Rockwell Automation 23P-DC User Manual
User Manual
PowerFlex DC Stand Alone Regulator and Gate
Amplifier
Important User Information
IMPORTANT
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.
available from
) describes some
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death,
property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the
consequence
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
dangerous voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
surfaces may reach dangerous temperatures.
Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, PowerFlex, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Summary of Changes
This manual contains new and updated information.
Topic Page
Removed the reference to the S12 / S12R configuration from the Features list. 12
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 3
Summary of Changes
4 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Table of Contents
Preface
Introduction
Stand Alone Regulator
Installation, Wiring and
Configuration
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
What This Manual Contains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drawing Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 1
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Stand Alone Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Gate Amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2
Prepare for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Terminal/Signal and Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Field Power Module Bridge and Ground Wiring. . . . . . . . . . . . . . . . . . . . 20
AC/DC Voltage and Motor Armature Voltage Feedback Wiring . . . . 21
Power Module Thermal Switch and Current Transformer Wiring . . . 24
SAR Gate Output Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control Circuit Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SAR Motor Field Current Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SAR Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SAR Current Feedback Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SAR Programming and Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Gate Amplifier Installation and
Wiring
Retrofit Guidelines
Power Interface and SCR Firing
Order
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 5
Chapter 3
Prepare for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Mounting and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power and Ground Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Chassis Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Chapter 4
Gate Interface to Non-Rockwell Power Module, Retrofit . . . . . . . . . . . . 59
Gate Interface to Reliance Electric U.S. Power Modules, Retrofit. . . . . 61
Gate Interface to Dierikon Power Modules. . . . . . . . . . . . . . . . . . . . . . . . . 64
Chapter 5
Parallel Power Modules and Load Share Reactors . . . . . . . . . . . . . . . . . . . 65
Phase Sequence and Armature SCR Firing Order . . . . . . . . . . . . . . . . . . . 65
Table of Contents
Appendix A
Specifications
History of Changes
Index
Stand Alone Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Gate Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Gate Coupler Assembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Gate Scaling Module Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Appendix B
23P-UM001C-EN-P, September, 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
23P-UM001B-EN-P,
April 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Preface
Purpose of This Manual
What This Manual Contains
Drawing Numbers
This manual provides installation instructions and connection and configuration
information for the PowerFlex® DC Stand Alone Regulator (SAR) and the Gate
Amplifier. It is intended for internal Rockwell Automation use only.
This user manual contains the following sections:
• Description of the SAR and Gate Amplifier products and general
integration information
• Installation, connection and configuration instructions for the SAR
• Installation and connection instructions for the Gate Amplifier
• Guidelines for retrofit installations with DC power modules
• SAR and Gate Amplifier specifications
• Specifications for additional components and cables used with the SAR
and Gate Amplifier products
Throughout this manual, drawings are identified by an eight-digit number, for
example, 99999999. Where a drawing number includes an asterisk (*) in the 8th
digit, the “*” represents the latest version number of the drawing, for example,
999999*.
Additional Resources
These documents contain additional information concerning the PowerFlex DC
Stand Alone Regulator and related Rockwell Automation products.
Resource Description
PowerFlex Digital DC Drive User Manual,
publication 20D-UM001
Industrial Automation Wiring and Grounding
Guidelines, publication 1770-4.1
Product Certifications website, http://ab.com
Provides additional installation, configuration,
and programming information for the Stand
Alone Regulator.
Provides general guidelines for installing a
Rockwell Automation industrial system.
Provides declarations of conformity, certificates,
and other certification details.
You can view or download publications at http://www.rockwellautomation.com/
literature/. To order paper copies of technical documentation, contact your local
Rockwell Automation distributor or sales representative.
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 7
preface
Notes:
8 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Introduction
Chapter
1
General Precautions
Prior to installation of either the Stand Alone Regulator or Gate Amplifier, read
the following precautions.
ATTENTION: Energized industrial control equipment can be hazardous.
Severe injury or death can result from electrical shock, burn, or unintended
actuation of controlled equipment. Hazardous voltages may exist in the
cabinet even with the circuit breaker in the off position. Recommended
practice is to disconnect and lock out control equipment from power
sources, and discharge stored energy in capacitors, if present. If it is
necessary to work in the vicinity of energized equipment, the Safety
Related Practices of NFPA 70E, “ELECTRICAL SAFETY FOR EMPLOYEE
WORKPLACES” must be followed. DO NOT work alone on energized
equipment!
ATTENTION: The following information is merely a guide for proper
installation. The National Electrical Code and any other governing regional
or local code will overrule this information. Rockwell Automation cannot
assume responsibility for the compliance or the noncompliance to any
code, national, local or otherwise for the proper installation of this drive
regulator or associated equipment. A hazard of personal injury and/or
equipment damage exists if codes are ignored during installation.
ATTENTION: The installation of the Stand Alone Regulator and/or the
Gate Amplifier must be planned such that all cutting, drilling, tapping and
welding can be accomplished with the Gate Amplifier removed from the
enclosure. The Stand Alone Regulator and Gate Amplifier are of the open
type construction and any metal debris must be kept from falling into the
enclosure. Metal debris or other foreign matter may become lodged in the
circuitry resulting in component damage.
ATTENTION: An incorrectly applied or installed Stand Alone Regulator or
Gate Amplifier can result in component damage or a reduction in product
life. Wiring or application errors, such as, incorrect or inadequate supply
voltage or excessive ambient temperatures may result in malfunction of
the system.
ATTENTION: Only qualified personnel familiar with DC drives and
associated machinery should plan or implement the installation, start-up
and subsequent maintenance of the system. Failure to comply may result
in personal injury and/or equipment damage.
ATTENTION: The Stand Alone Regulator and Gate Amplifier contain ESD
(Electrostatic Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or repairing
this assembly. Component damage may result if ESD control procedures
are not followed. If you are not familiar with static control procedures,
reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic
Damage” or any other applicable ESD protection handbook.
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 9
Chapter 1 Introduction
Product Overview
The PowerFlex DC Stand Alone Regulator (SAR) and Gate Amplifier products
provide an integrated solution for controlling external DC power modules.
Stand Alone Regulator (SAR)
The SAR is a DC drive regulator that provides armature regulation, armature
SCR gate signals and a regulated field supply. The SAR field supply consists of a
single phase, two quadrant (non-reversing,) full wave rectified bridge, available as
40 or 70 Amps. The SAR supports an AC line input voltage range of 230VAC to
690VAC and a field input voltage range of 100VAC to 460VAC.
The SAR uses feedback signals from the AC input line to monitor the incoming
voltage level in order to establish the SCR gate firing sequence relative to the AC
line. The SCR gate firing for the field bridge is established from the AC lines that
supply the field, independent of the armature firing circuit. DC feedback signals
are used to monitor the output voltage from the power module. Additionally,
current signals received from current transformers is used by the SAR regulator to
monitor and control current. The SAR catalog numbers are listed in Catalog
Numbers on page 12. The SAR must be used with the Gate Amplifier in order to
interface with a DC power module(s).
Gate Amplifier
The Gate Amplifier is used to amplify the SCR gate signals supplied by a DC
drive regulator. The gate signal source to the Gate Amplifier can be provided by
either the PowerFlex DC SAR, or the SD3000 PLUS. The Gate Amplifier unit
provides a separate input D-Shell connector for each product. The Power
Module Interface (PMI) Rack is also compatible with the Gate Amplifier and
uses the SD3000 PLUS inputs. The Gate Amplifier model number and
corresponding connection cables part numbers are listed in Model and Cable
Model/Part Numbers on page 12.
In addition to amplifying the gate signals, the forward and reverse signals
provided by the Gate Amplifier are “fanned-out” to enable the driving of multiple
power modules. Four S6 bridges forward and four S6 bridges reverse. When the
S6 bridges are connected in an anti-parallel configuration, the topology is an S6R
providing both motoring and regenerative capability.
The external 48V gate power supply capability of the Gate Amplifier provides the
means to supply additional gate current and voltage and also support the firing of
gate coupler boards connected in series (which requires additional voltage).
Connecting gate couplers in series forces the simultaneous firing of the SCRs,
with power connections in series or parallel. An internal “diode OR” circuit
ensures that the gates are powered by whichever gate power supply voltage is the
greater in amplitude, the internal or the external power supply.
10 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Introduction Chapter 1
+
-
PowerFlex DC
Stand Alone Regulator
SD3K
FWD IN
SD3K
REV IN
PFDC
Gate Input
FWD
REV
KPT11
(15 Pin D-Shell)
Field Supply
40 A or 70 A
(2 Quad)
To Motor
Field
Gate Cable
Normally
Open Contacts
to Stop Circuitry
RDY
Ext. P/S
120VAC
Gate Amplifier
48V Ext P/S
(If Required)
To Stop
Circuitry
P/S
MONITOR
RELAY
L1, L2, L3
AC
CT FDBK to PFDC SAR
AC
Input
From Stand-Alone
Regulator
Motor Field
To Encoder or Resolver
Feedback Port
Encoder or Resolver Feedback
Motor
M
+DC and -DC
Power Module
Output
CTs on
L1 and L3
FWD
1
REV
1
GATE COUPLER
ASSEMBLY
GATE COUPLER
ASSEMBLY
C1 D1 D C W V U 1A1 A1 1A2 A2 1 2 3 4 5 6 7 8
KPT31KAKP
Power Module
AC / DC
Feedback
Power Module
Armature Voltage
Feedback
Power Module
Thermostat and
CT Feedback
V1 U1
All Ter minals are located
on the bottom of the unit.
Figure 1 - Typical PowerFlex DC Stand Alone Regulator and Gate Amplifier
Interface to S6R
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 11
Chapter 1 Introduction
Stand Alone Regulator
Gate Amplifier
Features
• Rockwell Automation Architecture Class networking capable
Available Options
• Resolver Feedback
Catalog Numbers
This table lists the available catalog numbers for the SAR.
230V / 460V AC Input
Catalog Number
23PMD4 23PMF4 40
23PMD7 23PMF7 70
575V / 690V AC Input
Catalog Number:
Field Amps
Note: All models contain conformal coated circuit boards.
Features
• Interfaces to the PowerFlex DC, SD3000 PLUS or PMI regulators
• Flexible configurations S6 and S6R
•Power module interface
• Interlock via “Ready Relay” contacts to main drive control
Available Options
• 48V gate drive capability with an external power supply
Model and Cable Model/Part Numbers
This table lists the cable module numbers and part numbers for the Gate
Amplifier.
Product: Model/Part Number:
Gate Amplifier 23PAMP
PowerFlex DC to Gate Amplifier Cable See Cable Specifications
SD3000 PLUS to Gate Amplifier Forward Cable SD3K-CBLGSCLIFxxx
SD3000 PLUS to Gate Amplifier Reverse Cable SD3K-CBLGSCLIRxxx
PMI Rack to Gate Amplifier Forward Cable 612432-xxxS
PMI Rack to Gate Amplifier Reverse Cable 612433-xxxS
(1) xxx = length in inches.
12 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
on page 78.
(1)
(1)
(1)
(1)
Chapter
2
Stand Alone Regulator Installation, Wiring
and Configuration
Prepare for Installation
Mounting Considerations
Prior to installation of the PowerFlex DC Stand Alone Regulator (SAR) read the
General Precautions on page 9
.
Operating Conditions and Temperatures
The SAR is designed to operate at 0°…50° C (32°… 122° F) surrounding air
temperature without derating. The unit must be mounted in a clean, dry location.
Contaminants such as oils, corrosive vapors and abrasive debris must be kept out
of the enclosure. NEMA/UL Type Open, IP20 enclosures are intended for
indoor use primarily to provide a degree of protection against contact with
enclosed equipment. These enclosures offer no protection against airborne
contaminants.
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 13
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration
Min. 10 0 mm
(0.4 in.)
Min. 150 mm
(6.0 in.)
Min. 150 mm
(6.0 in.)
Min. 150 mm
(6.0 in.)
Min. 150 mm
(6.0 in.)
Min. 10 0 mm
(0.4 in.)
Min. 50 mm
(2.0 in.)
Min. 10 0 mm
(0.4 in.)
Airflow through the unit
must not be impeded.
Minimum Mounting Clearances
Minimum clearance requirements (indicated in Figure 2 - Drive Enclosure
Minimum Mounting Clearances) are intended to be from enclosure to enclosure.
Other objects can occupy this space; however, reduced airflow may cause
protection circuits to fault the SAR. The SAR must be mounted in a vertical
orientation as shown and must not be mounted at an angle greater than 30
degrees from vertical. In addition, inlet air temperature must not exceed the
product specification.
Figure 2 - Drive Enclosure Minimum Mounting Clearances
14 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2
8.4 (0.33) 250.0 (9.84)
19.5
(0.77)
23.3
(0.92)
341.0
(13.43)
275.0
(10.83)
266.8
(10.51)
397.9
(15.67)
285.4 (11.24)
Dimensions are shown in mm (in.)
IMPORTANT
Approximate Dimensions and Weights
The SAR is available in a NEMA/UL Type Open, IP20 enclosure only.
ATTENTION: Remove all loose packaging materials, including any
desiccant packages from the enclosure before mounting and energizing
the SAR.
Table 1 - Stand Alone Regulator Weights
Stand Alone Regulator Stand Alone Regulator and Packaging
12.0 kg (26.5 lb) 14.1 kg (31 lb)
Recommended Mounting Hardware: Metric M6, English 1/4 in.
Provide a minimum of 150 mm (6.0 in.) below the unit for cable
connections.
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 15
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration
CE Conformity
Conformity with the Low Voltage Directive and Electromagnetic Compatibility
Directive has been demonstrated using harmonized European Norm (EN)
standards published in the Official Journal of the European Communities. The
PowerFlex DC Stand Alone Regulator complies with the EN standards listed
when installed according to this User Manual.
CE Declarations of Conformity are available online at:
www.rockwellautomation.com/products/certification/ce/
Low Voltage Directive (2006/95/EC)
• EN 50178 Electronic equipment for use in power installations.
EMC Directive (2004/108/EC)
• EN 61800-3 Adjustable speed electrical power drive systems Part 3: EMC
product standard including specific test methods.
General Considerations
• For CE compliance, the SAR installation must satisfy requirements related
to both EN 50178 and EN 61800-3 provided in this document.
• The SAR complies with the EMC requirements of EN 61800-3 when
installed according to good EMC practices and the instructions provided
in this document. However, many factors can influence the EMC
compliance of an entire machine or installation, and compliance of the
SAR itself does not necessarily ensure compliance of all applications.
• The SAR is not intended to be used on public supply networks which
supply domestic premises. Without additional mitigation, radio frequency
interference is expected if used on such a network. The installer is
responsible to take measures such as supplementary line filters and
enclosures to prevent interference, in addition to the installation
requirements of this document.
Installation Requirements Related to EN 50178 and the Low Voltage Directive
• The SAR is compliant with the CE LV Directive when used at altitudes no
greater than 2000 m (6562 ft).
• The SAR provided in enclosure type IP20 must be installed in a pollution
degree 1 or 2 environment to be compliant with the CE LV Directive.
Characteristics of the different pollution degree ratings are provided in
Tab le 2 on p ag e 17
.
16 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2
Table 2 - Pollution Degree Ratings According to EN 61800-5-1
Pollution Degree Description
1 No pollution or only dry, non-conductive pollution occurs. The pollution has no
2 Normally, only non-conductive pollution occurs. Occasionally, however, a
3 Conductive pollution or dry non-conductive pollution occurs, which becomes
4 The pollution generates persistent conductivity caused, for example by
influence.
temporary conductivity caused by condensation is to be expected, when the
drive is out of operation.
conductive due to condensation, which is to be expected.
conductive dust or rain or snow.
• The SAR must be installed in a suitable enclosure with at least an IP4X
rating at the top of the enclosure.
• The SAR may produce leakage current in the protective earthing
conductor which exceeds 3.5 mA AC and/or 10 mA DC. The minimum
size of the protective earthing (grounding) conductor used in the
application must comply with local safety regulations for equipment with
high protective earthing conductor current.
• The SAR may not be powered from a “corner-earthed” supply system in
order to maintain compliance with the CE LV Directive.
Installation Requirements Related to EN 61800-3 and the EMC Directive
• The SAR must be earthed (grounded) as described in this User Manual.
• Output power wiring to the motor (field excitation) must employ cable
with a braided shield providing 75% or greater coverage, or the cable must
be housed in metal conduit, or equivalent shielding must be provided.
Continuous shielding must be provided from the SAR enclosure to the
motor enclosure. Both ends of the motor cable shield (or conduit) must
terminate with a low-impedance connection to earth.
• At the motor end, the motor field excitation cable shield or conduit must
terminate in a shielded connector which must be properly installed in an
earthed motor wiring box attached to the motor. The motor wiring box
cover must be installed and earthed.
• All control (I/O) and signal wiring to the SAR, including gate firing
control, must use cable with a braided or foil shield providing 75% or
greater coverage, or the cables must be housed in metal conduit, or
equivalent shielding must be provided. Only the SAR end of the cable
shield should be terminated with a low impedance connection to earth.
• Power cabling must be separated from control and signal wiring wherever
possible.
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 17
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration
D, “-”
C, “+”
W, AC_In
AC / DC Feedback
V 1, AC_In
U1, AC_In
C1, DC_Out “+”
Field Bridge, AC Input / DC Ouput
PE (GND)
12345
Power Module Thermal / CT Feedback
Connector
“KP”
Connector
“KPT31”
678
+V _therm, +15V
Therm_Com
IS O_Com
(Not_Used)
CT1 +
CT1 -
CT2 +
CT2 -
Gate Outpu t
Connector
“KPT11”
1A1 A1 1A2
Power Module Armature Feedback
Connector
“KA”
(P M O ut + “C”)A2Motor Arm Fdbk “+”
(PM Out - “D ”)
Motor Arm F dbk “-”
V , A C _I n
U, AC_In
D1, DC_Out “-”
Bottom View
Front of Unit
Terminal/Signal and Wiring Diagrams
Use the diagram in Figure 3 - Stand Alone Regulator Terminal/Signal Block
Diagram as a guide for the general location of and connection signals for the main
input/output terminal blocks on the SAR. The diagram in Figure 4 on page 19
represents the recommended wiring for a typical SAR interface to a S6R power
module.
Figure 3 - Stand Alone Regulator Terminal/Signal Block Diagram
18 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Pwr Mod / Arm Fdbk
Conn “KA”
213
4
5
6
7
8
Pwr Mod Thermal / CT Feedback
Conn “KPT31”
U
(L1)
U VW
MM
M
Internal Fuses
From AC Line Above
To SAR
Conn “KP”
Fault
To SAR
Conn “KPT31”
Warning
To Digital I/O
(if available)
Field Regulator (2 Quad)
U V
To Field Power
Module
Transformer
Incoming AC Line
From Incoming AC Line
Transformer
(External to SAR)
Field PM Therm
OT
+15 V ISO
+
-
Motor Field
Motor Field
Supplied by SAR
Field Power Module
(or separately excited)
U1 V1
C1
D1
Ext.
Rb
XCT
J4
J5
Armat ure
Current
Feedback
Gate Input
Gates
Gate Ou tput
Conn “KPT11”
To Gate Amplifier
(refer to gate wiring
diagrams)
Stand Alone Regulator (SAR)
* Note: Armature Voltage
Feedback. Jumpers
must always be in place.
From Gate
Amplifier Output
(refer to gate
wiring diagrams)
Armat ure
Voltage
Feedback
See page 21 for
Fuse Sizes
(External to SAR)
Motor Arm Fdbk “-” A2
(PM Out - “D”) 1A2
Motor Arm Fdbk “+” A1
(PM Out + “C”) 1A1
AC / DC Feedback
Conn “KP”
D, “-”
C, “+”
W, AC_In
V, AC_In
U, AC_In
CT2 -
CT2 +
CT1 -
CT1 +
(Not_Used)
Therm_Com
ISO_Com
+V_Therm, +15V
0V ISO
#S2
(Test
Pt.)
2.5
Ohms
2.5
Ohms
Therm
Fault
On Pwr Mod
V
(L2)
W
(L3)
U, (L1)
V, (L2)
W, (L3)
CT1
CT2
U
(L1)
V
(L2)
W
(L3)
“+”
C
“-”
D
5A, 700V
5A, 700V
*(See
Note)
*(See
Note)
To Voltage
Feedback
Circuits
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2
Figure 4 - Typical Stand Alone Regulator Interface to S6R Power Module
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 19
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration
1A1
(C)
A1 1A2
(D)
A2
1 2 3 4 5 6 7 8
V1 U1 C1 D1
D C W V U
KPT21 KPT11
KPT31
PE
Field Power
Module Bridge
Terminal Block
PE Terminal
Bottom View of SAR
1
2
Field Power Module Bridge and Ground Wiring
The SAR contains a two quadrant field power module bridge. The field bridge
input circuit is rated for 100VAC…460VAC, ±10%, 50/60 Hz. The input and
output connections to/from the field bridge are on the bottom of the SAR as
shown.
An external transformer with appropriate primar y fusing is required to supply the
field. External fusing is also required at the input terminals V1 and U1 to protect
the field bridge. The recommended fuse types are shown in the Tab le 4 o n
page 21.
The SAR motor field current must configured with a hardware DIP switch and in
firmware. See SAR Motor Field Current Configuration
on page 26 for more
information.
Figure 5 - Field Power Module Bridge Terminal Block and Ground Connection
20 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Table 3 - Field Power Module Bridge and Ground Terminal Specifications
Wire Size Range
No. Terminal Description
V1, U1 AC Input Power
1
1
PE Safety Ground
2
(1) See Safety Ground (PE) on page 21 for more information.
to Motor Field
(1)
25.0 mm
(2 AWG)
16.0 mm
(6 AWG)
2
2
10.0 mm
(10 AWG)
10.0 mm
(8 AWG)
2
2
Recommended
TorqueMaximum Minimum
4.0…4.5 N•m
(35.4…39.8 lb•in)C1, D1 DC Output Power
6.0…8.0 N•m
(53.1…70.8 lb•in)
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2
Table 4 - Recommended Field Power Module Bridge Input Fuses
SAR Field
Bridge Rating
40 A FWP-50A22Fa A70QS50-22F 5014006.50
70 A FWP-100A22Fa A70QS100-22F 5014006.100
The recommended fuse holder is a Cooper-Bussman, CH222D or equivalent - to
accommodate 22 mm x 58 mm fuses.
Fuse Type:
Bussmann Ferraz Shawmut Siba
Safety Ground (PE)
The Safety Ground - PE must be connected to system ground. Ground
impedance must conform to the requirements of national and local industrial
safety regulations and/or electrical codes. The integrity of all ground connections
should be periodically checked.
For installations within a cabinet, a single safety ground point or ground bus bar
connected directly to building steel should be used. All circuits should be
grounded independently and directly to this point/bar.
AC/DC Voltage and Motor Armature Voltage Feedback Wiring
The SAR requires AC feedback connections to connector KP (terminals U, V,
and W) from the incoming line to monitor the incoming voltage level and
establish the SCR gate firing sequence relative to the AC line. DC feedback
connections to connector KP (terminals C and D) are required to monitor the
voltage output from the DC power module. The combined information from the
AC and DC feedback inputs is used to determine if the SCRs are firing properly.
See Figure 4 on page 19
S6R.
Fuses are required between the DC output power wiring on the DC power
module to connector KP on the SAR. This will limit the current to the regulator
in the event of an internal fault in the SAR. The recommended fuse types are
shown in DC Feedback Fusing Requirements
for recommended wiring for a typical SAR interface to
on page 22.
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 21
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration
1 2 3 4 5 6 7 8
V1 U1 C1 D1
KPT21 KPT11
KPT31
PE
D C W V U
1A1
(C)
A1 1A2
(D)
A2
AC /DC Voltage
Feedback (KP)
Terminal Block
Bottom View of SAR
Motor Armature
Voltage Feedback
(KA) Terminal
Block
1
2
Figure 6 - AC /DC Voltage Feedback (KP) and Motor Armature Voltage Feedback
(KA) Terminal Blocks
Table 5 - AC / DC Voltage and Motor Armature Voltage Feedback Terminal
Specifications
No. Terminal Description
W, V, U AC Input
1
Feedback
(connector KP)
D, C DC Output
1
Feedback
(connector KP)
2
1A1, A1,
1A2, A2
Motor Armature
Voltage Feedback
(connector KA)
Wire Size Range
2
6.0 mm
(10 AWG)
0.2 mm
(24 AWG)
2
Recommended
TorqueMaximum Minimum
0.7…0.8 N•m
(6.2…7.1 lb•in)
DC Feedback Fusing Requirements
The recommended fuses are:
• Bussmann fuse FWP-5A14F (5 A, 700V, Type FWP, 14 x 51mm), or
equivalent.
Note: The AC voltage feedback inputs on the SAR are fused internally.
22 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2
1A1
(C)
A1 1A2
(D)
A2
Place jumpers between
terminals as shown
Connector KP Wiring
• Connect the motor armature terminal C to terminal C on connector KP
• Connect the motor armature terminal D to terminal D on connector KP
Connector KA Wiring
Connector KA must be wired to provide DC voltage feedback to the field
regulator to control the field current based on the armature voltage. Terminal
1A1 is connected internally to terminal C (on connector KP) and terminal 1A2
is connected internally to terminal D (on connector KP). The default
configuration is shown in Figure 7
• Jumper terminal 1A1 to terminal A1
• Jumper terminal 1A2 to terminal A2
The jumpers will provide the field regulator with the power module/armature
voltage feedback. This is the default wiring scheme for connector KA at the
factory.
and is wired as follows:
Figure 7 - Terminals on Connector KA Jumpered
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 23
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration
1A1
(C)
A1 1A2
(D)
A2
V1 U1 C1 D1
D C W V U
KPT21 KPT11
KPT31
PE
1 2 3 4 5 6 7 8
Power Module
Thermal Switch and
Current Transformer
(KPT31) Terminal
Block
Bottom View of SAR
Power Module Thermal Switch and Current Transformer Wiring
Connector KPT31 is used for power module thermal switch monitoring and
current feedback via current transformer connections. Note that the thermal
monitor circuit includes a thermal switch on the field power module within the
SAR.
Figure 8 - Power Module Thermal Switch and Current Transformer Terminal Block
(KPT31)
Table 6 - Power Module Thermal Switch and Current Transformer Terminal
Specifications
Terminal Description
1, 2, 3 Thermal Switch Monitor
5, 6, 7, 8 Current Transformer Feedback
(1) These terminals are jumpered by default. The jumper wires must remain in place if a power module thermal
switch is NOT connected.
Current Transformer Connections
Current transformer 1 (CT1) monitors the U phase, with the “+” output of CT1
connected to terminal 5 of KPT31 and the “-” output of CT1 connected to
terminal 6 of KPT31.
Current transformer 2 (CT2) monitors the W phase, with the “+” output of
(1)
Wire Size Range
2
2.5 mm
(12 AWG)
0.2 mm
(24 AWG)
Recommended
TorqueMaximum Minimum
2
0.5…0.6 N•m
(4.4…5.3 lb•in)
CT2 connected to terminal 7 of KPT31 and the “-” output of CT2 connected to
terminal 8 of KPT31.
The “-” side of the CTs are connected together internally in the SAR.
24 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2
1A1
(C)
A1 1A2
(D)
A2
1 2 3 4 5 6 7 8
V1 U1 C1 D1
D C W V U
KPT21 KPT11
KPT31
PE
SAR Gate Output
Cable (KPT11)
Connector
Bottom View of SAR
SAR Gate Output Cable
Connect the SAR gate output cable (23PAMP-Cx) to connector KPT11 on the
SAR unit. The opposite end connects to the POWERFLEX DC SAR GATE
INPUT on the Gate Amplifier. See Chapter 3
Gate Amplifier Installation and
Wiring on page 41 for more information on Gate Amplifier installation and
connections. See Cable Specifications
on page 78 for information on available
cable lengths for the 23PAMP-Cx cable.
Figure 9 - SAR Gate Output Cable Connection (KPT11)
Control Circuit Power Wiring
The control circuit for the SAR (not identified in the drawings contained in this
manual) must be powered by an external 230V AC or 115V AC, single phase
power supply. This power supply provides power for the SAR cooling fans and a
HIM, communication adapter, I/O, encoder, or DC analog tachometer (if
installed). See “Control Circuit Input Power” in the PowerFlex Digital DC Drive
User Manual, publication 20P-UM001
In addition, the control circuit power input terminals require short circuit
protection. See “Control Power Protection” in the PowerFlex Digital DC Drive
User Manual, publication 20P-UM001
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 25
for details.
for details.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration
Relay Output and Thermistor/Thermal Switch Wiring
Two normally open relay outputs and one motor thermistor (PTC) or thermal
switch input are available for use and must be configured with the appropriate
parameters. See “Relay Outputs” and “Thermistors and Thermal Switches” in the
PowerFlex Digital DC Drive User Manual, publication 20P-UM001
I/O, Digital Encoder, and DC Analog Tachometer Wiring
The following standard I/O and feedback options are available with the SAR.
• Eight digital inputs, four digital outputs, three analog inputs, and two
analog outputs are available. Additional digital and analog I/O is available
when using the optional I/O expansion circuit board.
• An input terminal block is available for an incremental, dual channel, two
channel optional (with jumper), differential (recommended) or singleended encoder with an input voltage configurable for +2.5V…5.2V or
+5.4V…15.2V.
for details.
SAR Motor Field Current Configuration
• An input terminal block is available for a DC analog tachometer with a
maximum input voltage of 22.7V, 45.4V, 90.7V, 181.6V, or 302.9V and an
input current of 8 mA full scale.
See “I/O Wiring” in the PowerFlex Digital DC Drive User Manual, publication
20P-UM001
for details.
Resolver Feedback Option Module Wiring
A resolver feedback module is available for purchase separately from the SAR.
The resolver feedback option module includes the PowerFlex DC Drive Resolver
Feedback Option Module Installation Instructions, publication 20P-IN071
the PowerFlex Digital DC Drive User Manual, publication 20P-UM001
resolver configuration details.
The SAR motor field current must be configured with both a hardware DIP
switch (S14) and by setting parameter 374 [Drv Fld Brdg Cur] to the appropriate
value. For each field current rating, in this case 40 and 70 A, there are several
ranges to choose from with regard to the maximum range of the field current.
The lowest range that is greater than the maximum motor field current should be
selected to ensure the best resolution. See “Field Current Configuration” in the
PowerFlex Digital DC Drive User Manual, publication 20P-UM001
instructions.
. See
for
for
26 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2
- A B C +
A+ A- B+ B- Z+ Z- COM +V
A+ A- B+ B- Z+ Z- COM +V
- A B C +
21 22 23 24 25 26 27 28 29 30
1 2 3 4 5 6 7 8 9 10
31 32 33 34 35 36 37 38 39 40
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
31 32 33 34 35 36 37 38 39 40
DEBUG
S15
S3
S2
S1
S0
RST
ACT
RUN
PWR
1 2 3 4 5 6 7 8
S18
S12
S10
S21
ENC_5 ENC_12
S4
1 2 3 4 5 6 7 8
S14
1 2 3 4 5 6 7 8
S20
S11
S9
ON
XR
XA
XFCD
LA LB
S15
S3
S2
S1
S0
RST
ACT
RUN
PWR
1 2 3 4 5 6 7 8
SAR Sizing
DIP switch S15 is configured for the appropriate SAR size at the factory. Do not
change the settings unless you are installing a replacement control board.
Table 7 - SAR DIP Switch S15 Settings
Description S15-1 S15-2 S15-3 S15-4 S15-5 S15-6 S15-7 S15-8
SAR 200V
(230V)
SAR 400V
(460V)
SAR 600V
(575V)
SAR 690V
(690V)
Figure 10 - DIP Switch S15 Location on Control Board
Off Off Off Off Off On Off Off
Off Off Off Off Off On On Off
Off Off Off Off Off On Off On
Off Off Off Off Off On On On
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 27
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