Summary of Contents for Eltroplan REVCON SVCS Series
- Page 1 ELTROPLAN-REVCON Operating instructions Power feedback unit ® REVCON SVCS Power range 7 ... 33kW Rated voltage 400V V 2.0 As of 03/10...
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Page 2: Table Of Contents
Internal fuses ......................35 3.3.5 RFI-filter ........................36 3.3.6 SKS-module ........................ 36 Installation ......................... 37 4.1 Mechanical installation ..................... 37 4.1.1 Important hints ......................37 4.2 Dimensions ........................38 4.2.1 Power feedback unit ....................38 4.2.2 RFI-filters ........................41 ELTROPLAN-REVCON page 1... - Page 3 5.1 First powering up ......................60 Configuration ........................61 Troubleshooting and fault elimination ................64 7.1 LED-messages ........................65 Service ..........................66 Appendix ........................... 67 9.1 Options ..........................67 9.2 REVCON Product overview ..................... 69 9.3 Contact ..........................70 Seite 2 ELTROPLAN-REVCON...
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Page 4: Preface And General Information
For the frequency inverter which is used together with the power feedback unit in the following the term „Controller“ is used. Drive system For a drive system with power feedback units, controller and other components of the drive system in the following the term „Drive system“ is used. ELTROPLAN-REVCON page 3... -
Page 5: Type Determinator
After receipt of delivery, check immediately whether the scope of supply matches with the accompanying papers. We do not accept any liability for de- ficiencies claimed subsequently. Claim • visible transport damage immediately to the forwarder . • visible deficiencies/incompleteness immediately to ELTROPLAN REVCON. page 4 ELTROPLAN-REVCON... -
Page 6: Legal Regulations
• The specifications, processes and circuitry described in these Operating Instructions are for guidance only and must be adapted to your own specific application. ELTROPLAN-REVCON does not take responsibility for the suitability of the process and circuit proposals. • The indications given in these Operating Instructions describe the features of the product with- out warranting them. -
Page 7: Ec-Directives / Declaration Of Conformity
• Aim of the Low-Voltage Directive is to put only those products into com- merce which don’t endanger the safety of persons and animals as well as the preservation of material assets. page 6 ELTROPLAN-REVCON... - Page 8 The power feedback units REVCON SVC have been developed, designed and manufactured in accordance with the above mentioned EC-Directive and in sole responsibility of ELTROPLAN-REVCON Elektrotechnische Anlagen GmbH, Edisonstraße 3, D-59199 Bönen Considered standards: Standard DIN VDE 0160 5.88 +A1 / 4.89 +A2 / 10.88...
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Page 9: Ec-Directive Machinery
(like treating, moving, processing of a mate- rial). page 8 ELTROPLAN-REVCON... - Page 10 SVC have been developed, designed and manufactured in accordance with the above mentioned EC Directive in exclu- sive responsibility of ELTROPLAN-REVCON Elektrotechnische Anlagen GmbH, Edisonstraße 3, D-59199 Bönen When installing the machines, commissioning (i.e. the staring of operation as directed) the power feedback units is prohibited until it is proven that the ma- chine corresponds to the regulations of the EC Directive 89/392/EEC (Machin- ery Directive).
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Page 11: Safety Information
Climatic conditions must be observed accord- The product-specific safety and application notes in ing to prEN 50178 these Operating Instructions must also be observed! page 10 ELTROPLAN-REVCON... -
Page 12: General Safety Information
• • Use the drive system only in flawless condition. Modifications of the power feedback units without consultation of a • REVCON -technician are not allowed generally. ELTROPLAN-REVCON page 11... - Page 13 ♦ Pay attention to the correct values of mains and DC-bus voltage. ♦ Separate power and control wires (> 15cm) ♦ Use shielded or twisted control wires. Connect both ends of the shield to ground! page 12 ELTROPLAN-REVCON...
- Page 14 620 the device has to be disconnected to avoid damage to the power semi- conductors. This procedure corresponds with the standard, as each device performs a high voltage test in accordance with VDE 0160 (EN 50178) in the course of final testing after manufacturing. ELTROPLAN-REVCON page 13...
- Page 15 Faults current circuit breaker, which are sensitive to all kinds of leakage currents, grant a good protection and are suitable as the only protection measurement for one ore three phase controllers. The connection instruc- tions of the manufacturer has to be observed. page 14 ELTROPLAN-REVCON...
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Page 16: Safety-Responsible Persons
3-phase asynchronous or per- manent magnet motors. The usage with other electrical loads is not permitted and may damage the devices. The power feedback unit may only be connected to symmetrical networks. Non-observance may damage the devices. ELTROPLAN-REVCON page 15... -
Page 17: Layout Of The Safety Information
Protection of the device STOP Cyclic connection and disconnection of the supply voltage at terminals L1, L2 und L3, may overload the internal input current limitation: Allow at least 1 minute between disconnection and reconnection. page 16 ELTROPLAN-REVCON... -
Page 18: General Instructions
Does the level of the supply voltage sink for a longer time, the maxi- mum feedback power is reduced. If only one phase fails, the device is able to work on, but the current in the two remaining conductors will rise up to 150% of the normal level. ELTROPLAN-REVCON page 17... - Page 19 200µF 160-200kW 420µF Table 2.6.1 Example: C=200µF, ∆U =100V, i=271A, a=80mm, r=8,5mm, µ =1,257 H/m ⇒ =26m For longer DC-Bus-wires additional capacitors have to be installed (please get in contact with our application-department if the occasion arrises). page 18 ELTROPLAN-REVCON...
- Page 20 STOP! Over voltages may cause serious damages to the connected frequency in- STOP verter and /or to the power feedback unit and to the other loads. ELTROPLAN-REVCON page 19...
- Page 21 (e.g. in the case of a braked slip-ring induction motor) is only al- lowed, if the quotient ratio of feedback-power and nominal power is much smaller than one 10kV 0,4kV 100kVA REVCON 20kW 20kW 60kW Figure 2.6.2 page 20 ELTROPLAN-REVCON...
- Page 22 Over voltages may cause serious damages to the connected frequency in- STOP verter and /or to the power feedback unit and to the other loads. Not allowed! REVCON 60kW Figure 2.6.3 The same things apply to the also non-admissible pre-connection of further commutation chokes. ELTROPLAN-REVCON page 21...
- Page 23 80A, at a bad made terminal of 100mW a voltage of 8V is dropped (A good made terminal has got a resistance of ca 1 mW.). During backfeed operation at seven serial terminals at the net switch there results an voltage of 456V. page 22 ELTROPLAN-REVCON...
- Page 24 (mm²) per phase (mm) current (A) 2x120 2x6,2 2x150 2x6,9 2x185 2x7,7 3x185 3x7,7 3x240 3x8,7 1000 4x240 4x8,7 1250 These values are based on a cable length of 100m and a maximum voltage drop of 5V.. Table 2.6.2 ELTROPLAN-REVCON page 23...
- Page 25 Is the power consumption of the loads to small, the DC-voltage and also the output voltage of the power feedback unit rises during the backfeed operation. This increased voltage may damage all con- nected components. wrong Supplying network false REVCON 60kW Figure 2.6.5 page 24 ELTROPLAN-REVCON...
- Page 26 Supplying network REVCON 60kW Figure 2.6.6 TIP! F F F F Same things apply to the structure like in figure 2.6.6. Even in this case it is necessary to place a circuit breaker in each backfeeding current circuit. ELTROPLAN-REVCON page 25...
- Page 27 This harmonic load is transmitted via the transformer and causes effects on the low voltage level. Most often the limits were exceeded for the 5th harmonic component. page 26 ELTROPLAN-REVCON...
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Page 28: Technical Data
Overload protection during backfeeding operation • Supervision of mains voltage, phase sequence and temperature • High efficiency • High dynamic braking processes are possible • User-friendly commissioning – no adjustment necessary • Including buit in harmonic filter SKS-R ELTROPLAN-REVCON page 27... -
Page 29: General Data / Application Conditions
EN 50082-2 criterion A Insulation strength Overvoltage category III according to VDE 0110 Packaging DIN 55468 for transport packaging materials Type of protection IP 20 Approvals Low-Voltage Directive *climatic conditions according to class 3K3 (EN 50178 Part 6.1) page 28 ELTROPLAN-REVCON... -
Page 30: Rated Data
40°C < Ta < 55°C ⇒ 3%/K Power derating [%/m] 1000m a.m.s.l.< h ≤4000m a.m.s.l. ⇒ 5%/1000m Table 3.3.1.1 depending on the size of the unit ( nominal power and nominal voltage) alternative case-type with minor changed dimensions at nominal current ELTROPLAN-REVCON page 29... -
Page 31: Current Load
From that results: P=400V x 65A x √3=45033W, that’s about 45,0kW If the momentary rms mains voltage is only 395V or even lower for a short time, the maximum possible regenerative power is reduced as well: P = 395V x·65A x √3 = 44470W, that’s about 44,5kW. page 30 ELTROPLAN-REVCON... - Page 32 SVCS 22-XXX-1-... with forced cooling have an al- lowed switch on duration time of 50% (referring to a cycle time of 10 min.). ® − For the devices from product line REVCON SVCS 33-XXX-1-... the following thermal limited load graphs are valid. ELTROPLAN-REVCON page 31...
- Page 33 In this case the point of intersection of braking time and intermission time is above the thermal limited power graph. That means this operation cycle is not al- lowed. Remark: In case of an intermission time of e.g. 3,5 min. this operation cycle would be allowed again. page 32 ELTROPLAN-REVCON...
- Page 34 Thermal limited load graphs: REVCON SV(C ) 33-XXX-1-... 27 kW with fan 100 % constant power with fan: 21,5 kW braking time 33 kW with fan 27 kW without fan 33 kW without fan intermission time Diagram 3.3.3.1.2 ELTROPLAN-REVCON page 33...
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Page 35: Fuses And Wire Cross Sections
CS M6 35mm² Table 3.3.4.1.1 ES ≅ end sleeve for strands CS ≅ cable socket with drill hole for M6 / M8 / M10 at the copper lug of the commutation choke. at the fuse holder respective disconnector page 34 ELTROPLAN-REVCON... -
Page 36: Internal Fuses
STOP If semiconductor fuses (figure 4.4.1.1.1 position 1 and 7) trip, please get in contact with ELTROPLAN-REVCON immediately, as possibly further protec- tive measures have tripped. If internal fuses are exchanged, please verify, that only the original types are used for replacement. -
Page 37: Rfi-Filter
RF-SVC 13-400 SVC(S) 22-400-1-0 RF-SVC 22-400 SVC(S) 33-400-1-0 RF-SVC 33-400 Table 3.3.5.1 3.3.6 SKS-module To decrease the low frequency harmonic back effects to mains a filter module REVCON SKS-R is built into the power feedback unit . page 36 ELTROPLAN-REVCON... -
Page 38: Installation
Keep a distance of min. 15 cm to the air- in- and air-out-openings and a distance of min. 7 cm to beside mounted parts or cabinet-walls. ELTROPLAN-REVCON page 37... -
Page 39: Dimensions
Installation Dimensions 4.2.1 Power feedback unit ® REVCON weight Type (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg) SVCS 7-400-1-0 SVCS 13-400-1-0 SVCS 22-400-1-0 SVCS 33-400-1-0 Table 4.2.1.2 page 38 ELTROPLAN-REVCON... - Page 40 Installation 4.2.1.1 Dimension diagrams 1. SVCS 7-400-... SVCS 22-400... ELTROPLAN-REVCON page 39...
- Page 41 Installation SVCS 33-400-... Cooling airflow in Cooling airflow out REVCON all cableinputs from bottom page 40 ELTROPLAN-REVCON...
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Page 42: Rfi-Filters
The radio interference filter of case-type 3 and 4 are mounted in housings, which should be placed beside the power feedback unit. The power feedback units were fixed with screws M6 , the RFI-filter with screws M8. 4.2.2.1 Dimension diagrams Diagram Case 1 ELTROPLAN-REVCON page 41... - Page 43 Installation Diagram Case 2 Diagram Case 3 page 42 ELTROPLAN-REVCON...
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Page 44: Electrical Installation
During working at the terminals the personnel has to observe the rules of the international standard IEC 747-1 chapter 9. Basically before starting the works the personnel has to free itself from electrostatic voltages: Discharge yourself by touching the PE-screw of the housing or another grounded surface in the cabinet. ELTROPLAN-REVCON page 43... -
Page 45: Mains Types / Mains Characteristics
Use screens tin- or nickel-plated copper screens only! - the swamp factor of the screen mesh: at least 70% to 80% with a swamp angle of 90° • Protect the mains wires of the power feedback unit with the provided wire protection fuses. page 44 ELTROPLAN-REVCON... -
Page 46: Connection
Protection of the power feedback unit at DC side (+UG, -UG): – fuses are part of the power feedback unit (refer to chapter 3.3.4.2). The erector/user of the plant bears the responsibility for the observance of further relevant standards (e.g.: VDE 0113, VDE 0289 and so on). ELTROPLAN-REVCON page 45... - Page 47 DC-fuse holder. It is absolutely necessary to observe the correct polarity. Tipp! F F F F Interchanging of + (PLUS) and – (MINUS) avoids the correct function of the power feedback unit. page 46 ELTROPLAN-REVCON...
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Page 48: Wiring Schematic
Wiring schematic of the power feedback unit REVCON SVC(S) and one ore more controllers Remark: This is an wiring example. Special features of a application (e.g. installation of a PLC) may require modifications of the wiring of the terminals X2.1 ... X2.12 . ELTROPLAN-REVCON page 47... - Page 49 The „ON“ or „RESET“ signal may be initiated via terminals 9 and 10 or 11 and 12: Terminals 9 and 10: potential free contact (short time contact) Terminals 11 and 12: positive pulse (12-24 V DC); practicable e.g. via PLC (terminal 11 +, terminal 12 -). page 48 ELTROPLAN-REVCON...
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Page 50: Fan Supply
From the control terminal strip the operating condition or rather the collective error can be connected to extern. There is also the possibility to execute the ex- ternal reset or the switch-functions and to connect them with the controller or the PLC. ELTROPLAN-REVCON page 49... - Page 51 X4 LED-messages mains supply and controlling connection to green: operation signalling board 1. red: phase failure type of 2. red: / overcurrent control board orange: overtemperature (example) yellow: collective error Figure 4.4.4.1 page 50 ELTROPLAN-REVCON...
- Page 52 In figure 4.4.4.2 the relay is displayed in rest position. The relay toggles, if: 1.) power supply is o.k., 2.) no error present, and after perhaps an ON-signal has been released. If an OFF-signal has been released, an collective error is display as the relay toggles. ELTROPLAN-REVCON page 51...
- Page 53 These terminals may be used for an external ON-signal (external voltage 12 – 24V DC [e.g. from PLC], short time pulse) to start / reset the power feedback unit. (connect „Plus“ to terminal 11, „Minus“ to terminal 12) page 52 ELTROPLAN-REVCON...
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Page 54: Application Example
To proportion such a plant it is important to look at the worst case. The maxi- mum feedback power of the power feedback unit has to be higher as or , at a minimum, equal to the total amount of the braking power of the connected mo- tors. ELTROPLAN-REVCON page 53... -
Page 55: Installation Of A Power Feedback Unit In A Ce-Typical Drive System
RFI-filter) have to be connected to one common earthing point (PE-bus bar). • Observe the in the safety guidelines defined minimum cross sections: For EMC not the cross section, but the surface of a wire and the contact to the mount- ing plate is important for the function. page 54 ELTROPLAN-REVCON... -
Page 56: Installation
EMC guideline has to be carried out by the erector / user of the ma- chine / plant. If the by ELTROPLAN-REVCON released RFI-filters are used and the following measures and installation guidelines are observed, the adher- ence to the prescribed data is cleared. -
Page 57: Connection Of A Rfi-Filter
Funkentstörfilter flächig RFI-filter connect to mounting Additional grounding bond Zusätzliches Masseband mit der Montageplatte plate with big surface verbunden Mounting plate Montageplatte Potential equalisation to Potentialausgleich zur building ground Gebäudeerde Connected protective wire Schutzleiter angeschlossen Mains wire Netzleitung page 56 ELTROPLAN-REVCON... -
Page 58: Design Of An Emc-Conformal Cabinet
12. power feedback unit and power feedback unit: 13. mains connection cross section in accordance with fusing 14. PLC or short circuit proof! 15. Controller 6. motor wiring 16. mains fuses 7. control wiring 17. mains magnetic switch ELTROPLAN-REVCON page 57... -
Page 59: Remarks
Supervision of the protective wire by an module, which trips in case of an fault. Install a second wire in parallel to the protective wire via separate ter- minals. This wire must be conformal with VDE 0100 / part 540. page 58 ELTROPLAN-REVCON... -
Page 60: Installation Of Control Wires
If the screen is grounded via a single wire, the noise discharge is getting worse by 70%. For screen connection commercial cable clamps are suitable. If unscreened signal wires are used, install only twisted pair wires. ELTROPLAN-REVCON page 59... -
Page 61: Commissioning
– If beside the green LED also other LED’s are on: A disturbance is present. Before proceeding with commission- ing, re move the disturbance (refer to chapter 7 "Troubleshoot- ing”). Check the readiness for service of the controller: – Proceed in accordance with the controller manual. page 60 ELTROPLAN-REVCON... -
Page 62: Configuration
The unit is equipped with an error storage where special failures can be as- signed to. Stored error messages have to be confirmed by RESET or interrup- tion of mains supply. "Storage" always leads to a "switch-off" and to a collec- tive-error-relay tripping. ELTROPLAN-REVCON page 61... - Page 63 "ON" means that the error "phase failure" is shown via LED until you con- firm. Error storage "OFF" how-ever means that the error "phase failure" is shown via LED only as long as the failure is really existing. page 62 ELTROPLAN-REVCON...
- Page 64 — green — yellow overvoltage X X 0 — green 1.red yellow constant phase failure Remark: Jumper open — Jumper closed Jumper random Standard adjustment of the device Autostart and no switching off in case of phase failure ELTROPLAN-REVCON page 63...
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Page 65: Troubleshooting And Fault Elimination
The cause of periodical U cut offs may be over load, under voltage in the network, a defective or oscillating controller, an oscillating reference input or a wrong design of the plant. page 64 ELTROPLAN-REVCON... -
Page 66: Led-Messages
System off, at least two phases lost lost With option IFP: I²t-tripping ⇒ reset necessary Voltage breakdown during commuta- tion but without tripping as jumper 3 and 7 are open (chapter 6e) ⇒ operation possible, mains supply improvement recommended Table 7.1.1 ELTROPLAN-REVCON page 65... -
Page 67: Service
(depending on the degree of pollu- tion approx. every 4 weeks). Stop! STOP Don’t use sharp or tapering objects like knife or screw driver to clean the cooling air input. Clean the cooling air input with a vacuum cleaner. page 66 ELTROPLAN-REVCON... -
Page 68: Appendix
For choosing the best overvoltage suppressor for your specific application, please get in contact with one of our technicians. RFI-filter For technical data concerning the RFI-filter refer to chapter 3.3.4 (type over- view), 4.2.2 (dimensions) and 4.6.2 (connection). ELTROPLAN-REVCON page 67... - Page 69 ON-RESTE push button switch. STOP Stop: Don’t put an external voltage to the socket X4 of the control board or to the external operating and signalling panel. This may damage the device. page 68 ELTROPLAN-REVCON...
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Page 70: Revcon Product Overview
All products are available for 400V mains voltage, most of them as well for 230V, 460V, 500V and 690V! Depending on the product power from 4 up to 200kW may be transmitted. Most of the products may be connected in parallel, so that a power up to 1MW is possible! ELTROPLAN-REVCON page 69... -
Page 71: Contact
Appendix Contact Eltroplan-REVCON Elektrotechnische Anlagen GmbH Edisonstraße. 3 D-59199 Bönen Phone +49 (0)2383 920 22 22 +49 (0)2383 920 22 66 E-Mail info@REVCON.de www.REVCON.de < S > UBJECT TO CHANGE WITHOUT NOTICE 03/10 page 70 ELTROPLAN-REVCON... - Page 72 ........... 6, 10, 28 voltage, external ............68 machinery guideline ............8 warranty ..............5, 12 Mains frequency ............29 wires mains terminals ............. 34 screened ..............44 mains types ..............44 wiring schematic............47 mounting position ............37 ELTROPLAN-REVCON page 71...
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