Rockwell Automation SA500 Series User manual

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Instra

Instruction Manual
Distributed Power System
SA500 AC Power Modules
615055-1R (14 Amp)
615055-1S (28 Amp)
615055-1T (35 Amp)
615055-1V (48 Amp)
S-3018-1
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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.
The thick black bar shown on the left margin of this paragraph will be used throughout this manual to signify
new or revised text or figures.
!ATTENTION:Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
The information in this user’s manual is subject to change without notice.
AutoMax™ is a trademark of Rockwell Automation.
©1998 Rockwell International Corporation
!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:Only qualified Rockwell personnel or other trained personnel who understand the
potential hazards involved may make modifications to the rack configuration, variable
configuration, and application tasks. Any modifications may result in uncontrolled machine
operation.Failuretoobservethisprecautioncouldresultindamagetoequipmentandbodilyinjury.
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:RegistersandbitsintheUDCmodulethataredescribedas“readonly”orfor“system
use only” must not be written to by the user. Writing to these registers and bits may result in
improper system operation. Failure to observe this precaution could result in bodily injury.
ATTENTION:For brushless motor applications, changing any resolver wiring, breaking the
resolver coupling, replacing the resolver, or replacing the motor and resolver for any reason
requires that the shaft alignment test be performed again. Resolver wiring changes always affect
shaft alignment. A resolver change and/or a new motor/resolver combination will affect the shaft
alignment.Impropershaftalignmentcancausemotoroverspeedwhenthemotorisstarted.Failure
to observe this precaution could result in bodily injury.
ATTENTION:The Power Module contains static-sensitive parts and assemblies. When not
installedinthe PowerModule,componentsshouldbe storedinanti-staticbags.Failuretoobserve
this precaution could result in damage to, or destruction of, the equipment.
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.
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Table of Contents
I
CONTENTS
Chapter 1 Introduction
1.1 Distributed Power System (DPS) Overview ....................................................1-2
1.2 SA500 Drive Overview ....................................................................................1-3
1.3 Related Publications........................................................................................1-4
Chapter 2 Power Module Mechanical Description
2.1 LED Indicators.................................................................................................2-3
2.2 Power Module Faceplate Connectors .............................................................2-6
2.2.1 Fiber-Optic Ports...................................................................................2-7
2.2.2 Rail Ports...............................................................................................2-7
2.2.3 Resolver Feedback Connector..............................................................2-8
2.2.4 Drive I/O Connector ............................................................................2-10
Chapter 3 Power Module Electrical Description
3.1 Power-Up Routine ........................................................................................... 3-1
3.2 DC-to-DC Converter........................................................................................3-2
3.3 Resolver Interface ...........................................................................................3-2
Chapter 4 Installation Guidelines
4.1 Wiring and Grounding......................................................................................4-1
4.2 Power Module Installation ...............................................................................4-1
4.3 Fiber-Optic Connection....................................................................................4-6
4.4 Drive I/O Connections .....................................................................................4-6
4.5 Rail Port Connection........................................................................................4-8
4.6 Resolver Feedback Connection ......................................................................4-8
4.6.1 Resolver Input Connections................................................................4-10
4.6.1.1 Resolver Calibration..............................................................4-11
4.6.1.2 Resolver Alignment...............................................................4-12
4.6.1.3 Resolver Feedback Precautions...........................................4-13
4.6.2 Analog Input........................................................................................4-14
4.7 Constant Power Calibration...........................................................................4-14
4.8 Power Module Replacement .........................................................................4-17
Chapter 5 Diagnostics and Troubleshooting
5.1 Drive Faults (UDC Register 202/1202)............................................................5-1
5.2 Power Module Warnings (UDC Register 203/1203)........................................5-3
5.3 Power Module Failure......................................................................................5-4
Appendix A Technical Specifications...........................................................................................A-1
Appendix B Brushless Industrial Motor Data and Curves............................................................B-1
Appendix C Custom DC Bus Supplies.........................................................................................C-1
Appendix D UDC Register Cross-Reference ...............................................................................D-1
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II
SA500 Power Modules
Appendix E Status of Data in the AutoMax Rack After a
STOP_ALL Command or STOP_ALL Fault.............................................................E-1
Appendix F PMI Regulator Block Diagram.................................................................................. F-1
Appendix G Power Circuitry Block Diagram ................................................................................G-1
Appendix H Compliance with Electromagnetic Compatibility Standards.....................................H-1
Appendix I SA500 Power Module Output Current Overload Ratings...........................................I-1
Index ...........................................................................................................................Index-1
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Table of Contents
III
List of Figures
Figure 1.1 – SA500 Drive Hardware Configuration ..................................................1-2
Figure 2.1 – SA500 Power Module With Cover and Without Cover.........................2-2
Figure 2.2 – Power Module External Connectors.....................................................2-6
Figure 2.3 – Location of Rail Fuse on PMI Regulator PC Board..............................2-8
Figure 2.4 – Resolver Feedback Connector Pinout..................................................2-9
Figure 2.5 – Analog Input Circuit............................................................................2-10
Figure 2.6 – Drive I/O Connector Pinout.................................................................2-11
Figure 2.7 – Auxiliary Input Circuit..........................................................................2-11
Figure 2.8 – Run Permissive Input (RPI) Circuit.....................................................2-12
Figure 3.1 – Resolver Data Format (12-Bit Mode)....................................................3-2
Figure 3.2 – Resolver Data Format (14-Bit Mode)....................................................3-3
Figure 3.3 – External Strobe Input Circuit.................................................................3-3
Figure 3.4 – External Strobe Input Circuit Timing Diagram......................................3-4
Figure 4.1 – Power Module Mounting Dimensions...................................................4-3
Figure 4.2 – DC Bus Supply Wiring..........................................................................4-5
Figure 4.3 – Terminal Block Connections for Drive I/O ............................................4-7
Figure 4.4 – Terminal Block Connections for Resolver and Analog Input................4-9
Figure 4.5 – Typical Motor Operation in the Constant Torque and
Constant Power Regions....................................................................4-15
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IV
SA500 Power Modules
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Table of Contents
V
List of Tables
Table 1.1 – SA500 Power Modules..........................................................................1-1
Table 1.2 – SA500 Documentation (Binder S-3002) ................................................1-4
Table 4.1 – Recommended Motor Wire Sizes..........................................................4-4
Table 4.2 – Rail I/O Instruction Manuals...................................................................4-8
Table 4.3 – Standard Resolver Connections..........................................................4-10
Table 4.4 – Recommended Resolver Cables.........................................................4-10
Table 4.5 – STATOR_IZ Tunable Values...............................................................4-16
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VI
SA500 Power Modules
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Introduction
1-1
CHAPTER 1
Introduction
The AutoMax Distributed Power System SA500 AC Power Modules provide AC power
to, and control of, brushless motors and squirrel-cage induction motors from 1–15HP.
Each Power Module contains the Power Module Interface (PMI) Regulator printed
circuit board and the inverter used to convert DC power to AC power for the motor.
Depending upon their power requirements, up to six Power Modules can be
daisy-chained together and operated from one SA500 DC Bus Supply, which provides
the Power Modules a nominal 325 VDC input power. The DC Bus Supply is described
in instruction manual S-3017.
The SA500 Power Modules are available in four sizes with a range of current ratings to
complement the variety of motors available. See table 1.1 below.
Table 1.1 – SA500 Power Modules
Part Number Continuous Current Rating (RMS)
Maximum Output
Current (RMS)
(0.5 seconds)1
1. Power Module output current overload rating charts are provided in Appendix I.
Power Module specifications are listed in Appendix A. Detailed speed-torque curves
and engineering data for SA500 motors are included in Appendix B.
Figure 1.1 shows a typical SA500 drive configuration.
615055-1R 14 A 17.5 A (125%)
615055-1S 28 A 35 A (125%)
615055-1T 35 A 70 A (200%)
615055-1V 48 A 106 A (220%)
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