CD Automation REVEX 1PH User Manual Download

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USER’S MANUAL

Rev. 10/2021

012

M-RX1-30-40

1PH

from 30A to 40A

CD Automation S.r.l.

Via Picasso, 34/36 - 20025 Legnano (MI)- Italy
Tel. +39 0331 577479 - Fax +39 0331 579479
E-mail: [email protected] - Web: www.cdautomation.com

Summary of Contents for REVEX 1PH

Page 1: ... MANUAL Rev 10 2021 012 M RX1 30 40 1PH from 30A to 40A 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: ... 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 ...

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: ...ronment 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 wit...

Page 6: ...UTION 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 Tout...

Page 7: ...orization 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: ...chnical Specifications 16 6 1 General features 16 6 2 Input features 16 6 3 Output features power device 16 6 4 Environmental installation conditions 16 6 5 Derating Curve 17 6 6 Calculating flow capacity of the fan 17 Installation 18 7 1 Dimensions and weight 19 7 2 Fixing holes 19 Wiring instructions 20 8 1 Command Terminals 21 8 2 Schematic 22 8 3 Connection Diagram 24 Control Panel 25 9 1 Menu...

Page 9: ... Limit 52 11 8 SHRT 52 Firing type 53 12 1 Zero Crossing 53 12 2 Single Cycle 53 12 3 Burst Firing 53 12 4 Soft Start with Burst Firing 54 12 5 Phase Angle 54 12 6 Soft Start with Phase Angle 54 12 7 Delay Triggering with Burst Firing 55 12 8 Half Cycle 55 Current Limit 56 13 1 Current Limit Setting 56 13 2 Current Limit tuning procedure 56 Heater bakeout function 57 14 1 Using Heater Bakeout 57 C...

Page 10: ...oller range 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 demand...

Page 11: ...e 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 installer will install as default the co...

Page 12: ... Nominal Current of the load by a REVEX Display version Option code 0 6 7 9 on Digit 12 using the frontal keypad Operator menu or Thyristor configurator software b REVEX NO Display version Option code 2 3 4 D on Digit 12 using Thyristor configurator software The Unit is ready to work The auxiliary voltage supply of the REVEX unit must be synchronized with load voltage power supply If the Auxiliary...

Page 13: ... Nominal current of the load P Nominal power of the load Single phase wiring with inductive load V Nominal voltage phase to phase I Nominal current to the load P Nominal power to the load Open Delta wiring with resistive load V Nominal voltage of the load I Nominal current of the load P Nominal power of the load 4 V V V I P V I P 3V I P Vcosφ ...

Page 14: ...e 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 5 with display Option code 0 6 7 9 on digit 12 without display Option code 2 3 4 D on digit 12 ...

Page 15: ...elayed Triggering No Soft Start D Linear Soft Starter T Zero Crossing No Soft Start Z Linear Soft Starter R CONTROL MODE 11 description code Open Loop 0 Voltage U Voltage Square Q Current I Current Square A Power VxI W External feedback X OPTION 12 description code Option code see below table FAN VOLTAGE 13 description code No Fan 90A 0 APPROVALS 14 description code CE EMC For European Market 0 LO...

Page 16: ... order code Max peak current 10ms 540A for unit type 030 540A for unit type 035 700A for unit type 040 Nominal Voltage range Ue 24 600V Repetitive peak reverse voltage Uimp 1200V 480V 1600V 600V Latching current 250mA Leakage current 15mA eff Frequency range 47 70Hz Power loss I Inom 38W for unit type 030 44W for unit type 035 50W for unit type 040 Isolation Voltage Ui 2500Vac 6 4 Environmental in...

Page 17: ... 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 ta ambient temperature C 100 250 meters f 3 2 m3k Wh tc cabinet temperature C 250 500 meters f 3 3 m3k...

Page 18: ... distances inverticaland 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 7 30 cm 20 cm 2 cm AIR FLOW IN V AIR FLOW OUT V FAN in ...

Page 19: ...REVEX 1PH from 30A to 40A User s manual 19 7 2 Fixing holes 7 1 Dimensions and weight Size SR6 1PH W mm 36 H mm 121 D mm 185 Weight kg 0 61 W D H 58 7 62 5 5 24 5 24 5 5 25 5 25 109 7 5 ...

Page 20: ...regulations regarding electrical installation should be rigidly observed Use 90 C copper CU conductor only wire ranges AWG wire terminal type ZMVV 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 030 035 040 Screw M5 26 6 3 0 1 5 10 16 8 40A Rigid Flexible Spade Term...

Page 21: ...n 8 GND 9 COM I Common Digital Input 10 DI 2 Enable Digital Input 11 DI 1 Configurable Input 12 Analog Input 1 0 10Vdc 4 20mA Analog Setpoint 13 for Analog Input 1 and Analog input 2 0 Volt 14 Output 10Vdc stabilized 1 mA MAX 15 Analog Input 2 0 10Vdc 4 20mA Analog Setpoint 8 1 3 Terminal block M3 Terminal Description 1 Auxiliary 24Vdc 500mA Input power supply for communication 2 Auxiliary 24Vdc 5...

Page 22: ...ed the auxiliary supply 3 Close the Enable contact to start with the regulation MICRO USB 2 0 SYNC SYNC 15 12 11 10 9 8 8 8 14 14 14 13 13 2 4 3 Analog Input 2 Analog Input 1 Analog Inp 1 Analog SetPoint Analog Inp 2 Reference Ext FeedBack Ext Current Limit Auxiliary Voltage 24Vdc Extra Rapid Fuse 1A Fuse BRANCH CIRCUIT PROTECTION TO LOAD Function Thermal SC HB CL Indicative connection diagrams Re...

Page 23: ... 14 15 M1 TOP VIEW DOWN VIEW M2 T1 L1 M3 14 8 9 11 10 12 13 Analog Input 1 SSR INPUT 8 2 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 ...

Page 24: ...ectromagnetic circuit breaker or by fuse isolator The Fuse must be branch circuit protection 2 Connect on the phase not controlled by the thyristor L2 N on Schematic above Both terminals are connected internally and may be possible to use any one of them Warning It is not possible to remove the M3 connector when the unit is powered Remove the AUX 24Vdc power supply before extracting the M3 connect...

Page 25: ...ome page Local Remote Switch between local and remote set point for power demand Up Increment power demand set point when set to local Down Decrement power demand set point when set to local Press and hold for about two seconds to access the menus To view the status parameters Press Function once to advance from one parameter to the next To set the set point locally Press Local Remote Note indicat...

Page 26: ...ing The parameter name stops flashing 10 Press and hold local remote and function together for about two seconds to exit the menus Menu Password Parameter used to Operator 0 View measured values and basic settings including current voltage and set point Setup 2 Configure the power controller for the load Adv Setup 10 Configure the operation and performance of the power controller in the applicatio...

Page 27: ...cription HeatBrk Heater Break if available Aux High Aux voltage too high Aux Low Aux voltage too low BakeOut Heater Bakeout function active ComError Communication Watchdog error Aux Line Loss Auxiliary voltage 24V not present Line Loss Line power not detected I Limit Output limited by current limit feature only single phase if available SHRT Short Circuit on SCR If you have the version without dis...

Page 28: ...eter Operator Setup Advanced Setup Hardware Communication Monitoring Set Point Out Scale Firing Type Analog in 1 Port 1 Baud Dig in 1 Volts Out I Limit SP Min Cycle Analog in 2 Port 1 Addr Dig in 2 Current Nom Line V Soft Start An2 Funct Port 2 Baud Enable Power Nominal I Start Ramp DI1 Functn Watchdog SP Source Volts In Soft Start Delay DI2 Functn WD Reset Analog In1 Frequency SP Select Cycle Tim...

Page 29: ...tes the average RMS voltage input 0 to 65535 V 47 Read Only Frequency Indicates frequency of the power input 0 to 655 35 Hz 9 Read Only Pwr Factor Indicates power factor of the output power 0 to 1000 102 Read Only Load Ω Indicates the resistance of the load 0 to 655 35 Ω 46 Read Only I Limit SP Indicates the maximum percent ofthe nominal current that the power control allows This parameter indicat...

Page 30: ...llows This parameter indicates RMS current by default When parameter 52 is set to 1 this parameter indicates peak current 100 0 to 100 0 17 Read Write Nom Line V Set the nominal value for the line voltage input 220V 0 to 1023 V 37 Read Write Nominal I Set the nominal load current Maximum current 0 to 999 9 A 38 Read Write Soft Start Set the duration of the soft start in increment of 100mSec The po...

Page 31: ...t Modbus Address Par Type Min Cycles Set the minimum number of On cycles and off cycles for burst firing 8 0 to 999 9 n 20 Read Write Soft Start Set the duration of the soft start in increment of 100mSec The power controller ramps set to point changes over the time set here For more information see Firing type page Soft Start with Burst Firing and Soft Start with Phase Angle 100 10 sec 0 to 255 0 ...

Page 32: ...for a given deviation 10 0 to 255 26 Read Write Ti Power Set how aggressively the integral part of the control algorithm acts A larger settings yields a larger adjustment for a given deviation over a given time 50 0 to 255 27 Read Write Pb Current Set the gain for the current loop A largervalue yields a larger adjustment for a given deviation 10 0 to 255 63 Read Write Ti Current Set how aggressive...

Page 33: ... a delay between when the resistance drops below the value set for a heater break sensitivity and when the heater break alarm is indicated This set increments of 50mSec 50 2 5 sec 0 to 255 0 to 12 75 sec 28 Read Write Htr Bake Enable or disable the heater bakeout feature 0 140 Read Write Option Value Off 0 On 1 DEFAULT Off 0 ...

Page 34: ...r 10 000Ω 1 4 20mA 4 to 20 mAdc 2 0 20mA 0 to 20 mAdc 3 DEFAULT 0 10V 1 Parameter Name Description Default Modbus Address Par Type Analog In 2 Choose the type of signal to be measured by analog input 2 1 105 Read Write Option Description Value 0 10V 0 to 10 Vdc or 10 000Ω 1 4 20mA 4 to 20 mAdc 2 0 20mA 0 to 20 mAdc 3 DEFAULT 0 10V 1 Parameter Name Description Default Modbus Address Par Type An2 Fu...

Page 35: ... ON 4Vdc OFF 1Vdc 3HZ Max on time min 100 ms When the Fast Enable input is enabled Phase Angle firing is automatically selected Parameter Name Description Default Modbus Address Par Type DI2 Functn Choose how the signal detected by digital input 2 is used 0 33 Read Write Option Description Value Enable Enable power output 0 V Feedback Use voltage feed back when on 2 Local Rmt Local when on Remote ...

Page 36: ...ion 1 34 Read Write Option Description Bit Heater Break Heater Break 0 Short Circuit Short circuit 1 Current Limit Current Limit 2 Therm SCR is over temperature 3 Communication Communication watchdog error 4 DEFAULT None Alarm Bitwise is allowed Parameter Name Description Default Modbus Address Par Type IL SP Src Choose how the current limit is set 16 14 bit 4 Read Write Option Description Value L...

Page 37: ...s Address Par Type Port 1 Addr Set the address for the primary serial port 1 0 to 255 31 Read Write Port 2 Baud Choose the baud rate for the primary serial port 2 45 Read Write Option Value 9600 0 19 2K 1 38 4K 2 115 2K 3 DEFAULT 38 4K 2 Parameter Name Description Default Modbus Address Par Type Watchdog Enable or disable the watchdog on the primary serial port 0 142 Read Write Option Value Off 0 ...

Page 38: ...lue Off 0 On 1 Parameter Name Description Modbus Address Par Type Dig In 2 Indicate the state of the signal to digital input 2 13 bit9 Read Only Option Value Off 0 On 1 Parameter Name Description Modbus Address Par Type Enable Indicate whether or not the power controller is enabled The enable signal must be on for the unit to output power to the load 14 bit2 Read Only Option Value Off 0 On 1 Param...

Page 39: ... Only Unit Type Indicates the type of power controller 36 Read Only Option Description Value RC 1 Single Phase 7 RC 2 Two Leg three phase 8 RC 3 Three Leg three phase 9 RC 3P Three Leg three phase with phase angle capability 9999 Parameter Name Description Range Unit Modbus Address Par Type Max Voltage Indicates the maximum voltage rating of the power controller 0 to 1023 V 41 Read Only Max Curren...

Page 40: ...fore applying power NOTE the power of the USB port is limited and not designed to power industrial cards so it manages to feed only the essential parts of the electronics For complete control you need to power up the auxiliaries of the power controller 10 3 Recipes A recipe is a file that store the settings of power controller s internal parameter It is used to save a power controller configuratio...

Page 41: ...r 2 or 3 phase power controller 4 Choose Serial Port From Setting Serial Port menu 5 In value Port select the COM port connected to the power controller see the note below 6 To verify communications click Test 7 Click OK NOTE to determine which port is connected to the power controller you can in the Windows Device Manager under Ports COM LPT looking for the COM port named LPC USB VCOM Port COMx w...

Page 42: ...e Click Save button NOTE In the simple view the change are not live so to take effect the change in simple section is necessary to download it following download procedure 10 5 2 To edit a setting in a recipe 1 Click Simple if not already on the simple view 2 Click Open existing recipe 3 Locate and select the recipe file and click Open 4 Click OK 5 Click the menu with the setting you want to chang...

Page 43: ... view 1 Click Test if not already on the test view 2 Click Online 10 5 5 To log in on the test view to change the digital input and analog input functions 1 Click the Access Level value zero when logged out 2 Type the password 1111 3 Click OK 10 5 6 To log out the test view 1 Click the Access Level value 2 Click Log out 3 Click OK 10 5 7 To view data on the scope 1 Click Test if not already on the...

Page 44: ... or three phase power controller MSG opens a serial communication message view Status Bar Indicates information such as time and date communications port and baud rate 10 6 2 Simple Section This section is used to create save upload and download recipes of parameters settings Can be used also to see the settings in a controller Simple page is the default page when select the model using the Model ...

Page 45: ...d them to the power controller using the Download to unit option 10 6 3 Test Section This section is used to monitor and adjust the operation of the power controller in real time using RS485 or USB communication port After select the model is possible access to this section clicking the TEST tab below the main menu Operating on TEST Section Online button is the button to start or stop communicatio...

Page 46: ...a heater break alarm active TH indicator light on when the heat sink over temperature alarm is active I Lim indicator light on when the load current exceeds the current limit setting Unit Size indicate the maximum rated current of the power controller Max Volt indicate the maximum rated voltage for the power controller V Aux indicate the voltage the auxiliary input is set to use for powering the e...

Page 47: ...ler Power Request show the set point signal from analog input 1 The value is a percent of full scale or can be set with the reference slider Soft Start Time show the time over which set point changes are ramped Output Scaling show the scaling applied to the set point signal before it is used by the control loop Voltage indicator show the RMS load voltage Power indicator show the RMS load power Cur...

Page 48: ...t data Stop Play click toggle the live view or Hystorical view of graphic signal Scroll right click move the chart right to view older data The Actions to Clear to clear the data from the graph Save to save a JPEG image of the Load Analyzer window with the current trends Export to open a window that includes the trend graph and table with the currently displayed data that can be saved as a JPEG or...

Page 49: ...anel on the right of the graph that shows the data points for the current sample Auto Scale select this option so that the Configurator automatically adjusts the X and Y axis settings Y Axis Max show or set the high end of the vertical axis Min show or set the low end of the vertical axis Marks set this option to display data markers along the trend in the graph area X Axis future use Max show act...

Page 50: ...ose user settable options for the Configurator software Language Available Languages choose the language used in the software NOTE to activate the language change you need to close and open again the Configurator software Serial Port Set the serial port parameter Test click to test for communication with a power controller via the selected port Port select the computer s COM port to use to communi...

Page 51: ...by the HB Sense parameter Example Resistance 2200W 220V power voltage A 2200 220 10A nominal V 220 V nominal I 10A Nominal resistance R 22 Ohm HB sense parameter 20 threshold value 22 22 x 20 100 22 4 4 Ohm 26 4 Ohm 11 22 R V I HB sense 20 26 4 NO ALARM 30 25 20 15 10 5 0 Ohm ALARM No HB delay 22 R V I HB sense 20 26 4 30 25 20 15 10 5 0 Ohm HB delay es 2 5 sec NO ALARM 22 R V I HB sense 20 26 4 3...

Page 52: ... watchdog function is enabled watchdog ON this alarm is activated when there is no data passage within the time established by the WD reset parameter 11 5 AUX Line Loss This alarm is activated when there is no auxiliary voltage 11 6 Line Loss This alarm is activated when L1 and L2 are not detected 11 7 I Limit This alarm is activatedwhen the operating current exceeds the current limitvalue set in ...

Page 53: ...ge 12 2 Single Cycle Single Cycle it s the fasterzero crossing switching method in relationship of the power demand from a temperature regulator or from an external signal With input signal at 25 the output is one cycle ON and three cycles OFF With input signal at 50 the output is one cycle ON and one cycle OFF With input signal at 75 the output is three cycles ON and one cycle OFF With input sign...

Page 54: ... in function of the input signal from 0 at 100 The PA firing is normally used for control the inductive loads and is also possible control a primary of transformer coupled with the cold resistances like Superkanthal Molybdenum Platinum Tungsten or Quartz Lamp The only disadvantage with phase angle is the possible generation of interferences that however can be reduced with opportune filters 12 6 S...

Page 55: ...erate transient over currents that can blow the fuses With Delay Triggering the firing of the thyristor are triggered with a delay until the instantaneous value of the current i1 0 i2 positive and i3 negative like represented In this case the risk of transient over currents is reduced and the fuses don t blow The angle alpha is the delay to have i1 0 and this angle depends on the power factor The ...

Page 56: ... procedure must be performed only by qualified persons 13 2 Current Limit tuning procedure Give the power supply and set the current limit to zero In analog mode set the analog input 2 to zero In digital mode set the parameter 0 Start the thyristor unit Set the primary input or the setpoint value at 100 Increase the current limit In analog mode increase the value of the analaog input In digital mo...

Page 57: ...et current and ramp time parameters for the heater bakeout function The heater bakeout function does not ramp the output above the normal process set point Once the function has run for the user set time the bakeout function terminates and the power controller attempts to perform control to set point normally Use Heater Bakeout Ramp Time to set the duration of the bakeout in minutes Use Heater Bak...

Page 58: ...ge 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 b...

Page 59: ...pply the Electronic Board The REVEX thyristor unit to work requires a voltage supply for the electronic boards of 24Vdc 500 mA on terminal M3 1 2 Warning Before connecting or disconnecting the unit check that power and control cables are isolated from voltage sources 16 ...

Page 60: ... 1 1 Configuration 12 13 14 description code note REVEX 1 2 3PH R V X N zones 15 16 description code note Not configured 0 0 2 1 zone 0 1 2 zones 0 2 3 zones 0 3 4 zones 0 4 5 zones 0 5 6 zones 0 6 7 zones 0 7 8 zones 0 8 9 zones 0 9 10 zones 1 0 11 zones 1 1 12 zones 1 2 13 zones 1 3 14 zones 1 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ORDER CODE T U R S 4 8 5 _ _ _ _ _ _ _ _ _ 17 1 FIELD BUS Modu...

Page 61: ...40 525 660 FFH1451 40A 1 035 FU1451 50A 50 1260 660 FFH1451 50A 1 040 FU1451 50A 50 1260 660 FFH1451 50A 1 I2 T are multiplied for K value in function of Vac at 500V K is equal to 0 7 750 X 0 7 525 1800 X 0 7 1250 At 660Vac K is equal to 1 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...

Page 62: ...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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