Key Topics Covered:

• Why SCRs are already 98.5%–99.7% efficient

• What the real energy-saving opportunity is: your process, not the controller

• How to use digital SCRs to track kilowatt-hour usage

• Reducing heat loss and improving oven/furnace design

• Power factor: Zero-cross vs. phase angle

• IEEE 519 and harmonics: What to watch for

• SCRs vs. IGBT systems: cost, efficiency, and heat

• Transitioning from gas to electric with green energy integration

What You’ll Learn:

• How to leverage SCR controllers for energy audits and process optimization

• Why phase angle control extends heater life

• When to use zero-cross to maintain unity power factor

• How digital control gives you true process visibility

• The long-term advantages of switching to electric systems with SCRs

Guest Info:

Cory Watkins
President, Control Concepts
Cory brings nearly two decades of experience leading a company at the forefront of power control technology. His knowledge of SCR systems, digital integration, and sustainability-focused design makes him a valuable voice in modern manufacturing and process control.

[Intro]

Narrator:
Welcome to In The Loop, a New England Temperature Solutions podcast.

In today’s episode, Dominick DeLuca, President of NETS, 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, here’s Dom and Cory—helping you get In The Loop.

[Main Interview]

Dominick DeLuca:
Hi, welcome back to In The Loop. I’m here again with Cory Watkins, President of Control Concepts, in beautiful Chanhassen, Minnesota.

Today’s 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:
“How do we improve the efficiency of our SCR power controllers?”

It’s a great question, but honestly, it’s 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 isn’t with the SCR itself—it’s with the process.

Improving Process Efficiency

Cory:
I tell customers:

“I can’t help you improve the SCR’s efficiency, but I can help you improve your process efficiency.”

Start by knowing how much power you’re 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 consumed—extremely 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

It’s not just efficient—it’s smarter.

Power Factor & Harmonics

Dominick:
What about power factor and harmonics?

Cory:
Great topic. Here’s the breakdown:

1. 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.

2. 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.

3. 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 we’re seeing it swing back.

Cory:
Exactly. We’ve seen more inquiries about electric conversions, and I believe that trend will continue. We’re ready for it.

[Closing]

Dominick:
That’s a wrap—short and sweet. Use an SCR and you’ll be in great shape.

Cory:
Thank you, Dom.

Dominick:
Thanks for joining us, Cory. And thank you to everyone listening. If you have questions, reach out via the contact info with this podcast. We’d love to help.

[Outro]

Narrator:
Thank you for getting In The Loop with us! We hope this episode has been informative.

If you need help in the thermal process industry, reach out at:
📞 808-48-NETS (808-486-387)
🌐 www.nets-inc.com

Have a topic idea? Send us a comment!
The team at NETS is here to help—and we hope you have an awesome day, every day.

Stay Tuned For Our Latest Episodes