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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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.

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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)

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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).

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1-8 Installation/Wiring

Power Connection Bus Bars and Terminals

Figure 1.4 400A Unit Bus Bar and Terminal Locations for Customer Wiring

➋

DC-

DC+

➍

Table 1.C 400A Unit Power Connection Specifications

Item Description Copper Bus Bars

AC Line Input

➊

L1, L2, L3

DC Bus

➋

DC+, DC-

Protective Earth PE M8 x 25 mm (0.98 in.) stud;

➌

Control Terminal Block See Tabl e 1. F

➍

(1)

Input/output power bus bar connections require the use of either lug type connectors to terminate field-installed conductors or bus bars.

40 x 5 mm (1.57 x 0.2 in.) with single 14 mm (0.55 in.) diameter hole for customer terminal

torque to 6 N•m (54 lb•in)

➊

➌

Recommended Minimum Size

(1)

Bus Bar Wire

40 x 5 mm 120 mm

(or 2 x 50 mm

40 x 5 mm 150 mm2

(or 2 x 70 mm

Size per NEC or local code

)

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Installation/Wiring 1-9

DC+

DC-

➋

➊

➍

➌

Figure 1.5 600A Unit Bus Bar and Terminal Locations for Customer Wiring

Table 1.D 600A Unit Power Connection Specifications

Recommended Minimum Size

Item Description Copper Bus Bars

AC Line Input

➊

L1, L2, L3

DC Bus

➋

DC+, DC-

Protective Earth PE M12 x 25 mm (0.98 in.) stud;

➌

Control Terminal Block See Table 1.F

➍

50 x 5 mm (1.97 x 0.2 in.) with two 14 mm (0.55 in.) diameter holes for customer terminal

torque to 15 N•m (133 lb•in)

(1)

Bus Bar Wire

50 x 5 mm 240 mm

(or 2 x 95 mm

60 x 5 mm 300 mm2

(or 2 x 120 mm

Size per NEC or local code

)

(1)

Input/output power bus bar connections require the use of either lug type connectors to terminate field-installed conductors or bus bars.

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1-10 Installation/Wiring

DC+

DC-

➋

➊

➍

➌

Figure 1.6 1000A Unit Bus Bar and Terminal Locations for Customer Wiring

Table 1.E 1000A Unit Power Connection Specifications

Recommended Minimum Size

Item Description Copper Bus Bars

AC Line Input

➊

L1, L2, L3

DC Bus

➋

DC+, DC-

Protective Earth PE M12 x 25 mm (0.98 in.) stud;

➌

Control Terminal Block See Ta b l e 1 . F

➍

(1)

Input/output power bus bar connections require the use of either lug type connectors to terminate field-installed conductors or bus bars.

50 x 10 mm (1.97 x 0.39 in.) with two 14 mm (0.55 in.) diameter holes for customer terminal

60 x 10 mm (2.36 x 0.39 in.) with two 14 mm (0.55 in.) diameter holes for customer terminal

torque to 15 N•m (133 lb•in)

(1)

Bus Bar Wire

50 x 10 mm (or 80 x 5 mm)

60 x 10 mm (or 100 x 5 mm)

Size per NEC or local code

2 x 240 mm2

2 x 300 mm2

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Installation/Wiring 1-11

115

GND

115

GND

Control Wiring

Important points to remember about control wiring:

• Use Copper wire only. Wire gauge requirements and recommendations are based on 75 °C (168 °F). Do not reduce wire gauge when using higher temperature wire.

• Wire with an insulation rating of 600V or greater is recommended.

• Control wires outside the cabinet should be separated from power wires

by at least 0.3 meters (1 foot).

Table 1.F Control Terminal Specifications

Wire Size Range

Item Name

Control Terminals 2.5 mm2

➍

(1)

Maximum/minimum sizes that the terminals will accept - these are not recommendations.

Figure 1.7 Control Terminal Arrangement

(14 AWG)

(1)

0.25 mm2 (22 AWG)

TorqueMaximum Minimum

0.8 N•m (7 lb•in)

Terminal Bus Supply Description Notes

115 and 0 All units 115V AC

Supply Input

1 and 2

4 and 5

6 and 7 400A and 600A

8 and 9 400A and 600A

10 and 11 All units NC Contact

12 and GND All units Jumper MOVs

(1)

units

1000A units Opens if any of the snubber circuit fuses or DC

units

1000A units Opens if any of the line input branch circuit fuses

Contactor Coil 115V AC

NC Contact

(2)

Output

NC Contact

(2)

Output

NC Contact

(2)

Output

(2)

Output

to Ground

For cooling blower (and power supply on the Gate Driver Board - on Master and Slave Units)

Contactor must be energized to enable the controller

Opens if the Enable Contactor is energized

Opens if any of the snubber circuit fuses (F6…F8) trip

bus feedback fuses (F7…F11) trip

Opens if any of the line input or DC bus branch circuit fuses (F1…F5) trip

(F1…F6) trip

Opens at power stack heat sink overtemperature

Disconnects MOVs from ground by removing this jumper. (See Disconnecting MOVs for details.)

on page 1-14

(1)

Not used on Slave Units.

(2)

Refer to Appendix A for contact rating.

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1-12 Installation/Wiring

NOTE: Optional HF Filter

(see page A-11

)

Drive Run Interlock

To protect the Bus Supply from overtemperature, the normally closed contacts (Bus Supply Overtemperature - terminals 10 and 11) should be wired to either the AC line input contactor for the Bus Supply or the Run interlock circuit (enable input) of each connected drive. This ensures that the drives are stopped in case of Bus Supply Overtemperature.

Control Wiring Example

Figure 1.8 Example of SCR Bus Supply, 1000A Single with Multiple Drives Using

Drive Run Interlocks, Running Simultaneous

115 VAC

K1M

Stop

Run

K1M

115

7 8

K1 *

F7-11

Precharge

AC Drive

110 kW

205A

Board

F1-6

>°C

K1M K1M K1M K1M

F7-F9

AC Drive

110 kW

205A

PowerFlex

SCR Bus

Supply

F1-F6

DC Bus

* The customer’s controls must, at a minimum, command the blower to run whenever contactor K1 is enabled.

AC Drive

110 kW

205A

AC Drive

45 kW

85A

Jumper Settings

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Publication 20S-UM001G-EN-P

The PowerFlex SCR Bus Supply precharge board has three jumpers. See

Figure 1.9 on page 1-13

for jumper locations and positions.

• LINE TYPE Jumper: Always set to the “3-ph” default right-side position (towards the board edge).

• SPARE 1 Jumper: For board firmware version 1.21 (or earlier), this jumper is non-functional. For firmware version 1.22 (or later), the SCR Bus Supply is shipped with this jumper in the right (default) inactive state position. When the jumper is placed in the left (RGU/AFE) or active position, the firmware is active for SCR and RGU/AFE parallel operation on common bus systems, where the SCR is in parallel with an

Installation/Wiring 1-13

active front end that is used only as a regenerative brake unit. The PowerFlex SCR Bus Supply will then deliver the required motoring power and the RGU/AFE will provide the possibility to feed the regenerative energy back to the AC power line. The auto-voltage limitation (allowing the SCRs to phase back) associated with high AC line will be disabled. The left (RGU/AFE) jumper position provides the best protection for parellel SCR and RGU/AFE operation.

• SPARE 2 Jumper: For board firmware version 1.21 (or earlier), this jumper is non-functional. For firmware version 1.22 (or later), this jumper is used for slow ramp-up, which slows the DC bus voltage charge up time (from 0.2 to 1.3 seconds). Slow ramp-up should be used when the connected DC bus capacitance is greater following table.

than the values shown in the

Max. Bus Capacitance

SCR Bus Supply

400A 40,000 µF 200,000 µF

600A 60,000 µF 300,000 µF

1000A @ 480V 100,000 µF 500,000 µF

1000A @ 690V 50,000 µF 250,000 µF

(1)

It is recommended to derate the capacitance value by 20% in master/slave configurations.

To operate the SCR Bus Supply with a slow ramp-up, set the SPARE 2 jumper to the left (SLOW) position.

For standard applications where only the PowerFlex SCR Bus Supply provides the required common DC power, make sure the SPARE 1 and SPARE 2 jumpers are in their default settings (right side—towards the board edge) shown in Figure 1.9

Figure 1.9 Location of LED Indicators and Jumpers on the Precharge Board

Precharge Board Firmware Version Label

with Normal Ramp

(1)

Max. Bus Capacitance with Slow Ramp

(Ramp-Up)

(SCR and RGU/AFE

Paralleling)

SPARE

LINE

TYPE

(1)

Slow Norm

Yes No

1-ph 3-ph

POWER

ALARM LEDs

FAULT

default positions

Jumpers shown in

TIP: To identify the firmware version, remove the SCR Bus Supply cover and check the firmware version label on the Precharge Board (Figure 1.9

PowerFlex SCR Bus Supply User Manual

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1-14 Installation/Wiring

Disconnecting MOVs

The PowerFlex SCR Bus Supply contains protective MOVs that are referenced to ground. To prevent damage, the MOVs should be

disconnected from ground if the Bus Supply is installed on any non-solid grounded distribution system where the line-to-ground voltages

on any phase could exceed 125% of the nominal line-to-line voltage. To disconnect the MOVs from ground, remove the jumper (12-GND) on the control terminal block shown in Figure 1.7 on page 1-11 non-solid grounded systems are defined in Table 1.G

Table 1.G Recommended MOV Configurations

MOV/Input Filter Capacitors

Connected • UL compliance

Disconnected • Helps avoid severe equipment

(2)

Power Source Type

Solid Grounded

• AC fed, solidly grounded

• DC fed from passive rectifier which has an AC source and solid ground

Non-Solid Grounded

• AC fed ungrounded

• Impedance grounded

• High resistive ground

• B phase ground

• Regenerative unit (common DC bus supply and brake)

• DC fed from an active converter

(1)

It is highly recommended to accurately determine the power source type and then configure appropriately.

(2)

When MOVs are disconnected, the power system must have its own transient protection to ensure known and controlled voltages.

(1)

Benefits of Correct Power Source Type Configuration

• Reduced electrical noise

• Most stable operation

• EMC compliance

• Reduced voltage stress on components and motor bearings

damage when ground fault occurs

. Solid and

For more information on non-solid grounded system installation, see Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives (publication DRIVES-UM001).

ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before removing the jumper. Measure the DC bus voltage at the +DC and –DC output terminals. The voltage must be zero.

Table 1.H Jumper Removal

Item Jumper Jumper Location Removes…

12 and GND Control Terminals

➍

(1)

For control terminal location, see Figure 1.4, Figure 1.5 or Figure 1.6.

(1)

MOVs from Ground

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Installation/Wiring 1-15

DC Bus

Power

Input

Master Unit Slave Unit #1 Slave Unit #n

Precharge

Board

Enable Contactor

Gate

Driver

Gate

Driver

Gate

Driver

Cable Cable

Main Switch or Main Input Contactor

Up to 5 Units Maximum

(4750A Maximum DC Bus Current

without altitude or ambient derating)

Aux. Supply

115 VAC

Parallel Connection of Slave Units

Up to four 1000A PowerFlex SCR Bus Supply Slave units may be connected in parallel with one 1000A Master. The derate for each additional slave is 5% plus 5% for the master. Thus, the maximum possible output rating without altitude or ambient derating is 4750 Amps (0.95 x 5 x 1000 amps) at 40 °C.

Figure 1.10 Example for Master-Slave Configuration

(shown without circuit protection for clarity)

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1-16 Installation/Wiring

1000A SCR Bus Supply Flexibility

The 1000A SCR Bus Supply can be converted in the following ways.

1000A SCR Bus Supply

Convert from: Standalone

Master Yes

Slave No No

Because of numerous internal changes (components, cables, and hardware) the following conversions are not allowed:

• Standalone to master

• Standalone to slave

• Slave to standalone

• Slave to master

NOTE: See Figure A.11 on page A-19

Converting Master Unit to Standalone Unit

No changes are required to run a master (without slave units) as a standalone SCR Bus Supply.

Convert to…

Standalone Master Slave

No No

Ye s

for circuit board location.

Converting Master Unit to Slave Unit

It is possible to reconfigure a master SCR Bus Supply to run as a slave SCR Bus Supply. To convert a master unit to a slave, perform these steps.

1. Remove the cables between the precharge board connectors (X2 and

X3) and the gate driver printed circuit board connector X4 (see

Figure P.3 on page P-7

2. Connect a cable from the gate driver printed circuit board connector

(X4) to the new master SCR Bus Supply or another slave SCR Bus Supply gate connector (X6, see Figure P.4 on page P-8 precharge board does not need to be removed from the converted SCR Bus Supply.

3. Ensure that the precharge relay is not energized (terminal

block…terminal 1 and 2, see page 1-11

4. Place a label near the data nameplate stating that the SCR bus supply

has been converted to catalog # 20Sx1K0NES, where x is the voltage class of the unit.

). Note that the

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Installation/Wiring 1-17

1000A SCR Bus Supply Redundancy

It is not recommended to install parallel master SCR Bus Supplies. The reason is that there is nothing to synchronize the SCR gate firing between the precharge printed circuit boards in separate SCR Bus Supplies. Each precharge board has circuitry designed to energize the DC bus, which has little to no impedance to limit the inrush current. This DC bus charging synchronization could lead to power device failure.

If redundancy of the SCR Bus Supply master is required by the application, there are two options.

• A microcontroller or other electronically or manually-controlled switch or contact network can be used to reconfigure the wire harnesses between the redundant master SCR Bus Supplies. Basically, one SCR Bus Supply becomes the master and the other becomes the slave by the logic selection of the controlling or steering network. One example of numerous possible configurations is shown in Figure 1.11

Figure 1.11 Basic Master/Slave Redundancy System Configuration

Enable

Control Logic

* Only one Master enabled.

Master

Precharge

PCB

Gate PCB

• Although not recommended, synchronization differences might be minimized by using the slower ramp time available in precharge printed circuit boards with firmware version 1.22 (or later). The standard ramp time is for the rise of DC bus to phase full on in approximately 0.2 seconds, while the slower ramp time will take approximately 1.3 seconds. This will help to limit the inrush current in the system.

For additional recommendations about SCR Bus Supply redundancy, contact Rockwell Automation Technical Support.

Slave Slave

Gate PCB

Slave

Gate PCB

Master

Precharge

PCB

Gate

PCB

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1-18 Installation/Wiring



Reactor

Standalone

Master

SCR Bus

Supply

Reactor

Fuses*

Gate

Harness

Fuses*

Enable

Slave

Reactor

12-Pulse Transformer

Slave

Reactor

AC Line

Standalone

Master

SCR Bus

Supply

Gate

Harness

Fuses* Fuses*

* Fuses are optional.

DC Bus

SCR Bus Supply 12-Pulse Configuration

Standalone or master/slave SCR Bus Supplies can be used on applications that use a 12-pulse transformer to minimize power line harmonics.

Important:Be sure to select the slow ramp time (see Jumper Settings

page 1-12).

Figure 1.12

optional slave SCR Bus Supplies.

Figure 1.12 12-Pulse System Configuration

shows a recommended 12-pulse system configuration with

For additional recommendations about SCR Bus Supply 12-pulse configurations, contact Rockwell Automation Technical Support.

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Installation/Wiring 1-19

CE Conformity

Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. The PowerFlex SCR Bus Supply complies with the EN standards listed below when installed according to the User Manual.

CE Declarations of Conformity are available online at:

http://www.ab.com/certification/ce/docs

Low Voltage Directive (73/23/EEC)

• EN50178 Electronic equipment for use in power installations

EMC Directive (89/336/EEC)

• EN61800-3 Adjustable speed electrical power drive systems Part 3: EMC product standard including specific test methods.

Harmonic Emissions

Electronic converters such as the Bus Supply can cause conducted low frequency disturbances (harmonic emissions) to the supply network. The mandatory three-phase AC line reactors will substantially reduce harmonic currents produced by the Bus Supply. However, the magnitude of the harmonic currents and resulting harmonic voltages depends upon the network impedance at the point where the unit is connected to the network. Currently there are no mandatory harmonic emission limits related to CE compliance for equipment connected to private power networks. Upon request, Rockwell Automation can provide information regarding harmonic emissions from the SCR Bus Supply.

General Notes

• The DC bus cable to the inverter(s) should be kept as short as possible to avoid electromagnetic emission and capacitive currents. Therefore the inverter(s) should be located in the same cabinet as the Bus Supply or next to the cabinet with the Bus Supply. If the connection leads between DC bus and inverter(s) are leaving the cabinet, shielded cables must be used.

• Use of line filters in non-solid grounded systems is not recommended.

• The PowerFlex SCR Bus Supply with external Line Reactor and HF

filter satisfies CE EMC emission limits for the industrial environment. If used in a residential or domestic environment it may cause radio interference. The user is required to take measures to prevent interference, in addition to the essential requirements for CE compliance listed below, if necessary.

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1-20 Installation/Wiring

• Conformity of the drive with CE EMC requirements does not guarantee an entire machine installation complies with CE EMC requirements. Many factors can influence total machine/installation compliance.

Essential Requirements for CE Compliance

Conditions 1…5 listed below must be satisfied for the PowerFlex SCR Bus Supply to meet the requirements of EN61800-3.

1. Bus Supply and inverter must be PowerFlex type and CE compatible.

2. Externally mounted Line Reactor and HF filter (specified in

Appendix Figure 1.8 on page 1-12

3. Review important precaution/attention statements throughout this

document before installing the drive(s).

A) must be connected to the line input as shown in

4. Grounding as described in General Grounding Requirements

page 1-5.

5. Control wiring and DC bus wiring leaving the cabinet must be braided,

shielded cable with a coverage of 75% or better, metal conduit or equivalent attenuation.

For additional conditions, refer to the respective drive Reference Manual.

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Chapter 2

Start Up/Troubleshooting

This chapter provides the necessary information for the start up and troubleshooting of the PowerFlex SCR Bus Supply.

Topic Page

Start-Up Precharge Board LED Indicators 2-4 Troubleshooting 2-6

ATTENTION: Power must be applied to the SCR Bus Supply and the Inverter to perform the following start-up procedure. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure. Thoroughly read and understand the procedure before beginning. If an event does not occur while performing this procedure, do not proceed. Remove power including user-supplied control voltages. User-supplied voltages may exist even when main AC power is not applied to the Bus Supply. Correct the malfunction before continuing.

2-2

ATTENTION: When operating the SCR Bus Supply, a minimum of one 7.5 kW (10 HP) PowerFlex 700/700S Inverter must be connected to the DC bus—otherwise the internal fault detection circuit will interpret the condition as an Output Voltage Loss and stop pulse firing. This is indicated on the Precharge Board by the Alarm LED (7 flashes) and after 30 seconds by the Fault LED (2 flashes). Refer to Table 2.A

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

and Table 2.B.

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2-2 Start Up/Troubleshooting

Start-Up

Before Applying Power to the Bus Supply

❏ 1. Verify that the minimum of one Inverter is connected to the DC bus.

❏ 2. Confirm that all inputs are connected to the correct terminals and are

properly torqued.

❏ 3. Using an ohmmeter or other continuity testing device, verify that shorts

do not exist between Source 1 and Source 2:

Source 1 Source 2 Checkmark Below if No Short Exists

L1 L2

L1 L3

L2 L3

L1 PE

L2 PE

L3 PE

L1 DC+ Bus

L2 DC+ Bus

L3 DC+ Bus

L1 DC- Bus

L2 DC- Bus

L3 DC- Bus

DC+ Bus DC- Bus

DC+ Bus PE

DC Bus PE

❏ 4. Verify that AC line power at the disconnect device is within the rated

value of the Bus Supply. See Appendix

❏ 5. Verify that control power voltage is correct.

❏ 6. Verify that the enable contactor coil K1 (not used on Slave units) is

correctly wired.

❏ 7. Verify that these four outputs are correctly wired:

❏ 8. Verify that the “Line Type” jumper on the Precharge Board shown in

– Bus Supply Overtemperature – Rectifier Fuse Trip – Snubber/DC feedback Fuse Trip – Enable Contactor Feedback (not used on Slave units)

These normally closed contact outputs are used to set alarms and to stop the drive(s). Verify that they have been wired correctly according to the user’s specification. Refer to the control wiring example shown in

Figure 1.8 on page 1-12

Figure 2.1

is set to the “3-ph” position (default).

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Start Up/Troubleshooting 2-3

❏ 9. Verify that the SPARE 1 and SPARE 2 jumpers on the Precharge Board

shown in Figure 2.1 (Refer to Jumper Settings more information).

❏ 10. Verify that the jumper between control terminals 12 and GND (Figure

1.7 on page 1-11) is present on grounded supply lines (default) or is

removed on non-solid grounded supply lines. (Refer to Disconnecting

MOVs on page 1-14 for more information).

Applying AC Power to the Bus Supply

❏ 1. Apply AC power and control voltage (115V AC) to the Bus Supply.

The green POWER OK LED on the Precharge Board should be on if power is applied to terminals L1 (R), L2 (S), L3 (T) and the enable contactor for the precharge board (not used on Slave units) is energized.

are set to appropriate positions for the application.

on page 1-12 and Figure 1.9 on page 1-13 for

❏ 2. If the green POWER OK LED is off at this point, refer to Table 2.B

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2-4 Start Up/Troubleshooting

SPARE

(Ramp-Up)

Precharge Board Firmware Version Label

(SCR and

RGU/AFE

Paralleling)

Slow Norm

Yes No

1-ph 3-ph

SPARE

LINE

TYPE

POWER

ALARM LEDs

Jumpers shown in

default positions

FAULT

Precharge Board LED Indicators

The three LEDs on the Precharge Board are visible through a small slot in the SCR Bus Supply cover. The 400A unit cover has one slot. The 600A unit cover has two slots but only the lower slot is used to view the LEDs. Since the Precharge Board for the 1000A unit is mounted either on the lower carrier plate (on Single Units) or on the upper carrier plate (on Master Units), the corresponding lower or upper slot is used to view the LEDs. For slot locations, see Figure A.1 on page A-3

ATTENTION: The SCR Bus Supply LEDs are only operational when the unit is energized. Servicing energized equipment can be hazardous. Severe injury or death can result from electrical shock, burn, or unintended actuation of the controlled equipment. Follow safety-related practices of NFPA 70E, Electrical Safety For Employee Workplaces. DO NOT work alone on energized equipment!

Figure 2.1 Location of LED Indicators and Jumpers on the Precharge Board

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Pause

0.3

sec.

0.3

sec.

0.9 sec.

Start Up/Troubleshooting 2-5

Table 2.A Precharge Board LED Indicators

Name Color State Description

POWER OK Green Steady Illuminates when precharge board power supply is operational.

ALARM Yellow Flashing The number [n] of flashes (see flashing pattern in Figure 2.2

indicates one of the following alarms

[1]

Low Line Voltage (< 90%) Low Line Voltage (< 65%) for SCR and RGU/AFE paralleling mode

Very Low Line Voltage (< 50%)

[2]

Low Phase (One phase < 80% of line voltage), or

[3]

Low Phase Voltage (One phase < 56% of line voltage) for SCR and RGU/AFE paralleling mode

Freq. out of range or asymmetry (Line synchronization failed)

[4]

Low DC Bus Voltage (triggers ride-through operation)

[5]

Input Frequency momentarily out of range (40…65 Hz)

[6]

DC Bus Short Circuit testing active (repetitive for appr. 120 s) or

[7]

no inverter connected to the bus

FAULT Red Flashing The number [n] of flashes (see flashing pattern in Figure 2.2

(1)

The ALARM indicator LED will continue the flashing pattern as long as the alarm condition exists. An alarm might trigger internal actions which may stop SCR gate firing.

(2)

If a fault occurs, the FAULT indicator LED will continue the flashing pattern, even if the fault condition no longer exists. Power must be cycled to clear the fault.

indicates one of the following faults

[2]

DC Bus Short (Udc < 2% after 20ms)

[4]

Line Synchronization failed or Low Line (Uac < 50% Unom)

[5]

Jumper setting wrong

(1)

(2)

)

Figure 2.2 Flashing Pattern for ALARM and FAULT LEDs

Example: Flashing pattern for ALARM LED showing a Low Phase alarm (where n = 3 flashes)

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2-6 Start Up/Troubleshooting

Troubleshooting

Table 2.B Possible Faults and Corrective Actions

Fault Cause Corrective Action

Heat sink Overtemperature

DC Output Voltage Loss

Heat sink temperature exceeds maximum rating

DC bus:

- Short Circuit FAULT [2] or

- Low Line FAULT [4] or

- No Load ALARM [7]

Refer to Table 2 . A

Loss of 115V AC power 1. Check 115V AC supply input voltage at control

Jumper setting wrong

Wrong jumper settings:

Single phase (1-ph) line type and one or both of the SPARE 1 or SPARE 2 jumpers set to their respective left positions.

1. Verify that maximum ambient temperature has not been exceeded.

2. Check Overtemperature Switch (N.C. contacts) at control terminals 10 and 11.

3. Check 115V AC supply input voltage at control terminals 0 and 115.

4. Check blower for correct operation.

5. Check for excess load on the bus supply.

6. Check for minimum mounting clearance around the bus supply.

7. Contact your local RA sales office.

1. Check 3-phase AC incoming power for undervoltage or phase loss.

2. Check all Bus Supply fuse trip indicator switches.

3. Verify the Inverter is connected.

4. Verify the power of the connected Inverter(s) is minimum 7.5 kW (10 HP). Refer to the 2nd Attention statement on page 2-1

5. Contact your local RA sales office.

terminals 0 and 115.

2. Check Enable Contactor function.

3. Contact your local RA sales office.

1. Check the jumper setting(s).

2. Set the jumper(s) correctly.

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Start Up/Troubleshooting 2-7

Important:Complete the tests listed in Table 2.C without power applied to

the SCR Bus Supply.

Table 2.C Control Terminal Block Continuity Test Conditions

Test Condition Possible Cause Corrective Action

N.C. contact on control terminals 6 and 7 is open

N.C. contact on control terminals 8 and 9 is open

N.C. contact on control terminals 10 and 11 is open

400A and 600A Unit: Open snubber fuse (F6…F8).

1000A Unit: Open snubber fuse or open DC bus fuse (F7…F11).

400A and 600A Unit: Open AC line fuse or open DC bus fuse (F1…F5).

1000A Unit: Open AC line fuse (F1…F6).

Open heat sink Overtemperature Switch

1. Check for evidence of power module failure (see Step 3 in Start-Up

2. Check for evidence of failure in snubber circuit. Check the snubber pcb diodes and snubber resistor and capacitor.

3. Replace entire SCR Bus Supply if any device has failed.

4. If there is no evidence of a failure, check for open fuse and replace.

1. Check for evidence of power module failure (see Step 3 in Start-Up

2. Replace entire SCR Bus Supply if any device has failed.

3. If there is no evidence of power module failure, check for open fuse and replace.

1. Verify that maximum ambient temperature is not exceeded.

2. Replace the Overtemperature Switch.

on page 2-2).

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2-8 Start Up/Troubleshooting

Notes:

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Appendix A

Specifications

This appendix provides electrical, environmental, functional and physical specifications for the PowerFlex SCR Bus Supply, and selection tables for AC input devices.

Topic Page

PowerFlex SCR Bus Supply Bus Supply Dimensions A-3 Accessories A-7 Spare Parts A-14

A-1

PowerFlex SCR Bus Supply

Category Specification

Input Ratings

Output Ratings

(1)

Includes appropriate AC line reactor.

Specifications Dependent on Power and Voltage

SCR Bus Supply Catalog Number

20SD400… 20SD600… 20SD1K0… 20SF1K0…

Nominal AC Input Voltage: 400/480V 600/690V

Frequency: 47…63 Hz 47…63 Hz

Operational AC Input Voltage Range: 187…528V 528…759V

Input Current (Max. Continuous rms): 355 521 843 843

Input kVA at Max. Continuous rms Amps: 246/295 361/433 584/700 876/1007

DC Bus Amps Normal Duty/Heavy Duty

Continuous: 1 minute: 3 Sec. every minute:

Max. Continuous DC Bus Amps without Overload:

Power Dissipation Maximum Continuous Amps:

The derate for each additional slave is 5% plus 5% for the master. See

Parallel Connection of Slave Units

(1)

— Watts at

300/240 330/360 450/480

400 600 1000 1000

1200 1600 2700 2800

on page 1-15.

500/400 550/600 750/800

800/720 880/1080 1200/1440

Specifications Dependent on Voltage

AC Input Vol ta ge

400V 540V 750V

480V 650V 750V

600V 810V 1080V

690V 930V 1080V

DC Bus Voltage

Nominal Maximum

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A-2 Specifications

Specifications Common to All SCR Bus Supplies

Category Specification Input/Output

Ratings

Control Input Enable Contactor Coil: Single Phase 115V AC, 30 VA (pick-up), 4.5 VA (hold)

Control Output

Approvals and Standards Compliance

Voltage Tolerance: –10% of minimum, +10% of maximum Frequency Tolerance: 47…63 Hz. Displacement Power Factor: 0.92 lagging (entire load range) Efficiency: 99.5% at rated amps, nominal line volts Line Transients: Up to 6000 volts peak per IEEE C62.41-1991 Max. Short Circuit Current Rating: 85 kA Cooling Forced ventilation cooled by tangential blower below heat sink Blower Power Consumption:

Cooling Air:

Blower Current Consumption: Single Phase 115V AC, 50/60 Hz, 1 A Heat Sink Temperature Sensor: The temperature sensor trips if heat sink temperature exceeds

NC Contact Output Rating (Max.): Resistive Rating: 15A at 125V AC, 10A at 250V AC,

Fuse Trip Indication Microswitches F1…F5 (400A & 600A) Microswitches F1…F6 (1000A) NC Contact Output Rating (Max.): Resistive Rating: 10A at 30…250V AC, 8A at 30V DC

Fuse Trip Indication Microswitches F6…F8 (400A & 600A) Microswitches F7…F11 (1000A) NC Contact Output Rating (Max.): Resistive Rating: 10A at 30…250V AC, 8A at 30V DC

Enable Contactor K1, NC Contact Output Rating (Max.): Resistive Rating: 10A at 24…230V AC, 3A at 30V DC

NFPA 70 - US National Electrical Code NEMA ICS 3.1 - Safety standards for Construction and Guide for Selection, Installation and Operation

of Adjustable Speed Drive Systems. NEMA 250 - Enclosures for Electrical Equipment IEC 146 - International Electrical Code.

200 VA

/hr.

600 m

maximum temperature.

7A at 24V DC

Inductive Rating: 10A at 125V AC, 6A at 250V AC

Inductive Rating: L/R = 25 ms, 10A at 30…250V AC

Inductive Rating: 2.2A at 24…230V AC

UL and cUL Listed to UL508C and CAN/CSA-C22.2

Environment Altitude: 1000 m (3300 ft.) max. without derating. Above 1000 m, the

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Marked for all applicable European Directives:

• EMC Directive (89/336/EEC)

Ambient Operating Temperature without Derating Open Type / IP00:

Storage Temperature (all const.): –40…70 °C (–40…158 °F) Relative Humidity: 5…95% non-condensing

• Emissions: EN 61800-3 Adjustable Speed electrical power drive systems Part 3

• Immunity: EN 61800-3 Second Environment, Restricted Distribution

• Low Voltage Directive (73/23/EEC)

• EN 50178 Electronic Equipment for Use in Power

Installations

derating for the output current is 1% per 100 m (330 ft.). 0…40 °C (32…104 °F); above 40 °C up to 50 °C (122 °F)

maximum temperature, the output Amps must be derated by:

1.2% per °C (2.2% per °F) for 400A unit

1.0% per °C (1.8% per °F) for 600A unit

1.0% per °C (1.8% per °F) for 1000A unit

Category Specification

Side ViewFront View

Environment

(continued)

Permitted Maximum Capacitance

Shock: 15G peak for 11 ms duration (± 1.0 ms) Vibration: 0.152 mm (0.006 in.) displacement, 1G peak Atmosphere: Important: The bus supply must

Surrounding Environment: The fan has a L10 rated life of 74,000 hours in a clean

Maximum Capacitance for Connection to the DC Bus Supply

Specifications A-3

where the ambient atmosphere contains volatile or corrosive gas, vapors or dust. If the bus supply is not going to be installed for a period of time, it must be stored in an area where it will not be exposed to a corrosive atmosphere.

environment. Execessive dust and heat will degrade fan life. This is the total DC Bus capacitance sum of the permitted

drives to connect. See Minimum Capacitance

Jumper Settings

on page 1-12.

not be installed in an area

on page 1-6 and

Bus Supply Dimensions

The overall dimensions and mounting holes of the PowerFlex SCR Bus Supply are shown in Figure A.1 in Figure A.2

Figure A.1 Bus Supply Mounting Dimensions

Not provided

on 400A Units

, Figure A.3, and Figure A.4.

200 (7.87)

Ø 9.5 (0.37)

30 (1.2)

339.5 (13.4)

. Connection Bus Bar dimensions are shown

Ø 35 (1.4) Holes for Lifting Hooks

9.5 (0.37)

SCR Bus Supply

400A 535 (21.1) 404 (15.9) 580 (22.8) 276 (10.9) 138.5 (5.5) 30 kg (66 lb.)

600A 740 (29.1) 490 (19.3) 785 (30.9) 276 (10.9) 104.5 (4.1) 43 kg (95 lb.)

1000A 740 (29.1) 490 (19.3) 785 (30.9) 276 (10.9) 104.5 (4.1) 67 kg (147 lb.)

(1.14)

Dimensions

17 x 5 (0.67 x 0.2) Slots for Precharge Board LEDs

Dimensions are in millimeters and (inches).

WeightABCDE

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A-4 Specifications

Side ViewFront View

Figure A.2 400A Unit Bus Bar Customer Connection Point Dimensions/Locations

DC+

15 (0.6)

77.5

(3.05)

190

(7.5)

(1.97)

144 (5.7)

DC-

(2.3)58(2.3)

Dimensions are in millimeters and (inches).

233 (9.2)

243 (9.6)

304 (12)

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Specifications A-5

DC+

DC-

100

(3.94)

(1.57)

160

(7.5)

243

(9.6)

243

(9.6)

304

(12)

40 (1.57)

(1.97)

(2.56)70(2.56)

147

(5.8)

(2.7)

Dimensions are in millimeters and (inches).

F12

F6-F8

Side ViewFront View

Figure A.3 600A Unit Bus Bar Customer Connection Point Dimensions/Locations

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A-6 Specifications

DC-

DC+

100

(3.94)

249

(9.8)

(1.57)

40 (1.57)

50 (1.97)

(2.56)70(2.56)

Dimensions are in millimeters and (inches).

249

(9.8)

338.5 (13.3)

157.5 (6.2)

(2.24)

61.5 (2.4)

Side ViewFront View

Figure A.4 1000A Unit Bus Bar Customer Connection Point Dimensions/Locations

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Specifications A-7

Accessories

Line Reactors

A minimum reactance is required to limit peak currents in the AC line and the bridge circuit. This can be accomplished either by a matched supply transformer or by adding line reactors to ensure the requested minimum voltage drop over the total line impedance. The preferred method is to install a minimum 3% line reactor, which will also reduce line harmonics.

Use Table A.A of the drive’s connected DC Amps and the supply transformer rating.

For more details on the 1321-Series line reactors, see the 1321 Power Conditioning Products Technical Data (publication 1321-TD001).

Table A.A 400V, 50Hz Line Reactor Selection

Drives Ranges of Drives DC Amp Sum for Typical Supply Transformers

Sum of DC Amps

up to 203

204 to 255

256 to 319

320 to 407

408 to 509

510 to 635

636 to 763

764 to 938

939 to 1K0

630 kVA 5% 43

120-150 120-154 120-160 120-165 120-168 120-173 120-176 230 3R160-C

151-203 155-203 161-203 166-203 169-203 174-203 177-203 150 3R160-B

— — — 204-206 204-209 204-219 204-224 185 3R200-C

204-255 204-255 204-255 207-255 210-255 220-255 225-255 110 3R200-B

— — — — — 256-260 256-275 150 3RB250-C

256-319 256-319 256-319 256-319 256-319 261-319 276-319 90 3RB250-B

320-335 320-370 320-390 320-407 320-407 320-407 320-407 75 3RB320-B

336-407 371-407 391-407 — — — — 40 3RB320-A

— 408-425 408-450 408-480 408-509 408-509 408-509 60 3RB400-B

408-509 426-509 451-509 481-509 — — — 30 3RB400-A

— — — 510-538 510-590 510-635 510-635 50 3R500-B

510-540 510-580 510-635 539-635 591-635 — — 25 3R500-A

— — — — 636-660 636-763 636-763 40 3R600-B

— 636-763 636-763 636-763 661-763 — — 20 3R600-A

— — — — — 764-900 764-938 29 3R750-B

— 764-800 764-870 764-900 764-938 901-938 — 15 3R750-A

— — — — — 939-1K0 939-1K0 27 3R850-B

— — — — 939-1K0 — — 15 3R850-A

µH

800 kVA 5% 35 µH

through Table A.D to select a line reactor based on the sum

1000 kVA

5.5% 31 µH

1250 kVA 6% 27 µH

1600 kVA 6% 22 µH

2500 kVA

6.5% 16 µH

(1)

3000 kVA

6.5% 13 µH

Line Reactor

Induct.

Catalog No.

[

µH]

1321-…

75 3R160-A

55 3R200-A

45 3RB250-A

125 3RB320-C

105 3RB400-C

(2)

(1)

The inductance value of the supply transformers includes 2.5 µH for 10 m feeder cable.

(2)

The number in the catalog string represents the fundamental AC current rating of the reactor.

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A-8 Specifications

Table A.B 480V, 60Hz Line Reactor Selection

Drives Ranges of Drives DC Amp Sum for Typical Supply Transformers

Sum of DC Amps

up to 203

204 to 255

256 to 319

320 to 407

408 to 509

510 to 635

636 to 763

764 to 938

939 to 1K0

µH

800 kVA 5% 41

630 kVA 5% 51

120-140 120-144 120-150 120-155 120-160 120-165 120-170 230 3R160-C

141-203 145-203 151-203 156-203 161-203 166-203 171-203 150 3R160-B

— — — — 204-209 204-214 204-218 185 3R200-C

204-255 204-255 204-255 204-255 210-255 215-255 219-255 110 3R200-B

— — — — — — 256-260 150 3RB250-C

256-290 256-319 256-319 256-319 256-319 256-319 261-319 90 3RB250-B

291-319 — — — — — — 45 3RB250-A

— 320-340 320-360 320-380 320-407 320-407 320-407 75 3RB320-B

320-407 341-407 361-407 381-407 — — — 40 3RB320-A

— — 408-420 408-450 408-490 408-509 408-509 60 3RB400-B

408-440 408-509 421-509 451-509 491-509 — — 30 3RB400-A

— — — — 510-540 510-620 510-635 50 3R500-B

510-560 510-585 510-600 510-635 541-635 621-635 — 25 3R500-A

— — — — — 636-700 636-763 40 3R600-B

— 636-680 636-763 636-763 636-763 701-763 — 20 3R600-A

— — — — — 764-840 764-938 29 3R750-B

— — — 764-938 764-938 841-938 — 15 3R750-A

— — — — — 939-1K0 939-1K0 27 3R850-B

— — — — 939-1K0 — — 15 3R850-A

µH

1000 kVA

5.5% 36

µH

1250 kVA 6% 32

µH

1600 kVA 6% 26

µH

2500 kVA

6.5% 19

µH

(1)

3000 kVA

6.5% 16

µH

Line Reactor

Induct.

Catalog No.

[µH]

1321-…

55 3R200-A

(2)

(1)

The inductance value of the supply transformers includes 2.5 µH for 10 m feeder cable.

(2)

The number in the catalog string represents the fundamental AC current rating of the reactor.

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Table A.C 600V, 60Hz Line Reactor Selection

Drives Ranges of Drives DC Amp Sum for Typical Supply Transformers

Sum of DC Amps

up to 203

204 to 255

256 to 319

320 to 407

408 to 509

510 to 635

636 to 763

764 to 938

939 to 1K0

µH

800 kVA 5% 62

630 kVA 5% 78

120-155 120-164 120-175 130-180 130-190 130-199 140-203 230 3R160-C

156-203 165-203 176-203 181-203 191-203 200-203 — 150 3R160-B

— — 204-209 204-230 204-230 204-255 204-255 185 3R200-C

204-255 204-255 210-255 231-255 231-255 — — 110 3R200-B

— — — — 256-270 256-295 256-319 150 3RB250-C

256-280 256-319 256-319 256-319 271-319 296-319 — 90 3RB250-B

281-319 — — — — — — 45 3RB250-A

— 320-340 320-360 320-390 320-407 320-407 320-407 75 3RB320-B

320-407 341-407 361-407 391-407 — — — 40 3RB320-A

— — — — — — 408-425 105 3RB400-C

— — — 408-440 408-509 408-509 426-509 60 3RB400-B

408-450 408-509 408-509 441-509 — — — 30 3RB400-A

— — — — 510-545 510-635 510-635 50 3R500-B

— 510-560 510-600 510-635 546-635 — — 25 3R500-A

— — — — — 636-740 636-763 40 3R600-B

— — — 636-750 636-763 741-763 — 20 3R600-A

— — — — — 764-840 764-938 29 3R750-B

— — — — 764-938 841-938 — 15 3R750-A

— — — — — 939-1K0 939-1K0 27 3R850-B

— — — — 939-1K0 — — 15 3R850-A

µH

1000 kVA

5.5% 55

µH

1250 kVA 6% 48

µH

1600 kVA 6% 38

µH

2500 kVA

6.5% 27

µH

(1)

3000 kVA

6.5% 21

Specifications A-9

Line Reactor

Induct.

Catalog No.

[µH]

µH

1321-…

75 3R160-A

55 3R200-A

(2)

(1)

The inductance value of the supply transformer includes 2.5 µH for 10 m feeder cable.

(2)

The number in the catalog string represents the fundamental AC current rating of the reactor.

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A-10 Specifications

Table A.D 690V, 50Hz Line Reactor Selection

Drives Ranges of Drives DC Amp Sum for Typical Supply Transformers

Sum of DC Amps

up to 203

204 to 255

256 to 319

320 to 407

408 to 509

510 to 635

636 to 763

764 to 938

939 to 1K0

µH

800 kVA 5% 95

630 kVA 5% 123

— 130-150 130-157 130-162 130-170 140-180 150-185 2x150 3R160-B

130-175 151-190 158-203 163-203 171--203 181-203 186-203 230 3R160-C

176-203 191-203 — — — — — 150 3R160-B

— — — — — 204-210 204-220 2x110 3R200-B

204-206 204-230 204-245 204-255 204-255 211-255 221-255 185 3R200-C

207-255 231-255 246-255 — — — — 110 3R200-B

— — — — — — 256-260 2x90 3RB250-B

— 256-260 256-270 256-290 256-319 256-319 261-319 150 3RB250-C

256-280 261-319 271-319 291-319 — — — 90 3RB250-B

281-319 — — — — — — 45 3RB250-A

— — — — 320-360 320-407 320-407 125 3RB320-C

— 320-360 320-380 320-407 361-407 — — 75 3RB320-B

320-407 361-407 381-407 — — — — 40 3RB320-A

— — — — — 408-465 408-509 105 3RB400-C

— — 408-414 408-450 408-509 466-509 — 60 3RB400-B

— 408-500 415-509 451-509 — — — 30 3RB400-A

— — — — — 510-520 510-580 85 3R500-C

— — — 510-538 510-570 521-635 581-635 50 3R500-B

— — 510-540 539-635 571-635 — — 25 3R500-A

— — — — — — 636-650 65 3R600-C

— — — — — 636-763 651-763 40 3R600-B

— — — — 661-763 — — 20 3R600-A

— — — — — — 764-780 48 3R750-C

— — — — — 764-850 781-938 29 3R750-B

— — — — — 851-938 — 15 3R750-A

— — — — — — — 42 3R850-C

— — — — — 939-1K0 939-1K0 27 3R850-B

— — — — — — — 15 3R850-A

µH

1000 kVA

5.5% 86

µH

1250 kVA 6% 75

µH

1600 kVA 6% 59

µH

2500 kVA

6.5% 42

µH

(1)

3000 kVA

6.5% 33

µH

Line Reactor

Induct.

Catalog No.

[µH]

1321-…

75 3R160-A

55 3R200-A

(2)

(3)

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(1)

The inductance value of the supply transformers includes 2.5 µH for 10 m feeder cable.

(2)

The number in the catalog string represents the fundamental AC current of the reactor.

(3)

Connect two reactors in series.

Specifications A-11

4mm

Wire

41.5

(1.63)

500

(19.7)

100

(3.94)

Ø 4.2

(0.17)

Ø 4.5 (0.18)

15.5

(0.61)

(1.38)

(0.8)

(0.7)

110

(4.3)

110

(4.3)

120

(4.7)

HF Filter

It is recommended to install one HF filter (Catalog No. 20S-RFC) in every system. When this filter is used, the HF emission limits for class A, group 2* (EN 55011) in the 2nd environment (industrial supply network) according to the product standard EN 61800-3 are met and the Bus Supply fulfills CE conformity.

The HF filter is connected in front of the AC line reactor between the three AC line input phases and the protection earth conductor PE (Figure A.5

Figure A.5 HF Filter Wiring Diagram

Filter

…

SCR

Bus Supply

Figure A.6 20S-RFC Filter Dimensions

SCR

Bus Supply

PowerFlex SCR Bus Supply User Manual

Publication 20S-UM001G-EN-P

A-12 Specifications

Solid Ground Systems

Using the hole location dimensions from Figure A.6, install the HF filter using the four (4) M4 x 20 screws through the four holes in the plastic body of the HF filter (Figure A.7 through the PE grounding plate. Do NOT use the nylon standoffs.

Figure A.7 Mounting the HF Filter

). Then install the three (3) M4 x 8 screws

M4 x 8

3 Places

(for solid ground

system only)

Grounding

Plate

Non-Solid Ground Systems

The HF filter may be installed with floating or HRG ground systems for line-to-line transient protection. In this type of installation, the PE grounding plate should NOT be connected to ground, but remain isolated from ground.

Important:The HF filter PE grounding plate will be floating with potential

high voltage with respect to earth ground when AC line power is applied.

M4 x 20

4 Places

M4 x 19 Nylon Standoffs 4 Places (for floating or HGR system only)

PowerFlex SCR Bus Supply User Manual

Publication 20S-UM001G-EN-P

Using the hole location dimensions from Figure A.6 using the four (4) M4 x 19 nylon standoffs and four (4) M4 x 20 screws through the four holes in the plastic body of the HF filter (Figure A.7 Finger tighten the nylon standoffs. Do NOT install the three (3) M4 x 8 screws through the PE grounding plate.

Install the High Voltage Warning label onto the PE grounding plate when the HF filter is installed with a floating or HRG ground system.

, install the HF filter

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Specifications A-13

PowerFlex SCR Bus Supply User Manual

Publication 20S-UM001G-EN-P

A-14 Specifications

Spare Parts

400A SCR Bus Supply

Important:SCR Bus Supplies are NOT designed to be field repaired, but

can be field maintained.

Figure A.8 400A Unit Spare Part Locations

PowerFlex SCR Bus Supply User Manual

Publication 20S-UM001G-EN-P

Specifications A-15

Table A.E 400A Unit Spare Part Numbers/Descriptions

Item Availability

3 — 400A SCR Set SK-20S-MCC162-18IO1 3

4 Yes Fan Assembly 6 — 400A and 600A MOV Assembly SK-20S-VBKSDK041 1 7 Yes 40A Fuse (Precharge fuses F6…F8)

8 Yes 400A, 700V Fuse (AC fuses F1…F3)

9 Yes 450A, 700V Fuse (DC fuses F4 and F5)

12 Yes Fuse Monitoring Switch SK-20S-MS3V1-5 5 13 — 85 °C Thermostat SK-20S-SWT85KSDKRW 1 16 — 400A SCR Wire Harness SK-20S-ZY041-400 1 18 Yes 400 and 600A Snubber Circuit Board SK-20S-PR-GR3 1 20 — 400A Cover SK-20S-RW9582300-B 1 21 — 400A Enclosure SK-20S-RW-U-SCR400 1 24 — 10 µF, 1200V Capacitor SK-20S-E62K85103D1W 2 25 — 5.6K Ohm, 90W Resistor SK-20S-RW35FST5K6K 2 27 — 4.7 Ohm, 45W Resistor SK-20S-RW33FST4R7K 1 30 — 400A Bus Bar Set SK-20S-BBKSDK041 1 31 — Terminal Block Assembly SK-20S-TBKSDKRW 1 32 — 40 mm tall x 40 mm O.D. Insulator

33 — 30 mm tall x 26 mm O.D. Insulator

35 Yes 480V SCR Precharge Circuit Board 38 Yes Precharge Relay SK-20S-CA2KN31F7 1

(1)

Description Rockwell Catalog No. Qty.

(2)

Torque to 13 N•m (115 lb•in).

with M10 Thread

with M8 Thread

SK-D9-FAN2 1

(3)

SK-20S-F070B040S or Westcode Type F070B040S or Ferraz Shawmut Type 6.921CPgRC14.51 40

SK-20S-069UR0S0400B or Westcode Type 069UR0S0400B or Ferraz Shawmut Type 6.9URD30TTF0400

SK-20S-069UR0S0450B or Westcode Type 069UR0S0450B or Ferraz Shawmut Type 6.9URD30TTF0450

SK-20S-IN551520 3

SK-20S-IN551450 2

(4)

SK-D9-SCRPRE1-D 1

(1)

Important: SCR Bus Supplies are designed to be field maintained only. Normal maintenance components (fan, fuses, fuse monitor switch, printed circuit boards (precharge, gate, and snubber), and precharge relay are available. Additional catalog numbers are provided for troubleshooting and technical support information only.

(2)

Extensive disassembly is required to replace the fan assembly. Please consider using Rockwell Automation Remanufacturing Services.

(3)

When replacing these fuses, always properly position them so that their fuse trip indicators (plungers) point toward the fuse trip detection board.

(4)

This is an ESD sensitive component.

PowerFlex SCR Bus Supply User Manual

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A-16 Specifications

7 13 11

600A SCR Bus Supply

Important:SCR Bus Supplies are NOT designed to be field repaired, but

can be field maintained.

Figure A.9 600A Unit Spare Part Locations

PowerFlex SCR Bus Supply User Manual

Publication 20S-UM001G-EN-P

Specifications A-17

Table A.F 600A Unit Spare Part Numbers/Descriptions

Item Availability

2 — 600A SCR Set SK-20S-MCC312-18IO1 3

4 Yes Fan Assembly 6 — 400A and 600A MOV Assembly SK-20S-VBKSDK041 1 7 Yes 40A Fuse (Precharge fuses F6…F8)

10 Yes 630A, 700V Fuse (AC fuses F1…F3)

11 Yes 1000A, 700V Fuse (DC fuses F4 and F5)

12 Yes Fuse Monitoring Switch SK-20S-MS3V1-5 5 13 — 85 °C Thermostat SK-20S-SWT85KSDKRW 1 15 — 600A SCR Wire Harness SK-20S-ZY065-600 1 18 Yes 400 and 600A Snubber Circuit Board SK-20S-PR-GR3 1 19 — 600A and 1000A Cover SK-20S-RW9582300-A 1 22 — 600A and 1000A Enclosure SK-20S-RWU600-1000 1 24 — 10 µF, 1200V Capacitor SK-20S-E62K85103D1W 2 25 — 5.6K Ohm, 90W Resistor SK-20S-RW35FST5K6K 2 27 — 4.7 Ohm, 45W Resistor SK-20S-RW33FST4R7K 1 29 — 600A Bus Bar Set SK-20S-BBKSDK065 1 31 — Terminal Block Assembly SK-20S-TBKSDKRW 1 32 — 40 mm tall x 40 mm O.D. Insulator

35 Yes 480V SCR Precharge Circuit Board 38 Yes Precharge Relay SK-20S-CA2KN31F7 1

(1)

Description Rockwell Catalog No. Qty.

(2)

Torque to 25 N•m (221 lb•in).

with M10 Thread

SK-D9-FAN2 1

(3)

SK-20S-F070B040S or Westcode Type F070B040S or Ferraz Shawmut Type 6.921CPgRC14.51 40

SK-20S-069UR5S0630B or Westcode Type 069UR2S0630B or Ferraz Shawmut Type 6.9URD32TTF0630

SK-20S-069UR2S1000B or Westcode Type 069UR2S1000B or Ferraz Shawmut Type 6.9URD32TTF1000

SK-20S-IN551520 5

(4)

SK-D9-SCRPRE1-D 1

(1)

(2)

Extensive disassembly is required to replace the fan assembly. Please consider using Rockwell Automation Remanufacturing Services.

(3)

When replacing these fuses, always properly position them so that their fuse trip indicators (plungers) point toward the fuse trip detection board.

(4)

This is an ESD sensitive component.

PowerFlex SCR Bus Supply User Manual

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A-18 Specifications

13 12

7 11 11

1000A SCR Bus Supply

Important:SCR Bus Supplies are NOT designed to be field repaired, but

can be field maintained.

Figure A.10 1000A Unit Spare Part Locations

PowerFlex SCR Bus Supply User Manual

Publication 20S-UM001G-EN-P

Specifications A-19

Precharge Board

SK-D9-SCRPRE1-x

Gate Drive Board

SK-D9-SCRGDB1

1000A

Slave Unit

1000A

Master Unit

1000A

Standalone Unit

Gate Driver Board SK-D9-SCRGDB1

Precharge Board

SK-D9-SCRPRE1-x

Table A.G 1000A Unit Spare Part Numbers/Descriptions

Item Availability

1 — 1000A SCR Set SK-20S-MCO600-22IO1 6 4 Yes Fan Assembly 5 — 1000A MOV Assembly SK-20S-VBKSDK110 1 7 Yes 40A Fuse (Precharge fuses F7…F11)

11 Yes 1000A, 700V Fuse (AC fuses F1…F6)

12 Yes Fuse Monitoring Switch SK-20S-MS3V1-5 6 13 — 85 °C Thermostat SK-20S-SWT85KSDKRW 1 14 — 1000A SCR Wire Harness SK-20S-ZY110-1000 1 17 Yes 1000A Snubber Circuit Board SK-20S-PR-GR3-5 1 19 — 600A and 1000A Cover SK-20S-RW9582300-A 1 22 — 600A and 1000A Enclosure SK-20S-RWU600-1000 1 23 — 15 µF, 1000V Capacitor SK-20S-E62K85153D1W 2 26 — 4.7K Ohm, 130W Resistor SK-20S-RW36FST4K7K 2 27 — 4.7 Ohm, 45W Resistor SK-20S-RW33FST4R7K 1 28 — 1000A Bus Bar Set SK-20S-BBKSDK110 1 31 — Terminal Block Assembly SK-20S-TBKSDKRW 1 32 — 40 mm tall x 40 mm O.D. Insulator

34 Yes Gate Driver Circuit Board 35 Yes 480V SCR Precharge Circuit Board 36 Yes 690V SCR Precharge Circuit Board 37 Yes Master/Slave or Slave/Slave Wire Harness 38 Yes Precharge Relay SK-20S-CA2KN31F7 1

(1)

Description Rockwell Catalog No. Qty.

(2)

(3)

Torque to 25 N•m (221 lb•in).

with M10 Thread

(4)(5)

(4)(6)

SK-D9-FAN2 1

SK-20S-F070B040S or Westcode Type F070B040S or Ferraz Shawmut Type 6.921CPgRC14.51 40

SK-20S-069UR2S1000B or Westcode Type 069UR2S1000B or Ferraz Shawmut Type 6.9URD32TTF1000

SK-20S-IN551520 5

SK-D9-SCRGDB1 1 SK-D9-SCRPRE1-D 1 SK-D9-SCRPRE1-F 1

(7)

SK-20S-D9-CBL1-DF 1

(1)

(2)

Extensive disassembly is required to replace the fan assembly. Please consider using Rockwell Automation Remanufacturing Services.

(3)

When replacing these fuses, always properly position them so that their fuse trip indicators (plungers) point toward the fuse trip detection board.

(4)

This is an ESD sensitive component.

(5)

Not required for 1000A Standalone unit, but required for 1000A Master unit or 1000A Slave unit (both mounted in lower location).

(6)

Not required for 1000A Slave unit, but required for 1000A Standalone unit (mounted in lower location) or 1000A Master unit (mounted in upper location).

(7)

Not required for a 1000A Standalone unit, but required to connect an existing 1000A Master or Slave unit to another 1000A Slave unit (gate driver circuit board mounted in lower location).

Figure A.11 1000A Unit Printed Circuit Board Locations (top view)

PowerFlex SCR Bus Supply User Manual

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A-20 Specifications

Notes:

PowerFlex SCR Bus Supply User Manual

Publication 20S-UM001G-EN-P

Appendix B

History of Changes

Topic Page

20S-UM001F-EN-P, March 2011

This appendix summarizes the revisions to this manual. Reference this appendix if you need information to determine what changes have been made across multiple revisions. This may be especially useful if you are deciding to upgrade your hardware or software based on information added with previous revisions of this manual.

B-1

20S-UM001F-EN-P, March 2011

Change

Reformatted document from half size (5.5 x 8.5 in.) to full size (8.5 x 11 in.). Removed reactors by DC Bus outputs on 12-Pulse System Configuration drawing. Added Atmosphere specification to the Environmental section. Added Surrounding Environment specification to the Environment section. Revised 400A, 600A, and 1000A Bus Supply spare part drawings and related tables. Added index to User Manual.

PowerFlex SCR Bus Supply User Manual

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B-2 History of Changes

Notes:

PowerFlex SCR Bus Supply User Manual

Publication 20S-UM001G-EN-P

Index

AC input

HF filter, A-11 line reactors, A-7 to A-10 voltages, A-1

AC supply

grounding, 1-5 non-grounded, 1-4 source considerations, 1-4 unbalanced, 1-4

ambient operating temperature, 1-3

before applying power, 2-2

cable trays, 1-7 catalog number explanation, P-4 CE conformity, 1-19 checklist, start-up, 2-2 clearances for mounting, 1-3 conduit, 1-7 control wiring, 1-11 converting

master unit (1000A only) to slave unit, 1-16 master unit (1000A only) to standalone unit,

1-16

cover, opening, 1-2

filter

HF, A-11 RFI, 1-5

firmware release, P-2 fusing

1000A unit, 1-7, A-19 400A unit, 1-7, A-15 600A unit, 1-7, A-17

general precautions, P-3 grounding

bus, 1-5 conductor, 1-5 general, 1-5 impedance, 1-5 safety, PE, 1-5

HF filter, A-11

jumper settings, 1-12

LEDs, 2-4 line reactors, A-7 to A-10

DC bus

capacitors, discharging, P-3

wiring guidelines, 1-7 dimensions, A-3 to A-6 discharging DC bus capacitors, P-3 disconnecting MOVs, 1-14 distribution systems

non-grounded, 1-4

unbalanced, 1-4 documentation, related, P-1

earthing, see grounding ESD, static discharge, P-3

manual

conventions, P-2 web site, P-2

master unit (1000A only) conversion to

slave unit, 1-16

standalone unit, 1-16 maximum loading, 1-6 minimum capacitance, 1-6 minimum mounting clearances, 1-3 MOVs, disconnecting, 1-14

opening the cover, 1-2

PowerFlex SCR Bus Supply User Manual

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Index-2

operating temperature, 1-3

parallel connection of slave units (1000A only),

1-15

PE ground, 1-5 power wiring, 1-7 powering up bus supply, 2-2 precautions, general, P-3

related documentation, P-1 removing cover, 1-2 replacing fuses

1000A unit, A-19 400A unit, A-15 600A unit, A-17

RFI filter grounding, 1-5

safety ground, 1-5 SCR bus supply

12-pulse configuration, 1-18 ambient operating temperature, 1-3 catalog number explanation, P-4 control wiring, 1-11 DC bus capacitor discharging, P-3 dimensions, A-3 to A-6 jumper settings, 1-12 line reactors, A-7 to A-10 power wiring, 1-7 redundancy (1000A unit only), 1-17 spare parts, A-14 to A-19 specifications, A-1 to A-3

setting jumpers, 1-12 short circuit protection, 1-7 slave unit (1000A only)

parallel connection, 1-15 spare parts, A-14 to A-19 specifications, A-1 to A-3 start-up checklist, 2-2 static discharge, ESD, P-3 status indicators, 2-4 supply source for AC, 1-4 system grounding, 1-5

technical support, P-2 troubleshooting, 2-6

unbalanced/non-grounded supply, 1-4

web site

Rockwell Automation 20GY- 755 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Summary of Changes

Table of Contents

Preface

Overview

Who Should Use this Manual?

Reference Documentation

General Drive Information

Specific Drive Information

Rockwell Automation Support

Conventions Used in This Manual

General Precautions

Catalog Number Explanation

Descriptions and Schematic Diagrams

Chapter 1

Installation/Wiring

Opening the Cover

Minimum Mounting Clearances

Ambient Operating Temperatures

AC Supply Source Considerations

Line Reactors

Unbalanced or Non-Solid Grounded Distribution Systems

General Grounding Requirements

Safety Ground Terminal - PE

RFI Filter Grounding

Minimum Capacitance

Maximum Loading

Fusing

Power Wiring

EMC Compliance

Cable Trays and Conduit

DC Bus Wiring Guidelines

Power Connection Bus Bars and Terminals

Control Wiring

Drive Run Interlock

Control Wiring Example

Jumper Settings

Disconnecting MOVs

Parallel Connection of Slave Units

1000A SCR Bus Supply Flexibility

Converting Master Unit to Standalone Unit

Converting Master Unit to Slave Unit

1000A SCR Bus Supply Redundancy

SCR Bus Supply 12-Pulse Configuration

CE Conformity

Low Voltage Directive (73/23/EEC)

EMC Directive (89/336/EEC)

Harmonic Emissions

General Notes

Essential Requirements for CE Compliance

Chapter 2

Start Up/Troubleshooting

Start-Up

Before Applying Power to the Bus Supply

Applying AC Power to the Bus Supply

Precharge Board LED Indicators

Troubleshooting

Appendix A

Specifications

PowerFlex SCR Bus Supply

Specifications Dependent on Power and Voltage

Specifications Dependent on Voltage

Specifications Common to All SCR Bus Supplies

Bus Supply Dimensions

Accessories

Line Reactors

HF Filter

Solid Ground Systems

Non-Solid Ground Systems

Spare Parts

400A SCR Bus Supply

600A SCR Bus Supply

1000A SCR Bus Supply

Appendix B

History of Changes

20S-UM001F-EN-P, March 2011

Index