CD Automation 1100A User manual

CD Automation S.r.l.
Via Picasso 34/36 - 20025 –Legnano (MI) –ITALY
Tel [phone] –Fax [phone]
E-Mail: [e-mail] - WEB: www.cdautomation.com
Custom HP 2Ph
Solid State Relay
1100A –1400A
1700A-1900A-2100A
USER’S MANUAL
Rev. 02/2015
00005

Custom HP User’s Manual
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1 Important warnings for safety .............................................................................................. 6
2 Note ...................................................................................................................................... 7
3 Quick Start ............................................................................................................................ 8
4 Basic Connections and sizing ................................................................................................ 9
5 Identification and Order Code ............................................................................................. 10
5.1 Identification of the unit 10
5.2 Order code 11
6 Technical Specifications ...................................................................................................... 12
6.1 General features: 12
6.2 Input features: 12
6.3 Output features 600V 12
6.4 Output features 690V 12
6.5 Environmental installation conditions 13
6.6 Derating Curve and Thermal conditions 13
6.7 Calculating flow capacity of the fan 13
7 Installation ......................................................................................................................... 14
7.1 Dimensions and Weight 15
7.2 Fixing holes 15
8 Wiring instructions ............................................................................................................. 16
8.1 Terminals Positions 16
8.2 Power Terminals 17
8.3 IP20 Cover OPTION 19
8.3.1 Removing the IP20 cover ............................................................................................. 19
8.3.2 IP20 Cover dimension.................................................................................................. 19
8.4 Power cable dimensions (suggested) 20
8.5 Cable dimensions (suggested) of Earth and of the Command Terminals 20
8.6 Commmand Terminals 21
8.6.1 Terminal M5 ............................................................................................................... 21
8.6.2 Terminal M4 ............................................................................................................... 21
8.6.3 Terminal MX 1-2 ......................................................................................................... 21
8.6.4 Terminal M9 ............................................................................................................... 22
8.6.5 Terminal M8 ............................................................................................................... 22
8.7 Fan Supply For Each Phase (MX1 –MX2) 22
8.8 Thermal Switch For Each Phase (MX1 –MX2) 22
8.9 Schematic 23
8.10 Connection Diagram for 3 phases (control on 2 phases) 24
9 Acces to the Electronic Board.............................................................................................. 25
10 Supply the Electronic Board .............................................................................................. 26
10.1 Fuse Board protection 27
11 Control Input type setting................................................................................................. 28
12 Input output signal ........................................................................................................... 29

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12.1 Digital Input 29
12.1.1 Configurable Inputs (Terminal 1 -2 of M5) ................................................................... 29
12.2 Digital Output 29
12.2.1 Configurable Outputs (Terminal 12 -13-14 and 15-16-17 of M5): ................................... 30
13 Heater Break alarm and SCR short circuit (HB Option) ......................................................31
13.1 Heater break Calibration procedure 31
13.2 HB alarm contact 31
14 Control Panel.....................................................................................................................32
14.1 Scroll the parameters 33
14.2 Operator Menu 34
14.3 Setup Menu 35
14.4 Hardware Menu 36
14.5 Displayed Alarms 37
15 Firing type .........................................................................................................................38
15.1 Zero Crossing (ZC) 38
15.2 Burst Firing (BF) 38
16 Internal Fuse.....................................................................................................................39
17 Maintenance ......................................................................................................................40
17.1 Warranty condition 40

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Dichiarazione di Conformità
Declaration of Conformity
The manufacturer
Dichiara che il prodotto:
Declare that the product:
Custom HP, 2ph 1100A-1400A-1700A-1900A-2100A
FULFILS THE REQUIREMENTS OF THE STANDARD:
Electrical safety Standard EN60947-1 :2008
EN60947-4-3:2001
Generic Emission standard EN60947-4-3:2000
Generic Immunity standard EN60947-4-3:2000
The manufacturer declares that The products above mentioned they am conforming to the directive
EMC 2004/108/CEE e alla direttiva Bassa Tensione (low Voltage) 2006/95/CEE
PRODUCT DESCRIPTION: Elettric power ontrol
SCOPE OF APPLICATION: Thermal ontrol process
Issued on: 20/04/2010
Signed:

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1Important warnings for safety
This chapter contains important information for the safety. The not observance of these instructions may
result in serious personal injury or death and can cause serious damages to the Thyristor unit and to the
components system included.
The installation should be performed by qualified persons.
The Thyristor unit are integral part of industrial equipments. When it is supply, the
Thyristor unit is subject to dangerous tensions.
Don't remove the protection Cover.
Don't use these unit in aerospace applications and/ or nuclear.
The nominal current corresponds to use at temperature not superior to 45°C.
The Thyristor unit must be mounted in vertical position and without obstruction above
and below to allow a good flow ventilation.
The hot air of one thyristor unit must not invest the unit positioned above.
For side by side placed leave a space of 15mm between the unit.
A suitable device must ensure that the unit can be electrically isolated from the supply, this
allows the qualified people to work in safety.
Protection (Protection, Protezione)
The unit have IP20 protection rating as defined by the specific international. Is necessary
consider the place of installation.
Earth (Terre, Messa a terra)
For safety, the Thyristor unit with isolated heat-sink must be connected to earth.
Earth impedance should be correspondent to local earth regulation. Periodically the earth
efficiency should be inspected.
Electronic supply (Alimentation électronique, Alimentazione elettronica)
The electronic circuit of the Thyristor unit must be supplied by dedicated voltage for all
electronic circuits and not in parallel with coil contactors, solenoids and other.
It's recommended to use a shielded transformer.
Electric Shock Hazard (Risque de choque électrique, Rischi di scosse elettriche)
When the Thyristor unit is energized, after the power supply is shut off, wait least a minute
for allow the discharge of the internal capacitors where there is a dangerous tension. Before
working, make sure that:
Only authorized personnel must perform maintenance, inspection, and replacement
operations.
The authorized personnel must read this manual before to have access to the unit.
Unqualified People don't perform jobs on the same unit or in the immediate vicinities.

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Important warnings (Attention, Avvertenze importanti)
During the operations with units under tension, local regulations regarding electrical
installation should be rigidly observed:
Respect the internal safety rules.
Don't bend components to maintain insulation distances.
Protect the units from high temperature humidity and vibrations.
Don't touch components to prevent electrostatic discharges on them.
Verify that the size is in line with real needs.
To measure voltage current etc. on unit, remove rings and other jewels from fingers
and hands.
Authorized personnel that work on thyristor unit under power supply voltage must be
on insulated board
This listing does not represent a complete enumeration of all necessary safety cautions.
Electromagnetic compatibility
(Compatibilità électromagnétique, Compatibilità elettromagnetica)
Our thyristor units have an excellent immunity to electromagnetic interferences if all
suggestions contained in this manual are respected. In respect to a good Engineering
practice, all inductive loads like solenoids contactor coils should have a filter in parallel.
Emissions (Emission, Emissioni)
All solid-state power controllers emit a certain amount of radio-frequency energy because
of the fast switching of the power devices.
The Thyristor unit are in accord with the EMC norms, CE mark.
In most installations, near by electronic systems will experience no difficulty with
interference. If very sensitive electronic measuring equipment or low-frequency radio
receivers are to be used near the unit, some special precautions may be required. These
may include the installation of a line supply filter and the use of screened (shielded) output
cable to the load.
2Note
Warning: This icon is present in all the operational procedures where the Improper
operation may result in serious personal injury or death
Caution: This icon is present in all the operational procedures where the Improper
operation can cause damage for the Thyristor unit.
Producer reserves the right to modify the own products and this manual without any
advise.

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3Quick Start
Attention: this procedure must be carried out by skilled people only.
If your Custom HP code is in line with what you really need, then the main configuration is already done
by Producer and you just need to do the following steps:
1. Verify Custom HP’s current sizing. Be sure that:
the load current is equal or less than the nominal one of Custom HP
the main voltage is equal or less than the nominal voltage of Custom HP
2. Verify the Installation
3. Verify the Wiring:
all auxiliary connections must be done in line with wirings on this manual
verify that there isn’t a short circuit on the load
4. Supply the auxiliary voltage of the unit
Give the main voltage supply.
Enable the unit.
Activate the test(calibration) input terminal 2 on M5 to start the tuning load procedure.
The tuning procedure supply 100% of voltage to the load for 10sec. and set in
automatically mode:
The load current  paremeter
The voltage on load paremeter.
Set Heater break value setpoint
This procedure must be done the real real load connected!
The tuning of the load can be done also manually by setting the
the parameters  (Operative Voltage) and P_Lo (Nominal Power of the load) using the
frontal keypad.

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4Basic Connections and sizing
Star wiring with resistive load
V
P
I731, 
V = Nominal voltage of the load
I = Nominal current of the load
P = Nominal power of the load
V
I
Delta wiring with resistive load
V
P
I731, 
V = Nominal voltage of the load
I = Nominal current of the load
P = Nominal power of the load
V
I

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5Identification and Order Code
5.1 Identification of the unit
Caution: Before to install, make sure that the Thyristor unit have not damages. If the product
has a fault, please contact the dealer from which you purchased the product.
The identification’s label give all the information regarding the factory settings of the Thyristor unit, this
label is on the unit, like represented in figure.
Verify that the product is the same thing as ordered .

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5.2 Order code

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6Technical Specifications
6.1 General features:
Utilization Category
AC-51
IP Code
00 (ip20 on request)
Method of Connecting
Load in Delta, Load in Star
Auxiliary voltage available:
(see order code)
90:130V (10 VA Max)
170:265V (10 VA Max)
230:345V (10 VA Max)
300:530V (10 VA Max)
510:690V (10 VA Max)
Relay output alarm:
0.5A a 125VAC
6.2 Input features:
Logic input SSR:
4 ÷ 30Vdc 5mA Max (ON 4Vdc OFF 1Vdc)
Volt Analogic input
0 ÷ 10Vdc impedance 15 K ohm
Current Analogic input
0 ÷ 20mA impedance 100 ohm
4 ÷ 20mA impedance 100 ohm
POT
10 K ohm min.
Digital Input
4 ÷ 24Vdc 5mA Max (ON 4Vdc OFF 1Vdc)
6.3 Output features 600V
Current
Nominal
Voltage
range
(Ue)
Repetitive
peak reverse
voltage
(Uimp)
Latching
current
Max peak
one cycle
Leakage
current
I2T value
max
Frequency
range
Power
loss
(A)
(V)
(480V)
(600V)
(mAeff)
(10msec.)
(A)
(mAeff)
tp=10msec
(Hz)
I=Inom
(W)
1100A
24÷690
1600
1600
700
12500
300
781x1E3
47÷70
2912
1400A
24÷690
1800
1800
700
22400
300
2509x1E3
47÷70
3352
1700A
24÷690
1800
1800
700
22400
300
2509x1E3
47÷70
4338
1900A
24÷690
1600
1600
700
26900
300
3618x1E3
47÷70
4268
2100A
24÷690
1800
1800
700
36000
300
6480x1E3
47÷70
4708
6.4 Output features 690V
Current
Nominal
Voltage
range
(Ue)
Repetitive
peak reverse
voltage
(Uimp)
Latching
current
Max peak
one cycle
Leakage
current
I2T value
max
Frequency
range
Power
loss
Number of
fans
(A)
(V)
(480V)
(600V)
(mAeff)
(10msec.)
(A)
(mAeff)
tp=10msec
(Hz)
I=Inom
(W)
1100A
24÷690
2200
2200
700
36000
300
6480x1E3
47÷70
2374
Two Fans
150W
(75W x 2 Fan)
1400A
24÷690
2200
2200
700
36000
300
6480x1E3
47÷70
3224
1700A
24÷690
2200
2200
700
36000
300
6480x1E3
47÷70
4160
1900A
24÷690
2200
2200
700
36000
300
6480x1E3
47÷70
4834

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6.5 Environmental installation conditions
Ambient temperature
0-40°C at nominal current. Over 40°C use the derating curve.
Storage temperature
-25°C a 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
Pollution Level
Up to 2nd Level ref. IEC 60947-1 6.1.3.2
6.6 Derating Curve and Thermal conditions
The nominal current of the units in specification are referred to continuos service at 40 ambient
temperature. For higher temperature multiply the nominal current times derating coefficient K below
Represented:
6.7 Calculating flow capacity of the fan
All the thyristor units when are in conduction produces power loss that is dissipated inside cubicle in
terms of heating. Due to this fact the internal temperature of cubicle is higher than ambient
temperature. To be cooled the thyristor need of fresh air cooling and to do it is normally used a fan
mounted on the front door or on the roof of the cabinet.
Procedure to size Fan air mass flow (V): see power loss for each thyristor and fuse mounted
indicated in the manual related to the current (Output feature and Internal fuse Chapter)
Qv= total power losses (w)
(thyristor + fuse power loss)
ta= ambient temperature (°C)
tc= cabinet temperature (°C)
V= fan air mass flow (m3/h)
f= altitude coefficient (see table on right)
Altitude
0:100 meters f= 3.1 m3k/Wh
100:250 meters f=3.2 m3k/Wh
250:500 meters f=3.3 m3k/Wh
500:750 meters f= 3.4 m3k/Wh
The formulas used are for information only and is not a substitute for a proper thermal rating
done by a qualified person.
tatcQv
f *V

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7Installation
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.
Verify that the product is the same thing as
ordered.
The Thyristor unit must be always mounted in
vertical position to improve air cooling on heat-
sink.
Maintain the minimum distances in vertical and in
horizontal as represented, this area must be free
from obstacle (wire, copper bar, plastic channel).
When more unit has mounted inside the cabinet
maintain the air circulation like represented in
figure without obstacle for the air flow.
Is necessary to install a fan to have better air
circulation as calculated previously.

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7.1 Dimensions and Weight
1100A A: 550mm Weight: 49 Kg
1400-1700-1900-2100A A: 650mm Weight: 60 Kg
7.2 Fixing holes
1100-1400A A: 217,5mm
1700-1900-2100A A: 267,5mm

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8Wiring 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 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.
Use copper cables and wires rated for use at 75°C only.
8.1 Terminals Positions

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8.2 Power Terminals
Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.
Terminal
Description
L1
Line Input Phase 1
L2
Line Input Phase 2
T1
Load Output Phase 1
T2
Load Output Phase 2

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600V
1100-1400A A: 124mm B: 54,5mm C: 140,5mm D: 150,5mm
1700-1900-2100A A: 125mm B: 52,5mm C: 142,5mm D: 151,5mm
690V
1100-1400A A: 136mm B: 42,5mm C: 152,5mm D: 150,5mm
1700-1900-2100A A: 137mm B: 40,5mm C: 154,5mm D: 151,5mm
1100A A: 315mm B: 220mm
1400-1700-1900-2100A A: 365mm B: 270mm

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8.3 IP20 Cover OPTION
8.3.1 Removing the IP20 cover
For each phase:
*1 Unscrew the two bottom M6 screws.
*2 Pull out the bottom cover.
*3 Unscrew the two upper M6 screws.
*4 Pull out the upper cover.
8.3.2 IP20 Cover dimension
600V
1100A A: 64mm B: 10mm
1400-1700-1900-2100A A: 65mm B: 11mm
690V
1100A A: 78mm B: 10mm
1400-1700-1900-2100A A: 79mm B: 11mm

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8.4 Power cable dimensions (suggested)
Supply
Load
Current
Bar type
Screw
Bar type
Screw
M
mm²
AWG
M
1100-1400A
Bus Bar 50x6mm
4xM8
Bus Bar 50x6mm
4xM8
1700-1900-2100A
Bus Bar 50x8mm
4xM8
Bus Bar 50x8mm
4xM8
8.5 Cable dimensions (suggested) of Earth and of the Command Terminals
Earth
Command Terminals
Current
Cable
Screw
Cable
mm²
AWG
M
mm²
AWG
1100
95
3/0
M8
0,50
18
1400
120
4/0
M8
0,50
18
1700-1900-2100A
2x95
2x3/0
M8
0,50
18