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CD3000M-2PH Thyristor Unit

1. Make link on reset terminals see wiring diagram Substitute the fuse Check the load Check the wiring Substitute the faulty thyristor Check the load wiring Substitute the thyristor Make HB calibration procedure Control current transformers wiring Make HB calibration procedure Control input signal setting Repeat input calibration procedure Verify the auxiliary voltage Supply CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 15 2 Fans The thyristor unit with forced ventilation uses fans that rotate permanently when the unit is supplied In case of fan failure the heat sink can be reach high temperature In this case to give protection to thyristor there is a thermal switch properly setted The function of this switch is to open the input signal until the heat sink temperature 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 this reason is important to control periodically the fans status checking that are rotating 15 3 Maintenance For maintain a correct cooling the consumer must clean the heat sink and the protective grate of the fans The 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 e E
2. Only with Input from RS485 Bit 3 1 gt Reset HB Alarm When unit is switch off all command parameter are set to 0 Input command signal R This parameter reads the Input command signal see par 7 4 When the P004 Biti 1 This parameter could be written and become the Input Command from RS485 O 255 O FF Hex Input 4mA gt POO5S O 0 Input 12mA gt P005 128 50 Input 20mA gt P005 255 100 Power adjust R W Its a scaling factor of the Input command signal O 255 O FF Hex from O 0 of Output To 255 100 of Output This parameter limit the Output Power OUT Power Adjust 100 100 fete poros oo o pro so eric ff Power Adjust 80 CO eee eres are AS de am ao ee ae Sia SS dee 20 JY qe E 39 CD Automation srl P121 H79 Function Value P122 H7A Function P123 H7B Function Min Max Value Note P124L H7C Function Min Max Value Default P124H H7C Function Min Max Value Default Note P125L H7D Function Value Default P125H H7D Function Min Max Value Default Note P126L H7E Function Min Max Value Default CD3000M 2PH from 125A to 700A User s Manual CD Unit ID R This parameter Identify the CD type Family CD01 Hex CD1000 CD3000M Family CD Ver R This parameter is for internal use Password R W This parameter give the access to configuration O FFFF Hex 9357 Hex Writing para
3. A RS485 B nc Riserved Txd0 Pin Riserved Rxd0 _ 6 _ 3 9 33 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 11 8 Address configuration The thyristor unit is assigned a unique device address by the user in the range 1 default to 255 This address is used to recognise the messages queries to her assigned The thyristor unit does not respond at the messages queries that don t have the same assigned address The thyristor unit will also accept global messages Broadcast sends 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 La T ENRRNNAN Convert the Address Number in Binary for Example 150 Dec 10010110 Bin The dip switch number corresponds to the bit number Address Number Number se ERRE al For convert the Number in Binary you can use this method Dip Switch Number have this value oa E Es The Address Number Ex 150 128 Dip 8 16 Dip 5 4 Dip 3 2 Dip2 34 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 12 MODBUS communication The serial communication port of the thyristor unit is two wire RS485 type This port use an half duplex system When a Unit must transmit active the transmission line and when there are not units in transmission the outputs are fixed to high impedance The serial communication port allows
4. CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 11 4 Digital Input CD3000M thyristor unit has two digital inputs 11 4 1 Configurable Input Terminals 15 and 16 see par 7 4 This digital input is configurable and can be External Calibration Standard The Calibration input activates the Calibration procedure that is necessary if you use the Heater break alarm see par 9 3 Supply with 24Vdc terminals 15 16 to start the Heater Break procedure External Enable Without Enable the out is always to zero and red led SC flashing otherwise the out will follow the input signal to configure the input type set the jumper as below represented Warning this procedure can be done just by specialized personnel Size S09 and S10 Size S14 p Tre o Ki at 0000 0000 0000 O CD 3x000 SIL O1 l l l l 1 l IO l els l elo cio G16 cio elo CIO e EEEE SEE cds as ocaso cas ossos If vou use the input like External Enable is not possible use the input for the q Heater Break procedure 30 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 11 4 2 Reset Terminals 7 and 8 see par 7 4 The Reset Alarm is used for restore the unit after an alarm occurs see par 9 2 Open link to terminals 7 8 to stop the CD3000M thyristor unit and reset the alarm 11 5 Digital Output CD3000M thyristor unit with HB option has 1 digital output with relay cont
5. SSR from controller 10 2 Burst Firing BF The Burst Firing is a burst of consecutive cycles the consecutive cycles ON are selectable between 2 and 255 with input signal equal at 50 Burst Firing is a method zero crossing that it reduces the electromagnetic interferences because the thyristor switches at zero voltage crossing The example show the Burst Firing with Burst cycles P126L 4 EON OFF VOLTAGE SUPPLY V LOAD VOLTAGE V Saba A AAAAA A A A A VU VV VV VU eee V A A A A A A A A ARA ARA AA AA ARA 100 25 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 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 CD3x00 Board 26 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 11 2 Supply the Electronic Board The CD3000M thyristor unit to work requires a voltage supply for the electronic boards The Max consumption is 10VA The voltage supply for the electronic boards is configured in line with customer requirements that are defined in the Order Code The Order Code is written on the identification label Warning Before connecting or disconnecting the unit check that power and control cables are isolated from voltage sources To cha
6. of cycles Burst R W This parameter defines the number of voltage cycles in ON condition at 50 of power demand 1 255 O FF Hex Each step is 1 cycle 8 if not specified in the Order Code 40 CD Automation srl User s Manual CD3000M 2PH from 125A to 700A P126H H7E Function Min Max Value Default Note P127L H7F Function Min Max Value Default P127H H7F Function Min Max Value Default Example P128L H80 Function Min Max Value Note Byte Hi HB Delay time R W This parameter set a delay to have HB alarm active O 255 O FF Hex Each step is 50msec 3 If Soft start option is enabled HB Delay time must be greater than Soft start time P126H x 50msec gt P125H x 10msec When Zero Crossing firing is used must be less than Cycle time P126H x 50msec lt P127H x 50msec Byte Lo Max power for SSR Input R W When SSR input is used it represent the value of the power when is in ON status O 255 O FF Hex from O 0 of Output to 255 100 of Output 255 Byte Hi Cycle time R W The Cycle Time is the time which the Thyristor modulates to obtain the power demand O 255 O FF Hex Each step is 50msec 60 3C Hex Zero Crossing 240 FO Hex Burst Firing With a Cycle time at 4 sec 25 gt 1sec On 3sec off 50 gt 2sec On 2sec off 75 gt 3sec On 1sec off Cycle Time Time Byte Lo Number of half period DT firing R W This parameter de
7. 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 the number of following Bytes fixed to 2 02 Hex two Byte for the CRC Address Address of the N of the N of oe ee Unit First Parameter Parameter Byte write 16 O lwe M to EEE EIS The answer is an echo of the first two Byte address and function two Byte for first written parameter two Byte with the N of parameters fixed to 1 0001 Hex two Byte for the CRC Address Address of the First N of the Unit Parameter Parameter 16 ow fi o AS 37 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 12 5 Error and exception responses If a message contains an altered character if fails the CRC or if the received message contains a syntax error for example the number of the byte or of the words is not correct then the unit will ignore the message If the received message is correct but contains a not valid value the unit will send an answer of exception 5 byte 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 esa mm o am NOTE If you write a parameter s value equal at his actual value th
8. to 700A User s Manual 2 4 Software Configurator BE Conllpur ator fe Genie amg ap Simpie TestUnkt On line Manuais Std Configurations Ir CD3000M CD1000 EN Selection Load Wiring D esto al eal Mio a O Dette E vines O Star 3 Wires O Star 4 Wires E Ld EN E 1 E 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 CD3000M 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 CD3000M 2PH from 125A to 700A User s Manual 3 Quick Start Caution this procedure must be performed only by qualified persons If t
9. CON 11 Connection description ssuccssccccssssssseseseseseseseseeeeaooa 11 1 Access to the Electronic boards 11 2 Supply the Electronic Board 11 3 Analog Inputs 11 4 Digital Input 11 5 Digital Output 11 6 PG Connector 11 7 RS485 Serial Port 11 8 Address configuration 12 MODBUS communication ssececencneeecneeenenneueusneeueueneneeuenens 12 1 MODBUS RTU Protocol 12 2 Message Format 12 3 Read Holding Registers 12 4 Preset Multiple Registers 12 5 Error and exception responses 13 Configuration ParameterS sssss2s222 2 222 2 2 14 Internal FUSE sense csccssccc cc aa aa aa RAR aii dei Ria ia de dd 14 1 Fuse Code 15 Maintenance ycccsmecccscctecccccsoccccctcsccadecsescescecscacsvarevaceeusecacers 15 1 Trouble Shooting 15 2 Fans 15 3 Maintenance 15 4 Repairing procedure 15 5 Warranty condition FO NOLO RAE CRARO RAEE DA DUE RRA CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 1 Important 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 gt PPR PEP PS The Thyristor unit are integral part of industrial equipments When it is supply the Thyristor unit is subject to dangerous tension
10. S09 200A S10 275A 700A S14 O meo 6 mo a E E A o neo 0 us 6 15 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 7 Wiring instructions Caution this procedure must be performed only by qualified persons The Thyristor unit could be susceptible to interferences lost by near equipments or by the power supply for this reason in accord to the fundamental practices rules is opportune take some precautions The electronic circuit of the Thyristor unit 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 electrical installation should be rigidly observed For safety connect the heat sink to the earth with his terminal 7 1 Removing the cover Instructions for open the thyristor unit size S09 amp S10 16 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 7 2 Wiring details Use copper cables and wires rated for use at 75 C only 7 2 1 Power cable torque suggested Connector Torque tll Wire Type Lb in N m ag ee Terminal 125A 150A Terminal Block 265 30 0 1 Copper wire 200A M8 3 0 Compact Solid Stranded Bus Bar 2x1 0 UL Li
11. USER S MANUAL cD3000 M 2PH Rev 01 2007 THYRISTOR UNIT from 125A to 700A CD Automation S r l UTOMA Aar Via Picasso 34 36 20025 Legnano MI ITALY AUTOMATION Tel 39 0331 577479 Fax 39 0331 579479 E Mail info cdautomation com WEB www cdautomation com Il SUMMARY 1 Important warnings for Safety sssss2s 2 5 2 25 252202 20 055 2 Introductio oia ees iicelcasiewceccsiicelieelcaasswanacancsesaseasweeenameenuceeees 2 1 Advantages compared with analog thyristor unit 2 2 CD KP 2 3 CD EASY 2 4 Software Configurator 3 QUICK STANE ass as nisi doa doa RAD A AS AE RARE RAER 4 CDI3000M SIZING nssr AN a da 5 Identification and Order COdeC sceseccccncncnccncuscccueueueueuueueuenueueuenenuauens 5 1 Identification of the unit 5 2 Order Code 6 InstallatiO MA A aaia 6 1 Environmental installation conditions 6 2 Dimensions and Weight 6 3 Fixing holes 7 Wirmo INStruUcUONS oirionn aA 7 1 Removing the cover 7 2 Wiring details 7 3 Power Terminals 7 4 Command Terminals 7 5 Diagram of control connection S POW er output feat r sS sisirin aa dada Ada aa aaia 8 1 Derating curve 8 2 Cooling fans 9 Led status and Alarms saasnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 9 1 LED Status Table 9 2 Not Critical Alarm 9 3 Calibration Procedure LO Firing CY DO nadie AAR N ada io Ar dd dadas 10 1 Zero Crossing ZC 10 2 Burst Firing BF W CO
12. act Max 500mA 125Vac that gives indications of the alarms state the contacts can be NO and NC 11 5 1 HB alarm contact Only with HB Option see par 9 2 The contact at terminals 19 20 is normally open NO e In normal conditions without alarm and with auxiliary power supply the contact to the terminals has opened relay coil energized e In alarm condition or without auxiliary power supply the contact to the terminals is closed relay coil not energized Also you can use the NC closed without alarm contact at terminals 18 19 31 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 11 6 PG Connector The PG Connector is used to configure the thyristor unit with the configuration software and with the programming cable The programming cable is not included Size S09 and S10 Size S14 OOOO 0000 0000 O 7 q q l A l l l l l l I i l l 1 O16 O10 O10 GIO GIO 019 O18 CIO E London Connettore PG 32 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 11 7 RS485 Serial Port CD3000M have a serial communication port RS485 On this port may be done a network up to 255 unit Size S09 and S10 Size S14 CD 3x000 SIL 01 l l l l l l 6 l l G16 ele ele olf eie oie ele e ae oe E A oer ae ae Lerner a Seer r z B RS485B RS485 A Description PMS5 5V GND OV GND OV GND OV RS485
13. enomisorrmem O e ones O EN ES SCR OK SC SCR short circuit No External Enable see par 11 4 HB o Load Fault O o 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 current in absence of the input signal This is possible if there are a short circuit on the thyristor or if there are a wrong wiring of the load When the problem is solved is necessary use the digital input Reset Terminals 7 8 23 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 9 2 2 Heater Break alarm HB only with the HB option This alarm is active when the load current decrease under the threshold set on the parameter P124H see par 13 The Heater Break alarm could be active also if there are a wrong wiring of the load When the problem is solved is necessary use the digital input Reset Terminals 7 8 H B circuit read load current via a current transformer internal to the unit Minimum current is 10 of the current transformer size s The current transformer size s depending to the thyristor unit size Caution In the first start and each time that the load is replaced it s necessary make the Calibration procedure 9 3 Calibration Procedure The Calibration procedu
14. ere there is a dangerous tension Before working make sure that e 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 CD3000M 2PH from 125A to 700A User s Manual N A N AN 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 e 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 Compatibilit lectromagn tique Compatibilit 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 ind
15. exclusive logical sum XOR are executed for setting the result in CR Added lto J Eight times of calculation is completed Added to I alculation of all charactersis completed gt All characters numbers Es C Language CRC 16 Example static short CRC16 unsigned char p_first unsigned char p_last unsigned int crc Oxffff short j for p_first lt p_last p_first crc p first for j 8 gt 0 if crc amp 0x0001 crc cre gt gt 1 crc 0xAO01 gt else crc crc gt gt 1 gt gt return crc 36 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 12 3 Read Holding Registers This function reads the instantaneous value of a specified number of parameters from an address The message is composed by 8 Byte one Byte is for the address one for the function 03 Hex two Byte for the first parameter to read two Byte for the total number of parameters to read and finally two Byte for the CRC Address Address of the First NiO ofthe Parameter Unit Parameter ee ao io mo The answer is an echo of the first two Byte address and function one byte with the number of following byte to exclusion of the CRC the demanded values and finally two Byte for the CRC Address 5 First Parameter Last parameter N of Byte Unit Value value 3 Oo Jae mio fimo from 12 4 Preset Multiple Registers This function could write only a
16. fines the number of half period in delay of firing 1 255 O FF Hex Each step is 1 half period Must be setted at 1 41 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 14 Internal Fuse The CD3000M thyristor unit have internal fuse extrarapid at low I2t for the thyristor protection of against the short circuits The fuse must have I2t lower than the thyristor one I2t max Caution USE ONLY EXTRARAPID FUSE WITH APPROPRIATE I2T AN 14 1 Fuse Code 200 kARMS Symmetrical A I C A RMS A2sec FUURB250 O oF lt 125A S09 150A S09 200A S10 275A S14 400A S14 450A S14 500A S14 600A S14 700A S14 FUZOOFEE FUSSOFMM 2XFU315FMM 2XFU315FMM Oe T 125A S09 FU200FEE o o 2 150A S09 FUURB250 o o 2 200A S10 FUURB3I5 o o 2 275A S14 FUURB3I5 so 3 400A S14 FUSSOFMM so 3 4500 S14 2xFUSISEMM so 3 500A S14 2xFUSISFMM O so 3 00a S14 2xFU4SOFMM so 3 700A S14 2xFU4SOFMM so 3 Caution The Fuses must have I2t 20 less than thyristor s T2t 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 user installation must be protected by electromagnetic circuit breaker or by fuse isolator e UL us C q LISTED gt gt gt gt 42 CD Automation srl CD3000M 2PH from 125A to 700A Use
17. he Order Code of the Thyristor unit is in line with what you really need then CD3000M has been already configured in Factory and you just need to do the following steps 1 Verify the CD3000M Sizing Making sure that e The load current is equal or less than the MAX current of CD3000M e The load voltage is equal or less than the MAX voltage of CD3000M see par 4 Verify the Order Code see par 5 2 Verify the Installation see par 6 Verify the Diagram of control connection e All auxiliary connections must be done in line with wirings on this manual e Verify that there isn t a short circuit on the load e Verify that the Reset Contact on terminal 7 and 8 are closed e With External Enable option give Enable to the unit see par 7 5 Supply the Electronic boards see Order Code Supply the Fan at 230VAC 15 50 60Hz 110VAC 15 50 60Hz Optional see par 8 2 Supply the Power unit see par 7 3 If you have HB option make the Calibration procedure see par 9 3 The CD3000M Thyristor unit is ready to start 4 CD3000M Sizing 4 1 1 Star wiring with resistive load P I 1 3V V Nominal voltage phase to phase I Nominal current of the load P Nominal power of the load 4 1 2 Delta wiring with resistive load P I 1 3V V Nominal voltage phase to phase I Nominal current of the load P Nominal power of the load 10 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 5 Iden
18. is is a valid transaction and don t cause an error 38 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 13 Configuration Parameters The Configuration Parameters are accessible from the software configurator or through the serial communication port RS485 P001 HO1 Function Min Max Value Example P002 HO2 Function Min Max Value P003 HO3 Function Value P004 H04 Function Value Note P005 HO5 Function Min Max Example P006 HOG Function Min Max Value Note Load Current R This parameter shows the Current rms value O 255 O FF Hex Value depends of current transformer and from his size s With current transformer CT 150 0 05A the max value corresponds to the max value of the CT Read value 255 FF Hex gt Load Current 150A Set point HB R W This parameter is the Set point of current below which HB alarm occurs O 255 O FF Hex This value is the load current P001 minus value of parameter P124H Status Table R It s a tab in bit that represent the Status of thyristor unit Bit O 1 gt Short circuit on SCR Bit 1 1 gt Load Failure HB Alarm Bit 2 1 gt Output signal ON Bit 3 1 gt HB Calibration in progress Command Table R W It s a tab in bit for remote commands via RS485 Bit O 1 gt Activate HB Calibration procedure Bit 1 1 gt Input Command from RS485 see P005 Bit 2 1 gt Disable Output signal
19. mA 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 e Set Point Ramp UP Down e Scroll selection of Set point Power output f Current A Voltage i e Display indication for 4 Heater Break alarm y SCR short circuit e Password for configuration parameters e Plug in connector on front to use software configurator e Retransmission 4 20mA or 0 10Vdc of one of these parameters Power PV Current Voltage Dimension 48x96x92mm LxAxP e Comply with EMC CE marked By 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 THYRISTOR UNIT 1 CD THYRISTOR UNIT 2 OPERATE OPERATE READ MREAD PUSH PUSH BUTTON BUTTON 22D MOVE AND CLONE CD Automation srl CD3000M 2PH from 125A
20. meters activated any value Writing parameters disabled When the CD3000M comes out and then re lighted for change the parameters you must re insert the password Byte Lo Delay trigger Only for 1PH version R W This parameter is the delay of firing in first half period with respect zero voltage crossing O 50 O 32 Hex Each step is 0 l1msec 30 Byte Hi HB sensibility R W This parameter is the maximum reduction of Load Current to establish the HB Alarm O 100 0 64 Hex O 0 of Nominal Current 255 100 of Nominal Current 51 When you change this parameter HB Calibration procedure is necessary Byte Lo Firing type R W This parameter set the Firing Type O1 Hex Zero Crossing 02 Hex Single Cycle Only for 1PH version 03 Hex Burst Firing 13 Hex Burst Firing Soft Start Only for 1PH version 23 Hex Burst Firing Delay trigger Only for 1PH version 24 Hex Phase Angle Only for 1PH version 3 if not specified in the Order Code Byte Hi Soft start time Only for 1PH version R W The Unit starts in phase angle mode with a ramp starting from zero up to full voltage in a presetted and Adjustable time The time is setted by this parameter O 255 O FF Hex Each step is 5msec 4 Value of this parameter must be less than cycle time For burst firing this parameter must be less than 50Hz gt 20msec x Number of cycles P126L 60Hz gt 16 6msec x Number of cycles P126L Byte Lo Number
21. nge auxiliary supply voltage sold the correct link jumper on CD3x00 board The type of mounted transformer depends of the chosen Voltage in the order code See par 5 2 Size SO9 and S10 O OCOO 0000 0000 O CD 3x000 250 01 I I I I I IO CIO CIO G16 010 GINO oio oio ole DRE a EEEE RR UP E EEEN EEEN EESE EE Link Jumper J9 J11 Link Jumper J10 Link Jumper J9 J11 Link Jumper J10 J9 J9 a Ca o O J10 J10 O O Co Jii Jii C q O O Link Jumper J9 J11 Link Jumper J10 O r siv 0 Gomw 0 TR 605 300V If the Auxiliary Voltage written on the identification label is different from Supply Voltage to the load use an external transformer with primary equal to load voltage and secondary equal to the Auxiliary Voltage 27 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 11 3 Analog Inputs CD3000M thyristor unit have an analogue input to drive the output power 11 3 1 Input command signal configuration Terminals 9 and 10 see par 7 4 The Input command signal is already configured in line with customer requirements that 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 AN Warning this procedure can be done just by specialized personnel Size S09 and S10 Size S14 J7 LO O OOOO 0000 0000 O ABC m _ p
22. oe SIL O1 CD 3x000 l l l l 1 l IO l els l elo cio lO cio elo cio e beset ee ee Re I diics oc boca s 2 To configure the input type set the jumper as below represented Input features 7 316 J17 SSR ON gt 4Vdc Max 30Vdc OFF lt 1Vdc When operator finishes to configure the hardware setting he must do the input calibration procedure 28 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 11 3 2 Input calibration procedure Warning this procedure can be done just by specialized personnel This procedure is needed only if you change the input type Start TUNE Auxiliary power supply IN Mantain Key CAL pushed and give the power supply 4 4 Release key O ON when red and yellow 7 O sic led are ON E o Yellow and Red leds arde are flashing JOC H B SSR Co ANALOG Wait for more than 10 sec Within 1O sec from start from start flashing flashing yellow and red leds 7 yellow and red leds push again momentary CAL Key E E The leds will Yellow led only is E a 5 H B stop flashing flashing apply SEC He O input Signal i I E OV for 0 10V 0 Signal AMA for 4 20mA ey ee V SSR Input Now press CAL Key again ly is tuned 4 Red led only is o flashing apply O HB 1OV for 0 10V input or 20mA for 4 20mA input Now press CAL Key again Analog input is tuned End TUNE 29 100 Signal
23. on 12 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 6 Installation Caution Don t install near the hot elements or near the units that could give electromagnetic interferences The CD3000M Thyristor unit must be always mounted in vertical position to improve air cooling on heat sink Maintain the minimum distances in vertical and in horizontal as represented When more unit has mounted inside the cabinet maintain the air circulation like represented in figure Sometimes is necessary installing a fan to have better air circulation AIR 6 1 Environmental installation conditions 0 45 C at nominal current Over 45 C use the Ambient temperature derating curve see par 8 1 Storage temperature 25 C to 70 C Don t install at direct sun light where there are Installation place conductive dust corrosive gas vibration or water and also in salty environmental Up to 1000 meter over sea level For higher Altitude altitude reduce the nominal current of 2 for each 100m over 1000m Humidity From 5 to 95 without condense and ice 13 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 6 2 Dimensions and Weight CD3000M 2PH CD3000M 2PH CD3000M 2PH 125A 150A S09 200A S10 275A 700A S14 sm mom mom com vomito 14 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 6 3 Fixing holes CD3000M 2PH CD3000M 2PH CD3000M 2PH 125A 150A
24. ons of the message in this case the receiver ignore the message The CRC is calculated in accordance with a formula that imply a recursive division of the data by a polynomial The polynomial divisor is 21 21 2 1 Hex 18005 but is modified in two ways e Since the bits order are reversed then the binary pattern is also reversed and the most significant bit MSB is the right most bit e Since interest only the remainder the right most bit could be discarded Therefore the polynomial divisor has value Hex A001 Normal bit order Mostsignificantbit Leastsignificant bit Reversed bit order Least significant bit Mostsignificant bit O N B With the reversed bit order also the CRC16 returns the with the reversed bit order 35 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual The following flow diagram show how to organize the CRC 16 bit CR CRC error check data 1 word Digits of calculation characters a E START in command message J Check on the member of times ot CR calewaton Setting FFFF Hex To CR Setting l tol Exclusive logical Sum XOR is executed on one character 1 byte at charactor of CR and designated message and results are set to CR Setting 1 to J Bit at right and of CR is 1 _ ICR is shifted by bit to right After shifting CR by 1 bit to night AOO1 Hex and
25. r s Manual 15 Maintenance 15 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 Indication on Thyristor unit doesn t go in conduction with input signal Load current flows also with no input signal Current flows at nominal value but Yellow LED HB is light on Current flows at nominal value but Red LED SC is light on Thyristor unit doesn t work properly Green LED Aux always light off Green LED Aux light on Green LED ON light off Green LED Aux light on Green LED ON light on Green LED ON always light off Yellow LED HB light on Red LED SC light on No voltage auxiliary power No input signal Reversed polarities of input signal Reset contact is open Fuse failure Load failure Load connection interruption Thyristor faulty and always in open circuit With HB option the yellow led HB is light on Wrong wiring Short circuit on thyristor If there is HB option the red LED SC is light on HB circuit not tuned Current transformers not properly wired HB circuit not tuned Wrong input signal selection Wrong input signal calibration out of range Auxiliary voltage supply out of limits 43 Give auxiliary voltage supply see wiring diagram Provide to give input signal Reverse the input signal polarity
26. re is an automatic procedure that save in memory the value of load current This procedure is necessary if you use the Heater Break Alarm To make the Calibration procedure follow these steps 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 procedure is active The CD3000M gives the maximum voltage output After a minute the values of voltage and current are stored in memory the CD3000M comes back to the initial situation The Calibration procedure is done 24 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 10 Firing type Choose an correct firing type allows to optimize the thyristor unit for the installed load The firing type has already configured in line with customer requirements that are defined in the Order Code The Order Code is written on the identification label However if you wish to change the firing type you can use the software configurator or the parameter on serial link see par 13 Caution this procedure must be performed only by qualified persons 10 1 Zero Crossing ZC ZC firing mode is used with Logic Output from temperature controllers and the Thyristor operates like a contactor The Cycle time is performed by temperature controller ZC minimizes interferences because the Thyristor unit switches ON OFF at zero voltage VOLTAGE SUPPLY V LOAD VOLTAGE V
27. s 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 e The Thyristor unit must be mounted in vertical position and without obstruction above and below to allow a good flow ventilation e 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 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 lectrique 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 wh
28. sted ZMVV with M8 screw TOR o Copper Tube Crimp Lug Bus Bar 505 57 0 2x3 0 UL Listed ZMVV with M10 screw 600 Copper Tube Crimp Lug 17 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 7 2 2 Power cable dimensions suggested 18 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 7 3 Power Terminals Warning Before connecting or disconnecting the unit check that power and control cables are isolated from voltage sources CD3000M 2PH CD3000M 2PH CD3000M 2PH 125A 150A S09 200A S10 275A 700A S14 19 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 7 4 Command Terminals Warning Before connecting or disconnecting the unit check that power and control cables are isolated from voltage sources 6 Fan supply voltage see par 8 2 8 REST O 9 input command signal SSR 0 10V 4 20MA POT Terminal Output command for Slave unit Common HB relay contact Max 500mA 125Vac Optional HB relay contact NO Max 500mA 125Vac Optional see par 11 5 20 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 7 5 Diagram of control connection Caution this procedure must be performed only by qualified persons AT TO LOAD L1 L2 L3 Uno Uno Fan Power y Supply a O e O 0 10Vdc 4 20mA POT 10K 8Vdc CDSO00M Digital Input 24Vdc NC a le Contact NOTE x1 The user installation mus
29. t be protecting by electromagnetic circuit breaker or by fuse isolator e 2 The auxiliary voltage supply of the CD3000M 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 e 3 only for size S14 e To work the Reset Contact on terminal 7 and 8 must be closed Load Type 21 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 8 Power output features Voltage Repetitive peak Latching Max peak Leakage I2T value Frequency Isolation Power loss range reverse voltage current one cycle current max range Voltage 8 1 Derating curve K 1 0 8 0 6 0 4 0 2 45 55 65 5 85 oC 8 2 Cooling fans The CD3000M thyristor unit is equipped with a cooling fans The supply voltage is standard 230VAC 15 50 60Hz or optional 110VAC 15 50 60HZ The fan s power consumption is below listed me Number of fans USTED Number of fans 125A 150A 200A One Fan 16W One Fan 16W 400A 500A 600A Two Fans 30W Four Fan 60W 275A 450A 700A Four Fan 60W Four Fan 60W 22 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 9 Led status and Alarms 9 1 LED Status Table In front of the thyristor unit there are LED that indicates the state of the Electronic cards 75 reaver i ores erin deed a imago ai tones nthe ERNE OK To orcom
30. tification and Order Code 5 1 Identification of the unit Caution Before to install make 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 ser No 12345 6 89 001 Date 01 2007 CE Mod CD3000M 2PHN1SOA 400V 480V1 70 265WSSRZOFANTIOWEM pr MUNIO NIU A T UNA o 11 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 5 2 Order Code e lt cp3000M 2PH EEE Max Current of CD3000M The Max Current must be equal or more than Load Current 2 Load Current Specify this value to configure the unit in CD Automation The Max Voltage must be equal or more than Load Voltage Auxiliary Voltage Voltage supply for the Electronic boards 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 Firing Type ZC Zero Crossing BF 1 Burst Firing 1 Specify the number of firing cycles at 50 of the input signal from 1 to 255 Internal fuses standard No fuses Heater Break Alarm External Keypad Fan voltage supply 110VAC 15 std 230VAC 15 50 60Hz UL Certificati
31. to communicate between the thyristor units and a MASTER device ex an computer or a terminal The cable must be rated for use to data transfer 12 1 MODBUS RTU Protocol The communication is based on the standard industrial MODBUS RTU with the following restrictions e The Baud rate is 9600 Baud e The Preset Multiple Registers Funct 16 is limited to the writing of a single parameter for message The following MODBUS functions are supported Function Description __ _ _ Read Holding Registers Preset Multiple Registers The unit support the Broadcast messages It possible send a Broadcast messages using the address O all the units respond at the message without sending back any reply 12 2 Message Format The transmission format is a 1 bit start 8 date bit and 1 bit stop with no parity verification Each message terminate 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 O 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 unit send an answer with the same structure but with the information demanded Each message is followed by CRC Cyclic Redundancy Check with two byte The CRC identify the incongruity situati
32. ts 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 Li Thyristor a Load 2 1 Advantages compared with analog thyristor unit Communication RS485 is a standard feature of CD3000M 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 THYRISTOR UNIT INSIDE CABINET CD KP ON FRONT DOOR Pc FOR CONFIGURATION 7 a So ts CD Automation srl CD3000M 2PH from 125A to 700A 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 20
33. uctive 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 e UL us LISTED CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 2 Introduction 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 uni
34. xplain 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 your distributor e Write a fault description and give the name of your personnel to which refers e Use a rugged packaging to ship the unit 15 5 Warranty condition CD Automation gives a 12 months warranty to its products The warranty is limited to repairing and parts substitution in our factory and does exclude products not properly used and fuses Warranty does not include products with serial numbers deleted The faulty product should be shipped to CD Automation at customer s cost and our Service will evaluate if product is under warranty terms Substituted parts remain of CD Automation property 44 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual 16 Note 45 CD Automation srl CD3000M 2PH from 125A to 700A User s Manual ENG CD3000M 2PH_125 700A 09 DOC 46

CD3000M-2PH Thyristor Unit

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