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 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

• 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.

Honeywell CD3200 up to110A User’s Manual ver. 2.0

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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 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.

User’s Manual ver. 2.0 CD3200 up to110A Honeywell

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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

User’s Manual ver. 2.0 CD3200 up to110A Honeywell

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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

0

45 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 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 (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

1

2

39

39 20

User’s Manual ver. 2.0 CD3200 up to110A Honeywell

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4.5 Fixing holes

A

B

C

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

User’s Manual ver. 2.0 CD3200 up to110A Honeywell

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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)

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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
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

mm

2

AWG

mm

2

AWG

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+3A1-

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

162738495

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).