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1. 3 4 Your 1650A DC Drive Figure 3 3 1650A DC Drive Schematic Sheet 2 1 1 v v CT 3 Continued 113 ontinued on Continued Next Page from Figure SP3 4 32 F20 A F2 F3 1 SP4 P4 3MOV ET L3A FCT 2 QO Continued on Next Page 0 09 mA 441 1612 9 9 e e ABC VAs VA Continued on Next Page TB5 F14 FIELD RANGE ED 43A Field FEEDBACK PCB 2 _ Hs 2 1 2 H1 H4 4 239 PT2 i A9 an n 43 138 1 02 4 FDBK FDBK Eu 24VD6 3 BURDEN 042 Jar X1 x2 BURDEN 1204 PWR SUPPLY RES RES Ouse 16 137825 ARM tH UNIT PWR SUPPLY A6 Gantinued on TPI TP2 TP4 3 30 Next Page H TP3 6 TPS gt 219 POWER STAGE 9 H ua 5 5 115V 2N ontinued on com e Next Page 12150 e 0 0 03 J 2 1395 MOTOR Le MOTO Continue
2. J10 Power Stage Interface Board Ji Unit Power Supply Board Configuration Field Pulse Transformer and Snubber Board CH1 CH1 zu Aare ee See I ee T PNOV i Option 14FX 3MOV zi 43A Field Field Bridge CN Bridge qe FCT 1 FCT 1 FAN 4 23 Gate Interface 4 23 1 FAN 4 gt rt Fr LL LI F15 F4 24V DC Supp 112131415 17 8 9 F20 m L mr s H Publication 2361 5 01 July 1998 1 8 Product Overview Publication 2361 5 01 July 1998 Power Stage Interface Board The power stage interface board is used as the chief interface between the main control board and other boards of the system This board is responsible for distributing power and control signals to and from the main control board gate interface board field pulse transformer board feedback board and unit power supply Refer to Figure 1 1 to see how this board is connected in the drive
3. 4 4 Your 3000A DC Drive Figure 4 3 3000A DC Drive Schematic Sheet 2 1 ACT 1 Continued 113 AGS Continued on from Figure 3 Next Page 20 FM F1 F2 F3 SP1 SP4 gt LIA 3M0V LBA FCT 2j Continued on Next Page i A e Deme 9 VA VA Continued on Next Page TB5 F14 FIELD RANGE Hl CI ai 904 Field FEEDBACK PCB m qu i ns an 2 Ei 2 H1 H4 J44 J39 PT2 m as TB2 J43 138 1 C2 4 FDBK TRIP Hm 24 0 3 BURDEN J42 337 1 2 PWR SUPPLY BURDEN RES RES Oy36 F16 137825 oap MM s UNIT PWR SUPPLY 6 Continued on J3A J3D 16 Next Page F4 TP3 Y TP6 TPS OR IS POWER STAGE N 12 12 INTERFACE PCB A7 1 J9 m r Continued on H 5 e 115V 24V B E e 4 00 02 03 Next Page 12100 2 cone Continued 15 IE 115V 24V from i 13787 01 02 03 12 J8 zr Fi
4. Continued from Previous Page Your 16504 DC Drive 3 5 M 24 2 2 4 B nm H 25 25 1 F12A F10A Continued from H H HH Previous Page im CH12 jeu CH15 F8B FOA FOB H HF7B DC MOTOR 2 2 Ek v E E E 95 2 A1 4 5 6F 5 2 SHUNT FIELD SCN NEE NSC F1 F2 F3 F4 PM1 2 HEATSINK zm Encoder FIELD PULSE Dual Out Example ARMATURE PULSE TFMR AND SNUBBER 1024PPR 1024PPR TFMR AND SNUBBER PCB AS TB3 qe 10785 1 TOTAL 12 COM COMMON COMMON J1 V 12 151 V 12 15V 12V U a oln H SIGNAL SIGNAL B 0 SIGNAL SIGNAL SIGNAL A SIGNAL A SIGNALA SIGNAL A mE SHIELD SHIELD J2 CONTROL PCB AB SYS CURR VEL PROC PROC PROC sp dum J5 m MOUNTED PROGRAMMING 18 TERMINAL PORT A PORT B 24V Out 12 24V ECOASTN male Vasen 24V ECOAST 10 EOOAST Ready2N Seiwa te a ee 8 Ready 1 7 Drive Ready Output 115V Common Out 6 115V 2 NN REI 115V AC Common 115V ECOAST1 115V ECOAST Reset In 3 Motor Temp In 2 24V DC or 115V Common In 1 Motor Thermostat Voltage Source Note More configurati
5. Symbol Description Option 460 575 660V A1 RES 1 PCB feedback scaling resistor 3 83 ohm 2 W 1 2 3MOV Field suppressors Al Feedback PCB A11F A16F Armature pulse transformer PCB A11R A16R Armature pulse transformer PCB Gate interface PCB A5 Field pulse transformer PCB Unit power supply PCB 7 Power stage interface PCB A8 Main control PCB Ag Feedback PCB power supply ACTI 3 Line current transducer 5000 1 AS5 6 Air flow sensor Y 500FPM C1 Armature snubber capacitors 2000V CB11 Circuit breaker Y 3000A SPB frame CH1 Field choke CH11 16 Cell chokes Solid core 3800 nH CR1 Field control D1 M1 bridge diode DHT DMT Configuration terminal Y EA2 Tachometer adapter scaling PCB EA3 DHT EHT configuration terminal Y EM Line RC suppressor Y EA5 Air flow sensor PCB Y F1 3 Control branch feedback PCB fuses 1A KTK 10A A70P F4 Terminal block control power fuse 9A KLDR F7 12 F A 12A Bridge cell fuses 900A 1250V 170M F14 15 PT2 control transformer primary fuses 10A KLDR F16 PT2 control transformer secondary fuses 5A KLDR F17 19 F27 29 Motor blower fuses Y 30A size 1 60A size 2 F20 21 Field fusing for 460V AC configuration 45A FRS Field transformer primary fusing for 575V AC 25A FRS configuration with 10kVA transformer Field transformer primary fusing for 575V AC Y 30A FRS configur
6. M1 M 3 phase Armature tu To DC AC Bridge m Motor MP E M1 X 115V AC bo 1 UN 185 3 12 10 9 6 PR 4 3 e e o4 Fa 1 6 J1 115VAC Gommon D 3 1 5 115VAC D 50 Note 24VDC must 6 not be used for any purpose other then ECOAST TP21 24VDC 183 ho 24V OUT 12 K3 pei 24 OUT O p olo 1 24V 24V DC 24 V ECOAST ECOAST 10 A optional oe F 24 V ECOAST READY FAULT2 External 8 Faub Ready READY FAULT1 Indication 7 115V COMMON OUT 115V AC Common 6 K1 115V ECOAST 2 5 ISO ECOAST T15V AN ECOAST i 115V ECOAST K2 Rogat 1 Reset In 3 Motor Temp In Voltage Source TUM 2 24V DC or Thermostat Common In 115V AC 1 24406 ENTERS A7 FAULTED J9 gt Power SYSTRIP SYSTRIP Stage DCPILOT DCPILOT Interface Publication 2361 5 01 July 1998 5 12 Installing Your Drive Publication 2361 5 01 July 1998 Table 5 M 115V AC Connections Rating A DC 115V AC Input Connections 1250 1650 3000 TB5 5 TB5 14 Table 5 N Terminals Used for External Control of Contactor Rating A DC External Control Connections 1250 1650 3000 TB5 9 to TB5 10 Note If an external control will be used remove the jumper across the terminals listed in the table above Table 5 P Torque Values Connections Torque 3 phase AC input L1
7. Publication 2361 5 01 July 1998 Appendix B Catalog Numbers and Spare Parts Kits Contents This appendix provides a description of catalog numbers and lists available spare parts kits Topic Page Understanding Catalog Numbers B 1 DC Drive Catalog Numbers B 3 DC Drive Spare Parts Kits B 6 Understanding Catalog Numbers Catalog numbers consist of various components that are used in a drive Each character of the catalog number helps identify a specific drive The first four numbers represent the family of products for example 2361 The remaining characters define a specific version or options Determining Catalog Numbers To help you to understand we will provide an example of how to determine a catalog number for a DC drive The beginning portion of the catalog number for high horsepower 1395 DC drive units would be 2361E or 2361F E for regenerative F for non regenerative The remaining portion of the catalog number will represent the options for which you need to make a selection The catalog number must appear in this order Regenerative Wiring Module AC Input Line Enclosure Trip Device Option Type Size Voltage Publication 2361 5 01 July 1998 2 Catalog Numbers and Spare Parts Kits Publication 2361 5 01 July 1998 For example if you were to use the table on the following page to select a drive that 15 aregenerative unit e supplies 100
8. A 5 Circuit Breaker Derating A 6 Input 5 7 a aca oa a A 9 Publication 2361 5 01 July 1998 toc iv Table of Contents Appendix B Catalog Numbers and Spare Parts Kits asado 8352325315 14043 4451454423224 594 B 1 Understanding Catalog Numbers B 1 Determining Catalog Numbers B 1 DC Drive Catalog B 3 DC Drive Spare Parts B 6 What Does a Spare Parts Kit Include B 6 Which Table Do I Use B 6 Significance of Level Numbers B 6 Definition of Terms Used to Describe Qty in Kit B 7 Catalog Number Description B 7 Publication 2361 5 01 July 1998 Contents Who Should Use This Manual Purpose of This Manual Preface Preface This preface will introduce you to the contents and purpose of this manual The following topics will be discussed in this preface Topic Page Who Should Use This Manual 1 Purpose of This Manual P 1 Safety Precautions P 2 Contents of This Manual P 3 Related Documentation P 4 Style of This Manual P 5 Terms and Abbreviations P 5 Receiving Your Drive System P 5 Rockwell Automation Support
9. 4 Rockwell Automation Bulletin 1395 U Ser Digital DC Drive in Bulletin 2361 M a n Motor Control Centers for Drive Systems 1250 1650 3000A DC Series C 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 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 be responsible or liable for indirect or consequential damages resulting from the use of 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 the Rockwell Automation cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation with respect use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part withou
10. 1 2 Hardware Overview 1 3 Control Boards 1 4 Main Control 1 5 Door Mounted Programming Terminal 1 6 Adapter Boards wal ax ow 1 6 Control Power Interface Boards 1 7 Power Stage Interface Board 1 8 Unit Power Supply Board 1 9 Feedback Board 1 10 24V DC Power 1 10 Gate Interface Board 1 11 Power Components 1 12 Incoming Power Components 1 12 Incoming Devices 1 12 AC Input Busbars 1 12 Main Disconnect Optional 1 12 AC Line Fuses Optional 1 12 Control and Field Power 1 13 AC Line RC Suppressor Optional 1 13 Publication 2361 5 01 July 1998 toc ii Table of Contents Chapter 2 Chapter 3 Chapter 4 Publication 2361 5 01 July 1998 Armature Power Components 1 14 Armature Bridge 1 14 DG Contactor 1 16 Field Power Components 1 17 F
11. 5 5V 660 V 40000 30000 20000 10000 Breaker Interupting Rating in Amps 0 0 5000 10000 15000 Altitude in Feet Figure 10 1650A DC Drive Breaker Derating 120000 100000 80000 480 V 5750 660V 60000 40000 20000 Breaker Interupting Rating in Amps 0 0 5000 10000 15000 Altitude in Feet Publication 2361 5 01 July 1998 Drive Specifications A 7 Input Busbars The AC input busbars are set up in the 1250 1650 and 3000A drives as shown in the following figures Figure 11 AC Input Busbars 1250A DC Drive Bus Dimensions lt 1 69 0 250 gt 4 4 0 87 Y 0 563 __ __ Diameter 1 750 Bus Arrangement QO 4 connections are O O O available for each phase Phase 1 Phase 2 Phase 3 L1 L2 L3 Important Ifthe AC line fuse option is selected for a 1250A unit 1650A busbars shown in Figure 12 will be equipped with the unit rather than the 1250A busbars Publication 2361 5 01 July 1998 8 Drive Specifications Publication 2361 5 01 July 1998 Figure 12 AC Input Busbars 1650A DC Drive Bus Dimensions 0 83 1 844 0 250 gt 4 4 0 88 0 563 Diameter 1 750 a Bus Arrangement CY Q 8 connections are available for each phase Phase 1 Phase 2 Phase 3 L1 L2 L3 Figure 13 AC Input Busbars 30
12. Table of Contents toc iii Installing Your Drive sa aan ara anna 5 1 Eden bee Da bee kur Rus ROS QUU Ro 5 1 Physically Installing the Drive at Your Site 5 2 Inspecting the Air Baffles 5 2 Preparing AC Input Entry 5 2 Installing and Configuring Your Drive 5 4 Drive Disconnect 5 4 Wiring Recommendations 5 4 Drive Grounding 5 5 Power Wiring 5 5 Field Transformer 5 6 Installing the Field Transformer 5 7 Circuit Board Jumper Connections 5 9 Armature Current Ratings 5 12 Starting Up Your Drive PERMIT 6 1 IRIOUUCHON Rc Rc SCR ee RR Bc OP Rp SCRIBE RC Dc 6 1 Voltage 6 1 Rated Armature and Field Currents 6 2 Drive Specifications B NIENIS 2252222222 535 1 General Specifications A 1 Unit Specifications A 2 Electrical Specifications A 3 Power Dissipation A 4 Circuit Breaker Settings
13. start up Information and installation instructions for the Bulletin 1395 Node Adapter Board Installation and 11395 5 9 1395 Node Adapter Board Operation Manual Information and installation instructions for the 1395 Discrete Adapter Board 1395 Discrete Adapter Board Installation and Operation Manual 1395 5 12 Information and installation instructions for the 1395 ControlNet Communication Board Bulletin 1395 ControlNet Communication Board User Manual 1395 5 37 Information and installation instructions for the 1395 Multi Communication Board Bulletin 1395 Multi Communication Board Hardware Software Reference Manual 1395 5 33 Information and installation instructions for the 1395 Digital Reference Adapter Board Bulletin 1395 Digital Reference Adapter Board Hardware Software Reference Manual 1395 5 55 A description of DriveTools software DriveTools Software Brochure 9303 1 0 Information on FD86N enclosures Standards for electrical procedures wiring sizes grounding etc FD86N Drive Systems Enclosure Hardware Installation Manual National Electrical Code Published by the National Fire Protection Association of Boston MA 5 3062 An article on safety procedures Standard for Electrical Safety Requirements for Employee Workplaces ANSI NFPA 70E A complete listing of current documentation Allen Bradley Publication Index 50499 including ordering instructi
14. 1 4 Product Overview Control Boards The control boards manage and control the system processing status information from system components and commanding drive components and activities Figure 1 2 Control Boards Main Control Board Adapter Boards TBi J2 O 40 50 TBI JO J30 J40 250 1 1 H 113 p anm J40 1 E TB3 J40 1 183 6 TBS Main Control Board behind adapter boards LJ CHI a Lj 1 1 TBl FCT H 1 1 TB2 14 15 Discrete or gt d Digital Communication d eile Reference Adap
15. This terminal has an LCD screen and a 24 key environment safe keypad Adapter Boards Optional adapter boards such as the discrete adapter board digital reference adapter board node adapter board and multi communication adapter board connect the drive to networks and provide I O capabilities Adapter board and programming terminal publications are listed in the preface of this manual Please refer to the appropriate manuals for more information Control Power Inte rface Boards Product Overview 1 7 Control power interface boards are used to provide a link between control boards which are responsible for managing the drive and power components which are closely associated with the actual drive hardware and operations The following items are used to provide this interfacing power stage interface board unit power supply board feedback board These items are located on the control module in the disconnect bay of the drive and are arranged as shown below Accessibility to the power stage interface board and the unit power supply is gained by lowering the front panel Figure 1 4 Control Power Interface Boards Feedback pard m Al lo o J40 1 EI Alternate Field Bridge
16. 1395 24V COMM 12 11 1 LOGIC 2 1 1 2 3 4 5 6 FAN 1 a pe 13 m n PILOT RELAY FAN 4 N gt lt Continued on Publication 2361 5 01 July 1998 Next Page Your 1250 DC Drive 2 5 Continued from Previous Page Continued Previous Page DC MOTOR ARM A2 A1 SHUNT FIELD F1 F2 F3 F4 Continued from 5 Previous Page PMI PM2 HEATSINK 2 Encoder N FIELD PULSE Dual Out Example PULSE AND SNUBBER 1024PPR 1024PPR PCB A5 1 TOTAL 12 COMMON COMMON V 12 15V V 12 15V 2 Gate Interface N Continued from PCB SIGNAL B SIGNAL Previous Page Uu SIGNAL B SIGNAL B SIGNAL A SIGNAL A K SIGNAL A SIGNAL A SHIELD SHIELD MAIN 12 CONTROL Continued from PCB AB n Previous Page SYS CURR VEL PROC PROC PROC D T T DOOR J5 u MOUNTED Continued from J7 16 PROGRAMMING Previous Page TERMINAL PORT POR
17. Catalog Numbers and Spare Parts Kits Table C Spare Parts Kits for RGUs with 660V AC Inputs Level Catalog Number Description Qty in Kit 1 2361 SPE05A Control Fuses No Field Voltage Step Down Option 1250 3000A DC units 2 sets 1 2361 SPEO6A Control Fuses Option 145028 1250 3000A DC units 2 sets 1 2361 SPEO6A Control Fuses Option 145040 1250 3000A DC units 2 sets 1 2361 SPEO7A Control Fuses Option 145090 1250 3000A DC units 2 sets 1 2361 SPE12A _ Fuses 1250A DC units 1 set 1 2361 SPE13A Fuses 16504 DC units 1 set 1 2361 SPE14A _ Fuses 3000A DC units 1 set 1 2361 SPMO1A Feedback Board 1250 3000A DC units 1 1 2361 SPMO3A Armature Pulse Transformer Board 1250 3000A DC units 1 1 2361 SPMO4A _ Pulse Transformer Board for Option 14FX 1250 3000A DC units 1 2 2300 Line RC Suppressor Option 14LSP 1250 3000A DC units 2 2300 5 Line MOVs 1250 3000A DC units 1 set 2 2300 SPJO4A Air Flow Switch PCB Kit Option 14AFL 3000A units N supply 1 1A 2300 SPPO1A Air Flow Switch PCB Kit Option 14AFL 1250 1650A DC units 1 1 power 2 supply 5A 2 2361 SPAO1A Positive Top Regenerative Armature Assemblies 1250A DC units 1 2 2361 SPA02A Negative Bottom Regenerative Armature Assemblies 12
18. DC Bus Current Incoming Wires A DC For Each Phase or Connection AWG 1250 4 500 kemil 1650 5 500 3000 8 500 Table 5 B Typical Wire Selections Armature Connection DC Bus Current Output Wires A DC AWG 1250 5 500 kemil 1650 6 500 3000 10 500 kemil Table 5 C Typical Wire Selections Field Connection DC Bus Current Output Lines Output Lines A DC 43A Field AWG 90A Field AWG 1250 8 4 1650 8 4 3000 8 4 Installing Your Drive Drive Grounding 5 5 The internal drive components should already be connected to the ground PE and zero potential TE buses Connect any additional items to PE and TE motor encoder etc as necessary and connect the PE and TE buses to ground as explained in publication 1395 5 40 Power Wiring Table 5 D Standard Field Voltage Output AC Incoming Voltage DC Supply Output To Drive V AC Voltage To Field V DC 460 300 575 300 660 300 Table 5 E Motor Connections for CCW Rotation Drive Terminal Connection Drive Motor Lead Connection Motor Field 1250 1650 3000A TB7 1 F1 TB7 3 F2 Motor Armature 1250 1650 3000A Al Al A2 A2 ATTENTION The motor field supply is phase sensitive To guard against possible drive or motor damage ensure that the connections comply to Figure 5 2 Publication 2361 5 01 July 1998 5 6 Installing Your Drive Figure 5 2 Power Connection
19. Drive Installation procedures and connection details 6 Starting Up Your Drive Information for starting up your drive A Drive Specifications Electrical environmental and operational specifications B Catalog Numbers and Spare Parts Kits Explanation of catalog numbers and listings of spare part kits Publication 2361 5 01 July 1998 4 Related Documentation For Information on the 1395 digital DC drives Several of the following documents will be needed to understand and install your drive and its components To obtain a copy of any Rockwell Automation publication please contact your local Rockwell Automation office or distributor Read This Document Bulletin 1395 Digital DC Drive User Manual Document Number 1395 5 40 Troubleshooting information for 1395 drives Bulletin 1395 Digital DC Drive Troubleshooting Manual 1395 5 45 Using the Bulletin 1300 programming terminal Bulletin 1300 Programming Terminal User Manual 1300 5 5 PLC 5 information PLC 5 Controllers Brochure 1785 1 2 Additional Information on joining and splicing Joining and Splicing Vertical Sections Instructions 2100 5 1 together MCCs Details on receiving handling and storing Receiving Handling and Storing Motor Control 2100 5 5 MCCs Centers Instructions Provides procedures for those tasks that need to be done at the customer s site before system Bulletin 2300 Installation Manual 2300 5 1
20. Figure 1 5 Power Stage Interface Board Connection to Unit Power Supply and TE Connection to Main Control Board ___ Connection to Main Control Board jg sp Connection to Connection to Field Transformer Feedback Board TP1 o 24V J3D Connections to Gate Interface Board Connection to Main Contactor Pilot Relay and Unit Power Supply 7 TP6 TPS Gnd 120 50 Connected to TB3 Standard Interface Connection to Unit Power Supply The test points and jumpers shown in the diagram used for startup and troubleshooting procedures Refer to the troubleshooting manual for more information on test points and jumpers Product Overview 1 9 The power stage interface board provides the following services between the main control board and other boards in the system e furnishes DC control power to the main control board from the unit power supply e provides 3 phase line synchronization signals to the main control board e accepts signals from the main control board and produces the logic and drivers for armature and field pulse transformers e accepts signals for start stop logic protection I O and drivers for operating the main DC contactor Unit Power Supply Board The unit power supply board converts 115V AC input into regulated 5V DC and 12V DC control voltages These control voltages are routed through the power stage interface board to
21. Input L3 to L1 Rated AC Input TB8 1 to TB8 2 Rated DC Field Output TB5 3 to TB5 12 115V AC 10 Main Control Board TP51 to TP52 5V DC 0 15V TP55 to TP57 12V DC 0 48V TP56 to TP57 12V DC 0 48V TP58 to TP53 5V DC 0 15V TP54 to TP53 12V DC 0 48V Power Stage Interface Board TP1 to TP7 24V DC 6V Armature and field current ratings are listed in the electrical specifications in Appendix A Contents General Specifications Appendix A Drive Specifications This appendix lists specifications for your drive The following topics are covered in this appendix Topic Page General Specifications A 1 Unit Specifications A 2 Electrical Specifications A 3 Power Dissipation A 4 Circuit Breaker Settings A 5 Circuit Breaker Derating A 6 Input Busbars A 7 Air Baffle Layouts A 9 The following table expresses the general specifications for the 1250 1650 and 3000A drives Table A General Specifications Subject Specifications AC Input Frequency Tolerance 50 60Hz 3Hz AC Input Voltage Tolerance 10 150 maximum DC bus current for 60 seconds Overload Capability 200 for 10 seconds 260 for 5 seconds following continuous operation Overload Duty Cycle 1 minute out of 20 minutes at rated load and temperature Minimum Continuous Load Requirement 33 of rated DC bus continuous current Operating Altitude Up to 1000 meters 3 300 feet Ambient Temperature O
22. Input Voltage The feedback board has terminals for the 3 phase AC inputs A B and C and for the armature power and a series of jumper connections to adjust for AC input voltage jumper connections for the field current a bus connection to the power stage interface board two terminals blocks for placing burden resistors in parallel to the circuit and a Phoenix connection terminal block connected to other drive components Note Jumper settings are defined in the installation chapter of this manual 24V DC Power Supply There are three 24V DC power supply units that may be installed in the drive There is a feedback board supply an optional air flow sensor supply and an optional control board supply used to power an optional adapter board These supply units are fed from the 115V AC control power circuit Publication 2361 5 01 July 1998 Product Overview 1 11 Gate Interface Board The gate interface board is the junction between the power stage interface board and the individual armature pulse transformer boards This board has four bus connections to the power stage interface board and four Phoenix terminal blocks distributing signals to the armature pulse transformer boards Figure 1 8 Gate Interface Board Connections to Power Stage
23. enabled by the field pulse transformer board Field Pulse Transformer Board The field pulse tranformer board provides the necessary gate voltage and current to trigger the SCRs on This board uses a resistor capacitor arrangement to protect the SCRs from rapid voltage changes Figure 1 13 Field Pulse Transformer Boards Connection to Power Stage Interface SCR Gate Pulses 2 C3 M 9 2 622 621 611 bt Connection to SCRs Connection to SCRs in PM1 of Field Bridge in PM2 of Field Connection to Power Stage Option 14FX Interface SCR Gate Pulses 08 peo 07 C3 Ti R4 2 R13 TI T2 2 in PM1 of Field Bridge Publication 2361 5 01 July 1998 eim Connection to SCRs in PM2 of Field Connection to SCRs Input Voltage VAC Nominal Output HP 460 700 750 575 750 900 660 750 1000 Contents Introduction Chapter 2 Your 1250A DC Drive This chapter is designed to help you understand the construction of your 1250A Bulletin 1395 DC drive The following topics will be covered in this chapter Topic Introduction 2 1 Drive Layout 2 2 Drive Schematics 2 3 Symbol Reference Chart 2 6 Drive Structure 2 8 Conclusion 2 8 Your 1250A DC drive functions with the following features The 1250A drive uses twelve SCRs regenerative
24. if it is still attached Remove the top plate from the disconnect bay If the drive has a top hat assembly this plate will not be needed If the drive has a top hat assembly mount the assembly to the drive according to the assembly instructions and remove the assembly s top plate ATTENTION The top plate must be removed from the drive before any cutting drilling tapping or welding can be done Failure to do so could result in damage to sensitive components Punch holes for the AC input into the top plate within the area shown in Figure 5 1 Clean the punched area to ensure that metal shavings will not fall into the drive Secure the top plate to the drive or top hat assembly and replace the lifting angle Publication 2361 5 01 July 1998 5 4 Installing and Configuring Your Drive Installing Your Drive Publication 2361 5 01 July 1998 Follow the installation instructions given in publication 1395 5 40 to set up your unit referring to this chapter for information specifically for the 1250 1650 and 3000A DC drives Drive Disconnect A 3 phase circuit breaker or AC line fuses are included with each drive For circuit breaker settings and derating refer to Appendix A Wiring Recommendations The following tables show recommended wiring for the 1250 1650 and 3000A DC drives according to NFPA 70 75 C wiring Refer to local codes for wire sizes Table 5 A Typical Wire Selections AC Input
25. labels J12 115V DC 15A duplex receptacle customer wired J11 Audio phone jack Footnotes 0000000 Catalog Numbers and Spare Parts Kits B 5 Non regenerative units not offered for 3000A modules Units accommodate top entry and bottom exit An additional section is required for bottom entry and a separate additional section is required for top exit Units configured for 575 or 660V AC inputs require field transformers The field supply modules require an input voltage of 460V AC and the field transformer is utilized to step down 575 660V AC inputs to 460V AC The base unit price of a 575 or 660V AC input drive includes a field transformer and fusing that provides up to 18A to the field supply module Select a field transformer upgrade option when you need to supply more current to the field supply module All field transformers come standard in a NEMA Type 1 enclosure Nominal field currents based on 85 efficiency unit control power usage and 300V field supply Add option codes here and separate option code with dashes Devices are 800T type If selected you must select 1 Drive Port A Card If you select 5 input devices or 3 output devices you must select Drive Port A Card 14DRA If selected you must also select option 1B Maximum number of cards allowed is one for Port A and one for Port B If your motor has a DC tachometer select the appropriate scaling board You may selec
26. 0 HP e 3 phase AC input of 460V AC e has a NEMA 1 enclosure without gaskets and door fan filters e has a high instantaneous trip circuit breaker e includes the options e ControlNet communication board e 115V AC discrete adapter board emergency stop The catalog number would be 2361EA SAB 68CM 14CN 14DAA 1B Catalog Numbers and Spare Parts Kits B 3 DC Drive Catalog Numbers Bulletin Unit Wiring Module AC Input HP Trip Number Type Type Size Line Voltage Device Options 2361 E Regenerative 1395 DC Drive F Non Regenerative 1395 DC Drive A Power Wiring 2 12504 5 16504 T 3000A Type 1 without gaskets and door fan filters J NEMA Type 1 with gaskets and door fan filters B 460V AC C 575VAC 3 660 64 700 hp 70 1500 hp 65 750 hp 71 1750 hp 66 800 hp 72 2000 hp 67 900 hp 73 2250 hp 68 1000 hp 74 2500 hp 69 1250 hp CM High AIC instantaneous trip circuit breaker with thermal magnetic plug trip function LF Line fuses only Refer to option table Publication 2361 5 01 July 1998 B 4 Catalog Numbers and Spare Parts Kits Options _ Door Mounted Pilot Lights 5 Door Mounted Pushbuttons 5 Door Mounted Illuminated Pushbuttons Door Mounted Switches 5 6 Drive Port A Cards Drive Port B Cards Tachometer Feedback Scaling Boards Configuration Terminals C
27. 00A DC Drive Bus Dimensions gt 0 88 1 938 ih 1 938 0 188 gt 4 0 88 1 750 0 625 Diameter Bus Arrangement 12 connections are available for each phase Phase 1 L1 Phase 2 L2 Phase 3 L3 Drive Specifications A 9 Air Baffle Layouts The following diagrams show how the air baffles and guards are arranged in the drives ATTENTION Air baffles are designed to distribute air to cool drive components Ensure that the baffles are in place when operating the drive to provide the proper airflow and to prevent the thermoswitches or optional airflow sensor from intermittently shutting down the drive ATTENTION Guards are designed to direct airflow in the drive and to prevent injury Ensure that the guards are in place when operating the drive Figure 14 Air Baffle Layout 1250 and 1650A Units Publication 2361 5 01 July 1998 Drive Specifications A 10 Air Baffle Layout 3000A Units Figure 15
28. 2 4 Your 1250 DC Drive Figure 2 3 1250A DC Drive Schematic Sheet 2 1L1 ACT 1 e ERES v Continued 113 AIR Continued on from Figure 1 1 Next Page 22 SP3 F20 F21 d Fl F2 F3 SP1 SPA gt lt 3MOV 13 FCT 2 QO Continued on Next Page M LL 0 464 Etter e ABC VA VA Continued on Next Page TB5 F14 FIELD RANGE ER L1 kid 43A Field FEEDBACK PCB QUO Hs iH 2 2 H1 H4 J44 J39 PT2 i o 9 183 143 One H e 02 4 FDBK FDBK E 2 0 3 WURDEN BURDEN J42 m m PWR SUPPLY RES o amp RES J41 136 F16 137825 jag APM tos UNIT PWR SUPPLY A6 Continued on 4 J2 J3A J3D J6 Next Page TP3 O TPG 5 219 POWER STAGE 12 INTERFACE PCB A7 1 9 I er gt gt Continued on 5 115V 24V Em COM e Next Page 12180 e 0 0 03 Jfi A 5 1395 MOTOR J7 Continued 15 TEMP 0 from m Figure 2 2 12542 o o IF Continued on PR MP a R RESET Next Page 9 11 1395 3 7 E COAST 1395 LOGIC 1K LOGIC 115V HI 4 25W ESR COAST 5 K2 K3 115V L0 6 C e i A A 7 EN 24 V DRIVE 14 READY cM J10 1395 SYSTEM 5 LOGIC TRIP NE kanns Continued on 6 ERS 10 Next Page e 241 11 a TB1
29. 22 11 1648 5 Um FE a 1 1 Continued from Previous Page DC MOTOR Sak Ey Y 5 7 _ 1 o_o 9 ARM A2 A1 SHUNT FIELD 1 TB7 F1 F2 F4 7 _ 3 PMI 2 HEATSINK ro mn Encoder 235 FIELD PULSE D Dual Out Example TFMR AND SNUBBER AND SNUBBER PCB AS TB3 1024PPR_ 1024PPR 12 TOTAL f s 1 TOTAL 12 13 COMMON COMMON J1 12 V 145 V 12 15V V 12 15V 215 zu 16 17 SIGNALB SIGNALE 180 SIGNAL B SIGNAL B 19 SIGNALA SIGNAL A 20 SIGNAL SIGNAL MAIN SHIELD SHIELD n CONTROL g NEZ 815 CURR VEL PROC PROC PROC gp A ve DOOR J5 J4 DHT MOUNTED PROGRAMMING J6 TERMINAL PORT PORT B 3 24 Out 12 24 ECOASTN ES Dae Sy 24V ECOASTK 110 COAST Ready2N ccm Sepe ee Ready 1 7 Drive Ready Output 115V Common Out 115V ECOAST2 MET UNE 115V AC Common 115V ECOASTI 4 115 AC ECOAST Reset In 3 Motor Temp In 2 1 24V DC 115V AC 1 Common In 1 Motor Thermostat Voltage Source Note More configuration details for TB3 are given in the installation chapter of publication 1395 5 40 Publication 2361 5 01 July 1998 4 6 Your 3000A DC Drive Symbol Reference Chart Table 4 A 3000A DC Drive Symbol to Component Reference
30. 5 Interface Board 2 m 9 S 4 amp S S daho S 0 mi J Al JS 116 je s is N H 919 Connections to Armature Pulse Transformer Boards 19019 S 116 91019 H H 6 j 6 SIR n EN HIR NIJD Publication 2361 5 01 July 1998 1 12 Product Overview Power Components Publication 2361 5 01 July 1998 This section will break down and define the incoming power armature power and field supply components Incoming Power Components Incoming Devices The 1250 and 1650A DC drives are intended to be used straight from the customer supplied power controlled incoming lines without any additional isolation transformer or line chokes however adding either of these would increase isolation to other equipment on the power lines The 3000A DC drive does not require an isolation transformer or line reactors if it is the only equipment on the power lines However if it shares power with other equipment on the same power lines it will be necessary to use either line reactors or an isolation transformer ahead of the drive The system designer needs to provide proper circuit impedence to limit the short circuit currents according to the breaker derating charts given in Appendix A Some drives may require an output inductor in series with the armature especially for older machines which do not have enough internal inductance for a proper armature co
31. 50 3000A DC units 2 sets 1 2361 SPE02A Control Fuses No Field Voltage Step Down Option 1250 3000A DC units 2 sets 1 2361 5 Control Fuses Option 145028 1250 3000A DC units 2 sets 1 2361 SPEO4A Control Fuses Option 145090 1250 3000A DC units 2 sets 1 2361 SPE12A Line Fuses 12504 DC units 1 set 1 2361 SPE13A Fuses 16504 DC units 1 set 1 2361 SPE14A Line Fuses 3000A DC units 1 set 1 2361 SPMO1A Feedback Board 1250 3000A DC units 1 1 2361 SPMO3A Armature Pulse Transformer Board 1250 3000A DC units 1 1 2361 SPMO4A _ Pulse Transformer Board Option 14FX 1250 3000A DC units 1 2 2300 Line RC Suppressor Option 14LSP 1250 3000A DC units i neg 2 2300 5 Line MOVs 1250 3000A DC units 1 set 2 2300 SPPO1A Air Flow Switch PCB Kit Option 14AFL 1250 16504 DC units i 1 1 power 2 2300 SPPO2A Air Flow Switch PCB Kit Option 14AFL 3000A units supply 1 1A 2 2361 SPAO1A Top Regenerative Armature Assemblies 1250A DC units 1 2 2361 SPA02A Negative Bottom Regenerative Armature Assemblies 12504 DC units 1 2 2361 SPA03A Top Regenerative Armature Assemblies 16504 DC units 1 2 2361 SPA04A Negative Bottom Regenerative Armature Assemblies 16504 DC units 1 2 2361 SPA05A Top Regenerative Ar
32. 50 660 1250 Contents Introduction Chapter 3 Your 16504 DC Drive This chapter is designed to help you understand the construction of your 1650A Bulletin 1395 DC drive The following topics will be covered in this chapter Topic Page Introduction Drive Layout 3 2 Drive Schematics 3 3 Symbol Reference Chart 3 6 Drive Structure 3 8 Conclusion 3 8 Your 1650A DC drive functions with the following features The 1650A drive uses twelve SCRs regenerative or six SCRs non regenerative in the armature bridge to convert the 3 phase AC input to a DC output The SCRs are built into a heatsink assembly and are cooled by the bridge fan e The 1650A drive is protected from incoming fault currents with a circuit breaker and the DC output is protected from fault currents with a DC contactor The components of your drive the armature bridge field bridge and control components are guarded with fuses MOVs snubbers and or chokes The 1650A drive is constructed and housed in three bays the first bay containing the AC input and control hardware the second bay containing the armature bridge hardware and the third bay containing the DC output hardware The 1650A drive has an optional top hat extension available for the AC input bay The 1650A drive can be built with an optional through bus assembly allowing the 1650A drive and other connected drives to tap off from the same AC input Publ
33. 50A DC drive has a 1200A N frame circuit breaker with a 1200A plug The circuit breaker should be set as shown in the following diagram Figure 5 Recommended Circuit Breaker Settings 1250A DC Drive Digitrip RMS Rating Plug Short Delay Push to 6 Digitrip RMS KB 3 7 Trip Unit Engaged 2 8 Remove Pickup xlr The 1650A DC drive has a 1600A R frame circuit breaker with a 1600A plug The circuit breaker should be set as shown in the following diagram Figure 6 Recommended Circuit Breaker Settings 1650A DC Drive Digitrip RMS Rating Plug Short Delay 6 Digitrip RMS 7 Trip Unit 8 Remove Pickup The 3000A DC drive has 3000 SPB frame circuit breaker The circuit breaker should be set as shown in the following diagram Figure 7 Recommended Circuit Breaker Settings 3000A DC Drive Long Delay Long Delay Setting lp Time 1 7 Sec 6x R Breaker Trips At 6T Test Amps Test Trip Reset O Unit Status O n Publication 2361 5 01 July 1998 6 Drive Specifications Circuit Breaker Derating Figure 8 1250A DC Drive Breaker Derating 70000 60000 50000 40000 480 V 5 V 30000 660V 20000 10000 0 0 5000 10000 15000 Altitude in Feet Breaker Interupting Rating in Amps Figure 9 1650A DC Drive Breaker Derating 70000 60000 50000 480 V
34. 50A DC units 1 2 2361 SPAO3A Top Regenerative Armature Assemblies 16504 DC units 1 2 2361 SPA04A Negative Bottom Regenerative Armature Assemblies 16504 DC units 1 2 2361 SPA05A Positive Top Regenerative Armature Assemblies 3000A DC units 1 2 2361 5 Negative Bottom Regenerative Armature Assemblies 3000A DC units 1 2 2361 5 7 _ SCR Module for Option 14FX 1250 3000A DC units 1 2 2361 SPA08A Top Non Regenerative Armature Assemblies 1250A DC units 1 2 2361 SPA09A Negative Bottom Non Regenerative Armature Assemblies 1250A DC units 1 2 2361 SPA10A Positive Top Non Regenerative Armature Assemblies 1650A DC units 1 2 2361 SPA11A Bottom Non Regenerative Armature Assemblies 16504 DC units 1 2 2361 SPBO1A Snubber Assembly 1250 1650A DC units 1 2 2361 SPBO2A Snubber Assembly 3000A DC units 1 2 2361 5 Individual Power Fuses 12504 DC units 2 2 2361 SPEO9A Individual Power Fuses 16504 DC units 2 2 2361 SPE10A Individual Power Fuses 3000A DC units 3 2 2361 SPE11A Power Fuse Assembly 30004 DC units pee j 2 2361 SPGO1A Armature SCRs 1250A DC units 2 2 2361 SPGO2A Armature SCRs 1650A DC units 2 2 2361 SPGO3A Armature SCRs 3000A DC units 2 2 2361 5 Additional Control Board Stack Power Supply 1250 3000A DC units 1 2 2361 SPMO2A Gate Interface Board 1250 3000A DC units 1 3 2361 SPHO1A Br
35. 75V AC 25A FRS configuration with 10kVA transformer Field transformer primary fusing for 575V AC Y 30A FRS configuration with 15kVA transformer Field transformer primary fusing for 575V AC Y 45A FRS configuration with 20kVA transformer Field transformer primary fusing for 575V AC Y 100A FRS configuration with 5OkVA transformer Field transformer primary fusing for 660V AC 25A 150X configuration with 10kVA transformer Field transformer primary fusing for 660V AC Y 40A 150X configuration with 15kVA transformer Field transformer primary fusing for 660V AC Y 40A 150X configuration with 20kVA transformer Field transformer primary fusing for 660V AC Y 100A 150X configuration with 5OkVA transformer F31 33 Line RC snubber fuses Y 25A KTK 25A KTK 25A A70P FA Terminal block control power fuse 7A KLDR F7 12 F7A 12A _ Bridge fuses 800A 1250V 170M F51 53 AC line fuses Y 1600 KRPC FAN1 C1 Armature fan capacitor 25yF FAN1 Armature bridge fans 2800CFM FAN4 Field heatsink fan 145 CFM FCT Field current transducer 1000 1 Publication 2361 5 01 July 1998 Your 1650A DC Drive 3 7 Symbol Description Option 460V AC 575V AC 660V AC J10 DHT EHT configuration terminal D shell v 1 DC armature contactor 3000A M12 Motor blower starter Y 27A size 1 45A size 2 MP Main pilot for pilot relay OL11 OL12 Motor blower overloa
36. B8 Field AC input terminal block TB11 Optional miscellaneous control terminal block TE Zero potential bus TP Publication 2361 5 01 July 1998 3 8 Your 1650A DC Drive Drive Structure Figure 3 4 1650A DC Drive Structure 20 inches 508 mm li t J 91 5 inches 2324 mm F E O eee Br inches gt 20 inches gt lt 35 inches 20 inches 20 inches 508 mm 508 mm 889 mm 508 mm 508 mm Conclusion This chapter covered the components schematics and structure of your 1650A DC drive Unit specifications derating charts a power dissipation chart a circuit breaker illustration an air baffle diagram and an input busbar diagram for the 1650A DC drive are all given in Appendix A Publication 2361 5 01 July 1998 Input Voltage VAC Nominal Output HP 460 1250 1750 575 1500 2250 660 1500 2500 Contents Introduction Chapter 4 Your 3000A DC Drive This chapter is designed to help you understand the construction of your 3000A Bulletin 1395 DC drive The following topics will be covered in this chapter Topic Page Introduction 4 1 Drive Layout 4 2 Drive Schema
37. HT EHT configuration terminal EA4 Line RC suppressor EAS Air flow sensor PCB Fl 3 Control branch feedback PCB fuses 1AKTK 1 KTK 10 F14 15 PT2 control transformer primary fuses 8A KLDR F16 PT2 control transformer secondary fuses 5A KLDR F17 19 Motor blower fuses 30A 3P size 1 or 60A 3P size 2 F20 21 Field fusing for 460V AC configuration 45A FRS Field transformer primary fusing for 575V AC 25A FRS configuration with transformer Field transformer primary fusing for 575V AC 30A FRS configuration with 15KVA transformer Field transformer primary fusing for 575V AC 45A FRS configuration with 20KVA transformer Field transformer primary fusing for 575V AC 100A FRS configuration with transformer Field transformer primary fusing for 660V AC 25A 150X configuration with 10 transformer Field transformer primary fusing for 660V AC 40A 150X configuration with 15kVA transformer Field transformer primary fusing for 660V AC 40A 150X configuration with 20 transformer Field transformer primary fusing for 660V AC 100A 150X configuration with 50 transformer F31 33 Line RC snubber fuses 25A KTK 25A KTK 25A A70P F4 Terminal block control power fuse 7A KLDR F 12 F A 12 Armature bridge fuses 630A 1250V 170M F51 53 AC line fuses 1200A KRPC FAN1 C1 Armature fan capacitor FAN1 Armature bridge fan FAN4 Field heatsink fan FCT Field current transducer J10 DHT EHT configuration t
38. International All Rights Reserved Printed in USA
39. L2 L3 45 lb ft DC output A1 A2 45 Ib ft Armature Current Ratings See Appendix A for electrical specification charts Contents Introduction Voltage Measurements Chapter 6 Starting Up Your Drive This chapter supplements the start up procedures in the 1395 Digital DC Drive User Manual with information for your high horsepower drive The following information will be covered in this chapter Topic Page Introduction 6 1 Voltage Measurements 6 1 Rated Armature and Field Currents 6 2 Feedback Scaling Parameters 6 2 When you use publication 1395 5 40 to start up your drive you will need to refer to this chapter for information pertaining to the high horsepower drives Table 6 A Field AC Voltage Measurements Drive Rating Field AC Input Measurement Points 1250 1650 3000A 8 1 TB8 3 Table 6 B 115V AC Voltage Measurements Drive Rating 115V AC Measurement Points 1250 1650 3000A 5 3 TB5 12 Table 6 C 24V DC Voltage Measurements Drive Rating 24V DC Measurement Points 1250 1650 3000A TP1 24V DC to TP7 gnd on power stage interface board Publication 2361 5 01 July 1998 6 2 Starting Up Your Drive Rated Armature and Field Currents Publication 2361 5 01 July 1998 Table 6 D Voltage Measurements 1250 1650 3000A Drives Test Points Expected Voltage Measured Voltage AC Voltages L1 to L2 Rated AC Input L2 to L3 Rated AC
40. P 6 This manual is intended for those who are responsible for installing or operating a Rockwell Automation high horsepower 1395 drive If you do not have a basic understanding of this unit please refer to the drive documentation or contact your local Rockwell Automation Drive Systems representative for more information before using this product This manual 15 a supplement to Publication 1395 5 40 titled 1395 Digital DC Drive User Manual This manual will cover hardware overviews e specifications e installation instructions e configuration and setup information e spare parts Publication 2361 5 01 July 1998 P 2 Safety Precautions Publication 2361 5 01 July 1998 The following general precautions apply to Bulletin 2361 drive system lineups ATTENTION Only those familiar with the drive system the products used in the system and the associated machinery should plan or implement the installation startup and future maintenance of the system Failure to comply can result in personal injury and or equipment damage ATTENTION Verify that all sources of AC and DC power are deenergized and locked out or tagged out in accordance with the requirements of ANSI NFPA 70E Part II ATTENTION The system may contain stored energy devices To avoid the hazard of electrical shock verify that all voltage on capacitors has been discharged before attempting to service repair or remove a drive system or its component
41. SCR silicon controlled rectifier used in power conversion snubber a resistor capacitor assembly used for limiting excess voltage You the Customer are responsible for thoroughly inspecting the equipment before accepting the shipment from the freight company Check the item s that you receive against your purchase order If any items are obviously damaged do not accept the delivery until the freight agent has noted the damage on the freight bill Should you discover any concealed damage during unpacking you are responsible for notifying the freight agent In such a case leave the shipping container intact and request that the freight agent make a visual inspection of the equipment Publication 2361 5 01 July 1998 6 Rockwell Automation Support Publication 2361 5 01 July 1998 Rockwell Automation offers support services worldwide with Sales Support Offices authorized distributors and authorized Systems Integrators located throughout the United States plus Rockwell Automation representatives in every major country in the world Local Product Support Please contact your local Rockwell Automation representative for e sales and order support e product technical training e warranty support e support service agreements Technical Product Assistance If you need to contact us for technical assistance please review the product and troubleshooting information in this manual first For the quickest possible response
42. T Continued from Previous Page 24V Out a se alee conn 24V ECOAST 24V ECOAST ECOAST Ready 2 Bere Ready 1 Drive Ready Output 115V Common Out 115V ECOAST2 115V AC Common 5 Q1Q 1 115V ECOASTI o mNACEDAST N Reset In Motor Temp In LL 24V DC or 115V md common th Motor Thermostat Voltage Source TB10 1 Note More configuration details for TB3 are given in the installation chapter of publication 1395 5 40 Publication 2361 5 01 July 1998 2 6 Your 1250A DC Drive Symbol Reference Chart Table 2 A 1250A DC Drive Symbol to Component Reference Symbol Description Option 460V AC 5751 660 A1 RES 1 PCB feedback scaling resistor 3 65 ohm 2 W 1 2 3MOV Field suppressors Al Feedback PCB A11F A16F Armature pulse transformer PCB A11R A16R Armature pulse transformer PCB Gate interface PCB A5 Field pulse transformer PCB A6 Unit power supply PCB A7 Power stage interface PCB A8 Main control PCB A9 Feedback PCB power supply ACT1 3 Line current transducer 2000 1 C1 Armature snubber capacitors 2 2000V CB11 Circuit breaker 1200A N frame CH1 Field choke CH11 16 Cell chokes Air core 3 5uH 1017A D1 M1 bridge diode DHT DMT Configuration terminal EA2 Tachometer adapter scaling PCB EA3 D
43. ade according to Figure 5 3 5 Wire the secondary back to drive TB8 X1 to TB8 1 X2 to TB8 3 6 Secure the top plate on the enclosure Publication 2361 5 01 July 1998 5 8 Installing Your Drive Figure 5 4 Field Transformer Enclosures 10 and 15kVA Transformer Enclosure HM 18 72 14 22 1713 0 88 1 13 Mounting Hole _ 16 50 e 12 00 gt 0 38 x 0 50 20kVA Transformer Enclosure 23 94 gt HK 16 00 000000000000000000000000000000000 2 50 o o 27 00 of 000000000000000000000000000000000 Mounting Hole 2200 _ gt Te 7400 0 56 Diameter o 50kVA Transformer Enclosure 26 50 M 2242 3 Q 0000000000000000000000000000000000 gt 0000000000000000000000000000000000 0000000000000000000000000000000000 2 50 o o 28 74 0000000000000000000000000000000000 0000000000000000000000000000000000 o 0000000000000000000000000000000000 Mounting Hole 2450 0 56 Diameter Publication 2361 5 01 July 1998 20 00 Installing Your Drive 5 9 Circuit Board Jumper Connections Table 5 G Feedback Board Jumper Setting Field Current Motor Field Current Jumper Settings 43A Field Bridge 90A Field Bridge 1 J36 to J41 1 0 2 4 2 0 4 9 2 J37
44. atics Figure 2 2 1250A DC Drive Electrical Schematic Sheet 1 Fg o ooo yr E 1 ty 1L1 ni 3 Phase 2 lt gt AC Input Continued in B Figure 2 3 ba Soars SiS Sil Tee Circuit Breaker s dora D o Be c Option Option DC MOTOR AC BLOWER MOTOR Continued in Figure 2 3 24VDC 0 5A TB230HI To 24V DC Discrete Adapter Board 161689 131200 24V DC Digital Reference Board 1 1 115V AC Discrete Adapter Board FOOTNOTES Part of 24V DC Discrete Adapter Option or 24V DC Digital Reference Option Publication 2361 5 01 July 1998
45. ation with 15kVA transformer Field transformer primary fusing for 575V AC Y 45A FRS configuration with 20kVA transformer Field transformer primary fusing for 575V AC Y 100A FRS configuration with 50kVA transformer Field transformer primary fusing for 660V AC 25A 150X configuration with 10kVA transformer Field transformer primary fusing for 660V AC Y 40A 150X configuration with 15kVA transformer Field transformer primary fusing for 660V AC Y 40A 150X configuration with 20kVA transformer Field transformer primary fusing for 660V AC Y 100A 150X configuration with transformer F31 33 Line RC snubber fuses Y 25A KTK 25A KTK 25A A70P F51 53 AC line fuses Y 3000A KRPC FAN1 C1 Armature fan capacitor 40uF FAN1 Armature bridge fan 1850 CFM FAN2 Slide fan fan 1589 CFM Publication 2361 5 01 July 1998 Your 3000A DC Drive 4 7 Symbol Description Option 460V AC 575V AC 660V AC FAN4 Field heatsink fan 145 CFM FCT Field current transducer 1000 1 J10 DHT EHT configuration terminal D shell Y M1 DC armature contactor 3000A M11 M12 Motor blower starter 27 size 1 45A size 2 MP Main pilot for pilot relay OL11 0112 Motor blower overload PB1 Stop pushbutton Y Red EH 1N0 1NC PB3 E stop pushbutton Y Red MH P P 2NC PBA Jog forward pushbutton Y Black FH 1N0 1NC PB5 Jog reverse pushbutton Y B
46. d 15 n J LOGIC TEMP from 15 115V 24V NIE D Figure 3 2 1125402 o o um J Continued on PR MP R RESET Next Page e 9 1395 Le i E COAST 1395 LOGIC 1K 0 LOGIC 115V HI 4 m 25W ESR COAST 5 i K2 K3 115V LO 6 e i 7 EN 24V DRIVE e 11 READY T 8 h M 1395 SYSTEM LOGIC TRIP NE hn Continued on FSR 10 Next Page 241 11 1395 24V COMM 12 11 1 LOGIC 2 TE 1 234 58 FAN 1 po 13 R PILOT RELAY FAN 4 N 4 Continued on Publication 2361 5 01 July 1998 Next Page Continued tun Previous Page Continued from Previous Page Gate Interface PCB Continued from Previous Page Continued from Previous Page OF Continued from Previous Page m Continued from Previous Page
47. d Y PB1 Stop pushbutton Y Red EH 1N0 1NC PB3 E stop pushbutton Y Red MH P P 2NC 4 Jog forward pushbutton v Black FH 1NO 1NC PB5 Jog reverse pushbutton v Black 1N0 1NC PBL2 Start running illuminated pushbutton v Amber PBL6 Fault clear faults illuminated pushbutton Y Clear 1N0 1NC PE Power ground bus PL1 Power on pilot light Y Red 115VAC XF type 2 Field SCRs 90A 1200V PP1 6 Armature power poles PR 1 contactor pilot relay 51 24V DC power supply 24V DC 0 5A PS2 Air flow sensor power supply v 24 DC 0 5A PT2 Control transformer Y 1 5 PT5 Field transformer 18A Field transformer 28A Y Field transformer 40A Y Field transformer 70A Y R1 M1 suppressor resistor 1k ohm 50 W Ri 2 Armature snubber resistors 40 ohm 240 W R11 12 Multi communication channels amp B terminal resistors 150 ohm 2 RH1 Speed potentiometer v 5k ohm 2W 51 3 Heatsink thermoswitches 170 F 55 Air flow sensor v 1000FPM SCR SCR 1800A 1800V SCR R SCR regeneration 1800A 1800V SP PR suppressor SP1 3 Line to line MOVs 460J 320V 1550J 385V AC 600J 420V AC 5 4 Y to ground 760J 680V 760J 680V 1050J 750V 553 Speed 1 2 3 selector switch Y Std op 2 N0 2 NC 51 Motor thermoguard TB1 FAN Bridge fan amp capacitor terminal block TB10 TE shield terminal block TB3 Option PCB terminal block TB5 Branch power amp 115 control terminal block TB7 Field DC output terminal block T
48. erminal D shell Publication 2361 5 01 July 1998 Your 1250 DC Drive 2 7 Symbol Description 460V AC 575V AC 660V AC 1 DC armature contactor 1800A M11 Motor blower starter 27 size 1 45 size 2 MP Main pilot for pilot relay OL11 OL12 Motor blower overload 1 Stop pushbutton Red EH 1NO 1NC PB3 E stop pushbutton Red MH P P 2NC PB4 Jog forward pushbutton Black FH 1N0 1NC PB5 Jog reverse pushbutton Black FH 1N0 1NC PBL2 Start running illuminated pushbutton Amber 1NO 1NC PBL6 Fault clear faults illuminated pushbutton Clear 1 Power ground bus PL1 Power on pilot light Red 115VAC XF type 2 Field SCRs 90A 1200V PP1 6 Armature power poles PR M1 contactor pilot relay PS1 24V DC power supply 24V DC 0 5A PS2 Air flow sensor power supply 24V DC 0 5A PT2 Control transformer 1 5 PT5 Field transformer 18A Field transformer 28A Field transformer 40A Field transformer 70A R1 M1 suppressor resistor 1k ohm 50 W R1 2 Armature snubber resistors 40 ohm 240 W R11 12 Multi communication channels A amp B terminal resistors 150 ohm 2 W RH1 Speed potentiometer 5k ohm 2 W 51 3 Heatsink thermoswitches 165 F 55 Air flow sensor 1000FPM SCR SCR 1200A 1800V SCR R SCR regeneration 1200A 1800V SP PR suppressor SP1 3 Line to line MOVs 460J 320V AC E 385V AC m 420V AC SP4 Y to gr
49. from 115V AC control bus to drive unit 6SC 115V AC control power supplied by others 14DB Dynamic braking contactor option M3EW White background with black lettering phenolic label N3EB Black background with white lettering phenolic label N3ER Red background with white lettering phenolic label 989X 2 Normally open and 2 normally closed contactors mounted internally if 1250 1650A OR 4 Normally open and 4 normally closed contactors mounted internally if 3000A unit 14BN 1 NEMA size 1 FVNR starter assembly with 30A fuse blocks mounted within the drive unit 14B2N 2 NEMA size 1 FVNR starter assembly with 30A fuse blocks mounted within the drive unit 14B2NX 2 NEMA size 2 FVNR starter assembly with 60A fuse blocks mounted within the drive unit 14Bl 1 IEC 24A starter assembly mounted with 30A fuse blocks within the drive unit 14 21 2 IEC 24A starter assembly mounted with 30A fuse blocks within the drive unit 14B2IX 2 IEC 30A starter assembly mounted with 60A fuse blocks within the drive unit 14LSP Line RC suppressor module 13 14AFL Air flow loss switches 14HBC AC power input is wired from the horizontal thru bus to the circuit breaker 14FX Field supply upgrade for fields requiring 43 to 90A 145028 Field transformer for field currents up to 28A 145040 Field transformer for field currents up to 40A 145090 Field transformer for field currents up to 90A 14WLBL Brady Datab wire
50. gure 4 2 PR H Continued on MP R RESET Next Page nt El 11 1395 amp 3 Rt D E COAST 1395 LOGIC 1K r LOGIC 25W ESR COAST 5 MP K2 K3 115V LO 6 si a 241 DRIVE READY T 8 h 1395 SYSTEM LOGIC TRIP NE fc Continued on 9 TED 10 Next Page 24 11 1395 24V COMM 12 11 1 LOGIC 2 23 4 58 FAN 1 13 e M N FAN 2 PILOT RELAY FAN 4 CRI N Continued on Publication 2361 5 01 July 1998 Next Page Continued from Previous Page Continued from Previous Page Continued from Previous Page Continued from Previous Page Continued from Previous Page Continued from Previous Page N Continued from Previous Page Your 3000A DC Drive 4 5
51. ication 2361 5 01 July 1998 3 2 Your 1650A DC Drive Drive Layout Figure 3 1 1650A DC Drive Layout 12 F12A F10 F10A 1 F32 F33 41142 J3 5 J40 DTB3 1395 Regulator Control Boards DHT TB3 F20 F21 Disconnect Bay Bridge Bay Contactor Bay Publication 2361 5 01 July 1998 Your 1650A DC Drive 3 3 Drive Schematics Figure 3 2 1650A DC Drive Electrical Schematic Sheet 1 Posse Ss een CB 1 Ed 51 iL m 3 Phase 2 lt gt AC Input Continued in L3 Figure 4 3 1 O Circuit Breaker Line Fuse Option Option DC MOTOR AC BLOWER MOTOR DC MOTOR AC BLOWER 0L12 MOTOR Continued in 1 Figure 4 3 24VDC 0 5A TB230HI To 24V DC Discrete Adapter Board 161689 Lu or 24V DC Digital Reference Board 1 1 i 1 1 1 115V AC Discrete Adapter Board Part of 24V DC Discrete Adapter Option Lust hee ee or 24V DC Digital Reference Option Publication 2361 5 01 July 1998
52. idge Fan and Capacitor 1250 1650A DC units 1 each 3 2361 SPHO2A Bridge Fan and Capacitor 3000A DC units 1 each 3 2361 5 Slide In Fan and Capacitor 3000A DC units 1 each Publication 2361 5 01 July 1998 Adapter Boards 7 4 1 6 See also References Air Baffles A 9 Altitude Derating A 2 Altitude Specifications 7 Armature Bridge 7 14 1 15 Busbar Dimensions A 7 Catalog Numbers B 1 B 7 Circuit Breaker Settings A 5 Components 24V DC Power Supply 7 70 AC Line RC Suppressor 7 73 Adapter Boards 1 4 1 6 See also References Armature Pulse Transformer Boards 7 3 1 16 Busbars 7 72 A 7 Circuit Breakers 1 12 A 5 DC Contactors 7 76 Feedback Board 7 3 1 7 1 10 Field Bridge 1 7 1 17 1 18 Field Transformer 1 17 5 6 5 8 Field Pulse Transformer Board 7 7 1 18 Gate Interface Board 1 3 7 11 Main Control Board 7 3 1 4 1 5 Overview 7 3 Power Stage Interface Board 7 3 1 7 1 8 Silicon Controlled Rectifiers SCRs 7 75 1 16 Snubbers 7 76 Index Symbols 1250A Drive 2 6 1650A Drive 3 6 3000A Drive 4 6 Unit Power Supply 7 7 Unit Power Supply Board 7 3 7 9 Connections 7 3 D Drives 1250A 2 1 2 8 1650A 3 1 3 8 3000A 4 1 4 8 Catalog Numbers B 1 B 7 Dimensions A 2 Electrical Specifications A 3 Installing 5 1 5 12 Operating Sound Levels A 2 Overload Capability A 7 Overview 7 7 Power Dissipation A 4 Receiving P 5 Safety Precautions P 2 Ship
53. ield Bridge nenn an 1 18 Field Pulse Transformer Board 1 18 Your 1250A DC Drive CONTENTS CUAL ACA 2 1 Introduction 252222329425024262434522940444 2582984544 2 1 Drive Layouts to 2 2 Drive Schematics 2 3 Symbol Reference Chart 2 6 Drive Structure 2 8 aca tt twat clot at alata al tat 2 8 Your 1650A DC Drive Mh oc aa det dee HSS 3 1 Introduction 3 1 DIVE LAVOU d 3 2 Drive Schematics 3 3 Symbol Reference 3 6 Drive Structure 3 8 CONCLUSION aod abi ates eie CREE a a Ra gee ee 3 8 Your 3000A DC Drive BONIENIS ad od au qu aed eu trt dra 9 E odiu 4 1 Introduction 4 1 Drive Layout uiia aac ia a ato at ato a o d a o n cc 4 2 Drive Schematics 4 3 Symbol Reference 4 6 Drive Structure s ses n RII 4 8 CONCUSSION o 4 8 Chapter 5 Chapter 6 Appendix A
54. ies Hardware Description Control Controls the drive system and interfaces with external devices Control Power Interface Interfaces the control components with the power components Power Converts AC input to a DC supply for the motor Figure 1 1 Drive Components 3 Phase Power 1 Circuit Breaker 4 Field Transformer Used For AC Inputs of 575 and 660V AC im ENTE Control 8 Transformer WE 1 Fuses AC Line Voltage Feedback HE 24V DC um Feedback m Power Supply Armature Current Feedback 5 Movs lt Feedback Board 77 m Field Current Feedback Power Stage Armature DC Voltage Feedback Interface Board i J9 Gate rmature J6 J3D Interface 3 Phase Single Phase Fiela PTE Board Pulse 9 Snubber SCR Armature SCR Field Transformer Brid Bridge ridge Boards o Pe 7 4 8 Encoder Feedback Fi F2 F3 F4 Encoder CONTROL POWER INTERFACE POWER Publication 2361 5 01 July 1998
55. igure 1 10 allows the bridge to regenerate or to direct power backwards onto the incoming lines Figure 1 10 Armature Bridge Regenerative Main Contactor peog Jaul0JSUeJ esing enjeuuy 3 Phase Input Armature Pulse Transformer Board esng eneuuy J8ULI0JSUPJ esng eneuuy Armature Pulse Transformer Board Armature Voltage ofl Armature Pulse Transformer Board BER SNUBI 1 esing eunjeuuy Armature Pulse Transformer Board 1 5 esng eunjeuuv Transformer Board N LA pJeog 1 1 es ng eJnjeuuy Armature Pulse A2 chokes on the AC line 2 The 3000A unit uses solid core ferrite Silicon Controlled Rectifiers SCRs Each drive uses silicon controlled rectifiers SCRs in the thyristor bridge to switch the incoming 3 phase AC power to DC output power These SCRs allow current to f
56. lack FH 1N0 1NC PBL2 Start running illuminated pushbutton Y Amber 1N0 1NC PBL6 Fault clear faults illuminated pushbutton Y Clear 1N0 1NC PE Power ground bus Power on pilot light Y Red 115VAC XF type 2 Field SCRs 90A 1200V 1 6 Armature power poles PR M1 contactor pilot relay PS1 24V DC power supply 24V DC 0 5A PS2 Air flow sensor power supply Y 24V DC 1 1A PT2 Control transformer Y 2 5 Field transformer 18 10 kVA Field transformer 28A v 15 Field transformer 40A Y 20 kVA Field transformer 90A Y 50 kVA R1 M1 suppressor resistor 1k ohm 50 W R1 4 Armature snubber resistors 40 ohm 240 W R11 12 Multi communication channels A amp terminal resistors 150 ohm 2 W RH1 Speed potentiometer Y 5k ohm 2 W 51 6 Heatsink thermoswitches 165 F 57 Disconnect bay thermoswitch 210 F SCR SCR 27854 1800V SCR R SCR regeneration 2785A 1800V SP PR suppressor SP1 3 Line to line MOVs 460J 320V AC 550J 385V 600J 420V AC SP4 Y to ground 760 680V 7600 680V 1050J 750V AC SS3 Speed 1 2 3 selector switch Y Std op 2 N0 2 NC TAS1 Motor thermoguard TB1 FAN Bridge fan amp capacitor terminal block TB10 TE shield terminal block TB3 Option 1 0 terminal block TB5 Branch power amp 115 control terminal block TB7 Field DC output terminal block TB8 Field AC input terminal block TB11 Optional miscellaneous control terminal block TE Zero potential bu
57. lation instructions Which Table Do I Use For a drive with an Refer to input voltage of 460V AC Table A 575V AC Table B 660V AC Table C Significance of Level Numbers Level numbers are used to recommend stocking locations for the various spare parts kits Level descriptions are as follows Level Number Level Description Recommended Stocking Location s 1 Major Assemblies Large users OEMs distributors and GTS 2 Minor Assemblies Distributors and GTS 3 Discrete Components GTS Catalog Numbers and Spare Parts Kits B 7 Definition of Terms Used to Describe Qty in Kit The column Qty in Kit in Tables A B and C represents how many components you can expect to find as follow Level Number Example Qty in Kit Kit Contains Kits containing 1 The specified quantity of the item one item described 1 each The specified quantity of each item described Kits containing 1 4 fuses The specified quantity of each item as multiple items described The quantity of the specified items required for one drive per set 1 set Catalog Number Description SP A 01 A Bulletin Spare Part Spare Part Kit Number Revision Number Designator Letter Publication 2361 5 01 July 1998 Catalog Numbers and Spare Parts Kits Table A Spare Parts Kits for Drives with 460V AC Inputs Level Catalog Number Description Qty in Kit 1 2861 5 Control Fuse
58. low from anode to cathode when two conditions are met First like a diode it must be forward biased Second an appropriate pulse must be applied to the gate through the pulse transformer board The current will continue through the SCR until the voltage across it reverses and the current drops to zero called line commutation Figure 1 11 shows a picture of an SCR depicting its polarity Publication 2361 5 01 July 1998 1 16 Product Overview Silicon Controlled Rectifier SCR Armature Pulse Transformer Board Publication 2361 5 01 July 1998 Snubbers Snubbers resistor capacitor assemblies are installed in parallel with the SCRs working with the cell reactors to provide adequate voltage suppression when the SCRs switch off Armature Pulse Transformer Boards Armature pulse transformer boards provide the appropriate gate voltage and current to trigger an SCR In addition these boards provide gate driver isolation from the control logic Figure 1 11 shows an armature pulse transformer board DC Contactor The main DC contactor is used to break the DC current to the motor armature Coil voltage to the contactor is controlled by contacts from the pilot relay Figure 1 11 Armature Bridge Hardware Anode Gate Anode Gate Leads Cathode Cathode DDD 5 J2 S S J1 Product Overview 1 17 Field Power Components The field
59. m Field Maximum Field Voltage VAC Power kVA Voltage V DC Current ADC Voltage VDC Current Apc Nominal HP 460 1374 500 2000 300 43 or 90 1250 460 1634 500 2400 300 43 or 90 1500 460 2024 500 3000 300 43 or 90 1750 575 1713 600 1995 300 43 or 90 1500 575 1985 600 2330 300 43 or 90 1750 575 2254 600 2660 300 43 or 90 2000 575 2531 600 3000 300 43 or 90 2250 660 1705 700 1715 300 43 or 90 1500 660 1971 700 2000 300 43 or 90 1750 660 2242 700 2290 300 43 or 90 2000 660 2508 700 2575 300 43 or 90 2250 660 2905 700 3000 300 43 or 90 2500 Publication 2361 5 01 July 1998 4 Drive Specifications Power Dissipation The 1250 1650 and 3000A DC drives dissipate power proportionally to the armature current as shown in the following figures Figure 2 Watts Dissipation vs Armature Current 1250A DC Drive 8000 7000 6000 5000 5 4000 3 3000 5 2000 1000 0 I Armature Current A Figure 3 Watts Dissipation vs Armature Current 1650A DC Drive 10000 8000 S 600 E 4000 2000 0 4 Armature Current A Figure 4 Watts Dissipation vs Armature Current 3000A DC Drive 14000 12000 10000 8000 6000 4000 Heat Dissipation W 2000 300 600 900 1200 1500 1800 2100 2400 2700 3000 Armature Current A Publication 2361 5 01 July 1998 Drive Specifications A 5 Circuit Breaker Settings The 12
60. mature Assemblies 3000A DC units 1 2 2361 5 Negative Bottom Regenerative Armature Assemblies 3000A DC units 1 2 2361 5 7 _ SCR Module for Option 14FX 1250 3000A DC units 1 2 2361 SPA08A Top Non Regenerative Armature Assemblies 1250A DC units 1 2 2361 SPA09A Negative Bottom Non Regenerative Armature Assemblies 1250A DC units 1 2 2361 SPA10A Positive Top Non Regenerative Armature Assemblies 1650A DC units 1 2 2361 SPA11A Bottom Non Regenerative Armature Assemblies 16504 DC units 1 2 2361 SPBO1A Snubber Assembly 1250 1650A DC units 1 2 2361 SPBO2A Snubber Assembly 3000A DC units 1 2 2361 5 Individual Power Fuses 12504 DC units 2 2 2361 SPEO9A Individual Power Fuses 16504 DC units 2 2 2361 SPE10A Individual Power Fuses 3000A DC units 3 2 2361 SPE11A Power Fuse Assembly 30004 DC units pee j 2 2361 SPGO1A Armature SCRs 1250A DC units 2 2 2361 SPGO2A Armature SCRs 1650A DC units 2 2 2361 SPGO3A Armature SCRs 3000A DC units 2 2 2361 5 Additional Control Board Stack Power Supply 1250 3000A DC units 1 2 2361 SPMO2A Gate Interface Board 1250 3000A DC units 1 3 2361 SPHO1A Bridge Fan and Capacitor 1250 1650A DC units 1 each 3 2361 SPHO2A Bridge Fan and Capacitor 3000A DC units 1 each 3 2361 5 Slide In Fan and Capacitor 3000A DC units 1 each Publication 2361 5 01 July 1998 B 10
61. mmutation process AC Input Busbars Tin plated busbars are supplied for all input connections through the top of the disconnect bay Busbar dimension diagrams are given in Appendix A Main Disconnect Optional A 3 phase circuit breaker can be supplied on the incoming line for each high horsepower drive Appendix A lists circuit breaker specifications and shows diagrams of the circuit breakers settings for the 1250 1650 and 3000A DC drives AC Line Fuses Optional AC line fuses can be supplied for the 3 phase incoming power Note Units require either a main disconnect or AC line fuses Product Overview 1 13 Control and Field Power The first L1 and third L3 phase of the incoming power are tapped off and fused to provide single phase AC power to the primary of control power transformer 115V AC field supply circuit 460V AC maximum and 24V DC power supply Note For drives using a 575 or 660V AC input a step down transformer will be required for the field supply circuit see Figure 1 12 AC Line RC Suppressor Optional The optional AC line RC suppressor is a device used for limiting line voltage spikes in drives when the medium voltage source to the primary of the distribution transformer is switched The option is offered for a distribution transformer primary voltage of 2300V or greater Publication 2361 5 01 July 1998 1 14 Product Overview Armature Power Components The armature power components
62. on details for TB3 are given in the installation chapter of publication 1395 5 40 Publication 2361 5 01 July 1998 3 6 Your 1650A DC Drive Symbol Reference Chart Table 3 A 1650A DC Drive Symbol to Component Reference Symbol Description Option 460V 575 AC 660v A1 RES PCB feedback scaling resistor 4 22 ohm 2 W 1 2 3MOV Field suppressors 1 Feedback PCB A11F A16F Armature pulse transformer PCB A11R A16R Armature pulse transformer PCB A3 Gate interface PCB A5 Field pulse transformer PCB A6 Unit power supply PCB A7 Power stage interface PCB A8 Main control PCB A9 Feedback PCB power supply ACTI 3 Line current transducer 3000 1 C1 Armature snubber capacitors 2yF 2000V CB11 Circuit breaker Y 1600A R frame CH1 Field choke CH11 16 Cell chokes Air core 3 5uH 1017A D1 M1 bridge diode DHT DMT Configuration terminal Y EA2 Tachometer adapter scaling PCB EA3 DHT EHT configuration terminal Y EM Line RC suppressor Y EA5 Air flow sensor PCB Y F1 3 Control branch feedback PCB fuses 1A KTK 1 KTK 10 F14 15 PT2 control transformer primary fuses 8A KLDR F16 PT2 control transformer secondary fuses 5A KLDR 17 19 F27 29 Motor blower fuses Y 30A 3P size 1 60A 3P size 2 F20 21 Field fusing for 460V AC configuration 45A FRS Field transformer primary fusing for 5
63. ons Also indicates whether the documents are available on CD ROM or in multi languages A glossary of industrial automation terms and Industrial Automation Glossary AG 7 1 abbreviations Publication 2361 5 01 July 1998 Style of this Manual Terms and Abbreviations Receiving Your Drive System The following conventions are used throughout this manual e ATTENTION statements preceded with the symbol shown indicate a circumstance that could could lead to personal injury death damage to property or economic loss e Important statements indicate key information for successfully performing procedures and understanding the product Reference statements preceded with the symbol shown lead you to other resources of information and instruction e Horsepower ratings are provided at the start of each drive chapter e Schematic and layout component abbreviations are explained in component reference charts in each drive chapter The following terms and abbreviations are used in this manual Term Definition armature rotating part of a motor bridge assembly for power AC DC conversion busbar a large tin plated copper conductor used for high power input and output feedback status signals voltages sent from components or external devices gate an electrical switch MCC motor control center an enclosure for drive systems MOV metal oxide varistor used for voltage spike protection
64. ontrol Power 11 Dynamic Braking Contactor Unit Door Nameplates 1 Auxiliary Contacts Blower Starters 10 Protection Input Option Field Supply Upgrade 5 Field Voltage Step Down Options for Units with 575 or 660V AC Inputs 3 Miscellaneous Publication 2361 5 01 July 1998 4R Power on 1B Drive stop 6 1JF Jog forward 1JR Jog reverse 1ES Hardwared stop interface 5G Start Running 7 5A Clear faults Drive faulted 3 Speed 0 1 2 selector 760A Single turn speed pot 14DAA Discrete adapter 115V AC 14DAD Discrete adapter 24V DC with 0 5A 24V power supply 14DRA Digital reference adapter 24V DC with 0 5A 24V power supply 14CN ControlNet adapter 14NA Node adapter 14 Multi communications adapter 14T033 Scaling board for resolvers with output voltages of 0 33V DC 141046 Scaling board for resolvers with output voltages of 34 46V DC 147070 Scaling board for resolvers with output voltages of 47 70V DC 141125 Scaling board for resolvers with output voltages of 71 125V DC 141178 Scaling board for resolvers with output voltages of 126 178V DC 147250 Scaling board for resolvers with output voltages of 179 250V DC 766 Door mounted D shell connector 766A Door mounted DHT Standard Terminal 766B Door mounted EHT Enhanced Terminal 6P Standard capacity control transformer with primary fusing 6TB 115V AC control power factory wired
65. or six SCRs non regenerative in the armature bridge to convert the 3 phase AC input to a DC output The SCRs are built into a heatsink assembly and are cooled by the bridge fan The 1250A drive is protected from incoming fault currents with a circuit breaker The components of your drive the armature bridge field bridge and control components are protected with fuses MOVs snubbers and or chokes The 1250A drive is constructed and housed in three bays the first bay containing the AC input and control hardware the second bay containing the armature bridge hardware and the third bay containing the DC output hardware e The 1250A drive has an optional top hat extension available for the AC input bay The 1250A drive can be built with an optional through bus assembly allowing the 1250A drive and other connected drives to tap off from the same AC input Publication 2361 5 01 July 1998 2 2 Your 1250A DC Drive Drive Layout Figure 2 1 1250A DC Drive Layout 12 F12A 10 FIOA 21 v2 J3 5 J40 DTB3 1395 Regulator Control Boards A2 1 DHT TB3 F20 F21 TB10 5 Disconnect Bay Bridge Bay Contactor Bay Publication 2361 5 01 July 1998 Your 1250A DC Drive 2 3 Drive Schem
66. or the 3000A unit includes the enclosure height 90 the base channel 1 5 and the the tophat assembly 20 The top hat assembly is shipped loose from the unit Drive Specifications A 3 Electrical Specifications Table Electrical Specifications 1250A DC Drive Input Output Nominal Input Nominal Input Nominal Armature Nominal Armature Maximum Field Maximum Field Voltage VAC Power kVA Voltage VDC Current ADC Voltage VDC Nominal HP 460 750 500 1100 300 43 or 90 700 460 848 500 1250 300 43 or 90 750 575 856 600 1000 300 43 90 750 575 909 600 1065 300 43 90 800 575 1060 600 1250 300 43 90 900 660 852 700 860 300 43 90 750 660 904 700 915 300 43 90 800 660 1011 700 1030 300 43 90 900 660 1217 700 1250 300 43 90 1000 Table D Electrical Specifications 16504 DC Drive ______ _ Nominal Input Nominal Input Nominal Armature Nominal Armature Maximum Field Maximum Field Nominal HP Voltage VAC Power kVA Voltage V DC Current A DC Voltage V DC Current A DC 460 867 500 1280 300 43 or 90 800 460 972 500 1440 300 43 or 90 900 460 1108 500 1650 300 43 or 90 1000 575 1125 600 1330 300 43 or 90 1000 575 1385 600 1650 300 43 90 1250 660 1590 700 1650 300 43 90 1250 Table E Electrical Specifications 3000A DC Drive Input Output Nominal Input Nominal Input Nominal Armature Nominal Armature Maximu
67. ound 760J 680V 1760J 680V AC 1050J 750V SS3 Speed 1 2 3 selector switch Std op 2 2 NC TAS1 Motor thermoguard TB1 FAN Bridge fan amp capacitor terminal block TB10 TE shield terminal block TB3 Option PCB 1 0 terminal block TB5 Branch power amp 115 control terminal block TB7 Field DC output terminal block TB8 Field AC input terminal block TB11 Optional miscellaneous control terminal block TE Zero potential bus Publication 2361 5 01 July 1998 2 8 Your 1250A DC Drive Drive Structure Figure 2 4 1250A DC Drive Structure 20 inches 508 mm L 91 5 inches 2324 mm 2 Fe 20 inches ke 20 inches 35 inches 20 inches l 20 inches BR 508 mm 508 mm 889 mm 508 mm 508 mm Conclusion This chapter covered the components schematics and structure of your 1250A DC drive Unit specifications derating charts a power dissipation chart a circuit breaker illustration an air baffle diagram and an input busbar diagram for the 1250A DC drive are all given in Appendix A Publication 2361 5 01 July 1998 Input Voltage VAC Nominal Output HP 460 800 1000 575 1000 12
68. p Non Regenerative Armature Assemblies 1250A DC units 1 2 2361 SPA09A Negative Bottom Non Regenerative Armature Assemblies 1250A DC units 1 2 2361 SPA10A Top Non Regenerative Armature Assemblies 1650A DC units 1 2 2361 SPA11A Bottom Non Regenerative Armature Assemblies 16504 DC units 1 2 2361 SPBO1A Snubber Assembly 1250 16504 DC units 1 2 2361 SPBO2A Snubber Assembly 3000A DC units 1 2 2361 5 Individual Power Fuses 12504 DC units 2 2 2361 SPE09A Individual Power Fuses 1650A DC units 2 2 2361 SPE10A Individual Power Fuses 3000A DC units 3 2 2361 SPE11A Power Fuse Assembly 3000A DC units 2 2361 SPGO1A Armature SCRs 12504 DC units 2 2 2361 SPGO2A _ SCRs 1650A DC units 2 2 2361 SPGO3A _ SCRs 3000A DC units 2 2 2361 SPKO1A Additional Control Board Stack Power Supply 1250 3000A DC units 1 2 2361 SPMO2A _ Gate Interface Board 1250 3000A DC units 1 3 2361 SPHO1A Bridge Fan and Capacitor 1250 1650A DC units 1 each 3 2361 SPHO2A Bridge Fan and Capacitor 3000A DC units 1 each 3 2361 5 Slide In Fan and Capacitor 3000A DC units 1 each Publication 2361 5 01 July 1998 Catalog Numbers and Spare Parts Kits B 9 Table B Spare Parts Kits for Drives with 575V AC Inputs Level Catalog Number Description Qty in Kit 1 2361 SPEO1A Control Fuses Option 145040 12
69. perating 0 to 40 C 32 to 104 F Relative Humidity Operating Storage 5 to 95 non condensing Ambient Temperature Storage 40 to 70 C 40 to 158 F For altitudes greater than 1000 meters refer to the altitude derate chart Publication 2361 5 01 July 1998 2 Drive Specifications Unit Specifications Publication 2361 5 01 July 1998 F igure 1 Altitude Derating Chart 3000 3000 3000 3000 2800 T 2600 T 2400 T Current Amps 1600 7 1400 T 1200 1000 2200 T 2000 T 1800 7 28802817 es 0250 1250 250 1250 1220 _2750_ 190 _ 162 1145 4130 15 1098 4081 1065 Z7 _ 2605 2650__ 2617 2583_ 2550 3000A 1320 0 1100 2200 3300 4400 5500 6600 7700 8800 9900 11000 12100 13200 Altitude Feet The following specifications apply to the 1250 1650 and 3000A DC drives with standard options Table B Unit Specifications Specifications 1250A Drive Height 91 5 2324 mm 1650A Drive 91 5 2324 mm 3000A Drive 111 5 2832 mm Width 75 1905 mm 75 1905 mm 95 2413 mm Depth 20 508 mm 20 508 mm 20 508 mm MCC Sections 3 3 4 Shipping Weight 2500 Ibs 1134 kg 2500 Ibs 1134 kg 3500 Ibs 1588 kg Operating Sound Level 83 dB wt A 83 dB wt A 82 dB wt A The height includes a 1 5 high base channel Q The height f
70. ping Weight A 2 Specifications 7 4 Startup 6 7 Support P 6 F Features Standard Features 7 7 B 3 B 5 Standard Options 1 2 B 3 B 5 Field Bridge 1 7 1 17 1 18 Field Transformer 1 17 5 6 5 8 Publication 2361 5 01 July 1998 Index Specifications 7 4 Altitude A 7 A 2 Drive Dimensions A 2 Drive Weight A 2 Incoming Devices 7 72 Installation 5 1 5 12 Electrical A 3 J Operating Sound Levels A 2 Temperature 7 Support P 6 Measurement Points 6 7 T 0 Temperature Specifications A 7 Options B 3 B 5 Overload Capability A 7 Wiring 5 4 5 5 5 7 Power Dissipation 4 Ratings A 3 Receiving Your Drive System P 5 References P 4 Related Documentation P 4 Safety Precautions 2 Schematics 115V AC and Contactor Control Connections 5 11 12504 Drive 2 2 2 5 1650A Drive 3 3 3 5 3000A Drive 4 3 4 5 Overview 7 3 Spare Parts Kits B 7 B 8 B 10 Publication 2361 5 01 July 1998 Rockwell Automation Rockwell Automation helps its customers receive a superior return on their investment by bringing ___ _ together leading brands in industrial automation creating a broad spectrum of easy to integrate products These are supported by local technical resources available worldwide a global network of system solutions providers and the advanced technology resources of Rockwell Worldwide representation Argentina Australia Aust
71. please have the catalog numbers of your products ready when you call Contents Standard Features Chapter 1 Product Overview The high horsepower line of 1395 DC drives are Bulletin 1395 regulator products with a high horsepower silicon controlled rectifier SCR bridge packaged in a Bulletin 2361 CENTERLINE motor control center providing DC power for your high horsepower applications This first chapter will introduce you to the high horsepower Bulletin 1395 drive covering these topics StndadFeaues Standard Options 1 2 Hardware Overview 1 3 Control Components 1 4 Control Power Interface Components 1 7 Power Components 1 12 The high horsepower Bulletin 1395 drive includes the following standard features e NEMA Class I construction e High AIC instantaneous trip circuit breaker or line fuses for the AC input armature cell fuses and a DC output contactor e a six pulse full wave rectified armature converter e 43A single phase field regulator regenerative 1250 1650 and 3000A or non regenerative 1250 and 1650A units only e 6 1 constant horsepower range e d digital control for current velocity and configuration e auto tuning for velocity loop current loop field flux table Publication 2361 5 01 July 1998 1 2 Product Overview Standard Options Publication 2361 5 01 July 1998 e programmable functions independent acceleration deceleration adjustment preset speeds cu
72. power components work together to convert single phase AC power to a DC output used for powering your motor field The following items make up the field power circuitry field bridge e field pulse transformer board In addition fuses metal oxide varistors MOVs and an inductor as shown in Figure 1 12 are used to protect the field bridge from extreme current and voltage conditions The field circuitry is fan cooled Note The field power components are rated for voltages up to 460V AC Drives with input voltages of 575 or 660V AC use a single phase field transformer PT5 to step down the voltage to 460V AC 5 shown in Figure 1 12 is connected at the customer site Figure 1 12 Field Bridge 1 AU AE Field Step BRAS nw s 3MoV Transformer Typical Transformer Arrangement used for 576 660V AC inputs 575 460V L3 612 GIF2 116216221 1L1 660V 1 H2 x2 Field Pulse Transformer Board 5 TB1 Feedback Board A1 Publication 2361 5 01 July 1998 1 18 Product Overview Standard Field Bridge The field bridge uses four SCRs to convert the single phase AC power into a DC output For the SCRs to conduct they must be forward biased and have a pulse applied to their gates The SCR gate is
73. provide power to all the printed circuit boards Figure 1 6 Unit Power Supply Board Connection to Power Stage Interface Board 5V and 12V Connection to Power Stage Interface Board 115V AC SQ Publication 2361 5 01 July 1998 1 10 Product Overview Feedback Board The feedback board receives status information from the drive components scales it to a signal level and supplies it to the main control board through the power stage interface board Figure 1 7 Feedback Board 28088088000 n n Lr 17 10 a 4 i r r i 150 301VAC 576VAC 1 TO 150 Jen AG LS soivac S76VAC 1sovac d s7avac N S00VAG 00 eoovac sovas 300 575 680 4 991 4 0 0 44 i 44 e io 4 E T82 BOS T83 e Rockwell Automation FEEDBACK BURDEN RESISTOR FEEDBACK BURDEN RESISTOR ARMATURE 1 300 VAC 575 690VAC 690VAC S 1 i 1 rina T Jumper Connection To Power Stage Not Used Jumper Connections Field Current Interface Board AC
74. ria Bahrain Belgium Bolivia Brazil Bulgaria Canada Chile China People s Republic of Colombia Costa Rica Croatia Cyprus Czech Republic Denmark Dominican Republic Ecuador Egypt El Salvador Finland France Germany Ghana Greece Guatemala Honduras Hong Kong Hungary Iceland India Indonesia Iran Ireland Israel Italy Jamaica Japan Jordan Korea Kuwait Lebanon Macau Malaysia Malta Mexico Morocco The Netherlands New Zealand Nigeria Norway Oman Pakistan Panama Peru Philippines Poland Portugal Puerto Rico Qatar Romania Russia Saudi Arabia Singapore Slovakia Slovenia South Africa Republic of e Spain Sweden Switzerland Taiwan Thailand Trinidad Tunisia Turkey United Arab Emirates United Kingdom United States Uruguay Venezuela Rockwell Automation Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Rockwell Automation European Headquarters SA NV avenue Herrmann Debrouxlaan 46 1160 Brussels Belgium Tel 32 2 663 06 00 Fax 32 2 663 06 40 Rockwell Automation Asia Pacific Headquarters 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 2361 5 01 July 1998 P N 185409 1998 Rockwell
75. rrent limit tapered current limit tach loss recovery system reset e protective features instantaneous overcurrent motor overload feedback loss field loss field economy tach loss recovery system reset e CENTERLINE Bulletin 2361 Motor Control Center enclosure The following options are available for the high horsepower 1395 drives e 115V AC discrete adapter board 24 DC discrete adapter board node adapter board e multi communications adapter board e door mounted DHT or programming terminal e start running and clear fault drive faulted door mounted illuminated pushbuttons e drive stop hardwired stop jog forward and jog reverse door mounted pushbuttons e power on door mounted pilot light e door mounted speed potentiometer e 1 2 3 speed selector blower starter NEMA IEC e single phase field regulator control circuit transformer e top hat input enclosure standard for 3000A drive line RC suppressor e AC power thru bus Note Additional options are listed in Appendix B Hardware Overview EI J4 Programming Terminal DHT DMT TB3 CONTROL 1 Product Overview 1 3 The hardware components shown in form the high horsepower 1395 DC drive These drive components can be broken down into the following three categor
76. s Publication 2361 5 01 July 1998 4 8 Your 3000A DC Drive Drive Structure Figure 4 4 3000A DC Drive Structure 20 inches 508 mm Top Hat Assembly 20 inches 508 mm 103 5 inches 2629 mm 91 5 inches 2324 mm CL C J T T 20 inches gt lt 20 inches 20 inches gt 508 mm 508 mm 508 mm Conclusion Publication 2361 5 01 July 1998 This chapter covered the components schematics and structure of your 3000A DC drive Unit specifications derating charts a power dissipation chart a circuit breaker illustration an air baffle diagram and an input busbar diagram for the 3000A DC drive are all given in Appendix A Contents Resources Chapter 5 Installing Your Drive This chapter will guide you in the installation of your new drive The following topics will be covered Topic Page Resources 5 2 Physically Installing the Unit at Your Site 5 2 Preparing AC Input Entry 5 2 Installing and Configuring Your Drive 5 4 To properly install and configure your drive you will need the following publications Publication Title 2300 5 1 Bulletin 2300 Family of Drive System
77. s 1250 3000A DC units 2 sets 1 2361 SPE12A Line Fuses 1250A DC units 1 set 1 2361 SPE13A _ Fuses 1650A DC units 1 set 1 2361 SPE14A Line Fuses 3000A DC units 1 set 1 2361 SPMO1A Feedback Board 1250 30004 DC units 1 1 2361 SPMO3A _ Armature Pulse Transformer Board 1250 3000A DC units 1 1 2361 SPMO4A _ Pulse Transformer Board for Option 14FX 1250 3000A DC units 1 2 2300 SPBO1A Line RC Suppressor Option 14LSP 1250 3000A DC units je a 2 2300 SPJ02A Line MOVs 1250 30004 DC units 1 set 2 2300 SPPO1A Air Flow Switch PCB Kit Option 14AFL 1250 16504 DC units i a 2300 SPP02A Air Flow Switch PCB Kit Option 14AFL 3000A units 1 PCB 1 power supply 1 1A 2 2 2361 SPAO1A _ Positive Top Regenerative Armature Assemblies 1250A DC units 1 2 2361 SPA02A Negative Bottom Regenerative Armature Assemblies 12504 DC units 1 2 2361 SPAO3A Top Regenerative Armature Assemblies 16504 DC units 1 2 2361 5 4 Negative Bottom Regenerative Armature Assemblies 16504 DC units 1 2 2361 SPA05A Top Regenerative Armature Assemblies 3000A DC units 1 2 2361 5 Negative Bottom Regenerative Armature Assemblies 3000A DC units 1 2 2361 5 7 _ SCR Module for Option 14FX 1250 3000A DC units 1 2 2361 SPA08A To
78. s You should only attempt the procedures in this manual if you are qualified to do so and are familiar with solid state control equipment and the safety procedures in ANSI NFPA 70E ATTENTION An incorrectly applied or incorrectly installed drive system can result in component damage and or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply and excessive ambient temperatures can result in the malfunction of hte drive equipment ATTENTION This drive system contains parts and assemblies that are sensitive to ESD electrostatic discharge Static control precautions are required when installing testing or repairing this assembly Component damage can result if ESD control procedures are not followed If you are not familiar with static control procedures refer to Rockwell Automation publication 8000 4 5 2 Guarding Against Electrostatic Damage or another adequate handbook on ESD protection 3 Contents of this Manual Chapter Title Contents Preface Purpose background and scope of this manual 1 Product Overview Theory of operation features and standard options 2 Your 1250A DC Drive Features components and schematics of the 1250A drive R frame 3 Your 1650A DC Drive Features components and schematics of the 1650A drive S frame 4 Your 3000A DC Drive Features components and schematics of the 3000A drive T frame 5 Installing Your
79. s Hardware Installation Manual 2100 5 5 Receiving Handling and Storing Motor Control Centers instructions 1395 5 40 1395 Digital DC Drive User Manual Plus you may need to refer to your system schematics motor encoder documentation and other documentation listed in the preface of this manual for adapter boards and NEC standards Physically Installing the Preparing AC Drive Your gt Input Entry RE Site This Manual This Manual References Reference ra References N Receiving Bulletin 2300 Top Hat Handling and Family of Drive 70 Assembly Installing and Storing Motor Systems Rae Local Codes Control Hardware Instructions Configuring Misc included with Your Drive Centers Installation f Reference top hat This Manual Instructions Manual assembly Manuals 2100 5 5 2300 5 1 ATTENTION Electric shock or equipment damage may occur if the drive is not installed properly Comply to the provisions listed in the National Electric Code NEC and in your local codes to safely install your drive Publication 2361 5 01 July 1998 5 2 Installing Your Drive Physically Installing the Drive To move and position the unit at your site you will need to follow the at Your Site instructions given in Publication 2100 5 5 titled Receiving Handling And Storing Motor Control Centers Instructions This publication will instr
80. s Standard Field Voltage Li 12 13 3 Phase Disconnect DC Motor DC Motor Shunt Field Armature Field Transformer For high horsepower units with a 575 or 660V AC input the field supply requires a transformer to step down the voltage to 460V Figure 5 3 shows the typical transformer wiring scheme 113 Figure 5 3 Field Transformer C ae 8 1 575 or To Field 460 660V 2 Bridge Field Transformer Enclosure Typical Transformer Arrangement used for 575V AC inputs or greater Publication 2361 5 01 July 1998 Installing Your Drive 5 7 The following table shows the transformer sizes available typical wire sizes used and the corresponding field currents Refer to local codes for all wiring Table 5 F Field Transformers Size Selections AWG Current A 10 12 18 15 10 28 20 8 40 50 3 90 Installing the Field Transformer 1 Mount the transformer enclosure and remove any input output knockouts as necessary see Figure 5 4 for enclosure details 2 Ground the enclosure according to local codes 3 Remove the top plate from the enclosure 4 Connect the first and third phases to the transformer primary 220 to HI F21 to 2 ATTENTION The motor field supply is phase sensitive To guard against possible drive or motor damage ensure that the connections are m
81. t up to one option from this group You must select one option from this group For 1250 to 3000A modules you may select option 1408 This option includes a dynamic braking contactor mounted in a separate 20 MCC section The line RC suppressor is recommended for installations where the primary of the distribution transformer is 2300V AC or greater This option is only valid for 1250A and 1650A DC drives You must specify a AC thru bus option with a current capacity larger than the continuous input current rating of the drive unit Units come standard with a field supply module rated to supply field currents up to 43A This field supply option allows you to supply up to 90A to the motor field If you are selecting a 575 or 660V AC input and this field supply option you must select field voltage step down option 145090 Units come standard with cloth wire labels Datab labels offer the added protection of a clear plastic cover on top of the labels Customer supplies 115V AC control power and wiring to the duplex receptacle Publication 2361 5 01 July 1998 6 Catalog Numbers and Spare Parts Kits DC Drive Spare Parts Kits Publication 2361 5 01 July 1998 These spare parts kits are designed to provide you with the necessary parts to repair and maintain your drive What Does a Spare Parts Kit Include A spare parts kit includes the items in the quantities described in Tables A B and C Each spare parts kit also contains instal
82. t written permission of Rockwell Automation is prohibited Throughout this manual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to e identify a hazard e avoid a hazard recognize the consequences Datab is a trademark of W H Brady Company CENTERLINE PLC 5 DriveTools and ControlNet are trademarks of Rockwell International or its subsidiaries Preface Chapter 1 Table of Contents CONTENTS iua a Pe ae cado Ne ee meee ee 1 Who Should Use This Manual P 1 Purpose of This Manual P 1 Safety Precautions P 2 Contents of this Manual P 3 Related Documentation P 4 Style of this Manual P 5 Terms and Abbreviations P 5 Receiving Your Drive System P 5 Rockwell Automation P 6 Local Product Support P 6 Technical Product Assistance P 6 Product Overview CONTENTS ana a EREE EE ENE EE ENEE E 4 1 1 Standard Features 1 1 Standard Options
83. ter Board Adapter Board Port B Port OPTIONAL 1 OPTIONAL JS J4 i 5 1 Im 1 L L TB3 IHE EE Main Control sP gt Board Br 4 n 7 Fe F20 Fell Fel e O 113 I 113 1 7 10 5 7 Ji J7 n J6 1 Publication 2361 5 01 July 1998 Product Overview 1 5 Main Control Board The main control board is the center of the control processing This board has a number of test points and jumpers that are used during startup and troubleshooting Refer to the troubleshooting manual for more information on test points and jumpers Figure 1 3 Main Control Board Connection to Power Connection to Connection to Power Stage Interface Board Programming Terminal Stage Interface Board 2 5 TP9 123 o o Connection TP24 TP27 TP26 123 000 o 1 2 3 TP33 TP34 o o TP31 TP29 o TP8 TP39 E TP47 TP44 o o TP20 1 2 3 TP54 TP53 TP58 o o 150 12V IGND 150 5V TP51 52 TP56 TP55 TP57 5V DGND 12V 12V AGND Publication 2361 5 01 July 1998 1 6 Product Overview Publication 2361 5 01 July 1998 Door Mounted Programming Terminal The door mounted Bulletin 1300 programming terminal is the interface module used to program and control the drive typically used in standalone applications
84. tics 4 3 Symbol Reference Chart 4 6 Drive Structure 4 8 Conclusion 4 8 Your 3000A DC drive functions with the following features 3000A drive uses twelve SCRs in the armature bridge to convert the 3 phase AC input to a DC output six for the positive DC output and six for the negative The SCRs are built into a heatpipe assembly and are cooled by the bridge fan e 3000A drive is protected from incoming fault currents with a circuit breaker and the DC output is protected from fault currents with a DC contactor The components of your drive the armature bridge field bridge and control components are protected with fuses MOVs snubbers and or chokes 3000A drive is constructed and housed in four bays the first bay containing the AC input and control hardware the second bay containing the fuses the third bay containing the armature bridge hardware and the fourth bay containing the DC output hardware 3000A drive has a standard top hat extension over the disconnect bay for the AC input Publication 2361 5 01 July 1998 4 2 Your 3000A DC Drive Drive Layout Figure 4 1 3000A DC Drive Layout Top Hat Assembly For AC Wire Entry 22 J4 15 TB2 TB1 1395 Regulator Con
85. to J42 2 5 9 8 5 17 5 3 J38 to 9 9 18 6 17 6 37 1 4 J39 to J44 18 7 43 37 2 86 Table 5 H Feedback Board Jumper Settings Input Voltage Line Voltage Jumper Settings V AC A B C VA VA 460 J7 to J22 7100425 1 28 Ji6toJ3i 19 to J34 575 J7toJ22 J10toJ25 J13toJ28 J16toJ31 J19 to J34 660 J8 to J23 11 40 426 14 29 Ji7toJ32 20 to J35 Table 5 J Power Stage Interface Board Jumper Settings Jumper Position Purpose J11 1 2 115V AC Motor Thermal Input 2 3 24V DC Motor Thermal Input J12 1 2 115V AC Reset Input 2 3 24V DC Reset Input Publication 2361 5 01 July 1998 5 10 Installing Your Drive Table 5 K Main Control Board Jumper Settings Jumper Position Purpose J8 J9 and J10 1 2 5V DC Encoder Power 2 3 12V DC Encoder Power J14 1 2 EE Write Enable 2 3 EE Write Disable Table 5 L 115V AC Control Circuit Current Requirements Current 1250A Drive 1650A Drive 3000A Drive Total Sealed Current 8A 8A 8A Total Inrush Current 14A 14A 14A Publication 2361 5 01 July 1998 Figure 5 5 115V AC Input and Contactor Control Connections Installing Your Drive
86. trol Boards DHT F20 F21 1 TB10 TBS 2 1 Disconnect Fuse Bay Bridge Bay Contactor Bay Publication 2361 5 01 July 1998 Your 3000A DC Drive 4 3 Drive Schematics Figure 4 2 3000A DC Drive Electrical Schematic Sheet 1 Fg 1 HC S F51 1 A u rO i Continued in ploy Figure 4 3 O Circuit Breaker Line Fuse Option Option DCMOTOR AC BLOWER MOTOR m u DCMOTOR AC BLOWER 1 MOTOR M12 0L12 1 1 1 1 1 1 1 1 1 1 Continued in i i Figure 4 3 eae ER aE a An 24VDC 0 5A TB230HI To 24V DC Discrete Adapter Board 161689 1812010 or 24 DC Digital Reference Board 115V Discrete Adapter Board FOOTNOTES TE Ae De Sa ee Part of 24V DC Discrete Adapter Option I_ or 24V DC Digital Reference Option Publication 2361 5 01 July 1998
87. uct you in the proper handling moving and positioning of your new drive After drive is properly positioned follow instructions given in Publication 2300 5 1 titled Bulletin 2300 Family of Drive Systems Hardware Installation Manual This publication will teach you how to splice busbars how to attach your unit in a multiple drive configuration and how to join MCC sections together if necessary Inspecting the Air Baffles Inspect the air baffles and guards according to the air baffle layouts shown in Appendix A Preparing AC Input Entry If your drive has an extra input bay installed you can skip this section To prepare input entry select the ideal hole placement within the constraints of the following diagram then follow the installation steps given The following instructions include directions for a top hat assembly Note When preparing the input entry you may need to consider the busbar arrangement and the wire sizes Busbar diagrams are shown in Appendix A and recommended wire sizes are listed later in this chapter Figure 5 1 Area Available For Conduit Entry Top View of Disconnect Bay 1 25 20 00 _ Y Back of Enclosure Area Available For 11 50 Conduit Entry 20 00 1 14 Front of Enclosure 3000A units allow a depth of 16 75 for conduit entry Publication 2361 5 01 July 1998 Installing Your Drive 5 3 Remove the lifting angle
88. work together to convert the 3 phase AC input to a DC output used for powering your motor armature The following items make up the armature power circuitry e armature bridge and its subordinate components e cell fuses e gate boards DC contactor Armature Bridge The armature bridge is designed to convert incoming AC power to DC power The non regenerative bridge is shown in Figure 1 9 Cell fuses protect the thyristors in the event of a bridge failure Figure 1 9 Armature Bridge Non Regenerative Main Contactor Armature Pulse Armature Pulse Transformer Board Transformer Board Armature Pulse Al y Transformer Board 3 Phase AC Input Armature Pulse Transformer Board Armature Pulse Armature Voltage Transformer Board Armature Pulse Transformer Board A2 Publication 2361 5 01 July 1998 Armature Pulse Transformer Board 1 Product Overview 1 15 The regenerative bridge shown in F

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