Rockwell-automation FlexPak 3000 DC Drive Version 4.3 User Manual

Instruction ManualFlexPak 3000 Digital DC DriveHardware Reference, Installationand TroubleshootingVersion 4.3D2-3404-2

1-2FlexPak 3000 DC Drive Hardware Reference Version 4.31.3 Model NumbersDrive specific data, such as horsepower (or output current), regenerative or n

Index-2FlexPak 3000 DC Drive Hardware Reference Version 4.3 motorwiring connections, 1-22 to 1-25mounting, 1-1EMC compliance requirements, 1-5moun

IndexIndex-3 Jjumper settings, 1-4 to 1-10analog tach voltage and analog tach scale (J14 and J11), 1-8armature current feedback (J18), 1-9enhanced fie

Index-4FlexPak 3000 DC Drive Hardware Reference Version 4.3troubleshootingAC line and power input, 1-1DC motor connections, 1-2OIM, 1-3optional kits,

U.S. Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives

Introduction to the FlexPak 3000 Drive1-3The drive employs a wireless construction and uses a keypad for drive setup, including parameter adjustments

1-4FlexPak 3000 DC Drive Hardware Reference Version 4.31.6 Optional KitsReliance offers modification kits that broaden the application range of the dr

Introduction to the FlexPak 3000 Drive1-51.7 Getting Assistance from Reliance ElectricIf you have any questions or problems with the products describe

1-6FlexPak 3000 DC Drive Hardware Reference Version 4.3

Install and Wire the Drive2-1CHAPTER 2Install and Wire the Drive2.1 Install the Drive - Panel LayoutMinimum clearances must be maintained when the dri

2-2FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure 2.2 – Drive Mounting Dimensions (1.5 to 30 HP @ 230 VAC / 3 to 60 HP @ 460 VAC / 7 to 11

Install and Wire the Drive2-3Figure 2.3 – Drive Mounting Dimensions (40 to 75 HP @ 230 VAC /75 to 150 HP @ 460 VAC / 265 Amp Rated Output)

2-4FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure 2.4 – Drive Mounting Dimensions (100 to 150 HP @ 230 VAC / 200 to 300 HP @ 460 VAC)

Install and Wire the Drive2-5Figure 2.5 – Drive Mounting Dimensions (400 to 600 HP @ 460 VAC)

©2004 Rockwell Automation. All rights reserved.The information in this manual is subject to change without notice.Throughout this manual, the followin

2-6FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure 2.6 – Integrator Drive Mounting Dimensions (1.5 to 30 HP @ 230 VAC / 3 to 60 HP @ 460 VA

Install and Wire the Drive2-7 Figure 2.7 – Integrator Drive Mounting Dimensions (40 to 75 HP @ 230 VAC / 75 to 150 HP @ 460 VAC)

2-8FlexPak 3000 DC Drive Hardware Reference Version 4.32.2 Install a TransformerInput transformers step up or step down input voltage and can be eithe

Install and Wire the Drive2-92.4 Install the MotorStep 1. Verify that the motor is the appropriate rating to use with the drive.Step 2. Install the DC

2-10FlexPak 3000 DC Drive Hardware Reference Version 4.3Step 4. Connect a suitable equipment grounding conductor to the motor frame, the transformer e

Install and Wire the Drive2-11Figure 2.8 – Drive Control and Power Ground Point Locations (1.5 to 30 HP @ 230 VAC /3 to 60 HP @ 460 VAC / 7-110 Amp Ra

2-12FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure 2.9 – Drive Control and Power Ground Point Locations (40 to 75 HP @ 230 VAC /75 to 150

Install and Wire the Drive2-13Figure 2.10 – Drive Control and Power Ground Point Locations (100 to 150 HP @ 230 VAC / 200 to 300 HP @ 460 VAC)

2-14FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure 2.11 – Drive Control and Power Ground Point Locations (400 to 600 HP @ 460 VAC)

Install and Wire the Drive2-15Figure 2.12 – Integrator Drive Control and Power Ground Point Locations (1.5 to 30 HP @ 230 VAC / 3 to 60 HP @ 460 VAC)

ContentsICONTENTSChapter 1 Introduction to the FlexPak 3000 Drive1.1 Store the Drive...

2-16FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure 2.13 – Integrator Drive Control and Power Ground Point Locations (40 to 75 HP @ 230 VAC

Install and Wire the Drive2-172.5.2 Recommended LugsThe following describes how to interpret lug model numbers used in grounding the drive. Refer to t

2-18FlexPak 3000 DC Drive Hardware Reference Version 4.32.5.3 Wire AC Power to the DriveStep 1. Size the AC line supply conductors for the specific dr

Install and Wire the Drive2-19Important: The tightening torque in the table applies to the wiring device (stud or terminal board) provided. When an in

2-20FlexPak 3000 DC Drive Hardware Reference Version 4.3 Figure 2.14 – AC Line Connection Location (1.5 to 30 HP @ 230 VAC 3 to 60 HP @ 460 VAC / 7-11

Install and Wire the Drive2-21Figure 2.16 – AC Line Connection Locations (100 to 150 HP @ 230 VAC / 200 to 300 HP @ 460 VAC)Figure 2.17 – AC Line Conn

2-22FlexPak 3000 DC Drive Hardware Reference Version 4.32.5.4 Wire the DC Motor to the DriveStep 1. Size the motor armature circuit conductors for the

Install and Wire the Drive2-23Figure 2.19 – DC Motor Field and Armature Connection Locations (40 to 75 HP @ 230 VAC /75 to 150 HP @ 460 VAC / 265 Amp

2-24FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure 2.20 – DC Motor Field and Armature Connection Locations (100 to 150 HP @ 230 VAC / 200

Install and Wire the Drive2-25Figure 2.21 – DC Motor Field and Armature Connection Locations (400 to 600 HP @ 460 VAC)

IIFlexPak 3000 DC Drive Hardware Reference Version 4.33.6 Verify the Correct Direction of Motor Rotation ...

2-26FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure 2.22 – DC Motor Connections (CCW Rotation Facing Commutator End Shown)

Install and Wire the Drive2-272.5.4.1 Wire Motor Overload ProtectionA software (internal) overload is provided that meets NEC/CEC and UL/C-UL requirem

2-28FlexPak 3000 DC Drive Hardware Reference Version 4.32.5.5 Wire the Stop InputThe FlexPak 3000 drive can be stopped by the assertion of a stop inp

Install and Wire the Drive2-292.5.5.1 Wire the COAST/STOP Digital InputThe user must provide an external operator-accessible coast/stop pushbutton at

2-30FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure 2.24 – Sample Regulator Board Terminal Strip Connection Diagram12341234StartStopRunJogR

Install and Wire the Drive2-31Figure 2.25 – Location of Regulator Board Terminal StripRS-232Connector

2-32FlexPak 3000 DC Drive Hardware Reference Version 4.32.5.6 Wire Optional Devices to the DriveRefer to figures 2.24 and 2.25 and table 2.5 when wiri

Install and Wire the Drive2-332.5.6.1 Logic InputsThe logic input circuits can be powered either from the internal +24 volt DC power supply or from an

2-34FlexPak 3000 DC Drive Hardware Reference Version 4.3

Drive Setup and Adjustment3-1CHAPTER 3Drive Setup and Adjustment3.1 Perform a Power Off InspectionInspect the drive and modification kits for possible

ContentsIIIList of FiguresFigure 1.1 – Sample FlexPak 3000 Nameplates ... 1-1Figure 1.2 – Model Num

3-2FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure 3.1 – Control Transformer Locations and Settings (380/415 VAC Drives)3.2.2 Converting a

Drive Setup and Adjustment3-3Step 4. Re-connect power to the drive.Step 5. Through the OIM, access the NOMINAL AC LINE VOLTS parameter (P.037). Set th

3-4FlexPak 3000 DC Drive Hardware Reference Version 4.3Verify that there is no path to ground in either the DC motor armature circuit, the shunt field

Drive Setup and Adjustment3-53.4.1 Set the Regulator Type (Jumper J15)J15 determines whether the drive uses speed/voltage or torque/current regulation

3-6FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure 3.3 – Regulator Board Jumpers3.4.2 Setting Program Protection (Jumper J16)The OIM progra

Drive Setup and Adjustment3-73.4.3 Set Field Loss Detection (Jumper J20)The FIELD LOSS DETECT jumper (J20) determines whether or not a fault is genera

3-8FlexPak 3000 DC Drive Hardware Reference Version 4.3To use the +10V power supply for the manual reference potentiometer, place the jumper on pins 2

Drive Setup and Adjustment3-93.4.7 Set the Analog Auto Mode Reference (Jumpers J12 and J10)The AUTOREF jumpers (J12 and J10) select the type of analog

3-10FlexPak 3000 DC Drive Hardware Reference Version 4.33.4.13 Inspect the Power Unit Jumper (J30)Important: An optional Power Interface module, for

Drive Setup and Adjustment3-11Step 4. After power-up, select ARMATURE VOLT for FEEDBACK SELECT by taking the following path from the main menu to acce

IVFlexPak 3000 DC Drive Hardware Reference Version 4.3Figure 2.25 – Location of Regulator Board Terminal Strip...2-

3-12FlexPak 3000 DC Drive Hardware Reference Version 4.3Step 1. Stop the drive.Step 2. Check the value of the output parameter ARMATURE VOLTAGE (P.289

Troubleshooting/Diagnostics4-1CHAPTER 4Troubleshooting/DiagnosticsThis chapter details troubleshooting and diagnostics information fro the FlexPak 300

4-2FlexPak 3000 DC Drive Hardware Reference Version 4.34.3 Verify DC Motor ConnectionsVerify that all DC motor connections are correct.• Recheck all m

Troubleshooting/Diagnostics4-34.5 Check the Regulator LED StatusTwo LEDs on the Regulator board indicate the operating status of the Regulator board.

4-4FlexPak 3000 DC Drive Hardware Reference Version 4.3

Replacement Parts5-1CHAPTER 5Replacement PartsThe spare or replacement parts for drives described in this manual are also listed in Replacement Parts

5-2FlexPak 3000 DC Drive Hardware Reference Version 4.3

Technical SpecificationsA-1APPENDIX ATechnical SpecificationsTable A.1 – Voltage and Current RatingsInput Voltage and Frequency RatingsNominal Voltage

A-2FlexPak 3000 DC Drive Hardware Reference Version 4.3Table A.2 – Service ConditionsService Factor 1.0 continuousOverload Capacity 150% of full load

Technical SpecificationsA-3Table A.6 – Power Ratings1 (230/460 VAC)1 When applying FlexPak 3000 drives to a power distribution system with KVA capacit

ContentsVList of TablesTable 1.1 – Drive Modification Kits ... 1-4Table 2.1 –

A-4FlexPak 3000 DC Drive Hardware Reference Version 4.3Table A.7 – Power Ratings1 (380/415 VAC)1 When applying FlexPak 3000 drives to a power distribu

Technical SpecificationsA-5Table A.10 – Analog InputsManual Mode Reference PotentiometerExternal Voltage Source5 KΩ minimum±10 VDC (when used for anal

A-6FlexPak 3000 DC Drive Hardware Reference Version 4.3

Compliance with European Union Electromagnetic Compatibility StandardsB-1APPENDIX BCompliance with European UnionElectromagnetic CompatibilityStandard

B-2FlexPak 3000 DC Drive Hardware Reference Version 4.3B.2 Selecting the EquipmentIn addition to the drive, you will need the following to install the

Compliance with European Union Electromagnetic Compatibility StandardsB-3Table B.1 – AC Mains Filter Model Numbers for 1.5 to 150 HP @ 230 VAC FlexPak

B-4FlexPak 3000 DC Drive Hardware Reference Version 4.3B.2.4 Selecting an Operator Control StationIf an operator control station is connected to the d

Compliance with European Union Electromagnetic Compatibility StandardsB-5B.3 Mounting the EquipmentMount all electronic and electromagnetic components

B-6FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure B.2 – 3DF4353 and 3DF4354 Filter DimensionsFigure B.3 – 3DF4355 Filter DimensionsL1 L2 L

Compliance with European Union Electromagnetic Compatibility StandardsB-7Figure B.4 – 3DF4357 Filter DimensionsFigure B.5 – 3DF4359 Filter DimensionsL

VIFlexPak 3000 DC Drive Hardware Reference Version 4.3

B-8FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure B.6 – Side Mounting the 3DF4359 Filter in the L BracketB.3.3 Mounting the AC Mains Induc

Compliance with European Union Electromagnetic Compatibility StandardsB-9B.4 Grounding RequirementsStar grounding must be used and must provide tradit

B-10FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure B.8 – Proper Termination of Screened Cables with a Termination FittingFigure B.9 – Prop

Compliance with European Union Electromagnetic Compatibility StandardsB-11Figure B.10 – Ground System and Conduit Screen TerminationThe minimum cross-

B-12FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure B.11 – Dressing Power and Control Wires When the AC power leads must leave the ground p

Compliance with European Union Electromagnetic Compatibility StandardsB-13The external motor wiring must be run in a screened cable or continuous cond

B-14FlexPak 3000 DC Drive Hardware Reference Version 4.3B.5.6.3 Pulse Encoder and AC Tachometer Feedback Kits (Model Numbers 907FK0101 and 907FK0301)T

Compliance with European Union Electromagnetic Compatibility StandardsB-15Figure B.13 – Typical FlexPak 3000 Wiring for EMC Compliance with Optional

B-16FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure B.14 – Typical FlexPak 3000 Wiring for EMC Compliance with Optional Dynamic Braking Kit

Recommended Parts for Integrator DrivesC-1APPENDIX CRecommended Parts forIntegrator DrivesTable C.1 lists the recommended parts that must be provided

Introduction to the FlexPak 3000 Drive1-1CHAPTER 1Introduction to the FlexPak 3000 DriveThe products described in this instruction manual are manufact

C-2FlexPak 3000 DC Drive Hardware Reference Version 4.3C.1 Wire Inverting Fault Protection to the Drive (S6R, Regenerative Drives Only)The AFB termina

Recommended Parts for Integrator DrivesC-3Figure C.1 – Integrator Drive AC Line Connection Locations (1.5 to 30 HP @ 230 VAC / 3 to 60 HP @ 460 VAC)4

C-4FlexPak 3000 DC Drive Hardware Reference Version 4.3Figure C.2 – Integrator Drive AC Line Connection Locations (40 to 75 HP @ 230 VAC / 75 to 150 H

Recommended Parts for Integrator DrivesC-5C.2 Wire Control Power to the Drive Connect the user supplied 115 VAC supply to terminals 188 and 189 of the

C-6FlexPak 3000 DC Drive Hardware Reference Version 4.3

Glossary Of TermsD-1APPENDIX DGlossary Of Termsaltitude: The atmospheric altitude (height above sea level) at which the motor or drive will be operati

D-2FlexPak 3000 DC Drive Hardware Reference Version 4.3inertial load: A load (flywheel, fan, etc.) which tends to cause the motor shaft to continue to

Glossary Of TermsD-3service factor (SF): When used on a motor nameplate, a number which indicates how much above the nameplate rating a motor can be l

D-4FlexPak 3000 DC Drive Hardware Reference Version 4.3

Index Index-1INDEXAAC lineconnection location, 1-18 to 1-211.5 to 30 HP @ 230 VAC 3 to 60 HP @ 460 VAC / 7-110 Amp, 1-20100 to 150 HP @ 230 VAC / 200