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)