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PowerFlex Diode Bus Supply User Manual

Publication 20T-UM001D-EN-P

Preface

Overview

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

™

Diode Bus

Supply.

Who Should Use this
Manual?

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

Reference Documentation

General Drive Information

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.

Topic

Page

Who Should Use this Manual?

Reference Documentation

Rockwell Automation Support

Conventions Used in This Manual

General Precautions

Catalog Number Explanation

Description and Schematic Diagram

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

For

See

Publication

PowerFlex

®

70/70EC Drive

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

20A-UM001
PFLEX-RM001
PFLEX-RM004

PowerFlex

®

700/700VC Series A Drive

PowerFlex

®

700VC Series B Drive

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

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

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Summary of Contents for Allen-Bradley PowerFlex 4M

Page 1: ...PowerFlex Diode Bus Supply User Manual ...

Page 2: ...n 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 Throughout this manual when necessary we use notes to make you aware of safety consideratio...

Page 3: ... section Power Wiring added a recommendation to keep all wired connections identical in size and length to maintain balanced impedance In the section Disconnecting MOVs and RFI Filter Capacitors added new Table 1 E Recommended MOV Configurations 1 2 1 6 1 10 In Chapter 2 In the subsection Before Applying Power to the Diode Bus Supply added new steps 2 and 5 In Table 2 A Possible Faults and Correct...

Page 4: ...soc ii Summary of Changes PowerFlex Diode Bus Supply User Manual Publication 20T UM001D EN P Notes ...

Page 5: ...1 3 General Grounding Requirements 1 4 Safety Ground Terminal PE 1 4 RFI Filter Grounding 1 4 Maximum Loading 1 5 AC Input Fusing 1 5 Power Wiring 1 6 Cable Types Acceptable for 200 600 Volt Installations 1 6 EMC Compliance 1 6 Cable Trays and Conduit 1 6 DC Bus Wiring Guidelines 1 7 Bus Supply Terminals 1 7 Control Wiring 1 8 Drive Run Interlock 1 8 Control Wiring Examples 1 9 Disconnecting MOVs ...

Page 6: ...User Manual Publication 20T UM001D EN P Appendix A Supplemental Information Specifications A 1 Dimensions A 3 AC Input Fusing A 4 Fuse Types A 4 Line Reactors A 5 Spare Parts A 5 Appendix B History of Changes 20T UM001C EN P September 2006 B 1 Index ...

Page 7: ...2 General Precautions P 3 Catalog Number Explanation P 4 Description and Schematic Diagram P 5 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 Contr...

Page 8: ...anual PFLEX IN006 20C PM001 PowerFlex 700S Drive PowerFlex 700S with Phase I Control Installation Manual Frames 1 6 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 I...

Page 9: ...ciated 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 Only connect Rockwell Automation common DC bus drives with built in precharge circuitry to the common DC bus output terminals of the Diode Bus Supply within the load rating guidelines See Specific Drive Inform...

Page 10: ...roduct Code Type 20T PowerFlex Diode Bus Supply b Voltage Rating Code Input Voltage Phase DC Output D 240 480V AC 3 325 650V DC E 500 600V AC 3 675 810V DC c Current Rating Code Output Frame 1 1 PowerFlex 700 drive equivalent frame size 120 120 0 Amp 2 d Enclosure Code Rating A NEMA Type 1 IP20 e Documentation Shipping Carton Code User Manual Carton E English Yes ...

Page 11: ...directly connected to the three line input terminals Bus Supply Overtemperature Sensors located in the heat sink are used for thermal protection of the diode bridge rectifier DC Chokes L1 L2 to reduce conducted HF emissions They also reduce line harmonics and peak currents in the AC line and the bridge circuit Input Filter Capacitors connected to the three input phases to reduce conducted HF emiss...

Page 12: ...P 6 Overview PowerFlex Diode Bus Supply User Manual Publication 20T UM001D EN P Notes ...

Page 13: ...ions 1 3 General Grounding Requirements 1 4 Maximum Loading 1 5 AC Input Fusing 1 5 Power Wiring 1 6 Control Wiring 1 8 Disconnecting MOVs and RFI Filter Capacitors 1 10 Paralleling Diode Bus Supplies 1 11 CE Conformity 1 12 ATTENTION The following information is merely a guide for proper installation Rockwell Automation Inc cannot assume responsibility for the compliance or the noncompliance to a...

Page 14: ...provided to the Diode Bus Supply to stay under the 40 C rated specification 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 Diode Bus Supply watt loss from specification section is 500 W at 120 A The three phase AC line reactor watt losses are listed in the 1321 Power Conditioning Products Technical Data publication 1321...

Page 15: ...ply transformer is larger than 1000 kVA If any or all of these conditions exist it is recommended that the user install a minimum amount of impedance between the Diode Bus Supply and the source This impedance could come from the supply transformer itself the cable between the transformer and Diode Bus Supply or an additional transformer or reactor Unbalanced or Non Solid Grounded Distribution Syst...

Page 16: ...nput ground conductor should be grounded independently and directly to this point bar Figure 1 1 Typical Grounding 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 g...

Page 17: ... The Diode Bus Supply can be installed with delay type AC input line fuses National and local industrial safety regulations and or electrical codes may determine additional requirements for these installations TIP When paralleling two Diode Bus Supplies see Paralleling Diode Bus Supplies on page 1 11 for details Drive Rating Drive DC Input Current Diode Bus Supply 1 1 No overload capability DC Vol...

Page 18: ...ambient should use 600V 75 C 168 F wire THHN THWN or similar wire is acceptable for Diode Bus Supply installation in dry environments provided adequate free air space and or conduit fill rate limits are provided Do not use THHN or similarly coated wire in wet areas EMC Compliance Refer to CE Conformity on page 1 12 for details Cable Trays and Conduit If cable trays or large conduits are to be used...

Page 19: ...ximum minimum sizes that the terminals will accept these are not recommendations Torque Maximum Minimum AC Line Input L1 L2 L3 35 mm2 2 AWG 0 75 mm2 18 AWG 3 3 N m 20 lb in PE Protective Earth Terminal DC Bus Terminals DC DC Control Terminals 8 11 2 5 mm2 14 AWG 0 25 mm2 22 AWG 0 8 N m 7 lb in Control Terminals 12 and GND MOV neutral disconnect see page 1 10 Jumper J4 see Disconnecting MOVs and RF...

Page 20: ...ls 10 and 11 should be wired to either the AC line input contactor for the Diode 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 PE 8 9 11 10 DC DC R L1 S L2 T L3 GND 12 MOV Terminal Description Notes Power Connections DC DC Bus DC Bus Connection DC DC Bus DC Bus Connection PE PE Ground Safe...

Page 21: ...ure 1 5 Multiple Drives Running Independently 2 wire control 3 115V K1 Run K1 11 10 K1M K1 PowerFlex Diode Bus Supply C F1 F2 DC Bus K1M K1M AC Drive 1 30 kW AC Drive 2 22 kW M 3 M 115V K1 Run Stop 2 Run Stop 1 3 M 3 M K1 K1M K2M 11 10 AC Drive 1 30 kW AC Drive 2 22 kW DC Bus PowerFlex Diode Bus Supply C F1 F2 K1 K1M K2M NOTE See Appendix A for Output Contact ratings ...

Page 22: ...ded Jumper Location see Figure 1 2 Removes Component see Figure 1 6 12 and GND Control Terminals MOV neutral from Ground J4 On DFPS Board Capacitors from Ground Power Source Type 1 1 It is highly recommended to accurately determine the power source type and then configure appropriately MOV Input Filter Capacitors 2 2 When MOVs are disconnected the power system must have its own transient protectio...

Page 23: ...us Supplies follow these guidelines A maximum of 2 two Diode Bus Supplies can be paralleled Each Diode Bus Supply must be derated by 3 This results in a DC Bus continuous output current rating of 233 Amps 0 97 x 2 x 120 It is recommended to use AC line fuses with an open fuse indicator See AC Input Fusing on page A 4 for details on recommended fusing Important It is recommended to keep all wired c...

Page 24: ...The Diode 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 stand...

Page 25: ...pt as short as possible to avoid electromagnetic emission and capacitive currents Therefore the drive s should be located in the same cabinet as the Diode Bus Supply or next to the cabinet with the Diode Bus Supply If the connection leads between DC bus and drive s are leaving the cabinet shielded cables must be used Use of line filters in non solid grounded systems is not recommended The Diode Bu...

Page 26: ...ling the drive s 4 Ground as described in General Grounding Requirements on page 1 4 5 Control wiring and DC bus wiring leaving the cabinet must be a braided shielded cable with a coverage of 75 or better metal conduit or equivalent attenuation For additional conditions see the respective drive Reference Manual and installation guidelines see Specific Drive Information on page P 1 ...

Page 27: ...orm 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 cont...

Page 28: ...op the drive s Verify that they have been wired correctly according to the user s specification See Control Wiring Examples on page 1 9 5 Verify that the jumper between control terminals 12 and GND and jumper P4 on DFPS circuit board are present on grounded supply lines default or removed on non solid grounded supply lines See Disconnecting MOVs and RFI Filter Capacitors on page 1 10 for more info...

Page 29: ...er On LED Fault Cause Corrective Action Heat sink Overtemperature Heat sink temperature exceeds maximum rating 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 fan for correct operation 4 Check for excess load on the Diode Bus Supply 5 Check for minimum mounting clearance around the Diode Bus Supply 6...

Page 30: ...2 4 Start Up Troubleshooting PowerFlex Diode Bus Supply User Manual Publication 20T UM001D EN P Notes ...

Page 31: ...us rms AC Input Current 105A 105A 105A 105A 105A Continuous DC Bus Current 1 120A 120A 120A 120A 120A Voltage Tolerance 10 minimum 10 maximum Frequency Tolerance 47 63 Hz Displacement Power Factor 0 92 lagging entire speed range Efficiency 99 5 at rated amps nominal line volts Line Transients up to 6000 volts peak per IEEE C62 41 1991 Heat Dissipation 500 W Max Short Circuit Current Rating using r...

Page 32: ...r Installations Environment Altitude 1000 m 3300 ft max without derating Above 1000 m the derating for the output current is 1 per 100 m 330 ft Ambient Operating Temperature without Derating 2 Open Type IP00 NEMA Type 1 IP20 0 50 C 32 122 F 0 40 C 32 104 F Storage Temperature all const 40 70 C 40 158 F Relative Humidity 5 to 95 non condensing Shock 15G peak for 11 ms duration 1 0 ms Vibration 0 15...

Page 33: ...A 1 Figure A 1 Diode Bus Supply Dimensions equivalent to PowerFlex 700 Frame 2 Drive 200 7 87 Ø 5 8 0 23 342 5 13 48 320 12 6 141 5 63 115 4 59 192 7 56 5 5 0 22 15 0 59 222 8 74 5 5 0 22 8 0 0 31 71 2 83 151 6 03 111 4 37 Ø 50 5 2 0 for Gland M50 Ø 16 5 0 66 for Gland M16 Front View Bottom View Side View Dimensions are in millimeters and inches Approximate Shipping Weight 23 kg 50 7 lb ...

Page 34: ...gG or equivalent should be used UL UL Class RK1 or J must be used 2 Table A A AC Input Current Ratings and Recommended Input Fusing 1 Typical designations include but may not be limited to the following Parts 1 2 AC AD BC BD CD DD ED EFS EF FF FG GF GG and GH 2 For 600V Ferraz Shawmut Class J AJT150 with open fuse indicator Class RK1 A6D150R Bussman Class J LPJ 150SP Class RK1 LPS RK 150SP or equi...

Page 35: ...nd the supply transformer rating For more details on the 1321 Series line reactors see 1321 Power Conditioning Products Technical Data publication 1321 TD001 Table A B Line Reactor Selection Spare Parts The Diode Bus Supply is not factory or field repairable therefore no spare parts exist for this product Drives Maximum Power Transformer Size 1 1 The inductance value of the supply transformers inc...

Page 36: ...A 6 Supplemental Information PowerFlex Diode Bus Supply User Manual Publication 20T UM001D EN P Notes ...

Page 37: ...de your hardware or software based on information added with previous revisions of this manual 20T UM001C EN P September 2006 Topic Page 20T UM001C EN P September 2006 B 1 Change In Chapter 1 In the section AC Supply Source Considerations revised information in the Input Power Conditioning subsection In the section Power Wiring added a new DC Bus Wiring Guidelines subsection that refers to the AC ...

Page 38: ...B 2 History of Changes PowerFlex Diode Bus Supply User Manual Publication 20T UM001D EN P Notes ...

Page 39: ...iring 1 8 DC bus capacitor discharging P 3 dimensions A 3 line reactors A 5 power wiring 1 6 specifications A 1 to A 2 discharging DC bus capacitors P 3 disconnecting MOVs 1 10 distribution systems non solid grounded 1 3 unbalanced 1 3 documentation related P 1 E earthing see grounding ESD static discharge P 3 F filter RFI 1 4 fusing AC input 1 5 G general precautions P 3 grounding bus 1 4 conduct...

Page 40: ... 1 5 spare parts A 5 specifications A 1 to A 2 start up checklist 2 2 static discharge ESD P 3 status indicator Power On 2 3 supply source for AC 1 3 system grounding 1 4 T technical support P 2 troubleshooting 2 3 U unbalanced non solid grounded supply 1 3 W web site related documentation P 2 Rockwell Automation technical support P 2 wiring control 1 8 power 1 6 ...

Page 41: ......

Page 42: ...ow these procedures Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com supp...

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