appear

read/write

Parameters, Chapter 6 Watlow Power Series ■ 6.7

NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features.

Active if controller is a 3 phase

system which only has one zone.

NOTE: The parameters available are dependent on the controller’s input/output configuration. The system does not operate unless this prompt is set to something other than

[[nnoonnee]]

NOTE: Changing this parameter will restart the system.

58 r/w

[none] un-

configured (3)

[2l`d] 3 ph, 2-leg

delta (0)

[2lod] 3 ph, 2-leg open

delta (1)

[2luy] 3 ph, 2-leg un-

grounded wye (2)

[none] unconfigured (3) [3lid] 3 ph, 3-leg, 6

SCR inside delta (4)

[3l`d] 3 ph, 3-leg, 6

SCR delta or ungrounded wye (5)

[3lgy] 3 ph, 3-leg, 6

SCR grounded wye (7)

[type] Load Type Select

(Control Zone 1 only, 3 phase only.)

Select the load type for Zone 1.

Active: Always. Go to [lrn| U], set the controller to

[`req]. Wait 5 sec. for automatic input of data for controller. The display will go back to [idle] when done.

5591 r/w [1] 5592 r/w [2] 5593 r/w [3]

[idle] idle

(0)

[`err] invalid input

signal (-1)

[idle] idle (0) [`req] learn request

(1)

[lrn| U] Baseline Voltage

Learn Request

Allows software to learn the baseline voltage on line connected to the zone chosen.

Active: Always.5594 r/w [1] 5595 r/w [2] 5596 r/w [3]

Line Voltage

rating

Minimum to maximum

line voltage

(minimum to maximum

line voltage)

[bl`U] Baseline Voltage

Read/Adjust

Shows the value for baseline voltage and allows manual adjustment of this value.

Active if [``In] is set to [`nna]

current or [Uolt] voltage.

Go to [lrn| a], set analog input to

low limit and set the controller to [``lO] low limit. Wait 5 sec. for automatic input of low data for controller. The display will go back to [idle] when done.

Go to [lrn| a], set the analog

input to high limit and set the controller to [``HI] high limit. Wait 5 sec. for automatic input of high data for controller. The display will go back to [idle] when done.

5019 r/w [1] 5029 r/w [2] 5039 r/w [3]

[idle] idle

(0)

[`err] invalid input

signal (-1)

[idle] idle (0) [``lO] low limit learn

request (1)

[``HI] high limit learn

request (2)

[lrn| a] Learn Input Learn

Request (Hi, Lo)

Allows software to learn the high and low limits of the analog input signal.

Active if [``In] is set to [Uolt]

voltage.

5014 r/w [1] 5024 r/w [2] 5034 r/w [3]

[1)00]

(1000)

[Uol_] [+ 2.5V] to

[9(99]

(Analog Input Low Voltage [+2.5V] to

9999)

[Uol–] Analog Input High

Voltage (Volts)

Sets voltage value which will correspond to 100% power if input is voltage type.

Page 40

Active if heater diagnostics is

installed.

Active unless controller is 3

phase, 2 leg configuration.

Active if [`Hbo] is set to [``On].

5116 r/w [1] 5216 r/w [2] 5316 r/w [3]

10.0% of load current

[```0] to [`Cur] 0 to

Load Current Amps [1 Amp increment; maximum will be determined by Load Rating] (0 to Load Current Amps)

[`HbC] Heater Bakeout

Over Current Trip

Sets the maximum heater current during heater bakeout. Output will shut down at this value.

Active if heater diagnostics is

installed.

Active unless controller is 3

phase, 2 leg configuration.

Active if [`Hbo] is set to [``On].

5111 r/w [1] 5211 r/w [2] 5311 r/w [3]

1440 minutes (1440)

[```0] to [9999] 0 to

9999 minutes [1 minute increments] (0 to 9999)

[Min] Heater Bakeout

Select Time

Selects the heater bakeout time in minutes for chosen zone.

Active if heater diagnostics is

installed.

Active unless controller is 3

phase, 2 leg configuration.

5110 r/w [1] 5210 r/w [2] 5310 r/w [3]

[`OFF] off (0)[`OFF] off (0)

[``On] selected (1)

[`Hbo] Heater Bakeout

Select (On/Off)

Select heater bakeout option for chosen zone.

[OPt1] OPt2] [OPt3] Setup Options Zones 1, 2, and 3 Menus

[`Set] [`Set] [`Set] Setup Page

This menu is used to set up the options for the chosen zone. This set of menus is available only if Heater Diagnostics is installed.

Zone 1 is used if Input/Output Configuration is single phase, single zone, or three phase. Zone 1 and Zone 2 are used if Input/Output configuration is single phase, two zones. All zones are used if Input/Output Configuration is single phase, three zones.

Active if [algo] is set to [Ph2t]

and [type] is set to [3ld] or [3lid].

5108 r/w

[``)0] (0) [``)0] to [`5)0]

(0 to 500)

[rdLy] Reactance Delay

for Transformer Loads

Prevents half cycle errors and restarts on inductive loads. Increase value until half cycle errors no longer appear.

Active unless Input/Output con-

figuration is 3 phase, 2-leg.

Active if [algo] is set to [Ph2t].

5105 r/w [1] 5205 r/w [2] 5305 r/w [3]

[``$0] (40) [``)0] to [12)0] 0.0 to 120 seconds (.1 second increments) (0 to 1200)

[Soft] Soft Start Time

(Sec)

Selects the time in seconds for the power level of the chosen zone to change from 0% to 100% when the power cycles.

Active unless Input/Output con-

figuration is 3 phase, 2-leg.

Active if [algo] is set to [Ph2t].

5104 r/w [1] 5204 r/w [2] 5304 r/w [3]

[`1)0] (100) [``)1] to [10)0] 0.0 to 100.0% [.1% increments] (1 to 1000)

[rATE] Maximum Rate of

Change (%/100msec)

Set maximum rate of power change of the power level for selected zone when input signal changes.

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

6.8 ■ Watlow Power Series Parameters, Chapter 6

Page 41

Active if heater diagnostics is

installed.

Active unless Input/Output con-

figuration is 3 phase, 2-leg.

Active if [algo] is set to [ph2t]

and [Indf] is set to [`req].

5107 r/w [1] 5207 r/w [2] 5307 r/w [3]

Active load

current

0 to load current rating

[ICur] Inductive Current

Sets the actual measured current for an inductive load.

Active if heater diagnostics is

installed.

Active unless Input/Output con-

figuration is 3 phase, 2-leg.

Active if [algo] is set to [ph2t].

NOTE: Selecting [`act] or [`CLr] will restart the system.

5106 r/w [1] 5206 r/w [2] 5306 r/w [3]

[Idle] idle

(0)

[`err] invalid request

(-1)

[Idle] idle (0) [`req] request induc-

tive load factor adjustment (1)

[`act] active load fac-

tor adjustment (2)

[`CLr] clears factor (3)

[Indf] Inductive Load

Factor Request

Requests an inductive load factor adjustment.

Active if heater diagnostics is

installed.

This set point will only be used if

the requested power is above 20%.

5115 r/w [1] 5215 r/w [2] 5315 r/w [3]

maximum

system current

[tol_] to maximum

system current [1 amp increments] (Heater Low Tolerance Set Point to max Load Current rating of the Power Series)

[tol–] High Tolerance

Set Point (A)

Set heater tolerance high current set point for the selected zone. Value is current level for 100% full on.

Active if heater diagnostics is

installed.

This set point will only be used if

the requested power is above 20%.

5114 r/w [1] 5214 r/w [2] 5314 r/w [3]

0 (0)

[```0] to [tol–] 0

amps to High Tolerance Set Point [1 amp increments] (0 to Heater High Tolerance Set Point)

[tol_] Low Tolerance Set

Point (A)

Set heater tolerance low current set point for the selected zone. Value is current level for 100% requested power and is adjusted actual percentage of requested power.

Active if heater diagnostics is

installed.

Active unless controller is 3

phase, 2 leg configuration.

Active if [algo] is set to [Ph2t]

and [`CLi] is set to [``On].

NOTE: Changing this parameter will restart the system.

5113 r/w [1] 5213 r/w [2] 5313 r/w [3]

10.0% of load current

[```0] to [`Cur] 0 to

Load Current Amps [1 Amp increment; maximum will be determined by Load Rating] (0 to Load Current Amps)

[CL`A] Current Limit Set

Point (A)

Selects the current limit set point for current limiting in chosen zone.

Active if heater diagnostics is

installed.

Active unless controller is 3

phase, 2 leg configuration.

Active if [algo] is set to [Ph2t].

NOTE: Changing this parameter will restart the system.

5112 r/w [1] 5212 r/w [2] 5312 r/w [3]

[`OFF] off (0)[`OFF] off (0)

[``On] on (1)

[`CLi] Current Limit Se-

lect (On/Off)

Selects current limit method for selected zone. Used in phase angle control only.

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Parameters, Chapter 6 Watlow Power Series ■ 6.9

NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features.

Page 42

Active if [glbl] is set to [`Off].

863 r/w

[`std]

active (0)

[`std] active (0) [`LaT] latched (1) [`SIl] silenced (2) [LaSI] latched and

silenced (3)

[Line] Line Loss Alarm

Configuration

Selects the line loss alarm configuration.

Active: Always. Output will de-energize at this

heatsink shut down temperature (degrees C). The default maximum temperature is model number dependent.

990 r/w Value equal to [`sdÇ] or less. User adjustable. See Factory Menu for actual safety shutdown temp.

[```0] to [`sdÇ] [alÇ`] Heat Sink Over Temperature Alarm Temperature

Select heat sink overtemp alarm configuration.

Active if [glbl] is set to [`Off].

862 r/w

[`std]

active (0)

[`std] active (0)

[`LaT] latched (1)

[`SIl] silenced (2)

[LaSI] latched and

silenced (3)

[``OT] Heat Sink Over

Temperature Alarm Config.

Select over temperature alarm configuration.

Active if heater diagnostics is

installed.

Active if [glbl] is set to [`Off].

861 r/w

[`std]

active (0)

[`std] active (0)

[`LaT] latched (1)

[`SIl] silenced (2)

[LaSI] latched and

silenced (3)

[`tol] Heater Tolerance

Alarm Config.

Selects heater tolerance alarm configuration.

Active if heater diagnostics is

installed.

Active if [glbl] is set to [`Off].

860 r/w

[`std]

active (0)

[`std] active (0)

[`LaT] latched (1)

[`SIl] silenced (2)

[LaSI] latched and

silenced (3)

[Open] Heater Open

Alarm Config.

Select heater open alarm configuration.

Active: Always.851 r/w

[`std] all

alarms active (0)

[`std] all alarms

active (0)

[`LaT] latched (1)

[`SIl] silenced (2)

[LaSI] latched and

silenced (3)

[`Off] off (4)

[glbl] Global Alarm

Configuration

Selects global alarm configuration. Configures all alarms to the same type or if set to OFF allows individual alarm configuration.

Active: Always.

850 r/w

[al`O] de-

energized on alarm (1)

[al`C] energized on

alarm (0)

[al`O] de-energized

on alarm (1)

[a| lgc] Active Relay State

Select the relay state on an alarm condition.

[`Alr] Setup Alarms Configuration Menu

[`Set] Setup Page

This menu is used to set up the alarm configuration. For a definition of the alarm types — standard, latched, silenced, latched and silenced, see page 5.7.

6.10 ■ Watlow Power Series Parameters, Chapter 6

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Page 43

Active if communications is

installed.

Active if [glbl] is set to [`Off].

869 r/w

[`std]

active (0)

[`std] active (0)

[`LaT] latched (1)

[`SIl] silenced (2)

[LaSI] latched and

silenced (3)

[C| wd] Comms Watchdog

Alarm Config.

Selects the communications watchdog alarm configuration.

Active if [glbl] is set to [`Off].

868 r/w

[`std]

active (0)

[`std] active (0)

[`LaT] latched (1)

[`SIl] silenced (2)

[LaSI] latched and

silenced (3)

[``OU] Over Voltage

Alarm Config.

Selects the line overvoltage alarm configuration.

Active if [glbl] is set to [`Off].

867 r/w

[`std]

active (0)

[`std] active (0)

[`LaT] latched (1)

[`SIl] silenced (2)

[LaSI] latched and

silenced (3)

[``UC] Voltage Compensa-

tion Alarm Config.

Selects the line compensation alarm configuration.

Active if [glbl] is set to [`Off].

866 r/w

[`std]

active (0)

[`std] active (0)

[`LaT] latched (1)

[`SIl] silenced (2)

[LaSI] latched and

silenced (3)

[Freq] Frequency Out of

Tolerance Alarm Configuration

Select frequency tolerance alarm configuration.

Active if heater diagnostics is

installed.

Active if controller is 3 phase.

991 r/w

[`100] (100)[```0] to [`100]

(0 to 100)

[Ldif] Load Balance

Percentage

Selects the minimum percentage difference between loads current in phases.

Active if heater diagnostics is

installed. Active if [glbl] is set to [`Off]. Active if controller is 3 phase.

865 r/w

[`std]

active (0)

[`std] active (0) [`LaT] latched (1) [`SIl] silenced (2) [LaSI] latched and

silenced (3)

[Lbal] Load Balance

Alarm Config.

Selects the load balance alarm configuration.

Active if controller is 3 phase, 3-

leg configuration. Active if [glbl] is set to [`Off].

864 r/w

[`std]

active (0)

[`std] active (0) [`LaT] latched (1) [`SIl] silenced (2) [LaSI] latched and

silenced (3)

[p| bAl] Phase Balance

Alarm Config.

Select phase balance configuration.

Parameters, Chapter 6 Watlow Power Series ■ 6.11

NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features.

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Page 44

Active if retransmit and heater

diagnostics options are installed.

871 r/w

[`CUr] cur-

rent (1)

[`Off] none (0) [`CUr] current (1) [`HUA] kVA (2)

[type] Retransmit Type

Select

Select type of retransmit information; amps or kVA.

Active if retransmit and heater

diagnostics options are installed.

870 r/w

{`nna] mA

(0)

{`nna] mA (0) {UOlt] volts (1)

[`Cf9] Retransmit

Config. Select

Select type of retransmit output.

[rEtr] Setup Retransmit Configuration Menu

[`Set] Setup Page

This menu is used to set up the retransmit parameters. The menu is not available unless Retransmit and Heater Diagnostics are installed.

Active if serial communications

option is installed and [`Wd]

Watchdog is set to {``On].

87 r/w

[``)0] 0 per-

cent (0)

[``)0] 0 percent to

[10)0] 100 percent

(0 to 1000)

[PWr] Watchdog Failure

Output Power Select

Selects the default power level for a watchdog timeout.

Active if serial communications

option is installed and [`Wd]

Watchdog is set to {``On].

86 r/w

[9999]

(9999)

[```0] to [9999] (0

to 9999)

[`seC] Watchdog Timeout

(Sec)

Selects a timeout in seconds for the communications watchdog.

Active if serial communications

option is installed.

85 r/w

{`Off] off (0){`Off] off (0)

{``On] on (1)

[`Wd] Watchdog Select

(On/Off)

Turns on a watchdog for communications.

Active if serial communications

option is installed.

[9600] 9600

baud

[1200] 1200 baud [2400] 2400 baud [4800] 4800 baud [9600] 9600 baud [1(2`] 19.2K baud

[baud] Unit Baud Rate

Select

Select baud rate for communications.

Active if serial communications

option is installed.

[```1] [```1] to [`247] [Addr] Unit Address Select

Select device address for communications.

[COm] Setup Comms Configuration Menu

[`Set] Setup Page

This menu is used to set up the communications parameters. This menu is not available unless Serial Communications is installed.

6.12 ■ Watlow Power Series Parameters, Chapter 6

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Register Parameters to Appear

read/write

Page 45

Active if retransmit and heater

diagnostics options are installed. Active if [`Cfg] is set to [`nna].

883 r/w

[2)00]

(2000)

[rt|C_] to [2)00]

(Retransmit Output Low Current to 2000)

[rt| C–] Retransmit Out-

put High Current (mA)

Select output current that will correspond to [Cur–] or [HUA–].

Active if retransmit and heater

diagnostics options are installed. Active if [`Cfg] is set to [`nna].

882 r/w

[```0] (0)[`)00] to [rt|C–] (0 to Retransmit Output High Current)

[rt| C_] Retransmit Out-

put Low Current (mA)

Select output current that will correspond to [Cur_] or [HUA_].

Active if retransmit and heater

diagnostics options are installed.

Active if [retr] ® [type] is set

to [`HUa].

879 r/w

[9999]

(9999)

[HUA_] to [9999]

(Minimum kVA Retransmit to 9999)

HUA–] Maximum kVA

Retransmit

Select maximum load power to be retransmitted.

Active if retransmit and heater

diagnostics options are installed.

Active if [retr] ® [type] is set

to [`HUa].

878 r/w

[```0] (0)[```0] to [HUA–] (0 to Maximum kVA Retransmit)

[HUA_] Minimum kVA

Retransmit

Select minimum load power to be retransmitted.

Active if retransmit and heater

diagnostics options are installed.

Active if [retr] ® [type] is set

to [`Cur].

877 r/wload current

[Cur_] to load current

(Minimum Amps Retransmit to load current)

[Cur–] Maximum Amps

Retransmit

Select maximum load current to be retransmitted.

Active if retransmit and heater

diagnostics options are installed.

Active if [retr] ® [type] is set

to [`Cur].

876 r/w

[``00] (0)[```0] to [Cur–] (0 to Maximum Amps Retransmit)

[Cur_] Minimum Amps

Retransmit

Select minimum load current to be retransmitted.

Active if retransmit and heater

diagnostics options are installed. Active if controller is multi zone. Active if [retr] ® [type] is set

to [`CUr] or [`HUa].

873 r/w

[```1] zone1

(1)

[```1] zone1 (1) [```2] zone2 (2) [```3] zone3 (3)

[2one] Retransmit Zone

Select

Select the zone with information to be retransmitted.

Active if retransmit and heater

diagnostics options are installed. Active if controller is three phase. Active if [retr] ® [type] is set

to [`CUr] or [`HUa].

872 r/w

[```1] phase

1 (1)

[```1] phase 1 (1) [```2] phase 2 (2) [```3] phase 3 (3)

[PhaS] Retransmit Phase

Select

Select the phase with information to be retransmitted.

Parameters, Chapter 6 Watlow Power Series ■ 6.13

NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features.

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Register Parameters to Appear

read/write

Page 46

6.14 ■ Watlow Power Series Parameters, Chapter 6

[dATA] System Data Manipulation [`Loc] Global/Menu Lockouts [Info] Unit Information [diag] Diagnostics [`pw] Factory Password [CIn1] Calibrate Analog Input Signal Zone 1* [CIn2] Calibrate Analog Input Signal Zone 2* [CIn3] Calibrate Analog Input Signal Zone 3* [C|rtr] Calibrate Retransmit*

[Fcty] Factory Page

Go to a factory menu.

Factory Mode ->

Requires factory password to access calibration parameters.

Factory Page

To enter the Factory Page, press the Home, Left and Right keys (± ¬ ® ) together while in the Setup Page. Each of the following menus in the Factory Page are selected by pressing the Increment/Decrement keys (Ó Î ). Each press of the button will scroll you up or down through these main menu options.

To select a parameter within a menu, use the Left/Right arrow keys (¬ ® ). The parameter appears in the bottom display.

To select a value for each parameter (either alpha or numeric), use the Increment/Decrement keys (Ó Î ). The value appears in the upper display.

Pressing the Home key (± ) in this menu will return you to the Display Loop. The Factory Page contains nine menus. The Factory Mode parameters of the Factory Page are used for calibration of the Power

Series. Since the Power Series is precalibrated at the factory; field calibration may only be necessary in the event that field service work is performed. Field calibration procedures are available at Watlow’s website, http://www.watlow.com/.

*NOTE: To enter the Factory Mode requires a password. Call Watlow at +1 (507) 454-5300, and ask an

applications engineer for this password. Once the password is entered, the controller is in Factory Mode. The controller’s power must be cycled to exit the Factory Mode.

Active if retransmit and heater

diagnostics options are installed. Active if [`Cfg] is set to [Uolt].

881 r/w

[1)00]

(1000)

[rt|U_] to [1)00]

(Retransmit Output Low Voltage to 1000)

[rt| U–] Retransmit Out-

put High Voltage (Volts)

Select voltage that will correspond to [Cur–] or [HUA–].

Active if retransmit and heater

diagnostics options are installed.

Active if [`Cfg] is set to [Uolt].

880 r/w

[```0] (0)[`)00] to [rt|U–] (0 to Retransmit Output High Voltage)

[rt| U_] Retransmit Out-

put Low Voltage (Volts)

Select voltage that will correspond to [Cur–] or [HUA–].

Display Parameter Range Default Modbus Conditions for

Address Parameters to Appear

read/write

Page 47

*NOTE: These prompts (Backup, Default, and Restore Data Set) allow the user to manipulate the EEPROM contents. See Appendix, p. A.7, for more information.

Active: Always.950 r/w

[idle] dis-

able restore (0)

[idle] (0) [`all] (1) [`sys] (2) [2n`1] (3) [2n`2] (4) [2n`3] (5)

NOTE: See “Backup Data Set” above for description of the Modbus values 0 - 5.

[rest] Restore Data Set*

Restores the appropriate user configurable parameters from backup memory. See page A.7 for Power Series Backup information.

Active: Always.952 r/w

[idle] dis-

able restore (0)

[idle] (0) [`all] (1) [`sys] (2) [2n`1] (3) [2n`2] (4) [2n`3] (5)

NOTE: See “Backup Data Set” above for description of the Modbus values 0 - 5.

[dFLt] Default Data Set*

Sets the appropriate parameters to the factory default values. See page A.7 for Power Series Backup information.

Active: Always.951 r/w

[idle] no

backup requested (0)

[idle] no backup re-

quested (0)

[`all] all parameters

listed in system, zone 1, 2 and 3 (1)

[`sys] system related

parameters, includes locks, alarms, retransmit, comms, algorithm, load type, voltage compensation (2)

[2n`1] zone 1 related

parameters, includes all parameters in menus [Ctr1] and

[Opt1] (3)

[2n`2] zone 2 related

parameters, includes all parameters in menus [Ctr2] and

[Opt2] (4)

[2n`3] zone 3 related

parameters, includes all parameters in menus [Ctr3] and

[Opt3] (5)

[BAuP] Backup Data Set*

Stores appropriate user configurable parameters into backup memory. See page A.7 for Power Series Backup information.

[dAtA] System Data Manipulation Menu

[Fcty] Factory Page

This menu is used to maintain the standard and backup system data.

Parameters, Chapter 6 Watlow Power Series ■ 6.15

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Page 48

Active if [glOC] is set to [`Unl]. Active if retransmit and heater

diagnostics options are installed.

1357 r/w

[`Unl] (0)[`Unl] Unlocked (0)

[`LOC] Locked (1)

[C| rtr] Retransmit Cal

Factory Menu Lockout

Sets lock on retransmit calibration menu.

Active if [glOC] is set to [`Unl].

1356 r/w

[`Unl] (0)[`Unl] Unlocked (0)

[`LOC] Locked (1)

{`CIn} Analog Input Fac-

tory Menus Lockout

Sets lock on input calibration menu.

Active if [glOC] is set to [`Unl]. Active if retransmit and heater

diagnostics options are installed.

1355 r/w

[`Unl] (0)[`Unl] Unlocked (0)

[`LOC] Locked (1)

{retr} Retransmit Setup

Menu Lockout

Sets lock on retransmit menu.

Active if [glOC] is set to [`Unl]. Active if serial communications

option is installed.

1354 r/w

[`Unl] (0)[`Unl] Unlocked (0)

[`LOC] Locked (1)

{COM} Comms Setup

Menu Lockout

Sets lock on communications menu.

Active if [glOC] is set to [`Unl].

1353 r/w

[`Unl] (0)[`Unl] Unlocked (0)

[`LOC] Locked (1)

{`Alr} Alarms Setup

Menu Lockout

Sets lock on alarm configuration menu.

Active if [glOC] is set to [`Unl]. Active if heater diagnostics

option is installed.

1352 r/w

[`Unl] (0)[`Unl] Unlocked (0)

[`LOC] Locked (1)

{`Opt} Options Setup

Menus Lockout

Sets lock on all options setup menus.

Active if [glOC] is set to [`Unl].

1351 r/w

[`Unl] (0)[`Unl] Unlocked (0)

[`LOC] Locked (1)

[`Ctr] Control Setup

Menus Lockout

Sets lock on all control setup menus.

Active: Always.1350 r/w

[`Unl] (0)[`Unl] Unlocked (0)

[`LOC] Locked (1)

{gLOC} Global Lockout

Sets the state of global lockout which allows all prompts to be write protected. If set to unlocked, individual menu locks can be set.

[`LOC] Global/Menu Lockouts Menu

[Fcty] Factory Page

This menu is used to set the lockout parameters. Locked means that the parameters in the menu cannot be changed.

Active: Always.959 r/w

[``On] (0)[``On] enable (0)

[`OFF] disable (1)

[nUOL] Enable NVOL

Storage

Enable/disable nonvolatile memory.

6.16 ■ Watlow Power Series Parameters, Chapter 6

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Page 49

Parameters, Chapter 6 Watlow Power Series ■ 6.17

NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features.

Active: Always.51 rn/a

[```0] to [`680]

(0 to 680)

[ratU] Unit Voltage Rating

(Volts)

Reads load voltage of the unit.

Active: Always.30 r n/a

[``)0] to [(999]

(0 to 9999)

[Sbld] Software Build

Number

Reads software build level of the unit.

Active: Always.4 r n/a

[``)0] to [(999]

(0 to 9999)

[SUEr] Software Version

Reads software version of the unit.

Active: Always.7 r n/a

[``)0] to [(999]

(0 to 9999)

[HUer] Hardware Version

Reads hardware version of the unit.

Active: Always.5 r n/a

[``00] to [``99] year

(00 to 99)

[``00] to [``99]

month (00 to 52)

[date] Manufactured

Date (yymm)

Reads month and year of manufacture.

Active: Always.2 r n/a

[```0] to [9999]

(0 to 9999)

[`Sn_] Unit Serial Num-

ber Low Digits

Reads the low digits of the serial number of the unit.

Active: Always.1 r n/a

[```0] to [9999]

(0 to 9999)

[`Sn–] Unit Serial Num-

ber High Digits

Reads the high digits of the serial number of the unit.

[InFo] Unit Information Menu

[Fcty] Factory Page

This menu is used to read unit information that is stored during manufacture.

Active if [glOC] is set to [`Unl].

1359 r/w

[`Unl] (0)[`Unl] Unlocked (0)

[`LOC] Locked (1)

[diAg] Diagnostics Facto-

ry Menu Lockout

Sets lock on diagnostics menu.

Active if [glOC] is set to [`Unl].

1358 r/w

[`Unl] (0)[`Unl] Unlocked (0)

[`LOC] Locked (1)

[dAtA] System Data

Factory Menu Lockout

Sets lock on system data menu.

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Page 50

Active: Always.1961 rn/a

[```0] to [9999]

(0 to 9999)

[HrS_] Accum Hours

(0 - 9999)

Accumulated system operating time (hours).

Active: Always. Masked if hours <10000

1960 r n/a

[```0] to [9999]

(0 to 9999)

[HrS–] Accum Hours

(10K - 100M)

Indicates accumulated system operating time (hours x 10000).

Active: Always.1591 r n/a

[```0] to [9999]

(0 to 9999)

[HIÇ`] Record High Heat

Sink Temp

Indicates record high heat sink temp.

Active: Always.57 rn/aFactory set.

[sdÇ`] Factory Safety

Shutdown Temp

Indicates set point for factory safety shutdown.

Active: Always. Same as alarm temp in Setup

Menu.

990 r/w n/a

[```0] to [`sdÇ][ALÇ`] Heat Sink Alarm

Temp

Set the set point for the heat sink over temp alarm.

Active: Always.1590 r n/a

[```0] to [9999]

(0 to 9999)

[```Ç] Heat Sink Temp

(°C)

Reads the current heat sink temp.

Active: Always.54 rn/a

[nOne] none (0) [```c] comms (1) [``r~] retransmit (2) [``rc] comms/retrans-

mit (3)

[`h``] heater diagnos-

tics (4)

[`h`c] heater diagnos-

tics/comms (5)

[`hr`] heater diagnos-

tics/retransmit (6)

[`hrc] heater diagnos-

tics/comms/retransmit 2 (7)

[`OPt] Configuration

Installed Options

Reads the configuration of the hardware options.

Active: Always.52 rn/a

[```1] single zone (1) [```2] two zone (2) [```3] three zone (3)

[2onC] Number Zones

Configured

Reads the number of zones that are configured.

Active: Always.50 rn/a

[```0] to [`245]

(0 to 245)

[ratA] Unit Current

Rating (Amps)

Reads load current of the unit.

6.18 ■ Watlow Power Series Parameters, Chapter 6

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Page 51

* Values 0 to 4095

Active for line on which line loss

alarm has occurred since power cycle.

1540 r 1543 r 1546 r

1541 r 1544 r 1547 r

1542 r 1545 r 1548 r

{none] (0){none] (0) no recorded

alarms

{uUOL] (1) under volt-

age

a|Cr] (2) extra zero

cross

n|Cr] (4) no zero cross {`pOl] (8) invalid line

polarity

{n|Cr] (16) no zero

cross

{freq] (32) invalid fre-

quency

{HCyC] (64) load half

cycle loss

[l_a1] Most Recent

Line Loss Alarm Type

[l_a2] Previous

Line Loss Alarm Type

[l_a3] Least Recent

Line Loss Alarm Type

[l_] indicates which

phase 1, 2 or 3 experienced the alarm

Line Loss Alarms:

The following nine parameters indicate line loss alarms that have occurred since power was last cycled. The parameters will only appear if there has been a line loss alarm and only for the line/s on which a line loss alarm has occurred. They will continue to appear until power is cycled again.

Active: Always.n/an/a

[```0] to [4095][Cnts] Read Selected A/D

Counts

Reads the selected analog to digital channel.

Active: Always.1560 r

1561 r

1562 r 1563 r 1564 r 1565 r 1566 r 1567 r 1568 r

1569 r

1570 r

1571 r

1572 r

1573 r

{Uref] voltage refer-

ence input*

{Tmp] heat sink temp

input*

{AIn1] analog input 1* {AIn2] analog input 2* {AIn3] analog input 3* {Uol1] voltage input1* {Uol2] voltage input2* {Uol3] voltage input3* {CUr1] positive current

input 1*

{CUr2] positive current

input 2*

{CUr3] positive current

input 3*

{CUr1] negative cur-

rent input 1*

{CUr2] negative cur-

rent input 2*

{CUr3] negative cur-

rent input 3*

[``Ad] Select A/D

Channel

Selects an analog to digital channel to read.

[diAg] Diagnostics Menu

[Fcty] Factory Page

This menu is to select diagnostics.

Parameters, Chapter 6 Watlow Power Series ■ 6.19

NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features.

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Page 52

Active if factory password is

valid.

1700 r/w

[`Off] idle

(0)

[`Off] idle (0) [`req] request factory

mode (1)

[`act] factory mode

active (2)

[fcty] Factory Mode

Request

Requests factory mode based on value set in Factory Password prompt.

Active: Always.1799 r/w

[1234][```0] to [9999]

(0 to 9999)

[`PW] Factory Password

Entry

Enter factory password.

[`pw] Factory Password

[Fcty] Factory Page

This menu is used to set the password for the Power Series' Factory Mode.

Factory Mode

The Factory Mode parameters of the Factory Page are used for calibration of the Power Series. Since the Power Series is precalibrated at the factory, field calibration may only be necessary in the event that field service work is performed. Field calibration procedures are available at Watlow’s website, http://www.watlow.com/.

NOTE: To enter the Factory Mode requires a password. Call Watlow at +1 (507) 454-5300, and ask an applications engineer for this password. Once the password is entered, the controller is in Factory Mode. The controller’s power must be cycled to exit the Factory Mode.

Active if retransmit option is

installed.

Factory mode only for write.

1555 r/w

[```0] (0)[```0] to [4095]

(0 to 4095)

[rEtr] Retransmit Set

Test Word

Sets retransmit test count.

Active if [``In] is not set to

[none].

1581 r

{----]{``LO] lo (0) {``HI] hi (1) {----] undeterminate

(2)

[`UAL] Read Selected

Input Value

Active: Always. Factory mode only for write.

1580 r/w

{none] (0){none] (0) {pOS1] (1) {pOS2] (2) {pOS3] (3) {)Cr1] (4) {)Cr2] (5) {)Cr3] (6)

[``In] Select Discrete

Input

Requests a display of the state of the chosen input.

Active: Always.1513 r/w

[idle] idle

(0)

[idle] idle (0) {`req] enable display

test (1)

[dIsp] Display Test

Requests a display test.

6.20 ■ Watlow Power Series Parameters, Chapter 6

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Page 53

Watlow Power Series Parameters ■ 6.21

NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Features.

✔ NOTE: The values entered in the preceding prompts are used with the corresponding analog to digital counts. The parameter [`Err] will be displayed if the calibrations fails; otherwise the parameter will return to [idle].

Active if in factory mode.5415 r/w [1] 5425 r/w [2] 5435 r/w [3]

[idle] cali-

bration inactive (0)

[`Err] invalid calibra-

tion (-1)

[idle] calibration

inactive (0)

[`req] enables cali-

bration request (1)

[CALA] Calibrate Analog

Input Request

Request analog input signal calibration.

Active if in factory mode.5414 r/w [1] 5424 r/w [2] 5434 r/w [3]

[(000]

(9000)

[Uol_] to [(999]

(Low V Cal Point to

9999)

[Uol–] High V Cal Point

Sets the high voltage value for the corresponding analog input calibration.

Active if in factory mode.5413 r/w [1] 5423 r/w [2] 5433 r/w [3]

[!000]

(1000)

[)000] to [UOL–]

(0 to High V Cal Point)

[Uol_] Low V Cal Point

Sets the low voltage value for the corresponding analog input calibration.

*NOTE: The display prompts are set to two decimal places because of the resolution of the display.

The comms registers are set and stored with three decimal places of resolution.

Active if in factory mode.5412 r/w [1] 5422 r/w [2] 5432 r/w [3]

[1^00]

(16000)

[nna_] to [2)00]

(Low mA Cal Point to

20000)*

[nna–] High mA Cal Point

Sets the high current value for the corresponding analog input calibration.

Active if in factory mode.5411 r/w [1] 5421 r/w [2] 5431 r/w [3]

[$000]

(4000)

[)000] to [nna–] [or

[(999] whichever is

smaller] (0 to High mA Cal Point [or 9999])

[nna_] Low mA Cal Point

Sets the low current value for the corresponding analog input calibration.

[CIn1] [CIn2] [CIn3] Calibrate Analog Input Signal Zones 1, 2, and 3 Menus

[Fcty] [Fcty] [Fcty] Factory Page

This menu is used to set up the analog inputs.

Input 1 is used if Input/Output Configuration is single phase, single zone or three phase. Input 1 and Input 2 are used if Input/Output Configuration is single phase, two zones. All zones are used if Input/Output Configuration is single phase, three zones.

NOTE: Care should be taken to allow a buffer between each of the settings and their respective hardware limits to prevent unexpected operation because of noise or signal variations.

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

Page 54

6.22 ■ Parameters Watlow Power Series

Display Parameter Range Default Modbus Conditions for

(Modbus Value) Address Parameters to Appear

read/write

*NOTE: The display prompts are set to two decimal places because of the resolution of the display.

The comms registers are set and stored with three decimal places of resolution.

Active if in factory mode. Active if retransmit option is

installed.

5700 r/w

[idle] cali-

bration inactive (0)

[`Err] invalid calibra-

tion (-1)

[idle] calibration

inactive (0)

[`req] enables cali-

bration request (1)

[CALr] Cal Retransmit

Request

Request a retransmit calibration.

Active if in factory mode. Active if retransmit option is

installed.

5721 r/w

[(000]

(9000)

[UOL_] to [(999]

(Retransmit Cal Volts Low to 9999)

[Uol–] Retransmit Cal

Volts High

Set the high voltage value for retransmit cal.

Active if in factory mode. Active if retransmit option is

installed.

5720 r/w

[!000]

(1000)

[```0] to [UOL–]

(0 to Retransmit Cal Volts High)

[Uol_] Retransmit Cal

Volts Low

Set the low voltage value for retransmit cal.

Active if in factory mode. Active if retransmit option is

installed.

5711 r/w

[1^00]

(16000)

[nnA_] to [2)00]

(Retransmit Cal mA Low to 20000)*

[nna–] Retransmit Cal

mA High

Set the high current value for retransmit cal.

Active if in factory mode. Active if retransmit option is

installed.

5710 r/w

[$000]

(4000)

[)000] to [nna–] [or

[(999] whichever is

smaller] (0 to Retransmit Cal mA High [or 9999])

[nna_] Retransmit Cal

mA Low

Selects the low current value for retransmit cal.

[C|rtr] Calibrate Retransmit Menu

[Fcty] Factory Page

This menu is used to calibrate the retransmit output. This menu is available if Retransmit is installed.

NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Features.

Page 55

Appendix Watlow Power Series ■ A.1

Appendix

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

Troubleshooting Alarms and Errors . . . .A.4

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

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

Modbus Registration Numbers . . . . . . . .A.8

Product Specification . . . . . . . . . . . . . . A.9

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

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

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

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

Warranty Information . . . . . . . . . back cover

Page 56

All Units

• If the controller has heater diagnostics installed, a shorted SCR will cause an error and shut down the remaining good SCRs. Return the unit to the factory for repair. If the controller does not have heater diagnostics installed, if output power (%) [`Out] reads [``)0] and there is power to the heater, the SCR is shorted; return the unit to the factory for repair.

• With input signal set for 0% power, check output power display; if it is not [``)0], check calibration. With input signal set for 100% power, check output power display; if it is not [10)0], check calibration.

• Return the unit to the factory for repair.

• Shorted SCR.

• Input out of calibration.

• Internal malfunction.

Full or Partial Uncontrollable Heat

• Insure that line power is connected and is on at the appropriate voltage.

• Return the unit to the factory for repair.

• Line input voltage low.

Partial Heat

• Check the load or load wire; connect if necessary.

• Check the fuses and replace any if necessary.

• See page 6.5 to set power control algorithm.

• Check the input wiring and ensure that it is connected properly. (See pages 3.2-3.3 for wiring.) Input can be monitored with [In``] parameter in the Display Loop. With keyboard control, test by increasing output by % and checking for heat. Be

careful to not over heat anything.

• Insure that line power is connected and is on at the appropriate voltage.

• Return the unit to the factory for repair.

• Heater or load wire is not connected.

• Blown fuse.

• [`set] > [algo] is set to [`OFF].

• Incorrect input wiring.

• Line not connected or off, or the voltage is too low. Controller will indicate [`alr] (Line Loss Alarm) [line].

• Internal malfunction (core PCB, open SCR, gate drive inoperative, core to power supply and LM connection, power supply and line monitor PCB not seated properly on SCR).

No Heat

• Record error and address the cause of the error.

• Record error and cycle controller power. If the problem persists, contact factory for assistance.

• Cycle controller power. If the problem persists, contact factory for assistance or return the unit to the factory for repair.

• Record alarm and address the cause of the alarm.

• Record alarm and cycle controller power. If the problem persists, contact the factory for assistance.

• System error.

• System error (no problem found).

• System error not displayed.

• Alarm.

• Alarm (no problem found).

Display Locked

• Insure that the unit is plugged in and the power is on.

• Check the display to make sure it is flush with plastic.

• Pull off the display and check the connection pins; repair or replace if necessary.

• Return the unit to the factory for repair.

• Controller power not present.

• Display not seated properly.

• Bent or broken pins.

• Faulty (malfunctioning) unit.

No LED Display

Corrective ActionProbable CauseIndication

A.2 ■ Watlow Power Series Appendix

Troubleshooting

Page 57

Appendix Watlow Power Series ■ A.3

All Units (continued)

Single Phase Units

Multizone Units

3 Phase, 2-Leg Units

3 Phase, 3-Leg Units

• For 3 phase, 3 grounded wye models only, reference connections must be connected to neutral. (See page

3.5 for wiring.)

• In the Setup Page, Setup Control Zone 1 menu, select the load type for Zone 1.

• Reference is not connected for 3 phase, 3leg grounded wye unit.

• Load Type Select [type] for 3 phase is set to unconfigured [none].

No Heat

Corrective ActionProbable CauseIndication

• If power is not routed through or connected to the internal bussbar, Ref. 1 or 3 (not both) must be connected to middle line. (See page 3.4 for wiring.)

• In the Setup Page, Setup Control Zone 1 menu, select the load type for Zone 1.

• Power not routed through the internal bussbar. Controller will indicate [`alr] (Line Loss Alarm) [line].

• Load Type Select [type] for 3 phase is set to unconfigured [none].

No Heat

Corrective ActionProbable CauseIndication

• When using the multizone feature, the 2 or 3 zones should be wired so that no two phases are 180° out of phase. See wiring diagram page 3.5, Figure 3.5C.

• Two phases are 180° out of phase of each other.

No current monitor on the display.

• Reference connections to other lines or neutral must be made appropriately for each zone. (See page 3.5 for wiring.)

• Reference not connected.No Heat

Corrective ActionProbable CauseIndication

• If power is not routed through or connected to the internal bussbar, Ref. 2 must be connected to another line or to neutral. (See page 3.4 for wiring.)

• Power not routed through the internal bussbar. Controller will indicate [`alr] (Line Loss Alarm) [line].

No Heat

Corrective ActionProbable CauseIndication

• Refer to page 2.1; insure the fuses have the correct current rating.

• Refer to page A.6 for guidelines on proper torquing of fuses.

• Refer to page 2.3 for enclosure guidelines and how to determine how much cooling is required.

• Replace heater.

• Improper fuse current rating.

• Fuses improperly torqued.

• Inadequate ventilation or cooling in the cabinet.

• Intermittent short in heater.

Frequent Nuisance Fuse Blowing

Corrective ActionProbable CauseIndication

Phase angle control ramps output power up, develops a [hCyL] error and shuts down

• Inductive load causing half cycle line loss errors [hCYL] . Reactance delay [rdLy] is set too low.

• Increase [rdLy] value until the half cycle line loss errors no longer occur..

Page 58

[`alr] Communications

[Cdog] Watchdog Alarm

Alarm will occur if no communications is detected for time specified in [`Out] Watchdog timeout. Not available unless Serial Communications is installed.

[`alr] Line Over Voltage

[``OU] Alarm

Alarm will occur if the line voltage is greater than the maximum rated voltage of the device. Caused by line voltage being over line voltage rating +10%.

Heater Open = 0x0001 Heater Tolerance = 0x0002 Over Temperature = 0x0004 Line Loss = 0x0008 Phase Balance = 0x0010 Load Balance = 0x0020 Frequency = 0x0040 Voltage Compensation = 0x0080 Over Voltage = 0x0100 Comms Watchdog = 0x0200

Any alarms that are active will be represented in binary. As an example, if a Comms Watchdog and a Phase Balance Alarm exists, Modbus register 180 will contain 0x0210. Comms Watchdog = 0000001000000000 Phase Balance = 0000000000010000

[`alr] Alarms

Troubleshooting Alarms and Errors

Alarm / Error

Condition For Alarm or Error To Occur

[`alr] Heater Open

[Open] Alarm

Alarm will occur when ≤ 2amps is detected (as measured by the Power Series) for > 20% requested power.

[`alr] Heater Tolerance

[`tol] Alarm

Alarm will occur when the load current detected is less than the value set in the Setup Page > Options Menu > [toL_] or is greater than the value set in [toL–]. This will accomplish both the overcurrent condition alarm and the heater failure low current alarm. This will only occur if requested power is greater than 20 percent.

[`alr] Heat Sink Over

[``Ot] Temperature

Alarm

Alarm will occur when the heat sink temperature is greater than the value set in the Setup Page > [`ALr] > [`ALÇ].

[`alr] Phase Balance

[pbal] Alarm

Alarm will occur when measured voltage of one phase of a 3 phase, 3-leg system is > 20% different from any other.

[`alr] Load Balance

[lbal] Alarm

Alarm will occur when the load current is determined to be out of balance. User specified in the Setup Page > [`ALr] > [ldif]. Default to 100%.

[`alr] Frequency Out of

[freq] Tolerance Alarm

Alarm will occur if frequency is not within 47 to 63 Hz.

[`alr] Line Compensation

[``UC] Alarm

Alarm will occur if the voltage compensation routines cannot compensate for input line voltage changes; occurs for requested power from 5% to 95%, [Urtb], [ph2t] control if

[``UC] = [``ON].

[`alr] Line Loss Alarm

[line]

Alarm will occur when the zero cross signal does not occur. Caused by loss of line polarity, zero cross or voltage level signal. Also caused by zero cross timing out of tolerance. This alarm will also occur when line voltage is < one-half baseline voltage.

A.4 I Watlow Power Series Appendix

Page 59

190 r/w

(0-4)*

Insure that the source of communications to the unit is communicating without long interruptions. Verify the integrity of the communications signals from the controlling device. Return to the factory for repair.

Yes No

No 189 r/w

(0-4)*

Lower line voltage or damage to the unit may occur. If line voltage is appropriate, check line voltage calibration.

See individual alarms below for recommendations.

180 r

See

individual

alarms

below.

See

individual

alarms

below.

Shutdown

Auto

Recovery

Corrective Action

Check wiring connections from load terminal to heater and heater return. Replace heater if necessary.

No Check wiring connections from load terminal to heater and heater

return. Verify adequate wire size. Replace heater if necessary.

Provide more cabinet ventilation or cooling. Check the fan; if faulty, return to the factory for repair. Check to see that the heat sink is clean. If necessary increase heat sink over temperature value if it is below factory safety shutdown temperature. Return to factory for SCR voltage drop and thermistor evaluation.

Yes if

[ph2t]

Yes

Insure that the line voltage is the same for each phase. If line voltages are the same, check line voltages calibrations.

Yes if

[ldif]

Yes

Address load balance on heaters. If loads are balanced, check calibration of current.

No Check the power supply line frequency. Power Series will not operate

reliably outside 47 to 63 Hz. specification.

Check for major line voltage fluctuations. If line voltage does not fluctuate, check line voltage calibration.

Yes Yes Check the line for high noise level and check wiring connections.

Possible line sense circuitry error, return to factory for repair. Check [fcty] -> [diag] for [l!a1], [l@a1], or [l#a1], to determine the type and location of the line loss.

[uUoL] can be caused by line voltage < one-half baseline voltage. [a|Cr] can be caused by noisy line supplies. [n|Cr] can be caused by a missing line. [`pOl] can be caused by a line half cycle or a missing line. [freq] can be caused by noisy line supplies. [HCYC] only active with heater diagnostics installed and indicates a half

cycle loss detected in the load; can be caused by SCR non-conduction.

Modbus Number

181 r/w

(0-4)*

182 r/w (2)

(0-4)*

183 r/w (4)

(0-4)*

184 r/w (8)

(0-4)*

185 r/w

(0-4)*

186 r/w

(0-4)*

187 r/w

(0-4)*

188 r/w

(0-4)*

Appendix Watlow Power Series I A.5

*Inactive - 0, Active - 1, Latched Active - 2, Latched Inactive - 3, Unlatched - 4

Page 60

A.6 I Watlow Power Series Appendix

Analog to digital failure error.

Condition For Alarm or Error To OccurAlarm / Error

[`err] System Errors

Heater Bakeout Overcurrent = 0x0001 SCR Short = 0x0002 System Configuration = 0x0004 AD Reference Fail = 0x0008 Checksum Error = 0x0010 Ram Error = 0x0020 Over Temperature Error = 0x0040 Half Cycle Loss = 0x0080 Phase Rotation = 0x0100

Any system-level errors that are active will be represented in binary. As an example, if the power source is losing half cycles and an over temperature condition exists, Modbus register 195 will contain 0x00C0. Over temperature Error = 0000000001000000 Half Cycle Loss = 0000000010000000

[`err] Heater Bakeout

[HbOC] Overcurrent Error

Error will occur when the maximum heater current during heater bakeout has been exceeded.

[`err] Shorted SCR Error

[shrt]

The shorted SCR error is detected by measuring current when the SCR is de-energized and comparing this reading to the current measured when the SCR is energized. A shorted SCR error is activated if the de-energized current reading is at least 10A and 25% or more of the energized current reading.

[`err] System Configur-

[shrt] ation Error

Invalid hardware configuration error.

[`err] Analog to Digital

[``Ad] Failure Error

Incorrect phasing. Error will occur on a three-phase system with a [3L`d] load or on a multizone (PC8 and PC9) operating on a three-phase power supply under phase angle control if the phasing is incorrect. Must be A,B,C phase rotation (CW).

[`err] Half Cycle Line

[HCyl] Loss Error

Error will occur if a load half cycle loss is detected during five consecutive zone restart attempts.

[`err] Phase Rotation

[p | ` rOt] Error

[`err] Over Temperature

[``Ot] Error

Error will occur when heat sink temperature is greater than factory shutdown temperature

[`sdÇ].

[`err] Ram Error

[ram]

Error will occur when RAM failure is detected.

[`err] Checksum Error

[`Che]

Invalid checksum in non-volatile memory error.

Checking and Replacing Fuses

Ensure that all high voltage power is off. Slide the fuse cover down. Using an ohmmeter, measure the dc resistance of the fuse to determine if it is open. (Typical dc resistance is less than 1 ohm.)

If fuse is open, replace it by removing the old fuse using a 1/2 inch socket and a #3 Phillips screwdriver. Be careful not to drop washers off the bolt or screw ends. If they have dropped into the case, shake them out gently.

The bolt will have 2 washers. The bottom machine screw will have 2 or 3 washers, depending on the size of the SCR in the unit. It is

important that the washers are replaced in the exact order in which they were removed. Take care installing the fuse so

that its orientation matches the image that is printed on the PC board.

With the new Cooper Bussman fuse in the unit, torque the bolt to 44 inch-pounds and the screw as follows: For models PXX-F20X-XXXX and PXX-N20X-XXXX torque to 26 in.-lbs. (2.93 Nm.). For models PXX-F25X-XXXX, PXX-N25X-XXXX, PXX-F30X-XXXX, PXX-F35XXXXX, and PXX-N30X-XXXX, torque to 44 in.-lbs. (4.95 Nm.). Close fuse cover. If unit was taken off the wall, observe all terminal torque specs when reconnecting wires. Unit should now be ready to resume operation. Reapply power to the controller and line/load terminals.

Fuse

Fuse Cover

Power Series Solid State Power Control

Figure A.6 — Fuse location.

Note: The fuse must be a Cooper Bussman to retain SCCR rating.

Page 61

Power Series Backup

There are three prompts which allow the user to manipulate the EEPROM contents: Backup Data Set, Default Data Set, and Restore Data Set. Each of these prompts have a choice of [`all], [`sys], [2n`1], [2n`2], or [2n`3].

There are two sets of data stored in the controller; the first is the User EEPROM and it is what is read on every power on. The second is the Backup EEPROM.

The Default Data Set prompt will update the chosen configuration parameters in the User EEPROM to values that are listed in the manual as default. It will update the chosen input and retransmit calibration parameters in the User EEPROM to the values that are stored in the Backup EEPROM by the factory.

The Backup Data Set prompt will update the chosen configuration parameters in the Backup EEPROM from the current values stored in the User EEPROM. It will NOT overwrite the calibration parameters.

The Restore Data Set prompt will update the chosen configuration parameters in the User EEPROM from the current values stored in the Backup EEPROM. It will NOT overwrite the calibration parameters.

Appendix Watlow Power Series I A.7

Cycle control power. If problem persists, return to factory for repair.

See individual errors below for recommendations.

Cycle control power. If problem persists, return to factory for repair.

195 r, (8)

Yes

Corrective ActionModbus Number

Auto

Recovery

Shutdown

195 r

Yes

195 r, (1)

It’s likely the heater is too wet for heater bakeout time selected. Increase heater bakeout time, cycle power to restart heater bakeout process.

Yes No 195 r, (2)

Check output with test instrument while Power (%) [`Out] is at [``)0]. If there is an output, return to the factory for a new SCR. If

there is no output, check current calibration.

Yes

195 r, (4)

Cycle control power. If problem persists, return to factory for repair.

Yes

195 r, (128)

Line voltage is losing half cycles or SCR is not gating properly. If load is inductive, increase [rdLY] until error no longer occurs. Cycle control power to clear error.

Yes No 195 r, (256)

Three phase power is connected with incorrect phasing. Swap any two incoming phases. Cycle control power to clear error message.

Yes

195 r, (64)

Provide more cabinet ventilation or cooling. Check the fan; if faulty, return to factory for repair. Check to see that the heat sink is clean. Cycle control power to clear error. Return to factory for SCR voltage drop and thermistor evaluation.

Yes

Cycle control power. If problem persists, return to factory for repair.

Yes

195 r, (16)

195 r, (32)

Figure A.7 — Power Series

Default

Values

Backup

EEPROM

Default Values

Default Prompt

Calibration Defaults

Default Prompt

Restore Prompt

Current Values (not calibration)

Backup Prompt

User

EEPROM

Page 62

A.8 ■ Watlow Power Series Appendix

1 Unit Serial Number High Digits 2 Unit Serial Number Low Digits 4 Software Version 5 Manufactured Date (yymm) 7 Hardware Version 30 Software Build Number 50 Unit Current Rating (Amps) 51 Unit Voltage Rating (Volts) 52 Number Zones Configured 53 Hardware Configured Type 54 Configuration Installed Options 55 Power Control Algorithm Select 56 Fixed Time Base (Sec) 57 Factory Safety Shutdown Temp 58 Load Type Select (Control Zone 1 only,

3 Phase only.) 80 Voltage Compensation (On/Off) 85 Comms Watchdog Select (On/Off) 86 Comms Watchdog Timeout (S) 87 Comms Watchdog Failure Output Power

Select 150 Analog (mA) Input 1 Signal 151 Analog (V) Input 1 Signal 152 Line Potential (Volts) rms Line 1 153 A/D Counts Input 1 154 Load Current (Amps) rms Line 1 155 Single Phase 0.1 kVA Zone 1 156 Load Power (kVA) Zone 1 157 Heater Bakeout Timeout Zone 1 159 Output 1 Power (%) 160 Analog (mA) Input 2 Signal 161 Analog (V) Input 2 Signal 162 Line Potential (Volts) rms Line 2 163 A/D Counts Input 2 164 Load Current (Amps) rms Line 2 165 0.1 kVA Zone 2 166 Load Power (kVA) Zone 2 167 Heater Bakeout Timeout Zone 2 169 Output 2 Power (%) 170 Analog (mA) Input 3 Signal 171 Analog (V) Input 3 Signal 172 Line Potential (Volts) rms Line 3 173 A/D Counts Input 3 174 Load Current (Amps) rms Line 3 175 0.1 kVA Zone 3 176 Load Power (kVA) Zone 3 177 Heater Bakeout Timeout Zone 3 179 Output 3 Power (%) 180 Active Alarms 181 Heater Open alarm 182 Heater Tolerance Alarm 183 Heat Sink Over Temperature Alarm 184 Line Loss Alarm 185 Phase Balance Alarm 186 Load Balance Alarm 187 Frequency Out of Tolerance Alarm 188 Line Compensation Alarm 189 Line Over Voltage Alarm 190 Communications Watchdog Alarm 195 Active Errors 198 Line Frequency (Hz) 850 Active Relay State 851 Global Alarm Configuration 860 Heater Open Alarm Config. 861 Heater Tolerance Alarm Config. 862 Over Temperature Alarm Config. 863 Line Loss Alarm Configuration 864 Phase Balance Alarm Config. 865 Load Balance Alarm Config. 866 Frequency Out of Tolerance Alarm

Configuration 867 Voltage Compensation Alarm Config. 868 Over Voltage Alarm Config. 869 Comms Watchdog Alarm Configuration 870 Retransmit Config. Select 871 Retransmit Type Select

872 Retransmit Phase Select 873 Retransmit Zone Select 876 Minimum Amps Retransmit 877 Maximum Amps Retransmit 878 Minimum kVA Retransmit 879 Maximum kVA Retransmit 880 Set Retransmit Output Low Voltage (Volts) 881 Set Retransmit Output High Voltage (Volts) 882 Set Retransmit Output Low Current (mA) 883 Set Retransmit Output High Current (mA) 950 Restore Data Set 951 Backup Data Set 952 Default Data Set 959 Enable NVOL Storage 990 Heat Sink Alarm Temp 991 Load Balance Percentage 1350 Global Lockout 1351 Control Setup Menus Lockout 1352 Options Setup Menus Lockout 1353 Alarms Setup Menu Lockout 1354 Comms Setup Menu Lockout 1355 Retransmit Setup Menu Lockout 1356 Analog Input Factory Menus Lockout 1357 Retransmit Cal Factory Menu Lockout 1358 System Data Factory Menu Lockout 1359 Diagnostics Factory Menu Lockout 1513 Display Test 1540 Line Loss Alarm, Most Recent Type, Line 1 1541 Line Loss Alarm, Previous Type, Line 1 1542 Line Loss Alarm, Least Recent Type, Line 1 1543 Line Loss Alarm, Most Recent Type, Line 2 1544 Line Loss Alarm, Previous Type, Line 2 1545 Line Loss Alarm, Least Recent Type, Line 2 1546 Line Loss Alarm, Most Recent Type, Line 3 1547 Line Loss Alarm, Previous Type, Line 3 1548 Line Loss Alarm, Least Recent Type, Line 3 1555 Retransmit Set Test Word 1560 to 1573 Read Selected A/D Counts 1580 Select Discrete Input 1581 Read Selected Input Value 1590 Heat Sink Temp (°C) 1591 Record High Heat Sink Temp 1700 Factory Mode Request 1799 Factory Password Entry 1960 Accum Hours (10K - 100M) 1961 Accum Hours (0 - 9999) 5011 Set Analog Input Low Current Scale (mA)

Zone 1

5012 Set Analog Input High Current Scale (mA)

Zone 1

5013 Set Analog Input Low Voltage Scale (Volts)

Zone 1

5014 Set Analog Input High Voltage Scale (Volts)

Zone 1 5019 Learn Input Request (Hi, Lo) Zone 1 5021 Set Analog Input Low Current Scale (mA)

Zone 2 5022 Set Analog Input High Current Scale (mA)

Zone 2 5023 Set Analog Input Low Voltage Scale (Volts)

Zone 2 5024 Set Analog Input High Voltage Scale (Volts)

Zone 2 5029 Learn Input Request (Hi, Lo) Zone 2 5031 Set Analog Input Low Current Scale (mA)

Zone 3 5032 Set Analog Input High Current Scale (mA)

Zone 3 5033 Set Analog Input Low Voltage Scale (Volts)

Zone 3 5034 Set Analog Input High Voltage Scale (Volts)

Zone 3 5039 Learn Input Request (Hi, Lo) Zone 3 5101 Input Signal Method Select (dig, mA, Volt)

Zone 1 5102 Numeric (%) Input 1 Signal

Modbus Register Numbers

Relative Parameter Numbers (For Absolute Numbers, add 40001 to the Relative Number.)

5103 Default Numeric Input Signal (%)

Zone 1

5104 Maximum Rate of Change (%/100msec)

Zone 1 5105 Soft Start Time (Sec) Zone 1 5106 Inductive Load Factor Request Zone 1 5107 Inductive Load Current Zone 1 5110 Heater Bakeout Select (On/Off) Zone 1 5111 Heater Bakeout Select Time Zone 1 5112 Current Limit Select (On/Off) Zone 1 5113 Current Limit Set Point (A) Zone 1 5114 Low Tolerance Set Point (A) Zone 1 5115 High Tolerance Set Point (A) Zone 1 5116 Heater Bakeout Overcurrent Trip Zone 1 5201 Input Signal Method Select (dig, mA,

Volt) Zone 2 5202 Numeric (%) Input 2 Signal 5203 Default Numeric Input Signal (%)

Zone 2 5204 Maximum Rate of Change (%/100msec)

Zone 2 5205 Soft Start Time (Sec) Zone 2 5206 Inductive Load Factor Request Zone 2 5207 Inductive Load Current Zone 2 5210 Heater Bakeout Select (On/Off) Zone 2 5211 Heater Bakeout Select Time Zone 2 5212 Current Limit Select (On/Off) Zone 2 5213 Current Limit Set Point (A) Zone 2 5214 Low Tolerance Set Point (A) Zone 2 5215 High Tolerance Set Point (A) Zone 2 5216 Heater Bakeout Overcurrent Trip Zone 2 5301 Input Signal Method Select (dig, mA,

Volt) Zone 3 5302 Numeric (%) Input 3 Signal 5303 Default Numeric Input Signal (%)

Zone 3 5304 Maximum Rate of Change (%/100msec)

Zone 3 5305 Soft Start Time (Sec) Zone 3 5306 Inductive Load Factor Request Zone 3 5307 Inductive Load Current Zone 3 5310 Heater Bakeout Select (On/Off) Zone 3 5311 Heater Bakeout Select Time Zone 3 5312 Current Limit Select (On/Off) Zone 3 5313 Current Limit Set Point (A) Zone 3 5314 Low Tolerance Set Point (A) Zone 3 5315 High Tolerance Set Point (A) Zone 3 5316 Heater Bakeout Overcurrent Trip Zone 3 5411 Adjust Low mA Cal Point Zone 1 5412 Adjust High mA Cal Point Zone 1 5413 Adjust Low V Cal Point Zone 1 5414 Adjust High V Cal Point Zone 1 5415 Calibrate Analog Input Request Zone 1 5421 Adjust Low mA Cal Point Zone 2 5422 Adjust High mA Cal Point Zone 2 5423 Adjust Low V Cal Point Zone 2 5424 Adjust High V Cal Point Zone 2 5425 Calibrate Analog Input Request Zone 2 5431 Adjust Low mA Cal Point Zone 3 5432 Adjust High mA Cal Point Zone 3 5433 Adjust Low V Cal Point Zone 3 5434 Adjust High V Cal Point Zone 3 5435 Calibrate Analog Input Request Zone 3 5591 Baseline Voltage Learn Request Zone 1 5592 Baseline Voltage Learn Request Zone 2 5593 Baseline Voltage Learn Request Zone 3 5594 Baseline Voltage Read/Adjust Zone 1 5595 Baseline Voltage Read/Adjust Zone 2 5596 Baseline Voltage Read/Adjust Zone 3 5700 Cal Retransmit Request 5710 Retransmit Cal mA Low 5711 Retransmit Cal mA High 5720 Retransmit Cal Volts Low 5721 Retransmit Cal Volts High

Page 63

Specifications (2214)

Power Bases

• Single phase, (2 SCRs)

• 3 phase, 2-leg control, (4 SCRs) Resistive load only, zero cross firing only

• 3 phase, 3-leg control, (6 SCRs)

• 3 phase, 3-leg control, (6 SCRs) for 4 wire wye loads

• Multizone, two and three single phase zones

Output Control Options

• Zero cross contactor, VÎ(dc) input

• Zero cross control, fixed time base

• Time base 1 or 4 seconds with digital programmer

• Zero cross control, variable time base

• Phase angle control and phase angle control with current limit (not for 3 phase, 2-leg models)

• Soft start factory default 4 seconds upon power-up, and

adjustable from 0.0 to 120 seconds

• Soft start upon input signal change, output rate of change

adjustable to limit max rate of change from 0.1 to 100% per 0.1 second. Factory default 10%.

• Current transformer included when required

• Line voltage compensated (variable time base and phase angle controllers only)

• Standby or non-operational mode

Output Voltage and Current Rating

• 24VÅ(ac) to 120VÅ(ac)(+10%, -15%)

• 200VÅ(ac) to 480VÅ(ac)(+10%, -15%)

• 200VÅ(ac) to 600VÅ(ac)(+10%, -15%)

• 65 through 250 amps per pole, model dependent; see Output Amperage Chart and Rating Curves

• Minimum load 1 amp rms ac

• Typical leakage current 5mA

• SCCR 200KA with fusing recommendations on page 3.6.

Alarms

• Single alarm relay

• Latching or non-latching

• Alarm silencing (inhibit) on power up for alarm

• Alarm indication LEDs, shorted SCR, open heater, fuse

• Electromechanical relay, form C contact, software configurable

• Minimum load current 10mA @ 5VÎ(dc)

• Rated resistive loads: 3 amps @ 250VÅ(ac) or 30VÎ(dc) max.,

inductive load rating 1.5 amps with a power factor ≥ 0.4 without contact suppression

Heater Bakeout

• For single phase (phase to neutral) and 3 phase 6 SCR models only (not for 3 phase, 2-leg models)

• Soft start with over current trip, runs until programmed bakeout time expires, then goes zero cross or phase angle firing. Factory default of 24 hours.

• Adjustable 0 - 9999 minutes with over current trip

• Internal current transformer included

Command Signal Input Analog

• DC contactor 3.5 to 10VÎ(dc), must turn off at 2.5VÎ(dc)

• Field selectable linear voltage and current of low and high points within 0-20mA and 0-10VÎ(dc)

• Manual control through front panel

• Factory default 0-20mA input

• Voltage input impedance 11kΩ nominal

• Current input impedance 100Ω nominal

Digital

• On-board digital programmer/display and optional serial communications

Retransmit

• Field selectable and scalable within 0-20mA , 800Ω maximum load or 0-10VÎ(dc), 1KΩ minimum load. The default is 4-20mA.

• Resolution:

mA ranges = 5μA nominal VÎ(dc) = ranges 2.5mV nominal

• Calibration accuracy:

mA ranges = ±20μA VÎ(dc) ranges = ±10mV

• Temperature Stability: 100ppm°C

Appendix Watlow Power Series I A.9

Digital Programmer/Display and Communications Capabilities

• Programming functions

• Adjust input and output control type, alarms and soft start. Heater bakeout and current limit prompts also.

• Monitoring functions

• Display input and output values along with actual output current

• Data retention of digital programmer/display upon power failure via nonvolatile memory

Serial Communications

• RS-232 for single drop control

• EIA-485 for single or multidrop control

• 32 units maximum can be connected. With additional 485

repeater hardware, up to 247 units may be connected

• Isolated

• Modbus™ RTU protocol

• 1200, 2400, 4800, 9600, 19200 baud rates

• Data format 8 data bits, no parity, one stop bit

Controller Power Supply

• Universal line voltage input range 100 to 240VÅ(ac) (+10%, -15%) @ 55VA maximum

• 50/60Hz ± 5% line frequency independent

• Controller line voltage for electronic power supply can be run on separate line voltage

Natural Convection and Fan Cooled Models

• Cabinet venting may be required

Power Dissipation (Watts)

• Approximately 1.25 watts/amp per controlled leg

Isolation

• Command signal to load and line/load to ground 2200VÅ(ac) minimum

• On-board semiconductor fuses provide SCR protection

Mounting

• Back panel mount on F35 models

• Other amperage ratings: Removable mounting plate

• Heat sink fins must be mounted in vertical orientation

High Current Terminals

• Touch safe

• 3/8 inch Allen head compression terminals will accept #6 AWG to 350 MCM wire. Allen wrench adapter (included) for 3/8 inch socket, or 10 mm, 6 point only.

• Torque to 180 in.-lbs. (20.3 Nm.)

• Wire strip to 30 mm (1-1/8 inch)

Controller Terminals

• Touch safe

• 2.5 mm (1/8 inch) blade screwdriver, accepts 12-22 AWG or 2 No. 22-18 AWG wires.

• Torque to 8 in.-lbs. (0.9 Nm.)

• Wire strip to 6 mm (0.24 inch)

• Requires 90C wire insulation rating on line and load terminals.

Operating Environment

• 50°C (122°F) base rating

• 0 to 60°C (32 to 140°F) fan cooled

• 0 to 65°C (32 to 149°F) natural convection cooled

• 0 to 90% RH, non-condensing

• Meets EN50178, Pollution degree 3

Storage Temperature

• -40 to 85°C (-40 to 185°F)

Dimensions

• Width x height x depth 191 mm x 354 mm x 200 mm on N20 through F30 models (7.5 in x 14.0 in x 7.9 in) 337 mm x 421 mm x 234.1 mm on F35 models (13.3 in x 16.6 in x 9.2 in)

Shipping Weight

• 10.3 kg. (23 lbs.) on N20 through F30 models

• 17.2 kg. (38 lbs.) on F35 models

Agency Approvals

• UL 508 and C-UL listed, file #E73741

• CE marked, see Declaration of Conformity on page A.14

Page 64

Ordering Information

(1528)

To order, complete the code number

to the right with the information below:

P C _ _ - _ _ _ _ - _ _ _ _

Power Series = Microprocessor-Based

Solid State Power Controller

Package Style

C=65 to 250 Amps

Phase

1=1-phase 2=3-phase, 2-leg control (4 SCRs) 3=3-phase, 3-leg control (6 SCRs) 4=3-phase, 4-wire, wye connected load 8 = 2 single-phase zones (specify 01 or 03 for Custom) 9=3 single-phase zones (specify 01 or 03 for Custom)

Heater Diagnostics (includes current limit)

0=None 1=Heater Diagnostics (Current Limiting and Heater Bakeout

are only available on single-phase and 3-phase, 3-leg Controllers)

Output Amperage Rating

(See Amperage Chart below; insert code number here.)

Output Voltage Rating

A=24 to 120V~ B=200 to 480V~ C=200 to 600V~

Communications

0=None 1=EIA/TIA 232/485 communications, isolated (field selectable)

Feedback/Retransmit

0=None 1=Load current feedback (0 to 10V or 0 to 20mA scalable retransmit output)

(Must have heater diagnostics selected.)

Custom

00 = None AA = No Watlow logo with agency approval marks AB - ZZ = Custom, consult factory for options

01 = Select for PC8 or PC9 using single-phase power supply, Watlow logo

03 = Select for PC8 or PC9 using multi-phase power supply, Watlow logo

IMPORTANT NOTES: Phase Angle:

Phase angle and phase angle with current limit are available on single phase, and 3 phase/3-leg models only. To get current limiting, you must also order heater diagnostics.

Heater Bakeout: Heater bakeout is available on single phase, and 3 phase/3-leg models with heater diagnostics.

Amperage Chart @ 50°C (122°F)

2 Single Phase Zones 3 Single Phase Zones

Single Phase 3 Phase, 2-Leg 3 Phase, 3-Leg

Code Amperage Code Amperage Code Amperage

Non N20 100A N20 80A N20 65A

Fan Cooled N25 140A N25 105A N25 85A

N30 165A N30 120A N30 105A

F20 125A F20 120A F20 90A

Fan Cooled F25 200A F25 160A F25 140A

F30 250A F30 185A F30 155A

F35 250A F35 225A

NOTE: User documentation may be available in French, German, Spanish, Italian, and Dutch, as well as English. Check Watlow’s website (www.watlow.com/) for availability.

NOTE: See semiconductor fuses and holders on pages 2.1 and 3.6.

A.10 I Appendix Watlow Power Series

Page 65

Appendix Watlow Power Series ■ A.11

Index

A to D Failure Error A.4 Accum Hours (0 - 9999) 6.18 Accum Hours (10K - 100M) 6.18 Active Alarms 6.1 Active Relay State 6.10 Adjust High mA Cal Point Zones 1-3

6.21 Adjust High V Cal Point Zones 1-3 6.21 Adjust Low mA Cal Point Zones 1-3

6.21 Adjust Low V Cal Point Zones 1-3 6.21 Alarms 5.7

active relay state 5.7 global 5.7 latched 5.7 latched and silenced 5.7 silencing 5.7

standard 5.7 Alarms Setup Menu Lockout 6.16 Alarms, troubleshooting A.4-A.5

communications watchdog alarm A.4

frequency out of tolerance alarm A.4

heat sink over temperature alarm A.4

heater open alarm A.4

heater tolerance alarm A.4

line compensation alarm A.4

line loss alarm A.4

line over voltage alarm A.4

load balance alarm A.4

phase balance alarm A.4

Ambient Temperature Rating 2.1 Analog (mA) Input 1 Signal 6.2, 6.3 Analog (mA) Input 2 Signal 6.2, 6.3 Analog (mA) Input 3 Signal 6.3 Analog (mA) Input Signal 6.1 Analog (V) Input 1 Signal 6.2, 6.3 Analog (V) Input 2 Signal 6.2, 6.3 Analog (V) Input 3 Signal 6.3 Analog (V) Input Signal 6.1, 6.4 Analog Input Factory Menus Lockout 6.16

Backup A.7 Backup Data Set 6.15 Baseline Voltage 5.6 Baseline Voltage Learn Req.

Zones 1-3

6.7

Baseline Voltage Read/Adj.

Zones 1-3

6.7

Cal Retransmit Request 6.22 Calibrate Analog Input Req.

Zones 1-3

6.21

Calibrate Analog Input Signal

Zones 1-3

Menus

6.21

Calibrate Retransmit

6.22 Comms Setup Menu Lockout 6.16 Comms Watchdog Alarm Config. 6.11 Communications 5.8 Communications Watchdog Alarm A.4 Configuration Installed Options 6.18

Control Configurations 1.2

3 phase, 2-leg 1.2 3 phase, 3-leg 1.2 3 phase, multizone 1.2

single phase 1.2 Control Setup Menus Lockout 6.16 Cooling 2.3 Current Limit Select (On/Off)

Zones 1-3

6.8

Current Limit Set Point (A)

Zones 1-3

6.9

Current Limiting 5.5

DC Contactor - Zero Cross 5.2 Default Data Set 6.15 Default Numeric Input Sig. (%)

Zones 1-3

6.6 Diagnostics Factory Menu Lockout 6.17 Diagnostics

Menu 6.19

-6.20 Dimensions 2.2 Display Loop Errors 6.1, A.4-A.7 Display Loop Menu 4.2, 4.3 Display Phase Selection 1-3 6.4 Display Test 6.20 Display Zone Selection 6.2, 6.3

Enable NVOL Storage 6.16 Enclosure Guidelines 2.3 Errors, troubleshooting

A.4-A.5 A to D failure error A.4 half cycle line loss error A.6 heater bakeout overcurrent error A.4 nonvolatile memory checksum error A.6 over temperature error A.6 phase rotation error A.6 RAM error A.6 shorted SCR error A.4 system configuration error A.4

Factory Mode 6.20 Factory Mode Request 6.20 Factory Page Menu 4.2, 4.4 Factory Page Parameters 6.14 - 6.22 Factory Password 6.20 Factory Password Entry 6.20 Factory Safety Shutdown Temp 6.18 Fan Cooled Output Rating Curves 2.5 Fast Start Guide 5.10 Fixed Time Base (Sec) 6.5 Fixed Time Base - Zero Cross 5.1 Frequency Out of Tol. Alarm Config. 6.11 Frequency Out of Tolerance Alarm A.4 Fuse Replacement A.6

Global Alarm Configuration 5.7, 6.10 Global Lockout 5.6, 6.16 Global/Menu Lockouts Menu

6.16-6.17

Half Cycle Line Loss Error A.6 Hardware Version 6.17 Harsh Environment 2.3 Heat Sink Alarm Temp 6.18 Heat Sink Over Temperature Alarm A.4 Heat Sink Over Temperature Alarm

Configuration 6.10

Heat Sink Over Temperature Alarm

Temperature 6.10 Heat Sink Temp (°C) 6.18 Heater Bakeout 5.4 Heater Bakeout Overcurrent Error A.4 Heater Bakeout Overcurrent Trip

Zones 1-3 6.8 Heater Bakeout Select (On/Off) Zones 1-3

6.8 Heater Bakeout Select Time Zones 1-3 6.8 Heater Bakeout Timeout 6.2 Heater Bakeout Timeout Zone 1 6.2, 6.3 Heater Bakeout Timeout Zone 2 6.2, 6.3 Heater Bakeout Timeout Zone 3 6.3 Heater Diagnostics Feature 1.2 Heater Open Alarm A.4 Heater Open Alarm Config. 6.10 Heater Tolerance Alarm A.4 Heater Tolerance Alarm Config. 6.10 Heater Tolerance Detection 5.4 High Tolerance Set Point (A) Zones 1-3

6.9

I J

Inductive Current 6.9 Inductive Load Factor Request 6.9 Input 5.6

signal selection 5.6

Input Signal Method Select (dig, mA, Volt)

Zones 1-3 6.6

Input Wiring 3.2-3.3

2 zone 3.3 3 zone 3.3 communications 3.2 control power and alarm 3.2 retransmit 3.2 single zone 3.3

Installation 2.1-2.6

Keys and Displays 4.1

Learn Input Learn Req. (Hi, Lo) Zones 1-3

6.7 Line Compensation Alarm A.4 Line Frequency (Hz) 6.1 Line Loss Alarms 6.19, A.4 Line Loss Alarm Configuration 6.10 Line Over Voltage Alarm A.4 Line Potential (Volts) rms Zone 1 6.3, 6.4 Line Potential (Volts) rms Zone 2 6.3, 6.4 Line Potential (Volts) rms Zone 3 6.3, 6.4 Line Potential (Volts) rms 6.2 Line Power Wiring 3.4 Line Voltage Compensation 6.6 Load Activity Indicator 6.1 Load Balance Alarm A.4 Load Balance Alarm Config. 6.11 Load Balance Percentage 6.11 Load Current (Amps) rms 6.2 Load Current (Amps) rms Zone 1

6.3, 6.4 Load Current (Amps) rms Zone 2 6.3, 6.4 Load Current (Amps) rms Zone 3 6.4 Load Power (kVA) 6.2, 6.4 Load Power (kVA) Zone 1 6.3, 6.4

Page 66

A.12 ■ Appendix Watlow Power Series

Load Power (kVA) Zone 2 6.3, 6.4 Load Power (kVA) Zone 3 6.4 Load Type Select (Control Zone 1

only, 3 phase only.) 6.7

Low Tolerance Set Point (A) Zone 1-3

6.9

Maintenance 2.4 Manufactured Date (yymm) 6.17 Maximum Amps Retransmit 6.13 Maximum kVA Retransmit 6.13 Maximum Rate of Change 5.3

adjustable on signal change 5.3

Maximum Rate of Change

(%/100msec) Zone 1-3 6.8 Menu Lock 5.6 Minimum Amps Retransmit 6.13 Minimum kVA Retransmit 6.13 Model Number A.10 Mounting 2.2-2.3

Natural Convection Output Rating

Curves 2.6 Navigation and Software 4.1-4.4 Nonvolatile Memory Checksum Error

A.4 Number Zones Configured 6.18 Numeric (%) Input 1 Signal 6.2, 6.3, 6.4 Numeric (%) Input 2 Signal 6.2, 6.3, 6.4 Numeric (%) Input 3 Signal 6.3, 6.4 Numeric (%) Input Signal 6.1

Options Setup Menus Lockout 6.16 Output 1 Power (%) 6.2, 6.3, 6.4 Output 2 Power (%) 6.2, 6.3 Output 3 Power (%) 6.2, 6.3 Output Power (%) 6.2, 6.4 Output Rating Curves 2.5-2.6 Output Wiring 3.4-3.5

3 phase, 2-leg, 4 SCR 3.4 3 phase, 3-leg,6 SCR, 4-wire wye 3.5 3 phase, 3-leg, SCR/diode hybrid 3.5 multizone 3.5

single phase 3.4 Over Temperature Error A.6 Over Voltage Alarm Config. 6.11

P Q

Phase Angle 5.2 Phase Balance Alarm A.4 Phase Balance Alarm Config. 6.11 Phase Rotation Error A.6 Power Control Algorithm Select 6.5 Prompt Index A.13

RAM Error A.6 Read Selected Analog to Digital

Counts 6.19 Read Selected Input Value 6.20 Record High Heat Sink Temp 6.18 Removing the Power Series 2.4 Restore Data Set 6.15 Retransmit 5.9 Retransmit Cal Factory Menu

Lockout 6.16 Retransmit Cal mA High 6.22 Retransmit Cal mA Low 6.22

Retransmit Cal Volts High 6.22 Retransmit Cal Volts Low 6.22 Retransmit Config. Select 6.12 Retransmit Phase Select 6.13 Retransmit Set Test Word 6.20 Retransmit Setup Menu Lockout 6.16 Retransmit Type Select 6.12 Retransmit Wiring 3.2 Retransmit Zone Select 6.13

Safety Information inside front cover Select Analog to Digital Channel 6.19 Select Discrete Input 6.20 Set Analog Input High Cur. (mA)

Zone 1-3 6.6

Set Analog Input High Volt. (Volts)

Zone 1-3 6.7

Set Analog Input Low Cur. (mA)

Zone 1-3 6.6

Set Analog Input Low Volt. (Volts)

Zone 1-3 6.6

Set Retransmit Output High Cur. (mA)

6.13

Set Retransmit Output High Volt. (Volts)

6.14 Set Retransmit Output Low Cur. (mA) 6.13 Set Retransmit Output Low Volt. (Volts) 6.14 Setup Alarms Configuration Menu 6.10-

6.11 Setup Comms Configuration Menu 6.12 Setup Control Algorithm 6.5 Setup Control Zone 1, 2, and 3 Menus

6.6-6.7 Setup Options Zone 1, 2, and 3 Menus

6.8-6.9 Setup Page Menu 4.2, 4.4 Setup Page Parameters 6.5 - 6.13 Setup Page Select 6.5 Setup Retransmit Configuration Menu

6.12-6.14 Shorted SCR Error A.4 Signal Selection 5.6 Soft Start 5.3

adjustable on power up 5.3 Soft Start Time (Sec) Zones 1-3 6.8 Software Build Number 6.17 Software Version 6.17 Specification A.9 System Configuration Error A.4 System Data Factory Menu Lockout 6.17 System Data Manipulation

6.15

Technical Assistance inside front cover Torque 3.1, 3.2, 3.4 Troubleshooting A.2-A.3 Troubleshooting Alarms and Errors

A.4-A.7

U V

Unit Address Select 6.12 Unit Baud Rate Select 6.12 Unit Current Rating (Amps) 6.18 Unit Information Menu 6.17-18 Unit Serial Number High Digits 6.17 Unit Serial Number Low Digits 6.17 Unit Voltage Rating (Volts) 6.17 Variable Time Base - Zero Cross 5.2 Voltage Compensation Alarm Config. 6.11

W X Y Z

Warnings and Cautions inside front

cover Warranty Information back cover Watchdog Failure Output Power Select

6.12 Watchdog Select (On/Off) 6.12 Watchdog Timeout 6.12 Wire Bending Radius 2.1 Wire Stripping 3.1, 3.2, 3.4 Wiring 3.1-3.6

input 3.2-3.3

output 3.4-3.5 Wiring Example 3.6 Your Comments inside front cover Zero Cross 5.1

Page 67

Appendix Watlow Power Series ■ A.13

Prompt Index

[``Ad] Select Analog to Digital Channel 6.19 [Addr] Unit Address Select 6.12 [ALÇ`] Heat Sink Alarm Temp 6.18 [aLÇ`] Heat Sink Over Temperature Alarm

Temperature 6.10

[a| lgc] Active Relay State 6.10 [ALgo] Power Control Algorithm Select 6.5 [Algo] Setup Control Algorithm Menu 6.5-

6.6

{`Alr} Alarms Setup Menu Lockout 6.16 [`ALr] Setup Alarms Configuration Menu 5.7,

6.10-6.11

[baud] Unit Baud Rate Select 6.12 [BAuP] Backup Data Set 6.15 [bl`U] Baseline Voltage Read/Adjust 6.7

[```Ç] Heat Sink Temperature (°C) 6.18 [CALA] Calibrate Analog Input Request 6.21 [CALr] Cal Retransmit Request 6.22 [`Cf9] Retransmit Configuration Select 6.12 {`CIn} Analog Input Factory Menus Lockout

6.16

[CIn1] [CIn2] [CIn3] Calibrate Analog Input

Signal Zone 1, 2, or 3 Menus 6.21-6.22

[CL`A] Current Limit Set Point (A) 5.5, 6.9 [`CLi] Current Limit Select (On/Off) 5.5, 6.8 {COM} Comms Setup Menu Lockout 6.16 [COM] Setup Comms Configuration Menu

6.12

[Cnts] Read Selected Analog to Digital

Counts 6.19

[cont] dc contactor 5.2 [C| rtr] Retransmit Cal Factory Menu Lockout

6.16

[Crtr] Calibrate Retransmit Menu 6.22 [`Ctr] Control Setup Menus Lockout 6.16 [Ctr1] [Ctr2] [Ctr3] Setup Control Zone 1,

2, and 3 Menus 6.6-6.8

[`Cur] Load Current (Amps) rms 6.2 [Cur1], [Cur2], [Cur3] Load Current (Amps)

rms 6.3, 6.4

[Cur–] Maximum Amps Retransmit 6.13 [Cur_] Minimum Amps Retransmit 6.13 [C| Wd] Comms Watchdog Alarm Configura-

tion 6.11

[dAtA] System Data Factory Menu Lockout

6.17

[dATA] System Data Manipulation Menu

6.15-6.16

[date] Manufactured Date (yymm) 6.17 [dFLt] Default Data Set 6.15 [dFlt] Default Numeric Input Signal (%) 6.6 [diAg] Diagnostics Factory Menu Lockout 6.17 [diag] Diagnostics Menu 6.19-6.20 [dIsp] Display Test 6.20

[fcty] Factory Mode Request 6.20 [Fcty] Factory Page 6.14 - 6.22 [Freq] Frequency Out of Tolerance Alarm

Configuration 6.11

[FrEq] Line Frequency (Hz) 6.1 [`FTB] Fixed Time Base 5.1 [`FTB] Fixed Time Base (Sec) 6.5

[glbl] Global Alarm Configuration 5.7, 6.10 {gLOC} Global Lockout 5.6, 6.16

[`HbC] Heater Bakeout Overcurrent Trip

6.8

[`Hbo] Heater Bakeout Select (On/Off) 5.4,

6.8

[`Hbt] Heater Bakeout Timeout 6.2 [Hbt1] [Hbt2] [Hbt3] Heater Bakeout Time-

out 6.2, 6.3

[HI`Ç] Record High Heat Sink Temp 6.18 [HrS–] Accum Hours (10K - 100M) 6.18 [HrS_] Accum Hours (0 - 9999) 6.18 [`HUa] Load Power (kVA) 6.2, 6.4 HUA–] Maximum kVA Retransmit 6.13 [HUA_] Minimum kVA Retransmit 6.13 [HUa1] [HUa2] [HUa3] Load Power (kVA) 6.3,

6.4

[HUer] Hardware Version 6.17

I J K

[ICur] Inductive Current 6.9 [``In] Analog (mA or V) or Numeric (%)

Input Signal 6.1, 6.4

[``In] Input Signal Method Select (dig, mA,

volt) 6.6

[``In] Select Discrete Input 6.20 [In`1], [In`2], [In`3] Analog (mA or V) or

Numeric (%) Input Signal 6.2, 6.3

[Indf] Inductive Load Factor Request 6.9 [Info] Unit Information Menu 6.17-6.18

[l!a1] Line Loss Alarm, Most Recent 6.19 [l!a2] [l@a2] [l#a2] Line Loss 6.19 [l!a3] [l@a3] [l#a3] Alarm Type 6.19 [l@a1] Line Loss Alarm, Previous 6.19 [l#a1] Line Loss Alarm, Least Recent 6.19 [Lbal] Load Balance Alarm Config. 6.11 [Ldif] Load Balance Percentage 6.11 [Line] Line Loss Alarm Config. 6.10 [LoAd] Load Activity Indicator 6.1 [`LOC] Global/Menu Lockouts Menu 6.16-6.17 [lrn| A] Learn Input Learn Request (Hi, Lo)

6.7

[lrn| U] Baseline Voltage Learn Request 6.7

M N

[Min] Heater Bakeout Select Time 5.4, 6.8 [nna–] Adjust High mA Cal Point 6.21 [nna_] Adjust Low mA Cal Point 6.21 [nna–] Retransmit Cal mA High 6.22 [nna_] Retransmit Cal mA Low 6.22 [nna–] Set Analog Input High Current (mA)

6.6

[nna_] Set Analog Input Low Current (mA)

6.6

[nUOL] Enable NVOL Storage 6.16

[Open] Heater Open Alarm Config. 6.10 [`OPt] Config. Installed Options 6.18 {`Opt} Options Setup Menus Lockout 6.16 [Opt1] [Opt2] [Opt3] Setup Options Zone 1,

2, and 3 Menus 6.8-6.9

[``OT] Heat Sink Over Temperature Alarm

Configuration 6.10

[``OU] Over Voltage Alarm Config. 6.11 [`Out] Output Power (%) 6.2, 6.4 [Out1], [Out2], [Out3] Output Power (%)

6.2, 6.3

P Q

[p| bAl] Phase Balance Alarm Config. 6.11 [Phas] Display Phase 6.4 [PhaS] Retransmit Phase Select 6.13 [Ph2t] Phase Angle 5.2 [`PW] Factory Password 6.20 [`PW] Factory Password Entry 6.20 [PWr] Watchdog Failure Output Power

Select (%) 6.12

[ratA] Unit Current Rating (Amps) 6.18 [rATE] Maximum Rate of Change (%/100msec)

6.8

[ratU] Unit Voltage Rating (Volts) 6.17 [rdLY] Reactance Delay 6.8 [reSt] Restore Data Set 6.15 [rEtr] Retransmit Set Test Word 6.20 {retr} Retransmit Setup Menu Lockout 6.16 [rEtr] Setup Retransmit Configuration Menu

6.12-6.14

[rt| C–] Set Retransmit Output High Current

(mA) 6.13

[rt| C_] Set Retransmit Output Low Current

(mA) 6.13

[rt| U–] Set Retransmit Output High Voltage

(Volts) 6.14

[rt| U_] Set Retransmit Output Low Voltage

(Volts) 6.14

[Sbld] Software Build Number 6.17 [sdÇ`] Factory Safety Shutdown Temp 6.18 [`seC] Watchdog Timeout (Sec) 6.12 [`Set] Setup Page Select 6.5-6.13 [`Sn–] Unit Serial Number High Digits 6.17 [`Sn_] Unit Serial Number Low Digits 6.17 [Soft] Soft Start 5.3 [Soft] Soft Start Time (Sec) 6.8 [SUEr] Software Version 6.17

[`tol] Heater Tolerance Alarm Configuration

6.10

[tol–] High Tolerance Set Point (A) 6.9 [tol_] Low Tolerance Set Point (A) 6.9 [type] Load Type Select 6.7 [type] Retransmit Type Select 6.12

U V W X Y Z

[`UAL] Read Selected Input Value 6.20 [``UC] Line Voltage Compensation 6.6 [``UC] Voltage Compensation Alarm

Configuration 6.11

[`UoL] Line Potential (Volts) rms 6.2 [Uol1], [Uol2], [Uol3] Line Potential (Volts)

rms 6.3, 6.4

[Uol–] Adjust High V Cal Point 6.21 [Uol_] Adjust Low V Cal Point 6.21 [Uol–] Retransmit Cal Volts High 6.22 [Uol_] Retransmit Cal Volts Low 6.22 [Uol–] Set Analog Input High Voltage (Volts)

6.7

[Uol_] Set Analog Input Low Voltage (Volts)

6.6

[Urtb] Variable Time Base 5.2 [`Wd] Watchdog Select (On/Off) 6.12 [2onC] Number Zones Configured 6.18 [2one] Retransmit Zone Select 6.13 [2one] Zone Display Selection 6.2, 6.3

Page 68

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A.14 I Appendix Watlow Power Series

Page 69

Watlow Power Series Appendix ■ A.15

Figure 1- Tank Filter, 1Ø 230V~ Abbildung 3. Tankfilter 1Ø; 230 V~ Figure 1 - Filtre cylindrique, 1Ø 230V~ Figura 1 - Filtro de tipo tanque, 1Ø 230V~

Figure 2- Tank Filter, 3Ø 440V~ Abbildung 3. Tankfilter 3Ø; 440 V~ Figure 2 - Filtre cylindrique, 3Ø 440V~ Figura 2 - Filtro de tipo tanque, 3Ø 440V~

Note 1: Protective earth (PE) connection required to minimize EMI. Hinweis 1: Schutzerdung (PE) erforderlich, um EMI auf ein Minimum zu halten. Remarque 1 : connexion de terre protectrice (PE) requise pour minimiser l’interférence EMI. Nota 1: Conexión a tierra de protección (PE) requerida para minimizar la interferencia electromagnética (EMI).

Breakers or Disconnect Unterbrecher oder Trenner Coupe-circuit Cortacircuitos o desconexión

See Note 1 Siehe Hinweis 1 Voir remarque 1 Ver Nota 1

Crydom

Power Series

341

Heater Last Elément chauffant

451

Calentador

Heater Last Elément chauffant Calentador

Required (EN61326) External EMI Filters for

An external EMI filter must be used in conjunction with the Power Series.

Power Series with

Watlow has verified that one type of filter will suppress electromagnetic interference (EMI) created by the Power Series power controller to within the EN61326 requirements:

1) A tank filter supplied by Crydom, installed across the power lines, suppresses EMI on the power lines. See Figures 1 and 2.

Wiring illustrations for the filters appear on the right. See Table 1 for the correct filter:

Description Filter # Watlow #

1Ø; 230V~ 1F25 14-0019 3Ø; 440V~ 3F20 14-0020

Table 1 - Power Series EMI Filters

Crydom

≥ 6A Loads

WARNING:

The tank filter specified may suppress desirable communications carried on power lines in the 150 to 250 kHz region. The filter may suppress carrier current such as that used for infant monitors and medical alert systems. Verify that suppressed carrier current or other desirable communications on power lines creates no hazard to people or property. Failure to observe this warning could result in damage to property, and injury or death for personnel.

WARNING:

All filter installation and wiring must be performed by qualified personnel, and conform to local and national electrical codes. Failure to observe this warning could result in damage to property, and injury or death for personnel.

Filtres externes EMI (EN61326) requis pour

les Power Series‚ à des charges de ≥ 6A

Un filtre externe EMI doit être utilisé conjointement avec le Power Series.

Watlow s’est assuré qu’un type de filtre supprimera l’interférence électromagnétique (EMI) créée par le bloc de puissance Power Series, afin de se conformer aux exigences de la norme EN61326 :

1) Un filtre cylindrique, fourni par Crydom, installé sur les lignes secteurs, supprime l’interférence EMI des lignes secteurs. Voir les figures 1 et 2.

Les illustrations de câblage des filtres figurent à droite. Voir le tableau 1 sur l’utilisation du filtre approprié :

Description N° de Filtre N° Watlow

1Ø; 230V~ 1F25 14-0019 3Ø; 440V~ 3F20 14-0020

Tableau 1 : Filtres EMI Power Series

Crydom

IMPORTANT :

Le filtre spécifié peut supprimer les communications désirables de lignes secteurs se situant entre 150 et 250 kHz. Le filtre peut supprimer le courant porteur, tel que celui utilisé sur les appareils de surveillance des nouveaux-nés et les systèmes d’alerte médicale. S’assurer que le courant porteur supprimé ou toute autre communication sur les lignes secteurs ne crée pas de danger pour les personnes ou les installations. La nonobservation de cet avertissement peut entraîner des dommages matériels, des blessures ou même la mort.

IMPORTANT :

Toute l’installation et tout le câblage du filtre doivent être réalisés par un personnel qualifié et être en conformité avec les réglementations électriques locales et nationales. La non-observation de cet avertissement peut entraîner des dommages matériels, des blessures ou même la mort.

Erforderliche Entstörfilter gemäß EN 61326 für

Ein externer EMI-Filter sollte mit dem Power Series.

Power Series mit Laststrom

Watlow hat nachgewiesen, daß eine Filterart die elektro-magnetischen Störungen, die durch den Leistungssteller der Bauart Power Series hervorgerufen werden, der Norm EN61326 entsprechend unterdrückt.

1) Ein Tankfilter von Crydom, welcher über die Stromleitungen installiert wird, unterdrückt die elektro-magnetischen Störungen auf den Stromleitungen. Siehe Abbildungen 1 und 2.

Schaltschemata für die Filter sind auf der rechten Seite zu sehen. Den richtige Filter finden Sie in Tabelle 1:

Beschreibung Filter Nummer Watlow Nummer

1Ø; 230V~ 1F25 14-0019 3Ø; 440V~ 3F20 14-0020

Tabelle 1. Power Series EMI-Filter

Crydom

≥ 6A.

WARNUNG:

Der angegebene Entstörfilter kann gewünschte Datenübertragungen im Bereich von 150 bis 250 kHz unterdrücken. Der Filter kann den Trägerstrom, der zum Beispiel bei Überwachungsgeräten für Kleinkinder oder medizinischen Warnsystemen verwendet wird, unterdrücken. Stellen Sie sicher, daß die Ünterdrückung des Trägerstroms oder anderer gewünschter Datenübertragungen auf den Stromleitungen keine Gefahr für Personen oder Sachen darstellt. Eine Nichtbeachtung dieser Sicherheitsmaßnahme kann Sachschäden, Verletzungen oder den Tod zur Folge haben

WARNUNG:

Alle Filterinstallationen und Verdrahtungen müssen von qualifiziertem Personal durchgeführt werden und den bestehenden elektrischen Vorschriften entsprechen. Das Nichtbeachten dieser Warnung kann zu Sachschäden, Verletzungen oder zum Tod des Personals führen.

Filtros de interferencia electromagnética (EMI) externos (EN61326)

requeridos para Power Series con cargas ≥ 6A

Se debe usar un filtro de EMI externo junto con el Power Series.

La empresa Watlow ha verificado que hay un tipo de filtro que suprimen la interferencia electromagnética (EMI) creada por el controlador de potencia Power Series, y la mantiene dentro de los límites establecidos por los requerimientos de la EN61326:

1) Al instalarse un filtro de tipo tanque provisto por Crydom en paralelo con las líneas de alimentación eléctrica se suprime la interferencia electromagnética (EMI) en ellas. Véanse las Figuras 1 y 2.

Las ilustraciones de los cableados para los filtros aparecen en la derecha. Véase la Tabla 1 para seleccionar el filtro correcto:

Descripción No. de filtro No. Watlow

1Ø; 230V~ 1F25 14-0019 3Ø; 440V~ 3F20 14-0020

Tabla 1 - Filtros de EMI de Power Series

Crydom

¡Advertencia!

El filtro de tipo tanque especificado puede suprimir ciertas comunicaciones deseables que se envían por las líneas de alimentación eléctrica en frecuencias que van desde 150 a 250 kHz. El filtro puede suprimir corrientes portadoras, como las que se usan para monitores para bebés y sistemas de alarma médica. Verifique que la corriente portadora u otras comunicaciones deseadas suprimidas en las líneas de alimentación eléctrica no presenten peligros para las personas o la propiedad. El no observar esta advertencia puede causar daños a la propiedad, y lesiones o muerte del personal.

¡Advertencia!

Todas las instalaciones y conexiones de filtros deben ser realizadas por personal calificado y en conformidad con los códigos locales y nacionales. El no observar esta advertencia puede causar daños a la propiedad, y lesiones o muerte del personal.

Page 70

A.16 ■ Appendix Watlow Power Series

Display Loop

(See the Power Series User’s Manual)

Setup Page

[algo] Control Algorithm

[ALgo] Power Control Algo Select _ _ _ _ _ _ _ [`FTB] Fixed Time Base _ _ _ _ _ _ _ _ _ _ _ _ [``UC] Line Voltage Comp _ _ _ _ _ _ _ _ _ _ _

[Ctr1] Control Zone 1

[``In] Input Signal Method Select _ _ _ _ _ _ [dFlt] Default Numeric Input Sig _ _ _ _ _ _ _ [nna_] Set Analog Input Lo Cur _ _ _ _ _ _ _ _ [nna–] Set Analog Input Hi Cur _ _ _ _ _ _ _ _ [Uol_] Set Analog Input Lo Volt _ _ _ _ _ _ _ _ [Uol–] Set Analog Input Hi Volt _ _ _ _ _ _ _ _ _ [lrn| a] Learn Input Learn Req _ _ _ _ _ _ _ _ _ [bl`U] Baseline Volt Read/Adj _ _ _ _ _ _ _ _ _ [lrn| U] Baseline Volt Learn Req _ _ _ _ _ _ _ _ [type] Load Type Select _ _ _ _ _ _ _ _ _ _ _ _ [rATE] Max Rate of Change _ _ _ _ _ _ _ _ _ _ [Soft] Soft Start Time _ _ _ _ _ _ _ _ _ _ _ _ _

[Opt1] Options Zone 1

[`Hbo] Heater Bakeout Select _ _ _ _ _ _ _ _ _ [Min] HBO Select Time _ _ _ _ _ _ _ _ _ _ _ _ [`HbC] HBO Current Trip _ _ _ _ _ _ _ _ _ _ _ [`CLi] Cur Limit Select _ _ _ _ _ _ _ _ _ _ _ _ _ [CL`A] Cur Limit Set Point _ _ _ _ _ _ _ _ _ _ _ [tol_] Lo Tol Set Point _ _ _ _ _ _ _ _ _ _ _ _ _ [tol–] Hi Tol Set Point _ _ _ _ _ _ _ _ _ _ _ _ _ [Indf] Induct Load Factor Req _ _ _ _ _ _ _ _ [ICur] Inductive Current _ _ _ _ _ _ _ _ _ _ _ _

[Ctr2] Control Zone 2

[``In] Input Signal Method Select _ _ _ _ _ _ [dFlt] Default Numeric Input Sig _ _ _ _ _ _ _ [nna_] Set Analog Input Lo Cur _ _ _ _ _ _ _ _ [nna–] Set Analog Input Hi Cur _ _ _ _ _ _ _ _ [Uol_] Set Analog Input Lo Volt _ _ _ _ _ _ _ _ [Uol–] Set Analog Input Hi Volt _ _ _ _ _ _ _ _ _ [lrn| a] Learn Input Learn Req _ _ _ _ _ _ _ _ _ [bl`U] Baseline Volt Read/Adj _ _ _ _ _ _ _ _ _ [lrn| U] Baseline Volt Learn Req _ _ _ _ _ _ _ _ [rATE] Max Rate of Change _ _ _ _ _ _ _ _ _ _ [Soft] Soft Start Time _ _ _ _ _ _ _ _ _ _ _ _ _

[Opt2] Options Zone 2

[Ctr3] Control Zone 3

[``In] Input Signal Method Select _ _ _ _ _ _ [dFlt] Default Numeric Input Sig _ _ _ _ _ _ _ [nna_] Set Analog Input Lo Cur _ _ _ _ _ _ _ _ [nna–] Set Analog Input Hi Cur _ _ _ _ _ _ _ _ [Uol_] Set Analog Input Lo Volt _ _ _ _ _ _ _ _ [Uol–] Set Analog Input Hi Volt _ _ _ _ _ _ _ _ _ [lrn| a] Learn Input Learn Req _ _ _ _ _ _ _ _ _ [bl`U] Baseline Volt Read/Adj _ _ _ _ _ _ _ _ _ [lrn| U] Baseline Volt Learn Req _ _ _ _ _ _ _ _ [rATE] Max Rate of Change _ _ _ _ _ _ _ _ _ _ [Soft] Soft Start Time _ _ _ _ _ _ _ _ _ _ _ _ _

[Opt3] Options Zone 3

[`Hbo] Heater Bakeout Select _ _ _ _ _ _ _ _ _ [Min] HBO Select Time _ _ _ _ _ _ _ _ _ _ _ _ [`HbC] HBO Current Trip _ _ _ _ _ _ _ _ _ _ _ [`CLi] Cur Limit Select _ _ _ _ _ _ _ _ _ _ _ _ [CL`A] Cur Limit Set Point _ _ _ _ _ _ _ _ _ _ [tol_] Lo Tol Set Point _ _ _ _ _ _ _ _ _ _ _ _ _ [tol–]] Hi Tol Set Point _ _ _ _ _ _ _ _ _ _ _ _ _ [Indf] Induct Load Factor Req _ _ _ _ _ _ _ _ _ [ICur] Inductive Current _ _ _ _ _ _ _ _ _ _ _ _

[`ALr] Alarms Configuration

[a| lgc] Active Relay State _ _ _ _ _ _ _ _ _ _ _ [glbl] Global Alarm _ _ _ _ _ _ _ _ _ _ _ _ _ _ [Open] Heater Open Alarm _ _ _ _ _ _ _ _ _ _ _ [`tol] Heater To Alarm _ _ _ _ _ _ _ _ _ _ _ _ [``OT] Heat Sink Over Temp Alarm _ _ _ _ _ [alÇ`] Heat Sink Over Temp Alarm Temp _ _ _ [Line] Line Loss Alarm _ _ _ _ _ _ _ _ _ _ _ _ [p| bAl] Phase Bal Alarm _ _ _ _ _ _ _ _ _ _ _ _ [Lbal] Load Bal Alarm _ _ _ _ _ _ _ _ _ _ _ _ [Ldif] Load Bal Percent _ _ _ _ _ _ _ _ _ _ _ _ [Freq] Freq Out of Tol Alarm _ _ _ _ _ _ _ _ _ [``UC] Volt Comp Alarm _ _ _ _ _ _ _ _ _ _ _ _ _ [``OU] Over Volt Alarm _ _ _ _ _ _ _ _ _ _ _ _ [C| wd] Comms Watchdog Alarm _ _ _ _ _ _ _

[COM] Comms Configurations

[Addr] Unit Address Select _ _ _ _ _ _ _ _ _ _ _ _ [baud] Unit Baud Rate Select _ _ _ _ _ _ _ _ _ [`Wd] Watchdog Select _ _ _ _ _ _ _ _ _ _ _ _ _ [`seC] Watchdog Timeout _ _ _ _ _ _ _ _ _ _ _ [PWr] Watchdog Fail Output Pwr Sel _ _ _ _

[rEtr] Retransmit Configuration

[`Cf9] Retrans Select _ _ _ _ _ _ _ _ _ _ _ _ _ [type] Retrans Type Select _ _ _ _ _ _ _ _ _ _ [PhaS] Retrans Phase Select _ _ _ _ _ _ _ _ _ _ [2one] Retrans Zone Select _ _ _ _ _ _ _ _ _ _ _ _ [Cur_] Min Amps Retrans _ _ _ _ _ _ _ _ _ _ _ _ [Cur–] Max Amps Retrans _ _ _ _ _ _ _ _ _ _ _ [HUA_] Min kVA Retrans _ _ _ _ _ _ _ _ _ _ _ _ HUA–] Max kVA Retrans _ _ _ _ _ _ _ _ _ _ _ _ [rt| C_] Set Retrans Output Lo Cur _ _ _ _ _ _ [rt| C–] Set Retrans Output Hi Cur _ _ _ _ _ _ [rt| U_] Set Retrans Output Lo Volt _ _ _ _ _ _ [rt| U–] Set Retrans Output Hi Volt _ _ _ _ _ _

Factory Page

[dATA] System Data Manipulation

[BAuP] Backup Data Set _ _ _ _ _ _ _ _ _ _ _ _ [dFLt] Default Data Set _ _ _ _ _ _ _ _ _ _ _ _ [rest] Restore Data Set _ _ _ _ _ _ _ _ _ _ _ _ [nUOL] Enable NVOL Storage _ _ _ _ _ _ _ _ _

[`Loc] Global/Menu Lockouts

{gLOC} Global Lockout _ _ _ _ _ _ _ _ _ _ _ _ _ [`Ctr] Control Setup Menus Lock _ _ _ _ _ _ _ {`Opt} Options Setup Menus Lock _ _ _ _ _ _ {`Alr} Alrms Setup Menu Lock _ _ _ _ _ _ _ _ {COM} Comms Setup Menu Lock _ _ _ _ _ _ _ {retr} Retrans Setup Menu Lock _ _ _ _ _ _ _ {`CIn} Analog Input Menu Lock _ _ _ _ _ _ _ _ [C| rtr] Retrans Menu Lock _ _ _ _ _ _ _ _ _ _ _ [dAtA] Sys Data Menu Lock _ _ _ _ _ _ _ _ _ _ [diAg] Diag Menu Lock _ _ _ _ _ _ _ _ _ _ _ _ _

[Info] Unit Information

[`Sn–] Unit Serial # Hi Digits _ _ _ _ _ _ _ _ _ [`Sn_] Unit Serial # Lo Digits _ _ _ _ _ _ _ _ _ [date] Mfg Date _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ [HUer] Hardware Version _ _ _ _ _ _ _ _ _ _ _ _ [SUEr] Software Version _ _ _ _ _ _ _ _ _ _ _ _ [Sbld] Software Build # _ _ _ _ _ _ _ _ _ _ _ _ [ratU] Unit Volt Rating _ _ _ _ _ _ _ _ _ _ _ _ _ [ratA] Unit Curt Rating _ _ _ _ _ _ _ _ _ _ _ _ [2onC] # Zones _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ [`OPt] Installed Options _ _ _ _ _ _ _ _ _ _ _ _ [```Ç] Heat Sink Temp _ _ _ _ _ _ _ _ _ _ _ _ _ [ALÇ`] Heat Sink Alarm Temp _ _ _ _ _ _ _ _ _ [sdÇ`] Safety Shutdown Temp _ _ _ _ _ _ _ _ _ [HIÇ`] Hi Heat Sink Temp _ _ _ _ _ _ _ _ _ _ _ [HrS–] Accum Hours _ _ _ _ _ _ _ _ _ _ _ _ _ _ [HrS_] Accum Hours _ _ _ _ _ _ _ _ _ _ _ _ _ _

[diag] Diagnostics

[``Ad] Select A/D Channel _ _ _ _ _ _ _ _ _ _ _ [Cnts] Read Selected A/D Counts _ _ _ _ _ _ _

Line Loss Alarms:

[l!a1] Most Recent _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ [l@a1] Line Loss _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ [l#a1] Alarm Type _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

[l!a2] Previous _ _ _ _ _ _ _ _ _ _ _ _ _ _ [l@a2] Line Loss _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ [l#a2] Alarm Type _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

[l!a3] Least Recent _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ [l@a3] Line Loss _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ [l#a3] Alarm Type _ _ _ _ _ _ _ _ _ _ _ _ _ _

[dIsp] Display Test _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ [``In] Select Discrete Input _ _ _ _ _ _ _ _ _ _ [`UAL] Read Selected Input Value _ _ _ _ _ _ _ [rEtr] Retrans Set Test Word _ _ _ _ _ _ _ _

The Factory Page also includes calibration parameters that are not necessary for everyday use of the controller. Calibration parameters and procedures are explained in the Power Series User’s manual.

Power Series Software Map

Enter your settings on a photocopy of this page.

Page 71

Page 72

■ Using the Manual

Watlow Power Series User’s Manual

Watlow Winona, 1241 Bundy Boulevard, P.O. Box 5580, Winona, Minnesota USA 55987-5580,

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

How to Reach Us

Quality and Mission Statement:

Watlow Winona will be the world’s best supplier of industrial temperature control products, services, and systems by exceeding our customers’, employees’, and shareholders’ expectations.

Contact

• Phone: +1 (507) 454-5300.

• Fax: +1 (507) 452-4507.

• For technical support, ask for an Applications Engineer.

• To place an order, ask for Customer Service.

• To discuss a custom option, ask for the Power Series Product Manager.

Warranty

The Watlow Power Series is warranted to be free of defects in material and workmanship for 36 months after delivery to the first purchaser for use, providing that the units have not been misapplied. Since Watlow has no control over their use, and sometimes misuse, we cannot guarantee against failure. Watlow's obligations hereunder, at Watlow's option, are limited to replacement, repair or refund of purchase price, and parts which upon examination prove to be defective within the warranty period specified. This warranty does not apply to damage resulting from transportation, alteration, misuse, or abuse.

Returns

• Call or fax Customer Service for a Return Material Authorization (RMA) number before returning a controller.

• Put the RMA number on the shipping label, along with a written description of the problem.

• A restocking charge of 20% of the net price is charged for all standard units returned to stock.

Your Authorized Watlow Distributor is:

TOTAL

CUSTOMER

SATISFACTION

3 Year Warranty