Summary of Contents for Eltroplan REVCON DC Series
- Page 1 ELTROPLAN-REVCON Elektrotechnische Anlagen GmbH Operating instructions ® Power feed- and feedback unit REVCON DC(S) Power range 13 ... 135kW Voltage range 400V and 460V V 3.2 Issue 14/02...
-
Page 2: Table Of Contents
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Contents Preface and general information ..................3 About these Operating Instructions ..................3 1.1.1 Terminology used ....................... 3 1.1.2 Ordering code ........................4 Scope of delivery ......................... 4 Legal regulations ......................... 5 EC-Directives / Declaration of conformity ................6 1.4.1... - Page 3 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Contents Dimensions ........................41 4.2.1 Power feed/feedback unit ....................41 Electrical installation ......................44 4.3.1 Operator’s safety ......................44 4.3.2 Protection of the power feed/feedback unit ..............44 4.3.3 Mains types / Mains characteristics ................... 45 4.3.4...
-
Page 4: Preface And General Information
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Preface and general information Preface and general information About these Operating Instructions • These Operating Instructions help you to work properly on and with the power feed/feedback units REVCON DC(S). They contain safety information which... -
Page 5: Ordering Code
After receipt of delivery, check immediately whether the scope of supply matches with the accompanying papers. We do not accept any liability for deficiencies claimed subse- quently. Claim • Visible transport damage immediately to the forwarder. • Visible deficiencies/incompleteness immediately to ELTROPLAN REVCON. Operating instructions DC(S) -
Page 6: Legal Regulations
Instructions. • 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. -
Page 7: Ec-Directives / Declaration Of Conformity
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Preface and general information EC-Directives / Declaration of conformity 1.4.1 What is the purpose of EC-Directives? The EC-Directives have been drawn up by the European council to define common tech- nical standards and certification procedures within the European Community. At the moment there are 21 EC-Directives for product sectors. - Page 8 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Preface and general information EC-declaration of conformity According to the EC-Low Voltage Directive (2006/95/EC) The power feed/feedback units REVCON DC(S) have been developed, designed and manufactured in accordance with the above mentioned EC-Directive and in sole respon- sibility of ...
-
Page 9: Directive Machinery
When installing the machines, commissioning (i.e. the staring of operation as directed) the power feed/feedback unit is prohibited until it is proven that the machine corresponds to the regulations of the EC Directive 2006/42/EG (Machinery Directive). ELTROPLAN-REVCON Elektrotechnische Anlagen GmbH, Edisonstraße 3, D-59199 Bönen Operating instructions DC(S) -
Page 10: Ec-Directive Electromagnetic Compatibility
EMC. The rating became detected for typical plant constructions, but not for the several products. ELTROPLAN-REVCON Elektrotechnische Anlagen GmbH, Edisonstraße 3, D-59199 Bönen Operating instructions DC(S) -
Page 11: Safety Information
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Safety information Safety and application notes for controller (according to: Low voltage directive 2006/95/EG) General Erection During operation, power feed/feedback unit may have, according The devices must be erected and cooled according to the regula- to their type of protection, live, bare, in some cases also movable tions of the corresponding documentation. -
Page 12: General Safety Information
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information General safety information • These safety regulations are not entitled to completeness. In case of questions please contact our technicians. • When commissioning the power feed/feedback unit it is compliant with the state of the art. - Page 13 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information • Modifications of the power feed/feedback units without consultation of a REVCON -technician are not allowed generally. • The warranty given by us expires, if the unit is modified or (even partially) dis- mantled or if it is used in contradiction to our instructions.
- Page 14 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information • An undisturbed operation of the power feed/feedback unit is only probable, if the following instructions are observed. If these instructions are not observed, tripping of the unit and damages may occur.
- Page 15 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information • A standard fault-current circuit breaker (sensitive on peak currents) is not al- lowed to be used as the only protective measure when using controller and power feed/feedback unit Caused by a DC-component in the mains current a controller with 3-phase input voltage may prevent a fault-current circuit breaker from tripping in case of an earth fault.
-
Page 16: Safety-Responsible Persons
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Safety-responsible persons User • User is any natural or legal entity, who uses the drive system or by whom order the drive system is used. • The user respectively his security officer have to grant –... -
Page 17: Layout Of The Safety Information
ELTROPLAN - REVCO Elektrotechnische e Anlagen GmbH Safety information Layout of the s e safety information • All safety notes have e a uniform layout: - The icon character terizes the type of danger. - The signal word ch characterizes the severity of danger. -
Page 18: General Instructions
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information General instructions By this information to erectors and users of a plant hints on properties and directions con- cerning the power feed/feedback unit are given. These hints are not entitled to complete- ness. - Page 19 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Length of the DC-connection The maximum inductivity of the DC-connection between output B6 bridge of the inverter and the power feed/feedback device mustn't exceed a certain level, as this inductivity in- ducts an additional voltage to the DC-bus, when the IGBT’s are switched off.
- Page 20 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Operation on a generator The usage of a power feed/feedback unit within an island network (e.g. with an diesel generator) is possible, but there are restrictive regulations concerning the power lim- its.
- Page 21 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Operation on a transformer If only a few loads operate within a network section the connected transformer must be able to transport the in this section not used power back to the next voltage level without producing a not allowed voltage increase inside the section.
- Page 22 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Placing of the commutation choke If the frequency converter is connected to an external commutation choke, the connection of the power feed/feedback unit has to be done at its network terminals (figure 2.6.3). Is...
- Page 23 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Line and contact resistances The values of current carrying capacity of conductors refer to the most often used copper conductors. Concerning to their higher specific resistance aluminium conductors must have greater dimensions.
- Page 24 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Danger! Over voltages may cause serious damages to the connected frequency inverter and /or to the power feed/feedback unit and to the other loads. Current capacity of copper conductors for frequency inverters and power...
- Page 25 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Connection of further loads The connection of further loads (e.g. cabinet ventilation or climatisation) parallel to the frequency inverter / power feed/feedback unit at a common circuit breaker like in figure 2.6.5 is not allowed. If it's done nevertheless, in case of tripping of the circuit breaker the connection to the network (energy sink and synchronising element for the power feed/feedback unit) misses.
- Page 26 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Danger! Over voltages may cause serious damages to the connected controller and /or to the power feed/feedback unit and to the other loads. Supplying network REVCON 60kW Figure 2.6.6 Note! 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 feed back current circuit.
- Page 27 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Unchoked compensation plants and resonance rise Compensation plants are used in the centre of the power supply of a company. Distur- bances or damages at these plants have effects on the power supply and may result in in- terrupted production processes.
-
Page 28: Ul- Permission
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information UL- permission UL Report File E241278, Volume 2 This chapter is valid for the devices: DC(S) 460- 22, 33, 45, 70, 90 und 135 kW. SCCR (Short-circuit current rating): 200kA Suitable for use on a circuit capable of delivering not more than 200000 rms symmetrical Amperes. -
Page 29: Technical Data
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Technical data Characteristics • Small compact enclosure • Power supply for one ore more controllers • Braking power of controller is fed back into mains • Power range 90kW • DC-bus coupling of several controllers possible •... -
Page 30: General Data / Application Conditions
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data General data / application conditions Range Values Permissible temperature During transport of the unit: -25°C...+70°C (to VDE 0160) range* During storage of the unit: -25°C...+55°C (to VDE 0160) During operation of the unit: 5°C... -
Page 31: Rated Data
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Rated data 3.3.1 Power feed/feedback unit REVCON type DC(S) 400V DC(S) 460V DC(S) 500V Nominal range of the [V] 380 ≤ U ≤ 415 440 ≤ U ≤ 480 interlinked mains voltage... -
Page 32: Current Load
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data 3.3.2 Current load Nominal voltage 400V Driving Operation Braking Operation ® REVCON Max. input current Max. input current Max. current Max. current DC(S)- 13-400-1-0 53 A 73 A 19 A 23 A... -
Page 33: Hints For Proportion
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data 3.3.3 Hints for proportion Driving Operation Braking Operation Flyback Diodes IGBT-modules (kW) max. (A) (kW) max. (A) Driving Eff/Phase Braking Eff/Phase ® REVCON 100% 1 min in 100% 1 min in... - Page 34 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Note! Like the input of a controller the input of the REVCON -feed- and feedback unit is not pro- tected for overload. Therefore it is necessary to pay attention not to exceed the maximum input ...
-
Page 35: Thermal Limited Load Graphs
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data 3.3.4 Thermal limited load graphs By means of these thermal limited load graphs you can find out the maximum switch-on- time depending on the needed braking power. The curves are valid for a maximum cool- ing air temperature of 40°C (108°F). - Page 36 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Thermal limited load graphs: REVCON DC(S) 90-460-1-0 100 % constant power: 45 kW Braking time 60 kW 90 kW Intermission time Diagram 3.3.4.1.2 REVCON DC(S) 45-400-1-0 and DC(S) 45-460-1-0...
- Page 37 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data REVCON DC(S) 90-400-1-0 and DC(S) 90-460-1-0 100 % constant power: 40 kW Braking time 60 kW 90 kW Intermission time Diagram 3.3.4.1.5 REVCON...
-
Page 38: Fuses And Wire Cross Sections
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data 3.3.5 Fuses and wire cross sections The power feed/feedback unit is connected to mains supply via the terminals L at the external commutation choke. Mains fuses must be designed according to the current load capacity of the supply wire. -
Page 39: Internal Fuses
CL ≅ Cable lug At the fuse holder respective disconnector Stop! If semiconductor fuses trip, please get in contact with ELTROPLAN-REVCON immediately, as STOP possibly further protective measures have tripped. If internal fuses are exchanged, please verify that only the original types are used for replacement. -
Page 40: Switch On Current Limiter
DC-bus capacitors. The maximum value of the inrush current must not ex- ceed the rated values of tables 3.3.2.1 to 3.3.2.2. Stop! An operation with other types of pre load circuits is allowed only after release by ELTROPLAN STOP –REVCON and after a corresponding modification of the units. -
Page 41: Installation
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Installation Mechanical installation 4.1.1 Important hints • Use the power feed/feedback units as build-in devices only! • Observe free spaces! Several power feed/feedback units in one cabinet may be installed next to each other without spacing. -
Page 42: Dimensions
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Dimensions 4.2.1 Power feed/feedback unit 4.2.1.1 Dimension diagrams Construction 1/500 DC(S) 13-400-... DC(S) 45-400-... und DC(S) 13-460-... DC(S) 45-460- Operating instructions DC(S) - Page 43 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Construction 1/500 DC(S) 70-400-… to DC(S) 135-460- DC(S) 70-460-… to DC(S) 135-400- Operating instructions DC(S)
- Page 44 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Construction 3/800 DC(S) 160-400... DC(S) 200-400 und DC(S) 160-460... DC(S) 200-460 Operating instructions DC(S)
-
Page 45: Electrical Installation
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Electrical installation 4.3.1 Operator’s safety Danger! After mains disconnection, the DC-bus terminals of the power feed/feedback unit remain live for several minutes! The exact time, till this voltage has decreased to a not dangerous value is de- pendant on the used controller and has to run down before any service operations or similar ac- tivities are started. -
Page 46: Mains Types / Mains Characteristics
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation 4.3.3 Mains types / Mains characteristics Danger! Observe the restrictions in accordance to the respective mains type! If you want to run power feed/feedback units at mains types, which are not listed in the table below please consult our technicians. -
Page 47: Mains Resp. Commutation Chokes (Option)
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation 4.3.5 Mains resp. Commutation chokes (Option) Wiring refer to figure 4.4.1.1.1 – Connected mains choke (commutation choke) ® REVCON Nominal inductance* Nominal current** Type brand Berg Type brand Berg DC(S) choke... - Page 48 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Stop! When choosing the mains chokes it is necessary to observe that they are also suitable for the STOP driving current. Note! When using the power feed/feedback unit with mains choke, at this choke the voltage is reduced.
-
Page 49: Connection
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Connection The supply line must be connected at the lead-through terminal at the bottom side of the enclosure. Stop! At the connection of cable lugs at screws or bolts which lead through conductor rails it must be... - Page 50 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Connection • All connections should be as short and low-impedance as possible. • For the observance of the EMC-guideline (in accordance to actual standards like VDE 0160 and EN 50178) screened wires have to be used.
-
Page 51: Wiring Schematic
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation 4.4.1.1 Wiring schematic RFI-filter The Connection of several controllers is possible! L2 L3 Preload ⇐ To the inverter REVCON DC(S)… Controller Control Relay Ext. ON Error message RESET PE U +24 V... - Page 52 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Legend for figure 4.4.1.1.1 (REVCON DC(S)) Fusing in accordance with this manual. It is not allowed to connect any other devices except the frequency inverter and the power feed/feedback unit behind the main magnetic switch.
-
Page 53: Control Wires
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation 4.4.2 Control wires • Connect the control wires to the terminal row X2 at the control terminal (case type 1/500) of the power feed/feedback unit. • Don’t parallel control wires to interfering power wires. - Page 54 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Space diagram of the control board REV 1.4.X terminal X3 connection to terminal X5, X8 driver board option J5 J3 REVCON V. 1.4.3 from version 1.4.2 terminal X1 terminal X2 synchronisation to ext.
- Page 55 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Terminal usage: Collective error relay Terminal 5 and 6 intern connected to the temperature supervision Stop Stop RESET RESET ON/RESET Figure 4.4.4.2 Terminals 1-4 (refer to figure 4.4.4.2) These terminals are contacted to two potential free (SELV) relay contacts (one NOC and one NCC) with a maximum current load of 5 A AC or 3 A DC.
- Page 56 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Terminals 5 and 6 These terminals are already used for the internal temperature supervision of the heat sink. Terminals 7 to 10 These terminals are internally used or unused. Terminal 11 and 12 (Used screened wires only) These terminals may be used for an external ON -signal (external voltage 12 –...
-
Page 57: Application Example
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Application example REVCON REVCON REVCON DC(S) 70... DC(S) 45... DC(S) 70... Monkey device Elevation device Driving device Figure 4.5.1 Within greater plants several power feed/feedback units may be coupled. Figure 4.5.1 shows an example of a crane system with some possible combinations. -
Page 58: Installation Of A Power Feed/Feedback Unit In A Ce-Typical Drive System
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Installation of a power feed/feedback unit in a CE-typical drive system General • The user is responsible for the compliance of his application with the EC directives. If you observe the following measure you can be sure that the drive system will not cause any power-feed/feedback-unit-caused EMC problems, i.e. -
Page 59: Installation
EMC guideline has to be carried out by the erector / user of the machine / plant. If the by ELTROPLAN-REVCON released RFI-filters are used and the following measures and installation guidelines are observed, the adherence to the prescribed data is cleared. -
Page 60: Connection Of A Rfi-Filter
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Use copper or tinned copper screened wires only, as steel screened wires are not suitable for high frequency applications. Connect the screen with metal clamps or metal glands to the equalisation bars or PE-connections. Don’t longer the screen with single wires! If external RFI-filters are use, these have to be mounted not more than 30cm away from the noise source and with a very good, low resistive based contact. -
Page 61: Design Of An Emc-Conformal Enclosure
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation 4.8.3 Design of an EMC-conformal enclosure 1. Cabinet 8. DC-bus wiring 2. - with power feed/feedback unit (DC) 9. Mounting plate (common star point) 3. RFI-filter 10. Potential equalisation 4. Mains supply wire 11. -
Page 62: Remarks
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation 4.6.4 Remarks Generally a system should be divided in an area for power electronics and an area for con- trol electronics. This is not only important, if the system is mounted in one cabinet, but even also if it is spread over several cabinets. -
Page 63: Installation Of Control Wires
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation 4.6.5 Installation of control wires The screen of digital signal wires, which are not connected to terminals, has to be con- nected to the screen bars to decrease the impedance of the screen. -
Page 64: Commissioning
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Commissioning Commissioning Danger! Prior to initial switch-on of the power feed/feedback unit check the wiring for completeness, short-circuit and earth fault. It is absolutely necessary to install the inrush current limit circuit of the controller between the DC-output to the REVCON and the DC-bus capacitors. -
Page 65: First Powering Up
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Commissioning First powering up When powering up the first time the jumper J3 on the control board must be closed (it is closed at all new units), to enable the phase loss supervision circuit to verify the phase sequence. -
Page 66: Configuration
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Configuration Configuration The coding of the jumpers enables different driving possibilities and different internal functions in accordance to specific error messages. In the following different definitions are explained which result from the specific possibili- ties of coding! a) „Switch on“... - Page 67 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Configuration The power feed/feedback unit reacts in different ways on phase failures. One possibility is the "2 phase operation", the other one let the system get out of operation and the collec- tive-error-relay signals the failure.
- Page 68 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Configuration e) „Overvoltage supervision“ Since the control board version 1.4.3 the device has an overvoltage supervision for the mains which switches off the device in the case of a voltage level of approximately 1,15 x U and above.
-
Page 69: Troubleshooting And Fault Elimination
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Troubleshooting and fault elimination Troubleshooting and fault elimination The five LED's in the cover of the power feed/feedback unit display the operating condi- tion. For easier visibility during service and first powering up similar LED's are placed on the control board. -
Page 70: Led-Messages
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Troubleshooting and fault elimination LED-messages LED – display LED-display: Operation Phase failure Overtemperature Disturbance Error code: Green Orange Yellow Table 7.1.1 Operating instructions DC(S) - Page 71 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Troubleshooting and fault elimination Status report Relay LED-display At commissioning During operation Error code: Ready to operate System in operation Relay in (after approx. 1s) resting position Ready for operation, but no power feedback...
-
Page 72: Service
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Serivice Service The power feed/feedback unit is maintenance-free, if the provided application conditions are observed (refer to chapter 3.2). If the cooling air is polluted, the cooling air input may be blocked. Therefore check the power feed/feedback unit periodically (depending on the degree of pollution approx. -
Page 73: Appendix
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Appendix Appendix Options Fuse holder with fuses for mains supply In accordance with table 3.3.3.1.1-5 for the power feed/feedback unit the following fuses are available: ® REVCON - type Order designation Case type... - Page 74 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Appendix Overvoltage-suppressor If the power feed/feedback unit (as well as a controller) is connected to ungrounded mains supply, it only may be run, either if it is connected via an isolating transformer or if the plant is protected by overvoltage suppressors.
-
Page 75: Revcon Product Overview
ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Appendix REVCON Product overview ® REVCON Power feedback units for continuous operation (Engine test beds, escalators, wind energy plants, elevators etc.) ® REVCON Power supply- and feedback unit For multiple motor applications with dynamic alternation of loads) ®... -
Page 76: Contact
Eltroplan- REVCON -staff, unless that these have acted inten- ® tional or grossly negligent. Eltroplan- REVCON reserves the right to perform, without previous an- nouncements within the appropriate and reasonable changes at their products - also at already com- missioned. - Page 77 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Index mounting position............40 application conditions ........... 29 operating and signalling board, external ...... 73 operator’s safety ............16, 44 ordering code ..............4 overvoltage suppressor ..........73 basic standard ............... 58 patents rights ..............5 cable glands ..............
Need help?
Do you have a question about the REVCON DC Series and is the answer not in the manual?
Questions and answers