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Watlow PC1X-N20 User Manual

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Power Series
User's Manual
Microprocessor-Based
SCR Power Controller
TOTAL
CUSTOMER
SATISFACTION
3Y ear Warranty
ISO 9001
Registered Company
Winona, Minnesota USA
1241 Bundy Boulevard, P.O. Box 5580, Winona, Minnesota USA 55987-5580
U.S. English
Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507 http://www.watlow.com
0600-0039-0000 Rev J
Made in the U.S.A.
January 2015
Supersedes: 0600-0039-0000 Rev H

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  • Page 1 ISO 9001 Registered Company Winona, Minnesota USA 1241 Bundy Boulevard, P.O. Box 5580, Winona, Minnesota USA 55987-5580 U.S. English Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507 http://www.watlow.com 0600-0039-0000 Rev J Made in the U.S.A. January 2015 Supersedes: 0600-0039-0000 Rev H...
  • Page 2 CAUTION or Technical Assistance WARNING If you encounter a problem with your Watlow controller, see the Trouble- shooting 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.

  • Page 3: Table Of Contents

    Factory Page ....6.14 Factory Mode ....6.20 Table of Contents Watlow Power Series...
  • Page 4 Watlow Power Series Table of Contents...

  • Page 5: Chapter 1: Overview

    Allen Wrench Used to torque terminals 1 to 6 and ground lug. Figure 1.1 — Power Series features. Over view, Chapter 1 Watlow Power Series 1. 1...
  • Page 6 SCR detection/error. Heater diagnostics must also be installed if you need phase angle control with current limit. Watlow Power Series Over view, Chapter 1...

  • Page 7: Chapter 2: Installation

    Installation ∫ 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. WARNING: Chapters 2 and 3 describe the steps required to install the Power Series To avoid potential electric controller.

  • Page 8: Dimensions

    Mounting Holes (4) (0.27 in.) Key Slots 178mm (7.00 in.) 39mm (1.53 in.) 102mm 25mm (4.00 in.) (0.97 in.) 151mm (5.93 in.) Figure 2.2b — Mounting plate dimensions. Figure 2.2c — Installing the controller. Watlow Power Series Installation, Chapter 2...

  • Page 9: Enclosure Guidelines

    “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. Installation, Chapter 2 Watlow Power Series 2.

  • Page 10: Removing The Power Series

    • 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. Watlow Power Series Installation, Chapter 2...

  • Page 11: Output Rating Curves

    Current (amps) into a Resistive Load 3-Phase, 2-Leg and 2-Zone Multizone Fan Cooled at 100% On Current (amps) into a Resistive Load 3-Phase, 3-Leg and 3-Zone Multizone Fan Cooled at 100% On Current (amps) into a Resistive Load Watlow Power Series Installation...
  • Page 12 Current (Amps) into a Resistive Load 3 Phase, 2-Leg and 2-Zone Multizone Natural Convection at 100% On Current (Amps) into a Resistive Load 3 Phase, 3-Leg and 3-Zone Multizone Natural Convection at 100% On Current (Amps) into a Resistive Load Installation Watlow Power Series...

  • Page 13: Chapter 3: Wiring

    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.

  • Page 14: Input Wiring

    232 REC (EIA/TIA-232 Receive In) flow. Re-torque after 232 TRAN (EIA/TIA-232 Transmit Out) 48 hours. 485 T/R - • All line connections should be re-torqued (Common) every 3-6 months. 485 T/R + 3 .2 Watlow Power Series Wiring, Chapter 3...
  • Page 15 (Voltage In, 0 to 10V) (Current In, 4 to 20mA) (Common) INPUT 2 (Voltage In, 0 to 10V) (Current In, 4 to 20mA) (Common) INPUT 3 (Voltage In, 0 to 10V) (Current In, 4 to 20mA) (Common) Wiring, Chapter 3 Watlow Power Series...

  • Page 16: Line Power/Output Wiring

    Limit Control Contacts • Install the controller (If Required) ç (Chapter Two); CAUTION: Figure 3.4a shows the Watlow-recommended output wiring • Wire the controller On-board using the internal bussbar as a (Chapter Three); and Semiconductor return current path and with ref. 2 Fuse •...
  • Page 17 ç∫ Figure 3.5a – 3-Phase, 3-Leg, Figure 3.5b – 3-Phase, 3-Leg, Figure 3.5c – 3 Phase, 3-Leg, 6-SCR Output Wiring for 6-SCR Inside Delta 6-SCR Output Wiring (Model PC3X-XXXX-XXXX) 4-Wire Wye Application WARNING: (Model PC4X-XXXX-XXXX) To avoid damage to property and equipment, and/or injury or loss of life, use National Electric Limit Control...

  • Page 18: Wiring Example

    5KA per UL508A and NEC guidelines. condition could present a fire hazard or other hazard. Failure to install Power Series Model Fuse Rating Watlow Fuse P/N Bussmann Fuse P/N temperature limit control PC1X-N20 0808-0102-0160 170M1319 protection where a...

  • Page 19: Chapter 4: Navigation And Software

    Display Loop, activity. moves between like prompts of different zones or phases. Figure 4.1 — Power Series keys and displays. Navigation and Software, Chapter 4 Watlow Power Series 4. 1...
  • Page 20 To go backward through the parameter list press ¬ . PressÎ or Ó to select a value, either alpha or numeric, within a specific parameter. Watlow Power Series Navigation and Software, Chapter 4...
  • Page 21 Current operating parameters may be modified at any time with the use of the keypad or communications port. 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. Navigation and Software, Chapter 4 Watlow Power Series 4. 3...
  • Page 22 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. 4 .4 Watlow Power Series Navigation and Software, Chapter 4...

  • Page 23: Chapter 5: Control Methods And Features .5.1

    Line voltage compensation is not used in the fixed time base control method. 24 Cycles ON 36 Cycles OFF 24 Cycles ON 36 Cycles OFF Figure 5.1b — 40% power, fixed time base, 60 Hz, 1 sec time base. Features, Chapter 5 Watlow Power Series 5. 1...

  • Page 24: Phase Angle

    Current limiting is a valid option with phase angle if the unit is equipped with heater diagnostics. Figure 5.2c— Phase angle firing. NOTE: The maximum output power is 99%. This is consid- ered full on for the Power Series. Watlow Power Series Features, Chapter 5...
  • Page 25 0.1 to 100.0% Change is set to 10%/0.1 second. 3) Press ± key to exit setup page and start the NOTE: Repeat this procedure for each zone Power Series. that you wish to configure. Features, Chapter 5 Watlow Power Series 5. 3...
  • Page 26 For example, in Figure 5.4b the alarm is pro- Percent Power grammed to trigger if the load current drops below 90 amps, or rises above 110 amps at 100 percent power. Figure 5.4b— Heater Tolerance Detection. Watlow Power Series Features, Chapter 5...
  • Page 27 [`Err] in the upper display and [Indf] the lower display. In the event of an error push the up or Using the Ó Î keys, select [`req] in the upper down key to [`req] and start the process over. display. Watlow Power Series Features...

  • Page 28: Other Features

    Note that the power will be fully off at the configure. current specified by prompt {Uol_] +.1V, and fully Analog is typically 0-5VÎ (dc), 1-5VÎ (dc), 0-10VÎ on at the current specified by prompt {Uol–] -.1V. (dc), 4-20mA. 5 .6 Watlow Power Series Features, Chapter 5...

  • Page 29: Alarms

    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. Features, Chapter 5 Watlow Power Series 5. 7...

  • Page 30: Communications

    The Power Series supports a maximum read of up to al computer, you need to run software that uses the 32 registers. See appendix A.8 for Modbus registers. Modbus™ RTU protocol to read or write to registers Features Watlow Power Series...

  • Page 31: Retransmit

    Figure 5.9b — Example circuit. a 50A to 250A current, set [Cur_] to 50 and [ C ur–] to 250. As the load current varies between 50 and 250A, the retransmit output will vary between 4mA and 20mA. Watlow Power Series Features...

  • Page 32: Fast Start Guide

    Fast Start Guide Get Your Power Series Controlling Heat [load] [`___] ± ¬ Ó [`set] [algo] ® [algo] Ó [cont] [`Off] [`Ftb] [Urtb] [PH2t] ¬ [`set] [algo] Î `set] [Ctr1] ® [``In] Ó [`nna] [Uolt] [`dig] [`Off] ® [nna_] [Uol_] Ó...
  • Page 33 Fast Start Guide [load] [`___] ± ¬ Ó [`set] [algo] ® [algo] Ó [cont] [`Off] [`Ftb] [Urtb] [PH2t] ¬ [`set] [algo] Î `set] [Ctr1] ® [``In] Ó [`nna] [Uolt] [`dig] [`Off] ® [nna_] [Uol_] Ó Î ® [nna–] [Uol–] Ó Î...

  • Page 34: Chapter 6: Parameters

    Appears in Display Loop. Input Signal [``)0] to [1)00] [V] 5102 r/w (0 to 1000) [dig] Displays mA/V ana- [``)0] to [10)0] [%] log input; selects (0 to 1000) numeric % power. 0.1 increments Parameters, Chapter 6 Watlow Power Series...
  • Page 35 Active if heater diagnostics option Bakeout Timeout [minutes] 167 r [2] is installed and heater bakeout (9999 to 0) is running in the zone. Displays the time left on a heater bakeout. 6 .2 Watlow Power Series Parameters, Chapter 6...
  • Page 36 The Input Signal Method Indicator will change depending on the Input Signal Method chosen — process, current, or volts. NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features. Parameters, Chapter 6 Watlow Power Series...
  • Page 37 [Cur2] [Cur1] [Cur3] [`HUA] Load Power (kVA) [```0] to [9999] 156 r Active with multiphase Read calculated [kVA] configuration and heater diag- (est.) load power. (0 to 9999) nostics option is installed. 6 .4 Watlow Power Series Parameters, Chapter 6...

  • Page 38: Setup Page

    [4SEC] 4 second (1) second (0) Set the fixed time base in seconds for selected zone. NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features. Parameters, Chapter 6 Watlow Power Series...
  • Page 39 Voltage (Volts) [Uol–] [- 2.5V] 5023 r/w [2] voltage. [0 to V high -2.5V] 5033 r/w [3] Sets voltage value which will corre- spond to 0% power if input is voltage type. ■ 6 .6 Watlow Power Series Parameters, Chapter 6...
  • Page 40 (5) [3lgy] 3 ph, 3-leg, 6 SCR grounded wye (7) NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features. Parameters, Chapter 6 Watlow Power Series...
  • Page 41 2 leg configuration. heater current dur- termined by Load Active if [`Hbo] is set to [``On]. ing heater bakeout. Rating] (0 to Load Output will shut Current Amps) down at this value. 6 .8 Watlow Power Series Parameters, Chapter 6...
  • Page 42 Active if [algo] is set to [ph2t] and [Indf] is set to [`req]. NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features. Parameters, Chapter 6 Watlow Power Series...
  • Page 43 [`std] active (0) [`std] 863 r/w Active if [glbl] is set to [`Off]. Configuration [`LaT] latched (1) active (0) [`SIl] silenced (2) Selects the line loss [LaSI] latched and alarm configuration. silenced (3) 6 .1 0 Watlow Power Series Parameters, Chapter 6...
  • Page 44 Active if [glbl] is set to [`Off]. Selects the commu- [LaSI] latched and nications watchdog silenced (3) alarm configuration. NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features. Parameters, Chapter 6 Watlow Power Series 6.11...
  • Page 45 [`CUr] cur- 871 r/w Active if retransmit and heater Select [`CUr] current (1) rent (1) diagnostics options are installed. [`HUA] kVA (2) Select type of retransmit informa- tion; amps or kVA. 6 .1 2 Watlow Power Series Parameters, Chapter 6...
  • Page 46 Active if [`Cfg] is set to [`nna]. Select output current that will correspond to [Cur–] or [HUA–]. NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features. Parameters, Chapter 6 Watlow Power Series 6.13...

  • Page 47: Factory Page

    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.
  • Page 48 Set” above for description information. of the Modbus values 0 - 5. *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. Parameters, Chapter 6 Watlow Power Series 6.15...
  • Page 49 1357 r/w Active if [glOC] is set to [`Unl]. Factory Menu [`LOC] Locked (1) Active if retransmit and heater Lockout diagnostics options are installed. Sets lock on retrans- mit calibration menu. 6 .1 6 Watlow Power Series Parameters, Chapter 6...
  • Page 50 51 r Active: Always. (Volts) (0 to 680) Reads load voltage of the unit. NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features. Parameters, Chapter 6 Watlow Power Series 6.17...
  • Page 51 Masked if hours <10000 Indicates accumulat- ed system operating time (hours x 10000). 1961 r Active: Always. [HrS_] Accum Hours [```0] to [9999] (0 - 9999) (0 to 9999) Accumulated system operating time (hours). 6 .1 8 Watlow Power Series Parameters, Chapter 6...
  • Page 52 [l_] indicates which cycle loss phase 1, 2 or 3 expe- rienced the alarm NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Control Methods and Features. Parameters, Chapter 6 Watlow Power Series 6.19...

  • Page 53: Factory Mode

    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.
  • Page 54 The parameter [`Err] will be displayed if the calibrations fails; otherwise the parameter will return to [idle]. NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Features. Watlow Power Series Parameters 6. 21...
  • Page 55 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. NOTE: For more information about how parameter settings affect the controller’s operation, see Chapter Five, Features. 6 .2 2 Parameters Watlow Power Series...

  • Page 56: Appendix

    Prompt Index ....A.13 CE Declaration of Conformity ..A.14 Warranty Information ..back cover Appendix Watlow Power Series...

  • Page 57: Troubleshooting

    [``)0], check calibration. With input signal set for 100% power, check output power display; if it is not [10)0], check calibration. • Internal malfunction. • Return the unit to the factory for repair. A. 2 Watlow Power Series Appendix...
  • Page 58 • Increase [rdLy] value until the half cycle line loss control ramps loss errors [hCYL] . Reactance delay errors no longer occur.. output power [rdLy] is set too low. up, develops a [hCyL] error and shuts down Appendix Watlow Power Series...

  • Page 59: Troubleshooting Alarms And Errors

    Caused by line voltage being over line voltage rating +10%. [``OU] [`alr] Communications Alarm will occur if no communications is detected for time specified in [`Out] Watch- Watchdog Alarm dog timeout. Not available unless Serial Communications is installed. [Cdog] A . 4 Watlow Power Series Appendix...
  • Page 60 Verify the integrity of the communications (0-4)* signals from the controlling device. Return to the factory for repair. Inactive - 0, Active - 1, Latched Active - 2, Latched Inactive - 3, Unlatched - 4 Appendix Watlow Power Series A. 5...

  • Page 61: Checking And Replacing Fuses

    Unit should now be ready to resume Figure A.6 — Fuse location. operation. Reapply power to the controller and line/load terminals. Note: The fuse must be a Cooper Bussman to retain SCCR rating. A . 6 Watlow Power Series Appendix...

  • Page 62: Power Series Backup

    The Restore Data Set prompt will update the chosen configuration Figure A.7 — Power Series 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 A. 7...

  • Page 63: Modbus Register Numbers

    Retransmit Cal Volts Low Comms Watchdog Alarm Configuration 5101 Input Signal Method Select (dig, mA, Volt) 5721 Retransmit Cal Volts High Retransmit Config. Select Zone 1 Retransmit Type Select 5102 Numeric (%) Input 1 Signal A. 8 Watlow Power Series Appendix...
  • Page 64 Agency Approvals • Calibration accuracy: • UL 508 and C-UL listed, file #E73741 mA ranges = ±20μA • CE marked, see Declaration of Conformity on page A.14 VÎ(dc) ranges = ±10mV • Temperature Stability: 100ppm°C Appendix Watlow Power Series A. 9...

  • Page 65: Ordering Information

    185A 155A 250A 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...

  • Page 66: Index

    Communications Watchdog Alarm A.4 Heat Sink Alarm Temp 6.18 Load Power (kVA) 6.2, 6.4 Configuration Installed Options 6.18 Heat Sink Over Temperature Alarm A.4 Load Power (kVA) Zone 1 6.3, 6.4 Heat Sink Over Temperature Alarm Appendix Watlow Power Series A.1 1...
  • Page 67 Unit Voltage Rating (Volts) 6.17 Retransmit Cal Factory Menu Variable Time Base - Zero Cross 5.2 Lockout 6.16 Voltage Compensation Alarm Config. 6.11 Retransmit Cal mA High 6.22 W X Y Z Retransmit Cal mA Low 6.22 A. 12 Appendix Watlow Power Series...

  • Page 68: Prompt Index

    Retransmit Phase Select 6.13 [Ph2t] Phase Angle 5.2 [`PW] Factory Password 6.20 [glbl] Global Alarm Configuration 5.7, 6.10 [`PW] Factory Password Entry 6.20 {gLOC} Global Lockout 5.6, 6.16 [PWr] Watchdog Failure Output Power Select (%) 6.12 Appendix Watlow Power Series A.1 3...

  • Page 69: Ce Declaration Of Conformity

    An external ElectroMagnetic Interference (EMI) filter must be used in conjunction with the Power Series for loads in excess of six amperes (6A) at 150 to 250 KHz. Watlow has verified that the following tank filters will suppress EMI created by SCR power controllers to comply with the conducted emissions limits.

  • Page 70: Ce Declaration Of Conformity

    Joe Millanes Winona, Minnesota, USA September 2014 Name of Authorized Representative Place of Issue Date of Issue Directory of Operations Title of Authorized Representative Signature of Authorized Representative Watlow Power Series Appendix A.15...
  • Page 71 [ r t|U–] Set Retrans Output Hi Volt _ _ _ _ parameters that are not necessary for photocopy of this page. everyday use of the controller. Calibration parameters and procedures are explained in the Power Series User’s manual. A . 1 6 Appendix Watlow Power Series...
  • Page 73 • 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, pro- viding that the units have not been misapplied.

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