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Honeywell CD3200 User Manual Download Page 53

User’s Manual ver. 2.0 

CD3200 up to110A 

Honeywell 

 

 51 

www.honeywell.com/imc

11. Maintenance 

11.1 Trouble Shooting 

 

Small problems sometimes can be solved locally with the help of the below tab of trouble shooting. 

If you don’t succeed, contact us or your nearest distributor. 

 

 

Symptom Indication 

on 

front unit 

Possible reasons of 

the symptom 

Actions 

 

Green LED is 

always light off. 

- 

No voltage auxiliary 

power supply to 

terminals 1-3 (see 

wiring diagram). 

- 

Give auxiliary voltage supply 

to terminals 1-3. 

Green LED (PW) 

light on and 

green LED (ON) 

in light off 

condition. 

- 

No input signal. 

- 

Reversed polarities of 

input signal. 

- 

Reset contact in open 

condition (see wiring 

diagram). 

- 

Provide to give input signal. 

- 

Reverse the input signal 

polarity. 

- 

Make link on reset terminals. 

 

 

 

 

Thyristor unit 

doesn’t go in 

conduction with 

input signal. 

Green LED (PW) 

in light on 

condition and 

green LED (ON) 

in light on 

condition. 

- 

Fuse failure. 

- 

Load failure. 

- 

Load connection 

interruption. 

- 

Thyristor faulty and 

always in open 

circuit. 

- 

With HB option the 

yellow led (HB) in 

light on condition. 

- 

Substitute the fuse. 

- 

Repair the load. 

- 

Provide to repair the wiring. 

 

- 

Substitute the faulty thyristor.

 

 

- 

Check the load. 

 

 

Load current 

flows also with 

no input signal. 

Green LED (ON) 

always in light 

off condition. 

- 

Short circuit on 

thyristor. If there is 

HB circuit the red 

LED (SC) is light on. 

- 

Substitute the thyristor. Check 

that load is not in short 

circuit. 

Current flows at 

nominal value 

but yellow LED 

(HB) in light on 

condition. 

Yellow HB in light 

on condition. 

- 

HB circuit not tuned.

 

 

- 

Current transformers 

not properly wired (if 

are external to 

CD3200). 

- 

Push CAL button in front unit 

to start HB calibration 

procedure. 

- 

Control current transformers 

wiring and Push CAL button in 

front unit to start HB 

calibration procedure. 

R

ED 

LED (SC) 

IS LIGHTED ALSO 
IF CURRENT IS AT 
NOMINAL VALUE

. 

Red LED in light 

on condition. 

- 

HB circuit not 

properly tuned. 

- 

Push CAL button in front unit 

to start HB calibration 

procedure. 

Thyristor unit 

doesn’t work 

properly. 

 

- 

Wrong input signal 

selection. 

- 

Wrong input signal 

calibration (out of 

range). 

- 

Auxiliary voltage 

supply out of limits. 

- 

Control input signal setting. 

 

- 

Repeat input calibration 

procedure. 

 

- 

Verify the auxiliary voltage 

supply. 

 

 

Summary of Contents for CD3200

Page 1: ...EN1I 6312 USER S MANUAL CD3200 THYRISTOR UNIT Up To 110A Rev 12 2004 ...

Page 2: ......

Page 3: ...of the unit 9 4 2 Installation 9 4 3 Dimensions 10 4 4 Dimension CT Heater Break HB 10 4 5 Fixing holes 11 5 Wiring Instructions 12 5 2 Cabling detail 13 5 3 Wiring connection 15 5 4 LED Status Table 17 6 Start up 18 6 1 To remove the board 19 6 2 Auxiliary supply 20 6 3 Analog input 21 6 4 Heater Break Alarm 23 6 5 Current Limit Tuning 28 7 Thyristor firing mode 29 7 1 Phase Angle Current Limit P...

Page 4: ... 2 10 Modbus communication 36 10 1 Physical requirements 36 10 2 ModBus RTU protocol 36 10 3 Word parameters 41 10 4 Address Configuration 48 11 Maintenance 51 11 1 Trouble Shooting 51 11 2 Repairing procedure 52 11 3 Fans 52 11 4 Servicing 52 11 5 Warranty conditions 52 ...

Page 5: ...ccess to thyristor unit is only permitted to specialized personnel the authorised personnel must read this manual before to have access to the unit the access to the units must be denied to unauthorized personnel Important warnings Local regulations regarding electrical installation should be rigidly observed Safety regulations must be rigidly observed Don t bend components to maintain insulation ...

Page 6: ...l electronic circuit but not in parallel with contactor s coil solenoids and other inductive or capacitive loads It s recommended to use a shielded transformer Electromagnetic compatibility Our thyristor unit has an excellent immunity to electromagnetic interferences if all suggestions contained in this manual are respected In respect to a good Engineering practise all inductive loads like solenoi...

Page 7: ...compared with power demand from controller the error signal is used to automatically hold the power at demanded level 1 4 What is a thyristor unit A thyristor unit is semiconductor device which acts as a switch formed by two thyristors in antiparallel To switch on the alternating current the input signal will be on and the thyristor will switch off at first zero crossing voltage with no input sign...

Page 8: ...ine via serial port Phase Angle Current Limit PA Soft Start Phase Angle Current Limit S PA Auxiliary voltage supply 230V 15 10VA power consumption 440V 15 10VA power consumption Fan voltage supply 230V 15 110V 15 on request Heater break alarm Discrimination better than 20 Circuit microprocessor based to diagnose partial or total load failure and short circuit on Thyristors Latching alarm plus rese...

Page 9: ...e for fusing Frequency range Power loss Isolation Voltage A V 440V 500V mAeff 10msec A mAeff tp 10msec Hz I Inom W Vac 15A 24 440 1200 NA 150 230 15 610 47 70 18 2500 25A 24 440 1200 NA 150 230 15 610 47 70 30 2500 35A 24 500 1200 1600 250 400 15 780 47 70 42 2500 45A 24 500 1200 1600 250 600 15 1800 47 70 54 2500 60A 24 500 1200 1600 450 1000 15 4750 47 70 72 2500 90A 24 500 1200 1600 450 2000 15...

Page 10: ...ltage The minimum voltage supply to the load is 24V 4 Auxiliary Voltage 230V 200 230V 15 10VA 460V 300 460V 15 10VA 600V 600V 15 10VA on request 5 Input SSR 4 30VDC 0 10V 0 10V analog input 4 20mA 4 20mA analog input 10K pot Potentiometer 6 Firing PA Phase Angle Current Limit S PA Soft Start Phase Angle Current Limit 7 Feedback V Voltage feedback V V2 Square Voltage feedback V VxI Power feedback V...

Page 11: ...___ ____ PA S S ZC An identification label provides all the informations regarding the factory settings of the unit This label is on the board inside the unit as represented 4 2 Installation CD3200 unit should be always mounted in vertical position to improve air cooling on heatsink Maintain minimum distances in vertical and in horizontal as below represented Don t install in proximity of hot elem...

Page 12: ... 0 www honeywell com imc 10 4 3 Dimensions Size W mm H mm D mm 15A S0C 63 120 120 25A S0C 63 120 120 35A S3C 85 120 120 45A S3C 85 120 120 60A S7C 148 120 159 90A S7C 148 120 159 110A S8C 148 138 159 4 4 Dimension CT Heater Break HB 8 1 2 39 39 20 ...

Page 13: ...anual ver 2 0 CD3200 up to110A Honeywell 11 www honeywell com imc 4 5 Fixing holes A B C D Size A mm B mm C mm D mm 15A S0C 110 25A S0C 110 35A S3C 110 45A S3C 110 60A S7C 110 65 90A S7C 110 65 110A S8C 110 65 ...

Page 14: ...observed 3 3 2 Auxiliary terminals Before connect or disconnect make sure that the power control cables and wires are insulated from the voltage Terminal Description 1 External Calibration command 24Vdc max 2 External Calibration command 24Vdc max 3 Reset 4 Reset 5 Output Command signal to CD3200 Internal Connections 6 Output Command signal to CD3200 Internal Connections A2 Input command signal 4 ...

Page 15: ...iliser conducteur de cuivre CU pour 75 C seulement avec les terminal suivants Current courant Torque couple Lb in N m Wire cable Wire terminal terminal 15A 25A 35A 45A 26 6 3 0 18 8 UL Listed ZMVV Wire Pin Terminal terminal avec cosse 60A 90A 110A 70 8 8 0 18 1 UL Listed ZMVV Fork Spade Terminal terminal avec cosse a fourche Copper Tube Cr Lug cosse tubulaire a plage étroite ...

Page 16: ... 12 M5 4 12 M5 25A 6 10 M5 6 10 M5 35A 10 8 M5 10 8 M5 45A 10 8 M5 10 8 M5 60A 16 6 M6 16 6 M6 90A 35 3 M6 35 3 M6 110A 35 2 M6 35 2 M6 Auxiliary connectors and earth Current Auxiliary Supply Earth Cable Clable mm2 AWG mm2 AWG Screw M 15A 0 50 18 4 12 M4 25A 0 50 18 4 12 M4 35A 0 50 18 6 10 M5 45A 0 50 18 6 10 M5 60A 0 50 18 6 10 M5 90A 0 50 18 10 8 M5 110A 0 50 18 16 6 M5 ...

Page 17: ...linked The auxiliary voltage supply of CD3200 unit must be connected as above and must be syncronized with load voltage power supply L1 L2 5 3 2 CD3200 35 45A POWER UNIT Input CT Reset RS485 A 1 6 2 7 3 8 4 9 5 10 RS485 B COM NO NC H B Contact 8V External Calibration 1 6 5 7 8 9 10 11 12 13 14 15 16 17 18 2 A2 3 A1 4 CT L1 L2 The user installation must be protect by electromagnetic circuit breaker...

Page 18: ...nit must be connected as above and must be syncronized with load voltage power supply L1 L2 5 3 4 CD3200 110A Input CT Reset RS485 A RS485 B COM NO NC H B Contact 8V External Calibration 1 6 5 7 8 9 10 11 12 13 14 15 16 17 18 2 A2 3 A1 4 CT L1 L2 L1 T1 FAN 220 Vac The user installation must be protect by electromagnetic circuit breaker or by fuse isolator If the Auxiliary Voltage written on the id...

Page 19: ... www honeywell com imc 5 4 LED Status Table LED STATUS DESCRIPTION PW Auxiliary supply is not connect Auxiliary supply is connect SC SCR OK SCR short circuit HB Laod OK Load Fault ON OFF Condition Load IS NOT Powered ON Condition Load IS Powered OFF ON ...

Page 20: ...n nominal verify that all auxiliary connections are right and syncronized to main voltage Fan voltage equal than nominal 230V std 120V optional After which supply thyristor unit giving the maximum input signal and verify that load current is equal or less than thyristor unit nominal current Warning this procedure can be done just by specialized personnel The thyristor unit is delivered configured ...

Page 21: ...User s Manual ver 2 0 CD3200 up to110A Honeywell 19 www honeywell com imc 6 1To remove the board 1 Remove plastic Cover 2 Pull the PCB ...

Page 22: ...jumper on main PCB 230V Auxiliary supply Main PCB 460V Auxiliary supply J9 J10 J11 J9 J11 J10 J9 J10 J11 If the Auxiliary Voltage written on the identification label is different from Supply Voltage to the load use an external transformer If load voltage is not included in range of 230V 15 or 460V 15 provide an external transformer with primary equal to load voltage and secondary 230V if your unit...

Page 23: ... this procedure can be done just by specialized personnel 6 3 1 Setting Analog input To change input type remove plastic cover and configure jumpers as represented below Jumpers Configuration FRONT PCB Input J7 J16 J17 SSR A B C A B C A B C 0 10V A B C A B C A B C 4 20MA A B C A B C A B C Front PCB ...

Page 24: ...ashing yellow and red leds 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 Red led only is flashing apply 10V for 0 10V input or 20mA for 4 20mA input Now press CAL Key again Now press CAL Key again The leds will stop flashing Release key when red and yellow led are ON Yello and red ...

Page 25: ...und current transformer H B circuit also diagnose fuse failure H B circuit reads load current via a current transformer 25 50 0 05 or 100 0 05 depending on thyristor size 6 4 1 Heater Break Alarm indication LED STATUS DESCRIPTION SC SCR OK SCR short circuit HB Laod OK Load Fault LED off LED on The thyristor unit is supplied with a normally closed N C contact In alarm condition and without auxiliar...

Page 26: ...e contact of the H B Relay is available on auxiliary terminals Terminal Descriprion 10 Common relay HB alarm 11 NO NC HB relay alarm To change relay status remove plastic cover and configure jumpers as represented below STATUS RELE STATUS MAIN PCB J19 IN Alarm Close Circuit not powered Close C B A std OK Open IN Alarm Open Circuit not powered Open C B A OK Close ...

Page 27: ...User s Manual ver 2 0 CD3200 up to110A Honeywell 25 www honeywell com imc Main PCB ...

Page 28: ...es it as set point Calibration procedure verify that connections are correct supply the thyristor unit push CAL button on front of CD3200 unit or supply with 24Vdc terminals 1 2 or send command via RS485 the thyristor unit goes in conduction state to measure load current all LEDS are ON this means that calibration procedure is active after one minute LEDS for H B and S C switch off calibration pro...

Page 29: ...C H B Contact POWER UNIT Reset 1 6 5 7 8 9 10 11 12 13 14 15 16 17 18 2 A2 3 A1 4 COM NO NC H B Contact If load current decreases for partial or total load failure sensitivity 20 standard adjustable via RS485 the yellow LED becomes ON and alarm relay changes status If CD3200 is still in conduction with no input signal LED green OFF it means that there is a short circuit on thyristors and red LED S...

Page 30: ...ure can be done just by specialized personnel To adjust the current limit remove the cover of the CD3200 module and tune the trimmer R13 as below represented Completely anti clockwise current limit 0 Completely clockwise current limit 100 of the maximum value of the used current transformer Front PCB Current Limit Pot ...

Page 31: ... Thyristor to be in conduction for a variable part of the voltage supply halt cycle The load power can be adjusted from 0 to 100 as a function of analog input signal normally delivered by temperature controller or by potentiometer Normal it s used with inductive loads The only disadvantage with phase angle is the generation of interferences that can be reduced with filters LINE VOLTAGE T V LOAD SU...

Page 32: ...l com imc 30 7 2 Configurator To configure CD3200 unit you can download the free software and the Configurator Manual from our web site www honeywell com imc To configure the unit you can use the standard communication on terminals 7 8 or use a programming cable ...

Page 33: ...oneywell 31 www honeywell com imc To connect the programming cable to the thyristor unit remove cover as in picture PROG CONN Once removed the cover put a side of cable in prog connector K10 and the other side in the PC RS232 9PIN serial port ...

Page 34: ...etrical A I C Sizes Fuse Mod No modéle fusible Current ARMS I t A2 sec V ac Fuse Mod No modéle fusible Current ARMS I t A2 sec Vac 15A FWC 16A10F 16 150 600 660 Grb 10 16 16 145 660 25A FWC 32A10F 32 600 600 660 Grb 10 32 32 740 660 35A FWP 40A14F 40 980 700 CP URC 14x51 40 40 700 660 45A FWP 50A14F 50 1800 700 CP URC 14x51 50 50 1500 660 60A FWP 80A22F 80 5100 700 CP URD 22x58 80 80 3800 660 90A ...

Page 35: ...anual ver 2 0 CD3200 up to110A Honeywell 33 www honeywell com imc 8 2 FuseHolder size 15 25A 35 45A 60 mm 80 mm 17mm 110 mm 77 mm 26mm 60A 90 110A 150 mm 107 mm 37mm 70 mm 9 mm 9 mm 6mm 19 mm 35mm 77 mm 125 mm ...

Page 36: ...r I2 t Sizes I T max A sec Size and current Fuse and Fuseholder Code Fuse Code 15 600 10 3X38 16A FFH1038 16A FU1038 16A 25 600 10 3X38 32A FFH1038 32A FU1038 32A 35 780 14X15 40A FFH1451 40A FU1451 40A 45 1500 14X15 50A FFH1451 50A FU1451 50A 60 3800 22X58 80A FFH2258 80A FU2258 80A 90 6970 22X58 125A FFH2258 125A FU2258 125A 110 11000 27x60 160A FFHPSI27 160A FFHPSI27 160A High speed fuses are o...

Page 37: ...anual ver 2 0 CD3200 up to110A Honeywell 35 www honeywell com imc 9 2 FuseHolder size 15 25A 35 45A 60 mm 80 mm 17mm 110 mm 77 mm 26mm 60 90A 110A 150 mm 107 mm 37mm 70 mm 9 mm 9 mm 6mm 19 mm 35mm 77 mm 125 mm ...

Page 38: ...rd 03 Preset Multiple Registers Write n Word 16 The Controller will identify itself in response to a Read Holding Registers message which enquires the values of word parameters 121 and 122 see Table 4 2 MODBUS Function 17 Report Slave ID is not supported 10 2 1 Message Formats The first character of every message is the Controller address in the range 1 255 and 0 for broadcast messages The second ...

Page 39: ...ding polynomial is 216 215 22 1 Hex 18005 but this is modified in two ways because the bit order is reversed the binary pattern is also reversed making the most significant bit MSB the right most bit because only the remainder is of interest the right most most significant bit can be discarded Thus the polynomial has the value Hex A001 10 2 2 Bit s order Normal bit order Most significant bit Least...

Page 40: ...CR is shifted by 1 bit to right Added 1to J Added 1 to I END After shifting CR by 1 bit to right A001 Hex and exclusive logical sum XOR are executed for setting the result in CR Bit at right and of CR is 1 NO NO NO YES YES YES Eight times of calculation is completed J 8 Calculation of all charactersis completed I All characters numbers Exclusive logical Sum XOR is executed on one character 1 byte ...

Page 41: ...ontroller to obtain the value of one or more registers comprises the following eight bytes Addr unit Func Address 1 word N of Word CRC 16 3 3Hex HI LO HI LO HI LO The normal reply will echo the first two characters of the message received followed by a single byte data byte count which will not include itself or the CRC For this message the count value equals the number of parameter values read mu...

Page 42: ... parity check failure framing error etc or if the CRC16 check fails or if the received message is otherwise syntactically flawed e g byte count or word count is incorrect the thyristor will ignore that message If the received message is syntactically correct but nonetheless contains an illegal value the thyristor will send a five byte exception response as follows Addr unit Func N Exception CRC 16...

Page 43: ... Scaling 0 FFH 6 Read Write if BIT1 in Command table i 1 0 0 FF 100 Current Limit 0 FFH 7 Read Write if BIT4 in Command table i 1 0 0 FF 100 Manufact ID 121 Read only Equipment ID 122 Read only 10 3 1 Actual Current Parameter 1H Operations Read 10 3 2 Actual Voltage Parameter 1L Operations Read 10 3 3 Set Current Parameter 2H Operations Read 10 3 4 Set Voltage Parameter 2L Operations Read 10 3 5 S...

Page 44: ...0 255 0 FF Hex It s power set point setted in thirst buffer Example 0 0 0 Hex 50 128 80 Hex 100 255 FF Hex 10 3 8 Output Power Ramping 0 FFH Operations Read 10 3 9 Power adjust Parameter 6 Operations Read Write Meaning It s a value in points 0 255 0 FF Hex It s a scaling factor of power demand Example 1 0 0 50 128 100 255 Example 2 Output Power 100 Power Limit 100 Real power 100 Output Power 100 P...

Page 45: ... set point setted in thirst buffer Example 0 0 0 Hex 50 128 80 Hex 100 255 FF Hex 10 3 11 Status Table Bit Meaning Notes 0 Short circuit on SCR Read only 1 Load Failure Read only 2 On Off Read only 3 HB Calibration in progress Read only 0 Normal 1 Calibration 4 Current Limit Flag Read only 0 Normal 1 Working in C L 5 Termal Read only 10 3 12Short circuit on SCR Bit 0 Operations Read Meaning It s a...

Page 46: ...orking in current limit 0 Normal 1 Working in current limit 10 3 17 Command Table Bit Meaning Notes 0 Calibration Read write 0 Off 1 ACTVATE Calibration normal mode set to 0 1 Firing command Read write 0 from terminal 1 from RS485 2 On Off Read write 0 Off 1 On 3 RESET HB Read write 0 Off 1 RESET normal mode set to 0 4 Current Limit control Read write 0 from C L pot 1 from RS485 N B When the unit ...

Page 47: ...rite Meaning It s a command bit to reset HB alarm This parameter has to be at 0 to have the alarm working properly 0 Reset disabled 1 Reset enabled 10 3 22 Current Limit control Bit 4 Operations Read Write Meaning It s a command bit used to switch from analog C L potentiometer to command via RS485 0 Command from Current Limit pot 1 Command from RS485 input 10 3 23 Configuration Parameter N Note Pa...

Page 48: ...th a ramp starting from zero up to full voltage in a presetted and Adjustable time The time is setted by this parameter 10 3 28 Delay time HB Parameter 126L Operations Read Write Meaning It s a value in point 0 255 0 FF Hex Each step is 50msec It represents a delay time before to have HB alarm active When is used with soft start this time must be longer than soft start time Par126H x 50msec Par125...

Page 49: ...2 0 CD3200 up to110A Honeywell 47 www honeywell com imc 10 3 29 1 Set power Parameter 127 Operations Read Write 10 3 29 2 Integral Parameter 128L Operations Read Write 10 3 29 3 Prop Parameter 128H Operations Read Write ...

Page 50: ...SS TABLE ID 8 7 6 1 ON OFF 2 3 4 5 6 7 8 5 4 3 2 1 ID 8 7 6 5 4 3 2 1 1 X 26 X X X 2 X 27 X X X X 3 X X 28 X X X 4 X 29 X X X X 5 X X 30 X X X X 6 X X 31 X X X X X 7 X X X 32 X 8 X 33 X X 9 X X 34 X X 10 X X 35 X X X 11 X X X 36 X X 12 X X 37 X X X 13 X X X 38 X X X 14 X X X 39 X X X X 15 X X X X 40 X X 16 X 41 X X X 17 X X 42 X X X 18 X X 43 X X X X 19 X X X 44 X X X 20 X X 45 X X X X 21 X X X 46...

Page 51: ... 118 X X X X X 69 X X X 119 X X X X X X 70 X X X 120 X X X X 71 X X X X 121 X X X X X 72 X X 122 X X X X X 73 X X X 123 X X X X X X 74 X X X 124 X X X X X 75 X X X X 125 X X X X X X 76 X X X 126 X X X X X X 77 X X X X 127 X X X X X X X 78 X X X X 128 X 79 X X X X X 129 X X 80 X X 130 X X 81 X X X 131 X X X 82 X X X 132 X X 83 X X X X 133 X X X 84 X X X 134 X X X 85 X X X X 135 X X X X 86 X X X X 1...

Page 52: ...X X 173 X X X X X 223 X X X X X X X 174 X X X X X 224 X X X 175 X X X X X X 225 X X X X 176 X X X 226 X X X X 177 X X X X 227 X X X X X 178 X X X X 228 X X X X 179 X X X X X 229 X X X X X 180 X X X X 230 X X X X X 181 X X X X X 231 X X X X X X 182 X X X X X 232 X X X X 183 X X X X X X 233 X X X X X 184 X X X X 234 X X X X X 185 X X X X X 235 X X X X X X 186 X X X X X 236 X X X X X 187 X X X X X X ...

Page 53: ...h HB option the yellow led HB in light on condition Substitute the fuse Repair the load Provide to repair the wiring Substitute the faulty thyristor Check the load Load current flows also with no input signal Green LED ON always in light off condition Short circuit on thyristor If there is HB circuit the red LED SC is light on Substitute the thyristor Check that load is not in short circuit Curren...

Page 54: ...ature falls below the setted value This means that also with input signal in ON condition the unit is switched OFF and the system can not work at full power For these reason is important to control periodically the fan status checking that is rotating 11 4 Servicing In order to have correct cooling the user must clean the heatsink and the protective grill of fan The frequence of this servicing dep...

Page 55: ...Austria Honeywell Austria GmbH Phone 43 316 400123 FAX 43 316 40017 Belgium Honeywell SA NV Phone 31 0 205656999 FAX 31 0 165330746 Bulgaria Honeywell EOOD Phone 359 2 79 40 27 FAX 359 2 79 40 90 Czech Republic Honeywell spol s r o Phone 420 54324 5014 FAX 420 54324 5011 Denmark Honeywell A S Phone 45 39 55 55 55 FAX 45 39 55 55 58 Finland Honeywell OY Phone 358 3 2727625 FAX 358 3 2728600 France ...

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