CD Automation Revo M Series 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
USER’S MANUAL
Rev. 06/2009 Revo
M
from 30A to 45A

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1 IMPORTANT WARNINGS FOR SAFETY __________________________________________5
2 NOTE ___________________________________________________________________
3 INTRODUCTION ___________________________________________________________7
4 ADVANTAGES COMPARED WITH ANALOG THYRISTOR UNIT _________________________7
5 SOFTWARE CONFIGURATOR CDA THYRISTOR CONFIGURATOR SOFTWARE _____________8
QUICK START _____________________________________________________________9
7 BASIC CONNECTIONS AND SIZING ___________________________________________10
8 IDENTIFICATION AND ORDER CODE __________________________________________11
8. Identification of the unit ______________________________________________________
8.2 Order Code ________________________________________________________________ 2
9 INTERNAL FUSE __________________________________________________________13
9. Fuses Replacement __________________________________________________________ 3
10 INSTALLATION __________________________________________________________14
0. Environmental installation conditions ___________________________________________ 4
0.2 Derating Curve ____________________________________________________________ 4
0.3 Dimensions and Weight _____________________________________________________ 5
0.4 Fixing holes _______________________________________________________________ 5
0.5 Technical Specifications _____________________________________________________ 6
11 WIRING INSTRUCTIONS __________________________________________________17
. Command Terminals ________________________________________________________ 8
. . Terminal block M2 Drive M_________________________________________________________________ 8
. .2 Terminal block M Drive M_________________________________________________________________ 8
. .3 Terminal block M3 Drive M _________________________________________________________________ 8
. .4 Terminal block M4 Drive M _________________________________________________________________ 8
.2 Schematic ________________________________________________________________ 9
.3 Connection Diagram for Single-phase___________________________________________20
.4 Connection Diagram for 3 phases (control on 2 phases) ____________________________2
.5 Connection Diagram for 3 phases (control on 3 phases) ____________________________22
12 CONTROL PANEL_________________________________________________________23
2. Scroll the parameters _______________________________________________________24
13 INPUT OUTPUT SIGNAL ___________________________________________________25
3. Digital Input ______________________________________________________________25
3. . Start/Stop (Terminal 3 of M2) ______________________________________________________________ 25
3. .2 Configurable Input (Terminal 4 of M2) ________________________________________________________ 25
3.2 Digital Output terminal (terminal 4- 5- 6 of M )_________________________________25
3.3 Analog Input ______________________________________________________________25
Primary Input (Terminals 5 and 6 of M2) ___________________________________________________________ 25
14 HEATER BREAK ALARM AND SCR SHORT CIRCUIT (HB OPTION) ____________________2
4. Heater break Calibration procedure ____________________________________________26
4.2 HB alarm contact (digital output) ______________________________________________26
15 FIRING TYPE ___________________________________________________________27

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5. Single Cycle SC ( Ph Only) __________________________________________________ 27
5.2 Burst Firing (BF) __________________________________________________________ 28
5.3 Soft Start with Burst Firing S+BF ( Ph Only) ____________________________________ 28
5.4 Phase Angle PA ( Ph Only) __________________________________________________ 29
5.5 Soft Start with Phase Angle (S+PA) ___________________________________________ 29
5.6 Delay Triggering DT ( Ph Only)_______________________________________________ 30
1 FEED-BACK TYPE________________________________________________________ 31
17 ELECTRONIC BOARDS ____________________________________________________ 32
7. How to access ____________________________________________________________ 32
7.2 Supply the Electronic Board__________________________________________________ 33
7.3 Analog Inputs ____________________________________________________________ 34
7.3. Primary Input (Terminals 5 and 6 of M2) ______________________________________________________34
18 PG CONNECTOR ________________________________________________________ 35
19 RS485 SERIAL PORT _____________________________________________________ 3
20 MODBUS COMMUNICATION _______________________________________________ 37
20. MODBUS RTU Protocol______________________________________________________ 37
20.2 Message Format___________________________________________________________ 37
20.3 Read Holding Registers _____________________________________________________ 39
20.4 Preset Multiple Registers ____________________________________________________ 39
20.5 Error and exception responses _______________________________________________ 40
20.6 Address Configuration ______________________________________________________ 40
21 CONFIGURATION PARAMETERS ____________________________________________ 41
22 MAINTENANCE _________________________________________________________ 47
22. Trouble Shooting __________________________________________________________ 47
22.2 Warranty condition ________________________________________________________ 47

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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 5mm 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.
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.

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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.

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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 = 9200(default)
and the address of Thyristor unit (default= ).
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.

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Quick 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:
. 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 ÷ 000V
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: ÷ 00.0 Ampere (for size up to 00A)
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.

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7Basic Connections and sizing
Single phase wiring with resistive load (with REVO M- PH)
V
P
I=
V = Nominal voltage of the load
I = Nominal current of the load
P = Nominal power of the load
V
I
Single phase wiring with inductive load (with REVO M- PH)
φ cosV
P
I=
V = Nominal voltage phase to phase
I = Nominal current to the load
P = Nominal power to the load
Star wiring with resistive load (control on two phases with REVO M-2PH)
V
P
I
731,
=
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
I
731,
=
V = Nominal voltage of the load
I = Nominal current of the load
P = Nominal power of the load
V
I
Star wiring with resistive load (control on three phases with REVO M-3PH)
V
P
I
731,
=
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 three phases with REVO M-3PH)
V
P
I
731,
=
V = Nominal voltage of the load
I = Nominal current of the load
P = Nominal power of the load
V
I
Open Delta wiring with resistive load (with 3 X REVO M- PH)
V
P
I
3
=
V = Nominal voltage of the load
I = Nominal current of the load
P = Nominal power of the load
V
I