Allen-Bradley PowerFlex Diode Bus Supply User Manual
The Allen-Bradley PowerFlex Diode Bus Supply is a single-direction power converter designed for common DC bus drive systems. It transforms incoming 3-phase AC line voltage into a shared DC bus voltage, providing power for multiple drives in a system. This device includes an RFI filter for compliance with industrial EMC standards and offers advanced features like overtemperature protection and DC bus snubber circuitry to ensure reliable performance and system stability.
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PowerFlex Diode Bus Supply Catalog Number 20T User Manual Original Instructions PowerFlex Diode Bus Supply User Manual 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. These 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). The following icon may appear in the text of this document. Identifies information that is useful and can help to make a process easier to do or easier to understand. Rockwell Automation Publication 20T-UM001E-EN-P - October 2023 Table of Contents Preface Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1 Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1 Reference Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1 General Drive Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1 Specific Drive Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2 Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2 Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3 Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4 Description and Schematic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5 Chapter 1 Installation/Wiring Opening the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Ambient Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Unbalanced or Non-Solid Grounded Distribution Systems. . . . . . . . . . . . . . . . . . . . . 1-3 General Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Safety Ground Terminal - PE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 RFI Filter Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Maximum Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 AC Input Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Cable Types Acceptable for 200…600 Volt Installations . . . . . . . . . . . . . . . . . . . . . . 1-6 EMC Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Cable Trays and Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 DC Bus Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Bus Supply Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Drive Run Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Control Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Disconnecting MOVs and RFI Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Paralleling Diode Bus Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Low Voltage Directive (73/23/EEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 EMC Directive (89/336/EEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Harmonic Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Essential Requirements for CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Chapter 2 Start Up/Troubleshooting Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Before Applying Power to the Diode Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Applying AC Power to the Diode Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Power On LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 ii Table of Contents Appendix A Supplemental Information Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 AC Input Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Fuse Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Line Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Appendix B History of Changes 20T-UM001D-EN-P, August 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 20T-UM001C-EN-P, September 2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1 PowerFlex Diode Bus Supply User Manual Publication 20T-UM001D-EN-P Preface The purpose of this manual is to provide you with the basic information needed to install, start up, and troubleshoot the PowerFlex™ Diode Bus Supply. Topic Who Should Use this Manual? Reference Documentation Rockwell Automation Support Conventions Used in This Manual General Precautions Catalog Number Explanation Description and Schematic Diagram Summary of Changes Page P-1 P-2 P-2 P-2 P-3 P-4 P-5 The information below summarizes the changes made to this manual since its last release: Description of Changes Removed 1321 watt loss and inductance information; added reference to 1321-TD001 Who Should Use this Manual? Page page A-5 This manual is intended for personnel that are qualified to install, program, and operate adjustable frequency AC drives and their use in common DC bus systems. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 P-2 Reference Documentation General Drive Information Title Publication Wiring and Grounding Guidelines for PWM AC Drives DRIVES-IN001 AC Drives in Common Bus Configurations DRIVES-AT002 Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001 Safety Guidelines for the Application, Installation and Maintenance of Solid State Control SGI-1.1 A Global Reference Guide for Reading Schematic Diagrams 0100-2.10 Guarding Against Electrostatic Damage 8000-4.5.2 1321 Power Conditioning Products Technical Data 1321-TD001 Specific Drive Information For detailed drive information, including specifications, refer to the following PowerFlex 70, PowerFlex 700, PowerFlex 700H, PowerFlex 700S, and PowerFlex 750-Series drive publications. For PowerFlex 70/70EC Drive PowerFlex 700/700VC Series A Drive PowerFlex 700VC Series B Drive PowerFlex 700H Drive PowerFlex 700S Drive PowerFlex 750-Series AC Drive See PowerFlex 70 User Manual PowerFlex 70/700 Reference Manual PowerFlex 70EC/700VC Reference Manual PowerFlex 700 Series A User Manual PowerFlex 700 Series B User Manual PowerFlex 70/700 Reference Manual PowerFlex 70EC/700VC Reference Manual PowerFlex 700H Installation Instructions PowerFlex 700H Programming Manual PowerFlex 700S with Phase I Control Installation Manual (Frames 1…6) PowerFlex 700S with Phase I Control Installation Manual (Frames 9 and 10) PowerFlex 700S with Phase I Control User Manual (All Frame Sizes) PowerFlex 700S with Phase I Control Reference Manual PowerFlex 700S with Phase II Control Installation Manual (Frames 1…6) PowerFlex 700S with Phase II Control Installation Manual (Frames 9…14) PowerFlex 700S with Phase II Control Programming Manual (All Frame Sizes) PowerFlex 700S with Phase II Control Reference Manual PowerFlex 750-Series Drive Installation Instructions PowerFlex 750-Series Drive Programming Manual PowerFlex 750-Series Reference Manual Publication 20A-UM001 PFLEX-RM001 PFLEX-RM004 20B-UM001 20B-UM002 PFLEX-RM001 PFLEX-RM004 PFLEX-IN006 20C-PM001 20D-IN024 PFLEX-IN006 20D-UM001 PFLEX-RM002 20D-IN024 PFLEX-IN006 20D-PM006 PFLEX-RM003 750-IN001 750-PM001 750-RM002 Documentation can be obtained online at rok.auto/literature. To order paper copies of technical documentation, contact your local Rockwell Automation distributor or sales representative. To find your local Rockwell Automation distributor or sales representative, visit www.rockwellautomation.com/locations. For information such as firmware updates or answers to drive-related questions, go to the Drives Service & Support web site at www.ab.com/ support/abdrives and click on the “Downloads” or “Knowledgebase” link. Conventions Used in This Manual PowerFlex Diode Bus Supply User Manual Publication 20T-UM001D-EN-P In this manual we may refer to the PowerFlex Diode Bus Supply as Diode Bus Supply or Bus Supply. P-3 The following words may be used throughout the manual to describe an action: Word Can Cannot May Must Shall Should Should Not General Precautions ! ! ! ! ! ! Meaning Possible, able to do something Not possible, not able to do something Permitted, allowed Unavoidable, you must do this Required and necessary Recommended Not Recommended ATTENTION: The Diode Bus Supply contains electrostatic discharge (ESD) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, see Guarding Against Electrostatic Damage, publication 8000-4.5.2, or any other applicable ESD protection handbook. ATTENTION: An incorrectly applied or installed Diode Bus Supply can result in component damage or a reduction in product life. Wiring or application errors, such as incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system. ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: Only connect Rockwell Automation common DC bus drives with built-in precharge circuitry to the common DC bus output terminals of the Diode Bus Supply within the load rating guidelines. See Specific Drive Information earlier in this Preface for available drives. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the DC bus terminals (which are connected to the DC bus capacitors of the Inverter) has discharged before performing any work on the Diode Bus Supply. Measure the DC bus voltage at the +DC and -DC output terminals. The voltage must be zero. ATTENTION: National Codes and standards (NEC, VDE, BSI, and so forth) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. Failure to do so may result in personal injury and/or equipment damage. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 P-4 Catalog Number Explanation 1-3 4 Position Number 5-7 8 9 20T D 120 A E a b c d e a Product Code 20T Type PowerFlex Diode Bus Supply b Voltage Rating Code D E Input Voltage 240/480V AC 500/600V AC Phase 3 3 DC Output 325…650V DC 675…810V DC c Current Rating Code 120 (1) Frame (1) Output 120.0 Amp 2 PowerFlex 700 drive equivalent frame size. d Enclosure Code A Rating NEMA Type 1 / IP20 e Documentation & Shipping Carton Code User Manual E English PowerFlex Diode Bus Supply User Manual Publication 20T-UM001D-EN-P Carton Yes P-5 Description and Schematic Diagram The Diode Bus Supply is a single-direction power converter for the front end of common DC bus drive systems. It converts the incoming 3-phase AC line voltage to a common DC bus voltage. Figure P.1 Diode Bus Supply Schematic Diagram >°C F1 10 2 >°C 11 F2 R/L1 To Incoming 3ø Power To Earth Ground +DC L1 3 S/L2 To Common DC Bus 1 T/L3 PE -DC L2 GND 8 12 TB1 TB1 M1 MOV M2 8 7 9 TB1 7 4 1 J3 2 1 J1 6 5 J6 1 1 J2 4 24V DC J4 4 DFPS Board 5 The primary electrical components for the Diode Bus Supply are listed below. Item Description ➊ Six-Pulse, Full-Wave, 3-Phase DIode Bridge Rectifier Unit directly connected to the three line input terminals. ➋ Bus Supply Overtemperature Sensors, located in the heat sink, are used for thermal protection of the diode-bridge rectifier. ➌ DC Chokes (L1, L2) to reduce conducted HF-emissions. They also reduce line harmonics and peak currents in the AC line and the bridge circuit. ➍ Input Filter Capacitors connected to the three input phases to reduce conducted HF-emissions. ➎ ➏ ➐ ➑ Common Mode Capacitors connected to the DC bus to reduce conducted HF-emissions. DC Bus Snubber Circuit for dampening and limiting overvoltages. MOV Circuit connected to the three input phases. Cooling Fans connected to the 24V DC supply on the Power Supply (DFPS Board). NOTE: Components ➌, ➍, and ➎ compose a Radio Frequency Interference Filter (RFI), which meets the EMC requirements of Product Standard 61800-3 for industrial environments. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 P-6 Notes: PowerFlex Diode Bus Supply User Manual Publication 20T-UM001D-EN-P Chapter 1 Installation/Wiring This chapter provides information on the installation and wiring of the PowerFlex Diode Bus Supply. Topic Opening the Cover Minimum Mounting Clearances AC Supply Source Considerations General Grounding Requirements Maximum Loading AC Input Fusing Power Wiring Control Wiring Disconnecting MOVs and RFI Filter Capacitors Paralleling Diode Bus Supplies CE Conformity Page 1-1 1-2 1-3 1-4 1-5 1-5 1-6 1-8 1-10 1-11 1-12 Most start-up difficulties are the result of incorrect wiring. Every precaution must be taken to assure that the wiring is done as instructed. All items must be read and understood before the actual installation begins. ! Opening the Cover ATTENTION: The following information is merely a guide for proper installation. Rockwell Automation, Inc. cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this product or associated equipment. A hazard of personal injury and/ or equipment damage exists if codes are ignored during installation. 2 2 ➋ Pull the cover straight off the two spring clips at the top edge. ➊ Loosen the two cover fastening screws at the bottom edge. 1 1 PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 1-2 Installation/Wiring Minimum Mounting Clearances No Adhesive Label on Top With Adhesive Label on Top 100 (4) 50 (2) 100 (4) 100 (4) 50 (2) 100 (4) Dimensions are in millimeters and (inches). See Appendix A for detailed dimension information. Ambient Operating Temperatures The Diode Bus Supply is designed to operate at 0…40 °C (32…104 °F) ambient without derating. Remove the label from the top to operate the Diode Bus Supply in ambients 41 °C up to 50 °C (104 °F up to 122 °F). Important: Removing the adhesive label changes the enclosure rating from NEMA Type 1 Enclosed to Open Type. This also changes the side-to-side mounting clearance requirement. Ensure that proper cooling is provided to the Diode Bus Supply to stay under the 40 °C rated specification. Add exhaust fans to the front or top of the enclosure bay and provide a filtered opening at the bottom of the cabinet bay. The Diode Bus Supply watt loss (from specification section) is 500 W at 120 A. The three-phase AC line reactor watt losses are listed in the 1321 Power Conditioning Products Technical Data, publication 1321-TD001. It is recommended that the system integrator completes a thermal evaluation to ensure adequate cooling to maintain proper operating conditions for each cabinet or bay. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 Installation/Wiring AC Supply Source Considerations 1-3 The Diode Bus Supply is suitable for use on a circuit capable of delivering a short circuit rating up to a maximum of 200,000 rms symmetrical amperes, and a maximum of 600 volts. ! ATTENTION: To guard against personal injury and/or equipment damage caused by improper fusing or circuit breaker selection, use only the recommended line fuses/circuit breakers specified in Appendix A. If a Residual Current Detector (RCD) is used as a system ground fault monitor, only Type B (adjustable) devices should be used to avoid nuisance tripping. Input Power Conditioning Certain events on the power system supplying a bus supply can cause component damage or shortened product life. These conditions include: The power system has power factor correction capacitors switched in and out of the system, either by the user or by the power company. The power source has intermittent voltage spikes in excess of 6000 volts. These spikes could be caused by other equipment on the line or by events such as lightening strikes. The power source has frequent interruptions. The nearest supply transformer is larger than 1000 kVA. If any or all of these conditions exist, it is recommended that the user install a minimum amount of impedance between the Diode Bus Supply and the source. This impedance could come from the supply transformer itself, the cable between the transformer and Diode Bus Supply, or an additional transformer or reactor. Unbalanced or Non-Solid Grounded Distribution Systems Where the potential exists for abnormally high phase-to-ground voltages (in excess of 125% of nominal), or the supply system is non-solid grounded, see the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001. ! ATTENTION: The Diode Bus Supply contains protective MOVs, and input filter and common mode capacitors that are referenced to ground. These devices should be disconnected from ground if the Diode Bus Supply is installed on any non-solid grounded power distribution system (IT-network). For jumper locations, see Figure 1.2 on page 1-7. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 1-4 Installation/Wiring General Grounding Requirements Safety Ground Terminal - PE The Safety Ground terminal (PE) must be connected to the building grounding scheme. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. This is the safety ground for the Diode Bus Supply. The integrity of all ground connections should be periodically checked. For installations within a cabinet, a single safety ground point or ground bus bar connected directly to building steel (girder, joist), a floor ground rod, bus bar or building ground grid should be used. All circuits including the AC input ground conductor should be grounded independently and directly to this point/bar. Figure 1.1 Typical Grounding R (L1) S (L2) T (L3) PE +DC - DC Ground Grid, Girder or Ground Rod (Building Ground Potential) RFI Filter Grounding Using an external RFI filter may result in relatively high ground leakage currents. Therefore, the filter must only be used in installations with grounded AC supply systems and be permanently installed and solidly grounded (bonded) to the building power distribution ground. Ensure that the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked. See the instructions supplied with the filter. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 Installation/Wiring Maximum Loading 1-5 To avoid overloading the Diode Bus Supply, the following requirement applies: The DC Input current sum (Normal Duty or Heavy Duty rating at 40 °C/ 104 °F) of the connected drive(s) must not exceed the Bus Supply continuous DC Bus output current rating of 120 amps at 40 °C/104 °F. For the DC Input Current values of the drives, see tables in the respective drive documentation. Table 1.A and Table 1.B provide guidance on the nominal operation of the Diode Bus Supply. No overload capability is built into the tables. When an overload is being utilized in connected drives or products, that overload current must be accounted for in the calculation to properly size the Diode Bus Supply. TIP: When paralleling two Diode Bus Supplies, see Paralleling Diode Bus Supplies on page 1-11 for details. Table 1.A Normal Duty ND Drive Rating Drive DC Input Current Diode Bus Supply (1) DC Voltage ND Power ND DC Input Currents ND DC Input Current Sum Maximum DC Output Amps AC Input Voltage 540V 30 + 22 = 52 kW 61.9 + 47.5 109.4 A 120 A 400V 650V 2 x 40 = 80 Hp 2 x 55.7 111.4 A 120 A 480V (1) No overload capability. Table 1.B Heavy Duty HD Drive Rating Drive DC Input Current Diode Bus Supply (1) DC Voltage HD Power HD DC Input Currents HD DC Input Current Sum Maximum DC Output Amps AC Input Voltage 540V 37 + 2 x 1.5 = 40 kW 95.1 + 2 x 5.3 105.7 A 120 A 400V (1) AC Input Fusing No overload capability. The Diode Bus Supply can be installed with delay type AC input line fuses. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations. ! ATTENTION: The PowerFlex Diode Bus Supply does not provide branch short circuit protection. Specifications for the recommended fusing to provide protection against short circuits are provided in Table A.A on page A-4. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 1-6 Installation/Wiring Power Wiring ! ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, and disconnect devices. Failure to do so may result in personal injury and/or equipment damage. To maintain balanced impedance, and thus balance current in the Diode Bus Supply, it is recommended to keep all wired connections identical in size and length. This includes the AC line connection to three-phase AC line reactors and from the three-phase AC line reactors to the Diode Bus Supply. Cable Types Acceptable for 200…600 Volt Installations A variety of cable types are acceptable for Diode Bus Supply installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 0.3 meters (1 foot) for every 10 meters (33 feet) of length. In all cases, long parallel runs must be avoided. Do not use cable with an insulation thickness less than or equal to 15 mils (0.4 mm/0.015 in.). UL installations in 50 °C (122 °F) ambient must use 600V, 90 °C (194 °F) wire. UL installations in 40 °C (104 °F) ambient should use 600V, 75 °C (168 °F) wire. THHN, THWN or similar wire is acceptable for Diode Bus Supply installation in dry environments provided adequate free air space and/or conduit fill rate limits are provided. Do not use THHN or similarly coated wire in wet areas. EMC Compliance Refer to CE Conformity on page 1-12 for details. Cable Trays and Conduit If cable trays or large conduits are to be used, refer to guidelines in the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001. ! PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled. This will help minimize the possible shock hazard from “cross coupled” motor leads. Installation/Wiring 1-7 DC Bus Wiring Guidelines For DC Bus wiring guidelines, refer to AC Drives in Common Bus Configurations, publication DRIVES-AT002. Bus Supply Terminals Figure 1.2 Terminal and Jumper Locations ➏ J4 J1 J2 ➌ J6 J3 L1 A A A A A ➊ L2 A A A A A A B B ➍ DC + DC - L1 L2 L3 12 GND 8 9 10 11 MOV B B A A F1 F2 B AC AC AC B A B ➋ (PE) DC V2 FAN1 B DC + A V1 ➎ V3 FAN2 Table 1.C Terminal Specifications and Jumper Information Wire Size Range (1) Item Description Maximum Minimum Torque 35 mm2 (2 AWG) 0.75 mm2 (18 AWG) 3.3 N•m (20 lb•in) 2.5 mm2 (14 AWG) 0.25 mm2 (22 AWG) 0.8 N•m (7 lb•in) ➊ AC Line Input L1, L2, L3 ➋ PE (Protective Earth) Terminal ➌ DC Bus Terminals (DC+, DC-) ➍ Control Terminals 8…11 ➎ Control Terminals 12 and GND (MOV neutral disconnect; see page 1-10) ➏ Jumper J4, see Disconnecting MOVs and RFI Filter Capacitors on page 1-10 (1) Maximum/minimum sizes that the terminals will accept - these are not recommendations. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 1-8 Installation/Wiring Figure 1.3 Power and Control Terminals DC + DC - PE R (L1) S (L2) Terminal Description Notes DC + DC Bus (+) DC Bus Connection (+) DC - DC Bus (-) DC Bus Connection (–) PE PE Ground Safety Ground R R (L1) AC Line Input Power S S (L2) AC Line Input Power T T (L3) AC Line Input Power T (L3) 12 GND 8 9 10 11 MOV Power Connections Control Connections 8 24V Fan Supply Internal connection to extend fan supply leads (must be disconnected in case of fan replacement) NC Contact Output (F1, F2) Opens with power stack overtemperature. (See Appendix A for contact ratings.) Jumper MOVs to Ground Disconnect MOV neutral point and ground by removing this jumper. (See page 1-10 for details.) 9 10 11 12 GND Control Wiring Important points to remember about control wiring: Use Copper wire only. Wire gauge requirements and recommendations are based on 75 °C (168 °F). Do not reduce wire gauge when using higher temperature wire. Wire with an insulation rating of 600V or greater is recommended. Control wires outside the cabinet should be separated from power wires by at least 0.3 meters (1 foot). Drive Run Interlock To protect the Diode Bus Supply from overtemperature, the normally closed contacts (Bus Supply Overtemperature - terminals 10 and 11) should be wired to either the AC line input contactor for the Diode Bus Supply or the Run interlock circuit (enable input) of each connected drive. This ensures that the drives are stopped in case of Bus Supply Overtemperature. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 Installation/Wiring 1-9 Control Wiring Examples Figure 1.4 Multiple Drives, Running Simultaneously 115V K1 K1 10 Run K1M PowerFlex Diode Bus Supply >°C F1, F2 11 K1 DC Bus K1M Figure 1.5 K1M AC - Drive 1 30 kW AC - Drive 2 22 kW M 3 M 3 Multiple Drives, Running Independently (2-wire control) 115V K1 K1 Run/ Stop 1 Run/ Stop 2 K1M K2M 10 11 >°C F1, F2 K1 PowerFlex Diode Bus Supply DC Bus K1M K2M AC - Drive 1 30 kW AC - Drive 2 22 kW M 3 M 3 NOTE: See Appendix A for Output Contact ratings. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 1-10 Installation/Wiring Disconnecting MOVs and RFI Filter Capacitors The Diode Bus Supply contains protective MOVs, and input filter and common mode capacitors that are referenced to ground. To prevent damage, the MOVs should be disconnected from ground if the Bus Supply is installed on any non-solid grounded distribution system where the line-to-ground voltages on any phase could exceed 125% of the nominal line-to-line voltage. To disconnect these devices from ground, remove the jumpers shown in Table 1.D. Jumpers can be removed by carefully pulling the jumper straight out. Solid and non-solid grounded systems are defined in Table 1.E. Table 1.D Jumper Removal Item Jumper (1) Jumper Location (see Figure 1.2) Removes Component (see Figure 1.6) ➎ 12 and GND Control Terminals MOV neutral from Ground ➏ J4 On DFPS Board Capacitors from Ground (1) Important: Do not remove jumpers if the distribution system is grounded. Table 1.E Recommended MOV Configurations Power Source Type (1) Solid Grounded MOV/Input Filter Capacitors (2) Connected • AC fed, solidly grounded • DC fed from passive rectifier which has an AC source and solid ground Non-Solid Grounded • • • • • AC fed ungrounded Impedance grounded High resistive ground B phase ground Regenerative unit (common DC bus supply and brake) • DC fed from an active converter Disconnected Benefits of Correct Power Source Type Configuration • UL compliance • Reduced electrical noise • Most stable operation • EMC compliance • Reduced voltage stress on components and motor bearings • Helps avoid severe equipment damage when ground fault occurs (1) It is highly recommended to accurately determine the power source type and then configure appropriately. (2) When MOVs are disconnected, the power system must have its own transient protection to ensure known and controlled voltages. For more information on non-solid grounded system installation, see Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001. ! PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before removing/ installing jumpers. Measure the DC bus voltage at the +DC and – DC output terminals. The voltage must be zero. Installation/Wiring Figure 1.6 1-11 Removing the Phase-to-Ground Jumpers for the MOV, Input FIlter, and Common Mode Capacitors TB1 R / L1 To Diode Bridge Rectifier Unit S / L2 T / L3 PE MOVs Ground Jumper To +DC, -DC GND 12 Input Filter Capacitors Input Filter and Common Mode Capacitors Ground Jumper MOV J3 7 J4 4 1 Power Supply Board DFPS 1 J2 4 Common Mode Capacitors Paralleling Diode Bus Supplies Up to two Diode Bus Supplies can be paralleled for operation. To parallel Diode Bus Supplies, an AC line reactor must be used at the input of each Bus Supply (see Figure 1.7). One-percent reactors (catalog number 1321-3R130-A) can be used, unless 3% reactors (catalog number 1321-3R130-B) are required based on the maximum transformer size listed in Line Reactors on page A-5. When paralleling Diode Bus Supplies, follow these guidelines: A maximum of (2) two Diode Bus Supplies can be paralleled. Each Diode Bus Supply must be derated by 3%. This results in a DC Bus continuous output current rating of 233 Amps (0.97 x 2 x 120). It is recommended to use AC line fuses with an open fuse indicator. See AC Input Fusing on page A-4 for details on recommended fusing. Important: It is recommended to keep all wired connections identical in size and length. This includes the AC line connection to the three-phase AC line reactors and from the three-phase AC line reactors to the Diode Bus Supply. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 1-12 Installation/Wiring Figure 1.7 Parallel Diode Bus Supply Wiring Diagram Power Input Main Switch or Main Input Contactor Line Reactor Diode Bus Supply Line Reactor Diode Bus Supply DC Bus CE Conformity AC - Drive 1 AC - Drive 2 M 3 M 3 Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. The Diode Bus Supply complies with the EN standards listed below when installed according to the User Manual. CE Declarations of Conformity are available online at rok.auto/certifications. Low Voltage Directive (73/23/EEC) EN50178 Electronic equipment for use in power installations EMC Directive (89/336/EEC) EN61800-3 Adjustable speed electrical power drive systems Part 3: EMC product standard including specific test methods. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 Installation/Wiring 1-13 Harmonic Emissions Electronic converters such as the Diode Bus Supply can cause conducted low frequency disturbances (harmonic emissions) to the supply network. The mandatory three-phase AC line reactors will substantially reduce harmonic currents produced by the Bus Supply. However, the magnitude of the harmonic currents and resulting harmonic voltages depends upon the network impedance at the point where the unit is connected to the network. Presently, there are no mandatory harmonic emission limits related to CE compliance for equipment connected to private power networks. Upon request, Rockwell Automation can provide information regarding harmonic emissions from the Diode Bus Supply. General Notes If the adhesive label is removed from the top of the Diode Bus Supply, it must be installed in an enclosure with side openings less than 12.5 mm (0.5 in.) and top openings less than 1.0 mm (0.04 in.) to maintain compliance with the LV Directive. The DC bus cable to the drive(s) should be kept as short as possible to avoid electromagnetic emission and capacitive currents. Therefore the drive(s) should be located in the same cabinet as the Diode Bus Supply or next to the cabinet with the Diode Bus Supply. If the connection leads between DC bus and drive(s) are leaving the cabinet, shielded cables must be used. Use of line filters in non-solid grounded systems is not recommended. The Diode Bus Supply with its inherent high frequency filtering satisfies CE EMC emission limits for the industrial environment. If used in a residential or domestic environment, it may cause radio interference. The user is required to take measures to prevent interference, in addition to the essential requirements for CE compliance listed below, if necessary. Conformity of the drive with CE EMC requirements does not guarantee an entire machine installation complies with CE EMC requirements. Many factors can influence total machine/installation compliance. Essential Requirements for CE Compliance Conditions 1…5 listed below must be satisfied for the Diode Bus Supply to meet the requirements of EN61800-3. 1. The Diode Bus Supply and drive must be PowerFlex type and CE compatible. 2. The externally mounted Line Reactor must be connected to the line input as shown in Figure 1.7 on page 1-12. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 1-14 Installation/Wiring 3. Review important precaution/attention statements throughout this document before installing the drive(s). 4. Ground as described in General Grounding Requirements on page 1-4. 5. Control wiring and DC bus wiring leaving the cabinet must be a braided, shielded cable with a coverage of 75% or better, metal conduit or equivalent attenuation. For additional conditions, see the respective drive Reference Manual and installation guidelines (see Specific Drive Information on page P-2). PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 Chapter 2 Start Up/Troubleshooting This chapter provides the necessary information for the start up and troubleshooting of the Diode Bus Supply. Topic Start-Up Power On LED Troubleshooting ! Page 2-2 2-3 2-3 ATTENTION: Power must be applied to the Diode Bus Supply and the drive to perform the following start-up procedure. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure. Thoroughly read and understand the procedure before beginning. If an event does not occur while performing this procedure, do not proceed. Remove power including user-supplied control voltages. User-supplied voltages may exist even when main AC power is not applied to the Diode Bus Supply. Correct the malfunction before continuing. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 2-2 Start Up/Troubleshooting Start-Up Before Applying Power to the Diode Bus Supply ❏ 1. Confirm that all inputs and outputs are connected to the correct terminals and are properly torqued. ❏ 2. Using an ohmmeter or other continuity testing device, verify that shorts do not exist between Source 1 and Source 2. Source 1 L1 L1 L2 L1 L2 L3 L1 L2 L3 L1 L2 L3 DC+ Bus DC+ Bus DC Bus Source 2 L2 L3 L3 PE PE PE DC+ Bus DC+ Bus DC+ Bus DC- Bus DC- Bus DC- Bus DC- Bus PE PE Checkmark Below if No Short Exists ❏ 3. Verify that AC line power at the disconnect device is within the rated value of the Diode Bus Supply. See Appendix A. ❏ 4. Verify that the Bus Supply Overtemperature is correctly wired. This normally closed contact output can be used to set alarms and to stop the drive(s). Verify that they have been wired correctly according to the user’s specification. See Control Wiring Examples on page 1-9. ❏ 5. Verify that the jumper between control terminals 12 and GND and jumper P4 (on DFPS circuit board) are present on grounded supply lines (default) or removed on non-solid grounded supply lines. See Disconnecting MOVs and RFI Filter Capacitors on page 1-10 for more information. Applying AC Power to the Diode Bus Supply ❏ 1. Apply AC power to the Diode Bus Supply. The green Power On LED should be on if power is applied to terminals L1 (R), L2 (S), and L3 (T). ❏ 2. If the green Power On LED is off at this point, see Table 2.A. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 Start Up/Troubleshooting Power On LED 2-3 The green Power On LED is visible through the front panel and will illuminated if power is applied. ! Figure 2.1 ATTENTION: The Power On LED is only operational when the unit is energized. Servicing energized equipment can be hazardous. Severe injury or death can result from electrical shock, burn, or unintended actuation of the controlled equipment. Follow safety-related practices of NFPA 70E, Electrical Safety For Employee Workplaces. DO NOT work alone on energized equipment! Power On LED Power On LED Troubleshooting Table 2.A Possible Faults and Corrective Actions Fault Cause Corrective Action Heat sink Overtemperature Heat sink temperature 1. Verify that maximum ambient temperature has not been exceeds maximum exceeded. rating 2. Check Overtemperature Switch (N.C. contacts) at control terminals 10 and 11. 3. Check fan for correct operation. 4. Check for excess load on the Diode Bus Supply. 5. Check for minimum mounting clearance around the Diode Bus Supply. 6. Contact your local Rockwell Automation sales office. DC Output Voltage Loss Loss of DC Bus power and loss of 24V power 1. Check 3-phase AC incoming power for undervoltage or phase loss. 2. Check Diode Bus Supply input circuit breaker or fuses. 3. Contact your local Rockwell Automation sales office. Loss of 24V power only 1. Check fans for correct operation. (used for fan power 2. Check Overtemperature switches. only) 3. Contact your local Rockwell Automation sales office. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 2-4 Start Up/Troubleshooting Notes: PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 Appendix A Supplemental Information This appendix provides electrical, environmental, functional, and physical specifications for the Diode Bus Supply, and selection tables for AC input devices. Topic Specifications Dimensions AC Input Fusing Line Reactors Spare Parts Specifications Page A-1 A-3 A-4 A-5 A-5 Category Specification Input/Output Ratings AC Input Voltage Range: 200…480V Unit 500…600V Unit Nominal AC Input Voltage: 240V 400V 480V 500V 600V Nominal DC Bus Voltage: 325V 540V 648V 675V 810V 105A 105A 105A 105A 105A 120A 120A 120A 120A 120A Continuous rms AC Input Current: Continuous DC Bus Current: (1) Voltage Tolerance: –10% minimum, +10% maximum Frequency Tolerance: 47…63 Hz. Displacement Power Factor: 0.92 lagging (entire speed range) Efficiency: 99.5% at rated amps, nominal line volts Line Transients: up to 6000 volts peak per IEEE C62.41-1991 Heat Dissipation: 500 W Max. Short Circuit Current Rating: (using recommended fuse or circuit breaker type) Maximum short circuit current rating to match specified fuse/circuit breaker capability Control Output Heat Sink Temperature Sensor: Contact Output Rating (Max.): The two temperature sensors trip if heat sink temperature exceeds 85°C Resistive Rating: 15A at 125V AC, 10A at 250V AC, 7A at 24V DC Inductive Rating: 10A at 125V AC, 6A at 250V AC PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 A-2 Supplemental Information Category Specification Approvals and NFPA 70 Standards NEMA ICS 3.1 Compliance NEMA 250 IEC 146 - US National Electrical Code - Safety standards for Construction and Guide for Selection, Installation and Operation of Adjustable Speed Drive Systems. - Enclosures for Electrical Equipment - International Electrical Code c UL US ‚ UL and cUL Listed to UL508C and CAN/CSA-C2.2 No. 14-M91 Marked for all applicable European Directives: · EMC Directive (89/336/EEC) · Emissions: EN 61800-3 Adjustable Speed electrical power drive systems Part 3 · Immunity: EN 61800-3 Second Environment, Restricted Distribution · Low Voltage Directive (73/23/EEC) · EN 50178 Electronic Equipment for Use in Power Installations Environment Altitude: 1000 m (3300 ft.) max. without derating. Above 1000 m, the derating for the output current is 1% per 100 m (330 ft.). Ambient Operating Temperature without Derating: (2) Open Type / IP00: NEMA Type 1 / IP20: 0…50 °C (32…122 °F) 0…40 °C (32…104 °F) Storage Temperature (all const.): –40…70 °C (–40…158 °F) Relative Humidity: 5 to 95% non-condensing Shock: 15G peak for 11 ms duration (± 1.0 ms) Vibration: 0.152 mm (0.006 in.) displacement, 1G peak Compatible AC Permitted DC Input (Common Bus) PowerFlex DC Input (Common Bus) drives with Drives Drives that Can Be Connected to Diode built-in precharge circuit (see Specific Drive Information on page P-2) Bus Supply: PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 (1) When paralleling Diode Bus Supplies (two maximum) for operation, the DC bus output current is derated by 3% for each Bus Supply. For more details, see Paralleling Diode Bus Supplies on page 1-11. (2) See page 1-2 for enclosure type conversion information. Supplemental Information Dimensions A-3 The overall and mounting dimensions for the Diode Bus Supply are shown in Figure A.1. Figure A.1 Diode Bus Supply Dimensions (equivalent to PowerFlex 700 Frame 2 Drive) Dimensions are in millimeters and (inches). 222 (8.74) 15 (0.59) 192 (7.56) Ø 5.8 (0.23) 5.5 (0.22) 200 (7.87) 342.5 (13.48) 320 (12.6) 8.0 (0.31) 5.5 (0.22) Front View Side View 151 (6.03) 111 (4.37) Ø 50.5 (2.0) for Gland M50 71 (2.83) Ø 16.5 (0.66) for Gland M16 141 (5.63) 115 (4.59) Bottom View Approximate Shipping Weight: 23 kg (50.7 lb.) PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 A-4 Supplemental Information AC Input Fusing Table A.A below provides output ampere ratings for the Diode Bus Supply (including continuous, 1 minute, and 3 seconds) and recommended AC line input fusing information. The short circuit protection fuses are acceptable for UL and IEC requirements. Sizes listed are recommended sizes based on 40 °C (104 °F) and the U.S. NEC. Other country, state or local codes may require different ratings. Fuse Types Refer to the recommended types listed below. · IEC – BS88 (British Standard) Parts 1 & 2 (1), EN60269-1, Parts 1 & 2, type gG or equivalent should be used. · UL – UL Class RK1 or J must be used. (2) Table A.A AC Input Current Ratings and Recommended Input Fusing Bus Supply Catalog Number Dual Element Time Delay Fuse Input Ratings Output Amps Amps Cont. 1 Min. 3 Sec. 120 180 240 120 180 240 87 120 180 240 91 120 180 240 109 120 180 240 kVA Amps 240 Volt / 60 Hz AC Input 20TD120 105 44 400 Volt / 50 Hz AC Input 20TD120 105 73 480 Volt / 60 Hz AC Input 20TD120 105 500 Volt / 50 Hz AC Input 20TE120 105 125 IEC - gG or 150 UL - Class RK1 or J 600 Volt / 60 Hz AC Input 20TE120 105 (1) Typical designations include, but may not be limited to, the following; Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, and GH. (2) For 600V, (Ferraz Shawmut) (Bussman) PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 Class J: AJT150 (with open fuse indicator), Class RK1: A6D150R Class J: LPJ-150SP, Class RK1: LPS-RK-150SP or equivalent Supplemental Information Line Reactors A-5 A minimum reactance is required to limit peak currents in the AC line and the diode bridge circuit. This can be accomplished either by a matched supply transformer or by adding line reactors to ensure the requested minimum voltage drop over the total line impedance. The preferred method is to install a minimum 3% line reactor, which will also reduce line harmonics. Use Table A.B to select a line reactor based on the sum of the drive’s connected DC Amps and the supply transformer rating. For more details on the 1321-Series line reactors, see 1321 Power Conditioning Products Technical Data, publication 1321-TD001 for specific information on dimensions, watts loss, and inductance. Table A.B Line Reactor Selection Drives Maximum Power Transformer Size (1) Line Reactor Sum of DC Amps 1000 kVA 5.5% 31 µH Catalog No. (2) 1400 kVA 6% 24 µH 400V, 50 Hz Up to 120 Yes — 1321-3R130-B 480V, 60 Hz Up to 120 Yes — 1321-3R130-B 600V, 60 Hz Up to 120 Spare Parts Yes Yes 1321-3R130-B (1) The inductance value of the supply transformers includes 2.5 µH for 10 m feeder cable. (2) The number in the catalog string represents the fundamental AC current rating of the reactor. The Diode Bus Supply is not factory or field repairable, therefore no spare parts exist for this product. PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 A-6 Supplemental Information Notes: PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 Appendix B History of Changes Topic 20T-UM001C-EN-P, September 2006 Page B-1 This appendix summarizes the revisions to this manual, starting with revision C. Reference this appendix if you need information to determine what changes have been made across multiple revisions. This may be especially useful if you are deciding to upgrade your hardware or software based on information added with previous revisions of this manual. 20T-UM001D-EN-P, August 2012 20T-UM001C-EN-P, September 2006 Change Reformatted document from half size (5.5 x 8.5 in.) to full size (8.5 x 11 in.) In Chapter 1: Revised the subsection “Ambient Operating Temperatures” to include more information. At the beginning of the section “Power Wiring,” added a recommendation to keep all wired connections identical in size and length to maintain balanced impedance. In the section “Disconnecting MOVs and RFI Filter Capacitors,” added new Table 1.E, Recommended MOV Configurations. In Chapter 2: In the subsection “Before Applying Power to the Diode Bus Supply,” added new steps 2 and 5. In Table 2.A, Possible Faults and Corrective Actions, added a corrective action and revised others. In Appendix A: In the section “Line Reactors,” added introductory information. Added the new section “Spare Parts.” Added the new Appendix B, History of Changes.” Change In Chapter 1: In the section “AC Supply Source Considerations,” revised information in the “Input Power Conditioning” subsection. In the section “Power Wiring,” added a new “DC Bus Wiring Guidelines” subsection that refers to the AC Drives In Common Bus Guidelines, publication DRIVES-AT002. Added the new section “Parallel Bus Supplies.” In Appendix A, added the new section “Line Reactors.” PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 B-2 History of Changes Notes: PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 Index A AC input line reactors, A-5 voltages, A-1 AC supply grounding, 1-4 non-solid grounded, 1-3 source considerations, 1-3 unbalanced, 1-3 ambient operating temperature, 1-2 B before applying power, 2-2 C cable trays, 1-6 E earthing, see grounding ESD, static discharge, P-3 F filter - RFI, 1-4 fusing, AC input, 1-5 G general precautions, P-3 grounding bus, 1-4 conductor, 1-4 general, 1-4 impedance, 1-4 safety, PE, 1-4 catalog number explanation, P-4 CE conformity, 1-12 checklist, start-up, 2-2 clearances for mounting, 1-2 conduit, 1-6 control wiring, 1-8 cover, opening, 1-1 D DC bus capacitors, discharging, P-3 wiring guidelines, 1-7 dimensions, A-3 Diode Bus Supply ambient operating temperature, 1-2 catalog number explanation, P-4 control wiring, 1-8 DC bus capacitor discharging, P-3 dimensions, A-3 line reactors, A-5 power wiring, 1-6 specifications, A-1 to A-2 L LED, Power On, 2-3 line reactors, A-5 M manual conventions, P-2 web site, P-2 maximum loading, 1-5 minimum mounting clearances, 1-2 MOVs, disconnecting, 1-10 O opening the cover, 1-1 operating temperature, 1-2 P paralleling two Diode Bus Supplies, 1-11 PE ground, 1-4 discharging DC bus capacitors, P-3 power wiring, 1-6 disconnecting MOVs, 1-10 powering up bus supply, 2-2 distribution systems non-solid grounded, 1-3 unbalanced, 1-3 precautions, general, P-3 documentation, related, P-1 PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 Index-2 R related documentation, P-1 removing cover, 1-1 RFI filter grounding, 1-4 S safety ground, 1-4 short circuit protection, 1-5 spare parts, A-5 specifications, A-1 to A-2 start-up checklist, 2-2 static discharge, ESD, P-3 status indicator, Power On, 2-3 supply source for AC, 1-3 system grounding, 1-4 T technical support, P-2 troubleshooting, 2-3 U unbalanced/non-solid grounded supply, 1-3 W web site related documentation, P-2 Rockwell Automation technical support, P-2 wiring control, 1-8 power, 1-6 PowerFlex Diode Bus Supply User Manual Publication 20T-UM001E-EN-P - October 2023 PowerFlex Diode Bus Supply User Manual Rockwell Automation Publication 20T-UM001E-EN-P - October 2023 Rockwell Automation Support Use these resources to access support information. 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Waste Electrical and Electronic Equipment (WEEE) At the end of life, this equipment should be collected separately from any unsorted municipal waste. Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec. Allen-Bradley, expanding human possibility, PowerFlex, and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Rockwell Otomasyon Ticaret A.Ş. Kar Plaza İş Merkezi E Blok Kat:6 34752, İçerenköy, İstanbul, Tel: +90 (216) 5698400 EEE Yönetmeliğine Uygundur Publication 20T-UM001E-EN-P - October 2023 Supersedes Publication 20T-UM001D-EN-P - August 2012 Copyright © 2023 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A. ">

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Key features
- Single-direction power converter
- Common DC bus power supply
- RFI filter
- Overtemperature protection
- DC bus snubber circuitry
Frequently asked questions
The maximum DC output current rating is 120 amps at 40 °C/104 °F.
Delay type AC input line fuses are recommended. Refer to Appendix A for specific fuse specifications.
The Diode Bus Supply is designed to operate at 0…40 °C (32…104 °F) ambient without derating. Removing the label from the top allows operation in ambients 41 °C up to 50 °C (104 °F up to 122 °F).