Reliance electric AutoMax DPS User manual

AutoMax DPS DC Power Module
Instruction Manual
User Manual: 49 1335-e (06)
Publication: AMXDPS-UM003D-EN

TABLE OF CONTENTS
49'1335 e AMX DPS DC-POWER MODULE
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 .......................................................................................... 8
Line impedance .................................................................................. 8
Ambient conditions ............................................................................. 8
Chapter 3. ADAPTATION........................................................................................ 9
Chapter 4. MOUNTING AND CONNECTION 10...16
Assembly..............................................................................................10
Cooling ................................................................................................10
Connection ..........................................................................................10
Dimensions...........................................................................................12
Chapter 5. START-UP, DIAGNOSTICS AND TROUBLESHOOTING 17...18
Checks with power off ..........................................................................17
Checks with power on ..........................................................................18
Safety precautions ...............................................................................18
Test instruments ..................................................................................18
Checking the cooling fan .....................................................................18
Trouble shooting ..................................................................................18
Chapter 6. REPLACEMENT OF THYRISTORS 19...20
Chapter 7. SPARE PARTS .................................................................................. 21
Chapter 8. ACCESSORIES ................................................................................ 22...27
Semiconductor protecting fuses .......................................................... 22
AC line reactors .................................................................................. 24
EMC filters........................................................................................... 26
APPENDIX A: CE CONFORMITY .............................................................................. 28...31
APPENDIX B: CROSS REFERENCE LIST PART NO. - CATALOGUE NO. .............32

.

GENERAL NOTES
49'1335 e AMX DPS DC-POWER MODULE I
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.
• A CAUTION alerts a person that, if procedures are not followed, damage to, or destruction
of equipment could result.
DANGER
:
Only qualified electrical personnel familiar with the construction and operation of this
equipment and the hazards involved should install, adjust, operate, and/or service this
equipment. Read and understand this manual in its entirety before proceeding. Failure
to observe this precaution could result in bodily injury.
WARNING
:
Earth fault detection devices must not be used on this converter as the sole protection
measure against unintentional touching. The DC-component in the earth fault current
may inhibit the correct function of the fault detector.
WARNING
:
The function of this electronic device, if not mounted in a metal control cabinet, can be
disturbed by electromagnetic radiation of nearby radio transceivers (walkie-talkies).
CAUTION
:
Electronic power converters cause disturbances to the supply network. The basic
version of this converter does not include any harmonic filters and may not fulfill the
limits of the national recommendations. The harmonic voltage disturbances produced
by the converter are dependent on the supply network impedance.
Machinery Directive
CAUTION
:
This converter device is a component intended for implementation in machines or
systems for the capital goods industry.
The start-up of the converter in the European market is not permitted until it has been
confirmed that the machine into which the converters are built is in conformance with
the regulations of the Council Directive Machinery 98/37/EWG.
WARNING
:
To inhibit uncontrolled machine operation in case of the malfunction of the drive, the
user must provide an external emergency stop circuit, which ensures disconnection of
the power source from the motor.
This circuit must be hardwired with electro-mechanic components and shall not depend
on electronic logic or software
. The stopping device (e.g. mushroom head pushbutton
with lock) must be accessible to the operator.
Failure to observe this precaution could result in bodily injury or loss of life.

GENERAL NOTES
II AMX DPS DC-POWER MODULE 49'1335 e
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. Guidelines for the installation according EMC-regulations - for shielding,
grounding, filter arrangement as well as wiring instructions - are summarized in
Appendix A, ‘CE-Conformance’ of this Instruction manual.

CHAPTER 1 - DESCRIPTION
49'1335 e AMX DPS DC-POWER MODULE 1
Features
RELIANCE ELECTRIC DC Power Modules are
3 phase AC/DC converters and are used for the
step less regulation of DC-motors. They are
available in two variants:
For single-quadrant operation S-6
Controlled rectifier bridge with two directions.
Clockwise rotation (I. Quadrant)
or CCW rotation (III. Quadrant) motoring.
For four-quadrant operation S-6R
This converter works as rectifier and inverter
and allows operation in both directions of
rotation in motoring and regenerative mode
(driving and braking).
AC-line reactors and super fast acting fuses are
not included in the device and have to be
mounted separately.
The DC Power Modules are designed as power
units for DC-drives in AutoMaxDistributed Power
Systems ( AMX DPS ).
They contain in addition to the power stack
PC-boards with the following functions:
- Firing pulse transmission
- Line synchronization signals
- Line voltage feedback
- Armature current feedback
- Armature voltage feedback
- Snubber circuit
All control and regulator functions of the
converter are executed fully digital in the
Universal Drive Controller Module (UDC)
mounted in an AutoMax rack and in the Power
Module Interface Rack (PMI).
Protective measures
A balanced protective concept ensures a high
degree of reliability.
- On single-quadrant drives fast acting fuses
must be provided on the mains supply side to
protect the thyristors against short circuits.
- On four-quadrant drives fuses are also
required in the armature circuit.
- Instantaneous electronic trip (IET) protects
the device against overcurrent and over-
voltage peaks.
- Summing RC-networks limit the voltage at the
thyristors.
- Converters with cooling fan (>=120A) are
protected against excessive temperatures
from overload or fan loss by thermostats on
the heatsink.
- The controller is electrically isolated from the
power unit.
- Regulator blocking on undervoltage or phase
loss.
- Mains connection with optional phase
sequence .
- Automatic adaptation to line frequency 50 Hz
or 60 Hz (on units <=1500A).
- The DPS checks the drive before power up
and during operation by the means of
extensive diagnostic-routines. The following
faults are detected:
* Instantaneous overcurrent
* Loss of line synchronization
* Loss of speed feedback
* Software detected overspeed /overvoltage
* External IET(Instantaneous electronic trip)
* Incorrect phase detection
* Shorted thyristor

CHAPTER 1 - DESCRIPTION
2 AMX DPS DC-POWER MODULE 49'1335 e
Configuration
PMI 3
4
6
7
5
1
X2 X1 X3
2
(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)

CHAPTER 1 - DESCRIPTION
49'1335 e AMX DPS DC-POWER MODULE 3
Schematic Diagram
AC line
PMI
1
1
1
1
PMI
AC 115V
2
2
motor armature
/1 On single quadrant units S-6 the thyristors V11-V16 and the firing pulse transformers are not fitted,
and armature fuses are not needed
/2 On Types < = 60 A cooling fan and thermostat F3 are not fitted.
Fig. 1-2: Schematic diagram Types < = 800 A

CHAPTER 1 - DESCRIPTION
4 AMX DPS DC-POWER MODULE 49'1335 e
3 x 380 V, 50 Hz
or 3 x 460 V, 60 Hz AC line
PMI
1
1
1
1
PMI
motor armature
/1 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. 1-3: Block diagram of the units 1500 A - 2000 A
Connection Function Remarks
181, 182, 183 - Converter AC-line supply input - for supply voltages
PE - Protecting earth connection see Chapter 2
45, 47 - Converter output
0, 115 - Cooling fan supply for type 120-800 A - 1-phase
187, 188, 189 - Cooling fan supply for type 1500-2000 A - 3-phase on 1500-2000 A units
29, 101 - Thermostat contact output - from 120 A on
- The power unit for single-quadrant operation consists of a fully controlled, three-phase bridge
rectifier, the four-quadrant variant comprising two antiparallel connected 3-phase bridges.
WARNING:
The output voltage of the converter is not limited. In case of a fault the output voltage (armature voltage)
may reach the following value: Ua= 1.35 x UN(observe the line voltage tolerance)

CHAPTER 1 - DESCRIPTION
49'1335 e AMX DPS DC-POWER MODULE 5
Functions of the PC-Boards
As already mentioned are all converter control
and regulation functions executed in the
AutoMax and Power Module Interface Rack
outside the power unit. This covers also the
functions for firing pulse generation including the
pulse amplification (final stage) and functions for
analogue to digital signal conversion and the
measuring signals for line voltage, line
synchronization, armature current and armature
voltage from the power stack.
The only function of the cards on the power unit
is to detect, calibrate and transfer the measuring
and feedback signals. In addition the firing
pulses are transferred to the power unit. The
cards contain also the snubber circuits for the
power unit.
The functions are distributed on the cards as
follows:
Driver Card
The firing pulse transformers are placed on the
card:
PDA for 4Q drives S-6R, or
PDB for 1Q drives S-6
The driver signals are distributed through series
resistors to the adjacent transformers. The
secondary side of the firing pulse transformers is
connected via twisted pairs to the thyristors.
Feedback Card
Synchronization
For the synchronization of the firing pulses the
DPS-System needs a 3-phase-AC voltage signal.
These signals are generated from the secondary
windings of the transformers T1-T3.
The transformers, on the primary side in delta
connection, are linked to the mains through input
fuses F1-F3.
The circuit calibrates the line voltage to the
required signal amplitude and isolates the
signals from the line voltage. The transformer
secondary windings in star-connection are linked
through resistive voltage dividers to connector
X1.
The signal amplitude is adapted for different line
voltages by means of jumper setting according to
Table 3-1 in Chapter 3.
Line Voltage and Armature Voltage Feedback
5 high resistance voltage dividers are provided
for 3 line voltage and 2 armature voltage
feedback signals. The signal amplitude is
adapted for different line voltages by means of
jumper setting accord. to Table 3-1 in Chapter 3.
Current Feedback
The current feedback signal originates from 2
current transformers (CT1 and CT3) monitoring
the AC line current to the SCR bridge. The CT
connections are directly linked to connector X1
and then rectified and summed on a burden
resistor in the PMI. The voltage across the
burden resistor is fed back to the feedback card
in the power module and there available at test
points ARM CT and GND.
Voltage Limitation (Snubber) Circuit
For power modules up to type 800 A the feed-
back card also includes the snubber circuit.
SBA card
This card contains the voltage limitation
(snubber) circuit for 1500 –2000 A units.

CHAPTER 2 - TECHNICAL DATA
6 AMX DPS DC-POWER MODULE 49'1335 e
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.................... ................................................... ±10 %
for the max. armature voltage according to Table 2-2
- Line frequency Type < = 1500 A............................................ 50 Hz or 60 Hz ±2 Hz
Type 1600 A and 2000 A.......................................standard 50 Hz ±2 Hz
on request 60 Hz ±2 Hz
Fan supply
Table 2-1
Unit Type Terminal Phases Volts Freq. Amps External
Protection
120 A 0,115 2 115 50/60 0.20
250 A 0,115 2 115 50/60 0.26 Fuse
450 A 0,115 2 115 50/60 0.26 < 6 A
800 A 0,115 2 115 50/60 0.52
1500 A 187, 188, 189 3 400 50 1.1
460 * 60 *
1600 A 187, 188, 189 3 400 50 1.1
2000 A 460 * 60 *
Thermal
Magnetic
Circuit
Breaker
* Units with 460V / 60 Hz blower are available on request.
Armature Voltages
Table 2-2: Armature Voltages for different Line Voltages
Negative Standard Motor Armature Voltage
Line Line Voltage
Voltage Tolerance Motoring Operation Regenerating Operation
Un Ut Ua nom Ua max Ua nom Ua max
200 V 10% 200 V 230 V 200 V 214 V
400 V 10% 460 V 490 V 400 V 440 V
415 V 10% 460 V 490 V 400 V 440 V
460 V 10% 520 V 570 V 500 V 500 V
500 V 5% 600 V 620 V 520 V 535 V
575 V 5% 700 V 710 V 600 V 615 V
660 V 5% 800 V 810 V 700 V 706 V
690 V 10% 800 V 850 V 700 V 738 V
Use of Standard Motor Armature Voltages implies:
- Inductive Voltage Drop Uk < = 4% per phase
- Max. Negative Line Voltage Tolerance Ut as stated
Max. permissible Motor Armature Voltage:
1-Quadrant Operation: Ua = Un *1.35* (100-Ut)/100* (100-Uk)/100
4-Quadrant Operation: Ua = Un *1.17* (100-Ut)/100* (100-Uk)/100

CHAPTER 2 - TECHNICAL DATA
49'1335 e AMX DPS DC-POWER MODULE 7
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. Input Armature Current Trans-
Voltage current former-Ratio
I
a nom I a d I a max ü
60 A 500 50 A 60 A 75 A 833:2
120 A 500 100 A 120 A 150 A 833:1
250 A 500 208 A 250 A 312 A 2000:1
450 A 500 375 A 450 A 562 A 3000:1
450 A 690 315 A 380 A 472 A 3000:1
800 A 500 666 A 800 A 1000 A 5230:1
800 A 690 500 A 600 A 750 A 5230:1
1500 A 500 1250 A 1500 A 1875 A 10500:1
1500 A 690 1170 A 1400 A 1750 A 10500:1
1600 A 690 1334 A 1600 A 2000 A 10500:1
2000 A 500 1667 A 2000 A 2500 A 10500:1
Ia nom: Permanent rated current with 50% overload during one minute every 10 minutes
Ia d: Permanent rated current without overload (Ia d = 1.2 . Ia nom)
Ia max: Maximum current during one minute after 9 minutes with Ia nom (Ia max = 1.5 . Ia nom)
Current transformer ratio: ü = Motor current / Burden current

CHAPTER 2 - TECHNICAL DATA
8 AMX DPS DC-POWER MODULE 49'1335 e
Heat dissipation
Heat dissipation in watts may be expressed by the following formula
Dissipation Pv = K + 3 . Ianom
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 – 2000 A
Line impedance considerations
So that the maximum permissible short circuit current capacity of the converter is not exceeded,
minimum supply network inductance is a mandatory requirement. Therefore a three phase iron core
reactor should be incorporated in the mains supply to terminals 181, 182, 183. The line impedance of
this reactor should be between 2 and 4%. Refer to Table 8-4 for selection.
No reactor is required when a matched line input transformer is provided.
Service Conditions
Ambient temperature
- Operation: 0 degree C ... +55 degree C
For temperatures higher than 45 degree the max. currents
must be derated by 1.5% per degree C.
- Storage: -25 degree C ... +55 degree C
- Transportation: -25 degree C ... +70 degree C
(+70 degree C during max. 24 hours)
Ambient relative humidity: max. 50% at 40 degree C unlimited
max. 90% at 20 degree C during max. 30 days/year
75% average (Class F, DIN 40 040)
NOTE: Condensation is not allowed!
Air pollution: The ambient air may contain some dry dust but must not
contain excessive dirt, chemical fumes, oil, vapor etc.
Installation altitude: max. 1000 m above sea level.
Above derate max. current by 1% for every 100 m.
Degree of protection (enclosure): IP00

CHAPTER 3 - MODIFICATION
49'1335 e AMX DPS DC-POWER MODULE 9
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:
For
Rated
AC Volts
Set
Jumpers
between Fastons
Set
The
Phasing Transformer
Voltage
Parameter to
Set
The AC Line Voltage Parameter to the
rated AC Line voltage 1)
100 - 230 690 - 230 230 116 =< AC Line Voltage Param. <= 240
231 - 380 690 - 380 380 241 =< AC Line Voltage Param. <= 390
381 - 460 690 - 460 460 391 =< AC Line Voltage Param. <= 480
461 - 575 690 - 575 575 481 =< AC Line Voltage Param. <= 615
576 - 690 no 690 616 =< AC Line Voltage Param. <= 750
1) The set value must be inside the chosen range in this column regardless of the actual measured
voltage.
Example: For Rated AC Volts = 400V (381 – 460) and actual measured voltage = 385V
the
AC Line Voltage Parameter may be set to 400V or any other value between 391 and 480
but not to 385.

CHAPTER 4 - INSTALLATION AND CONNECTION
10 AMX DPS DC-POWER MODULE 49'1335 e
Assembly
Always observe the following requirements when
installing the Power Module in control cabinets:
- Comply with mandatory protection standards to
prevent contact with live components (covers)
and shock when a fault occurs (safe ground),
e.g. as per EN60204; Therefore the installation
should be done by instructed and qualified
electrical personnel only.
- Provide studs accord. to dimension sheets
Fig. 4-3 - 4-7.
- Leave space for hinge down the driver unit
- Leave a gap of at least 100 mm for the free
circulation of cooling air and to eliminate the
possibility of internal hot spots.
Ventilation
The cabinet ventilation must be designed so that
the air entry temperature in the heatsink does not
exceed 45 degree C (nominal operating
temperature) under maximum permissible
continuous current loading. If these temperature
limits cannot be maintained, a reduction in power
must be taken into account (1.5% per degree C
above 45 degree C).
CAUTION: The maximum permissible ambient
operating temperature of 55 deg. C
must never be exceeded
Resulting heat dissipated must be exhausted by
suitably dimensioned fans. Power dissipation
values depending on controller output current
can be calculated according to chapter 2.
Connection
Refer to the schematic diagrams Figures 1-2
and 1-3.
Transient suppression of contactor and relay
coils:
Switching of contactor and relay coils (also
valves, fan motors etc) causes transient voltages
of high frequency (bursts), which can disturb
electronic circuits.
NOTE:
A proved measure, to avoid potential problems,
is to provide suppression networks on all
contactor and relay coils of the drive equipment:
AC-coils with RC-units, DC-coils with diodes in
non conducting direction. In any case such coils,
which contacts are connected to the drive, or
which are actuated by contacts from the drive,
must be suppressed. If cabinet blowers or power
unit fans are switched, the RC-unit (part No.
215.02.00) must be connected across the
contact.

CHAPTER 4 - INSTALLATION AND CONNECTION
49'1335 e AMX DPS DC-POWER MODULE 11
Fig. 4-1: Connection Cables between PMI-Rack and Power Module Types 60A and 120A
P1
P2
P3
P4
X1
X2 X3
PMI-Rack
PFA
PDA/B
1
2
3
DC-Power
Technology
Fig. 4-2: Connection Cables between PMI-Rack and Power Module Types 250A - 2000A
P1
P2
P3
P4
X1
X3 X2
PMI-Rack
PFB/C/D
PDA/B
1
2
3
DC-Power
Technology
Cable Function Part No.
1 Armature Feedback 840.30.07
2 Armature Forward Gates 840.31.07
3 Armature Reverse Gates 840.32.07

CHAPTER 4 - INSTALLATION AND CONNECTION
12 AMX DPS DC-POWER MODULE 49'1335 e
Dimensions
194
225
215
X3
X2 X1
125 40
X3
X1
X2
8
350
155
155
6.3
DISTRIBUTED POWER SYSTEM
DC POWER MODUL E
194
225
215
80
430
X3
X2 X1
125 40
X3
X1
X2
8
350
155
155
6.3
DISTRIBUTED POWER SYSTEM
DC POWER MODULE
60A Unit (top) 120A Unit
Weight: 8.8 kg 12.0 kg
Cooling air: 187 m3/h
Air flow direction: from bottom to top
Minimum clearances for air circulation: 100 mm
Power connections
181-183 (U,V,W) terminals 16mm2bolts M8
45(D),47(C) terminals 35mm2 bolts M8
Protection earth PE1 bolt M5 bolt M8
Control connections terminals 4mm2 4mm2
Fig. 4-3: Dimensions, weight and drilling plan for Type 60A and 120A

CHAPTER 4 - INSTALLATION AND CONNECTION
49'1335 e AMX DPS DC-POWER MODULE 13
X2
X3 X1
a)
a)
195
216
125
=
=
550 500
220
2
7
0
44
44
44
44
9
165
350
126 48
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
Cooling air: 407 m3/h
Air flow direction: from bottom to top
Minimum clearances
for air circulation: 100 mm
Power connections: 250A Unit 450A Unit
Motor 45(D), 47(C) bus bars 25x5, bus bars 40x5,
drilling 11 mm drilling 14 mm
AC-Line 181(U), 182(V), 183(W) bus bars 20x5, bus bars 30x5,
drilling 11 mm drilling 14 mm
Prot. earth PE1 bolt M10 bolt M10
Fig. 4-4: Dimensions, weight and drilling plan for Type 250/450A

CHAPTER 4 - INSTALLATION AND CONNECTION
14 AMX DPS DC-POWER MODULE 49'1335 e
X2
X3 X1
a) a)
216 95
195
125
660
==65
66
434
175
75
75
306
636
9266
159
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
Cooling air: 814 m3/h
Air flow direction: from bottom to top (2 fans)
Minimum clearances
for air circulation: 100 mm
Power connections:
Motor 45(D), 47(C) bus bars 50x10, drilling 13.5 mm
AC-Line 181(U), 182(V), 183(W) bus bars 40x10, drilling 13.5 mm
Prot. earth PE1 bolt M12
Fig. 4-5: Dimensions, weight and drilling plan for Type 800A