Honeywell HCL-1PH User manual

Honeywell Process Solutions
HCL-1PH
Thyristor Unit
from 60A to 210A
USER’S MANUAL
55-77-25-23
Rev. 1
October 2012

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Table of Contents
1 Important warnings for safety ..................................................................................... 5
2 Note ............................................................................................................................ 6
3 Introduction ................................................................................................................ 7
4 Advantages compared with analog thyristor unit ......................................................... 7
5 Software Configurator.................................................................................................. 8
6 Quick Start................................................................................................................... 9
7 Basic Connections and sizing ..................................................................................... 10
8 Identification and Order Code.................................................................................... 11
8.1 Identification of the unit 11
8.2 Order Code 12
9 Technical Specifications............................................................................................. 13
9.1 General features: 13
9.2 Input features: 13
9.3 Output features(power device): 13
9.4 Fan Specification (only from 120 to 210A) 13
10 Installation.............................................................................................................. 15
10.1 Environmental installation conditions 15
10.2 Derating Curve 15
11 Dimensions and Weight ........................................................................................... 16
11.1 Fixing holes 16
12 Wiring instructions .................................................................................................. 17
12.1 Power cable torque (suggested) 17
12.2 Cable dimensions of the Command Terminals 17
12.3 Cable dimensions of the Earth (suggested) 17
12.4 Terminals positions 17
12.5 Power Terminals 18
12.6 Command Terminals 18
12.6.1 TERMINAL BLOCK M1.........................................................................................................................18
12.6.2 TERMINAL BLOCK M2.........................................................................................................................18
12.6.3 TERMINAL BLOCK M3 (ONLY FROM 120 TO 210A) ......................................................................................18
12.7 Schematic 19
12.8 Connection Diagram for Single-phase 20

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13 Control Panel ...........................................................................................................21
13.1 Scroll the parameters 22
13.2 Operator Menu oper 23
13.3 Setup Menu Set 26
13.4 Hardware Menu HArd 29
13.5 Control Panel Led 32
13.6 Displayed Alarms 32
14 Input output signal ..................................................................................................33
14.1 Digital Input 33
14.1.1 START/STOP (TERMINAL 3OF M1) ........................................................................................................33
14.1.2 CONFIGURABLE INPUT (TERMINAL 4OF M1) .............................................................................................33
14.2 Digital Output (terminal 9-10 of M1) 33
14.3 Analog Inputs (Terminals 5 and 8 of M1) 34
14.3.1 PRIMARY INPUT CONFIGURATION. ..........................................................................................................34
14.3.2 PRIMARY INPUT CALIBRATION PROCEDURE ................................................................................................34
15 Heater Break alarm and SCR short circuit (HB Option)..............................................35
15.1 Heater break Calibration procedure 35
15.2 HB alarm contact (digital output) 35
15.3 Relay Jumper configuration on JP3 35
16 Firing type................................................................................................................36
16.1 Phase Angle (PA PA) 36
16.2 Soft Start with Phase Angle (S+PA PASt) 36
16.3 Delay Triggering with Burst Firing (DT+BF bFdt) 37
17 Current Limit............................................................................................................39
17.1.1 CURRENT LIMIT SETTING ....................................................................................................................39
17.1.2 CURRENT LIMIT TUNING PROCEDURE.......................................................................................................39
18 Feed-back type.........................................................................................................40
19 RS485 Serial Port.....................................................................................................41
20 PG Connector ...........................................................................................................41
21 Internal Fuse ...........................................................................................................42
21.1 Fuses Replacement 42
22 Maintenance.............................................................................................................43
22.1 Trouble Shooting 43
22.2 Warranty condition 43

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Dichiarazione di Conformità
Declaration of Conformity
The Manufacturer
Dichiara che il prodotto:
Declare that the product:
HCL, 1ph - 60 to 210A
FULFILS THE REQUIREMENTS OF THE STANDARD:
Electrical safety Standard EN60947-1 :2008
EN60947-4-3:2001
Generic Emission standard EN60947-4-3:2000
Generic Immunity standard EN60947-4-3:2000
The manufacturer declares that The products above mentioned they am conforming to the
directive
EMC 2004/108/CEE e alla direttiva Bassa Tensione (low Voltage) 2006/95/CEE
PRODUCT DESCRIPTION: Electric power control
SCOPE OF APPLICATION: Thermal control process
Issued on: 20/04/2010
Signed:

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1Important warnings for safety
This chapter contains important information for the safety. The not observance of these instructions may
result in serious personal injury or death and can cause serious damages to the Thyristor unit and to the
components system included.
The installation should be performed by qualified persons.
The Thyristor unit are integral part of industrial equipments. When it is supply, the
Thyristor unit is subject to dangerous tensions.
•Don't remove the protection Cover.
•Don't use these unit in aerospace applications and/ or nuclear.
The nominal current corresponds to use at temperature not superior to 45°C.
•The Thyristor unit must be mounted in vertical position and without obstruction above
and below to allow a good flow ventilation.
•The hot air of one thyristor unit must not invest the unit positioned above.
•For side by side placed leave a space of 15mm between the unit.
A suitable device must ensure that the unit can be electrically isolated from the supply, this
allows the qualified people to work in safety.
Protection (Protection, Protezione)
The unit have IP20 protection rating as defined by the specific international. Is necessary
consider the place of installation.
Earth (Terre, Messa a terra)
For safety, the Thyristor unit with isolated heat-sink must be connected to earth.
Earth impedance should be correspondent to local earth regulation. Periodically the earth
efficiency should be inspected.
Electronic supply (Alimentation électronique, Alimentazione elettronica)
The electronic circuit of the Thyristor unit must be supplied by dedicated voltage for all
electronic circuits and not in parallel with coil contactors, solenoids and other.
It's recommended to use a shielded transformer.
Electric Shock Hazard (Risque de choque électrique, Rischi di scosse elettriche)
When the Thyristor unit is energized, after the power supply is shut off, wait least a minute
for allow the discharge of the internal capacitors where there is a dangerous tension. Before
working, make sure that:
•Only authorized personnel must perform maintenance, inspection, and replacement
operations.
•The authorized personnel must read this manual before to have access to the unit.
•Unqualified People don't perform jobs on the same unit or in the immediate vicinities.

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Important warnings (Attention, Avvertenze importanti)
During the operations with units under tension, local regulations regarding electrical
installation should be rigidly observed:
•Respect the internal safety rules.
•Don't bend components to maintain insulation distances.
•Protect the units from high temperature humidity and vibrations.
•Don't touch components to prevent electrostatic discharges on them.
•Verify that the size is in line with real needs.
•To measure voltage current etc. on unit, remove rings and other jewels from fingers
and hands.
•Authorized personnel that work on thyristor unit under power supply voltage must be
on insulated board
This listing does not represent a complete enumeration of all necessary safety cautions.
Electromagnetic compatibility
(Compatibilità électromagnétique, Compatibilità elettromagnetica)
Our thyristor units have an excellent immunity to electromagnetic interferences if all
suggestions contained in this manual are respected. In respect to a good Engineering
practice, all inductive loads like solenoids contactor coils should have a filter in parallel.
Emissions (Emission, Emissioni)
All solid-state power controllers emit a certain amount of radio-frequency energy because
of the fast switching of the power devices.
The Thyristor unit are in accord with the EMC norms, CE mark.
In most installations, near by electronic systems will experience no difficulty with
interference. If very sensitive electronic measuring equipment or low-frequency radio
receivers are to be used near the unit, some special precautions may be required. These
may include the installation of a line supply filter and the use of screened (shielded) output
cable to the load.
2Note
Warning: This icon is present in all the operational procedures where the Improper
operation may result in serious personal injury or death
Caution: This icon is present in all the operational procedures where the Improper
operation can cause damage for the Thyristor unit.
Producer reserves the right to modify the own products and this manual without any
advise.

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3Introduction
A thyristor unit is semiconductor device which acts as a switch formed by two thyristors in ant parallel.
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 moving
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
Thyristor
4Advantages compared with analog thyristor unit
Communication RS485 is a standard feature of HCL this allows the use of many information like:
current, power, load state and all the parameters for diagnostic and configuration. Ulterior advantages
of the digital system vs the analogical is the flexibility and the possibility of implement special
characteristics without change the hardware. Several strategies can be implemented and selected
through the configuration parameters.
With software configuration, you can have access to the configuration parameters.
To connect the Thyristor unit to the computer use the USB\TTL converter.

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5Software Configurator
T
hyristor configurator software
is free and is possible download it from our site.
If the Order Code is in line with requirement, then
HCL has been already configured in Factory and
it's ready to use.
You need the software only to modify the ordered
configuration. Anyway we suggest to check the
unit on the machine with the "Test unit" section.
For install the software, launch the program and
follow the instructions on the screen.
Run the software configurator and set the serial
port of the PC with con baudrate =19200(default)
and the address of Thyristor unit (default=1).
To connect the unit at the PC, it's necessary use
the USB\TTL converter connected between the unit
and the USB port of the PC.
USB\TTL converter need a driver to work properly,
you can find it from our site.
Is available a full programmer kit composed by
•USB\TTL converter,
•Two cable
•Thyristor configurator software
•USB driver
With the CD-RS serial converter is possible
configure the Thyristor unit also through the
RS485 For this solution, the programming cable is
not necessary.

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6Quick Start
Attention: this procedure must be carried out by skilled people only.
If your HCL code is in line with what you really need, then the main configuration is already done by
Producer and you just need to do the following steps:
1. Verify HCL ’s current sizing. Be sure that:
•the load current is equal or less than the nominal one of HCL-1PH
•the main voltage is equal or less than the nominal voltage of HCL-1PH
2. Verify the Installation
3. Verify the Wiring:
•all auxiliary connections must be done in line with wirings on this manual
•verify that there isn’t a short circuit on the load
4. Supply the auxiliary voltage of the unit
Set the parameters U_OP (Operative Voltage) and A_Lo (Nominal Current of the load) using the
frontal keypad or Thyristor configurator software.
Υ_οΠ Operative Voltage V R/W
Function: It’s necessary to specify the operative voltage
Min/Max: 24 ÷ 1000V
Default: 230
Note: With voltage up to 330V and over 600V, HCL needs hardware
modifications: specify this in phase of ordination.
Α_Λο Load nominal current A R/W
Function: It’s necessary to specify the load current value at nominal voltage.
This current and voltage value are necessary to be able to read the
power in engineering units
Min/Max: 1 ÷ 100.0 Ampere (for size up to 100A)
Default: Nominal HCL current value if load current has not been specified.
If your HCL code is NOT in line with what you really need, use the enclosed configurator
software tool to set-up the unit. Install the software on your PC, select HCL and click on test
unit changing what you need.

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7Basic Connections and sizing
Single phase wiring with resistive load (with HCL-1PH)
V
P
I=
V = Nominal voltage of the load
I = Nominal current of the load
P = Nominal power of the load
V
I
Single phase wiring with inductive load (with HC
L
-1PH)
φ cosVP
I=
V = Nominal voltage phase to phase
I = Nominal current to the load
P = Nominal power to the load
Open Delta wiring with resistive load (with 3 X HC
L
-1PH)
V
P
I3 =
V = Nominal voltage of the load
I = Nominal current of the load
P = Nominal power of the load
V
I

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8Identification and Order Code
8.1 Identification of the unit
Caution: Before to install, make sure that the Thyristor unit have
not damages. If the product has a fault, please contact the dealer
from which you purchased the product.
The identification's label give all the information regarding the factory settings of the Thyristor unit, this
label is on the unit, like represented in figure.
Verify that the product is the same thing as ordered.

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8.2 Order Code

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9Technical Specifications
9.1 General features:
Cover and Socket material: PolymericV2
Utilization Category AC-51 AC-55a AC-55b AC-56A
IP Code 20
Method of Connecting Single Phase Load
Auxiliary voltage:
(10 VA Max)
90:130V
170:265V
230:345V
300:530V
510:690V
600:760V
Relay output for Heater Break Alarm
(only with HB option): 0.5A a 125VAC
9.2 Input features:
Logic input SSR: 4 ÷ 30Vdc 5mA Max (ON ≥4Vdc OFF <1Vdc)
Analogic input V: 0 ÷ 10Vdc impedance 15 K ohm
Analogic input A: 4 ÷ 20mA impedance 100 ohm
POT 10 K ohm min.
Digital Input 4 ÷ 24Vdc 5mA Max (ON ≥4Vdc OFF <1Vdc)
9.3 Output features(power device):
Current
Nominal
Voltage
range
(Ue)
Repetitive
peak reverse
voltage
(Uimp)
Latching
current Max peak one cycle Leakage current I2T value
max Frequency range Power loss Isolation
Voltage
(Ui)
(A) (V) (480V) (600V) (mAeff) (10msec.)
(A) (mAeff) tp=10mse
c(Hz) I=Inom
(W) Vac
60 24÷600 1200 1600 450 100 15 4750 47÷70 65 2500
90 24÷600 1200 1600 450 2000 15 19100 47÷70 84 2500
120 24÷600 1200 1600 450 1540 15 11300 47÷70 138 2500
150 24÷600 1200 1600 450 2000 15 19100 47÷70 162 2500
180 24÷600 1200 1600 300 4800 15 108000 47÷70 178 2500
210 24÷600 1200 1600 300 5250 15 128000 47÷70 202 2500
9.4 Fan Specification (only from 120 to 210A)
Supply: 230V Standard Power 16W (1 Fan)
Supply: 115V Option Power 14W (1 Fan)

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10 Installation
Before to install, make sure that the Thyristor unit
have not damages.
If the product has a fault, please contact the
dealer from which you purchased the product.
Verify that the product is the same thing as
ordered.
The Thyristor unit must be always mounted in
vertical position to improve air cooling on heat-
sink.
Maintain the minimum distances in vertical and in
horizontal as represented.
When more unit has mounted inside the cabinet
maintain the air circulation like represented in
figure.
Sometimes is necessary installing a fan to have
better air circulation.
10.1 Environmental installation conditions
Ambient temperature 0-40°C at nominal current. Over 40°C use the
derating curve.
Storage temperature -25°C a 70°C
Installation place
Don’t install at direct sun light, where there are
conductive dust, corrosive gas, vibration or water
and also in salty environmental.
Altitude
Up to 1000 meter over sea level. For higher
altitude reduce the nominal current of 2% for each
100m over 1000m
Humidity From 5 to 95% without condense and ice
Pollution Level Up to 2nd Level ref. IEC 60947-1 6.1.3.2
10.2 Derating Curve

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11 Dimensions and Weight
HCL 1PH
Size W(mm) D(mm) H(mm) Weight (kg)
1PH (60-90A no Fan) 93 170 269 3,4
1PH (120-210A with Fan) 93 170 273 3,6
11.1 Fixing holes
HCL 1PH
1PH (60-90A no Fan) 1PH (120-210A with Fan)

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H1 256 260
12 Wiring instructions
The Thyristor unit could be susceptible to interferences lost by near equipments or by the power supply,
for this reason in accord to the fundamental practices rules is opportune take some precautions:
•The coil contactor, the relays and other inductive loads must be equipped with opportune RC filter.
•Use shielded bipolar cables for all the input and output signals.
•The signal cables must not be near and parallel to the power cables.
•Local regulations regarding electrical installation should be rigidly observed.
Use co
pp
er cables and wires rated for use at 75°C onl
y
.
12.1 Power cable tor
q
ue
(
su
gg
ested
)
Type Connector
Type Torque Lb-in (N-m) Wire Range mm²(AWG ) MAX Current Terminals Wire Terminals UL Listed (ZMVV)
060
090
120
Screw M6 70.8 (8.0) 1
150
Fork/Spade Terminal
Copper Tube Crimp.Lug
150
180
210
Screw M8 265 (30.0) 1
3/0 250
Copper wire
Compact (Solid)
Stranded
12.2 Cable dimensions of the Command Terminals
0.5mm² (AWG 18)
12.3 Cable dimensions of the Earth
(
su
gg
ested
)
16 mm² (AWG 6) up to 120A
25 mm² (AWG 4) up to 210A
12.4 Terminals positions
123456 7 89 10 11 12
12
345678910
11 12
Tn
Ln
M1
M2
TOP VIEW DOWN VIEW
M3

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12.5 Power Terminals
Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.
Terminal Description
L1 Line Input Phase 1
T1 Load Output Phase 1
12.6 Command Terminals
Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.
12.6.1 Terminal block M1
Terminal Description
1 GND
2 COM I - Common Digital Input
3 DI 2 – Enable Digital Input
4 DI 1 - Configurable Input
5 + Control Input (SSR/0-10Vdc/4-20mA)
6 - Control Input (SSR/0-10Vdc/4-20mA)
7 Output +10Vdc stabilized 1 mA MAX
8 + Ext CL - External Current Profiler
9 C - Common contact alarm relay output (see HB Alarm contact for config.)
10 NC\NO -Normally Close\Open contact alarm relay output (see HB Alarm contact for config.)
11 RS485 A
12 RS485 B
12.6.2 Terminal block M2
Terminal Description
L1 Aux – Voltage Supply for elettronic boards and syncronizzation (See order code for the Value)
- Not Connected
L2/N Aux – Voltage Supply for elettronic boards and syncronizzation (See order code for the Value)
12.6.3 Terminal block M3 (only from 120 to 210A)
Terminal Description
F1 Fan supply (230V Standard – 115V Option)
F2 Fan supply (230V Standard – 115V Option)

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12.7 Schematic
NOTE:
•*The user installation must be protecting by electromagnetic circuit breaker or by fuse isolator.
The semiconductor I2t should be 20% less than power controller I2t.
Semiconductor fuses are classified for UL as supplemetar protection for semiconductor.
They are note approved for branch circuit protection.
•*² The auxiliary voltage supply of the HCL unit must be synchronized with load voltage power
supply. If the Auxiliary Voltage (written on the identification label) is different from Supply Voltage
(to the load), use an external transformer as designated.

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12.8 Connection Diagram for Single-phase
Caution: this procedure must be performed only by qualified persons.
*1 A suitable device must ensure that the unit can be electrically isolated from the supply, this allows
the qualified people to work in safety.
*2 See par. “Heater Break alarm and SCR short circuit (HB Option)”