distributed power system high power sb3000 ac power ......instruction manual distributed power...

Instruction Manual

Distributed Power SystemHigh Power SB3000AC Power Modules (Rittal)

804300-S (445 Amp)

804300-T (890 Amp)

804300-V (1335 Amp)

S-3031

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, then look at the built-in DC bus voltage meter. When the voltage is down to zero (0) volts, open the cabinet doors and check the voltage across the DC bus bars, 1247 A,B,C (+ bus) and 1145 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........................................................................................... 1-21.2 Power Module Part Numbers .......................................................................... 1-21.3 Related Publications........................................................................................ 1-3

Chapter 2 Power Module Description2.1 Mechanical Description ................................................................................... 2-12.2 Electrical Description ....................................................................................... 2-3

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

3.2.1 Fuses .................................................................................................... 3-23.2.2 Pre-charge Resistors and Fuses........................................................... 3-23.2.3 Line Filter Reactors ............................................................................... 3-33.2.4 Control Transformers ............................................................................ 3-33.2.5 Wire Sizes ............................................................................................. 3-43.2.6 Wire Routing ......................................................................................... 3-5

3.3 Grounding........................................................................................................ 3-53.4 Installing a Power Module Cabinet .................................................................. 3-5

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 Faults .................................................................................................... 4-54.3.1.1 DC Bus Overvoltage Fault ...................................................... 4-64.3.1.2 DC Bus Overcurrent Fault....................................................... 4-64.3.1.3 Ground Current Fault .............................................................. 4-64.3.1.4 Instantaneous Overcurrent Fault ............................................ 4-64.3.1.5 Local Power Interface Fault .................................................... 4-64.3.1.6 Gate Driver Interface Fault...................................................... 4-64.3.1.7 Charge Fault ........................................................................... 4-64.3.1.8 Overtemperature Fault ............................................................ 4-74.3.1.9 Power Loss Fault .................................................................... 4-74.3.1.10 Power Technology Fault ......................................................... 4-74.3.1.11 PMI Power Supply Fault ......................................................... 4-74.3.1.12 PMI Read/Write Fault.............................................................. 4-74.3.1.13 UDC Run Fault........................................................................ 4-74.3.1.14 Communication Lost Fault ...................................................... 4-7

4.3.2 Warnings ............................................................................................... 4-74.3.2.1 DC Bus Overvoltage Warning................................................. 4-84.3.2.2 DC Bus Undervoltage Warning............................................... 4-84.3.2.3 Ground Current Warning......................................................... 4-94.3.2.4 Phase Lost Warning................................................................ 4-94.3.2.5 Reference in Limit Warning..................................................... 4-94.3.2.6 Load Sharing Warning ............................................................ 4-94.3.2.7 Overtemperature Warning ...................................................... 4-9

II SB3000 Power Modules (Rittal)

Chapter 4 Diagnostics and Troubleshooting (Continued)4.3.2.8 Bad Gain Data Warning...........................................................4-94.3.2.9 Power Module Overload Warning............................................4-94.3.2.10 Power Loss Warning ...............................................................4-94.3.2.11 PMI Fan Loss Warning ..........................................................4-104.3.2.12 Rail Communication Warning ................................................4-104.3.2.13 CCLK Not Synchronized Warning .........................................4-104.3.2.14 PMI Communication Warning................................................4-10

4.4 Replacing the Power Module Cabinet............................................................4-104.5 Replacing Power Module Sub-Assemblies ....................................................4-11

4.5.1 Replacing Fuses ..................................................................................4-114.5.2 Replacing an IGBT Phase Module Assembly......................................4-15

4.5.2.1 Replacing an IGBT ................................................................4-174.5.3 Replacing a Blower Assembly .............................................................4-17

4.5.3.1 Replacing a Blower Filter.......................................................4-174.5.4 Replacing a Bus Capacitor Assembly..................................................4-18

4.6 Performing the Bridge Test ............................................................................4-19

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

Appendix B SB3000 Component Block Diagram ........................................................................ B-1

Appendix C Theory of Operation ................................................................................................. C-1

Appendix D SB3000 Interlock Sequencing.................................................................................. D-1

Appendix E Replacement Parts................................................................................................... E-1

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

Table of Contents III

List of Figures

Figure 2.1 – DC Bus Voltage.................................................................................... 2-3Figure 2.2 – 445A SB3000 Power Module Components .......................................... 2-5Figure 2.3 – 890A SB3000 Power Module Components .......................................... 2-6Figure 2.4 – 1335A SB3000 Power Module Components ........................................ 2-7Figure 2.5 – 445A SB3000 Power Module Circuitry ................................................. 2-8Figure 2.6 – 445A SB3000 Power Module Circuitry (Continued) ............................. 2-9Figure 2.7 – 890A SB3000 Power Module Circuitry ............................................... 2-10Figure 2.8 – 890A SB3000 Power Module Circuitry (Continued) ........................... 2-11Figure 2.9 – 890A SB3000 Power Module Circuitry (Continued) ........................... 2-12Figure 2.10 – 1335A SB3000 Power Module Circuitry ........................................... 2-13Figure 2.11 – 1335A SB3000 Power Module Circuitry (Continued) ....................... 2-14Figure 2.12 – 1335A SB3000 Power Module Circuitry (Continued) ....................... 2-15Figure 2.13 – 1335A SB3000 Power Module Circuitry (Continued) ....................... 2-16

Figure 3.1 – 445A SB3000 Power Module Mounting Dimensions............................ 3-6Figure 3.2 – 890A SB3000 Power Module Mounting Dimensions............................ 3-7Figure 3.3 – 1335A SB3000 Power Module Mounting Dimensions.......................... 3-8Figure 3.4 – SB3000 Power and Ground Connections............................................. 3-9

Figure 4.1 – DC Bus Voltage Measuring Points ....................................................... 4-3Figure 4.2 – 445A SB3000 Power Module Fuse Locations.................................... 4-12Figure 4.3 – 890A SB3000 Power Module Fuse Locations.................................... 4-13Figure 4.4 – 1335A SB3000 Power Module Fuse Locations .................................. 4-14Figure 4.5 – IGBT Module Assembly Mounting Bolt Locations ............................. 4-16

IV SB3000 Power Modules (Rittal)

Table of Contents V

List of Tables

Table 1.1 – SB3000 Power Module Current Ratings................................................ 1-1Table 1.2 – SB3000 Part Numbers........................................................................... 1-2

Table 2.1 – Meter Scaling......................................................................................... 2-2

Table 3.1 – AC Input and DC Bus Fuse Ratings ...................................................... 3-2Table 3.2 – Pre-charge Resistors and Fuses ........................................................... 3-3Table 3.3 – Line Filter Reactor Ratings .................................................................... 3-3Table 3.4 – Recommended AC Input and DC Bus Output Wire Sizes ..................... 3-4Table 3.5 – Terminal Tightening Torques................................................................. 3-4

Table 4.1 – DC Bus and Output Terminal Tests....................................................... 4-4Table 4.2 – IGBT Tests............................................................................................. 4-4Table 4.3 – SB3000 Fault Register 202/1202........................................................... 4-5Table 4.4 – SB3000 Warning Register 203 /1203 .................................................... 4-8Table 4.5 – Power Module Fuse Specifications...................................................... 4-15

VI SB3000 Power Modules (Rittal)

Introduction 1-1

CHAPTER 1Introduction

The High Power SB3000 Power Modules are variable-voltage, limited-frequency, high performance PWM power converters. They are designed to be used with Distributed Power System (DPS) SA3000 and SA3100 PWM inverter drives and other high performance PWM-type inverters that operate from a fixed voltage DC Bus input.

The SB3000 Power Modules operate as two- quadrant, fast-response, synchronous rectifiers converting fixed-frequency AC power to regulated voltage DC power using pulse-width-modulation (PWM) technology. They can operate in both the motoring and regeneration modes in response to the load applied to the DC output. SB3000 Power Modules are capable of full rating regeneration of power to the AC line and feature adjustable power factor operation.

The SB3000 Power Modules operate in conjunction with a separately-mounted input reactor and a separately-supplied power distribution cabinet, which provides AC power protection, disconnect, and soft-charge functionality for the SB3000 Power Modules. Refer to Appendixes C and D for more information on SB3000 theory of operation and interlock sequencing.

The SB3000 Power Modules are available in three output power ratings: 445 amp, 890 amp, and 1335 amp when used at a 4 kHz carrier frequency. They have a range of AC Input voltage ratings. Nominal DC bus voltage may range from 300 to 800 VDC.

Output current with a 2 kHz carrier frequency is 534A, 972A, and 1457A. A 4 kHz carrier frequency is typically used to minimize the size of the AC line reactor. Four kHz operation requires a derating of the AC input current and DC output load current when compared with operation at 2 kHz.

The SB3000 Power Module output current ratings are 100% continuous with no overload. They may be derated for lower current ratings with overload capability. See table 1.1.

Table 1.1 – SB3000 Power Module Current Ratings1

SB3000Part Number

ContinuousAC Input Current

(460VAC)

ContinuousDC Output Current

(800VDC)

5 MinuteAC Input and DC Output

Overload 2

804300-S 445A (rms) 445A DC 534A (rms)

804300-T 890A (rms) 890A DC 972A (rms)

804300-V 1335A (rms) 1335A DC 1457A (rms)

1. At 460 VAC Input/800 VDC Output/4kHz Carrier Frequency. For use with SA3000 Power Modules operating at a 2 kHz carrier frequency.2. With a 25% duty cycle

1-2 SB3000 Power Modules (Rittal)

1.1 Standard Features

The SB3000 Power Modules have the following standard features:

• Input power supplied from a separate disconnect/soft-charge cabinet and AC line reactor

• PWM synchronous rectifier converts AC power to DC power for a fixed-voltage PWM inverter DC bus

• IGBT power semiconductor bridge

• PWM output

• 4 kHz carrier switching frequency

• Ability to add or remove drives from the DC bus while the SB3000 Power Module is running

• Input and output short-circuit protection

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

• Auto-tuning without an identification test

• NEMA 1 Cabinet

• PMI Rack

• Top Entry of AC Input Power

• Top Exit of DC Output Power

• Standard Paint

1.2 Power Module Part Numbers

SB3000 Power Module part numbers are organized by the number of cabinet bays, e.g., one, two, or three-bay cabinet configurations. See table 1.2.

Table 1.2 – SB3000 Part Numbers

Cabinet Type SB3000

Part NumberSB3000

B/M Number

One-Bay (445A) 804300-S 101165-190S

Two-Bay (890A) 804300-T 101165-190T

Three-Bay (1335A) 804300-V 101165-190V

Introduction 1-3

1.3 Related Publications

This manual describes the hardware components of the SB3000 Power Module. Refer to the publications listed below for detailed descriptions of the remaining components of the SB3000 system and the configuration and programming necessary to control the SB3000 Synchronous Rectifier.

• S-3005 AutoMax Distributed Power System Overview

• S-3007 DPS Universal Drive Controller Module

• S-3009 DPS Fiber-Optic Cabling

• S-3034 DPS SB3000 Configuration and Programming

Refer to the following manuals for information on Distributed Power System AC Power Modules for use with the SB3000 Synchronous Rectifier:

• S-3038 DPS SA3000 High Power AC Power Modules (binder S-3001)

• S-3058 DPS SA3100 AC Power Modules (binder S-3053)

Power Module Description 2-1

CHAPTER 2Power Module Description

This chapter provides an overview the Power Module’s main components and their mechanical and electrical characteristics. Refer to Appendix B for a block diagram of the Power Module. The SB3000 theory of operation is described in Appendix C.

2.1 Mechanical Description

High Power SB3000 Power Modules are housed in protective sheet metal enclosures, as shown in figures 2.2 to 2.4. The Power Modules come in single, double, and triple bay cabinet configurations, depending upon the current rating. See figures 3.1 to 3.3 for Power Module dimensions.

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 regulated DC output voltage. Fuses and thermostats are provided to protect the IGBT modules.

Snubber/Gate Driver Module

Each Snubber/Gate Driver 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 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 transients produced 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 SB3000 Power Module and the PMI rack. It is through this module that information is sent to the SB3000 Power Module and feedback data is sent back to the PMI rack.


Capacitor Bank Assembly

The capacitor bank's electrolytic capacitors store DC power from the IGBTs.

DC Bus Voltage Meter

The DC Bus Voltage meter, which is connected directly across the DC bus, measures the DC bus voltage being supplied by the SB3000 Power Module.

AC Input Current Meter and DC Bus Current Meter

The AC Input Current and DC Bus Current meters measure the AC input current being provided to the Power Module and the DC bus output current supplied by the SB3000 Power Module. These meters are connected to the PMI meter ports on the PMI Processor. The meters are calibrated for +/-10V or +10V at full scale. See table 2.1. Note that PMI ports 3 and 4 are not used.

The AC Input Current meter indicates the RMS line current flowing into or out of the SB3000 Power Module. The current level is derived from the feedback signals coming from the Hall devices on the AC input leads to the phase modules.

The DC Bus Current meter indicates the DC current level produced by the SB3000 Power Module. The value is scaled from the feedback signal coming from the Hall device monitoring the Power Module’s DC output current. Its range is bi-directional. Positive current indicates that current is flowing from the rectifier to the load (motoring) and negative current indicates current flowing into the rectifier from the load (regenerating) to the AC line.

Softcharge Assembly

The Softcharge assembly is mounted separately and consists of pre-charge resistors and a contactor. The contactor bypasses the pre-charge resistors after the bus voltage reaches a programmable threshold value. A pre-charge contactor module communicates with the LPI module and controls the contactor. See figure 2.1.

Table 2.1 – Meter Scaling

SB3000 AC Input Current Rating at

4 kHz

PMI Processor Port 1DC Bus Current Meter

Scaling

PMI Processor Port 2AC Input Current Meter

Scaling

445 Amp -800 to +800A 0 to 600A

890 Amp -1,200 to +1,200A 0 to 1,000A

1,335 Amp -1,800 to +1,800A 0 to 1,500A


2.2 Electrical Description

AC power to the SB3000 Power Module is supplied from an AC power distribution/soft-charge cabinet through the AC input reactor.

The DC bus voltage is filtered by the electrolytic capacitors. Discharge resistors are designed to discharge the capacitors down to 50V DC within 5 minutes after power is removed from the input terminals. However, the user should wait ten minutes before working on the unit. Be sure to look at the built-in DC Bus Voltage meter and then measure the DC bus potential before touching any circuitry.

When AC power is applied to the SB3000 Power Module’s input terminals 181(L1), 182(L2) and 183(L3), the DC bus is charged through the IGBT emitter-collector diodes to the level of the rectified AC line voltage. See figure 2.1 and figures 2.5 to 2.13. Charging current is limited by the separately-mounted soft-charge resistors and the impedance of the AC input line reactor. Upon reaching the programmed level of DC bus voltage, the pre-charge resistors are bypassed by the pre-charge contactor, which places full line voltage across the AC line to the SB3000 Power Module.

The SB3000 Power Module’s inner control loop is enabled when the application task sets register 100/1100, bit 0, (VDC_RUN@). When this is done, the PMI Processor checks the interlocks as described in Appendix D. If the interlock conditions are satisfied, the DC bus voltage is ramped from the voltage produced by the diode rectification of the AC line voltage to the voltage reference value provided by the programmed outer control loop. The DC bus voltage is then regulated by the on-board voltage regulator. The ramp rate is 100 volts per second. When the preset reference voltage is reached, register 200/1200, bit 10, (VDC_ON@) is turned on to indicate that the Power Module is operating.

!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, then look at the built-in DC bus voltage meter. When the voltage is down to approximately zero (0) volts, open the cabinet doors and check the voltage across the DC bus bars, 1247 A,B,C (+ bus) and 1145 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.

Figure 2.1 – DC Bus Voltage

PowerOn

Vac ∗ 1.414

OVT_E0%

UVT_E0%

VDC_RUN

VDC_ON


When the DC bus operating voltage is reached, the connected SA3000/SA3100 Power Modules may be operated. Note that an SB3000 Power Module cannot support the loading of SA3000/SA3100 Power Modules when the soft-charge resistors are limiting the bus charging current.

The filtered SB3000 DC output voltage is then fed to the DC bus inputs of the SA3000/SA3100 Power Module(s). The IGBTs are switched by the Gate Driver Interface module(s) in the PMI rack. Three LEM sensors provide input current feedback, which is used for control and overcurrent protection. One LEM sensor is used to provide DC output current feedback.

Each SA3000/SA3100 Power Module connected to an SB3000 Power Module-supplied 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/SA3100 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/SA3100 Power Module. If the SB3000 Power Module is shut down due to a fault condition, controlled shutdown of the SA3000/SA3100 Power Module is the responsibility of the application program running in the SA3000/SA3100 UDC module.

!ATTENTION: SA3000/SA3100 Power Modules 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.

!ATTENTION: The SB3000 Power Module must be in run before the SA3000/SA3100 Power Module is put into run. If the pre-charge contactor supplying the SB3000 Power Module is not closed, running the SA3000/SA3100 Power Module will damage the SB3000 pre-charge resistors. Failure to observe this precaution could result in damage to, or destruction of, the equipment.


1. Blower Assembly 2. IGBT Phase Module Assembly 3. Capacitor Bank Assembly4. Pre-charge Assy. Mounting Bracket 5. LEM Sensor - DC Bus Output 6. DC Bus Fuses7. +/- 15V DC Power Supply 8. 110V AC Disconnect Switch 9. 24V DC Power Supply10. LPI Module 11. 250VA Isolation Transformer 12. PMI Rack13. 25KHz Power Supply 14. Reactor Assembly 15. LEM Sensors (3) - AC Input16. Power Supply Fuses 17. Feedback Resistors 18. Pre-charge Module19. DC Feedback Module 20. AC Input Current Meter 21. DC Output Current Meter22. DC Bus Voltage Meter 23. Input Phase Fuses 24. Blower Filter25. Line Synchronization Module

(On the Meter Bracket)

Figure 2.2 – 445A SB3000 Power Module Components

CAPACITOR BANK

PW

R. M

OD

. A

AC INPUT

181 182

F103A

LPI CIRCUIT

PHASE U

PMI RACK

PHASE W

BLOWER

F105A

PHASE VF104AP1

SLO

T 6

SLO

T 7

SLO

T 8

PW

R. M

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PW

R. M

OD

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110VD/S

±15VPS PS

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2FU3FU

PS+24V

1FU

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802268-16R

2FU

1FU

417114-81A

+ - 288289

24

15

15

1

12

2

17

GRD

14

15

3

GRD

2

5

13

CUSTOMER

NAMEPLATESALES ORDER

2021

11

10

78

9

16

19

22

25

CONTROLWIRING

GDIGDI GDI

POWER MODULE A

418

1836

F102A F101A

ASSEMBLY

23





CAPACITOR BANK

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F103B PHASE U

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AC INPUT

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BLOWER

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PHASE VF104AP1

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T 6

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T 7

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T 8

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R. M

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ASSEMBLYBLOWER

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BLOWER

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20

11

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3

2424

CAPACITOR BANKCAPACITOR BANK

15

23 23 23

16

ASSEMBLYBLOWER

1

ASSEMBLYBLOWER

1

ASSEMBLY

21


Figure 2.5 – 445A SB3000 Power Module Circuitry

1147

A

1145

A

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S

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S

147

145

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101A

F10

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B/M-60021

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RESOLVERB/M-60031

P2

P1

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D

GR

AY

(612183-29R)

(612183-29S)

(612183-26RR)

(612

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(612183-10S)

(61218

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(61218

3-1

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(612

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12183

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(61218

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(61362

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(612

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(61218

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(612183-15R)

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-29S

)

GR

D

H2

H1

1FU

BLK

WH

T

XF

MR

250V

A

6AB

LKW

HT

BLK

(612183-16W) (612183-50RS) (612183-10T)(612183-13R)

WH

TB

LK3A3F

U

BR

N

WH

T/

BR

N

WH

T/B

RN

BR

N

(612

183-

27R

)

WHT/YEL

GRYGRY

WHT/YEL

(803430-95RS)

-

+M

ORG

BLK

WHT ORGBLKWHT

ORGBLK

/6

WHT

31

422F

UD

ISC

ON

NE

CT

NL

BLK

110V

AC

RED/GRY

110V

AC

QU

ICK

CO

NN

EC

T B

LOC

K

BLK

RED/GRY

(612183-14RR)

(612

183

-12R

R)

(612183-18RR)

WHT

(8500

05-

10R

)

25A

WHT

O-6

0044

1P

4

1P3

1

P1

1

P2

OR

G

BLK

OR

G/B

LK

BRN

BRN/WHTRED

BLK

CLEAR

282

281

283

281

282

283

(612183-11R)

(850005-9R)

NL1 +15V

0V -15V

X2

X1

24V

0VL1 N

24V

0VL1 N

0V0V

0V

24V

24V

±15V

PS

+24

V P

S-2

4V P

S

BLU

GRN

RED

BLK

GR

N

BLU

BLK

RE

D

BR

N

WH

T

BR

NW

HT

/BR

N

WH

T

BR

N

BLK

BLU

RE

D

GR

N

WH

T

BR

N

BLK

BLU

RE

D

GR

N

GRN

BLK

RED

BLU

GRN

RED

BLK

BLU

25K

HZ

PS

288

289

23

1

BR

NW

HT

/BR

N

TAN

110V

AC

QU

ICK

CO

NN

EC

T B

LOC

K

ISO

LAT

ED

(612183-50RR)

(61218

3-5

1R)

(612183-55R)

(612183-52R)

(612183-19S)

WH

TB

RN

WH

T/B

RN

BR

N

WH

T/B

RN

BR

N

WH

T

OR

G

BLK

WHT-BRN

1

BRN

RED

ORG

REDWHT-

WHT-ORG

VIO

WHT-

YELWHT-YEL

GRN

BLU

GRN

WHT-BLU

VIOWHT-

GRY

GRYWHT-

WH

TB

RN

WH

TB

RN

BR

NW

HT

/BR

N

(O-55350-15)W PHASE P/M A

BLK

WH

T

2 /

2 /16/

(612

401

-36T

)

CN106

RED\GRY

RED\GRY

GRAY

WHT\YEL

WHT\YEL

GRAY

FA

N

GR

N/Y

EL

FIL

TE

R

183

182

181

+ -

40K

40K

GR

D

0-10

00V

OLT

SD

C B

US

RE

D/

YE

L

YE

LR

ED

/

RE

D

RE

D

R7

R6

(612

183-

8RR

)

(61218

3-2

9V

)

+ -

213

214

211

212

113

114

P2

N

P1

L3A

110VAC

MCR LO

AUX OUT HI

AUX OUT LO

AUX IN 4 LO

AUX IN 4 HI

AUX IN 5 LO

AUX IN 5 HI

AUX IN 3 HI

AUX IN 3 LO

MCR HI

RPI HI

RPI LO

AUX IN 1 HI

AUX IN 1 LO

AUX IN 2 HI

AUX IN 2 LO

DO

OR

SO

LEN

OID

RE

D

RE

D

11

12

21

22

42

41

32

31

BR

NB

LKB

LUR

ED

OR

GY

EL

WH

TG

RN

125%

-0-1

25%

0-12

5%C

UR

RE

NT

DC

BU

SC

UR

RE

NT

AC

INP

UT

(61218

3-5

R)

P1

GR

NW

HT

/BR

NB

RN

GR

N

(850005-11R)

2 /

OR

G

YE

L

VIO

LIN

ES

YN

C. B

OA

RD

A1

A2

INTERLOCKDOOR

(612

183

-11R

)

DR

AIN

WIR

EG

ND

AT

MT

G S

CR

EW

2 /6 /

TAN

US

ED

NO

T

CN

106

CN

106

CN

106

CN

106

CN

106

CN112

O-5

5350

-15

O-5

5350

-15

WV

CN112

O-5

5350

-15

U

CN112

–+

2 /

WARN.

FAULT

CLR

NO

TU

SE

D

NO

TU

SE

D

BLK

WARN.

FAULT BLK

CLRWARN.

FAULT

–+

–+

2 /

2/

4/

4 /

2 /

1

CO

N1

CN103

CN

101

1

1

1C

N10

5

CN

104

1

2 /9 /

TT

ULEM

LEM

VLE

MW

M+

-

REDWHTBLK

WHTRED

BLK

REDWHTBLK

M+

-M

+-

/P

AIR

S6

6 /6 /

CO

M+

2C

OM

+3

CO

M+

4

BLANK

15/

8 /

1>

4 /

CLR

BLK

BLK

CLR

FACEPLATE

BA

ND

BA

ND

BA

ND

BLANKFACEPLATE

BA

ND

BA

ND

(803

430-

95S

R)


Figure 2.6 – 445A SB3000 Power Module Circuitry (Continued)

1147

A

1145

A

MO

TOR

TE

RM

INA

L

CO

NN

EC

TO

R

RE

SIS

TO

RS

DC

PR

E-C

HA

RG

E

PO

WE

R M

OD

ULE

"A

"

-+ M

65

93

41

2

CO

N1

78

1247

A

BLO

WE

R A

SS

EM

BLY

110V

AC

QU

ICK

[U]

1249

A

IGB

TM

OD

ULE

LEM

ULE

M W

183

RE

AC

TO

RA

IR C

OR

E

182

181

DIS

CH

AR

GE

RE

SIS

TO

RS

1249A

LEM

V

ISO

LAT

ED

110V

AC

QU

ICK

[V]

IGB

TM

OD

ULE

[W]

IGB

TM

OD

ULE

CN105

CN

104

CN103

R1A

R2A

BLK

BLK

RE

D/G

RY

RE

D/G

RY

BR

N

WH

T/B

RN

1 4 1

CN101

1

CN101

3 3

TO

TB

(211

)

TO

TB

(11

4)

B/M

-600

27

CO

N1

12

35

41 2 6

BLK

BLK

CLR

CLR

CO

NN

EC

T B

LOC

K

GRAY

GRAY

WHT/YEL

WHT/YEL

1145

A

RE

DC

N10

2-1

0-55

350-

10R

ED

/YE

L

1 2

1 2

3 4

3 4

TK U2

U2

TK Z2

GR

DG

RD

GR

DG

RD

Z2

U2

TK

BLK

WH

T

BLKB

LK

BLK

1249

A12

49A

B/M

-600

27P

WR

.MO

D A

CO

N2

RE

D

WH

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BLK

RE

D

WH

T

BLK

M -+

1602

1601

1603

(FR

AM

E)

GR

D

PW

R.M

OD

A

0-55

350-

10

CN

102-

4

CO

NN

EC

T B

LOC

K

10 O

HM

S

10 O

HM

S

10 O

HM

SB

LOW

ER

BLO

CK

PR

E-C

HA

RG

EB

OA

RD

+C

12

O-5

5350

-4

1> D

OT

TE

D L

INE

IND

ICA

TE

S J

UM

PE

R L

OC

AT

ION

IF P

OW

ER

MO

DU

LE R

EQ

UIR

ES

GR

EA

TE

R A

IR F

LOW

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<1

NO

TE

S

RE

DB

AN

DR

ED

BA

ND

GR

AY

BA

ND

OR

GB

AN

DY

EL

BA

ND

VIO

BA

ND

VIO

OR

G

(612

183-

33R

R)

(612

183-

20R

)

(803

430-

95S

R) (803

430-

95S

R)

(612

183-

27R

)

(612

183-

16R

)(6

1218

3-16

T)

(612

183-

16S

)

(612

183-

20R

)

(612

183-

11R

)

(612

183-

19S

)

(612

183-

21R

)

(612

183-

14R

R)

(612

183-

15R

R)

(612

183-

15R

R)

(612

183-

32R

R)

(612

183-

22R

)

(803

430-

95R

R)

(803

430-

95R

T)

(NO

T U

SE

D)

TO

TB

(212

)T

O T

B (2

13)

TO

TB

(214

)

GR

AY

GR

AY

WH

T/Y

EL

WH

T/Y

EL

TO

TB

(11

3)

YE

L

U P

HA

SE

O-5

5350

-15

WA

RN

TH

ER

M.

FA

ULT

TH

ER

M.

WA

RN

TH

ER

M.

FA

ULT

TH

ER

M.

SH

IELD

W P

HA

SE

O-5

5350

-15

DR

AIN

WIR

E

2>(6

1218

3-28

S)

2> C

ON

NE

CT

LU

GG

ED

DR

AIN

WIR

E O

F T

HE

RM

OS

TA

TC

AB

LE 6

1218

3-28

S U

ND

ER

UP

PE

R L

EF

T C

OR

NE

RM

OU

NT

ING

SC

RE

W O

F P

RE

-CH

AR

GE

P.C

. BO

AR

DF

OR

GR

OU

ND

CO

NN

EC

TIO

N.

-+ M

RE

D

WH

T

BLK



1147

A

1145

A

BU

S

BU

S

147

145

47 45F

101A

F10

2A

CO

N1

890A

@ 4

KH

Z; M

ULT

IPLE

VO

LTA

GE

INP

UT

P/M

A

AS

SE

MB

LY

PW

R M

OD

A

O-5

5350

-10

CN

102

CO

N6

14

CO

N2

601

602

603

16

1

BLO

WE

R

CO

N2

PW

R M

OD

B1

F10

2B

F10

1B

603

602

601

112

CO

N5

1C

ON

2P

WR

MO

D C

OR

GY

EL

VIO

OR

GY

EL

VIOVIO

YE

LO

RG R

3R

4R

5

GR

D

(805

401-

5T)


PM

I RA

CK

B/M-60029


P2

P1


1> W

HE

N U

SIN

G C

HA

RT

RE

CO

RD

ER

CO

NN

EC

T

TO

TE

RM

INA

LS A

T B

AC

K O

F M

ET

ER

.

GR

D

B/M

-600

27

P1

P1

F/O


INTERFACESLOT 6

GD

I SLO

T 8

GD

I SLO

T 7

GD

I SLO

T 6

PO

WE

R M

OD

ULE

PO

WE

R

SE

E F

IGU

RE

2.9

SE

E F

IGU

RE

2.8

D S

HE

LLD S

HE

LL D S

HE

LL

1147

B

1145

B

CO

N4

RED/GRY

WH

T/

BR

NW

HT

/B

RN

CN

106

1

RE

DR

ED

/YE

L

P/M

BC

ON

1P

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CO

N1

RED

BLKWHT

WHT

BLKWHTRED

RED

BLK

CO

N3

112

CO

N6

TA

N

TA

N

1247

A11

45A

MO

DU

LE"A

"

25K

HZ

PS

(1)

25K

HZ

PS

(2)

"B"

CLR

BLK

BLK

1000

A

1000

A

1000

A

1000

A

/3

/3

2/

9 /

9 /9 /

BLO

WE

RA

SS

EM

BLY

LPI

P1

GR

DL2L1L1 L2

RE

DB

AN

D

GR

AY

BA

ND

CO

M

P1

RE

DB

LU

BR

NB

LK

GR

NW

HT

YE

LO

RG

+

PMI PROCESSOR

AND DRIVE I/O

B/M-60021

1

RESOLVERB/M-60031

P2

P1

RE

D

GR

AY

(612183-29R)(8

0343

0-95

RY

)

(8034

30-

95R

V)

(612183-26RR)

(612183-15R)

(612

183

-25S

)

(612183-10S)

(61218

3-1

0T

)

(61218

3-1

0R

)

(612

183

-20R

)(6

12183

-28S

)

(61218

3-2

3R

R)

(61362

1-1

2R

)

(612

183

-24R

)

(61218

3-2

2R

)

(6121

83-2

1R)

(803

430-

95R

X)

(612

183-

14R

S)

(612

183-

9R)

(612183-15R)

(612

183-

23R

S)

(612

183

-10V

)

(61218

3-2

9S

)

GR

D

(612

183-

29T

)

(612

183

-22S

)(6

121

83-

21S

)

(61218

3-2

8S

)

(61218

3-1

9R

)

H2

H1

1FU

BLK

WH

T

XF

MR

250V

A

6AB

LKW

HT

2

/B

LK

(612183-16W)

(612183-50RS)(612183-10T)

(612183-13R)

WH

TB

LK3A3F

U

BR

N

WH

T/

BR

N

WH

T/B

RN

BR

N

(612

183-

27R

)

WHT/YEL

GRYGRY

WHT/YEL

(85000

5-1

2T

)

-

+M

ORG

BLK

WHT ORGBLKWHT

ORGBLK

/6

WHT

31

422F

UD

ISC

ON

NE

CT

NL

BLK

110V

AC

RED/GRY

110V

AC

QU

ICK

CO

NN

EC

T B

LOC

K

BLK

RED/GRY

(612183-14RR)

(612

183

-12R

R)

(612183-18RR)

WHT

(8500

05-

10R

)

25A

WHT

O-6

0044

1P

4

1P3

1

P1

1

P2

OR

G

BLK

OR

G/B

LK

BRN

BRN/WHTRED

BLK

CLEAR

282

281

283

281

282

283

(612183-11R)

(850005-9R)

NL1 +15V

0V -15V

X2

X1

24V

0VL1 N

24V

0VL1 N

0V0V

0V

24V

24V

±15V

PS

+24

V P

S-2

4V P

S

BLU

GRN

RED

BLK

GR

N

BLU

BLK

RE

D

BR

N

WH

T

BR

NW

HT

/BR

N

WH

T

BR

N

BLK

BLU

RE

D

GR

N

WH

T

BR

N

BLK

BLU

RE

D

GR

N

GRN

BLK

RED

BLU

GRN

RED

BLK

BLU

25K

HZ

PS

288

289

23

1

BR

NW

HT

/BR

N

TAN

110V

AC

QU

ICK

CO

NN

EC

T B

LOC

K

ISO

LAT

ED

(612183-50RR)

(61218

3-5

1R)

(612183-55R)

(612183-52R)

(612183-19S)

WH

TB

RN

WH

T/B

RN

BR

N

WH

T/B

RN

BR

N

WH

T

OR

G

BLK

WHT-BRN

1

BRN

RED

ORG

REDWHT-

WHT-ORG

VIO

WHT-

YELWHT-YEL

GRN

BLU

GRN

WHT-BLU

VIOWHT-

GRY

GRYWHT-

WH

TB

RN

WH

TB

RN

BR

NW

HT

/BR

N


BLK

WH

T

2 /

2 /16/

(612

401

-36T

)

CN106

RED\GRY

RED\GRY

GRAY

WHT\YEL

WHT\YEL

GRAY

FA

N

GR

N/Y

EL

FIL

TE

R

BLK

WH

T

1

CO

N1

(612183-10V)

TAN

TANCN106(O-55350-15)

W PHASE P/M B

183

182

181

+ -

40K

40K

GR

D

0-10

00V

OLT

SD

C B

US

RE

D/

YE

L

YE

LR

ED

/

RE

D

RE

D

R7

R6

(6121

83-

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)

(612

183-

8RR

)

(61218

3-2

9V

)

RE

D/

GR

Y

(612

183-

9S)

+ -

213

214

211

212

113

114

P2

N

P1

L3A

110VAC

MCR LO

AUX OUT HI

AUX OUT LO

AUX IN 4 LO

AUX IN 4 HI

AUX IN 5 LO

AUX IN 5 HI

AUX IN 3 HI

AUX IN 3 LO

MCR HI

RPI HI

RPI LO

AUX IN 1 HI

AUX IN 1 LO

AUX IN 2 HI

AUX IN 2 LO

DO

OR

SO

LEN

OID

RE

D

RE

D

11

12

21

22

42

41

32

31

BR

NB

LKB

LUR

ED

OR

GY

EL

WH

TG

RN

125%

-0-1

25%

0-12

5%C

UR

RE

NT

DC

BU

SC

UR

RE

NT

AC

INP

UT

(61218

3-5

R)

P1

GR

NW

HT

/BR

NB

RN

GR

N

(850005-11R)

2 /

OR

G

YE

L

VIO

OR

G

YE

L

VIO

OR

G

YE

L

VIO

LIN

ES

YN

C. B

OA

RD

A1

A2

INTERLOCKDOOR

(612

183

-11R

)

DR

AIN

WIR

EG

ND

AT

MT

G S

CR

EW

DR

AIN

WIR

EG

ND

AT

MT

G S

CR

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2 /6 /

TAN

2 /

US

ED

NO

T

CN

106

CN

106

CN

106

CN

106

CN

106

CN112

O-5

5350

-15

O-5

5350

-15

WV

CN112

O-5

5350

-15

U

CN112

–+

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FAULT

CLR

NO

TU

SE

D

NO

TU

SE

D

BLK

WARN.

FAULT BLK

CLRWARN.

FAULT

–+

–+

2 /2/

4/

US

ED

NO

T

CN

106

CN

106

CN

106

CN

106

CN

106

CN112

O-5

5350

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O-5

5350

-15

WV

CN112

O-5

5350

-15

U

CN112

–+

2 /

WARN.

FAULT

CLR

NO

TU

SE

D

NO

TU

SE

D

BLK

WARN.

FAULT BLK

CLRWARN.

FAULT

–+

–+

2 /

2/

4/

TT

ULEM

LEM

VLE

MW

M+

-

REDWHTBLK

WHTRED

BLK

REDWHTBLK

M+

-M

+-

CN103

CN

101

1

1

1C

N10

5

CN

104

1

CLR

4 /

2 /

4 /

2 /

1

CO

N1

CN103

CN

101

1

1

1C

N10

5

CN

104

1

2 /9 /

TT

ULEM

LEM

VLE

MW

M+

-

REDWHTBLK

WHTRED

BLK

REDWHTBLK

M+

-M

+-

/P

AIR

S6

/P

AIR

S6

6 /6 /

CO

M+

2C

OM

+3

CO

M+

4

F/O

B/M-60028GATE DRIVERINTERFACESLOT 7

BLANK

15/

15/

8 /

1>

BR

NB

RN2 /

4 /

CLR

BLK

BLK

CLR

FACEPLATE



1147

A

1145

A

MO

TOR

TE

RM

INA

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CO

NN

EC

TO

R

RE

SIS

TO

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DC

PR

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E

PO

WE

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ULE

"A

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65

93

41

2

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1247

A

BLO

WE

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110V

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QU

ICK

[U]

1249

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IGB

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183

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AC

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182

181

DIS

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1249A

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ISO

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CN105C

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CN103

R1A

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BLK

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D/G

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1 4 1

CN101

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1249

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O-5

5350

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(612

183-

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(612

183-

20R

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(803

430-

95R

X) (803

430-

95R

X)

(612

183-

27R

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(612

183-

16R

)(6

1218

3-16

T)

(612

183-

16S

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(612

183-

20R

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(612

183-

11R

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(612

183-

19S

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(612

183-

21R

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(612

183-

14R

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(612

183-

15R

R)

(612

183-

15R

R)

(612

183-

32R

R)

(612

183-

22R

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(803

430-

95R

R)

(80

3430

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V)

(NO

T U

SE

D)

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B (

212)

TO T

B (

213)

TO T

B (

214)

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GR

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(11

3)

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O-5

5350

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ULT

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M.

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ULT

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M.

SH

IELD

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HA

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O-5

5350

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1218

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ON

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LU

GG

ED

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AIN

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F T

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TA

TC

AB

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1218

3-28

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ND

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UP

PE

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EF

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OR

NE

RM

OU

NT

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SC

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AR

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P.C

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AR

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GR

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CO

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EC

TIO

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D

WH

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BLK

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EB

OA

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101

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183-

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BR

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1147

B

1145

B

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INA

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TO

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SIS

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PR

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65

93

41

2

CO

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1247

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BLY

110V

AC

QU

ICK

[U]

1249

B

IGB

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ULE

LEM

ULE

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183

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AC

TO

RA

IR C

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E

182

181

DIS

CH

AR

GE

RE

SIS

TO

RS

1249B

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V

[V]

IGB

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OD

ULE

[W]

IGB

TM

OD

ULE

CN105

CN

104

CN103

R1B

R2B

BLK

BLK

RE

D/G

RY

BR

N

WH

T/B

RN

1 4 1

CN101

1

CN101

3 3

B/M

-600

27

CO

N1

12

35

41 2 6

BLK

BLK

CLR

CLR

CO

NN

EC

T B

LOC

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1145

B 1 2

1 2

3 4

3 4

TK U2

U2

U2

U2

TK

Z2

Z2

GR

DG

RD

GR

DG

RD

Z2

U2

TK

BLK

WH

T

BLKB

LK

BLK

1249

B12

49B

B/M

-600

27P

WR

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D B

CO

N2

RE

D

WH

T

BLK

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D

WH

T

BLK

M -+

1602

1601

1603

(FR

AM

E)

GR

D

PW

R.M

OD

B

10 O

HM

S

10 O

HM

S

10 O

HM

SB

LOW

ER

BLO

CK

PR

E-C

HA

RG

EB

OA

RD

+C

12

O-5

5350

-4

1> D

OT

TE

D L

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IND

ICA

TE

S J

UM

PE

R L

OC

AT

ION

IF P

OW

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MO

DU

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EQ

UIR

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GR

EA

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IR F

LOW

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NO

TE

S

RE

DB

AN

DR

ED

BA

ND

GR

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BA

ND

OR

GB

AN

DY

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BA

ND

VIO

BA

ND

VIO

OR

G

(612

183-

33R

R)

(803

430-

95R

Y) (803

430-

95R

Y)

(612

183-

16R

)(6

1218

3-16

T)

(612

183-

16S

)

(612

183-

9R)

(612

183-

19R

)

(612

183-

21S

)

(612

183-

14R

S)

(612

183-

15R

R)

(612

183-

15R

R)

(612

183-

32R

R)

(612

183-

22S

)

(803

430-

95R

R)

(803

430-

95R

V)

(NO

T U

SE

D)

YE

L

U P

HA

SE

O-5

5350

-15

WA

RN

TH

ER

M.

FA

ULT

TH

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M.

WA

RN

TH

ER

M.

FA

ULT

TH

ER

M.

SH

IELD

W P

HA

SE

O-5

5350

-15

DR

AIN

WIR

E

2>(6

1218

3-28

S)

2> C

ON

NE

CT

LU

GG

ED

DR

AIN

WIR

E O

F T

HE

RM

OS

TA

TC

AB

LE 6

1218

3-28

S U

ND

ER

UP

PE

R L

EF

T C

OR

NE

RM

OU

NT

ING

SC

RE

W O

F P

RE

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AR

GE

P.C

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AR

DF

OR

GR

OU

ND

CO

NN

EC

TIO

N.

-+ M

RE

D

WH

T

BLK

PR

E-C

HA

RG

EB

OA

RD

CN

101

PW

R. M

OD

A

RE

D/G

RY

(612

183-

9S)



1147

A

1145

A

BU

S

BU

S

147

145

47 45F

101A

F10

2A

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N1

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A @

4K

HZ

; MU

LTIP

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OLT

AG

E IN

PU

T

P/M

A

AS

SE

MB

LY

PW

R M

OD

A

O-5

5350

-10

CN

102

CO

N6

14

CO

N2

601

602

603

16

1

BLO

WE

R

CO

N2

PW

R M

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B1

F10

2B

F10

1B

603

602

601

112

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2P

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MO

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GY

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VIO

OR

GY

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VIOVIO

YE

LO

RG R

3R

4R

5

GR

D

(805

401-

5T)


PM

I RA

CK

B/M-60029


P2

P1


1> W

HE

N U

SIN

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HA

RT

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CO

RD

ER

CO

NN

EC

T

TO

TE

RM

INA

LS A

T B

AC

K O

F M

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ER

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GR

D

B/M

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27

P1

P1

F/O


INTERFACESLOT 6

GD

I SLO

T 8

GD

I SLO

T 7

GD

I SLO

T 6

PO

WE

R M

OD

ULE

PO

WE

R

SE

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IGU

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2.1

2

SE

E F

IGU

RE

2.1

1

D S

HE

LLD S

HE

LL D S

HE

LL

1147

B

1145

B

CO

N4

RED/GRY

WH

T/

BR

NW

HT

/B

RN

CN

106

1

RE

DR

ED

/YE

L

P/M

BC

ON

1P

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CO

N1

RED

BLKWHT

WHT

BLKWHTRED

RED

BLK

CO

N3

112

CO

N6

TA

N

TA

N

1247

A11

45A

MO

DU

LE"A

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25K

HZ

PS

(1)

25K

HZ

PS

(2)

"B"

CLR

BLK

BLK

1000

A

1000

A

1000

A

1000

A

/3

/3

2/

9 /

9 /9 /

BLO

WE

RA

SS

EM

BLY

LPI

P1

GR

DL2L1L1 L2

RE

DB

AN

D

GR

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BA

ND

CO

M

P1

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DB

LU

BR

NB

LK

GR

NW

HT

YE

LO

RG

+

PMI PROCESSOR

AND DRIVE I/O

B/M-60021

1

RESOLVERB/M-60031

P2

P1

RE

D

GR

AY

(612183-29R)

(803

430-

95R

Y)

(8034

30-

95R

V)

(612183-26RR)

(612183-15R)

(612

183

-25S

)

(612183-10S)

(61218

3-1

0T

)

(61218

3-1

0R

)

(612

183

-20R

)(6

12183

-28S

)

(61218

3-2

3R

R)

(61362

1-1

2R

)

(612

183

-24R

)

(61218

3-2

2R

)

(6121

83-2

1R)

(803

430-

95R

X) (612

183-

14R

S)

(612

183-

9R)

(612183-15R)

(6121

83-

23R

S)

(612

183

-10V

)

(61218

3-2

9T

)

GR

D

(612

183-

29T

)

(612

183

-22S

)(6

121

83-

21S

)

(612

183

-28S

)

(61218

3-1

9R

)

H2

H1

1FU

BLK

WH

T

XF

MR

250V

A

6AB

LKW

HT

2 /B

LK

(612183-16W) (612183-50RS)(612183-10T)

(612183-13R)

WH

TB

LK3A3F

U

BR

N

WH

T/

BR

N

WH

T/B

RN

BR

N

(612

183-

27R

)

WHT/YEL

GRYGRY

WHT/YEL

(85000

5-1

2T

)

-

+M

ORG

BLK

WHT ORGBLKWHT

ORGBLK

/6

WHT

31

422F

UD

ISC

ON

NE

CT

NL

BLK

110V

AC

RED/GRY

110V

AC

QU

ICK

CO

NN

EC

T B

LOC

K

BLK

RED/GRY

(612183-14RR)

(612

183

-12R

R)

(612183-18RR)

WHT

(8500

05-

10R

)

25A

WHT

O-6

0044

1P

4

1P3

1

P1

1

P2

OR

G

BLK

OR

G/B

LK

BRN

BRN/WHTRED

BLK

CLEAR

282

281

283

281

282

283

(612183-11R)

(850005-9R)

NL1 +15V

0V -15V

X2

X1

24V

0VL1 N

24V

0VL1 N

0V0V

0V

24V

24V

±15V

PS

+24

V P

S-2

4V P

S

BLU

GRN

RED

BLK

GR

N

BLU

BLK

RE

D

BR

N

WH

T

BR

NW

HT

/BR

N

WH

T

BR

N

BLK

BLU

RE

D

GR

N

WH

T

BR

N

BLK

BLU

RE

D

GR

N

GRN

BLK

RED

BLU

GRN

RED

BLK

BLU

25K

HZ

PS

288

289

23

1

BR

NW

HT

/BR

N

TAN

110V

AC

QU

ICK

CO

NN

EC

T B

LOC

K

ISO

LAT

ED

(612183-50RR)

(61218

3-5

1R)

(612183-55R)

(612183-52R)

(612183-19S)

WH

TB

RN

WH

T/B

RN

BR

N

WH

T/B

RN

BR

N

WH

T

OR

G

BLK

WHT-BRN

1

BRN

RED

ORG

REDWHT-

WHT-ORG

VIO

WHT-

YELWHT-YEL

GRN

BLU

GRN

WHT-BLU

VIOWHT-

GRY

GRYWHT-

WH

TB

RN

WH

TB

RN

BR

NW

HT

/BR

N


BLK

WH

T

2 /

2 /16/

(612

401

-36T

)

CN106

RED\GRY

RED\GRY

GRAY

WHT\YEL

WHT\YEL

GRAY

FA

N

GR

N/Y

EL

FIL

TE

R

BLK

WH

T

1

CO

N1

(612183-10V)

TAN

TANCN106(O-55350-15)

W PHASE P/M B

(612183-15R)

P1

(61218

3-2

3R

T) 15/

/P

AIR

S6

(612

183-

14R

T)

183

182

181

+ -

40K

40K

TT

ULEM

LEM

VLE

MW

601

602

603

F10

2C

F10

1C

GR

DM

+-

1147

C

1145

C

WH

T/

BR

NB

RN

REDWHTBLK

WHTRED

BLK

REDWHTBLK

US

ED

NO

T

CN

106

CN

106

CN

106

CN

106

CN

106

CN112

O-5

5350

-15

O-5

5350

-15

WV

CN112

O-5

5350

-15

U

CN112

–+

25K

HZ

PS

(3)

MO

DU

LEP

OW

ER

SE

E F

IGU

RE

2.1

3

"C"

0-10

00V

OLT

SD

C B

US

CLR

CLR

BLK

BLK

1000

A

1000

AR

ED

/Y

EL

YE

LR

ED

/

RE

DR

ED

R7

R6

9 /4 /A

SS

EM

BLY

BLO

WE

R

GRYRED/

2 /

4/

RE

DB

AN

D

BA

ND

GR

AY

(61218

3-2

9S

)

(6121

83-

10S

)

(612

183-

8RR

)

(803

430-

95R

Z)

(6121

83-

21T

)(6

12183

-19R

)

(612183-9R)

(61218

3-2

8S)

(612

183

-22T

)

(612183-10S)

(61218

3-1

0W

)G

RD

(80343

0-9

5R

V)

(61218

3-2

9V

)

BLK

WH

T

CN103

O-5

5350

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N10

11

CO

N1

1

11

CN

105

CN

104

1

GR

YR

ED

/

RE

D/

GR

Y(612

183-

9S)

(612

183-

9S)

BR

NB

RN

WH

T/

BLK

RED

REDWHTBLK

WHT

WHTBLK

RED

+ -

(O-55350-15)CN106

TAN

TANW PHASE P/M C

(612183-10W)

213

214

211

212

113

114

P2

N

P1

L3A

110VAC

MCR LO

AUX OUT HI

AUX OUT LO

AUX IN 4 LO

AUX IN 4 HI

AUX IN 5 LO

AUX IN 5 HI

AUX IN 3 HI

AUX IN 3 LO

MCR HI

RPI HI

RPI LO

AUX IN 1 HI

AUX IN 1 LO

AUX IN 2 HI

AUX IN 2 LO

DO

OR

SO

LEN

OID

RE

D

RE

D

11

12

21

22

42

41

32

31B

RN

BLK

BLU

RE

DO

RG

YE

LW

HT

GR

N

125%

-0-1

25%

0-12

5%C

UR

RE

NT

DC

BU

SC

UR

RE

NT

AC

INP

UT

(61218

3-5

R)

P1

GR

NW

HT

/BR

NB

RN

GR

N

(850005-11R)

2 /

OR

G

YE

L

VIO

OR

G

YE

L

VIO

OR

G

YE

L

VIO

OR

G

YE

L

VIO

LIN

ES

YN

C. B

OA

RD

A1

A2

INTERLOCKDOOR

(612

183

-11R

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DR

AIN

WIR

EG

ND

AT

MT

G S

CR

EW

DR

AIN

WIR

EG

ND

AT

MT

G S

CR

EWG

ND

AT

MT

G S

CR

EW

DR

AIN

WIR

E

WARN.

FAULT

CLR

NO

TU

SE

D

NO

TU

SE

D

BLK

WARN.

FAULT BLK

CLRWARN.

FAULT

2 /6 /

TAN

2 /2 /

M+

-M

+-

–+

–+

2 /

US

ED

NO

T

CN

106

CN

106

CN

106

CN

106

CN

106

CN112

O-5

5350

-15

O-5

5350

-15

WV

CN112

O-5

5350

-15

U

CN112

–+

WARN.

FAULT

CLR

NO

TU

SE

D

NO

TU

SE

D

BLK

WARN.

FAULT BLK

CLRWARN.

FAULT

–+

–+

2 /2/

4/

US

ED

NO

T

CN

106

CN

106

CN

106

CN

106

CN

106

CN112

O-5

5350

-15

O-5

5350

-15

WV

CN112

O-5

5350

-15

U

CN112

–+

2 /

WARN.

FAULT

CLR

NO

TU

SE

D

NO

TU

SE

D

BLK

WARN.

FAULT BLK

CLRWARN.

FAULT

–+

–+

2 /

2/

4/

TT

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Installation Guidelines 3-1

CHAPTER 3Installation Guidelines

This chapter describes the guidelines and wiring recommendations to be followed when installing High Power SB3000 Power Modules. An installation procedure for the 445A, 890A, and 1335A Power Modules is provided.

3.1 Installation Planning

Use the following guidelines when planning your SB3000 Power Module installation:

SB3000 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 thermal switch is used to indicate a warning condition (register 203/1203, bit 7, WRN_OT@) while the other switch 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) while the thermal fault switch closes at 85°C (185° F). Refer to the SB3000 Configuration and Programming Instruction Manual for more information.

• The relative humidity around the SB3000 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 SB3000 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 SB3000 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 SB3000 Power Module has one fan. Allow at least 30 cm (12") above and 2 m (6.6') in front of the SB3000 Power Module for adequate air clearance.

• AC input lead lengths, between the input reactor and the SB3000 Power Module’s AC input terminals, cannot exceed 100 meters (328 feet).

!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 3.2.6 provide additional information on input fuses, pre-charge components, AC line reactors, and recommended wire types.

3.2.1 Fuses

Fuses are provided to protect the SB3000 Power Module's three-phase AC input, DC bus output, and 115V AC input power lines. See table 3.1 for the fuse ratings.

3.2.2 Pre-charge Resistors and Fuses

The pre-charge circuit consists of three AC line resistors with an AC contactor bypass. The pre-charge resistors are protected by fuses in series with each resistor. See table 3.2. The pre-charge circuit is sized to support the charging of the SB3000 Power Module’s DC bus capacitors and up to four times the Power Module’s capacitance as a load. The pre-charge time is 10 seconds or less.

!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 – AC Input and DC Bus Fuse Ratings

FuseNumber Circuit

FuseCurrent Rating

FuseVoltage Rating Rockwell P/N

F101 A,B,C F102 A,B,C

DC Bus 1000 A 1000 VAC 64676-80P

F103 A,B,CF104 A,B,CF105 A,B,C

AC Line Input

630 A 1000 VAC 64676-79AZ

1FU 115V AC 5 Amp 600 VAC 64676-29R

2FU 115V AC 25 Amp 600 VAC 64676-72BB

3FU 115V AC 3.2 Amp 600 VAC 64676-29P


The pre-charge circuit is controlled by the PMI rack via the Pre-charge Controller module (B/M O-55350-4). This module is located in the master inverter cabinet and the 24V output is used to drive a pilot relay which in turn drives the pre-charge contactor’s 115 VAC coil.

The pre-charge contactor’s auxiliary contacts are wired back to the Pre-charge Controller Module in the SB3000 Power Module. This module expects to see the pre-charge contactor close after energizing its coil. This condition must be met before the drive can be put into run.

3.2.3 Line Filter Reactors

Three-phase AC line reactors are necessary to isolate the capacitor bank from the AC line and to provide energy storage for the voltage boosting function of the SB3000 Power Module. See table 3.3. The line reactors have iron-cores, copper windings, and 1000V insulation. They are rated at 70° C (158° F) ambient and are convection cooled.

3.2.4 Control Transformers

SB3000 control transformers should not be connected to the same AC power line that supplies the 3-phase power to SB3000 terminals 181, 182, and 183. The SB3000 Power Module, during normal operation, introduces high-frequency line notching in the 3-phase AC line. This type of line disturbance can be coupled through a control transformer into all connected loads and equipment.

SB3000 control transformers that provide power to electronic power supplies, I/O cards, PMI racks, and programmable controllers should be connected to a separate source of AC power that is free of line noise. If a noise-free source of power is not available, a Sola transformer, resonant filter, or a shielded, conditioning transformer must be used.

Table 3.2 – Pre-charge Resistors and Fuses

Power Module Rating Resistance

Resistor P/N Fuse Rating Fuse P/N

3-Phase Fuse Holder P/N

445 AmpOne 3.75Ω

Resistor/Phase402422-3A

15 Amps, 600VRK5 or Equivalent

64676-1BW 49454-21C

890 AmpTwo 1.65Ω

Resistors/Phase(3.3Ω/Phase)

402422-3C20 Amps, 600V

RK5 or Equivalent64676-1BX 49454-21C

1,335 Amp Two 1.65 Ω

Resistors/Phase (3.3Ω/Phase)

402422-3C20 Amps, 600V

RK5 or Equivalent64676-1BX 49454-21C

Table 3.3 – Line Filter Reactor Ratings

Power Module Inductance FrequencyHarmonic Current

at 4kHz

445 Amp 500 µH at 534 Amp 23 to 62 Hz 15%

890 Amp 250 µH at 972 Amp 23 to 62 Hz 15%

1,335 Amp 167 µH at 1457 Amp 23 to 62 Hz 15%


During normal operation, the SB3000 Power Module may also cause a large variation in the input isolation transformer’s neutral-to-ground voltage in ungrounded and high-resistance grounded systems. This may cause false ground fault detector indications.

This type of high frequency, high level line disturbance can be coupled through standard control transformers into all connected loads, such as electronic power supplies, I/O cards, and programmable controllers. This coupled, high level noise may cause improper operation or component failure.

To ensure proper ground fault detector operation, a ground fault detector with a 60 Hz filter is recommended. Standard magnetic relays and solenoids are not affected by this high frequency line noise.

3.2.5 Wire Sizes

Input wiring should be sized according to applicable codes to handle the SB3000 Power Module's continuous-rated input current. Output wiring should be sized according to applicable codes to handle the SB3000 Power Module's continuous-rated output current. Recommended wire sizes are shown in table 3.4. Terminals should be tightened to the torque values provided in table 3.5.

!ATTENTION: The SB3000 Power Module may cause a large variation in the input isolation transformer’s neutral-to-ground voltage in ungrounded and high-resistance grounded systems. This type of high frequency, high level line disturbance may cause improper ground fault detector operation or component failure.Failure to observe this precaution could result in damage to, or destruction of the equipment.

Table 3.4 – Recommended AC Input and DC Bus Output Wire Sizes

SB3000 Output Rating Size of Wire 1

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

445A 2 x 600 Kc Mil (304 mm2)

890A 3 x 600 Kc Mil (304 mm2)

1335A 4 x 1000 Kc Mil (507 mm2)

Table 3.5 – Terminal Tightening Torques

Terminals Tightening Torque

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

Ground: GND - Door 11.3 Nm (8.3 lb-ft)

Ground: GND - Hood Access Plate 22.6 Nm (16.5 lb-ft)

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

115 VAC Input Power: L, N 3.5 Nm (2.6 lb-ft)


3.2.6 Wire Routing

AC input wiring is routed through the top of the cabinet, above AC line terminals 181, 182 and 183. DC output wiring is also routed through the top of the cabinet. DC output wiring is usually connected directly to the D-C bus in the overhead enclosure that distributes the DC power to the common DC bus SA3000/SA3100 Power Modules.

The AC power distribution cabinet is mounted separately from the SB3000 Power Module but should be positioned conveniently close by. The AC disconnect is a thermal magnetic circuit breaker or a fused disconnect switch which is rated to protect the power wiring in the SB3000 Power Module. The AC disconnect is mounted such that it can be locked out, providing safe access to the inside of the power distribution cabinet and to the SB3000 Power Module.

3.3 Grounding

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 AC input 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 a Power Module Cabinet

Use the following procedure to install a SB3000 Power Module cabinet.

Step 1. Ensure that AC input power leading to the SB3000 Power Module is off.

Step 2. Position the SB3000 Power Module on a level mounting surface. See figure 3.1, 3.2, or 3.3 for cabinet dimensions. Floor mounting dimensions are included for applications where the cabinet is to be attached to the floor.

Step 3. Connect the AC input leads from the line reactor/pre-charge control directly to the 181 (L1), 182 (L2), and 183 (L3) terminals. Connect the GND terminal to earth ground. See figure 3.4.

Step 4. Connect DC bus terminals 45 and 47 (800V DC) to the SA3000/SA3100 Power Module bus terminals. Connect the GRD terminal to earth ground. See figure 3.4.

Step 5. 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 figure 3.4.

!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 – 445A SB3000 Power Module Mounting Dimensions

86.61 (2200.00)

18.87 (479.2)

2.63 (66.68)

14.67 (372.5)

10.50 (266.8)

1.00 (25.5)

1.34 (34.03)

8.00 (203.3)TOP VIEW

(+) BUS (47)

SEE DETAIL "A"

4.75 (120.5)

7.13 (180.98)

26.25 (667)

4.00 (101.6)

21.69 (550.9)

10.50 (266.7)

5.31 (134.4)

2.69 (68.2)

1.75 (44.5)

2 (50.8)

5.25 (133.4)

.24 (6.00)

10.31 (261.9)

4.56 (115.8)

(-) BUS (45)

1.125 (28.6)

1.75 (44.5)

1.00 (25.4)

.562 X .750 (4) PL.

FRONT VIEWCLCL

15.75 (400.26)

DETAIL "A"

FOR DIMENSIONS OF STAB.

AC INPUT

183182181GRDGRD

OFFO

N

3.85 (97.9)

39.84 (1012)

FLOOR MOUNTING HOLE LOCATIONS.

23.7 (602.0)

8.00 (203.2)

8.00 (203.2)

39.89 (1012)

21.29 (540.9) 18.55 (471.2)

.750 DIA.

(3) HOLESFRONT OF DRIVE

ALL DIMENSIONS ± .06 IN. (1.5mm).

AC INPUT

182 183181



86.61 (2200)

183

63.50 (1612.0)

15.64 (397.2)

48.14 (1222.8)

183

GRD

9.50 (241.3)

4.75 (120.7)

1.34 (66.7)

18.84 (478.7)

1.34 (34.03)

1.00 (25.5)

AC INPUT

181 182

AC INPUT

GRD181 182

21.69 (550.9)

2 (50.8)

10.31 (261.9)

2.69 (68.2)

4.56 (115.8)

(+) BUS (47)

10.50 (266.8)

TOP VIEW

(-) BUS (45)

14.66 (372.5)

8.00 (20

3.3)

6.00 (152.4)

FOR DIMENSIONS OF STAB.

FRONT VIEWSEE DETAIL "A"

7.13 (181.0)

L C L C

OFF

ON

4.75 (120.5)

63.51 (1612)

FLOOR MOUNTING HOLES LOCATIONS

ALL DIMENSIONS ± .06 in. (1.5 mm).

3 HOLES.750 DIA

18.55 (471.2)

8.00 (203.2)

23.7 (602)

3.85 (97.9)

8.00 (203.2)

23.58 (601)

FRONT OF DRIVE

1.75 (44.5)

4.00 (101.6)

1.00 (25.4)

DETAIL "A"

1.125 (28.6)

1.75 (44.5)

.562 x .750 (4) PL.



86.61 (2200)

FRONT VIEW

AC INPUT

183

AC INPUT183

87.09 (2212.0)

15.64 (397.2)

48.14 (1222.8

)

9.50 (241.3)

4.75 (120.7)

18.84 (478.7

)

2.63 (66.7)

1.34 (34.03)

1.00 (25.5)

182181

.562 x .750 (4) PL.

4.00 (101.6)

1.00 (25.4)

1.75 (44.5)

1.125 (28.6)

1.75 (44.5)

DETAIL "A"

181GRD

182

21.69 (550.9)

2 (50.8

)

10.31 (261.9)

2.69 (68.2)

4.56 (115.8)14.66 (3

72.5)

10.50 (266.8)

TOP VIEW

(+) BUS (47)

(-) BUS (45)

4.75 (120.5)

FOR DIMENSIONS OF STAB.SEE DETAIL "A"

7.13 (181.0)

6.00 (152.4)

L C CL

GRD

ON

OFF

FRONT OF DRIVE

FLOOR MOUNTING HOLE LOCATIONS87.13 (2212)

23.58 (601)

ALL DIMENSIONS ± .25 IN. (6.35 mm).

3.85 (97.9)

18.55 (471.2)

23.7 (602)

3 HOLES.750 DIA

8.00 (203.2)

8.00 (203.2)

23.58 (601)

8.00 (203.3)


Figure 3.4 – SB3000 Power and Ground Connections

OUTPUT VOLTAGEDC BUS

INPUT VOLTAGE115 VAC

FROM LINE REACTORTHREE PHASE AC INPUT

GND

FUSE

(+)(–)

CONNECT BLOCK115 VAC QUICK

4745

POWER MODULE

NL183182181

+–

GND

SB3000

Diagnostics and Troubleshooting 4-1

CHAPTER 4Diagnostics and Troubleshooting

This chapter describes the equipment needed to check the operation of the SB3000 Power Module and the tests to be performed. Also included are descriptions of the SB3000 Power Module faults monitored by the Distributed Power System software. Procedures are provided for replacing fuses and sub-assemblies.

4.1 Required Test Equipment

The following equipment is required when servicing the SB3000 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 SB3000 Power Module contains printed circuit boards that are static sensitive. Do not touch any components, connectors, or leads. Failure to observe this precaution could result in damage to equipment.


4.2 Power Module Tests with Input Power Off

Use the following procedure to perform the SB3000 Power Module tests:

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

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

Step 3. Look at the built-in DC Bus Voltage meter. When the DC bus potential is down to approximately zero volts, open the SB3000 Power Module cabinet's doors and measure the DC bus potential across the DC bus bars, 1247A (+ bus) and 1145A (- bus), with an external voltmeter before working on the unit. See figure 4.1.

Step 4. Check the AC input and DC bus output fuses.

Step 5. If a fuse is blown, use a multimeter to check the DC bus, bus capacitors, AC input terminals, and the input IGBTs. See tables 4.1 and 4.2.

Step 6. If a capacitor is defective, replace the capacitor bank assembly as described in section 4.5.4. If an IGBT is defective, refer to section 4.5.2.

!ATTENTION: The Power Module is not isolated from earth ground. The 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.



Figure 4.1 – DC Bus Voltage Measuring Points

CAPACITOR BANK

PW

R. M

OD

. A

AC MOTOR OUTPUT

U V

LPI CIRCUIT

PHASE U

PMI RACK

PHASE W

FAN

PHASE V

SLO

T 6

SLO

T 7

SLO

T 8

PW

R. M

OD

. C

PW

R. M

OD

. B

110VD/S

±15VPS PS

-24V

2FU3FU

PS+24V

1FU

25KHZ PS

2FU

1FU

+ - 288289

MOTOR

GRD

GDIGDI GDI

POWER MODULE A

WF102A F101A

GRD

DC BUS VOLTAGEMEASURING POINTS

1247A

1145A-BUS

ASSEMBLY+BUS

F104A

F105A

F103A


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 SB3000 Synchronous Rectifier is not operating in an optimum manner. Warnings will not shut down the SB3000. Faults are severe errors which will shut down the SB3000. See tables 4.3 and 4.4.

Refer to the SB3000 Synchronous Rectifier Configuration and Programming instruction manual (S-3034) for more information about the Fault and Warning registers.

Table 4.1 – DC Bus and Output Terminal Tests1

1. with the AC input lines 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

+ 1249 X10Capacitor Effect (0 to 500 ohms)

- 1249

601 +

X1 2 ohms602 +

603 +

+ 601

X10 Capacitor Effect (0 to 2k ohms)+ 602

+ 603

InputTerminals

181 (601) 182 (602)

X1000 4k to 6k ohms181 (601) 183 (603)

182 (602) 183 (603

Table 4.2 – IGBT Tests1

1. with the AC input lines disconnected

Meter Connections + - Scale

Expected Test Results(+/- 10%)

W Phase (lower) + 183 +1147 2k Ω/diode 0.300 ohms

V Phase (lower) + 182 +1147 2k Ω/diode 0.300 ohms

U Phase (lower) + 181 + 1147 2k Ω/diode 0.300 ohms

W Phase (upper) - 1245 - 183 2k Ω/diode 0.300 ohms

V Phase (upper) - 1245 - 182 2k Ω/diode 0.300 ohms

U Phase (upper) - 1245 - 181 2k Ω/diode 0.300 ohms


4.3.1 Faults

The following faults will cause the SB3000 Power Module to shut down. See table 4.3. In a fault situation, the PMI Processor will command zero current and will stop firing the IGBTs; however, the IGBT emitter-collector diodes will supply rectified line voltage to the DC bus until AC input power is disconnected. Faults must be reset before the SB3000 Power Module can be restarted.

Table 4.3 – SB3000 Fault Register 202/1202

Bit

Suggested Variable Name

UDC Error Code Description Summary

0 FLT_OV@ 1018 The DC Bus Overvoltage bit is set if the DC bus voltage exceeds 900 VDC.

1 FLT_DCI@ 1020 The DC Bus Overcurrent bit is set if the DC bus current exceeds 125% of the rated SB3000 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.

5 FLT_GDI@ 1023 The Gate Driver Interface Fault bit is set if the power supply voltage on the Gate Driver Interface (GDI) module is not within tolerance.

6 FLT_CHG@ 1024 The Charge Fault bit is set if either of the following occurs: the pre-charge contactor does not close when commanded to by the PMI Processor or the contactor opens without being commanded to do so.

7 FLT_OT@ 1016 The Overtemperature Fault bit is set if the fault level thermal switch (85o

C (185o F)) in the SB3000 Power Module opens.

10 FLT_PWR@ 1025 The Power Loss Fault bit is set if AC line power is lost for more than ten seconds while the SB3000 Power Module is running.

11 FLT_PTM@ 1011 The Power Technology Fault bit is set if the AC Power Technology module fails.

12 FLT_PS@ 1012 The PMI Power Supply Fault bit is set if the PMI rack’s power supply fails.

13 FLT_RW@ 1013 The PMI Read/Write Fault bit is set if a PMI Processor read or write operation fails.

14 FLT_RUN@ 1014 The UDC Run Fault bit is set if the UDC task stops while the voltage loop is running.

15 FLT_COM@ 1015 Communication Lost Fault bit is set if fiber-optic communication between the PMI Processor and the UDC module is lost due to two consecutive errors of any type.


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 900 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 SB3000 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. 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 SB3000 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.

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. Register 204/1204, bits 0-5, indicate which power device detected the overcurrent. When 890A and 1335A SB3000 Power Modules are being used, registers 220/1220 and 221/1221 indicate the status of the B and C Power Module cabinets. 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 Gate Driver Interface Fault

The Gate Driver Interface Fault bit (bit 5) is set in the Fault register (202/1202) if the power supply voltage on the Gate Driver Interface (GDI) module is not within tolerance. Error code 1023 will also be displayed in the error log of the UDC task in which the fault occurred.

If SB3000 Power Modules are connected in parallel, bit 7 in register 204/1204, 220/120, or 221/1221 will be set to indicate which GDI module is affected

4.3.1.7 Charge Fault

The Charge Fault bit (bit 6) is set in the Fault register (202/1202) if either of the following occurs: the pre-charge contactor did not close when commanded to by the PMI Processor or the contactor opened without being commanded to do so. Error code 1024 will also be displayed in the error log of the UDC task in which the fault occurred.


4.3.1.8 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 SB3000 Power Module opens. Bit 12 in register 204/1204, 220/1220, or 221/1221 will be set to indicate which SB3000 Power Module is affected. Error code 1016 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.9 Power Loss Fault

The Power Loss Fault bit (bit 10) is set in the Fault register (202/1202) if AC line power is lost for more than ten seconds while the SB3000 Power Module is running.This bit will also be set if one phase of the AC line is lost or if line synchronization is lost. Error code 1025 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.10 Power Technology Fault

The Power Technology Fault bit (bit 11) is set in the Fault register (202/1202) if the AC Power Technology module fails. Error code 1011 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.11 PMI Power Supply Fault

The PMI Power Supply Fault bit (bit 12) is set in the Fault register (202/1202) if the PMI rack’s power supply fails. Error code 1012 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.12 PMI Read/Write Fault

The PMI Read/Write Fault bit (bit 13) is set in the Fault register (202/1202) if a PMI Processor read or write operation fails. Error code 1013 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.13 UDC Run Fault

The UDC Run Fault bit (bit 14) is set in the Fault register (202/1202) if the UDC task stops while the voltage loop is running. Error code 1014 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.1.14 Communication Lost Fault

The Communication Lost Fault bit (bit 15) is set in the Fault register (202/1202) if the fiber-optic communication between the PMI Processor and the UDC module is lost due to two consecutive errors of any type. This bit is only set after communication between the PMI Processor and UDC module has been established. This bit should be used in the run permissive logic of the SB3000 Power Module. Error code 1015 will also be displayed in the error log of the UDC task in which the fault occurred.

4.3.2 Warnings

The following warnings indicate conditions which are not serious enough to shut down the SB3000 Synchronous Rectifier 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%.

Table 4.4 – SB3000 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 Under Voltage 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%.

3 WRN_PL@ The Phase Lost Warning bit is set if a phase loss occurs in the AC line.

4 WRN_RIL@ The Reference in Limit Warning bit is set if the UDC reference value (register 102/1102) is less than the minimum value or greater than the maximum value allowed. In the Bridge Test mode, this bit is used to indicate an illegal test code.

6 WRN_SHR@ The Load Sharing Warning bit is set if a current sharing problem develops between parallel SB3000 Power Modules.

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

(172.4o F)) in the SB3000 Power Module opens.

8 WRN_BGD@ The Bad Gain Warning bit is set when a tunable variable is changed to an illegal value when the UDC task is running.

9 WRN_OL@ The Power Module Overload Warning bit is set if the continuous current rating of the SB3000 Power Module is exceeded for approximately five minutes and does not decrease and maintain the continuous current rating for at least 45 minutes.

10 WRN_PWR@ The Power Lost Warning bit is set if the power dip ride-through feature of the SB3000 Power Module has been enabled.

12 WRN_FAN@ The PMI Fan Loss Warning bit is set if there is no airflow detected through the PMI rack.

13 WRN_RAL@ The Rail Communication Warning bit is set if a rail communication problem occurs and is logged in registers 4, 10, 16, or 22.

14 WRN_CLK@ The CCLK Not Synchronized Warning bit is set if the CCLK counters in the PMI Processor and UDC module are momentarily unsynchronized.

15 WRN_COM@ The PMI Communication Warning bit is set if a fiber-optic communication error occurs between the PMI Processor and the UDC module.


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 Phase Lost Warning

The Phase Lost Warning bit (bit 3) is set in the Warning register (203/1203) if a phase loss occurs in the AC line.

4.3.2.5 Reference in Limit Warning

The Reference in Limit Warning bit (bit 4) is set in the Warning register (203/1203) if the UDC reference value (register 102/1102) is less than the minimum value or greater than the maximum value allowed. In the Bridge Test mode, this bit is used to indicate an illegal test code.

4.3.2.6 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 SB3000 Power Modules. Bits 13, 14, or 15 in registers 204/1204, 220/1220, or 221/1221 will be set to indicate the phase and SB3000 Power Modules affected.

4.3.2.7 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 SB3000 Power Module opens. Bit 12 in register 204/1204, 220/1220, or 221/1221 will be set to indicate which SB3000 Power Module is affected.

4.3.2.8 Bad Gain Data Warning

The Bad Gain Data Warning bit (bit 8) is set in the Warning register (203/1203) if a tunable variable is changed to an illegal value when the UDC task is running. The value will be restored to its previous valid value by the PMI Processor.

4.3.2.9 Power Module Overload Warning

The Power Module Overload Warning bit (bit 9) is set in the Warning register (203/1203) if the continuous current rating of the SB3000 Power Module is exceeded for approximately five minutes and does not decrease and maintain the continuous current rating for at least 45 minutes.

4.3.2.10 Power Loss Warning

The Power Loss Warning bit (bit 10) is set in the Warning register (203/1203) if the power dip ride-through feature of the SB3000 Power Module has been enabled. This will occur if the PMI Processor detects that the AC input voltage is less than 75% or more than 125% of the configured value. When this bit is set, the PMI Processor disables the firing of the IGBTs. If power is restored within 10 seconds, the PMI Processor will resynchronize and resume operation. If power is not restored within 10 seconds, bit 10 in register 202/1202 will be set and the SB3000 Power Module will shut down.


4.3.2.11 PMI Fan Loss Warning

The PMI Fan Loss Warning bit (bit 12) is set in the Warning register (203/1203) if there is no airflow through the PMI rack.

4.3.2.12 Rail Communication Warning

The Rail Communication Warning bit (bit 13) is set in the Warning register (203/1203) if a rail communication problem occurs and is logged in registers 4, 10, 16, or 22.

4.3.2.13 CCLK Not Synchronized Warning

The CCLK Not Synchronized Warning bit (bit 14) is set in the Warning register (203/1203) if the CCLK counters in the PMI Processor and UDC module are momentarily unsynchronized.

4.3.2.14 PMI Communication Warning

The PMI Communication Warning bit (bit 15) is set in the Warning register (203/1203) if a fiber-optic communication error occurs between the PMI Processor and the UDC module. Communication errors in two consecutive messages will result in a fault.

4.4 Replacing the Power Module Cabinet

Use the following procedure to replace an SB3000 Power Module cabinet:

Step 1. Turn off and lock out the AC input power at the input reactor/pre-charge control cabinet.


Step 3. Look at the built-in DC Bus Voltage meter. When the DC bus potential is down to approximately zero volts, open the SB3000 Power Module cabinet's doors and measure the DC bus potential across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter before working on the unit. See figure 4.1.

Step 4. Disconnect the AC input leads from terminals 181 (L1), 182 (L2), and 183 (L3). Disconnect the GND wire from the ground terminal. See figure 3.4.

Step 5. Disconnect the AC input line (two-wire 110 VAC) from the L and N terminals. See figure 3.4.

Step 6. Disconnect the DC bus from terminals 45 and 47. See figure 3.4.

Step 7. Remove the SB3000 Power Module cabinet.



Step 8. Install the replacement SB3000 Power Module cabinet by following these steps in reverse order.

4.5 Replacing Power Module Sub-Assemblies

Use the procedures in sections 4.5.1 to 4.5.4 to replace the SB3000 Power Module’s fuses and sub-assemblies.

4.5.1 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. Look at the built-in DC Bus Voltage meter. When the DC bus potential is down to zero volts, open the SB3000 Power Module cabinet's doors and measure the DC bus potential across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter before working on the unit. See figure 4.1.

Step 4. Remove the blown fuse and install the replacement fuse. Figures 4.2, 4.3, and 4.4 show the location of the fuses in the 445A, 890A, and 1335A SB3000 Power Modules. Table 4.5 provides fuse specifications.

Step 5. Close the cabinet doors and reapply power to the SB3000 Power Module.

!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, then look at the built-in DC bus voltage meter. When the voltage is down to zero (0) volts, open the cabinet doors and check the voltage across the DC bus bars, 1247 A,B,C (+ bus) and 1145 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.


Figure 4.2 – 445A SB3000 Power Module Fuse Locations

PW

R. M

OD

. A

F104A

SLO

T 6

F103A

GDI

POWER MODULE A

CAPACITOR BANK

PMI RACKPHASE V

PHASE WF105A25KHZ.

PS

LPI CIRCUITPHASE U

±15VPS

110V.D/S

183

AC INPUT

181 182

2FU3FU

1FU

+24VPS

–24VPS

F102A F101ADC BusFuses

Control PowerFuses

AC InputPhaseFuses

∗∗

∗∗∗

∗SeeTable4.5

11FU12FU

21FU-26FU



F105B

F104B

PHASE W

PHASE V

POWER MODULE B

F103B PHASE U

AC INPUT

181 182 183

PMI RACK

PHASE WF105A

F104A

SLO

T 7

SLO

T 6

PW

R. M

OD

A

GDI

PW

R. M

OD

B

GDI

+

F101AF101BF102B F102A

PHASE UF103A

∗

PSPS

LPI CIRCUIT

2FU3FU

1FU

+24V±15V

D/S110V

- -24V

25KHZPS

(+)

POWER MODULE A

PHASE V

PS

DC BusFuses

Control PowerFuses

AC InputPhaseFuses

AC InputPhaseFuses

∗∗See Table 4.5 ∗∗∗

21FU-26FU

11FU12FU



F10

5CF

105B

F10

4B

F10

3B

P1

SLOT 6

**

PS

PS

2FU

+24

V

PS

F10

4C

F10

3C

AC

INP

UT

181

182

183

PM

I RA

CK

F10

5A

F10

4A

PH

AS

E W

P1

25K

HZ

.

GD

I PWR. MOD. A

* *

F10

2AF

102B

F10

1CF

102C

F10

1BF

101A

PO

WE

R M

OD

ULE

A

F10

3AP

HA

SE

U

PS LP

I CIR

CU

IT3FU

1FU

±15V

110V

D/S

–24V

SLOT 7

SLOT 8

PWR. MOD. A

GD

I

PWR. MOD. A

GD

I

PO

WE

R M

OD

ULE

B

PH

AS

E U

PH

AS

E V

PH

AS

E W

PO

WE

R M

OD

ULE

C

PH

AS

E U

PH

AS

E V

PH

AS

E W

PH

AS

E V

Con

trol

Pow

erF

uses

DC

Bus

Fus

es

AC

Inpu

tP

hase

Fus

es

AC

Inpu

tP

hase

Fus

es

AC

Inpu

tP

hase

Fus

es

∗∗∗

∗∗∗

See

Tab

le 4

.5

11F

U

12F

U21

FU

-

26F

U


4.5.2 Replacing an IGBT Phase Module Assembly

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.



Table 4.5 – Power Module Fuse Specifications1

Fuse Volts Class Type Rating Rockwell Part

Number Torque Specifications

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

2FU 600 CC CCMR 25 A 64676-72BB --

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

F101 1000 Semiconductor 1000 A 64676-80P 41 Nm (30 lb-ft)


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



+/- 15V PS* 250 -- F 1.8 A Replace with 1.6A

64676-82U

--

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

+/- 24V PS*** 250 -- F 2.0 A 64676-82V --

25 KHz PS11FU12FU

600 CC -- 8 A 64676-30H --

25 KHz PS21FU26FU

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

1. Fuse locations shown in figures 4.2, 4.3, and 4.4.



Step 4. Remove the wiring harnesses from the IGBT Phase module assembly. The wiring includes the power supply wiring, the temperature sensor wiring, and the fiber-optic cables. Remove the fiber-optic cables by pressing the sides of the connectors to release the locking mechanism. Label the harnesses to aid in re-installation. Refer to the wiring diagrams supplied with your system.

Note that due to tight mechanical tolerances, it may be necessary to remove IGBT Phase module assemblies U and/or V, in order to remove assemblies V and/or W.

Step 5. Remove the bolts from the fuses. See figure 4.5, callouts 1 and 2.

Step 6. Remove the 2 bolts from the AC bus bar. The bolts are located below the LEM device and above the fuse. See figure 4.5, callout 3.

Step 7. Remove the 2 hex nuts from the negative bus bar. See figure 4.5, callout 4.

Step 8. Remove the 2 hex nuts from the heatsink. One hex nut is located on each side of the heatsink. See figure 4.5, callout 5.

Step 9. Remove the IGBT module assembly from the SB3000 Power Module.

Step 10. Install the new IGBT module assembly by performing steps 1 through 9 in reverse order.


Figure 4.5 – IGBT Module Assembly Mounting Bolt Locations

5

4

1

2

3

PHASE V

PHASE W


4.5.2.1 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.

4.5.3 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.


4.5.3.1 Replacing a Blower Filter

Use the following procedure to replace the blower assembly's filter:

Step 1. Remove the filter by sliding it out.

Step 2. Slide the new filter in.



4.5.4 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 4.5.2 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 following steps 1 through 12 in reverse order.




4.6 Performing the Bridge Test

Important: This test is normally performed at the factory. It should not be necessary to perform it again unless the power devices or fiber-optic cables have been replaced.

The bridge test is used to verify fiber-optic gate cabling connections by test firing the IGBTs one at a time. As the IGBTs fire, the LEDs on the corresponding GDI module in the PMI rack will turn on and off in the following sequence:

1. U- (Lower Power Device)

2. U+ (Upper Power Device)

3. V- (Lower Power Device)

4. V+ (Upper Power Device)

5. W- (Lower Power Device)

6. W+ (Upper Power Device)

If the LEDs do not turn on and off in this order, the fiber-optic gate cables have been connected incorrectly and must be reconnected as shown on the wiring diagrams. Note that three-phase AC input power must be off and the DC bus capacitors must be discharged before the cables can be reconnected.

Three-phase AC input power to the SB3000 Power Module must be turned off and the inverter must be disconnected before the bridge test can be enabled. When the bridge test is running, the pre-charge contactor will be closed. 115 VAC control power must be applied for the pre-charge contactor. When the bridge test is turned off, the pre-charge contactor will open.

The PMI Processor will prevent the bridge test from executing if the DC bus voltage is greater than 10 VDC. However, the PMI Processor cannot prevent three-phase AC input power from being applied once the bridge test has been started. If three-phase AC input power is turned on while the bridge test is in progress, a line-to-line short circuit will result which may result in bodily injury and damage to the SB3000 Power Module.

Use the following procedure to perform the bridge test:

Step 1. Disconnect, lockout, and tag the three-phase AC input power to the SB3000 Power Module.

Step 2. Ensure that the DC bus is fully discharged. Refer to section 4.2.

Step 3. Enable the bridge test through register 100/1100, bit 2, and bits 10, 11, or 12, as applicable.

Step 4. Verify that the LEDs turn on and off in the order described. If the LEDs do not turn on and off in the proper order, reconnect the fiber-optic gate cables as shown on the wiring diagrams.

!ATTENTION: Disconnect and lock out three-phase AC input power to the SB3000 Power Module before enabling the bridge test. Ensure that three-phase AC input power cannot be turned on while the bridge test is running. If three-phase AC input power is turned on while the test is running, a line-to-line short circuit will occur. Failure to observe this precaution could result in bodily injury.

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 (445A SB3000 Power Module)

• Height: 2200 mm (86.6 inches)1

• Depth: 602 mm (23.7 inches)

• Width: 1012 mm (39.8 inches)

• Weight:500 kg (1100 pounds)




• Width: 1612 mm (63.5 inches)





• Width: 2212 mm (87.1inches)


1. Does not include upper bus bar connections

A-2 SB3000 Power Modules (Rittal)

AC Input Power

• Minimum AC Line Voltage: 208V nominal

• Maximum AC Line Voltage: 460V nominal

• Maximum AC Line Variation: +/- 10%

• AC Line Frequency: 25, 50, and 60 Hz, +/- 2 Hz

• Frequency Rate of Change: 1Hz/Second

• Maximum AC Line Current: 534A, 972A, 1457A

• Maximum Phase Imbalance: 5%

AC Control Power

• AC Input Voltage: 115 VAC

• AC Input Frequency: 50/60 Hz

DC Output Power

• Minimum Output Voltage: 1.414 x VAC x 1.1 x 1.1

• Maximum Output Voltage: 900V

• Output Voltage Regulation: +/- 1%

• Maximum DC Output Current: (1.70 x ELine x ILine x Power Factor) / VDC

• Maximum Short Circuit Current: 100KA

• Output Voltage Resolution: 0.5V

• Output Voltage Regulation: Less than 5% for +/- 100% current step change

• Voltage Regulator Response: 100 rad/sec.

• VAR/Power Factor Correction: The user can select the maximum amount of SB3000 VAR correction. The SB3000 Power Module will always give the voltage regulator priority over the VAR function. If the output of the SB3000 Power Module is less than its limit, it will attempt to produce VARs up to the limit set by the user. Refer to Appendix C, section C.2.1.

SB3000 Power Module Current Ratings 1

SB3000 Part Number

ContinuousAC Input Current

(460VAC)

ContinuousDC Output Current

(800VDC)

5 MinuteAC Input and DC Output

Overload 2

804300-S 445A (rms) 445A DC 534A (rms)

804300-T 890A (rms) 890A DC 972A (rms)

804300-V 1335A (rms) 1335A DC 1457A (rms)

1. At 460 VAC Input/800 VDC Output/4 kHz Carrier Frequency. For use with SA3000/SA3100 Power Modules operating at a 2 kHz carrier frequency.

2. With a 25% duty cycle

Technical Specifications A-3

Three-Phase AC Input Voltage

• Voltage Range: 200 to 500 Volts, +/- 10%

• Frequency Range: 25, 50, and 60 Hz (+/- 2 Hz)

• Frequency Rate of Change: 5 Hz per Second

• Maximum Phase Imbalance: 5%

Output Phase Signals (181-182, 182-183)

• Signal Waveform: 10 mA square wave

• Phase Accuracy: < 2%

• Phase Shift versus Frequency: Phase Shift = 0.637 x Input Frequency

• Output Open-Circuit Voltage: 15 Volts

• Short-Circuit Current: < 40 mA

Analog Output Voltage

• Gain: 675 VAC RMS = 10 VDC

• Filter Break Frequency: 23 Hz

• CMRR: 200:1

TSB3000 Power Module Replacement Fuse Specifications 1

Fuse Volts Class Type Rating Rockwell Part

Number Torque Specifications

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

2FU 600 CC CCMR 25 A 64676-72BB --

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






+/- 15V PS* 250 -- F 1.6 A 64676-82U --

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

+/- 24V PS*** 250 -- F 2.0 A 64676-82V --

25 KHz PS11FU12FU

600 CC -- 8 A 64676-30H --

25 KHz PS21FU26FU

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

1. Fuse locations shown in figures 4.2, 4.3, and 4.4.

A-4 SB3000 Power Modules (Rittal)

SB3000 Component Block Diagram B-1

APPENDIX BSB3000 Component Block Diagram

The following figure shows an overview of the components of the SB3000 Synchronous Rectifier. Refer to chapter 2 of this manual for detailed diagrams of the 445A, 890A, and 1335A configurations of the SB3000 Synchronous Rectifier.

B-2 SB3000 Power Modules (Rittal)

PM

IR

AC

KLP

IR

EM

OT

EO

PT

ION

AL

PO

WE

R M

OD

ULE

C

PO

WE

R M

OD

ULE

B

PO

WE

R M

OD

ULE

A

1000

AF1

02C

F10

1C10

00A

1000

A

F102

B10

00A

F10

1B

1000

A

F10

2A10

00A

F10

1A

4547

SB

300

0 S

YN

CH

RO

NO

US

RE

CT

IFIE

R A

/B/C

PO

WE

R M

OD

ULE

S

I/O H

EA

DS

+24

VD

C

-24

VD

C

+/-1

5 V

DC

WA

RN

ING

T

HE

RM

OS

TA

T 3

TR

IPT

HE

RM

OS

TA

T 3

LEM

CA

BLE

3

TO

LP

I

22

9F

AU

LT F

/O P

AIR

S6

GA

TE

DR

IVE

R A

ND

TO

PM

I RA

CK

TH

ER

MO

ST

AT

2T

HE

RM

OS

TA

T 2

WA

RN

ING

2

TO L

PI

TR

IP

TO

PM

I RA

CK

CA

BLE

22

LEM

96

GA

TE D

RIV

ER

AN

DF

AU

LT F

/O P

AIR

S

601

602

603 T

O

PO

WE

RM

OD

ULE

BF

AU

LT F

/O

DR

IVE

RA

ND

19

MO

TO

RF

DB

KT

RIP

LET

WIS

TED

CA

BLE

LEM

TR

IPT

HE

RM

O-

ST

AT

2

WA

RN

ING

THE

RM

O-

ST

AT

22

TH

ER

MO

-S

TA

T 2

ST

AT

2

WA

RN

ING

TH

ER

MO

-T

RIP

2C

AB

LELE

M

9

THE

RM

O-

WA

RN

ING

STA

T 2

LEM

CA

BLE

TR

IP

ST

AT

2T

HE

RM

O-

2

9

6 G

ATE

PA

IRS

15 15 15

115V

AC

CK

T B

RE

AK

ER

115V

AC

188

189

115V

AC

188

189

115V

AC

3145

3147

-+

DC

BU

S_3

-+

DC

BU

S_2

-+

DC

BU

S_1

2145

2147

1147

1145

TO P

OW

ER

MO

DU

LE B

TO P

OW

ER

MO

DU

LE C

22

22

22

1388

1189

1388

1189

1388

1188

1388

1189

RE

SO

LVE

R

FO

LIN

K T

O

CU

ST

OM

ER

898818

8

189

L N G

6 G

AT

E D

RIV

ER

AN

DF

AU

LT F

/O P

AIR

S

GGG 183

182

181

AC

INP

UT

603

602

601

603

602

601

G

SY

NC

LIN

E

TO

PR

E-C

HA

RG

EIN

PW

R. D

ISC

.C

AB

INE

T

LEM

189

188

DC

BU

S

+ -

TO

PO

WE

RM

OD

ULE

C

AU

TO

MA

X

I/OFD

BK

Theory of Operation C-1

APPENDIX CTheory of Operation

C.1 Typical SB3000 System

SB3000 Power Modules are used to supply regulated common DC bus power to one or more SA3000/SA3100 Power Modules. As illustrated in figure C.1, a typical SB3000 system is made up of the following:

• an AC power disconnect device with overcurrent protection

• a soft-charge assembly which consists of pre-charge resistors and a pre-charge contactor

• an AC line filter reactor

• a power bridge

• a regulator consisting of both hardware and software elements.

The power distribution cabinet is mounted separately from the SB3000 Power Module and typically contains the AC power disconnect/overcurrent protection device, the soft-charge assembly, and the AC line filter reactor.

The AC line filter reactor is an energy storage element that isolates the converter bridge. This reactor limits the current flow between the AC line and the DC bus while providing a voltage boost between the input AC voltage and the output DC voltage.

The pre-charge resistors provide for controlled soft-charging of the DC bus capacitors to an initial voltage from which the SB3000 regulator can be safely started.

The SB3000 power bridges are the same three-phase IGBT inverter bridges that are used in the High Power SA3000 Power Modules, but are connected such that the three-phase AC leads are connected to the AC line, instead of to a motor, and the DC leads are connected as an output to a DC bus designed to feed one or more SA3000/SA3100 Power Modules.

The regulator controls the operation of all the elements in the system and links the SB3000 Power Module to the application level.

C-2 SB3000 Power Modules (Rittal)

Figure C.1 – SB3000 System

UV

W

C EG

IGB

T

C EG

IGB

T

C EG

IGB

T

C EG

IGB

T

C EG

IGB

T

C EG

IGB

T

CA

PAC

ITO

RB

AN

K

PO

WE

R B

RID

GE

RE

GU

LATO

R(H

W &

SW

)

SB

3000

SY

NC

HR

ON

OU

S R

EC

TIF

IER

800

VO

LT

(+)

(–)

ISO

LAT

ION

TR

AN

SF

OR

ME

R

PR

IMA

RY

AC

FE

ED

ER

R R R

SE

CO

ND

AR

Y

DIS

CO

NN

EC

T

FU

SE

DP

RE

-CH

AR

GE

RE

SIS

TO

RS

PR

E-C

HA

RG

EC

ON

TAC

TOR

LIN

E F

ILT

ER

RE

AC

TO

R

460

VO

LT

181

182

183

PO

WE

R D

IST

RIB

UT

ION

CA

BIN

ET

(RE

MO

TE

LY M

OU

NT

ED

)

(SE

PAR

ATE

LY M

OU

NT

ED

)

DC

BU

STO

PW

MIN

VE

RT

ER

S


C.2 SB3000 Regulator

The main purpose of the SB3000 regulator is to maintain the proper voltage on the DC bus through the use of a vector algorithm executed in the PMI Processor.

The application task in the UDC module controlling the SB3000 Power Module passes the desired DC bus voltage reference command to the PMI Processor in register 102/1102. The PMI Processor uses proportional-integral-derivative (PID) logic to calculate DC bus current in response to the voltage reference and error values. See figure C.2.

The commanded current is actually made up of two parts: Iq and Id. The Iq current is in phase with the AC line voltage when motoring and is 180 degrees out of phase with the AC line when regenerating. The Id current leads the AC line voltage by 90 degrees. The Iq current is the real current that powers the DC bus. The Id current is the reactive current that produces the leading power factor.

The PMI Processor uses the AC line period to determine the frequency to command. It uses the offset between the zero crossing of the AC line and the commanded zero crossing to determine the angle offset. The AC line frequency may change up to 1 Hz per second.


Figure C.2 – Control Structure

Har

dwar

eS

oftw

are

Ki =

Vm

l - W

coV

ml -

A

Kp

= V

ml -

Wco

C

Gen

erat

eP

WM

Vu

Vv

Vw

2/3

Vq

PI

(Iq_

Fbk

)

(Iq_

Cm

d)

Cnf

I_Lm

t ∗ 1

.414

+ +

PI_

Lmt_

E1

+ +

PI_

Lmt_

E4

+ +

z-1

Ki

Kp

E1

Vd

PI

(Id_

Fbk

)

(Id_

Cm

d)Li

mit

Pow

erFa

ctor

Cur

rent

(Vdc

_Ref

_E0)

(Ipf

_Ref

_E1)

+ +

Ram

p Filt

er25

%V

ml_

Kd

z-1+ –

+ –

if (!

drv_

on||r

esta

rt)

Vdc

_Ref

_E0

= V

dc_R

amp

_E1

++

/10

Min

_Vdc

_Ref

_E

0=

Vac

_R

ms_

E0

∗ 1.

414

∗ 1.

1

Max

_Vdc

_Ref

_E0

= M

ax_V

olts

- 2

5=

875

(Pi_

Lmt_

E1)

(Pi_

Lmt_

E4)

1000

Vm

l_F

fF

ilter

40%

+ –(C

nf.I_

Lmt_

E1

∗ 1.

414)

(Idc

_Fbk

_E1)

(Vdc

_Ref

_E0)

(Vdc

_Fbk

_E0)

f(46

0) =

715


C.2.1 Leading Power Factor Operation

The regulator has the capability to operate with a leading power factor. This allows the regulator to calculate the Id current based on the capacity that is left over in the SB3000 Power Module rating after the Iq current has been determined.

If the UDC application task provides a leading power factor current reference value (IPF_REF%) in register 103/1103, the vector algorithm can compensate for a lagging power factor in the total AC line load with the second component of the current vector (Id). The Id current is calculated based on the value of Iq current and the current reference value in register 103/1103. The leading power factor current reference value is limited to not exceed the SB3000 Power Module’s current limit rating. When Id current is near zero, due to a small load on the DC bus, it can approach the reference value. As Iq current increases, Id current decreases. A status bit indicates when the power factor current is being limited.

If capacity is left over after power has been supplied to the inverter load, the vector algorithm can produce VARS (volt-amperes reactive) with a leading power factor to compensate for other machines with lagging power factors on the same AC line. The Id current is limited not to exceed the rectifier rating. The VARS produced will be reported in register 211/1211.

Assuming power factor current is not being limited, Id current is calculated based on the Iq current and IPF_REF%. See figure C.3. The amount of VAR that is produced will be displayed in the feedback data.

When Iq current is near zero because there is negligible load on the DC bus, Id current can be near the full value of IPF_REF%.

When Iq current becomes larger, Id current becomes smaller.

When Iq current becomes greater than IPF_REF, Id current is reduced to zero.

Figure C.3 – Leading Power Factor

,T

,G

,/,0B(

,3)B5()

,T

,G

,/,0B(

,3)B5()

,T

,G

,/,0B(

,3)B5()


C.3 SB3000 DC Bus Charging Sequence

The SB3000 pre-charge circuitry is controlled via a pre-charge contactor which is under the control of the PMI Processor in the SB3000 PMI rack. Any faults relating to pre-charge contactor operation are reported in registers 202/1202 and 205/1205. The closing and opening of the pre-charge contactor is a function of the measured DC bus voltage. See figure C.4.

Note that the RPI signal has no effect on the operation of the pre-charge contactor; however, the RPI input must be present for the voltage loop to be in run. Turning off the RPI signal does not disable output power. If AC input power is on, the diodes in the IGBTs will conduct rectified voltage to the output terminals, independent of the state of the RPI signal.

C.3.1 Pre-charge Contactor Requirements for SA3000/SA3100 Power Modules

The status of the SB3000 pre-charge contactor (CHG_FB@) must be used by the SA3000/SA3100 Power Module’s application tasks. The SA3000/SA3100 Power Module must not operate with the pre-charge contactor open. Doing so may damage the pre-charge resistor. It is the responsibility of the application tasks running in the SA3000/SA3100 UDC module to make sure the SB3000 Power Module is in run before the SB3000 Power Module is turned on.

If the SB3000 Power Module is shut down due to a fault condition, the controlled shutdown of the SA3000/SA3100 Power Module is the responsibility of the application.

Each SA3000/SA3100 Power Module must have its own pre-charge resistor and contactor to limit the current into its capacitors.

C.3.2 Pre-charge Sequencing During Normal Operation

When AC power is applied to the SB3000 Power Module, the diodes in the IGBT power devices allow the capacitors to begin charging immediately through the line fuses, input inductors, and pre-charge resistors up to near peak AC line voltage. When the DC bus has reached the close threshold voltage and is at a steady-state condition, the PMI Processor will close the pre-charge contactor if there is no fault. After the contactor is closed, the PMI Processor will turn on status bit CHG_FB@ to indicate this condition to the application task. If there is a fault, the PMI Processor will turn on the IC_FLT@ interlock to indicate that a fault needs to be reset.

!ATTENTION: The UDC application task must examine the pre-charge status bit (CHG_FB@) regularly. If the status bit turns off, the SA3000/SA3100 Power Module must be shut down. If the SA3000/SA3100 Power Module is not shut down, the pre-charge resistor may be damaged. Failure to observe this precaution could result in to damage to, or destruction of, the equipment.


C.3.3 Pre-charge Contactor’s Close Threshold Voltage

When control power is first turned on, the pre-charge contactor will be open. This allows the DC bus voltage to increase to near the peak voltage of the AC line. The pre-charge contactor’s close threshold voltage is equal to the following:

Close Threshold Voltage = 1.414 x (Peak Configured AC RMS Line Voltage) - 10%

This threshold voltage allows the SB3000 Power Module to turn on when the AC line is up to 10% low. The pre-charge contactor will stay open until the measured DC bus voltage reaches this threshold. When the pre-charge contactor closes, the PMI Processor will indicate this by turning on register 201/1201, bit 12 (CHG_FB@).

C.3.4 Pre-charge Contactor’s Open Threshold Voltage

The pre-charge contactor’s open threshold voltage is the peak voltage of the configured AC RMS line voltage, times the square root of two, minus 100 volts. The maximum step change on the capacitor is 100 volts. If the DC bus voltage drops below the open threshold voltage, the pre-charge contactor will be opened to protect the capacitors and CHG_FB@ will be turned off. In this case, register 201/1201, bit 12 (CHG_FB@) will be turned off. The pre-charge contactor will remain open until the bus voltage again reaches a steady-state voltage above the close threshold voltage.


Figure C.4 – Pre-charge State Diagram

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C.3.5 Pre-charge Contactor Sequencing During the Bridge Test

When the bridge test is commanded in register 100/1100, bit 2, the SB3000’s pre-charge contactor will close. After the results of the test have been displayed on the GDI module(s), the pre-charge contactor will be opened.

C.3.6 Charge Faults

The PMI Processor will generate a Charge Fault (register 202/1202, bit 6) if:

• the pre-charge contactor is closed when it should be open.

• the pre-charge contactor opens without being commanded to open.

• the pre-charge contactor is commanded to open and it does not open within one second.

C.4 Line Synchronization

The motoring operation of the SB3000 Power Module is analogous to the operation of an SA3000 Power Module regenerating power from a large synchronous motor to the DC bus. For the SB3000 Power Module, the AC line acts like a very large synchronous motor operating at a fixed frequency/speed. Whether the SB3000 Power Module is motoring (supplying power to the DC bus from the AC line) or regenerating (returning power to the AC line from the DC bus) is determined by the voltage level of the DC bus which the SB3000 Power Module is regulating. To operate, the SB3000 Power Module must be synchronized, in frequency and phase, with the AC line. Line synchronization specifications are provided in Appendix A.

Phase synchronization is maintained by the PMI and the Line Synchronization module. The period of the AC line is used to determine the frequency to command and the offset between the zero crossing of the AC line and the commanded zero crossing is used to determine the angle offset.

The Line Synchronization module, located in the SB3000 control cabinet, is connected to the +/- 24 and 15 volt power supplies. The AC line synchronization circuit monitors the AC line feeding the SB3000 Power Module and outputs a pair of signals locked in-phase with the AC line to the A-C Power Technology module in the PMI rack. The AC line synchronization circuit also contains the Burden resistor for the Hall device which monitors the DC bus current.

If the PMI detects AC input voltage to be less than 75% of the configured voltage or greater than 125% of the configured voltage, it will latch the WRN_PWR@ warning bit and disable the firing of the IGBTs. If power is restored within ten seconds, the PMI will re-synchronize and resume operation. If power is not restored within ten seconds, the PMI will latch the FLT_PWR@ fault bit and will not automatically restart.

If input voltage is out of tolerance, a bit is set in the UDC Module’s memory (VDC_SB@) to indicate that the voltage loop is in standby. The master speed reference task can then optionally begin to decelerate the inverter-driven load, using the inertia in the driven load (motor and machine) to maintain the DC bus voltage until power comes back or the machine is stopped. If any fault is detected while in standby, VDC_SB@ is turned off, and the drive will not automatically restart.

SB3000 Interlock Sequencing D-1

APPENDIX DSB3000 Interlock Sequencing

When a request is made to turn on the SB3000 Power Module’s voltage loop and a required precondition has not been met, a bit will be set in Interlock register 205/1205 indicating the problem. The interlock requirements are described in the following table. If an interlock problem is detected, the voltage loop will not go into run.

Interlock Precondition

Bit Set in Register 205/1205 by the PMI

Processor

Valid configuration parameters have not been downloaded into the UDC module from the Programming Executive or the parameters are outside of acceptable limits.

Bit 0 (IC_CNF@)

Pre-defined local tunables are zero or a UDC task containing the variables has not been loaded to the rack.

Bit 1 (IC_GAIN@)

The RPI input is not turned on. Bit 2 (IC_RPI@)

A fault that shut down the voltage loop has not been reset. Bit 3 (IC_FLT@)

A rising edge is not detected on a command bit in register 100/1100. Bit 4 (IC_RISE@)

More than one operating mode is requested at a time. Bit 5 (IC_MORE@)

The pre-charge contactor has not closed. Bit 7 (IC_PCHG@)

The number of GDI modules in the PMI rack does not match the number of GDI modules configured or the GDI modules have been incorrectly placed in the PMI rack.

Bit 8 (IC_GDI@)

During the bridge test, a Power Module has not been selected or an incorrect Power Module been selected.

Bit 8 (IC_GDI@)

The PMI rack has an incorrect backplane. Bit 9 (IC_IPBP@)

The bridge test is requested and the DC bus voltage is greater than 10V. Bit 11 (IC_VDC@)

D-2 SB3000 Power Modules (Rittal)

Replacement Parts E-1

APPENDIX EReplacement Parts

445 Amp SB3000 Synchronous Rectifier

Table E.1 – 445A SB3000 Power Module

Part Description 1

1. Components are identified in figure 2.2.

Quantity

RockwellPart Number

Blower Assembly 1 803430-9R

IGBT Module Assembly 3 803430-8S

Capacitor Bank Assembly 1 803430-6S

Pre-charge Assembly 1 803430-7R

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

+/- 15 VDC Power Supply (1A) 1 704323-33K

110V AC Disconnect Switch (40A, 600 VAC) 1 65242-10R

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

LPI 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

Reactor (7.5uH, 600A) 3 608895-60A

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

Fuse (1FU) (6 Amp, 600 VAC) 1 64676-64M

Fuse (2FU) (25 Amp, 600 VAC) 1 64676-72BB

Fuse (3FU) (3 Amp, 600 VAC) 1 64676-64J

9ROWDJH )HHGEDFN 5HVLVWRUV .Ω : 5 63481-102TFB

DC Feedback Module 1 0-55350-10

AC Input Current Meter 1 850012-R

DC Output Current Meter 1 850012-S

Blower Filter 1 69740-10G

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

Part Description

Quantity Rockwell

Part Number

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

E-2 SB3000 Power Modules (Rittal)

445 Amp SB3000 Synchronous Rectifier (Continued)

Table E.3 – Pre-charge Assembly (803430-7R)

Part Description

Quantity Rockwell

Part Number

'LVFKDUJH 5HVLVWRUV .Ω : 9 612183-36R

Pre-charge Module 1 0-55350-4

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

Table E.4 – Blower Assembly (803430-9R)

Part Description

Quantity Rockwell

Part Number

Blower (115 VAC) 1 69739-47R

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

9ROWDJH 5HVLVWRUV Ω : 3 63481-104QAA

Table E.5 – IGBT Module Assembly (803430-8S)

Part Description Quantity Rockwell

Part Number

IGBT Transistor (600A, 1200 VDC) 4 602909-808AW

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 E.6 – 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 (F101, F102) (1000A, 1000 VAC) 4 64676-80P






PMI Rack Assembly 1 805401-5S


1 802268-16R

Reactor (7.5uH, 600A) 6 608895-60A

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

Fuse (1FU) (6A, 600 VAC) 1 64676-64M

Fuse (2FU) (25A, 600 VAC) 1 64676-72BB

Fuse (3FU) (3A, 600 VAC) 1 64676-64J






Table E.8 – Capacitor Bank Assembly (803430-6S) (2 Required)

Part Description

Quantity Rockwell

Part Number


Table E.9 – Pre-charge Assembly (803430-7R) (2 Required)

Part Description

Quantity Rockwell

Part Number






Table E.10 – Blower Assembly (803430-9R) (2 Required)

Part Description

Quantity Rockwell

Part Number

Blower (115 VAC) 1 69739-47R



Table E.11 – IGBT Module Assembly (803430-8S) (2 Required)

Part Description

Quantity Rockwell

Part Number





Fuse (F103, F104, F105) (630A, 1000 VAC) 3 64676-79AZ

Table E.12 – PMI Rack Assembly (805401-5) (2 Required)

Part Description

Quantity Rockwell

Part Number










Part Description 1


Quantity

RockwellPart Number





Fuse (F101, F102) (1000A, 1000 VAC) 6 64676-80P






PMI Rack Assembly 1 805401-5T


1 802268-16R

Reactor (7.5uH, 600A) 9 608895-60A

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

Fuse (1FU) (6A, 600 VAC) 1 64676-64M

Fuse (2FU) (25A, 600 VAC) 1 64676-72BB

Fuse (3FU) (3A, 600 VAC) 1 64676-64J






Table E.14 – Capacitor Bank Assembly (803430-6S) (3 Required)

Part Description

Quantity Rockwell

Part Number


Table E.15 – Pre-charge Assembly (803430-7R) (3 Required)

Part Description

Quantity Rockwell

Part Number






Table E.16 – Blower Assembly (803430-9R) (3 Required)

Part Description

Quantity Rockwell

Part Number

Blower (115 VAC) 1 69739-47R



Table E.17 – IGBT Module Assembly (803430-8S) (3 Required)

Part Description

Quantity Rockwell

Part Number





Fuse (F103A, F104A, F105A) (630A, 1000 VAC)

3 64676-79AZ

Table E.18 – PMI Rack Assembly (805401-5) (3 Required)

Part Description

Quantity Rockwell

Part Number







Index Index-1

INDEX

B

Bridge test see Diagnostics and troubleshooting

C

Control structure, C-4Current ratings, 1-1

D

DC bus voltage, 2-3Diagnostics and troubleshooting, 4-1 to 4-19

bridge test, 4-19DC bus and output terminal tests, 4-4faults and warnings, 4-4 to 4-10IGBT tests, 4-4replacing a blower assembly, 4-17replacing a blower filter, 4-17replacing a bus capacitor assembly, 4-18replacing an IGBT phase module, 4-15 to 4-17replacing fuses, 4-11 to 4-15replacing sub-assemblies, 4-11 to 4-18replacing the cabinet, 4-10 to 4-11required test equipment, 4-1 to 4-2tests with input power off, 4-2 to 4-4

Drive fault register 202/1202, 4-5Drive warning register 203 /1203, 4-8

E

Electrical description, 2-3 to 2-4, 2-8 to 2-16circuitry, 2-8 to 2-16DC bus voltage, 2-3

F

Faults, 4-5 to 4-7charge fault, 4-6communication lost, 4-7DC bus overcurrent, 4-6DC bus overvoltage, 4-6gate driver interface fault, 4-6ground current fault, 4-6instantaneous overcurrent, 4-6

local power interface fault, 4-6overtemperature, 4-7power loss, 4-7power technology fault, 4-7

Fuse1335A power module fuse locations, 4-14445A power module fuse locations, 4-12890A power module fuse locations, 4-13AC input & DC bus fuse ratings, 3-2replacement, 4-11 to 4-15specifications, 4-15, A-3

G

Ground connections, 3-9

I

Installation guidelines, 3-1 to 3-9control transformers, 3-3 to 3-4grounding, 3-5installation planning, 3-1line filter reactors, 3-3power module cabinet, 3-5 to 3-9pre-charge resistors and fuses, 3-2 to 3-3wire sizes, 3-4wiring, 3-2 to 3-5

Interlock sequencing, D-1Introduction, 1-1 to 1-3

L

Leading power factor, C-5Line filter reactor ratings, 3-3

M

Mechanical description, 2-1 to 2-2, 2-5 to 2-7AC input current meter, 2-2capacitor bank assembly, 2-2components, 2-5 to 2-7DC bus current meter, 2-2DC bus voltage meter, 2-2fiber-optic communication, 2-1local power interface module (LPI), 2-1

Index-2 SB3000 Power Modules (Rittal)

phase modules, 2-1snubber/gate driver module, 2-1softcharge assembly, 2-2

Mechanical/electrical description, 2-1 to 2-16Meter scaling, 2-2Meters, 2-2Mounting dimensions

1335A power module, 3-8445A power module, 3-6890A power module, 3-7

P

Part numbers, 1-2Power connections, 3-9Power module circuitry

1335A power module, 2-13 to 2-16445A power module, 2-8 to 2-9890A power module, 2-10 to 2-12

Power module components1335A power module, 2-7445A power module, 2-5890A power module, 2-6

Pre-charge contactor, C-6 to C-9close threshold voltage, C-7contactor requirements, C-6open threshold voltage, C-7sequencing (normal operation), C-6sequencing during bridge test, C-9

Pre-charge resistors and fuses, 3-3

R

Related publications, 1-3Replacement parts, E-1 to E-6

1335A SB3000 power module, E-5 to E-6445A SB3000 power module, E-1 to E-2890A SB3000 power module, E-3 to E-4

Replacing components see Diagnostics and troubleshooting

S

SA3000/SA3100 Power Modulesbus connection, 3-5operation on DC bus, 2-4pre-charge contactor requirements, C-6

SB3000 component block diagram, B-1SB3000 system diagram, C-2Standard features, 1-2

T

Technical specifications, A-1 to A-3AC control power, A-2AC input power, A-2ambient conditions, A-1analog output voltage, A-3current ratings, A-2DC output power, A-2dimensions, A-1output phase signals, A-3replacement fuses, A-3three-phase AC input voltage, A-3

Terminal tightening torques, 3-4Theory of operation, C-1 to C-9

charge faults, C-9control structure, C-4DC bus charging sequence, C-6 to C-9leading power factor operation, C-5line synchronization, C-9pre-charge contactor, C-6 to C-9pre-charge state diagram, C-8SB3000 regulator, C-3 to C-5typical SB3000 system, C-1

W

Warnings, 4-7 to 4-10bad gain data, 4-9CCLK not synchronized, 4-10DC bus overvoltage, 4-8DC bus undervoltage, 4-8ground current warning, 4-9load sharing warning, 4-9phase lost, 4-9PMI communication warning, 4-10PMI fan loss, 4-10power loss, 4-9power module overload, 4-9rail communication warning, 4-10reference in limit, 4-9

Wiring see Installation guidelines

DIFDocumentation

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Printed in U.S.A. S-3031 August 1998

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