QPAC
User’s Guide
0600-0027-0001 Rev D
Modular SCR
Power Control
150 to 1,000A
1241 Bundy Blvd., P.O. Box 5580, Winona, MN 55987-5580,
Tel: +1 (507) 454-5300, Fax: +1 (507) 452-4507 http://www.watow.com
Made in the U.S.A.
August 2010
How to Use
this Manual
Notes
A bold text "NOTE" marks a short message in the margin to alert you to an
important detail.
NOTE:
Details of a "Note" appear here, on the left
side of each page.
ç
CAUTION:
Details of a "Caution"
appear here, on the left
side of each page.
WARNING:
Details of a "Warning"
appear here, on the left
side of each page.
Safety Information
This user's guide also has boldface safety information notes to protect both
you and your equipment. Please be attentive to them.
The CAUTION symbol ç (exclamation point) in the wide text column alerts
you to a "CAUTION," a safety or functional hazard which could affect your
equipment or its performance. A full explanation is in the narrow column on
the left side of the page.
The WARNING symbol
to a "WARNING," a safety hazard which could affect you and the equipment.
A full explanation is in the narrow column on the left side of the page.
(lightning bolt) in the wide text column alerts you
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: 507-454-5300; Fax: 507-452-4507. The QPAC User's
Guide is copyrighted by Watlow Winona, Inc. © August 2010 with all rights
reserved.
Technical Assistance
If you encounter a problem with your Watlow controller, review your conguration information to verify that your selections are consistent with your application: inputs, outputs, alarms, limits, etc. If the problem persists, you can get
technical assistance from your local Watlow representative (see back cover),
by e-mailing your questions to wintechsupport@watlow.com or by dialing +1
507-494-5656 between 7 a.m. and 5 p.m., Central Standard Time (CST). Ask
for for an Applications Engineer. Please have the following information available when calling:
• Complete model number • All conguration information
• User's Guide • Serial Number
The model, part number, and serial numbers can be found on the label on
the outside of the case.
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 150Amp (150A @ 480V
480VÅ (ac) Supply Burst Fired, Variable Time Base
3-Phase 2-Leg Open Heater, Shorted SCR Detector
Å (ac), 3-phase)
Q32-481-150-BV2
Refer to the model number breakdown in the Model Number Information chart in the
Appendix for a complete listing.
2 QPAC User's Guide
How to Use this Guide
Contents
Table of Contents
Chapter 1
Starting Out With The QPAC Power Control 4
General Description 4
Steps To Put Your Power Control To Work 5
Chapter 2
How to Install and Wire the QPAC 6
System Planning 6
Mounting the QPAC 6
Input Signal Wiring 14
CA Control Card — AC Input Contactor 14
CD Control Card — DC Input Contactor 14
Process Input - AF, AL, BF and BV Control Cards 15
AF, AL, BF and BV Potentiometer Input 15
CD Control Card — Contact Closure Input Contactor 15
AF, AL, BF and BV DC Input Connections 16
AF, AL, BF and BV Auto/Manual Input 16
Interlock 16
Soft Start 17
AL Control Card Current Transformer Connections 17
Single- and Three-Phase Current Transformer Wiring 19
DH Card Operation — Heater Diagnostics 19
Setup Procedure 19
QPAC system Wiring Example 20
Chapter 3
How to Operate the QPAC 21
Setup Adjustments 21
Phase Rotation Adjustment for Q32 and Q33 21
Bias And Gain Adjustments for AF, AL, BF, BV 21
Current Limit Adjustments 23
Appendix
QPAC Troubleshooting 24
Specic to QPAC-33 Diagnostics 25
QPAC Specications 26
Model Number Information 28
Accessories 29
Warranty 31
Returns 31
QPAC User's Guide 3How to Use this Manual
Starting Out
The Q32
SCR Power Control.
Chapter 1
Starting Out With The QPAC Power
Control
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 exibility.
The three modules of the QPAC are the Power Base, Transformer and
Control Card. See the QPAC Modularity Overview below. Power Bases are
available in 150 to 1,000A ratings with UL508 listed and cULus in singlephase, three-phase two-leg and three-phase three-leg congurations. A
Transformer plugged into the Power Base allows the QPAC to operate
4 QPAC User's Guide Chapter 1: Starting Out
Starting Out
Control Cards
• Solid-state contactor, ac input, CA
• Solid-state contactor, dc input, CD
• Burst ring (zero cross) xed time base, BF
• Burst ring (zero cross) variable time base, BV
• Phase angle control, AF *
• Phase angle control with current limiting, AL *
* Note: For 1Ø and 3Ø, 3-leg controls only; not for
3Ø, 3-leg controls.
Plug-in transformers (50/60 Hz.)
QPAC Modularity
Overview.
• 120VÅ (ac)
• 208/240VÅ (ac)
• 380VÅ (ac)
• 415VÅ (ac)
• 480VÅ (ac)
• 575VÅ (ac)
Power Bases With Motherboards
• QPAC-01: 1Ø, 150 to 1,000A
• QPAC-32: 3Ø, 2-leg, 150 to 1,000A
• QPAC-33: 3Ø, 3-leg, 150 to 1,000A
on any voltage from 120 to 575VÅ (ac). The plug-in Control Card sets the
QPAC’s ring mode. Control Cards are available in solid-state contactor, burst
ring (zero cross) or phase angle ring 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.
QPAC User's Guide 5Chapter 1: Starting Out
Steps To Put Your Power Control To Work
To put your QPAC to work, we suggest the following steps:
• Read the User's Guide.
• 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!
Mounting
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.
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 that describe the three steps to
installing the QPAC: mounting, power wiring and control card wiring. The rst
section lists the mounting information for each of the three types of QPACs,
which, depending on amperage, use one of two 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.
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 that
match your QPAC. The table and gure 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. 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.
6 QPAC User's Guide Chapter 2: Install & Wire
Mounting
7.9mm
(5/16 in - 18)
5.7mm
(0.225 in)
25.4mm
(1.00 in)
13.5mm
(0.53 in)
9.7mm
(0.38 in)
Template for Fuse Holders
with QPAC 150A, 575V.
3.8mm
(0.15 in)
88.9mm (3.50 in) minimum
106.4mm (4.19 in) maximum
19.1mm
(0.75 in)
Top View
31.8mm
(1.25 in)
Top View
40.4mm
(1.59 in)
Ensure nut and washer
are used below and above fuse
Right Side View
21.1mm
(0.83 in)
9.5mm
(0.375 in - 16)
Right Side View
Template for Fuse Holders
with QPAC 200 and 300A,
575V.
QPAC User's Guide 7Chapter 2: Install & Wire
152.0mm
(6.00 in)
103.17mm
(4.062 in)
9.7mm
(0.38 in) Typical
50.8mm
(2.00 in)
24.6mm
(0.97 in)
50.8mm
(2.00 in)
12.7mm
(0.50 in)
Ensure nut and washer
are used below and above fuse
12.7mm
(0.50 in)
25.4mm
(1.00 in)
7.1mm
(0.281 in)
330mm
(13.00 in)
178mm
(7.00 in)
10mm (0.38 in)
2 PL
FAN
U
P
MOUNT
89mm
(3.50 in)
299mm
(11.75 in)
92mm
(3.63 in)
Case Style C
Mounting
QPAC Case Style C.
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.
Model Amps Height Width Depth Fans Fuses
QPAC-01
QPAC-01
QPAC-01
QPAC-32
QPAC-32
QPAC-32
QPAC-33
QPAC-33
QPAC-33
Note: On 575 V~(ac) applications, the fuses are mounted external to the QPAC.
150
330mm (13 in)
200
330mm (13 in)
300
330mm (13 in)
150
330mm (13 in)
200
330mm (13 in)
300
330mm (13 in)
150
330mm (13 in)
200
330mm (13 in)
300
330mm (13 in)
175mm (6.9 in)
175mm (6.9 in)
175mm (6.9 in)
348mm (14.0 in)
348mm (14.0 in)
348mm (14.0 in)
533mm (21.0 in)
533mm (21.0 in)
533mm (21.0 in)
260mm (10.25 in)
260mm (10.25 in)
260mm (10.25 in)
260mm (10.25 in)
260mm (10.25 in)
260mm (10.25 in)
260mm (10.25 in)
260mm (10.25 in)
260mm (10.25 in)
1
on heat sink
1
on heat sink
1
on heat sink
2
on heat sink
2
on heat sink
2
on heat sink
3
on heat sink
3
on heat sink
3
on heat sink
∫
WARNING: Shock Hazard
Heatsinks are electrically
Live.
QPAC Case Style C,
QPAC-01, 150, 200, 300A
Single-Phase Mounting
Footprint.
ç
∫
8 QPAC User's Guide Chapter 2: Install & Wire
Case Style C
92mm
(3.63 in)
533mm
(21.00 in)
4 PL
P
U
MOUNT
FAN
FAN
16mm
(0.63 in)
298mm
(11.75 in)
33mm
(13.00 in)
178mm
(7.00 in)
10mm (0.375 in)
FAN
178mm
(7.00 in)
Mounting
178mm
(7.00 in)
356mm
(14.00 in)
89mm
(3.50 in)
16mm
(0.63 in)
QPAC Case
Style C, Q32,
150, 200, 300A,
3-Phase, 2-Leg
Mounting Footprint.
ç
CAUTION:
Mount the QPAC vertically (height dimension
vertical) for proper
cooling. Failure to do
so could result in power
control malfunction.
∫
WARNING: Shock Hazard
Heatsinks are electrically
Live.
FAN
U
P
MOUNT
FAN
10mm (0.375 in)
4 PL
298mm
(11.75 in)
33mm
(13.00 in)
∫
ç
∫
ç
QPAC Case Style C,
Q33, 150, 200, 300A,
3-Phase, 3-Leg Mounting
Footprint.
QPAC User's Guide 9Chapter 2: Install & Wire
Case Style E
Mounting
QPAC Case Style E.
QPAC Case Style E
Overall Dimensions.
Model Amps Height Width Depth Fans Fuses
QPAC-01
QPAC-01
QPAC-32
QPAC-32
QPAC-33
QPAC-33
400 to 600
800 to 1,000
400 to 600
800 to 1,000
400 to 600
800 to 1,000
685mm (27 in)
685mm (27 in)
685mm (27 in)
840mm (33 in)
840mm (33 in)
840mm (33 in)
430mm (17 in)
430mm (17 in)
535mm (21 in)
535mm (21 in)
685mm (27 in)
685mm (27 in)
300mm (11.7 in)
340mm (13.3 in)
300mm (11.7 in)
340mm (13.3 in)
300mm (11.7 in)
340mm (13.3 in)
111 on-board
1 on-board
222 on-board
2 on-board
333 on-board
3 on-board
ç
CAUTION:
Mount the QPAC vertically (height dimension
vertical) for proper
cooling. Failure to do
so could result in power
control malfunction.
∫
WARNING:Shock Hazard
Heatsinks are electrically
Live.
QPAC Case Style E
Mounting Footprint.
22mm
(0.88 in)
Width
L1 L2 L3
U
P
MOUNT
T1 T3
FAN
ELECTRONICS
PACKAGE
(Signal Connects Inside)
FAN
Height
GROUND
Fan Voltage Input
22mm
(0.88 in)
12.7mm (0.5 in)
10 QPAC User's Guide Chapter 2: Install & Wire
Wiring
QPAC Wiring Data.
Load
Current
(amps)
Semiconductor Fuse Rat-
ing (amps.)
150 200 3/0 102mm (4 in) 4 to 3/0 *onboard 240 in/lb 3/16 in
200 250 250 MCM 114 mm (4.5 in) 6 to 350 MCM *onboard 375 in/lb 3/8 in
300 400 500 MCM 203 mm (8 in) 4 to 500 MCM *onboard 375 in/lb 3/8 in
400 500 Dual 350 MCM 380mm (15 in) 2 to 600 MCM onboard 500 in/lb 1/2 in
500 600 Dual 350 MCM 380mm (15 in) 2 to 600 MCM onboard 500 in/lb 1/2 in
600 800 Dual 500 MCM 380mm (15 in) 2 to 600 MCM onboard 500 in/lb 1/2 in
800 1,000 Quad 250 MCM 380mm (15 in) 2 to 600 MCM onboard 375 in/lb 3/8 in
1,000 1,250 Quad 350 MCM 380mm (15 in) 2 to 600 MCM onboard 375 in/lb 3/8 in
Minimum
Recommended
Wire Size
Bending Radius Wire Sized that
Lugs Accept
Fuse
Mounting
Lug
Torque
*The fuses are external in Style C power controls over 575VÅ (ac).
Internal
Allen
Wrench
QPAC User's Guide 11Chapter 2: Install & Wire
Output Wiring
Circuit
Breakers
or
Disconnects
Contactors
If Required
On-board
factoryinstalled
semiconductor
fuses
Heater
Load
Fan 120VÅ (ac)/20W
L1
L2
L2
L1
L1
T1
L2
L3
T3
L3
1A
fuse
*2
*3
*4
G
∫
WARNING: Shock Hazard
Heatsinks are electrically
Live.
ç
CAUTION:
Check terminals for
tightness before applying power and then
recheck terminals after
one day of operation.
Loose connections can
damage the SCR.
NOTE:
A circuit breaker is required in addition to the
semiconductor fuses.
All semiconductor fuses
are mounted on board
the QPAC models 400 to
1,000. Where third-leg
fusing is selected, additional space is required.
L1
Circuit
Breakers
or
Disconnects
L2
G
QPAC-01 Output Wiring
for 150 to 1,000A Units.
*2
*1
On-board,
factory
installed
semicon-
ductor
fuses
Contactors
If Required
*4
1A Fuse
L1
L2
T1
Heater
Load
Fan 120VÅ (ac)/20W
L1
L2
*3
*1 NOTE: On 120VÅ
(ac) or 277V
neutral and cannot be
broken.
*2 NOTE: A contactor is
required if a high limit
control is used.
*3 NOTE: A separate
disconnect is required
for the fan(s) if used.
*4 NOTE: Use 14- to 16gauge wire for control
power only.
Å (ac), L2 is
NOTE:
QPAC models Q01, Q32
and Q33 up to 300A and
575V
Å (ac) are agency
listed. QPAC models Q01
and Q32 up to 1,000A
and 480V
agency listed. Q33 400
to 1,000A are not agency
listed.
Å (ac) are
∫
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 QPAC.
Failure to do so could
result in damage and/or
injury or death.
12 QPAC User's Guide Chapter 2: Install & Wire
QPAC-32 Output Wiring
for 150 to 1,000A Units.
Output Wiring
Circuit
Breakers
or
Disconnects
Contactors
If Required
3 factory-
supplied
semiconductor
fuses
Heater
Load
Fan 120VÅ (ac)/20W
L1
L2
L1
L2
L3
L1
T1 L2 T2 L3 T3
Hybrid
*1
*2
G
QPAC-33 Power and Load
Wiring for all Units.
∫
WARNING: Shock Hazard
Heatsinks are electrically
Live.
ç
CAUTION:
Check terminals for
tightness before applying power and then
recheck terminals after
one day of operation.
Loose connections can
damage the SCR.
NOTE:
A circuit breaker is required in addition to the
semiconductor fuses.
All semiconductor fuses
are mounted on-board
the QPAC models 400 to
1,000. Where third-leg
fusing is selected, additional space is required.
*1 NOTE: A contactor is
required if a high limit
control is used.
*2 NOTE: A separate
disconnect is required
for the fan(s) if used.
NOTE:
QPAC models Q01, Q32
and Q33 up to 300A and
575V
Å (ac) are agency
listed. QPAC models Q01
and Q32 up to 1,000A
and 480V
agency listed. Q33 400
to 1,000A are not agency
listed.
Å (ac) are
∫
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 QPAC.
Failure to do so could
result in damage and/or
injury or death.
QPAC User's Guide 13Chapter 2: Install & Wire
Input Wiring
ç
CAUTION:
Built-in noise reduction
circuitry on the CA card
requires an external load
resistor (1000Ω, 25W,
typical) across the input
when operating from a
triac source, to prevent
false triggering. Failure
to apply this resistor
could result in damage
to product and equipment or injury to personnel.
Input Signal Wiring
When wiring the input signal do not run any signal wires alongside or in the
same conduit with the ac power or load wires. Signal input should be provided by a shielded, two-conductor wire. Shield should be grounded at the
temperature control end only. Wrap the power control end with electrical
tape. The following gures show the wiring conguration for the input signal
to the QPAC Control Cards.
CA Control Card — AC Input Contactor
The 120VÅ (ac) input (24 volts input optional) signal lines for the CA (ac Input, Solid-State Contactor) Control Card are connected to pins 1 and 3 of the
input signal connector. A 120VÅ (ac) input signal turns the power control on.
The turn off voltage for the power control is 0VÅ (ac).
63.5mm (2.50 in)
CA Card Wiring SS
Contactor, 120V
Input.
CD Control Card, SolidState Contactor, 3 to
30V
Î (dc) Input.
Å (ac)
08-5285
38.1mm
(1.50 in)
120VÅ (ac)
Input
1
2
3
Motherboard Connector
CD Control Card — DC Input Contactor
For dc input, the input signal is wired into pin 2 (+) and pin 3 (-) of the input
signal connector. An input signal of 3 to 30VÎ (dc) turns the QPAC power
control on. 0 to 1VÎ (dc) turns the power control off.
51mm
(2.00 in)
08-5286
38mm
(1.50 in)
Pin 2 (+)
Pin 3 (-)
1
2 (+)
3 (-)
Motherboard Connector
14 QPAC User's Guide Chapter 2: Install & Wire
Input Wiring
Motherboard Connector
1KΩ Pot
56 to 57mm
(2.19 to 2.75 in)
CW-
CCW+
Pot
1
5 -
+
70 to 95mm
(2.75 to 3.75 in)
requires 0 to
5VÎ (dc) input
card setting
CD Control Card, SolidState Contactor, Contact
Closure Input.
CD Control Card — Contact Closure Input Contactor
For a contact closure input to the CD Control Card, the contact is wired to
pins 1 and 2 (+) of the input signal connector. A closed contactor input turns
the QPAC on and an open contact turns the QPAC off. The input impedance
is 10KΩ minimum.
51mm
(2.00 in)
1
2 (+)
3 (-)
08-5286
38mm
(1.50 in)
Motherboard Connector
Process Input - AF, AL, BF and BV Control Cards
Input Ranges
0 to 5V
Î (dc)
1 to 5V
Î (dc)
0 to 10V
0 to 20mA (dc)
4 to 20mA (dc)
1KΩ potentiometer
AF, AL, BF, BV
Potentiometer Input.
Î (dc)
The QPAC AF, AL, BF and BV Control Cards are dened as follows:
AF - Phase Angle Control
AL - Phase Angle Control with Current Limit
BF - Burst Firing (Zero Cross), Fixed Time Base
BV - Burst Firing (Zero Cross), Variable Time Base
All four of these cards can be wired for a manual potentiometer input or an
input from a temperature control. The following paragraphs give the connections for both congurations including an Auto/Manual conguration where
the input can be switched between manual and temperature control input.
AF, AL, BF and BV Potentiometer Input
For potentiometer input, wire a 1KΩ potentiometer to the “POT”, “+” and “-” connections of the control card. The wiper of the potentiometer should be connected to the “+” connection. The control card must be converted to a voltage input
by replacing a jumper. See "Bias and Gain Adjustments," Chapter 3.
QPAC User's Guide 15Chapter 2: Install & Wire
Input Wiring
Motherboard Connector
DC Input
+
-
56 to 57mm
(2.19 to 2.75 in)
Pot
1
5 -
+
70 to 95mm
(2.75 to 3.75 in)
AF, AL, BF and BV dc
Input.
AF, AL, BF and BV DC Input Connections
The temperature control output to the Control Cards is wired to the “+” and “-”
input terminals of the control card. These cards will accept a 0 to 12VÎ (dc),
or 0 to 25mA input signal. They are factory calibrated for 4 to 20mA. If using
a voltage or current range other than this, follow bias and gain adjustment instructions in Chapter 3. The control card can be converted to a voltage input
by removing a resistor or moving a jumper. Follow voltage input conversion
instructions in Chapter 3.
AF, AL, BF and BV Auto/Manual Input
AF, AL, BF and BV Auto/
Manual Input.
The AF, AL, BF and BV Control Cards can be wired to make it possible to
select an input from either a temperature control or a manual input potentiometer. A switch is used to select between the input from a 1KΩ potentiometer
or a 4 to 20mA temperature control. The control card must be converted to
voltage input by removing the appropriate resistor or replacing a jumper. See
"Voltage Input Conversions," Chapter 3. A 250Ω resistor must be placed in
parallel with the temperature control input, so that the temperature control
signal will be a 1 to 5VÎ (dc) input.
70 to 95mm
(2.75 to 3.75 in)
DC Input
1KΩ Pot
250Ω
CW
CCW
1
5 -
56 to 57mm
Pot
+
Motherboard Connector
(2.19 to 2.75 in)
Interlock
(Available on the AF, AL, BF and BV input card options.)
Opening the interlock connection between pins 1 and 2 of the input signal
connector will interrupt the input signal to the control card. Do not use the
interlock for limit or safety functions. Do not open the AF or AL Control Card
interlock, terminals 1 and 2, when "soft start" is desirable.
16 QPAC User's Guide Chapter 2: Install & Wire
Input Wiring
Soft Start
(Available on the Phase Angle input cards AF and AL only.)
Some heater elements change resistance with temperature. Certain types,
such as tungsten, change resistance very fast (tungsten increases resistance over 16 times from cold to hot). By slowly increasing the voltage to the
heater, the heater element is warmed to full resistance by the time full voltage is applied, thus reducing excessive surge currents. Soft start time on the
QPAC is about 6 seconds from power-up. If the QPAC is forced into emergency shut down (ESD) the QPAC will restart soft. Soft start is only available
on phase angle models.
AL Control Card Current Transformer Connections
Phase Angle Current Limit Option
The AL Control Card is wired to a transformer from the load line of the
QPAC. The transformer is wired into pins 1 and 2 of connector TB3 of the AL
card. The following table and gures show the transformer connections for
different load congurations and currents.
AL Control Card,Current
Transformer Selection.
Example of Current
Transformer (CT)
Connections One CT, 150
Amps and Above, 1Ø.
Current Transformer
(Part Number)
Not Used 5A : 20mA Interstage Transformer 16-0176
16-0008 150A : 5A Current Transformer 16-0176
16-0045 200A : 5A Current Transformer 16-0176
16-0073 300A : 5A Current Transformer 16-0176
0004-0286-0400 400A : 5A Current Transformer 16-0176
0004-0286-0500 500A : 5A Current Transformer 16-0176
0004-0286-0600 600A : 6A Current Transformer 16-0176
0004-0287-0800 800A : 5A Current Transformer 16-0176
0004-0288-1000 1,000A : 5A Current Transformer 16-0176
CT
Bk
Wh
Bk
5A
Bk
16-0176
Transformer
5A:20mA
Description Interstage
Load
Red
20mA
Red
1
5
T2T1
TB-3
AL Card
TB-2
Transformer
QPAC User's Guide 17Chapter 2: Install & Wire
Input Wiring
T1
CT
*1
Example of Current
Transformer Connection to
the AL (current limit) Card.
*1 NOTE: Both load
leads must pass through
the CTs in the same
direction.
Wh Bk
Bk Wh
T3
T2
CT
*1
5A
Bk
Bk
16-0176
Transformer
Red
20mA
Red
TB-3
AL Card
TB-2
18 QPAC User's Guide Chapter 2: Install & Wire
Input Wiring
Single- and Three-Phase
DH Option Open Heater or
Shorted SCR Detector.
*1 NOTE: Interstage
transformers (16-0176)
are required for all units
150A and above.
ç
CAUTION:
The shorted SCR detector feature will not work
with the manual control
input.
Single- and Three-Phase Current Transformer Wiring
120VÅ (ac)
N.C.
Momentary
Reset
Switch
To Alarm or Contactor
Open heater
when lit
1
J2
U4
56 mm
(2.20 in)
30 mm
(1.20 in)
Customer Supplied Relay
(Philips ECG PIY 1055 or equivalent)
Shorted SCR
when lit
Single-Phase
P1
DH
Interstage transformer
16-0176 for 150A
and above
J3J3
*1
J3
Load Wire
Three-Phase
Interstage transformer
16-0176 for 150A
and above
*1
T1
CT
T1
Load Wires
T3
08-5405
2
Motherboard
Connector
69 mm
(2.70 in)
DH Card Operation — Heater Diagnostics
The DH card uses a CT to monitor the load current and also detects when a
ring pulse is sent to the SCRs. The load current must be set by the pot on
the DH board (P1). If there is load current and no pulses to turn on the SCRs,
the "Shorted SCR" indicator light will be lit. The opto triac (U4) closes 3 or 4
seconds later and energizes an external alarm relay. If part of the load opens
(20% or more), and there are SCR pulses, the "Open Htr" indicator light is lit
and 3 to 4 seconds later, the alarm relay energizes.
This board only operates with the zero cross ring cards. For three-phase,
the CTs go in T1 and T3 lines.
Setup Procedure
1. With the DH card installed and the temperature control wired to the SCR
power control, set the temperature control output to "full on" (20mA for 4
to 20mA output, or 5V for 0 to 5V output).
2. Adjust P1 until the open heater light on the DH card is full on. No intermittent cycling.
3. Slowly adjust P1 until the open heater light just turns full off. No intermittent cycling.
If you are getting false alarms, adjustment is probably set too sensitive and
should be readjusted towards the off condition of the open heater light.
QPAC User's Guide 19Chapter 2: Install & Wire
A shorted SCR will energize the shorted SCR light.
System Wiring
QPAC System Wiring
Example, Overtemperature
Cutout.
QPAC system Wiring Example
The most common failure mode of an SCR is in the shorted state. If this happens, the temperature control can no longer control the SCR and a run-away
condition exists. An independent high limit control must be used that will
sense unsafe temperature and disengage the circuit breaker via undervoltage trip or a mechanical contactor as shown below.
L3
L2
L1
208/120V
N
RY1
2ASB
L3
L2
1A
1A
2ASB
F1
G1
+
H1
L4
K4
T1
S1
R1
T2
S2
R2
98
99
CC
CA
CB
B5
D6
D5
+
4
5
T1L1
Q32-202-300-BV0
Fan Assembly
T3
PM6C2FA - ALAJAAA
Controller
Thermocouple
Limit
Thermocouple
∫
WARNING:
Follow National
Electric Code safety
practices and other locally applicable codes to
avoid potential electric
shock when wiring this
unit to a power source,
and to electrical sensors
or peripheral devices.
Failure to do so could
result in serious injury or
death.
20 QPAC User's Guide Chapter 2: Install & Wire
Operation
Chapter 3
How to Operate the QPAC
Setup Adjustments
After the QPAC is installed and wired it may need a few minor adjustments.
The three-phase power controls require proper phase rotation. QPACs that
use the BF, BV, AF or AL Control Cards may need minor bias and gain calibrations. QPACs that use the AL Phase Angle Current Limit Control Card will
need current limit calibration. Refer to the following paragraphs.
Phase Rotation Adjustment for Q32 and Q33
Three-phase QPAC SCR controllers require the correct phase sequence of
the attached line voltage. To check for proper phase sequence of the QPAC32 power control, measure the voltage from T1 to T2, T2 to T3 and T3 to T1
with the power control turned full on. If any of the measurements of output
voltage are not equal (within 10%), exchange any two of the power input lines
(L1 and L2) to the QPAC.
To check for proper phase sequence of the QPAC-33 power control, apply
power to the QPAC and observe the indicator lights in the upper left hand corner of the Power Base motherboard. If the phase rotation indicator light is not
illuminated, exchange any two incoming power lines (L1 and L2).
Bias And Gain Adjustments for AF, AL, BF, BV
Bias and gain can be adjusted to interface with the output of most standard
temperature controls with a proportional output. Bias and gain is factory set for
an input control signal of 4 to 20mA but can be adjusted over a range of 0 to
12VÎ (dc) or 0 to 25mA to match the output of a specic temperature control.
Input impedance for 4 to 20mA input is 250Ω. The input impedance can be
changed to 5KΩ to accept a voltage by performing the following procedure for
each card.
Voltage Input Conversions
(See Accessories in the Appendix for card part numbers.)
AF: For 5KΩ input, move J2 jumper, located on the lower left of the AF
card next to the TB-2 connector, Terminal 5. See the AL (Rev. B) Control
Card gure in this chapter.
AL: For 5KΩ input, replace the J2 jumper to the 5V position, located on
the lower left of the AL card. See the AF (Rev. H) Control Card gure in
this chapter.
BF: For 5KΩ input, remove resistor R3, located on the lower left of the
QBF card next to the TB-2 connector, Terminal 5. See the BF (Rev. D)
Control Card gure in this chapter.
BV: For 5KΩ input, remove the external resistor attached to the J3 con-
nector plug. See the BV (Rev. B) Control Card gure in this chapter.
Adjustment Procedure
We recommended that bias and gain adjustment be performed using a dummy load. In some applications, a dummy load may be required if the controlled
load can not be turned full on. A dummy load can be easily made by connecting 150 watt lamps in series to match the operating voltage of the QPAC. Use
the following steps to make adjustments.
QPAC User's Guide 21Chapter 3: How to Operate
Bias and Gain
Gain
Pot
Bias
Pot
08-5288
1
5
TB-2
R39
R38
TB1
4 to 20mA
5V
move jumper for mA or volts dc input
Gain
Pot
Bias
Pot
08-5289
R17
1
5
TB-2
R3
TB1
cut resistor R3 for volts dc input
1. Connect a volt meter across the load or dummy load of the QPAC. Connect a volt meter across, or milliamp meter in series with, the input signal
from the temperature controller. NOTE: AL card should be calibrated with
a dummy load on the QPAC
2. Apply power to the system.
3. Set the output signal of the temperature controller to zero or its minimum
output. The QPAC input is factory calibrated for full off at 4.2mA. Adjust
the bias potentiometer slowly CCW (counterclockwise) until the QPAC
output just comes on. Then turn CW (clockwise) until the output is just full
off as observed on the output volt meter. See the following gures for the
location of the bias and gain potentiometer on the Control Cards.
NOTE: The QBV card does not include a bias adjustment. A bias and gain
adjustment card can be added to the QBV card in the eld. Order Watlow
part number 08-7210. Follow this calibration procedure when using the
bias and gain card.
4a. AF and BF: Adjust the output of the temperature controller to full on
(5Vdc, 20mA, etc.). Adjust the gain potentiometer CW until the QPAC output is just full on. The QPAC is factory calibrated to be full on at 19.8mA.
4b. BV and AL: Adjust the output of the temperature controller to full on
(5Vdc, 20mA, etc.). Adjust the gain potentiometer CCW until the QPAC
output is just full on. The QPAC is factory calibrated to be full on at
19.8mA.
5. When adjusting the bias and gain of the current limiting (AL) control card,
ensure that the current limiting is turned off. With the output of the temperature control full on, adjust the current limit potentiometer until the QPAC
output is full on.
6. Repeat steps 3 and 4 until the QPAC turns full on with a full on signal
from the temperature control, and full off with the minimum input signal
from the temperature control. Steps 3 and 4 may need to be repeated a
few times (an adjustment made on one of the potentiometers affects the
adjustment of the other potentiometer).
7. Remove power, disconnect the meters, and reconnect the controlled load
to the QPAC if required.
AF (Rev. H) Control Card.
BF (Rev. D) Control Card.
22 QPAC User's Guide Chapter 3: How to Operate
Bias and Gain
BV (Rev. B) Control Card.
Fixed Bias
Connector
Gain Pot
J3
BV Fixed Bias Connector
1
& Gain Adjustment
cut resistor for volts input
5
TB-1
J1
08-5342
AL (Rev. B) Control Card.
NOTE:
The AL Current Limit
must be disabled (pot
fully clockwise - CW)
before bias and gain can
be adjusted.
Bias Pot
Gain Pot
1
CT
2
1
5
TB-2
TB-1
Current Limit Pot
(AL Card only)
AL Bias, Gain, & Current Limit
Adjustments
move jumper for mA
or volts dc input
4 to 20mA
5V
08-5411
Motherboard Connector
Current Limit Adjustments
(AL Card only)
The AL Control Card is a phase angle control with the capability to limit the
maximum current to the load. A potentiometer on the AL adjusts the current
limit setting. See the AL (Rev. B) Control Card gure above. Use the following steps to adjust the current limit on initial setup. The purpose of the procedure is to bring the power to the load up slowly so that the maximum current
to the load is not exceeded before the current limit is adjusted.
QPAC User's Guide 23Chapter 3: How to Operate
Note: A short overcurrent through the load may occur, as the AL Card
circuitry detects the higher current, if the input signal from the temperature
control is abruptly increased.
1. Attach a clamp-on ammeter to the load line.
2. Adjust the AL card current limit potentiometer fully counterclockwise (for
minimum current ow).
3. Turn the temperature control on and adjust the input signal to the control
card for zero percent power.
4. Turn the power to the QPAC on.
5. Gradually increase the input signal.
6. Adjust the current limit potentiometer clockwise until current to the load
is measureable.
7. Gradually increase the input signal to 100% power, then adjust the current limit potentiometer to obtain the desired maximum current to the
load.
Troubleshoot
QPAC Troubleshooting
Guide.
Appendix
QPAC Troubleshooting
A technician can isolate a system problem by rst checking if the load is
good and the line voltage and temperature signals are present and correct. If
the above is true, then the power control may be the problem. The problem
may be with the QPAC's control card, transformer or power base. Use this
QPAC Troubleshooting Guide to assist with troubleshooting.
Symptom Probable Cause Corrective Action
No output Fuses blown Check and replace fuses
Incorrect input
wiring
Incorrect input
signal
Input signal reversed See “Input Wiring,” Chapter 2.
Input signal not
adjusted
Wrong or missing
control card
Transformer wiring Check transformer connections.
Missing load wiring See “Power and Load Wiring,” Chapter 2. The
Heatsink temperature
exceeded 86°C (187°F)
Transformer hot Incorrect trans-
Uncontrolled output
full on
Unbalanced output
(QPAC-32 and QPAC-33)
Clogged or nonoperational fan
former
Bad control card, or
bias and gain out of
adjustment
Bad transformer Unplug transformer wire and try again.
Bad power base If full on or half on output present with no
Incorrect phase
rotation
See “Input Wiring,” Chapter 2.
Check temperature control output.
See “Bias and Gain Adjustment," Chapter 3.
See “Input Wiring,” Chapter 2.
SCR(s) will not function without a load.
Check fan, power, and clean if necessary. Check
for shorted thermostat, replace fan or thermostat as necessary. #27-0005 thermostat is
normally open and closes on temperature rise.
Check product and transformer labels.
Unplug control card, try again. Readjust bias
and gain.
control card and no transformer, power base is
bad, replace it.
See "Phase Rotation Adjustment," Chapter 3.
The QPAC Service Manual is available at http://www.watlow.com/downloads/
en/manuals/qpacse_a.pdf .
24 QPAC User's Guide Appendix
Diagnostics
Specic to QPAC-33 Diagnostics
The QPAC-33 has four indicator lights for diagnostics. During normal operation, all four will be lit.
• Power on Yellow indicator light is on when power is applied to the control.
• Phase Loss Yellow indicator light is on when all three phases of line voltage are present. Indicator light will be off if one phase is low or lost.
• Phase Rotation Yellow indicator light is on when correct voltage phase exists, even when
load is not wired. Indicator light will be off when two phases are rotated,
and when one phase is missing.
• Phase Lock Loop Yellow indicator light is on when phase lock loop circuit is sychronized.
Indicator light can go off from noisy power line or if the phase synchronizing circuitry fails. Check power quality, then repair or replace power
base.
QPAC User's Guide 25Appendix
Specications
QPAC Specications
Operation
• Modular control base with plug-in card and transformer
• Plug-in control cards
Solid-state contactor, Å (ac) or Î (dc) input
Burst re control, xed or variable time base
Phase angle re control
Phase angle control with soft start and current limiting
• Plug-in transformers (50/60Hz)
• 120, 208, 240, 277, 380, 415, 480, 575VÅ(ac) operation
Power bases
• Single-phase (Q01), 1 pair of SCRs
• Three-phase (Q32), 2-leg control, 2 pair SCRs. Resistive load only, burst
ring only.
• Three-phase (Q33), 3 pair hybrid SCRs/diodes. Recommended for phase
angle only with balanced load.
• 120V~ (ac) through 575VÅ (ac)
• 150 through 1,000 amps per switched leg.
Agency Approvals
• UL 508 listed and cULus up to 1,000 amps on Q01 and Q32 models, File
#E73741.
• UL 508 listed and cULus up to 300 amps only on Q33 models, File
E73741.
SCCR - Short Circuit Rating
• UL witness tested to 200,000A available fault current Q01, Q32 150-1000A
to 480VÅ (ac) Q33 units and over 480VÅ (ac) units not tested
Control Card Inputs
CA Solid-state contactor, ac input
• 120VÅ (ac) @ 30mA minimum
• Å(ac) signal input sources (i.e., triacs or mechanical relay outputs with
noise suppression) require customer supplied resistors across the power
controller Å(ac) command signal input terminals to prevent false ring.
24VÅ (ac) input, 200Ω/10 watts typical;
120VÅ (ac) input, 1kΩ/25 watts typical;
240VÅ (ac) input, two 1kΩ/25 watts in series typical
CD Solid-state contactor, dc input
• On, 4 to 10VÎ (dc) @ 0.5mA; off, 0.5VÎ (dc)
• Built-in noise reduction network
BF Burst ring control xed time base
• Process input factory set @ 4 to 20mAÎ (dc)
• Input impedance 250Ω (clip resistor for 5kΩ voltage input), or manual control input
• Time base 4 seconds (clip resistor for 1 sec)
BV Burst ring control, variable time base
• Process input factory set @ 4 to 20mAÎ (dc)
• Input impedance 250Ω (clip resistor for 5kΩ voltage input), or manual control input
AF Phase angle control
• Process input factory set @ 4 to 20mAÎ (dc)
• Input impedance 250Ω (move jumper for 5kΩ voltage input), or manual
control input
• Soft start approximately 6 seconds upon power-up, 1 second upon set
point change
AL Phase angle control with current limit
• Process input factory set @ 4 to 20mAÎ (dc)
26 QPAC User's Guide Appendix
Specications
• Input impedance 250Ω (move jumper for 5kΩ voltage input), or manual
control input
• Soft start approximately 6 seconds upon power-up, 1 second upon set
point change
• Current and interstage transformers included.
• Available on Q01 and Q33 models only.
Line Voltage/Power
• 50/60 Hz Å (ac) line frequency, Q32 and Q33 calibration line frequency
dependent
• Voltage: ±10%, 120, 208, 240, 277, 380, 415, 480, 575VÅ (ac)
Line Voltage Compensation
• 10%Δ in line, 2%Δ in load in the 30% to 70% power region (AF, AL and BV)
Power Dissipation (Watts)
• 1.5 watts/amps per controlled leg
Isolation
• Command signal to load 1250VÅ (ac) minimum
Linearity
• 2%, 30% to 70% power region (All units except CA & CD)
Off-State Leakage Current
• 20mA @ 480VÅ (ac)
SCR Protection
• Semiconductor fuses provided
• dv/dt 200V/µsec minimum
• MOV and RC snubber network standard (MOV comes only on Q33
[3-phase, 3-leg])
• (Q32) third leg fuse kit may be used, but not required, with 3-phase, 2-leg
models
Mounting
• Heat sink ns must be mounted in vertical orientation
Operating Environment
• 0 to 50°C (32 to 122°F)
• 0 to 90% RH, non-condensing
Storage Temperature
• -40 to 85°C (-40 to 185°F)
Options
• Manual Control Kit for process input cards (1kΩ potentiometer) #08-5362
• 240VÅ (ac) cooling fans in place of 120VÅ (ac) cooling fans
Weight
QPAC User's Guide 27Appendix
Phase
Amps 1ø
Q01
150 6.8 kg (15 lbs) 16.3 kg (36 lbs) 22.7 kg (50 lbs)
200 6.8 kg (15 lbs) 16.3 kg (36 lbs) 22.7 kg (50 lbs)
300 6.8 kg (15 lbs) 16.3 kg (36 lbs) 22.7 kg (50 lbs)
400 to 600 19.9 kg (44 lbs) 38.5 kg (85 lbs) 45.4 kg (100 lbs)
800 to 1,000 22.2 kg (49 lbs) 54.4 kg (120 lbs) 61.2 kgs (135 lbs)
3ø,2 leg
Q32
3ø,3 wire
Q33
Model Number
Model Number Information
To order, complete the code number
to the right with the information below:
QPAC = Modular power controller; phase angle, burst,
or solid-state contactor with fuse(s) and holder(s) included.
Phase
01 = Single phase
32 = 3-phase, 2-leg
33 = 3-phase, 3-leg
Operating and Output Voltage
12 = 120V~ (ac)
20 = 208V~ (ac)
24 = 240V~ (ac)
27 = 277V~ (ac)
38 = 380V~ (ac)
41 = 415V~ (ac)
48 = 480V~ (ac)
57 = 575V~ (ac)
Cooling Fan Voltage
Customer to supply wiring and hook-up.
1 = 120V~ (ac); required on all 3-phase models
2 = 240V~ (ac); required on all 3-phase models
Output Current (Amps)
150 = 150 amps
200 = 200 amps
300 = 300 amps
400 = 400 amps
500 = 500 amps
600 = 600 amps
800 = 800 amps
01K = 1000 amps
Input Control Card
CA = Solid-state Å (ac) input (08-5285) contactor
CD = Solid-state Î (dc) input (08-5286) contactor
BF = Burst fired, fixed time base (08-5289) 4 to 20mA
BV = Burst fired, variable time base (08-5342) 4 to 20mA
AF = Phase angle fired (08-5288) 4 to 20mA, not available on Q32.
AL = Phase angle fired w/current limit (08-5411) 4 to 20mA, not available on Q32. Includes one
current transformer. Add a second CT for 3-phase, 3-leg models.
AL models 150 amps and above require one interstage transformer.
Open Heater/Shorted SCR Detector
0 = None
1 = Single-phase operation
2 = Three-phase operation
3
4,5
(burst fire, zero cross models only)
Q
28 QPAC User's Guide Appendix
Accessories
Accessories
Watlow Part Number Model Description
08-5362 Manual Control Kit
16-0176 5A : 20mA Interstage Transformer
0004-0286-0400 400 : 5A Current Transformer
0004-0286-0500 500 : 5A Current Transformer
0004-0286-0600 600 : 5A Current Transformer
0004-0287-0800 800 : 5A Current Transformer
0004-0288-1000 1000 : 5A Current Transformer
16-0008 150A : 5A Current Transformer
16-0045 200A : 5A Current Transformer
16-0073 300A : 5A Current Transformer
Watlow Part
Number
17-7053 QPAC 150A up to 480V Fuse, Semiconductor 200A @ 500V Blade, Bussmann FWH-200B
17-7015 QPAC 150A, 575V only Fuse, Semiconductor 200A @ 700V Blade, Bussmann FWP-200A
17-7054 QPAC 200A up to 480V Fuse, Semiconductor 250A @ 500V Blade, Bussmann FWH-250A
17-7016 QPAC 200A, 575V only Fuse, Semiconductor 250A @ 700V Blade, Bussmann FWP-250A
17-7056 QPAC 300A up to 480V Fuse, Semiconductor 400A @ 500V Blade, Bussmann FWH-400A
17-7019 QPAC 300A, 575V only Fuse, Semiconductor 400A @ 700V Blade, Bussmann FWP-400A
17-7057 QPAC 400A up to 480V Fuse, Semiconductor 500A @ 500V Blade, Bussmann FWH-500A
0808-0110-0000 QPAC 400A, 575V only Fuse, Semiconductor 500A @ 500V Blade, Bussmann FWP-500A
17-7058 QPAC 500A up to 480V Fuse, Semiconductor 600A @ 500V Blade, Bussmann FWH-600A
0808-0109-0000 QPAC 500A, 575V only Fuse, Semiconductor 600 A @ 700V Blade, Bussmann FWP-600A
0808-0108-0000 QPAC 600A up to 575V Fuse, Semiconductor 800 A @ 700V Blade, Bussmann FWP-600A
17-7082 QPAC 800A up to 575V Fuse, Semiconductor 1000A @ 700V Blade, Bussmann 170M6714
17-7012 QPAC 1000A up to 575V Fuse, Semiconductor 1250A @ 700V Blade, Bussmann 170M6766
17-5064 QPAC 150 to 300A, 575V
Applications only
08-7210 all Bias and Gain Card, use w/BV Input Control Card
25-0020 QPAC – 150 to 300A Cooling Fan, 115V, 105 CFM 114.3 x 114.3mm (4.5 x 4.5 in)
25-0027 QPAC – 400 to 1000A Cooling Fan, 115V, 260 CFM 152.4mm (6 in)
25-0022 QPAC – 150 to 300A Cooling Fan, 230V, 105 CFM 114.3 x 114.3mm (4.5 x 4.5 in)
25-0028 QPAC – 400 to 1000A Cooling Fan, 230V, 260 CFM 152.4mm (6 in)
18-1064 Q33 – 400 to 600 A Diode, 1400A 1200V, SD1100C..C Series IR
18-1068 Q33 – 1000A Diode, 1170A 1200V, SD1100C..L Series IR
18-1044 Q33 – 150 to 300A Diode, 250A, 1000V, 1N3742R ST
RPC-5405-0000 all DH (Open Heater/Shorted SCR Detector) Card
08-5288 Q01, Q33 Input Control Card, Phase-angle w/AF (4 to 20 mA)
RPC-5411-05-50H Q01, Q33
RPC-5411-05-60H Q01, Q33
RPC-5411-42-50H Q01, Q33 Input Control Card, Phase-angle, w/AL (4 to 20 mA, 50 Hz)
Models Description
Fuse Holder, Semiconductor, externally mounted
Input Control Card, Phase-angle, w/AL (0 to 5V
Input Control Card, Phase-angle, w/AL (0 to 5V
Î (dc), 50 Hz)
Î (dc), 60 Hz)
QPAC User's Guide 29Appendix
Accessories
Watlow Part
Number
RPC-5411-42-60H Q01, Q33 Input Control Card, Phase-angle, w/AL (4 to 20mA, 60 Hz)
08-5289 all Input Control Card, Zero-cross, w/BF (4 to 20mA)
RPC-5342-50HZ all Input Control Card, Zero-cross, w/BV (4 to 20mA, 50 Hz)
RPC-5342-60HZ all Input Control Card, Zero-cross, w/BV (4 to 20mA, 60 Hz)
08-5285 all Input Control Card, Zero-cross, w/CA (ac input)
08-5286 all Input Control Card, Zero-cross, w/CD (dc input)
08-5287 Q01 Motherboard Assembly
08-5320 Q32 Motherboard Assembly
08-5337 Q33 Motherboard Assembly
RPC-5338-150 Q33 all SCR Driver Board 08-5338
18-5052 Q01, Q32 – 150 to 300A SCR Stud, 300A, 1200V, ST
18-5214 QPAC – 400 to 600A SCR, 500A, 1200V, E-PUK
18-5215 QPAC – 800A SCR, 910A, 1200V, HP
18-5216 QPAC – 1000A SCR, 1470A, 1200V, HP
08-5302 QPAC – 150 to 400A, 120V Transformer Assembly, Plug-in, 120V
08-5303 QPAC – 150 to 300A,
208/240V
08-5304 QPAC – 150 to 300A, 277V Transformer Assembly, Plug-in, 277V
08-5306 QPAC – 150 to 300A, 380V Transformer Assembly, Plug-in, 380V
08-5308 QPAC – 150 to 300A, 415V Transformer Assembly, Plug-in, 415V
08-5305 QPAC – 150 to 300A, 480V Transformer Assembly, Plug-in, 480V
08-5307 QPAC – 150 to 300A, 575V Transformer Assembly, Plug-in, 575V
Z100-0818-0000 QPAC – 400 to 1000A, 120V Transformer Assembly, Plug-in, 120V
Z100-0819-0000 QPAC – 400 to 1000A,
208/240V
Z100-0820-0000 QPAC – 400 to 1000A, 277V Transformer Assembly, Plug-in, 277V
Z100-0823-0000 QPAC – 400 to 1000A, 380V Transformer Assembly, Plug-in, 380V
Z100-0822-0000 QPAC – 400 to 1000A, 415V Transformer Assembly, Plug-in, 415V
Z100-0821-0000 QPAC – 400 to 1000A, 480V Transformer Assembly, Plug-in, 480V
Z100-0824-0000 QPAC – 400 to 1000A, 575V Transformer Assembly, Plug-in, 575V
Models Description
Transformer Assembly, Plug-in, 208/240V
Transformer Assembly, Plug-in, 208/240V
30 QPAC User's Guide Appendix
Warranty
Warranty
The QPAC is warranted to be free of defects in material and workmanship
for 36 months after delivery to the rst purchaser for use, providing that
the units have not been misapplied. Since Watlow has no control over their
use, and sometimes misuse, we cannot guarantee against failure. Watlow's
obligations hereunder, at Watlow's option, are limited to replacement, repair
or refund of purchase price, and parts which upon examination prove to be
defective within the warranty period specied. This warranty does not apply
to damage resulting from transportation, alteration, misuse or abuse.
Returns
1. Call Watlow Customer Service, 507-454-5300, for a Return Material Au-
thorization (RMA) number before returning any item for repair. We need
this information:
• Ship-to address
• Bill-to address
• Contact name
• Phone number
• Method of return shipment
• Your P.O. number
• Detailed description of the problem
• Any special instructions
• Name and phone number of person returning the product.
2. Prior approval and an RMA number, from the Customer Service Depart-
ment, is needed when returning any unused product for credit. Make
sure the RMA number is on the outside of the carton and on all paperwork returned. Ship on a Freight Prepaid basis.
3. After we receive your return, we will examine it and try to verify the rea-
son for returning it.
4. In cases of manufacturing defect, we will enter a repair order, replace-
ment order or issue credit for material returned.
5. To return products that are not defective, goods must be be in new con-
dition, in the original boxes and they must be returned within 120 days of
receipt. A 20 percent restocking charge is applied for all returned stock
controls and accessories.
6. If the unit is unrepairable, it will be returned to you with a letter of expla-
nation.
7. Watlow reserves the right to charge for no trouble found (NTF) returns.
QPAC User's Guide 31Appendix
Index
A
ac input contactor 14
AF control card
auto/manual input 16
current transformer connec-
tions 17
input connections 16
potentiometer input 15
process input 15
AL control card
auto/manual input 16
current limit adjustments 23
current transformer connec-
tions 17–18
input connections 16
potentiometer input 15
process input 15
auto/manual input 16
B
BF control card
auto/manual input 16
input connections 16
potentiometer input 15
process input 15
bias and gain adjustments 15, 21
burst ring
control cards 5
model number 28
process input 15
specs 26
BV control card
auto/manual input 16
input connections 16
potentiometer input 15
process input 15
C
CA control card 14
Case Style C mounting 8–9
Case Style E mounting 10
CD control card 14
contact closure input 15
control cards 5, 14–18
bias and gain adjustments 21–
22
phase angle 5, 15
setup 21
current limit adjustments 23
current limiting 22, 26
current transformer connec-
tions 18
D
dc input 14
dc input contactor 16
DH option 19
dimensions 6
F
fuse, semiconductor 11, 27
fuses 8, 10, 24, 28
G
gain adjustments 15, 21, 22, 24
general description 4
I
input signal wiring 14
input wiring 14–19
install and wire the QPAC 6
interlock 16
M
manual potentiometer input 15
model number information 2, 28
mounting 6, 27
O
operate the QPAC 21
output wiring 12–13
overtemperature cutout 20
P
phase angle
control cards 21
specs 26
potentiometer input 15
Q
Q32 4
QPAC-01
case style C 8, 10
wiring 12
QPAC-32
case style C 8, 10
description 5
proper phase sequence 21
troubleshooting 24
wiring 12
QPAC-33
case style C 8, 10
description 5
diagnostics 25
proper phase sequence 21
troubleshooting 24
R
returns 31
S
semiconductor fuses 11, 27
setup adjustments 21
soft start
phase angle 17
specications 26
starting out 4
steps to put your power control to
work 5
system planning 6
system wiring example 20
T
troubleshooting 24
W
warranty 31
wiring 6–16
CD control card 16
control card current transformer
connections 18
data table 6
input 14–19
QPAC-01 12
QPAC-32 12
QPAC-33 13
single and three phase 19
specs 28
system 20
troubleshooting 24
wiring data 11
32 QPAC User's Guide Appendix
Watlow QPAC Modular SCR Power Control User's Guide
Watlow Controls, 1241 Bundy Blvd., P.O. 5580, Winona, MN 55987-5580
Phone: 507-454-5300 Fax: 507-452-4507
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