Rockwell Automation 20GY- 755 User Manual

PowerFlex SCR Bus Supply

Firmware Version 1.xxx

User Manual

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.

http://

Throughout this manual, when necessary we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

Important: Identifies information that is critical for successful application and

understanding of the product.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequences.

Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.

Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures.

Allen-Bradley and PowerFlex are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

PowerFlex SCR Bus Supply User Manual

Summary of Changes

The information below summarizes the changes made to this manual since its last release (March 2011):

Description of Changes Page

In Chapter 1 in the “1000A SCR Bus Supply Flexibility” section:

• Added information and a table at the beginning to show which conversions are possible and which are not possible.

• In the “Converting Master Unit to Slave Unit” subsection, added new steps 3 and 4.

• Deleted subsection “Converting Slave Unit to Master Unit” subsection.

In Appendix A in the “Accessories” section:

• Changed Table A.A cat. numbers for rows 256…509, and added new row for 939…1K0.

• Changed Table A.B cat. numbers for rows 256…509, and added new row for 939…1K0.

• Changed Table A.C cat. numbers for rows 256…509, and added new row for 939…1K0.

• Changed Table A.D cat. numbers for rows 256…509, and added new row for 939…1K0.

In Appendix A in the “HF Filter” section:

• Added new HF Filter Wiring Diagram Figure A.5.

• Added new subsection “Solid Ground Systems.”

• Added new subsection “Non-Solid Ground Systems.”

In Appendix A in the “Spare Parts” section:

• Added Important statement above Figure A.8.

• Added new “Availability” column to Table A.E

• Added Important statement above Figure A.9.

• Added new “Availability” column to Table A.F

• Added Important statement above Figure A.10.

• Added new “Availability” column and new footnote 1 to Table A.G

• Added new Figure A.11 to show locations of precharge and gate drive boards for 1000A

unit.

In Appendix A, revised Input Ratings “Operational AC Input Voltage Range” for catalog number 20SF1K0… from “269…759V” to “528…759V.”

Added new Appendix B. B-1

1-16

A-7 A-8 A-9 A-10

A-11 A-12 A-12

A-14 A-15 A-16 A-17 A-18 A-19 A-19

A-1

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soc-ii Summary of Changes

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Preface Overview

Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Reference Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4

Descriptions and Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5

Chapter 1 Installation/Wiring

Opening the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

General Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Minimum Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Maximum Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Disconnecting MOVs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Parallel Connection of Slave Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1000A SCR Bus Supply Flexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1000A SCR Bus Supply Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

SCR Bus Supply 12-Pulse Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Chapter 2 Start Up/Troubleshooting

Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Precharge Board LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Appendix A Specifications

PowerFlex SCR Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Bus Supply Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14

Appendix B History of Changes

20S-UM001F-EN-P, March 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Index

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ii Table of Contents

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Preface

Overview

The purpose of this manual is to provide you with the basic information needed to install, start up, and troubleshoot the PowerFlex SCR Bus Supply.

Topic Page

Who Should Use this Manual? Reference Documentation P-1 Rockwell Automation Support P-2 Conventions Used in This Manual P-2 General Precautions P-3 Catalog Number Explanation P-4 Descriptions and Schematic Diagrams P-5

P-1

Who Should Use this Manual?

Reference Documentation

This manual is intended for personnel that are qualified to install, program, and operate adjustable frequency drives and their use in common DC bus systems.

General Drive Information

Title Publication

Wiring and Grounding Guidelines for PWM AC Drives DRIVES-IN001 AC Drives in Common Bus Configurations DRIVES-AT002 Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001 Safety Guidelines for the Application, Installation and Maintenance of Solid State Control SGI-1.1 A Global Reference Guide for Reading Schematic Diagrams 0100-2.10 Guarding Against Electrostatic Damage 8000-4.5.2 1321 Power Conditioning Products Technical Data 1321-TD001

Specific Drive Information

For detailed drive information, including specifications, refer to the following PowerFlex 70, PowerFlex 700, PowerFlex 700H, PowerFlex 700S, and PowerFlex 750-Series drive publications.

For: Refer to: Publication

PowerFlex

PowerFlex PowerFlex

70/70EC Drive PowerFlex 70 User Manual

PowerFlex 70/700 Reference Manual

700/700VC Series A Drive

700VC Series B Drive

PowerFlex 70EC/700VC Reference Manual PowerFlex 700 Series A User Manual

PowerFlex 700 Series B User Manual PowerFlex 70/700 Reference Manual PowerFlex 70EC/700VC Reference Manual

20A-UM001 PFLEX-RM001 PFLEX-RM004

20B-UM001 20B-UM002 PFLEX-RM001 PFLEX-RM004

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P-2 Overview

For: Refer to: Publication

PowerFlex® 700H Drive PowerFlex 700H Installation Instructions

PowerFlex 700H Programming Manual

PowerFlex® 700S Drive PowerFlex 700S with Phase I Control Installation Manual (Frames 1…6)

PowerFlex

750-Series AC Drive PowerFlex 750-Series Drive Installation Instructions

PowerFlex 700S with Phase I Control Installation Manual (Frames 9 and 10) PowerFlex 700S with Phase I Control User Manual (All Frame Sizes) PowerFlex 700S with Phase I Control Reference Manual PowerFlex 700S with Phase II Control Installation Manual (Frames 1…6) PowerFlex 700S with Phase II Control Installation Manual (Frames 9…14) PowerFlex 700S with Phase II Control Programming Manual (All Frame Sizes) PowerFlex 700S with Phase II Control Reference Manual

PowerFlex 750-Series Drive Programming Manual PowerFlex 750-Series Reference Manual

Documentation can be obtained online at http://

literature.rockwellautomation.com. To order paper copies of technical

documentation, contact your local Rockwell Automation distributor or sales representative.

To find your local Rockwell Automation distributor or sales representative, visit www.rockwellautomation.com/locations

PFLEX-IN006 20C-PM001

20D-IN024 PFLEX-IN006 20D-UM001 PFLEX-RM002 20D-IN024 PFLEX-IN006 20D-PM006 PFLEX-RM003

750-IN001 750-PM001 750-RM002

Rockwell Automation Support

Conventions Used in This Manual

For information such as firmware updates or answers to drive-related questions, go to the Drives Service & Support web site at www.ab.com/

support/abdrives and click on the “Downloads” or “Knowledgebase” link.

Use the contacts below for PowerFlex SRC Bus Supply technical support.

Online… By Email… By Telephone…

www.ab.com/support/abdrives support@drives.ra.rockwell.com 262-512-8176

• In this manual we may refer to the PowerFlex SCR Bus Supply as SCR Bus Supply or Bus Supply.

• The firmware release is displayed as FRN X.xxx. The “FRN” signifies Firmware Release Number. The “X” is the major release number. The “xxx” is the minor update number.

• The following words may be used throughout the manual to describe an action:

Word Meani ng

Can Possible, able to do something Cannot Not possible, not able to do something May Permitted, allowed Must Unavoidable, you must do this Shall Required and necessary Should Recommended Should Not Not Recommended

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Overview P-3

General Precautions

ATTENTION: This Bus Supply contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to Allen-Bradley publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.

ATTENTION: An incorrectly applied or installed Bus Supply can result in component damage or a reduction in product life. Wiring or application errors, such as incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system.

ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.

ATTENTION: Connect products with or without precharge circuitry to the SCR Bus Supply common bus output terminals within the minimum and maximum capacitance and load rating guidelines.

ATTENTION: To avoid an electric shock hazard, verify that the voltage on the DC bus terminals (which are connected to the DC bus capacitors of the Inverter) has discharged before performing any work on the Bus Supply. Measure the DC bus voltage at the +DC and -DC output terminals. The voltage must be zero.

ATTENTION: A second source of power for the cooling blower is present. To avoid an electric shock hazard or moving blades, verify that the AC power supply has been removed prior to performing any maintenance or repairs.

ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.

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P-4 Overview

Catalog Number Explanation

Position Number

1-3 4 5-7 8 9 10

20S D 400 N E N

ab c d e f

Product Code Type

20S PowerFlex SCR Bus Supply

Voltage Rating Code Input Voltage Phase DC Output

D 400/480V AC 3 540 - 650V DC F 600/690V AC 3 675 - 930V DC

Current Rating Code Output

400 400A, 400/480V 600 600A, 400/480V 1k0 1000A, 400/480/600/690V

Enclosure Code Rating Conformal Coating

N Open / IP00 No

Documentation & Shipping Carton Code User Manual Carton

E English Yes

Configuration Code Type

N Stand Alone M Master (1000A only) S Slave (1000A only)

Important:PowerFlex SCR Bus Supply 1000A units with Master or Slave

configuration are available for 400/480 and 600/690 Volts.

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Overview P-5

>°C

V1 V3

V4 V2V6

F6-F8

GND

L1 L2 L3

GND

115

4 2

8 7

F12

4321 3313

443414

➋

➌

➊

➑

➏

➍

➎

Precharge

Board

+DC

-DC

Descriptions and Schematic Diagrams

The SCR Bus Supply is a single-direction power converter for the front end of common DC bus drive systems. It converts the incoming 3-phase AC line voltage to a common DC bus voltage.

Figure P.1 400A and 600A SCR Bus Supply Schematic Diagram

The primary electrical components for the 400A and 600A SCR Bus Supply are:

Item Description

➊

➋

➌

➍ ➎ ➏ ➑

Six-Pulse, Full-Wave, 3-Phase SCR Bridge Rectifier Unit connected to the line input and DC Bus output terminals through semi-conductor protection fuses with trip indicator switches.

Bus Supply Overtemperature Sensor located on the heat sink for thermal protection of the SCR bridge rectifier.

RC snubber circuit routed to the three input phases through semi-conductor protection fuses with trip indicator switches.

MOV snubber circuit routed to the three input phases.

Precharge Board

Enable Contactor (K1) for the precharge board.

Cooling Blower connected to a customer-supplied 115V AC Power Supply. The customer’s

controls must, at a minimum, command the blower to run whenever contactor K1 is enabled.

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P-6 Overview

Figure P.2 1000A SCR Bus Supply Single Unit Schematic Diagram

➌

F7 - 11

L1 L4L5L3L2

+ DC

12 11 10

9 8 7 6 5 4 2 1 0

115

GND

➍

>°C F12

➏

GND

➑

➋

443414

4321 3313

➎

1 2 4 5 7 8

1 2 3 4 5 6

L1 L2L3

Precharge

Board

➊

- DC

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The primary electrical components for the 1000A SCR Bus Supply Single Unit are:

Item Description

Six-Pulse, Full-Wave, 3-Phase SCR Bridge Rectifier Unit connected to the line input and DC

➊

Bus output terminals through semi-conductor protection fuses with trip indicator switches.

Bus Supply Overtemperature Sensor located on the heat sink for thermal protection of the

➋

SCR bridge rectifier.

RC snubber circuit routed to the three input phases through semi-conductor protection

➌

fuses with trip indicator switches.

MOV snubber circuit routed to the three input phases.

➍

Precharge Board

➎

Enable Contactor (K1) for the precharge board.

➏

Cooling Blower connected to a customer-supplied 115V AC Power Supply. The customer’s

➑

controls must, at a minimum, command the blower to run whenever contactor K1 is enabled.

NOTE: There is no DC output fuse protection in the 1000A SCR unit.

Figure P.3 1000A SCR Bus Supply Master Unit Schematic Diagram

>°C F12

F7-11

L1 L4L5L3L2

4321 3313

443414

GND

115

4 2

8 7

L1 L2 L3

1 3

4 5 6

7 9

12 7854126543X2

7 8

9 10 11 12

1 5

GND

Precharge

Board

Gate Driver Board

➋

➌

➊

➑

➐

➏

➍

➎

+DC

-DC

To Gate Driver X4 on the Slave (Figure P.4)

Overview P-7

The primary electrical components for the 1000A SCR Bus Supply Master Unit are:

Item Description

➊

➋

➌

➍ ➎ ➏ ➐

➑

NOTE: There is no DC output fuse protection in the 1000A SCR unit.

Six-Pulse, Full-Wave, 3-Phase SCR Bridge Rectifier Unit connected to the line input and DC Bus output terminals through semi-conductor protection fuses with trip indicator switches.

Bus Supply Overtemperature Sensor located on the heat sink for thermal protection of the SCR bridge rectifier.

RC snubber circuit routed to the three input phases through semi-conductor protection fuses with trip indicator switches.

MOV snubber circuit routed to the three input phases.

Precharge Board

Enable Contactor (K1) for the precharge board.

Gate Driver Board. The DC power supply is connected to a customer-supplied 115V AC Power

Supply.

Cooling Blower connected to a customer-supplied 115V AC Power Supply. The customer’s controls must, at a minimum, command the blower to run whenever contactor K1 is enabled.

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P-8 Overview

>°C F12

F7-11

L1 L4L5L3L2

GND

115

8 7

3 4 5 6

7854126543X2

7 8

9 10 11 12

1 5

GND

+DC

-DC

Gate Driver Board

From Gate

Driver X6

on the Master

(Figure P.3 or

previous Slave)

➋

➌

➊

➑

➐

➒

➍

To Gate Driver X4 on the next Slave

Figure P.4 1000A SCR Bus Supply Slave Unit Schematic Diagram

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The primary electrical components for the 1000A SCR Bus Supply Slave Unit are:

Item Description

➊

➋

➌

➍ ➐

➑

➒

NOTE: There is no DC output fuse protection in the 1000A SCR Unit.

Six-Pulse, Full-Wave, 3-Phase SCR Bridge Rectifier Unit connected to the line input and DC Bus output terminals through semi-conductor protection fuses with trip indicator switches.

Bus Supply Overtemperature Sensor located on the heat sink for thermal protection of the SCR bridge rectifier.

RC snubber circuit routed to the three input phases through semi-conductor protection fuses with trip indicator switches.

MOV snubber circuit routed to the three input phases.

Gate Driver Board. The DC power supply is connected to the customer-supplied 115V AC

Power Supply.

Cooling Blower connected to a customer-supplied 115V AC Power Supply. The customer’s controls must, at a minimum, command the blower to run whenever contactor K1 is enabled.

Connection Cable (1 m) connects the gate firing pulses from the Master to the first Slave or between any two Slaves (maximum 4).

Chapter 1

Installation/Wiring

This chapter provides information on the installation and wiring of the PowerFlex SCR Bus Supply.

Topic Page

Opening the Cover Minimum Mounting Clearances 1-3 AC Supply Source Considerations 1-4 General Grounding Requirements 1-5 Minimum Capacitance 1-6 Maximum Loading 1-6 Fusing 1-7 Power Wiring 1-7 Control Wiring 1-11 Jumper Settings 1-12 Disconnecting MOVs 1-14 Parallel Connection of Slave Units 1-15 1000A SCR Bus Supply Flexibility 1-16 1000A SCR Bus Supply Redundancy 1-17 SCR Bus Supply 12-Pulse Configuration 1-18 CE Conformity 1-19

1-2

Most start-up difficulties are the result of incorrect wiring. Every precaution must be taken to assure that the wiring is done as instructed. All items must be read and understood before the actual installation begins.

ATTENTION: The following information is merely a guide for proper installation. Rockwell Automation, Inc. cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this product or associated equipment. A hazard of personal injury and/ or equipment damage exists if codes are ignored during installation.

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1-2 Installation/Wiring

Opening the Cover

1. Remove the four fastening screws. (The steel sheet cover will stay in

place, even in the vertical position.)

2. Hold the cover with both hands at the bottom, and lift it upward about 2

cm (0.8 in.) and away from the enclosure (Figure 1.1

Figure 1.1 Opening the Cover

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Installation/Wiring 1-3

Refer to Appendix A for detailed dimension information.

below fan

Minimum Mounting Clearances

The cabinet air inlet and outlet areas for each SCR Bus Supply must be a minimum of 200 cm 4:1.

Figure 1.2 Mounting Clearances

Air Outlet

PowerFlex

Bus Supply

120 mm (4.7 in.)

SCR

(31 in.2). The length-to-width ratio must not exceed

Air Outlet

PowerFlex

SCR

Bus Supply

150 mm

(6 in.)

Air Flow Air FlowAir Flow

300 mm

(12 in.)

Air InletAir Inlet

120 mm

(4.7 in.)

Ambient Operating Temperatures

The PowerFlex SCR Bus Supply is designed to operate at 0…40 °C (32…104 °F) ambient without derating. For operation in ambients above 40 °C up to 50 °C (104 °F up to 122 °F), the PowerFlex SCR Bus Supply output Amps must be derated by 1.2% per 1 °C for 400A unit, and by 1.0% per 1 °C for 600A and 1000A units.

Ensure that proper cooling is provided to the SCR Bus Supply to maintain the 40 °C rated specification. If the ambient temperature is exceeded, apply the proper derate factors. Add exhaust fans to the front or top of the enclosure bay and provide a filtered opening at the bottom of the cabinet bay.

The SCR Bus Supply watt losses (from specification section) are 1200W at 400A, 1600W at 600A, 2700W at 480V 1000A, and 2800W at 690V 1000A. The three-phase AC line reactor watt losses are listed in the 1321 Power Conditioning Products Technical Data (publication 1321-TD001).

Because of the internal design of the SCR Bus Supply, it is NOT recommended to rely on an air dam surrounding the SCR Bus Supply.

It is recommended that the system integrator completes a thermal evaluation to ensure adequate cooling to maintain proper operating conditions for each cabinet or bay. A minimum air exchange of 725 CFM per SCR Bus Supply is recommended.

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1-4 Installation/Wiring

AC Supply Source Considerations

The PowerFlex SCR Bus Supply is suitable for use on a circuit capable of delivering a short circuit rating up to a maximum of 85,000 rms symmetrical amperes.

If a Residual Current Detector (RCD) is used as a system ground fault monitor, only Type B (adjustable) devices should be used to avoid nuisance tripping.

Line Reactors

A minimum 3% rated three-phase AC line reactor must be installed for minimum voltage drop unless the closest supply transformer is matched to the kVA rating of the PowerFlex SCR Bus Supply. For recommended line reactors, see Line Reactors

Install one three-phase AC line reactor for each is recommended to maintain cable length symmetry between the three-phase AC line reactors and the SCR Bus Supply connections. One method is to mount the three-phase AC line reactors on the cabinet floor under the SCR Bus Supply.

Important:It is recommended to keep all wired or bus bar connections

identical in size and length. This includes the AC line connection to the three-phase AC line reactors and from the three-phase AC line reactors to the SCR Bus Supply.

on page A-7.

SCR Bus Supply module. It

Unbalanced or Non-Solid Grounded Distribution Systems

Where the potential exists for abnormally high phase-to-ground voltages (in excess of 125% of nominal), or the supply system is non-solid grounded, refer to the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives (publication DRIVES-IN001).

ATTENTION: The PowerFlex SCR Bus Supply contains protective MOVs that are referenced to ground. The MOVs should be disconnected from ground if the SCR Bus Supply is installed on any non-solid grounded power distribution system (IT-network). For jumper location, see Figure 1.7 on page 1-11

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Publication 20S-UM001G-EN-P

Installation/Wiring 1-5

Ground Grid, Girder or Ground Rod (Building Ground Potential)

General Grounding Requirements

The Safety Ground terminal (PE) must be connected to the building grounding scheme. Ground impedance must conform to the requirements

of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked.

For installations within a cabinet, a single safety ground point or ground bus bar connected directly to building steel should be used. All circuits including the AC input ground conductor should be grounded independently and directly to this point/bar.

Figure 1.3 Typical Grounding

R (L1) S (L2) T (L3)

SCR

Bus Supply

+DC

- DC

Safety Ground Terminal - PE

The Bus Supply safety ground (PE) must be connected to the customer grounding scheme or earth ground. This is the safety ground for the Bus Supply that is required by code. This point must be connected to adjacent building steel (girder, joist), a floor ground rod, bus bar or building ground grid. Grounding points must comply with national and local industrial safety regulations and/or electrical codes.

RFI Filter Grounding

Using an external RFI filter may result in relatively high ground leakage currents. Therefore, the filter must only be used in installations with

grounded AC supply systems and be permanently installed and solidly grounded (bonded) to the building power distribution ground. Ensure that

the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked. Refer to the instructions supplied with the filter.

PowerFlex SCR Bus Supply User Manual

Publication 20S-UM001G-EN-P

1-6 Installation/Wiring

Minimum Capacitance

Maximum Loading

In order to commission and test the SCR Bus Supply, a minimum capacitance is required. The design of the final installation must assure that the minimum capacitance is connected whenever the bus supply is to be enabled. If this minimum capacitance is not present, the bus supply internal fault detection circuit will interpret the condition as a DC bus short and stop pulse firing. The minimum capacitance (110 µF per SCR bus supply) may be provided by an external capacitor bank (recommended) or a drive (as long as the drive remains connected to the DC bus). NOTE: A capacitance of 110 µF is typical of a 5 HP or 3.7 kW drive. To find DC bus capacitances for specific PowerFlex drives, refer to Appendix A tables in the Powe rF lex AC Drives in Common Bus Configurations Application Guidelines (publication DRIVES-AT002).

To avoid overloading the Bus Supply, the following requirement applies:

The DC Input current sum (Normal Duty rating at 40 °C/104 °F) of the connected drive(s) must not exceed the Bus Supply continuous DC Bus output current rating.

For the DC Input Current values of the drives, see tables in the respective drive documentation.

Table 1.A

SCR Bus Supply. No overload capability is built into the tables.

Important:See “Output Ratings

When an overload is being utilized in connected drives or products, that overload current must be accounted for in the calculation to properly size the SCR Bus Supply.

Table 1.A Normal Duty ND (110%, 1 minute; 150%, 3 seconds)

Drive Rating Drive Output Current Drive DC Input Current SCR Bus Supply

DC Volt ag e

540V 3 x 110 kW

650V 3 x 60 HP

(1)

Drive Rating Drive Output Current Drive DC Input Current SCR Bus Supply

DC Volt ag e

540V 3 x 90 kW 3 x 170 = 510A 510A 3 x 192.3 = 577A 577A 600A 400V

ND Power

1 x 45 kW

1 x 30 HP

No overload capability.

Table 1.B Heavy Duty HD (150%, 1 minute; 200%, 3 seconds)

HD Power

and Table 1.B provide guidance on the nominal operation of the

” in Appendix A for overload capability.

ND Output Currents

3 x 205 = 615A 1 x 85 = 85A

3 x 77 = 231A 1 x 40 = 40A

HD Output Currents

ND Output Current Sum

700A 3 x 226 = 678A

271A 3 x 84.5 = 253.5A

HD Output Current Sum

ND DC Input Currents

1 x 95 = 95A

1 x 42.9 = 42.9A

HD DC Input Currents

ND DC Input Current Sum

773A 1000A 400V

297A 400A 480V

HD DC Input Current Sum

Maximum DC Output Amps

(1)

AC Input Vol ta ge

(1)

AC Input Vol ta ge

(1)

PowerFlex SCR Bus Supply User Manual

Publication 20S-UM001G-EN-P

No overload capability.

Installation/Wiring 1-7

Fusing

Power Wiring

The 400A and 600A PowerFlex SCR Bus Supplies have built-in AC line and DC bus fuses. The 1000A unit has six in-path fuses which simultaneously protect AC and DC paths. All units are equipped with fuse trip indicator switches. For a list of recommended replacement fuses, refer to these pages.

SCR Bus Supply See Page…

400A A-15

600A A-17

1000A A-19

ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.

To maintain balanced impedance, and thus balance current in the SCR Bus Supply, it is recommended to keep all wired or bus bar connections identical in size and length. This includes the AC line connection to three-phase AC line reactors and from the three-phase AC line reactors to the SCR Bus Supply.

EMC Compliance

Refer to CE Conformity on page 1-19 for details.

Cable Trays and Conduit

If cable trays or large conduits are to be used, refer to guidelines in the

Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives (publication DRIVES-IN001).

ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled. This will help minimize the possible shock hazard from “cross coupled” motor leads.

DC Bus Wiring Guidelines

For DC Bus wiring guidelines, refer to AC Drives in Common Bus Configurations (publication DRIVES-AT002).

PowerFlex SCR Bus Supply User Manual

Publication 20S-UM001G-EN-P

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