Installing the 115 VAC
Control Option Board
M/N 917FK0101
FlexPakr 3000 and
MaxPakr III Drives
Instruction Manual D2Ć3338
The information in this manual is subject to change without notice.
Trademarks not belonging to Rockwell Automation are property of
their respective companies.
DANGER
ONLY QUALIFIED PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS
EQUIPMENT SHOULD INSTALL, ADJUST, OPERATE, AND/OR SERVICE THIS EQUIPMENT. READ
AND UNDERSTAND THIS INSTRUCTION MANUAL IN ITS ENTIRETY BEFORE PROCEEDING.
FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS
OF LIFE.
DANGER
THE DRIVE AND CONTROL OPTION BOARD ARE AT LINE VOLTAGES WHEN CONNECTED TO
SOURCES OF INCOMING AĆC POWER. DISCONNECT, TAG, AND LOCKOUT ALL SOURCES OF AĆC
POWER TO THE DRIVE AND THE CONTROL OPTION BOARD BEFORE PERFORMING THE
FOLLOWING PROCEDURE. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN
SEVERE BODILY INJURY OR LOSS OF LIFE.
CAUTION: The user is responsible for conforming with all applicable local, national, and international
codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
Reliancer, FlexPakr, and MaxPakr are trademarks of Reliance Electric Company
or its subsidiaries.
E Copyright Reliance Electric Industrial Company 1996.
Table of Contents
1.0 Product Description 1Ć1.................................................................
1.1 Kit Contents 1Ć1......................................................................
1.2 Wiring Guidelines 1Ć1.................................................................
2.0 Installing UserĆSupplied 115 VAC Control Power 2Ć1.......................................
2.1 Recommended Method 2Ć1............................................................
2.2 Precautions Using Other Methods 2Ć1...................................................
3.0 Installing the Control Option Board for a FlexPak 3000 Drive 3Ć1...........................
4.0 Installing the Control Option Board for a MaxPak III Drive 4Ć1..............................
I
Appendices
Appendix A
115 VAC Control Option Board Circuitry AĆ1...................................................
Appendix B
Technical Specifications BĆ1.................................................................
II
List of Figures
Figure 1.1 Ć 115 VAC Control Option Board 1Ć3.....................................................
Figure 1.2 Ć Mounting Dimensions 1Ć4.............................................................
Figure 2.1 Ć Recommended 115 VAC Supply Configuration 2Ć2.......................................
Figure 4.1 Ć Control Signal Wiring to a MaxPak III Drive (Example) 4Ć3.................................
Figure A.1 Ć 115 VAC Control Option Board Circuitry AĆ1.............................................
List of Tables
Table 1.1 Ć 115 VAC Control Option Board Parts List 1Ć1.............................................
Table 2.1 Ć AĆC Source Input Connector 2Ć1........................................................
Table 3.1 Ć Control Option Board Wiring to a FlexPak 3000 Drive 3Ć2..................................
Table 4.1 Ć Control Option Board Wiring to a MaxPak III Drive (Example) 4Ć2...........................
III
1.0 PRODUCT DESCRIPTION
This manual provides instructions for installing the 115 VAC Control Option Board for use with a
FlexPakr 3000 drive or MaxPakr III drive. It is intended for qualified electrical personnel. The
installation procedure consists of mounting the Control Option Board, wiring user control devices to
the board, and wiring the board to the existing control inputs on the FlexPak 3000 drive's regulator
board terminal strip or the MaxPak III drive's control and signal terminals. The source of control
power must be provided by the user.
The Control Option Board's component layout is shown in figure 1.1. A mounting hole template is
provided in figure 1.2. Appendices A and B describe circuit operation and provide technical
specifications.
No software configuration or parameter changes are required on the FlexPak 3000 drive. The
MaxPak III drive installation may require configuration and parameter changes on the part of the end
user. Separate installation procedures are provided for FlexPak 3000 drives and MaxPak III drives.
Perform the steps in the order in which they are presented in this manual.
1.1 Kit Contents
The 115 VAC Control Option Board is sold with the necessary connectors and mounting hardware as
kit model number 917FK0101. Table 1.1 provides a parts list for the kit.
Table 1.1 Ć 115 VAC Control Option Board Parts List
Item No.
1 115 VAC Control Option Board 1 OĆ60053Ć000
2 3ĆPin AĆC Source Input Connector 1 49455Ć124GC
3 14ĆPin AĆC Input Connector 1 49455Ć124GP
4 Cable Assembly 1 707973Ć13R
5 M4 x 30 Taptite Screw 4 419062Ć100PGN
6 M4 Flat Washer 4 419064Ć1SG
7 Label: Danger 1 610293Ć201A
1.2 Wiring Guidelines
It is the user's responsibility, and the responsibility of the installing electrical contractor, to ensure that
this equipment is installed properly according to this manual and in conformance with all applicable
codes. The primary code covering the installation of motors, drives, operator devices, controls, and
other related equipment is NFPA 70 "National Electrical Code," published by the National Fire
Protection Association. The local inspecting agency should be consulted for information about any
other local, national, or international codes that may also apply.
Wiring Levels and Classes
Drive systems include a wide variety of electrical and electronic circuits. These range from power
circuits that radiate considerable electromagnetic energy to sensitive electronic circuits susceptible to
induced voltages or currents. System wiring is divided into the following four basic levels, depending
upon each circuit's susceptibility to noise or its noiseĆgenerating capability.
Description Qty
Reliance Part Number
Level 1: (High Susceptibility) Ć Low Level Signal Circuits
Analog signals less than 50 V and digital signals less than 15 V.
Level 2: (Medium Susceptibility) Ć Medium Level Signal Circuits
Analog signals greater than 50V, switching signals less than 50 V.
Level 3: (Low Susceptibility) Ć Control Circuits
Switching signals greater than 50 V, analog signals greater than 50 V, regulating signals of
50 V with currents less than 20 A, and AĆC feeders 20 A or less.
1Ć1
Level 4 Power Circuits
AĆC and DĆC buses up to 1000 V with currents up to 800 A (Class 4S for power greater than
1000 V and/or 800 A.)
The installation wiring for these levels must be physically separated to prevent poor system
performance as a result of induced noise. Within each level there also may be classes that require
additional grouping and separation of installation wiring. These levels and classes are defined in
ANSI/IEEE Standard 518, Section 6.4.3.1.
1Ć2
Figure 1.1 Ć 115 VAC Control Option Board
TABLE 4.1 & FIGURE 4.1
1Ć3
1Ć4
Figure 1.2 Ć Mounting Dimensions
2.0 INSTALLING USERĆSUPPLIED 115 VAC CONTROL
POWER
DANGER
THE DRIVE AND CONTROL OPTION BOARD ARE AT LINE VOLTAGES WHEN CONNECTED TO
SOURCES OF INCOMING AĆC POWER. DISCONNECT, TAG, AND LOCKOUT ALL SOURCES OF AĆC
POWER TO THE DRIVE AND THE CONTROL OPTION BOARD BEFORE PERFORMING THE
FOLLOWING PROCEDURE. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN
SEVERE BODILY INJURY OR LOSS OF LIFE.
CAUTION: The user is responsible for conforming with all applicable local, national, and international
codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
The user is responsible for providing 115 VAC, 60 Hz. singleĆphase power to the control devices and
the Control Option Board. To ensure safety to personnel, the method described in section 2.1 is
recommended.
2.1 Recommended Method
The recommended configuration is shown in figure 2.1. This configuration will guarantee that
opening the drive disconnect will also remove the 115 VAC power from the Control Option Board. All
wiring, fuses, and the stepĆdown transformer must be sized to match the application and the
technical specifications listed in Appendix B. Disconnect, tag, and lockout power to the drive and the
115 VAC control voltage supply before proceeding.
The installation procedure should include the following steps:
D
Connect the control power leads to two phases of the A-C input between the user-supplied A-C
disconnect and the drive. Run these leads to appropriately sized fuses and a step-down
transformer as shown in figure 2.1.
D
Connect the output of the transformer to terminals L1 and L2 on the A-C source input connector
(CON3) as listed in table 2.1.
D
Connect the GND terminal on CON3 to earth ground.
Table 2.1 Ć AĆC Source Input Connector
Terminal
L1 1
L2 1
GND
2.2 Precautions Using Other Methods
If
you choose not to follow the recommended method of providing the 1
described in section 2.1, be aware that disconnecting A-C power from the drive will not necessarily
remove the 1
D
Attach the Danger label [
prominently displayed.
15 V
AC power from the Control Option Board or the control devices. In this case:
Item #7
] to the drive enclosure or cabinet door
Connection
15V HI
15V LO
Earth Ground
15 V
AC control power
, ensuring that it is
,
D
Make sure that both incoming A-C drive power and 1
tagged, and locked out before servicing any component of the drive system.
15 V
AC control power are disconnected,
2Ć1
USERĆSUPPLIED
TRANSFORMER
AND FUSES
AĆC INPUT
USERĆSUPPLIED
AĆC DISCONNECT
DĆC DRIVE
2Ć2
Figure 2.1 Ć Recommended 115 VAC Supply Configuration
3.0 INSTALLING THE CONTROL OPTION BOARD FOR A
FLEXPAK 3000 DRIVE
DANGER
THE DRIVE AND CONTROL OPTION BOARD ARE AT LINE VOLTAGES WHEN CONNECTED TO
SOURCES OF INCOMING AĆC POWER. DISCONNECT, TAG, AND LOCKOUT ALL SOURCES OF AĆC
POWER TO THE DRIVE AND THE CONTROL OPTION BOARD BEFORE PERFORMING THE
FOLLOWING PROCEDURE. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN
SEVERE BODILY INJURY OR LOSS OF LIFE.
CAUTION: The user is responsible for conforming with all applicable local, national, and international
codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
Use the following procedure to install the 115 VAC Control Option Board for use with a FlexPak 3000
drive. Refer to figures 1.1, 1.2, and 2.1 when performing the installation.
Step 1. Disconnect, tag, and lockout power to the drive and the 115 VAC control voltage supply.
Step 2. Remove the drive cover. For drives with NEMA 1 covers, continue to step 3. For
chassisĆmounted drives, proceed to step 4.
Step 3. For drives up to 150 HP, equipped with NEMA 1 covers, locate the 4 mounting holes in the
back of the bottom end cover. Mount the Control Option Board [Item #1] inside, using the
M4 x 30 Taptite screws [Item #5] and the M4 washers [Item #6]. Proceed to step 5.
NOTE: Older versions of the FlexPak 3000 NEMA 1 drives may not be provided with
mounting holes. If this is the case, continue to step 4 and follow the chassisĆmounted drive
instructions.
Step 4. For chassisĆmounted drives, mount the Control Option Board [Item #1] at an appropriate
panel location, using the four (4) M4 x 30 Taptite screws [Item #5] and the M4 washers
[Item #6]. The board must be located less than 48 inches from the FlexPak 3000 regulator
board terminal strip, ideally just below the drive. Drill the holes for the mounting screws
using the mounting hole pattern shown in figure 1.2.
Step 5. Wire your 115 VAC supply to the 3Ćpin AĆC source input connector [Item #2]. Refer to the
recommendations given in section 2.1 and see table 2.1. Make sure to connect the GND
terminal to earth ground. Attach the AĆC source input connector to the mating connector on
the Control Option Board.
Step 6. If the 115 VAC control supply will not be deĆenergized by opening the drive disconnect,
attach the Danger label [Item #7] to the drive enclosure or cabinet door, ensuring that it is
prominently displayed.
Step 7. Wire your 115 VAC control devices to the Control Option Board's 14Ćpin AĆC input
connector [Item #3]. See figure 1.1 and table 3.1. Connect the 14Ćpin AĆC input connector
to the mating connector on the Control Option Board. The wiring of 115 VAC control
devices to the Control Option Board should mirror that of +24V control devices to your
drive's regulator board. Refer to the section on wiring the drive in your FlexPak 3000
instruction manual.
3Ć1
Table 3.1 Ć Control Option Board Wiring to a FlexPak 3000 Drive
()
Control Option Board
FlexPak
Control
Device
RUN ⇒ 2 (IN1) 1 ⇒ 2
STOP ⇒ 3 (IN2) 2 ⇒ 3
JOG ⇒ 4 (IN3) 3 ⇒ 4
REV/FWD ⇒ 5 (IN4) 4 ⇒ 5
AUTO/MAN ⇒ 6 (IN5) 5 ⇒ 6
COAST/STOP ⇒ 8 (IN6) 6 ⇒ 8
INTERLOCK ⇒ 9 (IN7) 7 ⇒ 9
FAULT/ALARM RESET ⇒ 10 (IN8) 8 ⇒ 10
BRUSH WEAR ⇒ 12 (IN9) 9 ⇒ 12
MOTOR THERMOSTAT ⇒ 13 (IN10) 10 ⇒ 13
NOTE: 115V HI (L1) is at terminals
1, 7, 11, 14.
Step 8. Connect the 12Ćpin connector on the cable assembly [Item #4] to the mating DĆC output
connector on the Control Option Board. Refer to figure 1.1 for location.
AĆC Input
Terminal
DĆC Output
Terminal
11 (+V) ⇒
12 (GND) ⇒ 15
Regulator Board
1, 7, 1
3000
Terminal
1, or 14
Step 9. Wire the other end of the cable assembly to the regulator board's control input terminals.
The ends of the wires are numbered to correspond to the Control Option Board's DĆC
Output Terminals, as listed in table 3.1. Connect as shown in the table.
Step 10. Wire the Control Option Board's +V terminal (pin 11) to one of the regulator board's +24V
terminals. Terminal 1, 7, 11, or 14 can be used. Refer to your drive's instruction manual for
further illustration.
Step 11. Wire the Control Option Board's ground (pin 12) to the regulator board's 24V COM
(terminal 15).
Step 12. Route and secure the cable assembly away from the power and the 115 VAC control wiring.
Loop any excess cable as required.
Step 13. Reattach the cover to the drive.
Step 14. Remove the lockout and tag. Reconnect power to the drive and the 115 VAC source.
Step 15. Turn on power to the drive and check for proper drive operation.
This completes the installation of the Control Option Board for a FlexPak 3000 drive.
3Ć2
4.0 INSTALLING THE CONTROL OPTION BOARD FOR A
MAXPAK III DRIVE
DANGER
THE DRIVE AND CONTROL OPTION BOARD ARE AT LINE VOLTAGES WHEN CONNECTED TO
SOURCES OF INCOMING AĆC POWER. DISCONNECT, TAG, AND LOCKOUT ALL SOURCES OF AĆC
POWER TO THE DRIVE AND THE CONTROL OPTION BOARD BEFORE PERFORMING THE
FOLLOWING PROCEDURE. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN
SEVERE BODILY INJURY OR LOSS OF LIFE.
CAUTION: The user is responsible for conforming with all applicable local, national, and international
codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
The control/signal terminals on the MaxPak III drive can be programmed to suit the user application.
This procedure describes a typical installation of 115 VAC control devices using default factory
settings. Your control devices may not be the same as those described here. Use this procedure as a
guide and consult the wiring diagrams shipped with your system for custom engineered drives.
Refer to figures 1.1, 1.2, and 2.1 when performing the installation.
Control and signal wiring connections to the MaxPak III drive are made to the terminal strips located
at the bottom of the drive. These are pullĆapart" strips that can be removed for ease of wiring. Make
note of any jumper positions before removing. Replace these jumpers when the terminal strip is
plugged in after wiring.
Step 1. Disconnect, tag, and lockout power to the drive and the 115 VAC control voltage supply.
Step 2. Mount the Control Option Board [Item #1] at an appropriate panel location, using the four
(4) M4 x 30 Taptite screws [Item #5] and the M4 washers [Item #6]. The board must be
located less than 48 inches from the MaxPak III drive's control/signal terminal strips, ideally
just below the drive. Drill the holes for the mounting screws using the mounting hole pattern
shown in figure 1.2.
Step 3. Wire your 115 VAC supply to the 3Ćpin AĆC source input connector [Item #2]. Refer to the
recommendations given in the section 2.1 and see table 2.1. Make sure to connect the GND
terminal to earth ground. Attach the AĆC source input connector to the mating connector on
the Control Option Board.
Step 4. If the 115 VAC control supply will not be deĆenergized by opening the drive disconnect,
attach the Danger label [Item #7] to the drive enclosure or cabinet door, ensuring that it is
prominently displayed.
Step 5. Wire your 115 VAC control devices to the 14Ćpin AĆC input connector [Item #3]. Refer to
figure 1.1 and table 4.1. Connect the 14Ćpin AĆC input connector to the mating connector on
the Control Option Board. If you are using control devices other than those listed in table
4.1, record the substitutions you are making.
For example, wire your motor thermostat relay, brush wear contacts, and run permissive
interlock in series with Interlock Input IN7 (AĆC input terminal 9) on the Control Option
Board and the Interlock Output (DĆC output terminal 7) to terminal EM on the MaxPak III
drive, removing wire 46 to EM. See figure 4.1 at the end of this section.
4Ć1
Table 4.1 Ć Control Option Board Wiring to a MaxPak III Drive (Example)
()
Control Option Board
MaxPak III
Control
Device
RUN ⇒ 2 (IN1) 1 ⇒ 34
STOP ⇒ 3 (IN2) 2 ⇒ 63
JOG ⇒ 4 (IN3) 3 ⇒ 61
REV/FWD ⇒ 5 (IN4) 4 ⇒ 39
NOT USED ⇒ 6 (IN5) 5 ⇒ NOT USED
COAST/STOP ⇒ 8 (IN6) 6 ⇒ 43
INTERLOCK (RUN PERM) ⇒ 9 (IN7) 7 ⇒ EM*
NOT USED ⇒ 10 (IN8) 8 ⇒ NOT USED
NOT USED ⇒ 12 (IN9) 9 ⇒ NOT USED
NOT USED ⇒ 13 (IN10) 10 ⇒ NOT USED
NOTE: 115V HI (L1) is at
inputs 1, 7, 11, 14.
Step 6. Connect the 12Ćpin connector on the cable assembly [Item #4] to the mating DĆC output
connector on the Control Option Board. Refer to figure 1.1 for location.
AĆC Input
Terminal
* Remove wire 46 to EM on MaxPak III terminal.
DĆC Output
Terminal
11 (+V) ⇒ Any available 24V
12 (GND) ⇒ 66 (IGND)
Control/Signal
Terminal
Step 7. Wire the other end of the cable assembly to the drive's control and signal terminals, using
the pullĆapart" terminal strips on the bottom of the drive. The ends of the wires are
numbered to correspond to the Control Option Board's DĆC Output Terminals, as listed in
table 4.1. Refer to your MaxPak III instruction manual for control and signal terminal
identification. Wire as shown in table 4.1 or to suit your application.
Step 8. Wire the +V terminal (pin 11) on the Control Option Board's DĆC connector to one of the
drive's +24V terminals. Any available +24V terminal (38, 40, 42, etc.) may be used. Refer to
your MaxPak III instruction manual for terminal identification.
Step 9. Wire the Control Option Board's ground (pin 12) to the drive's IGND (terminal 66).
Step 10. Route and secure the cable assembly away from power and 115 VAC control wiring. Loop
any excess cable as required.
Step 11. Remove the lockout and tag. Reconnect power to the drive and the 115 VAC source.
Step 12. Turn on power to the drive and check for proper drive operation.
This completes the installation of the Control Option Board for a MaxPak III drive.
4Ć2
Figure 4.1 Ć Control Signal Wiring to a MaxPak III Drive (Example)
4Ć3
Appendix A
115 VAC Control Option Board Circuitry
The Control Option Board circuitry consists of ten identical AĆC inputs which are optically coupled to DĆC
source outputs. One of the circuits is shown below in figure A.1. The incoming AĆC is limited by an 8.2K resisĆ
tor and rectified and dropped across a 2.4K resistor in series with 182 ohms. The 182 ohm resistor limits the
turnĆon voltage of the optical isolator. When the optical isolator is turned on, it sinks the input of the Source
Driver, which supplies a DĆC voltage at its output. The Source Driver internally drops a maximum of 2 volts
from the DĆC source voltage (VS).
SOURCE DRIVER
AC HI
AC LO
VS
.
8.2K 2W
01
2.4K 1W
1uF
182
GND
10K
7.2K
7.2K
3K
DC OUT
GND
Figure A.1 Ć 115 VAC Control Option Board Circuitry
AĆ1
Appendix B
Technical Specifications
Dimensions
D Height: 216 mm (8.5 in)
D Width: 9 mm (3.5 in)
D Depth: 8 mm (1.5 in) (with standoff)
Input Circuit
D Number of inputs: 10
D Maximum operating voltage: 140 VAC
D Nominal operating voltage 120 VAC
D Minimum turnĆon voltage: 65 VAC
D Maximum turnĆoff voltage: 50 VAC
D Input current at 120 V: 12 mA per input
D Total maximum input current: 120 mA @ 120 VAC
D Maximum turnĆon delay: 8.0 msec
D Maximum turnĆoff delay: 2.0 msec
D Maximum input wire length: 300 m (1000 ft)
D Inputs have a common L2 connection.
Output Circuit
D Number of outputs: 10
D Maximum operating voltage: 35 VDC
D Nominal operating voltage: 24 VDC
D Maximum current: (single channel): 500 mA
(all channels): 3 A
D Maximum leakage current: 100 µA
D Maximum onĆstate voltage drop: 2 V
D Maximum output wire length: 3.6 m (12 ft)
D Outputs have a common ground.
BĆ1
U.S. Drives Technical Support
Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives
Publication D2-3338 – May 1996 Copyright © 1996 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
Loading...