AEG Thyro-P User Manual
BETRIEBSANLEITUNG/OPERATING INSTRUCTIONS
Thyro-P
Thyristor-Leistungssteller
kommunikationsfähig
1
Thyristor Power Controller
Communication Capable
DE EN
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.
The operator of this device is obliged to provide these operating instructions to all persons
transporting, commissioning, maintaining or performing other work on the Thyro-P without any
restrictions.
In accordance with the Product Liability Act, the manufacturer of a product has an obligation to
provide explanations and warnings as regards:
• the use of the product other than for the intended use,
• the residual product risk and
• operating error and its consequences.
The information given below must be understood in this respect. It is to warn the product
user and protect him and his systems.
PROPER USE
• The Thyristor Power Controller is a component which may only be used for control and regulation
of electrical energy in industrial alternating current or 3-phase networks.
• The Thyristor Power Controller may at maximum be operated using the maximum admissible
connected load according to information on the type plate.
• The Thyristor Power Controller may only be operated in connection with a suitable and series
connected power supply disconnecting device.
• As a component the Thyristor Power Controller is unable to operate alone and must be projected
for its intended use to minimize residual risks.
• The Thyristor Power Controller may only be operated in the sense of its intended use; otherwise,
personal hazards (for instance electrical shock, burns) and hazards for systems (for instance overload) may be caused.
RESIDUAL HAZARDS OF THE PRODUCT
• Even in case of proper use, in case of fault, it is possible that control of currents, voltages and
power is no longer performed in the load circuit by the Thyristor Power Controller.
In case of destruction of the power components (for instance breakdown or high resistance), the
following situations are possible: power interruption, half-wave operation, continuous power fl ow.
If such a situation occurs, then load voltages and currents are produced from the physical dimensions of the overall power circuit. It must be ensured by system design that no uncontrolled large
currents, voltages or power results. It is not possible to totally exclude that during operation of
Thyristor power controllers other loads show abnormal behaviour. The physically determined
network reactions, depending on the operating mode, must be considered.
DANGER OF ELECTRIC SHOCKS
Even if the Thyristor Power Controller is not triggered, the load circuit is not disconnected from the
mains.
It is possible to safely disconnect the Thyristor Power Controller as under IEC 60950
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. due to impact, being knocked, soiling).
INSTALLATION
• If the Thyristor Power Controller is brought into the operations room from a cold environment,
moisture can occur. Prior to it being commissioned, the Thyristor Power Controller must be
absolutely dry. For this reason, wait for a minimum period of two hours before commissioning.
• Install the device upright.
CONNECTION
• Prior to connection, it must be ensured that the voltage information on the type plate corresponds with the mains voltage.
• The electrical connection is carried out at the designated points with the required cross section
and the appropriate screw cross sections.
3
OPERATION
• The Thyristor Power Controller may only be connected to the mains voltage if it has been ensured
that any hazard to people and system, especially in the load section, has been eliminated.
• Protect the device from dust and moisture.
• Do not block vents.
MAINTENANCE, SERVICE, MALFUNCTIONS
The icons used below are explained in the chapter safety regulations.
CAUTION
Should smoke, smell or fi re occur the Power Controller must be disconnected from the mains
immediately.
CAUTION
For maintenance and repair work, the Power Controller must be disconnected from all external voltage sources and protected against restarting. Make sure to wait minimum 1 minute after switch-off
(discharge time of the attenuation capacitors). The voltage-free state is to be determined by means
of suitable measuring instruments. This work is only to be carried out by a skilled electrician. The
electrical regulations which are locally valid are to be adhered to.
CAUTION
The Thyristor Power Controller contains hazardous voltages. Repairs may generally only be performed by qualifi ed and trained maintenance personnel.
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 AEG Power Solutions GmbH.
TABLE OF CONTENTS
Safety instructions 2
Schedule of Illustrations and Tables 7
Safety Regulations 8
Remarks on the present operating instructions and Thyro-P 11
1. Introduction 13
1.1 General 13
1.2 Specific characteristics 13
1.3 Type designation 14
2. Functions 15
2.1 Overview of operating modes 15
2.2 Set point control characteristic 16
2.3 Control types 18
2.3.1 Controlled value 18
2.4 Indications 19
2.4.1 LED indications 19
2.4.2 Relay indications K1-K2-K3 19
2.5 Monitoring 20
2.5.1 Load monitoring 21
2.5.2 Ventilator monitoring 24
5
3. Mode of Operation 25
3.1 Local operating and display unit (LBA) 25
3.1.1 LBA keyboard functions 25
3.1.2 LBA main menu 26
3.1.3 LBA submenus 27
3.1.4 Copying function using the LBA 32
3.1.5 Operation display 32
3.1.6 Line diagram 33
3.1.7 Last function 33
3.1.8 Status line 33
3.1.9 LBA submenus with password protection 34
3.2 Cabinet installation kit (SEK) 34
3.3 Thyro-Tool Family 34
3.4 Diagnosis / fault indications 36
4. External Connections 38
4.1 Power supply for Thyro-P 38
4.2 Power supply for the control device A70 38
4.3 Power supply for the ventilator 38
4.4 RESET 39
4.4.1 Software-RESET 39
4.5 Controller lock 39
4.6 QUIT 40
4.7 Set point value inputs 40
4.8 ASM input 40
4.9 Analog outputs 40
4.10 Current transformer 41
4.11 Voltage transformer 41
4.12 Other connections and terminal strips 42
4.13 Synchronization 44
4.14 Component mounting diagram control device 45
5. Interfaces 46
5.1 RS 232 interface
47
6
5.2 Fibre optic interfaces 48
5.2.1 Fibre optic distribution system 48
5.3 Bus interfaces (option) 51
5.3.1 Profibus 51
5.3.2 Modbus RTU 55
5.3.3 DeviceNet 55
6. Mains Load Optimization 56
6.1 SYT-9 procedure 56
6.2 Software synchronization 56
6.3 ASM procedure (patented) 56
7. Connecting diagrams 58
7.1 1-phase 58
7.2 2-phase 59
7.3 3-phase 60
8. Special Remarks 61
8.1 Installation 61
8.2 Comissioning 61
8.3 Service 62
8.4 Checklist 62
9. Type Overview 64
9.1 Type range 400 volts 64
9.2 Type range 500 volts 65
9.3 Type range 690 volts 66
10. Specifications 67
11. Dimensional Drawings 70
12. Accessories and Options 83
13. Approvals and Conformities 84
SCHEDULE OF ILLUSTRATIONS AND TABLES
Fig. 1 Control characteristic for U control 17
Fig. 2 Total set point 17
Fig. 3 Switch-on fault bridging 20
Fig. 4 Absolute value monitoring 21
Fig. 5 Relative monitoring 21
Fig. 6 Local operating and display unit (LBA) 25
Fig. 7 Operation display 32
Fig. 8 Cabinet installation kit 34
Fig. 9 Example for the user interface Thyro-Tool Familiy 35
Fig. 10 File component mounting diagram control device 45
Fig. 11 Interfaces of Thyro-P 46
Fig. 12 Connection of a PC to Thyro-P via RS 232 47
Fig. 13 X10-allocation 48
Fig. 14 Signal converter RS 232/fibre optic 49
Fig. 15 Schematic diagram fibre optic Thyro-P with LLV and PC 50
Fig. 16 Profibus slot card 52
Fig. 17 Special function Motorpoti 53
Fig. 18 Special inputs 54
Fig. 19 Modbus slot card 55
Fig. 20 ASM wiring 57
7
Tab. 1 Behaviour in case of load change 19
Tab. 2 Partial load breakdown with heating elements switched in parallel, undercurrent 22
Tab. 3 Partial short-circuit with heating elements switched in series, overcurrent 23
Tab. 4 Overview monitoring 23
Tab. 5 Functions of the LBA-keys 26
Tab. 6 LBA main menu 27
Tab. 7 Copying function using the LBA 32
Tab. 8 Line diagram time base 33
Tab. 9 Elements of the status line 33
Tab. 10 Allocation of the message register 37
Tab. 11 Terminal strip X1 38
Tab. 12 RESET 39
Tab. 13 Controller lock 39
Tab. 14 QUIT 40
Tab. 15 Current transformer 41
Tab. 16 Voltage transformer 41
Tab. 17 Voltage measurement jumper 42
Tab. 18 Terminal strip X2 for K1, K2, K3 42
Tab. 19 Terminal strip X5 43
Tab. 20 Terminal strip X6 43
Tab. 21 Terminal strip X7 44
Tab. 22 Synchronization jumper 44
Tab. 23 Fibre optic distances 49
Tab. 24 Profibus baud rates 51
Tab. 25 Pin assignment X21 53
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. All work may only be performed by specialist personnel
trained for this purpose using the tools, devices, test instruments and consumables provided for
this purpose and in good shape.
In the present operating instructions, important instructions are marked using the terms
„CAUTION“, „ATTENTION“ and „REMARK“ as well as using the icons explained below.
CAUTION
This instruction shows work and operating procedures to be observed exactly to exclude hazards
for persons.
ATTENTION
This instruction refers to work and operating procedures to be observed exactly to avoid damage
or destruction of Thyro-P or parts thereof.
REMARK
This is where remarks about technical requirements and additional information is given, which the
user has to observe.
ACCIDENT PREVENTION RULES
The accident prevention rules of the application country and the generally applicable safety
regulations must be observed in any case.
CAUTION
Before starting any work on Thyro-P, the following safety regulations must be observed:
• switch voltage-free,
• secure against switching on,
• determine if it is voltage-free,
• ground and short-circuit it,
• cover or block neighboring parts under voltage.
QUALIFIED PERSONNEL
Thyro-P may only be transported, installed, connected, commissioned, maintained and operated
by specialists in command of the respective applicable safety and installation regulations. All work
must be monitored by the responsible specialist personnel. The specialist personnel must be
authorized for the work required by the person responsible for the safety of the system.
Specialists are persons who
- have received training and have experience in the respective fi eld of work,
- know the respective applicable standards, regulations, terms and accident prevention rules,
- have been familiarized with the function and operating conditions of Thyro-P,
- are able to detect and avoid hazards.
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 behaviour to colleagues and to
notify the offi ce or person responsible about defects detected.
INTENDED USE
CAUTION
The Thyristor Power Controller may only be employed in the sense of its purpose of use (see the
section of the chapter safety instructions under the same name), otherwise hazards for persons (for
instance electrical shock, burns) and systems (for instance overload) may occur.
Any unauthorized reconstruction and modifi cation of Thyro-P, use of spare and exchange parts not
approved by AEG Power Solutions as well as any other use of Thyro-P is not allowed. The person
responsible for the system must ensure that
- hints on safety and operating instructions are available and observed,
- operation conditions and specifi cations are observed,
- protective installations are used,
- required maintenance work is performed,
- maintenance personnel are immediately notifi ed or Thyro-P is immediately put out of commission
if abnormal voltages or noises, higher temperatures, vibrations or similar occur to determine the
causes.
These operating instructions contain all information required by specialists for use of Thyro-P.
Additional information and hints for unqualifi ed persons and for use of Thyro-P outside of industrial
installations are not contained in these operating instructions.
9
The warranty obligation of the manufacturer applies only if these operating instructions are observed.
10
LIABILITY
In case of use of Thyro-P for applications not provided for by the manufacturer, no liability is
assumed. The responsiblity for required measures to avoid hazards to persons and property is
borne by the operator respectively the user. In case of complaints, please immediately notify us
stating:
- type name,
- production number,
- 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 confi rms observation of the general EG guidelines for 2006/95/EG –
low voltage and for 2004/108/EG – electromagnet compatibility, if the instructions on installation
and commissioning described in the operating instructions are observed.
Regulations and defi nitions for qualifi ed personnel are contained in DIN 57105/VDE 0105 Part 1.
Safe isolation to VDE 0160 (EN 50178 Chapter 3)
REMARKS ON THE PRESENT OPERATING INSTRUCTIONS AND THYRO-P
VALIDITY
These operating instructions refer to latest technical specifi cation 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 specifi cation, 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 specifi cation. AEG PS cannot accept responsibility for damage, injury, loss or
expenses resulting therefrom.
HANDLING
These operating instructions for Thyro-P are organized so that all work required for commissioning,
maintenance and repair may be performed by corresponding specialist personnel.
If hazards to personnel and property cannot be excluded for certain work, then this work is marked
using certain icons. The meaning of these icons may be found in the prior chapter safety regulations.
ABBREVIATIONS
In this description, the following specifi c abbreviations are used:
11
AEG PS = AEG Power Solutions GmbH
ASM = automatic synchronization in multiple Power Controller application
(dynamic network load optimization)
DaLo = data logger (fault storage)
LBA = lokal operating and display unit
SEK = cabinet installation kit
LL = fi bre optic
LLS = fi bre optic transmitter
LLE = fi bre optic receiver
LLV.V = fi bre optic distribution supply
LLV.4 = fi bre optic distribution, 4-fold
SYT = synchronized clock
TAKT = Pulse full cycle
WARRANTY
Customer shall provide written particulars, enclosing the delivery note, within 8 working days to
AEG PS on becoming aware of any defects in the goods during the Warranty period and shall use
its best endeavours to provide AEG PS with all necessary access, facilities and information to
enable AEG PS to ascertain or verify the nature and cause of the defect and carry out its warranty
obligations.
If goods are found not to be defective or if any defect is attributable to Customer’s design or material in operation of the goods, AEG PS will levy a testing charge and where relevant will return the
goods to Customer at Customer’s expense, and shall be entitled to payment in advance of the
whole testing and transport charge before such return.
AEG PS accepts no liability for defects caused by the Customer’s design or installation of the
goods; or if the goods have been modifi ed or repaired otherwise than as authorised in writing by
AEG PS; or if the defect arises because of the fi tting of the goods to unsuitable equipment.
AEG PS will cancel all possible obligations incurred by AEG PS and its dealers, such as warranty
commitments, service agreements, etc., without prior notice if other than original AEG spare parts
or spare parts purchased from AEG PS are used for maintenance or repair.
12
SERVICE HOTLINE
Our service is available to you through the following hotline:
AEG Power Solutions GmbH
Emil-Siepmann-Straße 32
D-59581 Warstein
Phone +49 (0) 2902 763-100
http://www.aegps.com
powercontroller@aegps.com
INTERNET
Further information on our company or our products can be found on the internet under
http://www.aegps.com.
COPYRIGHT
Passing on, duplication and/or takeover of these operating instructions using electronic or mechanical means, even in excerpts, is subject to express prior written approval of AEG PS.
© Copyright AEG Power Solutions 2012. All rights reserved.
Copyright notice
Thyro-P is an internationally registered trademark of AEG Power Solutions GmbH.
Windows and Windows NT are registered trademarks of Microsoft Corporation.
All other company and product names are (registered) trademarks of their respective owners.
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.
1.1 GENERAL
Thyro-P is a Thyristor Power Controller able to communicate. Below, it is also referred to simply
as Power Controller. It may be employed in any place where voltage, current or power has to be
controlled or regulated in processing technology. Several modes of operation and control, good
coupling ability to process and automation technology, high control precision by application of a
32 bit RISC processor and simple handling ensure that Thyro-P is suitable for new applications as
well.
Thyro-P is suitable for
• direct supply of ohmic loads
• for loads with large R
• as primary Power Controller for a transformer with subsequent load
Due to use of state-of-the-art thyristors, the Thyristor Power Controller Thyro-P has a type range
up to 2900A, the nominal design loads reach up to about 2860kW.
hot/Rcold
ratio
13
1.2 SPECIFIC CHARACTERISTICS
Thyro-P is characterized by a multitude of specifi c characteristics, for instance:
• easy handling
• menu-driven user interface
• type range 230-690 Volts, 37-2900A, single, double, triple phase
• broadband power supply AC 200-500V, 45-65Hz
• ohmic load and transformer load
• as well as load with large R
• soft start function for transformer load
• load circuit monitoring
• automatical rotating fi eld recognition for 2P and 3P
• U, U2, I, I2, P control as well as without control
• operating modes TAKT, VAR, Soft-Start-Soft-Down, MOSI, ASM
(optional sub-operating mode of TAKT)
• control of analog set points or via interfaces
• fi bre optic and RS 232 interfaces as standard
• electrical separation according to EN 50178 chap. 3
• Measured values are given at analog outputs
• 4 set point channels incl. Motorpoti, which parameters can be set
The specifi c characteristics especially include the following options:
• Bus connection via bus adaptor cards to plug into the Thyro-P Power Controller, coupling to
different bus systems, for instance Profi bus, other bus systems upon enquiry.
• Patented ASM procedure for dynamic mains load optimization. The ASM procedure (automated
synchronization of multiple Power Controller applications) is used for dynamic mains load optimization. It reacts to changes in load and set point, minimizes mains load peaks and associated mains
feedback. Minimizing of mains load peaks means cost savings in operating and investment cost.
hot/Rcold
for 1P and 3P
14
• Local operating and display unit (LBA), able for graphics display, menu-driven, pluggable. The
integrated copying function by replugging the LBA enables simple transfer of Power Controller
parameters between power controllers of the type Thyro-P.
• Cabinet installation kit (SEK) for the local operating and display unit. The SEK enables installation
of the local operating and display unit into the switching cabinet door. It consists of cables and
an installation frame.
• The PC-Software Thyro-Tool Familiy for effective commissioning and simple visualization tasks.
Functions are for instance loading, storing, modifi cation, comparing and printing of parameters,
set points and actual value processing, line diagrams of process data (including printing and
storing option), bar diagrams, simultaneous display of process data from different Power Controllers, simultaneous connection of up to 998 Thyro-P Power Controllers.
1.3 TYPE DESIGNATION
The type designation of the Thyristor Power Controllers are derived from the construction of its
power section:
TYPE RANGE DESIGNATION FEATURES
Thyro-P 1P single phase power section,
for single phase operation
2P double phase power section, for three phase operation
in three phase economizing circuits,
not for phase-angle control (VAR)
3P three phase power section,
for three phase operation
.P400 Type voltage 230-400 Volt, 45-65 Hz
.P500 Type voltage 500 Volt, 45-65 Hz
.P690 Type voltage 690 Volt, 45-65 Hz
.P ...-0037 Type current 37A (Typecurrent range 37A-2900 A)
.. ...-.... . H Integrated semi-conductor fuse (all Thyro-P)
.. ...-.... . F Forced air cooling with integrated ventilators
The complete type range can be found in the type overview in chapter 9.
2. FUNCTIONS
15
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 OVERVIEW OF OPERATING MODES
This chapter gives an overview of the various, partly type-specifi c and optional operating modes.
Full wave switch mode (TAKT)
Depending on the prescribed set point, the
mains voltage is periodically switched. In this
operating mode, almost no harmonics are
created. Whole multiples of the mains periods
are switched, avoiding DC components. The full
oscillation clock principle is especially suited for
loads with thermal inertia. For optimization of
the mains load, the optional ASM process may
be applied in this operating mode.
Phase-angle principle (VAR, with 1P and 3P)
Depending on the prescribed set point, the sine
oscillation of the mains voltage is gated using a
larger or smaller control angle a. This operating
mode is characterized by high control dynamics.
In case of phase-angle control, it is possible to
compensate harmonics of the mains voltage by
using circuit variants (for instance vector group
transformer).
Soft-Start-Soft-Down (SSSD)
The operation of large individual loads using the operating mode TAKT may lead to voltage variations on the mains side. The operating mode SSSD greatly reduces the pulse-shaped mains load.
MOSI operation for 1P and 3P
MOSI is a sub-operating mode of the operating modes TAKT and VAR for sensitive heating materials with a high R
starts with phase-angle maximum value and actual value to avoid high current amplitudes during
the heating-up phase and then automatically switches to the set operating mode.
ratio, for instance molybdenum disilicide. The Power Controller always
hot/Rcold
16
Mains load optimization (ASM procedure)
For systems in which several Power Controllers are employed in full wave switch mode TAKT, it is
possible that individual Power Controllers are synchronized so that a regular mains load is achieved
by defi ned switching of the individual Power Controller in sequence. This avoids load peaks by
random simultaneous switching of many Power Controllers and load troughs are fi lled up. The
upstream transformer and/or the upstream feed point may be designed for a lower load. Besides
savings in investment and operating cost, lower mains reactions also result.
2.2 SET POINT CONTROL CHARACTERISTIC
The set point control characteristic 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.
The effective set point is the total set point. It is formed by adding the four set points as shown in
fi g. 2.
In the simplest case all the set point values are added algebraically. The prerequisite for a set point
to infl uence the total set point value is that it must be enabled by the set point Enable Register.
• Set point 1 (X5.2.10 - X5.1.13 ground) 0-20mA default
• 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 fi nal value), and they may be set to the
following signal ranges:
0(4)-20 mA (Ri about 250⍀) max. 24mA siehe ”ATTENTION“
0-5 V (Ri about 8,8k⍀) max. 12V
0-10 V (Ri about 5k
The following table shall be used for the hardware confi guration of the set point inputs (see also
FILE COMPONENT MOUNTING DIAGRAM CONTROL DEVICE, fi gure 10). If the hardware confi guration is changed, the Thyro-P parameters must be changed accordingly with the LBA or the
Thyro-Tool.
X221 for Set point input 1
Bridge X221 Signal range Set point input 1
closed* 0(4) -20mA (X5.2.10)
open 0-5V / 0-10V (X5.2.10)
X222 for Set point input 2
Bridge X222 Signal range Set point input 2
closded 0(4)-20mA (X5.2.11)
open* 0-5V / 0-10V (X5.2.11)
ATTENTION
If the open-circuit voltage of the connected set point exceeds 12V in the 20mA signal range, the
set point inputs can be destroyed, if the belonging bridge (X221, X222) is open.
Within the stated input ranges, these values with the control characteristic may be adjusted to any
common signal characteristic.
⍀) max. 12V
* default
FIG. 1 CONTROL CHARACTERISTIC FOR U CONTROL
For a set point poti (e.g. 5-10 K⍀) 5V supply voltage can be taken from terminal X5.2.5 (Ri = 220⍀,
short-circuit-proof).
17
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.
• Set point 3:
Set point of the superordinate system or PC via fibre optic connection (standard) X30, X31 or via
the optional bus interface.
• Set point 4:
Set point input (motor potentiometer function) via LBA or RS 232 from the superordinate system or
PC. Set point 4 is stored in case of mains failure.
EFFECTIVE TOTAL SET POINT VALUE
The algebraic addition of the results of set point (1,2) to set point 3 and 4 gives the (effective) total
set point value for the set point control characteristic as shown in the following figure.
FIG. 2
TOTAL
SET POINT
18
The prerequisite for a set point to infl uence the total set point value is that it must be enabled by
the set point Enable Register. Set point 1 and 2 can be linked using the following functions. The
result of this link is called set point (1,2).
Set point link
ADD Set point (1,2) = Set point 1 + Set point 2
IADD Set point (1,2) = Set point 1 - Set point 2
_Pro Set point (1,2) = Set point 1 *
Set point 2 [%]
100%
_IPro Set point (1,2) = Set point 1 * (1 -
Set point 2 [%]
)
100%
VALUE RANGE OF SET POINT (1,2)
For the link result of set point (1,2) the following value range applies:
울 Set point (1,2) 울 Set point max (U
0
max
, I
, P
).
max
max
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 and can thus, if necessary, be checked
before connecting.
The set point Enable Register can be changed from all service units (Bus, Thyro-Tool Familiy, LBA).
Example:
8 4 2 1 VALUE ABBR. EXPLANATION
1 1 1 1 15 STD Standard (all ON)
1 0 0 0 8 LOC Motor poti-set point 4 (LOCAL)
0 1 0 0 4 REMOTE Bus set point 3
0 0 1 1 3 ANA Analog-set points 1,2
0 0 0 0 0 All set points inactive
2.3 CONTROL TYPES
Thyro-P has fi ve control types effective as underlying controls. Mains voltage variations and load
changes are directly and therefore quickly adjusted by bypassing of the slow temperature control
system.
Before commissioning of the Power Controller and selection of a control type, you should be
familiar with the operating procedure respectively the effect for application.
2.3.1 CONTROLLED VALUE
The controlled value effective on the load is proportionate to the total set point, depending on the
control type:
CONTROL TYPE CONTROL VALUE (PROPORTIONATE TO THE TOTAL SET POINT)
P control output (active) power, P
U control output voltage, U
U2 control output voltage, U
I control output current, I
I2 control output current, I
LIMITING OF SIGNALS
Independent of the control type set, additionally minimum and maximum limiting values may be
set. For this purpose, also refer to Fig. 1 control characteristic.
The maximum limiting values determine the maximum modulation of the load.
rms
2
rms
rms
2
rms
The minimum limiting values should ensure minimum modulation via the control angle (for instance
minimum heating of the load).
CONTROLLER RESPONSE
If the load resistance changes, for instance due to temperature effect, ageing or load fault, then the
values effective on the load change as follows:
UNDERLYING LOAD RESISTANCE LOAD RESISTANCE EFFECTIVE*
DECREASES INCREASES LIMITATIONS
CONTROL LIMIT P U
U U
U2 (UxU) U
I I
I2 (IxI) I
P P
larger = larger smaller = smaller I
rms max
larger = larger smaller = smaller I
rms max
smaller smaller = larger larger = U
rms max
smaller smaller = larger larger = U
rms max
= smaller larger = larger smaller U
max
I
LOAD
without control larger = larger smaller = smaller U
P
P U
LOAD
I
LOAD
LOAD
rms max
rms max
rms max
rms max
rms max
rms max
max
P
P
P
P
I
I
* If one of the limits is exceeded, then the signaling relay K2 and the LED „limit“ react
(default values of parameter settings).
General modulation limit Ts=T
␣=␣
s max
max
19
max
max
max
max
rms max
rms max
TAB. 1 BEHAVIOUR IN CASE OF LOAD CHANGE
2.4 INDICATIONS
2.4.1 LED INDICATIONS
The LEDs on the front side signal the following states:
• ON green: operating indication, power supply controller board
red: RESET active
• CONTROL modulation percentage indication, fl ashing*
• LIMIT limitation is active, relay K2 switches*
• PULSE LOCK Controller Lock active, but load control is continued at pulse limits
(default value = 0)*
• FAULT fault present*
• OVERHEAT overheating of power section
(in case of ..HF types, check ventilator)*
* Default setting
Activation of the integrated semiconductor fuse may be signalled using the fault indicating relay K1
rest current, contactor, otherwise separate supply of the control device required). In case of Power
Controllers from model current 495A, additional signalling is performed via an indicator at the
semiconductor fuse.
2.4.2 RELAY INDICATIONS K1-K2-K3
The Thyro-P Power Controller is fi tted with three relays. Each of these relays has a change over
contact in principle be allocated a value in the event register. The following table shows the contactor allocation of the relays at the corresponding terminal strips. Presets of parameters by the works
(default values) may be found in chapter 3.4.
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ALARM RELAY K1
The relay K1 is activated if a fault is detected in the system. The effective direction, whether it
should close or open in case of fault, may be set using the parameter K1 closed-circuit OFF, ON by
using LBA or Thyro-Tool Familiy. Which indications lead to switching of the relay may also be set.
Recommendation: keep the default setting.
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.
OPTIONAL RELAY K3
If changes are made to the default relay settings due to the application, then preferrably the relay
K3 should be reparameterized.
It is possible to realize functions like for instance a follow-up relay for ventilator control or by pass
the alarm relay at startup of the system. It may also be used as a further alarm relay or limiting relay,
by reparameterization.
The illustration shows the relay K3 for bridging the startup alarm.
FIG. 3 SWITCH-ON FAULT BRIDGING
2.5 MONITORING
Faults occurring in the Power Controller or in the load circuit are signalled. Signalling is performed
via LED (FAULT) and via relay with potential-free change-over contact. The fault buffer may be
read via LBA or the interface after selecting the status line. Simultaneously with the fault signal,
the pulse shutdown may optionally also be set (Imp.-Absch. OFF, ON). Faults having occurred are
shown in the display of LBA by text status indications in the status line. After selecting the status
line, the indication may be called up.
21
2.5.1 LOAD MONITORING
MONITORING OF THE LOAD AND MAINS VOLTAGE
Each power section is fi tted with its own transformer for creating the synchronization voltages. This
also allows monitoring of the phase voltages. In the LBA menu monitoring, the limits may be set for
U
and U
Line min
ABSOLUTE OR RELATIVE MONITORING
Relative monitoring for heating elements for R
elements with R
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
T
L
. If larger deviations are detected, then a fault indication is generated.
Line max
≈ 1 and absolute monitoring for heating
≠ 1 are possible.
hot/Rcold
hot/Rcold
I < threshold
indication 16,17 (Chap. 3.4)
t
V
FIG. 4 ABSOLUTE VALUE MONITORING
This absolute value monitoring lends itself to one or more load resistances organized in parallel or
in series. Generally, the effective current value measured is continuously compared with a presettable absolute current limit for undercurrent or overcurrent. If these limits are undercut or exceeded
an indication shows. In case of resistor elements organized in parallel, it is therefore possible, using
the lower current limit, to select a partial load interruption. Using the upper current limit, in case of
resistors switched in series, short-circuiting of an element may be detected.
RELATIVE MONITORING
This monitoring is sensible if the resistance value of the load slowly changes. Changes in resistance
may for instance be caused by temperature changes or by ageing. The current (b) of the Power
Controller is regarded as 100% load current (current in fault-free state) after activation of the RESET
or CONTROLLER LOCK. The RESET is automatically activated after each startup, restart or after
mains outage. In case of relatively slow changes of the current, due to characteristics of the above
mentioned heating elements, automatic adjustment of the internal reference value to 100% is
performed (b‘).
FIG. 5 RELATIVE MONITORING
22
Quick current changes, which may for instance occur in case of partial.
Quick current changes, which may for instance occur in case of partial short-circuit, may be
detected by overcurrent monitoring (max., a – a‘).
Quick current changes, which may for instance occur in case of load breakdown may be detected
by undercurrent monitoring (min., c – c‘).
NOTE FOR LOAD MONITORING:
Changes of the burden resistor and parameters can be necessary in case of small load currents or
small current fl ow angles (i. e. small phase angles).
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. The adjustable %
values shown in the tables are load current variations on
the present operating values.
Star connection
with separate star points
Star connection
without neutral conductor
HEATING 1P 2P*/3P 3P
ELEMENTS
IN PARALLEL STAR CONNECTION STAR CONNECTION DELTA STAR CONNECFOR EACH WITH SEPARATE WITHOUT CONNEC- CONNECTION TION WITH
STRAND STARPOINTS TED NEUTRAL CONNECTED
CONDUCTOR NEUTRAL CONDUCTOR
5 10% 10% – – 10%
4 13% 13% 10% – 13%
3 17% 17% 13% 10% 17%
2 25% 25% 20% 12% 25%
1 50% 50% 50% 21% 50%
* for Thyro-P 2P: additional external converters in phase L2 are possible.
TAB. 2 PARTIAL LOAD BREAKDOWN WITH HEATING ELEMENTS SWITCHED IN PARALLEL,
UNDERCURRENT, RELATIVE MONITORING
Delta connection
Star connection
with neutral conductor
23
Star connection
without neutral conducter
Delta connection Star connection
with neutral conductor
HEATING 1P 2P 3P
ELEMENTS
IN SERIES FOR STAR CONNECTION DELTA CONNECTION STAR CONNECTION
EACH STRAND WITHOUT CONNECTED WITH CONNECTED
NEUTRAL CONDUCTOR NEUTRAL CONDUCTOR
6 10% – – 10%
5 13% 10% – 13%
4 17% 10% 10% 17%
3 25% 14% 13% 25%
2 50% 25% 26% 50%
TAB. 3 PARTIAL SHORT-CIRCUIT WITH HEATING ELEMENTS SWITCHED IN SERIES, OVERCURRENT, RELATIVE MONITORING
AGEING OF LOAD RESISTORS
Thyro-P determines the load conductance separately for each phase. These values are available
from LBA, Thyro-Tool Familiy and the Bus interface. The current resistance can be determined by
reading out and converting from the conductance.
The following table offers an overview of the possible monitoring functions of the Thyristor Power
Controller Thyro-P.
TYPE OF PARAMETER DEFAULT /
MONITORING SETTINGS REMARKS
U
mains overvoltage input in volts Type voltage + 20%
net max
mains undervoltage input in volts Type voltage - 20%
U
net min
I
overcurrent 0-100% REL_ABS = REL
load max-REL
overcurrent relative Re: measured load current UE_S = ON
after each RESET/control lock
I
load max-ABS
overcurrent input in ampere REL_ABS = ABS
absolute UE_S = ON
I
undercurrent 0 to 99% REL_ABS = REL
load min-REL
relative Re: measured load current UN_S = ON
after each RESET/control lock
I
undercurrent input in ampere REL_ABS = ABS
load min-ABS
absolute UN_S = ON
pulse switch pulse switch off ON: pulse switch off after indication is always
off by software fault indication issued
OFF: in case of fault
in case of synchronization
SYT 9, RESET of all Power
Controllers is required
K1 alarm relay K1 ON: relay K1
open circuit released in case of fault
OFF: relay K1 the alarm relay switches
pulled-in in case of fault upon activation of
RESET
TAB. 4 OVERVIEW MONITORING
24
2.5.2 VENTILATOR MONITORING
The separately ventilated Power Controllers (-...HF) are fi tted with thermal monitoring. The temperature is measured on the heat sink. In case of a temperature overrange, a fault inducation is issued
(Profi bus, LED OVERHEAT).
ATTENTION
Activating this monitoring function is obligatory if the Thyro-P is operated under UL conditions.
3. MODE OF OPERATION
This chapter shows the operating options of Thyro-P using LBA and Thyro-Tool Familiy.
3.1 LOCAL OPERATING AND DISPLAY UNIT (LBA)
The optional LBA (IP30, protection classifi cation 3) has fi ve keys and a backlit graphical LC display
for 7 x 19 characters respectively 64 x 114 pixels. In the standard version, the languages German,
English and French are available.
25
FIG. 6 LOCAL OPERATING AND
DISPLAY UNIT (LBA)
The LBA may be connected or disconnected from the RS 232 interface of the Thyro-P control device
during operation. After plugging into the interface and automatic loading of the parameters, the
LBA displays its main menu.
ATTENTION
Before storing (store in Thyro-P / LBA under Thyro-P) the parameters must always be saved in the
EEPROM of the LBA fi rst (store in LBA).
If no key is pressed for one minute the operation display appears. This does not apply if a line
diagram is running. If no communication is achieved after plugging in the LBA between LBA and
Power Controller in case of fault, then a self-test is performed. Using the LBA, Thyro-P may be
parameterized and monitored under menu control. It is possible to display up to three process
data values (for instance the actual values of current, voltage or power occurring at the load) in
double character height. Further values which may be displayed are the set point value as well as
parameter data and fault indications. Furthermore, display of a value in graphical form as line diagram is possible. The time and value axes may be set by parameters and so adjusted to requirements. Using the LBA, the parameters of one Thyro-P may be copied to another Thyro-P. More
details on this can be found in the chapter LBA menus.
3.1.1 LBA KEYBOARD FUNCTIONS
The LBA has a total of 5 standard keys: with an activatable parameterizing lock (see table 5). Four
arrow keys and one OK key. By moving the cursor mark (>) using the corresponding keys (up arrow,
down arrow), the desired function may then be selected using the OK key. An underlined language/
function is in each case selected. An unnamed 6th key is available behind the opening in the front
of the LBA, the reset key. If this is operated, then the functions RESET of Thyro-P is performed.
26
FUNCTIONS OF LBA KEYS:
KEY DISPLAY FUNCTION
Cursor before menu text: selection of the higher level (back)
Cursor on the figure: select prior (higher value) position
Cursor on the figure: select next (lower value) position
Cursor before menu text: move cursor to the prior line, possible scroll
upward (only indented lines may be scrolled)
Cursor on the figure: increase value
Cursor on the parameter: switch on
Cursor before menu text: cursor on subsequent line, possible scroll down-
ward
Cursor on the figure: reduce value until minimal admissible value is
reached
Cursor on the parameter: switch off
OK Cursor before menu text: selection of a figure or of an input field
Cursor on the figure: takeover of the modification into Thyro-P and
deselection of the selected field
Cursor on the parameter: takeover of the modification into Thyro-P and
deselection of the selected field
Operation display: deselection of the operation display
Thyro-P → LBA inactivated
OK OK Line diagram: deselection of the line diagram display
No key pressed operation display is activated; this does
(for 1 minute) not apply in case of selected line diagram
Operation display: Parameterizing lock is self-activating on release
Parameter loading process
Parameterizing process is temporarily
TAB. 5 FUNCTIONS OF THE LBA-KEYS
3.1.2 LBA MAIN MENU
The top line always contains the name of the menu or of the submenu. The lowest line, the status
line, always contains the confi guration of the Power Controller or in case of existing indications,
the word status indication.
The main menu (function selection menu) appears on the LBA display after plugging the LBA into
Thyro-P. It looks like this:
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