Page 1
VPAC
User's Manual
Solid State Relay
Power Control
Watlow Controls
1241 Bundy Boulevard, P.O. Box 5580, Winona, MInnesota USA 55987-5580
Phone: 507/454-5300, Fax: 507/452-4507 http://www.watlow.com
0600-0028-0000 Rev B
December, 1999, North American English
Supersedes:
WVPC-XUMN Rev A00
$5.00
Made in the U.S.A.
Printed on Recycled Paper
Page 2
General Description
The VPAC Series Power Controls are a family of Solid State Relay
(SSR) controls for electric heating applications. The VPAC
provides output power proportional to the input command signal
Starting Out
from a temperature control. The single phase VPAC-01 can be
ordered in either ON/OFF (solid state contactor), burst fired or
phase angle firing mode. The three phase, two leg VPAC-32 is for
solid state contactor or burst fired (loop powered) operation only.
Model Number (1821)
VPAC Series V _ _ - _ _ _ - _ _ - _ _ _
Phase
01 = Single Phase
32 = Three Phase, Two Leg,
Burst fired (BL) or SS
contactor (CA, CD) only.
Voltage
12 = 120V~(ac)
24 = 240V~(ac)
27 = 277V~(ac)
38 = 380V~(ac)
41 = 415V~(ac)
48 = 480V~(ac) (in 25A and up only)
Current
10 = 10Amps
25 = 25Amps
40 = 40Amps
50 = 50Amps
75 = 75Amps
Control Mode
BL0 = Burst fired, variable time base, loop powered,
4-20mA input-08-5399
*BT1 = Zero cross, variable time base, transformer powered.
Single phase only, 4-20mA input calibration.
*BT2 = Zero cross, variable time base, transformer powered.
Single phase only. 0 to 5VDC input calibration.
Can be used for manual potentiometer input.
*AT1 = Phase angle, transformer powered. Single phase only.
4-20mA input calibration.
*AT2 = Phase angle, transformer powered. Single phase only.
0 to 5VDC input calibration. Can be used for manual
potentiometer input.
CA0 = Contactor, AC Input
CD0 = Contactor, DC Input
*Transformer included for AT+ and BT.
Accessory
08-5362 = Manual Control Kit, 1K Potentiometer
(08-5362 for use with AT+ and BT Cards only)
Semiconductor Fuses for VPAC Through 75 Amps
Amp Voltage Bussmann Fuse Fuse Holder
VPAC SCRs and SSRs
10 amp 12 600 FWC12A10F 17-8012 17-5110
25 amp 32 600 FWC32A10F 17-8032 17-5110
40 amp 50 700 FWP50A14F 17-8050 17-5114
50 amp 63 700 FWP63A22F 17-8063 17-5122
75 amp 100 500 FWP100A22F 17-8100 17-5122
Rating Rating P/N P/N P/N
Watlow Watlow
Warranty
The VPAC 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, abuse, or improper fusing.
Watlow VPAC User's Manual 2
Specifications (1822)
Solid State Relay Power Control with Heat Sink
• Solid state contactor, AC input (CA)
• Solid state contactor, DC input (CD)
Optional Loop-Powered Control Card
• Burst firing (zero cross) control, 4-20mA (BL)
Optional Transformer-Powered Control Card
• Burst firing (zero cross) control, Process Input, 1Ø only (BT)
• Phase angle control, Process input, 1Ø only (AT+)
• SDA Shorted SSR Alarm (for Zero cross only)
Line Voltage (50/60Hz)
• 120V~(ac) operation
• 208/240V~(ac) operation
• 277V~(ac) operation
• 380V~(ac) operation
• 415V~(ac) operation
• 480V~(ac) operation
Solid State Relay Control
• Single phase, single SSR
• Three phase, two leg control for three wire (non-grounded load),
dual SSR.
• Resistive load only
Inputs
• Solid state contactor, AC input (CA)
ON, 90 to 240V~(ac); OFF, 0 to 10V~(ac)
• Solid state contactor, DC input (CD)
ON, 3 to 32VDC; OFF, 0VDC
• Burst firing (zero cross) control card (BL)
Input 4 to 20mA only
Bias and Gain adjustable
Input impedance 500 minimum
• Burst firing (zero cross) control card (BT), 1Ø only
Input factory adjusted for 4-20mA
Bias and Gain adjustable, 0 to 12VDC/0 to 25mA
Input impedance 300 (clip R-22 for 5K , voltage input)
• Phase angle control card (AT+), 1Ø only
Input factory adjusted for 4-20mA
Bias and Gain adjustable, 0 to 12VDC/0 to 25mA
Input impedance 300 (clip R-2 for 5K , voltage input)
Soft start 10 seconds (approx.)
• 120/240V~(ac) or 480V~(ac) to 24V~(ac) power transformer
included, model dependent for AT+ and BT options.
Outputs
• 120V~(ac) through 480V~(ac)
• 10-75A
Operating Ambient
• Temperature - 0 to 50°C
• RH - 0 to 90%, non-condensing
Specification subject to change without notice.
Returns
1. Call Customer Service, 507-454-5300, for a Return Material
Authorization (RMA) number before returning any item for repair. We
need:
• Ship to address • Bill to address • Contact name
• Phone number • Ship via • Your P.O. #
• Symptoms and/or special instructions
• Name & phone of person returning the material.
2. Prior approval and an RMA number, from the Customer Service
Department, 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 Freight Prepaid.
3. In cases of manufacturing defect, we will enter a repair order,
replacement order, or issue credit for material. A 25% restocking
charge is applied for all returned stock controls and accessories.
4. If the unit is unrepairable, it will be returned to you with a letter of
explanation. Repair costs will not exceed 50% of the original cost.
Page 3
VPAC Dimensions and Mounting
C
A
B
E
UP
WD
NOTE: *The 50Amp Single Phase width mounting dimension
includes four mounting clips (#56-0308) instead of the 1/2 round
cutouts.
Starting Out
çç
çWARNING:
çç
VPAC mounting and
spacing must conform to
local, state and national
safety codes. Failure to
H
conform to codes could
result in death or personal injury, or damage
to equipment.
çç
çCAUTION:
çç
Mount units with heat
sink fins oriented
vertically. Failure to do
so could result in unit
failure and damage to
the process.
∫∫
∫
∫∫
UP
NOTE: 3-Phase, 2-Leg 10-40A use 2 heat sinks for overall
dimensions.
NOTE: Mounting dimensions show maximum possible height and
depth with terminal-mounted control card attached. Unit height and
depth varies with control card configuration.
Maximum Overall Dimensions Mounting Dimensions
V01 10-40A
Amps Height (H) Width (W) Depth (D) A B C E Fan Cooled
10 5.60" 4.50" 1.50" 3.00" 0.50" 0.15" 4.20" No
25 5.50" 4.75" 3.60" 2.00" 0.50" 0.15" 4.45" No
40 6.30" 4.75" 3.60" 4.50" 0.50" 0.15" 4.45" No
V32 10-40A
Amps Height (H) Width (W) Depth (D) A B C E Fan Cooled
10 5.60" 9.00" 1.50" 3.00" 0.50" 0.15" 4.20" No
25 5.50" 9.50" 3.60" 2.00" 0.50" 0.15" 4.45" No
40 6.30" 9.50" 3.60" 4.50" 0.50" 0.15" 4.45" No
V01 50-75A
Amps Height (H) Width (W) Depth (D) A B C E Fan Cooled
C 50A 9.00" *6.90" 3.50" 7.00" N/A N/A 5.90" No
75A 10.50" 5.00" 5.50" 7.00" 1.00" 0.15" 4.70" Yes
V32 50-75A
Amps Height (H) Width (W) Depth (D) A B C E Fan Cooled
50A 10.50" 5.00" 5.50" 7.00" 1.00" 0.15" 4.70" Yes
75A 10.50" 5.00" 5.50" 7.00" 1.00" 0.15" 4.70" Yes
Watlow VPAC User's Manual 3
Page 4
Mount 120/240V Transformer AT+/BT Power
s
e
d
t
Mount Semiconductor Fuses
The AT+ or BT transformer powers the AT+ or BT control card.
Mount the transformer within 12 in. (30.5cm) of the VPAC it
connects to.
Starting Out
Panel
2.4"
(60mm)
1.4"
(35mm)
0.7"
(17mm)
2.0"
(51mm)
120/240V
Xformer
16-0238
1.3"
(33mm)
1.7"
(43mm)
0.2" (5mm)
Mtg. Holes
0.4"
(10mm)
Mount 277 to 480V Transformers AT+/BT Power
The AT+ or BT transformer powers the AT+ or BT control card.
Mount the transformer within 12 in. (30.5cm) of the VPAC it
connects to.
0.2" (5mm)
Mtg. Holes
#8 Screw
Blk
Wh
2.4"
(61mm)
Trans-
former
Connector to
AT+ or BT Car
0.4" (12mm) for 15A, 30A fus
0.5" (13mm) for 50A fuses
0.2" (6mm) for 15A, 30A fuse
0.3" (8mm) for 50A fuses
0.8"
(21mm)
0.2"
(56mm)
Mount 15/30A Semiconductor Fuse
4.5" (114mm)
3.9" (100mm)
2.5" (64mm)
0.4" (10mm)
Guide Lug
Hole
0.2" (6mm)
Mounting Hole
1.5"
(38mm)
Mount 50/100A Semiconductor Fuse
5.5" to 5.6" (140 to 143mm)
5.0" to 5.1" (127 to 130mm)
4.6" to 4.7"
(117 to 120mm)
0.4" (10mm)
Guide Lug
Hole
1.7"
(45mm)
0.6"
(16mm)
0.6"
(16mm)
∫∫
∫
∫∫
(32mm)
∫∫
∫
∫∫
1.3"
(32mm)
1.3"
Panel
.3"
(6mm)
1.7"
(42mm)
Watlow VPAC User's Manual 4
1.5"
(38mm)
0.2" (6mm)
Mounting Hole
1.5"
(38mm)
Mount Semiconductor Fuses
Mount optional semiconductor fuses near the VPAC. Mounting
must conform to code requirements. Wiring diagrams show
proper connections.
çç
çWARNING:
çç
Fuse mounting and spacing must conform to local, state and
national safety codes. Failure to conform to codes could
result in damage to equipment and/or injury to personnel.
∫∫
∫
∫∫
Page 5
Single Phase Wiring
1Ø Wiring for AC & DC Input Contactor
10-40A, Models (CA or CD)
L2
L1
Semiconductor
Fuse
V~(ac) or VDC Input
Command Signal
∫∫
∫
∫∫
∫∫
∫
∫∫
1
2
Limit Contactor
Contacts
(if required)
Depending on Model Ordered
CD
VDC
Starting Out
çç
WARNING:
ç
çç
Wiring must conform to National
Electric Code (NEC) safety standards,
as well as locally applicable codes.
T1L1
1Ø Wiring, 4-20mA Burst, 10-40A (BL)
Failure to do so could result in death or
personal injury.
çç
çWARNING
çç
Wiring examples show L2 in 240V~(ac)
or 480 V~(ac) configuration. In
120V~(ac) applications, L2 is neutral and
must not be fused or switched. Failure
to follow this guideline could result in
death or personal injury.
∫∫
∫
∫∫
∫∫
∫
∫∫
1
2
1Ø Wiring, 4-20mA Burst, 50 & 75A (BL)
L2
V~(ac)
L1
∫∫
∫
∫∫
∫∫
∫
∫∫
Limit Contactor
1
2
(if required)
Semi-
conductor
Fuse
L1 L2 T1 T2
L2
L1
∫∫
∫
∫∫
∫∫
∫
∫∫
1
Limit Contactor
Contacts
(if required)
2
Semiconductor
Fuse
4-20mA
Input
L1
T1
SBL
4-20mA
120V~(ac) Fan Power
20 Watts Max. - 75A Only
(Customer Supplied)
Separate Disconnect Required
Watlow VPAC User's Manual 5
Page 6
Single Phase Wiring
Starting Out
1Ø Wiring, 4-20mA Burst (BT) 1Ø Wiring, 4-20mA Phase Angle (AT+)
L2
∫∫
∫
∫∫
∫∫
∫
∫∫
1
2
çç
çWARNING:
çç
Wiring must conform to National Electric
Code (NEC) safety standards, as well as
locally applicable codes. Failure to do
so could result in death or personal
injury, or damage to equipment.
∫∫
∫
∫∫
1
L1
Limit Contactor Contacts
1A Fuses
Customer Supplied Wiring
240V~(ac) Power to
Transformer
4
1
24V~(ac) Power to
AT+ or BT Card
Customer Supplied Wiring
120V~(ac) Power to Transformer
L2-Wht
L1-Blk
Customer Supplied Wiring
277 to 480V~(ac) Power to Transformer
L2-Wht
L1-Blk
4
1
(if required)
24V~(ac) Power
to
AT+ or BT Card
Semiconductor
Fuse
Process +
Input -
L1 T1
BT
R22
(300 )
çç
çWARNING:
çç
Wiring examples show L2 in 240V~(ac)
or 480 V~(ac) configuration. In
120V~(ac) applications, L2 is neutral
and must not be fused or switched.
Failure to follow this guideline could
result in death or personal injury.
R2 (270 ) ->
CW
When using potentiometer input, remove
remove resistor R22 or R2 for 5K input
impedance, also for 1-5VDC input.
∫∫
∫
∫∫
AT+
+ -
W
2
CCW
˜˜
˜
˜˜
Transformer
24V~(ac) Power
to
AT+ or BT Card
NOTE: The control transformer must be on the same phase as the load. See
wiring diagram above. All hot lines to the transformer should be fused at 1
Amp with the proper line voltage.
Watlow VPAC User's Manual 6
NOTE: For manual control, a 1K
potentiometer may be connected to the
BT or AT+ card input terminals. Watlow
offers a kit as Manual Control Kit, part
number, 08-5362. Using this
potentiometer requires removing the
specified control card resistor for
higher impedance.
Bias and gain adjustment is required
when changing from 4-20mA input to a
manual control input or a voltage input.
Page 7
3Ø Wiring for AC & DC Input Contactor
10-40A, Models (CA or CD)
Semiconductor
Fuses
L1
L2
L3
Limit Contactor
(if required)
VDC
T1
T3
T2
∫∫
∫
∫∫
3-Phase, 2-Leg Wiring
Starting Out
çç
çWARNING:
çç
Wiring must conform to National Electric
Code (NEC) safety standards, as well as
locally applicable codes. Failure to do so
could result in death or personal injury,
or damage to equipment.
∫∫
∫
∫∫
90-240V~(ac) -
AC Input +
3Ø Wiring, Burst Fired, 4-20mA, 10-40 A (BL)
Semiconductor
Fuses
L1
L2
L3
Limit Contactor
(if required)
T1
T2
∫∫
∫
∫∫
3Ø Wiring, DC Contactor, 50 & 75 A (BL) (CD)
Semiconductor
L1
L2
L3
Limit Contactor
(if required)
Fuses
L1 T1 L3 T3
SBL
+
-
Fan
Fan
120/240V~(ac) Fan Power
(model # dependent)
(Customer Supplied)
Separate Disconnect Required
T2 T1
T3
4-20mA
20 Watts Max.
∫∫
∫
∫∫
4-20mA +
Input -
+ -
- +
+
-
T3
Watlow VPAC User's Manual 7
Page 8
Troubleshooting
To isolate a system problem involving the VPAC, answer these
questions:
• Are inputs to the VPAC present?
• Are outputs from the VPAC present?
• Are all connections good?
• Is the load good?
• Is line voltage within specification?
• Are temperature control signals present? If so, then the VPAC
power control itself may be the problem. The problem may be with
the VPAC's control card, transformer or solid state relay. Use the
table below to assist with troubleshooting.
Symptom Probable Cause Corrective Action
No output Fuses blown Check and replace fuses.
Transformer hot Incorrect transformer Check product & transformer
Uncontrolled Bad control card, Disconnect control card, try again.
output full ON or Bias and Gain If no output, SSR is okay. Check
Starting Out
Incorrect input wiring Verify input wiring.
Incorrect input signal Check temp. control output.
Input signal reversed Verify input wiring.
Input signal not adjusted “See Bias and Gain Adjustment.”
Wrong or missing
control card Verify input wiring.
Check transformer connections.
Missing load wiring Verify load wiring
The SSR(s) will not
function without a load.
labels (AT+ & BT only).
out of adjustment Bias and Gain Adjustment.
Bad transformer Unplug transformer wires
and try again. (AT+ & BT only.)
Bad SSR If full ON or half ON output
present with no control card
and no transformer, solid state
relay is bad; replace it.
Bias And Gain Adjustments
5. Repeat Steps 3 and 4 until the VPAC 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).
6. Remove power, disconnect the meters, and reconnect the
controlled load to the VPAC if required.
Replace SSR
Screw, 2 ea., #8-32
See Note 4.
Belleville Washer, #8
See Note 4.
Solid State Relay
See Note 3.
Thermal pad or
a thin coat of thermal
joint compound
(Dow DC-340)
Heat Sink (typical)
1. Surface must be clean and flat.
2. Use a thermal pad or a thin coat of thermal joint compound
(Dow DC-340 or equivalent).
3. Mount the SSR to the heat sink.
4. Use Belleville (spring) washers and tighten screws alternately
until the spring is deflected slightly.
The VPAC bias and gain can be adjusted for the output of most
standard, proportional output temperature controls. Bias and gain
is factory set for an input control signal (0-5VDC or 4-20mA), but
may require minor adjustments to match the output of a specific
temperature control.
We recommend 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 VPAC. Use the following steps
to make adjustments.
1. Connect an AC voltmeter across the load or dummy load of
the VPAC. Connect a DC voltmeter across, or milliampmeter
in series with, the input signal from the temperature controller.
2. Apply power to the system.
3. Set the output signal of the temperature controller to zero or
its minimum output. Adjust the bias potentiometer slowly until
the VPAC output just comes ON. Then turn it in the opposite
direction until the output is just full OFF as observed on the
output voltmeter.
4. Adjust the output of the temperature controller to full ON
(5VDC, 20mA, etc.). Adjust the gain potentiometer until the
VPAC output is just full ON.
Watlow VPAC User's Manual 8
çç
çCAUTION:
çç
Heat sink must be mounted so that the fins are vertically aligned.
çç
çCAUTION:
çç
Heat sensitive component; ambient temperature must not exceed
122°F (50°C). If overheated, unit could fail.
çç
çCAUTION:
çç
Heat sensitive component; do not mount SSRs on panels that are
painted, plastic, steel or stainless steel. These materials will not
remove heat generated by the SSR. If overheated, unit could fail.
UP
Feedback
Your comments and suggestions on this manual are welcome.
Please send them to: Technical Writer, Watlow Controls, P.O. Box
5580, Winona, MN 55987-5580, or call (507) 454-5300 or fax
(507) 45204507. The VPAC Users Manual is copyrighted by
Watlow Winona, Inc., © December 1999, with all rights reserved.
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