CD Automation CD3200 Bedienungsanleitung

CD Automation 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

SUMMARY

1 Important warnings for safety..................................................................................... 5

2 Introduction ................................................................................................................ 7

2.1 Advantages compared with analog thyristor unit 7

2.2 CD-KP 8

2.3 CD-EASY 8

2.4 Software Configurator 9

3 Quick Start ................................................................................................................ 10

4 CD3200 Sizing ........................................................................................................... 10

5 Identification and Order Code.................................................................................... 11

5.1 Identification of the unit 11

5.2 Order Code 12

6 Installation ................................................................................................................ 13

6.1 Environmental installation conditions 13

6.2 Dimensions and Weight 14

6.3 CT dimensions 14

6.4 Fixing holes 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

9.1 LED Status Table 23

9.2 Not Critical Alarm 23

9.3 Calibration Procedure 24

10 Firing type ............................................................................................................... 24

10.1 Phase Angle (PA) 25

10.2 Soft Start with Phase Angle (S+PA) 25

10.3 Action of the Limit Current 26

10.4 Feed-back type 27

11 Connection description ............................................................................................ 28

11.1 Access to the Electronic boards 28

11.2 Supply the Electronic Board 29

11.3 Analog Inputs 30

11.4 Digital Input 32

11.5 Digital Output 34

11.6 PG Connector 35

11.7 RS485 Serial Port 35

11.8 Address configuration 36

12 MODBUS communication ......................................................................................... 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

15.4 Repairing procedure 48

15.5 Warranty condition 48

16 Note ........................................................................................................................ 49

CD Automation srl CD3200-1PH from 15A to 110A User’s Manual

1Important warnings for safety

This chapter contains important information for the safety. The not observance of these instructions may

result in serious personal injury or death and can cause serious damages to the Thyristor unit and to the

components system included.

The installation should be performed by qualified persons.

The Thyristor unit are integral part of industrial equipments. When it is supply, the

Thyristor unit is subject to dangerous tensions.

•Don't remove the protection Cover.

•Don't use these unit in aerospace applications and/ or nuclear.

The nominal current corresponds to use at temperature not superior to 40°C.

•The Thyristor unit must be mounted in vertical position and without obstruction above

and below to allow a good flow ventilation.

•The hot air of one thyristor unit must not invest the unit positioned above.

•For side by side placed leave a space of 15mm between the unit.

A suitable device must ensure that the unit can be electrically isolated from the supply, this

allows 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

efficiency should be inspected.

Electronic supply (Alimentation électronique, Alimentazione elettronica)

The electronic circuit of the Thyristor unit must be supplied by dedicated voltage for all

electronic circuits and not in parallel with coil contactors, solenoids and other.

It's recommended to use a shielded transformer.

Electric Shock Hazard (Risque de choque électrique, Rischi di scosse elettriche)

When the Thyristor unit is energized, after the power supply is shut off, wait least a minute

for allow the discharge of the internal capacitors where there is a dangerous tension. Before

working, make sure that:

•Only authorized personnel must perform maintenance, inspection, and replacement

operations.

•The authorized personnel must read this manual before to have access to the unit.

•Unqualified People don't perform jobs on the same unit or in the immediate vicinities.

CD Automation srl CD3200-1PH from 15A to 110A User’s Manual

Important warnings (Attention, Avvertenze importanti)

During the operations with units under tension, local regulations regarding electrical

installation should be rigidly observed:

•Respect the internal safety rules.

•Don't bend components to maintain insulation distances.

•Protect the units from high temperature humidity and vibrations.

•Don't touch components to prevent electrostatic discharges on them.

•Verify that the size is in line with real needs.

•To measure voltage current etc. on unit, remove rings and other jewels from fingers

and hands.

•Authorized personnel that work on thyristor unit under power supply voltage must be

on insulated board

This listing does not represent a complete enumeration of all necessary safety cautions.

Electromagnetic compatibility

(Compatibilità électromagnétique, Compatibilità elettromagnetica)

Our thyristor units have an excellent immunity to electromagnetic interferences if all

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 EMC norms, CE mark.

In most installations, near by electronic systems will experience no difficulty with

interference. If very sensitive electronic measuring equipment or low-frequency radio

receivers are to be used near the unit, some special precautions may be required. These

may include the installation of a line supply filter and the use of screened (shielded) output

cable to the load.

Note

Warning: This icon is present in all the operational procedures where the Improper

operation may result in serious personal injury or death

Caution: This icon is present in all the operational procedures where the Improper

operation can cause damage for the Thyristor unit.

CD Automation reserves the right to modify the own products and this manual without any

advise.

CUS

LISTED

CD Automation srl CD3200-1PH from 15A to 110A User’s Manual

2Introduction

A thyristor unit is semiconductor device which acts as a switch formed by two thyristors in ant parallel.

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 signal.

The benefits of thyristor units compared with elettromechanical contactors are numerouses: no moving

parts, no maintenance and capacity to switch very fast. Thyristors are the only solution to control

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 flexibility and the possibility of implement special

characteristics without change the hardware. Several strategies can be implemented and selected

through the configuration parameters.

With CD-KP, you can have access to the configuration parameters without expose at the dangerous

voltage inside the cabinet and without stop the plant.

CD Automation srl CD3200-1PH from 15A to 110A User’s Manual

2.2 CD-KP

The CD-KP is designed to be connected with all CD Automation's Thyristor units via RS485

communication. On front unit is possible to read the principal operational parameters of the unit like:

power, tension, current, reference, alarms, etc.

One of these variables can be selected and retransmitted via an isolated output (4÷20mA or 0÷10V)

All the menus (except the operator menu) can be protected by password to avoid accidental change of

configuration parameters by unauthorised personnel.

On front unit is also available a plug-in connector RS485 for connect a PC with the Thyristor units

without open the cabinet and 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, Voltage.

•Dimension 48x96x92mm (LxAxP)

•Comply with EMC, CE marked

2.3 CD-EASY

CD-EASY is a Memory of support used for maintenance people that is not confident in personal

computer.

With the CD-EASY is possible memorize the configuration of one Thyristor Unit and paste it into another

in few seconds.

CD-EASY could be loaded with the personal configuration of the unit and stored together with the

system drawings in a convenient place, enabling unit reconfiguration within seconds if require.

CD Automation srl CD3200-1PH from 15A to 110A User’s Manual

2.4 Software Configurator

The software configuration is free and is possible

download it from our site:

www.cdautomation.com

If the Order Code is in line with requirement, then

CD3200 has been already configured in Factory

and it's ready to use.

You need the software only to modify the ordered

configuration. Anyway we suggest to check the

unit on the 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 the

RS485 (see par. 11.7).

For this solution, the programming cable is not

necessary.

Run the software configurator and set the serial

port of the PC with con baudrate =9600 and the

address of Thyristor unit (default=1).

CD Automation srl CD3200-1PH from 15A to 110A User’s Manual

3Quick Start

Caution: this procedure must be performed only by qualified persons.

If the Order Code of the Thyristor unit is in line with what you really need, then CD3200 has been

already configured in Factory and you just need to do the following steps:

1. Verify the CD3200 Sizing. Making sure that:

•The load current is equal or less than the MAX current of CD3200.

•The load voltage is equal or less than the MAX voltage of CD3200.

(see par. 4)

2. Verify the Order Code

(see par. 5.2)

3. Verify the Installation

(see par. 6)

4. Verify the Diagram of control 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. Supply the Power unit

(see par. 7.3)

8. Make the Calibration procedure

(see par. 9.3)

The CD3200 Thyristor unit is ready to start.

4CD3200 Sizing

4.1.1 Wiring with resistive load

V = Nominal voltage phase to phase

I = Nominal current to the load

P = Nominal power to the load

4.1.2 Wiring with inductive load

cosV

V = Nominal voltage phase to phase

I = Nominal current to the load

P = Nominal power to the load

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