USER’S MANUAL CS2 - 75A-200A

Rev. 07/2020 R30252.XX

005 CD 3000S 2PH

M-CS2-75-200

SSR Input

Analog Input or SSR Input + HB

 Declaration of conformity

Declaration of conformity - Dichiarazione di Conformità

PRODUCT MANUFACTURER / PRODUTTORE:

CD Automation S.R.L.
Controllers, Drives & Automation

Via Picasso, 34/36 - 20025 Legnano (MI)- Italy

P.I. 08925720156 -Tel. +39 0331 577479 - Fax +39 0331 579479
E-mail: [email protected] - Web: www.cdautomation.com

Declare that the product / Dichiara che il prodotto:

CD3000S 2PH R30252.xx

PRODUCT DESCRIPTION: Electric power control
SCOPE OF APPLICATION: Thermal control process
DESCRIZIONE DEL PRODOTTO: Unità di controllo potenza elettrica
UTILIZZO: Controllo processi termici

FULFILS THE REQUIREMENTS OF THE STANDARD:

Electrical safety Standard EN60947-1: 2007 + A1 2011, A2 2014
EN60947-4-3: 2014
Generic Emission standard EN60947-4-3: 2014 Group 1 Class A emissions
Generic Immunity standard EN60947-4-3: 2014 Industrial Immunity

SODDISFA I REQUISITI DELLA NORMA:

Specifica di sicurezza EN60947-1: 2007 + A1 2011, A2 2014
EN60947-4-3: 2014
Specifica sulle emissioni EN60947-4-3: 2014 gruppo 1 emissioni classe A
Specifica sulle Immunità EN60947-4-3: 2014 Immunità industriale

CDAutomation declares that the products above mentioned are conforming to the directive
CDAutomation dichiara che i prodotti sopra menzionati sono conformi alla direttiva
Bassa Tensione (low Voltage) EMC directive updated 2014/30/EU,
Low Voltage Directive updated 2014/35/EU

Issued on: 20/03/2017

Data di emissione: 20/03/2017

Amministratore Unico e
Legale Rappresentante
Simone Brizzi
CS2 R30252.xx from 75A to 200A User’s manual

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.
In the manual are used symbols to give more evidence at the notes of safety and operativity for the attention
for the user:

This icon is present in all the operational procedures where the Improper
operation may result in serious personal injury or death by Electrical Shock
Hazard Symbol (a lightning bolt in a triangle) precedes an electric shock hazard
CAUTION or WARNING safety statement.

Warning or Hazard that needs further explanation than the label on unit can
provide. Consult User’s Guide for further information.

Unit is compliant with European Union directives.

See Declaration of Conformity for further details on Directives and Standards
used for Compliance.

If available, unit is a Listed device per Underwriters Laboratories. It has been

investigated to ANSI/UL® 508 standards for Industrial Control Switches and
IND. CONT. EQ.
equivalent to CSA C22.2 #14.
E73741 2RD5
For more detail search for File E231578 on www.ul.com

ESD Sensitive product, use proper grounding and handling techniques when
installing or servicing product.

Do not throw in trash, use proper recycling techniques or consult manufacturer

for proper disposal.

A “NOTE” marks a short message to alert you to an important detail.

A “CAUTION” safety alert appears with information that is important for protecting your equipment and
performance. Be especially careful to read and follow all cautions that apply to your application.

A “WARNING” safety alert appears with information that is important for protecting you, others and equipment
from damage. Pay very close attention to all warnings that apply to your application.

Safety notes
WARNING! To avoid damage to property and equipment, injury and loss of life, adhere to applicable
electrical codes and standard wiring practices when installing and operating this product. Failure to do
so could result in damage, injury and death.
AVERTISSEMENT! Pour éviter d’endommager la propriété et l’équipement, les blessures et la perte
de vie, respecter les codes électriques en vigueur et les pratiques de câblage standard au moment
de l’installation et de l’utilisation de ce produit. Dans le cas contraire, cela peut entraîner la mort, des
blessures graves ou des dommages.

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CS2 R30252.xx from 75A to 200A User’s manual

WARNING! All service including inspection, installation, wiring, maintenance, troubleshooting, fuse
or other user serviceable component replacement must be performed only by properly qualified
personnel. Service personnel must read this manual before proceeding with work. While service is
being performed unqualified personnel should not work on the unit or be allowed in the immediate
vicinity.
AVERTISSEMENT! Tous les services, y compris l’inspection, l’installation, le câblage, l’entretien, le
dépannage, le remplacement de fusibles ou d’autres composants pouvant être réparés par l’utilisateur,
doivent être effectués uniquement par un personnel diment qualifié. Le personnel de service doit lire ce
manuel avant d’effectuer tout travail. Pendant que l’entretien est exécuté, tout personnel non qualifié ne
doit effectuer de travail sur l’appareil ni se trouver a proximité.
WARNING! When in use the power controller is connected to dangerous voltages. Do not remove the
protective covers without first disconnecting and preventing power from being restored while servicing
the unit.
AVERTISSEMENT! Au moment de l’utilisation, le régulateur de puissance est connecté a des tensions
dangereuses. Ne retirer aucun couvercle de protection sans d’abord débrancher l’appareil et ainsi
empêcher l’alimentation d’être rétablie pendant l’entretien.
WARNING! Do not use in aerospace or nuclear applications.
AVERTISSEMENT! Ne pas utiliser pour les applications aérospatiales ou nucléaires.
WARNING! The power controller’s protection rating is IP20 with all covers installed and closed. It must
be installed in an enclosure that provides all the necessary additional protections appropriate for the
environment and application.
AVERTISSEMENT! L’indice de protection du régulateur de puissance est de IP20 lorsque les couvercles
sont installés et fermés. L’appareil doit être installé dans une enceinte qui assure toute la protection
supplémentaire nécessaire pour l’environnement et l’application.
WARNING! Ground the power controller via the provided protective earth grounding terminal. Verify
ground is within impedance specifications. This should be verified periodically.
AVERTISSEMENT! Mise a la terre du régulateur de puissance par le biais de la borne de prise de terre
de protection fournie. Vérifier que la prise de terre est conforme aux spécifications de l’impédance. Cela
doit être vérifié périodiquement.
WARNING! Electric Shock Hazard: when the power controller has been energized, after shutting off the
power, wait at least one minute for internal capacitors to discharge before commencing work that brings
you in to contact with power connections or internal components.
AVERTISSEMENT! Risque de décharges électriques: lorsque le régulateur de puissance est mis sous
tension, après avoir été éteint, attendre au moins une minute pour que les condensateurs internes se
déchargent avant de commencer tout travail incluant le contact avec les connexions électriques ou les
composants internes.
WARNING! The installation must be protected by electromagnetic circuit breakers or by fuses. The
semiconductor fuses located inside the power controller are classified for UL as supplementary
protection for semiconductor devices. They are not approved for branch circuit protection.
AVERTISSEMENT! L’installation doit être protégée par des disjoncteurs électromagnétiques ou des
fusibles. Les fusibles pour semi-conducteurs situés a l’intérieur du régulateur de puissance sont classés
UL comme protection supplémentaire pour les dispositifs pour semi-conducteurs. Ils ne sont pas
approuvés pour la protection des circuits de dérivation.
WARNING! When making live voltage or current measurements, use proper personal protective
equipment for the voltages and arc-flash potentials involved.
AVERTISSEMENT! Au moment de relever des mesures de tension ou de courant en direct, utiliser un
équipement de protection individuelle approprié pour les tensions et les potentiels d’arc électrique
concernés.

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CS2 R30252.xx from 75A to 200A User’s manual

WARNING! Verify the voltage and current ratings of the power controller are correct for the application.
AVERTISSEMENT! Vérifier que les valeurs de tension et de courant du régulateur de puissance sont
correctes pour l’application.
CAUTION: To avoid compromising the insulation, do not bend wire or other components beyond their
bend radius specifications.
ATTENTION: Pour éviter de compromettre l’isolation, ne pas plier le fil ou tout autre composant au-delà
de ses spécifications en matière de rayon de courbure.
CAUTION: Protect the power controller from high temperature, humidity and vibrations.
ATTENTION: Protéger le régulateur de puissance contre les températures élevées, l’humidité et les
vibrations.
CAUTION: The power controller warranty is void if the tested and approved fuses are not used.
ATTENTION: La garantie du régulateur de puissance est nulle si aucun fusible testé et approuvé n’est
utilisé.
CAUTION: Only trained and authorized personnel should access and handle the internal electronics and
they must follow proper electro-static prevention procedures.
ATTENTION: Seul le personnel formé et autorisé peut accéder aux composants électroniques internes
et les gérer, et il doit se conformer a des procédures de prévention électrostatique appropriées.
CAUTION: Install an appropriately sized RC filter across contactor coils, relays and other inductive
loads.
ATTENTION: Installer un filtre RC de dimensions appropriées sur les bobines du contacteur, les relais et
autres charges par induction.
CAUTION: The thyristor units here described have been designed for use with sinusoidal networks with
nominal frequency 50-60 Hz. Any application with NON-SINUSOIDAL, distorted or disturbed networks
could compromise the correct operation of the unit.
ATTENTION: Les unités de thyristors décrites ici ont été conçues pour être utilisées avec des réseaux
sinusoïdaux d’une fréquence nominale de 50 à 60 Hz. Toute application utilisant des réseaux NON
SINUSOÏDAUX, déformés ou perturbés peut compromettre le bon fonctionnement de l’appareil.
NOTE: Provide a local disconnect to isolate the power controller for servicing.
REMARQUE: Fournir une déconnexion locale afin d’isoler le régulateur de puissance pour l’entretien.
NOTE: The nominal current is specified for ambient temperatures at or below 40° C. Ensure the application
design allows for adequate cooling of each power controller. The power controller must be mounted
vertically. The cooling design must prevent air heated by one power controller from causing power
controllers mounted above to exceed the ambient operating temperature limit. When power controllers
are mounted side by side allow a minimum spacing of 15mm between them.
REMARQUE: Le courant nominal est précisé pour des températures ambiantes égales ou inférieures
a 40°C. S’assurer que la conception de l’application permette le refroidissement adéquat de chaque
régulateur de puissance. Le régulateur de puissance doit être monté verticalement. La conception de
refroidissement doit empêcher l’air chauffé par le régulateur de puissance de dépasser la limite de
température de fonctionnement ambiante de la part des régulateurs de puissance montés au-dessus.
Lorsque les régulateurs de puissance sont montés côte a côte, il faut conserver un espacement minimal
de 15 mm entre les deux.
NOTE: Use only copper cables and wires rated for use at 75°C or greater.
REMARQUE: N’utiliser que des cables et des fils en cuivre pour l’utilisation a 75°C ou plus.

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CS2 R30252.xx from 75A to 200A User’s manual

Maintenance
In order to have a corrected cooling, the user must clean the heat-sink and the protective grill of the fans. The
frequency of this servicing depends on environmental pollution.
Also check periodically if the screw for the power cables and safety earth are tightened correctly
(See Connection Diagram)

Warranty condition
Producer 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 Producer at customer’s cost and our Service will
evaluate if product is under warranty terms.
Substituted parts remain of Producer property.

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CS2 R30252.xx from 75A to 200A User’s manual

Summary

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Important warnings for safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Basic Connections and sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2 Identification and Order Code . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.1 Identification of the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 General features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.2 Input features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Output features (power device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.4 Environmental installation conditions . . . . . . . . . . . . . . . . . . . . . . . . .13
3.5 Derating Curve and Thermal conditions . . . . . . . . . . . . . . . . . . . . . . . 14
3.6 Calculating flow capacity of the fan . . . . . . . . . . . . . . . . . . . . . . . . . .14

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Fixing holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5 Wiring instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1 Removing the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2 Power cable torque (suggested) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Power cable dimensions (suggested) . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4 Cable dimensions (suggested) of Earth and of the Command Terminals . .18
5.5 Power Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.6 Command Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.7 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6 Led status and alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7 Heater Break alarm and SCR short circuit . . . . . . . . . . . . . . . . . . . 23
7.1 Heater break Calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . .23

8 Input Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9 Burst Firing settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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CS2 R30252.xx from 75A to 200A User’s manual

10 Firing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

10.1 Zero Crossing (ZC) with SSR input . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.2 Burst Firing (BF) with Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . 26
11 Supply the electronic board . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

12 Internal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
13 Second Thermal Switch - Optional . . . . . . . . . . . . . . . . . . . . . . .29

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CS2 R30252.xx from 75A to 200A User’s manual

1 Basic Connections and sizing

Star wiring with resistive load

I= P
1,73V

V = Nominal voltage of the load

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

Delta wiring with resistive load

I= P
1,73V

V = Nominal voltage phase to phase

V
I = Nominal current to the load
P = Nominal power to the load

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CS2 R30252.xx from 75A to 200A User’s manual

2 Identification and Order Code

2.1 Identification of the unit

Caution: Before to install, make sure that the Thyristor unit have not damages. If the product
has a fault, please contact the dealer from which you purchased the product.

The identification’s label give all the information regarding the factory settings of the Thyristor unit, this label is
on the unit, like represented in figure.
Verify that the product is the same thing as ordered.

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CS2 R30252.xx from 75A to 200A User’s manual

2.1.1 Order code

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

CD3000S C S 2 _ _ _ - _ _ _ _ _ _ _ _ _ _

CURRENT 4 5 6 CONTROL MODE 11

description code description code

75A 0 7 5 Open Loop 0

125A 1 2 5
150A 1 5 0 OPTION 12

200A 2 0 0 description code

Heater Break H
MAX VOLTAGE 7 None 0
description code

480V 4 FAN VOLTAGE 13

600V 6 description code

24Vdc 3
AUX VOLTAGE SUPPLY 8

description code APPROVALS 14

24Vdc 4 description code

CE-EMC 0
INPUT 9

description code MANUAL 15

SSR S description code
0:20mA B None 0
4:20 mA A English 2
0:10V V

VERSION 16
FIRING 10 description code
description code Standard 1
Zero Crossing with SSR input Z Standard + second thermal switch 2
Burst Firing 2 cycles on at 50% Power 2

Burst Firing 4 cycles on at 50% Power 4

Burst Firing 8 cycles on at 50% Power 8

Burst Firing 16 cycles on at 50% Power 6

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CS2 R30252.xx from 75A to 200A User’s manual

3 Technical Specifications
3.1 General features
Cover and Socket material: PolymericV2
Utilization Category: AC-51 AC-55b
IP Code: 20
Method of Connecting: Load in Delta, Load in Star
Auxiliary voltage: 24Vdc (1A)
Relay output for Heater Break Alarm 0.5A a 125VAC
(only with HB option)

3.2 Input features

Digital Input: 4 ÷ 30Vdc 5mA Max (ON ≥ 4Vdc OFF < 1Vdc) 5Hz max
Volt Analogic input: 0 ÷ 10Vdc impedance 15 K ohm
Current Analogic input: 4 ÷ 20mA impedance 100 ohm
POT: 10 K ohm min.
Logic input SSR (Fast Enable): 4 ÷ 30Vdc 5mA Max (ON >4Vdc OFF <1Vdc)
3HZ Max duty cycle min. 100 ms)

3.3 Output features (power device)

Repetitive
Output FUSE I2T value Power loss Isolation
peak reverse Latching Max peak Leakage Frequency
Current Voltage Suggested A2s Thyristor Voltage
voltage current one cycle current range
range (Ue) (at 660V) + Fuse (Ui)
(Uimp)

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

75A 24÷600 1200 1600 450 2000 15 19100 47÷70 255 2500

125A 24÷600 1200 1600 450 2000 15 19100 47÷70 255 2500

150A 24÷600 1200 1600 300 5250 15 128000 47÷70 268 2500

200A 24÷600 1200 1600 300 5250 15 128000 47÷70 380 2500

3.4 Environmental installation conditions

Ambient temperature 0-40°C (32-104°F) at nominal current.
Over 40°C -104°F use the derating curve.
Storage temperature -25°C to 70°C -13°F to 158°F
Installation place Don’t install at direct sun light, where there are conductive
dust, corrosive gas, vibration or water and also
in salty environmental.
Altitude Up to 1000 meter over sea level. For higher altitude
reduce the nominal current of 2% for each 100m over 1000m
Humidity From 5 to 95% without condense and ice
Pollution Level Up to 2nd Level ref. IEC 60947-1 6.1.3.2

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CS2 R30252.xx from 75A to 200A User’s manual

3.5 Derating Curve and Thermal conditions

The nominal current of the units in specification are referred to continuos service at 40° ambient temperature.
For higher temperature multiply the nominal current times derating coefficient K below represented:

l max = l nominal x K 1,2

1 1 1 1 1
Derating 1
0,9
0,8
0,8

0,6
K

0,4

0,2

For higher cabinet

temperature 0
contact the producer 15 20 25 30 35 40 45 50 55
of the unit CABINET TEMPERATURE °C

3.6 Calculating flow capacity of the fan

All the thyristor units when are in conduction produces power loss that is dissipated inside cubicle in terms of
heating. Due to this fact the internal temperature of cubicle is higher than ambient temperature. To be cooled
the thyristor need of fresh air cooling and to do it is normally used a fan mounted on the front door or on the
roof of the cabinet.
Procedure to size Fan air mass flow (V): see power loss for each thyristor and fuse mounted indicated in the
manual related to the current (Output feature and Internal fuse Chapter).

Qv = total power losses (w) Altitude

(thyristor + fuse power loss) 0:100 meters f = 3.1 m3k/Wh

V=f * Qv
ta = ambient temperature (°C) 100:250 meters f = 3.2 m3k/Wh
tc = cabinet temperature (°C) 250:500 meters f = 3.3 m3k/Wh
tc-ta V = fan air mass flow (m3/h) 500:750 meters f = 3.4 m3k/Wh
f = altitude coefficient (see table on right)

The formulas used are for information only and is not a substitute for a proper thermal rating
done by a qualified person.

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CS2 R30252.xx from 75A to 200A User’s manual

4 Installation
AIR FLOW OUT (V)
Before to install, make sure that the Thyristor unit have not damages.
If the product has a fault, please contact the dealer from which you
purchased the product. Verify that the product is the same thing as FAN
in aspiration
ordered.
The Thyristor unit must be always mounted in vertical position to 30 cm
improve air cooling on heat-sink.

*
Maintain the minimum distances ( ) in vertical and in horizontal as
represented, this area must be free from obstacle (wire, copper bar,
plastic channel).
2 cm

When more unit has mounted inside the cabinet maintain the air
20 cm
circulation like represented in figure without obstacle for the air flow.
Is necessary to install a fan to have better air circulation as calculated
previously.

The V Air flow must be equal or more than the value calculated.
Air Grid
If the cabinet fan mounted by the customer have an air flow lower
than the correct value the warranty will decay.
AIR FLOW IN (V)

4.1 Dimensions and Weight

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

75A (S09) 116 316 187 5
125A (S09) 116 316 187 5
150A (S09) 116 316 187 5
200A (S10) 120 350 220 5,5

W D

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CS2 R30252.xx from 75A to 200A User’s manual

4.2 Fixing holes

up to 150A (S09) 200A (S10)

A A
5 6

B B

C
C

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

75A (S09) 96 290 104
125A (S09) 96 290 104
150A (S09) 96 290 104
200A (S10) 60 326 60

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CS2 R30252.xx from 75A to 200A User’s manual

5 Wiring instructions
The Thyristor unit could be susceptible to interferences lost by near equipments or by the power supply, for
this reason in accord to the fundamental practices rules is opportune take some precautions:
• The coil contactor, the relays and other inductive loads must be equipped with opportune RC filter.
• Use shielded bipolar cables for all the input and output signals.
• The signal cables must not be near and parallel to the power cables.
• Local regulations regarding electrical installation should be rigidly observed.

Use copper cables and wires rated for use at 75°C only.
For safety connect the heat-sink to the earth with his terminal

5.1 Removing the cover

5.2 Power cable torque (suggested)

Wire
Torque Wire
Current Connector type Range
Lb-in (N-m) Terminal
AWG / kcmil
Copper wire
75A, 125A, Terminal Block 1
265 (30.0) compact (solid)
150A, 200A M8 3/0
stranded

5.3 Power cable dimensions (suggested)

Supply Load
Current Cable Screw Cable Screw
mm² AWG M mm² AWG M
75A 50 1 M8 50 1 M8
125A 50 1 M8 50 1 M8
150A 70 1/0 M8 70 1/0 M8
200A 95 3/0 M8 95 3/0 M8

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CS2 R30252.xx from 75A to 200A User’s manual

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

Earth Command Terminals

Current Cable Screw Cable
mm² AWG M mm² AWG
75A 16 6 M6 0,50 18
125A 16 6 M6 0,50 18
150A 16 6 M6 0,50 18
200A 25 4 M6 0,50 18

5.5 Power Terminals

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

Terminal Description
L1 Line Input Phase 1
L2 Line Input Phase 2
L3 Line Input Phase 2
T1 Load Output Phase 1
T2 Load output Phase 2 (Not controlled by the thyristor
T3 Load Output Phase 2

Size S09 Size S10

L1 L2 L3 L1 L2 L3

T1 T2 T3 T1 T2 T3

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CS2 R30252.xx from 75A to 200A User’s manual

5.6 Command Terminals

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

Terminal Description
1 Voltage supply for synchronization (L1)
2 Not used
3 Voltage Supply for synchronization (L2)
4 Not used
5 24Vdc - Auxiliary supply and Fan supply
6 24Vdc + Auxiliary supply and Fan supply
7 Not used
8 COM I - Common Digital Input
9 + Input command signal SSR, 0-10V, 4-20mA, POT
10 - Input command signal SSR, 0-10V, 4-20mA, POT

Terminal Description
11 0V GND
12 Output +10Vdc stabilized 1 mA MAX
13 Not used
14 Not used
15 DI1 - Configurable Input
16 DA2 - Enable Digital Input
17 Not used
18 NC - Normally Close contact alarm relay output (HB)
19 C - Common contact alarm relay output
20 NO - Normally Open contact alarm relay output (HB)

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CS2 R30252.xx from 75A to 200A User’s manual

5.7 Schematic

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

Branch Circuit
Protection

Fuse 24Vdc
5A Max Fan Supply +
AUX Supply

M1 SYNC
- +

L3 L2 L1 1 3 5 6

T3 T2 T1 12 11 8 16 15 9 10 18 20 19
NC NO C

M1 HB relay
alarm

4
3

11 12

Analog Inp.1
Analog SetPoint

NOTE:
*1 The user installation must be protecting by electromagnetic circuit breaker or by fuse isolator.
The Fuse must be branch circuit protection. For UL any listed UL branch circuit fuse would be acceptable
as an external fuse, following national electric code guide for resistive heating of 125% load current rating to
protect external wires.
*2 The voltage on terminal 1 and 3 is used for firing synchronization and main voltage transducer.
*3 For SSR input connection follow next page schematic.
*4 IMPORTANT! Starting Strategy (Enable):
1: Feed the unit with L1-L2-L3 power voltage supply
2: Feed the auxiliaty supply
3: Close the Enable contact to start with the regulation

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CS2 R30252.xx from 75A to 200A User’s manual

5.7.1 SSR Control Input schematic

For SSR input use follow the schematic below and configure Digital Input 1 as Fast Enable.
* SSR Input: 4 ÷ 30Vdc 5mA Max
(ON >4Vdc OFF <1Vdc)
3HZ Max on time min. 100 ms

Analog Input 1

12 11 8 15 16 9 10

SSR
INPUT

For version cod. R30252.01 /.02 /.03 - see below

Version SSR Only: Cod: R30252.01 / .02 / .03

Terminal Description
1 Not used
2 Not used
3 Not used
4 Not used
5 24Vdc - Auxiliary supply and Fan supply
6 24Vdc + Auxiliary supply and Fan supply
7 Not used
AUX
8 - Input command signal SSR
9 + Input command signal SSR
10 Not used ON

Auxiliary Supply

5 6 8 9

24Vdc
SSR
INPUT

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CS2 R30252.xx from 75A to 200A User’s manual

6 Led status and alarms

LED status
LED STATUS DESCRIPTION
LED Flashing ( ) Waiting for Enable Signal
EN
LED ON ( ) Enable Signal to terminal
LED OFF ( ) Load is NOT powered
ON
LED ON ( ) Load is powered
LED OFF ( ) Load OK
LED ON ( ) SCR short circuit (only with HB option)
SC
LED Flashing ( ) Enable contact open or
Over temperature on heat sink
CAL
LED OFF ( ) Load OK
HB
LED ON ( ) Load Fault (only with HB option)

Input type informations Burst Firing informations

Wait more than 10 seconds Wait more than 10 seconds

after power on after power on

Keep pressed for 2 sec Keep pressed for 2 sec

The LEDs turn off for 2 seconds The LEDs turn off for 2 seconds
and the setting is displayed and the setting is displayed

0-10V 4-20mA 0-20mA SSR BF 2 BF 4 BF 8 BF 16

The LEDs turn off The LEDs turn off

for 4 seconds for 4 seconds

END END

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CS2 R30252.xx from 75A to 200A User’s manual

7 Heater Break alarm and SCR short circuit

(HB Option only)

Caution: to work properly the load must be powered at least about 160msec.

The Heater Break circuit read the load current with an Internal current transformer (C.T.).
Minimum current is 10% of the current transformer size.
If load current is below this value the Heater Break Alarm doesn’t work properly.

7.1 Heater break Calibration procedure

An automatic function sets the Heater Break Alarm.
The auto setting function can be activated by pressing the keys + simultaneously for 4 seconds.
The Heater Break calibration procedure is performed in this way:
• The Unit gives the maximum voltage output
• The leds light up in sequence until the procedure is completed
• The current and voltage value is stored in memory
• After about 15 second the unit comes back to the initial situation
If load resistance increase more than 20% (sensitivity 20%) the HB LED become ON and alarm relay change
status.
If the unit is still in conduction with no input signal (ON LED OFF) it means that there is a short circuit on
thyristors and SC LED become ON.
If the load has been changed the Heater Break calibration procedure must be done again.

The HB Alarm is detected with minimum ON time 100 ms

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CS2 R30252.xx from 75A to 200A User’s manual

8 Input Setting
The Input type is already configured in line with customer requirements that are defined in the order code.
However, if you need to to make changes you must follow the following procedure.

Remove
auxiliary power supply

Keep pressed

Supply the Unit

LED1 - LED2 flashing for 3 sec.

Release

Press to choose
the desired configuration

0-10V

4-20mA

0-20mA

SSR

Press to save
the configuration

END

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CS2 R30252.xx from 75A to 200A User’s manual

9 Burst Firing settings

The Burst Firing cycles is already configured in line with customer requirements that are defined in the Order
Code. However, if you wish to change the Burst Firing cycles (es. from 4 to 8) you must follow the following
procedure.

Remove
auxiliary power supply

Keep pressed

Supply the Unit

LED3 - LED4 flashing for 3 sec.

Release

Press to choose
the desired configuration

BF 2

BF 4

BF 8

BF 16

Press to save
the configuration

END

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CS2 R30252.xx from 75A to 200A User’s manual

10 Firing type
Choose a correct firing type allows to optimize the thyristor unit for the installed load.
The firing type has already configured in line with customer requirements Zero Crossing for SSR input and
Burst Firing for Analog Input.

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

10.1 Zero Crossing (ZC) with SSR input

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) with Analog Input

The Burst Firing is similar to the Single Cycle, but consecutive cycles ON are selectable between 2-4-8 or 16,
with input signal equal at 50%. When is specified 2 the firing type have very fast cycle time, this selection is
suggested with diesel generator application.
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: 4.

ON OFF
Voltage Supply (V)

Load Voltage (V)

25%

50%

75%

100%

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CS2 R30252.xx from 75A to 200A User’s manual

11 Supply the electronic board

The thyristor unit, to work, requires a voltage supply for the electronic boards of 24Vdc 1A on Terminal M1 (5, 6)
and the Synchronization signal between terminals 1 and 3.
The voltage used on Terminal 1 and 3 must be the same of load voltage (L1-L2/N).

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

Terminal M1 Description
1 Voltage for synchronization signal
2 Not used
3 Voltage for synchronization signal
4 Not used
5 24Vdc - Auxiliary supply and Fan supply
6 24Vdc + Auxiliary supply and Fan supply

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CS2 R30252.xx from 75A to 200A User’s manual

12 Internal Fuse
The thyristor unit have internal fuse extrarapid at low I²t for the thyristor protection of against the short-circuits.
The Fuses must have I²t 20% less than thyristor’s I²t. The warranty of thyristor is null if no proper fuses are used.

200 kARMS Symmetrical A.I.C.

Size FUSE I2T value Qty

Current
Fuse CODE Vac Suggested A2s
(ARMS)
(at660V)*

75A (S09) FU120FEE 120 660 3100 2

125A (S09) FU200FEE 200 660 11400 2

150A (S09) FUURE250 250 660 52000 2

200A (S10) FUURE315 315 660 82000 2

1.2
* I2T are multiplied for K value in function of Vac at 500V
K is equal to 0,7 (600V) (ex: 3100 X 0,7 = 2170).
1.0
At 660Vac K is equal to 1.

K
0.8

0.7
0.6

0.4

0.2
500
200 400 600 800

Vac
(Line voltage)

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: When it is supply, the Thyristor unit is subject to dangerous voltage, don’t open the
Fuse-holder module and don’t touch the electric equipments.

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CS2 R30252.xx from 75A to 200A User’s manual

13 Second Thermal Switch - Optional

This option detects the heat sink overtemperature.
The contact between terminals TS and TS of M6 normally closed, opens when the heat sink reaches the
temperature of 90 ° C
Free contact normally close.
230V max, 1A

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