Honeywell HCL-1PH Bedienungsanleitung

Honeywell Process Solutions

HCL-1PH

Thyristor Unit

from 60A to 210A

USER’S MANUAL

55-77-25-23

Rev. 1

October 2012

HCL-1PH User’s Manual

Table of Contents

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

2 Note ............................................................................................................................ 6

3 Introduction ................................................................................................................ 7

4 Advantages compared with analog thyristor unit ......................................................... 7

5 Software Configurator.................................................................................................. 8

6 Quick Start................................................................................................................... 9

7 Basic Connections and sizing ..................................................................................... 10

8 Identification and Order Code.................................................................................... 11

8.1 Identification of the unit 11

8.2 Order Code 12

9 Technical Specifications............................................................................................. 13

9.1 General features: 13

9.2 Input features: 13

9.3 Output features(power device): 13

9.4 Fan Specification (only from 120 to 210A) 13

10 Installation.............................................................................................................. 15

10.1 Environmental installation conditions 15

10.2 Derating Curve 15

11 Dimensions and Weight ........................................................................................... 16

11.1 Fixing holes 16

12 Wiring instructions .................................................................................................. 17

12.1 Power cable torque (suggested) 17

12.2 Cable dimensions of the Command Terminals 17

12.3 Cable dimensions of the Earth (suggested) 17

12.4 Terminals positions 17

12.5 Power Terminals 18

12.6 Command Terminals 18

12.6.1 TERMINAL BLOCK M1.........................................................................................................................18

12.6.2 TERMINAL BLOCK M2.........................................................................................................................18

12.6.3 TERMINAL BLOCK M3 (ONLY FROM 120 TO 210A) ......................................................................................18

12.7 Schematic 19

12.8 Connection Diagram for Single-phase 20

HCL-1PH User’s Manual

13 Control Panel ...........................................................................................................21

13.1 Scroll the parameters 22

13.2 Operator Menu oper 23

13.3 Setup Menu Set 26

13.4 Hardware Menu HArd 29

13.5 Control Panel Led 32

13.6 Displayed Alarms 32

14 Input output signal ..................................................................................................33

14.1 Digital Input 33

14.1.1 START/STOP (TERMINAL 3OF M1) ........................................................................................................33

14.1.2 CONFIGURABLE INPUT (TERMINAL 4OF M1) .............................................................................................33

14.2 Digital Output (terminal 9-10 of M1) 33

14.3 Analog Inputs (Terminals 5 and 8 of M1) 34

14.3.1 PRIMARY INPUT CONFIGURATION. ..........................................................................................................34

14.3.2 PRIMARY INPUT CALIBRATION PROCEDURE ................................................................................................34

15 Heater Break alarm and SCR short circuit (HB Option)..............................................35

15.1 Heater break Calibration procedure 35

15.2 HB alarm contact (digital output) 35

15.3 Relay Jumper configuration on JP3 35

16 Firing type................................................................................................................36

16.1 Phase Angle (PA PA) 36

16.2 Soft Start with Phase Angle (S+PA PASt) 36

16.3 Delay Triggering with Burst Firing (DT+BF bFdt) 37

17 Current Limit............................................................................................................39

17.1.1 CURRENT LIMIT SETTING ....................................................................................................................39

17.1.2 CURRENT LIMIT TUNING PROCEDURE.......................................................................................................39

18 Feed-back type.........................................................................................................40

19 RS485 Serial Port.....................................................................................................41

20 PG Connector ...........................................................................................................41

21 Internal Fuse ...........................................................................................................42

21.1 Fuses Replacement 42

22 Maintenance.............................................................................................................43

22.1 Trouble Shooting 43

22.2 Warranty condition 43

HCL-1PH User’s Manual

Dichiarazione di Conformità

Declaration of Conformity

The Manufacturer

Dichiara che il prodotto:

Declare that the product:

HCL, 1ph - 60 to 210A

FULFILS THE REQUIREMENTS OF THE STANDARD:

Electrical safety Standard EN60947-1 :2008

EN60947-4-3:2001

Generic Emission standard EN60947-4-3:2000

Generic Immunity standard EN60947-4-3:2000

The manufacturer declares that The products above mentioned they am conforming to the

directive

EMC 2004/108/CEE e alla direttiva Bassa Tensione (low Voltage) 2006/95/CEE

PRODUCT DESCRIPTION: Electric power control

SCOPE OF APPLICATION: Thermal control process

Issued on: 20/04/2010

Signed:

HCL-1PH 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 45°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.

HCL-1PH 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 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.

2Note

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.

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

advise.

HCL-1PH User’s Manual

3Introduction

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

4Advantages compared with analog thyristor unit

Communication RS485 is a standard feature of HCL 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 software configuration, you can have access to the configuration parameters.

To connect the Thyristor unit to the computer use the USB\TTL converter.

HCL-1PH User’s Manual

5Software Configurator

hyristor configurator software

is free and is possible download it from our site.

If the Order Code is in line with requirement, then

HCL 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.

Run the software configurator and set the serial

port of the PC with con baudrate =19200(default)

and the address of Thyristor unit (default=1).

To connect the unit at the PC, it's necessary use

the USB\TTL converter connected between the unit

and the USB port of the PC.

USB\TTL converter need a driver to work properly,

you can find it from our site.

Is available a full programmer kit composed by

•USB\TTL converter,

•Two cable

•Thyristor configurator software

•USB driver

With the CD-RS serial converter is possible

configure the Thyristor unit also through the

RS485 For this solution, the programming cable is

not necessary.

HCL-1PH User’s Manual

6Quick Start

Attention: this procedure must be carried out by skilled people only.

If your HCL code is in line with what you really need, then the main configuration is already done by

Producer and you just need to do the following steps:

1. Verify HCL ’s current sizing. Be sure that:

•the load current is equal or less than the nominal one of HCL-1PH

•the main voltage is equal or less than the nominal voltage of HCL-1PH

2. Verify the Installation

3. Verify the Wiring:

•all auxiliary connections must be done in line with wirings on this manual

•verify that there isn’t a short circuit on the load

4. Supply the auxiliary voltage of the unit

Set the parameters U_OP (Operative Voltage) and A_Lo (Nominal Current of the load) using the

frontal keypad or Thyristor configurator software.

Υ_οΠ Operative Voltage V R/W

Function: It’s necessary to specify the operative voltage

Min/Max: 24 ÷ 1000V

Default: 230

Note: With voltage up to 330V and over 600V, HCL needs hardware

modifications: specify this in phase of ordination.

Α_Λο Load nominal current A R/W

Function: It’s necessary to specify the load current value at nominal voltage.

This current and voltage value are necessary to be able to read the

power in engineering units

Min/Max: 1 ÷ 100.0 Ampere (for size up to 100A)

Default: Nominal HCL current value if load current has not been specified.

If your HCL code is NOT in line with what you really need, use the enclosed configurator

software tool to set-up the unit. Install the software on your PC, select HCL and click on test

unit changing what you need.

HCL-1PH User’s Manual

7Basic Connections and sizing

Single phase wiring with resistive load (with HCL-1PH)

V = Nominal voltage of the load

I = Nominal current of the load

P = Nominal power of the load

Single phase wiring with inductive load (with HC

-1PH)

cosVP

V = Nominal voltage phase to phase

I = Nominal current to the load

P = Nominal power to the load

Open Delta wiring with resistive load (with 3 X HC

-1PH)

V = Nominal voltage of the load

I = Nominal current of the load

P = Nominal power of the load

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