Rockwell Automation PowerFlex 40P Frame B, Frame C, PowerFlex 520-Series Frame A, B, and C, Frame D, Frame E, PowerFlex 70 Frame E, PowerFlex 700 Frame 0…4, Frame 5 and 6, Frame 7…10, Frame 7…10, PowerFlex 700S Frame 0…4, Frame 5 and 6 Application Guidelines

Application Guidelines

Drives in Common Bus Configurations

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

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.

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 consequence.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Allen-Bradley, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Summary of Changes

This manual contains new and updated information.

New and Updated

Information

This table contains the changes made to this revision.

Topic

In Chapter 1 in the Precharge section, added new subsections for:

• PowerFlex 520-Series Frame A, B, and C AC Drives

• PowerFlex 520-Series Frame D AC Drives

• PowerFlex 520-Series Frame E AC Drives

• PowerFlex 750-Series Frame 8…10 AC Input ‘Stand-alone’ Drives.

• PowerFlex 750-Series Frame 8…10 DC Input ‘Common Bus’ Drives.

In Chapter 2, expanded PowerFlex SCR Bus Supply section by adding information on solid ground, high resistance ground, and ungrounded systems.

In Chapter 3:

• Moved 1336 and AK DBU brake devices information to new Appendix C.

• Expanded PowerFlex SCR Bus Supply section by adding information on solid ground, high resistance ground, and ungrounded systems.

In Chapter 7, moved 1336 and AK DBU brake devices information to new Appendix D.

In Chapter 8, removed 1336REGEN bus supply information, and added new diagrams and related tables.

In Chapter 9, added new diagrams and related tables.

In Chapter 10, updated diagram and related table.

Deleted Chapters 11 and 12, and moved information on the 1336 REGEN bus supply to new Appendix C.

In Appendix A, added fusing tables for the following drives:

• 325V DC Input Fuses for PowerFlex 520-Series drives.

• 540V DC Input Fuses for PowerFlex 520-Series drives.

• 650V DC Input Fuses for PowerFlex 520-Series drives.

• 810V DC Input Fuses for PowerFlex 520-Series drives.

• 540V DC Input Fuses for PowerFlex 750-Series Frame 1…7 drives

• 540V DC Input Fuses for PowerFlex 750-Series Frame 8…10 drives.

• 650V DC Input Fuses for PowerFlex 750-Series Frame 1…7 drives.

• 650V DC Input Fuses for PowerFlex 750-Series Frame 8…10 drives.

• 810V DC Input Fuses for PowerFlex 750-Series Frame 3…7 drives.

• 810V DC Input Fuses for PowerFlex 750-Series Frame 8…10 drives.

• 932V DC Input Fuses for PowerFlex 750-Series Frame 6 and7 drives.

• 932V DC Input Fuses for PowerFlex 750-Series Frame 8…10 drives.

In Appendix B, added the following new sections:

• Common Mode Core

• DC Bus Conditioners—Designs A, B, C, D, or E

• DC Bus Clamp—Designs F or G

• Ground Fault Indicator Filter

• Zig-Zag Transformer

Added new Appendix C, 1336 REGEN Drives.

Added new Appendix D, 1336 and AK DBU Brake Devices.

Page

19

19

20

23

25

31

39

87

97

71

77

145

107

108

116

117

102

104

111

118

122

123

127

128

136

139

142

143

144

145

159

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

3

Summary of Changes

Notes:

4

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Table of Contents

Preface

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Definitions of Common Bus Configurations . . . . . . . . . . . . . . . . . . . . . . . 11

Common DC Bus—Non-regenerative . . . . . . . . . . . . . . . . . . . . . . . . . 11

Common DC Bus—Non-regenerative with Braking Chopper . . . 11

Shared AC/DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Shared AC/DC Bus—with Braking Chopper. . . . . . . . . . . . . . . . . . . 11

Shared DC Bus (Piggy Back) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Shared DC Bus (Piggy Back)—with Braking Chopper . . . . . . . . . . . 12

Regenerative Bus Supply (Active Front End). . . . . . . . . . . . . . . . . . . . 12

Regenerative Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Shared Regenerative Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Parallel Regenerative Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Technical Support (SupportPlus™). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

General Considerations

Chapter 1

DC Bus Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Drive Line-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

DC Bus Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

PowerFlex 40P Frame B AC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

PowerFlex 40P Frame C AC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

PowerFlex 520-Series Frame A, B, and C AC Drives. . . . . . . . . . . . . 19

PowerFlex 520-Series Frame D AC Drives . . . . . . . . . . . . . . . . . . . . . . 19

PowerFlex 520-Series Frame E AC Drives . . . . . . . . . . . . . . . . . . . . . . 20

PowerFlex 70 Frame E, PowerFlex 700/700S Frame 0…4, and PowerFlex 750-Series Frame 1…4 AC Drives . . . . . . . . . . 20

PowerFlex 700/700S Frame 5 and 6, and PowerFlex 700

Frame 7…10 AC Input ‘Stand-alone’ Drives. . . . . . . . . . . . . . . 21

PowerFlex 700H/700S Frame 9…14 AC Input

‘Stand-alone’ Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

PowerFlex 750-Series Frame 5…7 AC Drives . . . . . . . . . . . . . . . . . . . 22

PowerFlex 750-Series Frame 8…10 AC Input

‘Stand-alone’ Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

PowerFlex 700/700S Frame 5 and 6, and PowerFlex 700

Frame 7…10 DC Input ‘Common Bus’ Drives . . . . . . . . . . . . 23

PowerFlex 700H/700S Frame 9…14 DC Input

‘Common Bus’ Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

PowerFlex 750-Series Frame 5…7 DC Input

‘Common Bus’ Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

PowerFlex 750-Series Frame 8…10 DC Input

‘Common Bus’ Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

PowerFlex 700L Frame 2, 3A, and 3B AC Input

‘Stand-alone’ Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

5

Table of Contents

Common DC Bus Configuration—

Non-Regenerative

PowerFlex 700L Frame 3A and 3B DC Input

‘Common Bus’ Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Kinetix 7000 Catalog Number BM06…BM08 Servo Drives . . . . . . 27

Kinetix 7000 Catalog Number BM09…BM12 Servo Drives . . . . . . 27

Kinetix 6000 Bxxx-Series and Kinetix 6200/6500

Multi-Axis Servo Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Chapter 2

System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Supported Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Typical System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

PowerFlex Diode Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

PowerFlex SCR Bus Supply in Solid Ground System . . . . . . . . . . . . . 31

PowerFlex SCR Bus Supply in High Resistance Ground System . . 32

PowerFlex SCR Bus Supply in Ungrounded System. . . . . . . . . . . . . . 33

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

PowerFlex Diode Bus Supply Considerations . . . . . . . . . . . . . . . . . . . . . . . 35

PowerFlex SCR Bus Supply Considerations. . . . . . . . . . . . . . . . . . . . . . . . . 35

Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

PowerFlex Diode Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

PowerFlex SCR Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

DC Input Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

PowerFlex Diode Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

PowerFlex SCR Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6

Common DC Bus Configuration—

Non-Regenerative with Braking DC

Bus Regulation

Chapter 3

System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Supported Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Typical System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Brake Chopper Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Drive Internal Brake IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

PowerFlex Diode Bus Supply Considerations . . . . . . . . . . . . . . . . . . . . . . . 47

PowerFlex SCR Bus Supply Considerations. . . . . . . . . . . . . . . . . . . . . . . . . 48

Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Drive Internal Brake IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Bus Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

DC Input Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

PowerFlex Diode Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

PowerFlex SCR Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Table of Contents

Shared AC/DC Bus Configuration

Shared AC/DC Bus Configuration— with Braking DC Bus Regulation

Chapter 4

System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Supported Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Typical System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

AC Drives of Different Frame Sizes from the Same Product Line . 52

Same Frame Size AC Drives from Same Product Line . . . . . . . . . . . 53

PowerFlex 40P or PowerFlex 520-Series Drives . . . . . . . . . . . . . . . . . 55

General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Different Frame Size Drive Considerations. . . . . . . . . . . . . . . . . . . . . . . . . 56

Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Same Frame Size Drive Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

PowerFlex 40P or PowerFlex 520-Series Drive Considerations . . . . . . . 57

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Chapter 5

System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Supported Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Typical System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Different Size Drive Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Same Size Drive Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

PowerFlex 40P or PowerFlex 520-Series Drive Considerations . . . . . . . 65

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Shared DC Bus Configuration (Piggy

Back)

Chapter 6

System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Supported Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Typical System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

PowerFlex 40P or PowerFlex 520-Series Drive Considerations . . . . . . . 69

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Chapter 7

Shared DC Bus Configuration (Piggy

Back)—with Braking Chopper

System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Supported Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Typical System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

PowerFlex 40P or PowerFlex 520-Series Drive Considerations . . . . . . . 75

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

7

Table of Contents

8

Regenerative Bus Supply

Configuration

Multiple Regenerative Bus Supply

Configurations

Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Chapter 8

System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Supported Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Typical System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Solid Ground System with Single AFE and Single AC Drive. . . . . . 78

Solid Ground System with Single AFE and Multiple AC Drives . . 79

High Resistance Ground System with Single AFE and

Single AC Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

High Resistance Ground System with Single AFE and

Multiple AC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Ungrounded System with Single AFE and Single AC Drive . . . . . . 82

Ungrounded System with Single AFE and Multiple AC Drives . . . 83

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

DC Input Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

PowerFlex Active Front End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Chapter 9

System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Supported Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Typical System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Solid Ground System with Multiple AFEs and Single AC Drive . . 88

Solid Ground System with Multiple AFEs and

Multiple AC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

High Resistance Ground System with Multiple AFEs and

Single AC Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

High Resistance Ground System with Multiple AFEs and

Multiple AC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Ungrounded System with Multiple AFEs and Single AC Drive . . . 92

Ungrounded System with Multiple AFEs and

Multiple AC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

PowerFlex Active Front End Considerations. . . . . . . . . . . . . . . . . . . . . . . . 94

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

DC Input Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

PowerFlex Active Front End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Table of Contents

Paralleling Regenerative Bus

Supplies (AFEs) with One or More Non-

Regenerative PowerFlex SCR Bus

Supplies

Chapter 10

System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Supported Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Typical System Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

PowerFlex Active Front End and PowerFlex SCR Bus Supply

Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

DC Input Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

PowerFlex SCR Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

PowerFlex Active Front End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

PowerFlex Drive Ratings,

Recommended DC Bus Fuses, and

Drive DC Bus Capacitance

Appendix A

325 Volt DC Input Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

540 Volt DC Input Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

650 Volt DC Input Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

810 Volt DC Input Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

932 Volt DC Input Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Fuse Certification and Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

JKS Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

170M Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Power Component Accessories

Appendix B

Back-to-Back Diodes (Shared AC/DC Configurations) . . . . . . . . . . . . 133

Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Diode Sharing Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

HF Filter (SCR Bus Supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Bus Supply Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

SCR Bus Supply Minimum Capacitance. . . . . . . . . . . . . . . . . . . . . . . 134

Connecting High Power Drives and Low Power Drives on the DC Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

RC Snubber Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Common Mode Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Usage With SCR Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Usage With AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

External Drive Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Internal Drive Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

DC Bus Conditioner—Designs A, B, C, D, or E . . . . . . . . . . . . . . . . . . . 139

Design A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Design B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Design C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Design D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Design E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

9

Table of Contents

1336 REGEN Drives

1336 and AK DBU Brake Devices

DC Bus Clamp—Design F or G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Design F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Design G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Ground Fault Indicator Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Zig-Zag Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Appendix C

Supported Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Typical System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

1336 REGEN Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

AC Input 1336 REGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

1336 REGEN Drive in Regenerative Braking Configuration . . . . . . . . 150

System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Supported Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Typical System Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

1336 REGEN Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

1336 REGEN Drive in Shared Regenerative Braking Configuration . 154

System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Supported Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Typical System Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

1336 REGEN Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

PowerFlex 40P Drive Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . 156

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Appendix D

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

10

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Preface

Introduction

An increasing number of drive systems in a wide range of applications and power ranges are being configured today in common bus configurations. These common bus drive system configurations provide significant advantages such as, design flexibility, higher efficiency, and cost savings.

It is the objective of this publication to provide the necessary guidelines, considerations, and limitations for the proper application of PowerFlex drives used in common bus configurations.

For Allen-Bradley common bus standard products, see the Common DC Bus

Selection Guide, publication DRIVES-SG001.

Definitions of Common Bus

Configurations

Common DC Bus—Non-regenerative

Three-phase diode, SCR bridge front-end, or a combination of these two. A single-direction power flow, full-wave bridge converts 3-phase AC voltage to a fixed DC bus voltage. One or more drives are connected through the DC bus.

Common DC Bus—Non-regenerative with Braking Chopper

Same as Non-regenerative, but with an added resistive braking module to dissipate excess regenerative DC bus energy.

Shared AC/DC Bus

Stand alone drives fed by a common 3-phase AC voltage source with the DC bus of each drive connected together.

Shared AC/DC Bus—with Braking Chopper

Same as Shared AC/DC Bus, but with an added resistive braking module to dissipate excess regenerative DC bus energy.

Shared DC Bus (Piggy Back)

One stand-alone drive is used as the common converter section for multiple shared DC bus drives. The incoming AC power is fed to the drive used as the common converter only. The drive used as the common converter sources DC power to the smaller drive or drives through the DC link connections.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

11

Preface

Shared DC Bus (Piggy Back)—with Braking Chopper

Same as Shared DC Bus, but with an added resistive braking module to dissipate excess regenerative DC bus energy.

Regenerative Bus Supply (Active Front End)

A Pulse Width Modulated (PWM) controlled IGBT converter enables regeneration to the AC line. One or more drives are connected to the DC bus. An

Active Front End can be connected in parallel to a non-regenerative converter.

Regenerative Braking

A regenerative brake enables regeneration to the AC line. In this configuration, the drive has a connection to the AC line and draws the majority of the motoring power.

Shared Regenerative Braking

Similar to the Regenerative Braking configuration, except multiple drives are connected to a single regenerative unit. Steering diodes are used to control flow of current.

Parallel Regenerative Braking

12

Reference Materials

Similar to the Regenerative Braking configuration, except multiple regenerative units are connected to a single drive.

The following publications provide useful information when planning and installing common bus products.

Product

1336-WA / -WB / -WC Brake Chopper Module

See

Installation Instructions

1336-MOD-KA / -KB / -KC Heavy Duty Dynamic Braking Installation Instructions

AK DBU Dynamic Braking Unit AK DBU Dynamic Braking Unit 600/690 VAC User Manual

20S SCR Bus Supply PowerFlex SCR Bus Supply User Manual

PowerFlex Diode Bus Supply User Manual

®

40P Drive

20T Diode Bus Supply

PowerFlex

PowerFlex 520-Series Drive

PowerFlex 40P User Manual

PowerFlex 40P Quick Start

PowerFlex 520-Series Adjustable Frequency AC Drive User Manual

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Publication

1336-5.65

1336-5.64

AKDBU-UM001

20S-UM001

20T-UM001

22D-UM001

22D-QS001

520-UM001

PowerFlex 700/700VC Series A Drive

PowerFlex 700VC Series B Drive

PowerFlex 700H Drive

PowerFlex 700S Drive

PowerFlex 700L Drive

PowerFlex 750-Series Drive

PowerFlex AFE/PowerFlex 700AFE

1336 REGEN Drive

1321 Line Reactor & Isolation Transformers

Kinetix 7000 Servo Drive

Kinetix 6000 Multi-Axis Servo Drive

Kinetix 6200/6500 Modular Multi-Axis Servo Drives

PowerFlex 700 Series A User Manual

PowerFlex 700 Series B User Manual

PowerFlex 70/700 Reference Manual

PowerFlex 70EC/700VC Reference Manual

PowerFlex 700 Technical Data

PowerFlex Dynamic Braking Resistor Calculator

PowerFlex 700H Installation Instructions

PowerFlex 700H Programming Manual

PowerFlex 700H Technical Data

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 I Control Technical Data

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

PowerFlex 700S with Phase II Control Technical Data

PowerFlex Dynamic Braking Resistor Calculator

PowerFlex 700L Liquid-Cooled Drive User Manual

PowerFlex 700L Active Converter Power Module User Manual

For Vector Control, see PowerFlex 700 Series B User Manual

For Phase II Control, see PowerFlex 700S w/Phase II Control Programming Manual

PowerFlex 750-Series Drive Installation Instructions

PowerFlex 750-Series EMC Plate and Core(s) - Frames 1…7 Installation Instructions

PowerFlex 755 AC Drives EMC Cores Installation Instructions

PowerFlex 750-Series Drive Programming Manual

PowerFlex 750-Series Drive Technical Data

PowerFlex Active Front End User Manual

Line Regeneration Package User Manual

Line Reactor and Isolation Transformer Technical Data

1321-M Common Mode Chokes Instructions

Kinetix 7000 Installation Instructions

Kinetix 7000 User Manual

Kinetix 6000 Installation Instructions

Kinetix 6000 User Manual

Kinetix 6200 and Kinetix 6500 Installation Instructions

Kinetix 6200 and Kinetix 6500 User Manual

20B-UM001

20B-UM002

PFLEX-RM001

PFLEX-RM004

20B-TD001

PFLEX-AT001

PFLEX-IN006

20C-PM001

20C-TD001

20D-IN024

PFLEX-IN006

20D-UM001

PFLEX-RM002

20D-TD001

20D-IN024

PFLEX-IN006

20D-PM001

PFLEX-RM003

20D-TD002

PFLEX-AT001

20L-UM001

PFLEX-UM002

20B-UM002

20D-PM001

750-IN001

750-IN006

750-IN024

750-PM001

750-TD001

20Y-UM001

1336 REGEN-5.0

1321-TD001

1321-5.0

2099-IN003

2099-UM001

2094-IN001

2094-UM001

2094-IN012

2094-UM002

You can view or download publications at http://www.rockwellautomation.com/ literature . To order paper copies of technical documentation, contact your local

Allen-Bradley® distributor or Rockwell Automation sales representative.

To find your local Rockwell Automation distributor or sales representative, visit http://www.rockwellautomation.com/locations .

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

13

Preface

Preface

Technical Support

(SupportPlus™)

For consultation on high performance drive applications, the SupportPlus program is offered. SupportPlus uses expert-level Rockwell Automation system engineers to support the user’s engineering team. SupportPlus engineers work with the end user to lay out the appropriate architecture, configure drives, recommend programming techniques, and provide application assistance on the most effective ways to implement the control solution.

Service

One-Hour Design Consultation

Two-Hour Design Consultation

On-Site Power Analysis

Catalog No.

TS-SP1HR

TS-SP2HR

TS-PASIOS

For more information, see http://www.ab.com/support/abdrives/files/ supportplus.pdf

.

14

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Chapter

1

General Considerations

DC Bus Wiring Guidelines

Drive Line-up

Generally, it is desirable to have the drive line-up match the machine layout.

However, if there is a mix of drive frame sizes used in the line-up, the general system layout must have the largest drives located closest to the rectifier source.

The rectifier source can be anywhere within the system line-up. Many times it is advantageous to put the rectifier in the middle of the line-up, minimizing the distances to the farthest loads. This is needed to minimize the energy stored in the parasitic inductance of the bus structure and thus lower peak bus voltages during transient operation.

The system must be contained in one contiguous line-up. The bus cannot be interrupted to go to another cabinet for the remainder of the system drives. This is needed to maintain low inductance.

DC Bus Connections

General

The interconnection of drives to the DC bus, and the inductance levels between the drives, must be kept to a minimum for reliable system operation.

Bus Bar versus Cable

• Bus bar is recommended.

• When bus bar cannot be used, adhere to the following guidelines for DC bus cables:

– Keep the cable lengths as short as possible.

– Twist cable where possible, approximately 1 twist per foot.

– Use cable rated for the equivalent AC voltage rating. The peak AC voltage is equivalent to the DC voltage. For example, the peak AC voltage on a 480V AC system no load is 480 x 1.414 = 679 volts peak.

The 679 volts peak corresponds to 679 volts DC at no load.

– The DC bus connections cannot be ‘daisy chained’. Use a ‘star’ configuration of the DC bus connections as shown in the following figure to enable proper fusing.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

15

Chapter 1 General Considerations

Figure 1 - Star Configuration of Common Bus Connections

L1

L2

L3

Bus Supply

DC+ DC-

DC+ DC-

Power Distribution

Terminal Block

16

Precharge

DC+

BR1 BR2 DCDC+ BR1 BR2 DCDC+ BR1 BR2 DC-

L1

L2

L3

AC Drive 1

L1

L2

L3

AC Drive 2

L1

L2

L3

AC Drive 3

M1

M2 M3

Braking Chopper

Connection of the brake unit must be closest to the largest drive. If all are the same rating, then closest to the drive that regenerates the most.

The maximum wire length between the brake chopper and the highest power drive and between parallel brake choppers must be observed. See the respective braking product documentation for details.

An RC snubber can mitigate inductive voltage spike at brake off transitions.

Precharge is the process through which the DC bus voltage of a drive is gradually increased. During this increase in DC bus voltage, the DC bus filtering capacitors are charged in a controlled manner. The precharge assembly can be part of the drive’s design or provided and controlled externally by the user.

ATTENTION: An external source of power can be present. To avoid an electrical shock hazard, verify that the AC power supply has been removed prior to performing any maintenance.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

General Considerations Chapter 1

If an external voltage source is being used to power the logic boards of the drives, precaution must be taken to control the precharge sequence. We recommend using the ‘Precharge Enable’ digital input on the drive for common bus operation.

The logic input can be coordinated through a PLC or system-level control for precharge sequencing. This lets various horsepower drive charging time constants settle out before the precharge is closed. Generally, a 3 second delay after power application is acceptable.

When multiple drives are connected through disconnects to a common DC bus, it is generally necessary to provide an input to the drive that enables the precharge to close. Often this input is controlled by an auxiliary contact on the drive disconnect switch.

Figure 2 - Common DC Bus Example

M1 M2

The bus capacitors in the individual drives act as a low impedance voltage source.

Extra care is needed when connecting individual drives to an energized bus.

ATTENTION: Kinetix servo drives have no method for the user to control the precharge sequence. Never connect Kinetix servo drives to an energized DC bus. Severe drive and/or equipment damage can result due to an uncontrolled precharge of the Kinetix drives.

If ‘Precharge Enable’ is selected as a digital input, it must be energized to let the initial bus precharge complete. If it is de-energized, it is treated as a coast-to-stop command and it forces the drive to the initial bus precharge state. Fuse failure is probable unless coordination of precharge circuits in individual drives is implemented.

PowerFlex 700 drives and PowerFlex 700 Series B drives must have firmware revision 2.001 or later (Standard or Vector Control) for use in common bus configurations. When Kinetix 6000 drives are used in common bus configurations with PowerFlex drives, they must have firmware revision 1.92 or later. Kinetix 6200/6500 drives with any firmware revision can be used.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

17

18

Chapter 1 General Considerations

L1

L2

L3

PowerFlex 40P Frame B AC Drives

For PowerFlex 40P Frame B AC drives, the precharge hardware is located on the power circuit board. It is composed of a resistor in series with the negative DC bus, between the diode bridge and the bus capacitors. The resistor has a relay contact connected in parallel that closes when the bus precharge level has been reached, bypassing the precharge resistor. The precharge function operates the same way for either AC or DC input power.

Figure 3 - AC and DC Input Schematic for PowerFlex 40P Frame B AC Drives

DC+ BR+

+

BR-

U

V

W

L1

L2

L3

DC –

PowerFlex 40P Frame C AC Drives

For PowerFlex 40P Frame C AC drives, the precharge hardware is located on the power circuit board. It is composed of a resistor in series with the positive DC bus, between the diode bridge and the bus capacitors. An external DC link inductor can be installed in series between the diode bridge and the precharge resistor. The resistor has a relay contact connected in parallel that closes when the bus precharge level has been reached, bypassing the precharge resistor. The precharge function operates the same way for either AC or DC input power.

Figure 4 - AC and DC Input Schematic for PowerFlex 40P Frame C AC Drives

DC+ BR+

+

BR-

U

V

W

DC –

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

General Considerations Chapter 1

L1

L2

L3

PowerFlex 520-Series Frame A, B, and C AC Drives

For the PowerFlex 520-Series Frame A, B, and C AC drives, the precharge hardware is located on the power circuit board. It is composed of a resistor in series with the positive DC bus, between the diode bridge and the bus capacitors.

The resistor has a relay contact connected in parallel that closes when the bus precharge level has been reached, bypassing the precharge resistor. The precharge function operates the same way for either AC or DC input power.

Figure 5 - AC and DC Input Schematic for PowerFlex 520-Series Frame A, B, and C AC Drives

DC+/BR+

+

BR-

U

V

W

L1

L2

L3

DC –

This schematic represents 3-phase input voltage PowerFlex 520-Series drives in the designated frame size.

PowerFlex 520-Series Frame D AC Drives

For the PowerFlex 520-Series Frame D AC drives, the precharge hardware is located on the power circuit board. It is composed of a resistor in series with the negative DC bus, between the diode bridge and the bus capacitors. The resistor has a relay contact connected in parallel that closes when the bus precharge level has been reached, bypassing the precharge resistor. The precharge function operates the same way for either AC or DC input power.

Figure 6 - AC and DC Input Schematic for PowerFlex 520-Series Frame D AC Drives

DC+ / BR+

+

BR-

U

V

W

DC –

This schematic represents 3-phase input voltage PowerFlex 520-Series drives in the designated frame size.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

19

20

Chapter 1 General Considerations

L1

L2

L3

PowerFlex 520-Series Frame E AC Drives

For the PowerFlex 520-Series Frame E AC drives, the precharge hardware is located on the power circuit board. It is composed of a resistor in series with the negative DC bus, between the DC link inductor and the bus capacitors. The resistor has a relay contact connected in parallel that closes when the bus precharge level has been reached, bypassing the precharge resistor. The precharge function operates the same way for either AC or DC input power.

Figure 7 - AC and DC Input Schematic for PowerFlex 520-Series Frame E AC Drives

DC+/BR+

+

BR-

U

V

W

DC –

This schematic represents 3-phase input voltage PowerFlex 520-Series drives in the designated frame size.

PowerFlex 70 Frame E, PowerFlex 700/700S Frame 0…4, and PowerFlex 750-Series Frame 1…4 AC Drives

For PowerFlex 70 Frame E, PowerFlex 700/700S Frame 0…4, and PowerFlex 750-

Series Frame 1…4 AC drives, the precharge hardware is located on the power circuit board. It is composed of a resistor in series with the positive DC bus, between the DC link and the bus capacitors. The resistor has a relay contact connected in parallel that closes when the bus precharge level has been reached, bypassing the precharge resistor. The precharge function operates the same way for either AC or DC input power.

Figure 8 - AC and DC Input Schematic for PowerFlex 70 Frame E, PowerFlex 700/700S Frame 0…4, and PowerFlex 750-Series Frame 1…4 AC Drives

DC+ BR1

+

BR2

L1

L2

L3

DC –

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Optional for PowerFlex 700 Frame 4

U

V

W

General Considerations Chapter 1

PowerFlex 700/700S Frame 5 and 6, and PowerFlex 700

Frame 7…10 AC Input ‘Stand-alone’ Drives

For PowerFlex 700/700S Frame 5 and 6, and PowerFlex 700 Frame 7…10 drives

(AC Input), the precharge function is implemented with an SCR rectifier such that the SCRs are phase advanced to limit the inrush current into the bus capacitors. This phase-advanced precharge is not controlled by the drive and must normally be completed by the minimum precharge time required by the drive. The drive does not complete precharge until the bus voltage is stable and above the under voltage level.

ATTENTION: PowerFlex 700/700S Frame 5 and 6, and PowerFlex 700 Frame

7…10 AC input drives have no method for the user to control the precharge sequence. Never connect these drives to an energized DC bus. Severe drive and/or equipment damage can result due to an uncontrolled precharge of these drives.

Figure 9 - AC Input Schematic for PowerFlex 700/700S Frame 5 and 6 (Voltage Rating Catalog

Codes B, C, D, E, and F), and PowerFlex 700 Frame 7…10 AC Drives

DC + BR1

+

BR2

L1

L2

L3

DC

–

Optional for PowerFlex 700 Frames 5 and 6

PowerFlex 700H/700S Frame 9…14 AC Input ‘Stand-alone’ Drives

During the precharge phase of PowerFlex 700H/700S Frame 9…14 drives, the three SCR switches of the front end rectifier are open and the bus capacitors are charged through the resistors and diodes from the AC side of the bridge. After the DC bus has reached precharge level, the SCRs when turned on bypass the diode/resistor configuration.

ATTENTION: PowerFlex 700H/700S Frame 9…14 AC input drives have no method for the user to control the precharge sequence. Never connect these drives to an energized DC bus. Severe drive and/or equipment damage can result due to an uncontrolled precharge of these drives.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

21

U

V

W

22

Chapter 1 General Considerations

Figure 10 - AC Input Schematic for PowerFlex 700H/700S Frame 9…14 AC Drives (Voltage Rating

Catalog Codes B, C, D, E, and F)

DC + BR1

+

BR2

L1

L2

L3

DC –

Optional for PowerFlex 700H/S Frame 9

L1

L2

L3

PowerFlex 750-Series Frame 5…7 AC Drives

When ordered as an AC input drive, DC terminals are not provided on Frames 6 and 7. During precharge, the SCRs of the front end rectifier are open and the bus capacitors are charged through the diodes and resistors from the AC input. After the DC bus has reached precharge level, the SCRs when turned on bypass the diode resistor configuration.

ATTENTION: PowerFlex 750-Series Frame 5…7 AC input drives have no method for the user to control the precharge sequence. Never connect these drives to an energized DC bus. Severe drive and/or equipment damage can result due to an uncontrolled precharge of these drives.

Figure 11 - AC Input Schematic for PowerFlex 750-Series Frame 5…7 AC Drives (Voltage Rating

Catalog Codes 1 and A)

DC + BR1

+

BR2

DC –

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Optional for Frames 6 and 7

U

V

W

U

V

W

General Considerations Chapter 1

L1

L2

L3

PowerFlex 750-Series Frame 8…10 AC Input ‘Stand-alone’ Drives

For PowerFlex 750-Series Frame 8…10 AC input drives, the precharge function is implemented with a diode/SCR rectifier such that the SCRs are phase advanced to limit the inrush current into the bus capacitors. This phase-advanced precharge is controlled by a converter firing board within the drive and must normally be completed by the minimum precharge time required by the drive.

Figure 12 - AC Input Schematic for PowerFlex 750-Series Frame 8…10 AC Drives (Voltage Rating

Catalog Codes 1 and A)

DC +

Precharge

Control

+

U

V

W

DC –

PowerFlex 700/700S Frame 5 and 6, and PowerFlex 700

Frame 7…10 DC Input ‘Common Bus’ Drives

There are two versions of these DC Input or common bus drives. One version has a resistor in series with the positive DC bus, ahead of the bus capacitors. An SCR is connected in parallel and when gated on, it bypasses the resistor. PowerFlex

700/700S Frame 5 and 6, and PowerFlex 700 Frame 7…9 drives are available with this internal precharge.

Figure 13 - DC Input Schematic for PowerFlex 700/700S Frame 5 and 6 (Voltage Rating Catalog

Codes N, P, R, T, and W), and PowerFlex 700 Frame 7…9 DC Input Drives

DC + BR1

+

U

V

W

BR2

DC –

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Optional for PowerFlex 700/700S Frames 5 and 6

23

24

Chapter 1 General Considerations

PowerFlex 700/700S Frame 5 and 6, and PowerFlex 700 Frame 10 drives do not have an internal precharge option, which is intended for applications where the precharge hardware and control is provided by the user.

ATTENTION: PowerFlex 700/700S Frame 5 and 6, and PowerFlex 700 Frame 10

DC input drives have no method for the user to control the precharge sequence. Never connect these drives to an energized DC bus. Severe drive and/or equipment damage can result due to an uncontrolled precharge of these drives.

Figure 14 - DC Input Schematic for PowerFlex 700/700S Frame 5 and 6 (Voltage Rating Catalog

Codes H, J, K, and M), and PowerFlex 700 Frame 10 DC Input Drives

DC +

BR1

External

Precharge

Assembly

+

BR2

U

V

W

DC –

Optional for PowerFlex 700/700S Frames 5 and 6

PowerFlex 700H/700S Frame 9…14 DC Input ‘Common Bus’ Drives

PowerFlex 700H/700S Frame 9…14 drives (DC Input) do not include internal precharge. Precharge must be provided by an external precharge assembly.

ATTENTION: PowerFlex 700H/700S Frame 9…14 DC input drives have no method for the user to control the precharge sequence. Never connect these drives to an energized DC bus. Severe drive and/or equipment damage can result due to an uncontrolled precharge of these drives.

Figure 15 - DC Input Schematic for PowerFlex 700H/700S Frame 9…14 DC Input Drives

(Voltage Rating Catalog Codes H, J, K, and M)

DC +

BR1

+

BR2

External

Precharge

Assembly

DC –

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Optional for PowerFlex 700H/700S Frame 9

U

V

W

General Considerations Chapter 1

PowerFlex 750-Series Frame 5…7 DC Input ‘Common Bus’ Drives

The precharge has a resistor in series with the positive DC bus, ahead of the bus capacitors. An SCR is connected in parallel and when gated on, it bypasses the resistor.

Figure 16 - DC Input Schematic for PowerFlex 750-Series Frame 5…7 DC Input Drives

(Input Type Catalog Code 4)

DC + BR1

+

BR2

DC –

Optional for Frames 6 and 7

PowerFlex 750-Series Frame 8…10 DC Input ‘Common Bus’ Drives

For PowerFlex 750-Series Frame 8…10 DC input drives, the precharge function is implemented with a resistor and bypass contactor in both the positive and negative DC bus between the DC input and the bus capacitors. When the DC bus precharge level has been reached, the contactor closes bypassing the resistor.

Figure 17 - DC Input Schematic for PowerFlex 750-Series Frame 8…10 DC Input Drives

(Input Type Catalog Code 4)

DC +

+

DC –

➊

➊ A common mode core is included when ordering a Catalog No. 21G drive with a

‘P’ or ‘W’ enclosure. A Common Mode Core is also included with any of the following IP00 Input Termination kits:

• 20-750-BUS5-F8

• 20-750-BUS5-F9

• 20-750-BUS5-F10

➋ A motor output common mode core is included in kit 20-750-EMCCM1-F8.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

➋

U

V

W

25

U

V

W

Chapter 1 General Considerations

26

L1

L2

L3

LCL Filter

+ + +

PowerFlex 700L Frame 2, 3A, and 3B AC Input ‘Stand-alone’ Drives

PowerFlex 700L Frame 2, 3A, and 3B AC input drives are regenerative drives with an active converter and input filter. The precharge circuit is connected between the input filter and the active converter. This is a 3-phase precharge with resistors in parallel with AC contactors. When the precharge is complete, the AC contactors close to bypass the resistors.

Figure 18 - AC Input Schematic for PowerFlex 700L Frame 2, 3A, and 3B AC Drives

(Equipment Type Catalog Code A

)

Active Converter Inverter

Precharge

+

U

V

W

PowerFlex 700L Frame 3A and 3B DC Input ‘Common Bus’ Drives

PowerFlex 700L Frame 3A and 3B drives (DC Input) do not include internal precharge. Precharge must be provided by an external precharge assembly.

ATTENTION: PowerFlex 700L Frame 3A and 3B DC input drives have no method for the user to control the precharge sequence. Never connect these drives to an energized DC bus. Severe drive and/or equipment damage can result due to an uncontrolled precharge of these drives.

Figure 19 - DC Input Schematic for PowerFlex 700L Frame 3A and 3B DC Input Drives

(Equipment Type Catalog Codes K and L)

DC +

U

V

W

+

External

Precharge

Assembly

DC –

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

General Considerations Chapter 1

L1

L2

L3

Kinetix 7000 Catalog Number BM06…BM08 Servo Drives

For Kinetix 7000 servo drives, catalog numbers BM06…BM08, the precharge hardware is located on the power circuit board. It is composed of a resistor in series with the positive DC bus between the DC link and the bus capacitors. The resistor has a relay contact connected in parallel that closes when the bus precharge level has been reached, bypassing the precharge resistor. The precharge function operates the same way for either AC or DC power.

Figure 20 - AC and DC Input Schematic for Kinetix 7000 BM06…BM08 Servo Drives

DC+

+

U

V

W

L1

L2

L3

DC –

Kinetix 7000 Catalog Number BM09…BM12 Servo Drives

For Kinetix 7000 servo drives, catalog numbers BM09…BM12, the precharge hardware is implemented with an SCR rectifier such that the SCR's are phase advanced to limit the inrush current into the bus capacitors. This phase-advanced precharge is not controlled by the drive and must normally be completed by the minimum precharge time required by the drive. The drive does not complete precharge until the bus voltage is stable and above the undervoltage level.

Figure 21 - AC Input Schematic for Kinetix 7000 BM09…BM12 Servo Drives

DC +

+

U

V

W

DC

–

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

27

Chapter 1 General Considerations

L1

L2

L3

Kinetix 6000 Bxxx-Series and Kinetix 6200/6500

Multi-Axis Servo Drives

The Kinetix 6000 series and Kinetix 6200/6500 series is a packaged, highly configurable, common bus product with one converter module and multiple inverter modules mounted on a shared backplane. Precharge hardware, which consists of a resistor in series with a DC link inductor and the positive rail of the

DC bus, is mounted in the converter module. In all recommended common bus configurations with PowerFlex drives, the converter is not used; therefore, three phase AC power should never be connected to the converter in mixed

PowerFlex/Kinetix 6000 common bus configurations. An internal shunt module

(braking chopper) is built into each inverter module. To be used in a common bus system with PowerFlex drives, the Kinetix system must be set to the common-bus follower condition with the shunt modules disabled.

Figure 22 - System Schematic for Kinetix 6000 Bxxx-Series and Kinetix 6200/6500 Multi-Axis Servo Drives

DC+

+

U

V

W

U

V

W

DC –

28

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Chapter

2

Common DC Bus Configuration—Non-

Regenerative

System Characteristics

This system is characterized by a diode, an SCR rectifier front end, or a combination of these two, which converts the 3-phase AC line voltage into a nonfiltered DC bus voltage. No provisions exist for line regeneration or power dissipation of any recovered energy from the motor/load system.

Supported Products

At the time of publication, the following non-regenerative DC Bus Supplies and

PowerFlex drives are supported.

DC Bus Supply Products

PowerFlex Diode Bus Supply 20T

PowerFlex SCR Bus Supply 20S

Supported Drives

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings - Three phase only

PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: Frames 0…4

PowerFlex 700S: Frames 1…4

(2)

PowerFlex 750-Series: Frames 1…4

Kinetix 7000: BM06…BM08

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings - Three phase only

PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: All frame sizes

(3)

PowerFlex 700S: All frame sizes

(3)

PowerFlex 700H: All frame sizes

(3)

PowerFlex 700L: Frames 3A

(4)

and 3B

(3)

PowerFlex 750-Series: Frames 1…10

(5)

Kinetix 7000: All power ratings

Kinetix 6000 and Kinetix 6200/6500: All 460V configurations

(6)

(1) These drives require firmware revision 2.001 or later (Standard and Vector Control).

(2) There is no Frame 0 for PowerFlex 700S drives.

(3) PowerFlex 700 Frame 5…10, PowerFlex 700S Frame 5 and 6 and Frame 9…14, PowerFlex 700H Frame 9…14, and PowerFlex 700L

DC input drives are required when not connected to the AC source.

(4) Frame 3A dual inverter drives only.

(5) PowerFlex 750-Series Frame 5…10 DC input version drives with precharge must be selected.

(6) Kinetix 6000 configurations require firmware revision 1.92 or later.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

29

Chapter 2 Common DC Bus Configuration—Non-Regenerative

Typical System Configuration

PowerFlex Diode Bus Supply

Figure 23 - Diode Bus Supply with Stand-alone AC Drives Connected in Common Bus Configuration

3-Phase

Source

3-Phase

Reactor

L1

Diode

Bus Supply

DC+

See Special Bus Requirements in table below,

General

Considerations on page 34

, and

PowerFlex Diode Bus

Supply Considerations on page 35 .

L2

L3

DC-

➊

PowerFlex

DC+

DCDC+ DC-

➊ A line reactor may be required. For line reactor selection information, see the PowerFlex Diode Bus

Supply User Manual.

AC Drive AC Drive

M M

Drawing Designation

AC Drive

Supported Drives

PowerFlex 700/700S: Frames 0…4

PowerFlex 750-Series: Frames 1…4

Kinetix 7000: BM06…BM08

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings -

Three phase only

Special Bus Requirements

None

None

None

Important: Do not use PowerFlex 40P or

PowerFlex 520-Series drives on the same DC bus supply with PowerFlex 700/700S/750-

Series drives or Kinetix 7000 drives. This is due to the difference in capacitance/amps of the

PowerFlex 40P or PowerFlex 520-Series drives compared to the PowerFlex 700/700S/750-

Series drives and Kinetix 7000 drives.

30

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Common DC Bus Configuration—Non-Regenerative Chapter 2

PowerFlex SCR Bus Supply in Solid Ground System

Figure 24 - SCR Bus Supply with Stand-alone AC Drives and Kinetix 6000 Drive System in a

Common Bus Configuration

➋

3-Phase

AC Input

Transformer

3-Phase

Reactor

L1

SCR

Bus Supply

DC+

DC Bus

Conditioner

➌

See Special Bus Requirements in table below and

General Considerations on page 34

.

Drawing

AC Drive

Designation

L2

DC-

PE

L3

PowerFlex

➊ The common mode core mounting location (SCR Bus Supply DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with SCR bus supplies, the common mode core is placed at either the DC input terminals of each drive or at the motor output of each drive.

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

➌ A capacitor bank is required. See table below and

Bus Supply

Capacitors on page 134

for more information.

System

Ground Type

Supported Drives

Voltage Type

Solid

400/480

600

PowerFlex 700/700S: Frames 0…4

Solid

Solid

400/480

600/690

400/480

600/690

PowerFlex 700/700S: Frames 5 and 6

PowerFlex 700: Frames 7…10

(3)

(1) (2)

Solid

Solid

400/480

600/690

400/480

600/690

PowerFlex 700H/700S: Frames 9…14

PowerFlex 700L: Frames 3A

(3) (4)

(3)

and 3B

400/480 PowerFlex 750-Series: Frames 1…4

(3)

Solid

600 PowerFlex 750-Series: Frames 3 and 4

400/480

Common

Mode Core

➊

DC+

AC Drive

M

Solid

Solid

Solid

Solid

600/690

400/480

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frame 7

PowerFlex 750-Series: Frames 8…10

(5)

Kinetix 7000: BM06…BM08

(6)

400/480 Kinetix 7000: BM09…BM12

(7)

400/480

Kinetix 6000: Bxxx-Series (460V only)

(8)

Kinetix 6200/6500 Multi-Axis Servo Drives (460V only)

(8)

DC-

Common Mode Core

(9)

N/A

N/A

N/A

N/A

DC+

AC Drive

M

DCDC+ DC-

M M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

Contact Factory

Contact factory for

30339-319-01

Contact Factory

Design D

Design C

Design D

(12)

Design C

Design D

Design C

(12)

(12)

Design G

(12)

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

Design G

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also,

see Note 1 on page 25 for

catalog no. information.

Design G

Design G

Contact Factory

(10)

(12)

Contact Factory

(10)

Contact Factory

DC Bus

Conditioner

(10)

(10)

(10)

(11)

Kinetix 6000 and

Kinetix 6200/6500

(1) Internal precharge option must be selected if a disconnect between the DC bus and the drive’s DC input is used. Also, DC input ‘common bus’ drives are required—not AC stand-alone configuration.

(2) At 600 volts, PowerFlex 700/700S Frame 5 and 6 drives cannot be used on the same bus as PowerFlex 700/700S Frame 0…4 drives.

(3) Additional bus capacitance may be required; see

General Considerations on page 34 . External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used. DC

input ‘common bus’ drives are required—not AC stand-alone configuration.

(4) Frame 3A dual inverter drives only.

(5) DC input version with precharge must be selected.

(6) At 600 volts, PowerFlex 750-Series Frame 6…10 drives cannot be used on the same bus as PowerFlex 750-Series Frame 3…5 drives.

(7) External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used.

(8) No internal precharge; see

PowerFlex SCR Bus Supply Considerations on page 35

. Drives must be placed in a common bus follower configuration.

(9)

One common mode core is required for each drive. See Note 1 in the diagram above and Common Mode Core on page 136

for recommendations.

(10) For any non-listed PowerFlex drive, contact the factory. See

Technical Support (SupportPlus™) on page 14 for details.

(11) One DC bus conditioner is required for each PowerFlex SCR Bus Supply.

(12) Only for systems with more than 20 drives; otherwise not required.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

31

Chapter 2 Common DC Bus Configuration—Non-Regenerative

32

PowerFlex SCR Bus Supply in High Resistance Ground System

Figure 25 - SCR Bus Supply with Stand-alone AC Drives and Kinetix 6000 Drive System in a

Common Bus Configuration

➋

3-Phase

AC Input

Transformer

3-Phase

Reactor

L1

SCR

Bus Supply

DC+

DC Bus

Conditioner

➌

See Special Bus Requirements in table below and

General Considerations on page 34 .

L2

L3

DC-

PowerFlex

Common

Mode Core

➊

DC+ DCDC+ DC-

DC+ DC-

Drawing

Designation

AC Drive

➊ The common mode core mounting location

(SCR Bus Supply DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with SCR bus supplies, the common mode core is placed at either the DC input terminals of each drive or at the motor output of each drive.

System

Ground Type

High Resistance Ground

High Resistance Ground

400/480

600

Ground Fault

Indicator Filter

Supported Drives

Voltage Type

PE

➋ The DC bus conditioner must be electrically connected to the

DC bus as close to the DC source as possible.

➌ A capacitor bank is required.

See table below and

Bus

Supply Capacitors on page 134

for more information.

PowerFlex 700/700S: Frames 0…4

PowerFlex 700/700S: Frames 5 and 6

(1) (2)

400/480

600/690

AC Drive

M

Common Mode Core

(9)

N/A

N/A

N/A

N/A

AC Drive

M

DC Bus

Conditioner

(11)

Design E

Design E

Design E

Design E

M M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

Gnd. Fault

Indicator

Filter

(12)

Yes

Yes

High Resistance Ground

High Resistance Ground

High Resistance Ground

400/480

600/690

400/480

600/690

400/480

600/690

PowerFlex 700: Frames 7…10

(3)

PowerFlex 700H/700S: Frames 9…14

(3)

High Resistance Ground

High Resistance Ground

400/480 PowerFlex 750-Series: Frames 1…4

600

400/480

600/690

PowerFlex 750-Series: Frames 3 and 4

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frame 7

PowerFlex 750-Series: Frames 8…10

(5) (6)

High Resistance Ground 400/480 Kinetix 7000: BM06…BM08

High Resistance Ground 400/480 Kinetix 7000: BM09…BM12

(7)

High Resistance Ground 400/480

Kinetix 6000: Bxxx-Series (460V only)

(8)

Kinetix 6200/6500 Multi-Axis Servo Drives (460V only)

(8)

Contact factory for

30339-319-01

Contact Factory

(10)

Contact Factory

(10)

Contact Factory

(10)

Yes

Yes

Yes

Kinetix 6000 and

Kinetix 6200/6500

PowerFlex 700L: Frames 3A

(3) (4)

and 3B

(3)

Design E

Design E

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

Design E

Design E

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also,

see Note 1 on page 25 for

catalog no. information.

Design E

Design E

Contact Factory

(10)

Contact Factory

(10)

(1) Internal precharge option must be selected if a disconnect between the DC bus and the drive’s DC input is used. Also, DC input ‘common bus’ drives are required—not AC stand-alone configuration.

(2) At 600 volts, PowerFlex 700/700S Frame 5 and 6 drives cannot be used on the same bus as PowerFlex 700/700S Frame 0…4 drives.

(3)

Additional bus capacitance may be required; see General Considerations on page 34

. External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used. DC input ‘common bus’ drives are required—not AC stand-alone configuration.

(4) Frame 3A dual inverter drives only.

(5) DC input version with precharge must be selected.

(6) At 600 volts, PowerFlex 750-Series Frame 6…10 drives cannot be used on the same bus as PowerFlex 750-Series Frame 3…5 drives.

(7) External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used.

(8)

No internal precharge; see PowerFlex SCR Bus Supply Considerations on page 35 . Drives must be placed in a common bus follower configuration.

(9) One common mode core is required for each drive. See Note 1 in the diagram above and

Common Mode Core on page 136 for recommendations.

(10) For any non-listed PowerFlex drive, contact the factory. See Technical Support (SupportPlus™) on page 14

for details.

(11) One DC bus conditioner is required for each PowerFlex SCR Bus Supply.

(12) See

Ground Fault Indicator Filter on page 143 for recommendations.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Common DC Bus Configuration—Non-Regenerative Chapter 2

PowerFlex SCR Bus Supply in Ungrounded System

3-Phase

AC Input

Figure 26 - SCR Bus Supply with Stand-alone AC Drives and Kinetix 6000 Drive System in a

Common Bus Configuration

Transformer

3-Phase

Reactor

L1

SCR

Bus Supply

DC+

DC Bus

Conditioner

➌

➋

See Special Bus Requirements in table below

and General Considerations on page 34 .

L2

DC-

L3

PowerFlex

DCDC+

Common

Mode Core

➊

DC+

Zig-Zag

Transformer

Drawing

Designation

AC Drive

➊ The common mode core mounting location (SCR Bus

Supply DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with SCR bus supplies, the common mode core is placed at either the DC input terminals of each drive or at the motor output of each drive.

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

System

Ground Type

Ungrounded

Ungrounded

Ungrounded

Ground Fault

Indicator Filter

600/690

400/480

Voltage Type

400/480

600

400/480

600/690

Supported Drives

PowerFlex 700/700S: Frames 0…4

PowerFlex 700/700S: Frames 5 and 6

(1) (2)

PowerFlex 700: Frames 7…10

(3)

PE

➌ A capacitor bank is required.

See table below and Bus Supply

Capacitors on page 134

for more information.

Common Mode Core

(9)

N/A

N/A

N/A

N/A

AC Drive

M

DC Bus

Conditioner

(11)

Design E

Design E

Design E

Design E

AC Drive

M

Contact Factory

(10)

DC-

Gnd. Fault

Indicator

Filter

(12)

Yes

Yes

DC+ DC-

M M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

Zig Zag

Transformer

Required

(13)

Yes

Yes

Design E

Design E

Ungrounded

400/480

600/690

400/480

600/690

PowerFlex 700H/700S: Frames 9…14

(3)

Contact factory for

30339-319-01

Yes Yes

Ungrounded PowerFlex 700L: Frames 3A

(3) (4)

and 3B

(3)

Contact Factory

(10)

Kinetix 6000 and

Kinetix 6200/6500

Ungrounded

Ungrounded

Ungrounded

Ungrounded

Ungrounded

400/480 PowerFlex 750-Series: Frames 1…4

600

400/480

600/690

PowerFlex 750-Series: Frames 3 and 4

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frame 7

PowerFlex 750-Series: Frames 8…10

(5) (6)

400/480 Kinetix 7000: BM06…BM08

400/480 Kinetix 7000: BM09…BM12

(7)

400/480

Kinetix 6000: Bxxx-Series (460V only)

(8)

Kinetix 6200/6500 Multi-Axis Servo Drives (460V only)

(8)

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also,

see Note 1 on page 25

for catalog no. information.

Design E

Design E

Design E

Design E

Contact Factory

(10)

Contact Factory

(10)

Contact Factory

(10)

Yes

Yes

Yes

Yes

(1) Internal precharge option must be selected if a disconnect between the DC bus and the drive’s DC input is used. Also, DC input ‘common bus’ drives are required—not AC stand-alone configuration.

(2) At 600 volts, PowerFlex 700/700S Frame 5 and 6 drives cannot be used on the same bus as PowerFlex 700/700S Frame 0…4 drives.

(3) Additional bus capacitance may be required; see

General Considerations on page 34 . External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used. DC input ‘common bus’ drives are

required—not AC stand-alone configuration.

(4) Frame 3A dual inverter drives only.

(5) DC input version with precharge must be selected.

(6) At 600 volts, PowerFlex 750-Series Frame 6…10 drives cannot be used on the same bus as PowerFlex 750-Series Frame 3…5 drives.

(7) External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used.

(8) No internal precharge; see

PowerFlex SCR Bus Supply Considerations on page 35

. Drives must be placed in a common bus follower configuration.

(9)

One common mode core is required for each drive. See Note 1 in the diagram above and Common Mode Core on page 136

for recommendations.

(10) For any non-listed PowerFlex drive, contact the factory. See

Technical Support (SupportPlus™) on page 14 for details.

(11) One DC bus conditioner is required for each PowerFlex SCR Bus Supply.

(12) See

Ground Fault Indicator Filter on page 143

for recommendations.

(13) See

Zig-Zag Transformer on page 144 for recommendations.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

33

34

Chapter 2 Common DC Bus Configuration—Non-Regenerative

General Considerations

ATTENTION: The incorrect use or configuration of third party assemblies can result in reduced system reliability and drive damage.

1.

All system components (Bus Supply, and PowerFlex and Kinetix Drives) must be selected for the same AC-line voltage.

2.

A low inductance type DC bus must be used. See DC Bus Connections on page 15 for details.

3.

Take every precaution to minimize the distance between drives and wire lengths. The mixture of different frame size drives in this arrangement can cause high ripple current in the smaller frame drives. In this case, place the larger power drives physically closer to the bus supply. This helps current sharing among the various drives on the bus.

4.

If a disconnect switch between the common DC bus and the drive’s input is used, an auxiliary contact on the disconnect switch must be connected to a digital input of the drive. The corresponding digital input must be set to

‘PreCharge En’. This provides the proper precharge interlocking, guarding against possible damage to the drive when reconnecting the drive to an energized DC bus. Under this condition, the drives must have internal or externally-supplied precharge.

Drive

PowerFlex 40P

PowerFlex 523

PowerFlex 525

PowerFlex 700

PowerFlex 700L with vector control

PowerFlex 700S

PowerFlex 700L with 700S control

PowerFlex 700H

PowerFlex 750-Series

Parameter

Number

A051…A054 t062…t066 t062…t068

361…366

825…830

361…366

189 [DI Precharge]

Setting

29 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

Digital

Input

1…4

2…6

2…8

1…6

1…6

30 (PreCharge En) 1…6

See Drive Programming Manual for programming information.

ATTENTION: The Kinetix family of drives have no external means of controlling the precharge; therefore, a DC disconnect must not be used.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Common DC Bus Configuration—Non-Regenerative Chapter 2

5.

If a drive from column A in the table below is mixed with a drive from column B, a capacitor bank is required. See

Bus Supply Capacitors on page 134

for details.

Column A Drives

PowerFlex 700/700S: Frames 0…5

PowerFlex 750-Series: Frames 1…10

Kinetix 6000 and Kinetix 6200/6500

Kinetix 7000

Column B Drives

PowerFlex 700/700S: Frame 6

PowerFlex 700: Frames 8…10

PowerFlex 700H/700S: Frame 9 and up

PowerFlex 700L: All Frames

6.

PowerFlex 700 drives and PowerFlex 700 Series B drives must have firmware revision 2.001 or later (Standard and Vector Control).

7.

For further assistance with this Common Bus configuration, contact the

Rockwell Automation SupportPlus engineering team at: http://www.ab.com/support/abdrives/files/supportplus.pdf

PowerFlex Diode Bus Supply

Considerations

The Diode Bus Supply can only be used with PowerFlex 700/700S Frame 0…4 drives, PowerFlex 750-Series Frame 1…4 drives, Kinetix 7000 BM06…BM08 drives, PowerFlex 40P drives (all power ratings), or PowerFlex 520-Series (all power ratings). This is because the Diode Bus Supply does not include precharge.

The precharge function must be provided by the drives.

ATTENTION: Never connect Kinetix 7000 BM09…BM12 drives, Kinetix 6000-

Series drives, or Kinetix 6200/6500 drives to a PowerFlex Diode Bus Supply in common bus configuration because there is no controlled, current-limited precharge of the DC bus capacitors, resulting in drive damage.

PowerFlex SCR Bus Supply

Considerations

ATTENTION: The SCR Bus Supply includes precharge. The use of drives with precharge is not required if and only if power is removed and reconnected to the entire system, and if individual drives do not require to be isolated and reconnected to an energized bus through a disconnect switch. Failure to follow this recommendation results in drive damage.

1.

To commission and test the SCR Bus Supply, a minimum capacitance is required. See

Bus Supply Capacitors on page 134

for details.

2.

AC line reactors for di/dt limitation and current sharing must be externally mounted for each PowerFlex SCR Bus Supply. See the

PowerFlex SCR Bus Supply User Manual for line reactor information.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

35

Chapter 2 Common DC Bus Configuration—Non-Regenerative

Sizing

To avoid overloading the Bus Supply, the following requirements apply:

• The DC Input current sum (Normal Duty or Heavy Duty rating at 40 °C /

104 °F) of the connected drives must not exceed the continuous DC Bus output current rating of the Bus Supply.

• For the DC Input Current values of the drives, see the tables in

Appendix A . In addition, the guidelines provided in the product

documentation also apply.

• For Kinetix product ratings, see the Kinetix Motion Control Selection

Guide, and the Kinetix 6000 and 7000 User Manuals and Installation

Instructions.

PowerFlex Diode Bus Supply

The following examples show maximum loading of the Diode Bus Supply.

a) Normal Duty ND

DC Input Rating of Connected Drives

DC

Voltage

ND

Power

540V

650V

30 + 22 = 52 kW

2 x 40 = 80 HP

ND

Currents

ND

Current Sum

61.9 + 47.5 A 109.4 A

2 x 55.7 A 111.4 A

Diode Bus Supply

Rated Cont. DC

Output Amps

AC Input

Voltage

120 A

120 A

400V

480V b) Heavy Duty HD

DC Input Rating of Connected Drives

DC

Voltage

HD

Power

HD

Currents

540V

650V

2 x 15 = 30 kW

2 x 25 HP = 50 HP

2 x 40.9 A

2 x 42.9 A

HD

Current Sum

81.8 A

85.8 A

Diode Bus Supply

Rated Cont. DC

Output Amps

AC Input

Voltage

120 A

120 A

400V

480V

Total the DC Input currents for all drives connected to the DC bus. This total must be less than 120A.

36

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Fusing

Common DC Bus Configuration—Non-Regenerative Chapter 2

PowerFlex SCR Bus Supply

The following examples show maximum loading of the SCR Bus Supply.

a) Normal Duty ND, 110%, 1 minute; 150%, 3 seconds

DC Input Rating of Connected Drives

DC

Voltage

540V

ND

Power

3 x 110 kW

1 x 45 kW

ND

Currents

3 x 226 = 678 A

1 x 95 = 95 A

650V 3 x 60 HP

1 x 30 HP

3 x 84.5 = 253.5 A

1 x 42.9 = 42.9 A

(1) No overload capability.

ND

Current Sum

773 A

297 A

SCR Bus Supply

(1)

Maximum DC

Output Amps

1000 A

AC Input

Voltage

400V

400 A 480V b) Heavy Duty HD, 150%, 1 minute; 200%, 3 seconds

DC Input Rating of Connected Drives

DC Voltage HD

540V

650V

Power

HD

Currents

HD

Current Sum

3 x 90 kW 3 x 192.3 A = 577 A 577 A

3 x 125 HP 3 x 171 A = 513 A 513 A

(1) No overload capability.

SCR Bus Supply

(1)

Maximum DC

Output Amps

AC Input

Voltage

600 A

600A

400V

480V

DC Input Drives

See Appendix A

for the recommended Common DC Bus drive fusing.

PowerFlex Diode Bus Supply

See the PowerFlex Diode Bus Supply User Manual for recommended AC input fusing.

PowerFlex SCR Bus Supply

The PowerFlex SCR Bus Supply has built-in AC line and DC bus fuses (on 400A and 600A units). The 1000A unit has six in-path fuses which simultaneously protect AC and DC paths. All units are equipped with fuse trip indicator switches. See the PowerFlex SCR Bus Supply User Manual for fusing information.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

37

Chapter 2 Common DC Bus Configuration—Non-Regenerative

Notes:

38

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Chapter

3

Common DC Bus Configuration—Non-

Regenerative with Braking DC Bus Regulation

System Characteristics

This system is characterized by a diode, an SCR rectifier front end, or a combination of these two, which converts the 3-phase AC line voltage into a nonfiltered DC bus voltage. This system uses a Braking Chopper, Dynamic Brake

Unit, or the drive’s internal IGBT with a braking resistor for power dissipation of excess regenerative energy. Rockwell Automation does not offer external braking products. Please contact our Encompass Partners for these braking products.

Supported Products

At the time of publication, these non-regenerative DC Bus Supplies and drives are supported.

DC Bus Supply Products

(1)

PowerFlex Diode Bus Supply 20T

PowerFlex SCR Bus Supply 20S

Supported Drives

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings - Three phase only

PowerFlex 700

(2)

/ PowerFlex 700 Series B

(2)

: Frames 0…4

PowerFlex 700S: Frames 1…4

(3)

PowerFlex 750-Series: Frames 1…4

Kinetix 7000: BM06…BM08

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings - Three phase only

PowerFlex 700

(2)

/ PowerFlex 700 Series B

(2)

: All frame sizes

(4)

PowerFlex 700S: All frame sizes

(4)

PowerFlex 700H: All frame sizes

(4)

PowerFlex 700L: Frame 3A

(5)

and 3B

(4)

PowerFlex 750-Series: Frames 1…10

(6)

Kinetix 7000: All power ratings

Kinetix 6000 and Kinetix 6200/6500: All 460V configurations

(7)

(1) For Bus Supply product details, see

Chapter 2

.

(2) These drives require firmware revision 2.001 or later (Standard and Vector Control).

(3) There is no Frame 0 for PowerFlex 700S drives.

(4) PowerFlex 700 Frame 5…10, PowerFlex 700S Frame 5 and 6 and Frame 9…14, PowerFlex 700H Frame 9…14, and PowerFlex

700L DC input drives are required when not connected to the AC source.

(5) Frame 3A dual inverter drives only.

(6) PowerFlex 750-Series Frame 5…10 DC input version drives with precharge must be selected.

(7) Kinetix 6000 configurations require firmware revision 1.92 or later.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

39

Chapter 3 Common DC Bus Configuration—Non-Regenerative with Braking DC Bus Regulation

Typical System

Configurations

3-Phase

Source

Brake Chopper Modules

Diode Bus Supply

Figure 27 - Diode Bus Supply with Stand-alone AC Drives and Brake Chopper

3-Phase

Reactor

➊

L2

L3

L1

Diode

Bus Supply

DC+

DC-

See Special Bus Requirements in table below,

page 46 , and

General Considerations on

PowerFlex Diode Bus Supply Considerations on page 47

PowerFlex

DC+

DC-

RC Snubber

Braking Module

DC+ DCDC+

DC-

.

➊ A line reactor may be required. For line reactor selection information, see the

PowerFlex Diode Bus Supply User Manual.

BR1

BR2

AC Drive AC Drive

BR

M

M

Drawing Designation

AC Drive

Supported Drives

PowerFlex 700/700S: Frames 0…4

PowerFlex 750-Series: Frames 1…4

Special Bus Requirements

An RC snubber is required to limit DC bus voltage overshoot at

power-on. See RC Snubber Circuit on page 136 for more

information.

Kinetix 7000: BM06…BM08

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings -

Three phase only

Important: Do not use PowerFlex 40P or PowerFlex 520-Series drives on the same DC bus supply with PowerFlex 700/700S/

750-Series drives or Kinetix 7000 drives. This is due to the difference in capacitance/amps of the PowerFlex 40P or

PowerFlex 520-Series drives compared to the PowerFlex 700/

700S/750-Series drives and Kinetix 7000 drives.

40

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Common DC Bus Configuration—Non-Regenerative with Braking DC Bus Regulation Chapter 3

SCR Bus Supply in Solid Ground System

Figure 28 - SCR Bus Supply with Stand-alone AC Drives, Kinetix 6000 Drive System, and

Braking Module

➋

3-Phase

AC Input

Transformer

3-Phase

Reactor

L1

SCR

Bus Supply

DC+

DC Bus

Conditioner

➌

See Special Bus Requirements in table below

and General Considerations on page 46

.

L2

DC-

Kinetix 6000 and

Kinetix 6200/6500

Braking Module

Solid

Solid

Solid

Solid

Solid

600/690

400/480

400/480

400/480

—

PE

L3

DC+

PowerFlex

➊ The common mode core mounting location (SCR Bus Supply DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with SCR bus supplies, the common mode core is placed at either the DC input terminals of each drive or at the motor output of each drive.

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

➌ A capacitor bank is required. See table below and

Bus Supply Capacitors on page 134

for more information.

System

Ground Type

Supported Drives/Products

Voltage Type

AC Drive

Drawing

Designation

Solid

Solid

Solid

400/480

600

400/480

600/690

400/480

600/690

PowerFlex 700/700S: Frames 0…4

PowerFlex 700/700S: Frames 5 and 6

(1) (2)

PowerFlex 700: Frames 7…10

(3)

Braking Module

BR1

BR

BR2

Solid

Solid

Solid

400/480

600/690

400/480

600/690

400/480

600

PowerFlex 700H/700S: Frames 9…14

(3)

PowerFlex 700L: Frames 3A

(3) (4)

and 3B

(3)

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

400/480

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frame 7

PowerFlex 750-Series: Frames 8…10

(5) (6)

Common

DC-

Mode Core

➊

DC+

Kinetix 7000: BM06…BM08

Kinetix 7000: BM09…BM12

(7)

Kinetix 6000 (460V only): Bxxx-Series

(8)

Kinetix 6200/6500 Multi-Axis Servo Drives (460V only)

(8)

Encompass Partner product

(9)

Common Mode Core

(10)

N/A

N/A

N/A

N/A

N/A

AC Drive

M

DCDC+

AC Drive

M

DCDC+ DC-

M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

M

DC Bus

Conditioner

(12)

Design D

(13)

Design C

Design D

(13)

Design C

Contact Factory

(11)

Contact factory for

30339-319-01

Design D

(13)

Design C

Contact Factory

(11)

Design G

(13)

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

Design G

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also, see Note 1 on

page 25

for catalog no. information.

Design G

Design G

Contact Factory

(11)

Contact Factory

(11)

(13)

Contact Factory

(11)

N/A

(1) Internal precharge option must be selected if a disconnect between the DC bus and the drive’s DC input is used. DC input ‘common bus’ drives are required—not AC stand-alone configurations.

(2) At 600 volts, PowerFlex 700/700S Frame 5 and 6 drives cannot be used on the same bus as PowerFlex 700/700S Frame 0…4 drives.

(3) Additional bus capacitance may be required; see

General Considerations on page 46

. External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used. DC input

‘common bus’ drives are required—not AC stand-alone configuration.

(4) Frame 3A dual inverter drives only.

(5) DC input version with precharge must be selected.

(6) At 600 volts, PowerFlex 750-Series Frame 6…10 drives cannot be used on the same bus as PowerFlex 750-Series Frame 3…5 drives.

(7) External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used.

(8) No internal precharge; see

PowerFlex SCR Bus Supply Considerations on page 48

. Drives must be placed in a common bus follower configuration.

(9)

See PowerFlex SCR Bus Supply Considerations on page 48 . If the instantaneous Brake Chopper current is larger than 150% of the DC input rating of the largest drive, a capacitor bank is required.

(10) One common mode core is required for each drive. See Note 1 in the diagram above and Common Mode Core on page 136

for recommendations.

(11) For any non-listed PowerFlex drive, contact the factory. See

Technical Support (SupportPlus™) on page 14 for details.

(12) One DC bus conditioner is required for each PowerFlex SCR Bus Supply.

(13) Only for systems with more than 20 drives; otherwise not required.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

41

Chapter 3 Common DC Bus Configuration—Non-Regenerative with Braking DC Bus Regulation

SCR Bus Supply in High Resistance Ground System

Figure 29 - SCR Bus Supply with Stand-alone AC Drives, Kinetix 6000 Drive System, and

Braking Module

➋

3-Phase

AC Input

Transformer

3-Phase

Reactor

L1

SCR

Bus Supply

DC+

DC Bus

Conditioner

➌

See Special Bus Requirements in table below and

General Considerations on page 46 .

L2

DC-

L3

DC+ DCDC+ DCDC+ DC-

PowerFlex

DC-

Common

Mode Core

➊

DC+

➊ The common mode core mounting location (SCR Bus

Supply DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with SCR bus supplies, the common mode core is placed at either the DC input terminals of each drive or at the motor output of each drive.

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

Drawing

Designation

AC Drive

System

Ground Type

High Resistance Ground

High Resistance Ground

Supported Drives/Products

Voltage

400/480

600

400/480

600/690

Ground Fault

Indicator Filter

Type

PE

➌ A capacitor bank is required.

See table below and Bus

Supply Capacitors on page 134

for more information.

PowerFlex 700/700S: Frames 0…4

PowerFlex 700/700S: Frames 5 and 6

(1) (2)

High Resistance Ground

400/480

600/690

PowerFlex 700: Frames 7…10

(3)

High Resistance Ground

High Resistance Ground

High Resistance Ground

400/480

600/690

400/480

600/690

400/480

600

PowerFlex 700H/700S: Frames 9…14

PowerFlex 700L: Frames 3A

(3) (4)

(3)

and 3B

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

(3)

High Resistance Ground

High Resistance Ground 400/480

400/480

600/690

High Resistance Ground 400/480

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frame7

PowerFlex 750-Series: Frames 5…10

(5) (6)

Kinetix 6000 and

Kinetix 6200/6500

Braking Module

High Resistance Ground 400/480

High Resistance Ground —

Kinetix 7000: BM06…BM08

Kinetix 7000: BM09…BM12

(7)

Kinetix 6000 (460V only): Bxxx-Series

(8)

Kinetix 6200/6500 Multi-Axis Servo Drives (460V only)

(8)

Encompass Partner product

(9)

Braking Module

BR1

BR

N/A

N/A

N/A

N/A

BR2

AC Drive

Contact factory for

30339-319-01

M

Common Mode Core

(10)

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

Contact Factory

(11)

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also,

see Note 1 on page 25 for

catalog no. information.

Design E

Design E

Contact Factory

(11)

Contact Factory

(11)

N/A

AC Drive

M

Contact Factory

(11)

N/A

DC Bus

Conditioner

(12)

Design E

Design E

Design E

Design E

Design E

Design E

Design E

Design E

Contact Factory

(11)

M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

M

Gnd. Fault

Indicator

Filter

(13)

Yes

Yes

Yes

Yes

Yes

N/A

42

(1) Internal precharge option must be selected if a disconnect between the DC bus and the drive’s DC input is used. DC input ‘common bus’ drives are required—not AC stand-alone configurations.

(2) At 600 volts, PowerFlex 700/700S Frame 5 and 6 drives cannot be used on the same bus as PowerFlex 700/700S Frame 0…4 drives.

(3)

Additional bus capacitance may be required; see General Considerations on page 46

. External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used. DC input ‘common bus’ drives are required—not AC stand-alone configuration.

(4) Frame 3A dual inverter drives only.

(5) DC input version with precharge must be selected.

(6) At 600 volts, PowerFlex 750-Series Frame 6…10 drives cannot be used on the same bus as PowerFlex 750-Series Frame 3…5 drives.

(7) External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used.

(8)

No internal precharge; see PowerFlex SCR Bus Supply Considerations on page 48 . Drives must be placed in a common bus follower configuration.

(9)

See PowerFlex SCR Bus Supply Considerations on page 48

. If the instantaneous Brake Chopper current is larger than 150% of the DC input rating of the largest drive, a capacitor bank is required.

(10) One common mode core is required for each drive. See Note 1 in the diagram above and

Common Mode Core on page 136 for recommendations.

(11) For any non-listed PowerFlex drive, contact the factory. See Technical Support (SupportPlus™) on page 14

for details.

(12) One DC bus conditioner is required for each PowerFlex SCR Bus Supply.

(13) See Ground Fault Indicator Filter on page 143 for recommendations.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Common DC Bus Configuration—Non-Regenerative with Braking DC Bus Regulation Chapter 3

SCR Bus Supply in Ungrounded System

3-Phase

AC Input

Figure 30 - SCR Bus Supply with Stand-alone AC Drives, Kinetix 6000 Drive System, and

Braking Module

➋

Transformer

3-Phase

Reactor

L1

SCR

Bus Supply

DC+

DC Bus

Conditioner

➌

See Special Bus Requirements in table below and

General Considerations on page 46

.

L2

DC-

L3

DC+

PowerFlex

Zig-Zag

Transformer

➊ The common mode core mounting location (SCR Bus

Supply DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with SCR bus supplies, the common mode core is placed at either the DC input terminals of each drive or at the motor output of each drive.

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

Drawing

Designation

System

Ground Type

Supported Drives/Products

Type

AC Drive

Ungrounded

Ungrounded

Ungrounded

Voltage

400/480

600

400/480

600/690

400/480

600/690

Ground Fault

Indicator Filter

PowerFlex 700/700S: Frames 0…4

PowerFlex 700/700S: Frames 5 and 6

(1) (2)

PowerFlex 700: Frames 7…10

(3)

PE

➌ A capacitor bank is required.

See table below and

Bus

Supply Capacitors on page 134

for more information.

BR1

Common Mode Core

(10)

N/A

N/A

N/A

N/A

Braking Module

BR

BR2

DC-

Common

Mode Core

➊

DC+

AC Drive

M

DCDC+

DC Bus

Conditioner

(12)

Design E

Design E

Design E

Design E

Contact Factory

(11)

AC Drive

M

Gnd. Fault

Indicator

Filter

(13)

Yes

Yes

DCDC+ DC-

M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

M

Zig Zag

Transformer

Required

(14)

Yes

Yes

Ungrounded

Ungrounded

Ungrounded

400/480

600/690

400/480

600/690

400/480

600

PowerFlex 700H/700S: Frames 9…14

(3)

PowerFlex 700L: Frames 3A

(3) (4)

and 3B

(3)

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

Contact factory for

30339-319-01

Design E

Design E

Contact Factory

(11)

Yes

Yes

Yes

Yes

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

Design E

Design E

Kinetix 6000 and

Kinetix 6200/6500

Braking Module

Ungrounded

Ungrounded

Ungrounded

Ungrounded

Ungrounded —

400/480

600/690

400/480

400/480

400/480

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frame 7

PowerFlex 750-Series: Frames 8…10

(5) (6)

Kinetix 7000: BM06…BM08

Kinetix 7000: BM09…BM12

(7)

Kinetix 6000 (460V only): Bxxx-Series

(8)

Kinetix 6200/6500 Multi-Axis Servo Drives (460V only)

(8)

Encompass Partner product

(9)

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also,

see Note 1 on page 25

for catalog no. information.

N/A

Design E

Design E

Contact Factory

(11)

Contact Factory

(11)

Contact Factory

(11)

N/A

Yes

N/A

Yes

N/A

(1) Internal precharge option must be selected if a disconnect between the DC bus and the drive’s DC input is used. DC input ‘common bus’ drives are required—not AC stand-alone configurations.

(2) At 600 volts, PowerFlex 700/700S Frame 5 and 6 drives cannot be used on the same bus as PowerFlex 700/700S Frame 0…4 drives.

(3)

Additional bus capacitance may be required; see General Considerations on page 46

. External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used. DC input ‘common bus’ drives are required—not AC stand-alone configuration.

(4) Frame 3A dual inverter drives only.

(5) DC input version with precharge must be selected.

(6) At 600 volts, PowerFlex 750-Series Frame 6…10 drives cannot be used on the same bus as PowerFlex 750-Series Frame 3…5 drives.

(7) External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used.

(8)

No internal precharge; see PowerFlex SCR Bus Supply Considerations on page 48 . Drives must be placed in a common bus follower configuration.

(9) See

PowerFlex SCR Bus Supply Considerations on page 48

. If the instantaneous Brake Chopper current is larger than 150% of the DC input rating of the largest drive, a capacitor bank is required.

(10) One common mode core is required for each drive. See Note 1 in the diagram above and

Common Mode Core on page 136 for recommendations.

(11) For any non-listed PowerFlex drive, contact the factory. See Technical Support (SupportPlus™) on page 14

for details.

(12) One DC bus conditioner is required for each PowerFlex SCR Bus Supply.

(13) See

Ground Fault Indicator Filter on page 143 for recommendations.

(14) See

Zig-Zag Transformer on page 144

for recommendations.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

43

44

Chapter 3 Common DC Bus Configuration—Non-Regenerative with Braking DC Bus Regulation

3-Phase

Source

Drive Internal Brake IGBT

Figure 31 - Diode Bus Supply with Stand-alone AC Drives with Internal Brake IGBT

3-Phase

Reactor

See Special Bus Requirements in table below, General Considerations on page 46

, and PowerFlex Diode Bus Supply Considerations on page 47

.

➊

L2

L3

L1

Diode

Bus Supply

DC+

DC-

PowerFlex

➋ ➌

BR

DC+

BR1 BR2 DCDC+ DC-

➊ A line reactor may be required. For line reactor selection information, see the

PowerFlex Diode Bus Supply User Manual.

➋ See publication PFLEX-AT001 for minimum ohms.

➌ The braking IGBT should be connected to the largest frame size drive.

Drawing Designation Supported Drives

AC Drive 1

AC Drive 2

AC Drive 1

M1

AC Drive 2

M2

PowerFlex 700/700S: Frames 0…4

PowerFlex 750-Series: Frames 1…4

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings -

Three phase only

Special Bus Requirements

None

None

Important: Do not use PowerFlex 40P or PowerFlex 520-

Series drives on the same DC bus supply with PowerFlex

700/700S drives. This is due to the difference in capacitance/amps of the PowerFlex 40P or PowerFlex 520-

Series drives compared to the PowerFlex 700/700S drives.

None

None

PowerFlex 700/700S: Frames 0…4

PowerFlex 750-Series: Frames 1…4

Kinetix 7000: BM06…BM08

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings -

Three phase only

None

Important: Do not use PowerFlex 40P or PowerFlex 520-

Series drives on the same DC bus supply with PowerFlex

750-Series drives or Kinetix 7000 drives. This is due to the difference in capacitance/amps of the PowerFlex 40P or

PowerFlex 520-Series drives compared to the PowerFlex

750-Series drives and Kinetix 7000 drives.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Common DC Bus Configuration—Non-Regenerative with Braking DC Bus Regulation Chapter 3

Figure 32 - SCR Bus Supply with Stand-alone AC Drives with Internal Brake IGBT, and Kinetix 6000

Drive System

➋

3-Phase

Reactor

L1

SCR

Bus Supply

DC+

DC Bus

Conditioner

➌

See Special Bus Requirements in table below and

General Considerations on page 46

.

L2

DC-

L3

PowerFlex

BR

➍➎

Common

Mode Core

➊

DC+ R+

R-

DCDC+ DCDC+ DC-

➊ The common mode core mounting location (SCR Bus Supply

DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with

SCR bus supplies, the common mode core is placed at

either the DC input terminals of each drive or at the motor output of each drive. Also, see

Common Mode Core on page 136

for recommendations.

Capacitors on page 134

for more information.

➍ See publication PFLEX-AT001 for minimum ohms.

➎ The braking IGBT should be connected to the largest frame size drive.

AC Drive 1 AC Drive 2

M M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

➌ A capacitor bank may be required. See

Bus Supply

M1

M2

For all ground systems (solid, high resistance ground, and ungrounded), the same

guidelines as previously described on page 41

, page 42

, and page 43

apply. In addition, adhere to the following braking IGBT conditions:

• See publication PFLEX-AT001 for minimum ohms.

• The braking IGBT should be connected to the largest frame size drive.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

45

Chapter 3 Common DC Bus Configuration—Non-Regenerative with Braking DC Bus Regulation

46

General Considerations

ATTENTION: The incorrect use or configuration of third party assemblies can result in reduced system reliability and drive damage.

1.

All system components (Bus Supply, PowerFlex and Kinetix Drives, and

Braking Unit) must be selected for the same AC-line voltage.

2.

A low inductance type DC bus must be used.

3.

The braking chopper must be located next to the bus supply and the highest power drive.

4.

A low inductance type DC bus must be used. See DC Bus Connections on page 15 for details.

5.

The maximum wire length between the brake chopper and the highest power drive and between parallel brake choppers must be observed. See the respective braking product documentation for details.

6.

If a disconnect switch between the common DC bus and the drive’s input is used, an auxiliary contact on the disconnect switch must be connected to a digital input of the drive. The corresponding digital input must be set to

‘PreCharge En’. This provides the proper precharge interlocking, guarding against possible damage to the drive when reconnecting the drive to an energized DC bus. Under this condition, the drives must have internal or externally-supplied precharge.

Drive

PowerFlex 40P

PowerFlex 523

PowerFlex 525

PowerFlex 700

PowerFlex 700L with vector control

PowerFlex 700S

PowerFlex 700L with 700S control

PowerFlex 700H

PowerFlex 750-Series

Parameter

Number

A051…A054 t062…t066 t062…t068

361…366

825…830

361…366

189 [DI Precharge]

Setting

29 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

Digital

Input

1…4

2…6

2…8

1…6

1…6

30 (PreCharge En) 1…6

See Drive Programming Manual for programming information.

ATTENTION: The Kinetix family of drives have no external means of controlling the precharge; therefore, a DC disconnect must not be used.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Common DC Bus Configuration—Non-Regenerative with Braking DC Bus Regulation Chapter 3

7.

If a drive from column A in the table below is mixed with a drive from column B, a capacitor bank is required. See

Bus Supply Capacitors on page 134

for details.

Column A Drives

PowerFlex 700/700S: Frames 0…5

PowerFlex 750-Series: Frames 1…10

Kinetix 6000 and Kinetix 6200/6500

Kinetix 7000

Column B Drives

PowerFlex 700/700S: Frame 6

PowerFlex 700: Frames 8…10

PowerFlex 700H/700S: Frame 9 and up

PowerFlex 700L: All Frames

8.

PowerFlex 700 drives and PowerFlex 700 Series B drives must have firmware revision 2.001 or later (Standard and Vector Control).

9.

For further assistance with this Common Bus configuration, contact

Rockwell Automation SupportPlus engineering team at: http://www.ab.com/support/abdrives/files/supportplus.pdf

PowerFlex Diode Bus Supply

Considerations

The Diode Bus Supply can be used only with PowerFlex 700/700S Frame 0…4 drives, PowerFlex 750-Series Frame 1…4 drives, Kinetix 7000 BM06…BM08 drives, PowerFlex 40P drives (all power ratings), or PowerFlex 520-Series drives

(all power ratings). This is because the Diode Bus Supply does not include precharge. The precharge function must be provided by the drives.

ATTENTION: Never connect Kinetix 7000 BM09…BM12 drives, Kinetix 6000-

Series drives, or Kinetix 6200/6500 drives to a PowerFlex Diode Bus Supply in common bus configuration because there is no controlled, current-limited precharge of the DC bus capacitors, resulting in drive damage.

When using a PowerFlex Diode Bus Supply with the Brake Chopper, follow this additional recommendation:

An RC snubber circuit is required to prevent the DC bus voltage from exceeding the 1200V maximum Brake Chopper IGBT voltage. The RC snubber circuit must always be connected to the DC bus (located close to

the braking chopper) to absorb the power-on voltage overshoot. See RC

Snubber Circuit on page 136

for details.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

47

Chapter 3 Common DC Bus Configuration—Non-Regenerative with Braking DC Bus Regulation

48

PowerFlex SCR Bus Supply

Considerations

ATTENTION: The SCR Bus Supply includes precharge. The use of drives with precharge is not required if and only if power is removed and reconnected to the entire system, and if individual drives do not require to be isolated and reconnected to an energized bus through a disconnect switch. Failure to follow this recommendation results in drive damage.

1.

To commission and test the SCR Bus Supply, a minimum capacitance is required. See

Bus Supply Capacitors on page 134

for details.

2.

AC line reactors for di/dt limitation and current sharing must be externally mounted for each PowerFlex SCR Bus Supply. See the

PowerFlex SCR Bus Supply User Manual for line reactor information.

When using a PowerFlex SCR Bus Supply with a Braking Unit, follow this additional recommendation:

If the instantaneous Brake Chopper current is larger than 150% of the DC input rating of the largest drive, a capacitor bank is required and must be located as close as possible to the brake chopper and the rectifier source.

– Exception 1: The capacitor is not required if at least one drive without internal precharge (PowerFlex 700 Frames 5 and up, only DC input,

Catalog Codes H and J) is always connected to the common DC bus.

– Exception 2: If a PowerFlex 700H/700S Frame 9 and up drive is interconnected with PowerFlex 700/700S Frame 0…6 drives, or

PowerFlex 750-Series Frame 1…10 drives, and a capacitor bank with

appropriate capacitance is already used. See the subsection Connecting

High Power Drives and Low Power Drives on the DC Bus on page 134

for details.

Sizing

Drive Internal Brake IGBT

See the PowerFlex Dynamic Braking Resistor Calculator, publication

PFLEX-AT001, for minimum resistance values.

Bus Supplies

To avoid overloading the Bus Supply, the following requirements apply:

• The DC Input current sum (Normal Duty, Heavy Duty rating, or Light

Duty at 40 °C/104 °F) of the connected drives must not exceed the continuous DC Bus output current rating of the Bus Supply.

• For the DC Input Current values of the drives, see the tables in

Appendix A . In addition, the guidelines provided in the PowerFlex 700

User Manual, PowerFlex 700S/700H Installation Manual, or PowerFlex

750-Series Drive Technical Data

also apply.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Common DC Bus Configuration—Non-Regenerative with Braking DC Bus Regulation Chapter 3

PowerFlex Diode Bus Supply

The following examples show maximum loading of the Diode Bus Supply.

a) Normal Duty ND

DC Input Rating of Connected Drives

DC

Voltage

540V

650V

ND

Power

30 + 22 = 52 kW

2 x 40 = 80 HP

ND

Currents

ND

Current Sum

61.9 + 47.5 A 109.4 A

2 x 55.7 A 111.4 A

Diode Bus Supply

Rated Cont. DC

Output Amps

AC Input

Voltage

120 A

120 A

400V

480V b) Heavy Duty HD

DC Input Rating of Connected Drives

DC

Voltage

HD

Power

HD

Currents

540V

650V

2 x 15 = 30 kW

2 x 25 = 50 HP

2 x 40.9 A

2 x 42.9 A

HD

Current Sum

81.8 A

85.8 A

Diode Bus Supply

Rated Cont. DC

Output Amps

AC Input

Voltage

120 A

120 A

400V

480V

Total the DC Input currents for all drives connected to the DC bus. This total must be less than 120A.

PowerFlex SCR Bus Supply

The following examples show maximum loading of the SCR Bus Supply.

a) Normal Duty ND, 110%, 1 minute; 150%, 3 seconds

DC Input Rating of Connected Drives SCR Bus Supply

(1)

DC

Voltage

540V

650V

ND

Power

ND

Currents

3 x 110 kW

1 x 45 kW

3 x 226 = 678 A

1 x 95 = 95 A

3 x 60 HP

1 x 30 HP

3 x 84.5 = 253.5 A

1 x 42.9 = 42.9 A

ND

Current Sum

773 A

297 A

Maximum DC

Output Amps

1000 A

AC Input

Voltage

400V

400 A 480V

(1) No overload capability.

b) Heavy Duty HD, 150%, 1 minute; 200%, 3 seconds

DC Input Rating of Connected Drives SCR Bus Supply

(1)

DC

Voltage

540V

650V

HD

Power

HD

Currents

HD

Current Sum

3 x 90 kW 3 x 192.3 A = 577 A 577 A

3 x 125 HP 3 x 171 A = 513 A 513 A

Maximum DC

Output Amps

AC Input

Voltage

600 A

600 A

400V

480V

(1) No overload capability.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

49

Chapter 3 Common DC Bus Configuration—Non-Regenerative with Braking DC Bus Regulation

Fusing

DC Input Drives

See Appendix A

for the recommended Common DC Bus drive fusing.

PowerFlex Diode Bus Supply

See the PowerFlex Diode Bus Supply User Manual for recommended AC input fusing.

PowerFlex SCR Bus Supply

The PowerFlex SCR Bus Supply has built-in AC line and DC bus fuses (on 400A and 600A units). The 1000A unit has six in-path fuses which simultaneously protect AC and DC paths. All units are equipped with fuse trip indicator switches. See the PowerFlex SCR Bus Supply User Manual for fusing information.

50

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Chapter

4

Shared AC/DC Bus Configuration

System Characteristics

Supported Products

IMPORTANT

Although there are guidelines to help with AC input current sharing between drives for this configuration, current sharing cannot be assured. Therefore, the configurations shown in

Chapter 2

or

Chapter 6

are preferred.

This system is characterized by the use of stand-alone drives fed by a common

3-phase voltage source and the DC bus of each drive connected together.

At the time of publication, the following drives can be used on a shared AC/DC bus configuration.

Supported Drives

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings - Three phase only

PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: Frames 0…6

(2)

PowerFlex 700S: Frames 1…6

(2)

(3)

PowerFlex 750-Series: Frames 1…10

(4)

Kinetix 7000: BM06…BM12

(1) These drives require firmware revision 2.001 or later (Standard and Vector

Control).

(2) PowerFlex 700 Frame 5 and 6, and PowerFlex 700S Frame 5 and 6 DC input drives are required when not connected to the AC source.

(3) There is no Frame 0 for PowerFlex 700S drives.

(4) A DC input terminal kit must be ordered for PowerFlex 750-Series Frame 6, 7, and 8 drives.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

51

52

Chapter 4 Shared AC/DC Bus Configuration

Typical System

Configurations

AC Drives of Different Frame Sizes from the Same Product Line

Figure 33 - Different Frame Size Stand-alone AC Drives from the Same Product Line in a Shared

AC/DC Bus Configuration

See Special Bus Requirements in table below,

General Considerations on page 55

, and

Different Frame Size Drive Considerations on

DC+ DCDC+ DCDC+

3-Phase

Source

L1

L1

L1

L2

L2 L2

AC Drive 2

L3

L3 L3

AC Drive 1

➊

AC Drive 1 AC Drive 2 AC Drive 2

➊ This contactor or switch is for disconnection purpose only.

Drawing Designation Supported Drives

M1

M2

M2

Special Bus Requirements

PowerFlex 700/700S: Frames 5 and 6 • Back-to-back diodes are required for proportional current sharing in a shared

Kinetix 7000: BM09…BM12

AC/DC configuration with different size drives. See Back-to-Back Diodes

(Shared AC/DC Configurations) on page 133

for more information.

• At 600 volts, PowerFlex 700/700S Frame 0…4 drives cannot be used on the same bus as PowerFlex 700/700S Frame 5 and 6 drives.

PowerFlex 750-Series: Frames 5…10 • Back-to-back diodes are required for proportional current sharing in a shared

AC/DC configuration with different size drives. See Back-to-Back Diodes

(Shared AC/DC Configurations) on page 133

for more information.

• A DC input terminal kit must be ordered for Frames 6 and 7.

PowerFlex 750-Series: Frames 6…10 • At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

PowerFlex 700/700S: Frames 0…4

PowerFlex 750-Series: Frames 1…4

Kinetix 7000: BM06…BM08

• An individual or common contactor is required if AC bus is shared with

PowerFlex 700/700S Frame 5 and 6 drives, or Kinetix 7000 BM09…BM12 drives.

• At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

• Back-to-back diodes are required for proportional current sharing in a shared

AC/DC configuration with different size drives. See Back-to-Back Diodes

(Shared AC/DC Configurations) on page 133

for more information.

DC-

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Shared AC/DC Bus Configuration Chapter 4

Same Frame Size AC Drives from Same Product Line

Using AC Input Reactors

Figure 34 - Same Frame Size Stand-alone AC Drives from Same Product Line in a Shared AC/DC Bus

Configuration with AC Input Reactors for Proportional Current Sharing

See Special Bus Requirements in table below,

General Considerations on page 55

, and

Same Frame Size Drive Considerations on page 57 .

3-Phase

Source

DC-

3-Phase

Reactor

DC+

L1

DC-

3-Phase

Reactor

DC+

L1

L2

L3

AC Drive

L2

L3

AC Drive

M

M

Drawing Designation Supported Drives

AC Drive PowerFlex 700/700S: Frames 0…6

Kinetix 7000: BM06…BM12

Special Bus Requirements

3-Phase line reactors are required for proportional current sharing. See

Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC

Drives, publication DRIVES-UM001, for additional information.

PowerFlex 750-Series: Frames 1…10 • 3-Phase line reactors are required for proportional current sharing. See

Wiring and Grounding Guidelines for Pulse Width Modulated (PWM)

AC Drives, publication DRIVES-UM001, for additional information.

• A DC input terminal kit must be ordered for Frames 6, 7, and 8.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

53

Chapter 4 Shared AC/DC Bus Configuration

Using Back-to-Back Diodes

Figure 35 - Same Frame Size Stand-alone AC Drives from Same Product Line in a Shared AC/DC Bus

Configuration with Back-to-Back Diodes for Proportional Current Sharing

See Special Bus Requirements in table below, General Considerations on page 55

, and

Same Frame Size Drive Considerations on page 57

.

3-Phase

Source

DC+ DC-

DC+

L1

L2

L3

AC Drive

DC-

L1

L2

L3

M

AC Drive

M

Drawing Designation Supported Drives Special Bus Requirements

AC Drive PowerFlex 700/700S: Frames 0…6

Back-to-back diodes are required for proportional current sharing.

Kinetix 7000: BM06…BM12

PowerFlex 750-Series: Frames 1…7

(1)

• Back-to-back diodes are required for proportional current sharing.

(1) Back-to-back diodes are not supported on PowerFlex 750-Series Frame 8…10 drives.

• A DC input terminal kit must be ordered for Frames 6, 7, and 8.

54

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Shared AC/DC Bus Configuration Chapter 4

PowerFlex 40P or PowerFlex 520-Series Drives

Figure 36 - PowerFlex 40P or PowerFlex 520-Series Drives in a Shared AC/DC Bus Configuration with AC Input Reactors for Proportional Current Sharing

See Special Bus Requirements in table below,

General Considerations on page 55

, and

PowerFlex 40P or PowerFlex 520-Series Drive Considerations on page 57 .

3-Phase

Source

3-Phase

Reactor

DC+

L1

L2

L3

AC Drive

DC-

M

3-Phase

Reactor

DC+

L1

L2

L3

AC Drive

DC-

M

Drawing Designation Supported Drives

AC Drive PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings -

Three phase only

Special Bus Requirements

See

PowerFlex 40P or PowerFlex 520-Series

Drive Considerations on page 57 .

General Considerations

ATTENTION: The incorrect use or configuration of third party assemblies can result in reduced system reliability and drive damage.

1.

Minimizing bus inductance is imperative. Drives must be mounted physically as close to each other as possible with all power wiring ‘tied’ together to minimize loop area.

2.

If AC power is removed from one drive in a shared AC/DC bus, that drive can still be energized through the DC bus of another drive. Therefore, AC power to all of the drives in a shared AC/DC bus must be provided through a common disconnect switch or circuit breaker.

3.

PowerFlex 700 drives and PowerFlex 700 Series B drives must have firmware revision 2.001 or later (Standard and Vector Control).

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

55

Chapter 4 Shared AC/DC Bus Configuration

56

Different Frame Size Drive

Considerations

When the Shared AC/DC Bus line-up is composed of different frame size drives, two system phases must be taken into account. These are the precharge and loading phases of the drives within this configuration.

Precharge

Due to the difference in the precharge circuitry between PowerFlex 700/700S

Frame 0…4 drives and PowerFlex 750-Series Frame 1…7 drives when compared to

PowerFlex 700/700S Frame 5 and 6 drives or PowerFlex 750-Series Frame 8…10 drives, the following considerations must be followed:

• An individual or a common contactor on the AC-side must be used for

PowerFlex 700/700S Frame 0…4 drives or PowerFlex 750-Series Frame

1…7 drives. If PowerFlex 700/700S Frame 0…4 drives or PowerFlex 750-

Series Frame 1…7 drives are not kept isolated from the AC power during precharge, the following drives precharge through the diode front end of the PowerFlex 700/700S Frame 0…4 drives or PowerFlex 750-Series Frame

1…7 drives:

– PowerFlex 700/700S Frame 5 and 6 drives

– PowerFlex 700VC Frame 7…10 drives

– PowerFlex 700H/S Frame 9…14 drives

– PowerFlex 750-Series Frame 8…10 drives

This can result in diode front end or precharge resistor damage. See

Figure 33 on page 52 .

• Kinetix 7000 BM06…BM08 drives have the same precharge as PowerFlex

700/700S Frame 0…4 drives. Similarly, Kinetix 7000 BM09…BM12 drives have the same precharge as PowerFlex 700 Frame 5 drives. The same rules as described in the preceding bulleted text apply.

Loading

When the larger power frame drive—or the sum of the power for the larger frame drives relative to the smallest power frame drives in the lineup—is loaded, the current through the small frame drive can exceed its current rating. To prevent this condition, these considerations must be followed.

1. Diodes

- Back-to-back (dual pack) diodes with fuses must be used in the

DC link of each drive to enable proportional sharing of input current by the converter section of each drive. Failure to do so can result in drive

damage

. See Back-to-Back Diodes (Shared AC/DC Configurations) on page 133 for recommended part numbers.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Same Frame Size Drive

Considerations

Shared AC/DC Bus Configuration Chapter 4

2.

The wiring and interconnection distances to the Common AC Bus must be minimized to prevent large variations of the input impedances between the drive inverters.

1.

Individual line reactors for each drive or back-to-back diodes must be used for proportional current sharing. For line reactor information, see Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC

Drives, publication DRIVES-UM001. For recommended diodes, see

Back-to-Back Diodes (Shared AC/DC Configurations) on page 133

.

2.

The wiring and interconnection distances to the Common AC Bus must be minimized to prevent large variations of the input impedances between the drive inverters.

PowerFlex 40P or PowerFlex

520-Series Drive

Considerations

When using PowerFlex 40P or PowerFlex 520-Series drives in a shared bus configuration, the loading must be taken into account.

When the larger power frame drive—or the sum of the power for the larger frame drives relative to the smallest power frame drives in the lineup—is loaded, the current through the small frame drive can exceed its current rating. To prevent this condition, these guidelines must be followed.

1.

Individual line reactors for each drive must be used for proportional current sharing. For line reactor information, see Wiring and Grounding

Guidelines for Pulse Width Modulated (PWM) AC Drives, publication

DRIVES-UM001.

2.

The wiring and interconnection distances to the Common AC Bus must be minimized to prevent large variations of the input impedances between the drive inverters.

3.

Only multiple same size and type of drives on a shared AC/DC bus are

recommended in the system configuration shown in Figure 36 on page 55 .

PowerFlex 40P or PowerFlex 520-Series drives must not be combined with PowerFlex 700/700S/750-Series drives on the same shared AC/DC bus.

Sizing

Each drive must be sized for the motor load connected to it.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

57

Chapter 4 Shared AC/DC Bus Configuration

Fusing

Drives must not be ‘daisy chained’. Configure the shared DC bus in a ‘star’ configuration to enable proper fusing. Fast semiconductor fuses must be used in the DC links to minimize destructive energy in the event of a part or control malfunction. The fuses must be sized to handle large peak currents at the end of precharge.

See Appendix A

for the recommended Common DC Bus drive fusing.

58

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Chapter

5

Shared AC/DC Bus Configuration—with Braking

DC Bus Regulation

System Characteristics

IMPORTANT

Although there are guidelines to help with AC input current sharing between drives for this configuration, current sharing cannot be assured. Therefore, the configurations shown in

Chapter 3

or

Chapter 7

are preferred.

Supported Products

This system is characterized by the use of stand-alone drives fed by a common

3-phase voltage source and the DC bus of each drive connected together. In addition, a Braking Chopper, Dynamic Braking Unit, or the drive’s internal

IGBT with a braking resistor for power dissipation of regenerative energy is also used. Rockwell Automation does not offer external braking products. Please contact our Encompass Partners for these braking products.

At the time of publication, the following products are supported.

Products

Brake Chopper Module

Supported Drives

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings - Three phase only

PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: Frames 0…6

(2)

PowerFlex 700S: Frames 1…6

(2)

(3)

PowerFlex 750-Series: Frames 1…10

(4)

Kinetix 7000: BM06…BM12

Heavy Duty Dynamic Brake Unit PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings - Three phase only

PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: Frames 0…6

(2)

PowerFlex 700S: Frames 1…6

(2) (3)

PowerFlex 750-Series: Frames 1…10

(4)

Kinetix 7000: BM06…BM12

(1) These drives require firmware revision 2.001 or later (Standard and Vector Control).

(2) PowerFlex 700 Frame 5 and 6 and PowerFlex 700S Frame 5 and 6 DC input drives are required when not connected to the AC source.

(3) There is no Frame 0 for PowerFlex 700S drives.

(4) A DC input terminal kit must be ordered for PowerFlex 750-Series Frame 6 and 7 drives.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

59

Chapter 5 Shared AC/DC Bus Configuration—with Braking DC Bus Regulation

Note – When applicable and within the power limitation, the drive’s internal

IGBT can also be used.

Drive

PowerFlex 40P

PowerFlex 520-Series

PowerFlex 700

PowerFlex 700S

PowerFlex 750-Series

Kinetix 7000

Kinetix 6000 and Kinetix 6200/6500

Internal Brake IGBT

Standard on all power ratings

Standard on all power ratings

Standard on Frames 0…3; optional on Frames 4…6

Standard on Frames 1…3; optional on Frames 4…6, and 9

Standard on Frames 1…5; optional on Frames 6 and 7

No internal brake IGBT

Internal bus regulation cannot be used.

ATTENTION: The internal IGBT in a Kinetix 6000 Multi-Axis Servo Drive is disabled in ‘Common Bus Follower’ mode.

60

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Typical System

Configurations

Shared AC/DC Bus Configuration—with Braking DC Bus Regulation Chapter 5

Figure 37 - Stand-alone AC Drives with a Braking Module in a Shared AC/DC Bus Configuration

See Special Bus Requirements in table below and General Considerations on page 63 .

3-Phase

Source

DC+

➊

DC+

L1

DC-

RC

Snubber

DC+

Braking

Module

DC-

DC+

L1

DC-

L1

L2 L2 L2

BR1 BR2

L3

➋

AC Drive 1

➊ This contactor or switch is for disconnection purpose only.

➋ If drives are of the same size and type, see

Same Size Drive Considerations on page 65 . If

drives are of different size and type, see

Different Size Drive Considerations on page 64 .

M1

Drawing Designation Supported Drives/Products

AC Drive 1

BR

L3

➋

AC Drive 2

M2

L3

➋

AC Drive 2

M2

PowerFlex 700/700S: Frames 5 and 6

Kinetix 7000: BM09…BM12

Special Bus Requirements

• Back-to-back diodes are required for proportional current sharing in a shared

AC/DC configuration with different size drives. See Back-to-Back Diodes

(Shared AC/DC Configurations) on page 133

for more information.

• At 600 volts, PowerFlex 700/700S Frame 0…4 drives cannot be used on the same bus as PowerFlex 700/700S Frame 5 and 6 drives.

PowerFlex 750-Series: Frames 5…10 • Back-to-back diodes are required for proportional current sharing in a shared

AC/DC configuration with different size drives. See Back-to-Back Diodes

(Shared AC/DC Configurations) on page 133

for more information.

• A DC input terminal kit must be ordered for Frames 6, 7, and 8.

PowerFlex 750-Series: Frames 6…10 • At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

AC Drive 2

Braking Module

PowerFlex 700/700S: Frames 0…4

PowerFlex 750-Series: Frames 1…4

Kinetix 7000: BM06…BM08

Encompass Partner product

• An individual or common contactor is required if the AC bus is shared with

PowerFlex 700/700S Frame 5 and 6 drives or Kinetix 7000 BM09…BM12 drives.

• At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

• Back-to-back diodes are required for proportional current sharing in a shared

AC/DC configuration with different size drives. See Back-to-Back Diodes

(Shared AC/DC Configurations) on page 133

for more information.

An RC Snubber is required to limit DC bus voltage overshoot at power-on. See

RC

Snubber Circuit on page 136

for more information.

DC-

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

61

62

Chapter 5 Shared AC/DC Bus Configuration—with Braking DC Bus Regulation

Figure 38 - Stand-alone AC Drives with an Internal Brake IGBT in a Shared AC/DC Bus

Configuration

See Special Bus Requirements in table below and

General Considerations on page 63

.

BR

DC+ BR1 BR2 DCDC+ DCDC+

3-Phase

Source

L1 L1

L1

L2

L2 L2

➊

L3

L3 L3

➋

AC Drive 1

➋

AC Drive 2

➋

AC Drive 2

➊ This contactor or switch is for disconnection purpose only.

M1 M2

M2

➋ If drives are of the same size and type, see

Same Size Drive Considerations on page 65

. If drives are of different size and type, see

Different Size Drive Considerations on page 64 .

Drawing Designation Supported Drives

AC Drive 1 PowerFlex 700/700S: Frames 5 and 6 • Back-to-back diodes are required for proportional current sharing in a shared

Special Bus Requirements

AC/DC configuration with different size drives. See

Back-to-Back Diodes (Shared

Kinetix 7000: BM09…BM12

AC/DC Configurations) on page 133

for more information.

• At 600 volts, PowerFlex 700/700S Frame 0…4 drives cannot be used on the same bus as PowerFlex 700/700S Frame 5 and 6 drives.

• A Kinetix 7000 BM09…BM12 drive does not have an internal brake IGBT so it cannot be used to internally regulate the DC bus.

AC Drive 2

PowerFlex 750-Series: Frames 5…10 • Back-to-back diodes are required for proportional current sharing in a shared

AC/DC configuration with different size drives. See

Back-to-Back Diodes (Shared

AC/DC Configurations) on page 133

for more information.

• A DC input terminal kit must be ordered for Frames 6, 7, and 8.

PowerFlex 750-Series: Frames 6…10 • At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

PowerFlex 700/700S: Frames 0…4

PowerFlex 750-Series: Frames 1…4

Kinetix 7000: BM06…BM08

• Back-to-back diodes are required for proportional current sharing in a shared

AC/DC configuration with different size drives. See

Back-to-Back Diodes (Shared

AC/DC Configurations) on page 133

for more information.

• An individual or common contactor is required if AC bus is shared with

PowerFlex 700/700S Frame 5 or 6 drives.

• At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

• A Kinetix 7000 BM06…BM08 drive does not have an internal brake IGBT so it cannot be used to internally regulate the DC bus.

DC-

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Shared AC/DC Bus Configuration—with Braking DC Bus Regulation Chapter 5

3-Phase

Source

Figure 39 - Stand-alone PowerFlex 40P Drives (all Power Ratings) with Internal Brake IGBT in a

Shared AC/DC Bus Configuration

See PowerFlex 40P or PowerFlex 520-Series Drive Considerations on page 65

.

BR

3-Phase

Reactor

DC+ BR+ BRDC-

L1

L2

L3

AC Drive

3-Phase

Reactor

DC+ BR+ BRDC-

L1

L2

L3

AC Drive

3-Phase

Reactor

DC+ BR+ BRDC-

L1

L2

L3

AC Drive

M1 M2 M3

Drawing Designation Supported Drives

AC Drive PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings -

Three phase only

Special Bus Requirements

See PowerFlex 40P or PowerFlex 520-Series

Drive Considerations on page 65

.

General Considerations

ATTENTION: The incorrect use or configuration of third party assemblies can result in reduced system reliability and drive damage.

1.

Connection of the braking resistor must be on the highest power drive. If all are the same rating, then closest to the drive that regenerates the most.

Minimizing DC bus inductance is imperative. Drives must be mounted physically as close to each other as possible with all power wiring ‘tied’ together to minimize loop area. If minimizing the physical distance between the units is not possible, a capacitor bank is required which must be located closest to the drive with the braking resistor.

2.

An RC Snubber circuit must be used in a shared AC/DC Bus

Configuration when a PowerFlex 700/700S Frame 0…4 drive, PowerFlex

750-Series Frame 1…10 drive, Kinetix 7000 BM06…BM08 drive,

PowerFlex 40 drive, or PowerFlex 520-Series drive is used with a Brake

Chopper. See RC Snubber Circuit on page 136

for more information.

3.

If AC power is removed from one drive in a shared AC/DC bus, that drive can still be energized through the DC bus of another drive. Therefore, AC power to all of the drives in a shared AC/DC bus must be provided through a common disconnect switch or circuit breaker.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

63

Chapter 5 Shared AC/DC Bus Configuration—with Braking DC Bus Regulation

4.

PowerFlex 700 drives and PowerFlex 700 Series B drives must have firmware revision 2.001 or later (Standard and Vector Control).

64

Different Size Drive

Considerations

When the Shared AC/DC Bus line-up is composed of different frame size drives, two system phases must be taken into account. These are the precharge and loading phases of the drives within this configuration.

Precharge

Due to the difference in the precharge circuitry between PowerFlex 700/700S

Frame 0…4 drives and PowerFlex 750-Series Frame 1…7 drives when compared to

PowerFlex 700/700S Frame 5 and 6 drives or PowerFlex 750-Series Frame 8…10 drives, the following considerations must be followed:

• An individual or a common contactor on the AC-side must be used for

PowerFlex 700/700S Frame 0…4 drives or PowerFlex 750-Series Frame

1…7 drives. If PowerFlex 700/700S Frame 0…4 drives or PowerFlex 750-

Series Frame 1…7 drives are not kept isolated from the AC power during precharge, the following drives precharge through the diode front end of the PowerFlex 700/700S Frame 0…4 drives or PowerFlex 750-Series Frame

1…7 drives.

– PowerFlex 700/700S Frame 5 and 6 drives

– PowerFlex 700VC Frame 7…10 drives

– PowerFlex 700H/S Frame 9…14 drives

– PowerFlex 750-Series Frame 8…10 drives

This can result in diode front end damage. See

Figure 37 on page 61

and

Figure 39 on page 63 .

• Kinetix 7000 BM06…BM08 drives have the same precharge as PowerFlex

700/700S Frame 0…4 drives. Similarly, Kinetix 7000 BM09…BM12 drives have the same precharge as PowerFlex 700 Frame 5 drives. The same rules as described in the preceding bulleted text apply.

Loading

When the larger power frame drive—or the sum of the power for the larger frame drives relative to the smallest power frame drives in the lineup—is loaded, the current through the small frame drive can exceed its current rating. To prevent this condition, comply with the following considerations.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Shared AC/DC Bus Configuration—with Braking DC Bus Regulation Chapter 5

1. Diodes

- Back-to-back (dual pack) diodes with fuses must be used in the

DC link of each drive to enable proportional sharing of input current by the converter section of each drive. Failure to do so can result in drive

damage

. See Back-to-Back Diodes (Shared AC/DC Configurations) on page 133

for recommended part numbers.

2.

The wiring and interconnection distances to the AC input connections must be minimized to prevent large variations of the input impedances between the drives.

3.

If a 3-phase line reactor is used, the Common AC must be drawn from the load side of the reactor (see

Figure 37 on page 61 ).

Same Size Drive

Considerations

1.

Individual line reactors for each drive or back-to-back diodes must be used for proportional current sharing. For line reactor information, see Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC

Drives, publication DRIVES-UM001. For recommended diodes, see

Back-to-Back Diodes (Shared AC/DC Configurations) on page 133

.

2.

The wiring and interconnection distances to the Common AC Bus must be minimized to prevent large variations of the input impedances between the drive inverters.

PowerFlex 40P or PowerFlex

520-Series Drive

Considerations

When using PowerFlex 40P or PowerFlex 520-Series drives in a shared bus configuration, the loading must be taken into account.

When the larger power frame drive—or the sum of the power for the larger frame drives relative to the smallest power frame drives in the lineup—is loaded, the current through the small frame drive can exceed its current rating. To prevent this condition, these guidelines must be followed.

1.

Individual line reactors for each drive must be used for proportional current sharing. For line reactor information, see Wiring and Grounding

Guidelines for Pulse Width Modulated (PWM) AC Drives, publication

DRIVES-UM001.

2.

The wiring and interconnection distances to the Common AC Bus must be minimized to prevent large variations of the input impedances between the drive inverters.

3.

Only multiple same size and type of drives on a shared AC/DC bus are

recommended in the system configuration shown in Figure 39 on page 63 .

PowerFlex 40P or PowerFlex 520-Series drives must not be combined with PowerFlex 700/700S/750-Series drives on the same shared AC/DC bus.

Sizing

Each drive must be sized for the motor load connected to it.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

65

Chapter 5 Shared AC/DC Bus Configuration—with Braking DC Bus Regulation

Fusing

Drives must not be ‘daisy chained’. Configure the shared DC bus in a ‘star’ configuration to enable proper fusing. Fast semiconductor fuses must be used in the DC links to minimize destructive energy in the event of a part or control malfunction. The fuses must be sized to handle large peak currents at the end of precharge.

See Appendix A

for the recommended Common Bus DC drive fusing.

66

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Shared DC Bus Configuration (Piggy Back)

Chapter

6

System Characteristics

Supported Products

This system is characterized by the use of one stand-alone drive as the converter and additional common DC bus drives used in a shared DC bus configuration.

At the time of publication, the following drives are supported when used on a shared DC bus configuration.

Supported Drives

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings - Three phase only

PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: Frames 0…10

(2)

PowerFlex 700S: All frame sizes

(2)

PowerFlex 700H: All frame sizes

(2)

PowerFlex 700L: All frame sizes

(2)

PowerFlex 750-Series: Frames 1…10

(3)

Kinetix 7000: BM06…BM12

Kinetix 6000 and Kinetix 6200/6500: B-Series Configurations

(1) These drives require firmware revision 2.001 or later (Standard and Vector Control).

(2) PowerFlex 700 Frame 5…10, PowerFlex 700S Frame 5 and 6 and Frame 9…14,

PowerFlex 700H Frame 9…14, and PowerFlex 700L DC input drives are required when not connected to the AC source.

(3) A DC input terminal kit must be ordered for PowerFlex 750-Series Frame 6 and 7 drives.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

67

Chapter 6 Shared DC Bus Configuration (Piggy Back)

Typical System

Configurations

Figure 40 - Stand-alone AC Drives in a Shared DC Bus Configuration

➌

3-Phase

Source

See Special Bus Requirements footnotes in table below and

General Considerations on page 69

.

3-Phase

Reactor

➊

DC+

L1

L2

L3

➋

AC Drive 1

(supply)

DCDC+

AC Drive 2

DC-

M

M

➊ A 3-Phase line reactor is only required for special line considerations. See Wiring and Grounding Guidelines for

Pulse Width Modulated (PWM) AC Drives, publication DRIVES-UM001, for additional information.

➋ Supply drive must be sized to source current to all connected drives during all modes of operation that are encountered.

➌ At 600 volts, PowerFlex 700/700S Frame 0…4 drives cannot be used on the same bus as PowerFlex 700/700S

Frame 5 and 6 drives. Also, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as

PowerFlex 750-Series Frame 6…10 drives.

700/700S

Frames 0…4

Drive Compatibility Matrix

700/700S

Frames 5…6

AC Drive 1 (Supply)

PowerFlex

700

Frames 7…10

700H/700S

Frames 9…14

700L Frames

2, 3A, and 3B

750-Series

Frames 1…4

Kinetix

750-Series

Frames 5…10

BM06…BM08 BM09…BM12

6000 & 6200/

6500 (460V)

40P

40P

520-Series

700/700S

Frames 0…4

700/700S

Frames 5…6

700

Frames 7…10

750-Series

Frames 1…4

750-Series

Frames 5…10

700H/700S

Frames 9…14

700L Frames 3A and 3B

BM06…BM08

BM09…BM12

6000 and 6200/

6500 (460V)

Yes

(1)

Yes

(1)

520-

Series

Yes

(1)

Yes

(1)

Yes

Yes

Yes

(2)

Yes

(3)

Yes

Yes

Yes

Yes

Yes

(3)

Yes

(3)

Yes

(4)

Yes

(3) (4)

Yes

(3) (4)

Yes

(4)

Yes

(4)

Yes

(4)

Yes

(4)

Yes

(3) (4)

Yes

(3) (4)

Yes

(5)

Yes

(5)

(6)

Yes

(5) (6)

Yes

Yes

Yes

Yes

(3)

Yes

Yes

Yes

68

Special Bus Requirements

(1) See

PowerFlex 40P or PowerFlex 520-Series Drive Considerations on page 69

.

(2) At 600 volts, PowerFlex 700/700S Frame 0…4 drives cannot be used on the same bus as PowerFlex 700/700S Frame 5 and 6 drives.

(3) DC input ‘Common Bus’ drives are required when not connected to an AC source.

(4) Total capacitance of externally connected drives must not exceed the maximum allowable external capacitance of the supply drive or the precharge resistors will overheat. The maximum allowable external capacitance for each drive is listed in related tables in

Appendix A .

(5) At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

(6) A DC input terminal kit must be ordered for PowerFlex 750-Series Frame 6, 7, and 8 drives.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Shared DC Bus Configuration (Piggy Back) Chapter 6

General Considerations

ATTENTION: The incorrect use or configuration of third party assemblies can result in reduced system reliability and drive damage.

1.

Minimizing bus inductance is imperative. Drives must be mounted physically as close to each other as possible with all power wiring ‘tied’ together to minimize loop area.

2.

For further assistance with this Common Bus configuration, contact

Rockwell Automation SupportPlus engineering team at: http://www.ab.com/support/abdrives/files/supportplus.pdf

PowerFlex 40P or PowerFlex

520-Series Drive

Considerations

Sizing

PowerFlex 40P or PowerFlex 520-Series drives must not be used on the same DC bus supply as PowerFlex 700/700S/700H/700L/750-Series drives. This is due to the difference in capacitance/amps of the PowerFlex 40P or PowerFlex 520-Series drives compared to the PowerFlex 700/700S/700H/700L/750-Series drives.

The total motoring load must not exceed the rated load for the drive sourcing the

DC power. Each DC-fed drive must be sized for the motor load connected to it.

Fusing

Drives must not be ‘daisy chained’. Configure the shared DC bus in a ‘star’ configuration to enable proper fusing. Fast semiconductor fuses must be used in the DC links to minimize destructive energy in the event of a part or control malfunction. The fuses must be sized to handle large peak currents at the end of precharge.

See Appendix A

for the recommended Common DC Bus drive fusing.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

69

Chapter 6 Shared DC Bus Configuration (Piggy Back)

Notes:

70

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Chapter

7

Shared DC Bus Configuration (Piggy Back)— with Braking Chopper

System Characteristics

This system is characterized by the use of one stand-alone drive as the converter and additional common DC bus drives used in a shared DC bus configuration. In addition, a Braking Chopper, Dynamic Braking Unit, or the drive’s internal

IGBT with a braking resistor for power dissipation of regenerative energy is also used.

Supported Products

At the time of publication, the following products are supported.

Products

Brake Chopper Module

Heavy Duty Dynamic Brake Unit

Supported Drives

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings - Three phase only

PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: Frames 0…10

(2)

PowerFlex 700S: All frame sizes

(2)

PowerFlex 700H: All frame sizes

(2)

PowerFlex 700L: All frame sizes

(2)

PowerFlex 750-Series: Frames 1…10

(3)

Kinetix 7000: BM06…BM12

Kinetix 6000 and Kinetix 6200/6500 – All 460V configurations

(4)

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings - Three phase only

PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: Frames 0…10

(2)

PowerFlex 700S: All frame sizes

(2)

PowerFlex 700H: All frame sizes

(2)

PowerFlex 700L: All frame sizes

(2)

PowerFlex 750-Series: Frames 1…10

(3)

Kinetix 7000: BM06…BM12

Kinetix 6000 and Kinetix 6200/6500: All 460V configurations

(4)

(1) These drives require firmware revision 2.001 or later (Standard and Vector Control).

(2) PowerFlex 700 Frame 5…10, PowerFlex 700S Frame 5 and 6 and Frame 9…14, PowerFlex 700H Frame 9…14, and PowerFlex 700L

DC input drives are required when not connected to the AC source.

(3) A DC input terminal kit must be ordered for PowerFlex 750-Series Frame 6 and 7 drives.

(4) Kinetix 6000 configurations require firmware revision 1.92 or later.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

71

Chapter 7 Shared DC Bus Configuration (Piggy Back)—with Braking Chopper

Note – When applicable, the drive’s internal IGBT can also be used.

Drive

PowerFlex 40P

PowerFlex 520-Series

PowerFlex 700

PowerFlex 700S

PowerFlex 700H

PowerFlex 750-Series

Kinetix 7000

Kinetix 6000 and Kinetix 6200/6500

Internal Brake IGBT

Standard on all power ratings

Standard on all power ratings

Standard on Frames 0…3; optional on Frames 4…6

Standard on Frames 1…3; optional on Frames 4…6, and 9

Optional in Frame 9 only

Standard on Frames 1…5; optional on Frames 6 and 7;

Frames 8…10 have no internal brake IGBT

No internal brake IGBT

Internal bus regulation cannot be used

ATTENTION: The internal IGBT in a Kinetix 6000 Multi-Axis Servo Drive is disabled in ‘Common Bus Follower’ mode.

72

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Typical System

Configurations

Shared DC Bus Configuration (Piggy Back)—with Braking Chopper Chapter 7

Figure 41 - AC Drives with a Braking Module in a Shared DC Bus Configuration

See Special Bus Requirements in table below and

General Considerations on page 75 .

3-Phase

Source

RC Snubber

3-Phase

Reactor

➊

DC+

L1

L2

L3

➋

AC Drive 1

(supply)

DC-

DC+

Braking

Module

DC-

BR1

BR

➌

BR2

DC+

AC Drive 2

DC-

M1 M2

➊ A 3-Phase line reactor is only required for special line considerations. See Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-UM001, for additional information.

➋ Supply drive must be able to source current to all connected drives during all modes of operation that are encountered.

➌ The brake module must be connected closest to the supply drive. The brake and resistor must be sized no bigger than the capacity of the supply drive.

Drawing Designation Supported Drives/Product Special Bus Requirements

AC Drive 1 (supply)

AC Drive 2

Braking Module

See the Drive Compatibility Matrix on

page 74

for supported drives and special bus requirements.

Encompass Partner product An RC Snubber is required when supply drive is a

PowerFlex 700/700S Frame 0…4, PowerFlex 750-Series

Frame 1…10 drive, or a Kinetix 7000 BM06…BM08 drive. See

RC Snubber Circuit on page 136

for more information.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

73

74

Chapter 7 Shared DC Bus Configuration (Piggy Back)—with Braking Chopper

Figure 42 - AC Drives Using an Internal Braking IGBT in a Shared DC Bus Configuration

See Special Bus Requirements footnotes in table below and

General Considerations on page 75

.

➍

➋

BR

DC-

Yes

DC+

➊ A 3-Phase line reactor is only required for special line considerations. See Wiring and Grounding Guidelines for

Pulse Width Modulated (PWM) AC Drives, publication

DRIVES-UM001, for additional information.

➋ Only drives listed in the table on page 72 have internal brake

IGBTs. See publication PFLEX-AT001 for minimum resistance.

➌ Supply drive must be able to source current to all connected drives during all modes of operation that are encountered.

3-Phase

Source

➍ At 600 volts, PowerFlex 700/700S Frame 0…4 drives cannot be used on the same bus as PowerFlex 700/700S Frame 5 and 6 drives. Also, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series

Frame 6…10 drives.

Drive Compatibility Matrix

40P 520-

Series

700/700S

Frames 0…4

700/700S

Frames 5…6

PowerFlex

700H/700S

Frame 9

AC Drive 1 (Supply)

➊

750-Series

Frames 1…4

Yes

(1)

Yes

(1)

40P

520-Series

Yes

(1)

Yes

(1)

Yes

(2)

Yes

(4)

700/700S

Frames 0…4

Yes

Yes

(3)

Yes

(3) (4)

700/700S

Frames 5…6

Yes

(5)

750-Series

Frames 1…4

3-Phase

Reactor

750-Series

Frames 5…10

DC+ BR1 BR2

L1

L2

L3

➌

AC Drive 1

(supply)

Yes

(5)

(6)

M1

BM06…BM08 BM09…BM12

AC Drive 2

M2

Kinetix

Yes

Yes

(3)

Yes

(5) (6)

750-Series

Frames 5…10

700H/700S

Frame 9

BM06…BM08

BM09…BM12

6000 and 6200/

Special Bus Requirements

6500 (460V)

Yes Yes

Yes

Yes

Yes

(3) (4)

Yes

(4)

Yes

(4)

Yes

(4)

Yes Yes

Yes

Yes

DC-

6000 & 6200/

6500 (460V)

(1) See

PowerFlex 40P or PowerFlex 520-Series Drive Considerations on page 75

.

(2) At 600 volts, PowerFlex 700/700S Frame 0…4 drives cannot be used on the same bus as PowerFlex 700/700S Frame 5 and 6 drives.

(3) DC input ‘Common Bus’ drives are required when not connected to an AC source.

(4) Total capacitance of externally connected drives must not exceed the maximum allowable external capacitance of the supply drive or the precharge resistors will overheat. The maximum allowable external capacitance for each drive is listed in related tables in

Appendix A .

(5) At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

(6) A DC input terminal kit must be ordered for PowerFlex 750-Series Frame 6, 7, and 8 drives.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Shared DC Bus Configuration (Piggy Back)—with Braking Chopper Chapter 7

General Considerations

ATTENTION: The incorrect use or configuration of third party assemblies can result in reduced system reliability and drive damage.

1.

The brake unit must be connected to the terminals of the drive used as the converter. The brake module and resistor must be sized no bigger than the capacity of the supply drive. This enables the drives to regenerate power to the large drive capacitor bank at current limit values if necessary. The large drive can then dump large amounts of peak power to a properly-sized brake unit without stressing the small drives.

2.

Minimizing bus inductance is imperative. Drives must be mounted physically as close to each other as possible with all power wiring ‘tied’ together to minimize loop area.

3.

An R-C Snubber circuit must be used in a Shared DC Bus configuration when the main drive is a PowerFlex 700/700S Frame 0…4, PowerFlex 750-

Series Frame 1…10, PowerFlex 40P, or PowerFlex 520-Series drive, and a

Brake Chopper is used. See RC Snubber Circuit on page 136 for more

information.

4.

For further assistance with this Common Bus configuration, contact

Rockwell Automation SupportPlus engineering team at: http://www.ab.com/support/abdrives/files/supportplus.pdf

PowerFlex 40P or PowerFlex

520-Series Drive

Considerations

PowerFlex 40P or PowerFlex 520-Series drives must not be used on the same DC bus supply as PowerFlex 700/700S/700H/700L/750-Series drives. This is due to the difference in capacitance/amps of the PowerFlex 40P or PowerFlex 520-Series drives compared to the PowerFlex 700/700S/700H/700L/750-Series drives.

Sizing

Fusing

The total motoring load must not exceed the rated load for the drive sourcing the

DC power. Each DC-fed drive must be sized for the motor load connected to it.

Drives must not be ‘daisy chained’. Configure the shared DC bus in a ‘star’ configuration to enable proper fusing. Fast semiconductor fuses must be used in the DC links to minimize destructive energy in the event of a part or control malfunction. The fuses must be sized to handle large peak currents at the end of precharge.

See Appendix A

for the recommended Common DC Bus drive fusing.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

75

Chapter 7 Shared DC Bus Configuration (Piggy Back)—with Braking Chopper

Notes:

76

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Regenerative Bus Supply Configuration

Chapter

8

System Characteristics

Supported Products

This system is characterized by a PWM-controlled IGBT converter for full regeneration of power to the AC line. The regenerative bus supply puts energy back onto the distribution system instead of dissipating energy with resistor braking technology. This configuration provides low AC line harmonics and can be used to meet IEEE-519 when used with the appropriate filtering.

At the time of publication, the following products are supported.

Products

PowerFlex Active Front

End

Supported Drives

PowerFlex 40P: All power ratings

PowerFlex 520-Series: All power ratings - Three phase only

PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: All frame sizes

(2)

PowerFlex 700S: All frame sizes

(2)

PowerFlex 700H: All frame sizes

(2)

PowerFlex 750-Series: Frames 1…10

(3)

Kinetix 7000: BM06…BM12

Kinetix 6000 and Kinetix 6200/6500: All 460V configurations

(1) These drives require firmware revision 2.001 or later (Standard and Vector Control).

(2) PowerFlex 700 Frame 5…10, PowerFlex 700S Frame 5 and 6 and Frame 9…14, PowerFlex 700H Frame 9…14, and PowerFlex

700L DC input drives are required when not connected to the AC source.

(3) PowerFlex 750-Series Frame 5…10 DC input version drives with precharge must be selected.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

77

Chapter 8 Regenerative Bus Supply Configuration

78

Typical System

Configurations

This section is categorized by type of grounding (solid ground, high resistance ground, or ungrounded), a single AFE providing power to a single drive, and a single AFE providing power to multiple drives.

Solid Ground System with Single AFE and Single AC Drive

3-Phase

AC Input

Figure 43 - Solid Ground System with Single AFE and Single AC Drive

Transformer

L1

Active Front End

DC+

DC Bus

Conditioner

➌

➋

L2

See Special Bus Requirements in table below and

General

Considerations on page 84

.

DC-

PE

L3

PowerFlex

Common

Mode

Core

➊

Common

Mode Core

➊

DC+ DC-

➊ The common mode core mounting location (AFE DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with AFE bus supplies, the common mode core is placed at the DC output terminals of the AFE and the drive DC input terminals or at the motor output of each drive.

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

➌ A capacitor bank is required. See table below and

Bus Supply Capacitors on page 134 for more information.

AC Drive

M

Solid

Solid

AFE System Drive

Ground Type Voltage Qty Frame Size Qty Type

Solid

Solid

400/480

600

400/480

600/690

1

1

10

(1)

or 13

(2)

10

(1)

or 13

(2)

1

1

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frames 7

PowerFlex 750-Series: Frames 8…10

400/480

10

(1)

or 13

(2)

600/690

1 1 PowerFlex 700H/700S: Frames 9…14

400/480

600/690

1

10

(1)

or 13

(2)

1 Any other non-listed PowerFlex drive

Common Mode Core

(3)

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

Design G

Design G

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also, see Note 1 on

page 25 for

catalog no. information.

Design G

Design G

Contact factory for

30339-319-01

(4)

or

30201-031-01/1321-M670

(5)

Design E

Design E

Contact Factory

(6)

DC Bus

Conditioner

(7)

(1) For PowerFlex AFE Frame 10, use common mode core 30339-320-01 at the AFE output terminals.

(2) For PowerFlex AFE Frame 13, use common mode core 30339-319-01 at the AFE output terminals.

(3) One common mode core is required on each PowerFlex AFE output. See Note 1 in the diagram above and Common Mode Core on page 136

for recommendations.

(4) Drive DC input common mode core.

(5) Drive motor output common mode core.

(6) For any non-listed PowerFlex drive, contact the factory. See

Technical Support (SupportPlus™) on page 14 for details.

(7) One DC bus conditioner is required for each PowerFlex AFE. See

DC Bus Conditioner—Designs A, B, C, D, or E on page 139 for details.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Regenerative Bus Supply Configuration Chapter 8

3-Phase

AC Input

Solid Ground System with Single AFE and Multiple AC Drives

Figure 44 - Solid Ground System with Single AFE and Multiple AC Drives

Transformer

L1

Active Front End

DC+

DC Bus

Conditioner

➌

➋

See Special Bus Requirements in table below and

General

Considerations on page 84

.

PE

L2

L3

PowerFlex

DC-

Common

Mode

Core

➊

Common

Mode Core

➊

DC+

DC-

DC+ DC-

Solid

System

➊ The common mode core mounting location (AFE DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with AFE bus supplies, the common mode core is placed at the DC output terminals of the AFE and the drive DC input terminals or at the motor output of each drive.

AFE

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

➌ A capacitor bank is required. See table below and

Bus Supply Capacitors on page 134 for more information.

Drive

Ground Type Voltage Qty Frame Size Qty Type

400/480

600

(1)

1 10

(2)

or 13

(3)

2…20

(4)

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

AC Drive

M

Common Mode Core

(5)

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

M M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

400/480

Solid

Solid

Solid

400/480

600/690

400/480

600/690

600/690

(1)

1

1

1

10

(2)

or 13

(3)

10

(2)

or 13

(3)

10

(2)

or 13

(3)

2…20

(4)

2…20

(4)

2…20

(4)

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frames 7

PowerFlex 750-Series: Frames 8…10

PowerFlex 700H/700S: Frames 9…14

Any other non-listed PowerFlex drive

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also,

see Note 1 on page 25

for catalog no. information.

Contact factory for

30339-319-01

(6)

or

30201-031-01/1321-M670

(7)

Design G

Design E

Design E

Contact Factory

(4)

(1) At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

(2) For PowerFlex AFE Frame 10, use common mode core 30339-320-01 at the AFE output terminals.

(3) For PowerFlex AFE Frame 13, use common mode core 30339-319-01 at the AFE output terminals.

(4) For more than 20 drives, or for any non-listed PowerFlex drive, contact the factory. See Technical Support (SupportPlus™) on page 14

for details.

(5) One common mode core is required on each PowerFlex AFE output. See Note 1 in the diagram above and Common Mode Core on page 136

for recommendations.

(6) Drive DC input common mode core.

(7) Drive motor output common mode core.

(8) One DC bus conditioner is required for each PowerFlex AFE. See

DC Bus Conditioner—Designs A, B, C, D, or E on page 139 for details.

Design G

Design G

Design G

DC Bus Conditioner

(8)

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

79

Chapter 8 Regenerative Bus Supply Configuration

High Resistance Ground System with Single AFE and Single AC Drive

3-Phase

AC Input

Figure 45 - High Resistance Ground System with Single AFE and Single AC Drive

Active Front End

DC Bus

Conditioner

➋

Transformer

L1

DC+

➌

See Special Bus Requirements

in table below and General

Considerations on page 84 .

L2

DC-

L3

PowerFlex

Common

Mode

Core

➊

Common

Mode Core

➊

DC+ DC-

Ground Fault

Indicator Filter

80

System

PE

➊ The common mode core mounting location (AFE DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with

AFE bus supplies, the common mode core is placed at the DC output terminals of the

AFE and the drive DC input terminals or at the motor output of each drive.

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the

DC source as possible.

➌ A capacitor bank is required. See table below and

Bus Supply Capacitors on page 134

for more information.

AFE Drive Common Mode Core

(3)

Ground Type Voltage Qty Frame Size Qty Type

AC Drive

M

DC Bus

Conditioner

(7)

Gnd. Fault

Indicator

Filter

(8)

High Resistance

Ground

400/480

600

400/480

High Resistance

Ground

High Resistance

Ground

High Resistance

Ground

600/690

600/690

400/480

600/690

400/480

1

1

1

10

(1)

or 13

(2)

1

10

(1)

or 13

(2)

1

10

(1)

or 13

(2)

1

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frames 7

PowerFlex 750-Series: Frames 8…10

PowerFlex 700H/700S: Frames 9…14

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

Design E

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also,

see Note 1 on page 25

for catalog no. information.

Design E

Contact factory for

30339-319-01

(4)

or

30201-031-01/1321-M670

(5)

Design E

Yes

Yes

Yes

1 10

(1)

or 13

(2)

1 Any other non-listed PowerFlex drive Contact Factory

(6)

(1) For PowerFlex AFE Frame 10, use common mode core 30339-320-01 at the AFE output terminals.

(2) For PowerFlex AFE Frame 13, use common mode core 30339-319-01 at the AFE output terminals.

(3) One common mode core is required on each PowerFlex AFE output. See Note 1 in the diagram above and

Common Mode Core on page 136 for recommendations.

(4) Drive DC input common mode core.

(5) Drive motor output common mode core.

(6) For any non-listed PowerFlex drive, contact the factory. See Technical Support (SupportPlus™) on page 14

for details.

(8) See Ground Fault Indicator Filter on page 143

for recommendations.

(7) One DC bus conditioner is required for each PowerFlex AFE. See DC Bus Conditioner—Designs A, B, C, D, or E on page 139

for details.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Regenerative Bus Supply Configuration Chapter 8

3-Phase

AC Input

Ground Fault

Indicator Filter

High Resistance Ground System with Single AFE and Multiple AC

Drives

Figure 46 - High Resistance Ground System with Single AFE and Multiple AC Drives

Transformer

Active Front End

L1

DC+

DC Bus

Conditioner

➌

➋

See Special Bus Requirements in table below

and General Considerations on page 84 .

L2

L3

PowerFlex

DC-

Common

Mode

Core

➊

Common

Mode Core

➊

DC+

DC-

DC+ DC-

PE

➊ The common mode core mounting location (AFE DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with

AFE bus supplies, the common mode core is placed at the DC output terminals of the

AFE and the drive DC input terminals or at the motor output of each drive.

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

➌ A capacitor bank is required. See table below and

Bus Supply Capacitors on page 134

for more information.

System AFE Drive

Ground Type Voltage Qty Frame Size Qty Type

1 10

(2)

or 13

(3)

High Resistance

Ground

400/480

600

(1)

400/480

High Resistance

Ground

600/690

(1)

1

1

10

(2) or 13

(3)

10

(2) or 13

(3)

High Resistance

Ground

400/480

600/690

2…20

(4)

2…20

(4)

2…20

(4)

AC Drive

M

M M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

Common Mode Core

(5)

DC Bus

Conditioner

(8)

Gnd. Fault

Indicator

Filter

(9)

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

Design E

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frames 7

PowerFlex 750-Series: Frames 8…10

PowerFlex 700H/700S: Frames 9…14

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also,

see Note 1 on page 25 for

catalog no. information.

Design E

Contact factory for

30339-319-01

(6)

or

30201-031-01/1321-M670

(7)

Design E

Yes

Yes

Yes

High Resistance

Ground

400/480

600/690

1 10

(2) or 13

(3)

2…20

(4)

Any other non-listed PowerFlex drive Contact Factory

(4)

(1) At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

(2) For PowerFlex AFE Frame 10, use common mode core 30339-320-01 at the AFE output terminals.

(3) For PowerFlex AFE Frame 13, use common mode core 30339-319-01 at the AFE output terminals.

(4) For more than 20 drives, or for any non-listed PowerFlex drive, contact the factory. See

Technical Support (SupportPlus™) on page 14 for details.

(5) One common mode core is required on each PowerFlex AFE output. See Note 1 in the diagram above and

Common Mode Core on page 136 for recommendations.

(6) Drive DC input common mode core.

(7) Drive motor output common mode core.

(8) One DC bus conditioner is required for each PowerFlex AFE. See DC Bus Conditioner—Designs A, B, C, D, or E on page 139

for details.

(9) See Ground Fault Indicator Filter on page 143 for recommendations.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

81

Chapter 8 Regenerative Bus Supply Configuration

3-Phase

AC Input

Ungrounded System with Single AFE and Single AC Drive

Figure 47 - Ungrounded System with Single AFE and Single AC Drive

Active Front End

DC Bus

Conditioner

➋

Transformer

L1 DC+

➌

L2

L3

PowerFlex

DC-

Common

Mode

Core

➊

Common

Mode Core

➊

DC+

Zig-Zag

Transformer

See Special Bus Requirements in table below and

General

Considerations on page 84

.

DC-

➊ The common mode core mounting location

(AFE DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with AFE bus supplies, the common mode core is placed at the DC output terminals of the AFE and the drive DC input terminals or at the motor output of each drive.

Ground Fault

Indicator Filter

PE

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

➌ A capacitor bank is required. See table

below and Bus Supply Capacitors on page 134 for more information.

AC Drive

M

System AFE Drive

Ground Type Voltage Qty Frame Size Qty Type

Common Mode Core

(3)

DC Bus

Conditioner

(7)

Gnd. Fault

Indicator

Filter

(8)

Zig Zag

Transformer

Required

(9)

Ungrounded

Ungrounded

Ungrounded

Ungrounded

400/480

600

400/480

600/690

400/480

600/690

400/480

600/690

1

1

1

1

10

(1)

or 13

(2)

1

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

Design E

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

10

(1)

or 13

(2)

10

(1)

or 13

10

(1)

or 13

(2)

(2)

1

1

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frames 7

PowerFlex 750-Series: Frames 8…10

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or ’W’ and Input Type 4. Also, see

Note 1 on page 25

for catalog no. information.

Design E

PowerFlex 700H/700S: Frames 9…14

Contact factory for

30339-319-01

(4)

or

30201-031-01/1321-M670

(5)

Design E

1 Any other non-listed PowerFlex drive Contact Factory

(6)

Yes

Yes

(1) For PowerFlex AFE Frame 10, use common mode core 30339-320-01 at the AFE output terminals.

(2) For PowerFlex AFE Frame 13, use common mode core 30339-319-01 at the AFE output terminals.

(3) One common mode core is required on each PowerFlex AFE output. See Note 1 in the diagram above and

Common Mode Core on page 136 for recommendations.

(4) Drive DC input common mode core.

(5) Drive motor output common mode core.

(6) For any non-listed PowerFlex drive, contact the factory. See Technical Support (SupportPlus™) on page 14

for details.

(7) One DC bus conditioner is required for each PowerFlex AFE. See DC Bus Conditioner—Designs A, B, C, D, or E on page 139

for details.

(8) See Ground Fault Indicator Filter on page 143

for recommendations.

82

(9) See Zig-Zag Transformer on page 144 for recommendations.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Yes Yes

Yes

Yes

Regenerative Bus Supply Configuration Chapter 8

3-Phase

AC Input

Transformer

Zig-Zag

Transformer

Ungrounded System with Single AFE and Multiple AC Drives

Figure 48 - Ungrounded System with Single AFE and Multiple AC Drives

Active Front End

L1

DC+

DC Bus

Conditioner

➌

➋

See Special Bus Requirements in table below and

General Considerations on page 84

.

L2

L3

PowerFlex

DC-

Common

Mode

Core

➊

Common

Mode Core

➊

DC+

DC-

DC+ DC-

Ungrounded

Ungrounded

400/480

600

(1)

400/480

400/480

600/690

400/480

600/690

1

600/690

(1)

1

10

(2) or 13

(3)

10

(2)

or 13

10

(2)

or 13

(3)

(3)

AC Drive

M M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

System

Ground Type Voltage

Indicator Filter

Ground Fault

PE

➊ The common mode core mounting location (AFE DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with AFE bus supplies, the common mode core is placed at the DC output terminals of the AFE and the drive DC input terminals or at the motor output of each drive.

AFE Drive

Qty Frame Size Qty Type

M

Common Mode Core

(5)

DC Bus

Conditioner

(8)

Gnd. Fault

Indicator

Filter

(9)

Zig Zag

Transformer

Required

(10)

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

Fr. 1…3:

Fr. 4:

1321-M048

1321-M180

Design E

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frames 7

PowerFlex 750-Series: Frames 8…10

PowerFlex 700H/700S: Frames 9…14

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or ’W’ and Input Type 4. Also, see

Note 1 on page 25 for catalog

no. information.

Contact factory for

30339-319-01

(6)

or

30201-031-01/1321-M670

(7)

Design E

Design E

Yes

Yes

Yes

Yes

Yes

Yes Ungrounded 1

2…20

(4)

2…20

(4)

2…20

(4)

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

➌ A capacitor bank is required. See table below and

Bus

Supply Capacitors on page 134 for more information.

Ungrounded 1

10

(2)

or 13

(3)

2…20

(4)

Any other non-listed PowerFlex drive

Contact Factory

(4)

(1) At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

(2) For PowerFlex AFE Frame 10, use common mode core 30339-320-01 at the AFE output terminals.

(3) For PowerFlex AFE Frame 13, use common mode core 30339-319-01 at the AFE output terminals.

(4)

For more than 20 drives, or for any non-listed PowerFlex drive, contact the factory. See Technical Support (SupportPlus™) on page 14

for details.

(5)

One common mode core required on each PowerFlex AFE output. See Note 1 in the diagram above and Common Mode Core on page 136

for recommendations.

(6) Drive DC input common mode core.

(7) Drive motor output common mode core.

(8) One conditioner required for each PowerFlex AFE.

(9) See

Ground Fault Indicator Filter on page 143 for recommendations.

(10) See

Zig-Zag Transformer on page 144 for recommendations.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

83

84

Chapter 8 Regenerative Bus Supply Configuration

General Considerations 1.

Disconnect the common mode capacitors from the drives when using a regenerative module. See the drive's documentation for instructions on disconnecting the common mode capacitors.

2.

All system components (Bus Supply and PowerFlex Drives) must be selected for the same AC-line voltage.

3.

A low inductance type DC bus must be used. See DC Bus Connections on page 15 for details.

4.

If a drive from column A in the table below is mixed with a drive from column B, a capacitor bank is required. See

Bus Supply Capacitors on page 134 for details.

Column A Drives

PowerFlex 700/700S: Frames 0…5

PowerFlex 750-Series: Frames 1…10

Kinetix 6000 and Kinetix 6200/6500

Kinetix 7000

Column B Drives

PowerFlex 700/700S: Frame 6

PowerFlex 700: Frames 8…10

PowerFlex 700H/700S: Frame 9 and up

PowerFlex 700L: All Frames

5.

If a disconnect switch between the common DC bus and the drive's input is used, an auxiliary contact on the disconnect switch must be connected to a digital input of the drive. The corresponding digital input must be set to

‘Precharge Enable’. This provides the proper precharge interlocking, guarding against possible damage to the drive when reconnecting the drive to an energized DC bus. Under this condition, the drives must have an internal or externally-supplied precharge.

Drive

PowerFlex 40P

PowerFlex 523

PowerFlex 525

PowerFlex 700

PowerFlex 700L with vector control

PowerFlex 700S

PowerFlex 700L with 700S control

PowerFlex 700H

PowerFlex 750-Series

Parameter

Number

A051…A054 t062…t066 t062…t068

361…366

825…830

361…366

189 [DI Precharge]

Setting

29 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

Digital

Input

1…4

2…6

2…8

1…6

1…6

30 (PreCharge En) 1…6

See Drive Programming Manual for programming information.

Sizing

See the drive documentation for sizing information. In addition, when paralleling

PowerFlex AFE units, they must be derated by 5% of their rated power.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Fusing

Regenerative Bus Supply Configuration Chapter 8

DC Input Drives

See Appendix A

for the recommended Common DC Bus drive fusing.

PowerFlex Active Front End

See the PowerFlex Active Front End User Manual for recommended fusing.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

85

Chapter 8 Regenerative Bus Supply Configuration

Notes:

86

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Chapter

9

Multiple Regenerative Bus Supply

Configurations

System Characteristics

The power of the AFE input group can be increased by connecting several groups in parallel. Paralleling refers to AFE units connected on the same input transformer and the same DC bus. The regenerative bus supply puts energy back onto the distribution system instead of dissipating energy with resistor braking technology. This configuration provides low AC line harmonics and can be used to meet IEEE-519 when used with the appropriate filtering.

Supported Products

Paralleling is typically used when the power range of a single frame size is not sufficient, or when redundancy is needed.

At the time of publication, the following Regenerative Bus Supplies and

PowerFlex drives are supported.

Product

PowerFlex

Active

Front End

Voltage

Class (VAC)

400/480

600/690

Supported Drives

480V AC PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: All Frames

(2)

480V AC PowerFlex 700S: Frames 1…6

(2)

480V AC PowerFlex 750-Series: Frames 1…10

(3)

480V AC PowerFlex 700H/700S: Frames 9…14

(2)

600V AC PowerFlex 750-Series: Frames 3...5

600V AC PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: Frames 0…4

600/690V AC PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: Frames 5 and 6

(2)

600/690V AC PowerFlex 700/700S: Frames 5 and 6

(2)

600/690V AC PowerFlex 750-Series: Frame 6…10

690V AC PowerFlex 700H/700S: Frames 9…14

(2)

DC Bus

OverVoltage

Trip

(4)

810V DC

810V DC

810V DC

911V DC

1013V DC

1013V DC

1162V DC

1162V DC

1172V DC

1200V DC

(1) These drives require firmware revision 2.001 or later (Standard and Vector Control).

(2) PowerFlex 700 Frame 5…10, PowerFlex 700S Frame 5 and 6 and Frame 9…14, and PowerFlex 700H Frame 9…14 DC input drives are required when not connected to the AC source.

(3) PowerFlex 750-Series Frame 5…10 DC input version drives with precharge must be selected.

(4) The regenerative limit for the PowerFlex 700AFE must be less than the DC Bus Overload Trip voltage of the drive with the lowest DC Bus Overload

Trip voltage.

When the PowerFlex AFE is paralleled, the DC bus voltage at regeneration is 5% higher than with a single AFE due to the 5% droop.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

87

Chapter 9 Multiple Regenerative Bus Supply Configurations

Typical System Configuration

This section is categorized by type of grounding (solid ground, high resistance ground, or ungrounded), multiple AFEs providing power to a single drive, and multiple AFEs providing power to multiple drives.

88

Solid Ground System with Multiple AFEs and Single AC Drive

3-Phase

AC Input

Figure 49 - Solid Ground System with Multiple AFEs and Single AC Drive

Transformer

L1

Active Front End

DC+

DC Bus

Conditioner

➌

➋

See Special Bus Requirements in table below and

General

Considerations on page 94

.

L2

DC-

PE

L3

PowerFlex

Common

Mode

Core

➊

Common

Mode Core

➊

DC+ DC-

Active Front End

➊ The common mode core mounting location (AFE DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with AFE bus supplies, the common mode core is placed at the DC output terminals of the AFE and the drive DC input terminals or at the motor output of each drive.

➋ The DC bus conditioner must be electrically connected to the

DC bus as close to the DC source as possible.

➌ A capacitor bank is required. See table below and

Bus Supply

Capacitors on page 134

for more information.

L1

L2

L3

PowerFlex

DC+

DC-

Common

Mode

Core

➊

DC Bus

Conditioner

➋

AC Drive

M

System AFE

Ground Type Voltage Qty

(1)

Solid

400/480

600

400/480

2

Solid

Solid

600/690

400/480

2

2

Drive

Frame Size Qty Type

10

10

10

(2)

(2)

(2)

or 13

or 13

or 13

(3)

(3)

(3)

1

1

1

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frames 7

PowerFlex 750-Series: Frames 8…10

PowerFlex 700H/700S: Frames 9…14

Common Mode Core

(4)

DC Bus

Conditioner

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

Design G

Design G

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also, see

Note 1 on

page 25 for catalog

no. information.

Contact factory for

30339-319-01

(5)

or

30201-031-01/1321-M670

(6)

Design G

Design G

Design E

Design E

(8)

Solid

600/690

400/480

600/690

2

10

(2)

or 13

(3)

1 Any other non-listed PowerFlex drive Contact Factory

(7)

(1) For quantities greater than 2, contact factory.

(2) For PowerFlex AFE Frame 10, use common mode core 30339-320-01 at the AFE output terminals.

(3) For PowerFlex AFE Frame 13, use common mode core 30339-319-01 at the AFE output terminals.

(4) One common mode core is required on each PowerFlex AFE output. See Note 1 in the diagram above and

Common Mode Core on page 136 for recommendations.

(5) Drive DC input common mode core.

(6) Drive motor output common mode core.

(7) For any non-listed PowerFlex drive, contact the factory. See Technical Support (SupportPlus™) on page 14

for details.

(8) One DC bus conditioner is required for each PowerFlex AFE. See DC Bus Conditioner—Designs A, B, C, D, or E on page 139

for details.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Multiple Regenerative Bus Supply Configurations Chapter 9

3-Phase

AC Input

Solid Ground System with Multiple AFEs and Multiple AC Drives

Transformer

Figure 50 - Solid Ground System with Multiple AFEs and Multiple AC Drives

L1

Active Front End

DC+

DC Bus

Conditioner

➌

➋

See Special Bus Requirements in table below

and General Considerations on page 94 .

L2

DC-

PE

L3

PowerFlex

Common

Mode

Core

➊

Common

Mode Core

➊

DC+ DC-

DC+ DC-

Active Front End

➊ The common mode core mounting location (AFE DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with AFE bus supplies, the common mode core is placed at the DC output terminals of the AFE and the drive DC

L1

L2 input terminals or at the motor output of each drive.

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

➌ A capacitor bank is required. See table below and

Bus

Supply Capacitors on page 134

for more information.

System AFE

Ground Type Voltage Qty

(2)

Frame Size Qty

L3

Drive

PowerFlex

Type

DC+

DC-

Common

Mode

Core

➊

DC Bus

Conditioner

➋

AC Drive

M

M M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

Core

Conditioner

(9)

Solid 2 10

(3)

or 13

(4)

2…20

(5)

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

400/480

600

(1)

400/480

Solid

Solid

Solid

600/690

(1)

600/690

400/480

600/690

400/480

2

2

2

10

(3)

or 13

(4)

10

(3)

or 13

(4)

10

(3)

or 13

(4)

2…20

(5)

2…20

(5)

2…20

(5)

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frames 7

PowerFlex 750-Series: Frames 8…10

PowerFlex 700H/700S: Frames 9…14

Any other non-listed PowerFlex drive

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also, see

Note 1 on page 25

for catalog no. information.

Contact factory for

30339-319-01

(7)

or

30201-031-01/1321-M670

(8)

Contact Factory

(5)

(1) At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

(2) For quantities greater than 2, contact factory.

(3) For PowerFlex AFE Frame 10, use common mode core 30339-320-01 at the AFE output terminals.

(4) For PowerFlex AFE Frame 13, use common mode core 30339-319-01 at the AFE output terminals.

(5) For more than 20 drives, or for any non-listed PowerFlex drive, contact the factory. See Technical Support (SupportPlus™) on page 14

for details.

(6) One common mode core is required on each PowerFlex AFE output. See Note 1 in the diagram above and

Common Mode Core on page 136

for recommendations.

(7) Drive DC input common mode core.

(8) Drive motor output common mode core.

(9) One DC bus conditioner is required for each PowerFlex AFE. See

DC Bus Conditioner—Designs A, B, C, D, or E on page 139 for details.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Design G

Design E

Design E

Design G

Design G

Design G

89

Chapter 9 Multiple Regenerative Bus Supply Configurations

High Resistance Ground System with Multiple AFEs and Single AC

Drive

90

3-Phase

AC Input

Figure 51 - High Resistance Ground System with Multiple AFEs and Single AC Drive

Transformer

L1

Active Front End

DC+

DC Bus

Conditioner

➌

➋

See Special Bus Requirements in table below and

General

Considerations on page 94

.

L2

DC-

L3

PowerFlex

Common

Mode

Core

➊

Common

Mode Core

➊

DC+ DC-

Ground Fault

Indicator Filter

Active Front End

➊ The common mode core mounting location

(AFE DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with AFE bus supplies, the common mode core is placed at the DC output terminals of the AFE and the drive DC input terminals or at the motor output of each drive.

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

L1

L2

DC+

DC-

Common

Mode

Core

➊

DC Bus

Conditioner

➋

AC Drive PE

➌ A capacitor bank is required.

See table below and Bus

Supply Capacitors on page 134

for more information.

L3

PowerFlex

M

System AFE

Ground Type Voltage Qty

(1)

High Resistance

Ground

High Resistance

Ground

High Resistance

Ground

High Resistance

Ground

400/480

600

400/480

600/690

400/480

600/690

400/480

600/690

2

2

2

2

Frame Size

10

10

10

(2)

(2)

(2)

or 13

or 13

or 13

(3)

(3)

(3)

Drive

Qty

1

1

1

Type

Common Mode Core

(4)

DC Bus

Conditioner

(8)

Gnd. Fault

Indicator

Filter

(9)

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

Design E

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frames 7

PowerFlex 750-Series: Frames 8…10

PowerFlex 700H/700S: Frames 9…14

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also, see

Note 1 on

page 25 for catalog

no. information.

Design E

Contact factory for

30339-319-01

(5)

or

30201-031-01/1321-M670

(6)

Design E

Yes

Yes

Yes

10

(2)

or 13

(3)

1 Any other non-listed PowerFlex drive Contact Factory

(7)

(1) For quantities greater than 2, contact factory.

(2) For PowerFlex AFE Frame 10, use common mode core 30339-320-01 at the AFE output terminals.

(3) For PowerFlex AFE Frame 13, use common mode core 30339-319-01 at the AFE output terminals.

(4) One common mode core is required on each PowerFlex AFE output. See Note 1 in the diagram above and Common Mode Core on page 136

for recommendations.

(5) Drive DC input common mode core.

(6) Drive motor output common mode core.

(7) For any non-listed PowerFlex drive, contact the factory. See Technical Support (SupportPlus™) on page 14 for details.

(9) See

Ground Fault Indicator Filter on page 143

for recommendations.

(8) One DC bus conditioner is required for each PowerFlex AFE. See

DC Bus Conditioner—Designs A, B, C, D, or E on page 139 for details.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Multiple Regenerative Bus Supply Configurations Chapter 9

High Resistance Ground System with Multiple AFEs and Multiple AC

Drives

3-Phase

AC Input

Figure 52 - High Resistance Ground System with Multiple AFEs and Multiple AC Drives

Transformer

L1

Active Front End

DC+

DC Bus

Conditioner

➌

➋

See Special Bus Requirements

in table below and General

Considerations on page 94

.

L2

DC-

L3

PowerFlex

Common

Mode

Core

➊

Common

Mode Core

➊

DC+ DC-

DC+ DC-

System

Ground Type

High Resistance

Ground

High Resistance

Ground

High Resistance

Ground

High Resistance

Ground

Active Front End

L1 DC+

Ground Fault

Indicator Filter

PE

L2

L3

PowerFlex

DC-

➊ The common mode core mounting location (AFE DC output, drive DC input, or drive

Common

Mode

Core

➊

DC Bus

Conditioner motor output) changes for different common bus configurations. For systems with

AFE bus supplies, the common mode core is placed at the DC output terminals of the

AFE and the drive DC input terminals or at the motor output of each drive.

Voltage

400/480

600

(1)

400/480

400/480

600/690

400/480

600/690

600/690

(1)

2

2

2

AFE

Qty

(2)

2

Drive

Frame Size Qty

10

(3)

or 13

(4)

2…20

(5)

10

(3)

or 13

(4)

2…20

(5)

10

(3)

or 13

(4)

2…20

(5)

Type

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frames 7

PowerFlex 750-Series: Frames 8…10

PowerFlex 700H/700S: Frames 9…14

Any other non-listed PowerFlex drive

➋

AC Drive

M

Common Mode Core

(6)

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

M M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

➌ A capacitor bank is required. See table below and

Bus

Supply Capacitors on page 134

for more information.

DC Bus

Conditioner

(9)

Gnd. Fault

Indicator

Filter

(10)

Design E

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or ’W’ and Input

Type 4. Also, see Note 1 on page 25

for catalog no. information.

Design E

Contact factory for

30339-319-01

(7)

or

30201-031-01/1321-M670

(8)

Design E

Contact Factory

(5)

Yes

Yes

Yes

10

(3)

or 13

(4)

2…20

(5)

(1) At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

(2) For quantities greater than 2, contact factory.

(3) For PowerFlex AFE Frame 10, use common mode core 30339-320-01 at the AFE output terminals.

(4) For PowerFlex AFE Frame 13, use common mode core 30339-319-01 at the AFE output terminals.

(5) For more than 20 drives, or for any non-listed PowerFlex drive, contact the factory. See

Technical Support (SupportPlus™) on page 14 for details.

(6)

One common mode core is required on each PowerFlex AFE output. See Note 1 in the diagram above and Common Mode Core on page 136

for recommendations.

(7) Drive DC input common mode core.

(8) Drive motor output common mode core.

(9)

One DC bus conditioner is required for each PowerFlex AFE. See DC Bus Conditioner—Designs A, B, C, D, or E on page 139 for details.

(10) See Ground Fault Indicator Filter on page 143

for recommendations.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

91

Chapter 9 Multiple Regenerative Bus Supply Configurations

3-Phase

AC Input

Ungrounded System with Multiple AFEs and Single AC Drive

Transformer

Zig-Zag

Transformer

Figure 53 - Ungrounded System with Multiple AFEs and Single AC Drive

L1

Active Front End

DC+

DC Bus

Conditioner

➌

➋

See Special Bus Requirements in table below and

General

Considerations on page 94

.

L2

DC-

L3

PowerFlex

Common

Mode

Core

➊

Common

Mode Core

➊

DC+ DC-

Active Front End

L1 DC+

L2

DC-

Common

Mode

Core

➊

DC Bus

Conditioner

➋

AC Drive

L3

Ground Fault

Indicator Filter

PE

➊ The common mode core mounting location (AFE DC output, drive DC input, or drive

PowerFlex motor output) changes for different common bus configurations. For systems with

AFE bus supplies, the common mode core is placed at the DC output terminals of the

AFE and the drive DC input terminals or at the motor output of each drive.

M

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible.

➌ A capacitor bank is required. See table below and

Bus

Supply Capacitors on page 134

for more information.

System AFE

Ground Type Voltage Qty

(1)

Ungrounded

400/480

600

400/480

2

Ungrounded

600/690

2

2 Ungrounded

400/480

600/690

400/480

600/690

Ungrounded 2

Drive

Frame Size Qty Type

10

(2)

or 13

(3)

1

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

10

(2)

or 13

(3)

1

10

(2)

or 13

(3)

1

10

(2)

or 13

(3)

1

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frames 7

PowerFlex 750-Series: Frames 8…10

PowerFlex 700H/700S: Frames 9…14

Any other non-listed PowerFlex drive

Common Mode Core

(4)

Fr. 1…3: 1321-M048

Fr. 4: 1321-M180

(1) For quantities greater than 2, contact factory.

(2) For PowerFlex AFE Frame 10, use common mode core 30339-320-01 at the AFE output terminals.

(3) For PowerFlex AFE Frame 13, use common mode core 30339-319-01 at the AFE output terminals.

(4)

One common mode core is required on each PowerFlex AFE output. See Note 1 in the diagram above and Common Mode Core on page 136 for recommendations.

(5) Drive DC input common mode core.

(6) Drive motor output common mode core.

92

(7)

For any non-listed PowerFlex drive, contact the factory. See Technical Support (SupportPlus™) on page 14

for details.

(8) One DC bus conditioner is required for each PowerFlex AFE. See

DC Bus Conditioner—Designs A, B, C, D, or E on page 139

for details.

(9) See

Ground Fault Indicator Filter on page 143 for recommendations.

(10) See

Zig-Zag Transformer on page 144

for recommendations.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

DC Bus

Conditioner

(8)

Gnd. Fault

Indicator

Filter

(9)

Zig Zag

Transformer

Required

(10)

Design E

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or ’W’ and Input Type 4. Also, see

Note 1 on page 25

for catalog no. information.

Contact factory for

30339-319-01

(5)

or

30201-031-01/1321-M670

(6)

Design E

Design E

Contact Factory

(7)

Yes

Yes

Yes

Yes

Yes

Yes

Multiple Regenerative Bus Supply Configurations Chapter 9

3-Phase

AC Input

Transformer

Zig-Zag

Transformer

Ungrounded System with Multiple AFEs and Multiple AC Drives

Figure 54 - Ungrounded System with Multiple AFEs and Multiple AC Drives

L1

Active Front End

DC+

DC Bus

Conditioner

➌

➋

See Special Bus Requirements in table below and

General

Considerations on page 94

.

L2

L3

PowerFlex

DC-

Common

Mode

Core

➊

L1

Active Front End

DC+

Common

Mode Core

➊

DC+ DC-

DC+ DC-

L2

DC-

➋

AC Drive

Common

L3

PowerFlex

Indicator Filter

Ground Fault

PE

➊ The common mode core mounting location (AFE DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with

AFE bus supplies, the common mode core is placed at the DC output terminals of the

Mode

Core

➊

Conditioner

DC Bus

M

➋ The DC bus conditioner must be electrically connected

➌ A capacitor bank is required. See table below and

Bus

M M M

Kinetix 6000 or

Kinetix 6200/6500 Drives to the DC bus as close to the DC source as possible.

AFE and the drive DC input terminals or at the motor output of each drive.

Supply Capacitors on page 134

for more information.

System

Ground Type Voltage

Ungrounded

400/480

600

(1)

400/480

Ungrounded

Ungrounded

Ungrounded

400/480

600/690

400/480

600/690

AFE

Qty

(2)

2

600/690

(1)

2

2

2

Frame Size Qty

10

(3)

or 13

(4)

2…20

(5)

10

(3)

or 13

(4)

10

(3)

or 13

(4)

Drive

2…20

(5)

2…20

(5)

10

(3)

or 13

(4)

2…20

(5)

Common Mode Core

(6)

DC Bus

Conditioner

(9)

Type

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 3 and 4

Fr. 1…3:

Fr. 4:

1321-M048

1321-M180

Design e

PowerFlex 750-Series: Frames 5 and 6

PowerFlex 750-Series: Frames 7

PowerFlex 750-Series: Frames 8…10

PowerFlex 700H/700S: Frames 9…14

Fr. 5…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: Included with drives with enclosure ‘P’ or

’W’ and Input Type 4. Also, see

Note 1 on

page 25

for catalog no. information.

Design E

Contact factory for

30339-319-01

(7)

or

30201-031-01/1321-M670

(8)

Design E

Gnd. Fault

Indicator

Filter

(10)

Zig Zag

Transformer

Required

(11)

Yes

Yes

Yes

Yes

Yes

Yes

Any other non-listed PowerFlex drive

(1) At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750 Series Frame 6…10 drives.

(2) For quantities greater than 2, contact factory.

(3) for PowerFlex AFE Frame 10, use common mode core 30339-320-01 at the AFE output terminals.

(4) for PowerFlex AFE Frame 13, use common mode core 30339-319-01 at the AFE output terminals.

(5) For more than 20 drives, or for any non-listed PowerFlex drive, contact the factory. See

Technical Support (SupportPlus™) on page 14 for details.

(6)

One common mode core is required on each PowerFlex AFE output. See Note 1 in the diagram above and Common Mode Core on page 136

for recommendations.

(7) Drive DC input common mode core.

(8) Drive motor output common mode core.

(9)

One DC bus conditioner is required for each PowerFlex AFE. See DC Bus Conditioner—Designs A, B, C, D, or E on page 139 for details.

(10) See Ground Fault Indicator Filter on page 143

for recommendations.

(11) See Zig-Zag Transformer on page 144

for recommendations.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Contact Factory

(5)

93

Chapter 9 Multiple Regenerative Bus Supply Configurations

PowerFlex Active Front End

Considerations

See the PowerFlex Active Front End User Manual for AFE considerations.

Sizing

94

General Considerations 1.

Disconnect the common mode capacitors from the drives when using a regenerative module. See the drive's documentation for instructions on disconnecting the common mode capacitors.

2.

All system components (Bus Supply and PowerFlex Drives) must be selected for the same AC-line voltage.

3.

A low inductance type DC bus must be used. See DC Bus Connections on page 15 for details.

4.

If a disconnect switch between the common DC bus and the drive's input is used, an auxiliary contact on the disconnect switch must be connected to a digital input of the drive. The corresponding digital input must be set to

‘Precharge Enable’. This provides the proper precharge interlocking, guarding against possible damage to the drive when reconnecting the drive to an energized DC bus. Under this condition, the drives must have internal or externally-supplied precharge.

Drive

PowerFlex 40P

PowerFlex 523

PowerFlex 525

PowerFlex 700

PowerFlex 700L with vector control

PowerFlex 700S

PowerFlex 700L with 700S control

PowerFlex 700H

PowerFlex 750-Series

Parameter

Number

A051…A054 t062…t066 t062…t068

361…366

825…830

361…366

189 [DI Precharge]

Setting

29 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

Digital

Input

1…4

2…6

2…8

1…6

1…6

30 (PreCharge En) 1…6

See Drive Programming Manual for programming information.

5.

If a drive from column A in the table below is mixed with a drive from column B, a capacitor bank is required. See

Bus Supply Capacitors on page 134 for details.

Column A Drives

PowerFlex 700/700S: Frames 0…5

PowerFlex 750-Series: Frames 1…10

Kinetix 6000 and Kinetix 6200/6500

Kinetix 7000

Column B Drives

PowerFlex 700/700S: Frame 6

PowerFlex 700: Frames 8…10

PowerFlex 700H/700S: Frame 9 and up

PowerFlex 700L: All Frames

See the drive documentation for sizing information. In addition, when paralleling

PowerFlex 700AFE units, they must be derated by 5% of their power rating.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Fusing

Multiple Regenerative Bus Supply Configurations Chapter 9

DC Input Drives

See Appendix A

for the recommended Common DC Bus drive fusing.

PowerFlex Active Front End

See the PowerFlex Active Front End User Manual for recommended fusing.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

95

Chapter 9 Multiple Regenerative Bus Supply Configurations

Notes:

96

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Chapter

10

Paralleling Regenerative Bus Supplies (AFEs) with One or More Non-Regenerative PowerFlex

SCR Bus Supplies

System Characteristics

One or more AFEs can be paralleled with one or more PowerFlex SCR Bus

Supplies for applications that require partial regeneration capacity.

The AFE component of this system is characterized by a PWM-controlled IGBT converter for full regeneration of power to the AC line. The regenerative bus supply puts energy back onto the distribution system instead of dissipating energy with resistor braking technology. This configuration provides low AC line harmonics and can be used to meet IEEE-519 when used with the appropriate filtering.

The SCR bus supply component of this system is characterized by an SCR rectifier front end, which converts the 3-phase AC line voltage into a non-filtered

DC bus voltage.

Supported Products

At the time of publication, the following products are supported.

Products

PowerFlex Active Front End in parallel with

PowerFlex SCR Bus Supply

Supported Drives

PowerFlex 40P: All power ratings

PowerFlex520-Series: All power ratings - Three phase only

PowerFlex 700

(1)

/ PowerFlex 700 Series B

(1)

: All frame sizes

(2)

PowerFlex 700S: All frame sizes

(2)

PowerFlex 700H: All frame sizes

(2)

PowerFlex 700L: Frames 3A

(3)

and 3B

(2)

PowerFlex 750-Series: Frames 1…10

(4)

Kinetix 7000: BM06…BM12

Kinetix 6000 and Kinetix 6200/6500: All 460V configurations

(1) These drives require firmware revision 2.001 or later (Standard and Vector Control).

(2) PowerFlex 700 Frame 5…10, PowerFlex 700S Frame 5 and 6 and Frame 9…14, PowerFlex 700H Frame 9…14, and

PowerFlex 700L DC input drives are required when not connected to the AC source.

(3) Frame 3A dual inverter drives only.

(4) PowerFlex 750-Series Frame 5…7 DC input version drives with precharge must be selected.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

97

Chapter 10 Paralleling Regenerative Bus Supplies (AFEs) with One or More Non-Regenerative PowerFlex SCR Bus Supplies

Typical System Configuration Figure 55 - AFE in Parallel with PowerFlex SCR Bus Supply with AC Drives

L1

3 Phase

AC Input

3-Phase

Reactor

SCR Bus Supply

L1

(with internal fuses)

DC+

DC Bus

Conditioner

➌

➋

See Special Bus Requirements in table below and

PowerFlex Active Front End and PowerFlex SCR Bus Supply

Considerations on page 99

. Also, see all information in

Chapter 2

, Chapter 3 ,

Chapter 8

, and

Chapter 9

.

L2

L2

DC-

L3 L3

PowerFlex

Common

Mode Core

➊

DC+ DCDC+

DC-

Transformer

1.0 : 0.95 Ratio

L1

Active Front End

DC+

PE

➊ The common mode core mounting location (AFE DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with AFE bus supplies, the common mode core is placed at the DC output terminals of the AFE

and the drive DC input terminals or at the motor output of each drive.

Drawing Designation Supported Drives

L2

DC-

L3

PowerFlex

(AFE with disconnect, MCCB,

LCL Filter, and DC fuses)

Common

Mode

Core

➊

AC Drive

M

AC Drive

M

➋ The DC bus conditioner must be electrically connected to the DC bus as close to the DC source as possible. See

DC Bus Conditioner—Designs A, B, C, D, or E on page 139

➌ A capacitor bank is required. See table below and more information.

Special Bus Requirements

for details.

Bus Supply Capacitors on page 134 for

AC Drive PowerFlex 700/700S: Frames 0…4

PowerFlex 750-Series: Frames 1…4

PowerFlex 700/700S: Frames 5 and 6

PowerFlex 700: Frames 7…10

PowerFlex 700H/700S: Frames 9 …14

PowerFlex 700L: Frames 3A

(1)

and 3B

PowerFlex 750-Series: Frames 5…10

Kinetix 7000: BM06…BM08

Kinetix 7000: BM09…BM12

PowerFlex 40P: All power ratings

PowerFlex520-Series: All power ratings -

Three phase only

At 600 volts, PowerFlex 700/700S Frame 0…4 drives cannot be used on the same bus as

PowerFlex 700/700S Frame 5 and 6 drives.

At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as

PowerFlex 750-Series Frame 6…10 drives.

• Internal precharge option must be selected if a disconnect between the DC bus and the drive’s DC input is used.

• At 600 volts, PowerFlex 700/700S Frame 0…4 drives cannot be used on the same bus as PowerFlex 700/700S Frame 5 and 6 drives.

• DC input ‘common bus’ drives are required—not AC stand-alone configuration.

• Additional bus capacitance may be required. See General Considerations on page 99 .

• External precharge must be provided if a disconnect between the DC bus and the drive’s DC input is used.

• DC input ‘common bus’ drives are required—not AC stand-alone configuration.

• At 600 volts, PowerFlex 750-Series Frame 3…5 drives cannot be used on the same bus as PowerFlex 750-Series Frame 6…10 drives.

• DC input drive with precharge must be selected (input type code = 4).

None

External precharge must be provided if a disconnect between the DC bus and the drive’s

DC input is used.

Important: Do not use PowerFlex 40P or PowerFlex 520-Series drives on the same DC bus supply with PowerFlex 700/700H/700S drives or Kinetix 7000 drives. This is due to the difference in capacitance/amp of the PowerFlex 40P or PowerFlex 520-Series drives compared to the PowerFlex 700/700H/700S drives and Kinetix 7000 drives.

(1) Frame 3A dual inverter drives only.

98

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Paralleling Regenerative Bus Supplies (AFEs) with One or More Non-Regenerative PowerFlex SCR Bus Supplies Chapter 10

PowerFlex Active Front End and PowerFlex SCR Bus

Supply Considerations

• An isolating delta Y transformer with the secondary center tap ungrounded must be used on the input of the AFE (see

Figure 55 on page 98

). This minimizes circulating currents and avoids nuisance ground faults in the AFE.

• The transformer kVA must be equal to or greater than the AFE input kVA.

• The system impedance must be less than 10%.

• The isolating transformer on the input of the AFE must be tapped 5% below the input voltage for the PowerFlex SCR Bus Supply. This provides proper sharing of the load between the AFE and SCR Bus Supply during motoring operation.

• An input reactor must be used on the input of each PowerFlex SCR Bus

Supply. See the PowerFlex SCR Bus Supply User Manual for details.

• Set SCR Bus Supply jumper to ‘AFE’ mode. See SCR Bus Supply User

Manual, publication 20S-UM001 for details.

• Let the PowerFlex SCR Bus Supply precharge the DC bus of the system before letting the AFE complete its precharge and close its MCCB. See the

PowerFlex SCR Bus Supply User Manual for details on setting up the precharge rate.

• Parameter 75 - [Motor Power Lmt] of the AFE must be set to 10% to limit the motoring current that the AFE can supply and avoid overload faults on the AFE.

General Considerations 1.

Disconnect the common mode capacitors from the drives when using a regenerative module. See the drive's documentation for instructions on disconnecting the common mode capacitors.

2.

All system components (Bus Supply and PowerFlex Drives) must be selected for the same AC-line voltage.

3.

A low inductance type DC bus must be used. See for

DC Bus Connections on page 15

details.

4.

If a disconnect switch between the common DC bus and the drive's input is used, an auxiliary contact on the disconnect switch must be connected to a digital input of the drive. The corresponding digital input must be set to

‘Precharge Enable’. This provides the proper precharge interlocking, guarding against possible damage to the drive when reconnecting the drive to an energized DC bus. Under this condition, the drives must have internal or externally-supplied precharge.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

99

Sizing

Fusing

100

Chapter 10 Paralleling Regenerative Bus Supplies (AFEs) with One or More Non-Regenerative PowerFlex SCR Bus Supplies

Drive Parameter

Number

A051…A054 t062…t066 t062…t068

361…366

Digital

Input

PowerFlex 40P

PowerFlex 523

PowerFlex 525

PowerFlex 700

PowerFlex 700L with vector control

PowerFlex 700S

PowerFlex 700L with 700S control

PowerFlex 700H

PowerFlex 750-Series

825…830

361…366

189 [DI Precharge]

Setting

29 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En)

30 (PreCharge En) 1…6

30 (PreCharge En) 1…6

See Drive Programming Manual for programming information.

5.

If a drive from column A in the table below is mixed with a drive from column B, a capacitor bank is required. See

Bus Supply Capacitors on page 134 for details.

1…4

2…6

2…8

1…6

Column A Drives

PowerFlex 700/700S: Frames 0…5

PowerFlex 750-Series: Frames 1…10

Kinetix 6000 and Kinetix 6200/6500

Kinetix 7000

Column B Drives

PowerFlex 700/700S: Frame 6

PowerFlex 700: Frames 8…10

PowerFlex 700H/700S: Frame 9 and up

PowerFlex 700L: All Frames

See the drive documentation for sizing the AFE. See Chapter 2 for sizing the SCR

Bus Supply. In addition, the AFE must be sized for the regenerative power only, and the SCR Bus Supply must be sized to handle all of the motoring power because the AFE is programmed for a 10% [Motor Power Lmt].

DC Input Drives

See Appendix A

for the recommended Common DC Bus drive fusing.

PowerFlex SCR Bus Supply

The PowerFlex SCR Bus Supply has built-in AC line and DC bus fuses (on 400A and 600A units). The 1000A unit has six in-path fuses which simultaneously protect AC and DC paths. All units are equipped with fuse trip indicator switches. See the PowerFlex SCR Bus Supply User Manual for fusing information.

PowerFlex Active Front End

See the PowerFlex Active Front End User Manual for recommended fusing.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Appendix

A

PowerFlex Drive Ratings, Recommended DC Bus

Fuses, and Drive DC Bus Capacitance

325 Volt DC Input Fuses

The tables on the following pages provide drive ratings (including DC input currents), recommended DC input fuses (Manufacturer Catalog No.), and internal drive DC bus capacitance. The sizes listed are the recommended sizes based on 40 °C. If available amp ratings do not match the tables provided, the closest fuse rating that exceeds the drive rating should be chosen.

Table 1 - PowerFlex 40P Drives, 325V DC Input Fuses

Drive Cat. No.

22D…

B2P3

B5P0

B8P0

B012

B017

B024

B033

HP

Rating

3

5

7.5

10

0.5

1

2

DC Input

Amps

2.1

4.5

8.1

12.1

18.3

25.4

35.4

Non-Time Delay Fuse

(1)

Amps Catalog No.

6 Bussmann JKS-6

(2)

10

20

Bussmann JKS-10

(2)

Ferraz Shawmut HSJ20

(3)

25

40

50

70

Ferraz Shawmut HSJ25

(3)

Ferraz Shawmut HSJ40

(3)

Ferraz Shawmut HSJ50

(3)

Ferraz Shawmut HSJ70

(3)

Drive DC Bus

Capacitance (μF)

270

560

940

1,120

2,000

2,800

3,920

(1) The power source to Common Bus inverters must be derived from AC voltages 600V or less, as defined in NFPA70; Art 430-18

(NEC). Battery supplies or MG sets are not included. The following devices were validated to break current of the derived power

DC Bus: Disconnects: Allen-Bradley Bulletin No. 1494, 30 to 400 A; Bulletin No. 194, 30 to 400 A, or ABB: OESA, 600 & 800 A;

OESL, all sizes. Fuses: Ferraz Shawmut Type HSJ, all sizes. For any other devices, please contact the factory.

(2) See Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses

recommended for the DC bus fusing.

(3) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by

Allen-Bradley for the fuses on the common DC bus for all Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

101

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

Table 2 - PowerFlex 520-Series Drives, 325V DC Input Fuses

Drive Cat. No.

25x

(1)

B024

B032

B048

B062

B1P6

(2)

B2P5

B5P0

B8P0

B011

B017

7.5

10.0

15.0

20.0

1.0

2.0

3.0

5.0

HP Rating

ND HD

0.25

0.5

0.25

0.5

1.0

2.0

3.0

5.0

7.5

10.0

15.0

15.0

DC Input

Amps

11.3

18.6

25.9

35.1

1.5

2.3

4.6

8.2

53.3

69.3

Non-Time Delay Fuse

(3)

Amps Catalog No.

3 Bussmann JKS-3

(4)

6

10

Bussmann JKS-6

(4)

Bussmann JKS-10

(4)

20

25

40

50

Ferraz Shawmut HSJ20

(5)

Ferraz Shawmut HSJ25

(5)

Ferraz Shawmut HSJ40

(5)

Ferraz Shawmut HSJ50

(5)

70

80

100

Ferraz Shawmut HSJ70

(5)

Ferraz Shawmut HSJ80

(5)

Ferraz Shawmut HSJ100

(5)

Drive DC Bus

Capacitance (μF)

1122

1680

2232

3349

150

270

470

776

3912

5030

(1) The drive catalog number prefix is 25A for PowerFlex 523 drives, and 25B for PowerFlex 525 drives.

(2) PowerFlex 523 drive only.

(3) The power source to Common Bus inverters must be derived from AC voltages 600V or less, as defined in NFPA70; Art 430-18 (NEC).

Battery supplies or MG sets are not included. The following devices were validated to break current of the derived power DC Bus:

Disconnects: Allen-Bradley Bulletin No. 1494, 30 to 400 A; Bulletin No. 194, 30 to 400 A, or ABB: OESA, 600 & 800 A; OESL, all sizes.

Fuses: Ferraz Shawmut Type HSJ, all sizes. For any other devices, please contact the factory.

(4) See Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses

recommended for the DC bus fusing.

(5) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-

Bradley for the fuses on the common DC bus for all Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

102

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

540 Volt DC Input Fuses

Table 3 - PowerFlex 700/700S Drives — Frames 0…6, 325V DC Input Fuses

HP Rating DC Input Rating Non-Time Delay Fuse

(2)

Drive Cat. No.

20B… / 20D…

Frame

Size

Drive DC Bus

Capacitance (μF)

B2P2

B4P2

B6P8

B9P6

B015

B022

B028

B042

B052

B070

B080

N104

(1)

N130

(1)

N154

(1)

N192

(1)

0

0/1

1

1

1

1

2

3

3

4

4

5

5

6

ND

0.5

1

2

3

5

7.5

10

15

20

25

30

40

50

60

HD

0.33

0.75

1.5

2

3

5

7.5

10

15

20

25

30

40

50

Amps

2.0

3.8

6.9

9.7

16

23.3

30

45

55

75.3

85.8

114.1

142.6

169

Amps Catalog No.

6 Bussmann JKS-6

(3)

8

15

Bussmann JKS-8

(3)

Ferraz Shawmut HSJ15

(4)

20

30

45

60

Ferraz Shawmut HSJ20

(4)

Ferraz Shawmut HSJ30

(4)

Ferraz Shawmut HSJ45

(4)

Ferraz Shawmut HSJ60

(4)

90

100

150

175

225

250

300

400

Ferraz Shawmut HSJ90

(4)

Ferraz Shawmut HSJ100

(4)

Ferraz Shawmut HSJ150

(4)

Ferraz Shawmut HSJ175

(4)

Ferraz Shawmut HSJ225

(4)

Ferraz Shawmut HSJ250

(4)

Ferraz Shawmut HSJ300

(4)

Ferraz Shawmut HSJ400

(4)

440

440

1,120

1,120

2,000

2,000

3,000

4,800

4,800

7,000

7,000

9,000

12,000

13,800

6 75 60 210.6

16,800

272.1

400 Ferraz Shawmut HSJ400

(4)

16,800 N260

(1)

6 100

(1) Catalog number corresponds to drives with precharge only.

75

(2) The power source to Common Bus inverters must be derived from AC voltages 600V or less, as defined in NFPA70; Art 430-18 (NEC). Battery supplies or MG sets are not included. The following devices were validated to break current of the derived power DC Bus: Disconnects: Allen-Bradley Bulletin No. 1494, 30 to 400 A;

Bulletin No. 194, 30 to 400 A, or ABB: OESA, 600 & 800 A; OESL, all sizes. Fuses: Ferraz Shawmut Type HSJ, all sizes. For any other devices, please contact the factory.

(3) See

Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

(4) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-Bradley for the fuses on the common DC bus for all Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

Table 4 - PowerFlex 40P Drives, 540V DC Input Fuses kW

Rating

4

5.5

7.5

11

0.4

0.75

1.5

2.2

DC Input

Amps

11.6

13.4

19.4

28.0

1.4

2.2

4.1

6.4

Drive DC Bus

Capacitance (μF)

90

135

235

280

600

705

940

1,120

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

103

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

Table 5 - PowerFlex 520-Series Drives, 540V DC Input Fuses

Drive Cat. No.

25x

D1P4

D2P3

D4P0

D6P0

D010

D013

D017

D024

D030

D037

D043

(1)

1.5

2.2

4.0

5.5

kW Rating

ND HD

0.4

0.75

0.4

0.75

7.5

11.0

15.0

18.5

22.0

1.5

2.2

4.0

5.5

7.5

11.0

11.0

15.0

18.5

DC Input

Amps

1.3

2.2

3.8

5.7

11.1

13.8

18.7

26.7

33.7

42.1

49.5

Non-Time Delay Fuse

Amps Catalog No.

3 Bussmann JKS-3

(2)

6

8

Bussmann JKS-6

(2)

Bussmann JKS-8

(2)

15

25

30

40

Ferraz Shawmut HSJ15

(3)

Ferraz Shawmut HSJ25

(3)

Ferraz Shawmut HSJ30

(3)

Ferraz Shawmut HSJ40

(3)

50

50

70

80

Ferraz Shawmut HSJ50

(3)

Ferraz Shawmut HSJ50

(3)

Ferraz Shawmut HSJ70

(3)

Ferraz Shawmut HSJ80

(3)

Drive DC Bus

Capacitance (μF)

74

108

192

282

557

676

816

1200

1500

1399

1699

(1) The drive catalog number prefix is 25A for PowerFlex 523 drives, and 25B for PowerFlex 525 drives.

(2) See Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses

recommended for the DC bus fusing.

(3) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-

Bradley for the fuses on the common DC bus for all Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

104

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

C8P7

C011

C015

C022

C1P3

C2P1

C3P5

C5P0

C030

C037

C043

C056

C085

H105

(1)

H125

(1)

H140

(1)

H170

(1)

C072

Drive Cat. No.

20B… / 20D…

H205

(1)

H260

(1)

3

4

5

3

3

2

2

1

1

0/1

0/1

0

0/1

0/1

0/1

75

—

90

—

55

—

55

—

110

—

132

—

22

30

37

45

7.5

11

15

18.5

1.5

2.2

4

5.5

kW Rating

ND HD

0.37

0.75

0.25

0.55

1.1

1.5

3.0

4

18.5

22

30

37

5.5

7.5

11

15

—

55

—

75

—

45

—

45

—

90

—

110

Table 6 - PowerFlex 700/700S Drives — Frames 0…6, 540V DC Input Fuses

Frame

Size

5

5

6

6

6

DC Input Rating Non-Time Delay Fuse

(2)

Amps

1.3

2.1

3.7

5.3

9.3

12.6

16.8

24

33.2

40.9

47.5

61.9

80.5

95.1

120.2

95.1

120.2

95.1

159

120.2

192

159

226

192

298

226

Amps

3

6

8

10

15

20

25

40

50

70

90

100

125

150

175

175

200

200

250

250

350

350

350

350

400

400

Catalog No.

Bussmann JKS-3

(3)

Bussmann JKS-6

(3)

Bussmann JKS-8

(3)

Bussmann JKS-10

(3)

Ferraz Shawmut HSJ15

(4)

Ferraz Shawmut HSJ20

(4)

Ferraz Shawmut HSJ25

(4)

Ferraz Shawmut HSJ40

(4)

Ferraz Shawmut HSJ50

(4)

Ferraz Shawmut HSJ70

(4)

Ferraz Shawmut HSJ90

(4)

Ferraz Shawmut HSJ100

(4)

Ferraz Shawmut HSJ125

(4)

Ferraz Shawmut HSJ150

(4)

Ferraz Shawmut HSJ175

(4)

Ferraz Shawmut HSJ175

(4)

Ferraz Shawmut HSJ200

(4)

Ferraz Shawmut HSJ200

(4)

Ferraz Shawmut HSJ250

(4)

Ferraz Shawmut HSJ250

(4)

Ferraz Shawmut HSJ350

(4)

Ferraz Shawmut HSJ350

(4)

Ferraz Shawmut HSJ350

(4)

Ferraz Shawmut HSJ350

(4)

Ferraz Shawmut HSJ400

(4)

Ferraz Shawmut HSJ400

(4)

Drive DC Bus

Capacitance (μF)

6,000

6,000

6,900

8,400

8,400

(1) Also applies to ‘P’ voltage class. Fuses must be applied in the (+) leg and (-) leg of the DC Common Bus.

(2) The power source to Common Bus inverters must be derived from AC voltages 600V or less, as defined in NFPA70; Art 430-18 (NEC). Battery supplies or MG sets are not included. The following devices were validated to break current of the derived power DC Bus: Disconnects: Allen-Bradley Bulletin No. 1494, 30 to 400

A; Bulletin No. 194, 30 to 400 A, or ABB: OESA, 600 & 800 A; OESL, all sizes. Fuses: Bussmann Type JKS, all sizes; Type 170M, Case Sizes 1, 2 and 3, or Ferraz

Shawmut Type HSJ, all sizes. For any other devices, please contact the factory.

(3) See

Fuse Certification and Test Data on page 129

for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

(4) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-Bradley for the fuses on the common DC bus for all Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

1,200

1,500

1,800

2,400

3,000

3,500

4,500

110

110

165

280

330

560

680

1,000

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

105

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

Table 7 - PowerFlex 700 Drives — Frames 7…10, 540V DC Input Fuses kW Rating DC Input Rating Non-Time Delay Fuse Drive Cat. No.

20B…

Frame

Size

Drive DC Bus

Capacitance (μF)

P292

P325

P365

P415

P481

P535

7

7

8

8

8

8

ND

160

—

180

—

200

—

240

—

280

—

300

—

HD

—

150

—

180

—

180

—

200

—

240

—

280

Amps

342

309

381

381

428

381

487

428

564

487

627

564

kW

185

166

206

206

231

206

262

231

304

262

338

304

Amps Catalog No.

630 Bussmann 170M6608

(3)

630

800

Bussmann 170M6608

(3)

Bussmann 170M6612

(3)

800

800

800

800

Bussmann 170M6612

(3)

Bussmann 170M6612

(3)

Bussmann 170M6612

(3)

Bussmann 170M6612

(3)

800

900

900

1000

1000

1200

(1)

Bussmann 170M6612

(3)

Bussmann 170M6613

(3)

Bussmann 170M6613

(3)

Bussmann 170M6614

(3)

Bussmann 170M6614

(3)

Bussmann 170M6616

(3)

15,000

15,000

20,700

20,700

20,700

20,700

P600 8 350 — 703 379 20,700

P730

H875

No Precharge

9

10

—

400

—

500

—

300

—

350

—

400

(1) Two 630A Bussmann 170M6608 fuses can also be used.

(2) Two 700A Bussmann 170M6611 fuses can also be used.

627

855

703

1025

820

338

461

379

553

443

1200

(1)

1400

(2)

1400

Bussmann 170M6616

(3)

Bussmann 170M6617

(3)

Bussmann 170M6617

(3)

2 x 800 Bussmann 170M6612

(3)

2 x 800 Bussmann 170M6612

(3)

20,700

29,900

(3) See

Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

106

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

Table 8 - PowerFlex 750-Series Drives — Frames 1…7, 540V DC Input Fuses

6

6

6

6

7

7

7

5

1

1

1

1

1

1

2

2

3

3

3

4

4

5

Frame

Size

7.5

—

11

—

15

—

18.5

—

22

—

30

—

37

—

45

—

—

30

—

37

—

18.5

—

22

—

11

—

15

—

5.5

—

7.5

5.5

—

7.5

—

2.2

—

4

—

kW Rating

ND HD

0.75

—

1.5

—

—

0.37

—

0.75

—

4

—

5.5

—

1.5

—

2.2

—

160

—

200

—

110

—

132

—

75

—

90

—

45

—

55

55

—

75

—

90

—

110

—

132

—

160

—

200

—

250

—

Drive Cat. No.

20F…/20G…

C2P1

C3P5

C5P0

C8P7

C011

C015

C015

C022

C030

C037

C043

C060

C072

C085

C104

C140

C170

C205

C260

C302

C367

C456

82.4

67.1

97.3

82.4

48.1

41.4

67.1

48.1

33.6

24.6

41.4

33.6

17.0

12.6

24.6

17.0

12.6

9.3

17.0

12.6

5.3

3.7

9.3

5.3

DC Input Rating

Amps kW

2.1

1.3

3.7

2.1

1.1

0.7

2.0

1.1

6.8

5.0

9.2

6.8

2.9

2.0

5.0

2.9

44.5

36.2

52.5

44.5

26.0

22.3

36.2

26.0

18.1

13.3

22.3

18.1

9.2

6.8

13.3

9.2

297.7

234.7

345.7

297.7

420.2

345.7

522.0

420.2

120.2

97.3

160.3

120.2

194.6

160.3

234.7

194.6

160.7

126.7

186.7

160.7

226.9

186.7

281.9

226.9

64.9

52.5

86.5

64.9

105.1

86.5

126.7

105.1

Non-Time Delay Fuse

Amps Catalog No.

6

4

8

Bussman JKS-6

(1)

Bussman JKS-4

(1)

Bussman JKS-8

(1)

6

10

8

Bussman JKS-6

(1)

Bussman JKS-10

(1)

Bussman JKS-8

(1)

15

10

20

15

25

20

25

20

40

25

50

40

Ferraz Shawmut HSJ15

(2)

Ferraz Shawmut HSJ10

(2)

Ferraz Shawmut HSJ20

(2)

Ferraz Shawmut HSJ15

(2)

Ferraz Shawmut HSJ25

(2)

Ferraz Shawmut HSJ20

(2)

Ferraz Shawmut HSJ25

(2)

Ferraz Shawmut HSJ20

(2)

Ferraz Shawmut HSJ40

(2)

Ferraz Shawmut HSJ25

(2)

Ferraz Shawmut HSJ50

(2)

Ferraz Shawmut HSJ40

(2)

70

50

90

70

100

90

125

100

150

125

175

150

250

175

350

250

350

350

400

350

630

400

800

630

900

800

Ferraz Shawmut HSJ70

(2)

Ferraz Shawmut HSJ50

(2)

Ferraz Shawmut HSJ90

(2)

Ferraz Shawmut HSJ70

(2)

Ferraz Shawmut HSJ100

(2)

Ferraz Shawmut HSJ90

(2)

Ferraz Shawmut HSJ125

(2)

Ferraz Shawmut HSJ100

(2)

Ferraz Shawmut HSJ150

(2)

Ferraz Shawmut HSJ125

(2)

Ferraz Shawmut HSJ175

(2)

Ferraz Shawmut HSJ150

(2)

Ferraz Shawmut HSJ250

(2)

Ferraz Shawmut HSJ175

(2)

Ferraz Shawmut HSJ350

(2)

Ferraz Shawmut HSJ250

(2)

Ferraz Shawmut HSJ350

(2)

Ferraz Shawmut HSJ350

(2)

Ferraz Shawmut HSJ400

(2)

Ferraz Shawmut HSJ350

(2)

Bussman 170M6608

(1)

Ferraz Shawmut HSJ400

(2)

Bussman 170M6612

(1)

Bussman 170M6608

(1)

Bussman 170M6613

(1)

Bussman 170M6612

(1)

Drive DC Bus

Capacitance (μF)

165

165

280

410

560

680

705

1000

1230

1500

1800

2400

3000

3600

4500

4600

9200

9200

9200

13,800

13,800

18,400

Maximum External DC

Bus Capacitance (μF)

41.25

41.25

70

102.5

140

170

176

250

308

375

450

600

750

900

1125

1150

2300

2300

2300

3450

3450

4600

(1) See Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

(2) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-Bradley for the fuses on the common DC bus for all Allen-

Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

107

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

Table 9 - PowerFlex 750-Series Drives — Frames 8…10, 540V DC Input Fuses

Drive Cat. No.

20G…

C460

C540

C567

C650

C750

C770

C910

C1K0

C1K1

C1K2

C1K4

C1K5

C1K6

C2K1

(1)

Frame

Size kW Rating

ND HD

8 250

—

—

200

8

8

315

—

315

—

—

250

—

250

8

8

8

9

400

—

500

—

355

—

400

—

—

355

—

400

—

315

—

315

9

9

9

9

9

10

10

850

—

900

—

1250

—

710

—

800

—

560

—

630

—

—

710

—

710

—

1000

—

560

—

630

—

500

—

500

(1) These drives have factory-installed fusing.

1703

1352

1830

1525

2474

2071

1352

1197

1686

1254

1197

1013

1254

1047

886

739

1047

863

748

621

863

673

621

525

652

543

DC Input Rating Drive DC Bus

Amps kW

Capacitance (μF)

529

443

285.7

239.2

23,700

335.3

283.5

352.1

293.2

23,700

23,700

403.9

335.3

466.0

363.4

478.4

399.1

565.4

466.0

35,550

35,550

35,550

47,400

646.4

547.0

677.2

565.4

730.1

646.4

910.4

677.2

919.6

730.1

988.2

823.5

1336.0

1118.3

47,400

47,400

71,100

71,100

71,100

71,100

106,650

Maximum External DC

Bus Capacitance (μF)

65,175

65,175

65,175

97,762.5

97,762.5

97,762.5

41,475

41,475

41,475

62,212.5

62,212.5

62,212.5

62,212.5

26,662.5

108

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

Table 10 - PowerFlex 700H/700S Drives — Frames 9…14, 540V DC Input Fuses

Maximum External DC

Bus Capacitance (μF) kW Rating DC Input Rating Fuse Drive Cat. No.

20C… / 20D…

Frame

Size

Drive DC Bus

Capacitance (μF)

H261

H300

H385

H460

H500

H590

H650

H730

H820

H920

H1K0

H1K1

H1K3

9

9

10

10

10

11

11

11

12

12

12

13

13

ND

132

—

160

—

200

—

250

—

250

—

315

—

355

—

—

450

—

500

—

560

400

—

630

—

710

—

HD

—

110

—

132

—

160

—

200

—

250

—

250

—

315

—

355

—

400

—

450

—

500

—

560

—

630

Amps

307

241

353

288

453

353

541

453

589

494

695

612

765

695

859

765

965

859

1083

965

1213

1083

1354

1213

1530

1354

Amps

500

500

630

630

Catalog No.

Bussman 170M6608

(1)

Bussman 170M6608

(1)

Bussman 170M6610

(1)

Bussman 170M6610

(1)

700

700

Bussman 170M6611

(1)

Bussman 170M6611

(1)

Bussman 170M6613

(1)

900

900 Bussman 170M6613

(1)

500 (2 per phase) Bussman 170M6608

(1)

500 (2 per phase) Bussman 170M6608

(1)

550 (2 per phase) Bussman 170M6609

(1)

550 (2 per phase) Bussman 170M6609

(1)

630 (2 per phase) Bussman 170M6610

(1)

630 (2 per phase) Bussman 170M6610

(1)

700 (2 per phase) Bussman 170M6611

(1)

700 (2 per phase) Bussman 170M6611

(1)

700 (2 per phase) Bussman 170M6611

(1)

700 (2 per phase) Bussman 170M6611

(1)

550 (3 per phase) Bussman 170M6609

(1)

550 (3 per phase) Bussman 170M6609

(1)

630 (3 per phase) Bussman 170M6610

(1)

630 (3 per phase) Bussman 170M6610

(1)

2400 Bussman 170M7107

(1)

2400 Bussman 170M7107

(1)

2400

2400

2400

Bussman 170M7107

(1)

Bussman 170M7107

(1)

Bussman 170M7107

(1)

6,600

6,600

9,900

9,900

9,900

14,850

14,850

14,850

19,800

19,800

19,800

29,700

(2)

29,700

(2)

H1K4 13 800 — 1707

29,700

(2)

Bussman 170M7107

(1)

— 710 1413 2400

H1K7

H2K1

H2K7

14

14

14

1000

—

1200

—

1600

—

—

900

—

1100

—

1300

2084

1883

2531

2284

3178

2708

—

—

—

—

—

—

Bussman 170M8610

(1)

Bussman 170M8610

(1)

Bussman 170M8610

(1)

Bussman 170M8610

(1)

Bussman 170M8610

(1)

50,400

(3)

50,400

(3)

50,400

(3)

(1) See Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

Bussman 170M8610

(1)

0

0

26,400

26,400

26,400

21,450

21,450

21,450

16,500

16,500

16,500

0

0

0

0

0

0

(2) This listed capacitance is for Frame 13 Series B DC fed drives. For Frame 13 Series A DC fed drives, the capacitance is 50,400 μF. For Frame 13 Series B AC fed drives, the capacitance is 36,300 μF.

(3) The listed capacitance is for Frame 14 DC fed drives. For Frame 14 AC fed drives, the capacitance is 72,600 μF.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

109

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

Table 11 - PowerFlex 700L Drives — Frames 2, 3A, and 3B, 540V DC Input Fuses

Drive Cat. No.

20L…

C360

C650

C1K2

Frame

Size

2

3A

3B

kW Rating

ND

200

370

715

HD

150

270

525

DC Input Rating

Amps

N/A

1250

1250

(1)

(2)

Fuse

Amps

N/A

(1)

2000

2000

Catalog No.

N/A

(1)

Bussman 170M6621

(3)

Bussman 170M6621

(3)

(4)

(4)

Drive DC Bus

Capacitance (μF)

13,500

16,200

34,400

(5)

Maximum External DC

Bus Capacitance (μF)

21,850

19,150

(6)

38,301

(6)

(1) The PowerFlex 700L Frame 2 is not available as a DC input inverter.

(2) Only the Dual Inverter for PowerFlex 700L Frame 3A is available as a DC input inverter.

(3) Two 1000A Bussmann 170M6614 fuses per phase can also be used.

(4) See Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

(5) This 34,400 μF is the drive DC bus capacitance for a complete Frame 3B drive. For a Frame 3B common bus inverter, the bus capacitance is 16,200 μF.

(6) This value applies to the precharge of the Frame 3A and 3B complete regenerative drives. There is a field-installed input filter precharge resistor kit (20L-RESPRE-A1) for the Frame 3A and 3B complete drives that can be used to increase the maximum external DC bus capacitance. For details, see publication 20L-IN010.

650 Volt DC Input Fuses Table 12 - PowerFlex 40P Drives, 650V DC Input Fuses

Drive Cat. No.

22D…

D1P4

D2P3

D4P0

D6P0

D010

D012

D017

D024

HP

Rating

0.5

1

2

3

5

7.5

10

15

DC Input

Amps

1.3

2.1

3.6

5.4

10.6

12.1

17.8

25.4

Non-Time Delay Fuse

Amps Catalog No.

3 Bussmann JKS-3

(1)

6

8

Bussmann JKS-6

(1)

Bussmann JKS-8

(1)

15

25

25

40

50

Ferraz Shawmut HSJ15

(2)

Ferraz Shawmut HSJ25

(2)

Ferraz Shawmut HSJ25

(2)

Ferraz Shawmut HSJ40

(2)

Ferraz Shawmut HSJ50

(2)

Drive DC Bus

Capacitance (μF)

90

135

235

280

600

705

940

1,120

(1) See Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses

recommended for the DC bus fusing.

(2) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by

Allen-Bradley for the fuses on the common DC bus for all Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

110

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

Table 13 - PowerFlex 520-Series Drives, 650V DC Input Fuses

Drive Cat. No.

25x

D1P4

D2P3

D4P0

D6P0

D010

D013

D017

D024

D030

D037

D043

(1)

2.0

3.0

5.0

7.5

HP Rating

ND HD

0.5

1.0

0.5

1.0

10.0

15.0

20.0

25.0

30.0

2.0

3.0

5.0

7.5

10.0

15.0

15.0

20.0

25.0

DC Input

Amps

1.3

2.1

3.7

5.5

10.6

13.2

17.9

25.6

32.3

40.3

47.4

Non-Time Delay Fuse Drive DC Bus

Capacitance (μF)

Amps Catalog No.

3 Bussmann JKS-3

(2)

6

8

Bussmann JKS-6

(2)

Bussmann JKS-8

(2)

15

20

25

40

Ferraz Shawmut HSJ15

(3)

Ferraz Shawmut HSJ20

(3)

Ferraz Shawmut HSJ25

(3)

Ferraz Shawmut HSJ40

(3)

50

50

60

80

74

108

192

282

557

676

816

Ferraz Shawmut HSJ50

(3)

Ferraz Shawmut HSJ50

(3)

1200

1500

Ferraz Shawmut HSJ60

(3)

1399

Ferraz Shawmut HSJ80

(3)

1699

(1) The drive catalog number prefix is 25A for PowerFlex 523 drives, and 25B for PowerFlex 525 drives.

(2) See Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses

recommended for the DC bus fusing.

(3) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-

Bradley for the fuses on the common DC bus for all Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

111

112

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

D1P1

D2P1

D3P4

D5P0

D8P0

D011

D014

D022

D027

D034

D040

D052

D077

J096

J125

J140

J156

(1)

(1)

(1)

(1)

D065

Drive Cat. No.

20B… / 20D…

J180

(1)

J248

(1)

Frame

Size

3

4

5

3

3

2

2

1

1

0/1

0/1

0

0/1

0/1

0/1

5

5

6

6

6

100

—

125

—

75

—

100

—

150

—

200

—

30

40

50

60

10

15

20

25

2

3

5

7.5

HP Rating

ND HD

0.5

1

0.33

0.75

3

5

1.5

2

25

30

40

50

7.5

10

15

20

—

75

—

100

—

60

—

75

—

125

—

150

Table 14 - PowerFlex 700/700S Drives — Frames 0…6, 650V DC Input Fuses

DC Input Ratings Non-Time Delay Fuse

(2)

Amps

1.0

1.9

3.0

4.5

8.1

11.1

14.6

23.3

28.9

36.4

42.9

55.7

69.6

84.5

105.3

84.5

137.1

105.3

137

105.3

171

137.1

198

171.2

272

198

Amps

3

6

6

10

15

20

30

40

50

60

80

90

100

150

175

175

200

200

250

250

300

300

400

400

400

400

Catalog No.

Bussmann JKS-3

(3)

Bussmann JKS-6

(3)

Bussmann JKS-6

(3)

Bussmann JKS-10

(3)

Ferraz Shawmut HSJ15

(4)

Ferraz Shawmut HSJ20

(4)

Ferraz Shawmut HSJ30

(4)

Ferraz Shawmut HSJ40

(4)

Ferraz Shawmut HSJ50

(4)

Ferraz Shawmut HSJ60

(4)

Ferraz Shawmut HSJ80

(4)

Ferraz Shawmut HSJ90

(4)

Ferraz Shawmut HSJ100

(4)

Ferraz Shawmut HSJ150

(4)

Ferraz Shawmut HSJ175

(4)

Ferraz Shawmut HSJ175

(4)

Ferraz Shawmut HSJ200

(4)

Ferraz Shawmut HSJ200

(4)

Ferraz Shawmut HSJ250

(4)

Ferraz Shawmut HSJ250

(4)

Ferraz Shawmut HSJ300

(4)

Ferraz Shawmut HSJ300

(4)

Ferraz Shawmut HSJ400

(4)

Ferraz Shawmut HSJ400

(4)

Ferraz Shawmut HSJ400

(4)

Ferraz Shawmut HSJ400

(4)

Drive DC Bus

Capacitance (μF)

1,200

1,500

1,800

2,400

3,000

3,500

4,500

110

110

165

280

330

560

680

1,000

6,000

6,000

6,900

8,400

8,400

(1) Also applies to ‘R’ voltage class. Fuses must be applied in the (+) leg and (-) leg of the DC Common Bus.

(2) The power source to Common Bus inverters must be derived from AC voltages 600V or less, as defined in NFPA70; Art 430-18 (NEC). Battery supplies or MG sets are not included. The following devices were validated to break current of the derived power DC Bus: Disconnects: Allen-Bradley Bulletin No. 1494, 30 to 400 A;

Bulletin No. 194, 30 to 400 A, or ABB: OESA, 600 & 800 A; OESL, all sizes. Fuses: Bussmann Type JKS, all sizes; Type 170M, Case Sizes 1, 2 and 3, or Ferraz

Shawmut Type HSJ, all sizes. For any other devices, please contact the factory.

(3) See

Fuse Certification and Test Data on page 129

for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

(4) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-Bradley for the fuses on the common DC bus for all Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

Table 15 - PowerFlex 700 Drives — Frames 7…10, 650V DC Input Fuses

HP Rating DC Input Rating Non-Time Delay Fuse Drive Cat. No.

20B…

Frame

Size

Drive DC Bus

Capacitance (μF)

R292

R325

R365

R415

R481

R535

7

7

8

8

8

8

ND

250

—

250

—

300

—

350

—

400

—

450

—

HD

—

200

—

250

—

250

—

300

—

350

—

400

Amps

328

296

365

365

410

365

466

410

540

466

601

540

kW

212

191

236

236

265

236

302

265

350

302

389

350

Amps Catalog No.

630 Bussmann 170M6608

(3)

630

800

Bussmann 170M6608

(3)

Bussmann 170M6612

(3)

800

800

800

800

Bussmann 170M6612

(3)

Bussmann 170M6612

(3)

Bussmann 170M6612

(3)

Bussmann 170M6612

(3)

800

900

900

1000

1000

1200

(1)

Bussmann 170M6612

(3)

Bussmann 170M6613

(3)

Bussmann 170M6613

(3)

Bussmann 170M6614

(3)

Bussmann 170M6614

(3)

Bussmann 170M6616

(3)

15,000

15,000

20,700

20,700

20,700

20,700

R600 8 500 — 674 436 20,700

R730

J875

No precharge

9

10

—

600

—

700

—

450

—

500

—

600

(1) Two 630A Bussmann 170M6608 fuses can also be used.

(2) Two 700A Bussmann 170M6611 fuses can also be used.

601

820

674

983

786

389

533

436

636

509

1200

(1)

1400

(2)

1400

Bussmann 170M6616

(3)

Bussmann 170M6617

(3)

Bussmann 170M6617

(3)

2 x 800

Bussmann 170M6612

(3)

2 x 800

Bussmann 170M6612

(3)

20,700

29,900

(3) See

Fuse Certification and Test Data on page 129

for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

113

114

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

Table 16 - PowerFlex 700H/700S Drives — Frames 9…14, 650V DC Input Fuses

Maximum External DC

Bus Capacitance (μF)

HP Rating DC Input Rating Fuse Drive Cat. No.

20C… / 20D…

Frame

Size

Drive DC Bus

Capacitance (μF)

J261

J300

J385

J460

J500

J590

J650

J730

J820

J920

J1K0

J1K1

J1K3

9

9

10

10

10

11

11

11

12

12

12

13

13

ND

200

—

250

—

300

—

350

—

450

—

500

—

500

—

600

—

700

—

800

—

900

—

1000

—

1200

—

HD

—

150

—

200

—

250

—

300

—

350

—

450

—

500

—

500

—

600

—

700

—

800

—

900

—

1000

Amps

294

231

338

294

434

338

519

434

564

474

666

587

733

666

824

733

925

824

1038

925

1162

1038

1297

1162

1467

1297

Amps

500

500

630

Catalog No.

Bussman 170M6608

(1)

Bussman 170M6608

(1)

Bussman 170M6610

(1)

630

700

700

Bussman 170M6610

(1)

Bussman 170M6611

(1)

Bussman 170M6611

(1)

Bussman 170M6613

(1)

900

900

Bussman 170M6613

(1)

500 (2 per phase)

Bussman 170M6608

(1)

500 (2 per phase)

Bussman 170M6608

(1)

550 (2 per phase)

Bussman 170M6609

(1)

550 (2 per phase)

Bussman 170M6609

(1)

630 (2 per phase)

Bussman 170M6610

(1)

630 (2 per phase)

Bussman 170M6610

(1)

700 (2 per phase)

Bussman 170M6611

(1)

700 (2 per phase)

Bussman 170M6611

(1)

700 (2 per phase)

Bussman 170M6611

(1)

700 (2 per phase)

Bussman 170M6611

(1)

550 (3 per phase)

Bussman 170M6609

(1)

550 (3 per phase)

Bussman 170M6609

(1)

630 (3 per phase)

Bussman 170M6610

(1)

630 (3 per phase)

Bussman 170M6610

(1)

2400

Bussman 170M7107

(1)

2400

2400

Bussman 170M7107

(1)

Bussman 170M7107

(1)

2400

2400

Bussman 170M7107

(1)

Bussman 170M7107

(1)

6,600

6,600

9,900

9,900

9,900

14,850

14,850

14,850

19,800

19,800

19,800

29,700

(2)

29,700

(2)

J1K4 13 1250 — 1636

29,700

(2)

— 1000 1354 2400

Bussman 170M7107

(1)

J1K7

J2K1

J2K7

14

14

14

1500

—

1900

—

2300

—

—

1400

—

1700

—

2000

1997

1805

2425

2189

3046

2595

—

—

—

—

—

—

Bussman 170M8610

(1)

Bussman 170M8610

(1)

Bussman 170M8610

(1)

Bussman 170M8610

(1)

Bussman 170M8610

(1)

50,400

(3)

50,400

(3)

50,400

(3)

(1) See

Fuse Certification and Test Data on page 129

for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

Bussman 170M8610

(1)

0

0

26,400

26,400

26,400

21,450

21,450

21,450

16,500

16,500

16,500

0

0

0

0

0

0

(2) This listed capacitance is for Frame 13 Series B DC fed drives. For Frame 13 Series A DC fed drives, the capacitance is 50,400 μF. For Frame 13 Series B AC fed drives, the capacitance is 36,300 μF.

(3) The listed capacitance is for Frame 14 DC fed drives. For Frame 14 AC fed drives, the capacitance is 72,600 μF.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

Table 17 - PowerFlex 700L Drives — Frames 2, 3A, and 3B, 650V DC Input Fuses

Drive Cat. No.

20L…

D360

D650

D1K2

Frame

Size

2

3A

3B

HP Rating

ND

300

600

1150

HD

235

440

845

DC Input Rating Fuse

Amps

N/A

1250

1250

(1)

(2)

Amps

N/A

(1)

2000

2000

Catalog No.

N/A

(1)

Bussman 170M6621

(3)

Bussman 170M6621

(3)

(4)

(4)

Drive DC Bus

Capacitance (μF)

13,500

16,200

34,400

(5)

Maximum External DC

Bus Capacitance (μF)

11,049

8,349

(6)

16,698

(6)

(1) The PowerFlex 700L Frame 2 is not available as a DC input inverter.

(2) Only the Dual Inverter for PowerFlex 700L Frame 3A is available as a DC input inverter.

(3) Two 1000A Bussmann 170M6614 fuses per phase can also be used.

(4) See

Fuse Certification and Test Data on page 129

for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

(5) This 34,400 μF is the drive DC bus capacitance for a complete Frame 3B drive. The Frame 3B DC input inverter bus capacitance is 16,200 μF.

(6) This value applies to the precharge of the Frame 3A and 3B complete regenerative drives. There is a field-installed input filter precharge resistor kit (20L-RESPRE-A1) for the Frame 3A and 3B complete drives that can be used to increase the maximum external DC bus capacitance. For details, see publication 20L-IN010.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

115

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

116

Table 18 - PowerFlex 750-Series Drives — Frames 1…7, 650V DC Input Fuses

Drive Cat. No.

20F…/20G…

D2P1

D3P4

D5P0

D8P0

D011

D014

D014

D022

D027

D034

D040

D052

D065

D077

D096

D125

D156

D186

D248

D302

D361

D415

3

3

3

4

6

6

7

6

Frame

Size

1

1

1

1

1

1

2

2

4

5

5

6

7

7

50

—

60

—

30

—

40

—

20

—

25

—

10

—

15

—

7.5

—

10

—

3

—

5

—

HP Rating

ND HD

1

—

2

—

—

0.5

—

1

—

5

—

7.5

—

2

—

3

—

40

—

50

—

25

—

30

—

15

—

20

—

7.5

—

10

300

—

350

—

200

—

250

—

125

—

150

—

75

—

100

—

—

250

—

300

—

150

—

200

—

100

—

125

—

60

—

75

DC Input Rating Non-Time Delay Fuse

Amps

1.9

1.1

3.0

1.9

4.5

3.0

8.1

4.5

11.1

8.1

14.7

11.1

14.7

11.1

23.3

14.7

28.9

23.3

36.4

28.9

42.9

36.4

55.7

42.9

69.7

55.7

84.5

69.7

105.3

84.5

137.1

105.3

171.2

137.1

204.1

171.2

272.1

204.1

331.3

272.1

396.1

331.3

455.3

396.1

kW

1.2

0.72

2.0

1.2

2.9

2.0

5.3

2.9

7.2

5.3

9.6

7.2

9.5

7.2

15.1

9.5

18.8

15.1

23.6

18.8

27.8

23.6

36.1

27.8

45.1

36.1

54.7

45.1

68.3

54.7

88.9

68.3

110.9

88.9

132.2

110.9

176.3

132.2

214.7

176.3

256.6

214.7

295.0

256.6

Amps Catalog No.

6

4

6

Bussman JKS-6

(1)

Bussman JKS-4

(1)

Bussman JKS-6

(1)

6

6

10

Bussman JKS-6

(1)

Bussman JKS-10

(1)

Bussman JKS-6

(1)

15

10

20

15

30

20

30

20

40

30

50

40

Ferraz Shawmut HSJ15

(2)

Bussman JKS-10

(1)

Ferraz Shawmut HSJ20

(2)

Ferraz Shawmut HSJ15

(2)

Ferraz Shawmut HSJ30

(2)

Ferraz Shawmut HSJ20

(2)

Ferraz Shawmut HSJ30

(2)

Ferraz Shawmut HSJ20

(2)

Ferraz Shawmut HSJ40

(2)

Ferraz Shawmut HSJ30

(2)

Ferraz Shawmut HSJ50

(2)

Ferraz Shawmut HSJ40

(2)

60

50

80

60

90

80

100

90

150

Ferraz Shawmut HSJ60

(2)

Ferraz Shawmut HSJ50

(2)

Ferraz Shawmut HSJ80

(2)

Ferraz Shawmut HSJ60

(2)

Ferraz Shawmut HSJ90

(2)

Ferraz Shawmut HSJ80

(2)

Ferraz Shawmut HSJ100

(2)

Ferraz Shawmut HSJ90

(2)

Ferraz Shawmut HSJ150

(2)

100

175

150

200

175

300

200

400

300

400

400

630

400

800

630

900

800

Ferraz Shawmut HSJ100

(2)

Ferraz Shawmut HSJ175

(2)

Ferraz Shawmut HSJ150

(2)

Ferraz Shawmut HSJ200

(2)

Ferraz Shawmut HSJ175

(2)

Ferraz Shawmut HSJ300

(2)

Ferraz Shawmut HSJ200

(2)

Ferraz Shawmut HSJ400

(2)

Ferraz Shawmut HSJ300

(2)

Ferraz Shawmut HSJ400

(2)

Ferraz Shawmut HSJ400

(2)

Bussman 170M6608

(1)

Ferraz Shawmut HSJ400

(2)

Bussman 170M6612

(1)

Bussman 170M6608

(1)

Bussman 170M6613

(1)

Bussman 170M6612

(1)

Drive DC Bus

Capacitance (μF)

165

165

280

410

560

680

705

1000

1230

1500

1800

2400

3000

3600

4500

4600

9200

9200

9200

13,800

13,800

18,400

Maximum External DC

Bus Capacitance (μF)

41.25

41.25

70

102.5

140

170

176

250

308

375

450

600

750

900

1125

1150

2300

2300

2300

3450

3450

4600

(1) See Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

(2) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-Bradley for the fuses on the common DC bus for all

Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

Table 19 - PowerFlex 750-Series Drives — Frames 8…10, 650V DC Input Fuses

Drive Cat. No.

20G…

D430

D485

D545

D617

D710

D740

D800

D960

D1K0

D1K2

D1K3

D1K4

D1K5

D2K0

(1)

Frame

Size

HP Rating

ND HD

8 350

—

—

300

8

8

400

—

450

—

—

350

—

350

8

8

8

9

650

—

700

—

500

—

600

—

—

500

—

600

—

400

—

450

9

9

9

9

9

10

10

1250

—

1350

—

1750

—

1000

—

1100

—

800

—

900

—

—

1000

—

1100

—

1650

—

800

—

900

—

700

—

750

(1) These drives have factory-installed fusing.

1561

1248

1677

1396

2276

1902

1248

1055

1501

1149

1055

874

1149

880

814

678

880

781

678

533

781

599

533

455

599

499

DC Input Rating Drive DC Bus

Amps kW

Capacitance (μF)

473

407

307.5

264.6

23,700

346.5

295.8

389.4

324.4

23,700

23,700

440.7

346.5

507.7

389.4

529.1

440.7

572.0

507.7

35,550

35,550

35,550

47,400

685.8

568.1

746.9

572.0

811.2

685.8

975.7

746.9

1014.7

811.2

1090.1

907.4

1479.4

1236.3

47,400

47,400

71,100

71,100

71,100

71,100

106,650

Maximum External DC

Bus Capacitance (μF)

65,175

65,175

65,175

97,762.5

97,762.5

97,762.5

41,475

41,475

41,475

17,775

17,775

17,775

17,775

26,662.5

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

117

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

810 Volt DC Input Fuses Table 20 - PowerFlex 40P Drives, 810V DC Input Fuses

HP

Rating

7.5

10

15

3

5

1

2

DC Input

Amps

1.5

2.7

3.8

6.7

10.0

12.8

20.1

Drive DC Bus

Capacitance (μF)

75

110

135

280

330

440

440

118

Table 21 - PowerFlex 520-Series Drives, 810V DC Input Fuses

Drive Cat. No.

25x

E6P6

E9P9

E012

E019

E0P9

E1P7

E3P0

E4P2

E022

E027

E032

(1)

1.5

2.2

4.0

5.5

HP Rating

ND HD

0.4

0.75

0.4

0.75

7.5

11.0

15.0

18.5

22.0

1.5

2.2

4.0

5.5

7.5

11.0

11.0

15.0

18.5

DC Input

Amps

0.8

1.6

2.8

3.9

6.8

10.1

12.6

20.1

23.6

29.3

35.1

Non-Time Delay Fuse

Amps Catalog No.

3 Bussmann JKS-3

(2)

6

6

Bussmann JKS-6

(2)

Bussmann JKS-6

(2)

8

15

20

25

Bussmann JKS-8

(2)

Ferraz Shawmut HSJ15

(3)

Ferraz Shawmut HSJ20

(3)

Ferraz Shawmut HSJ25

(3)

40

40

50

60

Ferraz Shawmut HSJ40

(3)

Ferraz Shawmut HSJ40

(3)

Ferraz Shawmut HSJ50

(3)

Ferraz Shawmut HSJ60

(3)

Drive DC Bus

Capacitance (μF)

50

75

111

134

218

327

396

589

836

783

960

(1) The drive catalog number prefix is 25A for PowerFlex 523 drives, and 25B for PowerFlex 525 drives.

(2) See Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses

recommended for the DC bus fusing.

(3) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-

Bradley for the fuses on the common DC bus for all Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

Table 22 - PowerFlex 700/700S Drives — Frames 1…6, 810V DC Input Fuses

HP Rating DC Input Rating Non-Time Delay Fuse

(1)

Drive Cat. No.

20B… / 20D…

Frame

Size

Drive DC Bus

Capacitance (μF)

E1P7

E2P7

E3P9

E6P1

E9P0

E011

E017

E022

E027

E032

E041

E052

E062

T099

0/1

0/1

0/1

0/1

0/1

1

1

2

2

3

3

3

4

5

ND

1

2

3

5

7.5

10

15

20

25

30

40

50

60

100

HD

0.75

1.5

2

3

5

7.5

10

15

20

25

30

40

50

—

Amps

1.5

2.4

3.5

6.2

9.1

11.5

18

23.6

29

34.3

43.9

55.7

68.0

108.6

Amps Catalog No.

3

6

6

Bussmann JKS-3

(2)

Bussmann JKS-6

(2)

Bussmann JKS-6

(2)

10

15

20

Bussmann JKS-10

(2)

Ferraz Shawmut HSJ15

(3)

Ferraz Shawmut HSJ20

(3)

30

40

50

60

70

90

125

150

150

Ferraz Shawmut HSJ30

(3)

Ferraz Shawmut HSJ40

(3)

Ferraz Shawmut HSJ50

(3)

Ferraz Shawmut HSJ60

(3)

Ferraz Shawmut HSJ70

(3)

Ferraz Shawmut HSJ90

(3)

Ferraz Shawmut HSJ125

(3)

Ferraz Shawmut HSJ150

(3)

Ferraz Shawmut HSJ150

(3)

195

195

195

390

390

560

560

1,000

1,200

1,400

1,800

2,400

2,400

3,500

— 75 84.5

6 150

—

—

125

158

137.1

200

200

Ferraz Shawmut HSJ200

(3)

Ferraz Shawmut HSJ200

(3)

5,000 T144

(1) The power source to Common Bus inverters must be derived from AC voltages 600V or less, as defined in NFPA70; Art 430-18 (NEC). Battery supplies or MG sets are not included. The following devices were validated to break current of the derived power DC Bus: Disconnects: Allen-Bradley Bulletin No. 1494, 30 to 400 A; Bulletin No. 194, 30 to 400 A, or ABB: OESA, 600 & 800 A; OESL, all sizes. Fuses: Bussmann Type JKS, all sizes; Type 170M, Case Sizes 1, 2 and 3, or

Ferraz Shawmut Type HSJ, all sizes. For any other devices, please contact the factory.

(2) See

Fuse Certification and Test Data on page 129

for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

(3) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-Bradley for the fuses on the common DC bus for all Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

119

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

120

Table 23 - PowerFlex 700H/700S Drives — Frames 9…14, 810V DC Input Fuses

Frame

Size

9

9

10

10

10

10

11

12

13

13

11

11

12

12

13

14

14

14

1100

—

1300

—

900

—

1000

—

700

—

800

—

500

—

600

—

1600

—

2000

—

2400

—

450

—

500

—

350

—

400

—

200

—

250

—

HP Rating

ND HD

150

—

—

150

—

150

—

200

—

350

—

400

—

250

—

350

—

1400

—

1600

—

2000

—

1000

—

1100

—

700

—

900

—

650

—

700

—

500

—

500

Drive Cat. No.

20C… / 20D…

K170

K208

K261

K325

K385

K416

K460

K502

K590

K650

K750

K820

K920

K1K0

K1K1

K1K5

K1K9

K2K2

(1)

DC Input Rating Fuse

Amps

192

162

235

192

294

235

367

294

434

367

469

367

519

434

566

519

666

566

733

666

846

733

925

733

1038

925

1162

1038

1331

1162

1692

1467

2143

1692

2538

2143

Amps

400

400

450

450

450

450

Catalog No.

Bussman 170M5608

(2)

Bussman 170M5608

(2)

Bussman 170M5609

(2)

Bussman 170M5609

(2)

Bussman 170M5609

(2)

Bussman 170M5609

(2)

Bussman 170M6609

(2)

550

550

700

700

Bussman 170M6609

(2)

Bussman 170M6611

(2)

Bussman 170M6611

(2)

Bussman 170M6612

(2)

800

800 Bussman 170M6612

(2)

450 (2 per phase) Bussman 170M5609

(2)

450 (2 per phase) Bussman 170M5609

(2)

500 (2 per phase) Bussman 170M6608

(2)

500 (2 per phase) Bussman 170M6608

(2)

500 (2 per phase) Bussman 170M6608

(2)

500 (2 per phase) Bussman 170M6608

(2)

500 (2 per phase) Bussman 170M6608

(2)

500 (2 per phase) Bussman 170M6608

(2)

630 (2 per phase) Bussman 170M6610

(2)

630 (2 per phase) Bussman 170M6610

(2)

630 (2 per phase) Bussman 170M6610

(2)

630 (2 per phase) Bussman 170M6610

(2)

2400 Bussman 170M7107

(2)

2400

2400

2400

2400

Bussman 170M7107

(2)

Bussman 170M7107

(2)

Bussman 170M7107

(2)

Bussman 170M7107

(2)

2400

—

—

—

—

—

—

Bussman 170M7107

(2)

Bussman 170M8610

(2)

Bussman 170M8610

(2)

Bussman 170M8610

(2)

Bussman 170M8610

(2)

Bussman 170M8610

(2)

Bussman 170M8610

(2)

Drive DC Bus

Capacitance (μF)

3,600

3,600

7,467

7,467

7,467

7,467

11,200

11,200

11,200

14,933

14,933

14,933

22,400

22,400

22,400

44,800

44,800

44,800

(3)

(3)

(3)

(4)

(4)

(4)

(1) 20DK820 drives (ND) are only capable of producing 95% of starting torque under 10 Hz.

(2) See

Fuse Certification and Test Data on page 129

for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

(3) This listed capacitance is for Frame 13 DC fed drives. For Frame 13 AC fed drives, the capacitance is 26,800 μF.

(4) The listed capacitance is for Frame 14 DC fed drives. For Frame 14 AC fed drives, the capacitance is 53,600 μF.

Maximum External DC

Bus Capacitance (μF)

0

0

19,333

19,333

19,333

19,333

15,600

15,600

15,600

11,867

11,867

11,867

0

0

0

0

0

0

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

Table 24 - PowerFlex 700L Drives — Frames 3A and 3B, 810V DC Input Fuses

Drive Cat. No.

20L…

E425

E800

E1K1

Frame

Size

3A

3B

3B

HP Rating

ND HD

465

870

1275

345

640

935

DC Input Rating Fuse Drive DC Bus

Capacitance (μF)

Amps

850

(1)

Amps

1400

Catalog No.

Bussman 170M6701

(2)

800 1250

1175 900 (2 per phase) Bussman 170M6697

(3)

(3)

10,800

21,600

21,600

(5)

(5)

Maximum External DC

Bus Capacitance (μF)

4,911

(6)

9,823

(6)

9,823

(6)

(1) Only the Dual Inverter for PowerFlex 700L Frame 3A is available as a DC input inverter.

(2) Two 700A Bussmann 170M6695 fuses per phase can also be used.

(3) See Fuse Certification and Test Data on page 129 for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

(4) Two 630A Bussmann 170M6694 fuses per phase can also be used.

(5) This 21,600 μF is the drive DC bus capacitance for a complete Frame 3B drive. The Frame 3B DC input inverter bus capacitance is 10,800 μF.

(6) This value applies to the precharge of the Frame 3A and 3B complete regenerative drives. There is a field-installed input filter precharge resistor kit (20L-RESPRE-A1) for the Frame 3A and 3B complete drives that can be used to increase the maximum external DC bus capacitance. For details, see publication 20L-IN010.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

121

122

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

Table 25 - PowerFlex 750-Series Drives — Frames 3…7, 810V DC Input Fuses

E053

E063

E077

E099

E125

E144

E023

E024

E027

E028

E032

E022

Drive Cat. No.

20F…/20G…

E1P7

Frame

Size

3

—

200

—

250

—

300

—

—

125

—

150

—

75

—

100

—

50

—

60

—

40

—

50

—

30

—

40

—

25

—

30

—

20

—

25

—

20

—

20

—

15

—

15

—

10

—

10

—

5

—

7.5

—

2

—

3

HP Rating

ND

1

HD

—

2

—

3

—

0.5

—

1

—

15

—

20

—

10

—

15

—

7.5

—

10

—

5

—

7.5

—

125

—

150

—

200

—

250

75

—

100

—

50

—

60

—

40

—

40

—

30

—

30

—

25

—

25

—

20

—

20

—

Drive DC Bus

Capacitance (μF)

1500

Maximum External DC

Bus Capacitance (μF)

375

E2P7

E3P9

E6P1

E9P0

E011

E012

E017

E018

E033

E041

E042

E052

E192

E242

E289

3

3

3

3

3

6

3

6

3

6

6

4

6

4

6

5

6

5

6

6

6

6

6

6

7

7

7

DC Input Rating Non-Time Delay Fuse

Amps kW

1.9

1.0

3.0

1.9

4.3

3.0

6.7

4.3

9.9

6.7

12.0

9.9

13.1

10.0

18.6

12.0

19.7

13.1

24.1

18.6

25.2

19.7

26.3

24.1

29.6

24.1

30.7

25.2

35.0

29.6

36.1

30.7

44.9

35.0

46.0

36.1

56.9

44.9

58.0

46.0

69.0

58.0

84.3

69.0

108.4

84.3

136.8

108.4

157.6

136.8

210.2

157.6

264.9

210.2

316.4

264.9

1.5

0.8

2.4

1.5

3.5

2.4

5.4

3.5

8.0

5.4

9.7

8.0

10.6

8.1

15.1

9.7

16.0

10.6

19.5

15.1

20.4

16.0

21.3

19.5

24.0

19.5

24.9

20.4

28.4

24.0

29.2

24.9

36.4

28.4

37.3

29.2

46.1

36.4

47.0

37.3

55.9

47.0

68.3

55.9

87.8

68.3

110.8

87.8

127.7

110.8

170.3

127.7

214.6

170.3

256.3

214.6

Amps

4

2

5

4

8

5

10

8

15

10

20

15

20

15

30

20

30

20

40

30

40

30

40

40

50

40

50

40

60

50

60

50

70

60

70

60

90

70

90

70

110

90

150

110

175

150

225

175

250

225

350

250

400

350

500

400

Catalog No.

Bussman JKS-4

(1)

Bussman JKS-2

(1)

Bussman JKS-5

(1)

Bussman JKS-4

(1)

Bussman JKS-8

(1)

Bussman JKS-5

(1)

Bussman JKS-10

(1)

Bussman JKS-8

(1)

Ferraz Shawmut HSJ15

(2)

Ferraz Shawmut HSJ10

(2)

Ferraz Shawmut HSJ20

(2)

Ferraz Shawmut HSJ15

(2)

Ferraz Shawmut HSJ20

(2)

Ferraz Shawmut HSJ15

(2)

Ferraz Shawmut HSJ30

(2)

Ferraz Shawmut HSJ20

(2)

Ferraz Shawmut HSJ30

(2)

Ferraz Shawmut HSJ20

(2)

Ferraz Shawmut HSJ40

(2)

Ferraz Shawmut HSJ30

(2)

Ferraz Shawmut HSJ40

(2)

Ferraz Shawmut HSJ30

(2)

Ferraz Shawmut HSJ40

(2)

Ferraz Shawmut HSJ40

(2)

Ferraz Shawmut HSJ50

(2)

Ferraz Shawmut HSJ40

(2)

Ferraz Shawmut HSJ50

(2)

Ferraz Shawmut HSJ40

(2)

Ferraz Shawmut HSJ60

(2)

Ferraz Shawmut HSJ50

(2)

Ferraz Shawmut HSJ60

(2)

Ferraz Shawmut HSJ50

(2)

Ferraz Shawmut HSJ70

(2)

Ferraz Shawmut HSJ60

(2)

Ferraz Shawmut HSJ70

(2)

Ferraz Shawmut HSJ60

(2)

Ferraz Shawmut HSJ90

(2)

Ferraz Shawmut HSJ70

(2)

Ferraz Shawmut HSJ90

(2)

Ferraz Shawmut HSJ70

(2)

Ferraz Shawmut HSJ110

(2)

Ferraz Shawmut HSJ90

(2)

Ferraz Shawmut HSJ150

(2)

Ferraz Shawmut HSJ110

(2)

Ferraz Shawmut HSJ175

(2)

Ferraz Shawmut HSJ150

(2)

Ferraz Shawmut HSJ225

(2)

Ferraz Shawmut HSJ175

(2)

Ferraz Shawmut HSJ250

(2)

Ferraz Shawmut HSJ225

(2)

Ferraz Shawmut HSJ350

(2)

Ferraz Shawmut HSJ250

(2)

Ferraz Shawmut HSJ400

(2)

Ferraz Shawmut HSJ350

(2)

Ferraz Shawmut HSJ500

(2)

Ferraz Shawmut HSJ400

(2)

1500

1500

1500

1500

1500

5200

1500

5200

1500

5200

5200

1800

5200

1800

5200

3600

5200

3600

2600

5200

5200

5200

5200

5200

11,700

11,700

11,700

375

375

375

375

375

1300

375

1300

375

1300

1300

450

1300

450

1300

900

1300

900

650

1300

1300

1300

1300

1300

2925

2925

2925

(1)

See Fuse Certification and Test Data on page 129

for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

•

600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

•

Time constant minimum 3 milliseconds (maximum 15 milliseconds).

(2) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-Bradley for the fuses on the common DC bus for all Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

•

No over-load protection required.

•

Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

Table 26 - PowerFlex 750-Series Drives — Frames 8…10, 810V DC Input Fuses

Drive Cat. No.

20G…

E295

E355

E395

E435

E460

E510

E595

E630

E760

E825

E900

E980

E1K1

E1K4

(1)

Frame

Size

HP Rating

ND HD

8 300

—

—

250

8

8

350

—

400

—

—

300

—

350

8

8

8

9

500

—

600

—

450

—

500

—

—

450

—

500

—

350

—

400

9

9

9

9

9

10

10

1000

—

1100

—

1400

—

900

—

950

—

700

—

800

—

—

900

—

1000

—

1250

—

750

—

800

—

600

—

700

(1) These drives have factory-installed fusing.

1081

899

1224

1015

1577

1312

910

772

993

838

695

656

838

695

562

469

656

562

480

391

507

436

391

325

436

363

DC Input Rating Drive DC Bus

Amps kW

Capacitance (μF)

325

300

263.3

243.0

16,800

316.7

263.3

353.2

294.0

16,800

16,800

388.8

316.7

410.7

353.2

455.2

379.9

531.4

455.2

25,200

25,200

25,200

33,600

563.0

531.4

678.8

563.0

737.1

625.3

804.3

678.8

875.6

728.2

991.4

822.2

1277.4

1062.7

33,600

33,600

50,400

50,400

50,400

50,400

75,600

Maximum External DC

Bus Capacitance (μF)

46,200

46,200

46,200

69,300

69,300

69,300

29,400

29,400

29,400

44,100

44,100

44,100

12,600

18,900

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

123

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

Table 27 - PowerFlex 700/700S Drives — Frames 5 and 6, 932V DC Input Fuses 932 Volt DC Input Fuses

Drive Cat. No.

20B… / 20D…

Frame

Size kW Rating

ND HD

90

—

—

75

132

—

—

110

Drive DC Bus

Capacitance (μF)

W098

W142

5

6

DC Input Rating Non-Time Delay Fuse

(1)

Amps

92.3

92.3

162.2

134.9

Amps

160

160

250

250

Catalog No.

Ferraz Shawmut HSJ160

(2)

Ferraz Shawmut HSJ160

(2)

Ferraz Shawmut HSJ250

(2)

Ferraz Shawmut HSJ250

(2)

3,500

5,000

(1) The power source to Common Bus inverters must be derived from AC voltages 600V or less, as defined in NFPA70; Art 430-18 (NEC). Battery supplies or MG sets are not included. The following devices were validated to break current of the derived power DC Bus: Disconnects: Allen-Bradley Bulletin No. 1494, 30 to 400 A;

Bulletin No. 194, 30 to 400 A, or ABB: OESA, 600 & 800 A; OESL, all sizes. Fuses: Bussmann Type JKS, all sizes; Type 170M, Case Sizes 1, 2 and 3, or Ferraz

Shawmut Type HSJ, all sizes. For any other devices, please contact the factory.

(2) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-Bradley for the fuses on the common DC bus for all Allen-Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

124

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

Table 28 - PowerFlex 700H/700S Drives — Frames 9…14, 932V DC Input Fuses

Drive Cat. No. Frame kW Rating DC Input Rating Fuse Drive DC Bus

20C… / 20D…

M170

M208

M261

M325

M385

M416

M460

M502

M590

M650

M750

M820

(1)

M920

M1K0

M1K1

M1K5

Size

9

9

10

10

10

10

11

11

11

12

12

12

13

13

13

14

ND

160

—

200

—

250

—

315

—

355

—

400

—

450

—

500

—

560

630

—

710

—

800

—

900

—

—

1000

—

1100

—

1500

—

HD

—

132

—

160

—

200

—

250

—

315

—

315

—

355

—

400

—

500

—

560

—

630

—

630

—

800

—

900

—

Amps

200

170

245

200

307

245

383

307

453

383

490

383

542

453

591

542

695

591

765

695

883

765

965

765

1038

925

1162

1038

1331

1000 1162

— 1766

1300 1530

Amps

315

315

400

400

500

500

630

630

700

700

700

700

450 (2 per phase)

450 (2 per phase)

500 (2 per phase)

500 (2 per phase)

500 (2 per phase)

500 (2 per phase)

550 (2 per phase)

550 (2 per phase)

630 (2 per phase)

630 (2 per phase)

630 (2 per phase)

630 (2 per phase)

2400

2400

2400

2400

2400

2400

—

—

Catalog No.

Bussman 170M3746

(2)

Bussman 170M3746

(2)

Bussman 170M5742

(2)

Bussman 170M5742

(2)

Bussman 170M5744

(2)

Bussman 170M5744

(2)

Bussman 170M5746

(2)

Bussman 170M5746

(2)

Bussman 170M6745

(2)

Bussman 170M6745

(2)

Bussman 170M6745

(2)

Bussman 170M6745

(2)

Bussman 170M5743

(2)

Bussman 170M5743

(2)

Bussman 170M5744

(2)

Bussman 170M5744

(2)

Bussman 170M5744

(2)

Bussman 170M5744

(2)

Bussman 170M5745

(2)

Bussman 170M5745

(2)

Bussman 170M5746

(2)

Bussman 170M5746

(2)

Bussman 170M5746

(2)

Bussman 170M5746

(2)

Bussman 170M7107

(2)

Bussman 170M7107

(2)

Bussman 170M7107

(2)

Bussman 170M7107

(2)

Bussman 170M7107

(2)

Bussman 170M7107

(2)

Bussman 170M8610

(2)

Bussman 170M8610

(2)

Bussman 170M8610

(2)

Capacitance (μF)

3,600

3,600

7,467

7,467

7,467

7,467

11,200

11,200

11,200

14,933

14,933

14,933

22,400

(3)

22,400

(3)

22,400

(3)

44,800

(4)

M1K9 14 1800 — 2237 —

44,800

(4)

Bussman 170M8610

(2)

Bussman 170M8610

(2)

Bussman 170M8610

(2)

44,800

(4)

M2K2 14

—

2000

—

1500 1766

— 2649

1800 2237

—

—

—

(1) 20DM820 drives (ND) are only capable of producing 95% of starting torque under 10 Hz.

(2) See

Fuse Certification and Test Data on page 129

for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

(3) This listed capacitance is for Frame 13 DC fed drives. For Frame 13 AC fed drives, the capacitance is 26,800 μF

(4) The listed capacitance is for Frame 14 DC fed drives. For Frame 14 AC fed drives, the capacitance is 53,600 μF.

0

19,333

19,333

19,333

19,333

15,600

15,600

15,600

11,867

11,867

11,867

0

0

0

0

0

0

Maximum External DC

Bus Capacitance (μF)

0

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

125

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

Table 29 - PowerFlex 700L Drives — Frames 3A and 3B, 932V DC Input Fuses

Drive Cat. No.

20L…

F380

F705

F1K0

Frame

Size

3A

3B

3B

kW Rating

ND

355

657

980

HD

260

485

720

DC Input Rating Fuse

Amps

760

(1)

705

1050

Amps

1250

Catalog No.

Bussman 170M6700

(2) (3)

1100 Bussman 170M6699

(3)

800 (2 per phase) Bussman 170M6696

(3)

(4)

Drive DC Bus

Capacitance (μF)

10,800

21,600

(5)

21,600

(5)

Maximum External DC

Bus Capacitance (μF)

1,080

(6)

2,160

(6)

2,160

(6)

(1) Only the Dual Inverter for PowerFlex 700L Frame 3A is available as a DC input inverter.

(2) Two 630A Bussmann 170M6694 fuses per phase can also be used.

(3) See

Fuse Certification and Test Data on page 129

for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

(4) Two 550A Bussmann 170M6693 fuses per phase can also be used.

(5) This 21,600 μF is the drive DC bus capacitance for a complete Frame 3B drive. The Frame 3B DC input inverter bus capacitance is 10,800 μF.

(6) This value applies to the precharge of the Frame 3A and 3B complete regenerative drives. There is a field-installed input filter precharge resistor kit (20L-RESPRE-A1) for the Frame 3A and 3B complete drives that can be used to increase the maximum external DC bus capacitance. For details, see publication 20L-IN010.

126

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

Table 30 - PowerFlex 750-Series Drives — Frames 6 and 7, 932V DC Input Fuses kW Rating DC Input Rating Non-Time Delay Fuse Drive Cat. No.

20F…/20G…

Frame

Size

Drive DC Bus

Capacitance (μF)

Maximum External DC

Bus Capacitance (μF)

F012

F015

F020

F023

F030

F034

F046

F050

F061

F082

F098

F119

F142

6

6

6

6

6

6

6

6

6

6

6

6

6

ND

7.5

—

11

—

15

—

18.5

—

22

—

30

—

37

—

—

55

—

75

—

90

45

—

110

—

132

—

HD

—

5.5

—

7.5

—

11

—

15

—

18.5

—

22

—

30

—

37

—

45

—

55

—

75

—

90

—

110

Amps kW

13.2

9.9

16.5

13.2

21.9

16.5

25.2

21.9

32.9

25.2

37.3

32.9

50.5

37.5

54.8

50.5

66.9

54.8

89.9

66.9

107.5

89.9

130.5

107.5

155.7

130.5

12.3

9.2

15.4

12.3

20.4

15.4

23.5

20.4

30.7

23.5

34.8

30.7

47.1

34.8

51.1

47.1

62.4

51.1

83.8

62.4

100.2

83.8

121.6

100.2

145.1

121.6

Amps Catalog No.

20 Ferraz Shawmut HSJ20

(1)

15

25

Ferraz Shawmut HSJ15

(1)

Ferraz Shawmut HSJ25

(1)

20

35

25

40

Ferraz Shawmut HSJ20

(1)

Ferraz Shawmut HSJ35

(1)

Ferraz Shawmut HSJ25

(1)

Ferraz Shawmut HSJ40

(1)

35

50

40

60

50

80

60

90

Ferraz Shawmut HSJ35

(1)

Ferraz Shawmut HSJ50

(1)

Ferraz Shawmut HSJ40

(1)

Ferraz Shawmut HSJ60

(1)

Ferraz Shawmut HSJ50

(1)

Ferraz Shawmut HSJ80

(1)

Ferraz Shawmut HSJ60

(1)

Ferraz Shawmut HSJ90

(1)

80

100

90

150

100

175

150

200

175

250

200

300

Ferraz Shawmut HSJ80

(1)

Ferraz Shawmut HSJ100

(1)

Ferraz Shawmut HSJ90

(1)

Ferraz Shawmut HSJ150

(1)

Ferraz Shawmut HSJ100

(1)

Ferraz Shawmut HSJ175

(1)

Ferraz Shawmut HSJ150

(1)

Ferraz Shawmut HSJ200

(1)

Ferraz Shawmut HSJ175

(1)

Ferraz Shawmut HSJ250

(1)

Ferraz Shawmut HSJ200

(1)

Ferraz Shawmut HSJ300

(1)

5200

5200

5200

5200

5200

5200

5200

2600

5200

5200

5200

5200

5200

1300

1300

1300

1300

1300

1300

1300

650

1300

1300

1300

1300

1300

F171 7 160 — 187.5

174.8

11,700 2925

Ferraz Shawmut HSJ250

(1)

— 132 155.7

145.1

250

F212

F263

7

7

200

—

250

—

—

160

—

200

232.5

187.5

288.4

232.5

216.7

174.8

268.8

216.7

350

300

500

350

Ferraz Shawmut HSJ350

Ferraz Shawmut HSJ300

Ferraz Shawmut HSJ500

Ferraz Shawmut HSJ350

(1)

(1)

(1)

(1)

11,700

11,700

2925

2925

(1) A test program was developed to confirm that the HSJ (High Speed J) fuses can meet or exceed the requirements set forth by Allen-Bradley for the fuses on the common DC bus for all Allen-

Bradley PowerFlex drives, 1336 Plus drives, and so forth. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kVA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let thru must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

127

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

Table 31 - PowerFlex 750-Series Drives — Frames 8…10, 932V DC Input Fuses

Drive Cat. No.

20G…

F265

F330

F370

F415

F460

F500

F590

F650

F710

F765

F795

F960

F1K0

F1K4

(1)

Frame

Size kW Rating

ND HD

8 250

—

—

200

8

8

315

—

355

—

—

250

—

300

8

8

8

9

500

—

560

—

400

—

450

—

—

400

—

450

—

355

—

375

9

9

9

9

9

10

10

900

—

1000

—

1400

—

750

—

800

—

630

—

710

—

—

800

—

900

—

1120

—

630

—

710

—

500

—

590

(1) These drive have factory-installed fusing.

1056

875

1144

952

1540

1276

842

715

875

825

715

550

781

649

550

454

649

506

457

407

506

413

363

292

407

339

DC Input Rating Drive DC Bus

Amps kW

Capacitance (μF)

292

237

272.1

220.9

16,800

338.3

272.1

379.3

315.9

16,800

16,800

425.9

379.3

471.6

384.9

512.6

423.1

604.9

471.6

25,200

25,200

25,200

33,600

666.4

512.6

727.9

604.9

784.7

666.4

815.5

768.9

984.2

815.5

1066.2

887.3

1435.3

1189.2

33,600

33,600

50,400

50,400

50,400

50,400

75,600

Maximum External DC

Bus Capacitance (μF)

46,200

46,200

46,200

69,300

69,300

69,300

29,400

29,400

29,400

44,100

44,100

44,100

12,600

18,900

128

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

Fuse Certification and Test

Data

The following are copies of self-certification letters and test data for JKS and

170M fuses recommended in the previous tables in this Appendix for DC input fusing.

Configuration A indicates one fuse in the (+) leg and one fuse in the (-) leg of the

DC bus.

JKS Fuses

Cooper Bussmann

P. O. Box 14460

St. Louis, MO 63178-4460

January 25, 2002

Sr. Project Engineer

Rockwell Automation

6400 West Enterprise Drive

P.O. Box 760

Mequon, WI 53092

Subject: DC Testing for JKS Fuses

Dear Mr.

Per Rockwell Automation's request, Bussmann has completed the DC testing for the JKS fuses and is please to present the attached information indicating successful ‘Self Certification DC Rating’ on all subject fuses.

Bussmann tested fuses to the following parameters specified by Rockwell

Automation:

Short Circuit Current = 65 kA

Voltage

Time Constant

= 810V DC

≥ 0.4 ms

Additional tests were performed for acceptability.

Short Circuit Current

≅ 30 times fuse amperage

Voltage

Time Constant

= 810V DC

≥ 0.4 ms

The attached table identifies the fuses tested, the actual circuit parameters and the circuit configuration. In the attached table, the Interrupting Amps column specifies the fuses minimum and maximum amps the fuse will safely clear at 810V

DC.

Circuit Configuration A

Fuse Fuse

By way of this correspondence, Cooper Bussmann self-certifies the above fuses in end-user applications to the above parameters and the attached data sheet.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

129

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

Should you have any questions regarding this correspondence, please contact me at the listed address and numbers below.

Regards,

Strategic OEM Accounts Manager

Cooper Bussmann

Fuse Results

Acceptable

Acceptable

Cooper Bussmann JKS

DC Fuse Test for Rockwell Automation

Circuit Parameters

Interrupting Amps

Min Max

—

375 A

69.6 kA

—

Volts DC Time

Constant

810

810

2.78 ms

0.55 ms

JKS-(3A…15A)

JKS-(3A…15A)

JKS-(20A…30A)

JKS-(20A…30A)

JKS-(35A…60A)

JKS-(35A…60A)

JKS-(70A…100A)

JKS-(70A…100A)

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

JKS-(110A…200A) Acceptable

JKS-(110A…200A) Acceptable

—

920 A

—

1820 A

—

2950 A

—

5960 A

69.6 kA

—

69.6 kA

—

69.6 kA

—

69.6 kA

—

816

812

816

812

816

812

816

810

2.78 ms

0.4 ms

2.78 ms

0.5 ms

2.78 ms

0.86 ms

2.78 ms

3.34 ms

JKS-(225A…400A) Acceptable

JKS-(225A…400A) Acceptable

JKS-(450A…600A) Acceptable

JKS-(450A…600A) Acceptable

—

11.5 kA

—

15.5 kA

69.6 kA

—

69.6 kA

—

816

812

816

810

2.78 ms

2.92 ms

2.78 ms

0.4 ms

Circuit

Configuration

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

130

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance Appendix A

170M Fuses

Cooper Bussmann

P. O. Box 14460

St. Louis, MO 63178-4460

May 15, 2002

Sr. Project Engineer

Rockwell Automation

6400 West Enterprise Drive

P.O. Box 760

Mequon, WI 53092

Subject: DC Testing for 170M Fuses

Dear Mr.

Per Rockwell Automation's request, Bussmann has completed the DC testing for the 170M fuses and is please to present the attached information indicating successful ‘Self Certification DC Rating’ on all subject fuses.

Bussmann tested fuses to the following parameters specified by Rockwell

Automation:

Short Circuit Current = 65 kA and 100 kA

Voltage

Time Constant

= 810V DC

≥ 0.4 ms

Additional tests were performed for acceptability.

Short Circuit Current

≅ 30 times fuse amperage as minimum current interrupting rating or as tested

Voltage

Time Constant

= 810V DC

≥ 0.4 ms

The attached table identifies the fuses tested, the actual circuit parameters and the circuit configuration. In the attached table, the Interrupting Amps column specifies the fuses minimum and maximum amps the fuse will safely clear at 810V

DC.

Circuit Configuration A

Fuse Fuse

By way of this correspondence, Cooper Bussmann self-certifies the above fuses in end-user applications to the above parameters and the attached data sheet.

Should you have any questions regarding this correspondence, please contact me at the listed address and numbers below.

Regards,

Strategic OEM Accounts Manager

Cooper Bussmann

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

131

Appendix A PowerFlex Drive Ratings, Recommended DC Bus Fuses, and Drive DC Bus Capacitance

Fuse

170M6793

170M6793

170M6794

170M6794

170M6828

170M6828

170M6934

170M6934

170M7560

170M7560

170M6646

170M6646

170M6650

170M6650

170M7510

170M7510

170M6792

170M6792

Results

Acceptable

Acceptable

Cooper Bussmann 170M

DC Fuse Test for Rockwell Automation

Circuit Parameters

Interrupting Amps

Min

—

10.2 kA

Max

69.8 kA

—

Volts DC Time

Constant

812

812

2 ms

1.66 ms

Acceptable

Acceptable

Acceptable

Acceptable

—

27.5 kA

—

37 kA

—

45.2 kA

—

60 kA

—

19 kA

—

23 kA

—

21.1 kA

—

20 kA

65 kA

—

65 kA

—

69.6 kA

—

65 kA

—

65 kA

—

65 kA

—

105.4 kA 810

— 810

100 kA

—

810

810

810

810

810

810

810

810

810

810

812

812

810

810

2 ms

2 ms

2 ms

2 ms

1.8 ms

1.12 ms

2 ms

2 ms

2 ms

2 ms

2 ms

2 ms

2 ms

1.2 ms

2 ms

2 ms

Circuit

Configuration

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

132

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Appendix

B

Power Component Accessories

Back-to-Back Diodes (Shared

AC/DC Configurations)

Considerations

Consider the following information when selecting the Back-to-Back diodes:

• Size Back-to-Back diodes to 125% of the drive's DC input Amps

• Thermal impedance of panel to air

• Ambient temperature

• Any existing thermal compound between diodes and panel affecting thermal drop between the diodes and panel

• Consult diode vendor for proper diode installation

Diode Sharing Modules

Consider the following information when selecting Diode Sharing Modules for

the Shared Regenerative Braking Configuration shown in Figure 33 on page 52

,

Figure 35 on page 54

,

Figure 37 on page 61 , and

Figure 38 on page 62

. The following table lists Diode Sharing Modules offered by Bonitron at www.bonitron.com

Table 32 - Bonitron M3345D Diode Sharing Modules

20 HP

20 HP

30 HP

30 HP

20 HP

50 HP

3 HP

10 HP

10 HP

20 HP

Nominal Drive HP

230V AC 460V AC

1.5 HP

3 HP

3 HP

5 HP

5 HP

20 HP

20 HP

40 HP

40 HP

40 HP

60 HP

60 HP

40 HP

100 HP

Max.

Regen Amps

Drive DC

Bus Amps

Max. No. of Drives

Model

Number

30 A

30 A

60 A

90 A

90 A

90 A

90 A

90 A

90 A

90 A

90 A

120 A

4 A

10 A

10 A

30 A

30 A

60 A

60 A

60 A

90 A

90 A

60 A

200 A

6

3

6

3

6

3

4

6

2

3

2

2

M3345D-04F6

M3345D-10H3

M3345D-10J6

M3345D-30H3

M3345D-30J6

M3345D-60L3

M3345D-60P4

M3345D-60P6

M3345D-90N2

M3345D-90N3

M3345D-60L2

M3345D-200P2

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

133

Appendix B Power Component Accessories

HF Filter (SCR Bus Supply)

When the 20S-RFC filter is used, the HF emission limits for class A, group 2*

(EN55011) in the second environment (industrial supply network) according to the product standard EN61800-3 are met, and the Bus Supply fulfills CE conformity.

Description

HF Filter, 690V

Cat. No.

20S-RFC

Bus Supply Capacitors

134

SCR Bus Supply Minimum Capacitance

A minimum capacitance is required to commission and test the SCR bus supply.

If this minimum capacitance is not present, the bus supply internal fault detection circuit interprets the condition as a DC bus short and stops pulse firing. This minimum capacitance can be provided by a drive as long as it remains connected to the DC bus, or by a capacitor bank of at least 110 μF per SCR Bus Supply.

Connecting High Power Drives and Low Power Drives on the DC Bus

IMPORTANT When the DC bus system is comprised of drives from the same product family and the same frame size, no additional capacitance is required.

However, if drives from different product families or frame sizes are intermixed, the drive bus capacitance per amp ratio must be reviewed for compatibility.

All drives have a DC bus capacitance that is proportional to the drives power rating. When used in a common DC bus configuration, these capacitors are directly connected in parallel resulting in the DC bus ripple being shared proportionally to the power rating of the drive. When the ratio of the capacitance to the drive rated current is consistent, the best DC bus ripple sharing is promoted.

The target ratio is 40 μF/A or greater.

DC+

DC-

PE

Chassis

Therefore it is important to evaluate every common DC bus drive system for any mismatch. When a mismatch is found, the use of an external capacitor bank is required. The capacitor bank must be connected closest to the DC bus terminals of the largest drive.

Calculate the capacitance (μF) per drive current rating (Amp) using Equation 1 below, where the DC input current and drive capacitance values are found in

Appendix A

.

Equation 1

Capacitance Ratio =

Drive Capacitance in Microfarads (μF)

Drive DC Input Current in Amps (A)

If the ratio is below 40 μF/A, then additional capacitance is required and can be calculated using the following Equation 2.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Power Component Accessories Appendix B

Equation 2

Additional Capacitance = 40 μF x DC Input Amps - Drive DC Bus Capacitance

Fuse protection with diagnostic feedback is recommended and may be located internal or external to the capacitor bank. Follow the manufacturer's recommendation regarding wire length and mounting of the capacitor bank.

IMPORTANT The capacitor quantity and configuration will vary based on the total capacitance and DC bus voltage rating.

Here are some example calculations.

SCR Bus Supply or AFE

L1

DC+

L2

L3

PowerFlex

DC-

DC+

➊

DCDC+ DCDC+ DCDC+ DC-

AC Drive

M

Drive A

AC Drive

M

Drive B

AC Drive

M

Drive C

AC Drive

M

Drive D

➊ If a capacitor bank is required, place the capacitor bank as close as possible to the largest drive.

Example 1: 650V DC

Product Family and Frame Size

Additional Capacitance Required

Additional Capacitance μF Value

(use Equation 2)

Drive A

PowerFlex 750-

Series Frame 8

Cat. No.

DC Current (from Appendix A)

D545…

599 A

DC Bus Capacitance (from Appendix A) 23,700 μF

μF/A Ratio (use Equation 1) 39.5

No n/a

Drive B

PowerFlex 750-

Series Frame 6

D248…

272.1 A

9200 μF

33.8

Yes

1648 μF

Drive C

PowerFlex 750-

Series Frame 3

D034…

36.4 A

1500 μF

41.2

No n/a

Drive D

PowerFlex 750-

Series Frame 2

D022…

23.3 A

1000 μF

42.9

No n/a

Example 2: 650V DC

Product Family and Frame Size

Drive A

PowerFlex 700S

Frame 13

Cat. No.

DC Current (from Appendix A)

J1K0…

1162 A

DC Bus Capacitance (from Appendix A) 19,800 μF

μF/A Ratio (use Equation 1) 17.0

Additional Capacitance Required

Additional Capacitance μF Value

(use Equation 2)

Yes

26,680 μF

Drive B

PowerFlex 700S

Frame 6

J248…

272 A

8400 μF

30.8

Yes

2480 μF

Drive C

PowerFlex 700S

Frame 5

J140…

137A

6000 μF

43.7

No n/a

Drive D

PowerFlex 700S

Frame 5

J140…

137 A

6000 μF

43.7

No n/a

Supplier Reference: Contact factory for part number 30339-304-x, or contact a capacitor bank manufacturer for recommendations.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

135

Appendix B Power Component Accessories

RC Snubber Circuit

Fuse protection with diagnostic feedback is recommended and may be internal or external to the RC snubber. Follow the manufacturer's recommendation when mounting the RC snubber regarding wire length and thermal constraints due to the wattage rated components.

The specifications for the snubber are:

R = 10 ohm, 100 W, low inductance (less than 50 μH)

C = 20 μF, 2000V

Contact Bonitron for an RC snubber circuit at www.bonitron.com.

DC+

DC-

PE

Chassis

136

Common Mode Core

The common mode core (CMC) is a passive ring or disk shaped filter compromised of ferrite material that is designed to attenuate any high frequency transient or disturbance on the wire or cable passing through it, minimizing the risk of common mode interference to other circuitry.

The common mode core can be installed in one of three locations and are shown in the diagram below.

Figure 56 - Common Mode Core Locations

L2

L3

L1

SCR Bus Supply or AFE

DC+

Location # 1

Converter Output

DC-

PowerFlex

Location # 2

Drive DC Input

DC+ DC-

AC Drive

Location # 3

Drive Motor Output

M

Usage With SCR Bus Supply

The common mode core mounting location (SCR Bus Supply DC output, drive

DC input, or drive motor output) changes for different common bus

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Power Component Accessories Appendix B

Drive Product Family

PowerFlex 750-Series configurations. For systems with SCR bus supplies, the common mode core is placed at either the DC input terminals of each drive or at the motor output of

each drive. See Figure 56 for the mounting locations.

SCR Bus Supply DC

Output Location # 1

Drive DC Input Location # 2

(1)

Drive Motor Output

Location # 3

(2)

N/A

A common mode core is included for use on the AC line input when ordering a Catalog No. 21G drive with a ‘P’ or

‘W’ enclosure. A Common Mode Core is also included with any of the following IP00 Input Termination kits:

• 20-750-BUS5-F8

• 20-750-BUS5-F9

• 20-750-BUS5-F10

Fr. 1…3: 1321-M048

Fr. 4…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: 20-750-EMCCM1-F8

PowerFlex 700H/PowerFlex 700S

Frames 9…14

N/A

PowerFlex 700/PowerFlex 700S

Frames 0…6

Other drives

N/A

Contact Factory

30339-319-01

N/A

Contact Factory

N/A

N/A

Contact Factory

(1) One common mode core at each drive DC input

(2) One common mode core at each drive motor output.

Usage With AFE

The common mode core mounting location (AFE DC output, drive DC input, or drive motor output) changes for different common bus configurations. For systems with AFE bus supplies, the common mode core is placed at the DC output terminals of each AFE and drive DC input terminals or at the motor

output of each drive. See Figure 56

for the mounting locations.

Drive Product Family AFE DC Output

Location # 1

(3)

PowerFlex 750-Series

PowerFlex 700H/PowerFlex 700S

Frames 9…14

(1) (2)

PowerFlex 700/PowerFlex 700S

Frames 0…6

AFE Fr. 10: 30201-031-01

AFE Fr. 13: 30339-319-01

AFE Fr. 10: 30201-031-01

AFE Fr. 13: 30339-319-01

AFE Fr. 10: 30201-031-01

AFE Fr. 13: 30339-319-01

Contact Factory

Drive DC Input Location # 2

30339-319-01

(4)

Drive Motor Output

Location # 3

(5)

A common mode core is included for use on the AC line input when ordering a Catalog No. 21G drive with a ‘P’ or

‘W’ enclosure. A Common Mode Core is also included with any of the following IP00 Input Termination kits:

• 20-750-BUS5-F8

• 20-750-BUS5-F9

• 20-750-BUS5-F10

Fr. 1…3: 1321-M048

Fr. 4…6: 1321-M180

Fr. 7: 30201-031-01

Fr. 8…10: 20-750-EMCCM1-F8

(6)

Fr. 9…13: 30201-031-01 or 1321-M670

N/A N/A

Other drives Contact Factory Contact Factory

(1) For a single PowerFlex 700H/700S Frame 9…14 drive, the AFE DC output common mode core is not required if a common mode core is installed at the DC input of the PowerFlex 700H/700S Frame 9…14 drive—however, the drive motor output common mode core is always required.

(2) For multiple PowerFlex 700H/700S Frame 9…14 drives, the AFE DC output common mode core is required and either the common mode core on the drive DC input or the drive motor output of the PowerFlex 700H/700S Frame 9…14 drive is always required.

(3) One common mode core at each AFE DC output.

(4) One common mode core at each drive DC input.

(5) One common mode core at each drive motor output unless an output reactor dv/dt filter is used.

(6) For a single PowerFlex 750-Series Frame 8 drive, the AFE DC output common mode core is not required if a common mode core is installed at the DC input of the PowerFlex 750-Series Frame 8 drive.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

137

Appendix B Power Component Accessories

A variety of core shapes are available to allow various arrangements of wire diameters and turns ratios.

External Drive Options

The following external common mode core options are available.

4

5

6

2

3

Option

1

Part No.

1321-M048

1321-M180

1321-M670

30201-031-01

30339-319-01

30339-320-01

Additional Resources

See publication 1321-IN001 or publication 1321-TD001 for more information

Contact factory for more information. See Figure 57 for design details.

Contact factory for more information. See Figure 58 for design details.

Figure 57 - Drive Common Mode Core Option 4 (30201-031-01) Mounting Dimensions

Dimensions are in inches.

5.76

REF

5.71

REF

4.27

REF

0.33

REF

Ø3.75

REF

6.69 REF

6.00

REF

Figure 58 - Drive Common Mode Core Options 5 and 6 (30339-319-01 and

30339-320-01) Exploded View

138

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Power Component Accessories Appendix B

Internal Drive Options

The following internal common mode core options are available.

Option PowerFlex 750-Series Drive Voltage

5 Frame Size 1 400/480

6 Frame Size 2 400/480

400/480

7 Frame Size 3

600/690

400/480

8 Frame Size 4

600/690

400/480

9 Frame Size 5

600/690

Part No.

20-750-EMC1-F1

20-750-EMC1-F2

20-750-EMC1-F3

20-750-EMC3-F3

20-750-EMC1-F4

20-750-EMC3-F4

20-750-EMC1-F5

20-750-EMC3-F5

Additional Resources

See PowerFlex 750-Series EMC Plate and Core(s) -

Frames 1…7 Installation Instructions, publication 750-IN006 for more details.

13

14

Frame Size 6 in IP20 Enclosure

Frame Size 9

20-750-EMC3-F6

10

11

12

Frame 6 in IP54 Enclosure

Frame Size 7 in IP20 Enclosure

Frame 7 in IP54 Enclosure

Frame Size 8

20-750-EMC5-F6

20-750-EMC3-F7

20-750-EMC5-F7

(1) Internal common mode core is not available for 400/480 volt products.

Frame Size 10

600/690

(1)

600/690

(1)

For Frames 8, 9, and 10 with enclosure code ‘P’ or ‘W’, the common mode core is included. For enclosure code ‘T’, the common mode core is included with termination kit

20-750-BUS5-F*. See publication 750-IN020 for more details.

DC Bus Conditioner—

Designs A, B, C, D, or E

The DC bus conditioner is a device that is electrically connected across the +/- DC bus terminals and PE ground. A 120V AC internal fan provides internal circulating air to assist in thermal dissipation. An internal thermal switch provides overtemperature protection.

DC+

DC-

IMPORTANT Fuse protection with diagnostic feedback is recommended (100A,

1000V) and may be internal or external to the bus conditioner.

PE

120V AC

Follow the manufacturer's recommendation when mounting the DC bus conditioner regarding wire length and thermal constraints due to the high wattage rated components.

DC Bus Conditioner

Thermal Switch

Fan

Chassis

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

139

140

Appendix B Power Component Accessories

A warning label should be affixed to the bus conditioner similar to the one below.

WARNING: This conditioner is directly connected to the system’s common DC Bus. The drive’s disconnect switch will NOT disconnect power to this conditioner. Disconnect the DC source and the 120V AC source for the fan circuitry. Then measure the system DC bus voltage and the fan and thermal interlock system. They must be at zero before servicing this equipment.

A DC bus conditioner example is shown below.

10 x 30 mm GROUND STUD

SNUBBER

TERMINALS

FAN & TS

TERMINALS

Dimensions are in mm [inches].

Lifting Handles (2)

410 [16.14]

GROUND

STUD

498 [19.59]

633 [24.92]

458 [18.03]

508 [20.00]

Design A

DC Bus Conditioner—600/690V, 20 μF, 6800 W

The NEMA 1 enclosure is 633 mm wide x 498 mm high x 508 mm deep and has a connection terminal box included. The 47 kg enclosure is designed to be externally mounted on top of the cabinet lineup.

Supplier Reference: Contact factory for PN-184456 or Byrne & Schaefer for

SN-101204

NOTE:

This product has been replaced with Design E.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Power Component Accessories Appendix B

Design B

DC Bus Conditioner—400/480V, 20 μF, 6800 W

The NEMA 1 enclosure is 633 mm wide x 498 mm high x 508 mm deep and has a connection terminal box included. The 43 kg enclosure is designed to be externally mounted on top of the cabinet lineup.

Supplier Reference: Contact factory for PN-184460 or Bryne & Schaefer for

SN-101203.

NOTE:

This product has been replaced with Design E.

Design C

DC Bus Conditioner—600/690V, 20 μF, 2000 W

The NEMA 1 enclosure is 453 mm wide x 465 mm high x 424 mm deep and has a connection terminal box included. The 30 kg enclosure is designed to be internal to the cabinet or externally mounted on top of the cabinet lineup.

Supplier Reference: Contact factory for PN-184462 or Bryne & Schaefer for

SN-101202.

Design D

DC Bus Conditioner—400/480V, 6 μF, 2000 W

The NEMA 1 enclosure is 453 mm wide x 465 mm high x 424 mm deep and has a connection terminal box included. The 29 kg enclosure is designed to be internal to the cabinet or externally mounted on top of the cabinet lineup.

Supplier Reference: Contact factory for PN-184465 or Bryne & Schaefer for

SN-101201.

Design E

DC Bus Conditioner—480/575/600/690V, 20 μF, 6800 W

The NEMA 1 enclosure is 633 mm wide x 498 mm high x 508 mm deep and has a connection terminal box included. The 47 kg enclosure is designed to be externally mounted on top of the cabinet lineup.

Supplier Reference: Contact factory for PN-225798 or Bryne & Schaefer for

SN-101260.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

141

Appendix B Power Component Accessories

DC Bus Clamp—Design F or G

The DC bus clamp is a device that is electrically connected across the +/- DC bus terminals and

PE ground. A 120V AC internal fan provides internal circulating air to assist in thermal dissipation. An internal thermal switch provides overtemperature protection.

DC+

DC-

DC Bus Conditioner

IMPORTANT Fuse protection with diagnostic feedback is recommended (100A,

1000V) and may be internal or external to the bus clamp.

PE

Follow the manufacturer's recommendation when mounting the bus clamp regarding wire length and thermal constraints due to the high wattage rated components.

120V AC Fan

Chassis

Thermal Switch

A warning label should be affixed to the bus clamp similar to the one below.

WARNING: This conditioner is directly connected to the system’s common DC Bus. The drive’s disconnect switch will NOT disconnect power to this conditioner. Disconnect the DC source and the 120V AC source for the fan circuitry. Then measure the system DC bus voltage and the fan and thermal interlock system. They must be at zero before servicing this equipment.

142

Design F

DC Bus Clamp—400/480/600/690V, 5000 W

The NEMA 1 enclosure is 453 mm wide x 465 mm high x 424 mm deep and has a connection terminal box included. The 27 kg enclosure is designed to be externally mounted on top of the cabinet lineup.

Supplier Reference: Contact factory for PN-179166 or Bryne & Schaefer for

SN-101206.

NOTE:

This product has been replaced with Design G.

Design G

DC Bus Clamp—480/575/600/690V, 5 μF, 3000 W

The NEMA 1 enclosure is 453 mm wide x 465 mm high x 424 mm deep and has a connection terminal box included. The 27 kg enclosure is designed to be externally mounted on top of the cabinet lineup.

Supplier Reference: Contact factory for PN-239300 or Bryne & Schaefer for

SN-101268.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Power Component Accessories Appendix B

Ground Fault Indicator Filter

A ground fault occurs when there is an imbalance of current in a system. The sum of the currents entering the node must equal the sum leaving the node. The largest cause of the error is the leakage current through power devices and other high impedance paths to ground.

3 Phase

AC Input

Transformer

L1

L2

L3

HI

In

HI

Out

LO

In

LO

Out

Ground Fault

Indicator Filter

Ground Fault

Indicator Volt Meter

PE

In high resistance or ungrounded systems, a ground fault sensor is placed across the resistor to sense or detect these currents. When the threshold has been exceeded, the sensor will provide an alarm output that can engage safety circuitry to disable a system.

The current waveform associated with a drive has a harmonic-rich current signature which can cause the ground fault indicator filter to trip. This filter is designed to average this signature, while still providing protection.

Follow the manufacturer's recommendation when mounting the ground fault indicator filter.

The NEMA 1 enclosure is 335 mm wide x 226 mm high x 335 mm deep, and weighs 26 kg.

Supplier Reference: Contact factory for PN-50085 or Bryne & Schaefer for

ER-101011.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

143

Appendix B Power Component Accessories

Zig-Zag Transformer

When an ungrounded system is used for power distribution, a zig-zag transformer can be used to create an artificial neutral for sensing ground faults. A typical ground fault detection arrangement is with a zig-zag transformer sourcing a neutral resistor with a ground fault indicator filter sense circuit.

L2

L3

L1

3 Phase

AC Input

Transformer

Zig-Zag

Transformer

PE

HI

In

HI

Out

LO

In

LO

Out

Ground Fault

Indicator Filter

Ground Fault

Indicator Volt Meter

Contact the factory or a transformer manufacture for recommendations.

144

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Appendix

C

1336 REGEN Drives

Supported Products

D

D

This section is included only to support existing, installed systems with legacy

REGEN drives in this section are no longer available.

n u

At one time, the following products were supported.

t i

Products

1336 REGEN

(1)

PowerFlex 40P: All 400/480V AC power ratings

i s c o

PowerFlex 750-Series: Frames 1…7

(4)

Kinetix 7000: BM06…BM12

(1) The 1336 REGEN is not CE compliant.

Supported Drives

n

PowerFlex 700

(2)

/ PowerFlex 700 Series B

(2)

: 400/480V AC Frames 0…6

(3)

PowerFlex 700S: 400/480V AC Frames 1…6

(3)

e d

700L DC input drives are required when not connected to the AC source.

(4) PowerFlex 750-Series Frame 5…7 DC input version drives with precharge must be selected.

c o n t i n i s

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

145

146

Appendix C 1336 REGEN Drives

Figure 59 - 1336 REGEN DC Bus Supply with AC Drives and Kinetix 6000 Drive System Typical System

Configurations

3-Phase

Source

3%

Reactor

Power

Line Filter

1336R

Precharge

10%

Reactor

See Special Bus Requirements in table below, General Considerations

L1

L2

L3

1336

REGEN

DC+

DC-

DC+

t i

AC Drive

on page 152

, and

1336 REGEN Considerations on page 147 .

DC-

n

DC+

u

DC-

e d

DC+ DC-

AC Drive

M M M

Kinetix 6000 or

Kinetix 6200/6500 Drives

n c o

Drawing Designation Supported Drives

AC Drive

D i s

M

None PowerFlex 700/700S: Frames 0…4

PowerFlex 700/700S: Frames 5 and 6

n

configuration.

M

Special Bus Requirements

u e d

between the DC bus and the drive’s DC input is used.

PowerFlex 750-Series: Frames 1…4

n t i

• DC input ‘common bus’ drives are required—not AC stand-alone

None

PowerFlex 750-Series: Frames 5…7 DC input version with precharge must be selected.

Kinetix 7000: BM06…BM08 None

External precharge must be provided if a disconnect between the Kinetix 7000: BM09…BM12

c o i s

Kinetix 6000 and Kinetix 6200/6500:

DC bus and the drive’s DC input is used.

Important: Do not use PowerFlex 40P or PowerFlex 520-Series drives on the same DC bus supply with PowerFlex 700/700H/700S/

750-Series drives or Kinetix 7000 drives. This is due to the difference in capacitance/amps of the PowerFlex 40P or PowerFlex 520-Series drives compared to the PowerFlex 700/700H/700S/750-Series drives and Kinetix 7000 drives.

Drives must be placed in a common bus follower configuration.

All 460V configurations

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

1336 REGEN Drives Appendix C

1336 REGEN Considerations

Sizing

D

D

1.

The 1336 REGEN Parameter 1- [Operational Mode] must be set to ‘DC

Bus Supply Mode’.

2.

The 3% reactor and power line filter are separately ordered items, but both are required when the supplying transformer impedance is more than 10% of the 10% line reactor impedance. See the table below for Power Line

Filter part numbers. See the 1336 REGEN User Manual for 3% reactor part numbers.

Description

460V, 48A, Open Style

460V, 78A, Open Style

460V, 180A, Open Style

Part Number

1321-VB048FLT-AN

1321-VB078FLT-AN

n u e d

A 3% reactor is also required for use with the 1336 REGEN Power Line

Filter. See the 1336 REGEN User Manual for reactor selection.

n t i

(inductance, capacitance, inductance) type filter.

i s

– Example calculation of 10% Reactor Impedance versus Transformer

c o

180A Regen is used.

Transformer Impedance in mH = (Xpu x VAC

= (0.05 x 480

2

n u

2

e d

) / (2

π x f x kVA x 1000)

) / (2 x 3.14159 x 60 x 200 x 1000) = 0.153 mH

0.153 / 0.430 = 0.36 = 36%, which is higher than 10%, requiring a power line filter.

t i

1321-3LRA048 1.6 mH

1321-3LRA078 1.0 mH

1321-3LRA180

n

0.430 mH

1.

c o

2.

Determine the total power and input current required during acceleration

(1)

.

i s

For Motoring Loads: P

DRIVE

For Regenerating Loads: P

= P

MOTOR

/ Motor Efficiency

DRIVE

= P

MOTOR

x Motor Efficiency

P

ACCEL

= P

DRIVE1

+ P

DRIVE2

+ …

Calculate the input current required on the regenerative unit during acceleration, taking advantage of the 110% for 1 minute overload rating of the regenerative unit:

I

INPUT

= P

ACCEL

x 1000 / (

√ 3 x V

LL

x 1.1), where P

ACCEL

is in kW, and V

LL

= RMS line-to-line AC input voltage.

(1) P

MOTOR

is the motor power required for the application. The P

MOTOR

can be positive if that section of the machine is motoring or negative if that section of the machine is regenerating.

147

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

148

Appendix C 1336 REGEN Drives

3.

Determine the total power and input current required during steady state run operation

(1)

.

For Motoring Loads: P

DRIVE

= P

MOTOR

/ Motor Efficiency

D

D

Step 1

For Regenerating Loads: P

DRIVE

= P

MOTOR

x Motor Efficiency

Calculate the steady state input current required on the regenerative unit:

u e d

where P

RUN

P

RUN

= P

DRIVE1

+ P

DRIVE2

+ …

I

INPUT

= P

RUN

x 1000 / (

√ 3 x V

LL

),

is in kW, and V

LL

n

4.

Determine the total power and input current required during

deceleration

(1)

.

For Motoring Loads: P

DRIVE

n t i

= P

MOTOR

/ Motor Efficiency

For Regenerating Loads: P

DRIVE

= P

MOTOR

* Motor Efficiency

P

DECEL

= P

DRIVE1

+ P

DRIVE2

+ …

i s

Calculate the input current required on the regenerative unit during

c o

the regenerative unit:

I

INPUT

= P

DECEL

x1000 / (

u

√ 3 x V

e d

LL

x 1.1), where P

DECEL

is in kW, and V

LL

= RMS line-to-line AC input voltage.

5.

Compare the absolute values of the input current required for the regenerative unit during acceleration, deceleration, and steady state. Select the worst case input current.

Example Calculation:

n t i n

A machine contains 3 drives that are to be powered with a regenerative bus supply. The following motor powers were determined.

Roll Name

c o

Accel Power (HP) Run Power (HP) Decel Power (HP)

Feed Roll (DRIVE1) -10

Leveler (DRIVE2)

i s

75

20

-15

50

12

Motor efficiencies were estimated at 85%. Line voltage is 480V AC.

-30

-75

-30

All motor powers were converted to kW.

Roll Name Accel Power (kW) Run Power (kW) Decel Power (kW)

Feed Roll (DRIVE1) -7.5

-11.2

-22.4

Leveler (DRIVE2)

Winder (DRIVE3)

55.9

14.9

37.3

8.9

-55.9

-22.4

(1) P

MOTOR

is the motor power required for the application. The P

MOTOR

can be positive if that section of the machine is motoring or negative if that section of the machine is regenerating.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Fusing

1336 REGEN Drives Appendix C

Step 2

Drive power was calculated for each roll during acceleration:

P

DRIVE1

= -7.5 x 0.85 = -6.4 kW

P

DRIVE2

= 55.9 / 0.85 = 65.8 kW

P

DRIVE3

= 14.9 / 0.85 = 17.5 kW

D

D

Total power during acceleration:

P

ACCEL

= (-6.4) + (65.8) + (17.5) = 76.9 kW

Input current during acceleration:

I

INPUT

= 76.9 x 1000 / (

√ 3 x 480 x 1.5) = 61.7 Amps

Step 3

u e d

Input current during steady state run conditions:

Step 4

P

P

P

P

DRIVE1

= -11.2 x 0.85 = -9.5 kW

DRIVE2

= 37.3 / 0.85 = 43.9 kW

DRIVE3

= 8.9 / 0.85 = 10.5 kW

Total power during steady state run conditions:

P

ACCEL

n t i

I

INPUT

= 44.9 x 1000 / (

√ 3 x 480) = 54 Amps

c o

DRIVE1

= -22.4 x 0.85 = -19.0 kW

Drive power was calculated for each roll during deceleration:

P

P

i s

DRIVE3

= -55.9 x 0.85 = -47.5 kW

= -22.4 x 0.85 = -19.0 kW

Total power during deceleration:

n u e d

P

ACCEL

= (-19.0) + (-47.5) + (-19.0) = -85.5 kW

I

INPUT

Step 5

= -85.5 x 1000 / (

√ 3 x 480 x 1.5) = -68.6 Amps

Input current during deceleration:

n t i

Comparing the absolute values of the input current required during acceleration, deceleration, and steady state, the largest value is 68.6 Amps. Select a regenerative unit with a current rating of 68.6 Amps or more.

c o

AC Input 1336 REGEN

i s

1336 REGEN.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

149

150

Appendix C 1336 REGEN Drives

1336 REGEN Drive in

Regenerative Braking

Configuration

System Characteristics

In the regenerative braking configuration the drive has a connection to the AC

D

D

line and draws the majority of the motoring power. This allows the regenerative brake to be sized for the regenerative power only. The regenerative brake puts energy back onto the distribution system instead of dissipating energy with resistor braking technology.

u e d

Supported Products

At one time, these products were supported.

Products

t i n

1336 REGEN

(1)

Supported Drives

n

PowerFlex 700

(2)

/ PowerFlex 700 Series B

(2)

: All 400/480V AC frame sizes

c o

PowerFlex 700S: All 400/480V AC frame sizes

(3)

PowerFlex 700H: All 400/480V AC frame sizes

(3)

Kinetix 7000: BM06…BM12

(3)

PowerFlex 750-Series: Frames 1…7

(4)

i s

(2) These drives require firmware revision 2.001 or later (Standard and Vector Control).

n u e d

(3) PowerFlex 700 Frame 5…10, PowerFlex 700S Frame 5 and 6 and Frame 9…14, and PowerFlex 700H Frame 9…14 DC input drives

(4) A DC input terminal kit must be ordered for PowerFlex 750-Series Frame 6 and 7 drives.

are required when not connected to the AC source.

n t i c o i s

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

1336 REGEN Drives Appendix C

Typical System Configurations

Figure 60 - 1336 REGEN Brake with an AC Drive

AC Drive

Dwg. Designation

D

D

See Special Bus Requirements in table below, General Considerations on page 152 , and 1336 REGEN Considerations on page 152 .

3-Phase

Source

1336R

Precharge

3%

Reactor

L1

L2

n

L3

1336

REGEN

u

DC-

DC+

e d

input contactor.

n t i

REGEN to precharge the DC bus before closing the input contactor for

➊

➊ An input contactor for the drive may be necessary to allow the 1336

c o e d

DC+

L1

L2

L3

BR1 BR2

AC Drive

DC-

i s

the drive. See the table below to determine which drives require an

u

Supported Drives

PowerFlex 700/700S: Frames 0…2

Special Bus Requirements

n

M

See item 2 in 1336 REGEN Considerations on page 152

.

PowerFlex 700/700S: Frames 3 and 4

t i

See item 3 in 1336 REGEN Considerations on page 152

.

None PowerFlex 700/700S: Frames 5 and 6

PowerFlex 700: Frames 7…10

PowerFlex 700/700S: Frames 9…14

n

PowerFlex 750-Series: Frames 1…4

PowerFlex 750-Series: Frames 5…7

PowerFlex 40P: All power ratings

i s c o

See item 2 in 1336 REGEN Considerations on page 152

.

A DC input terminal kit must be ordered for Frames 6 and 7.

• See item 2 in

1336 REGEN Considerations on page 152 .

• Important: Do not use PowerFlex 40P or PowerFlex 520-Series drives on the same DC bus supply with PowerFlex 700/700H/700S/

750-Series drives or Kinetix 7000 drives. This is due to the difference in capacitance/amps of the PowerFlex 40P or PowerFlex 520-Series drives compared to the PowerFlex 700/700H/700S/750-Series drives and Kinetix 7000 drives.

Kinetix 7000: BM06…BM12

See item 2 in 1336 REGEN Considerations on page 152

.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

151

152

Appendix C 1336 REGEN Drives

General Considerations

D

D

1.

Disconnect the common mode capacitors from the drives when using a

2.

regenerative module. See the drive's documentation for instructions on disconnecting the common mode capacitors.

All system components (Bus Supply, PowerFlex Drives, and Braking Unit) must be selected for the same AC-line voltage.

u e d

3.

A low inductance type DC bus must be used. See DC Bus Connections on page 15 for details.

n

1336 REGEN Considerations

t i

1.

n

2.

When using a PowerFlex 40P, PowerFlex 700/700S Frame 0…2, PowerFlex

i s c o e d

precharge the DC bus before closing the AC input contactor on the drive.

u

REGEN in the Regenerative Brake Configuration, one of the following

3.

When using a PowerFlex 700/700S Frame 3 or 4 drive with a 1336 methods must be used: must be allowed to precharge the DC bus before closing the AC input contactor on the drive.

n n

– Provide an AC input contactor for the drive. The 1336 REGEN unit

t i

– An alternative to using an AC contactor on the PowerFlex 700/700S

Frame 3 or 4 drive is to connect to the BR1 terminal instead of the

DC+ terminal. This method can be used only with Frame 3 or 4 on a

c o i s

1.

Convert all motor powers to kW (kW = HP x 0.746).

2.

Determine the total power required during deceleration:

(1)

P

DECEL

= P

MOTOR

* Motor Efficiency

Calculate the input current required on the regenerative unit during deceleration, taking advantage of the 150% for 1 minute overload rating of the regenerative unit:

I

INPUT

= P

DECEL

x 1000 / (

√ 3 x V

LL

x 1.5), where P

DECEL

is in kW, and V

LL

= RMS line-to-line AC input voltage.

(1) P

MOTOR

is the motor power required for the application. The P

MOTOR

could be positive if that section of the machine is motoring or negative if that section of the machine is regenerating.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

1336 REGEN Drives Appendix C

3.

Determine the total power required during steady state run operation, if the steady state power is regenerative:

(1)

P

RUN

= P

MOTOR

* Motor Efficiency

Calculate the steady state input current required on the regenerative unit:

D

D

I

INPUT

= P

RUN

x 1000 / (

√ 3 x V

LL

), where P

RUN

is in kW, and V

LL

= RMS line-to-line AC input voltage.

n u e d

4.

Compare the input current required for the regenerative unit during deceleration, and steady state.

Select the regenerative unit with the input current rating that meets or

Fusing

exceeds the worst case regenerative input current.

n t i

AC Input Drives

c o

AC Input 1336 REGEN

i s

1336 REGEN unit.

DC Output 1336 REGEN

n u e d

See the 1336 REGEN User Manual for recommended AC input fusing of the unit.

The DC fusing is sized per the 1336 REGEN rating in this configuration because the regenerative unit is sized to handle only regenerative current. See the 1336

REGEN User Manual for recommended DC output fusing of the 1336 REGEN

i s c o n t i

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

153

154

Appendix C 1336 REGEN Drives

1336 REGEN Drive in Shared

Regenerative Braking

Configuration

System Characteristics

The shared regenerative braking configuration is used when regeneration is

D

D

needed for stopping or slowing down multiple drives. The regenerative brake puts energy back onto the distribution system instead of dissipating energy with resistor braking technology. Steering diodes only let regenerative current flow to the regenerative module so that one drive cannot source power to the other drives.

n u e d

Supported Products

At one time, these products were supported.

Products

1336 REGEN

(1)

n t i

PowerFlex 40P: All 400/480V AC power ratings

i s c o

PowerFlex 700

(2)

/ PowerFlex 700 Series B

(2)

: All 400/480V AC frame sizes

(3)

PowerFlex 700S: All 400/480V AC frame sizes

PowerFlex 700H: All 400/480V AC frame sizes

PowerFlex 750-Series: Frames 1…7

(4)

Kinetix 7000: BM06…BM12

Kinetix 7000: All 460V configurations

(1) The 1336 REGEN is not CE compliant.

t i n u

(2) These drives require firmware revision 2.001 or later (Standard and Vector Control).

(3) PowerFlex 700 Frame 5…7 DC input drives are required when not connected to the AC source.

(4) A DC input terminal kit must be ordered for PowerFlex 750-Series Frame 6 and 7 drives.

n c o i s e d

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

3-Phase

Source

Typical System Configurations

Figure 61 - Shared 1336 REGEN Brake with AC Drives

1336 REGEN Drives Appendix C

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

155

156

Appendix C 1336 REGEN Drives

General Considerations

D

D

1.

Disconnect the common mode capacitors from the drives when using a

2.

3.

regenerative module. See the drive's documentation for instructions on disconnecting the common mode capacitors.

All system components (Bus Supply, PowerFlex Drives, and Braking Unit) must be selected for the same AC-line voltage.

A low inductance type DC bus must be used. The system must be

n u

contained in one contiguous line-up. The bus cannot be interrupted to go to another cabinet for the remainder of the system drives.

1336 REGEN Considerations

n t i

1.

The 1336 REGEN Parameter 1- [Operational Mode] must be set to

2.

When using any of the following drives/drive systems with a 1336

i s

‘Regen Brake Mode’ (default).

c o

contactor must be provided for these drives.

PowerFlex 40P: All 400/480V AC power ratings

PowerFlex 700/700S: All 400/480V AC frame sizes

PowerFlex 750-Series: Frames 1…7

n u e d

Kinetix 7000: BM06…BM12

Kinetix 7000: All 460V configurations

n t i

closing the AC input contactor on the drives.

3.

Steering diodes must be used in a shared regeneration configuration to

c o i s

(www.bonitron.com) sells diode sharing modules for connecting multiple drives to one regenerative brake (see

Table 32 on page 133

).

PowerFlex 40P Drive Considerations

PowerFlex 40P drives must not be used on the same DC bus supply as PowerFlex

700/700S/700H/750-Series drives. This is due to the difference in capacitance/ amp of the PowerFlex 40P drives compared to the PowerFlex 700/700S/700H/

750-Series drives.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

1336 REGEN Drives Appendix C

Sizing

1.

Convert all motor powers to kW (kW = HP x 0.746).

2.

Determine the total power required during deceleration:

(1)

D

D

where P

DECEL

P

DECEL

= P

MOTOR

* Motor Efficiency

Calculate the input current required on the regenerative unit during deceleration, taking advantage of the 150% for 1 minute overload rating of the regenerative unit:

I

INPUT

= P

DECEL

is in kW, and V

LL

t i n u e d

x 1000 / (

√ 3 x V

LL

x 1.5),

= RMS line-to-line AC input voltage.

3.

Determine the total power required during steady state run operation, if

(1)

the steady state power is regenerative:

n

P

RUN

= P

MOTOR

* Motor Efficiency

Calculate the steady state input current required on the regenerative unit:

I

INPUT

= P

RUN

x 1000 / (

√ 3 x V

LL

), where P

c o

is in kW, and V

LL

= RMS line-to-line AC input voltage.

4.

Compare the input current required for the regenerative unit during

i s

deceleration, and steady state.

u e d

Select the regenerative unit with the input current rating that meets or exceeds the worst case regenerative input current.

Fusing

AC Input Drives

t i

See the drive's documentation for AC input fusing of the drives.

c o n n

DC Input Drives

See

i s

Appendix A

for the recommended Common DC Bus drive fusing.

AC Input 1336 REGEN

See the 1336 REGEN User Manual for recommended AC input fusing of the

1336 REGEN unit.

(1) P

MOTOR

is the motor power required for the application. The P

MOTOR

could be positive if that section of the machine is motoring or negative if that section of the machine is regenerating.

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

157

158

Appendix C 1336 REGEN Drives

Notes:

D i s c o n t i n u e d t i n u e d

D i s c o n

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

Appendix

D

1336 and AK DBU Brake Devices

D

D

This section is included only to support existing, installed systems with legacy

At one time, these braking module products were available:

t i

• 1336-MOD-KA / -KB / -KC Heavy Duty Dynamic Brake Unit

• AK DBU Dynamic Braking Unit

u

• 1336-WA / -WB / -WC Brake Chopper Module

n e d

products in this section are no longer available. Please contact our encompass partners for braking products.

n

For more information on these products, sizing, and fusing requirements, see

i s c o

In certain configurations, an RC snubber circuit is required when using a 1336-

n u e d

1336-W* Brake Chopper power-up delay time is 80 milliseconds. During this time, the IGBT does not turn on. The RC snubber circuit must always be connected to the DC bus (located close to the braking chopper) to absorb the

t i

RC

Snubber Circuit on page 136 .

n c o i s

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

159

160

Chapter D 1336 and AK DBU Brake Devices

Notes:

D i s c o n t i n u e d t i n u e d

D i s c o n

Rockwell Automation Publication DRIVES-AT002F-EN-P - April 2014

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