Honeywell CD3000M-3PH User Manual

EN1I-6310

CD3000M-3PH

THYRISTOR UNIT

Up To 90A

USER’S MANUAL
Rev. 12/2004

EN1I-6310

User’s Manual CD3000M-3PH up to 90A Honeywell

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CD3000M-3PH Thyristor Unit up to 90A

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 6

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 CT dimensions (Heater Break HB) 10

4.5 Fixing Holes 11

5. Wiring Instructions 12

5.2 Cabling detail 14

5.3 Wiring connections 16

5.4 LED Status Table 19

6. START UP 20

6.1 To remove the board 21

6.2 Auxiliary supply 22

6.3 Analog input 23

6.4 Heater Break Alarm 25

7. Thyristor firing mode 30

7.1 Zero Crossing (ZC) 30

7.2 Burst Firing (BF) 30

7.3 Configurator 31

8. Fuse and fuseholder for UL certification unit 33

8.1 Fuse and Fuse Code 33

8.2 FuseHolder size 34

9. Fuse and fuseholder for CE mark unit 35

9.1 Fuse and Fuse Code 35

9.2 FuseHolder size 36

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10. Modbus communication 37

10.1 Physical requirements 37

10.2 ModBus RTU protocol 37

10.3 Word parameters 42

10.4 Thyristor unit Configuration 47

10.5 Address configuration 51

11. Maintenance 54

11.1 Trouble Shooting 54

11.2 Repairing procedure 55

11.3 Fans 55

11.4 Servicing 55

11.5 Warranty conditions 55

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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 (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 minu te 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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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 an d for load cables.

CU

LISTED

S

U

L

®

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 deman d ed 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÷20 mA
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

Zero Crossing (ZC)
Burst Firing (BF)

Auxiliary voltage supply

230V range (230 ±15%) 10VA
460V range (380 –15%) ÷ (460 +15%); 10VA

(sincronized with supply Voltage)

Fan voltage supply

230V range (230 ±15%) 10VA
460V range (380 –15%) ÷ (460 +15%); 10VA

(sincronized with supply Voltage)

Heather 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

Line Drop Voltage Automatic compensation ±15% of supply voltage with analog input
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

Analog 0÷10V - 8200 ohm

Analog 4÷20mA - 100 ohm

Potentiometer

10K ohm

8200 ohm

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2.3 Output features

NA=not Available

Current Voltage

range

Ripetitive peak

reverse voltage

Latching

current

Max peak
one cycle

Leakage

current

I2T value
thyristor

Frequency

range

Power

loss

Isolation

Voltage

(A) (V) (480V) (600V) (mAeff)

(10msec.)

(A)

(mAeff) tp=10msec (Hz)

I=Inom

(W)

Vac

15 24÷480 1200 1200 150 230 15 610 47÷70 54 2500

30 24÷600 1200 1600 250 600 15 1800 47÷70 108 2500

45 24÷600 1200 1600 250 600 15 1800 47÷70 162 2500

60 24÷600 1200 1600 250 1000 15 4750 47÷70 216 2500

75 24÷600 1200 1600 450 1540 15 11300 47÷70 270 2500

90 24÷600 1200 1600 450 2000 15 19100 47÷70 324 2500

2.4 Derating curve

1

0.8

0.6

0.4

0.2

0

40 50 60 70 80

K

°

C

I = I x K

NOMMAX

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3. Ordering information

Model CD3000M 3PH

1 2 3 4 5 6 7

CD3000M-3PH

Ex:CD3000M 3PH/ 75A/

400V/ 480V/ 460V

/

SSR/ ZC/ UL

1 Nominal current of CD3000M

15A 60A
30A 75A
45A 90A

2 Operating Load Voltage (incoming voltage supply)

Specify the value of the line supply.

3 Max VOLTAGE of CD3000M

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

ZC Zero Crossing
BF Burst firing. Specify the number on ON cycles at 50% of

power.

7 Options

COMM MODBUS protocol in RS485 is standard
EF External fuses and fuseholders
NF No fuses
CD-KP External Keypad
HB Heater Break Alarm
FAN110

Fan voltage supply 110VAC ± 15% (std 230VAC ± 15%)
14W 50/60Hz

UL UL Certification

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4. Installation and wiring information

4.1 Identification of the unit

Before to install the CD3000M unit examine for damages or deficiencies. If any is
found, notify the carrier immediately. Check that the product features shown on
CD3000M 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

CD3000M 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 INP UT

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.

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4.3 Dimensions

Size W(mm) H(mm) D(mm)

15A (S2C) 123 120 120

30A (S4C) 148 120 123

45A (S6C) 148 138 123

60A (S8C) 148 138 159

75A (S8C) 148 138 159

90A (S8C) 148 138 159

4.4 CT dimensions (Heater Break HB)

8

1

2

39

39 20

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4.5 Fixing Holes

D

E

A

B C

Size A(mm) B(mm) C(mm) D(mm) E(mm)

15A (S2C) 110 30 30 - -

30A (S4C) - - - 110 65

45A (S6C) - - - 110 65

60A (S8C) - - - 110 65

75A (S8C) - - - 110 65

90A (S8C) - - - 110 65

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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 24 Vdc max
2 + External Calibration command 24 Vdc max
3 Reset

4 Reset
5 + Output Command signal to CD3000 (Internal Connections)

6 - Output Command signal to CD3000 (Internal Connections)

A2+ + Input command signal 4÷20mA,0÷10V,SSR

A1- - Input command signal 4÷20mA,0÷10V,SSR

7 RS485 A
8 RS485 B
9 Output +8Vdc stabilized 1 mA MAX

10 Common relay H.B. alarm
11 NC/NO H.B. relay alarm
12 Option

13 CT input with H.B. option
14 CT input with H.B. option
15 Nc not connected

16 Auxiliary supply voltage 230-460Vac
17 Ground

18 Auxiliary supply voltage 230-460Vac

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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

L2 Line Input

T2 Load Output

L3 Line Input

T3 Load Output

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5.2 Cabling 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 26.6 (3.0) 18-8

UL Listed (ZMVV)
Wire Pin Terminal

(terminal avec cosse)

30A, 45A

60A, 75A, 90A

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)

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Power terminals: wire details:

Current Supply Load

Cable Clable

mm

2

AWG

Screw

M

mm

2

AWG

Screw

M

15A 4 12 M5 4 12 M5
30A 6 10 M6 6 10 M6
45A 10 8 M6 10 8 M6
60A 16 6 M6 16 6 M6
75A 25 4 M6 25 4 M6
90A 35 3 M6 35 3 M6

Auxiliary connectors and earth:

Current Auxiliary Supply Earth

Cable Clable

mm

2

AWG

mm

2

AWG

Screw

M

15A 0,50 18 4 12 M4
30A 0,50 18 6 10 M5
45A 0,50 18 6 10 M5
60A 0,50 18 6 10 M5
75A 0,50 18 6 10 M5
90A 0,50 18 6 10 M5

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5.3 Wiring connections

5.3.1 CD3000 15-25-35-45A

POWER UNIT

Input

CT

Reset

-

+

RS485-B

1

65

7

8
9

10
11
12

13
14
15

16
17
18

2

A2+3A1-

4

RS485-A

COM
NO/NC

H.B.
Contact

10V

External

Calibration

+-

POWER UNIT

POWER UNIT

CT1

L3L2L1

CT2 CT3

T3T2T1

L2
L3

L1

L2
L3

L1

**

* 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.

Open Delta Load

Delta Load

Neutral

Start Load + Neutral

NOTE: IMPORTANT

To work, terminals 3-4 must be linked.
The auxiliary voltage supply of

Drive M unit

must be connected as above, and must be
syncronized with load voltage power supply (L1,
L3).

Start Load