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13

40 to 300A Models

1

Line / load voltage connector

11 Control input connector

2

“Line” terminals

12 Address Rotary Switch

3

Configuration keypad connector

13 input connector PID

4

Output connector

14 RJ10 connector serial RS485 (PORT 1)

5

Supply connector

15 Dip Switch serial line (PORT 1)

6

Digital input connector

16 Connector board Fieldbus (PORT 2)

7

4 input TCAUX connector

17 Cooling Fan

8

LED

18 24V fan connector power supply

9

Configuration Dip Switch

19 “Load” terminal

10 HB Key calibration

20 Internal fuse protection cover

5. Controller Overview

Содержание CFW

Страница 1: ...i PK558 0037 75584 March 2019 Hardware Instruction Manual CFW Modular SCR Power Controller with Independent PID control...

Страница 2: ...ii...

Страница 3: ...l 400 to 600 A Models 18 5 5 Card Insertion for Fieldbus Interface 40 to 300 A Models 19 5 6 Card Insertion for Fieldbus Interface 400 to 600 A Models 20 7 5 Connection of Expansion Modules for 2 Phas...

Страница 4: ...view 61 9 1 Trigger Modes 61 9 2 Digital Input or PWM 40 to 300A 65 9 3 Digital Input or PWM 400 to 600A 66 10 Installation of Modbus Serial Network 67 11 Technical Characteristics 68 12 Ordering Info...

Страница 5: ...risk to operational and service personnel This controller utilizes a heat sink which is de signed to cool the unit during operation Un der no circumstance should air flow around the controller be com...

Страница 6: ...ature levels Current Diagnostics Total and partial load interrupt alarm Self learn function of alarm limit for interrupted load Alarm for SCR in short circuit Alarm for load in short circuit or overcu...

Страница 7: ...ormation See paragraph Dimensions and mounting before in stalling the CFW on the machine host system control panel To configure with a PC use the Chromalox C PWR software and relative connection cable...

Страница 8: ...43 87 2 4 26 108 4 7 7 195 6 13 31 338 2 13 7 349 4 11 9 302 11 13 282 8 10 18 258 65 3 43 87 2 4 26 108 4 3 43 87 2 CFW 40A to 300A Dimensions In mm CFW1 CFW3 CFW2 Weights Lbs kg Model Amps Weight L...

Страница 9: ...65 2 56 65 13 34 339 13 78 350 9 45 240 7 48 190 2 56 65 2 56 65 2 56 65 2 56 65 13 19 335 11 22 285 2 56 65 2 56 65 13 34 339 13 78 350 CFW1 CFW2 CFW3 Weights Lbs kg Model Amps Weight Lbs kg CFW1 400...

Страница 10: ...ns Panel Mounting and Cutout Dimensions 40 to 300A Models Panel Mounting and Cutout Dimensions 400 to 600 A Models CFW MASTER CFW2 CFW3 Fastening may be done with 5MA All dimensions are expressed in m...

Страница 11: ...7 2 2 Installation Place here the remore keypad Place here the remore keypad 40 to 300A Models ATTENTION RESPECT THE MINIMUM DIS TANCES SHOWN TO PROVIDE ADEQUATE AIR CIRCULATION 400 to 600A Models...

Страница 12: ...ied with respect to the information in Tables 1 and 2 3 3 Recommendations for Correct Instal lation for purposes of EMC 3 3 1 Instrument Power Supply The power supply for the electronic instrumentatio...

Страница 13: ...based on the model presence of dispersion current in CFW in noncon ducting state current of a few mA due to RC Snub ber circuit to protect the thyristor Chromalox S p A assumes no liability for any d...

Страница 14: ...P Ethernet IP Ethercat CanOpen Profibus Supply 18 32V MODBus RS485 ANALOG COMMAND INPUT DIGITAL INPUTI DI1 DI2 DI3 DI4 TV INPUT V_line TV1 TV2 TV3 OUT 5 6 7 8 Analog Digital 2KV 5v 1KV DC DC 5v 1KV DC...

Страница 15: ...1 kV Magnetic fields immunity Tests are not required Immunity is demonstrated by the successful completion of the operating capability test Voltage dips short interruptions and voltage immunity tests...

Страница 16: ...2 kV Signal line line 1 kV Magnetic fields immunity Tests are not required Immunity is demonstrated by the successful completion of the operating capability test Voltage dips short interruptions and v...

Страница 17: ...D 4 Output connector 14 RJ10 connector serial RS485 PORT 1 5 Supply connector 15 Dip Switch serial line PORT 1 6 Digital input connector 16 Connector board Fieldbus PORT 2 7 4 input TCAUX connector 17...

Страница 18: ...nnector and power supply 12 V load measurement connector 4 Dip Switch configuration 13 V line measurement connector 5 Rotary Switch address 14 3 way external TA input connector 6 3 analog input connec...

Страница 19: ...liminate the problem do as follows 1 Remove the fan support grille by detaching the two support tabs 2 Disconnect the fan connector from the board 3 Check the condition of the fan 4 Clean or replace t...

Страница 20: ...s safety 1 Extract the 24V power supply connector from the fan 2 Use a crosshead screwdriver to unscrew the two screws holding the fan in place see drawing 3 Extract the fan complete with its protect...

Страница 21: ...this way the fuse is discovered 3 4 Loosen the two fastening nuts of fuse by means of tube shaped spanner N 13 CFW 40 150 5 It is not necessary to remove the nuts as the fuse N 17 CFW 200 300 A is sli...

Страница 22: ...or a No 17 spanner CFW 400A 5 There is no need to remove the bolts as the fuse is pulled out of its housing as shown by the arrows 5 6 Insert the new fuse as shown by the arrows 6 WARNING the washer...

Страница 23: ...er 3 Remove the cover 17 4 Place the interface card 19 in the connectors pre pared on card 21 5 Remove the pre formed blanks parts 20 on cover 17 according to the type of interface installed 6 Replace...

Страница 24: ...connec tors provided on the supporting card 6 Check that the card is inserted correctly 4 Put the CPU cover 4 back in place and fix it in place by tightening the screws 3 5 Use the new front piece 2...

Страница 25: ...undoing the fastening screw of the cover and cor rectly install the master module and the expansion module to the panel as described at paragraph 2 4 5 Fasten the screw to secure the product in posit...

Страница 26: ...n 1 L1 Line Connection 1 L1 Line Connection J1 mV TC input optional CFW OP keypad connector Address x 10 Address x 1 Screw front cover allows access to fuse Magnetic area keypad fixing CFW OP only CFW...

Страница 27: ...itch serial line INA1 GND EARTH INA2 INA3 GND Out 5V potentiometer J4 3 analog inputs connector Magnetic area keypad fixing CFW OP HB Button DipSwitch Load configuration RotarySwitch Modbus address FI...

Страница 28: ...5 O8 Output 8 0 2 2 5mm2 24 14 AWG 0 25 2 5mm2 23 14 AWG If auxiliary outputs O5 O8 are present connector J1a becomes J1 LOAD LOAD LOAD LOAD 1 5 4 3 2 O5 O6 O7 O8 Com 5 8 V I Outputs 5 8 logic contin...

Страница 29: ...25 When using the continuous C output option voltage or current is set using jumper links on the board Internal OUT C board optional Voltage settings OUT C Board Current settings OUT C Board...

Страница 30: ...LOAD LOAD LOAD 2 1 3 4 5 Vac O9 6 V V LOAD LOAD 7 8 9 O10 Com O9 Com O10 I I Outputs 9 10 Relay Type Outputs Out 9 10 relay 5A max V 250V 30Vdc cosj 1 I 5A max Connection scheme for relay outputs LOAD...

Страница 31: ...pply 2 GND 24V Supply 3 Earth Ground PIN Name Description 1 INDIG1 Digital Input 1 5 32 VDC 2 INDIG2 Digital Input 2 5 32 VDC 3 INDIG3 Digital Input 3 5 32 VDC 4 GND GND Common 0 2 2 5mm2 24 14 AWG 0...

Страница 32: ...2 I2 Auxiliary Input 2 3 I3 Auxiliary Input 3 4 I3 Auxiliary Input 3 5 I4 Auxiliary Input 4 6 I4 Auxiliary Input 4 7 I5 Auxiliary Input 5 8 5 Auxiliary Input 5 0 14 0 5mm2 28 20 AWG 0 25 0 5mm2 23 20...

Страница 33: ...Input Control 40 to 300A PIN Name Description 1 5V_Out Supply Outut 5V Potentiometer 2 IN Control Voltage Input 3 SHUNT Shunt for INput mA 4 GND GND Control Signal 0 2 2 5mm2 24 14 AWG 0 25 2 5mm2 23...

Страница 34: ...inearInput 0 2 2 5mm2 24 14 AWG 0 25 2 5mm2 23 14 AWG PIN Name Description 1 EARTH EMC Earth for shielded cable 2 IN Negative Input 3 IN Positive Input TC and RTD 4 IN1 3rd Wire RTD Positive IN mA PIN...

Страница 35: ...relay Ir 3A max NO V 250V 30Vdc cos 1 I 12A max Connection scheme for relay outputs 0 25 2 5mm2 23 14 AWG 0 25 2 5mm2 23 14 AWG PIN Name Description 1 Com 5 8 Outputs common 2 O5 Output 5 3 O6 Output...

Страница 36: ...with exchange contact C NC NO V 250V 30Vdc cos 1 I 5A max Connection Scheme for Relay Outputs PIN Name Description 1 C Out 9 Out 9 Common contact 2 NC Out 9 Out 9 Normally closed contact 3 NO Out 9 O...

Страница 37: ...n 1 24Vdc 24 Vdc supply 2 GND 24 Vdc supply 3 Earth Earth EMC 4 INDIG1 Digital input 1 5 32Vdc configurable NPN PNP 5 INDIG2 Digital input 2 5 32Vdc configurable NPN PNP 6 INDIG3 Digital input 3 5 32V...

Страница 38: ...2 5mm2 23 14 AWG Connection Scheme PIN Name Description 1 5V_POT Output 5V potentiometer s power supply max 30 mA 2 INA1 Analogue command input INA1 3 GND GND command signal 4 EARTH Earth EMC 5 INA2 A...

Страница 39: ...23 14 AWG Connection Scheme PIN Name Description 1 TA1 External TA1 input max 5 A rms 2 TA1 External TA1 input max 5 A rms 3 TA2 External TA2 input max 5 A rms 4 TA2 External TA2 input max 5 A rms 5 T...

Страница 40: ...PKC95025 6 Nm No 6 hex head wrench 250A 1 L1 2 T1 120 mm2 250 AWG Wire stripped for 25 mm 6 Nm No 6 hex head wrench 300A 1 L1 2 T1 185 mm2 350 KCMIL Wire stripped for 25 mm 6 Nm No 6 hex head wrench...

Страница 41: ...ted in ILSCO AU 350 lug Accessory N 1 Bolt M12x25 mm UNI 5739 hex head wrench n 18 Pair 50 Nm 500A 1 L1 2 T1 Copper rail W 40 32 24 mm H 3 4 5 mm Insulated copper rail with terminal non insulated for...

Страница 42: ...ot provided All LEDs flashing rapidly except LED DI2 30 _UNBALANCED_ERROR alarm only for three phase configuration All LEDs flashing rapidly except LED O1 SHORT_CIRCUIT_CURRENT alarm only for three ph...

Страница 43: ...ndent single phase load in open delta x x x ON ON OFF OFF OFF ON 3 phase load open delta star load with neutral x x x ON ON ON OFF OFF ON 3 phase load closed delta x x x ON OFF OFF ON OFF ON 3 phase s...

Страница 44: ...Description Note 4 3 2 1 1 GND1 Insert the RS485 line termination in the last device on the Modbus line see dip switches Connect the GND signal between Modbus devices with a line distance 100 m 2 Tx R...

Страница 45: ...S485 line termination in the last device on the Modbus line see dip switches Connect the GND signal between Modbus devices with a line distance 100 m 2 Tx Rx Data reception transmission A 3 Tx Rx Data...

Страница 46: ...4 V reserved Cable type flat telephone cable for pin 4 4 conductor 28 AWG Connector S5 D SUB 9 Pins Male Nr Pin Name Description Note 1 SHIELD EMC Protection Connect the terminal resistances as shown...

Страница 47: ...4 conductor 28 AWG Connector S5 D SUB 9 Pins Female Nr Pin Name Description Note 1 Reserved Connect the terminal resistances as shown in the figure 2 CAN_L CAN_L bus line domination low 3 RxD TxD P CA...

Страница 48: ...Tx Data reception transmission A 3 Rx Tx Data reception transmission B 4 V reserved Cable type flat telephone cable for pin 4 4 conductor 28 AWG Connector S5 RJ45 Nr Pin Name Description Note 8 1 1 T...

Страница 49: ...a line distance 100 m 2 Rx Tx Data reception transmission A 3 Rx Tx Data reception transmission B 4 V reserved Cable type flat telephone cable for pin 4 4 conductor 28 AWG Connector S5 RJ45 Nr Pin Na...

Страница 50: ...OSTIC AVAILABLE Partial and total load failure FAST FUSE needed only for controller with option Fuse 0 GG Fuse See Fuse section V phase voltage line L1 line L2 N P power of each single phase load Vloa...

Страница 51: ...dary load Id current in primary Is current in secondary transformer output typical 0 9 if resistive load cos 1 DELTA DELTA transformer Only symmetrical transformer Y Y Y Y transformer CFW Master Dip S...

Страница 52: ...quired with Vload measurement input option CFW Master Dip Switch Configuration Dip 1 Dip 2 Dip 3 Dip 4 Dip 5 ON OFF ON OFF ON FIRING MODE ZC BF HB DIAGNOSTIC AVAILABLE Par tial and total load failure...

Страница 53: ...d only for controller with option Fuse 0 GG Fuse See Fuse section DELTA DELTA transformer Only symmetrical transformer Y Y Y Y transformer V phase voltage line L1 line L2 N P power of each single phas...

Страница 54: ...ry load Id current in primary Is current in secondary transformer output type 0 9 if resistive load cos 1 CFW Master Dip Switches Configuration Dip 1 Dip 2 Dip 3 Dip 4 Dip 5 ON OFF OFF ON ON DELTA DEL...

Страница 55: ...HSC PA HB DIAGNOSTIC AVAILABLE Partial and total load failure of each single leg FAST FUSE needed only for controller with option Fuse 0 GG Fuse See Fuse section V line voltage P power of each single...

Страница 56: ...OFF FIRING MODE ZC BF HSC PA HB DIAGNOSTIC AVAILABLE Partial and total load failure of each single leg in PA mode HB diagnostic active with P 30 FAST FUSE needed only for controller with option Fuse 0...

Страница 57: ...ired with Vload measurement input option CFW Master Dip Switch Configuration Dip 1 Dip 2 Dip 3 Dip 4 Dip 5 OFF OFF OFF OFF ON V phase voltage line L1 line L2 N P power of each single phase load Vload...

Страница 58: ...Dip 4 Dip 5 OFF OFF OFF OFF OFF V line voltage P power of each single phase load Id load current if resistive load cos 1 FIRING MODE ZC BF HSC PA HB DIAGNOSTIC AVAILABLE Partial and total load failure...

Страница 59: ...FUSE GG 4 L2 6 T2 5 T1 4 L2 6 T2 5 T1 J7 3 L1 3 L1 J7 J6 J6 FUSE 1 L1 2 T1 J5 1 L1 2 T1 L2 L3 L1 FUSE GG R Load R Load R Load PE FUSE GG 4 L2 6 T2 5 T1 4 L2 6 T2 5 T1 J7 3 L1 3 L1 J7 J6 J6 TA2 TA1 to...

Страница 60: ...1 FUSE GG PE FUSE GG 4 L2 6 T2 5 T1 4 L2 6 T2 5 T1 J7 3 L1 3 L1 J7 J6 J6 to TA2 to TA1 TA1 TA2 imput J5 FUSE Y Y Y Y R Load R Load TA2 TA1 to J5 R Load Current Transformers CFW E CFW M L1 L2 L3 V 1 L1...

Страница 61: ...5 T1 4 L2 6 T2 5 T1 J7 4 L2 6 T2 5 T1 J6 J7 3 L1 3 L1 3 L1 J7 J6 J6 to TA3 to TA2 to TA1 TA1 TA2 TA3 imput J5 Y TA3 TA2 TA1 to J5 Current transformers Y CFW E CFW E CFW M L1 L2 L3 V 1 L1 2 T1 1 L1 2 T...

Страница 62: ...for PA mode HB diagnostics active with P 30 Fast Fuse Needed only for controller with option Fuse 0 GG Fast Fuse See Fuse section IMPORTANT Take care to connect terminals 1 L1 and 3 L1 to the same pha...

Страница 63: ...ion Fuse 0 GG Fast Fuse See Fuse section IMPORTANT Take care to connect terminals 1 L1 and 3 L1 to the same phase Only required with Vload measurement input option Dip 1 Dip 2 Dip 3 Dip 4 Dip 5 ON ON...

Страница 64: ...TIC AVAILABLE Partial and total load failure pof each single leg Fast Fuse Needed only for controller with option Fuse 0 GG Fast Fuse See Fuse section IMPORTANT Take care to connect terminals 1 L1 and...

Страница 65: ...d 9 1 Trigger Modes The CFW has the following power control modes modulation via variation of number of conduction cycles with zero crossing trigger modulation via variation of phase angle Zero Crossi...

Страница 66: ...ort medium wave IR lamp loads With these loads to limit operating current with low power it is useful to set a minimum power limit for example Lo P 10 ref CFW IR operation guide NB This mode is NOT al...

Страница 67: ...d shut off time settable is exceeded the ramp is reactivated at the next power on Example of firing ramp with phase Soft Start RMS Current Limit The option for controlling the load current limit is av...

Страница 68: ...Over Current Transient without Over Current Example of firing of inductive load with without delay triggering To conduct inductive loads controlled in PA mode do not use delay triggering instead use t...

Страница 69: ...me CycleTime TON TOFF The power level is given by the ratio TON CycleTime and is normally expressed in The CFW digital input automatically adapts to the cycle time from 0 03Hz to 100Hz and obtains the...

Страница 70: ...called Cy cleTime CycleTime TON TOFF The power level is given by the ratio TON CycleTime and is normally expressed in The CFW digital input INDIG1 automatically adapts to the cycle time from 0 03Hz t...

Страница 71: ...ect BaudRate value automatically detecting the master transmission frequency Autobaud Serial 1 Sequence Adapt the serial communication speed and parity of the CFW modules to the connected supervision...

Страница 72: ...tage in range 90 530Vac for model with work voltage range 480Vac 90 660Vac for model with work voltage range 600Vac 90 760Vac for model with work voltage range 690Vac Accuracy RMS voltage measurement...

Страница 73: ...115200 default 19 2Kbit s Node address Node address Settable with rotary switches Type RS485 isolation 1500V double connector RJ10 telephone type 4 4 PORT2 Fieldbus option Function Fieldbus serial com...

Страница 74: ...W 60 Nominal current 60Arms 40 C in continuous service Non repetitive overcurrent t 10ms 1500A I t for blowout 12000A s CFW 100 Nominal current 100Arms 40 C in continuous service Non repetitive overcu...

Страница 75: ...without peak current control Soft Start firing ramp specific for infrared lamps Timed shut off ramp Limitation of RMS current in load 0 90 Delay Triggering for firing inductive loads in ZC and BF mode...

Страница 76: ...2 O3 Yellow state of power control BT Yellow state key HB Protection IP20 Work storage temperature 0 50 C refer to dissipation curves 20 85 C Relative humidity 20 85 RH non condensing Ambient conditio...

Страница 77: ...uction angle 90 Function voltage measurement RMS on load Load voltage read Accuracy RMS voltage measurement on load 1 f s with VLOAD option measurement Otherwise the value is calculated from the value...

Страница 78: ...Alarm Function Function Configurable default alarms Relay Contact in exchange C NO NC 5A 250V 30Vdc cosf 1 COMMUNICATIONS PORTS 400 to 600A Models PORT CFW OP Function Serial comunication for KB ADL t...

Страница 79: ...ange 90 530 Vac 480V Models 90 660 Vac 600V Models 90 760Vac 690V Models Non repetitive voltage 1200 Vp 1600 Vp 600V Models 1600 Vp 690V Models Rated frequency 50 60Hz auto determination Critical Dv d...

Страница 80: ...one Expansion CFW2 2 single phase loads in ZC and BF trigger mode only 1 phase load closed delta controlled on two phases 1 phase load star without neutral controlled on two phases with one Master uni...

Страница 81: ...25 mm model 2PH or 3PH 410x355x260 mm 400 to 600A Models Model with Internal Fuse CFW1 CFW2 CFW3 Weight CFW 400 8kg 15 5kg 22 5kg CFW 500 600A 11kg 21kg 31kg Packaging Dimensions CFW1 420 x 480 x 250...

Страница 82: ...0 None 1 Current limit 2 Current limit and feedback V I P 3 Current limit and feedback V I P V Load input 4 Current limit and feedback V I P Vload input CT external inputs2 Code Auxiliary Output 0 No...

Страница 83: ...http www chromalox com en resources and support software Fuses Extra Rapid EXTRARAPID FUSES Model Size I2 t Code Format Part Number Power Dissipated In CFW 40 80A 2500A2 S FUS 080S 0024 07826 5 W CFW...

Страница 84: ...the Chromalox limited warranty applicable to this product at http www chromalox com customer service policies termsofsale aspx 2016 Chromalox Inc Chromalox Inc 1347 Heil Quaker Boulevard Lavergne TN 3...

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