Schneider Electric MNA01M001EN User Manual
LXM32
Common DC bus
Application note
MNA01M001EN, V1.01, 08.2014
MNA01M001EN, V1.01, 08.2014
www.schneider-electric.com
LXM32
The information provided in this documentation contains general
descriptions and/or technical characteristics of the performance of the
products contained herein. This documentation is not intended as a
substitute for and is not to be used for determining suitability or reliability of these products for specific user applications. It is the duty of
any such user or integrator to perform the appropriate and complete
risk analysis, evaluation and testing of the products with respect to the
relevant specific application or use thereof. Neither Schneider Electric
nor any of its affiliates or subsidiaries shall be responsible or liable for
misuse of the information contained herein. If you have any suggestions for improvements or amendments or have found errors in this
publication, please notify us.
No part of this document may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission of Schneider Electric.
All pertinent state, regional, and local safety regulations must be
observed when installing and using this product. For reasons of safety
and to help ensure compliance with documented system data, only
the manufacturer should perform repairs to components.
When devices are used for applications with technical safety requirements, the relevant instructions must be followed.
Failure to use Schneider Electric software or approved software with
our hardware products may result in injury, harm, or improper operating results.
Failure to observe this information can result in injury or equipment
damage.
© 2013 Schneider Electric. All rights reserved.
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MNA01M001EN, V1.01, 08.2014
LXM32 Table of contents
Table of contents
Table of contents 3
Safety Information 5
Hazard categories 5
Qualification of personnel 6
Intended use 6
Basic information 7
DC bus voltage measurement 9
Standards and terminology 9
About the book 11
1 Introduction 13
1.1 Permissible device types for common DC bus 14
2 Technical Data 15
2.1 Firmware version 15
2.2 DC bus data 16
2.3 Braking resistor 17
2.3.1 External braking resistors (accessories) 19
2.4 Cables for the DC bus 20
3 Engineering 21
3.1 Energy balance 22
3.1.1 Energy balance basics 22
3.2 Electromagnetic compatibility (EMC) 24
3.3 DC bus connection 24
3.4 Fuses 25
3.4.1 DC bus connection of single-phase drives 25
3.4.2 DC bus connection of three-phase drives 27
3.4.3 Supply via the DC bus 29
3.5 Braking resistors 32
3.5.1 Rating the braking resistor 32
3.5.2 Rating information 34
3.6 Mains reactor 36
3.7 Mains filter 38
3.8 Mains reactor and external mains filter 39
4 Installation 41
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Common DC bus 3
Table of contents LXM32
4.1 Assembling cables 42
4.2 Wiring the DC bus 45
4.2.1 Drives with connectors 45
4.2.2 Drives with terminals 47
4.2.3 Connecting the DC bus 48
4.3 Verifying installation 49
5 Commissioning 51
5.1 Commissioning procedure 52
5.1.1 DC bus connection LXM32 to LXM32 52
5.1.2 Supply via the DC bus 53
5.2 LXM32: Setting the braking resistor parameters 54
6 Accessories and spare parts 55
6.1 DC bus accessories 55
6.2 DC fuses 55
6.3 External braking resistors 56
Glossary 57
Units and conversion tables 57
Length 57
Mass 57
Force 57
Power 57
Rotation 58
Torque 58
Moment of inertia 58
Temperature 58
Conductor cross section 58
Terms and Abbreviations 59
Table of figures 61
Index 63
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LXM32
Safety Information
Safety Information
Read these instructions carefully, and look at the equipment to
become familiar with the device before trying to install, operate, or
maintain it. The following special messages may appear throughout
this documentation or on the equipment to warn of potential hazards
or to call attention to information that clarifies or simplifies a procedure.
The addition of this symbol to a Danger safety label indicates that an electrical hazard exists, which will result in
personal injury if the instructions are not followed.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or death.
Hazard categories
Safety instructions to the user are highlighted by safety alert symbols
in the manual. In addition, labels with symbols and/or instructions are
attached to the product that alert you to potential hazards.
Depending on the seriousness of the hazard, the safety instructions
are divided into 4 hazard categories.
DANGER
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation, which, if not
avoided, can result in death, serious injury, or equipment damage.
CAUTION
CAUTION indicates a potentially hazardous situation, which, if not
avoided, can result in injury or equipment damage.
NOTICE
NOTICE indicates a potentially hazardous situation, which, if not
avoided, can result in equipment damage.
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Common DC bus 5
Safety Information
Qualification of personnel
Intended use
LXM32
Only appropriately trained persons who are familiar with and understand the contents of this manual and all other pertinent product documentation are authorized to work on and with this product. In addition,
these persons must have received safety training to recognize and
avoid hazards involved. These persons must have sufficient technical
training, knowledge and experience and be able to foresee and detect
potential hazards that may be caused by using the product, by changing the settings and by the mechanical, electrical and electronic equipment of the entire system in which the product is used.
All persons working on and with the product must be fully familiar with
all applicable standards, directives, and accident prevention regulations when performing such work.
The functions described in this document are only intended for use for
the products described in this document.
The product may only be used in compliance with all applicable safety
regulations and directives, the specified requirements and the technical data.
Prior to using the product, you must perform a risk assessment in view
of the planned application. Based on the results, the appropriate
safety measures must be implemented.
Since the product is used as a component in an entire system, you
must ensure the safety of persons by means of the design of this
entire system (for example, machine design).
Operate the product only with the specified cables and accessories.
Use only genuine accessories and spare parts.
Any use other than the use explicitly permitted is prohibited and can
result in hazards.
Electrical equipment should be installed, operated, serviced, and
maintained only by qualified personnel.
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LXM32
Safety Information
Basic information
DANGER
HAZARD DUE TO ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
• Only appropriately trained persons who are familiar with and
understand the contents of this manual and all other pertinent
product documentation and who have received safety training to
recognize and avoid hazards involved are authorized to work on
and with this drive system. Installation, adjustment, repair and
maintenance must be performed by qualified personnel.
• The system integrator is responsible for compliance with all local
and national electrical code requirements as well as all other
applicable regulations with respect to grounding of all equipment.
• Many components of the product, including the printed circuit
board, operate with mains voltage. Do not touch. Use only electrically insulated tools.
• Do not touch unshielded components or terminals with voltage
present.
• The motor itself generates voltage when the motor shaft is rotated. Block the motor shaft to prevent rotation prior to performing
any type of work on the drive system.
• AC voltage can couple voltage to unused conductors in the motor
cable. Insulate both ends of unused conductors of the motor
cable.
• Do not short across the DC bus terminals or the DC bus capacitors.
• Before performing work on the drive system:
- Disconnect all power, including external control power that
may be present.
- Place a "Do Not Turn On" label on all power switches.
- Lock all power switches in the open position.
- Wait 15 minutes to allow the DC bus capacitors to discharge.
Measure the voltage on the DC bus as per chapter "DC bus
voltage measurement" and verify the voltage is <42 Vdc. The
DC bus LED is not an indicator of the absence of DC bus voltage.
• Install and close all covers before applying voltage.
Failure to follow these instructions will result in death or serious injury.
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Common DC bus 7
Safety Information
LXM32
WARNING
LOSS OF CONTROL
• The designer of any control scheme must consider the potential
failure modes of control paths and, for certain critical functions,
provide a means to achieve a safe state during and after a path
failure. Examples of critical control functions are emergency stop,
overtravel stop, power outage and restart.
• Separate or redundant control paths must be provided for critical
functions.
• System control paths may include communication links. Consideration must be given to the implication of unanticipated transmission delays or failures of the link.
• Observe all accident prevention regulations and local safety
guidelines.
• Each implementation of the product must be individually and thoroughly tested for proper operation before being placed into service.
Failure to follow these instructions can result in death, serious
injury, or equipment damage.
1)
1) For USA: Additional information, refer to NEMA ICS 1.1 (latest edition), “Safety
Guidelines for the Application, Installation, and Maintenance of Solid State Control”
and to NEMA ICS 7.1 (latest edition), “Safety Standards for Construction and Guide
for Selection, Installation and Operation of Adjustable-Speed Drive Systems”.
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MNA01M001EN, V1.01, 08.2014
LXM32
Safety Information
DC bus voltage measurement
The DC bus voltage can exceed 800 Vdc. The DC bus LED is not an
indicator of the absence of DC bus voltage.
DANGER
ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
• Disconnect the voltage supply to all connections.
• Wait 15 minutes to allow the DC bus capacitors to discharge.
• Use a properly rated voltage-sensing device for measuring
(>800 Vdc).
• Measure the DC bus voltage between the DC bus terminals (PA/+
and PC/-) to verify that the voltage is less than 42 Vdc.
• Contact your local Schneider Electric representative if the DC bus
capacitors do not discharge to less than 42 Vdc within a period of
15 minutes.
• Do not operate the product if the DC bus capacitors do not discharge properly.
• Do not attempt to repair the product if the DC bus capacitors do
not discharge properly.
Failure to follow these instructions will result in death or serious injury.
Standards and terminology
Technical terms, terminology and the corresponding descriptions in
this manual are intended to use the terms or definitions of the pertinent standards.
In the area of drive systems, this includes, but is not limited to, terms
such as "safety function", "safe state", "fault", "fault reset", "failure",
"error", "error message", "warning", etc.
Among others, these standards include:
• IEC 61800 series: "Adjustable speed electrical power drive systems"
• IEC 61158 series: "Digital data communications for measurement
and control – Fieldbus for use in industrial control systems"
• IEC 61784 series: "Industrial communication networks – Profiles"
• IEC 61508 series: "Functional safety of electrical/electronic/
programmable electronic safety-related systems"
Also see the glossary at the end of this manual.
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Common DC bus 9
Safety Information
LXM32
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MNA01M001EN, V1.01, 08.2014
LXM32
About the book
Source manuals The latest versions of the manuals can be downloaded from the Inter-
Work steps If work steps must be performed consecutively, this sequence of steps
About the book
This document describes how several Schneider Electric drives type
LXM32 can share a common DC bus.
This application note replaces application note MNA01D001.
The information provided in this document supplements the manuals.
Before beginning, fully read and understand the manuals of the products used.
net at:
http://www.schneider-electric.com
is represented as follows:
■
Special prerequisites for the following work steps
▶
Step 1
◁
Specific response to this work step
▶
Step 2
If a response to a work step is indicated, this allows you to verify that
the work step has been performed correctly.
Unless otherwise stated, the individual steps must be performed in the
specified sequence.
Making work easier Information on making work easier is highlighted by this symbol:
Sections highlighted this way provide supplementary information on
making work easier.
SI units Technical data are specified in SI units. Converted units are shown in
parentheses behind the SI unit; they may be rounded.
Example:
Minimum conductor cross section: 1.5 mm2 (AWG 14)
Glossary Explanations of special technical terms and abbreviations.
Index List of keywords with references to the corresponding page numbers.
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Common DC bus 11
About the book
LXM32
12 Common DC bus
MNA01M001EN, V1.01, 08.2014
LXM32
1 Introduction
Use of electrical energy If an application operates with multiple drive systems, it may be useful
Common DC bus Whether or not a common DC bus makes sense depends on the
1 Introduction
A drive system requires energy for acceleration or constant movement
that must be supplied to the system.
During deceleration, a motor acts as a generator. A considerable portion of the kinetic energy is re-generated as electrical energy.
Since electrical energy can only be stored to a limited extent in a single drive, a drive uses a braking resistor to transform the excess
energy into thermal energy.
to employ a common DC bus. By sharing a common DC bus, the
energy regenerated by one drive can be supplied to another drive.
acceleration and deceleration cycles of the drive systems.
A common DC bus is useful, for example, if one drive systems accelerates while another drive system decelerates.
If the drive systems accelerate and decelerate at the same time, a
common DC bus does not make sense.
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Common DC bus 13
1 Introduction
1.1 Permissible device types for common DC bus
The DC bus of drives with identical numbers of mains phases can be
connected.
Single-phase drives:
• LXM32∙∙∙∙M2 with LXM32∙∙∙∙M2
Three-phase drives:
• LXM32∙∙∙∙N4 with LXM32∙∙∙∙N4
LXM32
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Common DC bus
LXM32
2 Technical Data
2.1 Firmware version
2 Technical Data
A common DC bus requires the devices to have at least the specified
firmware versions:
Drive Firmware version
LXM32C, LXM32A V01.04.00
LXM32M V01.02.00
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Common DC bus
15
2 Technical Data
LXM32
2.2 DC bus data
Single-phase drives
LXM32∙... U45M2 U90M2 D18M2 D30M2
Nominal voltage (1 ∼) V 115 230 115 230 115 230 115 230
Nominal voltage DC bus V 163 325 163 325 163 325 163 325
Undervoltage limit V 55 130 55 130 55 130 55 130
Voltage limit: activation of Quick Stop V 60 140 60 140 60 140 60 140
Overvoltage limit V 450 450 450 450 450 450 450 450
Maximum continuous power via DC bus kW 0.2 0.5 0.4 0.9 0.8 1.6 0.8 2.2
Maximum continuous current via DC bus A 1.5 1.5 3.2 3.2 6.0 6.0 10.0 10.0
Three-phase drives
LXM32∙... U60N4 D12N4 D18N4 D30N4 D72N4 D85N4 C10N4
Nominal voltage (3 ∼) V 208 208 208 208 208 208 208
Nominal voltage DC bus V 294 294 294 294 294 294 294
Undervoltage limit V 150 150 150 150 150 150 150
Voltage limit: activation of Quick Stop V 160 160 160 160 160 160 160
Overvoltage limit V 820 820 820 820 820 820 820
Maximum continuous power via DC bus kW 0.4 0.8 1.7 2.8 6.5 7.0 11.0
Maximum continuous current via DC bus A 1.5 3.2 6.0 10.0 22.0 28.0 40.0
LXM32∙... U60N4 D12N4 D18N4 D30N4 D72N4 D85N4 C10N4
Nominal voltage (3 ∼) V 400 400 400 400 400 400 400
Nominal voltage DC bus V 566 566 566 566 566 566 566
Undervoltage limit V 350 350 350 350 350 350 350
Voltage limit: activation of Quick Stop V 360 360 360 360 360 360 360
Overvoltage limit V 820 820 820 820 820 820 820
Maximum continuous power via DC bus kW 0.8 1.6 3.3 5.6 13.0 15.0 22.0
Maximum continuous current via DC bus A 1.5 3.2 6.0 10.0 22.0 28.0 40.0
LXM32∙... U60N4 D12N4 D18N4 D30N4 D72N4 D85N4 C10N4
Nominal voltage (3 ∼) V 480 480 480 480 480 480 480
Nominal voltage DC bus V 679 679 679 679 679 679 679
Undervoltage limit V 350 350 350 350 350 350 350
Voltage limit: activation of Quick Stop V 360 360 360 360 360 360 360
Overvoltage limit V 820 820 820 820 820 820 820
Maximum continuous power via DC bus kW 0.8 1.6 3.3 5.6 13.0 15.0 22.0
Maximum continuous current via DC bus A 1.5 3.2 6.0 10.0 22.0 28.0 40.0
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LXM32
2 Technical Data
2.3 Braking resistor
LXM32 drives have an internal braking resistor and a connection for
an external braking resistor. If the internal braking resistor is insufficient for the dynamics of the application, one or more external braking
resistors must be connected.
Single-phase drives
LXM32∙... U45M2 U90M2 D18M2 D30M2
Resistance value of internal braking
resistor
Continuous power internal braking resistor P
PR
Peak energy E
CR
External braking resistor minimum
External braking resistor maximum
1)
Maximum continuous power external
braking resistor
Capacitance of internal capacitor μF 390 780 1170 1560
Parameter DCbus_compat = 0 (default value)
Switch-on voltage braking resistor V 430 430 430 430
Energy absorption of internal capacitors
E
at nominal voltage 115 V +10%
var
Energy absorption of internal capacitors
E
at nominal voltage 200 V +10%
var
Energy absorption of internal capacitors
E
at nominal voltage 230 V +10%
var
Parameter DCbus_compat = 1 (reduced switch-on voltage)
Switch-on voltage braking resistor V 395 395 395 395
Energy absorption of internal capacitors
E
at nominal voltage 115 V +10%
var
Energy absorption of internal capacitors
E
at nominal voltage 200 V +10%
var
Energy absorption of internal capacitors
E
at nominal voltage 230 V +10%
var
1) The maximum specified braking resistor can derate the peak power of the device. Depending on the application, it is possible to use
a higher ohm resistor.
Ω
94 47 20 10
W 10 20 40 60
Ws 82 166 330 550
Ω
68 36 20 10
Ω
110 55 27 16
W 200 400 600 800
Ws 30 60 89 119
Ws 17 34 52 69
Ws 11 22 33 44
Ws 24 48 73 97
Ws 12 23 35 46
Ws 5 11 16 22
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2 Technical Data
LXM32
Three-phase drives
LXM32∙... U60N4 D12N4 D18N4 D30N4 D72N4 D85N4 C10N4
Resistance value of internal braking resistor
Continuous power internal braking resistor P
PR
Peak energy E
CR
External braking resistor minimum
External braking resistor maximum
1)
Maximum continuous power external
braking resistor
Capacitance of internal capacitor μF 110 195 390 560 1120 1230 1230
Parameter DCbus_compat
2)
Switch-on voltage V 780 780 780 780 780 780 780
Energy absorption of internal capacitors
E
at nominal voltage 208 V +10%
var
Energy absorption of internal capacitors
E
at nominal voltage 380 V +10%
var
Energy absorption of internal capacitors
E
at nominal voltage 400 V +10%
var
Energy absorption of internal capacitors
E
at nominal voltage 480 V +10%
var
1) The maximum specified braking resistor can derate the peak power of the device. Depending on the application, it is possible to use
a higher ohm resistor.
2) Parameter DCbus_compat has no effect in the case of three-phase devices
Ω
132 60 30 30 10 10 10
W 20 40 60 100 150 150 150
Ws 200 400 600 1000 2400 2400 2400
Ω
70 47 25 15 8 8 8
Ω
145 73 50 30 12 11 11
W 200 500 800 1500 3000 4500 5500
Ws 28 49 98 141 282 310 310
Ws 14 25 50 73 145 159 159
Ws 12 22 43 62 124 136 136
Ws 3 5 10 14 28 31 31
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LXM32
2.3.1 External braking resistors (accessories)
The resistance values for external braking resistors must not be below
the minimum resistance specified for the drives.
2 Technical Data
VW3A760... 1Rxx
Resistance
Continuous power W 400 100 200 400 100 200 400
Maximum time in braking at 115 V /
230 V
Peak power at 115 V / 230 V kW 18.5 6.8 6.8 6.8 2.6 2.6 2.6
Maximum peak energy at 115 V / 230 V Ws 13300 3800 7400 18100 3700 9600 24700
Maximum time in braking at 400 V /
480 V
Peak power at 400 V / 480 V kW 60.8 22.5 22.5 22.5 8.5 8.5 8.5
Maximum peak energy at 400 V / 480 V Ws 7300 1900 4900 11400 2500 6600 16200
Degree of protection IP65 IP65 IP65 IP65 IP65 IP65 IP65
UL approval (file no.) - E233422 E233422 - E233422 E233422 -
1) Resistors with a continuous power of 400 W are not UL/CSA-approved.
VW3A77... 04 05
Resistance
Continuous power W 1000 1000
Maximum time in braking at 115 V /
230 V
Peak power at 115 V / 230 V kW 12.3 18.5
Maximum peak energy at 115 V / 230 V Ws 43100 36500
Maximum time in braking at 400 V /
480 V
Peak power at 400 V / 480 V kW 40.6 60.8
Maximum peak energy at 400 V / 480 V Ws 26500 22500
Degree of protection IP20 IP20
UL approval (file no.) E221095 E221095
Ω
s 0.72 0.552 1.08 2.64 1.44 3.72 9.6
s 0.12 0.084 0.216 0.504 0.3 0.78 1.92
Ω
s 3.5 1.98
s 0.65 0.37
1)
2Rxx 3Rxx 4Rxx
10 27 27 27 72 72 72
15 10
1)
5Rxx 6Rxx 7Rxx
1)
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19
2 Technical Data
2.4 Cables for the DC bus
Minimum requirement A cable for the common DC bus must meet the following require-
ments.
Shield: Shielded at cable lengths of > 0.2 m
Twisted Pair: Twisted pair at cable lengths of >
Cable: Two wires, shielded
Maximum cable length between 2
drives:
Special characteristics: • Insulation must be rated for the
The connection of the fuses for the DC bus must be rated for the total
maximum continuous current on the DC bus of all drives connected
via the DC bus. Analyze the most critical case in your application (for
example EMERGENCY STOP) and select an appropriate conductor
cross section.
LXM32
0.2 m
3 m
DC bus voltage
• Conductor cross section according to the calculated current, but
at least 2* 6 mm2 (2* AWG 10)
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