Rockwell Automation 23P-DC User Manual

User Manual

PowerFlex DC Stand Alone Regulator and Gate

Amplifier

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 Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some 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.

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.

IMPORTANT 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

	Chapter 3
Gate Amplifier Installation and	Prepare for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	41
Wiring	Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	41
	Mounting and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	42
	Power and Ground Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	44
	Chassis Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	45
	Control Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	48
	Chapter 4
Retrofit Guidelines	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
Power Interface and SCR Firing	Parallel Power Modules and Load Share Reactors . . . . . . . . . . . . . . . . . . .	65
Order	Phase Sequence and Armature SCR Firing Order . . . . . . . . . . . . . . . . . . .	65

Rockwell Automation Publication 23P-UM001D-EN-P - July 2012

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Table of Contents
	Appendix A
Specifications	Stand Alone Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	71
	Gate Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	71
	Gate Coupler Assembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	73
	Gate Scaling Module Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	76
	Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	78
	Appendix B
History of Changes	23P-UM001C-EN-P, September, 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . .	83
	23P-UM001B-EN-P,
	April 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	83
Index	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	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,	Provides additional installation, configuration,
publication 20D-UM001	and programming information for the Stand
	Alone Regulator.
Industrial Automation Wiring and Grounding	Provides general guidelines for installing a
Guidelines, publication 1770-4.1	Rockwell Automation industrial system.
Product Certifications website, http://ab.com	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

Chapter 1

Introduction

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

2012 July - P-EN-UM001D-23P Publication Automation Rockwell

11

			Gate Cable
V1 U1			Gate Amplifier
	PowerFlex DC		PFDC	FWD
			Gate Input
Stand Alone Regulator
Field Supply		KPT11
40 A or 70 A		(15 Pin D-Shell)
(2 Quad)				REV
	All Terminals are located		SD3K
	on the bottom of the unit.		FWD IN
	KP	KA	KPT31
C1 D1	D C W V U	1A1 A1 1A2 A2	1 2 3 4 5 6 7 8
			SD3K
			REV IN

Power Module

Power Module

120VAC

AC / DC

Thermostat and

Ext. P/S

Feedback

CT Feedback

+

RDY

-

To Motor

Power Module

Field

Armature Voltage

Feedback

Normally

48V Ext P/S

Open Contacts

to Stop Circuitry

(If Required)

AC

Input

	CT FDBK to PFDC SAR	CTs on
		L1 and L3

L1, L2, L3

AC

FWD	REV
1	1

GATE COUPLER

ASSEMBLY

GATE COUPLER

ASSEMBLY

	M	+DC and -DC
From Stand-Alone		Power Module
Regulator		Output
Motor Field		Motor

	To Stop	Encoder or Resolver Feedback
	Circuitry

To Encoder or Resolver

P/S Feedback Port

MONITOR

RELAY

PowerFlex Typical - 1 Figure S6R to Interface
Amplifier Gate and Regulator Alone Stand DC	Chapter Introduction
	1

Chapter 1 Introduction

Stand Alone Regulator 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	575V / 690V AC Input	Field Amps
	Catalog Number	Catalog Number:
	23PMD4	23PMF4	40
	23PMD7	23PMF7	70
	Note: All models contain conformal coated circuit boards.
Gate Amplifier	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 on page 78.
SD3000 PLUS to Gate Amplifier Forward Cable	SD3K-CBLGSCLIFxxx(1)
SD3000 PLUS to Gate Amplifier Reverse Cable	SD3K-CBLGSCLIRxxx(1)
PMI Rack to Gate Amplifier Forward Cable	612432-xxxS(1)
PMI Rack to Gate Amplifier Reverse Cable	612433-xxxS(1)

(1) xxx = length in inches.

12	Rockwell Automation Publication 23P-UM001D-EN-P - July 2012

Chapter 2

Stand Alone Regulator Installation, Wiring

and Configuration

Prepare for Installation

Prior to installation of the PowerFlex DC Stand Alone Regulator (SAR) read the General Precautions on page 9.

Mounting Considerations	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

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Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration

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

Min. 50 mm

Min. 150 mm

Min. 150 mm

(6.0 in.)

(6.0 in.)

(2.0 in.)

Min. 10 0 mm			Min. 10 0 mm			Min. 10 0 mm
(0.4 in.)			(0.4 in.)	Min. 150 mm		(0.4 in.)
		Min. 150 mm					Airflow through the unit
		(6.0 in.)		(6.0 in.)
							must not be impeded.

14	Rockwell Automation Publication 23P-UM001D-EN-P - July 2012

Stand Alone Regulator Installation, Wiring and Configuration	Chapter 2

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.

																																																																								Dimensions are shown in mm (in.)
8.4 (0.33)																									250.0 (9.84)																																											23.3																												285.4 (11.24)
																																																																																								(0.92)

19.5

(0.77)

275.0

(10.83) 397.9

(15.67)

341.0 (13.43)

266.8

(10.51)

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.

IMPORTANT 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 Table 2 on page 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
	influence.
2	Normally, only non-conductive pollution occurs. Occasionally, however, a
	temporary conductivity caused by condensation is to be expected, when the
	drive is out of operation.
3	Conductive pollution or dry non-conductive pollution occurs, which becomes
	conductive due to condensation, which is to be expected.
4	The pollution generates persistent conductivity caused, for example by
	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

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

Bottom View

Front of Unit

AC / DC Feedback

“-”	“+ ”	A C In	A C In	A C In
D ,	C ,	W,	V ,	U ,

Connector

“KP”

Field Bridge, AC Input / DC Ouput

		“+ ”	“- ”
In	In	O u t	O u t
A C	A C	D C	D C
V 1 ,	U 1 ,	C 1,	D 1 ,

PE (GND)

Power Module Armature Feedback

	“+ ”		“-”
ut + “C ”)	A r m F dbk	ut - “D ”)	A rm F d bk
(P M O	M otor	( P M O	Mo to r
1A1	A1	1A2	A2

Connector

“KA”

Gate Output

Connector

“KPT11”

Power Module Thermal / CT Feedback

	+ V therm , +15 V			IS O C om			Therm C om			( Not U sed)			C T1 +			C T1 -			C T2 +			C T2 -
Connector	1			2			3			4			5			6			7			8
“KPT31”

18	Rockwell Automation Publication 23P-UM001D-EN-P - July 2012

From Incoming AC Line

	Transformer	U	V
	(External to SAR)
	See page 21 for
	Fuse Sizes
	(External to SAR)
		U1	V1
Rockwell	Field Regulator (2 Quad)
Automation		C1	D1
		Field PM Therm
-UM001D-23PPublication		+	-
		Motor Field
P-EN
-		Current
July
2012		Armature
		Feedback

Armature

Voltage

Feedback

19

Stand Alone Regulator (SAR)

Pwr Mod Thermal / CT Feedback

			Conn “KPT31”
		+V_Therm, +15V		1
+15 V ISO
			ISO_Com
		#S2		2
	OT
		(Test	Therm_Com
				3
		Pt.)
			(Not_Used)	4
		0V ISO	CT1 +	5
	2.5		CT1 -	6
	Ohms
J4	2.5	XCT	CT2 +	7
	Ohms	Ext.	CT2 -
				8
		Rb
J5

AC / DC Feedback

Internal Fuses

Conn “KP”

U, AC_In

V, AC_In

W, AC_In

To Voltage

C, “+”

Feedback

D, “-”

Circuits

Pwr Mod / Arm Fdbk

Conn “KA”

(PM Out + “C”) 1A1

Motor Arm Fdbk “+” A1

(PM Out - “D”) 1A2

Motor Arm Fdbk “-” A2

Gate Output

Conn “KPT11”

Incoming AC Line

To Field Power
				U	V		W
Module
				(L1)	(L2)		(L3)
Transformer

Therm						U, (L1)
Fault						V, (L2)	To SAR
On Pwr Mod							Conn “KP”
						W, (L3)
		CT1
					CT2
			U	V	W		To SAR
					Fault
From AC Line Above							Conn “KPT31”
U	V	W			Warning		To Digital I/O
(L1)	(L2)	(L3)
							(if available)
					Gate Input		Gates
			“+”		“-”		From Gate
			C		D
							Amplifier Output
							(refer to gate
							wiring diagrams)
*(See		M			M
Note)		5A, 700V
		5A, 700V
*(See
Note)				M
		Motor Field
To Gate Amplifier				Supplied by SAR		* Note: Armature Voltage
(refer to gate wiring			Field Power Module			Feedback. Jumpers
diagrams)			(or separately excited)			must always be in place.

Interface Regulator Alone Stand Typical - 4 Figure	Installation, Regulator Alone Stand
Module Power S6R to	Configuration and Wiring
	2 Chapter

Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration

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 primary 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 Table 4 on

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

Bottom View of SAR

1Field Power Module Bridge Terminal Block

2PE Terminal

PE

D C W V U

V1 U1 C1 D1

1A1 (C)A1 1A2 (D)A2

KPT21 KPT11

KPT31

1

2

3

4

5

6

7

8

Table 3 - Field Power Module Bridge and Ground Terminal Specifications

			Wire Size Range		Recommended
No.	Terminal	Description	Maximum	Minimum	Torque
1	V1, U1	AC Input Power	25.0 mm2	10.0 mm2	4.0…4.5 N•m
1	C1, D1	DC Output Power	(2 AWG)	(10 AWG)	(35.4…39.8 lb•in)
		to Motor Field
2	PE	Safety Ground (1)	16.0 mm2	10.0 mm2	6.0…8.0 N•m
			(6 AWG)	(8 AWG)	(53.1…70.8 lb•in)

(1) See Safety Ground (PE) on page 21 for more information.

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Stand Alone Regulator Installation, Wiring and Configuration	Chapter 2

Table 4 - Recommended Field Power Module Bridge Input Fuses

SAR Field	Fuse Type:
Bridge Rating	Bussmann	Ferraz Shawmut	Siba
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.

AC/DC Voltage and Motor

ArmatureVoltageFeedback

Wiring

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.

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 for recommended wiring for a typical SAR interface to 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 on page 22.

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Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration

Figure 6 - AC /DC Voltage Feedback (KP) and Motor Armature Voltage Feedback

(KA) Terminal Blocks

Bottom View of SAR

		D	C	W V U
1	AC /DC Voltage
	Feedback (KP)	V1		U1	C1	D1
	Terminal Block

PE

1A1 (C)A1 1A2 (D)A2

2 Motor Armature

Voltage Feedback

(KA) Terminal

Block

KPT21 KPT11

KPT31

1

2

3

4

5

6

7

8

Table 5 - AC / DC Voltage and Motor Armature Voltage Feedback Terminal Specifications

			Wire Size Range		Recommended
No.	Terminal	Description	Maximum	Minimum	Torque
1	W, V, U	AC Input
		Feedback
		(connector KP)
	D, C	DC Output	2	2
1		Feedback	6.0 mm	0.2 mm	0.7…0.8 N•m
		(connector KP)	(10 AWG)	(24 AWG)	(6.2…7.1 lb•in)
2	1A1, A1,	Motor Armature
	1A2, A2	Voltage Feedback
		(connector KA)

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.

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Stand Alone Regulator Installation, Wiring and Configuration	Chapter 2

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 and is wired as follows:

•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.

Figure 7 - Terminals on Connector KA Jumpered

1A1(C) A1 1A2 (D) A2

Place jumpers between terminals as shown

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Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration

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)

Bottom View of SAR

				KPT21		KPT11
D	C	W V U
									Power Module
V1		U1	C1	D1		KPT31			Thermal Switch and
									Current Transformer
				1	2	3 4 5 6	7	8
									(KPT31) Terminal
									Block

PE

1A1 (C)A1 1A2 (D)A2

Table 6 - Power Module Thermal Switch and Current Transformer Terminal

Specifications

			Wire Size Range		Recommended
Terminal		Description	Maximum	Minimum	Torque
1, 2,	3	Thermal Switch Monitor(1)	2.5 mm2	0.2 mm2	0.5…0.6 N•m
5, 6,	7, 8	Current Transformer Feedback	(12 AWG)	(24 AWG)	(4.4…5.3 lb•in)

(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 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

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)

Bottom View of SAR

PE

D C W V U

V1 U1 C1 D1

1A1 (C)A1 1A2 (D)A2

KPT21 KPT11

KPT31

1

2

3

4

5

6

7

8

SAR Gate Output

Cable (KPT11)

Connector

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 for details.

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 for details.

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Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration

SAR Motor Field Current

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 for details.

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.

•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. See the PowerFlex Digital DC Drive User Manual, publication 20P-UM001 for 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 for instructions.

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Stand Alone Regulator Installation, Wiring and Configuration	Chapter 2

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	Off	Off	Off	Off	Off	On	Off	Off
(230V)
SAR 400V	Off	Off	Off	Off	Off	On	On	Off
(460V)
SAR 600V	Off	Off	Off	Off	Off	On	Off	On
(575V)
SAR 690V	Off	Off	Off	Off	Off	On	On	On
(690V)

Figure 10 - DIP Switch S15 Location on Control Board

							XR
XA
																S15
																1
																2
																3
																4
																5
																6
					LA LB	1										8 7
						2
						3										S3
						4
						5
						6										S2
						8 7										S1
					XFCD	S14										S0
					S20
		1
		2						ON
		3
		5 4				S11
S4
		6				S10
		7		S21		S9
		8
						21 22 23 24 25 26 27 28 29 30									31 32 33 34 35 36 37 38 39 40
-	A	B	C +	ENC_5 ENC_12	A+ A- B+ B- Z+ Z- COM +V	21 22 23 24 25 26 27 28 29 30									31 32 33 34 35 36 37 38 39 40	DEBUG
						1	2	3	4	5	6	7	8	9 10	11 12 13 14 15 16 17 18 19 20
-	A	B	C +		A+ A- B+ B- Z+ Z- COM +V	1	2	3	4	5	6	7	8	9 10	11 12 13 14 15 16 17 18 19 20

S15

8 7 6 5 4 3 2 1

S3

RST S2 ACT

S1 RUN PWR

S0

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