User's Guide
Contents
1. 56 to 57mm Pot 2 19 to 2 75 in SISIN Z DC Input i Motherboard Connector AF AL BF and BV Auto Manual Input 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 potentiom eter A switch is used to select between the input from a 1KQ potentiometer or a 4 to 20mA temperature control The control card must be converted to voltage input by removing the appropriate resistor or replacing a jumper See Voltage Input Conversions Chapter 3 A 2500 resistor must be placed in parallel with the temperature control input so that the temperature control signal will be a 1 to 5V dc input 70 to 95mm a ppp 2 75 to 3 75 in DC Input W 1KQ Pot S 1 Q 56 to 57mm ai Bat 2 19 to 2 75 in 2500 ecw O Dis Motherboard Connector Interlock Available on the AF AL BF and BV input card options 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 and 2 when soft start is desirable QPAC User s Guide Chapter 2 Install amp Wire AL Control Card Current Transformer Selection Example of Current Transformer CT Connections One CT 150 Amps and Above 12 Chapter 2 Install amp Wire S2. 63 5mm 2 50 in gt 08 5285 120V ac Input 38 1mm 1 50 in Motherboard Connector CD Control Card DC Input Contactor For dc input the input signal is wired into pin 2 and pin 3 of the input signal connector An input signal of 3 to 30V dc turns the QPAC power control on 0 to 1V dc turns the power control off 51mm 2 00 in 08 5286 38mm 1 50 in Motherboard Connector QPAC User s Guide Chapter 2 Install amp Wire CD Control Card Solid State Contactor Contact Closure Input Input Ranges 0 to 5V dc 1 to 5V dc 0 to 10V dc 0 to 20mA dc 4 to 20mA dc 1KQ potentiometer AF AL BF BV Potentiometer Input Chapter 2 Install amp Wire CD Control Card Contact Closure Input Contactor 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 10KO minimum i eooiny 08 5286 38mm 1 50 in Motherboard Connector 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 Control 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 potentiom
3. Chapter 2 Install amp Wire QPAC User s Guide 11 Output Wiring A WARNING Shock Hazard Heatsinks are electrically Live A CAUTION Check terminals for tightness before ap plying power and then recheck terminals after one day of operation Loose connections can damage the SCR NOTE A circuit breaker is re quired in addition to the semiconductor fuses All semiconductor fuses are mounted on board the QPAC models 400 to 1 000 Where third leg fusing is selected addi tional space is required NOTE QPAC models Q01 Q32 and Q33 up to 300A and 575V ac are agency listed QPAC models Q01 and Q32 up to 1 000A and 480V ac are agency listed Q33 400 to 1 000A are not agency listed A WARNING To avoid damage to property and equipment and or injury or loss of life use National Electric Code NEC standard wiring practices to install and operate the QPAC Failure to do so could result in damage and or injury or death 12 L1 sje _ _ __ Circuit z2 Breakers Contactors Heater or If Required Load Disconnects 1A Fuse Wao a l Fan 120V ac 20W G TE l l A 5 On board l 3 factory l installed semicon ductor fuses l QPAC 01 Output Wiring for 150 to 1 000A Units 1 NOTE On 120V ac or 277V ac L2 is neutral and cannot be broken 2 NOTE A contactor is required if a high limit control is used 3 NOTE A separate disconnect
4. and reconnect the controlled load to the QPAC if required Ga 08 5288 ain Pot gt R39 Bias_ d R38 Pot move jumper for mA or volts dc input 108 O9 00 4to20mA CO sy Bi A 08 5289 x R17 T Gain Bias Pot Pot cut resistor R3 for volts dc input 20000 R3 TB1 4 oO De QPAC User s Guide Chapter 3 How to Operate Bias and Gain BV Rev B Control Card AL Rev B Control Card NOTE The AL Current Limit must be disabled pot fully clockwise CW before bias and gain can be adjusted Chapter 3 How to Operate Fixed Bias Connector Gain Pot BV Fixed Bias Connector amp Gain Adjustment lt cut resistor for volts input J1 Bias Pot Gain Pot U G lt Current Limit Pot 98941 AL Card only AS TB 2 AL Bias Gain amp Current Limit Adjustments move jumper for mA e or volts dc input E 20mA Motherboard Connector Current Limit Adjustments AL Card only 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 the AL Rev B Control Card figure above Use the follow ing steps to adjust the current limit on initial setup The purpose of the proce dure is to bring the power to the load up slowly so that the maximum current to the load is not exceeded before the cur
5. control card auto manual input 16 input connections 16 potentiometer input 15 process input 15 bias and gain adjustments 15 21 burst firing control cards 5 model number 28 process input 15 specs 26 BV control card auto manual input 16 input connections 16 potentiometer input 15 process input 15 C CA control card 14 Case Style C mounting 8 9 Case Style E mounting 10 CD control card 14 contact closure input 15 control cards 5 14 18 bias and gain adjustments 21 22 phase angle 5 15 setup 21 current limit adjustments 23 current limiting 22 26 32 current transformer connec tions 18 D dc input 14 dc input contactor 16 DH option 19 dimensions 6 F fuse semiconductor 11 27 fuses 8 10 24 28 G gain adjustments 15 21 22 24 general description 4 input signal wiring 14 input wiring 14 19 install and wire the QPAC 6 interlock 16 M manual potentiometer input 15 model number information 2 28 mounting 6 27 O operate the QPAC 21 output wiring 12 13 overtemperature cutout 20 P phase angle control cards 21 specs 26 potentiometer input 15 Q Q32 4 QPAC 01 case style C 8 10 wiring 12 QPAC 32 case style C 8 10 description 5 proper phase sequence 21 troubleshooting 24 wiring 12 QPAC User s Guide QPAC 33 case style C 8 10 description 5 diagnostics 25 proper phase sequence 21 troubleshooting 24 R returns 31 S semiconductor fuses 11 27 setup ad
6. 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 differ ent 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 ap plications 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 inductive loads Steps To Put Your Power Control To Work To put your QPAC to work we suggest the following steps e Read the User s Guide e Plan your installation and wiring e Mount the QPAC e Wire your QPAC to the system e Start the system and if applicable adjust the bias and gain on the QPAC e That s all there is to it QPAC User s Guide 5 Ay 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 applicable codes 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 install when you receive it This chapter is divided into three section
7. is required for the fan s if used 4 NOTE Use 14 to 16 gauge wire for control power only L3 L2 Contactors If Required L1 Circuit Breakers or Disconnects O Z Fan 120V ac 20W o ote L1 L2 On board T3 factory installed semi conductor fuses QPAC 32 Output Wiring for 150 to 1 000A Units QPAC User s Guide Chapter 2 Install amp Wire Output Wiring QPAC 33 Power and Load Wiring for all Units A WARNING Shock Hazard Heatsinks are electrically Live A CAUTION Check terminals for tightness before ap plying power and then recheck terminals after one day of operation Loose connections can damage the SCR NOTE A circuit breaker is re quired in addition to the semiconductor fuses All semiconductor fuses are mounted on board the QPAC models 400 to 1 000 Where third leg fusing is selected addi tional space is required NOTE QPAC models Q01 Q32 and Q33 up to 300A and 575V ac are agency listed QPAC models Q01 and Q32 up to 1 000A and 480V ac are agency listed Q33 400 to 1 000A are not agency listed nN WARNING To avoid damage to property and equipment and or injury or loss of life use National Electric Code NEC standard wiring practices to install and operate the QPAC Failure to do so could result in damage and or injury or death Chapter 2 Install amp Wire L1 1 Circuit Breakers or L2 Disconnects C
8. listed and cULus up to 300 amps only on Q33 models File E73741 SCCR Short Circuit Rating e UL witness tested to 200 000A available fault current Q01 Q32 150 1000A to 480V ac Q33 units and over 480V ac units not tested Control Card Inputs CA Solid state contactor ac input e 120V ac 30mA minimum ac signal input sources i e triacs or mechanical relay outputs with noise suppression require customer supplied resistors across the power controller ac command signal input terminals to prevent false firing 24V ac input 2000 10 watts typical 120V ac input 1kO 25 watts typical 240V ac input two 1kQ 25 watts in series typical CD Solid state contactor dc input e On 4 to 10V dc 0 5mA off 0 5V dc Built in noise reduction network BF Burst firing control fixed time base e Process input factory set 4 to 20mA dc e Input impedance 2500 clip resistor for 5KQ voltage input or manual con trol input e Time base 4 seconds clip resistor for 1 sec BV Burst firing control variable time base e Process input factory set 4 to 20mA dc e Input impedance 2500 clip resistor for 5KQ voltage input or manual con trol input AF Phase angle control e Process input factory set 4 to 20mA dc e Input impedance 2500 move jumper 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 w
9. signal reversed See Input Wiring Chapter 2 Input signal not See Bias and Gain Adjustment Chapter 3 adjusted Wrong or missing See Input Wiring Chapter 2 control card 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 operational fan for shorted thermostat replace fan or ther mostat as necessary 27 0005 thermostat is normally open and closes on temperature rise Transformer hot Check product and transformer labels former Uncontrolled output Bad control card or Unplug control card try again Readjust bias full on bias and gain out of and gain adjustment 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 it Unbalanced output Incorrect phase See Phase Rotation Adjustment Chapter 3 QPAC 32 and QPAC 33 rotation The QPAC Service Manual is available at http Awww watlow com downloads en manuals qpacse_a pdf QPAC User s Guide Appendix Specific to QPAC 33 Diagnostics Diagnostics The QPAC 33 has four indicator lights for diagnostics During normal opera tion all four will be lit Yellow indicator light is on when power is applied to t
10. 2 Install amp Wire 5 7mm k s 13 5mm 0 225 In 0 53 in 25 4mm ALN 1 00in Pa D 7 9mm a a a 5 16 in 18 N REELS l Ss ees il 9 7mm NEA i 0 38 in ee 7 7 3 8mm Ensure nut and washer 0 15 in are used below and above fuse Top View Right Side View 88 9mm 3 50 in minimum 106 4mm 4 19 in maximum aN LE DA SY 40 4 N 4mm 19 1mm ines 0 75 in 1 59 in E peat 31 8mm 1 25 in Top View TA of 9 7mm 0 38 in Typical 152 0mm 6 00 in 103 17mm Ke 4 062 in 24 6mm 0 97 in k 50 8mm R 2 00 in QPAC User s Guide m o 21 1mm k a 0 83 in Ri ght Side View 9 5mm 0 375 in 16 WA qpa lt 2 00 in 50 8mm 4 12 7mm 0 50 in i a By Ensure nut and washer mmmH L 7 1mm 0 281 in 4 oF are used below and above fuse 25 4mm 1 00 in Case Style C Mounting QPAC Case Style C QPAC Case Style C Overall Dimensions A CAUTION Mount the QPAC vertically height dimension vertical for proper cooling Failure to do so could result in power control malfunction A WARNING Shock Hazard Heatsinks are electrically Live QPAC Case Style C QPAC 01 150 200 300A Single Phase Mounting Footpr
11. 4 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 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 avail able when calling e Complete model number e All configuration information e User s Guide e Serial Number The model part number and serial numbers can be found on the label on the outside of the case How to Read the QPAC Model Number The QPAC model number provides phase supply voltage amperage and control type information in that order For example 480V ac Supply 3 Phase 2 Leg Burst Fired Variable Time Base Heater Shorted SCR Detector Q32 481 150 BV2 Refer to the model number breakdown in the Model Number Information chart in the Appendix for a complete listing QPAC User s Guide How to Use this Guide Table of Contents Chapter 1 Starting Out With The QPAC Power Control General Description Steps To Put Your Power C
12. QPAC User s Guide Modular SCR Power Control 150 to 1 000A Bc LOW 1241 Bundy Blvd 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 D Made in the U S A UAE AA A August 2010 How to Use this Manual NOTE Details of a Note ap pear here on the left side of each page A CAUTION Details of a Caution appear here on the left side of each page Ay WARNING Details of a Warning appear here on the left side of each page 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 symbol A exclamation point in the wide text column alerts you to a CAUTION a safety or functional hazard which could affect your equipment or its performance A full explanation is in the narrow column on the left side of the page The WARNING symbol A lightning bolt in the wide text column alerts you to a WARNING a safety hazard which could affect you and the equipment A full explanation is in the narrow column on the left side 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 45
13. 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 indicator light 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 CTs 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 to 20mA output or 5V for O to 5V output 2 Adjust P1 until the open heater light on the DH card is full on No inter mittent cycling 3 Slowly adjust P1 until the open heater light just turns full off No intermit tent 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 QPAC User s Guide 19 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 QPAC System Wiring condition exists An independent high limit control must be used that will Example Overtemperature sense unsafe temperature and disengage the circuit breaker via undervolt Cutout age trip or a mechanica
14. e 3 leg models AL models 150 amps and above require one interstage transformer Open Heater Shorted SCR Detector 5 burst fire zero cross models only 0 None 1 Single phase operation 2 Three phase operation 28 QPAC User s Guide Appendix Accessories Accessories wallow Pari Number Modei Descriton C Manual Contant 16 0073 Ne a Number 17 7019 17 7012 QPAC 1000A up to 575V Fuse Semiconductor 1250A 700V Blade Bussmann 170M6766 17 5064 QPAC 150 to 300A 575V Fuse Holder Semiconductor externally mounted Applications only in in 25 0028 QPAC 400 to 1000A Cooling Fan 230V 260 CFM 152 4mm 6 in 18 1064 Q33 400 to 600 A Diode 1400A 1200V SD1100C C Series IR 08 7210 al Bias and Gain Card use w BV Input Control Card F i 25 0022 QPAC 150 to 300A Cooling Fan 230V 105 CFM 114 3 x 114 3mm 4 5 x 4 5 in F 18 1068 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 Input Control Card Phase angle w AL 0 to 5V dc 50 Hz PC 5411 05 60H Q01 Q33 Input Control Card Phase angle w AL 0 to 5V dc 60 Hz RPC 5411 42 50H Q01 Q33 Input Control Card Phase angle w AL 4 to 20 mA 50 Hz Appendix QPAC User s Guide 29 Accessories Watlow Part Descri
15. equire 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 indicator lights in the upper left hand cor ner of the Power Base motherboard If the phase rotation indicator light 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 to 20mA but can be adjusted over a range of 0 to 12V dc or 0 to 25mA to match the output of a specific temperature control Input impedance for 4 to 20mA input is 2500 The input impedance can be changed to 5KQ to accept a voltage by performing the following procedure for each card Voltage Input Conversions See Accessories in the Appendix for card part numbers AF For 5KOQ input move J2 jumper located on the lower left of the AF card next to the TB 2 connector Terminal 5 See the AL Rev B Control Card figure in this chapter AL For 5KOQ input replace t
16. eter input or an input from a temperature control The following paragraphs give the connec tions 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 con nections of the control card The wiper of the potentiometer should be connect ed to the connection The control card must be converted to a voltage input by replacing a jumper See Bias and Gain Adjustments Chapter 3 70 to 95mm a E a 2 75 to 3 75 in requires 0 to 5V dc input card setting CW 56 to 57mm Pot 2 19 to 2 75 in 1KQ Pot 5 CCW Motherboard Connector QPAC User s Guide 15 AF AL BF and BV dc Input AF AL BF and BV Auto Manual Input 16 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 dc or 0 to 25mA input signal They are factory calibrated for 4 to 20mA If using a voltage or current range other than this follow bias and gain adjustment in structions in Chapter 3 The control card can be converted to a voltage input by removing a resistor or moving a jumper Follow voltage input conversion instructions in Chapter 3 70 to 95mm a on 2 75 to 3 75 in
17. he J2 jumper to the 5V position located on the lower left of the AL card See the AF Rev H Control Card figure in this chapter BF For 5KQ input remove resistor R3 located on the lower left of the QBF card next to the TB 2 connector Terminal 5 See the BF Rev D Control Card figure in this chapter BV For 5KQ input remove the external resistor attached to the J3 con nector plug See the BV Rev B Control Card figure in this chapter Adjustment Procedure We recommended that bias and gain adjustment be performed using a dum my 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 connect ing 150 watt lamps in series to match the operating voltage of the QPAC Use the following steps to make adjustments QPAC User s Guide 21 Bias and Gain AF Rev H Control Card BF Rev D Control Card 22 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 Apply power to the system 3 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 2mA Adjust the bias potentiometer slowly CCW counterclockwise until the QPAC output just comes on Then turn CW clockwise unti
18. he control e Phase Loss Yellow indicator light is on when all three phases of line voltage are pres ent Indicator light will be off if one phase is low or lost e Phase Rotation Yellow indicator light is on when correct voltage phase exists even when load is not wired Indicator light will be off when two phases are rotated and when one phase is missing e Phase Lock Loop Yellow indicator light is on when phase lock loop circuit is sychronized Indicator light can go off from noisy power line or if the phase synchro nizing circuitry fails Check power quality then repair or replace power base Appendix QPAC User s Guide 25 QPAC Specifications 26 Operation e 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 Plug in transformers 50 60Hz 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 120V ac through 575V ac e 150 through 1 000 amps per switched leg Agency Approvals e UL 508 listed and cULus up to 1 000 amps on Q01 and Q32 models File E73741 e UL 508
19. int QPAC 32 QPAC 32 QPAC 32 348mm 14 0 in 348mm 14 0 in 348mm 14 0 in 533mm 21 0 in 533mm 21 0 in 330mm 13 in 533mm 21 0 in 178mm 7 00 in _ 89mm 92mm 50 in f 3 63 in 330mm 13 00 in 299mm 11 75 in 10mm 0 38 in 2PL QPAC User s Guide as on heat sink on heat sink on heat sink on heat sink on heat sink on heat sink on heat sink on heat sink on heat sink wo wf N Nw oo Note On 575 V ac applications the fuses are mounted external to the QPAC Chapter 2 Install amp Wire Case Style C H daoo Mounting 178mm m Bomm e 7 00 in 3 50 in 16mm 0 63 in QPAC Case Style C Q32 150 200 300A MOUNT 3 Phase 2 Leg N Mounting Footprint 298mm 11 75 in 33mm 13 00 in A FAN FAN CAUTION Mount the QPAC verti 1 cally height dimension a vertical for proper 10mm 0 375 in cooling Failure to do so could result in power control malfunction A WARNING Shock Hazard Heatsinks are electrically Live Has 533MM 21 00 in 178 178 s Hoon 700 in gemm Fa h T i F U 4 TTB MOUNT QPAC Case Style C 13 00 n Q33 150 200 300A 3 Phase 3 Leg Mounting Footprint FAN FAN FAN P A gt Fan L ES L 10mm 0 375 in 4 PL Chapter 2 Install amp Wire QPAC User s Guide 9 Case Style E Mou
20. ith current limit e Process input factory set 4 to 20mA dc QPAC User s Guide Appendix Appendix e Input impedance 2500 move jumper 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 and interstage transformers included e Available on Q01 and Q33 models only Line Voltage Power e 50 60 Hz ac line frequency Q32 and Q33 calibration line frequency dependent e Voltage 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 e dv dt 200V usec minimum e MOV and RC snubber network standard MOV comes only on Q33 3 phase 3 leg e Q32 third leg fuse kit may be used but not required with 3 phase 2 leg models Mounting Heat sink fins must be mounted in vertical orientation Operating Environment e 0 to 50 C 32 to 122 F e 0 to 90 RH non condensing Storage Temperature e 40 to 85 C 40 to 185 F Options e Manual Control Kit for process input cards 1kQ potentiometer 08 5362 e 240V ac cooling fans in place of 120V ac co
21. justments 21 soft start phase angle 17 specifications 26 starting out 4 steps to put your power control to work 5 system planning 6 system wiring example 20 T troubleshooting 24 W warranty 31 wiring 6 16 CD control card 16 control card current transformer connections 18 data table 6 input 14 19 QPAC 01 12 QPAC 32 12 QPAC 33 13 single and three phase 19 specs 28 system 20 troubleshooting 24 wiring data 11 Appendix 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
22. l contactor as shown below i3 208 120V L2 L1 N 0o00 OQ d L1 Ti L2 13 T3 1A 6 1A 2ASB 9 7 H94 F 98 l G1 99 5 32 202 300 BVO H1 cc L4 CA gt k4 cB Fan Assembly T1 T2 B5 S2 D6 HR2 D5 PM6C2FA ALAJAAA Controller Thermocouple Thermocouple A WARNING Follow National Electric Code safety practices and other lo cally 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 20 QPAC User s Guide Chapter 2 Install amp Wire Chapter 3 How to Operate 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 need minor bias and gain cali brations 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 r
23. l 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 4a AF and BF Adjust the output of the temperature controller to full on 5Vdc 20mA etc Adjust the gain potentiometer CW until the QPAC out put is just full on The QPAC is factory calibrated to be full on at 19 8mA 4b BV and 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 8mA 5 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 temper ature control full on adjust the current limit potentiometer until the QPAC output is full on 6 Repeat steps 3 and 4 until the QPAC 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 7 Remove power disconnect the meters
24. nting 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 1 on board QPAC 32 400 to 600 685mm 27 in 535mm 21 in 300mm 11 7 in 2 2 on board QPAC 33 400 to 600 840mm 33 in 685mm 27 in 300mm 11 7 in 3 3 on board QPAC Case Style E Overall Dimensions A CAUTION Mount the QPAC verti cally height dimension vertical for proper cooling Failure to do so could result in power control malfunction AN Height WARNING Shock Hazard Heatsinks are electrically Live QPAC Case Style E 35 ELECTRONICS GROUND Mounting Footprint o BB f PACKAGE in Signal Connects Inside Fan Voltage Input 22mm a 12 7mm 0 5 in 0 88 in 10 QPAC User s Guide Chapter 2 Install amp Wire QPAC Wiring Data Load Semiconduc Minimum Bending Radius Wire Sized that Fuse Lug Internal Current tor Fuse Rat Recommended Lugs Accept Mounting Torque Allen amps ing amps Wire Size Wrench 102mm in 10 51 240 inb 9 16 in 250 MCM 114 mm 4 5 in 6 to 350 MCM 375 in Ib 500 MCM 203mm 8in 4 to 500 MCM 375 in Ib sam 5 sof 600 dual 350 mem 280mm 15 im 210 600 MGM onboard 500 ivib 12m 200 s00 Duar soo mem 280mm 151m 210 600 MGM onboard 500 ivib 12n The fuses are external in Style C power controls over 575V ac
25. number Method of return shipment Your P O number Detailed description of the problem Any special instructions e 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 paper work returned Ship on a Freight Prepaid basis 3 After we receive your return we will examine it and try to verify the rea son for returning it 4 In cases of manufacturing defect we will enter a repair order replace ment order or issue credit for material returned 5 To return products that are not defective goods must be be in new con dition in the original boxes and they must be returned within 120 days of receipt A 20 percent restocking charge is applied for all returned stock controls and accessories 6 If the unit is unrepairable it will be returned to you with a letter of expla nation 7 Watlow reserves the right to charge for no trouble found NTF returns Appendix QPAC User s Guide 31 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 input connections 16 potentiometer input 15 process input 15 auto manual input 16 BF
26. oft Start 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 By slowly increasing the voltage to the heater the heater element is warmed to full resistance by the time full volt age 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 emer gency shut down ESD the QPAC will restart soft Soft start is only available on phase angle models AL Control Card Current Transformer Connections Phase Angle Current Limit Option 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 Part Number Transformer Not Used 5A 20mA Interstage Transformer 16 0008 150A 5A Current Transformer 16 0045 200A 5A Current Transformer 16 0073 300A 5A Current Transformer 16 0176 on04 0286 0600 500A SA Curent Tanstormer 160176 onne 0286 600 600A 6A Curent Tanstrmer 16 0176 0176 176 0176 0176 0176 0176 0176 TB 3 16 0176 Transformer 5A 20mA QPAC User s Guide 17 Example of Cur
27. oling fans Weight 19 30 2 leg 39 3 wire Q01 Q32 Q33 6 8 kg 15 Ibs 16 3 kg 36 Ibs 22 7 kg 50 Ibs 68 15 72 249 49 QPAC User s Guide 27 Model Number i Model Number Information To order complete the code number to the right with the information below Q _ a n E 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 Output Voltage 12 120V ac 20 208V ac 24 240V ac 27 277V ac 38 3880V ac 41 415V ac 48 480V ac 57 575V ac Cooling Fan Voltage Customer to supply wiring and hook up 1 120V ac required on all 3 phase models 2 240V ac required on all 3 phase models Output Current 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 put 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 to 20mA BV Burst fired variable time base 08 5342 4 to 20mA AF Phase angle fired 08 5288 4 to 20mA not available on Q32 AL 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 phas
28. ontactors If Required L1 L2 l 3 factory O supplied semiconductor fuses 2 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 User s Guide 13 aN CAUTION Built in noise reduction circuitry on the CA card requires an external load resistor 10000 25W 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 equip ment or injury to person nel CA Card Wiring SS Contactor 120V ac Input CD Control Card Solid State Contactor 3 to 30V dc Input 14 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 pro vided by a 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 AC Input Contactor The 120V ac input 24 volts input optional signal lines for the CA ac In put Solid State Contactor Control Card are connected to pins 1 and 3 of the input signal connector A 120V ac input signal turns the power control on The turn off voltage for the power control is OV ac lt
29. ontrol To Work Chapter 2 How to Install and Wire the QPAC ah How to Use this Manual System Planning Mounting the QPAC Input Signal Wiring CA Control Card AC Input Contactor CD Control Card DC Input Contactor Process Input AF AL BF and BV Control Cards AF AL BF and BV Potentiometer Input CD Control Card Contact Closure Input Contactor AF AL BF and BV DC Input Connections AF AL BF and BV Auto Manual Input Interlock Soft Start AL Control Card Current Transformer Connections Single and Three Phase Current Transformer Wiring DH Card Operation Heater Diagnostics Setup Procedure QPAC system Wiring Example Chapter 3 How to Operate the QPAC Setup Adjustments Phase Rotation Adjustment for Q32 and Q33 Bias And Gain Adjustments for AF AL BF BV Current Limit Adjustments Appendix QPAC Troubleshooting Specific to QPAC 33 Diagnostics QPAC Specifications Model Number Information Accessories Warranty Returns QPAC User s Guide The Q32 SCR Power Control Chapter 1 Starting Out With The QPAC 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 This proportional output power helps to produce a closely controlled heater temperature which saves energy and prolongs hea
30. ption Number ossa fa ino Contra ara Zero ross w8F 4t020m8 Recs a Input Control Card Zero ros wBV 410 20mA SOng Papc s942 60H2 a input Control Card Zero ros wBV 410 20mA 60H ossa fa inp comol Gar Zero rossw0A acinus foese36_ al_______ Input Conor Car Zero ross WCD doino RPC 5338 150 Q33 all SCR Driver Board 08 5338 g aot 03215010 300A OPAC 150 o 400A 1207 08 5303 QPAC 150 to 300A Transformer Assembly Plug in 208 240V 208 240V OPAC 1500 SODA 675V Z100 0819 0000 QPAC 400 to 1000A Transformer Assembly Plug in 208 240V 208 240V 30 QPAC User s Guide 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 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 or abuse Returns 1 Call Watlow Customer Service 507 454 5300 for a Return Material Au thorization RMA number before returning any item for repair We need this information Ship to address Bill to address Contact name Phone
31. rent Transformer Connection to the AL current limit Card 16 0176 Transformer 1 NOTE Both load leads must pass through the CTs in the same direction 18 QPAC User s Guide Chapter 2 Install amp Wire 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 AN CAUTION The shorted SCR detec tor feature will not work with the manual control input Chapter 2 Install amp Wire Single and Three Phase Current Transformer Wiring 120V ac N C To Alarm or Contactor Momentary Reset Switch y b Open heater Customer Supplied Relay Philips ECG PIY 1055 or equivalent Shorted SCR when lit when lit FSO gs0 _ Single Phase 1 Interstage transformer 2 Ipy e 16 0176 for 150A T1 J2 and above I U4 CT I 4 Load Wire l Be Uo ee eee E ao a ANAT 2 20 ih Motherboard Three Phase a ofa kits i Connector Interstage transformer TH i y 16 0176 for 150A and above l 1 I 30 mm i 1 20 in Be I let Load Wires mm 2 70 in I T3 J3 1 l DH Card Operation Heater Diagnostics The DH card uses a CT to monitor the load current and also detects when a firing pulse is sent to the SCRs 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
32. rent limit is adjusted Note A short overcurrent through the load may occur as the AL Card circuitry detects the higher current if the input signal from the temperature control is abruptly increased 1 Attach a clamp on ammeter to the load line 2 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 5 Gradually increase the input signal 6 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 cur rent limit potentiometer to obtain the desired maximum current to the load QPAC User s Guide 23 Troubleshoot QPAC Troubleshooting Guide 24 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 the QPAC s control card transformer or power base Use this QPAC Troubleshooting Guide to assist with troubleshooting Symptom Probable Cause Corrective Action No output Check and replace fuses Incorrect input See Input Wiring Chapter 2 wiring Incorrect input Check temperature control output signal Input
33. s that describe the three steps to installing 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 two case styles The second section describes the power and load wiring of the QPACs and semiconduc tor fuses if required The last section describes the input signal wiring to the QPAC Control Card Before you begin working read through this chapter to gain an under standing 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 The physical size and mounting dimensions of the QPACs are different for different current ratings Find the Case Style photo on the next pages that 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 mount ed fuses 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 QPAC User s Guide Chapter 2 Install amp Wire Template for Fuse Holders with QPAC 150A 575V Template for Fuse Holders with QPAC 200 and 300A 575V Chapter
34. ter 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 Card See the QPAC Modularity Overview below Power Bases are available in 150 to 1 000A ratings with UL508 listed and cULus in single phase three phase two leg and three phase three leg configurations A Transformer plugged into the Power Base allows the QPAC to operate QPAC User s Guide Chapter 1 Starting Out QPAC Modularity Overview Chapter 1 Starting Out Control Cards 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 Phase angle control AF Phase angle control with current limiting AL Note For 19 and 39 3 leg controls only not for 3G 3 leg controls Plug in transformers 50 60 Hz 120V ac 208 240V ac 380V ac 415V ac 480V ac 575V ac Power Bases With Motherboards e QPAC 01 19 150 to 1 000A e QPAC 32 3 2 leg 150 to 1 000A e QPAC 33 30 3 leg 150 to 1 000A on any voltage from 120 to 575V 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 approach using a standard Power Base with plug
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