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Rockwell Automation Allen-Bradley PowerFlex User Manual

Diode bus supply
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PowerFlex Diode Bus Supply
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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex

  • Page 1 PowerFlex Diode Bus Supply 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 (September 2006): Description of Changes Page Reformatted document from half size (5.5 x 8.5 in.) to full size (8.5 x 11 in.) Throughout manual In Chapter 1: •...
  • Page 4 soc-ii Summary of Changes Notes: PowerFlex Diode Bus Supply User Manual Publication 20T-UM001D-EN-P...

  • Page 5: Table Of Contents

    Rockwell Automation Support ........
  • Page 6 Table of Contents Appendix A Supplemental Information Specifications............A-1 Dimensions .

  • Page 7: Preface

    Diode Bus Supply. 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 Who Should Use this This manual is intended for personnel that are qualified to install, program,...

  • 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

    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.

  • Page 10: Catalog Number Explanation

    Overview Catalog Number Position Number Explanation Product Code Type PowerFlex Diode Bus Supply Voltage Rating Code Input Voltage Phase DC Output 240/480V AC 325…650V DC 500/600V AC 675…810V DC Current Rating Code Output Frame 120.0 Amp PowerFlex 700 drive equivalent frame size. Enclosure Code Rating...

  • Page 11: Description And Schematic Diagram

    Overview Description and Schematic The Diode 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 Diagram line voltage to a common DC bus voltage. Figure P.1 Diode Bus Supply Schematic Diagram >˚C >˚C R/L1...
  • Page 12 Overview Notes: PowerFlex Diode Bus Supply User Manual Publication 20T-UM001D-EN-P...

  • Page 13: Opening The Cover

    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 14: Minimum Mounting Clearances

    Installation/Wiring Minimum Mounting No Adhesive Label on Top With Adhesive Label on Top Clearances 50 (2) 100 (4) 100 (4) 50 (2) 100 (4) 100 (4) Dimensions are in millimeters and (inches). Appendix A for detailed dimension information. Ambient Operating Temperatures The Diode Bus Supply is designed to operate at 0…40 °C (32…104 °F) ambient without derating.

  • Page 15: Ac Supply Source Considerations

    Installation/Wiring AC Supply Source The Diode Bus Supply is suitable for use on a circuit capable of delivering a short circuit rating up to a maximum of 200,000 rms symmetrical amperes, Considerations and a maximum of 600 volts. ATTENTION: To guard against personal injury and/or equipment damage caused by improper fusing or circuit breaker selection, use only the recommended line fuses/circuit breakers specified in...

  • Page 16: General Grounding Requirements

    Installation/Wiring General Grounding Safety Ground Terminal - PE 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. This is the safety ground for the Diode Bus Supply. The integrity of all ground connections should be periodically checked.

  • Page 17: Maximum Loading

    Installation/Wiring Maximum Loading To avoid overloading the Diode Bus Supply, the following requirement applies: The DC Input current sum (Normal Duty or Heavy Duty rating at 40 °C/ 104 °F) of the connected drive(s) must not exceed the Bus Supply continuous DC Bus output current rating of 120 amps at 40 °C/104 °F.

  • Page 18: Power Wiring

    Installation/Wiring Power Wiring 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.

  • Page 19: Dc Bus Wiring Guidelines

    Installation/Wiring DC Bus Wiring Guidelines For DC Bus wiring guidelines, refer to AC Drives in Common Bus Configurations, publication DRIVES-AT002. Bus Supply Terminals Figure 1.2 Terminal and Jumper Locations A A A A DC + DC - DC + (PE) DC - FAN1 FAN2...

  • Page 20: Control Wiring

    Installation/Wiring Figure 1.3 Power and Control Terminals DC + DC - R (L1) S (L2) T (L3) Terminal Description Notes Power Connections DC + DC Bus (+) DC Bus Connection (+) DC - DC Bus (-) DC Bus Connection (–) PE Ground Safety Ground R (L1)

  • Page 21: Control Wiring Examples

    Installation/Wiring Control Wiring Examples Figure 1.4 Multiple Drives, Running Simultaneously 115V >°C PowerFlex F1, F2 Diode Bus Supply DC Bus AC - Drive 1 AC - Drive 2 30 kW 22 kW Figure 1.5 Multiple Drives, Running Independently (2-wire control) 115V Run/ Run/...

  • Page 22: Disconnecting Movs And Rfi Filter Capacitors

    1-10 Installation/Wiring Disconnecting MOVs and The Diode Bus Supply contains protective MOVs, and input filter and common mode capacitors that are referenced to ground. To prevent damage, RFI Filter Capacitors 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 23: Paralleling Diode Bus Supplies

    Installation/Wiring 1-11 Figure 1.6 Removing the Phase-to-Ground Jumpers for the MOV, Input FIlter, and Common Mode Capacitors R / L1 S / L2 To Diode Bridge Rectifier Unit T / L3 MOVs +DC, -DC Ground Jumper Power Supply Input Filter Board DFPS Capacitors Input Filter and...

  • Page 24: Ce Conformity

    1-12 Installation/Wiring Figure 1.7 Parallel Diode Bus Supply Wiring Diagram Power Input Main Switch or Main Input Contactor Line Line Reactor Reactor Diode Diode Bus Supply Bus Supply DC Bus AC - Drive 1 AC - Drive 2 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...

  • Page 25: Harmonic Emissions

    Presently, 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 Diode Bus Supply. General Notes •...
  • Page 26 1-14 Installation/Wiring 3. Review important precaution/attention statements throughout this document before installing 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.

  • Page 27: Chapter 2 Start Up/Troubleshooting

    Chapter Start Up/Troubleshooting This chapter provides the necessary information for the start up and troubleshooting of the Diode Bus Supply. Topic Page Start-Up Power On LED Troubleshooting ATTENTION: Power must be applied to the Diode Bus Supply and the drive to perform the following start-up procedure. Some of the voltages present are at incoming line potential.

  • Page 28: Start-Up

    Start Up/Troubleshooting Start-Up Before Applying Power to the Diode Bus Supply 1. Confirm that all inputs and outputs are connected to the correct terminals and are properly torqued. 2. Using an ohmmeter or other continuity testing device, verify that shorts do not exist between Source 1 and Source 2.

  • Page 29: Power On Led

    4. Check for excess load on the Diode Bus Supply. 5. Check for minimum mounting clearance around the Diode Bus Supply. 6. Contact your local Rockwell Automation sales office. DC Output Loss of DC Bus power 1. Check 3-phase AC incoming power for undervoltage...
  • Page 30 Start Up/Troubleshooting Notes: PowerFlex Diode Bus Supply User Manual Publication 20T-UM001D-EN-P...

  • Page 31: Specifications

    Appendix Supplemental Information This appendix provides electrical, environmental, functional, and physical specifications for the Diode Bus Supply, and selection tables for AC input devices. Topic Page Specifications Dimensions AC Input Fusing Line Reactors Spare Parts Specifications Category Specification Input/Output AC Input Voltage Range: 200…480V Unit 500…600V Unit Ratings...
  • Page 32 Supplemental Information Category Specification Approvals NFPA 70 - US National Electrical Code NEMA ICS 3.1 - Safety standards for Construction and Guide for Selection, Standards Installation and Operation of Adjustable Speed Drive Systems. Compliance NEMA 250 - Enclosures for Electrical Equipment IEC 146 - International Electrical Code UL and cUL Listed to UL508C and...

  • Page 33: Dimensions

    Supplemental Information Dimensions The overall and mounting dimensions for the Diode Bus Supply are shown Figure A.1. Figure A.1 Diode Bus Supply Dimensions (equivalent to PowerFlex 700 Frame 2 Drive) Dimensions are in millimeters and (inches). 222 (8.74) 15 (0.59) 192 (7.56) Ø...

  • Page 34: Ac Input Fusing

    Supplemental Information AC Input Fusing Table A.A below provides output ampere ratings for the Diode Bus Supply (including continuous, 1 minute, and 3 seconds) and recommended AC line input fusing information. The short circuit protection fuses are acceptable for UL and IEC requirements. Sizes listed are recommended sizes based on 40 °C (104 °F) and the U.S.

  • Page 35: Line Reactors

    Supplemental Information Line Reactors A minimum reactance is required to limit peak currents in the AC line and the diode 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 36 Supplemental Information Notes: PowerFlex Diode Bus Supply User Manual Publication 20T-UM001D-EN-P...

  • Page 37: Appendix B History Of Changes

    Appendix History of Changes Topic Page 20T-UM001C-EN-P, September 2006 This appendix summarizes the revisions to this manual, starting with revision C. 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 38 History of Changes Notes: PowerFlex Diode Bus Supply User Manual Publication 20T-UM001D-EN-P...
  • Page 39 Index AC input earthing, see grounding line reactors, A-5 ESD, static discharge, P-3 voltages, A-1 AC supply grounding, 1-4 filter - RFI, 1-4 non-solid grounded, 1-3 source considerations, 1-3 fusing, AC input, 1-5 unbalanced, 1-3 ambient operating temperature, 1-2 general precautions, P-3 grounding before applying power, 2-2 bus, 1-4...
  • Page 40 A-1 to A-2 start-up checklist, 2-2 web site static discharge, ESD, P-3 related documentation, P-2 status indicator, Power On, 2-3 Rockwell Automation technical support, P-2 supply source for AC, 1-3 wiring system grounding, 1-4 control, 1-8 power, 1-6 PowerFlex Diode Bus Supply User Manual...
  • Page 42 Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, 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 20T-UM001D-EN-P –...

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