Honeywell CD3000S-3PH User manual

EN1I-6305
USER’S MANUAL CD3000S-3PH
THYRISTOR UNIT
From 125A to 500A
Rev. 12/2004

EN1I-6305

User’s Manual CD3000S-3PH from 125A to 500A Honeywell
CD3000S-3PH Thyristor Unit from 125A to 500A
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
2.5 Fans 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 Fixing Holes 10
5. Wiring instructions 11
5.1 Removing the cover 11
5.2 Cabling detail 14
5.3 Wiring connection 16
5.4 LED Status Table 17
6. Start up 18
6.1 Auxiliary supply 19
6.2 Input configuration 20
7. Thyristor firing mode 21
7.1 Zero Crossing(ZC) 21
8. Fuses and fuseholder 22
8.1 Fuses and Fuse Code 22
9. Maintenance 23
9.1 Trouble Shooting 23
9.2 Repairing procedure 24
9.3 Fans 24
9.4 Servicing 24
9.5 Warranty conditions 24
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Honeywell CD3000S-3PH from 125A to 500A User’s Manual
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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User’s Manual CD3000S-3PH from 125A to 500A Honeywell
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.
CU
LISTED S
UL
®
NOTE
We reserves the right to apply modifications to the our products without any advice.
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Honeywell CD3000S-3PH from 125A to 500A User’s Manual
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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User’s Manual CD3000S-3PH from 125A to 500A Honeywell
2. Technical specifications
2.1 General Features:
Operating temperature 0÷45°C for higher temperature see derating curve
Voltage power supply 24V minimum, 480V max and 600V on request
Input signal SSR
Firing mode Zero Crossing (ZC)
Auxiliary voltage supply 230 Æ200÷230V ±15%; 10 VA power consumption
460 Æ300÷460V ±15%; 10 VA power consumption
Fan voltage supply 230V ±15%;
110V ±15% on request
Fuses Internal
Mounting Bulk head 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
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Honeywell CD3000S-3PH from 125A to 500A User’s Manual
2.3 Output features
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) (480V) (600V) (mAeff) (10msec.) (A) (mAeff) tp=10msec. (Hz) I=Inom
(W) Vac
125 24÷600 1200 1600 450 2000 15 19100 47÷70 450 2500
150 24÷600 1200 1600 450 2000 15 19100 47÷70 540 2500
225 24÷600 1200 1600 300 4800 15 108000 47÷70 810 2500
300 24÷600 1200 1600 300 5250 15 128000 47÷70 1080 2500
350 24÷600 1200 1600 200 7800 15 300000 47÷70 1260 2500
400 24÷600 1200 1600 200 8000 15 306000 47÷70 1440 2500
450 24÷600 1200 1600 1000 17800 15 1027000 47÷70 1620 2500
500 24÷600 1200 1600 1000 17800 15 1027000 47÷70 1800 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
2.5 Fans
The thyristor units are equiped with a fan. The fan supply must be protected with a fuse.
Fan voltage supply is standard 230VAC ±15% 50/60Hz or optional 110VAC ±15% 50/60Hz.
The power consumption is given in the table below.
Size Number of fans
CU
LISTED S
UL
®
Number of fans
125A, 150A One Fan - 14W One Fan - 14W
225A Two Fans - 30W Two Fans - 30W
300A, 400A, 500A Four Fans - 60W Four Fans - 60W
350A, 450A Two Fans - 30W Four Fans - 60W
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User’s Manual CD3000S-3PH from 125A to 500A Honeywell
3. Ordering information
Model CD3000S 3PH
1 2 3 4 5 6 7
CD3000S-3PH
Ex:CD3000S 3PH/ 150A/ 400V/ 480V/ 460V/ SSR/ ZC/ UL
1 Nominal CURRENT of CD3000S
125A 300A 450A
150A 350A 500A
225A 400A
2 Operating Load Voltage (incoming voltage supply)
Specify the value of the line supply.
3 Max VOLTAGE of CD3000S
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
6 Firing
ZC Zero Crossing
7 Options
FAN110 Fan voltage supply 110VAC ±15% (std 230VAC ±15%)
14W 50/60Hz
UL UL Certification
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Honeywell CD3000S-3PH from 125A to 500A User’s Manual
4. Installation and wiring information
4.1 Identification of the unit
Before to install the CD3000S unit examine for damages or deficiencies. If any is
found, notify the carrier immediately. Check that the product features shown on
CD3000S identification label corresponds to that ordered.
An identification label provide all the informations regarding the factory settings of the unit. This
label is on the board inside the unit, as represented below:
4.2 Installation
Identification Label
CD3000S 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 better air circulation.
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User’s Manual CD3000S-3PH from 125A to 500A Honeywell
4.3 Dimensions
Size W(mm) H(mm) D(mm)
125A (S11) 137 440 270
150A (S11) 137 440 270
225A (S13) 262 440 270
300A (S14) 262 520 270
350A (S14) 262 520 270
400A (S14) 262 520 270
450A (S14) 262 520 270
500A (S14) 262 520 270
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Honeywell CD3000S-3PH from 125A to 500A User’s Manual
4.4 Fixing Holes
A
B
C
Size A(mm) B(mm) C(mm)
125A (S11) 97 415 97
150A (S11) 97 415 97
225A (S13) 222 415 222
300A (S14) 222 495 222
350A (S14) 222 495 222
400A (S14) 222 495 222
450A (S14) 222 495 222
500A (S14) 222 495 222
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User’s Manual CD3000S-3PH from 125A to 500A Honeywell
5. Wiring instructions
5.1 Removing the cover
To open the unit apply as follow.
For S11 size you must open the cover to configure the unit and to view the fuses
For S13 and S14 sizes, you must open the cover to cable, to configure the unit and to view the fuses
Warning: this procedure can be done just by specialized personnel
CD3000S unit has isolated heatsink. For safety connect the heatsink to hearth using
its terminal with hearth symbol.
CD3000S 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.
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Honeywell CD3000S-3PH from 125A to 500A User’s Manual
5.1.1 Auxiliary Terminals
Before connect or disconnect, make sure that the power, control cables and wires are
insulated from the voltage
Terminal Description
1 Auxiliary supply voltage 230-460Vac (600V opt.)
2 N.C. not connected
3 Auxiliary supply voltage 230-460Vac (600V opt.)
4 N.C. not connected
5 Fan supply 230V (110V opt.)
6 Fan supply 230V (110V opt.)
7 Reset
8 Reset
9 + Input command signal SSR
10 - Input command signal SSR
11 ∅Volt GND
12 Output + 8Vdc stabilized, 1mA max
13 +Output command signal to CD3000 slave
14 - Output command signal to CD3000 slave
15 Not used
16 Not used
17 Not used
18 Not used
19 Not used
20 Not used
Auxiliary terminals
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User’s Manual CD3000S-3PH from 125A to 500A Honeywell
5.1.2 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 Phase 1
T1 Load Output Phase 1
L2 Line Input Phase 2
T2 Load Output Phase 2
L3 Line Input Phase 3
T3 Load Output Phase 3
S11 power connection S13 power connection
S14 power connection
T
1 T2 T3
L1 L2 L3 T1 T2
T
3
L3L1 L2
L1 T1 L2 T2 L3 T3
L1 L2 L3
T1 T2 T3
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Honeywell CD3000S-3PH from 125A to 500A User’s Manual
5.2 Cabling detail
Use 75°C copper (CU) conductor only, provided with the terminal type indicated below.
Current/courant Torque/couple
Lb-in (N-m) Wire Range/cable Wire Terminal/terminal
125A, 150A,
225A 310 (35.0) Polymeric Terminal Block M8
300A 372 (42.0) Bus Bar Adapter M8
350A, 400A
18 - 600kcmil
450A, 500A 505 (57.0) Bus Bar Bus Bar Adapter M10
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User’s Manual CD3000S-3PH from 125A to 500A Honeywell
Power terminals: wire details:
Current Supply
L1, L2 and L3 Load T1, T2 and T3
Cable Cable
mm2AWG
Screw
M mm2AWG
Screw
M
125A 50 1 M8 50 1 M8
150A 70 1/0 M8 70 1/0 M8
225A 120 4/0 M8 120 4/0 M8
300A 2 x 70 2 x 1/0 M8 2 x 70 2 x 1/0 M8
350A 2 x 95 2 x 3/0 M10 2 x 95 2 x 3/0 M10
400A 2 x 95 2 x 3/0 M10 2 x 95 2 x 3/0 M10
450A Bus Bar 30 x 6 mm Bus Bar 30 x 6 mm
500A Bus Bar 60 x 4 mm Bus Bar 60 x 4 mm
Auxiliary connectors and earth:
Current Auxiliary Supply Earth
Cable
Cable
mm2AWG
mm2AWG
Screw
M
125A 0,50 18 16 6 M6
150A 0,50 18 16 6 M6
225A 0,50 18 25 4 M8
300A 0,50 18 50 1 M8
350A 0,50 18 50 1 M8
400A 0,50 18 50 1 M8
450A 0,50 18 70 1/0 M8
500A 0,50 18 70 1/0 M8
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Honeywell CD3000S-3PH from 125A to 500A User’s Manual
5.3 Wiring connection
5.3.1 CD3000S 3PH 125-500A
RESET 7
RESET 8
INPUT + 9
INPUT - 10
0V GND 11
+ 8V 12
SLAVE + 13
SLAVE - 14
15
16
17
18
L2
L3
L3
L2L1
T3T2T1
L1
Open Delta Load
Delta Load
Star with or without Neutral
Load
Neutral
240/460V 3
PE 4
FAN 5
FAN 6
240/460V 1
2
19
20
FAN SUPPLY 230V Std
INPUT SIGNAL
SSR/Volt/mA
**
NOTE: IMPORTANT
* The user installation must be protected by electromagnetic circuit
breaker or by fuse isalator.
** If the auxiliary voltage (written on the identification label) is different
from supply voltage (to the load), use an external transformer, as
reported above.
To work terminals 7-8 must be linked.
Fan voltage supply is standard 230VAC ±15% 50/60Hz or optional 110VAC ±15% 50/60Hz. For
power consumption see fan paragraph.
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User’s Manual CD3000S-3PH from 125A to 500A Honeywell
5.4 LED Status Table
LED STATUS DESCRIPTION
PW
(green led) Auxiliary supply is not connect
Auxiliary supply is connect
ON
(green led) OFF Condition (Load IS NOT Powered)
ON Condition (Load IS Powered)
= Light OFF = Light ON
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Honeywell CD3000S-3PH from 125A to 500A User’s Manual
6. Start up
Before to supply the thyristor unit:
• verify that load current equal or less than nominal;
For resistive load (star or delta) For resistive load open delta
I
P
tot
=V
3
I3V
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;
• fan voltage equal than nominal (230V std , 110V 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.
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