CD Automation REVO S 2PH User Manual

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Page 1

USER’S MANUAL

Rev. 03/2019

2PH

001

M-RS2-60-800-690V

690V

from 60A to 800A

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

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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:

Revo S 2Ph 690V 60-800A

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:

Specica di sicurezza EN60947-1: 2007 + A1 2011, A2 2014

EN60947-4-3: 2014

Specica sulle emissioni EN60947-4-3: 2014 gruppo 1 emissioni classe A Specica 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 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

Claudio Brizzi

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REVO S 2PH from 60A to 800A - 690V 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 qualied 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 equivalent to CSA C22.2 #14. 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.

IND. CONT. EQ. E231578 2RD5

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REVO S 2PH from 60A to 800A - 690V 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 qualied

personnel. Service personnel must read this manual before proceeding with work. While service is

being performed unqualied 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 eectués uniquement par un personnel diment qualié. Le personnel de service doit lire ce manuel avant d’eectuer tout travail. Pendant que l’entretien est exécuté, tout personnel non qualié ne doit eectuer 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 rst 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 specications. This should be veried periodically.

AVERTISSEMENT! Mise a la terre du régulateur de puissance par le biais de la borne de prise de terre

de protection fournie. Vérier que la prise de terre est conforme aux spécications de l’impédance. Cela doit être vérié périodiquement.

WARNING! Electric Shock Hazard: when the power controller has been energized, after shutting o 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 classied 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-ash 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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REVO S 2PH from 60A to 800A - 690V User’s manual

WARNING! Verify the voltage and current ratings of the power controller are correct for the application.

AVERTISSEMENT! Vérier 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 specications.

ATTENTION: Pour éviter de compromettre l’isolation, ne pas plier le l ou tout autre composant au-delà de ses spécications 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 lter across contactor coils, relays and other inductive

loads.

ATTENTION: Installer un ltre 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 an d’isoler le régulateur de puissance pour l’entretien.

NOTE: The nominal current is specied 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 chaué 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 ls en cuivre pour l’utilisation a 75°C ou plus.

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REVO S 2PH from 60A to 800A - 690V 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.

Return Material Authorization (RMA)

Customers wishing to return any items, whether they are incorrectly supplied, faulty or damaged in transit,

must rst complete a Return Material Authorisation (RMA) form to obtain an RMA number from the Service

Department. A full repair service is available for customers. Prior to submitting the RMA form and returning products, customers are recommended to contact the technical support team to determine whether the issue can be resolved with telephone support.

How the RMA service works

The RMA form and details are availableon our web sites:

https://www.cdautomation.com/returns-material-authorisation/

When completing the RMA form, please be as specic as possible about the problem, including any pertinent

application details. The more information given, the more quickly and more thoroughly the problem can be solved. The minimum information required is:

1. The Full Model Number

2. Quantity of units being returned

3. The units Serial Number(s)

4. A description of the problem ( “faulty” or “unknown” is not sucient)

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REVO S 2PH from 60A to 800A - 690V User’s manual

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

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

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

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

Identication and Order Code . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.1 Identication of the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.2 Order Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Technical Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.1 General features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.2 Input features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.4 Fan Specication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.5 Environmental installation conditions . . . . . . . . . . . . . . . . . . . . . . . . 14

3.6 Derating Curve and Thermal conditions . . . . . . . . . . . . . . . . . . . . . . . 14

3.7 Calculating ow capacity of the fan. . . . . . . . . . . . . . . . . . . . . . . . . . 14

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.2 Fixing holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Wiring instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.1 Removing the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.2 Line power and Load cable/bar dimensions and torque (suggested). . . . 18

5.3 Cable dimensions (suggested) of Earth and of the Command Terminals . . 19

5.4 Terminals Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.5 Power Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.6 Control Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.7 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.8 Connection Diagram for 3 phases (control on 2 phases). . . . . . . . . . . . . 24

Indice

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REVO S 2PH from 60A to 800A - 690V User’s manual

Led status and alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Heater Break alarm and SCR short circuit . . . . . . . . . . . . . . . . . . 26

7.1 Heater break Calibration procedure. . . . . . . . . . . . . . . . . . . . . . . . . . 26

Input Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Burst Firing settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Firing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

10.1 Zero Crossing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

10.2 Burst Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Supply the electronic board . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Internal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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REVO S 2PH from 60A to 800A - 690V User’s manual

Basic Connections and sizing

Star wiring with resistive load (control on two phases with REVO S-2PH)

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

Delta wiring with resistive load (control on two phases with REVO S-2PH)

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

1,73V

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REVO S 2PH from 60A to 800A - 690V User’s manual

Identification and Order Code

2.1 Identication 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 identication’s label give all the information regarding the factory settings of the Thyristor unit, this label is on the unit, like represented in gure.

Verify that the product is the same thing as ordered.

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REVO S 2PH from 60A to 800A - 690V User’s manual

2.2 Order Code

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

REVO S 2PH R S 2 _ _ _ - _ _ _ _ _ _ _ _ _ _

CURRENT FUSES 4 5 6

description description code

60A Fixed Fuses Included 0 6 0

90A Fixed Fuses Included 0 9 0

120A Fixed Fuses Included 1 2 0

150A Fixed Fuses Included 1 5 0

180A Fixed Fuses Included 1 8 0

210A Fixed Fuses Include d 2 1 0

300A Fixed Fuses Included 3 0 0

400A Fixed Fuses Included 4 0 0

450A Fixed Fuses Included 4 5 0

500A Fixed Fuses Included 5 0 0

600A Fixed Fuses Included 6 0 0

700A Fixed Fuses Included 7 0 0

800A Fixed Fuses Included 8 0 0

MA X VO LTAGE 7

description code

480V 4

600V 6

690V 7

VOLTAGE SUPPLY AUX 8

Main Supply Voltage Aux Voltage Range code

100/1 20Vac 90 to 135V Vac 1

200/2 08/230/2 40Vac 180 to 265V Vac 2

277 Vac 238 to 330V Vac 3

3 80/4 1 5 /48 0Va c 342 to 528V Va c 5

600Vac 540 to 759V Vac 6

690Va c 540 to 75 9V Vac 7

INPUT 9

description code

SSR S

0:10V V

4:20mA A

FIRING 10

description code

Zero Crossin g Z

Burst Fi ring 4 Cyc les On at 50% Powe r Demand 4

Burst Fi ring 8 Cyc les On at 50% Powe r Demand 8

Burst Fi ring 16 Cycles On at 50% P ower Dema nd 6

CONTROL MODE 11

description code

Open Lo op 0

FUSES & OPTION 12

description code

Fixed Fuse s Std for all Un its > 40A F

Fixed Fuse s Std + CT + HB H

FAN VOLTA GE 13

description code

Fan 115Vac Opt ion 1

Fan 230Vac Std Versi on 2

Fan 24Vdc Optio n 3

APPROVALS 14

description code

CE EMC For Euro pean Ma rket 0

MANUAL 15

description code

None 0

Italian 1

English 2

German 3

Frenc h 4

VERSION 16

description code

Std unit wi th one fu se only 1

High Sensitivity HB below 5A 5

Note: The 690V unit is available with CE Only

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REVO S 2PH from 60A to 800A - 690V User’s manual

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:

Order code RS2_ _ _ -_1 = line voltage 100/120V transformer range 90:135V (8 VA Max) Order code RS2_ _ _ -_2 = line voltage 200/208/220/230/240V transformer range 180:265V (8 VA Max) Order code RS2_ _ _ -_3 = line voltage 277 transformer range 238:330V (8 VA Max) Order code RS2_ _ _ -_5 = line voltage 380/400/415/440/480V transformer range 342:528V (8 VA Max) Order code RS2_ _ _ -_6 = line voltage 600V transformer range 540:759V (8 VA Max) Order code RS2_ _ _ -_7 = line voltage 690V transformer range 540:759V (8 VA Max) Relay output for Heater Break Alarm

(only with HB option): 0.5A a 125VAC

3.2 Input features

Analogic input 0 ÷ 10Vdc impedance 15 K ohm Analogic input 4 ÷ 20mA impedance 100 ohm POT 10 K ohm min. Digital Input 4 ÷ 24Vdc 5mA Max (ON >4Vdc OFF <1Vdc)

3HZ Max duty cycle min. 100 ms

3.3 Output features (power device)

Current

Nominal

Voltage

range (Ue)

Repetitive peak reverse voltage

(Uimp)

Latching

current

Max peak one cycle

Leakage

current

FUSE I2T value Suggested A2s

(at690V)

Frequency

range

Power loss

Thyristor +

Fuse

Isolation

Voltage

(Ui)

(A) (V) (480V) (690V) (mAe) (10msec.)

(A)

(mAe) tp=10msec (Hz) I=Inom (W) Vac

60A 24÷600 1600 1800 600 1900 15 16940 47÷70 205 3000

90A 24÷600 1600 1800 600 1900 15 16940 47÷70 290 3000

120A 24÷600 1600 1800 600 1900 15 16940 47÷70 398 3000

150A 24÷600 1600 1800 400 1900 15 27500 47÷70 409 3000

180A 24÷600 1600 1800 400 1900 15 48400 47÷70 486 3000

210A 24÷600 1600 1800 400 1900 15 84700 47÷70 598 3000

300A 24÷600 1600 1800 400 1900 15 79750 47÷70 903 3000

400A 24÷600 1600 1800 200 7820 15 236500 47÷70 1092 3000

450A 24÷600 1600 1800 200 7820 15 338800 47÷70 1259 3000

500A 24÷600 1600 1800 200 7820 15 338800 47÷70 1407 3000

600A 24÷600 1600 1800 200 7820 15 462000 47÷70 1528 3000

700A 24÷600 1600 1800 200 7820 15 462000 47÷70 1753 3000

800A 24÷600 1600 1800 200 7820 15 387200 47÷70 2281 3000

Page 14

REVO S 2PH from 60A to 800A - 690V User’s manual

3.4 Fan Specication

Size

Number of fans

230Vac Standard

Number of fans

115Vac Option

Number of fans

24Vdc Option

S11 60A, 90A One Fan - 16W One Fan - 14W One Fan - 7W

S13

120A, 150A, 180A,

210A

Two Fans - (16W x 2) 32W Two Fans - (14W x 2) 28W Two Fans - (7W x 2) 14W

S14

300A, 400A, 500A,

600A

Two Fans - (16W x 2) 32W Two Fans - (14W x 2) 28W Two Fans - (7W x 2) 14W

S14 450A, 700A Four Fans - (16W x 4) 64W Four Fans - (14W x 4) 56W Four Fans - (7W x 4) 28W

S16 800A Four Fans - (16W x 4) 64W Four Fans - (14W x 4) 56W Four Fans - (7W x 4) 28W

3.5 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

3.6 Derating Curve and Thermal conditions

The nominal current of the units in specication are referred to continuos service at 40°C ambient temperature. For higher

temperature multiply the nominal current times derating

coecient K here represented:

3.7 Calculating ow 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 ow (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) (thyristor + fuse power loss) ta = ambient temperature (°C) tc = cabinet temperature (°C) V = fan air mass ow (m3/h) f = altitude coecient (see table on right)

Altitude

0:100 meters f = 3.1 m3k/Wh 100:250 meters f = 3.2 m3k/Wh 250:500 meters f = 3.3 m3k/Wh 500:750 meters f = 3.4 m3k/Wh

The formulas used are for information only and is not a substitute for a proper thermal

rating done by a qualied person.

V=f *

tc-ta

l max = l nominal x K

15 20 25 30 35 40 45 50 55

1,2

0,8

0,6

0,4

0,2

1 1 1 1

0,9

0,8

CABINET TEMPERATURE °C

Derating

For higher cabinet temperature contact the producer of the unit

Page 15

REVO S 2PH from 60A to 800A - 690V User’s manual

Installation

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 ordered. The 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, this area must be free from obstacle (wire, copper bar, plastic channel).

When more unit has mounted inside the cabinet maintain the air

circulation like represented in gure without obstacle for the air ow.Is necessary to install a fan to have better air circulation as

calculated previously.

*30 cm

*20 cm

*2 cm

AIR FLOW IN (V)

AIR FLOW OUT (V)

FAN in aspiration

Air Grid

The V Air ow must be equal or more than the value calculated.

If the cabinet fan mounted by the customer have an air ow lower than the correct value the warranty

will decay.

Page 16

REVO S 2PH from 60A to 800A - 690V User’s manual

4.1 Dimensions and weight

REVO-S 2PH

60A÷90A (S11)

W 137mm - H 440mm - D 270mm

Weight 10,5Kg

REVO-S 2PH

120A÷210A (S13)

W 262mm - H 440mm - D 270mm

Weight 18Kg

REVO-S 2PH

800A (S16)

W 275mm - H 560mm - D 270mm

Weight 22,5Kg

REVO-S 2PH

300A÷700A (S14)

W 262mm - H 520mm - D 270mm

Weight 22,5Kg

Page 17

REVO S 2PH from 60A to 800A - 690V User’s manual

4.2 Fixing holes

REVO-S 2PH

300A÷700A (S14)

REVO-S 2PH

60A÷90A (S11)

REVO-S 2PH

800A (S16)

REVO-S 2PH

120A÷210A (S13)

222

490

235

530

410

222

410

Page 18

REVO S 2PH from 60A to 800A - 690V User’s manual

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 lter.

• 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 75°C copper (CU) conductor only or use copper bus bars sized for eld wiring connection, wire ranges

(AWG), wire terminal type (ZMVV), tightening torque in the tables below.

5.1 Removing the cover

Instructions for open the thyristor unit

5.2 Line power and Load cable/bar dimensions and torque (suggested)

Current Connector Type

Torque Cable

Cable Terminal

Bar

Lb-in Nm AWG mm

kcmil

60A (S11) Terminal Block M8 177 20.0 5 16 33.1

UL Listed (ZMVV)

Copper Tube Crimp. Lug

90A (S11) Terminal Block M8 177 20.0 3 25 52.6

UL Listed (ZMVV)

Copper Tube Crimp. Lug

120A (S13) Terminal Block M8 177 20.0 2 35 66.4

UL Listed (ZMVV)

Copper Tube Crimp. Lug

150A (S13) Terminal Block M8 177 20.0 0 50 106

UL Listed (ZMVV)

Copper Tube Crimp. Lug

180A (S13) Terminal Block M8 177 20.0 00 70 133

UL Listed (ZMVV)

Copper Tube Crimp. Lug

210A (S13) Terminal Block M8 177 20.0 000 90 168

UL Listed (ZMVV)

Copper Tube Crimp. Lug

300A (S14)

Power eld wiring Bus

Bar with M10 screw

265 30.0 2 x 1/0 2 x 70 350

UL Listed (ZMVV)

Copper Tube Crimp. Lug

Bus bar

30x6mm

400A (S14)

Power eld wiring Bus

Bar with M10 screw

265 30.0 2 x 3/0 2 x 95 600

UL Listed (ZMVV)

Copper Tube Crimp. Lug

Bus bar

30x6mm

450A (S14)

Power eld wiring Bus

Bar with M10 screw

265 30.0 2 x 4/0 2 x 95 700

UL Listed (ZMVV)

Copper Tube Crimp. Lug

Bus bar

30x6mm

500A (S14)

Power eld wiring Bus

Bar with M10 screw

265 30.0 - 2 x 150

2x250

900

UL Listed (ZMVV)

Copper Tube Crimp. Lug

Bus bar

60x4mm

600A (S14)

Power eld wiring Bus

Bar with M10 screw

265 30.0 - 2 x 185

2x350

1500

UL Listed (ZMVV)

Copper Tube Crimp. Lug

Bus bar

60x5mm

700A (S14)

Power eld wiring Bus

Bar with M10 screw

265 30.0 - 2 x 300 2x500

UL Listed (ZMVV)

Copper Tube Crimp. Lug

Bus bar

60x6mm

800A (S16)

Power eld wiring Bus

Bar with M10 screw

265 30.0 - 2 x 300 2x500

UL Listed (ZMVV)

Copper Tube Crimp. Lug

Bus bar

60x6mm

Page 19

REVO S 2PH from 60A to 800A - 690V User’s manual

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

Current

Earth Command Terminals

Cable Screw Cable

mm² AWG M mm² AWG

60A (S11) 16 6 M8 0,50 18

90A (S11) 16 6 M8 0,50 18

120A (S13) 16 6 M8 0,50 18

150A (S13) 25 4 M8 0,50 18

180A (S13) 25 4 M8 0,50 18

210A (S13) 25 4 M8 0,50 18

300A (S14) 50 1 M8 0,50 18

400A (S14) 50 1 M8 0,50 18

450A (S14) 70 1/0 M8 0,50 18

500A (S14) 70 1/0 M8 0,50 18

600A (S14) 70 1/0 M8 0,50 18

700A (S14) 70 1/0 M8 0,50 18

800A (S16) 70 1/0 M8 0,50 18

5.4 Terminals Positions

Open and ip the cover

Page 20

REVO S 2PH from 60A to 800A - 690V User’s manual

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 (Only S14)

L3 Line Input Phase 3

T1 Load Output Phase 1

Load Output Phase 2 -

Not controlled by the thyristor (only S14)

T3 Load Output Phase 3

5.5.1 Bar dimensions S14

Current

A B C D E F G H M

300A (S14) 71mm 60mm 45mm 57mm 30mm - 350mm 174mm M10

400A (S14) 71mm 60mm 45mm 57mm 30mm - 350mm 174mm M10

450A (S14) 71mm 60mm 45mm 57mm 30mm - 350mm 174mm M10

500A (S14) 71mm 60mm 45mm 57mm 30mm - 350mm 174mm M10

600A (S14) 54mm 76mm 21mm 37mm 66mm 35mm 390mm 165mm M10

700A (S14) 54mm 76mm 21mm 37mm 66mm 35mm 390mm 165mm M10

2PH from 300 to 500A

2PH from 600 to 700A

L1 L2 L3

T1 T2 T3

REVO-S 2PH

300A÷700A (S14)

Page 21

REVO S 2PH from 60A to 800A - 690V User’s manual

5.6 Control Terminals

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

Terminal Description

1 NO - Normally Open contact alarm relay output (HB) 2 C - Common contact alarm relay output 3 NC - Normally Close contact alarm relay output (HB) 4 Not Connected 5 DI 2 – Enable Digital Input 6 DI 1 - Congurable Input 7 Not Connected 8 Not Connected 9 Output +10Vdc stabilized 1 mA MAX

10 0V GND

Terminal Description

11 - Analog Input 1 (0-10Vdc/4-20mA Analog Setpoint) 12 + Analog Input 1 (0-10Vdc/4-20mA Analog Setpoint) 13 COM I - Common Digital Input 14 Not Connected 15 Fan supply (230V Standard – 115 Option - for DC Fan Option +24Vdc)

16 Fan supply (230V Standard – 115 Option - for DC Fan Option -24Vdc)

17 Not Connected

18 Aux – Voltage Supply for electronic boards and synchronization (See order code for the Value) 19 Not Connected 20 Aux – Voltage Supply for electronic boards and synchronization (See order code for the Value)

Terminal Description

1 24V Out Max 5mA 2 Slave Output 3 Not Connected 4 0V GND

Page 22

REVO S 2PH from 60A to 800A - 690V User’s manual

5.7 Schematic

Caution: this procedure must be performed only by qualied persons.

NOTE:

1 The user installation must be protecting by electromagnetic circuit breaker or by fuse isolator.

The Fuse must be branch circuit protection.

2 The auxiliary voltage supply of the Revo C unit must be synchronized with load voltage power supply. If the

Auxiliary Voltage (written on the identication label) is dierent from Supply Voltage (to the load), use an

external transformer as designated.

3 On phase L2 fuse not available for size 600-700A

4 For SSR input connection follow next page schematic.

L3 L2 L1 18 15 1620

AUX AUX

T3 T2 T1

SLAVE

OUT

3 4

9 10 13 5 6 12 11 3 1 2 8

NC NO C

+24V GND

Function Thermal

SC/HB

Fan supply

230Vac Standard

115Vac option

24Vdc option

See Order Code

Analog Inp.1 Analog SetPoint

Fuse

5A Max

Branch Circuit Protection

Not connected

Page 23

REVO S 2PH from 60A to 800A - 690V User’s manual

5.7.1 SSR Control Input schematic

For SSR input use follow the schematic below and congure Digital Input 1 as Fast Enable.

SSR

INPUT

* SSR Input:

4 ÷ 30Vdc 5mA Max (ON >4Vdc OFF <1Vdc) 3HZ Max on time min. 100 ms

Page 24

REVO S 2PH from 60A to 800A - 690V User’s manual

Note: Aux Voltage and Load Voltage must be synchronized

5.8 Connection Diagram for 3 phases (control on 2 phases)

Caution: this procedure must be performed only by qualied persons.

X = not connected

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.

+24V

SLAVE OUT

Analog Inp.1

0-10VDC /4-20mA ANALOG SET POINT

Branch

Circuit

Protection

Relay

Thermal or

SC/HB

Fan Power Supply

See order code for the value

AUX Voltage Supply

See order code for the value

Load Type

Delta Star

T1 T2 T3

Page 25

REVO S 2PH from 60A to 800A - 690V User’s manual

Led status and alarms

LED status

LED STATUS DESCRIPTION

LED Flashing ( )

Waiting for Enable Signal

LED ON ( ) Enable Signal to terminal

LED OFF ( ) Load is NOT powered

LED ON ( ) Load is powered

LED OFF ( ) Load OK

LED ON ( ) SCR short circuit (only with HB option)

LED Flashing ( )

Enable contact open or Over temperature on heat sink

LED OFF ( ) Load OK

LED ON ( ) Load Fault (only with HB option)

CAL

BF 2 BF 4 BF 8 BF 16

Keep pressed for 2 sec

Wait more than 10 seconds

after power on

The LEDs turn o for 2 seconds

and the setting is displayed

END

The LEDs turn o

for 4 seconds

0-10V 4-20mA 0-20mA SSR

Keep pressed for 2 sec

Wait more than 10 seconds

after power on

The LEDs turn o for 2 seconds

and the setting is displayed

END

The LEDs turn o

for 4 seconds

Input type informations Burst Firing informations

Page 26

REVO S 2PH from 60A to 800A - 690V User’s manual

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

Page 27

REVO S 2PH from 60A to 800A - 690V User’s manual

Input Setting

The Input type is already congured in line with customer requirements that are dened in the order code.

However, if you need to to make changes you must follow the following procedure.

0-10V

4-20mA

0-20mA

SSR

Keep pressed

Release

Remove

auxiliary power supply

Supply the Unit

LED1 - LED2 ashing for 3 sec.

END

Press to save

the conguration

Press to choose

the desired conguration

Page 28

REVO S 2PH from 60A to 800A - 690V User’s manual

Burst Firing settings

The Burst Firing cycles is already congured in line with customer requirements that are dened 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.

BF 2

BF 4

BF 8

BF 16

Keep pressed

Release

Remove

auxiliary power supply

Supply the Unit

LED3 - LED4 ashing for 3 sec.

Press to save

the conguration

Press to choose

the desired conguration

END

Page 29

REVO S 2PH from 60A to 800A - 690V User’s manual

Firing type

Choose a correct ring type allows to optimize the thyristor unit for the installed load. The ring type has already congured in line with customer requirements, Zero Crossing for SSR input and Burst ring for Analog Input.

Caution: this procedure must be performed only by qualied persons.

10.1 Zero Crossing

ZC ring 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.

10.2 Burst Firing

The Burst Firing is similar to the Single Cycle, but consecutive cycles ON are selectable between 1 and 255,

with input signal equal at 50%. When is specied 1 the ring type is Single Cycle.

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)

SSR from controller

25%

50%

75%

100%

ON OFF

Voltage Supply (V)

Load Voltage (V)

Page 30

REVO S 2PH from 60A to 800A - 690V User’s manual

Supply the electronic board

The REVO S thyristor unit, to work, requires a voltage supply for the electronic boards. The Max consumption is 8VA.

The voltage supply for the electronic boards is congured in line with customer requirements that are dened in the Order Code. The Order Code is written on the identication label.

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

Terminal M1 Description

18 Voltage Supply for Electronic Boards (Auxiliary Voltage)

19 Not Used

20 Voltage Supply for Electronic Boards (Auxiliary Voltage)

To change auxiliary supply voltage sold the correct link-jumper on REVO S board, the type of mounted transformer depends of the chosen Voltage in the order code.

Order Code

As ordered Change to

Jumper JP1 + JP2 are linked Link only Jumper JP3

Transformer range Line voltage Transformer range Line voltage

RS2_ _ _-_1 90:135V 100/120V 180:265V 200/208/220/230/240 RS2_ _ _-_2 180:265V 200/208/220/230/240V 342:528V 380/400/415/440/480 RS2_ _ _-_3 238:330V 277V 540:759V 600/690

Only Jumper JP3 is linked Link Jumper JP1 + JP2

RS2_ _ _-_5 342:528V 380/400/415/440/480V 180:265V 200/208/220/230/240V RS2_ _ _-_6 540:759V 600V 238:330V 277V RS2_ _ _-_7 540:759V 690V 238:330V 277V

If the Auxiliary Voltage (written on the identication label) is dierent from Supply Voltage (to the load), use an

external transformer with primary equal to load voltage and secondary equal to the Auxiliary Voltage.

Attention! never link all the jumpers JP1+JP2+JP3 at the same time or JP3 + any other jumper, JP3 must be

always alone, follow only the conguration shown.

JP1

JP2

JP3

Page 31

REVO S 2PH from 60A to 800A - 690V User’s manual

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.

Size

200 kARMS Symmetrical A.I.C.

Qty

Fuse CODE

Current

(ARMS)

FUSE I2T value

Suggested A2s (at500V)*

FUSE I2T value

Suggested A2s (at660V)

Vac

60A (S11) 20 282 20.160 160 15400 16940 690 3

90A (S11) 20 282 20.160 160 15400 16940 690 3

120A (S13) 20 282 20.160 160 15400 16940 690 3

150A (S13) 20 282 20.200 200 25000 27500 690 3

180A (S13) 20 282 20.250 250 44000 48400 690 3

210A (S13) 20 282 20.315 315 77000 84700 690 3

300A (S14) FMM400 400 72500 79750 690 3

400A (S14) FMM550 550 215000 236500 690 3

450A (S14) 2x FM315 2 x 315 308000 338800 690 3

500A (S14) 2x FM315 2 x 315 308000 338800 690 3

600A (S14) 2x FMM450 2 x 450 420000 462000 690 2

700A (S14) 2x FMM450 2 x 450 420000 462000 690 2

800A (S16) 4x 20 559 20.250 4 x 250 352000 387200 690 2

*I2T are multiplied for K value in function of Vac at 690V K is equal to 1,1 (ex:15400 X 1,1 = 16940). At 660Vac K is equal to 1

Fuses replacement: Open the cover and remove the screws, then replace it with the correct fuse, use the screws with a proper suggested torque indicated below

TYPE Screw

Torque Lb-in

(N-m)

60A-210A M6 44.2 (5.0)

300A-800A M8 133.7(15.0)

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.

1.2

1.0

0.8

0.6

0.4

0.2

200 400 600 800

1.1

690

Vac

(Line voltage)

Page 32

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