Related Manuals for Reliance electric AutoMax DPS
Summary of Contents for Reliance electric AutoMax DPS
- Page 1 AutoMax DPS DC Power Module Instruction Manual User Manual: 49 1335-e (06) Publication: AMXDPS-UM003D-EN...
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Page 3: Table Of Contents
TABLE OF CONTENTS GENERAL NOTES Chapter 1. DESCRIPTION WITH SCHEMATIC DIAGRAM 1...5 Features ..................... 1 Configuration ..................2 Principle of Functions ................. 3 Functions of the Cards................. 5 Chapter 2. TECHNICAL DATA 6..8 Input Voltages ..................6 Armature current, ................6 Dissipation .................. -
Page 5: General Notes
GENERAL NOTES Safety Instructions DANGER, WARNING, and CAUTION point out potential trouble areas. • A DANGER alerts a person that high voltage is present which could result in severe bodily injury or loss of life. • A WARNING alerts a person to potential bodily injury if procedures are not followed. •... - Page 6 GENERAL NOTES Electromagnetic Compatibility (EMC-Directive) CAUTION : The operating of power converters in the European market is only permitted if the Council Directive Electromagnetic Compatibility 89/336/EWG has been observed. It is the responsibility of the manufacturer of the machine or system to observe the immunity and emission limits, requested by the Council Directive EMC in the European market.
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Page 7: Features
CHAPTER 1 - DESCRIPTION Features Protective measures RELIANCE ELECTRIC DC Power Modules are A balanced protective concept ensures a high 3 phase AC/DC converters and are used for the degree of reliability. step less regulation of DC-motors. They are - On single-quadrant drives fast acting fuses... -
Page 8: Configuration
CHAPTER 1 - DESCRIPTION Configuration (1) Power stack with heatsink (2) Motor- and line input connections (3) Control terminals (4) PC-board PDA (behind PFA) (5) PC-board PFA (front) (6) Connector (7) Cooling fan Fig. 1-1: Configuration of the controller 120 A (simplified layout S-6R) AMX DPS DC-POWER MODULE 49'1335 e... - Page 9 CHAPTER 1 - DESCRIPTION Schematic Diagram AC line AC 115V motor armature On single quadrant units S-6 the thyristors V11-V16 and the firing pulse transformers are not fitted, and armature fuses are not needed On Types < = 60 A cooling fan and thermostat F3 are not fitted. Fig.
- Page 10 CHAPTER 1 - DESCRIPTION 3 x 380 V, 50 Hz or 3 x 460 V, 60 Hz AC line motor armature On single quadrant units S-6 the thyristors V11-V16 and the firing pulse transformers are not fitted, and armature fuses are not needed Fig.
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Page 11: Functions Of The Cards
CHAPTER 1 - DESCRIPTION Line Voltage and Armature Voltage Feedback Functions of the PC-Boards 5 high resistance voltage dividers are provided As already mentioned are all converter control for 3 line voltage and 2 armature voltage regulation functions executed feedback signals. The signal amplitude is AutoMax and Power Module Interface Rack adapted for different line voltages by means of outside the power unit. -
Page 12: Technical Data
CHAPTER 2 - TECHNICAL DATA Converter input voltages: - 3-phase line input voltage (terminals 181, 182, 183) Type < = 250 A............3 AC 200-500 V Type 450 A - 2000 A..... 3 AC 200-500 V and 3 AC 525-690 V - Line voltage tolerance for the converter.... -
Page 13: Armature Current
CHAPTER 2 - TECHNICAL DATA Armature current The current ratings stated in Table 2-3 are valid for the service conditions (next sheet) concerning ambient temperature (45 degrees C) and installation altitude (1000 m). On deviations the derating factors must be taken into account. Table 2-3: Armature current, current transformers Unit type Max. -
Page 14: Dissipation
CHAPTER 2 - TECHNICAL DATA Heat dissipation Heat dissipation in watts may be expressed by the following formula Dissipation Pv = K + 3 . I anom where K = 100 for units Type < = 120 A K = 200 for units Type 250 and 450 A K = 400 for units Type 800 A K = 800 for units Type 1500 –... - Page 15 CHAPTER 3 - MODIFICATION Standard Equipment The Power Modules are to be adapted to the nominal line voltage by setting a total of 8 jumpers on the Feedback Board. In addition the two parameters Phasing Transformer Voltage and AC Line Voltage in the drive section AutoMax or ControlLogix 1756-DMD30 Software must be set as shown in the following Table: Table 3-1: The Phasing Transformer...
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Page 16: Assembly
CHAPTER 4 - INSTALLATION AND CONNECTION Assembly Connection Always observe the following requirements when Refer to the schematic diagrams Figures 1-2 installing the Power Module in control cabinets: and 1-3. - Comply with mandatory protection standards to prevent contact with live components (covers) Transient suppression of contactor and relay and shock when a fault occurs (safe ground), coils:... - Page 17 CHAPTER 4 - INSTALLATION AND CONNECTION Fig. 4-1: Connection Cables between PMI-Rack and Power Module Types 60A and 120A PDA/B DC-Power Technology PMI-Rack Fig. 4-2: Connection Cables between PMI-Rack and Power Module Types 250A - 2000A PFB/C/D PDA/B DC-Power Technology PMI-Rack Cable Function...
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Page 18: Dimensions
CHAPTER 4 - INSTALLATION AND CONNECTION Dimensions DISTRIBUTED POWER SYSTEM DC POWER MODULE DISTRIBUTED POWER SYSTEM DC POWER M ODULE 60A Unit (top) 120A Unit Weight: 8.8 kg 12.0 kg 187 m 3 /h Cooling air: Air flow direction: from bottom to top Minimum clearances for air circulation: 100 mm Power connections... - Page 19 CHAPTER 4 - INSTALLATION AND CONNECTION X3 X1 a) The RC-Snubber module for thyristor protection (Part No. 922.58.10) is mounted on 690 V S-6R units only (on the left or right side of the U-frame) Weight: 40 kg 407 m 3 /h Cooling air: Air flow direction: from bottom to top...
- Page 20 CHAPTER 4 - INSTALLATION AND CONNECTION X3 X1 a) The RC-Snubber module for thyristor protection (Part No. 922.58.10) is mounted on 690V S-6R units only (on the left or right side of the U-frame) Weight: 83 kg 814 m 3 /h Cooling air: Air flow direction: from bottom to top (2 fans)
- Page 21 CHAPTER 4 - INSTALLATION AND CONNECTION ø 1 4 49 50 100 40 X3 X1 ø 1 3.5 89.5 89.5 a) The RC-Snubber module for thyristor protection (Part No. 922.58.10) is mounted on 1500A, 690V S-6R units only (on the left or right side of the U-frame) Weight: 195 kg 2000 m 3 /h...
- Page 22 CHAPTER 4 - INSTALLATION AND CONNECTION 25 Ø 1) X3 X1 1) Holes for lifting hooks Weight: 195 kg 2000 m 3 /h Cooling air: Air flow direction: from bottom to top Minimum clearances 100 mm for air circulation: Power connections: Motor 45(D), 47(C) Bus bars 120 x 10, Drilling 4 x M12...
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Page 23: Chapter 5. Start-Up, Diagnostics And Troubleshooting 17
CHAPTER 5 - START-UP, DIAGNOSTICS AND TROUBLE SHOOTING General The variable jumpers according to Chapter 3 for Diagnostics and Troubleshooting must be set and checked before the drive is ready for start-up. As the converters are delivered fully tested, problems during start-up are caused in most cases by faults outside the power module (see chapter 6). -
Page 24: Safety Precautions
CHAPTER 5 - START-UP, DIAGNOSTICS AND TROUBLE SHOOTING Safety Precautions WARNING: Whenever work is done on the unit ac-input power must be disconnected and the voltage at terminals 45-47 checked with a voltmeter. WARNING: Static sensitive PC-boards. Handle without touching components, connectors or leads. -
Page 25: Chapter 6. Replacement Of Thyristors 19
CHAPTER 6 - REPLACEMENT OF THYRISTORS Replacement of Thyristors Replacement of a thyristor or thyristor Use original spare parts only. Selection module Type 60 - 800A according to Tables 7-1 and 7-2. The location of the parts is shown in Fig. 1-1 and - Loosen and swing out pc boards assembly on the layout label inside the U-frame. - Page 26 CHAPTER 6 - REPLACEMENT OF THYRISTORS Replacement of a thyristor on power unit Types 1500 – 2000A - Write protocol about the following procedure - Open controller and protection unit by tilting forwards. Layout of thyristor assembly is visible now on side wall. - Remove bus bars on front heat sink - Unscrew the upper cooling air deflector.
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Page 27: Chapter 7. Spare Parts
CHAPTER 7 - SPARE PARTS Spare Parts Table 7-1 : Urgent Recommended Spare Parts for 1-Quadrant Units S-6 (800 – 2000A) Max. Unit Thyristor Driver Feedback Snubber Fuses Supply Unit Input Board Board Board F1,F2,F3 Type Volt Frequ. Part No. 6 pieces 10 pieces 800A... -
Page 28: Chapter 8. Accessories
CHAPTER 8 - ACCESSORIES Semiconductor Protecting Fuses AC-Line Input and Motor Armature Circuit Protecting Fuses Protecting fuses in the AC-line input and in case of four-quadrant operation in the motor armature circuit are to be selected from the following tables. The fuses are externally mounted and not supplied with the power module. - Page 29 CHAPTER 8 - ACCESSORIES Table 8-2: Alternative Fuses (Tube Type) for Units <= 120A, Line Voltage <= 500V Motor Armature Circuit AC-Line Input Double Fuse Holder Triple Fuse Holder Power Ianom Fuse Fuse with Trip Indicator Fuse Fuse without Trip Indicator Unit Rating Part No.
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Page 30: Ac Line Reactors
CHAPTER 8 - ACCESSORIES AC-Line Reactors Table 8-4: Iron Core Choke Selection The AC-line input chokes 252.40.xx produce 2% voltage drop at 400V and rated current. The AC-line input chokes 252.44.xx produce 2% voltage drop at 690V and rated current. AC- Line Input Field AC-Input 3-Phase... - Page 31 CHAPTER 8 - ACCESSORIES W 2 W 1 V 2 V 1 U 2 U 1 ∆ Protection earth connection stud Line Reactor Used for Fig. [kg] Part No. 252.40.01 Converter 252.40.02 Input 252.40.03 252.40.04 252.40.05 252.40.06 252.40.07 252.40.08 252.40.09 252.40.10 252.40.11 252.40.12...
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Page 32: Emc Filters
Otherwise the filter inrush current may damage the fuses. HF Filter If this filter is used on AutoMax DPS converters with AC line input currents above 100A the HF emission limits for class A, group 2* (EN 55011) in the 2 environment (industrial supply network) according to the product standard EN 61800-3 are met and the drive fulfills CE conformity. - Page 33 The filter must be connected into the three AC line input phases L1 - L3 of the AutoMax DPS in front of the AC line reactor, as shown in figure A-1.
- Page 34 Converter or perform a harmonics analysis for the complete installation based on delivered data. Immunity Immunity against Conducted and Radiated, High Frequency Disturbances The AutoMax DPS DC-converters fulfill the immunity requirement in the first, as well as in the second environment. AMX DPS DC-POWER MODULE...
- Page 35 A - CE-CONFORMITY Essential Requirements for Conforming Installation The following items are required for CE conformance: 1. Connection of EMC filter (RFI-Filter on drives <100A or HF filter on drives >100A) as specified in Chapter 8, Accessories. 2. Because Converter and filter have protection class IP00 they must be built in a cabinet. Both units must be mounted on a blank (not painted) panel with good conductivity.
- Page 36 A - CE-CONFORMITY Configuration Cabinet 181,182,183 Panel AC-reactor AutoMax DPS AC-Input contactor SCR-protecting fuses 45, 47 RFI Filter HF Filter Rack Field Circuit breaker Terminals for 4-wire AC-Input cable (L1,L2,L3, PE) Cabinet protection ground busbar Cable bracket Screen Screened 3-wire...
- Page 37 A - CE-CONFORMITY Wiring Instruction Motor Cable • The cables between cabinet / armature output and DC-motor armature shall be 3-wire screened cable (+, - and earth conductor green/yellow) as specified in Figure A-2. • The cables between field supply output and DC-motor field shall be 2-wire screened cable. •...
- Page 38 B - CROSS REFERENCE LIST PART NUMBERS - CATALOGUE NUMBERS This appendix provides a cross reference list for part numbers of the AMX DPS DC-Power Module in numeric order and associated Rockwell Automation catalogue numbers. Part numbers without catalogue numbers are spare parts. (Refer to Tables 7-1 to 8-5). Table B.1 - Cross Reference List Part Catalogue...
- Page 40 Publication: AMXDPS-UM003D-EN – March 2005 Supersedes publication AMXDPS-UM003C-EN Copyright © 2005 Rockwell Automation, Inc.. All rights reserved.