Distributed Power System High Power SA3000 AC Power ......Instruction Manual Distributed Power...

Instruction Manual

Distributed Power SystemHigh Power SA3000AC Power Modules

850020 – 11xxx, 21xxx (534 Amp)

850020 – 12xxx, 22xxx (972 Amp)

850020 – 13xxx, 23xxx (1457 Amp)

S-3038

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

AutoMax™ is a trademark of Rockwell Automation

©1998 Rockwell International Corporation

Throughout this manual, the following notes are used to alert you to safety considerations:

Important: Identifies information that is critical for successful application and understanding of the product.

!ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

!ATTENTION: Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors to discharge. Open the cabinet doors and check the voltage across the DC bus bars, 347 A,B,C (+ bus) and 345 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

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

ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Table of Contents I

CONTENTS

Chapter 1 Introduction1.1 Standard Features........................................................................................... 1-11.2 Optional Features ............................................................................................ 1-21.3 Power Module Part Numbers .......................................................................... 1-31.4 Related Publications........................................................................................ 1-41.5 Related Hardware and Software ..................................................................... 1-4

Chapter 2 Mechanical/Electrical Description2.1 Mechanical Description ................................................................................... 2-1

2.1.1 Power Module Components .................................................................. 2-12.2 Electrical Description ....................................................................................... 2-6

Chapter 3 Installation Guidelines3.1 Installation Planning ........................................................................................ 3-13.2 Wiring .............................................................................................................. 3-2

3.2.1 Fuses .................................................................................................... 3-23.2.2 Wire Sizes ............................................................................................. 3-23.2.3 Wire Routing ......................................................................................... 3-3

3.3 Grounding........................................................................................................ 3-33.4 Installing the Power Module Cabinet ............................................................... 3-3

Chapter 4 Diagnostics and Troubleshooting4.1 Required Test Equipment ................................................................................ 4-14.2 Power Module Tests with Input Power Off ...................................................... 4-24.3 Power Module Faults and Warnings................................................................ 4-4

4.3.1 Power Module Faults ............................................................................ 4-54.3.1.1 DC Bus Overvoltage Fault ...................................................... 4-54.3.1.2 DC Bus Overcurrent Fault....................................................... 4-54.3.1.3 Ground Current Fault .............................................................. 4-54.3.1.4 Instantaneous Overcurrent Fault ............................................ 4-64.3.1.5 Local Power Interface Fault .................................................... 4-64.3.1.6 Charge Bus Time-Out Fault .................................................... 4-64.3.1.7 Overtemperature Fault ............................................................ 4-6

4.3.2 Power Module Warnings ....................................................................... 4-74.3.2.1 DC Bus Overvoltage Warning................................................. 4-74.3.2.2 DC Bus Undervoltage Warning............................................... 4-74.3.2.3 Ground Current Warning......................................................... 4-74.3.2.4 Load Sharing Warning ............................................................ 4-74.3.2.5 Overtemperature Warning ...................................................... 4-8

4.4 Replacing Power Module Fuses and Sub-Assemblies .................................... 4-84.4.1 Replacing Fuses ................................................................................... 4-84.4.2 Replacing an IGBT Phase Module Assembly ..................................... 4-15

4.4.2.1 Replacing an IGBT................................................................ 4-174.4.3 Replacing the Pre-charge Assembly ................................................... 4-174.4.4 Replacing a Blower Assembly............................................................. 4-18

4.4.4.1 Replacing a Blower Filter ...................................................... 4-194.4.5 Replacing a Bus Capacitor Assembly ................................................. 4-19

4.5 Replacing the Power Module Cabinet ........................................................... 4-20

II High Power SA3000 AC Power Modules

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

Appendix B SA3000 Internal DC Bus Control ............................................................................. B-1

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

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

Table of Contents III

List of Figures

Figure 1.1 – SA3000 Power Module Part Numbering Scheme ................................ 1-3

Figure 2.1 – 534A SA3000 Power Module Components .......................................... 2-3Figure 2.2 – 972A 3000A Power Module Components ............................................ 2-4Figure 2.3 – 1457A SA3000 Power Module Components ........................................ 2-5Figure 2.4 – Drive I/O and Processor Card Detail .................................................... 2-8Figure 2.5 – 534A SA3000 Power Module Circuitry ................................................. 2-9Figure 2.6 – 972A SA3000 Power Module Circuitry ............................................... 2-10Figure 2.7 – 1457A SA3000 Power Module Circuitry ............................................. 2-11

Figure 3.1 – 534A Power Module Mounting Dimensions (Single-Bay)..................... 3-4Figure 3.2 – 972A Power Module Mounting Dimensions (Double-Bay) ................... 3-5Figure 3.3 – 1457A Power Module Mounting Dimensions (Triple-Bay).................... 3-6Figure 3.4 – SA3000 Power and Ground Connections............................................. 3-7

Figure 4.1 – DC Bus Voltage Measuring Points ....................................................... 4-3Figure 4.2 – 534A SA3000 Power Module Fuse Locations.................................... 4-10Figure 4.3 – 972A SA3000 Power Module Fuse Locations.................................... 4-11Figure 4.4 – 1457A SA3000 Power Module Fuse Locations .................................. 4-12Figure 4.5 – 115VAC Control Power Supply Assemblies ....................................... 4-13Figure 4.6 – 25 KHz. Power Supply........................................................................ 4-14Figure 4.7 – IGBT Module Assembly Mounting Bolt Locations .............................. 4-17

IV High Power SA3000 AC Power Modules

Table of Contents V

List of Tables

Table 1.1 – SA3000 Power Module Configurations.................................................. 1-1Table 1.2 – SA3000 Documentation (Binder S-3001) .............................................. 1-4

Table 3.1 – Fuse Ratings.......................................................................................... 3-2Table 3.2 – Recommended DC Bus Input and AC Output Wire Sizes ..................... 3-2Table 3.3 – Terminal Tightening Torques................................................................. 3-3

Table 4.1 – DC Bus and Terminal Tests................................................................... 4-4Table 4.2 – IGBT Tests............................................................................................. 4-4Table 4.3 – SA3000 Power Module Faults (Register 202/1202) .............................. 4-5Table 4.4 – SA3000 Warning Register 203 /1203 .................................................... 4-7Table 4.5 – Power Module Replacement Fuse Specifications ................................. 4-9

VI High Power SA3000 AC Power Modules

Introduction 1-1

CHAPTER 1Introduction

The High Power SA3000 Power Modules are variable-voltage, variable-frequency power inverters for Distributed Power System (DPS) drives. They are designed to operate from a separate converter (diode bridge, phase-controlled rectifier, SB3000 Synchronous Rectifier, or a common DC bus supply) to drive induction motors at variable speeds using pulse-width modulation (PWM) technology.

The SA3000 Power Modules are configured in three output current ratings: 534 amp, 972 amp, and 1457 amp when used at a 2 kHz carrier frequency. They have a range of AC Input voltage ratings. See table 1.1. Nominal DC bus voltage may range from 300 to 800 VDC.

4 kHz operation requires a derating of the AC input current and DC output load current when compared with operation at 2 kHz. See table 1.1.

The SA3000 Power Module output current ratings given are 100% continuous with no overload. They may be derated for lower current ratings with overload capability.

1.1 Standard Features

High Power SA3000 Power Modules have the following standard features:

• IGBT power semiconductor bridge

• Carrier switching frequencies from 2 to 4 kHz

• Input and output short-circuit protection

• Fiber-optic communication with the DPS host, the Universal Drive Controller (UDC) module

Table 1.1 – SA3000 Power Module Configurations

Base PartNumber

Cabinet Type

DC Bus Input Volts

Output Amps

(2 KHz)

Output Amps 1

(4 KHz)Peak

Amps 2AC Input

Volts

850020-11xxx850020-21xxx

One Bay 250-820V3 534A 445A 700A 230-460V

850020-12xxx850020-22xxx

Two Bays 250-820V 972A 890A 1275A 230-460V

850020-13xxx850020-23xxx

Three Bays 250-820V 1457A 1335A 1900A 230-460V

1. Output current ratings at 40° C (104° F) ambient air temperature and 60 Hz. Reduce all output current ratings by 5% when the Power Module blowers are operated from a 50 Hz power source.

2. Contact Rockwell Automation for duty cycle ratings.3. 800 VDC if an SA3000/SA3100 unit is used to supply 575 VAC output to the motor.

1-2 High Power SA3000 AC Power Modules

• Auto-tuning

• Standard cabinet paint

1.2 Optional Features

The following optional features are available for High Power SA3000 Power Modules

• DC bus voltage meter

• Motor ammeter

• Motor voltmeter

• Motor torque meter

• Motor frequency meter

• Main disconnect

• Pre-charge

• Separation of critical and non-critical 115 VAC control power

• DC bus top hat enclosure

• Custom cabinet paint

Introduction 1-3

1.3 Power Module Part Numbers

SA3000 Power Module part numbers are organized by the number of cabinet bays, i.e., single (534A), double (972A), or triple (1457A) cabinet bay configurations, in combination with the supplied options. See figure 1.1.

Figure 1.1 – SA3000 Power Module Part Numbering Scheme

850020 - 1 1 R S T

Meters: T = Supplied - Standard Cabinet PaintY = Supplied - Custom Cabinet PaintX = Not Supplied - Standard Cabinet PaintZ = Not Supplied - Custom Cabinet Paint

Pre-charge: S = Supplied - Standard Cabinet PaintW = Supplied - Custom Cabinet PaintX = Not Supplied - Standard Cabinet PaintZ = Not Supplied - Custom Cabinet Paint

Main R = Supplied - Standard Cabinet PaintV = Supplied - Custom Cabinet PaintX = Not Supplied - Standard Cabinet PaintZ = Not Supplied - Custom Cabinet Paint

Disconnect:

Size of Unit 1 = 534A Output - 1 Bay Unit2 = 972A Output - 2 Bay Unit3 = 1457A Output - 3 Bay Unit

Cabinet Top 1 = DC Bus Assembly Enclosure2 = DC Bus Top Hat EnclosureEnclosures:

SA3000 Power Module - Base Part Number

(1)

1. Top Hat Enclosure accommodates bending radius of DC bus cable (customer supplied).


1.4 Related Publications

This manual describes the hardware components of the SA3000 Inverter Power Module. The other instruction manuals in binder S-3001 describe the SA3000 software, regulator, and communications. Table 1.1 lists the document part numbers.

SA3000 Power Modules are designed to be operated from a common DC bus, which can be supplied by a Distributed Power System SB3000 Synchronous Rectifier. Refer to the following manuals for information on the SB3000 Synchronous Rectifier system:

• S-3034 SB3000 Synchronous Rectifier Configuration and Programming

• S-3043 High Power SB3000 Power Modules

1.5 Related Hardware and Software

The following related hardware may be purchased separately:

• P/N 613613-xxS Fiber-optic cable (cable length xx is specified in meters)

• B/M O-57552 Universal Drive Controller (UDC) module

• B/M O-57652 Universal Drive Controller (UDC) module EM

Table 1.2 – SA3000 Documentation (Binder S-3001)

Document Document Part Number

SA3000 Information Guide S-3023

Drive System Overview S-3005

Universal Drive Controller Module S-3007

Fiber Optic Cabling S-3009

SA3000 Drive Configuration & Programming S-3016

SA3000 Power Module Interface Rack and Modules S-3019

Medium Power SA3000 Power Modules S-3020

SA300 Diagnostics, Troubleshooting, & Start-Up Guidelines

S-3021

High Power SA3000 Power Modules S-3038

Mechanical/Electrical Description 2-1

CHAPTER 2Mechanical/Electrical Description

This chapter provides an overview the SA3000 Power Module’s main components and their mechanical and electrical characteristics.

2.1 Mechanical Description

The High Power SA3000 Power Modules are variable-voltage, variable-frequency inverters that are housed in protective sheet metal enclosures. The Power Modules are supplied in single, double, and triple bay cabinet configurations, depending upon the current rating. See figures 2.1 to 2.3. Power Module dimensions are shown in figures 3.1 to 3.3.

2.1.1 Power Module Components

The Power Modules have the following main components:

Phase modules

Each Phase module contains four semiconductor IGBTs (insulated gate bi-polar transistors). IGBT pairs are switched on and off by the integrated Snubber/Gate Driver module to provide modulated phase voltages (U,V,W) to the motor. Fuses and thermostats are provided to protect the IGBT modules.

Snubber/Gate Driver Module

Each Snubber/Gate Driver module, mounted on the IGBT phase module, receives gating signals via fiber-optic cabling from the GDI module(s) in the PMI rack and translates the signals into the appropriate voltage and current levels to turn the IGBTs on and off. Feedback, indicating the integrity of the phase module and IGBTs, is then sent back to the GDI module(s).

This module also provides snubber circuitry (resistors, diodes, and capacitors) to control voltage overshoot and undershoot when the IGBTs are switching.

Fiber-Optic Communication

Fiber-optic cabling is used to transmit gate driver signals from the Gate Driver Interface (GDI) module.These signals are used to turn the IGBTs on and off. IGBT module feedback status information is sent via the fiber-optic cabling back to the GDI module(s) in the PMI rack. Fiber-optic cabling is immune to electromagnetic and radio frequency interference (EMI/RFI) and eliminates ground loops. For more information on fiber-optic cabling refer to the Distributed Power System Fiber-Optic Cabling instruction manual (S-3009).


Local Power Interface module (LPI)

The LPI module is the interface between the SA3000 Power Module and the PMI rack. It is through this module that information is sent to the SA3000 Power Module and feedback data is sent back to the PMI rack.

Capacitor Bank Assembly

The capacitor bank's electrolytic capacitors store power locally for the IGBTs.

115 VAC Power Supply Assembly

Power Supply Assembly P/N 850100-3S allows for the separation of critical (PMI rack, 25 KHz power supply, DC power supplies) and non-critical (blower motors) 115 VAC power via two 115 VAC terminal boards and two 25A circuit breakers. Removing the jumper wires between the two terminal boards provides the separation of critical and non-critical power. The circuit breakers can be locked in either the ON or OFF position when the optional locking mechanism is used.

Power Supply Assembly P/N 850100-3R provides one 115 VAC terminal board and one 25A circuit breaker. This assembly distributes 115 VAC power to the DC power supplies, the 25 KHz power supply, the PMI rack, and the Power Module blowers. See figure 4.5.

25 KHz Power Supply Assembly

The 25 KHz Power Supply Assembly provides power to the six IGBT gate drivers in each Power Module. 25KHz AC power is used for transformer isolation and noise immunity. Input power is provided by the 115 VAC power supply. See figure 4.6.

DC Bus Voltage Meter (Option)

The DC Bus Voltage meter, which is connected directly across the DC bus, measures the DC bus voltage being applied to the power module.

Output Meters (Option)

These meters measure the AC voltage (0-600V), current (0-200 percent of full load), torque (200-0-200 percent of full load), and frequency (120-0-120Hz) being applied to the motor. These meters are connected to the PMI Processor’s meter ports, which are under software control.

Main Disconnect (Option)

Depending on system requirements, a DC input disconnect may be provided. Note that if a disconnect is supplied, the pre-charge assembly option must also be used if the Power Module is operating from a constant potential DC bus supply.

Pre-charge Assembly (Option)

The Pre-charge Assembly consists of a contactor, pre-charge resistors, and a printed circuit board assembly. The contactor bypasses the pre-charge resistor after the bus voltage reaches a programmable threshold value. A pre-charge control module communicates with the LPI module and controls the pre-charge contactor.


1. Blower Assembly 2. IGBT Phase Module Assembly 3. Capacitor Bank Assembly4. Pre-charge Assembly 5. DC Disconnect Assembly1

1. Optional

6. DC bus fuse7. +/- 15V DC Power Supply 8. 24V DC Power Supplies 9. 115VAC C.B. - Non Critical Pwr10. Local Power Interface Module 11. 250VA Isolation Transformer 12. Power Module Interface Rack13. 25KHz Power Supply 14. Reactor Assembly 15. LEM Output Current Sensor16. Control Fuse (1FU) 17. Control Fuse (3FU) 18. DC Feedback Module19. 115VAC C.B. - Critical Power 20. Blower Filter 21. Motor Feedback Resistors22. Power Supply Assembly 23. Door Interlock Bypass Switch 1 24. DC Bus Voltage Meter1

25. Motor Ammeter1 26. Motor Voltmeter1 27. Motor Torque Meter1

28. Motor Frequency1

Figure 2.1 – 534A SA3000 Power Module Components

POWER MODULE A

DISCONNECT SWITCH

22

PHASE U

PMI RACK

ASSEMBLY

PHASE W

PHASE V

PRE-CHARGE ASSEMBLY

BANK

AC MOTOR OUTPUT

FP

MA

F103

F105

F104

SLO

T 6

PW

R. M

OD

. A

GDI

U V W

CUSTOMER CONTROL WIRING

20

25KHZ PS

12

NAMEPLATESALES ORDER

28

23

14MOTOR

GRDMOTOR

GRD

5

6

BLOWER

LPIMODULE

15

15

15

133

101

2

4

2

2

26

24

CAPACITOR

18

DOOR OF POWER MODULE A.

PANEL IS MOUNTED IN THE CABINET

IF USED, THE OUTPUT METER

25

27

OUTPUT METER PANEL(OPTIONAL)

CB

1

±15VPS 3F

U1F

U±15VPS

1CB

1

PS+24V

PS-24V

PS PS

8

9

19

11

17

16

7



1. Optional




Figure 2.2 – 972A 3000A Power Module Components

BA

NK

CA

PA

CIT

OR

CA

PA

CIT

OR

BA

NK

18

POWER MODULE APOWER MODULE B

7

16

17

11

19

9

8

5

22

DISCONNECT SWITCH

CB

1

±15VPS 3

FU

1F

U±15V

1CB

1

PS+24V

PS-24V+24V

PS PS

21

PHASE U

ASSEMBLY

PHASE W

PHASE V

PRE-CHARGE ASSEMBLY

AC MOTOR OUTPUT

F103

F105

F104

U V W

20

14

MOTORGRD

MOTORGRD

BLOWER

15

15

15

3

1

2

4

2

2 2

2

4

2

110

3

13

15

15

MODULELPI

BLOWER

--

6

GRDMOTOR

14

SALES ORDERNAMEPLATE

12

25KHZ PS

20

CUSTOMER

GDIGDI

PW

R. M

OD

. B

PW

R. M

OD

. A

SLO

T 7

SLO

T 6

F104

F105

F103

PRECHARGE ASSEMBLY

PHASE V

PHASE W

ASSEMBLY

PMI RACK

PHASE U

FP

MA

FP

MB

CONTROL WIRING

28

23

26

24

25

27



IF USED, THE OUTPUT METER

15

PANEL IS MOUNTED IN THE CABINET



1. Optional




Figure 2.3 – 1457A SA3000 Power Module Components

28

23

26

24

25

27

33 3

BA

NK

CA

PA

CIT

OR

BA

NK

CA

PA

CIT

OR

BA

NK

CA

PA

CIT

OR

POWER MODULE APOWER MODULE BPOWER MODULE C

7

16

17

11

19

9

8

5

22

DISCONNECT SWITCH

ASSEMBLYBLOWER

CB

1

±15VPS 3F

U1F

U±15V

1CB

1

PS+24V

PS-24V+24V

PS PS

WIRING

FP

MA

PHASE U

PMI RACK

ASSEMBLY

PHASE W

PHASE V

PRE-CHARGE ASSEMBLY

F103

F105

F104

SLO

T 6

SLO

T 7

PW

R. M

OD

. A

PW

R. M

OD

. B

GDIGDI

CUSTOMER CONTROL

20

25KHZ PS

12

NAMEPLATESALES ORDER

216

BLOWER

LPIMODULE

15

15

15

13

101

2

4

2

22

2

4

2

1BLOWER

GRDMOTOR

GRDMOTOR

WVU

F104

F105

F103

AC MOTOR OUTPUT

PRE-CHARGE ASSEMBLY

PHASE V

PHASE W

ASSEMBLY

PHASE UPHASE U

PHASE W

PHASE V

PRE-CHARGE ASSEMBLY

F103

F105

F104

1

2

4

2

215

15

15

2020

14

15

15

15

SLO

T 8

GDI

PW

R.

MO

D.

C

14 14

18

FP

MB

FP

MC



IF USED, THE OUTPUT METERPANEL IS MOUNTED IN THE CABINET


2.2 Electrical Description

DC bus input power is applied to the Power Module through terminals 45 (–) and 47 (+), passes through the optional DC bus disconnect and in-line fuses, and is then fed to the optional pre-charge circuitry. See figures 2.4 to 2.7.

When pre-charge circuitry is present and DC input power is applied, the internal DC bus begins charging through the pre-charge resistors. Once the DC bus capacitors are fully charged (per the programmable threshold value) and all pre-charge criteria are met, the internal pre-charge contactor closes and bypasses the pre-charge resistors. If the DC bus disconnect option is not used, the bus supply is responsible for the charging operation. Refer to Appendix B for additional information on SA3000 internal DC bus control.

The DC bus voltage is filtered and stored by the electrolytic capacitors. Discharge resistors are designed to discharge the capacitors down to 50 VDC within 5 minutes after power is removed from the input terminals. However, if a DC bus fuse has blown, it is possible for a charge to be stored on the DC bus capacitors without being indicated on the DC bus voltmeter. Wait 10 minutes before working on the unit. Be sure to measure the DC bus potential of each Power Module capacitor bank before touching any internal circuitry. See figure 4.1 for test point locations.

When the DC bus operating voltage is reached, the connected Inverter Power Modules may be operated. Note that if an SB3000 Power Module is used to supply the DC bus, the SB3000 Power Module cannot support the loading of SA3000 Inverter Power Modules when the soft-charge resistors in the SB3000 are limiting the bus charging current.

The SA3000 inverter power circuitry uses the filtered DC bus voltage to provide the variable-voltage, variable-frequency output to the motor (terminals U, V, W). The 972 Amp and 1457 Amp units have reactors for load sharing on their outputs. The IGBTs are switched by the gate drivers on the IGBT phase module under the control of the PMI rack. A LEM sensor is located on each output phase (U,V,W) of each SA3000 Inverter Power Module (A,B, or C) to provide output current feedback for overcurrent protection.

!ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors to discharge. Open the cabinet doors and check the voltage across the DC bus bars, 347 A,B,C (+ bus) and 345 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

!ATTENTION: When used with an SB3000 bus supply, the SA3000 Power Module must be in standby or in regeneration whenever the SB3000 Power Module’ s pre-charge contactor opens. The SB3000 Power Module’s soft-charge resistors may fail if this interlocking restriction is not observed. Failure to observe this precaution could result in damage to, or destruction of, the equipment.


Each SA3000 Inverter Power Module connected to an SB3000 Power Modulesupplied DC bus must have a separate pre-charge resistor and contactor to limit the current into its capacitor bank. It is the responsibility of the application tasks to make sure that the SB3000 Power Module is in run before the SA3000 Inverter Power Module is put into run.

If the SB3000 Power Module is not in run, the DC bus voltage will not be high enough to support the full rating of the SA3000 Inverter Power Module. If the SB3000 Power Module is shut down due to a fault condition, controlled shutdown of the SA3000 Power Module is the responsibility of the application program running in the SA3000 UDC module.

!ATTENTION: When used with an SB3000 Power Module, the SB3000 Power Module must be in run before the SA3000 Inverter Power Module is put into run. If the pre-charge contactor supplying the SB3000 Power Module is not closed, running the SA3000 Power Module will damage the SB3000 pre-charge resistors. Failure to observe this precaution could result in damage to, or destruction of, the equipment.


Figure 2.4 – Drive I/O and Processor Card Detail

MOUNTED TO CABINET DOOR

OPTIONAL METER PACKAGE

ANALOG

AC

AC

STARTER FEEDBACKBLOWER MOTOR

MOTOR THERMOSTAT

RUN PERMISSIVE INTERLOCK

2 RPI

(LO)B

(C3)

DRIVE I/O

RPIA

B/M O-60031

AUX

(LO)

IN14

D

6 IN2AUX

C AUX IN1

(C3-P2)

(LO)

AUX

F

8 IN3

(LO)J

E AUX IN2

H AUX IN3

IN4AUX

(LO)L

10

IN5AUX

12

K AUX IN4

N

(LO)R

14 MCR

M AUX IN5

MCRP

OFF-DELAY AFTER0.5 SECOND

(LO)

1RPI

(HI)

AUX

(HI)

IN1 3

5IN2AUX

(HI)

AUX7IN3

(HI)

9IN4AUX

(HI)

11IN5AUX

(HI)

13MCR

(HI)

FROM T.B. (P2 & N)

OUTAUX

(LO)T

16

S AUX OUT

OUTPUTB

A(-)

(+)REFERENCE

(C3-P1)

SINE

COSINE

INPUT

D(-)

(+)

E(+)

C

INPUT

H

F(+)

J(-)

(-)

TRIGGEREXTERNAL

+(P1)

P(+)

NSHLD

(-)

R

B/MPROCESSOR

O-60021

ISOLATED(±10V=(±2047)

COM

+

COM

+

(C2)

COMM LINKFIBER OPTIC

XMT

RCV(P3)

2(P2)

1

PMI RACK SLOT C5

TO PARALLELINTERFACE MODULE

COM

+

COM

(C4)

±10V

(P1)PORTSMETER(P4)

PORTS

0

1

AC POWER

4(P5)

TECH MODULE

(P1)

(P2)

B/M 60023

INTERFACEMODULEPOWER

SYNCH XFER

3RAIL

15AUXOUT

(HI)

2

1

REF. OUT(-)

REF. OUT(+)

4

3

5

7

8

6

EXT. TRIG(-)

EXT. TRIG(+)

COS INPUT(-)

COS INPUT(+)

SIN INPUT(-)

SIN INPUT(+)

1

3

2

SHIELD

ANALOG IN(-)

ANALOG IN(+)

RPI GOES "LOW"

R101_B4

R101_B1

R201_B5

R201_B4

R201_B3

R201_B2

R201_B1

R201_B0

XXX21

XXX22

XXX23

XXX24

XXX26

XXX25

XXX31

XXX32SIGNAL

FROM

XXX11

XXX01

DRIVEN BY (+)

FIBER OPTIC COMM. LINK

YYYL YYYN

XXX03

XXX05

XXX07

XXX14

XXX16

BLU

ORG

DC

AC

MOTOR

FROM 115VAC

ESR

(-)

(+)

(-)

(+)

(-)

(+)

6

5

4

3

2

1

INDUSTRIAL

COSINE

SINE

REFERENCE

R2

S4

S2

(STATOR)OUTPUT

(STATOR)OUTPUT

(ROTOR)INPUT

S3

S1

R1

P/NRESOLVERBRUSHLESSDUTY

800123-x

BN

IN POWER MODULEARE MOUNTED

AUTOMATE I/O RAILSPMI RACK AND OPTIONAL

FROM UDC CARD

FREQUENCYCALIB

200%-0-200%CALIB TORQUE

MOTOR

CABLE

CALIB

120Hz-0-120Hz

0-200%CALIB

0-600V

VOLTS

CURRENT

MOTOR

MOTOR

I/O RAIL

(IF USED)

OF POWER MODULE A

MOTOR


Figure 2.5 – 534A SA3000 Power Module Circuitry

(OP

TIO

NA

L)

PR

EC

HA

RG

E

TO

BELOWBLOWERS

FROM 115VAC

D2

SA3000INVERTER

D3S.R.DOOR

SOLENOID

W/D 30395-11

WW

WD

2

(RE

D)

800VDC FROM SB3000

D1GRD

DC BUSDISCONNECT

45(-)

0-1000 VDCK

11A

R

K11A

RCV

GATEDRIVERS

XMTA

F1

01A

F1

0 2A

47(+)GRD1L1

1CB

1

1L2

1F

U

5.0 A

PMI

FILTERLINE

P/S

A

INTER

DRIVEI/O

POWERTECH

PARA

PROC

RACK

250V

A

BLU

PRE-CHARGEBOARD

ORG

YY

Y47

YY

Y4 5

YY

YG

RD

WW

WD

1

(RE

D)

XX

XL1

XX

XL1

A

115VAC FROM A-CDISTRIBUTION

XX

XL 2

1L1AGRD

3FU

3. 2A

L2L1L1A

CB

1FAULT

WARNING

M

LEM

GRD

XX

XG

RD

GRD

W

XX

XW

U

XX

XV

V

A

CON1

CON1

LPI

A

GDI

GDI

GDI

LEM

LEM

CON1

CARD

TO

P2

XX

XP

2

N

XX

XP

1

P1

CON5

LEM

XX

XU

BLOWER ASSEMBLY

F103A-105A

THERMM

MOTOR

U V W G

P1 P2

RESOLVER

L

XX

XN

XX

XL

I/O CARDTO DRIVE115VAC

GDI

INTERLOCKBYPASS

NOTE: THESE JUMPERS ARE REMOVEDWHEN A SEPARATE 115 VAC SUPPLY IS USED FOR THE PMI RACK.

SUPPLY DISTRIBUTIONFROM CRITICAL 115VACCONDITIONED POWER

XX

X1

L1A

XX

X1

L 1

XX

X1

L2

(OPTIONAL)

(OPTIONAL)

(OPTIONAL)



CB

1

1C

B1

PR

EC

HA

RG

E

( OP

TIO

NA

L)

YY

Y4

5

YY

Y4

7

DISCONNECTDC BUS

(OPTIONAL)

DOORSOLENOID(OPTIONAL)0-1000 VDC

(OPTIONAL)


XX

XL

1A

XX

XL

2

XX

XL

1

CONDITIONED POWERFROM CRITICAL 115VACSUPPLY DISTRIBUTION

NOTE: THESE JUMPERS ARE REMOVEDWHEN A SEPARATE 115 VAC SUPPLY IS USED FOR THE PMI RACK.

XX

X1L

1 A

XX

X1L

1

XX

X1

L2

XX

XG

RD

TOTHERMM

MOTOR

U V W G

P1 P2

XX

XW

XX

XV

XX

XU

GRD

YY

YG

RD

800VDC FROM SB3000

RESOLVER

K1

1A

R

K1

1A

K1

1B

R

K1

1B

BYPASSINTERLOCK

D1

S.R. D3

WW

WD

1

(RE

D)

D2

WW

WD

2

(RE

D)

(+) (-)

LEM WARNINGWARNING LEM

BLOWER ASSEMBLY

U V

M

FAULT

BLOWER ASSEMBLY

W GRD

M

FAULT

RCVBLU

F103A-105A

PRE-CHARGEBOARD

ORG

GATEDRIVERS

XMT

F10

1A

47

RCVABLU

PRE-CHARGEBOARD

F103B-105B

ORGXMT

GATEDRIVERS

B

F10

2A

F1 0

1B

F10

2B

45 GRD

SA3000INVERTER

GDI

I/O CARDTO DRIVE115VAC

XX

XL

XX

XN

L

LEM

P1

CON5

XX

XP

1

N

XX

XP

2

P2

CARD

CON1

GDI

GDI

GDI

LEM

LEM

B

A

LPI

GDI

CON1

CON1

B

A

B

BLOWERSBELOW

TO

25A

L1AL1A L1 L2

3.2 A

3F

U

GRD 1L1A


250

VA

RACK

PROC

INTER

DRIVEI/O

POWERTECH

PARA

A

FILTERLINE

P/SPMI

5.0A

1F

U

1L2

25A

1L1 GRD

W/D 30395-12

FROM 115VAC



CB

1

1CB

1

(OPTIONAL)

PR

EC

HA

RG

E

(OP

TIO

NA

L)

TO

BELOWBLOWERS

(OPTIONAL)

0-1000 VDC (OPTIONAL)DISCONNECT

DC BUS

XX

XL1

A

XX

X1

L 2

XX

X1

L1

XX

X1

L1 A

DISTRIBUTION115VAC FROM A-C

IS USED FOR THE PMI RACK.WHEN A SEPARATE 115 VAC SUPPLY NOTE: THESE JUMPERS ARE REMOVED

SUPPLY DISTRIBUTIONFROM CRITICAL 115VACCONDITIONED POWER

DISTRIBUTION115VAC FROM A-C

XX

XG

RD

TOTHERMM

MOTOR

U V W G

P1 P2

XX

XW

XX

XV

XX

XU

XX

XP

1

XX

XP

2

GRD

YY

Y4 7

YY

Y45

800VDC FROM SB3000 ON SHEET YYY

XX

XL

XX

XN

115VAC

RESOLVER

TO DRIVEI/O CARD

K1

1A

R

K11

A

K11

B

R R

K1

1B

K11

C

K1 1

C

FROM 115VAC

SOLENOIDSDOOR

BYPASSINTERLOCK

D1

S.R. D3W

WW

D1

( RE

D)

D2

WW

WD

2

(RE

D)

YY

GR

D

(+) (-)1L11L1A 1L2 GRD 47 45 GRD

SA3000INVERTER

F10

2 B

F1 0

1B

F10

2A

F1 0

1A

BOARDPRE-CHARGE

DRIVERSGATE

XMT

RCV

F103A-105A

ORG

BLU

5.0 A

3FU

1F

U

25A

CON1A

LEM

CON5

LEM

LEM

GDI

GDI

GDI

CON1

CON1

A

C

B

CARDLPI

C

B

GDI

GDI

GDI

B

C

A

L N P1 P2 U V GRDW

LEM

BLOWER ASSEMBLY

FAULT

M

BLOWER ASSEMBLY

FAULT

M

WARNING

F103B-105B

WARNING

BOARD

LEM

BLOWER ASSEMBLY

FAULT

M

WARNING

F103C-105C

BOARD

LEM

C

F10

2 C

F10

1C

PRE-CHARGE

DRIVERS

XMT

RCVORG

BLU

GATE

B

PRE-CHARGE

DRIVERSGATE

XMT

RCVORG

BLUA

PARA

TECHPOWER

I/ODRIVE

P/S

PROC

LINEFILTER

RACKPMI

250

VA

3.2A

INTER

L1A

25A

L2L1 GRD

WW

WIV

L1

WW

WIV

L2

W/D 30395-13


Installation Guidelines 3-1

CHAPTER 3Installation Guidelines

This chapter describes the guidelines and wiring recommendations to be followed when installing High Power SA3000 Power Modules. Installation and replacement procedures are included for the 534A, 972A, and 1457A Power Modules.

3.1 Installation Planning

SA3000 Power Module current ratings are dependent upon inlet air temperature. Ratings are given at 40° C (104° F) ambient. Refer to table 1.1 for output current ratings.

Internal Power Module conditions are monitored by two thermal switches on the heatsink. One switch is used to indicate a warning condition (register 203/1203, bit 7, WRN_OT@); the other is used to indicate a fault condition (register 202/1202, bit 7, FLT_OT@). The thermal warning switch closes at 78° C (172.4° F); the thermal fault switch closes at 85°C (185° F). Refer to the SA3000 Configuration and Programming instruction manual (S-3042) for more information on faults and warnings.

Use the following guidelines when planning your SA3000 Power Module installation:

• The relative humidity around the SA3000 Power Module must be kept between 5 and 90% (non-condensing).

• Do not install above 1000 meters (3300 feet) without derating. For every 91.4 meters (300 feet) above 1000 meters (3300 feet), the SA3000 Power Module's current rating is derated 1%.

• /RFDWH WKH 6$ 3RZHU 0RGXOH LQ D FOHDQ FRRO DQG GU\ DUHD )ROORZ WKH recommendations given in IEC 68 concerning environmental operating conditions.

• Be sure surrounding equipment does not block service access to the SA3000 Power Module.

• $OORZ DGHTXDWH FOHDUDQFH IRU DLU YHQWLODWLRQ 6$ 3RZHU 0RGXOHV SXOO LQ DLU IURP

WKH bottom of the cabinet and exhaust it through the top of the cabinet. Each cabinet bay of the SA3000 Power Module has one fan. Allow at least 30 cm (12") above and 2 m (6.6') in front of the SA3000 Power Module for adequate air clearance.

• Individual motor lead lengths cannot exceed 100 meters (328 feet).

• Refer to the Drive System Installation manual (D2-3115) for more information.

!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.


3.2 Wiring

System wiring is to be done according to the supplied wiring diagrams (W/Es), which are application-specific. Sections 3.2.1 through 3.2.3 provide additional information on fuses and recommended wiring.

3.2.1 Fuses

Fuses are provided to protect the Power Module's DC bus, 115 VAC control power input lines, and individual IGBT phase modules. See table 3.1 for the fuse values.

3.2.2 Wire Sizes

Input wiring should be sized according to applicable codes to handle the SA3000 Power Module's continuous-rated input current. Output wiring should be sized according to applicable codes to handle the SA3000 Power Module's continuous-rated output current. Recommended wire sizes are shown in table 3.2. Terminals should be tightened to the torque values provided in table 3.3.

!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: The NEC/CEC requires that upstream branch circuit protection be provided to protect input power wiring. Install the fuses recommended in table 3.1. Do not exceed the fuse ratings. Failure to observe this precaution could result in damage to, or destruction of the equipment.

Table 3.1 – Fuse Ratings

Fuse CircuitFuse Current

RatingFuse Voltage

RatingRockwell

P/N

FPM A,B,C DC Bus 1000 A 1000 VAC 64676-80P

F103 A,B,CF104 A,B,C F105 A,B,C

IGBT Phase Modules

630 A 1000 VAC 64676-79AZ

1FU 115 VAC 5 A 600 VAC 64676-29R

3FU 115 VAC 3.2 A 600 VAC 64676-29P

Table 3.2 – Recommended DC Bus Input and AC Output Wire Sizes

SA3000 Output Rating Size of Wire 1

1. NEC-recommended cable types: 40oC (104oF) copper wire.

534A 2 x 600 Kc Mil (304 mm2)

972A 3 x 600 Kc Mil (304 mm2)

1457A 4 x 1000 Kc Mil (507 mm2)


3.2.3 Wire Routing

Ac output wiring is routed through the top of the cabinet, above terminals 181, 182 and 183. DC input wiring is also routed through the top of the cabinet. DC input wiring is usually connected to the DC bus in the overhead enclosure that distributes the DC power to the common DC bus Inverter Power Modules. A DC input disconnect switch is provided to disconnect DC bus power, providing safe access to the inside of the SA3000 Power Module cabinet.

3.3 Grounding

System grounding is to be done according to the supplied wiring diagrams (W/Es) in accordance with applicable codes. To prevent noise interference and possible malfunction of this equipment, it is imperative that a good cabinet ground be provided. The grounding conductor must be as short as possible and be run directly from the control panel ground terminal to a solid earth ground. It is recommended that the grounding conductor be the same size conductor as the power wiring. Multi-cabinet grounding wires should not be daisy-chained but should be run separately to the common point of earth ground.

3.4 Installing the Power Module Cabinet

Use the following procedure to install the SA3000 Power Module cabinet:

Step 1. Ensure that DC input power leading to the SA3000 Power Module is off.

Step 2. Position the SA3000 Power Module on a level mounting surface. See figures 3.1, 3.2, and 3.3 for cabinet dimensions. Floor mounting dimensions are included for applications in which the cabinet is to be attached to the floor.

Step 3. Connect the DC bus to terminals 45 (-) and 47(+). See the W/Es. Connect the GND terminal to earth ground.

Step 4. If used, connect the optional output contactor to the U, V, and W terminals.

Step 5. Connect the motor leads to the output contactor. If an output contactor is not used, connect the motor leads directly to the U, V, and W terminals. See the W/Es and figure 3.4.

Step 6. Connect the GND terminal to earth ground.

Step 7. Connect the AC control power input line (two-wire 115 VAC with ground) to terminals L1 (L), L2 (N), and GND on the control wiring terminal board. See the W/Es and figure 3.4.

Table 3.3 – Terminal Tightening Torques

Terminals Tightening Torque

DC Bus Input Power: 45, 47 41 Nm (30 lb-ft)

Output Power: U, V, W 41 Nm (30 lb-ft)

115 VAC Input Power: L1, L2 3.5 Nm (2.6 lb-ft)

!ATTENTION: Ungrounded equipment represents a shock hazard. Connect the power module's ground terminals to earth ground using properly-sized ground wires. Failure to observe this precaution could result in severe bodily injury or loss of life.


Figure 3.1 – 534A Power Module Mounting Dimensions (Single-Bay)

(73.

0 )

WE

IGH

T =

126

5 LB

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)

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IP S

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ER

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Figure 3.2 – 972A Power Module Mounting Dimensions (Double-Bay)

*

64.0

0

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Figure 3.3 – 1457A Power Module Mounting Dimensions (Triple-Bay)

DR

IP S

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LD

FIL

TE

RS

& F

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(127

.0)

(127

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.6).


Figure 3.4 – SA3000 Power and Ground Connections

INPUT VOLTAGE115 VAC

VOLTAGE 775VDC BUS INPUT

GND

FUSE

CONNECT BLOCK115 VAC QUICK

POWER MODULE

NL4745

+–

GND

SA3000

MOTOR

OUTPUT CONTACTOR(OPTIONAL)

MANUALDISCONNECT

U V W


Diagnostics and Troubleshooting 4-1

CHAPTER 4Diagnostics and Troubleshooting

This chapter describes the equipment needed to check the operation of the Power Module and the tests to be performed. Included are descriptions of the Power Module faults and warnings monitored by the Distributed Power System software. Procedures are also provided for replacing Power Module cabinets, sub-assemblies, and fuses.

4.1 Required Test Equipment

The following equipment is required when servicing the SA3000 Power Module:

• an oscilloscope with an impedance of at least 8 megohms

• a 10:1 probe

• an isolated voltmeter (1000V DC)

• a clamp-on ammeter (1500A)

Note that all measuring devices-meters-oscilloscopes that are AC line-powered must be connected to the AC line through an ungrounded isolation transformer.


ATTENTION: The SA3000 Power Module contains printed circuit boards that are static sensitive. Do not touch the boards’ components, connectors, or leads. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

!ATTENTION: The Power Module is not isolated from earth ground. AC line powered test instruments used to measure Power Module signals must be isolated from ground through an isolation transformer. This is not necessary for battery-powered test instruments. Failure to observe this precaution could result in bodily injury.

ATTENTION: If a megohmmeter (megger) is used to verify an inadvertent ground internal to the motor, make certain that all leads are disconnected between the rotating equipment and the Power Module cabinet. This will prevent damage to electronic circuitry (Power Modules and their associated circuitry) due to the high voltage generated by the megger. Failure to observe this precaution could result in damage to or destruction of the equipment.


4.2 Power Module Tests with Input Power Off

Use the following procedure to perform the SA3000 Power Module tests:

Step 1. Turn off and lock out DC input power.

Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.

Step 3. Open the Power Module’s cabinet doors and measure the voltage across each pair of DC bus bars, 347 A,B,C (+ bus) and 345 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. See figure 4.1.

Step 4. Disconnect the motor from the Power Module.

Step 5. Check the DC bus fuses.

Be sure to check the DC bus fuses for continuity if an IGBT phase module or fuse fails in a 972A or 1457A Power Module. Excessive current may have damaged the DC bus fuses. It is recommended that the DC bus fuses be replaced whenever an IGBT phase module or fuse fails due to a fault current. If the DC bus fuses have opened in Power Module A, a bus fault will be generated. If the DC bus fuses have opened in Power Modules B or C, a bus fault will not be generated, but an Instantaneous Overcurrent (IOC) fault will be indicated. This may be the only indication of a blown fuse in Power Modules B and C.

Step 6. If a fuse is blown, use a multimeter to check the DC bus, bus capacitors, output terminals, and the output IGBTs. See tables 4.1 and 4.2.

Step 7. If a capacitor is defective, replace the capacitor bank assembly as described in section 4.4.5. If an IGBT is defective, refer to section 4.4.2.



Figure 4.1 – DC Bus Voltage Measuring Points

LPIMODULE

AC

LIN

E S

YN

C

PC

BS

YN

CL

INE

PO

WE

R M

OD

ULE

ABANK CAPACITOR

BANK CAPACITOR

BANK CAPACITOR

-BU

S34

5C

+BU

S

347C

PH

AS

E W

PH

AS

E V

PH

AS

E U

PH

AS

E W

PH

AS

E V

PH

AS

E U

PH

AS

E W

PH

AS

E V

PH

AS

E U

PO

WE

R M

OD

ULE

CP

OW

ER

MO

DU

LE B

PR

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RG

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SS

EM

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AS

SE

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LY

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SS

EM

BLY

BLO

WE

RB

LOW

ER

-+-+

25K

HZ

PS

PR

E-C

HA

RG

E A

SS

EM

BLY

AS

SE

MB

LY

PM

I RA

CK

CB1

3FU1FU

±15

VP

S

1CB1

PS

-24V

+24

VP

S

BL

OW

ER

AS

SE

MB

LY

-BU

S34

5B

+B

US

34

7B

-BU

S34

5A

+B

US

34

7A

DIS

CO

NN

EC

T S

WIT

CH

FPMA

GR

DM

OT

OR

GR

DM

OT

OR

WV

UAC

MO

TO

R O

UT

PU

T

FPMB

FPMC


4.3 Power Module Faults and Warnings

The PMI Processor continually runs diagnostics which check for errors that may affect system operation. Warnings are errors which indicate that the SA3000 Power Module is not operating in an optimum manner. Warnings will not shut down the SA3000. Faults are severe errors which will shut down the SA3000. See tables 4.3 and 4.4.

Refer to the SA3000 Drive Configuration and Programming instruction manual (S-3042) for more information about the Fault and Warning registers.

Table 4.1 – DC Bus and Terminal Tests1

1. With the motor disconnected

Meter Connections+ -

Scale Expected Test Results

DC Bus- Bus (45) + Bus (47)

X10Capacitor Effect (0 to 50 ohms)

+ Bus (47) - Bus (45) Capacitor Effect (0 to 200 ohms)

Bus Capacitors

+ 349 A,B,C X10Capacitor Effect (0 to 500 ohms)

- 349 A,B,C

U +

X1 2 ohmsV +

W +

+ U

X10 Capacitor Effect (0 to 2k ohms)+ V

+ W

OutputTerminals

U V

X1000 4k to 6k ohmsU W

V W

Table 4.2 – IGBT Tests1

1. With the motor disconnected

Meter Connections + -

ScaleExpected Test

Results(+/- 10%)

W Phase (lower) + W +347 A,B,C 2k Ω/diode 0.300 ohms

V Phase (lower) + V +347 A,B,C 2k Ω/diode 0.300 ohms

U Phase (lower) + U +347 A,B,C 2k Ω/diode 0.300 ohms

W Phase (upper) - -345 A,B,C W 2k Ω/diode 0.300 ohms

V Phase (upper) - -345 A,B,C V 2k Ω/diode 0.300 ohms

U Phase (upper) - -345 A,B,C U 2k Ω/diode 0.300 ohms


4.3.1 Power Module Faults

The Power Module faults listed in table 4.3 will cause the SA3000 Power Module to shut down. In a fault situation, the PMI Processor will command zero current and will stop firing the Power Module’s IGBTs. Faults must be reset before the SA3000 Power Module can be restarted.

4.3.1.1 DC Bus Overvoltage Fault

The DC Bus Overvoltage bit (bit 0) is set in the Fault register (202/1202) if the DC bus voltage exceeds 925 VDC. Error code 1018 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.2 DC Bus Overcurrent Fault

The DC Bus Overcurrent bit (bit 1) is set in the Fault register (202/1202) if the DC bus current exceeds 125% of the rated SA3000 Power Module current. Error code 1020 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.3 Ground Current Fault

The Ground Current Fault bit (bit 2) is set in the Fault register (202/1202) if the ground current exceeds the hardware trip point value of 100 Amps. Error code 2021 will also be displayed in the error log of the UDC task in which the fault occurred.

Note that the Ground Current Fault bit (register 202/1202, bit 2) is not enabled on SA3000 Power Modules using AC Technology modules, B/M 60023-5 and later. Error code 2021 will not be displayed as the ground current hardware trip detector was removed from the AC Technology modules, B/M 60023-5 and later.

Table 4.3 – SA3000 Power Module Faults (Register 202/1202)

BitSuggested

Variable Name

UDC Error Code

Description Summary

0 FLT_OV@ 1018 The DC Bus Overvoltage bit is set if the DC bus voltage exceeds 925 VDC.

1 FLT_DCI@ 1020 The DC Bus Overcurrent bit is set if the DC bus current exceeds 125% of the rated SA3000 Power Module current.

2 FLT_GND@ 1021 The Ground Current Fault bit is set if the ground current exceeds the hardware trip point. See section 4.3.1.3.

3 FLT_IOC@ 1017 The Instantaneous Overcurrent Fault bit is set if an overcurrent is detected in one of the power devices.

4 FLT_LPI@ 1022 The Local Power Interface bit is set if the power supply voltage on the LPI module is not within tolerance.

6 FLT_CHG@ 1024 The Charge Bus Timeout Fault bit is set if the DC bus is not fully charged within 10 seconds of being enabled, if the drive is on and feedback indicates the pre-charge contactor has opened, or if DC bus voltage is less than the Power Loss Fault Threshold tunable variable (PLT_FLT%).

7 FLT_OT@ 1016 The Overtemperature Fault bit is set if the fault level thermal switch

(85o C (185o F)) in the SA3000 Power Module opens.


4.3.1.4 Instantaneous Overcurrent Fault

The Instantaneous Overcurrent Fault bit (bit 3) is set in the Fault register (202/1202) if an overcurrent is detected in one of the power devices (IGBTs). Register 204/1204, bits 0-5, indicates which power device experienced the overcurrent. When 972A and 1457A SA3000 Power Modules are being used, registers 220/1220 and 221/1221 indicate the status of the B and C Power Modules. Error code 1017 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.5 Local Power Interface Fault

The Local Power Interface Fault bit (bit 4) is set in the Fault register (202/1202) if the power supply voltage on the LPI module is not within tolerance. Error code 1022 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.6 Charge Bus Time-Out Fault

The Charge Bus Fault bit (bit 6) is set in the Fault register (202/1202) if one of the following occurs:

• the internal DC bus is not fully charged within 10 seconds after the bus enable bit (register 100/1100, bit 4) is set.

• the drive is on and feedback indicates that the pre-charge contactor has opened

• DC bus voltage is less than the value stored in the Power Loss Fault Threshold (PLT_E0%) tunable variable.

If this bit is set, verify that the incoming DC bus power is at the appropriate level. If the power level is correct the problem is in one of the SA3000 Power Modules. Bit 8 in register 204/1204, 220/1220, or 221/1221 will be set to indicate which Power Module is caused the fault. Error code 1024 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.7 Overtemperature Fault

The Overtemperature Fault bit (bit 7) is set in the Fault register (202/1202) if the fault level thermal switch (85o C (185o F)) in the Power Module opens. Bit 12 in register 204/1204, 220/1220, or 221/1221 will be set to indicate which SA3000 Power Module is caused the fault. Error code 1016 will also be displayed in the error log of the UDC task in which the fault occurred.


4.3.2 Power Module Warnings

The following warnings indicate conditions which are not serious enough to shut down the SA3000 Power Module but may affect its performance. See table 4.4. Warnings cause no action by themselves. Any response to a warning condition is the responsibility of the application task.

4.3.2.1 DC Bus Overvoltage Warning

The DC Bus Overvoltage bit (bit 0) is set in the Warning register (203/1203) if the DC bus voltage exceeds the overvoltage threshold value stored in local tunable OVT_E0%.

4.3.2.2 DC Bus Undervoltage Warning

The DC Bus Undervoltage bit (bit 1) is set in the Warning register (203/1203) if the DC bus voltage drops below the under voltage threshold value stored in local tunable UVT_E0%.

4.3.2.3 Ground Current Warning

The Ground Current Warning bit (bit 2) is set in the Warning register (203/1203) if the ground current exceeds the ground fault current level stored in local tunable GIT_EI%.

4.3.2.4 Load Sharing Warning

The Load Sharing Warning bit (bit 6) is set in the Warning register (203/1203) if a current sharing problem develops between parallel SA3000 Power Modules. Bits 13, 14, or 15 in registers 204/1204, 220/1220, or 221/1221 will be set to indicate the Power Module and phase that caused the warning.

Table 4.4 – SA3000 Warning Register 203 /1203

Bit

Suggested Variable Name

Description Summary

0 WRN_OV@ The DC Bus Overvoltage fault bit is set if the DC bus voltage exceeds the overvoltage threshold value stored in local tunable OVT_E0%.

1 WRN_UV@ The DC Bus Undervoltage bit is set if the DC bus voltage drops below the under voltage threshold value stored in local tunable UVT_E0%.

2 WRN_GND@ The Ground Current Warning bit is set if the ground current exceeds the ground fault current level stored in local tunable GIT_EI%.

6 WRN_SHR@ The Load Sharing Warning bit is set if a current sharing problem develops between parallel SA3000 Power Modules.

7 WRN_OT@ The Overtemperature Warning bit is set if the warning level thermal switch (78° C

(172.4o F)) in the SA3000 Power Module opens.


4.3.2.5 Overtemperature Warning

The Overtemperature Warning bit (bit 7) is set in the Warning register (203/1203) if the warning level thermal switch (78o C (172.4o F)) in the SA3000 Power Module opens. Bit 12 in register 204/1204, 220/1220, or 221/1221 will be set to indicate which SA3000 Power Module caused the warning.

4.4 Replacing Power Module Fuses and Sub-Assemblies

Follow the procedures given in sections 4.4.1 to 4.4.5 to replace the SA3000 Power Module’s fuses and sub-assemblies.

4.4.1 Replacing Fuses

Use the following procedure to replace a fuse that has blown:

Step 1. Turn off and lock out the AC input power.


Step 3. Open the cabinet doors and check the voltage across the DC bus bars, 347 A,B,C (+ bus) and 345 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. See figure 4.1.

Step 4. Remove the blown fuse and install the replacement fuse. Figures 4.2 to 4.6 show the locations of the fuses in the 534A, 972A, and 1457A SA3000 Power Modules. Table 4.5 provides fuse specifications.

Step 5. Close the cabinet doors and reapply power to the SA3000 Power Module.



1,2,3. Fuse locations shown in figures 4.2, 4.3, 4.4, and 4.5.4. Fuse locations shown in figures 4.2, 4.3, 4.4, and 4.6.

Table 4.5 – Power Module Replacement Fuse Specifications

Fuse Volts Class Type RatingRockwell

Part Number Torque Specifications

1FU 600 CC KLDR 5 A 64676-29R --

3FU 600 CC KLDR 3.2 A 64676-29P --

FPM A,B,C 1000 Semiconductor 1000 A 64676-80P 41 Nm (30 lb-ft)

F103 A,B,C 1000 Semiconductor 630 A 64676-79AZ 20.5 Nm (15 lb-ft)



+/-15V PS1 250 F 1.8 AReplace with

1.6A64676-82U

--

+/-24V PS2 250 T 2.5 A 64676-71P --

+/-24V PS3 600 -- F 2.0 A 64676-82V --

25 KHz PS4

11FU12FU

250 -- -- 8 A 64676-30H --

25 KHz PS4

21FU26FU

250 -- F 2 A 64676-66C --


Figure 4.2 – 534A SA3000 Power Module Fuse Locations

(4)

(4)

LPI

MO

DU

LE

LINESYNCPCB

BA

NK

CA

PA

CIT

OR

CB

1

±15V.PS 3F

U1F

U±15V.PS

1CB

1

PS+24V.

PS-24V.+24V.

PS-24V.

PS

POWER MODULE A

PHASE U

PMI RACKASSEMBLY

PHASE W

PHASE V

PRE-CHARGE ASSEMBLY

SLO

T 6

PW

R. M

OD

. A

GDI

25KHZ PS

BLOWER

F105A

F104A21FU-26FU

11FU, 12FU

(2)

3FU

1FU

F103A

(3)

(1)

Notes 1,2,3. See table 4.5 and figure 4.5Note 4. See table 4.5 and figure 4.6.

DISCONNECT SWITCH

FP

MA

F101AF102A

(FRONT)(REAR)

GNDMOTOR

GNDMOTOR

U V W

AC MOTOR OUTPUT



LPI

MO

DU

LE

PCBSYNCLINE

POWER MODULE B

PHASE W

PHASE V

PHASE U

PHASE W

PHASE V

PHASE U

POWER MODULE A

PMI RACKASSEMBLY

PRE-CHARGE ASSEMBLY

SL

OT

6

SL

OT

7

PW

R. M

OD

. A

PW

R. M

OD

. B

GDIGDI

25KHZ PS

BLOWERBLOWER

PRE-CHARGE ASSEMBLY

ASSEMBLY

CB

1

3F

U1

FU±15V

PS 1CB

1

+24VPS

-24VPS

F105B

F104B

F103B

F105A

F104A

F103A

21FU-26FU

11FU, 12FU

3FU1FU

CA

PA

CIT

OR

BA

NK

CA

PA

CIT

OR

BA

NK

Notes 1,2,3. See table 4.5 and figure 4.5Note 4. See table 4.5 and figure 4.6.

(2)

(3)

(1)

(4)

(4)

DISCONNECT SWITCH

FP

MB

FP

MA

F101A F101BF102BF102A

(FRONT)(REAR)

AC MOTOR OUTPUT

U V W

MOTORGRD

MOTORGRD GRD

MOTOR



LPI MODULE

PC

BS

YN

CLI

NE

F10

3A

F10

4A

F10

5A

PH

AS

E W

PH

AS

E V

PH

AS

E U

PH

AS

E W

PH

AS

E V

PH

AS

E U

PH

AS

E W

PH

AS

E V

PH

AS

E U

PO

WE

R M

OD

ULE

CP

OW

ER

MO

DU

LE B

PO

WE

R M

OD

ULE

A

PWR. MOD. C

GD

I SLOT 8

PR

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HA

RG

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EM

BLY

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MB

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PR

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HA

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BLO

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RB

LOW

ER

25K

HZ

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GD

IG

DI

PWR. MOD. B

PWR. MOD. A

SLOT 7

SLOT 6

PR

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RG

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BLY

AS

SE

MB

LYP

MI R

AC

K

CB1

±15V PS

3FU1FU

1CB1

PS

+24V

PS

-24V

BLO

WE

RA

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EM

BLY

1FU

3FU

BANK CAPACITOR

BANK CAPACITOR

CAPACITORBANK

11F

U, 1

2FU

F10

5B

F10

4B

F10

3B

F10

5C

F10

4C

F10

3C

21F

U-2

6FU

Not

es 1

,2,3

. See

tabl

e 4.

5 an

d fig

ure

4.5

Not

e 4.

See

tabl

e 4.

5 an

d fig

ure

4.6.

(2)

(3)

(1)

(4)

(4)

DIS

CO

NN

EC

T S

WIT

CH

(RE

AR

)(F

RO

NT

)F

102C

F10

2AF

102B

F10

1CF

101B

F10

1A

FPMA

GR

DM

OT

OR

GR

DM

OT

OR

WV

UAC

MO

TO

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UT

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T

FPMB

FPMC


Figure 4.5 – 115VAC Control Power Supply Assemblies

NON-CRITICAL

CRITICAL

TERMINAL BOARD115 VAC INPUT

115 VAC INPUTTERMINAL BOARD

TERMINAL BOARD115 VAC INPUT

850100-3S ASSEMBLY

850100-3R ASSEMBLY

CB

1 L1

L2

L1A

1L1A

1L2

1L1

L1A

L2

L1

3FU

1FU±15V

+24VPS

PS

-24VPS

CB

1

NON-CRITICAL (FAN) 115VAC

1QD 2QD

+24VPS

-24VPS

±15VPS

CRITICAL (PMI/PS) 115VAC

L1

N

+150

0-15

L1

N

24

0

1.8A F

L1

N

24

0

2.0A F 2.0A F

2.5A T 2.5A T

OUT-

OUT+

OUT

IN

CRITICAL (PMI/PS) 115VACNON-CRITICAL (FAN) 115VAC

1QD 2QD

OUT+

OUT-

1.8A F

1.8A F

IN

OUT

2.5A T 2.5A T

2.0A F 2.0A F

OUTPUT TB OUTPUT TB

-150

0+15

N

L1

0

24

N

L1

0

24

N

L1

1.8A F

3FU

1CB

1

1FU

(1)

(1)

(2)

(3)

(2)

(3)

(1)

(1)

Notes 1,2,3. See table 4.5 for fuse specifications.


Figure 4.6 – 25 KHz. Power Supply

-28

828

9+

289

288

-

1FU

2FU

115V

AC

INP

UT

13

45

62

25 K

Hz.

OU

TP

UT

NO

T U

SE

DT

O P

OW

ER

MO

DU

LE(S

)AB

C

112

FR

ON

T V

IEW

SI D

E V

IEW

21F

U

12F

U

8022

68-1

6R A

SS

EM

BLY

11F

U

TH

RU

26F

U

US

ED

NO

T

(4)

Not

e 4.

See

tabl

e 4.

5 fo

r fu

se s

peci

ficat

ions

.

(4)

(4)


4.4.2 Replacing an IGBT Phase Module Assembly

Important: When replacing an IGBT phase module assembly be sure to re-install, position, and tighten the hardware in the proper sequence. The IGBT phase module must be aligned correctly to prevent damage to the components.

If all three IGBT phase modules are to be replaced, it will be easier to remove them by starting at the top and working down, i.e., begin by removing module U, continue with module V, and then finish by removing module W. Be sure to re-install the IGBT phase modules in reverse order, beginning by installing module W, continuing with module V, and finishing by installing module U.

Use the following procedure to replace an IGBT phase module assembly (U, V, or W):

Step 1. Turn off and lock out AC input power.



Step 4. Remove all wires, connectors, and harnesses from the IGBT Phase module assembly to be replaced. Label all of the wires to aid in re-installation. Refer to the wiring diagrams supplied with your system.

Step 5. Remove the right M8 bolt from the fuse. See figure 4.7, callout 2. Note that if you are only replacing the fuse, remove both M8 bolts as shown in figure 4.7, callouts 1 and 2. Remove the fuse without disturbing the alignment of the IGBT Phase module.

Step 6. Remove the two M8 bolts from the AC LEM bus bar. The bolts are located above the fuse and under the LEM device. See figure 4.7, callout 3.

Step 7. Remove the two M6 hex nuts from the negative bus bar. See figure 4.7, callout 4.

Step 8. Remove the two 5/16” x 1” cap screws, flat washers, and lock washers from the heatsink. One cap screw is located on each side of the heatsink. See figure 4.7, callout 5.

Step 9. Remove the IGBT Phase module assembly from the Power Module.

Step 10. Install the new IGBT Phase module assembly by aligning the module's mounting holes with the studs. Push the module into place and hold it in position.



Step 11. Start and finger-tighten the two M6 hex nuts on the negative bus bar. See figure 4.7, callout 4.

Step 12. Start and finger-tighten the two 5/16” cap screws, flat washers, and lock washers on the heatsink. One cap screw is located on each side of the heatsink. See figure 4.7, callout 5.

Step 13. Start and finger-tighten the two M8 bolts on the AC bus bar. See figure 4.7, callout 3. Tighten the bolts evenly.

Step 14. Loosen the M8 bolt on the left side of the fuse. See figure 4.7, callout 1. This allows the fuse some movement.

Step 15. Start and finger-tighten the M8 bolt with a lockwasher and a flat washer on the positive bus bar on the left side of the fuse. See figure 4.7, callout 2.

Note that the fuse ends should be in contact with the left and right bus bars. If the fuse does not touch the bus bars, adjust the horizontal position of the IGBT Phase Module Assembly until the fuse ends are contacting the bus bars. In some cases, the positive bus bar may have to be moved to allow the fuse to make contact.

Step 16. Pull the fuse forward in the slots. Hold the fuse with its back side parallel to the middle AC bus bar.

Note that the fuse must be mounted with the label facing forward, e.g., the top of the label should be to the right. The auxiliary connection tabs on the fuse endplates should be facing down. Do not install the fuse with the tabs facing up or toward the rear.

Step 17. Tighten the right and left fuse bolts to 20.5 Nm (15 lb-ft). Be sure the fuse does not rotate while the bolts are being tightened.

Step 18. Tighten the two M6 hex nuts on the negative bus bar to 5 Nm (45 lb-in). See figure 4.7, callout 4.

Step 19. Tighten the two M8 bolts on the AC bus bar to 9.5 Nm (84 lb-in). See figure 4.7, callout 3.

Step 20. Tighten the two 5/16” cap screws on the heatsink to 9.5 Nm (84 lb-in). See figure 4.7, callout 5.

Step 21. Ensure that all nuts and bolts are tightened to the rated torque. Re-torque the nuts and bolts as necessary.

Step 22. Re-connect the wires, connectors, and harnesses to the IGBT Phase module assembly that were removed in step 4.

Step 23. Close the cabinet doors.

Step 24. Reapply power to the Power Module.


4.4.2.1 Replacing an IGBT

If an IGBT needs to be replaced, it is recommended that the IGBT module be returned to an authorized Rockwell repair facility.

4.4.3 Replacing the Pre-charge Assembly

Use the following procedure to replace the optional pre-charge assembly:

Step 1. Turn off and lock out DC input power.


Figure 4.7 – IGBT Module Assembly Mounting Bolt Locations

5

4

1

2

3

PHASE V

PHASE W



Step 3. Open the Power Module cabinet's doors and measure the DC bus potential across each pair of DC bus bars, 347 A,B,C (+ bus) and 345 A,B,C (- bus), with an external voltmeter before working on the unit. See figure 4.1.

Step 4. Remove the bracket that is fastened across the cabinet in front of the pre-charge assembly. The bracket is attached to the cabinet with two screws.

Step 5. Remove the two power cables marked with a red band from the pre-charge assembly.

Step 6. Remove the wiring control harnesses. Do not remove the CN104 cable on the pre-charge module itself.

Step 7. Remove the power cables marked with a gray band from the DC bus capacitors.

Step 8. Remove the control wiring that connects to the capacitor bank.

Step 9. Remove the four screws that fasten the pre-charge assembly to the back panel of the cabinet.

Step 10. Remove the pre-charge assembly.

Step 11. Install the new pre-charge assembly by following steps 1 through 10 in reverse order.

Step 12. Close the cabinet doors.

Step 13. Reapply power to the Power Module.

4.4.4 Replacing a Blower Assembly

Use the following procedure to replace a blower assembly:




Step 4. Turn off the AC power to the blower by turning the circuit breaker in the power supply panel off.

Step 5. Disconnect the wires from the right side of the blower assembly. The wire connectors are keyed.

Step 6. Remove the blower from the cabinet by sliding it out.



Step 7. Install the new blower assembly by performing steps 1 through 6 in reverse order.


4.4.4.1 Replacing a Blower Filter

To replace a blower filter:

Step 1. Remove the old filter by sliding it out.

Step 2. Slide the new filter in.

4.4.5 Replacing a Bus Capacitor Assembly

Use the following procedure to replace a DC bus capacitor assembly:




Step 4. Remove all three IGBT assemblies (U, V, and W). Refer to section 4.4.2 for information on IGBT assembly removal.

Step 5. Remove the AC input power wiring by removing the bolt from the LEM stud spacer. This wiring consists of three insulated, tinned-copper straps which have color-coded bands (orange, yellow, and purple).

Step 6. Remove the LEM device control wiring. Needle-nose pliers may be useful in removing the three wire connectors.

Step 7. Remove the three LEM devices. Four screws attach each LEM device to the capacitor bank.

Step 8. Remove the three insulator blocks. Each insulator block is secured by two hex nuts.

Step 9. Remove the power cable wiring harnesses from the top of the capacitor bank. The two wiring harnesses have color-coded bands. The positive bus bar cable has a red band while the negative bus bar cable has a gray band.

Step 10. Remove the control wiring from the top of the capacitor bank.

Step 11. Remove the capacitor bank's four mounting screws. Two are located at the top of the capacitor bank and two at the bottom.

Step 12. Slide the capacitor bank out of the cabinet.



Step 13. Install the new capacitor bank assembly by performing steps 1 through 12 in reverse order.


4.5 Replacing the Power Module Cabinet

Use the following procedure to replace the SA3000 Power Module cabinet:

Step 1. Turn off and lock out the AC input power to the DC bus supply control cabinet.



Step 4. Disconnect the DC bus leads from terminals 45 (-) and 47 (+). Disconnect the GND wire from the ground terminal. See figure 3.4.

Note that if an overhead DC bus assembly was supplied, disassembly of the overhead assembly is required. The assembly may be remounted on the replacement cabinet, if required.

Step 5. Disconnect the AC input line (two-wire 115 VAC with ground) from the L1 (L), L2 (N), and GND terminals on the control power board. See figure 3.4.

Step 6. Disconnect the AC output leads (U, V, W) from the motor and the motor ground wire(s) from the GND terminal(s). See figure 3.4.

Step 7. Remove the SA3000 Power Module cabinet.

Step 8. Install the replacement SA3000 Power Module cabinet by performing these steps in reverse order.


Technical Specifications A-1

APPENDIX ATechnical Specifications

Ambient Conditions

• Operating Temperature:0 to +40o C (32 to +104o F)

• Storage Temperature:-25 to +55o C (-13 to +131o F)

• Humidity: 5 to 95%, non-condensing.

• Altitude: Do not install above 1000 meters (3300 feet) without derating output current. For every 91.4 meters (300 feet) above 1000 meters (3300 feet), derate the output current by 1%.

• Vibration: Sine Wave: 1g., 10-500 Hz., all 3 axes.Shock: 15g., over 6 msec., half sine wave.

Dimensions (534A SA300 Power Module)

• Height: 2204 mm (86.8 inches)1

• Depth: 603 mm (23.8 inches)

• Width: 864 mm (34.0 inches)

• Weight:573 kg (1265 pounds)




• Width: 1626 mm (64.0 inches)





• Width: 2387.6 mm (94.0 inches)


Type of Enclosure

• NEMA 1

1. Additional height: DC Bus Assembly Enclosure installed: 254 mm (10.0 inches)DC Bus Top Hat Enclosure installed: 482.6 mm (19.0 inches)

A-2 High Power SA3000 Power Modules

DC Bus Specifications

• Pre-charge Time: 1 second

• Discharge time (below 50V): less than 5 minutes

• Pre-charge resistance/bus capacitance: 534A Unit: 7.6 Ω / 32.4 µF972A Unit: 3.8 Ω / 64.8 µF1457A Unit: 2.5 Ω / 97.2 µF

DC Bus Input Power

• Nominal Maximum DC Voltage: 800 VDC

• Input Voltage Range: 300 - 850 VDC

• Overvoltage Trip: 925 VDC

• Maximum DC Input Current: 534A Unit: 600A972A Unit: 1000A1457A Unit: 1500A

Use the following equation to calculate the approximate DC input current as a function of the connected horsepower:

115 VAC Control Power

• AC Input Voltage: 115 VAC, Single-phase (Critical and Non-critical supplies)

• AC Input Frequency: 50/60 Hz1

• Maximum Symmetrical Short Circuit Current: 5 KA

1. Derate Power Module output current by 5% for 50 Hz blower motor operation.

115 VAC Input Power Ratings

115 VAC Power SupplyPart Number

534 AmpPower Module

972 AmpPower Module

1457 AmpPower Module

850100-3R1

1. May be replaced by 850100-3S 115VAC Power Supply Assembly.

10.6 A 16.5 A 21.6 A

850100-3S(Non-Critical Power)

5.5 A 11.0 A 16.5 A

850100-3S(Critical Power)

1.5 A (Min)5.1 A (Max)

1.5 A (Min)5.1 A (Max)

1.5 A (Min)5.1 A (Max)

850100-3S (Criticaland Non-Critical Power)

10.6 A (Max) 16.5 A (Max) 21.6 A (Max)

DC Amps = horsepower x 746

motor efficiency x inverter efficiency x bus voltage

Technical Specifications A-3

Output Power

• Output Voltage: 575 VAC, maximum

• Modulation: Sine Wave, Pulse Width Modulation (PWM)

• Short Circuit Rating: 65 KA

• Power Dissipation: 534A Unit: 7500 W972A Unit: 15000 W1457A Unit: 22500 W

• Output Inductor: 7.5 µH per phase (972A and 1457A units only)

• Rail I/O Current Load:Power supply constraints dictate that any combination of analog and digital I/O rails may be used as long as current consumption does not exceed 1.5 A.

Output Current Ratings at 40° C (104° F) with 2 KHz Carrier Frequency:

Power ModulePart Number

Power Module Description

Output Current Rating 1


850020-11xxx, -21xxx One Bay Cabinet 534 A

850020-12xxx, -22xxx Two Bay Cabinet 972 A

850020-13xxx, -23xxx Three Bay Cabinet 1457 A

Output Current Ratings 1 Based on Carrier Frequencies at 575 VAC Output


Power ModulePart Number

Carrier Frequency

2 KHz 4 KHz2

2. The current limit is the continuous, maximum current rating and is duty cycle-dependent. The drive can be operated at the overload (maximum) current for up to five minutes with a 10% duty cycle.

850020-11xxx, -21xxx 534 A 445 A / 534 A

850020-12xxx, -22xxx 972 A 890 A / 972 A

850020-13xxx, -23xxx 1457 A 1335 A / 1457 A

Typical Power Module Current 1 and Motor Ratings

PartNumber

230V Motor 380V Motor 460V Motor 575V Motor

Amps KW HP Amps KW HP Amps KW HP Amps KW HP

850020-11xxx850020-21xxx

534 168 225 534 277 371 534 336 451 534 419 561

850020-12xxx850020-22xxx

972 305 409 972 505 677 972 611 819 972 765 1025

850020-13xxx850020-23xxx

1457 459 615 1457 757 1015 1457 918 1230 1457 1146 1536

1. 100% rated output current ratings at 40° C (104° F) ambient air temperature at 2 KHz. Reduce all output current ratings by 5% when the Power Module blowers are operated from a 50 Hz power source.

A-4 High Power SA3000 Power Modules

SA3000 Internal DC Bus Control B-1

APPENDIX BSA3000 Internal DC Bus Control

Each DC input High Power SA3000 Power Module contains a capacitor bank which must be charged before the Power Module can produce current. Because the capacitor bank acts like a DC bus, i.e., it supplies DC power to the inverter section of the Power Module, the capacitor bank is referred to as an “internal” DC bus.

An external DC bus, which can be used to supply DC voltage to the Power Module, is provided by the user. This external DC bus is not under the control of the SA3000 drive.

The internal DC bus in each Power Module consists of the capacitor bank and discharge/voltage sharing resistors. In addition, an optional pre-charge contactor and resistor may be part of this system. Note that if an optional disconnect switch is used, the pre-charge option must also be used. See figure B.1 for a simplified internal DC bus schematic.

If the pre-charge option is present, DC input power can be turned on either before or at the same time that bus control is enabled. Because the pre-charge contactor is initially open, bus charging actually begins as soon as power is turned on to the Power Module, regardless of whether or not bus control has been enabled by the programmer. In the absence of explicit control by the programmer, current to the bus is limited by the pre-charge resistors. Note that if the pre-charge option is not present, the external bus is responsible for controlling the charging of the inverter’s internal DC bus capacitors.

Figure B.1 – Internal DC Bus Schematic

Dischargeand

VoltageSharing

Resistors

(+)

(–)

Pre-chargeContactor

Pre-chargeResistor

(Optional)

Internal DC Bus

DC BusCapacitors

To B & CPower Modules

(If Used)

347

345

ExternalDC Bus

47(+)

45(–)

DisconnectSwitch

(Optional)

FPMA

PowerDevices

ACMotor

B-2 High Power SA3000 Power Modules

The programmer initiates control of the charging process by setting the BUS_ENA@ bit (register 100/100, bit 4). Normally, the PMI processor waits for the rising edge of this bit to start the process. However, if this bit is ON at power-up, the PMI processor will interpret this as a positive transition. The DC bus controller, though, will inhibit the system’s state machine until valid configuration and gain data is received.

Note that the BUS_ENA@ bit must be turned on before the programmer enables the bridge test or the inner control loop in the PMI processor in register 100/1100. If BUS_ENA@ is not enabled first, an interlock error will occur (register 205.1205, bit 6, IC_BUS@) and the drive will not be permitted to execute either the bridge test or the control loop.

In response to the rising edge of the BUS_ENA@ bit, the PMI processor will allow the bus voltage to rise above the undervoltage threshold and then close the pre-charge contactor. This will short out the pre-charge resistors. The PMI processor will set BUS_RDY@ (bit 4 in register 200/1200) when all of the following conditions have occurred:

• the internal DC bus has been enabled via the BUS_ENA@ input

• the internal DC bus voltage has reached the level specified in the tunable variable UVT_E0%

• the internal DC bus voltage is at a steady state

• the pre-charge contactor has closed

Important: The BUS_ENA@ bit must remain on during the bridge test or the execution of the control algorithm in the PMI processor, or the pre-charge contactor will open and the drive will shut down.

If BUS_ENA@ is turned off at any time, power to the power device gates is shut off. Approximately one second later, the pre-charge contactor is opened. If the pre-charge contactor closes when it is not commanded to do so by the PMI processor, register 202/1202, bit 6 (FLT_CHG@) is set and the drive is shut down. (Auxiliary contacts on the pre-charge contactor are used to verify that the pre-charge contactor is open or closed. These auxiliary contacts are pre-wired and require no connection by the user.)

There is a time limit of 10 seconds from the time when the rising edge of the BUS_ENA@ input is detected to the time when the bus voltage must reach the steady state voltage specified in the tunable variable UVT_E0% and the auxiliary contact is required to close. (See the following section for more information on tunable variable UVT_E0%.) If this time limit is exceeded, the pre-charge contactor is opened and the FLT_CHG@ bit (register 202/1202, bit 6) is set. If the bus voltage recovers to the appropriate level within 10 seconds, the pre-charge contactor will be closed and the drive will resume operation.

Refer to figure B.2, the internal DC bus control state diagram (with pre-charge option supplied), for more detailed information.


Figure B.2 – Internal DC Bus Control State Diagram

Idle

Wait for Bus toCharge

Nominal BusVoltage

Reached?

Open Pre-ChargeContactor

AuxiliaryContactsClosed?

PMI SetsBUS_RDY@

Bus Charged

PMI ClosesPre-ChargeContactor

More than 10SecondsElapsed?

Fault OccursRegister 202/1202

More than 10SecondsElapsed?

Open Pre-ChargeContactor

FaultOccurs?

No

BUS_ENA@ OnBegin 10 Second Timer

(2)

(2)

(2)

(2)

(2)

(2)

1. BUS_ENA@ must transistion from off to on to start the bus charging process.

2. BUS_ENA@ must remain on during the drive operation

No

No Yes

Yes

Yes

Yes

Yes

No

(1)


B.1 Modifying Internal DC Bus Voltage Thresholds

The programmer can use three different pre-defined tunable variables to specify three bus voltage thresholds:

• OVT_E0% overvoltage threshold

• UVT_E0% undervoltage threshold

• PLT_E0% power loss threshold

These thresholds define the boundaries for specific operating levels. Figure B.3 shows the relative bus voltage operating ranges and how the tunable variables can affect these ranges.

Important: The three tunable variables listed above should be tuned before enabling the execution of the control algorithm in the PMI Processor to ensure that internal DC bus voltage warning thresholds are set to levels appropriate for the application. See instruction manual S-3042, SA3000 Drive Configuration and Programming, for the acceptable value ranges.

Figure B.3 – Internal DC Bus Operating Range

0 1 2 Time inSeconds

Internal DCBus Voltage

Power Loss Threshold (Tunable PLT_E0%)

Undervoltage Minimum(Tunable UVT_E0% minus5% of nominal bus voltage)

Undervoltage Threshold (Tunable UVT_E0%)

Nominal Bus Voltage

Overvoltage Threshold (Tunable OVT_E0%)

Overvoltage Maximum (Tunable OVT_E0% plus5% of nominal bus voltage)

Hardware Overvoltage (a preset value)

Normal Charging


B.2 Internal DC Bus Protection

The PMI Processor will modify the regeneration or motoring torque limit set by the programmer during parameter entry (calculated from the maximum current and overload ratio parameters) to prevent bus voltage from rising (in the case of regeneration) or falling (in the case of motoring).

During regeneration, if bus voltage reaches the overvoltage threshold, the regeneration torque limit will be reduced, and will be set to zero if the overvoltage maximum is reached. During motoring, if bus voltage reaches the undervoltage threshold, the motoring torque limit will reduced, and will be set to zero if the undervoltage minimum is reached. The PMI processor will set register 203/1203, bit 4 (WRN_RIL@), to indicate that torque is being limited in either direction.

Note that the PMI processor does not modify the reference provided by the UDC task to the PMI processor via register 102/1202, TRQ_REF%. If required, the UDC task can include logic to begin regenerating when DC bus voltage is low.

Refer to Appendix A for specifications on the capacitance, resistance, and charging time of the bus pre-charge circuitry for the High Horsepower SA3000 Power Modules.


Replacement Parts C-1

APPENDIX CReplacement Parts

534 Amp SA3000 Power Module

Table C.1 – 534A SA3000 Power Module

Part Description 1

1. Components are identified in figure 2.2.

Quantity Rockwell

Part Number

Blower Assembly 1 850011-R

IGBT Phase Module Assembly 3 803430-8S

Capacitor Bank Assembly 1 803430-6S

Pre-charge Assembly 1 850022-3_

115 VAC Power Supply Assembly 1 850100-3_

Disconnect Switch (Optional) (600A, 1000 VAC) 1 65242-8B

Fuse (FPM A, F101A/F102A) (1000A,1000VAC) 2 64676-80P

Local Power Interface Module 1 0-60027

250VA Isolation Transformer (250 VA, 110 VAC) 1 417155-16B

PMI Rack Assembly 1 805401-5R

25KHz Power Supply (2A)(115 VAC input, 60 VDC output)

1 802268-16R

LEM Sensor (1000A, 5000:1) 3 600595-18A

0RWRU )HHGEDFN 5HVLVWRUV .Ω : 3 63481-102TFB

DC Feedback Module 1 0-55350-10

Motor Ammeter (Optional) 1 708208-20R

Motor Voltmeter (Optional) 1 708208-18R

Torque Meter (Optional) 1 708208-17R

Frequency Meter (Optional) 1 708208-19R

Blower Filter 1 69470-3RM

Table C.2 – Capacitor Bank Assembly (803430-6S)

Part Description

Quantity Rockwell

Part Number

Capacitor (7200µF, 500 VDC) 18 600442-30SX

Table C.3 – Blower Assembly (850011-R)

Part Description

Quantity Rockwell

Part Number

Blower (115 VAC) 1 69739-47R

Starter Capacitor (40µF, 240 VAC) 1 69932-24QQ

C-2 High Power SA3000 Power Modules

534 Amp SA3000 Power Module (Continued)

Table C.4 – Pre-charge Assembly (850022-3)

Part Description

Quantity Rockwell

Part Number

'LVFKDUJH 5HVLVWRUV .Ω : 10 63481-6V

Contactor (230A, 600 VAC) 1 705310-39BX

Pre-charge Module 1 0-55350-4

Pre-charge Capacitor (4700µH, 50 VDC) 1 600442-31TS

Pre-charge Resistors (3.819Ω) 2 48627-G

Voltage Feedback Module 1 O-55350-10

Table C.5 – 115 VAC Power Supply Assembly (850100-3R, -3S)

Part Description

Quantity Rockwell

Part Number

9'& 3RZHU 6XSSO\ $ 1 704323-33K

115 VAC Circuit Breaker (25A, 600 VAC) 1 or 2 91212-4RA

24 VDC Power Supply (2A) 2 704323-32G

Fuse (1FU) (5A, 600 VAC) 1 64676-29R

Fuse (3FU) (3.2A, 600 VAC) 1 64676-29P

Table C.6 – IGBT Phase Module Assembly (803430-8S)

Part Description Quantity Rockwell

Part Number

IGBT Transistor (600A, 1200 VDC) 4 423402-4S

Warning Thermostat 1 66012-16A

Fault Thermostat 1 66012-16B

Gate Driver/Snubber Module 1 0-55350-15

Fuse (F103A, F104A, F105A) (630A, 1000 VAC) 3 64676-79AZ

Table C.7 – PMI Rack Assembly (805401-5)

Part Description

Quantity Rockwell

Part Number

Power Supply 1 0-60007-2

Processor Module 1 0-60021-1

Resolver Module 1 0-60031-4

AC Technology Module 1 0-60023-3

AC Parallel Interface Module 1 0-60029-1

Gate Driver Interface Module 1 0-60028-1




Part Description 1


Quantity

RockwellPart Number







Fuse (FPM A,B) (F101A,B / F102A,B) (1000A,1000VAC)

4 64676-80P





1 802268-16R

LEM Sensor (1000A, 5000:1) 6 600595-18A

Reactor Assembly (600A, 7.5mH) 2 850022-5R









Part Description

Quantity Rockwell

Part Number



Part Description

Quantity Rockwell

Part Number

Blower (115 VAC) 1 69739-47R




Table C.11 – Pre-charge Assembly (850022-3_)

Part Description

Quantity Rockwell

Part Number








Part Description

Quantity Rockwell

Part Number

9'& 3RZHU 6XSSO\ $ 1 704323-33K



Fuse (1FU) (5A, 600 VAC) 1 64676-29R

Fuse (3FU) (3.2A, 600 VAC) 1 64676-29P



Part Number







Part Description

Quantity Rockwell

Part Number










Part Description 1


Quantity

RockwellPart Number







Fuse (FPM A,B) (F101A,B / F102A,B) (1000A,1000VAC)

6 64676-80P





1 802268-16R

LEM Sensor (1000A, 5000:1) 9 600595-18A

Reactor Assembly (600A, 7.5mH) 3 850022-5R









Part Description

Quantity Rockwell

Part Number



Part Description

Quantity Rockwell

Part Number

Blower (115 VAC) 1 69739-47R




Table C.18 – Pre-charge Assembly (850022-3_)

Part Description

Quantity Rockwell

Part Number








Part Description

Quantity Rockwell

Part Number

9'& 3RZHU 6XSSO\ $ 1 704323-33K



Fuse (1FU) (5A, 600 VAC) 1 64676-29R

Fuse (3FU) (3.2A, 600 VAC) 1 64676-29P



Part Number







Part Description

Quantity Rockwell

Part Number







Index Index-1

INDEX

C

Cabinet installation, 3-3 to 3-7double-bay cabinet (972A unit), 3-5power and ground connections, 3-7single-bay cabinet (534A unit), 3-4triple-bay cabinet (1457A unit), 3-6

Cabinet replacement, 4-20Capacitor bank assembly, 2-2Circuitry

1457A power module, 2-11534A power module, 2-9972A power module, 2-10

Components, 2-1 to 2-51457A power module, 2-5534A power module, 2-3972A power module, 2-4

Configurations, 1-1Control power, 4-13

D

DC bus voltage meter, 2-2Diagnostics and troubleshooting, 4-1 to 4-20

DC bus and output terminal tests, 4-4DC bus voltage measuring points, 4-3faults and warnings, 4-4 to 4-8IGBT tests, 4-4replacing fuses and sub-assemblies, 4-8 to

4-20replacing the cabinet, 4-20required test equipment, 4-1tests with input power off, 4-2 to 4-4

Documentation, 1-4

E

Electrical description, 2-6 to 2-111457A power module circuitry, 2-11534A power module circuitry, 2-9972A power module circuitry, 2-10Drive I/O and processor card, 2-8

F

Fault register 202/1202, 4-5Faults, 4-5 to 4-6

charge bus time-out, 4-6DC bus overcurrent, 4-5DC bus overvoltage, 4-5ground current fault, 4-5instantaneous overcurrent, 4-6local power interface fault, 4-6overtemperature, 4-6

Fiber-optic communication, 2-1Fuses, 3-2, 4-8 to 4-14

1457A power module fuse locations, 4-1215V and 24V power supplies, 4-1325KHz power supply, 4-14534A power module fuse locations, 4-10972A power module fuse locations, 4-11replacement fuse specifications, 4-9replacing fuses, 4-8 to 4-14

G

Grounding, 3-3, 3-7

I

Installation guidelines, 3-1 to 3-7cabinet installation, 3-3 to 3-7grounding, 3-3installation planning, 3-1terminal tightening torques, 3-3wire sizes, 3-2 to 3-3wiring, 3-2 to 3-3

Internal DC bus control, B-1 to B-5bus control state diagram, B-3bus protection, B-5internal DC bus schematic, B-1modifying DC bus voltage thresholds, B-4operating range, B-4

Introduction, 1-1 to 1-3

L

Local power interface module (LPI), 2-2

Index-2 High Power SA3000 AC Power Modules

M

Main disconnect, 2-2Mechanical description, 2-1 to 2-5

1457A power module components, 2-5534A power module components, 2-3972A power module components, 2-4

Mechanical/electrical description, 2-1 to 2-11Mounting dimensions

1335A triple-bay power module, 3-6534A single-bay power module, 3-4972A double-bay power module, 3-5

O

Optional features, 1-2Output meters, 2-2

P

Part numbers, 1-3Phase modules

description, 2-1mounting bolt locations, 4-17

Power and ground connections, 3-7Power supply

115VAC control power, 2-2, 4-1325 KHz, 2-2, 4-14

Pre-charge assembly, 2-2

R

Related publications, 1-4Replacement parts, C-1 to C-6

1457A power module, C-5 to C-6534A power module, C-1 to C-2972A power module, C-3 to C-4

Replacing components, 4-8 to 4-20

blower assembly, 4-18 to 4-19blower filter, 4-19bus capacitor assembly, 4-19 to 4-20fuses, 4-8 to 4-14IGBT phase module assemblies, 4-15 to 4-17pre-charge assembly, 4-17 to 4-18

Replacing the power module cabinet, 4-20

S

Snubber/gate driver module, 2-1Standard features, 1-1

T

Technical specifications, A-1 to A-3115VAc control power, A-2ambient conditions, A-1DC bus, A-2DC bus input power, A-2dimensions, A-1output power, A-3

Terminal tightening torques, 3-3

W

Warning register 203 /1203, 4-7Warnings, 4-7 to 4-8

DC bus overvoltage, 4-7DC bus undervoltage, 4-7ground current warning, 4-7load sharing warning, 4-7overtemperature, 4-8

Wiring, 3-2 to 3-3, 3-7see also Installation guidelineswire routing, 3-3wire sizes, 3-2 to 3-3

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Printed in U.S.A. S-3038 October 1998

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