Rockwell Automation FlexPak 3000 DC Drive User Manual
FlexPak 3000 Digital DC Drive
Hardware Reference, Installation
and Troubleshooting
Ver sion 4.3
Instruction Manual
D2-3404-2
The information in this manual is subject to change without notice.
Throughout this manual, the following notes are used to alert you to safety considerations:
ATTENTION:Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
!
Important: Identifies information that is critical for successful application and understanding of the product.
The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to
signify new or revised text or figures.
ATTENTION:Only qualified electrical personnel familiar with the construction and operation of
this equipment and the hazards involved should install, operate, or service this equipment. Read
!
and understand this manual in its entirety before proceeding. Failure to observe this precaution
could result in severe bodily injury or loss of life.
ATTENTION:380/415 VAC-rated FlexPak drives can be configured for either 380 VAC or 415
VAC input power. Before input power is applied to the drive, verify that the control transformer
taps are set to match the input power. Follow the instructions provided in chapter 3 of this manual
to set the control transformer taps. Failure to observe this precaution could result in damage to,
or destruction of, the equipment
Reliance, FlexPak, AutoMax, and E.S.P. are trademarks of Rockwell Automation.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
©2004 Rockwell Automation. All rights reserved.
Chapter 1 Introduction to the FlexPak 3000 Drive
1.1 Store the Drive................................................................................................. 1-1
1.2 Drive Identification Nameplate......................................................................... 1-1
1.3 Model Numbers ...............................................................................................1-2
1.4 Drive Description .............................................................................................1-2
1.5 Additional Information......................................................................................1-3
1.6 Optional Kits ....................................................................................................1-4
1.7 Getting Assistance from Reliance Electric.......................................................1-5
Chapter 2 Install and Wire the Drive
2.1 Install the Drive - Panel Layout........................................................................ 2-1
2.2 Install a Transformer .. ...... ....... ...... ...... ....... ...... ....... ...... ....... ...... ......................2-8
2.3 Install an Input Disconnect .............................................................................. 2-8
2.4 Install the Motor...................................................... ...... ....... ...... ....... ...... .........2-9
2.5 General Wiring Practices.................................................................................2-9
2.5.1 Ground the Drive and Enclosure, the Motor and the Operator's
Control Station.......................................................................................2-9
2.5.2 Recommended Lugs ...........................................................................2-17
2.5.3 Wire AC Power to the Drive................................................................ 2-18
2.5.4 Wire the DC Motor to the Drive........................................................... 2-22
2.5.4.1 Wire Motor Overload Protection............................................2-27
2.5.5 Wire the Stop Input ............................................................................2-28
2.5.5.1 Wire the COAST/STOP Digital Input .................................... 2-29
2.5.5.2 Compliance with EN 60204-1: 1992 .....................................2-29
2.5.6 Wire Optional Devices to the Drive .....................................................2-32
2.5.6.1 Logic Inputs...........................................................................2-33
2.5.6.2 Logic Outputs........................................................................ 2-33
2.5.6.3 Analog Inputs........................................................................2-33
2.5.6.4 Analog Outputs .....................................................................2-33
CONTENTS
Contents
Chapter 3 Drive Setup and Adjustment
3.1 Perform a Power Off Inspection ...................................................................... 3-1
3.2 Verify Control Transformer Tap Settings......................................................... 3-1
3.2.1 Converting a Drive for 380 VAC Input Power........................................ 3-1
3.2.2 Converting a Drive for 230 VAC Input Power........................................ 3-2
3.3 Perform a Motor Ground Check ...................................................................... 3-3
3.4 Set Jumpers .................................................................................................... 3-4
3.4.1 Set the Regulator Type (Jumper J15)................................................... 3-5
3.4.2 Setting Program Protection (Jumper J16).............................................3-6
3.4.3 Set Field Loss Detection (Jumper J20)................................................. 3-7
3.4.4 Set the Drive for the Enhanced Field Supply (Jumper J21) .................. 3-7
3.4.5 Set the Source for the Manual Mode Reference (Jumper J19)............. 3-7
3.4.6 Set the Voltage Range and Scale of an Analog Tachometer
(Jumpers J14 and J11)..........................................................................3-8
3.4.7 Set the Analog Auto Mode Reference (Jumpers J12 and J10).............3-9
3.4.8 Scale the Armature Current Feedback (Jumper 18) .............................3-9
3.4.9 Inspect Jumper J26.................. ....... ...... ....... ...... ....... ...... ....... ...... .........3-9
3.4.10Inspect the Spare 1 Jumper (J27).........................................................3-9
3.4.11Inspect the Filter Select Jumper (J28)...................................................3-9
3.4.13Inspect the Power Unit Jumper (J30)..................................................3-10
3.5 Power Up the Drive ................ ...... ...... ....... ...... ....... ...... .................................3-10
I
3.6 Verify the Correct Direction of Motor Rotation ...............................................3-10
3.7 Determine the DC Tachometer Lead Polarity................................................3-11
3.8 Make Tachometer and Armature Feedback Zero Adjustments .....................3-11
3.9 Make Final Adjustments................................... ...... ........................................ 3 -12
Chapter 4 Troubleshooting/Diagnostics
4.1 Check for Wiring Errors....................................................................................4-1
4.2 Verify AC Line and Power Input.......................................................................4-1
4.3 Verify DC Motor Connections...........................................................................4-2
4.4 Verify Optional Kits...........................................................................................4-2
4.5 Check the Regulator LED Status.....................................................................4-3
Chapter 5 Replacement Parts
Appendix A Technical Specifications........................................................................................... A-1
Appendix B Compliance with European Union Electromagnetic Compatibility Standards..........B-1
Appendix C Recommended Parts for Integrator Drives...............................................................C-1
Appendix D Glossary Of Terms....... ...... ....... ...... ....... ...... ...... ....... ...... .........................................D-1
Index ...........................................................................................................................Index-1
II
FlexPak 3000 DC Drive Hardware Reference Version 4.3
List of Figures
Figure 1.1 – Sample FlexPak 3000 Nameplates...................................................... 1-1
Figure 1.2 – Model Number Structure ......................................................................1-2
Figure 1.3 – FlexPak 3000 Functional Block Diagram..............................................1-3
Figure 2.1 – Enclosure Mounting Minimum Clearance Distances............................ 2-1
Figure 2.2 – Drive Mounting Dimensions (1.5 to 30 HP @ 230 VAC /
3 to 60 HP @ 460 VAC / 7 to 110 Amp Rated Output) ........................2-2
Figure 2.3 – Drive Mounting Dimensions (40 to 75 HP @ 230 VAC /75 to 150 HP @
460 VAC / 265 Amp Rated Output)...................................................... 2-3
Figure 2.4 – Drive Mounting Dimensions
(100 to 150 HP @ 230 VAC / 200 to 300 HP @ 460 VAC)....................2-4
Figure 2.5 – Drive Mounting Dimensions (400 to 600 HP @ 460 VAC)...................2-5
Figure 2.6 – Integrator Drive Mounting Dimensions (1.5 to 30 HP @ 230 VAC /
3 to 60 HP @ 460 VAC) ......................................................................... 2-6
Figure 2.7 – Integrator Drive Mounting Dimensions (40 to 75 HP @ 230 VAC / 75 to
150 HP @ 460 VAC) ............................................................................ 2-7
Figure 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 Rated Output)................. 2-11
Figure 2.9 – Drive Control and Power Ground Point Locations (40 to 75 HP @
230 VAC /75 to 150 HP @ 460 VAC / 265 Amp Rated Output)...........2-12
Figure 2.10 – Drive Control and Power Ground Point Locations
(100 to 150 HP @ 230 VAC / 200 to 300 HP @ 460 VAC)...............2-13
Figure 2.11 – Drive Control and Power Ground Point Locations (400 to 600 HP @
460 VAC) ............................................................................................ 2-14
Figure 2.12 – Integrator Drive Control and Power Ground Point Locations
(1.5 to 30 HP @ 230 VAC / 3 to 60 HP @ 460 VAC) .........................2-15
Figure 2.13 – Integrator Drive Control and Power Ground Point Locations
(40 to 75 HP @ 230 VAC / 75 to 150 HP @ 460 VAC) ......................2-16
Figure 2.14 – AC Line Connection Location (1.5 to 30 HP @ 230 VAC 3 to 60 HP
@ 460 VAC / 7-110 Amp Rated Output) ............................................. 2-20
Figure 2.15 – AC Line Connection Location (40 to 75 HP @ 230 VAC /75 to
150 HP @ 460 VAC / 265 Amp Rated Output)................................... 2-20
Figure 2.16 – AC Line Connection Locations (100 to 150 HP @ 230 VAC /
200 to 300 HP @ 460 VAC) ............................................................... 2-21
Figure 2.17 – AC Line Connection Locations (400 to 600 HP @ 460 VAC)...........2-21
Figure 2.18 – DC Drive Motor Field and Armature Connection Locations
(1.5 to 30 HP @ 230 VAC /3 to 60 HP @ 460 VAC / 7-110 Amp
Rated Output) .................................................................................... 2-22
Figure 2.19 – DC Motor Field and Armature Connection Locations
(40 to 75 HP @ 230 VAC /75 to 150 HP @ 460 VAC / 265 Amp
Rated Output) .................................................................................... 2-23
Figure 2.20 – DC Motor Field and Armature Connection Locations
(100 to 150 HP @ 230 VAC / 200 to 300 HP @ 460 VAC)...............2-24
Figure 2.21 – DC Motor Field and Armature Connection Locations
(400 to 600 HP @ 460 VAC) ..............................................................2-25
Figure 2.22 – DC Motor Connections (CCW Rotation Facing Commutator
End Shown)........................................................................................2-26
Figure 2.23 – Drive Cover Removal .......................................................................2-29
Figure 2.24 – Sample Regulator Board Terminal Strip Connection Diagram......... 2-30
Contents
III
Figure 2.25 – Location of Regulator Board Terminal Strip......................................2-31
Figure 3.1 – Control Transformer Locations and Settings (380/415 VAC Drives) ....3-2
Figure 3.2 – Control Transformer Settings (230/460 VAC).......................................3-3
Figure 3.3 – Regulator Board Jumpers.....................................................................3-6
Figure 3.4 – AUTO REF Jumpers (J12 and J10)......................................................3-9
IV
FlexPak 3000 DC Drive Hardware Reference Version 4.3
List of Tables
Table 1.1 – Drive Modification Kits...........................................................................1-4
Table 2.1 – Chassis Ground Torgue Requirements............................................... 2-10
Table 2.2 – Recommended Lug Model and Part Numbers ....................................2-17
Table 2.3 – AC Line Torque Recommendations.....................................................2-19
Table 2.4 – Armature Terminal Torqure Recommendations ..................................2-27
Table 2.5 – User Device Connections to the Regulator Board Terminal Strip........ 2-32
Table 3.1 – Jumper Settings.....................................................................................3-5
Contents
V
VI
FlexPak 3000 DC Drive Hardware Reference Version 4.3
Introduction to the FlexPak 3000 Drive
The products described in this instruction manual are manufactured by Reliance
Electric Industrial Company.
1.1 Store the Drive
After receipt inspection, repack the drive in its original shipping container until ready
for installation. To ensure satisfactory operation at startup and to maintain warranty
coverage, store the drive as follows:
• In its original shipping container in a clean, dry, safe place.
• In an ambient temperature that does not exceed 65°C (149°F) or go below -30°C
(-22°F).
• Within a relative humidity range of 5 to 95% without condensation.
• Away from a corrosive atmosphere. In harsh environments, cover the shipping/
storage container.
• At an altitude of less than 3,000 meters (10,000 ft.) above sea level.
CHAPTER 1
1.2 Drive Identification Nameplate
The FlexPak 3000 drive has a nameplate on the left side of the chassis that identifies
the specific model number design, applicable AC input power and DC output power
data. Refer to the sample nameplate in figure 1.1. All communication concerning this
product should refer to the appropriate model number information.
Figure 1.1 – Sample FlexPak 3000 Nameplates
Introduction to the FlexPak 3000 Drive
1-1
1.3 Model Numbers
Drive specific data, such as horsepower (or output current), regenerative or nonregenerative type, line voltage, chassis or enclosure type, software version and UL
certification, can be determined by the drive model number. The model number
structure is shown in figure 1.2.
Up to 300 HP, drives configured for 460 VAC input can be converted to 230 VAC input
at one half the 460 VAC horsepower rating by installing a 460 to 230 Volt Conversion
Kit (M/N 916FK0100, 1-60 HP, or M/N 916FK0200, 75-150 HP). Instruction manual
D2-3329, which is supplied with the kit, provides installation instructions. For drives
above 300 HP, contact your local Reliance Electric sales office for assistance.
For horsepower-rated drives:
Horsepower under 1000
For current-rated drives:
Rated output armature current
F = FlexPak 3000 product line
B = Regenerative drives with inverting fault breaker
R = Regenerative drives
N = Non-regenerative drives
K = Kits
150FR4042
2 = 230 volts
3 = 380/415 volts
4 = 460 volts
7 = Integrator
8 = European Power Module
0 = Chassis
7 = Integrator
Software version number 0-9, A-Z
0 = No listing
1 = U/L and C-U/L
2 = U/L, C-U/L, and CE
1.4 Drive Description
The drive is a full-wave power converter without back rectifier, complete with a digital
current minor loop and a digital major loop for armature voltage or speed regulation by
tachometer feedback. Figure 1.3 shows a block diagram of the drive.
Figure 1.2 – Model Number Structure
1-2
FlexPak 3000 DC Drive Hardware Reference Version 4.3
The drive employs a wireless construction and uses a keypad for drive setup,
including parameter adjustments and unit selection, monitoring, and diagnostics.
Multiple language capability in English, French, German, Spanish, Italian and
‘Numeric Code' is available. Reference, feedback, and metering signals can be
interfaced to the drive. The drive can be controlled locally by the Operator Interface
Module (OIM) keypad or remotely by using the terminals at the regulator board
terminal strip. You can select one of the following active control sources using the
CONTROL SOURCE SELECT key:
•KEYPAD
• TERMBLK (regulator board terminal strip)
• NETWORK (if an optional network communication board is installed)
• SERIAL (CS3000).
1.5 Additional Information
Refer to the following publications as necessary for more information.
• D2-3405 FlexPak 3000 DC Drives Software Start-up and Reference Manual
• D2-3344 FlexPak 3000 Operator Interface Module (OIM) User Guide
• D2-3348 Control and Configuration Software (CS3000)
• D2-3412 DC Contactor Use with Integrator Drives
Introduction to the FlexPak 3000 Drive
Figure 1.3 – FlexPak 3000 Functional Block Diagram
1-3
1.6 Optional Kits
Reliance offers modification kits that broaden the application range of the drive. A
summary of these kits is presented in table 1.1. Not all kits can be used with all drive
model numbers. Refer to the Standard Drives and Control Products catalog (D-406)
for more information.
Table 1.1 – Drive Modification Kits
Name Description
Model
Number I/M Number
115 VAC Control
Interface
460 VAC to 230 VAC
Conversion Kit
AC Line Disconnect
Kit
AC Tachometer
Feedback Kit
AutoMax Network
Communication Board
Blower Motor Starter
Kit
DeviceNet
Communication Board
Converts customer-supplied 115 VAC signals to
24 VDC for operating a FlexPak 3000. Mounts
separately on the panel or can be mounted in the
bottom of a NEMA 1 enclosed drive.
Allows conversion of the 460 VAC FlexPak 3000
to a 230 VAC FlexPak 3000 at one-half the 460
VAC horsepower rating.
Allows the three-phase line to be disconnected at
the drive. Molded case switch that mounts on the
chassis of the drive or NEMA 1 enclosure.
Allows the FlexPak 3000 to accept feedback
signals from AC tachometers to a maximum
voltage of 275 VAC RMS.
Allows the FlexPak 3000 to communicate on the
Reliance AutoMax Distributed Control System
(DCS).
Provides a fused AC starter with adjustable
overload and interlocking for control of the threephase blower motor used to cool the DC motor.
Allows a FlexPak 3000 to communicate over the
open protocol DeviceNet network. Mounts inside
the FlexPak 3000 and includes terminals for
network connections. You cannot use the
AutoMax Network Communication board when
using the DeviceNet board.
917FK0101 D2-3338
916FK series D2-3329
901FK series D2-3292,
D2-3365 or
D2-3395
907FK0301 D2-3297
915FK0101 D2-3318
902FK series D2-3295
915FK1100 n/a
Drive Control
Configuration
Software for FlexPak
3000
ControlNet Network
Communication
Board
1-4
Windows-based software that allows the user to
connect any personal computer running
Microsoft Windows version 3.1 or later to a
FlexPak 3000 drive. Allows you to create, store,
upload, and download drive configurations. You
can also start and stop the drive, monitor and
change parameters through the PC, and read
and reset the drive's fault log.
Allows a FlexPak 3000 to communicate over the
ControlNet network.
FlexPak 3000 DC Drive Hardware Reference Version 4.3
2CS3000 D2-3348
915FK2101 D2-3425
Table 1.1 – Drive Modification Kits
Name Description
Model
Number I/M Number
Dynamic Braking Kit Provides the hardware, including braking grids,
needed to provide dynamic braking on stop.
Enhanced Field
Supply Kit
Field Current
Regulator Kit
I/O Expansion Board Mounts on the FlexPak 3000 chassis and gives
Inverting Fault Circuit
Breaker Kit
NEMA 1 Conversion
Kit
Operator Interface
Module (OIM) Remote
Mounting Kit
Provides electronic field trim, field economy , and
the ability to supply 240V field voltage and other
special voltages. This kit replaces the standard
field supply.
Provides field economy, as well as preweakening of the field using a fixed reference or
field weakening for above base speed operation.
Tachometer feedback is required with this kit.
This kit replaces the standard field supply.
the FlexPak 3000 additional analog, frequency,
and digital I/O capability.
This kit is an alternative to drives supplied with
inverting fault fuses.
Converts the standard chassis to a NEMA 1
enclosure.
Allows mounting of the OIM up to five meters
from the drive.
908FK,
909FK,
912FK, and
913FK series
923FK series D2-3413
911FK series D2-3336
914FK0101 D2-3301
906FK series D2-3300 or
904FK series D2-3299 or
905FK0101 D2-3294
D2-3313 or
D2-3374
D2-3330
D2-3331
Pulse Encoder
Feedback Kit
Allows for digital pulse encoder speed feedback. 907FK0101 D2-3302
1.7 Getting Assistance from Reliance Electric
If you have any questions or problems with the products described in this instruction
manual, con tac t y our local R elia nce Elec tric sale s off ice . F o r tech nic al assi sta nce , call
864-284-5444.
Introduction to the FlexPak 3000 Drive
1-5
1-6
FlexPak 3000 DC Drive Hardware Reference Version 4.3
Install and Wire the Drive
2.1 Install the Drive - Panel Layout
Minimum clearances must be maintained when the drive is mounted within a cabinet
as shown in figure 2.1. This allows adequate ventilation for the drive.
Regardless of these placement guidelines, the user is responsible for ensuring that
the drive's ambient temperature specification. See appendix A for more information.
Install the drive(s) in the cabinet. Refer to figures 2.2 through 2.7 for mounting
dimensions.
CHAPTER 2
Install and Wire the Drive
Figure 2.1 – Enclosure Mounting Minimum Clearance Distances
2-1
Figure 2.2 – Drive Mounting Dimensions (1.5 to 30 HP @ 230 VAC /
3 to 60 HP @ 460 VAC / 7 to 110 Amp Rated Output)
2-2
FlexPak 3000 DC Drive Hardware Reference Version 4.3
Figure 2.3 – Drive Mounting Dimensions (40 to 75 HP @ 230 V AC /
75 to 150 HP @ 460 VAC / 265 Amp Rated Output)
Install and Wire the Drive
2-3
Figure 2.4 – Drive Mounting Dimensions (100 to 150 HP @ 230 VAC / 200 to 300 HP @ 460 VAC)
2-4
FlexPak 3000 DC Drive Hardware Reference Version 4.3
Figure 2.5 – Drive Mounting Dimensions (400 to 600 HP @ 460 VAC)
Install and Wire the Drive
2-5
Figure 2.6 – Integrator Drive Mounting Dimensions (1.5 to 30 HP @ 230 VAC / 3 to 60 HP @ 460 VAC
2-6
FlexPak 3000 DC Drive Hardware Reference Version 4.3
Figure 2.7 – Integrator Drive Mounting Dimensions (40 to 75 HP @ 230 VAC / 75 to 150 HP @ 460 VAC)
Install and Wire the Drive
2-7
2.2 Install a Transformer
ATTENTION:If an input transformer is installed ahead of the drive, a
power disconnecting device must be installed between the power line
!
Input transformers step up or step down input voltage and can be either auto or
isolation transformer types. Users should consider using an isolation transformer
instead of an auto transformer for the following advantages:
• AC power line disturbances and transients are minimized by an isolation
transformer, thus reducing or eliminating possible damage to solid state
components.
• An isolation transformer provides electrical isolation for the drive from plant power
system grounds. Damaging currents may be avoided in instances where the DC
output is accidentally grounded or where the DC motor circuits are grounded.
and the primary of the transformer. If this power disconnecting device is
a circuit breaker, the circuit breaker trip rating must be coordinated with
the inrush current (10 to 12 times full-load current) of the input
transformer. Distribution system capacity above the maximum
recommended system KV A requires using an isolation transformer , a line
reactor, or other means of adding similar impedance. Failure to observe
this precaution could result in damage to, or destruction of, the equipment
ATTENTION: Connection of a drive to a transformer with a primary rating
of 2300 VAC or more may require additional input line conditioning.
Contact your local Reliance Electric sales/service office for assistance
when this is required. Failure to observe this precaution could result in
damage to, or destruction of, the equipment.
Refer to tables A.1 and A.6 for more information. Reliance offers a series of isolation
transformers suitable for use with the drive. Call you local Reliance Electric sales
office for assistance.
2.3 Install an Input Disconnect
ATTENTION:The NEC/CEC requires that an input disconnect be
provided in the incoming power line and either be located within sight of
!
Any fused disconnect or circuit breaker in the incoming AC line must accommodate a
maximum symmetrical AC fault current as indicated in Appendix A of this instruction
manual. Size the disconnect to handle the transformer primary current as well as any
additional loads the disconnect may supply.
Step 1. Install an input disconnect in the incoming power line according to the NEC/
Step 2. Wire this disconnect in the primary circuit of the drive isolation transformer (if
the drive or have provisions for a padlock. Install an input disconnect in
the incoming power line that is located within sight of the drive or that
has provisions for a padlock. Failure to observe this precaution could
result in severe bodi ly injury or loss of life.
CEC if not provided with the drive. The disconnect switch should be within
clear view of machine operator and maintenance per s onn el for easy access
and safety. An open-type switch with provisions for a padlock is
recommended.
used).
2-8
FlexPak 3000 DC Drive Hardware Reference Version 4.3
2.4 Install the Motor
Step 1. Verify that the motor is the appropriate rating to use with the drive.
Step 2. Install the DC motor in accordance with its installation instructions.
Step 3. Make sure that coupled applications have proper shaft alignment with the
driven machine or that belted applications have proper sheave/belt alignment
to minimize unnecessary motor loading.
Step 4. If the motor is accessible while it is running, install a protective guard around
all exposed rotating parts.
Step 5. Wire the motor to the drive. Refer to section 2.6.4, “Wire the DC Motor to the
Drive.”
2.5 Genera l Wiring Practices
ATTENTION:The user is responsible for conforming to the National
Electric Code (NEC/CEC) and all other applicable local codes. Wiring
!
The drive is designed for AC power entry and DC power exiting at the top and control
and signal wiring entering from the bottom.
practices, grounding, disconnects, and overcurrent protection are of
particular importance. Size and install all wiring in conformance with the
NEC/CEC and all other applicable codes. Failure to observe this
precaution could result in severe bodily injury or loss of life.
Reference signal wiring should be run in a separate conduit isolated from all AC and
DC power and control. Signal wires should not be run in parallel with high voltage or
electrically noisy conductors. Always cross such conductors at 90°. All reference
signals should be wired with either twisted double or twisted triple conductor wire, 2
twists per inch, stranded copper, AWG No. 16, 600 VAC rated, poly-vinyl chloride
insulation, with a temperature range of 40°C to 105°C (104°F to 221°F).
Tachometer feedback and other signal wiring should be run in a separate conduit
isolated from all AC and DC power and logic control. Wiring should be the same as for
the reference signals. For mounting with external contacts and solenoids, coils should
be suppressed to reduce noise.
Important: The maximum recommended wire length from the drive to the motor is
1000 feet.
2.5.1 Ground the Drive and Enclosure, the Motor and the Operator's
Control Station
You must ground both the control and power wiring.
Step 1. Locate the drive ground points as shown in figures 2.8 through 2.13.
Step 2. Run a suitable equipment grounding conductor unbroken from any drive
ground point (see step 1) to the plant ground (grounding electrode). A ring
lug is recommended at the ground point.
Install and Wire the Drive
Step 3. Connect a suitable grounding conductor from each conduit to this drive
ground point.
2-9
Step 4. Connect a suitable equipment grounding conductor to the motor frame, the
transformer enclosure if used, and the drive enclosure. Run this conductor
unbroken to the grounding electrode.
Step 5. Connect the GND (green/ground) wire brought in with the incoming AC
power line to the drive ground point.
Step 6. Tighten chassis ground connections per table 2.1.
Table 2.1 – Chassis Ground Torgue Requirements
Hardware Size Tightening Torque
M5 18 lb/in (2 Nm)
M6 33 lb/in (3.7 Nm)
M8 100 lb/in (11.3 Nm)
M10 200 lb/in (23 Nm)
Lug with 14-10 AWG 35 lb/in (4 Nm)
Lug with 8 AWG 40 lb/in (4.5 Nm)
Lug with 6-4 AWG 45 lb/in (5.1 Nm)
2-10
FlexPak 3000 DC Drive Hardware Reference Version 4.3
Figure 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 Rated Output)
Install and Wire the Drive
2-11
Figure 2.9 – Drive Control and Power Ground Point Locations (40 to 75 HP @ 230 VAC /
75 to 150 HP @ 460 VAC / 265 Amp Rated Output)
2-12
FlexPak 3000 DC Drive Hardware Reference Version 4.3
Figure 2.10 – Drive Control and Power Ground Point Locations
(100 to 150 HP @ 230 VAC / 200 to 300 HP @ 460 VAC)
Install and Wire the Drive
2-13
Figure 2.11 – Drive Control and Power Ground Point Locations (400 to 600 HP @ 460 VAC)
2-14
FlexPak 3000 DC Drive Hardware Reference Version 4.3
Figure 2.12 – Integrator Drive Control and Power Ground Point Locations (1.5 to 30 HP @ 230 VA C / 3 to 60 HP @ 460 VAC)
Install and Wire the Drive
2-15
Figure 2.13 – Integrator Drive Control and Power Ground Point Locations (40 to 75 HP @ 230 VAC / 75 to 150 HP @ 460 VAC)
2-16
FlexPak 3000 DC Drive Hardware Reference Version 4.3
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