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REVCON RFE B3 Operating Instructions Manual
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REVCON RFE B3 Operating Instructions Manual

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ELTROPLAN-REVCON
Elektrotechnische Anlagen GmbH
Operating instructions
Power feed- feedback unit REVCON
Power range
Voltage range
V 1.3
Issue 13/06
30- ... 250 kW
400V, 460V, 500V
®
RFE

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Summary of Contents for REVCON RFE B3

  • Page 1 ELTROPLAN-REVCON Elektrotechnische Anlagen GmbH Operating instructions ® Power feed- feedback unit REVCON Power range 30- ... 250 kW Voltage range 400V, 460V, 500V V 1.3 Issue 13/06...
  • Page 2 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 111234564571 9A6BCD61C4E1F646AC14B3AC5341 AE6A4F1D3E61   D3613B1E66A1 6FC1A6FC5347 2 !A6D5671"1!6DCAC53413B1D34B3A51# 88 2 3$ %35CF61!A6D561  # 8 2 EA6D5616D5A3CF465D1D3C5&51  ' 8 2 !A6D561(CD)46A1* CB6514B3AC5341  8+ ,646AC17CB6514B3AC5341  88 CB65 A67347&616A73471  8 C3513B15)617CB6514B3AC53418# -67EC1)C.CAE71  8# ,646AC1475AD534718/...
  • Page 3 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 234564571 6AC53A8717CB651  ## 9A356D53413B15)613$6A1B66E"B66E&CD11451  ## (C4715671"1(C471D)CACD56A75D71  #/ 6DBDC534713B15)6176E1$A671  #/ 23446D5341#' 8 06A4C71C4E1D3446D5341475AD53471#* 9A4F17D)6C5D1-%221-314"!1  /8 9A4F17D)6C5D1-%221-314"!1  / 9A4F17D)6C5D1-%221-314"!1$5)1-73 -51(3E61/ 9A4F17D)6C5D1-%221-314"!1$5)1-73 -51(3E61// 2345A31$A671/* 2345A31B4D53471/* 2345A31$A671-%221-314"!1C4E1-%221-314"!1  '8 6475CC53413B1C13$6A1B66E"B66E&CD1145141C12 5DC1EA677561' 6475CC5341' 23446D53413B1C1-36 B56A1'# !67F413B1C41(2 D34B3AC1DC&4651'/...
  • Page 4 ® • All persons who work on and with the power feed/feedback units REVCON must have the Operation instructions available and observe all relevant notes and in- struction.
  • Page 5 • Nominal power: E.G. 30 kW E.G. 50Hz • Level D: With internal mains inductance and additional capacity RFE B3 030 - 400 - 50 - 0 - A 400V • 2 = Without precharge • Product type: Connection voltage: •...
  • Page 6 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 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 9A6BCD61C4E1F646AC14B3AC5341 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 techni- cal standards and certification procedures within the European Community. At the moment there are 21 EC-Directives for product sectors.
  • Page 8 EC-declaration of conformity According to the EC-Low Voltage Directive (2006/95/EEC) ® The power feed/feedback units REVCON RFE have been developed, designed and manu- factured in accordance with the above mentioned EC-Directive and in sole responsibility of ELTROPLAN-REVCON Elektrotechnische Anlagen GmbH, Edisonstraße 3, D-59199 Bönen...
  • Page 9 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 123456789A78B64CD67E8BAF1AFAAA...
  • Page 10 EC-declaration of the manufacturer in terms of the of the EC-Directive Machinery (2006/42/EG) ® The power feed/feedback units REVCON RFE have been developed, designed and manu- factured in accordance with the above mentioned EC Directive in exclusive responsibility ELTROPLAN-REVCON Elektrotechnische Anlagen GmbH, Edisonstraße 3, D-59199 Bönen...
  • Page 11 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH CB6514B3AC5341 Safety information Safety and application notes for controller (to : Low-Voltage Directive (2006/95/EEC) 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 • • Use the drive system only in flawless condition. ® • Modifications of the power feed/feedback units without consultation of a REVCON technician are not allowed generally. 123456789A78B64CD67E8BAF1AFA AA...
  • Page 13 Otherwise unintended voltage rises / excess voltages are generated, which may ® damage or destroy REVCON and combined units! • Before operating at nets without reference to neutral ground additional safety meas- ures (e.g.
  • Page 14 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111CB6514B3AC5341 • 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 15 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH CB6514B3AC5341 • 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 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 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111CB6514B3AC5341 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 ® ® 123456278 - 419A58 Elektrotechnische Anlagen G n GmbH CB6514B3AC5341 Layout of the s e safety information • All safety no notes have a uniform layout: The icon 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 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111CB6514B3AC5341 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 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH CB6514B3AC5341 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. To avoid an overload to the components of the power feed/feedback unit, this additional voltage must not exceed 100V.
  • Page 20 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111CB6514B3AC5341 Typical capacitance of the DC-connection inside the power feed/feedback unit: ® REVCON -type Power DC-capacity [kW] [µF] RFE B2/D2 400V RFE B2/D2 400V RFE B2/D2 400V RFE B2/D2 400V RFE B2/D2 400V...
  • Page 21 Typical capacitance of the DC-connection inside the power feed/feedback unit: ® REVCON -type Power DC-capacity [kW] [µF] RFE B3/D3 400V RFE B3/D3 400V RFE B3/D3 400V RFE B3/D3 400V RFE B3/D3 400V RFE B3/D3 400V RFE B3/D3 400V RFE B3/D3 400V RFE B3/D3 400V Table 2.6.1...
  • Page 22 The usage of a power feed/feedback unit within an island network (e.g. with a diesel gen- erator) is possible, but there are restrictive regulations concerning the power limits. 0,4kV 100kVA REVCON 20kW 20kW Figure 2.6.1 Within a network that is assembled like in figure 2.6.1, there are two additional restric- tions: First the power of the motor connected to the inverter must be lower than half of the nominal power of the generator.
  • Page 23 The operation of the power feed/feedback unit in combination with an adjusting trans- former (e.g. in the case of a braked slip-ring induction motor) is only allowed, if the quo- tient ratio of feed/feedback-power and nominal power is much smaller than one. 10kV 0,4kV 100kVA REVCON 20kW 20kW 60kW Figure 2.6.2 123456789A78B64CD67E8BAF1AFAAA...
  • Page 24 Over voltages may cause serious damages to the connected frequency inverter and /or to the power feed/feedback unit and to the other loads. Mains supply Not allowed! REVCON 60kW Figure 2.6.3 The same things apply to the also non-admissible pre-connection of further commutation chokes.
  • Page 25 ∆U ∆U Supplying network REVCON Figure 2.6.4 Proceeding from a stable network with e.g. 400V nominal voltage and a backward current of 80A, at a bad made terminal of 100mW a voltage of 8V is dropped (A good made ter- minal has got a resistance of ca 1 mW.).
  • Page 26 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111CB6514B3AC5341 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 feed/feedback operation Conductor cross section per phase Conductor radius...
  • Page 27 Is the power consumption of the loads to small, the DC-voltage and also the output voltage of the power feed/feedback unit rises during the feedback operation. This increased voltage may damage all connected compo- nents. Right Supplying network False REVCON 60kW Figure 2.6.5 123456789A78B64CD67E8BAF1AFAAA...
  • Page 28 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 feedback current circuit.
  • Page 29 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH CB6514B3AC5341 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 inter- rupted production processes.
  • Page 30 RFE B2 and RFE D2: Power range 30kW-250kW Available for mains voltages 400V, 460V and 500V – RFE B3 und D3: Power range 30kW to 285kW (855kW by parallel connection) Available for mains voltages 400V, 460V, 500V (230V and 690V on request)
  • Page 31 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 06D)4DC1EC5C1 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 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 111111111111111111111111111111111111111111111111111111111111111106D)4DC1EC5C1 Rated data 3.3.1 Power feed / feedback unit REVCON RFE B2/D2 RFE B2/D2 RFE B2/D2 RFE B2/D2 REVCON- type 400V 460V 500V Nominal range of the interlinked mains -15% / +10% -15% / +10%...
  • Page 33 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 06D)4DC1EC5C1 3.3.2 Power feed- and feedback unit REVCON RFE B3/D3 RFE B3/D3 RFE B3/D3 RFE B3/D3 REVCON- type 400V 460V 500V Nominal range of the interlinked mains -10% / +10% -10% / +10%...
  • Page 34 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111106D)4DC1EC5C1 Ampacity 3.4.1 REVCON RFE B2/D2 Nominal voltage 400V Driving Braking ® ® REVCON - Type REVCON Max. Max. Max. Max. input current I input current I current I current I RFE B2/D2 item-Nr.:...
  • Page 35 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 06D)4DC1EC5C1 Nominal voltage 500V Driving Braking ® ® REVCON - Type REVCON Max. Max. Max. Max. input current I input current I current I current I RFE B2/D2 item-Nr.: 22012124 / 30-500-50-230-A 52 A...
  • Page 36 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111106D)4DC1EC5C1 3.4.2 Dimensioning REVCON RFE B2/D2 Driving Braking Flyback diodes IGBT-modules eff/Phase eff/Phase eff/Phase eff/Phase [kW] [kW] [kW] [kW] Device type: 100% 150% 100% 120% RFE B2/D2 30-400-50-230-A 45-400-50-230-A 60-400-50-230-A 80-400-50-230-A 100-400-50-230-A 125-400-50-230-A...
  • Page 37 If the maximum input current of the controller exceeds this value nevertheless, the motor current limit of the controller must be adjusted on the maximum REVCON value. In any case it is important to calculate with the overload factor of the controller.
  • Page 38 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111106D)4DC1EC5C1 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 39 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 06D)4DC1EC5C1 REVCON RFE B3/D3 Nominal voltage 400V Driving Braking ® REVCON - type ® REVCON Max. Max. Max. Max. RFE B3/D3 input current I input current I current I current I item-Nr.: 22013004 /...
  • Page 40 Nominal voltage 500V Driving Braking ® REVCON - type ® REVCON Max. Max. Max. Max. RFE B3/D3 input current I input current I current I current I item-Nr.: 22013124 / 30-500-50-230-A 52 A 63 A 35 A 42 A 22017124...
  • Page 41 Mains fuses must be designed according to the current load capacity of the supply wire. 3.6.1 Series fuses REVCON RFE B2/D2 Semiconductor fuses have to be connected in series with the power feed/feedback unit as following tables (refer to figure 5.6.1 to 511.1 position 1). The listed manufacturer is rec- ommended, but naturally also comparative fuses of other manufacturer (e.g.
  • Page 42 80A 690V 22x58mm 25mm² RFE B3/D3 45-400-50-230-A Siba 5007406.125 125A 690V 22x58mm 25mm² RFE B3/D3 60-400-50-230-A Siba 2018920.160 160A 690V NH 00 25mm² RFE B3/D3 80-400-50-230-A Siba 2018920.160 160A 690V NH 00 25mm² RFE B3/D3 100-400-50-230-A Siba 2018920.200 200A 690V NH 00 50mm²...
  • Page 43 STOP bly further protective measures have tripped. If internal fuses are exchanged, please verify that only the original types are used for replacement. Danger! Before replacing a fuse, switch off all voltages! REVCON RFE B2/D2: ® REVCON - type DC-fuses (use fast acting semiconductor fuses only) RFE B2/D2 30-400-50-230-A Siba 5014006.100 100A 690V 22x58 mm...
  • Page 44 - type DC-fuses (use fast acting semiconductor fuses only) RFE B3/D3 30-400-50-230-A Siba 5014006.100 100A 690V 22x58 mm RFE B3/D3 45-400-50-230-A Siba 5014206.135 135A 600V 22x58 mm RFE B3/D3 60-400-50-230-A Siba 2018920.200 200A 690V NH 00 RFE B3/D3 80-400-50-230-A Siba 2018920.250 250A 690V NH 00 RFE B3/D3 100-400-50-230-A Siba 2018920.315 315A 690V NH 00...
  • Page 45 06D)4DC1EC5C1 Switch on current limiter RFE B2/D2 ® As the REVCON RFE B2/D2 has got no switch on current limiter (Pre load circuit), it may exclusively used in combination with controllers, which are equipped with an internal pre load circuit for their DC-bus capacitors. The maximum value of the switch on current must not exceed the rated values of tables 3.8.1.1 to 3.8.1.3.
  • Page 46 DC-bus capacitors ® The precharge limiter of the REVCON RFE B3/D3 is adapted (at a maximum switch-on frequency of 1/min) to the normally used DC-bus capacitance values of the controller. In table 3.9.1.1 the maximum allowed values are listed. ® ® ® ®...
  • Page 47 Elektrotechnische Anlagen GmbH 06D)4DC1EC5C1 3.10 RFI-filter To observe the EMC-rules in accordance with figure 5.6.1 to 5.11.1 a radio frequency in- ® terferences filter class A can be preconceived to the REVCON unit. 3.10.1 RFI-filter REVCON RFE B2/D2 ® REVCON...
  • Page 48 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 111111111111111111111111111111111111111111111111111111111111111106D)4DC1EC5C1 3.10.2 RFI- filter REVCON RFE B3/D3 ® REVCON - type Order designation for filter Case type RFE B3/D3 30-400-50-230-A RF-DCV 30-400 RFE B3/D3 45-400-50-230-A RF-DCV 45-400 RFE B3/D3 60-400-50-230-A RF-DCV 60-400 RFE B3/D3 80-400-50-230-A...
  • Page 49 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 5.6.1 to 5.11.1. In the tables 3.11.1.1 to 3.11.1.3 the corresponding filter modules are listed for the power feedback unit.
  • Page 50 ® REVCON Case Ordering code ® REVCON - type item number type RHF- module RFE B3/D3 30-400-50-230-A RHF-RA 43-400-50-20-A 25070001 internal RFE B3/D3 60-400-50-230-A RHF-RA 86-400-50-20-A 25070010 internal RFE B3/D3 80-400-50-230-A RHF-RA 144-400-50-20-A 25070012 internal RFE B3/D3 100-400-50-230-A RHF-RA 144-400-50-20-A...
  • Page 51 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6475CC5341 Installation Mechanical installation 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. Keep a horizontal distance of at least 70mm to other components and to the cabinet walls.
  • Page 52 Elektrotechnische Anlagen GmbH 1111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111116475CC5341 Dimensions Power feed/feedback unit: Dimension diagrams: ® REVCON - Feed- and feedback unit RFE case type 1/500 B2/D2 30-400-... to B2/D2 45-400-... B2/D2 30-460-... to B2/D2 45-460-... B2/D2 30-500-... to B2/D2 45-500-... B3/D3 30-400-... to B2/D2 45-400-...
  • Page 53 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6475CC5341 1. Enclosure 1/500 123456789A78B64CD67E8BAF1AFAAA...
  • Page 54 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111111111111111116475CC5341 2. Enclosure 2/700 123456789A78B64CD67E8BAF1AFA AA...
  • Page 55 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6475CC5341 3. Enclosure 3/800 123456789A78B64CD67E8BAF1AFAAA...
  • Page 56 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111111111111111116475CC5341 4. Enclosure 3/801 123456789A78B64CD67E8BAF1AFA AA...
  • Page 57 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6475CC5341 5. Enclosure 3/802 123456789A78B64CD67E8BAF1AFAAA...
  • Page 58 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111116475CC5341 RHF-Module Dimensions: Diagram X1 Diagram X2 123456789A78B64CD67E8BAF1AFA AA...
  • Page 59 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6475CC5341 Dimension X3 4. Dimension X4 123456789A78B64CD67E8BAF1AFAAA...
  • Page 60 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 1111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111116475CC5341 5. Dimension X5 Dimension X5 123456789A78B64CD67E8BAF1AFA AA...
  • Page 61 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6475CC5341 Dimension X6 Dimension X7 123456789A78B64CD67E8BAF1AFAAA...
  • Page 62 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111116475CC5341 Dimension X8: Fan internal Dimension X8: Fan outside 123456789A78B64CD67E8BAF1AFA AA...
  • Page 63 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6475CC5341 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 feed/feedback unit. The radio interference filter of case-type 3 and 4 are mounted in housings, which should be placed beside the power feed/feedback unit.
  • Page 64 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111111111111111116475CC5341 Diagram Case 2 Diagram Case 3 123456789A78B64CD67E8BAF1AFA AA...
  • Page 65 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6475CC5341 Diagram Case 4 Diagram Case 5 123456789A78B64CD67E8BAF1AFAAA...
  • Page 66 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111111111111111116475CC5341 Diagram Case 6 123456789A78B64CD67E8BAF1AFA AA...
  • Page 67 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6D5ADC16475CC5341 Electrical installation 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- pendent on the used controller and has to run down before any service operations or similar ac- tivities are started.
  • Page 68 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111116D5ADC16475CC5341 Mains types / Mains characteristics Stop! Observe the restrictions in accordance to the respective mains type! STOP If you want to run power feed/feedback units at mains types, which are not listed in the table be- low please consult our technicians.
  • Page 69 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6D5ADC16475CC5341 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 STOP locked, so that no power permeates into the mounting! Power connection:...
  • Page 70 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111116D5ADC16475CC5341 5.5.1 Terminals and connection instructions 1. Example REVCON RFE B2/D2 13-45 kW: Figure 5.5.1 2. Example REVCON RFE B3/D3 125-200 kW: Figure 5.5.2 123456789A78B64CD67E8BAF1AFA AA...
  • Page 71 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6D5ADC16475CC5341 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 72 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111116D5ADC16475CC5341 Wiring schematic REVCON RFE B2/D2 ® Figure 4.6.1: Wiring schematic of the power feed/feedback unit REVCON RFE B2/D2 and one or more controllers 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 73 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6D5ADC16475CC5341 ® ® ® ® Legend for figure 5.6.1 (REVCON RFE B2/D2) Fusing in accordance with controller 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 74 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111116D5ADC16475CC5341 Wiring schematic REVCON RFE B3/D3 ® Figure 5.7.1: Wiring schematic of the power feed/feedback unit REVCON RFE B3/D3 and one or more controllers 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 75 Terminals 11 and 12: Positive pulse (12-24 V DC); practicable e.g. via PLC (termi- nal 11 +, terminal 12 -). ® a) REVCON RFE B3/D3: The precharge limiter of the REVCON RFE B3/D3 is adapted (at a maximum switch-on frequency of 1/min) to the normally used DC-bus capacitance values of the controller.
  • Page 76 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111116D5ADC16475CC5341 Wiring schematic REVCON RFE B2/D2 with RHF-RA Module ® Figure 5.8.1: Wiring schematic of the power feed/feedback unit REVCON RFE B2/D2 and one or more controllers 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 77 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6D5ADC16475CC5341 ® ® ® ® Legend for figure 5.8.1 (REVCON RFE B2/D2) Fusing in accordance with controller 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 78 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111116D5ADC16475CC5341 Wiring schematic REVCON RFE B3/D3 with RHF-RA Module ® Figure 5.9.1: Wiring schematic of the power feed/feedback unit REVCON RFE B3/D3 with RHF-RA Module and one or more controllers 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 79 Terminals 11 and 12: Positive pulse (12-24 V DC); practicable e.g. via PLC (termi- nal 11 +, terminal 12 -). ® a) REVCON RFE B3/D3: The precharge limiter of the REVCON RFE B3/D3 is adapted (at a maximum switch-on frequency of 1/min) to the normally used DC-bus capacitance values of the controller.
  • Page 80 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111116D5ADC16475CC5341 Control wires • Connect the control wires to the terminal row X2 at the connection plate of the power feed/feedback unit. • Don’t parallel control wires to interfering power wires. • Connect the screening of the control wires with an as big as possible surface to the metal cable glands of the flange.
  • Page 81 Elektrotechnische Anlagen GmbH 6D5ADC16475CC5341 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. messages terminal X4 LED-messages...
  • Page 82 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111116D5ADC16475CC5341 Control wires REVCON RFE B3/D3 and REVCON RFE B2/D2 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.
  • Page 83 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6D5ADC16475CC5341 Stop! To avoid, that the frequency converter accelerate the motor already during the preload, a con- STOP tact of the error message relay must be integrated into the pulse release of the converter. If an OFF-signal has been released, an collective error is display as the relay toggles.
  • Page 84 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111116D5ADC16475CC5341 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 85 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 86 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111111111111111116475CC5341 Installation Appropriate design of pant and cabinet: To avoid noise incoupling lay a) mains/supply wires b) motor wires of controllers / servo amplifiers c) control- and data wires (small voltage range < 48 V) with a distance of at least 15 cm between each other.
  • Page 87 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6475CC5341 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 Interference filter connected Additional earthing strap superficially with the mounting plate...
  • Page 88 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111111111111111116475CC5341 Design of an EMC-conformal cabinet 1. Cabinet unit (DC) 8. DC-bus wiring with power feed/feedback 2. - 9. Mounting plate (common star point) 3. RFI-filter 10. Potential equalisation 4. Mains supply wire 11.
  • Page 89 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 6475CC5341 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 90 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111111111111111116475CC5341 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. The screen of digital signal wires, which are connected to terminals, has to be connected with as big surface as possible to ground.
  • Page 91 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 2377344F1 Commissioning Danger! Prior to initial switch-on of the power feed/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 feed/feedback unit is possible.
  • Page 92 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111111111111234BFAC5341 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) „Autostart“...
  • Page 93 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 234BFAC5341 d) Reset After the failure is removed, a stored error has to be reset by pushing the RESET-button or rather by switching-off and on again the main circuit voltage (3-ph.) Stop! A reset in case of too high DC-bus voltage during the braking operation is not recommended. If STOP it is done nevertheless, the power semiconductors are exposed to increased stress, which may lead to accelerated aging.
  • Page 94 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111111111111234BFAC5341 Stop! Pull off the jumper J3 is only allowed by interrupting the pulses of the frequency inverter or of the power feed/feedback unit in the case of switching off the mains by series interrupting devices like contactors, main switches or any others.
  • Page 95 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 0A3&67)3354F1C4E1BC5164C5341 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 LEDs are placed on the control board.
  • Page 96 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 1111111111111111111111111111111111111111111111111111111111111111111111111111110A3&67)3354F1C4E1BC5164C5341 LED-messages LED – display Operation Phase failure Overtemperature Disturbance LED-display: Green Orange Yellow Error code: Table 9.1.1 123456789A78B64CD67E8BAF1AFA AA...
  • Page 97 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 0A3&67)3354F1C4E1BC5164C5341 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 Relay in resting 1 Check the DC-fuses.
  • Page 98 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 1111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111116AD61 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 99 11.1 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 RFE 30 to RFE 60 SH RFE ZZZ-XXX...
  • Page 100 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111564E: External operating an signalling panel When mounting the device inside a cabinet it is possible to mount a operator panel in the door of the cabinet by using the external operating and signalling panel. The external oper- ating and signalling panel contains the complete display (LED’s) of all running and failure messages of the power feed/feedback unit and also the ON / RESET push button switch.
  • Page 101 Elektrotechnische Anlagen GmbH 564E:1 Option additional supply module REVCON EDC If there is for a certain application indeed enough feedback power but not enough supply power of the power feed- and feedback unit, it is possible by means of an individual to di- mensioning additional supply module to reach the necessary complete supply power.
  • Page 102 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111564E: ® REVCON Product overview ® REVCON Power feedback units for short time operation (Crane systems, discontinuous centrifugal, etc.) ® REVCON Power feedback units for continuous operation (Engine test beds, escalators, wind energy plants, elevators etc.) ®...
  • Page 103 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 104 ® 123456278 - 419A58 Elektrotechnische Anlagen GmbH 11111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111164E6: 8BD!"CBB#"3$$38AC8%A 8BD!"CBB!78&37B3A ' '''''''''''''''''AA $578BA-434C38D/A'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''AA 522"7D567E8ADE8%767E8BA'''''''''''''''''''''''''''''''''''''''''''''''''''AA $578BA634$785"B'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''AA $578BA6/23BA'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''AA $EC86789A2EB767E8A ' ''''''''''''''''''''''''''''''''''''''''''''''''''''''''AA D5("3A9"58%BA ' ''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''AA 525D76E4B)A*+,CBA''''''''''''''''''''''''''''''''''''''''''''''''''''A)AA 2 CA14FA ' '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''AA E23456789A58%AB7985""789A(E54%)A3563485"A''''''''''''''''''''''AA DE$238B567E8A2"586BA ' ''''''''''''''''''''''''''''''''''''''''''''''A)AA E23456E46BAB5-36/A ' ''''''''''''''''''''''''''''''''''''''''''''''''''''A)AA DE883D67E8'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''A)AA E4%34789ADE%3A ' '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''AA DE865D6A''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''AA E.34.E"6593ABC2243BBE4'''''''''''''''''''''''''''''''''''''''''''''''''AA DE864E"A-C8D67E8BA'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''AA DE864E""34A ' ''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''A)AA DEE"789A574A ' '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''AA...

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Rfe d3