WATLOW ASPYRE AT Power Controller User Guide
- June 13, 2024
- WATLOW
Table of Contents
WATLOW ASPYRE AT Power Controller
Product Information
The ASPYRE AT power controller is a product manufactured by Watlow. It is designed to provide power control for various applications. The power controller is compliant with European Union directives and comes with a protection rating of IP20. It is important to adhere to applicable electrical codes and standard wiring practices when installing and operating this product to avoid damage, injury, and loss of life.
Technical Assistance
For any technical assistance or inquiries regarding the ASPYRE AT power
controller, you can contact Watlow through the following channels:
- Website: www.watlow.com
- Phone: 1-800-WATLOW2 (1-800-928-5692)
- Email: [email protected]
Warranty
The ASPYRE AT power controller is covered by Watlow’s warranty. The terms
and conditions of the warranty can be found on Watlow’s website at
www.watlow.com/terms.
Product Usage Instructions
Before proceeding with any installation, wiring, maintenance, or troubleshooting work on the power controller, it is essential to read the provided user manual in its entirety. Only properly qualified personnel should perform any service on the unit.
Important Safety Precautions:
- Ensure that the power controller is disconnected and power is prevented from being restored before servicing.
- Avoid using the power controller in aerospace or nuclear applications.
- Install the power controller in an enclosure that provides additional protections suitable for the environment and application.
- Ground the power controller using the provided protective earth grounding terminal. Verify the ground impedance periodically.
- The installation must be protected by electromagnetic circuit breakers or fuses.
- Use proper personal protective equipment when making live voltage or current measurements.
- Verify that the voltage and current ratings of the power controller are suitable for the application.
- Avoid bending wires or components beyond their specified bend radius to prevent insulation compromise.
- Protect the power controller from high temperature, humidity, and vibrations.
- Install an appropriately sized RC filter across contactor coils, relays, and other inductive loads.
- Provide a local disconnect to isolate the power controller for servicing.
By following these safety precautions and adhering to the provided instructions, you can ensure safe and proper usage of the ASPYRE AT power controller.
WATLOW INFO
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 by e-mailing your questions to
wintechsupportwatlow.com or by dialing +1
507-494-5656 between 7 a.m. and 5 p.m.
Central Time USA & Canada. Ask for an Applications Engineer. Please have the
complete model number available when calling.
Warranty
The ASPYRE AT power controller is warranted by Watlow in accordance with the
terms and conditions set forth on Watlow’s website at
www.watlow.com/terms.
Registered Trademarks
Watlow®, ASPYRE® and COMPOSER® are registered trademarks of Watlow Electric
Manufacturing Company.
UL® is a registered trademark of Underwriter’s Laboratories, Inc.
Modbus® is a registered trademark of Schneider Automation Incorporated.
Document Number: 10-51914, Rev. -, August 2022
For assistance contact Watlow: www.watlow.com
1-800-WATLOW2 (1-800-928-5692)
[email protected]
SAFETY
Safety Information
- WARNING! To avoid damage to property or equipment, injury, and loss of life, adhere to applicable electrical codes and standard wiring practices when installing and operating this product. Failure to do so could result in damage, injury and death.
- WARNING! All service including inspection, installation, wiring, maintenance, and troubleshooting must be performed only by properly qualified personnel. Service personnel must read this manual before proceeding with work. While service is being performed other, unqualified personnel should not work on the unit or be allowed in the immediate vicinity.
- WARNING! When in use the power controller is connected to dangerous voltages. Do not service controller without first disconnecting and preventing power from being restored while servicing the power controller.
- WARNING! Do not use in aerospace or nuclear applications.
- WARNING! The power controller’s protection rating is IP20. It must be installed in an enclosure that provides all the necessary additional protections appropriate for the environment and application.
- WARNING! Ground the power controller via the provided protective earth grounding terminal. Verify ground is within impedance specifications of UL 508A 0.1 ohm. This should be verified periodically.
- WARNING! The installation must be protected by electromagnetic circuit breakers or by fuses.
- WARNING! When making live voltage or current measurements, use proper personal protective equipment for the voltages and arc-flash potentials involved.
- WARNING! Verify the voltage and current ratings of the power controller are correct for the application.
- CAUTION: To avoid compromising the insulation, do not bend wire or other components beyond their bend radius specifications.
- CAUTION: Protect the power controller from high temperature, humidity and vibrations.
- NOTE! Use only copper cables and wires rated for use at 90°C or greater, unless otherwise noted.
- CAUTION: Install an appropriately sized RC filter across contactor coils, relays and other inductive loads.
- NOTE! Provide a local disconnect to isolate the power controller for servicing.
- NOTE! The nominal current is specified for ambient temperatures at or below 40° C. Ensure the application design allows for adequate cooling of each power controller. The power controller must be mounted vertically. The cooling design must prevent air heated by one power controller from causing power controllers mounted above to exceed the ambient operating temperature limit.
SPECIFICATIONS
- Power Bases
- Single-phase, 1 controlled leg
- Load Amp Range
- 12A, 24A and 48A options (see derating curves in User Guide)
- SCR and Amperage Rating
- SCCR rating 100,000A up to 480VAC with coordinated fusing
- SCCR rating 10,000A up to 240VAC with recommended circuit breaker
- Power dissipation: Approximately 1 to 1.2 watts per amp
- Leakage current: 1mA at 25°C
- Environment
- 0 to 60°C (single unit) or 55°C (multiple units) see derating curves
- 5 to 90% RH (relative humidity), non-condensing
- Agency Approval and Regulatory
- UL® 508 Listing
- c-UL® Listed
- CE EMC Directive Class A Emissions
- CE Safety Directive EN 60947-4-3
- IP20
- RoHS 2015-863-EU
- W.E.E.E 2012-19-EU
- Enclosure Flammability Rating: 94-VO
MOUNTING INSTRUCTIONS
Mounting Dimensions
The power controller may be mounted on a DIN rail or with screws. See the
tables and Illustrations on the page for the product dimensions, spacing,
weight, and mounting locations.
| Model | W | H | D | Weight |
|---|---|---|---|---|
| 12A/24A DIN-Rail w/Heat Sink Option | Unit Width 36mm (1.42in) | 6.79 in. (172 | ||
| mm) | 12A/24A: 5.88 in. (149 mm) | 1.61 lb. (0.73 kg) |
Over-all Width 1.82 in. (46mm)
48A DIN-Rail w/Heat Sink Option| Unit Width 36mm (1.42in)| 6.79 in. (172 mm)|
48A: 7.07 in. (180 mm)| 1.89 lb. (0.86 kg)
Over-all Width 1.82 in. (46mm))
One Zone Cooling Plate Option| Unit Width 36mm (1.42in)| 7.29 in. (185 mm)|
3.97 in. (101mm)| 1.15 lb. (.52 kg)
Over-all Width 1.82 in. (46mm)
WIRING SCHEMATIC
WIRE SELECTION
Wire Selection, Prep and Torque
This section lists the recommended wire sizes for line power, load, earth
ground and control signal connections. There are also recommendations for
insulation stripping and termination torque.
Line Power and Load Wire Size and Termination:
| Stranded Wire Size | Wire Termination | Temperature Rating |
|---|---|---|
| 14 to 10 AWG solid (1.5 to 6 mm2) | Wire compression clamp | 90°C or greater |
| 14 to 6 AWG Stranded (1.5 to 16 mm2) | Wire compression clamp | 90°C or greater |
Ground Wire Size and Termination
| Wire Size | Wire Termination | Temperature Rating |
|---|---|---|
| 10 AWG (6 mm2) | UL Listed (ZMVV) ring or spade crimp lug | 75°C or greater |
Control and Signal Wire Size
- Range: 22 to 14 AWG (0.50 to 1.5 mm2)
- Recommended: 18 AWG (0.75 mm2)
- Temperature Rating: 75°C or greater
Insulation Stripping and Torque
- Insulation Stripping
Load & Line Power| Bare wire connection: 0.59 in. (15 mm) Connection with crimp lug: per lug manufacturer
---|---
Ground| Per crimp lug requirements
Control and Signal| 0.24 in. (6mm) - Control Signal and Ground Torque
- Line Power and Load Torque
WIRE CONNECTIONS
Note: Not all options identified below are on all units. See unit label for options present.
Terminal Block A
Position| Name| Description
R1| Analog In| 0-10V or 4-20mA analog input referenced to pin S1. Can be con-
figured as 0-10V or 4-20mA via the software interface.
S1| Analog In Reference
D1| Digital I/O1| Digital I/O 1 referenced to pin B1. Can be configured as a
24V input, output, or dry contact input via the software interface.
B1| Digital I/O 1 Reference
D2 B2| Digital I/O 2
Digital I/O 2 Reference| Digital I/O 2 referenced to pin B2. Can be configured
as a 24V Input, output, or dry contact input via the software interface.
Terminal Block B
Position| Name| Description
J2| Relay NC| Normally closed relay contact.
K2| Relay Com| Relay connections rated for 240VAC at 5A maximum.
L2| Relay NO| Normally open relay contact.
Power and Ground Connections
Position| Name| Description
L1| Line Connection| Line power connection Torque= 24 (in.-lbs.)
T1| Switched Leg| Switched power connection Torque = 24 (in.-lbs.)
Ground Screw| Earth Ground| #8-32 Screw head diameter: 0.341″ Torque = 15-17
(in.-lbs.)
Terminal Block C
Position| Name| Description
+| 24VIN| 24VDC power to the controller.
–| GND| 24VDC power reference to the controller.
CC/CZ| Modbus® Common or Inter-module bus common| MODBUS/WATBUS isolated bus
common. Configured per product part number.
CA/CX| Modbus® A(-) or Inter-module bus| MODBUS/WATBUS isolated bus A sig-
nal. Configured per product part number.
CB/CY| Modbus® B(+) Inter-module bus| MODBUS/WATBUS isolated bus B sig- nal.
Configured per product part number.
G1| Retransmit 0-10V| 0-10V retransmit output referenced to pin F1.
F1| Retransmit Reference| Retransmit ground reference.
H1| Retransmit 4-20mA| 4-20mA retransmit output referenced to pin F1.
Terminal Block D
Position| Name| Description
3| Reference| Connect to the unswitched phase of the heater.
3| Reference| Connect to the unswitched phase of the heater.
CE DECLARATION
1241 Bundy Boulevard., Winona, Minnesota USA 55987
Phone: +1 507-454-5300
Fax: +1 507-452-4507
http://www.watlow.com
For assistance contact Watlow: www.watlow.com
1-800-WATLOW2 (1-800-928-5692)
[email protected]
References
- UL Solutions
- Solutions for the Complete Thermal Loop | Watlow
- Solutions for the Complete Thermal Loop | Watlow
- ASPYRE AT Product Documentation | Watlow
- Terms and Conditions of Sale | Watlow