Rockwell Automation SA500 Series Instruction Manual
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Distributed Power System
SA500 AC Power Modules
615055-1R (14 Amp)
615055-1S (28 Amp)
615055-1T (35 Amp)
615055-1V (48 Amp)
Instruction Manual
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S-3018-1
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.
The thick black bar shown on the left margin of this paragraph will be used throughout this manual to signify
new or revised text or figures.
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:Only qualified Rockwell personnel or other trained personnel who understand the
potential hazards involved may make modifications to the rack configuration, variable
configuration, and application tasks. Any modifications may result in uncontrolled machine
operation. Failure to observe this precaution could result in damage to equipment and bodily injury .
A TTENTIO N: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 f ollowed. Failure to observe this precaution
could result in bodily injury.
ATTENTION:Registers and bits in the UDC module that are described as “read only” or for “system
use only” must not be written to by the user. Writing to these registers and bits may result in
improper system operation. Failure to observe this precaution could result in bodily injury.
ATTENTION:For brushless motor applications, changing any resolver wiring, breaking the
resolver coupling, replacing the resolver, or replacing the motor and resolver for any reason
requires that the shaft alignment test be performed again. Resolv er wiring changes always affect
shaft alignment. A resolver change and/or a new motor/resolver combination will affect the shaft
alignment. Improper shaft alignment can cause motor ov erspeed when the motor is started. Failure
to observe this precaution could result in bodily injury.
ATTENTION:The Power Module contains static-sensitive parts and assemblies. When not
installed in the P ower Module, components should be stored in anti-static bags. F ailure to observe
this precaution could result in damage to, or destruction of, the equipment.
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 user’s manual is subject to change without notice.
AutoMax™ is a trademark of Rockwell Automation.
©1998 Rockwell International Corporation
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Chapter 1 Introduction
1.1 Distributed Power System (DPS) Overview ....................................................1-2
1.2 SA500 Drive Overview .................................................................................... 1-3
1.3 Related Publications........................................................................................1-4
Chapter 2 Power Module Mechanical Description
2.1 LED Indicators.................................................................................................2-3
2.2 Power Module Faceplate Connectors .............................................................2-6
2.2.1 Fiber-Optic Ports ...................................................................................2-7
2.2.2 Rail Ports...............................................................................................2-7
2.2.3 Resolver Feedback Connect or........................................ ....... ...... ....... .. 2-8
2.2.4 Drive I/O Connector ............................................................................2-10
Chapter 3 Power Module Electrical Description
3.1 Power-Up Routine ........................................................................................... 3-1
3.2 DC-to-DC Converter........................................................................................3-2
3.3 Resolver Interface ........................................... ....... ...... ....... ...... ....... ...... ....... .. 3-2
Chapter 4 Installation Guidelines
4.1 Wiring and Grounding...................................................................................... 4-1
4.2 Power Module Installation ...............................................................................4-1
4.3 Fiber-Optic Connection....................................................................................4-6
4.4 Drive I/O Connections ..................................................................................... 4-6
4.5 Rail Port Connection........................................................................................4-8
4.6 Resolver Feedback Connect ion ............................. ...... ....... ...... ....... ...... .........4-8
4.6.1 Resolver Input Connections ............................................ ....... ...... ....... 4-10
4.6.1.1 Resolver Calibration....................................................... ....... 4-11
4.6.1.2 Resolver Alignment........................ ...... .................................4 -12
4.6.1.3 Resolver Feedback Precauti on s ........................................... 4-13
4.6.2 Analog Input........................................................................................4-14
4.7 Constant Power Calibration........................................................................... 4-14
4.8 Power Module Replacement .........................................................................4-17
C
ONTENTS
Chapter 5 Diagnostics and Troubleshooting
Appendix A Technical Specifications...........................................................................................A-1
Appendix B Brushless Industrial Motor Data and Curves............................................................B-1
Appendix C Custom DC Bus Supplies .........................................................................................C-1
Appendix D UDC Register Cross-Reference ...............................................................................D-1
Table of Contents
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5.1 Drive Faults (UDC Register 202/1202)............................................................ 5-1
5.2 Power Module Warnings (UDC Register 203/1203)........................................ 5-3
5.3 Power Module Failure......................................................................................5-4
I
Appendix E Status of Data in the AutoMax Rack After a
STOP_ALL Command or STOP_ALL Fault.............................................................E-1
Appendix F PMI Regulator Block Diagram.................................................................................. F-1
Appendix G Power Circuitry Block Diagram ................................................................................G-1
Appendix H Compliance with Electromagnetic Compatibility Standards.....................................H-1
Appendix I SA500 Power Module Output Current Overload Ratings...........................................I-1
Index ...........................................................................................................................Index-1
II
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SA500 Power Modules
List of Figures
Figure 1.1 – SA500 Drive Hardware Configuration ..................................................1-2
Figure 2.1 – SA500 Power Module With Cover and Without Cover ......................... 2-2
Figure 2.2 – Power Module External Connectors.....................................................2-6
Figure 2.3 – Location of Rail Fuse on PMI Regulator PC Board .............................. 2-8
Figure 2.4 – Resolver Feedback Connector Pinout.................................................. 2-9
Figure 2.5 – Analog Input Circuit............................................................................ 2-10
Figure 2.6 – Drive I/O Connector Pinout.................................................................2-11
Figure 2.7 – Auxiliary Input Circuit.......................................................................... 2-11
Figure 2.8 – Run Permissive Input (RPI) Circuit..................................................... 2-12
Figure 3.1 – Resolver Data Format (12-Bit Mode)....................................................3-2
Figure 3.2 – Resolver Data Format (14-Bit Mode)....................................................3-3
Figure 3.3 – External Strobe Input Circuit.................................................................3-3
Figure 3.4 – External Strobe Input Circuit Timing Diagram ...................................... 3-4
Figure 4.1 – Power Module Mounting Dimensions...................................................4-3
Figure 4.2 – DC Bus Supply Wiring..........................................................................4-5
Figure 4.3 – Terminal Block Connections for Drive I/O ............................................4-7
Figure 4.4 – Terminal Block Connections for Resolver and Analog Input................ 4-9
Figure 4.5 – Typical Motor Operation in the Constant Torque and
Constant Power Regions....................................................................4-15
Table of Contents
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III
IV
SA500 Power Modules
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List of Tables
Table 1.1 – SA500 Power Modules.......................................................................... 1-1
Table 1.2 – SA500 Documentation (Binder S-3002) ................................................1-4
Table 4.1 – Recommended Motor Wire Sizes..........................................................4-4
Table 4.2 – Rail I/O Instruction Manuals...................................................................4-8
Table 4.3 – Standard Resolver Connections..........................................................4-10
Table 4.4 – Recommended Resolver Cables.........................................................4-10
Table 4.5 – STATOR_IZ Tunable Values...............................................................4-16
Table of Contents
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V
VI
SA500 Power Modules
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C
HAPTER
1
Introduction
The AutoMax Distributed Power System SA500 AC Power Modules provide AC power
to, and control of, brushless motors and squirrel-cage induction motors from 1–15HP.
Each Power Module contains the Power Module Interface (PMI) Regulator printed
circuit board and the inverter used to convert DC power to AC power for the motor.
Depending upon their power requirements, up to six Power Modules can be
daisy-chained together and operated from one SA500 DC Bus Supply, which provides
the Power Modules a nominal 325 VDC input power. The DC Bus Supply is described
in instruction manual S-3017.
The SA500 Power Modules are available in four sizes with a range of current ratings to
complement the variety of motors available. See table 1.1 below.
Table 1.1 – SA500 Power Modules
Maximum Output
Current (RM S)
(0.5 seconds)
1
Part Number
Continuous Current
Rating (RMS)
615055-1R 14 A 17.5 A (125%)
615055-1S 28 A 35 A (125%)
615055-1T 35 A 70 A (200%)
615055-1V 48 A 106 A (220%)
1. Power Module output current overload rating charts are provided in Appendix I.
Power Module specifications are listed in Appendix A. Detailed speed-torque curves
and engineering data f or SA500 motors are included in Appendix B.
Figure 1.1 shows a typical SA500 drive configuration.
Introduction
1-1
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Universal Drive
Controller Module
AutoMax Rack
Fiber-Optic Link
(up to 750 m)
Drive I/O
AC Line
SA500
DC Bus
Supply
SA500
Power
Module
Resolver
Motor
Digital Rail Analog Rail
Figure 1.1 – SA500 Drive Hardware Configuration
Resolver Fe edback
1.1 Distributed Power System (DPS) Overview
The SA500 is a member of the AutoMax Distributed Power System (DPS) family of
drives. DPS is a programmable microprocessor-based control system that is capable
of real-time control of AC and DC drives. Each Universal Drive Controller (UDC)
module (B/M O-57552) in the AutoMax rack allows the AutoMax Processor to control
up to two drives (20 maximum from one rack). The UDC module communicates over a
fiber-optic link with the PMI located in the SA500 Power Module. The Power Module
can be located up to 750 meters (2500 feet) from the AutoMax rack.
Each DPS drive is controlled by an application task running in the UDC module. All
programming and configuration of the SA500 drive is performed using the AutoMax
Programming Executive software. The SA500 drive requires version 3.4 or later of the
Programming Executive.
1-2
SA500 Power Modules
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1.2 SA500 Drive Overview
An SA500 drive consists of a DC Bus Supply and a Power Module which supplies
three-phase AC power to an induction motor or a permanent magnet brushless motor .
The SA500 DC Bus Supply rectifies three-phase 230 VA C power to provide a constant
DC voltage for the Pow er Module. A three-phase bridge consisting of three SCRs and
three diodes controls the currents during charging of the DC bus capacitor. During
charging, the phase angle of the SCR firing is shifted as a function of time to control
the charging current.
The DC Bus Supply includes a braking circuit, consisting of a bi-polar transistor switch
and a resistor. A DC-to-DC converter within the Power Module senses the DC bus
voltage and switches the braking resistor across the DC bus if a preset threshold is
exceeded. If the capacity of the internal braking resistor is exceeded, the drive’s ability
to dissipate energy may be increased by using an external braking resistor. See
instruction manual S-3017 for more information.
Depending upon the power drawn by the individual Power Modules, the DC Bus
Supply can support up to six Power Modules, each powering one motor. If more than
six Power Modules need to be supplied by a common DC bus, if the capacity of the
DC bus is exceeded, or if the capacity of the braking circuit is exceeded, a
custom-designed DC b us supply may be used with the SA500 Power Modules. The
custom DC bus may be regenerative or non-regenerative. Energy storage capacitors
must be provided with the custom DC bus (or separately). See Appendix C for more
information.
The SA500 Power Module consists of the PMI Regulator (commonly referred to as the
PMI) and power circuitry to invert the DC bus voltage to three-phase 230 VAC for the
motor. The power bridge consists of six bipolar transistors (three dual-transistor
modules).
The PMI receives its operating system, all configuration data, and all commands
including the torque reference from a UDC module in the AutoMax rack via fiber-optic
cables. The PMI executes the torque control algorithm that controls the motor. The
control type is determined by the operating system contained in the PMI. There are
four types of control available: 1) vector, 2) brushless, 3) vector - speed loop
enhanced, and 4) brushless - speed loop enhanced. The operating system is selected
during UDC module configuration.
The UDC module executes the outer (major) control loops. The UDC task (task A or
task B, depending upon the fiber-optic port to which the Power Module is connected)
controls drive sequencing and the alignment of the resolver in brushless applications.
The UDC task provides the torque ref erence to the PMI and communicates with other
upper-level control tasks in the AutoMax rack.
The UDC module and the PMI are tightly synchronized through the fiber-optic link.
The PMI sends all feedback signals, including warning and fault information, speed
feedback, rail data, and gain data, to the UDC before each UDC task scan. Speed
feedback sampling in the Power Module is synchronized to within 1 µsec of the UDC
scan. The operating system in the PMI continuously performs diagnostic checks and
displays the results on the Power Module faceplate LEDs.
Introduction
The PMI also provides connections to digital and analog rails, as well as digital drive
I/O. The PMI scans the rail and drive I/O while the regulation algorithm is running. This
permits the I/O data to be integrated into the control algorithm as required.
1-3
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1.3 Related Publications
This instruction manual provides a description of the SA500 Power Module hardware.
Installation guidelines are also provided. Note that this instruction manual does not
describe specific applications of the standard hardware or software.
For more information, refer to the instruction manuals contained in the SA500 drive
binder, S-3002, as listed in table 1.2. It is assumed that the user is familiar with these
other manuals in S-3002 before installing, operating, or performing maintenance upon
SA500 Power Modules. Refer to these instruction manuals as needed.
:
7DEOH ¤ 6$ 'RFXPHQWDWLRQ %LQGHU 6
Document Document Part Number
DPS Overview S-3005
Universal Drive Controller Module S-3007
Fiber Optic Cabling S-3009
SA500 DC Bus Supply S-3017
SA500 AC Power Modules S-3018
SA500 Diagnostics, Troubleshooting, & Start-Up
S-3022
Guidelines
SA500 Information Guide S-3024
SA500 Drive Configuration & Programming S-3044
Additional information about using SA500 Power Modules is found in the other
instruction manuals, prints, and documents shipped with each drive system. Always
consult the prints shipped with the drive system for specific mounting and connecting
information about your drive.
1-4
SA500 Power Modules
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C
HAPTER
2
Power Module Mechanical Description
Power Modules of all four ratings are the same size, consisting of a sheet metal
enclosure, cooling fans, heatsink, a power supply PC board, inverter power devices,
and the PMI Regulator PC board. A DC-to-DC converter supplies power to the PMI
and to Hall-effect devices used for current feedback.
The faceplate of the Power Module has 15 LEDs, two rail I/O ports, fiber-optic transmit
and receive ports, a resolver f eedback connector for speed feedback and analog input
signals, and a drive I/O connector for dedicated and general-purpose drive I/O. A
push-button labeled “RE-BOOT” allows the PMI Regulator to be reinitialized. This
allows ne Power Module to be reset without powering down the entire DC bus and all
the Power Modules on it. When the button is pressed, all I/O is reset, the PMI executes
its power-up routine, and then requests its operating system from the UDC module.
The SA500 Power Module is cooled by forced air . Air enters through the bottom of the
module and exits through the top . The two f ans at the bottom of the Power Module are
internally connected and powered via a 24V supply produced by the DC-to-DC
converter. The PMI monitors the temperature of the Power Module heatsink and
reports an overtemperature condition in register 202/1202, bit 0.
Two quarter-turn fasteners on the faceplate allow removal of the Power Module cover.
Mounting holes are provided on flanges that extend above and below the module.
Module dimensions are listed in Appendix A. See figure 2.1 for views of the module
with and without its cover.
Note that motor-mounted resolvers are required for speed and position feedback on
SA500 drives. Resolvers are included with every SA500 brushless and induction
motor.
Power Module Mechanical Description
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2-1
PWR OK
OK
COMM OK
P.M. FLT
EXT FLT
RAIL FLT
FDBK OK
RPI
MCR
AUX IN1
AUX IN2
AUX IN3
AUX IN4
AUX IN5
AUX OUT
RE-BOOT
XMT
COMM
LINK
RCV
P1
P2
P3
RAIL
PORT 0
P4
RAIL
PORT 1
P5
RESOLVER
FEEDBACK
P6
DRIVE I/O
WITH COVER ON WITH COVER REMOVED
Figure 2.1 – SA500 Power Module With Cover and Without Cover
2-2
SA500 Power Modules
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2.1 LED Indicators
The LEDs on the faceplate of the Power Module indicate the status of the PMI,
inverter, fiber-optic link, rail I/O, resolver feedback signal, and drive I/O. The status of
the LEDs is also reported in the UDC module’s dual port memory. See the SA500
Drive Configuration and Programming instruction manual (S-3044) for a complete
description of the following status bits. Note that all faults indicated by the LEDs
(except for the RAIL FLT LED) will result in the PMI disabling the power device gates,
which will cause the motor to coast to a stop.
The LED indicators on the module faceplate are defined as follows:
PWR OK
OK
COMM OK
(green) - The “PWR OK” LED indicates that all power supply voltages
for the PMI are at acceptable operating levels. The status of
the DC-to-DC converter is available in the UDC module’s dual
port memory (register 202/1202, bit 12). This LED also
indicates that the DC bus is powered up.
(green) - When power is applied to the P ower Module, the LED will turn
on to indicate the PMI has passed its internal power-up
diagnostics. After power-up, this LED will turn off if the
internal watchdog times out. This will cause the drive to
disable the gate drive circuitry in the inverter.
(green) - When lit, this LED indicates messages are being received
correctly over the fiber-optic link from the UDC module. If this
LED is off, it indicates there is a fault in the link or that the
UDC module is unable to communicate.
If the PMI does not receiv e a message from the UDC module
for two or more CCLK periods, or logs two consecutive
communication errors of any type, the PMI processor will shut
the drive down.
Detailed information about the communication link (e.g.,
number of messages sent and received, CRC error count) is
displayed in the UDC/PMI Communication Status Registers
(80-89/1080-1089) on the UDC module.
P.M. FLT
Power Module Mechanical Description
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(red) - When lit, this LED indicates that one of the fault conditions
listed below has been detected in the Power Module:
•
Overtemperature
Corresponding UDC location: Register 202/1202, bit 0
•
DC bus overvoltage
Corresponding UDC location: Register 202/1202, bit 2
•
Vcc (+5V) supply undervoltage
Corresponding UDC location: Register 202/1202, bit 3
2-3
EXT FLT (red) - When lit, this LED indicates that one of the following external
fault conditions has occurred:
•
Overcurrent fault
Corresponding UDC location: Register 202/1202, bit 1
•
User-programmed fault
Corresponding UDC location: Register 101/1101, bit 2
•
Overspeed fault
Corresponding UDC location: Register 202/1202, bit 10
RAIL FLT (red) - When lit, this LED indicates communication between an I/O
rail and the PMI has been disrupted, or that a rail has been
configured but is not plugged in.
Registers 0-23 are available in the UDC module for rail
variable configuration and diagnostic purposes. If a rail
communication problem is detected and logged in register 4,
10, 16, or 22, then bit 13 in the Drive Warnings register
(203/1203) will be set.
Note that rail faults will not cause the drive to shut down. The
user must ensure that the application task tests the rail fault
registers and forces appropriate action in the event of a fault.
FDBK OK (green) - When lit, this LED indicates that the Resolver & Drive I/O
module is receiving feedback from the resolver and that no
resolver feedback faults have been detected.
If the LED is off, it indicates the following fault:
•
Feedback broken wire fault. The resolver sine and/or
cosine signals are missing, or the resolver gain tunable
(RES_GAN%) has been set too low.
Corresponding bit location: Register 202/1202, bit 8
The signals associated with the following LEDs interface to the Power Module via the
Drive I/O connector. See figure 2.6.
RPI (green) - When lit, this LED indicates that the run permissive input
(RPI) signal is detected on pin A. The RPI signal typically
originates from the drive's coast-to-rest stop circuit.
Corresponding bit location: Register 201/1201, bit 0.
MCR (amber) - When lit, this LED indicates the MCR (motor control relay)
output signal is being driven on (pin P). The MCR output is
under the control of the PMI. This LED will turn on when the
drive is put into run and will turn off when the drive is idle. The
use of a motor control relay is optional.
2-4
SA500 Power Modules
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AUX IN1 (green) - When lit, this LED indicates the presence of a 115 volt signal
on this input (pin C). This LED is used for M-contactor
feedback when the programmer has configured an output
contactor between the Power Module and the motor. The use
of an M-contactor is optional.
Corresponding bit location: Register 201/1201, bit 1.
AUX IN2 (green) - When lit, this LED indicates the presence of a 115 volt signal
on this input (pin E).
Corresponding bit location: Register 201/1201, bit 2.
AUX IN3 (green) - When lit, this LED indicates the presence of a 115 volt signal
on this input (pin H).
Corresponding bit location: Register 201/1201, bit 3.
AUX IN4 (green) - When lit, this LED indicates the presence of a 115 volt signal
on this input (pin K).
Corresponding bit location: Register 201/1201, bit 4.
.
AUX IN5 (green) - When lit, this LED indicates the presence of a 115 volt signal
on this input (pin M).
Corresponding bit location: Register 201/1201, bit 5.
.
AUX OU T (amber) - When lit, this LED indicates the output signal has been
turned on (pin S).
Corresponding bit location: Register 101/1101, bit 4.
Power Module Mechanical Description
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2-5
2.2 Power Module Faceplate Co nnectors
The following sections describe the Power Module faceplate connectors. Figure 2.2
shows the external connections to the Power Module.
CU
PS
DCP
U
PWR OK
OK
COMM OK
P.M. FLT
EXT FLT
RAIL FLT
FDBK OK
RPI
MCR
AUX IN1
AUX IN2
AUX IN3
AUX IN4
AUX IN5
AUX OUT
RE-BOOT
AutoMax
FROM
D-C BUS
SUPPLY
XMTCOMM
LINK
RCV
RAIL
PORT 0
RAIL
PORT 1
RESOLVER
FEEDBACK
DRIVE I/O
AutoMax SA500
DISTRIBUTED POWER SYSTEM
AC POWER MODULE
POS NEG U V W GND
RAIL I/O
MCR
AUX IN1
AUX IN2
AUX IN3
AUX IN4
AUX IN5
AUX OUT
RPI
RESOLVER FEEDBACK
ANALOG INPUT
TO MOTOR
2-6
Figure 2.2 – Power Module External Connectors
SA500 Power Modules
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2.2.1 Fiber-Optic Ports
Transmit (XTM) and receive (RCV) ports are provided on the faceplate of the Power
Module for connection to the fiber-optic link with the UDC module in the AutoMax rack.
The Power Module is shipped with dust caps covering the fiber-optic ports. To prevent
dust accumulation and the resulting loss of signal integrity, the dust caps should not
be removed until the fiber-optic cables are installed, and should be replaced if the
cables are disconnected.
!
2.2.2 Rail Ports
Two rail ports (0 and 1) on the faceplate of the Power Module support direct
connection to digital and analog rail modules. All combinations of the modules listed
below are supported.
•
M/N 45C001A
•
M/N 45C630
•
M/N 45C631
•
M/N 61C345
•
M/N 61C346
•
M/N 61C350
•
M/N 61C351
•
M/N 61C365
•
M/N 61C366
ATTENTION:
the UDC module and to its corresponding PMI Regulator before viewing
the fiber-optic cable or transmitter under magnification. Viewing a
powered fiber-optic transmitter or connected cable under magnification
may result in damage to the eye. For additional information ref er to ANSI
publication Z136.1-1981. Failure to observe this precaution could result
in bodily injury.
Digital I/O Rail (J-3012)
4-Decade Thumbwheel Switch Input Module (J-3654)
4-Digit LED Output Module (J-3655)
4-Channel Analog Current Input Rail (J-3689)
4-Channel Analog Voltage Input Rail (J-3688)
2-Channel Analog Voltage Input/Output Rail (J-3672)
2-Channel Analog Current Input/Output Rail (J-3673)
4-Channel Analog Current Output Rail (J-3694)
4-Channel Analog Voltage Output Rail (J-3695)
T urn off, lock out, and tag power to both the rack containing
Digital I/O modules can be mixed in an I/O rail connected to the P ower Module. Analog
rail modules must be used in the rail mode only. Note that Local Heads (M/N 61C22)
are not supported.
These rails receive the 5V power required for their operation through their connection
to the PMI. If the PMI is reset or power is removed, all outputs are turned off. Rail
cables must not be connected or disconnected under power.
The PMI contains the fusing f or the rail I/O. The P ower Module cov er must be removed
to replace the rail fuse. See figure 2.3 for the location of the rail fuse. See Appendix A
for the rail fuse specification.
The rail update rate is asynchronous to the UDC task and UDC-to-PMI
communications. While the regulation algorithm is running, digital rails are updated
every 5 msec (both ports). Analog rails are updated every 20 msec (both ports).
Power Module Mechanical Description
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2-7
RIGHT SIDE VIEW
RAIL FUSE
FAN
POWER
2-8
Figure 2.3 – Location of Rail Fuse on PMI Regulator PC Board
2.2.3 Resolver Feedback Connector
The faceplate connector labeled “RESOLVER FEEDBACK” is used to connect the
resolver to the Power Module. This connector will also accept a signal from an analog
tachometer or other analog field device as long as the signal is within the correct
voltage range. (Note that the tachometer cannot be used for speed feedback.) A 24V
digital input that serves as a strobe for latching the resolver position externally is also
supplied.
Both a resolver and an analog device may be connected to the module (e.g., the
analog input may be used for tension or position feedback at the same time that the
resolver input is used for speed feedback). However, only the resolver will be
monitored for an overspeed condition. See the SA500 Drive Configuration and
Programming instruction manual, S-3044, for more information.
SA500 Power Modules
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ATTENTION:For brushless motor applications, changing any resolver
wiring, breaking the resolver coupling, replacing the resolver , or replacing
!
the motor and resolver for any reason requires that the shaft alignment
test be performed again. Resolver wiring changes always affect shaft
alignment. A resolver change and/or a new motor/resolver combination
will affect the shaft alignment. Improper shaft alignment can cause motor
overspeed when the motor is started. F ailure to observe this precaution
could result in bodily injury.
The Resolver Feedback connector pinout is shown in figure 2.4.
Reference Out (+)
Reference Out (-)
Sine Input (+)
Cosine Input (+)
External Strobe Input (+)
External Strobe Input (-)
Not Used
Not Used
Analog Input (+)
Figure 2.4 – Resolver Feedback Connector Pinout
A
B
D
E
H
J
L
M
P
Sine Input (-)
C
Cosine Input (-)
F
K
Key Pin
N
Analog Input (-)
Analog Input Shield
R
The analog input operates over the range of +/-10V differential (+/-30V common
mode). It is the user's responsibility to ensure that the input signal is scaled to conform
to this range. The input is bandwidth-limited to 320 Hz. The resolution of the input is
12 bits (11 bits plus sign) or 4.88 mV per bit. The input impedance is 1.3 megohms
and is resistively isolated. The analog input circuit is shown in figure 2.5.
If an analog tachometer is not used, the input may be used f or other purposes as long
as the signal is within the correct voltage range. The PMI sends the analog input data
to the UDC module immediately before it is needed by the UDC module for the next
UDC task scan. The analog input data is stored in UDC register 214/1214. The v alue
may range from -2048 (-10 volts) to +2047 (+10 volts).
Power Module Mechanical Description
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2-9
312K
ANALOG -
ANALOG+
ANALOG SHIELD
1K
AGND
1.04M
1.04M
312K
DGND
.33
F
µ
AGND
+15 V
–
+
-15 V
THIS CONNECTION
IS MADE WITH THE
DC/DC CONVERTER
DGND
AGND
20K
5600 pF
TO A/D
SUBSYSTEM
AGND
THESE COMPONENTS
ARE ON THE PMI
REGULATOR
10K
.33 µF
Figure 2.5 – Analog Input Circuit
2.2.4 Drive I/O Connector
The connector labeled “DRIVE I/O” is used for digital I/O connections to standard
drive-related signals, such as M-contactor status, the run permissive input (RPI) for
the drive, or for other user-designated functions. Six digital inputs and two digital
outputs are provided. Five of the inputs (AUX IN1 to AUX IN5) and one of the outputs
are user-programmable.
The digital drive I/O operates with 115VAC (50/60Hz) nominal line voltage. All input
and output channels have isolated commons with an isolated voltage rating limited to
150VAC. All inputs and outputs have isolation voltage ratings of 1500 volts between
the I/O and the PMI Regulator's power supply. See figures through for the input and
output circuit diagrams.
The RPI input and the MCR output are interlocked in hardware on the module. The
MCR output is activated only when the RPI signal is asserted (by the user) and the
MCR output is being commanded on by the PMI. The PMI will begin the process to
turn off the MCR output when any of the following conditions occurs:
•
The RPI input signal is removed
•
A drive fault occurs
•
The torque control algorithm is turned off (TRQ_RUN = 0)
2-10
SA500 Power Modules
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If any of these events occurs, the PMI will wait f or 100 msec and then turn off the MCR
RPI IN (+)
AUX IN2 (+)
AUX IN1/MFDBK (+)
AUX IN3 (+)
AUX IN4 (+)
AUX IN5 (+)
MCR OUT (+)
AUX OUT (+)
Key Pin
A
C
E
H
K
M
P
S
U
B
D
F
J
L
N
R
T
V
RPI IN (-)
AUX IN1/MFDBK (-)
AUX IN2 (-)
AUX IN3 (-)
AUX IN4 (-)
AUX IN5 (-)
MCR OUT (-)
AUX OUT (-)
Not Used
330
15K
182
DIGITAL
OUT TO
MICROPROCESSOR
.1uF
AUX INPUTS
output. If the RPI signal is remov ed, the MCR output will be turned off and gate pow er
will be removed under hardware control within approximately 0.5 second to provide an
additional level of protection.
The user has the option of having an M-contactor (i.e., an output contactor) on the
output of the Power Module. This option is available during UDC parameter
configuration. The M-contactor is controlled by the MCR output, which is under the
control of the PMI processor. If the choice is made to connect the MCR to the output
contactor, the contacts must be wired to the AUX IN1/MFDBK input. The PMI will then
wait for this signal to turn on before executing the control algorithm. The status of the
AUX IN1/ MFDBK input is reported in register 201/1201, bit 1. If this configuration
choice is not made, the AUX IN1 input can be used for any user-designated purpose.
The status of the drive I/O is indicated in UDC register 201/1201 and by eight LEDs on
the module faceplate. In the event of a power loss or if a system reset command is
initiated by the PMI, all outputs are turned off.
The Drive I/O connector pinout is shown in figure 2.6.
Power Module Mechanical Description
Figure 2.6 – Drive I/O Connector Pinout
Figure 2.7 shows the auxiliary input interface circuit.
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The run permissive input (RPI) circuit is shown in figure 2.8.
Figure 2.7 – Auxiliary Input Circuit
2-11
DGND = ON
+15V
GATE KILL
+15V = OFF
DGND
MCR_OUT+
MCR_OUT-
6
124
5
3
1 = On
Other Faults
0 = Off
10
3 4
+5V
–
+
1
8
1/2
Second
Delay
M-Contactor
12
DGND
1
+
-
+
6
7
+15V
7
-
6
1
+5V +5V
+
–
DGND
6
4
1
3
Shunt
Regulator
3
2
2-12
RPI_IN+
RPI_IN-
Figure 2.8 – Run Permissive Input (RPI) Circuit
SA500 Power Modules
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C
HAPTER
3
Power Module Electrical Description
DC input voltage to the Power Module is supplied by a DC bus, normally the SA500
DC Bus Supply. The inverter bridge in the Power Module converts the constant
potential DC voltage from the DC bus to three-phase AC power for the motor. The
inverter bridge consists of six bi-polar transistors. Interlock circuitry ensures that the
upper phase and lower phase U, V, and W transistors are never turned on at the same
time.
The inverter bridge can regenerate energy to the DC bus. During regeneration, the
inverter returns energy from the motor to the DC bus. Howev er, the SA500 DC Bus
Supply cannot pass this regenerative current back to the AC line. Instead, it stores the
excess energy in its capacitors. It can then pass this surplus energy to other Power
Modules on the bus that need motoring current, or it can dissipate the energy through
DC bus braking resistors. See the DC Bus Supply instruction manual (S-3017) for
specifications on the regeneration limits of the DC Bus Supply and for more
information about braking resistors.
The regulator circuitry and UDC communication interface is contained on a single PC
board, the Power Module Interface (PMI) Regulator. This PC board contains control
circuitry for the inverter, resolver and drive I/O circuitry, and fiber-optic transceivers for
communication with the UDC module in the AutoMax rack. The PMI’s main function is
torque regulation for brushless motors and induction motors.
The PMI contains a RISC (reduced instruction set computer) microprocessor
operating at 16 MHz. High speed communication with the UDC module is controlled
by an onboard serial communications controller. Data is transmitted over the
fiber-optic link at 10 Mbit/sec using the High-Le vel Data Link Control (HDLC) protocol.
Data integrity is checked using a CRC (cyclic redundancy check) error detection
scheme.
The PMI contains an on-board watchdog timer that is enabled when power is applied
to the PMI. Once activated, the on-board CPU must continually reset the watchdog
timer within a specified time or the PMI will shut down. The MCR output, typically used
to control a motor contactor, will be turned off under hardware control within 0.5
seconds if the watchdog times out. (The MCR output is also turned off if the RPI input
turns off.) To reset the watchdog, you must either cycle power or press the RE-BOOT
button on the faceplate.
Any faults in the Po wer Module will cause the PMI to turn off the control signals to the
power devices (bipolar transistors) that switch the DC bus voltage to the motor.
3.1 Power-Up Routine
When power is applied to the Power Module, the LEDs will blink three times as a test
and the PMI will perform a series of internal diagnostics. The P.M. FLT LED on the
faceplate will flash if the Power Module fails any of these diagnostics. If the diagnostics
are passed, the OK LED on the faceplate will turn on.
Power Module Electrical Description
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3-1
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