manual - TMC Instruments
Contents
1. 52 13 1 Suggested recipe 52 14 Modbus communication 55 14 1 Physical requirements 55 14 2 Modbus Rtu Protocol 55 14 3 Message formats 55 14 4 Read holding registers read n words Function 03 58 14 5 Preset multiple registers write n words Function 16 58 14 6 Error and exception responses 59 14 7 Modbus parameters 60 15 Maintenance 65 15 1 Fans 65 15 2 Servicing 65 15 3 Repairing procedure 65 15 4 Warranty condition 65 16 CD Automation s distributors Error Bookmark not defined 17 Note 67 CD3000E 2PH User s Manual from 25A to 700A 5 1 Warnings 1 1 Important warning for safety This chapter contain instruction about safety The non observation of these warnings can cause serious accident and the loss of life of operator Serious damages can be also caused to the thyristor unit and to the component system in which is included The installation must be done by qualified people In manual description are used following icons Hazard This icon is present in all operative proced2. Voltage supply V R Function This parameter reads the voltage of power supply Value from 0 to incoming voltage supply Example 380 Volt P019 H13 Maximum output R W Function This parameter set in maximum output voltage Min Max 0 100 P023 H17 Firing mode Selection R W Function It Selects the firing type Value 0 BURST firing mode 2 DELAY TRIGGERING mode Default 0 P024 H18 Ramp up Sec R W Function This parameter sets ramp up time Min Max 0 1000 sec CD3000E 2PH User s Manual from 25A to 700A 61 Default 2 sec CD3000E 2PH User s Manual from 25A to 700A 62 P025 H19 Ramp down Sec R W Function This parameter sets ramp down time Min Max 0 1000 sec Default 2 sec P031 H1F Average voltage output on the three phases V R Function This parameter show the Average voltage output on the three phases P032 H20 Average power output on the three phases Kw R Function This parameter show the Average power output on the three phases P033 H21 Current rms value on phase R A R Function This parameter show the Current rms value on phase R P034 H22 Current rms value on phase S A R Function This parameter show the Current rms value on phase S P035 H23 Current rms value on phase T A R Function This parameter show the Current
3. CD3000E 2PH User s Manual from 25A to 700A 18 6 3 Fixing holes A B C Size A mm B mm C mm 25A S9 96 290 104 35A S9 96 290 104 45A S9 96 290 104 75A S9 96 290 104 100A S9 96 290 104 150A S9 96 290 104 200A S10 100 335 100 275A S14 222 495 222 400A S14 222 495 222 450A S14 222 495 222 500A S14 222 495 222 600A S14 222 495 222 700A S14 222 495 222 CD3000E 2PH User s Manual from 25A to 700A 19 7 Wiring instructions 7 1 Removing the cover For S9 and S10 size you must open the cover to configure the unit and to view the fuses For S14 sizes open the cover to wire to configure the unit and to inspect the fuses amp thyristors Warning this procedure can be done just by specialized personnel CD3000E unit has isolated heatsink For safety connect the heatsink to hearth using its terminal with hearth symbol CD3000E can be susceptible to airborne interferences from near equipment or from interferences on main supply so a number of precautions must be taken Contactors coils and chokes must have in parallel a RC filter and must be supplied with a different voltage line All input output signal must use screened bifilar wires Signal input and output must not routing in same cable try and must not be parallel Local regulations regarding electrical installation should be rigidly observed
4. It selects the baud rate of RS232 Value 0 4800 1 9600 2 19200 Default 2 CD3000E 2PH User s Manual from 25A to 700A 64 P115 H73 Address number R W Function It identifies the drive number on communication master slave Value 1 Drive 1 2 Drive 2 127 Drive 127 Default 1 P116 H74 Operative Voltage V R W Function It s necessary to specify the operative voltage Min Max 24 1000V Default 400 Note CD3000E with voltage out of range 342V to 602V needs hardware modifications specify this in phase of ordination P119 H77 Load nominal current A R W Function It s necessary to specify the load current value at nominal voltage This current and voltage value are necessary to be able to read the power in engineering units Min Max 1 100 0 Ampere for size up to 100A 1 1000 Ampere for size gt 100A Default Nominal CD3000E current value if load current has not been specified Example I have bought CD3000E size 100 A with current feed back The load current at nominal voltage is 50 A 0 input signal 0 A 50 input signal 50 A 100 input signal 100 A As it s possible to see at 50 input signal the current output is already at Max value From 50 to 100 of input signal there is no action on output To have a regulation from 0 to 100 it s necessary to set parameter P119 50 Amp Set of this parameter is neces
5. Attention this procedure must be carry out by skilled people only 10 1 Burst firing To configure Burst Firing via software configurator select P023 and set it at 0 Burst Firing deliveres to the load a package of complete voltage supply cycles Ton Toff Tc The number of complete periods is proportional to the input signal The power modulation is given by TC T ON T OFF This is a zero crossing firing that eliminates EMC interferences P083 parameter gives the possibility to decide how many voltage periods the operator wants to have at 50 of input signal This value is between 1 to 256 periods CD3000E becomes more or less fast depending on the set value When the value is 1 this type of firing is named Single Cycle CD3000E 2PH User s Manual from 25A to 700A 34 10 2 Delay triggering DT This firing mode is used to switch ON primary of transformer coupled with normal resistance on secondary Don t connect cold resistance on secondary superKanthal Molybdenum Platinum Tungsten Quartz Lamp It s used to prevent inrush surge current when zero voltage switching is used To avoid to saturate transformer these precaution are taken When start push button is operated the first firing of the first block of voltage periods is done in Phase Angle with Soft Start The first half cycle is positive and the last one is negative In this mode we know where we are in the magnetization curve for the residual ma
6. max A sec FUSE 25A 1030 FU50FE 600 35A 1030 FU63FE 750 45A 4750 FU80FE 1500 75A 4750 FU100FE 2800 100A 11300 FU160FEE 3700 125A 19100 FU200FEE 11400 150A 128000 FU250URB 52000 200A 128000 FU315URB 82000 275A 108000 FU315URB 82000 400A 300000 FU550FMM 215000 450A 300000 FU2x315FM 308000 500A 306000 FU2x315FM 308000 600A 1027000 FU2x450FMM 600000 700A 1027000 FU2x450FMM 600000 Other Fuses at your choice must have I2t 20 less than thyristor s I2t High speed fuses are only used for the thyristor protection and can not be used to protect the installation The user installation must be protect by electromagnetic circuit breaker or by fuse isolator The warranty of thyristor is null if no proper fuses are used See tab above CD3000E 2PH User s Manual from 25A to 700A 52 13 Parameters on software tools 13 1 Suggested recipe 13 1 1 ZC Zero Crossing firing mode OPERATOR MENU Parameter Name Val Description UM Mode P003 H03 02 Local remote Set point selection R W P004 H04 Local Set point value R W P019 H13 100 Maximum Output R W P024 H18 0 Ramp up Sec R W P025 H19 0 Ramp down Sec R W P116 H74 Load V Operative Voltage V R W P119 H77 Load I Load Nominal Current A R W SETUP MENU Parameter Nam
7. 47 70 660 2500 400A 330 600 1600 1600 200 7800 15 300000 47 70 960 2500 450A 330 600 1600 1600 200 8000 15 300000 47 70 1080 2500 500A 330 600 1600 1600 200 8000 15 306000 47 70 1200 2500 600A 330 600 1600 1600 1000 17800 15 1027000 47 70 1440 2500 700A 330 600 1600 1600 1000 17800 15 1027000 47 70 1680 2500 8 2 Derating curve 1 0 8 0 6 0 4 0 2 0 45 55 65 75 85 K C I I x K NOM MAX 8 3 Cooling fans The thyristor units are equipped with a cooling fan for currents gt 45A the supply votage is standard 240VAC 15 50 60Hz or optional 120VAC 15 50 60Hz The fan s power consumption is below listed Size Number of fans C US LISTED UL Number of fans 25A 35A 45A No fan One Fan 14W 75A 100A 125A 150 200A One Fans 14W One Fan 14W 275A 450A 700A Four Fans 60W Four Fans 60W 400A 500A 600A Two Fans 30W Four Fans 60W CD3000E 2PH User s Manual from 25A to 700A 29 9 Led status and alarms CD3000E has alarms and events grouped in 2 parameters on serial link P001 P002 Parameter P001 shows alarms that stop the CD3000E Parameter P002 shows events and alerts that does not stop the CD3000E 9 1 LED Status Table LED Size From 25 to 200A Size From 275 to 700A STATUS DESCRIPTION Auxiliary supply is not connected F
8. H62 0 star 2 delta Define the load type connection R W 2 Default value modification it s not necessary modification is necessary CD3000E 2PH User s Manual from 25A to 700A 55 14 Modbus communication The CD3000E is equipped with two wire RS485 serial communication This means that communication can be between the CD3000E and a master device e g a computer or terminal 14 1 Physical requirements Character Transmission Data format is fixed to be one start bit eight data bits one stop bit and the parity none 14 2 Modbus Rtu Protocol The standard RS485 Communications use the industry standard MODBUS RTU protocol The following restrictions are imposed Baud rates will be 4800 9600 19200 Baud Standard 19200 Support for multi parameter Write operations is limited to support of the Multi Word Write Function Number 16 but permits writing only one parameter per message The following MODBUS functions are supported Function Function Number Read Holding Registers Read n Word 03 Preset Multiple Registers Write n Word 16 14 3 Message formats The first character of every message is the Controller address in the range 1 255 and 0 for broadcast messages The second character is always the Function Number The contents of the remainder of the message depends upon this Function Number In most cases the Controller is required to reply to the message by echoing the address and Function N
9. air cooling on heatsink Maintain minimum distances in vertical and in horizontal as below represented Don t install in proximity of hot elements and near units generating electromagnetic interferences When many units are mounted inside a cubicle provide air circulation as below represented Sometimes it is necessary to provide 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 par 8 2 Stocking temperature 25 C to 70 C Installation place Don t install at direct sun light where there are conductive dust corrosive gas vibration or water and also in salty environmental Altitude Up to 1000 meter over sea level For higher altitude reduce the nominal current of 2 for each 100m over 1000m Humidity From 5 to 95 without condense and ice CD3000E 2PH User s Manual from 25A to 700A 17 6 2 Dimensions W H D CD3000E 2PH 25 150A S9 CD3000E 2PH 200A S10 CD3000E 2PH 275A 700A S14 W H D W H D Size W mm H mm D mm 25A S9 116 316 187 35A S9 116 316 187 45A S9 116 316 187 75A S9 116 316 187 100A S9 116 316 187 150A S9 116 316 187 200A S10 116 350 220 275A S14 262 520 270 400A S14 262 520 270 450A S14 262 520 270 500A S14 262 520 270 600A S14 262 520 270 700A S14 262 520 270
10. 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 CD3000E 2PH User s Manual from 25A to 700A 66 CD3000E 2PH User s Manual from 25A to 700A 67 16 Note CD3000E 2PH User s Manual from 25A to 700A 68 CD3000E 2PH User s Manual from 25A to 700A 69
11. local set point The local set point can be setted via RS485 CD KP and software configurator When the user removes the command terminals 4 20 open the set point is the input value Applied on terminals 7 8 CD3000E 2PH User s Manual from 25A to 700A 46 11 6 Digital output CD3000E thyristor unit has 3 digital output 4 for size from 275 to 700A to diagnose the thyristor status 11 6 1 Run Relay Terminals 13 14 This is a free contact relay output When the unit is in start mode the relay is energized This contact may be NC or NO from 25 to 200A from 275 to 700A Type JP202 NC A B NO B C Type JP22 NC A B NO B C This is the default configuration at which the wiring diagram are referred The RUN relay must be used to energize an external main contactor C B A C B CD3000E 2PH User s Manual from 25A to 700A 47 11 6 2 Critical Alarm Terminal 15 This is a logic NPN 12Vdc 20mA max output When no alarm occurs the terminal output 15 is 12Vdc when an alarm occurs this terminal is 0V This output goes to zero volt if one if those alarms is active Phase not found Incorrect phase rotation Over temperature on heatsink When one of these alarms occurs the unit stops To reset the alarm use RESET When the alarm is resetted this output returns to 12Vdc ATTENTION to drive an inductive load relay coil etc whit this output be sure to use a free whe
12. on CD3000E make sure that the voltage and auxiliary voltage supply are not connected CD3000E 2PH User s Manual from 25A to 700A 40 11 3 1 Main reference signal configuration Terminal 8 The main reference 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 Warning this procedure can be done just by specialized personnel To configure the input type set the jumper as below represented from 25 to 200A from 275 to 700A Type Impedanc e JP6 0 10V 40K Open POT 10K min 40K min Open 4 20mA 500 Close Type Impedanc e JP8 0 10V 40K Open POT 10K min 40K min Open 4 20mA 500 Close When operator finishes to configure the hardware setting he must do the input calibration procedure A A B CD3000E 2PH User s Manual from 25A to 700A 41 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 Auxiliary power supply OFF START TUNE END TUNE Mantain Kay CAL pushed and give the power supply Analog input is tuned Push again momentary CAL Key Yellow led only is flashing apply 0 input Signal I E 0V for 0 10V 4mA for 4 20mA Red led on
13. operations can also be done by the RS485 communication command NOTE also in case of one phase lost could be activated the alarm of incorrect phase rotation 9 2 3 Overtemperature on heatsink The temperature on the heatsink is under the control of a thermic switch If the temperature is too high it represents a critical alarm The output critical alarm terminal 15 will be actived 0Vdc immediately and will stop the thyristor stack When the problem is solved to start again the operator activates the reset command and start the unit All these operations can also be done by the RS485 communication command 9 3 Action to solve a critical alarm If a critical alarm occurs during the first start up check the main line voltage between terminals L1 L2 L3 if it s OK check the internal fuses if they are OK invert two phases i e invert phase S with phase T and start again the unit If a critical alarm occurs during the normal working operation check the main line voltage between terminals L1 L2 L3 if it s OK check the internal fuses if they are OK check the heatsink temperature The alarm type can be diagnosed via RS485 CD3000E 2PH User s Manual from 25A to 700A 31 9 4 Events and alerts that don t stop CD3000E The following events and alerts don t stop the unit SCR Short Circuit SC Heater Break HB Unbalanced Load Current Limit acti
14. the load current value at nominal voltage This current and voltage value are necessary to be able to read the power in engineering units Min Max 1 100 0 Ampere for size up to 100A 1 1000 Ampere for size gt 100A Default Nominal CD3000E current value if load current has not been specified Example I have bought CD3000E size 100 A with current feed back The load current at nominal voltage is 50 A 0 input signal 0 A 50 input signal 50 A 100 input signal 100 A As it s possible to see at 50 input signal the current output is already at Max value From 50 to 100 of input signal there is no action on output To have a regulation from 0 to 100 it s necessary to set parameter P119 50 Amp Set of this parameter is necessary also when there is a power feed back If your CD3000E code is NOT in line with what you really need use the enclosed configurator software tool to set up the unit Install the software on your PC select CD3000E and click on test unit changing what you need CD3000E 2PH User s Manual from 25A to 700A 13 4 CD3000E Sizing 4 1 1 Star wiring with resistive load V P I 73 1 V Nominal voltage phase to phase I CD3000E Nominal current P Nominal power to the load 4 1 2 Star wiring with inductive load cos V P I 73 1 V Nominal voltage phase to phase I CD3000E Nominal current P Nominal power to the load 4 1 3 Delta wiring with resist
15. 0A 63 P091 H5B Internal current limit value R W Function With P090 1 The setted value correspond at Internal current limit Min Max 0 0 100 0 Default 100 0 P097 H61 Offset Analog Output R W Function This parameter is used to set the Analog Output see par 11 4 Value 0 0 10Vdc 0 20mA 1 4 20mA Default 0 P098 H62 Define the load type connection R W Value 0 star connection without neutral 2 delta connection Default 0 P103 H67 Digital input configuration terminal 20 R W Function It selects the function of digital input Value 0 Reset 1 ON OFF unit 2 Feed back selection 3 Local Remote Set point Default 1 P104 H68 Analog Output Rescaling R W Function This parameter is used to adjust the full scale value Min Max 0 0 100 0 Default 100 0 P112 H70 Digital output 2 configuration R W Function It selects the signal to be connected on digital output 2 Value 0 Thyristor short circuit 1 HB 2 Unbalanced load 3 Current limit Default 1 P113 H71 Digital output 3 config For size from 275 to 700A R W Function It selects the signal to be connected on digital output 3 Value 0 Thyristor short circuit 1 HB 2 Unbalanced load 3 Voltage Low Default 0 P114 H72 Baud Rate on serial port R W Function
16. 25 7 6 Diagram of control connection from 275 to 700A 26 7 7 Wiring overview 27 8 Technical features 28 8 1 Power output features 28 8 2 Derating curve 28 8 3 Cooling fans 28 9 Led status and alarms 29 9 1 LED Status Table 29 9 2 Critical alarms 30 9 3 Action to solve a critical alarm 30 9 4 Events and alerts that don t stop CD3000E 31 9 5 Current limit see par 11 3 3 31 9 6 Heater break alarm and scr short circuit 32 10 Types of firing mode 33 10 1 Burst firing 33 CD3000E 2PH User s Manual from 25A to 700A 4 10 2 Delay triggering DT 34 10 3 Feed back control mode 36 11 Connection description 37 11 1 Electronic boards 37 11 2 Auxiliary power supply connections 39 11 3 Analog inputs 39 11 4 Analog outputs Terminal 10 43 11 5 Digital Input 44 11 6 Digital output 46 11 7 RS485 serial connection 49 11 8 PG Connector 50 12 Fuses and Fuseholder 51 12 1 Fuses and Fuse Code 51 13 Parameters on software tools
17. 2A 250Vac 0 10V 4 20mA To aux unit High breaking capacity fuses CD3000E 2PH User s Manual from 25A to 700A 26 7 6 Diagram of control connection from 275 to 700A Warning this procedure can be done just by specialized personnel Size S14 Control Sync Voltage Current T1 T2 T3 L1 L2 L3 5 Internal Fan M K1 20 19 18 17 4 Reset Start Cal Config Input Gnd 12V 12V Serial port 4 3 13 14 7 10 6 V mA 1 2 Heatsink over temperature switch 4 15 16 6 8 10V 7 Input Current profiler 9 Input 6 7 To Load A B RS485 3ph ac 50 60Hz 480Vmax Auxiliary voltage Critical Alarm KA2 KA3 HB Relay 12V max 20mA 0V mA Vdc 0V 10Vdc Power indicator Just one indicator 0 10Vdc 10 7 or 4 20mA 10 6 Run contact Semiconductor High speed fuses 1 2 Run Max 230Vac 0 10V 4 20mA To aux unit High breaking capacity fuses 11 12 Conf contact Conf Max 230Vac RS485 Conn CD3000E 2PH User s Manual from 25A to 700A 27 7 7 Wiring overview In the figure below is represented the wiring for power and auxiliary cables of CD3000E Delta Star T1 T2 T3 T1 T2 T3 Load Run KA1 K1 KA1 KA1 KA2 KA3 Main Contactor Run Critical Alarm Heater Break Alarm 1 2 2 1 6 7 2 1 Ritrasmission 0 20mA 4 20mA 0 10V CD
18. 70 1 0 M8 70 1 0 M8 200A 95 3 0 M8 95 3 0 M8 275A 2 x 70 2 x 1 0 M8 2 x 70 2 x 1 0 M8 400A 2 x 95 2 x 3 0 M10 2 x 95 2 x 3 0 M10 450A Bus Bar 30 x 6 mm Bus Bar 30 x 6 mm 500A Bus Bar 60 x 4 mm Bus Bar 60 x 4 mm 600A Bus Bar 60 x 5 mm Bus Bar 60 x 5 mm 700A Bus Bar 60 x 6 mm Bus Bar 60 x 6 mm CD3000E 2PH User s Manual from 25A to 700A 22 CD3000E 2PH User s Manual from 25A to 700A 23 7 3 3 Auxiliary cable dimensions suggested Current Auxiliary Supply Earth Cable Cable mm2 AWG mm2 AWG Screw M 25A 0 50 18 4 12 M6 35A 0 50 18 4 12 M6 45A 0 50 18 6 10 M6 75A 0 50 18 10 8 M6 100A 0 50 18 16 6 M6 125A 0 50 18 16 6 M6 150A 0 50 18 16 6 M6 275A 0 50 18 50 1 M8 400A 0 50 18 50 1 M8 450A 0 50 18 70 1 0 M8 500A 0 50 18 70 1 0 M8 600A 0 50 18 70 1 0 M8 700A 0 50 18 70 1 0 M8 CD3000E 2PH User s Manual from 25A to 700A 24 7 4 Auxiliary connections CD3000E MP BOARD Terminal Description 1 Auxiliary supply voltage 93 265Vac See order code 2 Auxiliary supply voltage 93 265Vac See order code 3 N C not connected 4 Supply Digital Input Output 12Vdc Max 20mA 5 Common Digital Output 0V 6 Output 10V stabilized 1mA max Pot Supply 7 Common Analogue input and output 8 Input command signal 4 20mA 0 10V 9 Input current limit p
19. CD3000E 2PH User s Manual from 25A to 700A 20 7 2 Power Terminals Before to connect or disconnect make sure that power cables and auxiliary wires are insulated from live voltage Terminal Description L1 Line Input Phase 1 T1 Load Output Phase 1 L2 Line Input Phase 2 T2 Load Output Phase 2 NOT controlled by the thyristor L3 Line Input Phase 3 T3 Load Output Phase 3 S9 and S10 power connection S14 power connection T1 T2 T3 L1 L2 L3 CD3000E 2PH User s Manual from 25A to 700A 21 7 3 Wiring details Use 75 C copper CU conductor only provided with the terminal type indicated below 7 3 1 Power cable torque suggested Current Torque Lb in N m Wire Range AWG kcmill Wire Terminal 25A 35A 45A 75A 100A 125A 150A 200A 265 30 0 8 3 0 Polymeric Terminal Block M8 275A 505 57 0 2x1 0 300 Bus Bar Adapter M8 400A 505 57 0 2x3 0 600 Bus Bar Adapter M10 450A 505 57 0 Field wiring bus bar 30x6mm 500A 505 57 0 Field wiring bus bar 60x4mm 600A 505 57 0 Field wiring bus bar 60x5mm 700A 505 57 0 Field wiring bus bar 60x6mm 7 3 2 Power cable dimensions suggested Current Supply Load Cable Cable mm2 AWG Screw M mm2 AWG Screw M 25A 10 8 M8 10 8 M8 35A 10 8 M8 10 8 M8 45A 10 8 M8 10 8 M8 75A 25 4 M8 25 4 M8 100A 35 3 M8 35 3 M8 125A 50 1 M8 50 1 M8 150A
20. KP 13 14 230Vac 110Vac Aux Unit RS485 Before give the Start command terminal 18 supply the auxiliary voltage to the terminals 1 and 2 With the Start command the relay is activated and close his contact between the terminals 13 and 14 The CD3000E verifies the presence of the three phases and their rotation If something is wrong the CD3000E stops itself and open the relay contact The RUN relay must be used to energize the external main contactor K1 CD3000E 2PH User s Manual from 25A to 700A 28 8 Technical features 8 1 Power output features Current Voltage range Ripetitive peak reverse voltage Latching current Max peak one cycle Leakage current I2T value thyristor Frequency range Power loss Isolation Voltage A V 480V 600V mAeff 10msec A mAeff tp 10msec Hz I Inom W Vac 25A 330 600 1600 1600 450 500 15 1030 47 70 60 2500 35A 330 600 1600 1600 450 500 15 1030 47 70 84 2500 45A 330 600 1600 1600 450 1000 15 4750 47 70 108 2500 75A 330 600 1600 1600 450 1000 15 4750 47 70 180 2500 100A 330 600 1600 1600 450 1540 15 11300 47 70 240 2500 125A 330 600 1600 1600 450 2000 15 19100 47 70 300 2500 150A 330 600 1600 1600 300 4800 15 128000 47 70 360 2500 200A 330 600 1600 1600 300 4800 15 128000 47 70 480 2500 275A 330 600 1600 1600 300 4800 15 108000
21. OPERATOR S MANUAL Rev 02 2006 CD3000E 2PH THYRISTOR UNIT 3 INDEX 1 Warnings 5 1 1 Important warning for safety 5 2 Introduction 8 2 1 Advantages compared with analog thyristor unit 8 2 2 CD KP high lights 9 2 3 Clone facility using CD EASY 10 2 4 Configurator 11 3 Quick Start 12 4 CD3000E Sizing 13 5 Installation and wiring information 14 5 1 Identification of the unit 14 5 2 Ordering code 15 6 Installation 16 6 1 Environmental installation conditions 16 6 2 Dimensions 17 6 3 Fixing holes 18 7 Wiring instructions 19 7 1 Removing the cover 19 7 2 Power Terminals 20 7 3 Wiring details 21 7 4 Auxiliary connections CD3000E MP BOARD 24 7 5 Diagram of control connection from 25 to 200A
22. On CD Automation web site is available free of charge the Configuration Software A cable with its built in converter and connector is available from CD Automation The configuration cable can be plugged into the PG connector of CD3000E 2PH or if a CD KP is available it s possible to have the connection above indicated on front unit This solution allow to engineers to verify configuration without to go inside the cubicle where there is high voltage and without to stop the plant 2 2 CD KP high lights 2 2 1 General description Local remote facility Set point ramp up down Scroll selection of Set point power Power read out Current Voltage Display indication for Heater Break Alarm SCR short circuit Retransmission 4 20mA or 0 10V selectable of one of these parameters power current voltage Dimensions 48x96x92mm WxHxD CD KP is designed to give two access levels First Level Access the operator is able to view the power current and voltage as well as set the power when the CD KP is in Local Mode At this level the password function is disabled to prevent accidental parameter changes by unauthorized personnel Second level access By connecting a PC to the RS232 port located on the front of the CD KP it s possible to have access to all parameters of the CD Automation Thyristor Unit using the free downloadable Configuration Software Configuration cha
23. ault on the electronic board Aux Run Auxiliary supply is connected and board is OK NO alarm In Alarm ON All ON Critical Alarm SCR OK SC SC SCR short circuit Laod OK Load Fault HB MB In current limit OFF ON Flashing CD3000E 2PH User s Manual from 25A to 700A 30 9 2 Critical alarms These alarms are active after a START command in case of Phase lost Incorrect phase rotation Over temperature on heatsink When one of these alarms is active the unit stops and must be reset before to start again Via RS485 MODBUS it s possible also to discriminate witch type of alarm occurred 9 2 1 Phase lost This alarm is activated when one of the three phases R S T is lost and is a critical alarm that stops the CD3000E The output critical alarm terminal 15 will be actived 0Vdc immediately and will stop the thyristor stack When the problem is solved before to restart again use the reset command or use the RS485 communication command To reset the unit The Phase lost alarm can be activated by phase lost or fuse failure on CD3000E 9 2 2 Incorrect phase rotation The system must have the phase rotation in clock wise If the sequence of the incoming voltage supply is not correct the output critical alarm terminal 15 will be actived 0Vdc immediately and will stop the thyristor stack Invert phase S with phase T reset the unit and start again All these
24. e Val Description UM Mode P023 H17 02 Firing mode Selection R W P066 H42 20 HB sensitivity R W P070 H46 12 Feed back selection R W P083 H53 82 Burst Firing Setting available only with Burst Firing Cycles R W P085 H55 02 delay triggering R W P090 H5A 12 Analog Digital current limit selection R W P091 H5B 100 02 Internal current limit value R W P098 H62 0 star 2 delta Define the load type connection R W 2 Default value modification it s not necessary modification is necessary CD3000E 2PH User s Manual from 25A to 700A 53 13 1 2 BF BURST firing mode OPERATOR MENU Parameter Name Val Description UM Mode P003 H03 02 Local remote Set point selection R W P004 H04 Local Set point value R W P019 H13 100 Maximum Output R W P024 H18 0 Ramp up Sec R W P025 H19 0 Ramp down Sec R W P116 H74 Load V Operative Voltage V R W P119 H77 Load I Load Nominal Current A R W SETUP MENU Parameter Name Val Description UM Mode P023 H17 02 Firing mode Selection R W P066 H42 20 HB sensitivity R W P070 H46 12 Feed back selection R W P083 H53 82 Burst Firing Setting avai
25. e instantaneous value of the current are i1 i2 and i3 and this status for magnetization curve can cause inrush currents that Blows Fuses If the thyristor are triggered with a delay up to when the instantaneous value of the current i1 0 like represented above the current status is i1 0 with i2 positive and i3 negative In this situation the fuses does not blow The alfa angle define the delay to have i1 0 and this angle depend on cosy power factor The suggested delay that is used in the most common application is 70 CD3000E 2PH User s Manual from 25A to 700A 36 10 3 Feed back control mode Attention this procedure must be carry out by skilled people only The feed back defines the Control Mode It s possible to have V Voltage feed back The output voltage of CD3000E is proportional to input signal This means that input signal becomes a voltage demand This control mode compensate the voltage fluctuation of the incoming line supply W Power feed back The power output of CD3000E is proportional to input signal This means that input signal becomes a power demand The power remains constant also if voltage and load impedance change This feed back is used with silicon carbide elements that change its resistive value with temperature and with age In addition are compensate also the voltage fluctuation of the incoming line supply When the user chooses this feed back it s necessary to run the auto calibration proced
26. ee performances Don t touch components to prevent electrostatic discharges on them Verify that all rating are in line with real needs If authorised personnel must measure voltage current etc on units take away rings and other jewels from fingers and hands Authorised personnel working on thyristor unit under power supply voltage must work on insulated board Be secure that board is not connected to earth This listing does not represent a complete enumeration of all necessary safety cautions CD3000E 2PH User s Manual from 25A to 700A 6 Protection protection CD3000E thyristor unit has an insulated cover to compliance to International specification IP20 To understand if IP20 protection is sufficient should be evaluated the installation place where the units are installed Earth terre CD3000E family has isolated heatsink For safety connect the heatsink to earth to avoid shocks in case that circuit board or THYRISTOR lose insulation Earth impedance should be correspondent to local earth regulation Periodically the earth efficiency should be inspected Electronic supply alimentation lectronique CD3000E family electronic circuit should be supplied by dedicated voltage supply for all electronic circuit but not in parallel with contactor s coil solenoids and other inductive or capacitive loads It s recommended to use a shielded transformer Electromagnetic compatibility compatibilit lectr
27. el diode in parallel to the coil 11 6 3 Programmable Output Terminal 16 This is a logic NPN 12Vdc 20mA max output When no alarm occurs the terminal output 16 is 12Vdc when an alarm occurs this terminal is 0V This output goes to zero volt if one if these alarms is active Thyristor Short circuit P112 0 HB active P112 1 Unbalanced load P112 2 Current limit active P112 3 When one of the selected alarms occurs the unit doesn t stop To reset an alarm status use RESET When the alarm is resetted this output returns to 12Vdc ATTENTION to drive an inductive load relay coil etc with this output be sure to use a free wheel diode in parallel to the coil TLP127 U15 COME 1 3 6 4 PEA12 15 5 R76 1K s Terminals 12V COME 4 PEA12 Ext Relay 12V 20mA TLP127 U15 COME 1 3 6 4 PEA12 16 5 R76 1K s Terminals 12V COME 4 PEA12 Ext Relay 12V 20mA CD3000E 2PH User s Manual from 25A to 700A 48 11 6 4 Conf Relay Terminals 11 12 only for size from 275 to 700A This is a free contact relay output This contact may be NC or NO from 275 to 700A Type JP23 NC A B NO B C This is the default configuration at which the wiring diagram are referred The output may be configured for one of following purposes Thyristor Shor
28. gnetism 0 Transient over current Current Zero Crossing Voltage Fig 1 Vload iload Delay angle 0 to 90 0 Fig 2 Zero Crossing Voltage Starting from this moment CD3000E switch ON a complete whole supply cycles to the transformer Starting with positive and stopping with negative The first half positive cycle firing signal is given with a delay Delay Triggering to avoid to generate transient over currents that can blow the fuses This delay is done on each phase The parameter that must be setted are P023 2 Select Delay Triggering Mode P083 Burst Firing Setting It define the number of complete cycles at 50 of power demand Default is 8 but can be setted up to 256 P085 This parameter set the delay of firing in millisecond Default value setted at 4 millisecond This value satisfy the majorities of applications CD3000E 2PH User s Manual from 25A to 700A 35 y V1 I1 V3 I3 I2 V2 x i2 i1 i3 y V1 I1 V3 I3 I2 V2 x i2 i3 Delay Angle Burst Firing without Delay Burst with Delay Triggering To better understand the sinusoidal waveform represented at figure 2 are generate by vectors rotating anticlockwise All the electronic circuits use the zero voltage crossing as a reference In Burst Firing without Delay when the V1 is zero its projection on x axle the unit switch ON In this case th
29. ification label must be equal or more than operating voltage 4 Load Voltage incoming voltage supply Specify this value that will be used to configure the unit in CD Automation If this is not specified must be configured by customer using software configurator 5 Load Connection 3D 3 Wire Delta 3S 3 Wire Star 6 Auxiliary Voltage 110V 110Vac 15 this require special fan at 110v 230V 230Vac 15 7 Load Type RES Normal resistance TRA Transformer If the load is transformer that supply a normal resistive load write TRA RES 8 Firing ZC Zero crossing BF_ _ _ Burst Firing fill one number from 1 to 128 This number represents the number of cycles in ON condition at 50 of input signal DT Delay triggering Can be used only with transformer coupled with normal resistance and not with cold resistance 9 Feedback V Voltage W Power VxI 10 Input 0 10V 0 10V 47K 4 20mA 4 20mA 470 POT 10K potentiometer Comm RS485 link 11 External Current Profiler 0 10V 0 10V 47K POT 10K potentiometer Comm RS485 link None No secondary input 12 Retrasmission W010 0 10V W020 0 20mA W420 4 20mA 13 Options CD KP External Keypad CD EASY Clone facility amp memory card UL UL Certification CD3000E 2PH User s Manual from 25A to 700A 16 6 Installation CD3000E unit should be always mounted in vertical position to improve
30. ive load V P I 73 1 V Nominal voltage phase to phase I CD3000E Nominal current P Nominal power to the load 4 1 4 Delta wiring with inductive load cos V P I 73 1 V Nominal voltage phase to phase I CD3000E Nominal current P Nominal power to the load CD3000E 2PH User s Manual from 25A to 700A 14 5 Installation and wiring information 5 1 Identification of the unit Before to install the CD3000E unit examine for damages or deficiencies If any is found notify the carrier immediately Check that the product features shown on CD3000E identification label corresponds to that ordered see par 5 2 An identification label provides all the information regarding the factory settings of the unit This label is on the board inside the unit as represented below Identification Label CD3000E 2PH User s Manual from 25A to 700A 15 5 2 Ordering code Model CD3000E 2PH 1 2 3 4 5 6 7 8 9 10 11 12 13 CD3000E 2PH Ex CD3000E 2PH 75A 50A 480V 300V 3D 230V TRA DT V 0 10V None W420 UL 1 Nominal CURRENT of CD3000E 25A 75A 150A 400A 600A 35A 100A 200A 450A 700A 45A 125A 275A 500A 2 Load Nominal CURRENT at operating Voltage Specify this value used to configure the unit in CD Automation If this is not specified must be configured by customer using software configurator 3 Nominal VOLTAGE of CD3000E 480V 600V The voltage on the ident
31. lable only with Burst Firing Cycles R W P085 H55 02 delay triggering R W P090 H5A 12 Analog Digital current limit selection R W P091 H5B 100 02 Internal current limit value R W P098 H62 0 star 2 delta Define the load type connection R W 2 Default value modification it s not necessary modification is necessary CD3000E 2PH User s Manual from 25A to 700A 54 13 1 3 DT Delay Triggering OPERATOR MENU Parameter Name Val Description UM Mode P003 H03 02 Local remote Set point selection R W P004 H04 Local Set point value R W P019 H13 100 Maximum Output R W P024 H18 0 Ramp up Sec R W P025 H19 0 Ramp down Sec R W P116 H74 Load V Operative Voltage V R W P119 H77 Load I Load Nominal Current A R W SETUP MENU Parameter Name Val Description UM Mode P023 H17 2 Firing mode Selection R W P066 H42 20 HB sensitivity R W P070 H46 12 Feed back selection R W P083 H53 82 Burst Firing Setting available only with Burst Firing Cycles R W P085 H55 0 100 delay triggering R W P090 H5A 12 Analog Digital current limit selection R W P091 H5B 100 02 Internal current limit value R W P098
32. lue equal to its current value is a valid transaction this will not cause an error response CD3000E 2PH User s Manual from 25A to 700A 60 14 7 Modbus parameters P001 H01 Status Code Alarm R Function This read only information gives following alarms that stop CD3000E Value 00 NO Alarm 01 Phase lost 02 Wrong phase rotation 40 Heatsink over temperature P002 H02 Status Code Alarm R Function This read only information gives following alarms Value 00 NO Alarm x1 Thyristor Failure x2 Heater Break failure x4 Unbalanced load P003 H03 Local remote Set point selection R W Function Select if the command is remote analog signal on terminals 7 8 or local signal generated by parameter P004 Value 1 local reference from parameter P004 0 remote reference from main analog input signal terminal 7 8 Default 0 Note The parameter is not memorized in EEPROM P004 H04 Local Set point value R W Function Local reference signal active with P003 1 Min Max 0 100 Default 0 Note The parameter is not memorized in EEPROM P008 H08 Remote Set point value R Function This parameter reads in the reference signal on input 1 terminals 7 8 Min Max 0 100 Example Input 4 mA P008 0 Input 12 mA P008 50 Input 20 mA P008 100 P011 H0B
33. ly is flashing apply 10V for 0 10V input or 20mA for 4 20mA input Now press CAL Key again Now press CAL Key again Release key when red and yellow led are ON Yellow and red leds are flashing 2sec S C S C H B M B H B M B S C H B M B S C H B M B 0 Signal 100 Signal CD3000E 2PH User s Manual from 25A to 700A 42 11 3 3 Secondary input Terminal 9 This analogue input 0 10V may be configured for External current limit profiling from 25 to 200A from 275 to 700A Type P090 JP3 External current limit profiling 0 A B Type P090 JP20 External current limit profiling 0 A B If you want to set the current limit via analog input with on board potentiometer set the jumpers as showed below Tuning on CD3000E from 25 to 200A Tuning on CD3000E from 275 to 700A Type P090 JP3 JP4 Internal current limit profiling 0 Ope n Close Type P090 JP2 0 JP1 1 Internal current limit profiling 0 Open Close C B A C B A A B A JP JP JP1 JP2 CD3000E 2PH User s Manual from 25A to 700A 43 11 4 Analog outputs Terminal 10 Warning this procedure can be done just by specialized personnel The thyristor unit is delivered configured and tuned in line with customer requirements If it s necessary to change the configuration on site proceed as below specified On CD3000E i
34. nges can be made interactively without powering down the unit removing the need to open the cabinet or to stop the process CD3000E 2PH User s Manual from 25A to 700A 10 2 3 Clone facility using CD EASY CD EASY is a Memory Support used by maintenance personnel in the shop floor The Clone Facility makes it possible to copy the configuration of one Thyristor Unit and paste it into another in a matter of seconds The CD EASY can be loaded with the standard unit operating configuration and stored together with the system drawings in a convenient place enabling unit reconfiguration within seconds if required For CD KP and CD EASY are available Maintenance Manuals on www thinkthyristors com CD3000E 2PH User s Manual from 25A to 700A 11 2 4 Configurator You can download the free software and the Configurator Manual from our web site www cdautomation com If the CD3000E code is in line with your requirement providing that the Operating voltage and Load current are inside the code the CD3000E has been already configured in our Factory and you are ready to run You need software tools only to modify the ordered configuration Anyway we suggest to check the unit on the machine with the test section To install the software download it from the website launch the installation program and follow the instruction on the screen To configure the unit you can use the standard communication port RS485 on terminals blocks or u
35. omagn tique 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 All thyristor switching at high speed generate some radiofrequency disturbance CD3000E serie compliance with EMC rules for CE mark In many installations near electronic devices has not been noted problems If radiofrequency devices at low frequency are used near the thyristor unit some precautions should be taken like line filters and shielded cables for input signal and for load cables NOTES We reserves the right to apply modifications to the our products without any advice The thyristor unit must be mounted vertically and with no obstruction above and below to allow a good flow ventilation When mounted side by side leave a gap of 15 mm between the units Hot air of one thyristor unit must not invest the unit positioned above The maximum cabinet temperature must not exceed 45 C A suitable electromechanical device must ensure that the unit can be electrically isolated from the incoming line supply C US LISTED UL CD3000E 2PH User s Manual from 25A to 700A 7 CD3000E 2PH User s Manual from 25A to 700A 8 2 Introduction CD3000E is a three phase Thyristor unit designed to control resistive or inductive loads incl
36. omething is wrong the CD3000E stops itself and open the relay contact If all is OK and there is an input signal the system will give an output following a ramp in line with the time setted in parameter P024 if ramp is used Opening run selector the CD3000E will go to zero output following a ramp in line with the time setted in parameter P025 Only when the output is equal to zero the RUN relay is de energized opening the contacts between terminals 13 and 14 11 5 3 Cal Unit Terminal 19 see par 7 4 Use a free voltage momentary contact normally open To work in best conditions the unit needs a current calibration and heater break calibration This procedure starts by closing CAL or setting via RS485 using software configurator The calibration procedure is performed in this mode The CD3000E gives the maximum voltage output The value of the voltage and current is stored in memory After which CD3000E comes back to the initial situation This procedure is requested with new installation or when load is changed CAUTION before to do this procedure set the nominal load current with the parameter P119 The CAL input is used also for the Input calibration procedure see par 11 3 2 CD3000E 2PH User s Manual from 25A to 700A 45 11 5 4 Configurable input Terminal 20 see par 7 4 Use a free voltage contact normally open NO This digital input may be configured fo
37. ored in memory current value of the three different phases this alarm is associated to digital output on terminal 16 The Heater Break circuit to work properly must have at least an input of 25 of the nominal current If the programmable alarm digital output is set with HB alarm P112 1 when the LEDs HB or SC is lighted this output goes to 0Vdc and its relay is energized All parameters may be adjusted via serial link using Thyristor Configurator 9 6 1 Calibration An automatic function sets the Heater Break Alarm The auto setting function can be activated using the digital input Cal terminal 19 or via serial link The Heater Break procedure is performed in this way The CD3000E gives the maximum voltage output The values of voltage and current are stored in memory After which CD3000E comes back to the initial situation If the CD3000E is working and one of the load resistances fails the current drops below the current set point set automatically or with parameter P066 and after a given delay the output alarm is activated 9 6 2 Heater Break sensitivity P066 The Heater Break sensitivity is set in parameter P066 in percentage The range goes from 0 0 to 100 0 The default value is 20 This means that if current drop is over 20 the alarm occurs CD3000E 2PH User s Manual from 25A to 700A 33 10 Types of firing mode
38. ost significant byte N B Reversed order applies so CRC16 returns Reversed bit order CD3000E 2PH User s Manual from 25A to 700A 57 C Language CRC 16 Example static short CRC16 unsigned char p_first unsigned char p_last unsigned int crc 0xffff short j for p_first lt p_last p_first crc p_first for j 8 j gt 0 j if crc amp 0x0001 crc crc gt gt 1 crc 0xA001 else crc crc gt gt 1 return crc CD3000E 2PH User s Manual from 25A to 700A 58 14 4 Read holding registers read n words Function 03 The message sent to the unit to obtain the value of one or more registers comprises the following eight bytes Addr Unit Func Addr of 1 Word N of Word CRC 16 3 3Hex HI LO HI LO LO HI The normal reply will echo the first two characters of the message received followed by a single byte data byte count which will not include itself or the CRC For this message the count value equals the number of parameter values read multiplied by two Following the byte count the specified number of parameter values are transmitted followed by the CRC16 bytes Addr unit Func Cont 1 Value Last Value CRC 16 3 3Hex HI LO HI LO LO HI 14 5 Preset multiple registers write n words Function 16 This is an eleven byte message only one parameter may be written for each received message The usual pre amble is followed by the addre
39. r one of following purposes Additional Reset alarm status To switch On off the unit maintaining the terminals 13 14 closed unit in running Feed Back Selection Ex The unit start with V feed back and revert to VxI when digital input is activated Local Remote set point selection The above functionality is done with parameter P103 11 5 4 1 Alarm reset P103 0 When an alarm occurs use reset to clear the alarm If the fault remains the alarm status come back If the fault has been overcome the alarm does not appear again 11 5 4 2 On off option P103 1 If the user gives this command terminals 4 20 closed the voltage output falls to zero also if the terminals 13 14 are closed unit in run condition When the user opens the terminals 4 20 the power output goes to the set point value 11 5 4 3 Feed Back Selection P103 2 If the user gives this command terminals 4 20 closed the unit works in V feed back When the user removes the command teminal 4 20 open the unit works with the feed back selected via configuration Example With silicon Carbide elements to avoid to reach high voltage when element are cold CD3000E start with voltage feed back and switch to power feed back when the heating elements are in temperature 11 5 4 4 Local Remote set point selection P103 3 If the user gives this command terminals 4 20 closed the unit works in
40. rms value on phase T P066 H42 HB sensitivity R W Function This parameter set the drop of current over which the HB alarm became active This value is in percentage with reference to the nominal resistance of the load Min Max 0 0 100 0 Default 100 0 Example Nominal current 100A P066 20 This means that the Heather Break Alarm became active when current goes below 80A P070 H46 Feed back selection R W Function It Selects the type of feed back on the main loop Value 1 voltage feed back rms value 2 power feed back VxI Default 1 Note value of feed back are the average value on the three phase R S T P083 H53 Burst Firing Setting available only with Burst Firing R W Function It defines the number of voltage cycles in ON condition at 50 of power demand Min Max 0 256 cycles Default 8 P085 H55 Delay triggering R W Function This parameter set delay firing in Min Max 0 100 Default 0 P090 H5A Analog Digital current limit selection R W Function This parameter select if the current limit of CD3000E is from Analog or Digital signal Digital is setted with parameter P091 Value 0 Analog current limit from main analog input see par 9 5 1 1 Digital current limit from parameter P091 Default 1 Note Parameter is stored in memory CD3000E 2PH User s Manual from 25A to 70
41. rofile 0 10V 10 Analogue output Max 20mA Min 500 11 RS485 B size S9 and S10 CONF relay contact Max 300mA 230V size S14 12 RS485 A size S9 and S10 CONF relay contact Max 300mA 230V size S14 13 RUN relay contact Max 300mA 230V 14 RUN relay contact Max 300mA 230V 15 NPN output 12Vdc 20mA max Critical Alarm 16 NPN output 12Vdc 20mA max Programmable Output 17 Reset alarm Digital input1 18 Start Unit Digital input2 19 Calibration Unit Digital input3 20 Configurable input Digital input4 Auxiliary terminals Auxiliary terminals CD3000E 2PH User s Manual from 25A to 700A 25 7 5 Diagram of control connection from 25 to 200A Warning this procedure can be done just by specialized personnel Size S9 and S10 Control Sync Voltage Current T1 T2 T3 L1 L2 L3 5 Internal Fan M K1 20 19 18 17 4 Reset Start Cal Config Input Gnd 12V 12V Serial port 12 11 13 14 7 10 6 V mA 1 2 Heatsink over temperature switch 4 15 16 6 8 10V 7 Input Current profiler 9 Input 6 7 To Load B A RS485 3ph ac 50 60Hz 480Vmax Auxiliary voltage Critical Alarm KA2 KA3 HB Relay 12V max 20mA 0V mA Vdc 0V 10Vdc Power indicator Just one indicator 0 10Vdc 10 7 or 4 20mA 10 6 To Run contact Semiconductor High speed fuses 1 2 Run
42. s available one analogue output 0 10V max 20mA or 4 0mA or 0 0mA 500ohm that represents the average power on the three phases from 25 to 200A from 275 to 700A Type P097 JP2 0 10V 0 A B 0 20mA 0 B C 4 20mA 1 B C Type P097 JP21 0 10V 0 A B 0 20mA 0 B C 4 20mA 1 B C 6 7 8 9 10 MONITOR 1 AO1 Output 0 10V Output 4 20mA 6 7 8 9 10 MONITOR 1 AO1 A digital filter is provided for discontinuous measures i e BURST firing The parameter P104 is a number that we have to write and is equal to full scale value of indicator Example Power indicator full scale 50KW P104 50 C B C B CD3000E 2PH User s Manual from 25A to 700A 44 11 5 Digital Input CD3000E thyristor unit has 4 opto isolated digital inputs 11 5 1 Reset Alarm Terminal 17 see par 7 4 Use a free voltage instantaneous contact normally open reset When an alarm occurs use reset to clear the alarm If the fault remains the alarm status come back If the fault has been overcome the alarm does not appear again 11 5 2 Start command Terminal 18 see par 7 4 Before give the Start command supply the auxiliary voltage to the terminals 1 and 2 With the Start command the relay is activated and close his contact between the terminals 13 and 14 The CD3000E verifies the presence of the three phases and their rotation If s
43. sary also when there is a power feed back CD3000E 2PH User s Manual from 25A to 700A 65 15 Maintenance 15 1 Fans The thyristor unit with forced ventilation uses fans that rotate permanently when the unit is supplied In case of accidental fan failure there is an over heating temperature on heatsink 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 heatsink 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 2 Servicing In order to have correct cooling the user must clean the heatsink and the protective grill of the fans The frequence of this servicing depends on environmental pollution Also check periodically if the screw for the power cables and safety earth are tightened correctly 15 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 refer Use a rugged packaging to ship the unit 15 4 Warranty condition CD Automation gives a 12 months warranty to
44. se the programming Cable and plug it inside the PG connector see par 11 8 Connect the other side of the programming cable to the PC RS232 9PIN serial port Set the PC serial port like the parameters P114 and P115 CD3000E 2PH User s Manual from 25A to 700A 12 3 Quick Start Attention this procedure must be carried out by skilled people only If your CD3000E code is in line with what you really need then the main configuration is already done by CD Automation and you just need to do the following steps 1 Verify CD3000E s current sizing Be sure that the load current is equal or less than the nominal one of CD3000E the main voltage is equal or less than the nominal voltage of CD3000E 2 Verify the Product code 3 Verify the Installation 4 Verify the Wiring all auxiliary connections must be done in line with wirings on this manual verify that there isn t a short circuit on the load 5 Supply the auxiliary voltage of the unit 6 Set the parameters P116 and P119 using the software tool P116 H74 Operative Voltage V R W Function It s necessary to specify the operative voltage Min Max 24 1000V Default 400 Note CD3000E with voltage out of range 342V to 602V needs hardware modifications specify this in phase of ordination P119 H77 Load nominal current A R W Function It s necessary to specify
45. ss of the parameter to be written a two byte word count always set to 1 a single byte byte count always set to 2 the value to be written and the CRC16 bytes Addr unit Func Addr of 1 Word N of Word Cont Valore CRC 16 16 10Hex HI LO 0 1 2 HI LO LO HI The unit normally responds with the following eight bit reply Addr unit Func N of Word N Word CRC 16 16 10Hex HI LO 0 1 LO HI CD3000E 2PH User s Manual from 25A to 700A 59 14 6 Error and exception responses If a received message contains a corrupted character parity check failure framing error etc or if the CRC16 check fails or if the received message is otherwise syntactically flawed e g byte count or word count is incorrect the CD3000E will ignore that message If the received message is syntactically correct but nonetheless contains an illegal value the thyristor will send a five byte exception response as follows Addr unit Func N Exception CRC 16 LO HI The Function Number byte contains the function number contained in the message which caused the error with its top bit set i e Function 3 becomes 0x83 and the Exception Number is on of the following codes Code Name Cause 1 ILLEGAL FUNCTION Function number out of range 2 ILLEGAL DATA ADDRESS Parameter ID out of range or not supported 3 ILLEGAL DATA VALUE Attempt to write invalid data required action not executed NOTE Writing a parameter va
46. t circuit P113 0 HB active P113 1 Unbalanced load P113 2 Voltage Low P113 3 C B A CD3000E 2PH User s Manual from 25A to 700A 49 11 7 RS485 serial connection The serial communication port is on terminal block and on 9 pin DIN connector On this port may be done a network up to 255 CD3000E On 9Pin DIN connector it s possible to use the CD EASY facility see par 2 3 Terminal Description 11 RS485 B 12 RS485 A Terminal Description 4 RS485 B 3 RS485 A Pin 1 PMS5 5V Pin 2 GND 0V Pin 3 GND 0V Pin 4 Reserved Rxd0 Pin 5 GND 0V Pin 6 RS485 A Pin 7 RS485 B Pin 8 nc Pin 9 Reserved Txd0 5 1 6 9 CD3000E 2PH User s Manual from 25A to 700A 50 11 8 PG Connector The programmer port PG is used to configure the thyristor unit with the configuration software and with the programmer cable PG Connector CD3000E 2PH User s Manual from 25A to 700A 51 12 Fuses and Fuseholder 12 1 Fuses and Fuse Code CD3000E unit must be protected by fuses against short circuit selecting the proper I t that must be lower than the thyristor one The same caution must be taken if Circuit Breaker is used Remember that is very difficult to protect the thyristor if this choise is done WARNING USE SEMICONDUCTOR FUSES ONLY WITH proper I2t SIZE I T max A sec THYRISTOR Fuse CODE I T
47. uding three phase transformers The current range is from 25A to 700A and the voltage range is from 24 to 600 Volt The electronic control circuit of CD3000E is full digital and is based on a powerful microprocessor RISC Embedded 16 Bit with high performance 2 1 Advantages compared with analog thyristor unit CD3000E 2PH is an universal thyristor unit and the same unit can work in different modes Burst Firing Delayed triggering On same unit can be used different fedd back that define the control mode Voltage Power VxI On same unit can be used different input Analog 4 20mA Analog 0 10V Potentiometer Communication RS485 that is a standard feature In addition CD3000E 2PH can be connected via RS485 to an Industrial Personal Computer On serial link are available many information like voltage current power load status and all the parameters for diagnostic and configuration Tele service and clone facility is also available The advantages over the analog and non Full digital versions are flexibility and the possibility to implement special features without to change any Hardware Several strategies can be implemented and selected via the parameter on serial link All these features are not available on analog thyristor unit that use also small micro just to perform dedicated task Ex for Heater Break Alarm CD3000E 2PH User s Manual from 25A to 700A 9
48. umber Broadcast messages are supported at address 0 to which the CD3000E responds by taking some action without sending back any reply Data is transmitted as eight bit binary bytes with one start bit one stop bit and parity checking set to none A message is terminated simply by a delay of more than three character lengths at the Baud rate used any character received after such a delay is considered to be the potential address at the start of a new message CD3000E 2PH User s Manual from 25A to 700A 56 Since only the RTU form of the protocol is supported each message is followed by a two byte CRC 16 a 16 bit cyclic redundancy checksum This checksum is calculated in accordance with a formula which involves recursive division of the data by a polynomial with the input to each division being the remainder of the results of the previous division The dividing polynomial is 216 215 22 1 Hex 18005 but this is modified in two ways because the bit order is reversed the binary pattern is also reversed making the most significant bit MSB the right most bit only the remainder is of interest the right most most significant bit can be discarded Thus the polynomial has the value Hex A001 Bit order Normal bit order Most significant bit Least significant bit Most significant byte Least significant Byte Reversed bit order Least significant bit Most significant bit Least significant Byte M
49. ure by closing contacts 4 19 CD3000E 2PH User s Manual from 25A to 700A 37 11 Connection description 11 1 Electronic boards To have access to the electronic boards the user must open the unit s cover see par 7 1 Warning this procedure can be done just by specialized personnel CD3000E MP board CD3000E 2PH User s Manual from 25A to 700A 38 11 1 1 Jumper s position on CD3000E MP board The jumper s position changes in function of the CD3000E size The control board and the jumper s position on CD3000E from 25 to 200A The control board and the jumper s position on CD3000E from 275 to 700A JP JP JP JP JP20 JP2 JP2 JP1 JP JP2 JP2 CD3000E 2PH User s Manual from 25A to 700A 39 11 2 Auxiliary power supply connections The auxiliary voltage supplies the electronic board and the fan so check the nominal voltage on the label Terminal Description 1 Auxiliary voltage supply 120 240V for the electronic board and fans 2 Auxiliary voltage supply 120 240V for the electronic board and fans 11 3 Analog inputs CD3000E thyristor unit has an analogue input to drive the output power and a second analogue input that can be configured for external current profiling CD3000E units are delivered already configured in line with customer requirements that are defined in the complete product code The product code is written on the identification label Before to operate
50. ure where if non executed properly can cause serious accident and loss of life of the operator Attention This icon is present in all operative procedure where if not executed can cause faults to the thyristor unit Thyristor units are used in power industrial equipment When the thyristor unit is working there are on the unit the following voltages Maximum main supply voltage on power terminals up to 600 V Auxiliary supply 230 460Vac Fan voltage 230Vac 50 60Hz Don t remove the cover which provides adequate protection against electric shock Don t use this thyristor units in aerospace and nuclear application Electric Shock Hazard Risque the choque lectrique When thyristor unit has been connected to main supply voltage and is switched off before to touch it be secure that the unit is isolated and wait at least one minute to allow to discharge internal capacitors Thus be secure that access to thyristor unit is only permitted to specialised personnel the authorised personnel must read this manual before to have access to the unit the access to the units must be denied to unauthorised personnel Important warnings attention Local regulations regarding electrical installation should be rigidly observed Safety regulations must be rigidly observed Don t bend components to maintain insulation distances Protect the units from high temperature humidity and vibrations s
51. ve When one of these alarms is active the terminal 16 is at 0V The user can connect a PC to the unit via RS485 to discriminate the alarm type 9 5 Current limit see par 11 3 3 To tune it proceed as below described Disconnect from main supply voltage CD3000E Move the current limit potentiometer fully anti clockwise Switch ON CD3000E again Set the input signal at 100 value Increase current limit potentiometer up to when the desired value of current is reached The current limit procedure is finished 9 5 1 Current limit set The current limit can be setted via digital mode with RS485 or via analog input with on board potentiometer or external reference P090 0 Current limit profiling with analog input internal or external 1 Current limit profiling in digital mode via RS485 P091 Set the max current from 0 to 100 If you choose to have the current limit profiling in digital mode via RS485 set the P090 parameter to 1 If you choose to have the current limit profiling with external analog input via terminals 7 9 or internal potentiometer set the P090 parameter to 0 and set properly the jumpers as showed in paragraph 11 3 3 CD3000E 2PH User s Manual from 25A to 700A 32 9 6 Heater break alarm and scr short circuit The Heater Break Alarm is a circuit to diagnostic partial or total load failure sensibility better than 20 alarm st
Download Pdf Manuals
Related Search