ASPYRE 690V Intelligent Power Controllers Instruction Manual
Watlow’s new ASPYRE® DT power controller family is flexible and scalable, and available with a variety of options allowing one platform to be re-used across a wide range of applications, which can help save time and money. ASPYRE DT models available include sizes from 35 to 2100 amps.
This power controller family features multiple advanced microprocessor-based firing and control mode algorithms.
Combined with diagnostics and several communications options the product enables equipment and factory automation.
Controller firing modes include zero cross, burst firing, single cycle, delayed triggering and phase angle. These smart algorithms enable the product to easily control a wide base of heater loads including nichrome, moly, silicon carbide, tungsten quartz and infrared lamps and transformer-coupled loads.
ASPYRE DT offers a comprehensive list of modular options that deliver space and labor savings including controlled legs (1, 2 or 3), semiconductor fusing, load current measurement, amperage size and user interface.
Typical Applications
- Furnace and ovens
- Autoclaves
- Kilns
- Heat treatment
- Glass industry
- Semiconductor
- Power generation
- Oil and gas
- HVAC
- Textiles
- Plastics
- Packaging
- Petrochemical
- Dryers and curing
Features and Benefits
Heater bakeout
- Protects heater on start up
- Eliminates labor and time associated with checking for wet heaters
Integrated semiconductor fusing, current transformer and user interface
- Saves installation time and eases setup and commissioning
- Delivers a user-friendly, intuitive interface
Industry-leading design and serviceability
- Offers a robust SCR design to meet a rugged industrial environment’s high quality and reliability needs
- Provides quick and easy access to maintain and service fuses and individual legs in minimal time
- Enables fast troubleshooting by providing helpful thermal system diagnostics
Comprehensive power controller range
- Provides wide range of options from simple single-phase to complex three-phase loads to 690V
100KA short circuit current rating (SCCR)
- Minimizes damage in the event of a short circuit
c-UL® 508 Listed
- Shortens project schedules, agency testing and expenses
Control modes: contactor, voltage, current or power
- Satisfies a wide range of demanding thermal applications
Load firing modes: zero-cross, burst fire, phase angle, soft start, half-cycle, single-cycle, delayed triggering
- Handles a wide range of load types including nichrome, medium and long waveform infrared lamps, moly (Kanthal® Super), transformers, silicon carbide, UV lamps and tungsten
- Protects and extends the life of connected loads
Wide range of communication protocols
- Enable factory and process automation with connectivity access to process and equipment data using Modbus® RTU, Modbus® TCP, EtherNet/IP™, Profibus, Profinet, USB device (configuration and data file transfers)
Open heater and shorted SCR indication
- Minimizes production downtime with easy to understand, intelligent, troubleshooting diagnostics
Integrated USB and user interface for configuration
- Easily and safely program configuration settings as the user interface can be powered through USB connection
- Eliminates need to work in a hazardous environment near high voltage when configuring the controller. High voltage to the controller and panel can be turned off while setting controller configuration.
Specifications
Power Bases
- Single-phase, 1 controlled leg (2 SCRs)
- Three-phase, 2 controlled legs (4 SCRs)
- Three-phase, 3 controlled legs (6 SCRs)
Load Amp Range
- 35A to 2100A @ 40°C ambient
- Amperage derating curve for other ambient temperatures
SCR Ratings
- Latching current 1A min.
- Power dissipation: approximate 1.25 to 1.5 watts per amp per controlled leg
- Leakage current (35A to 800A models): 15mA
- Leakage current (1100A to 2100A models): 300mA
- Short Circuit Current Rating (SCCR): 100,000A up to 600VAC
Line and Load Voltage Range
- 24 to 480V ±10% min./max.
- 24 to 600V ±10% min./max.
- 24 to 690V ±10% min./max. 690VAC only available for 60A and greater models
- Isolation voltage 2500V
Voltage frequency
- 50 to 60Hz
Feedback Types
- Voltage, voltage squared, current, current squared, power, open loop and external
- All feedback types available with any firing type combination
Load Types
- Normal resistive loads: nichrome, infrared lamps (medium and long waveform)
- Others: Moly (Kanthal® Super), transformers, silicon carbide, UV lamps, short wave infrared lamps (such as tungsten)
Current Limiting and Heater Bakeout
- Available on single-phase models and three-phase, three-leg models 60A to 2100A
| Firing Type Combinations | Single- Phase | 3-Phase, 2-Leg | 3-Phase 3-Leg |
| Zero Crossing | X | X | X |
| Zero Crossing + Start Ramp | X | X* | |
| Zero Crossing + Start Ramp + Soft Start | X | X* | |
| Zero Crossing + Soft Start | X | X | X |
| Burst Firing | X | X | X |
| Burst Firing + Soft Start | X | X | X |
| Burst Firing + Start Ramp | X | X* | |
| Burst Firing + Start Ramp+ Soft Start | X | X* | |
| Single Cycle | X | ||
| Single Cycle + Soft Start | X | ||
| Phase Angle | X | X* | |
| Phase Angle + Soft Start | X | X* | |
| Half Cycle | X | ||
| Half Cycle + Soft Start | X | ||
| Burst Firing + Delayed Triggering | X | X* | |
| Burst Firing + Delayed Triggering + Soft Start | X | X* | |
| Burst Firing + Delayed Triggering + Safety Ramp | X | X* | |
| Burst Firing + Delayed Triggering + Safety Ramp+ Soft Start | X | X* | |
| Half Cycle + Safety Ramp | X | ||
| Half Cycle + Safety Ramp+ Peak Current Limit | X |
* 60A to 2100A models
Digital Inputs 1 and 2
- On ≥ 4VDC, off <1VDC
- 4 to 30VDC @ 5mA max.
- Optically isolated
- Digital input functions: enable, SSR, alarm reset, change to voltage feedback, local/remote set point enable, change firing to phase angle, select analog input 1 or 2 for set point, enable data logging, enable heater bakeout
- A switched DC control output can be connected to the digital input as an open loop control mode command signal
Analog Inputs 1 and 2
- Voltage: 0 to 10VDC, 15KΩ impedance
- Current: 0 to 20mA or 4 to 20mA, 100Ω impedance
- Potentiometer: 10KΩ min.
- Analog Input 1 Function: set point reference
- Analog Input 2 Functions: current limit, feedback or set point reference
Analog Output
- 0 to 20mA or 4 to 20mA into 500Ω max. load with 50μA nominal resolution
- 0 to 10VDC into a 500Ω min. load with 50mV nominal resolution.
Analog Output Functions*
- Retransmit: load voltage, current, power or setpoint
Alarm Outputs
- Form C, electromechanical relay, 30VDC max. at 1A resistive load or 0.5A at 125VAC, 6000 cycles at 30VDC, 100,000 cycles at 120VAC
- Alarm Relay Functions: alarm output options for heater open/break, SCR short, current limit and/or communication watchdog and SCR over-temperature
- Open Fuse Relay Output: 1100A to 2100A models
DC Power Supply for Digital Inputs and Potentiometer Remote Set Point Input
- 10VDC @ 10mA max.
Auxiliary Power Input
- 35A to 800A: 8VA max.
- 1100A to 2100A: 14VA max.
- For 35A to 800A: must be same as nominal switched line voltage
| Auxiliary Power Option | Max. Operating Range |
| 100/120VAC | 90 to 135VAC |
| 200/208/220/230/240VAC | 180 to 265VAC |
| 277VAC | 249 to 305VAC |
| 380/400/415/440/480VAC | 342 to 528VAC |
| 600VAC | 540 to 660VAC |
| 690VAC | 621 to 759VAC |
Fusing
- Integrated semiconductor fuse
Diagnostics Messages
- Heater break (open), SCR short circuit (closed), current limit, thermal switch, SD card error, communication watchdog error, bakeout in process, auxiliary voltage too low or high,
voltage line loss
- Additional messages for 1100A to 2100A models: blown fuse, fan failure
Configuration
- ASPIRE Configuration PC software via EIA-485 or USB, and on-board operator interface
Operator Interface
- 0.96 in. white OLED display with 128 x 64 pixel resolution
- Four buttons: local/remote (L/R), function (F) up arrow and down arrow
- Four indicators: local/remote mode, enable, communication and alarm
Connectivity*
- Port 1: Modbus® RTU
- Port 2: Modbus® TCP , EtherNet/IP™, PROFIBUS DP or
PROFICIENT
- USB 2.0 device
Real Time Clock and Battery Back-up
- Typical battery life: 5 years at 77°F (25°C)
- CR2032 field replaceable battery
Integrated Data Logging
- Storage: 16 GB SD memory card
- File type: comma separated value (*.csv)
- User programmable logging interval 1 to 255 seconds
- Up to 10 parameters selectable by user: line frequency, output voltage (RMS), output current (RMS), output power (average), status, commands, set point, current limit set point (RMS), load resistance, input voltage (RMS)
Cooling Mode
- Forced air (fan) (Not required for all models. See ordering information)
- 24VDC, 120 or 240VAC (See ordering information for available options)
- 60A to 210A Models: one 17 W fan per switched leg
- 300A to 700A Models: 34 W (single-phase models), 68 W (two-leg and three-leg models)
- 800A Models: two 17 W fans per switched leg
- 1100A to 2100A Models: two 75 W fans per switched leg
Control Terminals
- Terminals are touch safe, removable, 12 to 22 AWG
Line and Load Terminals
- Compatible with crimp lug terminals or busbar
- Refer to user manual for wire size, compression and torque requirements
Mounting
• Panel mounting with screws
• Must be mounted with heat sink fins in vertical orientation
Environment
- 0 to 40°C without derating
- 5 to 90% RH (relative humidity), non-condensing
- Up to 6560 feet (2000 m) above sea level maximum
- Over 1000 meters of altitude reduce the nominal current by 2% for each 100 meters
- Storage temperature -25 to 70°C max.
- Pollution degree: Installation Category III, Pollution degree 2
- Install away from direct sun light, conductive dust, corrosive gas, vibration, water and corrosive salts
Agency Approval and Regulatory
- 35A to 700A models: cULus 508 Listed File E73741
- 35A to 700A models: cUL® Listed to C22.2 No. 14
- 800A to 2100A models: UL 508 Listed File E73741
- CE EMC Directive 2014-30-EU, EN 60947-4-3 Class A
Emissions
- CE Safety Directive 2014-35-EU, EN 60947-4-1, -4-3
- IP20 with all covers in place
- RoHS 2011-65-EU
- W.E.E.E 2012-19-EU
- 690VAC units not covered by UL
Accessories
- Free Watlow ASPYRE configuration software on the Watlow website at http://www.watlow.com/en/resources-andsupport/Technical-Library/Software-and-Demos
- 6 ft USB 2.0 to micro USB device cable (p/n 0219-0480-0000)
- External power supply UL® Class 2, 90-263VAC input, 24VDC output, 1.30A, 31W (p/n 0847-0299-0000)
- Fuses – see table on next page.
Note: If using both Analog Re transmit (digit 10, options A or D) and Additional Wired Communication (digit 12, options 1, 3, 4 or 5) an external power supply is required. See power supply accessory on page 8.
Fuses
| ASPYREModel Number | Watlow Fuse Part Number | Qty. Used Per Unit | |
| 480V and 600V | 690V | ||
| DT_ _ _ – 035 … | 17-8050 | N/A | 1/leg |
| DT_ _ _ – 040 … | |||
| DT_ _ _ – 060 … | 0808-0363-0160 | 2048-2760 | |
| DT_ _ _ – 090 … | |||
| DT_ _ _ – 120 … | 0808-0363-0180 | ||
| DT_ _ _ – 150 … | 0808-0363-0200 | 2048-4405 | |
| DT_ _ _ – 180 … | 0808-0363-0250 | 2048-4418 | |
| DT_ _ _ – 210 … | 0808-0363-0315 | 2048-4426 | |
| DT1_ _ – 300 … | 0808-0362-0000 | N/A | 1 |
| DT1_ _ – 400 … | 0808-0358-0000 | 0808-0358-0000 | 1 |
| DT1_ _ – 500 … | 0808-0359-0000 | 0808-0359-0000 | 1 |
| DT1_ _ – 600 … | 0808-0363-0250 | 0808-0363-0250 | 4 |
| DT1_ _ – 700 … | |||
| DT2_ _ – 300 … | 0808-0357-0000 | 2055-5072 | 3 |
| DT2_ _ – 400 … | 0808-0358-0000 | 0808-0358-0000 | 3 |
| DT2_ _ – 450 … | 0808-0360-0000 | 0808-0360-0000 | 6 |
| DT2_ _ – 500 … | |||
| DT2_ _ – 600 … | 0808-0357-0000 | 0808-0357-0000 | 4 |
| DT2_ _ – 700 … | |||
| DT3_ _ – 300 … | 0808-0357-0000 | 2055-5072 | 3 |
| DT3_ _ – 350 … | 0808-0358-0000 | 0808-0358-0000 | 3 |
| DT3_ _ – 400 … | |||
| DT3_ _ – 450 … | 0808-0359-0000 | 0808-0359-0000 | 3 |
| DT3_ _ – 500 … | |||
| DT_ _ _ – 800 … | 0808-0363-0250 | 0808-0363-0250 | 4 /leg |
| DT_ _ _ – 1K1 … | 2078-4948 | 2078-5301 | 2/leg |
| DT_ _ _ – 1K4 … | 2078-5257 | 2078-5358 | |
| DT_ _ _ – 1K6 … | 2078-5261 | 2078-5413 | |
| DT_ _ _ – 1K8 … | |||
| DT_ _ _ – 2K1 … | |||
N/A – Not available
Replacement Power Modules
| Item | Maximum Voltage | Amperage |
| 2148-0134 | 480/600VAC | 1100A |
| 2148-0169 | 480/600VAC | 1400A |
| 2148-0175 | 480/600VAC | 1600A |
| 2148-0188 | 480/600VAC | 1800A |
| 2148-0214 | 480/600VAC | 2100A |
| 2148-0238 | 690VAC | 1100A |
| 2148-0246 | 690VAC | 1400A |
| 2148-0251 | 690VAC | 1600A |
| 2148-0267 | 690VAC | 1800A |
| 2148-0272 | 690VAC | 2100A |
Replacement Connectors
| Price | Part Number | Description |
| $ 75.00 | 2306-2721 | Single phase, 35 or 40A |
| 75.00 | 2306-2737 | Two-leg, 35 or 40A |
| 75.00 | 2306-2745 | Three-leg, 35 or 40A |
| 85.00 | 2306-2759 | 60 to 210A, 480 or 600V |
| 85.00 | 2306-2768 | 300 to 800A, 480 or600V |
Ambient Temperature Derating
60A to 210A Models
300A to 800A Models
1100A to 2100A Models
35A to 40A Models
I/O Functional Block Diagram
Dimensions and Shipping Weight
| Current and Voltages | 1-Phase,1 Controlled Leg | 3-Phase,2 Controlled Legs | 3-Phase,3 Controlled Legs |
| 35 and 40A480 and 600VAC | 4.77 in. H x 2.84 in. W x7.28 in. D – 2.6 lbs |
4.77 in. H x 4.25 in. W x7.28 in. D – 4 lbs |
4.77 in. H x 5.67 in. W x7.28 in. D – 5.5 lbs |
| 60, 90, 120, 150,180 and 210A480 and 600VAC | 10.6 in. (60A) or 10.79 in. (90-210A) H x 3.66 in. W x6.7 in. D – 9 lbs |
10.6 in. (60A) or 10.79 in. (90-210A) H x 7.36 in. W x6.7 in. D – 18 lbs |
10.6 in. (60A) or 10.79 in. (90-210A) H x 11.1 in. W x6.7 in. D – 27 lbs |
| 60, 90, 120, 150,180 and 210A 690VAC | 17.33 in. H x 5.40 in. W x10.63 in. D – 23 lbs |
60-90A = 17.33 in. H x 5.40 in. W x 10.63 in. D – 23 lbs120-210A = 17.33 in H x 10.32 in. W x 10.63 in. D – 40 lbs |
|
| 1 and 2 leg:300, 400, 500, 600 and 700A3 leg:300, 350, 400, 450 and 500A480, 600 and 690VAC | 20.47 in. H x 5.4 in. W x10.63 in. D – 33 lbs |
20.47 in. H x 10.32 in. W x 10.63 in. D – 63 lbs |
|
| Current and Voltages | 1-Phase,1 Controlled Leg | 3-Phase,2 Controlled Legs | 3-Phase,3 Controlled Legs |
| 800A480, 600, 690VAC | 22.1 in. H x 5.4 in. W x10.7 in. D – 23.2 lbs |
22.1 in. H x 10.9 in. W x10.7 in. D – 46.3 lbs |
22.1 in. H x 16.2 in. W x10.7 in. D – 69.5 lbs |
| 1100A480, 600, 690VAC | 21.7 in. H x 13 in. W x13.7 in. D – 59.5 lbs |
21.7 in. H x 20.6 in. W x13.7 in. D – 108 lbs |
21.7 in. H x 28.3 in. W x13.7 in. D – 158.7 lbs |
| 1400, 1600, 1800, 2100A480, 600, 690VAC | 28.8 in. H x 13 in. W x13.7 in. D – 74.9 lbs |
28.8 in. H x 20.6 in. W x13.7 in. D – 143.3 lbs |
28.8 in. H x 28.3 in. W x13.7 in. D – 216.1 lbs |
Accessories
- ASPYRE Configurator software on the Watlow website at https://www.watlow.com/Products/Controllers/Software/aspyre-configurator
- External power supply UL® Class 2, 90-263VAC input, 24VDC output, 1.30A, 31W (p/n 0847-0299-0000)
- Fuses – see table on page 4
USB Cables
Earlier models use USB micro B, Later models use USB C.
- 6 ft USB 2.0 to micro USB device cable (p/n 0219-0480-0000)
- 6 ft USB type C to USB type C data and charging (p/n 2316- 7309)
- 6 ft USB type A to USB type C data and charging (p/n 2317- 0654)
Ordering Information
Base model includes: power control loop for open loop, voltage, current or power control, two analog inputs (0 10VDC, 4-20mA selectable), two digital inputs, semiconductor fusing and current transformers for each leg, mechanical relay heater break alarm, RS-485 Modbus® communications, pixel OLED user interface and keypad, 10VDC auxiliary power supply
Watlow® and ASPYRE® are registered trademarks of Watlow Electric Manufacturing Company.
Modbus® is a registered trademark of Schneider Automation Incorporated.
UL® and c-UL® are registered trademarks of Underwriter’s Laboratories, Inc.
Kanthal® Super is a registered trademark of Bulten-Kanthal Aktiebolag Joint Stock Company.
EtherNet/IP™ is a trademark of Open DeviceNet Vendors Association.
International Technical Sales Offices:
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UK +44 115 964 0777
To be automatically connected to the nearest North American Technical Sales Office:
1-800-WATLOW2
www.watlow.com
©2021 Watlow Electric Manufacturing Company all rights reserved. WIN-ASP-0521
Documents / Resources
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ASPYRE 690V Intelligent Power Controllers [pdf] Instruction Manual 690V Intelligent Power Controllers, 690V, Intelligent Power Controllers, Power Controllers, Controllers |
