Honeywell CD3200 User manual

EN1I-6312
USER’S MANUAL CD3200
THYRISTOR UNIT
Up To 110A
Rev. 12/2004

User’s Manual ver. 2.0 CD3200 up to110A Honeywell
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CD3200 Thyristor Unit up to 110A
Index:
1. Glossary 5
1.1 Terminology 5
1.2 Input signal 5
1.3 Power feed back 5
1.4 What is a thyristor unit 5
2. Technical specifications 6
2.1 General Features: 6
2.2 Input features 7
2.3 Output features 7
2.4 Derating curve 7
3. Ordering information 8
4. Installation and wiring information 9
4.1 Identification of the unit 9
4.2 Installation 9
4.3 Dimensions 10
4.4 Dimension CT (Heater Break HB) 10
4.5 Fixing holes 11
5. Wiring Instructions 12
5.2 Cabling detail 13
5.3 Wiring connection 15
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
6.5 Current Limit Tuning 28
7. Thyristor firing mode 29
7.1 Phase Angle + Current Limit (PA) 29
7.2 Configurator 30
8. Fuse and fuseholder for UL certification units 32
8.1 Fuse and Fuse Code 32
8.2 FuseHolder size 33
9. Fuse and fuseholder for CE mark unit 34
9.1 Fuse and Fuse Code 34
9.2 FuseHolder size 35

Honeywell CD3200 up to110A User’s Manual ver. 2.0
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10. Modbus communication 36
10.1 Physical requirements 36
10.2 ModBus RTU protocol 36
10.3 Word parameters 41
10.4 Address Configuration 48
11. Maintenance 51
11.1 Trouble Shooting 51
11.2 Repairing procedure 52
11.3 Fans 52
11.4 Servicing 52
11.5 Warranty conditions 52

User’s Manual ver. 2.0 CD3200 up to110A Honeywell
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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
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
• 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
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.
Maximum surrounding air temperature 40°C.
Earth
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
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
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
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.
CU
LISTED S
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÷20mA
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
Phase Angle + Current Limit (PA)
Soft Start + Phase Angle + Current Limit (S + PA)
Auxiliary voltage supply 230V ±15%; 10VA power consumption
440V ±15%; 10VA power consumption
Fan voltage supply 230V ±15%;
110V ±15%; on request
Heater 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
Feedback Voltage feedbak (V)
Square Voltage feedbak (V²)
Power feedback (VxI) (option)
Serial communication RS485 Modbus protocol (option)
Mounting Din rail mounting up to 45A
Bulk head over 45A
Protection IP20

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2.2 Input features
Input signal Input
Impedance
Analog 0÷10V 8200 ohm
Analog 4÷20mA 100 ohm
Potentiometer
10Kohm 8200 ohm
2.3 Output features
NA=not Available
Current Voltage range Ripetitive peak
reverse voltage Latching current Max peak one cycle Leakage current I2T value for fusing Frequency range Power loss Isolation Voltage
(A) (V) (440V) (500V)
(mAeff) (10msec.)
(A) (mAeff) tp=10msec (Hz) I=Inom
(W) Vac
15A 24÷440 1200 NA 150 230 15 610 47÷70 18 2500
25A 24÷440 1200 NA 150 230 15 610 47÷70 30 2500
35A 24÷500 1200 1600 250 400 15 780 47÷70 42 2500
45A 24÷500 1200 1600 250 600 15 1800 47÷70 54 2500
60A 24÷500 1200 1600 450 1000 15 4750 47÷70 72 2500
90A 24÷500 1200 1600 450 2000 15 19200 47÷70 108 2500
110A 24÷500 1200 1600 450 1350 15 8830 47÷70 137 2500
2.4 Derating curve
1
0.8
0.6
0.4
0.2
045 55 65 75 85
K
°C
I = I x K
NOMMAX

Honeywell CD3200 up to110A User’s Manual ver. 2.0
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3. Ordering information
Model CD3200
1 2 3 4 5 6 7 8
CD3200
Ex:CD3200 90A/ 400/ 480/ 460/ SSR/ ZC/ V2/ UL
1 Nominal current of CD3200M
15A 45A 110A
25A 60A
35A 90A
2 Operating Load Voltage (incoming voltage supply)
Specify the value of the line supply.
3 Max VOLTAGE of CD3200
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
PA Phase Angle + Current Limit
S + PA Soft Start + Phase Angle + Current Limit
7 Feedback
V Voltage feedback (V)
V2 Square Voltage feedback (V²)
VxI Power feedback (VxI) (option)
8 Options
COMM MODBUS protocol in RS485 is standard
CD-KP External Keypad
HB Heater Break Alarm
FAN110 Fan voltage supply 110VAC ±15% (std 230VAC ±15%) 14W
50/60Hz
UL UL Certification
EF External fuse and fuseholder
NF No Fuse

User’s Manual ver. 2.0 CD3200 up to110A Honeywell
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4.Installation and wiring information
4.1 Identification of the unit
Before to install the CD3200 unit examine for damages or deficiencies. If any is found,
notify the carrier immediately. Check that the product features shown on CD3200
cover and identification label corresponds to that ordered.
INPUTAMPS AUX. FIRING OPT.
0-10V15 60 240V
____
4-20mA25 90 440V SC DT
SSR35 110 POT45 ___ ____ PA
S.S
ZC
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
4.2 Installation
CD3200 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.
A
IR OUTPUT
A
IR INPUT
15cm
2 cm
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.

Honeywell CD3200 up to110A User’s Manual ver. 2.0
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4.3 Dimensions
Size W(mm) H(mm) D(mm)
15A (S0C) 63 120 120
25A (S0C) 63 120 120
35A (S3C) 85 120 120
45A (S3C) 85 120 120
60A (S7C) 148 120 159
90A (S7C) 148 120 159
110A (S8C) 148 138 159
4.4 Dimension CT (Heater Break HB)
8
12
39
39 20

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4.5 Fixing holes
ABC
D
Size A(mm) B(mm) C(mm) D(mm)
15A (S0C) 110 - - -
25A (S0C) 110 - - -
35A (S3C) - 110 - -
45A (S3C) - 110 - -
60A (S7C) - - 110 65
90A (S7C) - - 110 65
110A (S8C) - - 110 65

Honeywell CD3200 up to110A User’s Manual ver. 2.0
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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 hearth using its terminal
with hearth 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 24Vdc max
2 + External Calibration command 24Vdc max
3 Reset
4 Reset
5 + Output Command signal to CD3200 (Internal Connections)
6 - Output Command signal to CD3200 (Internal Connections)
A2+ + Input command signal 4÷20mA, 0÷10V
A1- - Input command signal 4÷20mA, 0÷10V
7 RS485 A
8 RS485 B
9 Output +8Vdc stabilized 1mA MAX potentiometer power supply
10 Common relay H.B. alarm
11 NC/NO H.B. relay alarm
12 External Current Profile
13 CT input with H.B. option
14 CT input with H.B. option
15 Nc not connected
16 Auxiliary supply voltage 240-440Vac
17 Ground
18 Auxiliary supply voltage 240-440Vac
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

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5.2Cabling 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)

Honeywell CD3200 up to110A User’s Manual ver. 2.0
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Power terminals wire details:
Current Supply Load
Cable Clable
mm2AWG
Screw
M mm2AWG
Screw
M
15A 4 12 M5 4 12 M5
25A 6 10 M5 6 10 M5
35A 10 8 M5 10 8 M5
45A 10 8 M5 10 8 M5
60A 16 6 M6 16 6 M6
90A 35 3 M6 35 3 M6
110A 35 2 M6 35 2 M6
Auxiliary connectors and earth:
Current Auxiliary Supply Earth
Cable Clable
mm2AWG
mm2AWG
Screw
M
15A 0,50 18 4 12 M4
25A 0,50 18 4 12 M4
35A 0,50 18 6 10 M5
45A 0,50 18 6 10 M5
60A 0,50 18 6 10 M5
90A 0,50 18 10 8 M5
110A 0,50 18 16 6 M5

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5.3 Wiring connection
5.3.1 CD3200 15-25A
POWER UNIT
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
+-
L1
L2
CT
**
* 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.
NOTE: IMPORTANT
To work, terminals 3-4 must be linked.
The auxiliary voltage supply of CD3200 unit must be connected as above, and must be
syncronized with load voltage power supply (L1, L2).
5.3.2 CD3200 35-45A
POWER UNIT
Input
CT
Reset
-+
RS485-A
1
6
2
7
3
8
4
9
5
10
RS485-B
COM
NO/NC H.B.
Contact
8V
External Calibration
+-
1
65
7
8
9
10
11
12
13
14
15
16
17
18
2
A
2+
3
A
1-
4
CT
L1
L2
**
* 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.
NOTE: IMPORTANT
To work, terminals 3-4 must be linked.
The auxiliary voltage supply of CD3200 unit must be connected as above, and must be
syncronized with load voltage power supply (L1, L2).

Honeywell CD3200 up to110A User’s Manual ver. 2.0
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5.3.3 CD3200 60-90A
Input
CT
Reset
-+
RS485-A
RS485-B
COM
NO/NC H.B.
Contact
8V
External Calibration
+-
1
65
7
8
9
10
11
12
13
14
15
16
17
18
2
A
2+
3
A
1-
4
CT
L1
L2
**
L1
T1
* 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.
NOTE: IMPORTANT
To work, terminals 3-4 must be linked.
The auxiliary voltage supply of CD3200 unit must be connected as above, and must be
syncronized with load voltage power supply (L1, L2).
5.3.4 CD3200 110A
Input
CT
Reset
-+
RS485-A
RS485-B
COM
NO/NC H.B.
Contact
8V
External Calibration
+-
1
65
7
8
9
10
11
12
13
14
15
16
17
18
2
A
2+
3
A
1-
4
CT
L1
L2
**
L1
T1
FAN
220 Vac
* 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.
NOTE: IMPORTANT
To work, terminals 3-4 must be linked.
The auxiliary voltage supply of CD3200 unit must be connected as above, and must be
syncronized with load voltage power supply (L1, L2).
Fan voltage supply standard 230VAC ±15% 14W 50/60Hz or optional110VAC ±15%
14W 50/60Hz

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5.4 LED Status Table
LED STATUS DESCRIPTION
PW Auxiliary supply is not connect
Auxiliary supply is connect
SC SCR OK
SCR short circuit
HB Laod OK
Load Fault
ON OFF Condition(Load IS NOT Powered)
ON Condition(Load IS Powered)
= OFF = ON

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6. Start up
Before to supply the thyristor unit:
• verify that load current equal or less than nominal;
For resistive load For inductive load
I =
V
P
Tot
I =V
cos φ
P
Tot
• verify that there is no short circuit on load;
• verify that main voltage equal or less than nominal;
• verify that all auxiliary connections are right and syncronized to main voltage!!!;
• Fan voltage equal than nominal (230V std, 120V optional)
After which supply thyristor unit giving the maximum input signal and verify that load current is
equal or less than thyristor unit nominal current.
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 on site the configuration, procede as below
specified.