Advanced Energy Thyro-Power Manager Manuel utilisateur

1.6. MANUFACTURER

AEG Power Solutions GmbH

Emil-Siepmann-Straße 32

D-59581 Warstein

1.7. CONTACT

TECHNICAL QUERIES

If you have any technical queries regarding the subjects dealt with in these operating

instructions, please get in touch with our team for power controllers:

Phone: +49 (0) 2902 763-520

COMMERCIAL QUERIES

If you have any commercial queries on power controllers, please get in touch with:

Phone: +49 (0) 2902 763-558

SERVICE-HOTLINE

Our team is at your service on the following hotline:

Phone: +49 (0) 2902 763-600

INTERNET

Further information about our company or products please visit:

http://www.aegps.com

1.8. COPYRIGHT

The forwarding, copying and/or receipt of this operations manual via electronic or

mechanical means, even in part, requires the expressive prior and written approval of AEG

PS.

1.9. FURTHER INFORMATION ON COPYRIGHT

Thyro- is an international registered trademark of AEG Power Solutions GmbH.

All other company and product names are (registered) trademarks of the respective owners.

TABLE OF CONTENTS

1. NOTES TO THESE OPERATING INSTRUCTIONS...........................................................2

1.1. INFORMATION DUTY...................................................................................................2

1.2. VALIDITY.......................................................................................................................2

1.3. LOSS OF GUARANTEE................................................................................................2

1.4. HANDLING.....................................................................................................................2

1.5. CONFORMITY...............................................................................................................2

1.6. MANUFACTURER.........................................................................................................3

1.7. CONTACT......................................................................................................................3

1.8. COPYRIGHT..................................................................................................................3

1.9. FURTHER INFORMATION ON COPYRIGHT...............................................................3

2. GENERAL DESCRIPTION.................................................................................................7

3. INTENDED USE.................................................................................................................8

3.1. APPLICATION...............................................................................................................8

3.2. LIABILITY.......................................................................................................................8

3.3. DEPLOYED SYMBOLS.................................................................................................8

3.4. SAFETY INSTRUCTIONS.............................................................................................9

3.4.1. ACCIDENT PREVENTION REGULATIONS.............................................................9

3.4.2. GENERAL SAFETY NOTES...................................................................................10

3.4.3. FIRE PROTECTION................................................................................................11

3.4.4. QUALIFIED PERSONNEL......................................................................................11

3.4.5. SAFETY CONSCIENTIOUS WORK BEHAVIOR....................................................12

4. INSTALLATION ................................................................................................................12

4.1. SAFETY NOTES..........................................................................................................12

4.2. SCOPE OF DELIVERY, ASSEMBLY ..........................................................................13

4.2.1. SCOPE OF DELIVERY...........................................................................................13

4.2.2. ASSEMBLY.............................................................................................................13

4.3. STORAGE....................................................................................................................13

4.4. REQUIREMENTS FOR INSTALLATION.....................................................................13

4.4.1. DIMENSIONS / WEIGHTS......................................................................................13

4.4.2. GENERAL REQUIREMENTS.................................................................................14

4.5. INSTALLATION............................................................................................................14

4.5.1. COOLING................................................................................................................14

4.5.2. GROUNDING..........................................................................................................14

4.5.3. ELECTRO TERMINALS..........................................................................................14

4.5.4. CONNECTION DIAGRAMS....................................................................................16

4.5.4.1. CONNECTION FOR VOLTAGE SUPPLY..........................................................16

4.5.4.2. CONNECTION FOR NETWORK LOAD OPTIMIZATION / POWER

CONTROLLER..........................................................................................................................16

4.5.4.3. CONNECTION FOR NETWORK PEAK VALUE MONITORING /

MEASUREMENTS ....................................................................................................................17

4.5.4.4. CONNECTION FOR ANALOG OUTPUTS.........................................................19

4.5.4.5. CONNECTION FOR ERROR AND ALARMOUTPUT.......................................21

4.5.4.6. CONNECTION FOR DIGITAL OUTOUTS.........................................................21

4.5.4.7. CONNECTION FOR ANALOG DC INPUTS ......................................................22

4.5.4.8. CONNECTION OF ANALOG AC INPUTS.........................................................23

5. SHUT DOWN, DISASSEMBLY.........................................................................................24

5.1. SAFETY NOTES..........................................................................................................24

5.2. ELECTRO TERMINALS...............................................................................................24

5.3. SEPERATION..............................................................................................................25

6. FUNCTIONAL DESCRIPTION..........................................................................................25

6.1. GENERAL INFORMATION..........................................................................................25

6.2. MAINS LOAD OPTIMIZATION ....................................................................................25

6.2.1. AUTOMATIC STATIC MAINS LOAD OPTIMIZATION............................................28

6.2.2. MANUAL STATIC MAINS LOAD OPTIMIZATION..................................................28

6.2.3. REDUCTION OF CONVERTER TYPE PERFORMANCE VIA NETWORK LOAD

OPTIMIZATION.........................................................................................................................31

6.3. ADDITIONAL MEASUREMENT DEVICE....................................................................32

6.3.1. ZME FUNCTION.....................................................................................................32

6.3.2. MONITORING OF NETWORK PEAK LOAD..........................................................33

6.3.3. VOLTAGE MEASUREMENT ..................................................................................34

6.3.4. POWER AND ENERGY MEASUREMENT.............................................................34

6.3.5. TEMPERATURE MEASUREMENT........................................................................35

6.3.6. MEASUREMENT OF THREE ANALOG INPUTS...................................................35

6.3.7. MEASUREMENT OF THREE ANALOG INPUTS...................................................35

6.4. I/O MODULE (BUS/PC)...............................................................................................36

6.5. MESSAGES.................................................................................................................36

6.5.1. MESSAGES AT THE ERROR OUTPUT.................................................................36

6.5.2. MESSAGES AT THE ALARM OUTPUT.................................................................36

6.5.3. FURTHER MESSAGES..........................................................................................36

6.5.4. FUSE TRIGGERING...............................................................................................37

7. DISPLAY AND OPERATING ELEMENTS........................................................................37

7.1. SWITCH S1..................................................................................................................37

7.2. SWITCH S2 – QUANTITY ...........................................................................................38

7.3. SWITCH S3 – OPERATING MODE.............................................................................39

7.4. POTENTIOMETER R309.............................................................................................40

7.5. POTENTIOMETER R310.............................................................................................41

7.6. ANALOG OUTPUTS....................................................................................................42

7.7. LEDs............................................................................................................................43

7.8. PC PROGRAMM..........................................................................................................43

8. COMMISSIONING............................................................................................................44

8.1. PROCESS OF COMMISSIONING...............................................................................44

8.1.1. SETTING OF THE OPERATING MODE.................................................................44

8.1.2. SETTING THE NUMBER OF DEVICES DEPLOYED.............................................45

8.1.3. SETTING THE LIMITING VALUE FOR MONITORING..........................................45

8.1.4. SETTING THE ELEMENTARY PERIOD DURATION T0........................................45

9. OPERATION.....................................................................................................................45

9.1. REGULAR OPERATION..............................................................................................45

9.2. SERVICE OPERATION...............................................................................................46

9.3. END OF OPERATION .................................................................................................46

10. MAINTANANCE................................................................................................................46

10.1. REPAIRS.................................................................................................................46

11. TECHNICAL DATA...........................................................................................................46

11.1. APPROVAL AND CONFORMITY...........................................................................48

2. GENERAL DESCRIPTION

The Thyro-Power Manager possesses numerous functions. The unit can also be deployed

for peak load network monitoring next to its use for network optimization (as a substitute for

the previously deployed SYT9 module). The measuring functions register the effective

values of up to three electrical currents (or voltages), and deliver their effective values as

DC signals (as a substitute for three previously deployed ZME modules). In the course of

this, the integration-time feature is capable for adjustment so that measurements can be

made during full frequency operations. Power and energy consumption may also be

measured. Furthermore, the measurement of mains voltage, temperature, and three DC

inputs is performed. These values may also be displayed. A monitoring function is available

for the most of these measurement values. The unit possesses a serial interface for the

purpose of PC connection, and an interface to the bus modules of the Thyro-Family. Thus,

the capability is provided for the query of all measurement values via a PC or bus system.

Next to the easily performed adjustment capability via a switch or potentiometer, the Unit

can also be configured via a comfortable PC program (or via a bus). In the operations mode

“I/O Module”, the analog inputs and outputs, as well as the digital outputs, may be set or

read via a bus (or via a PC). Furthermore, an operations time counter is integrated into the

unit.

Basically the unit is composed of the following components:

Voltage supply 110V /230V

Automatic frquency recognition

Terminal to bus module (PROFIBUS)

10x Syt-type potential-free terminals

RS232-PC terminal

Error and alarm output

6x analog outputs for 0 – 10V

3x analog inputs, energy levels are selectable

3x converter inputs 1V~ / 100%

Potentiometers, switches, LEDs

Figure 1: Block diagram

The unit is designed for extreme easy operations. Thus, the number of connected power

controllers can directly be adjusted via the rotary switch S2, and the operating mode can

directly be adjusted via the rotary switch S3.

In its delivery status, operating mode 1 for “Automatic Static Network Distribution” is set to

be activated (rotary switch S3 = 1). In this application case, the user must then only set the

number of connected power controllers or power controller groups, respectively, via the

rotary switch S2. Further settings are not necessary.

The unit is designed for assembly to an overhead rail. The connection is implemented via

screw / plug terminals. Voltage supply may selected to either 230V~ or 110V~. The network

frequency is automatically recognized, and all according times are adapted.

3. INTENDED USE

3.1. APPLICATION

This unit has the purpose for the network load optimization of power controllers, for use as

measurement map for analog measurement values, and for use as bus I/O module. The unit

is permitted to be used only for these purposes.

Any other application is an abuse of use, and can endanger persons. Any liabilities of the

manufacturer become void upon abuse of use. The operator and the user of the unit shall

solely burden the risks for abuse of use.

Intended use includes the observation of the operations manual and compliance with

inspection and maintenance intervals. All malfunctions must be remedied immediately,

especially those that impact the safety of the unit.

3.2. LIABILITY

No liability is burdened for non-intended use of the unit. The operator and user shall burden

the responsibility for possibly necessary measures for the prevention of people and asset

damage. In case of complaints regarding the unit, please contact us immediately and

include the following information:

Type designation

Fabrication number

Complaint description

Duration in operation

Envirnmental conditions

Operation mode

3.3. DEPLOYED SYMBOLS

The following warning, prohibition, command, and notice symbols are used in the operations

manual, around and within the unit, and at the entrance to the switch room:

Symbol Description

Mains Voltage - Danger!

This warning note refers to an especially endangering

situation. Upon non- compliance, death or major injuries may

occur due to electric shock. Please adhere to the described

work and process procedures exactly, in order to avoid

damage to people or to the unit.

Danger!

This warning note refers to an especially endangering situation. Upon non-

compliance, death or major injuries are risked. Please adhere to the described

work and process procedures exactly, in order to avoid dama

e to people or to

the unit.

Caution!

This warning note refers to a possibly endangering situation. Upon non-

compliance, minor or medium-level injuries or damage may occur.

Warning about Electro-Magnet Field!

Electrical devices, clocks, magnetic storage cards etc. may malfunction or be

uncharged.

Hot Surfaces!

Danger of burning. Prevent touching or wear protection clothes.

Information, Note

Notes regarding technical requirements and additional information are

provided here, which the user shall observe.

3.4. SAFETY INSTRUCTIONS

3.4.1. ACCIDENT PREVENTION REGULATIONS

Please unconditionally observe the accident prevention regulations of the host country as

deployed within, and the generally valid safety instructions in accordance with IEC 364.

The following 5 safety rules must be complied with, prior to the beginning of all work

performed to the unit:

Attention Mains Voltage!

Safety rules for work performed to electrical facilities:

1. Disconnect equipment from the mains (establish a voltage free status)

2. Secure equipment against re-activation

3. Determine voltage free status of equipment by measurement

4. Ground and short-circuit equipment

5. Cover or establish borders to neighboring parts under voltage

3.4.2. GENERAL SAFETY NOTES

Important instructions stand out by the use of warning symbols, prohibition symbols,

command symbols, or notice symbols.

The unit is designed in accordance with state-of-art

technology and accepted technical safety rules.

In spite of this, dangers for the user or third parties and

impairments to the unit and other assets may unfold in

the course of its use.

Poor knowledge about operations and maintenance may

create damage to persons or assets.

Operations and maintenance within the set rule

boundaries, as well as compliance with the following

listed safety regulations, are necessary for the protection

of personnel and for the conservation of operational

readiness.

Personnel, who assemble, dis-assemble, start-up,

operate, and maintain the units, must know and observe

these safety regulations.

All work may only be performed by expert personnel

trained for the task assigned using those tools, fixtures,

inspection means, and materials for consumption as

designed for.

Please observe all legal or otherwise committing

regulations for accident prevention and environmental

protection.

Prior to task start-up, personnel assigned for tasks to the

Unit must have read the general and special safety

notes, and have sufficiently become acquainted with the

operations of the unit.

No changes, assemblies, and re-fittings, which impact the safety of the

Unit, are allowed to be performed to the Unit without approval of the

manufacturer.

Please secure that only personnel, who are accordingly assigned for

work on the unit, are deployed. Third parties shall be held away from

the unit, and also be pointed to the possible dangers.

Work performed to the unit may only be performed by an electronic

technician expert or by vocationally trained persons under the

management and peer-overview of an electronic technician expert in

accordance with technical electronic regulations.

The user must install the unit within a casing or switch cabinet so that

no dangers exist due to touching and that those applicable standards

and safety regulations are complied with.

For all maintenance and repair work, the unit must be completely de-

activated and secured against unintended re-activation in accordance

with the 5 safety rules (see chapter 3.4.1.).

Existing safety switches are not permitted to be by-passed, de-

activated, or be manipulated in any manner within any operational mode

of the unit whatsoever.

3.4.3. FIRE PROTECTION

Danger of fire!

In the case of smoke or smell development, as well as in case of fire,

the unit shall immediatel

be switched free of volta

e, and a report shall

be made to maintenance personnel. Smoking or open fire is forbidden.

3.4.4. QUALIFIED PERSONNEL

The unit may only be transported, be assembled, be connected, be

started up, be maintained, and be operated by expert staff members

who master the respectively valid safety and assembly regulations.

Safety regulations shall unconditionally be complied with!

All work performed shall be controlled by responsible expert personnel.

The duly responsible manager for Unit safety with regard to the necessary tasks envisioned

must authorize expert personnel. Expert personnel are those staff members, who:

Possess the vocational training and experience within the according work area,

Are knowledgeable about the respectively valid legal regulations (laws and codes),

standards, rules, instructions, and accident prevention rules,

Are vocationally trained as to the functional features and operational conditions of the

unit,

Recognize dangers, and are capable of implementing measures in order to prevent

dangers,

Regulations and definitions regarding expert personnel are contained within DIN EN 50110-

1:2004 (DIN EN 50110-1:2004 substitutes DIN 57105-1 and DIN VDE 0105 part 1).

3.4.5. SAFETY CONSCIENTIOUS WORK BEHAVIOR

Qualified personnel as defined in chapter 4.2.6 are responsible for safety. These personnel

are also responsible that only accordingly qualified persons are located at the unit or within

the safety area. Observe the following items:

Caution!

Refrain from an

kind of workin

behavior, which impacts the safet

persons and the function of the Unit in any form.

Operate the Unit only in a proper condition.

No safety fixtures are allowed to be dis-assembled or be put out of

function. Operationally contingent measures shall be implemented

prior to the removal of safety fixtures for the execution of maintenance

and service, or other work tasks.

Always work in compliance with the 5 technical electrical safety

regulations!

4. INSTALLATION

4.1. SAFETY NOTES

The following 5 safety rules must be complied with, prior to the beginning of all work

performed to the unit:

Attention Mains Voltage!

Safety rules for work performed to electrical facilities:

1. Disconnect equipment from the mains (establish a voltage free status)

2. Secure equipment against re-activation

3. Determine voltage free status of equipment by measurement

4. Ground and short-circuit equipment

5. Cover or establish borders to neighboring parts under voltage

4.2. SCOPE OF DELIVERY, ASSEMBLY

4.2.1. SCOPE OF DELIVERY

The delivery is comprised of the following parts:

Thyro-Power Manager

Pouch with screws/ plug terminals

Operating instructions

4.2.2. ASSEMBLY

The units must be assembled on the overhead rail within a switch cabinet / casing.

Voltage supply is performed at terminal X1. In the course, the connection voltage must

be selected there, and the according jumpers must be set (230V~ jumper X1.5 – X1.6;

110V~ jumper X1.4 –X1.6 and jumper X1.5 – X1.7).

Grounding shall be performed at X1.1 or X1.2 in accordance with local regulations! For

this, see also chapter 4.5.4.1 connection for voltage supply.

4.3. STORAGE

The Unit may be stored in rooms, which are dry, ventilated, and equipped with a fixed

protection roof, and originally packaged.

Permissible ambient temperature: -25°C to +55°C

Permissible relative air humidity: max. 85%

For longer storage durations, the Units should be contained in airtight plastic skins with the

use of commercially available drying agents.

4.4. REQUIREMENTS FOR INSTALLATION

4.4.1. DIMENSIONS / WEIGHTS

The Unit possesses the following dimensions and weight:

Unit Width Height Depth Weight

Thyro-Power

Manager 150mm 95mm 60mm 0.35kg

Consider the following necessary free space upon assembly:

20 mm upwards

20 mm downwards

4.4.2. GENERAL REQUIREMENTS

The units may be assembled next to each other without a sideward gap.

The user must install the Unit within a casing or switch cabinet so that no dangers exist due

to touching and that those applicable standards and safety regulations are complied with!

4.5. INSTALLATION

4.5.1. COOLING

It shall be observed that the maximum ambient temperature of 55°C is not exceeded.

4.5.2. GROUNDING

Grounding shall be performed in accordance with the local regulations (terminal X1.1 / X

1.2)! Grounding is also achieved via EMC facilities (Y – capacitor 4.7nF).

4.5.3. ELECTRO TERMINALS

The unit shall only be connected to the voltage supply, and to further external components

(power controllers, measuring transformers), which are contingent to the application. For

this, the following connections are necessary:

Voltage supply: 110V~ / 230V~ at terminal X1

Mains load optimization: power controller at terminals X3, X4

Network peak load monitoring / measurements:

o up to 3 converters (1V~) at terminal X5

o up to 6 DC outputs (10V-) at terminals X7, X8

o Error / alarm message at terminal X8

I/O mdoule:

oup to 10 digital outputs at terminals X3, X4

oup to 6 analog outputs (10V-) at terminals X7, X8

oup to 3 analog DC-inputs at terminals X5, X6

oup to 3 analog AC-inputs at terminal X5

PC-connection: at terminal X9 (RS232)

Bus module interface connection: at terminal X2

As different applications can also be deployed simultaneously, it is necessary to connect the

most various of terminals, in part. E.g., network load optimization (connection of the power

controllers to X3 and X4) and simultaneously network peak-load monitoring (connection of

three electrical current converters to X5) could be deployed, as well as electrical current

measurement (connection of three measurement instruments to X7), and the output of three

analog values (connection of further equipment to X7 and X8). Additionally, three further

analog inputs could be used for reading, and be evaluated via a bus (connection of analog

inputs to X5 and X6, and a bus module connection to X2).

An overview of connection opportunities is displayed in the following

figure:

Figure 3: Connection overview

4.5.4. CONNECTION DIAGRAMS

As different connections may be necessary as contingent to the application, the connection

diagrams are illustrated in groups.

4.5.4.1. CONNECTION FOR VOLTAGE SUPPLY

Figure 4: Connection diagram for voltage supply 230V~; 50/60 Hz

Figure 5: Connection diagram for voltage supply 110V~; 50/60 Hz

4.5.4.2. CONNECTION FOR NETWORK LOAD OPTIMIZATION / POWER

CONTROLLER

The unit possesses 10 digital outputs at the terminals X3 and X4, in total. These are

designed as potential-free optical coupler outputs. They are deployed as synchronization

outputs (SYT) for the connected power controllers or power controllers groups during the

network load optimization process. Up to 10 Power Controllers can be connected per

channel. To operate a 2-wire shielded cable is required between Thyro-Power Manager and

each power controller.

Figure 6: Connection diagram for main load optimization using Thyro-A

Figure 7: Connection diagram for main load optimization using Thyro-P

4.5.4.3. CONNECTION FOR NETWORK PEAK VALUE MONITORING /

MEASUREMENTS

External electrical current converters including load resistances are necessary for

network peak-value monitoring and current measurement. Such must be designed so

that a measurement voltage of 1V~ unfolds as operating at a nominal electrical current

(voltage at the load resistance). These converters must be assembled into the network

supply of the facility for the purpose of network peak-value monitoring. The converter

type (for electrical current or for voltage), as well as their nominal values, should be

configured using a PC program!

Figure 8: Connection diagram for network peak load monitoring / Electrical current

measurement

An external electrical current converter (input 1) and an external voltage converter (input 2)

are needed for (single-phase) power and energy measurement. Input 3 may further be

deployed, additionally. Again, both converters must be configured in a manner so that a

1V~ measurement voltage is generated at a nominal electrical current and at a nominal

voltage. For this reason, the electrical current converter must be equipped with an

adequate load resistance, and possibly, an adequate series resistance must deploy

together with the voltage converter. The internal resistance of the measurement device is

7540 Ohms.

Figure 9: Connection diagram for power and energy measurement

An AEG voltage converter (order no. 2 000 000 399) can be deployed as voltage

transformer. This device possesses a transformer ratio of 16:1, and can primarily be used up

to 690V. If this converter is deployed, the following series resistance values result:

Series resistance

[Ohm]:

Mains

voltage

[V]:

Secondar

voltage. [V] Calculate

: Selected: Note:

110

6,875

44298 44000

22k + 22k

230

14,375

100848 101000

100k + 1k

400

180961 181000

180k + 1k

500

31,25

228087 228200

220k + 8k2

690

43,125

317625 320000

220k + 100k

Table 3: Series resistance values for AEG voltage converter

4.5.4.4. CONNECTION FOR ANALOG OUTPUTS

All measurement values may be read from one (or more) of the six analog outputs (0 –

10V).

Standard setting:

Output no.: Terminals Standard output:

1 X7.1 / X7.2 Converter 1

2 X7.3 / X7.4 Converter 2

3 X7.5 / X7.6 Converter 3

4 X7.7 / X7.8 Mains voltage

5 X7.9 / X7.10 Temperature

6 X8.1 / X8.2 Bus value 6 / adjustment

support

Table 4: Standard output values for analog outputs

Figure 10: Connection diagram for analog outputs

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