Rockwell Automation Allen-Bradley PowerFlex SCR User Manual
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Rockwell Automation Allen-Bradley PowerFlex SCR User Manual

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PowerFlex SCR Bus Supply
Firmware Version 1.xxx
User Manual

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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex SCR

  • Page 1 PowerFlex SCR Bus Supply Firmware Version 1.xxx User Manual...
  • Page 2 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.
  • Page 3 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 1-16 and which are not possible.
  • Page 4 soc-ii Summary of Changes PowerFlex SCR Bus Supply User Manual Publication 20S-UM001G-EN-P...

  • Page 5: Table Of Contents

    Rockwell Automation Support ........
  • Page 6 Table of Contents PowerFlex SCR Bus Supply User Manual Publication 20S-UM001G-EN-P...

  • Page 7: Preface

    PowerFlex SCR Bus Supply. Topic Page Who Should Use this Manual? Reference Documentation Rockwell Automation Support Conventions Used in This Manual General Precautions Catalog Number Explanation Descriptions and Schematic Diagrams Who Should Use this...

  • Page 8: Rockwell Automation Support

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

  • Page 9: General Precautions

    Overview 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”...

  • Page 10: Catalog Number Explanation

    Overview Catalog Number Position Number Explanation Product Code Type PowerFlex SCR Bus Supply Voltage Rating Code Input Voltage Phase DC Output 400/480V AC 540 - 650V DC 600/690V AC 675 - 930V DC Current Rating Code Output 400A, 400/480V 600A, 400/480V 1000A, 400/480/600/690V Enclosure Code...

  • Page 11: Descriptions And Schematic Diagrams

    Overview Descriptions and Schematic The SCR Bus Supply is a single-direction power converter for the front end Diagrams 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 F6-F8 >°C L1 L2 L3...
  • Page 12 Overview Figure P.2 1000A SCR Bus Supply Single Unit Schematic Diagram + DC F7 - 11 >°C - DC L1 L2 L3 Precharge Board 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 Bus output terminals through semi-conductor protection fuses with trip indicator switches.
  • Page 13 Overview Figure P.3 1000A SCR Bus Supply Master Unit Schematic Diagram F7-11 >°C L1 L2 L3 Precharge Board To Gate Driver X4 on the Slave (Figure P.4) Gate Driver Board The primary electrical components for the 1000A SCR Bus Supply Master Unit are: Item Description Six-Pulse, Full-Wave, 3-Phase SCR Bridge Rectifier Unit connected to the line input and DC...
  • Page 14 Overview Figure P.4 1000A SCR Bus Supply Slave Unit Schematic Diagram F7-11 >°C From Gate To Gate Driver X6 Driver X4 on the Master on the next (Figure P.3 or Slave previous Slave) Gate Driver Board The primary electrical components for the 1000A SCR Bus Supply Slave Unit are: Item Description Six-Pulse, Full-Wave, 3-Phase SCR Bridge Rectifier Unit connected to the line input and DC...
  • Page 15 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.

  • Page 16: Opening The Cover

    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).

  • Page 17: Minimum Mounting Clearances

    Installation/Wiring Minimum Mounting The cabinet air inlet and outlet areas for each SCR Bus Supply must be a Clearances minimum of 200 cm (31 in. ). The length-to-width ratio must not exceed 4:1. Figure 1.2 Mounting Clearances Air Outlet Air Outlet PowerFlex PowerFlex Bus Supply...

  • Page 18: Ac Supply Source Considerations

    Installation/Wiring AC Supply Source The PowerFlex SCR Bus Supply is suitable for use on a circuit capable of Considerations 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.

  • Page 19: General Grounding Requirements

    Installation/Wiring General Grounding The Safety Ground terminal (PE) must be connected to the building Requirements 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.

  • Page 20: Minimum Capacitance

    Installation/Wiring Minimum Capacitance 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.

  • Page 21: Fusing

    Installation/Wiring Fusing 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.
  • Page 22 Installation/Wiring Power Connection Bus Bars and Terminals Figure 1.4 400A Unit Bus Bar and Terminal Locations for Customer Wiring Table 1.C 400A Unit Power Connection Specifications Recommended Minimum Size Item Description Copper Bus Bars Bus Bar Wire AC Line Input 40 x 5 mm (1.57 x 0.2 in.) with 40 x 5 mm 120 mm...
  • Page 23 Installation/Wiring 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 Bus Bar Wire AC Line Input 50 x 5 mm (1.97 x 0.2 in.) with 50 x 5 mm 240 mm L1, L2, L3...
  • Page 24 1-10 Installation/Wiring 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 Bus Bar Wire AC Line Input 50 x 10 mm (1.97 x 0.39 in.) with 50 x 10 mm 2 x 240 mm L1, L2, L3...

  • Page 25: Control Wiring

    Installation/Wiring 1-11 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. •...

  • Page 26: Jumper Settings

    1-12 Installation/Wiring 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.
  • Page 27 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.

  • Page 28: Disconnecting Movs

    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.

  • Page 29: Parallel Connection Of Slave Units

    Installation/Wiring 1-15 Parallel Connection of Slave Up to four 1000A PowerFlex SCR Bus Supply Slave units may be Units 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.

  • Page 30: A Scr Bus Supply Flexibility

    1-16 Installation/Wiring 1000A SCR Bus Supply The 1000A SCR Bus Supply can be converted in the following ways. Flexibility Convert to… 1000A SCR Bus Supply Standalone Master Slave Convert from: Standalone Master Slave Because of numerous internal changes (components, cables, and hardware) the following conversions are not allowed: •...

  • Page 31: 1000A Scr Bus Supply Redundancy

    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. PowerFlex SCR Bus Supply User Manual Publication 20S-UM001G-EN-P...

  • Page 32: Scr Bus Supply 12-Pulse Configuration

    SCR Bus Gate Gate Supply Supply Harness Harness Fuses* Fuses* Fuses* Fuses* * Fuses are optional. DC Bus For additional recommendations about SCR Bus Supply 12-pulse configurations, contact Rockwell Automation Technical Support. PowerFlex SCR Bus Supply User Manual Publication 20S-UM001G-EN-P...

  • Page 33: Ce Conformity

    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 •...
  • Page 34 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.

  • Page 35: Chapter 2 Start Up/Troubleshooting

    Chapter 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 Troubleshooting 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.

  • Page 36: Start-Up

    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...
  • Page 37 Start Up/Troubleshooting 9. Verify that the SPARE 1 and SPARE 2 jumpers on the Precharge Board shown in Figure 2.1 are set to appropriate positions for the application. (Refer to Jumper Settings on page 1-12 Figure 1.9 on page 1-13 more information).

  • Page 38: Precharge Board Led Indicators

    Start Up/Troubleshooting Precharge Board LED The three LEDs on the Precharge Board are visible through a small slot in Indicators 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.
  • Page 39 Start Up/Troubleshooting 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 Low Line Voltage (<...

  • Page 40: Troubleshooting

    Start Up/Troubleshooting Troubleshooting Table 2.B Possible Faults and Corrective Actions Fault Cause Corrective Action Heat sink Heat sink temperature 1. Verify that maximum ambient temperature has Overtemperature exceeds maximum rating not been exceeded. 2. Check Overtemperature Switch (N.C. contacts) at control terminals 10 and 11. 3.
  • Page 41 Start Up/Troubleshooting 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 400A and 600A Unit: Open 1.
  • Page 42 Start Up/Troubleshooting Notes: PowerFlex SCR Bus Supply User Manual Publication 20S-UM001G-EN-P...

  • Page 43: Appendix A Specifications

    Appendix 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 Accessories Spare Parts A-14 PowerFlex SCR Bus Supply Specifications Dependent on Power and Voltage SCR Bus Supply Catalog Number Category Specification...
  • Page 44 Specifications Specifications Common to All SCR Bus Supplies Category Specification Input/Output Voltage Tolerance: –10% of minimum, +10% of maximum Ratings 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.

  • Page 45: Bus Supply Dimensions

    Specifications Category Specification Environment Shock: 15G peak for 11 ms duration (± 1.0 ms) (continued) Vibration: 0.152 mm (0.006 in.) displacement, 1G peak Atmosphere: Important: The bus supply must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors or dust.
  • Page 46 Specifications Figure A.2 400A Unit Bus Bar Customer Connection Point Dimensions/Locations 144 (5.7) 15 (0.6) 233 (9.2) 77.5 (2.3) (2.3) (3.05) (7.5) (1.97) 243 (9.6) Dimensions are in millimeters and (inches). 304 (12) Front View Side View PowerFlex SCR Bus Supply User Manual Publication 20S-UM001G-EN-P...
  • Page 47 Specifications Figure A.3 600A Unit Bus Bar Customer Connection Point Dimensions/Locations (3.94) (9.6) (7.5) (1.57) 40 (1.57) (2.56) (2.56) (2.7) (5.8) (1.97) (9.6) Dimensions are in millimeters and (inches). (12) Front View Side View PowerFlex SCR Bus Supply User Manual Publication 20S-UM001G-EN-P...
  • Page 48 Specifications Figure A.4 1000A Unit Bus Bar Customer Connection Point Dimensions/Locations 61.5 (3.94) (9.8) (2.4) (1.57) 40 (1.57) (2.56) (2.56) (2.24) 157.5 (6.2) 50 (1.97) (9.8) Dimensions are in millimeters and (inches). 338.5 (13.3) Front View Side View PowerFlex SCR Bus Supply User Manual Publication 20S-UM001G-EN-P...

  • Page 49: Accessories

    Specifications 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.
  • Page 50 Specifications Table A.B 480V, 60Hz Line Reactor Selection Drives Ranges of Drives DC Amp Sum for Typical Supply Transformers Line Reactor 630 kVA 800 kVA 1000 kVA 1250 kVA 1600 kVA 2500 kVA 3000 kVA Sum of Induct. Catalog No. 5.5% 6.5% 6.5%...
  • Page 51 Specifications Table A.C 600V, 60Hz Line Reactor Selection Drives Ranges of Drives DC Amp Sum for Typical Supply Transformers Line Reactor 630 kVA 800 kVA 1000 kVA 1250 kVA 1600 kVA 2500 kVA 3000 kVA Sum of Induct. Catalog No. 5.5% 6.5% 6.5%...
  • Page 52 A-10 Specifications Table A.D 690V, 50Hz Line Reactor Selection Drives Ranges of Drives DC Amp Sum for Typical Supply Transformers Line Reactor 630 kVA 800 kVA 1000 kVA 1250 kVA 1600 kVA 2500 kVA 3000 kVA Sum of Induct. Catalog No. 5.5% 6.5% 6.5%...
  • Page 53 Specifications A-11 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.
  • Page 54 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). Then install the three (3) M4 x 8 screws through the PE grounding plate.
  • Page 55 Specifications A-13 This page intentionally left blank. PowerFlex SCR Bus Supply User Manual Publication 20S-UM001G-EN-P...

  • Page 56: Spare Parts

    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...
  • Page 57 (precharge, gate, and snubber), and precharge relay are available. Additional catalog numbers are provided for troubleshooting and technical support information only. Extensive disassembly is required to replace the fan assembly. Please consider using Rockwell Automation Remanufacturing Services.
  • Page 58 A-16 Specifications 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...
  • Page 59 (precharge, gate, and snubber), and precharge relay are available. Additional catalog numbers are provided for troubleshooting and technical support information only. Extensive disassembly is required to replace the fan assembly. Please consider using Rockwell Automation Remanufacturing Services.
  • Page 60 A-18 Specifications 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...
  • Page 61 Extensive disassembly is required to replace the fan assembly. Please consider using Rockwell Automation Remanufacturing Services. When replacing these fuses, always properly position them so that their fuse trip indicators (plungers) point toward the fuse trip detection board.
  • Page 62 A-20 Specifications Notes: PowerFlex SCR Bus Supply User Manual Publication 20S-UM001G-EN-P...

  • Page 63: Appendix B History Of Changes

    Appendix 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.
  • Page 64 History of Changes Notes: PowerFlex SCR Bus Supply User Manual Publication 20S-UM001G-EN-P...

  • Page 65: Index

    Index AC input filter HF filter, A-11 HF, A-11 line reactors, A-7 to A-10 RFI, 1-5 voltages, A-1 firmware release, P-2 AC supply fusing grounding, 1-5 1000A unit, 1-7, A-19 non-grounded, 1-4 400A unit, 1-7, A-15 source considerations, 1-4 600A unit, 1-7, A-17 unbalanced, 1-4 ambient operating temperature, 1-3 general precautions, P-3...
  • Page 66 RFI filter grounding, 1-5 unbalanced/non-grounded supply, 1-4 safety ground, 1-5 web site SCR bus supply related documentation, P-2 12-pulse configuration, 1-18 Rockwell Automation technical support, P-2 ambient operating temperature, 1-3 wiring catalog number explanation, P-4 control, 1-11 control wiring, 1-11 power, 1-7...

  • Page 68: Installation Assistance

    Europe/Middle East/Africa: Rockwell Automation, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846 Publication 20S-UM001G-EN-P –...

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