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Common DC-Bus

Common DC-Bus. Motion & Drives Training. DC-Bus Sharing Guide Lexium32 – Altivar32. Common DC-Bus. Preface:

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Common DC-Bus

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  1. Common DC-Bus Motion & Drives Training DC-Bus Sharing Guide Lexium32 – Altivar32

  2. Common DC-Bus Preface: This DC-Bus Sharing Guide is an extract and a summary of the training unit, called „DC-Bus Sharing Select & Connect Guide“ - referring to Lexium32 and Atlivar32. The complete training documents are available on the Schneider Electric Motion training database. Intention: This guide is created in order to show and summarize step by step the most important aspects and facts that are mandatory in case of DC-Bus sharing due to Lexium32/Altivar32 design and engineering concept. In addition there is an application note available (e.g. via pl@net): mna01m001en_atv32_lxm32_dc_bus_v1xx.pdf

  3. Common DC-Bus • Simple Diagram • Why “DC-Bus sharing” ? • Common DC-Bus Lexium32 • Summary – “Golden Rules” • Common DC-Bus Lexium32 & Altivar32 • Summary – “Golden Rules” • Common DC-Bus Lexium32 & 3rd party devices • Summary – “Golden Rules”

  4. Common DC-Bus DC-Bus - A simple diagram: The DC-Bus connection is on the mains side of the charge circuit, therefore every Lexium32 and Altivar32 drive uses it's own circuit.

  5. Common DC-Bus • Why „DC-Bus Sharing“ ? • A drive system requires energy for acceleration or constant movement. During deceleration, a motor acts as a generator. A considerable portion of the kinetic energy is re-generated as electrical energy. Since electrical energy can only be stored to a limited extent in a single drive, it uses a braking resistor to transform the excess energy into thermal energy. • Energy savings because of „energy balance“ • Opportunity of sharing internal breaking resistors and capacitors • Less space and heat in the electical cabinet (no external breaking resistors) • -> increasing of energy efficiency !! • Optimum situation is during anti-cyclical operation, i.e. one motor decelerates while another motor accelerates at the same time.

  6. Common DC-Bus • When „DC-Bus Sharing“ ? • Benefit if: • anti-cyclical operation (e.g.: winding – unwinding application) • no identical motion profiles or movements • high dynamic movements / speed / load • No Benefit if: • identical movements (all axis accelerate / decelerate at the same time) • low dynamic movements / speed / load • Note: • DC-Bus Sharing does not make sense in all applications !! Click for details: Click for details:

  7. Common DC-Bus Lexium32 – Lexium32 Lexium32 – Lexium32 Lexium32 – Altivar32 Lexium32 – ? (3rd party device) Back to main contents

  8. Common DC-BusLexium32 – Lexium32 DC-Bus sharing: Lexium32 – Lexium32 Back to main page

  9. Common DC-BusLexium32 – Lexium32 Basic considerations LXM32 – LXM32: Power supply: Single Phase Three Phase DC-Bus input Calculation nom. DC-Bus power Identical nom. Voltage ? Identical nom. Voltage ? Identical phases input ? Switch off Power mains monitoring Main Fuse : > 25 A < 25 A >32 A <32 A (summary of all devices) Upstream current > 25A / 32A ? Divide in groups Divide in groups Yes No DC-Bus Fuse : Max. 25/32A Max. 25 A Max. 32 A Done Done Done Back to main page

  10. Common DC-BusLexium32 – Lexium32 Main power supply: Single Phase Three Phase • Note: • Only drives with identical nominal voltages may be connected via a common DC bus. • Only drives with the same number of phases may be connected via a common DC bus. • Only connect the DC bus of: • three-phase drives and three-phase drives • or • single-phase drives and single-phase drives. • Single phase drives must be connected to the same mains phase. Don´t mix phases!! Back to main page

  11. Common DC-BusLexium32 – Lexium32 Main fuse restriction: NOTE: Single phase devices: max. upstream fuse 25A Three phase devices: max. upstream fuse 32A WHY ?? The internal interfaces/connectors are certified and validated for this max values. A higher Current could destroy and eventually burn the device ! CONCLUSION: Ensure that in any situation the connectors are fused with max 25A/32A - e.g. short circuit Back to main page

  12. I max = 25A Common DC-BusLexium32 – Lexium32 Single Phase Main fuse restriction: 25A LXM32 LXM32 LXM32 DC + DC - Back to main page

  13. 25A 25A 25A I max > 25A Common DC-BusLexium32 – Lexium32 Single Phase Main fuse restriction: 25A 25A 25A LXM32 LXM32 LXM32 DC + DC - Back to main page

  14. Common DC-BusLexium32 – Lexium32 Common main fuse: Single Phase Main circuit breaker (max 25A) (8,4A) (8,4A) (8,4A) LXM32 MD18M2 (1,0kW) LXM32 MD18M2 (1,0kW) LXM32 MD18M2 (1,0kW) (max.6A) (max.6A) (max.6A) DC + DC - Back to main page

  15. Common DC-BusLexium32 – Lexium32 Separate main fuses: Single Phase 25A 10A 10A 10A (8,4A) (8,4A) (8,4A) LXM32 MD18M2 (1,0kW) LXM32 MD18M2 (1,0kW) LXM32 MD18M2 (1,0kW) (max.6A) (max.6A) (max.6A) DC + DC - Back to main page

  16. Common DC-BusLexium32 – Lexium32 Separate main fuses: Single Phase 10A 10A 10A (8,4A) (8,4A) (8,4A) LXM32 MD18M2 (1,0kW) LXM32 MD18M2 (1,0kW) LXM32 MD18M2 (1,0kW) (max.6A) (max.6A) (max.6A) DC + DC - Back to main page

  17. Common DC-BusLexium32 – Lexium32 Power supply via DC-Bus: Basic consideration Power supply: DC-Bus input Compatible DC-Bus voltage 1/3 ~ Calculation nom. DC-Bus power Switch off Power mains monitoring Main Fuse : (summary of all devices) Upstream current > 25A / 32A ? Yes No DC-Bus Fuse : Max. 25/32A Done

  18. Common DC-BusLexium32 – Lexium32 Power supply via DC-Bus: Single Phase 10A 10A (8,4A) (8,4A) LXM32 MD18M2 (1,0kW) LXM32 MD18M2 (1,0kW) LXM32 MD18M2 (1,0kW) ?? kW ?? kW ?? kW DC + DC - Back to main page

  19. Pout.= * Uout * Iout *cos(phi) Common DC-BusLexium32 – Lexium32 Power supply via DC-Bus: Basic power calculation Theoretical power calculation (example based on 6A single phase drive): Pinput Poutput PDCbus= UDCbus * IDCbus S= UNom_in * INom__in Back to main page

  20. Common DC-BusLexium32 – Lexium32 Power supply via DC-Bus: Basic power calculation Theoretical power calculation (example based on 6A single phase drive): S= 1,93 kVA (referring to 1kW nominal power) S= 230V * 8,4A (apparent power) Pout = Uout * * Iout *cos(phi) PoutMax= 2,1 kW (referring to max. cont. current) PoutMax = 230V * * 6A *cos(phi) Data sheet Lexium32 – e.g. LXM32xD18M2: Nominal power (without mains reactors) Pnom = 1,0 kW Limitation due to the engineering of rectifier package („input circle“) – in general usage a higher nominal power isn´t practicable. The IGBT´s are able to manage higher power. Please refer to the speed-torque curves…. Back to main page

  21. Common DC-BusLexium32 – Lexium32 Power supply via DC-Bus: Basic power calculation Data sheet Lexium32 – e.g. LXM32xD18M2: Nominal power (with mains reactors) Pnom = 1,6 kW Due to inductance influence of mains reactors the mains current RMS is decreased – there are less peaks to damage the rectifier unit. With this smoothed current a higher (average) power is possible. Back to main page

  22. Common DC-BusLexium32 – Lexium32 Power supply via DC-Bus: example: Lex32xD18M2, BMH100T Back to main page

  23. Common DC-BusLexium32 – Lexium32 Power supply via DC-Bus: example: Lex32xD18M2, BMH100T Back to main page

  24. * M P = IDC = = = 2,4 A IMot = = = 3,6 A Common DC-BusLexium32 – Lexium32 Power supply via DC-Bus: example: Lex32xD18M2, BMH100T P[W] = [Nm/s] * 2,5Nm 785,4 Nm/s 0,78 kW P = = = Iloadmax < 3,6 A (IDCmaxcont = 6A) Torque constant kt = 0,69 [Nm/A] Iload IDC IMot Back to main page

  25. n = IDC = = = 1,35 A 0,44 kW 0,78 kW 0,78 kW Common DC-BusLexium32 – Lexium32 Power supply via DC-Bus: example: Lex32xD18M2, BMH100T = 1680 rpm = 3 2 1 Conclusion for this example: If the average power of each unit 1&2 is 0,78 kW the unit 3 can be operated via DC-Bus in case of its average power is equal or less than 0,44 kW (<= 1680 rpm). A higher (average) power would overload the units 1&2 and thus will finally cause damages due to thermal influences. Back to main page

  26. Common DC-BusLexium32 – Lexium32 Accessories – external braking resistor: NOTE: If devices with a different nominal power are connected via the DC bus, you must connect braking resistors to the drive with the greatest nominal power. (25A) Single Phase (8,4A) (4,5A) (2,9A) LXM32 MD18M2 (1,0kW) LXM32 MU90M2 (0,5kW) LXM32 MU45M2 (0,2kW) ext. braking resistor Click for details: ? Ohm ? W Rating of external Resistor ? (max.6A) (max.3,2A) (max.1,5A) DC + DC - Back to main page

  27. Common DC-BusLexium32 – Lexium32 Accessories – external braking resistor: NOTE: Choose parameter „internal braking resistor“ (default setting) for devices that are not connected to an external braking resistor ! Back to main page

  28. Common DC-BusLexium32 – Lexium32 Summary – “Golden Rules” (LXM32 – LXM32): • Connect only devices with identical nominal voltages • Connect only devices with identical number of phases • Single phase / single phase -> don´t mix mains phases • Three phase / three phase • No restriction of connecting different sizes of nominal power and/or power stages • Max. main fuse: • Single phase -> 25 A • Three phase -> 32 A • No DC-Bus fuses mandatory if: • Single phase: summary of current all devices < 25 A (common main fuse) • Three phase: summary of current all devices < 32 A (common main fuse) • If DC-Bus fuses mandatory, max value: • Single phase: 25 A • Three phase: 32 A • If power supply via DC-Bus • calculate nominal DC-Bus power referring to all connected devices • deactivate power mains monitoring choose fuse according to device output Back to main page

  29. Common DC-BusLexium32 – Lexium32 Summary – “Golden Rules” (LXM32 – LXM32): • Max. DC-Bus cable length between 2 devices < 3m • no further restriction referring to complete dc-bus-connection cable length of all devices • In case of using an external braking resistor(s): • connect to the Lexium32 with greatest nominal power • check and edit min/max resistor values and max continuous power due to the unit • set parameter „RES_int_ext“ to „external“ • set parameter of the other devices „RES_int_ext“ to „internal“ (default setting) • Using mains reactor(s) means: • increase output power – see data sheet in manual… • reduction of current harmonics Back to main page

  30. Common DC-BusLexium32 – Altivar32 DC-Bus sharing: Lexium32 – Altivar32 Back to main page

  31. Common DC-BusLexium32 – Altivar32 Basic considerations LXM32 – ATV32: Power supply: Single Phase Main Fuse : > 25 A < 25 A (summary of all devices) Identical nom. Voltage ? Divide in groups Identical phases input ? DC-Bus Fuse : Size power stage(s) ? Max. 25 A Compatibility parameter ATV - LXM Done Back to main page

  32. Common DC-BusLexium32 – Altivar32 Basic considerations LXM32 – ATV32: Power supply: Three Phase Main Fuse : > 32 A < 32 A (summary of all devices) Identical nom. Voltage ? Divide in groups Identical phases input ? DC-Bus Fuse : Size power stage(s) ? Max. 32 A Compatibility parameter ATV - LXM Done Back to main page

  33. Common DC-BusLexium32 – Altivar32 Basic considerations LXM32 – ATV32: Power supply: DC-Bus input Calculation nom. DC-Bus power Size power stage(s) ? Switch off Power mains monitoring Switch on Compatibility Parameter ATV/LXM Main Fuse : Upstream current > 25A / 32A ? (summary of all devices) Yes No DC-Bus Fuse : Max. 25/32A (summary of all devices) Done Back to main page

  34. Common DC-BusLexium32 – Altivar32 Power stages / power modules LXM32 – ATV32: • For connecting LXM32 and ATV32 to a common DC-Bus it´s mandatory to check internal • data of power modules. For this combination the rules are: • Power module of ATV max. 1 size smaller than LXM32 power module • Power module of ATV may be stronger (> 1 size) than LXM32 power module • What does it mean – different size of power stage / power module ??? • Is the size of power stage similar to the size of power module ?? Back to main page

  35. Common DC-BusLexium32 – Altivar32 Power stages / power modules LXM32 – ATV32: Single phase drive data: Back to main page

  36. Common DC-BusLexium32 – Altivar32 Power stages / power modules LXM32 – ATV32: In concequence the following combinations for common DC-Bus are possible due to drive data of single phase devices: Back to main page

  37. Common DC-BusLexium32 – Altivar32 Power stages / power modules LXM32 – ATV32: Three phase drive data: Back to main page

  38. Common DC-BusLexium32 – Altivar32 Power stages / power modules LXM32 – ATV32: In concequence the following combinations for common DC-Bus are possible due to drive data of three phase devices: Back to main page

  39. Common DC-BusLexium32 – Altivar32 Main power supply: Single Phase Three Phase • Note: • Only drives with identical nominal voltages may be connected via a common DC bus. • Only drives with the same number of phases may be connected via a common DC bus. • Only connect the DC bus of: • three-phase drives and three-phase drives • or • single-phase drives and single-phase drives. • Single phase drives must be connected to the same mains phase. Don´t mix phases!! Back to main page

  40. Common DC-BusLexium32 – Altivar32 Common main fuse: Single Phase Main circuit breaker (max 25A) LXM/ATV LXM/ATV LXM/ATV DC + DC - Back to main page

  41. Common DC-BusLexium32 – Altivar32 Separate main fuses: Single Phase 25A 10A 10A 10A LXM/ATV LXM/ATV LXM/ATV DC + DC - Back to main page

  42. Common DC-BusLexium32 – Altivar32 Separate main fuses: Single Phase 10A 10A 10A LXM/ATV LXM/ATV LXM/ATV DC + DC - Back to main page

  43. Common DC-BusLexium32 – Altivar32 Power supply via DC-Bus: Single Phase 10A 10A (8,4A) (8,4A) LXM32 MD18M2 (1,0kW) LXM32 MD18M2 (1,0kW) ATV32 ?? kW ??kW ?? kW DC + DC - Back to main page

  44. Common DC-BusLexium32 – Altivar32 Power supply via DC-Bus: Single Phase Remaining average Power depending on the devices… 10A 10A (8,4A) (8,4A) LXM32 MD18M2 (1,0kW) LXM32 MD18M2 (1,0kW) ATV32 11M2/ 15M2 or 22M2 Calculated average Power depending on motion profile (similar example like before)… 0,78 kW 0,78 kW max. 0,44 kW DC + DC - Back to main page

  45. Common DC-BusLexium32 – Altivar32 Power supply via DC-Bus: Single Phase ATV32 HU15M2 (1,5kW) ATV32 HU15M2 (1,5kW) LXM32 ?? kW ??kW ?? kW DC + DC - Back to main page

  46. Common DC-BusLexium32 – Altivar32 Power supply via DC-Bus: Single Phase Remaining average Power depending on the devices… ATV32 HU15M2 (1,5kW) ATV32 HU15M2 (1,5kW) LXM32 U45M2/ U90M2/ D18M2 Calculated average Power depending on motion profile … 1 kW 1kW max. 1 kW DC + DC - Back to main page

  47. Common DC-BusLexium32 – Altivar32 Accessories – external braking resistor: NOTE: If ATV32 and LXM32 are connected via DC-Bus, an external braking resistor must be connected to the LXM with the greatest nominal power. If devices with a different nominal power are connected via the DC bus, you must connect braking resistors to the drive with the greatest nominal power. Click for Details: Rating of external Resistor ? Back to main page

  48. Common DC-BusLexium32 – Altivar32 Summary – “Golden Rules” (LXM32 – ATV32): • Switch on compatibility param LXM32/ATV32 „DCbus_compat“ /dCCC [DC-Bus compat.] • Connect only devices with identical number of phases and identical nominal voltages • Single phase / single phase -> don´t mix mains phases • Three phase / three phase • Restriction for different device power ratings: • Power module of ATV max. 1 size smaller than LXM32 power module • Power module of ATV may be stronger (> 1 size) than LXM32 power module • Max. main fuse: • Single phase -> 25 A • Three phase -> 32 A • No DC-Bus fuses mandatory if: • Single phase: summary of current all devices < 25 A (common main fuse) • Three phase: summary of current all devices < 32 A (common main fuse) • If DC-Bus fuses mandatory, max value: • Single phase: 25 A • Three phase: 32 A choose fuse according to device output Back to main page

  49. Common DC-BusLexium32 – Altivar32 Summary – “Golden Rules” (LXM32 – ATV32): • Max. DC-Bus cable length between 2 devices < 3m • no further restriction referring to complete dc-bus-connection cable length of all devices • For ATV32D11N4 and ATV32D15N4 DC-Bus fuses are mandatory in any case !! • Attention: max. allowed wire cross section of DC-Bus cable in combination with LXM32 is 6mm² • If power supply via DC-Bus • calculate nominal DC-Bus power referring to all connected devices • deactivate power mains monitoring • In case of using an external braking resistor(s): • connect to the Lexium32 with greatest nominal power • check and edit min/max resistor values and max continuous power due to the unit • set parameter „RES_int_ext“ to „external“ • set parameter of the other devices „RES_int_ext“ to „internal“ (default setting) Back to main page

  50. Common DC-BusLexium32 – 3rd party devices DC-Bus sharing: Lexium32 – 3rd party devices Back to main page

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