Advanced Energy Thyro-S 1S H 1 Series User manual

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THYROS
THYRISTORSCHALTER Thyro-S 1S...H 1 Thyro-S 1S...H RL1
THYRISTORSWITCH Thyro-S 1S...H 1 Thyro-S 1S...H RL1
AUGUST 2015 8000029341 DE/EN - V7

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THYROS
THYRISTORSCHALTER Thyro-S 1S...H 1 Thyro-S 1S...H RL1
THYRISTORSWITCH Thyro-S 1S...H 1 Thyro-S 1S...H RL1
AUGUST 2015 8000029341 DE/EN - V7

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CONTACT
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. [phone] or 763-290
Fax [phone]
COMMERCIAL QUERIES
Do you have any commercial queries on power controllers?
If so, please get in touch with our team for power controllers.
Tel. [phone] or [phone]
powercontr[email protected]
SERVICE
Our team is at your service on the following hotline:
Advanced Energy Industries GmbH
Emil-Siepmann-Straße 32
D-59581 Warstein
Tel. [phone]
www.advanced-energy.com
COPYRIGHT
No part of these operating instructions may be transmitted, reproduced
and/or copied by any electronic or mechanical means without the
express prior written permission of Advanced Energy.
© Copyright Advanced Energy Industries GmbH 2014.
All rights reserved.
FURTHER INFORMATION ON COPYRIGHT
Thyro-S is an registered trademark of Advanced Energy Industies
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.

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SAFETY INSTRUCTIONS
The following safety and operating instructions must be carefully
read before assembly, installation and commissioning.
OBLIGATION TO GIVE INSTRUCTIONS
The following safety and operating instructions must be carefully read
before initial assembly, installation and commissioning of Thyro-S by
those persons working with or on Thyro-S.
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, commissioning,
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
suitable 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 intended
use, otherwise hazards to persons (e.g. electric shocks, burns) and
systems (e.g. overload) may arise.

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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 interruption,
half-wave operation, continuous power flow. If such a situation occurs,
then load voltages and currents are produced from the physical dimen-
sions 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
damagad.
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 sections.
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

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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 discon-
nected from all external voltage sources and protected against restar-
ting. 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 switch contains dangerous voltages. Repairs may only be
carried out by qualified and trained maintenance personnel.
CAUTION
Danger of electric shock. Even after disconnection from the mains
voltage, capacitators may still contain a dangerously high power level.
CAUTION
Danger of electric shocks. Even when the Thyristor switch is not trigge-
red, the load circuit is not disconnected from the mains.
ATTENTION
Different components in the power section are screwed into place
using exact torques. For safety reasons, power component repairs must
be performed by Advanced Energy Industries GmbH.

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Contact 2
Safety instructions 3
Safety regulations 9
Remarks on the present operating instructions and Thyro-S 12
1. Introduction 13
1.1 General 13
1.2 Specific characteristics Thyro-S 13
1.2.1 Additional for 1S…H RL1 14
1.3 Type designation 14
2. Functions 15
2.1 Operating modes 15
2.1.1 Digital set point value inputs 15
2.1.2 Switching behaviour 15
2.2 Indications 16
2.3 Monitoring 16
2.3.1 Monitoring of the mains voltage 16
2.3.2 Equipment temperature monitoring 16
2.3.3 Ventilator monitoring 16
2.4 Additional indications using type S...H RL1 17
2.4.1 Error indication relay K1 17
2.5 Additional monitoring using type S...H RL1 17
2.5.1 Thyristor short-circuit monitoring 17
2.5.2 Load monitoring (undercurrent monitoring) 18
2.5.3 Load monitoring (overcurrent monitoring) 18
3. Operation 20
3.1 Configuration switch S1 20
3.2 Thyro-Tool Family 21
3.3 Diagnosis / status indications 21
4. External connections 23
4.1 Power supply for Thyro-S 23
4.2 Power supply for the control electronics 23
4.3 Additional control voltage input 23
4.4 Digital set point input 24
4.5 Block diagram 1S...H 1 25
4.6 Connections and terminal strips 1S...H1 26
4.7 Block connection diagram 1S ... H RL1 27
4.8 Connections and terminal strips 28
CONTENTS

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5. Interfaces 30
5.1 Bus module at the systems interface 30
5.2 PC-Interface RS232 at the system interface 30
5.2.1 Thyro-Tool Family 31
6. Mains load optimization 32
7. Connecting diagrams 32
8. Special remarks 37
8.1 Installation 37
8.2 Commissioning 37
8.3 Service 37
8.4 Checklist 38
9. Type overview 39
9.1 Typ 1S...H 1 39
9.2 Typ 1S...H RL1 39
10. Technical data 40
11. Dimensional drawings 42
Dimensional drawing Thyro-S 1S (16H, 30H) 42
Dimensional drawing Thyro-S 1S (45H, 60H) 42
Dimensional drawing Thyro-S 1S (100H) 43
Dimensional drawing Thyro-S 1S (130H, 170H) 43
Dimensional drawing Thyro-S 1S (280H) 44
12. Accessories and options 45
13. Approvals and conformities 46

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Fig. 1 Block diagram 1S...H1 25
Fig. 2 Terminal plan 1S...H1 26
Fig. 3 Operation 1S...H 1 26
Fig. 4 Block diagram 1S...H RL1 27
Fig. 5 Terminal plan 1S...H RL1 28
Fig. 6 Operation Thyro 1S...H RL 1 29
Fig. 7 User surface Thyro-Tool Family 31
Fig. 8 Connecting diagram Thyro-S 1S...H 1 33
Fig. 9 Connecting diagram 2x Thyro-S 1S...H 1 34
Fig. 10 Connecting diagram Thyro-S 1S...H RL 1 35
Fig. 11 Connecting diagram 2x Thyro-S 1S...H RL 1 36
Tab. 1 Load monitoring 19
Tab. 2 LED signals Thyro-S 22
LIST OF ILLUSTRATIONS AND TABLES

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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 informa-
tion is given which the user must observe.
ACCIDENT PREVENTION RULES
It is imperative that the accident prevention rules of the country of
application and the generally applicable safety regulations are observed.
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.

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QUALIFIED PERSONNEL
Thyro-S 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.
INTENDED USE
CAUTION
The Thyristor switch 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 to persons (e.g. electric shocks, burns)
and systems (e.g. overload) may occur.
Any unauthorized reconstruction and modification of Thyro-S, use of
spare and exchange parts not approved by Advanced Energy 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 special-
ists for the use of Thyro-S. Additional information and notes for unquali-
fied 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 operating
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:

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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.

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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 technical
data, operation, dimensions and weights, remain reserved at any time.
Advanced Energy reserves the right to content modifications and
technical changes within the present operating instructions without
obligation to notification.
Advanced Energy is not obliged to update these operating instructions
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 Advanced Energy and its dealers will be
cancelled without prior notice if other than original Advanced Energy
spare parts or spare parts purchased by Advanced Energy are used
for maintenance and repair.

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1. INTRODUCTION
Thyro-S meets the demands for simple assembly, speedy commissioning
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 processing
technology. With its good coupling ability to process and automation
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 24 V signal (> 3 V) or via optional bus module
• series system interface
• electrical separation according to EN 50178 chapt. 3
• Connection for optional visualization and commissioning

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Options:
• Bus connection via bus adapter
Coupling to different bus systems, e.g. Profibus, Modbus RTU,
CANopen and DeviceNet, other bus systems on request.
• PC software Thyro-Tool Familiy, visual and operational software
1.2.1 EXTENSION USING 1S...H RL1
• With additional 24 V 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.

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2. FUNCTIONS
2.1 OPERATING MODES
FULL WAVE SWITCH
Depending on the digital set point signal the mains voltage is switched.
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 11logic input 0-24 V DC (Ri> 3,3 kΩ) IN: UIN > 3 V
• 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 >3 V 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 crossover
otherwise it remains inactive. No new full wave is triggered if the trigger

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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 monitoring
and +10% for overvoltage monitoring. This produces the following
absolute limiting values:
Type Undervoltage Overvoltage
230 V 99 V 253 V
400 V 172 V 440 V
500 V 215 V 550 V
NOTE
The devices may only be operated up to the undervoltage limit if he
electronics are supplied by an ext. 24 V voltage. If the undervoltage
limit is undercut the pulse lock is activated and realy K1 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 and pulse inhibitor will be released, however,
it can be deactivated.
Please consider that by deactivation, the risk of overheating and/or
damage of the unit exist in case of error.
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.

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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 config-
ured 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
deenergizes, 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..

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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 monitoring
operates as undercurrent monitoring on absolute values and is suitable
for use in the nominal operating mode 1:1, and with limitations 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.