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CD Automation REVO I 2PH User Manual

2 phase unit to drive 3 phase load from 100a to 700a
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USER'S MANUAL
2PH
Rev. 07/2023
from 100A to 700A

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Summary of Contents for CD Automation REVO I 2PH

  • Page 1 USER’S MANUAL Rev. 07/2023 from 100A to 700A...

  • Page 2: Declaration Of Conformity

    P.I. 08925720156 -Tel. +39 0331 577479 - Fax +39 0331 579479 E-mail: info@cdautomation.com - Web: www.cdautomation.com Declare that the product / Dichiara che il prodotto: REVO I 2PH PRODUCT DESCRIPTION: Electric power control SCOPE OF APPLICATION: Thermal control process DESCRIZIONE DEL PRODOTTO: Unità di controllo potenza elettrica...
  • Page 3 P.I. 08925720156 -Tel. +39 0331 577479 - Fax +39 0331 579479 E-mail: info@cdautomation.com - Web: www.cdautomation.com Declare that the product / Dichiara che il prodotto: REVO I 2PH PRODUCT DESCRIPTION: Electric power control SCOPE OF APPLICATION: Thermal control process DESCRIZIONE DEL PRODOTTO: Unità di controllo potenza elettrica...

  • Page 4: Important Warnings For Safety

    User’s manual REVO I 2PH from 100A to 700A Important warnings for safety This chapter contains important information for the safety. The not observance of these instructions may result in serious personal injury or death and can cause serious damages to the Thyristor unit and to the components system included.
  • Page 5 User’s manual REVO I 2PH from 100A to 700A WARNING! All service including inspection, installation, wiring, maintenance, troubleshooting, fuse or other user serviceable component replacement must be performed only by properly qualified personnel. Service personnel must read this manual before proceeding with work. While service is being performed unqualified personnel should not work on the unit or be allowed in the immediate vicinity.
  • Page 6 User’s manual REVO I 2PH from 100A to 700A AVERTISSEMENT! Au moment de relever des mesures de tension ou de courant en direct, utiliser un équipement de protection individuelle approprié pour les tensions et les potentiels d’arc électrique concernés. WARNING! Verify the voltage and current ratings of the power controller are correct for the application. AVERTISSEMENT! Vérifier que les valeurs de tension et de courant du régulateur de puissance sont correctes pour l’application.

  • Page 7: Maintenance

    User’s manual REVO I 2PH from 100A to 700A Maintenance In order to have a corrected cooling, the user must clean the heat-sink and the protective grill of the fans. The frequency of this servicing depends on environmental pollution. Also check periodically if the screw for the power cables and safety earth are tightened correctly (See Connection Diagram).

  • Page 8: Table Of Contents

    User’s manual REVO I 2PH from 100A to 700A Summary Declaration of conformity....... . .2 Important warnings for safety .
  • Page 9 User’s manual REVO I 2PH from 100A to 700A Control Panel (Option) ........43 10.1 Menu navigation .

  • Page 10: Introduction

    User’s manual REVO I 2PH from 100A to 700A Introduction A thyristor unit is semiconductor device which acts as a switch formed by two thyristors in ant parallel.To switch on the alternating current the input signal will be on and the thyristor will switch off at first Zero Crossing voltage with no input signal.

  • Page 11: Advantages Compared With Analog Thyristor Unit

    User’s manual REVO I 2PH from 100A to 700A Advantages compared with analog thyristor unit Communication RS485 is a standard feature of REVO C this allows the use of many information like: current, power, load state and all the parameters for diagnostic and configuration. Ulterior advantages of the digital system vs the analogical is the flexibility and the possibility of implement special characteristics without change the hardware.

  • Page 12: Software Configurator

    User’s manual REVO I 2PH from 100A to 700A Software Configurator Thyristor configurator software is free and is possible download it from the website. If the Order Code is in line with requirement, then unit has been already configured in Factory and it’s ready to use.

  • Page 13: Quick Start

    User’s manual REVO I 2PH from 100A to 700A Quick Start Attention: this procedure must be carried out by skilled people only. If your REVO I code is in line with what you really need, then the main configuration is already done by Producer and you just need to do the following steps: Verify REVO I current sizing.

  • Page 14: Basic Connections And Sizing

    User’s manual REVO I 2PH from 100A to 700A Basic Connections and sizing Star wiring with resistive load (control on two phases) 1,73V V = Nominal voltage of the load I = Nominal current of the load P = Nominal power of the load Delta wiring with resistive load (control on three phases) 1,73V V = Nominal voltage of the load...

  • Page 15: Identification And Order Code

    User’s manual REVO I 2PH from 100A to 700A Identification and Order Code 5.1 Identification of the unit Caution: Before to install, make sure that the Thyristor unit have not damages. If the product has a fault, please contact the dealer from which you purchased the product. The identification’s label give all the information regarding the factory settings of the Thyristor unit, this label is on the unit, like represented in figure.

  • Page 16: Order Code

    User’s manual REVO I 2PH from 100A to 700A 5.2 Order Code REVO I-3PH Optional Current Description code Numeric code Description code Numeric code Touch Screen panel 100A Door Display 125A Front LED Display 150A 200A 300A Load Type/Connection 400A 450A Description code Numeric code...

  • Page 17: Technical Specifications

    User’s manual REVO I 2PH from 100A to 700A Technical Specifications 6.1 General features Operative voltage: 480V +10% max -10% min; 600V +10% max -10% min Cover and Socket material: Polymeric V2 Utilization Category: AC-51 AC-55b IP Code: Method of Connecting: Load in Delta, Load in Star Auxiliary voltage: Order code RI2_ _ _ -_1 = line voltage 100/120V transformer range 90:135V (8 VA Max)

  • Page 18: Fan Specification

    User’s manual REVO I 2PH from 100A to 700A 6.4 Fan Specification Number of fans Number of fans Number of fans Size 230Vac - Standard 115Vac - Option 24Vdc - Option 100A, 125A, 150A One Fan - 16W One Fan - 14W One Fan - 7W 200A Two Fans - (16W x 2) 32W...

  • Page 19: Installation

    User’s manual REVO I 2PH from 100A to 700A Installation AIR FLOW OUT (V) Before to install, make sure that the Thyristor unit have not damages. If the product has a fault, please contact the dealer from which you purchased the product. Verify that the product is the same in aspiration thing as ordered.

  • Page 20: Dimensions And Weight

    User’s manual REVO I 2PH from 100A to 700A 7.1 Dimensions and weight REVO I 2PH REVO I 2PH REVO I 2PH 100A / 125A / 150A (S11) 200A (S13) 300A - 700A (S14) W 137mm W 262mm W 262mm...

  • Page 21: Wiring Instructions

    User’s manual REVO I 2PH from 100A to 700A Wiring instructions The Thyristor unit could be susceptible to interferences lost by near equipments or by the power supply, for this reason in accord to the fundamental practices rules is opportune take some precautions: •...

  • Page 22: Cable Dimensions (Suggested) Of Earth And Of The Command Terminals

    User’s manual REVO I 2PH from 100A to 700A 8.3 Cable dimensions (suggested) of Earth and of the Command Terminals Earth Command Terminals Current Cable Screw Cable mm² mm² 100A (S11) 0,50 125A (S11) 0,50 150A (S11) 0,50 200A (S13) 0,50 300A (S14) 0,50...

  • Page 23: Terminals Positions

    User’s manual REVO I 2PH from 100A to 700A 8.4 Terminals Positions Size S13 / S14 Open and flip the cover Size S11...

  • Page 24: Power Terminals

    Line Input Phase 2 (only S14) Line Input Phase 3 Load Output Phase 1 Load Output Phase 2 - Not controlled by the thyristor (only S14) Load Output Phase 3 REVO I 2PH REVO I 2PH REVO I 2PH 100-125-150A (S11) 200A (S13)
  • Page 25 User’s manual REVO I 2PH from 100A to 700A 8.5.1 Bar dimensions S14 (300-500A) 300 to 400A To other screw To other 450 to 500A screw Current 300A (S14) 71mm 60mm 45mm 57mm 30mm 350mm 174mm 400A (S14) 71mm 60mm 45mm 57mm 30mm...

  • Page 26: Control Terminals

    User’s manual REVO I 2PH from 100A to 700A 8.6 Control Terminals Warning: Before connecting or disconnecting the unit check that power and control cables are isolated from voltage sources. Terminal Block M1 Terminal Description NO - Normally Open contact alarm relay output (Thermal or SC/HB) C - Common contact alarm relay output NC - Normally Close contact alarm relay output (Thermal or SC/HB) + Analog Input2 (0-10Vdc/4-20mA Reference/ext.feedback)

  • Page 27: Schematic

    User’s manual REVO I 2PH from 100A to 700A 8.7 Schematic Caution: this procedure must be performed only by qualified persons. Option Ethernet Profibus Branch circuit protection Fuse 1A Max Micro USB +24V GND 15 16 Power Microprocessor +24Vdc Retransmit Second supply power...
  • Page 28 User’s manual REVO I 2PH from 100A to 700A Caution: this procedure must be performed only by qualified persons. Indicative connection diagrams. Refer to local regulations for proper system protection. Branch Circuit Protection Fuse 1A Max MICRO Fan Supply USB 2.0 230Vac Standard 115Vac Option 24Vdc Option...
  • Page 29 User’s manual REVO I 2PH from 100A to 700A 8.7.1 SSR Schema di ingresso del controllo SSR Per l’ingresso SSR, seguire lo schema seguente e configurare Digital Input 1 come Fast Enable. Analog Input 1 INPUT * SSR Input: 4÷30Vdc 5mA Max (ON >4Vdc / OFF <1Vdc) Frequency 3Hz Max - On time min.

  • Page 30: Connection Diagram For 3 Phases

    User’s manual REVO I 2PH from 100A to 700A 8.8 Connection Diagram for 3 phases Caution: this procedure must be performed only by qualified persons. Relay Thermal or SC/HB Analog Inp.2 0-10VDC /4-20mA Reference Ext.FeedBack Analog Inp.1 0-10VDC /4-20mA ANALOG SET POINT Fan Power Supply See Order Code for the value AUX Voltage Supply...

  • Page 31: Using The Configurator

    User’s manual REVO I 2PH from 100A to 700A Using the Configurator Configurator software can be used like an alternative of the power controller’s keypad and set the advanced features not available via the power controller’s onboard user interface. Here we explain how to use it. 9.1 Typical Uses The software may be used during commissioning to: •...
  • Page 32 User’s manual REVO I 2PH from 100A to 700A Procedure to communicate with a power controller: 1) if used direct USB connection: - Connect the USB cable between the computer and the micro USB connector on the power controller’s keypad - if necessary, wait for the USB driver to install.

  • Page 33: Using The Configurator

    User’s manual REVO I 2PH from 100A to 700A 9.5 Using the Configurator After software has been installed, communication has been set up and model type selected, is possible operate with power controller. 9.5.1 To view or save a power controller’s settings using “Simple”...
  • Page 34 User’s manual REVO I 2PH from 100A to 700A 9.5.3 To download a recipe file into a power controller: 1) Click Simple, if not already on the Simple view 2) Click existing recipe Open 3) Locate and select the recipe file and click Open 4) Click 5) Click...
  • Page 35 User’s manual REVO I 2PH from 100A to 700A 9.5.8 To reset the power totals: 1) Click Test, if not already on the test view 2) Click Online 3) Click Reset Totals 4) Click 9.5.9 Setting Up and Using Data Logging To set up data logging: 1) Click Test, if not already on the test view 2) Click...

  • Page 36: Software General Information

    User’s manual REVO I 2PH from 100A to 700A 9.5.10 To retrieve a data log file from the power controller: 1) Click Test, if not already on the test view 2) Click Online 3) Click Load Analyzer 4) Click Connect 5) Select a file from the list 6) Click Download...
  • Page 37 User’s manual REVO I 2PH from 100A to 700A 9.6.2 Simple Section This section is used to create, save, upload and download recipes of parameters settings. Can be used also to see the settings in a controller. Simple page is the default page when select the model using the Model Button, but If not selected is possible access it clicking the Simple tab below the main menu.
  • Page 38 User’s manual REVO I 2PH from 100A to 700A 9.6.3 Test Section This section is used to monitor and adjust the operation of the power controller in real time using RS485 or USB communication port. After select the model, is possible access to this section clicking the “TEST”...
  • Page 39 User’s manual REVO I 2PH from 100A to 700A Buttons setup options: Firing: view and set the firing type and the associated parameters Feedback: view and set feedback type Communication: view and set communication options for ports, protocols and fieldbus Configure and monitor the analog inputs: Analog Input 1: click Ai 1 to view the signal type...
  • Page 40 User’s manual REVO I 2PH from 100A to 700A 9.6.4. Load Analyzer Load Analyzer is used for monitoring values graphically represent Click on Load Analyzer button on the test page will open Load Analyzer window. Is possible see 3 channels (Ch 1, Ch 2 and Ch 3). For each channel configure a pen on the graph: button: click to start trending data On/Off...
  • Page 41 User’s manual REVO I 2PH from 100A to 700A 9.6.5 Data Log Window In the power controller the data log window is used to manage files and set up logging parameter like log interval time and date/time in rtc Log Enabled/Log Disabled slider: Enable and disable data logging function.
  • Page 42 User’s manual REVO I 2PH from 100A to 700A 9.6.7 MSG view Message view display the communication activity between the computer and the power controller. PORT COM: use this view to see when the COM port is accessed and its settings MODBUS: Modbus communication protocol area READ Area: use this view to see parameters...

  • Page 43: Control Panel (Option)

    User’s manual REVO I 2PH from 100A to 700A Control Panel (Option) The Front LED Display can be selected as an option (Code FD at digit 15). The Control panel is placed on the front of the thyristor unit, on his display you can visualize the alarms, the input and output signals and all the configuration parameters.

  • Page 44: Menu Navigation

    User’s manual REVO I 2PH from 100A to 700A 10.1 Menu navigation The menus are accessible using the control panel keypad and display. Choose Enter Choose Edit HOME PAGE Menu Password Parameter Parameter Iout0.0A Password Set Point Iout0.0A 100% SP 100% Iout0.0A Set Point Menu...

  • Page 45: Control Panel Led

    User’s manual REVO I 2PH from 100A to 700A 10.2 Control Panel Led The four indicators on the control panel show the general state of the power controller. Flashing Power output set locally or via communications Aux High Local/Remote Power output set remotely (via analog input) SP 100% Output enabled Enable...

  • Page 46: Parameter List

    User’s manual REVO I 2PH from 100A to 700A 10.4 Parameter list This chapter describes the parameter on the menus accessed via the control panel and Configurator software. To learn how to access the menus described below see “Menu navigation” chapter. Menu Listing The table below lists the parameters found on each menu.

  • Page 47: Operator Menu

    User’s manual REVO I 2PH from 100A to 700A 10.4.1 Operator Menu This section describes each item on the operator menu. Use this menu to view the measured values and basic settings of the power controller. The password to access this menu is 0. Modbus Par.

  • Page 48: Setup Menu

    User’s manual REVO I 2PH from 100A to 700A 10.4.2 Setup Menu This section describes each item on the setup menu. Use this menu to configure the power controller for the load. The password to access this menu is 2. Modbus Par.

  • Page 49: Advanced Setup Menu

    User’s manual REVO I 2PH from 100A to 700A 10.4.3 Advanced Setup Menu This section describes each item on the advanced setup menu. Use this menu to configure the power switching, closed loop control of power and adjustable settings for data logging and heater bakeout. The password to access this menu is 10.
  • Page 50 User’s manual REVO I 2PH from 100A to 700A Modbus Par. Parameter Name Description Default Range Unit Address Type Pb Power Set the gain for the main loop. A larger Read value yields a larger adjustment for a 0 to 255 Write given deviation Ti Power...

  • Page 51: Hardware Menu

    User’s manual REVO I 2PH from 100A to 700A 10.4.4 Hardware Menu This section describes each item on the hardware menu. Use this menu to configure how the inputs and outputs are used in the application. The password to access this menu is 5. Modbus Par.
  • Page 52 User’s manual REVO I 2PH from 100A to 700A Modbus Par. Parameter Name Description Default Address Type DI1 Functn Choose how the signal detected by digital input 1 Read is used Write Option Description Value Enable Enable power output V Feedback Use voltage feed-back when on Local / Rmt Local when on / Remote when off...
  • Page 53 User’s manual REVO I 2PH from 100A to 700A Modbus Par. Parameter Name Description Default Address Type Alm Out Fn Choose for which conditions the digital output indicates alarm. The output always indicate an alarm when the heat sink is over temperature. The digital output is energized for normal operating condition and de-energized when the power Read...
  • Page 54 User’s manual REVO I 2PH from 100A to 700A Modbus Par. Parameter Name Description Default Range Address Type Rtx Scale Set the value of retransmitted parameter to be represented by the full scale of the Read 0 to 9999 analog output. Write See the table below Recommended...

  • Page 55: Communication Menu

    User’s manual REVO I 2PH from 100A to 700A 10.4.5 Communication Menu This section describes each item on the communication menu. Use this menu to configure the communication options. The password to access this menu is 3. Modbus Par. Parameter Name Description Default Address...
  • Page 56 User’s manual REVO I 2PH from 100A to 700A Modbus Par. Parameter Name Description Default Range Unit Address Type WD Reset Set the amount of time to wait for Read communication message before 0 to 255 Write triggering the watchdog error Field Name 79-80 Read...

  • Page 57: Monitoring Menu

    User’s manual REVO I 2PH from 100A to 700A 10.4.6 Monitoring Menu This section describes each item on the monitoring menu. Use this menu to view the states of digital input, values of analog input and information about the power controller such as serial number and software version. The password to access this menu is 0.
  • Page 58 User’s manual REVO I 2PH from 100A to 700A Modbus Par. Parameter Name Description Range Unit Address Type Analog In1 Indicates the percent of full scale measured Read 0 to 100.0 by analog input 1 Only Analog In2 Indicates the percent of full scale measured Read 0 to 100.0 by analog input 2...

  • Page 59: Configurable Inputs And Outputs

    User’s manual REVO I 2PH from 100A to 700A Configurable Inputs and Outputs The REVO I power controller features two digital inputs, up to two analog inputs and a relay output. Some models also include an analog output for retransmitting a measured value to other automation equipment. This section describes the various functions of these inputs and outputs and how they interact with other features of the power controller.

  • Page 60: Analog Input 2: Set Point Or Feedback

    User’s manual REVO I 2PH from 100A to 700A 11.3 Analog Input 2: Set Point or Feedback What this input does is user-configurable. Connect an analog signal that indicates: • An alternate set point signal • Measured power, voltage or current from an external device used as feedback. This input accepts current, voltage and potentiometer signals.

  • Page 61: Alarm Description

    User’s manual REVO I 2PH from 100A to 700A Alarm description 12.1 Heater Break Alarm This option allows you to diagnose any load breakage. The diagnostics is based on the comparison of the value of the nominal resistance of the load with respect to the resistance measured in real time. The nominal resistance is calculated using the Operative Load Voltage (Nom Line V) and Nominal Current of the load (Nominal I) parameters.

  • Page 62: Aux High

    User’s manual REVO I 2PH from 100A to 700A 12.2. AUX High This alarm is displayed when the auxiliary supply voltage exceeds the established ranges. If the alarm situation persists for more than 5 seconds, the unit will go into protection. 12.3 AUX Low This alarm is displayed when the auxiliary supply voltage is lower than the established ranges.

  • Page 63: 13 "Enable" Function In Static Unit

    User’s manual REVO I 2PH from 100A to 700A “Enable” Function in static Unit The “Enable” function can work in several ways • from Digital input • from Serial Port • from Digital Input + Serial Port To simplify in the various diagrams, the “enable” command from serial port will be represented by a “Software contact”...

  • Page 64: Using Serial Port Rs485 Only

    User’s manual REVO I 2PH from 100A to 700A 13.2 Using Serial Port RS485 only The static unit has an RS485 Modbus RTU serial port always present. By setting the Digital Input as “Not Used” or different from “Enable” it is possible to control the enable from serial port with bit 2 of parameter 14 If bit 2 = 1: Enabled If bit 2 = 0: Disabled...

  • Page 65: Firing Type

    User’s manual REVO I 2PH from 100A to 700A Firing type Choose a correct firing type allows to optimize the thyristor unit for the installed load. The firing type has already configured in line with customer requirements that are defined in the Order Code. The Order Code is written on the identification label.

  • Page 66: Control Mode (Feed-Back)

    User’s manual REVO I 2PH from 100A to 700A Control Mode (feed-back) The Control Mode (feed-back) type has already configured in line with customer requirements that are defined in the Order Code. The Order Code is written on the identification label. However, if you wish to change the Control Mode (feed-back) type you can use the software configurator or the Control Panel.

  • Page 67: Supply The Electronic Board

    User’s manual REVO I 2PH from 100A to 700A Supply the electronic board The REVO I thyristor unit, to work, requires a voltage supply for the electronic boards. The Max consumption is 10VA. The voltage supply for the electronic boards is configured in line with customer requirements that are defined in the Order Code.
  • Page 68 User’s manual REVO I 2PH from 100A to 700A Sequence for writing the Aux Voltage value: Click on ‘Actual Level’ and enter the password ‘1234’ to access level 4. Click on the ‘Fast Tune’ button Enter the voltage value in the ‘AuxVoltage’ field, press enter.

  • Page 69: Rs485 Serial Port

    User’s manual REVO I 2PH from 100A to 700A RS485 Serial port The serial communication port RS485 is available on the Command Terminals. On this port may be done a network up to 127 REVO I. Terminal M1 Description RS485 A RS485 B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20...

  • Page 70: Internal Fuse

    User’s manual REVO I 2PH from 100A to 700A Internal Fuse The thyristor unit have internal fuse extrarapid at low I t for the thyristor protection of against the short-circuits. The Fuses must have I²t 20% less than thyristor’s I t.
  • Page 71 TOSHCON TOSHCON CD AUTOMATION ( INDIA ) PVT. LTD., H 1 - 75, Gegal Industrial Area, Ajmer - 305023 (Raj.) INDIA CIN: U32200MH2009PTC197386 Phone: +91-145-2791112 E-mail: cd@toshcon.com Website: www.toshcon.com REGD OFFICE: 401, Manish Chamber, Sonawala Cross Lane, Goregaon (E), MUMBAI - 63...