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User`s Manual - Zesta Engineering Ltd.

1. Factory supplied customer installed QPAC 32 30 To 50A external semiconductor fuse ry L3 M Figure 19 Contactors QPAC 32 Wiring Circuit If Required for 30 50A Units Breakers or L2 Disconnects Factory supplied customer installed external semi conductor fuse L1 T3 NOTE A contactor is required if a high limit control is used NOTE A separate discon nect is required for QPAC 32 75 to 100A the fan s if used L3 Circuit Contactors Factory supplied If Required customer installed Breakers q external semiconductor fuse or L2 Disconnects Factory supplied customer installed external semiconductor fuse L1 Top end of heatsink Bottom end f heatsink Figure 20 Seve QPAC 32 Wiring for 75 100A Units Heater Load Heater Load Fan 120VAC 20W L1 2 Fan 120VAC 20W L1 L2 16 QPAC User s Manual How to Install and Wire the QPAC Chapter 2 AN Wire QPAC 33 CAUTION Check terminals for tightness before applying power and then recheck terminals after one day of operation Loose connections can damage the SCR QPAC 32 150 1000A Figure 21 QPAC 32 Wiring L3 for 150 1000A Units Circuit Breakers or L2 Disconnects Contactors If Required L1 Fan 120VAC 20W NOTE T3 L1 A contactor is Onboard L2 required if a high factory in limit control is used stalled semi conductor NOTE A s
2. Input Wiring Figure 29 Current Transformer C T Connections One C T 50 Amps Or Less 10 Figure 30 Example Current Transformer C T Connections One C T 75 Amps and Above 10 Figure 31 Example Current Transformer Connections Two C T s for Two LegSensing 75 Amps and Above NOTE Both load leads must pass through the C T s in the same direction 22 QPAC User s Manual AL Control Card Current Transformers cont d T1 TB 3 AL Card Load Wire T2 TB 3 AL Card Lo ad 16 0176 Transformer 5A 20mMA TB 2 16 0176 Transformer How to Install and Wire the QPAC Chapter 2 Single and Three Phase DH Option Input Wiring Open Heater or Shorted SCR Detector 120 VAC N C To Alarm Momentary or Contactor Reset E Switch l t Figure 32 Customer Supplied Relay t db Philips ECG PIY 1055 or equivalent Single and Three Hm Phase Wiring Open heater Shorted SCR when lit when lit NOTE I Single Phase i 08 54 DH 1 O 0 Interstage transformer Interstage P o 16 0176 for 75amps 74 transformers 1 6 J S ad apoye 0176 required for F j f T units 75 amps and 66 mm l 2 Load Wire above Motherboar Connector Three Phase Interstage transformer Ti 16 0176 for 75 amps and above 1 20 om Load Wires
3. 2 75 56 57mm O Pot DC Input Be f t Ne Motherboard Connector How to Install and Wire the QPAC Chapter 2 AF AL BF and BV Auto Manual Input Input Wiring 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 potentiome ter A switch is used to select between the input from a 1KQ potentiometer or a 4 20mA temperature control The control card must be converted to voltage input by removing the appropriate resistor or replacing a jumper See Page 25 A 250Q resistor must be placed in parallel with the temperature control input so that the temperature control signal will be a 1 5 volt input i Figure 28 AF AL e 2 75 3 75 70 95mm DC Input W 1KQ Pot 2 19 2 75 BF and BV 56 57mm Auto Manual Input 2509 CCW Motherboard Connector Interlock 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 amp 2 when soft start is desirable Soft Start 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 w
4. 7 Case Style B 8 Case Style C 11 12 Case Style F 13 o Overtemperature Cutout 24 P Phase Angle SCR Control 5 20 29 Phase Rotation Adjustments 25 Potentiometer Input 20 Power And Load Wiring 14 17 Q QPAC 01 Mounting 6 12 Power And Load Wiring 14 15 QPAC 32 Mounting 6 12 Power And Load Wiring 16 17 QPAC 33 Mounting 6 13 Power And Load Wiring 17 R Returns 33 S Semiconductor Fuses 6 14 17 30 Setup Adjustments 25 Specifications 29 30 Starting Out 4 Steps To Put Your Power Control To Work 5 System Planning 6 System Wiring Example 24 T Troubleshooting 28 WwW Warranty 33 Wiring Data Table 6 Input 18 23 Load 14 17 Power 14 17 System Example 24 Appendix Watlow QPAC Modular SCR Power Control User s Manual Watlow Controls 1241 Bundy Blvd P O 5580 Winona MN 55987 5580 Phone 507 454 5300 Fax 507 452 4507
5. 8 5 229 Two Three External 4 90 124 QPAC 33 100 12 5 318 10 2 259 8 5 229 Two Three External 4 90 124 Note See external fuse mounting drawing Figure 7 Page 9 Note See external fuse mounting drawing Figure 8 Page 10 AN CAUTION Mount the QPAC AN vertically height dimension vertical for proper cooling Failure to do so could result in power control malfunction 10 25 260mm 0 22 5 6mm 1 00 25 4mm 9 82 249mm Figure 14 QPAC Case Style F 30 50 75 100A Mounting Footprint 9 00 12 50 229mm 318mm Install and Wire Chapter 2 QPAC User s Manual 13 Wire QPAC 01 AN A 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 appli cable codes Figure 15 QPAC 01 Wiring for 30A Units NOTE On 120Vac or 277Vac L2 is neutral and cannot be broken NOTE A contactor is required if a high limit control is used Figure 16 QPAC 01 Wiring for 50A Units 14 QPAC User s Manual CAUTION Check terminals for tightness before applying power and then recheck terminals after one day of operation Loose connections can damage the SCR QPAC 01 Power and Load Wiring QPAC 01 30A Circuit Breakers Contactors Heater or If Required Load Disconnects Onboard factory inst
6. Bias and Gain Adjustment p 25 26 Wrong or missing control card See Input Wiring p 18 23 Transformer wiring Check transformer connections Missing load wiring See Power and Load Wiring p 14 17 The SCR s will not function without a load Heatsink Clogged or non operational fan Check fan power and clean if temperature necessary Check for shorted exceeded thermostat replace fan or thermo 187 F 86 C stat as necessary 27 0005 thermostat is normally open and closes on temperature rise Transformer hot Incorrect transformer Check product amp transformer labels Uncontrolled output full ON Bad control card or bias and gain out of adjustment Unplug control card try again Readjust bias amp gain Bad transformer Unplug transformer wire and try again Bad power base If full ON or half ON output present with no control card and no transformer power base is bad replace Unbalanced output QPAC 32 amp QPAC 33 Incorrect phase rotation See Phase Rotation Adjust p 25 QPAC 33 Diagnostics The QPAC 33 has four LEDs for diagnostic indication During normal opera tion all four LEDs will be illuminated Yellow LED is ON when power is applied to the control Yellow LED is ON when all three phases of line voltage are present LED will be OFF if one phase is low or lost e Power ON e Phase Loss e Phase Rotation e Phase Lock Loop Y
7. 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 result ing from transportation alteration misuse or abuse Returns 1 Call Watlow Customer Service 507 454 5300 for a Return Material Authorization RMA number before returning any item for repair We need this information e Ship to address e Bill to address e Contact name e Phone number e Method of return shipment e Your P O number e Detailed description of the problem e 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 reason for returning it 4 In cases of manufacturing defect we will enter a repair order replacement order or issue credit for material returned 5 To return products that are not defective goods must be be in new condi tion in the original boxes and they must be returned within 120 days of receipt A 20 perce
8. for 30 2 leg controls Figure 2 QPAC Modularity Plug in transformers 50 60 Hz Overview 120Vac 208 240Vac 380Vac 415Vac 480Vac 575Vac consult factory Power Bases With Motherboards e QPAC 01 1 30 300A e QPAC 32 3G 2 leg 30 300A e QPAC 33 30 3 wire 30 300A Card See Figure 2 Power Bases are avaliable in 30 to 300A ratings with UL508 and C UL listing and 400 1 000 amps non agency approved in single phase three phase two leg and three phase three wire configurations A Transformer plugged into the Power Base allows the QPAC to operate on any voltage from 120 to 480Vac fan 575Vac consult factory 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 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 applica tions 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 indu
9. for proper cooling Failure to do so could result in power control malfunction A WARNING Style C heatsinks are electrically HOT Figure 10 QPAC Case Style C QPAC 01 150 200 300A Single Phase Mounting Footprint QPAC User s Manual 11 A A Figure 11 14 00 356mm QPAC Case Style C Q32 150 200 300A Three Phase 2 Leg Mounting Footprint 3 50 7 00 178mm 89mm 0 63 16mm 11 75 298mm A CAUTION Mount the QPAC vertically height dimension vertical for proper cooling Failure to do so could result in power control malfunction 13 00 33mm 0 375 10mm 4 PL A 21 00 533mm WARNING 7 00 7 00 sa Style C heatsinks 178mm are electrically HOT 178mm 92mm 0 63 16mm Figure 12 QPAC Case MOUNT 11 75 Style C Q33 299mm 150 200 300A Three Phase 3 Wire Mounting Footprint 13 00 33mm 375 10mm 6 PL 12 gt QPAC User s Manual Install and Wire Chapter 2 Case Style F NOTE See separate Addendum page for Case Style E Figure 13 QPAC Case Style F Case Style F Dimensions Model Amps Height Width Depth Fans Fuses Holder max Table 5 in mm in mm in mm in _ mm QPAC Case Style F QPAC 33 30 12 5 318 10 2 259 8 5 229 Two Three External 5 69 145 Overall Dimensions QPAC 33 50 12 5 318 10 2 259 8 5 229 Two Three External 5 69 145 QPAC 33 75 112 5 318 10 2 259
10. performance A full explanation is in the narrow column on the outside of the page D The WARNING symbol lightning bolt in the wide text column alerts you to a WARN ING a safety hazard which could affect you and the equipment A full explanation is in the narrow column on the outside of the page 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 Manual is copyrighted by Watlow Winona Inc July 2003 with all rights reserved 2392 Technical Assistance If you encounter a problem with your Watlow controller review your configuration 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 e Complete model number e All configuration information e User s Manual e Serial Number The model part number and serial numbers can be found on the label on the outside of the case How to Use the Manual How to Read the QPAC Model Number The QP
11. 203 4 to 500 MCM All Onboard Install and Wire Chapter 2 Case Style A Figure 3 QPAC Case Style A Case Style A Dimensions Table 2 Model Amps Height H Width Depth Fans Fuses QPAC Case Style A in mm in mm in mm Overall Dimensions QPAC 01 30 7 178 See 6 5 165 None Two Onboard QPAC 01 50 9 229 Below 6 5 165 None Two Onboard Figure 4 AN QPAC Case Style A Mounting Footprint 5 00 127mm A CAUTION Mount the QPAC vertically height dimension vertical H less for proper cooling 2 00 50 8mm Failure to do so could result in power control malfunction Mounting Clip Hole 0 19 5mm 5 80 147mm gt 6 60 168mm Install and Wire Chapter 2 QPAC User s Manual 7 Case Style B Figure 5 QPAC Case Style B Table 3 Case Style B Dimensions QPAC Case Style B Overall Dimensions Model Amps Height H Width Depth Fans Fuses Holder max in mm in mm in mm in mm QPAC 32 30 105 267 5 127 8 5 208 One Two External 5 69 145 QPAC 01 75 10 5 267 127 8 5 208 One One External 4 90 124 QPAC 01 100 10 5 267 127 8 5 208 One One External 4 90 124 QPAC 32 50 10 5 267 127 8 5 165 One Two External 5 69 145 QPAC 32 75 145 368 127 8 5 229 One Two External 4 90 124 QPAC 32 100 14 5 368 5 127 8 5 208 One Two Exte
12. AC model number provides phase supply voltage amperage and control type information in that order For example Fan Cooled 30Amp 30A 480Vac 30 480Vac Supply Burst Fired Variable Time Base 3 Phase 2 Leg es Heater Shorted SCR Detector Q32 481 030 BV2 Refer to the model number breakdown on page 31 for a complete listing Table of Contents Page Item 2 How to Use the Manual 3 How to Read the QPAC Model Number 3 Contents 4 Starting Out With The QPAC Chapter 1 4 General Description 5 Steps To Put Your Power Control To Work 6 How To Install And Wire The QPAC Chapter 2 6 System Planning 6 Mounting The QPAC 7 Case Style A Mounting QPAC 01 30 50A 8 Case Style B Mounting QPAC 01 75 100A QPAC 32 30 100A 9 10 Fuse Templates 11 12 Case Style C Mounting QPAC 01 150 300A QPAC 32 150 300A QPAC 33 150 300A 13 Case Style E Mounting See Addendum for 400 to 1 000 Amp QPAC 13 Case Style F Mounting QPAC 33 30 100A 14 15 Power and Load Wiring QPAC 01 16 17 Power and Load Wiring QPAC 32 17 Power and Load Wiring QPAC 33 18 Input Signal Wiring 18 CA Control Card 19 CD Control Card dc Input 19 CD Control Card Contact Closure Input 20 AF AL BF and BV Control Cards 20 AF AL BF and BV Potentiometer Input 20 AF AL BF and BV dc Input Connections 21 AF AL BF and BV Auto Manual Input 21 Interlock 21 Soft Start 21 22 AL Control Card Current Transformer Connections 23 DH Option Open Heater or Sho
13. Control Card are connected to Pins 1 and 3 of the input signal connector A 120Vac input signal turns the power control ON The turn OFF voltage for the power control is OVac I 2 50in 63 5mm 08 5285 120VAC Input Motherboard Connector How to Install and Wire the QPAC Chapter 2 Input Wiring CD Control Card DC Input For DC input the input signal is wired into Pin 2 and Pin 3 of the input signal connector An input signal of 3 30VDC turns the QPAC power control ON 0 1VDC turns the power control OFF lt 2 00 51mm gt 08 5286 e Figure 24 CD Control Card Pin 3 1 50 Solid State Contac 38mm tor 3 30Vdc Input Motherboard Connector CD Control Card Contact Closure Input 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 10KQ minimum Figure 25 lt 2 00 51mm CD Control Card Solid State 08 5286 Contactor Contact Closure Input Motherboard Connector How to Install and Wire the QPAC Chapter 2 QPAC User s Manual 19 Input Wiring Figure 26 AF AL BF BV Potentiometer Input Figure 27 AF AL BF and BV DC Input 20 QPAC User s Manual Process Input AF AL BF and BV Control Cards The QPAC AF AL BF and BV Control Cards are defined as follows AF Phase Angle C
14. Load Wire Load Wire Passes Current Thru Current Transformer Thru Current 2 to 3 Amps Transformer 3 to 4 Amps 4 to 5 Amps 5 to 10 Amps 10 to 40 Amps How to Install and Wire the QPAC Chapter 2 QPAC User s Manual 23 System Wiring Figure 33 QPAC System Wiring Example A 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 24 QPAC User s Manual QPAC System Wiring Example pa AN Line a Neutral 1 Fuse Fuse Series i 147 Gusienip High Limit Neutral Indicator VEE Series 93 Thermocouple Input Process Output 93BA 1FA0 00ORR Tungsten Lamp Infrared Heater QPAC 33 with AF Control Card DC Input Overtemperature cutout 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 above How to Install and Wire the QPAC Chapter 2 Chapter 3 How to Operate the QPAC Setup Adjustments After the QPAC is installed and wired it may
15. QPAC User s Manual Modular SCR Power Control Bas LOW 1241 Bundy Bivd P O Box 5580 Winona MN 55987 5580 Tel 1 507 454 5300 Fax 1 507 452 4507 http www watow com 0600 0027 0001 Rev C Made in the U S A DNDN NOTU OONN OUOU N NONY DN N T July 2003 10 00 Use The Manual First Starting Out Install Wire Operation Appendix NOTE Details of a Note appear here in the narrow box on the outside of each page A CAUTION Details of a Caution appear here in the narrow box on the outside of each page WARNING Details of a Warning appear here in the narrow box on the outside of each page 2 QPAC User s Manual How to Use the Manual This manual will make your job easier Reading it and applying the information is a good way to become familiar with the QPAC An overview Introduction Chapter 1 Page 4 Installation and Wiring Chapter 2 Page 6 Operation Chapter 3 Page 25 Troubleshooting Page 28 Specifications Warranty Notes A bold text NOTE marks a short message in the margin to alert you to an important detail Safety Information This user s manual also has boldface safety information notes to protect both you and your equipment Please be attentive to them Here are explanations A The CAUTION symbol exclamation point in the wide text column alerts you to a CAUTION a safety or functional hazard which could affect your egujomentor its
16. ac command signal input terminals to prevent false firing 24V ac input 2009 10 watts typical 120V ac input 1kQ 25 watts typical 240V ac input two 1kQ 25 watts in series typical CD Solid state contactor dc input e ON 4 10V dc 0 5mA OFF 0 5V dc e Built in noise reduction network BF Burst firing control fixed time base e Process input factory set 4 20mA dc e Input impedance 2500 clip resistor for 5kQ voltage input or manual control input e Time base 4 seconds clip resistor for 1 sec BV Burst firing control variable time base e Process input factory set 4 20mA dc e Input impedance 2500 clip resistor for 5kQ voltage input or manual control input AF Phase angle control e Process input factory set 4 20mA dc e Input impedance 2500 clip resistor for 5kQ voltage input or manual control input e Soft start approximately 6 seconds upon power up 1 second upon set point change AL Phase angle control with current limit e Process input factory set 4 20mA dc e Input impedance 2500 clip resistor for 5kQ voltage input or manual control input e Soft start approximately 6 seconds upon power up 1 second upon set point change e Current transformer included e 120V ac through 575V ac e 1 or 3 pole only Appendix QPAC User s Manual 29 30 QPAC User s Manual Line Voltage Power e 50 60 Hz ac line frequency Q32 and Q33 calibration line frequency dependent e Volta
17. alled semicon ductor fuses QPAC 01 50A Circuit Breakers Contactors Heater or If Required Load Disconnects Onboard factory installed semicon ductor fuses How to Install and Wire the QPAC Chapter 2 A Wire QPAC 01 CAUTION Check terminals for tightness before applying power and then recheck terminals after one day of operation Loose connections can damage the SCR Figure 17 QPAC 01 Wiring QPAC 01 75 100A for 75 100A Units Circuit Breakers Contactors or If Required Heater i Load Disconnects Factory supplied Te customer installed T2 L1 external semi L2 conductor fuse NOTE On 120Vac or 277Vac L2 is neutral and cannot be broken NOTE A contactor is required if a high limit control is used NOTE A separate discon nect is required for the fan s if used QPAC 01 150 1000A D Circuit NOTE Breakers Contactors Heater Use 14 16 gauge or If Required a es Load wire for control Disconnects P A power only Fan 120VAC 20W Onboard i factory Figure 18 installed semicon ductor fuses QPAC 01 Wiring for 150 1000A Units How to Install and Wire the QPAC Chapter 2 QPAC User s Manual 15 Wire QPAC 32 iN CAUTION Check terminals for tightness before applying power and then recheck terminals after one day of operation Loose connections can damage the SCR QPAC 32 Power and Load Wiring
18. ariable time base 08 5342 4 20mA AF Phase angle fired not available on Q32 08 5288 4 20mA AL Phase angle fired w current limit not available on Q32 08 5411 4 20mA includes one current transformer Add second CT for 3 phase 3 leg AL models 75 amps and above require one interstage transformer Open Heater Shorted SCR Detector gt 0 None 1 Single phase operation 2 Three phase operation Appendix QPAC User s Manual 31 Accessories 32 QPAC User s Manual 08 5362 16 0246 16 0246 16 0246 16 0246 16 0071 16 0042 16 0008 16 0044 16 0072 16 0008 16 0045 16 0073 16 0069 16 0176 With wire leads Use two wire passes through current transformer 16 0008 Accessories Manual Control Kit 20A 20mA 30A 30mA 40A 40mA 50A 50mA 30A 5A 50A 5A 75A 5A 100A 5A 125A 5A 150A 5A 200A 5A 300A 5A 600A 5A 5A 20mA for 75A application Current Transformer Current Transformer Current Transformer Current Transformer Current Transformer Current Transformer Current Transformer Current Transformer Current Transformer Current Transformer Current Transformer Current Transformer Current Transformer Interstage Transformer Appendix 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
19. armed 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 re start soft Soft start s only available on phase angle models AL Control Card Current Transformer Connections 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 figures show the transformer connections for different load configurations and currents Current Transformer Description Interstage Table 6 Part Number Transformer AL Control Card 16 0246 20A 20mA Current Transformer Not Used Current Transformer 16 0246 30A 30mA Current Transformer Not Used Selection 16 0246 40A 40mA Current Transformer Not Used 16 0246 50A 50mA Current Transformer Not Used 16 0008 75A 5A Current Transformer 16 0176 16 0044 100A 5A Current Transformer 16 0176 16 0072 125A 5A Current 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 Not Used 5A 20mA Interstage Transformer 16 0176 Note With Wire Leads Use two wire passes through current transformer 16 0008 for 75A applications How to Install and Wire the QPAC Chapter 2 QPAC User s Manual 21
20. ctive loads Steps To Put Your Power Control To Work To put your QPAC to work we suggest the following steps Read the User s Manual 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 Getting Started Chapter 1 QPAC User s Manual 5 D WARNING To avoid potential electric shock and other hazards all mounting and wiring for the QPAC must conform to the Na tional Electric Code NEC and other lo cally applicable codes Table 1 QPAC Wiring Data 6 QPAC User s Manual Chapter 2 How to Install and Wire the QPAC System Planning This chapter tells you how to install the QPAC All mounting and wiring infor mation 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 which describe the three steps you need to do to install the QPAC mounting power wiring and control card wiring The first section lists the mounting information for each of the three types of QPACs which depending on amperage use one of five 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 t
21. current if the input signal from the temperature control is abruptly increased 1 Attach a clamp on ammeter to the load line Adjust the AL card current limit potentiometer fully counterclockwise for minimum current flow 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 Gradually increase the input signal 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 Oa How to Operate QPAC Chapter 3 QPAC User s Manual 27 Troubleshoot 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 This problem may be with the QPAC s control card transformer or power base Use Table 8 to assist with troubleshooting Table 8 QPAC Troubleshoot ing Guide 28 QPAC User s Manual Symptom Probable Cause Corrective Action No output Fuses blown Check and replace fuses Incorrect input wiring See Input Wiring p 18 23 Incorrect input signal Check temp control output Input signal reversed See Input Wiring p 18 23 Input signal not adjusted See
22. ellow LED is ON when correct voltage phase exists even when load is not wired LED will be OFF when two phases are rotated and when one phase is missing Yellow LED is ON when phase lock loop circuit is synchronized LED can go OFF from noisy power line or if the phase synchronizing circuitry fails Check power quality then repair or replace power base Appendix QPAC Specifications 2 5 Operation e Modular control base with plug in card and transformer e 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 e Plug in transformers 50 60Hz e 120 208 240 277 380 415 480 575V ac operation Power bases e Single phase Q01 1 pair of SCRs e Three phase Q32 2 leg control 2 pair SCRs Resistive load only burst firing only e Three phase Q33 3 pair hybrid SCRs diodes Recommended for phase angle only with balanced load e 30 through 1000 amps per switched leg Agency Approvals e UL 873 to 300 amps File E43684 formerly E67609 e UL 508 and C UL Listed to 300 amps File E73741 e No agency approvals beyond 300 amps Control Card Inputs CA Solid state contactor ac input e 120V ac 30mA minimum e ac signal input sources i e triacs or mechanical relay outputs with noise suppression require customer supplied resistors across the power controller
23. eparate discon nect is required for the fan s if used NOTE Use 14 16 gauge wire for control QPAC 33 Power and Load Wiring power only QPAC 33 All Models L1 Circuit Breakers or L2 Disconnects Contactors If Required Figure 22 Fan 120VAC 20W QPAC 33 Wiring All Units L3 L1 3 factory supplied ry supp L2 semiconductor fuses 30 100A customer installed 150 300A factory installed How to Install and Wire the QPAC Chapter 2 QPAC User s Manual 17 Input Wiring Input Signal Wiring A CAUTION Built in noise reduction circuitry on the CA card requires an external load resistor 10009 25watt 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 Figure 23 CA Card Wiring SS Contactor 120VAC Input 18 QPAC User s Manual When wiring the input signal do not run any signal wires alongside or in the same conduit with the A C power or load wires Signal input should be provided by shielded two conductor wire Shield should be grounded at the temperature control end only Wrap the power control end with electrical tape The following figures show the wiring configuration for the input signal to the QPAC Control Cards CA Control Card The 120Vac input 24 volts input optional signal lines for the CA ac Input Solid State Contactor
24. er to the system 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 2 mA 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 figures 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 field Order Watlow part number 08 7210 Follow this calibration procedure when using the bias and gain card AF amp 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 8 mA BV amp 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 8 mA 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 tem perature control full ON adjust the current limit potentiometer until the QPAC output is full ON Repeat steps 3 and 4 until the QPAC turns full ON with a full ON signal from the tem
25. ge 10 120 208 240 277 380 415 480 575V ac Line Voltage Compensation e 10 A in line 2 A in load in the 30 to 70 power region AF AL and BV Power Dissipation Watts e 1 5 watts amps per controlled leg Isolation e Command signal to load 1250V ac minimum Linearity e 2 30 to 70 power region All units except CA amp CD Off State Leakage Current e 20mA 480V ac SCR Protection e Semiconductor fuses provided dv dt 200V usec minimum e MOV and RC snubber network standard e Q32 3rd leg fuse kit may be used but not required with 3 phase 2 leg models Mounting e Heat sink fins must be mounted in vertical orientation Operating Environment e 32 to 122 F 0 to 50 C e 0 to 90 RH non condensing Storage Temperature e 40 to 185 F 40 to 85 C Options e Manual Control Kit for process input cards 1k potentiometer 08 5362 e 240V ac cooling fans in place of 120V ac cooling fans Weight e Ibs kg Phase Amps 190 Q01 30 2 leg Q32 39 3 wire Q33 30 6 2 7 8 3 6 20 9 1 50 6 2 7 8 3 6 20 9 1 75 10 4 5 15 6 8 50 22 7 100 10 4 5 Bi 6 8 0 22 7 150 15 6 8 36 16 3 0 22 7 200 15 6 8 36 16 3 0 22 7 300 15 6 8 36 16 3 0 22 7 See addendum for 400 1000 amp models NOTES 1 Q33 models operating on 575 V ac are not UL or C UL listed 2 MOV comes only on Q33 3 phase 3 leg 3 All cooling fans rated 20 watts each mus
26. need a few minor adjustments The three phase power controls require that proper phase rotation exists 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 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 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 LED indicators in the upper left hand corner of the Power Base motherboard If the phase rotation LED 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 20mA but can be adjusted over a range of 0 12VDC or 0 25mA to match the output of a specific temperature control Input imped ance for 4 20mA input is 250Q The input impedance can be cha
27. nged to 5KQ to accept a voltage by performing the following procedure for each card Voltage Input Conversions AF 08 5288 For 5KQ input move J2 jumper located on the lower left of the AF card next to the TB 2 connector Terminal 5 See Figure 34 AL 08 5411 For 5KQ input replace the J2 jumper to the 5V position located on the lower left of the AL card to the 5V position See Figure 37 BF 08 5289 For 5KQ input remove resistor R3 located on the lower left of the QBF card next to the TB 2 connector Terminal 5 See Figure 35 BV 08 5342 For 5KQ input remove the external resistor attached to the J3 connector plug See Figure 36 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 How to Operate QPAC Chapter 3 QPAC User s Manual 25 Bias amp Gain IN Figure 34 AF Rev H Control Card Figure 35 BF Rev D Control Card 26 QPAC User s Manual 4a 4b 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 Apply pow
28. nt restocking charge is applied for all returned stock controls and accessories 6 Ifthe unit is unrepairable it will be returned to you with a letter of explana tion 7 Watlow reserves the right to charge for no trouble found NTF returns Appendix QPAC User s Manual 33 Index A AL Control Card Auto Manual Input 21 Current Limit Transformer 21 22 dc Input 20 Potentiometer Input 20 AF Control Card Auto Manual Input 21 dc Input 20 Potentiometer Input 20 Appendix 28 Auto Manual Input 21 B BF Control Card Auto Manual Input 21 dc Input 20 Potentiometer Input 20 Bias and Gain Adjustments 25 26 Burst Firing SCR Control 5 20 29 BV Control Card Auto Manual Input 21 dc Input 20 Potentiometer Input 20 Cc CA Control Card 18 CD Control Card Contact Closure Input 19 dc Input 19 Case Style A Mounting 7 Case Style B Mounting 8 Case Style C Mounting 11 12 Case Style F Mounting 13 Contents 3 Control Cards 18 22 Current Limit Adjustments 27 Current Limiting 29 Current Transformer Connections 21 22 D dc Input 19 20 DH Option 23 Dimensions 7 13 F Fuse Semiconductor 14 17 24 30 Fuse Templates 9 10 G Gain Adjustments 25 26 General Description 4 H How To Install And Wire The QPAC 6 How to Operate The QPAC 25 How to Use the Manual 2 34 QPAC User s Manual I Input Signal Wiring 18 23 M Manual Potentiometer Input 20 21 Model Number Information 31 Mounting 6 Case Style A
29. o 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 AN The physical size and mounting dimensions of the QPACs are different for different current ratings Find the Case Style photo on the next pages which match your QPAC The table and figure 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 External fuse mounting templates also accompany the case style drawings 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 Current Semi Minimum Bending Radius Lugs QPAC Fuse Amps conduc Recom Accept Model Mounting tor Fuse mended inches mm Wire Number Rating Wire Size Amps 30 2ea 20 10 N A 18to4 Q01 Onboard 2ea 40 Q32 External 3ea 40 Q33 External 50 2ea 30 8 1 5 38 18to4 Q01 Onboard 2ea 70 Q32 External 3ea 70 Q33 External 75 100 4 2 51 8 to 0 All External 100 125 1 3 76 8 to 0 All External 150 200 3 0 4 102 4 to 3 0 All Onboard 200 250 250 MCM 4 5 114 6 to 350 MCM All Onboard 300 400 500 MCM 8
30. ocal electrical codes 4 28 109mm Drill amp tap 0 63 hole B Figure 8 16mm for 10 Fuse Holder Kit fasteners Mounting Template for QPAC 01 75 amp 100A 1 Fuse Kit QPAC 32 75 amp 100A 2 Fuse Kits QPAC 33 75 amp 100A 3 Fuse Kits Stud Size 5 16 Fuse Holder side view 10 QPAC User s Manual Install and Wire Chapter 2 Case Style C Dimensions Model Amps Height Width Depth Fans Fuses in mm in mm in mm QPAC 01 150 13 330 6 9 175 10 25 260 One On Heat Sink QPAC 01 200 13 330 6 9 175 10 25 260 One On Heat Sink QPAC 01 300 13 330 6 9 175 10 25 260 One On Heat Sink QPAC 32 150 13 330 14 0 348 10 25 260 Two On Heat Sink QPAC 32 200 13 330 14 0 348 10 25 260 Two On Heat Sink QPAC 32 300 13 330 14 0 348 10 25 260 Two On Heat Sink QPAC 33 150 13 330 21 0 533 10 25 260 Three On Heat Sink QPAC 33 200 13 330 21 0 533 10 25 260 Three On Heat Sink QPAC 33 300 13 330 21 0 533 10 25 260 Three On Heat Sink Note On 575 V ac applications the fuses are mounted external to the QPAC AN A 7 00 178mm ies E 3 50 89mm f 2mm 13 00 330mm 11 75 299mm 0 38 10mm 2 PL Install and Wire Chapter 2 Case Style C Figure 9 QPAC Case Style C Table 4 QPAC Case Style C Overall Dimensions A CAUTION Mount the QPAC vertically height dimension vertical
31. ontrol 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 configurations including an Auto Manual configuration where the input can be switched between manual and temperature control input AF AL BF and BV Potentiometer Input For potentiometer input wire a 1KQ potentiometer to the POT and connec tions 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 Page 25 e 2 75 3 75 70 95mm Hy 19 2 75 56 57mm Pot 1KQ Pot CCW Motherboard Connector 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 12VDC or 0 to 25mA input signal They are factory calibrated for 4 to 20mA If using a voltage or current range other than this see Chapter 3 Bias amp Gain Adjustments The control card can be converted to a voltage input by removing a resistor or replacing a jumper See Page 25 lt 2 75 3 75 70 95mm _ gt bk 1 2 19
32. perature 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 Remove power disconnect the meters and reconnect the controlled load to the QPAC if required 08 5288 08 5289 R3 How to Operate QPAC Chapter 3 Figure 36 BV Rev B Control Card Fixed Bias Connector BV Fixed Bias Connector amp Gain Adjustment J1 Bias Gain Current Limit Pot Pot Pot AL Card only 5 Figure 37 HDE oa AL Rev B Control Card 1 ca TB 2 2 AL Bias Gain amp Current Limit NOTE Adjustments The AL Current Limit must be disabled pot fully clockwise CW before bias and gain can be adjusted Motherboard Connector Current Limit Adjustments 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 Figure 37 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 Note A short overcurrent through the load may occur as the AL Card circuitry detects the higher
33. rnal 4 90 124 ann an Note See external fuse mounting drawing Figure 7 Page 9 Note See external fuse mounting drawing Figure 8 Page 10 Figure 6 QPAC Case Style B Mounting Footprint f 1 00 i 25mm CAUTION Mount the QPAC vertically height dimension vertical for proper cooling Failure to do so H could result in power control malfunction y 0 19 E ii jae 4 50 114mm lt lt 5 07 129mm gt 8 QPAC User s Manual Install and Wire Chapter 2 Fuse Template Use the next two pages as templates for mounting your fuse holder kit Choose the size that matches your kit and carefully punch out the template along the perforation CAUTION Spacing for multiple fuses must conform to the National Electric Code NEC 5 69 and any other local 145mm electrical codes 0 44 14mm 0 22 6mm Figure 7 Dull tap Fuse Holder Kit 16mm dies Mounting Template or fasteners QPAC 32 30 amp 50A 2 Fuse Kits QPAC 33 30 amp 50A Stud Size 5 16 3 Fuse Kits Fuse Holder side view Install and Wire Chapter 2 QPAC User s Manual 9 Fuse Template Use this page as a template for mounting your fuse holder kit Choose the size that matches your kit and carefully punch out the template along the perforation 4 90 124mm A CAUTION Spacing for multiple fuses must conform to the National Electric Code NEC and any other l
34. rted SCR Detector 24 QPAC System Wiring Example 25 How to Operate The QPAC Chapter 3 25 Setup Adjustments 25 Phase Rotation Adjustments 25 26 Bias And Gain Adjustments 27 Current Limit Adjustments Appendix 28 Troubleshooting 29 30 Specifications 31 Ordering Information 32 Accessories 33 Warranty Returns 34 Index How to Use the Manual QPAC User s Manual 3 Chapter 1 Starting Out With The QPAC Modular SCR Power Control Figure 1 The QPAC 01 SCR Power Conirol 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 tem perature 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 flexibility The three modules of the QPAC are the Power Base Transformer and Control 4 QPAC User s Manual Getting Started Chapter 1 Control Cards Solid state contactor AC input CA Sta rtin g ut Solid state contactor DC input CD Burst firing zero cross fixed time base BF Burst firing zero cross variable time base BV Phase angle control AF Phase angle control with current limiting AL Note For 10 and 39 3 wire controls only not
35. t be wired by customer 4 The open heater shorted SCR detector is for burst fire operation only 5 Included one current transformer for 1 phase and two current transformers for 3 phase Models 75 amps and above require one interstage trans former Appendix Model No Model Number Information 1294 To order complete the code number to the right with the information below Q Es al 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 optional 3rd leg fuse kit extra 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 0 No fan all 1 phase 30 and 50 amp models only 1 120V ac required on all 3 phase models 2 240V ac required on all 3 phase models Output Current Amps 030 30amps 050 50amps 075 75 amps 100 100 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 ac input 08 5285 contactor CD _ Solid state dc input 08 5286 contactor BF Burst fired fixed time base 08 5289 4 20mA BV Burst fired v
36. uae T3 CAUTION 69 mm a The shorted SCR detector feature will Three Phase gti not work with the Without o manual control Interstage 7 5 Transformer Load Wires input T3 7 Operation J3 The DH card uses a CT to monitor the load current and also detects when a firing pulse is sent to the SCR s 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 SCR s the Shorted SCR LED 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 LED is lit and 3 to 4 seconds later the alarm relay energizes This board only operates with the zero cross firing cards For three phase the CT s 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 20mA output or 5 volts for 0 to 5 volt 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 A shorted SCR will energize the shorted SCR light Table 7 Load Number of Passes of

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