USER’S MANUAL

Rev. 01/2007
CD3000M-3PH
Thyristor Unit
from 15A to 90A

CD Automation S.r.l.
Via Picasso 34/36 - 20025 – Legnano (MI) – ITALY
Tel +39 0331 577479 – Fax +39 0331 579479
E-Mail: [email protected] - WEB: www.cdautomation.com
 SUMMARY

1 Important warnings for safety..................................................................................... 5

2 Introduction ................................................................................................................ 7
2.1 Advantages compared with analog thyristor unit 7
2.2 CD-KP 8
2.3 CD-EASY 8
2.4 Software Configurator 9

3 Quick Start ................................................................................................................ 10

4 CD3000M Sizing......................................................................................................... 10

5 Identification and Order Code.................................................................................... 11

5.1 Identification of the unit 11
5.2 Order Code 12

6 Installation ................................................................................................................ 13
6.1 Environmental installation conditions 13
6.2 Dimensions and Weight 14
6.3 CT dimensions (only with the HB option) 14
6.4 Fixing holes 15

7 Wiring instructions .................................................................................................... 16

7.1 Removing the cover 16
7.2 Wiring details 17
7.3 Power Terminals 18
7.4 Command Terminals 18
7.5 Diagram of control connection from size 15A 19
7.6 Diagram of control connection from size 35A to 100A 20

8 Power output features ............................................................................................... 21

8.1 Derating curve 21
8.2 Cooling fans 21

9 Led status and Alarms ............................................................................................... 22

9.1 LED Status Table 22
9.2 Not Critical Alarm 22
9.3 Calibration Procedure 23

10 Firing type ............................................................................................................... 24

10.1 Zero Crossing (ZC) 24
10.2 Burst Firing (BF) 24
11 Connection description ............................................................................................ 25
11.1 Access to the Electronic boards 25
11.2 Supply the Electronic Board 26
11.3 Analog Inputs 27
11.4 Digital Input 29
11.5 Digital Output 30
11.6 PG Connector 31
11.7 RS485 Serial Port 31
11.8 Address configuration 32

12 MODBUS communication ......................................................................................... 33

12.1 MODBUS RTU Protocol 33
12.2 Message Format 33
12.3 Read Holding Registers 35
12.4 Preset Multiple Registers 35
12.5 Error and exception responses 36

13 Configuration Parameters ........................................................................................ 37

14 FuseHolder and Fuses .............................................................................................. 40

14.1 FuseHolder size 40
14.2 Fuses and Fuse Code for UL 41
14.3 Fuses and Fuse Code for CE 42

15 Maintenance ............................................................................................................ 43
15.1 Trouble Shooting 43
15.2 Fans 44
15.3 Maintenance 44
15.4 Repairing procedure 44
15.5 Warranty condition 44

16 Note ........................................................................................................................ 45
CD Automation srl CD3000M-3PH from 15A to 90A User’s Manual

1 Important 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 40°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 CD Automation’s 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.

Note

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.

CD Automation reserves the right to modify the own products and this manual without any
advise.

C
UL
® US
LISTED

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2 Introduction
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.

Thyristor

Load

2.1 Advantages compared with analog thyristor unit

Communication RS485 is a standard feature of CD3000M 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 CD-KP, you can have access to the configuration parameters without expose at the dangerous
voltage inside the cabinet and without stop the plant.

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2.2 CD-KP
The CD-KP is designed to be connected with all CD Automation's Thyristor units via RS485
communication. On front unit is possible to read the principal operational parameters of the unit like:
power, tension, current, reference, alarms, etc.
One of these variables can be selected and retransmitted via an isolated output (4÷20mA or 0÷10V)
All the menus (except the operator menu) can be protected by password to avoid accidental change of
configuration parameters by unauthorised personnel.
On front unit is also available a plug-in connector RS485 for connect a PC with the Thyristor units
without open the cabinet and without stop the production process.

Technical Specification:

• Use in Local/Remote
• Set Point Ramp UP - Down
• Scroll selection of:
- Set point
- Power output
- Current
- Voltage
• Display indication for:
- Heater Break alarm
- SCR short circuit
• Password for configuration parameters
• Plug-in connector on front to use software configurator
• Retransmission (4÷20mA or 0÷10Vdc) of one of these
parameters: Power PV, Current, Voltage.
• Dimension 48x96x92mm (LxAxP)
• Comply with EMC, CE marked

2.3 CD-EASY
CD-EASY is a Memory of support used for maintenance people that is not confident in personal
computer.
With the CD-EASY is possible memorize the configuration of one Thyristor Unit and paste it into another
in few seconds.
CD-EASY could be loaded with the personal configuration of the unit and stored together with the
system drawings in a convenient place, enabling unit reconfiguration within seconds if require.

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2.4 Software Configurator

The software configuration is free and is possible
download it from our site:
www.cdautomation.com

If the Order Code is in line with requirement, then

CD3000M 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.

To connect the unit at the PC, it's necessary use

the programming cable connected between the PG
connector (see par. 11.6) and the serial port
RS232 of the PC.

The programming cable is not included.

With the CD-RS serial converter is possible

configure the Thyristor unit also through the
RS485 (see par. 11.7).
For this solution, the programming cable is not
necessary.

Run the software configurator and set the serial

port of the PC with con baudrate =9600 and the
address of Thyristor unit (default=1).

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3 Quick Start

Caution: this procedure must be performed only by qualified persons.

If the Order Code of the Thyristor unit is in line with what you really need, then CD3000M has been
already configured in Factory and you just need to do the following steps:

1. Verify the CD3000M Sizing. Making sure that:

• The load current is equal or less than the MAX current of CD3000M.
• The load voltage is equal or less than the MAX voltage of CD3000M.
(see par. 4)
2. Verify the Order Code
(see par. 5.2)
3. Verify the Installation
(see par. 6)
4. Verify the Diagram of control connection:
• All auxiliary connections must be done in line with wirings on this manual.
• Verify that there isn’t a short circuit on the load.
• Verify that the Reset Contact on terminal 3 and 4 are closed.
• With External Enable option give Enable to the unit.
(see par. 7.5)
5. Supply the Electronic boards
(see Order Code)
6. Supply the Fan at 230VAC ±15% 50/60Hz (110VAC ±15% 50/60Hz Optional)
(only for size S6C and S8C)
7. Supply the Power unit
(see par. 7.3)
8. If you have HB option make the Calibration procedure (see par. 9.3)

The CD3000M Thyristor unit is ready to start.

4 CD3000M Sizing
4.1.1 Star wiring with resistive load
P
I=
1,73V

V = Nominal voltage phase to phase

I = Nominal current of the load
P = Nominal power of the load
4.1.2 Delta wiring with resistive load
P
I=
1,73V

V = Nominal voltage phase to phase

I = Nominal current of the load
P = Nominal power of the load
4.1.3 Open Delta wiring with resistive load
P
I=
3V

V = Nominal voltage phase to phase

I = Nominal current of the load
P = Nominal power of the load

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5 Identification and Order Code

5.1 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 (see par. 5.2).

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5.2 Order Code

Model 1 2 3 4 5 6 7

CD3000M-3PH

1 Max Current of CD3000M

15A 45A 75A
30A 60A 90A
The Max Current must be equal or more than Load Current

2 Load Current
Specify this value to configure the unit in CD Automation

3 Max Voltage of CD3000M

480V
600V
The Max Voltage must be equal or more than Load Voltage

4 Auxiliary Voltage (Voltage supply for the Electronic boards)

90:130 From 90 to 130Vac; 10VA
170:265 From 170 to 265Vac; 10VA
230:345 From 230 to 345Vac; 10VA
300:530 From 300 to 530Vac; 10VA
510:690 From 510 to 690Vac; 10VA

5 Input
SSR 4÷30Vdc
0÷10V 0÷10Vdc
4÷20mA 4÷20mA
POT Potentiometer 10KΩ

6 Firing Type
ZC Zero Crossing
BF___ Burst Firing

 Specify the number of firing cycles at 50% of the input signal (from 1 to 255)

7 Option
EF External fuses and fuse holders
NF No fuses
HB Heater Break Alarm
CD-KP External Keypad
110Fan Fan voltage supply 110VAC ± 15% (std 230VAC ± 15%) 50/60Hz
EP External Protection IP20 for size S7C and S8C
UL UL Certification

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6 Installation

Caution: Don't install near the hot elements or near the units that could give
electromagnetic interferences.

The CD3000M 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.

6.1 Environmental installation conditions

0-40°C at nominal current. Over 40°C use the

Ambient temperature
derating curve (see par. 8.1)

Storage temperature -25°C to 70°C

Don’t install at direct sun light, where there are

Installation place conductive dust, corrosive gas, vibration or water
and also in salty environmental.

Up to 1000 meter over sea level. For higher

Altitude altitude reduce the nominal current of 2% for each
100m over 1000m

Humidity From 5 to 95% without condense and ice

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6.2 Dimensions and Weight

CD3000M 3PH CD3000M 3PH CD3000M 3PH CD3000M 3PH
15A (S2C) 30A (S4C) 45A (S6C) 60A÷90A (S8C)

H H H H

D D D D
W W W W

Size W(mm) H(mm) D(mm) Weight (kg)

15A (S2C) 123 120 120 1,25

30A (S4C) 148 120 123 1,5

45A (S6C) 148 138 123 2

60A (S8C) 148 138 159 2,1

75A (S8C) 148 138 159 2,1

90A (S8C) 148 138 159 2,1

6.3 CT dimensions (only with the HB option)

39
12

39 20

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6.4 Fixing holes

CD3000M 3PH CD3000M 3PH CD3000M 3PH CD3000M 3PH
15A (S2C) 30A (S4C) 45A (S6C) 60A÷90A (S8C)

Size A(mm) B(mm) C(mm)

15A (S2C) 30 110 30

30A (S4C) 41 110 65

45A (S6C) 41 110 65

60A (S8C) 41 110 65

75A (S8C) 41 110 65

90A (S8C) 41 110 65

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7 Wiring instructions

Caution: this procedure must be performed only by qualified persons.

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 electronic circuit of the Thyristor unit must be supplied from a dedicated voltage and not with
inductive or capacitive loads. We recommend the use of a screened transformer.
• 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.

For safety connect the heat-sink to the earth with his terminal.

7.1 Removing the cover

Remove plastic Cover For all size To remove the board Pull the PCB

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7.2 Wiring details

Use copper cables and wires rated for use at 75°C only.

7.2.1 Power cable torque (suggested)

Wire
Connector Torque Wire
Current Range
Type Lb-in (N-m) Terminal
AWG / kcmil

15A,30A UL Listed (ZMVV)

M5 Screw 26.6 (3.0) 8
45A Wire Pin

UL Listed (ZMVV)
60A,75A
M6 Screw 70.8 (8.0) 1 Fork/Spade Terminal
90A
Copper Tube Crimp. Lug

7.2.2 Power cable dimensions (suggested)

Supply Load

Current Cable Screw Cable Screw

mm² AWG M mm² AWG M

15A (S2C) 4 12 M5 4 12 M5

30A (S4C) 6 10 M5 6 10 M5

45A (S6C) 10 8 M5 10 8 M5

60A (S8C) 16 6 M6 16 6 M6

75A (S8C) 25 4 M6 25 4 M6

90A (S8C) 35 3 M6 35 3 M6

7.2.3 Cable dimensions (suggested) of Earth and of the Command Terminals

Earth Command Terminals

Current Cable Screw Cable

mm² AWG M mm² AWG

15A (S2C) 4 12 M5 0,50 18

30A (S4C) 6 10 M5 0,50 18

45A (S6C) 6 10 M5 0,50 18

60A (S8C) 6 10 M5 0,50 18

75A (S8C) 6 10 M5 0,50 18

90A (S8C) 6 10 M5 0,50 18

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7.3 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
L2 Line Input Phase 2
L3 Line Input Phase 3
T1 Load Output Phase 1
T2 Load Output Phase 2
T3 Load Output Phase 3

7.4 Command Terminals

Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.

7.4.1 Upper Terminal

Terminal Description
1 (-) External Calibration 24 Vdc max
2 (+)External Calibration 24 Vdc max
3 Reset
4 Reset
5 (+) CD3000M Output Command signal (Internal Connections)
6 (-) CD3000M Output Command signal (Internal Connections)
A2+ (+) Input command signal SSR, 0÷10V,4÷20mA,POT
A1- (-) Input command signal SSR, 0÷10V,4÷20mA,POT
(See par. 11.1)

7.4.2 1 Lateral Terminal

Terminal Description
7 RS485 A
8 RS485 B
9 Output +8Vdc stabilized 1 mA MAX
10 HB relay contact (Max 500mA , 125Vac) Optional
11 HB relay contact (Max 500mA , 125Vac) Optional
12 Current Transformer “CT1” input (only with the HB option)
13 Current Transformer “CT2” input (only with the HB option)
14 Current Transformer “CT3” input (only with the HB option)
15 Not connected
16 Voltage Supply for Electronic Boards (Auxiliary)
17 Earth
18 Voltage Supply for Electronic Boards (Auxiliary)
(See par. 11.1)

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7.5 Diagram of control connection from size 15A

Caution: this procedure must be performed only by qualified persons.

L1 A1- L2 A1- L3 A1-

POWER UNIT

POWER UNIT

POWER UNIT

A2+ A2+ A2+

T1 T2 T3

CT1 CT2 CT3

NOTE:
• * The user installation must be protecting by electromagnetic circuit breaker or by fuse isolator.
• *² The auxiliary voltage supply of the CD3000M 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.
• The Current Transformer (CT1, CT2, CT3) must be mounted only with the HB option.
• To work, the Reset Contact on terminal 3 and 4 must be closed.

Load Type

T1 T2 T3 T1 T2 T3 L1 L3 L2 T1 T2 T3 T1 T2 T3 N

Delta Open Delta Star Star + Neutral

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7.6 Diagram of control connection from size 35A to 100A

Caution: this procedure must be performed only by qualified persons.

CT1 CT2 CT3

NOTE:
• * The user installation must be protecting by electromagnetic circuit breaker or by fuse isolator.
• *² The auxiliary voltage supply of the CD3000M 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.
• The Current Transformer (CT1, CT2, CT3) must be mounted only with the HB option.
• To work, the Reset Contact on terminal 3 and 4 must be closed.

Load Type

T1 T2 T3 T1 T2 T3 L1 L3 L2 T1 T2 T3 T1 T2 T3 N

Delta Open Delta Star Star + Neutral

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8 Power output features

Voltage Repetitive peak Latching Max peak Leakage I2T value Frequency Isolation
Current Power loss
range reverse voltage current one cycle current max range Voltage

(10msec.)
(A) (V) (480V) (600V) (mAeff) (mAeff) tp=10msec (Hz) I=Inom (W) Vac
(A)

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

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

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

60A 24÷600 1200 1600 450 100 15 4750 47÷70 216 2500

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

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

8.1 Derating curve

K
I MAX =I NOM xK
1

0.8

0.6

0.4

0.2

0
40 50 60 70 80
°C
8.2 Cooling fans
The thyristor units size S6C and S8C are equipped with a cooling fan. The supply voltage is standard
230VAC ±15% 50/60Hz or optional 110VAC ±15% 50/60Hz.
The fan’s power consumption is below listed:

Size C
UL
® US
Number of fans LISTED Number of fans

45A÷90A (S6C & S8C) One Fan - 16W One Fan - 16W

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9 Led status and Alarms

9.1 LED Status Table

In front of the thyristor unit there are LED that indicates the state of the Electronic cards:

LED
STATUS DESCRIPTION
For All size

The power supply is not connected or fault on the electronic board

Aux
The power supply is not connected and the Electronic board is OK

OFF Condition (Load IS NOT Powered)

ON
ON Condition (Load IS Powered)

SCR OK

SC SCR short circuit

No External Enable (see par. 11.4)

Load OK
HB
Load Fault

= OFF

= ON

= Flashing

9.2 Not Critical Alarm

The Not Critical Alarm, doesn’t stop the thyristor unit.
When one of these Not Critical Alarm is active, the HB relay change status (see par. 11.5)

9.2.1 SCR Short Circuit (only with the HB option)

This alarm is active when the thyristor unit read the output current in absence of the input signal. This is
possible if there are a short circuit on the thyristor or if there are a wrong wiring of the load.
When the problem is solved is necessary use the digital input: “Reset”
(Terminals 3-4)

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9.2.2 Heater Break alarm HB (only with the HB option)

This alarm is active when the load current decrease under the threshold set on the parameter P124H
(see par. 13).
The Heater Break alarm could be active also if there are a wrong wiring of the load.
When the problem is solved is necessary use the digital input: “Reset”
(Terminals 3-4).
The Heater Break circuit to work properly must have at least an input of 25% of the nominal current.
H.B. circuit read load current via a current transformer 25-50/0.05 or 100/0.05 depending on thyristor
size.
Minimum current is 30% of the current transformer size’s. If load current is below this value make two
turns or more around current transformer. H.B. circuit also diagnoses fuse failure.

Caution: In the first start, and each time that the load is replaced, it’s necessary make the
Calibration procedure.

9.3 Calibration Procedure

The Calibration procedure is an automatic procedure that save in memory the value of load current.
This procedure is necessary if you use the Heater Break Alarm.
To make the Calibration procedure follow these steps:

• Give the power supply.

• Press the “CAL” button on front unit, or use the configurable digital input (see par. 11.4).
• All LEDS are on, this means that calibration procedure is active.
• The CD3000M gives the maximum voltage output.
• After a minute the values of voltage and current are stored in memory.
• the CD3000M comes back to the initial situation.

The Calibration procedure is done.

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10 Firing type
Choose an correct firing type allows to optimize the thyristor unit for the installed load.
The firing type has already configured in line with customer requirements that are defined in the Order
Code. The Order Code is written on the identification label.
However, if you wish to change the firing type you can use the software configurator or the parameter
on serial link (see par. 13).

Caution: this procedure must be performed only by qualified persons.

10.1 Zero Crossing (ZC)

ZC firing mode is used with Logic Output from temperature controllers and the Thyristor operates like a
contactor. The Cycle time is performed by temperature controller. ZC minimizes interferences because
the Thyristor unit switches ON-OFF at zero voltage.

ON OFF
VOLTAGE SUPPLY (V)

LOAD VOLTAGE (V)

SSR from controller

10.2 Burst Firing (BF)

The Burst Firing is a burst of consecutive cycles, the consecutive cycles ON are selectable between 2 and
255, with input signal equal at 50%.
Burst Firing is a method zero crossing that it reduces the electromagnetic interferences because the
thyristor switches at zero voltage crossing.
The example show the Burst Firing with Burst cycles: P126L=4

ON OFF
VOLTAGE SUPPLY (V)

LOAD VOLTAGE (V)

25%

50%

75%

100%

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11 Connection description

11.1 Access to the Electronic boards

To have access to the electronic boards the user must removing the unit’s cover
(see par.7.1)

Warning: Before operate, be sure that power and control cables are isolated from voltage
sources

Front PCB

Main PCB

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11.2 Supply the Electronic Board

The CD3000M thyristor unit, to work, requires a voltage supply for the electronic boards. The Max
consumption is 10VA.
The voltage supply for the electronic boards is configured in line with customer requirements that are
defined in the Order Code. The Order Code is written on the identification label.

Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.

Terminal Description
16 Voltage Supply for Electronic Boards (Auxiliary Voltage)
17 Earth
18 Voltage Supply for Electronic Boards (Auxiliary Voltage)

To change auxiliary supply voltage sold the correct link-jumper on main PCB:

Warning: this procedure can be done just by specialized personnel.

Main PCB Link-Jumper J9+J11

J9

J10

J11

Link-Jumper J9+J11
J9
J9

J10
J10

J11
J11

Transformer Type Link-Jumper J9+J11 Link-Jumper J10

TR-605 120V 90:130V -
TR-605 230V 170:265V 300:530V
TR-605 300V 230:345V 510:690V

• The type of mounted transformer depends of the chosen Auxiliary Voltage in the order code.
(see par. 5.2)
• If the Auxiliary Voltage (written on the identification label) is different from Supply Voltage (to the
load), use an external transformer with primary equal to load voltage and secondary equal to the
Auxiliary Voltage.

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11.3 Analog Inputs

CD3000M thyristor unit have an analogue input to drive the output power.

11.3.1 Input command signal configuration (Terminals A2+ and A1- see par. 7.4)

The Input command 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.
However, if you wish to change the input type (i.e. from 0÷10V to 4÷20mA) proceed as follows:

Warning: this procedure can be done just by specialized personnel

J16 J17
A A
B B
C C
Front PCB

J7
A
B
C
To configure the input type, set the jumper as below represented:
Type Input features J7 J16 J17
Current drain 5mA
SSR ON ≥ 4Vdc Max 30Vdc C-B C-B C-B
OFF < 1Vdc

0÷10V Impedance 10KΩ C-B B-A B-A

POT Impedance 10KΩ min C-B B-A B-A

4÷20mA Impedance 100Ω B-A B-A B-A

When operator finishes to configure the hardware setting he must do the input calibration
procedure

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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

OFF

Mantain Key CAL pushed

2sec.
and give the power supply

Release key ON
when red and yellow S/C
H.B.
led are ON
ON
Yellow and Red leds S/C
are flashing H.B.

SSR ANALOG
INPUT TYPE

Wait for more than 10 sec. Within 10 sec. from start

from start flashing flashing yellow and red leds
yellow and red leds push again momentary
CAL Key

ON
The leds will Yellow led only is ON
S/C S/C
H.B. stop flashing flashing, apply H.B
0 input Signal
I.E.: 0V for 0-10V
0% Signal
4mA for 4-20mA

SSR Input Now press CAL Key again

is tuned

ON
Red led only is S/C
flashing, apply H.B
10V for 0-10V input
or
100% Signal
20mA for 4-20mA input

Now press CAL Key again

Analog input
is tuned

End
TUNE

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11.4 Digital Input

CD3000M thyristor unit has two digital inputs.

11.4.1 Configurable Input (Terminals 1 and 2 see par. 7.4)

This digital input is configurable and can be:
• External Calibration (Standard):
The Calibration input activates the Calibration procedure that is necessary if you use the Heater
break alarm (see par. 9.3). Supply with 24Vdc terminals 1-2 to start the Heater Break procedure.
• External Enable:
Without Enable the out is always to zero and red led (SC) flashing, otherwise the out will follow the
input signal.
to configure the input type, set the jumper as below represented:

Warning: this procedure can be done just by specialized personnel

Main PCB

CBA CBA

J12 J6 J14

Type J12 J6 J14

External Calibration C-B C-B Open

External Enable B-A Open Open

If you use the input like External Enable, is not possible use the input for the
“Heater Break procedure”.

11.4.2 Reset (Terminals 3 and 4 see par. 7.4)

The Reset Alarm is used for restore the unit after an alarm occurs (see par. 9.2).
Open link to terminals 3-4 to stop the CD3000M thyristor unit and reset the alarm.

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11.5 Digital Output

CD3000M thyristor unit with HB option has 1 digital output with relay contact (Max 500mA, 125Vac) that
gives indications of the alarms state, the contacts can be (NO or NC).

11.5.1 HB alarm contact (Only with HB Option - see par. 9.2)

The standard contact used for this output is normally open (NO):

• In normal conditions (without alarm) and with auxiliary power supply, the contact to the terminals
has opened (relay coil energized).
• In alarm condition or without auxiliary power supply the contact to the terminals is closed
(relay coil not energized).

if you wish to change the alarm contact put the jumper as shown:

Caution: this procedure must be performed only by qualified persons

Main PCB

J19

CBA

Type J19
NO (standard) C-B

NC B-A

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11.6 PG Connector
The PG Connector is used to configure the thyristor unit with the configuration software and with the
programming cable.
The programming cable is not included.

PG Connector

11.7 RS485 Serial Port

The serial communication port is on Terminals 7 and 8.
On this port may be done a network up to 255 CD3000M.

Terminal Description
7 RS485 A
8 RS485 B

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11.8 Address configuration

The thyristor unit is assigned a unique device address by the user in the range 1 (default) to
255. This address is used to recognise the messages queries to her assigned.

The thyristor unit does not respond at the messages queries that don't have the same assigned address.
The thyristor unit will also accept global messages (Broadcast) sends at the address 0. No responses are
returned for globally addressed queries.
To configure communication address remove cover and set the dip-switch as below specified:

Dip Switch
Convert the Address Number in Binary for Example: 150 Dec = 10010110 Bin
The dip switch number corresponds to the bit number:

Dip Switch Number

Address Number
8 7 6 5 4 3 2 1
1 0 0 1 0 1 1 0
150 Dec -> 10010110 Bin
(On) (Off) (Off) (On) (Off) (On) (On) (Off)

For convert the Number in Binary you can use this method:

Dip Switch Number have this value:

Dip Switch Number

8 7 6 5 4 3 2 1

Value 128 64 32 16 8 4 2 1

The Address Number Ex. 150 = 128(Dip 8) + 16(Dip 5) + 4(Dip 3) + 2(Dip2)

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12 MODBUS communication
The serial communication port of the thyristor unit is two-wire RS485 type.
This port use an half-duplex system.
When a Unit must transmit active the transmission line, and when there are not units in transmission
the outputs are fixed to high impedance.
The serial communication port allows to communicate between the thyristor units and a MASTER device
(ex. an computer or a terminal). The cable must be rated for use to data transfer.

12.1 MODBUS RTU Protocol

The communication is based on the standard industrial MODBUS RTU with the following restrictions:

• The Baud rate is 9600 Baud.

• The Preset Multiple Registers (Funct. 16) is limited to the writing of a single parameter
for message.
The following MODBUS functions are supported:

Function Description
03 Read Holding Registers
16 Preset Multiple Registers

The unit support the Broadcast messages:

It' possible send a Broadcast messages using the address 0, all the units respond at the
message without sending back any reply.

12.2 Message Format

The transmission format is a 1 bit start, 8 date bit, and 1 bit stop with no parity verification.
Each message terminate after a said time of "time out", equal at 3.5 time of a character transmission,
where there are not transitions on the transmission line.
The first Byte of each message is always the address of the unit that is a value from 1 to 255 or 0 for the
broadcast messages, the second is always the function number, and the rest of the message depends of
the function demand.

When a Slave receive an message, the unit send an answer with the same structure but
with the information demanded.

Each message is followed by CRC (Cyclic Redundancy Check) with two byte. The CRC identify the
incongruity situations of the message, in this case the receiver ignore the message.
The CRC is calculated in accordance with a formula that imply a recursive division of the data by a
polynomial.
The polynomial divisor is:
216 + 215 + 22 + 1(Hex 18005)
but is modified in two ways:
• Since the bits order are reversed, then the binary pattern is also reversed, and the most significant
bit (MSB) is the right-most bit.
• Since interest only the remainder, the right-most bit could be discarded.
Therefore, the polynomial divisor has value: Hex A001
Normal bit order:
Most significant bit Least significant bit
Most significant Byte Least significant Byte

Reversed bit order:

Least significant bit Most significant bit
Least significant Byte Most significant Byte

N.B.: With the reversed bit order, also the CRC16 returns the with the reversed bit order

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The following flow-diagram show how to organize the CRC 16 bit.

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;
crc ^= 0xA001;
}
else
{
crc = crc >> 1;
}
}
}
return (crc);
}

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12.3 Read Holding Registers

This function reads the instantaneous value of a specified number of parameters from an address.
The message is composed by 8 Byte: one Byte is for the address, one for the function (03 Hex), two
Byte for the first parameter to read, two Byte for the total number of parameters to read and finally two
Byte for the CRC:

Address Address of the First

Function N° of the Parameter CRC 16
Unit Parameter
3
HI LO HI LO LO HI
3Hex

The answer is an echo of the first two Byte (address and function), one byte with the number of
following byte to exclusion of the CRC, the demanded values and finally two Byte for the CRC:

Address First Parameter Last parameter

Function N° of Byte CRC 16
Unit Value value
3
HI LO … HI LO LO HI
3Hex

12.4 Preset Multiple Registers

This function could write only a parameter for each message.
The message is composed by 11 Byte: one Byte for the address, one for the function (10 Hex), two Byte
for first parameter to write, two Bytes for the N° of parameters, fixed to 1 (0001 Hex), one Byte with the
number of following Bytes, fixed to 2 (02 Hex), two Byte for the CRC:

Address Address of the N° of the N° of Value to

Function CRC 16
Unit First Parameter Parameter Byte write
16
HI LO 0 1 2 HI LO LO HI
10Hex

The answer is an echo of the first two Byte (address and function), two Byte for first written parameter,
two Byte with the N° of parameters, fixed to 1 (0001 Hex), two Byte for the CRC:

Address Address of the First N° of the

Function CRC 16
Unit Parameter Parameter
16
HI LO 0 1 LO HI
10Hex

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12.5 Error and exception responses

If a message contains an altered character, if fails the CRC, or if the received message contains a syntax
error (for example the number of the byte or of the words is not correct), then the unit will ignore the
message.

If the received message is correct but contains a not valid value, the unit will send an answer of
exception (5 byte):

Address Unit Function Error Code CRC 16

LO HI

The byte with the function number, represent the function number of the message that has caused the
error with the first Bit set to 1 (ex. the function 3 becomes 0x83) The error code could be one of the
followings:

Error Code Name Cause

1 ILLEGAL FUNCTION Function not supported.

2 ILLEGAL DATA ADDRESS Address out of range.

3 ILLEGAL DATA VALUE Attempt to write invalid or action not carried out.

NOTE: If you write a parameter's value equal at his actual value this is a valid transaction
and don't cause an error.

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13 Configuration Parameters
The Configuration Parameters are accessible from the software configurator or through the serial
communication port RS485.

P001 (H01) Load Current R

Function: This parameter shows the Current rms value.
Min/Max: 0 ÷ 255 (0 ÷ FF Hex)
Value: Value depends on when turns have current transformer and from his size’s.
Example: With one passage on the current transformer (CT) 25/0.05A, the max value
corresponds to the max value of the CT:
Read value=255 (FF Hex) -> Load Current= 25A

P002 (H02) Set-point HB R/W

Function: This parameter is the Set-point of current below which HB alarm occurs.
Min/Max: 0 ÷ 255 (0 ÷ FF Hex)
Value: This value is the load current(P001) minus % value of parameter P124H.

P003 (H03) Status Table R

Function: It’s a tab in bit that represent the “Status” of thyristor unit
Value: Bit 0 = 1 -> Short circuit on SCR
Bit 1 = 1 -> Load Failure (HB Alarm)
Bit 2 = 1 -> Output signal ON
Bit 3 = 1 -> HB Calibration in progress

P004 (H04) Command Table R/W

Function: It’s a tab in bit for remote commands via RS485
Value: Bit 0 = 1 -> Activate HB Calibration procedure
Bit 1 = 1 -> Input Command from RS485 (see P005)
Bit 2 = 1 -> Disable Output signal (Only with Input from RS485)
Bit 3 = 1 -> Reset HB Alarm
Note: When unit is switch off all command parameter are set to 0

P005 (H05) Input command signal R

Function: This parameter reads the Input command signal (see par. 7.4)
When the P004 Bit1 =1 This parameter could be written and become the Input
Command from RS485
Min/Max: 0 ÷ 255 (0 ÷ FF Hex)
Example: Input 4mA -> P005 = 0 (0%)
Input 12mA -> P005 = 128 (50%)
Input 20mA -> P005 = 255 (100%)

P006 (H06) Power adjust R/W

Function: Its’ a scaling factor of the Input command signal
Min/Max: 0 ÷ 255 (0 ÷FF Hex)
Value: from 0 = 0% of Output,
To 255 = 100% of Output.
Note: This parameter limit the Output Power
OUT %
Power Adjust = 100%
100

80 Power Adjust = 80%

60

Power Adjust = 40%

40

20

0
20 40 60 80 100 Input %

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P121 (H79) CD Unit ID R

Function: This parameter Identify the CD type Family
Value: CD01 Hex = CD1000-CD3000M Family

P122 (H7A) CD Ver R

Function: This parameter is for internal use

P123 (H7B) Password R/W

Function: This parameter give the access to configuration
Min/Max: 0 ÷ FFFF Hex
Value: 9357 Hex = Writing parameters activated
any value = Writing parameters disabled
Note: When the CD3000M comes out and then re-lighted, for change the parameters
you must re-insert the password.

P124L (H7C) Byte Lo = Delay trigger (Only for 1PH version) R/W
Function: This parameter is the delay of firing in first half period with respect zero voltage
crossing
Min/Max: 0 ÷ 50 (0 ÷32 Hex)
Value: Each step is 0,1msec
Default: 30

P124H (H7C) Byte Hi = HB sensibility R/W

Function: This parameter is the maximum reduction of Load Current to establish the HB
Alarm
Min/Max: 0 ÷ 100 (0 ÷64 Hex)
Value: 0 = 0% of Nominal Current
255 = 100% of Nominal Current
Default: 51
Note: When you change this parameter, HB Calibration procedure is necessary.

P125L (H7D) Byte Lo = Firing type R/W

Function: This parameter set the Firing Type
Value: 01 Hex = Zero Crossing
02 Hex = Single Cycle (Only for 1PH version)
03 Hex = Burst Firing
13 Hex = Burst Firing+ Soft Start (Only for 1PH version)
23 Hex = Burst Firing+ Delay trigger (Only for 1PH version)
24 Hex = Phase Angle (Only for 1PH version)
Default: 3 (if not specified in the Order Code)

P125H (H7D) Byte Hi = Soft start time (Only for 1PH version) R/W
Function: The Unit starts in phase angle mode with a ramp starting from zero up to full
voltage in a presetted and Adjustable time.
The time is setted by this parameter
Min/Max: 0 ÷ 255 (0 ÷FF Hex)
Value: Each step is 5msec
Default: 4
Note: Value of this parameter must be less than cycle time.
For burst firing this parameter must be less than:
50Hz -> 20msec x Number of cycles (P126L).
60Hz -> 16,6msec x Number of cycles (P126L).

P126L (H7E) Byte Lo = Number of cycles (Burst) R/W

Function: This parameter defines the number of voltage cycles in ON condition at 50% of
power demand
Min/Max: 1 ÷ 255 (0 ÷FF Hex)
Value: Each step is 1 cycle
Default: 8 (if not specified in the Order Code)

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P126H (H7E) Byte Hi = HB Delay time R/W

Function: This parameter set a delay to have HB alarm active
Min/Max: 0 ÷ 255 (0 ÷FF Hex)
Value: Each step is 50msec
Default: 3
Note: If Soft start option is enabled HB Delay time must be greater than Soft start
time: P126H x 50msec > P125H x 10msec
When Zero Crossing firing is used must be less than Cycle time:
P126H x 50msec < P127H x 50msec

P127L (H7F) Byte Lo = Max power for SSR Input R/W

Function: When SSR input is used it represent the value of the power (%) when is in ON
status
Min/Max: 0 ÷ 255 (0 ÷ FF Hex)
Value: from 0 = 0% of Output,
to 255 = 100% of Output
Default: 255

P127H (H7F) Byte Hi = Cycle time R/W

Function: The Cycle Time is the time which the Thyristor modulates to obtain the power
demand
Min/Max: 0 ÷ 255 (0 ÷ FF Hex)
Value: Each step is 50msec
Default: 60 (3C Hex) = Zero Crossing
240 (F0 Hex) = Burst Firing
Example: With a Cycle time at 4 sec:
25%-> 1sec 0n+3sec off
50%-> 2sec 0n+2sec off
75%-> 3sec 0n+1sec off

ON OFF Cycle Time

25%

50%

75%

100%
Time

P128L (H80) Byte Lo = Number of half period (DT firing) R/W

Function: This parameter defines the number of half period in delay of firing.
Min/Max: 1 ÷ 255 (0 ÷FF Hex)
Value: Each step is 1 half period
Note: Must be setted at 1

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14 FuseHolder and Fuses

CD3000M unit must be protected by fuses against short circuit selecting the proper I²t that must be
lower than the thyristor one (I²t max).

Caution: USE ONLY EXTRARAPID FUSE WITH APPROPRIATE I²T

14.1 FuseHolder size

for size 15A - 25A for size 30A - 45A

for size 60A - 90A(CE) for size 75A(UL) - 90A(UL)

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14.2 Fuses and Fuse Code for UL

Bussmann Div Cooper (UK) Ltd Ferraz Shawmut SA
(200 kARMS Symmetrical A.I.C.) (200 kARMS Symmetrical A.I.C.)
Qty
SIZE Fuse Current I²T Fuse Current I²T
Vac Vac
CODE (ARMS) (A²sec) CODE (ARMS) (A²sec)
660 Grb
15A FWC 16A10F 16 150 600 16 145 660 3
10-16
CP URC
30A FWP 40A14F 40 750 700 40 700 660 3
14x51/40
CP URC
45A FWP 50A14F 50 1800 700 50 1500 660 3
14x51/50
CP URD
60A FWP 80A22F 80 6600 700 80 3800 660 3
22x58/80
CP URQ
75A - - - - 100 3210 660 3
27x60/100
CP URQ
90A - - - - 125 6970 660 3
27x60/125

Caution: The Fuses must have I²t 20% less than thyristor's I²t.

Caution: High speed fuses are used only for the thyristor protection and can not be used to
protect the installation.

Caution: The warranty of thyristor is null if no proper fuses are used. See tab.

Warning: The user installation must be protected by electromagnetic circuit breaker or by

fuse isolator.

C
UL
® US
LISTED

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14.3 Fuses and Fuse Code for CE

Fuse and Fuse holder Current I²T (max)

SIZE Fuse CODE
CODE (ARMS) (A² sec.)

15A FFH1038/16A FU1038/16A 16 150

30A FFH1451/40A FU1451/40A 40 1650

45A FFH1451/50A FU1451/50A 50 2000

60A FFH2258/80A FU2258/80A 80 6550

75A FFH2258/100A FU2258/100A 100 13500

90A FFH2258/125A FU2258/125A 125 14000

Caution: The Fuses must have I²t 20% less than thyristor's I²t.

Caution: High speed fuses are used only for the thyristor protection and can not be used to
protect the installation.

Caution: The warranty of thyristor is null if no proper fuses are used. See tab.

Warning: The user installation must be protected by electromagnetic circuit breaker or by

fuse isolator.

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15 Maintenance

15.1 Trouble Shooting

Small problems sometimes can be solved locally with the help of the below tab of trouble shooting. If
you don’t succeed, contact us or your nearest distributor.

Indication on
Symptom Possible reasons of the symptom Actions
front unit

Green LED
• No voltage auxiliary power • Give auxiliary voltage supply
(Aux)
(see wiring diagram)
always light off

Green LED • No input signal • Provide to give input signal

Thyristor unit
(Aux) light on • Reversed polarities of input signal • Reverse the input signal
doesn’t go in
polarity
conduction with
Green LED • Reset contact is open • Make link on reset terminals
input signal
(ON) light off (see wiring diagram)

• Fuse failure • Substitute the fuse

Green LED • Load failure • Check the load
(Aux) light on • Load connection interruption • Check the wiring
• Thyristor faulty and always in open • Substitute the faulty thyristor
Green LED circuit
(ON) light on With HB option the yellow led (HB) is
light on

• Wrong wiring • Check the load wiring

• Short circuit on thyristor • Substitute the thyristor
Load current Green LED
flows also with no (ON)
input signal always light off.
If there is HB option the red LED (SC) is
light on

Current flows at
• HB circuit not tuned • Make HB calibration procedure
nominal value but Yellow LED
• Current transformers not properly • Control current transformers
Yellow LED (HB) (HB) light on
wired wiring
is light on

Current flows at
Red LED
nominal value but • HB circuit not tuned • Make HB calibration procedure
(SC) light on
Red LED (SC) is
light on

• Wrong input signal selection. • Control input signal setting.

Thyristor unit • Wrong input signal calibration (out • Repeat input calibration
doesn’t work of range). procedure.
properly • Auxiliary voltage supply out of • Verify the auxiliary voltage
limits supply

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15.2 Fans
The thyristor unit with forced ventilation uses fans that rotate permanently when the unit is supplied. In
case of fan failure, the heat-sink can be reach high temperature. In this case to give protection to
thyristor there is a thermal switch properly setted. The function of this switch is to open the input signal
until the heat-sink temperature falls below the setted value. This means that also with input signal in ON
condition the unit is switched OFF and the system can not work at full power. For this reason is
important to control periodically the fans status checking that are rotating.

15.3 Maintenance
For maintain a correct cooling, the consumer must clean the heat-sink and the protective grate of the
fans. The frequency of these operations depends on the atmospheric local pollution.
Check also that the screw of the power terminals and earth terminals are shut correctly
(see Diagram of control connection).

15.4 Repairing procedure

• Phone to CD Automation.
• Explain to Service Engineer the problem because sometimes it can be solved with a phone call.
If this is not possible, ship the unit to CD Automation or to your distributor.
• Write a fault description and give the name of your personnel to which refers.
• Use a rugged packaging to ship the unit.

15.5 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.
Warranty does not include products with serial numbers deleted. The faulty product should be shipped to
CD Automation at customer’s cost and our Service will evaluate if product is under warranty terms.
Substituted parts remain of CD Automation property.

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16 Note

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ENG CD3000M-3PH__15-90A - 09.DOC

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