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.

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

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

PS

25KHZ PS

1 B C

1

U

B

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. Optional

Mechanical/Electrical Description

23. Door Interlock Bypass Switch

26. Motor Voltmeter

Figure 2.1 – 534A SA3000 Power Module Components

1

24. DC Bus Voltage Meter

27. Motor Torque Meter

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

14

15

20

21

MOTOR

GRD

AC MOTOR OUTPUT

U V

MOTOR

GRD

W

14

MOTOR

GRD

B

A

M

P

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

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

PS

PMI RACK

-24V PS

1

U

B

F

C

3

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

O

M

.

R

R W

W

P

7

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

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

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

BLOWER

ASSEMBLY

DISCONNECT SWITCH

1

+24VPS-24V+24V

B

PS

PS PS

C

1

U

±15V

B

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

O

M

.

R

R W

W P

P

8

7

T

O

L

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

MOTOR

GRD

B

WVU

14

A M

M

P

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

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. Optional

Mechanical/Electrical Description

23. Door Interlock Bypass Switch

26. Motor Voltmeter

Figure 2.3 – 1457A SA3000 Power Module Components

1

24. DC Bus Voltage Meter

27. Motor Torque Meter

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

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

.

2

F

A

U

X

1

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

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 P

P

2

1

TO

RESOLVER

WARNING

FAULT

BLOWER ASSEMBLY

U

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

DISTRIBUTION

X

L

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

1

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

A

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

P

1

2

(OPTIONAL)

F 1

0

1

A

P

(

O

R E

P

K

C

T

1

I

H

1

O

A

N

R

A

G

L

E

)

GATE

DRIVERS

XMT

ORG

RCV

BLU

PRE-CHARGE

BOARD

F103A-105A

FAULT

BLOWER ASSEMBLY

U V

X

V

U

F

1

0

1

2

B

A

K 1

R

1

A

LEM

M

W GRD

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

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

115VAC FROM A-C

DISTRIBUTION

X X X L

1

A

L1A

25A

W W W I

V L

1

L2L1

C

B 1

TO

BLOWERS

BELOW

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

CONDITIONED POWER

FROM CRITICAL 115VAC

SUPPLY DISTRIBUTION

X

W W W I

V L

2

GRD

X

1

L

1

A

1L11L1A 1L2

25A

5

3

.

2

A

X

X X L

115VAC TO DRIVE I/O CARD

L

1

3

.

0

F

A

U

LINE

FILTER

P/S

PROC

DRIVE

I/O

POWER

TECH PARA

INTER

GDI GDI GDI

CON1 CON1 CON1

GDI GDI GDI LEM

LEM LEM

CON5

NP1P2 U V

X

P

N

1

800VDC FROM SB3000

ON SHEET YYY

X X X 1

L

2

GRD

1

C B 1

2

5

0

V A

PMI RACK

A B C

LPI CARD

A B C

X X X P 2

Y Y

Y 4

7

(+)

47 45

0-1000 VDC

(OPTIONAL)

F 1

0

1

A

P

(

O

R E

P

K

C

T

1

I

O

N A L

)

R

H

1

A

A R G E

GATE

DRIVERS

XMT

ORG

RCV

BLU

PRE-CHARGE

BOARD

F103A-105A

WARNING

FAULT

BLOWER ASSEMBLY

X

V

U

(-)

M

X X X W

W

Y Y Y 4

5

K 1

1

A

LEM

X X X G R D

Y Y G R D

GRD

DC BUS

DISCONNECT

(OPTIONAL)

F

1

0

2

A

ORG BLU

PRE-CHARGE

BOARD

F103B-105B

BLOWER ASSEMBLY

GRD

WARNING

W W W D

1

D1

F 1

0

1

B

K 1

1

B

DRIVERS

FAULT

(

R E D )

INTERLOCK BYPASS

R

GATE

XMT RCV

M

FROM 115VAC

D3

S.R.

SOLENOIDS (OPTIONAL)

F 1

0

2

B

K

1

B

LEM

W W W D

(

R

2

E D )

D2

SA3000 INVERTER W/D 30395-13

DOOR

F 1

0

1

C

K 1

1

C

GATE

DRIVERS

ORG BLU

PRE-CHARGE

BOARD

F103C-105C

WARNING

FAULT

BLOWER ASSEMBLY

XMT RCV

F 1

0

2

C

K 1

R

1

C

LEM

M

Mechanical/Electrical Description

TO

RESOLVER

UVWG

M

THERM

MOTOR

P1 P2

Figure 2.7 – 1457A SA3000 Power Module Circuitry

2-11

2-12

High Power SA3000 AC Power Modules

This chapter describes the guidelines and wiring recommendations to be followed when installing High Power SA3000 Power Modules. Installation and replacement procedures are included for the 534A, 972A, and 1457A Power Modules.

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.

3.1 Install at io n Planning

SA3000 Power Module current ratings are dependent upon inlet air temperature. Ratings are given at 40° C (104° F) ambient. Refer to table 1.1 for output current ratings.

Internal Power Module conditions are monitored by two thermal switches on the heatsink. One switch is used to indicate a warning condition (register 203/1203, bit 7, WRN_OT@); the other is used to indicate a fault condition (register 202/1202, bit 7, FLT_OT@). The thermal warning switch closes at 78° C (172.4° F) ; the thermal fault switch closes at 85°C (185° F). Refer to the SA3000 Configuration and Programming instruction manual (S-3042) for more information on faults and warnings.

C

HAPTER

3

Installation Guidelines

Use the following guidelines when planning your SA3000 Power Module installation:

•

The relative humidity around the SA3000 Power Module must be kept between 5 and 90% (non-condensing).

•

Do not install above 1000 meters (3300 feet) without derating. For every 91.4 meters (300 feet) above 1000 meters (3300 feet), the SA3000 Power Module's current rating is derated 1%.

•

/RFDWH WKH 6$ 3RZHU 0RGXOH LQ D FOHDQ FRRO DQG GU\ DUHD )ROORZ WKH

recommendations given in IEC 68 concerning environmental operating conditions.

•

Be sure surrounding equipment does not block service access to the SA3000 Power Module.

•

$OORZ DGHTXDWH FOHDUDQFH IRU DLU YHQWLODWLRQ 6$ 3RZHU 0RGXOHV SXOO LQ DLU IURP WKH

bottom of the cabinet and exhaust it through the top of the cabinet. Each cabinet bay of the SA3000 Po wer Module has one fan. Allow at least 30 cm (12") above and 2 m (6.6') in front of the SA3000 Power Module for adequate air clearance.

•

Individual motor lead lengths cannot exceed 100 meters (328 feet).

•

Refer to the Drive System Installation manual (D2-3115) for more information.

3-1

3.2 Wiring

!

System wiring is to be done according to the supplied wiring diagrams (W/Es), which are application-specific. Sections 3.2.1 through 3.2.3 provide additional information on fuses and recommended wiring.

3.2.1 Fuses

!

Fuses are provided to protect the Power Module's DC bus, 115 VAC control power input lines, and individual IGBT phase modules. See table 3.1 for the fuse values.

FPM A,B,C DC Bus 1000 A 1000 VAC 64676-80P F103 A,B,C

F104 A,B,C F105 A,B,C

ATTENTION:

local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION:

protection be provided to protect input power wiring. Install the fuses recommended in table 3.1. Do not exceed the fuse ratings. Failure to observe this precaution could result in damage to, or destruction of the equipment.

Fuse

IGBT Phase

1FU 115 VAC 5 A 600 VAC 64676-29R 3FU 115 VAC 3.2 A 600 VAC 64676-29P

The user is responsible for conforming with all applicable

The NEC/CEC requires that upstream branch circuit

Table 3.1 – Fuse Ratings

Circuit

Modules

Fuse Current

Rating

630 A 1000 VAC 64676-79AZ

Fuse Voltage

Rating

Rockwell

P/N

3-2

3.2.2 Wire Sizes

Input wiring should be sized according to applicable codes to handle the SA3000 Power Module's continuous-rated input current. Output wiring should be sized according to applicable codes to handle the SA3000 Power Module's continuous-rated output current. Recommended wire sizes are shown in table 3.2. Terminals should be tightened to the torque values provided in table 3.3.

SA3000 Output Rating

1. NEC-recommended cable types: 40oC (104oF) copper wire.

Table 3.2 – Recommended DC Bus Input and AC Output Wire Sizes

Size of Wire

534A 972A

1457A

2 x 600 Kc Mil (304 mm 3 x 600 Kc Mil (304 mm

4 x 1000 Kc Mil (507 mm

High Power SA3000 AC Power Modules

1

2

)

2

)

2

)

DC Bus Input Power: 45, 47 41 Nm (30 lb-ft) Output Power: U, V, W 41 Nm (30 lb-ft) 115 VAC Input Power: L1, L2 3.5 Nm (2.6 lb-ft)

3.2.3 Wire Routing

Ac output wiring is routed through the top of the cabinet, above terminals 181, 182 and 183. DC input wiring is also routed through the top of the cabinet. DC input wiring is usually connected to the DC bus in the overhead enclosure that distributes the DC power to the common DC bus Inverter Power Modules. A DC input disconnect switch is provided to disconnect DC bus power, providing safe access to the inside of the SA3000 Power Module cabinet.

3.3 Grounding

Table 3.3 – Terminal Tightening Torques

Terminals Tightening Torque

ATTENTION:

Connect the power module's ground terminals to earth ground using

!

System grounding is to be done according to the supplied wiring diagrams (W/Es) in accordance with applicable codes. To prevent noise interference and possible malfunction of this equipment, it is imperative that a good cabinet ground be provided. The grounding conductor must be as short as possible and be run directly from the control panel ground terminal to a solid earth ground. It is recommended that the grounding conductor be the same size conductor as the power wiring. Multi-cabinet grounding wires should not be daisy-chained but should be run separately to the common point of earth ground.

properly-sized ground wires. Failure to observe this precaution could result in severe bodily injury or loss of life.

Ungrounded equipment represents a shock hazard.

3.4 Installing the Power Module Cabinet

Use the following procedure to install the SA3000 Power Module cabinet: Step 1. Ensure that DC input power leading to the SA3000 Power Module is off. Step 2. Position the SA3000 Power Module on a level mounting surface. See figures

3.1, 3.2, and 3.3 for cabinet dimensions. Floor mounting dimensions are included for applications in which the cabinet is to be attached to the floor.

Step 3. Connect the DC bus to terminals 45 (-) and 47(+). See the W/Es. Connect

the GND terminal to earth ground.

Installation Guidelines

Step 4. If used, connect the optional output contactor to the U, V, and W terminals. Step 5. Connect the motor leads to the output contactor. If an output contactor is not

used, connect the motor leads directly to the U, V, and W terminals. See the

W/Es and figure 3.4. Step 6. Connect the GND terminal to earth ground. Step 7. Connect the AC control power input line (two-wire 115 VAC with ground) to

terminals L1 (L), L2 (N), and GND on the control wiring terminal board. See

the W/Es and figure 3.4.

3-3

5.85

3.00

(76.2)

(148.6)

9.50

4.00

(241.3)

(101.6)

METER LOCATION IN DOOR

OUTLINE OF OVERHEAD ENCLOSURE

DOOR WIDTH = 32.75 (831.9)

DOOR SWING = 120°

5

)

7

0

8

.

3

2

7

(

1.00 (25.4) MAX

CONDUIT PROTRUSION

AIR EXHAUST SLOTS

(IF USED)

FILTER & FAN

28.00

3.00

(711.2)

(76.2)

34.00

(863.6)

*

- 19.00 (482.6).

77.38 (1965.5)

5.38 (136.7)

86.75 (2203.5)

AVAILABLE CONDUIT

ENTRY AREA IN HOOD.

CONDUIT PLATE PROVIDED

.50 D (12.7)

DRIP SHIELD

4.00 (101.6)

MTG STUD - MIN

LENGTH 1.50 (38.1)

DC TOP HAT ENCLOSURE INSTALLED

1.37

(34.8)

COMMON DC BUS ENCLOS URE INSTALLED - 10.00 (254. 0).

3-4

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

High Power SA3000 AC Power Modules

23.75

22.38

(603.3)

(568.5)

ADDITIONAL HEIGHT:

ALL DIMENSIONS ARE IN INCHES (MILLIMETERS)

WEIGHT = 1265 LBS (573 KG )

*

5.85 (148.6)

9.50

4.00

(241.3)

(101.6)

3.00

(76.2)

(127.0)

28.00

(711.2)

5.00

25.00

(635.0)

2.875

(73.0)

OUTLINE OF OVERHEAD ENCLOSURE

LH DOOR WIDTH = 29.5 (749.3)

RH DOOR WIDTH = 32.75 (831.9)

DOOR SWING = 120°

VENT SLOTS

1.OO (25.4) MAX

CONDUIT PROTRUSION

METER LOCATION IN DOOR

(IF USED)

64.00 (1625.6)

FILTER & FAN

- 19.00 (482.6).

*

3.00 (76.2)

77.37

8

)

3

7

.

5

6 3 1

(

(1965.5)

4.00

86.75 (2203.5)

(101.6)

Installation Guidelines

AVAILABLE CONDUIT

ENTRY AREA IN HOOD.

CONDUIT PLATES PROVIDED

DRIP SHIELD

.50 D (12.7)

MTG STUD - MIN

LENGHT 1.50 (38.1)

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

DC TOP HAT ENCLOSURE INSTALLED

COMMON DC BUS ENCLOS URE INSTALLED - 10.00 (254. 0).

1.37

(34.8)

23.75

22.38

(603.3)

(568.5)

ALL DIMENSIONS ARE IN INCHES (MILLIMETERS)

WEIGHT = 2175 LBS (985 KG )

ADDITIONAL HEIGHT:

*

3-5

5.85 (148.6)

FILTERS & FANS

(127.0)

5.00 5.00

3.00

4.00

9.50

(101.6)

(241.3)

(76.2)

28.00

(711.2)

25.00

(635.0)

2.875

OUTLINE OF OVERHEAD ENCLOSURE

LH & CENTER DOOR WIDTH = 29.5 (749.3)

RH DOOR WIDTH = 32.75 (831.9)

DOOR SWING = 120°

)

0

. 3 7

(

1.00 (25.4)

MAX CONDUIT

PROTRUSION

METER LOCATION IN DOOR

(IF USED)

94.00 (2387.6)

- 19.00 (482.6).

25.00

(635.0)

(76.2)

*

77.37 (1965.5)

5.38 (136.7)

86.75 (2203.5)

4.00 (101.6)

3-6

AVAILABLE CONDUIT

ENTRY AREA IN HOOD.

CONDUIT PLATES PROVIDED

DRIP SHIELD

MTG STUD - MIN

.50 D (12.7)

LENGHT 1.50 (38.1)

1.37

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

DC TOP HAT ENCLOSURE INSTALLED

COMMON DC BUS ENCLOSURE INSTALLED - 10.00 (254.0).

23.75

(34.8)

22.38

(568.5)

(603.3)

WEIGHT = 3085 LBS (1398 KG)

ADDITIONAL HEIGHT:

∗

High Power SA3000 AC Power Modules

ALL DIMENSIONS ARE IN INCHES (MILLIMETERS)

INPUT VOLTAGE

115 VAC

VOLTAGE 775V

DC BUS INPUT

GND

FUSE

CONNECT BLOCK

115 VAC QUICK

POWER MODULE

NL

4745

+

–

GND

SA3000

MOTOR

OUTPUT CONTACTOR

(OPTIONAL)

MANUAL

DISCONNECT

UVW

Installation Guidelines

Figure 3.4 – SA3000 Power and Ground Connections

3-7

3-8

High Power SA3000 AC Power Modules

C

HAPTER

4

Diagnostics and Troubleshooting

This chapter describes the equipment needed to check the operation of the Power Module and the tests to be performed. Included are descriptions of the Power Module faults and warnings monitored by the Distributed Power System software. Procedures are also provided for replacing Power Module cabinets, sub-assemblies, and fuses.

ATTENTION:

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:

that are static sensitive. Do not touch the boards’ components, connectors, or leads. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

DC bus capacitors retain hazardous voltages after input

The SA3000 Power Module contains printed circuit boards

4.1 Required Test Equipment

The following equipment is required when servicing the SA3000 Power Module:

•

an oscilloscope with an impedance of at least 8 megohms

•

a 10:1 probe

•

an isolated voltmeter (1000V DC)

•

a clamp-on ammeter (1500A)

Note that all measuring devices-meters-oscilloscopes that are AC line-powered must be connected to the AC line through an ungrounded isolation transformer.

Diagnostics and Troubleshooting

ATTENTION:

line powered test instruments used to measure Power Module signals

!

must be isolated from ground through an isolation transformer. This is not necessary for battery-powered test instruments. Failure to observe this precaution could result in bodily injury.

ATTENTION:

inadvertent ground internal to the motor, make certain that all leads are disconnected between the rotating equipment and the Power Module cabinet. This will prevent damage to electronic circuitry (Power Modules and their associated circuitry) due to the high voltage generated by the megger. F ailure to observe this precaution could result in damage to or destruction of the equipment.

The Power Module is not isolated from earth ground. AC

If a megohmmeter (megger) is used to verify an

4-1

4.2 Power Module Tests with Input Power Off

Use the following procedure to perform the SA3000 Power Module tests: Step 1. Turn off and lock out DC input power. Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.

ATTENTION:

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

!

Step 3. Open the Power Module’s cabinet doors and measure the voltage across

Step 4. Disconnect the motor from the Power Module. Step 5. Check the DC bus fuses.

(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.

each pair of 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. See figure 4.1.

Be sure to check the DC bus fuses for continuity if an IGBT phase module or fuse fails in a 972A or 1457A Power Module. Excessive current may have damaged the DC bus fuses. It is recommended that the DC bus fuses be replaced whenever an IGBT phase module or fuse fails due to a fault current. If the DC bus fuses have opened in Power Module A, a bus fault will be generated. If the DC bus fuses have opened in Power Modules B or C, a bus fault will not be generated, but an Instantaneous Overcurrent (IOC) fault will be indicated. This may be the only indication of a blown fuse in Power Modules B and C.

DC bus capacitors retain hazardous voltages after input

4-2

Step 6. If a fuse is blown, use a multimeter to check the DC bus, bus capacitors,

output terminals, and the output IGBTs. See tables 4.1 and 4.2.

Step 7. If a capacitor is defective, replace the capacitor bank assembly as described

in section 4.4.5. If an IGBT is defective, refer to section 4.4.2.

High Power SA3000 AC Power Modules

DISCONNECT SWITCH

MODULE

L

P

I

CB1

1CB1

3FU

PS

-24V

1FU

PS

±15V

+24V

F

P

C

M

F

P

M

B

POWER MODULE A

F

P

M

A

GRD

MOTOR

PRE-CHARGE ASSEMBLY

-+-

+

PHASE U

BANK

25KHZ PS

PHASE V

K C A

PCB

LINE

SYNC

AC LINE SYNC

R I

M P

BLOWER

ASSEMBLY

PHASE W

CAPACITOR

347A

345A

+BUS

-BUS

W

BLOWER

VU

PHASE U

PHASE V

PHASE W

ASSEMBLY

POWER MODULE B

AC MOTOR OUTPUT

GRD

MOTOR

PRE-CHARGE ASSEMBLY

BANK

ITOR

CAPAC

347B

345B

+BUS

-BUS

Diagnostics and Troubleshooting

POWER MODULE C

PRE-CHARGE ASSEMBLY

PHASE U

BANKCAPACITOR

PHASE V

Figure 4.1 – DC Bus Voltage Measuring Points

PHASE W

BLOWER

ASSEMBLY

347C

345C

+BUS

-BUS

4-3

Table 4.1 – DC Bus and Terminal Tests

1

Meter Connections

Scale Expected Test Results

+ -

DC Bus

- Bus (45) + Bus (47)

+ Bus (47) - Bus (45) Capacitor Effect (0 to 200 ohms)

+ 349 A,B,C

X10

Capacitor Effect (0 to 50 ohms)

Capacitor Effect (0 to 500 ohms)

- 349 A,B,C

U+

Bus

Capacitors

W+

X1 2 ohmsV+

+U

X10 Capacitor Effect (0 to 2k ohms)+V +W UV

Output

Terminals

X1000 4k to 6k ohmsUW

VW

1. With the motor disconnected

Table 4.2 – IGBT Tests

1

Expected Test

Meter Connections

+ -

Scale

Results

(+/- 10%)

W Phase (lower) + W +347 A,B,C 2k Ω/diode 0.300 ohms

V Phase (lower) + V +347 A,B,C 2k Ω/diode 0.300 ohms U Phase (lower) + U +347 A,B,C 2k Ω/diode 0.300 ohms

W Phase (upper) - -345 A,B,C W 2k Ω/diode 0.300 ohms

V Phase (upper) - -345 A,B,C V 2k Ω/diode 0.300 ohms U Phase (upper) - -345 A,B,C U 2k Ω/diode 0.300 ohms

1. With the motor disconnected

4-4

4.3 Power Module Faults and Warnings

The PMI Processor continually runs diagnostics which check for errors that may affect system operation. Warnings are errors which indicate that the SA3000 Power Module is not operating in an optimum manner. Warnings will not shut down the SA3000. Faults are severe errors which will shut down the SA3000. See tables 4.3 and 4.4.

Refer to the SA3000 Drive Configuration and Programming instruction manual (S-3042) for more information about the Fault and Warning registers.

High Power SA3000 AC Power Modules

4.3.1 Power Module Faults

The Power Module faults listed in table 4.3 will cause the SA3000 Power Module to shut down. In a fault situation, the PMI Processor will command zero current and will stop firing the Power Module’s IGBTs. Faults must be reset before the SA3000 Power Module can be restarted.

Table 4.3 – SA3000 Power Module Faults (Register 202/1202)

Bit

Suggested

Variable

Name

UDC

Error

Code

Description Summary

0 FLT_OV@ 1018 The DC Bus Overvoltage bit is set if the DC bus voltage exceeds 925

VDC.

1 FLT_DCI@ 1020 The DC Bus Overcurrent bit is set if the DC bus current exceeds 125%

of the rated SA3000 Power Module current.

2 FLT_GND@ 1021 The Ground Current Fault bit is set if the ground current exceeds the

hardware trip point. See section 4.3.1.3.

3 FLT_IOC@ 1017 The Instantaneous Overcurrent Fault bit is set if an overcurrent is

detected in one of the power devices.

4 FLT_LPI@ 1022 The Local Power Interface bit is set if the power supply voltage on the

LPI module is not within tolerance.

6 FLT_CHG@ 1024 The Charge Bus Timeout Fault bit is set if the DC bus is not fully

charged within 10 seconds of being enabled, if the drive is on and feedback indicates the pre-charge contactor has opened, or if DC bus voltage is less than the Power Loss Fault Threshold tunable variable (PLT_FLT%).

7 FLT_OT@ 1016 The Overtemperature Fault bit is set if the fault level thermal switch

o

(85

C (185o F)) in the SA3000 Power Module opens.

4.3.1.1 DC Bus Overvoltage Fault

The DC Bus Overvoltage bit (bit 0) is set in the Fault register (202/1202) if the DC bus voltage exceeds 925 VDC. Error code 1018 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.2 DC Bus Overcurrent Fault

The DC Bus Overcurrent bit (bit 1) is set in the Fault register (202/1202) if the DC bus current exceeds 125% of the rated SA3000 Power Module current. Error code 1020 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.3 Ground Current Fault

The Ground Current Fault bit (bit 2) is set in the Fault register (202/1202) if the ground current exceeds the hardware trip point value of 100 Amps. Error code 2021 will also be displayed in the error log of the UDC task in which the fault occurred.

Note that the Ground Current Fault bit (register 202/1202, bit 2) is not enabled on SA3000 Power Modules using AC Technology modules, B/M 60023-5 and later. Error code 2021 will not be displayed as the ground current hardware trip detector was removed from the AC Technology modules, B/M 60023-5 and later.

Diagnostics and Troubleshooting

4-5

4.3.1.4 Instantaneous Overcurrent Fault

The Instantaneous Overcurrent Fault bit (bit 3) is set in the Fault register (202/1202) if an overcurrent is detected in one of the power devices (IGBTs). Register 204/1204, bits 0-5, indicates which power device experienced the overcurrent. When 972A and 1457A SA3000 Power Modules are being used, registers 220/1220 and 221/1221 indicate the status of the B and C Power Modules. Error code 1017 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.5 Local Power Interface Fault

The Local Power Interface Fault bit (bit 4) is set in the Fault register (202/1202) if the power supply voltage on the LPI module is not within tolerance. Error code 1022 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.6 Charge Bus Time-Out Fault

The Charge Bus Fault bit (bit 6) is set in the Fault register (202/1202) if one of the following occurs:

•

the internal DC bus is not fully charged within 10 seconds after the bus enable bit (register 100/1100, bit 4) is set.

•

the drive is on and feedback indicates that the pre-charge contactor has opened

•

DC bus voltage is less than the value stored in the Power Loss Fault Threshold (PLT_E0%) tunable variable.

If this bit is set, verify that the incoming DC bus power is at the appropriate level. If the power level is correct the problem is in one of the SA3000 Power Modules. Bit 8 in register 204/1204, 220/1220, or 221/1221 will be set to indicate which Power Module is caused the fault. Error code 1024 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.7 Overtemperature Fault

The Overtemperature Fault bit (bit 7) is set in the Fault register (202/1202) if the fault level thermal switch (85

204/1204, 220/1220, or 221/1221 will be set to indicate which SA3000 Power Module is caused the fault. Error code 1016 will also be displayed in the error log of the UDC task in which the fault occurred.

o

C (185o F)) in the Power Module opens. Bit 12 in register

4-6

High Power SA3000 AC Power Modules

4.3.2 Power Module Warnings

The following warnings indicate conditions which are not serious enough to shut down the SA3000 Power Module but may affect its performance. See table 4.4. Warnings cause no action by themselves. Any response to a warning condition is the responsibility of the application task.

Table 4.4 – SA3000 Warning Register 203 /1203

Suggested

Variable

Bit

Name

0 WRN_OV@ The DC Bus Overvoltage fault bit is set if the DC bus voltage exceeds the

overvoltage threshold value stored in local tunable OVT_E0%.

1 WRN_UV@ The DC Bus Undervoltage bit is set if the DC bus voltage drops below the under

voltage threshold value stored in local tunable UVT_E0%.

2 WRN_GND@ The Ground Current Warning bit is set if the ground current exceeds the ground

fault current level stored in local tunable GIT_EI%.

6 WRN_SHR@ The Load Sharing Warning bit is set if a current sharing problem develops

between parallel SA3000 Power Modules.

7 WRN_OT@ The Overtemperature Warning bit is set if the warning level thermal switch (78° C

o

(172.4

F)) in the SA3000 Power Module opens.

Description Summary

4.3.2.1 DC Bus Overvoltage Warning

The DC Bus Overvoltage bit (bit 0) is set in the Warning register (203/1203) if the DC bus voltage exceeds the overvoltage threshold value stored in local tunable OVT_E0%.

4.3.2.2 DC Bus Undervoltage Warning

The DC Bus Undervoltage bit (bit 1) is set in the Warning register (203/1203) if the DC bus voltage drops below the under voltage threshold value stored in local tunable UVT_E0%.

4.3.2.3 Ground Current Warning

The Ground Current Warning bit (bit 2) is set in the Warning register (203/1203) if the ground current exceeds the ground fault current level stored in local tunable GIT_EI%.

4.3.2.4 Load Sharing Warning

The Load Sharing Warning bit (bit 6) is set in the Warning register (203/1203) if a current sharing problem develops between parallel SA3000 Power Modules. Bits 13, 14, or 15 in registers 204/1204, 220/1220, or 221/1221 will be set to indicate the Power Module and phase that caused the warning.

Diagnostics and Troubleshooting

4-7

4.3.2.5 Overtemperature Warning

The Overtemperature Warning bit (bit 7) is set in the Warning register (203/1203) if the warning level thermal switch (78

opens. Bit 12 in register 204/1204, 220/1220, or 221/1221 will be set to indicate which SA3000 Power Module caused the warning.

o

C (172.4o F)) in the SA3000 Power Module

4.4 Replacing Power Module Fuses and Sub-Assemblies

Follow the procedures given in sections 4.4.1 to 4.4.5 to replace the SA3000 Power Module’s fuses and sub-assemblies.

4.4.1 Replacing Fuses

Use the following procedure to replace a fuse that has blown: Step 1. Turn off and lock out the AC input power. Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.

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.

Step 3. 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. See figure 4.1.

Step 4. Remove the blown fuse and install the replacement fuse. Figures 4.2 to 4.6

show the locations of the fuses in the 534A, 972A, and 1457A SA3000 Power Modules. Table 4.5 provides fuse specifications.

Step 5. Close the cabinet doors and reapply power to the SA3000 Power Module.

4-8

High Power SA3000 AC Power Modules

Table 4.5 – Power Module Replacement Fuse Specifications

Rockwell

Fuse Volts Class Type Rating

Part Number Torque Specifications

1FU 600 CC KLDR 5 A 64676-29R -3FU 600 CC KLDR 3.2 A 64676-29P --

FPM A,B,C 1000 Semiconductor 1000 A 64676-80P 41 Nm (30 lb-ft) F103 A,B,C 1000 Semiconductor 630 A 64676-79AZ 20.5 Nm (15 lb-ft) F104 A,B,C 1000 Semiconductor 630 A 64676-79AZ 20.5 Nm (15 lb-ft) F105 A,B,C 1000 Semiconductor 630 A 64676-79AZ 20.5 Nm (15 lb-ft)

Replace with

+/-15V PS

250 F 1.8 A

1.6A

--

1

64676-82U

2

+/-24V PS

+/-24V PS 25 KHz PS

11FU

250 T 2.5 A 64676-71P --

3

600 -- F 2.0 A 64676-82V --

4

250 -- -- 8 A 64676-30H --

12FU

25 KHz PS

21FU

4

250 -- F 2 A 64676-66C --

26FU

1,2,3. Fuse locations shown in figures 4.2, 4.3, 4.4, and 4.5.

4. Fuse locations shown in figures 4.2, 4.3, 4.4, and 4.6.

Diagnostics and Troubleshooting

4-9

MOTOR

GND

AC MOTOR OUTPUT

MOTOR

GND

DISCONNECT SWITCH

F103A

F104A

UV

W

F101A

F102A

POWER MODULE A

PRE-CHARGE ASSEMBL Y

PHASE U

BANK

PHASE V

CAPACITOR

FPMA

(FRONT)

+24V.PS-24V.+24V.PS-24V.

PS

±15V.

U F

PS

1

25KHZ PS

(REAR)

1 B C

1

U

B

F

C

3

1

(2)

(3)

3FU 1FU

(1)

(4)

11FU, 12FU

(4)

21FU-26FU

4-10

PHASE W

F105A

ASSEMBLY

Notes 1,2,3. See table 4.5 and figure 4.5 Note 4. See table 4.5 and figure 4.6.

Figure 4.2 – 534A SA3000 Power Module Fuse Locations

BLOWER

LINE

SYNC

PCB

PMI RACK

MODULE LPI

GDI

PWR. MOD. A

SLOT 6

High Power SA3000 AC Power Modules

MOTOR

GRD

AC MOTOR OUTPUT

MOTOR

GRD GRD

MOTOR

DISCONNECT SWITCH

F103B

F104B

F105B

U V W

POWER MODULE B

PRE-CHARGE ASSEMBLY

PHASE U

BANK

PHASE V

CAPACITOR

PHASE W

ASSEMBLY

F103A

F104A

F105A

FPMB

FPMA

F101A

F102A

F101B

F102B

(FRONT)

(REAR)

POWER MODULE A

PRE-CHARGE ASSEMBLY

PHASE U

BANK

PHASE V

CAPACITOR

PHASE W

BLOWERBLOWER

ASSEMBLY

+24V

-24V

PS

±15V

PS

1FU

3FU

25KHZ PS

LINE

SYNC

PCB

PMI RACK

(2)

CB1

(3)

1CB1

3FU

1FU

(1)

11FU, 12FU

21FU-26FU

MODULE

LPI

GDI

PWR. MOD. A

PWR. MOD. B

(4) (4)

Notes 1,2,3. See table 4.5 and figure 4.5 Note 4. See table 4.5 and figure 4.6.

Diagnostics and Troubleshooting

Figure 4.3 – 972A SA3000 Power Module Fuse Locations

SLOT 6

SLOT 7

4-11

(4)

DISCONNECT SWITCH

3FU

(2)

(REAR)

(FRONT)

F102CF102A F102B

F101CF101BF101A

F

P

M

C

F

P

M

B

F

P

M

A

GRD

MOTOR

(3)

CB1

PS

-24V

PS

+24V

±15V

PRE-CHARGE ASSEMBLY

1FU

1CB1 3FU 1FU

PS

PHASE U

F103A

(1)

BANK

11FU, 12FU

25KHZ PS

PHASE V

21FU-26FU

F104A

I

PWR. MOD. C

D

LPI MODULE

G

I D G

PCB

LINE

SYNC

PMI RACK

BLOWER

ASSEMBLY

SLOT 8

PWR. MOD. B

SLOT 7

PWR. MOD. A

SLOT 6

PHASE W

CAPACITOR

F105A

W

BLOWER

VU

PHASE U

PHASE V

PHASE W

ASSEMBLY

POWER MODULE B POWER MODULE A

AC MOTOR OUTPUT

GRD

MOTOR

PRE-CHARGE ASSEMBLY

BANK

CAPACITOR

4-12

F105B

PHASE W

F105C

POWER MODULE C

F103B

PHASE U

BANK

PRE-CHARGE ASSEMBLY

F103C

F104B

PHASE V

CAPACITOR

F104C

Figure 4.4 – 1457A SA3000 Power Module Fuse Locations

BLOWER

ASSEMBLY

Notes 1,2,3. See table 4.5 and figure 4.5

High Power SA3000 AC Power Modules

Note 4. See table 4.5 and figure 4.6.

850100-3R ASSEMBL Y

OUT+

OUT-

OUT

(2)

IN

(3)

OUT

(1)

OUT+

(1)

OUT-

(1)

(2)

IN

(3)

1.8A F

L1

N

+15

±15V

0 0

-15

L1

N

24

0

1QD 2QD

NON-CRITICAL (FAN) 115VAC

PS

1.8A F

2.5A T 2.5A T

+24V

PS

2.0A F

L1

N

24

0

850100-3S ASSEM BLY

2.5A T 2.5A T

L1

N

+24V

24

0

L1

N

+15

0 0

-15

PS

2.0A F 2.0A F

1.8A F

±15V

PS

1.8A F

1QD 2QD

L1 N

-24V

24

0

1FU

3FU

CB1

1FU

-24V PS

2.0A F

CRITICAL (PMI/PS) 115VAC

PS

3FU

1CB1

L1

115 VAC INPUT

L2

TERMINAL BOARD

L1A

CB1

L1

L2 L1A

1L1

1L2 1L1A

NON-CRITICAL 115 VAC INPUT TERMINAL BOARD

CRITICAL 115 VAC INPUT TERMINAL BOARD

OUTPUT TB OUTPUT TB

Notes 1,2,3. See table 4.5 for fuse specifications.

Figure 4.5 – 115VAC Control Power Supply Assemblies

Diagnostics and Troubleshooting

CRITICAL (PMI/PS) 115VACNON-CRITICAL (FAN) 115VAC

4-13

EW VI

E D

SI

2 1

802268-16R ASSEMBLY

1

A

1

2

B

3

C

TO POWER

MODULE(S) 4 5

6

NOT USED

25 KHz. OUTPUT

(4)

THRU

21FU

26FU

4-14

115VAC

NOT

INPUT

USED

9

8

2

2 8

8

2

-

+

1FU

2FU

FRONT VIEW

(4)

11FU

12FU

Figure 4.6 – 25 KHz. Power Supply

High Power SA3000 AC Power Modules

Note 4. See table 4.5 for fuse specifications.

4.4.2 Replacing an IGBT Phase Module Assembly

Important:

If all three IGBT phase modules are to be replaced, it will be easier to remove them by starting at the top and working down, i.e., begin by removing module U, continue with module V, and then finish by removing module W . Be sure to re-install the IGBT phase modules in reverse order, beginning by installing module W, continuing with module V, and finishing by installing module U.

Use the following procedure to replace an IGBT phase module assembly (U, V, or W): Step 1. Turn off and lock out AC input power. Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.

!

When replacing an IGBT phase module assembly be sure to re-install, position, and tighten the hardware in the proper sequence. The IGBT phase module must be aligned correctly to prevent damage to the components.

ATTENTION:

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.

DC bus capacitors retain hazardous voltages after input

Step 3. 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. See figure 4.1.

Step 4. Remove all wires, connectors, and harnesses from the IGBT Phase module

assembly to be replaced. Label all of the wires to aid in re-installation. Refer to the wiring diagrams supplied with your system.

Step 5. Remove the right M8 bolt from the fuse. See figure 4.7, callout 2. Note that if

you are only replacing the fuse, remove both M8 bolts as shown in figure 4.7, callouts 1 and 2. Remove the fuse without disturbing the alignment of the IGBT Phase module.

Step 6. Remove the two M8 bolts from the AC LEM bus bar. The bolts are located

above the fuse and under the LEM device. See figure 4.7, callout 3.

Step 7. Remove the two M6 hex nuts from the negative bus bar. See figure 4.7,

callout 4.

Step 8. Remove the two 5/16” x 1” cap screws, flat washers, and lock washers from

the heatsink. One cap screw is located on each side of the heatsink. See

figure 4.7, callout 5. Step 9. Remove the IGBT Phase module assembly from the Power Module. Step 10. Install the new IGBT Phase module assembly by aligning the module's

mounting holes with the studs. Push the module into place and hold it in

position.

Diagnostics and Troubleshooting

4-15

Step 11. Start and finger-tighten the two M6 hex nuts on the negative bus bar. See

figure 4.7, callout 4.

Step 12. Start and finger-tighten the two 5/16” cap screws, flat washers, and lock

washers on the heatsink. One cap screw is located on each side of the heatsink. See figure 4.7, callout 5.

Step 13. Start and finger-tighten the two M8 bolts on the AC bus bar. See figure 4.7,

callout 3. Tighten the bolts evenly.

Step 14. Loosen the M8 bolt on the left side of the fuse. See figure 4.7, callout 1. This

allows the fuse some movement.

Step 15. Start and finger-tighten the M8 bolt with a lockwasher and a flat washer on

the positive bus bar on the left side of the fuse. See figure 4.7, callout 2. Note that the fuse ends should be in contact with the left and right bus bars. If

the fuse does not touch the bus bars, adjust the horizontal position of the IGBT Phase Module Assembly until the fuse ends are contacting the bus bars. In some cases, the positive bus bar may have to be moved to allow the fuse to make contact.

Step 16. Pull the fuse forward in the slots. Hold the fuse with its back side parallel to

the middle AC bus bar. Note that the fuse must be mounted with the label facing forward, e.g., the

top of the label should be to the right. The auxiliary connection tabs on the fuse endplates should be facing down. Do not install the fuse with the tabs facing up or toward the rear.

Step 17. Tighten the right and left fuse bolts to 20.5 Nm (15 lb-ft). Be sure the fuse

does not rotate while the bolts are being tightened.

Step 18. Tighten the two M6 hex nuts on the negative bus bar to 5 Nm (45 lb-in). See

figure 4.7, callout 4.

Step 19. Tighten the two M8 bolts on the AC bus bar to 9.5 Nm (84 lb-in). See figure

4.7, callout 3.

Step 20. Tighten the two 5/16” cap screws on the heatsink to 9.5 Nm (84 lb-in). See

figure 4.7, callout 5.

Step 21. Ensure that all nuts and bolts are tightened to the rated torque. Re-torque the

nuts and bolts as necessary.

Step 22. Re-connect the wires, connectors, and harnesses to the IGBT Phase module

assembly that were removed in step 4. Step 23. Close the cabinet doors. Step 24. Reapply power to the Power Module.

4-16

High Power SA3000 AC Power Modules

PHASE V

3

2

1

Figure 4.7 – IGBT Module Assembly Mounting Bolt Locations

4.4.2.1 Replacing an IGBT

If an IGBT needs to be replaced, it is recommended that the IGBT module be returned to an authorized Rockwell repair facility.

PHASE W

4

4.4.3 Replacing the Pre-charge Assembly

Use the following procedure to replace the optional pre-charge assembly: Step 1. Turn off and lock out DC input power.

5

Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.

Diagnostics and Troubleshooting

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.

4-17

Step 3. Open the Power Module cabinet's doors and measure the DC bus potential

across each pair of DC bus bars, 347 A,B,C (+ bus) and 345 A,B,C (- bus),

with an external voltmeter before working on the unit. See figure 4.1. Step 4. Remove the bracket that is fastened across the cabinet in front of the

pre-charge assembly . The brac k et is attached to the cabinet with two screws. Step 5. Remove the two power cables marked with a red band from the pre-charge

assembly. Step 6. Remove the wiring control harnesses. Do not remove the CN104 cable on

the pre-charge module itself. Step 7. Remove the power cables marked with a gray band from the DC bus

capacitors. Step 8. Remove the control wiring that connects to the capacitor bank. Step 9. Remove the four screws that fasten the pre-charge assembly to the back

panel of the cabinet. Step 10. Remove the pre-charge assembly. Step 11. Install the new pre-charge assembly by following steps 1 through 10 in

reverse order. Step 12. Close the cabinet doors. Step 13. Reapply power to the Power Module.

4.4.4 Replacing a Blower Assembly

Use the following procedure to replace a blower assembly: Step 1. Turn off and lock out the AC input power. Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.

ATTENTION:

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

!

Step 3. Open the cabinet doors and check the voltage across the DC bus bars,

Step 4. T urn off the AC power to the blower by turning the circuit breaker in the power

Step 5. Disconnect the wires from the right side of the blower assembly. The wire

(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.

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. See figure 4.1.

supply panel off.

connectors are keyed.

DC bus capacitors retain hazardous voltages after input

4-18

Step 6. Remove the blower from the cabinet by sliding it out.

High Power SA3000 AC Power Modules

Step 7. Install the new blower assembly by performing steps 1 through 6 in reverse

order.

Step 8. Close the cabinet doors and reapply power to the SA3000 Power Module.

4.4.4.1 Replacing a Blower Filter

To replace a blower filter: Step 1. Remove the old filter by sliding it out. Step 2. Slide the new filter in.

4.4.5 Replacing a Bus Capacitor Assembly

Use the following procedure to replace a DC bus capacitor assembly: Step 1. Turn off and lock out the AC input power. Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.

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.

Step 3. 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. See figure 4.1.

Step 4. Remove all three IGBT assemblies (U, V, and W). Refer to section 4.4.2 for

information on IGBT assembly removal.

Step 5. Remove the AC input power wiring by removing the bolt from the LEM stud

spacer. This wiring consists of three insulated, tinned-copper straps which have color-coded bands (orange, yellow, and purple).

Step 6. Remove the LEM device control wiring. Needle-nose pliers may be useful in

removing the three wire connectors.

Step 7. Remove the three LEM devices. Four screws attach each LEM device to the

capacitor bank.

Step 8. Remove the three insulator blocks. Each insulator block is secured by two

hex nuts.

Step 9. Remove the power cable wiring harnesses from the top of the capacitor

bank. The two wiring harnesses have color-coded bands. The positive bus

bar cable has a red band while the negative bus bar cable has a gray band. Step 10. Remove the control wiring from the top of the capacitor bank. Step 11. Remove the capacitor bank's four mounting screws. Two are located at the

top of the capacitor bank and two at the bottom. Step 12. Slide the capacitor bank out of the cabinet.

Diagnostics and Troubleshooting

4-19

Step 13. Install the new capacitor bank assembly by performing steps 1 through 12 in

reverse order.

Step 14. Close the cabinet doors and reapply power to the SA3000 Power Module.

4.5 Replacing the Power Module Cabinet

Use the following procedure to replace the SA3000 Power Module cabinet: Step 1. Turn off and lock out the AC input power to the DC bus supply control

cabinet.

Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.

ATTENTION:

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

!

Step 3. Open the cabinet doors and check the voltage across the DC bus bars,

Step 4. Disconnect the DC bus leads from terminals 45 (-) and 47 (+). Disconnect the

Step 5. Disconnect the AC input line (two-wire 115 VA C with ground) from the L1 (L),

Step 6. Disconnect the AC output leads (U, V, W) from the motor and the motor

Step 7. Remove the SA3000 Power Module cabinet.

(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.

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. See figure 4.1.

GND wire from the ground terminal. See figure 3.4. Note that if an overhead DC bus assembly was supplied, disassembly of the

overhead assembly is required. The assembly may be remounted on the replacement cabinet, if required.

L2 (N), and GND terminals on the control power board. See figure 3.4.

ground wire(s) from the GND terminal(s). See figure 3.4.

DC bus capacitors retain hazardous voltages after input

4-20

Step 8. Install the replacement SA3000 Power Module cabinet by performing these

steps in reverse order.

High Power SA3000 AC Power Modules

A

PPENDIX

Technical Specifications

Ambient Conditions

•

Operating Temperature:0 to +40o C (32 to +104o F)

•

Storage Temperature:-25 to +55o C (-13 to +131o F)

•

Humidity: 5 to 95%, non-condensing.

•

Altitude:Do not install above 1000 meters (3300 feet) without derating output

current. For every 91.4 meters (300 feet) above 1000 meters (3300 feet), derate the output current by 1%.

•

Vibration: Sine Wave: 1g., 10-500 Hz., all 3 axes.

Shock: 15g., over 6 msec., half sine wave.

Dimensions (534A SA300 Power Module)

•

Height: 2204 mm (86.8 inches)

•

Depth: 603 mm (23.8 inches)

1

A

•

Width: 864 mm (34.0 inches)

•

Weight:573 kg (1265 pounds)

Dimensions (972A SA3000 Power Module)

•

Height: 2204 mm (86.8 inches)

•

Depth: 603 mm (23.8 inches)

•

Width: 1626 mm (64.0 inches)

•

Weight:985 kg (2175 pounds)

Dimensions (1457A SA3000 Power Module)

•

Height: 2204 mm (86.8 inches)

•

Depth: 603 mm (23.8 inches)

•

Width: 2387.6 mm (94.0 inches)

•

Weight:1398 kg (3085 pounds)

Type of Enclosure

•

NEMA 1

1

Technical Specifications

1. Additional height: DC Bus Assembly Enclosure installed: 254 mm (10.0 inches)

DC Bus Top Hat Enclosure installed: 482.6 mm (19.0 inches)

A-1

DC Bus Specifications

•

Pre-charge Time: 1 second

•

Discharge time (below 50V): less than 5 minutes

•

Pre-charge resistance/bus capacitance: 534A Unit: 7.6 Ω / 32.4 µF

972A Unit: 3.8 Ω / 64.8 µF 1457A Unit: 2.5 Ω / 97.2 µF

DC Bus Input Power

•

Nominal Maximum DC Voltage: 800 VDC

•

Input Voltage Range: 300 - 850 VDC

•

Overvoltage Trip: 925 VDC

•

Maximum DC Input Current: 534A Unit: 600A

972A Unit: 1000A 1457A Unit: 1500A

Use the following equation to calculate the approximate DC input current as a function of the connected horsepower:

DC Amps =

115 V AC Control Power

•

AC Input Voltage: 115 VAC, Single-phase (Critical and Non-critical supplies)

•

AC Input Frequency: 50/60 Hz

•

Maximum Symmetrical Short Circuit Current: 5 KA

115 VAC Power Supply

850100-3R 850100-3S

(Non-Critical Power) 850100-3S

(Critical Power) 850100-3S (Critical

and Non-Critical Power)

1. May be replaced by 850100-3S 115VAC Power Supply Assembly.

motor efficiency x inverter efficiency x bus voltage

Part N umber

1

horsepower x 746

1

115 VAC Input Power Ratings

534 Amp

Power Module

10.6 A 16.5 A 21.6 A

5.5 A 11.0 A 16.5 A

1.5 A (Min)

5.1 A (Max)

10.6 A (Max) 16.5 A (Max) 21.6 A (Max)

972 Amp

Power Module

1.5 A (Min)

5.1 A (Max)

1457 Amp

Power Module

1.5 A (Min)

5.1 A (Max)

A-2

1. Derate Power Module output current by 5% for 50 Hz blower motor operation.

High Power SA3000 Power Modules

Output Power

•

Output Voltage: 575 VAC, maximum

•

Modulation: Sine Wave, Pulse Width Modulation (PWM)

•

Short Circuit Rating: 65 KA

•

Power Dissipation: 534A Unit: 7500 W

972A Unit: 15000 W 1457A Unit: 22500 W

•

Output Inductor: 7.5 µH per phase (972A and 1457A units only)

Output Current Ratings at 40° C (104° F) with 2 KHz Carrier Frequency:

Power Module

Part Number

Power Module

Description

Output Current

Rating

1

850020-11xxx, -21xxx One Bay Cabinet 534 A 850020-12xxx, -22xxx Two Bay Cabinet 972 A 850020-13xxx, -23xxx Three Bay Cabinet 1457 A

1. Derate Power Module output current by 5% for 50 Hz blower motor operation.

1

Output Current Ratings

Power Module

Part Number

Based on Carrier Frequencies at 575 VAC Output

Carrier Frequency

2 KHz 4 KHz

2

850020-11xxx, -21xxx 534 A 445 A / 534 A 850020-12xxx, -22xxx 972 A 890 A / 972 A 850020-13xxx, -23xxx 1457 A 1335 A / 1457 A

1. Derate Power Module output current by 5% for 50 Hz blower motor operation.

2. The current limit is the continuous, maximum current rating and is duty cycle-dependent. The driv e can be

operated at the overload (maximum) current for up to five minutes with a 10% duty cycle.

Typical Power Module Current1 and Motor Ratings

Part

Number

850020-11xxx

230V Motor 380V Motor 460V Motor 575V Motor

Amps KW HP Amps KW HP Amps KW HP Amps KW HP

534 168 225 534 277 371 534 336 451 534 419 561

850020-21xxx 850020-12xxx

972 305 409 972 505 677 972 611 819 972 765 1025

850020-22xxx 850020-13xxx

1457 459 615 1457 757 1015 1457 918 1230 1457 1146 1536

850020-23xxx

1. 100% rated output current ratings at 40° C (104° F) ambient air temperature at 2 KHz. Reduce all output current ratings by 5% when the Power Module blo wers are operated from a 50 Hz power source.

Technical Specifications

•

Rail I/O Current Load:Power supply constraints dictate that any combination of

analog and digital I/O rails may be used as long as current consumption does not exceed 1.5 A.

A-3

A-4

High Power SA3000 Power Modules

External DC Bus

47(+)

45(–)

A

PPENDIX

SA3000 Internal DC Bus Control

Each DC input High Power SA3000 Power Module contains a capacitor bank which must be charged before the Power Module can produce current. Because the capacitor bank acts like a DC bus, i.e., it supplies DC power to the inverter section of the Power Module, the capacitor bank is referred to as an “internal” DC bus.

An external DC bus, which can be used to supply DC voltage to the Power Module, is provided by the user. This external DC bus is not under the control of the SA3000 drive.

The internal DC bus in each Power Module consists of the capacitor bank and discharge/voltage sharing resistors. In addition, an optional pre-charge contactor and resistor may be part of this system. Note that if an optional disconnect switch is used, the pre-charge option must also be used. See figure B.1 for a simplified internal DC bus schematic.

(Optional)

Pre-charge

Disconnect

Switch

(Optional)

FPMA

To B & C

Power Modules

347

(If Used)

345

Resistor

Pre-charge

Contactor

DC Bus

Capacitors

Discharge

and Voltage Sharing

Resistors

Internal DC Bus

(+)

Power

Devices

(–)

B

AC

Motor

SA3000 Internal DC Bus Control

Figure B.1 – Internal DC Bus Schematic

If the pre-charge option is present, DC input power can be turned on either before or at the same time that bus control is enabled. Because the pre-charge contactor is initially open, bus charging actually begins as soon as power is turned on to the Power Module, regardless of whether or not bus control has been enabled by the programmer. In the absence of explicit control by the programmer, current to the bus is limited by the pre-charge resistors. Note that if the pre-charge option is not present, the external bus is responsible for controlling the charging of the inverter’s internal DC bus capacitors.

B-1

The programmer initiates control of the charging process by setting the BUS_ENA@ bit (register 100/100, bit 4). Normally, the PMI processor waits for the rising edge of this bit to start the process. However, if this bit is ON at power-up, the PMI processor will interpret this as a positive transition. The DC bus controller, though, will inhibit the system’s state machine until valid configuration and gain data is received.

Note that the BUS_ENA@ bit must be turned on before the programmer enables the bridge test or the inner control loop in the PMI processor in register 100/1100. If BUS_ENA@ is not enabled first, an interlock error will occur (register 205.1205, bit 6, IC_BUS@) and the drive will not be permitted to execute either the bridge test or the control loop.

In response to the rising edge of the BUS_ENA@ bit, the PMI processor will allow the bus voltage to rise above the undervoltage threshold and then close the pre-charge contactor. This will short out the pre-charge resistors. The PMI processor will set BUS_RDY@ (bit 4 in register 200/1200) when all of the following conditions have occurred:

•

the internal DC bus has been enabled via the BUS_ENA@ input

•

the internal DC bus voltage has reached the level specified in the tunable variable UVT_E0%

•

the internal DC bus voltage is at a steady state

•

the pre-charge contactor has closed

Important: The BUS_ENA@ bit must remain on during the bridge test or the

ex e cu t io n of t h e c o nt ro l al go rith m in t h e P MI p ro c es s or, or the pr e- ch arge contactor will open and the drive will shut down.

If BUS_ENA@ is turned off at any time, power to the power device gates is shut off. Approximately one second later, the pre-charge contactor is opened. If the pre-charge contactor closes when it is not commanded to do so by the PMI processor, register 202/1202, bit 6 (FLT_CHG@) is set and the drive is shut down. (Auxiliary contacts on the pre-charge contactor are used to verify that the pre-charge contactor is open or closed. These auxiliary contacts are pre-wired and require no connection by the user.)

There is a time limit of 10 seconds from the time when the rising edge of the BUS_ENA@ input is detected to the time when the bus voltage must reach the steady state voltage specified in the tunable variable UVT_E0% and the auxiliary contact is required to close. (See the following section for more information on tunable variable UVT_E0%.) If this time limit is exceeded, the pre-charge contactor is opened and the FLT_CHG@ bit (register 202/1202, bit 6) is set. If the bus voltage recovers to the appropriate level within 10 seconds, the pre-charge contactor will be closed and the drive will resume operation.

Refer to figure B.2, the internal DC bus control state diagram (with pre-charge option supplied), for more detailed information.

B-2

High Power SA3000 Power Modules

Idle

Open Pre-Charge

Contactor

(2)

Wait for Bus to

Charge

Nominal Bus

Voltage

Reached?

Yes

PMI Closes Pre-Charge

Contactor

Auxiliary

Contacts

Closed?

BUS_ENA@ On

(1)

Begin 10 Second Timer

No

More than 10

No

Seconds

Elapsed?

Seconds Elapsed?

Yes

Fault Occurs

Register 202/1202

Open Pre-Charge

Contactor

Yes

(2)

1. BUS_ENA@ must transistion from off to on to start the bus charging process.

2. BUS_ENA@ must remain on during the drive operation

PMI Sets

BUS_RDY@

Bus Charged

Figure B.2 – Internal DC Bus Control State Diagram

SA3000 Internal DC Bus Control

Yes

Fault

Occurs?

No

B-3

B.1 Modifying Internal DC Bus Voltage Thresholds

The programmer can use three different pre-defined tunable variables to specify three bus voltage thresholds:

•

OVT_E0% overvoltage threshold

•

UVT_E0% undervoltage threshold

•

PLT_E0% power loss threshold

These thresholds define the boundaries for specific operating levels. Figure B.3 shows the relative bus voltage operating ranges and how the tunable variables can affect these ranges.

Important:

Internal DC Bus Voltage

Hardware Overvoltage (a preset value)

Overvoltage Maximum (Tunable OVT_E0% plus 5% of nominal bus voltage)

Overvoltage Threshold (T unable OVT_E0%)

Nominal Bus Voltage

The three tunable variables listed above should be tuned before enabling the execution of the control algorithm in the PMI Processor to ensure that internal DC bus voltage warning thresholds are set to levels appropriate for the application. See instruction manual S-3042, SA3000 Drive Configuration and Programming, for the acceptable value ranges.

Normal Charging

Undervoltage Threshold (Tunable UVT_E0%)

Undervoltage Minimum (Tunable UVT_E0% minus 5% of nominal bus voltage)

Power Loss Threshold (Tunable PLT_E0%)

B-4

0

Figure B.3 – Internal DC Bus Operating Range

1

2 Time in

Seconds

High Power SA3000 Power Modules

B.2 Internal DC Bus Protection

The PMI Processor will modify the regeneration or motoring torque limit set by the programmer during parameter entry (calculated from the maximum current and overload ratio parameters) to prevent bus voltage from rising (in the case of regeneration) or falling (in the case of motoring).

During regeneration, if bus voltage reaches the overvoltage threshold, the regeneration torque limit will be reduced, and will be set to zero if the overvoltage maximum is reached. During motoring, if bus voltage reaches the undervoltage threshold, the motoring torque limit will reduced, and will be set to zero if the undervoltage minimum is reached. The PMI processor will set register 203/1203, bit 4 (WRN_RIL@), to indicate that torque is being limited in either direction.

Note that the PMI processor does not modify the reference provided by the UDC task to the PMI processor via register 102/1202, TRQ_REF%. If required, the UDC task can include logic to begin regenerating when DC bus voltage is low.

Refer to Appendix A for specifications on the capacitance, resistance, and charging time of the bus pre-charge circuitry for the High Horsepower SA3000 Power Modules.

SA3000 Internal DC Bus Control

B-5

B-6

High Power SA3000 Power Modules

534 Amp SA3000 Power Module

Table C.1 – 534A SA3000 Power Module

A

PPENDIX

C

Replacement Parts

Part Description

Blower Assembly 1 850011-R IGBT Phase Module Assembly 3 803430-8S Capacitor Bank Assembly 1 803430-6S Pre-charge Assembly 1 850022-3_ 115 VAC Power Supply Assembly 1 850100-3_ Disconnect Switch (Optional) (600A, 1000 VAC) 1 65242-8B Fuse (FPM A, F101A/F102A) (1000A,1000VAC) 2 64676-80P Local Power Interface Module 1 0-60027 250VA Isolation Transformer (250 VA, 110 VAC) 1 417155-16B PMI Rack Assembly 1 805401-5R 25KHz Power Supply (2A)

(115 VAC input, 60 VDC output) LEM Sensor (1000A, 5000:1) 3 600595-18A

0RWRU )HHGEDFN 5HVLVWRUV .Ω:

DC Feedback Module 1 0-55350-10 Motor Ammeter (Optional) 1 708208-20R Motor Voltmeter (Optional) 1 708208-18R Torque Meter (Optional) 1 708208-17R Frequency Meter (Optional) 1 708208-19R Blower Filter 1 69470-3RM

1. Components are identified in figure 2.2.

1

Quantity

1 802 268 -1 6R

3 63481-102TFB

Rockwell

Part Number

Replacement Parts

Table C.2 – Capacitor Bank Assembly (803430-6S)

Part Description

Capacitor (7200µF, 500 VDC) 18 600442-30SX

Table C.3 – Blower Assembly (850011-R)

Part Description

Blower (115 VAC) 1 69739-47R Starter Capacitor (40µF, 240 VAC) 1 69932-24QQ

Quantity

Rockwell

Part Number

Rockwell

Part Number

C-1

534 Amp SA3000 Power Module (Continued)

Table C.4 – Pre-charge Assembly (850022-3)

Part Description

'LVFKDUJH 5HVLVWRUV .Ω :

Quantity

10 63481-6V

Rockwell

Part N umber

Contactor (230A, 600 VAC) 1 705310-39BX Pre-charge Module 1 0-55350-4 Pre-charge Capacitor (4700µH, 50 VDC) 1 600442-31TS Pre-charge Resistors (3.819Ω) 2 48627-G Voltage Feedback Module 1 O-55350-10

Table C.5 – 115 VAC Power Supply Assembly (850100-3R, -3S)

Part Description

   9'& 3RZH U 6XSSO\ $

Quantity

1 704323-33K

Rockwell

Part N umber

115 VAC Circuit Breaker (25A, 600 VAC) 1 or 2 91212-4RA 24 VDC Power Supply (2A ) 2 70432 3-32G Fuse (1FU) (5A, 600 VAC) 1 64676-29R Fuse (3FU) (3.2A, 600 VAC) 1 64676-29P

Table C.6 – IGBT Phase Module Assembly (803430-8S)

Rockwell

Part Description Quantity

Part Number

IGBT Transistor (600A, 1200 VDC) 4 423402-4S Warning Thermostat 1 66012-16A Fault Thermostat 1 66012-16B Gate Driver/Snubber Module 1 0-55350-15 Fuse (F103A, F104A, F105A) (630A, 1000 VAC) 3 64676-79AZ

Table C.7 – PMI Rack Assembly (805401-5)

Part Description

Quantity

Rockwell

Part N umber

Power Supply 1 0-60007-2 Processor Module 1 0-60021-1 Resolver Module 1 0-60031-4 AC Technology Module 1 0-60023-3 AC Parallel Interface Module 1 0-60029-1 Gate Driver Interface Module 1 0-60028-1

C-2

High Power SA3000 Power Modules

972 Amp SA3000 Power Module

Table C.8 – 972A SA3000 Power Module

Part Description

1

Quantity

Rockwell

Part Number

Blower Assembly 2 850011-R IGBT Phase Module Assembly 6 803430-8S Capacitor Bank Assembly 2 803430-6S Pre-charge Assembly 2 850022-3_ 115 VAC Power Supply Assembly 1 850100-3_ Disconnect Switch (Optional) (600A, 1000 VAC) 1 65242-8B Fuse (FPM A,B) (F101A,B / F102A,B)

4 64676-80P

(1000A,1000VAC) Local Power Interface Module 1 0-60027 250VA Isolation Transformer (250 VA, 110 VAC) 1 417155-16B PMI Rack Assembly 1 805401-5R 25KHz Power Supply (2A)

1 802268-16R

(115 VAC input, 60 VDC output) LEM Sensor (1000A, 5000:1) 6 600595-18A Reactor Assembly (600A, 7.5mH) 2 850022-5R

0RWRU )HHGEDFN 5HVLVWRUV .Ω:

3 63481-102TFB DC Feedback Module 1 0-55350-10 Motor Ammeter (Optional) 1 708208-20R Motor Voltmeter (Optional) 1 708208-18R Torque Meter (Optional) 1 708208-17R Frequency Meter (Optional) 1 708208-19R Blower Filter 2 69470-3RM

1. Components are identified in figure 2.3.

Replacement Parts

Table C.9 – Capacitor Bank Assembly (803430-6S)

Part Description

Quantity

Rockwell

Part Number

Capacitor (7200µF, 500 VDC) 18 600442-30SX

Table C.10 – Blower Assembly (850011-R)

Part Description

Quantity

Rockwell

Part Number

Blower (115 VAC) 1 69739-47R Starter Capacitor (40µF, 240 VAC) 1 69932-24QQ

C-3

972 Amp SA3000 Power Module (Continued)

Table C.11 – Pre-charge Assembly (850022-3_)

Part Description

'LVFKDUJH 5HVLVWRUV .Ω :

Quantity

10 63481-6V

Rockwell

Part N umber

Contactor (230A, 600 VAC) 1 705310-39BX Pre-charge Module 1 0-55350-4 Pre-charge Capacitor (4700µH, 50 VDC) 1 600442-31TS Pre-charge Resistors (3.819Ω) 2 48627-G Voltage Feedback Module 1 O-55350-10

Table C.12 – 115 VAC Power Supply Assembly (850100-3R, -3S)

Part Description

   9'& 3RZH U 6XSSO\ $

Quantity

1 704323-33K

Rockwell

Part N umber

115 VAC Circuit Breaker (25A, 600 VAC) 1 or 2 91212-4RA 24 VDC Power Supply (2A ) 2 70432 3-32G Fuse (1FU) (5A, 600 VAC) 1 64676-29R Fuse (3FU) (3.2A, 600 VAC) 1 64676-29P

Table C.13 – IGBT Phase Module Assembly (803430-8S)

Rockwell

Part Description Quantity

Part Number

IGBT Transistor (600A, 1200 VDC) 4 423402-4S Warning Thermostat 1 66012-16A Fault Thermostat 1 66012-16B Gate Driver/Snubber Module 1 0-55350-15 Fuse (F103A, F104A, F105A) (630A, 1000 VAC) 3 64676-79AZ

Table C.14 – PMI Rack Assembly (805401-5)

Part Description

Quantity

Rockwell

Part N umber

Power Supply 1 0-60007-2 Processor Module 1 0-60021-1 Resolver Module 1 0-60031-4 AC Technology Module 1 0-60023-3 AC Parallel Interface Module 1 0-60029-1 Gate Driver Interface Module 2 0-60028-1

C-4

High Power SA3000 Power Modules

1457 Amp SA3000 Power Module

Table C.15 – 1457A SA3000 Power Module

Part Description

1

Quantity

Rockwell

Part Number

Blower Assembly 3 850011-R IGBT Phase Module Assembly 9 803430-8S Capacitor Bank Assembly 3 803430-6S Pre-charge Assembly 3 850022-3_ 115 VAC Power Supply Assembly 1 850100-3_ Disconnect Switch (Optional) (600A, 1000 VAC) 1 65242-8B Fuse (FPM A,B) (F101A,B / F102A,B)

6 64676-80P (1000A,1000VAC)

Local Power Interface Module 1 0-60027 250VA Isolation Transformer (250 VA, 110 VAC) 1 417155-16B PMI Rack Assembly 1 805401-5R 25KHz Power Supply (2A)

1 802268-16R (115 VAC input, 60 VDC output)

LEM Sensor (1000A, 5000:1) 9 600595-18A Reactor Assembly (600A, 7.5mH) 3 850022-5R

0RWRU )HHGEDFN 5HVLVWRUV .Ω:

3 63481-102TFB DC Feedback Module 1 0-55350-10 Motor Ammeter (Optional) 1 708208-20R Motor Voltmeter (Optional) 1 708208-18R Torque Meter (Optional) 1 708208-17R Frequency Meter (Optional) 1 708208-19R Blower Filter 3 69470-3RM

1. Components are identified in figure 2.3.

Replacement Parts

Table C.16 – Capacitor Bank Assembly (803430-6S)

Part Description

Quantity

Rockwell

Part Number

Capacitor (7200µF, 500 VDC) 18 600442-30SX

Table C.17 – Blower Assembly (850011-R)

Part Description

Quantity

Rockwell

Part Number

Blower (115 VAC) 1 69739-47R Starter Capacitor (40µF, 240 VAC) 1 69932-24QQ

C-5

1457 Amp SA3000 Power Module (Continued)

Table C.18 – Pre-charge Assembly (850022-3_)

Part Description

'LVFKDUJH 5HVLVWRUV .Ω :

Quantity

10 63481-6V

Rockwell

Part N umber

Contactor (230A, 600 VAC) 1 705310-39BX Pre-charge Module 1 0-55350-4 Pre-charge Capacitor (4700µH, 50 VDC) 1 600442-31TS Pre-charge Resistors (3.819Ω) 2 48627-G Voltage Feedback Module 1 O-55350-10

Table C.19 – 115 VAC Power Supply Assembly (850100-3R, -3S)

Part Description

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Quantity

1 704323-33K

Rockwell

Part N umber

115 VAC Circuit Breaker (25A, 600 VAC) 1 or 2 91212-4RA 24 VDC Power Supply (2A ) 2 70432 3-32G Fuse (1FU) (5A, 600 VAC) 1 64676-29R Fuse (3FU) (3.2A, 600 VAC) 1 64676-29P

Table C.20 – IGBT Phase Module Assembly (803430-8S)

Rockwell

Part Description Quantity

Part Number

IGBT Transistor (600A, 1200 VDC) 4 423402-4S Warning Thermostat 1 66012-16A Fault Thermostat 1 66012-16B Gate Driver/Snubber Module 1 0-55350-15 Fuse (F103A, F104A, F105A) (630A, 1000 VAC) 3 64676-79AZ

Table C.21 – PMI Rack Assembly (805401-5)

Part Description

Quantity

Rockwell

Part N umber

Power Supply 1 0-60007-2 Processor Module 1 0-60021-1 Resolver Module 1 0-60031-4 AC Technology Module 1 0-60023-3 AC Parallel Interface Module 1 0-60029-1 Gate Driver Interface Module 2 0-60028-1

C-6

High Power SA3000 Power Modules

I

NDEX

C

Cabinet installation, 3-3 to 3-7

double-bay cabinet (972A unit), 3-5 power and ground connections, 3-7 single-bay cabinet (534A unit), 3-4

triple-bay cabinet (1457A unit), 3-6 Cabinet replacement, 4-20 Capacitor bank assembly, 2-2 Circuitry

1457A power module, 2-11

534A power module, 2-9

972A power module, 2-10 Components, 2-1 to 2-5

1457A power module, 2-5

534A power module, 2-3

972A power module, 2-4 Configurations, 1-1 Control power, 4-13

D

DC bus voltage meter, 2-2 Diagnostics and troubleshooting, 4-1 to 4-20

DC bus and output terminal tests, 4-4

DC bus voltage measuring points, 4-3

faults and warnings, 4-4 to 4-8

IGBT tests, 4-4

replacing fuses and sub-assemblies, 4-8 to

4-20 replacing the cabinet, 4-20 required test equipment, 4-1 tests with input power off, 4-2 to 4-4

Documentation, 1-4

E

Electrical description, 2-6 to 2-11

1457A power module circuitry, 2-11 534A power module circuitry, 2-9 972A power module circuitry, 2-10 Drive I/O and processor card, 2-8

F

Fault register 202/1202, 4-5 Faults, 4-5 to 4-6

charge bus time-out, 4-6 DC bus overcurrent, 4-5 DC bus overvoltage, 4-5 ground current fault, 4-5 instantaneous over cu rren t, 4-6 local power interface fault, 4-6

overtemperature, 4-6 Fiber-optic communication, 2-1 Fuses, 3-2, 4-8 to 4-14

1457A power module fuse locations, 4-12

15V and 24V power supplies, 4-13

25KHz power supply, 4-14

534A power module fuse locations, 4-10

972A power module fuse locations, 4-11

replacement fuse specifications, 4-9

replacing fuses, 4-8 to 4-14

G

Grounding, 3-3, 3-7

I

Installation guidelines, 3-1 to 3-7

cabinet installation, 3-3 to 3-7

grounding, 3-3

installation planning, 3-1

terminal tightening torques, 3-3

wire sizes, 3-2 to 3-3

wiring, 3-2 to 3-3 Internal DC bus control, B-1 to B-5

bus control state diagram, B-3

bus protection, B-5

internal DC bus schematic, B-1

modifying DC bus voltage thresholds, B-4

operating range, B-4 Introduction, 1-1 to 1-3

Index

L

Local power interface module (LPI), 2-2

Index-1

M

Main disconnect, 2-2 Mechanical description, 2-1 to 2-5

1457A power module components, 2-5 534A power module components, 2-3

972A power module components, 2-4 Mechanical/electrical description, 2-1 to 2-11 Mounting dimensions

1335A triple-bay power module, 3-6

534A single-bay power module, 3-4

972A double-bay power module , 3-5

blower assembly, 4-18 to 4-19 blower filter, 4-19 bus capacitor assembly, 4-19 to 4-20 fuses, 4-8 to 4-14 IGBT phase module assemblies, 4-15 to 4-17 pre-charge assembly, 4-17 to 4-18

Replacing the power module cabinet, 4-20

S

Snubber/gate driver module, 2-1 Standard features, 1-1

O

Optional features, 1-2 Output meters, 2-2

P

Part numbers, 1-3 Phase modules

description, 2-1

mounting bolt locations, 4-17 Power and ground connections, 3-7 Power supply

115VAC control power, 2-2, 4-13

25 KHz, 2-2, 4-14 Pre-charge assembly, 2-2

R

Related publications, 1-4 Replacement parts, C-1 to C-6

1457A power module, C-5 to C-6

534A power module, C-1 to C-2

972A power module, C-3 to C-4 Replacing components, 4-8 to 4-20

T

Technical specifications, A-1 to A-3

115VAc control power, A-2 ambient co nditions, A-1 DC bus, A-2 DC bus input power, A-2 dimensions, A-1 output power, A-3

Terminal tightening torques, 3-3

W

Warning register 203 /1203, 4-7 Warnings, 4-7 to 4-8

DC bus overvoltage, 4-7 DC bus undervoltage, 4-7 ground current warning, 4-7 load sharing warning, 4-7 overtemperature, 4-8

Wiring, 3-2 to 3-3, 3-7

Rockwell Automation SA3000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual