AEG Network Cables Thyro P User Manual

BETRIEBSANLEITUNG/OPERATING INSTRUCTIONS

Thyro-P

Thyristor-Leistungssteller

kommunikationsfähig

Thyristor Power Controller

Communication Capable

DE EN

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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 corres-

ponds 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 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 ﬁre 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 vol-

tage 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 perfor-

med by qualiﬁed and trained maintenance personnel.

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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.

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TABLE OF CONTENTS

Safety instructions

Schedule of Illustrations and Tables

Safety Regulations

Remarks on the present operating instructions and Thyro-P

1. Introduction

1.1 General

1.2 Specific characteristics

1.3 Type designation

2. Functions

2.1 Overview of operating modes

2.2 Set point control characteristic

2.3 Control types

2.3.1 Controlled value

2.4 Indications

2.4.1 LED indications

2.4.2 Relay indications K1-K2-K3

2.5 Monitoring

2.5.1 Load monitoring

2.5.2 Ventilator monitoring

3. Mode of Operation

3.1 Local operating and display unit (LBA)

3.1.1 LBA keyboard functions

3.1.2 LBA main menu

3.1.3 LBA submenus

3.1.4 Copying function using the LBA

3.1.5 Operation display

3.1.6 Line diagram

3.1.7 Last function

3.1.8 Status line

3.1.9 LBA submenus with password protection

3.2 Cabinet installation kit (SEK)

3.3 Thyro-Tool Family

3.4 Diagnosis / fault indications

4. External Connections

4.1 Power supply for Thyro-P

4.2 Power supply for the control device A70

4.3 Power supply for the ventilator

4.4 RESET

4.4.1 Software-RESET

4.5 Controller lock

4.6 QUIT

4.7 Set point value inputs

4.8 ASM input

4.9 Analog outputs

4.10 Current transformer

4.11 Voltage transformer

4.12 Other connections and terminal strips

4.13 Synchronization

4.14 Component mounting diagram control device

5. Interfaces

5.1 RS 232 interface

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5.2 Fibre optic interfaces

5.2.1 Fibre optic distribution system

5.3 Bus interfaces (option)

5.3.1 Profibus

5.3.2 Modbus RTU

5.3.3 DeviceNet

6. Mains Load Optimization

6.1 SYT-9 procedure

6.2 Software synchronization

6.3 ASM procedure (patented)

7. Connecting diagrams

7.1 1-phase

7.2 2-phase

7.3 3-phase

8. Special Remarks

8.1 Installation

8.2 Comissioning

8.3 Service

8.4 Checklist

9. Type Overview

9.1 Type range 400 volts

9.2 Type range 500 volts

9.3 Type range 690 volts

10. Specifications

11. Dimensional Drawings

12. Accessories and Options

13. Approvals and Conformities

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SCHEDULE OF ILLUSTRATIONS AND TABLES

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Fig. 9

Control characteristic for U control

Total set point

Switch-on fault bridging

Absolute value monitoring

Relative monitoring

Local operating and display unit (LBA)

Operation display

Cabinet installation kit

Example for the user interface Thyro-Tool Familiy

Fig. 10 File component mounting diagram control device

Fig. 11 Interfaces of Thyro-P

Fig. 12 Connection of a PC to Thyro-P via RS 232

Fig. 13 X10-allocation

Fig. 14 Signal converter RS 232/fibre optic

Fig. 15 Schematic diagram fibre optic Thyro-P with LLV and PC

Fig. 16 Profibus slot card

Fig. 17 Special function Motorpoti

Fig. 18 Special inputs

Fig. 19 Modbus slot card

Fig. 20 ASM wiring

Tab. 1

Tab. 2

Tab. 3

Tab. 4

Tab. 5

Tab. 6

Tab. 7

Tab. 8

Tab. 9

Behaviour in case of load change

Partial load breakdown with heating elements switched in parallel, undercurrent

Partial short-circuit with heating elements switched in series, overcurrent

Overview monitoring

Functions of the LBA-keys

LBA main menu

Copying function using the LBA

Line diagram time base

Elements of the status line

Tab. 10 Allocation of the message register

Tab. 11 Terminal strip X1

Tab. 12 RESET

Tab. 13 Controller lock

Tab. 14 QUIT

Tab. 15 Current transformer

Tab. 16 Voltage transformer

Tab. 17 Voltage measurement jumper

Tab. 18 Terminal strip X2 for K1, K2, K3

Tab. 19 Terminal strip X5

Tab. 20 Terminal strip X6

Tab. 21 Terminal strip X7

Tab. 22 Synchronization jumper

Tab. 23 Fibre optic distances

Tab. 24 Profibus baud rates

Tab. 25 Pin assignment X21

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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 ﬁeld 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.

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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 ofﬁce 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 modiﬁcation 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 speciﬁcations are observed,

- protective installations are used,

- required maintenance work is performed,

- maintenance personnel are immediately notiﬁed 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 unqualiﬁed persons and for use of Thyro-P outside of industrial

installations are not contained in these operating instructions.

The warranty obligation of the manufacturer applies only if these operating instructions are observed.

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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 conﬁrms 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 deﬁnitions for qualiﬁed personnel are contained in DIN 57105/VDE 0105 Part 1.

Safe isolation to VDE 0160 (EN 50178 Chapter 3)

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REMARKS ON THE PRESENT OPERATING INSTRUCTIONS AND THYRO-P

VALIDITY

These operating instructions refer to latest technical speciﬁcation of Thyro-P at the time of publi-

cation and are for information purposes only. Every effort has been taken to ensure the accuracy of

this speciﬁcation, however, in order to maintain our technological lead and for product enhance-

ment, we are continually improving our products which could, without notice, result in amendments

or omissions to this speciﬁcation. 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 regula-

tions.

ABBREVIATIONS

In this description, the following speciﬁc abbreviations are used:

AEG PS

ASM

AEG Power Solutions GmbH

automatic synchronization in multiple Power Controller application

(dynamic network load optimization)

data logger (fault storage)

lokal operating and display unit

cabinet installation kit

DaLo

LBA

SEK

ﬁbre optic

LLS

ﬁbre optic transmitter

LLE

ﬁbre optic receiver

LLV.V

LLV.4

SYT

TAKT

ﬁbre optic distribution supply

ﬁbre optic distribution, 4-fold

synchronized clock

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 mate-

rial 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 modiﬁed or repaired otherwise than as authorised in writing by

AEG PS; or if the defect arises because of the ﬁtting 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.

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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

[email protected]

INTERNET

Further information on our company or our products can be found on the internet under

http://www.aegps.com.

Passing on, duplication and/or takeover of these operating instructions using electronic or mechani-

cal means, even in excerpts, is subject to express prior written approval of AEG PS.

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.

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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 Con-

troller 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_hot/R_coldratio

• 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.

1.2 SPECIFIC CHARACTERISTICS

Thyro-P is characterized by a multitude of speciﬁc 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_hot/R_coldfor 1P and 3P

• soft start function for transformer load

• load circuit monitoring

• automatical rotating ﬁeld 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

• ﬁbre 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 speciﬁc 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 Proﬁbus, 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 optimi-

zation. 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.

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• 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, modiﬁcation, 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 Con-

trollers, 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

single phase power section,

for single phase operation

double phase power section, for three phase operation

in three phase economizing circuits,

not for phase-angle control (VAR)

three phase power section,

for three phase operation

.P400

Type voltage 230-400 Volt, 45-65 Hz

Type voltage 500 Volt, 45-65 Hz

Type voltage 690 Volt, 45-65 Hz

Type current 37A (Typecurrent range 37A-2900 A)

Integrated semi-conductor fuse (all Thyro-P)

Forced air cooling with integrated ventilators

.P500

.P690

.P ...-0037

.. ...-.... . H

.. ...-.... . F

The complete type range can be found in the type overview in chapter 9.

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2. FUNCTIONS

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-speciﬁc 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 varia-

tions 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 materi-

als with a high R_hot/R_coldratio, for instance molybdenum disilicide. The Power Controller always

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.

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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 deﬁned switching of the individual Power Controller in sequence. This avoids load peaks by

random simultaneous switching of many Power Controllers and load troughs are ﬁlled 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 characte-

ristic. 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

ﬁg. 2.

In the simplest case all the set point values are added algebraically. The prerequisite for a set point

to inﬂuence 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 ﬁnal value), and they may be set to the

following signal ranges:

0(4)-20 mA (Ri about 250⍀)

max. 24mA

max. 12V

siehe ”ATTENTION“

0-5

(Ri about 8,8k⍀)

(Ri about 5k⍀)

0-10

The following table shall be used for the hardware conﬁguration of the set point inputs (see also

FILE COMPONENT MOUNTING DIAGRAM CONTROL DEVICE, ﬁgure 10). If the hardware con-

ﬁguration 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

closed*

Signal range

0(4) -20mA

0-5V / 0-10V

Set point input 1

(X5.2.10)

open

(X5.2.10)

X222 for Set point input 2

Bridge X222

closded

Signal range

Set point input 2

(X5.2.11)

0(4)-20mA

open*

0-5V / 0-10V

(X5.2.11)

* default

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.

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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).

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. Inver-

ted 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

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The prerequisite for a set point to inﬂuence 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

Set point 2 [%]

_Pro Set point (1,2) = Set point 1 *

100%

Set point 2 [%]

_IPro Set point (1,2) = Set point 1 * (1 -

)

100%

VALUE RANGE OF SET POINT (1,2)

For the link result of set point (1,2) the following value range applies:

0 ͨ Set point (1,2) ͨ Set point max (U_max, I_max, P_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:

VALUE ABBR.

EXPLANATION

STD

Standard (all ON)

LOC

Motor poti-set point 4 (LOCAL)

Bus set point 3

REMOTE

ANA

Analog-set points 1,2

All set points inactive

2.3 CONTROL TYPES

Thyro-P has ﬁve 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

P control

CONTROL VALUE (PROPORTIONATE TO THE TOTAL SET POINT)

output (active) power, P

U control

U²control

output voltage, U_rms

output voltage, U²_rms

I control

I²control

output current, I_rms

output current, I²_rms

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.

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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

DECREASES

LOAD RESISTANCE

INCREASES

EFFECTIVE*

LIMITATIONS

CONTROL

LIMIT

U_{rms max}

I_{rms max}

P_max

U_LOAD

I_LOAD

larger

U_LOAD

I_LOAD

larger

smaller

larger

smaller

I_{rms max}

P_max

U²(UxU)

I_{rms max}

P_max

smaller

larger

U_{rms max}

P_max

I²(IxI)

P_max

smaller larger

larger

smaller

I_{rms max}

without control

larger

smaller

U_{rms max}

P_max

* 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

T_s=T_{s max}

␣=␣_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

• LIMIT

modulation percentage indication, ﬂashing*

limitation is active, relay K2 switches*

Controller Lock active, but load control is continued at pulse limits

(default value = 0)*

• PULSE LOCK

• 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 ﬁtted 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 contac-

tor 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.

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2.5.1 LOAD MONITORING

MONITORING OF THE LOAD AND MAINS VOLTAGE

Each power section is ﬁtted 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_{Line min}and U_{Line max}. If larger deviations are detected, then a fault indication is generated.

ABSOLUTE OR RELATIVE MONITORING

Relative monitoring for heating elements for R_hot/R_cold≈ 1 and absolute monitoring for heating

elements with R_hot/R_cold≠ 1 are possible.

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 < 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 preset-

table 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

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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 ﬂow 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 hea-

ting 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

with neutral conductor

Delta connection

Star connection

without neutral conductor

HEATING

2P*/3P

ELEMENTS

IN PARALLEL

FOR EACH

STRAND

STAR CONNECTION

WITH SEPARATE

STARPOINTS

STAR CONNECTION

DELTA

STAR CONNEC-

WITHOUT CONNEC-

CONNECTION TION WITH

CONNECTED

TED NEUTRAL

CONDUCTOR

NEUTRAL CONDUCTOR

10%

13%

17%

25%

50%

10%

13%

17%

25%

50%

–

10%

13%

20%

50%

–

13%

17%

25%

50%

10%

12%

21%

* 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

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Star connection

Delta connection

Star connection

without neutral conducter

with neutral conductor

HEATING

ELEMENTS

IN SERIES FOR

EACH STRAND

STAR CONNECTION

DELTA CONNECTION

STAR CONNECTION

WITH CONNECTED

WITHOUT CONNECTED

NEUTRAL CONDUCTOR

10%

13%

17%

25%

50%

–

10%

13%

17%

25%

50%

10%

14%

25%

–

10%

13%

26%

TAB. 3 PARTIAL SHORT-CIRCUIT WITH HEATING ELEMENTS SWITCHED IN SERIES, OVERCUR-

RENT, 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

U_{net max}

SETTINGS

REMARKS

mains overvoltage

mains undervoltage

overcurrent

input in volts

Type voltage + 20%

Type voltage - 20%

REL_ABS = REL

UE_S = ON

U_{net min}

input in volts

I_{load max-REL}

0-100%

overcurrent relative

Re: measured load current

after each RESET/control lock

input in ampere

I_{load max-ABS}

I_{load min-REL}

overcurrent

absolute

REL_ABS = ABS

UE_S = ON

undercurrent

relative

0 to 99%

REL_ABS = REL

UN_S = ON

Re: measured load current

after each RESET/control lock

input in ampere

I_{load min-ABS}

undercurrent

absolute

REL_ABS = ABS

UN_S = ON

pulse switch

pulse switch off

ON: pulse switch off after

fault indication

indication is always

issued

off by software

OFF: in case of fault

in case of synchronization

SYT 9, RESET of all Power

Controllers is required

alarm relay K1

ON: relay K1

open circuit

released in case of fault

OFF: relay K1

the alarm relay switches

upon activation of

RESET

pulled-in in case of fault

TAB. 4 OVERVIEW MONITORING

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2.5.2 VENTILATOR MONITORING

The separately ventilated Power Controllers (-...HF) are ﬁtted with thermal monitoring. The tempe-

rature is measured on the heat sink. In case of a temperature overrange, a fault inducation is issued

(Proﬁbus, LED OVERHEAT).

ATTENTION

Activating this monitoring function is obligatory if the Thyro-P is operated under UL conditions.

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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 classiﬁcation 3) has ﬁve 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.

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 ﬁrst (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 dia-

gram is possible. The time and value axes may be set by parameters and so adjusted to require-

ments. 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.

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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

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

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

Parameter loading process Parameterizing process is temporarily

Thyro-P → LBA

inactivated

OK OK

Line diagram:

deselection of the line diagram display

operation display is activated; this does

not apply in case of selected line diagram

Parameterizing lock is self-activating on release

No key pressed

(for 1 minute)

Operation display:

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 conﬁguration 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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MAIN MENU

FUNCTION

Language

selection operating language

load and store data

Load/store data

Set points/characteristics

Parameter

set point processing

display and modification of parameters

select operation display

energy and operating hours

Operation display

Last function

TAB. 6 LBA MAIN MENU

3.1.3 LBA SUBMENUS

The first six lines of the above main menu contain the names of the sub-menus. These are shown

below, with explanations, in the sequence they are contained in the menu.

= Main menu (appears after plugging in the LBA)

Default User

Remarks

Value Value

Sprache/language

Deutsch

English

Francais

Open/save data

Thyro-P -> LBA

Loading, storing, copying of parameter sets

LBA

-> Thyro-P

Parameter from LBA-EEPROM to Thyro-P RAM

Parameter from LBA-RAM to LBA-EEPROM

Parameter from Thyro-P RAM to Thyro-P EEPROM

Store in LBA

Save Thyro-P

Open data again

Thyro-P -> LBA

waiting time

Store parameters from Thyro-P in LBA

Observe waiting time! OK key during charging releases

the parameter lock

ASIC-SW

Code LBA

Shows production date of controller software

Shows version of LBA software

Save data again

LBA -> Thyro-P

waiting time

Store parameters from LBA in Thyro-P

Observe waiting time!

Set points/curve

motor pot.

Term. (10)

Remark: Display is refreshed after max. 10 sec.

Display and modification set point 4

Display set point 1

Term. (11)

Master(bus)

Display set point 2

Display set point 3 (bus)

Display total set point

Act.pwr.tot:xx,xxmA

Absolute set points

During active circuit set point is displayed

in a submenue depending on control mode

Choice of set point inputs

STD,LOC,REMOTE,ANA

ADD,IADD, PRO,IPRO

5V,10V,mA term(10)

5V,10V,mA term(11)

Ctrl.start1 4.00mA

Ctrl.end1 20.00mA

Ctrl.start220.00V

Ctrl.end2 10.00V

STD

ADD

SW1+SW2, SW1-SW2, SW1*SW2%/100%, SW1*(1-SW2%/100%)

Selection signal type for set point 1*

Selection signal type for set point 2*

Control start set point SW1

0.3mA

20.0mA

0.07V

5.0V

Control start set point SW1

Control start set point SW2

Control end set point SW2

* refer to ”ATTENTION” on page 16

Adress

Bus+LL-compound xxx

100

xxx for fibre optic 001 - 998

in case of Profibus DP 001 - 125

000 and 999 have specific functions

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= Main menu (appears after plugging in the LBA)

Default User

Remarks

Value Value

Act. val. select

Analog outp.(32)

Parameterization for analog output 1, terminal 32

Parameterization for analog output 2, terminal 33

Parameterization for analog output 3, terminal 34

Parameterization for operation display, value top

Parameterization for operation display, value middle

Parameterization for operation display, value bottom

Mean value analog display of xx mains/cycle periods

Parameterization line diagram

Analog outp.(33)

Analog outp.(34)

Display top

Display middle

Display bottom

Average xx

Graphics

Analog outp.(32)

Analog outp.(33)

Analog outp.(34)

Analog outp.(xx)

Select and OK

Selected analog output 1,2,3 (terminal 32,33,34)

Selection of (if ecisting in the Power Controller):

U1, I1, P1, PG

U2, I2, P2

U1(32)

I1(33)

P1(34)

U2, I2, P2

U3, I3, P3, alpha

U3, I3, P3, setpoint

U ,I ,P

U3, I3, P3, alpha, total set point

Display total set point

Minimum and maximum values of U, I, P since

last RESET respectively voltage startup.

Changeover 10V/20mA

min

U ,I ,P

max

Current output OFF,ON

Full scale xx,xmA

Offset

Measuring device end scale deflection e.g. 20mA

Offset signal for output value, for instance 4mA

Y=dimension depending on display V, A, kW

0mA

Full scale value xxx y

Display top

Display middle

Display bottom

Display

Operation display: top, middle, bottom (3 values)

Selection of (if ecisting in the Power Controller):

U1, I1, P1, PG

Select and OK

U1, I1, P1, PG

U2, I2, P2

U3, I3, P3, alpha

U3, I3, P3, setpoint

U ,I ,P

U3, I3, P3, alpha, total set point

Display total set point

Minimum and maximum values of U, I, P since

last RESET respectively voltage startup.

min

U ,I ,P

max

Line diagram

X - axis - time

1,5min;30min;1h;3h

Y - axis - value

U1, I1, P1, PG

Scaling of the time axis (resolution pixels)

Selection of (if existing in the Power Controller type):

1.5min

U1, I1, P1, PG

(resolution 50 pixels)

U2, I2, P2, alpha

U3, I3, P3, setpoint

Start graphic

U2, I2, P2, alpha,

U3, I3, P3, total set point,

Start line diagram

bar, average value

Display band (all measured values) or average value

limitations

Presets limiting values

xxxxV

xxxxA

xxxxkW

xxxxms

xxx°e

type

Display/default (at 3P default setting phase voltage)

Display/default

rms max

type

rms max

type

Display/default

max

op. time

1000ms

Only for the operating modes TAKT and SSSD (< T_o)

Only for the operating mode VAR

Only for VAR

max

Ft.

180

Imp End

Rr.

xxx°e

Imp End

on. time

xxxxms

xxxxV

xxxxA

xxxxkW

min

rms min

min

Phase swingL xxx

* password protection

Phase swing for L1, L2, L3

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= Main menu (appears after plugging in the LBA)

Default User

Remarks

Value Value

Operating mode

TAKT/FC

VAR /PA

TAKT

Operating mode selection fulloscillationclockprinciple

Operating mode selectionphase-angle principle

Operating mode selectionSoft-Start-Soft-Down

Reserve

SSSD/FC-PA

Res

No.ctrld.phase 123

Load R,RL,transf.,C

Number of phases controlled (power paths)

R: without startup ramps, C: like R, only for TAKT

Operation without controls or limitations

Display for ASM process

Service

ASM OFF,

OFF,ON

ON, OFF

OFF

Uses analog output 2, terminal 33

R: ramp, S: steer

Only for 3-phase and VAR

MoSi OFF,R,S

Afterpulse OFF,ON

OFF

TDS

Neutral

OFF,ON

OFF

Only for 3-phase and VAR

Only for 3-phase

Hardware parameters

Curr.conv.

Volt.conv.

X501-3 1-2,2-3,3-4

xxxxx

xxxx

100

Transformation ratio ü:1

Voltage adjustment measurement range 3 see chapter

Voltage transformer

See name plate

Type current xxxxx

Type voltage xxxx

Burden load. xxx,xx

type

1 Ohm

See name plate

current transformer adjustment incl. tolerances

Frequency

Date

Time

Only display of the mains frequency

Input and display

yyyymmdd

hhmmss

Cntr. data log. x

Peak value xxxxx

Current count of data logger counter 1 to 16

Peak current value at which instant impulse lock

shall be set (in Ampere)

65000

SW_FA_1-6

list_L1-3_FA

DAC1-3_FA

TI_FA

KP_FA

Puls.s.off OFF,ON

K1 closed-c OFF,ON

IMAB: shutdown of the Power Controller in case of fault

K1RU: switching open contact/closed contact (only K1)

Monitoring

Display/setting of the monitoring values

Relative/Absolute

Undercurrent OFF/ON

Overcurrent OFF/ON

R/A

Monit. L2

Monit. L3

OFF/ON

xxxV

absolute limiting value, see Fig. 4

line max

xxxV

line max

Temperature

Messages

change of absolute limiting value is only possible if

the corresponding relative limiting value are zero/255.

change of absolute limiting value is only possible if

the corresponding relative limiting value are zero/5000.

Monitoring Relativ

Undercurrent

Overcurrent

Value unequal

ZERO!

xx %

Cursor is in front of the selected value

Monitoring absolut

Undercurrent

Overcurrent

ZERO!

xx A

xxx A

Cursor is in front of the selected value

* password protection

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= Main menu (appears after plugging in the LBA)

Default User

Remarks

Value Value

Temperature

PT1000,PT100,NTC

Ch.curve no.

PT1000

type

Sensor used

Type-dependent, see chapter type overview

Display actual temperature (relative value)

Temperature xxx°C

Lev.wire br.

Lev. sh-circ.

Comp.val.DAC

No.,DaLo,K1,K2,K3

Status- / fault name

Communication with RS 232 active

Communication with fibre optic active

Power value negative

Communication fault RS 232 or fibre optic

Synchr. interfacesfailure(e.g. Profibus)

External processor on the SSC signals fault

K3 after RESET

RESET active

Data in EEPROM invalid (reload parameters)

Internal message

Limiting value is exceed

Excess device temperature is present

Instant current interruption has responded

Internal message

Fault exists in load circuit-collective fault 16,17

Undercurrent exists in the load circuit

Overcurrent exists in the load circuit

Internal message

Dalo

Circuit OK

Undervoltage exists in the power section

Overvoltage in the power section

Internal message

Synchronization fault

Collective fault 4,6,9,10,11,12,14-24

(each fault leads to switching)

Internal message

Power Controller is in peak current limitation

(only for operating mode MOSI)

Temperature sensor, short circuit or sensor break

Controls

U ^

load

Parameterization control characteristic

Selection control characteristic U

load

UxU

Selection control characteristic U

load rms

load

I ^

load

IxI

Selection control characteristic I

load

Selection control characteristic I

load rms

load

Active power

No control

PID factors

Selection control characteristic effective load, P

Selection set operation (phase-angle control angle)

Parameterization controller parameters, password prot.

PID factors

Sta.-Regl. OFF,ON

With standard control OFF the control parameters

can be stipulated

P - part

I - part

D - part

type

Controller parameters, P-part

Controller parameters, I-part

Controller parameters, D-part

* password protection

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= Main menu (appears after plugging in the LBA)

Default User

Remarks

Value Value

Times

Approach 1.

Softdown

xx°e

xx,xs

60°el

0.3

60°el. in case of 1P, otherwise 90°el., default value for transformers

0 to (To-20ms), default value 400ms, ramp time up

0 to (To-20ms), default value 400ms, ramp time down

Display/Default of pulse period duration To

Display of on-time Ts

Softdown

xx,xs

0.3

Cl.puls.dur

On-time

xxxxxms

xxxxms

xxxms

1.000

Sync.del.

Min. pause

Puls.dur.max

Display of on-time Ts

60ms

50s

Transformer dependent, default value

Fixed parameter control range, default value,

password protection

Set pointm2 OFF/ON

OFF

On activating, a jump is made from the operation

display directly into this set point menu. The main

menu can be reached from here with the left key

9 Local/Remote

Local/Remote

Set point menu 2 direct from the operation display

when parameter set point 2=ON

Motorp SW

Master SW

Total Pwr

%, kW, A depending on set cascade control

%, total power; U1, I1 depending on set cascade

control

Total SW

Total set point value also in %, kW, V, A

Pa-lock OFF,ON

OFF

With parameter lock ON, the lock, which is enabled

with OK, is reactivated after one minute of operation

display

Password

Password entry

Enabling of password functions

Condition: Consultation/training

Valid until LBA is unplugged from the Power

-----------------

****** o.k.

Controller

-----------------

Code xxxxxxxxxx

EEPROM version number

Operation display

Current operation indication, exit using OK

Display top

456,7V

1567,9A

1234,8kW

Display middle

Display bottom

Status messages

Display of status information: select this line

and confirm using OK

11 State messages

jjjjmmtt ddmmss

Limit

Examples for status indications

jjjjmmtt ddmmss

Limit

jjjjmmtt ddmmss

Undervoltage

Last function

Return to the parameter last processed

REMARK

Type

setting dependent on the type

Some further menues are only accessible after input of a password.

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3.1.4 COPYING FUNCTION USING THE LBA

It is possible to load the complete user-specific data record (parameters) of a Power Controller

(for instance no. 1) into the memory of the LBA (RAM), store it in the LBA (EEPROM) and then

copy it into another Power Controller (for instance no. 2):

PLUG LBA INTO POWER CONTROLLER NO. 1

1. reload data (data is stored in the LBA RAM)

2. storing in the LBA

(data is copied into the LBA-EEPROM)

After the waiting time unplug LBA from Power Controller 1.

Plug LBA into Power Controller no. 2

3. LBA -> Thyro-P

After the waiting time data from LBA are in Power Controller 2.

4. Save Thyro-P

TAB. 7 COPYING FUNCTION USING THE LBA

Data from Power Controller 1 have now been copied to Power Controller 2.

ATTENTION

Only parameters of equal Power Controllers (for instance type voltage, type current, phase

number) may be copied.

3.1.5 OPERATION DISPLAY

On the operation display, one, two or three actual values are optionally displayed in double digit

size. An example for the operation display able to be configured using parameters is shown

below:

456.7V

1567.9A

1234.8kW

Status messages

FIG. 7 OPERATION DISPLAY

The operating data displayed are the values U, I and P (P_gesfor 3-phase system) of phase 1. It is

also possible to display data of other phases. The lowest line is the status line; this is where the

device configuration is displayed, if no indications are waiting. Otherwise, „status messages“ is

displayed. By selecting the key, the indications are displayed:

Status messages

fault type, load, Power

yyyymmdd

limit

hhmmss

1250kW

Controller type, limitations,

etc. are notified with the

corresponding time of day. etc.

yyyymmdd

hhmmss

<360V

undervoltage

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With the ǟ key it is possible to leave the status messages display. The operation display now

appears without the word status message. Only when new information arrives does status message

appear again in the bottom line of the operation display.

Additionally, input error indications or further parameters may be stated, which are self-explaining

in connection with the menu heading.

As shown before, automatic switch to this display is made if more than one minute has passed

since the last key has been pressed. The operation display is exited by simple acknowledgement

(OK key).

3.1.6 LINE DIAGRAM

The line diagram has the same functionality as a page recorder. The „writing pen“ and therefore

the current measurement value are found on the Y axis. The line diagram is scrolled left pixel by

pixel. Measured value collection supplies one measured value each second. Because the time axis

is resolved in 90 pixels, the following values result for the time bases from 1.5min up to 3h:

TIME BASE

1.5 min

30 min

1 h

MEASURED VALUES PER TIME-PIXEL

1 *

3 h

120

*) for this resolution, no band display is possible

TAB. 8 LINE DIAGRAM TIME BASE

There are two display modes: band and average value display. In case of band display, each measu-

red value is displayed unﬁltered. The number of measured values displayed for each time pixel

is shown in the above table.

In case of average value display, the average value is formed from several measured values and

displayed in one pixel.

The „windmill“ icon on the LBA display shows current data transfer between LBA and Power

Controller. In case of still or non-existant icon, the data transfer is faulty.

To exit the line diagram, the OK key must be pressed twice.

3.1.7 LAST FUNCTION

If the OK key is pressed during operation display, then the LBA will display the main menu. If the

lowest menu item last function is selected, then the menu is displayed which has been processed

last before operation display.

3.1.8 STATUS LINE

The status line is the lowest line of each menu. It looks like this:

1P VAR Trafo UxU

Example for status line

and may contain the following values:

1P, 2P or 3P

for the Power Controller type

for the operating mode

for the load type

VAR, TAKT, SSSD

Trafo, R-Last or RL-La.

U, UxU, I, IxI or P

for the control type

TAB. 9 ELEMENTS OF THE STATUS LINE

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3.1.9 LBA SUBMENUS WITH PASSWORD PROTECTION

REMARK

After password input, further parameters may be modiﬁed. These are mainly adjusting parameters

required for achieving power control speciﬁcations. The modiﬁcation of these parameters requires

extended specialist knowledge (for instance by training) and is not required under normal circum-

stances.

3.2 CABINET INSTALLATION KIT (SEK)

Using the cabinet installation kit, the LBA may be installed in switching cabinet doors with a thick-

ness of up to 4 mm. It consists of an adaptor frame 96x72mm (cut-out dimensions 92x68mm) and

a cable. Using the cable, the LBA is connected to the RS 232 interface of Thyro-P.

The LBA locks in the adaptor frame and may only be removed with the cabinet door open. This

enables an instructed specialist to set parameters (for instance adjustment to changing tools) and

manual setting of set points (motor potentiometer) as well as for reading the actual value display

without opening the cabinet door (VBG4). In order to avoid the accidental input of data by touch-

ing the LBA, there is a self-activating parameterizing lock to enable (see Table 5).

FIG. 8 CABINET

INSTALLATION KIT

If the LBA is connected to the Power Controller using a longer cable and does not operate, then

this may possibly be remedied by increasing the supply voltage (open the jumper R 155 in the

control device).

ATTENTION

In case of open jumper R 155, the LBA may not be connected to the Power Controller without

cable (hazard of destruction). The position of the jumper on the control device PCB can be found in

the component mounting diagram (Fig. 10, page 45).

3.3 THYRO-TOOL FAMILY

Thyro-Tool Familiy is an optional software for commissioning and visualization under Windows

95/98/NT 4.0/XP and higher. It includes all functions of Thyro-Tool P and it is connected to Thyro-P

via either one of the two standard interfaces (RS 232 respectively ﬁbre optic).

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Thyro-Tool Familiy may be employed as an alternative to LBA and as already stated above has the

following functions, for which several windows may be opened simultaneously:

• set point and actual value processing with overview display for 22 set point/actual value input

options for Motorpoti and total set points.

• loading, storing, modiﬁcation and printing of parameters

• comparison of parameters

It is possible to compare two sets of parameters (Power Controller or data ﬁle). It is thus possible,

to detect deviations from the desired conﬁguration.

• line diagrams of process data with printing function, as well as storage of faults (diverse measured

values from different Thyristor Power Controllers may be displayed simultaneously).

• bar diagram display

It is possible to simultaneously display several bar diagrams. Each diagram has its own window.

These can be adjusted in size and location. The conﬁguration of the display may be stored.

• simultaneous display of data and parameters from several Power Controllers

• simultaneous connection of up to 998 Thyro-P Power Controllers using ﬁbre optic distributors

• settings of the interface (baud rate, com...)

Thyro-Tool Familiy is supplied with a help system and installed on the PC under user guidance

using an installation software.

FIG. 9 EXAMPLE FOR THE USER INTERFACE THYRO-TOOL FAMILY

In the above illustration, you can see windows containing:

- 1 line diagram with several measured values

- 4 bar diagram (several are possible), as well as

- 1 parameter input section

- 1 actual value display

The location of the windows may be adjusted to the requirements by the user.

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3.4 DIAGNOSIS / FAULT INDICATIONS

Faults can occur in the load circuit and in the Power Controller itself. Often, the sequence of fault

indications or events is decisive for a positive diagnosis. Diagnosis of unexpected operating behavi-

our is performed by LEDs on the front panel of the control device, with parameter comparison

(whereby the modiﬁed parameters may be listed), as well as by reading from the Thyro-P fault

memory (data log). In Thyro-P, faults occurring and indications are entered in the fault memory with

the event time and are preserved in case of mains outage as well. Up to 16 entries are possible.

If further entries are made, then the ﬁrst entry is overwritten. Therefore, the most current 16 events

may be recalled at any time. Should faults or incidents occur, the selected operation display on the

LBA will show status indications.

The indication is of the format

yyyymmdd hhmmss [ fault ] [ value ]

The status line only appears in the operation display (see ﬁg. 7).

When using Thyro-Tool Familiy and an active line diagram, for any faults occuring their respective

indications are displayed in a window and stored on disk associated with the line diagram.

Using an optional bus interfecace (e.g. Proﬁbus DP, a corresponding indication is automatically

issued.

The status indications (faults, warnings, messages) generated by Thyro-P may, as already menti-

oned, be classiﬁed as load and as Power Controller faults. Depending on the application, warnings

or status messages may be read.

Data log

yyyymmdd hhmmss

[ fault no. ] [ limiting value ]

All indications may be switched to the data log and the relays deviating from default settings.

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EVENT NO.

PRESET

LOG

STATUS MESSAGE

RELAY

Communication RS 232 interface active

Communication ﬁbre optic interface active

Negative power (calculated value)

Communication fault RS 232 or ﬁbre optic interface

Synchronous interface fault (for instance Proﬁbus)

External processor on the SSC signals fault

after RESET - monoﬂop function

Controller lock is active

Data in the EEPROM invalid

(then reload Thyro-P parameter memory using

Thyro-Tool Familiy)

Internal message

Limiting exceeded

Device overtemperature

Quick circuit interruption has responded

Internal message

Failure in load circuit, collective failure

Undercurrent in load circuit, when activated

Overcurrent in load circuit, when activated

Internal message

DaLo

Indication appears on return of supply

Undervoltage in the power section

Overvoltage in the power section

Internal message

Synchronization fault

Collective fault

(each fault leads to switching of the output)

Internal message

For the operating mode MOSI:

Power Controller has run into peak current limitation

Temperature sensor, short circuit or sensor break

TAB. 10 ALLOCATION OF THE MESSAGE REGISTER

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4. EXTERNAL CONNECTIONS

This chapter describes external connections of the Thyro-P as well as all available terminal strips

and signals as necessary. Shielded cables grounded on the Thyro-P side must be used for the con-

nection of the control signals (setpoint inputs and analogue outputs). For the connections to RESET,

Controller lock and QUIT, twisted cables must be used.

Bus interfaces can be found in chapter 5 INTERFACES. To operate the Thyro-P at least the following

signals described up to chapter 4.5 QUIT must be connected.

4.1 POWER SUPPLY FOR THYRO-P

In the case of types 400V and 500V, connecting the regulator to the power supply also connects the

control device Thyro-P to the power supply (see also chapter POWER SUPPLY FOR THE CONTROL

DEVICE A70). The control device for 690V types must be supplied separately.

Details on connecting power supply can be taken from the chapters TECHNICAL DATA and con-

necting diagrams. This particularly applies when using the control device in UL applications.

4.2 POWER SUPPLY FOR THE CONTROL DEVICE A7

The Thyristor Power Controller Thyro-P is ﬁtted with a wide-band power supply. The mains connec-

tion is designed for input voltages from 230V -20% to 500V +10% and nominal frequencies from

45Hz to 65Hz. The power consumption is max. 30W. Depending on the switch mode power supply,

a 100VA control transformer must be used.

For the type ranges 400V (230-400V) and 500V nominal mains voltage, the control device is sup-

plied directly from the power section. It is therefore a unit ready to connect.

STRIP TERMINAL X1

mains supply connected internally

phase

N or phase

TAB. 11 STRIP TERMINAL X1

REMARK

If required, e.g. when operating with Proﬁbus, the control device can also be supplied separately.

With supply voltages outside the nominal range the control device must be supplied separately

with an input voltage within the above-mentioned voltage range. The phase position of this control

voltage is optional. In this case the plug (A70/X1) must be pulled.

CAUTION

The pulled plug has mains voltage of the load circuit! The new connecting lines must be fused

according to the applicable regulations (plug see chapter 12).

4.3 POWER SUPPLY FOR THE VENTILATOR

With Thyro-P Thyristor Power Controllers furnished with integrated ventilators (HF types), the venti-

lator must be supplied with a voltage of 230V 50/60Hz according to the connecting plans and the

dimensional drawings. The ventilator’s power consumption is given in chapter 10, Technical Data.

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ATTENTION

The ventilator must run when the Power Controller is switched on.

4.4 RESET

The input RESET (terminals X5.2.12-X5.1.14) is separated from the remaining system by an opto-

electronic coupler. By opening the RESET jumper the Thyristor Power Controller is locked (load:

24V/20mA), i.e. the power sections are no longer triggered. On activating RESET, LED “ON” lights

up red.

Functional procedure:

TERMINALS

FUNCTION

X5.12-14 closed

X5.12-14 open

Enables the power sections, Power Contr. in operation

Power Controller out of operation, communication via interfaces not

possible

X5.12-14

system reinitialisation

is closed

TAB. 12 RESET

The hardware RESET must be applied when synchronising the software of several Power Controllers

(chapter 6.2 Software synchronisation). If the Power Controller is equipped with a Bus option, a Bus

RESET also ensues from the hardware RESET. Apart from opening the jumper terminal X5.2.12-

X5.1.14, the hardware RESET is also activated by supply voltage OFF or by reducing the supply

voltage at the Power Controller (A70-X1) to below 160V.

4.4.1 SOFTWARE-RESET

The RESET function can be activated by signals via the status register (software RESET). The soft-

ware RESET does not inﬂuence the Bus function.

4.5 CONTROLLER LOCK

The input controller lock (terminals X5.2.15 and X5.1.14) is electrically identical to the input RESET

(electrical data as under 4.4.).

ATTENTION

When activating controller lock, the LED „PULSE LOCK“ is lit and the control device remains com-

pletely in operation. The total set point is therefore without effect, but the min. limiting values (TS-

MIN, HIME) remain active. This enables securing a certain quantity of electrical energy at the load.

TERMINALS

FUNCTION

X5.15-14 closed

X5.15-14 open

Power Controller operating

control pulses OFF (default value) or pulse limit

TAB. 13 CONTROLLER LOCK

All other functions of the Power Controller remain in operation. The state of the signalling relay

does not change (parameter-dependent) and communications remains active. After closing the

controller lock jumper, the controller is back in operation.

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4.6 QUIT

The input acknowledge (Quit, X5.2.19) has a circuit identical with the input RESET. It must be

short-circuited against ground (X5.1.14) so that any faults are acknowledged. The fault signalling

relay is reset. The input must remain closed for at least 2 line periods to perform acknowledgement.

After acknowledgement, the contactor must in turn be opened.

Function:

TERMINALS

FUNCTION

X5.19-14 open

controller operating

faults are reset

X5.19-14 closed*

* for at least 2 line periods

TAB. 14 QUIT

If the QUIT contact is reopened the Controller will reassume operation with its preset operating

and control modes as well as its set point and limiting values.

4.7 SET POINT VALUE INPUTS

The set point inputs are described in chapter 2.2. Set point control characteristic.

4.8 ASM INPUT

This input (analog voltage signal) serves to measure the total current signal of the external apparent

ohmic resistance. For further information refer to chapter ”ASM procedure“.

4.9 ANALOG OUTPUTS

The electrical values for current, voltage and power at the load as well as the set point are recorded

by the Power Controller Thyro-P and may be optionally displayed using an external instrument or

logged using a graph recorder.

For connection of external instruments, there are three actual value outputs (terminals X5.2.32,

X5.2.33, X5.2.34, against X5.1.13). The selectable signal levels are 0-10 volts, 0-20mA, 4-20mA or -

setting different parameters at a maximum compliance voltage of 10V. In case of active ASM proce-

dure, only two of these three analog outputs are freely available (terminal X5.2.32, X5.2.34).

Each output has its own D/A converter. By setting parameters, it is possible to adjust the outputs

to stored-program controls, measuring instruments, etc.

For instance, the following values may be output:

• currents, voltages or power of the individual phases, total power

• minimum or maximum values

• set points

• phase angles

The signals of the analog outputs are updated in each line (VAR) or TAKT period. Actual values

always relate to the previous period. In operation mode VAR at a net period (e.g. 50Hz:20ms) and

in operation mode TAKT at T0 (e.g. 1 sec.). Different factors (e.g. set point variations, load varia-

tions, limitings and the inﬂuence of operating modes with SSSD and MOSI) give the actual value

signals dynamic rations which can be smoothed with a smoothing stage. The MEAN (VALUE) para-

meter is applied here. The following setting is recommended: MEAN(VALUE) = 25.

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4.10 CURRENT TRANSFORMER

ATTENTION

By standard, each power section of the Power Controller has a current transformer. When using

external current transformers, for instance on the secondary side of a transformer, these must be

connected to the terminals X7.1 and X7.2 and terminated using a burden resistor! The burden

resistor must be designed so that at nominal current a voltage drop of 1.0Vrms occurs at the bur-

den resistance. For connection, take care to have the respective correct phase angle.

The internal current transformers may not be shunted, because the burden resistor R 40 is on the

control cards. If load current monitoring of the phase 2 (not controlled) is desired for Thyro-P 2P,

then an external current transformer and an external voltage transformer must be provided for

this purpose.

CURRENT TRANSFORMER

phase L1

TERMINAL X7.2

.11(k)

TERMINAL X7.1

.12(l)

phase L2

.21(k)

.22(l)

phase L3

.31(k)

.32(l)

TAB. 15 CURRENT TRANSFORMER

The following parameters must be checked or adjusted:

HARDWARE PARAMETER

current transformer

type current

xxxxx

xxx,xx

UE_I

I_TYP

burden resistance

R_BUERDE_I

LIMITATIONS

Irms maxI1

xxxx

A IEMA

REMARK

Current measuring in not-controlled phases

Thyro-P 2P

Although phase 2 is not controlled in Thyro-P 2P, it is possible to take measuring values during this

phase. A current transformer corresponding to T1 must be used and burdened (see type overview).

It is connected as in table 23 to X7.1.22 – X7.2.21.

Thyro-P 1P

As only phase 1 is controlled with Thyro-P 1P, the measuring systems of phase 2 and 3 can be used

freely. The corresponding current transformers (with max. 1V at nominal current) must be applied

and burdened. Connection is carried out as in table 23 to terminal strips X7.1.22 – X7.2.21 for

“phase 2”, and to X7.1.32 – X7.2.31 for “phase” 3.

The measuring values given do not inﬂuence the controller and are available for Bus interfaces,

display and analog outputs. Parameter values must not be changed.

4.11 VOLTAGE TRANSFORMER

As standard, each power section is ﬁtted with a voltage transformer for recording the load voltage.

It is possible to measure voltages of up to 690V. The voltage transformers are wired to the control

device A70 by the works.

LOAD VOLTAGE

phase L1

TERMINAL X7.2

TERMINAL X7.1

.15

.25

.35

.16

.26

.36

phase L2

phase L3

TAB. 16 VOLTAGE TRANSFORMER

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In case of the Power Controller type 2P, the voltage transformers output the voltages L1-L2 and

L3-L1. To achieve a good resolution of the voltage measurement, 3 measuring ranges are provided.

Selection of the ranges is performed by means of 4-pin bars, which have been set to the Power

Controller type voltage by the works. The pin bars are found on the control device A70 above the

terminal X7.

MAINS

SHORT CIRCUIT JUMPERS

MAX.

VOLTAGE

X501, X502, X503

MEASURING

253V

230V

1 - 2

2 - 3

3 - 4

400V

440V

500V respectively 690V

760V

TAB. 17 VOLTAGE MEASUREMENT JUMPER

If the jumpers are changed, then a change of parameters is required.

Hardware parameters

Type voltage

U eﬀ max

U_TYP

UEMA

X501-3,1-2,2-3,3-4

Mains voltage

TYP-BEREICH

U_NETZ_ANW

(Thyro-Tool Family)

REMARK

Voltage readings in not-controlled phases

Thyro-P 2P

Although phase 2 is not controlled with Thyro-P 2P, it is possible to take measuring values during

this phase. The voltage transformer suitable for standard rail assembly (order no. 2000000399) is

to be used. Connection is made as in table 21 to X7.1.26 – X7.2.25. The maximum induced voltage

of the transformer (incl. over-voltage) must be less than 50 volts.

Thyro-P 1P

As only phase 1 is controlled with Thyro-P 1P, the reading systems of phase 2 and 3 can be used

freely. The voltage transformer suitable for rail assembly (order no. 2000000399) is to be used.

Connection is made as in table 23 to terminals X7.1.26 – X7.2.25 for “phase 2” and X7.1.36 –

X7.2.35 for “phase 3”.

The measuring values do not inﬂuence the controller and are available for Bus interfaces, display

and analog outputs. Parameter values must not be changed.

4.12 OTHER CONNECTIONS AND TERMINAL STRIPS

ROOT*

X2.7

BREAK CONTACT CLOSER

Alarm relay K1

Limiting K2

Option K3

X2.8

X2.9

X2.10

X2.13

X2.11

X2.14

X2.12

X2.15

* tie point

TAB. 18 TERMINAL STRIP X2 FOR K1, K2, K3

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TERMINAL STRIP X5 IN THE CONTROL DEVICE

X5.1

FUNCTION

+5V

X5.2

FUNCTION

+5V

ground 5V

-15V

set point 1

set point 2

analog output 1

analog output 2

analog output 3

ASM input

GSE connection

RESET

ground 24V

+24V*

controller lock

SYT9 connection

QUIT

+24V*

* Loading: I_X5.1.20+ I_X5.2.20+ I_X21.9ͨ max. 80mA

TAB. 19 TERMINAL STRIP X5

Terminal strip X6 in the control device

At the terminal strip X6, wiring between the control device A70 and the control cards A1, A3 and

A5 of the power section is performed by the works. Allocation of the terminal strip is as follows:

Name

thyristor L1 neg.

+5V

thyristor L1 pos.

thyristor L2 neg.

+5V

thyristor L2 pos.

thyristor L3 neg.

+5V

thyristor L3 pos.

input temperature sensor

ground temperature sensor

TAB. 20 TERMINAL STRIP X6

Each thyristor is controlled by 20mA current supply switching to ground.

The ventilator monitor is connected to the terminals X6.41 and X6.42 in separately ventilated

devices (..HF). The temperature of the power section is monitored using a PT 1000 temperature

sensor. In case of overheating of the power section, for instance caused by outage of the ventilator,

a fault indication is generated and the alarm relay is activated (default values). The temperature

may be enquired by the interfaces.

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4.13 SYNCHRONIZATION

By standard, each power section is ﬁtted with a transformer for an input voltage of up to 690V.

After ﬁltering, the synchronization signal for control of the thyristors is generated from the secondary

voltage. The connections are wired by the works. This includes the following terminals:

TERMINAL STRIP X7

X7.1

X7.2

NAME

current transformer phase L1

sync phase L1

load voltage phase L1

current tranformer phase L2

sync phase L2

load voltage phase L2

current tranformer phase L3

sync phase L3

load voltage phase L3

TAB. 21 TERMINAL STRIP X7

For the synchronization the following jumpers are necessary on the componentry of the control

device.

THYRO-P

SHORT CIRCUIT JUMPER

X507

X508

TAB. 22 SYNCHRONIZATION JUMPER

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4.14 COMPONENT MOUNTING DIAGRAM CONTROL DEVICE

BR155

BR806

BR808

X700

X702

X706

X701

X707

X713

X603

+5V output

for poti, etc.

X509

setpoint 1 10

setpoint 2 11

analog output 1 32

analog output 2 33

analog output 3 34

M 5V setpoint 1 13

M 5V setpoint 2

X510

X201

X221

X222

GND 5V, 0-20mA, 10V 13

ASM input

GND 5V

-3,3V

GND 24V, open=blocked

M 24V

signal

pulse lock

controller lock

SYT 9

acknowledgement

+24V output

function

V261

V271

V281

R147

GND 24V, short circuit

+24V

application reference

X501

X502

X503

X7.1 (-)

X7.2 (+)

X 6

FIG. 10 FILE COMPONENT MOUNTING DIAGRAM CONTROL DEVICE

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5. INTERFACES

Necessary process optimization as well as the requirements made of high, continuous and docu-

mentable quality in production processes often require the use of digital process communications.

It allows interlinking of many signals and enables their evaluation in an efﬁcient manner.

FIG. 11 INTERFACES OF THYRO-P

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With the Power Controller Thyro-P, the following interfaces may be used for this (see also ﬁg. 11 on

previous page):

• X10, RS 232

• X30, ﬁbre optic receiver

• X31, ﬁbre optic transmitter

as well as optional interfaces, for instance

• X20, bus interface, e.g. for Proﬁbus DP

All internally processed data like current, voltage, power, set point value, limitations, etc. may be

enquired, processed and modiﬁed during operation (online operation) in master-slave process.

Under assistance of corresponding automation technology, it is possible to do without connection

of process controls, potentiometers, instruments, LBA, etc.

The existing interfaces may operated simultaneously, so that for instance the following system

conﬁguration would be possible: a stored-program control via Proﬁbus supplies the set points,

a PC visualizes (ﬁbre optic interface/Thyro-Tool Familiy) the data and on location the device status

and selected operating values are displayed via LBA (using the RS 232).

Therefore, the Power Controller Thyro-P is transparent to all levels of production and the process

may therefore be securely handled.

5.1 RS 232 INTERFACE

The isolated RS 232 interface is provided for direct connection of an LBA (with cabinet installation

kit also indirect via cable) or a PC. Setting of parameters of the interface is performed using Thyro-

Tool Familiy or LBA. The default baud rate is set to 9600 baud, no parity, 8 data bits, 1 stop bit.

The following illustration shows connection of a Thyro-P to a PC using the RS 232 interface (also

possible via ﬁbre optic or Proﬁbus).

RS 232

COM 1

COM 2

FIG. 12 CONNECTION OF A PC TO

THYRO-P VIA RS 232

For connecting the PC, an RS 232 cable is required. On the Thyro-P side, a 9-pin sub-D plug and on

the PC side a 9-pin sub-D socket must be available.

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The connecting socket X10 of the Power Controller is allocated as follows (1:1 connection):

FIG. 13 X10-ALLOCATION

ATTENTION

The LBA receives its power supply (+5V) via pin 8 of the socket X10. It is imperative that this voltage

is not short-circuited. Otherwise, damage to Thyro-P may be incurred.

If a PC is connected to the RS 232 interface, then this pin should be left unconnected, since it is not

needed for data transfer.

Generally, all devices with an RS 232 interface may communicate with Thyro-P. The protocol used

may simply be created by the user himself.

For this purpose, a detailed description of the protocol used may be requested from AEG PS (refer

to application document).

5.2 FIBRE OPTIC INTERFACE

This widely used interface (LL, X30 LLE blue, X31 LLS grey) for quick and secure data transfer is

ﬁtted to Thyro-P as standard and enables connection of up to 998 Thyro-P Power Controllers. Due

to the good interference immunity, larger distances can be bridged and data can be transferred at

higher speeds.

To install a ﬁbre optic system, the following interface components can be used.

5.2.1 FIBRE OPTIC DISTRIBUTION SYSTEM

Using the components described below, a complete ﬁbre optic system for connection of up to 998

Thyro-P may be created.

SIGNAL CONVERTER RS 232 / FIBRE OPTIC

Connection of the ﬁbre optic to the PC interface (RS 232) is performed using the ﬁbre optic / RS 232

signal converter shown below. Power supply is via the plug-in power supply enclosed.

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to the plug-in power supply

fibre optic transmitter (LLS) X30

fibre optic receiver (LLE) X31

FIG. 14 SIGNAL CONVERTER RS 232/FIBRE OPTIC

LLV.V

The ﬁbre optic distributor supply LLV.V is the basic component for the ﬁbre optic system. It serves

to connect star distributors and to amplify the light signals received. Its power supply is sufﬁcient

for supply of ﬁve ﬁbre optic distribution components of the type LLV.4.

The ampliﬁcation of LLV.V in the ﬁbre optic data path is sufﬁcient for increasing the distance for

each LLV.V by about 50 m, so that overall longer transmission paths are possible then.

LLV.4

The ﬁbre optic distributor LLV.4 is connected to the base component LLV.V. It is able to distribute

the optical signal to respectively receive from four connections and therefore multiplies the signal

from the computer to Thyro-P by four units each. The maximum distance from LLV.4 to Thyro-P

should not exceed about 25 m.

In case of optimum installation conditions (number of bends, connection mounting, etc.), the dis-

tances stated in the following table may be realized:

DEVICE PC

LLV.V

50 m

25 m

LLV.4

– –

THYRO-P

25 m

– –

LLV.V

LLV.4

50 m

– –

Thyro-P 25 m

25 m

TAB. 23 FIBRE OPTIC DISTANCES

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The following ﬁgure shows the ﬁbre optic system with LLV, Thyro-P and PC.

FIG. 15 SCHEMATIC DIAGRAM FIBRE OPTIC THYRO-P WITH LLV AND PC

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5.3 BUS INTERFACES (OPTION)

The control device of Thyro-P may be optionally ﬁtted with interface cards for interfaces customary

for the industry. In case of bus systems not listed, please enquire about availability.

5.3.1 PROFIBUS-DPV1

With a Proﬁbus interface card (order no. 2000000393) it is possible to connect the Thyro-P to a

wide ranging Bus system. For use of Thyro-P in an automation network with SIEMENS PCS7,

software modules are available (at SIEMENS).

The Proﬁbus slot card is plugged into the front of the control device and is immediately ready to

operate after parametrization. In case of Proﬁbus control, the control device should be supplied

separately, so that should the power supply be switched off, the Power Controller is not interrupted

resulting in an alarm message. The connector supplied must be removed (see chapter 4.2).

Three 24V inputs are additionally available, which may be polled via Proﬁbus (for instance for swit-

ching state, power interruptor, monitoring the cabinet ventilator, monitoring the cabinet door, etc.).

The Proﬁbus option includes

• 1 Proﬁbus slot card

• 1 diskette for conﬁguration of Thyro-P as Proﬁbus slave,

• 1 covering frame for secure ﬁxing of the slot card,

• 1 short instruction booklet

ATTENTION

The mounting of the option must be made in voltageless state.

GENERAL

Up to 125 slaves may be connected to a Proﬁbus system. 32 slaves are possible for each Proﬁbus

segment. Coupling of individual segments is performed using so-called repeaters. Proﬁbus systems

may be organized as line, bus or tree structures. Besides the usual electrical connections (RS 485

technology), it is possible, for instance in highly interfering environment (magnetic ﬁelds, etc.) to

use ﬁbre optic as transmitting medium.

The line length depends on the respective transmission rate and is possible up to 1200m (also refer

to the table).

Baud rate [kbits/s]

Line length [m]

9.6

19.2

45.45

1200

93.75

1200

187.5

1000

500

400

1500

200

1200

TAB. 24 PROFIBUS BAUD RATES

PROFIBUS SLOT CARD

The Proﬁbus slot card (about 86 x 70 mm) has two 9-pin SUB-D sockets on the front side. On the

other side, there is a 9-pin SUB-D plug to be inserted into the Thyro-P control device. The Proﬁbus

slot card for instance contains driver circuits, galvanic separation for the bus circuit as well as a

microcontroller for controlling bus access and other functions.

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X21

4 inputs for

Profibus

LED

X24

X20

connection

Thyro-P

Profibus

connection

FIG. 16 PROFIBUS SLOT CARD

After switching on Thyro-P, it will automatically detect the Proﬁbus slot card. On the Thyro-P side,

the device address must be set using the LBA or Thyro-Tool Familiy.

After conﬁguration of the Proﬁbus, Thyro-P is ready for operation on the Proﬁbus.

CONNECTION TO THE PROFIBUS

The Proﬁbus is connected to the 9-pin SUB-D socket X20. The usual plug (see table) or an OLP

module (ﬁbre optic) may be used for this.

The following plugs are recommended

ORDER NO.

DESCRIPTION:

(SIEMENS)

6ES7 972-0BA40-0XA0

6ES7 972-0BA30-0XA0

35° cable outlet including terminating resistors

30° cable outlet without terminating resistors

For connection of the OLP modules (Proﬁbus via ﬁbre optic), a 5V power supply voltage is provided

on the Proﬁbus socket X20, pin 6. This bears a load of at max. 80mA.

TERMINATING RESISTORS

Within a Proﬁbus segment, terminating resistors must be switched in the ﬁrst and the last device.

Because the Proﬁbus slot card does not have internal terminating resistors, plugs containing inte-

grated terminating resistors must be used and these must be switched on, if the ﬁrst or last device

is a Thyro-P!

REMARK

FAILURE OF THYRO-P OR PROFIBUS

If the Proﬁbus fails during operation of Thyro-P, set points or actual values cease to be transmitted.

Thyro-P continues to operate using the last current set point. If the Thyro-P fails as Proﬁbus slave,

then this fault is signaled on the Proﬁbus system. If the RESET function on Thyro-P is activated,

there will also be a RESET period the Bus function is interrupted.

Additional digital inputs

On the 9-pin SUB-D plug X21, the Proﬁbus slot card has four digital inputs which are mapped to

the 1st data byte of the reply from Thyro-P.

Pin assignment of the plug is as follows:

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X21

ASSIGNMENT

PE (potential earthing)

ground M1

input 0/M1

input 1/M1

ground M24

ground M2

input 2/M2

input 3/M2

+24V

/ 24V supply for the Proﬁbus card

/ special function = Motorpoti enable

/ 24V supply for the Proﬁbus card

* Loading: I_X5.1.20+ I_X5.2.20+ I_X21.9≤ max. 80mA

TAB. 25 PIN ASSIGNMENT X21

The inputs 0 and 1 refer to ground M1, the inputs 2 and 3 refer to ground M2. To connect simple

transmitters like limit switches, etc., a 24V power supply is also available. The input IN3 (PIN 8) is

taken up by a special function.

Therefore, connection could for instance be as follows:

local: Switch closed

remote: Switch open

FIG. 17 SPECIAL FUNCTION MOTORPOTI

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If the special function Motorpoti is not applied, 3 free inputs of the Bus card are available.

Set out below are the most important features of the Proﬁbus option.

FIG. 18 SPECIAL INPUTS

DETAILS OF THE PROFIBUS

Further details for use of Thyro-P with Proﬁbus like

• organization of the messages

• parameter setting messages

(setting which data is to be cyclically transmitted)

• cyclical parameters (REAL data format)

• PKW interface, PNU table

• diagnostic indications

• GSD ﬁle

are described in a separate ﬁle on the Proﬁbus data media.

The user can choose between different conﬁgurations and establish, for instance, the number of

actual values etc. within them.

HARDWARE CHARACTERISTICS

The Proﬁbus card has the following characteristics:

• transmission speeds of 9600 Baud up to 12 MBaud

• RS 485 galvanically separated up to 140V

• optional ﬁbre optic interface

• 5V power supply, pin 6 max. 80mA

• 3 additional inputs

• 24V stored-program controller compatible

• current consumption <20mA

• galvanically separated (140V)

IDENTIFICATION NO.

A Thyro-P with Proﬁbus slot card corresponds to a Proﬁbus device according to EN 50170.

Ident no.:

06B4

Associated GSD-ﬁle:

PSS106B4.GSD

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5.3.2 MODBUS RTU

With the Modbus interface component a connection is possible between Thyro-P and the wide-

spread Modbus RTU. The slot card is inserted into the front of the control device and is ready for

operation after parameterization. The control device must be supplied separately so that should

the power supply be switched off, the Power Controller is not interrupted resulting in an alarm

message (see chapter 4.2).

As shown in both previous ﬁgures, Modbus RTU can also use either the special function Motorpoti

or three available digital inputs (24V DC).

Using commercial gateways it is possible to interconnect to various ﬁeld buses as well as Ethernet

systems with TCP/IP protocol.

Further information can be obtained from the operating instructions of the Modbus option.

FIG. 19 MODBUS SLOT CARD

5.3.3 DEVICENET

With the DeviceNet interface component (order no. 2.000.000.394) a connection is possible bet-

ween Thyro-P and the wide ranging bus system. The slot card is inserted into the front of the con-

trol device and is ready for operation after parameterization. The control device must be supplied

separately so if the power supply is switched off, the power controller is not interrupted resulting in

an alarm message (see chapter 4.2).

DeviceNet can also use either the special function motor potentiometer or three available digital

inputs (24 V DC).

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6. MAINS LOAD OPTIMIZATION

Mains load optimization (option) is possible in multiple controller applications. The application of

mains load optimization offers substantial advantages: reduction of mains load peaks and mains

reactions, smaller sizes (for instance for the transformer, feed and other installations) and associated

smaller operating and investment cost. Mains load optimization is possible in a dynamic (ASM

process) and a static (SYT-9 process) mode. Both modes may also be used in combination with the

Thyristor Power Controller Thyro-M.

6.1 SYT-9 PROCEDURE

A process for static mains load optimization: minimizes mains load peaks and associated mains

reaction shares. For the SYT-9 process, set points and load changes are not automatically included

in mains load optimization.

The SYT-9 process requires an additional component. For Thyro-P, it should only be employed in

connection with already installed controllers (Thyro-M, Thyrotakt MTL) under SYT-9 process.

Then, the pulse of the SYT card must be connected to the terminal X5.1:18 and ground to X5.1:14.

On the Thyro-P Power Controller, the jumper X201 (behind X5) must be pulled off. For this purpose,

the texts BAL 00180 and operating instructions SYT-9 must be observed as described under Thyro-M.

THYRO-P

SYT9 NO. 1

THYRO-P

SYT9 NO. 1

NO.

X5.2.5 - A10

X5.2.18 - C10

A12

A14

A16

A18

A20

A22

A24

A26

C12

C14

C16

C18

C20

C22

C24

C26

Connection of up to 9 Thyro-P at one SYT9-Module

6.2 SOFTWARE SYNCHRONIZATION

By means of different settings in the storage location SYNC_Adresse, a different startup of the

individual Power Controllers (counter x 10ms) may be achieved. The counter is set to 0 after

switching on the mains or RESET. While the counter is running, the Power Controller is switched

passive, as during controller lock.

It is possible to enter values in SYNC_Adresse larger than the clock time T0. Then, startup of the

Power Controller is only during the next clock time. For instance, in an emergency power plant,

slow switching of the total load is possible. The max. delay is 65535 x 10ms. This value also forms

the base setting for the ASM process.

6.3 ASM PROCEDURE (PATENTED)

In systems, in which several equal Power Controllers are operated in the operating mode TAKT, the

ASM process may be sensibly used for dynamic and automatic mains load optimization in multiple

Power Controller applications. This patented world premiere independently minimizes mains load

peaks and therefore mains reaction shares during the current process. In case of the ASM process

(automated synchronization of multiple controller applications), changes in set point and load (for

instance due to temperature-dependent load) are included in mains load optimization online. Espe-

cially when using heating elements with a large aging effect, which during new operation have high

current amplitudes with short startup time, lower investment cost may be achieved. For the ASM

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process the controller requires an ASM control device. An additional burden resistor is used for all

controllers. Schematic wiring of Power Controllers for the ASM process can be seen in the following

illustration:

Power

Controller 1

Controller 2

0-20mA

X5.2.16

X5.2.33

twisted/shielded

U_burden

X5.1.13

U_burden= ( I₁+...+ I_n) x R_burden

U_burden= 0 -10 volts

total burden

FIG. 20 ASM WIRING

When using the ASM option, the analog output 2 (X5.2.33 against ground X5.1.13) becomes an

output proportionate to the current during the on-period T_S. All Power Controllers connected to

synchronization work on the same external burden. The burden resistor is calculated approximately

R_burden[k⍀] = 10V / (n x 20mA)

n = number of Power Controller

The burden voltage is measured at the ASM input. The Power Controller searches within the clock

control the place with the lowest mains load.

Due to this automated, independent procedure, the process chain is ensured through the tempe-

rature control circuit and the Power Controller without effects; negative effects like ﬂicker and sub-

harmonics of the mains frequency are balanced out during a current dynamic process. In this case,

unfavorableshort-term overlapping may occur, for instance after set point jumps or voltage swing.

The application document ASM-procedure gives further information on this.

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7. CONNECTING DIAGRAMS

7.1 1-PHASE

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7.2 2-PHASE

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7.3 3-PHASE

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8. SPECIAL REMARKS

8.1 INSTALLATION

The installation orientation of Thyro-P is vertical, so that ventilation of the thyristors fastened to

heat sinks is ensured. In case of cabinet mounting, additionally sufﬁcient ventilation of the cabi-

net must be ensured. The distance between Power Controller and the bottom should be at least

100mm; the distance to the ceiling 150mm. The devices may be installed next to each other with-

out lateral distance. Heating up of the device by heat sources must be avoided. The dissipation of

the Power Controller is stated in the table chapter type overview.

Grounding must be performed according to local regulations of the utility company (grounding

screw for protective conductor connection).

8.2 COMMISSIONING

The device must be connected to the mains and the associated load according to the wiring

diagrams.

REMARK

It must be observed that with 1P, terminal A1 X1:3 is connected to the U2 on the opposite load

side. With 2P it must be observed that terminal A1 X1:3 is connected to the non-controlled phase.

Depending on connection system of the load (star, delta, etc.), it must be ensured that the load vol-

tage transformers in the power sections are wired correctly (terminal strip X1 of the power section).

The correct terminals may be found in the connecting diagrams.

If the units 1P and 2P are operated at over 600 V and without load at the output side, voltages can

occur above input voltage at the connection points U2 and W2. In this case, an additional 690 V

damping card is to be used. (Section 12, Accessories and Options)

On delivery, the device is parameterized adjusted to the respective power section. The operating

mode TAKT is set. If a different operating mode is desired, then the user must set this using the

LBA, PC, etc. Generally, the standard parameters (see menu list) should be reviewed and adjusted

to the respective conditions for use by the user (for instance operating mode, control mode, limi-

tations, monitoring, times, characteristics, actual value outputs, fault indications, relays, time and

date, etc.).

Besides the load, some control signals must be connected as well (refer to chapter 4). The following

signals are always required for operation of the device:

Set point

(terminal 10 or 11/or via interfaces)

RESET

(on ground, on terminal 12, jumper set as standard)

(on ground, on terminal 15, jumper set as standard)

Regular inhibit

If the RESET is not connected, then the device is in reset state and is not operating (LED „ON“

shows red light), i.e. no communications is possible via interface. Further details of the RESET are

described in chapter 4.4. If the regulator inhibit is not connected, then the device is fully operable,

but the power section is only controlled using the values of the minimal limitations (LED „PULSE

LOCK“ is on). Further details on the regulator inhibit may be found in the chapter 4.5 of the same

name.

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ATTENTION

The controller lock may also be set via the interfaces!

ATTENTION

The control device is to be operated only with casing.

8.3 SERVICE

The devices delivered have been tested according to the state of the art and have been produced

to a high quality standard (DIN EN ISO 9001). Still, should any faults or problems occur, our 24 hour

service hotline, Tel.: +49 (0) 2902/763-100 is available to you.

8.4 CHECKLIST

No frontside LED is on:

• for 690V devices, the power supply for the control device A70 to be provided by the customer is

missing. (Attention, maximum nominal input voltage 500V)

• check voltage at terminal X1.1 and X1.2 of the control device A70

• check semiconductor fuse and the fuses F2 and F3 on the controller card A1.

CAUTION

In any case, set the device voltageless and check if it is voltageless

Terminal X1.3 on the controller card A1 not connected.

• if the semiconductor fuse is defective, then the following parameters must be checked in case of

transformer load for the operating modes TAKT and SSSD:

phase angle of the ﬁrst half-wave (phase angle 1) = 60 degrees;

possibly optimize. Check for the model type 1P, 2P or 3P

Menu: Parameters/Operating mode/Number of phases controlled 1 2 3)

No load current

• RESET X5.2.12 is not jumpered for X5.1.14 (LED ON lit in red)

• supply voltage of the control device outside of the tolerable range

• controller lock X5.2.15 is not jumpered for X5.1.14 (LED PULSE LOCK is on)

• no set point is set. Using the LBA, check the total set point (effective total), or measure set point

on X5.2.10 and X5.2.11.

• set points are not cleared (STD, Local, Remote, ANA)

• parameterization of the set point inputs 20mA, 5V, 10V, does not matched to output of the

temperature controller

• parameters STA and STE of the control characteristic are wrong

• parameter for linkage of the set points is not set to ”ADD“

• parameters IEMA, UEMA, PMA are set too small

• controller parameters T_iand K_pare set too large.

CAUTION

Check fuses on the controller cards A1, A3, A5. In any case, set the device voltageless and check if

it is voltageless.

• Load connection by the customer is missing (only for type 1P).

Check connection on A1 terminal X1.3.

• Check synchronization voltage at the control device A70 at the terminal blocks X7.1 and X7.2.

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The thyristors are set to full scale

• Was the set point set via motor potentiometer function? Check value using the LBA.

• Check the control characteric (STA, STE, ADD).

• Controller feedback signal available? Check current transformer and voltage transformer

connections at the terminal blocks X7.1 and X7.2.

• Parameters TSMI and H_IE, U_{rms min}, I_{rms min}, P_minare larger than 0.

• Controller parameters Ti and Kp are set too small.

• Parameters IEMA, UEMA, PMA are set too large or the load current is too small.

• Possibly thyristor short-circuit

REMARK

In case the load current is too small (connection of a test load), the device must be parameterized

for U, U²control or ”without control“. The regulation limits continue to remain active. Connection

of a minimal load (e.g. 100W lightbulb) is necessary.

Measures in case of other malfunction

• Evaluation of incident register (data logger) with LBA or Thyro-Tool

• Comparison of actual parameters of Thyro-P with parameters in type list.

• Comparison of actual parameters of Thyro-P with the system dependent parameters stored in the

PC.

• Correct number of controlled phases ((parameters)

• With activated trouble signal relay Evaluation which faults led to a response, eliminate the fault.

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9. TYPE OVERVIEW

9.1 TYPE RANGE 400 VOLTS

TYPE VOLTAGE 230-400 VOLTS

TYPE

TYPE POWER

(KVA)

DISSIPA- DIMENSIONS

WEIGHT DIM.

TEMP.

CURRENT BURDEN

SEMICON-

CURRENT

(A)

TION

(W)

(MM)

(NET ABOUT DRAW. CHARACTE- TRANSF.

RESISTOR DUCTOR FUSE*

230V

400V

KG)

(NO.)

RISTIC (NO.) T1

R40 (Ω)

F1 (A)

508

THYRO-P 1P

37 H

105

150 320 229

200 320 229

200 370 229

174 414 340

240 685 505

521 577 445

603 577 470

260

100/1

2.70

1.30

0.91

1.10

1.00

0.91

1.00

75 H

130

175

100/1

150/1

200/1

300/1

500/1

700/1

1000/1

1500/1

2000/1

3000/1

100

180

110 H

130 H

190

263

200

170 H

220

315

280 HF

495 HF

650 HF

1000 HF

1500 HF

2100 HF

2900 HF

112

198

260

400

600

840

365

265

266

350

114

149

230

345

483

595

630

750

900

1450

1775

2600

3400

268

2x1000

4x900

4x1000

4x1500

270

271

667 1160

THYRO-P 2P

37 H

175

220

225 320 229

325 320 229

325 397 229

261 414 340

410 685 505

526 837 445

272

275

100/1

150/1

200/1

300/1

500/1

700/1

1000/1

1500/1

2000/1

3000/1

2.70

1.30

0.91

1.10

1.00

100

75 H

110 H

310

180

130 H

350

200

170 H

118

194

343

450

693

410

315

280 HF

495 HF

650 HF

1000 HF

1500 HF

2000 HF

2750 HF

111

197

259

398

700

277

278

350

1150

1465

2865

3510

4800

6200

630

900

280

2x1000

4x900

4x1000

4x1500

597 1039

796 1385

1095 1905

282

283

603 837 470 107

THYRO-P 3P

37 H

330

400

300 320 229

450 320 229

450 397 229

348 430 340

575 685 505

284

287

100/1

150/1

200/1

300/1

500/1

700/1

1000/1

1500/1

2000/1

3000/1

2.70

1.30

0.91

1.10

1.00

1.10

100

75 H

110 H

540

180

130 H

560

200

170 H

118

194

343

450

693

650

315

280 HF

495 HF

650 HF

1000 HF

1500 HF

1850 HF

2600 HF

111

197

259

398

1070

1800

2265

4370

5335

6900

8700

289

290

350

630

900

292

2x1000

4x900

4x1000

4x1500

597 1039

736 1281

1035 1801

526 1094 445 119

603 1094 470 152

294

295

* number of fuses per path of power section, built in

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9.2 TYPE RANGE 500 VOLTS

TYPE VOLTAGE 500 VOLTS

TYPE

TYPE POWER

(KVA)

DISSIPA- DIMENSIONS

WEIGHT DIM.

TEMP.

CURRENT BURDEN

SEMICON-

CURRENT

(A)

TION

(W)

(MM)

(NET ABOUT DRAW. CHARACTE- TRANSF.

RESISTOR DUCTOR FUSE*

KG)

(NO.)

RISTIC (NO.) T1

R40 (Ω)

F1 (A)

508

THYRO-P 1P

37 H

105

130

150 320 229

200 320 229

200 370 229

174 414 340

240 685 505

521 577 445

603 577 470

260

100/1

2.70

1.30

0.91

1.10

1.00

0.91

1.00

75 H

100/1

150/1

200/1

300/1

500/1

700/1

1000/1

1500/1

2000/1

3000/1

100

180

110 H

175

130 H

190

263

200

170 H

220

315

280 HF

495 HF

650 HF

1000 HF

1500 HF

2100 HF

2900 HF

140

248

325

500

750

1050

1450

365

265

266

350

595

630

750

900

1450

1775

2600

3400

268

2x1000

4x900

4x1000

4x1500

270

271

THYRO-P 2P

37 H

175

220

225 320 229

325 320 229

325 397 229

261 414 340

410 685 505

526 837 445

272

275

100/1

150/1

200/1

300/1

500/1

700/1

1000/1

1500/1

2000/1

3000/1

2.70

1.30

0.91

1.10

1.00

100

75 H

110 H

310

180

130 H

112

147

242

429

563

866

1300

1732

2381

350

200

170 H

410

315

280 HF

495 HF

650 HF

1000 HF

1500 HF

2000 HF

2750 HF

700

277

278

350

1150

1465

2865

3510

4800

6200

630

900

280

2x1000

4x900

4x1000

4x1500

282

283

603 837 470 107

THYRO-P 3P

37 H

330

400

300 320 229

450 320 229

450 397 229

348 430 340

575 685 505

284

287

100/1

150/1

200/1

300/1

500/1

700/1

1000/1

1500/1

2000/1

3000/1

2.70

1.30

0.91

1.10

1.00

1.10

100

75 H

110 H

540

180

130 H

112

147

242

429

563

866

1300

1602

2251

560

200

170 H

650

315

280 HF

495 HF

650 HF

1000 HF

1500 HF

1850 HF

2600 HF

1070

1800

2265

4370

5335

6900

8700

289

290

350

630

900

292

2x1000

4x900

4x1000

4x1500

526 1094 445 119

603 1094 470 152

294

295

* number of fuses per path of power section, built in

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9.3 TYPE RANGE 690 VOLT

TYPE VOLTAGE 690 VOLTS

TYPE

TYPE POWER

(KVA)

DISSIPA- DIMENSIONS

WEIGHT DIM.

TEMP.

CURRENT BURDEN

SEMICON-

CURRENT

(A)

TION

(W)

(MM)

(NET ABOUT DRAW. CHARACTE- TRANSF.

RESISTOR DUCTOR FUSE*

KG)

(NO.)

RISTIC (NO.) T1

R40 (Ω)

F1 (A)

THYRO-P 1P

80 H

138

125

260

200 320 229

200 370 229

174 414 340

240 685 505

521 577 445

603 577 470

263

265

266

268

100/1

1.20

1.00

1.20

1.00

1.10

100

200 HF

300 HF

500 HF

780 HF

1400 HF

2000 HF

2600 HF

200/1

300/1

250

350

207

360

345

625

500/1

630

538

910

1000/1

1500/1

2000/1

3000/1

2x630

4x700

4x900

4x1400

966

1900

3200

3450

1380

1794

270

271

THYRO-P 2P

80 H

239

225

485

325 320 229

325 397 229

261 414 340

410 685 505

526 837 445

275

277

278

280

100/1

200/1

1.20

1.00

1.20

1.00

1.20

100

250

200 HF

300 HF

358

640

300/1

350

500 HF

597

1225

1700

3750

5700

6400

500/1

630

780 HF

932

1000/1

1500/1

2000/1

3000/1

2x630

4x700

4x900

4x1400

1400 HF

1850 HF

2400 HF

1673

2210

2868

282

283

603 837 470 107

THYRO-P 3P

80 H

239

350

740

450 320 229

450 397 229

348 430 340

575 685 505

287

289

290

292

100/1

200/1

1.20

1.00

1.20

1.00

1.10

1.30

100

250

200 HF

300 HF

358

1020

1825

2740

5600

8000

9000

300/1

350

500 HF

597

500/1

630

780 HF

932

1000/1

1500/1

2000/1

3000/1

2x630

4x700

4x900

4x1400

1400 HF

1700 HF

2200 HF

1673

2031

2619

526 1094 445 119

603 1094 470 152

294

295

* number of fuses per path of power section, built in

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10. SPECIFICATIONS

TYPE VOLTAGE

...P400...

...P500...

...P690...

230 volts -20%

500 volts -20%

400 volts +10%

500 volts +10%

690 volts +10%

MAINS FREQUENCY

LOAD DESCRIPTION

all models

45Hz to 65Hz

ohmic load (minimum 100W)

ohmic load R_hot/R_coldratio up to 20 (MOSI operation)

transformer load

TRANSFORMER

The induction of the load side transformer should not exceed

1.45T in case of mains overvoltage when using grain-oriented,

cold-rolled plates. This corresponds to a nominal induction of

approx. 1.3T.

OPERATING MODES

TAKT = full oscillation clock principle = default setting for the

models 1P, 2P and 3P

VAR = phase-angle control = only for the models 1P and 3P

SSSD = soft-start-soft-down; a combination of

„VAR“ und „TAKT“, for the models 1P, 2P and 3P,

i.e. reduced mains surge load

SET POINT INPUTS

The Power Controller Thyro-P has 4 set point inputs.

The set point inputs are indirectly connected to the mains

(SELV, PELV).

Set points 1, 2: external set point input

signal ranges:

0(4) - 20 mA Ri about 250⍀ max. 24mA*

Ri about 8,8k⍀ max. 12V

Ri about 5k⍀ max. 12V

10 V

* refer to ”ATTENTION” on page 16

Set point 3: connection for ﬁbre optic (LL) from the wuper-

ordinate PC or automation system

Set point 4: set point assignment via RS 232 (for instance LBA)

The four set points are added internally and the total of the

set points, for instance for power control, is proportionate to

output power. For set point 2, there are different valuation

options: it may be added to set point 1 or subtracted from set

point 1.

ANALOG OUTPUTS

3 outputs: signal level 0-10 volts, 0-20mA or parameters may be

set differently. The maximum burden voltage is 10V

The control characteristic is established by the maximum value

of the dimensions to be controlled and the key values of the

set point. Using these key values, the linear control characte-

ristic may be set at will.

CONTROL CHARACTERISTIC

Every controller (for instance temperature controller), whose

output signal is in the range of 0-20mA/0-5V/0-10V may be

easily adapted to the Power Controller.

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CONTROL TYPES

Voltage control U_rms

Voltage control U²_rms= default setting

Current control I_rms

Current control I²_rms

Power control P

Without control

PRECISION

U-control: Better than 0.5% and 1 digit with reference to

the end value.

LIMITATIONS

Voltage limitation U_rms

Current limitaion I_rms= default setting

Effective power limitation P

Peak current limitation, MOSI operation

Upon reaching one of these limits, the LED ”Limit“ on the

front panel of Thyro-P is on and the relay K2 is activated.

(terminal strip X2, terminals 10/11/12)

Relay K1, K2, K3

Contact load:

AC max:

AC min:

DC max:

DC min :

250V/6A (1500VA)

>10VA;

300V/0.25A (62.5W)

5V/20mA

contactor material: AgCdO

AC max: 250V/4A

WITH UL APPLICATIONS

AMBIENT TEMPERATURE

35°C external cooling (F models)

45°C self air cooling

At higher temperatures it is possible to operate with reduced

type current:

I/I_{RATED CURRENT}

COOLANT

TEMPERATURE

FORCED COOLING

SELF COOLING

[°C]

(VENTILATOR TYPES)

-10 bis 25

1.10

1.05

1.00

0.96

0.91

0.87

0.81

1.10

1.05

1.00

0.95

0.88

WITH UL APPLICATIONS UP TO +40°C

I/I_Rating

1.2

Coolant temperature

Self cooling

1.1

1.0

0.9

0.8

0.7

0.6

Forced cooling

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TABLE TERMINAL SCREWS

THYRO-P 1P, 2P, 3P

CONNECTOR

EARTHING SCREW

U1, V1, W1, U2, V2, W2

37H, 75H

M 6

M 8

M 6

M 8

M 10

80H

M 10

110H

130H, 170H

M 10

200HF, 280HF, 300HF

495HF, 500HF, 650HF

780HF, 1000HF, 1400HF,

1500HF, 1700HF, 1850HF,

2000HF, 2100HF, 2200HF,

2400HF, 2600HF, 2750HF,

2900HF

M 12

WITH UL APPLICATIONS

POWER CONNECTION

USE ONLY 60°/75°C COPPER CONDUCTORS (UL SPECIFICATION)

STUD TORQUE FOR

TABLE TERMINAL SCREWS

[Nm]

SCREW

MIN

0.2

RATED

0.25

4.4

MAX

5.9

3.0

22.5

11.5

22.0

38.0

17.0

33.0

56.0

M 10

M 12

75.0

[Pound inches]

SCREW

MIN

1.9

RATED

2.2

MAX

2.5

26.1

101.8

194.7

336.3

38.9

52.2

150.5

292.1

495.6

199.1

389.4

663.8

M 10

M 12

THYRO-P (HF-TYPES)

TYPE CURRENT

50HZ 60HZ

AIR VOLUME SOUND PRESS.

IN 1 M DIST.

VENTILATOR 230 V,

50-60 HZ

I [A]

[M³/H]

[DBA]

200HF, 280HF

0.22

0.50

0.55

1.00

0.22

0.38

0.60

1.20

120

150

300HF, 495HF, 500HF, 650HF

780HF, 1000HF, 1400HF, 1500HF

2000HF, 2100HF, 2600HF, 2900HF

580

2200

200HF, 280HF

0.50

1.00

0.38

1.20

200

230

300HF, 495HF, 500HF, 650HF

780HF, 1000HF, 1400HF, 1500HF

1850HF, 2000HF, 2400HF, 2750HF

1200

2100

200HF, 280HF

0.50

1.20

1.00

0.38

0.85

1.20

260

450

300HF, 495HF, 500HF, 650HF

780HF, 1000HF, 1400HF, 1500HF

1700HF, 1850HF, 2200HF, 2600HF

1600

2000

The ventilators (with HF types) must run with Thyro-P switched on.

Connection according to connecting diagrams.

Longer cooling fan start-up times can be expected when operating.

Thyro-P at temperatures below 10° C. Therefore the adjustment range of upstream protection

devices should be at least the 2-fold of the indicated steady current.

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11. DIMENSIONAL DRAWINGS

Thyro-P 1P (37 H, 75 H, 110 H)

Dimensional Drawing 260

M 1:5

Thyro-P 1P (80 H, 130 H, 170 H)

Dimensional Drawing 263

M 1:5

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Thyro-P 1P (200 HF, 280 HF)

Dimensional Drawing 265

M 1:5

495 HF

650 HF

300 HF

Thyro-P 1P (300 HF, 495 HF, 500 HF, 650 HF)

Dimensional Drawing 266

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780 HF

1000 HF - 1500 HF

Thyro-P 1P (780 HF, 1000 HF, 1400 HF, 1500 HF)

Dimensional Drawing 268

M 1:8

Thyro-P 1P (2000 HF, 2100 HF)

Dimensional Drawing 270

M 1:8

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Thyro-P 1P (2600 HF, 2900 HF)

Dimensional Drawing 271

M 1:8

Thyro-P 2P (37 H, 75 H, 110 H)

Dimensional Drawing 272

M 1:5

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Thyro-P 2P (80 H, 130 H, 170 H)

Dimensional Drawing 275

M 1:5

Thyro-P 2P (200 HF, 280 HF)

Dimensional Drawing 277

M 1:5

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495 HF

650 HF

300 HF

Thyro-P 2P (300 HF, 495 HF, 500 HF, 650 HF)

Dimensional Drawing 278

780 HF

1000 HF - 1500 HF

Thyro-P 2P (780 HF, 1000 HF, 1400 HF, 1500 HF)

Dimensional Drawing 280

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X10

X30

X31

X50

Cu 80x10; ø14

Cu 3.149x0.393; ø 0.551

ø9 für Erdung

210

365

9x15

1.575

8.268

14.370

.591

0.354 for earthing

0.54x0.590

225

2.480

395

8.858

1.220

15.551

3.583

284

549

21.614

11.161

445

17.526

470 bei 2P 690-1850 HF

18.5 for 2P 690- 1850 HF

Thyro-P 2P (1850 HF, 2000 HF)

Dimensional Drawing 282

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Thyro-P 2P (2400 HF, 2750 HF)

Dimensional Drawing 283

Thyro-P 3P (37 H, 75 H, 110H)

Dimensional Drawing 284

M 1:5

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Thyro-P 3P (80 H, 130 H, 170 H)

Dimensional Drawing 287

Thyro-P 3P (200 HF, 280 HF)

Dimensional Drawing 289

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495 HF

650 HF

300 HF

Thyro-P 3P (300 HF, 495 HF, 500 HF, 650 HF)

Dimensional Drawing 290

M 1:6

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780 HF

1000 HF - 1500 HF

Thyro-P 3P (780 HF, 1000 HF, 1400 HF, 1500 HF)

Dimensional Drawing 292

M 1:9

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457

17.973

X10

X30

X31

X50

Cu 80x10; ø14

Cu 3.149x0.393;ø0.551

ø9 für Erdung

0.354 for earthing

365

210

14.370

395

.591

9x15

2.480

1.575

8.268

15.551

3.583

225

1.220

549

21.614

8.858

284

11.161

445

17.520

470 bei 3P 690-1700 HF

18.5 for 3P 690-1700 HF

Thyro-P 3P (1700 HF, 1850 HF)

Dimensional Drawing 294

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Thyro-P 3P (2200 HF, 2600 HF)

Dimensional Drawing 295

M 1:9

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12. ACCESSORIES AND OPTIONS

ORDER NO.

DESCRIPTION

Thyro-Tool Familiy, commissioning and visualization tool for simple visualization

2000000380

tasks; software under Windows 95/NT4.0 and later

Thyro-P interface card Proﬁbus-DP

2000000393

2000000392

2000000394

2000000400

2000000401

Thyro-P interface card Modbus RTU

Thyro-P interface card DeviceNet

control device for Thyro-1P, -2P and -3P

control device as above, but using the ASM process for dynamic mains load

optimization

2000000406

2000000405

2000000399

37259800

37259900

37295190

0017381

LBA, local operating and display unit, menu-driven, including copy function

SEK, cabinet installation kit for LBA installation in switching cabinet door

Voltage transformer 690V/43V (UE_U=016), for mounting on standard rails

LLV.V, ﬁbre optic distribution power supply

LLV.4, ﬁbre optic distribution

LL/RS 232 plug, (interface 9-pin) including power supply

ﬁbre optic plug

0017574

ﬁbre optic cable

8000007874

0048764

plug 2 pin for A70, X1

data cable to the PC (RS 232)

2000003203

Damping card 690V

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13. APPROVALS AND CONFORMITIES

Due to European harmonization and international reconciliation, the standards will be subject to

years of adjustment and renumbering. The detailed schedule therefore contains the current stan-

dards as well, even if the date for their expiry has already been set. There is no product norm for

Thyristor Power Controllers, so that a sensible norm structure must be created from the correspon-

ding basic norms, which ensures safe application and opportunity for comparison.

CAUTION

Thyristor Power Controllers are non-valid devices for disconnection and may therefore be operated

only in connection with a suitable mains isolating device (for instance switch) connected on line side.

Approvals and conformities are available for Thyro-P:

• Quality standard according to ISO 9001

• Registration in acc. to UL 508, ﬁle no. E 135074

Investigated under consideration to Canadian National Standard C22.2 No. 14-95

• UL Markings:

· Field wiring terminal markings (see Chapter 4. „External Connections“)

· Use 60/75°C Copper Conductors only

· Tightening torque (pound inches) see Chapter 10. „Technical data“

· Devices are suitable for the following short circuit current ratings:

Devices rated 300A

„Suitable For Use On A Circuit Capable Of Delivering Not More Than 100kA rms Symmetrical

Amperes, xxx Volts Maximum, When Protected by RK5 Class Fuses, sized max. 600A / 600V“

Devices rated 495A and 695A:

„Suitable For Use On A Circuit Capable Of Delivering Not More Than 100kA rms Symmetrical

Amperes, xxx Volts Maximum“

NOTE:

xxx = max. allowable voltage depending upon rating of the device

· „Branch circuit protection must be provided and sized according National Electrical Code and

any additional local codes“

• CE conformity

Low Voltage Directive 73/23 EEC;

EMV Directive 89/336 EEC;

Marking Directive 93/68 EEC

• Interference suppression

The RegTP conﬁrms the compliance with the interference suppression regulations for the power

control device

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IN DETAIL:

CONDITIONS FOR USE OF THE DEVICE

Built-in unit

EN 50 178

General requirements

Design, vertical installation

Operating conditions

EN 60146-1-1

EN 60 146-1-1; K. 2.5

CISPR 6

Operating location, industry sector

Temperature performance

Storage temperature

EN 60 146-1-1; K 2.2

-25°C - +55°C

Transport temperature

Operating temperature

-25°C - +70°C

-10°C - +35°C for external cooling ( 280A)

-10°C - +45°C for self air cooling

-10°C - +55°C for reduced type current -2%/°C

up to 40°C

with UL applications

Load class

EN 60 146-1-1 T.2

Humidity class

EN 50 178 Tab. 7

Overvoltage voltage category ÜIII

Degree of pollution

Air pressure

EN 50 178 Tab. 3

EN 50 178 Tab. 2

900mbar

≤ 1000m above zero level

Safe isolation

up to 500V mains voltage:

EN 50 178 chap. 3

Air and creeping distances according

to DIN EN 50178

casing/mains potential

≥ 5.3mm

casing/control potential

mains voltage/control

potential

≥ 5.3mm

≥ 7.2mm and 10mm

in the power section

≥ 2.5mm

interface/control potential

mains voltage/interface

≥ 7.2mm

mains voltage among themselves ≥ 5.5mm

EN 50 178 Tab 18

Test voltage

Tests according to

EN 60 146-1-1 4.

EMV noise emission

Moise suppression (control device)

EN 61000-6-4

class A

CISPR 11

EMV noise resistance

Compatibility level

ESD

EN 61000-6-2

EN 61000-2-4

EN 61000-4-2

class 3

≥ 8 kV

Electromagnetic fields

Burst on mains lines

Burst on control lines

Surge on mains lines

Surge on control lines

Line-conducted

≥ 10V/m EN 61000-4-3

≥ 2kV

EN 61000-4-4

EN 61000-4-5

EN 61000-4-6

≥ 0.5kV

≥ 2kV

≥ 0.5kV

Further norms are observed, for instance voltage dips according to 61000-4-11 are ignored by the control

device, or registered by triggering of monitoring. Generally, an automated start is made after the mains

returns within tolerances.

Therefore, the conditions of the norm EN 61326 (controller standard) are also observed, even though this

norm by its structure is not applicable to power electronics > 10 respectively > 25A.

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OPERATING INSTUCTION / BETRIEBSANLEITUNG BAL 8000003232,

DE - EN, 06/12 - V6

Due to our policy of continuous development, the data in this document is subject to change without notice.

AEG is a registered trademark used under licence from AB Electrolux.

Aufgrund unserer kontinuierlichen Weiterentwicklung können die Daten in diesem Dokument ohne vorherige Ankündigung geändert werden.

AEG ist ein eingetragenes Warenzeichen verwendet unter Lizenz von AB Electrolux

AEG Power Solutions GmbH

Emil-Siepmann-Str. 32

59581 Warstein-Belecke - Germany

Tel.: +49 (0) 2902 763-520/-290 - Fax: +49 (0) 2902 763-1201

www.aegpowercontrollers.com - www.aegps.com

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