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PowerFlex SCR Bus Supply User Manual

Publication 20S-UM001G-EN-P

 

 

 

Chapter

 1

Installation/Wiring

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

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.  

Topic

Page

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

!

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.

Содержание Allen-Bradley PowerFlex SCR

Страница 1: ...PowerFlex SCR Bus Supply Firmware Version 1 xxx User Manual...

Страница 2: ...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 conte...

Страница 3: ...ble 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 A 7 A 8 A 9 A 10 In Appendix A in the HF Filter section...

Страница 4: ...soc ii Summary of Changes PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P...

Страница 5: ...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...

Страница 6: ...ii Table of Contents PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P...

Страница 7: ...l Precautions P 3 Catalog Number Explanation P 4 Descriptions and Schematic Diagrams P 5 Title Publication Wiring and Grounding Guidelines for PWM AC Drives DRIVES IN001 AC Drives in Common Bus Config...

Страница 8: ...ve PowerFlex 700H Installation Instructions PowerFlex 700H Programming Manual PFLEX IN006 20C PM001 PowerFlex 700S Drive PowerFlex 700S with Phase I Control Installation Manual Frames 1 6 PowerFlex 70...

Страница 9: ...ion 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...

Страница 10: ...N E N a b c d e f a Product Code Type 20S PowerFlex SCR Bus Supply b Voltage Rating Code Input Voltage Phase DC Output D 400 480V AC 3 540 650V DC F 600 690V AC 3 675 930V DC c Current Rating Code Ou...

Страница 11: ...12 115 0 1 4 2 5 6 8 7 9 10 11 F12 K1 22 43 21 33 13 44 34 14 F5 F4 Precharge Board DC DC Item Description Six Pulse Full Wave 3 Phase SCR Bridge Rectifier Unit connected to the line input and DC Bus...

Страница 12: ...7 5 4 2 6 M N GND L1 Precharge Board DC DC Item Description Six Pulse Full Wave 3 Phase SCR Bridge Rectifier Unit connected to the line input and DC Bus output terminals through semi conductor protect...

Страница 13: ...Board DC DC To Gate Driver X4 on the Slave Figure P 4 Item Description Six Pulse Full Wave 3 Phase SCR Bridge Rectifier Unit connected to the line input and DC Bus output terminals through semi condu...

Страница 14: ...the next Slave Item Description 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 indicato...

Страница 15: ...rounding 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...

Страница 16: ...G EN P 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 abo...

Страница 17: ...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 1...

Страница 18: ...try 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 re...

Страница 19: ...equired 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...

Страница 20: ...put current rating For the DC Input Current values of the drives see tables in the respective drive documentation Table 1 A and Table 1 B provide guidance on the nominal operation of the SCR Bus Suppl...

Страница 21: ...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 DC Bus Wiring Guidelines For DC Bus w...

Страница 22: ...se of either lug type connectors to terminate field installed conductors or bus bars Recommended Minimum Size Bus Bar Wire AC Line Input L1 L2 L3 40 x 5 mm 1 57 x 0 2 in with single 14 mm 0 55 in diam...

Страница 23: ...e connectors to terminate field installed conductors or bus bars Recommended Minimum Size Bus Bar Wire AC Line Input L1 L2 L3 50 x 5 mm 1 97 x 0 2 in with two 14 mm 0 55 in diameter holes for customer...

Страница 24: ...nectors to terminate field installed conductors or bus bars Recommended Minimum Size Bus Bar Wire AC Line Input L1 L2 L3 50 x 10 mm 1 97 x 0 39 in with two 14 mm 0 55 in diameter holes for customer te...

Страница 25: ...C Supply Input For cooling blower and power supply on the Gate Driver Board on Master and Slave Units 1 and 2 1 1 Not used on Slave Units Contactor Coil 115V AC Contactor must be energized to enable t...

Страница 26: ...tions 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 F...

Страница 27: ...values shown in the following table 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...

Страница 28: ...r source type and then configure appropriately MOV Input Filter Capacitors 2 2 When MOVs are disconnected the power system must have its own transient protection to ensure known and controlled voltage...

Страница 29: ...hus 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 protectio...

Страница 30: ...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...

Страница 31: ...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 nume...

Страница 32: ...per Settings on page 1 12 Figure 1 12 shows a recommended 12 pulse system configuration with optional slave SCR Bus Supplies Figure 1 12 12 Pulse System Configuration For additional recommendations ab...

Страница 33: ...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...

Страница 34: ...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 A must be connected to the line input as shown in...

Страница 35: ...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...

Страница 36: ...hat the enable contactor coil K1 not used on Slave units is correctly wired 7 Verify that these four outputs are correctly wired Bus Supply Overtemperature Rectifier Fuse Trip Snubber DC feedback Fuse...

Страница 37: ...ol 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 informati...

Страница 38: ...or upper slot is used to view the LEDs For slot locations see Figure A 1 on page A 3 Figure 2 1 Location of LED Indicators and Jumpers on the Precharge Board ATTENTION The SCR Bus Supply LEDs are only...

Страница 39: ...Voltage 90 Low Line Voltage 65 for SCR and RGU AFE paralleling mode Very Low Line Voltage 50 Low Phase One phase 80 of line voltage or Low Phase Voltage One phase 56 of line voltage for SCR and RGU AF...

Страница 40: ...local RA sales office DC Output Voltage Loss DC bus Short Circuit FAULT 2 or Low Line FAULT 4 or No Load ALARM 7 Refer to Table 2 A 1 Check 3 phase AC incoming power for undervoltage or phase loss 2...

Страница 41: ...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...

Страница 42: ...2 8 Start Up Troubleshooting PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Notes...

Страница 43: ...n SCR Bus Supply Catalog Number 20SD400 20SD600 20SD1K0 20SF1K0 Input Ratings Nominal AC Input Voltage 400 480V 600 690V Frequency 47 63 Hz 47 63 Hz Operational AC Input Voltage Range 187 528V 528 759...

Страница 44: ...6 F8 400A 600A Microswitches F7 F11 1000A NC Contact Output Rating Max Resistive Rating 10A at 30 250V AC 8A at 30V DC Inductive Rating L R 25 ms 10A at 30 250V AC Enable Contactor K1 NC Contact Outpu...

Страница 45: ...t be exposed to a corrosive atmosphere Surrounding Environment The fan has a L10 rated life of 74 000 hours in a clean environment Execessive dust and heat will degrade fan life Permitted Maximum Capa...

Страница 46: ...ation 20S UM001G EN P Figure A 2 400A Unit Bus Bar Customer Connection Point Dimensions Locations 144 5 7 15 0 6 190 7 5 50 1 97 M8 PE 304 12 243 9 6 233 9 2 PE L1 L3 L2 58 2 3 58 2 3 77 5 3 05 DC DC...

Страница 47: ...P Figure A 3 600A Unit Bus Bar Customer Connection Point Dimensions Locations DC DC F5 F4 L1 L2 L3 PE 100 3 94 40 1 57 160 7 5 243 9 6 243 9 6 PE 304 12 40 1 57 50 1 97 70 2 56 70 2 56 147 5 8 68 2 7...

Страница 48: ...M001G EN P Figure A 4 1000A Unit Bus Bar Customer Connection Point Dimensions Locations PE L1 PE L3 L2 DC DC 100 3 94 249 9 8 40 1 57 40 1 57 50 1 97 70 2 56 70 2 56 Dimensions are in millimeters and...

Страница 49: ...talog No 1321 2 up to 203 120 150 120 154 120 160 120 165 120 168 120 173 120 176 230 3R160 C 151 203 155 203 161 203 166 203 169 203 174 203 177 203 150 3R160 B 75 3R160 A 204 to 255 204 206 204 209...

Страница 50: ...19 256 260 150 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 to 407 320 340 320 360 320 380 320 407 320 407 320 407 75 3RB320 B 320 407 341 407 3...

Страница 51: ...R200 A 256 to 319 256 270 256 295 256 319 150 3RB250 C 256 280 256 319 256 319 256 319 271 319 296 319 90 3RB250 B 281 319 45 3RB250 A 320 to 407 320 340 320 360 320 390 320 407 320 407 320 407 75 3RB...

Страница 52: ...2x90 3RB250 B 3 256 260 256 270 256 290 256 319 256 319 261 319 150 3RB250 C 256 280 261 319 271 319 291 319 90 3RB250 B 281 319 45 3RB250 A 320 to 407 320 360 320 407 320 407 125 3RB320 C 320 360 32...

Страница 53: ...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 phase...

Страница 54: ...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 ap...

Страница 55: ...Specifications A 13 PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P This page intentionally left blank...

Страница 56: ...al Publication 20S UM001G EN P 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 20...

Страница 57: ...er SK 20S RW9582300 B 1 21 400A Enclosure SK 20S RW U SCR400 1 24 10 F 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...

Страница 58: ...Manual Publication 20S UM001G EN P 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 19 35 38...

Страница 59: ...K 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 F 1200V Capacitor SK 20S E62K85103D1W 2 25 5 6K Ohm 90W Resistor SK 20S RW35FST5K6K 2...

Страница 60: ...l Publication 20S UM001G EN P 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 19 34 38 37...

Страница 61: ...R Precharge Circuit Board 4 6 SK D9 SCRPRE1 D 1 36 Yes 690V SCR Precharge Circuit Board 4 6 SK D9 SCRPRE1 F 1 37 Yes Master Slave or Slave Slave Wire Harness 7 SK 20S D9 CBL1 DF 1 38 Yes Precharge Rel...

Страница 62: ...A 20 Specifications PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Notes...

Страница 63: ...or software based on information added with previous revisions of this manual 20S UM001F EN P March 2011 Topic Page 20S UM001F EN P March 2011 B 1 Change Reformatted document from half size 5 5 x 8 5...

Страница 64: ...B 2 History of Changes PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Notes...

Страница 65: ...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 E e...

Страница 66: ...ation 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...

Страница 67: ......

Страница 68: ...rned follow 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 publ...

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