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PowerFlex SCR Bus Supply User Manual

1. Ramp Up ar OW sa cc SCR and cue Norm Z E RGU AFE gt 45 om 58 Paralleling Yes No 53 LINE es ofool 3 TYPE t ph3 ph gt er r BBB F gt O00 cooooo pooooo oo ooo Start Up Troubleshooting 2 5 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 1 1 Low Line Voltage lt 90 Low Line Voltage lt 65 for SCR and RGU AFE paralleling mode 2 Very Low Line Voltage lt 50 3 Low Phase One phase lt 80 of line voltage or Low Phase Voltage One phase lt 56 of line voltage for SCR and RGU AFE paralleling mode 4 Freq out of range or asymmetry Line synchronization failed 5 Low DC Bus Voltage triggers ride through operation 6 Input Frequency momentarily out of range 40 65 Hz 7 DC Bus Short Circuit testing active repetitive for appr 120 s or no inverter connected to the bus FAULT Red Flashing The number n of flashes see flashing pattern in Figure 2 2 indicates one of the following faults 2 DC Bus Short Udc lt 2 after 20ms 4 Line Synchronization failed or Low Line Uac lt 50
2. 764 938 764 938 841 938 15 3R750 A 939 1KO 939 1KO 27 3R850 B 939 to 1KO 939 1KO 15 3R850 A 1 The inductance value of the supply transformers includes 2 5 uH for 10 m feeder cable The number in the catalog string represents the fundamental AC current rating of the reactor PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Specifications A 9 Table A C 600V 60Hz Line Reactor Selection Drives Ranges of Drives DC Amp Sum for Typical Supply Transformers 1 Line Reactor Simo 630 kVA goo kVA 1000 kVA 120 kVA 1600 kVA 2500 kVA aooo kVA Induct Catalog No 5 5 5 5 6 6 6 5 6 5 2 DC Amps UH 1321 78 uH 62 uH 55 pH 48 uH 38 uH 27 uH 21 pH 120 155 120 164 120 175 130 180 130 190 130 199 140 203 230 3R160 C up to 203 156 203 165 203 176 203 181 203 191 203 200 203 150 3R160 B 75 3R160 A 204 209 204 230 204 230 204 255 204 255 185 3R200 C 204 to 255 204 255 204 255 210 255 231 255 231 255 110 3R200 B 55 3R200 A 256 270 256 295 256 319 150 3RB250 C 256 to 319 256 280 256 319 256 319 256 319 271 319 296 319 90 3RB250 B 281 319 45 3RB250 A anwa 320 340 320 360 320 390 320 407 320 407 320 407 75 3RB320 B o 320 407 341 407 361 407 391 407 40 3RB
3. Canada your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure 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 Rockwell Otomasyon Ticaret A S Kar Plaza Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 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 2
4. 15 uF 1000V Capacitor SK 20S E62K85153D1W 2 26 4 7K Ohm 130W Resistor SK 20S RW36FST4K7K 2 27 4 7 Ohm 45W Resistor SK 20S RW33FST4R7K 1 28 1000A Bus Bar Set SK 20S BBKSDK110 1 31 J Terminal Block Assembly SK 20S TBKSDKRW 1 32 40 mm tall x 40 mm O D Insulator SK 20S IN551520 5 with M10 Thread 34 Yes Gate Driver Circuit Board SK D9 SCRGDB1 1 35 Yes 480V SCR Precharge Circuit Board SK D9 SCRPRE1 D 1 36 Yes 690V SCR Precharge Circuit Board SK D9 SCRPRE1 F 1 37 Yes Master Slave or Slave Slave Wire Harness SK 20S D9 CBL1 DF 1 38 Yes Precharge Relay SK 20S CA2KN31F7 1 1 Important SCR Bus Supplies are designed to be field maintained only Normal maintenance components fan fuses fuse monitor switch printed circuit boards precharge gate and snubber and precharge relay are available Additional catalog numbers are provided for troubleshooting and technical support information only 2 Extensive disassembly is required to replace the fan assembly Please consider using Rockwell Automation Remanufacturing Services 3 When replacing these fuses always properly position them so that their fuse trip indicators plungers point toward the fuse trip detection board 4 This is an ESD sensitive component 5 Not required for 1000A Standalone unit but required for 1000A Master unit or 1000A Slave unit both mounted in lower location 8 Not required for 1000A Slave
5. undervoltage or phase loss Check all Bus Supply fuse trip indicator switches Verify the Inverter is connected 4 Verify the power of the connected Inverter s is minimum 7 5 kW 10 HP Refer to the 2nd Attention statement on page 2 1 Contact your local RA sales office Loss of 115V AC power Check 115V AC supply input voltage at control terminals 0 and 115 Check Enable Contactor function Contact your local RA sales office Jumper setting wrong Wrong jumper settings Single phase 1 ph line type and one or both of the SPARE 1 or SPARE 2 jumpers set to their respective left positions po Check the jumper setting s Set the jumper s correctly PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Start Up Troubleshooting 2 7 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 N C contact on control terminals 6 and 7 is open Possible Cause 400A and 600A Unit Open snubber fuse F6 F8 1000A Unit Open snubber fuse or open DC bus fuse F7 F11 Corrective Action MD Check for evidence of power module failure see Step 3 in Start Up on page 2 2 Check for evidence of failure in snubber circuit Check the snubber pcb diodes and snubber resistor and capacitor Replace entire SCR B
6. 3 Connect two reactors in series PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 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 The HF filter is connected in front of the AC line reactor between the three AC line input phases and the protection earth conductor PE Figure A 5 Figure A 5 HF Filter Wiring Diagram ac OY HF Filter o SCR SCR Bus Supply Bus Supply Figure A 6 20S RFC Filter Dimensions 500 19 7 4mm Wire A SSI 120 4 7 G Y gt 18 a 110 ia 0 7 4 3 PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P A 12 Specifications PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 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 Do NOT use t
7. Cooling Forced ventilation cooled by tangential blower below heat sink Blower Power Consumption 200 VA Cooling Air 600 m hr Control Input Enable Contactor Coil Single Phase 115V AC 30 VA pick up 4 5 VA hold Blower Current Consumption Single Phase 115V AC 50 60 Hz 1A Control Heat Sink Temperature Sensor The temperature sensor trips if heat sink temperature exceeds Output maximum temperature NC Contact Output Rating Max Resistive Rating 15A at 125V AC 10A at 250V AC 7A at 24V DC Inductive Rating 10A at 125V AC 6A at 250V AC Fuse Trip Indication Microswitches F1 F5 400A amp 600A Microswitches F1 F6 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 Fuse Trip Indication Microswitches F6 F8 400A amp 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 Output Rating Max Resistive Rating 10A at 24 230V AC 3A at 30V DC Inductive Rating 2 2A at 24 230V AC Approvals and Standards Compliance Environment PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P NFPA 70 US National Electrical Code NEMA ICS 3 1 Safety standards for Construction and Guide for Selection Installation and Operation of Adjustable Speed Drive
8. Overview Preface The purpose of this manual is to provide you with the basic information needed to install start up and troubleshoot the PowerFlex SCR Bus Supply Topic Page Who Should Use this Manual P 1 Reference Documentation P 1 Rockwell Automation Support P 2 Conventions Used in This Manual P 2 General Precautions P 3 Catalog Number Explanation P 4 Descriptions and Schematic Diagrams P 5 This manual is intended for personnel that are qualified to install program and operate adjustable frequency drives and their use in common DC bus systems Reference Documentation General Drive Information Title Publication Wiring and Grounding Guidelines for PWM AC Drives DRIVES INO01 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 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 For Refer to Publication PowerFlex 70 70EC Drive PowerFlex 70 Use
9. Unom 5 Jumper setting wrong 1 The ALARM indicator LED will continue the flashing pattern as long as the alarm condition exists An alarm might trigger internal actions which may stop SCR gate firing 2 if a fault occurs the FAULT indicator LED will continue the flashing pattern even if the fault condition no longer exists Power must be cycled to clear the fault Figure 2 2 Flashing Pattern for ALARM and FAULT LEDs Pause tee ka 0 3 0 3 0 9 sec sec Sec Example Flashing pattern for ALARM LED showing a Low Phase alarm where n 3 flashes PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Cause Heat sink temperature exceeds maximum rating Table 2 B Possible Faults and Corrective Actions Corrective Action 1 Verify that maximum ambient temperature has not been exceeded Check Overtemperature Switch N C contacts at control terminals 10 and 11 Check 115V AC supply input voltage at control terminals 0 and 115 Check blower for correct operation Check for excess load on the bus supply Check for minimum mounting clearance around the bus supply Contact your local RA sales office 2 6 Start Up Troubleshooting Troubleshooting Fault Heat sink Overtemperature 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 o nm Check 3 phase AC incoming power for
10. Z2 2 5 Slo a n ols a io 2 OOOOOCQQQQOQOOO of O OOO0D0000000000 O O OOO 00000000000101 2 F 2 a lt 0 n ola e o 2 L Terminal Bus Supply Description Notes 115 and 0 All units 115V AC For cooling blower and power supply on the Supply Input Gate Driver Board on Master and Slave Units 1and 2 1 Contactor Coil Contactor must be energized to enable the 115V AC controller 4 and 5 1 NC Contact Opens if the Enable Contactor is energized Output 2 6 and7 400A and 600A NC Contact Opens if any of the snubber circuit fuses units Output F6 F8 trip 1000A units Opens if any of the snubber circuit fuses or DC bus feedback fuses F7 F11 trip 8 and 9 400A and 600A _ NC Contact Opens if any of the line input or DC bus branch units Output 2 circuit fuses F1 F5 trip 1000A units Opens if any of the line input branch circuit fuses F1 F6 trip 10 and 11 All units NC Contact Opens at power stack heat sink overtemperature Output 2 12 and GND All units Jumper MOVs Disconnects MOVs from ground by removing this to Ground jumper See Disconnecting MOVs on page 1 14 for details 1 Not used on Slave Units Refer to Appendix A for contact rating PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 1 12 Installation Wiring Jumper Settings PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Drive Run Interlock To protect the Bus Supply from overtemperature the normally c
11. 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 O O O 6 H o o OF P fh p PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Specifications A 19 Table A G 1000A Unit Spare Part Numbers Descriptions Item Availability Description Rockwell Catalog No Qty 1 1000A SCR Set SK 20S MCO600 22101 6 4 Yes Fan Assembly SK D9 FAN2 1 5 j 1000A MOV Assembly SK 20S VBKSDK110 1 7 Yes 40A Fuse Precharge fuses F7 F11 SK 20S F070B040S or 5 Westcode Type F070B040S or Ferraz Shawmut Type 6 921CPgRC14 51 40 11 Yes 1000A 700V Fuse AC fuses F1 F6 SK 20S 069UR2S1000B or 6 Torque to 25 Nem 221 Ibein Westcode Type 069UR2S1000B or Ferraz Shawmut Type 6 9URD32TTF1000 12 Yes Fuse Monitoring Switch SK 20S MS3V1 5 6 13 85 C Thermostat SK 20S SWT85KSDKRW 1 14 1000A SCR Wire Harness SK 20S ZY110 1000 1 17 Yes 1000A Snubber Circuit Board SK 20S PR GR3 5 1 19 600A and 1000A Cover SK 20S RW9582300 A 1 22 600A and 1000A Enclosure SK 20S RWU600 1000 1 23
12. 21 or earlier this jumper is non functional For firmware version 1 22 or later the SCR Bus Supply is shipped with this jumper in the right default inactive state position When the jumper is placed in the left RGU AFE or active position the firmware is active for SCR and RGU AFE parallel operation on common bus systems where the SCR is in parallel with an 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 The left RGU AFE jumper position provides the best protection for parellel SCR and RGU AFE operation e SPARE 2 Jumper For board firmware version 1 21 or earlier this jumper is non functional For firmware version 1 22 or later this jumper is used for slow ramp up which slows the DC bus voltage charge up time from 0 2 to 1 3 seconds Slow ramp up should be used when the connected DC bus capacitance is greater than the values shown in the following table Max Bus Capacitance Max Bus Capacitance SCR Bus Supply with Normal Ramp with Slow Ramp 400A 40 000 pF 200 000 pF 600A 60 000 uF 300 000 pF 1000A 480V 100 000 uF 500 000 pF 1000A 690V 50 000 uF 250 000 pF 1 tis re
13. For a list of recommended replacement fuses refer to these pages SCR Bus Supply See Page 400A A 15 600A A 17 1000A A 19 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 A ATTENTION National Codes and standards NEC VDE BSI To maintain balanced impedance and thus balance current in the SCR Bus Supply it is recommended to keep all wired or bus bar connections identical in size and length This includes the AC line connection to three phase AC line reactors and from the three phase AC line reactors to the SCR Bus Supply EMC Compliance Refer to CE Conformity on page 1 19 for details Cable Trays and Conduit If cable 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 ATTENTION To avoid a possible shock hazard caused by A induced voltages unused wires in the conduit must be grounded at both ends For the same reason if a drive sharing a conduit is being serviced or installed all drives using this conduit should be disabled This will help minimize the possible shock hazard from cross coupled motor leads DC Bus Wiring Guidelines For DC Bus wiring guidelines refer to
14. In Chapter 1 in the 1000A SCR Bus Supply Flexibility section e Added information and a table at the beginning to show which conversions are possible 1 16 and which are not possible e Inthe Converting Master Unit to Slave Unit subsection added new steps 3 and 4 1 16 e Deleted subsection Converting Slave Unit to Master Unit subsection In Appendix A in the Accessories section e Changed Table A A cat numbers for rows 256 509 and added new row for 939 1KO A 7 e Changed Table A B cat numbers for rows 256 509 and added new row for 939 1KO A 8 e Changed Table A C cat numbers for rows 256 509 and added new row for 939 1K0 A 9 e Changed Table A D cat numbers for rows 256 509 and added new row for 939 1K0 A 10 In Appendix A in the HF Filter section e Added new HF Filter Wiring Diagram Figure A 5 A 11 e Added new subsection Solid Ground Systems A 12 e Added new subsection Non Solid Ground Systems A 12 In Appendix A in the Spare Parts section e Added Important statement above Figure A 8 A 14 e Added new Availability column to Table A E A 15 e Added Important statement above Figure A 9 A 16 e Added new Availability column to Table A F A 17 e Added Important statement above Figure A 10 A 18 e Added new Availability column and new footnote 1 to Table A G A 19 e Added new Figure A 11 to show locations of precharge and gate drive boards fo
15. Installation Wiring 1 17 It is not recommended to install parallel master SCR Bus Supplies The reason is that there is nothing to synchronize the SCR gate firing between the precharge printed circuit boards in separate SCR Bus Supplies Each precharge board has circuitry designed to energize the DC bus which has little to no impedance to limit the inrush current This DC bus charging synchronization could lead to power device failure If redundancy of the SCR Bus Supply master is required by the application there are two options e A microcontroller or other electronically or manually controlled switch or contact network can be used to reconfigure the wire harnesses between 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 numerous possible configurations is shown in Figure 1 11 Figure 1 11 Basic Master Slave Redundancy System Configuration i Enable Control Logic Only one Master enabled Master Slave Slave Slave Master Precharge Precharge PCB PCB Gate Gate Gate Gate Gate PCB PCB PCB PCB PCB e Although not recommended synchronization differences might be minimized by using the slower ramp time available in precharge printed circuit boards with firmware version 1 22 or later The standard ramp time is for the rise o
16. 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 recommended to keep all wired or bus bar connections identical in size and length This includes the AC line connection to the three phase AC line reactors and from the three phase AC line reactors to the SCR Bus Supply Unbalanced or Non Solid Grounded Distribution Systems Where the potential exists for abnormally high phase to ground voltages in excess of 125 of nominal or the supply system is non solid grounded refer to the Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES INO01 ATTENTION The PowerFlex SCR Bus Supply contains A protective MOVs that are referenced to ground The MOVs should be disconnected from ground if the SCR Bus Supply is installed on any non solid grounded power distribution system IT network For jumper location see Figure 1 7 on page 1 11 General Grounding Requirements Installation Wiring 1 5 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 The integrity of all ground connections should be periodically checked For installations within a cabinet a single safety ground point or ground bus bar conn
17. the SCR bridge rectifier RC snubber circuit routed to the three input phases through semi conductor protection fuses with trip indicator switches MOV snubber circuit routed to the three input phases Precharge Board Enable Contactor K1 for the precharge board Gate Driver Board The DC power supply is connected to a customer supplied 115V AC Power Supply Cooling Blower connected to a customer supplied 115V AC Power Supply The customer s controls must at a minimum command the blower to run whenever contactor K1 is enabled 0000 NOTE There is no DC output fuse protection in the 1000A SCR unit PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P P 8 Overview Figure P 4 1000A SCR Bus Supply Slave Unit Schematic Diagram in GND Seq i p pe J 10 5 tee 694 684 aoe Q aon oto o3 L oe aa i t i tl bal tt x O her TE IE TEILLE GND Hol Zi lan i 20 H 8i 4 8 N i ip On 19 f m From Gate fo Zia OY To Gate 4 im onthe next eae 3 Figure P3 or 104 L 4 gt Slave previous Slav
18. the DC bus voltage at the DC and DC output terminals The voltage must be zero A ATTENTION To avoid an electric shock hazard verify that the Table 1 H Jumper Removal O 12 and GND Control Terminals MOVs from Ground 1 For control terminal location see Figure 1 4 Figure 1 5 or Figure 1 6 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 Figure 1 10 Example for Master Slave Configuration shown without circuit protection for clarity Power Input Main Switch or Up to 5 Units Maximum Main Input Contactor 4750A Maximum DC Bus Current without altitude or ambient derating Aux Supply 115 VAC Enable za Contactor y y Precharge Gate Gate Gate Board Driver D Driver Di Driver D Cable Cable Master Unit Slave Unit 1 Slave Unit n DC Bus PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 1 16 Installation Wiring 1000A SCR Bus Supply Flexibility PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P The 1000A SCR Bus Supply can be converted in the followi
19. the Environment section Revised 400A 600A and 1000A Bus Supply spare part drawings and related tables Added index to User Manual PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P B 2 History of Changes Notes PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P A AC input HF filter A 11 line reactors A 7 to A 10 voltages A 1 AC supply grounding 1 5 non grounded 1 4 source considerations 1 4 unbalanced 1 4 ambient operating temperature 1 3 B before applying power 2 2 C cable trays 1 7 catalog number explanation P 4 CE conformity 1 19 checklist start up 2 2 clearances for mounting 1 3 conduit 1 7 control wiring 1 11 converting master unit 1000A only to slave unit 1 16 master unit 1000A only to standalone unit 1 16 cover opening 1 2 D DC bus capacitors 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 earthing see grounding ESD static discharge P 3 Index F filter HF A 11 RFI 1 5 firmware release P 2 fusing 1000A unit 1 7 A 19 400A unit 1 7 A 15 600A unit 1 7 A 17 G general precautions P 3 grounding bus 1 5 conductor 1 5 general 1 5 impedance 1 5 safety PE 1 5 H HF filter A 11 J jumper settings 1 12 L LEDs 2 4
20. 000 12 Yes Fuse Monitoring Switch SK 20S MS3V1 5 5 13 J 85 C Thermostat SK 20S SWT85KSDKRW 1 15 600A SCR Wire Harness SK 20S ZY065 600 1 18 Yes 400 and 600A Snubber Circuit Board SK 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 uF 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 29 600A Bus Bar Set SK 20S BBKSDK065 1 31 Terminal Block Assembly SK 20S TBKSDKRW 1 32 40 mm tall x 40 mm O D Insulator SK 20S IN551520 5 with M10 Thread 35 Yes 480V SCR Precharge Circuit Board SK D9 SCRPRE1 D 1 38 Yes Precharge Relay SK 20S CA2KN31F7 1 Important SCR Bus Supplies are designed to be field maintained only Normal maintenance components fan fuses fuse monitor switch printed circuit boards 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 When replacing these fuses always properly position them so that their fuse trip indicators plungers point toward the fuse trip detection board This is an ESD sensitive component PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P A
21. 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 17 Power Wiring 1 7 Control Wiring pai jami Jumper Settings eis M Disconnecting MOVs a r Parallel Connection of Slave Units eed OT 1000A SCR Bus Supply Flexibility ak ee e gt 1000A SCR Bus Supply Redundancy _ r IN SCR Bus Supply 12 Pulse Configuration ae ee CE Conformit ik i Ko 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 proper installation Rockwell Automation Inc cannot assume A ATTENTION The following information is merely a guide for 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 PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 1 2 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 up
22. 2 pulse configurations contact Rockwell Automation Technical Support PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P CE Conformity Installation Wiring 1 19 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 European Communities The PowerFlex SCR 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 e EN50178 Electronic equipment for use in power installations EMC Directive 89 336 EEC e EN61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods Harmonic Emissions Electronic converters such as the Bus Supply can cause conducted low frequency disturbances harmonic emissions to the supply network The mandatory three phase AC line reactors will substantially reduce harmonic currents produced by the Bus 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 mandatory harmonic emission limits related to CE compliance for equipment connected to private power networks Upon reques
23. 320 A 408 425 105 3RB400 C 408 to 509 408 440 408 509 408 509 426 509 60 3RB400 B 408 450 408 509 408 509 441 509 30 3RB400 A m 510 545 510 635 510 635 50 3R500 B 510 to 635 510 560 510 600 510 635 546 635 25 3R500 A 636 740 636 763 40 3R600 B 636 to 763 636 750 636 763 741 763 20 3R600 A 764 840 764 938 29 3R750 B 764 to 938 764 938 841 938 15 3R750 A 939 1KO 939 1KO 27 3R850 B 939 to 1KO 939 1K0 15 3R850 A 1 The inductance value of the supply transformer includes 2 5 uH for 10 m feeder cable The number in the catalog string represents the fundamental AC current rating of the reactor PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P A 10 Specifications Table A D 690V 50Hz Line Reactor Selection Drives Ranges of Drives DC Amp Sum for Typical Supply Transformers 1 Line Reactor ar it kVA 2 kVA be kVA a kVA 1o kVA 2500 kVA op KVA duct Catalog No DCAmps oguH 95uH 86uH 75yH 59pH 42uH o3uH WH 1321 130 150 130 157 130 162 130 170 140 180 150 185 2x150 3R160 B S 130 175 151 190 158 203 163 203 171 203 181 203 186 203 230 3R160 C 176 203 191 203 150 3R160 B 75 3R160 A 20
24. 3R160 B 75 3R160 A a 204 206 204 209 204 219 204 224 185 3R200 C 204 to 255 204 255 204 255 204 255 207 255 210 255 220 255 225 255 110 3R200 B 55 3R200 A 256 260 256 275 150 3RB250 C 256 to 319 256 319 256 319 256 319 256 319 256 319 261 319 276 319 90 3RB250 B 45 3RB250 A 125 3RB320 C 320 to 407 320 335 320 370 320 390 320 407 320 407 320 407 320 407 75 3RB320 B Induct Catalog No uH 1321 Sum of DC Amps 836 407 371 407 391 407 40 3RB320 A 105 3RB400 C 408 to 509 408 425 408 450 408 480 408 509 408 509 408 509 60 3RB400 B 408 509 426 509 451 509 481 509 30 3RB400 A EN 510 538 510 590 510 635 510 635 50 3R500 B 510 to 635 510 540 510 580 510 635 539 635 591 635 25 3R500 A 636 660 636 763 636 763 40 3R600 B 636 to 763 636 763 636 763 636 763 661 763 20 3R600 A TE 764 900 764 938 29 3R750 B 764 to 938 764 800 764 870 764 900 764 938 901 938 15 3R750 A 939 1KO 939 1K0 27 3R850 B 939 to 1KO 939 1KO 15 3R850 A 1 The inductance value of the supply transformers includes 2 5 uH for 10 m feeder cable The number in the catalog string represents the fundamental AC current rating of the reactor PowerFlex SCR Bus Supply User Manual Publicat
25. 4 210 204 220 2x110 3R200 B Heis 204 206 204 230 204 245 204 255 204 255 211 255 221 255 185 3R200 C 207 255 231 255 246 255 110 3R200 B 55 3R200 A 256 260 2x90 3RB250 B ETT 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 320 360 320 407 320 407 125 3RB320 C 320 to 407 320 360 320 380 320 407 361 407 75 3RB320 B 320 407 361 407 381 407 40 3RB320 A 408 465 408 509 105 3RB400 C 408 to 509 408 414 408 450 408 509 466 509 60 3RB400 B 408 500 415 509 451 509 30 3RB400 A _ 510 520 510 580 85 3R500 C 510 t0635 510 538 510 570 521 635 581 635 50 3R500 B 510 540 539 635 571 635 25 3R500 A 636 650 65 3R600 C 636 to 763 636 763 651 763 40 3R600 B 661 763 20 3R600 A 764 780 48 3R750 C 764 to 938 764 850 781 938 29 3R750 B 851 938 15 3R750 A 42 3R850 C 939 to 1KO 939 1K0 939 1KO 27 3R850 B 15 3R850 A 1 The inductance value of the supply transformers includes 2 5 uH for 10 m feeder cable The number in the catalog string represents the fundamental AC current of the reactor
26. 6 400A SCR Wire Harness SK 20S ZY041 400 1 18 Yes 400 and 600A Snubber Circuit Board SK 20S PR GR3 1 20 400A Cover SK 20S RW9582300 B 1 21 400A Enclosure SK 20S RW U SCR400 1 24 10 uF 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 30 400A Bus Bar Set SK 20S BBKSDK041 1 33 j Terminal Block Assembly SK 20S TBKSDKRW 1 32 40 mm tall x 40 mm O D Insulator SK 20S IN551520 3 with M10 Thread 33 30 mm tall x 26 mm O D Insulator SK 20S IN551450 2 with M8 Thread 35 Yes 480V SCR Precharge Circuit Board SK D9 SCRPRE1 D 1 38 Yes Precharge Relay SK 20S CA2KN31F7 1 Important SCR Bus Supplies are designed to be field maintained only Normal maintenance components fan fuses fuse monitor switch printed circuit boards 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 When replacing these fuses always properly position them so that their fuse trip indicators plungers point toward the fuse trip detection board This is an ESD sensitive component PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Specifications A 16 600A SCR Bus Suppl
27. 887 4788 Fax 852 2508 1846 Publication 20S UM001G EN P March 2012 Supersedes 20S UM001F EN P March 2011 Copyright 2012 Rockwell Automation Inc All rights reserved Printed in USA
28. AC Drives in Common Bus Configurations publication DRIVES AT002 PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 1 8 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 1 Bus Bar Wire AC Line Input 40x 5mm 1 57x0 2in with 40x5mm 120 mm L1 L2 L3 single 14 mm 0 55 in diameter or 2 x 50 mm hole for customer terminal DC Bus 40x 5mm 1 57 x0 2in wih 40x5mm_ 150 mm DC DC single 14 mm 0 55 in diameter or 2 x 70 mm hole for customer terminal Protective Earth PE M8 x 25 mm 0 98 in stud torque to 6 Nem 54 Ibein Size per NEC or local code 4 Control Terminal Block See Table 1 F 1 Input output power bus bar connections require the use of either lug type connectors to terminate field installed conductors or bus bars PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Installation Wiring 1 9 Figure 1 5 600A Unit Bus Bar and Terminal Locations for Customer Wiring fh a Or OLO OL2 O o 2 Table 1 D 600A Unit Power C
29. Bus 60 x 10 mm 2 36 x 0 39 in with 60 x 10 mm 2 x 300 mm DC DC two 14 mm 0 55 in diameter or 100 x 5 mm holes for customer terminal Protective Earth PE M12 x 25 mm 0 98 in stud torque to 15 Nem 133 Ibein Size per NEC or local code Control Terminal Block See Table 1 F 1 Input output power bus bar connections require the use of either lug type connectors to terminate field installed conductors or bus bars PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Control Wiring Installation Wiring 1 11 Important points to remember about control wiring e 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 e Wire with an insulation rating of 600V or greater is recommended e Control wires outside the cabinet should be separated from power wires by at least 0 3 meters 1 foot Table 1 F Control Terminal Specifications Wire Size Range Item Name Maximum Minimum Torque Control Terminals 2 5 mm 0 25mm2 0 8 Nem 14AwG 22AWG 7 Ibein 1 Maximum minimum sizes that the terminals will accept these are not recommendations Figure 1 7 Control Terminal Arrangement
30. Bus Supply Specifications Spare Parts A 14 Pc O F4 oF o Zld m mm a a oXeXels oleKorKe PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Specifications A 15 Table A E 400A Unit Spare Part Numbers Descriptions Item Availability tf Description Rockwell Catalog No Qty 3 400A SCR Set SK 20S MCC162 18101 3 4 Yes Fan Assembly SK D9 FAN2 1 6 400A and 600A MOV Assembly SK 20S VBKSDK041 1 7 Yes 40A Fuse Precharge fuses F6 F8 SK 20S F070B040S or 3 Westcode Type F070B040S or Ferraz Shawmut Type 6 921CPgRC14 51 40 8 Yes 400A 700V Fuse AC fuses F1 F3 SK 20S 069UR0S0400B or 3 Torque to 13 Nem 115 Ibein Westcode Type 069UR0S0400B or Ferraz Shawmut Type 6 9URD30TTF0400 9 Yes 450A 700V Fuse DC fuses F4 and F5 SK 20S 069UR0S0450B or 2 Torque to 13 Nem 115 Ibein Westcode Type 069UROS0450B or Ferraz Shawmut Type 6 9URD30TTF0450 12 Yes Fuse Monitoring Switch SK 20S MS3V1 5 5 13 85 C Thermostat SK 20S SWT85KSDKRW 1 1
31. E Verify that AC line power at the disconnect device is within the rated value of the Bus Supply See Appendix A Verify that control power voltage is correct Verify that the enable contactor coil K1 not used on Slave units is correctly wired Verify that these four outputs are correctly wired Bus Supply Overtemperature Rectifier Fuse Trip Snubber DC feedback Fuse Trip Enable Contactor Feedback not used on Slave units These normally closed contact outputs are used to set alarms and to stop the drive s Verify that they have been wired correctly according to the user s specification Refer to the control wiring example shown in Figure 1 8 on page 1 12 Verify that the Line Type jumper on the Precharge Board shown in Figure 2 1 is set to the 3 ph position default Start Up Troubleshooting 2 3 1 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 and Figure 1 9 on page 1 13 for more information LY 10 Verify that the jumper between control 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 information Applying AC Power to the Bus Supply 1 1 Apply AC power and control voltage 115V AC to the Bus Supply The g
32. N Stand Alone M Master 1000A only S Slave 1000A only Important PowerFlex SCR Bus Supply 1000A units with Master or Slave configuration are available for 400 480 and 600 690 Volts Descriptions and Schematic Diagrams Overview P 5 The SCR 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 line voltage to a common DC bus voltage Figure P 1 400A and 600A SCR Bus Supply Schematic Diagram z le WRB Precharge Board ial i3 The primary electrical components for the 400A and 600A SCR Bus Supply are Item 0 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 Bus Supply Overtemperature Sensor located on the heat sink for thermal protection of the SCR bridge rectifier RC snubber circuit routed to the three input phases through semi conductor protection fuses with trip indicator switches MOV snubber circuit routed to the three input phases Precharge Board Enable C
33. PowerFlex SCR Bus Supply Allen Bradley Firmware Version 1 xxx User Manual Allen Bradley Rockwell Software Automation Important User Information PowerFlex SCR Bus Supply User Manual Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 available from your local Rockwell Automation sales office or online at_http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable 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 The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or
34. 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 Figure 1 8 on page 1 12 3 Review important precaution attention statements throughout this document before installing the drive s 4 Grounding as described in General Grounding Requirements on page 1 5 5 Control wiring and DC bus wiring leaving the cabinet must be braided shielded cable with a coverage of 75 or better metal conduit or equivalent attenuation For additional conditions refer to the respective drive Reference Manual Chapter 2 Start Up Troubleshooting This chapter provides the necessary information for the start up and troubleshooting of the PowerFlex SCR Bus Supply Topic Pae Start Up 2 2 Precharge Board LED Indicators 2 4 Troubleshooting 2 6 A 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 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 control voltages User supplied voltages may exist even when main AC power is no
35. Systems NEMA 250 Enclosures for Electrical Equipment IEC 146 International Electrical Code UL and cUL Listed to UL508C and c US CAN CSA C22 2 Marked for all applicable European Directives C e EMC Directive 89 336 EEC e Emissions EN 61800 3 Adjustable Speed electrical power drive systems Part 3 e Immunity EN 61800 3 Second Environment Restricted Distribution e Low Voltage Directive 73 23 EEC e EN 50178 Electronic Equipment for Use in Power Installations 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 0 40 C 32 104 F above 40 C up to 50 C 122 F without Derating maximum temperature the output Amps must be derated by Open Type IP00 1 2 per C 2 2 per F for 400A unit 1 0 per C 1 8 per F for 600A unit 1 0 per C 1 8 per F for 1000A unit Storage Temperature all const 40 70 C 40 158 F Relative Humidity 5 95 non condensing Specifications A 3 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 If the bus supply is not going to be installed for a per
36. commended to derate the capacitance value by 20 in master slave configurations 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 provides the required common DC power make sure the SPARE 1 and SPARE 2 jumpers are in their default settings right side towards the board edge shown in Figure 1 9 Figure 1 9 Location of LED Indicators and Jumpers on the Precharge Board MA C ooo Precharge Board Firmware Version Label Ramp Up o0 oO Slow Norm SCR and RGuaFE SPARE omm Paralleling Yes No vee OO 1 ph 3 ph POWER OK ALARM FAULT SPARE z 2 default positions Jumpers shown in EF g O00 TIP To identify the firmware version remove the SCR Bus Supply cover and check the firmware version label on the Precharge Board Figure 1 9 PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 1 14 Installation Wiring Disconnecting MOVs PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 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 g
37. d Refer to the instructions supplied with the filter PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 1 6 Minimum Capacitance Maximum Loading Installation Wiring 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 The minimum capacitance 110 uF per SCR bus supply may be provided by an external capacitor bank recommended or a drive as long as the drive remains connected to the DC bus NOTE A capacitance of 110 uF is typical of a5 HP or 3 7 kW drive To find DC bus capacitances for specific PowerFlex drives refer to Appendix A tables in the PowerFlex AC Drives in Common Bus Configurations Application Guidelines publication DRIVES AT002 To avoid overloading the Bus Supply the following requirement applies The DC Input current sum Normal Duty rating at 40 C 104 F of the connected drive s must not exceed the Bus Supply continuous DC Bus output 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 Supply No overload capability is built i
38. e 13 3 I 3 idod an I 4 i504 5i 4 5 1604 1I YE g X5 af gt H 4 Q Gate Driver Board PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 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 Bus output terminals through semi conductor protection fuses with trip indicator switches Bus Supply Overtemperature Sensor located on the heat sink for thermal protection of the SCR bridge rectifier RC snubber circuit routed to the three input phases through semi conductor protection fuses with trip indicator switches MOV snubber circuit routed to the three input phases Gate Driver Board The DC power supply is connected to the customer supplied 115V AC Power Supply Cooling Blower connected to a customer supplied 115V AC Power Supply The customer s controls must at a minimum command the blower to run whenever contactor K1 is enabled 00 0 Connection Cable 1 m connects the gate firing pulses from the Master to the first Slave or between any two Slaves maximum 4 NOTE There is no DC output fuse protection in the 1000A SCR Unit Installation Wiring Chapter 1 This chapter provides information on the installation and wiring of the PowerFlex SCR Bus Supply Topic Page Opening the Cover
39. e E a LF ig 40 1 57 70 70 57 2 56 ls 2 56 2 24 157 5 249 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 Specifications A 7 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 The preferred method is to install a minimum 3 line reactor which will also reduce line harmonics Use Table A A through Table A D to select a line reactor based on the sum of the drive s connected DC Amps and the supply transformer rating For more details on the 1321 Series line reactors see the 1321 Power Conditioning Products Technical Data publication 1321 TD001 Table A A 400V 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 5 5 5 5 6 6 6 5 6 5 43 uH 35 pH 31 pH 27 uH 22 uH 16 uH 13 pH 120 150 120 154 120 160 120 165 120 168 120 173 120 176 230 3R160 C upto 203 151 203 155 203 161 203 166 203 169 203 174 203 177 203 150
40. ected directly to building steel should be used All circuits including the AC input ground conductor should be grounded independently and directly to this point bar Figure 1 3 Typical Grounding R L1 SCR S L2 Bus Supply 7 DC DC Ground Grid Girder or Ground Rod Building Ground Potential Safety Ground Terminal PE The Bus Supply safety ground PE must be connected to the customer grounding scheme or earth ground This is the safety ground for the Bus Supply that is required 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 safety regulations and or electrical codes 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 ground Ensure that the incoming supply neutral is solidly connected bonded to the same building power distribution ground Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection Some local codes may require redundant ground connections The integrity of all connections should be periodically checke
41. f DC bus to phase full on in approximately 0 2 seconds while the slower ramp time will take approximately 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 1 18 Installation Wiring SCR Bus Supply 12 Pulse Standalone or master slave SCR Bus Supplies can be used on applications Configuration that use a 12 pulse transformer to minimize power line harmonics Important Be sure to select the slow ramp time see Jumper 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 AC Line A 12 Pulse A Y Transformer EJ A sS 4 A Reactor Reactor Reactor Reactor N N N h Enable h Standalone Standalone i or or f i i Slave l Master Master l Slave i i SCR Bus SCR Bus Gate Gate i Harness Supply Supply Harness a Fuses Fuses Fuses K i Fuses 2 1 So 4 ee eee ae L SR ee Oa aes E pea EEE EE E J e EENE E x Fuses are optional DC Bus For additional recommendations about SCR Bus Supply 1
42. ged before performing any work on the Bus Supply Measure the DC bus voltage at the DC and DC output terminals The voltage must be zero ATTENTION A second source of power for the cooling blower is present To avoid an electric shock hazard or moving blades verify that the AC power supply has been removed prior to performing any maintenance or repairs 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 branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P P 4 Overview Catalog Number Explanation PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Position Number 1 3 4 5 7 8 9 10 20S D 400 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 Output 400 400A 400 480V 600 600A 400 480V 1k0 1000A 400 480 600 690V d Enclosure Code Rating Conformal Coating N Open IP00 No e Documentation amp Shipping Carton Code User Manual Carton E English Yes f Configuration Code Type
43. he nylon standoffs Figure A 7 Mounting the HF Filter M4x8 T M4 x 20 3 Places 4 Places for solid ground system only N U 7 4 y 1 IB i pE 4 mer PE M4 x 19 ake id Nylon Standoffs ate 4 Places r for floating or HGR system only Non Solid Ground Systems The HF filter may be installed with floating or HRG ground systems for line to line transient protection In this type of installation the PE grounding plate should 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 applied Using the hole location dimensions from Figure A 6 install the HF filter using the four 4 M4 x 19 nylon standoffs and four 4 M4 x 20 screws through the four holes in the plastic body of the HF filter Figure A 7 Finger tighten the nylon standoffs Do NOT install the three 3 M4 x 8 screws through the PE grounding plate Install the High Voltage Warning label onto the PE grounding plate when the HF filter is installed with a floating or HRG ground system Specifications A 13 This page intentionally left blank PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Important SCR Bus Supplies are NOT designed to be field repaired but can be field maintained Figure A 8 400A Unit Spare Part Locations 400A SCR
44. iod of time it must be stored in an area where it will not 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 Capacitance for Connection This is the total DC Bus capacitance sum of the permitted Maximum to the DC Bus Supply drives to connect See Minimum Capacitance on page 1 6 and Capacitance Jumper Settings on page 1 12 Bus Supply Dimensions The overall dimensions and mounting holes of the PowerFlex SCR Bus Supply are shown in Figure A 1 Connection Bus Bar dimensions are shown in Figure A 2 Figure A 3 and Figure A 4 Figure A 1 Bus Supply Mounting Dimensions 200 7 87 s 995 0 37 B 1 k 30 1 2 ry H 35 1 4 Holes for Lifting Hooks seamen on 400A Units A c 339 5 13 4 t Ne ra A G g eee J PI Aa J i cae Dimensions are in millimeters and inches Board LEDs e D gt Front View Side View SCR Bus Dimensions Supply A B 0 D E Weight 400A 535 21 1 1404 15 9 1580 22 8 276 10 9 138 5 5 5 130 kg 66 Ib 600A 740 29 1 490 19 3 785 30 9 276 10 9 104 5 4 1 43 kg 95 Ib 1000A 740 29 1 1490 19 3 785 30 9 276 10 9 104 5 4 1 167 kg 147 Ib PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P A 4 Specifica
45. ion 20S UM001G EN P A 8 Specifications Table A B 480V 60Hz Line Reactor Selection Drives Ranges of Drives DC Amp Sum for Typical Supply Transformers 1 Line Reactor Simor og kVA ie kVA 1000 kVA 1230 kVA 1600 kVA Fo kVA 2000 kVA Induct Catalog No 5 5 5 5 6 6 6 5 6 5 2 DC Amps MH 1321 51 uH 41 uH 36 uH 32 uH 26 pH 19 H 16 H oae 120 140 120 144 120 150 120 155 120 160 120 165 120 170 230 3R160 C up to p 141 203 145 203 151 203 156 203 161 203 166 203 171 203 150 3R160 B 204 209 204 214 204 218 185 3R200 C 204 to 255 204 255 204 255 204 255 204 255 210 255 215 255 219 255 110 3R200 B 55 3R200 A 256 260 150 3RB250 C 256 to 319 256 290 256 319 256 319 256 319 256 319 256 319 261 319 90 3RB250 B 291 319 45 3RB250 A hie den 320 340 320 360 320 380 320 407 320 407 320 407 75 3RB320 B o 320 407 341 407 361 407 381 407 40 3RB320 A mbio Z 408 420 408 450 408 490 408 509 408 509 60 3RB400 B 0 408 440 408 509 421 509 451 509 491 509 30 3RB400 A P 510 540 510 620 510 635 50 3R500 B 510 to 635 510 560 510 585 510 600 510 635 541 635 621 635 25 3R500 A 636 700 636 763 40 3R600 B 636 to 763 636 680 636 763 636 763 636 763 701 763 20 3R600 A 764 840 764 938 29 3R750 B 764 to 938
46. line reactors A 7 to A 10 M manual conventions P 2 web site P 2 master unit 1000A only conversion to slave unit 1 16 standalone unit 1 16 maximum loading 1 6 minimum capacitance 1 6 minimum mounting clearances 1 3 MOVs disconnecting 1 14 O opening the cover 1 2 PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Index 2 PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P operating temperature 1 3 P parallel connection of slave units 1000A only 1 15 PE ground 1 5 power wiring 1 7 powering up bus supply 2 2 precautions general P 3 R related documentation P 1 removing cover 1 2 replacing fuses 1000A unit A 19 400A unit A 15 600A unit A 17 RFI filter grounding 1 5 S safety ground 1 5 SCR bus supply 12 pulse configuration 1 18 ambient operating temperature 1 3 catalog number explanation 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 A 19 specifications A 1 to A 3 setting jumpers 1 12 short circuit protection 1 7 slave unit 1000A only parallel connection 1 15 spare parts A 14 to A 19 specifications A 1 to A 3 start up checklist 2 2 static discharge ESD P 3 status indicators 2 4 supply source for AC 1 4 system grounding 1 5 T technical support P 2 trouble
47. losed 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 This ensures that the drives are stopped in case of Bus Supply Overtemperature Control Wiring Example Figure 1 8 Example of SCR Bus Supply 1000A Single with Multiple Drives Using Drive Run Interlocks Running Simultaneous NOTE Optional HF Filter m 115 VAC a Re 4 see page A 11 Hs Stop DZ L1 i 1 115 R PowerFl m Run ete PowerFlex iki 4 SCR Bus Ki Suppl rs ee upply 6 RC x x F1 F6 The customer s controls 7 7 F7 11 must at a minimum Prechar command the blower 8 a te to run whenever contactor g 7 F16 se K1 is enabled 10 11 f gt C 2 val KIM DC Bus KIM KIM i AC Drive 110 kw 205A KIM KIM AC Drive 110 kW 205A C AC Drive AC Drive 45 kW 205A 85A 110 kW f f f f M M 3a 3a The PowerFlex SCR Bus Supply precharge board has three jumpers See Figure 1 9 on page 1 13 for jumper locations and positions e LINE TYPE Jumper Always set to the 3 ph default right side position towards the board edge e SPARE 1 Jumper For board firmware version 1
48. mentation can be obtained online at http literature rockwellautomation com 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 amp Support web site at www ab com support abdrives and click on the Downloads or Knowledgebase link Rockwell Automation Support Use the contacts below for PowerFlex SRC Bus Supply technical support Online By Email By Telephone www ab com support abdrives 262 512 8176 support drives ra rockwell com Conventions Used in This Manual In this manual we may refer to the PowerFlex SCR Bus Supply as SCR Bus Supply or Bus Supply e The firmware release is displayed as FRN X xxx The FRN signifies Firmware Release Number The X is the major release number The xxx is the minor update number e The following words may be used throughout the manual to describe an action Word Meaning Can Possible able to do something Cannot Not possible not able to do something May Permitted allowed Must Unavoidable you must do this Shall Required and necessary Should Recommended Should Not Not Recommended PowerFlex SCR Bus Supply User Ma
49. ng ways 1000A SCR Bus Supply Convert from Standalone Convert to Standalone Master Slave Because of numerous internal changes components cables and hardware the following conversions are not allowed Standalone to master Standalone to slave Slave to standalone Slave to master NOTE See Figure A 11 on page A 19 for circuit board location Converting Master Unit to Standalone Unit No changes are required to run a master without slave units as a standalone SCR Bus Supply Converting Master Unit to Slave Unit It is possible to reconfigure a master SCR Bus Supply to run as 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 X4 see Figure P 3 on page P 7 Connect a cable from the gate driver printed circuit board connector X4 to the new master SCR Bus Supply or another slave SCR Bus Supply gate connector X6 see Figure P 4 on page P 8 Note that the precharge board does not need to be removed from the converted SCR Bus Supply Ensure that the precharge relay is not energized terminal block terminal 1 and 2 see page 1 11 Place a label near the data nameplate stating that the SCR bus supply has been converted to catalog 20Sx1 KONES where x is the voltage class of the unit 1000A SCR Bus Supply Redundancy
50. nput Voltage 400 480V 600 690V Ratings Frequency 47 63 Hz 47 63 Hz Operational AC Input Voltage Range 187 528V 528 759V Input Current Max Continuous rms 355 521 843 843 Input kVA at Max Continuous rms Amps 246 295 361 433 584 700 876 1007 Output DC Bus Amps Normal Duty Heavy Duty Ratings Continuous 300 240 500 400 800 720 1800 720 1 minute 330 360 550 600 880 1080 880 1080 3 Sec every minute 450 480 750 800 1200 1440 1200 1440 Max Continuous DC Bus Amps without Overload 400 600 1000 1000 Power Dissipation Watts at Maximum Continuous Amps 1200 1600 2700 2800 1 Includes appropriate AC line reactor The derate for each additional slave is 5 plus 5 for the master See Parallel Connection of Slave Units on page 1 15 Specifications Dependent on Voltage AC Input DC Bus Voltage Voltage Nominal Maximum 400V 540V 750V 480V 650V 750V 600V 810V 1080V 690V 930V 1080V PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P A 2 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 Short Circuit Current Rating 85 kA
51. nto the tables Important See Output Ratings in Appendix A for overload capability When an overload is being utilized in connected drives or products that overload current must be accounted for in the calculation to properly size the SCR Bus Supply Table 1 4 Normal Duty ND 110 1 minute 150 3 seconds Drive Rating Drive Output Current Drive DC Input Current SCR Bus Supply DC ND ND Output ND Output ND DC Input ND DC Input Maximum DC AC Input Voltage Power Currents Current Sum Currents Current Sum Output Amps Voltage 540V 3x110kW 3x205 615A 700A 3 x 226 678A 773A 1000A 400V 1x45kW 1x85 85A 1x95 95A 650V 3x60HP 3x77 231A 271A 3 x 84 5 253 5A 297A 400A 480V 1x30HP 1x40 40A 1 x 42 9 42 9A 1 No overload capability Table 1 B Heavy Duty HD 150 1 minute 200 3 seconds Drive Rating Drive Output Current Drive DC Input Current SCR Bus Supply DC HD HD Output HD Output HD DC Input HD DC Input Maximum DC AC Input Voltage Power Currents Current Sum Currents Current Sum Output Amps Voltage 1 No overload capability PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 400V Fusing Power Wiring Installation Wiring 1 7 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
52. nual Publication 20S UM001G EN P General Precautions A gt D Overview P 3 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 or any other applicable ESD protection handbook ATTENTION An incorrectly applied or installed Bus Supply can result in component damage or a reduction in product life Wiring or application errors such as incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system ATTENTION Only qualified personnel familiar with adjustable frequency AC drives and associated 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 Connect products with or without precharge circuitry to the SCR Bus Supply common bus output terminals within the minimum and maximum capacitance and load rating guidelines ATTENTION To avoid an electric shock hazard verify that the voltage on the DC bus terminals which are connected to the DC bus capacitors of the Inverter has dischar
53. onnection Specifications Recommended Minimum Size Item Description Copper Bus Bars 1 Bus Bar Wire AC Line Input 50x 5mm 1 97x0 2in wih 50x5mm 240 mm L1 L2 L3 two 14 mm 0 55 in diameter or 2 x 95 mm holes for customer terminal DC Bus 50x 5mm 1 97x0 2in wih 60x5mm 1300 mm DC DC two 14 mm 0 55 in diameter or 2 x 120 mm holes for customer terminal Protective Earth PE M12 x 25 mm 0 98 in stud torque to 15 Nem 133 Ibein Size per NEC or local code 4 Control Terminal Block See Table 1 F 1 Input output power bus bar connections require the use of either lug type connectors to terminate field installed conductors or bus bars PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 1 10 Installation Wiring Figure 1 6 1000A Unit Bus Bar and Terminal Locations for Customer Wiring Os 4 O oF o fo f 0O i roo odo S 5 S e Ki rT Reale ti Po oN 40 40 jo oF OF 9 r ad l o ake O O Table 1 E 1000A Unit Power Connection Specifications Recommended Minimum Size Item Description Copper Bus Bars 1 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 two 14 mm 0 55 in diameter or 80 x 5 mm holes for customer terminal DC
54. ontactor K1 for the precharge board 0 9 6 Cooling Blower connected to a customer supplied 115V AC Power Supply The customer s controls must at a minimum command the blower to run whenever contactor K1 is enabled PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P P 6 Overview Figure P 2 1000A SCR Bus Supply Single Unit Schematic Diagram T N i i 7 i i i TEGI i 2113 33 43 Gi Q A i ore ez 4 a a cr gt O00 i X1 oie aag ets O i G4 a SDD ICZ K1 i E O Perge fs ie Board 8 E 7 c6 EA G5 ATE c2 ET 3E i87 c5 rd HAN 3 3f i 4 G i X2 PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 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 Bus Supply Overtemperature Sensor located on the heat sink for thermal protection of the SCR bridge rectifier RC snubber circuit routed to the three input phases thro
55. r 1000A A 19 unit In Appendix A revised Input Ratings Operational AC Input Voltage Range for catalog A 1 number 20SF1K0 from 269 759V to 528 759V Added new Appendix B B 1 PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P soc ii Summary of Changes PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Preface Chapter 1 Chapter 2 Appendix A Appendix B Index Installation Wiring Opening the Cover Minimum Mounting Clearances AC Supply Source Considerations General Grounding Requirements Minimum Capacitance Maximum Loading Control Wiring Jumper Settings Disconnecting MOVs Parallel Connection of Slave Units 1000A SCR Bus Supply Flexibility 1000A SCR Bus Supply Redundancy SCR Bus Supply 12 Pulse Configuration CE Conformity Start Up Troubleshooting Precharge Board LED Indicators Troubleshooting Specifications PowerFlex SCR Bus Supply Bus Supply Dimensions History of Changes 20S UM001F EN P March 2011 Table of Contents Who Should Use this Manual 00000 ccc cee eee eee eens P 1 Reference Documentation Rockwell Automation Support Conventions Used in This Manual General Precautions Catalog Number Explanation Descriptions and Schematic Diagrams PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P ii Table of Contents PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Who Should Use this Manual
56. r Manual 20A UM001 PowerFlex 70 700 Reference Manual PFLEX RM001 PowerFlex 70EC 700VC Reference Manual PFLEX RM004 PowerFlex 700 700VC Series A Drive PowerFlex 700 Series A User Manual 20B UM001 PowerFlex 700VC Series B Drive PowerFlex 700 Series B User Manual 20B UM002 PowerFlex 70 700 Reference Manual PFLEX RM001 PowerFlex 70EC 700VC Reference Manual PFLEX RM004 PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P P 2 Overview For Refer to Publication PowerFlex 700H Drive PowerFlex 700H Installation Instructions PFLEX IN006 PowerFlex 700H Programming Manual 20C PM001 PowerFlex 700S Drive PowerFlex 700S with Phase Control Installation Manual Frames 1 6 20D IN024 PowerFlex 700S with Phase Control Installation Manual Frames 9 and 10 PFLEX INO06 PowerFlex 700S with Phase Control User Manual All Frame Sizes 20D UM001 PowerFlex 700S with Phase Control Reference Manual PFLEX RM002 PowerFlex 700S with Phase II Control Installation Manual Frames 1 6 20D IN024 PowerFlex 700S with Phase II Control Installation Manual Frames 9 14 PFLEX INO06 PowerFlex 700S with Phase II Control Programming Manual All Frame Sizes 20D PM006 PowerFlex 700S with Phase II Control Reference Manual PFLEX RM003 PowerFlex 750 Series AC Drive PowerFlex 750 Series Drive Installation Instructions 750 IN001 PowerFlex 750 Series Drive Programming Manual 750 PM001 PowerFlex 750 Series Reference Manual 750 RM002 Docu
57. reen POWER OK LED on the Precharge Board should be on if power is applied to terminals L1 R L2 S L3 T and the enable contactor for the precharge board not used on Slave units is energized l 2 Ifthe green POWER OK LED is off at this point refer to Table 2 B PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 2 4 Start Up Troubleshooting Precharge Board LED Indicators PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P The three LEDs on the Precharge Board are visible through a small slot in 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 For slot locations see Figure A 1 on page A 3 when the unit is energized Servicing energized equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of the controlled equipment Follow safety related practices of NFPA 70E Electrical Safety For Employee Workplaces DO NOT work alone on energized equipment A ATTENTION The SCR Bus Supply LEDs are only operational Figure 2 1 Location of LED Indicators and Jumpers on the Precharge Board Precharge Board Firmware Version Label
58. round voltages on any phase could exceed 125 of the nominal line to line voltage To disconnect the MOVs from ground remove the jumper 12 GND on the control terminal block shown in Figure 1 7 on page 1 11 Solid and non solid grounded systems are defined in Table 1 G Table 1 G Recommended MOV Configurations MOV Input Filter Benefits of Correct Power Source Power Source Type Capacitors Type Configuration Solid Grounded Connected e AC fed solidly grounded DC fed from passive rectifier which has an AC source and solid ground UL compliance Reduced electrical noise Most stable operation EMC compliance Reduced voltage stress on components and motor bearings Non Solid Grounded Disconnected AC fed ungrounded Impedance grounded High resistive ground B phase ground Regenerative unit common DC bus supply and brake DC fed from an active converter Helps avoid severe equipment damage when ground fault occurs Itis highly recommended to accurately determine the power source type and then configure appropriately 2 When MOVs are disconnected the power system must have its own transient protection to ensure known and controlled voltages For more information on non solid grounded system installation see Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES UM001 voltage on the bus capacitors has discharged before removing the jumper Measure
59. shooting 2 6 U unbalanced non grounded supply 1 4 W web site related documentation P 2 Rockwell Automation technical support P 2 wiring control 1 11 power 1 7 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support For US Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support abdrives Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact
60. 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 considerations circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss i WARNING Identifies information about practices or Important Identifies information that is critical for successful application and understanding of the product circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequences A ATTENTION Identifies information about practices or Shock Hazard labels may be located on or inside the equipment e g drive or motor to alert people that dangerous voltage may be present Burn Hazard labels may be located on or inside the equipment e g drive or motor to alert people that surfaces may be at dangerous temperatures gt gt Allen Bradley and PowerFlex are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes The information below summarizes the changes made to this manual since its last release March 2011 Description of Changes Page
61. t Rockwell Automation can provide information regarding harmonic emissions from the SCR Bus Supply General Notes e The DC bus cable to the inverter s should be kept as short as possible to avoid electromagnetic emission and capacitive currents Therefore the inverter s should be located in the same cabinet as the Bus Supply or next to the cabinet with the Bus Supply If the connection leads between DC bus and inverter s are leaving the cabinet shielded cables must be used e Use of line filters in non solid grounded systems is not recommended e The PowerFlex SCR Bus Supply with external Line Reactor and HF filter satisfies CE EMC emission limits for the industrial environment If used in a residential or domestic environment it may cause radio interference The user is required to take measures to prevent interference in addition to the essential requirements for CE compliance listed below if necessary PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 1 20 Installation Wiring PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P e 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 1 Bus
62. t applied to the Bus Supply Correct the malfunction before continuing ATTENTION When operating the SCR Bus Supply a minimum of one 7 5 kW 10 HP PowerFlex 700 700S Inverter must be connected to the DC bus otherwise the internal fault detection circuit will interpret the condition as an Output Voltage Loss and stop pulse firing This is indicated on the Precharge Board by the Alarm LED 7 flashes and after 30 seconds by the Fault LED 2 flashes Refer to Table 2 A and Table 2 B ATTENTION Second source of power for cooling blower is present To avoid an electric shock hazard or moving blades verify the AC power supply has been removed prior to performing any maintenance or repairs PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 2 2 Start Up Troubleshooting Start Up PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Before Applying Power to the Bus Supply Verify that the minimum of one Inverter is connected to the DC bus Confirm that all inputs are connected to the correct terminals and are properly torqued Using an ohmmeter or other continuity testing device verify that shorts do not exist between Source 1 and Source 2 Source 1 Source 2 Checkmark Below if No Short Exists ao fe L1 L3 L2 L3 L1 PE L2 PE L3 PE Li DC Bus L2 DC Bus L3 DC Bus L1 DC Bus L2 DC Bus L3 DC Bus DC Bus DC Bus DC Bus PE DC Bus P
63. t 600A 2700W at 480V 1000A and 2800W at 690V 1000A The three phase AC line reactor watt losses are listed in the 1321 Power Conditioning Products Technical Data publication 1321 TDO01 Because of the internal design of the SCR Bus Supply it is NOT recommended to rely on an air dam surrounding the SCR Bus Supply It is recommended that the system integrator completes a thermal evaluation to ensure adequate cooling to maintain proper operating conditions for each cabinet or bay A minimum air exchange of 725 CFM per SCR Bus Supply is recommended PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 1 4 Installation Wiring AC Supply Source Considerations PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P The PowerFlex SCR Bus Supply is suitable for use on a circuit capable of 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 Line Reactors A minimum 3 rated three phase AC line reactor must be installed for minimum voltage drop unless the closest supply transformer is matched to the KVA rating of the PowerFlex SCR Bus Supply For recommended line reactors see Line Reactors on page A 7 Install one three phase AC line reactor for each SCR Bus Supply module It is recommended to maintain cable length symmetry
64. tions Figure A 2 400A Unit Bus Bar Customer Connection Point Dimensions Locations 144 5 7 15 0 6 i 233 9 2 a Q o 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 Specifications A 5 Figure A 3 600A Unit Bus Bar Customer Connection Point Dimensions Locations 100 3 94 T 243 9 6 1 57 Front View Dimensions are in millimeters and inches a 304 Side View 12 PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P A 6 Specifications Figure A 4 1000A Unit Bus Bar Customer Connection Point Dimensions Locations 100 615 249 3 94 2 4 9 8 i sl Teo eL ri 5 L Le 40 L r 1 57 A a DURP a o j aoe Boo LW is 40 i
65. ugh semi conductor protection fuses with trip indicator switches MOV snubber circuit routed to the three input phases Precharge Board Enable Contactor K1 for the precharge board 00O Cooling Blower connected to a customer supplied 115V AC Power Supply The customer s controls must at a minimum command the blower to run whenever contactor K1 is enabled NOTE There is no DC output fuse protection in the 1000A SCR unit Overview P 7 Figure P 3 1000A SCR Bus Supply Master Unit Schematic Diagram a ST Were a jo ah Precharge Board To Gate o Driver X4 7 on the Slave Figure P 4 0 0 0004 ii fofos EERE et a ix 1 fotos i M 4 3 Li Xii iil l iaa Jem ww Sl oO i oO w fo D a 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 Bus output terminals through semi conductor protection fuses with trip indicator switches Bus Supply Overtemperature Sensor located on the heat sink for thermal protection of
66. unit but required for 1000A Standalone unit mounted in lower location or 1000A Master unit mounted in upper location 0 Not required for a 1000A Standalone unit but required to connect an existing 1000A Master or Slave unit to another 1000A Slave unit gate driver circuit board mounted in lower location Figure A 11 1000A Unit Printed Circuit Board Locations top view Precharge Board SK D9 SCRPRE1 x 1000A 1000A 1000A Standalone Unit Master Unit Slave Unit Precharge Board Gate Drive Board Gate Driver Board SK D9 SCRPRE1 x SK D9 SCRGDB1 SK D9 SCRGDB1 PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P A 20 Specifications Notes PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 20S UM001F EN P March 2011 Appendix B History of Changes Topic Page 20S UM001F EN P March 2011 B1 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 Change Reformatted document from half size 5 5 x 8 5 in to full size 8 5 x 11 in Removed reactors by DC Bus outputs on 12 Pulse System Configuration drawing Added Atmosphere specification to the Environmental section Added Surrounding Environment specification to
67. us Supply if any device has failed If there is no evidence of a failure check for open fuse and replace N C contact on control terminals 8 and 9 is open 400A and 600A Unit Open AC line fuse or open DC bus fuse F1 F5 1000A Unit Open AC line fuse F1 F6 r Check for evidence of power module failure see Step 3 in Start Up on page 2 2 Replace entire SCR Bus Supply if any device has failed If there is no evidence of power module failure check for open fuse and replace N C contact on control terminals 10 and 11 is open Open heat sink Overtemperature Switch Verify that maximum ambient temperature is not exceeded Replace the Overtemperature Switch PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P 2 8 Start Up Troubleshooting Notes PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Specifications Appendix A 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 A 1 Bus Supply Dimensions A 3 Accessories A 7 Spare Parts A 14 PowerFlex SCR Bus Supply Specifications Dependent on Power and Voltage a SCR Bus Supply Catalog Number Category Specification 20SD400 20SD600 20SD1KO 20SF1KO Input Nominal AC I
68. ward about 2 cm 0 8 in and away from the enclosure Figure 1 1 Figure 1 1 Opening the Cover e yi PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Minimum Mounting Clearances Installation Wiring 1 3 The cabinet air inlet and outlet areas for each SCR Bus Supply must be a 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 SCR SCR Bus Supply Bus Supply 150 qin in D arn foital 300 mm 12 in TSG ee below fan Air Inlet Air Inlet Refer to Appendix A for detailed dimension information Ambient Operating Temperatures The PowerFlex SCR Bus Supply is designed to operate at 0 40 C 32 104 F ambient without derating For operation in ambients above 40 C up to 50 C 104 F up to 122 F the PowerFlex SCR Bus Supply output Amps must be derated by 1 2 per 1 C for 400A unit and by 1 0 per 1 C for 600A and 1000A units Ensure that proper cooling is provided to the SCR Bus Supply to maintain the 40 C rated specification If the ambient temperature is exceeded apply the proper derate factors 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 1600W a
69. y Important SCR Bus Supplies are NOT designed to be field repaired but can be field maintained Figure A 9 600A Unit Spare Part Locations a CPO F5 F4 L9G V4 F6 F8 Al O F2 F3 9 O40 Ho oXeXerXe eXeKere PowerFlex SCR Bus Supply User Manual Publication 20S UM001G EN P Specifications A 17 Table A F 600A Unit Spare Part Numbers Descriptions Item Availability tf Description Rockwell Catalog No Qty 2 600A SCR Set SK 20S MCC312 18101 3 4 Yes Fan Assembly SK D9 FAN2 1 6 400A and 600A MOV Assembly SK 20S VBKSDK041 1 7 Yes 40A Fuse Precharge fuses F6 F8 SK 208 F070B040S or 3 Westcode Type F070B040S or Ferraz Shawmut Type 6 921CPgRC14 51 40 10 Yes 630A 700V Fuse AC fuses F1 F3 SK 20S 069UR5S0630B or 3 Torque to 25 Nem 221 Ibein Westcode Type 069UR2S0630B or Ferraz Shawmut Type 6 9URD32TTF0630 11 Yes 1000A 700V Fuse DC fuses F4 and F5 SK 20S 069UR2S1000B or 2 Torque to 25 Nem 221 Ibein Westcode Type 069UR2S1000B or Ferraz Shawmut Type 6 9URD32TTF1

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