Trumpf TruConvert AC 3025 Operator's Manual
  1. Manuals
  2. Brands
  3. Trumpf Manuals
  4. Inverter
  5. TruConvert AC 3025
  6. Operator's manual
Trumpf TruConvert AC 3025 Operator's Manual

Trumpf TruConvert AC 3025 Operator's Manual

Hide thumbs Also See for TruConvert AC 3025:
Table of Contents

Advertisement

Quick Links

Download this manual
Operator's manual
TruConvert AC 3025,
TruConvert System Control

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the TruConvert AC 3025 and is the answer not in the manual?

Questions and answers

Related Manuals for Trumpf TruConvert AC 3025

Summary of Contents for Trumpf TruConvert AC 3025

  • Page 1 Operator's manual TruConvert AC 3025, TruConvert System Control...
  • Page 3 Operator's manual TruConvert AC 3025, TruConvert System Control Original operator's manual 2020-06-10 Edition...
  • Page 4 Please specify when ordering this document: Order Information Operator's manual TruConvert AC 3025, TruConvert System Control Edition 2020-06-10 Document number A67-0141-00.BKEN-001-05 TRUMPF Hüttinger GmbH + Co. KG Address for orders Technische Redaktion Bötzinger Straße 80 D-79111 Freiburg Fon: +49 761 8971 - 0 Fax: +49 761 8971 - 1150 Internet: http://www.trumpf-huettinger.com...
  • Page 5 Provide the serial number when you contact the Service depart- ment. The serial number can be found on the name plate of the device. How to reach our Service department: Telephone +49 761 8971-2170 +49 761 8971-1178 E-mail Service.Elektronik@de.trumpf.com A67-0141-00.BKEN- 2020-06-10 Good to know 001-05...
  • Page 6 Good to know 2020-06-10 A67-0141-00.BKEN- 001-05...

  • Page 7: Table Of Contents

    Fields of application Function description Configurations Construction Overview Rear side Display elements Technical specifications Data TruConvert AC 3025 TruConvert System Control data Interfaces Mains power connection Potential equalization DC link Contactor release contact and mains voltage measurement 24 V supply voltage (DC)
  • Page 8 Standards and directives CE certification EU declaration of conformity TruCon- vert AC 3025 Installation Inspecting the delivery Disposing of packaging material Transport Storage conditions Requirements for the site Electrical connection Establishing electrical connection Connection diagram Setting grid codes Dismantling Shipping the module 6.10 Disposing of the module Operation...
  • Page 9 Actual values Display actual values Process set values Set process set values Data backup Saving data 7.10 System configuration Setting the system configuration 7.11 System control Setting the system time Changing network settings 7.12 Software update Perform software update 7.13 Device information Displaying device information 7.14...

  • Page 10: Safety

    Safety Storing the operating instructions These operating instructions contain safety notices that must be observed during installation and maintenance. Therefore, keep the operating instructions in a safe place for the entire life cycle of the device. Include the operating instructions if you sell the device or set it up at another location.

  • Page 11: Authorized Personnel

    Liability exclusion Any use not listed under "Typical fields of application" contra- venes the intended purpose. TRUMPF is not liable for any ensu- ing damages, in particular for property damage, personal injury and loss of production. The operator bears all risks. The war- ranty is rendered null and void.

  • Page 12: Warning Signs On The Ac-Dc Module

    What you must know as an operator Note All warning signs must be present and legible. If one or more of these warning signs is missing or not legible, contact TRUMPF to request new warning signs. Warning sign Meaning This sign indicates that the operat- ing instructions must be read.

  • Page 13: Dangers From High Voltages

    Warning sign Meaning Sign warns of hazardous residual voltage. This sign warns of dangers that arise from the weight of the device. Sign warns of contact current. Meaning of the warning signs Tab. 2 Dangers from high voltages Life threatening voltage! WARNING The voltages present at the AC-DC module are life- threatening.

  • Page 14: Protective Measures Taken By The Manu

    Protective measures taken by the manufacturer The AC-DC module is installed in an enclosed metal casing. What you must know as an operator 1. The AC-DC module must not be opened. There are no parts within the device that can be serviced by the user.

  • Page 15: Description

    (see "Fig. 3", pg. 10). Configurations Permissible configurations ■ The TruConvert AC 3025 must always be operated together with a TruConvert System Control. ■ TruConvert AC 3025 can be operated on its own on a DC link ("DC link"). A67-0141-00.BKEN- 2020-06-10 Description 001-05...
  • Page 16 ■ Multiple TruConvert AC 3025 units can be operated simulta- neously on the DC link. ■ One TruConvert AC 3025 can be operated together with up to 16 TruConvert DC 1008. Impermissible configurations ■ The connection of other DC voltage converters is only per- missible in consultation with TRUMPF.
  • Page 17 One TruConvert System Control controls several TruConvert AC 3025 PC with web browser or Mod- DC link bus master Terminating resistor TruConvert System Control 1 x TruConvert System Control, n x TruConvert AC 3025 Fig. 4 A67-0141-00.BKEN- 2020-06-10 Description 001-05...

  • Page 18: Construction

    One TruConvert System Control controls one TruConvert AC 3025 and several TruConvert DC 1008 DC-Zwischenkreis TruConvert System Control Terminating resistor One TruConvert System Control controls one TruCon- Fig. 5 vert AC 3025 and m x TruConvert DC 1008 Construction The AC-DC module is housed in an enclosed 19-inch metal housing.

  • Page 19: Overview

    Overview Device name Status LEDs Fan (air is sucked) Name plate Overall view of the TruConvert AC 3025 Fig. 6 Rear side Mains input ("Mains") DC link voltage ("DC Link") Threaded bolts for potential equalization Contactor release contact and LED status display mains voltage measurement Data cable "SLAVE IN"...

  • Page 20: Display Elements

    Display elements Status LEDs on TruConvert AC 3025 and TruConvert Sys- Fig. 8 tem Control Device condition Bootloader Initialize Errors Idling Operation 1 (green) Flashing Flashing Flashing 2 (yellow) Flashing Flashing LED indicates the energy direction. ■ Illuminates if the energy flows from mains to the DC link.

  • Page 21: Technical Specifications

    Technical specifications Data TruConvert AC 3025 Entire device Description Value Max. efficiency 98 % Voltage supply 24 VDC ± 10 % / 8 A Note Observe for external fuse: switch- on current is briefly three times the nominal current. Reaction time (change in energy <...
  • Page 22 N conductor and PE conductor are not connected in the TruCon- vert AC 3025. N conductor and PE conductor must be connected outside of the TruConvert AC 3025. Ground leakage current < 3 mA (If residual current circuit breakers are used: use type B.) Mains connection data Tab.
  • Page 23 Description Value Maximum output voltage 950 VDC, balanced to earth Deviations possible upon consulta- tion with TRUMPF Recommended external fuses The DC fuses must be provided on-site by the customer. No DC fuses are required for installations with max. 4 TruCon- vert DC 1008.
  • Page 24 Derating operation At ambient temperatures > 40 °C, the output apparent power is reduced. Derating Fig. 9 Interfaces Description Connection DC link DC Link ■ − PCB plug connector, 3-pin 24 V supply voltage (DC) ■ − PCB plug connector, 2-pin Mains power connection ■...
  • Page 25 Housing Description Value Dimensions W x H x D 437 mm x 129 mm x 500 mm (without connection components) Dimensions of front panel W x H 482 mm x 132 mm Weight 27 kg Housing material Galvanized sheet steel Protection class IP 20 Housing...

  • Page 26: Truconvert System Control Data

    Environmental conditions Condi- Temperature Humid- Air pres- Contamination tion sure Micro-environ- ment com- plies with IEC 62109-1 Rated -5 °C to +40 °C 5 … 90 Up to Pollution opera- approx. degree 2 +23 °F to +104 °F tion 78 kPa (≙...
  • Page 27 Dimensional drawing Dimensional drawing Fig. 11 Environmental conditions Condi- Temperature Humid- Air pres- Contamination tion sure Micro-environ- ment com- plies with IEC 62109-1 Opera- -5 °C to +65 °C 5 … 90 Up to Pollution tion approx. degree 2 23 °F to +149 °C 78 kPa Storage -20 °C to +80 °C...

  • Page 28: Interfaces

    The information applies to: ■ Ambient temperature 30 °C, 86 °F ■ Cable operating temperature: 90 °C, 194 °F ■ Installation type: Open air ■ If the environmental conditions differ from those listed above, contact TRUMPF Service. Interfaces 2020-06-10 A67-0141-00.BKEN- 001-05...

  • Page 29: Potential Equalization

    Potential equalization View Threaded bolts for potential equalization Potential equalization Fig. 13 Connection ■ M6 threaded bolt, torque: 5 Nm Cable requirement ■ 1 x 4 mm / 1 x AWG 10 DC link View Fig. 14 Connection ■ At the AC-DC module: Phoenix PCB plug connector ■...

  • Page 30: Contactor Release Contact And Mains Voltage

    Cable operating temperature: 90 °C, 194 °F − Installation type: Open air − If the environmental conditions differ from those listed above, contact TRUMPF Service. Note To keep inductivity at a minimum cables should be twisted. Contactor release contact and mains voltage measurement...

  • Page 31: Supply Voltage (Dc)

    24 V supply voltage (DC) Note The negative terminal of the supply voltage is not connected to PE in the AC-DC module. Grounding must be performed by the customer, as close to the housing as possible. View 24 V supply voltage (DC) Fig.

  • Page 32: Interfaces On The System Control

    The use of the communication interfaces is dependent on the configuration (see "Configurations", pg. Example Connect system control (RS-485 connection) to the AC-DC mod- ule (RS-485 SLAVE IN connection). Connect the AC-DC module (RS-485 SLAVE OUT connection) to the supplied terminating resistor. A DC-DC module (RS-485 IN connection) is connected from the AC-DC module (RS-485 MASTER connection).

  • Page 33: Ethernet

    Connection Connector for 24 V supply voltage (DC) Fig. 20 ■ On the device: Phoenix PCB plug connector ■ Required counterpart: connector, 2-pin, 8A, CS 3.5 mm Fuse External fuse protection must be provided by the customer. Ethernet View Ethernet data connection Fig.
  • Page 34 Connection ■ RJ-45 male connector Cable requirement ■ Twisted pair patch cable in accordance with standard TIA/ EIA-568A/B ■ CAT 5 or higher ■ Max. length: 30 m Interfaces 2020-06-10 A67-0141-00.BKEN- 001-05...

  • Page 35: Standards And Directives

    Standards and directives CE certification EU directives: ■ Low-voltage directive 2014/35/EU ■ Electromagnetic compatibility directive 2014/30/EU Standards taken into account: ■ EN 62040-2: 2006/AC class C2 ■ EN 62109-1:2010 ■ UL 1741 A67-0141-00.BKEN- 2020-06-10 Standards and directives 001-05...

  • Page 36: Eu Declaration Of Conformity Truconvert Ac 3025

    EU declaration of conformity TruConvert AC 3025 EU declaration of conformity TruConvert AC 3025 Fig. 23 Standards and directives 2020-06-10 A67-0141-00.BKEN- 001-05...

  • Page 37: Installation

    2. In order to retain the right of recourse, report any shipping damages immediately in writing to the forwarding agent, the insurance company and TRUMPF. Disposing of packaging material If you do not want to keep the packaging material for a subse- quent transport: Ø...

  • Page 38: Electrical Connection

    Air intake and air outlet Sufficient space must be present for air intake and air outlet. Minimum distance for air out- Minimum distance for air let: 300 mm intake: 200 mm Air circulation intervals Fig. 24 Maximum back pressure Sufficient cooling of the module is only ensured if a sufficient air flow rate up to a maximum permissible back pressure is pro- vided.

  • Page 39: Establishing Electrical Connection

    Danger of fire DANGER Ø Observe the installation regulations of the installation site. Ø Fuse the DC link connection (DC Link) with 40 ADC. Failure to observe the torques can damage the AC-DC NOTICE module. Ø Note torques when screwing. Establishing electrical connection Condition ■...
  • Page 40 Connect mains supply Mains input ("Mains") DC link voltage ("DC Link") Data cable "SLAVE IN" Contactor release contact and Data cable "MASTER OUT" Data cable "SLAVE OUT" mains voltage measurement Threaded bolts for potential ("Contactor / Mains Measure- equalization ment") 24 V supply voltage Connection points Fig.
  • Page 41 Connecting DC link Connection cables carry life-threatening voltage. DANGER Ø Do not work under voltage. Ø Before connecting, check DC link voltage cables to ensure that they are not electrically live. 8. Attach the 3-pin connector to the DC link line and PE line. Assignment (see "DC link", pg.

  • Page 42: Connection Diagram

    Connection diagram Mains Mains contactor Circuit breaker for mains volt- age measurement Mains and system protection AC-DC module 10 Mains voltage measurement Fuses / power circuit breakers DC link 11 Contact for contactor release Contactor supply 24 VDC supply voltage 12 Potential equalization Electrical connection Fig.

  • Page 43: Setting Grid Codes

    ■ Contactor supply (4) − Is switched via device-internal switching contact (11). − Permissible operational data for switching contact: 24 – 60 VDC, 5 A or 85 – 277 VAC, 5 A. − The 24 VDC supply voltage can be used to supply the mains contactor if necessary if voltage and power are sufficient.
  • Page 44 (see "Commissioning", 41). ■ AC-DC module is in idling condition ("Activate power stage" = 0). To connect and operate the TruConvert AC 3025 in parallel NOTICE operation with the public low-voltage grid, the following points are to be adhered to: Ø...

  • Page 45: Dismantling

    Dismantling Connection cables carry life threatening voltage! WARNING Ø Open the external mains separation device between mains and the power connection of the device. Ø De-energize the cable between mains and the mains syn- chronization connection. Ø De-energize the connection cables to the DC link voltage. Ø...

  • Page 46: Shipping The Module

    Ø Use packaging material which can withstand transport stresses to ship the module. If the original packaging is no longer available: Suitable packaging material can be purchased from TRUMPF. 6.10 Disposing of the module Ø Observe the local regulations when disposing of the module. Installation 2020-06-10 A67-0141-00.BKEN-...

  • Page 47: Operation

    Operation Commissioning Performing initial commissioning Conditions ■ PC on which one of the following browsers is installed: − Microsoft Internet Explorer from version 11. − Microsoft Edge. − Google Chrome from version 46. − Firefox from version 40. ■ Ethernet cable for connecting PC and TruConvert Sys- tem Control.
  • Page 48 System configuration Save settings Restart system control Initial commissioning display Fig. 27 The browser displays the user interface of the TruCon- vert System Control and the connected modules. Several system controls are used in one system? Ø Connect one system control after another to the PC and change the default IP address to a unique IP address.
  • Page 49 Display of the current device Software update Submenu status Device identification (display Sidebar (alarm, warning and Main operating parameters only) event messages) (start page) Device configuration (time and network settings) Start screen Fig. 28 The system control balances the set system configuration with the actually connected modules.
  • Page 50 − User interface: For "Slave module selection" enter "0". − Modbus: Enter the number of the slave to be addressed = "0" . 15. Under "Grid voltage", enter the mains voltage and mains fre- quency as well as the operating mode: −...

  • Page 51: Operation Via Web-Based User Interface

    − 0 = DC link voltage is not loaded from the AC-DC mod- ule. − 1 = DC link voltage is loaded from the AC-DC module. 22. To start the transmission of power: − For "Activate power stage [bit]", enter = "1". Press key ↲.
  • Page 52 Display of the current device Software update Submenu status Device identification (display Sidebar (alarm, warning and Main operating parameters only) event messages) (start page) Device configuration (time and network settings) Start screen Fig. 30 The browser displays the user interface of the TruCon- vert System Control and the connected modules.

  • Page 53: Menu Structure

    Menu structure Main menu Submenu Description >HOME — Start screen (see "Calling up the web-based user inter- face", pg. 45) >OPERATION >Device control AC-DC (see "User interface: displaying and resetting mes- sages", pg. 56) >AC-DC module settings (see "Setting process set values (AC settings)", pg. 43) >DC-DC module settings Menu item only present if the DC-DC modules are also connected to the AC-DC module.

  • Page 54: Establishing A Connection

    Establishing a connection Condition ■ Initial commissioning was performed (see "Commissioning", 41). 1. Connect the TruConvert System Control to the Modbus mas- ter with an Ethernet cable. 2. To switch on the system control and the modules: switch on the 24 V supply voltage. The PCS (Power Conversion System) is ready for communica- tion via Modbus.

  • Page 55: Modbus Register Map

    "Slave- Register Slave no. Description ID" slave no. Subslave To subslave 4 from slave 16. Subslave To all subslaves from slave 1 Subslave To all subslaves from slave 16 Subslave To all subslaves. Examples: Structure of slave ID Tab. 17 Modbus Register Map ■...
  • Page 56 Addr Description Unit Default olu- atyp tion 1018 Setting for connected sys- Regi tem configuration: ster No config = 0, Simulator = 1, DC-DC only = 2, n*AC-DC m*DC-DC = 3 1028 Variable to save or reset Regi customer values: ster 1: save parameter -1: restore default settings...
  • Page 57 Addr Description Unit Default olu- atyp tion 4008 Error handling policy for Regi systems with multiple ster slaves: 0 = relaxed (Sys- tem keeps running even if some slaves are in error state.); 1 = strict (System shuts down as soon as one component is in error state.) 4009...
  • Page 58 Addr Description Unit Default olu- atyp tion 4200 Power nominal value AC 0.00 Regi ster 4201 Power nominal value AC 0.00 Regi ster 4202 Power nominal value AC 0.00 Regi ster 4203 Maximum grid current 0.01 8000 Regi RMS L1 (charging and ster discharging) 4204...
  • Page 59 Addr Description Unit Default olu- atyp tion 4306 0 = power distribution, 1 Regi = current distribution, 2 = ster auto ActualValues 5000 State of device: 0 = Regi Power up, 1 = Alarm, 2 ster = Idle, 3 = Operation, 4 = Maintenance 5001 Number of connected...
  • Page 60 Addr Description Unit Default olu- atyp tion 5152 Grid current RMS L3 0.01 Regi ster 5160 Grid voltage RMS L1 Regi ster 5161 Grid voltage RMS L2 Regi ster 5162 Grid voltage RMS L3 Regi ster 5170 cos phi L1 0.01 -100 Regi...

  • Page 61: Transmission Of Power

    Transmission of power Switching the transmission of power on/off Conditions ■ Initial commissioning was performed (see "Commissioning", 41). ■ Operation via web-based user interface and/or Modbus. Enter process set values 1. Selection of an AC-DC module (only relevant if multiple mod- ules are connected to a TruConvert System Control).

  • Page 62: Displaying And Resetting Messages

    − "inductive" (default setting) − "capacitive" 5. For "DC link precharge config", enter: 1. Start transmission of power 6. Start transmission of power. − User interface: Select >Operation >Device control AC-DC. For "Activate power stage [bit]", enter = "1". Press key ↲. −...
  • Page 63 02 (AC-DC module). DC-DC mod- ule number 4 has caused the message. ■ If TRUMPF Service is to be contacted, it is recom- mended to note down the message number. To display the window of the sidebar larger: click on the arrow.

  • Page 64: Modbus: Displaying And Resetting Mes

    To hide the window of the sidebar: click on the active icon again. Download alarm list 2. To download a list of all alarm messages that have occurred: − Press the "Download alarm history" (3) button. − Save as a csv file. Reset messages 3.

  • Page 65: Overload

    Displaying the number of 1. Read out the number of current alarm/warning/info mes- pending messages sages that have occurred on the entire system . The number of all messages that occurred in the system is output. Reading out message 2. Read out message numbers (alarm/warning/info messages 1 numbers to 20) that have occurred on the entire system.

  • Page 66: Examples: Reduce And Then Again

    2. Start transmission of power. Status bar for the overload capacity (user interface) Fig. 35 As soon as a higher phase current and AC power that is higher than the nominal apparent power is called, the sys- tem can supply this for a certain time span. During overload operation, the overload capacity is reduced continuously.

  • Page 67: Actual Values

    Actual values Display actual values Display AC values Ø Display the current values at the mains connection of the AC-DC module. − User interface: Select >Operation >Device control AC-DC. In the "Status AC modules" area, enter the desired mod- ule under "Slave module selection". Or enter 0 in order to display the generally applicable or sum values of all modules (0 is displayed in the case of values that can- not be summed).

  • Page 68: Data Backup

    Data backup Saving data The general settings can be exported and then imported into another device. Conditions ■ Operation via web-based user interface ■ Settings to be stored were entered under >Operation >AC- DC module settings with "Slave module selection" = "0" and "Subslave module selection"...

  • Page 69: Setting The System Configuration

    Setting the system configuration Conditions ■ Operation via web-based user interface ■ Devices (AC-DC module, DC-DC modules) are connected to the system control 1. To switch on the system control and the modules: switch on the 24 V supply voltage. Most recently saved configura- Most recently saved configura- Most recently saved configura-...
  • Page 70 − 2: DC-DC only Only DC-DC modules are connected to the system control. − 3: n (AC-DC + m DC-DC) AC/DC and DC/DC modules are connected to the sys- tem control. 3. To save the selection: press "Save selection". 4. To restart the TruConvert System Control: press "Restart CPU".

  • Page 71: 7.11 System Control

    ration" is displayed again and a message output. Press side- bar (7) to display the messages. 7.11 System control Setting the system time User interface As soon as the device is connected to the PC, the local time of the PC is converted to UTC and adopted in the system control as system time.

  • Page 72: 7.12 Software Update

    Opening for reset button Reset button on the system control Fig. 38 5. Insert a small pen tip or piece of wire into the opening for the Reset button and press and hold down the Reset button for 3 seconds. 6.

  • Page 73: 7.13 Device Information

    7.13 Device information Displaying device information System control 1. Select >DEVICE INFO. 2. In the "Software package" area, read the details on the installed software package. Relevant details are: "Integration level" and "Buildnumber". 3. In the "System control" area, read off the individual items of information for the system control: −...

  • Page 74: 7.14 State Diagram

    13. In the "DC-DC module" area, read off the number of availa- ble DC-DC modules under "Available sub slave modules". The DC-DC module, which is directly connected to the AC- DC module with the data cable, is "Sub slave" = 1. The next DC-DC module, which is connected to data output "OUT"...

  • Page 75: Maintenance

    If necessary, clean the module with a dry cloth. Exchanging fans TRUMPF recommends replacing the ventilator after an operation lifetime of 6 years. Ø Only have fans exchanged by TRUMPF personnel or trained staff. Performing software updates Software updates can only be made via the user interface.

  • Page 76: Troubleshooting

    Status LEDs on the TruConvert System Control. ■ On the web-based user interface. ■ Via the Modbus. Fault indication with the LEDs Status LEDs on TruConvert AC 3025 and TruConvert Sys- Fig. 40 tem Control Errors 1 (green) 2 (yellow)
  • Page 77 If a message reappears repeatedly after resetting and restarting the device, please contact TRUMPF Service. If a message appears whose number is not listed in the table, please also contact TRUMPF Service.
  • Page 78 Alarm messages Number Message 40302 BMS communication timeout has occured. 40303 RS-485 communication alarm. 40412 Software versions of system control and module(s) do not match. 40413 Software versions of system control and module(s) do not match. 40414 Software versions of system control and module(s) do not match. 40415 Software versions of system control and module(s) do not match.
  • Page 79 Number Message 50097 DC link discharge unit alarm. 50098 DC link could not be charged. 50099 DC link control alarm. 50100 DC link relay could not be closed. 50101 DC link relay was forced to disconnect. 50102 Fan alarm. 50030 DC current component L1 too high.
  • Page 80 Number Message 60132 RS485 communication alarm. 60129 Battery voltage under threshold setting. 60150 Battery voltage over threshold setting. 60168 Ambient temperature over allowed range. 60186 Ambient temperature under allowed range. 60192 Fan defective or stuck. 10016 Power failure of 24-V auxiliary power supply has been detected. Alarm messages Tab.

This manual is also suitable for:

Truconvert system control

Table of Contents