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REVO RT

from 35A to 90A

User’s manual

13

Identification and Order Code

4.1 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 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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Summary of Contents for REVO RT

Page 1: ...1 001 M RT 35 90 from 35A to 90A REVO RT MULTIZONE TEMPERATURE CONTROLLER CD Automation S r l Via Picasso 34 36 20025 Legnano MI Italy Tel 39 0331 577479 Fax 39 0331 579479 E mail info cdautomation com Web www cdautomation com ...

Page 2: ......

Page 3: ...fety 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 EN6094...

Page 4: ...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 ...

Page 5: ...onment 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 with...

Page 6: ...TION 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...

Page 7: ...rization RMA Customers wishing to return any items whether they are incorrectly supplied faulty or damaged in transit must first 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 ...

Page 8: ...6 5 2 Input and Output features power device 16 5 3 Input features electronic control board 16 5 4 Output features electronic control board 16 5 5 Software features 17 5 6 Environmental installation conditions 17 5 7 Fan Specification 17 5 8 Derating Curve 17 5 9 Calculating flow capacity of the fan 18 Installation 19 6 1 Dimensions and weight 20 6 2 Fixing holes 20 Wiring instructions 21 7 1 Comm...

Page 9: ...DO Function selection 34 9 10 Customizable reading area 35 Configuration parameter list 36 10 1 Analog Input 36 10 2 SSR control outputs 38 10 3 Autotuning and PID 40 10 4 Alarms 44 10 5 Digital Relay Outputs 47 10 6 Digital input 48 10 7 Soft Start 49 10 8 Current Transformer Input 50 10 9 Serial RS485 MODBUS RTU 51 Firing type 52 11 1 Zero Crossing 52 Control Mode feed back 53 Electronic board 5...

Page 10: ... Provides wide range of options from simple single phase to complex three phase loads to 600V 100kA short circuit current rating SCCR Not reviewed by UL Enables greater protection in the event of a short circuit c UL 508 Listed PRELIMINARY to be tested Shortens project schedules agency testing and expenses Control modes contactor voltage current or power Satisfies a wide range of demanding thermal...

Page 11: ...ection For install the software launch the program and follow the instructions on the screen Run the software configurator and set the correct serial port number by menu setting serial com port number 2 To connect the unit at the PC it s necessary to use the micro USB 2 0 Modbus RTU cable USB connection need a driver to work properly you can find it from our site However the configuration software...

Page 12: ...oad I Nominal current of the load P Nominal power of the load Delta wiring with resistive load control on three phases V Nominal voltage of the load I Nominal current of the load P Nominal power of the load Star Neutral wiring V Nominal voltage of the load I Nominal current of the load P Nominal power of the load 3 I P 1 73V I P 1 73V I P 1 73V V V V N ...

Page 13: ...hat the Thyristor unit have not damages If the product has a fault please contact the dealer from which you purchased the product The identification 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 4 ...

Page 14: ...ut as Tc J K S or Analog 4 20mA o 0 10V 0 FIRING 10 description code Zero Crossing Z CONTROL MODE 11 description code N 2 Loop Heating and Cooling or Heating Only to be configured by the customer 0 FUSES OPTION 12 description code Fixed Fuse No Option F Fixed Fuse Heater Break Alarm H FAN VOLTAGE 13 description code 24Vdc Fan standard 3 APPROVALS 14 description code CE EMC For European Market 0 MA...

Page 15: ... 10 description code Zero Crossing Z CONTROL MODE 11 description code N 3 Loop Heating and Cooling or Heating Only to be configured by the customer 0 FUSES OPTION 12 description code Fixed Fuse No Option F Fixed Fuse Heater Break Alarm H FAN VOLTAGE 13 description code 24Vdc Fan standard 3 APPROVALS 14 description code CE EMC For European Market 0 MANUAL 15 description code None 0 Italian 1 Englis...

Page 16: ... Voltage Ui A V 480V 600V mAeff 10 msec A mAeff tp 10msec Hz I Inom W Vac 30 24 600 1600 600 520 15 546 47 70 36 3000 3000 50 24 600 1600 600 1500 15 1750 47 70 54 3000 3000 75 24 600 1600 600 1900 15 4305 47 70 102 3000 3000 90 24 600 1600 600 1900 15 4305 47 70 145 3000 3000 5 3 Input features electronic control board configurable via software Input n 3 Resolution 16Bit Thermocouple Type K S R J...

Page 17: ...re 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 5 7 Fan Specification Supply 24 Vdc Power 7W 1 fan 5 8 Derating Curve The nominal cur...

Page 18: ...or 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 ta ambient temperature C 100 250 meters f 3 2 m3k Wh tc cabinet temperature C 250 500 meters f 3 3 m3k Wh...

Page 19: ...ances 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 figure without obstacle for the air flow Is necessary to install a fan to have better air circulation as calculated previously 6 The V Air flow must be equal or more than the value calc...

Page 20: ...20 REVO RT from 35A to 90A User s manual 6 2 Fixing holes 6 1 Dimensions and weight Size SR25 W mm 116 H mm 180 D mm 183 Weight kg 2 35 Size SR25 5 5 5 5 10 10 96 116 180 7 18 155 169 W D H H ...

Page 21: ...MVV terminal tightening torque in the table below Power cable torque suggested Type Connector Type Torque Lb in N m Wire Range mm AWG MAX Current Terminals Wire Terminals UL Listed ZMVV 035 050 075 090 Screw M6 44 2 5 0 18 5 25 3 90A Fork Spade Terminal Copper Tube Crimp Lug Cable dimensions of the Command Terminals 0 5 mm AWG 18 Cable dimensions of the Earth suggested 6 mm AWG 10 Warning Before c...

Page 22: ...output 3 3 Digital output 2 4 Digital output 1 5 COM I Common Digital Input 6 not used 7 Input 3 Misure 1 Input 3 Loop 3 8 Input 3 Misure 1 Input 3 Loop 3 9 Input 2 Loop 2 Input 2 Loop 2 10 Input 2 Loop 2 Input 2 Loop 2 11 Input 1 Loop 1 Input 1 Loop 1 12 Input 1 Loop 1 Input 1 Loop 1 7 1 3 Terminal block M2 Terminal Description 13 Auxiliary 24Vdc Input power supply 14 Auxiliary 24Vdc Input power ...

Page 23: ...ge sources NOTE 1 The user installation must be protecting by electromagnetic circuit breaker or by fuse isolator The Fuse must be branch circuit protection 18 19 20 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 L1 L1 L1 L3 T3 T1 L3 L3 RS485 AL5 A B GND 24V COM I DO3 DO2 DO1 AL4 TOP VIEW BRANCH CIRCUIT PROTECTION to LOAD DOWN VIEW Input Measure Input Loop 1 Input Loop 2 Digital Input ...

Page 24: ...24 REVO RT from 35A to 90A User s manual 13 14 15 16 17 18 19 20 M2 1 2 3 4 5 6 7 8 9 10 11 12 TOP VIEW DOWN VIEW M1 L3 T3 T1 L1 M1 M2 ...

Page 25: ...urces NOTE 1 The user installation must be protecting by electromagnetic circuit breaker or by fuse isolator The Fuse must be branch circuit protection 18 19 20 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 L1 L2 L1 L1 L3 T3 T1 L2 T2 L2 L3 L3 RS485 AL5 A B GND 24V COM I DO3 DO2 DO1 AL4 TOP VIEW BRANCH CIRCUIT PROTECTION to LOAD DOWN VIEW Input Loop 1 Input Loop 2 Input Loop 3 Digital Input ...

Page 26: ...26 REVO RT from 35A to 90A User s manual 13 14 15 16 17 18 19 20 M2 1 2 3 4 5 6 7 8 9 10 11 12 TOP VIEW DOWN VIEW M1 L3 L1 T3 T2 T1 L2 M1 M2 ...

Page 27: ...le canal 2 Solid Red Thermocouple error Canal 2 Off OK Loop3 Thermocouple canal 3 Solid Red Thermocouple error Canal 3 Off OK D I Digital Input Solid Green ON Off DO1 Relay status 1 Solid Red Relay error 1 Off DO2 Relay status 2 Solid Red Relay error 2 Off DO3 Relay status 3 Solid Red Relay error 3 Off AL4 Relay status 4 Solid Red Relay error 4 Off AL5 Relay status 5 Solid Red Relay error 5 Off CA...

Page 28: ...p 1 P111 Add 2111 for Loop 2 P137 Add 2137 for Loop 3 If the function is enabled the Pre Tune button in the Test section of the configurator will also be enabled To execute the Pre Tune function press the key PT Pre Tune o by serial write the value 1 on parameters with modbus address 1216 for Loop1 1217 for Loop2 1218 for Loop3 Once the function is completed the parameter will be reset to 0 automa...

Page 29: ... Tune parameter in the configurator for each Loop o via serial by setting 1 on the following parameters P85 Add 2085 for Loop 1 P111 Add 2111 for Loop 2 P137 Add 2137 for Loop 3 the controller analyzes the process oscillations and optimizes the PID parameters to obtain a stable process if the regulation oscillates outside a threshold established by the parameters P101 threshold value for Loop 1 P1...

Page 30: ...r Add 1010 or in the status table on parameter Add 1016 even if assigned No Function 9 5 Automatic Manual regulation for output control This function allows to switch from automatic functioning to manual command of the output percentage The Automatic Manual selection is given by the parameters 1219 value 0 Manual value 1 Automatic for Loop 1 1220 value 0 Manual value 1 Automatic for Loop 2 1221 va...

Page 31: ...rks in this way Parameter Proportional band Banda Proporzionale Heating Proportional band Parameter Integral Time Tempo Integrale Integral time of heating and cooling Parameter Derivative Time Tempo Derivativo Derivative time of heating and cooling Parameter Heating time Cycle Tempo Ciclo Riscaldamento Heating Time Cycle Parameter Cooling PB Multiplier Moltiplicatore PB Freddo Cooling Proportional...

Page 32: ...ameter has elapsed P244 Add 2244 Soft start time hh mm for Loop 1 P254 Add 2254 Soft start time hh mm for Loop 2 P264 Add 2264 Soft start time hh mm for Loop 3 Percentual When the regulator is turned on or enabled the output goes to the power set in the parameter Soft Start Percentage P242 Add 2242 Output Soft Start percentage 0 100 for Loop 1 P252 Add 2252 Output Soft Start percentage 0 100 for L...

Page 33: ...oids the overlapping of the three ignitions limiting the current peaks If on the other hand the 33 threshold is exceeded the power demand is added to the next zone but in a much less burdensome way By avoiding overlaps consumption is optimized Z2 25 Z2 20 Z1 30 Z2 25 Z2 20 Z1 30 Z2 25 Z2 20 Z1 30 Z2 25 Z2 20 Z1 30 Without ECO function Cycle time Time Cycle time Time 33 33 100 100 Current Current W...

Page 34: ... Watch Dog on RS485 Error on an input Replication of DI status RUN status for Loop 1 2 and 3 Remote command 1 and 2 The various functions can also be combined with each other to have different functions on a single output See parameters P219 P221 P223 P225 P227 on chapter 11 Configuration parameter list Es The status of 2 alarms the status of the sensors the status of the Heater Break can be assoc...

Page 35: ...ameter Description R W 2501 N of parameter to visualize in the parameter Add 1401 R W 2502 N of parameter to visualize in the parameter Add 1402 R W 2530 N of parameter to visualize in the parameter Add 1430 R W 2531 N of parameter to visualize in the parameter Add 1431 R W The values will be read on parameters Parameter Description R W 1401 Value of parameter contained in parameter Add 2501 R 140...

Page 36: ...s 2002 P16 Lower limit Loop 2 Address ModBus 2016 P30 Lower limit Loop 3 Address ModBus 2030 Lower limit of the analog input Example with 4 20 mA input this parameter assumes the value associated with 4 mA 32767 32767 digit Default 0 P3 Upper limit Loop 1 Address ModBus 2003 P17 Upper limit Loop 2 Address ModBus 2017 P31 Upper limit Loop 3 Address ModBus 2031 Upper limit of the analog input Exampl...

Page 37: ...dBus 2035 Filter used to increase the stability of the reading Increasing the value slows down the speed of the control loop 1 15 Default 10 P8 Unit of measurement for all Loops Address ModBus 2008 0 1 2 C Celsius Degrees Default F Fahrenheit Degrees K Kelvin P9 Conversion rate for all Loops Address ModBus 2009 Sampling frequency of the input Increasing the conversion speed decreases the reading s...

Page 38: ...nitial state of the adjustment zone 1 after switching on 0 1 2 Start Stop Last state Zone enabled Default Zone disabled Start Stop status prior to shutdown P45 Input selection Loop 1 Address ModBus 2045 P59 Input selection Loop 2 Address ModBus 2059 P73 Input selection Loop 3 Address ModBus 2073 Select the input connected to the regulation loop 0 1 2 Input 1 Default Input 2 Input 3 P46 Setpoint co...

Page 39: ...in Stop Loop 1 Address ModBus 2051 P65 Percentage of output when in Stop Loop 2 Address ModBus 2065 P79 Percentage of output when in Stop Loop 3 Address ModBus 2079 Fixed percentage of control output with controller in STOP mode If configured in Heating Cooling the negative value indicates the percentage of the cooling output 100 100 Percentage of control output Default 0 P52 Enabling storage Manu...

Page 40: ... Pretune function 0 10000 digit 0 0 1000 0 with thermocouple Default 30 0 P87 Proportional band Loop 1 Address ModBus 2087 P113 Proportional band Loop 2 Address ModBus 2113 P139 Proportional band Loop 3 Address ModBus 2139 Proportional band for PID process control process inertia If Proportional band 0 and Integral Time 0 the regulation becomes type ON OFF 1 10000 digit 0 1 1000 0 with thermocoupl...

Page 41: ...oop 1 Address ModBus 2092 P118 Auto power off above a threshold Loop 2 Address ModBus 2118 P144 Auto power off above a threshold Loop 3 Address ModBus 2144 In PID operation it enables the SCR control output to be switched off when a certain threshold is exceeded setpoint P93 0 1 Disabled Default Enabled P93 Auto power off over a threshold Loop 1 Address ModBus 2093 P119 Auto power off over a thres...

Page 42: ...123 Overlap Dead Band Loop 2 Address ModBus 2123 P149 Overlap Dead Band Loop 3 Address ModBus 2149 When the process is configured as a hot cold PID the Overlap Deadband function defines whether the heating action and the cooling action can overlap or must have a dead band between the two actions 20 0 50 0 Negative Dead Band Positive Overlap Default 0 0 Output Power Output Power Output Power Overla...

Page 43: ...portional band value for automatic PID calculation Pretune 0 10000 digit 0 0 1000 0 with thermocouple Default 3 0 P103 Maximum proportional band Loop 1 Address ModBus 2103 P129 Maximum proportional band Loop 2 Address ModBus 2129 P155 Maximum proportional band Loop 3 Address ModBus 2155 Maximum proportional band value for automatic PID calculation Pretune 0 10000 digit 0 0 1000 0 with thermocouple...

Page 44: ...lute of high Absolute referred to PV active when PV exceeds threshold 2 Absolute of low Absolute referred to PV active when PV below threshold 3 Band alarm SP alarm setpoint 4 Asymmetrical band Alarm SP AL_H and SP AL_L 5 High deviation Deviation alarm active when PV exceeds SP AL 6 Low deviation Deviation alarm active when PV goes below SP AL 7 Absolute on high of SP Absolute on SP active when SP...

Page 45: ...ault N C Start normally closed operational from start N O Threshold operational when the alarm is reached N C Threshold operational when the alarm is reached N C Threshold Variation inhibited after command set change N C Threshold Variation inhibited after command set change P167 Hysteresis Alarm 1 Address ModBus 2167 P181 Hysteresis Alarm 2 Address ModBus 2181 P195 Hysteresis Alarm 2 Address ModB...

Page 46: ...s 2170 P184 Alarm 2 State Stop Address ModBus 2184 P198 Alarm 3 State Stop Address ModBus 2198 P212 Alarm 4 State Stop Address ModBus 2212 Alarm output status with controller in STOP mode 0 1 open close Open contact Default Closed contact P171 Alarm 1 delay Address ModBus 2171 P185 Alarm 2 delay Address ModBus 2185 P199 Alarm 3 delay Address ModBus 2199 P213 Alarm 4 delay Address ModBus 2213 Alarm...

Page 47: ... on DO1 are raised this output will be active if Alarm1 or Alarm2 is active Functions associated with the output relay DO Bit 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Function Cooling Loop 1 Cooling Loop 2 Cooling Loop 3 Alarm 1 Alarm 2 Alarm 3 Alarm 4 Heater Break RS485 Watch dog Probe error Status DI 1 RUN Loop 1 RUN Loop 2 RUN Loop 3 Remote 1 Remote 2 Default 0 P220 Alarm contact type DO1 Address ...

Page 48: ...e Run if closed in run Manual reset alarm External alarm The controller goes into STOP and the alarms are disabled The controller does not automatically return to START user intervention is required for this operation P234 Digital Input 1 contact Address ModBus 2234 Defines the break contact of digital input 1 0 1 Normally open Default Normally closed ...

Page 49: ...ntage Address ModBus 2252 P262 Soft Start 3 percentage Address ModBus 2262 Percentage of output during soft start function 1 0 100 Default 50 P243 Soft Start threshold Loop 1 Address ModBus 2243 P253 Soft Start threshold Loop 2 Address ModBus 2253 P263 Soft Start threshold Loop 3 Address ModBus 2263 Threshold below which the percentage soft start function is activated on power up 30000 30000 digit...

Page 50: ...rm Default 0 0 200 0 Ampere P274 Heater Break sensitivity Loop 1 Address ModBus 2274 P284 Heater Break sensitivity Loop 2 Address ModBus 2284 P294 Heater Break sensitivity Loop 3 Address ModBus 2294 Percentage of reduction of the measured current below which the H B error is generated 0 80 Default 20 P275 Overcurrent Loop 1 Address ModBus 2275 P285 Overcurrent Loop 2 Address ModBus 2285 P295 Overc...

Page 51: ...rial Port Parameters Address ModBus 2302 Selects the format for Modbus RTU serial communication 0 1 2 3 4 5 8 bit no parity 1 stop bit Default 8 bit even parity 1 stop bit 8 bit odd parity 1 stop bit 8 bit no parity 2 stop bit 8 bit even parity 2 stop bit 8 bit odd parity 2 stop bit P303 Serial Delay Address ModBus 2303 Select serial delay 0 100 ms Default 5 ms P304 RS458 MODBUS RTU WatchDog Addre...

Page 52: ...ge the firing type you can use the software configurator or the Control Panel Caution this procedure must be performed only by qualified persons 11 1 Zero Crossing L accensione ZC è usata con un uscita logica dal regolatore di temperatura ed il thyristor opera come un contattore Il tempo di ciclo è stabilito dal regolatore di temperatura L accensione ZC minimizza le interferenze elettro magnetiche...

Page 53: ...e demand This control mode compensates the voltage fluctuation of the incoming line supply I Current feed back The input signal is proportional to the current output This means that input signal becomes a current demand This control mode maintain the current also if the load impedance changes P VxI Power feed back The input signal is proportional to the power output This means that input signal be...

Page 54: ... 1A on terminal M2 13 14 Warning Before connecting or disconnecting the unit check that power and control cables are isolated from voltage sources RS485 Serial port Terminal M3 Description 15 RS485 A 16 RS485 B The serial communication port RS485 is available on the Command Terminals On this port may be done a network up to 127 units 13 14 13 14 15 16 17 18 19 20 DOWN VIEW M2 ...

Page 55: ...y of thyristor is null if no proper fuses are used Tipo Codice fusibile ricambio Corrente ARMS Vac Fusibile I2 t suggerito A2s a 500V Fusibile I2 t suggerito A2s a 690V Quantità per ogni fase 035 FU5007306 50 50 690 546 780 1 050 FU5007306 80 80 690 1750 2500 1 075 FU5007306 100 100 690 2170 3100 1 090 FU5007306 100 100 690 2170 3100 1 I2 t are multiplied for K value in function of Vac at 500V K i...

Page 56: ...CD Automation S r l Via Picasso 34 36 20025 Legnano MI Italy Tel 39 0331 577479 Fax 39 0331 579479 E mail info cdautomation com Web www cdautomation com ...

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