Eurotherm 7000 Series User manual

Solid state
contactor
User Manual
ε
ε
7200
7200
SS
ENG
•DATAMANAGEMENT • CONTROLS • PROCESS AUTOMATION•
Two phase
Load Control

i
7000 Range
7200S
SMART CONTROLLER
THYRISTOR UNIT
CONTROLLING TWO PHASES
OF A THREE-PHASE LOAD
USER MANUAL
© Copyright EurothermAutomation 2004
All rights reserved. All reproduction or transmission in any form whatsoever and using any procedure
(electronic or mechanical, including photocopying and recording) without written permission from
Eurotherm is strictly prohibited.
7200S User Manual Ref.: HA176662 ENG - Issue 2 - 03/2009

7200S User Manual
ii
Check characteristics
Wiring
Fan power supply
Apply control signal
Power on.
Check firing
Adjust DLF alarm
(if conditions met)
Normal operation
CHK/SET push button
Characteristics correspond
to product code
and specifications
Chapter 1
Supply protection,
protective earth (PE)Chapter 2
For fan cooled
solid state contactors Chapter 2
Chapter 2
Chapter 4
Alarms signaled Chapter 3
Chapter 3
DLF LEDs
DC logic signal :
'LDC' terminal block
AC logic signal :
'HAC' terminal block
4-20 mA analogue signal :
'ATP' terminal block
Chapter 2
ON, HEAT LEDs
Power:
Supply side :
terminals 1/L1, 3/L2
Load side :
terminals 2/T1, 4/T2
Chapter 2
Mounting DIN rail mounting or
Bulkhead mounting Chapter 2
Fuse protection Chapter 4
COMMISSIONING FLOWCHART

7200S user Manual iii
Contents
CONTENTS
Page
Commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
European directives and applicable standards . . . . . . . . . . . . . . . . .iv
Chapter 1 Identification of solid state contactor . . . . . . . . . . .1-1
Chapter 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Chapter 3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Chapter 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Eurotherm Limited ....................................5-1
PURPOSE OF MANUAL
This manual (Issue 2)describes the Basic Version and all Options for 7200S series solid state
contactors with current ratings up to 200 A.

7200S User Manual
iv
EUROPEAN DIRECTIVES AND APPLICABLE STANDARDS
COMPLIANCE WITH PRODUCT STANDARD
7200S products comply with the terms of product standard EN 60947-4-3 ‘Contactors and
motor-starters - AC semiconductor controllers and contactors for non-motor loads’.
CE LABELLING
7200S products, installed and operated in accordance with their user manual, bear
CE labelling on the basis of compliance with the essential requirements of :
•the European Low Voltage Directive 73/23 EEC dated 19 February 1973
modified by 93/68 EEC dated 22 July 1993
•the Electromagnetic Compatibility Directive 89/336/EEC dated 3 May 1989
modified by 92/31/EEC dated 28 April 1992 and 93/68/EEC dated 22 July 1993.
SAFETY
The units have IP20 protection rating as defined by standard IEC 60529.
External wiring must comply with standards IEC 60364-4-43 and IEC 60943.
Copper cables and conductors must be used, rated to a temperature of 75°C (167°F).
ELECTROMAGNETIC COMPATIBILITY (EMC) TEST STANDARDS
7300S products installed and used in accordance with the user manual, are designed for
an industrial environment and not a commercial or light industrial premises and must
not be used in the home.
IMMUNITY
The EMC immunity test standards required by product standard EN 60947-4-3 are given
in the table following :
European directives and applicable standards
Test type Minimum level EMC test standard
Electrostatic discharge 4 kV on contact; 8 kV in air EN 61000-4-2
Radiated, radio frequency 10 V/m 80 MHz ≤f≤1 GHz ;
electromagnetic field 80% modulation 1 kHz sinusoid EN 61000-4-3
Electrical fast transient / burst 2 kV / 5 kHz EN 61000-4-4
Electrical Surge 4 kV line to earth
2 kV line to line EN 61000-4-5
Conducted disturbances 140 dBµV;150 kHz ≤f≤80 MHz EN 61000-4-6
Voltage dips and 5 s interruptions EN 61000-4-11
short interruptions
Table 1 EMC immunity standards compliance

7200S User Manual v
EMC GUIDE
To help you deal with installation-dependent electromagnetic interference effects,
Eurotherm provides an ‘Electromagnetic compatibility’ installation guide (ref. HA 025464)
which sets out best current practice regarding EMC.
DECLARATION OF CONFORMITY
ACE declaration of conformity is available on request.
European directives and applicable standards
EMISSIONS
The EMC emissions test standards required by product standard EN 60947-4-3 are given
in the table following :
Table 2 EMC emissions standards compliance
Emission type Firing mode EMC test standard
Radiated at radio All firing modes CISPR 11 Class A
frequencies
Conducted at radio All firing modes CISPR 11 Class A
frequencies Group 2

7200S User Manual
vi

7200S User Manual 1-1
Identification
Chapter 1
1. IDENTIFICATION OF SOLID STATE
CONTACTOR UNITS
Contents Page
1.1. General presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.2. Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.2.1. Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.2.2. Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.2.3. Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.2.4. Signalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.2.5. Firing Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.2.6. Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.2.7. Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.2.8. Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.2.8.1. DLF Otpion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.2.8.2. Over temperatureAlarm.........................1-7
1.2.8.3. Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.2.9. Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.2.10. Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.2.11. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.2.12. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.2.13. Digital Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.3. Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

Identification
7200S User Manual
1-2
1. Chapter 1 IDENTIFICATION
1.1. GENERAL PRESENTATION
7200S series solid state contactors control the electrical power to three-phase industrial
loads such as low temperature coefficient and short wave infrared elements.
Standard ratings in the series range from 16 A to 200 A,at voltages from 200 V to 500 V.
7200S series solid state contactors comprise two channels, controlled by thyristors.
Depending on the type of control signal and the type of input specified, 2 operating modes
are available: logic (‘on/off ’) or modulation (‘Burst mode’).
Figure 1-1 General view of 7200S with digital communication control - ratings from 16 A to 63 A
GRF
DLF CHK
ON
HEAT
SET
7200S
EUROTHERM
PE
3/L2
4/T2
2/T1
1/L1
ε
5/L3
6/T3
Protective earth
terminal
Power terminals
(supply)
Ratings
(nominal current
and nominal voltage)
Power terminals
(load)
Internal
power wiring
diagram
Control terminal
pinouts
Serious alarms
(if DLF option)
User labelling
Electronics supply
Zero crossing firing mode :
Firing request LED
Diagnostic alarm
(if DLF option)
63 A / 500 V
EN 60947-4-3
Communication Option :
Transmission LEDs and
configuration switches
ON/
Dxch
Rx
Tx
ON
12345678
Control connector
DLF option :
CHK/SET
push button
ALR
1a 1b
73 74
COM
BA
91 92
Aux1
230 N
16 17 18
Aux2
GND 24V 0VS
15 19 20

7200S User Manual 1-3
Identification
GRF
DLF CHK
ON
HEAT
SET
7200S
EUROTHERM
PE
3/L2
4/T2
2/T1
1/L1
ε
5/L3
6/T3
80 A / 500 V
EN 60947-4-3
ALR
1a 1b
73 74
Aux1
230 N
16 17 18
Protective earth
terminal
Power terminals
(supply)
Power terminals
(load)
Internal
power wiring
diagram
Control terminal
pinouts
Serious alarms
(if DLF option)
Electronics supply
Zero crossing firing mode :
Firing request LED
Diagnostic alarm
(if DLF option)
Control connector
ATP
0VA R1
11 12
Figure 1-2 General view of 7200S with analogue control - ratings from 80 A to 100 A

Identification
7200S User Manual
1-4
1/L1
2/T1
EUROTHERM
ε
7200
S
125 A / 500 V
PE
GRF
DLF
ON
HEAT
CHK
SET
EN 60947-4-3
1/L1
2/T1
LDC
0VL LD
11 12
ALR
1a 1b
73 74
T°
FAN
230 N
16 17 18
EXT
L2
21 22
MSF
3a 3b
75 76
Internal wiring diagram
internal fuses for
units ≥ 125 A)
Control terminal
block
Controlled phase terminal
supply side)
Control terminal
labelling
Signalling LEDs
alarms and operation)
Internal fuse
compartment
Protective earth
terminal
DLF option :
CHK/SET
push button :
DLF alarm
setting / diagnosis
Fuse blown
contact
code MSFU)
Controlled phase
terminal
loas side)
Fan
Fan power
supply
Over-temperature Alarm
for units ≥ 125 A)
2 attachment screws
for internal fuse
compartment
3/L2
4/T2
4/T2
3/L2
Not
used
Figure 1-3 General view of 7200S with analogue control - ratings ≥ 125 A
72S 1.Identification 20/12/04 17:46 Page 1-4

7200S User Manual 1-5
Identification
7200S User Manual
1.2. TECHNICAL SPECIFICATIONS
1.2.1. USE In accordance with product standard EN 60947-4-3 :
Units for uninterrupted service :
1. Semiconductor contactor (DOL) variant 5:
logic input signal :
DC (LDC input) or AC (HAC input).
2. Thyristor unit variant 4:
4-20 mA analogue input signal :
ATP input or digital communication option.
Configuration on order.
1.2.2. POWER
Nominal current per phase 16 A to 200 A (defined at 45°C) depending on product code
The unit can be used up to 60°C ambient temperature,
following derating curves. Please consult Eurotherm.
Nominal line to line voltage 200 V to 500 V depending on product code (+10% and -15%).
Frequency Use from 47 to 63 Hz (automatic matching)
Dissipated power Approx : 1.3 W (typical) - 2 W max
per amp and per phase (with fuses).
Cooling Ratings ≤100 A: natural convection
Ratings ≥125 A: fan (115 V or 230 V external supply),
consumption 10 VA.
1.2.3. LOAD Three-phase Industrial Load.
Categories of use The categories of use applicable for each unit are indicated
on the identification label
• AC-51 Non-inductive or low inductance loads, furnace
resistances
(Resistive load with low temperature coefficient).
•
AC-55b Switching of incandescent lamps, short wave
infrared elements (SWIR), for ≤100 A units.
Connections Independent of order of phase rotation
Load configuration • Star without neutral (3 wires)
• Closed delta (3 wires)
1.2.4. SIGNALLING
Basic version
Supply present Green ‘ON’ LED.
Thyristor firing request
Green ‘HEAT’ LED.
With options
Alarms Red and orange LEDs, alarm relay contact.

Identification
7200S User Manual
1-6
1.2.5. FIRING MODES
Thyristor switching At thyristor zero voltage crossing.
‘Logic’ mode DC signal applied to LDC input (Low Direct Current).
AC signal applied to HAC input (High Alternating Current).
‘Burst’ mode Supply voltage modulated by the 4-20 mA analogue signal
applied to the ATP input
(Analogue to Time Proportional).
Firing base time (@ 50% of the power):
0.4 s (approx. 20 cycles at 50 Hz).
with ‘Digital Communication’ option
base modulation time: from 1 cycles to 255 cycles
1.2.6. INPUTS
Power Supply Self-powered electronics.
‘Logic’ firing:
•DC signal Conducting from 4.5 Vdc to 32 Vdc max, current ≥9 mA.
(LDC input) Off < 1.5 V or < 0.1 mA. Response time ≤10 ms.
If the unit has the DLF option, ant that you want to drive it
using a REMIO output, please contact the Eurotherm’s
application sevices
•ACsignal
Conducting from 85 to 253 Vac max. Impedance ≈7 kΩat 50 Hz.
(HAC input) Off < 10 Vac. Response time ≤60 ms.
(If an RC snubber contact protection circuit or control
optotriac is used, the maximum capacitor value is 22 nF for
240 Vac).
• With DLF option: • According to the control signal, one of the two following
critera must be respected:
• T conduction min = T non-conduction min ≥0.3 second
• T modulation ≥4 seconds
If DLF option is used with Short Wave Infrared loads
(SWIR), the product is not UL approved.
‘Burst mode’ firing:
• Analogue signal 4 - 20 mA (10 Vdc max).
(ATP input) Modulation depending on signal.
Firing base time: 0.4 s @ 50% and 50 Hz.
• Digital communication
(MOP option) Digital signals, Modbus®protocol
1.2.7. CONTROL
(ATP input only)
Control type Open loop
Linearity and Stability Better than ±2% of full scale.

7200S User Manual 1-7
Identification
1.2.8. ALARMS (Options)
1.2.8.1. DLF option
Serious alarms Total load failure (TLF) and thyristor short circuit (THSC)
detection.
Signalling When a serious alarm is detected:
• the red ‘GRF’ LED is lit
• the alarm relay contact is activated.
Diagnostic alarm Partial load failure detection and diagnosis.
Signalling If a partial load failure (PLF fault) is detected:
•the orange ‘DLF’ LED is lit
• the alarm relay contact is activated.
Settings The front panel push button is used for:
• monitoring and diagnosis
• adjusting and resetting the alarm.
Sensitivity Detects the failure of at least one heating element
for four
identical elements connected in parallel.
Warning! DLF Option can not be used with SWIR loads.
1.2.8.2. Over-temperature alarm
For all fan-cooled units (≥125 A),
the unit cuts out if the temperature threshold is exceeded,
whether or not options are fitted.
Signalling If an over-temperature alarm is detected:
• the red ‘T°’ LED is lit
• the alarm relay contact is activated
provided one of the alarm options is selected.
1.2.8.3. Alarm relay Available with one of the Alarm options.
The relay contact (0.25 A/230 Vac or 30 Vdc) is either open
on alarm or closed on alarm depending on the product code.
1.2.9. PROTECTION
Short circuits
co-ordination type Type 1 (high-speed fuses).
Electrical protection IP20 without adding additional protection.
Thyristors Varistors and RC snubbers.
High-speed fuses:
•ratings ≤100 A: external (selected in product code)
• ratings ≥125 A: internal.
No fuse for short wave infrared elements.
Replacement fuses See chapter 4.

1.2.12. MOUNTING
Attachment Attachment plate fixed to unit:
• on symmetrical EN50022 DIN rail or
• bulkhead mounting
(for ratings ≥80 A: bulkhead mounting only).
1.2.13. DIGITAL COMMUNICATION
Availability The digital communication option is exclusive with:
•control using the logic or analogue input signal.
Protocol Modbus® RTU.
Compliance Communication complies with the specifications given in
‘GOULD MODICON Protocol Reference Guide PI-MBUS-300 rev J’.
Power supply 24 Vac (±20%), 47 to 63 Hz or
24 Vdc (±20%) non-polarised.
Typical consumption 1.5 VA
Protection: external 2 A fuse.
External wiring should comply with standard IEC 60364.
Transmission Standard RS485, 2 wires.
Speed: 9600 or 19200 bauds.
Selected by switch on front panel. The speed is factory set to
correspond to the selected product code.
Identification
7200S User Manual
1-8
Ratings Height Width Depth (mm)
Basic With With DLF With DLF and
Modbus only only Modbus
16 A to 63 A 220 mm 96 mm 164 189 214 239
80 A to 100 A 305 mm 144 mm 295 295 372 372
125 A to 200 A 498 mm 144 mm 295 295 372 372
1.2.10. ENVIRONMENT
Use 0 to 45°C at nominal current, at maximum altitude of 1000 m.
Storage -10°C to 70°C.
Isolation voltage Assigned isolation voltage Vi=500 Vrms
Pollution Degree 2 acceptable (defined by IEC 60664).
Humidity RH 5% to 95%, non-condensing, non-streaming.
Over-voltage Over-voltage category II (as defined by IEC 60664)
Vimp = 4 kV.
1.2.11. DIMENSIONS
Table 1-1 Units dimensions according to the ratings and the options chosen

Eurotherm’s policy of continuous product improvement and development means that the specifications
in this document may be modified without prior notice.
7200S User Manual 1-9
Identification
Termination The communication bus must have termination resistors fitted
at each end: • one line impedance matching resistor.
• two RS485 bus polarisation resistors.
Address Adjustable between 1 and 127 using front panel switches
only. The physical address is factory configured to 32 by default.
Diagnostic • Green LED on front panel indicates power presence, waiting
for frames, communication established.
• Two orange LEDs show the status of the communication bus
(transmission or reception).
Control Supply voltage compensation operates for variations up to ±20%
of nominal voltage, using V2control
Parameters and
operating mode Read and write by digital communication
(see Digital communication manual, part No. HA176664ENG).
Firing base time
Configurable over communication link (@ 50% of power):
• 1 or 255 cycles (‘Burst mode’).
The default base time is factory configured to 16 cycles.

Identification
7200S User Manual
1-10
Identification
6. Input Code
‘On/off’ firing
DC logic signal
4.5 Vdc to 32 Vdc LDC
AC logic signal
85 Vac to 253 Vac HAC
‘Burst mode’ firing
Analogue DC signal
4 mA to 20 mA ATP
No logic or analogue
input but Modbus
communication NONE
1.3. CODING
7200S Current / Voltage / Fan / Configuration / Fuses / Input / Language / Options /
1. Nominal current Code
per phase
16 amps 16A
25 amps 25A
40 amps 40A
63 amps 63A
80 amps 80A
100 amps 100A
125 amps 125A
160 amps 160A
200 amps 200A
3. Fan Code
≤100 A:
no fan XXXX
≥125 A: fan
• 115 V supply 115V
•230 V supply 230V
5.High-speed fuses Code
Thyristor protection fuses only
• without microswitch FUSE
•with microswitch MSFU
(≤100 A: external fuses
≥125 A: internal fuses)
No fuses or control of
Short wave infrared elements NONE
4.Load configuration Code
Star without neutral 3S
Closed delta 3D
2. Nominal line-to-line Code
voltage
200 volts to 230 volts 230V
277 volts 277V
400 volts to 500 volts 500V
7. Manual language Code
French FRA
English ENG
German GER
8. Selected options Code
No options
End of code NONE
Selection of options YES

Alarm option: Communication option: Certificate
Alarm / Load / Contact / Protocol / Transmission / option / Warranty
Type Type
7200S User Manual 1-11
Identification
11. Alarm relay contact Code
GRF or DLF option:
Alarm relay contact
• Closed on alarm NC
•Open on alarm NO
Without alarm option XX
9. Alarm option Code
(Options selected: YES)
Serious Alarms:
Thyristor short-circuit,
Total Load failure (over-
temperature for ratings ≥125 A)
Partial load failure
and Serious alarms DLF
No alarms NONE
10. Load type Code
For DLF option:
Resistive load with
low temperature coefficient LTCL
Short wave infrared elements* SWIR
Without DLF option XXXX
13. Transmission speed Code
(if Comm. option other than NONE)
Code MOP :
Transmission speed:
9.6 kbaud 9K6
19.2 kbaud 19K2
Code None
No communication XXXX
14. Certification option Code
Without Certificate of
‘Compliance with Order’ NONE
With certificate of
‘Compliance with Order’ CFMC
12. Communication option Code
Digital communication
Communication protocol:
Modbus® MOP
No communication NONE
15. Warranty extension Code
Without warranty extension NONE
With warranty extension WL005
*DLF Option with SWIR loads is not UL
approved.

Identification
7200S User Manual
1-12

7200S User Manual 2-1
Installation
Chapter 2
2. INSTALLATION
Contents Page
2.1. Safety during installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.2. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.2.1. Types of mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.2.2. Attachment plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.2.3. Mounting on DIN rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.2.4. Bulkhead mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.3. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.3.1. General connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.3.2. Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2.3.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2.3.2.2. Power connection details . . . . . . . . . . . . . . . . . . . . . . .2-7
2.3.2.3. Three-phase load wiring schemes . . . . . . . . . . . . . . . .2-7
2.4. Control terminal blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.4.1. Control signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.4.2. Alarm relay contact (option) . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2.4.3. Fan power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2.4.4. Connecting the digital communication . . . . . . . . . . . . . . . . .2-10