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23P-UM001 - Rockwell Automation

1. G a oo Cg orb 3 OO e i maggy A Q000df 5 car dut ii m p 3 o Binary Gain Amp 9 Md LI DIP Switches DITIONI 0010 Iu B ESERE DDI IE MSB LSB Ud 9 lt SSE 2 i i TE C o a OHHO HEHBHEHH c Hes 00 TE g ESWS SWA are 2 EuS Em IE TE o 6606066 G aoe F EB xc i HB F f E gt Burden Resistor External Burden Resistor E pa eg Jumpers Terminal Block XCT i HB WR O M tL o TIT 0 Eun 4 2o o OO es EEEEERER Figure 14 Binary Gain Amp DIP Switch to Bit Layout MSB q W LSB SW3 SW4 ON INA mm m NRRENENN 100 IMPORTANT The labels on DIP switches SW3 and SW4 do NOT correspond to the bit numbers used to set the amplifier gain Rockwell Automation Publication 23P UM001D EN P July 2012 39 Chapter2 Stand Alone Regulator Installation Wiring and Configuration
2. SAR Sizing DIP switch S15 is configured for the appropriate SAR size at the factory Do not change the settings unless you are installing a replacement control board Table 7 SAR DIP Switch S15 Settings Description S15 1 15 2 15 3 15 4 15 5 S15 6 15 7 15 8 SAR 200V 0 Of Off Off Off On Off Off 230V SAR 400V 0 Of Off Off Off On On Off 460V SAR 600V 0 Of Off Off Off On Off On 575V SAR 690V 0 Of Off Off Off On On On 690V Figure 10 DIP Switch S15 Location on Control Board I E LI e oO a O XA D mibi e HI 2 S15 g4 LE CN LI rn o ooo P CM LN CT Lp o CM LN jo ovo o c Tm o L O ON sii Oooo 21 s9 SEC Oo o O oo iOOOOOOOOOOjOOOOOOOOOO S 60000 ar 900000000 0000000000 Rockwell Automation Publication 23P UM001D EN P July 2012 21 Chapter2 Stand Alone Regulator Installation Wiring and Configuration SAR Current Feedback Configuration 28 Overview The current feedback to the SAR provided via current transformers CTs that monitor the U and W phase inputs to the power module is rectified via a three phase diode bridge The output of the diode bridge is connected to a burden resistor The voltage across the burden resistor is directly proportional to the amount of current being drawn by the motor load This voltage is used by the regulator to monitor and control the cur
3. pauinbey ji Kaoiro dois 0 X souo uedo S d X3 A8 ASULON yoegpee aBeyon enjeuuv pied ejnpoj 18Mod JOJON OL Add M yoeqpee 19 ypeqpee4 S va pue yejsouueu o0 ov OVAOZL LJ ainpoy JOMOd QINPOY JeMod NI AJY yeas e 829sv621 evevi v ivi namoa 1a 19 IS fm L LdN Y di gt NI aud Yun ey jo woyoq ey uo weds payeoo ee sjeuIWal Iv EN peno 2 y 0210 V Ob eus q ul i saia si Aiddng piel i3 m JoyeinBay euo e pueis NL pn OQ X9 419MOd lejiduiy 349 eiqeo aep bL Pm T 53 Rockwell Automation Publication 23P UM001D EN P July 2012 Chapter 3 Gate Amplifier Installation and Wiring I LLJ rpm Gate Amplifier Cascade Configurations It is permissible to cascade Gate Amplifiers The time delay through the Gate Amplifier is 0 5 uSec This amount of time delay is not significant with regard to the gate firing of parallel power modules For any configuration with multiple Gate Amplifiers be sure to connect the Ready relay into the Run Permissive circuit The external 48V power supply cannot be used on a Gate Amplifier or SD3000 PLUS whose output acts as an input source for a downstream Gate Amplifier The continuous application of the high amplitude gate pulses to the input will cause excessive heating of the
4. 00000000000000 UU S UU M NA UUUUUUUUYUYUY Table 6 Power Module Thermal Switch and Current Transformer Terminal Specifications Wire Size Range Recommended Terminal Description Maximum Minimum Torque 1 2 3 Thermal Switch Monitor 25mm 0 2 mm 0 5 0 8 Nem Current Transformer Feedback 12 AWG 24 AWG 4 4 5 3 lbein 1 These terminals are jumpered by default The jumper wires must remain in place if a power module thermal Switch is NOT connected Current Transformer Connections Current transformer 1 CT 1 monitors the U phase with the output of CTI connected to terminal 5 of KPT31 and the output of CT 1 connected to terminal 6 of KPT31 Current transformer 2 CT2 monitors the W phase with the output of CT2 connected to terminal 7 of KPT31 and the output of CT2 connected to terminal 8 of KPT31 The side of the CTs are connected together internally in the SAR Rockwell Automation Publication 23P UM001D EN P July 2012 SAR Gate Output Cable Control Circuit Power Wiring Stand Alone Regulator Installation Wiring and Configuration Chapter 2 Connect the SAR gate output cable 23PAMP Cx to connector KPT11 on the SAR unit The opposite end connects to the POWERFLEX DC SAR GATE INPUT on the Gate Amplifier See Chapter 3 Gate Amplifier Installat
5. 34 Rockwell Automation Publication 23P UM001D EN P July 2012 Stand Alone Regulator Installation Wiring and Configuration Example 3 Chapter 2 The only difference between Example 2 and Example 3 is the value of the burden resistor In this example the burden resistor is chosen as Rb 5 0 Ohms In this example a standard CT ratio is chosen and the ratio no longer exceeds the recommended CT ratio based on the gain calculation This is due to the change of the burden resistor from 2 5 Ohms to 5 0 Ohms CT Burden Resistor and Gain Calculation Input Values Units Description IdN pm rtg 226 Amp Power module rating Rb 5 0 Ohms Jumper J5 in the On position and jumper J4 in the Off position See Figure 13 on page 39 for jumper locations CT pri 2000 Amp CT sec 1 Amp Minimum CT Primary based on IOC trip point of 2 5 x Power Module rating Value Calculation Units Description IOC mult 2 5 CT pri min 0 85 is the ratio of AC to DC IOC mult x IdN pm rtg x 0 85 current CT pri min 480 Amp Based on IOC trip point CT ratio min based on ioc CT pri min CT sec CT ratio min based on ioc 480 Based on IOC trip point Maximum CT ratio based on Gain Range of Scaling Op Amp in the Current Feedback circuit Value Calculation CT_ratio_max 1 2 x IdN_rtg x Rb 0 612 Units Description CT ratio max 2 216 x 10 Value Calcula
6. The SAR may not be powered from a corner earthed supply system in order to maintain compliance with the CE LV Directive Installation Requirements Related to EN 61800 3 and the EMC Directive The SAR must be earthed grounded as described in this User Manual Output power wiring to the motor field excitation must employ cable with a braided shield providing 7596 or greater coverage or the cable must be housed in metal conduit or equivalent shielding must be provided Continuous shielding must be provided from the SAR enclosure to the motor enclosure Both ends of the motor cable shield or conduit must terminate with a low impedance connection to earth e At the motor end the motor field excitation cable shield or conduit must terminate in a shielded connector which must be properly installed in an earthed motor wiring box attached to the motor The motor wiring box cover must be installed and earthed All control I O and signal wiring to the SAR including gate firing control must use cable with a braided or foil shield providing 7596 or greater coverage or the cables must be housed in metal conduit or equivalent shielding must be provided Only the SAR end of the cable shield should be terminated with a low impedance connection to earth Power cabling must be separated from control and signal wiring wherever possible Rockwell Automation Publication 23P UM001D EN P July 2012 17 Chapter2 Stand Alone R
7. SAR Programming and Startup 40 SAR programming and startup require a Human Interface Module HIM or DriveExplorer or DriveTools SP software with a network connection made using a communication adapter The SAR is not sold with a HIM or communication adapter These products must be purchased separately See Appendix B HIM Overview and Appendix E Installing a Communication Adapter respectively in the PowerFlex Digital DC Drive User Manual publication 20P UMO001 for details SAR Parameter Configuration To accommodate incoming line voltages that are greater than 690VAC parameter 464 SAR Volts Scale is used to scale the actual values of the system voltages so that they can be displayed on the HIM or in programming software without having the regulator directly connected to the higher voltage levels The upper limit is 1200VAC However there are means to accommodate greater voltages The SAR has a maximum rating of 690VAC The incoming AC line and the power module output motor voltage needs to be scaled to ensure that the voltages the regulator receives are within its rating When the voltage is reduced the scaling parameter 464 provides the means to add a multiplier to the voltage values so that the displayed voltages reflect those at the actual regulator input and output Example If the actual voltage that appears at the AC input to the SAR is 400VAC due to resistor scaling and the incoming line is at
8. 1 Bl 1 BO 1 DIP Switch SW3 1 SW3 2 SW3 3 SW3 4 SW4 1 SW4 2 SW4 3 SW4 4 SW4 5 SW4 6 SW4 7 SW4 8 Setting Off Off Off Off Off Off 0n Off On On On On R_fdbk For DIP switch SW3 and SW4 layout refer to Table 14 Binary Gain Amp DIP Switch to Bit Layout on page 39 Resistor values are in K Ohms 1 B11 0 50 B10 1 9 2 B8 4 B7 8 B6 16 B5 32 B4 64 B3 128 B2 256 B1 512 BO 1024 Rockwell Automation Publication 23P UM001D EN P July 2012 Stand Alone Regulator Installation Wiring and Configuration Chapter 2 Value Calculation Units Description R_fdbk 21 787 R_input 20 Fixed input resistor Gain_Binary_OA R_fdbk R_input Gain_Binary_OA 1 089 versus Gain_Required 1 083 Comparing the Binary Gain Amp to the Calculated Required Gain Per Cent Gain Error Gain Binary 0A Gain Required Gain Required x 100 Per Cent Gain Error 0 57 The error is now less than 196 Figure 11 Bridge Rectifier and Burden Resistor Circuit Diagram Off Park Position for Jumper J4 J4A a J4 m o CT11 e OR CT12 CT22 CT21 amp OR e e OR Z ZN e e ZN A e Off Park Position for Jumper J5 Rockwell Automation Publication 23P UM001D EN P J
9. Rockwell Automation Publication 23P UM001D EN P July 2012 75 AppendixA Specifications Gate Scaling Module Information 76 Gate Scaling Module Part No 97331001 The Gate Scaling Module provides a means to interface with Reliance Electric Power Modules with existing Gate Coupler Modules that are electrically equivalent to the O 51378 19 Gate Coupler The Gate Scaling Module provides a resistor in each of the SCR gate lines to reduce the voltage applied to the gate couplers in the power module The O 51378 19 Gate Coupler and equivalent gate couplers have 0 5 Watt resistors on the primary of the isolation transformer The Gate Amplifier provides a higher maximum gate voltage than the Distributed Power System Power Module Interface DPS PMI rack The Gate Scaling Module ensures that the power dissipation of the resistors stays within their maximum ratings The configuration using the Gate Scaling Module is covered in detail in the Retrofit Guidelines section of this manual beginning on page 59 Operating Temperatures The surrounding air temperature must be within 0 C to 50 C 32 F to 122 F Humidity must remain between 5 and 95 non condensing Power dissipation is 1 Watt Mounting Instructions Mountto a flat grounded metal panel Mountinasuitable enclosure in a clean dry location Contamination from oils corrosive vapors and abrasive debris must be kept out of the enclosure Mountin a horizonta
10. SD3000 PLUS to Gate Amplifier Reverse Cable SD3K CBLGSCLIRxxx PMI Rack to Gate Amplifier Forward Cable 612432 xxxS PMI Rack to Gate Amplifier Reverse Cable 6124332oxSU 1 xxx length in inches Rockwell Automation Publication 23P UM001D EN P July 2012 Prepare for Installation Mounting Considerations Chapter 2 Stand Alone Regulator Installation Wiring and Configuration Prior to installation of the PowerFlex DC Stand Alone Regulator SAR read the General Precautions on page 9 Operating Conditions and Temperatures The SAR is designed to operate at 0 50 C 32 122 F surrounding air temperature without derating The unit must be mounted in a clean dry location Contaminants such as oils corrosive vapors and abrasive debris must be kept out of the enclosure NEMA UL Type Open IP20 enclosures are intended for indoor use primarily to provide a degree of protection against contact with enclosed equipment These enclosures offer no protection against airborne contaminants Rockwell Automation Publication 23P UM001D EN P July 2012 13 Chapter2 Stand Alone Regulator Installation Wiring and Configuration 14 Minimum Mounting Clearances Minimum clearance requirements indicated in Figure 2 Drive Enclosure Minimum Mounting Clearances are intended to be from enclosure to enclosure Other objects can occupy this space however reduced airflow may cause protection circuits to fault the SAR
11. The SAR must be mounted in a vertical orientation as shown and must not be mounted at an angle greater than 30 degrees from vertical In addition inlet air temperature must not exceed the product specification Figure 2 Drive Enclosure Minimum Mounting Clearances Min 150 mm Min 150 mm Min 50 mm 6 0 in 6 0 in 2 0 in UUUUUUUU UUUUUUUDUUUUUUUUUUDU p hh Lol m iy lau a rA eal P Cal _ EF E L E Lo n Va m o al 0000000 00000010000000000000 Co Ld a ES o OrqoHnongo eJ Orq1OoHuono MIB PAU Min 10 0 mm Min 10 0 mm Min 10 0 mm 0 4 in 0 4 in 0 4 in Min 150 mm Min 150 mm 6 0 in 6 0 in Airflow through the unit 6 0 in pape must not be impeded v Y Rockwell Automation Publication 23P UM001D EN P July 2012 Stand Alone Regulator Installation Wiring and Configuration Chapter 2 Approximate Dimensions and Weights The SAR is available in a NEMA UL Type Open IP20 enclosure only ATTENTION Remove all loose packaging materials including an
12. With the Alpha Test the output of the gates can be checked by using a spare gate output port on the Gate Amplifier along with a Gate Coupler assembly module Incandescent light bulbs connected in series at the output ofthe power module serve as a load Be sure that the rating of all of the incandescent bulbs connected in series is greater than the power module maximum output voltage rating For the gate waveforms shown here two diodes connected in series are connected to each gate coupler output with the anode connected to the G Gate pin The output can also be checked in an open circuit mode the peak voltage will be 15 to 30 volts The waveform shown in Figure 31 was generated by using the Alpha Test with the firing angle set at 5 Degrees full on Figure 31 Power Module Thyristor Firing Pattern Positive Phase Rotation L1 L2 L3 2 ms Thy1 Gate 2 ms Thy2 Gate 2 ms Thy3 Gate 2 ins Thy Gate 2ms Thy5 Gate 2 ms Thy Gate Rockwell Automation Publication 23P UM001D EN P July 2012 67 Chapterb Power Interface and SCR Firing Order Figure 32 below shows an actual oscilloscope image of the gate pulse output relative to the AC Line L1 to L3 with negative phase rotation L3 L2 L1 The waveform shown in Figure 32 was generated by using the Alpha Test with the firing angle set at 5 Degrees full on Figure 32 Power Module Thyristor Firing Pattern Negative Phase Rotation L3 L2 L1 V 2ms
13. call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Ig Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 23P UMO001D EN P July 2012 Supersedes Publication Supersedes Publication 23P UM001C EN P September 2011 Copyright 2012 Rockwell Automation Inc All rights reserved Printed in the U S A
14. lt 252s cia ree exe vd ERR YR HE Chapter 3 Gate Amplifier Installation and Prepare for Installation 000 00 cece eee e eect cnet eee teases Wiring Retrofit Guidelines Operating Temperdtures s sias do Roe Henn edad aadadn des RN RENE ES Mounting and CoOlng coeevekus eet hebr Y NR NAR aos PARA Power and Ground Wiring od cess az eere Nd oie sere e pend Chassis Grounding 44x eue Hd x I e e RT TY Control Wiring Connections suco dani me ER na ic are U acenscins s Chapter 4 Gate Interface to Non Rockwell Power Module Retrofit Gate Interface to Reliance Electric U S Power Modules Retrofit Gate Interface to Dierikon Power Modules ususus Chapter 5 Power Interface and SCR Firing Parallel Power Modules and Load Share Reactors Order Phase Sequence and Armature SCR Firing Order se Rockwell Automation Publication 23P UM001D EN P July 2012 Table of Contents Specifications History of Changes Index Appendix A Stand Alone Regnlatot 7 5 coese tesa E EE UC e E ER aes 71 Gare AumpliBet s coto ese tossed a Son dr Reb dto eta Tani 71 Gate Coupler Assembly Information cee e seen neces 73 Gate Scaling Module Informatl hes secos SOY TENUERE RR RENE ES 76 Cable Specifications a resanse a E RERE tates ae Sese 78 Appendix B 23P UM001C EN P September 2011 seuss ue deve EE HERES 83 23P UMO001 B EN P AXpEIEZO0TL siu cu
15. 1snui sjeduinp 2eqpaa eDey oA eunjeuny 93ON y MOOL VS NOOL VS i N N sweep Bui 9jeD 0 13431 suieJDeip Buum 91eb 0 19 91 Jenijduiy ayep 01 l Lid uuo yndjng 31429 VAn uuo qp4 uuy Poy Jd inding jeijidury EU aye WOl4 O uon uin t9 jndu 91er ur IY M y eqp 4 sunauig gt abeyo op yoeqpaa4 eBeyoA amuy gt oeqpesj juan eJnjeuuv u OW A eIqejiene 41 urov n sasn4 jeuJa E qu GA lg ot Bul M 0 y tum i uuo dl l M A n yoeqpss4 90 9v LELAY uuo 8 0qy aur JY Wo4 uvso Os A z 1H d dy uuo p o powind uo EB acus t 1591 10 uvs OL I inej eS I T way Iz wog OSI s VELd5I uuo yoegpes 19 jeuuau pojN Md JAWJOJSUEL u a 4 apon uv 10 e n M A n J9MOd Pal 01 aul Jy Buruoau Bay auo y puels OSI ASL VS 01 jeuiei saziS asn4 Jo Z aBed aas HYS 01 ewerx3 l9UlI0J SUeJ aul 9y Buruoou wo 19 Rockwell Automation Publication 23P UM001D EN P July 2012 C
16. A to include SAR specifications and cables Rockwell Automation Publication 23P UM001D EN P July 2012 83 Appendix B History of Changes Notes 84 Rockwell Automation Publication 23P UM001D EN P July 2012 Numerics 120VAC Input 49 A AC feedback connections Stand Alone Regulator 21 C cabinet panels high frequency grounding 47 cable size high frequency grounding 47 cables Gate Interface to Reliance Electric U S power modules 62 Gate Interface to Rockwell Automation power modules 58 gate output SAR 25 specifications 78 CE conformity Stand Alone Regulator 16 chassis ground Gate Amplifier 45 configuration motor field current SAR 26 connections field power module bridge SAR 20 motor armature voltage feedback SAR 23 power module thermal switch SAR 24 control circuit power SAR wiring 25 control wiring Gate Amplifier 48 cooling Gate Amplifier 42 current feedback calculations Stand Alone Regulator 30 configuration Stand Alone Regulator 28 current transformer SAR connections 24 D DC analog tachometer Stand Alone Regulator 26 DC feedback SAR fuses 22 DC feedback connections Stand Alone Regulator 21 digital encoder Stand Alone Regulator 26 Index dimensions Gate Amplifier 43 Gate Coupler Assembly 75 Gate Scaling Module 77 Stand Alone Regulator 15 drawing numbers explanation 7 E EXT GATE P S 49 external gate power supply 49 Gate Amplifier 44 51 F field power modu
17. CBLREVELCxxx Table 19 Gate Amplifier to Gate Scaling Module Forward Gates Cables Catalog Number SD3K CBLGSCLIFO24 2 Feet Length SD3K CBLGSCLIF036 3 Feet SD3K CBLGSCLIFO60 5 Feet 1 Before using this cable length consider the mounting position of the Gate Scaling Module as the cable may not be long enough to reach between the gate output port of the Gate Amplifier and the panel where the Gate Scaling Module is mounted Additional lengths can be found on drawing 97330000 Rockwell Automation Publication 23P UM001D EN P July 2012 Retrofit Guidelines Chapter 4 Table 20 Gate Amplifier to Gate Scaling Module Reverse Gates Cables Catalog Number Length SD3K CBLGSCLIRO24 2 Feet SD3K CBLGSCLIRO36 3 Feet SD3K CBLGSCLIRO60 5 Feet 1 Before using this cable length consider the mounting position of the Gate Scaling Module as the cable may not be long enough to reach between the gate output port of the Gate Amplifier and the panel where the Gate Scaling Module is mounted Additional lengths can be found on drawing 97330100 Table 21 Round Style Connector Forward Gates Cables Catalog Number SD3K CBLFWDPM060 Length 5 Feet SD3K CBLFWDPM120 10 Feet SD3K CBLFWDPM180 15 Feet SD3K CBLFWDPM240 20 Feet Additional lengths can be found on drawing 97305100 Table 22 Round Style Connector Reverse Gates Cables Catalog Number Length
18. Gate Amplifier for mounting connector with cable Output Gate Coupler A 61 WHT E yim pm i id H1 oec RED K a ce RS iene lt Gate Coup er E 6 EE cL WHT Lr HO KE rai E i G WH RED K G2 RED A G3 WHT K G3 RED u A G4 WHT To additiona Butt splice to A 64 RED gate coupling SCR gate leads 65 WHT terminal blocks G5 RED G6 WHT K G6 RED V d Notes An external 48V gate power supply must be used to supply sufficient voltage to each gate coupler The power supply connects to the faceplate connector of the Gate Amplifier Do not route gate leads with power wiring Itis suggested to use A and B suffixes on the gate lead labels to each SCR pair to aid in wiring and troubleshooting Rockwell Automation Publication 23P UM001D EN P July 2012 69 Chapter 5 70 Power Interface and SCR Firing Order Figure 34 Firing Parallel SCRs Thyristors Or Catalog Number SD3K CBLFWDPMxxx xxx length in inches Drawing 97305100 Forward Catalog Number SD3K CBLREVPMxxx xxx length in inches Drawing 97305300 Reverse D Shell to Gate Amplifier Output One of six twisted pair in cable Catalog Number SD3K CBLCANNONxxx xxx Length in inches drawing 97305500 Cut off the box connectors that are on the cable ends and attach the wires directly to the terminal block Harness
19. Input for the PowerFlex DC Stand Alone Regulator SAR Gates INPUT See POWERFLEX DC SAR GATE INPUT on page 50 for more information SD3000 PLUS FWD GATE SD3000 PLUS Forward Gate Input Input for the SD3000 PLUS forward gates See SD3000 PLUS FWD e INPUT GATE INPUT on page 50 for more information SD3000 PLUS REV GATE SD3000 PLUS Reverse Gate Input Input for the SD3000 PLUS reverse gates See SD3000 PLUS REV o INPUT GATE INPUT on page 50 for more information RDY Normally Open relay contacts Used to indicate that the Gate Amplifier is ready to run See RDY_ on page 51 for more information EXT GATE P S External Gate Power Supply This input is used to increase the gate driver level See EXT GATE P S on page 51 for more information FWD GATES Armature Forward Gates Four forward gate outputs to provide gate signals for up to four 9 power modules See FWD GATES and REV GATES on page 52 or more information REV GATES Armature Reverse Gates Four reverse gate outputs to provide gate signals for up to four power modules See FWD GATES and REV GATES on page 52 or more information 120VAC Power Input to Gate Amplifier Cabinet control power See 120VAC on page 52 for more nformation GPS The 28V Gate power supply provides all of the DC power for the Gate Amplifier All other voltages are derived from the 28V Gate power supply If the GPS LED is off all of the other indicating LEDs will also be off Confirm that 120VAC is pre
20. Power Modules To Reverse Power Modules M d M d Gate Amplifier 1of2 To Forward Power Modules To Reverse Power Modules M d M d Gate Amplifier 2of2 57 Chapter 3 Gate Amplifier Installation and Wiring Gate Interface to Rockwell Automation Power Modules Rockwell Automation power modules 356405 Cxx 356406 Cxx and 356407 Cxx do not contain gate couplers The gate couplers are contained in a separate unit called the Gate Coupler Assembly The basic interface configuration is shown in Figure 25 Connection to Rockwell Automation Power Modules Cables appear in the tables following the illustration below Figure 25 Connection to Rockwell Automation Power Modules Gate Amplifier FWD GATES REV GATES Drawing 97305100 Power Modules SD3K CBLFWDPMxxx piss ie FWD Gate Coupler Assembly ounted on SOS RTHDLHIGH Drawing 97329101 power module Module SD3K CBLCPLR072 9732017 to view drawing Make as short as possible Do not route with power leads Terminal Block REV Mounted on Gate Coupler Assembly Drawing 97329101 power module Module Drawing 97305300 SD3K GATMDLHIGH SD3K CBLREVPMxxx SD3K CBLCPLR072 Make as short as possible Do not route with power leads 9732017 to view drawing 58 Table 12 Round Style Connector Forward Gate Cables Catalog Number Length SD3K C
21. Required x 100 Per Cent Gain Error 0 222 32 Rockwell Automation Publication 23P UM001D EN P July 2012 Stand Alone Regulator Installation Wiring and Configuration Example 2 CT Burden Resistor and Gain Calculation Chapter 2 Input Values Units Description IdN_pm_rtg 226 Amp Power module rating Rb 2 5 Ohms Jumpers J4 and J5 in the On position See Figure 13 on page 39 for jumper locations CT pri 2000 Amp CT_sec 1 Amp Minimum CT Primary based on IOC trip point of 2 5 x Power Module rating Value Calculation Units Description IOC mult 2 5 CT pri min 0 85 is the ratio of AC to DC IOC mult x IdN pm rtg x 0 85 current CT pri min 480 Amp Based on IOC trip point CT_ratio_min_based_on_ioc CT_pri_min CT_sec CT_ratio_min_based_on_ioc 480 Based on IOC trip point Maximum CT ratio based on Gain Range of Scaling Op Amp in the Current Feedback circuit Value Calculation Units Description CT_ratio_max 1 2 x IdN_rtg x Rb 0 612 CT ratio max 1 108 x 10 Based on Gain lt 1 2 Value Calculation Units Description Vf at IdN pm rtg 0 612 Volts Fixed Value CT ratio CT pri CT sec CT ratio 2 x 10 Ib at IdN pm rtg IdN pm rtg CT ratio lb at IdN pm rtg 0 113 Amps Vb at IdN pm rtg IN pm rtg CT ratio x Rb Vb at IdN pm rtg 0 283 Volts Gain Required Vf at IdN pm
22. Rockwell Automation interface are already defined There may be unique cases where there is a need to re use existing gate coupler hardware in a non Rockwell power module if this occurs consult with Development Engineering The diagram in Figure 26 shows a gate interface where the gate coupler boards are individually mounted to accommodate physical constraints that may exist in the assembly A bracket 608877 6A is used as a landing point for the gate cabling Between the Gate Amplifier and the 608877 6A bracket the SD3K CBLFWDPMxxx or SD3K CBLREVPMxxx cable is used The flange of cable SD3K CBLCANNONxxx is mounted to the 608877 6A bracket The opposite end of the cable has box connectors that plug into the gate couplers The output of the gate couplers are connected to the SCR gates using cable SD3K CBLBOXA048 or SD3K CBLBOXBO048 for S6R The SD3K CBLBOXA048 cable has box connectors on one end to interface with the gate coupler output and pig tails on the SCR gate side of the cable for connection to a terminal board The SD3K CBLBOXAO048 and SD3K CBLBOXB048 cables for the S6R are pre labeled as forward and reverse They are 48 inches long and are cut to the required length when installed Figure 26 Retrofit of Non Rockwell Power Module S6R w Six Gate Couplers Gate Amplifier Regenerative connectors Mount to 608877 6A bracket One bracket Power for both Motoring and Module FWD GAT
23. SAR requires AC feedback connections to connector KP terminals U V and W from the incoming line to monitor the incoming voltage level and establish the SCR gate firing sequence relative to the AC line DC feedback connections to connector KP terminals C and D are required to monitor the voltage output from the DC power module The combined information from the AC and DC feedback inputs is used to determine if the SCRs are firing properly See Figure 4 on page 19 for recommended wiring for a typical SAR interface to S6R Fuses are required between the DC output power wiring on the DC power module to connector KP on the SAR This will limit the current to the regulator in the event of an internal fault in the SAR The recommended fuse types are shown in DC Feedback Fusing Requirements on page 22 Rockwell Automation Publication 23P UM001D EN P July 2012 21 Stand Alone Regulator Installation Wiring and Configuration Figure 6 AC DC Voltage Feedback KP and Motor Armature Voltage Feedback KA Terminal Blocks Bottom View of SAR GJ l U LE AC DC Voltage UU Feedback KP nn Terminal Block UU v Ut C DIJO UrmsiUU eeduddddHHHeoe J ce L
24. SD3K CBLBOXA048 S6 These cables have box connectors on one end to interface SD3K CBLBOXB048 S6R with the gate coupler output and pig tails on the SCR gate side for connection to a terminal board Do not route with power leads To view drawing 97305400 If there is sufficient mounting space for the mounting of the Gate Coupler Assembly it is recommended to use the configuration shown in Figure 27 on page 61 This will greatly simplify the mechanical aspects of the retrofit 60 Rockwell Automation Publication 23P UM001D EN P July 2012 Figure 27 Retrofit of Non Rockwell Power Module S6R w Gate Coupler Assembly Retrofit Guidelines Chapter 4 Gate Amplifier Gate Coupler Assembly SD3K GATMDLHIGH Drawing 97305100 SD3K CBLFWDPMxxx FWD GATES 8732017 to view drawing Gate Coupler Assembly Drawing 97305300 SD3K GATMDLHIGH SD3K CBLREVPMxxx REV GATES 9732017 to view drawing Drawing 97329101 TB Recommended SD3K CBLCPLR072 Make as short as possible Do not route with power leads Drawing 97329101 o o TB Recommended EA SD3K CBLCPLRO72 Make as short as possible o o Do not route with power leads Gate Interface to Reliance Electric U S Power Modules Retrofit To interface the Gate Coupler Assembly to the SCR gates the SD3K CBLCPLR072 cables are used as shown in the diagram above The labeling
25. altitudes no greater than 2000 m 6562 ft The SAR provided in enclosure type IP20 must be installed in a pollution degree 1 or 2 environment to be compliant with the CE LV Directive Characteristics of the different pollution degree ratings are provided in Table 2 on page 17 Rockwell Automation Publication 23P UM001D EN P July 2012 Stand Alone Regulator Installation Wiring and Configuration Chapter 2 Table 2 Pollution Degree Ratings According to EN 61800 5 1 Pollution Degree Description 1 No pollution or only dry non conductive pollution occurs The pollution has no influence 2 Normally only non conductive pollution occurs Occasionally however a temporary conductivity caused by condensation is to be expected when the drive is out of operation 3 Conductive pollution or dry non conductive pollution occurs which becomes conductive due to condensation which is to be expected 4 The pollution generates persistent conductivity caused for example by conductive dust or rain or snow The SAR must be installed in a suitable enclosure with at least an IP X rating at the top of the enclosure TheSAR may produce leakage current in the protective earthing conductor which exceeds 3 5 mA AC and or 10 mA DC The minimum size of the protective earthing grounding conductor used in the application must comply with local safety regulations for equipment with high protective earthing conductor current
26. and Armature SCR Firing Order Sequence L1 L2 L3 AC Line Pairs Gated Pairs z L1 L3 4THY amp 3THY L2 L3 5THY amp 3THY L2 L1 5THY amp 1THY L3 L1 6THY amp 1THY L3 L2 6THY amp 2THY L1 L2 4THY amp 2THY Table 26 Phase Sequence and Armature SCR Firing Order Sequence L3 L2 L1 AC Line Pairs Gated Pairs z L1 L2 4 THY amp 2 THY L3 L2 6 THY amp 2 THY L3 L1 6 THY amp 1 THY L2 L1 5 THY amp 1 THY L2 L3 5 THY amp 3 THY L1 L3 4 THY amp 3 THY Rockwell Automation Publication 23P UM001D EN P July 2012 65 Chapterb Power Interface and SCR Firing Order Figure 30 SCR Thyristor Positions MOTORING RE GEN 66 Rockwell Automation Publication 23P UM001D EN P July 2012 Power Interface and SCR Firing Order Chapter 5 If the power module is not firing properly check the timing relative to the AC Line with the L1 to L3 signal acting as the reference point Using a two channel oscilloscope the L1 to L3 waveform will be on channel 1 and then the gate pulse positions relative to the AC line can be checked one at a time with channel 2 Caution Be certain that the oscilloscope probe is rated for the line voltage before taking the measurement from L1 to L3 Figure 31 below shows an actual oscilloscope image of the gate pulse output relative to the AC Line L1 to L3 with positive phase rotation L1 L2 L3
27. cables between the Gate Amplifier and the Gate Scaling Module are the SD3K CBLGSCLIFxxx forward and SD3K CBLGSCLIRxxx reverse The output cables to the power modules are dependent on the power module type One type uses the round style of connector and an older line of the power module uses a rectangular style of connector Cables appear in the following tables Rockwell Automation Publication 23P UM001D EN P July 2012 61 62 Chapter 4 Retrofit Guidelines Figure 28 Retrofit of Reliance Electric Power Module S6R with Round Style Gate Connector and with 0 51378 19 or Equivalent Gate Couplers Gate Amplifier Drawing 97330000 FWD GATES SD3K CBLGSCLIFxxx Drawing 97330100 REV GATES SD3K CBLGSCLIRxxx Gate Scaling module Part No 97331001 Gate Scaling module Part No 97331001 Reliance Electric S6R Power Module Drawing 97305100 SD3K CBLFWDPMxxx Drawing 97305300 SD3K CBLREVPMxxx Figure 29 Retrofit of Reliance Power Module S6R with Rectangular Style Gate Connector and with 0 51378 19 or Equivalent Gate Couplers Gate Amplifier Drawing 97330000 FWD GATES SD3K CBLGSCLIFxxx Drawing 97330100 REV GATES SD3K CBLGSCLIRxxx Gate Scaling module Part No 97331001 Gate Scaling module Part No 97331001 Drawing 97305000 Reliance Electric S6R SD3K CBLFWDELCxxx Drawing 97305200 SD3K
28. control panel Figure 18 DC Drive High Frequency Grounding Bonding Configuration One Welding Cable One Welding Cable One Welding Cable Fine Strand Fine Strand Fine Strand See Table 10 for See Table 10 for See Table 10 for Internal Bay to Bay 1 0 Ground Cable see detail at right Z j Drive Drive Drive Cabinet Cabinet Cabinet Recommended Size Recommended Size Recommended Size O Internal Bay to Bay Grounding Cable Detail 1 0 kemil compression lug Burdy YA25L6 or equal Stud size 1 2 inch both ends of jumper 1 0 kcmil welding cable anixter 5J1011 or equal Length determined in the field to suit need Power Transf One Welding Cable One Welding Cable al Fine Strand Fine Strand See Table 10 for See Table 10 for Ground to Frame of Transformer Ensure that all Paint is Removed Before Attaching Lugs Recommended Size or CAD Weld Wire to the Frame Recommended Size Rockwell Automation Publication 23P UM001D EN P July 2012 47 Chapter3 Gate Amplifier Installation and Wiring Control Wiring Connections Refer to Table 11 on page 49 for a description of the control connections identified in Figure 19 Gate Amplifier Drive Control Figure 19 Gate Amplifier Drive Control Engineered by Rockwell Automation D O GPS C O GATE FUSE OK FWD GATES LPS C CO GATE POWER POWER
29. feedback option module includes the PowerFlex DC Drive Resolver Feedback Option Module Installation Instructions publication 20P IN071 See the PowerFlex Digital DC Drive User Manual publication 20P UM001 for resolver configuration details The SAR motor field current must be configured with both a hardware DIP switch S14 and by setting parameter 374 Drv Fld Brdg Cur to the appropriate value For each field current rating in this case 40 and 70 A there are several ranges to choose from with regard to the maximum range of the field current The lowest range that is greater than the maximum motor field current should be selected to ensure the best resolution See Field Current Configuration in the PowerFlex Digital DC Drive User Manual publication 20P UMO001 for instructions Rockwell Automation Publication 23P UM001D EN P July 2012 Stand Alone Regulator Installation Wiring and Configuration Chapter 2
30. gate pulses to the power module From Gate Amplifier REV Output 120VAC D Gate Amplifier 4of4 56 Rockwell Automation Publication 23P UM001D EN P July 2012 Gate Amplifier Installation and Wiring Chapter 3 Figure 24 Cascading Gate Amplifiers Using the SD3000 PLUS Mixed Configuration From Gate Amplifier FWD Output From Gate Amplifier FWD Output Cables REV Output SD3K CBLGSCLIFxxx SD3000 PLUS To Gate Amplifier L1 of 2 SD3K FWD Input To Gate Amplifier 2 of 2 SD3K FWD Input PFDC Gate Input 120VAC ooo0o000000 To Forward Power Modules REV Output Cables SD3K CBLGSCLIRxxx To Gate Amplifier L1 of 2 SD3K REV Input To Gate Amplifier 2 of 2 SD3K REV Input To Reverse Power Modules Ext P S 120VAC Caution Do NOT use the external power supply Ext P S From Gate Amplifier when the gate pulse output is connected to the input of a FWD Output downstream Gate Amplifier s Only use the external power supply on a final stage Gate Amplifier s that provides the gate pulses to the power module From Gate Amplifier REV Output Rockwell Automation Publication 23P UM001D EN P July 2012 PFDC Gate Input 120VAC To Forward
31. ratio lb at IdN pm rtg 0 26 Amps Vb at IdN pm rtg IQN pm rtg CT ratio x Rb Vb at IdN pm rtg 1 3 Volts Gain Required Vf at IdN pm rtg Vb at IdN pm rtg Gain Required 0 471 Rockwell Automation Publication 23P UM001D EN P July 2012 Note Recommended Gain lt 1 2 for best accuracy 31 Chapter2 Stand Alone Regulator Installation Wiring and Configuration Binary Gain Calculation and Checking Gain Error Binary Sw Setting 108 758 Value to use 109 Binary 1101101 MSB LSB Bit Value B11 0 B10 20 B9 20 B8 0 B7 0 B6 1 Bb 1 B4 0 B3 1 B2 1 B1 0 BO 1 DIP Switch SW3 1 SW3 2 SW3 3 SW3 4 SW4 1 SW4 2 SW4 3 SW4 4 SW4 5 SW4 6 SW4 7 SW4 8 Setting Off Off Off Off Off On 0n Off On On Off On For DIP switch SW3 and SW4 layout refer to Table 14 Binary Gain Amp DIP Switch to Bit Layout on page 39 Resistor values are in K Ohms 1 R_fdbk E B11 0 50 B10 1 9 2 BB 44 B7 8 BB 16 B5 32 BA 64 amp B3 128 B2 256 B1 512 BO 1024 Value Calculation Units Description R_fdbk 9 394 R_input 20 Fixed input resistor Gain_Binary_OA R_fdbk R_input Gain_Binary_OA 0 47 versus Gain Required 0 471 Comparing the Binary Gain Amp to the Calculated Required Gain Per Cent Gain Error Gain Binary OA Gain Required Gain
32. the field bridge is established from the AC lines that supply the field independent of the armature firing circuit DC feedback signals are used to monitor the output voltage from the power module Additionally current signals received from current transformers is used by the SAR regulator to monitor and control current The SAR catalog numbers are listed in Catalog Numbers on page 12 The SAR must be used with the Gate Amplifier in order to interface with a DC power module s Gate Amplifier The Gate Amplifier is used to amplify the SCR gate signals supplied by a DC drive regulator The gate signal source to the Gate Amplifier can be provided by either the PowerFlex DC SAR or the D3000 PLUS The Gate Amplifier unit provides a separate input D Shell connector for each product The Power Module Interface PMI Rack is also compatible with the Gate Amplifier and uses the SD3000 PLUS inputs The Gate Amplifier model number and corresponding connection cables part numbers are listed in Model and Cable Model Part Numbers on page 12 In addition to amplifying the gate signals the forward and reverse signals provided by the Gate Amplifier are fanned out to enable the driving of multiple power modules Four S6 bridges forward and four S6 bridges reverse When the S6 bridges are connected in an anti parallel configuration the topology is an S6R providing both motoring and regenerative capability The external 48V gate power supply capabi
33. 0 PLUS forward gates This input is also compatible with the PMI Rack DC Drive Regulator Note The SAR port cannot be used at the same time as the SD3000 PLUS ports SD3000 PLUS REV GATE INPUT Input for the SD3000 PLUS reverse gates This input is also compatible with the PMI Rack DC Drive Regulator Note The SAR port cannot be used at the same time as the SD3000 PLUS ports Rockwell Automation Publication 23P UM001D EN P July 2012 Gate Amplifier Installation and Wiring Chapter 3 RDY This is the Ready relay interlock The Gate Amplifier has Normally Open relay contacts that close when the Gate Amplifier is ready to run The Ready relay is to be wired into the drive Run Permissive logic The Ready relay will drop out when the Gate Amplifier has a malfunction The Ready relay circuit is rated at 1 4 Amps fused at 2 Amps relay contacts rated at 2 Amps EXT GATE P S If an external power supply is required it should meet the following ratings For the PowerFlex DC SAR 48V DC 5 A minimum 250 W For the SD3000 PLUS 48V DC 3 A minimum 150 W The power supply must also have current limit protection For noise protection an AC line filter must be used in the 120V AC supply line to the 48V power supply The filter is Corcom part number 10VVI Rockwell Automation part number 612421 1C or equivalent Note When using the external power supply the Gate Coupler Assembly SD3K GATMDL HIGH must b
34. 1 4 i i 269 4 t T e CT E UID QO000000000000000000000000000000 00000000000000 g oooo0Q0000000000000000000000000000 ME OO000000000000 j OooO00000000000000000000000000000 OO000000000000 OoooO0QOoOO0QOQGOO0QOQOOQOQOOOOQOQOO0Q OQOQOOQOQOOQOQ 9OOO00OQOOOOOOOOOOOOOOOOOOOOOOOO DOOOOOOOOOOOOO OOQO0Q0000000000000000000000 QOQOQOOQOQOQQOO UE uu ES oooo0Q00o00000000000000000000000000 OO000000000000 11 05 ooooQ0000000000000000000000000000 o 000000000000 o o0000000000000000000000000000000 OO000000000000 fi 90000000000000 280 7 OOO0000000 I 90000000000009 H 90000000000000 11 63 OOOO0000000 IID 0000000000000 295 3 20000000000000 OOQOQ000000000 g QOOQOQOOQOQOQOD QQGOQOQQOGQQOO QOOQOQOOQOQOQQO QQGOQOQOOGOQOO 10 08 OOQOQOO0QOQOQQO QOQOQOOQOQOQQO 256 1 20000000000000 QQ9QQOQOOGOOO oo000000000000 D QOQOOQOOQOQOQQO QOQOOOOOQOQOOQO QOOQOQOO0QOQOQOQ 99999900999099990999099990999009 DOODOOOOOOOOOQO OOQOQOQOOQOQOOQOQOOQOQOQO OOQOQOOQOQOQOO Q 90000000000000000000000000000 QQGOQOQQOGOQOO QOOOGOHOOGOHOOGOGOOOGOHOOS QOQOOOOQOQOQQO 90000000000000000000000000000009 888Q998800008 S 0900000000000000000000000 988 20000000900000 90000000O0QOOOOOOOOOOOOOOOOOOOOO DOOODOOOOOOOOO S OCOOXOOOOQOQOOQOQOQOOSOSOOSOS 00000000000000 BOOOOSOOOHOOOOHOOOOHOOOOHOOOOHO GODOOSOOOOOOOO 0 33 8 3 3 00 ias 0 86 76 2 296 2 21 8 Table 8 Gate Amplifier Weights Gate Amplifier Gate Amplifier amp Pack
35. 1000VAC then the scaling value is the ratio of the two voltages 464 SAR Volts Scale 1000VAC 400VAC 2 5 The external scaling of the voltage to the regulator will be done via resistors Consult with Development Engineering for component sizing and gate configuration wiring guidelines for systems greater than 690VAC incoming line or low voltage All other parameter settings for the SAR are the same as those documented in Chapter 3 Programming and Parameters in the PowerFlex Digital DC Drive User Manual publication 20P UM001 SAR Startup When installation of the SAR is complete perform the procedures in Chapter 2 Drive Start Up in the PowerFlex Digital DC Drive User Manual publication 20P UMO01 Rockwell Automation Publication 23P UM001D EN P July 2012 Chapter J Gate Amplifier Installation and Wiring Prep are for Installation Prior to installation of the Gate Amplifier read the General Precautions on pag 2 Operating Temperatures The surrounding air temperature must be within 0 C to 50 C 32 F to 122 F Humidity must remain between 596 and 9596 non condensing Rockwell Automation Publication 23P UM001D EN P July 2012 2 Chapter3 Gate Amplifier Installation and Wiring Mounting and Cooling 42 The Gate Amplifier is an open type construction and is intended to be installed on a flat surface in a suitable enclosure The unit must be mounted in the upright position faceplate lett
36. 200 current instead of the 1 minute desired In the SAR configuration the power module rating will be entered by the user and the regulator will use this value to determine overload and IOC trip points e Power Module Overload 150 for 1 minute or 200 for 10 seconds Motor Overload Standard Duty 150 for 1 minute selection via parameter 376 MtrOvrld Type OR Motor Overload Heavy Duty 200 for 1 minute selection via parameter 376 MtrOvrld Type Motor Full Load Amps entered in parameter 179 Nom Mtr Arm Amps Rockwell Automation Publication 23P UM001D EN P July 2012 29 Chapter 2 30 Stand Alone Regulator Installation Wiring and Configuration Current Feedback Calculations Inputs to the CT Calculation The variable IdN pm rtg used in the calculations is the value of parameter 465 Drive Size Rbisthe burden resistor which can be either 2 5 Ohms or 5 0 Ohms CT priis the current transformer primary rating CT secis the current transformer secondary rating A range of CT values is initially calculated based on the system constraints of IOC and the recommended gain range of the Binary Gain Amp For the constraint based on IOC the CT minimum size would be at the IOC trip point of 250 The CT sizing based on the Binary Gain Amp is based on the error encountered when using the DIP switch configuration to select the gain versus exact resistor values As the gain is increased the gain becom
37. 3K GATMDLHIGH nor the SD3K GATMDLLOW would be used Instead the Gate Scaling Module would be used in series with the gate leads This configuration is covered in detail in the Retrofit section of this manual Refer to SD3K GATMDLHIGH 9732017 to view drawing Refer to SD3K GATMDLLOW 9732027 to view drawing Operating Temperatures e The surrounding air temperature must be within 0 C to 50 C 32 F to 122 F Ifany heat generating equipment is mounted underneath the unit ensure that the exhaust air of this equipment is not greater than 50 C Humidity must remain between 5 and 95 non condensing Power dissipation 20 Watts Rockwell Automation Publication 23P UM001D EN P July 2012 73 AppendixA Specifications Gate Coupler Assembly Mounting Instructions The Gate Coupler Assembly is an open type construction and is intended to be installed on a flat surface in a suitable enclosure e Mount ina clean dry location Contamination from oils corrosive vapors and abrasive debris must be kept out of the enclosure Mount the unit in a vertical or horizontal position depending on the panel layout It is permissible to have all gate leads exit from one side of the assembly if needed two pairs per exit port or one pair of gate leads from each exit port Figure 35 Minimum Mounting Clearances 0 75 in 19 mm 0 75 in Gate Coupler 0 75 in 19 mm Assembly 19 mm Extra clearance P requir
38. 94809301 10 AWG Twisted Pair 18 AWG Twisted Pair 0 68 Nem Power Supply Power Supply 2 Twists in 2 Twists in 6 0 Ibein if used Ready Relay Ready Relay Drive PN 26501 4 0 mm 2 50 mm 0 55 Nem Q un ie ud 10 AWG 14 AWG 5 0 Ibein nterloc 1 Ready relay contacts are normally open rated at 2 Amps 120VAC 44 Rockwell Automation Publication 23P UM001D EN P July 2012 Gate Amplifier Installation and Wiring Chapter 3 Chassis Grounding A ground stud is provided on the lower right corner of the chassis mounting flange for making a ground connection Connect the grounding wire provided to the ground stud and the metal panel Make sure that the lug makes a good connection to the panel To provide additional grounding with regard to noise immunity the upper and lower mounting feet of the unit have areas that are free of paint to provide a positive connection between the unit and the enclosure mounting panel It is important that the panel that the Gate Amplifier is mounted to is properly grounded to the power system ground in the customer s plant Ideally the panel that the Gate Amplifier is mounted on as well as the associated components should be at the same potential as the Armature Power Module and the Motor Each of the signals that go to from the Gate Amplifier are bypassed to chassis ground through small capacitors These capacitors aid in removing noise from the signal lines If t
39. BLFWDPMOG60 5 Feet SD3K CBLFWDPM120 10 Feet SD3K CBLFWDPM180 15 Feet SD3K CBLFWDPM240 20 Feet Additional lengths can be found on drawing 97305100 Table 13 Round Style Connector Reverse Gate Cables Catalog Number Length SD3K CBLREVPM060 5 Feet SD3K CBLREVPM120 10 Feet SD3K CBLREVPM180 15 Feet SD3K CBLREVPM240 20 Feet Additional lengths can be found on drawing 97305300 Table 14 Output of Gate Coupler Assembly to SCR Gate Cable Description The cable is a twisted pair wire with box connectors on one end that plug onto the Gate Coupler Boards that are in the Gate Coupler Assembly The opposite ends are pig tails for connecting the power module gate input terminal blocks Use a second set of this cable type for an S6R configuration Cut to desired length as short as possible Do not route with power leads Catalog Number SD3K CBLCPLR072 To view drawing 97329100 an increased length cable may be added in the future it will appear on the drawing when available Rockwell Automation Publication 23P UM001D EN P July 2012 Gate Interface to Non Rockwell Power Module Retrofit Chapter Retrofit Guidelines To interface to the SCR gates of a non Rockwell power module any existing gate couplers in the power module should be replaced with the Rockwell Automation gate couplers This will greatly simplify the gate interface because the characteristics of a standard
40. ES 6 Gate Couplers 97306101 TB Drawing 97305100 Drawing 97305500 Drawing 97305401 Recommended m o OF SD3K CBLFWDPMxxx SD3K CBLCANNONxxx SD3K CBLBOXA048 for S6 SD3K CBLBOXB048 for S6R Make as short as possible B EA Do not route with power leads TB Drawing 97305300 Q Drawing 97305500 Drawing 97305402 2 m o REV GATES SD3K CBLREVPMxxx SD3K CBLCANNONxxx SD3K CBLBOXBOA for S6R Make as short as possible Do not route with power leads Rockwell Automation Publication 23P UM001D EN P July 2012 59 Chapter4 Retrofit Guidelines Cables appear in the following tables Table 15 Round Style Connector Forward Gate Cables Catalog Number Length SD3K CBLFWDPM060 5 Feet SD3K CBLFWDPM120 10 Feet SD3K CBLFWDPM180 15 Feet SD3K CBLFWDPMe240 20 Feet Additional lengths can be found on drawing 97305100 Table 16 Round Style Connector Reverse Gate Cables Catalog Number Length SD3K CBLREVPM060 5 Feet SD3K CBLREVPM120 10 Feet SD3K CBLREVPM180 15 Feet SD3K CBLREVPM240 20 Feet Additional lengths can be found on drawing 97305300 Table 17 Round Style Connector to Gate Coupler Catalog Number Length SD3K CBLCANNONO60 5 Feet SD3K CBLCANNONO72 6 Feet SD3K CBLCANNONO96 8 Feet SD3K CBLCANNON120 10 Feet To view drawing 97305500 Table 18 Output of Gate Coupler Boards to SCR Gate Cable Catalog Number Description
41. FLEX DC SAR GATE INPUT 969 SD3000 PLUS 25 FWD GATE INPUT SD3000 PLUS o 596 Q 22 REV 080 ofo GATE INPUT FUSE TYPE 250VAC 3AG 5A O EXT GATE P S RUE u e T3 a O GATE AMPLIFIER T iH amp 48 Rockwell Automation Publication 23P UM001D EN P July 2012 Label on Gate Amplifier GPS Description 28V Gate Power Supply output present LED Gate Amplifier Installation and Wiring Chapter 3 Table 11 Indicators and Control Connection Descriptions Function This LED is illuminated when the gate power supply output is present See GPS below for more information LPS 5V Logic Power Supply output present LED This LED is illuminated when the logic power supply output is present See LPS below for more information GATE FUSE OK External Power Supply fuse OK LED This LED is illuminated when the fuse is OK See GATE FUSE OK on page 50 for more information GATE POWER Gate power systems OK LED This LED is illuminated when all onboard systems are functioning normally See GATE POWER on page 50 for more information POWERFLEX DC SAR GATE PowerFlex DC Stand Alone Regulator Gate Input
42. Features list 12 Rockwell Automation Publication 23P UM001D EN P July 2012 3 Summary of Changes 4 Rockwell Automation Publication 23P UM001D EN P July 2012 Preface Introduction Stand Alone Regulator Installation Wiring and Configuration Table of Contents Purpose of This Manual ic idi HM eEEE EREE What This Manual Cobtalfis cu Latet Luecod race e e ea tae Poe Drawing Numbers 3 Spa E 1394540 REOS S ce PEE I Peete Additional ResoUntees esque iater tel esae trea da d ks Chapter 1 General Precautions is eov ER HS UE E dad ue Product OVERVIEW oos pe does debe ped Mo aU peau saan Dict Stand Alone Regulatote eid vtah tek ee EARN ER AEE RR So tenda Gate Amplifier ooo date eode ott ma Pob ix eic wae AE Chapter 2 Prepare for InstallatiOn 5 o o eve e Laos Ee AL Mead Mounting Considerations 54 ous oet id oos tesa de pr aree ep NS CE COonforitye 3o alleen artes otv cide arate iuste e adit Sacha Terminal Signal and Wiring Diagrams 0 00 eee e ees Field Power Module Bridge and Ground Wiring se AC DC Voltage and Motor Armature Voltage Feedback Wiring Power Module Thermal Switch and Current Transformer Wiring SAR Gate Output Cable sneen ueser eL e T Beh eli Control Circuit Power Wiring iicet x ee e euer EY SAR Motor Field Current Configuration 0 00 ccee eee a ee Sr dh pA PR SAR Current Feedback Configuration isses sepes vero ua see Pe SAR Programming and Startiip
43. IL AN AAA PE kJ KJ x a Aus Ac Ne N e Motor Armature Nc 9 PE s Voltage Feedback KA Terminal Block Table 5 AC DC Voltage and Motor Armature Voltage Feedback Terminal Specifications Wire Size Range No Terminal Description Maximum Minimum W VU AC Inpu o Feedback connector KP amp D C DO ERU 6 0 mm 0 2 mm connector KP 10 AWG 24 AWG 1A1 M Motor Armature 142 A2 Voltage Feedback connector KA DC Feedback Fusing Requirements The recommended fuses are Recommended Torque M ce co a e 3 ao N Bao Ibein e Bussmann fuse FWP SAIAF 5 A 700V Type FWP 14x 51mm or equivalent Note The AC voltage feedback inputs on the SAR are fused internally Rockwell Automation Publication 23P UM001D EN P July 2012 Stand Alone Regulator Installation Wiring and Configuration Chapter 2 Connector KP Wiring Connect the motor armature terminal C to terminal C on connector KP Connect the motor armature terminal D to terminal D on connector KP Connector KA Wiring Connector KA must be wired to provide DC voltage feedback to the field regulator to control the field current based on the armature voltage Terminal 1A1 is connected internally to terminal C on connector KP and terminal 1A2 is connected internally to terminal D on connector KP The default configuration is shown in Figure 7 a
44. July 2012 relay outputs Stand Alone Regulator 26 resolver feedback Stand Alone Regulator 26 REV GATES 49 reverse gates output 49 52 S safety ground Stand Alone Regulator 21 SD3000 PLUS forward gates input 50 SD3000 PLUS FWD Gate Input 49 D3000 PLUS REV gate input 49 SD3000 PLUS reverse gates input 50 specifications cables 78 electrical Gate Amplifier 71 electrical SAR 71 environmental Gate Amplifier 71 environmental SAR 71 watts loss SAR 71 Stand Alone Regulator AC feedback connections 21 catalog numbers 12 CE conformity 16 current feedback calculations 30 current feedback configuration 28 DC analog tachometer 26 DC feedback connections 21 digital encoder 26 dimensions 15 features 12 Index 1 0 wiring 26 motor field current 26 motor thermistor 26 mounting hardware 15 operating termperatures 13 options 12 parameter configuration 40 PE terminal 20 relay outputs 26 resolver feedback 26 safety ground 21 startup 40 thermal switch 26 weight 15 startup Stand Alone Regulator 40 Status LEDs Gate Amplifier 72 T thermal switch Stand Alone Regulator 26 W watts loss Stand Alone Regulator 71 weight Gate Amplifier 43 Stand Alone Regulator 15 wiring control circuit power SAR 25 Rockwell Automation Publication 23P UM001D EN P July 2012 87 Index 88 Rockwell Automation Publication 23P UM001D EN P July 2012 Rockwell Automation Support Rockwell Automation provid
45. LACES must be followed DO NOT work alone on energized equipment ATTENTION The following information is merely a guide for proper installation The National Electrical Code and any other governing regional or local code will overrule this information Rockwell Automation cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this drive regulator or associated equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation ATTENTION The installation of the Stand Alone Regulator and or the Gate Amplifier must be planned such that all cutting drilling tapping and welding can be accomplished with the Gate Amplifier removed from the enclosure The Stand Alone Regulator and Gate Amplifier are of the open type construction and any metal debris must be kept from falling into the enclosure Metal debris or other foreign matter may become lodged in the circuitry resulting in component damage ATTENTION An incorrectly applied or installed Stand Alone Regulator or Gate Amplifier can result in component damage or a reduction in product life Wiring or application errors such as incorrect or inadequate supply voltage or excessive ambient temperatures may result in malfunction of the system ATTENTION Only qualified personnel familiar with DC drives and associated machinery should plan or implement the installation st
46. Part Number for S6 97305401 Drawing 97305400 Harness Part Number for S6R 97305402 Drawing 97305400 Notes 97305401 contains six twisted pairs labeled 1THY through 6THY 97305402 contains two sets of six twisted pairs labeled 1THY through 6THY and 11THY through 16THY respectively Use bracket 608877 6A nector with cable for mounting con TB not included Gate Coupler A H2 E wn G E 1 M ki oo I Notes RED Gate Coupler H2 t WHT 6 CL H1 RED KE T Butt splice to SCR gate leads To additiona 1 G4 RED I gate coupling V Aj 65 WHT terminal blocks K G5 RED V G6 WHT Do not route gate leads with power wiring V 1 An external 48V gate power supply must be used to supply sufficient voltage to each gate coupler The power supply connects to the faceplate connector of the Gate Amplifier It is suggested to use A and B suffixes on the gate lead labels to each SCR pair to aid in wiring and troubleshooting Rockwell Automation Publication 23P UM001D EN P July 2012 Stand Alone Regulator Gate Amplifier Specifications Electrical Field Bridge Inpu
47. SD3K CBLREVPMO60 5 Feet SD3K CBLREVPM120 10 Feet SD3K CBLREVPM180 15 Feet SD3K CBLREVPM240 20 Feet Additional lengths can be found on drawing 97305300 Table 23 Rectangular Style Connector Forward Gates Cables Catalog Number SD3K CBLFWDELC060 Length 5 Feet SD3K CBLFWDELC120 10 Feet SD3K CBLFWDELC180 15 Feet Additional lengths can be found on drawing 97305000 Table 24 Rectangular Style Connector Reverse Gates Cables Catalog Number SD3K CBLREVELC060 Length 5 Feet SD3K CBLREVELC120 10 Feet SD3K CBLREVELC180 15 Feet Additional lengths can be found on drawing 97305200 Rockwell Automation Publication 23P UM001D EN P July 2012 63 Chapter4 Retrofit Guidelines Gate Interface to Dierikon To interface to the SCR gates ofa Dierikon power module a direct connection Power Modules can be made to the gate input without the need for the Gate Scaling Module e Forward Gate Cable to interface Gate Amplifier to Dierikon Power Module 612436 xxxW where xxx is the length in inches To view drawing 612436 e Reverse Gate Cable to interface Gate Amplifier to Dierikon Power Module 612567 xxxW where xxx is the length in inches To view drawing 612567 64 Rockwell Automation Publication 23P UM001D EN P July 2012 Parallel Power Modules and Load Share Reactors Phase Sequence and Armature SCR Firing Order Chapter 5 Power Interface and SCR Firing Order When power mod
48. Thy Gate V 2ms Thy2 Gate V 2wm amp Thy3_Gite CH2Z 2 V 2m Thy4 Gie 5 CH2 2 V 2m ThyS Gate 6 CH2 2 V 2ms ThyS Gate 7 CH1 200 V 2 ms L1 to L3 Phase Rotationp Negative L3 L2 L1 LL Era LLLDEDCECLCUIL LLLI 68 Rockwell Automation Publication 23P UM001D EN P July 2012 Power Interface and SCR Firing Order Figure 33 Firing Series SCRs Thyristors Chapter 5 Catalog Number SD3K CBLFWDPMxxx xxx length in inches Drawing 97305100 Forward Or Catalog Number SD3K CBLREVPMxxx xxx length in inches Drawing 97305300 Reverse One of six twisted pair in cable xxx Length in inches drawing cable ends and attach the wires to the terminal block Catalog Number SD3K CBLCANNONxxx Cut off the box connectors that are on the 97305500 directly Harness Part Number for S6 97305401 Drawing 97305400 Harness Part Number for S6R 97305402 Drawing 97305400 Notes 97305401 contai labeled 1THY ns six twisted pairs through 6THY 97305402 contains two sets of six twisted pairs labeled 1THY through 6THY and 1THY through 16THY respectively D Shell to Use bracket 608877 6A TB not included
49. User Manual Allen Bradley PowerFlex DC Stand Alone Regulator and Gate Amplifier Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual R
50. ack CT Feedback To Motor Power Module Field Armature Voltage Feedback 2 of 4 SD3K REV Input 3 of 4 SD3K REV Input To Gate Amplifier IS 120VAC supply on a final s gate pulses to the power module Caution Do NOT use the external power supply Ext P S when the gate pulse output is connected to the input of a downstream Gate Amplifiers Only use the external power age Gate Amplifier s that provides the gt To Gate Amplifier 4 of 4 SD3K REV Input REV Output Cables SD3K CBLGSCLIRxxx From Gate Amplifier FWD Output From Gate Amplifier REV Output PFDC Gate Input xt P S 120VAC Rockwell Automation Publication 23P UM001D EN P July 2012 To Forward Power Modules To Reverse Power Modules Gate Amplifier 4of4 dE Gate Amplifier Installation and Wiring Chapter 3 Figure 22 Cascading Gate Amplifiers Using the Stand Alone Regulator Mixed Configuration Gate Cable PowerFlex DC Stand alone Regulator KPT11 Field Supply 15 Pin D Shell 40 A or 70 A 2 Quad All Terminals are located on the bottom of the unit PFDC Gate Input Saa PFDC Gate Input From Gate Amplifier FWD Output From G
51. aging 5 0 kg 11 0 Ib 57 kg 12 5 Ib Recommended Mounting Hardware Metric M5 English 410 IMPORTANT Provide at least 114 millimeters 4 5 inches in front of unit for connectors and cable bend radius Rockwell Automation Publication 23P UM001D EN P July 2012 43 Chapter 3 Power and Ground Wiring Gate Amplifier Installation and Wiring Figure 17 Power and Ground Connections Engineered by ers O O LPs OO GATE FUSE OK GATE POWER POWERFLEX DC SAR GATE INPUT SD3000 PLUS FWD GATE INPUT SD3000 PLUS REV GATE INPUT A nora p utomation FWD GATES 9 REV GATES 9 EO GATE AMPLIFIER o oe f Table 9 Terminal Specifications 29 Part Number for Customer Plug Wire Size Range Recommended No Name Description provided with Gate Amplifier Maximum Minimum Torque Input Power Input power Line 94809302 4 0 mm 2 5mm 0 68 Nem o Terminal Block L1 Neutral L2 10 AWG 14 AWG 6 0 Ibein L1 L2 Ground and Ground e Ground Stud Chassis Ground Refer to Chassis Grounding on page 45 for more information External Gate External Gate
52. annon style mating connector on the Power Box or Gate Coupler Assembly SD3K CBLREVELC 97305200 01 02 03 04 05 06 07 08 09 substitute 00 with desired 60 120 180 240 300 360 480 600 720 length in inches length code Connects the REVERSE gate signals from the Gate Amplifier Control to a Power Box using an ELCO style connector Picture Details cj H al REV GATES OUT 973052xx C PWR BOX REV GATES This end connects to one of the REVERSE OUTPUT connectors on the This end connects to the ELCO connector on the Gate Amplifier Power Box SD3K CBLREVPM 97305300 01 02 03 04 05 06 07 08 09 substitute 00 with desired 60 120 180 240 300 360 480 600 720 length in inches 78 length code Connects the REVERSE gate signals from the Gate Amplifier Control to a Power Box using a Round Cannon style connector Picture Details d JT Ad REV GATES OUT 973053xx K g PWR BOX REV GATES 0 This end connects to one of the REVERSE OUTPUT connectors on the This end connects to the R
53. art up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION The Stand Alone Regulator and Gate Amplifier contain ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook Rockwell Automation Publication 23P UM001D EN P July 2012 9 Chapter 1 Introduction Product Overview 10 The PowerFlex DC Stand Alone Regulator SAR and Gate Amplifier products provide an integrated solution for controlling external DC power modules Stand Alone Regulator SAR The SAR is a DC drive regulator that provides armature regulation armature SCR gate signals and a regulated field supply The SAR field supply consists of a single phase two quadrant non reversing full wave rectified bridge available as 40 or 70 Amps The SAR supports an AC line input voltage range of 230VAC to 690VAC and a field input voltage range of 100VAC to 460VAC The SAR uses feedback signals from the AC input line to monitor the incoming voltage level in order to establish the SCR gate firing sequence relative to the AC line The SCR gate firing for
54. ate Amplifier FWD Output Cables SD3K CBLGSCLIFxxx REV Output 120VAC Gate Amplifier To Gate Amplifier L 1 of 2 SD3K FWD Input To Gate Amplifier 2 of 2 SD3K FWD Input To Forward Power Modules To Gate Amplifier L 1 of 2 SD3K REV Input REV Output Cables SD3K CBLGSCLIRxxx To Gate Amplifier 2 of 2 SD3K REV Input PFDC Gate Input To Reverse Power Modules KP KA KPT31 U C1 D1 DCWVU 1A1 A1 1A2 A2 12345678 JE SD3K REV Power Module Power Module q AC DC Thermostat and Feedback CT Feedback x RDY To Motor Power Module Field Armature Voltage Feedback 120VAC Caution Do NOT use the external power supply Ext P S when the gate pulse output is connected to the input of a downstream Gate Amplifier s Only use the external power From Gate Amplifier FWD Output gate pulses to the power module supply on a final stage Gate Amplifier s that provides the From Gate Amplifier REV Output LP S 120VAC Rockwell Automation Publication 23P UM001D EN P July 2012 To Forward Power Modules To Reverse Power Modules Gate Amplifier 1of2 To Forward Power Modules To Reverse Power Module
55. components of the input stage If the external 48V power supply is used the interlocking relay must also be used as described in the EXT GATE P S section on page 51 Illustrations are included for both the Stand Alone Regulator see Figure 21 below and Figure 22 on page 55 and the SD3000 PLUS see Figure 23 on page 56 and Figure 24 on page 57 Figure 21 Cascading Gate Amplifiers Using the Stand Alone Regulator PFDC Gate Input To Forward Power Modules From Gate Amplifier FWD Output To Reverse Power Modules From Gate Amplifier FWD Output Cables SD3K CBLGSCLIFxxx REV Output Gate Cable 120VAC Gate Amplifier 1 of 4 Gate Amplifier To Gate Amplifier PFDC 1 of 4 SD3K FWD Input Gate Input To Gate Amplifier 2 of 4 SD3K FWD Input To Gate Amplifier 3 of 4 SD3K FWD Input Up to Four Gate Amplifier To Gate Amplifier 4 of 4 SD3K FWD Input To Gate Amplifier 1 of 4 SD3K REV Input To Gate Amplifier 54 V1 U1 PowerFlex DC Stand alone Regulator Field Supply Ker 40 A or 70 15 Pin D Shell 2 Quad All Terminals are located on the bottom of the unit KP KA KPT31 C1 D1 DCWVU 1A1 A1 1A2 A2 12345678 Power Module Power Module AC DC Thermostat and Feedb
56. e INPUT A connec or on Gate Amplifier the Power Supply Module of the Parallel Gate Amplifier PGA SD3K CBLPGAREV 97330300 01 02 03 04 05 06 07 08 09 substitute 00 with desired 18 24 60 120 180 240 300 360 480 length in inches length code Connects the REVERSE gate signals from the Gate Amplifier Control to the PGA Power Supply Module INPUT B connector Picture Details g 80 REV GATES OUT d 973303XX K PGA INPUT B HI Gate Amplifier This end connects to one of the REVERSE OUTPUT connectors of the This end connects to PGA he INPUT B connector on the Power Supply Module of the Parallel Ga Amplifier NA 80 608877 6A Mounting Bracket Suitable for mo up to two 2 cable assemblies tha Round Cannon style connectors 612435 973055xx unting utilize Rockwell Automation Publication 23P UM001D EN P July 2012 Specifications Appendix A Catalog Number Part Number Description Length 23PAMP C2 PN 104829 2 feet 24 inches PowerFlex DC SAR Gate Output to Gate Amplifier cable 23PAMP C1 PN 104828 5 feet 60 inches Po
57. e dependent on the gate power supply that is used internal or external The internal ORing diode determines whether the internal or external power supply is used The maximum gate voltage is 28V with the internal gate supply and 48V when using the external gate power supply 120VAC This is the control power input to the Gate Amplifier Wire into the cabinet control power 52 Rockwell Automation Publication 23P UM001D EN P July 2012 Chapter 3 Gate Amplifier Installation and Wiring Figure 20 Typical Gate Amplifier Interface to Multiple S6Rs yoeqpee JeAose 10 Jepoou3 O Mog xoeqpoo JaAjOsay JO 1 pP09UF OL 4 4 4 dino e npo N J0MOd Oq pue 9q See Parallel Power Modules and Load Share Reactors on page 65 for more information dino e Jnpojy J9MOd Oa pue 9q SI0Joe9H aleys peo wojeg sebpug esie eu OL OV W noqy u044 Indu 9Y pet 10104 ae Ser tl JoyeinBay Od uoi Av Hu HOLINOW Sid W3 ld AIGWASSV v9 H3 ld AI8N3SSV v9 U3 ld AIdIN3SSV v9 aJld AANISSY V9 H3 ld AIdN3SSV V9 H3 ld Ala N3ssv NO9 31V9 Yad AIdN3SSV N09 31V9 H3 ld AIGWASSV NO9 31V9 ov 1pue uos19 HYS oddd 9 MEd LO gt Aninoi9 E dols oL T salvo Aad s31v9 Au salvo 0M4
58. e used for firing the SCRs If the Gate Coupling boards are to be separately mounted then the 97306101 Gate Coupler board should be used Twisted pair should be used for the output wiring ofthe power supply The power supply should be mounted near the Gate Amplifier As a general rule the wiring between the external power supply and the Gate Amplifier should be approximately 40 inches 1 meter or less When installing a 48V external gate power supply and or wiring the 120VAC input a fuse block with a 10 A fuse and line filter as mentioned above are required The output is wired to the two point connector that plugs into the front of the Gate Amplifier 48V Relay part number 700 HC24Z48 3 4 Socket part number 700 HN104 Series D e Hy Back Diode LED part number 700 ADL2 Series B Note The coil is polarity sensitive when the Fly Back diode is connected Aninterlock relay is required for the external gate power supply The relay coil is wired to the output of the 48V external gate power supply to indicate that the power supply is active The contacts of the relay need to be wired into the Run Permissive logic Rockwell Automation Publication 23P UM001D EN P July 2012 51 Chapter3 Gate Amplifier Installation and Wiring FWD GATES and REV GATES Four identical forward and four identical reverse gate outputs provide gate signals for up to four power modules The output is a burst pattern that has a maximum amplitud
59. ed at the input port for the connector ll 74 Rockwell Automation Publication 23P UM001D EN P July 2012 Specifications Appendix A Figure 36 Gate Coupler Assembly Mounting Dimensions Ground Terminal and Input Output Connections H 3 13 2 63 H 280 4 H 0 22 4 PLACES i J U D 9 88899000995 N 28000000000 V OOOQO0QOO000 60000060000 3388398830 Exit Port each side for SCR Gate Cables 12 75 Gate Coupler 3 13 Assembly 12 25 3999888999 00000000000 J QOQOOOOOOOOQ i OOO000000000 OOOO0O0000000 OOOO00000000 o o Ground Stud ground cable provided L with unit See Table 29 Terminal o E 3 n E nef Specifications Input Connection nm Table 28 Gate Coupler Assemblies Catalog Numbers SD3K GATMDLHIGH and SD3K GATMDLLOW Weights Gate Coupler Assembly Gate Coupler Assembly and Packaging 1 5 kg 3 4 Ibs 1 94 kg 4 4 lbs Recommended Mounting Hardware Metric M5 English 10 IMPORTANT Provide at least 114 mm 4 5 in for the input connection cable Table 29 Terminal Specifications Use the grounding cable that is provided with the unit Refer to Ground Stud Chassis Ground Chassis Grounding on page 45 for more information Tighten the terminal to 20 Ibein 2 3 Nem
60. ed by the interposing current transformer s turns ratio The type of transformer for this application is a wound primary current transformer The advantage of this implementation is that existing current transformers can remain in place which eliminates the need to disassemble reassemble heavy bus bars and the wiring to the existing and interposing current transformers is signal level wiring Care must be taken in the implementation of the interposing current transformers to ensure that all considerations of sizing the current transformer configuration are met such as the following IOC Limits for the existing and interposing current transformers Minimum magnetization currents required Proper resulting turns ratio Consult with Engineering for assistance in implementing a current feedback configuration with interposing cascade current transformers The voltage across the burden resistor must be normalized for the fullload rating of the power module The regulator expects a value of 0 612 Volts at the current feedback input at 10096 load of the power module To ensure that the regulator receives 0 612 Volts at 10096 load of the power module a scaling operational Rockwell Automation Publication 23P UM001D EN P July 2012 Stand Alone Regulator Installation Wiring and Configuration Chapter 2 amplifier Op Amp circuit has been provided For reference the name of this circuit will be called the Binary Gain Amp because t
61. egulator Installation Wiring and Configuration Terminal Sign al and Wiring Use the diagram in Figure 3 Stand Alone Regulator Terminal Signal Block Dia grams Diagram as a guide for the general location of and connection signals for the main input output terminal blocks on the SAR The diagram in Figure 4 on page 19 represents the recommended wiring for a typical SAR interface to a SGR power module Figure 3 Stand Alone Regulator Terminal Signal Block Diagram Bottom View AC DC Feedback e Output Front of Unit 9 Connector Kp Connector KPT11 Field Bridge ut DC Ouput Power Module Thermal CT Feedback C1 DC Our D1 DC_Out 5V V_therm 1 m IS0 Com 4 Not Used PE GND Connector KPT31 E Therm Com Power Module Armature Feedback zu gt Motor Arm Fdbk Motor Arm F dbk gt PM Out C Connector KA 18 Rockwell Automation Publication 23P UM001D EN P July 2012 Chapter 2 Stand Alone Regulator Installation Wiring and Configuration Figure 4 Typical Stand Alone Regulator Interface to SOR Power Module pe1xe Ajayesedas 10 8 npojN J8 Mod pJ8H uvs Aq paliddng l LJ ppum e9ejd ul aq s emje
62. ent Descriptions Board Component Description Main Board The Main board provides an optical isolation layer between the Regulator and PN 25913 he Gate Amplifier circuits In addition it provides the necessary permissive interlock circuits and LED annunciation of system status The output of the Main board is connected to the Gate Driver Output board for the final stage of amplification of the gate signals Gate Driver Output The basic overall functionality of the Gate Driver Output board is as follows GDO Board Faceplate connections are as follows 964310 Four top D Shell connectors are for the SCR Forward Gates square wave burst iring output to power module gates in the range of 28V to 48V Four lower D Shell connectors are for the SCR Reverse Gates square wave burst firing output to power module gates in the range of 28V to 48V An external power supply for the gates of up to 48V can be used A diode OR unction ensures that the module utilizes the 48V supply when it is connected When the use of an external gate power supply is required an interlock is required with the drive control in case the external power supply fails The interlocking is accomplished with a relay with a 48VDC coil that is connected across the external power supply and the normally open contacts are connected into a stop circuit Internal Power The Power Supply provides 28V for the SCR gate firing circuits and is further Supply reduced for on board logic circuit fu
63. eproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence SHOCK HAZARD labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures PEPPP IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley PowerFlex Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes This manual contains new and updated information Topic Page Removed the reference to the 12 S12R configuration from the
64. er2 Stand Alone Regulator Installation Wiring and Configuration SAR Motor Field Current Configuration 26 Relay Output and Thermistor Thermal Switch Wiring Two normally open relay outputs and one motor thermistor PTC or thermal switch input are available for use and must be configured with the appropriate parameters See Relay Outputs and Thermistors and Thermal Switches in the PowerFlex Digital DC Drive User Manual publication 20P UMO001 for details 1 0 Digital Encoder and DC Analog Tachometer Wiring The following standard I O and feedback options are available with the SAR Eight digital inputs four digital outputs three analog inputs and two analog outputs are available Additional digital and analog I O is available when using the optional I O expansion circuit board Aninput terminal block is available for an incremental dual channel two channel optional with jumper differential recommended or single ended encoder with an input voltage configurable for 2 5V 5 2V or 5 4V 15 2V An input terminal block is available for a DC analog tachometer with a maximum input voltage of 22 7V 45 4V 90 7V 181 6V or 302 9V and an input current of 8 mA full scale See I O Wiring in the PowerFlex Digital DC Drive User Manual publication 20P UMO001 for details Resolver Feedback Option Module Wiring A resolver feedback module is available for purchase separately from the SAR The resolver
65. ering legible and the mounting back plate vertical to ensure effective convection cooling Follow these instructions when mounting the Gate Amplifier e Mount in aclean dry location Contamination from oils corrosive vapors y and abrasive debris must be kept out of the enclosure e Do not mount heat generating equipment directly underneath the unit Mount the unit in a vertical position only Power dissipation 50 Watts Figure 15 Minimum Mounting Clearances Les 125in 31 75 mm 2 0 in 50 8 mm Engineered by Rockwell Automation D GPS GATE FUSE OK FWD GATES LPS GATE POWER POWERFLEX DC GATE NPUT 28e Sb3000 PLUS 95 GATE NPUT 28g Sb3000 PLUS E Fu 38 REV 5 GATH NPUT EXT GATE P S im 120VAC 3AG5A E T GATE AMPLI AER Rockwell Automation Publication 23P UM001D EN P July 2012 1 25 in 31 75 mm Gate Amplifier Installation and Wiring Chapter 3 Figure 16 Approximate Dimensions Dimensions in inches and millimeters od 10 6
66. es more granular and the error is greater when compared with the exact gain A gain value of 1 2 has been chosen as a guideline to keep the error to 196 or less Lower values of CT ratio result in the improvement of real system resolution The comparison between the exact value of gain and the actual gain is shown at the end of the calculation There are trade offs between the value of the burden resistor and the gain of the amplifier With a larger value of burden resistor 5 0 Ohms the required gain is less and the binary value calculated is greater resulting in a more accurate signal However the feedback level at IOC needs to be considered as discussed later in this section Again a value of 0 612 Volts represents 100 power module current The required gain of the Binary Gain Amp is calculated with this in mind The value of 0 612 Volts is divided by the actual voltage across the burden resistor at 100 power module current This provides the value of gain required to ensure that 0 612 Volts is fed back to the regulator at 100 power module current There is a maximum limit of 2 5 Volts that can be accepted by the regulator current feedback Beyond 2 5 Volts the circuitry will saturate To ensure that this does not occur the maximum value of current feedback is calculated at the IOC level The binary switch setting is based on the gain desired The actual binary switch setting will be obtained by rounding the calculated value to the nea
67. es technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Use the Worldwide Locator at http www rockwellautomation com support americas phone en html or contact Canada your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number
68. g JOJO OL yoeqpse 1D xoeqpee pue je SoUu9u 920 2V N NPON JMO MNPON J9MOd e N 3 8219S8v 2L evevl IV LVL DAMOQ kd 19 c I Ldy D d gt E ca yun y jo Wo og y uo peje50 ae speu IV 2 peno 2 5 V 0210 V Ob eus q Uld SL 5 eie q a st jddng piel E S Es JoyeinBay euo y puels E c Od X9 449M0d S o In IA E E ane oO eo cc Lud Cp Chapter 1 Introduction Stand Alone Regulator Gate Amplifier 12 Features e Rockwell Automation Architecture Class networking capable Available Options e Resolver Feedback Catalog Numbers This table lists the available catalog numbers for the SAR 230V 460V AC Input Field Amps Catalog Number Catalog Number 23PMD4 23PMF4 40 23PMD7 23PMF7 70 Note All models contain conformal coated circuit boards Features e Interfaces to the PowerFlex DC D3000 PLUS or PMI regulators e Flexible configurations S6 and S6R e Power module interface e Interlock via Ready Relay contacts to main drive control Available Options e 48V gate drive capability with an external power supply Model and Cable Model Part Numbers This table lists the cable module numbers and part numbers for the Gate Amplifier Product Model Part Number Gate Amplifier 23PAMP PowerFlex DC to Gate Amplifier Cable See Cable Specifications on page 78 SD3000 PLUS to Gate Amplifier Forward Cable SD3K CBLGSCLIPoo
69. g information for the Stand Alone Regulator Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Product Certifications website http ab com Provides general guidelines for installing a Rockwell Automation industrial system Provides declarations of conformity certificates and other certification details You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Rockwell Automation distributor or sales representative Rockwell Automation Publication 23P UM001D EN P July 2012 7 preface Notes 8 Rockwell Automation Publication 23P UM001D EN P July 2012 Chapter 1 Introduction General Prec autions Prior to installation of either the Stand Alone Regulator or Gate Amplifier read the following precautions A gt e bP D ATTENTION Energized industrial control equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Hazardous voltages may exist in the cabinet even with the circuit breaker in the off position Recommended practice is to disconnect and lock out control equipment from power sources and discharge stored energy in capacitors if present If it is necessary to work in the vicinity of energized equipment the Safety Related Practices of NFPA 70E ELECTRICAL SAFETY FOR EMPLOYEE WORKP
70. h code Connects the output side of the six 6 gate couplers inside of the Gate Coupler Assembly to their corresponding SCR gates in the Power Box S6 only use a second set for an S6R application or consider using 97305402 Picture Details 1 of 6 pairs This end connects to the output pins on the Gate Coupler Board This end connects to the gate white and identified as WW2 cathode red terminals of the SCR SD3K CBLGSCLIF length in inches 97330000 substitute 00 with desired length code 01 02 03 04 05 06 07 08 09 24 36 60 120 180 240 300 360 480 Connects the FORWARD gate signals from the Gate Amplifier Control to the Gate Scaling Module INPUT connector Picture Details d 81 FWD GATES OUT 973300xx GATE SCALING IN FWD II d 1 p This end connects to one of the FORWARD OUTPUT connectors of the This end connects to the INPUT connector of the Gate Amplifier Gate Scaling Module Rockwell Automation Publication 23P UM001D EN P July 2012 79 Appendix A Catalog Number SD3K CBLGSCLIR length in inches Specifications Part Number 97330100 substitute 00 w
71. hapter2 Stand Alone Regulator Installation Wiring and Configuration Field Power Module Bridge The SAR contains a two quadrant field power module bridge The field bridge and Ground Wiring 20 input circuit is rated for 100VAC 460VAC 10 50 60 Hz The input and output connections to from the field bridge are on the bottom of the SAR as shown An external transformer with appropriate primary fusing is required to supply the field External fusing is also required at the input terminals V1 and U1 to protect the field bridge The recommended fuse types are shown in the Table 4 on page 21 The SAR motor field current must configured with a hardware DIP switch and in firmware See SAR Motor Field Current Configuration on page 26 for more information Figure 5 Field Power Module Bridge Terminal Block and Ground Connection Bottom View of SAR wm 1 Field Power Module Bridge Terminal Block PE Terminal eo E PE c AR AAA SES PS A PN 1ATPA1 1A2 A2 A eee U dU U U JUUS L DOLUDDOLUDU PD DDDDDDD ODD DD DDDDDUUUS Table 3 Field Powe
72. he Gate Amplifier or the panel that it mounts to is not properly grounded the bypass capacitors can actually inject noise onto the signal lines resulting in nuisance trips For example if the motor frame and the Gate Amplifier chassis are not grounded together the motor frame potential can fluctuate as the drive is run If the motor frame fluctuates in potential the case of the feedback device resolver or encoder will also see this fluctuation The capacitive coupling between the case of the feedback device and the internal wiring and or electronics can result in a common mode noise signal being injected into the wiring This can result in noise on the feedback lines Another source of noise in the feedback path are the voltage fluctuations of the motor shaft especially in higher hp motors above 300 Hp In these cases an insulated Thomas coupling is recommended for interfacing with the feedback device The internal part number of an insulated Thomas coupling is 406041 17 Power Division Part Number For retrofit installations lack of sufficient bonding grounding is often the cause of noise problems If the regulator components are installed on a sub panel a 1 0 fine strand welding cable should be used to connect the panel to the ground bus Panels within the cabinet s must be bonded together If the panels within the cabinet are not bonded together use 1 0 fine strand welding cable to connect the panels Be sure that all paint is scra
73. he gain of the amplifier is set via binary DIP switches See Figure 12 on page 38 for a diagram of the Binary Gain Amp circuit and Figure 13 on page 39 for DIP switch locations When properly configured the output of the Binary Gain Amp is 0 612 Volts at 100 load of the power module Note that the basis for scaling the current feedback is the power module not the motor This is a different approach than legacy systems where the motor was used as the basis for all of the current loop feedback scaling This scaling works well as long as the power module and the motor are closely matched However when multiple power modules of the same size are used in the same process to run different size motors it may be desirable to enter lower values for parameter 465 Drive Size and scale the regulator rating from the motor full load amps This will reduce the size of the CT required and increase the resolution of the current feedback signal Though the power module is used as the basis for the current feedback calculation the motor load must fall within the rating of the power module If it does not the power module may trip on an overload or IOC when the motor is running within its rating For example if the regulator is configured so that the power module rating and the motor rating are equal and the Heavy Duty option is chosen for the motor the regulator will trip on a power module overload in 10 seconds when the system is running at
74. high frequencies are generated through the switching action of the drive power components The capacitive coupling of the high frequencies to the metal that is within proximity to the conductors creates ground currents ic Cdv dt The major components of the system motor conduit and cabinet will all be charged by this capacitive coupling effect The ground currents seek a return path back to the source the drive and ultimately the transformer If a known good path is not provided more currents will flow through the machine and other undesirable paths The power transformer provides a magnetic isolation barrier that prevents the ground currents from going into the power grid In the transformer there is capacitive coupling between the transformer core and the windings Attachment of the transformer frame which is attached to the core to the drive cabinet s will complete the ground current path for these components through a known path Motor to cabinet the connections for the motor ground must be made directly to the frame of the motor not the conduit box The connection between the motor frame and the conduit box does not provide a good high frequency conduction path Drive cabinet to bus power entry cabinet Power entry cabinet to power transformer case frame If insufficient grounding bonding is suspected then additional wiring must be added as shown in the system diagram that follows to ensure that there is a proper pa
75. ion and Wiring on page 41 for more information on Gate Amplifier installation and connections See Cable Specifications on page 78 for information on available cable lengths for the 23PAMP Cx cable Figure 9 SAR Gate Output Cable Connection KPT11 Bottom View of SAR w SAR Gate Output Cable KPT11 Connector The control circuit for the SAR not identified in the drawings contained in this manual must be powered by an external 230V AC or 115V AC single phase power supply This power supply provides power for the SAR cooling fans and a HIM communication adapter I O encoder or DC analog tachometer if installed See Control Circuit Input Power in the PowerFlex Digital DC Drive User Manual publication 20P UMO001 for details In addition the control circuit power input terminals require short circuit protection See Control Power Protection in the PowerFlex Digital DC Drive User Manual publication 20P UM001 for details Rockwell Automation Publication 23P UM001D EN P July 2012 25 Chapt
76. ith desired length code Description Length 01 02 03 04 05 06 07 08 09 24 36 60 120 180 240 300 360 480 Connects the REVERSE gate signals from the Gate Amplifier Control to the Gate Scaling Module INPUT connector Picture Details d Rem al REV GATES OUT 973301xx K GATE SCALING IN REV al 5i This end connects to one of the REVERSE OUTPUT connectors of the This end connects to the INPUT connector of Gate Amplifier Gate Scaling Module SD3K CBLPGAFWD length in inches 97330200 substitute 00 with desired length code 01 02 03 04 05 06 07 08 09 18 24 60 120 180 240 300 360 480 Connects the FORWARD gate signals from the Gate Amplifier Control to the PGA Power Supply Module INPUT A connector Picture Details d RT FWD GATES OUT 973302xx Ei PGA INPUT A Al io This end connects to one of the FORWARD OUTPUT connectors of the This end connects to th
77. l position only in order to provide proper cooling The lettering on the face ofunit should be in a readable position as shown in Figure 37 on page 77 Note Grounding of the Gate Scaling Module is accomplished through the mounting screws The case is made of a unpainted cast metal box Rockwell Automation Publication 23P UM001D EN P July 2012 Specifications Appendix A Figure 37 Gate Scaling Module Mounting Dimensions Input Output Connections Reni 4 INPUT OUTPUT 0 2 38 in J GATE SCALING 37 25 mm 1 47 in MODULE Center Diameter u Reckwell Part No 97331001 Engineered by Autemation I 124 0 mm gt 4 88 in gr 5 43 in Notes Module Depth 31 0 mm 1 22 in Mounting Holes 4 25 mm 0 17 in Part No 97331001 To view drawing 97331000 Table 30 Gate Scaling Module Part No 97331001 Weights Gate Scaling Module Gate Scaling Module and Packaging 0 9 kg 0 4 Ibs 1 3 kg 0 6 Ibs Recommended Mounting Hardware Metric M4 English 8 lt 138 0 mm a IMPORTANT When mounting the Gate Scaling Module washers may be required because the mounting holes are tapered If a mounting screw is over tightened then the cast metal could break Rockwell Automation Publication 23P UM001D EN P July 2012 71 Appendix A Cable Specifications Catalog Number SD3K CBLFWDELC length in inches Specifications Stand Alo
78. le bridge SAR connections 20 input fuses 21 firing parallel SCRs thyristors 70 firing series SCRs thyristors 69 forward gates output 49 52 fuses DC feedback SAR 22 FWD GATES 49 G Gate Amplifier 45 control power Input 52 cooling 42 dimensions 43 external gate power supply 44 features 12 ground connections 44 ground stud 44 hardware descriptions 72 high frequency grounding 46 humidity 41 input power terminal block 44 model number 12 mounting 42 mounting clearances 42 mounting hardware 43 operating temperatures 41 options 12 part numbers 12 power connections 44 ready relay 44 weight 43 Gate Coupler Assembly catalog numbers 73 dimensions 75 ground terminal location 75 input output connections 75 mounting hardware 75 mounting instructions 74 operating temperatures 73 Rockwell Automation Publication 23P UM001D EN P July 2012 85 Index 86 Gate Interface to non Rockwell power module retrofit 59 to Reliance Electric Dierikon power modules 64 to Reliance Electric U S power modules retrofit 61 gate output SAR cable 25 GATE POWER 49 LED 49 gate power function 50 gate power supply 49 Gate Scaling Module cooling 76 dimensions 77 mounting 76 mounting hardware 77 operating temperatures 76 part number 76 General Precautions 9 GPS LED 49 ground stud Gate Amplifier 44 grounding 45 Gate Amplifier 45 H hardware descriptions Gate Amplifier 72 high frequency grounding cabine
79. lity of the Gate Amplifier provides the means to supply additional gate current and voltage and also support the firing of gate coupler boards connected in series which requires additional voltage Connecting gate couplers in series forces the simultaneous firing of the SCRs with power connections in series or parallel An internal diode OR circuit ensures that the gates are powered by whichever gate power supply voltage is the greater in amplitude the internal or the external power supply Rockwell Automation Publication 23P UM001D EN P July 2012 Chapter 1 Introduction Figure 1 Typical PowerFlex DC Stand Alone Regulator and Gate Amplifier Interface to S6R Hod JaN OSH yoeqpee JeAoseH 10 Jepoou3 C indino e npo N JaMOd 9q pue 9q 4 4 1 yoeqpss AV T3H YOLINOW S d peuinbey 41 10 Jepoou3 OL amano L dois oL T Play 1010 N JoyeinBay euo v puejs Wo S d IX3 A8 uinoito dois 01 Sjoejuo uedo euJON Sid XF OVAOCL AlBiN3SSV YJ1dN09 31v9 AIaIN3SSV u31dhno9 31v9 OV 171 pue dvs 90H UO 2 d 01804 19 Jeyiduy ayes 11 eje eie xoeqpee aeon eunjeuuy pial aINPOW J8MO
80. mplies with the EN standards listed when installed according to this User Manual CE Declarations of Conformity are available online at www rockwellautomation com products certification ce Low Voltage Directive 2006 95 EC EN 50178 Electronic equipment for use in power installations EMC Directive 2004 108 EC EN 61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods General Considerations For CEcompliance the SAR installation must satisfy requirements related to both EN 50178 and EN 61800 3 provided in this document The SAR complies with the EMC requirements of EN 61800 3 when installed according to good EMC practices and the instructions provided in this document However many factors can influence the EMC compliance ofan entire machine or installation and compliance of the SAR itself does not necessarily ensure compliance of all applications The SAR is not intended to be used on public supply networks which supply domestic premises Without additional mitigation radio frequency interference is expected if used on such a network The installer is responsible to take measures such as supplementary line filters and enclosures to prevent interference in addition to the installation requirements of this document Installation Requirements Related to EN 50178 and the Low Voltage Directive TheSAR is compliant with the CE LV Directive when used at
81. nctions Line Fuse 5 A 250V AC 3AG Time Delay Status LEDs Each LED is briefly described in this table Label Description GPS 28V Gate Power Supply output is present GPS O GATE FUSE OK LPS 5V Logic Power Supply output is present LPS 5 O GATE POWER GATE FUSE OK Indicates that the fuse for the External Power Supply is OK The fuse is mounted on the Gate Driver Output board GATE POWER Indicates that all on board systems are functioning normally 72 Rockwell Automation Publication 23P UM001D EN P July 2012 Gate Coupler Assembly Information Specifications Appendix A Gate Coupler Assemblies Catalog Numbers SD3K GATMDLHIGH and SD3K GATMDLLOW The Gate Coupler Assembly provides an isolation barrier between the Gate Amplifier and the SCR Gates Two different units are available depending on the load requirements The SD3K GATMDLHIGH provides a higher output than the SD3K GATMDLLOW The SD3K GATMDLLOW is usually used in special cases where the power rating of the power module is low and there is concern about excessive SCR gate power dissipation As a general guideline for retrofits non Reliance power module when the power output of the power module exceeds 200HP use the SD3K GATMDLHIGH For the Reliance Electric Power Modules with existing Gate Coupler Modules that are O 51378 19 or electrically equivalent with Watt resistors on the transformer primary neither SD
82. nd is wired as follows e Jumper terminal 1A1 to terminal Al e Jumper terminal 1A2 to terminal A2 The jumpers will provide the field regulator with the power module armature voltage feedback This is the default wiring scheme for connector KA at the factory Figure 7 Terminals on Connector KA Jumpered SS eS LA TAI A1 1A2 01 A2 uus Place jumpers between terminals as shown Rockwell Automation Publication 23P UM001D EN P July 2012 23 Chapter2 Stand Alone Regulator Installation Wiring and Configuration Power Module Thermal Switch and Current Transformer Wiring 24 Connector KPT31 is used for power module thermal switch monitoring and current feedback via current transformer connections Note that the thermal monitor circuit includes a thermal switch on the field power module within the SAR Figure 8 Power Module Thermal Switch and Current Transformer Terminal Block KPT31 Bottom View of SAR m E N IC COC Power Module Thermal Switch and Current Transformer KPT31 Terminal e NS Block T 3 gt Q 2C 2C 2C
83. ne Regulator Part Number Description Length 97305000 01 02 03 04 05 06 07 08 09 Substitute 00 with desired 60 120 180 240 300 360 480 600 720 length code Following are the cable assemblies available for use with the Gate Amplifier and Connects the FORWARD gate signals from the Gate Amplifier Control to a Power Box using an ELCO style connector Picture Details n L mb N 080 FWD GATES OUT 973050xx PWR BOX FWD GATES This end connects to one of the FORWARD OUTPUT connectors on This end connects to the ELCO connector on the the Gate Amplifier Power Box SD3K CBLFWDPM 97305100 l l 01 02 03 04 05 06 07 08 09 substitute 00 with desired 60 120 180 240 300 360 480 600 720 length in inches length code Connects the FORWARD gate signals from the Gate Amplifier Control to a Power Box using a Round Cannon style connector Picture Details FWD GATES OUT 973051xx K PWR BOX FWD GATES This end connects to one of the FORWARD OUTPUT connectors on the Gate Amplifier This end connects to the Round C
84. on the SD3K CBLCPLR072 cable set identifies the SCRs as THYI THY2 THY6 The same cable set is used for both forward and reverse If the forward and reverse gate labeling are needed then SD3K CBLBOXA048 or SD3K CBLBOXB048 for the S6R 48 inch cables can be used instead of the SD3K CBLCPLRO072 72 inch cables To interface to the SCR gates of a Reliance Electric U S power module a Gate Scaling Module is used in the SCR gate circuit The Gate Scaling Module inserts a resistor into each of the SCR gate circuits to reduce the gate drive current This is necessary because the gate driver voltage from the Gate Amplifier is 28V versus the 18V that would be produced by the Distributed Power System Power Module Interface PMI rack The reduced drive current ensures that the resistors on the primary side of the gate coupler transformer are running well within their maximum power dissipation ratings The most common type of gate coupler used in the Reliance Electric power modules is the O 51378 19 There are several variations of the O 51378 19 gate coupler with regard to physical interface methods but the basic components are the same To confirm this compare the schematic of the O 51378 19 gate coupler with the schematic of the gate couplers of the retrofit power module The Gate Scaling Module was designed to interface the Gate Amplifier to a Reliance Electric power module with O 51378 19 gate couplers or electrically equivalent gate couplers The
85. ound Cannon style mating connector on the Power Box or Gate Coupler Gate Amplifier Assembly Rockwell Automation Publication 23P UM001D EN P July 2012 Catalog Number SD3K CBLBOXA048 SD3K CBLBOXB048 Part Number 97305400 substitute 00 with desired code Specifications Appendix A Description Length 01 02 Motoring S6 48 gate leads Motoring amp Regen S6R 48 gate leads 6 total 12 total Connects the output side of one 1 gate coupler to its corresponding SCR in the Power Box Picture Details 1 of 6 pairs This end connects to the output pins on the Gate Coupler Board This end connects to the gate white and identified as WWZ2 cathode red terminals of the SCR SD3K CBLCANNON 97305500 01 02 03 04 substitute 00 with desired 60 72 96 120 length in inches length code Connects the FORWARD or REVERSE gate signals from a cable with a Round Cannon style mating connector to the primary side of six 6 individual gate couplers This cable assembly should be mounted to bracket P N 608877 6A for strain relief Picture Details SD3K CBLCPLR length in inches This end connects to Gate Amplifier cable assembly 973051xx or Each connector on this end connects to the input 973053xx pins on the Gate Coupler Board identified as WWI 97329100 01 substitute 00 with desired 72 lengt
86. ped off at the connection points a 2 milli Ohms connection or less is ideal In the absence of a milli Ohm or micro Ohm meter to actually measure the connection resistance the connections should be made suitable enough to support the cranking current required to start a car This means that the connection must be clean and free of paint and other debris The supply transformer frame drive cabinet panels and motor frame must be bonded together to provide a preferred path for high frequency noise Rockwell Automation Publication 23P UM001D EN P July 2012 45 Chapter 3 46 Gate Amplifier Installation and Wiring Key Grounding Bonding Points Outside of the Cabinet The high frequency grounding bonding outside of the cabinet should be treated in a manner similar to a power supply mounted on a ground plane with all of the components that it supplies mounted on the same ground plane In the case of the drive system the transformer can be thought of as the power supply for the downstream components AC entry bay drive cabinets and motors The high frequency grounding bonding of the components is effectively like mounting them on a virtual ground plane All components from the power transformer to the motor needs to viewed as a whole system All currents used to run the drives and motors originate at the power transformer As the power is being controlled by the drive system to regulate the amount of the energy supplied to the motor
87. r Module Bridge and Ground Terminal Specifications Wire Size Range Recommended No Terminal Description Maximum Minimum Torque V1 U1 AC Input Power o 25 0 mm 10 0 mm 40 4 5 Nem C1 D1 DC Output Power 2 AWG 10 AWG 35 4 39 8 Ibe in o to Motor Field PE Safety Ground 16 0 mm 10 0 mm 6 0 8 0 Nem o 6 AWG 8 AWG 53 1 70 8 Ibein 1 See Safety Ground PE on page 21 for more information Rockwell Automation Publication 23P UM001D EN P July 2012 AC DC Voltage and Motor Armature Voltage Feedback Wiring Stand Alone Regulator Installation Wiring and Configuration Chapter 2 Table 4 Recommended Field Power Module Bridge Input Fuses Fuse Type SAR Field Bridge Rating Bussmann Ferraz Shawmut Siba 40A FWP 50A22Fa A7008S50 22F 5014006 50 70A FWP 100A22Fa A7008100 22F 5014006 100 The recommended fuse holder is a Cooper Bussman CH222D or equivalent to accommodate 22 mm x 58 mm fuses Safety Ground PE The Safety Ground PE must be connected to system ground Ground impedance must conform to the requirements of national and local industrial safety regulations and or electrical codes The integrity of all ground connections should be periodically checked For installations within a cabinet a single safety ground point or ground bus bar connected directly to building steel should be used All circuits should be grounded independently and directly to this point bar The
88. rent by comparing its value with the reference command There are two on board burden resistor settings to choose from depending on the variables of the application In addition an optional external burden resistor may be used for very specific cases However consult with Rockwell Automation Development Engineering prior to using this option to ensure that the circuit board ratings as well the power dissipation ratings of the burden resistor are properly considered See Figure 11 on page 37 for details on the burden resistor circuit and Figure 13 on page 39 for burden resistor jumper locations Note The current limit of the on board burden resistors is 1 Amp This includes not exceeding 1 Amp for the internal burden resistors in the event of an instantaneous over current IOC For retrofit situations current transformers are often already in place on the L1 U and L3 W AC incoming line conductors to the power module However the secondary current rating of the current transformers may not be 1 Amp and not well suited for the current feedback scaling and burden resistors of the SAR For high current systems current transformers with 5 Amp secondary windings are not unusual These cases can be handled by using an interposing set of current transformers cascading the current transformers between the existing current transformers and the SAR The resulting turns ratio is the product of the existing current transformer s turns ratio multipli
89. rest integer To convert from decimal to the required binary value a calculator or personal computer can be used Rockwell Automation Publication 23P UM001D EN P July 2012 Stand Alone Regulator Installation Wiring and Configuration Chapter 2 SAR Current Feedback Calculation Examples Example 1 CT Burden Resistor and Gain Calculation Input Values Units Description IdN pm rtg 2600 Amp Power module rating Rb 5 0 Ohms Jumper J5 in the On position and jumper J4 in the Off position See Figure 13 on page 39 for jumper locations CT pri 10000 Amp CT sec 1 Amp Minimum CT Primary based on IOC trip point of 2 5 x Power Module rating Value Calculation Units Description IOC mult 2 5 CT pri min 0 85 is the ratio of AC to DC IOC mult x IdN pm rtg x 0 85 current CT pri min 5 525 x 10 Amp Based on IOC trip point CT ratio min based on ioc CT pri min CT sec CT ratio min based on ioc 5 525 x 10 Based on IOC trip point Maximum CT ratio based on Gain Range of Scaling Op Amp in the Current Feedback circuit Value Calculation Description CT ratio max 1 2 x IdN_rtg x Rb 0 612 CT ratio max 2 55 x 104 Based on Gain lt 1 2 Value Calculation Units Description Vf_at_IdN_pm_rtg 0 612 Volts Fixed Value CT ratio CT pri CT sec CT ratio 1 x 10 Ib at IdN pm rtg IdN pm rtg CT
90. rtg Vb at IdN pm rtg Gain Required 2 166 Rockwell Automation Publication 23P UM001D EN P July 2012 Note Required Gain 2 166 which is greater than the Recommended Gain lt 1 2 for best accuracy 33 Chapter2 Stand Alone Regulator Installation Wiring and Configuration Binary Gain Calculation and Checking Gain Error Binary Sw Setting 23 634 Value to use 24 Binary 11000 MSB LSB Bit Value B11 0 B10 0 B9 0 B8 0 B7 0 B6 0 B5 0 B4 1 B3 1 B2 0 B1 0 BO 0 DIP Switch SW3 1 SW3 2 SW3 3 SW3 4 SW4 1 SW4 2 SW4 3 SW4 4 SW4 5 SW4 6 SW4 7 SW4 8 Setting Off Off Off Off Off Off Off On On Off Off Off For DIP switch SW3 and SW4 layout refer to Table 14 Binary Gain Amp DIP Switch to Bit Layout on page 39 Resistor values are in K Ohms 1 B11 0 50 B10 1 9 2 B8 4 B7 8 B6 16 Bd 32 B4 64 B3 128 B2 256 B1 512 BO 1024 R_fdbk Value Calculation Units Description R_fdbk 42 667 R_input 20 Fixed input resistor Gain_Binary_OA R_fdbk R_input Gain_Binary_OA 2 133 versus Gain_Required 2 166 Comparing the Binary Gain Amp to the Calculated Required Gain Per Cent Gain Error Gain Binary OA Gain Required Gain Required x 100 Per Cent Gain Error 1 525 The error exceeds 196 The application will work but it is not optimal
91. s Gate Amplifier 2of2 55 Chapter3 Gate Amplifier Installation and Wiring Figure 23 Cascading Gate Amplifiers Using the SD3000 PLUS PFDC Gate Input To Forward Power Modules From Gate Amplifier FWD Ouiput To Reverse Power Modules From Gate Amplifier FWD Output Cables REV Output SD3K CBLGSCLIFxxx 120VAC rgs PIS Gate Amplifier 1 of 4 D3000 PLUS To Gate Amplifier 1 of 4 SD3K FWD Input 9 y To Gate Amplifier o 2 of 4 SD3K FWD Input O o z To Gate Amplifier E gt 3 of 4 SD3K FWD Input G sa 7 he o To Gate Amplifier ate Ampittier 4 of 4 SD3K FWD Input To Gate Amplifier 1 of 4 SD3K REV Input To Gate Amplifier 2 of 4 SD3K REV Input PFDC To Gate Amplifier Gate Input 3 of 4 SD3K REV Input C NX T To Gate Amplifier To Forward 4 of 4 SD3K REV Input Power Modules ta REV Output Cables Caution Do NOT use the external power supply Ext P S SD3K CBLGSCLIRxxx From Gate Amplifier when the gate pulse output is connected to the input of a FWD Output To Reverse downstream Gate Amplifier s Only use the external power Power Modules supply on a final stage Gate Amplifier s that provides the
92. sent at the power input terminal if the GPS LED is not illuminated LPS The 5V Logic Power Supply voltage is derived from the 28V Gate power supply If the 28V Gate power supply power is not present the logic power supply LED will not be illuminated Rockwell Automation Publication 23P UM001D EN P July 2012 49 Chapter 3 50 Gate Amplifier Installation and Wiring GATE FUSE OK The GATE FUSE OK LED circuit is used to monitor the fuse for the external power supply To sense whether the fuse is open the voltage across the fuse is monitored If the fuse is open and the Gate Amplifier is provided with gate firing pulses the GATE FUSE OK LED will turn off and the Ready Relay will drop out The fuse is internal to the Gate Amplifier and is soldered to the Gate Driver Output board it is not replaceable in the field GATE POWER The Gate Power function also picks up the Ready relay The Ready relay is a Double Pole Single Throw relay One set of the Normally Open contacts provides the power connection for the Gate Power LED and the second pair of Normally Open contacts provides the Ready relay contacts for the drive control interlocks POWERFLEX DC SAR GATE INPUT Input for the PowerFlex DC Stand Alone Regulator SAR gates includes both forward and reverse gates at this connector Note The D3000 PLUS ports cannot be used at the same time as the SAR port SD3000 PLUS FWD GATE INPUT Input for the SD300
93. t Voltage Control Supply Input Current Environmental Operating Temperature Storage Temperature Relative Humidity Appendix A 100VAC 460VAC 10 50 60 Hz 115VAC 1AAC or 230VAC 0 5AAC 0 C to 50 C 32 F to 122 F 25 C to 55 C 13 F to 131 F 596 to 9596 Non condensing Note Contamination from oils corrosive vapors and abrasive debris must be kept out of the enclosure Power Dissipation Power Bridge AC Total Watts Catalog Input Field Ratings Loss Number Vac Input Vac Input Aac Output Apc W 23PMD4 230 to 500 230 to 460 40 40 303 23PMD7 230 to 500 230 to 460 70 70 357 23PMF4 575 to 690 230 to 460 40 40 374 23PMF7 575 to 690 230 to 460 70 70 428 Electrical Control Input Replacement fuse Environmental Operating Temperature Storage Temperature Relative Humidity 120VAC 10 1 9 A 47 63 Hz Littelfuse 312005 5 A 250VAC 3AG Time Delay or equivalent 0 C to 50 C 32 F to 122 F 40 C to 70 C 40 F to 158 F 5 to 95 Non condensing Note Contamination from oils corrosive vapors and abrasive debris must be kept out of the enclosure Rockwell Automation Publication 23P UM001D EN P July 2012 n AppendixA Specifications Hardware Descriptions The following table provides a functional description of each printed circuit board and component of the Gate Amplifier Table 27 Printed Circuit Board and Compon
94. t panels 47 cable size 47 Gate Amplifier 46 humidity Gate Amplifier 41 I 1 0 wiring Stand Alone Regulator 26 input fuses field power module bridge SAR 21 input power terminal block Gate Amplifier 44 internal power supply Gate Amplifier 72 L line fuse Gate Amplifier 72 load sharing 65 Logic power supply 49 LPS LED 49 Main board Gate Amplifier 72 motor armature voltage feedback SAR connections 23 motor field current SAR configuration 26 motor thermistor Stand Alone Regulator 26 mounting Gate Amplifier 42 Gate Scaling Module 76 Stand Alone Regulator 14 mounting clearances Gate Amplifier 42 Stand Alone Regulator 14 mounting hardware Gate Amplifier 43 Gate Coupler Assembly 75 Gate Scaling Hardware 77 Stand Alone Regulator 15 0 operating temperatures Gate Amplifier 41 Gate Coupler Assembly 73 Gate Scaling Module 76 Stand Alone Regulator 13 P parallel power modules load share reactors 65 parameter configuration Stand Alone Regulator 40 PE terminal Stand Alone Regulator 20 phase sequence and armature SCR firing order 65 power connections Gate Amplifier 44 power dissipation Stand Alone Regulator 71 power module thermal switch SAR connections 24 power modules Dierikon 64 Reliance Electric 61 Rockwell Automation 58 PowerFlex DC SAR gate input 49 50 RDY 49 reactors load sharing 65 ready relay 49 Gate Amplifier 44 interlock 51 Rockwell Automation Publication 23P UM001D EN P
95. th for electrical noise Welding cable is needed for grounding bonding where high frequency noise currents are present Table 10 Recommended Welding Cable for High Frequency Grounding Bonding on page 47 provides an overall guideline for the wire size to use for the high frequency bonding between the major system components shown in Figure 18 DC Drive High Frequency Grounding Bonding Configuration on page 47 Rockwell Automation Publication 23P UM001D EN P July 2012 Gate Amplifier Installation and Wiring Chapter 3 Table 10 Recommended Welding Cable for High Frequency Grounding Bonding Drive System Nominal Recommended Welding Motor FLA Per Section Cable Size Cable Type 100 3000 Amps 2 0 Anixter 5J 2021 or Equivalent 3001 5000 Amps 3 0 Anixter 5J 3031 or Equivalent 5001 9000 Amps 250 MCM Anixter 5J 2501 or Equivalent 9001 20000 Amps 500 MCM Anixter 25 5001 or Equivalent DC Drive High Frequency Grounding of Adjacent Cabinet Panels Unless there is good continuity from panel to panel the potential between the panels will be different Notes on cabinet grounding This grounding scheme is for high frequency grounding only The customer is responsible for all safety grounds and meeting local and state equipment grounding codes Ifthe DC Drive Regulator components are mounted to a sub panel then there must be a 1 0 Welding cable ground jumper between the sub panel and the main cabinet
96. tion Vf at dN pm rtg 0 612 Units Volts Based on Gain lt 1 2 Description Fixed Value CT ratio CT pri CT sec CT ratio 2 x 10 Ib at IdN pm rtg IdN pm rtg CT ratio lb at IdN pm rtg 0 113 Amps Vb at IdN pm rtg IN pm rtg CT ratio x Rb Rockwell Automation Publication 23P UM001D EN P July 2012 35 Chapter 2 36 Stand Alone Regulator Installation Wiring and Configuration Value Calculation Vb at ldN pm rtg 0 565 Units Volts Description Gain Required Vf at IdN pm rtg Vb at IdN pm rtg Gain Required 1 083 Note Required Gain 1 083 which is within the Recommended Gain lt 1 2 for best accuracy Checking the Maximum Voltage Feedback to Regulator Value Calculation Units Description Binary Sw Setting 51 2 Gain Required Binary Sw Setting 47 268 Ib at IOC IQN pm trg x IOC mult CT ratio Ib at IOC 0 282 Amps Vb at IOC ION pm rtg x IOC mult CT ratio Vb at IOC 1 412 Volts V curr fdbk to reg at lOC Gain Required x Maximum allowable value of Vb at lOC V curr fdbk to reg at IOC 2 5V V curr fdbk to reg at lOC 1 53 Volts Binary Gain Calculation and Checking Gain Error Binary Sw Setting 47 268 Value to use 47 Binary 101111 MSB LSB Bit Value B11 0 B10 0 B9 0 B8 0 B7 0 B6 0 BS 1 B4 0 B3 1 B2
97. ual Reference this appendix if you need information to determine what changes have been made across multiple revisions This may be especially useful if you are deciding to upgrade your hardware or software based on information added with previous revisions of this manual Topic Updated Figure 4 Typical Stand Alone Regulator Interface to S6R Power Module to reflect corrected motor armature voltage feedback connections Updated the Connector KA Wiring section to reflect corrected motor armature voltage feedback connections Updated the Binary Gain Calculation and Checking Gain Error sections for each of the SAR Current Feedback Calculations examples Added Figure 14 Binary Gain Amp DIP Switch to Bit Layout for clarification Updated the wire length specification for an external power supply and removed the recommended power supply part numbers Topic Updated the Preface to include information on the PowerFlex DC Stand Alone Regulator SAR Updated the Introduction to include information on the SAR Changed Chapter 2 to be Installation of the SAR Changed Chapter 3 to include all Gate Amplifier installation instructions Updated the Chassis Grounding information for retrofits involving the Gate Amplifier Updated all drawings in new Chapter 3 to reflect SAR connections Added Chapter 5 to capture information specific to the power interface and SCR firing order Updated Appendix
98. ules are placed in parallel load share reactors must be in place on the AC side of the power modules on each of the phases see Figure 20 on page 53 The purpose of the load share reactors is to ensure that any one of the group of parallel power modules does not take up more than its share of the load When one of the parallel legs of the power module circuit has an increase in current an increased voltage drop will appear across the load share reactor in that leg of the circuit The increased voltage drop of the reactor will result in a reduced current in that leg of the circuit The reactors provide a self regulating passive means to ensuring balance of current between the parallel power modules The inductance of the load share reactors is typically 3 5uH For retrofit situations the site review must cover this issue For new installations the reactors need to be included in the order If reactors are not used then current sharing cannot be expected to work effectively As Thyristors SCRs increase in temperature from additional current their voltage drop may actually decrease due to their construction as two bipolar transistors parallel bipolar transistors do not share load very well unless they are matched This causes less voltage drop to occur across the SCR and thus more current will result in that leg of the circuit and the SCR could ultimately fail due to a condition termed thermal runaway Table 25 Phase Sequence
99. uly 2012 37 Chapter2 Stand Alone Regulator Installation Wiring and Configuration Figure 12 Binary Gain Amplifier Circuit Diagram P r SW3 MSB ue ES 500 A 1K l 3K i pr r SW4 b l 8K eet b 2 eK 3K I I L 1 7 4 Bak b lo 18K 7 256K I 512K 1 I 1024K i LSB ovi OVI 38 Rockwell Automation Publication 23P UM001D EN P July 2012 Stand Alone Regulator Installation Wiring and Configuration Chapter 2 Figure 13 Burden Resistor Jumpers J4 and J5 Binary Gain Amp DIP Switches SW3 and SW4 and External Burden Resistor Terminal Block XCT Locations Pulse Transformer Board
100. um rtp edu eed te mes E x ay Eee ut o Reed 83 Rockwell Automation Publication 23P UM001D EN P July 2012 Purpose of This Manual What This Manual Contains Drawing Numbers Additional Resources Preface This manual provides installation instructions and connection and configuration information for the PowerFlex DC Stand Alone Regulator SAR and the Gate Amplifier It is intended for internal Rockwell Automation use only This user manual contains the following sections Description of the SAR and Gate Amplifier products and general integration information Installation connection and configuration instructions for the SAR Installation and connection instructions for the Gate Amplifier Guidelines for retrofit installations with DC power modules SARand Gate Amplifier specifications Specifications for additional components and cables used with the SAR and Gate Amplifier products Throughout this manual drawings are identified by an eight digit number for example 99999999 Where a drawing number includes an asterisk in the 8th digit the represents the latest version number of the drawing for example 999999 These documents contain additional information concerning the PowerFlex DC Stand Alone Regulator and related Rockwell Automation products Resource Description PowerFlex Digital DC Drive User Manual publication 20D UM001 Provides additional installation configuration and programmin
101. werFlex DC SAR Gate Output to Gate Amplifier cable 23PAMP C PN 54636 10 feet 120 inches PowerFlex DC SAR Gate Output to Gate Amplifier cable 15 PIN D Shell Low Density Female 10 Conductor Shielded Cable 25 PIN D Shell P di Low Density Female Strain Relief l Strain Relief ln This end connects on the PowerFlex to the 15 PIN D Shell connector labeled KPT11 DC Stand Alone Regulator This end connects to the 25 PIN D Shell connector labeled PFDC Gate Input on the Gate Amplifier 23PAMP C CT060 PN 92598 5 feet 60 inches Legacy power module to SAR current feedback cable 23PAMP C CT096 PN 92599 8 feet 96 inches Legacy power module to SAR current feedback cable 23PAMP C CT120 PN 92601 10 feet 120 inches Legacy power module to SAR current feedback cable Picture Details m lt R om NS PWR MOD PFDC SAR This end connects to a legacy power module to acquire current feedback from the internal CTs on the SAR unit Rockwell Automation Publication 23P UM001D EN P July 2012 This end connects to the current feedback terminal 81 AppendixA Specifications Notes 82 Rockwell Automation Publication 23P UM001D EN P July 2012 Appendix B 23P UM001C EN P September 2011 23P UM001B EN P April 2011 History of Changes This appendix summarizes the revisions to this man
102. y A desiccant packages from the enclosure before mounting and energizing the SAR Dimensions are shown in mm in 23 3 8 4 0 33 gt 250 0 9 84 gt 0 92 28540144 gt A 55555386555 E A 19 5 0 77 275 0 397 9 Ma l HUM fo 15 67 e 341 0 oe 13 43 E un x BECDPEREPET Y Le eJ ere LP Y 4 BI HEAT o 266 8 10 51 Table 1 Stand Alone Regulator Weights Stand Alone Regulator Stand Alone Regulator and Packaging 12 0 kg 26 5 Ib 14 1 kg 31 Ib Recommended Mounting Hardware Metric M6 English 1 4 in IMPORTANT Provide a minimum of 150 mm 6 0 in below the unit for cable connections Rockwell Automation Publication 23P UM001D EN P July 2012 15 Chapter2 Stand Alone Regulator Installation Wiring and Configuration CE Conformity 16 Conformity with the Low Voltage Directive and Electromagnetic Compatibility Directive has been demonstrated using harmonized European Norm EN standards published in the Official Journal of the European Communities The PowerFlex DC Stand Alone Regulator co

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