Medium Voltage AC Drive - Rockwell Automation

306 Pages·2001·5.15 MB·English

by  Rockwell Automation

Medium Voltage
AC Drive
Bulletin 1557
User Manual
Important User Information
Read this document and the documents listed in the Additional Resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
TABLE OF CONTENTS

Chapter 1 .......................................................... Using This Manual

Chapter 2 ......................................................... Introduction

Chapter 3 .......................................................... Specifications

Chapter 4 .......................................................... Hardware Description

Chapter 5 .......................................................... Description of Operation

Chapter 6 .......................................................... Parameter and Variable
Descriptions

Chapter 7 .......................................................... Operator Interface Terminal

Chapter 8 .......................................................... Installation

Chapter 9 .......................................................... Commissioning

Chapter 10 ........................................................ Troubleshooting

Chapter 11 ........................................................ Spare Parts

1557-UM050F-EN-P – June 2013
1557-UM050F-EN-P – June 2013
USING THIS MANUAL 1-1

Manual Objectives

This manual is intended for use by personnel familiar with Medium Voltage and variable speed solid-state
drive equipment. The manual contains material which will allow the user to operate, maintain, and
troubleshoot the drive system.

IMPORTANT USER INFORMATION

Because of the variety of uses for this equipment and because of the differences between this solid-state
equipment and electromechanical equipment, the user of and those responsible for applying this
equipment must satisfy themselves as to the acceptability of each application and use of the equipment.
In no event will Rockwell Automation be responsible or liable for indirect or consequential damages
resulting from the use or modification of this equipment.

The illustrations shown in this manual are intended solely to illustrate the text of this manual Because of
the many variables and requirements associated with any particular installation, Rockwell Automation
cannot assume responsibility or liability for actual use based upon the illustrative uses and applications.

No patent liability is assumed by Rockwell Automation with respect to use of information, circuits,
equipment or software described in this text.

Reproduction of the content of this manual, in whole or in part, without written permission of Rockwell
Automation is prohibited.

Warnings tell readers where people may be hurt if

procedures are not followed properly.

Cautions tell readers where machinery may be damaged
or economic loss can occur if procedures are not
followed properly.

Both of these:

• Identify a possible trouble spot.
• Tell what causes the trouble.
• Give the result of improper action.
• Tell the reader how to avoid trouble.

This symbol alerts the user to a potential electrical shock
hazard which exists on a component or printed circuit
board.

1557-UM050F-EN-P – June 2013
1-2 USING THIS MANUAL

REPAIR OR REPAIR/EXCHANGE PROCEDURE

For your convenience, Rockwell Automation and Rockwell Automation Global Technical Services(GTS),
provide an efficient and convenient method of returning equipment eligible for repair or repair/exchange.

A Product Service Report (P.S.R.) number is required to return any equipment for repair. This may be
obtained from your area Rockwell Automation Distributor, Sales Office or Area Support Division.

Return any equipment to be repaired to the Area Support Division nearest you. Be sure to reference the
P.S.R. number on the carton and packing slip. Include your company name and address, your repair
purchase order number, and a brief description of the problem. This will facilitate quick return of your
equipment.

A complete listing of Global Technical Services offices may be obtained by calling your area Rockwell
Automation Distributor or Sales Office.

1557-UM050F-EN-P – June 2013
INTRODUCTION CHAPTER 2

The Bulletin 1557 drive is a Pulse Width Modulated Current Source Machine side converter (PWM - CSI).
It is designed to supply 3 phase currents to standard induction motor loads. The Bul. 1557 MV (medium
voltage) drive converts 3 phase 50/60 Hz input power to an adjustable AC frequency current source for
speed control of AC squirrel cage motors.

The solid state technology used in the design is of proven reliability. A number of circuit implementation
techniques used are unique to the Allen-Bradley Bulletin 1557 drive.

The basic design philosophy emphasizes the isolation of single component failures, such that multiple
component failures do not occur. This leads to a low MTTR, (Mean Time To Repair), with extensive fault
diagnostic circuits and easy accessibility.

The basic design features of the Allen-Bradley Bulletin 1557 drive are as follows:

The three phase motor currents are sinusoidal with low total harmonic distortion.

The design uses isolated driver circuits, one per gate turn off thyristor (GTO), and
silicon controlled line side converter (SCR).

Two output phases are individually current sensed, ensuring protection and control.

The design is capable of producing smooth low speed torque with low harmonic current
to the motor.

A fuseless electronic protection scheme is used in the power circuit for normal fault
conditions. Power fuses provide back up protection and ensure safety.

Heatsinks are monitored with temperature sensors to detect overtemperatures.
(BUL 1557 Air-cooled units only)

The 1557 Drive uses a North American design base with all components readily
accessible from the front without need to extensively dismantle the unit.

The drive system logic is microcomputer based, thus eliminating numerous trimpots
for system calibration.

Fault and alarm indication is performed using an operator interface panel.

1557-UM050F-EN-P – June 2013
2-2 INTRODUCTION

An Input contactor with fused isolating switch is optional on the 1557 drive and is only supplied
when specified or if the customer does not have an existing full voltage starter.

The standard 1557 drive is a tachless design. A tachometer is recommended for applications
requiring an output frequency lower than 6 hertz or applications with a starting torque greater than
30%.

A drive isolation transformer or AC line reactor is required with each drive. An isolation
transformer is mandatory when existing motors are used, 12-Pulse line side converters are used,
or for stepping down the main supply voltage. An AC line reactor may only be used when new
motors are used with the proper level of phase to ground insulation. Consult your Rockwell
Automation representative for more information.

1557-UM050F-EN-P – June 2013
SPECIFICATIONS CHAPTER 3

The electrical and environmental specifications of the Bulletin 1557 MV Drive are provided below:

Input Voltages: 2300Vac ± 10%, 3-Phase
3300Vac ± 10%, 3-Phase
4160Vac ± 10%, 3-Phase
6900Vac ± 10%, 3-Phase

Input Frequency: 50/60Hz ± 3Hz

Efficiency: 97% at full load (minimum)

Output Voltage: 0 to 2300Vac, 3-Phase
0 to 3300Vac, 3-Phase
0 to 4160Vac, 3-Phase
0 to 6900Vac, 3-Phase

Output Frequency: 6Hz to 75Hz (Without Tach)
0.2Hz to 75 Hz (With Tach)

Speed Regulation: 0.5% of maximum speed (Without Tach)
0.1% of maximum speed (With Tach)

Speed Reference: 0 to 10V dc or
4 to 20 mA dc

Operating Temperature: Ambient temperature must be within the range of 0° to 40°C
with a relative humidity of up to 95% (non-condensing)

Storage Temperature: Ambient temperature must be within the range of –40° to 70°C

Altitude: No derating below 1000 m above sea level

1557-UM050F-EN-P – June 2013
3-2 SPECIFICATIONS

1557-UM050F-EN-P – June 2013