Distributed Power System SD3100 DC Power Modules

Transcription

1 Distributed Power System SD3100 DC Power Modules 1250A, 1650A, 3000A DC Instruction Manual S-3064

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 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 , Guarding Against Electrostatic Damage, or another adequate handbook on ESD protection. The information in this users manual is subject to change without notice. AutoMax is a trademark of Rockwell Automation 1998 Rockwell International Corporation

3 CONTENTS Chapter 1 Chapter 2 Chapter 3 Introduction 1.1 Field Power Module Standard Features Optional Features Related Publications Terms Used in this Manual Mechanical/Electrical Description 2.1 Mechanical Overview Control Components Power Components Incoming Power Armature Power Components Field Power Module Components Electrical Overview A Power Module Description A Power Module Component Layout A Power Module Dimensions A Power Module Description A Power Module Component Layout A Power Module Dimensions A Power Module Description A Power Module Component Layout A Power Module Dimensions Installation Guidelines 3.1 Planning the Installation Physically Installing the Power Module Wiring AC Input Power to the Power Module AC Input Wire Selection Making an Input Entry Hole Connecting the AC Input Wires to the Busbars Wiring AC Input to the Field Power Module Installing the Field Isolation Transformer Wiring the Motor Selecting Wires for the Armature and Field Lines Connecting the Motor to the Power Module Installing Feedback Devices Meter Port Connections Grounding the Drive For Information on Initial Start-Up of the Drive Table of Contents I

4 Chapter 4 Maintenance and Troubleshooting 4.1 Recommended Test Equipment System Diagnostics Power Module Faults Shorted SCR Fault (Bit 0) AC Line Synchronization Fault (Bit 3) Instantaneous Overcurrent Fault (Bit 4) Conduction Timeout Fault (Bit 5) Loss of Field Fault (Bit 6) Power Module Warnings Three-phase Bridge SCR Not Firing Warning (Bit 0) Low Line Voltage/Phase Missing Warning (Bit 1) Synchronization Loss Fault Avoided Warning (Bit 3) Current Reference Limit Warning (Bit 4) Identification Test Error Warning (Bit 5) Field Power Module Overcurrent Warning (Bit 6) Fan Loss Warning (Bit 12) Component Replacement Spare Parts Kits PMI Regulator Parallel Gate Amplifier Field Power Module Replacing Internal Field Power Module AC Input Fuses Replacing Field Power Module Components Appendix A Technical Specifications... A-1 Appendix B Schematics... B-1 Appendix C Replacement Parts... C-1 Index...Index-1 II SD3100 Power Modules

5 List of Figures Figure 1.1 SD3100 Catalog Numbering Scheme Figure 2.1 SD3100 Power Module System Components Figure 2.2 Regulator Assembly Figure 2.3 Armature Bridge (Non-Regenerative) Figure 2.4 Armature Bridge (Regenerative) Figure A Power Module Component Layout Figure A Power Module Dimensions Figure A Power Module Component Layout Figure A Power Module Dimensions Figure A Power Module Component Layout Figure A Power Module Dimensions Figure 3.1 Area Available for Conduit Entry (Top View of Leftmost Bay) Figure 3.2 Field Terminal Wiring Figure 3.3 Drive I/O Connections (TB4) Figure 3.4 Resolver and Analog Input Connections (TB5) Figure 3.5 Meter Port Connections (TB6) Figure 3.6 SD3100 Grounding 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 A and 1650A Power Modules (Non-Regenerative), Sheet 1...B-2 Figure B A and 1650A Power Modules (Non-Regenerative), Sheet 2...B-3 Figure B A and 1650A Power Modules (Regenerative), Sheet 1...B-4 Figure B A and 1650A Power Modules (Regenerative), Sheet 2...B-5 Figure B A Power Module (Regenerative), Sheet 1...B-6 Figure B A Power Module (Regenerative), Sheet 2...B-7 Table of Contents III

6 IV SD3100 Power Modules

7 List of Tables Table 1.1 SD3100 Drive Options Table 1.2 Field Power Module Part Numbers Table 1.3 Distributed Power System DC Drives Documentation Table 1.4 Related Motor Control Center Documentation Table A Configurations Table A Power Module Symbol-to-Component Reference Table A Configurations Table A Power Module Symbol-to-Component Reference Table A Configurations Table A Power Module Symbol-to-Component Reference Table 3.1 Recommended AC Input Wiring Table 3.2 Isolation Transformer Wiring Requirements Table 3.3 Armature Wire Selection Table 3.4 Field Wire Selection Table 4.1 Field Power Module Input Fuses 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

8 VI SD3100 Power Modules

9 CHAPTER 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 Number AC Input Voltage1 HP Unit 2 4 Configuration Enclosure Options SD3100 B 64 N AA B = 460 VAC C = 575 VAC F = 660 VAC 64 = 700 HP 65 = 750 HP 66 = 800 HP 67 = 900 HP 68 = 1000 HP 69 = 1250 HP 70 = 1500 HP 71 = 1750 HP 72 = 2000 HP 73 = 2250 HP 74 = 2500 HP N = Non-regenerative, 6-pulse R = Regenerative, 6-pulse 3 AA = NEMA Type 1 without gaskets and door fan filters AJ = NEMA Type 1 with gaskets and door fan filters Refer to table 1.1, SD3100 Drive Options. 1. A separately-ordered, separately-mounted 7.5 to 25kVA field isolation transformer is required. See section Units accommodate top entry and bottom exit. An additional section is required for 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

10 Table 1.1 SD3100 Drive Options Drive Option Code Description 6P Standard capacity control transformer with primary fusing Control Power Source 1 6TB 115 VAC control power, factory wired from 115 VAC control bus to drive unit (1250 and 1650A units only). Requires option CB90 6SC 115 VAC control power supplied by others Dynamic Braking Contactor 2 14DB Dynamic braking contactor option Unit Door Nameplate 1 M3EW White background with black lettering; phenolic label Miscellaneous Auxiliary Contacts Blower Starters 5, 6 14WLBL Brady Datab wire labels 3 J12 15 VDC, 15A duplex receptacle, user-wired 4 J11 989X 14BN 14B2N 14B2NX 14BI 14B2I 14B2IX Audio phone jack (2) normally open and (2) normally closed contactors mounted internally in 1250/1650A unit, or (4) normally open and (4) normally closed contactors mounted internally in 3000A unit (1) NEMA 1 FVNR starter assembly internally mounted with 30A fuse blocks (2) NEMA 1 FVNR starter assemblies internally mounted with 30A fuse blocks (2) NEMA 2 FVNR starter assemblies internally mounted with 60A fuse blocks (1) IEC 24A starter assembly internally mounted with 30A fuse blocks (2) IEC 24A starter assemblies internally mounted with 30A fuse blocks (2) IEC 30A starter assemblies internally mounted with 60A fuse blocks 14LSP Line RC suppressor module 7 Protection 14AFL Air flow loss switches Field Supply Upgrade 8, 9 14FX Field supply upgrade for fields requiring 15 to 60A Incoming Protection 1 CM Circuit breaker LF Line fuses Horizontal Power Bus 5 HB A AC power bus for 1250 and 1650A units with 460 or 575 VAC inputs HB A AC power bus for 1250A units with 460 or575 VAC inputs HB A AC power bus for 1250 and 1650A units with 460 or 575 VAC inputs Horizontal Control Bus CB90 Input Option 14HBC 90A AC control bus for 1250 and 1650A units that have a horizontal power bus option AC power input is wired from the horizontal thru-bus to the circuit breaker/line fuses for 1250 and 1650A units that have a horizontal power bus option 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. 1-2 SD3100 Power Modules

11 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 Power 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 Standard Features Table 1.2 Field Power Module Part Numbers Part No. Amps AC Input Description Mounting R / 460 VAC Reversing (S2R) Integral R / 460 VAC Reversing (S2R) Integral 1. For application information see instruction manual S 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 Power through-bus (1250A and 1650A Power Modules) Introduction 1-3

12 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

13 Installation of the motor control center (MCC) is described in the manuals listed in table 1.4. 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 Table 1.4 Related Motor Control Center Documentation Publication Number Description Instructions - Receiving, Handling, And Storing Motor Control Centers Bulletin 2300 Family of Drive Systems Hardware The terms listed in this section have the specific meanings given below when they appear in this manual. Application - The process for which the combination of hardware and control software is being used. Armature Power Module - the power structure containing the three-phase SCR power bridge and related hardware components used to control the armature current. Diagnostic - a software routine or hardware circuit specifically designed to check for error conditions. Drive - the combination of a UDC, a PMI, a Field Power Module, and an Armature Power Module as a means or apparatus for transmitting motion to a machine or machine part. Drive warning - a potentially hazardous or undesirable operating condition checked 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 - any operating condition other than the desired one. Drive fault - an error, specifically checked for by the PMI Processor operating system, that will shut down the drive. Drive faults are reported in register 202/1202 in the UDC. Field Power Module - a single-phase power unit, used to supply the motor field. The Field Power Module is integrally mounted within the SD3100 Power Module. Non-regenerative drive - a drive capable of motoring operation only (S6 configuration). Regenerative drive - a drive capable of motoring or regenerating operation, forward or reverse (S6R configuration). Introduction 1-5

14 1-6 SD3100 Power Modules

15 CHAPTER 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. LINE FUSES OR CIRCUIT BREAKER CURRENT XFMRS FU-A FU-B EXTERNAL FIELD ISO XFMR L1 L2 L3 RESISTOR SCALING MODULE DELTA/WYE PHASING XFMR L1 L2 L3 FIELD POWER MODULE FROM DC ARMATURE FWD GATE SIGNALS TO P4/ DCPT SCALING UNIT ARMATURE FEEDBACK REV GATE SIGNALS GATE COUPLING CIRCUITS + FWD GATE SIGNALS REV GATE SIGNALS TO FIELD POWER MODULE 115 VAC ARMATURE POWER STRUCTURE (S6R) DC MOTOR PMI RACK PGA RACK RESOLVER DRIVE I/O RESOLVER FEEDBACK TO RESISTOR SCALING UNIT Figure 2.1 SD3100 Power Module System Components Mechanical/Electrical Description 2-1

16 2.1 Mechanical Overview The SD3100 Power Module is composed of the basic components shown in figure 2.1. These components consist of: Control components that provide the interface to the AutoMax Distributed Power System and control for the Power Module, and Power components that convert AC line power to DC power for the motor 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 FU-B FIELD ISOLATION XFRM FUSES SCALING UNIT TB1 PMI RACK FIELD POWER MODULE PGA RACK TB2 TB3 TB4 TB5 TB6 FWD REV TO GATE COUPLERS Figure 2.2 Regulator Assembly 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 Power 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

17 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. Terminal 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 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 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: Failure to use an input isolation device may result in damage to the Power Module during regeneration. Mechanical/Electrical Description 2-3

18 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 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 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

19 The non-regenerative bridge is shown in figure 2.3. Cell fuses protect the thyristors in the event of a bridge failure. Main Contactor SNUBBER *&& SNUBBER *&& SNUBBER *&& A1 3-Phase AC Input Armature Voltage SNUBBER *&& *&& *&& SNUBBER SNUBBER A2 Figure 2.3 Armature Bridge (Non-Regenerative) Mechanical/Electrical Description 2-5

20 The regenerative bridge, shown in figure 2.4, allows the bridge to direct regenerated power back onto the incoming lines. Main Contactor SNUBBER *&& SNUBBER *&& SNUBBER *&& A1 *&& *&& *&& 3-Phase AC Input Armature Voltage *&& *&& *&& SNUBBER *&& SNUBBER *&& SNUBBER *&& A2 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 Figure 2.4 Armature Bridge (Regenerative) 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. 2-6 SD3100 Power Modules

21 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 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. $ ILHOG FODPS DVVHPEO\ LV SURYLGHG WR PRQLWRU WKH YROWDJH EHWZHHQ WKH )LHOG 3RZHU 0RGXOH V RXWSXW WHUPLQDOV DQG,I DQ RYHUYROWDJH RFFXUV WKH ILHOG FODPS ILUHV D FURZEDU 6&5 WKDW VDIHO\ GLVVLSDWHV WKH HQHUJ\ LQ WKH ILHOG 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

22 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 SD3100 Power Modules

23 A Power Module Description Table A Configurations Input Voltage (VAC) Output HP 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

24 A Power Module Component Layout PP1 PP2 PP3 CB11* or F51* F52* F53* A14R A11F A16R A13F A12R A15F M1 F12 F12A F11 F11A F10 F10A SP1 SP2 SP3 SP4 ACT1 F31, F32, F33 L1 L2 L3 * EA4 * ACT3 F1, F2, F3 F9 F9A F8 F8A F7 F7A D1 MP R1 F17, F18, F19 M11 * * F27, F28, F29 * * M12 FU-A FU-B SCALING UNIT TB1 A14F A16F A12F A11R A13R A15R F16 F14 F14 F15 F15 PMI RACK TB1- FAN PP4 PP5 PP6 A2(-) A1(+) FIELD SUPPLY PGA RACK TB2 TB6 TB3 TB4 TB5 FWD REV PT2 'LVFRQQHFW %D\ %ULGJH %D\ &RQWDFWRU %D\ Figure A Power Module Component Layout 2-10 SD3100 Power Modules

25 Table A 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 A, 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 Armature bridge cell fuses $ 9 0 F14, F15 Control power transformer, primary fuses $./'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 Forward gate connector Reverse gate connector 15A unit: 30A, 700V 60A unit: 100A, 700V FWD REV M1 DC armature contactor 1800A M11, M12 Blower motor starters MP Main pilot for pilot relay PP1-6 Armature power poles PT2 Control transformer 2kVA 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-FAN 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 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

26 A Power Module Dimensions 20 inches (508 mm) 91.5 inches (2324 mm) 20 inches (508 mm) 20 inches (508 mm) 35 inches (889 mm) 20 inches (508 mm) 20 inches (508 mm) Figure A Power Module Dimensions For other details on the 1250A Power Module and its components, please refer to the appendices of this manual SD3100 Power Modules

27 A Power Module Description Table A Configurations Input Voltage (VAC) Output HP 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

28 A Power Module Component Layout PP1 PP2 PP3 CB11* or F51* F52* F53* A14R A11F A16R A13F A12R A15F M1 F12 F12A F11 F11A F10 F10A SP1 SP2 SP3 SP4 ACT1 F31, F32, F33 L1 L2 L3 * EA4 * ACT3 F1, F2, F3 F9 F9A F8 F8A F7 F7A D1 MP R1 F17, F18, F19 M11 * * F27, F28, F29 * * M12 FU-A FU-B SCALING UNIT TB1 A14F A16F A12F A11R A13R A15R F16 F14 F14 F15 F15 PMI RACK TB1- FAN PP4 PP5 PP6 A2(-) A1(+) FIELD SUPPLY PGA RACK TB2 TB6 TB3 TB4 TB5 FWD REV PT2 'LVFRQQHFW %D\ %ULGJH %D\ &RQWDFWRU %D\ Figure A Power Module Component Layout 2-14 SD3100 Power Modules

29 Table A 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 Armature bridge cell fuses $ 9 0 F14, F15 Control power transformer, primary fuses $./'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 Forward gate connector Reverse gate connector 15A unit: 30A, 700V 60A unit: 100A, 700V FWD REV M1 DC armature contactor 3000A M11, M12 Motor blower 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, 680VAC 760J, 680VAC 1050J, 750VAC TB1-FAN 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

30 A Power Module Dimensions 20 inches (508 mm) 91.5 inches (2324 mm) 20 inches (508 mm) 20 inches (508 mm) 35 inches (889 mm) 20 inches (508 mm) 20 inches (508 mm) Figure A Power Module Dimensions For other details on the 1650A Power Module and its components, please refer to the appendices of this manual SD3100 Power Modules

31 A Power Module Description Table A Configurations Input Voltage (VAC) Output HP 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

32 A Power Module Component Layout F11 PP1 PP2 PP3 CB11* or F51* F52* F53* F10 F12 M1 S1 S2 S3 L1A L2A L3A ACT1 ACT3 A14R A11F A16R A13F A12R A15F FU-A SP1 SP2 SP3 SP4 FU-B SCALING UNIT F1, F2, F3 TB1 F7 F8 F9 PP4 PP5 PP6 S1A S2A S3A MP F17 F18 F19 R1 M11 F27 F28 F29 M12 F14 F15 PMI RACK F16 A11R A14F A13R A16F A15R A12F F14 F15 FAN1 FIELD SUPPLY PGA RACK A2(-) A1(+) TB2 TB6 TB3 TB4 TB5 FWD REV FAN2-C1 FAN2 PT2 'LVFRQQHFW %D\ )XVH %D\ %ULGJH %D\ &RQWDFWRU %D\ Figure A Power Module Component Layout 2-18 SD3100 Power Modules

33 Table A 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-frame 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 $ 9 0 F14, F15 Control power transformer, primary fuses $./'5 9 F16 Control power xfmr, secondary fuse 9A KLDR, 600V F17 - F19, Blower motor fuses F27 - F29 FU-A, FU-B External field isolation transformer fuses Forward gate connector Reverse gate connector 15A unit: 30A, 700V 60A unit: 100A, 700V 10A, 1500V Form 101-Type 4 FWD REV 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, 680VAC 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 terminal block TB6 Meter ports connector Mechanical/Electrical Description 2-19

34 A Power Module Dimensions 20 inches (508 mm) 91.5 inches (2324 mm) 20 inches (508 mm) 20 inches (508 mm) 20 inches (508 mm) 35 inches (889 mm) 20 inches (508 mm) 20 inches (508 mm) Figure A 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

35 CHAPTER 3 Installation Guidelines! 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. 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. 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. Installation Guidelines 3-1

36 3.2 Physically Installing the Power Module! ATTENTION: The Power Module is at line voltage when connected to incoming AC power. Disconnect, lock out, and tag all incoming power to the drive before performing the following procedures. Failure to observe this precaution could result in severe bodily injury or loss of life. To move and position the unit at your site, follow the instructions given in publication , titled Instructions - Receiving, Handling, And Storing Motor Control Centers. 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 , titled Bulletin 2300 Family of Drive Systems Hardware. This 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). 3.3 Wiring AC Input Power to the Power Module! 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. To wire AC input power to the Power Module, you will need to do the following: install an isolation transformer select and provide appropriate input 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 D Refer to figure 2.5 (1250A units), figure 2.7 (1650A units), or figure 2.9 (3000A units) for component and terminal locations 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. DC Bus Current (Amps) Table 3.1 Recommended AC Input Wiring Incoming Wires (For Each Phase or Connection, AWG) kcmil kcmil kcmil 3-2 SD3100 Power Modules

37 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. 1.25" 20.00" (Back of Enclosure) 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) 11.50" Area Available For Conduit Entry 1.14" 17.72" 20.00" (Front of Enclosure) c 3000A units allow a depth of 16.75" for conduit entry. Figure 3.1 Area Available for Conduit Entry (Top View of Leftmost Bay) Step 1. Step 2. Remove the lifting angle, if it is still attached. 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. Step 4. Step 5. Replace the top plate on the drive. Replace the lifting angle 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. Step 2. Step 3. Thread the input wires through the entry hole on the top of your drive. Fasten the input wires for each phase onto the appropriate phase busbar (see the busbar illustrations shown in Appendix A). Torque all bolts to 45 lb-ft. Installation Guidelines 3-3

38 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 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. Field Power Module (Amps) Table 3.2 Isolation Transformer Wiring Requirements Isolation Transformer Fuse Rating (Maximum Amps) Minimum Required Wire Size (AWG) # #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 L1A L3A TERMINAL BLOCK TB2 TO MOTOR FIELD + H1 H2 FIELD ISOLATION TRANSFORMER X1 X2 Figure 3.2 Field Terminal Wiring 3-4 SD3100 Power Modules