CD Automation REVO E 3PH User manual

CD Automation S.r.l.
Via Picasso 34/36 - 20025 –Legnano (MI) –ITALY
Tel [phone] –Fax [phone]
E-Mail: [e-mail] - WEB: www.cdautomation.com
REVO E -3PH BASIC
Thyristor Unit
USER’S MANUAL
Rev. 10/2014
00004
from 25A to 600A

SUMMARY
1 Important warnings for safety..................................................................................... 6
2 Introduction ................................................................................................................ 8
2.1 Advantages compared with analog thyristor unit 8
2.2 Software Configurator 9
3 Quick Start ................................................................................................................ 10
4 REVO E Sizing ............................................................................................................ 11
5 Identification and Order Code.................................................................................... 12
5.1 Identification of the unit 12
5.2 Order Code 13
6 Installation................................................................................................................ 14
6.1 Environmental installation conditions 14
6.2 Dimensions and Fixing holes 15
6.3 Removing the cover 16
7 Wiring instructions .................................................................................................... 17
7.1 Wiring details 17
7.2 Power Terminals 19
7.3 Command Terminals Size S09 20
7.4 Diagram of control connection Size S09 21
7.5 Command Terminals Size S11/S13/S14 22
7.6 Diagram of control connection Size S11/S13/S14 23
8 Power output features ............................................................................................... 24
8.1 Derating curve 24
8.2 Cooling fans 24
9 Led status and Alarms ............................................................................................... 25
9.1 LED Status Table 25
9.2 Critical Alarms 26
9.3 Not Critical Alarm 27
9.4 Calibration Procedure 27
10 Firing type ............................................................................................................... 28
10.1 Single Cycle (SC) 28
10.2 Burst Firing (BF) 30
10.3 Phase Angle (PA) 32

10.4 Delay Triggering (DT) 34
10.5 Feed-back type 36
11 Connection description ............................................................................................ 37
11.1 Access to the Electronic boards 37
11.2 Supply the Electronic Board 37
11.3 Analog Inputs 38
11.4 Analog Outputs 39
11.5 Digital Input 40
11.6 Digital Output 41
11.7 PG Connector 42
12 Internal Fuse ........................................................................................................... 43
12.1 Fuse Code 43
13 Maintenance ............................................................................................................ 44
13.1 Fans 44
13.2 Maintenance 44
13.3 Repairing procedure 44
13.4 Warranty condition 44

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1Important warnings for safety
This chapter contains important information for the safety. The not observance of these instructions may
result in serious personal injury or death and can cause serious damages to the Thyristor unit and to the
components system included.
The installation should be performed by qualified persons.
The Thyristor unit are integral part of industrial equipments. When it is supply, the
Thyristor unit is subject to dangerous tensions.
Don't remove the protection Cover.
Don't use these unit in aerospace applications and/ or nuclear.
The nominal current corresponds to use at temperature not superior to 45°C.
The Thyristor unit must be mounted in vertical position and without obstruction above
and below to allow a good flow ventilation.
The hot air of one thyristor unit must not invest the unit positioned above.
For side by side placed leave a space of 15mm between the unit.
A suitable device must ensure that the unit can be electrically isolated from the supply, this
allows the qualified people to work in safety.
Protection (Protection, Protezione)
The unit have IP20 protection rating as defined by the specific international. Is necessary
consider the place of installation.
Earth (Terre, Messa a terra)
For safety, the Thyristor unit with isolated heat-sink must be connected to earth.
Earth impedance should be correspondent to local earth regulation. Periodically the earth
efficiency should be inspected.
Electronic supply (Alimentation électronique, Alimentazione elettronica)
The electronic circuit of the Thyristor unit must be supplied by dedicated voltage for all
electronic circuits and not in parallel with coil contactors, solenoids and other.
It's recommended to use a shielded transformer.
Electric Shock Hazard (Risque de choque électrique, Rischi di scosse elettriche)
When the Thyristor unit is energized, after the power supply is shut off, wait least a minute
for allow the discharge of the internal capacitors where there is a dangerous tension. Before
working, make sure that:
Only authorized personnel must perform maintenance, inspection, and replacement
operations.
The authorized personnel must read this manual before to have access to the unit.
Unqualified People don't perform jobs on the same unit or in the immediate vicinities.

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Important warnings (Attention, Avvertenze importanti)
During the operations with units under tension, local regulations regarding electrical
installation should be rigidly observed:
Respect the internal safety rules.
Don't bend components to maintain insulation distances.
Protect the units from high temperature humidity and vibrations.
Don't touch components to prevent electrostatic discharges on them.
Verify that the size is in line with real needs.
To measure voltage current etc. on unit, remove rings and other jewels from fingers
and hands.
Authorized personnel that work on thyristor unit under power supply voltage must be
on insulated board
This listing does not represent a complete enumeration of all necessary safety cautions.
Electromagnetic compatibility
(Compatibilità électromagnétique, Compatibilità elettromagnetica)
Our thyristor units have an excellent immunity to electromagnetic interferences if all
suggestions contained in this manual are respected. In respect to a good Engineering
practice, all inductive loads like solenoids contactor coils should have a filter in parallel.
Emissions (Emission, Emissioni)
All solid-state power controllers emit a certain amount of radio-frequency energy because of
the fast switching of the power devices.
The CD Automation’s Thyristor unit are in accord with the EMC norms, CE mark.
In most installations, near by electronic systems will experience no difficulty with
interference. If very sensitive electronic measuring equipment or low-frequency radio
receivers are to be used near the unit, some special precautions may be required. These
may include the installation of a line supply filter and the use of screened (shielded) output
cable to the load.
Note
Warning: This icon is present in all the operational procedures where the Improper
operation may result in serious personal injury or death
Caution: This icon is present in all the operational procedures where the Improper
operation can cause damage for the Thyristor unit.
CD Automation reserves the right to modify the own products and this manual without any
advise.
CUS
LISTED
UL
®

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2Introduction
A thyristor unit is semiconductor device which acts as a switch formed by two thyristors in ant parallel.
To switch on the alternating current the input signal will be on and the thyristor will switch off at first
Zero Crossing voltage with no input signal.
The benefits of thyristor units compared with elettromechanical contactors are numerouses: no moving
parts, no maintenance and capacity to switch very fast. Thyristors are the only solution to control
transformers and special loads that change resistance with temperature and with age.
2.1 Advantages compared with analog thyristor unit
REVO E is an universal Thyristor unit, designed to control resistive or inductive loads including three
phase transformers. The electronic circuit is completely digital and is based on a powerful
microprocessor with high performance that allow the use in different ways:
Single cycle
Burst Firing with soft start
Delayed triggering
Phase Angle with soft start
On same unit can be used different feed back that define the control mode:
Voltage
Current
Power VxI
External 0÷10Vdc
On same unit can be used different input:
4÷20mA
0÷10Vdc
Potentiometer 10KΩ
SSR

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2.2 Software Configurator
The software configuration is free and is possible
download it from our site:
www.cdautomation.com
If the Order Code is in line with requirement, then
REVO E has been already configured in Factory and
it's ready to use.
You need the software only to modify the ordered
configuration. Anyway we suggest to check the
unit on the machine with the "Test unit" section.
For install the software, launch the program and
follow the instructions on the screen.
To connect the unit at the PC, it's necessary use
the USB\TTL converter connected between the unit
and the USB port of the PC.
USB\TTL converter need a driver to work properly,
you can find it from our site.
Is available a full programmer kit composed by
USB\TTL converter,
Two cable
Thyristor configurator software
USB driver.

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3Quick Start
Caution: this procedure must be performed only by qualified persons.
If the Order Code of the Thyristor unit is in line with what you really need, then REVO E has been
already configured in Factory and you just need to do the following steps:
1. Verify the REVO E Sizing. Making sure that:
The load current is equal or less than the MAX current of REVO E.
The load voltage is equal or less than the MAX voltage of REVO E.
(see par. 4)
2. Verify the Order Code
(see par. 5.2)
3. Verify the Installation
(see par. 6)
4. Verify the Diagram of control connection:
All auxiliary connections must be done in line with wirings on this manual.
Verify that there isn’t a short circuit on the load.
(see par. 7.4)
5. Supply the Electronic boards
(see Order Code)
6. If not specified in the Order Code:
Set the Load Voltage in the parameter P116 .
Set the Load Current in the parameter P119 .
7. With Burst Firing (BF) or Heater Break Alarm (HB)
make the Calibration procedure
(see par. 9.4)
The REVO E Thyristor unit is ready to start.

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4REVO E Sizing
4.1.1 Star wiring with resistive load
V
P
I731, 
V = Nominal voltage phase to phase
I = Nominal current of the load
P = Nominal power of the load
4.1.2 Star wiring with inductive load

cos, V
P
I731 
V = Nominal voltage phase to phase
I = Nominal current of the load
P = Nominal power of the load
4.1.3 Delta wiring with resistive load
V
P
I731, 
V = Nominal voltage phase to phase
I = Nominal current of the load
P = Nominal power of the load
4.1.4 Delta wiring with inductive load
 cos, V
P
I731 
V = Nominal voltage phase to phase
I = Nominal current of the load
P = Nominal power of the load
4.1.5 Open Delta wiring with resistive load
V
P
I3 
V = Nominal voltage phase to phase
I = Nominal current of the load
P = Nominal power of the load

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5Identification and Order Code
5.1 Identification of the unit
Caution: Before to install, make sure that the Thyristor unit have not damages. If the
product has a fault, please contact the dealer from which you purchased the product.
The identification's label give all the information regarding the factory settings of the Thyristor unit, this
label is on the unit, like represented in figure.
Verify that the product is the same thing as ordered (see par. 5.2).

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5.2 Order Code

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6Installation
Caution: Don't install near the hot elements or near the units that could give
electromagnetic interferences.
The REVO E Thyristor unit must be always mounted in vertical position to improve air cooling on heat-
sink. Maintain the minimum distances in vertical and in horizontal as represented.
When more unit has mounted inside the cabinet maintain the air circulation like represented in figure.
Sometimes is necessary installing a fan to have better air circulation.
6.1 Environmental installation conditions
Ambient temperature
0-40°C at nominal current. Over 40°C use the
derating curve (see par. 8.1)
Storage temperature
-25°C to 70°C
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

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6.2 Dimensions and Fixing holes
Size S09
(25A÷75A)
Weight 5kg
290mm
96mm
104mm
5mm
7mm
440mm
270mm
137mm
Size S11
(100A÷150A)
Weight 10,5kg
97mm
410mm
97mm
7mm
12mm
440mm
270mm
262mm
Size S13
(225A)
Weight 18kg
410mm
222mm
222mm
7mm
12mm
460mm
270mm
262mm
Size S14
(300A÷600A)
Weight 22,5kg
222mm
222mm
490mm
7mm
12mm

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6.3 Removing the cover
Size S09
Remove the screw, if present
Open the unit
Screw
Open
Size S11
Remove the screw, if present
Remove the plastic cover
Open the unit
Screw
Screw
Open
Size S13/S14
Remove the screw
Remove the plastic cover
Open the unit
Screw
Screw
Screw
Screw
Open

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7Wiring instructions
Caution: this procedure must be performed only by qualified persons.
The Thyristor unit could be susceptible to interferences lost by near equipments or by the power supply,
for this reason in accord to the fundamental practices rules is opportune take some precautions:
The electronic circuit of the Thyristor unit must be supplied from a dedicated voltage and not with
inductive or capacitive loads. We recommend the use of a screened transformer.
The coil contactor, the relays and other inductive loads must be equipped with opportune RC filter.
Use shielded bipolar cables for all the input and output signals.
The signal cables must not be near and parallel to the power cables.
Local regulations regarding electrical installation should be rigidly observed.
For safety connect the heat-sink to the earth with his terminal.
7.1 Wiring details
Use copper cables and wires rated for use at 75°C only.
7.1.1 Power cable torque (suggested)
Current
Connector
Type
Torque
Lb-in (N-m)
Wire
Range
AWG / kcmil
Wire
Terminal
25A÷225A
Terminal Block
M8
265 (30.0)
8
4/0
Copper wire
Compact (Solid) Stranded
300A
Bus Bar
with M8 screw
505 (57.0)
2x1/0
350
UL Listed (ZMVV)
Copper Tube Crimp. Lug
350A÷400A
Bus Bar
with M10 screw
505 (57.0)
2x3/0
600
UL Listed (ZMVV)
Copper Tube Crimp. Lug
450A
Bus Bar
with M10 screw
505 (57.0)
Bus Bar 30x6mm
500A÷600A
Bus Bar
with M10 screw
505 (57.0)
Bus Bar 60x4mm

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7.1.2 Power cable dimensions (suggested)
Current
Power Supply Cable
Load Cable (Output)
Earth
mm²
AWG
mm²
AWG
mm²
AWG
25A (S09)
10
8
10
8
4
12
35A (S09)
10
8
10
8
6
10
45A (S09)
10
8
10
8
6
10
75A (S09)
25
4
25
4
10
8
100A (S11)
35
3
35
3
16
6
125A (S11)
50
1
50
1
16
6
150A (S11)
70
1/0
70
1/0
16
6
225A (S13)
120
4/0
120
4/0
25
4
300A (S14)
2 x 70
2 x 1/0
2 x 70
2 x 1/0
50
1
350A (S14)
2 x 95
2 x 3/0
2 x 95
2 x 3/0
50
1
400A (S14)
2 x 95
2 x 3/0
2 x 95
2 x 3/0
50
1
450A (S14)
Bus Bar 30 x 6 mm
Bus Bar 30 x 6 mm
70
1/0
500A (S14)
Bus Bar 60 x 4 mm
Bus Bar 60 x 4 mm
70
1/0
600A (S14)
Bus Bar 60 x 4 mm
Bus Bar 60 x 4 mm
70
1/0
7.1.3 Cable dimensions of the Command Terminals
Maximum connection capacity for all size: 1.5 mm2 (14 AWG)

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7.2 Power Terminals
Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.
Terminal
Description
L1
Line Input Phase 1
L2
Line Input Phase 2
L3
Line Input Phase 3
T1
Load Output Phase 1
T2
Load Output Phase 2
T3
Load Output Phase 3
Size S09
L1 L2 L3
T1 T2 T3
Size S11
L1 L2 L3
Size S13
L1 L2 L3
Size S14
L2L1 L3

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7.3 Command Terminals Size S09
Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.
Terminal
Description
1
Voltage Supply for Electronic Boards (See par. 11.2)
2
Voltage Supply for Electronic Boards (See par. 11.2)
3
Not used
4
Isolated output +12Vdc MAX 20mA
5
GND for Digital Input
6
Output +10Vdc MAX 5mA
7
GND for Analogue Input
8
(+)Analogue Input 1: Primary (See par. 11.3)
9
Not used
10
Analogue Output 1: Power (See par. 11.4)
11
Not used
12
Not used
13
Output relay: Run (Max 500mA, 125Vac)
14
Common of the contact relay: Run
15
NPN Output 1: Critical Alarm (12Vdc max 20mA)
16
NPN Output 2: Configurable (12Vdc max 20mA)
17
Digital Input: Reset Alarm
18
Digital Input: Start/Stop
19
Digital Input: Calibration
20
Digital Input: Configurable
(See par. 11)