Rockwell Automation SB3000 User Manual
Distributed Power System
High Power SB3000
AC Power Modules (RCS)
850021 – 21xxx, 31xxx (445 Amp)
850021 – 22xxx, 32xxx (890 Amp)
850021 – 23xxx, 33xxx (1335 Amp)
Instruction Manual
S-3043
Throughout this manual, the following notes are used to alert you to safety considerations:
ATTENTION: Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
!
Important: Identifies information that is critical for successful application and understanding of the product.
ATTENTION: Only qualified personnel familiar with the construction and operation of this
equipment and the hazards involved should install, adjust, operate, or service this equipment.
!
Read and understand this manual and other applicable manuals in their entirety before
proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION: DC bus capacitors retain hazardous voltages after input power has been
disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors
to discharge. Open the cabinet doors and check the voltage across the DC bus bars, 347 A,B,C
(+ bus) and 345 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are
discharged before touching any internal components. Failure to observe this precaution could
result in severe bodily injury or loss of life.
ATTENTION: The user must provide an external, hardwired emergency stop circuit outside of the
drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled
machine operation may result if this procedure is not followed. Failure to observe this precaution
could result in bodily injury.
ATTENTION: The user is responsible for conforming with all applicable local, national, and
international codes. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.
The information in this users manual is subject to change without notice.
AutoMax™ is a trademark of Rockwell Automation
©1998 Rockwell International Corporation
Chapter 1 Introduction
1.1 Standard Features........................................................................................... 1-2
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 Pre-charge Resistors and Fuses........................................................... 3-2
3.2.3 Line Reactors........................................................................................3-3
3.2.4 Control Transformers ............................................................................ 3-3
3.2.5 Wire Sizes.............................................................................................3-4
3.2.6 Wire Routing .........................................................................................3-5
3.3 Grounding........................................................................................................ 3-5
3.4 Installing the Power Module Cabinet.. ....... ...... ....... ...... ....... ...... ....... ...... .........3-5
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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 Faults ....................................................................................................4-5
4.3.1.1 DC Bus Overvoltage Fault ......................................................4-6
4.3.1.2 DC Bus Overcurrent Fault.......................................................4-6
4.3.1.3 Ground Current Fault..............................................................4-6
4.3.1.4 Instantaneous Overcurrent Fault ............................................4-6
4.3.1.5 Local Power Interface Fault ....................................................4-6
4.3.1.6 Gate Driver Interface Fault......................................................4-6
4.3.1.7 Charge Fault ...........................................................................4-6
4.3.1.8 Overtemperature Fault...................................... ....... ...... ....... .. 4-7
4.3.1.9 Power Loss Fault ....................................................................4-7
4.3.1.10 Power Technology Fault ......................................................... 4-7
4.3.1.11 PMI Power Supply Fault ......................................................... 4-7
4.3.1.12 PMI Read/Write Fault.............................................................. 4-7
4.3.1.13 UDC Run Fault........................................................................ 4-7
4.3.1.14 Communicati on Los t Fault ............. ...... ....... ............................ 4-7
4.3.2 Warnings............................................... ....... ...... ....... ...... ....... ...... .........4-7
4.3.2.1 DC Bus Overvoltage Warning................................................. 4-8
4.3.2.2 DC Bus Undervoltage Warning............................................... 4-8
4.3.2.3 Ground Current Warning.........................................................4-9
4.3.2.4 Phase Lost Warning................................................................4-9
Table of Contents
I
Chapter 4 Diagnostics and Troubleshooting (Continued)
4.3.2.5 Reference in Limit Warning .....................................................4-9
4.3.2.6 Load Sharing Warning.............................................................4-9
4.3.2.7 Overtemperature Warning.......................... ....... ...... ................ 4-9
4.3.2.8 Bad Gain Data Warning...........................................................4-9
4.3.2.9 Power Module Overload Warning............................................4-9
4.3.2.10 Power Loss Warning ...............................................................4-9
4.3.2.11 PMI Fan Loss Warning..........................................................4-10
4.3.2.12 Rail Communication Warning................................................4-10
4.3.2.13 CCLK Not Synchronized Warning .........................................4-10
4.3.2.14 PMI Communication Warning................................................4-10
4.4 Replacing Power Module Fuses and Sub-Assemblies ..................................4-10
4.4.1 Replacing Fuses..................................................................................4-10
4.4.2 Replacing an IGBT Phase Module Assembly......................................4-17
4.4.2.1 Replacing an IGBT ................................................................4-19
4.4.3 Replacing a Blower Assembly.............................................................4-20
4.4.3.1 Replacing a Blower Filter.......................................................4-20
4.4.4 Replacing a Bus Capacitor Assembly..................................................4-20
4.5 Replacing the Power Module Cabinet............................................................4-21
Appendix A Technical Specifications........................................................................................... A-1
Appendix B Theory of Operation .................................................................................................B-1
Appendix C SB3000 Interlock Sequencing.................................................................................. C-1
Appendix D Performing the Bridge Test ......................................................................................D-1
Appendix E Replac em ent Parts.................... ...... ....... ...... ...... ....... ...... ....................................... .. E-1
Index ..................................... ...... ....... ...... ....... ...... ....................................... ...... ....... ..Index-1
II
SB3000 Power Modules (RCS)
List of Figures
Figure 1.1 – SB3000 Power Module Part Numbering Scheme ................................ 1-3
Figure 2.1 – 445A SB3000 Power Module Components..........................................2-3
Figure 2.2 – 890A SB3000 Power Module Components..........................................2-4
Figure 2.3 – 1335A SB3000 Power Module Components........................................2-5
Figure 2.4 – DC Bus Voltage....................................................................................2-6
Figure 2.5 – Drive I/O and Processor Card Detail .................................................... 2-8
Figure 2.6 – 445A SB3000 Power Module Circuitry ................................................. 2-9
Figure 2.7 – 890A SB3000 Power Module Circuitry ...............................................2-10
Figure 2.8 – 1335A SB3000 Power Module Circuitry .............................................2-11
Figure 3.1 – 445A Power Module Mounting Dimensions (Single-Bay).....................3-6
Figure 3.2 – 890A Power Module Mounting Dimensions (Double-Bay) ................... 3-7
Figure 3.3 – 1335A Power Module Mounting Dimensions (Triple-Bay)....................3-8
Figure 3.4 – SB3000 Power and Ground Connections............................................. 3-9
Figure 4.1 – DC Bus Voltage Measuring Points.......................................................4-3
Figure 4.2 – 445A SB3000 Power Module Fuse Locations.................................... 4-12
Figure 4.3 – 890A SB3000 Power Module Fuse Locations.................................... 4-13
Figure 4.4 – 1335A SB3000 Power Module Fuse Locations.................................. 4-14
Figure 4.5 – 115VAC Power Supply Assemblies....................................................4-15
Figure 4.6 – 25 KHz. Power Supply........................................................................4-16
Figure 4.7 – IGBT Module Assembly Mounting Bolt Locations ..............................4-19
Table of Contents
III
IV
SB3000 Power Modules (RCS)
List of Tables
Table 1.1 – SB3000 Power Module Configurations..................................................1-1
Table 2.1 – Meter Scaling.........................................................................................2-2
Table 3.1 – Fuse Ratings.......................................................................................... 3-2
Table 3.2 – Pre-charge Resistors and Fuses........................................................... 3-3
Table 3.3 – Line Filter Reactor Ratings .................................................................... 3-3
Table 3.4 – Recommended AC Input and DC Bus Output Wire Sizes..................... 3-4
Table 3.5 – Terminal Tightening Torques.................................................................3-4
Table 4.1 – DC Bus and Output Terminal Tests.......................................................4-4
Table 4.2 – IGBT Tests............................................................................................. 4-4
Table 4.3 – SB3000 Fault Register 202/1202........................................................... 4-5
Table 4.4 – SB3000 Warning Register 203 /1203 .................................................... 4-8
Table 4.5 – Power Module Replacement Fuse Specifications ...............................4-11
Table of Contents
V
VI
SB3000 Power Modules (RCS)
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1
Introduction
The High Power SB3000 Power Modules are variable-voltage, limited-frequency, high
performance PWM power converters. They are designed to be used with Distributed
Power System (DPS) SA3000 and SA3100 PWM inverter drives and other high
performance PWM-type inverters that operate from a fixed voltage DC Bus input.
The SB3000 Power Modules operate as two-quadrant, fast-response, synchronous
rectifiers converting fixed-frequency AC power to regulated voltage DC power using
pulse-width-modulation (PWM) technology. They can operate in both the motoring and
regeneration modes in response to the load applied to the DC output. SB3000 Power
Modules are capable of full rating regeneration of power to the AC line and feature
adjustable power factor operation.
The SB3000 Power Modules operate in conjunction with a separately-mounted input
reactor and a separately-supplied power distribution cabinet, which provides AC
power protection, disconnect, and soft-charge functionality for the SB3000 Power
Modules. Refer to Appendixes B and C for more information on SB3000 theory of
operation and interlock sequencing.
The SB3000 Power Modules are configured in three output power ratings: 445 amp,
890 amp, and 1335 amp when used at a 4 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.
Output current with a 2 kHz carrier frequency is 534A, 972A, and 1457A. A 4 kHz
carrier frequency is typically used to minimize the size of the AC line reactor. The
4 kHz operation requires a derating of the AC input current and DC output load current
when compared with operation at 2 kHz.
The SB3000 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 – SB3000 Power Module Configurations
Output
Base Part
Number
850021-21xxx
850021-31xxx
850021-22xxx
850021-32xxx
850021-23xxx
850021-33xxx
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 208-460V
Three Bays 250-820V 1457A 1335A 1900A 208-460V
DC Bus
Volts
250-820V
3
Output
Amps
(2 KHz)
534A 445A 700A 208-460V
Output
Amps
(4 KHz)
1
Peak
Amps
2
AC Input
Volts
Introduction
1-1
1.1 Standard Features
High Power SB3000 Power Modules have the following standard features:
•
Input power supplied from a separate disconnect/soft-charge cabinet and AC line
reactor
•
PWM synchronous rectifier converts AC power to DC power for a fixed-voltage
PWM inverter DC bus
•
IGBT power semiconductor bridge
•
Carrier switching frequencies from 2 to 4 kHz
•
Ability to add or remove drives from the DC bus while the SB3000 Pow er Module is
running
•
Input and output short-circuit protection
•
Fiber-optic communication with the DPS host, the Universal Drive Controller (UDC)
module
•
Auto-tuning without an identification test
•
Standard cabinet paint
1.2 Optional Features
The following optional features are available for High Power SB3000 Power Modules
•
DC bus voltage meter
•
AC input current meter
•
DC bus current meter
•
Main disconnect
•
Pre-charge
•
Separation of critical and non-critical 115 VAC control power
•
DC bus assembly enclosure
•
Custom cabinet paint
1-2
SB3000 Power Modules (RCS)
1.3 Power Module Part Numbers
SB3000 Power Module part numbers are organized by the number of cabinet bays,
i.e., single (445A), double (890A), or triple (1335A) cabinet bay configurations, in
combination with the supplied options. See figure 1.1.
850021 -2
DC Bus Assembly
Enclosure:
R
1
Size of Unit:
S
T
Pre-charge:
Main
Disconnect:
Meters:
1 = 445A Output - 1 Bay Unit
2 = 890A Output - 2 Bay Unit
3 = 1335A Output - 3 Bay Unit
2 = Supplied
3 = Not Supplied
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
Introduction
SB3000 Power Module - Base Part Number
Figure 1.1 – SB3000 Power Module Part Numbering Scheme
1-3
1.4 Related Publications
This manual describes the hardware components of the SB3000 Power Module. Ref er
to the publications listed below for detailed descriptions of the remaining components
of the SB3000 system and the configuration and programming necessary to control
the SB3000 Power Modules.
•
S-3005 AutoMax Distributed Power System Overview
•
S-3007 DPS Universal Drive Controller Module
•
S-3009 DPS Fiber-Optic Cabling
•
S-3034 DPS SB3000 Configuration and Programming
Refer to the following manuals for information on Distributed Power System AC P o w er
Modules for use with the SB3000 Power Modules:
•
S-3038 DPS SA3000 High Power AC Power Modules (binder S-3001)
•
S-3058 DPS SA3100 AC Power Modules (binder S-3053)
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
1-4
SB3000 Power Modules (RCS)
Mechanical/Electrical Description
This chapter provides an overview the SB3000 Power Module’ s main components and
their mechanical and electrical characteristics. The SB3000 theory of operation is
described in Appendix B.
2.1 Mechanical Description
High Power SB3000 Power Modules are housed in protective sheet metal enclosures,
as shown in figures 2.1 to 2.3. The Power Modules come in single, double, and triple
bay cabinet configurations, depending upon the current rating. See figures 3.1 to 3.3
for Power Module dimensions.
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 regulated DC output voltage. Fuses and thermostats are provided
to protect the IGBT modules.
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2
Snubber/Gate Driver Module
Each Snubber/Gate Driver 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 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 transients produced 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 SB3000 Power Module and the PMI rack.
It is through this module that information is sent to the SB3000 Power Module and
feedback data is sent back to the PMI rack.
Capacitor Bank Assembly
The capacitor bank's electrolytic capacitors store DC power from the IGBTs.
DC Bus Voltage Meter (Option)
The DC Bus Voltage meter, which is connected directly across the DC bus, measures
the DC bus voltage being supplied by the SB3000 Power Module.
AC Input Current Meter and DC Bus Current Meter (Option)
The AC Input Current and DC Bus Current meters measure the AC input current being
provided to the Power Module and the DC bus output current supplied by the SB3000
Power Module. These meters are connected to the PMI meter ports on the PMI
Processor. The meters are calibrated for +/-10V or +10V at full scale. See table 2.1.
Note that PMI ports 3 and 4 are not used.
Table 2.1 – Meter Scaling
SB3000 AC Input
Current Rating at
4kHz
PMI Processor Port 1
DC Bus Current Meter
Scaling
PMI Processor Port 2
AC Input Current Meter
Scaling
445 Amp -800 to +800A 0 to 600A
890 Amp -1,200 to +1,200A 0 to 1,000A
1,335 Amp -1,800 to +1,800A 0 to 1,500A
The AC Input Current meter indicates the RMS line current flowing into or out of the
SB3000 Power Module. The current level is derived from the feedback signals coming
from the Hall devices on the AC input leads to the phase modules.
The DC Bus Current meter indicates the DC current level produced by the SB3000
Power Module. The value is scaled from the feedback signal coming from the Hall
device monitoring the Power Module’s DC output current. Its range is bi-directional.
Positive current indicates that current is flowing from the rectifier to the load (motoring)
and negative current indicates current flowing into the rectifier from the load
(regenerating) to the AC line.
Softcharge Assembly
The Softcharge Assembly is mounted separately and consists of pre-charge resistors
and a contactor. The contactor bypasses the pre-charge resistors after the bus voltage
reaches a programmable threshold value. A pre-charge contactor module
communicates with the LPI module and controls the contactor. See figure 2.4.
2-2
SB3000 Power Modules (RCS)
1. Blower Assembly
4. Pre-charge Assy. Mounting Bracket
7. +/- 15V DC Power Supply
10. LPI Module
13. 25KHz P ower Supply
16. Fuse - Critical Power Supplies
19. 115VAC C.B. - Critical Power
22. Power Supply Assembly
25. DC Bus Current Meter
Figure 2.1 – 445A SB3000 Power Module Components
2. IGBT Phase Module Assembly 3. Capacitor Bank Assembly
5. LEM Sen s or - DC Bus Output 6. DC bus fuse
8. 24V DC Power Supplies 9. 115VAC C.B. - Non Critical Pwr
11. 250VA Isolation Transformer 12. PMI Rack
14. Reactor Assembly 15. LEM Sensors (3) - AC Input
17. Fuse - Aux. 115VAC (TB1) 18. Pre-charge module
20. Blower Filter 21. Line Sync Module
23. Door Interlock Bypass Switch 24. DC Bus Voltage Meter
26. AC Input Current Meter
Mechanical/Electrical Description
2-3
1. Blower Assembly
4. Pre-charge Assy. Mounting Bracket
7. +/- 15V DC Power Supply
10. LPI Module
13. 25KHz P ower Supply
16. Fuse - Critical Power Supplies
19. 115VAC C.B. - Critical Power
22. Power Supply Assembly
25. DC Bus Current Meter
Figure 2.2 – 890A SB3000 Power Module Components
2-4
2. IGBT Phase Module Assembly 3. Capacitor Bank Assembly
5. LEM Sensor - DC Bus Output 6. DC bus fuse
8. 24V DC Power Supplies 9. 115VAC C.B. - Non Critical Pwr
11. 250VA Isolation Transformer 12. PMI Rack
14. Reactor Assembly 15. LEM Sensors (3) - AC Input
17. Fuse - Aux. 115VAC (TB1) 18. Pre-charge module
20. Blower Filter 21. Line Sync Module
23. Door Interlock Bypass Switch 24. DC Bus Voltage Meter
26. AC Input Current Meter
SB3000 Power Modules (RCS)
1. Blower Assembly
4. Pre-charge Assy. Mounting Bracket
7. +/- 15V DC Power Supply
10. LPI Module
13. 25KHz P ower Supply
16. Fuse - Critical Power Supplies
19. 115VAC C.B. - Critical Power
22. Power Supply Assembly
25. DC Bus Current Meter
Figure 2.3 – 1335A SB3000 Power Module Components
2. IGBT Phase Module Assembly 3. Capacitor Bank Assembly
5. LEM Sensor - DC Bus Output 6. DC bus fuse
8. 24V DC Power Supplies 9. 115VAC C.B. - Non Critical Pwr
11. 250VA Isolation Transformer 12. PMI Rack
14. Reactor Assembly 15. LEM Sensors (3) - AC Input
17. Fuse - Aux. 115VAC (TB1) 18. Pre-charge module
20. Blower Filter 21. Line Sync Module
23. Door Interlock Bypass Switch 24. DC Bus Voltage Meter
26. AC Input Current Meter
Mechanical/Electrical Description
2-5
2.2 Electrical Description
AC power to the SB3000 Power Module is supplied from an AC power distribution/
soft-charge cabinet through the AC input reactor.
ATTENTION:
power has been disconnected. After disconnecting input power , wait ten
!
The DC bus voltage is filtered by the electrolytic capacitors. Discharge resistors are
designed to discharge the capacitors down to 50V DC within 5 minutes after power is
removed from the input terminals. However, the user should wait ten minutes before
working on the unit. Be sure to look at the built-in DC Bus Voltage meter, if supplied,
and then measure the DC bus potential before touching any circuitry.
When AC power is applied to the SB3000 Pow er Module’s input terminals 181(L1),
182(L2) and 183(L3), the DC bus is charged through the IGBT emitter-collector diodes
to the level of the rectified AC line voltage. See figures 2.4 to 2.8. Charging current is
limited by the separately-mounted soft-charge resistors and the impedance of the AC
input line reactor. Upon reaching the programmed level of DC bus voltage, the
pre-charge resistors are bypassed by the pre-charge contactor, which places full line
voltage across the AC line to the SB3000 Power Module.
The SB3000 Power Module’s inner control loop is enabled when the application task
sets register 100/1100, bit 0, (VDC_RUN@). When this is done, the PMI Processor
checks the interlocks as described in Appendix C. If the interlock conditions are
satisfied, the DC bus voltage is ramped from the voltage produced by the diode
rectification of the AC line voltage to the voltage reference value provided by the
programmed outer control loop. The DC bus voltage is then regulated by the on-board
voltage regulator. The ramp rate is 100 volts per second. When the preset reference
voltage is reached, register 200/1200, bit 10, (VDC_ON@) is turned on to indicate that
the Power Module is operating.
(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
2-6
Power
On
OVT_E0%
UVT_E0%
Vac ∗ 1.414
VDC_RUN
VDC_ON
Figure 2.4 – DC Bus Voltage
SB3000 Power Modules (RCS)
When the DC bus operating voltage is reached, the connected inverter power
modules may be operated. Note that an SB3000 Power Module cannot support the
loading of SA3000/SA3100 Pow er Modules when the soft-charge resistors are limiting
the bu s charging current.
ATTENTION: SA3000/SA3100 Power Modules must be in standby or in
regeneration whenever the SB3000 Power Module’ s pre-charge
!
The filtered SB3000 DC output voltage is then fed to the DC bus inputs of the
SA3000/SA3100 Power Module(s). The IGBTs are switched by the Gate Driver
Interface module(s) in the PMI rack. Three LEM sensors provide input current
feedback, which is used for control and overcurrent protection. One LEM sensor is
used to provide DC output current feedback.
Each SA3000/SA3100 Power Module connected to an SB3000 Power Modulesupplied 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/SA3100 Power
Module is put into run.
!
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.
ATTENTION: The SB3000 Power Module must be in run before the
SA3000/SA3100 Power Module is put into run. If the pre-charge
contactor supplying the SB3000 Power Module is not closed, running the
SA3000/SA3100 Power Module will damage the SB3000 pre-charge
resistors. Failure to observe this precaution could result in damag e to ,
or destruction of, the equipment.
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/SA3100 Inverter Power Module. If the SB3000
Power Module is shut down due to a fault condition, controlled shutdown of the
SA3000/SA3100 Power Module is the responsibility of the application program
running in the SA3000/SA3100 UDC module.
Mechanical/Electrical Description
2-7
Figure 2.5 – Drive I/O and Processor Card Detail
2-8
SB3000 Power Modules (RCS)
Figure 2.6 – 445A SB3000 Power Module Circuitry
Mechanical/Electrical Description
2-9
Figure 2.7 – 890A SB3000 Power Module Circuitry
2-10
SB3000 Power Modules (RCS)
Figure 2.8 – 1335A SB3000 Power Module Circuitry
Mechanical/Electrical Description
2-11
2-12
SB3000 Power Modules (RCS)
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3
Installation Guidelines
This chapter provides guidelines and wiring recommendations to be followed when
installing SB3000 Power Modules. Hardware installation of the 445A, 890A, and
1335A units is covered. Please refer to the appropriate SA3000/SA3100 instruction
manual for information on properly connecting your AC inverter power module to the
SB3000 DC bus output.
ATTENTION:
local, national, and international codes. Failure to observe this precaution
!
could result in damage to, or destruction of, the equipment.
The user is responsible for conforming with all applicable
3.1 Installatio n Pla n nin g
SB3000 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 SB3000 Configuration and Programming
instruction manual (S-3034) for more information on faults and warnings.
Use the following guidelines when planning your SB3000 Power Module installation:
•
The relative humidity around the SB3000 Power Module must be kept between
5 and 95% (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 SB3000 Power Module's
current rating is derated 1%.
Installation Guidelines
•
Locate the SB3000 Power Module in a clean, cool, and dry area. Follow the
recommendations given in IEC 68 concerning environmental operating conditions.
•
Be sure surrounding equipment does not block service access to the SB3000
Power Module.
•
Allow adequate clearance for air ventilation. SB3000 Power Modules pull in air from
bottom of the cabinet and exhaust it through the top of the cabinet. Each cabinet
the
bay of the SB3000 Po wer Module has one fan. Allow at least 30 cm (12") above and
2 m (6.6') in front of the SB3000 Power Module for adequate air clearance.
•
AC input lead lengths, between the input reactor and the SB3000 Power Module’s
AC input terminals, cannot exceed 10 meters (33 feet).
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 3.2.6 provide additional information on
input fuses, pre-charge components, AC line reactors, and recommended wire types.
3.2.1 Fuses
!
Fuses are provided to protect the SB3000 Power Module's AC line input, DC bus
output, and 115V AC input power lines. See table 3.1 for the input 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 Circuit
1FU 115V AC 5 A 600 VAC 64676-29R
3FU 115V AC 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
AC Line
Input
Fuse Current
Rating
630 A 1000 VAC 64676-79AZ
Fuse Voltage
Rating
Rockwell
P/N
3-2
3.2.2 Pre-charge Resistors and Fuses
The pre-charge circuit consists of three AC line resistors with an AC contactor bypass.
The pre-charge resistors are protected by fuses in series with each resistor. See
table 3.2. The pre-charge circuit is sized to support the charging of the SB3000 Power
Module’s DC bus capacitors and up to four times the Power Module’ s capacitance as a
load. The pre-charge time is 10 seconds or less.
SB3000 Power Modules (RCS)
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