Rockwell Automation 1395 User Manual
Bulletin 1395
Digital DC Drive
User
in Bulletin 2361
Motor Control Centers for
Drive Systems
1250, 1650, 3000A DC
Series C
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 Cont rols”
(Publication SGI-1.1) describes some important differences between
solid-state equi pment 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 th emse lves that e ach inte nded appl ication
of this equipment is acceptable .
In no event will Rockwell Automation be responsible or liable for
indirect or consequential damages resulting from the use of
application of this equipment.
The examples and diagrams in this manual are included solely for
illustrati ve purpose s. Bec ause of th e many var iable s and requi rements
associated with any partic ular installation, the Rockwell Automation
cannot assume responsibility or liability for actua l use based on the
examples and diagrams.
No patent liability is assumed by Rockwell Automation with respect
use of information, circu its, 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 is prohibit ed.
Throughout this manual we use notes to make you aware of safety
consideration s:
ATTENTION: Identifies infor mation about practi ces
or circumstances that can lead to personal injury or
!
Attention statements help you to:
• identify a hazard
• avoid a hazard
• recognize the consequences
Datab is a trademark of W . H. Brady Company
CENTERLINE, PLC-5, DriveT ools, and ControlNet are trad emarks of Rockwell International or its
subsidiaries.
death, property damage or economic loss.
Table of Contents
Preface Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Style of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Terms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Receiving Your Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . P-6
Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-6
Technical Product Assistance . . . . . . . . . . . . . . . . . . . . . . . . . P-6
Chapter 1 Product Overview
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Standard Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hardware Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Control Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Door-Mounted Programming Terminal . . . . . . . . . . . . . . . . . . 1-6
Adapter Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Control/Power Interface Boards . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Power Stage Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Unit Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Feedback Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
24V DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Gate Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Power Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Incoming Power Components . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Incoming Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
AC Input Busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Main Disconnect (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 1-12
AC Line Fuses (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Control and Field Power . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
AC Line RC Suppressor (Optional) . . . . . . . . . . . . . . . . . . . 1-13
Publicatio n 2361-5.01 July 1998
toc–ii Table of Contents
Armature Power Components . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Armature Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
DC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Field Power Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Field Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Field-Pulse Transformer Board . . . . . . . . . . . . . . . . . . . . . 1-18
Chapter 2 Your 1250A DC Drive
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Drive Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Drive Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Symbol Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Drive Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Chapter 3 Your 1650A DC Drive
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Drive Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Drive Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Symbol Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Drive Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Chapter 4 Your 3000A DC Drive
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Drive Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Drive Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Symbol Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Drive Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Publicatio n 2361-5.01 July 1998
Chapter 5 Installing Your Drive
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Physically Installing the Drive at Your Site . . . . . . . . . . . . . . . . . 5-2
Inspecting the Air Baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Preparing AC Input Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Installing and Configuring Your Drive . . . . . . . . . . . . . . . . . . . . . 5-4
Drive Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Wiring Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Drive Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Field Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Installing the Field Transformer . . . . . . . . . . . . . . . . . . . . . . 5-7
Circuit Board Jumper Connections . . . . . . . . . . . . . . . . . . . . . 5-9
Armature Current Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Chapter 6 Starting Up Your Drive
Table of Contents toc–iii
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Voltage Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Rated Armature and Field Currents . . . . . . . . . . . . . . . . . . . . . . . 6-2
Appendix A Drive Specifications
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Power Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Circuit Breaker Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Circuit Breaker Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Input Busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Air Baffle Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
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toc–iv Table of Contents
Appendix B Catalog Numbers and Spare Parts Kits
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Understanding Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . B-1
Determining Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . B-1
DC Drive Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
DC Drive Spare Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
What Does a Spare Parts Kit Include? . . . . . . . . . . . . . . . . . . . B-6
Which Table Do I Use? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Significance of Level Numbers . . . . . . . . . . . . . . . . . . . . . . . . B-6
Definition of Terms Used to Describe "Qty in Kit" . . . . . . . . . . B-7
Catalog Number Description . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Publicatio n 2361-5.01 July 1998
Preface
Preface
Contents This preface w ill introduce you to the contents and purpose of this
manual. The following topics will be discussed in this preface:
Topic Pa ge
Who Should Use This Manual P-1
Purpose of This Manual P-1
Safety Precautions P-2
Contents of This Manual P-3
Related Documentation P-4
Style of This Manual P-5
Terms and Abbreviations P-5
Receiving Your Drive System P-5
Rockwell Automation Support P-6
Who Should Use This Manual This manual is intende d for those who are re sponsible for instal ling or
operating a Rockwell Automation high-horsepower 1395 drive.
If you do not have a basic understanding of this unit, please refer to
the drive documentation, or contact your local Rockwell Automation
Drive Systems representative for more information before using this
product.
Purpose of This Manual This manual is a supplement to Publication 1395-5.40, titled 1395
Digital DC Drive–User Manual. This manual will cove r:
• hardwa re ove rv ie ws
• specifications
• installation instructions
• configuration and setup information
• spare parts
Publicatio n 2361-5.01 July 1998
P-2
Safety Precautions The following general precautions apply to Bulletin 2361 drive
system lineups:
ATTENTION: Only those familiar with the drive
system, the products used in the system, and the
!
associated machinery should plan or implement the
installation, startup, and future maintenance of the
system. Failure to comply can result in personal injury
and/or equipment damage.
ATTENTION: Verify that all sources of AC and DC
power are deenergized and locked out or tagged out in
accordance with the requirements of ANSI/NFPA 70E,
Part II.
ATTENTION: The system may contain stored ener gy
devices. To avoid the hazard of electric al shock, ve rify
that all voltage on capacitors has b een discharge d before
attempting to service, repair, or remove a drive system
or its components. You shou ld only at tempt the
procedures in this manual if you are qualified to do so
and are familiar with solid-state control equipment a nd
the safety procedures in ANSI/NFPA 70E.
ATTENTION: An incorrectly applied o r incorrectly
installed drive sys tem can result in component damage
and/or a reduction in product life . Wiring or applicati on
errors–such as undersizing the motor, incorrect or
inadequate AC supply, and excessive ambient
temperatures–can r esult in the malfunction of hte drive
equipment.
A TTENTION: This dr ive system contains parts and
assemblies that are sensitive to ESD (electrostatic
discharge). Sta tic control precautions are requir ed when
installing, testing, or repairing this assembly.
Component damage can r esult if ESD cont rol procedures
are not followed. If you are not familiar with static
control procedures, refe r to Rockwell Automation
publication 8000-4. 5.2, Guar ding Agains t Electrost atic
Damage, or another adequate handbook on ESD
protection.
Publicatio n 2361-5.01 July 1998
Contents of this Manual
Chapter Title Contents
Preface Purpose, background, and scope of this manual
1 Product Overview Theory of operation, features, and standard options
2 Your 1250A DC Drive Features, components, and schematics of the 1250A drive (R-frame)
3 Your 1650A DC Drive Features, components, and schematics of the 1650A drive (S-frame)
4 Your 3000A DC Drive Features, components, and schematics of the 3000A drive (T-frame)
5 Installing Your Drive Installation procedures and connection details
6 Starting Up Your Drive Information for starting up your drive
A Drive Specifications Electrical, environmental, and operational specifications
P-3
B Catalog Numbers and Spare Parts Kits Explanation of catalog numbers and listings of spare part kits
Publicatio n 2361-5.01 July 1998
P-4
Related Documentation Several of the f ollowing documents will be needed to understa nd and
install your drive and its components. To obtain a copy of any
Rockwell Automation publication, please contact your local
Rockwell Automation office or distributor.
For Read This Document Document Number
Information on the 1395 digital DC drives Bulletin 1395 Digital DC Drive–User Manual 1395-5.40
Troubleshooting information for 1395 drives Bulletin 1395 Digital DC Drive–Troubleshooting
Manual
Using the Bulletin 1300 programming terminal Bulletin 1300 Programming Terminal–User Manual 1300-5.5
PLC-5™ information PLC-5 Controllers Brochure 1785-1.2
Additional Information on joining and splicing
together MCCs
Details on receiving, handling, and storing
MCCs
Provides procedures for those tasks that need
to be done at the customer’s site before system
start up
Information and installation instructions for the
1395 Node Adapter Board
Information and installation instructions for the
1395 Discrete Adapter Board
Information and installation instructions for the
1395 ControlNet Communication Board
Information and installation instructions for the
1395 Multi-Communication Board
Information and installation instructions for the
1395 Digital Reference Adapter Board
A description of DriveTools™ software DriveTools Software Brochure 9303-1.0
Information on FD86N enclosures FD86N Drive Systems Enclosure Hardware–
Standards for electrical procedures (wiring
sizes, grounding, etc.)
An article on safety procedures Standard for Electrical Safety Requirements for
A complete listing of current documentation,
including ordering instructions. Also indicates
whether the documents are available on CDROM or in multi-languages
A glossary of industrial automation terms and
abbreviations
Joining and Splicing Vertical Sections–Instructions 2100-5.1
Receiving, Handling, and Storing Motor Control
Centers–Instructions
Bulletin 2300 Installation Manual 2300-5.1
Bulletin 1395 Node Adapter Board–Installation and
Operation Manual
1395 Discrete Adapter Board–Installation and
Operation Manual
Bulletin 1395 ControlNet Communication Board–
User Manual
Bulletin 1395 Multi-Communication
Board–Hardware/Software Reference Manual
Bulletin 1395 Digital Reference Adapter
Board–Hardware/Software Reference Manual
Installation Manual
National Electrical Code
(Published by the National Fire Protection
Association of Boston, MA)
Employee Workplaces
Allen-Bradley Publication Index SD499
Industrial Automation Glossary AG-7.1
1395-5.45
2100-5.5
1395-5.9
1395-5.12
1395-5.37
1395-5.33
1395-5.55
S-3062
ANSI / NFPA 70
ANSI / NFPA 70E
Publicatio n 2361-5.01 July 1998
Style of this Manual The following conventio ns are used throughout this m anual:
• ‘ATTENTION’ statements, preceded with the symbol shown,
indicate a circumstanc e that could could lead to personal injury,
!
death, damage to property, or economic loss
• ‘Important’ statements i ndicate key infor matio n for suc cessful ly
performing procedures and understanding the product
P-5
&
• Reference statements, preceded with the symbol shown, lead you
to other resou rces o f info rm ation and instruction
• Horsepower ratings are pr ovided at the start of each drive chapter
• Schematic and layout component abbreviations are explained in
component reference charts in each drive chapter
Terms and Abbreviations The following terms and abbrevia tions are used in this manual:
Term Definition
armature rotating part of a motor
bridge assembly for power (AC/DC) conversion
busbar a large tin-plated copper conductor, used for high-power input and output
feedback status signals/voltages sent from components or external devices
gate an electrical switch
MCC motor control center, an enclosure for drive systems
MOV metal-oxide varistor, used for voltage spike protection
SCR silicon-controlled rectifier, used in power conversion
snubber a resistor/capacitor assembly, used for limiting excess voltage
Receiving Your Drive System You, the Customer, are responsible for thoroughly inspecting the
equipment before accepting the shipment f rom the freight company.
Check the item(s) that you receive against your purchase order. If
any items are obviously damaged, do not accept the delivery until the
freight age nt has noted the damage on the freight bill. Should you
discover any concealed damage during unpacking, you are
responsible for notifying the freight agent. In such a case, leave the
shipping container intact and request that the freight agent make a
visual inspec tion of the equipment.
Publication 2361-5.01 July 1998
P-6
Rockwell Automation Support Rockwell Automation offers support services worldwide, with Sales/
Support Office s, a uthorized distributors, and authorized Systems
Integrators loc ated throughout the United States, plus Rockwell
Automation representa tives in every major country in the world.
Local Product Support
Please contac t your local Rockwell Automation representative for:
• sales and order support
• product technical training
• warranty suppor t
• support service agreements
Technical Product Assistance
If you need to contact us for tec hnical assistance, please review the
product and troubleshooting information in this manual first.
For the quickest possible response, please have the catalog num bers
of your products ready when you call.
Publication 2361-5.01 July 1998
Chapter
Product Overview
Contents The high-horsepower lin e of 1395 DC drives are Bull etin 1395
regulator product s, with a high-horsepower silicon-controlled
rectifier (S CR) bridge, packaged in a Bulleti n 2361 C ENTERLINE™
motor control center, providing DC power for your high-horsepower
applications.
This first chapter wil l intr oduce you to the high-horsepower Bulletin
1395 drive c overing these topics:
To pi c Pa ge
Standard Features 1-1
Standard Options 1-2
Hardware Overview 1-3
Control Components 1-4
Control/Power Interface Components 1-7
Power Components 1-12
1
Standard Features The high-horsepower Bulletin 1395 drive includes the following
standard features:
• NEMA Class I construction
• High AIC insta ntaneous trip circuit breaker or line fuses for the
AC input, arm ature cell fuses, a nd a DC output contactor
• a six pulse, full-wave rectified armature converter
• 43A single-phase fiel d regula tor
• regenerative (12 50, 1650, and 3000A) or non-regenerative (1250
and 1650A units only)
• 6:1 constant horsepower range
• digital control for cu rre nt, velocity, and configuration
• auto tuning for velocity loop, current loop, field flux table
Publication 2361-5.01 July 1998
1-2 Product Overview
• programmable functions ( independent acceleration/deceleration
adjustment, preset speeds, current limit, tapered current limit,
tach loss recovery, system reset)
• protective featur es (instantaneous overc urrent, motor overload ,
feedback loss, field loss, field economy, tach loss recovery,
system reset)
• CENTERLINE Bulletin 2361 Motor Control Center enclosure
Standard Options The following options are available for the high-horsepower 1395
drives:
• 115V AC discret e adapter board
• 24V DC discrete adapter board
• node adapter board
• multi-communications adapter board
• door-mounted DHT or EHT programming terminal
• ‘start/running’ and ‘clear fault/drive faulted’ door- mounted
illuminated pushbuttons
• ‘drive stop’, ‘hardwired stop’, ‘jog forward’, and ‘jog reverse’
door-mounted pushbuttons
• ‘power on’ door-mounte d pilot light
• door-mounted speed potentiometer
• 1-2-3 speed selector
• blower starter (NEMA, IEC)
• 90A single-phase fiel d regula tor
• control circ uit transformer
• top-hat input enclos ure (s tandard for 3000A drive)
• line RC suppressor
• AC power thru bus
Note: Additional options are listed in Appendix B.
Publication 2361-5.01 July 1998
Product Overview 1-3
Hardware Overview The hardware components shown in form the high-horsepower 1395
DC drive. These drive components can be broken down into the
following three categor ies:
Hardware Description
Control Controls the drive system and interfaces with external devices
Control/Power Interface Interfaces the control components with the power components
Power Converts AC input to a DC supply for the motor
Figure 1.1
Drive Components
3-Phase AC Power
Circuit Breaker
Field Transformer
(Only Used For AC Inputs of
575 and 660 V AC)
J7 J6
Main Control Board
J4 J1
Programming
Terminal
DHT/DMT
TB3
Control
Transformer
Unit
Power Supply
J1
J7
J5
J8
24V DC
Feedback
Power Supply
J2
Feedback Board
J40
Power Stage
Fuses
AC Line Voltage Feedback
Armature Current Feedback
Field Current Feedback
Armature DC Voltage Feedback
Interface Board
J2
J9
J6
J3A
J3D
-
Gate
Interface
Board
Armature
Pulse
Transformer
Boards
Encoder Feedback
Encoder
3-Phase
SCR Armature
Bridge
-
Motor
Armature
F1 F2 F3 F4
+
M1
A1A2
MOVs
TB8
Single-Phase
SCR Field
Bridge
TB7
Field PT &
Snubber
J1
CONTROL CONTROL/POWER INTERFACE POWER
Publication 2361-5.01 July 1998
1-4 Product Overview
Control Boards The control boards mana ge and control the system, processing status
information from syste m components a nd commanding drive
components and activit ies .
Figure 1.2
Control Boards
Main Control Board Adapter Boards
CH1
FCT
F14 F 15
Feedback Board
Main C ontrol
Board
Feedback Board
Main Control Board
(behind adapter boards)
Discrete or
Digital
Reference
Adapter Board
(Port A )
O
PTIONAL
Communication
Adapter Board
(Port B )
O
PTIONAL
MP
24V DC Supply
Publication 2361-5.01 July 1998
Product Overview 1-5
Main Control Board
The main control board is the center of the control pr ocessing. This
board has a number of test points and jumpers that are us ed during
startup and troubleshooting. Refer to the troubleshooting manua l for
more information on test point s and jumpers.
Figure 1.3
Main Control Board
J2 J4 J5
Connection
To
Encoder
TP42
TP50
Connection to Power
Stag e Interface Board
TP2 TP5
TP13
TP12
TP11
TP15
TP23
TP32
TP35
VP
1 2 3
1 2 3
1 2 3
J10
J9
J8
Connection to
Programm ing Terminal
TP9 TP6
TP24
TP8 TP3 9TP17
TP25
TP33
TP21
TP34
TP43
TP1
Connection to Power
Stage Interface Board
TP27 TP26
TP31 TP29
TP30TP38
CP
TP28
TP41
TP20
TP19
TP10
J7
Port A
(To Adapter Board)
SP
TP45
TP46
J6
TP47
TP44
TP20
TP49
1
2
3
TP54
ISO+12V
TP52
TP56
TP51
DGND
-12V
+5V
Port B
(To Adapter Board)
TP58
J14
TP55
+12V
TP53
IGN D
TP58
ISO +5 V
TP57
AGND
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1-6 Product Overview
Door-Mounted Programming Terminal
The door-mounted Bul letin 1300 programming terminal is the
interface m odule used to program and control the drive (typically
used in standalone applic ations). This terminal has an LCD screen
and a 24-key environment-sa fe keyp ad.
Adapter Boards
Optional adapter boards (such as the discrete a dapter board, digital
reference adapter board, node adapter board, and multicommunication adapter boa rd) connect the drive to networks and
provide I/O capabili ties.
&
Adapter board and programming terminal publications are listed in
the preface o f this manual. Please refer to the appropriate manuals for
more information.
Publication 2361-5.01 July 1998
Product Overview 1-7
Control/Power Interface Boards Control/power interface boards are used to provide a link between
control boards (which are responsible for managing the drive), and
power components ( which ar e clos ely assoc iated wit h the actua l drive
hardware and operations).
The following items are used to provide this interfacing:
• power stage int erfa ce b o ard
• unit power supply board
• feedback board
These items a re located on the control module in the disconnect bay
of the drive, and are arranged as shown below. Accessibility to the
power stage interface board and the unit powe r supply is gained by
lowering the front panel.
Figure 1.4
Control/Power Interface Boards
Feedback Board
Alternate Field Bridge
Configuration
Field Pulse Transformer
and Snubber Board
CH1
43A Field
FCT
F16
F14
F15
F4
F20
F21
J9
Bridge
FAN 4
24V DC Supply
12345 789
MP
TB1
Power Stage
Interface Board
2MOV
3MOV
Gate Interface
Board
10
CH1
Option 14FX
Field Bridge
FCT
FAN 4
2MOV
3MOV
Unit Power Supply
Board
Publication 2361-5.01 July 1998
1-8 Product Overview
Power Stage Interface Board
The power stage int erface boar d is used as the c hief interfac e between
the main control board and other boards of the system. This board is
responsible f or distributing power and control signals to and from the
main control board, gate interface board, field-pulse transform er
board, feedback board, and unit power supply. Refer to Figure 1.1 to
see how this board is connected in the drive.
Figure 1.5
Power Stage Interface Board
Connection to Unit Power
Supply and TE
J8 J9
Connection to M ain Control Board Connection to M ain Control Board
Connection to
Field Transformer
TP1
(+24V)
J3D
TP8
TP7
TP6
TP5
(-12V)
(Gnd )
(+12V)
(+5V)
TB1
J2J6
Connection to
Feedback Board
J3C J3B J3A
Connections to
Gate Interface Board
Connection to
Main Cont actor , Pilot Re lay,
and Unit Power Supply
TP2
TP3
J1
J11
J12
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&
J7
Connection to
Un it Pow er S upp ly
TP9
Connected to T B3
(Standard Interface)
J10
The test points and jumpers shown in the diagra m are used for startup
and troubleshooting pr ocedures. Refer to the troubles hooti ng manual
for more information on test poin ts and jumpers.
Product Overview 1-9
The power stage interface boa rd provide s the following services
between the main control board and othe r boar ds in the system:
• furnishes DC control power to the main cont ro l board (from the
unit power supply)
• provides 3-phas e li ne synchronization signals to the main c ontrol
board
• accepts signals from the main cont r ol board and produces the
logic and drivers for armature and f ield-pulse transformers
• accepts signals f or start/stop logic, protection I/O, and drivers for
operating the main DC contactor
Unit Power Supply Board
The unit power supply board convert s 115V AC input into regulated
+5V DC and ±12V DC control voltages. These control vol tages are
routed through the power stage interfa ce board to provide power to all
the printed circuit boards.
Figure 1.6
Unit Power Supply Board
Connection to Power
Stage Interface Board
(+5V and ±12V)
F1
J1
Connection to Power
1
Stage Interface Board
2
3
(115V AC)
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1-10 Product Overview
Feedback Board
The feedback board receives sta tus information from the drive
components, scales it to a signal le vel, and supplies it to the main
control board (through the power stage interface board).
Figure 1.7
Feedback Board
TB1
(1) (2) (3) (4)
Jumper Connection
(Field Current)
150 VAC
TO
300 VAC
AB
576VAC
690VAC
150 VAC
TO
TO
300 VAC
TO
575VAC
690VAC
TO
301VAC
TO
575VAC
576VAC
301VAC
J40
To Pow er Stage
Interface Board
The feedback board has terminals f or the 3-phase AC inputs (A, B,
and C) and for the armature power (VA+ and VA-), a series of jumper
connections to adjust for AC input voltage, jumper connections for
the field current, a bus connection to the power stage interface board,
two terminals blocks for placing burden resistors in parallel to the
circuit, and a Phoenix connection terminal block connect ed to other
drive components.
Note: Jumper settings are defined in the installation chapter of
this manual.
150 VAC
TO
300 VAC
301VAC
TO
575VAC
576VAC
TO
690VAC
C
150 VAC
TO
300 VAC
301VAC
TO
575VAC
VA+
576VAC
690VAC
TO
TB2 TB3
FEEDBACK BURDEN RESISTOR FEEDBACK BURDEN RESISTO R ARMATURE
Not Used
150 VAC
TO
300 VAC
301VAC
TO
575VAC
576VAC
690VAC
VA-
TO
Jumper Connections
(AC In put Voltage )
Publication 2361-5.01 July 1998
24V DC Power Supply
There are three 24V DC power supply units that may be install ed in
the drive. There is a feedback board supply, an optional air flow
sensor supply, and an optional cont rol board supply (us ed to powe r an
optional adapter board) . These supply units are fed from the 1 15V
AC control power circuit.
Product Overview 1-11
Gate Interface Board
The gate interface board is the junction between the power stage
interface boar d and the individua l armature-puls e transformer boards.
This board ha s four bus connections to the power stage interface
board and four Phoenix terminal bloc ks distributing signals to the
armature-pulse transformer boards.
Figure 1.8
Gate Interface Board
Connections to Power Stage
Interface Board
TB1
J4
J3
Co nnections to Arm ature-Pulse
Transformer Boards
J2
J1
TB2
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1-12 Product Overview
Power Components This section will break down and define the incoming power,
armature power, and field supply components.
Incoming Power Components
Incoming Devices
The 1250 and 1650A DC drives a re intended to be used straight from
the customer- supplied, power controlled incoming lines, without any
additional isolation transformer or line chokes (however, adding
either of these would increa se isolation to other equipment on the
power lines).
The 3000A DC drive does not require an isolation transformer or line
reactors if it is the only eq uipment on the power lines. However, if it
shares power with ot her equipm ent on th e same power lines, it will be
necessary to use eithe r line reactors or an isolation transformer ahead
of the drive.
The system designer needs to provide proper circuit impedence to
limit the sho rt circui t c urrents according t o the break er derat ing cha rts
given in Appendix A.
Some drives may require an output inductor in serie s with the
armature, especially for older machines which do not have enough
internal inductance for a proper armature commutation process.
AC Input Busbars
Tin plated busbars are supplied for all input connections through the
top of the disconnect bay. Busbar dimension dia grams are given in
Appendix A.
Main Disconnect (Optional)
A 3-phase circuit breaker can be supplied on the incoming line for
each high-horsepower drive. Appendix A lists circuit breaker
specifications, and shows diagrams of the circuit breakers settings for
the 1250, 1650, and 3000A DC drives.
AC Line Fuses (Optional)
AC line fuses can be supplied for the 3-phase incoming power.
Note: Units require either a main disconnect or AC line fuses.
Publication 2361-5.01 July 1998
Product Overview 1-13
Control and Field Power
The first (L1) an d thir d (L3 ) pha s e of the inco m ing p ow er are t app ed
off and fused to provide single-phase AC power to the primary of
control power t ransformer (115V AC), field supply circuit (460V AC
maximum), and 24V DC power supply.
Note: For drives using a 575 or 660V AC input, a step-down
transformer will be required for the field supply circuit (see
Figur e 1. 12).
AC Line RC Suppressor (Optional)
The optional AC line RC suppressor is a device used for limiting line
voltage spikes in drives when the medium volta ge source to the
primary of the distribution transformer is switched. The option is
offered for a dist ri bution transformer primary voltage of 2300V or
greater.
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1-14 Product Overview
Armature Power Components
The armature power components work together to convert the 3phase AC input to a DC output used for powering your motor
armature.
The following items make up the armature power circuitry:
• armature bridge (and its subordinate components)
• cell fuses
• gate board s
• DC contactor
Armature Bridge
The armature bridge is design ed to convert incoming AC power to
DC power. The non-regenerative bridge is shown in Figure 1.9. Cell
fuses protect the thyristors in the event of a bridge failure.
Figure 1.9
Armature Bridge (Non-Regenerative)
3-Phase
AC
Input
Main
Contactor
SNUBBER
Armature-Pulse
Transformer Board
SNUBBER
Armature-Pulse
Transformer Board
SNUBBER
Armature-Pulse
Transformer Board
A1
Armature
Voltage
Armature-Pulse
SNUBBER
Transformer Board
SNUBBER
Armature-Pulse
Transformer Board
SNUBBER
Armature-Pulse
Transformer Board
A2
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Product Overview 1-15
The regenerative bridge , shown in Figure 1.10, allows the bridge to
regenerate, or to di rect p owe r ba ck wards onto the inco ming lines.
Figure 1.10
Armature Bridge (Regenerative)
Main
Contactor
Armature-Pulse
3-Phase
AC
Input
Transformer Board
SNUBBER
Transformer Board
Armature-Pul se
SNUBBER
Armature-Pulse
Transformer Board
Transformer Board
Armature-Pul se
SNUBBER
Armature-Pulse
Transformer Board
Transformer Board
Armature-Pul se
A1
Armature
Voltage
Transformer Board
Armature-Pulse
Armature-Pulse
Transformer Board
SNUBBER
Armature-Pulse
Transformer Board
SNUBBER
Transformer Board
Armature-Pulse
Armature-Pulse
Transformer Board
SNUBBER
Transformer Board
Armature-Pulse
A2
The 3000A unit uses solid core (ferrite)
chokes on the AC line.
Silicon-Controlled Rectifiers (SCRs)
Each drive uses silicon-c ontrolled rectifiers (SCRs) in the thyristor
bridge to switch the incoming 3-phase AC power to DC output
power.
These SCRs allow current to flow from anode to cathode when two
conditions are met. First, like a diode, it must be forward biased.
Second, an appropriate pulse must be applied to the gate (through the
pulse transformer board).
The current will continue thr ough the SCR until the voltage across it
reverses and the current drops to zero (called line commutation).
Figure 1.11 shows a picture of an SCR, depicting its polarity.
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1-16 Product Overview
Silicon-Co ntrolled Rectifier
(SCR )
Snubbers
Snubbers (resistor/capacitor assemblies) are installed in para llel with
the SCRs, working with the cell reactors to provide adequate voltag e
suppression when the SCRs switch off.
Armatur e-Pulse Transformer Boards
Armature-pulse transformer boards provide the appropriate gate
voltage and current to trigger an SC R. In addition, these boards
provide gate driver isolation from the control logic. Figure 1.11
shows an armature-pulse tr ans former board.
DC Contactor
The main DC contactor is used to break the DC current to the motor
armature. Coil voltage to the con tacto r is controll ed by contacts from
the pilot relay.
Figure 1.11
Armature Bridge Hardware
Armature-Pulse Transformer
Board
Anode
Cathode
J2
Gate
Leads
Gate
Anode
Cathode
Publication 2361-5.01 July 1998
J1
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