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Watlow SCR User manual

Manual is about: Power Control 150 to 1,000A

Summary of SCR

  • Page 1

    Made in the u.S.A. Qpac user’s guide modular scr power control 150 to 1,000a 0600-0027-0001 rev d august 2010 thermal devices, inc. Mount airy, maryland usa www.Thermaldevices.Com thermal devices, inc. Mount airy, maryland usa www.Thermaldevices.Com.

  • Page 2

    2 qpac user's guide how to use this guide notes a bold text "note" marks a short message in the margin to alert you to an important detail. 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...

  • Page 3

    Qpac user's guide 3 how to use this manual 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 cont...

  • Page 4: Control

    4 qpac user's guide chapter 1: starting out starting out 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 s...

  • Page 5

    Qpac user's guide 5 chapter 1: starting out starting out on any voltage from 120 to 575v b (ac). The plug-in control card sets the qpac’s firing mode. Control cards are available in solid-state contactor, burst firing (zero cross) or phase angle firing with a wide variety of options. This modular ap...

  • Page 6

    6 qpac user's guide chapter 2: install & wire 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 ...

  • Page 7

    Qpac user's guide 7 chapter 2: install & wire 7.9mm (5/16 in - 18) 5.7mm (0.225 in) 9.7mm (0.38 in) 3.8mm (0.15 in) 88.9mm (3.50 in) minimum 106.4mm (4.19 in) maximum top view right side view 25.4mm (1.00 in) 13.5mm (0.53 in) 31.8mm (1.25 in) 21.1mm (0.83 in) 40.4mm (1.59 in) ensure nut and washer a...

  • Page 8

    8 qpac user's guide chapter 2: install & wire model amps height width depth fans fuses qpac-01 qpac-01 qpac-01 150 200 300 330mm (13 in) 330mm (13 in) 330mm (13 in) 175mm (6.9 in) 175mm (6.9 in) 175mm (6.9 in) 260mm (10.25 in) 260mm (10.25 in) 260mm (10.25 in) 1 1 1 on heat sink on heat sink on heat...

  • Page 9

    Qpac user's guide 9 chapter 2: install & wire case style c mounting qpac case style c, q32, 150, 200, 300a, 3-phase, 2-leg mounting footprint. Qpac case style c, q33, 150, 200, 300a, 3-phase, 3-leg mounting footprint. E caution: mount the qpac verti- cally (height dimension vertical) for proper cool...

  • Page 10

    10 qpac user's guide chapter 2: install & wire case style e mounting fan mount u p fan width t1 t3 l1 l2 l3 height fan voltage input 22mm (0.88 in) 12.7mm (0.5 in) electronics package (signal connects inside) 22mm (0.88 in) ground model amps height width depth fans fuses qpac-01 qpac-01 400 to 600 8...

  • Page 11

    Qpac user's guide 11 chapter 2: install & wire load current (amps) semiconduc- tor fuse rat- ing (amps.) minimum recommended wire size bending radius wire sized that lugs accept fuse mounting lug torque internal allen wrench 150 200 3/0 102mm (4 in) 4 to 3/0 *onboard 240 in/lb 3/16 in 200 250 250 mc...

  • Page 12

    12 qpac user's guide chapter 2: install & wire qpac-01 output wiring for 150 to 1,000a units. Warning: shock hazard heatsinks are electrically live. E caution: check terminals for tightness before ap- plying power and then recheck terminals after one day of operation. Loose connections can damage th...

  • Page 13

    Qpac user's guide 13 chapter 2: install & wire output wiring *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. Qpac-33 power and load wiring for all units. Circuit breakers or disconnects contactors if required 3 fact...

  • Page 14

    14 qpac user's guide chapter 2: install & wire 63.5mm (2.50 in) motherboard connector 1 120v b (ac) ,qsxw 38.1mm (1.50 in) 2 3 08-5285 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...

  • Page 15

    Qpac user's guide 15 chapter 2: install & wire motherboard connector 38mm (1.50 in) 51mm (2.00 in) 1 2 (+) 3 (-) 08-5286 input wiring cd control card, solid- state contactor, contact closure input. Cd control card — contact closure input contactor for a contact closure input to the cd control card, ...

  • Page 16

    16 qpac user's guide chapter 2: install & wire input wiring 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 12v z (dc), or 0 to 25ma ...

  • Page 17

    Qpac user's guide 17 chapter 2: install & wire input wiring al control card,current transformer selection. Example of current transformer (ct) connections one ct, 150 amps and above, 1Ø. Ct al card bk bk bk 16-0176 transformer red red wh tb-3 tb-2 5a 20ma 5a:20ma t2 t1 1 5 load soft start (available...

  • Page 18

    18 qpac user's guide chapter 2: install & wire input wiring 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. Tb-3 al card bk red red wh bk bk wh bk 16-0176 transformer tb-2 ct ct t1 t3 t2 5a 20ma *1 *1...

  • Page 19

    Qpac user's guide 19 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. Dh card operation — heater diagnostics the dh card uses a ct to monitor the load cu...

  • Page 20

    20 qpac user's guide chapter 2: install & wire qpac system wiring example 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

    Qpac user's guide 21 chapter 3: how to operate 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 ...

  • Page 22

    22 qpac user's guide chapter 3: how to operate 1. Connect a volt meter across the load or dummy load of the qpac. Con- nect 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. App...

  • Page 23

    Qpac user's guide 23 chapter 3: how to operate fixed bias connector gain pot j3 tb-1 1 5 j1 08-5342 bv fixed bias connector & gain adjustment cut resistor for volts input motherboard connector current limit pot (al card only) bias pot gain pot 08-5411 tb-2 tb-1 4 to 20ma 5v ct 1 2 1 5 al bias, gain,...

  • Page 24

    24 qpac user's guide appendix appendix qpac troubleshooting a technician can isolate a system problem by first 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 t...

  • Page 25

    Qpac user's guide 25 appendix specific to qpac-33 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. • phase loss yellow indicator light is on when all three...

  • Page 26

    26 qpac user's guide appendix specifications qpac specifications operation • modular control base with plug-in card and transformer • plug-in control cards solid-state contactor, b(ac) or z(dc) input burst fire control, fixed or variable time base phase angle fire control phase angle control with so...

  • Page 27

    Qpac user's guide 27 appendix specifications • 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. ...

  • Page 28

    28 qpac user's guide appendix 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 o...

  • Page 29

    Qpac user's guide 29 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...

  • Page 30

    30 qpac user's guide appendix watlow part number models description 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 a...

  • Page 31

    Qpac user's guide 31 appendix warranty 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...

  • Page 32

    32 qpac user's guide appendix 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...

  • Page 33

    Thermal devices, inc. Mount airy, maryland usa www.Thermaldevices.Com thermal devices, inc. Mount airy, maryland usa www.Thermaldevices.Com.

  • Page 34

    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 thermal devices, inc. Mount airy, maryland usa www.Thermaldevices.Com.