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 2022-03-23 Edition Material number –...
Page 4 Please specify when ordering this document: Order Information Operator's manual TruConvert AC 3025, TruConvert System Control Edition 2022-03-23 Document number A67-0141-00.BKen-001-09 Material number – TRUMPF Hüttinger GmbH + Co. KG Address for orders Technische Redaktion Bötzinger Straße 80 D-79111 Freiburg...
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-0 2022-03-23 Good to know 01-09...
Page 6 Good to know 2022-03-23 A67-0141-00.BKen-0 01-09...
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 Connection acc. to IEC 62109-2 Isolated operation Setting grid codes Dismantling...
Page 9 Overload Operating with overload Examples: Reduce and then again increase overload capacity Actual values Display actual values Process set values Set process set values 7.10 Setting the DC link 7.11 Isolated operation Function description of isolated operation Setting isolated operation Parameterization of isolated operation More information about "Inselbetrieb"...
Page 10: Safety
Safety Storing the operating instructions IMPORTANT SAFETY INSTRUCTIONS CAUTION Ø SAVE THESE 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.
Page 11: Using The Device
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. Safety 2022-03-23 A67-0141-00.BKen-0 01-09...
Page 13: Dangers From High Voltages
Warning sign Meaning This sign indicates that the operat- ing instructions must be read. Sign warns of hazardous voltage. Sign warns of hazardous residual voltage. This sign warns of dangers that arise from the weight of the device. Sign warns of contact current. Sign warns against connecting the photovoltaic modules without string optimizers.
Page 14: Protective Measures Taken By The Manu
The AC-DC module produces voltages that can endanger human life and health. These voltages occur both in the AC-DC module as well as at the outputs of the AC-DC module. The AC-DC module's connection cables carry voltages that are life-threatening. A person who comes into contact with live AC-DC module parts may be killed or severely injured.
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-0 2022-03-23 Description 01-09...
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 4 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 TruConvert System Control Terminating resistor 1 x TruConvert System Control, n x TruConvert AC 3025 Fig. 4 A67-0141-00.BKen-0 2022-03-23 Description 01-09...
Page 18: Construction
One TruConvert System Control controls one TruConvert AC 3025 and several TruConvert DC 1008 DC link 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 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. At ambient temperatures of: charging: -5°C to 35°C, discharging: -5°C to 40°C. Technical specifications 2022-03-23 A67-0141-00.BKen-0...
Page 23 Description Value Ground leakage current < 3 mA (If residual current circuit breakers are used: use type B.) AC short-circuit values ■ Conditional short circuit current ]: 80 A rms ■ Rated short-time withstand cur- rent [I ]: 80 A/500 ms ■...
Page 24 For an installation with max. 4 TruCon- vert DC 1008/1010, it is – after consulting with TRUMPF – possible to forego the use of DC fuses. The parameters required for dimensioning the fuses depend on the installation situation in the customer system.
Page 25 Description Value PV input operating current (maxi- 36 A mum continuous value) (determined by the TruConvert AC 3025) PV (absolute maximum value) 50 A (determined by the TruConvert AC 3025) Maximum regenerative current of the inverter in the PV system Recommended PV string optimizer Ampt, LLC PV module type...
Page 26 Description Connection Measurement of mains voltage Contactor Mains Measurement ■ and contact for contactor release − PCB plug connector, 10-pin Recommended external fuses ■ Circuit breaker, 4-pin ■ Current [I]: 1 A ■ For region EN / IEC acc. to IEC/ EN60947-2: −...
Page 27 Dimensional drawing Dimensional drawing Fig. 10 A67-0141-00.BKen-0 2022-03-23 Technical specifications 01-09...
Page 28: 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 29 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 30: 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 2022-03-23 A67-0141-00.BKen-0 01-09...
Page 31: 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 32: 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 33: Supply Voltage (Dc)
24 V supply voltage (DC) Destruction of the device through improper grounding of NOTICE the 24 V supply voltage source. The negative terminal of the supply voltage is not connected to PE in the AC-DC module. If the incorrect terminal (positive terminal) of the external 24 V supply voltage source is grounded, the device will be damaged or destroyed.
Page 34: Interfaces On The System Control
Cable requirement ■ Twisted pair patch cable in accordance with standard TIA/ EIA-568A/B ■ CAT 5 or higher ■ Max. length: 100 m 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).
Page 35: Ethernet
View 24 V supply voltage (DC) Fig. 19 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...
Page 36 RS-485 View RS-485 data connection Fig. 22 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 Note The total length of the data cable must not exceed 30 m from the PC to the last system control.
Page 37: 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 ■ IEC 62109-2 ■ IEC 62477-1 A67-0141-00.BKen-0 2022-03-23 Standards and directives 01-09...
Page 38: 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 2022-03-23 A67-0141-00.BKen-0 01-09...
Page 39: 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 40: Requirements For The Site
Requirements for the site Installation indoors ■ Operation is permissible in a closed electrical operating room only. ■ Installation, mounting and operation according to IEC 62109-2: − Access restriction for the electrical operating room. − Only electrically instructed persons may work within the operating room.
Page 41: Electrical Connection
Fuses Fuses must be provided on-site by the customer (see "Grid con- nection data", pg. 15). Dependent safety The TruConvert AC 3025 device is a transformerless inverter: requirements ■ Without internal voltage isolation. ■ Without integrated, automatic separation device. ■...
Page 42: Establishing Electrical Connection
Establishing electrical connection Condition ■ Components to be provided by the customer are installed (see "Connection diagram", pg. 39). Means, Tools, Materials ■ Terminating resistor for the data output (provided). ■ The following connectors are provided on request: − Connector "Mains", 5-pin −...
Page 43 7. Switch on 24 V supply voltage on the AC-DC module. Connecting DC link If photovoltaic modules are connected to the DC link: ■ Connection permissible only via a string optimizer approved by TRUMPF. ■ Only use photovoltaic modules and string optimizers that may be used together. ■...
Page 44 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. Mounting 3-pin male connectors on DC link cables: − DC+ and DC-. −...
Page 45: 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 46: Connection Acc. To Iec 62109-2
■ 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 47 TruConvert system control nor by the TruConvert AC 3025. In order to depict the various fields of use of the TruConvert sys-...
Page 48 TruConvert AC 3025 cannot be reconnected until after trou- bleshooting and subsequent active acknowledgment of the fault. ■ Monitoring unit at the place of TruConvert AC 3025 installa- tion triggers an optical or acoustic warning signal for the duration of the error state until active acknowledgment. −...
Page 49 The PV systems must not be connected directly to the DC link of the AC-DC module. − The used PV string optimizers must be approved by TRUMPF. − Installation notes, regulations and operating parameters of the used PV string optimizer must be observed and complied with.
Page 50 TT- and TN-S systems. ■ IT systems: The suggested combination is not permissible here. Please contact TRUMPF to obtain more detailed information on the implementation possibilities. Connection and settings of the RCMS460 monitoring unit: ■ Integrate in the safety circuit to cause the external mains separation device to switch off in the event of a fault: relay contacts K1, K2.
Page 51 TruConvert AC 3025 For economic reasons, connection variant A is recommended for 1 to 4 TruConvert AC 3025 units in grouped systems up to a combined total power of 100 kVA. Here, double the basic insula- tion is used. This insulation consists of the monitored 4-pin mains contactors and basic insulation within the AC-DC modules.
Page 52 Connection variant C can, in principle, also be implemented for 1 to 4 AC-DC modules. Connection diagram for variant C: recommended for 5 to 16 TruConvert AC 3025 Fig. 28 The figure shows the block diagram of a possible complete sys-...
Page 53 Overview of fuse and power components for a 400 kVA system Fig. 29 Meaning Number Design Shown in: (see "Fig. 29", pg. 47) Cross section – 1000 A busbar 5 x 800 mm² (L1, 2, 3, N, PE) Cross section –...
Page 54: Isolated Operation
TruConvert AC 3025 or for the implementation of load cases that are not listed here, contact TRUMPF service. Permissible system types in A system consisting of TruConvert AC 3025 may be operated in isolated operation isolated operation in the following system configurations: ■...
Page 55: Setting Grid Codes
N conductor and PE conductor are not connected in the Tru- Convert AC 3025. ■ N conductor and PE conductor must be connected outside of the TruConvert AC 3025. ■ In TN-C systems and in the TN-C part of a TN-C-S system, the PEN conductor must not be separated.
Page 56 ■ AC-DC module is idling: In the status bar under "Device sta- tus" = "Idle". 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 57: Dismantling
After a 24 V reset, restart of the CPU or a software update, the settings are lost. 6. To save the changes: − Select >Configuration >System configuration. − In the "Grid code conriguration" area, click on "Save grid code settings". Dismantling Connection cables carry life threatening voltage! WARNING...
Page 58: 6.10 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. 6.11 Disposing of the module Ø Observe the local regulations when disposing of the module. Installation 2022-03-23 A67-0141-00.BKen-0...
Page 59: 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 60 Message: Invalid system configuration Initial commissioning display Fig. 30 The browser displays the web GUI. 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. Setting the system 8.
Page 61 − DC-DC configuration Only DC-DC modules are connected to the system control. − n*(AC-DC + m*DC-DC) AC/DC and DC/DC modules are connected to the sys- tem control. 10. Under "Select AC3025 generation", select the device genera- tion: "AC3025". 11. To save the selection: press "Save selection". 12.
Page 62 − "Producer": producer reference arrow system. Positive sign for cosφ means: energy flows from DC link towards mains. Negative sign for cosφ means: energy flows from mains towards DC link. (see "Fig. 33", pg. 56) − "Consumer": consumer reference arrow system. Positive sign for cosφ...
Page 63 Consumer reference arrow system Fig. 34 18. Under "Grid contactor delay", enter the maximum delay time in ms that may elapse between the "Close contactor" com- mand and the actual closing of the contactor. If there is no feedback within the delay time, an alarm is out- put.
Page 64 − LED flashes green: The device is ready for use. − LED flashes red: The device is not ready for use. An alarm message is pending (see "Displaying and resetting messages", pg. 81). 21. Select >Operation >Device control AC-DC mode. 22.
Page 65: Active Interface
In the status bar, the status changes from "Idle" to "Opera- tion". The status LEDs on the AC-DC module and system control light up orange. The contactor connects the mains. Stop transmission of power 26. To stop the transmission of power: press "Activate power stage"...
Page 66: Operation Via Web-Based User Interface
Operation via web-based user interface Calling up the web GUI Condition ■ Initial commissioning was performed (see "Commissioning", 53). 1. To switch on the TruConvert System Control and the con- nected modules: switch on the 24 V supply voltage. 2. Open the web browser on the PC. 3.
Page 67 Start screen Status bar (operating state) Software update Sidebar (user level, settings, current messages) Main operating parameters Message history Submenu (start page) System configuration Device information (display only) Start screen Fig. 36 User interface Status bar Submenu Input area Main menu Expandable sidebar Arrangement of the user interface Fig.
Page 68 Status bar signaling Pending alarm, warning and Active interface Grid code info messages Operating state Detected system configuration Status bar: information Fig. 38 Expandable sidebar The sidebar is divided into three menu items that are labeled with an icon. ■ User settings ■...
Page 69 Main menu Diagnostics and input values Software update Device information Parameter settings Message history Main menu Fig. 39 Input area Clicking on the submenu items opens the input area. Displayed here are the areas of the submenu items for reading or editing. Operation is explained in the individual chapters of the function descriptions.
Page 70: Menu Structure
Menu structure Global menu structure (expandable sidebar) Main menu Area Description Operation Settings >Change User Role. Setting the user roles (Nur für Service) ■ ■ ■ >Interface Control. ■ Enabling interface, (see "Active interface", pg. 59). ■ System clock and time ■...
Page 71: Establishing A Connection
Configuration, initial commissioning and software update of the TruConvert System Control and the connected modules can be performed via the user interface. Function User interface Modbus Operation System configuration Software update — Changing the IP — address Data backup — Differences in operation Tab.
Page 72 Addressing modules via Modbus registers 4007 and 4010 1. To address an AC-DC module (slave modules), enter the fol- lowing in register 4007: − 0 = Address all slave modules. − 1 – n = Address selected slave module. 2. To address a DC-DC module (subslave modules), enter the following in register 4010: −...
Page 73: Modbus Register Map
Register Slave no. "Slave- Description slave no. ID" Subslave To all subslaves from slave 16 Subslave To all subslaves. Examples: structure of the module address Tab. 27 Modbus Register Map ■ Base settings: address range 1000 to 1999 ■ Info system: address range 2000 to 2399 ■...
Page 74 Addr Description Unit Default olu- atyp tion 1018 Setting for connected sys- Regi tem configuration: ster No config = 0, Simulator config = 1, DC-DC only config = 2, n*AC-DC m*DC-DC con- fig = 3 1026 1: triggerst automatic sys- Regi tem software update (if ster...
Page 75 Addr Description Unit Default olu- atyp tion 4006 Sets reference frame con- Regi vention (0 = producer ref- ster erence frame; 1 = con- sumer reference frame) 4007 Specifies the slave that Regi will be addressed (0 = ster broadcast / same values for all slaves) 4008 Error handling policy for...
Page 76 Addr Description Unit Default olu- atyp tion 4183 0 = Idle Regi ster 1 = Send power setpoints 4184 Switch to change inputs Regi from S, cosphi, Phase- ster Cap to P, Q 4185 Active Power set value 0.00 -375 Regi AC (Only available with ster...
Page 77 Addr Description Unit Default olu- atyp tion 4204 Maximum grid current 0.01 8000 Regi RMS L2 (charging and ster discharging) 4205 Maximum grid current 0.01 8000 Regi RMS L3 (charging and ster discharging) 4206 Set value cos phi L1 0.01 -100 Regi ster...
Page 78 Addr Description Unit Default olu- atyp tion 4235 DC link max voltage Regi 480V grid ster 4236 Frequency slope in func- 0.01 Regi tion fN = f(active grid ster power) of droop control in island operation. 4237 Voltage slope in function 0.01 Regi VN = f(reactive grid...
Page 79 Addr Description Unit Default olu- atyp tion 4300 Configuration DC stage: Regi ster 0 = DC module is off, power electronic circuit is deactivated, battery volt- age can be measured. 1 = DC module is active (DC link voltage control) 2 = DC module is active (current source mode or in DC droop mode)
Page 80 Addr Description Unit Default olu- atyp tion 5027 Active DC link max volt- Regi ster 5028 Voltrage threshold of DC 0.01 Regi link half ster 5030 State inverter: Regi ster 0 = IDLE DC_LINK_CHARGE_DIS- CHARGE_TEST DC_LINK_SYNC_TO_EXT 3 = DC_LINK_CHARGE 4 = AC_SYNC_TO_GRID 5 = AC_CLOSE_CON- TACTOR 6 = AC_CONNECTED...
Page 81 Addr Description Unit Default olu- atyp tion 5140 Active power L1 with cor- 0.00 Regi rected sign ster 5141 Active power L2 with cor- 0.00 Regi rected sign ster 5142 Active power L3 with cor- 0.00 Regi rected sign ster 5150 Grid current RMS L1 0.01...
Page 82 Addr Description Unit Default olu- atyp tion 5221 Voltage external N to PE Regi ster 5231 Reactive Power L1 with kVAr 0.00 Regi corrected sign ster 5232 Reactive Power L2 with kVAr 0.00 Regi corrected sign ster 5233 Reactive Power L3 with kVAr 0.00 Regi...
Page 83 Addr Description Unit Default olu- atyp tion 2414 Regi ster 2415 Regi ster 2416 Regi ster 2417 Regi ster 2418 Regi ster 2419 Regi ster 2420 Regi ster 2421 Regi ster 2422 Regi ster 2808 Sum of all pending alarms Regi ster 2809...
Page 84: Transmission Of Power
Addr Description Unit Default olu- atyp tion 2824 Regi ster 2825 Regi ster 2826 Regi ster 2827 Regi ster 2828 Regi ster 2829 Regi ster Modbus Tab. 28 Transmission of power Switching the transmission of power on/off Conditions ■ Initial commissioning was performed (see "Commissioning", 53).
Page 85 − User interface: Select >Operation >Device control AC-DC mode. In the "Device control AC-DC" area under "Apparent power AC", enter the value Press key ↲. − Modbus: (see "Tab. 28", pg. 78) 3. For "Power factor cos(φ)", enter: − User interface: Value between: -1 to +1 (in increments of 0.01) Press key ↲.
Page 86 − User interface: Select >Operation >Device control AC-DC mode. Under "Activate power stage": click on the slide control. − Modbus: (see "Tab. 28", pg. 78) For the Modbus register for power operation, set bit = 1. The regulator slides to the right and is displayed in blue. Stop transmission of power 7.
Page 87: Displaying And Resetting Messages
− Register 4182 "Activate power setpoint trigger": Set bit = − In the registers for the set values: Enter the new set val- ues. − Register 4183 "Send power setpoints" Set bit = 1. Displaying and resetting messages Messages of the web GUI There are various options for reading the pending messages: ■...
Page 88 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 89: Modbus: Displaying And Resetting Mes
To hide the window of the sidebar: click on the active icon again. Icon inactive: no message Sidebar, collapsed, no messages Fig. 44 If the message is not reset: Ø If MASTER is displayed under "Source", enter 0 under "Slave module selection". All messages are reset, includ- ing the messages from the master (system control).
Page 90: Overload
Reading out message 3. Read out message numbers (alarm/warning messages 1 to numbers 20) that have occurred on the selected module: − Alarm messages: registers 2810 – 2829 − Warning message: registers 2403 – 2422 − The corresponding message number is stored in each register.
Page 91 Increase the maximum values for the apparent power. Increase the apparent power up to max. 37.5 kVA. 2. Start transmission of power. 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.
Page 92: Examples: Reduce And Then Again
Examples: Reduce and then again increase overload capacity Reduce overload capacity The overload capacity drops from 100% to 0% if the system is from 100% to 0% operated at overload with: ■ AC power set value between 100% and 125%. For 10 minutes.
Page 93: Process Set Values
ues of all modules (0 is displayed in the case of values that cannot be summed). Read the actual values in the "Status AC module(s)" area. DC link voltage is displayed under "DC link voltage +" and "DC link voltage -" in V. The apparent power output/draw of the individual phases (L1, L2, L3) are displayed under "Apparent power Lx"...
Page 94 2. In the "DC link settings" area, change the values on the first or second line. − First line ("@400 grid") is valid if a voltage of 380 V or 400 V was selected in the "General AC settings" area under "Grid type selection".
Page 95: 7.11 Isolated Operation
7.11 Isolated operation Function description of isolated operation The isolated grid controller of the TruConvert AC series 3000 can replicate the behavior of a synchronous machine. Thus, its operating performance can be compared to that of a rotating machine, e.g., a diesel generator or steam turbine. The system can be operated parallel to the grid or to support a stand-alone network...
Page 96 Example: = 50 Hz, f = 50 Hz, P = 0 W, P = 25 kW DroopKP = 2 % = 0.02 f = 50 Hz + 0.02 × 50 Hz/25000 W × (0 W – 25000 W) = 50 Hz + 40E-6 Hz/W × (-25000 W) = 49 Hz Voltage - reactive power For the operation of an single device, the off-grid voltage is...
Page 97: Setting Isolated Operation
(see "Tab. 31", pg. 91) can be immediately switched on or off without notable influence on the grid voltage. Load type Power [kVA] Resistive 100 % Capacitive Inductive Non-linear 50% (max. crest factor = 3%) Supported stand-alone network load types relative to the Tab.
Page 98 Performing a black start With a black start, the off-grid voltage is built up by one or more AC-DC modules from 0 V. All AC-DC modules that are connected together on one system control must be in the same AC grid. Depending on the composition of the system (1 or n AC mod- ules and 0 or m connected DC modules), the appropriate pre- charging mechanism must be selected for the internal DC link...
Page 99: Parameterization Of Isolated Operation
− Under "DC link precharge config", select "external". − The BMS must ensure that the DC link voltage is stable before the power release of the AC-DC module is requested. Starting with available stand- 6. Select appropriate precharging mechanism for the internal alone network DC link voltage: −...
Page 100 Parameter Description Unit Adjustment range Factory Step settings size Mini- Maxi- DroopkP Parameter influences the % of f 0.01 slope "Frequency slope" (kP) (referred to as of the characteristic curve. "Frequency slope" in the web GUI) Frequency lin. Linearization point 0.01 point offset Maximum neg.
Page 101 Parameter Description Maximum neg. flin delta f The individual specification of the parameters for slope and linearization point of the droop characteristic curve can, under certain operating conditions, lead to relatively Maximum pos. flin delta f large deviations of the nominal frequency of the stand-alone network. For this rea- son, it is possible to define the minimum and maximum limit of the linearization point.
Page 102: More Information About "Inselbetrieb
More information about "Inselbetrieb" Virtual impedance Due to the nature of the system, rotating machines, such as syn- chronous generators, have reactances on account of their wind- ing impedances. In dynamic processes, these reactances have an attenuating effect and typically limit short-circuit currents to approximately 10 times the nominal current.
Page 103 Fig. 48 Fig. 49 For the case that all n devices are given identical parameters for frequency offset, voltage factor, DroopKP and DroopKQ, the resulting frequency and voltage of the stand-alone network are simplified to: Fig. 50 Fig. 51 The output effective and reactive power of the individual device (index k) is determined as a function of its specified set value using: Fig.
Page 104: 7.12 Data Backup
Fig. 53 The given relationships apply provided the settings of the lineari- zation points f and U are within the limits defined by the limit- ing parameters (see "Parameterization of isolated operation", 93). 7.12 Data backup Saving parameters and resetting to factory settings All general settings that were made under >Operation >AC-DC module settings and >DC-DC module settings with "Select slave...
Page 105: 7.13 System Configuration
5. In the "Import & export parameters" area, press search for and select a file on a hard drive of the PC. 6. To load the selected file to the system control: − Press the button to upload the file. −...
Page 106 Status LEDs on the system control: All 3 LEDs flash syn- chronously. Status LEDs on the AC-DC module: The green and red LEDs light up and the yellow LED flashes. Setting the system 2. Select >Configuration >System configuration. configuration Select system configuration Save settings Restart system control Select device generation...
Page 107: 7.14 System Settings
If the set system configuration differs from the automatically detected system configuration, "None" is displayed in the sta- tus bar under "Detected Configuration". In addition, a message is output. Press in the sidebar to display the messages. Status LEDs on the AC-DC module and system control: The LEDs remain off immediately after the restart.
Page 108: Changing Network Settings
Changing network settings Note Network settings can only be changed via the web GUI. Changing the IP address 1. In the sidebar, click on "Settings" 2. In the "Network" area under "IP address", enter new values. IP address of the device on delivery: −...
Page 109: 7.15 Software Update
10. To restart the system control: press "Reboot". 7.15 Software update Perform software update Conditions ■ Operation via web GUI ■ Zip file with new software stored on PC. 1. Select >Software Update . 2. In the "Software update" area, press the button and open the zip file.
Page 110 The AC-DC module, which is directly connected to the sys- tem control with the data cable, is "Module 1". The next AC- DC module, which is connected to data output "OUT" of "Module 1", is "Module 2", etc. 5. Under "Select slave module", select the desired AC-DC mod- ule.
Page 111: 7.17 State Diagram
7.17 State diagram State machine Fig. 57 A67-0141-00.BKen-0 2022-03-23 Operation 01-09...
Page 112: 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 113: 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. 58 tem Control Errors 1 (green) 2 (yellow)
Page 114 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 115 Alarm messages Number Message Effect Cause Action Detecte d by 40300 RS-485 communica- No operation possi- Communication Check RS-485 com- System tion alarm. ble. problem on RS-485 munication. control bus. 40301 RS-485 communica- No operation possi- Communication Check RS-485 com- System tion alarm.
Page 116 Number Message Effect Cause Action Detecte d by 50003 Overtemperature No operation possi- Overtemperature Check the fan and AC-DC balancer. ble. balancer bridge. the ambient temper- module ature. 50004 Ambient tempera- No operation possi- Ambient tempera- Check the ambient AC-DC ture over allowed ble.
Page 117 Number Message Effect Cause Action Detecte d by 50019 Overcurrent L2 Device switches off. Overcurrent L2. Check cabling of AC-DC hardware. L2, grid voltage module sense lines and AC contactor. 50020 Overcurrent L3 Device switches off. Overcurrent L3. Check cabling of AC-DC hardware.
Page 118 Number Message Effect Cause Action Detecte d by 50049 Overvoltage L3 No operation possi- Overvoltage L3 Check grid settings, AC-DC RMS. ble. RMS. grid voltage L3 and module external devices. 50050 Undervoltage L1 No operation possi- Undervoltage L1 Check grid settings, AC-DC RMS.
Page 119 Number Message Effect Cause Action Detecte d by 50097 DC link discharge No operation possi- Discharge unit Contact service. AC-DC unit alarm. ble. failed or balancer module failed. 50098 DC link could not No operation possi- Charging of DC link Check DC link bus AC-DC be charged.
Page 120 Number Message Effect Cause Action Detecte d by 60102 DC link voltage too No operation possi- DC link voltage too Check DC link pre- DC-DC low for operation. ble. low. charge. module 60129 Battery voltage No operation possi- Battery voltage Change battery DC-DC under threshold set-...

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