8720MC Regenerative Power Supply Installation Manual
Important User Information Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.
European Communities (EC) Directive Compliance If this product has the CE mark it is approved for installation within the European Union and EEA regions. It has been designed and tested to meet the following directives.
Table of Contents Contents of This Manual About 8720MC-RSP Regenerative Power Supply Chapter 1 Introduction .................................................................................. Finding Information ...................................................................... Assumptions About the Audience ................................................ Notes on Handling the 8720MC-RPS Regenerative Power Supply ........................................................................................
ii Table of Contents Installing Main Magnetic Contactor ........................................ Installing Reactor .................................................................... Installing Varistor .................................................................... Installing Harmonic Filter ........................................................ Installing Input Fuses ............................................................. Installing Line Filters ...........................................
Table of Contents Error Codes and Warning Buzzer Chapter 8 Inspecting Trouble and Recovering Chapter 9 Special Replacement Parts Chapter 10 Outline Drawings of the Peripheral Devices Chapter 11 Technical Specifications Appendix A Default Parameter Settings Appendix B Control Block Diagram Appendix C Contents of Error Codes and Recovering ...................................... Accessing and Clearing the Entries in the Error Log ..................... Recovering from Fatal Error ................
iv Table of Contents End of Table of Contents
Chapter 1 Contents of This Manual Introduction The 8720MC-RPS Regenerative Power Supply Bidirectional Converter is a sinusoidal PWM converter which can control increase of DC bus voltage and perform continuous power generation. The 8720MC-RPS Regenerative Power Supply, therefore, can be used as power supply unit for various drives and inverter units.
1-2 Contents of This Manual • Chapter 2: About 8720MC-RPS Regenerative Power Supply Identifies components of the 8720MC-RPS Regenerative Power Supply, shows their locations, and describes the main components. • Chapter 3: Installation Describes how to mount the 8720MC-RPS Regenerative Power Supply properly. • Chapter 4: Wiring Describes how to properly wire and connect the 8720MC-RPS Regenerative Power Supply.
Contents of This Manual The following three labels are put on the 8720MC-RPS Regenerative Power Supply, advising the user of the notes on handling the unit. Read and understand the contents before using the unit. ! PWR CAUTION! WHEN YOU APPLY POWER AGAIN, VERIFY THAT THIS LAMP "PWR" IS TURNED OFF. ME-B6013 ! DANGER RISK OF ELECTRICAL SHOCK. DISCONNECT INPUT POWER BEFORE SERVICING EQUIPMENT.
1-4 Contents of This Manual End of Chapter
Chapter 2 About 8720MC-RPS Regenerative Power Supply This chapter describes model numbers, major components, their locations, and terminal blocks of 8720MC-RPS Regenerative Power Supply. Model Numbers of the 8720MCRPS Regenerative Power Supply and its Accessories For operation of the 8720MC-RPS Regenerative Power Supply, a line reactor is required for each incoming phase as well as a varistor, a harmonic filter and a contactor.
2-2 About 8720MC-RPS Regenerative Power Supply Power Rating Power rating of 8720MC-RPS Regenerative Power Supply depends on the number of units connected in parallel as shown in the table below. Up to three units can be connected. Table 2.
About 8720MC-RPS Regenerative Power Supply 2-3 When the front cover is removed from the 8720MC-RPS027 and 8720MC-RPS065 , the main power terminal block (TB1) and the Regulator Board (only for master unit) will appear as shown in the following figure. To remove the front cover, first remove the screw at the upper left corner of the unit, and then lift up the cover. Note, however, that Model 8720MC-RPS027 has the cover fixing screw at the upper right corner instead of the upper left corner.
2-4 About 8720MC-RPS Regenerative Power Supply Appearance of Model 8720MC-RPS190 The figure below shows the front view of the 8720MC-RPS190 covered by the front cover. This unit has the main power terminals L1 to L3 at the top of the unit, and DC bus terminals P and N at the bottom of the unit.
About 8720MC-RPS Regenerative Power Supply Main Components and Locations 2-5 Model 8720MC-RPS027BM has the following main components. The identification numbers provided correspond to the numbers used in the following figure. The main components are included in the special replacement part list shown in Chapter 10. 1. Regulator Board (BDSR) (only master unit has a Regulator Board, not on slave unit) 2. Power Interface Board (PIFS) 3. Driver Board (RCPB) 4. Bus Capacitors 5. Cooling Fan 6.
2-6 About 8720MC-RPS Regenerative Power Supply Model 8720MC-RPS065BM and 8720MC-RPS065BS have the following main components. 1. Regulator Board (BDSR) (only master unit has a Regulator Board, not on slave unit) 2. Power Interface Board (PIFS) 3. Driver Board (RCPB) 4. Bus Capacitors 5. Cooling Fan 6. Power Modules 7. Fuse-1 8. Precharge/Discharge Resistor The following figure shows the locations of main components of Model 8720MC-RPS065BM and 8720MC-RPS065BS.
About 8720MC-RPS Regenerative Power Supply 2-7 Model 8720MC-RPS190BM and 8720MC-RPS190BS have the following main components. 1. Regulator Board (BDSR) (only master unit has a Regulator Board, not on slave unit) 2. Power Interface Board (PIFS) 3. Bus Capacitors 4. Cooling Fan 5. Power Modules 6. Fuses 1, 2, 3 The following figure shows the locations of main components of Model 8720MC-RPS190BM and 8720MC-RPS190BS.
2-8 About 8720MC-RPS Regenerative Power Supply Model 8720MC-RPS027 and 8720MC-RPS065 are composed of the following components. 1) 8720MC-RPS 2) Line filter for main circuit* 3) Line filter for sequence power* 4) Circuit breaker 5) AC input fuse 6) DC output fuse 7) Varistor 8) Harmonic filter 9) Main magnetic contactor 10) Reactor * Not necessary when compliance with CE mark is not required. The following figure shows system configuration of 8720MCRPS027 and 8720MC-RPS065.
About 8720MC-RPS Regenerative Power Supply 2-9 Model 8720MC-RPS190 is composed of the following components. 1) 8720MC-RPS 2) Circuit breaker 3) AC input fuse 4) DC output fuse 5) EMC filter unit 6) ACL unit The following figure shows system configuration of Model 8720MC-RPS190.
About 8720MC-RPS Regenerative Power Supply This section provides the main circuit block diagram and the description of the main power terminal block (TB1) and the control power terminal block (TB2). The main circuit block diagram for Model 8720MC-RPS027BM, 8720MC-RPS065BM and 8720MCRPS065BS is shown in Figure 2.1. Terminal Blocks on the Main Circuit Figure 2.
About 8720MC-RPS Regenerative Power Supply 2-11 Figure 2.2 shows the main circuit block diagram for Model 8720MC-RPS190BM and 8720MC-RPS190BS. Figure 2.
2-12 About 8720MC-RPS Regenerative Power Supply Main Power Terminal Block (TB1) for Model 8720MC-RPS027 and 8720MC-RPS065 The table below provides the information of the terminals on use of the terminals on the main power terminal block (TB1) for Model 8720MC-RPS027 and 8720MC-RPS065. Terminal Name Symbol Main Power Terminals L1, L2, L3 To connect three-phase AC input power to the main circuit.
About 8720MC-RPS Regenerative Power Supply 2-13 Main Power Terminal Bar for Model 8720MC-RPS190 The table below describes the terminals on the main power terminal bar for Model 8720MC-RPS190. Description Terminal Name Symbol Main Power Terminals L1, L2, L3 To connect three-phase AC input power to the main circuit. For 460 V unit: 380 to 460 VAC +10%, -15%, 50/60 Hz +/-5% DC Bus Terminals P, N To connect the 8720MC-RPS Regenerative Power Supply to load equipment.
2-14 About 8720MC-RPS Regenerative Power Supply Regulator Board The Regulator Board exists only on master unit. The slave unit for parallel connection has no Regulator Board and is controlled by the microprocessor of the Regulator Board on the master unit. The 8720MC-RPS Regenerative Power Supply regulation is performed by a microprocessor on the Regulator Board. The figure below shows the locations of the main components on the Regulator Board.
About 8720MC-RPS Regenerative Power Supply 2-15 Jumpers and Switches ! ! ! ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should set jumpers and switches. Read and understand this manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life. ATTENTION: Do not press the reset button switch (SW6) during operation.
2-16 About 8720MC-RPS Regenerative Power Supply When two units are connected in parallel, turn the switches SW7-1 and SW7-2 to the ON side, and when three units are connected in parallel, turn the switches SW7-1 through SW7-3 to the ON side. SW7-4 Slave Unit 2 SW7-3 Slave Unit 1 SW7-2 Master Unit SW7-1 ON ENABLE Keep SW7-4 always to the OFF side. OFF BASE BLOCK When the switch is turned to the OFF side, the base signal is interrupted, and the unit will be in the OFF condition.
About 8720MC-RPS Regenerative Power Supply 2-17 Sequence Signal Terminal Block (TB3) As shown in the figure in page 2-14, there is a sequence signal terminal block (TB3) on the Regulator Board. The following table provides the information on each terminal of TB3. Name of Terminal Symbol Description Sequence Input Signals MC Enter the supplemental contact signal (normally open contact) of the main magnetic contactor.* MC 4.
2-18 About 8720MC-RPS Regenerative Power Supply End of Chapter
Chapter 3 Installation This chapter shows how to mount the 8720MC-RPS Regenerative Power Supply properly, and provides information on the items to be checked. ! ! Installation Site ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual in its entirety before proceeding.
3-2 Installation • Check that the temperatures within the vicinity of the units are between -10 to 50 degree C (14 to 122 degree F). In case of 8720MC-RPS190, however, the ambient temperature must be between -10 to 40 degree C (14 to 104 degree F). • Check that the relative humidity is between 5 and 95% without condensation. • Do not install the units above 1,000 meters (3,300 feet) without derating output power.
Installation 3-3 Figure 3.1 Overall Dimensions of a Single Unit of Model 8720MC-RPS027 and 8720MC-RPS065 Units H dia. D B K F E C G dia. A READY V FAULT PROGRAM kW RST PRG ENT 8720 MC REGENERATIVE POWER SUPPLY H L Model A 8720MC- 179.4 RPS065 (7.06) 8720MC- 167 RPS027 (6.57) E F C A B C D 395 (15.6) 320 (12.6) 127 (5.0) 120 (4.72) 333.2 (131.2) 260 (10.24) E 10 (0.39) 10 (0.39) F 30 (1.2) 30 (1.2) G 18 (0.71) 17 (0.67) H 9 (0.35) 8.2 (0.32) K 9 (0.35) 8 (0.31) L 318.3 (12.
Installation 3-4 10 (0.39) dia. 20 (0.79) dia. 125 (4.92) 30 58 (1.2) (2.3) M10 L2 110 (4.3) L1 110 (4.3) L2 86 (3.4) L3 573 (22.6) 550 (21.7) 503 (19.8) 566.5 (22.30) READY A FAULT FAUL V PROGRAM kW RST PRG ENT 8720 MC REGENERATIVE POWER SUPPLY 20 (08) N 30 (1.2) 125 (4.9) 10 (0.4) E P 30 (1.2) M8 P 10 (0.4) E 33 (1.3) 639.5 (25.18) 14 (0.6) L1 , L3 40 (1.6) 59.5 (2.34) 13 (0.5) 20 (0.79) Figure 3.
Installation 3-5 Figure 3.3 Required Distance between Units in Case of Two Paralleled Units of Model 8720MC-RPS027 or 8720MC-RPS065 Units READY A FAULT V PROGRAM kW RST PRG ENT 8720 MC 8720 MC REGENERATIVE POWER SUPPLY REGENERATIVE POWER SUPPLY Max. 250 (9.8) Unit: Millimeter (Inch) Note: In case two units of Model 8720MC-RPS027 or 8720MC-RPS065 unit are installed in parallel, the master unit must be on the right hand side as shown in the above. Figure 3.
3-6 Installation Figure 3.5 Required Distance between Units in Case of Two Paralleled Units of Model 8720MC-RPS190 Unit POWER POWER READY READY A FAUL FAULT V PROGRAM PROGRAM kW kW RST PRG ENT 8720 MC 8720 MC REGENERATIVE SUPPLY POWER SUPPLY REGENERATIVE POWER REGENERATIVE SUPPLY POWER SUPPLY REGENERATIVE POWER Max. 620 (24.
Installation 3-7 Recommended Air Flow Clearance Be sure that there is adequate clearance for air ventilation around the 8720MC-RPS Regenerative Power Supply. Cooling air flows from the bottom to the top of the units. For best cooling effect, do not mount the 8720MC-RPS Regenerative Power Supply directly above each other. The figure below shows recommended air flow clearance. 150 (5.9) Exhaust 150 (5.9) 150 (5.9) A READY V FAULT PROGRAM kW RST PRG ENT 8720 MC 150 (5.
3-8 Installation • Do not expose the units to excessive electrical noise. If it is not avoidable to install the 8720MC-RPS Regenerative Power Supply close to a noise source or to use the units in environment where noise trouble is expected, take sufficient noise suppression measures.
Chapter 4 Wiring This chapter provides instructions on how to properly wire the 8720MC-RPS Regenerative Power Supply units. It also provides information on the selection of the circuit breaker, the main magnetic contactor, reactor, and the harmonic filter, etc. ! ! ! ! Recommended Wire Sizes ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment.
4-2 Wiring Recommended Wire Sizes for Power Wiring to the Main Power Terminal Block (TB1) and the Main Power Terminal Bars Table 4.1 to 4.3 show the recommended wire sizes for power wiring to the main power terminal block (TB1) and the Main Power Terminal Bars. Table 4.1 shows the wire sizes for Model 8720MCRPS027 unit, Table 4.2 shows the wire sizes for Model 8720MCRPS065 unit, and Table 4.3 shows the wire sizes for Model 8720MC-RPS190 unit.
Wiring AC Input Power Wiring for Model 8720MC-RPS027 and 8720MC-RPS065 ! ! ! 4-3 ATTENTION: Equipment as the 8720MC-RPS Regenerative Power Supply units using high speed switching elements generates noise regarding emission due to noise generated during switching. To avoid influence of such noise, it is very important to use as thick and short grounding wire as possible.
4-4 Wiring ATTENTION: Special caution must be paid to wiring to the 8720MC-RPS Regenerative Power Supply when connecting multiple units in parallel. The phases of AC input power to the main power supply terminals (L 1, L2 and L3) and to the control power terminals (L1AUX, L2AUX, and L3AUX) and the polarity of DC bus output (P and N) of all the connected units must be the same. Failure to observe this precaution could result in destruction of the equipment, severe bodily injury or loss of life.
4-5 Wiring Figure 4.
4-6 Wiring Figure 4.
Wiring 4-7 When Model 8720MC-RPS027 or 8720MC-RPS065 is operated in the Power Regeneration Mode only Figure 4.
4-8 Wiring • Rating of regenerative power of the 8720MC-RPS is less than rated power both in the instantaneous rating and continuous rating. • When rectifier portion of inverter is composed of thyristor, CR snubber circuit between anode and cathode of thyristor may become overloaded. Therefore, treating time for regenerative power must be within 5 seconds for 3 minutes.
Wiring 4-9 When Model 8720MC-RPS027 and 8720MC-RPS065 are adapted to Capacitors having large capacity 8720MC-RPS027 and 8720MC-RPS065 units charge to capacitors with a single phase, full-wave rectification circuit through the built-in precharge/discharge resistor. When the load capacitors have large capacitance, it takes more time for charging, and the wattage of the internal resistor becomes insufficient.
4-10 Wiring required. Table 4.5 provides the minimum resistance value for the external precharge resistor, 30 ohms in the case of the RPS027 and 20 ohms in the case of the RPS065. The wattage [W] is determined by the equation presented above. Connect the external precharge resistor to terminals PR1 and PR2 on terminal block TB2. Terminal PR3 should be left open. See Chapter 2, Figure 2.1 under "Terminal Blocks on the Main Circuit". The Precharge/Discharge Time (F.
Wiring 4-11 Parameter F.015 should be set to the sum of the wattage for both resistors. Installing Circuit Breaker To protect the AC input power, install a circuit breaker with supplemental contact (CB) in the AC input power line. Refer to Figures 4.1 to 4.3 for the wiring.
4-12 Wiring For Model 8720MC-RPS065BM and 8720MC-RPS065BS units: Allen-Bradley Fuji Electric - 100-C43x10 (CE marked) (where x is voltage suffix code of operating coil) - SC-N2S (UL listed component) (Select an adequate operating coil for the magnetic contactor within the range of 100 to 230 VAC depending on the used voltage.) Be sure to provide required quantity of magnetic contactors (MC) for all units connected in parallel (see Figure 4.2 or 4.3).
Wiring 4-13 The following are the designated reactors. These reactors are integrated for three phases consisting of three single phase reactors. When selected reactors are installed, set their capacity to the parameter F.013.
4-14 Wiring Installing Harmonic Filter Install an adequate harmonic filter as shown in Figure 4.1, 4.2 or 4.3 to remove higher order harmonics generated by switching operation of Power Modules, from AC input power. Also be sure to connect the harmonic filter on the incoming AC line side of the AC contactor. The following are the designated harmonic filter and wire size. 8720MC-HF-B2 Wire size: 3.5 square millimeters Installing Input Fuses Install a fuse on the AC incoming power line.
Wiring 4-15 Install also a line filter on single phase AC incoming power line for a main magnetic contactor. The following are designated single phase line filters: For Model 8720MC-RPS027BM, 8720MC-RPS065BM and 8720MC-RPS065BS units: Schaffner FN2010-6-06 or Soshin Electric NF2005A-YX Bus Bar and Output Fuses When multiple drives and/or master/slave RPS units are needed for a common bus application, bus bar is recommended. Size the bus bar to at least 175% of the total continuous RPS output current.
4-16 Wiring AC Input Power Wiring for Model 8720MC-RPS190 ! ! ! ATTENTION: Equipment as the 8720MC-RPS Regenerative Power Supply units using high speed switching elements generates noise regarding emission due to noise generated during switching. To avoid influence of such noise, it is very important to use as thick and short grounding wire as possible.
Wiring 4-17 Figure 4.
4-18 Wiring Figure 4.
Wiring 4-19 1> Refer to the lower left corner of Figure 4.7 indicating the terminals on the ACL unit. When the fan inside the ACL unit is connected with an external power supply, do not fail to connect with the power supply designated by NEC Class 2 (Power supply limited to 100VA and below, and 8A and below even in case of Error). Avoid the high voltage portion and the high temperature portion of the ACL unit when wiring the fan inside the ACL unit.
Wiring Figure 4.
Wiring 1> Refer to the lower left corner of Figure 4.7 indicating the terminals on the ACL unit. When the fan inside the ACL unit is connected with an external power supply, do not fail to connect with the power supply designated by NEC Class 2 (Power supply limited to 100VA and below, and 8A and below even in case of Error). Avoid the high voltage portion and the high temperature portion of the ACL unit when wiring the fan inside the ACL unit.
4-22 Wiring When Model 8720MC-RPS190 is operated in the Power Regeneration Mode only. Figure 4.
Wiring 4-23 It is possible to select the 8720MC-RPS units depending on the regenerative power when only regenerated power of the unit integrating converter and inverter is used. In this case, however, the following cautions must be observed. Figure 4.4 shows wiring of the 8720MC-RPS027 or 8720MC-RPS065 unit used as a converter for the power regeneration mode only. • Rating of regenerative power of the 8720MC-RPS is less than rated power both in the instantaneous rating and continuous rating.
4-24 Wiring When Model 8720MC-RPS190 is adapted to Capacitors having large capacity 8720MC-RPS190 unit charges to capacitors with a single phase, full-wave rectification circuit through the built-in precharge/ discharge resistor. When the load capacitors have large capacitance, it takes more time for charging, and the wattage of the internal resistor becomes insufficient.
Wiring 4-25 on the terminal block TB2. Terminal PR3 should be left open. See Chapter 2, Figure 2.2 "Terminals Blocks on the Main Circuit". The Precharge/Discharge Time (F.014) may require a larger value to accommodate the increased precharge time. The Wattage of Precharge/Discharge Resistor (F.015) should also be increased to the external precharge resistor wattage.
4-26 Wiring If a totally external resistor network is used as shown in figure 4.10, the calculated wattage, [W] = 17,000 x C farads, is divided in half to size the precharge and discharge resistors. Parameter F.015 should be set to the sum of the wattage for both resistors. Installing Circuit Breaker - 8720MC-RPS190 To protect AC input power, install a circuit breaker with supplemental contact (CB) in the AC input power line. Refer to Figures 4.6 to 4.8 for wiring.
Wiring 4-27 The following inductance of the reactor must be maintained in a high frequency as 10 to 20 kHz. Note that use of a reactor for commercial power supply may not maintain the required inductance, resulting in increased heat generation or saturation due to iron loss. When multiple units are connected in parallel, a current unbalance between the units is produced due to vibration of reactor inductance.
4-28 Wiring Installing 8720MC-EF190-VB EMC Filter Unit The 8720MC-EF190-VB EMC filter unit contains line filter, magnetic contactor, varistor and harmonic filter, and are used for Model 8720MC-RPS190BM and 8720MC-RPS190BS units. Because the 8720MC-EF190-VB unit is completely assembled, wiring can be simplified in combination with Model 8720MCLR10-100B reactor, and also the space to be required can be reduced considerably.
Wiring Installing DC Bus Power Output Wiring - All RPS units ! ! 4-29 ATTENTION: When connecting the DC bus to plural number of external load equipment, the user is responsible for installing fuses to protect the DC bus from shorting, if no fuse is provided in the load equipment. Failure to observe this precaution could result in damage to, or destruction of, the equipment ATTENTION: Exercise extreme caution for polarity of wiring when wiring DC bus.
4-30 Wiring Wiring To Comply with EMC To declare the conformity with the requirements for CE Mark, 8720MC-RPS Regenerative Power Supply must comply with both EMC directive and low voltage directive. This section describes notes on wiring to comply with EMC directive. Important: 8720MC-RPS Regenerative Power Supply itself is not subject to Machine directive.
Wiring 4-31 5. The input and output line of the 8720MC-RPS units must be separated from the output line of the inverter unit as far as possible. 6. Wiring of the control signal must be terminated within the control cabinet. Should the control cable be needed to extend out of the control cabinet, it is recommended to use shielded cables. When ferrite cores are used, install them possibly to the side of the 8720MC-RPS units. The following are the ferrite cores for the control cables recommended.
4-32 Wiring Sequence Signal Wiring Figure 4.11 shows a typical connection of sequence control signals. Figure 4.11 Typical Connection of Sequence Control Signals Terminal Block TB3 of 8720MC-RPS Regenerative Power Supply Unit Unit 4.7K 1K 1K MC 4.7K RST 4.7K PWR 1K 0V 24V +VC COM 0VC IP RDY IP RDY 4.64K 4.64K 4.
Wiring 4-33 Operation Timing of Sequence Control Signals Figures 4.12 through 4.17 show timing of various sequence control signal operations. Figure 4.12 Sequence Operation of Precharging DC Bus Voltage Main Magnetic Contactor (MC) On Off PWR Input On Off RST Input On Off RDY Output Open Close FR Output Open Close IP Output Open Close Figure 4.
4-34 Wiring Figure 4.14 Sequence Operation of Error Detection DC Bus Voltage Main Magnetic Contactor (MC) On Off PWR Input On Off RST Input On Off RDY Output Open Close FR Output Open Close IP Output Open Close Figure 4.
Wiring 4-35 Figure 4.16 Sequence Operation of Detecting Instantaneous Power Loss (When Main Magnetic Contactor is not Turned OFF) PWM-ON Inst. PWM-OFF PWM-ON DC Bus Voltage Main Magnetic Contactor (MC) On Off PWR Input On Off RST Input On Off RDY Output Open Close FR Output Open Close IP Output Open Close Figure 4.
4-36 Wiring Installing Ribbon Cables Ribbon cables are used for connecting: • Between Regulator Board (BDSR) and Power Interface Board (PIFS), • Between Power Interface Boards (PIFS). For a single unit or for master unit with multiple units connected in parallel, the Regulator Board is connected to the Power Interface Board with a ribbon cable.
Wiring Notes on Wiring 4-37 8720MC-RPS units comply with the requirements of CE Mark and a Declaration of Conformity was issued for these units. Insert the specified line filter into the power supply line if these units are used as the units conforming to the requirements of CE Mark.
4-38 Wiring End of Chapter
Chapter 5 Start and Adjustment This chapter provides instructions on how to perform a final check before power is applied to the 8720MC-RPS Regenerative Power Supply, how to power up the unit and how to operate the unit. ! ! ! ! Checking before Powering up the 8720MC-RPS Regenerative Power Supply ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment.
5-2 Start and Adjustment • Verify that there is no debris such as metal shavings around the unit. • Check that there is adequate clearance around the unit. Verifying the Rating of the 8720MC-RPS Regenerative Power Supply Before powering up the 8720MC-RPS Regenerative Power Supply, check the following: • Check the unit's nameplate and confirm that the installed 8720MC-RPS Regenerative Power Supply has an enough rating for the load.
Start and Adjustment 5-3 Step 4. Verify that the unit powers up properly without incident such as abnormal sound or nasty smell. Step 5. Verify that there is no input power voltage drop or short circuit. Step 6. Verify that the rating of the 8720MC-RPS Regenerative Power Supply matches the parameter setting of the Unit Selection (F.001). For Step 6, more information will be given in the section "Operating the 8720MC-RPS Regenerative Power Supply" in this Chapter.
5-4 Start and Adjustment Step 1. Power Up the 8720MC-RPS Regenerative Power Supply This step verifies that the 8720MC-RPS Regenerative Power Supply powers up and passes the power-up self-diagnostics. After the unit passes the diagnostics, the operation panel automatically enters monitor mode, with input current displayed. Step 1.1 Turn power ON. READY A FAULT V PROGRAM kW RST PRG ENT READY A FAULT V PROGRAM kW RST PRG ENT Step 2.
Start and Adjustment Step 2.4 Press the key. READY A FAULT V PROGRAM 5-5 The display indicates the second Factory parameter. kW RST PRG ENT Step 2.5 Press the ENT key. READY A FAULT V PROGRAM kW RST PRG ENT The display shows that 37 KW (65 Amps.) unit for 460 V is selected. If the display does not match the actual unit rating, first set the password (F.000), and then set again the Unit Selection conforming to the unit rating (refer to the section "Factory Parameters" in Chapter 7).
5-6 Start and Adjustment Step 3. Precharging In this step, you will turn the RUN sequence control signal ON. When the RUN sequence signal is enabled, the 8720MC-RPS Regenerative Power Supply will start precharge operation. When precharge operation is completed, the main magnetic contactor will be turned ON and the PWM switching will begin. Step 3.1 Turn the RUN sequence signal ON. READY A FAULT V PROGRAM kW RST PRG ENT Step 4. The precharge operation starts.
Start and Adjustment Step 5. 5-7 Changing the DC Bus Voltage Reference Value The default value of the DC Bus Voltage Reference (U.000) is 750 V. This procedure assumes that the DC Bus Voltage Reference value is to be changed to 650 V. In the actual procedure, use the value of your application. Step 5.1 Press the PRG key. READY A FAULT V PROGRAM kW RST PRG ENT The operation panel is now in program mode, and the "PROGRAM" status LED is ON. The display shows "U.
5-8 Start and Adjustment Step 5.6 Press the PRG key. READY A FAULT V PROGRAM kW The display shows "U.---" indicating that the User parameters can be accessed. RST PRG ENT Step 5.7 Press the PRG key. READY A FAULT V PROGRAM kW RST PRG ENT Step 5.8 Press the key. READY A FAULT V PROGRAM kW RST PRG ENT Step 5.9 Press the The display shows the AC input power voltage and the "V" status LED turns ON. This display shows that the input power voltage is 412 V. key.
Start and Adjustment Step 7. 5-9 Disconnecting Power to the 8720MC-RPS Regenerative Power Supply As the final step, disconnect power to the 8720MC-RPS Regenerative Power Supply. Step 7.1 Disconnect input power. READY A FAULT V PROGRAM RST PRG ENT kW Power to the Regulator Board is turned OFF, and the display and the LEDs are turned OFF. But when you desire to touch the internal portion of the 8720MCRPS Regenerative Power Supply, pay extreme caution to the DC bus voltage which might be retained.
5-10 Start and Adjustment End of Chapter
Chapter 6 Operation Panel This chapter describes the configuration of operation panel and the operation modes. Configuration of the Operation Panel The operation panel is used for setting parameters, monitoring operating conditions and resetting faults. The figure below shows the configuration of the operation panel and the names of the components.
6-2 Operation Panel Monitor Mode Monitor mode is the operation mode to display operating conditions. The following data can be displayed in this mode: • Input current * • AC input power voltage • DC bus voltage • Power • Load ratio. * The displayed value of input current is only an approximate value and no accuracy can be guaranteed. If you need an accurate input current, measure it by using a dedicated measuring device.
Operation Panel 6-3 The following figure shows an example of display in monitor mode. The "PROGRAM" status LED will not turn ON. READY A FAULT V PROGRAM kW A status LED ( "A", "V" or "KW") will turn ON, corresponding to the selected monitor display. RST PRG ENT Program Mode Program mode allows you to display and modify parameter values, and to display the error log.
6-4 Keypad Operation Panel The keypad portion of the operation panel has five push-button switches that are used to select monitoring items, to set parameters and to reset faults. The UP ( used to: ) and DOWN ( ) arrow keys are • Select monitoring items in monitor mode. • Select parameters, and move through the error log in case of program mode. • Increase or decrease a numeric value when a parameter value is displayed. Holding down these keys will increase the scroll speed.
Operation Panel Status LEDs 6-5 The operation panel contains six LEDs that show the present status of the 8720MC-RPS Regenerative Power Supply. Each status LED has the following meaning. LED Status Meaning READY On PWM switching is being performed. Off PWM switching is not performed. On Fault occurred, or the error log is being displayed. Off Operation is normal. On The operation panel is in program mode. FAULT PROGRAM Off The operation panel is in monitor mode.
6-6 Operation Panel End of Chapter
Chapter 7 Parameters The parameters are used to define characteristics of the 8720MCRPS Regenerative Power Supply. To program the unit for a specific application, you display the appropriate parameter and adjust it as required. This chapter provides information on parameter types as well as detailed descriptions of each parameter. This chapter also describes how to access, display, and modify parameters.
7-2 Parameters • Parameter Description This is a description of the parameter's function. • Parameter Range This shows the predefined upper and lower limits of the parameter value. • Default Setting The parameters are initially set before shipping from the factory, and the default setting is such factory setting. • Parameter Type The parameter type identifies whether the parameter can be modified at any time, is protected by password, or cannot be modified during operation.
Parameters Protecting Parameters with Password 7-3 Factory parameter values are password protected using Parameter F.000 (Setting Password). But even after the password has been set, some Factory parameters cannot be modified. Such parameters must be set after operation stopped. Note that Parameter F.018 (Version Information) is a read-only parameter, and therefore, cannot be modified.
7-4 Parameters U.000 DC Bus Voltage Reference This parameter sets the DC bus voltage reference value. The 8720MC-RPS Regenerative Power Supply controls to maintain the DC bus voltage at the set value. Parameter Range: 275 to 750 V Default Setting: 700 V Parameter Type: Configurable only when the unit is normal Refer also to Parameters: U.001 U.002 F.005 F.007 F.
Parameters 7-5 Factory Parameters F.000 Password A password must be set to this parameter to change the Factory parameters. Parameter Range: 0 to 999 Default Setting: 0 Parameter Type: Configurable Refer also to Parameters: F.001 ! Unit Selection ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should change the Factory Parameters. Read and understand this instruction manual in its entirety before proceeding.
7-6 Parameters F.001 Unit Selection (Note 1) As the type of the 8720MC-RPS Regenerative Power Supply, this parameter sets a character code representing the input power supply voltage and the unit capacity. For most applications, it is recommended that this parameter not be adjusted. Note 1: This parameter is available from software version No. 3.00 (to be shown on the parameter F.018) or later only. Parameter Range: 027.b 054.b 081.b 065.b 130.b 195.b 190.b 380.b 570.
Parameters 7-7 F.002 Rated Current (Note 1) This parameter sets the rated input current of the 8720MC-RPS Regenerative Power Supply. In case of multiple units connected in parallel, the total current of the connected units must be set. For most applications, it is recommended that this parameter not be adjusted.
7-8 Parameters F.004 Current Control Integral Gain This parameter determines the dynamic characteristics of the current control. For most applications, it is recommended that this parameter not be adjusted. Parameter Range: 1 to 3,000 rad/sec Default Setting: 64 rad/sec Parameter Type: Requiring the password, configurable only when the unit is normal Refer also to Parameters: F.
Parameters ! 7-9 ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should change this parameter. Read and understand this instruction manual in its entirety before proceeding. Failure to change parameter values could result in destruction of the equipment, severe bodily injury or loss of life. F.008 Bus Low Voltage Detection Level This parameter sets the voltage level to detect the DC bus low voltage error.
7-10 Parameters F.010 Carrier Frequency (Note 1) This parameter sets the carrier frequency of the PWM switching. Parameter Range: 5 kHz, 10 kHz, or 15 kHz Default Setting: 10 kHz: For Model 8720MC-RPS027 and 8720MC-RPS065 5 kHz: For Model 8720MC-RPS190 Note 1: This parameter is available from software version 3.00 (to be shown on the parameter F.018) or later only. Parameter Type: Requiring the password, configurable only when the unit is normal Refer also to Parameters: F.
Parameters 7-11 F.013 AC Reactor Capacity (Note 1) This parameter sets the capacity of the AC reactor installed in the main power wiring. Note 1: This parameter is available from software version No. 3.00 (to be shown on the parameter F.
7-12 Parameters F.016 DC Bus Voltage Offset (Note 1) This parameter is used to compensate error of monitored DC bus voltage from actual value, by multiplying feedback value of DC bus voltage by offset (gain). Note 1: This parameter is available from software version No. 2.00 (to be shown on the parameter F.018) or later only. Parameter Range: 0.900 to 1.100 Default Setting: 1.000 Parameter Type: Requiring the password, configurable only while the unit is normal Refer also to Parameters: U.
Parameters F.018 Version Information This parameter displays the software version number. Parameter Range: N/A Default Setting: N/A Parameter Type: Read only Refer also to Parameters: N/A F.019 Selection of Wiring Error (LE) Detecting Function (Note 1) This parameter selects whether detecting function of wiring error (LE) during operation is used or not. When "On" is selected, existence of wiring error will be verified when operation is started.
7-14 Parameters End of Chapter
Chapter 8 Error Codes and Warning Buzzer This chapter describes contents of error codes and how to correct problems. When an error occurs in the 8720MC-RPS Regenerative Power Supply, an error code corresponding to the error is shown on the display. The error codes are two- or three-letter codes flashing on the display.
8-2 Error Codes and Warning Buzzer Contents of Error Codes and Recovering The error codes are shown in tables 8.A to 8.D. Table 8.A shows the error codes common to all units regardless of single unit connection or parallel connection of multiple units. Table 8.B shows the error codes caused by master unit (unit having Regulator Board) regardless of single unit connection or parallel connection of multiple units. Table 8.
Error Codes and Warning Buzzer 8-3 Error Code Error Description Error Cause Corrective Action IPL Input Phase Loss Error Phase loss occurred for the AC input power. Check the AC input power voltage and the line fuse. Power loss occurred (The allowable time for instantaneous power loss was exceeded.) Check that the set value of the Allowable Time for Instantaneous Power Loss (F.012) is adequate. If no other problem is found, increase the set value.
8-4 Error Codes and Warning Buzzer Table 8.C List of Error Codes Relating to Slave Units 1 Error Code Error Description Error Cause Corrective Action P.U2 Power Module Phase L1 Error The Phase L1 Power Module of the slave unit 1 is faulty. Check the wiring of the AC input power. Check the ambient temperature, the cooling fan, and the clearances around the unit. If the error occurs intermittently, contact the Allen-Bradley Company or replace the unit. PU.
Error Codes and Warning Buzzer 8-5 Table 8.D List of Error Codes Relating to Slave Units 2 Error Code Error Description Error Cause Corrective Action P.U3 Power Module Phase L1 Error The Phase L1 Power Module of the slave unit 2 is faulty. Check the wiring of the AC input power. Check the ambient temperature, the cooling fan, and the clearances around the unit. If the error occurs intermittently, contact the Allen-Bradley Company or replace the unit. PU.
8-6 Error Codes and Warning Buzzer Step 3. Press the ENT key. READY A FAULT V PROGRAM If there is no error that occurred, "0---" will be displayed. kW RST PRG ENT READY A FAULT V PROGRAM kW If there is any error that occurred, the last error that occurred will be displayed. RST PRG ENT Step 4. When the RST key is pressed while the error log is being displayed, all the entries of the error log will be cleared, and "Err" will be displayed again, indicating that the error log became empty.
Chapter 9 Inspecting Trouble and Recovering This chapter describes how to inspect troubles and take recovery actions. ! ! ! Safety Precautions ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate or service this equipment. Read and understand this instruction manual in its entirety before proceeding.
9-2 Inspecting Trouble and Recovering Preliminary Review 1. Turn OFF the input power to the 8720MC-RPS Regenerative Power Supply and wait until "POWER" lamp goes OFF. 2. Verify that the DC bus voltage is zero and the DC bus capacitors are completely discharged. 3. Check the following: • Check that no terminal is loose and that termination to the connectors is correct. • Check that the incoming power voltage is correct. • Check that the unit was installed correctly.
Inspecting Trouble and Recovering 9-3 DC Bus Voltage Does Not Go Up DC bus voltage does not go up. Wiring correct? NO Check the following: • Wiring to main power supply • Main magnetic contactor • Protection fuse NO The unit is defective. Replace the unit. NO Check the following parameters: • Unit Selection (F.000) • DC Bus Voltage Reference (U.000) • FWD Current Limit (U.001) • REV Current Limit (U.002) YES POWER lamp lights ON? YES Setting of parameters correct? YES The unit is defective.
9-4 Inspecting Trouble and Recovering End of Chapter
Chapter 10 Special Replacement Parts This chapter describes the required replacement parts. The table below lists the replacement parts. The figures shown in the table show required quantities of the corresponding parts. The standards or specifications of the parts in the table might be changed by integration or abolition of parts. If you need spare parts, contact The Allen-Bradley Company.
10-2 Special Replacement Parts Required Quantities Part Name Standards and Specifications Capacitor for EMC Filter Unit SME35LGSN 68000 Cooling Fan for ACL Unit 60-03177-00 REJ Part Number 8720MCRPS027BM 8720MCRPS065BM 8720MCRPS065BS 8720MCRPS190BM 8720MCRPS190BS 450071 0 0 0 2 2 926529 0 0 0 2 2 Decide the quantities of spare parts in consideration of the number of the connected units.
11 Chapter Outline Drawings of the Peripheral Devices This chapter provides dimensional outline drawings of reactors, varistors, harmonic filters, line filters and EMC filter unit out of the peripheral devices to be connected to the 8720MC-RPS Regenerative Power Supply. The figure below shows the dimensional outline drawing of the recommended reactors for Model 8720MC-RPS027BM, 8720MCRPS065BM and 8720MC-RPS065BS units. Outline Drawing of the Reactors G+/-2 F +/-1 B +1/-0.
Outline Drawings of the Peripheral Devices The figure below shows the dimensional outline drawing of the recommended ACL units (AC reactor assemblies, Model 8720MCLR10-100B) for Model 8720MC-RPS190BM and 8720MCRPS190BS units. 26.6 414 10 29 9 26.6 10 260 AIR FLOW 6 x R38-8 488 max. 467.2 80 80 75 80 75 38.6 L1 L4 L2 L5 L3 L6 L1 L4 L2 L5 L3 L6 R BL Y BRBR 217 38.6 Equivalent Circuit R BL Y BRBR 217 360 max.
Outline Drawings of the Peripheral Devices Outline Drawing of the Varistors The following figure shows the dimensional outline drawing of the varistors to be used for Model 8720MC-RPS027BM, 8720MCRPS065BM and 8720MC-RPS065BS units. 21 +/- 1 21 + 10 + (10.5) 48 +/- 1 Equivalent Circuit 5 (5.5) 11-3 φ4.2 +/- 0.15 33.5 +/- 1 4 25.
11-4 Outline Drawings of the Peripheral Devices The following figure shows the dimensional outline drawing of the recommended harmonic filters to be used for Model 8720MCRPS027BM, 8720MC-RPS065BM and 8720MC-RPS065BS units. Outline Drawing of the Harmonic Filters 35 +/- 1 35 +/- 1 17.5 +/-1.5 13+/-1.5 17.5 +/-1.5 22.5 +/- 1.5 N E 39 +/- 1.5 15 +/-0.5 T 65 +/- 1.5 2 Oval Holes of 5.5 mm x 8 mm S R 55 +/- 1.5 6 +/- 1 M5 Screw t1.5 40 +/- 1.5 105 +/- 1.5 119.5 +/- 1.5 131.5 +/- 1.5 t1.
Outline Drawings of the Peripheral Devices 11-5 For your reference, the following figure shows the dimensional outline drawing of the harmonic filter used for Model 8720MCRPS027BM, 8720MC-RPS065BM and 8720MC-RPS065BS units. 35 +/-1 35 +/-1 17.5 +/-1.5 13+/-1.5 17.5 +/-1.5 22.5 +/-1.5 4 Screws of M5 39 +/-1.5 15+/-0.5 W 65 +/-1.5 2 Oval Holes of 5.5 mm x 8 mm V U E t1.5 55 +/-1.5 6 +/-1 105 +/-1.5 119.5 +/-1.5 131.5 +/-1.5 t1.
11-6 Outline Drawings of the Peripheral Devices Outline Drawing of the Line Filters Figure 11.1 and 11.2 show the dimensional outline drawing of the recommended line filters for AC input power to be used for Model 8720MC-RPS027BM, 8720MC-RPS065BM and 8720MCRPS065BS units when these units must conform with the requirements of CE Mark. Figure 11.1 shows Schaffner's products and Figure 11.2 shows Soshin Electric's product. G F Figure 11.
Outline Drawings of the Peripheral Devices 11-7 Figure 11.
Outline Drawings of the Peripheral Devices 8720MC-EF190-VB EMC Filter Unit for Model 8720MCRPS190BM and 8720MC-RPS190BS Figure 11.3 shows the outline dimensions of Model 8720MCEF190-VB EMC filter unit for Model 8720MC-RPS190BM and 8720MC-RPS190BS units. The Model 8720MC-EF190-VB unit includes the varistor, magnetic contactor, harmonic filter, line filter, grounding capacitor, fan and MC interface card and cable assembly for this unit.
Outline Drawings of the Peripheral Devices 11-9 Figure 11.
11-10 Outline Drawings of the Peripheral Devices End of Chapter
Appendix A Technical Specifications Specifications for 8720MC Regenerative Power Supply Voltage Class Number of Units Connected in Parallel Model Number Output Input Capacity of Motor to be Applied (kW) Rated Capacity of Power Supply (kVA) Input Power Factor Power Supply Rated Current (Arms) Maximum Current (1 min.) (Arms) PWM Carrier Frequency (kHz) Rated Output Capacity (kVA) Voltage (V) Rated Current (A) Maximum Current (1 min.
A-2 Technical Specifications End of Appendix
B Appendix Default Parameter Settings Default Parameter Settings Depending on the Unit and Number of Units Connected in Parallel Unit Capacity 8720MC-RPS027 Parameter Number Parameter Name F.001 Unit Selection F.002 Rated Current F.013 F.015 Unit 8720MC-RPS065 8720MC-RPS065 Single Unit 2 Units in Single Unit Parallel 8720MC-RPS190 3 Units in Parallel Single Unit 2 Units in Parallel 3 Units in Parallel 130.b 195.b 190.b 380.b 570.b 130 195 190 380 570 027.b 065.
B-2 Default Parameter Settings Default Settings of All Parameters Parameter Name Setting Range Default Value U.000 DC Bus Voltage Reference 275 to 750 V 750 V U.001 FWD Current Limit 0 to 150% 150% U.002 REV Current Limit 0 to 150% 150% F.000 Password 0 to 999 0 F.001 Unit Selection 027.b 065.b 130.b 190.b 195.b 380.b 570.b 28 Amps 65 Amps 130 Amps 190 Amps 195 Amps 380 Amps 570 Amps F.002 Rated Current 027.b: 10 to 35Amps 065.b: 10 to 70 Amps 130.b: 20 to 140 Amps 190.
Appendix C Control Block Diagram d-Axis Current Reference (0) ＋ d-Axis Voltage Reference PI Calculation Limit ＋q-Axis Voltage Rotating Shaft/ Static Shaft Reference Conversion R-Phase Voltage F/B 3-Phase/ q-Axis Feedback d-Axis Feedback ωL Compensation (Non-interference Control) ＋ PI Calculation Limit ＋ Input Voltage Compensation Static Shaft/ Rotating Shaft Conversion T-Phase 2-Phase Voltage F/B Conversion AC Input Power Supply Voltage Since θ Phase θ Sine Table Cosine θ DC Bus Voltag
C-2 Control Block Diagram End of Appendix
Publication 8720MC-RM001C-US-P, Nov 01 © 2001 Rockwell International Corporation.
