Watlow QPAC-01, QPAC-33, QPAC-32, Q32-481-030-BV2, QPAC User Manual

QPAC

User’s Manual

0600-0027-0001 Rev C

Modular SCR

Power Control

1241 Bundy Blvd., P.O. Box 5580, Winona, MN 55987-5580,

Tel: [phone], Fax: [phone] http://www.watow.com

Made in the U.S.A.

July 2003

$10.00

Use The Manual

Starting Out

First…

Starting Out

Install/Wire

Operation

Appendix

NOTE:
Details of a "Note"
appear here, in the
narrow box on the
outside of each page.

How to Use the Manual

This manual will make your job easier.

good way to become familiar with the QPAC. An overview:

Introduction, Chapter 1, Page 4.

Installation and Wiring, Chapter 2, Page 6.

Operation, Chapter 3, Page 25.

Troubleshooting, Page 28
Specifications
Warranty

Reading it and applying the information is a

Notes

A bold text "NOTE" marks a short message in the margin to alert you to an important
detail.

Safety Information

This user's manual also has boldface safety information notes to protect both you and
your equipment. Please be attentive to them. Here are explanations:

ç

CAUTION:
Details of a "Caution"
appear here, in the
narrow box on the
outside of each page.

∑

WARNING:
Details of a "Warning"
appear here, in the
narrow box on the
outside of each page.

ç

The CAUTION symbol (exclamation point) in the wide text column alerts you to a
"CAUTION," a safety or functional hazard which could affect your
performance. A full explanation is in the narrow column on the outside of the page.

equipment

or its

∑

The WARNING symbol (lightning bolt) in the wide text column alerts you to a "WARN­ING," a safety hazard which could affect you and the equipment. A full explanation is in

the narrow column on the outside of the page.

Your Feedback

We welcome comments or suggestions on this manual, please contact:
Technical Writer, Watlow Winona, 1241 Bundy Blvd, P.O. Box 5580, Winona, MN
55987-5580. Phone: [phone]; Fax: [phone]. The QPAC User's Manual is
copyrighted by Watlow Winona, Inc. © July 2003 with all rights reserved. (2392)

Technical Assistance

If you encounter a problem with your Watlow controller, review your configuration
information to verify that your selections are consistent with your application: inputs,
outputs, alarms, limits, etc. If the problem persists, you can get technical assistance
from your local Watlow representative (see back cover), by e-mailing your questions to
[e-mail] or by dialing [phone] between 7 a.m. and 5
p.m., Central Standard Time (CST). Ask for for an Applications Engineer. Please have
the following information available when calling:

• Complete model number • All configuration information

• User’s Manual • Serial Number

The model, part number, and serial numbers can be found on the label on the outside of
the case.

2

QPAC User's Manual

How to Use the Manual

Contents

How to Read the QPAC Model Number

The QPAC model number provides phase, supply voltage, amperage, and
control type information, in that order. For example:

Fan Cooled 30Amp (30A @ 480Vac, 3Ø)

480Vac Supply Burst Fired, Variable Time Base

3 Phase 2-Leg Open Heater, Shorted SCR Detector

Q32-481-030-BV2

Refer to the model number breakdown on page 31 for a complete listing.

Table of Contents

Page Item

2 How to Use the Manual
3 How to Read the QPAC Model Number
3 Contents

4 Starting Out With The QPAC - Chapter 1
4 General Description
5 Steps To Put Your Power Control To Work

6 How To Install And Wire The QPAC - Chapter 2
6 System Planning
6 Mounting The QPAC
7 Case Style A Mounting: QPAC-01, 30-50A
8 Case Style B Mounting: QPAC-01, 75-100A; QPAC-32, 30-100A
9, 10 Fuse Templates
11, 12 Case Style C Mounting: QPAC-01, 150-300A; QPAC-32, 150-300A;

QPAC-33, 150-300A
13 Case Style E Mounting: See Addendum for 400 to 1,000 Amp QPAC
13 Case Style F Mounting: QPAC-33, 30-100A
14, 15 Power and Load Wiring, QPAC-01
16, 17 Power and Load Wiring, QPAC-32
17 Power and Load Wiring, QPAC-33
18 Input Signal Wiring
18 CA Control Card
19 CD Control Card dc Input
19 CD Control Card Contact Closure Input
20 AF, AL, BF and BV Control Cards
20 AF, AL, BF and BV Potentiometer Input
20 AF, AL, BF and BV dc Input Connections
21 AF, AL, BF and BV Auto/Manual Input
21 Interlock
21 Soft Start
21, 22 AL Control Card Current Transformer Connections
23 DH Option, Open Heater or Shorted SCR Detector
24 QPAC System Wiring Example

25 How to Operate The QPAC - Chapter 3
25 Setup Adjustments
25 Phase Rotation Adjustments
25, 26 Bias And Gain Adjustments
27 Current Limit Adjustments

Appendix

28 Troubleshooting
29, 30 Specifications
31 Ordering Information
32 Accessories
33 Warranty, Returns
34 Index

Starting Out

QPAC User's ManualHow to Use the Manual

3

Starting Out

Starting Out

Figure 1 ­The QPAC-01
SCR Power Control

Chapter 1

Starting Out With The QPAC,

Modular SCR Power Control

4

QPAC User's Manual

General Description

The QPAC Power Controls are a family of solid state controls used for electric
heating applications. A solid state power control provides output power that is
proportional to the input command signal from a temperature control. This
proportional output power helps to produce a closely controlled heater tem­perature, which saves energy and prolongs heater life by holding heater
elements at a nearly constant temperature.

The QPAC has a modular construction with plug-in features for flexibility. The
three modules of the QPAC are the Power Base, Transformer, and Control

Getting Started, Chapter 1

Plug-in transformers (50/60 Hz.)

• 120Vac

• 208/240Vac

• 380Vac

• 415Vac

• 480Vac

• 575Vac, consult factory

Power Bases With Motherboards

• QPAC-01: 1Ø, 30 - 300A

• QPAC-32: 3Ø, 2 leg, 30 - 300A

• QPAC-33: 3Ø, 3 wire, 30 - 300A

Control Cards

• Solid state contactor, AC input, CA

• Solid state contactor, DC input, CD

• Burst firing (zero cross) fixed time base, BF

• Burst firing (zero cross) variable time base, BV

• Phase angle control, AF *

• Phase angle control with current limiting, AL *
* Note: For 1Ø and 3Ø, 3 wire controls

only; not for 3Ø, 2 leg controls.

QBF 08-5289

U2

1

U

TB1

Starting Out

Starting Out

Figure 2 ­QPAC Modularity
Overview

Card. See Figure 2. Power Bases are avaliable in 30 to 300A ratings with
UL508 and C-UL listing and 400-1,000 amps non-agency approved in single
phase, three phase-two leg and three phase-three wire configurations. A
Transformer plugged into the Power Base allows the QPAC to operate on any
voltage from 120 to 480Vac fan. 575Vac consult factory. The plug-in Control
Card sets the QPAC’s firing mode. Control Cards are available in solid state
contactor, burst firing (zero cross), or phase angle firing with a wide variety of
options. This modular approach, using a standard Power Base with plug-in
Transformers and Control Cards, allows power control users, distributors and
OEMs to maintain minimum inventories while still providing rapid service.

The different QPACs provide the types of power control needed for different
power sources and loads. The QPAC-01 is designed for all single phase
power sources and loads. The QPAC-32 is for three phase zero cross applica­tions such as resistance heating elements, balanced or unbalanced. The
QPAC-33 is best suited for balanced three phase, phase angle applications
requiring soft start or current limiting, or with inductive loads.

Steps To Put Your Power Control To Work

To put your QPAC to work, we suggest the following steps:

• Read the User's Manual.

• Plan your installation and wiring.

• Mount the QPAC.

• Wire your QPAC to the system.

• Start the system and, if applicable, adjust the bias and gain on the QPAC.

• That's all there is to it!

QPAC User's ManualGetting Started, Chapter 1

5

Mounting

Starting Out

Installation

Chapter 2

How to Install and Wire the QPAC

System Planning

This chapter tells you how to install the QPAC. All mounting and wiring infor­mation is right here. Watlow power controls are thoroughly tested before
leaving the factory, so the QPAC is ready to install when you receive it.

This chapter is divided into three sections which describe the three steps you
need to do to install the QPAC—mounting, power wiring and control card
wiring. The first section lists the mounting information for each of the three
types of QPACs, which, depending on amperage, use one of five case styles.
The second section describes the power and load wiring of the QPACs and
semiconductor fuses, if required. The last section describes the input signal
wiring to the QPAC Control Card.

Before you begin working, read through this chapter to gain an understanding
of the entire installation. Consider the installation carefully. Plan the power,
load, and input signal wiring before mounting the QPAC. Also refer to any
noise guidelines in the temperature control documentation before proceeding.

∑

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

Table 1 ­QPAC Wiring Data

Mounting the QPAC ∫

The physical size and mounting dimensions of the QPACs are different for
different current ratings. Find the "Case Style" photo on the next pages which
match your QPAC. The table and figure accompanying each case style will
give you corresponding physical dimensions and mounting footprint. The table
also indicates if the units are equipped with fans and externally-mounted fuses.
External fuse mounting templates also accompany the case style drawings. All
QPACs must be mounted vertically, power connections on top, for proper
cooling. Use the wiring data table below for wire sizes and bending radii.

Current Semi- Minimum Bending Radius Lugs QPAC Fuse

(Amps) conduc- Recom- Accept Model Mounting

tor Fuse mended inches (mm) # Wire Number

Rating Wire Size

(Amps)

30 2ea, 20 10 N/A 18 to 4 Q01 Onboard

2ea, 40 Q32 External

3ea, 40 Q33 External

50 2ea, 30 8 1.5 (38) 18 to 4 Q01 Onboard

2ea, 70 Q32 External

3ea, 70 Q33 External

75 100 4 2 (51) 8 to 0 All External

100 125 1 3 (76) 8 to 0 All External

150 200 3/0 4 (102) 4 to 3/0 All Onboard

200 250 250 MCM 4.5 (114) 6 to 350 MCM All Onboard

300 400 500 MCM 8 (203) 4 to 500 MCM All Onboard

QPAC User's Manual

6

Install and Wire, Chapter 2

Case Style A

Starting Out

Figure 3 ­QPAC Case Style A

Case Style A Dimensions
Model Amps Height (H) Width Depth Fans Fuses

in (mm) in (mm) in (mm)

QPAC-01 30 7 178 See 6.5 165 None Two, Onboard
QPAC-01 50 9 229 Below 6.5 165 None Two, Onboard

ç

5.00 (127mm)

H

H less

2.00 (50.8mm)

Table 2 ­QPAC Case Style A
Overall Dimensions

Figure 4 ­QPAC Case Style A
Mounting Footprint

ç

CAUTION:
Mount the QPAC
vertically (height
dimension vertical)
for proper cooling.
Failure to do so
could result in
power control
malfunction.

5.80 (147mm)

6.60 (168mm)

Mounting Clip

Hole 0.19 (5mm)

QPAC User's ManualInstall and Wire, Chapter 2

7

Case Style B

Starting Out

Figure 5 ­QPAC Case Style B

Table 3 ­QPAC Case Style B
Overall Dimensions

Figure 6 ­QPAC Case Style B
Mounting Footprint

ç

CAUTION:
Mount the QPAC
vertically (height
dimension vertical)
for proper cooling.
Failure to do so
could result in
power control
malfunction.

Case Style B Dimensions
Model Amps Height (H) Width Depth Fans Fuses Holder (max.)

in (mm) in (mm) in (mm) in (mm)

QPAC-32 30 10.5 267 5 127 8.5 208 One Two, External* 5.69 145
QPAC-01 75 10.5 267 5 127 8.5 208 One One, External** 4.90 124
QPAC-01 100 10.5 267 5 127 8.5 208 One One, External** 4.90 124
QPAC-32 50 10.5 267 5 127 8.5 165 One Two, External* 5.69 145
QPAC-32 75 14.5 368 5 127 8.5 229 One Two, External** 4.90 124
QPAC-32 100 14.5 368 5 127 8.5 208 One Two, External** 4.90 124
* Note: See external fuse mounting drawing, Figure 7, Page 9.
**Note: See external fuse mounting drawing, Figure 8, Page 10.

ç

1.00

(25mm)

H

QPAC User's Manual

8

0.19

(5mm)

4.50 (114mm)

5.07 (129mm)

Install and Wire, Chapter 2

Use the next two pages as templates for mounting your fuse holder kit. Choose
the size that matches your kit and carefully punch out the template along the
perforation.

5.69

(145mm)

5.07

(129mm)

3.63

(92mm)

Fuse Template

Starting Out

ç

CAUTION:
Spacing for multiple
fuses must conform
to the National
Electric Code (NEC)
and any other local
electrical codes.

B

A

B

(16mm)

A

0.63

0.44

(11mm

0.22

(6mm)

Drill & tap

hole "B"

for #10

fasteners

Stud Size 5/16"

Fuse Holder

(side view)

Figure 7 ­Fuse Holder Kit
Mounting Template
for:
QPAC-32, 30 & 50A
(2 Fuse Kits)
QPAC-33, 30 & 50A
(3 Fuse Kits)

QPAC User's ManualInstall and Wire, Chapter 2

9

Fuse Template

Starting Out

4.90

(124mm)

ç

CAUTION:
Spacing for multiple
fuses must conform
to the National
Electric Code (NEC)
and any other local
electrical codes.

Use this page as a template for mounting your fuse holder kit. Choose the size
that matches your kit and carefully punch out the template along the perforation.

4.28

(109mm)

2.84

(72mm)

Figure 8 ­Fuse Holder Kit
Mounting Template
for:
QPAC-01, 75 & 100A
(1 Fuse Kit)
QPAC-32, 75 & 100A
(2 Fuse Kits)
QPAC-33, 75 & 100A
(3 Fuse Kits)

A

B

0.63

(16mm)

0.44

(11mm

0.22

(6mm)

Drill & tap

hole "B"

for #10

fasteners

Stud Size 5/16"

Fuse Holder

(side view)

QPAC User's Manual

10

B

A

Install and Wire, Chapter 2

Case Style C

Starting Out

Figure 9 ­QPAC Case Style C

Case Style C Dimensions
Model Amps Height Width Depth Fans Fuses

in (mm) in (mm) in (mm)

QPAC-01 150 13 330 6.9 175 10.25 260 One On Heat Sink
QPAC-01 200 13 330 6.9 175 10.25 260 One On Heat Sink
QPAC-01 300 13 330 6.9 175 10.25 260 One On Heat Sink
QPAC-32 150 13 330 14.0 348 10.25 260 Two On Heat Sink
QPAC-32 200 13 330 14.0 348 10.25 260 Two On Heat Sink
QPAC-32 300 13 330 14.0 348 10.25 260 Two On Heat Sink
QPAC-33 150 13 330 21.0 533 10.25 260 Three On Heat Sink
QPAC-33 200 13 330 21.0 533 10.25 260 Three On Heat Sink
QPAC-33 300 13 330 21.0 533 10.25 260 Three On Heat Sink

Note: On 575 V~(ac) applications, the fuses are mounted external to the QPAC.

ç∫

7.00 (178mm)

3.50 (89mm)

U
P

MOUNT

3.63
(92mm)

13.00
(330mm)

11.75
(299mm)

Table 4 ­QPAC Case Style C
Overall Dimensions

ç

CAUTION:
Mount the QPAC
vertically (height
dimension vertical)
for proper cooling.
Failure to do so
could result in
power control
malfunction.

∫

WARNING:
Style C heatsinks
are electrically HOT.

FAN

0.38 (10mm)
2 PL

Figure 10 ­QPAC Case Style C,
QPAC-01, 150, 200,
300A Single Phase
Mounting Footprint

QPAC User's ManualInstall and Wire, Chapter 2

11