Rockwell Automation Allen-Bradley PowerFlex 4M User manual

PowerFlex Diode Bus Supply
User Manual

PowerFlex Diode Bus Supply User Manual
Important User Information 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 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.
Important: Identifies information that is critical for successful application and
understanding of the product.
Allen-Bradley and PowerFlex are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
!
WARNING: Identifies information about practices or
circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property
damage, or economic loss.
!
ATTENTION: Identifies information about practices or
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.
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.

PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Summary of Changes
The information below summarizes the changes made to this manual since
its last release (September 2006):
Description of Changes Page
Reformatted document from half size (5.5 x 8.5 in.) to full size (8.5 x 11 in.) Throughout
manual
In Chapter 1:
•Revised the subsection “Ambient Operating Temperatures” to include more
information.
•At the beginning of the section “Power Wiring,” added a recommendation to keep all
wired connections identical in size and length to maintain balanced impedance.
•In the section “Disconnecting MOVs and RFI Filter Capacitors,” added new Table 1.E,
Recommended MOV Configurations.
1-2
1-6
1-10
In Chapter 2:
•In the subsection “Before Applying Power to the Diode Bus Supply,” added new steps
2 and 5.
•In Table 2.A, Possible Faults and Corrective Actions, added a corrective action and
revised others.
2-2
2-3
In Appendix A:
•In the section “Line Reactors,” added introductory information.
•Added the new section “Spare Parts.”
A-5
A-5
Added the new Appendix B, History of Changes.” B-1

soc-ii Summary of Changes
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Notes:

PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Table of Contents
Preface Overview
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Reference Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
General Drive Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Specific Drive Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Description and Schematic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Chapter 1 Installation/Wiring
Opening the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Ambient Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Unbalanced or Non-Solid Grounded Distribution Systems. . . . . . . . . . . . . . . . . . . . . 1-3
General Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Ground Terminal - PE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
RFI Filter Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Maximum Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
AC Input Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Cable Types Acceptable for 200…600 Volt Installations . . . . . . . . . . . . . . . . . . . . . . 1-6
EMC Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Cable Trays and Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
DC Bus Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Bus Supply Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Drive Run Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Control Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Disconnecting MOVs and RFI Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Paralleling Diode Bus Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Low Voltage Directive (73/23/EEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
EMC Directive (89/336/EEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Harmonic Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Essential Requirements for CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Chapter 2 Start Up/Troubleshooting
Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Before Applying Power to the Diode Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Applying AC Power to the Diode Bus Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Power On LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

ii Table of Contents
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Appendix A Supplemental Information
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
AC Input Fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Fuse Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Line Reactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Appendix B History of Changes
20T-UM001C-EN-P, September 2006. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Index

PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Preface
Overview
The purpose of this manual is to provide you with the basic information
needed to install, start up, and troubleshoot the PowerFlex™ Diode Bus
Supply.
Who Should Use this
Manual?
This manual is intended for personnel that are qualified to install, program,
and operate adjustable frequency AC drives and their use in common DC
bus systems.
Reference Documentation General Drive Information
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.
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
Description and Schematic Diagram P-5
Title Publication
Wiring and Grounding Guidelines for PWM AC Drives DRIVES-IN001
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
For See Publication
PowerFlex®70/70EC Drive PowerFlex 70 User Manual
PowerFlex 70/700 Reference Manual
PowerFlex 70EC/700VC Reference Manual
20A-UM001
PFLEX-RM001
PFLEX-RM004
PowerFlex®700/700VC Series A Drive
PowerFlex®700VC Series B Drive
PowerFlex 700 Series A User Manual
PowerFlex 700 Series B User Manual
PowerFlex 70/700 Reference Manual
PowerFlex 70EC/700VC Reference Manual
20B-UM001
20B-UM002
PFLEX-RM001
PFLEX-RM004

P-2 Overview
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Documentation 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 & 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 Diode Bus Supply technical support.
Conventions Used in This
Manual
•In this manual we may refer to the PowerFlex Diode Bus Supply as
Diode Bus Supply or Bus Supply.
•The following words may be used throughout the manual to describe an
action:
PowerFlex®700H Drive PowerFlex 700H Installation Instructions
PowerFlex 700H Programming Manual
PFLEX-IN006
20C-PM001
PowerFlex®700S Drive PowerFlex 700S with Phase I Control Installation Manual (Frames 1…6)
PowerFlex 700S with Phase I Control Installation Manual (Frames 9 and 10)
PowerFlex 700S with Phase I Control User Manual (All Frame Sizes)
PowerFlex 700S with Phase I Control Reference Manual
PowerFlex 700S with Phase II Control Installation Manual (Frames 1…6)
PowerFlex 700S with Phase II Control Installation Manual (Frames 9…14)
PowerFlex 700S with Phase II Control Programming Manual (All Frame Sizes)
PowerFlex 700S with Phase II Control Reference Manual
20D-IN024
PFLEX-IN006
20D-UM001
PFLEX-RM002
20D-IN024
PFLEX-IN006
20D-PM006
PFLEX-RM003
PowerFlex®750-Series AC Drive PowerFlex 750-Series Drive Installation Instructions
PowerFlex 750-Series Drive Programming Manual
PowerFlex 750-Series Reference Manual
750-IN001
750-PM001
750-RM002
For See Publication
Online By E-mail By Telephone
www.ab.com/support/abdrives [e-mail] 262-512-8176
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

Overview P-3
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
General Precautions
!
ATTENTION: The Diode Bus Supply contains electrostatic
discharge (ESD) 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, see Guarding Against Electrostatic
Damage, publication 8000-4.5.2, or any other applicable ESD
protection handbook.
!
ATTENTION: An incorrectly applied or installed Diode 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: Only connect Rockwell Automation common DC
bus drives with built-in precharge circuitry to the common DC bus
output terminals of the Diode Bus Supply within the load rating
guidelines. See Specific Drive Information earlier in this Preface
for available drives.
!
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 discharged before performing
any work on the Diode Bus Supply. Measure the DC bus voltage at
the +DC and -DC output terminals. The voltage must be zero.
!
ATTENTION: National Codes and standards (NEC, VDE, BSI,
and so forth) 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.

P-4 Overview
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Catalog Number
Explanation
Position Number
1-3 4 5-7 8 9
20T D 120 A E
abcde
a
Product
Code Type
20T PowerFlex Diode Bus Supply
b
Voltage Rating
Code Input Voltage Phase DC Output
D 240/480V AC 3 325…650V DC
E 500/600V AC 3 675…810V DC
c
Current Rating
Code Output Frame (1)
(1) PowerFlex 700 drive equivalent frame size.
120 120.0 Amp 2
d
Enclosure
Code Rating
A NEMA Type 1 / IP20
e
Documentation & Shipping Carton
Code User Manual Carton
E English Yes

Overview P-5
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Description and Schematic
Diagram
The Diode Bus Supply is a single-direction power converter for the front
end of common DC bus drive systems. It converts the incoming 3-phase AC
line voltage to a common DC bus voltage.
Figure P.1 Diode Bus Supply Schematic Diagram
The primary electrical components for the Diode Bus Supply are listed
below.
NOTE: Components ➌, ➍, and ➎compose a Radio Frequency Interference
Filter (RFI), which meets the EMC requirements of Product Standard
61800-3 for industrial environments.
Item Description
➊Six-Pulse, Full-Wave, 3-Phase DIode Bridge Rectifier Unit directly connected to the three
line input terminals.
➋Bus Supply Overtemperature Sensors, located in the heat sink, are used for thermal
protection of the diode-bridge rectifier.
➌DC Chokes (L1, L2) to reduce conducted HF-emissions. They also reduce line harmonics and
peak currents in the AC line and the bridge circuit.
➍Input Filter Capacitors connected to the three input phases to reduce conducted
HF-emissions.
➎Common Mode Capacitors connected to the DC bus to reduce conducted HF-emissions.
➏DC Bus Snubber Circuit for dampening and limiting overvoltages.
➐MOV Circuit connected to the three input phases.
➑Cooling Fans connected to the 24V DC supply on the Power Supply (DFPS Board).
+DC
-DC
S/L2
R/L1
T/L3
L1
L2
J4
89
TB1
TB1
GND
12
PE
J3 J1 J6 J2
741 21 5 1 1 4
DC
DFPS Board
24V
M1 M2
MOV
10
11
TB1
>˚C
F1
>˚C
F2
To
Common
DC Bus
To
Earth
Ground
To
Incoming
3ø Power
➋
➌
➊
➑
➐➏
➍➎

P-6 Overview
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Notes:

PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Chapter 1
Installation/Wiring
This chapter provides information on the installation and wiring of the
PowerFlex Diode Bus Supply.
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.
Opening the Cover
Topic Page
Opening the Cover 1-1
Minimum Mounting Clearances 1-2
AC Supply Source Considerations 1-3
General Grounding Requirements 1-4
Maximum Loading 1-5
AC Input Fusing 1-5
Power Wiring 1-6
Control Wiring 1-8
Disconnecting MOVs and RFI Filter Capacitors 1-10
Paralleling Diode Bus Supplies 1-11
CE Conformity 1-12
!
ATTENTION: The following information is merely a guide for
proper installation. Rockwell Automation, Inc. cannot assume
responsibility for the compliance or the noncompliance to any
code, national, local or otherwise for the proper installation of this
product or associated equipment. A hazard of personal injury and/
or equipment damage exists if codes are ignored during
installation.
➊➊
➋➋
➊Loosen the two cover
fastening screws at
the bottom edge.
➋Pull the cover straight
off the two spring clips
at the top edge.

1-2 Installation/Wiring
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Minimum Mounting
Clearances
Ambient Operating Temperatures
The Diode Bus Supply is designed to operate at 0…40 °C (32…104 °F)
ambient without derating. Remove the label from the top to operate the
Diode Bus Supply in ambients 41 °C up to 50 °C (104 °F up to 122 °F).
Important:Removing the adhesive label changes the enclosure rating from
NEMA Type 1 Enclosed to Open Type. This also changes the
side-to-side mounting clearance requirement.
Ensure that proper cooling is provided to the Diode Bus Supply to stay
under the 40 °C rated specification. 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 Diode Bus Supply watt loss (from specification section) is 500 W at
120 A. The three-phase AC line reactor watt losses are listed in the 1321
Power Conditioning Products Technical Data, publication 1321-TD001.
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.
100 (4)
100 (4)
100 (4)
100 (4)
50 (2)
50 (2)
No Adhesive Label on Top With Adhesive Label on Top
Dimensions are in millimeters and (inches).
See Appendix A for detailed dimension information.

Installation/Wiring 1-3
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
AC Supply Source
Considerations
The Diode Bus Supply is suitable for use on a circuit capable of delivering a
short circuit rating up to a maximum of 200,000 rms symmetrical amperes,
and a maximum of 600 volts.
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.
Input Power Conditioning
Certain events on the power system supplying a bus supply can cause
component damage or shortened product life. These conditions include:
•The power system has power factor correction capacitors switched in and
out of the system, either by the user or by the power company.
•The power source has intermittent voltage spikes in excess of 6000 volts.
These spikes could be caused by other equipment on the line or by events
such as lightening strikes.
•The power source has frequent interruptions.
•The nearest supply transformer is larger than 1000 kVA.
If any or all of these conditions exist, it is recommended that the user install
a minimum amount of impedance between the Diode Bus Supply and the
source. This impedance could come from the supply transformer itself, the
cable between the transformer and Diode Bus Supply, or an additional
transformer or reactor.
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,
see the Wiring and Grounding Guidelines for Pulse Width Modulated
(PWM) AC Drives, publication DRIVES-IN001.
!
ATTENTION: To guard against personal injury and/or
equipment damage caused by improper fusing or circuit breaker
selection, use only the recommended line fuses/circuit breakers
specified in Appendix A.
!
ATTENTION: The Diode Bus Supply contains protective MOVs,
and input filter and common mode capacitors that are referenced to
ground. These devices should be disconnected from ground if the
Diode Bus Supply is installed on any non-solid grounded power
distribution system (IT-network). For jumper locations, see Figure
1.2 on page 1-7.

1-4 Installation/Wiring
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
General Grounding
Requirements
Safety Ground Terminal - PE
The Safety Ground terminal (PE) must be connected to the building
grounding scheme. Ground impedance must conform to the requirements
of national and local industrial safety regulations and/or electrical codes.
This is the safety ground for the Diode Bus Supply. The integrity of all
ground connections should be periodically checked.
For installations within a cabinet, a single safety ground point or ground bus
bar connected directly to building steel (girder, joist), a floor ground rod,
bus bar or building ground grid should be used. All circuits including the
AC input ground conductor should be grounded independently and directly
to this point/bar.
Figure 1.1 Typical Grounding
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
checked. See the instructions supplied with the filter.
+DC
- DC
R (L1)
S (L2)
T (L3)
PE
Ground Grid, Girder or Ground
Rod (Building Ground Potential)

Installation/Wiring 1-5
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Maximum Loading To avoid overloading the Diode Bus Supply, the following requirement
applies:
The DC Input current sum (Normal Duty or Heavy Duty rating at 40 °C/
104 °F) of the connected drive(s) must not exceed the Bus Supply
continuous DC Bus output current rating of 120 amps at 40 °C/104 °F.
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
Diode Bus Supply. No overload capability is built into the tables.
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 Diode Bus Supply.
Table 1.A Normal Duty ND
Table 1.B Heavy Duty HD
AC Input Fusing The Diode Bus Supply can be installed with delay type AC input line fuses.
National and local industrial safety regulations and/or electrical codes may
determine additional requirements for these installations.
TIP: When paralleling two Diode Bus Supplies, see Paralleling Diode Bus
Supplies on page 1-11 for details.
Drive Rating Drive DC Input Current Diode Bus Supply (1)
(1) No overload capability.
DC
Voltage
ND
Power
ND DC Input
Currents
ND DC Input
Current Sum
Maximum DC
Output Amps
AC Input
Voltage
540V 30 + 22 = 52 kW 61.9 + 47.5 109.4 A 120 A 400V
650V 2 x 40 = 80 Hp 2 x 55.7 111.4 A 120 A 480V
Drive Rating Drive DC Input Current Diode Bus Supply (1)
(1) No overload capability.
DC
Voltage
HD
Power
HD DC Input
Currents
HD DC Input
Current Sum
Maximum DC
Output Amps
AC Input
Voltage
540V 37 + 2 x 1.5 = 40 kW 95.1 + 2 x 5.3 105.7 A 120 A 400V
!
ATTENTION: The PowerFlex Diode Bus Supply does not
provide branch short circuit protection. Specifications for the
recommended fusing to provide protection against short circuits
are provided in Table A.A on page A-4.

1-6 Installation/Wiring
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Power Wiring
To maintain balanced impedance, and thus balance current in the Diode Bus
Supply, it is recommended to keep all wired 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 Diode Bus Supply.
Cable Types Acceptable for 200…600 Volt Installations
A variety of cable types are acceptable for Diode Bus Supply installations.
For many installations, unshielded cable is adequate, provided it can be
separated from sensitive circuits. As an approximate guide, allow a spacing
of 0.3 meters (1 foot) for every 10 meters (33 feet) of length. In all cases,
long parallel runs must be avoided. Do not use cable with an insulation
thickness less than or equal to 15 mils (0.4 mm/0.015 in.). UL installations
in 50 °C (122 °F) ambient must use 600V, 90 °C (194 °F) wire. UL
installations in 40 °C (104 °F) ambient should use 600V, 75 °C (168 °F)
wire.
THHN, THWN or similar wire is acceptable for Diode Bus Supply
installation in dry environments provided adequate free air space and/or
conduit fill rate limits are provided. Do not use THHN or similarly coated
wire in wet areas.
EMC Compliance
Refer to CE Conformity on page 1-12 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: National Codes and standards (NEC, VDE, BSI,
etc.) and local codes outline provisions for safely installing
electrical equipment. Installation must comply with specifications
regarding wire types, conductor sizes, and disconnect devices.
Failure to do so may result in personal injury and/or equipment
damage.
!
ATTENTION: To avoid a possible shock hazard caused by
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.

Installation/Wiring 1-7
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
DC Bus Wiring Guidelines
For DC Bus wiring guidelines, refer to AC Drives in Common Bus
Configurations, publication DRIVES-AT002.
Bus Supply Terminals
Figure 1.2 Terminal and Jumper Locations
Table 1.C Terminal Specifications and Jumper Information
Item Description
Wire Size Range (1)
(1) Maximum/minimum sizes that the terminals will accept - these are not recommendations.
Torque
Maximum Minimum
➊AC Line Input L1, L2, L3
35 mm2
(2 AWG)
0.75 mm2
(18 AWG)
3.3 N•m
(20 lb•in)
➋PE (Protective Earth) Terminal
➌DC Bus Terminals (DC+, DC-)
➍Control Terminals 8…11 2.5 mm2
(14 AWG)
0.25 mm2
(22 AWG)
0.8 N•m
(7 lb•in)
➎Control Terminals 12 and GND
(MOV neutral disconnect; see page 1-10)
➏Jumper J4, see Disconnecting MOVs and RFI Filter Capacitors on page 1-10
J4
J1 J2 J6 J3
L1 L2
8
9
11
10
AAAA AA
DC + DC -
AAA
L1 L2 L3
BB BB
GND
12
AA
MOV
F1
A
B
A
F2
B
AC
B
B
AC AC
A DC +
ADC -
V1 V2 V3
FAN1 FAN2
(PE)
➊
➎
➋
➌
➍
➏

1-8 Installation/Wiring
PowerFlex Diode Bus Supply User Manual
Publication 20T-UM001D-EN-P
Figure 1.3 Power and Control Terminals
Control Wiring Important points to remember about control wiring:
•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.
•Wire with an insulation rating of 600V or greater is recommended.
•Control wires outside the cabinet should be separated from power wires
by at least 0.3 meters (1 foot).
Drive Run Interlock
To protect the Diode Bus Supply from overtemperature, the normally closed
contacts (Bus Supply Overtemperature - terminals 10 and 11) should be
wired to either the AC line input contactor for the Diode 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.
PE
8 9
11 10
DC + DC - R (L1) S (L2) T (L3)
GND
12
MOV
Terminal Description Notes
Power Connections
DC + DC Bus (+) DC Bus Connection (+)
DC - DC Bus (-) DC Bus Connection (–)
PE PE Ground Safety Ground
R R (L1) AC Line Input Power
S S (L2) AC Line Input Power
T T (L3) AC Line Input Power
Control Connections
8 24V Fan Supply Internal connection to extend fan supply leads
(must be disconnected in case of fan replacement)
9
10 NC Contact Output
(F1, F2)
Opens with power stack overtemperature.
(See Appendix A for contact ratings.)
11
12 Jumper
MOVs to Ground
Disconnect MOV neutral point and ground by removing this
jumper. (See page 1-10 for details.)
GND