Chauvin Arnoux THYRITOP 500 Series User manual

THYRITOP
 SERIES
25 to 250 A Power Controller
GB - Installation and operation manual

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906121686_THYRITOP 500_04-2019
Indicates contents of sections, general instructions, notes, and
other points to which the reader’s attention needs to be called.
Indicates a particularly delicate situation that could affect
the safety or correct operation of the controller, or an
instruction that MUST be followed to prevent hazards.
Indicates a risk to the user’s safety due to high voltage at the
points indicated.
Indicates a suggestion based on the experience
of CA PYROCONTROLE Technical Personnel that
could be especially useful under certain circumstances.
Indicates a reference to Detailed Technical Documents
available on the website www.pyrocontrole.com
GRAPHIC SYMBOLS
INDICE
To indicate the type and importance of the information provided in this User’s Guide, graphic reference symbols have been use to facilitate
interpretation of the information.
1 Preliminary instructions 2
1.1 Prole
1.2 General description
1.3 Preliminary instructions
2 Installation and Connection 4
2.1 Electrical power supply
2.2 Notes on electrical safety
and electromagnetic compatibility
2.3 Recommendations for correct installation
for purposes of EMC
2.4 Dimensions
2.5 Installation
2.6 General description THYRITOP 500 25-120A
2.7 General description THYRITOP 500 150-250A
2.8 Cleaning/checking or replacing the fan
for THYRITOP 500 150-250A
2.9 Substitution of Internal Fuse
(Option only for THYRITOP 500 150-250A)
3 Electrical connections 12
3.1 Power connections
3.2 Connections input/output 25-120A
3.3 Connections input/output THYRITOP 500 150-250A
3.4 Functions of indicator leds
3.5 Control connectors
3.6 Conguration TTL port
(THYRITOP 500 standard)
3.7 Serial comunication port Modbus RS485 (option)
3.8 Connection example: comunication ports
3.9 Connection example: power section
3.10 Digital input (PWM)
4 Installation of serial network 33
4.1 “AUTOBAUD SERIAL” sequence
5 Technical Characteristics 35
5.1 Derating Curves THYRITOP 500
6 Technical-Commercial information 38
6.1 Accessories
6.2 Fuses / Fuseholders

2906120686_THYRITOP 500_04-2019
1.1 Profile
The THYRITOP 500 series of microprocessor advanced solid
state power units controls, in compact and optimized size, high
electric powers with different types of heating elements, single-
phase, biphase or triphase. Current levels range from 40A
to 250A, nominal voltage from 480 VAC to 600VAC.
The command input is congurable and accepts 0-10V, 0/4-20mA
signals, potentiometer, logic signals, including with PWM modes
for cost effective solutions.
The device can also be operated via Modbus RTU serial
communication, with IN/OUT chain connections facilitated
by plug-in RJ10 (telephone) connectors.
The several trigger modes are software congurable and provide:
- ZC : Zero Crossing constant cycle time (settable in range
1-200sec), for conventional loads.
- BF : Burst-Firing, Zero crossing with optimized minimum cycle
time, for systems with low thermal inertia, medium-wave IR lamps.
- HSC : Half Single Cycle Zero Crossing corresponds to Burst
Firing that manages single semi-cycles of conduction or stop
cycles, useful for short-wave IR lamps, reduces ickering and
limits generation of EMC noise on the power line (applied only
to single-phase load or open delta).
- PA: Phase angle control, useful for short-wave IR lamps,
transformer primaries. Completely eliminates ickering of load
laments, but generates EMC noise on power line (harmonics).
Soft Start and soft stop ramp functions can be assigned to these
controls with limitation of current peaks and/or maximum RMS
current level.
Thanks to sophisticated Hardware and Software solutions,
you can precisely control different types of loads.
Phase angle control (the only control method that completely
eliminates IR lamp ickering), matched with current, voltage,
or load power feedback functions, allows the easy use of “critical”
applications such as (for example), special resistors such
as special Super Khantal™ heating elements, Silicon Carbide
resistors, or transformer primaries either single-phase or triphase.
THYRITOP 500 runs complete diagnostics of current, voltage,
power, and temperature levels:
Current Diagnostics:
- Total and partial load interrupt alarm
- Self-learn function of alarm limit for interrupted load
- Alarm for SCR in short circuit
- Alarm for load in short circuit or overcurrent
Voltage Diagnostics:
- Alarm for absence of phase
Temperature Diagnostics:
- Alarm for over temperature of power module
1 • PRELIMINARY INSTUCTIONS
Power control with Soft start ramp limits load, optimizes
the consumptions and increases the load operating duration.
Device parameters can be congured from PC, by means of
a simple conguration SW which lets you save all parameters
in a conguration le that is easy to manage and to copy to other
devices.
Moreover, an RS485 serial connection of THYRITOP 500 is
offered with Modbus RTU protocol to control currents, voltages,
powers, load status, and device status from the supervisor terminal
(HMI) or PLC.
The section contains general information and
warnings to be read before installing, conguring
and using the controller.
1.2 General DescriPtion
THYRITOP 500 is single-zone advanced solid state power unit,
extremely compact, equipped with different optional functions;
it offers an exclusive combination of performance, reliability,
and exibility.
In particular, this new line of CA PYROCONTROLE controllers
is the ideal solution for sectors demanding high performance
and continuity of service, such as :
• Thermoforming
• Blowing
• Hot runners for injection presses
• Texturizing of bers
• Heat treatment furnaces
• Woodworking machines
• Glass tempering furnaces
The modules series THYRITOP 500 controllers are based
on an extremely versatile hardware and software platform,
with options to select the best I/O conguration for your system.
THYRITOP 500 is used for the power control of single-phase
and 2-phase loads, including resistive loads with high and low
temperature coefficient, short wave IR lamps, or transformer
primaries.
Attention : the description of programming
and configuration parameters are contained
in the “Programming and configuration”
manual, downloadable from the website
www.pyrocontrole.com.

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1.3 Preliminary instruction
Read the following preliminary instructions before
installing and using the THYRITOP 500 modular
power controller. This will make start-up faster and
avoid some problems that could be mistakenly
interpreted as malfunctions or limitations of the
controller.
Immediately after unpacking the unit, check the order code and
the other data on the label attached to the outside of the container.
Write them on the following table. This data must always be
available and given to CA PYROCONTROLE Customer Care
representatives are available if technical service is needed.
SN (Serial number)
CODE (Product code)
TYPE (Order code)
SUPPLY (Power Supply)
VERS (Firmware version)
Check that the controller is in perfect condition, was not
damaged during shipment, and that the package also contains
the “Conguration and Programming” manual.
Immediately report any errors, shortages, or signs of damage
to your CA PYROCONTROLE dealer. Check that the order
code matches the configuration requested for the intended
application by consulting the section: “Technical-Commercial
Information”.
Example TH 500 90 480 0 1 0 M
Model
Nominal current
Nominal voltage
Control option,
Absent
Diagnostic option: HB
Fuse : absent
Serial Modbus
See paragraph 2.1 “ Dimensions and mounting” before installing
the THYRITOP 500 on the machine/host system control panel.
For conguration via PC, use the PYROTOOLS software and its
connection cable.
For the order code, see Section: “Technical-Commercial Information ”.
Users and/or systems integrators seeking more
detailed information on serial communication
between a standard PC and/or an industrial PC and
CA PYROCONTROLE programmable instruments
can access the various technical reference
documents in Adobe Acrobat format on the
www.pyrocontrole.com website :
• Serial Communication
• MODBus Protocol
Before calling CA PYROCONTROLE Customer Care in case
of assumed malfunctions, please see the Troubleshooting
Guide in the “Maintenance” section and, if necessary,
the F.A.Q. (Frequently Asked Questions) section on the website
www.pyrocontrole.com

4906120686_THYRITOP 500_04-2019
This section contains the instructions needed for
correct installation of THYRITOP 500 controllers
on the machine/host system control panel and for
correct connection of the power supply, inputs,
outputs and interfaces.
Carefully read the following warnings before
installing the instrument. Disregard of such
warnings could create electrical safety
and electromagnetic compatibility problems,
as well as void the warranty.
2.1 electrical Power suPPly
• The controller THYRITOP 500 DOES NOT have an On/Off
switch: the user must install switch/isolator conforming to
safety requisites (CE mark) to cut off the power supply up-line
of the controller. The switch must be installed in the immediate
vicinity of the controller in easy reach of the operator.
A single switch can be used for multiple devices.
* The earth connection must be made with a specic lead
• If the product is used in applications with risk of harm
torisques persons or damage to machines or materials,
it must be equipped with auxiliary alarm devices.
It is advisable to provide the ability to check for tripped alarms
during regular operation.
Do not install the THYRITOP 500 in rooms with hazardous
(inammable or explosive) atmosphere; it may be connected
to elements that operated in such atmosphere only by means
of appropriate interfaces that conform to current safety
standards.
2.2 notes on electrical safety
anD electromaGnetic comPatibility:
2.2.1 CE MARKING:
EMC (electromagnetic compatibility) conformity
in compliance with Directive EMC 2014/30/EU.
THYRITOP 500 power controllers are mainly intended
to operate in industrial environments, installed
in the control cabinets of machines or production
systems. For electromagnetic compatibility, the most
restrictive general standards have been applied,
as indicated in the corresponding table.
2.2.2 LV conformity (low voltage)
in compliance with Directive 2014/35/EU.
EMC conformity has been veried.
See the information in tables 1 and 2.
2 • INSTALLATION AND CONNECTION
2.3 recommenDations for correct installation
for PurPoses of emc:
2.3.1 Instrument power supply
• The power supply for the electronic instrumentation
on the panels must always come directly from a cut-off
device with fuse for the instrument part.
•Electronic instrumentation and electromechanical
power devices such as relays, contactors, solenoids,
etc., MUST ALWAYS be powered by separate lines.
• When the power supply line of electronic instruments
is heavily disturbed by switching of thyristor power
groups or by motors, you should use an isolation
transformer only for the controllers, grounding
its sheathing.
• It is important for the system to be well-grounded:
- voltage between neutral and ground must not be
> 1V
- Ohmic resistance must be < 6Ω;
• If the grid voltage is highly unstable, use a voltage
stabilizer.
• In proximity of high-frequency generators or arc
welders, use adequate grid lters.
• The power supply lines must be separate from
instrument input and output lines.
2.3.2 Input and output connections
Before connecting or disconnecting any connection,
always check that the power and control cables
are isolated from voltage.
Appropriate devices must be provided : fuses or
automatic switches to protect power lines.
The fuses present in the module function solely as
a protection for the THYRITOP 500 semiconductors.
• Connected outside circuits must be doubly isolated.
• It is necessary to :
- physically separate the input cables from those of
the power supply, outputs, and power connections.
- use braided and shielded cables, with sheathing
grounded at a single point.
2.3.3 Installation notes
Use the extra-rapid fuse indicated in the catalogue according
to the connection example equipped.
- Moreover, the applications with solid-state units require
a safety automatic switch to section the load power line.
To ensure maximum reliability, the device must be
correctly installed in the panel in such a way as to obtain
adequate heat exchange between the heat sink and the
surrounding air under conditions of natural convection.
Fit the device vertically (maximum angle 10° to the vertical
axis) see gure 3.

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• Vertical distance between a device and the panel wall
>100mm
• Horizontal distance between a device and the panel wall at
last 20mm
• Vertical distance between a device and the next one at last
300mm
• Horizontal distance between a device and the next one at last
20mm.
Check that the cable holder runners do not reduce these
distances ; in this case t the cantilever units opposite the
panel so that the air can ow vertically on the dissipator
without any obstacles.
• Dissipation of device thermic power with effects on installation
room temperature.
• Thermal power dissipation with limits on installation room
temperature.
• Obligation d’installation (distance entre les produits pour
garantir la dissipation en condition de convection naturelle)
• Tension maxi de ligne du thyristor et limites en transitoire, le
relais statique est équipé de dispositifs de sécurité internes
(en fonction des modèles).
• présence de courant de dispersion dans le THYRITOP 500
en condition de non-conduction (courant de quelques mA, dû
au circuit RC Snubber de protection du thyristor).
CA PYROCONTROLE ne saurait être tenue en
aucun cas pour responsable d’éventuels dommages
corporels ou matériels résultant d’altérations ou
d’une utilisation erronée, inappropriée ou non
conforme aux caractéristiques du contrôleur et aux
prescriptions contenues dans le présent Manuel
Utilisateur.
Tableau 1 Emission EMC
AC semiconductor motor controllers and conductors for
non-motor loads EN 60947-4-3
Classe A Group 2
Emission enclosure Class A Group 2
compliant in ring mode single cycle and phase angle
if external lter tted
EN 60947-4-3
CISPR-11
EN 55011
Tableau 2 EMC Immunity
Generic standards, immunity standard for industrial
environments EN 60947-4-3
ESD immunity EN 61000-4-2 4 kV contact discharge
8 kV air discharge
RF interference immunity EN 61000-4-3 /A1
10 V/m amplitude modulated 80
MHz-1 GHz
10 V/m amplitude modulated 1.4
GHz-2 GHz
Conducted disturbance immunity EN 61000-4-6 10 V/m amplitude modulated 0.15
MHz-80 MHz
Burst immunity EN 61000-4-4 2 kV power line
2 kV I/O signal line
Surge immunity EN 61000-4-4/5
Power line-line 1 kV
Power line-earth 2 kV
Signal line-earth 2 kV
Signal line-line 1 kV
Magnetic elds immunity Test are not required. Immunity is demostrated by the successfully
completion of the operating capability test
Voltage dips, short interruptions and voltage immunity
tests EN 61000-4-11 100%U, 70%U, 40%U
Tableau 3 LVD Safety
Safety requirements for electrical equipment for
measurement, control and laboratory use
EN 61010-1
UL 508
ATTENTION
This product has been designed for class A equipment. Use of the product in domestic environments may cause radio
interference, in which case the user may be required to employ additional mitigation methods.
EMC lters are required in PA mode (Phase Angle, i.e., SCR trigger with phase angle modulation). The lter model and current
level depend on the conguration and load used. The power lter MUST by connected as close as possible to the THYRITOP 500.
You can use a lter connected between the power line and GTF or an LC group connected between the THYRITOP 500 output
and the load.
The CE declaration of conformity is available on request.

6906120686_THYRITOP 500_04-2019
POWER SUPPLY
18...32Vdc
LEDs
OUTPUTSCPUINPUTS CONTROLLER POWER
SUPPLY
MAIN INPUT IN1
DIGITAL INPUT
TRANSFORMER INPUT
Main Processor LOGIC
EEprom
RAM
Connected to 7.5V CPU
Connected to 18...32Vdc
Connected to 5 V (PORT 1)
Connected to 90...600 V
Légende
1KV
7.5V
1KV DC / DC
5V
4KV
max 600Vac
SSR
OUT HB
1KV
1KV
MODBus RS485

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DIAGRAMME D’ISOLATION
2.4 Dimensions
Fastening may be done on DIN guide (EN50022) or with (5MA). See gures 1 and 2.
All dimensions are expressed in mm.
Figure 1
Depth 143 mm
Depth 170.4 mm
Modèle 25 A
Modèle 40 A
2.4.1 TemPlate for Panel mountinG
Figure 2
W
L
M5
THYRITOP 500 H (mm) L (mm)
25 - 40 - 50 - 60 A 112 44
75 - 90 - 120 A 112 113
150 - 200 - 250A 287 42
THYRITOP 500 I 150 A
THYRITOP 500 I 200 A
THYRITOP 500 I 250 A
THYRITOP 500 I 75 A (Without Fan)
THYRITOP 500 I 90 A (Without Fan)
THYRITOP 500 I 120 A (With Fan)
THYRITOP 500 I 50 A
(Without Fan)
THYRITOP 500 I 60 A
(Without Fan)

8906120686_THYRITOP 500_04-2019
2.5 installation
Attention: respect the minimum distances shown in gure 3 to provide adequate air circulation.
Figure 3
For correct attachment/release of the module on the DIN guide, do as follows: :
- keep the attach/release cursor pressed
- insert/remove the module
- release the cursor
Figure 4 Figure 5 Figure 6
PHASE ATTACHMENT THYRITOP 500
locked properly to DIN bar PHASE RELEASE
1
2
1
2
PIVOTER PIVOTER
APPUYERAPPUYER
PRESSPRESS
TURNTURN