DC SCR Precharge Module

User Manual

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http:// www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited. Throughout this manual, when necessary we use notes to make you aware of safety considerations. 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.

Important: Identifies information that is critical for successful application and understanding of the product. 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 the hazard recognize the consequences Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present. Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures.
Allen-Bradley, PowerFlex, and 1336 PLUS II are either registered trademarks or trademarks of Rockwell Automation, Inc.

Summary of Changes
This is the first release of this publication.

soc-ii

Summary of Changes

Table of Contents
Preface
Overview
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description and Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1 P-1 P-1 P-2 P-2 P-3 P-4

Chapter 1

Installation/Wiring
Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Ambient Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 General Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Minimum Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Maximum Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Control Wiring and Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Control Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Drive Run Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Typical Power and Control Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Chapter 2

Start-Up / Troubleshooting
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Precharge Control Relay CR LED Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Appendix A

Specifications and Dimensions

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Index

ii

Table of Contents

Preface

Overview

The purpose of this manual is to provide you with the basic information needed to install, start-up, and troubleshoot the DC SCR Precharge Module.
For information on ... Who Should Use this Manual? Installation Requirement Reference Materials Manual Conventions General Precautions Part Number Explanation Description and Block Diagram See page ... P-1 P-1 P-1 P-2 P-2 P-3 P-4

Who Should Use this Manual?

This manual is intended for personnel qualified in the installation, programming, and operation of Adjustable Frequency AC Drives and their use in common DC bus systems.

Installation Requirement

The DC SCR Precharge Module must be installed only within the drives enclosure.

Reference Materials

The following publications are recommended for general drive information:

Title Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives Preventive Maintenance of Industrial Control and Drive System Equipment Reactors and Isolation Transformers Safety Guidelines for the Application, Installation and Maintenance of Solid State Control A Global Reference Guide for Reading Schematic Diagrams Guarding Against Electrostatic Damage Publication DRIVES-IN001 DRIVES-TD001 1321-TD001 SGI-1.1 0100-2.10 8000-4.5.2

Publications can be obtained online at http://www.rockwellautomation.com/literature.

P-2

Overview

Manual Conventions

The following words are used throughout the manual to describe an action:
Word Can Cannot May Must Shall Should Should Not 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

General Precautions

ATTENTION: The DC SCR Precharge Module contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this Module. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to Allen-Bradley publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD protection handbook. ATTENTION: An incorrectly applied or installed DC SCR Precharge Module can result in component damage or a reduction in product life. Wiring or application errors, such as incorrect or inadequate DC 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 Allen-Bradley Common Bus AC drives with this DC SCR Precharge Module. Failure to comply may result in personal injury and/or equipment damage. 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 drive) has discharged before performing any work on the DC SCR Precharge Module. Measure the DC bus voltage between the +DC and -DC terminal of the Output Power Terminals. The voltage must be zero. ATTENTION: A second source of power for the cooling fan and control is present. To avoid an electric shock hazard or moving blades, verify that the AC power supply has been removed before performing any maintenance or repairs.

! !

Overview

P-3

Part Number Explanation

The available ratings for the DC SCR Precharge Module are shown below:
Module Rating (DC Amps) 500A 750A 1000A 1600A DC SCR Precharge Module Part Number with Aluminum Heatsink with Nickel-Plated Heatsink 370696 370724 370711 370729 370715 370733 370707 370737

Important: These DC SCR Precharge Modules are available for 380-480 VAC drive applications only.

P-4

Overview

Description and Block Diagram

The DC SCR Precharge Module has been designed to limit the current draw by the drives capacitor bank during precharge operation. This is accomplished using precharge resistors. When the operational DC bus voltage has been achieved, the continuous current is then conducted through the SCR in the SCR Power Module. In addition, a diode integrated into the SCR Power Module provides regenerative capability.
Figure P.1 DC SCR Precharge Module Block Diagram

F1 R1

R11 A T Jumper Busbar TB2A-9 TB2A-10

Power Module Sub-Assembly

+DCin

Fan

Diode

+DCout

SCR DC Input Power

AK

T G HK K TB1A-2
CATHODE

TB1A-3

DC Output Power -DC

-DC

TB1A-1

+DCout -DC

Jumpers
TB2A-1 TB2A-2 TB2A-3 TB2A-4 TB2A-5 TB2A-6 TB2A-7 TB2A-8 TB2A-11 TB2A-12

1 4 7 10 1 J2 TB1 3

1 J1

1 3 TB2

+DCout

+DCin -DC

+DCin

GATE

1 7 J1 8 9 10 11 12 +15V -15V COMMON +5V /CHARGE AC LINE 8 6 J1 7 5 CR 1

1 4 J3

A2 350840-AXX DC Precharge Control Board

A1 319433-AXX Power Supply Board

GND

CR

GND

CR

Precharge_Complete CR

The primary electrical components for the DC SCR Precharge Module are:
Item Description SCR-Diode Power Module (Sub-Assembly) conducts the continuous DC bus current once the precharge of the drives capacitor bank has been achieved. A diode in parallel with the SCR provides energy regeneration up to the SCR Precharge Module nameplate Amp rating. Protection fuse is for over-current protection during precharge.

Precharge Resistors limit the current during the charging of the drives capacitor bank when power is initially applied to the drive. Power Supply PCB provides a logic power to the Precharge Control board. DC Precharge Control PCB generates the gating signal to the SCR Power Module. Control Relay enables the SCR gating signal. Terminal Block for interfacing the SCR Precharge Module with the drives main control circuit. Cooling Fan connected to a customer-supplied 120 VAC supply. The fan must run when the SCR is gated.

Chapter

Installation/Wiring
This chapter provides information on installing and wiring the DC SCR Precharge Module.
For information on ... Minimum Mounting Clearances Ambient Operating Temperature AC Supply Source Considerations General Grounding Requirements Fuses Minimum Capacitance Maximum Loading Power Wiring Control Wiring and Terminals Control Wiring Requirements Drive Run Interlock Typical Power and Control Wiring Examples See page ... 1-2 1-2 1-3 1-3 1-4 1-4 1-4 1-5 1-8 1-9 1-9 1-10

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 information must be read and understood before the actual installation begins. 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 module or associated equipment. A hazard of personal injury and/ or equipment damage exists if codes are ignored during installation.

1-2

Installation/Wiring

Minimum Mounting Clearances

The air inlet and outlet areas for each DC SCR Precharge Module must be a minimum of 200 square centimeters (31 square inches). The Length-to-Width Ratio must not exceed 4:1.
Figure 1.1 Minimum Mounting Clearance for 500A and 750A DC SCR Precharge Modules
Air Outlet

Air Flow
GND

Fan

AK

DATA NAMEPLATE

120 mm (4.7 in.)

HK

DANGER
CAN CAUSE SHOCK BURNS, OR DEATH SURFACES MAY BE HOT

120 mm (4.7 in.)

DANGER

REMOTE SOURCE

+DCin

+DCout

Air Inlet

Air Flow

Figure 1.2 Minimum Mounting Clearance for 1000A and 1600A DC SCR Precharge Modules
Air Outlet

Air Flow

Fan
GND

120 mm (4.7 in.)

HK

+DCin

120 mm (4.7 in.)

REMOTE SOURCE

G
DANGER
CAN CAUSE SHOCK BURNS, OR DEATH SURFACES MAY BE HOT

DANGER

+DCout

Air Inlet

Air Flow

Ambient Operating Temperature

All DC SCR Precharge Modules are designed to operate at 0 to 50C (32 to 122F) surrounding air ambient without derating.

Installation/Wiring

1-3

AC Supply Source Considerations

The DC SCR Precharge Modules are suitable for use on a circuit capable of delivering a short circuit rating up to a maximum of 65,000 rms symmetrical amperes. 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. For Unbalanced or Ungrounded Distribution Systems where the potential exists for abnormally high phase-to-ground voltages (in excess of 125% of nominal) or the supply system is ungrounded, please refer to Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives (Allen-Bradley Publication No. DRIVES-IN001). For Input Power Conditioning information, please refer to Chapter 2 of Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives (Allen-Bradley Publication No. DRIVES-IN001).

General Grounding Requirements

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. 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 should be used. All circuits including the AC input ground conductor should be grounded independently and directly to this point or bus bar. Figure 1.3 shows a typical grounding scheme.
Figure 1.3 Typical Grounding Scheme

Input Transformer A R +DC X0 B S T C PE XFMR Enclosure -DC Converter

AC Drive DC SCR Precharge Inverter U V W AC Motor

M
Motor Frame

PE Panel Ground Bus Connection to Ground Grid, Girder or Ground Rod (Building ground Potential) Drive Enclosure Connection to Cabinet Ground Bus Building Ground Potential

Safety Ground Terminal PE: The DC SCR Precharge Module safety ground (PE) must be connected to the customer grounding scheme or earth ground. This is the safety ground for the DC SCR Precharge Module that is required by code. This point must be connected to adjacent building steel

1-4

Installation/Wiring

(girder, joist), a floor ground rod, bus bar or building ground grid. Grounding points must comply with national and local industrial safety regulations and/or electrical codes.

Fuses

The DC SCR Precharge Module is designed for internal application inside the drive(s) enclosure. The customer may install the external DC bus fuses if the fuse protection does not exist inside the drive. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations.

Minimum Capacitance

To operate and test the module, at least one drive must be connected at the power terminals +DCin and +DCout to provide a minimum DC bus capacitance (470 microfarads). One 7.5 kW (10 HP) PowerFlex 700H or PowerFlex 700S drive provides the required minimum capacitance. Important: If the drive (inverter) is disconnected from the DC bus, the DC SCR Precharge Module internal fault detection circuit will not interpret the condition as a Precharge Not Completed and will not stop gating the SCR.

Maximum Loading

To avoid overloading the DC SCR Precharge Module, the following requirements apply: The DC input current sum (Normal Duty rating at 50C/122F) of the connected drive(s) must not exceed the continuous DC bus output current rating of the DC SCR Precharge Module at 50C/122F. Multiple drives may be connected as long as the maximum current rating is not exceeded. For the DC input current values of the drives (PowerFlex 700H, PowerFlex 700S or 1336 PLUS II), please refer to tables in Appendix A of their respective User Manuals. Table 1.A shows examples for maximum loading of the DC SCR Precharge Module when it is used for PowerFlex 700H or PowerFlex 700S drive applications.
Table 1.A Maximum Loading when Used with PowerFlex 700H/700S Drive(s)
DC Input Rating of Connected Drive(s) 700H/700S Normal Duty Input DC Frame Size Input DC Amps Voltage 10 490A 650V 11 690A 650V 12 870A 650V 13 1507A 650V DC SCR Precharge Module Rated Cont. Part Number DC Amps 500A 370696 750A 370711 1000A 370715 1600A 370707 Drive(s) Normal Duty Output AC Amps 460A 650A 820A 1421A Output AC Volts 460V 460V 460V 460V

Installation/Wiring

1-5

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.

Cable Trays and Conduit

If cable trays or large conduits are to be used, please refer to guidelines presented in Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives (Publication No. DRIVES-IN001). 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 must be disabled. This will help minimize the possible shock hazard from cross-coupled motor leads. Failure to observe these precautions could result in bodily injury.

General Notes
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 should be located in the same cabinet or next to the cabinet with the DC SCR Precharge Module. If the connection leads between the DC bus and drive are leaving the cabinet, shielded cables must be used. Conformity of the drive with CE EMC requirements does not guarantee that an entire machine installation complies with CE EMC requirements. Many factors can influence total machine/installation compliance.

1-6

Installation/Wiring

Power Connection for 500A and 750A DC SCR Precharge Modules

Figure 1.4 shows typical locations of bus bars and terminals on 500A and 750A DC SCR Precharge Modules for customer wiring.
Figure 1.4 Bus Bar and Terminal Locations for Wiring 500A and 750A Modules

GND

AK

HK

DANGER
CAN CAUSE SHOCK BURNS, OR DEATH SURFACES MAY BE HOT

DATA NAMEPLATE

DANGER

REMOTE SOURCE

+DCin

+DCout

Table 1.B Power Connection Specifications for 500A and 750A Modules
Item Name

(1)

Amps 500 DC Bus +DCin 750 500 DC Bus +DCout 750 500 Protective Earth (GND) 750 Control Terminal Blocks

Bus Bars (1) Holes 50mm x 5mm (1.968 x 0.197 in.) 6 x 10mm (0.393 in.) 50mm x 5mm (1.968 x 0.197 in.) 6 x 10mm (0.393 in.) 50mm x 13mm (1.968 x 0.512 in.) 4 x 10mm (0.393 in.) 50mm x 13mm (1.968 x 0.512 in.) 4 x 10mm (0.393 in.) Bolt M10 x 25mm (0.984 in.) Torque 10Nm (88 lb-in.) Bolt M10 x 25mm (0.984 in.) Torque 10Nm (88 lb-in.) Refer to Table 1.D on page 1-8.

Input/output power bus bar connections require the use of either lug-type connectors to terminate field-installed conductors or bus bars.

Installation/Wiring

1-7

Power Connection for 1000A and 1600A DC SCR Precharge Modules

Figure 1.5 shows typical locations of bus bars and terminals on 1000A and 1600A DC SCR Precharge Modules for customer wiring.
Figure 1.5 Bus Bar and Terminal Locations for Wiring 1000A and 1600A Modules

GND
HK

+DCin

REMOTE SOURCE

G
DANGER
CAN CAUSE SHOCK BURNS, OR DEATH SURFACES MAY BE HOT

DANGER

+DCout

Table 1.C Power Connection Specifications for 1000A and 1600A Modules
Item Name Amps Bus Bars (1) Holes 76.2mm x 12.7mm (3.0 x 0.5 in.) 2 slots: 10mm x 20mm 1000 4 holes x 12.7mm (0.5 in.) (0.4 x 0.8 in.) DC Bus +DCin 76.2mm x 12.7mm (3.0 x 0.5 in.) 2 slots: 10mm x 20mm 1600 4 holes x 12.7mm (0.5 in.) (0.4 x 0.8 in.) 76.2mm x 12.7mm (3.0 x 0.5 in.) 2 slots: 10mm x 20mm 1000 4 holes x 12.7mm (0.5 in.) (0.4 x 0.8 in.) DC Bus +DCout 76.2mm x 12.7mm (3.0 x 0.5 in.) 2 slots: 10mm x 20mm 1600 4 holes x 12.7mm (0.5 in.) (0.4 x 0.8 in.) 1000 Bolt M10 x 25mm (0.984 in.) Torque 10Nm (88 lb-in.) Protective Earth (GND) 1600 Bolt M10 x 25mm (0.984 in.) Torque 10Nm (88 lb-in.) Control Terminal Blocks Refer to Table 1.D on page 1-8.

(1)

Input/output power bus bar connections require the use of either lug-type connectors to terminate field-installed conductors or bus bars.

1-8

Installation/Wiring

Control Wiring and Terminals

Terminal blocks TB1A and TB2A contain connection points for control wiring of the DC SCR Precharge Module.
Table 1.D Control Terminal Specifications for TB1A and TB2A
Name Control Terminal Blocks
(1)

Wire Size Range (1) Maximum Minimum 2.5 sq. mm 0.25 sq. mm (14 AWG) (22 AWG)

Torque 0.8 Nm (7 lb.-in.)

Maximum/minimum sizes that the terminals will accept these are not recommendations.

Figure 1.6 Control Terminal Block TB2A (located on precharge control board)

F1 1

Customer Side

12 11 10 9 8 7 6 5 4 3 2 1 2

TB2A
Terminal No. 1 2 3 4 5 6 7 8 9 10 11 12
(1)

Wiring Customersupplied Customersupplied Customersupplied Customersupplied Customersupplied Customersupplied

Description 120 VAC or 24 VDC Input 120 VAC 120 VAC Normally Open contact (1) Normally Closed contact (1) Normally Closed contact (1) Ground (GND)

Polarity Phase Neutral Phase Neutral Phase GND

Notes For interlocking with input system power. See Start-Up on page 2-2 for voltage selection. For supplying 120 VAC power to a cooling fan From external Normally Open contact that energizes the Precharge Control Relay CR Output contacts from the Precharge Control Relay CR Output contacts from the Precharge Control Relay CR - Precharge Enable Thermo switchs contacts that open if the Power Module has over-temperature failure Spare Ground for a cooling fan

Refer to Appendix A for contact rating.

Installation/Wiring

1-9

Figure 1.7 Control Terminal Block TB1A (located on precharge control board)

CR

8 7 6 5 4 3 2 1
3 2 1

14

13

12 11 10 9

TB1A
Terminal No. 1 2 3
(1) (2)

Wiring

Description +DCin (1) (2) -DC (1) (3) +DCout (1) (2)

Notes +DC (positive) Bus Input Power -DC (negative) Bus Power +DC (positive) Bus Output Power

Refer to Appendix A for contact rating. Terminal TB1A-1 is supplied jumpered to +DCin, and TB1A-2 is supplied jumpered to +DCout. Wiring to these terminals by the user is not required. Terminal TB1A-2 must be wired to -DC of the drive by the user.

(3)

Control Wiring Requirements

Important points about control wiring: Use Tinned-Copper wire only. Wire gauge requirements and recommendations are based on 75C (168F). 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 DC SCR Precharge Module from over-temperature failure, the normally closed contacts of the thermo-switches on the DC SCR Precharge Module should be wired to the Drive Run interlock circuit (Enable Input or Auxiliary Input). This will ensure that the drive(s) are stopped if a DC SCR Precharge Module over-temperature failure occurs.

1-10

Installation/Wiring

Typical Power and Control Wiring Examples

Figure 1.8 Typical Power and Control Wiring of DC SCR Precharge Module for PowerFlex 700H/700S Drive Applications

EA1
I/O Terminal Block 11 Digital IN1 (Stop) (Parameter 361 = 4)

480 VAC 3-Phase Input Power

12 Digital IN2 (Start) (Parameter 362 = 5) 13 Digital IN3

EA10 2 Bridge Thermostats + D1 K Snubber Board(s) AK A Bridge Fans 1 2 Neutral Phase +DCin IN DC+ 120 VAC From Control Power -DC OUT 3 1 TB1A 2 1 2 3 4 5 CR 6 7 CR CR Precharge Module EA11 +DCout 8 TB2A Thermostats 9 10 11 12 A A 6-Pulse Diode Bridge K 1 1 AK D2 K 1 AK D3 1

Digital IN4 (Speed Sel. 1) 14 (Parameter 364 = 15) 15 Digital IN5 (Aux Fault) (Parameter 365 = 3) 16 Digital IN6 (Enable) (Parameter 366 = 1) 17 Digital IN Common 18 Digital IN Common Digital IN Terminal Strip 1 2 5 Enable 6 Main Control Board J1 X 0-10V 10V 0-20 mA J2 X 0-10V 10V 0-20 mA X50: Precharge Terminal Strip Precharge

Hardware Enable J5 IN

1 Analog IN 1 (-) 2 Analog IN 1 (+) 3 Analog IN 2 (-) 4 Analog IN 2 (+) Analog IN Terminal Strip

J3 X 0-10V 10V 0-20 mA 9 Analog OUT Common J4 X 0-10V 10 Analog OUT 2 (+) 10V Analog OUT Terminal Strip 0-20 mA 8 Analog OUT 1 (+) Shield Bus 5 -10V Pot Reference 6 Pot Common

To Drive

Remove jumpers when 24 VDC input power is wired to TB2A-1 and TB2A-2 for interlocking with system power. Then 120 VAC power must be connected to TB2A-3 and TB2A-4.
A2 Precharge Board Jumper Settings

7 +10V Pot Reference Pot Terminal Strip

PowerFlex 700H/700S Control

(W1) JMP1 24 VDC 1-2 120 VAC 2-3

(W2) JMP2 INTLK 1-2 BYPASS 2-3

(W3) JMP3 NORMAL 1-2 BYPASS 2-3

For jumper locations, see Figure 2.1.

Installation/Wiring

1-11

Figure 1.9 Typical Power and Control Wiring of DC SCR Precharge Module for 1336 PLUS II Drive Applications
Input Power EA1 EA10 2 Bridge Thermostats +
20 STOP 1336F Control Board MOD-L6 115 VAC Interface Board

TB3 19 START

D1 K Snubber Board(s) AK A Bridge Fans 1 2 Neutral Phase A K

D2 K

D3 1
Terminal Block TB3

1 1 AK

AK
21 COMMON

A
22 REVERSE

6-Pulse Diode Bridge

23 JOG 24 AUXILIARY 25 COMMON 26 SPD SEL 3

+DCin IN DC+ 120 VAC From Control Power -DC OUT 3 1 TB1A 2 1 2 3 4 5 CR 6 7 CR CR Precharge Module EA11 +DCout 8 TB2A Thermostats 9 10 11 12

27 SPD SEL 2

28 SPD SEL 1 29 COMMON 30 ENABLE

To Drive

Remove jumpers when 24 VDC input power is wired to TB2A-1 and TB2A-2 for interlocking with system power. Then 120 VAC power must be connected to TB2A-3 and TB2A-4.
A2 Precharge Board Jumper Settings

1336F Control

(W1) JMP1 1-2 24 VDC 120 VAC 2-3

(W2) JMP2 INTLK 1-2 BYPASS 2-3

(W3) JMP3 NORMAL 1-2 BYPASS 2-3

For jumper locations, see Figure 2.1.

1-12

Installation/Wiring

Notes:

Chapter

Start-Up / Troubleshooting

This chapter describes how to start up the DC SCR Precharge Module and provides basic troubleshooting information.
For information on ... Start-Up Precharge Control Relay CR LED Indicator Troubleshooting See page ... 2-2 2-3 2-4

ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before removing the connection. Measure the DC bus voltage at the +DCin and +DCout terminals of the Power Module, and at the +DCin, +DCout, and -DC terminals of terminal block TB1A. The voltage must be zero. ATTENTION: Power must be applied to the DC SCR Precharge Module 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 DC power is not applied to the DC SCR Precharge Module. Correct the malfunction before continuing. ATTENTION: There is a second source of power used for the cooling fan. To avoid an electric shock hazard or moving blades, verify that the AC-power supply has been removed before performing any maintenance or repairs.

2-2

Start-Up / Troubleshooting

Start-Up

Before Applying Power to the DC SCR Precharge Module

1. Verify that a minimum of one drive is connected to the DC bus. See Minimum Capacitance on page 1-4 for details. 2. Verify that all inputs are connected to the correct terminals and are properly torqued. 3. Using an ohmmeter or other continuity testing device, verify that shorts do not exist between the +DCin, +DCout, and -DC terminals. 4. Verify that AC line power at the disconnect device is within the rated value of the DC SCR Precharge Module. See Appendix A for product electrical specification. 5. Verify that control power voltage is correct. 6. Verify that the enable precharge relay coil CR is correctly wired. 7. Verify that these two outputs are correctly wired: DC SCR Precharge Overtemperature (TB2-9 and TB2-10) Precharge Enable (TB2-6 and TB2-7) These NC (normally closed) and NO (normally open) contacts are used to set alarms and to stop the drive(s). Verify that they have been wired correctly according to the users specification. Refer to Figure 1.8 on page 1-10 or Figure 1.9 on page 1-11. 8. Verify that the W1, W2, and W3 jumpers on the Precharge Control Board A2 are set to the positions shown in Table 2.A. Jumper W1 W2 W3 Function System control voltage selection Interlock enable/bypass Handshake normal/bypass

Table 2.A A2 Precharge Board Jumper Settings

(W1) JMP1 (W2) JMP2 (W3) JMP3

24 VDC 120 VAC

For PowerFlex 700H/700S Drive Applications 1-2 INTLK 1-2 X NORMAL 2-3 X BYPASS 2-3 BYPASS For 1336 PLUS II Drive Applications INTLK 1-2 NORMAL X BYPASS 2-3 X BYPASS

1-2 2-3

24 VDC 120 VAC

1-2 2-3

1-2 2-3

9. Verify that the jumpers between control terminals TB2A-1 and TB2A-3, and TB2A-2 and TB2A-4 are present. Important: When supplying 24 VDC control power, these jumpers must be removed from the terminals on TB2A, and 120 VAC power must be wired to terminals TB2A-3 and TB2A-4.

Start-Up / Troubleshooting

2-3

Applying AC Power to the Drive with the DC SCR Precharge Module

10.Apply AC power and control voltage (115 VAC) to the DC SCR Precharge Module. The green LED on the Precharge Control Relay CR should be on if the drive control logic completes precharge and the SCR control starts gating the SCR power module. 11.If the green LED on the Precharge Relay CR is not on at this point, disconnect incoming power and refer to Table 2.B for troubleshooting.

Precharge Control Relay CR The DC SCR Precharge LED (Figure 2.1) on the Precharge Control Relay CR is visible from the boards side of the Module, depending on the LED Indicator

position of the Module. The Precharge Control Relay CR is mounted on the terminal block TB1. When the LED is lit solid green, it indicates that the DC SCR Precharge Module is gating properly and the precharge sequence is complete.
Figure 2.1 Location of LED on the Precharge Control Relay CR and W* Jumpers
AIR FLOW

GND

LED
A2

DANGER
REMOTE SOURCES

DANGER
RISK OF SHOCK REPLACE AFTER SERVICING

CR
J1 J3

AK

HK

DANGER
CAN CAUSE SHOCK BURNS, OR DEATH SURFACES MAY BE HOT

T
+DC IN

+DC OUT

(W3) JMP3

(W2) JMP2

(W1) JMP1

LEFT SIDE VIEW

TOP VIEW

ATTENTION: The DC SCR Precharge Module 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!

A1 CR

REMOTE SOURCES

DANGER
TB2

TB1A

NAMEPLATE

J3 W3

J1 W2

J2 TB1 W1

2-4

Start-Up / Troubleshooting

Troubleshooting

Table 2.B provides information for troubleshooting the DC SCR Precharge Module.
Table 2.B Possible Symptoms and Corrective Actions
Symptom DC output voltage loss Cause/Indication DC bus: Short circuit or Low line Corrective Action 1. Check 3-phase AC incoming power for undervoltage or phase loss. 2. Check the protection Precharge fuse F1. 3. After precharge is completed, verify that the values of the +DCin and +DCout voltages are within 1 volt. Loss of 120 VAC or 24 VDC supply voltage 4. Contact your local RA Sales Office. 1. Verify 120 VAC or 24 VDC supply input voltage is present at control terminals TB2A-1 and TB2A-2. 2. Enable the contactor function. Heat sink overtemperature Heat sink temperature (contacts TB2A-9 and exceeds maximum rating TB2A-10 have opened) 3. Contact your local RA Sales Office. 1. Verify that the maximum ambient temperature has not been exceeded. 2. Check Overtemperature Switch T at control terminals TB2A-9 and TB2A-10 that has normally closed contacts. 3. Verify 120 VAC supply input voltage at control terminals TB2A-3 and TB2A-4. 4. Verify fan for correct operation. Airflow should be outward from the unit. 5. Check for excess load on the DC SCR Precharge Module. 6. Check for proper spacing around the DC SCR Precharge Module. 7. Contact your local RA Sales Office.

Appendix

Specifications and Dimensions

For information on ... Specifications Dimensions

See page ... A-1 A-2

Specifications
Category Specification Environment Ambient Operating Temperature: IP00, Open: Storage Temperature: Atmosphere: 0 to 50C (32 to 122F) 40 to 70C (40 to 158F) Important: The DC SCR Precharge Module must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors or dust. If the Module is not going to be installed for a period of time, it must be stored in an area where it will not be exposed to a corrosive atmosphere. 5 to 95% non-condensing 1000 m (3300 ft.) without derating 15G peak for 11 ms duration ( 1.0 ms) 0.152 mm (0.006 in.) displacement, 1G peak Internal (inside enclosure only) Nominal Maximum 540V 810V 650V 810V 500A-1600A 100% 150% 99.5% typical at rated current Single-phase 120 VAC, 30 VA (pick-up), 4.5 VA (hold) Single-phase 120 VAC 10%, 50/60 Hz, 1A

Application Electrical

Relative Humidity: Altitude: Shock: Vibration: Packaging: DC Bus Voltage for: 400 VAC Input Voltage: 480 VAC Input Voltage: DC Bus Current: Overload Capability: Continuous Amps: 3 Seconds Every Minute: Efficiency: Control Inputs: Control Relay CR Coil:

Cooling Compliance

Fan Current Consumption: Control Outputs: Heatsink Temperature Sensor with NC Contact: Trip Temperature: 100C Resistive Rating: 15A at 125 VAC, 10A at 250 VAC, 7A at 24 VDC Inductive Rating: 10A at 125 VAC, 6A at 250 VAC Control Relay CR with NO and NC Resistive Rating: 7A at 24-277 VAC, Contacts: 7A at 30 VDC Inductive Rating: 15A at 120 VAC, 7.5A at 240 VAC Forced Ventilation: 500A and 750A Modules: 7.447 cub. m/min (263 CFM) 1000A and 1600A Modules: 17.18 cub. m/min (607 CFM) UL Recognized to: UL508C and CAN/CSA-C22.2

A-2

Specifications and Dimensions

Dimensions

Figure A.1 shows the recommended dimensions for panel mounting the DC SCR Precharge Module.
Figure A.1 DC SCR Precharge Module Panel Mounting Dimensions

Front View

10 mm 0.43 in. 4 Holes

Precharge Module Dimensions DC Rating A B 500A 285 mm 325 mm (11.22 in.) (12.8 in.) 750A 285 mm 325 mm (11.22 in.) (12.8 in.) 1000A 285 mm 325 mm (11.22 in.) (12.8 in.) 1600A 285 mm 325 mm (11.22 in.) (12.8 in.)

Weight 17 kg (37 lbs.) 17 kg (37 lbs.) 29 kg (64 lbs.) 29 kg (64 lbs.)

Figure A.2 and Figure A.3 show the overall dimensions for the DC SCR Precharge Modules.

Specifications and Dimensions

A-3

Figure A.2 Overall Dimensions for 500A and 750A Precharge Modules

GND

AK

HK

DANGER
CAN CAUSE SHOCK BURNS, OR DEATH SURFACES MAY BE HOT

DATA NAMEPLATE

DANGER

REMOTE SOURCE

+DCin

+DCout

C A Front View D Side View

Precharge Module Dimensions DC Rating A B 500A 369 mm 394 mm (14.5 in.) (15.5 in.) 750A 369 mm 394 mm (14.5 in.) (15.5 in.)

C 275 mm (10.8 in.) 275 mm (10.8 in.)

D 302 mm (11.9 in.) 302 mm (11.9 in.)

A-4

Specifications and Dimensions

Figure A.3 Overall Dimensions for 1000A and 1600A Precharge Modules

GND
HK G

+DCin

D B

DANGER
CAN CAUSE SHOCK BURNS, OR DEATH SURFACES MAY BE HOT

DANGER

REMOTE SOURCE

+DCout

A Front View

C Side View

Precharge Module Dimensions DC Rating A B 1000A 428 mm 465 mm (16.8 in.) (18.3 in.) 1600A 428 mm 465 mm (16.8 in.) (18.3 in.)

C 317 mm (12.5 in.) 317 mm (12.5 in.)

D 810 mm (31.9 in.) 810 mm (31.9 in.)

Index
A
AC supply source considerations, 1-3 ambient operating temperature, 1-2

J
jumper W1, W2, and W3 locations, 2-3

L B
block diagram/description, P-4 bus bar and terminal locations 1000A and 1600A modules, 1-7 500A and 750A modules, 1-6 bus capacitors, discharging, P-2 LED, precharge Control Relay CR, 2-3

M
manual conventions, P-2 maximum loading, 1-4 minimum mounting clearances, 1-2 minimum required capacitance, 1-4 module applying power, 2-2 part number explanation/ratings, P-3 precharge Control Relay CR LED, 2-3 start-up checklist, 2-2

C
capacitors - bus, discharging, P-2 checklist for module start-up, 2-2 considerations, AC supply source, 1-3 control wiring and terminals, 1-8 control wiring requirements, 1-9 conventions used in this manual, P-2

O
operating temperature ambient, 1-2

D
description/block diagram, P-4 dimensions overall 1000A and 1600A modules, A-4 500A and 750A modules, A-3 panel mounting - all modules, A-2 drive run interlock, 1-9

P
part number explanation/ratings, P-3 power wiring, 1-5 powering up the module, 2-2 precautions, general, P-2 precharge board jumper settings 1336 PLUS II drive applications, 2-2 PowerFlex 700H/700S drive applications, 2-2 precharge status indicator, 2-3

E
Electrostatic Discharge (ESD), P-2

F
fuses, 1-4

R
reference literature web site, P-1 requirements control wiring, 1-9 grounding, 1-3 maximum loading, 1-4 minimum capacitance, 1-4 minimum mounting clearances, 1-2

G
general precautions, P-2 grounding requirements, 1-3

I
interlock, drive run, 1-9

Index-2

S
specifications electrical, A-1 environment, A-1 start-up checklist, 2-2 static discharge (ESD), P-2

T
troubleshooting, 2-4 typical power and control wiring 1336 PLUS II drive applications, 1-11 PowerFlex 700H/700S drive applications, 1-10

W
W1, W2, and W3 jumper locations, 2-3 web site for drive reference literature, P-1

Index-3

Index-4

U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives

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Publication DRIVES-UM002A-EN-P March, 2006

Copyright 2006 Rockwell Automation, Inc. All rights reserved. Printed in USA.