AEG THYRO-S 1S*H 1 Series Bedienungsanleitung

Betriebsanleitung/Operating Instructions

Thyristor-Schalter

THYRO-S 1S...H 1

THYRO-S 1S...H RL1

Thyristor-Switch

THYRO-S 1S...H 1

THYRO-S 1S...H RL1

Thyro-S

The following safety and operating instructions must be careful-

ly read before assembly, installation and commissioning.

Safety Instructions

Obligation to give instructions

The following safety and operating instructions must be carefully read

before initial assembly, installation and commissioning of Thyro-A by

those persons working with or on Thyro-A.

These operating instructions are part of the Thyristor switch Thyro-S.

The operator of this device is obliged to provide, without restriction,

these operating instructions to all persons transporting, commissio-

ning, maintaining or performing other work on this device.

In accordance with the Product Liability Act, the manufacturer of a

product has an obligation to provide explanations and warnings as

follows:

• the use of the product other than for the intended use,

• the residual product risk as well as

• operating errors and their 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 switch is a component which may only be used for

control and regulation of electrical energy.

•The Thyristor switch may at most be operated using the maximum

admissible connected load according to information on the type

plate.

•The Thyristor switch may only be operated in connection with a sui-

table and series connected power supply disconnecting device.

•As a component, the Thyristor switch is unable to operate alone and

must be projected for its intended use to minimize residual risks.

• The Thyristor switch may only be operated in the sense of its inten-

ded use, otherwise hazards to persons (e.g. electric shocks, burns)

and systems (e.g. overload) may arise.

Residual hazards of the product

• Even in case of proper use, should a fault occur, it is possible that

control of currents, voltages and power is no longer performed in the

load circuit by the Thyristor switch.

In case of destruction of the power components (e.g break-down or

high resistance), the following situations are possible: power interrup-

tion, half-wave operation, continuous power flow. If such a situation

occurs, then load voltages and currents are produced from the phy-

sical dimensions of the overall power circuit. It must be ensured by

system design that no uncontrolled large currents, voltages or power

occur.

Maloperation and its results

• With maloperation it is possible that power, voltage or flow levels

which are higher than planned reach the Thyristor switch or load.

On principle, this can lead to the Thyristor switch or load being da-

magad.

Transport

• Thyristor switches are only to be transported in their original

packaging (protection against damage e.g. due to jolting, knocking,

soiling).

Installation

• If the Thyristor switch is brought into the operation room from a cold

environment, moisture can occur. Prior to it being commissioned,

the Thyristor switch must be absolutely dry. Therefore, wait for a

minimum of two hours before commissioning.

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 sec-

tions.

Operation

• The Thyristor switch 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

CAUTION

For maintenance and repair work the Thyristor switch

must be disconnected from all external voltage sources

and protected against restarting. Make sure to wait mini-

mum 1 minute after switch-off (discharge time of the at-

tenuation capacitors). The voltage-free state is to be de-

termined 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 switch contains dangerous voltages. Repairs

may only be carried out by qualified and trained mainte-

nance personnel.

CAUTION

Danger of electric shock. Even after disconnection from

the mains voltage, capacitators may still contain a dan-

gerously high power level.

CAUTION

Danger of electric shocks. Even when the Thyristor switch

is not triggered, the load circuit is not disconnected from

the mains.

ATTENTION

Different components in the power section are scre-

wed into place using exact torques. For safety reasons,

power component repairs must be performed by AEG

Power Solutions GmbH.

Contents

Safety instructions 47

Safety regulations 53

Remarks on the present operating instructions

and Thyro-S 56

1. Introduction 58

1.1 General 58

1.2 Specific characteristics Thyro-S 58

1.2.1 Additional for 1S…H RL1 59

1.3 Type designation 59

2. Functions 60

2.1 Operating modes 60

2.1.1 Digital set point value inputs 60

2.1.2 Switching behaviour 60

2.2 Indications 61

2.3 Monitoring 61

2.3.1 Monitoring of the mains voltage 61

2.3.2 Equipment temperature monitoring 62

2.3.3 Ventilator monitoring 62

2.4 Additional indications using type S...H RL1 62

2.4.1 Error indication relay K1 62

2.5 Additional monitoring using type S...H RL1 62

2.5.1 Thyristor short-circuit monitoring 63

2.5.2 Load monitoring (undercurrent monitoring) 63

2.5.3 Load monitoring (overcurrent monitoring) 63

3. Operation 65

3.1 Configuration switch S1 65

3.2 Thyro-Tool Family 65

3.3 Diagnosis / status indications 66

4. External connections 68

4.1 Power supply for Thyro-S 68

4.2 Power supply for the control electronics 68

4.3 Additional control voltage input 68

4.4 Digital set point input 68

4.5 Block diagram 1S...H 1 70

4.6 Connections and terminal strips 1S...H1 71

4.7 Block connection diagram 1S ... H RL1 72

4.8 Connections and terminal strips 73

5. Interfaces 75

5.1 Bus module at the systems interface 75

5.2 PC-Interface RS232 at the system interface 75

5.2.1 Thyro-Tool Family 76

6. Mains load optimization 77

7. Connecting diagrams 77

8. Special remarks 82

8.1 Installation 82

8.2 Commissioning 82

8.3 Service 82

8.4 Checklist 83

9. Type overview 84

9.1 Typ 1S...H 1 84

9.2 Typ 1S...H RL1 84

10. Technical data 85

11. Dimensional drawings 87

Dimensional drawing Thyro-S 1S (16H, 30H) 87

Dimensional drawing Thyro-S 1S (45H, 60H) 87

Dimensional drawing Thyro-S 1S (100H) 88

Dimensional drawing Thyro-S 1S (130H, 170H) 88

Dimensional drawing Thyro-S 1S (280H) 89

12. Accessories and options 89

13. Approvals and conformities 90

List of illustrations and tables

Fig. 1 Block diagram 1S...H1 70

Fig. 2 Terminal plan 1S...H1 71

Fig. 3 Operation 1S...H 1 71

Fig. 4 Block diagram 1S...H RL1 72

Fig. 5 Terminal plan 1S...H RL1 73

Fig. 6 Operation Thyro 1S...H RL 1 74

Fig. 7 User surface Thyro-Tool Family 76

Fig. 8 Connecting diagram Thyro-S 1S...H 1 78

Fig. 9 Connecting diagram 2x Thyro-S 1S...H 1 79

Fig. 10 Connecting diagram Thyro-S 1S...H RL 1 80

Fig. 11 Connecting diagram 2x Thyro-S 1S...H RL 1 81

Tab. 1 Load monitoring 64

Tab. 2 LED signals Thyro-S 67

Safety regulations

Important instructions and explanations

The skilled personnel assembling and disassembling the devices,

commissioning them and maintaining them must know and observe

these safety regulations.

CAUTION

This instruction indicates work and operating procedures

to be observed exactly to exclude hazards to persons.

ATTENTION

This instruction refers to work and operating procedures

to be observed exactly to avoid damage or destruction of

Thyro-S or parts thereof.

REMARK

This is where remarks on technical requirements and

additional information is given which the user must ob-

serve.

ACCIDENT PREVENTION RULES

It is imperative that the accident prevention rules of the country of

application and the generally applicable safety regulations are obser-

ved.

CAUTION

Before commencing any work on Thyro-S, the following

safety regulations must be observed:

• switch voltage-free

• secure against switching on

• determine voltage-free state

• ground and short-circuit device

• cover or block neighbouring parts under voltage.

Qualified personnel

Thyro-S may only be transported, installed, connected, commissi-

oned, maintained and operated by specialists in command of the re-

spective applicable safety and installation regulations. All work must

be monitored by the responsible specialist personnel.

Intendet use

CAUTION

The Thyristor switch may only be employed in the sen-

se of its purpose of use (see the section of the chapter

Safety instructions under the same name), otherwise

hazards to persons (e.g. electric shocks, burns) and sy-

stems (e.g. overload) may occur.

Any unauthorized reconstruction and modification of Thyro-S, use of

spare and exchange parts not approved by AEG Power Solutions as

well as any other use of Thyro-S is not permitted.

The person responsible for the system must ensure that

- safety and operating instructions are available and observed,

- operating conditions and specifications are observed,

- protective installations are used,

- maintenance personnel are immediately notified or Thyro-S is imme-

diately 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 spe-

cialists for the use of Thyro-S. Additional information and notes for

unqualified persons and for the use of Thyro-S outside of industrial

installations are not contained in these operating instructions.

The warranty given by the manufacturer is only valid if these opera-

ting instructions are observed and adhered to.

Warranty

No liability is assumed for employing applications not provided for by

the manufacturer. The responsibility for the necessary measures to

avoid hazards to persons and property is borne by the operator or the

user. In case of complaints, please notify us immediately stating:

Type name Production number

Complaint Ambient conditions

Operating mode Duration of use

Guidelines

The CE mark on the device confirms adherence to the general EC

guidelines for 2006/95 EEC – low voltage and for 2004/108 EEC

electromagnetic compatibility if the instructions on installation and

commissioning described in the operating instructions are observed.

Remarks on the present operating

instructions and Thyro-S

Validity

These operating instructions refer to the latest technical specification

of Thyro-S at the time of publication. The contents are not subject

matter of the contract, but serve only as information. Modification of

information contained in these operating instructions, especially tech-

nical data, operation, dimensions and weights, remain reserved at

any time. AEG Power Solutions reserves the right to content modifica-

tions and technical changes within the present operating instructions

without obligation to notification.

AEG Power Solutions is not obliged to update these operating instruc-

tions constantly.

Loss of warranty

Our supplies and services are subject to the general terms and condi-

tions of delivery of the electrical industry as well as our general sales

conditions. Any complaints on goods delivered are to be submitted,

together with the delivery note, within eight days of receipt.

All guarantees made by AEG Power Solutions and its dealers will

be cancelled without prior notice if other than original AEG Power

Solutions spare parts or spare parts purchased by AEG Power

Solutions are used for maintenance and repair.

Passing on, duplication and/or takeover of these operating instruc-

tions by electronic or mechanical means, including excerpts, is sub-

ject to the express prior written approval of AEG Power Solutions.

Additional remark on copyright

Thyro-S is an internationally registered trademark of AEG Power

Solutions GmbH.

All other companies and product names are the (registered) trade-

marks of the respective owners.

1. Introduction

Thyro-S meets the demands for simple assembly, speedy commissi-

oning and safer operation.

For transport, assembly, installation, commissioning, operation and

decommissioning, it is essential that the safety instructions included

in these operating instructions are observed and made available to all

persons handling this product.

In case of uncertainties or missing information, please contact your

supplier.

1.1 General

Thyro-S is a Thyristor switch with the ability to communicate. It will

also be referred to as Power Controller or simply controller. It can be

used wherever voltages or currents need to be controlled in proces-

sing technology. With its good coupling ability to process and automa-

tion technology, high control precision and simple handling, Thyro-S

is also future-orientated for new applications. The Thyro-S is suitable

for a direct supply of ohmic loads.

1.2 Specfic characteristics Thyro-S

Thyro-S has a wide range of distinguishing features, for instance

• easy handling

• type range 230-500 Volts, 16-280 A, single phase, 2-phase and

3-phase structure is possible

• ohmic load

• operating modes 1:1, as well as 1:2, 1:3 and 1:5 (e.g. for commis-

sioning)

• Digital control with 24V signal (> 3V) or via optional bus module

• series system interface

• electrical separation according to EN 50178 chapt. 3

• Connection for optional visualization and commissioning

Options:

• Bus connection via bus adapter

Coupling to different bus systems, e.g. Profibus, Modbus RTU,

CANopen and Device Net, other bus systems on request.

• PC software Thyro-Tool Familiy, visual and operational software

1.2.1 Extension using 1S...H RL1

• With additional 24V control voltage supply also applicable for mains

voltages > 0.43 x Unom

• Load circuit monitoring

• Indication relay

1.3 Type key

The type name of the thyristor switches is based on the construction

of the power unit:

Thyro-S 1S Thyristor switch with 1 phase power unit, suited to

1 phase loads

Example

...400- with 400 Volt type voltage

...280 with 280 Amp type current

H with integrated semi-conductor fuse

F with ventilator (only 280 Amp types)

R with indication relay

L with load monitoring

1 designation Thyro-S, series

The complete type range can be found in chapter 9, TYPE

OVERVIEW.

2. Functions

2.1 Operating modes

Full wave switch

Depending on the digital set point signal the mains voltage is swit-

ched. In the operating mode 1:1 almost no harmonics are created in

the mains frequency. Whole multiples of the mains periods are always

switched.

For commissioning etc, a reduced supply can be switched with the

S1 switch or via the optional bus module, the control system thereby

either forces the switching of every 2. wave or an equal number of

positive and negative half waves.

In all operation modes d.c. components are avoided:

Operating mode Load voltage

1:1 every mains full wave

(nom. oper. mode, default setting)

1:2 every 2. mains full wave (DC-free)

1:3 every 3. mains full wave (DC-free)

1:5 every 5. mains full wave (DC-free)

2.1.1 Digital set point inputs

The Thyristor switch Thyro-S is equipped with two set point inputs

which are electrically isolated from the mains for triggering signals:

• Set point input 11 logic input 0-24V DC (Ri > 3,3 k

) IN: UIN > 3V

• Set point input 2 via bus module

2.1.2 Switching behaviour

The Thyro-S can switch single or continuous full waves in the mains

voltage to the load. If a voltage of >3V is fed into X22.1 the following

mains period is switched.

If a full wave is to be switched to the load, the trigger signal ON must

be switched on not later than 1 ms before the mains voltage cross-

over otherwise it remains inactive. No new full wave is triggered if the

trigger signal is interrupted up to 1.25 ms before the crossover of the

full wave.

With a pulse trigger the pulse duration must be min. 1 ms.

2.2 Indications

The LEDs on the front signal the following states:

• ON GREEN operating indication,

power supply controller device

Blinking indications are described in table 2.

2.3 Monitoring

2.3.1 Monitoring of the mains voltage

The limiting values of the voltage are -57% for undervoltage monito-

ring and +10% for overvoltage monitoring. This produces the follo-

wing absolute limiting values:

Type Undervoltage Overvoltage

230V 99V 253V

400V 172V 440V

500V 215V 550V

NOTE

The devices may only be operated up to the undervol-

tage limit if he electronics are supplied by an ext. 24V

voltage. If the undervoltage limit is undercut the pulse

lock is activated and realy K! is released (default).

1) See also chapter 4.4 digital set point input

2.3.2 Equipment temperature monitoring

The control board is equipped with a temperature monitor.

If a fault occurs, the red LED blinks.

2.3.3 Ventilator monitoring

The separately ventilated power controllers (F) are fitted with thermal

monitoring. The temperature of the heat sink is measured. In case of

a temperature overrange a fault indication (red LED) ensues.

2.4 Additional indications using type S...H RL1

The LEDs on the front indicate the following situations:

• Diagnosis GREEN additonal error diagnosis

• LOAD FAULT RED error present

Flashing LED indications are described in table 2. Whether the semi-

conductor fuse is responding can be indicated by the error indication

relay K1 (undercurrent detection).

2.4.1 Error indication relay K1

The K1 relay has a changer and deenergizes if an error is detected in

the system (chapter 3.2). The table shows the pin connections on the

terminal strip concerned.

Root N/O contact N/C contact

Error indication relay K1 X3.1 X3.2 X3.3

2.5 Additional indications using type S...H RL1

Thyro-S ... H RL1 indicates errors occurring in the controller or load

circuit.

Indications are given via LED (LOAD FAULT) and via the K1 relay.

The device continues to run during errors as standard (can be confi-

gured using the Thyro-Tool Family).

2.5.1 Thyristor short-circuit monitoring

The devices of the Thyro-S...H RL1 series have built in thyristor short-

circuit monitoring. If no set point signal is available at the device, the

thyristor short-circuit monitoring checks the current flow to the load.

If a current >10% of the controller current is measured, the indication

„thyristor short-circuit“ is given. In the case of an error the relay dee-

nergizes, the Test-LED as well as the Load Fault LED flash intermit-

tently and Bit 14 appears in the status word.

The relay function can be configured with the Thyro-Tool Family soft-

ware.

The indication is only given if the error has been detected 3x and the

break time is >2 mains periods.

2.5.2 Load monitoring (undercurrent monitoring)

Thyro-S ... H RL1 is suitable for monitoring loads resulting from one or

several resistances in parallel or parallel series connection.

Thyro-S detects an increase in the load resistance. The load monito-

ring operates as undercurrent monitoring on absolute values and is

suitable for use in the nominal operating mode 1:1, and with limita-

tions in the operating modes 1:2. 1:3 and 1:5.

The load monitoring is supplied with the default configuration OFF =

left stop R205 (=0)

For all other configurations:

If the load current falls below the level set the error indication relay will

respond with a delay (4-10 sec depending on operating mode). The

result is indicated via an optionally connected bus system.

This can be set in accordance with the following table.

2.5.3 Load monitoring (overcurrent monitoring)

Along with undercurrent monitoring 2.5.2 the device also has over-

current monitoring. This can only be configured using Thyro-Tool

Family.

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