THYRO-P THYRISTOR-LEISTUNGSSTELLER / THYRISTOR POWER CONTROLLER KOMMUNIKATIONSFÄHIG / COMMUNICATION CAPABLE October 2014 8000003232 DE/EN - V9
1 THYRO-P THYRISTOR-LEISTUNGSSTELLER / THYRISTOR POWER CONTROLLER KOMMUNIKATIONSFÄHIG / COMMUNICATION CAPABLE October 2014 8000003232 DE/EN - V9
2 SAFETY INSTRUCTIONS THE SAFETY INSTRUCTIONS AND OPERATING MANUAL ARE TO BE CAREFULLY READ PRIOR TO INSTALLATION AND COMMISSIONING. OBLIGATION TO GIVE INSTRUCTIONS The following safety and operating instructions must be carefully read before assembly, installation and commissioning of Thyro-P by those persons working with or on Thyro-P. These operating instructions are part of the Power Controller Thyro-P.
3 MALOPERATION AND THE RESULTS With maloperation, it is possible that power, voltage or current levels which are higher than planned reach the Thyristor Power Controller or load. On principle, this can lead to the Power Controller or load being damaged. It is important that preset parameters are not adjusted in any way that may cause the Power Controller to overload. TRANSPORT Thyristor Power Controllers are only to be transported in their original packaging (protection against damage, e.g.
4 CAUTION Hazard of electrical shock. Even after disconnection from the mains voltage, capacitors may still contain a dangerously high power level. CAUTION Hazard of electrical shock. Even when the Thyristor Power Controller is not triggered, the load circuit is not disconnected from the mains. ATTENTION Different components in the power section are screwed in place using exact torques. For safety reasons, power components repairs must be performed by Advanced Energy Industries GmbH.
5 TABLE OF CONTENTS Safety instructions List of illustrations and tables Safety regulations Remarks on the present operating instructions and Thyro-P 2 7 8 11 1. 13 13 13 14 Introduction 1.1 General 1.2 Specific characteristics 1.3 Type designation 2. Functions 2.1 Operating modes 2.2 Set point control characteristic 2.3 Control types 2.3.1 Controlled value 2.4 Indications 2.4.1 LED indications 2.4.2 Relay indications K1-K2-K3 2.5 Monitoring 2.5.
6 5.3 Bus interfaces (optional) 60 6. Mains load optimization for operating mode TAKT 6.1. dASM mains load optimization 6.2 SYT-9 procedure 6.3 Software synchronization 6.3 ASM procedure (patented) 61 61 67 67 68 7. Mains load optimization VSC 69 8. Connecting diagrams 71 9. Special Remarks 9.1 Installation 9.2 Protection against contact IP20 9.3 Commissioning 9.4 Service 9.5 Checklist 79 79 79 80 80 80 10. Type Overview 10.1 Type range 400 Volt 10.
7 LIST OF ILLUSTRATIONS AND TABLES Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.
8 SAFETY REGULATIONS IMPORTANT INSTRUCTIONS AND EXPLANATIONS Operation and maintenance according to regulation as well as observance of the listed safety regulations is required for protection of the staff and to preserve readiness to operate. Personnel installing/uninstalling the devices, commissioning them, operating them, maintaining them must know and observe these safety regulations.
9 WORK OBSERVING SAFETY REGULATIONS Before removing safety installations for performance of maintenance and repair work or other work, measures due to operation must be initiated. Work observing safety regulations also means to point out faulty behavior to colleagues and to notify the office or person responsible about defects detected.
10 - objection, - duration of use, - ambient conditions, - operating mode. GUIDELINES The devices of the type range Thyro-P conform to the currently applicable EN 50178 and EN 60146-1-1. The CE mark on the device confirms observation of the general EG guidelines for 2006/95/EC (LVD) – low voltage and for 2004/108/EC (EMC) – electromagnet compatibility, if the instructions on installation and commissioning described in the operating instructions are observed.
11 REMARKS ON THE PRESENT OPERATING INSTRUCTIONS AND THYRO-P VALIDITY These operating instructions refer to latest technical specification of Thyro-P at the time of publication and are for information purposes only. Every effort has been taken to ensure the accuracy of this specification, however, in order to maintain our technological lead and for product enhancement, we are continually improving our products which could, without notice, result in amendments or omissions to this specification.
12 in writing by Advanced Energy Industries; or if the defect arises because of the fitting of the goods to unsuitable equipment. Advanced Energy Industries will cancel all possible obligations incurred by Advanced Energy Industries and its dealers, such as warranty commitments, service agreements, etc., without prior notice if other than original AEI spare parts or spare parts purchased from Advanced Energy Industries are used for maintenance or repair.
13 1. INTRODUCTION For transport, assembly, installation, commissioning, operation and decommissioning, the safety instructions contained in these operating instructions must be applied in any case and made available to all persons handling this product. CAUTION It is important that preset parameters are not adjusted in any way that may cause the Power Controller to overload. In case of uncertainties or missing information, please contact your supplier. 1.
14 • Measured values are given at analog outputs • 4 set point channels incl. motor potentiometer to set parameters The specific characteristics especially include the following options: • LBA-2 local touch display with integrated process data recorder of up to 6 channels • LBA-2 is downward compatible with LBA and can replace it. • Cabinet installation kit (SEK) for LBA-2 with touch display. The SEK allows the installation of LBA-2 in cabinet doors. It comes with wiring and installation frame.
15 2. FUNCTIONS For optimum adjustment to different products and production processes as well as differently electrical loads, the most favorable operating and control modes may be set according to the following overview. 2.1 OPERATING MODES This chapter gives an overview of the different operating modes. FULL WAVE SWITCH (TAKT) Depending on the prescribed set point, the mains voltage is periodically switched. In this operating mode, almost no harmonics are created.
16 SOFT-START-SOFT-DOWN (SSSD) The operating mode SSSD operated similar to operating mode TAKT. However, it can be used especially advantageous in operation of large single loads to reduce pulse-shaped mains loads and therefore to reduce voltage variations. Switching on and off of turn on-time Ts occurs by applying periods with phase-angle firing (VAR). Please see following diagram.
17 • Set point 2 (X5.2.11 - X5.1.13 ground) 0-5V default The inputs set point 1, 2 are two electrically equal analogue inputs for current or voltage signals, with subsequent A/D converter (resolution 0.025% of the final value), and they may be set to the following signal ranges: 0(4)-20 mA (Ri = ca. 250 V / max. 24mA) 0-5 V (Ri = ca. 8,8 kV / max. 12V) 0-10 V (Ri = ca. 5 kV / max.
18 SET POINT CONTROL CHARACTERISTICS The set point control characteristic (Fig. 1) of Thyro-P may be easily adapted for the control output signal of the upstream process controller or automation system. All signals customary on the market may be used. The adaption is made by changing the starting and ending points of the control characteristic. Inverted operation (ending value is smaller than the starting value in voltage or current) is also possible.
19 SET POINT ENABLE REGISTER The set point Enable Register (AD_P_SW_ENABLE, adr. 94) enables the 4 set points to be shut off or enabled independently. Only enabled set point inputs are part of the effective total set point value. The shut off or inactive set points are shown by the LBA-2 and can thus, if necessary, be checked before connecting. The set point Enable Register can be changed from all service units (Bus, Thyro-Tool Family, LBA-2).
20 CONTROLLER RESPONSE If the load resistance changes, for instance due to temperature effect, ageing or load fault, then the values (depending on control type) effective on the load change as follows: CONTROL LOAD RESISTANCE DECREASES LIMIT LOAD RESISTANCE INCREASES EFFECTIVE* LIMITATIONS P ULOAD ILOAD P ULOAD ILOAD Urms max larger = larger smaller = smaller Irms max Pmax TYPE U U (UxU) Urms max larger = larger smaller = smaller Irms max Pmax I Irms max smaller smal
21 LIMITING RELAY K2 The relay K2 only closes (in default setting) if at least one of the following values is exceeded: • 1. max. admissible effective value of the load current • 2. max. admissible effective value of the load voltage • 3. max. admissible active power of the load The relay releases if none of the values is exceeded anymore. It is possible to set which indications lead to switching of the relay. Recommendation: keep the default setting.
22 2.5.2. LOAD MONITORING It is possible to monitor load by absolute monitoring of heating elements with Rhot/Rcold ≈ 1 and relative monitoring of heating elements with Rhot/Rcold ≠ 1. 2.5.2.1 ABSOLUTE VALUE MONITORING CURRENT This function allows monitoring of a freely selectable absolute current limit. The parameters for the value may be set in ampere. i I < threshold TL indication 16,17 (Chap. 3.4) tV FIG.
23 NOTE FOR LOAD MONITORING: Load threshold I Load threshold U 35LSB 35LSB If a Thyro-P 3P is used in phase-angle operating mode, the star point of the load and the star point of the (built-in) voltage transformers should be connected together to ensure an accurate load monitoring. Please contact us in case of need.. The values in the following table apply to ohmic loads. Different values apply may be required for specific heating resistors, for instance IR radiators.
24 Star connection without neutral conductor HEATING ELEMENTS 1P Star connection with neutral conductor Delta connection 2P* / 3P 3P IN SERIES FOR EACH STRAND STAR CONNECTION DELTA CONNECTION WITHOUT CONNECTED STAR CONNECTION WITH CONNECTED 6 10% 5 13% 4 17% 3 25% 2 50% NEUTRAL CONDUCTOR 10% 13% 17% 25% 50% NEUTRAL CONDUCTOR 7% 6% 8% 7% 10% 9% 14% 13% 25% 26% TAB.
25 2.5.2.3 OVERVIEW MONITORING The following table offers an overview of the possible monitoring functions of the thyristor power controller Thyro-P.
26 2.5.4 FAN MONITORING The separately ventilated power controllers (-...HF) are fitted with thermal monitoring. The temperature is measured on the heat sink. In case of a temperature overrange, a fault indication is issued: Unit excess temp. As a standard the device will be switched off and LED Overheat will be lit. ATTENTION When using the device under UL conditions, this feature has to be switched on.
27 3. OPERATION This chapter presents the operating options of Thyro-P using local operating and display unit LBA-2 and visualization and commissioning software Thyro-Tool Family. LBA-2 for Thyro-P parameterization and process data LBA-2 Tool for visualization /analysis of saved process data and messages of LBA-2 SEK for operating of Thyro-P with LBA-2 on cabinet doors Thyro-Tool Family for Thyro-P parameterization and process visualization 3.
28 3.1.2 SETTINGS LBA-2 Thyro-P Thyro-P FIG. 7: MAIN MENU LBA-2 (SAMPLE) To change anything on LBA-2, the button SETTINGS in the main menu has to be pressed. By using the button LBA-2 the following menus will be available: Settings for LBA-2 • Operation display, bar chart, and line chart settings • Display settings • Startscreen • Languages • Bluetooth • Authorization and passwords • Information about the device • Address • Reset to factory settings 3.1.
29 3.1.4 EASYSTART This menu enables the user to easily adjust the Thyro-P. For details on the EasyStart function and its selection possibilities, see table LBA-2 MENU STRUCTURE. When the user first starts LBA-2, the EasyStart will be displayed. Once the EasyStart prompt has been conducted successfully on LBA-2, it will not appear each time LBA-2 is started. Irrespective of this, EasyStart can be selected at any time if required via the LBA-2 menu. 3.1.
30 Additional parameter sets and configurations can be stored permanently in the EEProm of the LBA-2. 3.1.7 BLUETOOTH This option is only available with model no 2.000.000.409. It can be switched on and off in the submenu of the LBA-2. It offers a wireless operation of Thyro-P • Via Thyro-App* (by Android smartphone or tablet PC) • Thyro-Tool Family (e.g. by laptop and Bluetooth) *free download from www.advanced-energy.
31 3.1.9 UPLOAD NEW LBA-2 FIRMWARE This function enables, if required, current LBA-2 firmware to be uploaded (if available). The software update can be copied by PC or Notebook on to the SD card of the corresponding LBA-2. Do not open up a new folder on the SD card, but copy the file in the SD card’s root directory and if necessary, replace the existing file. As soon as the SD card is inserted in the LBA-2, and the latter is inserted into the active Thyro-P, the firmware update will load automatically.
Display of events Calendar navigation Y scale panel Value panel Zoom & daily navigation Select LOG file Slider Slider - Labels Diagram PDF export Language selection 32 3.2.
33 3.2.2 LANGUAGES The languages available in the LBA-2 Tool are German, English, Chinese, French, Swedish, Czech, Turkish and Spanish. The language selected for the application changes the language during runtime. The language selected will be stored in the user’s Windows profile and will be applied again when the program is restarted. FIG. 10: LANGUAGE SELECTION 3.2.3 SELECT LOG FILE FOLDER A folder with valid log files can be selected via the folder selection.
34 3.2.5 TIME AXIS STANDARD ZOOM Once the program has been turned on, each diagram will be displayed with the 24h zoom setting. This corresponds to the data stored in the log file. By clicking on the other zoom settings, the data view will be reduced accordingly. With the aid of the displayed scrollbar under the diagram, the data view can be shifted horizontally along the time axis. The buttons Back and Next, next to the standard zoom, direct to the previous or following day of an saved LOG file. FIG.
35 3.2.7 VALUES DISPLAY The values display panel can change the appearance of the diagram with regard to the value sequences. By deactivating the checkboxes, the value sequences can be switched off and with the help of color settings, the color of the values sequences (bar chart) can be changed. By pressing the UP and DOWN buttons, the value times series can be displayed as a diagram in an active drawing layer above or below the other times series.
36 3.3 CABINET INSTALLATION KIT (SEK) The cabinet installation kit (optional: model 2.000.000.405) enables the LBA-2 to be mounted on a cabinet door with a thickness of up to 4mm. It consists of one 96x72mm adapter frame (cut-out dimensions 92x68mm) and a cable. The LBA-2 is connected to the RS232 interface of the Thyro-P via the cable. The LBA-2 clicks into the adapter frame and can only be removed when the cabinet door is open. In this way the technician can set the parameters (e.g.
37 It is possible to compare two sets of parameters (power controller or data file). It is thus possible, to detect deviations from the desired configuration. • line diagrams of process data with printing function, as well as storage of faults (diverse measured values from different thyristor power controllers may be displayed simultaneously). • bar diagram display It is possible to simultaneously display several bar diagrams. Each diagram has its own window. These can be adjusted in size and location.
38 3.5.1 LBA-2 Thyro-P DISPLAY OF ERROR MESSAGES If there are status messages, a red or yellow reference will appear in the LBA-2 status line (see illustration). Yellow: Red: Status messages / Warnings Error messages Incl. further status messages By pressing the status field, individual events can be displayed on the LBA-2 in the data logger view. Then previous events can also be seen.
Thyro-Tool Family LBA-2 - X X No extension - - X External error message - X X External message to forward, e.g. to relay After reset - - X Mains failure detection of control device supply X X X Controller inhibit is active - X X All parameters are useless (factory and customer parameter) X X X dyn., non regulated values are at limit X X X Fast current shut-off - X X Incorrect no.
40 3.6 LBA-2 MENU STRUCTURE "* * ! "* Settings LBA-2 Operation display Bar chart '' , .7 C "" ' , 6 8 % & "" 5 $$' " , & .7 B "" ' , 6 8 % & "" 5 $$' " , & " $ $& .
41 VSC_VAR Control mode Control parameters * " # ! 5 26 &# ! 2% $ ) 26 &# ! 2% $ 26 * #! * 26 26 26 !0 ! $% $ !' # "" )% # $&# % 26 26 26 : : 26 26 26 26 26 26 ! ! %#! # % # + % ! ! ! %#! # % # $% $ % # % 26 26 26 26 26 26 26 26 26 26 26 *" *" *" *" *" *" *" *" *" ) 26 *" ) ) $ % 26 26 27 27 27 27 *" *"
42 $! $ 5 /$ " 540 $! $ 6 /$ " 550 #$ " / %#0 $ Settings of setpoint inputs #! ( # $! $ 5 #! ( # $! $ 6 .5 .5 Setpoint 4 mopo Setpoint 1 analog (10) .5 .5 $(! .5 $" #$ "$ $" .5 .5 .5 $(! .5 $" #$ "$ $" .5 .5 .5 .5 Setpoint 2 analog (11) $! $ Relay / LED / pulse inhibit K1 Setpoint 3 remote Select event * K2 K3 LED Limit .5 .5 .
43 LED Pulse Lock *# ) $# ! )/ Select event * $ LED Fault ! / ) " 6> *# ) $# ! )/ 6> 6> 6> 6> Select event * $ LED Overheat ''$' #$-! $ $#)'$!! ' # ) ''$' #$-! $ #%*) B4?4>F ! / ) " 6> *# ) $# ! )/ 6> 6> 6> 6> Select event * $ Address Hardware Monitoring 6> 6> 6> 6> )) # ' ! / # $' ) " (( %) ' ''$' #$-! " #) 5 ) # !$ ' ! ) $# )- # (- ) 1 () ) 1 $#$ !$%1 ! # 1 !% 1 (- ) ! / 1 / !
44 * & )&& "( !#" (#& " "1 # & 27 27 6 ,1 # & 27 6 28 28 #" (#& " 8 " #" (#& " 9 " :( '( )&& "( !#" (#& " Temperature 766 & ( & '( "#1 * + & & * ' "'#& ' #&( & ) ( 7666 & ( & '( "#1 * + & & * ' "'#& ' #&( & ) ( & ( & '( "#1 * + & & * ' "'#& ' #&( & ) ( Data logger Thyro-P EasyStart 28 (( " # '( )&& "( !#" (#& " #& 7/ 8 " 9 28 -$ ( ' #" - ()&"
45 4. EXTERNAL CONNECTIONS This chapter describes external connections of Thyro-P as well as all available terminal strips and signals as necessary. The connections of the interfaces • X10 • X30 • X31 • X20 • X40 • X41 RS232 (optional with Bluetooth adapter or LBA-2) Fiber optic receiver Fiber optic sender Bus interfaces dASM input dASM output are described in chapter 5. Shielded cables grounded on Thyro-P must be used for the connections of control signals (set point inputs and analogue outputs).
46 CAUTION The pulled plug has mains voltage of the load circuit! The new connecting lines must be fused according to the applicable regulations (for applicable plug, see chapter 13). 4.3 POWER SUPPLY FOR THE VENTILATOR With Thyro-P Thyristor Power Controllers furnished with integrated ventilators (HF types), the ventilator must be supplied with a voltage of 230V 50/60Hz according to the connecting plans and the dimensional drawings.
47 short-circuited against ground (X5.1.14) so that any faults are acknowledged. The fault signalling relay is reset. The input must remain closed for at least 2 line periods to perform acknowledgement. After acknowledgement, the contactor must in turn be opened. Function: TERMINALS X5.19-14 open X5.19-14 closed* * for at least 2 line periods FUNCTION controller operating faults are reset TAB.
48 tions, limiting and the influence of operating modes with SSSD and MOSI) give the actual value signals dynamic rations which can be smoothed with a smoothing stage. The MEAN (VALUE) parameter is applied here. The following setting is recommended: MEAN(VALUE) = 25. 4.11 CURRENT TRANSFORMER By standard, each power section of the power controller has a current transformer.
49 REMARK Current measuring in not-controlled phases Thyro-P 2P Although phase 2 is not controlled in Thyro-P 2P, it is possible to take measuring values during this phase. A current transformer corresponding to T1 must be used and burdened (see type overview). It is connected as in table 23 to X7.1.22 – X7.2.21. Thyro-P 1P As only phase 1 is controlled with Thyro-P 1P, the measuring systems of phase 2 and 3 can be used freely. The corresponding current transformers (with max.
50 Example 2 Thyro-P 3P400-110 H • the power controller is a 3-phase power controller of Thyro-P 3P 400-110H with 110A type current • three similar current transformers with transformation ratio of tr = 100:1 The calculation and selection of the three similar load resistor has to be done according to example 1. After selecting the resistors, which value must be between 0,818 Ω and 1 Ω, the the value has to be entered with Thyro-Tool Family or LBA-2 in parameter U_Load resistor. 4.
51 Afterwards the voltage transformer ratio Uprimary / Usecondary has to be entered in parameter (Voltage transformer ratio: UE_U). Example: Usage of an external voltage transformer with Uprimary = 500V and U secondary = 25V. Measurement range 2 will be selected due to Usecondary = 25V.
52 13 13 13 13 13 13 21 14 14 14 14 20 ground 5V ground 5V ground 5V ground 5V ground 5V ground 5V +3,3V ground 24V ground 24V ground 24V ground 24V +24V* 10 11 32 33 34 16 17 12 15 18 19 20 set point 1 set point 2 analog output 1 analog output 2 analog output 3 ASM input GSE input RESET controller lock SYT9 connection QUIT +24V* * Loading: IX5.1.20 + IX5.2.20 + IX21.9 m max. 80mA TAB.
53 After filtering, the synchronization signal for control of the thyristors is generated from the secondary voltage. The connections are wired by the works. This includes the following terminals: TERMINAL STRIP X7 X7.1 12 14 16 22 24 26 32 34 36 X7.2 11 13 15 21 23 25 31 33 35 NAME current transformer phase L1 sync phase L1 load voltage phase L1 current transformer phase L2 sync phase L2 load voltage phase L2 current transformer phase L3 sync phase L3 load voltage phase L3 TAB.
54 4.15 COMPONENT MOUNTING DIAGRAM CONTROL DEVICE H104 H105 H106 S102 H102 BR806 V132 V116 BR155 BR155 (Connection for LBA-2) S101 T101 V114 V112 H103 X10 P7 H401 X700 X701 X702 X707 X706 BR807 H402 X713 X24 G800 X703 H404 V700 H403 X800 X603 K1 X5.1 X602 V600 H405 K2 K3 R101 X508 X507 5 5 for poti, etc.
55 5. INTERFACES Necessary process optimization as well as the requirements made of high, continuous and documentable quality in production processes often require the use of digital process communications. It allows interlinking of many signals and enables their evaluation in an efficient manner. LBA-2 per RS232 X40 / X41 dASM FIG.
56 With the power controller Thyro-P, the following interfaces may be used for this (see also fig. 11 on previous page): • X10, RS232 (optional with Bluetooth adapter or LBA-2) • X30, fibre optic receiver • X31, fibre optic transmitter as well as optional interfaces, for instance • X20, bus interface, e.g.
57 The connecting socket X10 of the power controller is allocated as follows (1:1 connection): FIG. 23 X10 ALLOCATION ATTENTION The LBA-2 receives its power supply (+5V) via pin 8 of the socket X10. It is imperative that this voltage is not short-circuited. Otherwise, damage to Thyro-P may be incurred. If a PC is connected to the RS232 interface, then this pin should be left unconnected, since it is not needed for data transfer. Generally, all devices with an RS232 interface may communicate with Thyro-P.
58 to the plug-in power supply fiber optic transmitter (LLS) X30 fiber optic receiver (LLE) X31 FIG. 24 SIGNAL CONVERTER RS232/FIBER OPTIC LLV.V The fiber optic distributor supply LLV.V is the basic component for the fiber optic system. It serves to connect star distributors and to amplify the light signals received. Its power supply is sufficient for supply of five fiber optic distribution components of the type LLV.4. The amplification of LLV.
59 The following figure shows the fibre optic system with LLV, Thyro-P and PC. FIG.
60 5.3 BUS INTERFACES (OPTIONAL) The control device of Thyro-P may be optionally fitted with interface cards, e.g. - Profibus DPV1 - Profinet - DeviceNet - Ethernet IP - Modbus RTU - Modbus TCP All available interface cars support the usage of motor potentiometer feature for set point processing. If the motor potentiometer feature is not used, signals can be transmitted on three inputs (Input 0, Input 1 and Input 2) of the bus interface via bus to the higher control system.
61 6. MAINS LOAD OPTIMIZATION FOR OPERATING MODE TAKT In operating mode TAKT, mains load optimization is possible for multiple power controller applications in the following described ways. The most efficient way is to use the digital and dynamic dASM process. Furthermore it is possible to use previous dynamic ASM procedure or statistic SYT-9 procedure for mains load optimization.
Installation der dA ASM-Steuerlleitungen 62 g auf das dAS SM Verfahren n sind ein paa ar einfache R Regeln bei de er elektrischen Installatio In Bezug Steuerge eräte sind zu beachten: Für undcontrol 3--phasige - ofF Installation the1dASM cablesLastten sind getrennte dASM--Gruppen zu verdrahten.
63 The LEDS can be interpreted as follows: CONNECTOR LED X40 1 X40 1 X40 1 X40 1 X40 1 X40 1 X40 2 X40 2 X40 2 COLOUR STATUS INTERPRETATION OFF A connection to the preceding device (in the direction of the master) is in place FLASHING Not all data could be sent to the preceding (in the direction of the master) device (dynamic communication error) If LED 3 is also flashing then a ring has been made with the RJ45 cables yellow There is no RJ45 cable connected ON green Connector
64 Installation of the power units for dASM operation Amongst other things the following points are important for successful installation of dASM grid load optimization • Power/grid connection of all power controllers to be executed in phase (see the diagrams of the following examples 1, 2, 3).
65 Example 2 In the following diagram 3 dASM groups are connected to the three-phase network with three single-phase Thyro-P devices each. L1 L2 L3 X41 Unit 1 (M) X40 X41 Unit 2 X40 Unit 3 X41 Unit 4 (M) X40 X41 Unit 5 (M) X40 Unit 6 RJ 45 patchcable X41 Unit 7 (M) X40 X41 Unit 8 X40 Unit 9 Even in a case where patch cables were connected between units 3 and 4, or 6 and 7, this configuration would generate the 3 dASM groups illustrated.
66 Example 3 The following illustration shows a total of 6 power controllers with symmetrical load distribution in a three-phase network: 4 Thyro-P 2P power controllers 2 Thyro-P 3P power controllers All ThyroP units in the following diagram are set up with an in phase grid connection.
67 L1 L2 L3 X41 Unit 1 (M) X40 Unit 2 X41 X40 Unit 3 X41 X40 Unit 4 X41 X40 Unit 5 X41 X40 Unit 6 X41 X40 Unit 7 (M) X41 X40 Unit 8 X41 X40 Unit 9 X41 X40 Unit 10 Unit 7 now operates additionally as a master for units 7-10. The quality of grid load optimization of the two now newly formed dASM groups (units 1-6, units 7-10) is of a similar level to the previously formed dASM group units 1-10. 6.
68 6.4 ASM PROCEDURE (PATENTED) In systems, in which several equal power controllers are operated in the operating mode TAKT, the ASM process may be sensibly used for dynamic and automatic mains load optimization in multiple Power Controller applications. This patented world premiere independently minimizes mains load peaks and therefore mains reaction shares during the current process.
69 7. MAINS LOAD OPTIMIZATION VSC General Alongside being highly dynamic, regulated heating processes with power controllers in VSC connection offer considerable advantages for practical usage in terms of reducing operating costs through savings in electricity charges. This is a result of - Considerable reduction in reactive power - Considerable improvement of power factors - Significant reduction in grid harmonics.
70 OTHER FEATURES If load monitoring is required with the VSC connection then external converters are needed on the secondary side. The wiring required by the type series Thyro-P…VSC is different with regards to both the power and control connections when compared with standard power controllers from the type series Thyro-P. OPERATING WITH LBA-2 To operate the VSC power controllers you need software for the LBA-2 version V1.2. or higher.
71 8. CONNECTING DIAGRAMS 8.1 THYRO-P 1P 1-PHASE POWER CONTROLLER 8.2 THYRO-P 2P 2-PHASE POWER CONTROLLER 8.3 THYRO-P 3P 3-PHASE POWER CONTROLLER 8.4 THYRO-P VSC 2 2-STEP PRIMARY VSC 8.5 THYRO-P VSC 3 3-STEP PRIMARY VSC 8.6 THYRO-P VSC 2 2-STEP SECONDARY VSC 8.
-X1 2 1 3 4 6 5 230 VAC -20% to 500 VAC +10% Input 14 3 4 16 12 X7.1 11 X7.2 15 -X3 5 6 1 2 Power Section Driver A1 X6 11 12 13 2 8 9 10 11 12 K2 K1 X2 7 Limit Alarm 13 14 15 K3 Option Relay Outputs X7.1 X7.2 23 X6 21 22 23 5 X5.1 X5.2 5 5V / 1mA 10 13 11 13 17 5 21 16 13 26 22 X7.1 21 X7.
#1) -X1 2 1 3 4 6 230 VAC -20% to 500 VAC +10% Input Broad band Power Supply 13 14 2 3 4 9 10 11 12 K2 K1 8 Limit Alarm 13 14 15 K3 Option Relay Outputs 1 -X4 16 12 X7.1 11 X7.2 15 -X3 5 6 1 2 Power Section Driver A1 X6 11 12 13 -X2 1 -R40 X7.1 X7.2 23 X6 21 22 23 5 X5.1 X5.2 5 5V / 1mA 10 13 11 13 17 5 21 16 13 26 22 X7.1 21 X7.
230 VAC -20% to 500 VAC +10% Input 13 14 K 1 2 3 4 G2 2 9 10 11 12 K2 K1 8 Limit Alarm 13 14 15 K3 Option Relay Outputs 1 -X4 16 12 X7.1 11 X7.2 15 -X3 5 6 1 2 -R40 AK Power Section Driver A1 X6 11 12 13 -X2 G1 -F3 -F2 23 -X3 3 X7.1 X7.2 A3 1 2 5 X5.1 X5.2 5 5V / 1mA 10 13 11 13 17 5 21 16 13 3 X6 21 22 23 -X2 G1 4 AK G2 18 X41 32 RJ45 patch cable X40 2 1 26 22 X7.1 21 X7.
#1) -X1 2 1 3 4 230 VAC -20% to 500 VAC +10% Input Broad band Power Supply 13 14 2 3 4 9 10 11 12 K2 K1 8 Limit Alarm 13 14 15 K3 Option Relay Outputs 1 16 12 X7.1 11 X7.2 15 -X3 5 6 1 2 Power Section Driver A1 X6 11 12 13 -X2 1 -R40 2 5 X5.1 X5.2 5 5V / 1mA -X4 -F3 -F2 23 -X3 3 X7.1 X7.2 A3 1 10 13 11 13 17 5 21 16 13 2 3 X6 21 22 23 -X2 G1 4 AK G2 18 X41 32 RJ45 patchcable X40 33 13 34 13 T3 2 12 * #2) #1) #2) 14 15 #2) 14 19 T1.
#1) 1 -X1 2 3 230 VAC -20% to 500 VAC +10% Input 13 14 2 3 4 2 9 10 11 12 K2 K1 8 Limit Alarm 13 14 15 K3 Option Relay Outputs 1 -X4 16 12 X7.1 11 X7.2 15 -X3 5 6 1 2 -R40 AK Power Section Driver A1 X6 11 12 13 -X2 1 G2 5 X5.1 X5.2 5 5V / 1mA -F3 -F2 23 -X3 3 X7.1 X7.2 A3 1 10 13 11 13 17 5 21 16 13 2 3 X6 21 22 23 -X2 G1 1 (G1) (4G) 4 AK G2 18 X41 32 RJ45 patchcable X40 2 1 26 22 X7.1 21 X7.
#1) -X1 2 1 3 4 230 VAC -20% to 500 VAC +10% Input Broad band Power Supply 13 14 2 3 4 9 10 11 12 K2 K1 8 Limit Alarm 13 14 15 K3 Option Relay Outputs 1 -X4 16 12 X7.1 11 X7.2 15 -X3 5 6 1 2 Power Section Driver A1 X6 11 12 13 -X2 1 -R40 2 5 X5.1 X5.2 5 5V / 1mA -F3 -F2 23 -X3 3 X7.1 X7.2 A3 1 10 13 11 13 17 5 21 16 13 2 3 X6 21 22 23 -X2 G1 1 (G1) (4G) 4 2 -X3 5 6 1 26 22 X7.1 21 X7.
Separate power supply for all other types possible Separate power supply for 690V types is required #1) Remarks These connections must be wired by the user Terminal descrition on the device * Delivery state #2) 1 -X1 2 3 4 230 VAC -20% to 500 VAC +10% Input 13 14 2 3 4 2 9 10 11 12 K2 K1 8 Limit Alarm 13 14 15 K3 Option Relay Outputs 1 -X4 16 12 X7.1 11 X7.2 15 -X3 5 6 1 2 -R40 AK Power Section Driver A1 X6 11 12 13 -X2 1 G2 5 X5.1 X5.
79 9. SPECIAL REMARKS 9.1 INSTALLATION The installation orientation of Thyro-P is vertical, so that ventilation of the thyristors fastened to heat sinks is ensured. In case of cabinet mounting, additionally sufficient ventilation of the cabinet must be ensured. The distance between Power Controller and the bottom should be at least 100mm; the distance to the ceiling 150mm. The devices may be installed next to each other without lateral distance. Heating up of the device by heat sources must be avoided.
80 Afterwards safe gaps (according to IP20) have to be cut into the covers. Please be consider that an adequate IP20 protection has to be secured. Then the according coverages have to be fixed again on the device. 9.3 COMMISSIONING The device must be connected to the mains and the associated load according to the wiring diagrams.
81 • check voltage at terminal X1.1 and X1.2 of the control device A70 • check semiconductor fuse and the fuses F2 and F3 on the controller card A1. CAUTION In any case, set the device de-energized and check if it is de-energized Terminal X1.3 on the controller card A1 not connected.
82 10. TYPE OVERVIEW 10.1 TYPE RANGE 400 VOLT TYPE VOLTAGE 230-400 VOLTS TYPE CURRENT TYPE POWER DISSIPA- DIMENSIONS WEIGHT (A) TION (MM) (W) W (NET ABOUT DRAW. CHARACTE- TRANSF. KG) (NO.) RISTIC (NO.) T1 (KVA) DIM. TEMP.
83 10.2 TYPE RANGE 500 VOLT TYPE VOLTAGE 500 VOLTS TYPE CURRENT TYPE POWER DISSIPA- DIMENSIONS WEIGHT (A) TION (MM) (W) W (NET ABOUT DRAW. CHARACTE- TRANSF. KG) (NO.) RISTIC (NO.) T1 (KVA) H D DIM. TEMP. CURRENT BURDEN SEMICON- RESISTOR DUCTOR FUSE* R40 (Ω) F1 (A) 508 THYRO-P 1P 5H 16 H 2.5 8 25 H 58 71 150 150 320 320 229 229 6 6 260 260 1 1 400/1 400/1 82.5 27.4 50 50 12 83 150 320 229 6 260 1 400/1 15.
84 TYPE VOLTAGE 500 VOLTS TYPE CURRENT TYPE POWER DISSIPA- DIMENSIONS WEIGHT (A) TION (MM) (W) W (NET ABOUT DRAW. CHARACTE- TRANSF. KG) (NO.) RISTIC (NO.) T1 (KVA) H D 320 320 320 320 320 320 397 414 414 685 685 837 229 229 229 229 229 229 229 340 340 505 505 445 DIM. TEMP. CURRENT BURDEN SEMICON- RESISTOR DUCTOR FUSE* R40 (Ω) F1 (A) THYRO-P 1P...
85 10.3 TYPE RANGE 690 VOLT TYPE VOLTAGE 690 VOLTS TYPE CURRENT TYPE POWER DISSIPA- DIMENSIONS WEIGHT (A) TION (MM) (W) W (NET ABOUT DRAW. CHARACTE- TRANSF. KG) (NO.) RISTIC (NO.) T1 (KVA) H D 320 370 412 412 762 762 577 577 229 229 340 340 505 505 445 470 DIM. TEMP. CURRENT BURDEN SEMICON- RESISTOR DUCTOR FUSE* R40 (Ω) F1 (A) 1.20 1.00 1.00 1.00 1.20 1.00 1.00 1.
86 11. TECHNICAL DATA TYPE VOLTAGE MAINS FREQUENCY ...P400... 230 volts -20% to 400 volts +10% ...P500... 230 volts -20% to 500 volts +10% ...P690... 500 volts -20% to 690 volts +10% all models 45Hz to 65Hz LOAD DESCRIPTION ohmic load (minimum 100W) ohmic load Rhot/Rcold ratio up to 20 (MOSI operation) transformer load TRANSFORMER The induction of the load side transformer should not exceed OPERATING MODES 1.
87 Power control P Without control PRECISION U-control: Better than ± 0.5% I-Control: ± 0,5% P-Control: ± 1% All specifications are relating to the respective final value. LIMITATIONS Voltage limitation Urms Current limitation Irms = default setting Effective power limitation P Peak current limitation, MOSI operation Upon reaching one of these limits, the LED ”Limit“ on the front panel of Thyro-P is on and the relay K2 is activated.
88 TABLE TERMINAL SCREWS THYRO-P 1P, 2P, 3P CONNECTOR 37H, 75H M 6 80H M 8 110H M 6 130H, 170H M 8 200HF, 280HF, 300HF M 10 495HF, 500HF, 650HF 780HF, 1000HF, 1400HF, M 12 1500HF, 1700HF, 1850HF, 2000HF, 2100HF, 2200HF, 2400HF, 2600HF, 2750HF, 2900HF EARTHING SCREW U1, V1, W1, U2, V2, W2 M 6 M 10 M 6 M 10 M 10 M 12 WITH UL APPLICATIONS POWER CONNECTION USE ONLY 60°/75°C COPPER CONDUCTORS (UL SPECIFICATION) STUD TORQUE FOR TABLE TERMINAL SCREWS [Nm] SCREW M 2 M 6 M 8 M 10 M 12 MIN 0.2 3.0 11.
89 REMARK In general the fan is subject to abrasion, therefore fan typical actions are recommended to check the fan on regular basis (scheduled maintenance), including testing of propeller on abrasion / deposition / corrosion and abnormal operating noise. The used fans are quality products and have a life time of L10=37500 h. Depending on working conditions, it is recommended to change them after approx. 5 years.
90 12. DIMENSIONAL DRAWINGS 1 2 3 4 5 6 7 8 9 10 11 12 A A Seitenansicht / siede view Vorderansicht / front view B B X10 C C * 320 12,598 300 11,811 X24 D D Cu 25x2; M6 Cu 0,987x0,078; M6 X5.1 X5.2 Cu 17x2; M6 Cu 0,669x0,078; M6 X2 U1 U2 E E X30 F 32,5 1,280 Observe protection note to DIN 34.
91 1 2 3 4 5 6 7 8 9 10 11 12 A A Vorderansicht / front view Seitenansicht / side view X7 B B C C X10 D 370 14,567 350 13,780 D * X24 X5.1 X5.2 E E Cu 43x5; O11 Cu 1,692x0,196; O0,433 X2 X50 Cu 25x5; O11 Cu 0,984x0,196; O0,433 X30 Observe protection note to DIN 34. X31 F U2 U1 37,9 1,492 F M10 für Erdung M10 for earthing G 138,5 5,453 17,75 ,699 64 2,520 66,5 2,618 Thyro-P 1P ...
92 1 2 3 4 5 6 8 9 10 11 12 Seitenansicht / side view Vorderansicht / front view A 7 A 55 2,165 X7 X24 X5.1 X5.2 B B X2 X30 X31 X50 C 762 30,000 650 25,591 C D D O14 für Erdung O,551 for earthing 3P 690-1400 HF 3P ... -1500 HF U2 U2 U1 E 57 2,244 99,5 3,917 137 5,394 E Observe protection note to DIN 34.
93 Thyro-P 1P (2600 HF, 2900 HF) 1 2 1 3 2 4 3 Dimensional Drawing 271 5 4 6 5 7 6 8 7 9 Vorderansicht / front view Vorderansicht / front view A A B B C 10 9 11 Seitenansicht / side view X10 X10 X24 X24 10 12 11 Seitenansicht / side view C * * W1 U1 W1 U2 W2 U2 W2 B B C C X5.1 X5.
94 1 2 3 4 5 6 7 8 9 10 11 12 A A Vorderansicht / front view Seitenansicht / side view B B X10 C C * * 320 12,598 300 11,811 X24 D D X5.1 Cu 43x5; O9 Cu 1,692x0,196; O0,354 X5.2 X2 X30 U1 W2 W1 U2 E 37,9 1,492 Observe protection note to DIN 34.
95 1 2 3 4 5 Vorderansicht / front view 6 7 8 Seitenansicht / side view A B M10 für Erdung M10 for earthing 412 16,207 370 14,567 350 13,780 X24 X5.1 X5.2 26 1,024 X50 34,5 1,358 U1 U2 W1 W2 U2 Cu 46x3 O11 Cu 1.811x0,118 O 0,433 U1 40 14 1,575 ,551 C X7 10 ,394 6,5 ,256 90 3,543 Observe protection note to DIN 34. D 2P ... - 495 HF 2P ...
96 1 2 3 4 5 6 7 8 9 10 11 A X7 X10 X2 X5.2 X5.1 X24 B X30 X31 C X50 Cu 80x10; ø14 U1 U2 W1 W2 837 32.953 675 26.575 Cu 3.149x0.393; ø 0.551 257 10.118 Observe protection Schutzvermerk nachnote DIN to 34DIN beachten. 34. D 70 2.756 130 5.118 40 1.575 E F 40 1.575 9x15 210 8.268 225 8.858 31 1.220 365 14.370 0.54x0.590 ø9 für Erdung 15 .591 395 15.551 63 2.480 ø 0.354 for earthing 91 3.583 549 21.614 284 11.161 445 17.526 470 bei 2P 690-1850 HF G 18.
97 Thyro-P 2P (2400 HF, 2750 HF) 1 A 1 2 2 3 3 Dimensional Drawing 283 4 4 5 5 6 6 7 7 8 8 9 10 10 11 11 12 12 A B B X10 C * * X24 X24 X5.1 X5.1 X5.2 X5.
98 1 2 3 4 5 6 7 8 9 10 11 12 A A Vorderansicht / front view Seitenansicht / side view B B X10 C C * * * 320 12,598 300 11,811 X24 D D X5.1 Cu 43x5; O9 Cu 1,692x0,196; O0,354 X5.2 X2 X30 Cu 25x5; O9 Cu 0,984x0,196; O0,354 X31 E U1 U2 V1 V2 E W2 Observe protection note to DIN 34.
99 1 2 3 4 5 6 7 8 Seitenansicht / side view Vorderansicht / front view A 437 17,207 B M10 für Erdung M10 for earthing C X2 X30 X31 U1 U2 V1 V2 U2 Cu 46x3 O11 Cu 1.811x0,118 O 0,433 U1 40 14 1,575 ,551 34,5 1,358 X50 W1 W2 X7 90 3,543 10 ,394 6,5 ,256 90 3,543 Observe protection note to DIN 34. D 3P ... - 495 HF 3P ... - 650 HF 26 1,024 527 20,750 370 14,567 350 13,781 X24 X5.1 X5.
100 1 2 3 4 5 6 7 Vorderansicht / front view 8 9 10 11 12 Seitenansicht / side view X7 55 2,165 A X24 X5.1 X5.2 B X2 X30 X31 X50 762 30,000 650 25,591 C 780 HF 3P 690-1400 HF 3P ... -1500 HF O14 für Erdung O,551 for earthing Cu 60x10 O14 Cu 2,236x0,939 O 0,551 U2 U2 V1 V2 W1 U1 W2 57 2,244 E 99,5 3,917 137 5,394 U1 166,5 6,555 17 ,669 Observe protection note to DIN 34.
101 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 8 9 10 11 457 17.973 457 17.973 X7 X7 A A X10 X5.2 X5.2 X5.1 X5.1 B B X2 X2 X24 X24 X10 X30 X31 X30 X31 X50 X50 Cu 80x10; ø14 Cu3.149x0.393;ø0.551 80x10; ø14 Cu Cu 3.149x0.393;ø0.551 C U1 U1 U2 U2 V1 V1 V2 V2 W1 W1 W2 W2 D Schutzvermerk Observe protection nach note DIN to 34note DIN beachten. Observe Schutzvermerk protection nach DIN34. to 34DIN beachten. 34. D 10941094 43.071 43.071 925 925 36.417 36.
102 Thyro-P 3P (2200 HF, 2600 HF) Dimensional Drawing 295
103 13. ACCESSORIES AND OPTIONS ORDER NO. DESCRIPTION 2.000.000.380 Thyro-Tool Family, commissioning and visualization tool for simple visualization tasks; software under Windows 95/NT4.0 and later 2.000.000.408 LBA-2 with touch display, Bluetooth and SD card 2.000.000.409 with touch display, Bluetooth and SD card 2.000.000.407 Thyro-P Bluetooth adapter 2.000.000.405 SEK, cabinet installation kit for LBA-2 installation in cabinet door 2.000.000.393 2.000.000.392 2.000.000.394 2.000.000.
104 14. APPROVALS AND CONFORMITIES Due to European harmonization and international reconciliation, the standards will be subject to years of adjustment and renumbering. The detailed schedule therefore contains the current standards as well, even if the date for their expiry has already been set. There is no product norm for Thyristor Power Controllers, so that a sensible norm structure must be created from the corresponding basic norms, which ensures safe application and opportunity for comparison.
105 IN DETAIL: CONDITIONS FOR USE OF THE DEVICE Built-in unit VDE 0160 5.5.1.3 DIN EN 50 178 VDE 0106 T 100:3.83 General requirements VDE 0558 T 11 DIN EN 60146-1-1 Design, vertical installation VDE 0558 T 1 Operating conditions DIN EN 60 146-1-1; K. 2.5 Operating location, industry sector VDE 0875 part 3 CISPR 6 Temperature performance VDE 0558 T 1 DIN EN 60 146-1-1; K 2.
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109 World Headquarters 1625 Sharp Point Drive Fort Collins, CO 80525 USA 970.221.4670 Main 970.221.5583 Fax www.advanced-energy.com Specifications are subject to change without notice. © 2014 Advanced Energy Industries, Inc. All rights reserved. Advanced Energy® and Thyro-P™ are trademarks of Advanced Energy Industries, Inc.
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