On Tue, May 3, 2016, at 10:00 AM, andy pugh wrote:
> If there is no reason not to leave the pre-charge relay closed during
> operation, I could even use the existing mechanical relay that brings
> in the discharge resistor. Is there a reason to switch-out the
> precharge relay once the main contactor is closed? I guess the danger
> is that if the main contactor fails to operate the machine would run
> through the precharge resistor. Though I imagine that that would cause
> an easily-detected undervoltage fault in the drives.

You can certainly leave the pre-charge relay closed after closing the
bypass (main) contactor.

The vast majority of the AC drives on the market don't even have a
pre-charge contactor.  When power is applied, the bus immediately
charges thru the resistor.  The low voltage power supply for the 
electronics runs off the DC bus (great for power dip ride-thru.)  
Once the bus is up, the low-voltage power supply starts and the
microcontroller comes alive.  Then the micro-controller makes the
decision to close the bypass contactor.

If the bypass contactor opens during normal operation, the drive 
typically trips on low bus voltage.  Although the worst case situation
is a motor load that's not quite enough to drag the bus down to the
low bus trip point, but is high enough to cook the pre-charge resistor.
Pre-charge resistors are usually sized for intermittent duty, so they
need to be a type that fails safely under continuous overload (no
arcing or fire).  On large (expensive) drives we sometimes use an
auxiliary contact on the bypass contactor as an interlock.




-- 
  John Kasunich
  [email protected]

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