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Magnetek 144-45117-R3 manual

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Table of contents for the manual

  • Page 1

    Regenerative Power Module And Common Bus RPM Panels Instruction Manual Part Number 144-45117-R3 September 2010 ©Copyright 2010 Magnetek Material Handling[...]

  • Page 2

    [...]

  • Page 3

    Regenerative Power Module - September 2010 144-45117- R3 Page 3 of 20 PRODUCT MANUAL SAFETY INFORMATION Magnetek, Inc. (Magnetek) offers a broad range of radio remote control pro ducts, control products and adjustable frequency drives, and industrial braking systems for material handling applications. This manual has been prepared by Magnetek to pr[...]

  • Page 4

    Regenerative Power Module - September 2010 144-45117- R3 Page 4 of 20 Disclaimer of Warranty Magnetek, hereafter referred to as Company, assum es no responsibility for improper programming of a drive by untrained personnel. A drive should onl y be programmed by a trained technician who has read and understands the contents of this manual. Imprope r[...]

  • Page 5

    Regenerative Power Module - September 2010 144-45117- R3 Page 5 of 20 General Description The Regenerative Power Module (RPM) is a univer sal brake chopper circuit designed to dissipate regenerative energy produced by a motor into a fixed resistor load. The unive rsal module covers the DC supply voltage range from 200V to 660V. The volta ge selecto[...]

  • Page 6

    Regenerative Power Module - September 2010 144-45117- R3 Page 6 of 20 Voltage Display A 10-LED Switch Level bar graph provides a visual display of the approxima te bus voltage level when the brake transistor turns on. Simplified Switching Level Selection An 8-position DIP switch provides transistor turn on switching level selection in 15 steps. Lin[...]

  • Page 7

    Regenerative Power Module - September 2010 144-45117- R3 Page 7 of 20 • LED Fault and Status Indicators LED status indicators provide the following indications: COLOR MARKING DESCRIPTION GREEN POWER Indicates that th e brake chopper power supply is present GREEN INTERLOCK Indicates that the ex ternal contact is closed when the interlock is enable[...]

  • Page 8

    Regenerative Power Module - September 2010 144-45117- R3 Page 8 of 20 External Control Terminals A pluggable Phoenix screw terminal connector is pr ovided to facilitate additional functionalit y: Pin Signal Name Function 1 External +24V Supply Allows control circuit of the br ake module to be powered from an external supply. (Eliminates 25ms delay [...]

  • Page 9

    Regenerative Power Module - September 2010 144-45117- R3 Page 9 of 20 FIGURE 1 Turn On Dynamic Adjustment FIGURE 2 Syncrhonization Connection Normal switching level 0V 10V Terminal 7 Volta g e Switching level 100V RP M UNI T[...]

  • Page 10

    Regenerative Power Module - September 2010 144-45117- R3 Page 10 of 20 Power Terminal Connections TERM Function L1+ DC Bus Positive L2- DC Bus Negative R1+ Resistor Positive (Same potential as DC Bus Positive) R2- Resistor Negative (Switched Output) R3+ Terminal must be connected to the external resistor whenever the separate mounted RPM panel with[...]

  • Page 11

    Regenerative Power Module - September 2010 144-45117- R3 Page 11 of 20 Resistor Sizing The minimum connected resistor to the standard RPM m odule is 1 ohm. The resistor value can be greater than this but never lower. Use the following procedure to calculate th e continuous current rating of the resistor chosen. 1. Tabulate all motion Full Load Amps[...]

  • Page 12

    Regenerative Power Module - September 2010 144-45117- R3 Page 12 of 20 R1 R2 L1 ( + ) R3 L2(-) L1(+) L2(-) IN THIS CONFIGURATION SET DIP SWITCH - 3 “TERMINAL RESISTOR” TO OFF POSITION ON RPM UNIT FIGURE 3 400 AMP Single RPM Unit The connection shown in FIGURE 3 is a single 400 AMP RPM Unit that is connected to the DDC bus after the M contactor.[...]

  • Page 13

    Regenerative Power Module - September 2010 144-45117- R3 Page 13 of 20 FIGURE 4 400 AMP 230-320V Common Bus RPM Panel The connection in FIGURE 4 shows a separately mount ed 400 AMP RPM Panel that is connected across the 230-320V. The panel is generally connected on th e load side of the Manual Magnetic Disconnect Switch. Connections direct to the D[...]

  • Page 14

    Regenerative Power Module - September 2010 144-45117- R3 Page 14 of 20 FIGURE 5 400 AMP 360-720V Separate Mounted The connection in FIGURE 5 shows a separately mount ed 400 AMP RPM Panel that is connected across the 360-720V. The panel is generally connected on th e load side of the Manual Magnetic Disconnect Switch. Connections direct to the DC Bu[...]

  • Page 15

    Regenerative Power Module - September 2010 144-45117- R3 Page 15 of 20 FIGURE 6 800 AMP 230-320V Separate Mounted RPM Panel The connection in FIGURE 6 shows an 800 AMP RPM Panel that is connected across the 230-320V. The panel is generally connected on the load side of the Manual Magnetic Disconnect Switch. The Synchronization line is connected bet[...]

  • Page 16

    Regenerative Power Module - September 2010 144-45117- R3 Page 16 of 20 FIGURE 7 800 AMP 360-720V Separate Mounted RPM Panel The connection in FIGURE 7 shows an 800 AMP RPM Panel that is connected across the 360-720V. The panel is generally connected on the load side of the Manual Magnetic Disconnect Switch. The Synchronization line is connected bet[...]

  • Page 17

    Regenerative Power Module - September 2010 144-45117- R3 Page 17 of 20 FIGURE 8 1200 AMP 230-360V Common Bus RPM Panel The connection in FIGURE 8 shows a 1200 AMP RPM Panel that is connected across the 230-360V. The panel is generally connected on the load side of the Manual Magnetic Disconnect Switch. The Synchronizati on line is con nected betwee[...]

  • Page 18

    Regenerative Power Module - September 2010 144-45117- R3 Page 18 of 20 FIGURE 9 1200 AMP 360-720V Common Bus RPM Panel The connection in FIGURE 9 shows a 1200 AMP RPM Panel that is connected across the 360-720V. The panel is generally connected on the load side of the Manual Magnetic Disconnect Switch. The Synchronizati on line is con nected betwee[...]

  • Page 19

    Regenerative Power Module - September 2010 144-45117- R3 Page 19 of 20 Troubleshooting Taking the following measurem ents can check the transistor and diode. Q1 POSITIVE PROBE NEGATIVE PROBE READING DP R2 L1 0.312 DN L2 R2 0.312 QP L1 R2 > 0.6 QN R2 L2 > 0.6 TRANSISTOR AND DIODE CHECK US ING D.M.M. SET ON DIODE SCALE FIGURE 10 If the Green PO[...]

  • Page 20

    Regenerative Power Module - September 2010 144-45117- R3 Page 20 of 20 FIGURE 11 Dimensions 400 AMP RPM Unit Enclosure Dimensions The following table describes the dimensions for th e common bus RPM panels. The NEMA 4 enclosures have screw latches to secure the hinged door. Dimensions (in) Part Number Description Height Width Length 144-45111 400 A[...]