CD Automation Revo M 2PH 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 M 2PH
from 30A to 40A
USER’S MANUAL
Rev. 3/2016
00029

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
2

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
3
1 IMPORTANT WARNINGS FOR SAFETY __________________________________________6
2 NOTE ___________________________________________________________________7
3 INTRODUCTION ___________________________________________________________8
4 ADVANTAGES COMPARED WITH ANALOG THYRISTOR UNIT _________________________8
5 SOFTWARE CONFIGURATOR CDA THYRISTOR CONFIGURATOR SOFTWARE _____________9
6 QUICK START ____________________________________________________________10
7 BASIC CONNECTIONS AND SIZING ___________________________________________11
8 IDENTIFICATION AND ORDER CODE __________________________________________12
8.1 Identification of the unit ______________________________________________________12
8.2 Order Code ________________________________________________________________13
9 TECHNICAL SPECIFICATIONS _______________________________________________14
9.1 General features: ___________________________________________________________14
9.2 Input features: _____________________________________________________________14
9.3 Output features(power device): ________________________________________________14
10 INSTALLATION __________________________________________________________15
10.1 Environmental installation conditions ___________________________________________15
10.2 Derating Curve ____________________________________________________________15
10.3 Dimensions and Weight _____________________________________________________16
10.4 Fixing holes _______________________________________________________________16
11 WIRING INSTRUCTIONS __________________________________________________17
11.1 Access to L1-L3 and T1-T3 terminal Screw_______________________________________18
11.2 Command Terminals ________________________________________________________19
11.2.1 Terminal block M2 _______________________________________________________________________ 19
11.2.2 Terminal block M1 _______________________________________________________________________ 19
11.2.3 Terminal block M3 _______________________________________________________________________ 19
11.2.4 Terminal block M4 _______________________________________________________________________ 19
11.3 Schematic ________________________________________________________________20
11.4 Connection Diagram for 3 phases (control on 2 phases) ____________________________22
12 CONTROL PANEL_________________________________________________________23
12.1 Scroll the parameters _______________________________________________________24
12.2 Operator Menu ______________________________________________________25
12.3 Setup Menu __________________________________________________________28
12.4 Hardware Menu _____________________________________________________31
12.5 Control Panel Led __________________________________________________________33
12.6 Displayed Alarms __________________________________________________________33
13 INPUT OUTPUT SIGNAL ___________________________________________________34
13.1 Digital Input ______________________________________________________________34
13.1.1 Start/Stop (Terminal 3 of M2) ______________________________________________________________ 34
13.1.2 Configurable Input (Terminal 4 of M2) ________________________________________________________ 34
13.2 Digital Output terminal (terminal 14-15-16 of M1)_________________________________34
13.3 Analog Input ______________________________________________________________34

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
4
14 HEATER BREAK ALARM AND SCR SHORT CIRCUIT (HB OPTION) ___________________ 35
14.1 Heater break Calibration procedure____________________________________________ 35
14.2 HB alarm contact (digital output) _____________________________________________ 35
15 FIRING TYPE___________________________________________________________ 36
15.1 Zero Crossing (ZC - )____________________________________________________ 36
15.2 Burst Firing (BF - ) ______________________________________________________ 36
16 FEED-BACK TYPE________________________________________________________ 37
17 ELECTRONIC BOARDS ____________________________________________________ 38
17.1 How to access ____________________________________________________________ 38
17.2 Supply the Electronic Board__________________________________________________ 39
17.3 Analog Inputs Configuration _________________________________________________ 40
17.3.1 Primary Input calibration procedure __________________________________________________________40
18 PG CONNECTOR ________________________________________________________ 41
19 RS485 SERIAL PORT _____________________________________________________ 42
20 INTERNAL FUSE ________________________________________________________ 43
20.1 Fuses Replacement ________________________________________________________ 43
21 MAINTENANCE _________________________________________________________ 44
21.1 Trouble Shooting __________________________________________________________ 44
21.2 Warranty condition ________________________________________________________ 44

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
5
CD Automation s.r.l.
Controllers, Drives & Automation
Via Picasso, 34/36 - 20025 Legnano (MI)- Italia
P.I. 08925720156 -Tel. [phone] - Fax [phone]
Internet : www.cdautomation.com - E-MAIL: [e-mail]
Dichiarazione di Conformità
Declaration of Conformity
PRODUTTORE:
PRODUCT MANUFACTURER: CD Automation S.R.L.
INDIRIZZO:
ADDRESS: Via Pablo Picasso 34//36
20025 Legnano (Mi)
Italia
Dichiara che il prodotto:
Declare that the product:
RevoM, 2ph da 30 a 40A
SODDISFA I REQUISITI DELLA NORMA :
Specifica di sicurezza EN60947-1 :2008
EN60947-4-3:2001
Specifica sulle emissioni EN60947-4-3:2000
Specifica sulle Immunità EN60947-4-3:2000
FULFILS THE REQUIREMENTS OF THE STANDARD:
Electrical safety Standard EN60947-1 :2008
EN60947-4-3:2001
Generic Emission standard EN60947-4-3:2000
Generic Immunity standard EN60947-4-3:2000
CDAutomation dichiara che I prodotti sopra menzionati sono conformi alla direttiva
CDAutomation declares that The products above mentioned they am conforming to the directive
EMC 2004/108/CEE e alla direttiva Bassa Tensione (low Voltage) 2006/95/CEE
DESCIZIONE DEL PRODOTTO: Unità di controllo potenza elettrica
PRODUCT DESCRIPTION: Elettric power controll
UTILIZZO: Controllo processi termici
SCOPE OF APPLICATION: Thermal controll process
Data di emissione: 20/04/2010 Amministratore Unico e
Issued on: 20/04/2010 Legale Rappresentante
Claudio Brizzi

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
6
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.

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
7
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.
2Note
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.

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
8
3Introduction
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.
Load
Thyristor
4Advantages compared with analog thyristor unit
Communication RS485 is a standard feature of REVO M this allows the use of many information like:
current, power, load state and all the parameters for diagnostic and configuration. Ulterior advantages
of the digital system vs the analogical is the flexibility and the possibility of implement special
characteristics without change the hardware. Several strategies can be implemented and selected
through the configuration parameters.
With CDA software configuration, you can have access to the configuration parameters.
To connect the Thyristor unit to the computer use the USB\TTL converter.

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
9
5Software Configurator CDA Thyristor configurator software
CDA Thyristor configurator software
is free and is possible download it from our site:
www.cdautomation.com
If the Order Code is in line with requirement,
then REVO M 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.
Run the software configurator and set the serial
port of the PC with con baudrate =19200(default)
and the address of Thyristor unit (default=1).
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 at
www.cdautomation.com
Is available a full programmer kit composed by
USB\TTL converter,
Two cable
CDA Thyristor configurator software
USB driver on CD Rom
Utility\driver USB
With the CD-RS serial converter is possible
configure the Thyristor unit also through the
RS485 For this solution, the programming cable
is not necessary.

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
10
6Quick Start
Attention: this procedure must be carried out by skilled people only.
If your REVO M code is in line with what you really need, then the main configuration is already done by
CD Automation and you just need to do the following steps:
1. Verify REVO M’s current sizing. Be sure that:
the load current is equal or less than the nominal one of REVO M
the main voltage is equal or less than the nominal voltage of REVO M
2. Verify the Installation
3. Verify the Wiring:
all auxiliary connections must be done in line with wirings on this manual
verify that there isn’t a short circuit on the load
4. Supply the auxiliary voltage of the unit
Set the parameters U_OP (Operative Voltage) and A_Lo (Nominal Current of the load) using the
frontal keypad or CDA Thyristor configurator software.

Operative Voltage
V
R/W
Function:
It’s necessary to specify the operative voltage
Min/Max:
24 ÷ 1000V
Default:
230
Note:
With voltage up to 330V and over 600V, REVO M needs hardware
modifications: specify this in phase of ordination.

Load nominal current
A
R/W
Function:
It’s necessary to specify the load current value at nominal voltage.
This current and voltage value are necessary to be able to read the
power in engineering units
Min/Max:
1 ÷ 100.0 Ampere (for size up to 100A)
Default:
Nominal REVO M current value if load current has not been specified.
If your REVO M code is NOT in line with what you really need, use the enclosed configurator
software tool to set-up the unit. Install the software on your PC, select REVO M and click on
test unit changing what you need.

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
11
7Basic Connections and sizing
Star wiring with resistive load (control on two phases with REVO M-2PH)
V
P
I731, 
V = Nominal voltage of the load
I = Nominal current of the load
P = Nominal power of the load
V
I
Delta wiring with resistive load (control on two phases with REVO M-2PH)
V
P
I731, 
V = Nominal voltage of the load
I = Nominal current of the load
P = Nominal power of the load
V
I

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
12
8Identification and Order Code
8.1 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.

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
13
8.2 Order Code

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
14
9Technical Specifications
9.1 General features:
Cover and Socket material:
PolymericV2
Mounting:
DIN bar (thickness type 1mm Max)
Utilization Category
AC-51 AC-55b
IP Code
20
Method of Connecting
Load in Delta, Load in Star
Auxiliary voltage, power supply Control Circuit:
90:130V (8 VA Max)
170:265V (8 VA Max)
230:345V (8 VA Max)
300:530V (8 VA Max)
510:690V (8 VA Max)
600:760V (8 VA Max)
Relay output for Heater Break Alarm
(only with HB option):
0.5A a 125VAC
9.2 Input features:
Logic input SSR:
4 ÷ 30Vdc 5mA Max (ON 4Vdc OFF 1Vdc)
Analog Input V:
0 ÷ 10Vdc impedance 15 K ohm
Analog Input A:
4 ÷ 20mA impedance 100 ohm
POT
10 K ohm min.
Digital Input
4 ÷ 30Vdc 5mA Max (ON 4Vdc OFF 1Vdc)
9.3 Output features(power device):
Nominal current in continuous service:
See order code
Max peak current (10ms)
360A 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
FUSE I²T value suggested at 500Vac tp=10msec:
525 A²s for unit type 030
1260 A²s for unit type 035
1260 A²s for unit type 040
Frequency range:
47÷70Hz
Power loss (I=Inom):
76W for unit type 030
88W for unit type 035
100W for unit type 040
Isolation Voltage Ui :
2500Vac

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
15
10 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.
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.
10.1 Environmental installation conditions
Ambient temperature
0-40°C at nominal current. Over 40°C use the
derating curve.
Storage temperature
-25°C a 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
Pollution Level
Up to 2nd Level ref. IEC 60947-1 6.1.3.2
10.2 Derating Curve

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
16
10.3 Dimensions and Weight
REVO M 2PH
Size
W(mm)
H(mm)
D(mm)
Weight (kg)
2PH
108
121
185
1,76
10.4 Fixing holes

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
17
11 Wiring instructions
The Thyristor unit could be susceptible to interferences lost by near equipments or by the power supply,
for this reason in accord to the fundamental practices rules is opportune take some precautions:
The coil contactor, the relays and other inductive loads must be equipped with opportune RC filter.
Use shielded bipolar cables for all the input and output signals.
The signal cables must not be near and parallel to the power cables.
Local regulations regarding electrical installation should be rigidly observed.
Use copper cables and wires rated for use at 75°C only.
Power cable torque (suggested)
Type
Connector
Type
Torque
Lb-in (N-m)
Wire Range
mm²(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 Terminal
Cable dimensions of the Command Terminals
0.5mm² (AWG 18)
Cable dimensions of the Earth (suggested)
6 mm² (AWG 10)
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
T1
Load Output Phase 1
L3
Line Input Phase 2
T3
Load Output Phase 2

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
18
11.1 Access to L1-L3 and T1-T3 terminal Screw
Repeat for each phase.

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
19
11.2 Command Terminals
Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.
11.2.1 Terminal block M2
Terminal
Description
1
GND
2
COM I - Common Digital Input
3
DI 2 –Enable Digital Input
4
DI 1 - Configurable Input
5
+ Control Input (SSR/0-10Vdc/4-20mA)
6
-Control Input (SSR/0-10Vdc/4-20mA)
7
+10V Output
8
Slave Output - (factory connection)
9
Slave Output + (factory connection)
11.2.2 Terminal block M1
Terminal
Description
10
GND
11
TA1 Input (factory connection)
12
TA1 or TA2 input (factory connection)
13
TA3 input (factory connection)
14
C - Common contact alarm relay output
15
NO - Normally Open contact alarm relay output (HB)
16
NC - Normally Close contact alarm relay output (HB)
11.2.3 Terminal block M3
Terminal
Description
A+
RS485 A
B-
RS485 B
11.2.4 Terminal block M4
Terminal
Description
L1
Aux –Voltage Supply for elettronic boards and syncronizzation (See order code for the Value)
-
Not Connected
L2/N
Aux –Voltage Supply for elettronic boards and syncronizzation (See order code for the Value)

CD Automation srl REVO M User’s Manual
CD-Eng-REVO-M-2PH-30-40A-Thyristors-Units
20
11.3 Schematic
NOTE:
The user installation must be protecting by electromagnetic circuit breaker or by fuse isolator.
The Fuse I2t should be 20% less than I2t of power controller.
Semiconductor fuses are classified for UL as supplemetar protection for semiconductor.
They are note approved for branch circuit protection.
*² The auxiliary voltage supply of the Revo M unit must be synchronized with load voltage power
supply. If the Auxiliary Voltage (written on the identification label) is different from Supply Voltage
(to the load), use an external transformer as designated.