THYRO-A THYRISTOR-LEISTUNGSSTELLER / THYRISTOR POWER CONTROLLER MARCH 2015 8000029381 DE/EN - V11
1 THYRO-A THYRISTOR-LEISTUNGSSTELLER / THYRISTOR POWER CONTROLLER MARCH 2015 8000029381 DE/EN - V11
2 3 CONTENTS 1. General 1.1 Type designations/Validity 1.2 Abbreviations 1.3 Special Features 1.4 Warranty 2. 7 7 10 10 11 Safety 2.1 Identification in the operating instructions 2.2 General danger information 2.3 Operator requirements 2.4 Personnel requirements 2.5 Intended use 2.6 Use of the device 2.6.1 Operation 2.6.2 Prior to installation/commissioning 2.6.3 Maintenance, service, faults 2.6.4 Transport 12 12 13 13 14 14 15 15 15 16 17 3.
10. Dimension drawings 5 90 11. Accessories and options 105 12. Approvals and conformity 106 LIST OF FIGURES AND TABLES 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 Setpoint inputs and effective setpoint Operating elements User surface THYRO-TOOL FAMILY Connection diagram Thyro-A 1A...H1 Connection diagram Thyro-A 2A...H1 Connection diagram Thyro-A 1A ...H RL1, ... H RLP1 Connection diagram Thyro-A 2A ...H RL1, ...
6 7 CONTACT 1. GENERAL 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 powercontroller@aei.
8 9 TYPE CODE THYRO-A ...H1 The type designation of the thyristor-power controller is derived from the configuration of the power unit as well as from other features. Thyro-A 1A Thyristor controller with single phase power unit, suited for single phase loads in operating modes TAKT, VAR and QTM. Thyro-A 2A Thyristor controller with two phase power unit, suited for symmetrical loads in three phase operation in three phase saver circuit in operating mode TAKT.
10 11 1.2 ABBREVIATIONS Advanced Energy AN1 SST SYT T0 TS TAKT VAR QTM Advanced Energy Industries GmbH Phase angle of the 1st half-wave Soft start time Synchro cycle Cycle period Switch-on time Full wave switch principle - Thyrotakt Phase-angle principle - Thyrovar Half wave switch principle - Quick takt mode 1.
12 13 2. SAFETY NOTE Content of note 2.1 IDENTIFICATION IN THE OPERATING INSTRUCTIONS In these operating instructions, there are warnings before dangerous actions. These warnings are divided into the following danger categories: 2.2 GENERAL DANGER INFORMATION DANGER DANGER Dangers that can lead to serious injuries or fatal injuries. WARNING Dangers that can lead to serious injuries or considerable damage to property. Electric current Risk of injury from current carrying parts.
14 15 • The national and regional safety regulations are observed. • The personnel has access to the operating instructions and safety regulations at all times. • The operating conditions and restrictions resulting from the technical data are observed. • Should abnormal voltages, noises, increased temperatures, vibration or similar occur, the device is immediately put out of operation and the maintenance personnel is informed. 2.
16 17 control mode, limitations, monitoring, control characteristic curves, actual value output, fault messages etc.) NOTE Connecting the control signals The following control signals are absolutely necessary for operating the devices: - Setpoint (terminal X2.4 or via bus option) - Pulse blocking (to ground, on terminal X2.1, X2.2; bridge present) > U se shielded control conductors to connect the control signals. If the pulse blocking bridge is not connected, the device is blocked and is not operating.
18 19 3. FUNCTIONS In order for the Thyro-A to be adapted as best possible to the required application, it has numerous functions. These functions are described in this chapter. 3.1.2 PHASE ANGLE PRINCIPLE VAR In this operating mode, the sinus wave of the mains voltage is shifted. The shift depends on the setpoint value. Characteristic of this operating mode are the high control dynamics. When phase angle control VAR is used, harmonics of the mains voltage form.
20 21 The user can adapt the setpoint signal to process controllers or to the automation system (see page 42, Set point input range). This is done by altering the starting and finishing points of the control characteristic curve. All common signals can be used. As soon as the power controller reaches a limit value (Umax, Imax, Pmax), this is indicated by LEDs (see page 29, LED messages).
22 23 3.4 LIMITS In addition to setting the control mode, it is also possible to set limits for the following variables: • Voltage limitation (U) • Current limitation (I) (only for ...H RL1 aund ...H RLP1) • Power limitation (P) (only for ...H RLP1) SECONDARY CONTROL FINAL VALUE OF LIMITS THE CONTROLLER U Ueff max Ieff max1 Pmax1 2 U Ueff max Ieff max1 Pmax1 1 Ieff max Ueff max1 Pmax1 Ieff max Ueff max1 Pmax1 Pmax Ieff max1 Ueff max1 I* 2 1 I* 2 P* P OUTPUT POWER (ONLY FOR ...
24 25 3.7 DISPLAY VIA ANALOG OUTPUT (only for ...H RL1 and ...H RLP1) The following variables are output at the analog output (e.g. when an external measuring instrument is connected): Load current (highest phase current from L1, L2, L3) Load voltage (highest conductor voltage) Effective power (total power) (only with ...H RLP1) Additional variables (can be selected via PC/bus, e.g. mains voltage setpoint etc.
26 27 The following tables show the various messages and classification of default settings (X).
28 29 POSSIBLE SETTINGS IN THYRO-TOOL FAMILY 3.8.
30 31 LED MESSAGES MESSAGE LED LED LED INTERNAL INTERNAL INTERNAL DESCRIPTION ON PULSE LOAD LED AT LED AT INHIBIT FAULT MASTER SLAVE 1 SLAVE 2 (RED) (GREEN) (GREEN) (GREEN) (GREEN) (RED) LED AT Device without OFF OFF OFF OFF Device not operating voltage supply Voltage supply ON Voltage supply present present Control display ON OFF Flash*1 Flash*1 Flash*1 Depending on the control the internal LEDs flasch at diff.
32 33 3.9 MONITORING 3.9.2 LOAD MONITORING Power controller and load circuit are monitored for malfunctions. Messages are sent via LED (see page 29, LED messages), by bus or by fault signalling relay K1 (see page 31, Fault signalling relay K1). (only for ...H RL1 and ...H RLP1) The load can consist of one or more resistors connected in parallel or in parallel-series. It can be monitored up to a freely selectable absolute undercurrent limit value.
34 35 3.10.1 EXTENDED OPERATING MODES / CIRCUIT TYPES With the aid of Thyro-Tool Family, it is possible to 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) 3.10.
36 37 4. SETTINGS AND OPERATION DANGER Dangers involved in settings and operation Risk of injury / Risk of damage to the device or plant • Observe all safety regulations in the chapter on safety. Setting and operating the thyristor power controller is described in this chapter.
38 39 9 10 11 22 16 25 19 l 15 24 23 18 12 17 13 21 20 14 l 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Connection terminal U1 Connection terminal V1 Connection terminal W1 Connection terminal U2 Connection terminal V2 Connection terminal W2 Terminal X2 Terminal X3 Terminal X1 Master Terminal X11 Master Terminal X22 Master Terminal X1 Slave1 Terminal X11 Slave1 Terminal X22 Slave1 Terminal X1 Slave2 Terminal X11 Slave2 Terminal X22 Slave2 Type plate 4.2 DIP SWITCH S1 S1.10 S1.
40 41 DEFAULT SETTINGS OF DIP SWITCH S1 S1.
42 43 HRLP1 H1/HRL1/ HRLP1 1 0 1 P with analog output Pload Pload max 0 1 1 P with analog output Iload Pload max 1 1 1 Thyro-Tool mode 4.3 POTENTIOMETER There are five potentiometers below the LEDs with approx. 18 turns for the setting range. 4.2.3 SET POINT INPUT RANGE S1.
44 45 Setting aid for ...H RL1 and ...H RLP1 There is a setting aid for the potentiometers. • Connect the measuring device to the analog output (X2.9 (+) to X2.5 ground). > If a potentiometer is altered, the set value of the potentiometer is output at the analog output and not the actual value. > If the device is operated on mains voltage, the red LEDs flicker for the duration. > If the potentiometer is not greatly altered for 30 secs.
46 47 NOTE Setting AN1, SST and T0 independently When a bus module or Thyro-Tool Family are used, parameters AN1, SST and T0 can be set independently of one another. • Setting potentiometer TRAFO ADAPTION R201 to left stop. > At <30°el the device automatically switches to a faster TAKT operation with T0 = 5 periods without SST. Then terminal X2.7 can be used as control input for switch operation. When using the synchronization options, via R201 must be set parameter AN1 >30° el (T0 = 1000ms).
48 49 • Set maxiumum load value (of U or P) at control end on potentiometer R202 SCALE SETPOINT. 4.3.5 SETTING EXAMPLE FOR MAXIMUM LOAD VALUE AT CONTROL END / MAXIMUM LOAD CURRENT For ...H1 When DIP switch S1.5 is at „ON“, the maximum load voltage (with U/U2 control) can be defined on potentiometer R201 TRAFO ADAPTION. Example for maximum load value / maximum load current The control characteristic curve is adapted in accordance with the following equation: Uload max = (No.
50 51 4.3.6 ADAPTING ANALOG OUTPUT (SCALE) (ONLY FOR ...H RL1 AND ...H RLP1) The scale of the analog output is adapted with potentiometer R204 SCALE OUTPUT, if, for example, the scale of the display does not correspond to the nominal data (see page 42, Analog output).
52 53 conductor a>117°el.) - The signalling delays can be up to 15 secs. in operating mode VAR and up to 30 secs. in operating mode TAKT. - Convert deviating values as a percentage. The set monitoring value should always be an average of the value for load nominal current and the value after failure.
54 55 Thyro-A 2A Load with common star point and without neutral conductor NO. OF PARALLEL LOAD RESISTORS ILOAD NOM / ITYPE CONTROLLER CURRENT IN CASE OF FAULT RECOMMENDED SETTING FOR POTI R205 SETTING AID AT ACTUAL VALUE OUTPUT X2.9 [0-10 V] SETTING AID NO. OF POTENTIOMETER TURN AT ACTUAL VALUE OUTPUT FROM LEFT STOP X2.9 [0-20 mA] 1 100% 80% 60% 40% 20% 100% 80% 60% 40% 20% 100% 80% 60% 40% 100% 80% 60% 0% 50.0% 40.0% 30.0% 20.0% 10.0% 80.0% 63.0% 48.0% 32.0% 16.0% 87.0% 70.0% 52.0% 35.0% 90.
56 57 Thyro-3A Load in delta connection Load with common star point and without neutral conductor Thyro-3A NO. OF PARALLEL LOAD RESISTORS ILOAD NOM / ITYPE CONTROLLER CURRENT IN CASE OF FAULT RECOMMENDED SETTING FOR POTI R205 SETTING AID AT ACTUAL VALUE OUTPUT X2.9 [0-10 V] SETTING AID NO. OF POTENTIOMETER TURN AT ACTUAL VALUE OUTPUT FROM LEFT STOP X2.9 [0-20 mA] 1 100% 80% 60% 40% 20% 100% 80% 60% 40% 20% 100% 80% 100% 0% 50.0% 40.0% 30.0% 20.0% 10.0% 80.0% 64.0% 48.0% 32.0% 16.0% 87.5% 70.
58 59 Thyro 3A Load with common star point with neutral conductor (1) Load with separate star point without neutral conductor (2) Load in open delta connection (3) 5. INSTALLATION DANGER Dangers during Installation Risk of injury / Risk of damage to the device or plant >O bserve all safety regulations in the safety chapter NO. OF PARALLEL LOAD RESISTORS ILOAD NOM / ITYPE CONTROLLER CURRENT IN CASE OF FAULT RECOMMENDED SETTING FOR POTI R205 SETTING AID AT ACTUAL VALUE OUTPUT X2.
60 61 NOTE Connecting the control signals The following control signals are necessary for operating the devices: - Setpoint (terminal X2.4 or via bus option) - Pulse inhibition (to ground, on terminal X2.1, X2.2; bridge present) If the pulse inhibition bridge is not connected, the device is blocked and is not operating. Communication is still possible via the interface (see page 64, Connecting pulse inhibition). The device is parameterised when delivered and also adapted to the particular power unit.
62 63 5.2 CONNECTING POWER SUPPLY H 100 LED gn ON H 101 LED rt PULSE INHIBIT H 250 LED rt LOAD FAULT H 350 LED gn Diagnosis/percent modulation indication S1.10 S1.9 S1.8 S1.7 S1.6 S1.5 S1.4 S1.3 S1.2 S1.1 Analog output 10 V / 20 mA Live Zero analog output Setpoint value input Setpoint value input Live Zero setpoint Control mode / Thyro-Tool mode Control mode / Thyro-Tool mode Control mode / Thyro-Tool mode Operation mode Operation mode Chap. 4.2.
64 65 5.4 CONNECTING PULSE INHIBITION Certain errors (see page 24, Error and status messages) trigger pulse inhibition internally. Triggering of pulse inhibition can be configured. Preparing to use pulse inhibition • Switch off mains supply and secure against accidentally being switched back on. • Replace bridge from X2.1 to X2.2 with a switching contact (lowcurrent contact). Activating pulse inhibition (with device switched on) • Open switching contact. > Pulse inhibition is activated.
66 67 5.8 USING THE ANALOG OUTPUT (only for ...H RL1 and ...H RLP1) • Switch off mains supply and secure against accidentally being switched back on. • Connect terminals X2.9 (+) and X2.5 (ground) to a display device. Ensure the correct polarity! • Configure the signal level (see page 42, Analog output). • Adapt the signal level to the scale (page 42, Analog output (Adapting scale)). 5.9 USING THE THYRO-TOOL FAMILY • Switch off mains supply and secure against accidentally being switched back on.
68 69 6. MAINS LOAD OPTIMIZATION DANGER Danger when making adjustments Risk of injury / Risk of damage to the device or plant > Observe all safety regulations in the safety chapter. Mains load optimization offers considerable advantages, e.g. reducing mains load peaks and system disturbances.
70 71 All of these negative effects can be avoided or reduced to a minimum level by using the Thyro-Power Manager. The Thyro-Power Manager has a total of 10 digital outputs at the terminals (figure 12, page 79) X3 and X4. These are set up as potentialfree optical coupler outputs. When optimising the network load they are used as synchronization outputs (SYT) for the connected power controllers or power controller groups. All cables are to be laid shielded with the shield grounded at the output switch.
72 73 7. CONNECTION DIAGRAMS FIG. 4 CONNECTION DIAGRAM THYRO-A 1A… H1 FIG.
ϑ K1 X11 1 2 + - DC 24V ~ ~ AC Use shielded control lines! X2 1 Pulse Inhibit Load Fault Diagnose (Intern) H 101 H 250 H 350 5 6 5..10 K + 2 3 4 7 8 mA,V Connection for bus module option 4 5-7 10 9 8 7 6 5 4 3 2 1 2 PE X1 1 U2 L2 (N) RLoad Mains supply L1 U1 F1 SemiconductorFuse Set Point Input Set Point Input Set Point Live Zero Control Mode / Thyro-Tool Control Mode / Thyro-Tool Control Mode / Thyro-Tool Operating Mode Operating Mode Analog.-Output 10V/20mA Analog.
76 77 FIG. 8 CONNECTION DIAGRAM THYRO-A 3A…H1 FIG.
78 79 FIG. 12 CONNECTION DIAGRAM MAINS LOAD OPTIMIZATION WITH THYRO-POWER MANAGER * Pay attention to setting (S1.1 and S1.2) FIG. 10 LOAD CONNECTION TYPES Thyro-A ... H(F) RL1 ... H(F) RLP1 X1 1 2 X11 1 2 X2 1 2 3 4 5 6 7 8 System - Interface 9 10 X22 1 2 3 4 5 6 7 X3 1 2 connection for option. bus module 24V AC or DC supply connections see bus module manual FIG. 11 ADDITIONAL ELECTRONICS SUPPLY AND CONNECTION WITH OPTIONAL BUS MODULE 3 Sync. Out Thyro-A Sync. Out Thyro-A Sync.
80 81 8. HELP IN THE EVENT OF PROBLEMS The devices delivered correspond to quality standard ISO 9001. Should you experience any malfunctions or other problems, please contact our technical support team, see Contacts on page 6. Here are several tips to help resolve problems: Error: LED ON green does not light up or LED „pulse inhibit“ flashes slowly • Check power unit fuse F1: If the fuse is defective: • Check if there is a short-circuit at the load or wiring. • Check the type of load.
82 83 • Check load of the output: • Check the load at the 5 V DC output. Minimum resistance: Rmin = 5 kΩ. 9. TECHNICAL DATA • 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 0-20 mA, but the setpoint value however is 4-20 mA, then the controller will always adjust.
84 85 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, the induction of the downstream transformer should not exceed 1.45 T for mains overvoltage = 1.2 T nominal induction.
86 87 CONNECTION GROUNDING SCREW U1, V1, W1, U2, V2, W2 8 / 16 / 30 A lug / M4 lug / M4 45 A* M6 M 6 max. 60* / 100 A* M 6 M 6 max. 130 / 170 A M 8 M 10 280 A M 10 M 10 350 A M 10 M 10 495 A M 10 M 10 650 A M 10 M 10 1000 A M12 M12 1400 A M12 M12 1500 A M12 M12 Fan data CONDUCTOR CROSS SECTION max.
88 89 Thyro-A 2A… H1, …H RL1, …H RLP1 Type overview TYPE POWER [KW] CURRENT 230 V 400 V 500 V 600 V POWER LOSS [A] [W] 8 3.2 3.2 4 9 16 3.7 6.4 8 30 30 6.9 12 15 47 45 10 18 22.
90 91 10.
92 93 THYRO-A 1A (495 HF, 650 HF) THYRO-A 1A (280 HF)
94 95
96 97 THYRO-A 2A (130 H, 170 H) THYRO-A 2A (350 HF) THYRO-A 2A (280 H
98 99
100 101 THYRO-A 3A (45 H, 60 H) THYRO-A 3A (100 H)
102 103 THYRO-A 3A (350 HF) THYRO-A 3A (130 H, 170 H)
104 105 11.
106 107 12. APPROVALS AND CONFORMITY The Thyro-A has the following approvals and conformities: • Quality standard in acc. with DIN EN ISO 9001 • UL-approval, file No. E 135074, taking into account the Canadian National Standard C 22.2 No. 14-95, certification 8-350 A, under preparation 495-1500 A. • UL Markings: ·T ightening torque (in pound inches) see Chapter 9. „Technical data“ · Use 75 °C Copper Conductors only (except models Thyro-A 1A 48..., Thyro-A 1A 230-4, and Thyro-A 1A 230-8).
108 109 In Detail DEVICE APPLICATION CONDITIONS Built-in device (VDE0160) General requirements Design, vertical installation Operating conditions Area of application, industrial Temperature behaviour Storage temperature D Transport temperature E Operating temperature better B Load category 1 Humidity class B Overvoltage category III Degree of contamination 2 Air pressure Degree of protection IP00 Protection class I Air and creepage distances
World Headquarters 1625 Sharp Point Drive Fort Collins, CO 80525 USA Specifications are subject to change without notice. 970.221.4670 Main 970.221.5583 Fax © 2014 Advanced Energy Industries, Inc. All rights reserved. Advanced Energy® and Thyro-A are trademarks of Advanced Energy Industries, Inc. www.advanced-energy.
