Product manual REVCON SVC
1.0 SAFETY INSTRUCTIONS
Before commissioning the power-feedback-unit REVCON• it is important to read this manual
carefully. It is intended to give all information for an undisturbed operation together
with the exploitation of all advantages of the system.
Only authorised specialists are allowed to work at the device in consideration of all relevant
regulations of the electrical industry. The guarantee given by us expires if the unit is changed
or (even partially) dismantled or if it is used in contradiction to our instructions.
The operation of the device is only allowed with a closed cover of the housing and with mounted
flanges for the reasons of personnel safety, the observance of the EMC-regulations and for the
regular working of the cooling of the device.
These safety regulations are not entitled to completeness. In case of questions or problems please
contact our technicians.
The units, operational data and circuit details described in this manual have to be understood
analogously and have to be checked for transferability to each application.
The statements of this manual describe the product attributes without guaranteeing them.
The constructor of the plant, who has to know the technical guidelines, bears the responsibility for
the correct selection and arrangement of the electrical components.
Caution
Putting into operation is only admissible at VDE conform nets. Non observance can damage
the device!
In accordance with the corresponding standards and guidelines the operation on even for a
short time over-compensated networks (cos••1) respectively on un-choked compensation-units
is not admissible. If this is done nevertheless overvoltages (caused by oscillating
currents) will occur, which may damage all connected loads, especially electronic units like
frequency inverters and power feedback units.
To low-powered or unloaded generators and to regulating transformers it is never allowed to
feed back power without a previous consultation of our application department. Otherwise
you can get unintended voltage rises / excess voltages, which can damage or destroy
•
REVCON and combined units.
The connecting instructions have to be observed absolutely, because an incorrect connection can

damage REVCON and combined units.
Before operating at nets without neutral ground you must inform our technicians because the
devices must be modified in this case. In addition there are separate safety measures
necessary which must be agreed with our technicians. With every order you must tell us the
form of the net and of the neutral point (grounded or ungrounded)!
Version 1.4 12/98
page 1
Product manual REVCON SVC
SAFETY INSTRUCTIONS
DC-bus terminals
After switching off the main circuit voltage the DC-bus terminals of the frequency inverter and of
the REVCON still have dangerous high voltage until disconnecting the supply voltage of the
frequency inverter.
Therefore its necessary to disconnect both supply voltages at the same time!
After disconnecting the supply voltage of the frequency inverter the DC-bus terminals of the powerfeedback-unit REVCON still have dangerous high voltage for a few minutes. The exact duration
until voltage has decreased to a harmless level depends on the used frequency inverter and has to be
observed absolutely (in agreement with the frequency inverter manual).
In any case it’s necessary to switch off the main circuit voltage of the frequency inverter and of the
REVCON when working at the system. Before opening the cover of the housing it is absolutely
necessary to wait a few minutes after switching off the frequency inverter.
Warning:
Touching active parts – even after switching
off the supply voltage – is extremely dangerous.
VLT 5001 - 5006: wait min. 4 minutes!
VLT 5008 - 5250: wait min. 15 minutes!
1.1 Patent rights
The power-feedback-unit REVCON is protected in Germany and Europe by patents:
no. DE3938654C1 and no. 90123584.6-2207.
Patent infringements become prosecute.
page 2
Product manual REVCON SVC
Table of Contents
Page
1.0
Safety instructions
01
1.1
Patent rights
02
2.0
General information
04
3.0
Technical data
05
4.0
Mounting
07
4.1
Dimension diagram
08
4.2
Space-diagram of the control board
10
5.0
Main circuit connection
11
5.1
Connection of the auxiliary voltage
21
5.2
Connecting diagram of the REVCON• SV
22
5.3
Series fuses
24
5.4
Internal fuses
25
5.5
DC-bus connection
26
5.6
General instructions
29
6.0
Allowed operating data
36
6.1
Thermal limited load graphs
37
7.0
REVCON• control board Version 1.4.x
41
7.1-7.5
Occupation of the control terminal strip
42
8.0
Connecting the external operating and signalling panel
44
8.1
LED messages
45
9.0
Function description of the device
49
10.0
Options
48
10.1
External operating and signalling board
48
10.2
Radio frequency interference filter
48
Appendix
page 3
Product manual REVCON SVC
2.0 General information
Type description and project-instructions
The released energy which results from braking of rotary field motors managed by frequency
inverters must no more be converted into heat in resistors. The power-feedback-unit REVCON
makes it possible to feed back this power economically into the mains.
By using highest modern IGBT-technology in combination with the latest synchronising control
module the operator gets a real 4-quadrant inverter with minimal expenditure.
The power-feedback-unit REVCON can be used instead of a brake chopper with a brake
resistance as braking device for frequency inverters with constant DC-Bus supply and with a main
circuit voltage of 400V (3-ph.).
The units are no-load constant and they have got the following protective functions and messages:
¦ Protective function:
- Short circuit-overcurrent control
(UCE-control)
- Commutation control
¦ Messages
- Operation
: LED
- False of rotary field
or phase failure
: LED
- Undervoltage control
- Short circuit (UCE)
: LED
- Phase failure control
- Overtemperature
: LED
- Protection of D.C. branches
- Control of dissipaters temperature
- Collective fault message: LED and
potential free
contacts
The housing has to be connected to ground via PE-terminal or by PE-Screw (from SV50...)
respectively.
It is recommended to protect the unit separately at mains side 3-ph. with semiconductor fuses.
Caution: EMC-measures
If the REVCON power-feedback-unit is mounted in plants, which must be build according to
EMC-regulations, all connections between the inverter and the power-feedback-unit as well as the
synchronise-wires to the mains and the feeding wires to the interference suppression filter must be
shielded.
page 4
Product manual REVCON SVC
3.0 Technical data
General technical data:
*1 nom. voltage (V)
3 x 400 ± 10 %
3 x 460 ± 10 %
3 x 500 ± 10 %
frequency (Hz)
40 - 60 ± 10 %
40 - 60 ± 10 %
40 - 60 ± 10 %
*2 overload capacity
ca. 1,2 x Ieff (dynamic)
ca. 1,2 x Ieff (dynamic)
ca. 1,2 x Ieff (dynamic)
efficiency (%)
ca. 97 %
(3 % therm. losses)
ca. 97 %
(3 % therm. losses)
ca. 97 %
(3 % therm. losses)
∼1
∼1
∼1
∼ 0,7- 0,95
∼ 0,7- 0,95
∼ 0,7- 0,95
power factor
fundamental
frequency component
Climatic conditions according to Class 3K3 (EN 50178 part 6.1)
temperature of environment
temperature of cooling air
*3 need of airflow
*4 altitude above sea level
air pressure
relative humidity
+5 +40°C(+41 +104°F)
+5...+35 C (+41...+95°F)
a) 200m3/h /b) 350m³/h
c) 700m³/h
+5 +40°C(+41 +104°F)
+5...+35 C (+41...+95°F)
a) 200m3/h /b) 350m³/h
c) 700m³/h
+5 +40°C(+41 +104°F)
+5...+35 C (+41...+95°F)
a) 200m3/h /b) 350m³/h
c) 700m³/h
1000m (3280ft)
1000m (3280ft)
1000m (3280ft) l
86kPa – 106kPa
86kPa – 106kPa
86kPa – 106kPa
5-85% not dewy!
5-85% not dewy!
5-85% not dewy!
•
•
•
storage temperature
-25...+55°C (-13...+131°F)
-25...+55°C (-13...+131°F)
-25...+55°C (-13...+131°F)
transport temperature
-25...+70°C (-13...+158°F)
-25...+70°C (-13...+158°F)
-25...+70°C (-13...+158°F)
Table 3.0
*1 Other voltages on inquiry.
*2 Allowed operating duration see "Allowed operating data".
*3 Depending on the size of the model (nominal power a) 7-45kW /b) 70-135kW /c) 140-200kW).
*4 By mounting on a altitude higher than 1000m (3280ft) above sea level it is necessary to reduce the power
rating or rather use the forced cooling (by fan) or reduce the temperature of the cooling air respectively.
page 5
Product manual REVCON SVC
Current load (400 V, 460 V and 500 V):
REVCON ® - Type
SVC 11-400-1-230
SVC 18-400-1-230
SVC 28-400-1-230
SVC 38-400-1-230
SVC 50-400-1-230
SVC 70-400-1-230
SVC 100-400-1-230
SVC 135-400-1-230
SVC 160-400-1-230
SVC 200-400-1-230
REVCON ® - Type
SVC 15-460-1-115
SVC 24-460-1-115
SVC 33-460-1-115
SVC 42-460-1-115
SVC 64-460-1-115
SVC 83-460-1-115
SVC 105-460-1-115
SVC 138-460-1-115
SVC 160-460-1-115
REVCON ® - Type
SVC 17-500-1-230
SVC 27-500-1-230
SVC 37-500-1-230
SVC 45-500-1-230
SVC 70-500-1-230
SVC 90-500-1-230
SVC 115-500-1-230
SVC 150-500-1-230
AC
max. current Ieff
16 A
26 A
40 A
55 A
72 A
101 A
144 A
195 A
231 A
289 A
DC
max. current I
19 A
31 A
48 A
66 A
87 A
122 A
157 A
236 A
279 A
350 A
AC
max. current Ieff
19 A
30 A
41 A
53 A
81 A
104 A
133 A
173 A
201 A
DC
max. current I
23 A
36 A
50 A
64 A
98 A
126 A
161 A
209 A
242 A
AC
max. current Ieff
20 A
31 A
43 A
53 A
81 A
104 A
133 A
173 A
DC
max. current I
24 A
38 A
52 A
64 A
98 A
126 A
161 A
209 A
Table 3.1
Type key
SVC 11 -
400 - 1
- 230 V AC
(example)
auxiliary voltage (V)
Number of fans
voltage (V)
constant power rating (kW)*
REVCON• for VLT 5000
page 6
Product manual REVCON SVC
4.0 Mounting
The power-feedback-unit REVCON is provided for vertical wall-mounting (+ 15°). Mounting is
only allowed on a flat surface without using any kind of spacers. When mounting inside of cabinets
it is necessary to mount the device directly on the mounting plate without using any kind of spacers
and to drain away the waste heat.
This kind of mounting is necessary to guarantee the right way for the cooling air.
A power loss of 3% from the max. nominal power rating has to be calculated.
Air-temperature may not exceed 40 °C (104 °F) near the unit. Air-in- and air-out-openings at the
top and the bottom of the unit may not be concealed by installation materials such as cable ducts or
other equipment.
Keep a distance of min. 15 cm to the air-in- and air-out-openings and a distance of min. 7 cm to
beside mounted parts or cabinet-walls.
REVCON• SVC (choke included)
REVCON ®
type
SVC 11-400-1-230
SVC 18-400-1-230
SVC 28-400-1-230
SVC 38-400-1-230
SVC 50-400-1-230
SVC 70-400-1-230
SVC 100-400-1-230
SVC 135-400-1-230
SVC 160-400-1-230
SVC 200-400-1-230
REVCON ®
type
SVC 15-460-1-115
SVC 24-460-1-115
SVC 33-460-1-115
SVC 42-460-1-115
SVC 64-460-1-115
SVC 83-460-1-115
SVC 105-460-1-115
SVC 138-460-3-115
SVC 160-460-3-115
*
Danfoss H+H1 H
e
f1
H1
B
B1
T
T1
f2
f3 weight type of
protection
order-no. (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg)
192H3445
192H3446
192H3447
192H3448
192H3449
192H3450
192H3451
192H3452
192H3453
192H3454
530
530
610
610
710
758
758
758
867
867
420
420
500
500
600
600
600
600
804
804
80
80
80
80
80
128
128
128
33
33
245
245
245
245
245
245
245
245
306
306
270
270
270
270
270
270
270
270
380
380
295
295
295
295
295
295
295
295
395
395
85
85
260
260
260
260
260
260
260
260
350
350
80
80
80
80
80
80
80
80
80
80
400
400
680
680
14
15
19
25
26
33
35
41
75
80
IP 20
IP 20
IP 20
IP 20
IP 20
IP 20
IP 20
IP 20
IP 20
IP 20
*
H1
B1
T1
f1
Danfoss H+H1 H
B
T
f2
f3 weight type of
e
protection
order-no. (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg)
192H3455
192H3456
192H3457
192H3458
192H3459
192H3460
192H3461
192H3462
530
610
610
710
758
758
758
867
867
420
500
500
600
600
600
600
804
804
80
80
80
80
128
128
128
33
33
245
245
245
245
245
245
245
306
306
270
270
270
270
270
270
270
380
380
295
295
295
295
295
295
295
395
395
85
85
260
260
260
260
260
260
260
350
350
80
80
80
80
80
80
80
80
80
400
400
680
680
15
19
25
26
33
35
41
75
80
IP 20
IP 20
IP 20
IP 20
IP 20
IP 20
IP 20
IP 20
IP 20
*
REVCON ® type Danfoss H+H1 H
H1
B
B1
T
T1
f2
f3 weight type of
e
f1
order.-no. (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg) protection
SVC 17-500-1-230
SVC 27-500-1-230
SVC 37-500-1-230
SVC 45-500-1-230
SVC 70-500-1-230
SVC 90-500-1-230
SVC 115-500-1-230
SVC 150-500-3-230
192H3463
192H3464
192H3465
192H3466
192H3467
192H3468
192H3469
192H3470
530
610
610
710
758
758
758
867
420
500
500
600
600
600
600
804
80
80
80
80
128
128
128
33
245
245
245
245
245
245
245
306
270
270
270
270
270
270
270
380
295
295
295
295
295
295
295
395
85
260
260
260
260
260
260
260
350
80
80
80
80
80
80
80
80
400
680
15
19
25
26
33
35
41
70
IP 20
IP 20
IP 20
IP 20
IP 20
IP 20
IP 20
IP 20
*inclusive metal cable-glands (30mm)
page 7
Product manual REVCON SVC
All types will be delivered with flange with metal cable glands for shielded cables and fan.
page 8
Product manual REVCON SVC
4.1 Dimension diagrams
1.
2.
3.
SVC 11-400-1-... to SVC 135-400-1-...
SVC 15-460-1-... to SVC 105-460-1-...
SVC 17-500-1-... to SVC 115-500-1-...
B2
cooling airflow out
H2
H1
f
f
4'8%10
H
7
f
f
B
e
B1
T
cooling airflow in
All cable inputs from bottom.
page 9
Product manual REVCON SVC
1. SVC 160-400-1-... up to SVC 200-400-1-...
2. SVC 138-460-1-... up to SVC 160-460-1-...
3. SVC 150-500-1-...
Kühlluftaustritt
H1
4'8%10
f3
H
f2
8,5
f1
B
e
B1
T
Kühllufteintritt
Alle Kabeleinführungen von unten.
page 10
Product manual REVCON SVC
4.2 Space diagram of the control board (REV 1.4.X)
terminal X3
connection to
driver board
terminal X5, X8
option
X8
J4
X3
X5
TR1
TR2
L4
TR3
TR5
TR4
TR6
J1
LD5
LD3
SW 1
J5 J3
J6
LD4
J7
LD2
LD1
X1
REVCON
V. 1.4.3
X2
X4
from version 1.4.2
terminal X1
synchronisation to
mains supply
terminal X4
connection to
signalling board
type of
control board
(example)
LED-messages
green:
operation
1. red:
phase failure
2. red:
UCE / overcurrent
orange: overtemperature
yellow: collective error
terminal X2
ext. messages
and controlling
push-button
„Quit/Reset“
(only version 1.4.1)
Figure 4.2
page 11
Product manual REVCON SVC
5.0 Main circuit connection
Power unit
: main circuit connection L1, L2, L3, PE
DC-bus connection
: plus and minus (directly from the DC-bus
of the frequency inverter) 530 - 750 V
Control unit
: supplied by power unit
CAUTION:
The DC-bus terminals of the frequency inverter must be connected directly to the capacitor unit.
The mains connection consists of one connection for the power unit at terminals L1, L2, L3 and PE.
For devices from SVC50... the PE-wire must be connected directly to the housing via 8mm earthing
screw.
The mains connection of the control unit is protected by fuses build in the fuse-terminals or by the
control fuses integrated on the control board respectively. The power unit is not protected at the
input-side, but it is advisable to protect it according to the power of the device by semiconductor
fuses (3-ph.) in addition to the line protection , according to the valid VDE regulations. The input,
coming from the DC-bus, is protected internal with semiconductor fuses and will be connected to
the DC-bus of the frequency inverter, where each plus- and minus-connection of the frequency
inverter and the REVCON• must be coupled.
At the standard design the chokes have a switch-on-time of 50% (in 10 min.).
Chokes for a higher switch-on-time e.g. 100% on inquiry.
page 12
Product manual REVCON SVC
F Connection instructions
All connections should be made as short and low-inductance as possible.
In according to the EMC-regulations it is necessary to use shielded cables.
A defined phase sequence (clockwise rotation field) must be observed at the main circuit
connection of the power unit. REVCON• is equipped with a phase-sequence control unit. In case of
an incorrect rotation field it is not possible to put REVCON• into operation. You get an error
message via LED as follows: "rotation field failure" or "phase failure" and "collective error".
In this case two phases, connected to the power unit, have to be exchanged.
For frequency inverters, whose parameters for running mode and generating mode can be adjusted
separately, it is advisable to adjust the generating parameters for the current limit or rather the
power limit under the maximum value of the Power-Feedback-Unit. In this connection the possibly
existing time ramps for the generating mode must be adjusted, too.
To find out the correct value of regenerating power it is necessary to note that the real momentary
regenerating power is dependent on the real existing main circuit voltage all the times. To calculate
the regenerating power the following formula will be used:
P = Ueff · Ieff · v3 · cos• (at regenerating power : cosϕ = 1)
The maximum possible regenerating power referred to the momentary voltage value is calculated
from the momentary effective main circuit voltage and the maximum root-mean-square current of
the respective device.
Example:
Model SVC 50, maximum root-mean-square current 72A (see technical data),
nominal mesh voltage rating e.g. 400V.
From it results: P = 400V · 72A · v3 = 49883, that's about 45.0kW.
If the momentary effective main circuit voltage is only 395V or even lower for a short time, the
maximum possible regenerating power is reduced, too:
P = 395V · 72A · v3 = 49259W, that's about 49.2kW.
Concerning the parallel connection of Power-Feedback-Units it is to note that the summery of the
regenerating power must be reduced by 7% of the whole value.
Example: 3 pieces 50kW parallel
3 · 50kW = 150kW - 7% = 139.5kW (at 400V)
So the maximum possible regenerating power results in only 139.5kW at the parallel connection of
three 50kW devices.
page 13
Product manual REVCON SVC
Application example:
Figure 5.2.1
Within greater plants several power feedback units may be coupled. Figure 5.2.1 shows an example
of a crane plant with some possible combinations.
The operation of several inverters at one common DC-circuit allows to reduce the amount of power
feedback units. On the other hand several power feedback units may be coupled to transmit more
power. It’s also possible to drive several motors at one inverter, as they react, seen from the DCcircuit (and that’s, what the REVCON®-unit sees), like one big motor.
To proportion such a plant it is important to look at the worst case. The maximum feedback power
of the REVCON®-unit has to be higher as or , at a minimum, equal to the total amount of the
braking power of the connected motors.
page 14
Product manual REVCON SVC
Danfoss offers a complete range of power feedback units for VLT frequency converters, types
5001-5051.
Œ
Œ
Example 1 - Conveyor belt
Fig. 1 shows the relation between the braking
power and the acceleration/braking of a
conveyor belt. During braking the motor power
is negative, as the torque on the motor shaft is
Description of the braking system
When the speed reference of a frequency
negative, too. The braking power, i.e. the power
converter is reduced, the motor acts as a
emitted at the REVCON-unit, corresponds
generator and brakes. In this case it supplies
almost to the negative motor power, reduced by
energy to the frequency converter, where it is
the losses in the motor and the VLT frequency
collected in the intermediate circuit. As soon as converter.
the energy respectively the voltage in the VLT- In addition it can be seen that the motor power
intermediate circuit rises, the energy will be fed is time-dependent.
back into the supplying network by the external
REVCON -unit (option).
Kinetic energy (E) of conveyor belt + motor

Without using a REVCON -unit, the
E = ½ ⋅ m ⋅ v 2 + ½ ⋅ j⋅ω 2
[Ws]
intermediate circuit voltage would continue to
increase, until the converter cuts off for
protection. The advantage of using a REVCON m ≅ mass in linear movement
[kg]
-unit is, that even heavy loads, i.e. with
v ≅ speed of the mass in liner movement [m/s]
conveyor belts or cranes, could be braked
j ≅ inertia factor of motor and gear
[kgm²]
rapidly to standstill. In addition, the VLT 5000
n ⋅ 2π
ω ≅ motor speed =
[rad/s]
incorporates brake monitoring to ensure, that
60
the maximum current indicated at the REVCON

-unit won’t exceed a specific limit.
Œ
This formula may also be expressed as follows:
Danfoss has chosen a solution, where the power
[Ws]
E = ½ ⋅ m ⋅ v 2 + 0.0055 ⋅ j ⋅ n 2
feedback unit REVCON is no integral part of
the frequency converter.
However, not all of this energy is released to
the power feedback unit REVCON. The
To the user this offers the advantage, that the
friction of the conveyor belt and the power loss
regenerative power respectively the braking
current of the REVCON-unit can be selected as of the motor also contribute to the braking
function. Consequently the formula for energy
required.
release (Eb) to the REVCON-unit is as follows:
Knowledge of the system
2
2
To select the right size of the REVCON-unit, it E b = (½ ⋅ m ⋅ v ⋅ j ⋅ ω - ½ ⋅ M f ⋅ ω )η Motor [Ws]
is necessary to know how often and how
powerful the motors brake.
[Nm]
Mf ≅ Friction torque
ηm ≅ Motor efficiency
In the following, calculations of the
regenerative power are given by the examples
n ⋅ 2π
, the result is like this:
Replacing ω by
of a conveyor belt, a crane plant and a
60
centrifuge.
E b = (½ ⋅ m ⋅ v 2 ⋅ 0.0055 ⋅ j ⋅ n 2 - 0.052 ⋅ n ⋅ M f ) ⋅ηMotor
page 15
Product manual REVCON SVC
Œ
Fig. 1
The relation between braking power and acceleration/braking of a conveyor belt.
Geschwindigkeit
Geschwindigkeit
Drehmoment
Leistung
Beschleunigung
Tp ≅ Process period time
Tb ≅ Braking time
page 16
Verzögerung
Product manual REVCON SVC
Œ
Example 2
Crane plant (conveyor belt with ramp)
Part 1
Determination of the power when decelerating
with constant speed.
When decelerating loads with constant speed
the energy is calculated according to the
following formula:
E pot = m ⋅ g ⋅ ∆h
Epot
m
g
h
≅ potential energy
[Ws]
≅ mass
[kg]
≅ acceleration due to gravity
[9.81 kg m/s²]
≅ difference in altitude
[m]
Losses of the motor as well as losses of gear
and friction reduce the braking power.
EBpot = m ⋅ g ⋅ h ⋅ ηmotor ⋅ η gearing ⋅ η friction
Œ
Part 2
Determination of the maximum power, which is
transmitted from constant decelerating speed
till stoppage.
If a load is slowed down from constant
decelerating speed up to stoppage, so the total
energy is the sum of the energy determined in
example 2 part 1 and the kinetic energy
determined in example 1 (conveyor belt).
EBΣ max = Ebkin + EBpot
Even in this case the maximum braking power
is determined by division of EBΣmax with the
time in which the load is slowed down from
constant speed to zero.
PB =
EBΣ max  averavge power during 

= 
TB
 the total braking time 
TB ≅ deceleration time from constant
decelerating up to stoppage [s]
Consequently the braking power PB is
calculated as follows:
PB =
EBpot
TB
TB ≅ braking time with constant speed [s]
The power feedback unit REVCON must be
able to transmit this power according to the
temperature-limited-load graphs.
page 17
Product manual REVCON SVC
Œ
Example 3 - Centrifuge
Another typical application where braking is
required are centrifuges. The weight of the
centrifuge content is m.
j
≅ inertia factor of the centrifuge =
1 ⋅ m ⋅ (r 2 + r 2 )
[kgm²]
2
1
2
jm ≅ inertia factor of the gearmotor [kgm²]
ηm ≅ efficiency of the gearmotor
n1 ≅ max. motor speed
[rpm]
[rpm]
n2 ≅ max. centrifuge speed
C
2
2
E b = (0.0055 ⋅ jc ⋅ n2 - 0.0055 ⋅ jm ⋅ n1 ) ⋅ηm [Ws]
Œ
Calculation of braking power
When calculating the braking power it has to be
ensured that the Feedback-Unit transmits the
average power during the braking process and
the peak power. The average power results from
the temperature-limited load graph. Here the
relation between braking time and break has to
be kept. The peak power is determined by the
braking torque, i.e. during the braking process
the Feedback-Unit has to be able to release the
delivered energy to the network.
Pict. 3 shows the relation between average
power and peak power.
page 18
Product manual REVCON SVC
Œ
Calculation of the peak braking power
Ppeak,mec is the peak power of the motor when
braking at the motor shaft. It can be calculated
as follows:
Ppeak , mec = Pmotor ⋅ M BR (%)
[W]
Ppeak is the description of the peak power
released to the Feedback-Unit when the motor
brakes. Ppeak is lower than Ppeak,mec, as the power
is reduced by the efficiency of the motor and
the VLT frequency inverter. The peak power
can be calculated as follows:
Ppeak = Pmotor ⋅ M BR(%) ⋅ ηmotor ⋅ ηvit
[W]
page 19
Product manual REVCON SVC
As with falling frequency the motor-terminal
voltage falls proportionally, inversely
For braking proceedings with variable frequency proportional the motor current has to rise to keep
the power constant.
(fmax ⇒ f0) some special features have to be
considered.
In practice this would be possible, if the
frequency output signal is predetermined as
Braking with constant torque / current
analog value e.g. 0-10 V to the momentAs a rule at the nominal frequency rating fnom the controller input 10-0 V of the frequency inverter.
voltage at the motor terminals corresponds to the
Another possibility of dynamic braking can be
nominal voltage rating Unom and with falling
frequency the motor voltage falls proportionally. achieved by the adaptation of the braking ramp, if
the ramp with falling frequency is vanished more
As a consequence with the given constant back- steeply, hyperbolic steplessly or in several steps.
feeding current the transmitted power of the
Remark:
REVCON-unit falls with the frequency.
For applications like motor test stands, wind- and
The same is valid for a linear braking ramp-down water-power plants in principle constant power
devices with 100% duty-time have to be used.
time.
In principle, the dimensioning is normally
The power results from the division of the energy realised according to the expected constant
braking power or the feedback power to the
with the braking time TB [s] (see examples of
network.
use).
Dimensioning the Power feedback unit
For these cases the power feedback unit has to be
designed for the max. generatoring current of
motor or frequency inverter with fmax; or the
generatoring current of the inverter has to be
limited to the max. current of the power feedback
unit.
Braking with constant power
The advantage of dynamic braking is the optimal
utilisation of the power feedback unit during the
whole braking time so that in this case the
REVCON-unit has not to be designed for the
max. current or the max. power with fNenn, but
only for the average current or the average power
of the braking process.
To allow the optimal utilisation of the capacity of
the power feedback unit, the following settings
are possible to realise a braking with constant
power.
page 20
Product manual REVCON SVC
f [Hz]
P
I/M
50
FI-Frequency f
FI-CurrentI
FI-Power
0
t
Fig. 1: Braking with linear falling frequency at working machines with square load torque
f [Hz]
P
I/M
FI-Frequency
F
FI-Power P
50
FI-Current I
0
t
Fig. 2: Braking with constant current / torque at working machines with square load torque
f [Hz]
P
I/M
FI-Frequency F
50
FI-Power P
FI-Current I
0
t
Fig. 3: Braking with constant power at working machines with square load torque
page 21
Product manual REVCON SVC
Œ
distributor.
Decelerating of the inertia
In the case of braking of high inertia values on
the motor shaft, the power feedback units can
be based on the inertia moment, ∆ω and ∆t.
ω Start
∆ω/∆t
ω Ende
∆t
Abb. 4
∆t is determined by the ramp-down time in
parameter 208.
G ATTENTION!
The ramp-down time goes from the rated
motor frequency in parameter 104 to 0 Hz.
Ppeak can be calculated as:
Ppeak = η motor ⋅ηVLT ⋅ ω start ⋅ j ⋅
∆ω
∆t
 2π  ∆n
Ppeak = η motor ⋅ηVLT ⋅ nstart ⋅ j ⋅ 
 ⋅
 60  ∆t
2
j is the inertia moment at the motor shaft
The values of the power feedback unit can be
calculated as described under the preceding
paragraphs.
Œ
Continuos braking
For continuos braking a power feedback unit
has to be selected, in which the constant
braking power does not exceed the power
defined in the limiting-load graphs.
G ATTENTION!
For further information contact your Danfoss
page 22
Product manual REVCON SVC
Œ
Optimal braking conditions
Dynamic braking is useful from the maximum
speed down to about 8% of the nominal speed.
Below 8% of the nominal speed DC braking is
to be applied as required.
The most efficient way to do this is to change
from dynamic to DC braking at this point. See
fig. 5.
f[Hz
50 ]
dynamic braking
DC-Braking
4
Fig. 5
t[s]
G ATTENTION!
Only the types REVCON SVC released
by Danfoss are to be used. Otherwise the
frequency inverter and /or the power feedback unit may be damaged.
page 23
Product manual REVCON SVC
5.1
Connection of the auxiliary voltage for fan and temperature
supervision
At devices with fan and/or temperature supervision two additional terminals [blue one = N, grey
fuse-terminal = L11] are present. They are for connecting the auxiliary voltage used by the fan or
rather by the temperature supervision.
+
-
to the DCbus of the
inverter
L1
L2
L3
mains
N
L11
PE
fan and
temperature
supervision
230 V AC*
* Other voltages on inquiry
Caution:
Non-connection of the 230V auxiliary voltage results in non-working of the temperature
supervision and can damage the device by overheat!
page 24
Product manual REVCON SVC
5.2 Connecting diagram of the REVCON• SVC
L1
L2
L3
N
PE
1
L1
N
230V
2
3
4
5
Funkentstörfilter
L11 N PE
L1 L2 L3
PE
L1 L2 L3
Funkentstörfilter
89+
VLT 5000
88-
6
+
REVCON SVC...(Typ)
-
(mit int. Drossel)
Steuerelektronik
Relaiskontakte
Fehlermeldung
PE U
V
W
Regler+24 V freigabe
ext.
AUS
X2 2
1
4
3
X2 7
8
ext. EIN ext. EIN
RESET RESET
9
10 11 12
+
-
M
3~
7
Figure 5.2
page 25
Product manual REVCON SVC
Legend for figure 5.2 (REVCON• SVC)
1- Attention! Behind the pre-connected main switch except the frequency inverter and the power
feedback unit no additional loads have to be connected. If this is done nevertheless in case of
switching off the supplying network during feeding back a dangerous rise of the output voltage
would occur. This high voltage within the disconnected network area could damage these
additional loads, the frequency inverter and even the power feedback unit itself.
Protection according to frequency inverter product manual.
2- In case of different power/sections it is necessary to provide a separate protection according to
DIN VDE 0298 or to install short circuit proof wires. In case of equal power/sections (InverterREVCON) line-protection is given by position 1.
3- Line-section according to the valid VDE-regulations.
4- Protection (230 V auxiliary voltage) according to DIN VDE 0298 or short circuit-proofed
wiring.
5- If the radio interference filter is mounted inside the frequency inverter’s housing, an additional
radio interference filter has to be mounted at the AC-connectors of the REVCON-unit.
6- Line-section according to valid VDE-regulations. The DC-bus connection at the inverter must
be made directly at the DC-capacitor-unit of the inverter.
7- Via the terminal pairs 9/10 and 11/12 it is possible to connect an external „ON“ respectively
„RESET“.
terminal 9 and 10:
potential free contact (short time contacting)
terminal 11 and 12: positive pulse (12 - 24 VDC); practicable via e.g. PLC-driving
(terminal 11 +, terminal 12 -)
page 26
Product manual REVCON SVC
5.3 Series fuses
The power-feedback-unit is connected to mains supply by the terminals L1, L2, L3 and PE. Mains
fuses must be designed according to the current load capacity of allowed connection cables.
Semiconductor fuses have to be connected in series of the power-feedback unit as follows:
REVCON ® - type
SVC 11-400-1-230
SVC 18-400-1-230
SVC 28-400-1-230
SVC 38-400-1-230
SVC 50-400-1-230
SVC 70-400-1-230
SVC 100-400-1-230
SVC 135-400-1-230
SVC 160-400-3-230
SVC 200-400-3-230
REVCON ® - type
SVC 15-460-1-115
SVC 24-460-1-115
SVC 33-460-1-115
SVC 42-460-1-115
SVC 64-460-1-115
SVC 83-460-1-115
SVC 105-460-1-115
SVC 138-460-3-115
REVCON ® - type
SVC 17-500-1-230
SVC 27-500-1-230
SVC 37-500-1-230
SVC 45-500-1-230
SVC 70-500-1-230
SVC 90-500-1-230
SVC 115-500-1-230
SVC 150-500-3-230
max. fuse AC
Ferraz 6,9xx CP gRC 14.51 32A
Ferraz 6,9xx CP gRC 14.51 40A
Ferraz 6,9xx CP gRC 14.51 63A
Ferraz 6,621 CP URQ 27x60 / 80A
Ferraz 6,621 CP URQ 27x60 / 100A
Ferraz 6,621 CP URQ 27x60 / 160A
Ferraz 6,621 CP URQ 27x60 / 200A
Ferraz 6,621 CP URQ 27x60 / 315A
Ferraz 6,6 URD 31 D11A 0350A
Ferraz 6,6 URD 31 D11A 0400A
max. fuse AC
Ferraz 6,9xxCPgRC 14.51 32A
Ferraz 6,9xxCPgRC 14.51 50A
Ferraz 6,621CPURQ 27x60 / 63A
Ferraz 6,621CPURQ 27x60 / 80A
Ferraz 6,621CPURQ 27x60 / 125A
Ferraz 6,621CPURQ 27x60 / 160A
Ferraz 6,621CPURQ 27x60 / 200A
Ferraz 6,621CPURQ 27x60 / 250A
max. fuse AC
Ferraz 6,9xxCPgRC 14.51 32A
Ferraz 6,9xxCPgRC 14.51 50A
Ferraz 6,621CPURQ 27x60 / 63A
Ferraz 6,621CPURQ 27x60 / 80A
Ferraz 6,621CPURQ 27x60 / 125A
Ferraz 6,621CPURQ 27x60 / 160A
Ferraz 6,621CPURQ 27x60 / 200A
Ferraz 6,621CPURQ 27x60 / 250A
Connection and max. cross section of
the supply line *
CS M6
35mm²
CS M6
35mm²
CS M6
35mm²
CS M8
95mm²
CS M8
95mm²
CS M8
95mm²
CS M10
150mm²
CS M10
150mm²
CS M10
150mm²
CS M10
150mm²
Connection and max. cross section of
the supply line *
CS M6
35mm²
CS M6
35mm²
CS M8
95mm²
CS M8
95mm²
CS M8
95mm²
CS M10
150mm²
CS M10
150mm²
CS M10
150mm²
Connection and max. cross section of
the supply line *
CS M6
35mm²
CS M6
35mm²
CS M8
95mm²
CS M8
95mm²
CS M8
95mm²
CS M10
150mm²
CS M10
150mm²
CS M10
150mm²
Table 5.3
CS ≅ cable socket with drill hole for M6 /M8 / M10
* at the copper lug of the commutation choke
page 27
Product manual REVCON SVC
5.4 Internal fuses
REVCON ® - type
SVC 11-400-1-230
SVC 18-400-1-230
SVC 28-400-1-230
SVC 38-400-1-230
SVC 50-400-1-230
SVC 70-400-1-230
SVC 100-400-1-230
SVC 135-400-1-230
SVC 160-400-3-230
SVC 200-400-3-230
Ferraz gRB -16A 660V 10x38mm
Ferraz gRC -50A 660V 10x38mm
Ferraz gRC -63A 660V 22x58mm
Siba 50 160 06 gR-80A 660V 22x58mm
Siba 50 160 06 gR-100A 660V 22x58mm
Ferraz URQ-160A 660V 27x60mm
Ferraz URQ-200A 660V 27x60mm
Ferraz URQ-250A 660V 27x60mm
Ferraz 6,6 URD 31 D11A 0350A
Ferraz 6,6 URD 31 D11A 500A
REVCON ® - Type
DC-fuses
(use fast acting semiconductor fuses only)
SVC 15-460-1-115
SVC 24-460-1-115
SVC 33-460-1-115
SVC 42-460-1-115
SVC 64-460-1-115
SVC 83-460-1-115
SVC 105-460-1-115
SVC 138-460-3-115
Ferraz gRB 30A 660V 10x38mm
Ferraz gRC 50A 660V 14x51mm
Siba 50 160 06 gR-80A 660V 22x58mm
Siba 50 160 06 gR-100A 660V 22x58mm
Ferraz URQ-160A 660V 27x60mm
Ferraz URQ-200A 660V 27x60mm
Ferraz URQ-250A 660V 27x60mm
Ferraz 6,6 URD 31 D11A 0315A
REVCON ® - Type
DC-fuses
(use fast acting semiconductor fuses only)
SVC 17-500-1-230
SVC 27-500-1-230
SVC 37-500-1-230
SVC 45-500-1-230
SVC 70-500-1-230
SVC 90-500-1-230
SVC 115-500-1-230
SVC 150-500-3-230
Table 5.4
Connection and max. cross
DC-fuses
(use fast acting semiconductor fuses only)
Ferraz gRC 50A 660V 14x51mm
Ferraz gRC 63A 660V 22x58mm
Siba 50 160 06 gR-80A 660V 22x58mm
Siba 50 160 06 gR-100A 660V 22x58mm
Ferraz URQ-160A 660V 27x60mm
Ferraz URQ-200A 660V 27x60mm
Ferraz URQ-250A 660V 27x60mm
Ferraz 6,6 URD 31 D11A 0350A
section of the supply line *
ES
ES
ES
ES
ES
CS
CS
CS
CS
CS
M8
M8
M8
M10
M10
10mm²
10mm²
35mm²
35mm²
35mm²
95mm²
95mm²
95mm²
185mm²
185mm²
Connection and max. cross
section of the supply line *
ES
ES
ES
ES
CS
CS
CS
CS
M8
M8
M8
M10
10mm²
10mm²
35mm²
35mm²
95mm²
95mm²
95mm²
185mm²
Connection and max. cross
section of the supply line *
ES
ES
ES
ES
CS
CS
CS
CS
M8
M8
M8
M10
10mm²
10mm²
35mm²
35mm²
95mm²
95mm²
95mm²
185mm²
ES ≅ end sleeve for strands
CS ≅ cable socket with drill hole for M6 /M8 / M10
** at the fuse holder resp. disconnector
Please note that replacing an internal fuse is only allowed with original types of fuses (see Table
5.4).
page 28
Product manual REVCON SVC
Before replacing a fuse you must switch-off all voltages!
page 29
Product manual REVCON SVC
5.5 DC-bus connection
Power unit
:
mains connection L1, L2, L3, PE
DC-bus connection
:
plus and minus (from DC-bus of the frequency inverter) 530 - 750 V
The installation must be done in accordance with fig. 5.2 between the DC-bus of the frequency
inverters and the DC-input of the REVCON•.
The input, coming from DC-bus, is internal protected with semiconductor fuses and will be
connected to the DC-bus of the frequency inverter, where each plus- and minus-connection must be
coupled.
CAUTION:
An exchange or incorrect connection of + (plus) and - (minus) can damage the frequency inverter!
At the frequency inverters VLT 5000-5250 the power-feedback-unit (DC-connection) can be
connected directly to the DC-terminals for + (terminal 88) and – (terminal 89) of the inverter.
CAUTION:
If you get an error message and a switch-off of the power-feedback-unit during a retardation, it is
not allowed to reset the error directly. You have to wait until the end of the retardation and until the
DC-bus voltage has fallen to normal values.
To avoid any kind of problems you can block the impulse-release of the inverter by connecting the
collective-error-relay-contact of the power-feedback-unit with the corresponding connection of the
frequency inverter.
The safety instructions of chapter 1 must absolutely be observed!!
page 30
Product manual REVCON SVC
Electrical installation, power cables
page 31
Product manual REVCON SVC
Electrical installation, power cables
page 32
Product manual REVCON SVC
5.6 General instructions
By these information to erectors and users of a plant hints on properties and directions concerning a
REVCON power feedback unit are given. These hints are not entiteld to completeness.
Special features in comparison towards a chopper
Unlike a braking resistor a power feedback device isn’t a constant sink, but it’s dependent on the
momentary characteristics of the supplying net. Commutation brake downs and voltage-flicker in
the net have an considerable effect to the backward current of the device. In case of a short time
voltage brake down the backward current has to rise correspondingly to feedback the demanded
power-amount. Does the level of the supply voltage sink for a longer time, the maximum feedback
power is reduced.
If only one phase fails, the device is able to work on, but the current in the two remaining
conductors will rise up to 150% of the normal level.
Length of the DC-connection
The maximum conductor inductivity of the DC-connection between the inverter and the power
feedback device mustn’t exceed a certain level. The maximum conductor inductivity concerning the
power feedback unit Lmax =
L+ / − =
µ 0l
π
(ln ar + 0,25)
2
C ⋅ U GL
and the couple inductivity between the two DC-conductors
i$ 2
give an result in the maximum length of the connection line if the current
capacity is fixed by the diameter of the conductors. If the values of the input capacitance C, the
during power backfeeding maximum allowed rise of the DC-voltage •UGL=100V, the top level of
the AC-current of the device iˆ (=2xIeff), the average distance of the conductors a and the radius of a
conductor r are known the maximum longitude of the conductors can be calculated with the
following equation:
lmax =
2
C ⋅ U GL
⋅π
2
a
i$ ⋅ µ 0 ⋅ (ln r + 0,25)
page 33
Product manual REVCON SVC
Typical capacitance of the DC-connection inside the REVCON :
REVCON®-Type
SV
SVC
Power
7-45kW
70-135kW
≤45kW
≤135kW
≤200kW
DC-capacitance
4,2µF
7,5µF
100µF
200µF
>600µF
Table 5.6.1
Example:
C=7,5µF, UGL=100V, i=195A, a=20mm, r=2,8mm, µ 0=1,257.10-6 H/m
⇒
lmax=2,2m
If there are long distances to span with the DC-conductors supplemental capacities should be
installed (If the occasion arises, please contact our application-engineers).
Operation on a generator
The usage of a power feedback unit within an island network (e.g. with an diesel generator) is
possible, but there are restrictive regulations concerning the power limits.
G
0,4kV
100kVA
REVCON
RD
R
20kW
M
20kW
ID
FU
RD = rectifier device
ID = inverter device
M
Within a network, that is assembled like in figure 5.6.1, there are two additional restrictions: First
the power of the motor connected to the inverter must be lower than half of the nominal power of
page 34
Product manual REVCON SVC
the generator. Second the total amount of the power of the two other loads must be more than
double of the backfeed-power.
If these conditions aren’t checked up a change from motory to generatory operation may result in
load shocks. These shocks are too dynamic for the voltage regulator of the generator. The regulator
reacts with an overshoot and as a result of this with an over voltage within the island network.
Over voltages may cause serious damages to the connected frequency inverter and /or to the power
feedback unit and to the other loads.
Operation on a transformer
If only a few loads operate within a network section the connected transformer must be able to
transport the in this section not used power back to the next voltage level without producing a not
allowed voltage increase inside the section. Therefore the nominal power of the transformer has to
be one and a half higher than the backfeeded power out of the section, so that also the harmonic and
reactive components of the current can be transmitted. In the network section displayed in figure
3.1 these conditions are checked up, even when the other loads are switched off.
Is the backfeeded power in the order of the nominal power of the transformer, it’s impedance
voltage has to be small enough (max. 6%) to limit the voltage increase in the section.
The operation of the REVCON-unit in combination with an adjusting transformer (e.g. in the case
of a braked slip-ring induction motor) is only allowed, if the quotient ratio of fed-back-power and
nominal power is much smaller than one.
page 35
Product manual REVCON SVC
10kV
0,4kV
Tr
100kVA
REVCON
RD
R
20kW
M
20kW
ID
FU
RD = rectifier device
ID = inverter device
page 36
M
60kW
Product manual REVCON SVC
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 it’s network terminals (figure 5.6.3). Is the connection done at
the load terminals of the commutation choke it’s inductivity prevents the synchronising to the
supplying net and the induction voltage of the choke when it is switched of under load may result in
damages to the power feedback device.
Over voltages may cause serious damages to the connected frequency inverter and /or to the power
feedback unit and to the other loads.
Speisendes Netz
REVCON
GR
WR
FU
Bild 5.1
M
60kW
the same things apply to the also non-admissible pre-connection of further commutation chokes.
page 37
Product manual REVCON SVC
Line and contact resistances
The values of current carrying capacity of conductors refer to the most often used copper
conductors. Concerning to it’s higher specific resistance aluminium conductors must have greater
dimensions.
Regardless of which conducting materials is used, the contact terminals of the conductors have to
be low resistive and their number has to be reduced to the minimum.
Too much or too high resistive terminals may result in a unsafe voltage magnification during the
power feedback operation.
∆U ∆U ∆U ∆U ∆U ∆U ∆U
I
Supplying network
REVCON
RD
RD = rectifier device
ID = inverter device
ID
FU
Figure 6.1
M
Proceeding from a stable network with e.g. 400V nominal voltage and a backward current of 80A,
at a bad made terminal of 100mΩ a voltage of 8V is dropped (A good made terminal has got a
resistance of ca 1 mΩ.). During backfeed operation at seven serial terminals at the net switch there
results an voltage of 465V.
Over voltages may cause serious damages to the connected frequency inverter and /or to the power
feedback unit and to the other loads.
page 38
Product manual REVCON SVC
Current capacity of copper conductors for frequency inverters and power feedback operation
conductor cross section
(mm²) per phase
16
25
35
50
70
95
120
185
2x120
2x150
2x185
3x185
3x240
4x240
conductor radius
(mm)
2,3
2,8
3,3
4,0
4,7
5,5
6,2
7,7
2x6,2
2x6,9
2x7,7
3x7,7
3x8,7
4x8,7
fuse
(A)
63
80
100
125
160
200
250
315
400
500
630
800
1000
1250
max. permanent current
(A)
46
59
73
90
106
140
206
250
300
390
485
570
740
920
All values are based on a cable length of 100m and a max. voltage drop of 5V
table 5.6.2
Connecting further loads
Speisendes Netz
The connection of further loads ( e.g. cabinet
ventilation or climatisation) parallel to the
frequency inverter / REVCON® unit at a
common circuit breaker like in figure 5.6.5 is
REVCON
GR
not allowed. If it’s done nevertheless, in case of
tripping of the circuit breaker the connection to
the network ( energy sink and synchronising
WR
element for the power feedback unit) misses.
FU
The IGBT’s now switch the DC-voltage directly
to the other loads. The resulting nearly
Bild 7.1
M
60kW
M
rectangular "net"-voltage drives a current
through the loads, which level and form
depends on their impedance. Is the power consumption of the loads to small, the DC-voltage and
also the output voltage of the REVCON-unit rises during the backfeed operation.
page 39
Product manual REVCON SVC
Over voltages may cause serious damages to the connected frequency inverter and /or to the
power feedback unit and to the other loads.
Supplying network
RD
RD
RD
ID
ID
ID
FU
FU
Figure 7.2
M
M
REVCON
FU
M
60kW
Same things apply to the structure like in figure 5.6.6. Even in this case it is necessary to place a
circuit breaker in each backfeeding current circuit.
UCE-cut-off
The power feedback unit cuts off via the UCE-protective-circuitry if the specific maximum current
of the device is exceeded. The principle of this protective-circuitry implies that for a short time
(less than one millisecond) the IGBT is stressed over its specification for normal operation. For an
isolated case this means no problem for the REVCON-unit. However, if the over current cut off
arises often or even periodically, the high power semiconductors will age very rapid and fail
premature.
The cause of periodical UCE cut offs may be over load, under voltage in the network, a defective or
oscillating controller, e.g. of the frequency inverter, an oscillating reference input or a wrong
dimensionation of the plant.
page 40
Product manual REVCON SVC
6.0 Allowed operating data with max. braking power
− Devices of product line REVCON® SV 11-400-1 without forced cooling have an allowed
operating duration of 100%.
− Devices of product line REVCON® SV 18-400-1 without forced cooling have an allowed
operating duration of 50% (referring to a cycle time of 10 min.). With forced cooling they have
an allowed operating duration of 100%.
− Devices of product line REVCON® SV 28-400-1 with forced cooling have an allowed switch on
duration time of 50% (referring to a cycle time of 10 min.).
− For the devices from product line REVCON® SV 38-400-1 the following thermal limited load
graphs are valid.
Remark:
The specification of the actual mains voltage (between 380V and 500V) serves to the adaptation
resp. to the optimal adjustment of the control board. However, the dimensioning of the powercomponents keeps to the nominal voltage of the device ( either 400V or 500V).
The power value, named as type-power, ( e.g. 70kW with a SVC70) always refers to the nominal
voltage. If the actual voltage is 440V with a 500V-unit, even the power, which can be fed back, is
reduced by 12% from 70kW to 61.1kW. On the other hand, if the actual voltage is 415V with a
400V-unit, the power, which can be fed back, is increased by 3.7% from 70kW to 72.6kW.
page 41
Product manual REVCON SVC
6.1 Thermal limited load graphs
By means of these thermal limited load graphs you can find out the max. switch-on-time depending
on the needed braking power. The curves are valid for a max. cooling air temperature of 35°C
(95°F).
REVCON SV 45-XXX-YY-...
10
33 kW with fan
100 % constant power with fan: 26 kW
min
9
braking
time 8
7
6
45 kW with fan
5
4
2
33 kW without fan
3
1
2
37 kW without fan
1
2
1
0
0
1
2
3
4
5
6
7
8
9
10 min 11
intermission time
Example of an application:
Diagram 6.1.1
Example
å:
Evaluation:
Example
:
Evaluation:
Remark:
page 42
necessary braking power
: 50 kW
braking duration
: 2 min.
time between two brakes
: 5 min.
In this case the point of intersection of braking time and intermission time is below
the thermal limited power graph in the allowed area (with forced cooling).
necessary braking power
: 50 kW
braking duration
: 3 min.
time between two brakes
: 3 min.
In this case the point of intersection of braking time and intermission time is above
the thermal limited power graph. That means this operation cycle is not allowed.
In case of an intermission time of e.g. 4 min. this operation cycle would be allowed
again.
Product manual REVCON SVC
Thermal limited load graphs:
REVCON SVC 38-400-1
10
min
9
Bremszeit
8
38 kW mit Lüfter
100 % Dauerleistung mit Lüfter: 30 kW
7
6
5
4
3
2
1
0
0
1
2
3
4
5
6
7
9
10 min 11
Pausenzeit
8
Diagram 6.1.2
REVCON SVC 50-400-1
10
min
40 kW mit Lüfter
100 % Dauerleistung mit Lüfter: 30 kW
9
Bremszeit
8
7
6
50 kW mit Lüfter
5
4
3
2
1
0
0
1
2
3
4
5
6
7
9
10 min 11
Pausenzeit
8
Diagram 6.1.3
REVCON SVC 70-400-1
5
min
4,5
Bremszeit
4
100 % Dauerleistung mit Lüfter: 35 kW
50 kW mit Lüfter
3,5
3
2,5
2
1,5
70 kW mit Lüfter
1
0,5
0
0
1
2
3
4
5
6
7
8
9
10 min11
Pausenzeit
Diagram 6.1.4
page 43
Product manual REVCON SVC
REVCON SVC 100-400-1
5
min
4,5
Bremszeit
4
100 % Dauerleistung mit Lüfter S3:38 kW
60 kW mit Lüfter S3
3,5
3
2,5
2
1,5
100 kW mit Lüfter S3
1
0,5
0
0
1
2
3
4
5
6
8
9
10 min 11
Pausenzeit
7
Diagram 6.1.5
REVCON SVC 135-400-1
5
min
4,5
Bremszeit
4
100 % Dauerleistung mit Lüfter S3:40 kW
3,5
65 kW mit Lüfter S3
3
2,5
2
1,5
135 kW mit Lüfter S3
1
0,5
0
0
1
2
3
4
5
6
7
8
9
10 min 11
Pausenzeit
Diagram 6.1.6
REVCON SV(C) 160-XXX-3-...
5
min 100 % constant power with fan S3: 70 kW
4,5
braking
4
time
3,5
100 kW with fan S3
3
2,5
2
1,5
160 kWwith fan S3
1
0,5
0
0
1
2
3
Diagram 6.1.7
page 44
4
5
6
7
8
9
10 min 11
intermission time
Product manual REVCON SVC
REVCON SV(C) 200-XXX-3-...
5
min
4,5
braking
time 4
100 % constant power with fan S3: 70 kW
3,5
120 kW with fan S3
3
2,5
2
1,5
1
200 kW with fan S3
0,5
0
0
1
2
3
4
5
6
7
8
9
10 min 11
intermission time
Diagram 6.1.8
page 45
Product manual REVCON SVC
7.0 REVCON• control board version 1.4.X
The control terminal strip is placed on the control board and is indicated with X2. It is also fitted
with a plug-in device for easy handling (see figure 4.2).
The control board must always be designed for the respective main circuit voltage. Therefore the
main circuit voltage (400V) must be declared with every order. This is also necessary for an
exchange of the device.
From the control terminal strip the operating condition or rather the collective error can be
connected to extern. There is also the possibility to execute the external reset or the switchfunctions and to connect them with the frequency inverter.
Terminal occupation
X2
1
2
3
collective error
relay
4
5
6
terminal 5 and 6 intern connected
to the temperature supervision
7
external
OFF
8
9
external
ON/RESET
10
11
12
figure 7.0
page 46
+
-
ON/RESET
Product manual REVCON SVC
7.1 Terminal 1-4 (valid for REV 1.4.X) s. figure 4.2
There are 2 potential-free relay-contacts (one by one make-/brake-contact) with a load-capacity of
250 V ~ / 5 A or 30 V = / 3 A.
In figure 7.0 the relay is shown in neutral position.
The relay operates when:
1. main circuit voltage is present
2. no collective error exists
and after possibly an ON-signal was given.
If there is an OFF-signal at the control terminal a collective error will be signalled because in this
case the collective error relay falls.
7.2 Terminal 5, 6 (valid for REV 1.4.X)
These terminals are used by the internal temperature supervision.
7.3 Terminal 7, 8 (valid for REV 1.4.X)
(run the cable shielded)
OFF
Possibility to connect an external potential-free push button switch (make contact) to switch-off
the power-feedback-unit REVCON from external.
F
Remark
Power-feedback will be suddenly interrupted when an OFF-signal is given to the device. When
giving the OFF-signal during the retardation it can happen that an error-message of too high DC-bus
voltage is displayed at the frequency inverter.
page 47
Product manual REVCON SVC
7.4 Terminal 9, 10 (valid for REV 1.4.X)
(run the cable shielded and separated from power cables, max. length 2,5m)
( if there are longer distances to span, use terminals 11 and 12)
ON / RESET
Possibility to connect an external potential-free push button switch (make contact) to switch-on or
rather reset the power-feedback-unit REVCON from external.
F
Remark
Power-feedback will be suddenly interrupted when an OFF-signal is given to the device. When
giving the OFF-signal during the retardation it can be happen that an error-message of too high DCbus voltage is displayed at the frequency inverter.
CAUTION
Don’t put an external voltage at terminals 5 - 10. This may cause failures and can damage the
device.
7.5 Terminal 11, 12 (valid for REV 1.4.X)
Possibility to connect an external voltage 12-24 V DC (e.g. PLC) to switch on or rather reset the
power-feedback-unit REVCON.
(Plus to terminal 11, Minus to terminal 12)
page 48
Product manual REVCON SVC
8.0 Connection of the ext. operating and signalling board (option)
When mounting the device inside a cabinet it is possible to mount the operator panel in the door of
the cabinet by using the external operating and signalling board. The external board contains the
complete display (LED’s) of all running and failure messages and also the ON / RESET push button
switch.
The connection is realised by means of the ribbon cables at the pin-type-socket X4 (see figure 4.2,
page 10) of the control board.
The external operating and signalling board is available as option.
F
Remark
The operation of the device with the external operating and signalling board has no influence on
signalling the operating and error messages of the LED’s placed on the control board. Both signals
are working together.
In case of an operation together with the board and an ON-OFF-function by the control terminal X2
the switch-off signal always has priority, independent of the ON-RESET push button switch.
CAUTION
Don’t put an external voltage to the pin-type-socket X4 or to the external operating and signalling
board. This can damage the devices.
page 49
Product manual REVCON SVC
8.1 LED messages (control board version 1.4.X)
evaluation
LED – display
LED display
operation
phase
failure
UCE
overtemp.
disturbance
green
red
red
orange
yellow
At first starting
During operation
Error code:
1
X
2
X
3
X
3a
X
4
X
5
X
6
X*
7
X*
8
X
X
X
X
ready to operate
(after about 1 sec.)
system in operation
X
system is switched off
(external OUT)
⇒release necessary
system is switched off
(external OUT)
⇒release necessary
X
rotary field incorrect or
one phase is missing
phase failure has been detected
⇒confirmation necessary
in addition from version 1.4.3:
overvoltage switch-off
X
error code 6
heatsink temperature declined to normal
and the error is resetable.
X
X
overcurrent has been detected
⇒ confirmation necessary
X
X
X
X*
X
X*
X
error code 3 and 4
overtemperature of the heat sink
⇒ error-message is not resetable
as long as the temperature is
too high
several errors at the same several errors at the same time
time
ready for operation, but no power feedback
⇒ check the DC-fuses
out of operation,
min. 2 phases without
voltage
9
10
X
11**
X
overcurrent has been detected with phase
failure, based on a voltage breakdown
during commutation
X
X
out of operation,
min. 2 phases without voltage
overcurrent has been detected
⇒ confirmation is necessary
massive voltage breakdown during
commutation but without switching off
as Jumper 3 and 7 are open (chapter 9e)
⇒ operation possible,
mains improvement advisable
Table 8.1
*Remark:
**
page 50
A separate orange LED in the cover of the housing is not existing. The green LED in the cover is
changing the colour from green to orange in the case of failure (only for version 1.4.3 and higher).
For control board version 1.4.2 or higher
Product manual REVCON SVC
9.0 Function description of the device
The coding of the jumpers enables different driving possibilities and different internal functions at
special error messages.
In the following different definitions are explained which result from specific possibilities of
coding.
a)
"Autostart"
Autostart means that the device is starting with a delay-time of about 1 sec. after connecting mains
voltage by itself ("automatical switch-on").
Coding via jumper, see figure 4.2:
J1 open
: no Autostart
J1 closed : Autostart
b)
"Switch off" - "Switch on"
Switch-off means that the driving of the semiconductors and the power feedback will be
interrupted. A braking operation of the frequency inverter is no longer possible.
Switch-on is the activation of driving the semiconductors.
c)
"Storage"
REVCON is equipped with an error storage where special failures can be assigned to. Stored
error messages have to be confirmed by RESET or interruption of mains supply. "Storage" always
leads to a "switch-off" and to a collective-error-relay drop out.
page 51
Product manual REVCON SVC
d)
"Confirmation"
After a storage, when the failure is removed, the error storage must be confirmed by pushing the
RESET-button or rather by switching-off the main circuit voltage (3-ph.).
CAUTION
A confirmation in case of to high DC-bus voltage during the braking operation is not allowed and
can damage the device.
e)
"Phase failure"
The phase failure control unit controls the mains supply in all 3 phases.
In case of phase failure REVCON stays still in function for internal supplies, e.g. for the error
storage.
REVCON 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.
Coding via jumper, see figure 4.2:
J3
phase-failure-supervision
sensitive
0 Jumper open
___
___
___
___
___
insensitive
Jumper closed
___
0
X
X
off, storage “ON”
X Jumper random
0
0
X
X
off, Storage “OFF”
Remark: Jumper J7 is mounted on control boards version 1.4.2 or higher. Storage “ON” means,
that the “Phase-failure” LED will be active, until the fault is confirmed. “OFF” means, that the LED
is active as long as the fault is present.
___
J5
0
J6
0
J7
___
Disconnecting the Jumper J3 is only allowed, if the pre-connected main switches cut off the pulses
of the frequency inverter or the REVCON-unit when the supplying network is switched off. Only
with this additional contact it is sure, that in such a case the voltage in the specific network area
would not rise up to a dangerous level. The Jumper J7 should only be disconnected, if J3 is
page 52
Product manual REVCON SVC
disconnected too, because a phase failure would only be displayed as long as it is present and would
not be stored.
page 53
Product manual REVCON SVC
f) Over voltage control
With version 1.4.3 or higher an over voltage control for the AC-voltage is mounted inside the unit.
It switches off the power feedback unit at an AC-voltage off about 1.15xUN.
In this case the error code 3 is displayed (see chapter 8.1). To difference between the error
messages “Phase failure” and “Over voltage” it is possible to deactivate the phase failure control by
disconnecting Jumper 3 . If then the unit is switched of and the red and the yellow LED are active
(error code 3), an over voltage is the cause of the error.
Standard setting of the unit
Autostart and Switching off in case of phase failure with storage.
10.0 Options
10.1. External operating and signalling board.
10.2
Radio interference filter
REVCON ® - type
SVC 11-400-1-230
SVC 18-400-1-230
SVC 28-400-1-230
SVC 38-400-1-230
SVC 50-400-1-230
SVC 70-400-1-230
SVC 100-400-1-230
SVC 135-400-1-230
SVC 160-400-1-230
SVC 200-400-1-230
page 54
Order-designation / part-number for filter
RF-SVC 11
RF-SVC 18
RF-SVC 28
RF-SVC 38
RF-SVC 50
RF-SVC 70
RF-SVC 100
RF-SVC 135
RF-SVC 160
RF-SVC 200
/
/
/
/
/
/
/
/
/
/
192H3622
192H3622
192H3643
192H3643
192H3644
192H3645
192H3645
192H3646
192H3646
192H3647
Case-type
1
1
1
1
2
2
2
3
3
3
Product manual REVCON SVC
The radio interference filter of case-type 1 and 2 are mounted in footprint-housings, which could be
placed between cabinet-wall and REVCON-unit.
Diagram case-type 1
REVCON 
PE,L1,L2,L3
Netz
PE,L1,L2,L3
Diagram case-type 2
REVCON
PE,L1,L2,L3
Netz
PE,L1,L2,L3
The radio interference filter of case-type 3 are mounted in housings, which should be placed beside
the REVCON-unit.
Diagram case-type 3
The power feedback units were
fixed with screws M6 , the RFI-filter
with screws M8.
page 55
Product manual REVCON SVC
> Subject to change without notice <
Danfoss Antriebs- und
Regeltechnik GmbH,
Geschäftsbereich Elektrische Antriebe
Carl-Legien-Straße 8
63073 Offenbach
Tel.: (069) 8902-0
Telefax: (069) 8902-106
www.danfoss-sc.de
Danfoss can accept no responsibillity for possible errors in catalogues, brochures and other printed material.
Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without
subsequential changes being necessary in specifications already agreed.
MP.50.R1.32
page 56
Made for Danfoss by ELTROPLAN-REVCON