OPERATING INSTRUCTIONS Thyrobox vR 125 kvA/250 kvA EN Instructions for Transport Storage Installation Commissioning Operation Maintenance
CONTACT TECHNICAL QUERIES If you have any technical queries regarding the subjects dealt with in these operating instructions, please get in touch with our team for power controllers: Phone +49 (0) 2902 763-520 or +49 (0) 2902 763-290 Service-Hotline Our team is at your service on the following hotline: AEG Power Solutions GmbH Emil-Siepmann-Straße 32 D-59581 Warstein Phone +49 (0) 2902 763-600 http://www.aegps.
1. NOTES ON THESE OPERATING INSTRUCTIONS OBLIGATORY INSTRUCTION The operating instructions contain important information on the avoidance of hazards and assist you in installing and operating the Thyrobox VR safely, properly and in accordance with regulations. If you have questions relating to the Thyrobox VR which pertain to safety or other questions which are not covered in the operating instructions then please get in touch with our power controller team.
2. INTENDED USAGE • The Thyrobox VR is a component whose intended usage is as a voltage regulator at the feed point when feeding renewable energies (e.g. photovoltaic systems) into low voltage networks. This is what the Thyrobox VR is designed for and it may only be used as such. • The Thyrobox VR may only be operated in connection with an appropriate upstream and downstream mains disconnecting device (e.g. switch, take note of VDE 0105 T1).
CONNECTION Before connection of the Thyrobox VR, the indicated voltage on the type plate is to be compared with the mains voltage to make sure they match. • The electric connection is to be made using the required cross-section in accordance with the device type details; connection using cable lugs. COMMISSIONING Before commissioning the Thyrobox VR needs to be absolutely dry (particularly, without moisture and condensation).
2.2 LOSS OF WARRANTY Our supplies and services are subject to the general conditions of supply for products of the electrical industry, as well as our general sales conditions. Claims in connection with supplied goods must be submitted within eight days upon receipt, along with the packing slip. Claims made later cannot receive consideration. AEG PS will rescind all possible obligations such as warranty agreements, service contracts, etc.
3. CONTENT 1. Notes on these operating instructions 3 2. Intended usage 2.1 Non-liability 2.2 Loss of warranty 4 5 6 3. Content 3.1 List of illustrations 3.2 Abbreviations 7 8 8 4. Safety 4.1 Deployed symbols 4.2 Safety instructions 4.2.1 Accident prevention regulations 4.2.2 General safety notes 4.2.3 Special safety notes 4.2.4 Fire protection 4.2.5 Qualified personnel 4.2.6 Safety conscious working 9 9 10 10 10 11 11 11 11 5. Scope of supply 12 6.
14. Disassembly 14.1 Disassembly in detail 32 32 15. Maintenance 15.1 Maintenance plan 15.2 Maintenance activities 15.3 Repairs 15.4 Spare parts 33 33 33 33 33 16. Technical data 17. Error diagnoses 35 37 3.1 LIST OF ILLUSTRATIONS Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 11 Fig. 12 Fig. 13 Fig.
4. Safety 4.1 DEPLOYED SYMBOLS The following warning, prohibition, command and notice symbols are deployed in these operating instructions, around and within the Thyrobox, and in the immediate vicinity: WARNING ABOUT A HAZARD AREA – DANGER! This warning notice refers to an endangering situation. Upon non-compliance, death or major injuries may occur. WARNING ABOUT HAZARDOUS ELECTRICAL VOLTAGE – DANGER! This warning notice refers to an especially endangering situation.
4.2 SAFETY INSTRUCTIONS 4.2.1 ACCIDENT PREVENTION REGULATIONS Please unconditionally observe the accident prevention regulations of your country and the generally valid safety instructions.
Only AEG PS original spare parts or original spare parts purchased from AEG PS may be used for maintenance or repair. Personnel must always wear safety shoes during repair and maintenance work. Only physically and psychologically healthy staff members are allowed to work on the device. Personnel under the influence of impairing medication or under the influence of alcohol are not permitted to work on the device. 4.2.
Refrain from any kind of working behavior, which impacts the safety of persons and the function of the device in any form. Operate the device only in a proper condition. No safety fixtures are allowed to be dis-assembled or be put out of function. Operationally contingent measures shall be implemented prior to the removal of safety fixtures for the execution of maintenance and service, or other work tasks.
6. Transport The Thyrovox VR was fixed to a transport pallet with four screws at the factory ready for transport and packaged in foil to protect against moisture and paint damage. To prepare for transport at the installation site remove the packaging and the transport pallet from the Thyrobox VR. 6.1 TRANSPORT WITH CRANE OR HOIST Fig. 1 CRANE TRANSPORT EYES ON THE THYROBOX VR After removing the packaging the Thyrobox VR and the concrete pedestal can be transported to the set-up site.
PROCEDURE FOR TRANSPORT WITH THE CRANE/HOIST: • Open the cabinet doors of the Thyrobox VR. • After releasing two‚ concealed front mounted screws (Fig. 10) at the top of the cabinet frame the roof cover can be removed. Carefully lay the roof cover to one side. On the upper side at the corners of the frame are four eyes for inserting slinging gear into (Fig. 1). • Close cabinet doors. • Insert the four sets of slinging gear. • Carefully hoist the cabinet and lift to the set-up site.
7. Storage The devices in original packaging may be stored in dry, aerated rooms with a solid protective roof for a maximum of six months. • permissible storage temperature: –25 °C to 70 °C • permissible relative air humidity: max. 85% 8. ASSEMBLY OF CONCRETE PEDESTAL AND THYROBOX VR Procedure for the assembly of the Thyrobox VR: • For setting up the Thyrobox VR a suitable open air site is to be used.
9. FUNCTIONAL DESCRIPTION 9.1 GENERAL DESCRIPTION The Thyrobox VR is a component which can be used as a voltage regulator at the feed point when feeding renewable energies (e.g. systems for photovoltaic, combined heat and power, wind energy) into low voltage networks. The Thyrobox VR permanently measures the direction of energy flow in the network.
9.3 Thyrobox VR ILLUSTRATIONS Below are depictions of several of the components to make things clearer. The components depicted are examples and may, in some circumstances, differ in appearance. Fig. 2 CONNECTIONS FOR POWER CABLES Fig. 3 CONNECTIONS FOR POWER CABLES Fig.
Fig. 5 LIGHTNING CURRENT AND SURGE ARRESTER Fig. 6 AUTOMATIC CIRCUIT BREAKERS F3-F6 FOR CONTROL VOLTAGE Fig.
fig. 8 FRONT FAN IN SWITCH CABINET DOOR fig. 9 TEMPERATURE MONITORING OF THE Thyrobox VR WITH PT1000 fig.
fan test by manual operation of K4 fig. 11 Relay K4 9.4 GENERAL (PURPOSE) Voltage regulation in local networks – also see Chapter 1: General Description 9.5 ON SITE POWER SUPPLY OF THE Thyrobox VR For the on site power supply of the Thyrobox VR (for activation, measurement, regulation, for monitoring and internal notifications) the Thyrobox VR takes its auxiliary supply directly from the local network; 3/PEN, 230 VAC, 10 A.
10. ELECTRICAL INSTALLATION 10.1 SAFETY NOTES Before starting any work on the system the 5 safety rules must be adhered to (see also Chapter on Safety instructions). • If required regionally specific warning and restriction symbols must be mounted on the Thyrobox VR in addition by the operator. 10.2 REQUIREMENTS FOR ELECTRICAL INSTALLATION The electrical installation refers to the following illustrations: Fig. 12 Block diagram Thyrobox VR and cable distribution cabinet, Fig.
PV system Utility (EVU) Cable distribution cabinet PEN bus bar ground connection to cable distribution cabinet 4-pole cable 4-pole cable Danger of short circuit: F1 and F30 must never be switched on together! fig.
Fig.
Fig.
11. COMMISSIONING Following the technically correct installation of the Thyrobox VR commissioning takes place. The following steps apply for commissioning and initial start-up at the installation site. WARNING ABOUT HAZARDOUS ELECTRICAL VOLTAGE – DANGER! Accessing voltage carrying components within the device is prevented by transparent window coverings. They must not be removed during operation.
With this configuration (initial situation) the 6 following switch actions are now to be carried out in the sequence indicated: 1. Switch on Q1 ThyroboxVR 2. Switch on F3, F4, F5, F6 ThyroboxVR 3. Open fuse load switch F1(125A) ThyroboxVR 4. Close F10 and F20 cable distribution cabinet 5. Open F30 cable distribution cabinet 6.
12. OPERATION After commissioning or switching on the Thyrobox VR does not require any further operational handling. Note If required the setpoint for the voltage to be regulated can be configured for each phase – however, this is not normally required. For this requirement the PC software Thyro-Tool Family, which is supplied as part of the package, is needed as well as a data cable (9-pole) and possibly the adapter cable for the implementation of USB 1.1 RS 232 (also included in the scope of supply).
The start window of theThyro-Tool software appears: 4. Under the menu entry extras transmission parameters, select the serial COM interface to which the data cable is connected: 5. For the transmission speed the value 9600 Baud must be configured! Confirm the input with the “OK“. 6. Using the “IST“ (actual) button you can open the actual value view. Here, at the start, you need to enter the address of the control device/controller.
7. After inputting the controller address and pressing “OK“ the actual value view opens. In the actual value view the current actual values of each phase can be seen. Here, the key actual values: voltage load U_L1 = voltage UL1PV voltage mains U_L1 = voltage UL1EVU current I_L1 = current L1 Motorpoti = voltage setpoint of the regulation 8. Under the entry motor potentiometer (Motorpoti) the voltage setpoint of the control device can now be altered. 9.
The new setpoint is now displayed in the Motorpoti field. The output voltage of the Thyrobox VR is displayed in the field “Voltage Load U_L1“. Here you can check if the device is regulating the newly inputted setpoint. With this configuration the voltage setpoint for a phase is configured. If required the other two phases can also be configured.
13. DECOMMISSIONING If the Thyrobox VR is only to be temporarily shut down then the following steps are necessary for decommissioning. The decommissioning of the Thyrobox VR refers to fig. 12 Block diagram Thyrobox VR and Cable Distribution Cabinet. 13.1 SEQUENCE OF DECOMMISSIONING ATTENTION Danger of short circuit F30 in the cable distribution cabinet and F1 in the Thyrobox VR must not be closed simultaneously, otherwise there is a short circuit.
14. DISASSEMBLY Note The prerequisite for the disassembly of the Thyrobox VR is that all steps of the decommissioning have initially been carried out. Following this the Thyrobox VR can be disconnected from the power cables and then mechanically separated from the concrete pedestal (remove screws). The subsequent procedure for handling the Thyrobox VR can then be taken from the chapters Transport/Storage/Assembly according to the intended further usage (e.g. further use at a different location).
15. MAINTENANCE To ensure the highest level of operational safety both in terms of protecting personnel and equipment, regular monitoring, maintenance and repair works of electronic assemblies are required by law. 15.1 MAINTENANCE PLAN The Thyrobox VR is to be included by the operator in the plans for maintenance management strategy with regard to monitoring, maintenance and repair measures. 15.
Material no.
16. Technical Data Weight Thyrobox VR, circa Concrete pedestal, circa Total weight 385 kg 260 kg 645 kg Type Thyrobox VR 125 kVA Thyrobox VR 250 kVA Thyrobox VR In the case of load flow from the PV side to the utility (EVU) side it regulates continuously to 230 V (can be parameterized, conductor against N); regulation becomes active from 10% (can be parameterized) of the nominal current.
Measurements - width - height 1250 mm 1355 mm (cabinet without concrete pedestal) 1000 mm (total height concrete pedestal), of which 700 mm in the ground as well as 300 mm above the ground circa 460mm 1250 mm 1355 mm (cabinet without concrete pedestal) 1000 mm (total height concrete pedestal), of which 700 mm in the ground as well as 300 mm above the ground circa 460mm Standard Applicable parts of the technical connecting conditions for the connection to the low voltage distribution network (TAB 200
17. error diagnoses OPERATING STATUS ERROR STATUS POSSIBLE CAUSE OF ERROR F3, F4, F5 LED ON Control device LED ON lit LED ON not lit F1 Check mains voltage F1, F3 - F5 LED CONTROL Control device LED CONTROL flashing or lit LED CONTROL not flashing, not lit Check current value for regulation activation Current is capacitive (cos phi < 0.
OPERATING INSTRUCTIONS 8000048621 EN, 06/13 - V1 Due to our policy of continuous development, the data in this document is subject to change without notice. AEG is a registered trademark used under licence from AB Electrolux. AEG Power Solutions GmbH Emil-Siepmann-Str. 32 59581 Warstein-Belecke - Germany Phone: +49 (0) 2902 763-520/-290 - Fax: +49 (0) 2902 763-1201 www.aegpowercontrollers.com - www.aegps.
