AEG THYRO-A User manual

PERFECT IN FORM AND FUNCTION
Betriebsanleitung/Operating Instructions
Thyristor-Leistungssteller
Thyro-A
Thyristor Power Controller
Thyro-A
Thyro-A

2
Contents
1. General 7
1.1 Type designations/Validity 7
1.2 Abbreviations 10
1.3 Special Features 10
1.4 Warranty 11
2. Safety 12
2.1 Identification in the operating instructions 12
2.2 General danger information 13
2.3 Operator requirements 13
2.4 Personnel requirements 14
2.5 Intended use 14
2.6 Use of the device 15
2.6.1 Operation 15
2.6.2 Prior to installation/commissioning 15
2.6.3 Maintenance, service, faults 16
2.6.4 Transport 17
3. Functions 18
3.1 Operating modes 18
3.1.1 Full wave switch principle TAKT 18
3.1.2 Phase angle principle VAR 19
3.1.3 Half wave switch principle QTM 19
3.2 Setpoint processing 19
3.3 Control modes 20
3.4 Limits 23
3.5 Pulse inhibition 23
3.6 Current and voltage transformer
(only for ...H RL1 and ...H RLP1) 23
3.7 Display via analog output
(only for ...H RL1 and ...H RLP1) 24
3.8 Error and status messages 24
3.8.1 LED messages 29
3.8.2 Fault signalling relay K1
(only for ...H RL1 and ...H RLP1) 31
3.9 Monitoring 32
3.9.1 Monitoring the mains voltage 32

3
EN
3.9.2 Load monitoring (only for ...H RL1 and ...H RLP1) 33
3.9.3 Device temperature monitoring 33
3.9.4 Fan monitoring (for ...F...) 33
3.10 Extended functions
(with bus module / THYRO-TOOL FAMILY) 33
3.10.1 Extended operating modes / circuit types 34
3.10.2 Averaging for the analog output 35
3.10.3 Control limits 35
3.10.4 Controller parameters 35
3.10.5 Mains load optimization 35
4. Settings and operation 36
4.1 Device overview 37
4.2 DIP switches S1 39
4.2.1 Operating mode and load types 41
4.2.2 Control mode / Analog output 41
4.2.3 Live zero and setpoint input range 43
4.2.4 Analog output (only for ...H RL1 and ...H RLP1) 43
4.3 Potentiometer 44
4.3.1 Setting the transformer load (AN1, SST, T0) 45
4.3.2 Setting ohmic load 46
4.3.3 Setting maximum load value with control end U, U2
and P control 47
4.3.4 Setting maximum load current
(only for ...H RL1 and ...H RLP1) 48
4.3.5 Setting example for maximum load value at control
end / maximum load current 49
4.3.6 Adapting analog output (scale)
(only for ...H RL1 and ...H RLP1) 50
4.3.7 Setting load monitoring (undercurrent monitoring)
(only for ...H RL1 and ...H RLP1) 51
5. Installation 58
5.1 Connecting terminals (Overview) 60
5.2 Connecting power supply 62
5.3 Connecting additional electronics supply
(only for ...H RL1 and ...H RLP1) 62
5.4 Connecting pulse inhibition 63

4
5.5 Connecting analog setpoint input 63
5.6 Connecting control input for switch operation 63
5.7 Connecting the bus module 64
5.8 Using the analog output
(only for ...H RL1 and ...H RLP1) 65
5.9 Using the THYRO-TOOL FAMILY 65
6. Mains load optimization 68
6.1 Internal mains load optimization 68
6.2 Synchronization with Thyro-Power Manager 68
6.3 Software synchronization (operating mode TAKT) 69
7. Connecting diagrams 71
8. Help in the event of problems 79
9. Technical data 82
10. Dimension drawings 89
11. Accessories and options 104
12. Approvals and conformity 105

5
EN
List of figures and tables
Fig. 1 Setpoint inputs and effective setpoint 19
Fig. 2 Operating elements 61
Fig. 3 User surface THYRO-TOOL FAMILY 67
Fig. 4 Connection diagram Thyro-A 1A...H1 71
Fig. 5 Connection diagram Thyro-A 2A...H1 72
Fig. 6 Connection diagram Thyro-A 1A ...H RL1, ... H RLP1 73
Fig. 7 Connection diagram Thyro-A 2A ...H RL1, ... H RLP1 74
Fig. 8 Connection diagram Thyro-A 3A...H1 75
Fig. 9 Connection diagram Thyro-A 3A ...H RL1, ... H RLP1 76
Fig. 10 Load connection types 77
Fig. 11 Additional electronics supply and connection with
optional bus module 77
Fig. 12 Connection diagram mains load optimization
with Thyro-Power Manager 78
Fig. 13 Connection diagram mains load optimization
for operating mode TAKT 78
Tab. 1 Effects of a change in the load resistance 22
Tab. 2 Effective limits 23
Tab. 3 Limit values for mains voltage monitoring 32
Tab. 4 Maximum load value at control end 48
Tab. 5 Maximum load current 49
Tab. 6 Analog output (scale) 50
Tab. 7a Load monitoring A 1A/2A, star delta, without neutral 52
Tab. 7b Load monitoring Load with common star point and
without neutral conductor 53
Tab. 7c Load monitoring , A 2A, star point 54
Tab. 8 Load with common star point and without neutral
conductor 55
Tab. 9 Load in delta connection 56
Tab. 10 Other possibilities of load monitoring 57
Tab. 11 Connecting terminals (Overview) 60

6
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]
[email protected]
Service-Hotline
Our team is at your service on the following hotline:
AEG Power Solutions GmbH
Emil-Siepmann-Strase 32
D-59581 Warstein
Tel. [phone] or [phone]
http://www.aegps.de
Copyright
No part of these operating instructions may be transmitted, reprodu-
ced and/or copied by any electronic or mechanical means without the
express prior written permission of AEG PS.
© Copyright AEG Power Solutions GmbH 2011.
All rights reserved
Further information on copyright
Thyro-A is an international registered trademark of AEG Power
Solutions 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.

7
EN
1. General
The Thyro-A is a communication-capable thyristor power controller.
It can be used wherever alternating voltages, alternating currents or
outputs in thermal process technology need to be controlled. The
Thyro-A has several different control and regulation modes, can
easily be connected to process and automation technology, has a
high degree of control accuracy and is simple to handle.
These operating instructions describe the configuration and functions
of the Thyro-A and are designed to enable qualified personnel to per-
form the following work:
• planning
• commissioning
• maintenance and repair
1.1 Type designations / Validity
These operating instructions describe the Thyro-A series versions
...H 1, H RL1 and ...H RLP1. Product characteristics that are only
provided by the Thyro-A ...H RL1 and ...H RLP1 series are marked
in the text.
These operating instructions comply with the current technical speci-
fications of the device at the time of publication. The contents do not
constitute a subject matter of the contract, but serve for information
purposes only.
We reserve the right to alter any specifications given in these opera-
ting instructions, especially with regard to technical data, operation,
weights and dimensions. AEG PS reserves the right to make modifi-
cations with regard to the content and technical data in these opera-
ting instructions.

8
Type code
The type designation of the thyristor-power controller is derived from
the configuration of the power unit as well as from other features.
Thyro-A 1A Thyristor controller with single phase power unit,
suited for single phase loads
Thyro-A 2A Thyristor controller with two phase power unit, sui-
ted for symmetrical loads in three phase operation
in three phase saver circuit
Thyro-A 3A Thyristor controller with three phase power unit,
suited for three phase loads
Designation Characteristics Different version
(example) of the
power controller
Thyro-A 3A Three phase power controller with three
phase power unit
...400- with 400V type voltage 230V, 400V,
500V, 600V
...280 with 280A type current 16 ... 1500A
H with integrated semiconductor fuse
F with fan (from 280A types) *
R with signalling relay *
L with load monitoring *
P with additional power control
(H RLP) *
1 Identification Thyro-A, series *
Example:
Thyro-A 3A...H1
* device-specific

9
EN
Thyro-A ...H1
Thyristor power controller with integrated semiconductor fuse, sys-
tem bus interface, TAKT and VAR operating modes, synchronization
option (in TAKT operating mode with Thyro-Power Manager option)
and control modes U, U2. Suitable for 3-phase operation in 3-phase
circuit. Suitable for visualization and commissioning software from the
Thyro-Tool Family.
Thyro-A …HRL1
Thyristor power controller with integrated semi conductor fuse, sys-
tem bus interface, additional 24 DC/AC electronic power supply,
signalling relay, load monitoring and analog output, channel separa-
tion, with operating modes TAKT and VAR, synchronization option
(in operating mode TAKT with Thyro-Power Manager), control modes
U, U2, I ,I2. Suitable for the visualization and commissioning software
Thyro-Tool Family.
Thyro-A ...H RLP1
Thyristor power controller with integrated semiconductor fuse, system
bus interface, additional 24 VDC/AC electronic power supply, signal-
ling relay, load monitoring and analog output, channel separation,
with TAKT and VAR operating modes, synchronization option (in ope-
rating mode TAKT with Thyro-Power Manager) and control modes U,
U2, I ,I2and P. Suitable for visualization and commissioning software
Thyro-Tool Family.

10
1.2 Abbreviations
AEG PS AEG Power Solutions GmbH
AN1 Phase angle of the 1st half-wave
SST Soft start time
SYT Synchro cycle
T0Cycle period
TSSwitch-on time
Takt Full wave switch principle - Thyrotakt
Var Phase-angle principle - Thyrovar
QTM Half wave switch principle - Quick takt mode
1.3 Special Features
• Integrated semiconductor fuse
• Type range 230-600V, 16-1500A, single phase, two phase and three
phase
• Additional electronic supply, therefore also operation with mains vol-
tages up to 0.43 x Unom possible (only ...HRL 1 and ...H RLP1)
• Ohmic load and transformer load, as well as load with high
Rwarm /Rcold (≤6) peak current limitation of 3 x Inom (only ...H RL1 and
...H RLP1) in operating mode VAR
• Soft start function for transformer load
• Channel separation, necessary with countervoltage
• Load current monitoring (only ...H RL1 and ...H RLP1)
• Signalling relay (only ...H RL1 and ...H RLP1)
• Analog output (only ...H RL1 and ...H RLP1)
• Control modes U, U2; with ...H RL1 additional I, I2, with ...H RLP1
additional P
• Operating modes TAKT, VAR and QTM (with Thyro-A 1A)
• Synchronization option (for TAKT: with Thyro-Power Manager, for
QTM: with internal mains load optimization)
• Triggering with analog setpoint via PC or optional bus adapter
• System interface standard
• Safe isolation in acc. with EN 50178 ch. 3
• UL approval (for standard devices 16-350A, 495-1500A in prepara-
tion)