Rockwell Automation FlexPak 3000 Drive Field Current Regulator User Manual

FlexPak 3000 Field Current Regulator Kit Installation Instructions

Instruction Manual

D2-3336-2

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, adjust, operate, or service this equipment.

Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:Do not install or remove modification kits with power applied to the drive. Disconnect and lock out incoming power before attempting such installation or removal. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: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.

FlexPak and Reliance are trademarks of Rockwell Automation.

CONTENTS

Chapter 1 Introduction

1.1 Related Publications........................................................................................1-3

1.2 Getting Assistance from Reliance Electric.......................................................1-3

Chapter 2 Installing the Field Current Regulator Kit on 1.5 - 30 HP @ 230 VAC and

3 - 60 HP @ 460 VAC Drives

2.1 Opening the Drive Cover and Carrier..............................................................2-1

2.2 Removing the Standard or Enhanced Field Supply Board..............................2-2

2.3 Installing the Field Current Regulator Board ...................................................2-2

2.4 Wiring the Field Current Regulator Board .......................................................2-2

2.5 Replacing the Drive Fuses ..............................................................................2-3

2.6 Replacing the Carrier and Drive Cover............................................................ 2-3

2.7 Modifying the Drive Configuration ................................................................... 2-3

Chapter 3 Installing the Field Current Regulator Kit on 40 - 75 Hp @ 230 VAC and

75 - 150 HP @ 460 VAC Drives

3.1 Opening the Drive Cover and Carrier, and Removing the AC Disconnect...... 3-2

3.2 Removing the Standard or Enhanced Field Supply Board..............................3-2

3.3 Installing the Field Current Regulator Board ...................................................3-2

3.4 Wiring the Field Current Regulator Board .......................................................3-3

3.5 Replacing the Drive Fuses ..............................................................................3-3

3.6 Reinstalling the Auxiliary Chassis Cover, Carrier and Drive Cover.................3-4

3.7 Modifying the Drive Configuration ................................................................... 3-4

Chapter 4 Installing the Field Current Regulator Kit on 100 - 150 HP @ 230 VAC and

200 - 300 HP @ 460 VAC Drives

4.1 Opening the Cover and Carrier ....................................................................... 4-2

4.2 Removing the Enhanced Field Supply Board.................................................. 4-2

4.3 Installing the Field Current Regulator Board ...................................................4-2

4.4 Wiring the Field Current Regulator Board .......................................................4-3

4.5 Reinstalling the OIM Carrier and Cover........................................................... 4-3

4.6 Replacing the Drive Fuses ..............................................................................4-3

4.7 Reinstalling the Drive Cover............................................................................4-3

4.8 Modifying the Drive Configuration ................................................................... 4-4

Chapter 5 Modifying the Drive Configuration

5.1 Setting Parameter 510 (MOTOR HOT FLD AMPS) ........................................ 5-2

5.2 Setting Parameter 511 (FIELD ECONOMY REF) ........................................... 5-4

5.3 Tuning the Field Curent Regulator ...................................... ...... ....... ...... ....... .. 5-5

Appendix A Field Current Regulator Description.....................................................................A-1

Contents

FlexPak 3000 Field Current Regulator Installation Instructions

List of Figures

Figure 1.1 – Field Current Regulator Board..............................................................1-2

Figure 1.2 – Cable Assemblies.................................................................................1-2

Figure 2.1 – Removing the Standard/Enhanced Field Supply..................................2-4

Figure 2.2 – Cable Routing (3 - 60 HP Drives)......................................................... 2-5

Figure 2.3 – Regulator Board Cable Connectors......................................................2-5

Figure 2.4 – Attaching Replacement Drive Fuse Labels (3 - 60 HP Drives)............. 2-6

Figure 3.1 – Removing the Standard/Enhanced Field Supply (75 - 150 HP Drives) 3-5

Figure 3.2 – Cable Routing (75 - 150 HPDrives)...................................................... 3-5

Figure 3.3 – Attaching Replacement Drive Fuse Labels (75 - 150 HP Drives).........3-6

Figure 4.1 – Removing the Standard/Enhanced Field Supply (200 - 300 HP Drives) 4-4

Figure 4.2 – Cable Routing (200 - 300 HP Drives)................................................... 4-4

Contents

III

FlexPak 3000 Field Current Regulator Installation Instructions

List of Tables

Table 1.1 – Verifying the Field Current Regulator Kit Matches the Drive ................. 1-1

Table 1.2 – Field Current Regulator Kit Contents.....................................................1-1

Contents

FlexPak 3000 Field Current Regulator Installation Instructions

CHAPTER 1

Introduction

This instruction manual describes how to install and configure the optional Field Current Regulator kits used by FlexPak which includes a field regulator and a field supply, can be used only in drives that have

software version 3.00 (

REGULAT O R SW VERSION parame ter = 3.00 ) or late r . W hen t he ki t

is installed, a field control loop is enabled, allowing the user to adjust field control functions. The field control loop operates in both the constant torque (armature control) range and the constant power (field control) range. See Appendix A for a description of the field control loop.

There are three Field Current Regulator kits available for use in FlexPak 3000 drives. They differ according to the maximum motor field current they support. Use the kit that provides the maximum motor field current required for your application. Note that using a Field Current Regulator with a higher amperage rating than is needed will decrease control resolution. Refer to table 1.1 to ensure you have the correct kit for your application and to table 1.2 for a list of the kit contents. See figures 1.1 and 1.2 for illustrations of the Field Current Regulator board and cable assemblies.

Table 1.1 – Verifying the Field Current Regulator Kit Matches the Drive

™ 3000 drives. The Field Current Regulator,

Field Current Regulator

Model Number

Maximum Motor

Field Current

911FK0041 4 A 911FK0101 10 A 911FK0151 15 A

Table 1.2 – Field Current Regulator Kit Contents

Part Number Description Quantity

707973-10R 707973-10S 707973-10T

1 2

Printed Circuit Board Assembly 1

64676-30M 25 A Fuse, UL Class CC, 600 V 3 179540 Fuse Rating Label 4

707973-12R 707973-12S

Cable Assembly 1 Cable Assembly 1

69306-3D Cable Tie Wrap 8 69752-146D Plug Cap 1 D2-3336-2 Instruction Manual 1

Kit M/N 911FK0041

Kit M/N 911FK0101

Kit M/N 911FK0151

Used for 3-60 HP @ 460 VAC drives

Used for 75-150 HP @ 460 VAC and 200-300 HP @ 460 VAC drives

Introduction

1-1

Top View

FLD P6 Connector

FLD P3 Connector

Side View

12-pin PCB C onnector (REG P25)

2 P

12-pin PCB C onnector (REG P25)

Figure 1.1 – Field Current Regulator Board

Part Number Label

FlexPak 3000 P/N 707973-12R

Part Number Label

FlexPak 3000 P/N 707973-12S

Figure 1.2 – Cable Assemblies

4-pin Square Connector (FL D P3 )

10-pin PCB Connector

(FL D P 6)

4-pin Square Connector (FL D P3 )

PIN-1

10-pin PCB Connector

(FL D P6 )

PIN-1

D L

1-2

FlexPak 3000 Field Current Regulator Installation Instructions

1.1 Related Publications

Refer to the following related publications as necessary for more information:

• D2-3404

• D2-3405

FlexPak 3000 DC Drive Hardware Reference Manual FlexPak 3000 Digital DC Drive Software Reference Manual

1.2 Getting Assistance from Reliance Electric

If you have any questions or problems with the products described in this instruction manual, contact your local Reliance Electric sales office. For technical assistance, call 1-800-726-8112.

Introduction

1-3

1-4

FlexPak 3000 Field Current Regulator Installation Instructions

CHAPTER 2

Installing the Field Current Regulator Kit

on 1.5 - 30 HP @ 230 VAC and

3 - 60 HP @ 460 VAC Drives

ATTENTION:Only qualified personnel familiar with the construction and

operation of this equipment and the hazards involved should install,

Installing the Field Current Regulator kit on 3 - 60 HP drives requires completing the following steps. When you have finished installing the kit, adjust the required drive parameters as described in chapter 5 before using the drive.

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.

ATTENT IO N:The drive is at line voltage when connected to incoming ac power. Disconnect, tag, and lockout all incoming power to the drive before performing the following procedure. Failure to observe this precaution could result in severe bodily injury or loss of life.

• Opening the cover and carrier

• Removing the Standard or Enhanced Field Supply board

• Installing the Field Current Regulator board

• Wiring the Field Current Regulator board

• Replacing the drive fuses

• Reinstalling the drive carrier and cover

• Modifying the drive configuration

These steps are descri bed in the following sections.

Installing the Field Current Regulator Kit on 1.5 - 30 HP @ 230 VAC and 3 - 60 HP @ 460 VAC Drives

2-1

2.1 Opening the Drive Cover and Carrier

ATTENTION:The drive contains ESD- (Electrostatic Discharge)

sensitive parts and assemblies. Static control precautions are required

Step 1. Turn off, lockout, and tag power to the drive. Step 2. Loosen the cover retaining screws and remove the cover. Step 3. Loosen the captive screw at the upper right corner of the drive’s Operator

when installing, testing, servicing, or repairing the drive. Erratic machine operation and damage to, or destruction of, equipment can result if this procedure is not followed. Failure to observe this precaution can result in bodily injury.

Interface Module (OIM) carrier and swing open the carrier.

2.2 Removing the Standard or Enhanced Field Supply Board

Step 1. Locate the Standard or Enhanced Field Supply board in the drive. See figure

2.1.

Step 2. Disconnect the drive’s wire harness connections from the existing field

supply board’s 581, 582, 583, F2/35 and F1/37 spade connectors. Follow the field supply board’s wire harness to the P4 connector on the Power Interface board. Unplug the harness from the P4 connector.

Step 3. Follow the field supply board’s wire harness to the P4 connector on the

Power Interface board. Unplug the harness from the P4 connector.

Step 4. Install the plug cap (P/N 69752-146D) on the Power Interface board’s P4

connector. See figure 2.1.

Step 5. Locate the field supply’s four mounting screws on the outside of the drive’s

right side panel.

Step 6. Remove the four mounting screws from the outside of the dive and remove

the field supply board.

2.3 Installing the Field Current Regulator Board

Step 1. Remove the four mounting screws from the back of the Field Current

Regulator assembly.

Step 2. Connect the wire harness connectors labeled 581, 582, 583, F2/35 and

F1/37 to the corresponding terminals on the Field Current Regulator board. See figure 1.1.

Step 3. Attach the Field Current Regulator cable assembly’s (P/N 707973-12R) FLD

P6 and FLD P3 connectors to the corresponding terminals on the Field Current Regulator board. See figure 1.1.

Step 4. Working from the inside of the drive, align the Field Current Regulator

board’s mounting holes with the mounting holes on the drive’s right side panel. See figure 2.2.

Step 5. Working from the outside of the drive, insert one of the mounting screws

(removed in step 1) through one of the mounting holes on the drive’s right side panel and into the corresponding mounting hole on the Field Current Regulator board.

Step 6. Repeat step 5 for the remaining three mounting holes.

2-2

FlexPak 3000 Field Current Regulator Installation Instructions

2.4 Wiring the Field Current Regulator Board

Step 1. The Operator Interface Module (OIM) or Drive Configuration Module (DCM)

must be removed to provide access to the Regulator board. Remove the screws that hold the OIM or DCM to the carrier, and remove the OIM/DCM.

Step 2. Remove the three screws that hold the Regulator board in place, and slide

the Regulator board slightly to the right.

Step 3. From the back of the carrier, push the end of the Field Current Regulator

cable assembly with the REG P25 connector through the opening in the carrier (above the ribbon cable). See figure 2.2.

Step 4. Connect the REG P25 connector to the J25 terminal on the Regulator board.

See figure 2.3.

Step 5. Slide the Regulator board back into place and secure it with its mounting

screws. Step 6. Reinstall the OIM/DCM. Step 7. Use the supplied cable ties to fasten the Field Current Regulator cable

assembly to the drive’s fan or support bar.

2.5 Replacing the Drive Fuses

Step 1. Remove the three fuses labeled 6FU, 7FU, and 8FU from the drive’s fuse

block. Step 2. Install the three provided 25 A, 600 V fuses (P/N 64676-30M) in the fuse

block in positions 6FU, 7FU, and 8FU. Step 3. Locate the replacement fuse table on the back of the carrier. Attach one of

the adhesive fuse rating labels (P/N 179540) over each of the places

indicated in figure 2.4.

2.6 Replacing the Carrier and Drive Cover

Step 1. Close the carrier and secure it in place with its captive screw. Step 2. Reinstall the drive cover and secure it in place with its screws. Step 3. Reconnect power to the drive. Hardware installation is complete. Step 4. Remove the lockout and tag. Step 5. Turn on power to the drive.

2.7 Modifying the Drive Configuration

Go to chapter 5 for information on setting parameters for the Field Current Regulator kit.

Installing the Field Current Regulator Kit on 1.5 - 30 HP @ 230 VAC and 3 - 60 HP @ 460 VAC Drives

2-3

Power I/F Board P4 Connector

FlexPak Wire Harness

Standard or Enhanced

Carrier

Figure 2.1 – Removing the Standard/Enhanced Field Supply

Field Supply

2-4

FlexPak 3000 Field Current Regulator Installation Instructions

Front View

Side View

Carrier

Fan

J25 Connector

Field Supply Attaching Screws

(Q ty 4)

FlexPak Wire

Harness

Field Current Regulator

Field Current Regulator Cable Assembly

Figure 2.2 – Cable Routing (3 - 60 HP Drives))

J6 Connector

Field Current Regulator Cable Assembly

J7 Connector

Figure 2.3 – Regulator Board Cable Connectors

Installing the Field Current Regulator Kit on 1.5 - 30 HP @ 230 VAC and 3 - 60 HP @ 460 VAC Drives

J5 Connector

2-5

Figure 2.4 – Attaching Replacement Drive Fuse Labels (3 - 60 HP Drives)

600V 25A

2-6

FlexPak 3000 Field Current Regulator Installation Instructions

CHAPTER 3

Installing the Field Current Regulator Kit

on 40 - 75 HP @ 230 VAC and

75 - 150 HP @ 460 VAC Drives

ATTENTION:Only qualified personnel familiar with the construction and

operation of this equipment and the hazards involved should install,

Installing the Field Current Regulator kit on 75-150 HP drives requires completing the following steps. When you have finished installing the kit, adjust the required drive parameters as described in chapter 5 before using the drive.

• Opening the cover and carrier

• Removing the Standard or Enhanced Field Supply board

• Installing the Field Current Regulator board

• Wiring the Field Current Regulator board

• Replacing the drive fuses

• Reinstalling the drive carrier and cover

• Modifying the drive configuration

These steps are descri bed in the following sections.

Installing the Field Current Regulator Kit on 40 - 75 HP @ 230 VAC and 75 - 150 HP @ 460 VAC Drives

3-1

3.1 Opening the Drive Cover and Carrier, and Removing the AC Disconnect

ATTENTION:The drive contains ESD- (Electrostatic Discharge)

sensitive parts and assemblies. Static control precautions are required

Step 1. Turn off, lockout, and tag power to the drive. Step 2. Loosen the drive cover retaining screws and remove the cover. Step 3. Loosen the captive screw at the upper right corner of the drive’s Operator

Step 4. Drives with an AC line disconnect only: Remove the four screws that

Step 5. Loosen the two screws at the right side of the motor terminal panel to free the

Step 6. Remove the top and bottom screws fastening the auxiliary chassis cover to

Step 7. Loosen the middle screw that fastens the auxiliary chassis cover/circuit

Interface Module (OIM) carrier and swing open the carrier. If the drive is equipped with an AC line disconnect, go to step 4. Otherwise, go to step 5.

fasten the AC line disconnect to the auxiliary chassis cover. Then, lift and remove the AC line disconnect from the auxiliary chassis cover. See figure

3.1.

tabs on the auxiliary chassis cover. Do not to remove the screws completely. See figure 3.1.

the drive’s right side panel.

breaker panel to the drive’s right side panel. Slightly swing out the auxiliary chassis cover and remove it.

3-2

3.2 Removing the Standard or Enhanced Field Supply Board

Step 1. Locate the Standard or Enhanced Field Supply board in the drive. See figure

3.1.

Step 2. Disconnect the drive’s wire harness connections from the existing field

supply board’s 581, 582, 583, F2/35 and F1/37 spade connectors.

Step 3. Follow the field supply board’s twisted-pair harness to the P4/S4 connectors.

Unplug the harness from the P4/S4 connector.

Step 4. Install the plug cap (P/N 69752-146D) on the drive control harness S4

connector.

Step 5. Remove the four (4) mounting screws from the outside of the drive’s right

side panel and remove the field supply board.

3.3 Installing the Field Current Regulator Board

Step 1. Remove the four (4) mounting screws from the back of the Field Current

Regulator board.

FlexPak 3000 Field Current Regulator Installation Instructions

Step 2. Connect the drive’s wire harness connectors labeled 581, 582, 583, F2/35

and F1/37 to the corresponding terminals on the Field Current Regulator board. See figure 1.1 for the location of the terminals.

Step 3. Attach the Field Current Regulator cable assembly (P/N 707973-12S) FLD

P6 and FLD P3 connectors to the corresponding terminals on the Field Current Regulator. See figure 1.1.

Step 4. Route the free end of the Field Current Regulator cable assembly under the

fuse block, through the grommet, and across the heat sink, to the left side of the drive following the same path as the red and blue control wiring harness. Then run the cable assembly inside the front of the drive to the OIM carrier. See figure 3.2.

Step 5. Working from the inside of the drive, align the Field Current Regulator

board’s mounting holes with the mounting holes on the drive’s right side panel.

Step 6. Working from the outside of the drive, insert one of the mounting screws

(removed in step 1) through one of the mounting holes on the drive’s right side panel and into the corresponding mounting hole on the Field Current Regulator board. Tighten the screw to hold the board in place.

Step 7. Repeat step 6 for the remaining three mounting screws.

3.4 Wiring the Field Current Regulator Board

Step 1. The Operator Interface Module (OIM) or Drive Configuration Module (DCM)

must be removed to provide access to the Regulator board. Remove the screws that hold the OIM (or DCM) to the carrier, and remove the OIM/DCM.

Step 2. Remove the three screws that hold the Regulator board in place, and slide

the Regulator board slightly to the right.

Step 3. From the back of the carrier, push the end of the Field Current Regulator

cable assembly with the REG P25 connector through the opening in the carrier (above the ribbon cable). See figure 3.2.

Step 4. Connect the REG P25 connector to the J25 terminal on the Regulator board.

See figure 2.3.

Step 5. Slide the Regulator board back into place and secure it with its mounting

screws. Step 6. Reinstall the OIM/DCM. Step 7. Use the supplied cable ties to fasten the Field Current Regulator cable

assembly to the drive control harness. See figure 3.2

3.5 Replacing the Drive Fuses

Step 1. Remove the three fuses labeled 6FU, 7FU, and 8FU from the drive’s fuse

block. Step 2. Install the three provided 25 A, 600 V fuses (P/N 64676-30M) in the fuse

block in positions 6FU, 7FU, and 8FU. Step 3. Locate the replacement fuse table on the back of the carrier. Attach one of

the adhesive fuse rating labels (P/N 179540) over each of the places

indicated in figure 3.3.

Installing the Field Current Regulator Kit on 40 - 75 HP @ 230 VAC and 75 - 150 HP @ 460 VAC Drives

3-3

3.6 Reinstalling the Auxiliary Chassis Cover , Carrier and Drive Cover

Step 1. Insert the tabs on the left side of the auxiliary chassis cover into the slots on

the right side of the drive’s motor terminal panel.

Step 2. Align the auxiliary chassis cover over the middle screw on the drive’s right

side panel and over the top and bottom mounting holes.

Step 3. Insert the top and bottom screws into the mounting screw holes and then

tighten all three mounting screws (top, bottom, and middle).

Step 4. Tighten the two screws on the right side of the motor terminal panel to secure

the auxiliary chassis cover’s tabs in place.

Step 5. Drives with an AC line disconnect only: Align the AC line disconnect over

the mounting holes on the auxiliary chassis cover, then secure it in place with

the four screws removed earlier. Step 6. Close the OIM carrier and secure it i n place with its captive screw. Step 7. Reinstall the drive cover and secure it in place with its screws. Hardware

installation is complete. Step 8. Reconnect power to the drive. Step 9. Remove the lockout and tag. Step 10. Turn on power to the drive.

3.7 Modifying the Drive Configuration

Go to chapter 5 for information on setting parameters for the Field Current Regulator kit.

3-4

FlexPak 3000 Field Current Regulator Installation Instructions

Motor Terminal Panel

Loosen screws

Remove 4 screws

Auxiliary Chassis Cover

Drive without AC D isconnect

Rem ove top and bo tto m scre w s ; loosen middle screw

Drive with Aux. Chassis Cover Removed

R e mo v e to p a n d bo tto m scre w s ; loosen middle screw

Drive with AC Disconnect

Field Supply

Figure 3.1 – Removing the Standard/Enhanced Field Supply (75 - 150 HP Drives)

Top View Front Vie w

Field Current

Regulator Cable

Assembly

Field Current Regulator Cable Assembly

Figure 3.2 – Cable Routing (75 - 150 HP Drives)

Field Current Regulator

Installing the Field Current Regulator Kit on 40 - 75 HP @ 230 VAC and 75 - 150 HP @ 460 VAC Drives

3-5

Figure 3.3 – Attaching Replacement Drive Fuse Labels (75 - 150 HP Drives)

600V 25A

3-6

FlexPak 3000 Field Current Regulator Installation Instructions

CHAPTER 4

Installing the Field Current Regulator Kit

on 100 - 150 HP @ 230 VAC and

200 - 300 HP @ 460 VAC Drives

ATTENTION:Only qualified personnel familiar with the construction and

operation of this equipment and the hazards involved should install,

Installing the Field Current Regulator kit on 200-300 HP drives requires completing the following steps. When you have finished installing the kit, adjust the required drive parameters as described in chapter 5 before using the drive.

• Opening the cover and carrier

• Removing the Enhanced Field Supply board

• Installing the Field Current Regulator board

• Wiring the Field Current Regulator board

• Replacing the drive fuses

• Reinstalling the drive carrier and cover

• Modifying the drive configuration

These steps are descri bed in deta il below.

Installing the Field Current Regulator Kit on 100 - 150 HP @ 230 VAC and 200 - 300 HP @ 460 VAC Drives

4-1

4.1 Opening the Cover and Carrier

ATTENTION:The drive contains ESD- (Electrostatic Discharge)

sensitive parts and assemblies. Static control precautions are required

Step 1. Turn off, lockout, and tag power to the drive. Step 2. Remove the plastic cover from the right side of the drive. Step 3. Loosen the two screws holding the OIM cover in place and remove the OIM

Step 4. Loosen the captive screw at the upper right corner of the OIM carrier and

Step 5. Locate the two plastic anchors holding the hinged mounting panel in place.

cover.

then swing the carrier open. Note that the screw is designed to stay attached

to the carrier when it is loosened; do not attempt to remove it.

Release the anchors by inserting the tip of a flat-bladed screwdriver into the

notch on the anchors and twist so the notch is vertical. Then swing the panel

open.

4.2 Removing the Enhanced Field Supply Board

Step 1. Locate the Enhanced Field Supply board. It is attached to the right side of the

drive, behind the line fuse panel, and can be accessed through the bottom of

the drive. See figure 4.1. Step 2. Remove the four field supply mounting screws from the outside of the drive’s

right side panel and remove the field supply. Step 3. Disconnect the drive’s wire harness from the field supply board’s 581, 582,

583, F2/35, and F1/37 connectors. Step 4. Follow the field supply board’s twisted-pair harness to the P4/S4 connectors.

Unplug the harness from the P4/S4 connector. Step 5. Install the plug cap (P/N 69752-146D) on the drive control harness S4

connector.

4.3 Installing the Field Current Regulator Board

Step 1. Remove the four (4) mounting screws from the back of the Field Current

Regulator board. Step 2. Connect the drive’s wire harness connectors labeled 582, 582, 583, F2/35,

and F1/37 to the corresponding terminals on the Field Current Regulator

board. See figure 1.1 for the location of the terminals. Step 3. Attach the Field Current Regulator cable assembly (P/N 707973-12S)

connectors FLD P6 and FLD P3 to the corresponding terminals on the Field

Current Regulator. Step 4. Route the free end of the Field Current Regulator cable assembly to the left

side of the drive and into the OIM carrier. Follo w the path illustrated in figure

4.2. This is the same path used by the control wiring harness.

4-2

FlexPak 3000 Field Current Regulator Installation Instructions

Step 5. Working from the inside of the bottom of the drive, align the Field Current

Regulator board’s mounting holes with the mounting holes on the drive’s right side panel. See figure 4.2.

Step 6. Working from the outside of the drive, insert one of the mounting screws

Step 7. Repeat step 6 for the remaining three mounting screws.

4.4 Wiring the Field Current Regulator Board

Step 1. The Operator Interface Module (OIM) or Drive Configuration Module (DCM)

must be removed to provide access to the Regulator board. Remove the screws that hold the OIM (or DCM) to the carrier, and remove the OIM/DCM.

Step 2. Remove the three screws that hold the Regulator board in place, then slide

the Regulator board slightly to the right.

Step 3. From the back of the OIM carrier, push the end of the Field Current Regulator

cable assembly with the REG P25 connector through the opening in the carrier (above the ribbon cable).

Step 4. Connect the REG P25 connector to the J25 terminal on the Regulator board.

See figure 2.3.

Step 5. Slide the Regulator board back into place and secure it with its mounting

screws.

Step 6. Reinstall the OIM/DCM.

4.5 Reinstalling the OIM Carrier and Cover

Step 1. Swing the mounting panel back into the closed position, and secure it by

twisting the notches on the two plastic anchors into a horizontal position. Step 2. Close the OIM carrier and secure it i n place with its captive screw. Step 3. Reinstall the OIM/DCM cover.

4.6 Replacing the Drive Fuses

Step 1. Locate the fuse block on the drive’s line fuse panel. See figure 4.2. Step 2. Remove the three fuses labeled 6FU, 7FU, and 8FU from the fuse block. Step 3. Install the three provided 25 A, 600 V fuses (P/N 65676-30M) in the fuse

block in positions 6FU, 7FU, and 8FU.

4.7 Reinstalling the Drive Cover

Step 1. Reinstall the cover over the right side of the drive. Step 2. Reinstall the plastic cover over the drive’s line fuse panel. Hardware

installation is complete. Step 3. Reconnect power to the drive. Step 4. Remove the lockout and tag. Step 5. Turn on power to the drive.

Installing the Field Current Regulator Kit on 100 - 150 HP @ 230 VAC and 200 - 300 HP @ 460 VAC Drives

4-3

4.8 Modifying the Drive Configuration

Go to chapter 5 for information on setting parameters for the Field Current Regulator kit.

Enhanced Field Supply Board

Figure 4.1 – Removing the Standard/Enhanced Field Supply (200 - 300 HP Drives)

Control Harness

Field Current Regulator Cable

4-4

Figure 4.2 – Cable Routing (200 - 300 HP Drives)

FlexPak 3000 Field Current Regulator Installation Instructions

Installing the Field Current Regulator Kit on 100 - 150 HP @ 230 VAC and 200 - 300 HP @ 460 VAC Drives

4-5

4-6

FlexPak 3000 Field Current Regulator Installation Instructions

CHAPTER 5

Modifying the Drive Configuration

Before you can use the Field Current Regulator kit, you must set the parameters listed below in the FlexPak 3000 drive. These parameters are described in sections 5.1 and

5.2.

• Parameter 510 (MOTOR HOT FLD AMPS)

• Parameter 511 (FIELD ECONOMY REF)

In addition, the input parameters listed below may need to be adjusted in order to tune the field control loop. Refer to your drive’s instruction manual for a complete description of these parameters.

• Parameter 501 (FIELD ECONOMY DELAY)

• Parameter 512 (FIELD LOSS THRESHOLD)

• Parameter 513 (FIELD REF REGISTER)

• Parameter 514 (FIELD PI PROP GAIN)

• Parameter 515 (FIELD PI LEAD FREQ)

• Parameter 516 (FLD FEEDBACK GAIN ADJ)

• Parameter 517 (FIELD AUTO WEAKEN)

• Parameter 518 (FLD WEAKEN THRESHOLD)

• Parameter 519 (FLD WEAKEN PROP GAIN)

• Parameter 520 (FLD WEAKEN LEAD FREQ)

• Parameter 587 (FIELD DELTA HIGH LIM)

• Once the Field Current Regulator kit is installed and the drive is configured, the

following output parameters can be used. Refer to your drive instruction manual for complete descriptions of these output parameters.

• Parameter 586 (FLD CURRENT REGULATOR)

• Parameter 588 (FIELD DELTA)

• Parameter 589 (FIELD FEEDBACK)

• Parameter 590 (FIELD REFERENCE)

If you are installing and setting up the Field Current Regulator kit as part of your initial drive setup, and are using the quick start procedure described in the drive’s instruction manual, you will be prompted for parameter 510 ( after you finish with the quick start procedure, make sure that you set parameter 511

FIELD ECONOMY REF).

(

MOTOR HOT FLD AMPS). In this case,

Modifying the Drive Configuration

5-1

If you are installing and setting up the Field Current Regulator kit after you have already set up the drive, you do not need to rerun the quick start procedure. Simply access the parameters and set the values as described in sections 5.1 and 5.2.

5.1 Setting Parameter 510 (MOTOR HOT FLD AMPS)

When the driv e is fir st pow ered up after inst allin g the Fiel d Current Regula tor , the F ield Current Regulator will operate in a fixed voltage mode until a valid value is entered for

MOTOR HOT FLD AMPS. This fixed voltage will produce 150 VDC on a 230 VAC line or

300 VDC on a 460 VAC line. If your motor field voltage is significantly less than this, begin with step 1. Otherwise, begin with step 7 if your drive is equipped with an OIM, or step 18 if your drive is equipped with a DCM.

If the motor field voltage is less than 150 VDC on a 230 V AC line or less than 300 VDC on a 460 VAC line, complete steps 1-6 first. Otherwise, go to step 9.

Step 1. Disconnect, tag, and lockout power to the drive. Step 2. Disconnect the motor field winding from the drive. Step 3. Reconnect power to the drive. Step 4. Remove the lockout and tag. Step 5. Turn on power to the drive. Step 6. After completing power-up diagnostics, the drive will generate a field current

loss fault. Ignore this fault.

Step 7. Access the Fault menu by pressing the FAULT key until FAULT appears on

the OIM directly above the FAULT key.

Step 8. Select Clear Fault Log and Reset Faults, and then press ENTER. The fault

log will be cleared and all drive faults will be reset.

If the drive is equipped with an OIM, complete the following steps to set MO TOR HOT FLD AMPS. Otherwise, go to step 18.

Step 9. Select

MOTOR HOT FLD AMPS by taking the following path from the main menu:

Field |____Field Current Regulator |____Field Loop Feedback Scaling

Step 10.Set

MOTOR HOT FLD AMPS to the value printed on the motor nameplate.

Step 11. Select MEMORY SAVE by taking the following path from the main menu:

Operator Interface |____Memory Operations

Step 12. Perform the Memory Save operation.

If the motor field winding was disconnected in step 2 above, perform steps 13-17. Otherwise, go to step 18.

Step 13. Disconnect, tag, and lockout power to the drive. Step 14. Reconnect the motor field winding to the drive. Step 15. Reconnect power to the drive.

5-2

Step 16. Remove the lockout and tag.

FlexPak 3000 Field Current Regulator Installation Instructions

Step 17. Turn on power to the drive. Step 18. Access the Fault menu by pressing the FAULT key until FA ULT appears on

the OIM directly above the FAULT key. Step 19. Select Clear Fault Log and Reset Faults, and then press ENTER. The fault

log will be cleared and all drive faults will be reset. If you have an OIM, you

are done with setting parameter 510. Go to section 5.1 to set parameter 511

FIELD ECONOMY REF).

( Important: Performing a Restore Defaults operation will cause the Field Current

Regulator to re-enter the fixed voltage mode of operation and require the re-execution of the above s teps.

If the drive is equipped with a DCM, use the following steps to set MOTOR HOT FLD AMPS.

Step 20. From the main menu, scroll to Input Parameters and press ENTER. Step 21. Scroll to

HOT FLD AMPS.

Step 22.Set

HOT FLD AMPS to the value printed on the motor nameplate.

Step 23. From the main menu, scroll to Memory Operations and press ENTER. Step 24. Scroll to Memory Save, and then perform the memory save operation.

If the motor field winding was disconnected in step 2 above, perform steps 25-29. Otherwise, proceed to step 30.

Step 25. Disconnect, tag, and lockout power to the drive. Step 26. Reconnect the motor field winding to the drive. Step 27. Reconnect power to the drive Step 28. Remove the lockout and tag. Step 29. Turn on power the drive. Step 30. Access the Fault menu and press ENTER. Step 31. Scroll to Clear Fault Log and Reset Faults, and then press ENTER. The fault

log will be cleared and all drive faults will be reset. Important: Performing a Restore Defaults operation will cause the Field Current

Regulator to re-enter the fixed voltage mode of operation and require the re-execution of the above s teps.

Modifying the Drive Configuration

5-3

5.2 Setting Parameter 511 (FIELD ECONOMY REF)

ATTENTION:Improper setting of the field economy ref parameter can

cause a motor overvoltage condition. Set the

parameter to the motor’s nameplate value. Make sure the

REF parameter and/or FIELD REF parame ter (P.513) are above the FIELD LOSS THRESHOLD parameter (P.512). Failure to observe this precaution

could result in bodily injury and damage to the equipment.

For proper drive operation, the value for parameter 511 (FIELD ECONOMY REF) must be set above the value for parameter 512 ( value for

THRESHOLD is 60% of MOTOR HOT FLD AMPS. Using the defaults for parameters 511 and

FIELD ECONOMY REF is 0% and that the default value for FIELD LOSS

FIELD LOSS THRESHOLD). Note that the default

512 will result in a drive fault.

MOTOR HOT FLD AMPS

FIELD ECONOMY

See your drive’s manual for more information on setting the

FIELD LOSS THRESHOLD

parameter properly. Then complete the following steps.

If the drive is equipped with an OIM, complete steps 1-6. If the drive is equipped with a DCM, skip to step 7.

Step 1. Select

FIELD LOSS THRESHOLD by taking the following path form the main

menu:

Field |____Field Current Regulator

|____Field Loop Configure Step 2. Note the value of Step 3. Back up to the Field Loop Configure menu and select Step 4. Set the value of

THRESHOLD.

FIELD LOSS THRESHOLD.

FIELD ECONOMY REF.

FIELD ECONOMY REF to a value higher than that of FIELD LOSS

Step 5. Select MEMORY SAVE by taking the following path from the main menu:

Operator Interface

|____ Memory Operations Step 6. Perform the Memory Save operation.

If the drive is equipped with a DCM, complete the following steps:

Step 7. From the main menu, scroll to Input Parameters and press ENTER. Step 8. Scroll to

FIELD LOSS THRESHOLD and note its value.

5-4

Step 9. Scroll to Step 10.Set the value of

THRESHOLD.

FIELD ECONOMY REF.

FIELD ECONOMY REF to a value higher than that of FIELD LOS S

Step 11. From the main menu, scroll to Memory Operations and press ENTER. Step 12. Scroll to Memory Save, and then perform the memory save operation.

The installation procedure for the Field Current Regulator kit is now complete.

FlexPak 3000 Field Current Regulator Installation Instructions

5.3 Tuning the Field Current Regulator

Important: Please review Appendix A for a complete description of the functions of

the field current regulator prior to proceeding with manual tuning.

In order to provide proper and responsive field current control the user may be required to modify the tuning parameters to meet the needs of the application. Adjustment of the field regulator tuning may be required to properly clamp and regulate the armature voltage at or above base speed motor operation.

Typically the regulator parameter settings should be adjusted so that the armature terminal transient voltage does not exceed 115% of the rated terminal volts when the motor is operated at or above base speed. Operation above base speed requires the use of an extended speed range rated motor.

Typical maximum armature transient voltage levels:

• 575 VDC for 500 VDC rated motor

• 275 VDC for 240 VDC rated motor.

Over voltage of the armature could result from:

• Speed overshoot above base speed of the motor during acceleration

• Acceleration into the extended speed range operation of the motor.

Note that steady state operating armature voltage levels should be rated voltage.

5.3.1 Verifying Proper Field Regulator Tuning

During initial setup of the drive and motor, the commissioning engineer should verify that the armature voltage is properly clamped during acceleration to motor base speed and beyond. The motor armature voltage should be monitored during acceleration. If the motor voltage exceeds the recommended levels during operation, the field regulator tuning may need to be adjusted.

Tuning Techniques:

The field current regulator can be tuned using the following PC-based software:

• The PC scope function of CS3000 or WebPak CS

• The OIM can provide a step field current reference to the field economy setpoint.

This parameter can be accessed via the OIM Field Current Regulator menu structure.

• Observe the actual field current response on the PC scope.

• If the response is over-damped (ie. slow reaction) then increase the field PI

proportional gain, P514 and/or field PI Lead Freq. P515 until proper response is achieved.

• If the response is under-damped (ie. overshoots setpoint ) then decrease the field PI

proportional gain, P514 and/or field PI Lead Freq. P515 until proper response is achieved.

Modifying the Drive Configuration

5-5

Typically, increasing P514 and P515 will increase the field weakening controller response. Decreasing the value of P514 and P515 will slow down the field weakening controller response.

After tuning the field regulator, verify that the proper field current regulation and armature voltage clamping occurs under all operating conditions. If the motor is to be operated in the extended speed range, the user may be required to adjust the parameters that relate to field weakening control P518, P519 & P520.

To obtain the proper field and armature voltage response, adjustments may need to be made to the following parameters:

• P512 FIELD LOSS THRESHOLD

• P514 FIELD PI PROP GAIN

• P515 FIELD PI LEAD FREQ

• P518 FIELD WEAKEN THRESHOLD

• P519 FIELD WEAKEN PROP GAIN

• P520 FIELD WEAKEN LEAD FREQ

5-6

FlexPak 3000 Field Current Regulator Installation Instructions

APPENDIX A

Field Current Regulator Description

Description of the Field Control Loop

The FlexPak 3000 version 3 regulator will detect the presence of the Field Current Regulator kit at power-up. The output parameter whether or not the Field Current Regulator kit is in-stalled. When t he Field Current Regulator kit is installed, the field current control loop operates and drive parameters

ENHANCED FLD VOLT ADJ and J21 FLD SUPPLY JUMPER are ignored. The regulated field

loss and field economy circuits become active in place of those used by the standard and enhanced field supplies. See figure A.1 for a block diagram of the field control loop.

FLD CURRENT REGULATOR indicates

Important: The regulator board jumper J20 (

Field Current Regulator is in-stalled. Therefore, setting J20 to the DISABLE position will NOT disable field loss detection.

The field control loop contains two regulators: a field current regulator and an armature voltage (counter-EMF or CEMF) regulator. The field control loop can be configured to decrease armature voltage when the armature voltage feedback

ARMATURE VOLTAGE) exceeds the FLD WEAKEN THRESHOLD voltage and the field begins

( to weaken (see figures A.1 and A.2). The armature IR drop can be compensated for by using the

The output of the Field Current Regulator determines the firing angle of the regulated field supply gate firing circuit. The output parameter in degrees. If the factory defaults for the Field Current Regulator are in effect, it will

operate in a fixed voltage mode by firing the field SCRs at a fixed angle of 117º. This will produce a field voltage of 150 VDC at 230 VAC line input or 300 VDC at 460 VAC line input. For other motor field voltages, before the motor field is connected. While the Field Current Regulator is producing fixed voltage, the value for value is entered for

THRESHOLD becomes effective. The Field Current Regulator will NOT regulate field

current until a valid value for mode, a field loss fault will only occur if there is a complete loss of field current. This is similar to having a standard or enhanced field supply installed.

IR COMPENSATION parameter (P.206).

MOTOR HOT FLD AMPS will be set to 0.01 amps. After a valid

MOTOR HOT FLD AMPS, the user-assigned value for FIELD LOSS

MOTOR HOT FLD AMPS is entered. While in fixed voltage

ATTENTION:If the factory defaults for the Field Current Regulator are not in effect (e.g., CS3000), extreme care must be exercised to ensure the correct value

MOTOR HOT FLD AMPS is present when power is applied to the drive.

for Failure to observe this precaution could result in damage to, or destruction of, the equipment.

MOTOR HOT FLD AMPS was modified via the network or

FIELD LOSS DETECT) is ignored when the

FIELD DELTA represents the angle

MOTOR HOT FLD AMPS must be set properly

Field Current Regulator Description

A-1

Both field loop regulators contain proportional plus integral (PI) control. There is no user-configurable low limit parameter associated with these PI blocks. The low limit is always fixed at zero. The high limit (

FIELD DELTA HI LIM) is user-configurable up to 180

degrees, allowing full-on field voltage of 207 VDC @ 230 VAC and 414 VDC @ 460 VAC. To regulate greater field voltages, a step-up transformer must be used to supply the AC side of the Field Current Regulator.

As the motor speed increases beyond base speed, the armature voltage will increase above rated voltage. The PI block monitoring armature voltage will reduce the high limit of the PI block controlling field current. As field current decreases, field flux and armature voltage will also decrease. Field current continues to decrease until armature volt-age is reduced to voltage during field weakening is only permitted when a tachometer is used (

SELECT ≠ ARMATURE VOLTS). Automatic field weakening can be disabled by setting FIELD AUTO WEAKEN = DISABLED. The drive can also be operated in the constant power

(field control) range by controlling the field current reference exclusively (

FLD WEAKEN THRESHOLD volts. Control of armature

FEEDBACK

FIELD REF

A-2

FlexPak 3000 Field Current Regulator Installation Instructions

Field Current Regulator Description

FIELD REF REGISTER

MOTOR H OT FLD AM P S

MOTOR HO T FLD AM PS

FIELD ECONOMY REF

GAIN

MUL DIV

Field Current Regulator

FIELD PI PROP GAIN

(FIELD ECONOMY AC TIVE)

OFF

100

(FIELD REFERENCE)

(FIELD FEEDBACK)

FIELD PI LEAD FREQ

KP WLD

LO HI

(FIELD DELTA)

Field Phase Firing Logic

FIELD REGULATOR SUPPLY

A-3

Figure A.1 – Field Control Loop

FIELD CURRENT FEEDBACK

FLD WEAKEN THRESHOLD

MOTOR R ATED ARM AMPS

(ARMATURE VOLTAGE)

(CML FEEDBACK) 8 Sample Average

A/D

SOFTWARE

SCALING

IR COMPENSATION

SOFTWARE

SCALING

IR COMPENSATION

So ftwa re

Sc a lin g

MOTOR HO T FLD AM PS

ABS

GAIN

MUL

FLD FEEDBACK GA IN A DJ

FLD WEAKEN PRO P G A IN

FIELD DELTA HI LI M

WLDKP

FLD WEAKEN LEAD FREQ

FIELD DELTA HI LI M

(note 1)

Armature Voltage (Cemf) Regulator

Note 1: Field Auto Weaken Is Clamped To Disabled W h e n F e e d b a c k Se le c t = A rmature V o lt

Inp u t p a ra meters a re s h own U P P ERCAS E . Output parameters are shown (UPPE RC ASE ).

FIELD AUTO WEAKEN

ENABLED

DISABLED

Figure A.2 – Drive Operation Over the Constant Torque and Constant Power Range

Field Current Feedback Scaling

There are three Field Current Regulator ratings: 4 amps, 10 amps, and 15 amps. The Regulator board hardware provides three different gains for the field current feedback signal: 1, 2, and 5. The user must enter the motor nameplate value for rated field

MOTOR HOT FLD AMPS) to properly scale the feedback signal. The software will

amps ( automatically select the feedback gain (in hardware) which produces the largest full scale digital value in the analog-to-digital converter.

MOTOR HOT FLD AMPS will be

limited based on the rating of the Field Current Regulator kit installed. T ab le A.1 shows what the software will select as the feedback gain depending on motor hot field amps.

Table A.1 – Field Current Feedback Scaling

Field Current

Filed Current

Rating (Amps)

4 0.11 to 0.8

10 0.28 to 2.00

15 0.55 to 4.00

Motor Hot F ield

Amps Gain

0.81 to 2.00

2.01 to 4.00

2.01 to 5.00

5.01 to 10.00

4.01 to 10.00

10.1 to 20.00

Rated Output

(Amps)

5 2 1

0.8 2 4

2 5

10 15

Resolution (milliamps)

4 10 20

10 25 50

20 50

100

A-4

FlexPak 3000 Field Current Regulator Installation Instructions

Field Loss

When the Field Current Regulator is operating in fixed voltage mode, a field current loss fault will be generated only when there is a complete loss of field current. When the Field Current Regulator is regulating field current (that is, not in fixed voltage mode), a field current loss fault will be generated when the field current drops below the user-set

FIELD LOSS THRESHOLD.

The same field feedback signal used by the Field Current Regulator is used by the field loss detection circuit. The field current feedback will be compared against a user-entered fault will be generated.

MOTOR HOT FLD AMPS (0-100% (speed regulator), 50-100% (armature voltage

regulator)).

FIELD LOSS THRESHOLD. If the feedback is less than the threshold value, a

FIELD LOSS THRESHOLD is entered as a percentage of

FIELD ECONOMY REF must be s et abo v e FIEL D LOSS THRESHOLD to av oid field

loss faults when the drive enters field economy. A field loss fault will also occur if the digital value on the A/D converter reaches full

scale (approximately 28% above the rated field output). The Regulator board hardware jumper, J20

FIELD LOSS DETECT, is designed to allow

the user to separately excite the motor field winding, and is not intended as a means of bypassing field loss detection when using an internal field supply. Therefore, when the Field Current Regulator kit is installed, this jumper is ignored. Note that leaving J20 in the DISABLE position will NOT disable field loss detection.

Field Economy

The output parameter Field economy becomes active after a user-defined time delay (

FIELD ECONOMY ACTIVE indicates when field economy is active.

FIELD ECONOMY DELAY)

from the time the motor stops or the drive is powered up. When the Field Current Regulator is operating in fixed voltage mode, a constant field voltage is generated, regardless of the state of

FIELD ECONOMY ACTIVE.

The Field Current Regulator will provide field economy with a user-adjustable field current reference (

MOTOR HOT FLD AMPS. FIELD ECONOMY REF m ust be set above FIELD LOSS THRESHOLD to

FIELD ECONOMY REF). This parameter is entered as a percentage of

avoid nuisance field loss faults.

Overspeed Protection

Overspeed detection is active only when a tachometer is being used (

SELECT ≠ ARMATURE VOLT). Because of this, the amount of field weakening is limited

when the drive is configured as a voltage regulator (

VOLT).

FEEDBACK SELECT = ARMATURE

FEEDBACK

Overvoltage Protection

Armature overvoltage protection is always active, regardless of the type of feedback. This will reduce the chance of overvoltaging the armature due to a weakened field. An overvoltage fault will occur when the armature terminal voltage exceeds 130 percent of

Field Current Regulator Description

MOTOR RATED ARM VOLTS.

A-5

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

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Rockwell Automation FlexPak 3000 Drive Field Current Regulator User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual