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REVCON RLD E0 Operating Instructions Manual

Power feedback unit
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ELTROPLAN-REVCON
Elektrotechnische Anlagen GmbH
Operating instructions
Power feedback unit REVCON
Power range
Voltage range
500V, 690V
V 1.0
Issue 15/07
®
RLD E0
4 ... 400 kW
230V, 400V, 460V,

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Summary of Contents for REVCON RLD E0

  • Page 1 ELTROPLAN-REVCON Elektrotechnische Anlagen GmbH Operating instructions ® Power feedback unit REVCON RLD E0 Power range 4 ... 400 kW Voltage range 230V, 400V, 460V, 500V, 690V V 1.0 Issue 15/07...

  • Page 2: Table Of Contents

    Characteristics ............................. 29 General data / application conditions ....................30 Rated data ............................31 3.3.1 Power feedback unit REVCON RLD B0 ....................31 3.3.2 Power feedback unit REVCON RLD D0 ....................32 3.3.3 Power feedback unit REVCON RLD B1/D1 .................... 33 3.3.4...
  • Page 3 4.4.1.2 Wiring schematic REVCON RLD D0/D1 ....................88 4.4.1.3 Wiring schematic REVCON RLD B0/D0 with RHF-RA ................90 4.4.1.4 Wiring schematic REVCON RLD B0/D0 and FC with RHF-RA ..............92 4.4.2 Fan supply ............................95 4.4.3 Control wires ............................95 4.4.4...

  • Page 4: Preface And General Information

     • All persons who work on and with the power feedback units REVCON RLD must have the Operation instructions available and observe all relevant notes and instruc- tion.

  • Page 5: Ordering Code

    For up to 50% duty cycle harmonic filter Scope of delivery  • 1 Power feedback unit REVCON • 1 Operating instructions • After receipt of the delivery verify immediately, if the scope of supply correspond to the shipping documents. We make no warranty for later complained defects Claim •...

  • Page 6: Product Selection

    → REVCON Type RLD B is sufficient for drives with direct DC-Bus connection. → REVCON Type RLD D is required for drives with DC-Bus connection via the DC- choke(s). This unit contains additional capacity to compensate the magnetic energy from the DC choke in case of a system shutdown.

  • Page 7: 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 8: Ec-Directives / Declaration Of Conformity

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Preface and general information EC-Directives / Declaration of conformity 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 mo- ment there are 21 EC-Directives for product sectors.

  • Page 9: Ec-Directive Electromagnetic Compatibility

    EC-declaration of conformity According to the EC-Low Voltage Directive (2006/95/EEC)  The power feedback units REVCON RLD have been developed, designed and manufac- tured in accordance with the above mentioned EC-Directive and in sole responsibility of ELTROPLAN-REVCON Elektrotechnische Anlagen GmbH, Edisonstraße 3, D-59199 Bönen...

  • Page 10: Ec-Directive Machinery

    Elektrotechnische Anlagen GmbH, Edisonstraße 3, D-59199 Bönen  The operation of the Energy feedback units REVCON RLD is prohibited as long as it is determined, that the machine, in which it should be installed, conforms to the regulations of the EG-directive machines.

  • Page 11: Safety Information

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Safety information Safety and application notes for drive converters (Low-Voltage Directive (2006/95/EEC) General Erection During operation, power feedback unit may have, according to The devices must be erected and cooled according to the regula- their type of protection, live, bare, in some cases also movable or 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 feedback unit is compliant with the state of the art.
  • Page 13 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information  • Modifications of the power 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) dismantled 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 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 allowed to be used as the only protective measure when using controller and power feedback unit Caused by a DC-component in the mains current a controller with 3-phase input volt- age may prevent a fault-current circuit breaker from tripping in case of a 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 he Anlagen GmbH Safety information Layout of the s e safety information • All safety no notes have a uniform layout: The icon c n characterizes the type of danger. The signa nal word characterizes the severity of danger. The note d te describes the danger and suggests how to avo void the 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 feedback unit are given. These hints are not entitled to completeness.
  • 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 frequen- cy converter and the power feedback device must not exceed an assigned value, as this in- ductivity inducts an additional voltage to the DC-bus of the frequency converter, when the IGBT’s are switched off.
  • Page 20  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Typical capacitance of the DC-connection inside the power feedback unit: ® REVCON -type Power DC-capacitance [kW] [µF] RLD B 400V RLD B 400V RLD B 400V RLD B 400V RLD B 400V...
  • Page 21  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Example: C=220µF, ∆U =100V, î =160A, a=80mm, r=8,5mm, µ =1,257 ∆ ⋅ µ ⋅ − ´ ˆ ′ ′ ⋅ π ⇒ l =26m For longer DC-Bus-wires additional capacitors have to be installed (please get in contact with our application-department if the occasion arises).
  • Page 22  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Operation on a generator The usage of a power feedback unit within an isolated network (e.g. with a diesel genera- tor) is possible, but there are restrictive regulations concerning the power limits.
  • Page 23  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Operation on a transformer Is the energy balance of an installation negative (i.e. even for short periods more braking energy is fed in as the other loads in the same mains section collect), the nominal (com-...
  • Page 24  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 feedback unit has to be done at its network terminals (figure 2.6.3). Is the...
  • Page 25  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 its higher specific resistance aluminium conductors must have greater dimensions.
  • Page 26  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Danger! Over voltages may cause serious damages to the connected frequency converter and /or to the power feedback unit and to the other loads. Current capacity of copper conductors for frequency converters and power feed-...
  • Page 27  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 feedback unit at a common circuit breaker like in figure 2.6.5 is not allowed.
  • Page 28  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Safety information Danger! Over voltages may cause serious damages to the connected controller and /or to the power feed- back 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.
  • Page 29  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. Disturb- ances or damages at these plants have effects on the power supply and may result in inter- rupted production processes.

  • Page 30: Technical Data

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Technical data Characteristics • Small compact housing • Braking power of controller is fed back into mains • Power range 4kW to 400kW • Up to 4 units can be paralleled (more on request) •...

  • Page 31: 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 32: Rated Data

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Rated data 3.3.1 Power feedback unit REVCON RLD B0 RLD B0 RLD B0 RLD B0 RLD B0 RLD B0 ® REVCON type 230V 400V 460V 500V 690V Nominal range of the [V] 220 ≤...

  • Page 33: Power Feedback Unit Revcon Rld D0

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data 3.3.2 Power feedback unit REVCON RLD D0 RLD D0 RLD D0 RLD D0 RLD D0 RLD D0 REVCON type 230V 400V 460V 500V 690V Nominal range of the [V] 220 ≤ U 380 ≤...

  • Page 34: Power Feedback Unit Revcon Rld B1/D1

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data 3.3.3 Power feedback unit REVCON RLD B1/D1 REVCON type RLD B1/D1 400V Nominal range of the interlinked mains 380 ≤ U ≤ 415 voltage Tolerance of the -15% / +10% interlinked mains...

  • Page 35: Current Load Revcon Rld B0

    Elektrotechnische Anlagen GmbH Technical data 3.3.4 Current load REVCON RLD B0 Note! To calculate the correct value of regenerating power it is necessary to note, that the real momen- tary regenerating power is dependent on the real existing main circuit voltage at any time. To calculate the regenerative power the following formula should be used: ·...
  • Page 36  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Nominal voltage 400V ® REVCON ® REVCON - type item number Max. current I Max. current I [A] RLD B0 7-400-50-0-A 21011001 RLD B0 13-400-50-0-A 21011002 RLD B0 22-400-50-0-A 21011003 RLD B0 33-400-50-0-A...
  • Page 37  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Nominal voltage 500V ® REVCON ® REVCON - type item number Max. current I Max. current I [A] RLD B0 22-500-50-0-A 21011021 RLD B0 33-500-50-0-A 21011022 RLD B0 45-500-50-0-A 21011023 RLD B0 70-500-50-230-A...

  • Page 38: Current Load Revcon Rld D0

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data 3.3.5 Current load REVCON RLD D0 Nominal voltage 230V ® REVCON ® REVCON - type item number Max. current I Max. current I [A] RLD D0 6-230-50-0-A 21014142 RLD D0 10-230-50-0-A...
  • Page 39  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Nominal voltage 460V ® REVCON ® REVCON - type item number Max. current I Max. current I [A] RLD D0 15-460-60-0-A 21014022 RLD D0 24-460-60-0-A 21014023 RLD D0 33-460-60-0-A 21014024 RLD D0 42-460-60-0-A...

  • Page 40: Current Load Revcon Rld B1/D1

    RLD B 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 RLD B 33-XXX-1-... the following thermal limited load graphs are valid.

  • Page 41: Thermal Limited Load Graphs

    By means of these thermal limited load graphs you can find out the maximum switching- on time depending on the needed braking power. The curves are valid for a maximum cooling air temperature of 35°C (95°F). Example of an application: REVCON RLD B 45-XXX-1-... 33 kW 100 % constant power: 26 kW braking...
  • Page 42  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Thermal limited load graphs: REVCON RLD B 33-XXX-1-... 27 kW 100 % constant power : 21,5 kW braking time 33 kW intermission time Diagram 3.5.1.1.2 REVCON RLD B -XXX-1-... 100 % constant power with fan: 26 kW...
  • Page 43  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data     REVCON RLD B 90-XXX-1-... 100 % constant power : 38 kW braking time 52 kW 90 kW intermission time Diagram 3.5.1.1.5     REVCON RLD B 135-XXX-1-...
  • Page 44 RLD B 200-XXX-1-... 100 % constant power : 120 kW braking time 135 kW 200 kW intermission time Diagram 3.5.1.1.8 REVCON RLD B 250-XXX-1-... 100 % constant power: 135 kW Braking time 170 kW 250 kW Intermission time Diagram 3.5.1.1.9 REVCON RLD B 345-XXX-1-...
  • Page 45  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data REVCON RLD B 345-XXX-1-... 100 % constant power: 200 kW Braking time 230 kW 345 kW Intermission time Diagram 3.5.1.1.11 Operating instructions RLD...

  • Page 46: Fuses And Wire Cross Sections

    Stop! If semiconductor fuses (figure 4.4.1.1 position1and 8, figure 4.4.1.2 and 4.4.1.3 position 1 and 7 and figure 4.4.1.4 position 1 and 9) trip, please get in contact with ELTROPLAN-REVCON STOP immediately, as possibly further protective measures have tripped. If internal fuses are ex- changed, please verify that only the original types are used for replacement.
  • Page 47  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Connection terminal ® REVCON - type Max. fuse AC and max. Cross section RLD B0 of the supply line* 7-400-50-0-A Siba 5012406.20 20A 690V 10x38mm 25mm² 13-400-50-0-A Siba 5017906.30 30A 690V 14x51mm 25mm²...
  • Page 48 Siba 2071332.630 630A 1100V NH 01 240mm² Table 3.6.1.5 ES ≅ End sleeve for strands CL ≅ Cable lug At the fuse holder respective disconnector Series fuses REVCON RLD D0 Connection terminal ® REVCON - type Max. fuse AC and max. Cross section...
  • Page 49  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Connection terminal ® REVCON - type Max. fuse AC and max. Cross section RLD D0 of the supply line* 15-460-60-0-A Siba 5012406.32 32A 690V 14x51mm 25mm² 24-460-60-0-A Siba 5012406.50 50A 690V 14x51mm 25mm²...
  • Page 50 (e.g. Jean Müller, Ferraz, and Bussmann) are suitable. 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 51: Revcon - Type Rld

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data DC-fuses ® REVCON - type (use fast acting semiconductor fuses only) RLD B0 7-400-50-0-A RLD B0 13-400-50-0-A RLD B0 22-400-50-0-A RLD B0 33-400-50-0-A Siba 5014006.80 80A 690V 22x58mm RLD B0 45-400-50-0-A Siba 5014206.135 135A 690V 22x58mm...
  • Page 52 Siba 2018920.315 315A 690V NH 00 RLD B0 300-690-50-230-A Siba 2018920.400 400A 690V NH 00 RLD B0 350-690-50-230-A Siba 2077132.500 500A 1250V NH 01 Table 3.6.1.16 Internal fuses REVCON RLD D0 DC-fuses ® REVCON - type (use fast acting semiconductor fuses only)

  • Page 53: Siba 5012406.32

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data DC-fuses ® REVCON - type (use fast acting semiconductor fuses only) RLD D0 15-460-60-0-A Siba 5012406.32 32A 690V 14x51mm RLD D0 24-460-60-0-A Siba 5012406.50 50A 690V 14x51mm RLD D0 33-460-60-0-A Siba 5014006.80...

  • Page 54: Rfi-Filter Revcon Rld B0

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data Internal fuses REVCON RLD B1/D1 DC-fuses ® REVCON - type (use fast acting semiconductor fuses only) RLD B1/D1 7-400-50-0-A Siba 5012406.20 20A 690V 14x51mm RLD B1/D1 13-400-50-0-A Siba 5012406.50 50A 690V 14x51mm RLD B1/D1 22-400-50-0-A Siba 5014006.63...

  • Page 55: 7-400-50-0-A

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data ® REVCON - type Order designation Item-Number Max. Mains connection RLD B0 filter RFI cross-section 7-400-50-0-A RFI-RA 01 31300101 13-400-50-0-A RFI-RA 01 31300101 22-400-50-0-A RFI-RA 01 31300101 33-400-50-0-A RFI-RA 12 31300102...

  • Page 56: Rfi-Filter Revcon Rld D0

    RFI-RA V4 31300112 250-690-50-230-A RFI-RA V7 31300113 300-690-50-230-A RFI-RA V7 31300113 350-690-50-230-A RFI-RA V7 31300113 Table 3.7.1.5 RFI-filter REVCON RLD D0 ® REVCON - type Order designation Item-Number Max. Mains connection RLD D0 filter RFI cross-section 6-230-50-0-A RFI-RA 12 31300102...
  • Page 57  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data ® REVCON - type Order designation Item-Number Max. Mains connection RLD D0 filter RFI cross-section 15-460-60-0-A RFI-RA 12 31300102 24-460-60-0-A RFI-RA 12 31300102 33-460-60-0-A RFI-RA 12 31300102 42-460-60-0-A RFI-RA 12 31300102...

  • Page 58: Rfi-Filter Revcon Rld B1/D1

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data RFI-filter REVCON RLD B1/D1 ® REVCON - type Order designation Order number Max. Supply connection RLD B1/D1 RFI cross- section 7-400-50-0-A RFI-RA 12 31300102 13-400-50-0-A RFI-RA 12 31300102 22-400-50-0-A RFI-RA 12...

  • Page 59: Harmonic Filter Module Rhf-Ra Module

    Harmonic filter module RHF-RA module  To decrease the low frequency harmonic back effects to mains a filter module REVCON RHF-RA can be connected to the power feedback unit according figure 4.4.1.3 and 4.4.1.4* In the tables 3.11.1.1 to 3.12.1.4 the corresponding filter modules are listed for the power feedback unit.

  • Page 60: Rhf-Ra Module Rld D0

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data ® ® REVCON REVCON - type Ordering code Case type item number RHF- module RLD B0 22-500-50-0-A RHF-RA 29-500-50-0-A 25070083 inside RLD B0 33-500-50-0-A RHF-RA 36-500-50-0-A 25070084 inside RLD B0 45-500-50-0-A...
  • Page 61  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Technical data ® ® REVCON - type Ordering code REVCON Case type item number RHF- module RLD D0 15-460-60-0-A RHF-RA 19-460-60-20-A 25070022 inside RLD D0 24-460-60-0-A RHF-RA 31-460-60-20-A 25070024 inside RLD D0 33-460-60-0-A...

  • Page 62: Installation

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Installation Mechanical installation 4.1.1 Important hints • Use the power feedback units as build-in devices only! • Observe free spaces! Several power feedback units in one cabinet may be installed next to each other without spacing.

  • Page 63: Dimensions

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Dimensions Nominal voltage 230V Dimensions Weight Power loss* ® REVCON Type Enclosure Height Width Depth [kg] [mm] [mm] [mm] RLD-B0 4-230-50-0-A 1/500 RLD-B0 7-230-50-0-A 1/500 RLD-B0 12-230-50-0-A 1/500 RLD-B0 18-230-50-0-A 1/500 RLD-B0 22-230-50-0-A...
  • Page 64  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Nominal voltage 460V Dimensions Weight Power loss* ® REVCON Type Enclosure Height Width Depth [kg] [mm] [mm] [mm] RLD-B0 22-460-60-0-A 1/500 RLD-B0 33-460-60-0-A 1/500 RLD-B0 45-460-60-230-A 1/500 RLD-B0 70-460-60-230-A 2/700 RLD-B0 90-460-60-230-A...
  • Page 65  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Nominal voltage 690V Dimensions Weight Power loss* ® REVCON Type Enclosure Height Width Depth [kg] [mm] [mm] [mm] RLD-B0 24-690-50-230-A 2/700 RLD-B0 45-690-50-230-A 2/700 RLD-B0 70-690-50-230-A 2/700 RLD-B0 90-690-50-230-A 2/700 RLD-B0 150-690-50-230-A...
  • Page 66  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Nominal voltage 400V Dimensions Weight Power loss* ® REVCON Type Enclosure Height Width Depth [kg] [mm] [mm] [mm] RLD-D0 8-400-50-0-A 0/340 RLD-D0 11-400-50-0-A 0/340 RLD-D0 18-400-50-0-A 0/340 RLD-D0 28-400-50-0-A 1/500 RLD-D0 38-400-50-0-A...
  • Page 67  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Nominal voltage 500V Dimensions Weight Power loss* ® REVCON Type Enclosure Height Width Depth [kg] [mm] [mm] [mm] RLD-D0 17-500-50-0-A 1/500 RLD-D0 27-500-50-0-A 1/500 RLD-D0 37-500-50-0-A 1/500 RLD-D0 45-500-50-0-A 2/700 RLD-D0 70-500-50-230-A...
  • Page 68  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation 1. Enclosure 0/340 Operating instructions RLD...
  • Page 69  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation 2. Enclosure 1/500 Operating instructions RLD...
  • Page 70  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation 3. Enclosure 2/700 Operating instructions RLD...
  • Page 71  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation 4. Enclosure 3/800 Operating instructions RLD...
  • Page 72  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation 5. Enclosure 3/801 Operating instructions RLD...
  • Page 73  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation 6. Enclosure 3/802 Operating instructions RLD...

  • Page 74: Rfi-Filter

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation 4.2.1 RFI-filter The radio interference filter of case-type 1 and 2 are mounted in footprint-housings, which could be placed between cabinet-wall and power feedback unit. The radio interference filter of case-type 3 and 4 are mounted in housings, which should be placed beside the power feedback unit.
  • Page 75  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Diagram RFI-RA 12 Diagram RFI-RA 23 Operating instructions RLD...
  • Page 76  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Diagram RFI-RA X5 Diagram RFI-RA X6 Operating instructions RLD...
  • Page 77  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Diagram RFI-RA X7 and X8 7. Diagram RFI-RA V2, V4 und V7 Operating instructions RLD...

  • Page 78: Rhf-Ra-Filter

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation 4.2.2 RHF-RA-filter Diagram X1 Diagram X2 Operating instructions RLD...
  • Page 79  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Diagram X3 4. Diagram X4 Operating instructions RLD...
  • Page 80  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation 5. Diagram X5 Diagram X5 Operating instructions RLD...
  • Page 81  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Diagram X6 Diagram X7 Operating instructions RLD...
  • Page 82  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Installation Diagram X8: Internal fan Diagram X8: external fan Operating instructions RLD...

  • Page 83: 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 feedback unit remain live for sev- eral minutes! The exact time, till this voltage has decreased to a not dangerous value is depend- ent on the used controller and has to run down before any service operations or similar activities are started.

  • Page 84: 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 feedback units at mains types, which are not listed in the table below please consult our technicians.

  • Page 85: 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. 4.4.1 Power connection Fusing (also refer to chapter 3.3.4) • The specifications of chapter 3.3.4 (fuses and wire cross sections) are recommenda- tions and refer to the operation –...
  • Page 86  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 87: Wiring Schematic Revcon Rld B0/B1

    4.4.1.1 Wiring schematic REVCON RLD B0/B1  Figure 4.4.1.1: Wiring schematic of the power feedback unit REVCON RLD B0/B1 and one or more controller Note! This is a wiring example. Special features of an application (e.g. installation of a PLC) may re- quire modifications of the wiring of the terminals X2.1 ...
  • Page 88 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation     Legend for figure 4.4.1.1 (REVCON RLD B0/B1) Fusing in accordance with controller manual. It is not allowed to connect any other devices except the frequency inverter and the power feedback unit behind the main magnetic switch.

  • Page 89: Wiring Schematic Revcon Rld D0/D1

    4.4.1.2 Wiring schematic REVCON RLD D0/D1  Figure 4.4.1.2: Wiring schematic of the power feedback unit REVCON RLD B0/B1 and one or more controller Note! This is a wiring example. Special features of an application (e.g. installation of a PLC) may re- quire modifications of the wiring of the terminals X2.1 ...
  • Page 90 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation     Legend for figure 4.4.1.2 (REVCON RLD D0/D1) Fusing in accordance with controller manual. It is not allowed to connect any other devices except the frequency inverter and the power feedback unit behind the main magnetic switch.

  • Page 91: Wiring Schematic Revcon Rld B0/D0 With Rhf-Ra

    Electrical Installation 4.4.1.3 Wiring schematic REVCON RLD B0/D0 with RHF-RA  Figure 4.4.1.3: Wiring schematic of the power feedback unit REVCON RLD B0/D0 with RHF-RA and one or more controller Note! This is a wiring example. Special features of an application (e.g. installation of a PLC) may re- quire modifications of the wiring of the terminals X2.1 ...
  • Page 92 ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation     Legend for figure 4.4.1.3 (REVCON RLD B0/D0 with RHF-RA) Fusing in accordance with controller manual. It is not allowed to connect any other devices except the frequency inverter and the power feedback unit behind the main magnetic switch.

  • Page 93: Wiring Schematic Revcon Rld B0/D0 And Fc With Rhf-Ra

    Electrical Installation 4.4.1.4 Wiring schematic REVCON RLD B0/D0 and FC with RHF-RA  Figure 4.4.1.4: Wiring schematic of the power feedback unit REVCON RLD B0/B1 and FC with RHF-RA and one or more controller Note! This is a wiring example. Special features of an application (e.g. installation of a PLC) may re- quire modifications of the wiring of the terminals X2.1 ...
  • Page 94 RHF-RA! At non observance damages at the RHF-RA and / or the frequency converter cannot be excluded!     Legend for figure 4.4.1.4 (REVCON RLD B0/D0 and FC with RHF-RA Fusing in accordance with controller manual.
  • Page 95  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation The „ON“ or „RESET“ signal may be initiated via terminals 11 and 12: Terminals 11 and 12: Positive pulse (12-24 V DC); practicable e.g. via PLC (terminal 11 +, terminal 12 -).

  • Page 96: Fan Supply

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation 4.4.2 Fan supply Power feedback modules of a higher power stage are equipped with two terminals (blue terminal = neutral [N], grey fuse terminal = phase [L]) for the supply of the internal fan(s).
  • Page 97  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 98  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Terminal usage: Common fault relay Terminal 5 and 6 intern connected to the temperature supervision External used ON/RESET Figure 4.4.4.2 Note! The terminals 5,6,9 and 10 are not lead through. Operating instructions RLD...
  • Page 99  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation 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. It is not allowed to con- nect other voltage types than SELV! In figure 4.4.4.2 the relay is displayed in rest position.

  • Page 100: Application Example

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Application example Figure 4.5.1 Within greater plants several power feedback units may be coupled. Figure 4.5.1 shows an example of a crane system with some possible combinations. The operation of several inverters at one common DC-bus allows reducing the amount of power feedback units.

  • Page 101: Installation Of A Power Feedback Unit In A Ce-Typical Drive System

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation Installation of a power 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 102 EMC directive 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 directives are observed, the adherence to the prescribed data is cleared.

  • Page 103: Installation

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation 4.6.1 Installation Appropriate design of pant and cabinet: To avoid noise in coupling lay a) Mains/supply wires b) Motor wires of controllers / servo amplifiers c) Control- and data wires (small voltage range < 48 V)

  • Page 104: Connection Of A Rfi-Filter

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation 4.6.2 Connection of a RFI-filter The following figure shows mounting and connection of an external RFI-filter: Shield bus of copper, connected Filtered line to the superficially with the mounting plate frequency converter...

  • Page 105: Design Of An Emc-Conformal Cabinet

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Electrical Installation 4.6.3 Design of an EMC-conformal cabinet 1. Cabinet 8. DC-bus wiring 2. Wiring between RFI-filter with power feedback unit (DC) and controller 9. Mounting plate (common star point) 3. RFI-filter 10. Potential equalisation 4.

  • Page 106: 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 107: 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 connect- ed to the screen bars to decrease the impedance of the screen.

  • Page 108: Commissioning

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Commissioning Commissioning Danger! Prior to initial switch-on of the power feedback unit check the wiring for completeness, short- circuit and earth fault. Danger! If the wiring is not correct, a non-intended operation of controller and/or power feedback unit is possible.

  • Page 109: 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 110  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Configuration The power 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 collective- error-relay signals the failure.
  • Page 111  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 and above.

  • Page 112: Troubleshooting And Fault Elimination

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Troubleshooting and fault elimination Troubleshooting and fault elimination The five LEDs in the cover of the power feedback unit display the operating condition. For easier visibility during service and first powering up similar LED's are placed on the con- trol board.

  • Page 113: Led-Messages

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Troubleshooting and fault elimination LED-messages LED – display Operation Phase failure Over temperature Disturbance LED-display: Green Orange Yellow Error code: Table 7.1.1 Operating instructions RLD...
  • Page 114  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Troubleshooting and fault elimination Status report Relay status 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 115: Service

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Service Service The power 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 feedback unit periodically (depending on the degree of pollution approx.

  • Page 116: Options

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Appendix Options Fuse holder with fuses for mains supply In accordance with table 3.3.3.1.1-5 for the power feedback unit the following fuses are available: ® REVCON - type Order designation Case type RLD 7 to RLD 135...
  • Page 117  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Appendix 3. The quality of the mains voltage is visibly reduced by commutation breakdowns, which are caused by e.g. neighbouring I-inverters. As the value of the feedback current is mainly determined by the difference between the actual values of DC-bus voltage and mains volt- age this current increases rapidly caused by the commutation breakdown of the mains volt- age.
  • Page 118  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Appendix 4. Overvoltage-suppressor If the power feedback unit (as well as a controller) is connected to ungrounded mains sup- ply, it only may be run, either if it is connected via an isolating transformer or if the plant is protected by overvoltage suppressors.
  • Page 119  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Appendix Option EST Synchronisation terminals for the connection of a RHF-RA harmonic line filter with phase interchanging protection. Option SLM The option SLM adds the possibility to activate the sleep mode to reduce the standby pow- er consumption.

  • Page 120: 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 121: Contact

     ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Appendix 10.1 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...
  • Page 122  ELTROPLAN - REVCON Elektrotechnische Anlagen GmbH Index mounting position ..........61 application conditions .......... 30 operating and signalling board, external ... 117 operator’s safety ..........16, 82 ordering code ............4 cable glands............100 overvoltage suppressor........117 CE-marking ............. 7 compensation plants ........

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