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AEG THYRO-A, Operating Instructions Manual

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Technical queries

Do you have any technical queries regarding the subjects dealt with 
in these operating instructions?
If so, please get in touch with our team for power controllers:
Tel. +49(0)2902 763-520 or 763-290 
Fax +49(0)2902 763-1201 

Commercial queries

Do you have any commercial queries on power controllers?
If so, please get in touch with our team for power controllers.
Tel. +49 (0)2902 763-558 or (02902) 763-591
[email protected]

Service-Hotline

Our team is at your service on the following hotline:
AEG Power Solutions GmbH
Emil-Siepmann-Strase 32
D-59581 Warstein
Tel. +49 (0)2902 763-558 or +49 (0)2902 763-100
http://www.aegps.de

Copyright

No part of these operating instructions may be transmitted, reprodu-
ced and/or copied by any electronic or mechanical means without the 
express prior written permission of AEG PS.
© Copyright AEG Power Solutions GmbH 2011.
All rights reserved

Further information on copyright

Thyro-A is an international registered trademark of AEG Power 
Solutions GmbH.
Windows and Windows NT are registered trademarks of the Microsoft 
Corporation.
All other company and product names are (registered) trademarks of 
the respective owners.

Summary of Contents for THYRO-A

Page 1: ...PERFECT IN FORM AND FUNCTION Betriebsanleitung Operating Instructions Thyristor Leistungssteller Thyro A Thyristor Power Controller Thyro A Thyro A ...

Page 2: ... 3 Maintenance service faults 16 2 6 4 Transport 17 3 Functions 18 3 1 Operating modes 18 3 1 1 Full wave switch principle TAKT 18 3 1 2 Phase angle principle VAR 19 3 1 3 Half wave switch principle QTM 19 3 2 Setpoint processing 19 3 3 Control modes 20 3 4 Limits 23 3 5 Pulse inhibition 23 3 6 Current and voltage transformer only for H RL1 and H RLP1 23 3 7 Display via analog output only for H RL...

Page 3: ...nd setpoint input range 43 4 2 4 Analog output only for H RL1 and H RLP1 43 4 3 Potentiometer 44 4 3 1 Setting the transformer load AN1 SST T0 45 4 3 2 Setting ohmic load 46 4 3 3 Setting maximum load value with control end U U2 and P control 47 4 3 4 Setting maximum load current only for H RL1 and H RLP1 48 4 3 5 Setting example for maximum load value at control end maximum load current 49 4 3 6 ...

Page 4: ...RLP1 65 5 9 Using the THYRO TOOL FAMILY 65 6 Mains load optimization 68 6 1 Internal mains load optimization 68 6 2 Synchronization with Thyro Power Manager 68 6 3 Software synchronization operating mode TAKT 69 7 Connecting diagrams 71 8 Help in the event of problems 79 9 Technical data 82 10 Dimension drawings 89 11 Accessories and options 104 12 Approvals and conformity 105 ...

Page 5: ...nnection diagram mains load optimization with Thyro Power Manager 78 Fig 13 Connection diagram mains load optimization for operating mode TAKT 78 Tab 1 Effects of a change in the load resistance 22 Tab 2 Effective limits 23 Tab 3 Limit values for mains voltage monitoring 32 Tab 4 Maximum load value at control end 48 Tab 5 Maximum load current 49 Tab 6 Analog output scale 50 Tab 7a Load monitoring ...

Page 6: ...r service on the following hotline AEG Power Solutions GmbH Emil Siepmann Strase 32 D 59581 Warstein Tel 49 0 2902 763 558 or 49 0 2902 763 100 http www aegps de Copyright No part of these operating instructions may be transmitted reprodu ced and or copied by any electronic or mechanical means without the express prior written permission of AEG PS Copyright AEG Power Solutions GmbH 2011 All rights...

Page 7: ...issioning maintenance and repair 1 1 Type designations Validity These operating instructions describe the Thyro A series versions H 1 H RL1 and H RLP1 Product characteristics that are only provided by the Thyro A H RL1 and H RLP1 series are marked in the text These operating instructions comply with the current technical speci fications of the device at the time of publication The contents do not ...

Page 8: ...ree phase saver circuit Thyro A 3A Thyristor controller with three phase power unit suited for three phase loads Designation Characteristics Different version example of the power controller Thyro A 3A Three phase power controller with three phase power unit 400 with 400V type voltage 230V 400V 500V 600V 280 with 280A type current 16 1500A H with integrated semiconductor fuse F with fan from 280A ...

Page 9: ...y signalling relay load monitoring and analog output channel separa tion with operating modes TAKT and VAR synchronization option in operating mode TAKT with Thyro Power Manager control modes U U2 I I2 Suitable for the visualization and commissioning software Thyro Tool Family Thyro A H RLP1 Thyristor power controller with integrated semiconductor fuse system bus interface additional 24 VDC AC ele...

Page 10: ... load as well as load with high Rwarm Rcold 6 peak current limitation of 3 x Inom only H RL1 and H RLP1 in operating mode VAR Soft start function for transformer load Channel separation necessary with countervoltage Load current monitoring only H RL1 and H RLP1 Signalling relay only H RL1 and H RLP1 Analog output only H RL1 and H RLP1 Control modes U U2 with H RL1 additional I I2 with H RLP1 addit...

Page 11: ...erial number reason for the complaint environmental conditions of the device operating mode period of use Goods and services are subject to the general conditions of supply for products of the electrical industry and our general sales conditions Claims in connection with supplied goods must be submitted within one week of receipt along with the delivery note AEG PS will rescind all obligations suc...

Page 12: ...juries WARNING Dangers that can lead to serious injuries or considerable damage to property CAUTION Dangers that can lead to injuries and damage to property CAUTION Dangers that can lead to minor damage to property The warnings can also be supplemented with a special danger sym bol e g Electric current or Hot parts e g risk of electric current or risk of burns In addition to the warnings there is ...

Page 13: ...without the cover DANGER Hot device Risk of burns from heat sinks and neighbouring plastic parts 70 C possible Do not touch the hot parts of the device Affix the Risk of burns warning symbol in the immediate vicinity of the device 2 3 Operator requirements The operator must ensure the following The safety regulations of the operating instructions are observed The accident prevention regulations va...

Page 14: ...nitial start up 2 5 Intended use The device may only be used for the purpose for which it was inten ded as persons may otherwise be exposed to dangers e g electric shock burns and plants also e g overload The user must therefo re observe the following points It is not permitted to make any unauthorised modifications to the unit or to use any spare parts or replacement parts not approved by AEG PS ...

Page 15: ...or to installation commissioning If stored in a cold environment ensure that the device is absolutely dry Allow the device a period of at least two hours to acclimatise before commissioning Check that the voltage data on the type plate matches the mains voltage Only install the device in an upright position Ensure sufficient ventilation of the cabinet if mounted in a cabinet Observe minimum spacin...

Page 16: ...ecting pulse blocking 2 6 3 Maintenance service faults In order to avoid personal and material damages the user must ob serve the following Before all work Disconnect the device from all external voltage sources Secure the device against accidentally being switched back on Use suitable measuring instruments and check that there is no vol tage present Ground and short circuit the device Provide pro...

Page 17: ...17 EN 2 6 4 Transport Only transport the device in the original packaging Protect the device against damage caused by jolts knocks and contamination for instance ...

Page 18: ...arious applications and manufacturing processes as well as to different electrical loads 3 1 1 Full wave switch principle TAKT In this operating mode the mains voltage is switched periodically relative to the defined setpoint Integer multiples of the mains periods are switched to avoid d c components The operating mode full wave switch principle TAKT is particularly suited for loads with thermal i...

Page 19: ...nt fast operating mode which works on the half wave switch principle QTM is suitable for ohmic loads De pending on the predetermined setpoint value mains half waves are switched DC components are avoided for the phase duration The fast phase control is particularly suited for IR beams as an alternative to phase angle control When using several controllers it is possible by synchronization to keep ...

Page 20: ... terminal X22 1 see page 36 Settings and operation 3 3 Control modes The power controller has various different control modes Before commissioning the power controller and selecting a control mode familiarization with the operating procedure and the effect upon the application is important Control modes H1 Control mode Control variable U U2 highest conductor voltage Control modes H RL1 Control mod...

Page 21: ...nal to the effec tive setpoint in the case of control modes U I P In control modes U2 I2 the control variable influencing the load is a square of the effective setpoint U Output voltage Ueff U2 Output voltage U2 eff I Output current Ieff I2 Output current I2 eff only with H RL1 und H RLP1 Umax H1 R201 HRL1 R202 ...

Page 22: ...fects of a change in the load resistance Control mode Load resistance becomes smaller Load resistance becomes greater P ULoad ILoad P ULoad ILoad U greater greater smaller smaller U2 greater greater smaller smaller I 1 smaller smaller greater greater I2 1 smaller smaller greater greater P 2 smaller greater greater smaller 1 for H RL1 and H RLP1 2 only for H RLP1 ...

Page 23: ...is activated the LED PULSE INHIBIT lights up red After switching on or after pulse inhibition the first Takt pulse in Takt operation takes place with the Soft Start function This is important for the transformer load if it was previously switched off for an undefined reason remanence For Thyro A 2A or Thyro 3A the pulse inhibition is only wired to the master L1 left 3 6 Current and voltage transfo...

Page 24: ...The analog output can also be used as a setting aid for potentiometer settings see page 44 Potentiometer 3 8 Error and status messages The Thyro A has internal error and status messages The THYRO TOOL FAMILY can be used to configure the consequences The user can define what the reactions are to be in the event of a particular message Possible reactions that can be set are blocking the load current...

Page 25: ... phase x Status messages Pulse inhibition fixed configurable Undervoltage in mains x Overvoltage in mains x Pulse inhibition x Error message Pulse inhibition Frequency error x SYNC error x Device excess temperature Flash values invalid x Master Slave error x Failure in rotating field phase x Default settings Status messages Pulse inhibition Undervoltage in mains x Overvoltage in mains Pulse inhibi...

Page 26: ...ed configu rable rable Undervoltage in mains x x Overvoltage in mains x x Pulse inhibition x x U limit x x I limit x x P limit x x Please refer also to chapter LED messages see page 29 and chapter Fault signalling relay K1 see page 31 No message Message Closed circuit principle closed open Open circuit principle open closed Fault signaling relay K1 Error message Pulse inhibition Fault signalling r...

Page 27: ...es Pulse inhibition Fault signalling relay K1 Undervoltage in mains x x Overvoltage in mains Pulse inhibition x U limit I limit P limit Closed circuit principle Fault signalling relay K1 Default settings Default settings ...

Page 28: ...28 Possible settings in THYRO TOOL FAMILY ...

Page 29: ...essages 1 2 3 4 5 6 7 8 1 LED ON green Master 2 LED PULSE INHIBIT red 3 LED LOAD FAULT red 4 Internal LED green Master 5 LED ON green Slave1 6 Internal LED green Slave1 7 LED ON green Slave2 8 Internal LED green Slave2 ...

Page 30: ... 95 C internal external Undercurrent in ON OFF ON OFF Undercurrent limit load curcuit exceeded Flash values ON Flash 1 Flash 1 OFF Parameters in Flash invalid fast fast faulty or deleted Undervoltage ON ON ON ON Mains voltage than in mains undervoltage limit 57 Pulse inhibition ON ON OFF OFF Bridge X2 1 X2 2 open or set via bus U limit ON Flash Flash OFF U I or P limit reached I limit slow slow fl...

Page 31: ... O contact X3 3 N C contact Fault signalling relay K1 has a changeover contact Messages that cause the fault signalling relay to switch can be set with THYRO TOOL FAMILY In the default state fault signalling relay K1 functions on the closed circuit principle In the event of the following errors the fault signalling relay de ener gizes and the power controller switches off SYNC error internal error...

Page 32: ... results in absolute limit values for the monitoring of the mains voltage Tab 3 Limit values for mains voltage monitoring Only for H RL1 and H RLP1 In the event of more than 15 below the type voltage the devices can only be operated right up to the undervoltage limit if the electro nics are supplied from an external 24V source For H1 H RL1 and H RLP1 In default state pulse inhibition is switched i...

Page 33: ...can be changed with a bus module or with THYRO TOOL FAMILY The Thyro A has temperature monitoring If the temperature is excee ded 90 a message is sent via LED see page 29 LED messages via the bus module or via fault signalling relay K1 see page 31 Fault signalling relay K1 Pulse inhibition is not actuated 3 9 4 Fan monitoring for F The forced ventilated thyristor power controllers have temperature...

Page 34: ... set the operating mode and circuit type independently of one another Combinations are thus possible which cannot be set with DIP switch S1 1 and S1 2 Operating modes TAKT VAR Load circuits Star with neutral conductor delta or star without neutral conductor open delta Possible settings in THYRO TOOL FAMILY operating mode Possible settings in THYRO TOOL FAMILY circuit type ...

Page 35: ...witch on period Tsmin Minimum switch on period For VAR V_IE Front pulse end position H_IE Rear pulse end position 3 10 4 Controller parameters The parameters of the controller can be adapted to the path if needed Parameters TI 20 Controller I share KP 60 Controller P share KR 5 Controller amplification Default setting 3 10 5 Mains load optimization The time for software synchronization can be set ...

Page 36: ...o longer possible Operation with bus module see also page 64 Connecting the bus module Ground to X22 1 Setpoint comes from bus DIP switch and potenti ometer are read in once after being switched on and the setting can then be changed with the bus module No ground to X22 1 DIP switch and potentiometer are always read in Setpoint is read via the analog input Operation with THYRO TOOL FAMILY Device i...

Page 37: ...tructions 16A 30A The operation and display elements and terminals are arranged the same in all sizes see page 89 Dimension drawings a LEDs g DIP switch S1 e Potentiometer h Fuse a e g h a LEDs b Power section Slave2 c Power section Slave1 d Power section Master e Potentiometer f Heat sink a b c d e f ...

Page 38: ...terminal V2 14 Connection terminal W2 15 Terminal X2 16 Terminal X3 17 Terminal X1 Master 18 Terminal X11 Master 19 Terminal X22 Master 20 Terminal X1 Slave1 21 Terminal X11 Slave1 22 Terminal X22 Slave1 23 Terminal X1 Slave2 24 Terminal X11 Slave2 25 Terminal X22 Slave2 10 11 9 16 19 15 18 12 17 13 21 20 14 25 24 23 22 ...

Page 39: ...39 EN l l Type plate 4 2 DIP switches S1 S1 10 S1 9 S1 8 S1 7 S1 6 S1 5 S1 4 S1 3 S1 2 S1 1 off on ...

Page 40: ...itch Function Default setting S1 10 Analog output 10V 20mA ON 0 10V S1 9 Live zero analog output OFF S1 8 Setpoint input ON 0 20mA S1 7 ON S1 6 Live zero setpoint OFF 0mA S1 5 Control mode Thyro Tool mode ON P S1 4 OFF S1 3 ON S1 2 Operating mode OFF Takt S1 1 ON DIP switches S1 Thyro A 1A HRLP1 and Thyro A 2A HRLP1 Switch Function Default setting S1 10 Analog output 10V 20mA ON 0 10V S1 9 Live ze...

Page 41: ... A 3A 4 2 2 Control mode Analog output The highest value of the load voltage or load current is always used for control and display The total power is used for power control If a bus module or PC is connected control mode and analog output can be set separately e g U control with I display S1 1 S1 2 Load type and load connection OFF OFF VAR with open delta ON OFF TAKT with delta or star without ne...

Page 42: ... S1 4 S1 5 Control mode Function R201 OFF OFF OFF U2 Transformer load phase angle 1st half wave OFF OFF ON U2 Uload max ON OFF OFF U Transformer load ON OFF ON U Control characteristic ON ON ON Configurable with None since in THYRO TOOL FAMILY THYRO TOOL mode Default setting S1 3 S1 4 S1 5 Control mode Analog Function R202 output OFF OFF OFF U2 Uload Uload max ON OFF OFF U Uload Uload max OFF ON O...

Page 43: ...rious process controllers with the setpoint and live zero switches The following signal ranges can be set 0 4 20mA Ri approx 250 0 5V Ri approx 44k 0 10V Ri approx 88k 5V supply voltage can be taken from terminal X2 8 for a setpoint potentiometer 5k RPoti 10kΩ 4 2 4 Analog output only with H RL1 and H RLP1 The analog output allows the effective values Uload Iload or P H RLP to be displayed The out...

Page 44: ...ion Function Default setting Nr meter 26 R201 TRAFO ADAPTION Phase angle 1st Thyro A 1A 60 el half wave for Thyro A 2A 90 el transformer load Thyro A 3A 90 el 27 R202 SCALE SETPOINT Control end U Regelung Utype 10 P Regelung Ptype 10 28 R203 CURRENT LIMIT Current Itype limit 29 R204 SCALE OUTPUT Amplification Utype Itype Utype P depend ing on output variable of analog output 30 R205 LOAD FAULT Loa...

Page 45: ... 0 mA or 2 5V 50 or 50 el 2 5 mA or 1 25V 25 etc Setting aid for H1 H RL1 and H RLP1 There are two setting options Count the no of turns of the potentiometer The potentiometers have a setting range of 18 turns The setting range is not guaranteed and may deviate If accurate settings are required the potentiometer must be checked using a different method Visualize the setting with PC and THYRO TOOL ...

Page 46: ...T set to 0 Soft start time SST The SST is set at the same time This also applies to operating mode VAR The soft start time has the following values depending on AN1 For a soft start time SST of 30 periods or 600ms the power con troller remains in the SST ramp until setting time Ts is greater than 600ms The power controller then pulses without SST ramp even if Ts is less than 600ms As soon as the p...

Page 47: ... parameter AN1 30 el T0 1000ms Analog output setting aid 10 0mA 5V 100 el 6 0mA 3 0V 60 el Thyro A 1A default 9 0mA 4 5V 90 el Thyro A 2 3A default 3 0mA 1 5V 30 el 2 5mA 1 25V 0 el 4 3 3 Setting maximum load value with control end U U2 and P control For H RL1 and H RLP1 With potentiometer R202 SCALE SETPOINT the maximum voltage for U U2 control or the maximum power for P control is set on the loa...

Page 48: ...lue see page 82 Technical Data Tab 4 Maximum load value at control end 4 a Thyro A 1A A2A 4 b Thyro A 3A Setting Uload max P 1 load max Potentiometer R202 Potentiometer R202 SCALE SETPOINT SCALE SETPOINT Potentiometer turns 9 Uload max Utype 5 2 Pload max Ptype from left stop Setting aid analog 10mA Uload max Utype 5 77mA Pload max Ptype output in mA Switch S1 10 OFF Setting aid analog 5V Uload ma...

Page 49: ... potentiometer R203 CURRENT LIMIT Tab 5 Maximum load current Example for maximum load value maximum load current Thyro A 3A 400 30 H RLP1 Utype 400V Itype 30A Ptype 20 7kW Power control with limit to 15kW Current limit to 25A Setpoint 4 20mA Pmax Setting aid 1st setting R202 7 8 15kW 20 7kW 5 65 turns from left stop Setting aid in mA 8 66mA 15kW 20 7kW 6 25mA Setting aid in volts 4 33V 15kW 20 7kW...

Page 50: ...ent voltage power SCALE OUTPUT SCALE OUTPUT Potentiometer turns 3 6 turns type value power 6 24 turns Ptype power controller from left stop controller scale end value scale end value Setting aid analog output 4mA type value power 6 93mA Ptype power controller in mA controller scale end value scale end value Switch S1 10 OFF Setting aid analog ouput 2V type value power 3 46V Ptype power controller ...

Page 51: ...ring on the potentiometer R205 LOAD FAULT The de fault setting of this monitoring is OFF left stop of the potentiometer R205 A measuring instrument connected to the analog output can be used as setting aid see page 44 Potentiometer If the actual value is fallen below the set value a message is sent LED by bus and fault signalling relay K1 NOTE Remarks on settings tables Settings over 90 and fewer ...

Page 52: ...1 20 10 0 0 50 1 00 2 5 2 100 75 0 3 75 7 50 12 0 2 80 60 0 3 00 6 00 9 5 2 60 100 45 0 2 25 4 50 7 5 2 40 30 0 1 50 3 00 6 0 2 20 15 0 0 75 1 50 3 5 3 100 83 3 4 15 8 35 13 0 3 80 66 7 3 35 6 65 10 5 3 60 50 50 0 2 50 5 00 8 5 3 40 33 3 1 65 3 35 6 0 4 100 87 5 4 40 8 75 13 5 4 80 70 0 3 50 7 00 11 5 4 60 33 52 5 2 65 5 25 9 0 4 40 35 0 1 75 3 50 6 0 5 100 90 0 4 50 9 00 14 0 5 80 72 0 3 60 7 20 ...

Page 53: ...ns 1 100 50 0 2 50 5 00 8 5 1 80 40 0 2 00 4 00 7 0 1 60 Infinite 30 0 1 50 3 00 6 0 1 40 20 0 1 00 2 00 4 5 1 20 10 0 0 50 1 00 2 5 2 100 80 0 4 00 8 00 12 0 2 80 63 0 3 15 6 30 10 0 2 60 67 48 0 2 40 4 80 8 0 2 40 32 0 1 60 3 20 5 5 2 20 16 0 0 80 1 60 3 5 3 100 87 0 4 35 8 70 13 5 3 80 70 0 3 50 7 00 11 5 3 60 33 52 0 2 60 5 20 8 5 3 40 35 0 1 75 3 50 6 0 4 100 90 0 4 50 9 00 14 0 4 80 72 0 3 6...

Page 54: ...in case of fault Recommen ded setting for Poti R205 in X2 9 V 0 10V X2 9 0 20mA ca turns 1 100 79 0 3 95 7 90 12 0 1 80 63 0 3 15 6 30 10 0 1 60 73 48 0 2 40 4 80 8 0 1 40 32 0 1 60 3 20 5 5 1 20 16 0 0 80 1 60 3 5 2 100 88 0 4 40 8 80 13 5 2 80 66 0 3 30 6 60 10 5 2 60 31 50 0 2 50 5 00 8 5 2 40 33 0 1 65 3 30 6 0 2 20 17 0 0 85 1 70 4 0 3 100 90 0 4 50 9 00 14 0 3 80 72 0 3 60 7 20 11 5 3 60 20 ...

Page 55: ...load in fault in for Poti value output value output turns from resitors R205 in X2 9 in mA X2 9 in Volt left stop 1 100 0 50 5 2 5 7 8 80 40 4 2 6 6 60 30 3 1 5 5 4 40 20 2 1 4 2 20 10 1 0 5 2 9 2 100 60 80 8 4 11 4 80 64 6 4 3 2 9 5 60 48 4 8 2 4 7 5 40 32 3 2 1 6 5 7 20 16 1 6 0 8 3 7 3 100 75 87 5 8 75 4 375 12 3 80 70 7 3 5 10 3 4 100 82 91 9 1 4 55 12 8 Tab 8 Load with common star point and w...

Page 56: ...ng at actual at actual potentiometer load in fault in for Poti value output value output turns from resitors R205 in X2 9 in mA X2 9 in Volt left stop 1 100 57 78 5 7 85 3 925 11 3 80 62 8 6 28 3 14 9 4 60 47 1 4 71 2 355 7 5 40 31 4 3 14 1 57 5 6 20 15 7 1 57 0 785 3 7 2 100 76 88 8 8 4 4 4 0 80 70 4 7 04 3 52 10 3 Tab 9 Load in delta connection ...

Page 57: ...value output turns from resitors R205 in X2 9 in mA X2 9 in Volt left stop 1 100 0 50 5 2 5 7 8 80 40 4 2 6 7 60 30 3 1 5 5 4 40 20 2 1 4 2 20 10 1 0 5 3 0 2 100 50 75 7 5 3 75 10 9 80 60 6 3 9 0 60 45 4 5 2 25 7 2 40 30 3 1 5 5 4 20 15 1 5 0 75 3 6 3 100 66 83 8 3 4 15 11 8 80 66 4 6 64 3 32 9 8 60 49 8 4 98 2 49 7 8 40 33 2 3 32 1 66 5 9 20 16 6 1 66 0 83 3 8 4 100 75 87 5 8 75 4 375 12 3 80 70 ...

Page 58: ...an be installed next to each other without spacing between Ensure that the device cannot be heated up by heat sources below it The power loss is given in the type overview table see page 87 Technical data Ground the device in accordance with local regulations grounding screw nut for protective conductor connec tion to fixing adapter Grounding also serves for EMC means Y capacitor 4 7 nF CAUTION Us...

Page 59: ...when delivered and also adapted to the particular power unit Default setting Operating mode VAR S1 1 and S1 2 Transformer load R201 90 el 60 el depending on the type of device Other default settings are listed in the chapter Operation and Settings DIP switches see page 39 DIP switch S1 and potentiometers see page 44 Potentiometer Check default settings and adjust to application conditions if neces...

Page 60: ...ction setpoint selection X2 10 Ground potential maybe shield control conductor 9 Analog output 0 10V or 0 4 20mA 8 5V output e g for a setpoint potentiometer 5k RPoti 10k 7 Sync In SYT 9 6 Sync Out 3 5 5 Control ground 4 Analog setpoint input max 10V max 20mA 3 Control ground 2 Pulse inhibition PULSE INHIBIT 1 Control ground X11 2 24V extra electronics supply AC or DC 3 5 1 24V extra electronics s...

Page 61: ... Chap 4 2 3 S1 7 Setpoint value input S1 6 Live Zero setpoint Chap 4 2 3 S1 5 Control mode Thyro Tool mode Chap 4 2 2 S1 4 Control mode Thyro Tool mode S1 3 Control mode Thyro Tool mode S1 2 Operation mode Chap 4 2 1 S1 1 Operation mode Phase angle 1st for transformer TRAFO ADAPTION Chap 4 3 1 load SCALE SETPOINT Chap 4 3 3 Control end CURRENT LIMIT Chap 4 3 4 Current limit SCALE OUTPUT Chap 4 3 6...

Page 62: ... and X1 2 1 5 mm2 grid 3 5 are bridged internally When connecting a phase to X1 a fused connec tion is necessary see Tab 11 page 60 Exception When an additional electronics supply is connected 5 3 Connecting additional electronics supply only for H RL1 and H RLP1 The thyristor power controller Thyro A is equipped with an additio nal 24V AC DC power supply input X11 1 and X11 2 1 5 mm2 grid 3 5 If ...

Page 63: ...uitable for process controllers with output signals from 0 4 20mA 0 5V 0 10V Switch off mains supply and secure against accidentally being switched back on Configure analog setpoint input see page 43 Live zero and setpoint input range Connect process controller output signals of 0 4 20mA 0 5V 0 10V to terminal X2 3 ground and X2 4 5 6 Connecting control input for switch operation With a purely ohm...

Page 64: ... 1 Only the value of the bus module is used as setpoint Defined setpoint for bus failure There are two possibilities Connect terminal X22 1 on the master of the power controller to terminals X1 1 X8 1 of the bus module Cable to X22 1 is switched in the event of a malfunction In the event of malfunctions along the bus line the system automa tically switches to the analog setpoint at the control ter...

Page 65: ...nd X2 5 ground to a display device Ensure the correct polarity Configure the signal level see page 41 Analog output Adapt the signal level to the scale see page 43 Analog output Adapting scale 5 9 Using the THYRO TOOL FAMILY 15 Terminal X22 17 Serial interface COM RS232 18 PC Interface RS232 19 Connector Connection to Slave only necessary for Thyro 2A and Thyro 3A ...

Page 66: ...a sured values and parameters are displayed in the software Exten ded functions can be set see page 33 Extended functions Only for operation of the device in Thyro Tool mode S1 3 to S1 5 to ON All parameters can be set with the THYRO TOOL FAMILY NOTE Switching over defined setpoint on the PC interface A switch can be connected to terminals X1 2 and X1 3 of the PC interface RS232 to switch over the...

Page 67: ... for working with the THYRO TOOL FAMILY is that there is a connection between the PC and power controller This means that measured values can be visualized and parameters displayed If the Thyro A is not operated in Thyro Tool mode certain parameters can be altered In Thyro Tool mode almost all parame ters can be altered Fig 3 User surface THYRO TOOL FAMILY ...

Page 68: ...hed and blocked half waves at a set time interval 1 second also known as T0 In order where possible to create in mains a balance from the start not after T0 the individual controllers synchronize by offsetting themselves by a network period The first of the controllers connected has the SYT input X2 7 bridged to 5V X2 8 The following controllers get their signal to X2 7 from the sync out put X2 6 ...

Page 69: ... already existing AEG power controllers 6 3 Software synchronization operating mode TAKT Software synchronization is a method of mains load optimiza tion where an optional bus module is used or the THYRO TOOL FAMILY The software synchronization is set by entering a parameter Parameter 36 Set the cycle period T0 to the same value for all power controllers recommended T0 1 sec When setting with the ...

Page 70: ...70 Example 4 controllers e g with 100A load triggering approx 30 contents of Sync_Adr 0 100 25 50 75 ...

Page 71: ...1 Trafo adaption or end value controller S1 5 H 101 H 100 Pulse Inhibit Power On H 350 Diagnostic Intern Parameter F1 Semi conductor Fuse F 2A slow acting only required in case of phase connection e g L2 R Load X1 1 2 Thyro A 1A H F 1 Operating Mode Set Point Input Set Point Input Set Point Live Zero Function R201 Thyro Tool Control Mode Thyro Tool Control Mode Thyro Tool Operating Mode 10 9 8 7 6...

Page 72: ...T 9 Pot supply X2 1 2 3 4 5 6 7 8 9 10 R 201 Trafo adaption or end value controller S1 5 Operating Mode Set Point Input Set Point Input Set Point Live Zero Function R201 Thyro Tool Control Mode Thyro Tool Control Mode Thyro Tool Operating Mode 10 9 8 7 6 5 4 3 2 1 H 101 H 100 Pulse Inhibit Power On H 350 Diagnostic Intern Parameter F1 Semi conductor Fuse for UL applications refer to Technical Data...

Page 73: ...Output Operating Mode Set Point Input Set Point Input Set Point Live Zero Control Mode Thyro Tool Control Mode Thyro Tool Control Mode Thyro Tool Operating Mode 10 9 8 7 6 5 4 3 2 1 Analog Output 10V 20mA Analog Output Life Zero Status fan only for HF Types 230V 50 60Hz X7 2 3 ϑ F1 Semi conductor Fuse Use shielded control lines Pulse inhibit Setpoint Pot supply Shield Ground Connection for bus mod...

Page 74: ...iliary Voltage Supply mA V Analogue Output Operating Mode Set Point Input Set Point Input Set Point Live Zero Control Mode Thyro Tool Control Mode Thyro Tool Control Mode Thyro Tool Operating Mode 10 9 8 7 6 5 4 3 2 1 Analog Output 10V 20mA Analog Output Life Zero Status fan only for HF Types 230V 50 60Hz X7 2 3 ϑ F1 Semi conductor Fuse F1 Semi conductor Fuse F 2A slow acting for UL applications r...

Page 75: ...Status PE Shield Ground Pulse inhibit Setpoint Sync Out Sync In SYT 9 Pot supply X2 1 2 3 4 5 6 7 8 9 10 V1 V2 R 201 Trafo Adaption Operating Mode Load description Set Point Input Set Point Input Set Point Live Zero Control Mode Thyro Tool Control Mode Thyro Tool Control Mode Thyro Tool Operating Mode Load description 8 7 6 5 4 3 2 1 H 101 H 100 Pulse Inhibit Power On H 350 Diagnose Intern Paramet...

Page 76: ...Sync Out Sync In SYT 9 Pot supply mA V Analogue Output X2 1 2 3 4 5 6 7 8 9 10 V1 V2 R 205 R 204 R 203 R 202 R 201 Trafo Adaption Scale Setpoint Current Limit Scale Output Load Fault Analog Output 10V 20mA Operating Mode Load description Analog Output Life Zero Set Point Input Set Point Input Set Point Live Zero Control Mode Thyro Tool Control Mode Thyro Tool Control Mode Thyro Tool Operating Mode...

Page 77: ... and connection with optional bus module X2 1 2 3 4 5 6 7 8 9 10 X1 1 2 X22 1 2 3 4 5 6 7 System Interface Thyro A H F RL1 H F RLP X3 1 2 3 X11 1 2 24V AC or DC supply connections see bus module manual connection for option bus module Pay attention to setting S1 1 and S1 2 ...

Page 78: ...tion diagram mains load optimization for operating mode TAKT interne Netzlastoptimierung für QTM und TAKT Sync Out Thyro A X2 5 6 7 8 Sync Out Thyro A X2 5 6 7 8 Sync Out Thyro A X2 5 6 7 8 Sync Out Thyro A X2 5 6 7 8 Internal mains load optimization mode Takt channel possibly further Thyro A ...

Page 79: ... rush currents With high temperature elements with a larger Rwarm Rcold ratio you must check that in operating mode TAKT the switch on current does not ex ceed the rated current of the device With a transformer load an alloyed thyristor can generate a pulsed DC voltage and thus lead to a case of fusing Check with an ohmic load e g 100W light bulbs single phase in star connection Check microfuse F2...

Page 80: ...e transformer is not properly dimensioned or the load has increased the resistance through ageing An intermittent flashing of the Pulse Inhibit and Load Fault LEDs indicates an active limitation value Check setpoint value control value Check setpoint setting at terminal X2 4 against X2 3 ground When using the analog setpoint value make sure the DIP switches 6 7 8 are set up correctly even if the d...

Page 81: ...d of the output Check the load at the 5V DC output Minimum resistance Rmin 5kOhm Check all parallel load resistors for current flow Error Load current flows without triggering Check Live Zero Check the alignment of the control characteristics U I live Zero If the input is set to 0 20mA but the setpoint value however is 4 20mA then the controller will always adjust Check thyristor for short circuit...

Page 82: ...d Normally the supply of the Master modules is sufficient 24VAC 10 20 24VDC 18V to 32V Mains frequency All types 47 Hz to 63 Hz Max frequency change 5 per half wave Load type ohmic load ohmic load with Rwarm Rcold ratio up to 6 peak current limiting to Î 3xInom for H RLP1 HRL 1 in VAR operation Transformer load Thyro A 2A symmetrical load CAUTION If grain oriented cold rolled sheet metal is used t...

Page 83: ... Control characteristic Each controller e g temperature controller with an output signal in the range of 0 20mA 0 5V 0 10V can be adapted to the power controller Control input for switching mode Maximum switching frequency 5Hz ton min 100ms toff min 100ms Analog output only for H RL1 and H RLP1 Signal level 0 10V 2 10V 0 20mA 4 20mA Maximum load voltage10V Control modes H1 without current transfor...

Page 84: ...perature 35 C at F with forced cooling 45 C with natural air cooling without fan If the maximum ambient temperature is reduced the maximum load current can be increased up to 110 of the nominal current The following applies 1 more current requires a temperature reduction of 1 C The maximum ambient temperature can be increased up to a maxi mum of 55 C if the maximum load current is reduced The foll...

Page 85: ...8x3 2xø11 650A M 10 M 10 Cu 48x3 2xø11 1000A M12 M12 Cu 60x10 2xø14 1400A M12 M12 Cu 60x10 2xø14 1500A M12 M12 Cu 60x10 2xø14 In UL applications use only 60 C or 60 C 75 C copper conductors except for control lines In UL applications use only 75 C copper conductors except for control lines Screw Min value Nom value Max value M 2 0 22 0 25 0 28 Phoenix terminals M 4 0 85 1 3 1 7 M 6 2 95 4 4 5 9 M ...

Page 86: ...58dB A 2A 280F 0 50A 0 38A 200m3 h 70dB A 2A 350F 0 50A 0 38A 200m3 h 70dB A 2A 495 F 0 31A 0 25A 380 m3 h 49dB A 2A 650 F 0 31A 0 25A 380m3 h 49dB A 2A 1000 F 0 56A 0 79A 1970m3 h 69dB A 2A 1400 F 0 56A 0 79A 1970m3 h 70dB A 2A 1500 F 0 56A 0 79A 1970m3 h 70dB A 3A 280 F 0 38A 0 38A 260m3 h 70dB A 3A 350 F 0 50A 0 38A 260m3 h 70dB A 3A 495 F 0 29A 0 35A 880m3 h 58dB A 3A 650 F 0 29A 0 35A 880m3 h...

Page 87: ...55 239 729 516 35 4x900 Current A Type power kW 230V 400V 500V 600V Power loss W W H D Weight Fuse F1 Dimensions in mm kg Thyro A 2A H1 H RL1 H RLP1 16 11 14 60 90 131 127 1 4 20 30 21 26 94 90 131 127 1 4 40 45 31 39 96 104 190 182 3 4 63 60 42 52 160 104 190 182 3 4 80 100 69 87 210 150 190 190 3 8 200 130 90 112 300 250 320 241 8 200 170 118 147 420 250 320 241 8 315 280 194 242 660 250 393 241...

Page 88: ...20 241 12 200 170 118 147 630 375 320 241 12 315 280 194 242 990 375 397 241 15 350 350 242 303 1170 375 430 261 25 5 500 495 343 429 514 1822 276 407 345 30 630 650 450 563 675 2192 276 407 345 30 900 1000 693 866 1039 4127 583 685 516 74 2x1000 1400 1212 1454 5086 583 685 516 74 4x900 1500 1039 5206 583 685 516 74 4x900 Type power kW 600V W H D Weight Dimensions in mm kg Current A Power loss W F...

Page 89: ...89 EN 10 Type overview Thyro A 1A 16 H 30 H Thyro A 1A 45 H 60 H ...

Page 90: ...90 75 190 Thyro A 1A 100 H Thyro A 1A 130 H 170 H M 10 for grounding ...

Page 91: ...91 EN Thyro A 1A 280 HF M 10 for grounding Thyro A 1A 350A To unlock push spring hook to the right ...

Page 92: ...92 Thyro A 1A 495A 650A Thyro A 1A 1000A 1500 A ...

Page 93: ...93 EN Thyro A 2A 16 H 30 H Thyro A 2A 45 H 60 H side view refer to 1 phase model side view refer to 1 phase model M 6 for grounding M 4 for grounding ...

Page 94: ...94 Thyro A 2A 100 H M 6 for groun ding side view refer to 1 phase model Thyro A 2A 130 H 170 H M 10 for grounding ...

Page 95: ...95 EN Thyro A 2A 280 HF M 10 for grounding Thyro A 2A 350A To unlock push spring hook to the right ...

Page 96: ...96 Thyro A 2A 495 650HF Thyro A 2A 1000 1500HF ...

Page 97: ...97 EN Dimension drawing Thyro A 3A with 16A 30A The dimension drawings are for type H RLP1 ...

Page 98: ...98 Dimension drawing Thyro A 3A with 45A 60A The dimension drawings are for type H RLP1 ...

Page 99: ...99 EN Dimension drawing Thyro A 3A with 100A The dimension drawings are for type H RLP1 ...

Page 100: ...100 Dimension drawing Thyro A 3A with 130A 170A The dimension drawings are for type H RLP1 ...

Page 101: ...101 EN Dimension drawing Thyro A 3A with 280A The dimension drawings are for type H RLP1 ...

Page 102: ...102 Dimension drawing Thyro A 3A with 350A The dimension drawings are for type H RLP1 To unlock push spring hook to the right ...

Page 103: ...103 EN Thyro A 3A 1000 1500HF Thyro A 3A 495 650HF ...

Page 104: ...dbus RTU Order no 2000 000 843 Bus module CANopen Order no 2000 000 844 Bus module DeviceNet Order no 2000 000 848 Bus module connection cable for 4 control lers 2 5 m long Order no 2000 000 849 Bus module connection cable for 4 control lers 1 5 m long Order no 2000 000 380 PC software THYRO TOOL FAMILY Order no 2000 000 845 PC interface RS232 Order no 0048764 Data cable to PC RS232 9 pin SUB D 5 ...

Page 105: ...w voltage and 2004 108 EGfor electromagne tic compatibility if the instructions on installation and commissioning described in the operating instructions are followed There is no product standard for thyristor power controllers so it is necessary to build up a sensible framework of standards from the corresponding basic standards to guarantee safe application and possibilities for comparison CAUTI...

Page 106: ...N 60 146 1 1 P 2 Humidity class B EN 50 178 Tab 7 EN 60 721 Overvoltage category III EN 50 178 Tab 3 849V Degree of contamination 2 EN 50 178 Tab 2 Air pressure 900 mbar 1000 m above sea level Degree of protection IP00 EN 69 529 Protection class I EN 50178 chap 3 Air and creepage distances housing mains potential 5 5 mm housing control pot 1 mm mains volt control pot 10 mm mains volt among each ot...

Page 107: ...107 EN Burst main lines 2 kV A EN 61000 4 4 control lines 2 kV A Surge main lines 2 kV control lines asym EN 61000 4 5 1 kV sym EN 61000 4 5 0 5 kV Conducted EN 61000 4 6 ...

Page 108: ...ers com www aegps com AEG is a registered trademark used under license from AB Electrolux Betriebsanleitung Operating Instructions 8000029381 DE EN 02 11 Version 03 Due to our policy of continuous development data in this document is subject to change without notice and becomes contractual only after written confirmation ...

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