Rockwell Automation SF3000 User Manual

Distributed Power System SD3000/SF3000 Parallel Gate Amplifier System

Instruction Manual

S-3045-2

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 electrical 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 inury or loss of life.

ATTENTION:The user must provide an external, hardwired emergency stop circuit outside of the drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled machine operation may result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.

ATTENTION:Inserting or removing a module or its connecting cables may result in unexpected machine motion. Turn off power to the rack before inserting or removing a module or its connecting cables.

A TTENTION:The user is responsible for conforming with all applicable local, national, and international codes.

ATTENTION:The modules in the Parallel Gate Amplifier rack contain static-sensitive components.

Do not touch the modules’ circuit boards or the connectors on the backs of the modules. When not in the rack, modules should be stored in anti-static bags.

The information in this user’s manual is subject to change without notice.

Chapter 1 Introduction

1.1 Standard Features........................................................................................... 1-2

1.2 Related Hardware and Software ..................................................................... 1-2

1.3 Related Publications........................................................................................ 1-4

Chapter 2 About the PGA Rack

2.1 PGA Rack Mechanical Description.................................................................. 2-1

2.2 PGA Rack Electrical Description .....................................................................2-1

Chapter 3 About the PGA Power Supply Module

3.1 PGA Power Supply Module Mechanical Description.......................................3-1

3.2 PGA Power Supply Module Electrical Description ..........................................3-2

Chapter 4 About the PGA Module

4.1 PGA Module Mechanical Description.............................................................. 4-1

4.2 PGA Module Electrical Description.................................................................. 4-1

Chapter 5 Installation Guidelines

5.1 Wiring the PGA Rack.......................................................................................5-1

5.2 Installing the PGA Rack ... ....... ...................................... ....... ...... ....... ...... ....... .. 5-2

5.3 Grounding Considerations............................................................................... 5-5

5.4 Module Installation/Replacement Guidelines ..................................................5-6

5.5 Installing the PGA Power Supply Module..................... ....... ...... ....... ...... ....... .. 5-6

5.5.1 Connecting AC Input Power.................................................................. 5-7

5.5.2 Installing an Optional External Supply Greater Than +28 VDC ............5-7

5.5.3 Connecting the PMI DC Power Technology Module to the PGA Power

Supply Module ............................................. ...... ....... ...... ....... ...... .........5-7

5.6 Connecting the PGA Module to the Gate Coupling Circuits............................ 5-8

CONTENTS

Table of Contents

Appendix A Rack Specifications.................................................................................................. A-1

Appendix B Power Supply Module Specifications....................................................................... B-1

Appendix C PGA Module Specifications......................................................................................C-1

Appendix D PGA Maximum System Power Requirements .........................................................D-1

Appendix E External PGA Power Supply Interface .....................................................................E-1

Appendix F Replacement Parts ....... ...... ....... ...... ....... ...... ...... ....... ...... ....................................... .. F-1

Parallel Gate Amplifier

List of Figures

Figure 1.1 – Four-Slot PGA Rack and Modules (Part No. 805401-7T) ....................1-5

Figure 1.2 – Eight-Slot PGA Rack and Modules (Part No. 805401-9CC).................1-6

Figure 1.3 – PGA Parallel Motoring and Regenerating System Example ................1-7

Figure 3.1 – Power Supply Module Component Layout........................................... 3-3

Figure 3.2 – Power Supply Module Functional Block Diagram.................................3-4

Figure 4.1 – PGA Gate Driver Circuitry ....................................................................4-3

Figure 4.2 – PGA Module Functional Block Diagram............................................... 4-4

Figure 5.1 – Four-Slot PGA Rack Mounting Dimensions ......................................... 5-3

Figure 5.2 – Eight-Solt PGA Rack Mounting Dimensions.........................................5-4

Figure 5.3 – Location of Power Supply Ground Terminal and

Four-Slot Rack Grounding Lug............................................................. 5-5

Figure 5.4 – Location of Power Supply Ground Terminal

and Eight-Slot Rack Grounding Lug............................... ....... ...... ....... .. 5-5

Figure 5.5 – Gate Driver Plug for Cable Assemblies 612436 and 612567............... 5-9

Figure 5.6 – PGA System Hardware Connections ................................................. 5-10

Table of Contents

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Parallel Gate Amplifier

List of Tables

Table 1.1 – Parallel Gate Amplifier System Configurations ......................................1-3

Table 1.2 – DPS Documentation...............................................................................1-4

Table 5.1 – Input Power Connections.......................................................................5-7

Table 5.2 – Connection Sequence for Cable Assemblies 612436 and 612567........5-9

Parallel Gate Amplifier

CHAPTER 1

Introduction

The Parallel Gate Amplifier (PGA) system is used to amplify and distribute the gate

pulse signals produced by the AutoMax™ Distributed Power System's DC Power Technology module. It can be used with multiple Reliance Power Modules or with certain other vendor Power Modules. Please contact Reliance regarding the suitability of other vendor Power Modules for use with the PGA system.

The system is comprised of three major components: the PGA Rack/Backplane, the Power Supply module, and the PGA modules.

The Power Supply and PGA modules reside in a modular rack of either four slots or eight slots. The four-slot rack holds the Power Supply and one or two PGA modules (figure 1.1). The eight-slot rack holds the Power Supply and one to six PGA modules (figure 1.2). Two channels (A and B) are provided for gate signals on the rack's backplane. Channel A is used for forward gate signals and channel B for reverse gate signals.

To connect to the two channels, two types of PGA modules are used. The Output-A PGA module is used to access the signals from channel A. The Output-B PGA module is used to access the signals from channel B. The two types of modules are not interchangeable, but may be combined in the rack as needed to meet the requirements of the application.

The amplified PGA output signals drive the gate coupling circuits in the DC Power Modules. Each PGA module can simultaneously drive four six-thyristor power bridges in one direction, either forward or reverse. With the maximum of six PGA modules used in the system, a total of 24 power bridges (6 x 4) can be driven.

The PGA's standard DC bus voltage is +28 VDC, but the PGA module is capable of handling DC bus voltages up to +100 VDC, if required by the application. Voltages greater than the standard +28 VDC must be provided by an externally mounted power supply, as described in chapter 3.

The available PGA configurations are listed in table 1.1. A two card PGA parallel motoring and regenerating system example is shown in figure 1.3.

Introduction

1-1

1.1 Standard Features

The PGA system has the following features:

• Connects to DPS DC Power Technology module

• Capable of driving up to 24 six-thyristor power bridges in parallel (144 gate coupling

circuits)

• Overcurrent protection provided by PCB fuses

• Overtemperature detection by NC faceplate contacts on Power Supply module

• Optical isolation of gate signals from biasing networks and firing circuits

• Physical isolation of gate signals from Power Supply and other circuitry

• Externally mounted 100 VDC power supply option

• UR/CUR Recognized

1.2 Related Har dw are and Software

The following related DPS components are available separately:

• AutoMax Universal Drive Controller

• Power Module Interface rack and modules

• Fiber-Optic Cables

• AutoMax Programming Executive software

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Parallel Gate Amplifier

Table 1.1 – Parallel Gate Amplifier System Configurations

Reliance Part No. Description

805401-7R 4-Slot PGA Rack, w/Fan, Power Supply, Output-A 805401-7S 4-Slot PGA Rack, w/Fan, Power Suppl y, Output-A/A

805401-7T 4-Slot PG A Rac k, w/Fan, Power Suppl y, Output-A/B 805401-9AX 8-Slot PGA Rack, w/Fan, Power Supply, Output-A 805401-9BX 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A 805401-9CX 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/A 805401-9DX 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/A/A 805401-9EX 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/A/A/A 805401-9FX 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/A/A/A/A 805401-9AA 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/B 805401-9BA 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/B 805401-9CA 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/A/B 805401-9DA 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/A/A/B 805401-9EA 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/A/A/A/B 805401-9AB 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/B/B 805401-9BB 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/B/B 805401-9CB 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/A/B/B 805401-9DB 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/A/A/B/B 805401-9AC 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/B/B/B 805401-9BC 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/B/B/B 805401-9CC 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/A/B/B/B 805401-9AD 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/B/B/B 805401-9BD 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/A/B/B/B/B 805401-9AE 8-Slot PGA Rack, w/Fan, Power Supply, Output-A/B/B/B/B/B

Introduction

1-3

1.3 Related Publications

This manual provides a description of each component of the Parallel Gate Amplifier system as well as installation guidelines. Note that this instruction manual does not describe specific applications of the standard hardware.

Additional information about using the Parallel Gate Amplifier as part of an AutoMax Distributed Power System is found in the instruction manuals, prints, and other documents shipped with each drive system. Always consult the prints shipped with the drive system for specific mounting and connecting information about your drive.

The other instruction manuals located in binder S-3000, Distributed Power System DC Drive, are listed in table 1.2. It is assumed that the user is familiar with these other manuals in S-3000 before using the PGA system.

Table 1.2 – DPS Documentation

Document Part Number

Document SD/SF3000 Binder S-3000

DPS Overview S-3005 UDC Module S-3007 Fiber-Optic Cabling S-3009 Configuration and Programming S-3006 (for SD3000)

S-3036 (for SF3000) Power Module Interface Rack and Modules S-3008 Diagnostics, Troubleshooting, and Startup Guidelines S-3011 Information Guide S-3012

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Parallel Gate Amplifier