Rockwell Automation SA3000 User Manual

Distributed Power System
High Power SA3000
AC Power Modules

850020 – 11xxx, 21xxx (534 Amp)
850020 – 12xxx, 22xxx (972 Amp)
850020 – 13xxx, 23xxx (1457 Amp)

Instruction Manual

S-3038

Throughout this manual, the following notes are used to alert you to safety considerations:

ATTENTION:Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.

!

Important: Identifies information that is critical for successful application and understanding of the product.

ATTENTION:Only qualified personnel familiar with the construction and operation of this

equipment and the hazards involved should install, adjust, operate, or service this equipment.

!

Read and understand this manual and other applicable manuals in their entirety before
proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:DC bus capacitors retain hazardous voltages after input power has been
disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors
to discharge. Open the cabinet doors and check the voltage across the DC bus bars, 347 A,B,C
(+ bus) and 345 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are
discharged before touching any internal components. Failure to observe this precaution could
result in severe bodily injury or loss of life.

ATTENTION:The user must provide an external, hardwired emergency stop circuit outside of the
drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled
machine operation may result if this procedure is not followed. Failure to observe this precaution
could result in bodily injury.

ATTENTION: The user is responsible for conforming with all applicable local, national, and
international codes. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.

The information in this users manual is subject to change without notice.

AutoMax™ is a trademark of Rockwell Automation
©1998 Rockwell International Corporation

Chapter 1 Introduction

1.1 Standard Features...........................................................................................1-1

1.2 Optional Features............................................................................................1-2

1.3 Power Module Part Numbers ..........................................................................1-3

1.4 Related Publications........................................................................................ 1-4

1.5 Related Hardware and Software ..................................................................... 1-4

Chapter 2 Mechanical/Electrical Description

2.1 Mechanical Description ...................................................................................2-1

2.1.1 Power Module Components..................................................................2-1

2.2 Electrical Description .......................................................................................2-6

Chapter 3 Installation Guidelines

3.1 Installation Planning ........................................................................................3-1

3.2 Wiring .............................................................................................................. 3-2

3.2.1 Fuses ....................................................................................................3-2

3.2.2 Wire Sizes.............................................................................................3-2

3.2.3 Wire Routing ......................................................................................... 3-3

3.3 Grounding........................................................................................................ 3-3

3.4 Installing the Power Module Cabinet.. ....... ...... ....... ...... ....... ...... ....... ...... .........3-3

C

ONTENTS

Chapter 4 Diagnostics and Troubleshooting

4.1 Required Test Equipment................................................................................4-1

4.2 Power Module Tests with Input Power Off ...................................................... 4-2

4.3 Power Module Faults and Warnings................................................................ 4-4

4.3.1 Power Module Faults ............................................................................ 4-5

4.3.1.1 DC Bus Overvoltage Fault ......................................................4-5

4.3.1.2 DC Bus Overcurrent Fault....................................................... 4-5

4.3.1.3 Ground Current Fault..............................................................4-5

4.3.1.4 Instantaneous Overcurrent Fault ............................................4-6

4.3.1.5 Local Power Interface Fault ....................................................4-6

4.3.1.6 Charge Bus Time-Out Fault ....................................................4-6

4.3.1.7 Overtemperature Fault...................................... ....... ...... ....... .. 4-6

4.3.2 Power Module Warnings ....................................................................... 4-7

4.3.2.1 DC Bus Overvoltage Warning................................................. 4-7

4.3.2.2 DC Bus Undervoltage Warning............................................... 4-7

4.3.2.3 Ground Current Warning......................................................... 4-7

4.3.2.4 Load Sharing Warning ............................................................4-7

4.3.2.5 Overtemperature Warning .................................................... .. 4-8

4.4 Replacing Power Module Fuses and Sub-Assemblies.................................... 4-8

4.4.1 Replacing Fuses ...................................................................................4-8

4.4.2 Replacing an IGBT Phase Module Assembly ..................................... 4-15

4.4.2.1 Replacing an IGBT................................................................ 4-17

4.4.3 Replacing the Pre-charge Assembly...................................................4-17

4.4.4 Replacing a Blower Assembly............................................................. 4-18

4.4.4.1 Replacing a Blower Filter...................................................... 4-19

4.4.5 Replacing a Bus Capacitor Assembly ................................................. 4-19

4.5 Replacing the Power Module Cabinet ........................................................... 4-20

Table of Contents

I

Appendix A Technical Specifications........................................................................................... A-1

Appendix B SA3000 Internal DC Bus Control ............................................................................. B-1

Appendix C Replacement Parts ....... ...... ....... ...... ....... ...... ...... ....... ....................................... ...... .. C-1

Index ..................................... ...... ....... ...... ....... ...... ....................................... ...... ....... ..Index-1

II

High Power SA3000 AC Power Modules

List of Figures

Figure 1.1 – SA3000 Power Module Part Numbering Scheme ................................1-3

Figure 2.1 – 534A SA3000 Power Module Components.......................................... 2-3

Figure 2.2 – 972A 3000A Power Module Components ............................................2-4

Figure 2.3 – 1457A SA3000 Power Module Components........................................ 2-5

Figure 2.4 – Drive I/O and Processor Card Detail .................................................... 2-8

Figure 2.5 – 534A SA3000 Power Module Circuitry ................................................. 2-9

Figure 2.6 – 972A SA3000 Power Module Circuitry ...............................................2-10

Figure 2.7 – 1457A SA3000 Power Module Circuitry .............................................2-11

Figure 3.1 – 534A Power Module Mounting Dimensions (Single-Bay).....................3-4

Figure 3.2 – 972A Power Module Mounting Dimensions (Double-Bay) ...................3-5

Figure 3.3 – 1457A Power Module Mounting Dimensions (Triple-Bay)....................3-6

Figure 3.4 – SA3000 Power and Ground Connections.............................................3-7

Figure 4.1 – DC Bus Voltage Measuring Points ....................................................... 4-3

Figure 4.2 – 534A SA3000 Power Module Fuse Locations.................................... 4-10

Figure 4.3 – 972A SA3000 Power Module Fuse Locations.................................... 4-11

Figure 4.4 – 1457A SA3000 Power Module Fuse Locations.................................. 4-12

Figure 4.5 – 115VAC Control Power Supply Assemblies....................................... 4-13

Figure 4.6 – 25 KHz. Power Supply........................................................................4-14

Figure 4.7 – IGBT Module Assembly Mounting Bolt Locations ..............................4-17

Table of Contents

III

IV

High Power SA3000 AC Power Modules

List of Tables

Table 1.1 – SA3000 Power Module Configurations..................................................1-1

Table 1.2 – SA3000 Documentation (Binder S-3001) .............................................. 1-4

Table 3.1 – Fuse Ratings..........................................................................................3-2

Table 3.2 – Recommended DC Bus Input and AC Output Wire Sizes..................... 3-2

Table 3.3 – Terminal Tightening Torques.................................................................3-3

Table 4.1 – DC Bus and Terminal Tests...................................................................4-4

Table 4.2 – IGBT Tests.............................................................................................4-4

Table 4.3 – SA3000 Power Module Faults (Register 202/1202) ..............................4-5

Table 4.4 – SA3000 Warning Register 203 /1203 .................................................... 4-7

Table 4.5 – Power Module Replacement Fuse Specifications .................................4-9

Table of Contents

V

VI

High Power SA3000 AC Power Modules

C

HAPTER

1

Introduction

The High Power SA3000 Power Modules are variable-voltage, variable-frequency
power inverters for Distributed Power System (DPS) drives. They are designed to
operate from a separate converter (diode bridge, phase-controlled rectifier, SB3000
Synchronous Rectifier, or a common DC bus supply) to drive induction motors at
variable speeds using pulse-width modulation (PWM) technology.

The SA3000 Power Modules are configured in three output current ratings: 534 amp,
972 amp, and 1457 amp when used at a 2 kHz carrier frequency. They have a range
of AC Input voltage ratings. See table 1.1. Nominal DC bus voltage may range from
300 to 800 VDC.

4 kHz operation requires a derating of the AC input current and DC output load current
when compared with operation at 2 kHz. See table 1.1.

The SA3000 Power Module output current ratings given are 100% continuous with no
overload. They may be derated for lower current ratings with overload capability.

Table 1.1 – SA3000 Power Module Configurations

Output

Base Part

Number

850020-11xxx
850020-21xxx

850020-12xxx
850020-22xxx

850020-13xxx
850020-23xxx

1. Output current ratings at 40° C (104° F) ambient air temperature and 60 Hz. Reduce all output current ratings by 5% when the Power
Module blowers are operated from a 50 Hz power source.

2. Contact Rockwell Automation for duty cycle ratings.

3. 800 VDC if an SA3000/SA3100 unit is used to supply 575 VAC output to the motor.

Cabinet

Type

One Bay

Two Bays 250-820V 972A 890A 1275A 230-460V

Three Bays 250-820V 1457A 1335A 1900A 230-460V

DC Bus

Input Volts

250-820V

Amps

(2 KHz)

3

534A 445A 700A 230-460V

Output
Amps

(4 KHz)

1

Peak

Amps

2

AC Input

Volts

1.1 Standard Features

High Power SA3000 Power Modules have the following standard features:

•

IGBT power semiconductor bridge

•

Carrier switching frequencies from 2 to 4 kHz

•

Input and output short-circuit protection

Introduction

•

Fiber-optic communication with the DPS host, the Universal Drive Controller (UDC)
module

1-1

•

Auto-tuning

•

Standard cabinet paint

1.2 Optional Features

The following optional features are available for High Power SA3000 Power Modules

•

DC bus voltage meter

•

Motor ammeter

•

Motor voltmeter

•

Motor torque meter

•

Motor frequency meter

•

Main disconnect

•

Pre-charge

•

Separation of critical and non-critical 115 VAC control power

•

DC bus top hat enclosure

•

Custom cabinet paint

1-2

High Power SA3000 AC Power Modules

1.3 Power Module Par t Numbers

SA3000 Power Module part numbers are organized by the number of cabinet bays,
i.e., single (534A), double (972A), or triple (1457A) cabinet bay configurations, in
combination with the supplied options. See figure 1.1.

850020 -1

Cabinet Top
Enclosures:

R

1

Size of Unit

S

T

Pre-charge:

Main
Disconnect:

Meters:

1 = 534A Output - 1 Bay Unit
2 = 972A Output - 2 Bay Unit
3 = 1457A Output - 3 Bay Unit

1 = DC Bus Assembly Enclosure
2 = DC Bus Top Hat Enclosure

T = Supplied - Standard Cabinet Paint
Y = Supplied - Custom Cabinet Paint
X = Not Supplied - Standard Cabinet Paint
Z = Not Supplied - Custom Cabinet Paint

S = Supplied - Standard Cabinet Paint
W = Supplied - Custom Cabinet Paint
X = Not Supplied - Standard Cabinet Paint
Z = Not Supplied - Custom Cabinet Paint

R = Supplied - Standard Cabinet Paint
V = Supplied - Custom Cabinet Paint
X = Not Supplied - Standard Cabinet Paint
Z = Not Supplied - Custom Cabinet Paint

(1)

Introduction

SA3000 Power Module - Base Part Number

1. Top Hat Enclosure accommodates bending radius of DC bus cable (customer supplied).

Figure 1.1 – SA3000 Power Module Part Numbering Scheme

1-3

1.4 Related Publications

This manual describes the hardware components of the SA3000 Inverter Power
Module. The other instruction manuals in binder S-3001 describe the SA3000
software, regulator, and communications. Table 1.1 lists the document part numbers.

Table 1.2 – SA3000 Documentation (Binder S-3001)

Document Document Part Number

SA3000 Information Guide S-3023
Drive System Overview S-3005
Universal Drive Controller Module S-3007
Fiber Optic Cabling S-3009
SA3000 Drive Configuration & Programming S-3016
SA3000 Power Module Interface Rack and Modules S-3019
Medium Power SA3000 Power Modules S-3020
SA300 Diagnostics, Troubleshooting, & Start-Up

Guidelines
High Power SA3000 Power Modules S-3038

SA3000 Power Modules are designed to be operated from a common DC bus, which
can be supplied by a Distributed Power System SB3000 Synchronous Rectifier. Refer
to the following manuals for information on the SB3000 Synchronous Rectifier system:

•

S-3034 SB3000 Synchronous Rectifier Configuration and Programming

•

S-3043 High Power SB3000 Power Modules

1.5 Related Hardware and Software

The following related hardware may be purchased separately:

•

P/N 613613-xxS Fiber-optic cable (cable length xx is specified in meters)

•

B/M O-57552 Universal Drive Controller (UDC) module

•

B/M O-57652 Universal Drive Controller (UDC) module EM

S-3021

1-4

High Power SA3000 AC Power Modules

Mechanical/Electrical Description

This chapter provides an overview the SA3000 Power Module’s main components and
their mechanical and electrical characteristics.

2.1 Mechanical Description

The High Power SA3000 Power Modules are variable-voltage, variable-frequency
inverters that are housed in protective sheet metal enclosures. The Power Modules
are supplied in single, double, and triple bay cabinet configurations, depending upon
the current rating. See figures 2.1 to 2.3. Power Module dimensions are shown in
figures 3.1 to 3.3.

2.1.1 Power Module Components

The Power Modules have the following main components:

Phase modules

Each Phase module contains four semiconductor IGBTs (insulated gate bi-polar
transistors). IGBT pairs are switched on and off by the integrated Snubber/Gate Driver
module to provide modulated phase voltages (U,V,W) to the motor. Fuses and
thermostats are provided to protect the IGBT modules.

C

HAPTER

2

Snubber/Gate Driver Module

Each Snubber/Gate Driver module, mounted on the IGBT phase module, receives
gating signals via fiber-optic cabling from the GDI module(s) in the PMI rack and
translates the signals into the appropriate voltage and current levels to turn the IGBTs
on and off. Feedback, indicating the integrity of the phase module and IGBTs, is then
sent back to the GDI module(s).

This module also provides snubber circuitry (resistors, diodes, and capacitors) to
control voltage overshoot and undershoot when the IGBTs are switching.

Fiber-Optic Communication

Fiber-optic cabling is used to transmit gate driver signals from the Gate Driver
Interface (GDI) module.These signals are used to turn the IGBTs on and off. IGBT
module feedback status information is sent via the fiber-optic cabling back to the GDI
module(s) in the PMI rack. Fiber-optic cabling is immune to electromagnetic and radio
frequency interference (EMI/RFI) and eliminates ground loops. For more information
on fiber-optic cabling refer to the Distributed Power System Fiber-Optic Cabling
instruction manual (S-3009).

Mechanical/Electrical Description

2-1

Local Power Interface module (LPI)

The LPI module is the interface between the SA3000 Power Module and the PMI rack.
It is through this module that information is sent to the SA3000 Power Module and
feedback data is sent back to the PMI rack.

Capacitor Bank Assembly

The capacitor bank's electrolytic capacitors store power locally for the IGBTs.

115 VAC Power Supply Assemb ly

Power Supply Assembly P/N 850100-3S allows for the separation of critical (PMI rack,
25 KHz power supply, DC power supplies) and non-critical (blower motors) 115 VAC
power via two 115 VAC terminal boards and two 25A circuit breakers. Removing the
jumper wires between the two terminal boards provides the separation of critical and
non-critical power. The circuit breakers can be locked in either the ON or OFF position
when the optional locking mechanism is used.

Power Supply Assembly P/N 850100-3R provides one 115 VAC terminal board and
one 25A circuit breaker. This assembly distributes 115 VAC power to the DC power
supplies, the 25 KHz power supply, the PMI rack, and the Power Module blowers. See
figure 4. 5.

25 KHz Power Supply Assembly

The 25 KHz Power Supply Assembly provides power to the six IGBT gate drivers in
each Power Module. 25KHz AC power is used for transformer isolation and noise
immunity. Input power is provided by the 115 VAC power supply. See figure 4.6.

DC Bus Voltage Meter (Option)

The DC Bus Voltage meter, which is connected directly across the DC bus, measures
the DC bus voltage being applied to the power module.

Output Meters (Option)

These meters measure the AC voltage (0-600V), current (0-200 percent of full load),
torque (200-0-200 percent of full load), and frequency (120-0-120Hz) being applied to
the motor. These meters are connected to the PMI Processor’s meter ports, which are
under software control.

Main Disconnect (Option)

Depending on system requirements, a DC input disconnect may be provided. Note
that if a disconnect is supplied, the pre-charge assembly option must also be used if
the Power Module is operating from a constant potential DC bus supply.

Pre-charge Assembly (Option)

The Pre-charge Assembly consists of a contactor, pre-charge resistors, and a printed
circuit board assembly. The contactor bypasses the pre-charge resistor after the bus
voltage reaches a programmable threshold value. A pre-charge control module
communicates with the LPI module and controls the pre-charge contactor.

2-2

High Power SA3000 AC Power Modules

18

15

15

15

20

14

6

OUTPUT METER PANEL

(OPTIONAL)

MOTOR

GRD

AC MOTOR OUTPUT

U

MOTOR

GRD

V

W

DISCONNECT SWITCH

A
M
P

F

5

8
9

24
26

23
25

19

POWER MODULE A

PRE-CHARGE ASSEMBLY

4

2

F103

CAPACITOR

3

BANK

PHASE U

2

F104

PHASE V

+24VPS-24V

PS

PS PS

±15V

±15V

PS

PS

25KHZ PS

1
B
C

1

U

U

B

F

F

C

1

3

1

22
11

17
16

7

SALES ORDER

NAMEPLATE

13

CUSTOMER CONTROL WIRING

28

IF USED, THE O U TPUT METER
PANEL IS MOUNTED IN THE CABINET
DOOR OF POWER MODULE A.

27

2

F105

PHASE W

BLOWER

1

ASSEMBLY

PMI RACK

LPI

MODULE

GDI

A
.
D
O
M
.
R
W
P

6
T
O

L
S

10

12

1. Blower Assembly 2. IGBT Phase Module Assembly 3. Capacitor Bank Assembly

4. Pre-charge Assembly

5. DC Disconnect Assembly

1

6. DC bus fuse

7. +/- 15V DC Power Supply 8. 24V DC Power Supplies 9. 115VAC C.B. - Non Critical Pwr

10. Local Power Interface Module 11. 250VA Isolation Transformer 12. Power Module Interface Rack

13. 25KHz Power Supply 14. Reactor Assembly 15. LEM Output Current Sensor

16. Control Fuse (1FU) 17. Control Fuse (3FU) 18. DC Feedback Module

19. 115VAC C.B. - Critical Power 20. Blower Filter 21. Motor Feedback Resistors

22. Power Supply Assembly

25. Motor Ammeter

28. Motor Frequency

1

1

1. Optional

Mechanical/Electrical Description

23. Door Interlock Bypass Switch

26. Motor Voltmeter

Figure 2.1 – 534A SA3000 Power Module Components

1

1

24. DC Bus Voltage Meter

27. Motor Torque Meter

1

1

2-3

OUTPUT METER PANEL

(OPTIONAL)

IF USED, THE O U TPUT METER
PANEL IS MOUNTED IN THE CABINET
DOOR OF POWER MODULE A.

24
26
28

23
25
27

15

15

14

15

20

21

MOTOR

GRD

AC MOTOR OUTPUT

U V

MOTOR

GRD

W

14

MOTOR

GRD

B

A

M

M

P

P

F

F

18

POWER MODUL E B

PRE-CHARGE ASSEM B LY

POWER MODUL E A

PRECHARGE ASSEMBLY

4

2

F103

PHASE U

K
N
A
B

15

F103

2

F104

3

F105

PHASE V

R
O

T

I
C
A
P
A

C

2

PHASE W

BLOWER

1

ASSEMBLY

15

15

F104

3

F105

2

PHASE U

K
N
A
B

2

PHASE V

R
O

T

I
C
A
P
A
C

2

PHASE W

1

ASSEMBLY

20

6

DISCONNECT SWITCH

+24V

4

BLOWER

+24V

PS

PS PS

±15V

±15V

PS

PMI RACK

-24V
PS

1

U

U

B

F

F

C

3

1

1

--

25KHZ PS

MODULE

5

8

9
19
22

1
B
C

11
17
16

7

SALES ORDER

NAMEPLATE

13

CUSTOMER
CONTROL WIRING

LPI

GDIGDI

B

A
.

.

D

D

O

O

M

M

.

.

R

R
W

W

P

P

7

6

T

T

O

O

L

L

S

S

10

12

1. Blower Assembly 2. IGBT Phase Module Assembly 3. Capacitor Bank Assembly

4. Pre-charge Assembly

5. DC Disconnect Assembly

1

6. DC bus fuse

7. +/- 15V DC Power Supply 8. 24V DC Power Supplies 9. 115VAC C.B. - Non Critical Pwr

10. Local Power Interface Module 11. 250VA Isolation Transformer 12. Power Module Interface Rack

13. 25KHz Power Supply 14. Reactor Assembly 15. LEM Output Current Sensor

16. Control Fuse (1FU) 17. Control Fuse (3FU) 18. DC Feedback Module

19. 115VAC C.B. - Critical Power 20. Blower Filter 21. Motor Feedback Resistors

22. Power Supply Assembly

25. Motor Ammeter

1

28. Motor Frequency

1. Optional

1

23. Door Interlock Bypass Switch

26. Motor Voltmeter

Figure 2.2 – 972A 3000A Power Module Components

1

2-4

1

24. DC Bus Voltage Meter

27. Motor Torque Meter

High Power SA3000 AC Power Modules

1

1

OUTPUT METER PANEL

(OPTIONAL)

IF USED, THE O U TPUT METER
PANEL IS MOUNTED IN THE CABINET
DOOR OF POWER MODULE A.

24
26
28

23
25
27

21

6

C
M
P
F

4

22

2

2

BLOWER

ASSEMBLY

DISCONNECT SWITCH

1

+24VPS-24V+24V

B

PS

PS PS

C

1

U

U

±15V

±15V

B

F

F

C

PS

1

3

1

25KHZ PS

LPI

MODULE

GDIGD

A
.
D

PMI RACK

O
M
.
R
W
P

6
T
O
L
S

I

GDI

B

C

.

.

D

D

O

O

M

M

.

.

R

R
W

W
P

P

8

7

T

T

O

O

L

L

S

S

5

8
9

19

22
11
17
16

7

SALES ORDER

NAMEPLATE

13

CUSTOMER CONTR OL

WIRING

10

12

MOTOR

GRD

AC MOTOR OUTPUT

14

14

MOTOR

GRD

B

WVU

14

A
M

M

P

P

F

F

18

POWER MODULE APOWER MODULE BPOWER MODULE C

PRE-CHARGE AS SE MBLY

4

PRE-CHARGE ASSEMBLY

4

PRE-CHARGE ASSEMBL Y

2

15

F103

PHASE U

K
N
A
B

2

15

F104

3

15

F105

PHASE V

R
O
T

I
C
A
P
A
C

2

PHASE W

BLOWER

1

ASSEMBLY

15

F103

PHASE U

K
N
A
B

2

15

F104

3

15

F105

PHASE V

R
O
T

I
C
A
P
A
C

2

PHASE W

BLOWER

1

ASSEMBLY

2020

15

15

F103

F104

3

15

F105

PHASE U

K

N
A
B

PHASE V

R
O
T

I
C
A
P
A

C

PHASE W

1

20

1. Blower Assembly 2. IGBT Phase Module Assembly 3. Capacitor Bank Assembly

4. Pre-charge Assembly

5. DC Disconnect Assembly

1

6. DC bus fuse

7. +/- 15V DC Power Supply 8. 24V DC Power Supplies 9. 115VAC C.B. - Non Critical Pwr

10. Local Power Interface Module 11. 250VA Isolation Transformer 12. Power Module Interface Rack

13. 25KHz Power Supply 14. Reactor Assembly 15. LEM Output Current Sensor

16. Control Fuse (1FU) 17. Control Fuse (3FU) 18. DC Feedback Module

19. 115VAC C.B. - Critical Power 20. Blower Filter 21. Motor Feedback Resistors

22. Power Supply Assembly

25. Motor Ammeter

28. Motor Frequency

1

1

1. Optional

Mechanical/Electrical Description

23. Door Interlock Bypass Switch

26. Motor Voltmeter

Figure 2.3 – 1457A SA3000 Power Module Components

1

1

24. DC Bus Voltage Meter

27. Motor Torque Meter

1

1

2-5

2.2 Electrical Description

DC bus input power is applied to the Power Module through terminals 45 (–) and
47 (+), passes through the optional DC bus disconnect and in-line fuses, and is then
fed to the optional pre-charge circuitry. See figures 2.4 to 2.7.

When pre-charge circuitry is present and DC input power is applied, the internal DC
bus begins charging through the pre-charge resistors. Once the DC bus capacitors
are fully charged (per the programmable threshold value) and all pre-charge criteria
are met, the internal pre-charge contactor closes and bypasses the pre-charge
resistors. If the DC bus disconnect option is not used, the bus supply is responsible for
the charging operation. Refer to Appendix B for additional information on SA3000
internal DC bus control.

The DC bus voltage is filtered and stored by the electrolytic capacitors. Discharge
resistors are designed to discharge the capacitors down to 50 VDC within 5 minutes
after power is removed from the input terminals. However, if a DC bus fuse has blown,
it is possible for a charge to be stored on the DC bus capacitors without being
indicated on the DC bus voltmeter. Wait 10 minutes before working on the unit. Be
sure to measure the DC bus potential of each Power Module capacitor bank before
touching any internal circuitry. See figure 4.1 for test point locations.

ATTENTION:

power has been disconnected. After disconnecting input power, wait ten

!

When the DC bus operating voltage is reached, the connected Inverter Power
Modules may be operated. Note that if an SB3000 Power Module is used to supply the
DC bus, the SB3000 Power Module cannot support the loading of SA3000 Inverter
Power Modules when the soft-charge resistors in the SB3000 are limiting the bus
charging current.

!

The SA3000 inverter power circuitry uses the filtered DC bus voltage to provide the
variable-voltage, variable-frequency output to the motor (terminals U, V, W). The 972
Amp and 1457 Amp units have reactors for load sharing on their outputs. The IGBTs
are switched by the gate drivers on the IGBT phase module under the control of the
PMI rack. A LEM sensor is located on each output phase (U,V,W) of each SA3000
Inverter Power Module (A,B, or C) to provide output current feedback for overcurrent
protection.

(10) minutes for the DC bus capacitors to discharge. Open the cabinet
doors and check the voltage across the DC bus bars, 347 A,B,C (+ bus)
and 345 A,B,C (- bus), with an external voltmeter to ensure the DC bus
capacitors are discharged before touching any internal components.
Failure to observe this precaution could result in severe bodily injury or
loss of life.

ATTENTION:

Module must be in standby or in regeneration whenever the SB3000
Power Module’ s pre-charge contactor opens. The SB3000 Power
Module’s soft-charge resistors may fail if this interlocking restriction is
not observed. Failure to observe this precaution could result in damage
to, or destruction of, the equipment.

DC bus capacitors retain hazardous voltages after input

When used with an SB3000 bus supply , the SA3000 Power

2-6

High Power SA3000 AC Power Modules

Each SA3000 Inverter Power Module connected to an SB3000 Power Module
supplied DC bus must have a separate pre-charge resistor and contactor to limit the
current into its capacitor bank. It is the responsibility of the application tasks to make
sure that the SB3000 Power Module is in run before the SA3000 Inverter Power
Module is put into run.

ATTENTION:When used with an SB3000 Power Module, the SB3000
Power Module must be in run before the SA3000 Inverter Power Module

!

If the SB3000 Power Module is not in run, the DC bus voltage will not be high enough
to support the full rating of the SA3000 Inverter Power Module. If the SB3000 Power
Module is shut down due to a fault condition, controlled shutdown of the SA3000
Power Module is the responsibility of the application program running in the SA3000
UDC module.

is put into run. If the pre-charge contactor supplying the SB3000 Power
Module is not closed, running the SA3000 Power Module will damage
the SB3000 pre-charge resistors. Failure to observe this precaution could
result in damage to, or destruction of, the equipment.

Mechanical/Electrical Description

2-7

YYYL

FROM 115VAC

YYYN

INDUSTRIAL
DUTY
BRUSHLESS
RESOLVER
P/N

800123-x

DRIVEN BY

MOTOR

PMI RACK AND OPTIONAL

AUTOMATE I/O RAILS

ARE MOUNTED

IN POWER MODULE

ESR

BN

REFERENCE
INPUT

(ROTOR)

SINE
OUTPUT
(STATOR)

COSINE
OUTPUT
(STATOR)

(+)

R1

(-)

R2

(+)

S1

(-)

S3

(+)

S2

(-)

S4

FROM
ANALOG
SIGNAL

FIBER OPTIC COMM. LINK
FROM UDC CARD

I/O RAIL

(IF USED)

FROM T.B. (P2 & N)

DRIVE I/O
B/M O-60031
(C3)

XXX01

XXX03

XXX05

XXX07

XXX11

REF. OUT(+)
XXX21
XXX22
XXX23
XXX24
XXX26
XXX25

XXX31
XXX32

AC

AC

AC

DC

REF. OUT(-)

SIN INPUT(+)

SIN INPUT(-)

COS INPUT(+)

COS INPUT(-)

EXT. TRIG(+)

EXT. TRIG(-)

ANALOG IN(+)

ANALOG IN(-)

SHIELD

1
2
3
4
5
6

(+)

(HI)

AUX
IN1

(HI)

AUX
IN2

(HI)

AUX
IN3

(HI)

AUX
IN4

(HI)

AUX
IN5

(HI)

MCR

(HI)

AUX
OUT

(HI)

ORG

BLU

1RPI

A

3

C AUX IN1

5

E

7

H

9

K AUX IN4

11

M AUX IN5

13

15

S AUX OUT

(+)

1

A

(-)

2

B

3

(+)

D

4

(-)

C

(+)

5

E

(-)

6

F

(+)

7

H

(-)

8

J

1

(+)

P

2

(-)

N

SHLD

3

R

PROCESSOR
B/M
O-60021
(C2)

FIBER OPTIC
COMM LINK

(P2)

XMT

(P3)

RCV

RAIL

PORTS

0

(P5)

1

AC POWER
TECH MODULE
B/M 60023

SYNCH XFER

INTERFACE

RPI

R201_B0

(C3-P2)

R201_B1

AUX IN2

R201_B2

AUX IN3

R201_B3

R201_B4

R201_B5

MCRP

R101_B1

0.5 SECOND
OFF-DELAY AFTER
RPI GOES "LOW"

R101_B4

(C3-P1)

REFERENCE
OUTPUT

SINE
INPUT

COSINE
INPUT

EXTERNAL
TRIGGER

ISOLATED

(±10V=(±2047)

±10V
METER(P4)
PORTS

(P1)

POWER

MODULE

2RPI

(LO)

B

AUX
IN1

4

(LO)

D

AUX
IN2

6

(LO)

F

AUX
IN3

8

(LO)

J

AUX
IN4

10

(LO)

L

AUX
IN5

12

(LO)

N

14

MCR

XXX14

(LO)

R

AUX
OUT

16

T

(P1)

+

1

COM

+

2

COM

+

3

COM

+

4

COM

(C4)

(P1)

(P2)

(LO)

XXX16

CABLE

RUN PERMISSIVE
INTERLOCK

MOTOR THERMOSTAT

BLOWER MOTOR
STARTER FEEDBACK

OPTIONAL METER PACKAGE

0-600V

CALIB

0-200%

CALIB

120Hz-0-120Hz

CALIB

200%-0-200%

CALIB

MOUNTED TO CABINET DOOR

OF POWER MODULE A

TO PARALLEL
INTERFACE MODULE
PMI RACK SLOT C5

MOTOR
VOLTS

MOTOR
CURRENT

MOTOR
FREQUENCY

MOTOR
TORQUE

2-8

Figure 2.4 – Drive I/O and Processor Card Detail

High Power SA3000 AC Power Modules

NOTE: THESE JUMPERS ARE REMOVED
WHEN A SEPARATE 115 VAC SUPPLY
IS USED FOR THE PMI RACK.

115VAC FROM A-C

DISTRIBUTION

X
X
X
L

1

A

L1A

X
X
X
L

1

L2L1

C
B
1

TO

BLOWERS

BELOW

CONDITIONED POWER

FROM CRITICAL 115VAC

SUPPLY DISTRIBUTION

W
W
W
D

1

D1

FROM 115VAC

(

R
E
D
)

INTERLOCK
BYPASS

S.R.

D3

SOLENOID
(OPTIONAL)

DOOR

W
W
W
D

(

R

2

E
D
)

D2

SA3000
INVERTER
W/D 30395-11

800VDC FROM SB3000

X

X
X
X
L

2

X
X
X
1

L

1

A

1L1AGRD

3

3

.

2

F

A

U

X

X

X

X

X

1

1

L

L

1

2

GRD

1L1

1L2

1

C
B
1

5

1

.

0

F

A

U

2

5

0

V
A

LINE

FILTER

PMI

P/S

RACK

PROC

DRIVE

I/O

POWER

TECH
PARA

INTER

A

GDI

Y
Y
Y
4

7

(+)

47

P

(

O

R
E

P

C

T
I

H

O

A

N

R

A

G

L

E

)

ORG
BLU

PRE-CHARGE

0-1000 VDC

(OPTIONAL)

F

1

0

1

A

K
1

1

A

GATE

DRIVERS

XMT
RCV

BOARD

F103A-105A

(-)

R

Y
Y
Y
4

5

45

K
1

1

A

GRD

F
1

0

2

A

A

Y
Y
Y
G

R
D

DC BUS

DISCONNECT

(OPTIONAL)

L

X
X
X
L

115VAC

TO DRIVE

I/O CARD

M

V

X
X
X
W

W

M

THERM

P1 P2

LEM

GRD

W

X
X
X
G

R
D

G

A

CON1
CON1
CON1

GDI

LPI

GDI

CARD

GDI

A

LEM
LEM
LEM

CON5

N

X
X
X
N

P2

P1

X

X

X

X
X

X
P

P

2

1

TO

RESOLVER

WARNING

FAULT

BLOWER ASSEMBLY

U

X

X

X

X

X

X
U

V

U

V

MOTOR

Figure 2.5 – 534A SA3000 Power Module Circuitry

GRD

Mechanical/Electrical Description

2-9

115VAC FROM A-C

115VAC FROM A-C

DISTRIBUTION

DISTRIBUTION

X

X

X

X

X

X

L

L

1

1

A

L1AL1A L1 L2

25A

NOTE: THESE JUMPERS ARE REMOVED
WHEN A SEPARATE 115 VAC SUPPLY
IS USED FOR THE PMI RACK.

CONDITIONED POWER

FROM CRITICAL 115VAC

SUPPLY DISTRIBUTION

1L1A

X
X
X
1

L

1

A

1L1 GRD

25A

X
X
X
L

2

GRD

C

B
1

800VDC FROM SB3000

X

X

X

X

X

X

1

1

L

L

1

2

1L2

1

C
B
1

Y
Y
Y
4

7

(+) (-)

47

0-1000 VDC

Y
Y
Y
4

5

45 GRD

DISCONNECT

Y
Y
Y
G
R
D

DC BUS

(OPTIONAL)

W
W
W
D

1

D1

(

R
E
D
)

INTERLOCK
BYPASS

S.R.

FROM 115VA C

D3

SOLENOID
(OPTIONAL)

DOOR

W

(

R

W

E

W

D
)

D
2

D2

SA3000
INVERTER
W/D 30395-12

TO

BLOWERS

BELOW

3

.

2

A

X
X
X
L

115VAC

TO DRIVE

I/O CA R D

5

1

3

.

0

F

F

A

U

U

2

5

0

V
A

LINE

FILTER

PMI

P/S

RACK

PROC

DRIVE

I/O

POWER

TECH
PARA

INTER

A

GDI

B

GDI

A

CON1

B

CON1
CON1

GDI

LPI

GDI

CARD

GDI

A

LEM

B

LEM
LEM

CON5

L

P1

N

X
X
X
N

P2

X

X

X

X

X

X

P

P

1

2

(OPTIONAL)

F
1

0

1

A

P

(

O

R
E

P

K

C

T

1

I

H

1

O

A

A

N

R

A

G

L

E

)

GATE

DRIVERS

XMT

ORG

RCV

BLU

PRE-CHARGE

BOARD

F103A-105A

FAULT

BLOWER ASSEMBLY

U V

X

X

X

X

X

X

V

U

F

F

1

1

0

0

1

2

B

A

K
1

R

1

A

A

LEM

M

W GRD

X

X

X

X

X

G

X
W

R
D

K
1

1

B

GATE

DRIVERS

XMT

ORG

RCV

BLU

PRE-CHARGE

BOARD

F103B-105B

WARNINGWARNING

FAULT

BLOWER ASSEMBLY

GRD

R

F
1

0

2

B

K
1

1

B

B

LEM

M

2-10

V

W

TO

RESOLVER

U

MOTOR

M

THERM

P1 P2

G

Figure 2.6 – 972A SA3000 Power Module Circuitry

High Power SA3000 AC Power Modules