Rockwell Automation SA3000 High Power Modules - Manual (Page 3)

Table of Contents I
C
ONTENTS
Chapter 1 Introduction
1.1
Standard Features ........................................................................................... 1-1
1.2 Optional Features ............................................................................................ 1-2
1.3 Power Module Part Numbers .......................................................................... 1-3
1.4 Related Publications ........................................................................................ 1-4
1.5 Related Hardware and Software ..................................................................... 1-4
Chapter 2 Mechanical/Electrical Description
2.1
Mechanical Description ................................................................................... 2-1
2.1.1 Power Module Components .................................................................. 2-1
2.2 Electrical Description ....................................................................................... 2-6
Chapter 3 Installation Guidelines
3.1
Installation Planning ........................................................................................ 3-1
3.2 Wiring .............................................................................................................. 3-2
3.2.1 Fuses .................................................................................................... 3-2
3.2.2 Wire Sizes ............................................................................................. 3-2
3.2.3 Wire Routing ......................................................................................... 3-3
3.3 Grounding ........................................................................................................ 3-3
3.4 Installing the Power Module Cabinet ............................................................... 3-3
Chapter 4 Diagnostics and Troubleshooting
4.1
Required Test Equipment ................................................................................ 4-1
4.2 Power Module Tests with Input Power Off ...................................................... 4-2
4.3 Power Module Faults and Warnings................................................................ 4-4
4.3.1 Power Module Faults ............................................................................ 4-5
4.3.1.1 DC Bus Overvoltage Fault ...................................................... 4-5
4.3.1.2 DC Bus Overcurrent Fault....................................................... 4-5
4.3.1.3 Ground Current Fault .............................................................. 4-5
4.3.1.4 Instantaneous Overcurrent Fault ............................................ 4-6
4.3.1.5 Local Power Interface Fault .................................................... 4-6
4.3.1.6 Charge Bus Time-Out Fault .................................................... 4-6
4.3.1.7 Overtemperature Fault ............................................................ 4-6
4.3.2 Power Module Warnings ....................................................................... 4-7
4.3.2.1 DC Bus Overvoltage Warning ................................................. 4-7
4.3.2.2 DC Bus Undervoltage Warning ............................................... 4-7
4.3.2.3 Ground Current Warning......................................................... 4-7
4.3.2.4 Load Sharing Warning ............................................................ 4-7
4.3.2.5 Overtemperature Warning ...................................................... 4-8
4.4 Replacing Power Module Fuses and Sub-Assemblies .................................... 4-8
4.4.1 Replacing Fuses ................................................................................... 4-8
4.4.2 Replacing an IGBT Phase Module Assembly ..................................... 4-15
4.4.2.1 Replacing an IGBT................................................................ 4-17
4.4.3 Replacing the Pre-charge Assembly ................................................... 4-17
4.4.4 Replacing a Blower Assembly............................................................. 4-18
4.4.4.1 Replacing a Blower Filter ...................................................... 4-19
4.4.5 Replacing a Bus Capacitor Assembly ................................................. 4-19
4.5 Replacing the Power Module Cabinet ........................................................... 4-20