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Watlow SCR User Manual

Power control 150 to 1,000a
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Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
0600-0027-0001 Rev D
August 2010
Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com
QPAC
User's Guide
Modular SCR
Power Control
150 to 1,000A
Made in the U.S.A.

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  • Page 1 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com QPAC User’s Guide Modular SCR Power Control 150 to 1,000A 0600-0027-0001 Rev D Made in the U.S.A. August 2010 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com...
  • Page 2 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 configu- ration information to verify that your selections are consistent with your appli- cation: inputs, outputs, alarms, limits, etc.

  • Page 3: Table Of Contents

    Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Contents Table of Contents Chapter 1 Starting Out With The QPAC Power Control General Description Steps To Put Your Power Control To Work Chapter 2 How to Install and Wire the QPAC System Planning Mounting the QPAC Input Signal Wiring...

  • Page 4: Starting Out With The Qpac Power Control

    Chapter 1 Starting Out With The QPAC Power Control The Q32 SCR Power Control. General Description The QPAC Power Controls are a family of solid-state controls used for elec- tric heating applications. A solid-state power control provides output power that is proportional to the input command signal from a temperature control.

  • Page 5: Steps To Put Your Power Control To Work

    Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Control Cards Starting Out • 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 •...

  • Page 6: 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.
  • Page 7 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com 5.7mm 13.5mm (0.225 in) Mounting (0.53 in) 25.4mm (1.00 in) 7.9mm (5/16 in - 18) 9.7mm (0.38 in) Ensure nut and washer 3.8mm are used below and above fuse (0.15 in) Template for Fuse Holders Top View Right Side View with QPAC 150A, 575V.
  • Page 8 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Case Style C Mounting QPAC Case Style C. Model Amps Height Width Depth Fans Fuses QPAC-01 330mm (13 in) 175mm (6.9 in) 260mm (10.25 in) on heat sink QPAC Case Style C QPAC-01 330mm (13 in) 175mm (6.9 in)
  • Page 9 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Case Style C 356mm (14.00 in) Mounting 178mm 89mm (7.00 in) (3.50 in) 16mm (0.63 in) QPAC Case Style C, Q32, 150, 200, 300A, MOUNT 3-Phase, 2-Leg Mounting Footprint. 298mm (11.75 in) 33mm (13.00 in) CAUTION:...
  • Page 10 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Case Style E Mounting QPAC Case Style E. Model Amps Height Width Depth Fans Fuses QPAC-01 400 to 600 685mm (27 in) 430mm (17 in) 300mm (11.7 in) 1 on-board QPAC-01 800 to 1,000 685mm (27 in) 430mm (17 in) 340mm (13.3 in)
  • Page 11 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Wiring QPAC Wiring Data. Load Semiconduc- Minimum Bending Radius Wire Sized that Fuse Internal Current tor Fuse Rat- Recommended Lugs Accept Mounting Torque Allen (amps) ing (amps.) Wire Size Wrench 102mm (4 in) 4 to 3/0 *onboard 240 in/lb 3/16 in...

  • Page 12: Output Wiring

    (ac) or 277V (ac), L2 is one day of operation. neutral and cannot be Loose connections can broken. damage the SCR. *2 NOTE: A contactor is NOTE: required if a high limit A circuit breaker is re- control is used.
  • Page 13 *2 NOTE: A separate one day of operation. disconnect is required Loose connections can for the fan(s) if used. damage the SCR. NOTE: A circuit breaker is re- quired in addition to the semiconductor fuses. All semiconductor fuses...

  • Page 14: Input Signal Wiring

    Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Input Signal Wiring Input 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 pro- vided by a shielded, two-conductor wire.

  • Page 15: Process Input - Af, Al, Bf And Bv Control Cards

    Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com CD Control Card — Contact Closure Input Contactor Input Wiring 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.

  • Page 16: Af, Al, Bf And Bv Dc Input Connections

    Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com AF, AL, BF and BV DC Input Connections Input Wiring 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 12V (dc), or 0 to 25mA input signal.

  • Page 17: Soft Start

    Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Soft Start Input Wiring (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 resis- tance over 16 times from cold to hot).
  • Page 18 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Input Wiring Example of Current TB-3 20mA Transformer Connection to AL Card the AL (current limit) Card. TB-2 16-0176 Transformer *1 NOTE: Both load leads must pass through the CTs in the same direction.

  • Page 19: Single- And Three-Phase Current Transformer Wiring

    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"...

  • Page 20: Qpac System Wiring Example

    QPAC system Wiring Example System Wiring The most common failure mode of an SCR is in the shorted state. If this hap- pens, 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...

  • Page 21: How To Operate The Qpac

    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 QPAC- 32 power control, measure the voltage from T1 to T2, T2 to T3 and T3 to T1 with the power control turned full on.
  • Page 22 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 field. Order Watlow part number 08-7210. Follow this calibration procedure when using the bias and gain card.

  • Page 23: Current Limit Adjustments

    Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Fixed Bias Bias and Gain Gain Pot Connector BV Fixed Bias Connector & Gain Adjustment BV (Rev. B) Control Card. cut resistor for volts input TB-1 08-5342 Bias Pot Gain Pot 08-5411 Current Limit Pot (AL Card only) TB-2...

  • Page 24: Appendix

    Transformer wiring Check transformer connections. Missing load wiring See “Power and Load Wiring,” Chapter 2. The SCR(s) will not function without a load. Heatsink temperature Clogged or non- Check fan, power, and clean if necessary. Check exceeded 86°C (187°F)

  • Page 25: Specific To Qpac-33 Diagnostics

    Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Specific to QPAC-33 Diagnostics Diagnostics The QPAC-33 has four indicator lights for diagnostics. During normal opera- tion, all four will be lit. • Power on Yellow indicator light is on when power is applied to the control. •...

  • Page 26: Qpac Specifications

    Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com QPAC Specifications Specifications Operation • Modular control base with plug-in card and transformer • Plug-in control cards Solid-state contactor, (ac) or (dc) input Burst fire control, fixed or variable time base Phase angle fire control Phase angle control with soft start and current limiting •...
  • Page 27 • 2%, 30% to 70% power region (All units except CA & CD) Off-State Leakage Current • 20mA @ 480V (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]) •...

  • Page 28: Model Number Information

    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 (burst fire, zero cross models only) None...

  • Page 29: Accessories

    Q33 – 1000A Diode, 1170A 1200V, SD1100C..L Series IR 18-1044 Q33 – 150 to 300A Diode, 250A, 1000V, 1N3742R ST RPC-5405-0000 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...
  • Page 30 08-5337 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 –...

  • Page 31: Warranty

    The QPAC 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...
  • Page 32 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Index current transformer connec- QPAC-33 tions 18 case style C 8, 10 ac input contactor 14 description 5 AF control card diagnostics 25 auto/manual input 16 proper phase sequence 21 dc input 14 current transformer connec- troubleshooting 24 dc input contactor 16...
  • Page 33 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com...
  • Page 34 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com 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 Thermal Devices, Inc. Mount Airy, Maryland USA www.thermaldevices.com...

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