REVCON RHF-5P User manual

Version 01/2021
Product manual
RHF-5P and RHF-8P
High efficient double-stage passive harmonic filter
Power Range 4kW - -- 450kW
Voltage available 380V - -- 690V (50Hz / 60Hz)

Contents
2Operating instructions RHF
1 Important information ...................................................................................4
1.1 About the operating instructions .........................................................................................4
1.2 Uses terms and definitions .................................................................................................4
1.4 Unit designation.................................................................................................................5
1.5 Legal regulations ...............................................................................................................6
1.6 Scope of supply .................................................................................................................7
2 Safety instructions........................................................................................8
2.1 Layout of the safety instructions .........................................................................................9
2.2 General safety guidelines .................................................................................................10
2.3 For the safety responsible persons....................................................................................12
2.4 Specification of the used wires .........................................................................................13
2.5 Remaining danger............................................................................................................13
3 Introduction into the subject harmonics .......................................................14
3.1 Linear and non-linear loads ..............................................................................................14
3.2 Evaluation of harmonic distortion ......................................................................................15
3.3 The effect of harmonics in a power distribution system ......................................................15
3.2 The negative effect of harmonics ......................................................................................16
3.3 Harmonic limitation standards and requirements ...............................................................18
3.4 Harmonic Mitigation.........................................................................................................21
4 Introduction into the subject filter modules ..................................................22
4.1 Function principle REVCON RHF ........................................................................................22
4.2 Harmonic line filter for frequency converters......................................................................24
5 EU- directives / Declaration of conformity ....................................................26
5.1 What is the purpose of EU-directives? ...............................................................................26
5.2 What is the meaning of the CE- marking?..........................................................................26
5.3 EG-directive low voltage...................................................................................................26
5.4 Standards and permission ................................................................................................27
6 Selection of the right filter module and technical data ...................................28
6.1 Calculation ......................................................................................................................28
6.2 Worked sample................................................................................................................29
6.3 General Data / Operation conditions ..................................................................................30
6.5 Rating values...................................................................................................................32
6.6 Available RHF size and current rating, weight and power loss .............................................33
6.7 Cable cross section..........................................................................................................44
6.8 General information..........................................................................................................44
6.9 Connections ....................................................................................................................45
6.11 Dimension diagrams ........................................................................................................46
Enclosure X0.3 IP20................................................................................................................47
Enclosure X1.3 if IP20 (fan placed on inside or not required) .....................................................48
Enclosure X1.3 ef IP20 (fan placed on outside) ..........................................................................50

Contents
Operating instructions RHF 3
Enclosure X2.3 if IP20 (fan placed on inside) .............................................................................52
Enclosure X2.3 ef IP20 (fan placed on outside) .........................................................................53
Enclosure X3.3 if IP20 (fan placed on inside) ............................................................................56
Enclosure X3.3 ef IP20 (fan placed on outside) .........................................................................58
Enclosure X4.3 if IP20 (fan placed on inside) ............................................................................60
Enclosure X4.3 ef IP20 (fan placed on outside) .........................................................................62
Enclosure X5.3 if IP20 (fan placed on inside) ............................................................................64
Enclosure X5.3 ef IP20 (fan placed on outside) .........................................................................66
Enclosure X6.3 if IP20 (fan placed on inside) ............................................................................68
Enclosure X6.3 ef IP20 (fan placed on outside) .........................................................................70
Enclosure X7.3 if IP20 (fan placed on inside) ............................................................................72
Enclosure X7.3 ef IP20 (fan placed on outside) .........................................................................74
Enclosure X8.3 if IP20 (fan placed on inside) ............................................................................76
Enclosure X8.3 ef IP20 (fan placed on outside) .........................................................................78
7 Installation .................................................................................................80
7.1 Mechanical installation.....................................................................................................80
7.2 International protection rating ...........................................................................................81
7.3 Specified mounting position..............................................................................................82
7.4 The air ventilation ............................................................................................................83
8 Electrical installation...................................................................................84
8.1 Network configuration / Net conditions...............................................................................84
8.2 Operation principle RHF.....................................................................................................85
8.3 Wiring diagram RHF ..........................................................................................................86
8.4 Line connection ................................................................................................................89
8.5 Fuses...............................................................................................................................90
8.6 Installation in a CE- typical drive system.............................................................................91
8.7 Installation........................................................................................................................92
8.8 Installation of a EMC- conform electrical enclosure .............................................................93
8.9 Note.................................................................................................................................94
9 Commissioning............................................................................................95
9.1 First switching-on ............................................................................................................95
10 Capacitor disconnection.............................................................................96
11 Option Nema 1- IP21 enclosure...................................................................98
12 REVCON®product overview ......................................................................101
13 Contact.....................................................................................................102

Contents
4Operating instructions RHF
1 Important information
1.1 About the operating instructions
•These present operating instructions are the translation of the original instructions, which were
composed in the official EU language German.
•These operating instructions shall ensure safe operation of and with the filter module REVCON
RHF. They contain security advices which must be observed and information which is necessary
for an undisturbed operation of the units and for the exploitation of all advantages of the system.
•All persons who work on and with the filter module REVCONRHF must have accessible the oper-
ating instructions, or the equal chapters of the operating instructions for other with this option
equipped REVCONproducts available. All persons must follow the relevant notes and designa-
tions.
•The operating instructions must be complete and perfectly legible.
1.2 Uses terms and definitions
Filter module
For “Filter module REVCONRHF“ the term “Filter module“ is used in the following chapters, if the
designation refers to all types (A, B).
For different characteristics, the complete marking (for example RHF-8P) is used.
Drive system control
For the frequency convert which is used together with the filter module,
the term “Controller” is used.
Drive system
For a drive system with filter modules, controller and other components of the
drive system in the following the term “Drive system“ is used.

Important information
Operating instructions RHF 5
1.4 Unit designation
Example: Nameplate RHF-8P 55-380-60-20-C:
Figure 1: The REVCON®RHF nameplate

Important information
6Operating instructions RHF
1.5 Legal regulations
Marking
Name plate
CE-marking
Manufacturer
Filter modules REVCONRHF are clearly
marked by the content of the nameplate
Conformable
to EG directive “low-voltage“
ELTROPLAN-REVCON
Edisonstraße 3
D-59199 Bönen
Trade mark
rights
The filter module REVCONRHF is protected in the Federal Republic of Germany by utility patents. Patent-Nr.: DE
3938654C1 und Patent-Nr.: 90123584.6-2207. Violation of this utility patent and the verbalized trade mark rights will
be prosecuted criminally.
Intended use
Filter module REVCON

RHF
•only to use under the terms of this operating instructions and the required operational conditions
•are components
– to reduce the harmonic distortions of the electrical network by specific B6 rectifiers and inverters
– to fit in a machine
– to assembly with other components to a machine together
•are electric equipment to assembly in a electrical enclosure or similar
•locked up operations rooms
•conform to the protection requirements of the EG directive “low-voltage “
•are no machines in terms of the EG directive “machines“
•are no household appliances, but components which are determined only for the further application in commercial
use
Drive system with filter module REVCON

RHF
•conform to the EG directive “Electromagnetic Compatibility“, if they are installed by the specifications of the CE-
typical drive control system
•are applicable
– in the public electrical network and closed electrical networks.
– in the industrial sector and in living areas as well as in business units.
The responsibility for the compliancy of the EG directive with the machine application is one for the user.
Liability
•
The indicated information, technical data and notes in this operating instruction were updated at the time of the
printing. No demands for changing a delivered filter module can be asserted by the information, figures and de-
scriptions of these operating instructions.
•The represented process engineering notes in this operating instructions and circuit details are suggestions, which
transferability on the respective application must be verified. For the suitability of the specified procedures and cir-
cuit suggestions accepts the ELTROPLAN-
REVCON GmbH no guarantee.
•The data in these operating instructions describe the characteristic of the products without ensuring them.
•No Liability will be taken over for damages and malfunctions which result by:
– disregard of the operating instructions
– arbitrary changes on the filter module
– operating errors
– improper works on and with the inverter
Warranty
•
Warranty conditions: Look at the sales - and delivery conditions of the
ELTROPLAN- REVCON GmbH.
•Immediately announce guarantee claims after the discovery of defects or faults
•The warranty expires in all cases, in which even no liability claims can be asserted.
Disposal
Material
Recycling
Disposal
Metal

-
Plastic

-

Important information
Operating instructions RHF 7
1.6 Scope of supply
•1 filter module RHF
•1 operating instructions
–After receipt of the delivery verify immediately, if the scope of supply correspond to the ship-
ping documents. We make no warranty for later complained defects
–Complain
•visible damages in transit immediately at the deliverer
•visible defects / incompleteness immediately at ELTROPLAN REVCON

Safety instructions
8Operating instructions RHF
2 Safety instructions
Safety- and application instructions
for propulsion converters
(in conformity with low- voltage directive 2006/95/EG)
1. General
During the operation filter modules can own according to their protection
class live, blank and if necessary even movable parts, as well as hot sur-
faces.
The hazard of severe person or property damage exists at not permissible
removal of the required coverage, at inadmissible application, at false In-
stallation or operation.
Further information can be learned from the documentation.
All works for transport for installation and commissioning as well as
maintenance has to be done by specialized staff (IEC 60364 or CENELEC
HD 384 or DIN VDE 0100 und IEC-Report 664 or DIN VDE 0110 and ob-
serve national accident prevention regulations).
Specialized staffs in terms of these fundamental safety instructions are
persons who are acquainted with installation,
assembly, commissioning and operation of the product and who dispose
through their work of the corresponding Qualifications.
2. Conventional application
Filter modules are components that are conventional for the installation in
electrical systems or machines.
At the installation in machines is the start-up of the filter modules (the
start of the conventional operation) prohibited until it is determined that
the machine complies with the regulations of the EG directive 2006/42/EG
(Machine directive); EN 60204 is to observe.
The start-up (the start of the conventional operation) is only allowed under
compliance of the EMC-directive. The filter modules comply with the re-
quirement of the low- voltage directive 2006/95/EG. The technical Data
and also the data of the connecting conditions have to be taken from the
nameplate and the documentation and they have to be necessarily ob-
served.
3. Transport, storage
Notes on transport, storage and appropriate handling must be observed
At non-observance any warranty expires.
The power feedback unit has to be protected from inadmissible stress.
The transport is only valid in original packaging and in the thereon by picto-
grams marked transport position.
In particular during transport and handling no components are allowed to
be bent and / or isolating distances may not be altered. The units are
equipped with electrostatic sensitive devices, which may be damaged by
improper handling. Therefore it has to be avoided to get in contact with
electronic components. If electronic components are damaged mechani-
cally the unit must not be put into operation, as it cannot be ensured, that
all relevant standards are observed. Climatic conditions must be observed
according to prEN 50178.
These safety instructions have to be kept!
4. Assembly
The Assembly and cooling of the devices must occur accordingly the in-
structions of the respective documentation.
The filter modules have to be protected of not permissible stress. Par-
ticularly at transport und handling no components must have to be bent
and / or insulation distances being changed. The touch of electric com-
ponents and contacts is therefore to avoid. Electric components must
not be mechanical damaged or destroyed. (Under conditions health
hazards!).
At mechanical defects at electric and other components it is not al-
lowed to start up the device, because a compliance of applied stand-
ards is not longer guaranteed.
5. Electrical connection
At live-line working on filter modules apply national accident prevention
regulations (VBG 4) must be observed. Before any installation- and con-
nection works the system must be operated on dead voltage and ac-
cordingly must be secured.
The electric installation must be performed according to the respective
instructions (e.g. cable cross- section, fuses, connection to the protec-
tive conductor). At usage of the filter module with drive system control
without a safe disconnect from the supplying circuit (according to VDE
0100) all control cables must be included in additional protective
measures (e.g. double insulated or shielded, grounded and insulated).
Notes for the EMV-conform installation – like shielding, grounding, ar-
rangements of filter modules and the installing of conductors – are lo-
cated in the chapter “Installation of these operating instructions”.
These notes must even be observed at CE-marked propulsion convert-
ers. The compliance of the required limit values by the EMV- legislation
is up to the responsibility of the manufacturer of the system or the ma-
chine.
6. Operation
After disconnect of the filter modules of the supply voltage, it is not al-
lowed to touch live-line device parts and line connections because pos-
sibly charged capacitors must not be touched immediately.
During the operation all covers and doors must be closed.
7. Service and Maintenance
The operation of the manufacturer must be observed.
Observe also the product specific safety- and application notes of these operating instructions!

Safety instructions
Operating instructions RHF 9
2.1 Layout of the safety instructions
All safety instructions are built uniformly:
•The pictogram marks the type of danger.
•The signal word marks the severity of danger.
•The legend marks the danger and gives notes, how to avoid the danger.
Used pictograms
Signal words
Warning of
injury to per-
sons
Imminent danger by
current
Danger!
Warns of an immediately imminent Danger.
Consequences by disregard:
Death or severe injuries
Warning of an immi-
nent danger
Warning!
Warns of a possible, very danger
situation.
Possible consequences by disregard:
Death or severe injuries
Dangerous
situation
Caution!
Warns of a possible, dangerous situation.
Possible consequences by disregard:
Minor or small injuries
Warning of hot sur-
face
Warning!
Warns of touching a hot surface.
Possible consequences by disregard:
Burnings
Warning of prop-
erty damages
Harmful situation
Stop!
Warns of possible property damages.
Possible consequences by disregard:
Damage of the drive system or its surroundings
Useful infor-
mation and ap-
plication notes
Information
Note!
Marks a generally, useful note, tip.
If you follow it, you make the handling of the
filter module easier
Table 1: Layout of the safety instructions
Signal word
Legend
STOP

Safety instructions
10 Operating instructions RHF
2.2 General safety guidelines
•These safety guidelines make no demand to be complete.
•In case of questions and problems please confer with a technician of our company.
•The filter module complies with the state of technology at date of delivery and is considered as
reliable basically.
•The data of these operation instructions describe the characteristics of the products, without as-
suring them.
•The filter module may cause danger of risk for persons, the filter module itself and for other ma-
terial assets, if
non qualified staff are working on and with the filter module
-the filter module is used improperly
•The Filter modules must be planned and commissioned so that they fulfil their intended function
in a proper installation, at intended use and at error-free operation and cause no danger for per-
sons. This is valid even for their interaction with the complete plant.
•The represented procedural notes and circuit details in these operation instructions have to be
understood analogously and have to be verified to assign ability to the current application.
•Operate the drive system only at perfect status.
•Changes to or modifications of the filter module are fundamentally prohibited.
They require in any event the confer with a technician of our company
•The granted guarantee from us expires, if the device is changed or (even partly) dismantled, or if
it is deployed in contradiction to our instruction.
•The installer of the plant must know the technical rules and guidelines and is responsible for the
correct selection and arrangement of the electrical equipment .
•The operation of the filter module is only permitted on standard conform grids of the electrical
energy supply! Disregard can lead to reduction of the filter effect and possibly to destruction of the
filter module.

Safety instructions
Operating instructions RHF 11
•According to the corresponding standards and guidelines is the operation even at for a short time
overcompensated grids (cosϕ≤1) respectively at compensation plants without chokes is not per-
mitted, because the otherwise caused by oscillation recurrent surges can damage all connected
loads, particularly electronic equipment for example drive controller and power feedback units .
Stop!
An undisturbed and safe operation of the filter module is only to expect under the observance of the fol-
lowing connection instructions.
At deviations of these guidelines in individual case malfunctions and damages could occur:
–Observe the grid voltage.
–Run power- and control lines separated (> 15cm)
–Use shielded / twisted control lines only
–Run the shielding riveted to PE!
–Ground the enclosure of drive, drive control, power feedback unit and filter module safe. Connect
Shielding of power lines riveted and extensive (Remove the lacquer)!
–Ground the electrical enclosure or the plant to main ground star point sigmoid
(necessarily avoid ground loops!)
–The filter module is only determined for a solid connection, because particularly at the applica-
tion of interference filter leakage current of 3,5 mA appear. The protective earth conductor must
average minimum 10 mm² copper, or one second conductor must be ran electrical parallel to
Ground (grounded neutral point sigmoid).
STOP

Safety instructions
12 Operating instructions RHF
2.3 For the safety responsible persons
Operator
•Operator is every natural or legal person, which uses the drive system or in which order the drive
system is used.
•The operator respectively his safety representative must assure:
-That all relevant instructions, notes and laws will be abided
-That only qualified staff works on and with the drive system
-That the staff has the operating instructions at all respective works availably
-That non qualified staff must not work on and with the drive system .
Qualified staff
Stop!
Qualified staff means persons, that are entitled (by the safety responsible) due to their training, experience,
education, their knowledge in relevant norms, directives, accident directives and operation conditions to
execute the necessary works and to recognize possible danger and to avoid it. (Definition of qualified staff
IEC 364)
STOP

Safety instructions
Operating instructions RHF 13
2.4 Specification of the used wires
•The used wires must conform to the required specification on site
•The regulations about the minimum cross- section of PE-conductors must be observed.
Connection:
•The connection has to be done by the terminals X1.1-X1.3 and X2.1-X2.3
•The temperature monitoring must be connected with the terminals A/B of the filter module with
the pulse stop of the converter.
Stop!
If this connection is not made at all or at least analogously (for example via an PLC), the filter module
may be damaged at constant overload operation.
Caution!
If this connection is not made at all or at least analogously (for example via na PLC) and the installation
instructions (chapter 8) are not observed, this may lead to a thermal overload of the filter module and
possibly to a smoke emission and/or a fire.
2.5 Remaining danger
Danger!
After switching off the electrical network, all connections could lead a dangerous contact voltage for up
to 10 minutes!
STOP

Introduction
14 Operating instructions RHF
3 Introduction into the subject harmonics
The following chapter gives you quick introduction into the topic of harmonic distortion. In order to give
a more detailed picture, please visit the learning area of www.revcon.de or ask for the REVCON Har-
monic Solution Guide.
3.1 Linear and non-linear loads
Ideally all loads and sources have a pure sinusoidal current waveform. But unfortunately the true wave-
form of most equipment is very different.
Electrical loads where the current is not proportional to the voltage are called non-linear loads. LiAnear
loads are pure sinusoidal, and either resistive, inductive or capacitive. The most typical nonlinear load a
6-pulse rectifier as used with any standard Variable Frequency Drive (VFD).
The red signal in the first picture is showing the input-current-shape of a standard 6-Pulse drive with
about 4% inductance and clearly, this is far away from sinus. Of course, the input-current-shape of any
drive without inductance is significantly worse.
The red signal in the second picture I showing a clean input current such as achieved when using a
RHF-5P

Safety instructions
Operating instructions RHF 15
3.2 Evaluation of harmonic distortion
The THD Total Harmonic Distortion is the most used evaluation for harmonic distortion, and is defined
for voltage THDv and current THDi, both typically consider the harmonics up to the 40th or 50th.
 = �∑
2
=40
=2
1•100% = �ℎ2
2+ℎ3 2+ℎ4 2+ℎ5 2+ℎ6 2+⋯+ ℎ40 2
1•100
Basically the THD is a good evaluation for Harmonic Distortion but it is not sufficient to give a full evalu-
ation of the problems that may be caused by harmonics as individual limits must be taken into account.
3.3 The effect of harmonics in a power distribution system
In figure 2 a transformer is connected on the primary side to a common point of coupling PCC1 on the
medium voltage supply. The transformer has an impedance ZTund supplies a number of loads.
At a common coupling point PCCP2 all loads are connected. Each load is connected through wires that
have the corresponding impedances Z1, Z2und Z3:
Figure 2: The effects of harmonics

Introduction
16 Operating instructions RHF
Harmonic currents drawn by non-linear loads cause distortion of the voltage because of the voltage
drop on the impedances of the distribution system. Higher impedances result in higher levels of voltage
distortion.
Current distortion relates to the device performance and it relates to the individual load. Voltage distor-
tion relates to system performance .It is not possible to determine the voltage distortion in the PCC
knowing only the load’s harmonic performance .
The configuration of the distribution system and the relevant impedances must be known to calculate
the distortion in the PCC.
A commonly used term to describe the impedance of a grid is the short circuit ratio Rsce, defined as the
ratio between the short circuit apparent power of the supply at the PCC (Ssc) and the rated apparent
power of the load (Sequ).
 =/
with
 =2/
and
 =× 
3.2 The negative effect of harmonics
Non-linear loads are causing various different problems. The most obvious one is that equipment such
as VFD´s are causing harmonic currents that will increase the input current of the system. A three-
phase VFD without any inductance will cause a THDi of about 105%, which will increase the input cur-
rent IRMS by 43%.
Typically these harmonics have reactive characteristics, but this higher input current will require signifi-
cant higher sizing of wires, protective devices and will also cause significant higher power losses in the
system.

Safety instructions
Operating instructions RHF 17
Ohm´s law teach us, V = I • Z, which means that due to the impedance of the system, every harmonic
current, will cause a distortion of the voltage. The impact of this voltage distortion THDv is diverse, and
the most typical effect is overheat of transformer and PFC applications
Transformers and PFC.
Significant increase of power loss on any inductances or capacity
results in reduced rating, lower expected lifetime, lower efficiency
or even damaged equipment
Electronic equipment usually have a rectifier with capacitor
input, whose lifetime is significantly affected by voltage distortion.
This results in immediate damage or significant reduced lifetime
Motors and Generators direct on line follow the connected fre-
quency! Supply voltage with additional frequencies (harmonics)
are lethal for both mechanical and electrical side
System Efficiency is directly affected by the harmon-
ics as nearly all equipment and wires produce more
heat when voltage distortion rises

Introduction
18 Operating instructions RHF
3.3 Harmonic limitation standards and requirements
The requirements for harmonic limitation are:
•Application specific requirements
•Requirements from standards that have to be observed
The application specific requirements are related to a specific installation with technical reasons
for limiting the harmonics.
For example: A 250kVA transformer is connected with two 110kW motors. One is connected di-
rect and the other motor is supplied by a frequency converter.
If the other motor should also be supplied by a frequency converter, the transformer will, in this
case, sized too small.
If the system should be retrofitted without changing the transformer, the harmonic distortion
caused by two drives must be mitigated using RHF filters.
There are various harmonic mitigation standards, regulations and recommendations. Different
standards are applied in different geographical areas and industries. The following standards that
are applicable will be specified:
•IEC/EN 61000-3-2
•IEC/EN 61000-3-12
•IEC/EN 61000-3-4
•IEC 61000-2-2
•IEC 61000-2-4
•IEEE 519
•G5/4
IEC 61000-3-2:

Safety instructions
Operating instructions RHF 19
The scope of IEC 61000-3-2 is equipment connected to the public low-voltage distribution sys-
tem with an input current up to and including 16 A per phase. Four emission classes are defined:
Class A through D.
IEC 61000-3-12:
The scope of IEC 61000-3-12 is equipment connected to the public low-voltage distribution sys-
tem having an input current between 16A and 75A.
The emission limits are currently only for 230/400V 50Hz systems and limits for other systems
will be added in the future. The emission limits that apply for drives are given in Table 4 in the
standard. There are requirements for individual harmonics (5th, 7th, 11th, and 13th) and for THD
and PWHD.
IEC 61000-3-4:
Limits, Limitation of emission of harmonic currents in low-voltage power supply systems for equip-
ment with rated current greater than 16A.
The IEC 61000-3-12 supersedes IEC 61000-3-4 for currents up to 75A. Therefore the scope of IEC
61000-3-4 is equipment with rated current greater than 75A connected to the public low voltage
distribution system. It has the status of a Technical report and should not be seen as an interna-
tional standard.
A three-stage assessment procedure is described for the connection of equipment to the public
supply and equipment above 75A is limited to stage 3 connection based on the load's agreed
power . The supply authority may accept the connection of the equipment on the basis of the
agreed active power of the load's installation and local requirements of the power supply author-
ity apply. The manufacturer shall provide individual harmonics and the values for THD and PWHD.
IEC 61000-2-2 and IEC 61000-2-4: The IEC 61000-2-2 and IEC 61000-2-4 are standards that
stipulate compatibility levels for low-frequency conducted disturbances in public low-voltage
supply systems (IEC 61000-2-2) and industrial plants (IEC 61000-2-4).
These low-frequency disturbances include harmonics, but are not limited to harmonics.
The values prescribed in these standards should be taken into consideration when planning in-
stallations. In some situations the harmonic compatibility levels cannot be observed in installa-
tions with frequency converters and harmonic mitigation is needed.
IEEE519,: