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

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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.

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8.2 Order Code
2 3 4 5 6 - 7 8 9 0 2 3 4 5 6
CODE R
M _ _ _ _ - _ _ _ _ _ _ _ _ _ _
PHASES CONTROLLED
PH
2PH
2
3PH
3
Current Rathing
30A With Heat
-
sink (this size is not available on PH)
0
3
0
35A With Heat
-
sink
0
3
5
40A
With Heat
-
sink
0
4
0
45A With Heat
-
sink (this size is available on PH only)
0
4
5
MA VOLTAGE
480V
4
600V
6
Load Voltage and Aux.Voltage Supply Range
90: 30V
70:265V
2
230:345V
3
300:530V
5
5 0:690V
6
INPUT
0
-
0V dc
V
4
-
20 mA
A
0k Pot
K
SSR
S
Firing
ZC Zero Crossing
Z
BF Burst Firing
B
SC Single Cycle (only PH unit)
C
S+BF Soft Start + Burst Firing (only PH unit)
J
PA Phase Angle (only PH unit)
P
PA+S Phase Angle + Soft Start (only PH unit)
E
DT Delayed Triggering
(only PH unit)
D
Control Mode
None
0
V Voltage (available with BF,SC,S+BF and DT)
U
VxI Power (available with BF,SC,S+BF and DT)
W
Options
IFH (
≤45A) or IF(>45A) + CT
Y
IFH (
≤45A) or IF(>45A) + CT + HB
H
110V fan option
None
0
0V fan option available
≥ 20A
Approval
None
0
cUL us (soon available)
L
Manual
None
0
Italian
English
2
German
3
French
(soon availabl
e)
4
Version
Version

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9Internal Fuse
The thyristor unit have internal fuse extrarapid at low I²t for the thyristor protection of
against the short-circuits.
The Fuses must have I²t 20% less than thyristor's I²t. The warranty of thyristor is null
if no proper fuses are used.
Type Fuse Code
Spare Part Vac Current (ARMS)
I²T
(A² sec.)
Max Power
Lost (W)
030 FU 45 /40A 40 980 660 9
035 FU 45 /50A 50 800 660 9
040 FU 45 /50A 50 800 660 9
045 FU 45 /50A 50 800 660 9
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 no proper fuses are used. See tab.
Warning: When it is supply, the Thyristor unit is sub ect to dangerous voltage, don't open
the Fuse-holder module and don’t touch the electric equipments.
9.1 Fuses Replacement
Open the Fuse-Holder Pull out the fuse
The I²t on the table is related to 660 Vac, for real
value see this correction factor graphic.

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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 000 meter over sea level. For higher
altitude reduce the nominal current of 2% for each
00m over 000m
Humidity From 5 to 95% without condense and ice
10.2 Derating Curve

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10.3 Dimensions and Weight
REVO M 1PH REVO M 2PH REVO M 3PH
Size W(mm) H(mm) D(mm) Weight (kg)
PH 72 20,7 84 , 48
2PH 08 20,7 84 ,756
3PH 44 20,7 84 2,354
10.4 Fixing holes

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10.5 Technical Specifications
General features:
Cover and Socket material: PolymericV2
Mounting: DIN bar
Auxiliary voltage:
90: 30V
70:265V
230:345V
300:530V
5 0:690V
Relay output for Heater Break Alarm
(only with HB option): 0.5A a 25VAC
Input features:
Logic input SSR: 4 ÷ 30Vdc 5mA Max (ON ≥ 4Vdc OFF < Vdc)
Analogic input
0 ÷ 0Vdc impedance 5 K ohm
Analogic input
4 ÷ 20mA impedance 00 ohm
POT 5 K ohm min.
Digital Input 4 ÷ 30Vdc 5mA Max (ON ≥ 4Vdc OFF < Vdc)
Output features(power device):
Nominal current in continuous service: See order code
Max peak current ( 0ms)
400A for unit type 030
600A for unit type 035
800A for unit type 040-45
Voltage range: 24÷600V
Repetitive peak reverse voltage: 200V
Latching current: 250mA
Leakage current: 5mA eff
I²T value tp= 0msec:
830 A/s for unit type 030
750 A/s for unit type 035
3 0 A/s for unit type 040-45
Frequency range: 47÷70Hz
Power loss (I=Inom):
38W for unit type 030
44W for unit type 035
50W for unit type 040
57W for unit type 045
Isolation Voltage: 2500Vac

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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
045
Screw M5 26.6 (3.0) .5- 0 ( 6-8) 45A Rigid / Flexible
Spade Terminal
Cable dimensions of the Command Terminals
0.5mm² (AWG 8)
Cable dimensions of the Earth (suggested)
6 mm² (AWG 0)
Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.
Terminal Description
L Line Input Phase
T Load Output Phase
L2 Line Input Phase 2 (only for 3pH)
T2 Load Output Phase 2 (only for 3pH)
L3 Line Input Phase 3 (only for 2Ph and 3Ph)
T3 Load Output Phase 3 (only for 2Ph and 3Ph)

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11.1 Command Terminals
Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.
11.1.1 Terminal block M2 Drive M
Terminal Description
GND
2 COM digital Input
3 Configurable Enable
4 Configurable Input
5 Control Input +
6 Control Input -
7 + 0V Output
8 Slave Output - (factory connection)
9 Slave Output + (factory connection)
11.1.2 Terminal block M1 Drive M
Terminal Description
0 GND
TA Input (factory connection)
2 TA or TA2 input (factory connection)
3 TA3 input (factory connection)
4 Common alarm relay output
5 Normally open alarm relay output
6 Normally close alarm relay output
11.1.3 Terminal block M3 Drive M
Terminal Description
A+ RS485
B- RS485
11.1.4 Terminal block M4 Drive M
Terminal Description
L Aux L
- Not Connected
L2/N Aux L2/N

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11.2 Schematic

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11.3 Connection Diagram for Single-phase
TOP VIEW DOWN VIEW
Caution: this procedure must be performed only by qualified persons.