In this podcast with president and engineer Cory Watkins, learn how power factor, harmonics, and digital control can help you achieve better control of your system at lower cost. Discover how Control Concepts SCR power controllers support green initiatives, energy efficiency, and more.
Transcript Summary
Narrator:
Welcome to In The Loop, a New England Temperature Solutions podcast.
In todayโs episode, Dominick DeLuca, Control Concepts’ Director of Marketing, sits down for a second time with Cory Watkins, President of Control Concepts, on location in Chanhassen, Minnesota.
This episode is a deep dive into SCR power controllers and the real-world energy and cost savings they deliver.
Without further ado, hereโs Dom and Coryโhelping you get In The Loop.
Efficiency and SCR Power Controllers
Dominick DeLuca:
Hi, welcome back to In The Loop. Iโm here again with Cory Watkins, President of Control Concepts, in beautiful Chanhassen, Minnesota.
Todayโs episode is focused on green technology and energy efficiency in power control.
Cory, what kind of questions do you get around environmental impact and reducing energy usage with SCR power controllers?
Cory Watkins:
The most common question I get is:
โHow do we improve the efficiency of our SCR power controllers?โ
Itโs a great question, but honestly, itโs the wrong one. Let me explain.
SCR Efficiency: Already High
Cory:
SCR power controllers are already extremely efficient, typically between 98.5% to 99.7%, especially when operating above 120 volts.
So, the issue usually isnโt with the SCR itself, itโs with the process.
Improving Process Efficiency
Cory:
I tell customers:
โI canโt help you improve the SCRโs efficiency, but I can help you improve your process efficiency.โ
Start by knowing how much power youโre using. That requires a digital power controller.
Our MicroFUSION series includes instrument-grade power meters, measuring:
- Line voltage
- Load voltage
- Load current
- True RMS power
- Power factor
- Kilowatt hours used
You can reset the controller before a process run and check exactly how many kilowatt hours were consumedโextremely useful for evaluating energy usage batch to batch.
Process Analysis: The Key to Savings
Cory:
To improve overall efficiency, analyze:
- Heat losses (e.g. flue stack, radiative losses)
- Cycle times (are you dwelling too long at a temperature?)
- Chamber design (can interlocks prevent cold air intrusion?)
These changes can drastically reduce energy waste.
The Role of SCR Control
Dominick:
And just using an SCR instead of a contactor improves efficiency, right?
Cory:
Exactly. SCRs, especially in Phase Angle control, allow more precise power modulation. That means:
- Less overshoot and undershoot
- More stable temperature control
- Extended heater life due to less thermal cycling
Itโs not just efficient, itโs smarter.
Power Factor & Harmonics
Dominick:
What about power factor and harmonics?
Cory:
Great topic. Hereโs the breakdown:
- Power Factor
- If you can run in Zero Cross mode, do it.
- We offer both normal and Fast Zero Cross modes.
- They maintain unity power factor, which reduces your load on the grid.
- Phase Angle Mode
- Can lower power factor depending on conduction angle.
- The worst-case scenario is 50% output.
- You can improve this by adjusting line voltage, which alters output range and power factor.
- Harmonics (IEEE 519 Compliance)
- Zero Cross minimizes harmonic distortion.
- If Phase Angle is necessary (e.g. transformer loads), use a Fluke power quality analyzer to assess compliance at the utility entrance.
IGBTs vs. SCRs
Dominick:
How do SCRs compare to IGBTs?
Cory:
IGBTs typically run at 83% to 92% efficiency. Newer silicon carbide designs can reach 96%, but they:
- Generate more heat
- Take more panel space
- Cost more
- Are less efficient than SCRs for simple AC switching
So for most thermal applications, SCRs remain the better option.
Gas vs. Electric: The Green Shift
Dominick:
What about gas vs. electric?
Cory:
Gas is still cheaper in many areas of the U.S., but electric systems using SCRs allow you to tap into:
- Solar
- Wind
- Other renewable sources
So, if your facility is shifting toward decarbonization, SCRs are a future-proof solution.
Dominick:
Years ago everyone went from electric to gas. Now weโre seeing it swing back.
Cory:
Exactly. Weโve seen more inquiries about electric conversions, and I believe that trend will continue. Weโre ready for it.
Closing
Dominick:
Thatโs a wrap, short and sweet. Use an SCR and youโll be in great shape.
Cory:
Thank you, Dom.
Dominick:
Thanks for joining us, Cory. And thank you to everyone listening. If you have questions, weโd love to help.
