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CD Automation CD3000E-2PH Operator's Manual

Thyristor unit
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OPERATOR'S MANUAL
Rev. 02/2006
CD Automation S.r.l.
Via Picasso 34/36 - 20025 – Legnano (MI) – ITALY
Tel +39 0331 577479 – Fax +39 0331 579479
E-Mail:
info@cdautomation.com
CD3000
THYRISTOR UNIT
from 25A to 700A
- WEB:
www.cdautomation.com
E
-2PH

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Summary of Contents for CD Automation CD3000E-2PH

  • Page 1 CD3000 -2PH OPERATOR’S MANUAL Rev. 02/2006 THYRISTOR UNIT from 25A to 700A CD Automation S.r.l. Via Picasso 34/36 - 20025 – Legnano (MI) – ITALY Tel +39 0331 577479 – Fax +39 0331 579479 E-Mail: info@cdautomation.com - WEB: www.cdautomation.com...
  • Page 3 INDEX 1 Warnings ........................5 1.1 Important warning for safety 2 Introduction ........................7 2.1 Advantages compared with analog thyristor unit. 2.2 CD-KP high lights 2.3 Clone facility using CD-EASY 2.4 Configurator 3 Quick Start ........................11 4 CD3000E Sizing ......................12 5 Installation and wiring information ................
  • Page 4 14.5 Preset multiple registers (write n words) - Function 16 14.6 Error and exception responses 14.7 Modbus parameters 15 Maintenance ......................62 15.1 Fans 15.2 Servicing 15.3 Repairing procedure 15.4 Warranty condition 16 CD Automation’s distributors..................63 17 Note .......................... 65...
  • Page 5 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 1 Warnings 1.1 Important warning for safety This chapter contain instruction about safety. The non observation of these warnings can cause serious accident and the loss of life of operator. Serious damages can be also caused to the thyristor unit and to the component system in which is included.
  • Page 6 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A Protection(protection) CD3000E thyristor unit has an insulated cover to compliance to International specification IP20. To understand if IP20 protection is sufficient should be evaluated the installation place where the units are installed Earth(terre) CD3000E family has isolated heatsink.

  • Page 7: Advantages Compared With Analog Thyristor Unit

    The electronic control circuit of CD3000E is “full digital” and is based on a powerful microprocessor RISC Embedded 16 Bit with high performance. 2.1 Advantages compared with analog thyristor unit. CD3000E-2PH is an universal thyristor unit and the same unit can work in different modes: • Burst Firing •...
  • Page 8 • Second level access: By connecting a PC to the RS232 port, located on the front of the CD-KP, it’s possible to have access to all parameters of the CD Automation Thyristor Unit using the free downloadable Configuration Software. Configuration changes can be made interactively, without powering down the unit, removing...
  • Page 9 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 2.3 Clone facility using CD-EASY CD-EASY is a Memory Support used by maintenance personnel in the shop floor. The Clone Facility makes it possible to copy the configuration of one Thyristor Unit and paste it into another in a matter of seconds.
  • Page 10 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 2.4 Configurator You can download the free software and the Configurator Manual from our web site. www.cdautomation.com If the CD3000E code is in line with your requirement , providing that the...

  • Page 11: Quick Start

    Attention: this procedure must be carried out by skilled people only. If your CD3000E code is in line with what you really need, then the main configuration is already done by CD Automation and you just need to do the following steps: 1. Verify CD3000E’s current sizing. Be sure that: •...
  • Page 12 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 4 CD3000E Sizing 4.1.1 Star wiring with resistive load V = Nominal voltage phase to phase I = CD3000E Nominal current P = Nominal power to the load 4.1.2 Star wiring with inductive load φ...

  • Page 13: Installation And Wiring Information

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 5 Installation and wiring information 5.1 Identification of the unit Before to install the CD3000E unit examine for damages or deficiencies. If any is found, notify the carrier immediately. Check that the product features shown on CD3000E identification label corresponds to that ordered (see par.5.2)

  • Page 14: Ordering Code

    Load Voltage(incoming voltage supply) 4÷20mA 4÷20mA 470Ω Specify this value that will be used to configure 10KΩ potentiometer the unit in CD Automation. If this is not specified Comm RS485 link must be configured by customer using software configurator External Current Profiler 0÷10V...

  • Page 15: Environmental Installation Conditions

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 6 Installation CD3000E 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.
  • Page 16 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 6.2 Dimensions CD3000E 2PH CD3000E 2PH CD3000E 2PH 25-150A (S9) 200A (S10) 275A-700A (S14) Size W(mm) H(mm) D(mm) 25A (S9) 35A (S9) 45A (S9) 75A (S9) 100A (S9) 150A (S9)

  • Page 17: Fixing Holes

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 6.3 Fixing holes Size A(mm) B(mm) C(mm) 25A (S9) 35A (S9) 45A (S9) 75A (S9) 100A (S9) 150A (S9) 200A (S10) 275A (S14) 400A (S14) 450A (S14) 500A (S14) 600A (S14)

  • Page 18: Wiring Instructions

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 7 Wiring instructions 7.1 Removing the cover For S9 and S10 size you must open the cover to configure the unit and to view the fuses For S14 sizes, open the cover to wire, to configure the unit and to inspect the fuses & thyristors Warning: this procedure can be done just by specialized personnel CD3000E unit has isolated heatsink.

  • Page 19: Power Terminals

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 7.2 Power Terminals Before to connect or disconnect, make sure that power cables and auxiliary wires are insulated from live voltage. Terminal Description Line Input Phase 1 Load Output Phase 1...

  • Page 20: Wiring Details

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 7.3 Wiring details Use 75°C copper (CU) conductor only, provided with the terminal type indicated below. 7.3.1 Power cable torque (suggested) Current Torque Wire Wire Lb-in (N-m) Range Terminal AWG / kcmill 25A, 35A, 45A, 265 (30.0)
  • Page 21 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 7.3.3 Auxiliary cable dimensions (suggested) Current Auxiliary Supply Earth Cable Cable Screw 0,50 0,50 0,50 0,50 100A 0,50 125A 0,50 150A 0,50 275A 0,50 400A 0,50 450A 0,50 500A 0,50...
  • Page 22 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 7.4 Auxiliary connections, CD3000E MP BOARD Terminal Description Auxiliary supply voltage 93-265Vac ( See order code) Auxiliary supply voltage 93-265Vac ( See order code) N.C. not connected Supply Digital Input/Output +12Vdc (Max 20mA)
  • Page 23 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 7.5 Diagram of control connection from 25 to 200A Warning: this procedure can be done just by specialized personnel. Size S9 and S10...
  • Page 24 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 7.6 Diagram of control connection from 275 to 700A Warning: this procedure can be done just by specialized personnel. Size S14...

  • Page 25: Wiring Overview

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 7.7 Wiring overview In the figure below is represented the wiring for power and auxiliary cables of CD3000E RS485 Before give the Start command (terminal 18) supply the auxiliary voltage to the terminals 1 and 2.

  • Page 26: Technical Features

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 8 Technical features 8.1 Power output features Current Voltage Ripetitive peak Latching Max peak Leakage T value Frequency Power Isolation range reverse voltage current one cycle current thyristor range loss...

  • Page 27: Led Status And Alarms

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 9 Led status and alarms CD3000E has alarms and events grouped in 2 parameters on serial link (P001 AL_1, P002 AL_2). Parameter P001 AL_1 shows alarms that stop the CD3000E.

  • Page 28: Critical Alarms

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 9.2 Critical alarms These alarms are active after a START command in case of: • Phase lost • Incorrect phase rotation • Over temperature on heatsink When one of these alarms is active, the unit stops and must be reset before to start again. Via RS485 (MODBUS) it’s possible also to discriminate witch type of alarm occurred.
  • Page 29 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 9.4 Events and alerts that don’t stop CD3000E The following events and alerts don’t stop the unit: • SCR Short Circuit (SC) • Heater Break (HB) • Unbalanced Load •...

  • Page 30: Heater Break Alarm And Scr Short Circuit

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 9.6 Heater break alarm and scr short circuit The Heater Break Alarm is a circuit to diagnostic partial or total load failure. • sensibility better than 20%; • alarm stored in memory;...
  • Page 31 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 10 Types of firing mode Attention: this procedure must be carry out by skilled people only. 10.1 Burst firing To configure Burst Firing via software configurator select P023 Fir and set it at 0. Burst Firing deliveres to the load a package of complete voltage supply cycles.

  • Page 32: Delay Triggering (Dt)

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 10.2 Delay triggering (DT) This firing mode is used to switch ON primary of transformer coupled with normal resistance on secondary. Don’t connect cold resistance on secondary(superKanthal, Molybdenum, Platinum, Tungsten Quartz Lamp).
  • Page 33 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A Delay Angle α Burst Firing without Delay Burst with Delay Triggering To better understand, the sinusoidal waveform represented at figure 2 are generate by vectors rotating anticlockwise. All the electronic circuits use the zero voltage crossing as a reference. In Burst Firing without Delay when the V1 is zero (its projection on x axle) the unit switch ON.
  • Page 34 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 10.3 Feed back (control mode) Attention: this procedure must be carry out by skilled people only. The feed-back defines the Control Mode. It’s possible to have: Voltage feed-back. The output voltage of CD3000E is proportional to input signal. This means that input signal becomes a voltage demand.

  • Page 35: Connection Description

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11 Connection description 11.1 Electronic boards To have access to the electronic boards the user must open the unit’s cover(see par.7.1) Warning: this procedure can be done just by specialized personnel.
  • Page 36 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.1.1 Jumper’s position on CD3000E-MP board The jumper’s position changes in function of the CD3000E size. The control board and the jumper’s position on The control board and the jumper’s position on...

  • Page 37: Auxiliary Power Supply Connections

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.2 Auxiliary power supply connections The auxiliary voltage supplies the electronic board and the fan, so check the nominal voltage on the label. Terminal Description Auxiliary voltage supply 120/240V (for the electronic board and fans) Auxiliary voltage supply 120/240V (for the electronic board and fans) 11.3 Analog inputs...
  • Page 38 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.3.1 Main reference signal configuration (Terminal 8) The main reference signal is already configured in line with customer requirements that are defined in the complete product code.The product code is written on the identification label.
  • Page 39 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.3.2 Input calibration procedure Warning: this procedure can be done just by specialized personnel. This procedure is needed only if you change the input type START TUNE Auxiliary power supply Mantain Kay CAL pushed 2sec.
  • Page 40 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.3.3 Secondary input (Terminal 9) This analogue input 0-10V may be configured for External current limit profiling: from 25 to 200A from 275 to 700A JP20 JP11 P090 P090 Type...
  • Page 41 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.4 Analog outputs (Terminal 10) 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 the configuration on site, proceed as below specified.

  • Page 42: Digital Input

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.5 Digital Input CD3000E thyristor unit has 4 opto-isolated digital inputs. 11.5.1 Reset Alarm (Terminal 17 see par.7.4) Use a free voltage instantaneous contact normally open (reset) When an alarm occurs use reset to clear the alarm.
  • Page 43 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.5.4 Configurable input (Terminal 20 see par.7.4) Use a free voltage contact normally open (NO). This digital input may be configured for one of following purposes: • Additional Reset alarm status •...

  • Page 44: Digital Output

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.6 Digital output CD3000E thyristor unit has 3 digital output (4 for size from 275 to 700A)to diagnose the thyristor status. 11.6.1 Run Relay (Terminals 13-14) This is a free contact relay output. When the unit is in start mode the relay is energized.
  • Page 45 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.6.2 Critical Alarm (Terminal 15) This is a logic NPN 12Vdc (20mA max) output. When no alarm occurs the terminal output 15 is 12Vdc, when an alarm occurs this PEA12...
  • Page 46 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.6.4 Conf Relay (Terminals 11-12 only for size from 275 to 700A) This is a free contact relay output. This contact may be NC or NO. from 275 to 700A...

  • Page 47: Rs485 Serial Connection

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.7 RS485 serial connection The serial communication port is on terminal block and on 9 pin DIN connector. On this port may be done a network up to 255 CD3000E.
  • Page 48 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 11.8 PG Connector The programmer port (PG) is used to configure the thyristor unit with the configuration software and with the programmer cable. PG Connector...

  • Page 49: Fuses And Fuseholder

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 12 Fuses and Fuseholder 12.1 Fuses and Fuse Code CD3000E unit must be protected by fuses against short circuit selecting the proper I²t that must be lower than the thyristor one. The same caution must be taken if Circuit Breaker is used. Remember that is very difficult to protect the thyristor if this choise is done.
  • Page 50 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 13 Parameters on software tools 13.1 Suggested recipe 13.1.1 ZC - Zero Crossing firing mode OPERATOR MENU Parameter Name Description Mode P003 (H03) L--r Local/remote Set-point selection P004 (H04) L_Sp...
  • Page 51 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 13.1.2 BF - BURST firing mode OPERATOR MENU Parameter Name Description Mode P003 (H03) L--r Local/remote Set-point selection P004 (H04) L_Sp Local Set-point value P019 (H13) OutN Maximum Output P024 (H18)
  • Page 52 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 13.1.3 DT - Delay Triggering OPERATOR MENU Parameter Name Description Mode P003 (H03) L--r Local/remote Set-point selection P004 (H04) L_Sp Local Set-point value P019 (H13) OutN Maximum Output P024 (H18)

  • Page 53: Modbus Communication

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 14 Modbus communication The CD3000E is equipped with two-wire RS485- serial communication.This means that communication can be between the CD3000E and a master device (e.g. a computer or terminal). 14.1 Physical requirements Character Transmission Data format is fixed to be one start bit, eight data bits, one stop bit and the parity none.
  • Page 54 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A Since only the RTU form of the protocol is supported, each message is followed by a two-byte CRC 16 (a 16-bit cyclic redundancy checksum). This checksum is calculated in accordance with a formula which involves recursive division of the data by a polynomial, with the input to each division being the remainder of the results of the previous division.
  • Page 55 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A C Language CRC 16 Example static short CRC16 (unsigned char *p_first,unsigned char *p_last) unsigned int crc=0xffff; short j; for (;p_first<=p_last;p_first++) crc ^= *p_first; for(j=8;j>0;j--) if(crc & 0x0001) crc = crc >> 1;...
  • Page 56 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 14.4 Read holding registers (read n words) – Function 03 The message sent to the unit to obtain the value of one or more registers comprises the following eight bytes: Addr.
  • Page 57 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 14.6 Error and exception responses If a received message contains a corrupted character (parity check failure, framing error etc.) or if the CRC16 check fails, or if the received message is otherwise syntactically flawed (e.g. byte count or word count is incorrect), the CD3000E will ignore that message.

  • Page 58: Modbus Parameters

    C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 14.7 Modbus parameters P001 (H01) AL_1 Status Code/Alarm Function: This read only information gives following alarms that stop CD3000E Value: 00 = NO Alarm 01 = Phase lost 02 = Wrong phase rotation...
  • Page 59 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A P025 (H19) rP-d Ramp down Function: This parameter sets ramp down time Min/Max: 0 ÷ 1000 sec Default: 2 sec P031 (H1F) Uout Average voltage output on the three phases...
  • Page 60 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A P091 (H5B) Internal current limit value Function: With P090 CL_i =1 The setted value correspond at Internal current limit Min/Max: 0,0 ÷ 100,0% Default: 100,0 P097 (H61) Offset Analog Output Function: This parameter is used to set the Analog Output (see par.11.4)
  • Page 61 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A P115 (H73) Addr Address number Function: It identifies the drive number on communication master/slave. Value: 1 = Drive 1 2 = Drive 2 … 127 = Drive 127 Default: P116 (H74)

  • Page 62: Maintenance

    Use a rugged packaging to ship the unit. 15.4 Warranty condition CD Automation gives a 12 months warranty to its products. The warranty is limited to repairing and parts substitution in our factory and does exclude products not properly used and fuses.
  • Page 63 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 16 CD Automation’s distributors For a more precise and rapid service, please contact the distributor nearest to you: ITALY CABE S.r.l. Vectra Misure S.r.l. Via Ferrara, 15/17 Via Gaidano, 109/17 40018 S.
  • Page 64 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A CasCade Automation Systems BV Paragon Alliance Ltd Ridderhaven, 16 PO Box 104 - Pevensey 2984 BT Ridderkerk BN23 5WZ - East Sussex The Netherlands England Tel: +31 180463870 Tel: +44 1323740800...
  • Page 65 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A 17 Note...
  • Page 66 C.D. Automation srl CD3000E-2PH User’s Manual from 25A to 700A...

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