Rockwell Automation Allen-Bradley PowerFlex SCR User manual

PowerFlex SCR Bus Supply
Firmware Version 1.xxx
User Manual

PowerFlex SCR 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 SCR Bus Supply User Manual
Publication 20S-UM001G-EN-P
Summary of Changes
The information below summarizes the changes made to this manual since
its last release (March 2011):
Description of Changes Page
In Chapter 1 in the “1000A SCR Bus Supply Flexibility” section:
•Added information and a table at the beginning to show which conversions are possible
and which are not possible.
•In the “Converting Master Unit to Slave Unit” subsection, added new steps 3 and 4.
•Deleted subsection “Converting Slave Unit to Master Unit” subsection.
1-16
1-16
In Appendix A in the “Accessories” section:
•Changed Table A.A cat. numbers for rows 256…509, and added new row for 939…1K0.
•Changed Table A.B cat. numbers for rows 256…509, and added new row for 939…1K0.
•Changed Table A.C cat. numbers for rows 256…509, and added new row for 939…1K0.
•Changed Table A.D cat. numbers for rows 256…509, and added new row for 939…1K0.
A-7
A-8
A-9
A-10
In Appendix A in the “HF Filter” section:
•Added new HF Filter Wiring Diagram Figure A.5.
•Added new subsection “Solid Ground Systems.”
•Added new subsection “Non-Solid Ground Systems.”
A-11
A-12
A-12
In Appendix A in the “Spare Parts” section:
•Added Important statement above Figure A.8.
•Added new “Availability” column to Table A.E
•Added Important statement above Figure A.9.
•Added new “Availability” column to Table A.F
•Added Important statement above Figure A.10.
•Added new “Availability” column and new footnote 1 to Table A.G
•Added new Figure A.11 to show locations of precharge and gate drive boards for 1000A
unit.
A-14
A-15
A-16
A-17
A-18
A-19
A-19
In Appendix A, revised Input Ratings “Operational AC Input Voltage Range” for catalog
number 20SF1K0… from “269…759V” to “528…759V.”
A-1
Added new Appendix B. B-1

soc-ii Summary of Changes
PowerFlex SCR Bus Supply User Manual
Publication 20S-UM001G-EN-P

PowerFlex SCR Bus Supply User Manual
Publication 20S-UM001G-EN-P
Table of Contents
Preface Overview
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
Chapter 1 Installation/Wiring
Opening the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Jumper Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Disconnecting MOVs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Parallel Connection of Slave Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1000A SCR Bus Supply Flexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1000A SCR Bus Supply Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
SCR Bus Supply 12-Pulse Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Chapter 2 Start Up/Troubleshooting
Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Precharge Board LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Appendix A Specifications
PowerFlex SCR Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Bus Supply Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Appendix B History of Changes
20S-UM001F-EN-P, March 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Index

ii Table of Contents
PowerFlex SCR Bus Supply User Manual
Publication 20S-UM001G-EN-P

PowerFlex SCR Bus Supply User Manual
Publication 20S-UM001G-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 SCR Bus Supply.
Who Should Use this
Manual?
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
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
Descriptions and Schematic Diagrams 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: Refer to: 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 SCR Bus Supply User Manual
Publication 20S-UM001G-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 SRC Bus Supply technical support.
Conventions Used in This
Manual
•In this manual we may refer to the PowerFlex SCR Bus Supply as SCR
Bus Supply or Bus Supply.
•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.
•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: Refer to: Publication
Online… By Email… 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 SCR Bus Supply User Manual
Publication 20S-UM001G-EN-P
General Precautions
!
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 discharged 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.

P-4 Overview
PowerFlex SCR Bus Supply User Manual
Publication 20S-UM001G-EN-P
Catalog Number
Explanation
Important:PowerFlex SCR Bus Supply 1000A units with Master or Slave
configuration are available for 400/480 and 600/690 Volts.
Position Number
1-3 4 5-7 8 9 10
20S D 400 N E N
ab 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 & Shipping Carton
Code User Manual Carton
E English Yes
f
Configuration
Code Type
N Stand Alone
M Master (1000A only)
S Slave (1000A only)