Regenerative Power Module And Common Bus RPM Panels Instruction Manual Part Number 144-45117-R3 September 2010 ©Copyright 2010 Magnetek Material Handling
PRODUCT MANUAL SAFETY INFORMATION Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products and adjustable frequency drives, and industrial braking systems for material handling applications. This manual has been prepared by Magnetek to provide information and recommendations for the installation, use, operation and service of Magnetek’s material handling products and systems (Magnetek Products).
Disclaimer of Warranty Magnetek, hereafter referred to as Company, assumes no responsibility for improper programming of a drive by untrained personnel. A drive should only be programmed by a trained technician who has read and understands the contents of this manual. Improper programming of a drive can lead to unexpected, undesirable, or unsafe operation or performance of the drive. This may result in damage to equipment or personal injury.
General Description The Regenerative Power Module (RPM) is a universal brake chopper circuit designed to dissipate regenerative energy produced by a motor into a fixed resistor load. The universal module covers the DC supply voltage range from 200V to 660V. The voltage selector link located on the outside front cover of the unit configures the module for LOW voltage (200V to 300V), MED voltage (300V to 500V) or HIGH voltage (500V to 660V).
Voltage Display A 10-LED Switch Level bar graph provides a visual display of the approximate 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. Link Setting 330 495 660 Adj Range 256 – 400 VDC 384 - 600 512 - 800 Volt/Step 16 24 32 Choose the appropriate setting for the voltage link set up and set the appropriate corresponding DIP switch position on.
• LED Fault and Status Indicators LED status indicators provide the following indications: COLOR MARKING GREEN POWER • GREEN INTERLOCK GREEN READY AMBER AMBER RED ACTIVE RESET OVERTEMP RED IGBT FAULT DESCRIPTION Indicates that the brake chopper power supply is present Indicates that the external contact is closed when the interlock is enabled or that the interlock is in the disabled position Indicates that no fault condition exists and that the external interlock is not open Indicates that the b
External Control Terminals A pluggable Phoenix screw terminal connector is provided to facilitate additional functionality: Pin 1 Signal Name External +24V Supply 2 Fault 3 Sync 4 Reset 5 Fan 6 7 Ready Level 8 I-Lock 9 10 0V 0V Function Allows control circuit of the brake module to be powered from an external supply. (Eliminates 25ms delay for control power to become established from main DC bus power.
Switching level Normal switching level 100V 0V Terminal 7 Voltage 10V FIGURE 1 RPM UNIT Turn On Dynamic Adjustment FIGURE 2 Syncrhonization Connection Regenerative Power Module - September 2010 144-45117-R3 Page 9 of 20
Power Terminal Connections TERM L1+ L2R1+ R2R3+ Function DC Bus Positive DC Bus Negative Resistor Positive (Same potential as DC Bus Positive) Resistor Negative (Switched Output) Terminal must be connected to the external resistor whenever the separate mounted RPM panel with the required additional protective components is connected directly to the DC bus. See FIGURE 4 for example connections. External Power Connection An external 24V supply may be connected to the brake chopper at pins 1 and 10.
Resistor Sizing The minimum connected resistor to the standard RPM module is 1 ohm. The resistor value can be greater than this but never lower. Use the following procedure to calculate the continuous current rating of the resistor chosen. 1. Tabulate all motion Full Load Amps (FLA) • • 2. ½ hour FLA for hoist motion 1 hour FLA for travel motions Calculate Regen Current for simultaneous motion operation ⎛ ⎞ ⎛ ⎞ IREGEN= ⎜∑FLA * 0.8⎟ + ⎜∑FLA * 0.3⎟ HOIST TRAVEL ⎝ ⎠ ⎝ ⎠ 3.
L1(+) R1 L1 (+) for RPM is connected between M contactor and the DDC drive L1(+) RPM resistor R2 144-45087 RPM * R3 FAULT SYNCH RESET FAN READY BRAKE LEVEL INTERLOCK 0 VDC 0VDC L2(-) + 24 VDC L2(-) 1 2 3 4 5 6 7 8 9 10 * EXTERNAL RESISTOR GRIDS WITH NORMALLYCLOSED OVER TEMPERATURE SWITCH 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
FIGURE 4 400 AMP 230-320V Common Bus RPM Panel The connection in FIGURE 4 shows a separately mounted 400 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. Connections direct to the DC Bus require additional protective components that are included on the separately mounted RPM panel.
FIGURE 5 400 AMP 360-720V Separate Mounted The connection in FIGURE 5 shows a separately mounted 400 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. Connections direct to the DC Bus require additional protective components that are included on the separately mounted RPM panel.
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 between both RPMs in order to have proper load sharing.
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 between both RPMs in order to have proper load sharing.
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 Synchronization line is connected between both RPMs in order to have proper load sharing.
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 Synchronization line is connected between both RPMs in order to have proper load sharing.
Troubleshooting Taking the following measurements 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 USING D.M.M. SET ON DIODE SCALE FIGURE 10 If the Green POWER indicator light on the front cover is out make the following checks. 1. Check for the supply voltage between L1+ and L22. If the supply voltage is present replace the entire RPM unit.
FIGURE 11 Dimensions 400 AMP RPM Unit Enclosure Dimensions The following table describes the dimensions for the common bus RPM panels. The NEMA 4 enclosures have screw latches to secure the hinged door.
