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Rockwell Automation SD3100 Instruction Manual

Rockwell Automation SD3100 Instruction Manual

Distributed power system, dc power modules
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Distributed Power System
SD3100 DC Power Modules
1250A, 1650A, 3000A DC
Instruction Manual
S-3064

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  • Page 1 Distributed Power System SD3100 DC Power Modules 1250A, 1650A, 3000A DC Instruction Manual S-3064...
  • Page 2 (electrostatic discharge). Static control precautions are required when installing, testing, or repairing this assembly. Component damage can result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to Rockwell Automation publication 8000-4.5.2, Guarding Against Electrostatic Damage , or another adequate handbook on ESD protection.

  • Page 3: Table Of Contents

    ONTENTS Chapter 1 Introduction Field Power Module ..................1-3 Standard Features ................... 1-3 Optional Features .................... 1-4 Related Publications ..................1-4 Terms Used in this Manual ................1-5 Chapter 2 Mechanical/Electrical Description Mechanical Overview ..................2-2 2.1.1 Control Components ................2-2 2.1.2 Power Components................
  • Page 4 4.3.4 Field Power Module ................4-5 4.3.4.1 Replacing Internal Field Power Module AC Input Fuses ..4-5 4.3.4.2 Replacing Field Power Module Components ......4-6 Appendix A Technical Specifications................... A-1 Appendix B Schematics....................... B-1 Appendix C Replacement Parts....................C-1 Index ...........................Index-1 SD3100 Power Modules...
  • Page 5 List of Figures Figure 1.1 – SD3100 Catalog Numbering Scheme ..........1-1 Figure 2.1 – SD3100 Power Module System Components ........2-1 Figure 2.2 – Regulator Assembly ................2-2 Figure 2.3 – Armature Bridge (Non-Regenerative)........... 2-5 Figure 2.4 – Armature Bridge (Regenerative)............2-6 Figure 2.5 –...
  • Page 6 SD3100 Power Modules...
  • Page 7 List of Tables Table 1.1 – SD3100 Drive Options ................1-2 Table 1.2 – Field Power Module Part Numbers............1-3 Table 1.3 – Distributed Power System DC Drives Documentation......1-4 Table 1.4 – Related Motor Control Center Documentation........1-5 Table 2.1 – 1250A Configurations ................2-9 Table 2.2 –...
  • Page 8 SD3100 Power Modules...

  • Page 9: Chapter 1 Introduction

    Power Module Interface (PMI) rack, which contains the drive’s control circuits and executes the motor control algorithm. The SD3100 configuration provides control of DC motors, rated 700 to 2500 HP, with current ratings of 1250, 1650, and 3000A. Input voltages of 460, 575, and 660 VAC are available.

  • Page 10: Table 1.1 - Sd3100 Drive Options

    Table 1.1 – SD3100 Drive Options Drive Option Code Description Standard capacity control transformer with primary fusing 115 VAC control power, factory wired from 115 VAC control bus to drive unit Control Power Source (1250 and 1650A units only). Requires option CB90...

  • Page 11: Field Power Module

    The Field Power Module requires a separately-ordered, separately-mounted field isolation transformer. The Field Power Module’s AC input lines are connected through the isolation transformer to the L1 and L3 inputs of the SD3100. The 15A module requires a step-down transformer rated up to 7.5kVA (application dependent). The 60A module requires a step-down transformer rated 7.5kVA to 25kVA (application...

  • Page 12: Optional Features

    1.3. It is assumed that the user is familiar with these manuals before installing, operating, or performing maintenance upon SD3100 DC Power Modules. Further information pertaining to SD3100 Power Modules can be found in instruction manuals S-3045 and S-3060, as listed in the table.

  • Page 13: Terms Used In This Manual

    2300-5.1 Bulletin 2300 Family of Drive Systems Hardware Additional information about using SD3100 Power Modules as part of a Distributed Power System is found in the wiring diagrams, prints, and other documentation shipped with each drive system. Always consult the prints shipped with the drive for specific mounting and connecting information about your system.
  • Page 14 SD3100 Power Modules...

  • Page 15: Chapter 2 Mechanical/Electrical Description

    HAPTER Mechanical/Electrical Description Rockwell Automation SD3100 DC Power Modules are built using a Distributed Power System PMI regulator and a high-horsepower silicon-controlled rectifier (SCR) bridge. All components are housed in a NEMA 1 metal enclosure. This chapter provides general information on the mechanical and electrical characteristics of SD3100 Power Modules, followed by specific information on the 1250A, 1650A, and 3000A units.

  • Page 16: Mechanical Overview

    2.1 Mechanical Overview The SD3100 Power Module is composed of the basic components shown in figure 2.1. These components consist of: • Control components that provide the interface to the AutoMax Distributed Power System and control for the Power Module, and •...

  • Page 17: Power Components

    Recommended circuit breaker settings are shown in Appendix A. Input Line Reactor or Isolation Transformer The SD3100 system requires a user-supplied line reactor or isolation transformer to reduce peak currents and harmonics in the incoming power lines. This device is needed to provide isolation to other equipment on the power lines during regeneration.

  • Page 18: Armature Power Components

    The armature power components convert the 3-phase AC input to a DC output used for powering the motor armature. The following components make up the armature power circuitry: • armature SCR bridge (and its subordinate components) • leg fuses • gate coupler cards (GCCs) • DC contactor SD3100 Power Modules...
  • Page 19 The non-regenerative bridge is shown in figure 2.3. Cell fuses protect the thyristors in the event of a bridge failure. Main Contactor *&& *&& *&& 3-Phase Armature Voltage Input *&& *&& *&& Figure 2.3 – Armature Bridge (Non-Regenerative) Mechanical/Electrical Description...
  • Page 20 (line commutation). • Snubbers Snubbers (resistor/capacitor assemblies) are installed in parallel with the SCRs to protect the SCRs from rapid voltage changes (inductive kick) when the SCRs switch off by suppressing and dissipating the excess voltage. SD3100 Power Modules...

  • Page 21: Field Power Module Components

    ILUHV D FURZEDU 6&5 WKDW VDIHO\ GLVVLSDWHV WKH HQHUJ\ LQ WKH ILHOG 2.2 Electrical Overview SD3100 DC Power Modules convert fixed voltage and frequency three-phase AC power to adjustable voltage DC power for motor armatures, fields, or other applications that require controlled DC power. Power Module operation is programmed and controlled in the UDC module in the AutoMax rack and the PMI Processor in the drive’s internal PMI rack.
  • Page 22 UDC module in the AutoMax rack. The UDC runs the application task that provides overall control of the application. For a full description of the Field Power Module, please refer to instruction manual S-3060. SD3100 Power Modules...

  • Page 23: 1250A Power Module Description

    2.3 1250A Power Module Description Table 2.1 – 1250A Configurations Input Voltage (VAC) Output HP 700-750 750-900 700-1000 The 1250A Power Module is supplied in the configurations shown in table 2.1. The 1250A Power Module has the following features: • The 1250A Power Module uses twelve SCRs (regenerative) or six SCRs (non-regenerative) in the armature bridge to convert the 3-phase AC input to a DC output.

  • Page 24: 1250A Power Module Component Layout

    F18, F32, SCALING UNIT A14F A16F A12F A13R A15R F14 F15 RACK TB1- A2(-) A1(+) FIELD SUPPLY RACK TB4 TB5 FWD REV 'LVFRQQHFW %D\ %ULGJH %D\ &RQWDFWRU %D\ Figure 2.5 – 1250A Power Module Component Layout 2-10 SD3100 Power Modules...

  • Page 25: Table 2.2 - 1250A Power Module Symbol-To-Component Reference

    Table 2.2 – 1250A Power Module Symbol-to-Component Reference Symbol Description Option 460 VAC 575 VAC 660 VAC A1(+), A2(-) Armature outputs A11F - A16F Armature pulse transformer PCB A11R - A16R Armature pulse transformer PCB ACT1, ACT3 Line current transformers 2000:1 ∗...

  • Page 26: 1250A Power Module Dimensions

    (508 mm) (508 mm) (889 mm) (508 mm) (508 mm) Figure 2.6 – 1250A Power Module Dimensions For other details on the 1250A Power Module and its components, please refer to the appendices of this manual. 2-12 SD3100 Power Modules...

  • Page 27: 1650A Power Module Description

    2.4 1650A Power Module Description Table 2.3 – 1650A Configurations Input Voltage (VAC) Output HP 800-1000 1000-1250 1250 The 1650A Power Module is supplied in the configurations shown in table 2.3. The 1650A Power Module has the following features: • The 1650A Power Module uses twelve SCRs (regenerative) or six SCRs (non-regenerative) in the armature bridge to convert the 3-phase AC input to a DC output.

  • Page 28: 1650A Power Module Component Layout

    F18, F32, SCALING UNIT A14F A16F A12F A13R A15R F14 F15 RACK TB1- A2(-) A1(+) FIELD SUPPLY RACK TB4 TB5 FWD REV 'LVFRQQHFW %D\ %ULGJH %D\ &RQWDFWRU %D\ Figure 2.7 – 1650A Power Module Component Layout 2-14 SD3100 Power Modules...

  • Page 29: Table 2.4 - 1650A Power Module Symbol-To-Component Reference

    Table 2.4 – 1650A Power Module Symbol-to-Component Reference Symbol Description Option 460 VAC 575 VAC 660 VAC A1(+), A2(-) Armature outputs A11F - A16F Armature pulse transformer PCB A11R - A16R Armature pulse transformer PCB ACT1, ACT 3 Line current transducer 3000:1 ∗...

  • Page 30: 1650A Power Module Dimensions

    (508 mm) (508 mm) (889 mm) (508 mm) (508 mm) Figure 2.8 – 1650A Power Module Dimensions For other details on the 1650A Power Module and its components, please refer to the appendices of this manual. 2-16 SD3100 Power Modules...

  • Page 31: 3000A Power Module Description

    2.5 3000A Power Module Description Table 2.5 – 3000A Configurations Input Voltage (VAC) Output HP 1250-1750 1500-2250 1500-2500 The 3000A Power Module is supplied in the configurations shown in table 2.5. The 3000A Power Module has the following features: • The 3000A Power Module uses twelve SCRs in the armature bridge to convert the 3-phase AC input to a DC output.

  • Page 32: 3000A Power Module Component Layout

    ∗ SCALING UNIT ∗ ∗ F14 F15 RACK FAN1 FIELD SUPPLY A2(-) A1(+) RACK TB4 TB5 FWD REV FAN2-C1 FAN2 'LVFRQQHFW %D\ )XVH %D\ %ULGJH %D\ &RQWDFWRU %D\ Figure 2.9 – 3000A Power Module Component Layout 2-18 SD3100 Power Modules...

  • Page 33: Table 2.6 - 3000A Power Module Symbol-To-Component Reference

    Table 2.6 – 3000A Power Module Symbol-to-Component Reference Symbol Description Option 460 VAC 575 VAC 660 VAC A1(+), A2(-) Armature outputs A11F - A16F Armature pulse transformer PCB A11R - A16R Armature pulse transformer PCB ACT1, ACT3 Line current transducer 5000:1 ∗...

  • Page 34: 3000A Power Module Dimensions

    (508 mm) (508 mm) (889 mm) (508 mm) (508 mm) Figure 2.10 – 3000A Power Module Dimensions For other details on the 3000A Power Module and its components, please refer to the appendices of this manual. 2-20 SD3100 Power Modules...

  • Page 35: Chapter 3 Installation Guidelines

    This chapter describes the guidelines and wiring recommendations to be followed when installing SD3100 DC Power Modules. Additional information on installing SD3100 drives can be found in the instruction manuals listed in tables 1.3 and 1.4 on page 1-4 of this manual.

  • Page 36: Physically Installing The Power Module

    NFPA 70, 75° C wiring. Refer to the applicable local codes for specific guidelines. Table 3.1 – Recommended AC Input Wiring DC Bus Current Incoming Wires (Amps) (For Each Phase or Connection, AWG) 1250 4-500 kcmil 1650 5-500 kcmil 3000 8-500 kcmil SD3100 Power Modules...

  • Page 37: Making An Input Entry Hole

    3.3.2 Making an Input Entry Hole If your Power Module has an extra input bay installed, proceed as follows. If your Power Module will have a top-hat enclosure over the disconnect bay, mount the top-hat enclosure before continuing. To make an input entry hole, select the ideal hole placement (within the constraints shown in figure 3.1), then perform the steps that follow.

  • Page 38: Wiring Ac Input To The Field Power Module

    3.2. Improper drive regulation and/or fuse clearing may result if the Field Power Module’s AC inputs are incorrectly wired. TERMINAL BLOCK TO MOTOR – FIELD FIELD ISOLATION TRANSFORMER Figure 3.2 – Field Terminal Wiring SD3100 Power Modules...

  • Page 39: Wiring The Motor

    3.5 Wiring the Motor To wire DC power to the motor, you will need to do the following: • select appropriate wires for the armature and field lines • connect the motor armature and motor field to the Power Module Refer to your motor’s installation manual for additional information.

  • Page 40: Installing Feedback Devices

    3.6 Installing Feedback Devices All feedback devices interface to the SD3100 Power Module through the PMI Regulator. Terminal blocks TB4 and TB5 at the bottom of the control compartment provide the connections for drive I/O, analog input, and the resolver, as shown in figures 3.3 and 3.4.

  • Page 41: Meter Port Connections

    3.7 Meter Port Connections Terminal block TB6 at the bottom of the control compartment contains four analog output ports, as shown in figure 3.5. Each port can be connected to a separate analog device (e.g., a meter or other data-logging device). The meter port output circuit is described in the PMI Rack and Modules instruction manual (S-3008).

  • Page 42: For Information On Initial Start-Up Of The Drive

    Note that the TE signal ground is not used by the SD3100 drive’s control components, but may be used by other drives in the lineup. Figure 3.6 shows the typical grounding of the SD3100 drive. SD3100 Drive Enclosure Control Xfmr...

  • Page 43: Chapter 4 Maintenance And Troubleshooting

    HAPTER Maintenance and Troubleshooting ATTENTION: Equipment is at line voltage when AC power is connected to the Power Module. All phases of the AC power line and control power must be disconnected from the Power Module before it is safe to touch any internal parts of this equipment.

  • Page 44: System Diagnostics

    AC line voltage is missing for more than 2 seconds. The system will immediately go idle when this fault is detected. NOTE: A temporary loss of AC line voltage will set bit 3 in Drive Warning Register 202/1202. SD3100 Power Modules...

  • Page 45: Instantaneous Overcurrent Fault (Bit 4)

    4.2.1.3 Instantaneous Overcurrent Fault (Bit 4) LED indicator: EXT FLT UDC Error Code: 1004 The armature current feedback value is greater than the Max Current Limit value (plus 75%) entered as a configuration parameter. The system will immediately go idle when this fault is detected.

  • Page 46: Synchronization Loss Fault Avoided Warning (Bit 3)

    4.3 Component Replacement SD3100 Power Modules have a modular design that permits fast and easy component replacement. Spare parts kits are provided for armature power structure components. The regulator assembly is serviced by replacing a damaged module in the rack or by replacing the entire rack.

  • Page 47: Pmi Regulator

    • Bridge fan and bridge fan door filter • Slide-in Fan • Power fuses • Power fuse assembly • AC input line fuses • Snubber assembly 4.3.2 PMI Regulator The PMI modules and the PMI rack are serviced by removing the damaged modules or by replacing the complete PMI rack.

  • Page 48: Replacing Field Power Module Components

    Replacement part numbers are listed in Appendix C. Due to the complexity of alignment, however, it is recommended that the Field Power Module be returned to Rockwell for repair and/or replacement of components. SD3100 Power Modules...

  • Page 49: Appendix A Technical Specifications

    PPENDIX Technical Specifications A.1 General Specifications The following specifications apply to the 1250, 1650, and 3000A Power Modules: • AC Input Frequency Range: 48 to 62 Hz • AC Input Voltage Tolerance: ±10% • Overload Capability: 150% maximum DC bus current for 60 seconds 200% for 10 seconds following continuous operation •...

  • Page 50: Table A.1 - Electrical Specifications (1250A Power Module

    Input Voltage Input Power Voltage Current Field Voltage Field Current (VAC) (kVA) (VDC) (ADC) (VDC) (ADC) Nominal HP 1100 1250 1000 1065 Dependent on options 1060 1250 selected. Refer to section A.6. 1011 1030 1217 1250 1000 SD3100 Power Modules...

  • Page 51: Figure A.2 - Power Dissipation Vs. Armature Current (1250A Power Module

    Power Dissipation The 1250A Power Module dissipates power proportionally to the armature current, as shown in figure A.2.         Armature Current (A) Figure A.2 – Power Dissipation vs. Armature Current (1250A Power Module) Circuit Breaker Settings The 1250A Power Module has a 1200A N-frame circuit breaker with a 1200A plug.

  • Page 52: Figure A.4 - Ac Input Busbars (1250A Power Module

    1650A unit’s busbars. See figure A.7. Bus Dimensions 1.69" 0.250" 0.87" 0.563" Diameter 1.750" Bus Arrangement 4 connections are available for each phase Phase 1 Phase 2 Phase 3 (L1) (L2) (L3) Figure A.4 – AC Input Busbars (1250A Power Module) SD3100 Power Modules...

  • Page 53: Table A.2 - Electrical Specifications (1650A Power Module

    A.3 1650A Power Module Specifications The following specifications apply to the 1650A Power Module. Height 91.5” (2324 mm) Width 75” (1905 mm) Depth 20” (508 mm) Shipping Weight 2500 lbs (1134 kg) MCC Sections Operating Sound Level 83 dB, wt. A 1.

  • Page 54: Figure A.5 - Power Dissipation Vs. Armature Current (1650A Power Module

    The circuit breaker should be set as shown in figure A.6. 'LJLWULS 506 5DWLQJ 3OXJ 6KRUW 'HOD\ 3XVK 'LJLWULS 506 7ULS 7ULS 8QLW ,Q ,U (QJDJHG 3LFNXS ‡ [ ,U 5HPRYH Figure A.6 – Recommended Circuit Breaker Settings (1650A Power Module) SD3100 Power Modules...

  • Page 55: Figure A.7 - Ac Input Busbars (1650A Power Module

    AC Input Busbars The 1650A Power Module has two AC input busbars per phase, as shown in figure A.7. These busbars are also used in the 1250A Power Module with the AC line fuse option. Bus Dimensions 0. 83 1.844 0.250 0.88 0.563 Diameter...

  • Page 56: Table A.3 - Electrical Specifications (3000A Power Module

    3000 1750 1713 1995 1500 1985 2330 1750 Dependent on options 2254 2660 2000 selected. Refer to 2531 3000 2250 section A.6. 1705 1715 1500 1971 2000 1750 2242 2290 2000 2508 2575 2250 2905 3000 2500 SD3100 Power Modules...

  • Page 57: Figure A.8 - Power Dissipation Vs. Armature Current

    Power Dissipation The 3000A Power Module dissipates power proportionally to the armature current, as shown in figure A.8.        Armature Current (A) Figure A.8 – Power Dissipation vs. Armature Current (3000A Power Module Circuit Breaker Settings The 3000A Power Module has a 3000A SPB-frame circuit breaker.

  • Page 58: Figure A.10 - Ac Input Busbars (3000A Power Module

    0. 88 1.938 1.938 0.188 0.88 1.750 0.625 Diameter Bus Arrangement 12 connections are available for each phase Phase 1 Phase 2 Phase 3 (L1) (L2) (L3) Figure A.10 – AC Input Busbars (3000A Power Module) A-10 SD3100 Power Modules...

  • Page 59: Figure A.11 - Air Baffle Layout (1250A And 1650A Power Modules

    A.5 Air Baffle Layouts ATTENTION: Guards are designed to direct airflow in the drive and to prevent injury. Ensure that the guards are in place when operating the drive. Failure to observe this precaution may result in bodily injury. Important: Air baffles are designed to distribute air to cool drive components. Ensure that the baffles are in place when operating the drive to provide the proper airflow and to prevent the thermoswitches or optional airflow sensor from intermittently shutting down the drive.

  • Page 60: Figure A.12 - Air Baffle Layout (3000A Power Module

    Baffle Baffle Guards Figure A.12 – Air Baffle Layout (3000A Power Module) A-12 SD3100 Power Modules...
  • Page 61 A.6 Field Power Module Specifications Ambient Conditions • Storage temperature: -40 to 85° C (-40 to 185° F) • Operating temperature: 0 to 40° C (32 to 104° F) • Humidity: 5 to 95%, non-condensing • Altitude: Up to 1000 meters (3300 feet) without derating output power. For every 91.4 meters (300 feet) above 1000 meters, derate the output current 1%.
  • Page 62 A-14 SD3100 Power Modules...

  • Page 63: Appendix B Schematics

    PPENDIX Schematics CB11 3-Phase AC Input DC MOTOR AC BLOWER MOTOR OL11 (T1) (T2) (T3) DC MOTOR AC BLOWER MOTOR OL12 (T1) (T2) (T3) Figure B.1 – DC Blower Motor Connections Schematics...
  • Page 64 NC. COM F10B F10A SNUBBER SNUBBER F11B F11A SNUBBER SNUBBER F12A F12B SNUBBER SNUBBER Figure B.2 – 1250A and 1650A Power Modules (Non-Regenerative), Sheet 1 SD3100 Power Modules...
  • Page 65 Figure B.3 – 1250A and 1650A Power Modules (Non-Regenerative), Sheet 2 Schematics...
  • Page 66 NC. COM F10B F10A SNUBBER SNUBBER F11B F11A SNUBBER SNUBBER F12A F12B SNUBBER SNUBBER Figure B.4 – 1250A and 1650A Power Modules (Regenerative), Sheet 1 SD3100 Power Modules...
  • Page 67 Figure B.5 – 1250A and 1650A Power Modules (Regenerative), Sheet 2 Schematics...
  • Page 68 NC. COM F10 A,B,C F7 A,B,C SNUBBER SNUBBER F11 A,B,C SNUBBER SNUBBER F8 A,B,C F12 A,B,C F9A,B,C SNUBBER SNUBBER Figure B.6 – 3000A Power Module (Regenerative), Sheet 1 SD3100 Power Modules...
  • Page 69 ∗ Figure B.7 – 3000A Power Module (Regenerative), Sheet 2 Schematics...
  • Page 70 SD3100 Power Modules...

  • Page 71: Appendix C Replacement Parts

    PPENDIX Replacement Parts C.1 Regulator Assembly Please refer to the following instruction manuals for replacement parts information: Component Manual Number PMI Rack and Modules S-3008 Parallel Gate Amplifier Rack and S-3045 Modules C.2 Field Power Module Replacement Parts 15 Amp, S2R Field Power Module (#805405-3R) Description Part Number AC Input Line Fuses (2)
  • Page 72 2361-SPE13A 2361-SPE13A 2361-SPE13A 2361-SPE14A 2361-SPE14A 2361-SPE14A 2361-SPB03A 2361-SPB03A 2361-SPB03A Snubber Assembly 2361-SPB01A 2361-SPB01A 2361-SPB01A 2361-SPB02A 2361-SPB02A 2361-SPB02A 1. R = 1250A, S = 1650A, T = 3000A. 2. Drive requires 12 fuses. 3. Drive requires 18 fuses. SD3100 Power Modules...

  • Page 73: Index

    NDEX conduction timeout, 4-3 instantaneous overcurrent, 4-3 AC input busbars loss of field, 4-3 1250A Power Module, A-4 shorted SCR, 4-2 1650A Power Module, A-7 Feedback devices, 3-6 3000A Power Module, A-10 Field isolation transformer, 3-4 connecting AC input wires to, 3-3 Field Power Module Air baffles, A-11 to A-12 AC line input fuses, 4-5...
  • Page 74 2-13 three-phase bridge SCR not firing, 4-3 dimensions, 2-16 Wires schematics, B-2 to B-5 for AC input, 3-2 technical specifications, A-5 to A-7 for armature and field lines, 3-5 Power Module - 3000A component layout, 2-18 Index-2 SD3100 Power Modules...
  • Page 75 Use this form to give us your comments concerning this publication or to report an error that you have found. For convenience, you may attach copies of the pages with your comments. After you have completed this form, please return it to: Rockwell Automation RGA (Technical Publications) 25001 Tungsten Road Cleveland, Ohio 44117 Fax: 216.266.7120...
  • Page 76 Rockwell Automation / 24703 Euclid Avenue / Cleveland, Ohio 44117 / (216) 266-7000 Printed in U.S.A. S-3064 July 1998...

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