About the PGA Power Supply Module
Contents
1. 5 4 Figure 5 3 Location of Power Supply Ground Terminal and Four Slot Rack Grounding Lg 5 5 Figure 5 4 Location of Power Supply Ground Terminal and Eight Slot Rack Grounding 40 5 5 Figure 5 5 Gate Driver Plug for Cable Assemblies 612436 and 612567 5 9 Figure 5 6 PGA System Hardware Connections 5 10 Table of Contents Parallel Gate Amplifier Table 1 1 Parallel Gate Amplifier System Configurations 1 3 Table 1 2 DPS Documentation ss 1 4 Table 5 1 Input Power Connections 5 7 Table 5 2 Connection Sequence for Cable Assemblies 612436 and 612567 5 9 Parallel Gate Amplifier Parallel Gate Amplifier Introduction The Parallel Gate Amplifier PGA system is used to amplify and distribute the gate pulse signals produced by the AutoMax Distributed Power System s DC Power Technology module It can be used with multiple Reliance Power Modules or with certain other vendor Power Modules Please contact Reliance regarding the suitability of other vendor Power Modules for use with the PGA system The system is comprised of three major components the PGA Rack Backplane the Power Supply module and the PGA modules The Power Supply and PGA modules reside in a modular rack of either four slots or eight slots The four slot rack ho2. ELECTRICHE Distributed Power System SD3000 SF3000 Parallel Gate Amplifier System Instruction Manual S 3045 2 Rockwell Throughout this manual the following notes are used to alert you to safety considerations Important ATTENTION Identifies information about practices circumstances that can lead to personal injury or death property damage or economic loss Identifies information that is critical for successful application and understanding of the product ATTENTION Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this equipment Read and understand this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily inury or loss of life ATTENTION The user must provide an external hardwired emergency stop circuit outside of the drive circuitry This circuit must disable the system in case of improper operation Uncontrolled machine operation may result if this procedure is not followed Failure to observe this precaution could result in bodily injury ATTENTION Inserting or removing a module or its connecting cables may result in unexpected machine motion Turn off power to the rack before inserting or removing a module or its connecting cables ATTENTION The user is responsible for conforming with all appl
3. 1 7 Introduction 1 8 Parallel Gate Amplifier About the PGA Rack 2 1 2 2 The PGA rack provides the mechanical means for mounting the Power Supply module and the PGA modules The following sections provide mechanical and electrical descriptions of the rack PGA Rack Mechanical Description The PGA rack consists of a sheet metal card cage type enclosure and a backplane The backplane contains a proprietary parallel bus with DIN style connectors in each slot for the modules The leftmost slot is provided for the Power Supply module The remaining slots are provided for the PGA modules The four slot version of the rack see figure 5 1 has three identical 48 pin backplane connectors one for the Power Supply module and two for PGA modules The eight slot version see figure 5 2 has seven identical 48 pin backplane connectors one for the Power Supply module and six for PGA modules The Power Supply connector in each rack is vertically offset so that the Power Supply and PGA modules cannot accidentally be interchanged The PGA rack must be installed within 18 3 m 60 ft of the drive s DC Power Module to ensure the integrity of the Power Module interface signals The rack is designed to be panel mounted Mounting holes are provided on the flanges that extend above and below the rack A grounding lug is provided on the bottom mounting flange The rack s fan assembly is mounted on the bottom of the rack Rack installation is
4. 3 Location of Power Supply Figure 5 4 Location of Power Supply Ground Terminal Ground Terminal and Four Slot Rack and Eight Slot Rack Grounding Lug Grounding Lug Installation Guidelines 5 5 5 4 5 5 Module Installation Replacement Guidelines ATTENTION Inserting or removing a module or its connecting cables may result in unexpected machine motion Turn off power to the PGA rack before inserting or removing a module or its connecting cables ATTENTION The modules in the Parallel Gate Amplifier rack contain static sensitive components Do not touch the module s circuit board or the connector on the back of the module When not in the rack the module should be stored in an anti static bag The Power Supply module must be placed in the leftmost slot in the rack The remaining slots are used for the PGA modules Observe the following guidelines when installing or removing a module Ensure that power to the rack as well as power to the wiring leading to the rack is off Use the metal guides provided in the rack to facilitate sliding the module into and out of the rack e Use care when inserting a module into the rack to avoid bending the connector pins Ensure that the module is well seated in the rack Use the thumbscrews provided at the top and bottom of the module faceplate to secure the module to the rack individual modules are not enclosed therefore module s circuit board is exposed whe
5. A A A A A A 805401 9AA 8 Slot PGA Rack w Fan Power Supply Output A B 805401 9BA 8 Slot PGA Rack w Fan Power Supply Output A A B 805401 9CA 8 Slot PGA Rack w Fan Power Supply Output A A A B 805401 9DA 8 Slot PGA Rack w Fan Power Supply Output A A A A B 805401 9EA 8 Slot PGA Rack w Fan Power Supply Output A A A A A B 805401 9AB 8 Slot PGA Rack w Fan Power Supply Output A B B 805401 9BB 8 Slot PGA Rack w Fan Power Supply Output A A B B 805401 9CB 8 Slot PGA Rack w Fan Power Supply Output A A A B B 805401 9DB 8 Slot PGA Rack w Fan Power Supply Output A A A A B B 805401 9AC 8 Slot PGA Rack w Fan Power Supply Output A B B B 805401 9BC 8 Slot PGA Rack w Fan Power Supply Output A A B B B 805401 9CC 8 Slot PGA Rack w Fan Power Supply Output A A A B B B 805401 9AD 8 Slot PGA Rack w Fan Power Supply Output A B B B 805401 9BD 8 Slot PGA Rack w Fan Power Supply Output A A B B B B 805401 9AE 8 Slot PGA Rack w Fan Power Supply Output A B B B B B 1 3 Related Publications This manual provides a description of each component of the Parallel Gate Amplifier system as well as installation guidelines Note that this instruction manual does not describe specific applications of the standard hardware Additional information about using the Parallel Gate Amplifier as part of an AutoMax Distributed P
6. PGA module has failed and must be A functional block diagram of the PGA module is provided in figure 4 2 Specifications are listed in Appendix C 4 2 Parallel Gate Amplifier Power Module Parallel Gate Amplifier Circuit Circuit Gate Circuit Circuit Circuit Circuit Gate Driver 6 P1 Connector Shown P2 P3 and P4 are identical to P1 Figure 4 1 PGA Gate Driver Circuitry About the PGA Module 4 3 ALVD SIVNOIS 3199 9 S IVNOIS 3179 WOOAS NOLLV IOSI 0140 31NION 12009 JI 1aow 95009 W 4 S1O8NAS 319 SIVNOIS 3109 8 AYOLOVA 193138 5 31V9 SIVNOIS ALVS V zl Figure 4 2 PGA Module Functional Block Diagram Parallel Gate Amplifier 4 4 Installation Guidelines ATTENTION Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this equipment Read and understand this manual and other applicable manuals in their entirety before proceeding ATTENTION The modules in the Parallel Gate Amplifier rack contain static sensitive components Do not touch the module s circuit board the connectors on the back of the module When not in the rack the module should be stored in an anti static bag This section provides guidelines for
7. described in chapter 5 Rack specifications are given in Appendix A PGA Rack Electrical Description The four slot and eight slot versions of the rack backplane differ only in the number of PGA modules they support The backplane provides power and ground and two identical channels A and B for gate signals Six gate signals run on channel A and six on channel B Each of the gate signals has an associated common signal The connection between the DC Power Technology module and the PGA Power Supply module determines whether the channel carries the forward or reverse gate signals see section 3 2 The gate signals run to the top portion of each 48 pin connector Four power and ground signals 5V DCBUS 5VCOM and DCCOM run to the bottom The power signals reside on the inside layers of the backplane s four layer printed circuit board The inner power plane shares both the 5V and DCBUS signals The inner ground plane shares the two commons 5VCOM and DCCOM A noise filter connects DCCOM to earth ground About the PGA Rack 2 1 Parallel Gate Amplifier About the PGA Power Supply Module Through its faceplate connectors the PGA Power Supply module 60055 provides the interface with the DC Power Technology module in the PMI rack The Power Supply module provides the gate signals and the DC voltages necessary for the proper operation of the PGA modules through the backplane of the PGA rack The following sectio
8. installing and replacing the PGA rack the modules and the cable assemblies This section provides general guidelines only Always refer to the wiring diagrams supplied with your system for specific installation information Wiring the PGA Rack ATTENTION The user is responsible for conforming with all applicable local national and international codes The user must ensure that the installation of wiring conforms to all applicable codes To reduce the possibility of noise interfering with the control system exercise care when installing wiring from the system to external devices For detailed recommendations refer to IEEE Standard 518 Installation Guidelines 5 1 5 2 Installing the PGA Rack The rack is designed to be panel mounted using M6 or 1 4 20 screws The holes in the top flange have a keyhole shape and the lower holes are U shaped to facilitate mounting Refer to figure 5 1 four slot rack or figure 5 2 eight slot rack for mounting dimensions Use the following guidelines when installing the PGA rack Ensure that there is enough space for the rack terminal strips and other devices that must be mounted near the rack Allow a large enough clearance around the rack to provide access for inspection maintenance and module replacement Allow 50 mm 2 in of clearance above and below the rack for ventilation Do not mount heat generating equipment underneath the rack Mount the rack in a verti
9. to full load Noise ripple 150 mV Efficiency 80 minimum Overcurrent protection Constant current above 50 Vout Current feedback below 50 Vout Holdover time 16 7 mS max load low line Optional External P S 2 Power Supply Ratings Input voltage 100 VDC max Input current 2 3A rms External fuse 10A 250V B 2 Parallel Gate Amplifier PGA Module Specifications Ambient Conditions Operating temperature 0 to 40 C 32 to 104 F ambient allowing for a maximum 20 C 36 F temperature rise inside enclosure e Storage temperature 30 to 85 C 22 to 185 F Humidity 5 to 95 non condensing Dimensions Height 205 mm 8 063 in e Width 35 mm 1 375 in Depth 174 mm 6 813 in Maximum Module Power Dissipation Maximum Module Power Requirements 28V Q Coupler Circuits Using 28V Supply B M O 60072 High Output Gate Driver Open circuit voltage Voc 12V nominal Short circuit current Isc 1000 mA nominal Isolation voltage 1200V B M O 60073 1 Open circuit voltage 12 nominal Short circuit current Isc 700 mA nominal Isolation voltage 1200V 1 Replaces O 51378 19 Coupler Circuits Using External P S 2 Supply Maximum Conditions e Open circuit voltage Voc 100V max Short circuit current Isc 1300 mA max PGA Module Specifications C 1 Number Power Boxes Permitted 4 Boxes per PGA Module PGA Output Loading v
10. used The power supply s output current must be limited to 10A To add the external supply to the system jumpers TB1 and TB2 on the Power Supply module s printed circuit board must be configured as described below Refer to figure 3 1 TBt1 Disconnect the jumper from the INTERNAL terminal the default setting Connect the jumper from COMMON to the EXTERNAL 2 terminal e TB2 Insert a jumper between the two terminals of TB2 EXT and P S The regulated external power supply should be mounted at an appropriate location as described by the manufacturer It should be connected to terminals P S 2 and COM on the Power Supply module s faceplate through an appropriate filter network as shown in Appendix E e Connect the regulated external power supply s positive output to terminal P S 2 e Connect the regulated external power supply s common to the COM terminal Connecting the PMI DC Power Technology Module to the PGA Power Supply Module For a regenerative drive both the forward and reverse gate signals from the PMI DC Power Technology module are connected to the PGA Power Supply module s faceplate connectors For a non regenerative drive only the forward gate signals are used The part numbers of the forward and reverse gate cables are stamped onto the cables and should be compared to the wiring diagrams shipped with your system Each cable has a 14 pin male connector on one end that mates with one of the DC Power Technology
11. Electrical Description The PGA module will input the gate signals from its designated channel A or B on the rack backplane The channel carries the forward or the reverse gate pulses depending upon the connection between the DC Power Technology module and the PGA Power Supply module as described in chapter 3 Other than channel selection both types of PGA module operate identically The incoming gate pulses from the six inputs on each channel are optically isolated from their respective biasing networks and FET gate firing circuits and physically isolated from the remaining circuitry on the Power Supply module backplane and PGA module Each of the PGA module s six FET outputs has a fan out of four providing each module with the capability of driving up to four power bridges A maximum of six PGA modules can be used in the system If all six PGA modules are used a total of 24 power bridges 6 x 4 can be driven Figure 4 1 shows one of the four gate signal outputs About the PGA Module 4 1 The standard DC bus voltage is 28 VDC but the PGA module is capable of handling DC bus voltages up to 100 if required by the application Voltages greater than the standard 28 VDC must be provided by an externally mounted power supply connected to the Power Supply module s 5 2 and COM faceplate terminals See chapter 3 The PGA module has one internal fuse The fuse is not user serviceable blown fuse indicates that the
12. External Supply Greater Than 28 VDC 5 7 5 5 3 Connecting the PMI DC Power Technology Module to the PGA Power Supply Module tense lt eee 5 7 5 6 Connecting the PGA Module to the Gate Coupling Circuits 5 8 Table of Contents Rack Specifications Ren 1 Power Supply Module Specifications B 1 PGA Module Specifications C 1 PGA Maximum System Power Requirements D 1 External PGA Power Supply Interface E 1 Replacement Parts agente niet eerte nea tte boite t Ve et e ten tte ten F 1 Parallel Gate Amplifier Figure 1 1 Four Slot PGA Rack and Modules Part No 805401 7 1 5 Figure 1 2 Eight Slot PGA Rack and Modules Part No 805401 9 1 6 Figure 1 3 PGA Parallel Motoring and Regenerating System Example 1 7 Figure 3 1 Power Supply Module Component Layout 3 3 Figure 3 2 Power Supply Module Functional Block 3 4 Figure 4 1 PGA Gate Driver Circuitry sis 4 3 Figure 4 2 PGA Module Functional Block Diagram 4 4 Figure 5 1 Four Slot PGA Rack Mounting Dimensions 5 3 Figure 5 2 Eight Solt PGA Rack Mounting
13. N431X3 VOd EN 3219 6 d 001 82 AlddNS H3MOd External PGA Power Supply 4 5 H3MOd 1 uo Sul 1 01 84 zSd YOLONANI E 1 External PGA Power Supply Interface Parallel Gate Amplifier Replacement Parts PGA Rack Backplane Part or Rack Assy Description Enclosure Fan Assembly Backplane 805401 6S 4 Slot PGA Rack Assembly with Fan 805400 R 805400 17R 805401 8S 8 Slot PGA Rack Assembly with Fan 805400 14R 805400 18R Modules Part or Assy Description 60055 PGA Power Supply Module 60056 Output A PGA Module O 60071 Output B PGA Module 707311 94R Blank Faceplate Assembly Connector Cables cable length xxx is specified in inches Base P N Description Connections 612432 xxxS0 Forward DC Gate Signals DC Tech Module P2 to PGA Power Supply Module P1 612433 1 Reverse DC Gate Signals DC Tech Module to PGA Power Supply Module P2 612434 xxxS 0 PGA Module Output A to DC Power Module Elco square receptacle 612435 3 Cable Assemblies 612436 612567 to Gate Coupling Circuits 612436 xxxS 2 PGA Module Output A to DC Power Module Cannon round receptacle 612566 xxxS 2 PGA Module Output B to DC Power Module Elco square receptacle 612567 xxxS 2 PGA Module Output A to DC Power Module Cannon round receptacle 1 Maximum length not to exceed 3 7 m 144 in 2 Maximum length no
14. and access to pair of normally closed contacts TW1 and TW2 for over temperature warning Terminal L1 is the connection for the AC hot input line Terminal L2 is the connection for the AC neutral input line These terminals are internally hardwired to the L1 and 12 terminals labeled 115 OUTPUT TO FAN The Power Supply module s ground terminal must be connected to earth ground in addition to the PGA rack s grounding lug ATTENTION Ungrounded equipment presents a shock hazard The ground terminal on the PGA power supply module and the grounding lug on the PGA rack are not connected together Connect both points to an external earth ground About the PGA Power Supply Module 3 1 3 2 PGA Power Supply Module Electrical Description The PGA Power Supply module includes an internal 28 VDC regulated power supply and a 28 volt to 5 volt DC to DC converter The internal regulated supply requires a 115 input Its output provides the DC bus power for the six FET gate firing circuits on each PGA module The internal regulated supply also powers the DC to DC converter which in turn generates the 5 VDC output necessary for the six biasing networks on each PGA module The Power Supply module also has provisions for interfacing with an optional externally mounted regulated power supply if the application requires a DC bus voltage greater than 28 VDC The Power Supply module will work with a regulated external supply
15. cal position only The cabling distance between the PGA rack and the Power Module must not exceed 18 3 m 60 ft Rack surrounding air temperature must be between 0 C 32 F and 60 140 F Relative humidity must be between 5 and 95 non condensing Surrounding air must be clean and dry e g free of flammable or combustible vapors chemical fumes oil vapor steam excessive moisture and dirt 5 2 Parallel Gate Amplifier 068 IN 30 1 1 1 1 1 4 1 UUOB OFUUTE LLO UWOB OFUWOD E 8T DIELEN EIN VIT TEE RELSAS uEBMOd GELNEIULSIQ 0 0 Figure 5 1 Four Slot PGA Rack Mounting Dimensions 012 07 148 gt lt 7 uupposuugest ET WUGZ OFWWOO FI 00 0 uu py DFWWGE 9 9 5 3 Installation Guidelines Srorest NE 161210062 FEN FEN EEE nn Sp ER E gt 08 0 90 81 BO0F6T L0E OSOFIE LLE OY OFITTIE 0028 08 0r00v G2 Ov 0F00 GE 80 0F S S NELLO ETE EN 54 RTT SERRHRBERRS Ce 9 nd Od Osa 9 sd Ohd 9 Tag 0r 0rE9 02 0rorcE 9 6520 00 62 0r 0 69 82 0
16. d by an external 8A line fuse on its faceplate and an internal 1A fuse at the input to the DC to DC converter The internal fuse is not user serviceable A blown internal fuse indicates that the Power Supply module has failed and must be replaced The temperature of the internal power supply is monitored by a thermostat If the temperature exceeds the rated operating level see Appendix B a set of normally closed contacts is opened The contacts are accessible to the user through faceplate connectors TW1 and TW2 Parallel Gate Amplifier BACKPLANE FACEPLATE 1 EXTERNAL e ap COMMON INTERNAL Default Move jumper to P S 2 position when using externol power supply EXT P S COM Add jumper when using external power supply Figure 3 1 Power Supply Module Component Layout About the PGA Power Supply Module 3 3 MONA IVLSOWYSAHL INODAS Ast NOISH3ANOO AS OL A82 OL LNO OL LNO AlddNS QNO H LHV3 STVNDIS 3179 STVNDIS 3459 Figure 3 2 Power Supply Module Functional Block Diagram Parallel Gate Amplifier 3 4 4 1 4 2 About the PGA Module The PGA module isolates and amplifies the gate signal pulses received from one of the two rack backplane channels or The type of PGA module used depends upon the channel it will access An Ou
17. has the following features Connects to DPS DC Power Technology module Capable of driving up to 24 six thyristor power bridges in parallel 144 gate coupling circuits Overcurrent protection provided by PCB fuses Overtemperature detection by NC faceplate contacts on Power Supply module Optical isolation of gate signals from biasing networks and firing circuits Physical isolation of gate signals from Power Supply and other circuitry Externally mounted 100 VDC power supply option UR CUR Recognized Related Hardware and Software The following related DPS components are available separately AutoMax Universal Drive Controller Power Module Interface rack and modules Fiber Optic Cables AutoMax Programming Executive software Parallel Gate Amplifier 805401 7R Table 1 1 Parallel Gate Amplifier System Configurations Reliance Part No Description 4 Slot PGA Rack w Fan Power Supply Output A 805401 7S 4 Slot PGA Rack w Fan Power Supply Output A A 805401 7T 4 Slot PGA Rack w Fan Power Supply Output A B 805401 9AX 8 Slot PGA Rack w Fan Power Supply Output A 805401 9BX 8 Slot PGA Rack w Fan Power Supply Output A A 805401 9CX 8 Slot PGA Rack w Fan Power Supply Output A A A 805401 9DX 8 Slot PGA Rack w Fan Power Supply Output A A A A 805401 9EX 8 Slot PGA Rack w Fan Power Supply Output A A A A A 805401 9FX 8 Slot PGA Rack w Fan Power Supply Output
18. icable local national and international codes ATTENTION The modules in the Parallel Gate Amplifier rack contain static sensitive components Do not touch the modules circuit boards or the connectors on the backs of the modules When not in the rack modules should be stored in anti static bags The information in this user s manual is subject to change without notice Reliance and AutoMax are trademarks of Rockwell Automation 1997 Rockwell International Corporation Introduction 14 Standard Features 2 1 2 1 2 Related Hardware and Software 1 2 1 3 Related Publications ss 1 4 About the PGA Rack 2 1 PGA Rack Mechanical Description 2 1 2 2 PGA Rack Electrical Description 2 1 About the PGA Power Supply Module 3 1 PGA Power Supply Module Mechanical Description 3 1 3 2 PGA Power Supply Module Electrical Description 3 2 About the PGA Module 4 1 PGA Module Mechanical Description 4 1 42 PGA Module Electrical Description 4 1 Installation Guidelines 5 1 Wiring the PGA Rack iii 5 1 5 2 Installing the PGA Rack sr 5 2 5 3 Grounding Considerations 5 5 54 Module Installation Replacement Guidelines 5 6 5 5 Installing the PGA Power Supply Module 5 6 5 5 1 Connecting AC Input Power 5 7 5 5 2 Installing an Optional
19. lds the Power Supply and one or two PGA modules figure 1 1 The eight slot rack holds the Power Supply and one to six PGA modules figure 1 2 Two channels A are provided for gate signals on the rack s backplane Channel A is used for forward gate signals and channel B for reverse gate signals To connect to the two channels two types of PGA modules are used The Output A PGA module is used to access the signals from channel A The Output B PGA module is used to access the signals from channel B The two types of modules are not interchangeable but may be combined in the rack as needed to meet the requirements of the application The amplified PGA output signals drive the gate coupling circuits in the DC Power Modules Each PGA module can simultaneously drive four six thyristor power bridges in one direction either forward or reverse With the maximum of six PGA modules used in the system a total of 24 power bridges 6 x 4 can be driven The PGA s standard DC bus voltage is 28 VDC but the PGA module is capable of handling DC bus voltages up to 100 VDC if required by the application Voltages greater than the standard 28 VDC must be provided by an externally mounted power supply as described in chapter 3 The available PGA configurations are listed in table 1 1 A two card PGA parallel motoring and regenerating system example is shown in figure 1 3 Introduction 1 1 1 1 1 2 Standard Features The PGA system
20. module s faceplate connectors The connectors contain key pins to ensure that the forward and reverse cables are not connected to the wrong signals Near the connector each cable is normally labeled C4 Pn where n is the DC Power Technology module s connector number For example the forward gate signal cable labeled C4 P2 mates with the P2 connector Installation Guidelines 5 7 5 6 The other end of each cable has fifteen pin female D shell connector that mates with the faceplate connectors on the PGA Power Supply module The forward gate signal cable should be connected to Input and the reverse gate signal cable to Input Appendix F provides a list of the Power Supply module cables used with the PGA system Note that the Power Supply cable length must not exceed 3 7 m 12 ft Refer to the wiring diagrams supplied with your system for the connection instructions specific to your installation Connecting the PGA Module to the Gate Coupling Circuits The cables that are required for connecting the PGA modules to the gate coupling circuits are specific to your drive system Each cable is supplied with a 15 pin male D shell connector on one end that mates with the PGA module s faceplate connector The cable connectors are color coded black for Output A type PGA modules and gray for Output B type The other end of the cable is supplied with either a Cannon round connector plug cable 612436 612567 or an Elco squa
21. n it is out of the PGA rack Wear a ground strap and handle the module by the edges only When not in use the module should be stored in an anti static bag Installing the PGA Power Supply Module The following sections describe the input power and fan connections for the PGA Power Supply module and the cabling between the PGA Power Supply module and the PMI DC Power Technology module ATTENTION The PGA power supply module operates using AC input voltage capable of producing severe shock Make certain that the external AC supply circuit is turned off before inserting or removing the module or connecting any wires or cables Parallel Gate Amplifier 5 5 1 5 5 2 5 5 3 The 115 Input terminals on the Power Supply module must be wired to the power source using twisted pair wire Refer to table 5 1 when connecting AC input power to the Power Supply module Table 5 1 Input Power Connections Wire Color Wire Label 115VAC Input Red AC Line High L1 White AC Line Neutral L2 Green Earth Ground NOTE The PGA rack is shipped with the fan internally connected to the L1 and L2 terminals labeled 115 VAC OUTPUT TO FAN Installing an Optional External Supply Greater Than 28 VDC In the rare case that the 28 VDC supply does not supply sufficient power to fire the gate coupling circuits in the Power Module an external supply of up to 100 VDC may be
22. ng diagrams shipped with your system for the connection instructions specific to your installation The cable part numbers are stamped onto the cables and should be compared to those listed in the wiring diagrams Installation Guidelines 5 9 612432005 612433 5 PGA OUTPUT GATE CABLES jor 9 a 3 1 PGA OUTPUT GATE CABLES BELANGE Paratoi Gate Amplifier LECT T S6R TYPICAL CONFIGURATION UP TO 4 POWER MODULES 4 SLOT SHOWN 8 SLOT SIMILAR Figure 5 6 PGA System Hardware Connections 612436 5 MOTORING POWER MODULES 612567 5 REGEN POWERING MODULES 5 10 Parallel Gate Amplifier Rack Specifications Ambient Conditions Operating temperature 0 to 40 C 32 to 104 F ambient allowing for a maximum 20 C 36 F temperature rise inside enclosure Storage temperature 30 to 85 C 22 to 185 F Humidity 5 to 95 non condensing Rack Dimensions Four Slot Rack with Fan e Height 290 mm 11 5 in Width 180 mm 7 09 in Depth 184 mm 7 25 in Eight Slot Rack with Fan Height 290 mm 11 5 in Width 324 mm 12 75 in Depth 184 mm 7 25 in Bus Specifications Proprietary Fan Assembly 805400 17R four slot Rack 805400 18R eight slot Rack e vol
23. ns provide mechanical and electrical descriptions of the Power Supply module Component layout is shown in figure 3 1 A functional block diagram is shown in figure 3 2 3 1 PGA Power Supply Module Mechanical Description ATTENTION This equipment must be connected to a power source for which it was designed Verify that the available power is 115 volts AC 10 KVA maximum input source The PGA Power Supply module plugs into the leftmost slot of the PGA rack The module consists of an internal regulated power supply a printed circuit board containing a DC to DC converter and a faceplate The faceplate has two thumbscrews at the top and two at the bottom to secure the module in the rack The back of the module connects to the rack backplane Power Supply module specifications are given in Appendix B The faceplate of the module contains a green LED indicator two fifteen pin male D Shell connectors an 8A fuse and a ten point power connector The LED labeled PWR OK indicates that the module s 28 VDC and 5 VDC output voltages are present If either supply fails the LED will turn off The two D shell connectors labeled Input A and Input are used to connect the forward and reverse gate signals from the DC Power Technology module to backplane channels A and B The ten point power connector provides the 115 VAC input to the Power Supply module 115 VAC output to the rack fan connection to an optional external power supply
24. of up to 100 VDC The regulated external supply s current must be limited to 10 amps See section 5 5 2 and Appendices B and E for further information If a regulated external power supply is used two circuit board jumpers TB1 and TB2 have to be configured The regulated external supply is hardwired to the Power Supply module via the faceplate connector using terminals P S 2 and COM Jumper configuration and installation of the regulated external supply is described in section 5 5 2 The Power Supply module also has a provision for connecting to an optional externally mounted 28 VDC power supply via terminals P S 1 and COM This option is normally not used The Power Supply module must be configured for this option at the factory Both the regulated external power supply and the internal 28 VDC supply are referenced to the same negative point DCCOM accessible through the module s faceplate COM The 5 VDC output of the DC to DC converter has its own negative reference point 5VCOM The power and ground signals are transmitted to the PGA modules through the rack backplane In addition to powering the PGA modules the Power Supply module also receives the gate pulses from the DC Power Technology module in the PMI rack via cables connected to the two 15 pin D shell connectors Input A and Input B on its faceplate The gate signals are transmitted to the PGA modules through the rack backplane The Power Supply module is fuse
25. ower System is found in the instruction manuals prints and other documents shipped with each drive system Always consult the prints shipped with the drive system for specific mounting and connecting information about your drive The other instruction manuals located in binder S 3000 Distributed Power System DC Drive are listed in table 1 2 It is assumed that the user is familiar with these other manuals in S 3000 before using the PGA system Table 1 2 DPS Documentation Document Part Number Document SD SF3000 Binder S 3000 DPS Overview 5 3005 UDC Module S 3007 Fiber Optic Cabling 5 3009 Configuration and Programming 5 3006 for 503000 S 3036 for SF3000 Power Module Interface Rack and Modules S 3008 Diagnostics Troubleshooting and Startup Guidelines S 3011 Information Guide S 3012 1 4 Parallel Gate Amplifier PGA POWER SUPPLY 1900 MODULE OUTPUT A OUTPUT B OK 9 FUSE 250V 00000 O 00000 00000 00000 00000 115VAC INPUT 115VAC OUTRUT FAN 9 TEMPERATURE WARNING EXTERNAL POWER SUPPLY OPTIONAL sam 7 es 60055 60056 6007 1277717737 RELIANCE BE AUTOMAX DISTRIBUTED POWER SYSTEM Parallel Gate Amplifier RELANGE ELECTRIC Figure 1 1 Fo
26. re connector plug cable 612434 or 612566 to mate with the connector on the DC Power Module needed a cable 612435 with individual connectors for the six gate coupling circuits on the Power Module can be supplied as well This cable mates with the connector plug on the end of cable 612436 Output A or 612567 Output B Table 5 2 describes the gate signals that are transmitted via these cables The connector plug is shown in figure 5 5 Appendix F provides a list of the PGA cables that can be supplied with the system Note that the total cable length from the PGA module to the gate coupling circuit must not exceed 18 3 m 60 ft 5 8 Parallel Gate Amplifier Table 5 2 Connection Sequence for Cable Assemblies 612436 612567 From D Shell To Gate Driver Connector Pin Wire Color Plug Pin Thyristor 1 Gate 1 5 BRN 1 lt 15 WHT BRN 2 Thyristor 2 Gate 2 4 RED 3 DC Bus 14 WHT RED 4 Thyristor 3 Gate 3 3 ORG 5 DC Bus 13 WHT ORG 6 Thyristor 4 Gate 4 2 YEL 9 lt 12 WHT YEL 10 Thyristor 5 Gate 5 7 GRN 11 DC Bus 11 WHT GRN 12 Thyristor 6 Gate 6 1 BLU 13 DC Bus 6 WHT BLU 14 200 GATE DRIVER PLUG 6606006006 FRONT VIEW 1000007 eee PINS USED TOC C FEMALE CONTACTS Figure 5 5 Gate Driver Plug for Cable Assemblies 612436 and 612567 Figure 5 6 on the following page shows a typical example of PGA module cabling Refer to the wiri
27. s Temperature 25 20 75 4 Gate Coupler O 60073 RR 64 lt At Maximum Conditions Gate Coupler O 60072 10 20 30 40 50 60 Surrounding Temperature C Parallel Gate Amplifier PGA Maximum System Power Requirements 2 PGA MODULES POWER SUPPLY amp FAN 3 PGA MODULES 4 PGA MODULES 5 PGA MODULES 6 PGA MODULES PGA MODULES MAXIMUM SYSTEM POWER REQUIRED NOTE These values apply when using Reliance O 60073 gate coupling circuits Values may vary if using other gate coupling circuits PGA Maximum System Power Requirements D 1 Parallel Gate Amplifier Interface Q801 SSr6r YSTINNGISAM VOL LNNOW 89d 0018 WHIL V6lL vSv6v 1 9060091 39031311 INNON TANVd 9079 3504 9 79 9 979 01 Yat 3503419111 A00 VOL AVIA ANIL 00 SSVIO asna 5 9669 SEXSEINCOLNAOOZHIAM NOO Q3LINn A003U4 0001 93713 WNIV YOLIOVdVO As 0 6209 00r E1 NS NMOL V9 HNZ6 YOLONANI 144 N d SAW d34NLOVANNVN NOILdIH9S34 LNd3NOdWOO ONIBS33NION3 LN3INdO T3 A3G LINSNOO SI a3l3 dWNOO N338 13A LON SVH SLYVd ASSHL SNIVLNOO LVHL 0 1INOHI9 IVNNVWN SIHL JO ONILIHM AHL JO SV 410 7109 YIMOd dy vOg 39V4ua NI AlddNS H3MOd IV
28. t B PGA Module 1 1 4 1 parallel motoring regenerating example 1 7 PGA modules electrical description 4 1 functional block diagram 4 4 gate driver circuitry 4 3 mechanical description 4 1 PGA system 1 7 configurations 1 3 hardware connections 5 10 overview 1 1 Power supply external 3 1 5 7 E 1 requirements D 1 Power Supply module component layout 3 3 electrical description 3 2 functional block diagram 3 4 ground terminal 5 5 mechanical description 3 1 R Rack eight slot PGA rack and modules 1 6 eight slot PGA rack mounting dimensions 5 4 electrical description 2 1 four slot PGA rack and modules 1 5 four slot PGA rack mounting dimensions 5 3 grounding lug 5 5 mechanical description 2 1 Related hardware and software 1 2 Related publications 1 4 Replacement parts F 1 Index Index 1 5 Standard features 1 2 System power requirements D 1 T Technical specifications PGA module C 1 PGA rack A 1 Power Supply module B 1 Wiring See Installation Index 2 Parallel Gate Amplifier Rockwell Automation 24703 Euclid Avenue Cleveland Ohio 44117 216 266 7000 Rockuvell Printed in U S A S 3045 2 July 1999
29. t to exceed 18 3 m 720 in Wire lengths for each gate coupling circuit are specified in bill of material Maximum length not to exceed 3 m 120 in Replacement Parts F 1 Cable assemblies are available in the following standard lengths Cable Assy Length inches Part Number 612432 612432 0135 612433 612433 0135 612434 612434 0605 612434 0965 612436 612436 0605 612436 0965 612436 1205 612566 612566 0605 612566 0965 612567 612567 0605 612567 0965 612567 1205 Note that cable assembly 61235 does have defined standard length as its individual lengths of twisted pairs may all vary Parallel Gate Amplifier Cables cable assemblies 5 9 F 2 connector cables F 1 PGA module cables 5 8 5 9 F 1 Power Supply module cables 5 8 5 9 F 1 D DPS documentation 1 4 E External power supply installing 5 7 interface E 1 F Fuse PGA module 4 2 Power Supply module 3 2 G Gate coupling circuits 1 1 5 8 Grounding See Installation Input power connections See Installation Installation 5 1 to 5 10 AC input power 5 7 connecting to DC Power Technology module 5 7 connecting to gate coupling circuits 5 8 external power supply 5 7 grounding 5 5 guidelines 5 1 module installation replacement 5 6 mounting dimensions 5 3 5 4 PGA module 5 6 Power Supply module 5 6 rack 5 1 wiring 5 1 Output A PGA Module 1 1 4 1 Outpu
30. tage 115 10 103 126 Frequency 50 60 Hz 47 63 Hz Power Dissipation 14 11 W Rack Specifications A 1 Parallel Gate Amplifier Power Supply Module Specifications Ambient Conditions e Operating temperature 0 to 40 C 32 to 104 F ambient allowing for a maximum 20 C 36 F temperature rise inside enclosure Storage temperature 30 to 85 C 22 to 185 F Humidity 5 to 95 non condensing Maximum Module Power Dissipation e 30W Dimensions e Height 205 mm 8 063 in e Width 103 0 mm 4 055 in e Depth 178 8 mm 7 039 Maximum Source KVA 10 Short Circuit Limitation 10 000 VA Power Requirements e voltage 115VAC 10 103 126 VAC e Current 2 0A maximum Frequency 47 63 Hz Input protection Fuse 8 A fast acting Temperature Sensor TW1 TW2 Contact Ratings 115VAC 2A 47 63 Hz Power Supply Module Specifications B 1 DC Outputs 5 Volt supply Output voltage 5V 1 0 2 A 60 Line regulation 0 2 18V 36V Load regulation 1 0 to full load Noise ripple 75 mV Efficiency 78 Overcurrent protection Can sustain short circuit indefinitely Overvoltage protection Overvoltage clamping 6 2 6 5V Protection Fuse not user serviceable 28 Volt supply Output voltage 28V 5 0 9 40 C 0 4 4A 50 C 0 3 7A 60 C Line regulation 0 1 103 126 Load regulation 0 1 0
31. tput A PGA module B M O 60056 receives its signals from channel Output B PGA module O 60071 receives its signals from channel B The user must ensure that the correct type of PGA module is used for the channel desired Except for the interface to the rack backplane channels the two PGA modules are mechanically and electrically identical as described in the following sections PGA Module Mechanical Description The PGA module is a printed circuit board assembly that plugs into slot 3 or 4 four slot PGA rack or slot 3 to 8 eight slot PGA rack One or two modules can be used in a four slot rack Up to six modules can be used in an eight slot rack The two types of modules can be combined in any desired configuration Each module consists of a printed circuit board and a faceplate The top of the faceplate is labeled OUTPUT A or OUTPUT B to indicate which set of backplane signals the module will accept Thumbscrews at the top and bottom the faceplate secure the module in the rack The back of the module plugs into the rack backplane The faceplate contains a green OK LED indicator and four fifteen pin female D shell connectors The LED lights to indicate that the 5 VDC supply is present and the module is functioning normally The four fifteen pin D shell connectors are used to output the amplified forward or reverse gate signals from the PGA module to the gate coupling circuits in the Power Modules PGA Module
32. ur Slot PGA Rack and Modules Part No 805401 7T Introduction 1 5 PGA PGA PGA PGA PGA POWER SUPPLY MODULE MODULE MODUL MODULE MODULE MODULE OUTPUT A OUTPUT A OUTPUT B OUTPUT B OUTPUT B OK P1 FUSE TYPE 7 250V 3AG 8A L1 115VAC INPUT 115VAC 45 12 WT D a WARNING N C EN EXTERNAL POWER SUPPLY P S 2 OPTIONAL Ri ICE ea 7 7 60055 5 B M 600 B M 600 AUTOMAX Parallel date Amplifier 4 8 RELIANGE ELECTRIC Figure 1 2 Eight Slot PGA Rack and Modules Part No 805401 9CC 1 6 Parallel Gate Amplifier WIS 411515384 01 P N 4952 a3 Ud 54 CAT ASSY ASSY 4952 33 Dd 34 STWNOIS 3199 MIVA VOd IVA SIT HAT 14 1109 01313 S WNOSIS 3199 A38 SIYNDIS 31v9 SENI STWNDIS 3199 34 WOA 3130 3 81 ONISVHd 9113 STWNOIS 3199 A38 79 91 3199 J 9 171925 301SIS3Y 22981333 1424 N3NTUS3H a AS And SAIWAIDISNVAL 1 7 Figure 1 3 PGA Parallel Motoring and Regenerating System Example
33. v 0r00v2E Figure 5 2 Eight Solt PGA Rack Mounting Dimensions Parallel Gate Amplifier 5 4 5 3 Grounding Considerations ATTENTION Ungrounded equipment presents a shock hazard The ground terminal on the power supply module and the grounding lug on the rack are not connected together Connect both points to an external earth ground The ground terminal on the Power Supply module and the grounding lug on the rack are not connected Both points must be connected externally to earth ground and checked with an ohmmeter before power is applied Use a star washer toothed lock washer to ensure effective grounding Refer to figure 5 3 four slot rack or figure 5 4 eight slot rack for the location of the Power Supply module ground terminal and the rack grounding lug POWER SUPPLY MD a OUTPUT A PWR INPUT Pl A bend bed 2 TEMPERATURE WARNING N C EXTERNAL POWER SUPPLY OPTIONAL D 60055 B m 60058 7 6007 AUTOMAX Parallel Ampiitier 2 o BELANGE ELEGTRIGLE n Figure 5
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