Power Controller

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POWERSOLUTIONS

PRODUCT

BROCHURE


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AEG POWERSOLUTIONS

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04A history of innovation

06Research and development

08Local customer serviceworldwide

10Certified quality

12ApplicationsIn tune with industry needs

14Thyrobox FamilyFor AC and DCapplications

16Thyrobox SiSilicon Ingot mono crystalgrowth

18Thyrobox SaSapphire crystal growth

20Thyrobox H2Hydrogen electrolysis

22Thyrobox AFArc furnace power supply

24Thyrobox VR

Voltage regulation ofdistribution grids

26Thyro-FamilyDigital power controllers

28Thyro-SThyristor switches fast,reliable, economical

30Thyro-AThyristor power controller16 A 1500 A

32Thyro-AXThe next generation ofthyristor power controllers

34Thyro-PDigital thyristorpower controller

36Communication withcontrol systems

38

Configuration Tools andmains load optimization

40AccessoriesPerfecting operations

42Power ServicesGuaranteed availabilityand efficiency

CONTENTS


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A HISTORY OFINNOVATION

COMPANYPROFILE

The Allgemeine Elektricitts-Gesellschaft (AEG) wasfounded in 1887 by EmilRathenau as a direct rival toUS company General Electric.The young company verysoon widened its activities

and performed pioneeringwork in the field of ACtransmission systems.

AEG grew rapidly, alwaysleading the world in innovationand delivering solutions tothe particular technologicalchallenges of the time.

Since 1947, AEG PowerSolutions has establisheditself anew as a leader in thetechnological field ofelectrical interfaces to themains power grid, where itcontinues to excel to this day.

First single-phase powercontroller for transformer-type loads

1969

SAFT Power Systems takesover Harmer & Simmonsand subsequently AEG SVSPower Supply Systems

1955

The AEG history helps us inour development of solutionsfor the future. AEG PowerSolutions was founded in thewake of the industrial revolutionand thus, we see our roots asgoing back to the early days

of the energy revolution.From the very outset,ourcompanys innovative prowesshas been geared towardsenergy management. Thisbackground gives us thenecessary competitive edge totake a defining role in todaysglobal markets. Few matterswill occupy people more in theyears to come than how to deal

with natural resources and howto ensure a supply of power.

Green solutions forthe future of theglobal energy market

The planets population isgrowing rapidly. In many partsof the world the infrastructure,economy and levels of personalprosperity are also growing.As both move forward instep, the demand for energyincreases. With todaysknowledge of the limitedavailability of energy resources,new challenges arise andmarkets open up for innovativeproducts and solutions. Justas we have always paved

We see our companyshistory as a commitmentto the future. The valuesand philosophies thatit produced are thecornerstones of globalsuccess.

AEG is foundedas the Germancounterpart to

General Electric

1887

SAFT founded as a batterymanufacturer in France

1918

AEG SVS Power Supply Systems is founded inWarstein-Belecke (Germany) with 25 employees

1945

The SAFT Power Systemsdivision is set up

1947

Worlds first

100 % digital UPS1995

First fully digital power controllerwith 32-bit micro-controller and

high-performance ASIC

2000


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First ultra-small medium voltageignition system for polysiliconreactors and processes

2007

the way through innovation,today too we are constantlydelivering improvements toenergy supply solutions aroundthe globe. By virtue of thecompanys unique expertise inAC and DC power technology,

AEG Power Solutions isalmost uniquely positioned todevelop innovative solutionsfor intelligent electricitynetworks (smart grids).

Our leading globalrole confirms themerit of our approach

Our clientele range fromtraditional power generatorsand companies in the oil, gasand petrochemical sector

Highly efficient and easilyscalable rectifier systemfor the industrial sector

2008

SAFT Power SystemsGroup is renamedAEG Power Solutions

2008

Pioneering device for the integration ofrenewable energy intro smart microgrids andtechnological breakthrough in efficiency ofpolysilicon production using the new Thyrobox PI

2010

The company is floated and listed on theEuronext exchange in Amsterdam and thenon the Frankfurt Stock Exchange (FWB)

2010

A production facility for solar invertersis opened in Bangalore, India, witha production capacity of 400 MW

2011

all the way to polysiliconproducers and pioneers ofpower generation fromrenewable forms of energy.Issues such as quality, know-how, service and reliabilityare very much a part of our

everyday internal discussions.Our longstanding relationshipswith our customers confirmthat the standards we setourselves are measuredagainst these criteria ofoutstanding performance.It is for this reason that AEGPower Solutions is one of theworlds leading manufacturersof electronic systems andsolutions for industrial powersupply and offers one of themost comprehensive portfolios

of products and services forpower conversion and control.Through our expertise inrenewable energy and ourknowledge of the globalpower supply infrastructure,we are able to intelligently

combine electricity supplyand consumption. Togetherwith our customers wecreate innovative energymanagement systems thatfacilitate intelligent controlappropriate to demand.

Merges withAlcatel Converters

2002

Ripplewood purchasesSAFT Power Systems

from Alcatel

2005

Extremely efficientinverter for solarpower stations(efficiency level>98.7 %)

2009

AEG POWERSOLUTIONS


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RESEARCH ANDDEVELOPMENT

INNOVATION

The capabilities andinventiveness of the staffat our company produceoutstanding productsand system solutionsaround the globe.

As Voltaire used to say:The best is the enemy ofthe good. This sentenceencapsulates in just a fewwords what drives and inspiresour research and developmentwork at AEG Power Solutions.We really do work every dayon bettering our achievementsand turning our ideas intoreality in the shape of newproducts. With the optionof controlling energy andusing it selectively, innovationand speed of development

increased enormously inthe era of mechanization.Every innovation openedup a whole new spectrumof further possibilities. Thisturning point in the historyof mankind generated amomentum in developmentthat continues unabatedto this day. Digitalizationand global networking hasincreased this acceleratedrate of innovation still further.

The future is createdin the minds of ourstaff

The multitude of new ideas,products and possibilitiesalways brings with it newdemands. As decisively aspower-consuming technologyis defining our lives, develop-ment across the entire powersupply sector is just as influen-tial and momentous. Creativetechnicians, engineers andscientists work day in, day outfor AEG Power Solutions onnew products that, for instance,provide protection from powercuts and the associated lossof data and costly downtime.With over 250 engineers,technicians and projectmanagers, the AEG PowerSolutions Group performspioneering work in R&D andapplication engineering. Thisconstant searching for andworking toward the best isevidenced by the AEG PowerSolutions Groups current totalof over 97 active patents inthe area of power supply.

International researchin support of globaladvances

The worldwide use of oursystems and products callsfor close global monitoring oftrends and market changes. Inrelation to the switch to greenenergy, which AEG PowerSolutions among others ispromoting, we are investinggreat effort in internationallycoordinated research anddevelopment within our group.In order to ensure that we areas close as we need to be toour customers and marketsand to pick up on the latestrequirements and scientificfindings, we are representedin all key markets around theglobe. We currently employaround 1700 people in 17subsidiaries and centres ofexpertise within the AEGPower Solutions Group, allof them sharing the aim ofcreating improved solutionsfor reliable power supplysystems of all sizes.


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LOCAL CUSTOMERSERVICE WORLDWIDE

AEG POWERSOLUTIONS

Milan

Prague

Cape Town

Plano Dallas

London

Lannion

Nanterre Paris

Tours

Minano Vitoria

Madrid

Zwanenburg

Amsterdam

Warstein-BeleckeDortmund

Budapest

Kiev

Dubai


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Our customers requirementsare ultimately always veryindividual. This calls for notonly a broad spectrum ofproducts and possible waysto use them, but also requiresdirect and individual support.

In order to be able to reactto new market developmentsas flexibly as we can and tosupport our customers asquickly and continuously aspossible, the 17 subsidiariesof the AEG Power SolutionsGroup provide the appropriateservice with the requiredproximity to our customersall around the globe.

Ultimately any system only everworks as well as the peoplewho understand and maintainit. Because we know that, our

technical support operationforms an integral part of howwe perceive our business.

LOCATIONS

Beijing, ChinaCape Town, South AfricaWarstein-Belecke, Germany

scow

Beijing

galore

la Lumpur

gapore Shanghai

Guangzhou

Hong Kong

Sydney


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CERTIFIEDQUALITY

CERTIFICATES

Germany Warstein-Belecke

Belecke (Germany)ISO 9001 certificate

Belecke (Germany)KTA certificate

Belecke (Germany)IRIS certificate

Belecke (Germany)SCC certificate

Manufacturers declarationfor implementing REACH

Manufacturers declarationof CCC-Mark for China

Manufacturers declarationof compliance with HSE

Belecke (Germany)ISO 14001 certificate

Beleck (Germany)ISO 50001 certificate

China Beijing

Beijing (China)ISO 9001 certificate



A quality assurance systemfully certified to ISO 9000.AEG Power Solutions strictquality control policy isrecognised through everybusiness division havingISO 9000 certification andour quality accreditationfrom many large clients.

France Lannion

Lannion (France)ISO 9001 certificate

United Kingdom London (Hainault)

Hainault (UK)ISO 9001 certificate

India Bangalore

Bangalore (India)ISO 9001 certificate

Italy Milan

Milan (Italy)ISO 9001 certificate

Milan (Italy)

ISO 14001 certificate

The Netherlands Amsterdam(Zwanenburg)

Zwanenburg(The Netherlands)ISO 9001 certificate

Zwanenburg(The Netherlands)SCC certificate

Singapore

SingaporeISO 9001 certificate

SingaporeISO 14001 certificate

Singapore

ISO 18001 certificate

SingaporebizSAFE STAR certificate

Spain Vitoria

Vitoria (Spain)ISO 9001 certificate




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IN TUNE WITHINDUSTRY NEEDS

APPLICATIONS

Switching, controlling,regulating. From simpleapplications to highly complexprocesses, AEG PowerSolutions products are usedevery day as the powercontroller (SCR) of choice all

over the world.

In hydrogenproduction

For around 200 years, hydrogenhas been produced for industryby means of electrolysis.Electrolysis takes place whentwo direct current electrodesget submerged into anelectrolyte. Today, energy isincreasingly being obtainedfrom renewable sources (e.g.wind and sun). This has to be

stored, as renewable sourcesmay not provide power aroundthe clock. Hydrogen is a cleanand ideally suited mediumfor doing this. AEG PowerSolutions offers a broadspectrum of power controllersfor all of the requirements ofyour electrolysis processes.

In solar cellproduction

Here silicon nitride (SiN) is

used as an anti-reflectivecoating on wafers and surfaceneutralisation. Duringpreheating and coating,AEG Power Solutions Thyristorpower controllers regulatethe electrical power in orderto control the processtemperature within the heating

elements. Via an inexpensivebus interface it is possible toconnect up to eight powercontrollers attached to one busto connect practically anyprocess control system. Usingthe Thyro-Tool software, youcan easily set the requiredparameters, so that you arequickly in a position to deliver

quality that can be reliablyreproduced.

In glass production

Greater demands areconstantly being made forever-thinner glass, as they aretoo for precision glass. Themanufacturers therefore needhighly precise productionenvironments in order to beable to offer products of topquality. Accurate control oftemperature during theheating up and cooling downprocesses has an impact on thequality and reliability of thefinished glass. That applies toall stages at the hot end ofthe production process, frommelting to the final annealing.

Extreme reliability andprecision are key for anysuccessful production plant, asa breakdown at any one of theindividual stages would bringthe entire production processto a standstill.

In solar panel

productionSpecial glass for solar moduleshas chemical and physicalcharacteristics that aredifferent from ordinary glass.It is made on float or specialcast glass lines. The powercontroller solutions for theseapplications work using AEGPower Solutions patentedASM procedure designedto optimize mains loadand increase the efficiencyfactor for consistent and

high quality production.


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Thyristor powercontrollers from AEGPower Solutions are usedwherever heating, meltingdrying and moulding haveto be done in an exactand reproducible way.


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THYROBOX FOR AC AND DCAPPLICATIONS

Based on long provendesigns, standard parts andhigh-tech AEG PowerSolutions components, wecreate power supply solutionsperfectly tailored to our

customers needs.Successfully used around theglobe, Thyrobox powersupply systems have fordecades been synonymouswith highly reliable andreproducible manufacturingprocesses.

As a global leader in powersupply concepts, AEG PowerSolutions provides customizedsystems that are specificallytailored to the manufacturingprocess concerned. Thanks to

highly developed

AC and DC technology, AEGPower Solutions Thyroboxpower supply systems areextremely energy efficient andreliable in comparison withother technologies.

With a view to minimizingboth capital and operatingexpenditure, our power supplysolutions are conceived,designed, built and tested atour Warstein-Belecke site inGermany all in accordancewith industry standards andspecified requirements.

Thyrobox-Applications

For all power supply

solutions, extreme efficiency,total reliability and fullreproducibility are top prioritiesin order to be competitivearound the globe. AEGPower Solutions quality highcurrent supply systems havebeen leading the way in thisrespect for many years.

Silicon ingot monocrystal growth

Thyrobox Sipower supply solutions

Sapphire crystal growth

Thyrobox Sapower supply solutions

Hydrogen electrolysis

Thyrobox H2power supply solutions

ARC furnaces

Thyrobox AFpower supply solutions


Thyrobox VRpower supply solutions

THYROBOXFAMILY


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SILICON INGOTMONO CRYSTALGROWTH

THYROBOX SIPOWER SUPPLY

SOLUTIONS

For the high-tech industryalong the polysilicon solarvalue chain AEG PowerSolutions in Germany has for

many years been the leadingsupplier of quality high currentsupply systems. This startswith the supply of power toCVD reactors for polysilicondeposition, includes powersupply systems for the differentprocesses of crystal growthand for wafer, cell and moduleproduction and extends allthe way to transforming thesolar energy obtained andfeeding it into the medium orlow voltage grid by means ofstring and central inverters.

Silicon crystal growth

In addition to the Czochralskiprocess for monocrystallinesilicon crystal growth and theingot casting method formulticrystalline crystal growth,many other and, in part,very similar procedures, areused to grow crystals in orderto produce wafers in aneconomically efficient mannerfrom the polysilicon obtained.The focus of the differentprocesses here is on the endproducts that the wafersrequire in either electronic orsolar grade purity. For solargrade wafers, which areneeded in the especiallycompetitive renewable energymarket, the key now, more thanever, is to manufacture in areliable and economic way.

Process power supply

High cost efficiency, reliabilityand reproducibility are thus theconditions for competitivenessand at the same time a mustfor the essential requirementsto be fulfilled by the powersupply. As every method ofgrowing crystals has its owntechnical idiosyncrasies, thespecified demands made ofthe power supply varyaccordingly.

Thyrobox Si

Under the name Thyrobox Si,AEG Power Solutions providescost efficient DC power supplysolutions that are especially well

suited to the supply of powerfor crystal growing facilities.


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AEGPowerSolutions

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THYROBOX SITECHNICAL DATA

Melting the polysilicon chunks

Ingot growth Cooling down the monocrystalline ingots

Start of the monocrystalline crystallization

* others on request** in relation to type values

Load current* up to 15,000 ADC

Voltage rating* up to 200 VDC

Grid frequency 47 Hz 63 Hz

Control mode U, U, I, I, P, unregulated

SPECIALLY DEVELOPED ASIC AND 32 BIT MICROCONTROLLER

Operation / sec up to 45 million

Frequency 50 MHz

Load current resolution 15 bit, equating to 0.03 %**

Output voltage resolution 14 bit, equating to 0.06 %**

Target value resolution 14 bit, equating to 0.06 %**

HIGH PRECISION / REPRODUCIBILITY

Load current / output voltage 0.5 %

Power 1 %

ADDITIONAL TECHNICAL DATA

Set point inputs (freely selectable)2 analog inputs

2 digital inputs(incl. motorpoti function)

System interfaces optionally with the PROFIBUS DPV1, Modbus RTU, DeviceNet, EtherNet/IPand /or PROFINET bus systems; alternatively with RS 232 and fiber optics

Load circuit monitoring yes

Self monitoring yes

Visualization via touch screen display or Thyro-Tool Family

Data logger with operating hours counter in real time


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SAPPHIRECRYSTAL GROWTH

THYROBOX SAPOWER SUPPLY

SOLUTIONS

Many years of experience inthe field of industrial highcurrent supply, e.g. forpolysilicon, means for AEGPower Solutions customersaccess to a very high degree ofexpertise. Monocrystalline

crystal growth for silicon ingots(the Czochralski process) andthe ingot casting process formulticrystalline growth are alsotried and tested areas of usefor AEG power controllers.Somewhat newer in relation tothe application, but also verymuch in the focus of Thyropower controllers and systems,is the related growing ofsapphire crystals (e.g. based onthe Kyropoulos or Czochralskimethod).

Sapphire crystalgrowth

With the increasing importanceof sapphire production, causedin particular through the everstronger demand for efficientLED lighting equipment andalso through other applicationssuch as sapphire windows and

glass. The requirements arealso rising in terms of volumeproduced, quality and costefficiency of the sapphireproduction process. Anotherimportant factor in sapphireproduction is also the stabilityof the batch process. Thus forall components and systemsinvolved in this process manykey requirements are alreadylaid down, which is particularlyimportant for more critical,large volume batches.

Process power supply

High cost efficiency, reliabilityand reproducibility are thus asynonym for competitivenessand at the same time a must inrelation to the essentialrequirements to be fulfilled bythe power supply. As every

method of growing crystals hasits own technical idiosyncrasies,the specified demands madeof the power supply varyaccordingly.

Thyrobox Sa

Under the name Thyrobox Sa,AEG Power Solutions nowprovides cost efficient DCpower supply solutions thatare especially suited to thesupply of power for sapphirecrystal growing facilities.


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AEGPowerSolutions

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Input voltage 3 x AC 400 V -20 % +10 % 3 x AC 500 V -20 % +10 %

Output voltage DC 6 15 V, can be regulated by the user




Operations / sec up to 45 million

Frequency 50 MHz






Power 1 %


Set point inputs (freely selectable) 2 analog inputs 2 digital inputs(incl. motorpoti function)

System interfaces optionally with the PROFIBUS DPV1, Modbus RTU, DeviceNet, EtherNet/IP and/

or PROFINET bus systems; alternatively with RS 232 and fiber opticsLoad circuit monitoring yes

Self monitoring yes



Sapphire mono crystal


THYROBOX SATECHNICAL DATA


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HYDROGENELECTROLYSIS

THYROBOX H2POWER SUPPLY

SOLUTIONS

The need to utilize greenenergy efficiently calls fortechnical know-how and manyyears of experience. Know-howand experience, such as ours,which covers the supply ofpower to CVD reactors for

polysilicon deposition, includespower supply systems for thedifferent processes of crystalgrowth and for wafer, cell andmodule production. It extendsall the way to transforming thesolar energy obtained andfeeding it into the medium orlow voltage grid by means ofstring and central inverters.For storing the intermittentlyavailable renewable energyfrom sun and wind thereare now tailored powersupply systems available for

the electrolysis process: theThyrobox H2 range.

Hydrogen electrolysis

Producing hydrogen by meansof electrolysis has been knownfor industrial purposes fora long time. By connectinga DC voltage source to twoelectrodes located in waterthe electrolysis process is

able to take place. Hydrogenand oxygen separate at theelectrodes. The significantgrowth of available forms ofrenewable energy (e.g. windand solar) puts the focus onthe importance of hydrogen asa clean and suitable mediumfor energy storage and thusalso on hydrogen electrolysis.

Electrolysis powersupply

High cost efficiency, reliabilityand reproducibility areessential and thus vitalrequirements that have to befulfilled by the electrolysispower supply process. Withinthe environment of renewable

energy forms, additionaldemands are made ofelectrolysis systems, inparticular, of the functionalityof the power supply and theirperformance figures.

Thyrobox H2

Under the name Thyrobox H2,AEG Power Solutions providescost efficient DC power supplysolutions that are especiallysuited to the supply of powerfor hydrogen electrolysis

facilities.


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AEGPowerSolutions


Voltage rating* from 12 VDC to 400 VDC




Operations / sec up to 45 million

Frequency 50 MHz






Power 1 %


Set point inputs (freely selectable)2 analog inputs

2 digital inputs(incl. motorpoti function)

System interfaces optionally with the PROFIBUS DPV1, Modbus RTU, DeviceNet, EtherNet/IPand/or PROFINET bus systems; alternatively with RS 232 and fiber optics

Load circuit monitoring yes

Self monitoring yes



Hydrogen electrolysis schematic


THYROBOX H2TECHNICAL DATA


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ARC FURNACEPOWER SUPPLY

THYROBOX AFPOWER SUPPLY

SOLUTIONS

AEG Power Solutions powercontroller solutions are wellestablished in differentapplications where high-endpower supply is key.Theexpertise across the entirerenewable energy sector (PV

value chain) starts with powersupplies for CVD reactors forpolysilicon deposition process,electric power supplies forcrystal growing (e.g.Czochralsky process) as wellas for arc furnaces (e.g. quarzcrucible production), wafers,cell and module production tostring and central inverterswhich convert and feed solarenergy into the medium andlow voltage grid.

Arc furnaces are used in

different processes where highenergy needs to impactdifferent metal and non-metalraw materials. Arc furnacepower supplies are powered bya medium voltage transformerwhich has pure capacitive varcompensation to increase thepower factor to >0.9.

The arc furnace power supplyhas to ensure a high powerfactor and a high efficiencyas well as a low harmonicdistortion (THD). Thyrobox AFis an adequate solution for thearc furnace application andoperates withoutelectromechanically adjustabletransformers. It fulfills the high

requirements of arc furnaceload curves (e.g. the typicalstrong non-linearity of the loadcurve, combined with therequirements of a fast dynamiccurrent source, as well as highcurrent changes at smallvoltage changes).

One of the key aspects ofThyrobox AF is a precisecontrol performance. This hasbeen implemented usingestablished Thyristortechnology with a high degreeof efficiency, low harmonicdistortion and flickers. It isregulated and monitored bythe highly efficient Thyro-P

control unit.


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AEGPowerSolutions

voltageU [V]I [A]

t [s]

230.00 m 240.00 m 260.00 m 280.00 m 290.00 m

current

Thyrobox AF

Arc furnace power supply

VAR Compensation

3

3

Thyrobox AF

Arc furnace power supply

3

VAR Compensation

3

3

3

Thyrobox AFhighlights

state of the art technology

high degree of reliability

high degree of availability

long operating life precise reproducibility

digital technology withprecise accuracy

monitoring functions

excellent technical support

suitable for worldwideapplication

good price/performance ratio

adequate delivery times

high degree of efficiency

high power factor

minimized systemperturbation

small footprint

Waveforms showing low THD and phase shift between voltage and current

THYROBOX AFTECHNICAL DATA

** e.g. EtherNet/IP, PROFINET, PROFIBUS DP, Modbus RTU, DeviceNet

Output current up to 60 kA

Output voltage up to 1000 V

Monitoring fully digital

Cooling water cooled

HMI touch screen, field bus interface**, Thyro-Tool Family

Interlock function in case of two arc furnaces powered by one Thyrobox AF

further data / characteristics on request


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VOLTAGEREGULATION OFDISTRIBUTION GRIDS

THYROBOX VRPOWER SUPPLY

SOLUTIONS

With the growing number of

solar installations, requirementsincrease for local distributionsystem operators and theirexisting network infrastructures.In the past, electrical distributionsystems have been designedfor a power flow from high-voltage via medium-voltage tolow-voltage with the consumeror end-user being a sink ofelectrical energy. Now, theuser can become a source ofelectrical energy. In this casethe power flow is reversed andvoltage drops on impedance

reverse as well. This can resultin exceeding the upper voltagetolerance (+10 %) especially innetwork spur lines. Without anychanges at the existing networkinfrastructure this would causeautomatic switch-off of solarinverters with the consequencesof dissatisfied customers andadditional failure to meet legalobjectives as preferred byrenewable energies.


These requirements confront

local distribution gridoperators, especially in thecountryside, i.e. where farms orsports clubs are connected viaspur lines. Up until now the onlysolution has been to install newcables in expensive and timeconsuming installations. Thiscauses undesirable delay andadditional cost for the operator.With Thyrobox VR, AEG PowerSolutions offers a new concept.

Thyrobox VR

Thyrobox VR operates asa voltage regulator withinlow-voltage networks. Oncethe power flow reverses, thevoltage of the secondaryconnected network segmentwill be adjusted downwardsby up to 8%. Regulation iscontinuously step-less withno switching operations anda degree of efficiency >99%according to power rating.Therefore, the voltage rangeis significantly easier to utilize

and the installation of cables

can be avoided in manycases. The basic technologyhas been known of sincethe late 1920s and has beenupgraded in the 1970s usingSCR semiconductor deviceswith step control. AEG PShas further developed thetechnology for continuousregulation and brought it toa state of the art hardwareplatform using best in classthyristors and controllers.The Thyro-P control unithas been proven over

many years in demandingapplications and alsoprovides necessary interfacesto various communicationtools. The dimensionalconstruction of Thyrobox VRis similar to common cabledistribution cabinets. Theinstallation is similar to cabledistribution cabinets i.e. ona concrete base, throughwhich the cables will passand therefore an installationis possible along sidewalks,cycle ways and side roads.

110 kV

+10 %

Un length

-10 %

0...-8 %

0.4 kV

10 kV / 20 kV

Thyrobox VR

N

Thyro-P Controller

212

...

230

V

0...-8%

230

V

Voltage curve with Thyrobox VR on distribution grid spur lines


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THYROBOX VRTECHNICAL DATA

TYPE DATA RANGE* OF THYROBOX VR

Phase voltage 3 x 400 VAC

Transmission load 250 kVA

Controlling range / voltage 0 up to -8 %

Regulation continuous voltage regulation

Short circuit voltage UK


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THYRO-FAMILYDIGITAL POWERCONTROLLER

THYRO-FAMILY

AEG Power Solutions presents

the new Thyro-Family ofproducts, featuring theThyro-S, Thyro-A, Thyro-AXand Thyro-P digital powercontrollers. As an importantcomponent within theapplication process theyimpress through quality,reproducibility, communicationscapability and high availability.AEG Power Solutions Thyristorpower controllers switch orregulate electrical energyworldwide for use in practicallyevery area of industry, starting

from simple systems andranging all the way to complexapplications for high-endcontrollers.

By virtue of their precisionand reliability, AEG PowerSolutions power controllersoffer certainty for all applicationprocesses in which melting,heating, drying and mouldingare required. These alsoinclude crystal growthapplications (e.g. silicon andsapphire).

Applications automotive industry

chemical and oil industry crystal growth

furnace manufacturing

furniture industry

glass industry

infrared drying

mechanical engineering

packaging industry

paint and print shops

Certificates

quality standard to ISO 9001 accreditation as per UL 508

SCCR, certified to UL 508A(100 kA short circuit test)

Canadian National Standard

CE compliant

RoHS compliant 5/6

safe separation between con-troller and power module

integrated semiconductorfuse

AEG Power Solutions provides,

in the Thyro-Family, a verycomprehensive model range ofpower controllers that iscompletely digital and buscompatible.

This produces affordablesolutions with enhancements inthe areas of:

process control

process documentation

system availability

cabling complexity

commissioning time andcosts

installation complexity


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The Thyro-FamilyThyro-S

Thyristor switches reliable,quick, economical andcommunication enabled

Thyro-A

16 A 1500 A thyristorpower controllers

Thyro-AX

Thyristor power controllerswith touch screen display

Thyro-P

High-precision thyristorpower controllers for allindustrial applications


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THYRO-S

The digital, communicationenabled Thyro-S thyristorswitch is equipped withlots of useful functions for

a wide range of uses andsupports the customerssystem requirements.

As a connection readythyristor switch with secureoperational behavior andload monitoring, it switchescurrents, voltages and powersources. It can be used inbus systems, in stand-aloneoperations or in combinationwith all standard 2-pointprocess controllers, PLCsystems or computer systems.

Through simple assembly,fast commissioning andreliable operation, the Thyro-Sintegrates itself very wellinto the wide area of use ofmodern process technology,

e.g. into the following areas: automotive industry (e.g.

paint drying facilities)

chemical industry (traceheating and preheatingsystems)

furnace construction(industrial, diffusionand drying furnaces)

glass processing(drying of coatings)

machine building(extruders, automoulders)

packaging industry(shrink tunnels)

print shop machines(IR drying)

THYRISTOR SWITCHES FAST, RELIABLE,ECONOMICAL


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In addition to operating with no wear and high levels of efficiency, further impressive features of this range include:

KEY FEATURES

Voltage rating 230 V, 400 V, 500 V

Current rating (A) 16, 30, 45, 60, 100, 130, 170, 280

Semiconductor fuses integrated

Load circuit monitoring integrated

Status indicators LED

Signal relay 1

AUTOMATION LEVEL

System interface standard for connection to an optional bus module (PROFIBUS DPV1, Modbus RTU,DeviceNet, CANopen, PROFINET, Modbus TCP or EtherNet/IP)

connection option for connecting to the Thyro-Tool Family software

Safety Safe separation between controller and power module


Logic signal control 24 V logic signal control (> 3 V) or over standard system interface

Load type Ohm resistive load

Operating modes 1:1 1:2* 1:3* 1:5*

Frequency range 47 Hz 63 Hz

3-phase set up by connecting two Thyro-S units

External electronic supply 24 VAC / DC

* reduced power output e.g. for commissioning

THYRO-STECHNICAL DATA


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THYRISTOR-POWERCONTROLLER16 A 1500 A

THYRO-A

Fast, reliable andwith communicationcapability

Through its powerful digitaltechnology the new,communication enabledThyro-A thyristor powercontroller allows a preciselyregulated feed of power witha high level of availability.

Heating, melting andmoulding

Its great flexibility in relation toconnection on the load andpower supply side extends its

area of use considerably. Forstandard processes there aresetting options available on thecontroller that enable it to beeasily operated and quicklycommissioned. Optionalconnection at the automationlevel makes it possible to use amultitude of further functions.All measurements, status levelsand set points can beprocessed by PLC or process

computer. Naturally, stand-alone operation or directcombination with processcontrollers is still possible.Thyro-A power controllers areexcellently suited to numerous

areas of use in the entireprocess technology field,such as:

automotive industry(paint drying facilities)

chemical industry(trace heating andpreheating systems)


glass industry (plateglass systems, feeders,finishing machines)





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KEY FEATURES

Voltage rating 230 V, 400 V, 500 V, 600 V

Current rating (A) 16, 30, 45, 60, 100, 130, 170, 280, 350, 495, 650, 1000, 1400, 1500


Connection type Single, dual and three-phase versions (dual-phase version for three-phase load withoutdeploying the neutral conductor in a cost-saving three-phase circuit)

Semiconductor fuses integrated


Status indicators LED

Signal relay 1

Analog output 0 (4) 20 mA, 0 (2) 10 V

AUTOMATION LEVEL

System interface standard for connection to an optional bus module (PROFIBUS DPV1,Modbus RTU, Device-Net, CANopen, PROFINET, Modbus TCP and EtherNet/IP)

for processing set point and actual values and status reports

connection option for connecting to the Thyro-Tool Family software

Safety safe separation between controller and power module

ADDITIONAL TECHNICAL DATAAnalog set point 0 20 mA, 0 10 V, control characteristic line adjustable in range

2 point controller Off = 0...3 V, On = 3...24 V

Load type ohm resistive load and inductive mixed load(suitable for transformer load due to integrated soft-start function, phase angle firing of

1st half wave and channel separation)

Control modes U, U2, I, I2, P

Operating mode TAKT VAR QTM

Mains voltage up to 0.43 x UNom

Frecuency range 47 Hz 63 Hz

Other simple operation, minimal space requirement

high short circuit current resistance and power semiconductor cut-off voltage

internal mains load optimization in operating modes TAKT and QTM

optional external mains load optimization (Thyro-Power Manager)

THYRO-ATECHNICAL DATA


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THE NEXTGENERATION OFTHYRISTOR POWERCONTROLLERS

THYRO-AX

A continuing story ofsuccess

In introducing the newThyro-AX, AEG PowerSolutions is extending itsproven family of Thyroproducts through theaddition of a new generationof digital thyristor powercontrollers. With numerousnew features, the Thyro-AXis setting new standards.

Supporting voltages of 24 to

600 V, the Thyro-AX rangeoffers what is probably aunique array of products from16 to 1500 A and is availablein single, dual or three-phaseunits. A flexible connectiontechnology allows thecontrollers to be connectedcompletely free from belowand /or above.

Making its debut, the touchscreen display with fullgraphic capability is usedhere for the first time ever byany manufacturer in a powercontroller and enables highlyintuitive operation. In relationto using the power controller,especially for viewing andsetting parameters, wholenew possibilities are created.Set points, actual values andoperating status details aredisplayed in plain text. Thecontrollers operating status isadditionally indicated byalternating backgroundillumination. The standardinterfaces include both

Ethernet and USB 2.0.

Via the USB 2.0 interfaceit is possible to setparameters even without

an external supply usingthe Thyro-Tool AX program.Alternatively, parametersetting/ viewing can beperformed via web browser.

For communication with toplevel control systems variousbus modules are available, e.g.for DeviceNet, Modbus RTU,PROFIBUS or CANopen, plusothers for TCP/IP-basedcommunication usingPROFINET, Modbus TCP orEtherNet/IP. Another of the

new generations importantand defining features is the useof intelligent technologies toreduce circuit feedback, plusthe mains load optimizationfunction to reduce costs. Aswith all power controllers in theThyro range, it goes withoutsaying that the Thyro-AXalso features high levels ofefficiency for saving power inlive operation.

Thyro-AX thyristor powercontrollers are suited to allapplications in the field of

heating, melting, mouldingand drying and can be used,not least due to their simpleoperation, in diverse ways andin all sorts of areas of modernprocess technology, e.g.

automotive industry(paint drying facilities)

chemical industry (traceheating and preheatingsystems)

crystal growth(sapphire, silicon)


glass industry (plateglass systems, feeders,finishing machines)





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THYRO-AXTECHNICAL DATA


KEY FEATURES

Voltage rating 230 V, 400 V, 500 V, 600 V

Current rating (A) 16, 30, 45, 60, 100, 130, 170, 230, 280, 350, 495, 650, 1000, 1400, 1500

Connection type single, dual and three-phase versions (dual-phase version for three-phase load without

deploying the neutral conductor in a cost-saving three-phase circuit)Semiconductor fuses integrated

Display touch screen display

Protection type IP20

Signal relay 1

Analog output 3 x 0 (4) 20 mA, 0 (2) 10 V

Data logger via internal error memory with real-time clock

Communication USB and Ethernet for setting parameters andviewing actual values via Thyro-Tool AX software

webserver via RJ45 connection

firmware update via USB possible

AUTOMATION LEVEL

Standard system interface for connection to an optional bus module (PROFIBUS DPV1, Modbus RTU,

DeviceNet, CANopen, PROFINET, Modbus TCP and EtherNet/IP)connection option via USB or Ethernet for connecting to the Thyro-Tool AX software



Input 2 set point inputs, 2 digital inputs, 1 gate input

Analog set point input signal ranges in each case 0 (4) 20 mA, 0 (1) 5 V, 0 (2) 10 V

Load type ohm resistive load with Rhot

/Rcold

ratio, transformer load, limitation to 3 x INom

Control input for switch operation two-point regulation possible (Uon

= 3 24 V)

Control modes U, U, I, I, P

Operating modes TAKT VAR QTM SWITCH

Frequency range 47 Hz 63 Hz

Mains load optimization internal mains load optimisation in operating modes TAKT and QTM

optional external mains load optimisation (Thyro-Power Manager)

Other simple operation, minimal space requirement

flexible connection: supply and outflow from above or below as selected


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DIGITAL THYRISTORPOWERCONTROLLER

THYRO-P

Reliable, fast,efficient and withcommunication

capabilityThe Thyro-P is the result of theconcerted application of over40 years of experience in thefield of thyristor powercontrollers.

The Thyro-P range of powercontrollers can be usedwherever voltage, current oroutput levels have to beprecisely and reliablyregulated.

With a wideband powersupply, an optional mainsload optimization module,the patented ASM procedureand a user friendly interface,it is ideal for use in manyareas, such as:

automotive industry

chemical and oil industry

extruders and automoulders

furnace manufacturing

furniture industry

glass industry

infrared drying

mechanical engineering

packaging industry

paint and print shops

trace heating systems

Numerous operating andcontrol modes, goodconnection options toprocess and automationsystems, high levels of controlprecision through the use ofa 32 bit RISC processor andsimple handling, make theThyro-P a future orientedcontroller, also for newapplications. Parameterscan be adjusted via menus,while set points and actualprocess values can be

processed via analogoutputs or, as an option,via bus systems.

By virtue of using high qualitynetwork thyristors the Thyro-Prange includes powercontrollers with rated currentsof up to 2900 A and voltages ofup to 690 V.

Application specific solutionswith significantly highercurrents and voltages are alsoavailable.


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THYRO-PTECHNICAL DATA

The Thyro-P range features impressively easy handling for quick and safe commissioning:

KEY FEATURES

Voltage rating 400 V, 500 V, 690 V

Current rating (A) 37, 75, 110, 130, 170, 280, 495, 650, 1000, 1500, 2100, 2900

Connection type single, dual and 3-phase versions (dual-phase version for three-phase load without

deploying the neutral conductor in a cost-saving three-phase circuit)Semiconductor fuses integrated


Status reporting 6 x LED

Signal relay 3 x free programmable

Analog output 3 x 0 (4) 20 mA, 0 (2) 10 V

Data logger error memory with incident time recording

Other high level of efficiency, zero-wear operation

connection to SELF/PELF circuits

local display and operating unit (LBA) for menu driven operation and display ofparameters and readings

patented ASM procedure for automatic synchronization of multiple power controllerapplications to achieve dynamic network load optimization

wideband power supply for control voltage

AUTOMATION LEVEL

System interface standard system interface for connection to an optional bus plug-in card(PROFIBUS DPV1, Modbus RTU, DeviceNet, CANopen or PROFINET.

Coming soon: Modbus TCP/IP and EtherNet/IP)

RS232 and fiber optic connection for connecting to the Thyro-Tool Family software



Analog set point 0 20 mA, 0 10 V

Load type integrated soft start function for operating with downstream transformerTransformer load, Ohm resistive load and heating elements with large R

hot/R

cold

Control modes U, U, I, I, P and unregulated

Operating modes TAKT VAR SSSD

Mains voltage up to 0.43 x UNom

Frequency range 47 Hz 63 HzOperating hour counter display in min. / hours

Energy meter releasable in Ws / kWh

Current resolution 15 bit, equivalent to 0.03 %

Voltage / power/set point resolution 14 bit

Number of A / D transformers 7

Sample rate per transformer 1.5 Mio. / sec

Mains load optimization internal mains load optimisation in operating modes TAKT and QTM,optional external grid load optimisation (Thyro-Power Manager)


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COMMUNICATIONWITH CONTROLSYSTEMS

The bus componentsenable one or more powercontrollers to be connectedto control systems.

Bus components are availablefor the following bus systems:

EtherNet/IP

PROFINET

PROFIBUS DP V1

DeviceNet

Modbus RTU

CANopen

others types on request

All bus components work asslave bus participants andneed only one bus address.

Depending on the powercontroller being used, thedata transfer incorporatesthe following:

set point

actual value

load voltage

mains voltage

load current

effective power

remote signals

status messages

Other power controller datacan be accessed if required,making it possible to execute

additional functions.

Bus modules can be mountedon a top-hat rail and arepowered using a supplyvoltage of 24 VDC (150 mA).

Key features include:

only one address neededper bus module

access to the powercontrollers set points, actualvalues and parameters

transfer of the actual valuesas a floating point numberinto physical units

check of correct functioningvia LEDs

8 free outputs

control of Thyro-S usingdigital set points (equatingto OFF, 1/5, 1/3, 1/2, ON)

electrical power supply

24 VDC, 150 mA

BUSCOMPONENTS

PROFIBUS DPV1 bus modulePROFIBUS-DP plug-in card Ethernet plug-in card


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Thyro-Tool Family

Thyro-Tool Family is acommissioning and

visualization software for theThyro-S, Thyro-A and Thyro-Prange of power controllers. Theuser interface is multilingual.

Thyro-Tool Family operatesunder Windows and isdesigned for the connection tothe power controller via a serialinterface or fiber optics.

Key functions include:

setting the limitsof the devices

set point processing

operating hours counter

power display (in kWh)

displaying, loading, storing,changing and printing ofall relevant measurementsand display values

comparison for twoparameter sets

The Thyro-Tool Family allows asimultaneous presentation ofseveral bar and line charts withvariable size and composition.Furthermore data andparameters as inputted can bedisplayed from several powercontrollers. A maximum of 998Thyro-P power controllers canbe connected via an opticalcable distribution (LLV).

Thyro-Tool AXBeing a customizedprogram for the Thyro-AX,this is an extension of theThyro-Tool Family.

The focus here is on ease ofuse and a greater overviewwhen monitoring lots ofconnected thyristor powercontrollers.

Thyro-Tool AX can be easilyconnected to the Thyro-AX

via a USB interface.

The system then assignscontrollers by IP address.That makes it possible toperform individual analysesfor each connected Thyro-AX:

actual value

set point

line chart

parameter evaluation

It is also possible, as with the

Thyro-Tool Family software,to compare the controlparameters with each other.

CONFIGURATION-TOOLS AND MAINSLOAD OPTIMIZATION

THYRO-TOOLFAMILY ANDTHYRO-TOOL

AX


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THYRO-POWERMANAGERAND ASM-

PROCEDURE

Key Thyro-Power

Manager features easy to use (switch

and potentiometer)

fault and alarm output

power and energymeasurement

can be connectedat field bus level

measurement of mainsvoltage and temperature

integrated operatinghours counter

electrical power supplyof 110/230 V; 50/60 Hz

Thyro-Power Manager

The Thyro-Power Manager isan additional device for static

mains load optimization whenusing multiple configurationsof up to 10 power controllersin the (TAKT) operating mode.The Thyro-Power Manager canalso be used for tasks such asmonitoring mains load peaks,monitoring and recordingmeasured values and as anE/A module. The Thyro-PowerManager facilitates, forexample, a reduction inoperating costs as a resultof reduced peak loads andcircuit feedback one of the

primary challenges for everyapplication.

Very early on, AEG PowerSolutions were alreadydeveloping synchronizationprocedures that broughtconsiderable benefits forusers when dealing withlarge volumes of power.

ASM-procedure

For dynamic networksynchronization of power

controllers AEG PowerSolutions patented ASMprocedure (automaticsynchronization in multi-controller applications) isideal. It reacts to any setpoint or mains load changes,thus setting optimummains loading conditionsfor the application.

with ASM

without ASM

without ASM

Improved Mains with ASM-procedure

Mains load with ASM-procedure

t = 0

t = 0

TON

(c)

TON

(c)

TON

(b)

TON

(b)

TON

(d)

TON

(d)

TON

(g)

TON

(g)

TON

(f)

TON

(f)

TON

(a)

TON

(a)T

ON(a)

TON

(e)

TON

(e)

TON

(e)

TON

(e)

T0


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ACCESSORIES PERFECTINGOPERATIONS

Accessories

mains load optimization

communication

cables and adapters

fiber optics

Using innovative ideas, AEGPower Solutions engineers andtechnicians work constantly onenabling optimum integrationof our products applications.

Mains loadoptimization

ASM procedure

Thyro-Power Manager

Fiber optic systems

fiber optic splitter

fiber optic mains adapter

Visualization

graphic user interface (LBA)

cabinet mounting kit

Communication

Modules and expansioncards for:

CANopen

DeviceNet

Software

Thyro-Tool Family

Thyro-Tool AX

Modbus

PROFIBUS

EtherNet/IP

PROFINET

visualization

measuring equipment

Thyro-Step Controller

software

other accessories


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Thyro-Step Controller

Combines multiple loadcontrol (10+1 circuits) andtraditional tasks, such asmonitoring mains loadpeaks and data logging.

Cables and adapters

RS232-cable

RS232-to-PC-adapter

RS232 top-hat rail adapter

RS232-to-USB-adapter

RS232 to fiber optic

Other accessories 24 VDC mains adapter

24 VDC relay

direct current reduction

top-hat rail adapter(16 / 30 A)

top-hat rail adapter(45 / 60 A)

Measuring equipment

Thyro-measurementunit (TMU)

measuring unit ZME1

measuring unit ZME5

voltage transformer

ACCESSORIES


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POWERSERVICES GUARANTEED

AVAILABILITY ANDEFFICIENCY

Our high-quality productsare reliable. However, it isonly when something goeswrong that true quality isshown through the excellenceof the technical support.Put your faith in our experts

and ensure your systems arefunctional and productive.

With our unparalleledexperience from over 60years of technical supportand industry training, wehave installed, through ournetwork of over 200 expertfield technicians and now

maintain, more than 30,000systems around the world.

AEG Power Solutions offersa complete range of servicesfrom planning, commissioningand installation, includingdiagnosis, repair andmaintenance packages andextending all the way tomonitoring and leasingprograms for appliances.

Our customer support isavailable 24/7, wherever inthe world you need our help.We offer you technical know-how on our product rangeand applications for yourindustry. AEG Power Solutions

products are certified innumerous countries to thestrictest of standards. Thisensures that our productsprovide the same high levelof availability and reliabilityas our technical supportoperation does for you.


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Documents

Power Controller