CD Automation CD3000M 2PH Series User manual

USER’S MANUAL
Rev. 12/2004
CD3000M-
2PH
THYRISTOR UNIT
Up To100A
CD Automation S.r.l.
Via Picasso 34/36 -20025 –Legnano (MI) –ITALY
Tel [phone] –Fax [phone]
E-Mail: [email protected] -WEB: www.cdautomation.com

CD3000M-2PH Thyristor Unit up to 100A
Index:
1. Glossary 4
1.1 Terminology 4
1.2 Input signal 4
1.3 Power feed back 4
1.4 What is a thyristor unit 4
2. Technical specifications 5
2.1 General Features: 5
2.2 Input features 5
2.3 Output features 6
2.4 Derating curve 6
3. Ordering information 7
4. Installation and wiring information 8
4.1 Identification of the unit 8
4.2 Installation 8
4.3 Dimensions 9
4.4 CT dimensions (Heater Break HB) 9
4.5 Fixing Holes 10
5. Wiring Instructions 11
5.2 Cabling detail 12
5.3 Wiring connections 14
5.4 LED Status Table 17
6. Start up 18
6.1 To remove the board 19
6.2 Auxiliary supply 20
6.3 Analog input 21
6.4 Heater Break Alarm 23
7. Thyristor firing mode 28
7.1 Zero Crossing (ZC) 28
7.2 Burst Firing (BF) 28
7.3 Configurator 29
8. Fuse and fuseholder for UL certification unit 31
8.1 Fuse and Fuse Code 31
8.2 FuseHolder size 32

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9. Fuse and fuseholder for CE mark unit 33
9.1 Fuse and Fuse Code 33
9.2 FuseHolder size 34
10. Modbus communication 35
10.1 Physical requirements 35
10.2 ModBus RTU protocol 35
10.3 Word parameters 40
10.4 Thyristor unit Configuration 45
10.5 Address configuration 49
11. Maintenance 52
11.1 Trouble Shooting 52
11.2 Repairing procedure 53
11.3 Fans 53
11.4 Servicing 53
11.5 Warranty conditions 53
12. CD Automation’s distributors 54

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CAUTION
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 600V.
-Auxiliary supply 230-460Vac.
-Fan voltage 230Vac 50/60Hz Power consumption 14W.
Don't remove the plastic cover which provides adequate protection against electric shock.
Don’t use this thyristor in aerospace and nuclear application.
Electric Shock Hazard (Risque the choque électrique)
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 permit to discharge internal
capacitors. Thus be secure that:
•access to thyristor unit is only permitted to specialized personnel;
•the authorised personnel must read this manual before to have access to the unit;
•the access to the units must be denied to unauthorized 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.
•Don't touch components to prevent elettrostatichal discharges on them.
•Verify that all ratings are in line with real needs.
•If authorized personnel must measure voltage, current etc. on units, take away rings and other
jewels from fingers and hands.
•Authorized 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.

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Protection(protection)
CD3000 thyristor family has a polymeric plastic cover in compliance to International specification
IP20. To understand if IP20 protection is sufficient should be evaluated the installation place where
the units are installed.
Open Type Equipment(équipment de type ouvert).
Maximum surrounding air temperature 40°C(Temperature de l’air environnante maximum 40°C).
Earth(terre)
CD3000 family has isolated heatsink. For safety connect the heatsink to earth to avoid shocks in
case that circuit board or thyristors lost insulation. Earth impedance should be correspondent to
local earth regulation. Periodically the earth efficiency should be inspected.
Electronic Supply(alimentation électronique)
CD3000 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 (compatibilité électromagnétique)
Our thyristor unit has an excellent immunity to electromagnetic interferences if all suggestions
contained in this manual are respected. In respect to a good Engineering practise, 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. CD3000 serie
complies with EMC rules for CE mark. In many installations near electronic devices has not been
noted problems. If radiofrequency device 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.
C
US
LISTED
UL
®
NOTE
We reserves the right to apply modifications to the our products without any advice.

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1. Glossary
1.1 Terminology
V: voltage power supply.
I: the full circulating current in thyristor unit.
P: total load power.
1.2 Input signal
SSR: This input type is a square waveform generated by a temperature controller.
AN: Analog input.
IRS: Communication command.
1.3 Power feed back
Feedback: supply voltage fluctuation changes the power to the load. To overcome this effect
the voltage supplied to the load is measured and compared with power demand from
controller, the error signal is used to automatically hold the power at demanded level.
1.4 What is a thyristor unit
A thyristor unit is semiconductor device which acts as a switch formed by two thyristors in
antiparallel. 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 mooving parts, no maintenance
and capacity to switch very fast. Thyristors are the only solution to control transformers and
special loads that change resistance with temperature and with age.
LOAD

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2. Technical specifications
2.1 General Features:
Operating temperature 0÷40°C for higher temperature see derating curve
Voltage power supply 24V minimum, 480V max and 600V on request
Input signal SSR
4÷20 mA
0÷10V
potentiometer (10k ohm)
customer configurable with automatic zero/span calibration
Firing mode One of these firing modes can be configured on line via serial port
Zero Crossing (ZC)
Burst Firing (BF)
Auxiliary voltage supply 230V range (230 ±15%) 10VA
460V range (380 –15%) ÷ (460 +15%); 10VA
(sincronized with supply Voltage)
Fan voltage supply 230V ±15%;
110V ±15%; on request
Heather break alarm Discrimination better than 20%. Circuit microprocessor based to
diagnose partial or total load failure and short circuit on Thyristors.
Latching alarm plus reset. Relay output 0,5A at 125V
Line Drop Voltage Automatic compensation ±15% of supply voltage with analog input
Mounting Din rail mounting
Protection IP20
2.2 Input features
Input signal Maximum current
drain
Input
Impedance ON condition OFF condition
SSR 5mA constant current ≥4V -max 30V ≤1V
Analog 0÷10V -8200 ohm
Analog 4÷20mA -100 ohm
Potentiometer
10K ohm 8200 ohm

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2.3 Output features
NA=not Available
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
15A 24÷480 V 1200 1200 150 230 15 610 47÷70 36 2500
25A 24÷480 V 1200 1200 150 230 15 610 47÷70 60 2500
35A 24÷600 V 1200 1600 250 600 15 1800 47÷70 88 2500
45A 24÷600 V 1200 1600 450 1000 15 4750 47÷70 108 2500
75A 24÷600 V 1200 1600 450 1350 15 8830 47÷70 180 2500
100A 24÷600 V 1200 1600 450 2000 15 19100 47÷70 240 2500
2.4 Derating curve
1
0.8
0.6
0.4
0.2
040 50 60 70 80
K
°C
I = I x K
NOMMAX

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3. Ordering information
Model CD3000M 2PH
1234567
CD3000M-2PH
Ex:CD3000M 2PH/ 75A/ 400V
/
480V
/
460V
/SSR/ ZC/ UL
1 Nominal current of CD3000M
15A 45A
25A 75A
35A 100A
2 Operating Load Voltage (incoming voltage supply)
Specify the value of the line supply.
3 Max VOLTAGE of CD3000M
480V
600V
The voltage on the identification label must be equal or more than
operating voltage. The minimum voltage supply to the load is 24V.
4 Auxiliary Voltage
230V 200÷230V ±15%; 10VA
460V 300÷460V ±15%; 10VA
600V 600V ±15%; 10VA (on request)
5 Input
SSR 4÷30VDC
0-10V 0÷10V analog input
4-20mA 4÷20mA analog input
10K pot Potentiometer
6 Firing
ZC Zero Crossing
BF Burst firing. Specify the number on ON cycles at 50% of
power.
7 Options
COMM MODBUS protocol in RS485 is standard
EF External fuses and fuseholders
NF No fuses
CD-KP External Keypad
HB Heater Break Alarm
FAN110Fan voltage supply 110VAC ±15% (std 230VAC ±15%)
14W 50/60Hz
UL UL Certification

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4. Installation and wiring information
4.1 Identification of the unit
Before to install the CD3000M unit examine for damages or deficiencies. If any is found,
notify the carrier immediately. Check that the product features shown on CD3000M
cover and identification label corresponds to that ordered.
INPUT
AMPS AUX.
FIRING
OPT.
0-10V15 60 240V
____
4-20mA
25 90 440V SC DT
SSR35 110 POT45 ___ ____ PA
S.S
ZC
4.2 Installation
CD3000M unit should be always
mounted in vertical position to
improve 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 more units are mounted inside a cubicle
provide air circulation as below represented.
Sometimes it is necessary to provide a fan to
have a better air circulation.
AIR OUTPUT
AIR INPUT
15cm
2 cm
An identification label provides all the
informations regarding the factory
settings of the unit. This label is on the
board inside the unit, as represented

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4.3 Dimensions
W
H
D
CD3000M 2PH
15-25A (S1C)
CD3000M 2PH
35A (S4C)
CD3000M 2PH
45A (S7C)
W
H
D
W
H
D
CD3000M 2PH
75A-100A (S8C)
W
H
D
Size W(mm) H(mm) D(mm)
15A (S1C) 95 120 120
25A (S1C) 95 120 120
35A (S4C) 148 120 123
45A (S7C) 148 120 159
75A (S8C) 148 138 159
100(S8C) 148 138 159
4.4 CT dimensions (Heater Break HB)
8
1
2
39
39
20

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4.5 Fixing Holes
AB
C
Size A(mm) B(mm) C(mm)
15A (S1C) 110 --
25A (S1C)110 --
35A (S4C) -110 65
45A (S7C) -110 65
75A (S8C) -110 65
100(S8C)-110 65

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5. Wiring Instructions
Warning: this procedure can be done just by specialized personnel.
CD3000M unit has isolated heatsink. For safety connect the heatsink to earth using its terminal with
earth symbol.
CD3000M 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.
3.3.2 Auxiliary terminals
Before connect or disconnect, make sure that the power, control cables and wires are
insulated from the voltage.
Terminal Description
1-External Calibration command 24 Vdc max
2+ External Calibration command 24 Vdc max
3Reset
4Reset
5+ Output Command signal to CD3000 (Internal Connections)
6-Output Command signal to CD3000 (Internal Connections)
A2+ + Input command signal 4÷20mA,0÷10V,SSR
A1--Input command signal 4÷20mA,0÷10V,SSR
7RS485 A
8RS485 B
9Output +8Vdc stabilized 1 mA MAX
10 Common relay H.B. alarm
11 NC/NO H.B. relay alarm
12 Option
13 CT input with H.B. option
14 CT input with H.B. option
15 Nc not connected
16 Auxiliary supply voltage 230-460Vac
17 Ground
18 Auxiliary supply voltage 230-460Vac
5.1.1 Power Terminals
Before connect or disconnect, make sure that the power, control cables and wires are
insulated from the voltage.
Terminal Description
L1 Line Input
T1 Load Output
L2 Line Input
T2 Load Output

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5.2 Cabling detail
Use 75°C copper (CU) conductor only, provided with the terminal type indicated below.
(Utiliser conducteur de cuivre (CU) pour 75°C seulement, avec les terminal suivants )
Current/courant Torque/couple
Lb-in (N-m) Wire/cable Wire terminal/terminal
15A, 25A, 35A, 45A 26.6 (3.0) 18-8
UL Listed (ZMVV)
Wire Pin Terminal
(terminal avec cosse)
60A, 90A, 110A 70.8 (8.0) 18-1
UL Listed (ZMVV)
-Fork/Spade Terminal
(terminal avec cosse a
fourche)
-Copper Tube Cr. Lug
(cosse tubulaire a plage
étroite)

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Power terminals: wire details:
Current Supply Load
Cable Clable
mm2AWG
Screw
Mmm2AWG
Screw
M
15A 412 M5 412 M5
25A 610 M5 610 M5
35A 10 8M5 10 8M5
45A 10 8M5 10 8M5
60A 16 6M6 16 6M6
90A 35 3M6 35 3M6
110A 35 2M6 35 2M6
Auxiliary connectors and earth:
Current Auxiliary Supply Earth
Cable Clable
mm2AWG
mm2AWG
Screw
M
15A 0,50 18 412 M4
25A 0,50 18 412 M4
35A 0,50 18 610 M5
45A 0,50 18 610 M5
60A 0,50 18 610 M5
90A 0,50 18 10 8M5
110A 0,50 18 16 6M5

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5.3 Wiring connections
5.3.1 CD3000 15-25A
P
O
W
E
R
U
N
I
T
Input
CT
Reset
-+
RS485-B
1
65
7
8
9
10
11
12
13
14
15
16
17
18
2
A2+
3
A1-
4
RS485-A
COM
NO/NC H.B.
Contact
8V
External Calibration
+-
L2
L3
POWERUNIT
CT3
L2L1
CT1 CT2
T2T1
L1
L2
L3
L1
**
Delta Load
Start Load
NOTE: IMPORTANT
To work, terminals 3-4 must be linked.
The auxiliary voltage supply of Drive M unit must be connected as above, and must
be syncronized with load voltage power supply (L2, L3).
* The user installation must be
protect by electromagnetic circuit
breaker or by fuse isolator
** If the Auxiliary Voltage (written
on t
he identification label) is
different from Supply Voltage (to
the load ), use an external
transformer as designated above.

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5.3.2 CD3000 34-45A
P
O
W
E
R
U
N
I
T
Input
CT
Reset
-+
RS485-B
1
65
7
8
9
10
11
12
13
14
15
16
17
18
2
A2+
3
A1-
4
RS485-A
COM
NO/NC H.B.
Contact
8V
External Calibration
+-
CT3
L2L1
CT1 CT2
T2T1
L2
L3
L1
L2
L3
L1
**
L3
T3
Delta Load
Star Load
NOTE: IMPORTANT
To work, terminals 3-4 must be linked.
The auxiliary voltage supply of Drive M unit must be connected as above, and must
be syncronized with load voltage power supply (L2, L3).
* The
user installation must be
protect by electromagnetic circuit
breaker or by fuse isolator
** If the Auxiliary Voltage (written
on the identification label) is
different from Supply Voltage (to
the load )
, use an external
transformer as designated above.

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5.3.3 CD3000 75-100A
P
O
W
E
R
U
N
I
T
Input
CT
Reset
-+
RS485-B
1
65
7
8
9
10
11
12
13
14
15
16
17
18
2
A2+
3
A1-
4
RS485-A
COM
NO/NC H.B.
Contact
8V
External Calibration
+-
CT3
L2L1
CT1 CT2
T2T1
L2
L3
L1
FAN
220 Vac
L2
L3
L1
**
L3
T3
Delta Load
Star Load
NOTE: IMPORTANT
To work, terminals 3-4 must be linked.
The auxiliary voltage supply of Drive M unit must be connected as above, and must
be syncronized with load voltage power supply (L2, L3).
* The user installation must be
protect by electromagnetic circuit
breaker or by fuse isolator
** If the Auxiliary Voltage (written
on the identification label) i
s
different from Supply Voltage (to
the load ), use an external
transformer as designated above.