Instruction Manual
Distributed Power SystemHigh Power SB3000AC Power Modules (Rittal)
804300-S (445 Amp)
804300-T (890 Amp)
804300-V (1335 Amp)
S-3031
The information in this users manual is subject to change without notice.
AutoMax™ is a trademark of Rockwell Automation
©1998 Rockwell International Corporation
Throughout this manual, the following notes are used to alert you to safety considerations:
Important: Identifies information that is critical for successful application and understanding of the product.
!ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.
!ATTENTION: Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors to discharge, then look at the built-in DC bus voltage meter. When the voltage is down to zero (0) volts, open the cabinet doors and check the voltage across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION: The user must provide an external, hardwired emergency stop circuit outside of the drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled machine operation may result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.
ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
Table of Contents I
CONTENTS
Chapter 1 Introduction1.1 Standard Features........................................................................................... 1-21.2 Power Module Part Numbers .......................................................................... 1-21.3 Related Publications........................................................................................ 1-3
Chapter 2 Power Module Description2.1 Mechanical Description ................................................................................... 2-12.2 Electrical Description ....................................................................................... 2-3
Chapter 3 Installation Guidelines3.1 Installation Planning ........................................................................................ 3-13.2 Wiring .............................................................................................................. 3-2
3.2.1 Fuses .................................................................................................... 3-23.2.2 Pre-charge Resistors and Fuses........................................................... 3-23.2.3 Line Filter Reactors ............................................................................... 3-33.2.4 Control Transformers ............................................................................ 3-33.2.5 Wire Sizes ............................................................................................. 3-43.2.6 Wire Routing ......................................................................................... 3-5
3.3 Grounding........................................................................................................ 3-53.4 Installing a Power Module Cabinet .................................................................. 3-5
Chapter 4 Diagnostics and Troubleshooting4.1 Required Test Equipment ................................................................................ 4-14.2 Power Module Tests with Input Power Off ...................................................... 4-24.3 Power Module Faults and Warnings................................................................ 4-4
4.3.1 Faults .................................................................................................... 4-54.3.1.1 DC Bus Overvoltage Fault ...................................................... 4-64.3.1.2 DC Bus Overcurrent Fault....................................................... 4-64.3.1.3 Ground Current Fault .............................................................. 4-64.3.1.4 Instantaneous Overcurrent Fault ............................................ 4-64.3.1.5 Local Power Interface Fault .................................................... 4-64.3.1.6 Gate Driver Interface Fault...................................................... 4-64.3.1.7 Charge Fault ........................................................................... 4-64.3.1.8 Overtemperature Fault ............................................................ 4-74.3.1.9 Power Loss Fault .................................................................... 4-74.3.1.10 Power Technology Fault ......................................................... 4-74.3.1.11 PMI Power Supply Fault ......................................................... 4-74.3.1.12 PMI Read/Write Fault.............................................................. 4-74.3.1.13 UDC Run Fault........................................................................ 4-74.3.1.14 Communication Lost Fault ...................................................... 4-7
4.3.2 Warnings ............................................................................................... 4-74.3.2.1 DC Bus Overvoltage Warning................................................. 4-84.3.2.2 DC Bus Undervoltage Warning............................................... 4-84.3.2.3 Ground Current Warning......................................................... 4-94.3.2.4 Phase Lost Warning................................................................ 4-94.3.2.5 Reference in Limit Warning..................................................... 4-94.3.2.6 Load Sharing Warning ............................................................ 4-94.3.2.7 Overtemperature Warning ...................................................... 4-9
II SB3000 Power Modules (Rittal)
Chapter 4 Diagnostics and Troubleshooting (Continued)4.3.2.8 Bad Gain Data Warning...........................................................4-94.3.2.9 Power Module Overload Warning............................................4-94.3.2.10 Power Loss Warning ...............................................................4-94.3.2.11 PMI Fan Loss Warning ..........................................................4-104.3.2.12 Rail Communication Warning ................................................4-104.3.2.13 CCLK Not Synchronized Warning .........................................4-104.3.2.14 PMI Communication Warning................................................4-10
4.4 Replacing the Power Module Cabinet............................................................4-104.5 Replacing Power Module Sub-Assemblies ....................................................4-11
4.5.1 Replacing Fuses ..................................................................................4-114.5.2 Replacing an IGBT Phase Module Assembly......................................4-15
4.5.2.1 Replacing an IGBT ................................................................4-174.5.3 Replacing a Blower Assembly .............................................................4-17
4.5.3.1 Replacing a Blower Filter.......................................................4-174.5.4 Replacing a Bus Capacitor Assembly..................................................4-18
4.6 Performing the Bridge Test ............................................................................4-19
Appendix A Technical Specifications........................................................................................... A-1
Appendix B SB3000 Component Block Diagram ........................................................................ B-1
Appendix C Theory of Operation ................................................................................................. C-1
Appendix D SB3000 Interlock Sequencing.................................................................................. D-1
Appendix E Replacement Parts................................................................................................... E-1
Index ........................................................................................................................... Index-1
Table of Contents III
List of Figures
Figure 2.1 – DC Bus Voltage.................................................................................... 2-3Figure 2.2 – 445A SB3000 Power Module Components .......................................... 2-5Figure 2.3 – 890A SB3000 Power Module Components .......................................... 2-6Figure 2.4 – 1335A SB3000 Power Module Components ........................................ 2-7Figure 2.5 – 445A SB3000 Power Module Circuitry ................................................. 2-8Figure 2.6 – 445A SB3000 Power Module Circuitry (Continued) ............................. 2-9Figure 2.7 – 890A SB3000 Power Module Circuitry ............................................... 2-10Figure 2.8 – 890A SB3000 Power Module Circuitry (Continued) ........................... 2-11Figure 2.9 – 890A SB3000 Power Module Circuitry (Continued) ........................... 2-12Figure 2.10 – 1335A SB3000 Power Module Circuitry ........................................... 2-13Figure 2.11 – 1335A SB3000 Power Module Circuitry (Continued) ....................... 2-14Figure 2.12 – 1335A SB3000 Power Module Circuitry (Continued) ....................... 2-15Figure 2.13 – 1335A SB3000 Power Module Circuitry (Continued) ....................... 2-16
Figure 3.1 – 445A SB3000 Power Module Mounting Dimensions............................ 3-6Figure 3.2 – 890A SB3000 Power Module Mounting Dimensions............................ 3-7Figure 3.3 – 1335A SB3000 Power Module Mounting Dimensions.......................... 3-8Figure 3.4 – SB3000 Power and Ground Connections............................................. 3-9
Figure 4.1 – DC Bus Voltage Measuring Points ....................................................... 4-3Figure 4.2 – 445A SB3000 Power Module Fuse Locations.................................... 4-12Figure 4.3 – 890A SB3000 Power Module Fuse Locations.................................... 4-13Figure 4.4 – 1335A SB3000 Power Module Fuse Locations .................................. 4-14Figure 4.5 – IGBT Module Assembly Mounting Bolt Locations ............................. 4-16
IV SB3000 Power Modules (Rittal)
Table of Contents V
List of Tables
Table 1.1 – SB3000 Power Module Current Ratings................................................ 1-1Table 1.2 – SB3000 Part Numbers........................................................................... 1-2
Table 2.1 – Meter Scaling......................................................................................... 2-2
Table 3.1 – AC Input and DC Bus Fuse Ratings ...................................................... 3-2Table 3.2 – Pre-charge Resistors and Fuses ........................................................... 3-3Table 3.3 – Line Filter Reactor Ratings .................................................................... 3-3Table 3.4 – Recommended AC Input and DC Bus Output Wire Sizes ..................... 3-4Table 3.5 – Terminal Tightening Torques................................................................. 3-4
Table 4.1 – DC Bus and Output Terminal Tests....................................................... 4-4Table 4.2 – IGBT Tests............................................................................................. 4-4Table 4.3 – SB3000 Fault Register 202/1202........................................................... 4-5Table 4.4 – SB3000 Warning Register 203 /1203 .................................................... 4-8Table 4.5 – Power Module Fuse Specifications...................................................... 4-15
VI SB3000 Power Modules (Rittal)
Introduction 1-1
CHAPTER 1Introduction
The High Power SB3000 Power Modules are variable-voltage, limited-frequency, high performance PWM power converters. They are designed to be used with Distributed Power System (DPS) SA3000 and SA3100 PWM inverter drives and other high performance PWM-type inverters that operate from a fixed voltage DC Bus input.
The SB3000 Power Modules operate as two- quadrant, fast-response, synchronous rectifiers converting fixed-frequency AC power to regulated voltage DC power using pulse-width-modulation (PWM) technology. They can operate in both the motoring and regeneration modes in response to the load applied to the DC output. SB3000 Power Modules are capable of full rating regeneration of power to the AC line and feature adjustable power factor operation.
The SB3000 Power Modules operate in conjunction with a separately-mounted input reactor and a separately-supplied power distribution cabinet, which provides AC power protection, disconnect, and soft-charge functionality for the SB3000 Power Modules. Refer to Appendixes C and D for more information on SB3000 theory of operation and interlock sequencing.
The SB3000 Power Modules are available in three output power ratings: 445 amp, 890 amp, and 1335 amp when used at a 4 kHz carrier frequency. They have a range of AC Input voltage ratings. Nominal DC bus voltage may range from 300 to 800 VDC.
Output current with a 2 kHz carrier frequency is 534A, 972A, and 1457A. A 4 kHz carrier frequency is typically used to minimize the size of the AC line reactor. Four kHz operation requires a derating of the AC input current and DC output load current when compared with operation at 2 kHz.
The SB3000 Power Module output current ratings are 100% continuous with no overload. They may be derated for lower current ratings with overload capability. See table 1.1.
Table 1.1 – SB3000 Power Module Current Ratings1
SB3000Part Number
ContinuousAC Input Current
(460VAC)
ContinuousDC Output Current
(800VDC)
5 MinuteAC Input and DC Output
Overload 2
804300-S 445A (rms) 445A DC 534A (rms)
804300-T 890A (rms) 890A DC 972A (rms)
804300-V 1335A (rms) 1335A DC 1457A (rms)
1. At 460 VAC Input/800 VDC Output/4kHz Carrier Frequency. For use with SA3000 Power Modules operating at a 2 kHz carrier frequency.2. With a 25% duty cycle
1-2 SB3000 Power Modules (Rittal)
1.1 Standard Features
The SB3000 Power Modules have the following standard features:
• Input power supplied from a separate disconnect/soft-charge cabinet and AC line reactor
• PWM synchronous rectifier converts AC power to DC power for a fixed-voltage PWM inverter DC bus
• IGBT power semiconductor bridge
• PWM output
• 4 kHz carrier switching frequency
• Ability to add or remove drives from the DC bus while the SB3000 Power Module is running
• Input and output short-circuit protection
• Fiber-optic communication with the DPS host, the Universal Drive Controller (UDC) module
• Auto-tuning without an identification test
• NEMA 1 Cabinet
• PMI Rack
• Top Entry of AC Input Power
• Top Exit of DC Output Power
• Standard Paint
1.2 Power Module Part Numbers
SB3000 Power Module part numbers are organized by the number of cabinet bays, e.g., one, two, or three-bay cabinet configurations. See table 1.2.
Table 1.2 – SB3000 Part Numbers
Cabinet Type SB3000
Part NumberSB3000
B/M Number
One-Bay (445A) 804300-S 101165-190S
Two-Bay (890A) 804300-T 101165-190T
Three-Bay (1335A) 804300-V 101165-190V
Introduction 1-3
1.3 Related Publications
This manual describes the hardware components of the SB3000 Power Module. Refer to the publications listed below for detailed descriptions of the remaining components of the SB3000 system and the configuration and programming necessary to control the SB3000 Synchronous Rectifier.
• S-3005 AutoMax Distributed Power System Overview
• S-3007 DPS Universal Drive Controller Module
• S-3009 DPS Fiber-Optic Cabling
• S-3034 DPS SB3000 Configuration and Programming
Refer to the following manuals for information on Distributed Power System AC Power Modules for use with the SB3000 Synchronous Rectifier:
• S-3038 DPS SA3000 High Power AC Power Modules (binder S-3001)
• S-3058 DPS SA3100 AC Power Modules (binder S-3053)
1-4 SB3000 Power Modules (Rittal)
Power Module Description 2-1
CHAPTER 2Power Module Description
This chapter provides an overview the Power Module’s main components and their mechanical and electrical characteristics. Refer to Appendix B for a block diagram of the Power Module. The SB3000 theory of operation is described in Appendix C.
2.1 Mechanical Description
High Power SB3000 Power Modules are housed in protective sheet metal enclosures, as shown in figures 2.2 to 2.4. The Power Modules come in single, double, and triple bay cabinet configurations, depending upon the current rating. See figures 3.1 to 3.3 for Power Module dimensions.
The Power Modules have the following main components:
Phase modules
Each Phase module contains four semiconductor IGBTs (insulated gate bi-polar transistors). IGBT pairs are switched on and off by the integrated Snubber/Gate Driver module to provide regulated DC output voltage. Fuses and thermostats are provided to protect the IGBT modules.
Snubber/Gate Driver Module
Each Snubber/Gate Driver module receives gating signals via fiber-optic cabling from the GDI module(s) in the PMI rack and translates the signals into the appropriate voltage and current levels to turn the IGBTs on and off. Feedback, indicating the integrity of the module and IGBTs, is then sent back to the GDI module(s).
This module also provides snubber circuitry, resistors, diodes, and capacitors, to control voltage transients produced when the IGBTs are switching.
Fiber-Optic Communication
Fiber-optic cabling is used to transmit gate driver signals from the Gate Driver Interface (GDI) module.These signals are used to turn the IGBTs on and off. IGBT module feedback status information is sent via the fiber-optic cabling back to the GDI module(s) in the PMI rack. Fiber-optic cabling is immune to electromagnetic and radio frequency interference (EMI/RFI) and eliminates ground loops. For more information on fiber-optic cabling refer to the Distributed Power System Fiber-Optic Cabling instruction manual (S-3009).
Local Power Interface module (LPI)
The LPI module is the interface between the SB3000 Power Module and the PMI rack. It is through this module that information is sent to the SB3000 Power Module and feedback data is sent back to the PMI rack.
2-2 SB3000 Power Modules (Rittal)
Capacitor Bank Assembly
The capacitor bank's electrolytic capacitors store DC power from the IGBTs.
DC Bus Voltage Meter
The DC Bus Voltage meter, which is connected directly across the DC bus, measures the DC bus voltage being supplied by the SB3000 Power Module.
AC Input Current Meter and DC Bus Current Meter
The AC Input Current and DC Bus Current meters measure the AC input current being provided to the Power Module and the DC bus output current supplied by the SB3000 Power Module. These meters are connected to the PMI meter ports on the PMI Processor. The meters are calibrated for +/-10V or +10V at full scale. See table 2.1. Note that PMI ports 3 and 4 are not used.
The AC Input Current meter indicates the RMS line current flowing into or out of the SB3000 Power Module. The current level is derived from the feedback signals coming from the Hall devices on the AC input leads to the phase modules.
The DC Bus Current meter indicates the DC current level produced by the SB3000 Power Module. The value is scaled from the feedback signal coming from the Hall device monitoring the Power Module’s DC output current. Its range is bi-directional. Positive current indicates that current is flowing from the rectifier to the load (motoring) and negative current indicates current flowing into the rectifier from the load (regenerating) to the AC line.
Softcharge Assembly
The Softcharge assembly is mounted separately and consists of pre-charge resistors and a contactor. The contactor bypasses the pre-charge resistors after the bus voltage reaches a programmable threshold value. A pre-charge contactor module communicates with the LPI module and controls the contactor. See figure 2.1.
Table 2.1 – Meter Scaling
SB3000 AC Input Current Rating at
4 kHz
PMI Processor Port 1DC Bus Current Meter
Scaling
PMI Processor Port 2AC Input Current Meter
Scaling
445 Amp -800 to +800A 0 to 600A
890 Amp -1,200 to +1,200A 0 to 1,000A
1,335 Amp -1,800 to +1,800A 0 to 1,500A
Power Module Description 2-3
2.2 Electrical Description
AC power to the SB3000 Power Module is supplied from an AC power distribution/soft-charge cabinet through the AC input reactor.
The DC bus voltage is filtered by the electrolytic capacitors. Discharge resistors are designed to discharge the capacitors down to 50V DC within 5 minutes after power is removed from the input terminals. However, the user should wait ten minutes before working on the unit. Be sure to look at the built-in DC Bus Voltage meter and then measure the DC bus potential before touching any circuitry.
When AC power is applied to the SB3000 Power Module’s input terminals 181(L1), 182(L2) and 183(L3), the DC bus is charged through the IGBT emitter-collector diodes to the level of the rectified AC line voltage. See figure 2.1 and figures 2.5 to 2.13. Charging current is limited by the separately-mounted soft-charge resistors and the impedance of the AC input line reactor. Upon reaching the programmed level of DC bus voltage, the pre-charge resistors are bypassed by the pre-charge contactor, which places full line voltage across the AC line to the SB3000 Power Module.
The SB3000 Power Module’s inner control loop is enabled when the application task sets register 100/1100, bit 0, (VDC_RUN@). When this is done, the PMI Processor checks the interlocks as described in Appendix D. If the interlock conditions are satisfied, the DC bus voltage is ramped from the voltage produced by the diode rectification of the AC line voltage to the voltage reference value provided by the programmed outer control loop. The DC bus voltage is then regulated by the on-board voltage regulator. The ramp rate is 100 volts per second. When the preset reference voltage is reached, register 200/1200, bit 10, (VDC_ON@) is turned on to indicate that the Power Module is operating.
!ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors to discharge, then look at the built-in DC bus voltage meter. When the voltage is down to approximately zero (0) volts, open the cabinet doors and check the voltage across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.
Figure 2.1 – DC Bus Voltage
PowerOn
Vac ∗ 1.414
OVT_E0%
UVT_E0%
VDC_RUN
VDC_ON
2-4 SB3000 Power Modules (Rittal)
When the DC bus operating voltage is reached, the connected SA3000/SA3100 Power Modules may be operated. Note that an SB3000 Power Module cannot support the loading of SA3000/SA3100 Power Modules when the soft-charge resistors are limiting the bus charging current.
The filtered SB3000 DC output voltage is then fed to the DC bus inputs of the SA3000/SA3100 Power Module(s). The IGBTs are switched by the Gate Driver Interface module(s) in the PMI rack. Three LEM sensors provide input current feedback, which is used for control and overcurrent protection. One LEM sensor is used to provide DC output current feedback.
Each SA3000/SA3100 Power Module connected to an SB3000 Power Module-supplied DC bus must have a separate pre-charge resistor and contactor to limit the current into its capacitor bank. It is the responsibility of the application tasks to make sure that the SB3000 Power Module is in run before the SA3000/SA3100 Power Module is put into run.
If the SB3000 Power Module is not in run, the DC bus voltage will not be high enough to support the full rating of the SA3000/SA3100 Power Module. If the SB3000 Power Module is shut down due to a fault condition, controlled shutdown of the SA3000/SA3100 Power Module is the responsibility of the application program running in the SA3000/SA3100 UDC module.
!ATTENTION: SA3000/SA3100 Power Modules must be in standby or in regeneration whenever the SB3000 Power Module’ s pre-charge contactor opens. The SB3000 Power Module’s soft-charge resistors may fail if this interlocking restriction is not observed. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
!ATTENTION: The SB3000 Power Module must be in run before the SA3000/SA3100 Power Module is put into run. If the pre-charge contactor supplying the SB3000 Power Module is not closed, running the SA3000/SA3100 Power Module will damage the SB3000 pre-charge resistors. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
Power Module Description 2-5
1. Blower Assembly 2. IGBT Phase Module Assembly 3. Capacitor Bank Assembly4. Pre-charge Assy. Mounting Bracket 5. LEM Sensor - DC Bus Output 6. DC Bus Fuses7. +/- 15V DC Power Supply 8. 110V AC Disconnect Switch 9. 24V DC Power Supply10. LPI Module 11. 250VA Isolation Transformer 12. PMI Rack13. 25KHz Power Supply 14. Reactor Assembly 15. LEM Sensors (3) - AC Input16. Power Supply Fuses 17. Feedback Resistors 18. Pre-charge Module19. DC Feedback Module 20. AC Input Current Meter 21. DC Output Current Meter22. DC Bus Voltage Meter 23. Input Phase Fuses 24. Blower Filter25. Line Synchronization Module
(On the Meter Bracket)
Figure 2.2 – 445A SB3000 Power Module Components
CAPACITOR BANK
PW
R. M
OD
. A
AC INPUT
181 182
F103A
LPI CIRCUIT
PHASE U
PMI RACK
PHASE W
BLOWER
F105A
PHASE VF104AP1
SLO
T 6
SLO
T 7
SLO
T 8
PW
R. M
OD
. C
PW
R. M
OD
. B
110VD/S
±15VPS PS
-24V
2FU3FU
PS+24V
1FU
2
25KHZ PS
802268-16R
2FU
1FU
417114-81A
+ - 288289
24
15
15
1
12
2
17
GRD
14
15
3
GRD
2
5
13
CUSTOMER
NAMEPLATESALES ORDER
2021
11
10
78
9
16
19
22
25
CONTROLWIRING
GDIGDI GDI
POWER MODULE A
418
1836
F102A F101A
ASSEMBLY
23
2-6 SB3000 Power Modules (Rittal)
1. Blower Assembly 2. IGBT Phase Module Assembly 3. Capacitor Bank Assembly4. Pre-charge Assy. Mounting Bracket 5. LEM Sensor - DC Bus Output 6. DC Bus Fuses7. +/- 15V DC Power Supply 8. 110V AC Disconnect Switch 9. 24V DC Power Supply10. LPI Module 11. 250VA Isolation Transformer 12. PMI Rack13. 25KHz Power Supply 14. Reactor Assembly 15. LEM Sensors (3) - AC Input16. Power Supply Fuses 17. Feedback Resistors 18. Pre-charge Module19. DC Feedback Module 20. AC Input Current Meter 21. DC Output Current Meter22. DC Bus Voltage Meter 23. Input Phase Fuses 24. Blower Filter25. Line Synchronization Module
(On the Meter Bracket)
Figure 2.3 – 890A SB3000 Power Module Components
CAPACITOR BANK
PW
R. M
OD
. A
F103B PHASE U
F105B
F104B
AC INPUT
181 182
F103A
LPI CIRCUIT
PHASE U
PMI RACK
PHASE W
BLOWER
F105A
PHASE VF104AP1
SLO
T 6
SLO
T 7
SLO
T 8
PW
R. M
OD
. C
PW
R. M
OD
. B
110VD/S
±15VPS PS
-24V
2FU3FU
PS+24V
1FU
22
25KHZ PS
802268-16R
2FU
1FU
417114-81A
+ - 288289
24
15
1515
1
12
2
17
GRD
14
15
3 3
GRD
2
14 5
13
CUSTOMER
NAMEPLATESALES ORDER
2021
11
10
78
9
164
18
19
22
25
CONTROLWIRING
GDIGDI GDI
6
POWER MODULE B POWER MODULE A
418
183
215
215
PHASE V
PHASE W
24
CAPACITOR BANK
F101BF102B F101AF102A
(+)
2323
ASSEMBLYBLOWER
1
ASSEMBLY
Power Module Description 2-7
1. Blower Assembly 2. IGBT Phase Module Assembly 3. Capacitor Bank Assembly4. Pre-charge Assy. Mounting Bracket 5. LEM Sensor - DC Bus Output 6. DC Bus Fuses7. +/- 15V DC Power Supply 8. 110V AC Disconnect Switch 9. 24V DC Power Supply10. LPI Module 11. 250VA Isolation Transformer 12. PMI Rack13. 25KHz Power Supply 14. Reactor Assembly 15. LEM Sensors (3) - AC Input16. Power Supply Fuses 17. Feedback Resistors 18. Pre-charge Module19. DC Feedback Module 20. AC Input Current Meter 21. DC Output Current Meter22. DC Bus Voltage Meter 23. Input Phase Fuses 24. Blower Filter25. Line Synchronization Module
(On the Meter Bracket)
Figure 2.4 – 1335A SB3000 Power Module Components
CAPACITOR BANK
F102AF102C F101C F101BF102B
PW
R. M
OD
. A
F103BF103C PHASE U
F105C
F104C
F105B
F104B
POWER MODULE C
AC INPUT
181 182
F103A
LPI CIRCUIT
PHASE U
PMI RACK
PHASE W
BLOWER
F105A
PHASE VF104AP1
SLO
T 6
SLO
T 7
SLO
T 8
PW
R. M
OD
. C
PW
R. M
OD
. B
110VD/S
±15VPS
F101A
PS -24V
2FU3FU
PS+24V
1FU
22
25KHZ PS
802268-16R
2FU
1FU
417114-81A
+ - 288289
24
15
1515
1
12
2
19
GRD
14 14
15
3 3
GRD
2
6 5
13
CUSTOMER
NAMEPLATESALES ORDER
20
11
10
7 8
9
(+)(-)
4
18
418
19
22
25
CONTROLWIRING
GDIGDI GDI
14
POWER MODULE B POWER MODULE A
418
183
2
2
2 15
2 215
PHASE V
PHASE W
PHASE U
PHASE V
PHASE W
15
15
3
2424
CAPACITOR BANKCAPACITOR BANK
15
23 23 23
16
ASSEMBLYBLOWER
1
ASSEMBLYBLOWER
1
ASSEMBLY
21
2-8 SB3000 Power Modules (Rittal)
Figure 2.5 – 445A SB3000 Power Module Circuitry
1147
A
1145
A
BU
S
BU
S
147
145
47 45F
101A
F10
2A
CO
N1
445A
@ 4
KH
Z; M
ULT
IPLE
VO
LTA
GE
INP
UT
P/M
A
AS
SE
MB
LY
PW
R M
OD
A
O-5
5350
-10
CN
102
CO
N6
14
CO
N2
601
602
603
16
1
BLO
WE
R
CO
N2
PW
R M
OD
B1
112
CO
N5
1C
ON
2P
WR
MO
D C
OR
GY
EL
VIO
OR
GY
EL
VIOVIO
YE
LO
RG R
3R
4R
5
(805
401-
5T)
POWER SUPPLYB/M-60007
PM
I RA
CK
B/M-60029
TECHNOLOGYAC POWERB/M-60023
P2
P1
AC PARALLELINTERFACE
1> W
HE
N U
SIN
G C
HA
RT
RE
CO
RD
ER
CO
NN
EC
T
TO
TE
RM
INA
LS A
T B
AC
K O
F M
ET
ER
.
GR
D
B/M
-600
27
P1
F/O
B/M-60028GATE DRIVER
INTERFACESLOT 6
GD
I SLO
T 8
GD
I SLO
T 7
GD
I SLO
T 6
PO
WE
R
SE
E F
IGU
RE
2.6
D S
HE
LLD S
HE
LL D S
HE
LL
CO
N4
CN
106
1
RE
DR
ED
/YE
L
P/M
BC
ON
1P
/M C
CO
N1
CO
N3
112
CO
N6
TA
N
TA
N
1247
A11
45A
MO
DU
LE"A
"
25K
HZ
PS
(1)
1000
A
1000
A
/3
/3
2/
LPI
P1
GR
DL2L1L1 L2
CO
M
P1
RE
DB
LU
BR
NB
LK
GR
NW
HT
YE
LO
RG
+
PMI PROCESSOR
AND DRIVE I/O
B/M-60021
1
RESOLVERB/M-60031
P2
P1
RE
D
GR
AY
(612183-29R)
(612183-29S)
(612183-26RR)
(612
183
-25S
)
(612183-10S)
(61218
3-1
0T
)
(61218
3-1
0R
)
(612
183
-20R
)(6
12183
-28S
)
(61218
3-2
3R
R)
(61362
1-1
2R
)
(612
183
-24R
)
(61218
3-2
2R
)
(6121
83-2
1R)
(612183-15R)
(612
183
-29S
)
GR
D
H2
H1
1FU
BLK
WH
T
XF
MR
250V
A
6AB
LKW
HT
BLK
(612183-16W) (612183-50RS) (612183-10T)(612183-13R)
WH
TB
LK3A3F
U
BR
N
WH
T/
BR
N
WH
T/B
RN
BR
N
(612
183-
27R
)
WHT/YEL
GRYGRY
WHT/YEL
(803430-95RS)
-
+M
ORG
BLK
WHT ORGBLKWHT
ORGBLK
/6
WHT
31
422F
UD
ISC
ON
NE
CT
NL
BLK
110V
AC
RED/GRY
110V
AC
QU
ICK
CO
NN
EC
T B
LOC
K
BLK
RED/GRY
(612183-14RR)
(612
183
-12R
R)
(612183-18RR)
WHT
(8500
05-
10R
)
25A
WHT
O-6
0044
1P
4
1P3
1
P1
1
P2
OR
G
BLK
OR
G/B
LK
BRN
BRN/WHTRED
BLK
CLEAR
282
281
283
281
282
283
(612183-11R)
(850005-9R)
NL1 +15V
0V -15V
X2
X1
24V
0VL1 N
24V
0VL1 N
0V0V
0V
24V
24V
±15V
PS
+24
V P
S-2
4V P
S
BLU
GRN
RED
BLK
GR
N
BLU
BLK
RE
D
BR
N
WH
T
BR
NW
HT
/BR
N
WH
T
BR
N
BLK
BLU
RE
D
GR
N
WH
T
BR
N
BLK
BLU
RE
D
GR
N
GRN
BLK
RED
BLU
GRN
RED
BLK
BLU
25K
HZ
PS
288
289
23
1
BR
NW
HT
/BR
N
TAN
110V
AC
QU
ICK
CO
NN
EC
T B
LOC
K
ISO
LAT
ED
(612183-50RR)
(61218
3-5
1R)
(612183-55R)
(612183-52R)
(612183-19S)
WH
TB
RN
WH
T/B
RN
BR
N
WH
T/B
RN
BR
N
WH
T
OR
G
BLK
WHT-BRN
1
BRN
RED
ORG
REDWHT-
WHT-ORG
VIO
WHT-
YELWHT-YEL
GRN
BLU
GRN
WHT-BLU
VIOWHT-
GRY
GRYWHT-
WH
TB
RN
WH
TB
RN
BR
NW
HT
/BR
N
(O-55350-15)W PHASE P/M A
BLK
WH
T
2 /
2 /16/
(612
401
-36T
)
CN106
RED\GRY
RED\GRY
GRAY
WHT\YEL
WHT\YEL
GRAY
FA
N
GR
N/Y
EL
FIL
TE
R
183
182
181
+ -
40K
40K
GR
D
0-10
00V
OLT
SD
C B
US
RE
D/
YE
L
YE
LR
ED
/
RE
D
RE
D
R7
R6
(612
183-
8RR
)
(61218
3-2
9V
)
+ -
213
214
211
212
113
114
P2
N
P1
L3A
110VAC
MCR LO
AUX OUT HI
AUX OUT LO
AUX IN 4 LO
AUX IN 4 HI
AUX IN 5 LO
AUX IN 5 HI
AUX IN 3 HI
AUX IN 3 LO
MCR HI
RPI HI
RPI LO
AUX IN 1 HI
AUX IN 1 LO
AUX IN 2 HI
AUX IN 2 LO
DO
OR
SO
LEN
OID
RE
D
RE
D
11
12
21
22
42
41
32
31
BR
NB
LKB
LUR
ED
OR
GY
EL
WH
TG
RN
125%
-0-1
25%
0-12
5%C
UR
RE
NT
DC
BU
SC
UR
RE
NT
AC
INP
UT
(61218
3-5
R)
P1
GR
NW
HT
/BR
NB
RN
GR
N
(850005-11R)
2 /
OR
G
YE
L
VIO
LIN
ES
YN
C. B
OA
RD
A1
A2
INTERLOCKDOOR
(612
183
-11R
)
DR
AIN
WIR
EG
ND
AT
MT
G S
CR
EW
2 /6 /
TAN
US
ED
NO
T
CN
106
CN
106
CN
106
CN
106
CN
106
CN112
O-5
5350
-15
O-5
5350
-15
WV
CN112
O-5
5350
-15
U
CN112
–+
2 /
WARN.
FAULT
CLR
NO
TU
SE
D
NO
TU
SE
D
BLK
WARN.
FAULT BLK
CLRWARN.
FAULT
–+
–+
2 /
2/
4/
4 /
2 /
1
CO
N1
CN103
CN
101
1
1
1C
N10
5
CN
104
1
2 /9 /
TT
ULEM
LEM
VLE
MW
M+
-
REDWHTBLK
WHTRED
BLK
REDWHTBLK
M+
-M
+-
/P
AIR
S6
6 /6 /
CO
M+
2C
OM
+3
CO
M+
4
BLANK
15/
8 /
1>
4 /
CLR
BLK
BLK
CLR
FACEPLATE
BA
ND
BA
ND
BA
ND
BLANKFACEPLATE
BA
ND
BA
ND
(803
430-
95S
R)
Power Module Description 2-9
Figure 2.6 – 445A SB3000 Power Module Circuitry (Continued)
1147
A
1145
A
MO
TOR
TE
RM
INA
L
CO
NN
EC
TO
R
RE
SIS
TO
RS
DC
PR
E-C
HA
RG
E
PO
WE
R M
OD
ULE
"A
"
-+ M
65
93
41
2
CO
N1
78
1247
A
BLO
WE
R A
SS
EM
BLY
110V
AC
QU
ICK
[U]
1249
A
IGB
TM
OD
ULE
LEM
ULE
M W
183
RE
AC
TO
RA
IR C
OR
E
182
181
DIS
CH
AR
GE
RE
SIS
TO
RS
1249A
LEM
V
ISO
LAT
ED
110V
AC
QU
ICK
[V]
IGB
TM
OD
ULE
[W]
IGB
TM
OD
ULE
CN105
CN
104
CN103
R1A
R2A
BLK
BLK
RE
D/G
RY
RE
D/G
RY
BR
N
WH
T/B
RN
1 4 1
CN101
1
CN101
3 3
TO
TB
(211
)
TO
TB
(11
4)
B/M
-600
27
CO
N1
12
35
41 2 6
BLK
BLK
CLR
CLR
CO
NN
EC
T B
LOC
K
GRAY
GRAY
WHT/YEL
WHT/YEL
1145
A
RE
DC
N10
2-1
0-55
350-
10R
ED
/YE
L
1 2
1 2
3 4
3 4
TK U2
U2
TK Z2
GR
DG
RD
GR
DG
RD
Z2
U2
TK
BLK
WH
T
BLKB
LK
BLK
1249
A12
49A
B/M
-600
27P
WR
.MO
D A
CO
N2
RE
D
WH
T
BLK
RE
D
WH
T
BLK
M -+
1602
1601
1603
(FR
AM
E)
GR
D
PW
R.M
OD
A
0-55
350-
10
CN
102-
4
CO
NN
EC
T B
LOC
K
10 O
HM
S
10 O
HM
S
10 O
HM
SB
LOW
ER
BLO
CK
PR
E-C
HA
RG
EB
OA
RD
+C
12
O-5
5350
-4
1> D
OT
TE
D L
INE
IND
ICA
TE
S J
UM
PE
R L
OC
AT
ION
IF P
OW
ER
MO
DU
LE R
EQ
UIR
ES
GR
EA
TE
R A
IR F
LOW
.
<1
NO
TE
S
RE
DB
AN
DR
ED
BA
ND
GR
AY
BA
ND
OR
GB
AN
DY
EL
BA
ND
VIO
BA
ND
VIO
OR
G
(612
183-
33R
R)
(612
183-
20R
)
(803
430-
95S
R) (803
430-
95S
R)
(612
183-
27R
)
(612
183-
16R
)(6
1218
3-16
T)
(612
183-
16S
)
(612
183-
20R
)
(612
183-
11R
)
(612
183-
19S
)
(612
183-
21R
)
(612
183-
14R
R)
(612
183-
15R
R)
(612
183-
15R
R)
(612
183-
32R
R)
(612
183-
22R
)
(803
430-
95R
R)
(803
430-
95R
T)
(NO
T U
SE
D)
TO
TB
(212
)T
O T
B (2
13)
TO
TB
(214
)
GR
AY
GR
AY
WH
T/Y
EL
WH
T/Y
EL
TO
TB
(11
3)
YE
L
U P
HA
SE
O-5
5350
-15
WA
RN
TH
ER
M.
FA
ULT
TH
ER
M.
WA
RN
TH
ER
M.
FA
ULT
TH
ER
M.
SH
IELD
W P
HA
SE
O-5
5350
-15
DR
AIN
WIR
E
2>(6
1218
3-28
S)
2> C
ON
NE
CT
LU
GG
ED
DR
AIN
WIR
E O
F T
HE
RM
OS
TA
TC
AB
LE 6
1218
3-28
S U
ND
ER
UP
PE
R L
EF
T C
OR
NE
RM
OU
NT
ING
SC
RE
W O
F P
RE
-CH
AR
GE
P.C
. BO
AR
DF
OR
GR
OU
ND
CO
NN
EC
TIO
N.
-+ M
RE
D
WH
T
BLK
2-10 SB3000 Power Modules (Rittal)
Figure 2.7 – 890A SB3000 Power Module Circuitry
1147
A
1145
A
BU
S
BU
S
147
145
47 45F
101A
F10
2A
CO
N1
890A
@ 4
KH
Z; M
ULT
IPLE
VO
LTA
GE
INP
UT
P/M
A
AS
SE
MB
LY
PW
R M
OD
A
O-5
5350
-10
CN
102
CO
N6
14
CO
N2
601
602
603
16
1
BLO
WE
R
CO
N2
PW
R M
OD
B1
F10
2B
F10
1B
603
602
601
112
CO
N5
1C
ON
2P
WR
MO
D C
OR
GY
EL
VIO
OR
GY
EL
VIOVIO
YE
LO
RG R
3R
4R
5
GR
D
(805
401-
5T)
POWER SUPPLYB/M-60007
PM
I RA
CK
B/M-60029
TECHNOLOGYAC POWERB/M-60023
P2
P1
AC PARALLELINTERFACE
1> W
HE
N U
SIN
G C
HA
RT
RE
CO
RD
ER
CO
NN
EC
T
TO
TE
RM
INA
LS A
T B
AC
K O
F M
ET
ER
.
GR
D
B/M
-600
27
P1
P1
F/O
B/M-60028GATE DRIVER
INTERFACESLOT 6
GD
I SLO
T 8
GD
I SLO
T 7
GD
I SLO
T 6
PO
WE
R M
OD
ULE
PO
WE
R
SE
E F
IGU
RE
2.9
SE
E F
IGU
RE
2.8
D S
HE
LLD S
HE
LL D S
HE
LL
1147
B
1145
B
CO
N4
RED/GRY
WH
T/
BR
NW
HT
/B
RN
CN
106
1
RE
DR
ED
/YE
L
P/M
BC
ON
1P
/M C
CO
N1
RED
BLKWHT
WHT
BLKWHTRED
RED
BLK
CO
N3
112
CO
N6
TA
N
TA
N
1247
A11
45A
MO
DU
LE"A
"
25K
HZ
PS
(1)
25K
HZ
PS
(2)
"B"
CLR
BLK
BLK
1000
A
1000
A
1000
A
1000
A
/3
/3
2/
9 /
9 /9 /
BLO
WE
RA
SS
EM
BLY
LPI
P1
GR
DL2L1L1 L2
RE
DB
AN
D
GR
AY
BA
ND
CO
M
P1
RE
DB
LU
BR
NB
LK
GR
NW
HT
YE
LO
RG
+
PMI PROCESSOR
AND DRIVE I/O
B/M-60021
1
RESOLVERB/M-60031
P2
P1
RE
D
GR
AY
(612183-29R)(8
0343
0-95
RY
)
(8034
30-
95R
V)
(612183-26RR)
(612183-15R)
(612
183
-25S
)
(612183-10S)
(61218
3-1
0T
)
(61218
3-1
0R
)
(612
183
-20R
)(6
12183
-28S
)
(61218
3-2
3R
R)
(61362
1-1
2R
)
(612
183
-24R
)
(61218
3-2
2R
)
(6121
83-2
1R)
(803
430-
95R
X)
(612
183-
14R
S)
(612
183-
9R)
(612183-15R)
(612
183-
23R
S)
(612
183
-10V
)
(61218
3-2
9S
)
GR
D
(612
183-
29T
)
(612
183
-22S
)(6
121
83-
21S
)
(61218
3-2
8S
)
(61218
3-1
9R
)
H2
H1
1FU
BLK
WH
T
XF
MR
250V
A
6AB
LKW
HT
2
/B
LK
(612183-16W)
(612183-50RS)(612183-10T)
(612183-13R)
WH
TB
LK3A3F
U
BR
N
WH
T/
BR
N
WH
T/B
RN
BR
N
(612
183-
27R
)
WHT/YEL
GRYGRY
WHT/YEL
(85000
5-1
2T
)
-
+M
ORG
BLK
WHT ORGBLKWHT
ORGBLK
/6
WHT
31
422F
UD
ISC
ON
NE
CT
NL
BLK
110V
AC
RED/GRY
110V
AC
QU
ICK
CO
NN
EC
T B
LOC
K
BLK
RED/GRY
(612183-14RR)
(612
183
-12R
R)
(612183-18RR)
WHT
(8500
05-
10R
)
25A
WHT
O-6
0044
1P
4
1P3
1
P1
1
P2
OR
G
BLK
OR
G/B
LK
BRN
BRN/WHTRED
BLK
CLEAR
282
281
283
281
282
283
(612183-11R)
(850005-9R)
NL1 +15V
0V -15V
X2
X1
24V
0VL1 N
24V
0VL1 N
0V0V
0V
24V
24V
±15V
PS
+24
V P
S-2
4V P
S
BLU
GRN
RED
BLK
GR
N
BLU
BLK
RE
D
BR
N
WH
T
BR
NW
HT
/BR
N
WH
T
BR
N
BLK
BLU
RE
D
GR
N
WH
T
BR
N
BLK
BLU
RE
D
GR
N
GRN
BLK
RED
BLU
GRN
RED
BLK
BLU
25K
HZ
PS
288
289
23
1
BR
NW
HT
/BR
N
TAN
110V
AC
QU
ICK
CO
NN
EC
T B
LOC
K
ISO
LAT
ED
(612183-50RR)
(61218
3-5
1R)
(612183-55R)
(612183-52R)
(612183-19S)
WH
TB
RN
WH
T/B
RN
BR
N
WH
T/B
RN
BR
N
WH
T
OR
G
BLK
WHT-BRN
1
BRN
RED
ORG
REDWHT-
WHT-ORG
VIO
WHT-
YELWHT-YEL
GRN
BLU
GRN
WHT-BLU
VIOWHT-
GRY
GRYWHT-
WH
TB
RN
WH
TB
RN
BR
NW
HT
/BR
N
(O-55350-15)W PHASE P/M A
BLK
WH
T
2 /
2 /16/
(612
401
-36T
)
CN106
RED\GRY
RED\GRY
GRAY
WHT\YEL
WHT\YEL
GRAY
FA
N
GR
N/Y
EL
FIL
TE
R
BLK
WH
T
1
CO
N1
(612183-10V)
TAN
TANCN106(O-55350-15)
W PHASE P/M B
183
182
181
+ -
40K
40K
GR
D
0-10
00V
OLT
SD
C B
US
RE
D/
YE
L
YE
LR
ED
/
RE
D
RE
D
R7
R6
(6121
83-
10S
)
(612
183-
8RR
)
(61218
3-2
9V
)
RE
D/
GR
Y
(612
183-
9S)
+ -
213
214
211
212
113
114
P2
N
P1
L3A
110VAC
MCR LO
AUX OUT HI
AUX OUT LO
AUX IN 4 LO
AUX IN 4 HI
AUX IN 5 LO
AUX IN 5 HI
AUX IN 3 HI
AUX IN 3 LO
MCR HI
RPI HI
RPI LO
AUX IN 1 HI
AUX IN 1 LO
AUX IN 2 HI
AUX IN 2 LO
DO
OR
SO
LEN
OID
RE
D
RE
D
11
12
21
22
42
41
32
31
BR
NB
LKB
LUR
ED
OR
GY
EL
WH
TG
RN
125%
-0-1
25%
0-12
5%C
UR
RE
NT
DC
BU
SC
UR
RE
NT
AC
INP
UT
(61218
3-5
R)
P1
GR
NW
HT
/BR
NB
RN
GR
N
(850005-11R)
2 /
OR
G
YE
L
VIO
OR
G
YE
L
VIO
OR
G
YE
L
VIO
LIN
ES
YN
C. B
OA
RD
A1
A2
INTERLOCKDOOR
(612
183
-11R
)
DR
AIN
WIR
EG
ND
AT
MT
G S
CR
EW
DR
AIN
WIR
EG
ND
AT
MT
G S
CR
EW
2 /6 /
TAN
2 /
US
ED
NO
T
CN
106
CN
106
CN
106
CN
106
CN
106
CN112
O-5
5350
-15
O-5
5350
-15
WV
CN112
O-5
5350
-15
U
CN112
–+
WARN.
FAULT
CLR
NO
TU
SE
D
NO
TU
SE
D
BLK
WARN.
FAULT BLK
CLRWARN.
FAULT
–+
–+
2 /2/
4/
US
ED
NO
T
CN
106
CN
106
CN
106
CN
106
CN
106
CN112
O-5
5350
-15
O-5
5350
-15
WV
CN112
O-5
5350
-15
U
CN112
–+
2 /
WARN.
FAULT
CLR
NO
TU
SE
D
NO
TU
SE
D
BLK
WARN.
FAULT BLK
CLRWARN.
FAULT
–+
–+
2 /
2/
4/
TT
ULEM
LEM
VLE
MW
M+
-
REDWHTBLK
WHTRED
BLK
REDWHTBLK
M+
-M
+-
CN103
CN
101
1
1
1C
N10
5
CN
104
1
CLR
4 /
2 /
4 /
2 /
1
CO
N1
CN103
CN
101
1
1
1C
N10
5
CN
104
1
2 /9 /
TT
ULEM
LEM
VLE
MW
M+
-
REDWHTBLK
WHTRED
BLK
REDWHTBLK
M+
-M
+-
/P
AIR
S6
/P
AIR
S6
6 /6 /
CO
M+
2C
OM
+3
CO
M+
4
F/O
B/M-60028GATE DRIVERINTERFACESLOT 7
BLANK
15/
15/
8 /
1>
BR
NB
RN2 /
4 /
CLR
BLK
BLK
CLR
FACEPLATE
Power Module Description 2-11
Figure 2.8 – 890A SB3000 Power Module Circuitry (Continued)
1147
A
1145
A
MO
TOR
TE
RM
INA
L
CO
NN
EC
TO
R
RE
SIS
TO
RS
DC
PR
E-C
HA
RG
E
PO
WE
R M
OD
ULE
"A
"
-+ M
65
93
41
2
CO
N1
78
1247
A
BLO
WE
R A
SS
EM
BLY
110V
AC
QU
ICK
[U]
1249
A
IGB
TM
OD
ULE
LEM
ULE
M W
183
RE
AC
TO
RA
IR C
OR
E
182
181
DIS
CH
AR
GE
RE
SIS
TO
RS
1249A
LEM
V
ISO
LAT
ED
110V
AC
QU
ICK
[V]
IGB
TM
OD
ULE
[W]
IGB
TM
OD
ULE
CN105C
N10
4
CN103
R1A
R2A
BLK
BLK
RE
D/G
RY
RE
D/G
RY
BR
N
WH
T/B
RN
1 4 1
CN101
1
CN101
3 3
TO T
B (
211) TO
TB
(11
4)
B/M
-600
27
CO
N1
12
35
41 2 6
BLK
BLK
CLR
CLR
CO
NN
EC
T B
LOC
K
GRAY
GRAY
WHT/YEL
WHT/YEL
1145
A
RE
DC
N10
2-1
0-55
350-
10R
ED
/YE
L
1 2
1 2
3 4
3 4
TK U2
U2
U2
U2
TK
Z2
Z2
GR
DG
RD
GR
DG
RD
Z2
U2
TK
BLK
WH
T
BLKB
LK
BLK
1249
A12
49A
B/M
-600
27P
WR
.MO
D A
CO
N2
RE
D
WH
T
BLK
RE
D
WH
T
BLK
M -+
1602
1601
1603
(FR
AM
E)
GR
D
PW
R.M
OD
A
0-55
350-
10
CN
102-
4
CO
NN
EC
T B
LOC
K
10 O
HM
S
10 O
HM
S
10 O
HM
SB
LOW
ER
BLO
CK
PR
E-C
HA
RG
EB
OA
RD
+C
12
O-5
5350
-4
1> D
OT
TE
D L
INE
IND
ICA
TE
S J
UM
PE
R L
OC
AT
ION
IF P
OW
ER
MO
DU
LE R
EQ
UIR
ES
GR
EA
TE
R A
IR F
LOW
.
<1
NO
TE
S
RE
DB
AN
DR
ED
BA
ND
GR
AY
BA
ND
OR
GB
AN
DY
EL
BA
ND
VIO
BA
ND
VIO
OR
G
(612
183-
33R
R)
(612
183-
20R
)
(803
430-
95R
X) (803
430-
95R
X)
(612
183-
27R
)
(612
183-
16R
)(6
1218
3-16
T)
(612
183-
16S
)
(612
183-
20R
)
(612
183-
11R
)
(612
183-
19S
)
(612
183-
21R
)
(612
183-
14R
R)
(612
183-
15R
R)
(612
183-
15R
R)
(612
183-
32R
R)
(612
183-
22R
)
(803
430-
95R
R)
(80
3430
-95R
V)
(NO
T U
SE
D)
TO T
B (
212)
TO T
B (
213)
TO T
B (
214)
GR
AY
GR
AY
WH
T/Y
EL
WH
T/Y
EL
TO
TB
(11
3)
YE
L
U P
HA
SE
O-5
5350
-15
WA
RN
TH
ER
M.
FA
ULT
TH
ER
M.
WA
RN
TH
ER
M.
FA
ULT
TH
ER
M.
SH
IELD
W P
HA
SE
O-5
5350
-15
DR
AIN
WIR
E
2>(6
1218
3-28
S)
2> C
ON
NE
CT
LU
GG
ED
DR
AIN
WIR
E O
F T
HE
RM
OS
TA
TC
AB
LE 6
1218
3-28
S U
ND
ER
UP
PE
R L
EF
T C
OR
NE
RM
OU
NT
ING
SC
RE
W O
F P
RE
-CH
AR
GE
P.C
. BO
AR
DF
OR
GR
OU
ND
CO
NN
EC
TIO
N.
-+ M
RE
D
WH
T
BLK
PR
E-C
HA
RG
EB
OA
RD
CN
101
WH
T/B
RN
PW
R. M
OD
B (612
183-
19R
)
BR
N
2-12 SB3000 Power Modules (Rittal)
Figure 2.9 – 890A SB3000 Power Module Circuitry (Continued)
1147
B
1145
B
MO
TOR
TE
RM
INA
L
CO
NN
EC
TO
R
RE
SIS
TO
RS
DC
PR
E-C
HA
RG
E
PO
WE
R M
OD
ULE
"B
"
-+ M
65
93
41
2
CO
N1
78
1247
B
BLO
WE
R A
SS
EM
BLY
110V
AC
QU
ICK
[U]
1249
B
IGB
TM
OD
ULE
LEM
ULE
M W
183
RE
AC
TO
RA
IR C
OR
E
182
181
DIS
CH
AR
GE
RE
SIS
TO
RS
1249B
LEM
V
[V]
IGB
TM
OD
ULE
[W]
IGB
TM
OD
ULE
CN105
CN
104
CN103
R1B
R2B
BLK
BLK
RE
D/G
RY
BR
N
WH
T/B
RN
1 4 1
CN101
1
CN101
3 3
B/M
-600
27
CO
N1
12
35
41 2 6
BLK
BLK
CLR
CLR
CO
NN
EC
T B
LOC
K
1145
B 1 2
1 2
3 4
3 4
TK U2
U2
U2
U2
TK
Z2
Z2
GR
DG
RD
GR
DG
RD
Z2
U2
TK
BLK
WH
T
BLKB
LK
BLK
1249
B12
49B
B/M
-600
27P
WR
.MO
D B
CO
N2
RE
D
WH
T
BLK
RE
D
WH
T
BLK
M -+
1602
1601
1603
(FR
AM
E)
GR
D
PW
R.M
OD
B
10 O
HM
S
10 O
HM
S
10 O
HM
SB
LOW
ER
BLO
CK
PR
E-C
HA
RG
EB
OA
RD
+C
12
O-5
5350
-4
1> D
OT
TE
D L
INE
IND
ICA
TE
S J
UM
PE
R L
OC
AT
ION
IF P
OW
ER
MO
DU
LE R
EQ
UIR
ES
GR
EA
TE
R A
IR F
LOW
.
<1
NO
TE
S
RE
DB
AN
DR
ED
BA
ND
GR
AY
BA
ND
OR
GB
AN
DY
EL
BA
ND
VIO
BA
ND
VIO
OR
G
(612
183-
33R
R)
(803
430-
95R
Y) (803
430-
95R
Y)
(612
183-
16R
)(6
1218
3-16
T)
(612
183-
16S
)
(612
183-
9R)
(612
183-
19R
)
(612
183-
21S
)
(612
183-
14R
S)
(612
183-
15R
R)
(612
183-
15R
R)
(612
183-
32R
R)
(612
183-
22S
)
(803
430-
95R
R)
(803
430-
95R
V)
(NO
T U
SE
D)
YE
L
U P
HA
SE
O-5
5350
-15
WA
RN
TH
ER
M.
FA
ULT
TH
ER
M.
WA
RN
TH
ER
M.
FA
ULT
TH
ER
M.
SH
IELD
W P
HA
SE
O-5
5350
-15
DR
AIN
WIR
E
2>(6
1218
3-28
S)
2> C
ON
NE
CT
LU
GG
ED
DR
AIN
WIR
E O
F T
HE
RM
OS
TA
TC
AB
LE 6
1218
3-28
S U
ND
ER
UP
PE
R L
EF
T C
OR
NE
RM
OU
NT
ING
SC
RE
W O
F P
RE
-CH
AR
GE
P.C
. BO
AR
DF
OR
GR
OU
ND
CO
NN
EC
TIO
N.
-+ M
RE
D
WH
T
BLK
PR
E-C
HA
RG
EB
OA
RD
CN
101
PW
R. M
OD
A
RE
D/G
RY
(612
183-
9S)
Power Module Description 2-13
Figure 2.10 – 1335A SB3000 Power Module Circuitry
1147
A
1145
A
BU
S
BU
S
147
145
47 45F
101A
F10
2A
CO
N1
1335
A @
4K
HZ
; MU
LTIP
LE V
OLT
AG
E IN
PU
T
P/M
A
AS
SE
MB
LY
PW
R M
OD
A
O-5
5350
-10
CN
102
CO
N6
14
CO
N2
601
602
603
16
1
BLO
WE
R
CO
N2
PW
R M
OD
B1
F10
2B
F10
1B
603
602
601
112
CO
N5
1C
ON
2P
WR
MO
D C
OR
GY
EL
VIO
OR
GY
EL
VIOVIO
YE
LO
RG R
3R
4R
5
GR
D
(805
401-
5T)
POWER SUPPLYB/M-60007
PM
I RA
CK
B/M-60029
TECHNOLOGYAC POWERB/M-60023
P2
P1
AC PARALLELINTERFACE
1> W
HE
N U
SIN
G C
HA
RT
RE
CO
RD
ER
CO
NN
EC
T
TO
TE
RM
INA
LS A
T B
AC
K O
F M
ET
ER
.
GR
D
B/M
-600
27
P1
P1
F/O
B/M-60028GATE DRIVER
INTERFACESLOT 6
GD
I SLO
T 8
GD
I SLO
T 7
GD
I SLO
T 6
PO
WE
R M
OD
ULE
PO
WE
R
SE
E F
IGU
RE
2.1
2
SE
E F
IGU
RE
2.1
1
D S
HE
LLD S
HE
LL D S
HE
LL
1147
B
1145
B
CO
N4
RED/GRY
WH
T/
BR
NW
HT
/B
RN
CN
106
1
RE
DR
ED
/YE
L
P/M
BC
ON
1P
/M C
CO
N1
RED
BLKWHT
WHT
BLKWHTRED
RED
BLK
CO
N3
112
CO
N6
TA
N
TA
N
1247
A11
45A
MO
DU
LE"A
"
25K
HZ
PS
(1)
25K
HZ
PS
(2)
"B"
CLR
BLK
BLK
1000
A
1000
A
1000
A
1000
A
/3
/3
2/
9 /
9 /9 /
BLO
WE
RA
SS
EM
BLY
LPI
P1
GR
DL2L1L1 L2
RE
DB
AN
D
GR
AY
BA
ND
CO
M
P1
RE
DB
LU
BR
NB
LK
GR
NW
HT
YE
LO
RG
+
PMI PROCESSOR
AND DRIVE I/O
B/M-60021
1
RESOLVERB/M-60031
P2
P1
RE
D
GR
AY
(612183-29R)
(803
430-
95R
Y)
(8034
30-
95R
V)
(612183-26RR)
(612183-15R)
(612
183
-25S
)
(612183-10S)
(61218
3-1
0T
)
(61218
3-1
0R
)
(612
183
-20R
)(6
12183
-28S
)
(61218
3-2
3R
R)
(61362
1-1
2R
)
(612
183
-24R
)
(61218
3-2
2R
)
(6121
83-2
1R)
(803
430-
95R
X) (612
183-
14R
S)
(612
183-
9R)
(612183-15R)
(6121
83-
23R
S)
(612
183
-10V
)
(61218
3-2
9T
)
GR
D
(612
183-
29T
)
(612
183
-22S
)(6
121
83-
21S
)
(612
183
-28S
)
(61218
3-1
9R
)
H2
H1
1FU
BLK
WH
T
XF
MR
250V
A
6AB
LKW
HT
2 /B
LK
(612183-16W) (612183-50RS)(612183-10T)
(612183-13R)
WH
TB
LK3A3F
U
BR
N
WH
T/
BR
N
WH
T/B
RN
BR
N
(612
183-
27R
)
WHT/YEL
GRYGRY
WHT/YEL
(85000
5-1
2T
)
-
+M
ORG
BLK
WHT ORGBLKWHT
ORGBLK
/6
WHT
31
422F
UD
ISC
ON
NE
CT
NL
BLK
110V
AC
RED/GRY
110V
AC
QU
ICK
CO
NN
EC
T B
LOC
K
BLK
RED/GRY
(612183-14RR)
(612
183
-12R
R)
(612183-18RR)
WHT
(8500
05-
10R
)
25A
WHT
O-6
0044
1P
4
1P3
1
P1
1
P2
OR
G
BLK
OR
G/B
LK
BRN
BRN/WHTRED
BLK
CLEAR
282
281
283
281
282
283
(612183-11R)
(850005-9R)
NL1 +15V
0V -15V
X2
X1
24V
0VL1 N
24V
0VL1 N
0V0V
0V
24V
24V
±15V
PS
+24
V P
S-2
4V P
S
BLU
GRN
RED
BLK
GR
N
BLU
BLK
RE
D
BR
N
WH
T
BR
NW
HT
/BR
N
WH
T
BR
N
BLK
BLU
RE
D
GR
N
WH
T
BR
N
BLK
BLU
RE
D
GR
N
GRN
BLK
RED
BLU
GRN
RED
BLK
BLU
25K
HZ
PS
288
289
23
1
BR
NW
HT
/BR
N
TAN
110V
AC
QU
ICK
CO
NN
EC
T B
LOC
K
ISO
LAT
ED
(612183-50RR)
(61218
3-5
1R)
(612183-55R)
(612183-52R)
(612183-19S)
WH
TB
RN
WH
T/B
RN
BR
N
WH
T/B
RN
BR
N
WH
T
OR
G
BLK
WHT-BRN
1
BRN
RED
ORG
REDWHT-
WHT-ORG
VIO
WHT-
YELWHT-YEL
GRN
BLU
GRN
WHT-BLU
VIOWHT-
GRY
GRYWHT-
WH
TB
RN
WH
TB
RN
BR
NW
HT
/BR
N
(O-55350-15)W PHASE P/M A
BLK
WH
T
2 /
2 /16/
(612
401
-36T
)
CN106
RED\GRY
RED\GRY
GRAY
WHT\YEL
WHT\YEL
GRAY
FA
N
GR
N/Y
EL
FIL
TE
R
BLK
WH
T
1
CO
N1
(612183-10V)
TAN
TANCN106(O-55350-15)
W PHASE P/M B
(612183-15R)
P1
(61218
3-2
3R
T) 15/
/P
AIR
S6
(612
183-
14R
T)
183
182
181
+ -
40K
40K
TT
ULEM
LEM
VLE
MW
601
602
603
F10
2C
F10
1C
GR
DM
+-
1147
C
1145
C
WH
T/
BR
NB
RN
REDWHTBLK
WHTRED
BLK
REDWHTBLK
US
ED
NO
T
CN
106
CN
106
CN
106
CN
106
CN
106
CN112
O-5
5350
-15
O-5
5350
-15
WV
CN112
O-5
5350
-15
U
CN112
–+
25K
HZ
PS
(3)
MO
DU
LEP
OW
ER
SE
E F
IGU
RE
2.1
3
"C"
0-10
00V
OLT
SD
C B
US
CLR
CLR
BLK
BLK
1000
A
1000
AR
ED
/Y
EL
YE
LR
ED
/
RE
DR
ED
R7
R6
9 /4 /A
SS
EM
BLY
BLO
WE
R
GRYRED/
2 /
4/
RE
DB
AN
D
BA
ND
GR
AY
(61218
3-2
9S
)
(6121
83-
10S
)
(612
183-
8RR
)
(803
430-
95R
Z)
(6121
83-
21T
)(6
12183
-19R
)
(612183-9R)
(61218
3-2
8S)
(612
183
-22T
)
(612183-10S)
(61218
3-1
0W
)G
RD
(80343
0-9
5R
V)
(61218
3-2
9V
)
BLK
WH
T
CN103
O-5
5350
-4C
N10
11
CO
N1
1
11
CN
105
CN
104
1
GR
YR
ED
/
RE
D/
GR
Y(612
183-
9S)
(612
183-
9S)
BR
NB
RN
WH
T/
BLK
RED
REDWHTBLK
WHT
WHTBLK
RED
+ -
(O-55350-15)CN106
TAN
TANW PHASE P/M C
(612183-10W)
213
214
211
212
113
114
P2
N
P1
L3A
110VAC
MCR LO
AUX OUT HI
AUX OUT LO
AUX IN 4 LO
AUX IN 4 HI
AUX IN 5 LO
AUX IN 5 HI
AUX IN 3 HI
AUX IN 3 LO
MCR HI
RPI HI
RPI LO
AUX IN 1 HI
AUX IN 1 LO
AUX IN 2 HI
AUX IN 2 LO
DO
OR
SO
LEN
OID
RE
D
RE
D
11
12
21
22
42
41
32
31B
RN
BLK
BLU
RE
DO
RG
YE
LW
HT
GR
N
125%
-0-1
25%
0-12
5%C
UR
RE
NT
DC
BU
SC
UR
RE
NT
AC
INP
UT
(61218
3-5
R)
P1
GR
NW
HT
/BR
NB
RN
GR
N
(850005-11R)
2 /
OR
G
YE
L
VIO
OR
G
YE
L
VIO
OR
G
YE
L
VIO
OR
G
YE
L
VIO
LIN
ES
YN
C. B
OA
RD
A1
A2
INTERLOCKDOOR
(612
183
-11R
)
DR
AIN
WIR
EG
ND
AT
MT
G S
CR
EW
DR
AIN
WIR
EG
ND
AT
MT
G S
CR
EWG
ND
AT
MT
G S
CR
EW
DR
AIN
WIR
E
WARN.
FAULT
CLR
NO
TU
SE
D
NO
TU
SE
D
BLK
WARN.
FAULT BLK
CLRWARN.
FAULT
2 /6 /
TAN
2 /2 /
M+
-M
+-
–+
–+
2 /
US
ED
NO
T
CN
106
CN
106
CN
106
CN
106
CN
106
CN112
O-5
5350
-15
O-5
5350
-15
WV
CN112
O-5
5350
-15
U
CN112
–+
WARN.
FAULT
CLR
NO
TU
SE
D
NO
TU
SE
D
BLK
WARN.
FAULT BLK
CLRWARN.
FAULT
–+
–+
2 /2/
4/
US
ED
NO
T
CN
106
CN
106
CN
106
CN
106
CN
106
CN112
O-5
5350
-15
O-5
5350
-15
WV
CN112
O-5
5350
-15
U
CN112
–+
2 /
WARN.
FAULT
CLR
NO
TU
SE
D
NO
TU
SE
D
BLK
WARN.
FAULT BLK
CLRWARN.
FAULT
–+
–+
2 /
2/
4/
TT
ULEM
LEM
VLE
MW
M+
-
REDWHTBLK
WHTRED
BLK
REDWHTBLK
M+
-M
+-
CN103
CN
101
1
1
1C
N10
5
CN
104
1
CLR
4 /2 /
9 /
2 /
2 / 4 /
2 /
1
CO
N1
CN103
CN
101
1
1
1C
N10
5
CN
104
1
2 /9 /
TT
ULEM
LEM
VLE
MW
M+
-
REDWHTBLK
WHTRED
BLK
REDWHTBLK
M+
-M
+-
9 /
/P
AIR
S6
/P
AIR
S6
15/
15/
6 /6 /
CO
M+
2C
OM
+3
CO
M+
4
F/O
B/M-60028GATE DRIVERINTERFACESLOT 7
F/O
B/M-60028GATE DRIVER
INTERFACESLOT 8
15/
15/
15/
8 /
1>
BR
NB
RN2 /
4 /
CLR
BLK
BLK
CLR
2-14 SB3000 Power Modules (Rittal)
Figure 2.11 – 1335A SB3000 Power Module Circuitry (Continued)
1147
A
1145
A
MO
TOR
TE
RM
INA
L
CO
NN
EC
TO
R
RE
SIS
TO
RS
DC
PR
E-C
HA
RG
EP
OW
ER
MO
DU
LE "
A"
-+ M
65
93
41
2
CO
N1
78
1247
A
BLO
WE
R A
SS
EM
BLY
110V
AC
QU
ICK
[U]
1249
A
IGB
TM
OD
ULE
LEM
ULE
M W
183
RE
AC
TO
RA
IR C
OR
E
182
181
DIS
CH
AR
GE
RE
SIS
TO
RS
1249A
LEM
V
ISO
LAT
ED
110V
AC
QU
ICK
[V]
IGB
TM
OD
ULE
[W]
IGB
TM
OD
ULE
CN105
CN
104
CN103
R1A
R2A
BLK
BLK
RE
D/G
RY
RE
D/G
RY
BR
N
WH
T/B
RN
1 4 1
CN101
1
CN101
3 3
TO T
B (
211) TO
TB
(11
4)
B/M
-600
27
CO
N1
12
35
41 2 6
BLK
BLK
CLR
CLR
CO
NN
EC
T B
LOC
K
GRAY
GRAY
WHT/YEL
WHT/YEL
1145
A
RE
DC
N10
2-1
0-55
350-
10R
ED
/YE
L
1 2
1 2
3 4
3 4
TK U2
U2
U2
U2
TK
Z2
Z2
GR
DG
RD
GR
DG
RD
Z2
U2
TK
BLK
WH
T
BLKB
LK
BLK
1249
A12
49A
B/M
-600
27P
WR
.MO
D A
CO
N2
RE
D
WH
T
BLK
RE
D
WH
T
BLK
M -+
1602
1601
1603
(FR
AM
E)
GR
D
PW
R.M
OD
A
0-55
350-
10
CN
102-
4
CO
NN
EC
T B
LOC
K
10 O
HM
S
10 O
HM
S
10 O
HM
SB
LOW
ER
BLO
CK
PR
E-C
HA
RG
EB
OA
RD
+C
12
O-5
5350
-4
1> D
OT
TE
D L
INE
IND
ICA
TE
S J
UM
PE
R L
OC
AT
ION
IF P
OW
ER
MO
DU
LE R
EQ
UIR
ES
GR
EA
TE
R A
IR F
LOW
.
<1
NO
TE
S
RE
DB
AN
DR
ED
BA
ND
GR
AY
BA
ND
OR
GB
AN
DY
EL
BA
ND
VIO
BA
ND
VIO
OR
G
(612
183-
33R
R)
(612
183-
20R
)
(803
430-
95R
X) (803
430-
95R
X)
(612
183-
27R
)
(612
183-
16R
)(6
1218
3-16
T)
(612
183-
16S
)
(612
183-
20R
)
(612
183-
11R
)
(612
183-
19S
)
(612
183-
21R
)
(612
183-
14R
R)
(612
183-
15R
R)
(612
183-
15R
R)
(612
183-
32R
R)
(612
183-
22R
)
(803
430-
95R
R)
(80
3430
-95R
V)
(NO
T U
SE
D)
TO T
B (
212)
TO T
B (
213)
TO T
B (
214)
GR
AY
GR
AY
WH
T/Y
EL
WH
T/Y
EL
TO
TB
(11
3)
YE
L
U P
HA
SE
O-5
5350
-15
WA
RN
TH
ER
M.
FA
ULT
TH
ER
M.
WA
RN
TH
ER
M.
FA
ULT
TH
ER
M.
SH
IELD
W P
HA
SE
O-5
5350
-15
DR
AIN
WIR
E
2>(6
1218
3-28
S)
2> C
ON
NE
CT
LU
GG
ED
DR
AIN
WIR
E O
F T
HE
RM
OS
TA
TC
AB
LE 6
1218
3-28
S U
ND
ER
UP
PE
R L
EF
T C
OR
NE
RM
OU
NT
ING
SC
RE
W O
F P
RE
-CH
AR
GE
P.C
. BO
AR
DF
OR
GR
OU
ND
CO
NN
EC
TIO
N.
-+ M
RE
D
WH
T
BLK
PR
E-C
HA
RG
EB
OA
RD
CN
101
WH
T/B
RN
PW
R. M
OD
B (612
183-
19R
)
BR
N
Power Module Description 2-15
Figure 2.12 – 1335A SB3000 Power Module Circuitry (Continued)
1147
B
1145
B
MO
TOR
TE
RM
INA
L
CO
NN
EC
TO
R
RE
SIS
TO
RS
DC
PR
E-C
HA
RG
EP
OW
ER
MO
DU
LE "
B"
-+ M
65
93
41
2
CO
N1
78
1247
B
BLO
WE
R A
SS
EM
BLY
110V
AC
QU
ICK
[U]
1249
B
IGB
TM
OD
ULE
LEM
ULE
M W
183
RE
AC
TO
RA
IR C
OR
E
182
181
DIS
CH
AR
GE
RE
SIS
TO
RS
1249B
LEM
V
[V]
IGB
TM
OD
ULE
[W]
IGB
TM
OD
ULE
CN105C
N10
4
CN103
R1B
R2B
BLK
BLK
RE
D/G
RY
BR
N
WH
T/B
RN
1 4 1
CN101 CN101
3
B/M
-600
27
CO
N1
12
35
41 2 6
BLK
BLK
CLR
CLR
CO
NN
EC
T B
LOC
K
1145
B 1 2
1 2
3 4
3 4
TK U2
U2
U2
U2
TK
Z2
Z2
GR
DG
RD
GR
DG
RD
Z2
U2
TK
BLK
WH
T
BLKB
LK
BLK
1249
B12
49B
B/M
-600
27P
WR
.MO
D B
CO
N2
RE
D
WH
T
BLK
RE
D
WH
T
BLK
M -+
1602
1601
1603
(FR
AM
E)
GR
D
PW
R.M
OD
C
10 O
HM
S
10 O
HM
S
10 O
HM
SB
LOW
ER
BLO
CK
PR
E-C
HA
RG
EB
OA
RD
+C
12
O-5
5350
-4
1> D
OT
TE
D L
INE
IND
ICA
TE
S J
UM
PE
R L
OC
AT
ION
IF P
OW
ER
MO
DU
LE R
EQ
UIR
ES
GR
EA
TE
R A
IR F
LOW
.
<1
NO
TE
S
RE
DB
AN
DR
ED
BA
ND
GR
AY
BA
ND
OR
GB
AN
DY
EL
BA
ND
VIO
BA
ND
VIO
OR
G
(612
183-
33R
R)
(803
430-
95R
Z) (8
0343
0-95
RZ
)
(612
183-
16R
)(6
1218
3-16
T)
(612
183-
16S
)
(612
183-
9R)
(612
183-
19R
)
(612
183-
21T
)
(612
183-
14R
T)
(612
183-
15R
R)
(612
183-
15R
R)
(612
183-
32R
R)
(612
183-
22T
)
(803
430-
95R
R)
(80
3430
-95R
V)
(NO
T U
SE
D)
YE
L
U P
HA
SE
O-5
5350
-15
WA
RN
TH
ER
M.
FA
ULT
TH
ER
M.
WA
RN
TH
ER
M.
FA
ULT
TH
ER
M.
SH
IELD
W P
HA
SE
O-5
5350
-15
DR
AIN
WIR
E
2>(6
1218
3-28
S)
2> C
ON
NE
CT
LU
GG
ED
DR
AIN
WIR
E O
F T
HE
RM
OS
TA
TC
AB
LE 6
1218
3-28
S U
ND
ER
UP
PE
R L
EF
T C
OR
NE
RM
OU
NT
ING
SC
RE
W O
F P
RE
-CH
AR
GE
P.C
. BO
AR
DF
OR
GR
OU
ND
CO
NN
EC
TIO
N.
-+ M
RE
D
WH
T
BLK
PR
E-C
HA
RG
EB
OA
RD
CN
101
PW
R. M
OD
B
RE
D/G
RY
(612
183-
9S)
1 3
2-16 SB3000 Power Modules (Rittal)
Figure 2.13 – 1335A SB3000 Power Module Circuitry (Continued)
1147
C
1145
C
MO
TOR
TE
RM
INA
L
CO
NN
EC
TO
R
RE
SIS
TO
RS
DC
PR
E-C
HA
RG
E
PO
WE
R M
OD
ULE
"C
"
-+ M
65
93
41
2
CO
N1
78
1247
C
BLO
WE
R A
SS
EM
BLY
110V
AC
QU
ICK
[U]
1249
C
IGB
TM
OD
ULE
LEM
ULE
M W
183
RE
AC
TO
RA
IR C
OR
E
182
181
DIS
CH
AR
GE
RE
SIS
TO
RS
1249C
LEM
V
[V]
IGB
TM
OD
ULE
[W]
IGB
TM
OD
ULE
CN105
CN
104
CN103
R1B
R2B
BLK
BLK
RE
D/G
RY
BR
N
WH
T/B
RN
1 4 1
CN101
1
CN101
3 3
B/M
-600
27
CO
N1
12
35
41 2 6
BLK
BLK
CLR
CLR
CO
NN
EC
T B
LOC
K
1145
C 1 2
1 2
3 4
3 4
TK U2
U2
U2
U2
TK
Z2
Z2
GR
DG
RD
GR
DG
RD
Z2
U2
TK
BLK
WH
T
BLKB
LK
BLK
1249
C12
49C
B/M
-600
27P
WR
.MO
D B
CO
N2
RE
D
WH
T
BLK
RE
D
WH
T
BLK
M -+
1602
1601
1603
(FR
AM
E)
GR
D
PW
R.M
OD
B
10 O
HM
S
10 O
HM
S
10 O
HM
SB
LOW
ER
BLO
CK
PR
E-C
HA
RG
EB
OA
RD
+C
12
O-5
5350
-4
1> D
OT
TE
D L
INE
IND
ICA
TE
S J
UM
PE
R L
OC
AT
ION
IF P
OW
ER
MO
DU
LE R
EQ
UIR
ES
GR
EA
TE
R A
IR F
LOW
.
<1
NO
TE
S
RE
DB
AN
DR
ED
BA
ND
GR
AY
BA
ND
OR
GB
AN
DY
EL
BA
ND
VIO
BA
ND
VIO
OR
G
(612
183-
33R
R)
(803
430-
95R
Y) (803
430-
95R
Y)
(612
183-
16R
)(6
1218
3-16
T)
(612
183-
16S
)
(612
183-
9R)
(612
183-
19S
)
(612
183-
21R
)
(612
183-
14R
S)
(612
183-
15R
R)
(612
183-
15R
R)
(612
183-
32R
R)
(612
183-
22S
)
(803
430-
95R
R)
(80
3430
-95R
V)
(NO
T U
SE
D)
YE
L
U P
HA
SE
O-5
5350
-15
WA
RN
TH
ER
M.
FA
ULT
TH
ER
M.
WA
RN
TH
ER
M.
FA
ULT
TH
ER
M.
SH
IELD
W P
HA
SE
O-5
5350
-15
DR
AIN
WIR
E
2>(6
1218
3-28
S)
2> C
ON
NE
CT
LU
GG
ED
DR
AIN
WIR
E O
F T
HE
RM
OS
TA
TC
AB
LE 6
1218
3-28
S U
ND
ER
UP
PE
R L
EF
T C
OR
NE
RM
OU
NT
ING
SC
RE
W O
F P
RE
-CH
AR
GE
P.C
. BO
AR
DF
OR
GR
OU
ND
CO
NN
EC
TIO
N.
-+ M
RE
D
WH
T
BLK
PR
E-C
HA
RG
EB
OA
RD
CN
101
PW
R. M
OD
A
RE
D/G
RY
(612
183-
9S)
Installation Guidelines 3-1
CHAPTER 3Installation Guidelines
This chapter describes the guidelines and wiring recommendations to be followed when installing High Power SB3000 Power Modules. An installation procedure for the 445A, 890A, and 1335A Power Modules is provided.
3.1 Installation Planning
Use the following guidelines when planning your SB3000 Power Module installation:
SB3000 Power Module current ratings are dependent upon inlet air temperature. Ratings are given at 40° C (104° F) ambient. Refer to table 1.1 for output current ratings.
Internal Power Module conditions are monitored by two thermal switches on the heatsink.
One thermal switch is used to indicate a warning condition (register 203/1203, bit 7, WRN_OT@) while the other switch is used to indicate a fault condition (register 202/1202, bit 7, FLT_OT@). The thermal warning switch closes at 78° C (172.4° F) while the thermal fault switch closes at 85°C (185° F). Refer to the SB3000 Configuration and Programming Instruction Manual for more information.
• The relative humidity around the SB3000 Power Module must be kept between 5 and 90% (non-condensing).
• Do not install above 1000 meters (3300 feet) without derating. For every 91.4 meters (300 feet) above 1000 meters (3300 feet), the SB3000 Power Module's current rating is derated 1%.
• /RFDWH WKH 6% 3RZHU 0RGXOH LQ D FOHDQ FRRO DQG GU\ DUHD )ROORZ WKH recommendations given in IEC 68 concerning environmental operating conditions.
• Be sure surrounding equipment does not block service access to the SB3000 Power Module.
• $OORZ DGHTXDWH FOHDUDQFH IRU DLU YHQWLODWLRQ 6% 3RZHU 0RGXOHV SXOO LQ DLU IURP
WKH bottom of the cabinet and exhaust it through the top of the cabinet. Each cabinet bay of the SB3000 Power Module has one fan. Allow at least 30 cm (12") above and 2 m (6.6') in front of the SB3000 Power Module for adequate air clearance.
• AC input lead lengths, between the input reactor and the SB3000 Power Module’s AC input terminals, cannot exceed 100 meters (328 feet).
!ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
3-2 SB3000 Power Modules (Rittal)
3.2 Wiring
System wiring is to be done according to the supplied wiring diagrams (W/Es), which are application-specific. Sections 3.2.1 through 3.2.6 provide additional information on input fuses, pre-charge components, AC line reactors, and recommended wire types.
3.2.1 Fuses
Fuses are provided to protect the SB3000 Power Module's three-phase AC input, DC bus output, and 115V AC input power lines. See table 3.1 for the fuse ratings.
3.2.2 Pre-charge Resistors and Fuses
The pre-charge circuit consists of three AC line resistors with an AC contactor bypass. The pre-charge resistors are protected by fuses in series with each resistor. See table 3.2. The pre-charge circuit is sized to support the charging of the SB3000 Power Module’s DC bus capacitors and up to four times the Power Module’s capacitance as a load. The pre-charge time is 10 seconds or less.
!ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
!ATTENTION: The NEC/CEC requires that upstream branch circuit protection be provided to protect input power wiring. Install the fuses recommended in table 3.1. Do not exceed the fuse ratings. Failure to observe this precaution could result in damage to, or destruction of the equipment.
Table 3.1 – AC Input and DC Bus Fuse Ratings
FuseNumber Circuit
FuseCurrent Rating
FuseVoltage Rating Rockwell P/N
F101 A,B,C F102 A,B,C
DC Bus 1000 A 1000 VAC 64676-80P
F103 A,B,CF104 A,B,CF105 A,B,C
AC Line Input
630 A 1000 VAC 64676-79AZ
1FU 115V AC 5 Amp 600 VAC 64676-29R
2FU 115V AC 25 Amp 600 VAC 64676-72BB
3FU 115V AC 3.2 Amp 600 VAC 64676-29P
Installation Guidelines 3-3
The pre-charge circuit is controlled by the PMI rack via the Pre-charge Controller module (B/M O-55350-4). This module is located in the master inverter cabinet and the 24V output is used to drive a pilot relay which in turn drives the pre-charge contactor’s 115 VAC coil.
The pre-charge contactor’s auxiliary contacts are wired back to the Pre-charge Controller Module in the SB3000 Power Module. This module expects to see the pre-charge contactor close after energizing its coil. This condition must be met before the drive can be put into run.
3.2.3 Line Filter Reactors
Three-phase AC line reactors are necessary to isolate the capacitor bank from the AC line and to provide energy storage for the voltage boosting function of the SB3000 Power Module. See table 3.3. The line reactors have iron-cores, copper windings, and 1000V insulation. They are rated at 70° C (158° F) ambient and are convection cooled.
3.2.4 Control Transformers
SB3000 control transformers should not be connected to the same AC power line that supplies the 3-phase power to SB3000 terminals 181, 182, and 183. The SB3000 Power Module, during normal operation, introduces high-frequency line notching in the 3-phase AC line. This type of line disturbance can be coupled through a control transformer into all connected loads and equipment.
SB3000 control transformers that provide power to electronic power supplies, I/O cards, PMI racks, and programmable controllers should be connected to a separate source of AC power that is free of line noise. If a noise-free source of power is not available, a Sola transformer, resonant filter, or a shielded, conditioning transformer must be used.
Table 3.2 – Pre-charge Resistors and Fuses
Power Module Rating Resistance
Resistor P/N Fuse Rating Fuse P/N
3-Phase Fuse Holder P/N
445 AmpOne 3.75Ω
Resistor/Phase402422-3A
15 Amps, 600VRK5 or Equivalent
64676-1BW 49454-21C
890 AmpTwo 1.65Ω
Resistors/Phase(3.3Ω/Phase)
402422-3C20 Amps, 600V
RK5 or Equivalent64676-1BX 49454-21C
1,335 Amp Two 1.65 Ω
Resistors/Phase (3.3Ω/Phase)
402422-3C20 Amps, 600V
RK5 or Equivalent64676-1BX 49454-21C
Table 3.3 – Line Filter Reactor Ratings
Power Module Inductance FrequencyHarmonic Current
at 4kHz
445 Amp 500 µH at 534 Amp 23 to 62 Hz 15%
890 Amp 250 µH at 972 Amp 23 to 62 Hz 15%
1,335 Amp 167 µH at 1457 Amp 23 to 62 Hz 15%
3-4 SB3000 Power Modules (Rittal)
During normal operation, the SB3000 Power Module may also cause a large variation in the input isolation transformer’s neutral-to-ground voltage in ungrounded and high-resistance grounded systems. This may cause false ground fault detector indications.
This type of high frequency, high level line disturbance can be coupled through standard control transformers into all connected loads, such as electronic power supplies, I/O cards, and programmable controllers. This coupled, high level noise may cause improper operation or component failure.
To ensure proper ground fault detector operation, a ground fault detector with a 60 Hz filter is recommended. Standard magnetic relays and solenoids are not affected by this high frequency line noise.
3.2.5 Wire Sizes
Input wiring should be sized according to applicable codes to handle the SB3000 Power Module's continuous-rated input current. Output wiring should be sized according to applicable codes to handle the SB3000 Power Module's continuous-rated output current. Recommended wire sizes are shown in table 3.4. Terminals should be tightened to the torque values provided in table 3.5.
!ATTENTION: The SB3000 Power Module may cause a large variation in the input isolation transformer’s neutral-to-ground voltage in ungrounded and high-resistance grounded systems. This type of high frequency, high level line disturbance may cause improper ground fault detector operation or component failure.Failure to observe this precaution could result in damage to, or destruction of the equipment.
Table 3.4 – Recommended AC Input and DC Bus Output Wire Sizes
SB3000 Output Rating Size of Wire 1
1. NEC-recommended cable types: 40oC (104oF) copper wire.
445A 2 x 600 Kc Mil (304 mm2)
890A 3 x 600 Kc Mil (304 mm2)
1335A 4 x 1000 Kc Mil (507 mm2)
Table 3.5 – Terminal Tightening Torques
Terminals Tightening Torque
DC Bus Output Power: 45, 47 41 Nm (30 lb-ft)
Ground: GND - Door 11.3 Nm (8.3 lb-ft)
Ground: GND - Hood Access Plate 22.6 Nm (16.5 lb-ft)
Input Power: U, V, W 41 Nm (30 lb-ft)
115 VAC Input Power: L, N 3.5 Nm (2.6 lb-ft)
Installation Guidelines 3-5
3.2.6 Wire Routing
AC input wiring is routed through the top of the cabinet, above AC line terminals 181, 182 and 183. DC output wiring is also routed through the top of the cabinet. DC output wiring is usually connected directly to the D-C bus in the overhead enclosure that distributes the DC power to the common DC bus SA3000/SA3100 Power Modules.
The AC power distribution cabinet is mounted separately from the SB3000 Power Module but should be positioned conveniently close by. The AC disconnect is a thermal magnetic circuit breaker or a fused disconnect switch which is rated to protect the power wiring in the SB3000 Power Module. The AC disconnect is mounted such that it can be locked out, providing safe access to the inside of the power distribution cabinet and to the SB3000 Power Module.
3.3 Grounding
To prevent noise interference and possible malfunction of this equipment, it is imperative that a good cabinet ground be provided. The grounding conductor must be as short as possible and be run directly from the control panel ground terminal to a solid earth ground. It is recommended that the grounding conductor be the same size conductor as the AC input power wiring. Multi-cabinet grounding wires should not be daisy-chained but should be run separately to the common point of earth ground.
3.4 Installing a Power Module Cabinet
Use the following procedure to install a SB3000 Power Module cabinet.
Step 1. Ensure that AC input power leading to the SB3000 Power Module is off.
Step 2. Position the SB3000 Power Module on a level mounting surface. See figure 3.1, 3.2, or 3.3 for cabinet dimensions. Floor mounting dimensions are included for applications where the cabinet is to be attached to the floor.
Step 3. Connect the AC input leads from the line reactor/pre-charge control directly to the 181 (L1), 182 (L2), and 183 (L3) terminals. Connect the GND terminal to earth ground. See figure 3.4.
Step 4. Connect DC bus terminals 45 and 47 (800V DC) to the SA3000/SA3100 Power Module bus terminals. Connect the GRD terminal to earth ground. See figure 3.4.
Step 5. Connect the AC control power input line (two-wire 115 VAC with ground) to terminals L1 (L), L2 (N), and GND on the control wiring terminal board. See figure 3.4.
!ATTENTION: Ungrounded equipment represents a shock hazard. Connect the power module's ground terminals to earth ground using properly-sized ground wires. Failure to observe this precaution could result in severe bodily injury or loss of life.
3-6 SB3000 Power Modules (Rittal)
Figure 3.1 – 445A SB3000 Power Module Mounting Dimensions
86.61 (2200.00)
18.87 (479.2)
2.63 (66.68)
14.67 (372.5)
10.50 (266.8)
1.00 (25.5)
1.34 (34.03)
8.00 (203.3)TOP VIEW
(+) BUS (47)
SEE DETAIL "A"
4.75 (120.5)
7.13 (180.98)
26.25 (667)
4.00 (101.6)
21.69 (550.9)
10.50 (266.7)
5.31 (134.4)
2.69 (68.2)
1.75 (44.5)
2 (50.8)
5.25 (133.4)
.24 (6.00)
10.31 (261.9)
4.56 (115.8)
(-) BUS (45)
1.125 (28.6)
1.75 (44.5)
1.00 (25.4)
.562 X .750 (4) PL.
FRONT VIEWCLCL
15.75 (400.26)
DETAIL "A"
FOR DIMENSIONS OF STAB.
AC INPUT
183182181GRDGRD
OFFO
N
3.85 (97.9)
39.84 (1012)
FLOOR MOUNTING HOLE LOCATIONS.
23.7 (602.0)
8.00 (203.2)
8.00 (203.2)
39.89 (1012)
21.29 (540.9) 18.55 (471.2)
.750 DIA.
(3) HOLESFRONT OF DRIVE
ALL DIMENSIONS ± .06 IN. (1.5mm).
AC INPUT
182 183181
Installation Guidelines 3-7
Figure 3.2 – 890A SB3000 Power Module Mounting Dimensions
86.61 (2200)
183
63.50 (1612.0)
15.64 (397.2)
48.14 (1222.8)
183
GRD
9.50 (241.3)
4.75 (120.7)
1.34 (66.7)
18.84 (478.7)
1.34 (34.03)
1.00 (25.5)
AC INPUT
181 182
AC INPUT
GRD181 182
21.69 (550.9)
2 (50.8)
10.31 (261.9)
2.69 (68.2)
4.56 (115.8)
(+) BUS (47)
10.50 (266.8)
TOP VIEW
(-) BUS (45)
14.66 (372.5)
8.00 (20
3.3)
6.00 (152.4)
FOR DIMENSIONS OF STAB.
FRONT VIEWSEE DETAIL "A"
7.13 (181.0)
L C L C
OFF
ON
4.75 (120.5)
63.51 (1612)
FLOOR MOUNTING HOLES LOCATIONS
ALL DIMENSIONS ± .06 in. (1.5 mm).
3 HOLES.750 DIA
18.55 (471.2)
8.00 (203.2)
23.7 (602)
3.85 (97.9)
8.00 (203.2)
23.58 (601)
FRONT OF DRIVE
1.75 (44.5)
4.00 (101.6)
1.00 (25.4)
DETAIL "A"
1.125 (28.6)
1.75 (44.5)
.562 x .750 (4) PL.
3-8 SB3000 Power Modules (Rittal)
Figure 3.3 – 1335A SB3000 Power Module Mounting Dimensions
86.61 (2200)
FRONT VIEW
AC INPUT
183
AC INPUT183
87.09 (2212.0)
15.64 (397.2)
48.14 (1222.8
)
9.50 (241.3)
4.75 (120.7)
18.84 (478.7
)
2.63 (66.7)
1.34 (34.03)
1.00 (25.5)
182181
.562 x .750 (4) PL.
4.00 (101.6)
1.00 (25.4)
1.75 (44.5)
1.125 (28.6)
1.75 (44.5)
DETAIL "A"
181GRD
182
21.69 (550.9)
2 (50.8
)
10.31 (261.9)
2.69 (68.2)
4.56 (115.8)14.66 (3
72.5)
10.50 (266.8)
TOP VIEW
(+) BUS (47)
(-) BUS (45)
4.75 (120.5)
FOR DIMENSIONS OF STAB.SEE DETAIL "A"
7.13 (181.0)
6.00 (152.4)
L C CL
GRD
ON
OFF
FRONT OF DRIVE
FLOOR MOUNTING HOLE LOCATIONS87.13 (2212)
23.58 (601)
ALL DIMENSIONS ± .25 IN. (6.35 mm).
3.85 (97.9)
18.55 (471.2)
23.7 (602)
3 HOLES.750 DIA
8.00 (203.2)
8.00 (203.2)
23.58 (601)
8.00 (203.3)
Installation Guidelines 3-9
Figure 3.4 – SB3000 Power and Ground Connections
OUTPUT VOLTAGEDC BUS
INPUT VOLTAGE115 VAC
FROM LINE REACTORTHREE PHASE AC INPUT
GND
FUSE
(+)(–)
CONNECT BLOCK115 VAC QUICK
4745
POWER MODULE
NL183182181
+–
GND
SB3000
3-10 SB3000 Power Modules (Rittal)
Diagnostics and Troubleshooting 4-1
CHAPTER 4Diagnostics and Troubleshooting
This chapter describes the equipment needed to check the operation of the SB3000 Power Module and the tests to be performed. Also included are descriptions of the SB3000 Power Module faults monitored by the Distributed Power System software. Procedures are provided for replacing fuses and sub-assemblies.
4.1 Required Test Equipment
The following equipment is required when servicing the SB3000 Power Module:
• an oscilloscope with an impedance of at least 8 megohms
• a 10:1 probe
• an isolated voltmeter (1000V DC)
• a clamp-on ammeter (1500A)
Note that all measuring devices-meters-oscilloscopes that are AC line-powered must be connected to the AC line through an ungrounded isolation transformer.
!ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors to discharge, then look at the built-in DC bus voltage meter. When the voltage is down to approximately zero (0) volts, open the cabinet doors and check the voltage across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION: The SB3000 Power Module contains printed circuit boards that are static sensitive. Do not touch any components, connectors, or leads. Failure to observe this precaution could result in damage to equipment.
4-2 SB3000 Power Modules (Rittal)
4.2 Power Module Tests with Input Power Off
Use the following procedure to perform the SB3000 Power Module tests:
Step 1. Turn off and lock out AC input power.
Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.
Step 3. Look at the built-in DC Bus Voltage meter. When the DC bus potential is down to approximately zero volts, open the SB3000 Power Module cabinet's doors and measure the DC bus potential across the DC bus bars, 1247A (+ bus) and 1145A (- bus), with an external voltmeter before working on the unit. See figure 4.1.
Step 4. Check the AC input and DC bus output fuses.
Step 5. If a fuse is blown, use a multimeter to check the DC bus, bus capacitors, AC input terminals, and the input IGBTs. See tables 4.1 and 4.2.
Step 6. If a capacitor is defective, replace the capacitor bank assembly as described in section 4.5.4. If an IGBT is defective, refer to section 4.5.2.
!ATTENTION: The Power Module is not isolated from earth ground. The test instruments used to measure Power Module signals must be isolated from ground through an isolation transformer. This is not necessary for battery-powered test instruments. Failure to observe this precaution could result in bodily injury.
ATTENTION: If a megohmmeter (megger) is used to verify an inadvertent ground internal to the motor, make certain that all leads are disconnected between the rotating equipment and the Power Module cabinet. This will prevent damage to electronic circuitry (Power Modules and their associated circuitry) due to the high voltage generated by the megger. Failure to observe this precaution could result in damage to or destruction of the equipment.
!ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors to discharge, then look at the built-in DC bus voltage meter. When the voltage is down to approximately zero (0) volts, open the cabinet doors and check the voltage across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.
Diagnostics and Troubleshooting 4-3
Figure 4.1 – DC Bus Voltage Measuring Points
CAPACITOR BANK
PW
R. M
OD
. A
AC MOTOR OUTPUT
U V
LPI CIRCUIT
PHASE U
PMI RACK
PHASE W
FAN
PHASE V
SLO
T 6
SLO
T 7
SLO
T 8
PW
R. M
OD
. C
PW
R. M
OD
. B
110VD/S
±15VPS PS
-24V
2FU3FU
PS+24V
1FU
25KHZ PS
2FU
1FU
+ - 288289
MOTOR
GRD
GDIGDI GDI
POWER MODULE A
WF102A F101A
GRD
DC BUS VOLTAGEMEASURING POINTS
1247A
1145A-BUS
ASSEMBLY+BUS
F104A
F105A
F103A
4-4 SB3000 Power Modules (Rittal)
4.3 Power Module Faults and Warnings
The PMI Processor continually runs diagnostics which check for errors that may affect system operation. Warnings are errors which indicate that the SB3000 Synchronous Rectifier is not operating in an optimum manner. Warnings will not shut down the SB3000. Faults are severe errors which will shut down the SB3000. See tables 4.3 and 4.4.
Refer to the SB3000 Synchronous Rectifier Configuration and Programming instruction manual (S-3034) for more information about the Fault and Warning registers.
Table 4.1 – DC Bus and Output Terminal Tests1
1. with the AC input lines disconnected
Meter Connections+ - Scale Expected Test Results
DC Bus- Bus (45) + Bus (47)
X10Capacitor Effect (0 to 50 ohms)
+ Bus (47) - Bus (45) Capacitor Effect (0 to 200 ohms)
Bus Capacitors
+ 1249 X10Capacitor Effect (0 to 500 ohms)
- 1249
601 +
X1 2 ohms602 +
603 +
+ 601
X10 Capacitor Effect (0 to 2k ohms)+ 602
+ 603
InputTerminals
181 (601) 182 (602)
X1000 4k to 6k ohms181 (601) 183 (603)
182 (602) 183 (603
Table 4.2 – IGBT Tests1
1. with the AC input lines disconnected
Meter Connections + - Scale
Expected Test Results(+/- 10%)
W Phase (lower) + 183 +1147 2k Ω/diode 0.300 ohms
V Phase (lower) + 182 +1147 2k Ω/diode 0.300 ohms
U Phase (lower) + 181 + 1147 2k Ω/diode 0.300 ohms
W Phase (upper) - 1245 - 183 2k Ω/diode 0.300 ohms
V Phase (upper) - 1245 - 182 2k Ω/diode 0.300 ohms
U Phase (upper) - 1245 - 181 2k Ω/diode 0.300 ohms
Diagnostics and Troubleshooting 4-5
4.3.1 Faults
The following faults will cause the SB3000 Power Module to shut down. See table 4.3. In a fault situation, the PMI Processor will command zero current and will stop firing the IGBTs; however, the IGBT emitter-collector diodes will supply rectified line voltage to the DC bus until AC input power is disconnected. Faults must be reset before the SB3000 Power Module can be restarted.
Table 4.3 – SB3000 Fault Register 202/1202
Bit
Suggested Variable Name
UDC Error Code Description Summary
0 FLT_OV@ 1018 The DC Bus Overvoltage bit is set if the DC bus voltage exceeds 900 VDC.
1 FLT_DCI@ 1020 The DC Bus Overcurrent bit is set if the DC bus current exceeds 125% of the rated SB3000 Power Module current.
2 FLT_GND@ 1021 The Ground Current Fault bit is set if the ground current exceeds the hardware trip point. See section 4.3.1.3.
3 FLT_IOC@ 1017 The Instantaneous Overcurrent Fault bit is set if an overcurrent is detected in one of the power devices.
4 FLT_LPI@ 1022 The Local Power Interface bit is set if the power supply voltage on the LPI module is not within tolerance.
5 FLT_GDI@ 1023 The Gate Driver Interface Fault bit is set if the power supply voltage on the Gate Driver Interface (GDI) module is not within tolerance.
6 FLT_CHG@ 1024 The Charge Fault bit is set if either of the following occurs: the pre-charge contactor does not close when commanded to by the PMI Processor or the contactor opens without being commanded to do so.
7 FLT_OT@ 1016 The Overtemperature Fault bit is set if the fault level thermal switch (85o
C (185o F)) in the SB3000 Power Module opens.
10 FLT_PWR@ 1025 The Power Loss Fault bit is set if AC line power is lost for more than ten seconds while the SB3000 Power Module is running.
11 FLT_PTM@ 1011 The Power Technology Fault bit is set if the AC Power Technology module fails.
12 FLT_PS@ 1012 The PMI Power Supply Fault bit is set if the PMI rack’s power supply fails.
13 FLT_RW@ 1013 The PMI Read/Write Fault bit is set if a PMI Processor read or write operation fails.
14 FLT_RUN@ 1014 The UDC Run Fault bit is set if the UDC task stops while the voltage loop is running.
15 FLT_COM@ 1015 Communication Lost Fault bit is set if fiber-optic communication between the PMI Processor and the UDC module is lost due to two consecutive errors of any type.
4-6 SB3000 Power Modules (Rittal)
4.3.1.1 DC Bus Overvoltage Fault
The DC Bus Overvoltage bit (bit 0) is set in the Fault register (202/1202) if the DC bus voltage exceeds 900 VDC. Error code 1018 will also be displayed in the error log of the UDC task in which the fault occurred.
4.3.1.2 DC Bus Overcurrent Fault
The DC Bus Overcurrent bit (bit 1) is set in the Fault register (202/1202) if the DC bus current exceeds 125% of the rated SB3000 Power Module current. Error code 1020 will also be displayed in the error log of the UDC task in which the fault occurred.
4.3.1.3 Ground Current Fault
The Ground Current Fault bit (bit 2) is set in the Fault register (202/1202) if the ground current exceeds the hardware trip point. Error code 2021 will also be displayed in the error log of the UDC task in which the fault occurred.
Note that the Ground Current Fault bit (register 202/1202, bit 2) is not enabled on SB3000 Power Modules using AC Technology modules, B/M 60023-5 and later. Error code 2021 will not be displayed as the ground current hardware trip detector was removed from the AC Technology modules, B/M 60023-5 and later.
4.3.1.4 Instantaneous Overcurrent Fault
The Instantaneous Overcurrent Fault bit (bit 3) is set in the Fault register (202/1202) if an overcurrent is detected in one of the power devices. Register 204/1204, bits 0-5, indicate which power device detected the overcurrent. When 890A and 1335A SB3000 Power Modules are being used, registers 220/1220 and 221/1221 indicate the status of the B and C Power Module cabinets. Error code 1017 will also be displayed in the error log of the UDC task in which the fault occurred.
4.3.1.5 Local Power Interface Fault
The Local Power Interface Fault bit (bit 4) is set in the Fault register (202/1202) if the power supply voltage on the LPI module is not within tolerance. Error code 1022 will also be displayed in the error log of the UDC task in which the fault occurred.
4.3.1.6 Gate Driver Interface Fault
The Gate Driver Interface Fault bit (bit 5) is set in the Fault register (202/1202) if the power supply voltage on the Gate Driver Interface (GDI) module is not within tolerance. Error code 1023 will also be displayed in the error log of the UDC task in which the fault occurred.
If SB3000 Power Modules are connected in parallel, bit 7 in register 204/1204, 220/120, or 221/1221 will be set to indicate which GDI module is affected
4.3.1.7 Charge Fault
The Charge Fault bit (bit 6) is set in the Fault register (202/1202) if either of the following occurs: the pre-charge contactor did not close when commanded to by the PMI Processor or the contactor opened without being commanded to do so. Error code 1024 will also be displayed in the error log of the UDC task in which the fault occurred.
Diagnostics and Troubleshooting 4-7
4.3.1.8 Overtemperature Fault
The Overtemperature Fault bit (bit 7) is set in the Fault register (202/1202) if the fault level thermal switch (85o C (185o F)) in the SB3000 Power Module opens. Bit 12 in register 204/1204, 220/1220, or 221/1221 will be set to indicate which SB3000 Power Module is affected. Error code 1016 will also be displayed in the error log of the UDC task in which the fault occurred.
4.3.1.9 Power Loss Fault
The Power Loss Fault bit (bit 10) is set in the Fault register (202/1202) if AC line power is lost for more than ten seconds while the SB3000 Power Module is running.This bit will also be set if one phase of the AC line is lost or if line synchronization is lost. Error code 1025 will also be displayed in the error log of the UDC task in which the fault occurred.
4.3.1.10 Power Technology Fault
The Power Technology Fault bit (bit 11) is set in the Fault register (202/1202) if the AC Power Technology module fails. Error code 1011 will also be displayed in the error log of the UDC task in which the fault occurred.
4.3.1.11 PMI Power Supply Fault
The PMI Power Supply Fault bit (bit 12) is set in the Fault register (202/1202) if the PMI rack’s power supply fails. Error code 1012 will also be displayed in the error log of the UDC task in which the fault occurred.
4.3.1.12 PMI Read/Write Fault
The PMI Read/Write Fault bit (bit 13) is set in the Fault register (202/1202) if a PMI Processor read or write operation fails. Error code 1013 will also be displayed in the error log of the UDC task in which the fault occurred.
4.3.1.13 UDC Run Fault
The UDC Run Fault bit (bit 14) is set in the Fault register (202/1202) if the UDC task stops while the voltage loop is running. Error code 1014 will also be displayed in the error log of the UDC task in which the fault occurred.
4.3.1.14 Communication Lost Fault
The Communication Lost Fault bit (bit 15) is set in the Fault register (202/1202) if the fiber-optic communication between the PMI Processor and the UDC module is lost due to two consecutive errors of any type. This bit is only set after communication between the PMI Processor and UDC module has been established. This bit should be used in the run permissive logic of the SB3000 Power Module. Error code 1015 will also be displayed in the error log of the UDC task in which the fault occurred.
4.3.2 Warnings
The following warnings indicate conditions which are not serious enough to shut down the SB3000 Synchronous Rectifier but may affect its performance. See table 4.4. Warnings cause no action by themselves. Any response to a warning condition is the responsibility of the application task.
4-8 SB3000 Power Modules (Rittal)
4.3.2.1 DC Bus Overvoltage Warning
The DC Bus Overvoltage bit (bit 0) is set in the Warning register (203/1203) if the DC bus voltage exceeds the overvoltage threshold value stored in local tunable OVT_E0%.
4.3.2.2 DC Bus Undervoltage Warning
The DC Bus Undervoltage bit (bit 1) is set in the Warning register (203/1203) if the DC bus voltage drops below the under voltage threshold value stored in local tunable UVT_E0%.
Table 4.4 – SB3000 Warning Register 203 /1203
Bit
Suggested Variable Name Description Summary
0 WRN_OV@ The DC Bus Overvoltage fault bit is set if the DC bus voltage exceeds the overvoltage threshold value stored in local tunable OVT_E0%.
1 WRN_UV@ The DC Bus Under Voltage bit is set if the DC bus voltage drops below the under voltage threshold value stored in local tunable UVT_E0%.
2 WRN_GND@ The Ground Current Warning bit is set if the ground current exceeds the ground fault current level stored in local tunable GIT_EI%.
3 WRN_PL@ The Phase Lost Warning bit is set if a phase loss occurs in the AC line.
4 WRN_RIL@ The Reference in Limit Warning bit is set if the UDC reference value (register 102/1102) is less than the minimum value or greater than the maximum value allowed. In the Bridge Test mode, this bit is used to indicate an illegal test code.
6 WRN_SHR@ The Load Sharing Warning bit is set if a current sharing problem develops between parallel SB3000 Power Modules.
7 WRN_OT@ The Overtemperature Warning bit is set if the warning level thermal switch (78° C
(172.4o F)) in the SB3000 Power Module opens.
8 WRN_BGD@ The Bad Gain Warning bit is set when a tunable variable is changed to an illegal value when the UDC task is running.
9 WRN_OL@ The Power Module Overload Warning bit is set if the continuous current rating of the SB3000 Power Module is exceeded for approximately five minutes and does not decrease and maintain the continuous current rating for at least 45 minutes.
10 WRN_PWR@ The Power Lost Warning bit is set if the power dip ride-through feature of the SB3000 Power Module has been enabled.
12 WRN_FAN@ The PMI Fan Loss Warning bit is set if there is no airflow detected through the PMI rack.
13 WRN_RAL@ The Rail Communication Warning bit is set if a rail communication problem occurs and is logged in registers 4, 10, 16, or 22.
14 WRN_CLK@ The CCLK Not Synchronized Warning bit is set if the CCLK counters in the PMI Processor and UDC module are momentarily unsynchronized.
15 WRN_COM@ The PMI Communication Warning bit is set if a fiber-optic communication error occurs between the PMI Processor and the UDC module.
Diagnostics and Troubleshooting 4-9
4.3.2.3 Ground Current Warning
The Ground Current Warning bit (bit 2) is set in the Warning register (203/1203) if the ground current exceeds the ground fault current level stored in local tunable GIT_EI%.
4.3.2.4 Phase Lost Warning
The Phase Lost Warning bit (bit 3) is set in the Warning register (203/1203) if a phase loss occurs in the AC line.
4.3.2.5 Reference in Limit Warning
The Reference in Limit Warning bit (bit 4) is set in the Warning register (203/1203) if the UDC reference value (register 102/1102) is less than the minimum value or greater than the maximum value allowed. In the Bridge Test mode, this bit is used to indicate an illegal test code.
4.3.2.6 Load Sharing Warning
The Load Sharing Warning bit (bit 6) is set in the Warning register (203/1203) if a current sharing problem develops between parallel SB3000 Power Modules. Bits 13, 14, or 15 in registers 204/1204, 220/1220, or 221/1221 will be set to indicate the phase and SB3000 Power Modules affected.
4.3.2.7 Overtemperature Warning
The Overtemperature Warning bit (bit 7) is set in the Warning register (203/1203) if the warning level thermal switch (78o C (172.4o F)) in the SB3000 Power Module opens. Bit 12 in register 204/1204, 220/1220, or 221/1221 will be set to indicate which SB3000 Power Module is affected.
4.3.2.8 Bad Gain Data Warning
The Bad Gain Data Warning bit (bit 8) is set in the Warning register (203/1203) if a tunable variable is changed to an illegal value when the UDC task is running. The value will be restored to its previous valid value by the PMI Processor.
4.3.2.9 Power Module Overload Warning
The Power Module Overload Warning bit (bit 9) is set in the Warning register (203/1203) if the continuous current rating of the SB3000 Power Module is exceeded for approximately five minutes and does not decrease and maintain the continuous current rating for at least 45 minutes.
4.3.2.10 Power Loss Warning
The Power Loss Warning bit (bit 10) is set in the Warning register (203/1203) if the power dip ride-through feature of the SB3000 Power Module has been enabled. This will occur if the PMI Processor detects that the AC input voltage is less than 75% or more than 125% of the configured value. When this bit is set, the PMI Processor disables the firing of the IGBTs. If power is restored within 10 seconds, the PMI Processor will resynchronize and resume operation. If power is not restored within 10 seconds, bit 10 in register 202/1202 will be set and the SB3000 Power Module will shut down.
4-10 SB3000 Power Modules (Rittal)
4.3.2.11 PMI Fan Loss Warning
The PMI Fan Loss Warning bit (bit 12) is set in the Warning register (203/1203) if there is no airflow through the PMI rack.
4.3.2.12 Rail Communication Warning
The Rail Communication Warning bit (bit 13) is set in the Warning register (203/1203) if a rail communication problem occurs and is logged in registers 4, 10, 16, or 22.
4.3.2.13 CCLK Not Synchronized Warning
The CCLK Not Synchronized Warning bit (bit 14) is set in the Warning register (203/1203) if the CCLK counters in the PMI Processor and UDC module are momentarily unsynchronized.
4.3.2.14 PMI Communication Warning
The PMI Communication Warning bit (bit 15) is set in the Warning register (203/1203) if a fiber-optic communication error occurs between the PMI Processor and the UDC module. Communication errors in two consecutive messages will result in a fault.
4.4 Replacing the Power Module Cabinet
Use the following procedure to replace an SB3000 Power Module cabinet:
Step 1. Turn off and lock out the AC input power at the input reactor/pre-charge control cabinet.
Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.
Step 3. Look at the built-in DC Bus Voltage meter. When the DC bus potential is down to approximately zero volts, open the SB3000 Power Module cabinet's doors and measure the DC bus potential across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter before working on the unit. See figure 4.1.
Step 4. Disconnect the AC input leads from terminals 181 (L1), 182 (L2), and 183 (L3). Disconnect the GND wire from the ground terminal. See figure 3.4.
Step 5. Disconnect the AC input line (two-wire 110 VAC) from the L and N terminals. See figure 3.4.
Step 6. Disconnect the DC bus from terminals 45 and 47. See figure 3.4.
Step 7. Remove the SB3000 Power Module cabinet.
!ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors to discharge, then look at the built-in DC bus voltage meter. When the voltage is down to approximately zero (0) volts, open the cabinet doors and check the voltage across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.
Diagnostics and Troubleshooting 4-11
Step 8. Install the replacement SB3000 Power Module cabinet by following these steps in reverse order.
4.5 Replacing Power Module Sub-Assemblies
Use the procedures in sections 4.5.1 to 4.5.4 to replace the SB3000 Power Module’s fuses and sub-assemblies.
4.5.1 Replacing Fuses
Use the following procedure to replace a fuse that has blown:
Step 1. Turn off and lock out the AC input power.
Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.
Step 3. Look at the built-in DC Bus Voltage meter. When the DC bus potential is down to zero volts, open the SB3000 Power Module cabinet's doors and measure the DC bus potential across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter before working on the unit. See figure 4.1.
Step 4. Remove the blown fuse and install the replacement fuse. Figures 4.2, 4.3, and 4.4 show the location of the fuses in the 445A, 890A, and 1335A SB3000 Power Modules. Table 4.5 provides fuse specifications.
Step 5. Close the cabinet doors and reapply power to the SB3000 Power Module.
!ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors to discharge, then look at the built-in DC bus voltage meter. When the voltage is down to zero (0) volts, open the cabinet doors and check the voltage across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.
4-12 SB3000 Power Modules (Rittal)
Figure 4.2 – 445A SB3000 Power Module Fuse Locations
PW
R. M
OD
. A
F104A
SLO
T 6
F103A
GDI
POWER MODULE A
CAPACITOR BANK
PMI RACKPHASE V
PHASE WF105A25KHZ.
PS
LPI CIRCUITPHASE U
±15VPS
110V.D/S
183
AC INPUT
181 182
2FU3FU
1FU
+24VPS
–24VPS
F102A F101ADC BusFuses
Control PowerFuses
AC InputPhaseFuses
∗∗
∗∗∗
∗SeeTable4.5
11FU12FU
21FU-26FU
Diagnostics and Troubleshooting 4-13
Figure 4.3 – 890A SB3000 Power Module Fuse Locations
F105B
F104B
PHASE W
PHASE V
POWER MODULE B
F103B PHASE U
AC INPUT
181 182 183
PMI RACK
PHASE WF105A
F104A
SLO
T 7
SLO
T 6
PW
R. M
OD
A
GDI
PW
R. M
OD
B
GDI
+
F101AF101BF102B F102A
PHASE UF103A
∗
PSPS
LPI CIRCUIT
2FU3FU
1FU
+24V±15V
D/S110V
- -24V
25KHZPS
(+)
POWER MODULE A
PHASE V
PS
DC BusFuses
Control PowerFuses
AC InputPhaseFuses
AC InputPhaseFuses
∗∗See Table 4.5 ∗∗∗
21FU-26FU
11FU12FU
4-14 SB3000 Power Modules (Rittal)
Figure 4.4 – 1335A SB3000 Power Module Fuse Locations
F10
5CF
105B
F10
4B
F10
3B
P1
SLOT 6
**
PS
PS
2FU
+24
V
PS
F10
4C
F10
3C
AC
INP
UT
181
182
183
PM
I RA
CK
F10
5A
F10
4A
PH
AS
E W
P1
25K
HZ
.
GD
I PWR. MOD. A
* *
F10
2AF
102B
F10
1CF
102C
F10
1BF
101A
PO
WE
R M
OD
ULE
A
F10
3AP
HA
SE
U
PS LP
I CIR
CU
IT3FU
1FU
±15V
110V
D/S
–24V
SLOT 7
SLOT 8
PWR. MOD. A
GD
I
PWR. MOD. A
GD
I
PO
WE
R M
OD
ULE
B
PH
AS
E U
PH
AS
E V
PH
AS
E W
PO
WE
R M
OD
ULE
C
PH
AS
E U
PH
AS
E V
PH
AS
E W
PH
AS
E V
Con
trol
Pow
erF
uses
DC
Bus
Fus
es
AC
Inpu
tP
hase
Fus
es
AC
Inpu
tP
hase
Fus
es
AC
Inpu
tP
hase
Fus
es
∗∗∗
∗∗∗
See
Tab
le 4
.5
11F
U
12F
U21
FU
-
26F
U
Diagnostics and Troubleshooting 4-15
4.5.2 Replacing an IGBT Phase Module Assembly
Use the following procedure to replace an IGBT Phase module assembly (U, V, or W):
Step 1. Turn off and lock out AC input power.
Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.
Step 3. Look at the built-in DC Bus Voltage meter. When the DC bus potential is down to zero volts, open the SB3000 Power Module cabinet's doors and measure the DC bus potential across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter before working on the unit. See figure 4.1.
Table 4.5 – Power Module Fuse Specifications1
Fuse Volts Class Type Rating Rockwell Part
Number Torque Specifications
1FU 600 CC KLDR 5 A 64676-29R --
2FU 600 CC CCMR 25 A 64676-72BB --
3FU 600 CC KLDR 3.2 A 64676-29P --
F101 1000 Semiconductor 1000 A 64676-80P 41 Nm (30 lb-ft)
F102 1000 Semiconductor 1000 A 64676-80P 41 Nm (30 lb-ft)
F103 1000 Semiconductor 630 A 64676-79AZ 20.5 Nm (15 lb-ft)
F104 1000 Semiconductor 630 A 64676-79AZ 20.5 Nm (15 lb-ft)
F105 1000 Semiconductor 630 A 64676-79AZ 20.5 Nm (15 lb-ft)
+/- 15V PS* 250 -- F 1.8 A Replace with 1.6A
64676-82U
--
+/- 24V PS** 250 -- T 2.5 A 64676-71P --
+/- 24V PS*** 250 -- F 2.0 A 64676-82V --
25 KHz PS11FU12FU
600 CC -- 8 A 64676-30H --
25 KHz PS21FU26FU
250 -- F 2 A 64676-66C --
1. Fuse locations shown in figures 4.2, 4.3, and 4.4.
!ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors to discharge, then look at the built-in DC bus voltage meter. When the voltage is down to zero (0) volts, open the cabinet doors and check the voltage across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.
4-16 SB3000 Power Modules (Rittal)
Step 4. Remove the wiring harnesses from the IGBT Phase module assembly. The wiring includes the power supply wiring, the temperature sensor wiring, and the fiber-optic cables. Remove the fiber-optic cables by pressing the sides of the connectors to release the locking mechanism. Label the harnesses to aid in re-installation. Refer to the wiring diagrams supplied with your system.
Note that due to tight mechanical tolerances, it may be necessary to remove IGBT Phase module assemblies U and/or V, in order to remove assemblies V and/or W.
Step 5. Remove the bolts from the fuses. See figure 4.5, callouts 1 and 2.
Step 6. Remove the 2 bolts from the AC bus bar. The bolts are located below the LEM device and above the fuse. See figure 4.5, callout 3.
Step 7. Remove the 2 hex nuts from the negative bus bar. See figure 4.5, callout 4.
Step 8. Remove the 2 hex nuts from the heatsink. One hex nut is located on each side of the heatsink. See figure 4.5, callout 5.
Step 9. Remove the IGBT module assembly from the SB3000 Power Module.
Step 10. Install the new IGBT module assembly by performing steps 1 through 9 in reverse order.
Step 11. Close the cabinet doors and reapply power to the SB3000 Power Module.
Figure 4.5 – IGBT Module Assembly Mounting Bolt Locations
5
4
1
2
3
PHASE V
PHASE W
Diagnostics and Troubleshooting 4-17
4.5.2.1 Replacing an IGBT
If an IGBT needs to be replaced, it is recommended that the IGBT module be returned to an authorized Rockwell repair facility.
4.5.3 Replacing a Blower Assembly
Use the following procedure to replace a blower assembly:
Step 1. Turn off and lock out the AC input power.
Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.
Step 3. Look at the built-in DC Bus Voltage meter. When the DC bus potential is down to zero volts, open the SB3000 Power Module cabinet's doors and measure the DC bus potential across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter before working on the unit. See figure 4.1.
Step 4. Turn off the AC power to the blower by turning the circuit breaker in the power supply panel off.
Step 5. Disconnect the wires from the right side of the blower assembly. The wire connectors are keyed.
Step 6. Remove the blower from the cabinet by sliding it out.
Step 7. Install the new blower assembly by performing steps 1 through 6 in reverse order.
Step 8. Close the cabinet doors and reapply power to the SB3000 Power Module.
4.5.3.1 Replacing a Blower Filter
Use the following procedure to replace the blower assembly's filter:
Step 1. Remove the filter by sliding it out.
Step 2. Slide the new filter in.
!ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors to discharge, then look at the built-in DC bus voltage meter. When the voltage is down to zero (0) volts, open the cabinet doors and check the voltage across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.
4-18 SB3000 Power Modules (Rittal)
4.5.4 Replacing a Bus Capacitor Assembly
Use the following procedure to replace a DC bus capacitor assembly:
Step 1. Turn off and lock out the AC input power.
Step 2. Wait ten minutes to allow the DC bus voltage to dissipate.
Step 3. Look at the built-in DC Bus Voltage meter. When the DC bus potential is down to zero volts, open the SB3000 Power Module cabinet's doors and measure the DC bus potential across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter before working on the unit. See figure 4.1.
Step 4. Remove all three IGBT assemblies (U, V, and W). Refer to section 4.5.2 for information on IGBT assembly removal.
Step 5. Remove the AC input power wiring by removing the bolt from the LEM stud spacer. This wiring consists of three insulated, tinned-copper straps which have color-coded bands (orange, yellow, and purple).
Step 6. Remove the LEM device control wiring. Needle-nose pliers may be useful in removing the three wire connectors.
Step 7. Remove the three LEM devices. Four screws attach each LEM device to the capacitor bank.
Step 8. Remove the three insulator blocks. Each insulator block is secured by two hex nuts.
Step 9. Remove the power cable wiring harnesses from the top of the capacitor bank. The two wiring harnesses have color-coded bands. The positive bus bar cable has a red band while the negative bus bar cable has a gray band.
Step 10. Remove the control wiring from the top of the capacitor bank.
Step 11. Remove the capacitor bank's four mounting screws. Two are located at the top of the capacitor bank and two at the bottom.
Step 12. Slide the capacitor bank out of the cabinet.
Step 13. Install the new capacitor bank assembly by following steps 1 through 12 in reverse order.
Step 14. Close the cabinet doors and reapply power to the SB3000 Power Module.
!ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait ten (10) minutes for the DC bus capacitors to discharge, then look at the built-in DC bus voltage meter. When the voltage is down to zero (0) volts, open the cabinet doors and check the voltage across the DC bus bars, 1247 A,B,C (+ bus) and 1145 A,B,C (- bus), with an external voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.
Diagnostics and Troubleshooting 4-19
4.6 Performing the Bridge Test
Important: This test is normally performed at the factory. It should not be necessary to perform it again unless the power devices or fiber-optic cables have been replaced.
The bridge test is used to verify fiber-optic gate cabling connections by test firing the IGBTs one at a time. As the IGBTs fire, the LEDs on the corresponding GDI module in the PMI rack will turn on and off in the following sequence:
1. U- (Lower Power Device)
2. U+ (Upper Power Device)
3. V- (Lower Power Device)
4. V+ (Upper Power Device)
5. W- (Lower Power Device)
6. W+ (Upper Power Device)
If the LEDs do not turn on and off in this order, the fiber-optic gate cables have been connected incorrectly and must be reconnected as shown on the wiring diagrams. Note that three-phase AC input power must be off and the DC bus capacitors must be discharged before the cables can be reconnected.
Three-phase AC input power to the SB3000 Power Module must be turned off and the inverter must be disconnected before the bridge test can be enabled. When the bridge test is running, the pre-charge contactor will be closed. 115 VAC control power must be applied for the pre-charge contactor. When the bridge test is turned off, the pre-charge contactor will open.
The PMI Processor will prevent the bridge test from executing if the DC bus voltage is greater than 10 VDC. However, the PMI Processor cannot prevent three-phase AC input power from being applied once the bridge test has been started. If three-phase AC input power is turned on while the bridge test is in progress, a line-to-line short circuit will result which may result in bodily injury and damage to the SB3000 Power Module.
Use the following procedure to perform the bridge test:
Step 1. Disconnect, lockout, and tag the three-phase AC input power to the SB3000 Power Module.
Step 2. Ensure that the DC bus is fully discharged. Refer to section 4.2.
Step 3. Enable the bridge test through register 100/1100, bit 2, and bits 10, 11, or 12, as applicable.
Step 4. Verify that the LEDs turn on and off in the order described. If the LEDs do not turn on and off in the proper order, reconnect the fiber-optic gate cables as shown on the wiring diagrams.
!ATTENTION: Disconnect and lock out three-phase AC input power to the SB3000 Power Module before enabling the bridge test. Ensure that three-phase AC input power cannot be turned on while the bridge test is running. If three-phase AC input power is turned on while the test is running, a line-to-line short circuit will occur. Failure to observe this precaution could result in bodily injury.
4-20 SB3000 Power Modules (Rittal)
Technical Specifications A-1
APPENDIX ATechnical Specifications
Ambient Conditions
• Operating Temperature:0 to +40o C
32 to +104o F
• Storage Temperature:-25 to +55o C
-13 to +131o F
• Humidity: 5 to 95%, non-condensing.
• Altitude: Do not install above 1000 meters (3300 feet) without derating output current. For every 91.4 meters (300 feet) above 1000 meters (3300 feet), derate the output current by 1%.
• Vibration: Sine Wave: 1g., 10-500 Hz., all 3 axes.
• Shock: 15g., over 6 msec., half sine wave.
Dimensions (445A SB3000 Power Module)
• Height: 2200 mm (86.6 inches)1
• Depth: 602 mm (23.7 inches)
• Width: 1012 mm (39.8 inches)
• Weight:500 kg (1100 pounds)
Dimensions (890A SB3000 Power Module)
• Height: 2200 mm (86.6 inches)1
• Depth: 602 mm (23.7 inches)
• Width: 1612 mm (63.5 inches)
• Weight:910 kg (2002 pounds)
Dimensions (1335A SB3000 Power Module)
• Height: 2200 mm (86.6 inches)1
• Depth: 602 mm (23.7 inches)
• Width: 2212 mm (87.1inches)
• Weight:320 kg (2904 pounds)
1. Does not include upper bus bar connections
A-2 SB3000 Power Modules (Rittal)
AC Input Power
• Minimum AC Line Voltage: 208V nominal
• Maximum AC Line Voltage: 460V nominal
• Maximum AC Line Variation: +/- 10%
• AC Line Frequency: 25, 50, and 60 Hz, +/- 2 Hz
• Frequency Rate of Change: 1Hz/Second
• Maximum AC Line Current: 534A, 972A, 1457A
• Maximum Phase Imbalance: 5%
AC Control Power
• AC Input Voltage: 115 VAC
• AC Input Frequency: 50/60 Hz
DC Output Power
• Minimum Output Voltage: 1.414 x VAC x 1.1 x 1.1
• Maximum Output Voltage: 900V
• Output Voltage Regulation: +/- 1%
• Maximum DC Output Current: (1.70 x ELine x ILine x Power Factor) / VDC
• Maximum Short Circuit Current: 100KA
• Output Voltage Resolution: 0.5V
• Output Voltage Regulation: Less than 5% for +/- 100% current step change
• Voltage Regulator Response: 100 rad/sec.
• VAR/Power Factor Correction: The user can select the maximum amount of SB3000 VAR correction. The SB3000 Power Module will always give the voltage regulator priority over the VAR function. If the output of the SB3000 Power Module is less than its limit, it will attempt to produce VARs up to the limit set by the user. Refer to Appendix C, section C.2.1.
SB3000 Power Module Current Ratings 1
SB3000 Part Number
ContinuousAC Input Current
(460VAC)
ContinuousDC Output Current
(800VDC)
5 MinuteAC Input and DC Output
Overload 2
804300-S 445A (rms) 445A DC 534A (rms)
804300-T 890A (rms) 890A DC 972A (rms)
804300-V 1335A (rms) 1335A DC 1457A (rms)
1. At 460 VAC Input/800 VDC Output/4 kHz Carrier Frequency. For use with SA3000/SA3100 Power Modules operating at a 2 kHz carrier frequency.
2. With a 25% duty cycle
Technical Specifications A-3
Three-Phase AC Input Voltage
• Voltage Range: 200 to 500 Volts, +/- 10%
• Frequency Range: 25, 50, and 60 Hz (+/- 2 Hz)
• Frequency Rate of Change: 5 Hz per Second
• Maximum Phase Imbalance: 5%
Output Phase Signals (181-182, 182-183)
• Signal Waveform: 10 mA square wave
• Phase Accuracy: < 2%
• Phase Shift versus Frequency: Phase Shift = 0.637 x Input Frequency
• Output Open-Circuit Voltage: 15 Volts
• Short-Circuit Current: < 40 mA
Analog Output Voltage
• Gain: 675 VAC RMS = 10 VDC
• Filter Break Frequency: 23 Hz
• CMRR: 200:1
TSB3000 Power Module Replacement Fuse Specifications 1
Fuse Volts Class Type Rating Rockwell Part
Number Torque Specifications
1FU 600 CC KLDR 5 A 64676-29R --
2FU 600 CC CCMR 25 A 64676-72BB --
3FU 600 CC KLDR 3.2 A 64676-29P --
F101 1000 Semiconductor 1000 A 64676-80P 41 Nm (30 lb-ft)
F102 1000 Semiconductor 1000 A 64676-80P 41 Nm (30 lb-ft)
F103 1000 Semiconductor 630 A 64676-79AZ 20.5 Nm (15 lb-ft)
F104 1000 Semiconductor 630 A 64676-79AZ 20.5 Nm (15 lb-ft)
F105 1000 Semiconductor 630 A 64676-79AZ 20.5 Nm (15 lb-ft)
+/- 15V PS* 250 -- F 1.6 A 64676-82U --
+/- 24V PS** 250 -- T 2.5 A 64676-71P --
+/- 24V PS*** 250 -- F 2.0 A 64676-82V --
25 KHz PS11FU12FU
600 CC -- 8 A 64676-30H --
25 KHz PS21FU26FU
250 -- F 2 A 64676-66C --
1. Fuse locations shown in figures 4.2, 4.3, and 4.4.
A-4 SB3000 Power Modules (Rittal)
SB3000 Component Block Diagram B-1
APPENDIX BSB3000 Component Block Diagram
The following figure shows an overview of the components of the SB3000 Synchronous Rectifier. Refer to chapter 2 of this manual for detailed diagrams of the 445A, 890A, and 1335A configurations of the SB3000 Synchronous Rectifier.
B-2 SB3000 Power Modules (Rittal)
PM
IR
AC
KLP
IR
EM
OT
EO
PT
ION
AL
PO
WE
R M
OD
ULE
C
PO
WE
R M
OD
ULE
B
PO
WE
R M
OD
ULE
A
1000
AF1
02C
F10
1C10
00A
1000
A
F102
B10
00A
F10
1B
1000
A
F10
2A10
00A
F10
1A
4547
SB
300
0 S
YN
CH
RO
NO
US
RE
CT
IFIE
R A
/B/C
PO
WE
R M
OD
ULE
S
I/O H
EA
DS
+24
VD
C
-24
VD
C
+/-1
5 V
DC
WA
RN
ING
T
HE
RM
OS
TA
T 3
TR
IPT
HE
RM
OS
TA
T 3
LEM
CA
BLE
3
TO
LP
I
22
9F
AU
LT F
/O P
AIR
S6
GA
TE
DR
IVE
R A
ND
TO
PM
I RA
CK
TH
ER
MO
ST
AT
2T
HE
RM
OS
TA
T 2
WA
RN
ING
2
TO L
PI
TR
IP
TO
PM
I RA
CK
CA
BLE
22
LEM
96
GA
TE D
RIV
ER
AN
DF
AU
LT F
/O P
AIR
S
601
602
603 T
O
PO
WE
RM
OD
ULE
BF
AU
LT F
/O
DR
IVE
RA
ND
19
MO
TO
RF
DB
KT
RIP
LET
WIS
TED
CA
BLE
LEM
TR
IPT
HE
RM
O-
ST
AT
2
WA
RN
ING
THE
RM
O-
ST
AT
22
TH
ER
MO
-S
TA
T 2
ST
AT
2
WA
RN
ING
TH
ER
MO
-T
RIP
2C
AB
LELE
M
9
THE
RM
O-
WA
RN
ING
STA
T 2
LEM
CA
BLE
TR
IP
ST
AT
2T
HE
RM
O-
2
9
6 G
ATE
PA
IRS
15 15 15
115V
AC
CK
T B
RE
AK
ER
115V
AC
188
189
115V
AC
188
189
115V
AC
3145
3147
-+
DC
BU
S_3
-+
DC
BU
S_2
-+
DC
BU
S_1
2145
2147
1147
1145
TO P
OW
ER
MO
DU
LE B
TO P
OW
ER
MO
DU
LE C
22
22
22
1388
1189
1388
1189
1388
1188
1388
1189
RE
SO
LVE
R
FO
LIN
K T
O
CU
ST
OM
ER
898818
8
189
L N G
6 G
AT
E D
RIV
ER
AN
DF
AU
LT F
/O P
AIR
S
GGG 183
182
181
AC
INP
UT
603
602
601
603
602
601
G
SY
NC
LIN
E
TO
PR
E-C
HA
RG
EIN
PW
R. D
ISC
.C
AB
INE
T
LEM
189
188
DC
BU
S
+ -
TO
PO
WE
RM
OD
ULE
C
AU
TO
MA
X
I/OFD
BK
Theory of Operation C-1
APPENDIX CTheory of Operation
C.1 Typical SB3000 System
SB3000 Power Modules are used to supply regulated common DC bus power to one or more SA3000/SA3100 Power Modules. As illustrated in figure C.1, a typical SB3000 system is made up of the following:
• an AC power disconnect device with overcurrent protection
• a soft-charge assembly which consists of pre-charge resistors and a pre-charge contactor
• an AC line filter reactor
• a power bridge
• a regulator consisting of both hardware and software elements.
The power distribution cabinet is mounted separately from the SB3000 Power Module and typically contains the AC power disconnect/overcurrent protection device, the soft-charge assembly, and the AC line filter reactor.
The AC line filter reactor is an energy storage element that isolates the converter bridge. This reactor limits the current flow between the AC line and the DC bus while providing a voltage boost between the input AC voltage and the output DC voltage.
The pre-charge resistors provide for controlled soft-charging of the DC bus capacitors to an initial voltage from which the SB3000 regulator can be safely started.
The SB3000 power bridges are the same three-phase IGBT inverter bridges that are used in the High Power SA3000 Power Modules, but are connected such that the three-phase AC leads are connected to the AC line, instead of to a motor, and the DC leads are connected as an output to a DC bus designed to feed one or more SA3000/SA3100 Power Modules.
The regulator controls the operation of all the elements in the system and links the SB3000 Power Module to the application level.
C-2 SB3000 Power Modules (Rittal)
Figure C.1 – SB3000 System
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Theory of Operation C-3
C.2 SB3000 Regulator
The main purpose of the SB3000 regulator is to maintain the proper voltage on the DC bus through the use of a vector algorithm executed in the PMI Processor.
The application task in the UDC module controlling the SB3000 Power Module passes the desired DC bus voltage reference command to the PMI Processor in register 102/1102. The PMI Processor uses proportional-integral-derivative (PID) logic to calculate DC bus current in response to the voltage reference and error values. See figure C.2.
The commanded current is actually made up of two parts: Iq and Id. The Iq current is in phase with the AC line voltage when motoring and is 180 degrees out of phase with the AC line when regenerating. The Id current leads the AC line voltage by 90 degrees. The Iq current is the real current that powers the DC bus. The Id current is the reactive current that produces the leading power factor.
The PMI Processor uses the AC line period to determine the frequency to command. It uses the offset between the zero crossing of the AC line and the commanded zero crossing to determine the angle offset. The AC line frequency may change up to 1 Hz per second.
C-4 SB3000 Power Modules (Rittal)
Figure C.2 – Control Structure
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0) =
715
Theory of Operation C-5
C.2.1 Leading Power Factor Operation
The regulator has the capability to operate with a leading power factor. This allows the regulator to calculate the Id current based on the capacity that is left over in the SB3000 Power Module rating after the Iq current has been determined.
If the UDC application task provides a leading power factor current reference value (IPF_REF%) in register 103/1103, the vector algorithm can compensate for a lagging power factor in the total AC line load with the second component of the current vector (Id). The Id current is calculated based on the value of Iq current and the current reference value in register 103/1103. The leading power factor current reference value is limited to not exceed the SB3000 Power Module’s current limit rating. When Id current is near zero, due to a small load on the DC bus, it can approach the reference value. As Iq current increases, Id current decreases. A status bit indicates when the power factor current is being limited.
If capacity is left over after power has been supplied to the inverter load, the vector algorithm can produce VARS (volt-amperes reactive) with a leading power factor to compensate for other machines with lagging power factors on the same AC line. The Id current is limited not to exceed the rectifier rating. The VARS produced will be reported in register 211/1211.
Assuming power factor current is not being limited, Id current is calculated based on the Iq current and IPF_REF%. See figure C.3. The amount of VAR that is produced will be displayed in the feedback data.
When Iq current is near zero because there is negligible load on the DC bus, Id current can be near the full value of IPF_REF%.
When Iq current becomes larger, Id current becomes smaller.
When Iq current becomes greater than IPF_REF, Id current is reduced to zero.
Figure C.3 – Leading Power Factor
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C-6 SB3000 Power Modules (Rittal)
C.3 SB3000 DC Bus Charging Sequence
The SB3000 pre-charge circuitry is controlled via a pre-charge contactor which is under the control of the PMI Processor in the SB3000 PMI rack. Any faults relating to pre-charge contactor operation are reported in registers 202/1202 and 205/1205. The closing and opening of the pre-charge contactor is a function of the measured DC bus voltage. See figure C.4.
Note that the RPI signal has no effect on the operation of the pre-charge contactor; however, the RPI input must be present for the voltage loop to be in run. Turning off the RPI signal does not disable output power. If AC input power is on, the diodes in the IGBTs will conduct rectified voltage to the output terminals, independent of the state of the RPI signal.
C.3.1 Pre-charge Contactor Requirements for SA3000/SA3100 Power Modules
The status of the SB3000 pre-charge contactor (CHG_FB@) must be used by the SA3000/SA3100 Power Module’s application tasks. The SA3000/SA3100 Power Module must not operate with the pre-charge contactor open. Doing so may damage the pre-charge resistor. It is the responsibility of the application tasks running in the SA3000/SA3100 UDC module to make sure the SB3000 Power Module is in run before the SB3000 Power Module is turned on.
If the SB3000 Power Module is shut down due to a fault condition, the controlled shutdown of the SA3000/SA3100 Power Module is the responsibility of the application.
Each SA3000/SA3100 Power Module must have its own pre-charge resistor and contactor to limit the current into its capacitors.
C.3.2 Pre-charge Sequencing During Normal Operation
When AC power is applied to the SB3000 Power Module, the diodes in the IGBT power devices allow the capacitors to begin charging immediately through the line fuses, input inductors, and pre-charge resistors up to near peak AC line voltage. When the DC bus has reached the close threshold voltage and is at a steady-state condition, the PMI Processor will close the pre-charge contactor if there is no fault. After the contactor is closed, the PMI Processor will turn on status bit CHG_FB@ to indicate this condition to the application task. If there is a fault, the PMI Processor will turn on the IC_FLT@ interlock to indicate that a fault needs to be reset.
!ATTENTION: The UDC application task must examine the pre-charge status bit (CHG_FB@) regularly. If the status bit turns off, the SA3000/SA3100 Power Module must be shut down. If the SA3000/SA3100 Power Module is not shut down, the pre-charge resistor may be damaged. Failure to observe this precaution could result in to damage to, or destruction of, the equipment.
Theory of Operation C-7
C.3.3 Pre-charge Contactor’s Close Threshold Voltage
When control power is first turned on, the pre-charge contactor will be open. This allows the DC bus voltage to increase to near the peak voltage of the AC line. The pre-charge contactor’s close threshold voltage is equal to the following:
Close Threshold Voltage = 1.414 x (Peak Configured AC RMS Line Voltage) - 10%
This threshold voltage allows the SB3000 Power Module to turn on when the AC line is up to 10% low. The pre-charge contactor will stay open until the measured DC bus voltage reaches this threshold. When the pre-charge contactor closes, the PMI Processor will indicate this by turning on register 201/1201, bit 12 (CHG_FB@).
C.3.4 Pre-charge Contactor’s Open Threshold Voltage
The pre-charge contactor’s open threshold voltage is the peak voltage of the configured AC RMS line voltage, times the square root of two, minus 100 volts. The maximum step change on the capacitor is 100 volts. If the DC bus voltage drops below the open threshold voltage, the pre-charge contactor will be opened to protect the capacitors and CHG_FB@ will be turned off. In this case, register 201/1201, bit 12 (CHG_FB@) will be turned off. The pre-charge contactor will remain open until the bus voltage again reaches a steady-state voltage above the close threshold voltage.
C-8 SB3000 Power Modules (Rittal)
Figure C.4 – Pre-charge State Diagram
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Theory of Operation C-9
C.3.5 Pre-charge Contactor Sequencing During the Bridge Test
When the bridge test is commanded in register 100/1100, bit 2, the SB3000’s pre-charge contactor will close. After the results of the test have been displayed on the GDI module(s), the pre-charge contactor will be opened.
C.3.6 Charge Faults
The PMI Processor will generate a Charge Fault (register 202/1202, bit 6) if:
• the pre-charge contactor is closed when it should be open.
• the pre-charge contactor opens without being commanded to open.
• the pre-charge contactor is commanded to open and it does not open within one second.
C.4 Line Synchronization
The motoring operation of the SB3000 Power Module is analogous to the operation of an SA3000 Power Module regenerating power from a large synchronous motor to the DC bus. For the SB3000 Power Module, the AC line acts like a very large synchronous motor operating at a fixed frequency/speed. Whether the SB3000 Power Module is motoring (supplying power to the DC bus from the AC line) or regenerating (returning power to the AC line from the DC bus) is determined by the voltage level of the DC bus which the SB3000 Power Module is regulating. To operate, the SB3000 Power Module must be synchronized, in frequency and phase, with the AC line. Line synchronization specifications are provided in Appendix A.
Phase synchronization is maintained by the PMI and the Line Synchronization module. The period of the AC line is used to determine the frequency to command and the offset between the zero crossing of the AC line and the commanded zero crossing is used to determine the angle offset.
The Line Synchronization module, located in the SB3000 control cabinet, is connected to the +/- 24 and 15 volt power supplies. The AC line synchronization circuit monitors the AC line feeding the SB3000 Power Module and outputs a pair of signals locked in-phase with the AC line to the A-C Power Technology module in the PMI rack. The AC line synchronization circuit also contains the Burden resistor for the Hall device which monitors the DC bus current.
If the PMI detects AC input voltage to be less than 75% of the configured voltage or greater than 125% of the configured voltage, it will latch the WRN_PWR@ warning bit and disable the firing of the IGBTs. If power is restored within ten seconds, the PMI will re-synchronize and resume operation. If power is not restored within ten seconds, the PMI will latch the FLT_PWR@ fault bit and will not automatically restart.
If input voltage is out of tolerance, a bit is set in the UDC Module’s memory (VDC_SB@) to indicate that the voltage loop is in standby. The master speed reference task can then optionally begin to decelerate the inverter-driven load, using the inertia in the driven load (motor and machine) to maintain the DC bus voltage until power comes back or the machine is stopped. If any fault is detected while in standby, VDC_SB@ is turned off, and the drive will not automatically restart.
C-10 SB3000 Power Modules (Rittal)
SB3000 Interlock Sequencing D-1
APPENDIX DSB3000 Interlock Sequencing
When a request is made to turn on the SB3000 Power Module’s voltage loop and a required precondition has not been met, a bit will be set in Interlock register 205/1205 indicating the problem. The interlock requirements are described in the following table. If an interlock problem is detected, the voltage loop will not go into run.
Interlock Precondition
Bit Set in Register 205/1205 by the PMI
Processor
Valid configuration parameters have not been downloaded into the UDC module from the Programming Executive or the parameters are outside of acceptable limits.
Bit 0 (IC_CNF@)
Pre-defined local tunables are zero or a UDC task containing the variables has not been loaded to the rack.
Bit 1 (IC_GAIN@)
The RPI input is not turned on. Bit 2 (IC_RPI@)
A fault that shut down the voltage loop has not been reset. Bit 3 (IC_FLT@)
A rising edge is not detected on a command bit in register 100/1100. Bit 4 (IC_RISE@)
More than one operating mode is requested at a time. Bit 5 (IC_MORE@)
The pre-charge contactor has not closed. Bit 7 (IC_PCHG@)
The number of GDI modules in the PMI rack does not match the number of GDI modules configured or the GDI modules have been incorrectly placed in the PMI rack.
Bit 8 (IC_GDI@)
During the bridge test, a Power Module has not been selected or an incorrect Power Module been selected.
Bit 8 (IC_GDI@)
The PMI rack has an incorrect backplane. Bit 9 (IC_IPBP@)
The bridge test is requested and the DC bus voltage is greater than 10V. Bit 11 (IC_VDC@)
D-2 SB3000 Power Modules (Rittal)
Replacement Parts E-1
APPENDIX EReplacement Parts
445 Amp SB3000 Synchronous Rectifier
Table E.1 – 445A SB3000 Power Module
Part Description 1
1. Components are identified in figure 2.2.
Quantity
RockwellPart Number
Blower Assembly 1 803430-9R
IGBT Module Assembly 3 803430-8S
Capacitor Bank Assembly 1 803430-6S
Pre-charge Assembly 1 803430-7R
Fuse (F101A, F102A) (1000A, 1000 VAC) 2 64676-80P
+/- 15 VDC Power Supply (1A) 1 704323-33K
110V AC Disconnect Switch (40A, 600 VAC) 1 65242-10R
24 VDC Power Supply (2A) 2 704323-32G
LPI Module 1 0-60027
250VA Isolation Transformer (250 VA, 110 VAC) 1 417155-16B
PMI Rack Assembly 1 805401-5R
25KHz Power Supply (2A)(115 VAC input, 60 VDC output)
1 802268-16R
Reactor (7.5uH, 600A) 3 608895-60A
LEM Sensor (1000A, 5000:1) 3 600595-18A
Fuse (1FU) (6 Amp, 600 VAC) 1 64676-64M
Fuse (2FU) (25 Amp, 600 VAC) 1 64676-72BB
Fuse (3FU) (3 Amp, 600 VAC) 1 64676-64J
9ROWDJH )HHGEDFN 5HVLVWRUV .Ω : 5 63481-102TFB
DC Feedback Module 1 0-55350-10
AC Input Current Meter 1 850012-R
DC Output Current Meter 1 850012-S
Blower Filter 1 69740-10G
Table E.2 – Capacitor Bank Assembly (803430-6S)
Part Description
Quantity Rockwell
Part Number
Capacitor (7200uF, 500 VDC) 18 600442-30SX
E-2 SB3000 Power Modules (Rittal)
445 Amp SB3000 Synchronous Rectifier (Continued)
Table E.3 – Pre-charge Assembly (803430-7R)
Part Description
Quantity Rockwell
Part Number
'LVFKDUJH 5HVLVWRUV .Ω : 9 612183-36R
Pre-charge Module 1 0-55350-4
Pre-charge Capacitor (4700uH, 50 VDC) 1 600442-31TS
Table E.4 – Blower Assembly (803430-9R)
Part Description
Quantity Rockwell
Part Number
Blower (115 VAC) 1 69739-47R
Starter Capacitor (40uF, 240 VAC) 1 69932-24QQ
9ROWDJH 5HVLVWRUV Ω : 3 63481-104QAA
Table E.5 – IGBT Module Assembly (803430-8S)
Part Description Quantity Rockwell
Part Number
IGBT Transistor (600A, 1200 VDC) 4 602909-808AW
Warning Thermostat 1 66012-16A
Fault Thermostat 1 66012-16B
Gate Driver/Snubber Module 1 0-55350-15
Fuse (F103A, F104A, F105A) (630A, 1000 VAC) 3 64676-79AZ
Table E.6 – PMI Rack Assembly (805401-5)
Part Description
Quantity Rockwell
Part Number
Power Supply 1 0-60007-2
Processor Module 1 0-60021-1
Resolver Module 1 0-60031-4
AC Technology Module 1 0-60023-3
AC Parallel Interface Module 1 0-60029-1
Gate Driver Interface Module 1 0-60028-1
Replacement Parts E-3
890 Amp SB3000 Synchronous Rectifier
Table E.7 – 890A SB3000 Power Module
Part Description 1
1. Components are identified in figure 2.3.
Quantity
RockwellPart Number
Blower Assembly 2 803430-9R
IGBT Module Assembly 6 803430-8S
Capacitor Bank Assembly 2 803430-6S
Pre-charge Assembly 2 803430-7R
Fuse (F101, F102) (1000A, 1000 VAC) 4 64676-80P
+/- 15 VDC Power Supply (1A) 1 704323-33K
110V AC Disconnect Switch (40A, 600 VAC) 1 65242-10R
24 VDC Power Supply (2A) 2 704323-32G
LPI Module 1 0-60027
250VA Isolation Transformer (250 VA, 110 VAC) 1 417155-16B
PMI Rack Assembly 1 805401-5S
25KHz Power Supply (2A)(115 VAC input, 60 VDC output)
1 802268-16R
Reactor (7.5uH, 600A) 6 608895-60A
LEM Sensor (1000A, 5000:1) 6 600595-18A
Fuse (1FU) (6A, 600 VAC) 1 64676-64M
Fuse (2FU) (25A, 600 VAC) 1 64676-72BB
Fuse (3FU) (3A, 600 VAC) 1 64676-64J
9ROWDJH )HHGEDFN 5HVLVWRUV .Ω : 3 63481-102TFB
DC Feedback Module 1 0-55350-10
AC Input Current Meter 1 850012-R
DC Output Current Meter 1 850012-S
Blower Filter 2 69740-10G
Table E.8 – Capacitor Bank Assembly (803430-6S) (2 Required)
Part Description
Quantity Rockwell
Part Number
Capacitor (7200uF, 500 VDC) 18 600442-30SX
Table E.9 – Pre-charge Assembly (803430-7R) (2 Required)
Part Description
Quantity Rockwell
Part Number
'LVFKDUJH 5HVLVWRUV .Ω : 9 612183-36R
Pre-charge Module 1 0-55350-4
Pre-charge Capacitor (4700uH, 50 VDC) 1 600442-31TS
E-4 SB3000 Power Modules (Rittal)
890 Amp SB3000 Synchronous Rectifier (Continued)
Table E.10 – Blower Assembly (803430-9R) (2 Required)
Part Description
Quantity Rockwell
Part Number
Blower (115 VAC) 1 69739-47R
Starter Capacitor (40uF, 240 VAC) 1 69932-24QQ
9ROWDJH 5HVLVWRUV Ω : 3 63481-104QAA
Table E.11 – IGBT Module Assembly (803430-8S) (2 Required)
Part Description
Quantity Rockwell
Part Number
IGBT Transistor (600A, 1200 VDC) 4 602909-808AW
Warning Thermostat 1 66012-16A
Fault Thermostat 1 66012-16B
Gate Driver/Snubber Module 1 0-55350-15
Fuse (F103, F104, F105) (630A, 1000 VAC) 3 64676-79AZ
Table E.12 – PMI Rack Assembly (805401-5) (2 Required)
Part Description
Quantity Rockwell
Part Number
Power Supply 1 0-60007-2
Processor Module 1 0-60021-1
Resolver Module 1 0-60031-4
AC Technology Module 1 0-60023-3
AC Parallel Interface Module 1 0-60029-1
Gate Driver Interface Module 2 0-60028-1
Replacement Parts E-5
1335 Amp SB3000 Synchronous Rectifier
Table E.13 – 1335A SB3000 Power Module
Part Description 1
1. Components are identified in figure 2.4.
Quantity
RockwellPart Number
Blower Assembly 3 803430-9R
IGBT Module Assembly 9 803430-8S
Capacitor Bank Assembly 3 803430-6S
Pre-charge Assembly 3 803430-7R
Fuse (F101, F102) (1000A, 1000 VAC) 6 64676-80P
+/- 15 VDC Power Supply (1A) 1 704323-33K
110V AC Disconnect Switch (40A, 600 VAC) 1 65242-10R
24 VDC Power Supply (2A) 2 704323-32G
LPI Module 1 0-60027
250VA Isolation Transformer (250 VA, 110 VAC) 1 417155-16B
PMI Rack Assembly 1 805401-5T
25KHz Power Supply (2A)(115 VAC input, 60 VDC output)
1 802268-16R
Reactor (7.5uH, 600A) 9 608895-60A
LEM Sensor (1000A, 5000:1) 9 600595-18A
Fuse (1FU) (6A, 600 VAC) 1 64676-64M
Fuse (2FU) (25A, 600 VAC) 1 64676-72BB
Fuse (3FU) (3A, 600 VAC) 1 64676-64J
9ROWDJH )HHGEDFN 5HVLVWRUV .Ω : 3 63481-102TFB
DC Feedback Module 1 0-55350-10
AC Input Current Meter 1 850012-R
DC Output Current Meter 1 850012-S
Blower Filter 3 69740-10G
Table E.14 – Capacitor Bank Assembly (803430-6S) (3 Required)
Part Description
Quantity Rockwell
Part Number
Capacitor (7200uF, 500 VDC) 18 600442-30SX
Table E.15 – Pre-charge Assembly (803430-7R) (3 Required)
Part Description
Quantity Rockwell
Part Number
'LVFKDUJH 5HVLVWRUV .Ω : 9 612183-36R
Pre-charge Module 1 0-55350-4
Pre-charge Capacitor (4700uH, 50 VDC) 1 600442-31TS
E-6 SB3000 Power Modules (Rittal)
1335 Amp SB3000 Synchronous Rectifier (Continued)
Table E.16 – Blower Assembly (803430-9R) (3 Required)
Part Description
Quantity Rockwell
Part Number
Blower (115 VAC) 1 69739-47R
Starter Capacitor (40uF, 240 VAC) 1 69932-24QQ
9ROWDJH 5HVLVWRUV Ω : 3 63481-104QAA
Table E.17 – IGBT Module Assembly (803430-8S) (3 Required)
Part Description
Quantity Rockwell
Part Number
IGBT Transistor (600A, 1200 VDC) 4 602909-808AW
Warning Thermostat 1 66012-16A
Fault Thermostat 1 66012-16B
Gate Driver/Snubber Module 1 0-55350-15
Fuse (F103A, F104A, F105A) (630A, 1000 VAC)
3 64676-79AZ
Table E.18 – PMI Rack Assembly (805401-5) (3 Required)
Part Description
Quantity Rockwell
Part Number
Power Supply 1 0-60007-2
Processor Module 1 0-60021-1
Resolver Module 1 0-60031-4
AC Technology Module 1 0-60023-3
AC Parallel Interface Module 1 0-60029-1
Gate Driver Interface Module 3 0-60028-1
Index Index-1
INDEX
B
Bridge test see Diagnostics and troubleshooting
C
Control structure, C-4Current ratings, 1-1
D
DC bus voltage, 2-3Diagnostics and troubleshooting, 4-1 to 4-19
bridge test, 4-19DC bus and output terminal tests, 4-4faults and warnings, 4-4 to 4-10IGBT tests, 4-4replacing a blower assembly, 4-17replacing a blower filter, 4-17replacing a bus capacitor assembly, 4-18replacing an IGBT phase module, 4-15 to 4-17replacing fuses, 4-11 to 4-15replacing sub-assemblies, 4-11 to 4-18replacing the cabinet, 4-10 to 4-11required test equipment, 4-1 to 4-2tests with input power off, 4-2 to 4-4
Drive fault register 202/1202, 4-5Drive warning register 203 /1203, 4-8
E
Electrical description, 2-3 to 2-4, 2-8 to 2-16circuitry, 2-8 to 2-16DC bus voltage, 2-3
F
Faults, 4-5 to 4-7charge fault, 4-6communication lost, 4-7DC bus overcurrent, 4-6DC bus overvoltage, 4-6gate driver interface fault, 4-6ground current fault, 4-6instantaneous overcurrent, 4-6
local power interface fault, 4-6overtemperature, 4-7power loss, 4-7power technology fault, 4-7
Fuse1335A power module fuse locations, 4-14445A power module fuse locations, 4-12890A power module fuse locations, 4-13AC input & DC bus fuse ratings, 3-2replacement, 4-11 to 4-15specifications, 4-15, A-3
G
Ground connections, 3-9
I
Installation guidelines, 3-1 to 3-9control transformers, 3-3 to 3-4grounding, 3-5installation planning, 3-1line filter reactors, 3-3power module cabinet, 3-5 to 3-9pre-charge resistors and fuses, 3-2 to 3-3wire sizes, 3-4wiring, 3-2 to 3-5
Interlock sequencing, D-1Introduction, 1-1 to 1-3
L
Leading power factor, C-5Line filter reactor ratings, 3-3
M
Mechanical description, 2-1 to 2-2, 2-5 to 2-7AC input current meter, 2-2capacitor bank assembly, 2-2components, 2-5 to 2-7DC bus current meter, 2-2DC bus voltage meter, 2-2fiber-optic communication, 2-1local power interface module (LPI), 2-1
Index-2 SB3000 Power Modules (Rittal)
phase modules, 2-1snubber/gate driver module, 2-1softcharge assembly, 2-2
Mechanical/electrical description, 2-1 to 2-16Meter scaling, 2-2Meters, 2-2Mounting dimensions
1335A power module, 3-8445A power module, 3-6890A power module, 3-7
P
Part numbers, 1-2Power connections, 3-9Power module circuitry
1335A power module, 2-13 to 2-16445A power module, 2-8 to 2-9890A power module, 2-10 to 2-12
Power module components1335A power module, 2-7445A power module, 2-5890A power module, 2-6
Pre-charge contactor, C-6 to C-9close threshold voltage, C-7contactor requirements, C-6open threshold voltage, C-7sequencing (normal operation), C-6sequencing during bridge test, C-9
Pre-charge resistors and fuses, 3-3
R
Related publications, 1-3Replacement parts, E-1 to E-6
1335A SB3000 power module, E-5 to E-6445A SB3000 power module, E-1 to E-2890A SB3000 power module, E-3 to E-4
Replacing components see Diagnostics and troubleshooting
S
SA3000/SA3100 Power Modulesbus connection, 3-5operation on DC bus, 2-4pre-charge contactor requirements, C-6
SB3000 component block diagram, B-1SB3000 system diagram, C-2Standard features, 1-2
T
Technical specifications, A-1 to A-3AC control power, A-2AC input power, A-2ambient conditions, A-1analog output voltage, A-3current ratings, A-2DC output power, A-2dimensions, A-1output phase signals, A-3replacement fuses, A-3three-phase AC input voltage, A-3
Terminal tightening torques, 3-4Theory of operation, C-1 to C-9
charge faults, C-9control structure, C-4DC bus charging sequence, C-6 to C-9leading power factor operation, C-5line synchronization, C-9pre-charge contactor, C-6 to C-9pre-charge state diagram, C-8SB3000 regulator, C-3 to C-5typical SB3000 system, C-1
W
Warnings, 4-7 to 4-10bad gain data, 4-9CCLK not synchronized, 4-10DC bus overvoltage, 4-8DC bus undervoltage, 4-8ground current warning, 4-9load sharing warning, 4-9phase lost, 4-9PMI communication warning, 4-10PMI fan loss, 4-10power loss, 4-9power module overload, 4-9rail communication warning, 4-10reference in limit, 4-9
Wiring see Installation guidelines
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