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.
AutoMax™ is a trademark of Rockwell Automation
©1998 Rockwell International Corporation
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
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
*&&
*&&
SNUBBER
SNUBBER
*&&
*&&
Figure 2.3 – Armature Bridge (Non-Regenerative)
SNUBBER
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
*&&
*&&
SNUBBER
Figure 2.4 – Armature Bridge (Regenerative)
*&&
*&&
*&&
*&&
SNUBBER
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
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