User Manual PowerFlex DC Stand Alone Regulator and Gate Amplifier
Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices.
Summary of Changes This manual contains new and updated information. Topic Page Removed the reference to the S12 / S12R configuration from the Features list.
Summary of Changes 4 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Table of Contents Preface Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 What This Manual Contains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Drawing Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Specifications History of Changes Index 6 Appendix A Stand Alone Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gate Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gate Coupler Assembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gate Scaling Module Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface Purpose of This Manual This manual provides installation instructions and connection and configuration information for the PowerFlex® DC Stand Alone Regulator (SAR) and the Gate Amplifier. It is intended for internal Rockwell Automation use only.
preface Notes: 8 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Chapter 1 Introduction General Precautions Prior to installation of either the Stand Alone Regulator or Gate Amplifier, read the following precautions. ATTENTION: Energized industrial control equipment can be hazardous. Severe injury or death can result from electrical shock, burn, or unintended actuation of controlled equipment. Hazardous voltages may exist in the cabinet even with the circuit breaker in the off position.
Chapter 1 Introduction Product Overview The PowerFlex DC Stand Alone Regulator (SAR) and Gate Amplifier products provide an integrated solution for controlling external DC power modules. Stand Alone Regulator (SAR) The SAR is a DC drive regulator that provides armature regulation, armature SCR gate signals and a regulated field supply. The SAR field supply consists of a single phase, two quadrant (non-reversing,) full wave rectified bridge, available as 40 or 70 Amps.
Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 To Motor Field C1 D1 Power Module AC / DC Feedback DCWVU KP Power Module Armature Voltage Feedback 1A1 A1 1A2 A2 KA All Terminals are located on the bottom of the unit. Power Module Thermostat and CT Feedback 12345678 KPT31 KPT11 (15 Pin D-Shell) PowerFlex DC Stand Alone Regulator Field Supply 40 A or 70 A (2 Quad) V1 U1 Normally Open Contacts to Stop Circuitry Gate Cable RDY + - Ext.
Chapter 1 Introduction Stand Alone Regulator Features • Rockwell Automation Architecture Class networking capable Available Options • Resolver Feedback Catalog Numbers This table lists the available catalog numbers for the SAR. 230V / 460V AC Input Catalog Number 23PMD4 23PMD7 575V / 690V AC Input Catalog Number: 23PMF4 23PMF7 Field Amps 40 70 Note: All models contain conformal coated circuit boards.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration Prepare for Installation Prior to installation of the PowerFlex DC Stand Alone Regulator (SAR) read the General Precautions on page 9. Mounting Considerations Operating Conditions and Temperatures The SAR is designed to operate at 0°…50° C (32°… 122° F) surrounding air temperature without derating. The unit must be mounted in a clean, dry location.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration Minimum Mounting Clearances Minimum clearance requirements (indicated in Figure 2 - Drive Enclosure Minimum Mounting Clearances) are intended to be from enclosure to enclosure. Other objects can occupy this space; however, reduced airflow may cause protection circuits to fault the SAR. The SAR must be mounted in a vertical orientation as shown and must not be mounted at an angle greater than 30 degrees from vertical.
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2 Approximate Dimensions and Weights The SAR is available in a NEMA/UL Type Open, IP20 enclosure only. ATTENTION: Remove all loose packaging materials, including any desiccant packages from the enclosure before mounting and energizing the SAR. Dimensions are shown in mm (in.) 8.4 (0.33) 23.3 (0.92) 250.0 (9.84) 285.4 (11.24) 19.5 (0.77) 275.0 (10.83) 397.9 (15.67) 341.0 (13.43) 266.8 (10.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration CE Conformity Conformity with the Low Voltage Directive and Electromagnetic Compatibility Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. The PowerFlex DC Stand Alone Regulator complies with the EN standards listed when installed according to this User Manual. CE Declarations of Conformity are available online at: www.rockwellautomation.
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2 Table 2 - Pollution Degree Ratings According to EN 61800-5-1 Pollution Degree Description 1 No pollution or only dry, non-conductive pollution occurs. The pollution has no influence. 2 Normally, only non-conductive pollution occurs. Occasionally, however, a temporary conductivity caused by condensation is to be expected, when the drive is out of operation.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration Terminal/Signal and Wiring Diagrams Use the diagram in Figure 3 - Stand Alone Regulator Terminal/Signal Block Diagram as a guide for the general location of and connection signals for the main input/output terminal blocks on the SAR. The diagram in Figure 4 on page 19 represents the recommended wiring for a typical SAR interface to a S6R power module.
U1 V1 V D1 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 Armature Voltage Feedback Armature Current Feedback Motor Field C1 + Field PM Therm Field Regulator (2 Quad) See page 21 for Fuse Sizes (External to SAR) Transformer (External to SAR) U From Incoming AC Line J4 Ext. Rb XCT #S2 (Test Pt.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration Field Power Module Bridge and Ground Wiring The SAR contains a two quadrant field power module bridge. The field bridge input circuit is rated for 100VAC…460VAC, ±10%, 50/60 Hz. The input and output connections to/from the field bridge are on the bottom of the SAR as shown. An external transformer with appropriate primary fusing is required to supply the field.
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2 Table 4 - Recommended Field Power Module Bridge Input Fuses Fuse Type: SAR Field Bridge Rating Bussmann Ferraz Shawmut Siba 40 A FWP-50A22Fa A70QS50-22F 5014006.50 70 A FWP-100A22Fa A70QS100-22F 5014006.100 The recommended fuse holder is a Cooper-Bussman, CH222D or equivalent - to accommodate 22 mm x 58 mm fuses. Safety Ground (PE) The Safety Ground - PE must be connected to system ground.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration Figure 6 - AC /DC Voltage Feedback (KP) and Motor Armature Voltage Feedback (KA) Terminal Blocks Bottom View of SAR KPT21 KPT11 D C W V U 1 AC /DC Voltage Feedback (KP) Terminal Block V1 U1 C1 D1 KPT31 1 2 3 4 5 6 7 8 PE 1A1 (C)A1 1A2 (D)A2 2 Motor Armature Voltage Feedback (KA) Terminal Block Table 5 - AC / DC Voltage and Motor Armature Voltage Feedback Terminal Specifications No.
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2 Connector KP Wiring • Connect the motor armature terminal C to terminal C on connector KP • Connect the motor armature terminal D to terminal D on connector KP Connector KA Wiring Connector KA must be wired to provide DC voltage feedback to the field regulator to control the field current based on the armature voltage.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration Power Module Thermal Switch and Current Transformer Wiring Connector KPT31 is used for power module thermal switch monitoring and current feedback via current transformer connections. Note that the thermal monitor circuit includes a thermal switch on the field power module within the SAR.
Stand Alone Regulator Installation, Wiring and Configuration SAR Gate Output Cable Chapter 2 Connect the SAR gate output cable (23PAMP-Cx) to connector KPT11 on the SAR unit. The opposite end connects to the POWERFLEX DC SAR GATE INPUT on the Gate Amplifier. See Chapter 3 Gate Amplifier Installation and Wiring on page 41 for more information on Gate Amplifier installation and connections. See Cable Specifications on page 78 for information on available cable lengths for the 23PAMP-Cx cable.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration Relay Output and Thermistor/Thermal Switch Wiring Two normally open relay outputs and one motor thermistor (PTC) or thermal switch input are available for use and must be configured with the appropriate parameters. See “Relay Outputs” and “Thermistors and Thermal Switches” in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001 for details.
Stand Alone Regulator Installation, Wiring and Configuration SAR Sizing Chapter 2 DIP switch S15 is configured for the appropriate SAR size at the factory. Do not change the settings unless you are installing a replacement control board.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration SAR Current Feedback Configuration Overview The current feedback to the SAR, provided via current transformers (CTs) that monitor the U and W phase inputs to the power module, is rectified via a three phase diode bridge. The output of the diode bridge is connected to a burden resistor. The voltage across the burden resistor is directly proportional to the amount of current being drawn by the motor load.
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2 amplifier (Op-Amp) circuit has been provided. For reference, the name of this circuit will be called the “Binary Gain Amp,” because the gain of the amplifier is set via binary DIP switches. See Figure 12 on page 38 for a diagram of the Binary Gain Amp circuit and Figure 13 on page 39 for DIP switch locations. When properly configured, the output of the Binary Gain Amp is 0.612 Volts at 100% load of the power module.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration Current Feedback Calculations Inputs to the CT Calculation: • The variable “IdN_pm_rtg” used in the calculations is the value of parameter 465 [Drive Size] • Rb is the burden resistor which can be either 2.5 Ohms or 5.
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2 SAR Current Feedback Calculation Examples Example 1: CT, Burden Resistor and Gain Calculation Input Values Units Description IdN_pm_rtg: = 2600 Amp Power module rating Rb:= 5.0 Ohms Jumper J5 in the “On” position and jumper J4 in the “Off” position. See Figure 13 on page 39 for jumper locations. CT_pri: = 10000 Amp CT_sec: = 1 Amp Minimum CT Primary based on IOC trip point of 2.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration Binary Gain Calculation and Checking Gain Error Binary_Sw_Setting = 108.
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2 Example 2: CT, Burden Resistor and Gain Calculation Input Values Units Description IdN_pm_rtg: = 226 Amp Power module rating Rb:= 2.5 Ohms Jumpers J4 and J5 in the “On” position. See Figure 13 on page 39 for jumper locations. CT_pri: = 2000 Amp CT_sec: = 1 Amp Minimum CT Primary based on IOC trip point of 2.5 x Power Module rating Value/Calculation Units Description IOC_mult: = 2.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration Binary Gain Calculation and Checking Gain Error Binary_Sw_Setting = 23.
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2 Example 3: The only difference between Example 2 and Example 3 is the value of the burden resistor. In this example the burden resistor is chosen as Rb = 5.0 Ohms. In this example a standard CT ratio is chosen and the ratio no longer exceeds the recommended CT ratio based on the gain calculation. This is due to the change of the burden resistor from 2.5 Ohms to 5.0 Ohms.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration Value/Calculation Units Vb_at_IdN_pm_rtg = 0.565 Volts Description Gain_Required: = Vf_at_IdN_pm_rtg / Vb_at_IdN_pm_rtg Gain_Required = 1.083 Note: Required Gain = 1.083, which is within the Recommended Gain <= 1.2 (for best accuracy) Checking the Maximum Voltage Feedback to Regulator Value/Calculation Units Description Binary_Sw_Setting: = 51.2 / Gain_Required Binary_Sw_Setting = 47.
Stand Alone Regulator Installation, Wiring and Configuration Value/Calculation Units Chapter 2 Description R_fdbk = 21.787 R_input = 20 Fixed input resistor Gain_Binary_OA: = R_fdbk / R_input Gain_Binary_OA = 1.089 versus Gain_Required = 1.083 Comparing the “Binary Gain Amp” to the “Calculated Required Gain” Per_Cent_Gain_Error: = (Gain_Binary_OA Gain_Required / Gain_Required) x 100 Per_Cent_Gain_Error = 0.57 The error is now less than 1%.
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration Figure 12 - Binary Gain Amplifier Circuit Diagram 500 SW3 MSB 1K 0VI 2K 3K 8K SW4 16K 32K 64K 128K 256K 512K 1024K LSB 0VI 0VI 0VI 38 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012 0VI
Stand Alone Regulator Installation, Wiring and Configuration Chapter 2 Figure 13 - Burden Resistor Jumpers (J4 and J5), Binary Gain Amp DIP Switches (SW3 and SW4), and External Burden Resistor Terminal Block (XCT) Locations Pulse Transformer Board Binary Gain Amp DIP Switches LSB MSB ON Off SW3 SW4 On J5 J4 0VI Burden Resistor Jumpers XCT RCT External Burden Resistor Terminal Block (XCT) Figure 14 - Binary Gain Amp DIP Switch to Bit Layout MSB LSB SW3 SW4 ON 1 2 3 Bit 11 Bit 10 Bit 9 IM
Chapter 2 Stand Alone Regulator Installation, Wiring and Configuration SAR Programming and Startup SAR programming and startup require a Human Interface Module (HIM) or DriveExplorer™ or DriveTools SP™ software with a network connection made using a communication adapter. The SAR is not sold with a HIM or communication adapter. These products must be purchased separately.
Chapter 3 Gate Amplifier Installation and Wiring Prepare for Installation Prior to installation of the Gate Amplifier read the General Precautions on page 9. Operating Temperatures The surrounding air temperature must be within 0 ° C to 50 ° C (32 ° F to 122 ° F). Humidity must remain between 5% and 95% non-condensing.
Chapter 3 Gate Amplifier Installation and Wiring Mounting and Cooling The Gate Amplifier is an open type construction and is intended to be installed on a flat surface in a suitable enclosure. The unit must be mounted in the upright position (faceplate lettering legible and the mounting back plate vertical) to ensure effective convection cooling. Follow these instructions when mounting the Gate Amplifier: • Mount in a clean, dry location.
Gate Amplifier Installation and Wiring Chapter 3 Figure 16 - Approximate Dimensions Dimensions in inches and (millimeters) 4.63 (117.6) 10.61 (269.4) 11.05 (280.7) 11.63 (295.3) 10.08 (256.1) 0.33 (8.3) 0.86 (21.8) 3.00 (76.2) 11.66 (296.2) Table 8 - Gate Amplifier Weights Gate Amplifier 5.0 kg (11.0 lb) Gate Amplifier & Packaging 5.7 kg (12.5 lb) Recommended Mounting Hardware: Metric M5, English #10 IMPORTANT Provide at least 114 millimeters (4.
Chapter 3 Gate Amplifier Installation and Wiring Power and Ground Wiring Figure 17 - Power and Ground Connections 4 1 2 3 Table 9 - Terminal Specifications No. Name Input Power 1 Terminal Block L1, L2, Ground Ground Stud 2 External Gate 3 Power Supply 4 Ready Relay Wire Size Range Part Number for Customer Plug Description (provided with Gate Amplifier) Maximum Input power - Line 94809302 4.
Gate Amplifier Installation and Wiring Chassis Grounding Chapter 3 A ground stud is provided on the lower right corner of the chassis mounting flange for making a ground connection. Connect the grounding wire provided to the ground stud and the metal panel. Make sure that the lug makes a good connection to the panel.
Chapter 3 Gate Amplifier Installation and Wiring Key Grounding/Bonding Points Outside of the Cabinet The high frequency grounding/bonding outside of the cabinet should be treated in a manner similar to a power supply mounted on a ground plane with all of the components that it supplies, mounted on the same ground plane. In the case of the drive system, the transformer can be thought of as the power supply for the downstream components; AC entry bay, drive cabinets, and motors.
Gate Amplifier Installation and Wiring Chapter 3 Table 10 - Recommended Welding Cable for High Frequency Grounding/Bonding Drive System Nominal Motor FLA Per Section Recommended Welding Cable Size Cable Type 100…3000 Amps 2/0 Anixter #5J-2021 or Equivalent 3001…5000 Amps 3/0 Anixter #5J-3031 or Equivalent 5001…9000 Amps 250 MCM Anixter #5J-2501 or Equivalent 9001…20000 Amps 500 MCM Anixter #5J-5001 or Equivalent DC Drive High Frequency Grounding of Adjacent Cabinet Panels Unless there is go
Chapter 3 Gate Amplifier Installation and Wiring Control Wiring Connections Refer to Table 11 on page 49 for a description of the control connections identified in Figure 19 - Gate Amplifier Drive Control.
Gate Amplifier Installation and Wiring Chapter 3 Table 11 - Indicators and Control Connection Descriptions No. Label on Gate Amplifier GPS 1 LPS GATE FUSE OK GATE POWER 2 3 4 5 6 7 8 9 POWERFLEX DC SAR GATE INPUT SD3000 PLUS FWD GATE INPUT SD3000 PLUS REV GATE INPUT RDY EXT GATE P/S FWD - GATES REV - GATES 120VAC Description +28V Gate Power Supply output present LED Function This LED is illuminated when the gate power supply output is present. See GPS below for more information.
Chapter 3 Gate Amplifier Installation and Wiring GATE FUSE OK The “GATE FUSE OK” LED circuit is used to monitor the fuse for the external power supply. To sense whether the fuse is open, the voltage across the fuse is monitored. If the fuse is open and the Gate Amplifier is provided with gate firing pulses, the “GATE FUSE OK” LED will turn off and the Ready Relay will drop out. The fuse is internal to the Gate Amplifier and is soldered to the Gate Driver Output board, it is not replaceable in the field.
Gate Amplifier Installation and Wiring Chapter 3 RDY This is the Ready relay interlock. The Gate Amplifier has Normally Open relay contacts that close when the Gate Amplifier is “ready to run.” The Ready relay is to be wired into the drive “Run Permissive” logic. The Ready relay will “drop out” when the Gate Amplifier has a malfunction. The Ready relay circuit is rated at 1.4 Amps, (fused at 2 Amps, relay contacts rated at 2 Amps).
Chapter 3 Gate Amplifier Installation and Wiring FWD - GATES and REV - GATES Four identical forward and four identical reverse gate outputs provide gate signals for up to four power modules. The output is a burst pattern that has a maximum amplitude dependent on the gate power supply that is used, internal or external. The internal “ORing” diode determines whether the internal or external power supply is used.
To Motor Field C1 D1 Power Module AC / DC Feedback DCWVU KP Power Module Armature Voltage Feedback 1A1 A1 1A2 A2 KA All Terminals are located on the bottom of the unit. Power Module Thermostat and CT Feedback 12345678 KPT31 KPT11 (15 Pin D-Shell) PowerFlex DC Stand-alone Regulator Field Supply 40 A or 70 A (2 Quad) V1 U1 Normally Open Contacts to Stop Circuitry Gate Cable RDY + - Ext.
Chapter 3 Gate Amplifier Installation and Wiring Gate Amplifier, Cascade Configurations It is permissible to cascade Gate Amplifiers. The time delay through the Gate Amplifier is 0.5 μSec. This amount of time delay is not significant with regard to the gate firing of parallel power modules. For any configuration with multiple Gate Amplifiers, be sure to connect the Ready relay into the “Run Permissive” circuit.
Gate Amplifier Installation and Wiring Chapter 3 Figure 22 - Cascading Gate Amplifiers Using the Stand Alone Regulator, Mixed Configuration PFDC Gate Input FWD To Forward Power Modules SD3K FWD IN REV From Gate Amplifier, FWD Output To Reverse Power Modules SD3K REV IN FWD Output Cables SD3K-CBLGSCLIFxxx Gate Cable From Gate Amplifier, REV Output 120VAC Ext.
Chapter 3 Gate Amplifier Installation and Wiring Figure 23 - Cascading Gate Amplifiers Using the SD3000 PLUS PFDC Gate Input FWD To Forward Power Modules SD3K FWD IN REV From Gate Amplifier, FWD Output To Reverse Power Modules SD3K REV IN FWD Output Cables SD3K-CBLGSCLIFxxx From Gate Amplifier, REV Output 120VAC Ext.
Gate Amplifier Installation and Wiring Chapter 3 Figure 24 - Cascading Gate Amplifiers Using the SD3000 PLUS, Mixed Configuration PFDC Gate Input FWD To Forward Power Modules SD3K FWD IN REV From Gate Amplifier, FWD Output To Reverse Power Modules SD3K REV IN FWD Output Cables SD3K-CBLGSCLIFxxx From Gate Amplifier, REV Output 120VAC Ext.
Chapter 3 Gate Amplifier Installation and Wiring Gate Interface to Rockwell Automation Power Modules Rockwell Automation power modules 356405-Cxx, 356406-Cxx and 356407Cxx do not contain gate couplers. The gate couplers are contained in a separate unit called the Gate Coupler Assembly. The basic interface configuration is shown in Figure 25 - Connection to Rockwell Automation Power Modules. Cables appear in the tables following the illustration below.
Chapter 4 Retrofit Guidelines Gate Interface to NonRockwell Power Module, Retrofit To interface to the SCR gates of a “non-Rockwell” power module, any existing gate couplers in the power module should be replaced with the Rockwell Automation gate couplers. This will greatly simplify the gate interface because the characteristics of a standard Rockwell Automation interface are already defined.
Chapter 4 Retrofit Guidelines Cables appear in the following tables. Table 15 - Round Style Connector Forward Gate Cables Catalog Number SD3K-CBLFWDPM060 SD3K-CBLFWDPM120 SD3K-CBLFWDPM180 SD3K-CBLFWDPM240 Length 5 Feet 10 Feet 15 Feet 20 Feet Additional lengths can be found on drawing 97305100.
Chapter 4 Retrofit Guidelines Figure 27 - Retrofit of Non-Rockwell Power Module (S6R) w/Gate Coupler Assembly Power Module Gate Amplifier (Drawing 97305100) FWD GATES SD3K-CBLFWDPMxxx (Drawing 97305300) REV GATES SD3K-CBLREVPMxxx Gate Coupler Assembly SD3K-GATMDLHIGH (Drawing 97329101) (9732017* to view drawing) SD3K-CBLCPLR072 (Make as short as possible. Do not route with power leads.
Chapter 4 Retrofit Guidelines Figure 28 - Retrofit of Reliance Electric Power Module (S6R) with “Round” Style Gate Connector and with O-51378-19 (or Equivalent) Gate Couplers Reliance Electric (S6R) Power Module Gate Amplifier (Drawing 97330000) FWD GATES SD3K-CBLGSCLIFxxx (Drawing 97330100) REV GATES Gate Scaling module (Part No. 97331001) SD3K-CBLGSCLIRxxx FWD (Drawing 97305100) SD3K-CBLFWDPMxxx Gate Scaling module (Part No.
Retrofit Guidelines Chapter 4 Table 20 - Gate Amplifier to Gate Scaling Module Reverse Gates Cables Catalog Number SD3K-CBLGSCLIR024 SD3K-CBLGSCLIR036 SD3K-CBLGSCLIR060 Length 2 Feet(1) 3 Feet 5 Feet (1) Before using this cable length consider the mounting position of the Gate Scaling Module, as the cable may not be long enough to reach between the gate output port of the Gate Amplifier and the panel where the Gate Scaling Module is mounted. Additional lengths can be found on drawing 97330100.
Chapter 4 Retrofit Guidelines Gate Interface to Dierikon Power Modules To interface to the SCR gates of a Dierikon power module a direct connection can be made to the gate input without the need for the Gate Scaling Module. • Forward Gate Cable to interface Gate Amplifier to Dierikon Power Module. 612436-xxxW, where xxx is the length in inches. To view drawing: 612436* • Reverse Gate Cable to interface Gate Amplifier to Dierikon Power Module. 612567-xxxW, where xxx is the length in inches.
Chapter 5 Power Interface and SCR Firing Order Parallel Power Modules and Load Share Reactors When power modules are placed in parallel, load share reactors must be in place on the AC side of the power modules on each of the phases (see Figure 20 on page 53). The purpose of the load share reactors is to ensure that any one of the group of parallel power modules does not take up more than “its share” of the load.
Chapter 5 Power Interface and SCR Firing Order Figure 30 - SCR (Thyristor) Positions L1 MOTORING RE -GEN L3 4 THY 1 THY 5 THY 2 THY 6 THY 3 THY 11 THY 14 THY 12 THY 15 THY 13 THY 16 THY M 66 L2 A1 + M A2 - Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Power Interface and SCR Firing Order Chapter 5 If the power module is not firing properly, check the timing relative to the AC Line, with the L1 to L3 signal acting as the reference point. Using a two channel oscilloscope, the L1 to L3 waveform will be on channel 1 and then the gate pulse positions relative to the AC line can be checked one at a time with channel 2. Caution: Be certain that the oscilloscope probe is rated for the line voltage before taking the measurement from L1 to L3.
Chapter 5 Power Interface and SCR Firing Order Figure 32 below shows an actual oscilloscope image of the gate pulse output relative to the AC Line, L1 to L3, with negative phase rotation (L3, L2, L1). The waveform shown in Figure 32 was generated by using the Alpha Test with the firing angle set at 5 Degrees (full on).
Power Interface and SCR Firing Order Chapter 5 Figure 33 - Firing Series SCRs (Thyristors) Harness Part Number for S6: 97305401 Drawing 97305400 Catalog Number - SD3K-CBLFWDPMxxx (xxx = length in inches) Drawing 97305100 (Forward) Or Catalog Number - SD3K-CBLREVPMxxx (xxx = length in inches) Drawing 97305300 (Reverse) D-Shell to Gate Amplifier Output Use bracket 608877-6A for mounting connector Harness Part Number for S6R: 97305402 Drawing 97305400 One of six twisted pair in cable.
Chapter 5 Power Interface and SCR Firing Order Figure 34 - Firing Parallel SCRs (Thyristors) Harness Part Number for S6: 97305401 Drawing 97305400 One of six twisted pair in cable.
Appendix A Specifications Stand Alone Regulator Electrical Field Bridge Input Voltage 100VAC…460VAC, ±10%, 50/60 Hz Control Supply Input Current 115VAC/1AAC or 230VAC/0.5AAC Environmental Operating Temperature 0 ° C to 50 ° C (32 ° F to 122 ° F) Storage Temperature -25 ° C to 55° C (-13 ° F to 131 ° F) Relative Humidity 5% to 95%, Non-condensing Note: Contamination from oils, corrosive vapors and abrasive debris must be kept out of the enclosure.
Appendix A Specifications Hardware Descriptions The following table provides a functional description of each printed circuit board and component of the Gate Amplifier. Table 27 - Printed Circuit Board and Component Descriptions Board/Component Description Main Board The Main board provides an optical isolation layer between the Regulator and the Gate Amplifier circuits. In addition, it provides the necessary permissive PN-25913 interlock circuits and LED annunciation of system status.
Specifications Gate Coupler Assembly Information Appendix A Gate Coupler Assemblies, Catalog Numbers SD3K-GATMDLHIGH and SD3K-GATMDLLOW The Gate Coupler Assembly provides an isolation barrier between the Gate Amplifier and the SCR Gates. Two different units are available depending on the load requirements. The “SD3K-GATMDLHIGH” provides a higher output than the “SD3K-GATMDLLOW”.
Appendix A Specifications Gate Coupler Assembly Mounting Instructions The Gate Coupler Assembly is an open type construction and is intended to be installed on a flat surface in a suitable enclosure. • Mount in a clean, dry location. Contamination from oils, corrosive vapors and abrasive debris must be kept out of the enclosure. • Mount the unit in a vertical or horizontal position depending on the panel layout.
Specifications Appendix A Figure 36 - Gate Coupler Assembly Mounting Dimensions, Ground Terminal, and Input / Output Connections 3.13" 2.63" 2.80" 0.22" - 4 PLACES Exit Port (each side) for SCR Gate Cables Gate Coupler Assembly 12.75" 3.13" 12.25" Ground Stud, (ground cable provided with unit). See Table 29 - Terminal Specifications. Input Connection 4.75" Table 28 - Gate Coupler Assemblies, Catalog Numbers SD3K-GATMDLHIGH and SD3K-GATMDLLOW Weights Gate Coupler Assembly 1.5 kg ( 3.
Appendix A Specifications Gate Scaling Module Information Gate Scaling Module, Part No. 97331001 The Gate Scaling Module provides a means to interface with Reliance Electric Power Modules with existing Gate Coupler Modules that are electrically equivalent to the “O-51378-19” Gate Coupler. The Gate Scaling Module provides a resistor in each of the SCR gate lines to reduce the voltage applied to the gate couplers in the power module. The O-51378-19 Gate Coupler (and equivalent gate couplers) have 0.
Specifications Appendix A Figure 37 - Gate Scaling Module Mounting Dimensions Input / Output Connections INPUT 60.5 mm (2.38 in.) OUTPUT GATE SCALING MODULE 37.25 mm (1.47 in.) (Center Diameter) Engineered by Part No. 97331001 124.0 mm (4.88 in.) 138.0 mm (5.43 in.) Notes: Module Depth = 31.0 mm (1.22 in.) Mounting Holes: 4.25 mm (0.17 in.) Part No. 97331001 - To view drawing, 97331000. Table 30 - Gate Scaling Module, Part No. 97331001 Weights Gate Scaling Module 0.9 kg (0.
Appendix A Specifications Cable Specifications Catalog Number SD3K-CBLFWDELC*** *** (length in inches) Following are the cable assemblies available for use with the Gate Amplifier and Stand Alone Regulator: Part Number 97305000 (Substitute “00” with desired length code) Description/Length 01 02 03 04 05 06 07 08 09 60” 120” 180” 240” 300” 360” 480” 600” 720” Connects the FORWARD gate signals from the Gate Amplifier Control to a Power Box using an “ELCO” style connector.
Appendix A Specifications Catalog Number SD3K-CBLBOXA048 SD3K-CBLBOXB048 Part Number 97305400 (substitute “00” with desired code) Description/Length 01 02 Motoring (S6), 48” gate leads Motoring & Regen (S6R), 48” gate leads (6 total) (12 total) Connects the output side of one (1) gate coupler to its corresponding SCR in the Power Box. Picture/Details XXX (1 of 6 pairs) This end connects to the output pins on the Gate Coupler Board identified as “WW2”.
Appendix A Specifications Catalog Number SD3K-CBLGSCLIR*** *** (length in inches) Part Number 97330100 (substitute “00” with desired length code) Description/Length 01 02 03 04 05 06 07 08 09 24” 36” 60” 120” 180” 240” 300” 360” 480” Connects the REVERSE gate signals from the Gate Amplifier Control to the Gate Scaling Module (INPUT connector).
Specifications Catalog Number Part Number Description/Length 23PAMP-C2 23PAMP-C1 23PAMP-C PN-104829 PN-104828 PN-54636 2 feet (24 inches) PowerFlex DC SAR Gate Output to Gate Amplifier cable 5 feet (60 inches) PowerFlex DC SAR Gate Output to Gate Amplifier cable 10 feet (120 inches) PowerFlex DC SAR Gate Output to Gate Amplifier cable 15 PIN D-Shell Low Density (Female) Appendix A 25 PIN D-Shell Low Density (Female) 10 Conductor Shielded Cable Strain Relief This end connects to the 15 PIN D-Shell
Appendix A Specifications Notes: 82 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Appendix B History of Changes This appendix summarizes the revisions to this manual. Reference this appendix if you need information to determine what changes have been made across multiple revisions. This may be especially useful if you are deciding to upgrade your hardware or software based on information added with previous revisions of this manual.
Appendix B History of Changes Notes: 84 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
Index Numerics 120VAC Input 49 A AC feedback connections Stand Alone Regulator 21 C cabinet panels high frequency grounding 47 cable size high frequency grounding 47 cables Gate Interface to Reliance Electric U.S.
Index Gate Interface to non-Rockwell power module, retrofit 59 to Reliance Electric Dierikon power modules 64 to Reliance Electric U.S.
Index relay outputs Stand Alone Regulator 26 resolver feedback Stand Alone Regulator 26 REV GATES 49 reverse gates output 49, 52 S safety ground Stand Alone Regulator 21 SD3000 PLUS forward gates input 50 SD3000 PLUS FWD Gate Input 49 SD3000 PLUS REV gate input 49 SD3000 PLUS reverse gates input 50 specifications cables 78 electrical (Gate Amplifier) 71 electrical (SAR) 71 environmental (Gate Amplifier) 71 environmental (SAR) 71 watts loss (SAR) 71 Stand Alone Regulator AC feedback connections 21 catalog
Index 88 Rockwell Automation Publication 23P-UM001D-EN-P - July 2012
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