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CD3200-1PH from 15A to 110A

User’s Manual

28

11

Connection description

11.1

Access to the Electronic boards

To have access to the electronic boards the user must removing the unit’s cover

(see par.7.1)

Warning:

Before operate, be sure that power and control cables are isolated from voltage

sources

Front PCB

Main PCB

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Summary of Contents for CD3200

Page 1: ...ation S r l Via Picasso 34 36 20025 Legnano MI ITALY Tel 39 0331 577479 Fax 39 0331 579479 E Mail info cdautomation com WEB www cdautomation com USER S MANUAL Rev 01 2007 CD3200 Thyristor Unit from 15A to 110A ...

Page 2: ......

Page 3: ...es 15 7 Wiring instructions 16 7 1 Removing the cover 16 7 2 Wiring details 17 7 3 Power Terminals 18 7 4 Command Terminals 18 7 5 Diagram of control connection from size 15A to 25A 19 7 6 Diagram of control connection from size 35A to 45A 20 7 7 Diagram of control connection from size 60A to 110A 21 8 Power output features 22 8 1 Derating curve 22 8 2 Cooling fans 22 9 Led status and Alarms 23 9 ...

Page 4: ...mmunication 37 12 1 MODBUS RTU Protocol 37 12 2 Message Format 37 12 3 Read Holding Registers 39 12 4 Preset Multiple Registers 39 12 5 Error and exception responses 40 13 Configuration Parameters 41 14 FuseHolder and Fuses 44 14 1 FuseHolder size 44 14 2 Fuses and Fuse Code for UL 45 14 3 Fuses and Fuse Code for CE 46 15 Maintenance 47 15 1 Trouble Shooting 47 15 2 Fans 48 15 3 Maintenance 48 15 ...

Page 5: ...ows the qualified people to work in safety Protection Protection Protezione The unit have IP20 protection rating as defined by the specific international Is necessary consider the place of installation Earth Terre Messa a terra For safety the Thyristor unit with isolated heat sink must be connected to earth Earth impedance should be correspondent to local earth regulation Periodically the earth ef...

Page 6: ...ll suggestions contained in this manual are respected In respect to a good Engineering practice all inductive loads like solenoids contactor coils should have a filter in parallel Emissions Emission Emissioni All solid state power controllers emit a certain amount of radio frequency energy because of the fast switching of the power devices The CD Automation s Thyristor unit are in accord with the ...

Page 7: ...l transformers and special loads that change resistance with temperature and with age Load Thyristor 2 1 Advantages compared with analog thyristor unit Communication RS485 is a standard feature of CD3200 this allows the use of many information like current power load state and all the parameters for diagnostic and configuration Ulterior advantages of the digital system vs the analogical is the fle...

Page 8: ...d without stop the production process Technical Specification Use in Local Remote Set Point Ramp UP Down Scroll selection of Set point Power output Current Voltage Display indication for Heater Break alarm SCR short circuit Password for configuration parameters Plug in connector on front to use software configurator Retransmission 4 20mA or 0 10Vdc of one of these parameters Power PV Current Volta...

Page 9: ... machine with the Test unit section For install the software launch the program and follow the instructions on the screen To connect the unit at the PC it s necessary use the programming cable connected between the PG connector see par 11 6 and the serial port RS232 of the PC The programming cable is not included With the CD RS serial converter is possible configure the Thyristor unit also through...

Page 10: ...rol connection All auxiliary connections must be done in line with wirings on this manual Verify that there isn t a short circuit on the load Verify that the Reset Contact on terminal 3 and 4 are closed With External Enable option give Enable to the unit see par 7 5 5 Supply the Electronic boards see Order Code 6 Supply the Fan at 230VAC 15 50 60Hz 110VAC 15 50 60Hz Optional only for size S8C 7 Su...

Page 11: ...sure that the Thyristor unit have not damages If the product has a fault please contact the dealer from which you purchased the product The identification s label give all the information regarding the factory settings of the Thyristor unit this label is on the unit like represented in figure Verify that the product is the same thing as ordered see par 5 2 ...

Page 12: ... boards 90 130 From 90 to 130Vac 10VA 170 265 From 170 to 265Vac 10VA 230 345 From 230 to 345Vac 10VA 300 530 From 300 to 530Vac 10VA 510 690 From 510 to 690Vac 10VA 6 Input 0 10V 0 10Vdc 4 20mA 4 20mA POT Potentiometer 10KΩ 7 Firing Type S PA Soft Start Phase Angle PA Phase Angle 8 Feed Back V Voltage I Current V2 Voltage square VxI Power VxI 9 Option NCL No current limit CLP External current lim...

Page 13: ...net maintain the air circulation like represented in figure Sometimes is necessary installing a fan to have better air circulation 6 1 Environmental installation conditions Ambient temperature 0 40 C at nominal current Over 40 C use the derating curve see par 8 1 Storage temperature 25 C to 70 C Installation place Don t install at direct sun light where there are conductive dust corrosive gas vibr...

Page 14: ...0C CD3200 35A 45A S3C CD3200 60A 90A S7C CD3200 110A S8C Size W mm H mm D mm Weight kg 15A S0C 63 120 120 0 7 25A S0C 63 120 120 0 7 35A S3C 85 120 120 0 95 45A S3C 85 120 120 0 95 60A S7C 148 120 159 2 90A S7C 148 120 159 2 110A S8C 148 138 159 2 15 6 3 CT dimensions 8 1 2 39 39 20 D H W D H W D H W D H W ...

Page 15: ...0A User s Manual 15 6 4 Fixing holes CD3200 15A 25A S0C CD3200 35A 45A S3C CD3200 60A 90A S7C CD3200 110A S8C Size A mm B mm C mm 15A S0C 30 110 25A S0C 30 110 35A S3C 41 110 45A S3C 41 110 60A S7C 41 110 65 90A S7C 41 110 65 110A S8C 41 110 65 ...

Page 16: ...t must be supplied from a dedicated voltage and not with inductive or capacitive loads We recommend the use of a screened transformer The coil contactor the relays and other inductive loads must be equipped with opportune RC filter Use shielded bipolar cables for all the input and output signals The signal cables must not be near and parallel to the power cables Local regulations regarding electri...

Page 17: ...e Crimp Lug 7 2 2 Power cable dimensions suggested Supply Load Current Cable Screw Cable Screw mm AWG M mm AWG M 15A S0C 4 12 M5 4 12 M5 25A S0C 6 10 M5 6 10 M5 35A S3C 10 8 M5 10 8 M5 45A S3C 10 8 M5 10 8 M5 60A S7C 16 6 M6 16 6 M6 90A S7C 35 3 M6 35 3 M6 110A S8C 35 3 M6 35 3 M6 7 2 3 Cable dimensions suggested of Earth and of the Command Terminals Earth Command Terminals Current Cable Screw Cab...

Page 18: ...c max 2 External Calibration 24 Vdc max 3 Reset 4 Reset 5 CD32000 Output Command signal Internal Connections 6 CD3200 Output Command signal Internal Connections A2 Input command signal 0 10V 4 20mA POT A1 Input command signal 0 10V 4 20mA POT see par 11 1 7 4 2 Lateral Terminal Terminal Description 7 RS485 A 8 RS485 B 9 Output 8Vdc stabilized 1 mA MAX 10 HB relay contact Max 500mA 125Vac Optional ...

Page 19: ...breaker or by fuse isolator The auxiliary voltage supply of the CD3200 unit must be synchronized with load voltage power supply If the Auxiliary Voltage written on the identification label is different from Supply Voltage to the load use an external transformer as designated To work the Reset Contact on terminal 3 and 4 must be closed Load Type L2 T1 L2 T1 L2 T1 Resistances and Infrared Lamps Vari...

Page 20: ...breaker or by fuse isolator The auxiliary voltage supply of the CD3200 unit must be synchronized with load voltage power supply If the Auxiliary Voltage written on the identification label is different from Supply Voltage to the load use an external transformer as designated To work the Reset Contact on terminal 3 and 4 must be closed Load Type L2 T1 L2 T1 L2 T1 Resistances and Infrared Lamps Vari...

Page 21: ... fuse isolator The auxiliary voltage supply of the CD3200 unit must be synchronized with load voltage power supply If the Auxiliary Voltage written on the identification label is different from Supply Voltage to the load use an external transformer as designated To work the Reset Contact on terminal 3 and 4 must be closed Load Type L2 T1 L2 T1 L2 T1 Resistances and Infrared Lamps Variable Resistan...

Page 22: ...4 600 1200 1600 250 400 15 780 47 70 42 2500 45A 24 600 1200 1600 250 600 15 1800 47 70 54 2500 60A 24 600 1200 1600 450 1000 15 4750 47 70 72 2500 90A 24 600 1200 1600 450 2000 15 19100 47 70 108 2500 110A 24 600 1200 1600 450 1540 15 11300 47 70 137 2500 8 1 Derating curve 1 0 8 0 6 0 4 0 2 0 40 50 60 70 80 K C I I x K NOM MAX 8 2 Cooling fans The thyristor units from size 110A are equipped with...

Page 23: ...ition Load IS Powered SCR OK SCR short circuit SC No External Enable see par 11 4 Load OK HB Load Fault OFF ON Flashing 9 2 Not Critical Alarm The Not Critical Alarm doesn t stop the thyristor unit When one of these Not Critical Alarm is active the HB relay change status see par 11 5 9 2 1 SCR Short Circuit only with the HB option This alarm is active when the thyristor unit read the output curren...

Page 24: ...bration Procedure The Calibration procedure is an automatic procedure that save in memory the value of load current To make the Calibration procedure follow these steps Turned completely in counter clockwise sense the trimmer R13 see par 10 3 Give the power supply Press the CAL button on front unit or use the configurable digital input see par 11 4 All LEDS are on this means that calibration proce...

Page 25: ...Platinum Tungsten or Quartz Lamp The only disadvantage with phase angle is the possible generation of interferences that however can be reduced with opportune filters VOLTAGE SUPPLY V 100 ON OFF LOAD VOLTAGE V 75 50 25 10 2 Soft Start with Phase Angle S PA This is an additional function to the Phase Angle The firing angle of the thyristor increase or decrease up to the final setpoint value The Sof...

Page 26: ...B see par 11 1 Turned completely in counter clockwise sense will be Current limit 0 Turned completely in clockwise sense will be Current limit 100 of the Max value of current transformer 25 0 05 50 0 05 o 100 0 05 depending on thyristor size Minimum current is 25 of the current transformer size s If load current is below this value make two turns or more around current transformer H B circuit also...

Page 27: ...mes a voltage demand This control mode compensates the voltage fluctuation of the incoming line supply I Current feed back The input signal is proportional to the current output This means that input signal becomes a current demand This control mode maintain the current also if the load impedance changes V2 Square Voltage feed back The input signal is proportional to the output square voltage This...

Page 28: ... Connection description 11 1 Access to the Electronic boards To have access to the electronic boards the user must removing the unit s cover see par 7 1 Warning Before operate be sure that power and control cables are isolated from voltage sources Front PCB Main PCB ...

Page 29: ...onic Boards Auxiliary Voltage 17 Earth 18 Voltage Supply for Electronic Boards Auxiliary Voltage To change auxiliary supply voltage sold the correct link jumper on main PCB Warning this procedure can be done just by specialized personnel Link Jumper J9 J11 Main PCB Link Jumper J9 J11 Transformer Type Link Jumper J9 J11 Link Jumper J10 TR 605 120V 90 130V TR 605 230V 170 265V 300 530V TR 605 300V 2...

Page 30: ...t are defined in the complete product code The product code is written on the identification label However if you wish to change the input type i e from 0 10V to 4 20mA proceed as follows Warning this procedure can be done just by specialized personnel Front PCB J16 A B C J17 A B C To configure the input type set the jumper as below represented J7 A B C Type Input features J7 J16 J17 0 10V Impedan...

Page 31: ...pushed and give the power supply Analog input is tuned Within 10 sec from start flashing yellow and red leds push again momentary CAL Key Yellow led only is flashing apply 0 input Signal I E 0V for 0 10V 4mA for 4 20mA Now press CAL Key again Release key when red and yellow led are ON Yellow and Red leds are flashing ON ON 2sec S C S C H B H B ON S C H B ON S C H B 0 Signal 100 Signal Red led only...

Page 32: ...ver if you wish to change the input type proceed as follows Warning this procedure can be done just by specialized personnel Front PCB J2 A B C J1 A B C To configure the input type set the jumper as below represented Current Limit J2 J1 Regulation through the R13 trimmer mounted on the front PCB secondary input not used C B C B Regulation through the secondary input External current limit profilin...

Page 33: ...eed back V Without Digital Input the Unit use the voltage Feed back otherwise use the set Feed back To configure the input type set the jumper as below represented Warning this procedure can be done just by specialized personnel Main PCB Type J12 J6 J14 External Calibration C B C B Open External Enable B A Open Open Feed back Selection C B Open Close With the Feed back Selection open the jumper J1...

Page 34: ... par 9 2 The standard contact used for this output is normally open NO In normal conditions without alarm and with auxiliary power supply the contact to the terminals has opened relay coil energized In alarm condition or without auxiliary power supply the contact to the terminals is closed relay coil not energized if you wish to change the alarm contact put the jumper as shown Caution this procedu...

Page 35: ...configure the thyristor unit with the configuration software and with the programming cable The programming cable is not included PG Connector 11 7 RS485 Serial Port The serial communication port is on Terminals 7 and 8 On this port may be done a network up to 255 unit Terminal Description 7 RS485 A 8 RS485 B ...

Page 36: ...nds at the address 0 No responses are returned for globally addressed queries To configure communication address remove cover and set the dip switch as below specified Dip Switch Convert the Address Number in Binary for Example 150 Dec 10010110 Bin The dip switch number corresponds to the bit number Dip Switch Number Address Number 8 7 6 5 4 3 2 1 150 Dec 10010110 Bin 1 On 0 Off 0 Off 1 On 0 Off 1...

Page 37: ... after a said time of time out equal at 3 5 time of a character transmission where there are not transitions on the transmission line The first Byte of each message is always the address of the unit that is a value from 1 to 255 or 0 for the broadcast messages the second is always the function number and the rest of the message depends of the function demand When a Slave receive an message the uni...

Page 38: ...ow diagram show how to organize the CRC 16 bit C Language CRC 16 Example static short CRC16 unsigned char p_first unsigned char p_last unsigned int crc 0xffff short j for p_first p_last p_first crc p_first for j 8 j 0 j if crc 0x0001 crc crc 1 crc 0xA001 else crc crc 1 return crc ...

Page 39: ...the CRC Address Unit Function N of Byte First Parameter Value Last parameter value CRC 16 3 3Hex HI LO HI LO LO HI 12 4 Preset Multiple Registers This function could write only a parameter for each message The message is composed by 11 Byte one Byte for the address one for the function 10 Hex two Byte for first parameter to write two Bytes for the N of parameters fixed to 1 0001 Hex one Byte with ...

Page 40: ...ill send an answer of exception 5 byte Address Unit Function Error Code CRC 16 LO HI The byte with the function number represent the function number of the message that has caused the error with the first Bit set to 1 ex the function 3 becomes 0x83 The error code could be one of the followings Error Code Name Cause 1 ILLEGAL FUNCTION Function not supported 2 ILLEGAL DATA ADDRESS Address out of ran...

Page 41: ...value is the load current P001H minus value of parameter P126H P003 H03 Status Table R Function It s a tab in bit that represent the Status of thyristor unit Value Bit 0 1 Short circuit on SCR Bit 1 1 Load Failure HB Alarm Bit 2 1 Output signal ON Bit 3 1 HB Calibration in progress Bit 4 1 Current Limit Flag Bit 5 1 Thermal switch P004 H04 Command Table R W Function It s a tab in bit for remote co...

Page 42: ...ransformer and from his size s Example With one passage on the current transformer CT 25 0 05A the max value corresponds to the max value of the CT Read value 255 FF Hex Load Current 25A P121 H79 CD Unit ID R Function This parameter Identify the CD type Family Value CD32 Hex CD3200 Family P122 H7A CD Ver R Function This parameter is for internal use P123 H7B Password R W Function This parameter gi...

Page 43: ... time P126L x 50msec P125H x 50msec P126H H7E Byte Hi HB sensibility R W Function This parameter is the maximum reduction of Load Current to establish the HB Alarm Min Max 0 100 0 64 Hex Value Each step is 1 from Nominal Current Default 14 Hex Note When you change this parameter HB Calibration procedure is necessary P127 H7F Power Set R W Function This parameter show the Power set saved by the Cal...

Page 44: ...s CD3200 unit must be protected by fuses against short circuit selecting the proper I t that must be lower than the thyristor one I t max Caution USE ONLY EXTRARAPID FUSE WITH APPROPRIATE I T 14 1 FuseHolder size for size 15A 25A for size 35A 45A for size 60A 90A CE for size 90A UL 110A ...

Page 45: ... 40 750 700 CP URC 14x51 40 40 700 660 1 45A FWP 50A14F 50 1800 700 CP URC 14x51 50 50 1500 660 1 60A FWP 80A22F 80 6600 700 CP URD 22x58 80 80 3800 660 1 90A CP URQ 27x60 125 125 6970 660 1 110A CP URQ 27x60 160 160 15000 660 1 Caution The Fuses must have I t 20 less than thyristor s I t Caution High speed fuses are used only for the thyristor protection and can not be used to protect the install...

Page 46: ...451 50A 50 2000 60A FFH2258 80A FU2258 80A 80 6550 90A FFH2258 125A FU2258 125A 125 14000 110A FFH2760 160A FU2760 160A 160 15000 Caution The Fuses must have I t 20 less than thyristor s I t Caution High speed fuses are used only for the thyristor protection and can not be used to protect the installation Caution The warranty of thyristor is null if no proper fuses are used See tab Warning The use...

Page 47: ...oad connection interruption Thyristor faulty and always in open circuit With HB option the yellow led HB is light on Substitute the fuse Check the load Check the wiring Substitute the faulty thyristor Load current flows also with no input signal Green LED ON always light off Wrong wiring Short circuit on thyristor If there is HB option the red LED SC is light on Check the load wiring Substitute th...

Page 48: ...frequency of these operations depends on the atmospheric local pollution Check also that the screw of the power terminals and earth terminals are shut correctly see Diagram of control connection 15 4 Repairing procedure Phone to CD Automation Explain to Service Engineer the problem because sometimes it can be solved with a phone call If this is not possible ship the unit to CD Automation or to you...

Page 49: ...CD Automation srl CD3200 1PH from 15A to 110A User s Manual 49 16 Note ...

Page 50: ...CD Automation srl CD3200 1PH from 15A to 110A User s Manual 50 ENG CD3200 1PH__15 110A 10 DOC ...

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