CD Automation CD3000E 3PH User Manual

USER’S MANUAL

Rev. 01/2012

00002

CD3000

E

-3PH

Thyristor Unit

With PROFIBUS-DP from 25A to 600A

CD Automation S.r.l.

Via Picasso 34/36 - 20025 – Legnano (MI) – ITALY

Tel +39 0331 577479 – Fax +39 0331 579479

E-Mail: [email protected]

- WEB: www.cdautomation.com

SUMMARY

1 Important warnings for safety ..................................................................................... 4

2 Introduction ................................................................................................................ 6

2.1 Advantages compared with analog thyristor unit

2.2 CD-KP

2.3 CD-EASY

2.4 Software Configurator

6

7

7

8

3 Quick Start .................................................................................................................. 9

4 CD3000E Sizing ......................................................................................................... 10

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

5.1 Identification of the unit

5.2 Order Code

11

12

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

6.1 Environmental installation conditions

6.2 Dimensions and Fixing holes

6.3 Removing the cover

13

14

15

7 Wiring instructions .................................................................................................... 16

7.1 Wiring details

7.2 Power Terminals

7.3 Command Terminals Size S09

7.4 Diagram of control connection Size S09

7.5 Command Terminals Size S11/S13/S14

7.6 Diagram of control connection Size S11/S13/S14

16

18

19

20

21

22

8 Power output features ............................................................................................... 23

8.1 Derating curve

8.2 Cooling fans

23

23

9 Led status and Alarms ............................................................................................... 24

9.1 LED Status Table

9.2 Critical Alarms

9.3 Not Critical Alarm

9.4 Calibration Procedure

24

25

26

26

10 Control Panel ........................................................................................................... 27

10.1 Scroll the parameters 28

11 Firing type ............................................................................................................... 29

11.1 Single Cycle (SC)

11.2 Burst Firing (BF)

11.3 Phase Angle (PA)

11.4 Delay Triggering (DT)

11.5 Action of the Limit Current

11.6 Feed-back type

29

31

33

35

37

38

12 Connection description ............................................................................................ 39

12.1 Access to the Electronic boards

12.2 Supply the Electronic Board

12.3 Analog Inputs

12.4 Analog Outputs

12.5 Digital Input

12.6 Digital Output

12.7 PG Connector

39

39

40

42

43

44

45

13 Configuration Parameters ........................................................................................ 46

13.1 Operator Menu

13.2 Hardware Menu

13.3 Setup Menu

46

48

50

14 PROFIBUS DP .......................................................................................................... 52

14.1 Connections (S14)

14.2 How to set PROFIBUS ID

14.3 PROFIBUS Termination

14.4 Leds Status

14.5 PLC Configuration

14.6 Profibus data table exchange

52

53

53

53

54

55

15 Internal Fuse ........................................................................................................... 59

15.1 Fuse Code 59

16 Maintenance ............................................................................................................ 60

16.1 Fans

16.2 Maintenance

16.3 Repairing procedure

16.4 Warranty condition

60

60

60

60

CD Automation srl CD3000E-3PH from 25A to 500A

1 Important warnings for safety

User’s Manual

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.

4

CD Automation srl CD3000E-3PH from 25A to 500A 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.

C

LISTED

US

5

CD Automation srl

2 Introduction

CD3000E-3PH from 25A to 500A User’s Manual

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.

2.1 Advantages compared with analog thyristor unit

CD3000E is an universal Thyristor unit, designed to control resistive or inductive loads including three phase transformers. The electronic circuit is completely digital and is based on a powerful microprocessor with high performance that allow the use in different ways:

 Single cycle

 Burst Firing with soft start and current limit

 Delayed triggering

 Phase Angle with soft start and current limit

On same unit can be used different feed back that define the control mode:

 Voltage

 Current

 Power VxI

 External 0÷10Vdc

On same unit can be used different input:

 4÷20mA

 0÷10Vdc

 Potentiometer 10KΩ

 SSR

Communication RS485 is a standard feature of CD3000E this allows the use of many information like: tension, 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.

6

CD Automation srl

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.

7


2.4 Software Configurator

User’s Manual

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

CD3000E 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. 12.7) and the serial port

RS232 of the PC.

The programming cable is not included.

8

With the CD-RS serial converter is possible configure the Thyristor unit also through the

RS485 (see par. 14).

For this solution, the programming cable is not necessary.

Run the software configurator and set the serial port of the PC like the parameters P114  and

P115  of the Thyristor unit.

CD Automation srl

3 Quick 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 CD3000E has been already configured in Factory and you just need to do the following steps:

1. Verify the CD3000E Sizing. Making sure that:

 The load current is equal or less than the MAX current of CD3000E.

 The load voltage is equal or less than the MAX voltage of CD3000E.

(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.

(see par. 7.4)

5. Supply the Electronic boards

(see Order Code)

6. If not specified in the Order Code:

 Set the Load Voltage in the parameter P116 .

 Set the Load Current in the parameter P119 .

(see par. 13.1)

7. Make the Current Limit Procedure

(see par. 11.5)

8. With Burst Firing (BF) or Heater Break Alarm (HB) make the Calibration procedure

(see par. 9.4)

The CD3000E Thyristor unit is ready to start.

9

CD Automation srl

4 CD3000E Sizing

CD3000E-3PH from 25A to 500A

4.1.1 Star wiring with resistive load

I



P

1, 73

V

V = Nominal voltage phase to phase

I = Nominal current of the load

P = Nominal power of the load

4.1.2 Star wiring with inductive load

I



1

,

73

V

P

cos






4.1.3 Delta wiring with resistive load

I



P

1, 73

V




4.1.4 Delta wiring with inductive load

I



1

,

73

V

P

cos






4.1.5 Open Delta wiring with resistive load

I



P

3

V




User’s Manual

10


5 Identification and Order Code

5.1 Identification of the unit

User’s Manual

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).

11

CD Automation srl

5.2 Order Code


Model

CD3000E-3PH

1 2 3 4 5 6 7 8 9 10

1 Max Current of CD3000E

25A

35A

45A

75A

100A

125A

150A

225A

The Max Current must be equal or more than Load Current

2 Load Current

Specify this value to configure the unit in CD Automation

300A

350A

3 Load Voltage

Specify this value to configure the unit in CD Automation

4 Max Voltage of CD3000E

480V

5 Load Connection

3S

4S

Star

Star + neutral

600V

The Max Voltage must be equal or more than Load Voltage

3D

6D

Delta

Open Delta

400A

450A

6 Voltage supply for the Electronic boards

110V From 100 to 130Vac 230V From 210 to 265Vac

7 Load Type

RES

TRA

Resistive

Transformer

IRSW

IRW

Infrared short wave form

Infrared medium and long

CR Cold resistance

If the load is transformer that supply a normal resistive load write TRA+RES

8 Firing Type

SC

PA

Single Cycle

Phase Angle

S+PA Soft Start + Phase Angle

V

I

10 Input

DT Delay Triggering

Burst Firing

S+BF___ Soft Start + Burst Firing

Specify the number of firing cycles at 50% of the input signal (from 1 to 255)

9 Feed-Back

Voltage

Current

W

EX

Power

External (0÷10Vdc)

0÷10V 0÷10Vdc

4÷20mA 4÷20mA

POT

Comm

Potentiometer 10KΩ

RS485

Specify if you use the second analogical input, example: 0÷10V + 4÷20mA

11 External Current Profiler or External Feed-Back

0÷10V 0÷10Vdc POT Potentiometer 10KΩ

Comm RS485

If you don't use the External Current Profiler or External Feed-Back, write: NONE

12 Retransmission

010 0÷10Vdc 020 0÷20mA 420 4÷20mA

13 Option

CD-KP External Keypad

FUMS Fuse Microswitch

NO-HB Without Heater Break alarm

UL UL Certification

11

12

User’s Manual

12

500A

600A

13

CD Automation srl

6 Installation


Caution: Don't install near the hot elements or near the units that could give electromagnetic interferences.

The CD3000E Thyristor unit must be always mounted in vertical position to improve air cooling on heatsink. 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.

6.1 Environmental installation conditions

Ambient temperature

0-45°C at nominal current. Over 45°C use the

derating curve (see par. 8.1)

Storage temperature

Installation place

Altitude

Humidity

-25°C to 70°C

Don’t install at direct sun light, where there are conductive dust, corrosive gas, vibration or water and also in salty environmental.

Up to 1000 meter over sea level. For higher altitude reduce the nominal current of 2% for each

100m over 1000m

From 5 to 95% without condense and ice

13


6.2 Dimensions and Fixing holes

User’s Manual

96mm

5mm

7mm

Size S09

(25A÷75A)

Weight 5kg

116 mm

18

7m m

104mm

97mm

7mm

12mm

Size S11

(100A÷150A)

Weight 10,5kg

137 mm

27

0m m

97mm

222mm

7mm

12mm

Size S13

(225A)

Weight 18kg

262 mm

27

0m m

222mm

222mm

7mm

12mm

Size S14

(300A÷600A)

Weight 22,5kg

262 mm

27

0m m

222mm

14

CD Automation srl

6.3 Removing the cover


Remove the screw, if present

Size S09

Open the unit

Screw

Open

Remove the screw, if present

Screw

Size S11

Remove the plastic cover

User’s Manual

Open the unit

Open

Screw

Remove the screw

Screw

Screw

Size S13/S14

Remove the plastic cover Open the unit

Open

Screw

Screw

15

CD Automation srl

7 Wiring instructions



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 Wiring details

Use copper cables and wires rated for use at 75°C only.

7.1.1 Power cable torque (suggested)

Current

Connector

Type

Torque

Lb-in (N-m)

Wire

Range

AWG / kcmil

Wire

Terminal

25A÷225A

Terminal Block

M8

265 (30.0)

8

4/0

Copper wire

Compact (Solid) Stranded

300A

Bus Bar with M8 screw

505 (57.0)

2x1/0

350

UL Listed (ZMVV)

Copper Tube Crimp. Lug

505 (57.0)

2x3/0

600

UL Listed (ZMVV)

Copper Tube Crimp. Lug

350A÷400A


450A


500÷600A


505 (57.0)

505 (57.0)

Bus Bar 30x6mm

Bus Bar 60x4mm

16


7.1.2 Power cable dimensions (suggested)

Power Supply Cable Load Cable (Output)

Current

25A (S09)

35A (S09)

45A (S09)

75A (S09)

100A (S11)

125A (S11)

150A (S11)

25

35

50

70

mm²

10

10

10

AWG

8

8

8

4

3

1

1/0

25

35

50

70

mm²

10

10

10

225A (S13)

300A (S14)

350A (S14)

400A (S14)

120

2 x 70

2 x 95

2 x 95

4/0

2 x 1/0

2 x 3/0

2 x 3/0

120

2 x 70

2 x 95

2 x 95

4/0

2 x 1/0

2 x 3/0

2 x 3/0

450A (S14)

500A (S14)

Bus Bar 30 x 6 mm

Bus Bar 60 x 4 mm

Bus Bar 30 x 6 mm

Bus Bar 60 x 4 mm

600A (S14) Bus Bar 60 x 4 mm Bus Bar 60 x 4 mm

7.1.3 Cable dimensions of the Command Terminals

Maximum connection capacity for all size: 1.5 mm2 (14 AWG)

AWG

8

8

8

4

3

1

1/0

User’s Manual

70

70

70

25

50

50

50

10

16

16

16

mm²

4

6

6

Earth

1/0

1/0

1/0

1

1

4

1

6

6

8

6

AWG

12

10

10

17

CD Automation srl

7.2 Power Terminals


Terminal

Warning: Before connecting or disconnecting the unit check that power and control cables are isolated from voltage sources.

Description

L1

L2

Line Input Phase 1

Line Input Phase 2

L3

T1

T2

T3

Line Input Phase 3

Load Output Phase 1

Load Output Phase 2

Load Output Phase 3

Size S14

L1 L2 L3

Size S11

L1 L2 L3

L1

Size S13

L2 L3

Size S09

L1 L2 L3

T1 T2 T3

18


7.3 Command Terminals Size S09

User’s Manual


Terminal

1

2

3

4

5

10

11

12

13

6

7

8

9

14

15

16

17

18

19

20

Description

Voltage Supply for Electronic Boards (See par. 12.2)


Not used

Isolated output +12Vdc MAX 20mA

GND for Digital Input

Output +10Vdc MAX 5mA

GND for Analogue Input

(+)Analogue Input 1: Primary (See par. 12.3)

(+)Analogue Input 2: Ext. Current (See par. 12.3)

Analogue Output 1: Power (See par. 12.4)

RS485 B

RS485 A

Output relay: Run (Max 500mA, 125Vac)

Common of the contact relay: Run

NPN Output 1: Critical Alarm (12Vdc max 20mA)

NPN Output 2: Configurable (12Vdc max 20mA)

Digital Input: Reset Alarm

Digital Input: Start/Stop

Digital Input: Calibration

Digital Input: Configurable

(See par. 12)

19


7.4 Diagram of control connection Size S09

L1


L2 L3

* 1

K1

* 2

CD-KP

(option)

Pot.10K

0-10Vdc

-

4-20mA

-

+

+

-

+

User’s Manual

+

mA

+

V

L1 L2 L3

M

1 2 A B

RS485

T1 T2 T3

8

Input 1

9

Input 2

4

12Vdc

+ -

5 17 18 19 20 15 16

6 7

+

10Vdc

-

10

Run

*

13

4

14

* 3

K1

* 4

TO LOAD

NOTE:









The user installation must be protecting by electromagnetic circuit breaker or by fuse isolator.

*² Use an appropriate external transformer based on the voltage supply of the electronic board

(see the identification label)

*³ The coil contactor, the relays and other inductive loads must be equipped with opportune RC

filter.

Before give the Start command supply the auxiliary voltage.

Load Type

T1 T2 T3 T1 T2 T3 L1 L3 L2 T1 T2 T3 T1 T2 T3 N

Delta Open Delta

20

Star Star + Neutral


7.5 Command Terminals Size S11/S13/S14

User’s Manual


Terminal

1

2

3

4

Internal use

Internal use

RS485 A

RS485 B

(See par. 14)

Description

Terminal

1

2

3

4

5

6

7

12

13

14

15

8

9

10

11

16

17

18

19

20

Description



Not used

Isolated output +12Vdc MAX 20mA

GND for Digital Input

Output +10Vdc MAX 5mA

GND for Analogue Input

(+)Analogue Input 1: Primary (See par. 12.3)

(+)Analogue Input 2: Ext. Current (See par. 12.3)

Analogue Output 1: Power (See par. 12.4)

Output relay: Conf (Max 500mA, 125Vac)

Common of the contact relay: Conf

Output relay: Run (Max 500mA, 125Vac)

Common of the contact relay: Run

NPN Output 1: Critical Alarm (12Vdc max 20mA)

NPN Output 2: Configurable (12Vdc max 20mA)

Digital Input: Reset Alarm

Digital Input: Start/Stop

Digital Input: Calibration

Digital Input: Configurable

(See par. 12)

21


7.6 Diagram of control connection Size S11/S13/S14

L1


L2 L3

* 1

K1

* 2

CD-KP

(option)

Pot.10K

0-10Vdc

-

4-20mA

-

+

+

-

+

User’s Manual

+

mA

+

V

L1 L2 L3

M

1 2 A B

RS485

T1 T2 T3

8

Input 1

9

Input 2

4

12Vdc

+ -

5 17 18 19 20 15 16

6 7

+

10Vdc

-

10

Conf

*

11

4

12

Run

*

13

4

14

* 3

K1

* 4

TO LOAD

NOTE:









The user installation must be protecting by electromagnetic circuit breaker or by fuse isolator.

*² Use an appropriate external transformer based on the voltage supply of the electronic board

(see the identification label)

*³ The coil contactor, the relays and other inductive loads must be equipped with opportune RC

filter.

Before give the Start command supply the auxiliary voltage.

Load Type

T1 T2 T3 T1 T2 T3 L1 L3 L2 T1 T2 T3 T1 T2 T3 N

Delta Open Delta

22

Star Star + Neutral


8 Power output features

Current

(A)

25A

35A

45A

Voltage range

(V)

Repetitive peak reverse voltage

(480V) (600V)

330÷600

330÷600

330÷600

1600

1600

1600

1600

1600

1600

Latching current

(mAeff)

450

450

450

Max peak one cycle

(10msec.)

(A)

500

1000

1000

Leakage current

(mAeff)

15

15

15

User’s Manual

I

2

T value max

tp=10msec

Frequency range

(Hz)

Power loss

I=Inom (W)

Isolation

Voltage

Vac

1030

4750

4810

47÷70

47÷70

47÷70

90

126

162

2500

2500

2500

75A

100A

125A

150A

225A

300A

350A

400A

450A

500A

330÷600

330÷600

330÷600

330÷600

330÷600

330÷600

330÷600

330÷600

330÷600

330÷600

1600

1600

1600

1600

1600

1600

1600

1600

1600

1600

600A 330÷600 1600 1600

8.1 Derating curve

1600

1600

1600

1600

1600

1600

1600

1600

1600

1600

300

300

200

200

450

450

450

450

1000

1000

1000

1000

1540

2000

2000

4800

5250

7800

8000

17800

17800

17800

15

15

15

15

15

15

15

15

15

15

15

4810

11300

19100

19100

108000

128000

300000

306000

1027000

1027000

1027000

47÷70

47÷70

47÷70

47÷70

47÷70

47÷70

47÷70

47÷70

47÷70

47÷70

47÷70

810

1080

1260

1440

270

360

450

540

1620

1800

2160

2500

2500

2500

2500

2500

2500

2500

2500

2500

2500

2500

K

1

0.8

0.6

0.4

0.2

0

45 55 65 75 85

°C

8.2 Cooling fans

The CD3000E thyristor unit is equipped with a cooling fans. The supply votage is the same of the

electronic board (see par. 12.2). The fan’s power consumption is below listed:

Size

25A ÷ 150A

225A

350A, 450A

300A, 400A, 500A,600A

Number of fans

One Fan - 17W

Two Fans - 30W

Two Fans - 30W

Four Fan - 60W

C

LISTED

US

Number of fans

One Fan - 17W

Two Fans - 30W

Four Fan - 60W

Four Fan - 60W

23


9 Led status and Alarms

9.1 LED Status Table

On the Electronic board there are LED that indicates the state of the Electronic cards:

LED

For All size

STATUS DESCRIPTION

User’s Manual

The power supply is not connected or fault on the electronic board

AUX Fault on the electronic board

All ON

SC

HB

Electronic board is OK

No alarm

In Alarm

Critical Alarm

SCR OK

SCR short circuit

Laod OK

Load Fault

Current limit active

= OFF

= ON

= Lampeggiante

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9.2 Critical Alarms


When a critical alarm is active, it stops the CD3000E thyristor unit and activates the relative digital output (terminal 15).

The parameter P001  allows to visualize the state of these alarms (see par. 13.1).

9.2.1 Phase loss

This critical alarm is active when one of the three phases R-S-T is loss. The phase loss could be also activated by an interrupted fuse.

For restart the thyristor unit, check the presence of the line voltage on the power terminals L1, L2, L3 and check the state of the internal fuses, When the problem is solved before to restart is necessary use

the digital input: "Reset Alarm" (see par. 12.5).

9.2.2 External Alarm

This critical alarm is active when the Digital input 4 is configured like “External Alarm" and is activated.

For restart the thyristor unit, you must disarm the external alarm. When the problem is solved before to

restart is necessary use the digital input: "Reset Alarm" (see par. 12.5).

9.2.3 Heat-sink Over temperature

This critical alarm is active when the thermal switch mounted on the heat-sink is activated.

For restart the thyristor unit, you must wait that the heat-sink returns at the safety temperature. When the problem is solved before to restart is necessary use the digital input: "Reset Alarm"

(see par. 12.5).

If this alarm becomes active, check if the indications described in the “par. 6” of this manual are

respected.


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9.3 Not Critical Alarm


The Not Critical Alarm, doesn’t stop the CD3000E thyristor unit, but is possible to associate an digital

output at these alarms (see par. 12.6).

The parameter P002  allows to visualize the state of these alarms (see par. 13.1).

9.3.1 SCR Short Circuit

This alarm is active when CD3000E 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 Alarm" (see par. 12.5).

9.3.2 Unbalanced Load

This alarm is active when one of the three load current (read on the terminals T1, T2, T3) differs from the others more than 30%.

The unbalanced alarm could be active also if there are a wrong wiring of the load.


9.3.3 Heater Break alarm (HB)

This alarm is active when the load current decrease under the threshold set on the parameter P066 

(see par. 13.3).

The Heater Break alarm could be active also if there are a wrong wiring of the load.


The Heater Break alarm to work properly must have an input signal more then 25% of the nominal current value.

Caution: In the first start, and each time that the load is replaced, it’s necessary make the

Calibration procedure.

9.4 Calibration Procedure

The Calibration procedure is an automatic procedure that save in memory the three different values of load current (for each phase)

This procedure is necessary if you use the Burst Firing (BF) or if you use the Heater Break Alarm.

To make the Calibration procedure follow these steps:



Give the power supply and start the thyristor unit (see par. 12.5).

 Activate the digital input: "Cal" (terminal 19).

 The CD3000E thyristor unit give the maximum output voltage.

 After a few seconds the values of voltage and current are stored in memory.

 The CD3000E thyristor unit returns to the initial situation.

 Stop the thyristor unit.

The Calibration procedure is done.

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10 Control Panel


The Control Panel is placed on the front of the thyristor unit, on his display you can visualize the alarms,

the input and output signals and all the configuration parameters (see par. 0).

SELECTION Key ENTER Key

DOWN Key UP Key

The function keys is the following:

 The SELECTION key is used for enter and exit from the menu.

 The UP key and DOWN key is used to scroll the parameters in the menu and to change data.

 The ENTER key is used to edit the parameters and to save the modified values.

The Control Panel have three menu, and to enter in one of them you must set correctly the parameter

P000  :

 Operator Menu (P000  = 0)

This menù contains a reading parameters that give information on the state of the unit, it include also the base parameters for quick start, like the value of current and voltage load and the Set-point data.

 Hardware Menu (P000  = 5)

This menu contains all the configuration parameters for analogic and digital I/O, and the parameters to set the serial port like the address and the baudrate.

 Setup Menu (P000  = 10)

This menù contains all the setting parameters to configure the thyristor unit, like the firing type, the current limit, [ecc].

27


10.1 Scroll the parameters

 



Operator Menu





Hardware Menu





Setup Menu































































28

User’s Manual

























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11 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 Control Panel

(see par. 10).


11.1 Single Cycle (SC)

Single Cycle it's the faster zero crossing switching method in relationship of the power demand from a temperature regulator or from an external signal.

With input signal at 25% the output is one cycle ON and three cycles OFF

With input signal at 50% the output is one cycle ON and one cycle OFF

With input signal at 75% the output is three cycles ON and one cycle OFF

With input signal at 76% the output is the same of 75% but for each ON cycle the microprocessor divides 76/75, and when the sum of rests is one, the unit does one more cycle ON. For this firing is necessary to have analog input.

The Single Cycle is used to control the loads with low inertia or for infrared lamps to short wave.

ON OFF

VOLTAGE SUPPLY (V)

LOAD VOLTAGE (V)

25%

50%

75%

100%

29


11.1.1 Suggested recipe for Single Cycle

User’s Manual




(see par. 10).


Parameter Name

P003 (H03) 

P004 (H04) 

P019 (H13) 

P024 (H18) 

P025 (H19) 

P116 (H74) 

P119 (H77) 

Value

0

100

0

0

V Load

I Load

OPERATOR MENU

Description

Setpoint selection Analog/Digital

Digital Setpoint value

Maximum Output

Setpoint Ramp Up

Setpoint Ramp Down

Operative load voltage

Load nominal current

Parameter Name

P023 (H17)



P066 (H42) 

P070 (H46) 

P083 (H53) 

P084 (H54) 

P085 (H55)



P090 (H5A) 

P091 (H5B)



P098 (H62) 

0÷

Value

0

20

1

1

0

0

1

0÷3

SETUP MENU

Description

Firing Type

HB sensitivity

Feed back selection

Burst Firing Cycles (Not used in Phase Angle)

Ramp Cycles of Burst (Not used in Phase Angle)

Delay triggering

Limit current Analog/Digital

Digital Limit current value

Define the load type connection:

0=star

1=star+N

2=delta

3=open delta

= modification is not necessary

= modification is necessary

If the current limit is not used set this value to 100,0%

%

UM Mode

R/W

R/W

%

Sec

Sec

V

A

%

°

R/W

R/W

R/W

R/W

R/W

UM Mode

R/W

%

R/W

R/W

Cycles R/W

Cycles R/W

R/W

R/W

R/W

R/W

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11.2 Burst Firing (BF)


The Burst Firing is similar to the Single Cycle, but 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: P083  =4

ON OFF

VOLTAGE SUPPLY (V)

LOAD VOLTAGE (V)

25%

50%

75%

100%

11.2.1 Soft Start with Burst Firing (S+BF)

This is an additional function to the Burst Firing. The unit start in phase angle mode with a ramp starting from zero up to the full tension in the cycles number set in the parameter P084 .

When the ramp is over, the thyristor unit will stay in conduction at full voltage up to the end of cycles of burst. The S+BF firing is used to control small inductive loads to avoid inrush surge current and to reduce the electromagnetic interferences.

The example show the firing with Burst cycles: P083  =4 and ramp cycles: P084  =3

ON OFF

VOLTAGE SUPPLY (V)

LOAD VOLTAGE (V)

25%

50%

75%

100%

31


11.2.2 Suggested recipe for Burst Firing

User’s Manual




(see par. 10).


Parameter Name

P003 (H03) 

P004 (H04) 

P019 (H13) 

P024 (H18) 

P025 (H19) 

P116 (H74) 

P119 (H77) 

Value

0

100

0

0

V Load

I Load

OPERATOR MENU

Description



Maximum Output

Setpoint Ramp Up

Setpoint Ramp Down



Parameter Name

P023 (H17)



Value

0

SETUP MENU

Firing Type

Description

P066 (H42) 

P070 (H46) 

20

1

HB sensitivity

Feed back selection

P083 (H53)  8 Burst Firing Cycles (Not used in Phase Angle)

P084 (H54)  <P083  ² Ramp Cycles of Burst (Not used in Phase Angle)

P085 (H55)



P090 (H5A) 

P091 (H5B)



P098 (H62) 

0÷

0

1

0÷3

Delay triggering




0=star

1=star+N

2=delta

3=open delta



If the current limit is not used set this value to 100,0%.

² If don't use the ramp soft start (S+BF) set this value to 0.

%

UM Mode

R/W

R/W

%

Sec

Sec

V

A

R/W

R/W

R/W

R/W

R/W

%

UM Mode

R/W

R/W

R/W

Cycles R/W

Cycles R/W

°

%

R/W

R/W

R/W

R/W

32

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11.3 Phase Angle (PA)


The Phase Angle firing allow the control of the power on the load, for this firing the thyristor can be in conduction only for a part of the voltage cycle.

This part of the voltage cycle is adjustable in function of the input signal from 0 at 100%.

The PA firing is normally used for control the inductive loads, and is also possible control a primary of transformer coupled with the cold resistances like: Superkanthal, Molybdenum, Platinum, Tungsten or

Quartz Lamp. The only disadvantage with phase angle is the possible generation of interferences that however can be reduced with opportune filters.

ON OFF

VOLTAGE SUPPLY (V)

LOAD VOLTAGE (V)

25%

50%

75%

100%

11.3.1 Soft Start with Phase Angle (S+PA)

This is an additional function to the Phase Angle. The firing angle of the thyristor increase or decrease up to the final setpoint value.

The Soft start ramp is an important feature to reduce the inrush current with transformers during the during the cycle of magnetization or with cold resistance that are near to the short circuit when they are supplied.

Setpoint Ramp Up : P024 

Setpoint Ramp Down: P025 

ON OFF

VOLTAGE SUPPLY (V)

Setpoint Value (%)

100%

0%

Load voltage RMS (V)

Ramp Up

OUTPUT VOLTAGE (V)

Ramp Down

33


11.3.2 Suggested recipe for Phase Angle

User’s Manual




(see par. 10).


Parameter Name

P003 (H03) 

P004 (H04) 

P019 (H13) 

Value

0

100

OPERATOR MENU

Description



Maximum Output

P024 (H18)  0÷1000² Setpoint Ramp Up

P025 (H19)  0÷1000² Setpoint Ramp Down

P116 (H74) 

P119 (H77) 

V Load

I Load



Parameter Name

P023 (H17)



P066 (H42) 

P070 (H46) 

P083 (H53) 

P084 (H54) 

P085 (H55)



P090 (H5A) 

P091 (H5B)



P098 (H62) 

0÷

Value

1

20

1

0

1

0÷3

SETUP MENU

Description

Firing Type

HB sensitivity

Feed back selection



Delay triggering




0=star

1=star+N

2=delta

3=open delta




² If don't use the ramp soft start (S+PA) set this value to 0.

%

UM Mode

R/W

R/W

%

Sec

Sec

V

A

%

°

R/W

R/W

R/W

R/W

R/W

UM Mode

R/W

%

R/W

R/W

Cycles R/W

Cycles R/W

R/W

R/W

R/W

R/W

34


11.4 Delay Triggering (DT)

User’s Manual

The Delay Triggering firing is used the control a primary of transformer coupled with the normal resistances on the secondary (N.B. don't connect cold resistances on the secondary like: Superkanthal,

Molybdenum, Platinum, Tungsten, Quartz Lamp).

For an inductive load (ex transformer), switching the thyristors at zero crossing can generates transient over currents that can blow the fuses, to avoid this problem you must use the Delay Triggering. This firing delay the first half cycle of Burst for an angle from 0 to 100° relative to the zero, besides all the first burst start with soft start ramp to reduce the inrush current during the cycle of magnetization.

Without Delay Triggering With Delay Triggering

Transient over-current

Delay angle

(0° to 100°)

Voltage

Current

Voltage

Current

0 0

Zero

Crossing

Voltage

Zero

Crossing

Voltage

For understand the Delay Triggering firing, we have represented the waves generate by vectors that rotates in counterclockwise:

Without Delay Triggering With Delay Triggering

V

2 y y

I

2

V

2

I

2

V

1 i

3 i

1 i

2

I

1

V x

1 i

3 i

2



Delay Angle

I

1 x

I

3

I

3

V

3

V

3

Without delay at zero crossing when V1 is to zero (projected on the X axis) the unit switch On.

In this case the instantaneous value of the currents are i1, i2 and i3 and this condition, for the curve of magnetization, could generate transient over currents that can blow the fuses.

With Delay Triggering the firing of the thyristor are triggered with a delay until the instantaneous value of the curret i1=0, i2 positive and i3 negative like represented.

In this case the risk of transient over currents is reduced and the fuses don't blow.

The angle alpha is the delay to have i1=0 and this angle depends on the power factor.

The delay angle suggest for most applications is 80°

35


11.4.1 Suggested recipe for Delay Triggering

User’s Manual




(see par. 10).


Parameter Name

P003 (H03) 

P004 (H04) 

P019 (H13) 

Value

0

100

OPERATOR MENU

Description



Maximum Output

P024 (H18)  0÷1000² Setpoint Ramp Up

P025 (H19)  0÷1000² Setpoint Ramp Down

P116 (H74) 

P119 (H77) 

V Load

I Load



Parameter Name

P023 (H17)



P066 (H42) 

P070 (H46) 

P083 (H53) 

P084 (H54) 

P085 (H55)



P090 (H5A) 

P091 (H5B)



P098 (H62) 

Value

2

20

1

0÷100³

1

0÷

8

0

0÷3

SETUP MENU

Description

Firing Type

HB sensitivity

Feed back selection



Delay triggering




0=star

1=star+N

2=delta

3=open delta




² If don't use the setpoint ramp set this value to 0.

³ The delay angle suggest for most applications is 80°

%

UM Mode

R/W

R/W

%

Sec

Sec

V

A

%

°

R/W

R/W

R/W

R/W

R/W

UM Mode

R/W

%

R/W

R/W

Cycles R/W

Cycles R/W

R/W

R/W

R/W

R/W

36


11.5 Action of the Limit Current

User’s Manual

The Current Limit is available for each firing type.

It control the firing angle of the thyristor to maintain the three RMS current under the set value.

When the current exceeds this value, the voltage is decreased up to reach the current limit set.

I Load <= I Limit Set I Load > I Limit Set

11.5.1 Current Limit Procedure

The current limit could be set through the analogic input 2: External Current Profiler, or in digital mode through the parameter P091  .

To select Analog/Digital mode use the parameter P090 

0 = Analog, Current Limit from analog input (terminals 9-7)

1 = Digital, Current Limit from parameter P091 

To make Current Limit Procedure follow these steps:


 Give the power supply and set the current limit to zero:

- In analog mode, set the analog input 2 at the min value (ex. 0V for 0÷10Vdc or 4 for 4÷20mA)

- In digital mode, set the parameter P091  =0



Start the thyristor unit (see par. 12.5).



Set the primary input or the setpoint value at 100% (see par. 12.3).

 Increase the current limit until to reach the desired value.

 Stop the thyristor unit.

The Current Limit Procedure is done.

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11.6 Feed-back type


The Feed-back 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 Feed-back type you can use the software configurator or the Control

Panel (see par. 10).


The Feed-back type is defined by the parameter P070  (see par. 13.3).

If the configurable digital input has set like Feed-Back Selection (see par. 12.5), it's possible to change

the select Feed-Back with the Voltage Feed-Back (V) simply activating the input.

The feed-back defines the Control Mode. It’s possible to have:

 V=Voltage feed-back.

The input signal is proportional to the output voltage. This means that input signal becomes a voltage demand. This control mode compensates the voltage fluctuation of the incoming line supply.

 I=Current feed-back.

The input signal is proportional to the current output. This means that input signal becomes a current demand. This control mode maintain the current also if the load impedance changes.

 W=Power feed-back.

The input signal is proportional to the power output. This means that input signal becomes a power demand. The power remains constant also if voltage and load impedance change. This control mode is used with silicon carbide elements that change its resistive value with temperature and with age.

In addition it compensates the voltage fluctuation of the incoming line supply.



EX=External feed-back 0÷10Vdc (see par. 12.3).

The input signal is proportional to an external signal. This means that input signal becomes a demand to maintain this signal always constant. This control mode is used for example with galvanic systems, where it's necessary to control the current value through the electrodes.

38


12 Connection description

12.1 Access to the Electronic boards

To have access to the electronic boards the user must removing the unit’s cover

(see par.6.3)

User’s Manual

Warning: Before operate, be sure that power and control cables are isolated from voltage sources

Size S09 Size S11/S13/S14

12.2 Supply the Electronic Board

The CD3000E thyristor unit, to work, requires a voltage supply for the electronic boards. This voltage is used also to supply the internal fans.

The consumption is 20VA max, at this you must add the consumption of the internal fans (see par. 8.2).

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.

Terminal

1

2

Description

Voltage Supply for Electronic Boards

Voltage Supply for Electronic Boards

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12.3 Analog Inputs


The CD3000E thyristor unit has 2 configurable analog inputs (0÷10V, 4÷20mA, ecc):

The primary input for the analog setpoint, the secondary input for the Current Profiler or Ext. Feed-Back.

12.3.1 Primary Input (Terminals 8 and 7)

The primary input is already configured in line with customer requirements that are defined in the Order


However, if you wish to change the primary input (ex. from 0÷10V to 4÷20mA) proceed as follows:


JP6

Type Input features

0  10V (default) Impedance 40K 

POT

4  20mA

Impedance

Impedance

10K

500





min

Jumper

Open

Open

Close

Primary Input calibration procedure

When you change the hardware setting is necessary make the Input calibration procedure.

To make the Input calibration procedure follow these steps:

 Give the power supply.

 With Control Panel go in the Hardware menu (P000  = 5)

 Set the input signal to the min value (ex. 0V for 0÷10V or 4mA for 4÷20mA)

 Set the parameter P057  = 1

 Press ENTER key

 Set the input signal to the max value (ex.10V for 0÷10V or 20mA for 4÷20mA)

 Set the parameter P058  = 1

 Press ENTER key

The Input calibration procedure is done.

40

JP8


12.3.2 External Current Profiler (Terminals 9 and 7)

User’s Manual

The secondary input is for the External Current Profiler or for the External Feed-Back. The secondary input is 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 secondary input proceed as follows:

Caution: this procedure must be performed only by qualified persons


JP3

C

B

A

Type (0÷10Vdc)

Current Profiler

External Feed-Back

P070  P090 

0÷2 0

3 1

Jumper

A-B

B-C





External Current Profiler or External Feed-Back Input calibration procedure

When you change the hardware setting is necessary make the Input calibration procedure.

To make the Input calibration procedure follow these steps:

 Give the power supply.

With Control Panel go in the Hardware menu (P000  = 5)

Set the input signal to the min value (ex. 0V for 0÷10V)

 Set the parameter P061  = 1

 Press ENTER key

 Set the input signal to the max value (ex.10V for 0÷10V 5V for 0÷5V)





Set the parameter P062  = 1

Press ENTER key

The Input calibration procedure is done.

41

JP20

C

B

A

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12.4 Analog Outputs


The CD3000E thyristor unit have 1 analog output (0÷10V, 4÷20mA, ecc).

The output is for retransmitting the average power on the three phases.

User’s Manual

12.4.1 Output 1: Average Power (Terminals 10 and 6 or 10 and 7)

The average power output is 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 average power output (ex. from 0÷10V to 4÷20mA) proceed as follows:

Caution: this procedure must be performed only by qualified persons


JP2

C B A

Type

4  20mA

Output features

0  10V (default) 20mA Max

0  20mA 500  Max

500  Max

P097



0

0

1

Jumper

A-B

B-C

B-C

Setting the Output Value

The parameter P104  allows to set the full scale value to have the maximum output, for example if you use an indicator with full scale 50Kw set the parameter P104  = 50.

42

JP21

C B A

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12.5 Digital Input


The CD3000E thyristor unit has 4 digital inputs opto-isolated to 12Vdc.

You can activate the inputs with the internal supply (see par. 7.4) or with an external source for

example the PLC.

12.5.1 Reset alarm (Terminal 17)

The Reset Alarm is used for restore the unit after an alarm occurs.

Before using this input you must resolve the fault or the alarm status come back.

12.5.2 Start/Stop (Terminal 18)

This is the start command of the CD3000E thyristor unit and active the relative digital output (terminal

13 and 14) connected to the main contactor, if no alarm occurs, the CD3000E thyristor unit give an output proportional at the input signal.

If you Remove the Start command the CD3000E thyristor unit will be stopped and the output will return at zero following the ramp. When the ramp is over the Run contact will be reopened and the main contactor goes down.

12.5.3 Calibration (Terminal 19)

The Calibration input activates the Calibration procedure that is necessary if you use the Burst Firing

(BF) or the Heater break alarm (see par. 9.4).

12.5.4 Configurable Input (Terminal 20)

This digital input is configured by the parameter P103  and could perform different functions:

 Additional Reset Alarm:

This function is the same of the Reset Alarm command.

 Setpoint zero:

This function forces the output at zero maintaining the Run contact closed.

 Feed-Back Selection:



With this function, when you active the input, the feed-back setted in the parameter P070  change in Voltage Feed-Back (V).

Analog/Digital Setpoint:

With this function, when you active the input, the setpoint reference change from Analog input to

Digital value, setted in the parameter P004  (see par. 13.1).

 External Alarm:

With this function the thyristor unit, to work, must not have this digital input active.

When the unit is in Run and you active the External Alarm, the unit will be stopped and the output goes at zero without follow the ramp. The Run contact at the terminals 13 and 14 will be immediately reopened and the main contactor goes down. The External Alarm activates also the

Critical Alarm digital output.

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12.6 Digital Output


The CD3000E thyristor unit has 2 digital output (1 for size S09) with relay contact (Max 500mA,

125Vac) and 2 digital output with logic NPN 12Vdc (20ma Max).

12.6.1 Configurable Relay (Terminals 11 and 12 not available for size S09)

This digital output can be configured in order to activate itself after that one of these alarms occors:









SCR in short circuit

Unbalanced Load

Heater Break Alarm (HB)

Low Voltage

The parameter for configurate the output is the P113  (see par. 13.2).

The standard contact used for this output is normally open (NO), but is possible change the contact type:

Size S11/S13/S14

Type

NC

NO (standard)

Jumper

A-B

B-C

JP23

C B A

12.6.2 Run Relay (Terminals 13 and 14)

This digital output is used to control the main contactor, when the thyristor unit is in run the output is active and the contact is closed.

12.6.3 Critical Alarm (Terminal 15)

This digital output is active when a critical alarm occurs (see par. 9.2).

12.6.4 Configurable Relay Digital Output (Terminal 16)

This digital output can be configured in order to activate itself after that one of these alarms occors:

 SCR in short circuit

 Unbalanced Load

 Heater Break Alarm (HB)

 Current Limit active

The parameter for configurate the output is the P112  (see par. 13.2).

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12.7 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.

Connettore PG

45


13 Configuration Parameters

User’s Manual

The Configuration Parameters are accessible from the Control Panel (place in front of unit), from the software configurator or through the serial communication port RS485.

With the RS485 Serial Port the parameters are not divided by menu, but only by numerical order.

13.1 Operator Menu

P000 (H00)



Function:

Value:

Password

This parameter gives access at the available menus.

0 = Operator Menu

5 = Setup Menu

10 = Hardware Menu

With the RS485 Serial Port this parameter are not used. Note:

P001 (H01)



Function:

Valore:

Note:

R/W

Code of Critical alarm R

This parameter read only gives information on the following alarms that they stop the CD3000E.

00 = No Alarm

01 = Phase Loss

20 = External Alarm

40 = Heat-sink over temperature

If more alarms occur, the value will be equal at the sum of the two alarms. example: External Alarm + Phase Loss= 20 + 01 = 21

P002 (H02)



Function:

Value:

Note:

Code of Not Critical alarm R

This parameter read only gives information on the following alarms that don't stop the CD3000E.

00 = No Alarm

01 = Thyristor Failure

02 = Heater Break Alarm

04 = Unbalanced Load

If more alarms occur, the value will be equal at the sum of the two alarms. example: Thyristor Failure + Heater Break Alarm = 01 + 02 = 03

P003 (H03)



Function:

Value:

Default:

Note:

P004 (H04)



Function:

Min/Max:

Default:

Note:

P008 (H08)



Function:

Setpoint selection Analog / Digital R/W

This parameter determines the use of the analog setpoint (terminal 7-8) or of the digital setpoint setted in the parameter P004 .

0 = Analog setpoint

1 = Digital setpoint

0

The parameter is not memorized in EEPROM.

Setpoint Digital Value

This parameter contains the digital setpoint value, active with

P003  = 1

0 ÷ 100%

0

The parameter is not memorized in EEPROM.

% R/W

Min/Max:

Example:

Valore Setpoint Analogico % R

This parameter read only contains the analog setpoint value present at the terminals 7-8 of the command terminals.

0 ÷ 100%

With input 4÷20mA:

Input 4mA P008  = 0

Input 12mA P008  = 50

Input 20mA P008  = 100

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P011 (H0B)



Function:

P019 (H13)



Function:

Min/Max:

Default:

P024 (H18)



Function:

Min/Max:

Default:

P025 (H19)



Function:

Min/Max:

Default:

P031 (H1F)



Function:

P032 (H20)



Function:

P033 (H21)



Function:

P034 (H22)



Function:

P035 (H23)



Function:

P116 (H74)



Function:

Min/Max:

Default:

Note:

P119 (H77)

Function:

Min/Max:

Default:

Example:

Note:




Voltage supply V

This parameter read only contains the voltage value of the power supply.

R

Maximum output

This parameter set in % the maximum output voltage.

0 ÷ 100%

100

% R/W

Setpoint Ramp Up

This parameter set the Setpoint Ramp Up.

0 ÷ 1000 seconds

2

Setpoint Ramp Down

This parameter set the Setpoint Ramp Down.

0 ÷ 1000 seconds

2

Sec

Sec

R/W

R/W

Average voltage output on the three phases V R

This parameter read only show the Average voltage output on the three phases.

Average power output on the three phases Kw R

This parameter read only show the Average power output on the three phases.

RMS Current on the phase R A R

This parameter read only shows the RMS current present on the power terminal

L1.

RMS Current on the phase S A R


L2.

RMS Current on the phase T A R


L3.

Operative Load Voltage V R/W

This parameter is used to set in volt the operative voltage of the load.

24 ÷ 1000V

400 (if not specified in the Order Code)

For voltage under the 330V or upper to 600V its necessary makes hardware modification. For this reason it's very important specify this value in the Order

Code.

Load nominal Current

This parameter is used to set the Load nominal Current.

0 ÷ 300.0 Ampere for size from 25 to 300A

0 ÷ 3000 Ampere for size upper to 300A

Max Current of CD3000E (if not specified in the Order Code)

Size of CD3000E (Max Current) : 100A

Load nominal Current: 50A

A R/W

P119  =50.0

This parameter is necessary to have the correct rescaling inside the unit. For this reason it's very important specify this value in the order code.

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13.2 Hardware Menu

P057 (H39)



Function:

Value:

Note:


Calibration min value of analog input 1 R/W

This parameter saves in memory the min value of the primary analog input

(see par. 12.3.1)

0 = Default

1 = Save value

The input Calibration procedure is necessary only if you change the input type

(ex. from 0÷10V to 4÷20mA) and must be performed only by qualified persons.

P058 (H3A)



Function:

Value:

Note:

Calibration max value of analog input 1 R/W

This parameter saves in memory the max value of the primary analog input

(see par. 12.3.1)

0 = Default

1 = Save value


(ex. from 0÷10V to 4÷20mA) and must be performed only by qualified persons.

P061 (H3D)



Function:

Value:

Default:

Note:

Calibration min value of analog input 2 R/W

This parameter saves in memory the min value of the External Current Profiler

analog input (see par. 12.3.2)

0 = Default

1 = Save value

0


(ex. from 0÷10V to 0÷5V) and must be performed only by qualified persons.

P062 (H3E)



Function:

Value:

Default:

Note:

Calibration max value of analog input 2 R/W

This parameter saves in memory the max value of the External Current Profiler

analog input (see par. 12.3.2)

0 = Default

1 = Save value

0


(ex. from 0÷10V to 0÷5V) and must be performed only by qualified persons.

P097 (H61)



Function:

Value:

Offset of the Analog Outputs

This parameter is used to set the offset for the Analog Outputs.

0 = 0 ÷ 10Vdc / 0 ÷ 20mA

1 = 4 ÷ 20mA


R/W

Default:

P103 (H67)



Function:

Value:

Digital input configuration (terminal 20)

This parameter selects the function of digital input.

0 = Additional Reset Alarm

1 = Setpoint Zero

2 = Feed-back Selection

3 = Setpoint Analog/Digital

4 = External Alarm

1

R/W

Default:

P104 (H68)



Function:

Min/Max:

Default:

Full scale of Analog Output 1 (Power Avarage) Kw R/W

This parameter is used to adjust the full scale value of the analog output.

0 ÷ 300.0 Kw for size from 25 to 300A

0 ÷ 3000 Kw for size upper to 300A

1000

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P112 (H70)



Function:

Value:

Default:

P113 (H71)



Function:

Value:

Default:

Note:

P114 (H72)



Function:

Value:

Default:

P115 (H73)



Function:

Min/Max:

Default:


Digital output configuration (terminal 16)

This parameter selects the function of the digital output.


1 = Heater Break Alarm (HB)

2 = Unbalanced Load

3 = Current limit active

1

Digital output configuration (terminal 11 and 12)

This parameter selects the function of the digital output.


1 = Heater Break Alarm (HB)

2 = Unbalanced Load

3 = Low voltage

0

Not available for size S09

R/W

R/W

Baud Rate

This parameter selects the Baud rate on the serial port.

0 = 4800

1 = 9600

2 = 19200

2

R/W

Address R/W

This parameter selects the Address on the serial port for the thyristor unit.

1 ÷ 127

1

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13.3 Setup Menu

P023 (H17)



Function:

Value:


Firing Type

This parameter selects the Firing Type.

0= BURST firing mode

1= PHASE ANGLE mode

2= DELAY TRIGGERING mode

1 (if not specified in the Order Code) Default:

P066 (H42)



Function:

Min/Max:

Default:

Example:

User’s Manual

R/W

HB sensitivity % R/W

This parameter defines the threshold of current that activates the HB alarm

This value is in percentage respect the nominal load value

0,0 ÷ 100,0%

100,0

Nominal Current 100A P066  =20. This means that the Heather Break

Alarm became active when the current goes below 80A

P070 (H46)



Function:

Value:

Default:

Note:

P083 (H53)



Function:

Min/Max:

Default:

P084 (H54)



Function:

Feed back selection

This parameter selects the Feed-back type.

0 = Current feed-back (rms value)

1 = Voltage feed-back (rms value)

2 = Power feed-back VxI

3 = External feed-back


Feed-back value is the average value on the three phase R, S, T

R/W

Burst Firing Cycles (Not used in PHASE ANGLE) Cycles R/W

It defines the number of voltage cycles in ON condition at 50% of power demand

1 ÷ 255 cycles


Ramp Cycles of Burst (Not used in PHASE ANGLE)

In Burst Firing is possible to have a soft start ramp.

Cycles R/W

With this parameter you can define how much cycles are necessary to reach the complete wave form. You must set a value between 0 and the number of cycles setted in the parameter P083  . If you set 0 value the ramp is disabled

0 ÷ 100 cycles

4 (con accensione S+BF) 0 (per altre accensioni)

Min/Max:

Default:

P085 (H55)



Function:

Min/Max:

Default:

P090 (H5A)



Function:

Value:

Default:

Note:

P091 (H5B)



Function:

Min/Max:

Default:

Delay triggering (Not used in others firing)

This parameter set firing delay in °

0 ÷ 100°

80

°

Digital Limit current value %

This parameter contains the digital Current Limit value, active with

P091  = 1

0,0 ÷ 100,0%

100,0

R/W

Current Limit select Analog/Digital

This parameter determines the use of the analog or digital Current Limit

0 = Analog, Current Limit from analog input (terminals 9-7)

1 = Digital, Current Limit from parameter P091 

1

This parameter is saved in EEPROM

R/W

R/W

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P098 (H62)



Value:

Default:


Load Type

0=star

1=star+N

2=delta

3=open delta


User’s Manual

R/W

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14 PROFIBUS DP


14.1 Connections (S14)

The communication port RS485 is available on the Command Terminals.

User’s Manual

We planned on routing the cables on the left side of the cover

To connect the Profibus we suggest use a 90° PROFIBUS connector

52


14.2 How to set PROFIBUS ID

Low High

To set the PROFIBUS ID address use rotary switch “ID Low” and “ID

14.3 PROFIBUS Termination

Is possible use a terminato for Profibus

To enable set to ON, di disble set to OFF

14.4 Leds Status

LED

1,2,3

4

State

Status

Scrolling

Fixed

1 Fash

No flash

Red

Green

Meaning

Communication Active

Communication Stopped

Write a value

No data are sent

Communicatio error present

Communication OK

omation

PROFIBUS-DP

LED

Bus

State

Status

Green

Red

Green

Meaning

Profibus ok

Profibus error

Profibus in state data exchange

Flash green

Gateway waits for profibus comminication data

Flash green/red

Gateway waits for profibus parametercomminication data

Red

General profibus error

53

User’s Manual

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14.5 PLC Configuration


To work right the PLC configurator need a GSD file that are supplied with CD

Install on developer Software the GSD file and configure hardware like follow

You need to use only the universal module with

Input: length = 122

= Word – Format Unit

Output length = 16

Unit = Word – Format

User’s Manual

1.1.1 To start read data

To start the read data function set the bit 0 offset 0 to 1

To stop the read data function set the bit 0 offset 0 to 0

When the communication on RS485 side is active the led 1, 2 and 3 will scroll.

When the communication on RS485 side is not active the led 1, 2 and 3 will stop scroll.

If a communication error (time out) is active the led State (near led 8) on RS485 side will light red otherwise will light green

1.1.2 To start write data

To be enabled to write data set the bit 2 offset 0 to 1

To be disabled to write data set the bit 2 offset 0 to 0

When a data are sent to a MODBUS device the led 4 will flash

54

OFFS

Byte

6

7

8

9

10

11

12

13

14

15

2

3

4

5

30

31

32

33

34

35

36

37

38

39

40

41

16

17

18

19

20

21

22

23

24

25

26

27

28

29


14.6 Profibus data table exchange

14.6.1 Read Area (E)

OFFS

Byte

0

1

15

16

17

18

19

20

8

9

10

11

12

13

14

4

5 word

3

6

7

Word

Meaning

0

1.1.3 Tab status

Bit

0 Error communication wit board

(0=OK , 1=comm

Error)

1

2

3

4

5

6

7

1 Internal use

2 Internal use

Meaning

P001 AL1

P002 AL2

P003 L—r

0=Form Analogue input ; 1=from Bus

P004 L_SP

0 ÷ 4095 (Rescaled 0 ÷ 100.0%)

P005 Enab Supervisor

0=Disable

1=Enable

P006 Internal use

P007 Internal use

P008 r_SP

0 ÷ 4095 ((Rescaled 0 ÷ 100.0%)

P009 Internal use

P010 Internal use

P011 V_Ln

0 ÷ 4095 ((Rescaled 0 ÷ 1000V)

P012 Internal use

P013 Internal use

P014 Internal use

P015 Internal use

P016 Internal use

P017 Internal use

P018 Internal use

55

User’s Manual

67

68

69

70

71

72

73

74

75

76

77

57

58

59

60

61

62

63

64

65

66

52

53

54

55

56

34

35

36

37

38

29

30

31

32

33

26

27

28

48

49

50

51

78

79

80

81

82

83

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42

43

44

45

46

47

21

22

23

84

85

86

87

88

89

90

91

24

25

39

40

41

42

43

44

45


P019 OutN

0 ÷ 4095 (Rescaled 0 ÷ 100.0%)

P020 Internal use

P021 Enable CL

0= Disabled

1= Enabled

P022 Internal use

P023 Fir

0= BURST firing

1= ANGOLO di FASE

2= DELAY TRIGGERING

P024 rP_u

0 ÷ 1000 Sec

P025 rP_d

0 ÷ 1000 Sec

P026 Internal use

P027 Internal use

P028 Internal use

P029 Internal use

P030 Internal use

P031 Vout

0 ÷ 4095 V

P032 Po

0 ÷ 4095 KW

P033 A__r

0 ÷ 4095 A

P034 A__s

0 ÷ 4095 A

P035 A__t

0 ÷ 4095 A

P045 Start/Stop Serial

0= Stop

1= Start

P046 Internal use

P047 RESET Serial

0->1 Reset Action

P048 DI Status

00 = No DI Input

01 = Reset Allarm Input

02 = Start / StopInput

04 = Enable Input (Always 1 con CD3000E)

10 = External alarm Input

20 = Na

40 = Configurable input

P049 DO Status

00 = No DO

01 = Run Output

02 = Critical Alarmo Output

04 = COnfigurable Output

P050 Flag cyle

0= Ok

1= Inverted

P051 Current Limit active

0= Disabled

1= Enabled

P052 Internal use

56

User’s Manual

104

105

106

107

108

109

110

111

112

113

114

115

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92

93

94

95

96

97

98

99

100

101

102

103

46

47

48

49

50

51

116

117

118

119

132

133

134

135

136

137

138

139

120

121

122

123

124

125

126

127

128

129

130

131

66

67

68

69

60

61

62

63

64

65

52

53

54

55

56

57

58

59


P053 Frequency

0 ÷ 4095

P066 HB Sens

0 ÷ 4095 (Rescaled 0 ÷ 160.0%)

P067 HB dealy

0 ÷ 4095 (Rescaled 0 ÷ 10.00Sec)

P068 Internal use

P069 Internal use

P070 Feed back type

0 = Feed-back I

1 = Feed-back V

2 = Feed-back VxI

3 = Feed-back External

P071 Internal use

P072 Internal use

P083 bF_n Burst Number

1 ÷ 255

P084 bF_r Burst Ramp

P085 dt Delay triggeing

1 ÷ 100

P090 CL_i CL selection

0= From Analogueinput

1= From Bus

P091 CL Value

0 ÷ 4095 (Rescaled 0 ÷ 100.0%)

P098 LoAd Load Type

0= Star

1= Star+Neutral

2= Delta

3= Open Delta

P116 V_OP

100 ÷ 4095 (Rescaled 24 ÷ 1000V)

P117 Internal use

P118 Internal use

P119 A_Lo

0 ÷ 3000°

P120 Internal use

P121 tipo Unit type

302 = RE2

318 = RE3

P122 CT installed

0 ÷ 4095A

P123 Max Volt

100 ÷ 4095 (RRescaled 24 ÷ 1000V)

P124 Fw rev

P125 Comma

0= XXXX

1= XXX.X

57

User’s Manual

OFFS

Byte

6 H

7 L

8

9

10

11

12

13

14

15

16

2

3

4

5

CD Automation srl

14.6.2 Write Area (A)

OFFS

Byte

0

1

word

0

Word

3

L—r

4

L_SP

5

P005

6

P045

7

P047

8

CL

1

2


Meaning

1.1.4 Tab Comand

Bit ID

0 1= Start read ,

0= Stop read

1 Internal use

2 1=Write on data madific. enabled

0= Write on data madific. disabled

3 1=Enable retransmission measure

4

5

6

7

Bit

0

1

2

3

4

5

6

7

Internal use

Internal use

Meaning

Local/Remote selection

0=Form Analogue input ; 1=from Bus

Local Set-Poin

0 ÷ 4095 (Riscalato in 0 ÷ 100.0%)

Enable Start/Stop from Bus

0=Disable ; 1=Enable

Start/Stop from Bus

0=Stop ; 1 =Start

Reset From Bus

0 -> 1 Reset

Current Limit Value

0 ÷ 4095 (Riscalato 0 ÷ 100.0%)

User’s Manual

58

CD Automation srl

15 Internal Fuse


The CD3000E 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)

25A (S09)

35A (S09)

45A (S09)

75A (S09)

100A (S11)

125A (S11)

150A (S11)

225A (S13)

300A (S14)

350A (S14)

400A (S14)

450A (S14)

500A (S14)

600A (S14)

Caution:

USE ONLY EXTRARAPID FUSE WITH APPROPRIATE I²

T

15.1 Fuse Code

Size

FU50FE

FU63FE

FU80FE

FU100FE

FU2x80FE

FU2x100FE

FU2x100FE

FUURB315

FU450FMM

FU550FMM

FU550FMM

FU700FMM

FU700FMM

FU700FMM

Fuse CODE

200 kARMS Symmetrical A.I.C.

Current

(A RMS)

50

I²T

(A²sec)

600

63

80

750

1500

100

160

200

2800

6000

11200

200

315

450

550

550

700

700

700

11200

82000

105000

215000

215000

420000

420000

420000

Vac

660

660

660

660

660

660

660

660

660

660

660

660

660

660

Qty

3

3

3

3

3

3

3

3

3

3

3

3

3

3

Caution:

The Fuses must have I²t 20% less than thyristor's I²t.

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.

C

LISTED

US

59

CD Automation srl

16 Maintenance


16.1 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.

16.2 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).

16.3 Repairing procedure

 Phone to CD Automation.

 Explain 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.

 Write a fault description and give the name of your personnel to which refers.

 Use a rugged packaging to ship the unit.

16.4 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.

ENG CD3000E-3PH_25-500A - 02.DOC

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