AEG THYRO-A User manual

Betriebsanleitung
Operating Instructions
THYRISTOR-LEISTUNGSSTELLER
THYRO-A 1A...H RL1, 2A...H RL1
THYRO-A 1A...H RLP, 2A...H RLP
THYRISTOR POWER CONTROLLER
THYRO-A 1A...H RL1, 2A...H RL1
THYRO-A 1A...H RLP, 2A...H RLP
THYRO-A
SVS POWER SUPPLY
SYSTEMS
➜➜➜

56
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 initial
assembly, installation and commissioning of Thyro-A by those persons working with
or on Thyro-A.
These operating instructions are part of the Power Controller Thyro-A.
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,
· operating error and its consequences.
The information given below must be understood in this respect. It is to advise 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.
• The Thyristor Power Controller may at most 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 (e.g. switch,
VDE 0150 T1).
• As a component, the Thyristor Power Controller is unable to operate alone and
must be projected for its intended use to minimize residual risks.

57
The Thyristor Power Controller may only be operated in the sense of its intended
use; otherwise personal hazards, (e.g. electric shocks, burns) and hazards for
systems (e.g. system overload) may arise.
Residual hazards of the product
• Even in 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
Power Controller.
In case of destruction of the power components (e.g. break-down or high resi-
stance), the following situations are possible: power interruption, half-wave opera-
tion, continuous power flow.
If such a situation occurs, then load voltages and currents are produced from the
power circuit. It must be ensured by system design that no uncontrolled large
currents, voltages or power occur.
Malfunction and the results
With malfunction it is possible that power, voltage or flow levels which are higher
than planned reach the Thyristor Power Controller or load. In principle, this can
lead to the Power Controller or load being damaged.
Transport
Thyristor Power Controllers are only to be transported in their original packaging
(protection against damage e.g. due to jolting, knocking, soiling).
Installation
If the Thyristor Power Controller is brought into the operation room from a cold envi-
ronment, moisture due to condensation can occur. Prior to it being commissioned,
the Thyristor Power Controller must be absolutely dry. Therefore, wait for a mini-
mum 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 cable and the appropriate screw cross sections.

58
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
CAUTION
For maintenance and repair work the Power Controller must be
disconnected from all external voltage sources and protected against
restarting. The voltage-free state is to be determined by means of sui-
table 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 dangerous voltages. Repairs
may only be carried out by qualified and trained maintenance per-
sonnel.
CAUTION
Danger of electric shocks. Even after disconnection from the mains
voltage, capacitors may still contain a dangerously high power
level.
CAUTION
Danger of electric shocks. 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 into place
using exact torques. For safety reasons, power component repairs
must be performed by AEG SVS Power Supply Systems GmbH.
SAFETY INSTRUCTIONS

59
CONTENTS
➜Safety instructions 56
➜Safety regulations 62
➜Remarks on the present operating instructions and Thyro-A 64
➜1. Introduction 66
1.1 General 66
1.2 Specific characteristics 66
1.3 Type designation 67
➜2. Functions 67
2.1 Operating modes 67
2.2 Set point control characteristic 68
2.3 Control types 69
2.3.1 Controlled value 70
2.3.2 Limitations 70
2.3.3 Controller response 70
2.4 Indications 70
2.4.1 LED indications 70
2.4.2 Alarm relay K1 71
2.5 Monitoring 71
2.5.1 Monitoring of load and mains voltage 71
2.5.2 Absolute value monitoring current 71
2.5.3 Equipment temperature monitoring 71
2.5.4 Ventilator monitoring 72
2.6 Set point processing when employing a bus module 72
2.7 Additional functions for Thyro-A 73
➜3. Operation 75
3.1 Configuration switch S1 75
3.1.1 Operating mode 75
3.1.2 Control types / analog output 75
3.1.3 Live zero set point 75
3.1.4 Set point input 76
3.1.5 Analog output 76
3.2 Potentiometer 76
3.2.1 Phase angle 1. half wave operation TAKT 76
3.2.2 Control end set point input 77
3.2.3 Current limitations 78
3.2.4 Increased analog output 78
3.2.5 Load monitoring (undercurrent monitoring) 78
3.3 Diagnosis / status indications 83

60
➜4. 4. External connections 83
4.1 Power supply for Thyro-A 83
4.2 Power supply for the control device 83
4.3 Additional control voltage input 84
4.4 Pulse lock 84
4.5 Analog set point value input 84
4.6 Digital set point value input 84
4.7 Analog output 85
4.8 Current transformer 85
4.9 Voltage transformer 85
4.10 Block connection diagram 86
4.11 Operating elements and terminal strips 87
➜5. Interfaces 89
➜6. Mains load optimization 89
6.1 Synchronization SYT-9 (operating mode TAKT) 90
6.2 Synchronization in operating mode QTM (1A) 90
6.3 Software synchronization (operating mode TAKT) 90
➜7. Connecting plans 91
➜8. Special remarks 94
8.1 Installation 94
8.2 Commissioning 94
8.3 Service 95
8.4 Checklist 96
➜9. Type overview 96
9.1 Thyro-A 1A...H RL 1, ...H RLP 97
9.2 Thyro-A 2A...H RL 1, ...H RLP 97
➜10. Technical data 98
➜11. Dimensional drawings 101
➜12. Accessories and options 107
➜13. Approvals and conformities 107
Addresses 112

61
List of illustrations and tables
Fig. 1 Control characteristic 68
Fig. 2 Set point inputs and total set point 69
Fig. 3 Block connecting diagram 86
Fig. 4 Terminal plan 87
Fig. 5 Operating elements 88
Fig. 6 Thyro-A...H RL1, ...H RLP 89
Fig. 7 Connecting diagram 1A 91
Fig. 8 Connecting diagram 2A 92
Fig. 9 Connecting diagram for auxiliary supply and bus module 93
Fig. 10 Connecting diagram for QTM 93
Fig. 11 Connecting diagram for SYT9 93
Tab. 1 Behaviour with load change 70
Tab. 2a Load monitoring 79
Tab. 2b Load monitoring 80
Tab. 2c Load monitoring 81
Tab. 2d Load monitoring 82
Tab. 3 Allocation of message register 83
Tab. 4 Default values DIP switch S1 94
Tab. 5 Default values potentiometer 95

62
➜Safety regulations
Important instructions and explanations
Operation and maintenance according to regulations, as well as observance of the
listed safety regulations is required for the protection of the staff and to maintain rea-
diness to operate. Personnel assembling/disassembling the devices, commissioning
them, operating them and maintaining them must know and observe these safety
operations.
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 indicates work and operating procedures to be obser-
ved exactly to exclude hazards to persons.
ATTENTION
This instruction refers to work and operating procedures to be obser-
ved exactly to avoid damage or destruction of Thyro-A or parts there-
of.
NOTE
This is where remarks on technical requirements and additional infor-
mation 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 starting any work on Thyro-A, 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

63
Qualified personnel
Thyro-A may only be transported, installed, connected, commissioned, maintained
and operated by specialists in command of the respective applicable safety and in-
stallation regulations. All work must be monitored by the responsible specialist per-
sonnel.
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 on 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-A, use of spare and ex-
change parts not approved by AEG SVS as well as any other use of Thyro-A 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-A is immediately put out
of commission if abnormal voltages or noises, higher temperatures, vibrations or si-
milar occur to determine the causes.
These operating instructions contain all information required by specialists for the
use of Thyro-A. Additional information and notes for unqualified persons and for the
use of Thyro-A outside of industrial installations are not contained in these operating
instructions.
The warranty obligation of the manufacturer applies only if these operating instruc-
tions are observed.
Warranty
No liability is assumed when using Thyro-A for applications not provided for by the
manufacturer. The responsibility for the necessary measures to avoid hazards to per-
sons and property is borne by the operator or the user. In case of complaints on
Thyro-A, please notify us immediately stating:
Type name, production number, complaint, ambient conditions, operating mode,
duration of use.

64
➜Remarks on the present operating instructions
and Thyro-A
Validity
The following operating instructions describe the type range Thyro-A of models
...H RL and H RLP. Product characteristics which are only available for the type
range Thyro-A...H RLP are marked with (H RLP).
These operating instructions correspond to the technical state of Thyro-A 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. AEG SVS reserves the right to content modifications and technical chan-
ges within the present operating instructions without obligation of notification. AEG
SVS is not obliged to update these operating instructions constantly.
Handling
These operating instructions for Thyro-A are set out so that all work required for com-
missioning, maintenance and repair may be performed by corresponding specialist
personnel.
Abbreviations
In this description the following specific abbreviations are used:
AEG SVS = AEG SVS Power Supply Systems GmbH
SYT = synchronized clock
TAKT = full wave switch mode Thyrotakt
VAR = phase-angle mode Thyrovar
Loss of warranty
Our supplies and services are subject to the general terms and conditions 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 SVS and its dealers will be cancelled without prior
notice if other than original AEG SVS spare parts or spare parts purchased by
AEG SVS are used for maintenance and repair.

65
Copyright
Passing on, duplication and/or takeover of these operating instructions by electronic
or mechanical means, including excerpts, is subject to the express prior written
approval of AEG SVS.
Copyright AEG SVS Power Supply Systems GmbH 2003.
All rights reserved.
Further Copyright advice
Thyro- is an internationally registered trademark of AEG SVS Power Supply Systems
GmbH.
Windows and Windows NT are registered trademarks of the Microsoft Corporation.
All other companies and product names are the (registered) trademarks of the
respective owners.

66
➜1. Introduction
Thyro-A has been conceived to meet the demands for simple assembly, speedier
commissioning and safer operation.
For transport, assembly, installation, commissioning, operation and decommissio-
ning, 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.
The described operating mode QTM is in preparation.
1.1 General
Thyro-A is a Thyristor Power Controller with the ability to communicate. It will also
simply be referred to as Power Controller or Controller. It can be used wherever vol-
tages or currents need to be controlled or regulated in processing technology.
Thyro-A’s distinguishing features are its several operating and control modes, good
coupling ability to process and automation technology, high control precision and
simple handling through a 16-Bit processor.
1.2 Specific characteristics
Thyro-A has a wide range of distinguishing features, for instance:
➜easy handling
➜type range 230-500V, 8-280A, single and double phase with additional 24V
24V control voltage power supply also for mains voltages 0.43 x Unom
➜ohmic load and transformer load, as well as load with large Rhot /Rcold (6)
peak current limit to 3 x Inom
➜soft start function for transformer load
➜channel separation, required with countervoltage
➜load circuit monitoring
➜relay indication
➜control modes U, U2, I, I2as well as P-control with H RLP)
➜operating modes TAKT, as well as VAR and QTM with Thyro-A 1A
➜control with analog set points and / or via optional bus adapter
➜series system interface
➜electrical separation according to EN 50178 chapt. 3
Options:
➜bus connections via bus adapter.
Coupling to different bus systems, e.g. Profibus DP, Modbus RTU, other bus
systems on request.

67
1.3 Type designation
The type designation of the Thyristor Power Controllers is derived from the construc-
tion of its power section:
Thyro-A 1A Thyristor controller with single phase power section
suited for single phase loads
Thyro-A 2A Thyristor controller with double phase power section
suited for symmetrical loads in three phase operation in
three phase saver circuit
Example
Thyro-A 1A Thyristor controller with single phase power section
...400- with 400 Volt type voltage
...280 with 280 Ampere type current
H with integrated semi-conductor fuse
F with ventilator (only 280 Ampere types)
R with indication relay
L with load monitoring
P with additional power control
1 designation Thyro-A, 2002 series
The complete type range can be found in chapter 9, TYPE OVERVIEW.
➜2. Functions
To enable Thyro-A to adjust optimally to the desired application, it is equipped with
a wide range of functions. These are described below. Further functions are possible
by applying Thyro-A within a bus system. See also chapter 5 INTERFACES.
2.1 Operating modes
For optimum adjustment to different applications and production processes, as well
as different electrical loads, the most favourable operating mode can be set.
Full wave switch TAKT (for 1A, 2A)
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, thus avoiding d.c. components. The full wave switch mode is
especially suited for loads with thermal inertia. Depending on the function angle 1.
half wave, the phase frequency is adjusted independently to 5 or 50 mains
periods = T0.

68
The TAKT operating mode creates minimal mains reactions. Should there be a
flicker, this can be minimized with the aid of the mains load optimization.
Phase-angle principle VAR (for 1A)
Depending on the prescribed set point, the sine oscillation of the mains voltage is
gated using a larger or smaller control angle . This operating mode is characteri-
zed by high control dynamics. With phase-angle control harmonics of the mains
voltage occur. It is possible to compensate these by using circuit variants.
Half-wave switch mode QTM (Quick-Takt-Mode for 1A)
QTM is the patented fast operating mode which works on the half wave switch prin-
ciple. Depending on the prescribed set point, mains half waves are switched. D.c.
components are avoided for the phase duration. The fast phase control is particular-
ly suited for IR beams as an alternative to phase-angle control. When using several
controllers it is possible, by synchronisation, to keep the mains reactions small.
2.2 Set point control characteristic
The set point control characteristic of Thyro-A can easily be adapted to the control
output signal of an 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.
Fig. 1 Control characteristic
1,6 k
1,4 k
1,2 k1,0 k
0,8 k
0,6 k
0,4 k

69
If the controller is within a limit (Umax, Imax,P
max), both LED PULSE INHIBIT and LOAD
FAULT blink alternatively in second intervals (chapt. 3.3).
Input set points
The Power Controller Thyro-A is equipped with two input set points which are
isolated from the mains, of which only one is always active.
• Set point 1 analog (X2.4 – X2.3 ground)
• Set point 2 via bus module
The analog input can be adapted to the various process controllers by means of
the set point and live zero switches as well as the potentiometer controlling set point
input. The following signal ranges can be set:
0(4)-20 mA (Ri= ca. 250 ), 0-5 V (Ri= ca. 44 k), 0-10 V (Ri= ca. 88 k).
+5V supply voltage can be taken for a set point potentiometer from terminal X2.8.
(5 kRPoti 10 k)
The effective set point is the patched through set point. Within the stated input
ranges these values with the control characteristic may be adjusted to any common
signal characteristic.
Fig. 2 Set point inputs and total set point
2.3 Control types
Thyro-A has four control types Thyro-A...H RLP with additional P-control). Mains
voltage variations and load changes are directly and quickly adjusted by bypassing
the sluggish temperature control system.
Before commissioning the Power Controller and selecting a control mode, familiari-
sation with the operating procedure and the effect upon the application is important.

70
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)
U Voltage output, Urms
U2Voltage output, U2rms
I Current output, Irms
I2Current output, I2rms
P Power output (only with H RLP type)
2.3.2 Limitations
Independent of the voltage output control, limiting current values can additionally be
set (chapt. 3.2.3).
2.3.3 Controller response
If the load resistance changes, e.g. due to temperature effect, ageing or load break,
the values effective on the load change as follows:
Underlying Load resistance decreases
PULoad ILoad PULoad ILoad
Load resistance increases Effective
limitations
control
UUrms max larger =
=
smaller
smaller
larger
larger
=
=
smaller
smaller
smaller
smaller
=
=
larger
larger
smaller Irms max Pmax*
Irms max Pmax*
Urms max Pmax*
Urms max Pmax*
smaller
=
=
larger
smaller
smaller
Urms max
Irms max
Irms max
U2(UxU)
I
I2(IxI)
smaller larger = larger Irms max Urms max
smaller=
Pmax
P *
limit
Tab. 1 Behaviour with load change * (H RLP)
2.4 Indications
2.4.1 LED indications
The LEDs on the front signal the following states:
• ON green operating indication, power supply for controller device
• PULSE INHIBIT red pulse lock active
• LOAD FAULT red fault present
Blinking indications are described in chapter 3.3.
Activation of the integrated semiconductor fuse can be signalled using the K1 fault
indicating relay (undercurrent detection).

71
2.4.2 Alarm relay K1
The relay K1 is deactivated if a fault is detected in the system (Chapt. 3.3).
This has a relay. The following table shows the configuration of the corresponding
terminals.
Root Closer Opener
Alarm relay K1 X3.1 X3.2 X3.3
2.5 Monitoring
Faults occurring in the Power Controller and the load circuit are signalled. Signalling
ensues via LED (LOAD FAULT) and via the K1 relay.
2.5.1 Monitoring of load and mains voltage
The limiting values of the voltage are -57% of the type voltage for undervoltage
monitoring and +10% of the type voltage for overvoltage monitoring. This produces
the following absolute limiting values:
Type Undervoltage Overvoltage
230V 99V 253V
400V 172V 440V
500V 215V 550V
NOTE
When operating below the type voltage (-15%), the devices may only be
operated down to the undervoltage limit if the electronics are supplied
by an ext. 24V voltage. If the undervoltage limit is undercut, the pulse
lock is activated internally and relay K1 is released.
2.5.2 Absolute value monitoring current
This function allows monitoring of a freely selectable absolute current limit. The
value is set by potentiometer R205. During the setting procedure an instrument
connected to the analog output indicates the monitoring value. (Chapt 3.2) This
absolute value monitoring lends itself to one or more load resistances arranged in
parallel. Generally, the effective current value measured is continuously compared
with a presettable absolute current limit for undercurrent. If this limit is undercut, an
indication shows. In the case of resistance elements arranged in parallel, it is possi-
ble to select a partial load interruption by setting the undercurrent limit accordingly.
(Chapt 3.2.5).
2.5.3 Equipment temperature monitoring
The control board is equipped with a temperature monitor.

72
If a fault occurs the LED LOAD FAULT blinks and the alarm relay K1 is released.
2.5.4 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 ensues and relay K1 switches default settings.
2.6 Set point processing when employing a bus module
The set point processing depends on how the bus module is connected to the Power
Controller. Different variations can be realized depending on the requirements. The
circuit of Thyro-A’s terminal X22.1 controls the procedures (Chap. 2.2, fig. 2).
• No connection to X22.1
The bus module is fully functional, the set point value is, however, only accepted at
the controller via the control terminal as analog signal.
• Connection to X22.1 with ground potential
The setpoint value is only accepted by the bus module. The controller’s terminal
X22.1 can be directly connected to earth if an alternative operation is excluded.
• Connection to X22.1 is switched
• Thyro-A’s circuit X22.1 is connected to one of the terminals X1.1 to X8.1
of the bus module (Fig. 2). In case of malfunctions on the bus line, the set point
value will be taken automatically from the Power Controller analog input
(2 000 000 848 / 849).
• Thyro-A’s circuit X22.1 is connected to one of the terminals X1.5 to X8.5 of the
bus module (Fig. 2). In case of malfunctions on the bus line, the set point value
will be taken automatically from the Power Controller analog input, as indica-
ted in Chapter 3.2, or the last set point value is held.
Additionally, every controller connected to the bus module can be released by
”hand” (Chapter 3.2 ”set output data=0”).

2.7 Additional functions for Thyro-A
Applying the bus module provides access to further data on the controller (e.g. para-
meters, actual values). It is thus possible to perform additional application functions.
The data, which can be accessed via the bus module, is specified in the correspon-
ding bus module operating instructions.
Examples:
In order to achieve a narrower line width with a line recorder the output signal can
be smoothed as required.
Sliding mean value for the analog output
MEAN 100
(Default setting: with VAR mains periods, with TAKT 100 pulse periods)
For the operating modes TAKT and VAR control limits (final position limit) can be
set:
Control limits
Ts max, Ts min with TAKT
V_IE, H_IE with VAR
If required the controller’s parameters can be adjusted to the route:
Control parameters
TI 20 (default value)
KP 60 (default value)
A function of Thyro-A which is often used in the TAKT operating mode is the software
synchronization (mains load optimization). A numerical value can be entered via IN-
DEX 38 (SYNC_ADR) which is multiplied by 10ms or 8.33ms (duration of a mains
half wave) and results in a delay time up to the first connection.
Mains load optimization with SYNC_ADR
(50Hz) => delay time after mains recovery 10ms * 100 = 1000ms
(60Hz) => delay time after mains recovery 8.33ms * 100 = 833ms
(Default setting: 100)
73

74
In-
dex
Controller parameters
38 36
Addr. Symbol
SYNC_ADR Synchrotakt address 0... period/2 r/w 100
Name Value
Range
Combo-
Opt. Unit S
R/W
ADe-
fault
Re-
mark
Thye SYNC address contents of the individual controllers then contain different
values. As a result, the time up to the initial switch-on varies. This makes staggered
switching possible, particularly with the slow pulse time of 1 sec. Values with an
interval of 100 mean a delayed switch-on by one pulse period T0(group formation).
This function also allows switch-on to, for instance, an emergency power
generator (step-by-step switch-on of the load).
Example: 4 controllers e.g. with 100 A, load level control ca. 30%
contents of Sync_Adr: 0 (100), 25, 50, 75
NOTE
The mains load optimizations with SYT9 and QTM are not depen-
dent on connection of a controller to a bus module.
Controller a, b, c, d with a load
level control of 30%
Mains load
Contents Sync. Addr.