Rockwell Automation SD3100 User Manual

Distributed Power System SD3100 DC Power Modules

1250A, 1650A, 3000A DC

Instruction Manual

S-3064

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:Verify that all sources of AC and DC power are deenergized and locked out or tagged out in accordance with the requirements of ANSI/NFPA 70E, Part II.

ATTENTION:The user must provide an external, hardwired 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 system may contain stored energy devices. To avoid the hazard of electrical shock, verify that all voltage on capacitros has been discharged before attempting to service, repair, or remove a drive system or its components. You should only attempt the procedures in this manual if you are qualified to do so and are familiar with solid-state control equipment and the safety procedures in publication 70E.

ATTENTION:An incorrectly applied or incorrectly installed drive system can result in component damage and/or a reduction in product life. Wiring or application errors–such as undersizing the motor, incorrect or inadequate AC supply, and excessive ambient temperatures–can result in the malfunction of hte drive 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.

ATTENTION:This drive system contains parts and assemblies that are sensitive to ESD (electrostatic discharge). Static control precautions are required when installing, testing, or repairing this assembly. Component damage can result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to Rockwell Automation publication 8000-4.5.2, on ESD protection.

Guarding Against Electrostatic Damage

, or another adequate handbook

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

Chapter 1 Introduction

1.1 Field Power Module.........................................................................................1-3

1.2 Standard Features...........................................................................................1-3

1.3 Optional Features............................................................................................1-4

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

1.5 Terms Used in this Manual..............................................................................1-5

Chapter 2 Mechanical/Electrical Description

2.1 Mechanical Overview ......................................................................................2-2

2.1.1 Control Components .............................................................................2-2

2.1.2 Power Components............................................................................... 2-3

2.1.2.1 Incoming Power ...................................................................... 2-3

2.1.2.2 Armature Power Components.................................................2-4

2.1.2.3 Field Power Module Components........................................... 2-7

2.2 Electrical Overview..........................................................................................2-7

2.3 1250A Power Module Description ................................................................... 2-9

2.3.1 1250A Power Module Component Layout........................................... 2-10

2.3.2 1250A Power Module Dimensions...................................................... 2-12

2.4 1650A Power Module Description .................................................................2-13

2.4.1 1650A Power Module Component Layout........................................... 2-14

2.4.2 1650A Power Module Dimensions...................................................... 2-16

2.5 3000A Power Module Description .................................................................2-17

2.5.1 3000A Power Module Component Layout........................................... 2-18

2.5.2 3000A Power Module Dimensions...................................................... 2-20

C

ONTENTS

Chapter 3 Installation Guidelines

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

3.2 Physically Installing the Power Module ...........................................................3-2

3.3 Wiring AC Input Power to the Power Module .................................................. 3-2

3.3.1 AC Input Wire Selection ........................................................................ 3-2

3.3.2 Making an Input Entry Hole................................................................... 3-3

3.3.3 Connecting the AC Input Wires to the Busbars..................................... 3-3

3.4 Wiring AC Input to the Field Power Module..................................................... 3-4

3.4.1 Installing the Field Isolation Transf ormer .............................................. 3-4

3.5 Wiring the Motor .............................................................................................. 3-5

3.5.1 Selecting Wires for the Armature and Field Lines.................................3-5

3.5.2 Connecting the Motor to the Power Module..........................................3-5

3.6 Installing Feedback Devices................................... ...... ....... ...... ....... ...... ....... .. 3-6

3.7 Meter Port Connections...................................................................................3-7

3.8 Grounding the Drive ........................................................................................3-7

3.9 For Information on Initial Start-Up of the Drive................................................ 3-8

Table of Contents

I

Chapter 4 Maintenance and Troubleshooting

4.1 Recommended Test Equipment.......................................................................4-1

4.2 System Diagnostics..........................................................................................4-2

4.2.1 Power Module Faults.............................................................................4-2

4.2.1.1 Shorted SCR Fault (Bit 0)........................................................4-2

4.2.1.2 AC Line Synchronization Fault (Bit 3)......................................4-2

4.2.1.3 Instantaneous Overcurrent Fault (Bit 4) ..................................4-3

4.2.1.4 Conduction Timeout Fault (Bit 5).............................................4-3

4.2.1.5 Loss of Field Fault (Bit 6).........................................................4-3

4.2.2 Power Module Warnings........................................................................4-3

4.2.2.1 Three-phase Bridge SCR Not Firing Warning (Bit 0)...............4-3

4.2.2.2 Low Line Voltage/Phase Missing Warning (Bit 1)....................4-3

4.2.2.3 Synchronization Loss Fault Avoided Warning (Bit 3) ..............4-4

4.2.2.4 Current Reference Limit Warning (Bit 4) .................................4-4

4.2.2.5 Identification Test Error Warning (Bit 5) ..................................4-4

4.2.2.6 Field Power Module Overcurrent Warning (Bit 6)....................4-4

4.2.2.7 Fan Loss Warning (Bit 12).......................... .............................4-4

4.3 Component Replacement ................................................................................4-4

4.3.1 Spare Parts Kits.....................................................................................4-4

4.3.2 PMI Regulator........................................................................................4-5

4.3.3 Parallel Gate Amplifier...........................................................................4-5

4.3.4 Field Power Module...............................................................................4-5

4.3.4.1 Replacing Internal Field Power Module AC Input Fuses.........4-5

4.3.4.2 Replacing Field Power Module Components ..........................4-6

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

Appendix B Schematics............................................................................................................... B-1

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

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

II

SD3100 Power Modules

List of Figures

Figure 1.1 – SD3100 Catalog Numbering Scheme .................................................. 1-1

Figure 2.1 – SD3100 Power Module System Components ......................................2-1

Figure 2.2 – Regulator Assembly .............................................................................2-2

Figure 2.3 – Armature Bridge (Non-Regenerative)................................................... 2-5

Figure 2.4 – Armature Bridge (Regenerative)...........................................................2-6

Figure 2.5 – 1250A Power Module Component Layout..........................................2-10

Figure 2.6 – 1250A Power Module Dimensions .....................................................2-12

Figure 2.7 – 1650A Power Module Component Layout..........................................2-14

Figure 2.8 – 1650A Power Module Dimensions .....................................................2-16

Figure 2.9 – 3000A Power Module Component Layout..........................................2-18

Figure 2.10 – 3000A Power Module Dimensions ................................................... 2-20

Figure 3.1 – Area Available for Conduit Entry (Top View of Leftmost Bay).............. 3-3

Figure 3.2 – Field Terminal Wiring............................................................................3-4

Figure 3.3 – Drive I/O Connections (TB4) ................................................................ 3-6

Figure 3.4 – Resolver and Analog Input Connections (TB5) .................................... 3-6

Figure 3.5 – Meter Port Connections (TB6)..............................................................3-7

Figure 3.6 – SD3100 Grounding...............................................................................3-8

Figure A.1 – Altitude Derating Chart.........................................................................A-1

Figure A.2 – Power Dissipation vs. Armature Current (1250A Power Module) ........A-3

Figure A.3 – Recommended Circuit Breaker Settings (1250A Power Module) ........A-3

Figure A.4 – AC Input Busbars (1250A Power Module)...........................................A-4

Figure A.5 – Power Dissipation vs. Armature Current (1650A Power Module) ........A-6

Figure A.6 – Recommended Circuit Breaker Settings (1650A Power Module) ........A-6

Figure A.7 – AC Input Busbars (1650A Power Module)...........................................A-7

Figure A.8 – Power Dissipation vs. Armature Current (3000A Power Module .........A-9

Figure A.9 – Recommended Circuit Breaker Settings (3000A Power Module) ........A-9

Figure A.10 – AC Input Busbars (3000A Power Module) .......................................A-10

Figure A.11 – Air Baffle Layout (1250A and 1650A Power Modules).....................A-11

Figure A.12 – Air Baffle Layout (3000A Power Module).........................................A-12

Figure B.1 – DC Blower Motor Connections.............................................................B-1

Figure B.2 – 1250A and 1650A Power Modules (Non-Regenerative), Sheet 1........B-2

Figure B.3 – 1250A and 1650A Power Modules (Non-Regenerative), Sheet 2........B-3

Figure B.4 – 1250A and 1650A Power Modules (Regenerative), Sheet 1 ...............B-4

Figure B.5 – 1250A and 1650A Power Modules (Regenerative), Sheet 2 ..............B-5

Figure B.6 – 3000A Power Module (Regenerative), Sheet 1....................................B-6

Figure B.7 – 3000A Power Module (Regenerative), Sheet 2....................................B-7

Table of Contents

III

IV

SD3100 Power Modules

List of Tables

Table 1.1 – SD3100 Drive Options........................................................................... 1-2

Table 1.2 – Field Power Module Part Numbers........................................................1-3

Table 1.3 – Distributed Power System DC Drives Documentation........................... 1-4

Table 1.4 – Related Motor Control Center Documentation.......................................1-5

Table 2.1 – 1250A Configurations............................................................................ 2-9

Table 2.2 – 1250A Power Module Symbol-to-Component Reference....................2-11

Table 2.3 – 1650A Configurations.......................................................................... 2-13

Table 2.4 – 1650A Power Module Symbol-to-Component Reference....................2-15

Table 2.5 – 3000A Configurations.......................................................................... 2-17

Table 2.6 – 3000A Power Module Symbol-to-Component Reference....................2-19

Table 3.1 – Recommended AC Input Wiring ............................................................3-2

Table 3.2 – Isolation Transformer Wiring Requirements ..........................................3-4

Table 3.3 – Armature Wire Selection........................................................................3-5

Table 3.4 – Field Wire Selection...............................................................................3-5

Table 4.1 – Field Power Module Input Fuses ........................................................... 4-5

Table A.1 – Electrical Specifications (1250A Power Module)...................................A-2

Table A.2 – Electrical Specifications (1650A Power Module)...................................A-5

Table A.3 – Electrical Specifications (3000A Power Module)...................................A-8

Table of Contents

V

VI

SD3100 Power Modules

C

HAPTER

1

Introduction

SD3100 DC Power Modules convert fixed voltage and frequency three-phase AC power to adjustable voltage DC power, which can be used to supply the armature or field of a DC motor. An SD3100 Power Module operates within the AutoMax Distributed Power System (DPS) environment, and is controlled by the AutoMax Programming Executive software. The Power Module communicates with the AutoMax system via an internally mounted Power Module Interface (PMI) rack, which contains the drive’s control circuits and executes the motor control algorithm.

The SD3100 configuration provides control of DC motors, rated 700 to 2500 HP, with current ratings of 1250, 1650, and 3000A. Input voltages of 460, 575, and 660 VAC are available. Figure 1.1 shows the SD3100 catalog numbering scheme.

Distributed Power System Drive Numb er

SD3100

B = 460 VAC C = 575 VAC F = 660 V AC

64 = 700 HP 65 = 750 HP 66 = 800 HP 67 = 900 HP

N = Non-regenerative, 6-pulse R = Regenerative, 6-pulse

AA = NEMA Type 1 w ithout gaskets and door fan filters AJ = NEMA Type 1 with g askets and door fan filters

Refer to table 1.1, SD3100 Drive Options.

68 = 1000 HP 69 = 1250 HP 70 = 1500 HP 71 = 1750 HP

AC Input

Voltage

72 = 2000 HP 73 = 2250 HP 74 = 2500 HP

3

B

1

HP

64

Unit

Configuration

N

2

Enclosure Options

AA

4

1. A separately-ordered, separately-mounted 7.5 to 25kVA field isolation transformer is required. See section 1.1.

2. Units accommodate top ent ry and bottom exit. An additional sec ti on is required f or bottom entry. A separate additional section is required for top exit.

3. Non-regenerative units not offered for 3000A modules.

4. Add option codes here. Separate option codes with dashes.

Figure 1.1 – SD3100 Catalog Numbering Scheme

Introduction

1-1

Table 1.1 – SD3100 Drive Options

Drive Option Code Description

6P Standard capacity control transformer with primary fusing

Control Po w er Sourc e

1

6TB 6SC 115 VAC control power supplied by others

2

Dynamic Braking Cont act or

Unit Door Nameplate

1

14DB Dynamic braking contactor option

M3EW White background with black lettering; phenolic label

14WLBL

Miscellaneous

J12 J11 Audio phone jack

Auxiliary Contact s 989X

14BN (1) NEMA 1 FVNR starter assembly internally mounted with 30A fuse blocks

14B2N (2) NEMA 1 FVNR starter assemblies internally mounted with 30A fuse

Blower Starters

5, 6

14B2NX (2) NEMA 2 FVNR starter assemblies internally mounted with 60A fuse

14BI (1) IEC 24A starter assembly internally mounted with 30A fuse blocks

14B2I (2) IEC 24A starter assemblies internally mounted with 30A fuse blocks

14B2IX (2) IEC 30A starter assemblies internally mounted with 60A fuse blocks

14LSP

Protection

14AFL Air flow loss swit ches

Field Su pply Upgra de

Incoming Protecti on

8, 9

1

14FX Field supply upgrade for fields requiring 15 to 60A

CM Circuit breaker

LF Line fuses

HB1600 1600A AC power bus for 1250A units with 460 or575 VAC inputs

5

Horizontal Power Bus

HB2000 2000A AC power bus for 1250 and 1650A units with 460 or 575 VAC inputs HB3000 3000A AC power bus for 1250 and 1650A units with 460 or 575 VAC inputs

Horizontal Control Bus CB90

Input Option 14HBC

1. User must select one option from this group.

2. This option includes a dynamic braking contactor mounted in a separate 20” MCC section.

3. Cloth wire labels are standard. Datab labels provide a clear plastic cover on top of the labels for added protection.

4. User must supply 115 VAC control power and wiring to the duplex receptacle.

5. User may select one option from this group.

6. Fuses and overload elements are user-supplied and must be power-matched to the installation.

7. Line RC suppressor is required for installations where the primary of the distribution transformer is 2300 VAC or greater.

8. Standard Field Power Module is rated to supply field currents up to 15A. The upgrade provides a Field Power Module rated up to 60A. (Nominal field currents based on 85% efficiency, unit control power usage, and a 300V field supply.)

9. A separately-ordered, separately-mounted 7.5kVA to 25kVA field isolation transformer is required. See the following section.

115 VAC control power, factory wired from 115 VAC control bus to drive unit (1250 and 1650A units only). Requires option CB90

Brady Datab™ wire labels 15 VDC, 15A duplex receptacle, user-wired

(2) normally open and (2) normally close d contactors mounted in ternally in

•

3

4

1250/1650A unit, or (4) normally open and (4) normally close d contactors mounted in ternally in

•

3000A unit

blocks

Line RC suppressor module

7

90A AC control bus for 1250 and 1650A units that have a horizontal power bus option

AC pow er input is wired from the horizo ntal thru-bu s to the circuit br eake r/line fuses for 1250 and 1650A units that have a horizontal power bus option

1-2

SD3100 Power Modules

1.1 Field Power Module

The single-phase Field Power Module is integrally mounted within the SD3100 Power Module to provide the motor field excitation. The Field Po wer Module is rated 15 or 60 amps at 230/460 VAC . The 15A unit is supplied as standard. The 60A unit is available as an option.

The Field Power Module requires a separately-ordered, separately-mounted field isolation transformer. The Field Power Module’s AC input lines are connected through the isolation transformer to the L1 and L3 inputs of the SD3100. The 15A module requires a step-down transformer rated up to 7.5kVA (application dependent). The 60A module requires a step-down transformer rated 7.5kVA to 25kVA (application dependent). All systems operate on three-phase 50/60 Hz., 460 to 660 VAC.

The Field Power Module is available in the configurations listed in table 1.2.

Table 1.2 – Field Power Module Part Numbers

Part No. Amps AC Input Description Mounting

805405-3R 805405-5R

1. For application information see instruction manual S-3060.

1 1

15 230 / 460 VAC Reversing (S2R) Integral 60 230 / 460 VAC Reversing (S2R) Integral

1.2 Standard Features

SD3100 DC Power Modules have the following features:

•

Three-phase 460, 575, or 690 VAC input

•

1250, 1650, and 3000 amp units

•

S6 (non-regenerating) and S6R (regenerating) configurations

•

15 amp Field Power Module

•

DC output contactor

•

PE / TE bus

•

Choice of incoming circuit breaker or input line fuse protection

•

Electronic motor overload protection

•

SCR power semiconductors / dv/dt protection

•

SCR leg fuses

•

Cell chokes

•

Protection against unequal current sharing among SCRs

•

Protection from AC line dips and transients

•

Top AC entry / Bottom DC exit

Introduction

•

Power through-bus (1250A and 1650A Power Modules)

1-3

•

115VAC control bus (90A)

•

Fiber-optic communication with the Distributed Power System Universal Drive Controller (UDC) module

•

Drive nameplate - white/black letters

1.3 Optional Features

The following features are available as options:

•

60 amp Field Power Module

•

NEMA blower starter

•

IEC blower starter

•

Air flow switch

•

Line suppressor

•

115 VAC convenience outlet

•

Phone jack

1.4 Related Publications

The instruction manuals in binder S-3000 describe the other system hardware, system software, and communications, as listed in table 1.3. It is assumed that the user is familiar with these manuals before installing, operating, or performing maintenance upon SD3100 DC Power Modules. Further information pertaining to SD3100 Power Modules can be found in instruction manuals S-3045 and S-3060, as listed in the table.

Table 1.3 – Distributed Power System DC Drives Documentation

Publication Number Description

S-3000 Distributed Power System DC Drives Binder

S-3005 AutoMax Distributed Power System Overview S-3006 SD3000 Drive Configuration and Programming S-3007 Universal Drive Controller Module S-3008 Power Module Interface Rack and Modules S-3009 Fiber Optic Cabling S-3011 Diagnostics, Troubleshooting and Start-up Guidelines

Related DPS Documentation

S-3045 DPS Parallel Gate Amplifier System S-3060 DPS Single-Phase Field Power Modules

1-4

SD3100 Power Modules

Installation of the motor control center (MCC) is described in the manuals listed in table 1.4.

Table 1.4 – Related Motor Control Center Documentation

Publication Number Description

2100-5.5 Instructions - Receiving, Handling, And Storing Motor

Control Centers

2300-5.1 Bulletin 2300 Family of Drive Systems Hardware

Additional information about using SD3100 Power Modules as part of a Distributed Power System is found in the wiring diagrams, prints, and other documentation shipped with each drive system. Always consult the prints shipped with the drive for specific mounting and connecting information about your system.

1.5 Terms Used in this Manual

The terms listed in this section have the specific meanings given below when they appear in this manual.

Application

software is being used.

Armature Power Module

power bridge and related hardware components used to control the armature current.

Diagnostic

error conditions.

Drive

Power Module as a means or apparatus for transmitting motion to a machine or machine part.

Drive warning

for by the PMI operating system. Drive warnings are reported in register 203/1203 in the UDC. A drive warning will not shut down the drive. System response is determined by the application task.

Error Drive fault

that will shut down the drive. Drive faults are reported in register 202/1202 in the UDC.

Field Power Module

Field Power Module is integrally mounted within the SD3100 Power Module.

- The process for which the combination of hardware and control

- the power structure containing the three-phase SCR

- a software routine or hardware circuit specifically designed to check for

- the combination of a UDC, a PMI, a Field Power Module, and an Armature

- a potentially hazardous or undesirable operating condition checked

- any operating condition other than the desired one.

- an error, specifically checked for by the PMI Processor operating system,

- a single-phase power unit, used to supply the motor field. The

Introduction

Non-regenerative drive

(S6 configuration).

Regenerative drive

or reverse (S6R configuration).

- a drive capable of motoring operation only

- a drive capable of motoring or regenerating operation, forward

1-5

1-6

SD3100 Power Modules

LINE FUSES OR CIRCUIT BREAKER

L1

L2

C

HAPTER

2

Mechanical/Electrical Description

Rockwell Automation SD3100 DC Power Modules are built using a Distributed Power System PMI regulator and a high-horsepower silicon-controlled rectifier (SCR) bridge. All components are housed in a NEMA 1 metal enclosure.

This chapter provides general information on the mechanical and electrical characteristics of SD3100 Power Modules, followed by specific information on the 1250A, 1650A, and 3000A units.

FU-A

CURRENT XFMRS

FU-B

EXTERNAL FIELD ISO

XFMR

L3

PMI RACK

RESISTOR SCALING MODULE

ARMATURE FEEDBACK

FWD GATE SIGNALS

REV GATE SIGNALS TO FIEL D

POWER MODULE

DELTA/WYE

PHASING

XFMR

FROM DC ARMATURE

SCALING UNI T

115 VAC

PGA RACK

DRIVE I/O

Figure 2.1 – SD3100 Power Module System Components

FWD GATE SIGNALS

REV GATE SIGNALS

RESOLVER FEEDBACK

GATE COUPLING CIRCUITS

ARMATURE PO WER STRUCTURE (S6R)

FIELD

POWER

MODULE

L1

L2

L3

TO P4/ DCPT

+

DC

MOTOR

–

RESOLVER

TO RESISTOR SCALING UNIT

Mechanical/Electrical Description

2-1

2.1 Mechanical Overview

The SD3100 Power Module is composed of the basic components shown in figure 2.1. These components consist of:

Contr ol components

•

System and control for the Power Module, and

Power components

•

2.1.1 Control Components

The control components are contained in the regulator assembly, along with the Field Power Module. The regulator assembly is mounted in the lower compartment of the Power Module’s Disconnect Bay.

FU-A

FIELD ISOLATION

XFRM FUSES

that provide the interface to the AutoMax Distributed Power

that convert AC line power to DC power for the motor.

FU-B

SCALING UNIT

TB1

PMI RACK

FIELD POWER MODULE

PGA RACK

FWD REV

TO GATE COUPLERS

TB2

TB3 TB4

Figure 2.2 – Regulator Assembly

TB5

TB6

The PMI rack contains the four modules that make up the PMI Regulator: the PMI’s Power Supply, Processor module, Resolver and Drive I/O module, and DC Power Technology module. The PMI Processor executes the control algorithm and communicates with the AutoMax processor via its fiber-optic ports. The Resolver and Drive I/O module provides the interface for speed feedback and control signals. The DC Pow er Technology module provides the armature feedback, armature forward gate control, armature reverse gate control (regenerative models only), and the field feedback and gate control signals for the Field Power Module.

2-2

SD3100 Power Modules

Below the PMI rack is a DPS Parallel Gate Amplifier (PGA), which provides isolation and amplification of the forward and reverse gate drive signals. The Field Power Module is mounted to the left of the PMI and PGA racks. At the top of the assembly are the field isolation transformer fuses and a scaling unit that conditions the armature feedback signals received via terminal block TB1. T erminal blocks at the bottom of the assembly provide connection for the field gate and feedback signals (TB2), control power (TB3), drive I/O (TB4), the resolver (TB5), and the meter ports (TB6). The forward and reverse armature gate coupler circuits connect to the control circuitry at the lower right of the compartment.

The Power Module is shipped with the PMI Regulator and all related control components installed. The PMI is described in detail in the Power Module Interface Rack and Modules instruction manual (S-3008). Please refer to this manual for further information. Additional information on the PGA can be found in instruction manual S-3045.

2.1.2 Power Components

Power components manage and handle the power of the drive under the direction of the PMI regulator. The power components consist of:

•

the incoming power components

•

the armature power bridge components

•

the Field Power Module

2.1.2.1 Incoming Power

The incoming power components handle the input power and provide it to the Field Power Module and armature power bridge assemblies.

The following components are used to provide incoming power:

•

circuit breaker or input line fuses

•

user-supplied input line reactor or isolation transformer

•

control power and Field Power Module tap

•

user-supplied field isolation transformer

•

AC line RC suppressor

Circuit Breaker

Power Modules are provided with circuit breakers to protect the input power wiring. Recommended circuit breaker settings are shown in Appendix A.

Input Line Reactor or Isolation Transformer

The SD3100 system requires a user-supplied line reactor or isolation transformer to reduce peak currents and harmonics in the incoming power lines. This device is needed to provide isolation to other equipment on the power lines during regeneration.

Important:

Mechanical/Electrical Description

Failure to use an input isolation device may result in damage to the Power Module during regeneration.

2-3

Control Power and Field Power Module Tap

The first (L1) and third (L3) phase of the incoming power are tapped off and fused to provide single-phase AC power to the primary of the control power transformer and the Field Power Module.

Field Isolation Transformer

A user-supplied field isolation transformer must be installed on the AC input of the Field Power Module as described in section 3.4.1 of this manual. Using a field isolation transformer provides the following advantages:

•

Provides power matching to the Field Power Module.

•

Permits the Field Power Module to continue operating in the event of a ground fault in the field windings of the motor.

•

Provides a known minimum AC input impedance for the snubbers to operate against.

•

Protects other circuits sharing the same power source from line notching interference caused by the Field Power Module.

•

Provides source impedance to guarantee SCR protection in the event of a short circuit.

AC Line RC Suppressor

The optional AC line RC suppressor is a device used for limiting line voltage spikes when the medium voltage source to the primary of the distribution transformer is switched. This option is required for a primary voltage of 2300V or greater.

Output Inductor

Note that some systems may require an output inductor in series with the armature, especially for some DC motors that do not have enough internal inductance for a proper armature commutation process.

2.1.2.2 Armature Power Components

The armature power components convert the 3-phase AC input to a DC output used for powering the motor armature.

The following components make up the armature power circuitry:

•

armature SCR bridge (and its subordinate components)

•

leg fuses

•

gate coupler cards (GCCs)

•

DC contactor

2-4

SD3100 Power Modules

The non-regenerative bridge is shown in figure 2.3. Cell fuses protect the thyristors in the event of a bridge failure.

Main

Contactor

3-Phase

AC

Input

SNUBBER

*&&

SNUBBER

*&&

Figure 2.3 – Armature Bridge (Non-Regenerative)

SNUBBER

*&&

A1

Armature

Voltage

A2

Mechanical/Electrical Description

2-5

The regenerative bridge, shown in figure 2.4, allows the bridge to direct regenerated power back onto the incoming lines.

Main

Contactor

*&&

3-Phase

AC

Input

*&&

SNUBBER

*&&

SNUBBER

*&&

SNUBBER

Figure 2.4 – Armature Bridge (Regenerative)

*&&

SNUBBER

*&&

A1

Armature

Voltage

A2

2-6

Armature Bridge Components

The armature bridge consists of the following components:

•

Silicon-Controlled Rectifiers (SCRs) Each Power Module uses silicon-controlled rectifiers (SCRs) in the armature bridge

to switch the incoming 3-phase AC power to DC output power. These SCRs allow current to flow from anode to cathode when two conditions are

met. First, like a diode, the SCR must be forward biased. Second, an appropriate pulse must be applied to the gate (through the pulse transformer board).

The current will continue through the SCR until the voltage across it reverses and the current drops to zero (line commutation).

•

Snubbers Snubbers (resistor/capacitor assemblies) are installed in parallel with the SCRs to

protect the SCRs from rapid voltage changes (inductive kick) when the SCRs switch off by suppressing and dissipating the excess voltage.

SD3100 Power Modules

•

Gate Coupler Cards Gate coupler cards amplify the gate signal pulses from the DC Power Technology

module to trigger the SCRs. In addition, these cards provide gate driver isolation from the control circuits in the PMI rack.

•

Main DC Contactor The main DC contactor is used to isolate the DC motor armature and to interrupt

the DC current to the motor armature. Coil voltage to the contactor is controlled by contacts from the pilot relay.

2.1.2.3 Field Power Module Components

The Field Power Module operates on single-phase AC, which must be taken from the three-phase armature power bridge’s L1 and L3 input lines. The incoming AC must be supplied to the Field Power Module through an isolation transformer.

The Field Power Module rectifier consists of 8 SCRs in two full-wave bridges, connected in anti-parallel. Snubber protection is provided to permit operation on a common bus with other Power Modules. A Hall effect device is used to monitor the DC output current.

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2.2 Electrical Overview

SD3100 DC Power Modules convert fixed voltage and frequency three-phase AC power to adjustable voltage DC power for motor armatures, fields, or other applications that require controlled DC power. Power Module operation is programmed and controlled in the UDC module in the AutoMax rack and the PMI Processor in the drive’s internal PMI rack.

Incoming power is supplied from a three-phase AC line. A phasing transformer provides AC line sequencing and zero-crossing information for each input phase to determine when SCRs should be fired. The Power Module is capable of auto-phasing under software control and can adapt to ABC or ACB phase rotation.

The non-regenerative Power Module rectifier consists of 6 SCRs, configured in a full-wave power bridge. The regenerative Power Module rectifier consists of 12 SCRs in two full-wave bridges, connected in anti-parallel. Snubber circuits provide dv/dt protection for the SCRs in each bridge leg.

The firing angle for each SCR is determined by the current regulation algorithm executing in the PMI Processor. SCR gating signals are provided by the DC Power Technology module, under the control of the PMI Processor. The gating signals and firing angles are synchronized with the AC line. The PMI Processor regulates the current for the application by varying the point in the AC line cycle at which forward SCR conduction begins. The PMI Processor receives the current reference from the UDC module in the AutoMax rack. The UDC runs the application task that provides overall control of the Power Module.

The three-phase SCR power bridge in a non-regenerative Power Module controls forward rotation (motoring) only. Torque is in the same direction as rotation.

Mechanical/Electrical Description

2-7

The two anti-parallel SCR power bridges in a regenerative Power Module control the direction of motor rotation and the direction of torque, in both forward (motoring) and reverse (regenerating) directions. The regenerative Power Module allows for regeneration of power into the AC line under the condition of an overhauling load.

Field Power Module

Operation of the Field Power Module is programmed and controlled in the UDC module in the AutoMax rack and the PMI Processor in the PMI rack. The firing angle for each SCR is determined by the field current regulation algorithm executing in the PMI Processor. The field SCR gating signals are provided by the DC Power Technology module, under the control of the PMI Processor.

The firing angle for each SCR is synchronized with the AC line feeding it. The PMI Processor regulates the amount of motor field current by varying the point in the AC line cycle at which forward conduction begins. The PMI Processor receives the field current reference from the UDC module in the AutoMax rack. The UDC runs the application task that provides overall control of the application.

For a full description of the Field Power Module, please refer to instruction manual S-3060.

2-8

SD3100 Power Modules

2.3 1250A Power Module Description

Table 2.1 – 1250A Configurations

Input Voltage (VAC) Output HP

460 700-750 575 750-900 660 700-1000

The 1250A Power Module is supplied in the configurations shown in table 2.1. The 1250A Power Module has the following features:

•

The 1250A Power Module uses twelve SCRs (regenerative) or six SCRs (non-regenerative) in the armature bridge to convert the 3-phase AC input to a DC output. The SCRs are built into a heatsink assembly that is cooled by the bridge fan.

•

The 1250A Power Module is protected from incoming fault currents by a circuit breaker or input line fuses. The components of the Power Module (the armature bridge, field bridge, and control components) are protected by fuses, MOVs, snubbers, and/or chokes.

•

The 1250A Power Module is constructed and housed in three bays. The first bay contains the AC input and control hardware, the second bay contains the armature bridge hardware, and the third bay contains the DC output hardware.

•

The 1250A Power Module can be built to allow alternative input entry, using either an optional bottom-entry bay (on the left of the disconnect bay) or an optional top-hat extension over the AC input bay.

•

The 1250A Power Module can be built with an optional through bus assembly, allowing the 1250A Power Module and other connected Power Modules to tap off power from the same AC input.

Figures 2.5 and 2.6 show component locations and Power Module dimensions. Please refer to these figures when installing or servicing the Power Module. Refer to Appendix B for wiring diagrams of both the regenerative and non-regenerative versions of the Power Module.

Mechanical/Electrical Description

2-9

2.3.1 1250A Power Module Component Layout

PP1 PP2 PP3

F51*

ACT1 ACT3

L1 L2 L3

SP1 SP2 SP3 SP4

*

F31, F32,

F33

FU-B

FU-A

F14 F 15

F16

F14 F15

CB11*

or

F52*

EA4

SCALING

UNIT

MP

R1

A2(-)

M1

F17, F18, F19

M11

*

F27,

*

F28, F29

M12

A1(+)

*

A14R

F53*

F1,

*

F2,

F3

TB1

PMI RACK

TB1FAN

A11F

F12

F12A

F9 F9A

A14F

A11R

PP4 PP5 PP6

A16R

A13F

F11 F11A F10

F8

F8A

A16F

A13R

F7

A12R

A12F

A15F

F10A

F7A

A15R

D1

2-10

FIELD SUPPLY

TB2

TB3

TB4

PT2

TB5

PGA RACK

TB6

FWD REV

'LVFRQQHFW %D\ %ULGJH %D\ &RQWDFWRU %D\

Figure 2.5 – 1250A Power Module Component Layout

SD3100 Power Modules

Table 2.2 – 1250A Power Module Symbol-to-Component Reference

Symbol Description Option 460 VAC 575 VAC 660 VAC

A1(+), A2(-) Armature outputs A11F - A16F Armature pulse transformer PCB A11R - A16R Armature pulse transformer PCB ACT1, ACT3 Line current transformers 2000:1 CB11 Circuit breaker ∗ 1200A, N-frame

F51 - F53

AC line fuses

1

∗ 1200A, KRPC

D1 M1 bridge diode EA4 Line RC suppressor ∗ F1 - F3 Control branch/feedback PCB fuses 1A KTK 1A KTK 10A A70P F7 - F12,

F7A - F12A F14, F15

Armature bridge cell fuses Control power transformer, primary

fuses

$ 9 0

$ ./'5 9

10A, 1500V

Form 101-Type 4

F16 Control power xfmr, secondary fuse 9A KLDR, 600V F17 - F19,

F27 - F29

Blower motor fuses ∗ F31 - F33 Line RC snubber fuses ∗ 25A KTK 25A KTK 25A A70P FU-A, FU-B

External field isolation

transformer fuses

15A unit: 30A, 700V

60A unit: 100A, 700V FWD Forward gate connector REV Reverse gate connector M1 DC armature contactor 1800A M11, M12 Blower motor starters ∗ MP Main pilot for pilot relay PP1 - 6 Armature power poles PT2 Control transformer 2kV A R1 M1 suppressor resistor 1k Ω, 50Ω SP1 - 3 Line-to-line MOVs 460J, 320VAC 550J, 385VAC 600J, 420VAC SP4 Neutral-to-ground MOV 760J, 680VAC 760J, 680VAC 1050J, 750VAC TB1-F AN Bridge fan & capacitor terminal block TB1 Armature fee dback terminal block TB2 Field terminal block TB3 Control power terminal block TB4 Drive I/O terminal block TB5 Resolver feedback terminal block TB6 Meter ports connector

1. Note that if the 1250A unit has the AC line fuse option, the 1650A unit’s busbars are used in place of the standard 1250A busbars. See Appendix A for busbar illustrations.

Mechanical/Electrical Description

2-11

2.3.2 1250A Power Module Dimensions

20 inches (508 mm)

91.5 inches (2324 mm)

2-12

20 inches

(508 mm)

20 inches (508 mm)

Figure 2.6 – 1250A Power Module Dimensions

35 inches (889 mm)

20 inches (508 mm)

For other details on the 1250A Power Module and its components, please refer to the appendices of this manual.

SD3100 Power Modules

2.4 1650A Power Module Description

Table 2.3 – 1650A Configurations

Input Voltage (VAC) Output HP

460 800-1000 575 1000-1250 660 1250

The 1650A Power Module is supplied in the configurations shown in table 2.3. The 1650A Power Module has the following features:

•

The 1650A Power Module uses twelve SCRs (regenerative) or six SCRs (non-regenerative) in the armature bridge to convert the 3-phase AC input to a DC output. The SCRs are built into a heatsink assembly that is cooled by the bridge fan.

•

The 1650A Power Module is protected from incoming fault currents by a circuit breaker or input line fuses. The DC output is protected from fault currents by a DC contactor. The components of the Power Module (the armature bridge, field bridge, and control components) are guarded by fuses, MOVs, snubbers, and/or chokes.

•

The 1650A Power Module is constructed and housed in three bays. The first bay contains the AC input and control hardware, the second bay contains the armature bridge hardware, and the third bay contains the DC output hardware.

•

The 1650A Power Module can be built to allow alternative input entry, using either an optional bottom-entry bay (to the left side of the disconnect bay) or an optional top-hat extension over the AC input bay.

•

The 1650A Power Module can be built with an optional through bus assembly, allowing the 1650A Power Module and other connected Power Modules to tap off power from the same AC input.

Figures 2.7 and 2.8 show component locations and Power Module dimensions. Please refer to these figures when installing or servicing the Power Module. Refer to Appendix B for wiring diagrams of both the regenerative and non-regenerative versions of the Power Module.

Mechanical/Electrical Description

2-13

2.4.1 1650A Power Module Component Layout

PP1 PP2 PP3

F51*

ACT1 ACT3

L1 L2 L3

SP1 SP2 SP3 SP4

*

F31, F32,

F33

FU-B

FU-A

F14 F 15

F16

F14 F15

CB11*

or

F52*

EA4

SCALING

UNIT

MP

R1

A2(-)

M1

F17, F18, F19

M11

*

F27,

*

F28, F29

M12

A1(+)

*

A14R

F53*

F1,

*

F2,

F3

TB1

PMI RACK

TB1FAN

A11F

F12

F12A

F9 F9A

A14F

A11R

PP4 PP5 PP6

A16R

A13F

F11 F11A F10

F8

F8A

A16F

A13R

F7

A12R

A12F

A15F

F10A

F7A

A15R

D1

2-14

FIELD SUPPLY

TB2

TB3

TB4

PT2

TB5

PGA RACK

TB6

FWD REV

'LVFRQQHFW %D\ %ULGJH %D\ &RQWDFWRU %D\

Figure 2.7 – 1650A Power Module Component Layout

SD3100 Power Modules

Table 2.4 – 1650A Power Module Symbol-to-Component Reference

Symbol Description Option 460 VAC 575 VAC 660 VAC

A1(+), A2(-) Armature outputs A11F - A16F Armature pulse transformer PCB A11R - A16R Armature pulse transformer PCB ACT1, ACT 3 Line current transducer 3000:1 CB11 Circuit breaker ∗ 1600A, R-frame F51 - F53 AC line fuses ∗ 1600A, KRPC D1 M1 bridge diode EA4 Line RC suppressor ∗ F1 - F3 Control branch/feedback PCB fuses 1A KTK 1A KTK 10A A70P F7 - F12,

F7A - F12A F14, F15

Armature bridge cell fuses Control power transformer, primary

fuses

$ 9 0

$ ./'5 9

10A, 1500V

Form 101-Type 4

F16 Control power xfmr, secondary fuse 9A KLDR, 600V F17 - F19,

F27 -F 29

Motor blower fuses ∗ F31 - F33 Line RC snubber fuses ∗ 25A KTK 25A KTK 25A A70P FU-A, FU-B

External field isolation

transformer fuses

15A unit: 30A, 700V

60A unit: 100A, 700V FWD Forward gate connector REV Reverse gate connector M1 DC armature contactor 3000A M11, M12 Motor blower starters ∗ MP Main pilot for pilot relay PP1 - PP6 Armature power poles PT2 Con tr ol transfor mer 2kVA R1 M1 suppressor resistor 1k Ω, 50Ω SP1 - SP3 Line-to-line MOVs 460J, 320VAC 550J, 385VAC 600J, 420VAC SP4 Neutral-to-ground MOV 760J, 680VAC 760J, 680VAC 1050J, 750VAC TB1-F AN Bridge fan & capacitor terminal block TB1 Armature feedback terminal block TB2 Field terminal block TB3 Control power terminal block TB4 Drive I/O terminal block TB5 Resolver feedback terminal block TB6 Meter port connector

Mechanical/Electrical Description

2-15

2.4.2 1650A Power Module Dimensions

20 inches (508 mm)

91.5 inches (2324 mm)

2-16

20 inches

(508 mm)

20 inches (508 mm)

Figure 2.8 – 1650A Power Module Dimensions

35 inches (889 mm)

20 inches (508 mm)

For other details on the 1650A Power Module and its components, please refer to the appendices of this manual.

SD3100 Power Modules

2.5 3000A Power Module Description

Table 2.5 – 3000A Configurations

Input Voltage (VAC) Output HP

460 1250-1750 575 1500-2250 660 1500-2500

The 3000A Power Module is supplied in the configurations shown in table 2.5. The 3000A Power Module has the following features:

•

The 3000A Power Module uses twelve SCRs in the armature bridge to convert the 3-phase AC input to a DC output. The SCRs are built into a heatpipe assembly that is cooled by the bridge fan.

•

The 3000A Power Module is protected from incoming fault currents by a circuit breaker or line fuses. The DC output is protected from fault currents by a DC contactor. The components of the Power Module (the armature bridge, field bridge, and control components) are protected by fuses, MOVs, snubbers, and/or chokes.

•

The 3000A Power Module is constructed and housed in four bays. The first bay contains the AC input and control hardware, the second bay contains the fuses, the third bay contains the armature bridge hardware, and the fourth bay contains the DC output hardware.

•

The 3000A Power Module has a standard top-hat extension over the disconnect bay for the AC input. The Power Module can also be built to allow an alternative input entry, using an optional bottom-entry bay (on the left side of the disconnect bay).

Figures 2.9 and 2.10 show component locations and Power Module dimensions. Please refer to these figures when installing or servicing the Power Module. Refer to Appendix B for wiring diagrams of both the regenerative and non-regenerative versions of the Power Module.

Mechanical/Electrical Description

2-17

2.5.1 3000A Power Module Component Layout

F51

*

L1A L2A L3A

SP1

FU-B

FU-A

F15

F14

F16

F14 F15

FIELD SUPPLY

CB11*

SP2

SP3

SCALING

UNIT

or

F52*

SP4

F53*

ACT3ACT1

F1, F2,

F3

TB1

PMI RACK

PGA RACK

F10

F11

F12

S1

A14R

A11F

A16R

A13F

F8

F7

F9

S1A S2A

A11R

A14F

A13R

A16F

PP3PP2PP1

M1

S2

PP6PP5PP4

A12R

A15F

S3

R1

MP

∗

F27 F28 F29

∗

F17 F18 F19

∗

M11 M12

S3A

A15R

A12F

FAN1

A2(-) A1(+)

2-18

TB2

TB3

FAN2-C1

TB4

FAN2

TB5

TB6

FWD REV

PT2

'LVFRQQHFW %D\ )XVH %D\ %ULGJH %D\ &RQWDFWRU %D\

Figure 2.9 – 3000A Power Module Component Layout

SD3100 Power Modules

Table 2.6 – 3000A Power Module Symbol-to-Component Reference

Symbol Description Option 460 VAC 575 VAC 660 VAC

A1(+), A2(-) Armature outputs A11F - A16F Armature pulse transformer PCB A11R - A16R Armature pulse transformer PCB ACT1, ACT3 Line current transducer 5000:1 CB11 Circuit breaker ∗ 3000A, SPB-fram e F51 - F53 AC line fuses ∗ 3000A, KRPC FAN1 Armature bridge fan 1850 CFM FAN2 Slide-fan 1589 CFM FAN2-C2 Fan capacitor 40µF F1, F2, F3 Control branch/feedback PCB fuses 1A KTK 1A KTK 10A A70P F7 - F12 Armature bridge cell fuses

F14, F15

Control power transformer, primary fuses

$ 9 0

$ ./'5 9

10A, 1500V

Form 101-Type 4

F16 Control power xfmr, secondary fuse 9A KLDR, 600V F17 - F19,

F27 - F29 FU-A, FU-B

Blower motor fuses ∗ External field isolation

transformer fuses

15A unit: 30A, 700V

60A unit: 100A, 700V FWD Forward gate connector REV Reverse gate connector M1 DC armature contactor 3000A M11, M12 Blower motor starters ∗ MP Main pilot for pilot relay PP1 - PP6 Armature power poles PT2 Control transformer 2kVA R1 M1 suppressor resistor 1k Ω, 50Ω SP1 - SP3 Line-to-line MOVs 460J, 320VAC 550J, 385VAC 600J, 420VAC SP4 Neutral-to-ground MOV 760J, 680V AC 760J, 680VAC 1050J, 750VAC TB1 Armature feedback terminal block TB2 Field terminal block TB3 Control power terminal block TB4 Drive I/O terminal block TB5 Resolver feedback ter mi nal block TB6 Meter ports connector

Mechanical/Electrical Description

2-19

2.5.2 3000A Power Module Dimensions

20 inches (508 mm)

91.5 inches (2324 mm)

2-20

20 inches (508 mm)

20 inches

(508 mm)

35 inches (889 mm)

20 inches (508 mm)

Figure 2.10 – 3000A Power Module Dimensions

For other details on the 3000A Power Module and its components, please refer to the appendices of this manual.

SD3100 Power Modules

C

HAPTER

3

Installation Guidelines

ATTENTION:

operation of this equipment and the hazards involved should install,

!

This chapter describes the guidelines and wiring recommendations to be followed when installing SD3100 DC Power Modules. Additional information on installing SD3100 drives can be found in the instruction manuals listed in tables 1.3 and 1.4 on page 1-4 of this manual.

The installation of the Power Module can be broken down into the following tasks:

•

physically installing the unit

•

wiring AC power into the Power Module

•

wiring DC power out to the motor armature and field

•

grounding the drive

•

installing feedback devices

Note that System wiring is to be done according to the supplied wiring diagrams (W/Es), which are application-specific.

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.

Only qualified personnel familiar with the construction and

Installation Guidelines

3.1 Planning the Installation

Use the following guidelines when planning your Power Module installation:

•

Verify that the selected site will provide sufficient ventilation for the Power Module. The Power Module’s fan pulls in air from the bottom of the chassis and exhausts it from the top. The ambient temperature must remain between 0 and 40° C (32 to 131° F).

•

Be sure surrounding components do not block service access to the Power Module.

•

Verify that the relative humidity will be between at 5 and 95% (non-condensing).

•

Do not install the Power Module above 1000 meters (3300 ft) without derating. See figure A.1, Altitude Derating Chart, in Appendix A.

Refer to figure 2.6 (1250A units), figure 2.8 (1650A units), or figure 2.10 (3000A units) for Power Module dimensions.

3-1

3.2 Physically Installi ng the Power Module

ATTENTION:

incoming AC power. Disconnect, lock out, and tag all incoming power to

!

To move and position the unit at your site, follow the instructions given in publication 2100-5.5, titled This publication contains instructions for the proper handling, moving, and positioning of the Power Module.

After the Power Module is properly positioned, follow the instructions given in publication 2300-5.1, titled publication describes how to splice busbars, how to attach the Power Module in a multiple drive configuration, and how to join MCC sections together (if necessary).

the drive before performing the following procedures. Failure to observe this precaution could result in severe bodily injury or loss of life.

Instructions - Receiving, Handling, And Storing Motor Control Centers

The Power Module is at line voltage when connected to

Bulletin 2300 Family of Drive Systems Hardware

3.3 Wiring AC Input Power to the Power Modul e

ATTENTION:

local, national, and international codes. Failure to observe this precaution

!

To wire AC input power to the Power Module, you will need to do the following:

could result in damage to, or destruction of, the equipment.

The user is responsible for conforming with all applicable

.

. This

•

install an isolation transformer

•

select and provide appropria te inpu t power wire

•

prepare the drive enclosure

•

connect the input power

Take precautions to separate AC and DC power leads from signal leads, such as resolver or tach wiring, to minimize electromagnetic interference. Wiring should comply with ANSI/IEEE Standard 518. Follow the instructions on separating wiring found in the wiring diagrams and in instruction manual D2-3115.

Refer to figure 2.5 (1250A units), figure 2.7 (1650A units), or figure 2.9 (3000A units) for component and terminal locations.

3.3.1 AC Input Wire Selection

Table 3.1 shows the recommended AC input wiring. Note that this table reflects NFPA 70, 75° C wiring. Refer to the applicable local codes for specific guidelines.

Table 3.1 – Recommended AC Input Wiring

DC Bus Current

(Amps)

1250 4-500 kcmil 1650 5-500 kcmil 3000 8-500 kcmil

Incoming Wires

(For Each Phase or Connection, AWG)

3-2

SD3100 Power Modules

3.3.2 Making an Input Entry Hole

If your Power Module has an extra input bay installed, proceed as follows. If your Power Module will have a top-hat enclosure over the disconnect bay, mount the top-hat enclosure before continuing.

To make an input entry hole, select the ideal hole placement (within the constraints shown in figure 3.1), then perform the steps that follow.

The width allowed is 2.28 inches shorter than your cabinet's width, as shown.

Cabinet Width Width of Area

20.00" (508 mm) 17.72" (450 mm)

25.00" (635 mm) 22.72" (577 mm)

30.00" (762 mm) 27.72" (704 mm)

35.00" (889 mm) 32.72" (831 mm)

c

Figure 3.1 – Area Available f or Conduit Entry (Top View of Leftmost Bay)

1.25"

11.50" •

1.14"

3000A units allow a depth of 16.75" for conduit entry.

20.00"

(Back of Enclosure)

Area Available For

Conduit Entry

20.00"

17.72"

(Front of Enclosure)

Step 1. Remove the lifting angle, if it is still attached. Step 2. Remove the top plate from the disconnect bay (or from the top-hat

enclosure).

Step 3. Punch hole(s) for the AC input entry within the area shown in figure 3.1.

Installation Guidelines

Step 4. Replace the top plate on the drive. Step 5. Replace the lifting angle.

3.3.3 Connecting the AC Input Wires to the Busbars

Use the following procedure to connect the input wires to the input busbars in the disconnect bay. Refer to Appendix A for busbar specifications.

Step 1. Thread the input wires through the entry hole on the top of your drive. Step 2. Fasten the input wires for each phase onto the appropriate phase busbar

(see the busbar illustrations shown in Appendix A).

Step 3. Torque all bolts to 45 lb-ft.

3-3

3.4 Wiring AC Input to the Field Power Module

AC power connections to the single-phase Field Power Module are made to terminal block TB2 at the bottom left of the control compartment. Phase control for the Field Power Module is determined by the PMI Regulator, which also controls phasing for the armature power devices. The Field Power Module’s AC input terminals must be connected to AC input lines L1 and L3 through an isolation transformer. Terminal block TB2 has been provided for these connections.

3.4.1 Installing the Field Isolation Transformer

The field isolation transformer should be installed at an appropriate location external to the Power Module, and in conformance with the NEC/CEC and all applicable local, national, and international codes. The transformer’s input fuse ratings and required minimum wire sizes for use with the Field Power Module are listed in table 3.2.

Table 3.2 – Isolation Transformer Wiring Requirements

Field Power Module

(Amps)

Isolation Transformer Fuse

Rating (Maximum Amps)

Minimum Required

Wire Size (AWG)

15 30 #10 60 100 #4

Wire the field isolation transformer as shown in figure 3.2. Connect terminal 31 on TB2 to H2 on the field isolation transformer and terminal 30 to H1. Connect X1 to terminal L1A and X2 to terminal L3A.

Important:

The isolation transformer must be connected to terminal block TB2 as shown in figure 3.2. Improper drive regulation and/or fuse clearing may result if the Field Power Module’s AC inputs are incorrectly wired.

31

TERMINAL

BLOCK

TB2

TO MOTOR

FIELD

37

35

+

–

30

L1A

L3A

3-4

H1

FIELD

ISOLATION

TRANSFORMER

X1

Figure 3.2 – Field Terminal Wiring

H2

X2

SD3100 Power Modules

3.5 Wiring the Motor

To wire DC power to the motor, you will need to do the following:

•

select appropriate wires for the armature and field lines

•

connect the motor armature and motor field to the Power Module

Refer to your motor’s installation manual for additional information.

3.5.1 Selecting Wires for the Armature and Field Lines

ATTENTION:

local, national, and international codes. Failure to observe this precaution

!

Refer to table 3.3 for the wire to be used for armature connection and to table 3.4 for the wire to be used for the field connection.

Power Module Rating

could result in damage to, or destruction of, the equipment.

DC Bus Current

(Amps) Output Wires (AWG)

1250 5-500 kcmil 1650 6-500 kcmil 3000 10-500 kcmil

1250A 10 #4 1650A 10 #4 3000A 10 #4

The user is responsible for conforming with all applicable

Table 3.3 – Armature Wire Selection

Table 3.4 – Field Wire Selection

Output Wires (AWG)

(15 Amp Field)

Output Wires (AWG)

(60 Amp Field)

Installation Guidelines

3.5.2 Connecting the Motor to the Power Module

To connect the motor to the Power Module perform the following steps: Step 1. Connect the Power Module’s armature outputs, A1(+) and A2(-), to the

motor’s armature leads, A1 and A2. Refer to figure 2.5 (1250A units), figure

2.7 (1650A units), or figure 2.9 (3000A units).

Step 2. Connect the Field Power Module outputs, terminals 37 (+) and 35 (-), to the

motor’s field leads, F1 and F2. Refer to figure 3.2.

Note that for counter-clockwise rotation, connect output A1 to motor lead A1 and output A2 to motor lead A2. Connect terminal 37 to lead F1 and terminal 35 to lead F2.

For alternative wiring configurations, please check the motor’s installation manual.

3-5

3.6 Installing Feedback Devices

All feedback devices interface to the SD3100 Power Module through the PMI Regulator. Terminal blocks TB4 and TB5 at the bottom of the control compartment provide the connections for drive I/O, analog input, and the resolver, as shown in figures 3.3 and 3.4. Selection and installation of feedback devices is described in the PMI Rack and Modules instruction manual (S-3008). Please refer to S-3008 when installing feedback devices.

TB4

39785

412

2

1

3579

6

11

10 12 14 16

864

11 13 15

13 15

16141210

Terminal Signal

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

RPI (HI) RPI (LO) AUX IN 1 (HI) AUX IN 1 (LO) AUX IN 2 (HI) AUX IN 2 (LO) AUX IN 3 (HI) AUX IN 3 (LO) AUX IN 4 (HI) AUX IN 4 (LO) AUX IN 5 (HI) AUX IN 5 (LO) MCR (HI) MCR (LO) AUX OUT (HI) AUX OUT (LO)

Figure 3.3 – Drive I/O Connections (TB4)

TB5

1

2

3

2

3

1

Analog Input: 1 (+) 2 (–) 3 GND

56341

7

2

8

2468

1357

Resolver Input: 1 (+) Reference 2 (–) Output 3 (+) Sine 4 (–) Input

Note: 7,8 Not used

5 (+) Cosine 6 (–) Input

Figure 3.4 – Resolver and Analog Input Connections (TB5)

3-6

SD3100 Power Modules

3.7 Meter Port Connections

2468

1357

2468

Terminal

1 2

3 4

5 6

7 8

+

COM

+

COM

+

COM

+

COM

Port 1

Port 2

Port 3

Port 4

TB6

} }

Terminal block TB6 at the bottom of the control compartment contains four analog output ports, as shown in figure 3.5. Each port can be connected to a separate analog device (e.g., a meter or other data-logging device). The meter port output circuit is described in the PMI Rack and Modules instruction manual (S-3008). Meter port configuration is described in the Drive Configuration and Programming instruction manual (S-3006). Please refer to these two manuals for further information on using the meter ports. If not configured, the ports default to “not used” and output zero volts.

Installation Guidelines

Figure 3.5 – Meter Port Connections (TB6)

3.8 Grounding the Drive

ATTENTION:

the drive’s ground terminals to earth ground using properly-sized ground

!

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

To properly ground the drive, all of the following components of the system must be grounded:

•

safety ground (PE) to building steel or floor ground loop

•

signal ground (TE) to zero potential bus

•

power feeder

•

motor connections

•

resolver connections

The TE and PE busbars run through the bottom of the drive’s enclosure. The grounding conductors must be supplied by the user and must be adequately sized in accordance with NEC/CEC and all applicable local, national, or international codes.

Important:

The TE and PE conductors must be separated by a minimum distance of 20 feet within the user facility.

Ungrounded equipment presents a shock hazard. Connect

3-7

Note that the TE signal ground is not used by the SD3100 drive’s control components, but may be used by other drives in the lineup.

Figure 3.6 shows the typical grounding of the SD3100 drive.

SD3100 Drive Enclosure

Control Xfmr

To control components on other drives

To Bldg Steel

Ground Rod or Grid

(only one grounding point

per system)

Figure 3.6 – SD3100 Grounding

X2

TE PE

Motor

3.9 For Information on Initial Start-Up of the Drive

ATTENTION:

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.

Instruction manual S-3011,

Troubleshooting, and Start-Up Guidelines

precautions that should be taken when first powering up the SD3100 drive. Please refer to the appropriate sections of this manual when starting up your drive.

Only qualified personnel familiar with the construction and

Distributed Power System SD3000 Diagnostics,

, describes the procedures to follow and the

3-8

SD3100 Power Modules

C

HAPTER

4

Maintenance and Troubleshooting

ATTENTION:

to the Power Module. All phases of the AC power line and control power

!

Routine maintenance should include the periodic checking of all electrical power connections into and out of the Power Module. The Power Module, its enclosure, and the PMI rack should be kept clean. Any air filters should be checked and cleaned or replaced as needed. Adequate cooling air must be provided to the Power Module whenever the unit is operating.

must be disconnected from the Power Module before it is safe to touch any internal parts of this equipment. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:

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Equipment is at line voltage when AC power is connected

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4.1 Recommended Test Equipment

ATTENTION:The Power Module’s common is not isolated from earth

ground. The test instruments used to measure power module signals

!

An oscilloscope can be used to check the current feedback and the output voltage waveform. An isolated or portable volt/ohmmeter is also needed for continuity and ground checks and to test output voltage.

must be isolated from ground through an isolation transformer unless they are battery powered. Failure to observe this precaution could result in bodily injury.

The oscilloscope should have an impedance of at least 8 M ohms, a 1:10 probe for signal circuits, and a 1:100 probe for power circuits. An ungrounded oscilloscope with differential inputs and two 1:10/1:100 probes is recommended. All measuring devices that are AC line powered must be connected through an isolation transformer. There must be no ground connection through the transformer.

Maintenance and Troubleshooting

ATTENTION:

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4-1

The Power Module may be checked with an ohmmeter for continuity and grounds. Do not test the Power Module or associated circuitry with a megohmmeter (megger). Disconnect all leads to the motor if the motor is to be ground-checked with a megger. Failure to follow proper procedure when using a megger may cause damage to the Power Module.

4.2 System Diagnostics

Operation of the Power Module is monitored by the PMI Processor. Fault and warning registers (202/1202 and 203/1203) in the UDC must be used when the system detects a fault or a warning.

The fault conditions reported in the Drive Fault register result in turning off the drive. The UDC task is not stopped automatically when a drive fault occurs unless it is specifically instructed to do so in an application task. The user must ensure that the AutoMax application task tests register 202/1202 and takes appropriate action if a fault occurs.

The warnings indicated by the Drive Warning register cause no action by themselves. Any resulting action is determined by the application task. The user must ensure that the AutoMax application task monitors register 203/1203 and takes appropriate action if any of these conditions occurs.

The user should refer to instruction manual S-3006 (SD3000 Drive Configuration and Programming) for further details on the Drive Fault and Drive Warning registers.

4.2.1 Power Module Faults

The following Power Module faults will cause the drive to shut down by commanding zero current and stopping the firing of the SCRs. Most faults are signaled by an LED indicator on the PMI Processor module. The bits in the Drive Fault register (202/1202) should be examined to determine the cause of the fault. When a fault occurs the identifying bit will be set. The fault will also be recorded in the error log for the UDC task in which it occurred.

4.2.1.1 Shorted SCR Fault (Bit 0)

LED indicator: PM FLT UDC Error Code: 1000 The PMI Processor will not be permitted to enter the run mode if a shorted SCR is

detected. Check register 204/1204 to identify the SCR that has shorted. Refer to Instruction Manual S-3006.

4.2.1.2 AC Line Synchronization Fault (Bit 3)

LED indicator: EXT FLT UDC Error Code: 1003 AC line voltage is missing for more than 2 seconds. The system will immediately go

idle when this fault is detected. NOTE: A temporary loss of AC line voltage will set bit 3 in Drive Warning Register 202/1202.

4-2

SD3100 Power Modules

4.2.1.3 Instantaneous Overcurrent Fault (Bit 4)

LED indicator: EXT FLT UDC Error Code: 1004 The armature current feedback value is greater than the Max Current Limit value (plus

75%) entered as a configuration parameter. The system will immediately go idle when this fault is detected.

4.2.1.4 Conduction Timeout Fault (Bit 5)

LED indicator: N/A UDC Error Code: 1005 Discontinuous conduction has not been detected within 2 seconds of CML_RUN

(register 100/1100, bit 0) being turned off.

4.2.1.5 Loss of Field Fault (Bit 6)

LED indicator: PM FLT UDC Error Code: 1006 The field current feedback value is less than the Field Loss Trip P oint parameter value.

Refer to instruction manual S-3006 for detailed information regarding the occurrence of this fault.

4.2.2 Power Module Warnings

The following Power Module warnings cause the identifying bit in the UDC Drive Warning Register (203/1203) to be set. The bits in this register should be examined to determine the cause of the warning. Any resulting action is determined by the application task. No LED indicator or UDC error code is provided for drive warnings.

4.2.2.1 Three-phase Bridge SCR Not Firing Warning (Bit 0)

Check the SCR Diagnostic register (204/1204) to determine which SCR is not working properly. Ref er to the SD3000 Drive Configuration and Programming manual (S-3006) for detailed information on register 204/1204.

4.2.2.2 Low Line Voltage/Phase Missing Warning (Bit 1)

The system has detected that the AC line voltage is less than 85% of the nominal value entered as a configuration parameter. This can be caused by a low line condition or a missing phase. The system will automatically adjust the phase angle to give the correct current amount and will continue to fire SCRs as long as zero crossings are detected. If zero crossings are no longer detected, a fault condition will result.

Maintenance and Troubleshooting

4-3

4.2.2.3 Synchronization Loss Fault Avoided Warning (Bit 3)

The system has continued to operate through a temporary loss of AC line voltage. If the AC line voltage is missing for more than 2 seconds, the system will immediately go idle and set bit 3 in register 202/1202 (AC Line Synchronization fault).

4.2.2.4 Current Reference Limit Warning (Bit 4)

The current reference has exceeded the value entered as the Max Current Limit configuration parameter.

4.2.2.5 Identification Test Error Warning (Bit 5)

An armature identification or field identification test has failed. (This bit is also set when the resolver balance calibration test fails or yields unexpected results.)

4.2.2.6 Field Power Module Overcurrent Warning (Bit 6)

The Field Power Module’s field current feedback value is greater than 1.5 times the Hot Field Amps parameter for one second. This condition can cause errors during the field ID test or when the field is turned on. These errors can be caused by miswiring of the L1 and L3 AC input lines to the Field Power Module.

4.2.2.7 Fan Loss Warning (Bit 12)

A fan loss is detected by the air flow switch located in the PMI power supply module. Normally, the drive should be stopped in a reasonably short time by the application task to prevent damage to the unit. Check that the fan is running and that the air passages are clear and clean.

4.3 Component Replacement

SD3100 Power Modules have a modular design that permits fast and easy component replacement. Spare parts kits are provided for armature power structure components. The regulator assembly is serviced by replacing a damaged module in the rack or by replacing the entire rack.

4.3.1 Spare Parts Kits

Spare parts kits for AC line input and armature power structure components of the SD3100 drive are listed in Appendix C. These spare parts kits contain the replacement parts as well as installation instructions. Kits for the following components are available:

•

Line RC suppressor option

•

Air flow printed circuit board with power supply

•

Air flow switches

•

Line MOVs

•

Armature assemblies

•

Armature SCRs

4-4

SD3100 Power Modules

•

Bridge fan and bridge fan door filter

•

Slide-in Fan

•

Power fuses

•

Power fuse assembly

•

AC input line fuses

•

Snubber assembly

4.3.2 PMI Regulator

The PMI modules and the PMI rack are serviced by removing the damaged modules or by replacing the complete PMI rack. The PMI rack is attached by four retaining screws through its backplane and a ground lead to the panel ground.

Refer to the Power Module Interface Rack and Modules instruction manual, S-3008, for technical information and replacement part numbers.

4.3.3 Parallel Gate Amplifier

The PGA modules and the PGA rack are serviced by removing the damaged modules or by replacing the complete PGA rack.

Refer to the Parallel Gate Amplifier instruction manual, S-3045, for technical information and replacement part numbers.

4.3.4 Field Power Module

The Field Power Module can be replaced by disconnecting the power and signal cables and unfastening the mounting screws from the mounting panel. Mount the replacement module and connect the power and signal cables to it.

Refer to Appendix C for replacement part numbers.

4.3.4.1 Replacing Internal Field Power Module AC Input Fuses

Internal Field Power Module AC input fuses may be replaced by removing the Field Power Module’ s cov er . The fuses on the 60A unit are held in place by retaining washer nuts. The fuses in the 15A unit are retained by pop-in fuse clamps.

Input fuse ratings are listed in Table 3.1. Replace Field Power Module fuses only with fuses of the same type and rating as those originally supplied. Refer to Appendix C for Rockwell replacement part numbers.

Table 4.1 – Field Power Module Input Fuses

Power Module

Part No.

805405-3R 1FU, 3FU 20A, 600V 200 kA 805405-5R 1FU, 3FU 90A, 700V 200 kA

Fuse

Number

Fuse

Ratings

Fuse Current

Interrupt Rating

Maintenance and Troubleshooting

4-5

4.3.4.2 Replacing Field Power Module Components

Field Power Module components, including the gate driver PC board, snubber PC board, and field clamp assembly, can be replaced. Replacement part numbers are listed in Appendix C. Due to the complexity of alignment, however, it is recommended that the Field Power Module be returned to Rockwell for repair and/or replacement of components.

4-6

SD3100 Power Modules

Technical Specifications

A.1 General Specifications

The following specifications apply to the 1250, 1650, and 3000A Power Modules:

•

AC Input Frequency Range: 48 to 62 Hz

•

AC Input Voltage Tolerance: ±10%

•

Overload Capability: 150% maximum DC bus current for 60 seconds

200% for 10 seconds following continuous operation

•

Overload Duty Cycle: 1 minute out of 20 minutes at rated load and temperature

•

Ambient Operating temperature: 0 to 40° C (32 to 104° F).

•

Ambient Storage temperature: -40 to 70° C (-40 to 158° F)

•

Humidity: 5 to 95%, non-condensing

•

Operating Altitude: Up to 1000 meters (3300 feet).

For altitudes greater than 1000 meters refer to the altitude derating char t.

A

PPENDIX

A

Technical Specifications

  

3000



2800 2600 2400 2200 2000 1800

Current (Amps)

1650 1650

1600 1400

1250 1250 1250 1250

1200 1000

0 1100 2200 3300 4400 5500 6600 7700 8800 9900 11000 12100 13200

1600

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

1550

1525

1500

1475

1450

1220

1190

1162

1145

Altitude (F eet)

Figure A.1 – Altitude Derating Chart



1425

1130



1400

1115



1375

1098



1350

1081



1320

1065

3000A 1650A 1250A

A-1

A.2 1250A Power Module Specifications

The following specifications apply to the 1250A Power Module.

Height

91.5” (2324 mm)

1

Width 75” (1905 mm) Depth 20” (508 mm) Shipping Weight 2500 lbs (1134 kg) MCC Sections 3 Operating Sound Level 83 dB, wt. A

1. Note that the height of the 1250A Power Module includes a 1.5”-high base channel.

Table A.1 – Electrical Specifications (1250A Power Module)

Input Output

Nominal

Input V olt age

(V AC)

Input Power

(kVA)

Armature

Voltage

(VDC)

Armature

Current

(ADC)

Field V oltage

(VDC)

Field Current

(ADC) Nominal HP

460 750 500 1100 460 848 500 1250 750 575 856 600 1000 750 575 909 600 1065 800 575 1060 600 1250 900 660 796 700 800 700

Dependent on options

selected. Refer to

section A.6.

660 852 700 860 750 660 904 700 915 800 660 1011 700 1030 900 660 1217 700 1250 1000

700

A-2

SD3100 Power Modules

Power Dissipation

The 1250A Power Module dissipates power proportionally to the armature current, as shown in figure A.2.

      

Heat Dissipation (W)





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







Armature Current (A)

Figure A.2 – Power Dissipation vs. Armature Current (1250A Power Module)

Circuit Breaker Settings

The 1250A Power Module has a 1200A N-frame circuit breaker with a 1200A plug. The circuit breaker should be set as shown in figure A.3.

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Figure A.3 – Recommended Circuit Breaker Settings (1250A Power Module)

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Technical Specifications

A-3

AC Input Busbars

The 1250A Power Module is normally supplied with two AC input busbars per phase, as shown in figure A.4.

Note that if the AC line fuse option is selected, the 1250A Power Module is supplied with the 1650A unit’s busbars. See figure A.7.

Bus Dimensions

0.87"

1.750"

Bus Arrangement

4 connections are available for each phase

1.69"

Phase 1

(L1)

0.563" Diameter

Phase 2

(L2)

0.250"

Phase 3

(L3)

A-4

Figure A.4 – AC Input Busbars (1250A Power Module)

SD3100 Power Modules

A.3 1650A Power Module Specifications

The following specifications apply to the 1650A Power Module.

Height

91.5” (2324 mm)

1

Width 75” (1905 mm) Depth 20” (508 mm) Shipping Weight 2500 lbs (1134 kg) MCC Sections 3 Operating Sound Level 83 dB, wt. A

1. Note that the height of the 1650A Power Module includes a 1.5”-high base channel.

Table A.2 – Electrical Specifications (1650A Power Module)

Input Output

Nominal

Input V oltage

(VAC)

Input Power

(kVA)

Armature

Voltage

(VDC)

Armature

Current

(ADC)

Field V oltage

(VDC)

Field Current

(ADC) Nominal HP

460 867 500 1280 460 972 500 1440 900 460 1108 500 1650 1000 575 1125 600 1330 1000

Dependent on options

selected. Refer to

section A.6.

575 1385 600 1650 1250 660 1590 700 1650 1250

800

Technical Specifications

A-5

Power Dissipation

The 1650A Power Module dissipates power proportionally to the armature current, as shown in figure A.5.











Heat Dissipation (W)













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







Armature Current (A)

Figure A.5 – Power Dissipation vs. Armature Current (1650A Power Module)

Circuit Breaker Settings

The 1650A Power Module has a 1600A R-frame circuit breaker with a 1600A plug. The circuit breaker should be set as shown in figure A.6.

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Figure A.6 – Recommended Circuit Breaker Settings (1650A Power Module)

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A-6

SD3100 Power Modules

AC Input Busbars

The 1650A Power Module has two AC input busbars per phase, as shown in figure A.7. These busbars are also used in the 1250A Power Module with the AC line fuse option.

Bus Dimensions

0.88

1.750

Bus Arrangement

8 connections are available for each phase

0. 83

Phase 1

(L1)

1.844

Phase 2

(L2)

0.250

0.563 Diameter

Phase 3

(L3)

Technical Specifications

Figure A.7 – AC Input Busbars (1650A Power Module)

A-7

A.4 3000A Power Module Specifications

The following table of specifications applies to the 3000A Power Module

Height

91.5” (2324 mm)

1

Width 95” (2413 mm) Depth 20” (508 mm) MCC Sections 4 Shipping Weight 3500 lbs (1588 kg) Operating Sound Level 82 dB, wt. A

1. Note that A 20”-high tophat assembly (which mounts over the disconnect bay), is included with each 3000A Power Module.

Table A.3 – Electrical Specifications (3000A Power Module)

Input Output

Nominal

Input V oltage

(V AC)

Input Power

(kVA)

Armature

Voltage

(VDC)

Armature

Current

(ADC)

Field V oltage

(VDC)

Field Current

(ADC) Nominal HP

460 1374 500 2000 460 1634 500 2400 1500 460 2024 500 3000 1750 575 1713 600 1995 1500 575 1985 600 2330 1750 575 2254 600 2660 2000 575 2531 600 3000 2250

Dependent on options

selected. Refer to

section A.6.

660 1705 700 1715 1500 660 1971 700 2000 1750 660 2242 700 2290 2000 660 2508 700 2575 2250 660 2905 700 3000 2500

1250

A-8

SD3100 Power Modules

Power Dissipation

The 3000A Power Module dissipates power proportionally to the armature current, as shown in figure A.8.









 

Heat Dissipation (W)

























Armature Current (A)

Figure A.8 – Power Dissipation vs. Armature Current (3000A Power Module

Circuit Breaker Settings

The 3000A Power Module has a 3000A SPB-frame circuit breaker. The circuit breaker should be set as shown in figure A.9.

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Technical Specifications

Figure A.9 – Recommended Circuit Breaker Settings (3000A Power Module)

A-9

AC Input Busbars

The 3000A Power Module has a busbar arrangement allowing up to twelve connections per phase, as shown in figure A.10.

Bus Dimensions

0.625

Diameter

Bus Arrangement

12 connections are available for each phase

0.88

1.750

0. 88

Phase 1

(L1)

1.938

Phase 2

(L2)

0.188

Phase 3

(L3)

A-10

Figure A.10 – AC Input Busbars (3000A Power Module)

SD3100 Power Modules

A.5 Air Baffle Layouts

Guards

ATTENTION:

Guards are designed to direct airflow in the drive and to

prevent injury. Ensure that the guards are in place when operating the

!

Important:

drive. Failure to observe this precaution may result in bodily injury.

Air baffles are designed to distribute air to cool drive components. Ensure that the baffles are in place when operating the drive to provide the proper airflow and to prevent the thermoswitches or optional airflow sensor from intermittently shutting down the drive.

The following diagrams show how the air baffles and guards are arranged in the drives.

Baffle

Baffle Baffle

Guard

Baffle

Figure A.11 – Air Baffle Layout (1250A and 1650A Power Modules)

Technical Specifications

A-11

Guards

Baffle

A-12

Figure A.12 – Air Baffle Layout (3000A Power Module)

SD3100 Power Modules

A.6 Field Power Module Specifications

Ambient Conditions

•

Storage temperature: -40 to 85° C (-40 to 185° F)

•

Operating temperature: 0 to 40° C (32 to 104° F)

•

Humidity: 5 to 95%, non-condensing

•

Altitude: Up to 1000 meters (3300 feet) without derating output power. For every

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

Enclosure

•

Enclosed chassis with all circuits covered and protected.

Cooling

•

Convection cooled.

Dimensions

Part Number Height Width Depth

805405-3R 340 mm (13.4 in) 128 mm (5 in) 127 mm (5 in) 805405-5R 523 mm (20.6 in) 180 mm (7.1 in) 220 mm (8.7 in)

Input Ratings

•

AC field input voltage: 230 to 460 VAC +/- 10%, continuous operation

•

AC line frequency: 48 to 62 Hz.

•

Source rating: 2 kVA to 30 kVA

•

Maximum short circuit current: 10kA

•

Internal field fuse rating:15A unit: 20A, 600V

60A unit: 90A, 700V

•

One minute overload: 150% of maximum current (once per hour)

Output Ratings

Maximum

Part Number AC Input

805405-3R (S2R) 460V 15kW 15A 805405-5R (S2R)

1. Maximum ambient temperature with a 15° C internal maximum temperature (Minimum Field Power Module ambient: 55° C)

Additional Information

230V 12kW 60A 460V 24kW 60A

Rated Power

Rated Current

@ 40º C

1

Technical Specifications

For additional information on DPS single-phase Field Power Modules, refer to instruction manual S-3060.

A-13

A-14

SD3100 Power Modules

A

PPENDIX

B

Schematics

CB11

L1

1L1

3-Phase

AC Input

L2

L3

1L2

1L3

F17

F18

F19

F27

F28

F29

Figure B.1 – DC Blower Motor Connections

M11

M12

OL11

OL12

DC MOTOR

AC BLOWER

MOTOR

(T1)

(T2)

(T3)

DC MOTOR

AC BLOWER

MOTOR

(T1)

(T2)

(T3)

Schematics

B-1

A 3 L

A 1 L

)

-

+

(

2

1

-

D

L

F

1

2

A

1 A

1 M

2 A

3 L

/ 3 8 1

1 L

/ 1 8 1

37

TB2

7 3

5

3

35

TB2

1

M

)

.

2

(

T

X

P

U A

O

) 1

(

1 M

)

.

4

T

(

X

P

1

O

)

M

3

(

5

8

5

E

-

L

5

U

0 4

D

5

O

0 8

M

R

K

E

C

W

A

O

B

e

l

P

D

b a

E

D

C

E

L

F

E

n

I

i

&

F

P

.

S

4

p

1

E

m

T

A

0

G

6

1 M

)

.

6

T

X

(

P

U

A

O ) 5

(

P M

1 1

)

1

8

(

M

4

)

2

7

(

)

7

-

)

(

1

2

)

C

)

-

(

) +

( 1

1

A

(

C

W

1

5

A

1

D

(

2

R

K

5

1

)

6

4

+

(

1

P M

DCA1

S1

7

5

COM

NC.

F10B

F 5

F10A

F7B

F

2

F7A

SNUBBER

F11B

F 3

F11A

SNUBBER

) +

(

F12A

BRIDGE

F 1

F12B

SNUBBER

2

9 1

2 X

1

:

N

1

0

R

T

0

U

0

C

T

0

A

1

4 P S

J

1

2

P

A

S

1

3

B

L

T

5

TB2

T P

)

2

4

X

H

(

) 3 H

C

( A V

)

2

H

( )

1 X

(

SALES ORDER SPECIFIC

) 1

V

H

0

(

6 6

TB2

CB11

1

1 X

1 9 1

3 P

J

S

2 P S

1 3

B U F

0

C

6

A

4

V

V 5 7 5

1

0

L

3

1

FUA

OR

AC LINE FUSES

1 L

2

6

X

9 1

1

:

3

0

T

0 0

C

0

A

1

5

X

9 1

2

3

L

1

2

3

L

SNUBBER

F8B

F 6

F8A

SNUBBER

E G

)

D

-

I

(

R B

F9B

F 4

F9A

) R

( K

G(W)

) R

( K

G(W)

SNUBBER

N R U T 1

3 8 2

3

A

F

2

1

8 2

2

A

1

F

1

8 2

1

A

F

1

5

A

1

0

F

1

A 3 L

L1A

4 1 F

POWER

OPTIONAL

∗

E P

4

TB10 (4-6)

A V

4

5

2

K

T

5

62

.

P

1

TB3

....

...

)

6

)

H

2

(

2

(H5)

C A

V 0 8 3

)

1 H

(

1

A 0 1

20

X

(

) 4 H

C

(

A

) 3

V

H

5

(

1

)

1

2 H

(

(X1)

3

6

A

1

8

F

5

) 3

1

( 0 1

1

B

3

T

5

5 7

TB3

....

...

19

4

N

1

A

N

F

A

R

F

C S

5

COMPONENTS

2

)

H

R

(

K

2

G(W)

H

) W

( 1

A16F

H

)

R

(

R

( K

G(W)

) R

( K

2

G(W)

H

) W

( 1

A13F

H

)

R

(

R

( K

G(W)

3

)

1

W

(

6

1

5

3

A12F

H

0

)

0

R

6

(

-

4

3

O

1

A

M

/

4

B

2

A14F

A15F

2

A11F

) A

H

5

)

G

1

P

W

(

)

R

1 H

) R

( 2

H

) W

( 1 H

) R

(

H

) W

( 1 H

) R

(

2 A

1 A

G

5

E

I

N

F

I

1

L

R

A

P

O

T

M

T

A

U

6

O

E

P

DRIVER UNIT B/M O-805401-7

T

M

N

A

I

1

G

D

L

W

E

1

L

F

1

L

(

A R

7

A P

2 1

1

2

L

2

& E

N 5 4 7

TB1

4

2 9

1

1 9 1

6 9

1

5 9 1

3 8 2

2 8 2

1 8 2

G N

I L A

1

-

C

7

T

I

S

2

1

4

N

K

A

5

U

C

0

A

8 B D E E F

I L

C

DC ARM

SIGNALS

A

TB1

D A

2

1

O

L

C

L

A V

R

5

E

1

T

N

1

I

2

1

I

L

I

L

F

1

L2L

5

B-2

Figure B.2 – 1250A and 1650A Power Modules (Non-Regenerative), Sheet 1

SD3100 Power Modules

)

M H

0

O

2

T T

U O X U A

S

(IF USED)

E C N

T

E

U

R

P

E

T

F

U

E

O

R

A

(+)

(–)

213

AC

1

2

)

–

+

(

R1

INPUT

(ROTOR)

REFERENCE

(

2 R

)

K

M

R

H

0

O

2

(

W

1

T

R

E N

R

)

E

D

B

F

B

3

2

U

M

(

N

C

S R

C

S

G N

I

0

T

5

A

6

2

R

1

T

I N U

DC MOVEMENTS

METERS ARE 10 VOLT

OPTIONAL METERS

L A

R

)

N

E

1

R

N

P

T

G

T

I

-

E

U

E

U

G

3

S

T

I

P

N

I S

D

B

(+)

(–)

4

C

O

X

±10V

R

ISOLATED

(

N

I

C

I

F

E

C

(+)

(–)

5

6

=(±2047)

E

T

N

R

P

J

H

)

–

+

(

(+)

(–)

(

SHLD

2

3

1

8

7

1

1 B C

(P1)

PROCESSOR

+

B/M O-60000

1 M

N A F

(-) BRIDGE

(+) BRIDGE

S

' B C P

2

1

3

4

567

TWISTED

COM

1

(C2)

TWISTED

+

COM

2

3

±10V

METER

RCV

XMT

(P4)0RAIL

(P3)

(P2)

PORTS

FIBER OPTIC

COMM LINK

ORG

BLU

3 Y

A B

2 Y

A B

1 Y

A B

T P 6

8

TB6

TWISTED

+

COM

4

PORTS

1

(P5)

TB5

4

5

6

3

)

–

+

–

(

S1

R2

S3S4S2

SINE

COSINE

OUTPUT

(STATOR)

FROM UDC CARD

FIBER OPTIC COMM. LINK

BRUSHLESS

RESOLVER

INDUSTRIAL

DUTY

MOTOR

DRIVEN BY

R

Y

C

T

S

/

Q

2

)

2

1 F

-

7 F

(

G

E

N

0

S

I

S

0

3

E

T

U

8

6

S

A

F

U

R

F R

C S

G

0

T

N

I

5

N

T

6

2

1

A

U

R

E P

4

K

FWD

(P3)

REV

(P2)

(P4)

ARM GATES

FLD GATES

& FDBK

DC POWER TECH

B/M O-60002

AC LINE &

DC ARM

(P1)

S 1

1 0 4 5 0

E

K

8

P

C

M

A

/

R

B

D

2 L

N G

2 L

5

1

L

1

(C4)

SIGNALS

R 6

0

N

0 4

A

5

F

0

K

8

C

M

A

/

TB4

R

B

1

Y

L

L P

N

1

P

7

A

3

0

U

F

0

S

O

0

/

I

6

R

-

)

E

C

O

1

V

A

I

W

C

M

(

V

R

/

O

D

B

P

TB4

4

C A B D E E F

R O T C A T N O C

2

4

D

B

)

1

2

N

I

P

-

P

X

3

R

U

C

(

) 3 C

(

1

A

C

A

3

Ω

W

K

5

7

.

6

4

8

4

T A T

T

S

A

O

T

M

S

E

R

T L

U A F

D N U O R G

6

F 2

N

I X U

A E

5

O

L

E

U

M

H

D

R

T

E

O

K

H

M

T

N

I

R

S

R

E

T

O

W

A

T

E

O

H

P

M 0

8

1

L

J

4

3

N

I

X

U

A

K

H

7

9

7

(IF USED)

MOTOR THERMOSTAT

ESR

LINE

(FAIL SAFE)

EMERGENCY STOP

DOOR INTERLOCK

V

A

U

0

F

0

5

.

T

2

1

GROUND FAULT

4

P M

3 1

) D E S U F

I

(

2 1

N 5

N

I X U

A

M

1 1

(IF USED)

EXTERNAL DEVICE

CONTACTOR PILOT

6

4 1

1

R

R E

"

D

T

W

F

N

O

A

O

L

"

R

C

Y

E

A

C

S

L

S

E

M

E

5

O

.

D

-

0

G

I

F F

P

O

R

5

3

1

5

Schematics

Figure B.3 – 1250A and 1650A Power Modules (Non-Regenerative), Sheet 2

B-3

A 3 L

A 1 L

)

-

+

(

2

1

-

D

L

F

1

2

A

1 A

1 M

2 A

DCA1

F10B

F 5

R

F10A

2

SNUBBER

F11B

F 3

R

F11A

6

SNUBBER

) +

(

BRIDGE

SNUBBER

F12A

F 1

R

F12B

4

3 L

/

3 8 1

1 L

/ 1 8 1

37

TB2

7 3

5 3

35

TB2

1

M

)

.

2

(

T

X

P

U A

O

) 1

(

1 M

)

.

4

T

(

X

P

1

O

)

M

3

(

5

8

5

E

-

L

5

U

0 4

D

5

O

0 8

M

R

K

E

C

W

A

O

B

e

l

P

D

b a

E

D

C

E

L

F

E

n

I

i

&

F

P

.

S

4

p

1

E

m

T

A

0

G

6

1 M

)

.

6

T

X

(

P

U

A

O ) 5

(

F7B

F7A

F8B

F8A

1 1

)

1

8

(

M

4

)

2

7

(

7

NC.

SNUBBER

S1

COM

P M

)

7

-

)

(

1

2

)

C

)

-

(

) +

( 1

1

A

(

C

W

1

5

A

1

D

(

2

R

K

5

1

)

6

4

+

(

1

P M

5

F

R

2

5

F 6

R 3

SNUBBER

E G

)

D

-

I

(

R B

F9B

F 4

R

F9A

1

=

9

1

D

-

R

8 7

A

3

O

1

B

5

-

H

0

C

M

A

/

E

B

) R

( K

(W)H2

A13R

G(W)

(R)H1

2

)

H

R

)

(

R

W

K

(

6

1

A

H

) R

G(W)

(

2

)

H

R

)

(

W

K

( 1

A16F

H

) R

G(W)

(

2

)

H

R

)

(

W

K

( 1

A13F

H

) R

G(W)

(

SNUBBER

S E L B A C

O W

T

2

) R

( K

A15RA11R

G(W)

2

)

H

R

)

( K

W

(

G(W)

) R

( K

A12R

G(W)

2

) R

( K

A14R

G(W)

) R

(

K

A12F

G(W)

2

) R

( K

A14F

G(W)

) R

( K

A15F

G(W)

2

) R

( K

A11F

G(W)

6

H

)

5

3

W

( 1 H

) R

(

1 H

) R

( 2

H

) W

( 1 H

) R

(

H

) W

( 1 H

) R

( 2

H

) W

( 1 H

) R

(

H

) W

( 1 H

) R

( 2

H

) W

( 1 H

) R

(

H

) W

( 1 H

) R

(

0

1

0 6

-

3

O

4

M

/

1

B )

4

A G

5

P

1

(

)

R

G

5

E

N

I

F

1

I

R

B

L

P

O

P

T

U

M

6

O

P

A

M

N

E

I

1

V

T

E

A

1

R

G

(

1

L E

7

L L

2

A

1

R A

2

P

3

3 1

A

6 5

3

0 0 6

-

4

O

1

M

/

4

B ) A

DRIVER UNIT B/M O-805401-7

5

G

1

P

(

)

R

G

5

E

I

N

F

I

1

L

R

A

P

O

T

M

T

A

U

6

O

E

P

T

M

N

A

I

1

G

D

L

W

E

1

L

F

1

L

(

A R

7

A P

2 1

1

2

L

2

2 A

5 4

7

TB1

4

1 A

AC LINE &

DC ARM

SIGNALS

2 9 1

2 X

1

:

N

1

0

R

T

0

U

0

C

T

0

A

1

4 P S

J

1

2

P

A

S

1

3

B

L

T

5

TB2

T P

)

2

4

X

H

(

) 3 H

C

( A V

)

2

H

( )

1 X

(

SALES ORDER SPECIFIC

) 1

V

H

0

(

6 6

TB2

1

1 X

1 9 1

3 P

J

S

2 P S

1 3

B U F

0

C

6

A

4

V

V 5 7 5

1

0

L

3

1

FUA

OR

CB11

AC LINE FUSES

1 L

2

6

X

9 1

1

:

N

3

0

R

T

0

U

0

C

0

T

A

1

5

X

9 1

3 8 2

3

A

F

2

1

8 2

2

A

1

F

1

8 2

1

A

F

1

5

A

1

0

F

1

A 3 L

2 L 1

2

L

L1A

3 L 1

4 1 F

POWER

OPTIONAL

3

∗

L

E P

4

TB10 (4-6)

2

A V

4

5

2

K

T

5

6

.

P

1

TB3

....

...

)

6

)

H

2

(

2

)

(H5)

4

C

H

A

(

V

)

0

3

8

H

3

)

1 H

(

1

A 0 1

20

X

(

C A V 5

(

1

)

1

2 H

(

(X1)

3

6

A

1

8

F

5

) 3

1

( 0 1

1

B

3

T

5

5 7

TB3

....

...

19

4

N

1

A

N

F

A

R

F

C S

5

COMPONENTS

2 9

1

1 9 1

6 9

1

5 9 1

TB1

3 8 2

2 8 2

1 8 2

A1

UNIT

805427-1

1

FEEDBACK SCALING

D A

2

1

O

L

C

L

A V

R

5

E

1

T

N

1

I

2

1

I

L

I

L

F

L2L

5

B-4

Figure B.4 – 1250A and 1650A Power Modules (Regenerative), Sheet 1

SD3100 Power Modules

)

M H

0

O

2

T T

U O X U A

S

(IF USED)

E C N

T

E

U

R

P

E

T

F

U

E

O

R

A

(+)

(–)

213

AC

1

2

)

–

+

(

R1

INPUT

(ROTOR)

REFERENCE

(

2 R

)

K

M

R

H

0

O

2

(

W

1

T

R

E N

R

)

E

D

B

F

B

3

2

U

M

(

N

C

S R

C

S

G N

I

0

T

5

A

6

2

R

1

T

I N U

DC MOVEMENTS

METERS ARE 10 VOLT

OPTIONAL METERS

L A

R

)

N

E

1

R

N

P

T

G

T

I

-

E

U

E

U

G

3

S

T

I

P

N

I S

D

B

(+)

(–)

4

C

O

X

±10V

R

ISOLATED

(

N

I

C

I

F

E

C

(+)

(–)

5

6

=(±2047)

E

T

N

R

P

J

H

)

–

+

(

(+)

(–)

(

SHLD

2

3

1

8

7

1

1 B C

(P1)

PROCESSOR

+

B/M O-60000

1 M

N A F

(-) BRIDGE

(+) BRIDGE

S

' B C

P

2

1

4

678

3

5

TWISTED

COM

1

(C2)

TWISTED

+

COM

2

3

±10V

METER

RCV

XMT

(P4)0RAIL

(P3)

(P2)

PORTS

FIBER OPTIC

COMM LINK

ORG

BLU

3 Y

A B

2 Y

A B

1 Y

A B

T P 6

TB6

TWISTED

+

COM

4

PORTS

1

(P5)

TB5

4

5

6

3

)

–

+

–

(

S1

R2

S3S4S2

SINE

COSINE

OUTPUT

(STATOR)

FROM UDC CARD

FIBER OPTIC COMM. LINK

BRUSHLESS

RESOLVER

INDUSTRIAL

DUTY

MOTOR

DRIVEN BY

R

Y

C

T

S

/

Q

2

)

2

1 F

-

7 F

(

G

E

N

0

S

I

S

0

3

E

T

U

8

6

S

A

F

U

R

F R

C S

G

0

T

N

I

5

N

T

6

2

1

A

U

R

E P

4

K

FWD

(P3)

REV

(P2)

(P4)

ARM GATES

FLD GATES

& FDBK

DC POWER TECH

B/M O-60002

AC LINE &

DC ARM

(P1)

S 1

1 0 4 5 0

E

K

8

P

C

M

A

/

R

B

D

2 L

N G

2 L

5

1

L

1

(C4)

SIGNALS

R 6

0

N

0 4

A

5

F

0

K

8

C

M

A

/

TB4

R

B

1

Y

L

L P

N

1

P

7

A

3

0

U

F

0

S

O

0

/

I

6

R

-

)

E

C

O

1

V

A

I

W

C

M

(

V

R

/

O

D

B

P

TB4

4

C A B D E E F

R O T C A T N O C

2

4

D

B

)

1

2

N

I

P

-

P

X

3

R

U

C

(

) 3 C

(

1

A

C

A

3

Ω

W

K

5

7

.

6

4

8

4

T A T

T

S

A

O

T

M

S

E

R

T L

U A F

D N U O R G

6

F 2

N

I X U

A E

5

O

L

E

U

M

H

D

R

T

E

O

K

H

M

T

N

I

R

S

R

E

T

O

W

A

T

E

O

H

P

M 0

8

1

L

J

4

3

N

I

X

U

A

K

H

7

9

7

(IF USED)

MOTOR THERMOSTAT

ESR

LINE

(FAIL SAFE)

EMERGENCY STOP

DOOR INTERLOCK

V

A

U

0

F

0

5

.

T

2

1

GROUND FAULT

4

P M

3 1

) D E S U F

I

(

2 1

N 5

N

I X U

A

M

1 1

(IF USED)

EXTERNAL DEVICE

CONTACTOR PILOT

6

4 1

1

R

R E

"

D

T

W

F

N

O

A

O

L

"

R

C

Y

E

A

C

S

L

S

E

M

E

5

O

.

D

-

0

G

I

F F

P

O

R

5

3

1

5

Schematics

Figure B.5 – 1250A and 1650A Power Modules (Regenerative), Sheet 2

B-5

A 3 L

A 1 L

)

-

+

(

2

1

-

D

L

F

1

2

A

1 A

1 M

2 A

DCA1

F10 A,B,C

F 5

R 2

SNUBBER

F11 A,B,C

F 3

R 6

SNUBBER

) +

(

BRIDGE

F12 A,B,C

F 1

R 4

SNUBBER

3 L

/

3 8 1

1 L

/ 1 8 1

37

TB2

7 3

5 3

35

TB2

1

M

)

.

2

(

T

X

P

U A

O

) 1

(

1 M

)

.

4

T

(

X

P

1

O

)

M

3

(

5

8

5

E

-

L

5

U

0 4

D

5

O

0 8

M

R

K

E

C

W

A

O

e

B

l

P

D

b a

E

D

E

C

L

F

E

n

I

i

&

F

P

.

S

4

p

1

E

m

T

A

0

G

6

1 M

)

.

6

T

X

(

P

U

A

O ) 5

(

F7 A,B,C

F8 A,B,C

E G

)

D

-

I

(

R B

1 1

)

1

8

(

M

4

)

2

7

(

7

NC.

SNUBBER

S1

COM

P M

)

7

-

)

(

1

2

)

C

)

-

(

) +

( 1

1

A

(

C

W

1

5

A

1

D

(

2

R

K

5

1

)

6

4

+

(

1

P M

5

F

2

R 5

F 6

R 3

F 4

R 1

=

9

1

D

-

R

8 7

A

3

O

1

B

5

-

H

0

C

M

A

/

E

B

) R

( K

(W)H2

A13R

G(W)

(R)H1

2

)

H

R

)

(

R

K

W

(

6

1

A

H

) R

G(W)

(

2

)

H

R

)

( K

W

( 1

A16F

H

) R

G(W)

(

2

)

H

R

)

( K

W

( 1

A13F

H

) R

G(W)

(

F9A,B,C

SNUBBER

S E L B A C

O W

T

2

) R

( K

A15RA11R

G(W)

2

)

H

R

)

( K

W

(

G(W)

) R

( K

A12R

G(W)

2

) R

( K

A14R

G(W)

) R

(

K

A12F

G(W)

2

) R

( K

A14F

G(W)

) R

( K

A15F

G(W)

2

) R

( K

A11F

G(W)

6

H

)

5

3

0

1

W

( 1 H

) R

(

1 H

) R

( 2

H

) W

( 1 H

) R

(

H

) W

( 1 H

) R

( 2

H

) W

( 1 H

) R

(

H

) W

( 1 H

) R

( 2

H

) W

( 1 H

) R

(

H

) W

( 1 H

) R

(

0 6

-

3

O

4

M

/

1

B )

4

A G

5

P

1

(

)

R

G

5

E

N

I

F

1

I

R

B

L

P

O

P

T

M

U

6

O

A

P

M

N

E

I

1

V

T

E

A

1

R

G

(

1

L E

7

L L

2

A

1

R A

2

P

3

3 1

A

6 5

3

0 0 6

-

4

O

1

M

/

4

B ) A

DRIVER UNIT B/M O-805401-7

5

G

1

P

(

)

R

G

5

E

I

N

F

I

1

L

R

A

P

O

T

M

T

A

U

6

O

E

P

T

M

N

A

I

1

G

D

L

W

E

1

L

F

1

L

(

A R

7

A P

2 1

1

2 L

L

2

&

2 A

5 4

7

TB1

4

1 A

E N

I L

C

DC ARM

SIGNALS

A

2

9 1

2 X

1

:

N

1

0

R

T

0

U

0

C

T

0

A

1

4 P S

J

1

2

P

A

S

1

3

B

L

T

5

TB2

T P

)

2

4

X

H

(

) 3 H

C

( A V

)

2

H

( )

1 X

(

SALES ORDER SPECIFIC

) 1

V 0

H

(

6 6

TB2

CB11

1

X1

1 9 1

3 P

J

S

2 P S

1 3

B U F

0

C

6

A

4

V

V 5 7 5

1

0

L

3

1

FUA

OR

AC LINE FUSES

1 L

2

6

X

9 1

1

:

N

3

0

R

T

0 0

U

C

0

T

A

1

5

X

9 1

3 8 2

3

A

F

1

2 8 2

2

A

1

F

1

8 2

1

A

F

1

5

A

1

0

F

1

A 3 L

2 L 1

2

L

L1A

3 L 1

4 1 F

POWER

OPTIONAL

3

∗

L

E P

4

TB10 (4-6)

2

A V

4

5

2

K

T

5

6

.

P

1

TB3

....

...

)

6

)

H

2

(

2

)

(H5)

4

C

H

A

(

V

)

0

3

8

H

3

(

) 2 H

(

)

1 H

(

1

A 0 1

20

X

(

C A V 5 1 1

(X1)

3

6

A

1

8

F

5

) 3

1

( 0

1

3

B T

5

5 7

TB3

....

...

19

4

N

1

A

N

F

A

R

F

C S

5

COMPONENTS

2 9

1

1 9 1

6 9

1

5 9 1

TB1

3 8 2

2 8 2

1 8 2

G N

I L A

1

-

C

7

T

I

S

2

1

4

N

K

A

5

U

C

0

A

8 B D E E

1 L

F

D A

1

2

O

L

C

L

A V

R

5

E

1

T

N

1

I

2

1

I

L

I

L

F

2 L

5

B-6

Figure B.6 – 3000A Power Module (Regenerative), Sheet 1

SD3100 Power Modules

40

R4(OHM)

Y T

QTY

Q

3/SCR

0 0 9

FUSE

RATING

SCR FUSES (F7-F12)

0 0 0 3

UNIT

RATING

40

R3(OHM)

∗

E T

5

O

40

T P

M E

R2(OHM)

R

40

R1(OHM)

SCR SNUBBER NETWORK

3

C (MFD)

CB11

0 0 0 3

M1

FAN

(-) BRIDGE

(+) BRIDGE

BAY 3

BAY 2

DPS

PCB'S

BAY 1

2 T P

UNIT RATING

E P

4

K

FWD

(P3)

REV

(P2)

(P4)

ARM GATES

FLD GATES

& FDBK

DC POWER TECH

B/M O-60002

AC LINE &

DC ARM

(P1)

S 1

1 0 4 5 0

E

K

8

P

C

M

A

/

R

B

D

2 L

N G

2 L

5

1

L

1

(C4)

SIGNALS

R 6

0

N

0 4

A

5

F

0

K

8

C

M

A

/

TB4

R

B

1

Y

L

L P

N

1

P

7

A

3

0

U

F

0

S

O

0

/

I

6

R

-

)

E

C

O

1

V

A

I

W

C

M

(

V

R

/

O

D

B

P

TB4

4

C A B D E E F

R O T C A T N O C

2

4

D

B

)

1

2

N

I

P

-

P

X

3

R

U

C

(

) 3 C

(

1

A

C

A

3

Ω

W

K

5

7

.

6

4

8

4

T A T

T

S

A

O

T

M

S

E

R

T L

U A F

D N U O R G

6

F 2

N

I X U

A E

5

O

L

E

U

M

H

D

R

T

E

O

K

H

M

T

N

I

R

S

R

E

T

O

W

A

T

E

O

H

P

M 0

8

1

L

J

4

3

N

I

X

U

A

K

H

7

9

7

(IF USED)

MOTOR THERMOSTAT

ESR

LINE

(FAIL SAFE)

EMERGENCY STOP

DOOR INTERLOCK

V

A

U

0

F

0

5

.

T

2

1

GROUND FAULT

4

P M

3 1

) D E S U F

I

(

2

4

1

N 5

N

I X U

A

M

1

3

1

(IF USED)

EXTERNAL DEVICE

(IF USED)

EXTERNAL DEVICE

CONTACTOR PILOT

6 1

T

R

R C M

P

E

R E

C

"

D

T

N

T

W

F

N

T

E

U

O

A

U

O

R

L

O

P

"

C

E

Y

E

T

F

E

A

S

X

N

U

L

E

S

E

5

.

D

-

0

F F O

I

E

U

O

R

S

O

A

G

D

B

A

I

(+)

(–)

P

(+)

(–)

S

R

5

4

213

1

AC

1

4

2

3

)

–

+

–

+

(

R1

S1

R2

SINE

OUTPUT

INPUT

(ROTOR)

REFERENCE

OPTIONAL METERS

L A

R

)

N

E

1

R

N

P

T

G

T

I

-

E

U

G

3

S

T

I

P

C

O

X

R

(

N

I

C

E

T

I

F

E

J

C

H

) +

(+)

(–)

(

(+)

(–)

1

8

5

6

7

5

6

)

–

+

(

S3S4S2

COSINE

OUTPUT

(STATOR)

1

2

4

678

3

5

DC MOVEMENTS

METERS ARE 10 VOLT

TWISTED

+

COM

(P1)

1

±10V

ISOLATED

=(±2047)

N

R

P

)

–

(

SHLD

PROCESSOR

B/M O-60000

(C2)

2

3

TWISTED

+

COM

2

3

RCV

XMT

(P3)

(P2)

PORTS

FIBER OPTIC

COMM LINK

ORG

BLU

TB6

TWISTED

+

COM

4

±10V

METER

PORTS

1

(P4)0RAIL

(P5)

TB5

FROM UDC CARD

FIBER OPTIC COMM. LINK

BRUSHLESS

RESOLVER

INDUSTRIAL

5

DUTY

MOTOR

DRIVEN BY

Schematics

Figure B.7 – 3000A Power Module (Regenerative), Sheet 2

B-7

B-8

SD3100 Power Modules

A

PPENDIX

Replacement Parts

C.1 Regulator Assembly

Please refer to the following instruction manuals for replacement parts information:

Component M anual Number

PMI Rack and Modules S-3008 Parallel Gate Amplifier Rack and

Modules

C.2 Field Power Module Replacement Parts

15 Amp, S2R Field Power Module (#805405-3R)

Description Part Number

AC Input Line Fuses (2) 64676-3CL Power Cubes (3)

FPC1 (1,2,3,4 THY) RPC1 (11,12,13,14 THY)

CLAMP (Q1,Q2) Field Gate Coupling Card B/M O-60014 - ∗∗ Hall Device Assembly 615051-R

PMI Cable

1. Specify cable length in inches

∗∗

Revision level

1

701819-303AW

612418-S

S-3045

C

Replacement Parts

60 Amp, S2R Field Power Module (#805405-5R) Part Description Reliance Part Number

AC Input Line Fuses (2) 64676-130ASX Power Cubes (5):

(FPC1 - 1,4THY)

(FPC2 - 3,6THY)

(RPC1 - 11,14THY)

(RPC2 - 13,16THY)

(CLAMP - Q1,Q2)

Field Gate Coupling Card B/M 60033-∗∗ Snubber P.C. Board B/M 60034-∗∗ Gate Pin Extension (10) 615050-15R 37 (+) Cable Assembly 805417-R

PMI Cable

1. Specify required length in inches.

∗∗

Revision level

1

701819-201AW

612418-S

C-1

C.3 Spare Parts Kits

Current

Type of Kit

Line RC Suppressor (Option 14LSP)

Air Flow Switch PCB (Option 14AFL)

Air Flow Switch (Option 14AFL)

Line MOVs R,S,T 2300-SPJ02A 2300-SPJ03A 2300-SPJ04A 1 set

Armature SCRs

Positive (Top) Regenerative Armature Assemblies

Negative (Bottom) Regenerative Armature Assemblies

Positive (Top) NonRegenerative Armature Assemblies

Negative (Bottom) NonRegenerative Armature Assemblies

Bridge Fan

Bridge Fan Door Filter T 2361-SPK02A 2361-SPK02A 2361-SPK0 2A Slide-In Fan T 2361-SPH03A 2361-SPH03A 2361-SPH03A

Loose Power Fuses

Power Fuse Assembly T 2361-SPE11A 2361-SPE11A 2361-SPE11A

Input Line Fuses

Snubber Assembly

1. R = 1250A, S = 1650A, T = 3000A.

2. Drive requires 12 fuses.

3. Drive requires 18 fuses.

1

Code

R,S,T 2300- SPB01A 2300-SPB01A 2300-SPB02A 1 PCB with 2 sets of fuses

R,S 2300-SPP01A 2300-SPP01A 2300-SPP01A 1 PCB with 0.5A power supply

T 2300-SPP02A 2300-SPP02A 2300-SPP02A 1 PCB with 1.1A power supply

R,S 2300-SPK03A 2300-SPK03A 2300-SPK03A

T 2300-SPK01A 2300-SPK01A 2300-SPK01A

R 2361-SPG01A 2361-SPG01A 2361-SPG01A 2 SCRs

S 2361-SPG02A 2361-SPG02A 2361-SPG02A 2 SCRs T 2361-SPG03A 2361-SPG03A 2361-S PG03A 2 SCRs

R SD3100-SPA01A SD3100-SPA01A SD3100-SP A01A

S SD3100-SPA05A SD3100-SPA05A SD3100-SPA05A T 2361-SPA05A 2361-SPA05A 2361-SPA05A

R SD3100-SPA02A SD3100-SPA02A SD3100-SP A02A

S SD3100-SPA06A SD3100-SPA06A SD3100-SPA06A T 2361-SPA06A 2361-SPA06A 2361-SPA06A

R SD3100-SPA03A SD3100-SPA03A SD3100-SP A03A

S SD3100-SPA07A SD3100-SPA07A SD3100-SPA07A

R SD3100-SPA04A SD3100-SPA04A SD3100-SP A04A

S SD3100-SPA08A SD3100-SPA08A SD3100-SPA08A

R,S 2361-SPH01A 2361-SPH01A 2361-SPH01A

T 2361-SPH02A 2361-SPH02A 2361-SPH02A

R 2361-SPE08A 2361-SPE08A 2361-SPE08A

S 2361-SPE09A 2361-SPE09A 2361-SPE09A T 2361-SPE10A 2361-SPE10A 2361-SPE10A

R 2361-SPE12A 2361-SPE12A 2361-SPE12A

S 2361-SPE13A 2361-SPE13A 2361-SPE13A T 2361-SPE14A 2361-SPE14A 2361-SPE14A

R 2361-SPB03A 2361-SPB03A 2361-SPB03A

S 2361-SPB01A 2361-S PB 01A 2361-SPB01A T 2361-SPB02A 2361-SPB02A 2361-SPB02A

460 VAC 575 VAC 660 VAC Brief Description

Fiberglass 20” x 30” x 1”, 1 required, 6 per kit.

2 fuses per kit 2 fuses per kit 3 fuses per kit

1 assembly containing 3 fuses in parallel

2

3

C-2

SD3100 Power Modules

I

NDEX

A

AC input busbars

1250A Power Module, A-4 1650A Power Module, A-7 3000A Power Module, A-10

connecting AC input wires to, 3-3 Air baffles, A-11 to A-12 Altitude derating chart, A-1 Analog input connections (TB5), 3- 6 Armature power components, 2-4 to 2-7

bridge components, 2-6 to 2-7

B

Blower motor connections, B-1

C

Circuit breaker, 2-3 Circuit breaker settings

1250A Power Module, A-3

1650A Power Module, A-6

3000A Power Module, A-9 Component replacement, 4-4 to 4-6

Field Power Module, 4-5

Parallel Gate Amplifier, 4-5

PMI regulator, 4-5

spare parts kits, 4-4 Control components, 2-2 to 2-3 Control power and field supply tap, 2-4

D

DC drive binder (S-3000), 1-4 Diagnostics, 4-2 to 4-4 Drive I/O connections (TB4), 3-6

E

Electrical description, 2-7 to 2-8

conduction timeout, 4-3 instantaneous over cu rren t, 4-3 loss of field, 4-3

shorted SCR, 4-2 Feedback devices, 3-6 Field isolation transformer, 3-4 Field Power Module

AC line input fuses, 4-5

component replacement, 4-5

electrical description, 2-8

introduction, 1-3

mechanical description, 2-7

part numbers, 1-3

replacement parts, C-1

specifications, A-13

G

Grounding, 3-7 to 3-8

I

Installation guidelines, 3-1 to 3-8

AC input power, 3-2 to 3-3

AC input wire selection, 3-2

analog input, 3-6

armature and field wire selection, 3-5

connecting the AC busbars, 3-3

drive I/O, 3-6

feedback devices, 3-6

field isolation transformer, 3-4

field power module, 3-4

grounding the drive, 3-7

making an input entry hole, 3-3

meter ports, 3-7

motor connection and wiring, 3-5

physically installing the Power Module, 3-2

planning the installation, 3-1

resolver, 3-6 Introduction, 1-1 to 1-5 Isolation transformer, 3-4

requirement for, 2-3

F

Faults, 4-2 to 4-3

AC line synchronization, 4-2

Index

M

Main components of Power Module, 2-1

Index-1

Maintenance and troubleshooting, 4-1 to 4-6

component replacement, 4-4 to 4-6 faults, 4-2 to 4-3 Field Power Module, 4-5 PMI rack and modules, 4-5 recommended test equipment, 4-1 to 4-2 system diagnostics, 4-2 to 4-4

warnings , 4-3 to 4-4 Mechanical description, 2-2 to 2-7 Meter port connections, 3-7 Motor control center documentation, 1-5 Motor installation, 3-5

N

component reference, 2-19 configurations, 2-17 description, 2-17 dimensions, 2-20 schematics, B-6 to B-7 technical specifications, A-8 to A-10

R

RC suppressor, 2-4 Regenerative armature bridge, 2-6 Related publications, 1-4 Replacement parts, C-1 to C-2 Resolver connections (TB5 ), 3-6

Non-regenerative armature bridge, 2-5

O

Optional features, 1-4

P

Power components, 2-3 to 2-7

armature power, 2-4 to 2-7

incoming power, 2-3 to 2-4 Power dissipation

1250A Power Module, A-3

1650A Power Module, A-6

3000A Power Module, A-9 Power Module - 1250A

component layout, 2-10

component reference, 2-11

configurations, 2-9

description, 2-9

dimensions, 2-12

schematics, B-2 to B-5

technical specifications, A-2 to A-4 Power Module - 1650A

component layout, 2-14

component reference, 2-15

configurations, 2-13

description, 2-13

dimensions, 2-16

schematics, B-2 to B-5

technical specifications, A-5 to A-7 Power Module - 3000A

component layout, 2-18

S

Schematics, B-1 to B-7 Spare parts kits, 4-4, C -2 Standard features, 1-3 Start-up, 3-8

T

Technical specifications, A-1 to A-10

1250A Power Module, A-2 to A-4 1650A Power Module, A-5 to A-7 3000A Power Module, A-8 to A-10 Field Power Module, A-13

general specifications, A-1 Terms used in this manual, 1-5 Test equipment, 4-1 to 4-2

W

Warnings, 4-3 to 4-4

current reference limit warning, 4-4

fan loss, 4-4

Field Power Module overcurrent, 4-4

identification test error, 4-4

low line voltage/phase missing, 4-3

synchronization loss fault avoided, 4-4

three-phase bridge SCR not firing, 4-3 Wires

for AC input, 3-2

for armature and field lines, 3-5

Index-2

SD3100 Power Modules

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Rockwell Automation SD3100 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual