Rockwell Automation FlexPak 3000 Power Module User Manual

FlexPak 3000 Power Module SW-Version 4.3

Instruction Manual

Europe North America Manual Part No: 899.07.41 D2-3475-1 Firmware Part No: 790.30.72

Publication: FP3OIM-UM043M-EN

Table of Contents

1.0 General Notes

1.1 Safety Instructions....................................................................................................... 1-1

1.2 General Notes............................................................................................................. 1-2

1.3 Manual Scope..............................................................................................................1.2

1.4 Related Documentation................................................................................................1-2

2.0 Introduction to the Drive 2-1..2-15

2.1 Drive Identification ...................................................................................................... 2-1

2.1.1 Nameplate ....................................................................................................... 2-1

2.1.2 Drive Selection ................................................................................................ 2-1

2.2 Drive Specifications..................................................................................................... 2-2

2.2.1 AC-Line Considerations................................................................................... 2-2

2.2.2 Service Conditions........................................................................................... 2-2

2.2.3 Input Voltage and Frequency Ratings............................................................. 2-3

2.2.4 Regulator Supply ............................................................................................ 2-3

2.2.5 Relay Output.................................................................................................... 2-3

2.2.6 DC Voltage Ratings......................................................................................... 2-3

2.2.7 Regulation (with 95% load change)................................................................. 2-4

2.2.8 Speed Range................................................................................................... 2-4

2.2.9 Drive Efficiency................................................................................................ 2-4

2.2.10 Displacement Power Factor, Power Loss, Output Current.............................. 2-4

2.3 Drive Input/Output Specifications................................................................................ 2-5

2.3.1 Logic Inputs..................................................................................................... 2-5

2.3.2 Logic Outputs .................................................................................................. 2-5

2.3.3 Analog Inputs................................................................................................... 2-5

2.3.4 Analog Outputs................................................................................................ 2-6

2.4 Drive Description......................................................................................................... 2-7

2.5 Controls/Indicators...................................................................................................... 2-9

2.5.1 Indicators......................................................................................................... 2-9

2.5.2 Controls......................................................................................................... 2-10

3.0 Install and Wire the Drive 3-1...3-18

3.1 General ....................................................................................................................... 3-1

3.2 Recommended AC Line and DC Armature Fuses ...................................................... 3-1

3.3 Install the Drive, Dimensions....................................................................................... 3-1

3.4 Install a Transformer (If needed)................................................................................. 3-8

3.5 Install an Input Disconnect - Guidelines...................................................................... 3-8

3.6 Install the Motor........................................................................................................... 3-9

3.7 General Wiring Practices ............................................................................................ 3-9

3.8 Wire the Drive ........................................................................................................... 3-10

3.8.1 Ground the Drive, the Motor and the Operator's Control Station................... 3-10

3.8.2 Wire AC Power to the Drive........................................................................... 3-10

3.8.3 Wire the DC Motor to the Drive...................................................................... 3-10

3.8.3.1 Motor Overload Protection ............................................................ 3-10

3.8.4 Main Contactor ............................................................................................. 3-10

3.8.5 Emergency Stop Function............................................................................. 3-11

3.8.6 Stopping Modes............................................................................................. 3-11

3.8.6.1 COAST-STOP Digital Input........................................................... 3-11

3.8.6.2 STOP Digital Input......................................................................... 3-11

3.8.6.3 Interlock Digital Input..................................................................... 3-11

3.8.7 Wire User Devices to the Drive ..................................................................... 3-11

49’1340 e FlexPak 3000

TABLE OF CONTENTS

4.0 Drive Setup and Adjustment 4-1...4-16

4.1 General....................................................................................................................... 4-1

4.2 Test Equipment Needed............................................................................................. 4-1

4.3 Power Off Inspection................................................................................................... 4-1

4.4 Motor Ground Check................................................................................................... 4-1

4.5 Jumper Settings.......................................................................................................... 4-2

4.5.1 Set Regulator Type - J15 Jumper ................................................................... 4-3

4.5.2 Set Program Disable/Enable (OIM PROGRAM) - J16 Jumper....................... 4-4

4.5.3 Set Field Loss Enable/Disable (FIELD LOSS DETECT) - J20........................ 4-4

4.5.4 Set Tacho Loss / Open Arm. Enable/Disable (TACHO LOSS DET) - J26 ..... 4-4

4.5.5 Field Supply Jumper Connection (FIELD SUPPLY) - J21............................... 4-5

4.5.6 Manual Reference (MANUAL REF) - J19 Jumper .......................................... 4-5

4.5.7 Tachometer Voltage Range/Scale (TACH V RANGE/SCALE) - J14 / J11...... 4-5

4.5.8 Analog Auto Reference (AUTO REF) - J12 and J10 Jumpers........................ 4-6

4.5.9 Armature Current Feedback Scaling (ARM I FB RB) - J18 Jumper................ 4-6

4.5.10 Check position of the FILTER SELECT - J28 Jumper ................................... 4-6

4.5.11 Check position of the POWER INTERFACE- J30 Jumper.............................. 4-6

4.6 Powering Up the Drive................................................................................................ 4-7

4.7 OIM Screen Contrast Adjustment............................................................................... 4-7

4.8 About the Main Menu.................................................................................................. 4-8

4.9 How to Access the Menus/Parameters....................................................................... 4-8

4.10 Verify the Correct Direction of Motor Rotation.......................................................... 4-10

4.11 Determination of DC Tachometer Lead Polarity....................................................... 4-10

4.12 Adjustments.............................................................................................................. 4-10

4.12.1 Perform Armature Voltage Zero Adjust....................................................... 4-11

4.12.2 Perform Analog Tachometer Zero Adjust.................................................... 4-11

4.13 Language Selection.................................................................................................. 4-11

4.14 Programming Features............................................................................................. 4-12

4.14.1 Password (PASSWORD) .............................................................................. 4-12

4.14.2 How to Enable/Disable Program Protection.................................................. 4-13

4.14.3 Memory Operations....................................................................................... 4-13

4.14.4 Reset Clock................................................................................................... 4-14

4.14.5 Define User Units.......................................................................................... 4-14

4.14.5.1 Define Speed Units....................................................................... 4-14

4.14.5.2 Define Load Units.......................................................................... 4-16

5.0 How to Change Parameter Values 5-1..5-4

5.1 Introduction................................................................................................................. 5-1

5.2 Integer Value Entry Screen......................................................................................... 5-1

5.3 Standard Choice Integer Value Entry Screen............................................................. 5-2

5.4 Selector Switch or Boolean Value Entry Screen......................................................... 5-4

6.0 Quick Start 6-1..6-10

6.1 Introduction................................................................................................................. 6-1

6.2 About the Quick Start Exit Menu................................................................................. 6-1

6.3 How to Step through Quick Start................................................................................. 6-1

6.4 Self Tuning.................................................................................................................. 6-7

6.4.1 Self Tune Setup............................................................................................ 6-7

6.4.2 Execute Self Tuning...................................................................................... 6-8

6.5 Final Adjustments...................................................................................................... 6-10

6.5.1 Nominal A-C Line Adjustments...................................................................... 6-10

6.5.1.1 Perform Nominal AC-Line Frequency Adjust................................... 6-10

6.5.1.2 Perform Nominal AC-Line Volts Adjust............................................ 6-10

FlexPak 3000 49’1340 e

TABLE OF CONTENTS

7.0 Troubleshooting/Diagnostics 7-1..7-8

7.1 General ....................................................................................................................... 7-1

7.2 Wiring Errors............................................................................................................... 7-1

7.3 AC Line and Power Input............................................................................................ 7-1

7.4 DC Motor..................................................................................................................... 7-1

7.5 Remote M Contactor................................................................................................... 7-2

7.6 Optional Kits................................................................................................................ 7-2

7.7 Fault/Alarm/Diagnostic (FAD) Menus.......................................................................... 7-2

7.7.1 About The Fault Menu..................................................................................... 7-2

7.7.1.1 Review Log........................................................................................ 7-2

7.7.1.2 Reset Faults....................................................................................... 7-3

7.7.1.3 Clear Fault Log and Reset Faults...................................................... 7-3

7.7.2 About the Alarm Menu..................................................................................... 7-3

7.7.2.1 Review Log........................................................................................ 7-4

7.7.2.2 Reset Alarm Indicator........................................................................ 7-4

7.7.2.3 Clear Alarm Log and Reset Alarms................................................... 7-4

7.7.3 Diagnostics Menu............................................................................................ 7-5

7.7.4 Diagnostics Configure ..................................................................................... 7-5

7.7.5 Regulator LED Status Information................................................................... 7-6

7.7.6 Phase Firing Test Mode .................................................................................. 7-7

7.7.7 Power Supply Test Pin Identification............................................................... 7-8

8.0 Replacement Parts and Accessories 8-1..8-21

8.0 Replacement of Components...................................................................................... 8-1

8.1 Recommended Spare Parts........................................................................................ 8-3

8.2 Accessories................................................................................................................. 8-6

Appendices

Appendix A

Glossary of Terms ................................................................................................................ A-1...A-2

Appendix B

FlexPak 3000 User Input Parameters ................................................................................. B-1..B-52

Appendix C

FlexPak 3000 User Output Parameters ............................................................................ C-1...C-12

Appendix D

Index Block Diagrams.................................................................................................................... D-I

Block Diagrams................................................................................................................... D-1..D-14

Appendix E

Program Error Messages and Fault and Alarm Codes......................................................... E-1...E-8

Appendix F

OIM Parameter Menu Tree................................................................................................... F-1...F-8

Appendix G

User Quick Reference Table ............................................................................................... G-1...G-8

Appendix H

CE-Conformity..................................................................................................................... H-1...H-4

Appendix J

Cross Reference Part Numbers – Catalogue Numbers........................................................ J-1...J-2

49’1340 e FlexPak 3000

III

TABLE OF CONTENTS

List of Figures

Figure 2.1 - FlexPak 3000 Functional Block Diagram ............................................................... 2-7

Figure 2.2 - Operator Interface Module (OIM)........................................................................... 2-9

Figure 3.1 - Mounting Dimensions for FlexPak 3000, 25 and 60 A........................................ 3-2

Figure 3.2 - Mounting Dimensions for FlexPak 3000, 150 A.................................................... 3-3

Figure 3.3 - Mounting Dimensions for FlexPak 3000, 250 and 450 A...................................... 3-4

Figure 3.4 - Mounting Dimensions for FlexPak 3000, 800 A.................................................... 3-5

Figure 3.5 - Mounting Dimensions for FlexPak 3000, 1200 and 1600 A.................................. 3-6

Figure 3.6 - Mounting Dimensions for FlexPak 3000, 2000 A.................................................. 3-7

Figure 3.8a - CTB Connection Diagram - Example................................................................... 3-12

Figure 3.8b - Main Contactor Connection Diagram - Example.................................................. 3-13

Figure 3.9/10 - Principle Wiring Diagram, 150 A..................................................................... 3-14

Figure 3.11/12 - Principle Wiring Diagram, 1600 A.................................................................... 3-16

Figure 4.1 - Regulator Board Jumpers ...................................................................................... 4-3

Figure 4.2 - AUTO REF Jumpers .............................................................................................. 4-6

Figure 5.1 - Integer Value Entry Screen................................................................................... 5-1

Figure 8.2 - AC-Line Choke Dimensions................................................................................ 8-10

Figure 8.3 - HF Filter Dimensions........................................................................................... 8-11

Figure 8.4 to 8.12 - RFI-Filter Dimensions ................................................................................ 8-13

Figure D.1 - Drive Control Signals............................................................................................. D-1

Figure D.2 - Speed Reference Overview .................................................................................. D-2

Figure D.3 - Speed Reference Source Select........................................................................... D-3

Figure D.4 - Speed Reference Ramp........................................................................................ D-4

Figure D.5 - Speed Reference Mode Select ............................................................................. D-5

Figure D.6 - Speed Loop........................................................................................................... D-6

Figure D.7 - Digital and Analog Outputs.................................................................................... D-7

Figure D.8 - Meter Outputs........................................................................................................ D-8

Figure D.9 - Current Minor Loop Reference.............................................................................. D-9

Figure D.10 - Current Minor Loop ............................................................................................. D-10

Figure D.11 - Field Block........................................................................................................... D-11

Figure D.12 - Outer Control Loop.............................................................................................. D-12

Figure D.13 - I/O Expansion Board Inputs ................................................................................ D-13

Figure D.14 - Level Detectors ................................................................................................... D-14

Figure H.1 - Cabinet Configuration............................................................................................ H-3

Figure H.2 - Specification for screened cable ........................................................................... H-4

List of Tables

Table 1.1 - Related Documentation.......................................................................................... 1-2

Table 2.1 - Armature Voltage ................................................................................................... 2-3

Table 2.2 - Tachometer Speed Regulation .............................................................................. 2-4

Table 2.3 - Drive Specifications................................................................................................ 2-4

Table 2.4 - Drive Modification Kits............................................................................................ 2-8

Table 2.5 - OIM Drive Fault and Status Indicators ................................................................ 2-10

Table 2.6 - Drive Monitor Capabilities .................................................................................... 2-11

Table 3.6 - User Device Connections to the Control Terminal Board..................................... 3-13

Table 3.7 - Recommended Lugs for Grounding FlexPak Drives in UL / cUL Version............ 3-18

Table 4.1 - Jumper and Adjustment Settings. .......................................................................... 4-2

Table 6.1 - Quick Start Jumper Settings....................................................................................6-2

Table 6.2 - Quick Start Parameter Modification Sequence. ..................................................... 6-3

Table 8.1/2 - Replacement Parts for FlexPak 3000 25-150 A.................................................. 8-3

Table 8.3/4 - Replacement Parts for FlexPak 3000 250-800 A.................................................. 8-4

Table 8.5/6 - Replacement Parts for FlexPak 3000 1200-2000 A.............................................. 8-5

Table 8.7 to 8.10 - Accessories..................................................................................................... 8-6

Table 8.10 - RFI Filter Selection............................................................................................... 8-12

Table E.1 - Fault Codes........................................................................................................... E-2

Table E.2 - Alarm Codes.......................................................................................................... E-7

Table G.1 - Quick Reference.................................................................................................... G-1

Table J.1 - Cross Reference Part Numbers – Catalogue Numbers.........................................J-1

FlexPak 3000 49’1340 e

GENERAL NOTES

NOTE: The term converter is used throughout this manual for the FlexPak 3000 Power Module.

1.1 Safety Instructions

DANGER, WARNING, and CAUTION point out potential trouble areas.

• A DANGER alerts a person that high voltage is present which could result in severe bodily injury or loss of life.

• A WARNING alerts a person to potential bodily injury if procedures are not followed.

• A CAUTION alerts a person that, if procedures are not followed, damage to, or destruction

of equipment could result.

DANGER:

WARNING:

CAUTION:

Before installing and/or operating this device, this manual must be understood by the qualified electrical maintenance person who is familiar with this type of equipment and the hazards involved. Failure to observe this precaution could result in bodily injury.

Earth fault detection devices must not be used on this converter as the sole protection measure against unintentional touching. The DC-component in the earth fault current may inhibit the correct function of the fault detector.

Electronic converters cause disturbances to the supply network. The basic version of this converter does not include any harmonic filters and may not fulfil the limits of the national recommendations. The harmonic voltage disturbances produced by the converter are dependent on the supply network impedance.

Machinery Directive

CAUTION:

WARNING:

This inverter device is a component intended for implementation in machines or systems for the capital goods industry.

The start-up of the inverter in the European market is not permitted until it has been confirmed that the machine into which the inverters are built is in conformance with the regulations of the Council Directive Machinery 98/37/EWG.

To inhibit uncontrolled machine operation in case of the malfunction of the drive, the user must provide an external emergency stop circuit, which ensures disconnection of the power source from the motor. This circuit must be hardwired with electro-mechanic components and shall not depend on electronic logic or software. The stopping device (e.g. mushroom head pushbutton with lock) must be accessible to the operator. Failure to observe this precaution could result in bodily injury or loss of life.

Electromagnetic Compatibility (EMC-Directive)

CAUTION :

49’1340 e FlexPak 3000 1-1

The operating of inverters in the European market is only permitted if the Council Directive Electromagnetic Compatibility 89/336/EWG has been observed.

It is the responsibility of the manufacturer of the machine or system to observe the immunity and emission limits, requested by the Council Directive EMC in the European market. Guidelines for the installation according EMC-regulations - for shielding, grounding, filter arrangement as well as wiring instructions - are summarized in Appendix H, ‘CE-Conformance’ of this Instruction manual.

1.2 General Notes

Each reproduction of this manual may be prosecuted. The copyright of the user's manual remains at Rockwell Automation AG, CH-6036 Dierikon.

Trade mark Reliance® is a registered trade mark of Rockwell Automation AG. SW-Version This manual is valid for Regulator Software Version 4.3.

Regulator SW Versions can be read in Parameter 794.

1.3 Manual Scope

This manual contains information on drive installation, drive startup, parameter descriptions, and troubleshooting procedures. It also describes the controller and how to use the Keypad OIM to configure the drive.

Specific terms used in this manual are described in Appendix A. Measures for CE Conformity on Electro Magnetic Compatibility (EMC) are shown in Appendix H.

GENERAL NOTES

1.4 Related User Manuals

Table 1-1: Available User Manuals

Item Publication No. Language (-xx) Access

FlexPak3000 Power Module (this manual) FP3OIM-UM043M-xx EN, DE, FR, IT, ES (1) Pulse Tacho Feedback Kit FP3TIF-UMyyyy-xx EN, DE, FR, IT, ES (1) Field Current Regulator Kit FP3FCR-UMyyyy-xx EN, DE, FR, IT, ES (1) I/O Expansion Board FP3IOE-UMyyyy-xx EN, DE, FR, IT, ES (1) IBSF Communication Kit FP3IBS-UMyyyy-xx EN (1) PDPF Communication Kit FP3PDP-UMyyyy-xx EN (1) CS3000 Drive Control Configuration Software CS3000-UMyyyy-xx EN (1) Lifting Instructions D2-3414 EN (2) OIM Remote Mounting kit D2-3294 EN (2) Enhanced Field Supply Kit D2-3413 EN (2) AutoMax Network Communication Kit D2-3318 EN (2) ControlNet Communication Board D2-3425 EN (2) DeviceNet Communication Board HEC-FP3-DN EN (3)

xx: EN = English, DE = German, FR = French, IT = Italian, ES = Spanish yyyy: Manual Index

(1) You can order hardcopies of these manuals or download files from the Automation Bookstore via

www.theautomationbookstore.com, then Public – search - Item Number: begins with FP3.

(2) You can order hardcopies of D2-xxxx using the U.S. Manual Ordering Form D-203 (D-202)

or download PDF-files of the manuals. Both are available at the following internet page: www.reliance.com/docs_onl/online_stdrv.htm, then Manual Ordering or Listing User Manuals.

(3) This Horner Electric Manual can be downloaded from the Internet via:

www.heapg.com/devicenet.htm, then Manuals.

1-2

FlexPak 3000 49’1340 e

INTRODUCTION TO THE DRIVE

2.0 Introduction to the Drive

This section provides specifications and a description of the FlexPak 3000 Drive.

2.1 Drive Identification

2.1.1 Nameplate

The FlexPak 3000 drive has a nameplate on the right side of the carrier that identifies the drive by its specific Hardware and Software Part Numbers and applicable AC input power and DC output power data. Refer to this nameplate example. All communication concerning this product should refer to the appropriate Part Number information.

The technical power information should be referenced to verify proper power application.

P.N. -EQUIPMENT P.N. -VERSION TYPE S/W VERSION US M/N 650FR8742 I/M US P.N. D2-3475

INPUT OUTPUT SHORT CIRCUIT SYM RMS RATING

ENCLOSURE

MADE IN SWITZERLAND BY ROCKWELL AUTOMATION AG, DIERIKON

500 VAC 3PH 50/60 Hz, 700 A 0 -520 VDC, 800 A

CE, UL, CUL

848.11.73 A

790.30.72 A FP3000-S6R-800-AN-FC

4.3

IP00

CHARACTER OF LOAD M

SER. No. EU I/M

30 k

49‘1340

Sample FlexPak 3000 Nameplate

2.1.2 Drive Selection

The following table lists the European part numbers and North America Model No’s (where available) for ordering a specific drive type. For options refer to Table 2-4, sheet 2-8.

Unit Type

Nominal

Current

25 A 500 V, 50 Hz

60 A 500 V, 50 Hz

150 A 500 V, 50 Hz

250 A 500 V 848.06.03 848.06.73 200FN8742 848.07.03 848.07.73 200FR8742 450 A 500 V 848.08.03 848.08.73 375FN8742 848.09.03 848.09.73 375FR8742 800 A 500 V 848.10.03 848.10.73 650FN8742 848.11.03 848.11.73 650FR8742 1200 A 500 V, 50 Hz - 848.12.73* - - 848.13.73* 1200 A 500 V, 60 Hz - 848.12.43 - - 848.13.43 1600 A 500 V, 50 Hz - 848.14.73* - - 848.15.73* 1600 A 500 V, 60 Hz - 848.14.43 - - 848.15.43 2000 A 500 V, 50 Hz - 848.18.73* - - 848.19.73* 2000 A 500 V, 60 Hz - 848.18.43 - - 848.19.43 1600 A 690 V, 50 Hz - 848.16.73* - - 848.17.73* 1600 A 575 V, 60 Hz - 848.16.43 - - 848.17.43 -

Max. AC-Line

Voltage

460 V, 60 Hz

S-6 with Field Rectifier

848.00.03 848.00.73 20FN8742 848.01.03 848.01.73 20FR8742

848.02.03 848.02.73 50FN8742 848.03.03 848.03.73 50FR8742

848.04.03 848.04.73 125FN8742 848.05.03 848.05.73 125FR8742

S-6 with Field Current Regulator U.S. Model No

Power Unit (Basic) 1)

S-6R

with Field

Rectifier

S-6R with Field Current Regulator U.S. Model No

* FlexPak 3000 converters 1200 A to 2000 A for 50 Hz are not UL, cUL.

1) The Keypad Operator Interface Module (OIM) is not included in the basic unit 848.xx.xx.

49’1340 e FlexPak 3000 2-1

INTRODUCTION TO THE DRIVE

2.2 Drive Specifications

2.2.1 AC-Line Considerations

Requirement Measures

1) Limiting the AC line symmetrical fault current to 100 kA (max. for fuses) or values acc. table below for UL, cUL, as well as limiting commutation notches at the line input (terminals 1U, 1V, 1W).

2) Limiting the A-C line symmetrical fault current (RMS) at the field rectifier input (terminals 3V, 3W) to 10 kA.

3) Minimum supply system (source) capacity kVA.

4) Limiting line transformer impedance to 4% and continuous undervoltage to 10%.

5) Avoiding damage of drive components due to overvoltage transients caused by medium voltage switching on supply transformers with a primary rating of 2300 VAC or more.

Full Load

Rated DC

Current

25 15 18 20 - - 18 kA

60 36 41 45 - - 18 kA 150 90 102 111 - - 18 kA 250 150 175 188 - - 30 kA 450 270 306 333 - - 30 kA 800 480 545 592 - - 30 kA

1200 720 818 888 - - 85 kA 1600 960 1100 1190 1400 1630 85 kA 2000 1200 1373 1486 - - 85 kA

Minimum Source Capacity (kVA) for different AC line voltages at 50 Hz

400 V 460 V 500 V 575 V 690 V

Always adding an impedance in the line input. This can be a 3-phase line reactor with 2% voltage drop minimum (refer to Table 8-6) or a matched isolation transformer.

Adding a 1-phase line reactor acc. to Table 8-6. Exception: No reactor is required when a matched transformer is provided in the input to the converter on drives up-to 450 A. Connecting to a source (supply transformer) with minimum kVA rating acc. to the following table. Derating of armature voltage if impedance exceeds 4% or continuous undervoltage. Providing additional input line conditioning on the drive (e.g. Capacitance to ground). Please Contact Rockwell Automation for assistance when this is required.

Max. Source Capacity

Symmetr. fault current (rms)

(for UL, cUL)

2.2.2 Service Conditions

Standard altitude ......................................................................................up to 1000 meters

(Above 1000 m the output current must be reduced by 1% per 100m)

Standard ambient temperature at:

Operation with nominal current......................................................................0°C to 40°C

Storage ...................................................................................................... -25°C to 55°C

Transportation............................................................................................ -25°C to 70°C

Max. ambient temperature .......................................................................................... 55°C

(Above 40°C output current must be reduced by 1.5% per °C)

Relative humidity ........................................................ max 50% at 40°C unlimited time

Non-Condensating max 90% at 20°C (30 days/year) max 75% average per year

Environment: The drive should be located in an area that is free of dust, dirt, acidic vapors, vibration and shock, temperature extremes, and electrical or electromagnetic noise interference.

Degree of protection...................................................................................................... IP00

2-2

FlexPak 3000 49’1340 e

INTRODUCTION TO THE DRIVE

2.2.3 Input Voltage and Frequency Ratings:

Nominal voltage for three-phase at terminals 1U, 1V, 1W and 2U, 2V, 2W

On units 25, 60, 150 A........................................................200 - 500 VAC at 50 Hz

200 - 460 VAC at 60 Hz

On units 500 V, 250, 450, 800, 1200, 1600 and 2000 A ..................... 200 - 500 VAC

On units 575 V, 60 Hz, 1600 A............................................................ 300 - 575 VAC

On units 690 V, 50 Hz, 1600 A............................................................ 300 - 690 VAC

Input voltage for Field Controller Supply (on FlexPak 25 - 800 A)................. max. 415 VAC

Input voltage for Field Current Regulator Kit (Option).................................... max. 460 VAC

Voltage variation .......................................................................+10% and -10% of Nominal

Nominal line frequency ....................................................................................... 50 or 60 Hz

Frequency variation ................................................................................................... ±2 Hz

Fan Supply Voltage and Current Consumption on Units 1200 - 2000 A

Three-phase input voltage

at terminals 5U, 5W, 5W ................................ ... 400 V, 50 Hz or. 460 V, 60 Hz, 1A

NOTE: On units 60 Hz, 1200 -2000 A in UL, cUL version the fan must be external protected

by the following, thermal magnetic circuit breaker: Dierikon part No. 610.11.05, RA catalog No. 140M-C2E1316.

2.2.4 Regulator Supply Voltage and Power Consumption

Single-phase input voltage, via autotransformer.......................230 VAC at terminals 0, 230

Power Consumption (including fan on type 150 - 800 A)..................................max. 120 VA

Thermal magnetic protection by external circuit breaker NOTE: On units with terminals 4U, 4V (without autotransformer) input voltage 230 VAC is

required.

2.2.5 Relay Output for Main Contactor

Relay MCR at terminals X1:5 and X1:6

Nominal contact rating at AC 230 V, cos phi = 0.5 ...................................................330 VA

Maximum current............................................................................................................. 3 A

2.2.6 DC Voltage Ratings:

Maximum permissible armature voltage U and max. 10% line undervoltage. At Uk = 4 to 7% U

a nom

voltage and operation mode. Table 2-1: Armature voltage for various line voltages

AC Line Motoring operation (S-6 / S-6R) Regenerating operation (S-6R) Voltage Armature Voltage Armature Voltage

UN U

is the recommended standard motor armature voltage for the selected line

a nom

a max

or 115 VAC at terminals 0, 115

at inductive voltage drop of Uk ≤ 4% per phase

must be derated per 5%.

a max

a nom

a max

200 V 200 V 230 V 200 V 214 V 400 V 460 V 490 V 400 V 440 V 460 V 520 V 570 V 500 V 500 V 500 V 600 V 620 V 520 V 535 V 575 V 700 V 710 V 600 V 615 V 660 V 800 V 810 V 700 V 706 V 690 V 800 V 850 V 700 V 738 V

Field voltage ..........................................................................max. 90% of line input voltage

Protection by external fuses according to table 8-8.

49’1340 e FlexPak 3000 2-3

INTRODUCTION TO THE DRIVE

2.2.7 Regulation (with 95% load change):

Table 2-2 - Tachometer Speed Regulation

Regulation Arrangement

Armature Voltage Regulation

Speed Change with 95% Load Change

2-3 % 15% Not applicable.

Speed Change from All other Variables

with IR Comp.

Closed Loop

with Analog tach 1% 2% with Pulse tach 1) 0.01% 0.01% 762.70.00

1) Optional Pulse Tachometer Feedback kit required (See instruction manual 49’1343).

2.2.8 Speed Range:

Operator's Speed Adjustment............................................................................... 0 to rated speed

Specification Speed Range ........................................100:1 based on top speed and tachometer

2.2.9 Drive Efficiency:

Drive Only........................................................................................98.6% (rated load and speed)

Drive and Motor............................................................................................................85% typical

2.2.10 Displacement Power Factor, Power Loss PV and Output Current: Power Factor: 88% typical (rated load & speed, decreasing linearly with speed)

Typical percent speed depends on motor operating speed and motor frame size. Power Consumption at no load: see P

in Table 2-3.

Part Number

Table 2-3 - Drive Specifications

Unit-Type I

anom

amax

(-73/43) I

(-03) P

Pv (at I

25 A 25 A 20 A 30 A 4 A 6 A 60 VA 120 W

60 A 60 A 50 A 75 A 4 A 6 A 60 VA 210 W 150 A 150 A 125 A 187 A 10 A 6 A 85 VA 460 W 250 A 250 A 208 A 312 A 10 A 12 A 90 VA 715 W 450 A 450 A 375 A 562 A 10 A 12 A 90 VA 1215 W 800 A 800 A 667 A 1000 A 12 A 12 A 120 VA 2120 W

1200 A, 500V 1200 A 1000 A 1500 A 15 A * - 400 VA 2680 W 1600 A, 500V 1600 A 1334 A 2000 A 15 A * - 400 VA 3750 W 2000 A, 500V 2000 A 1667 A 2500 A 15 A * 400 VA 4600 W 1600 A, 575V 1600 A 1334 A 2000 A 15 A * - 400 VA 3900 W 1600 A, 690V 1600 A 1334 A 2000 A 15 A * - 400 VA 4100 W

= Maximum continuous current without overload capability (I

= Nominal continuous current with overload capability 50% during 1 minute

a nom

every 10 minutes

= Maximum current during 1 minute after 9 minutes operation with Ia nom

a max

= 1.5 x I

a max

= Field current without overload capability

a nom

)

= 1.2 x I

a nom

)

a nom

)

* A maximum field current of 20 A is permitted, if the power unit blower is switched on

together with the motor field.

2-4

FlexPak 3000 49’1340 e

INTRODUCTION TO THE DRIVE

2.3 Drive Input/Output Specifications

The following sections describe drive inputs and outputs. Refer to section 3.8 for terminal strip connections and wiring diagrams.

2.3.1 Logic Inputs:

CAUTION: Connecting an external power source to any of the +24 volt connections (terminals 1, 7, 11, and 14) on the regulator board terminal strip will damage the drive. DO NOT connect the external power source to the +24 volt connections on the regulator board terminal strip. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

The logic input circuits can be powered either from the internal +24 V DC power supply or from an external +24 V DC power source. The internal +24 V DC power supply is available at the regulator board terminal strip (see Figure 3-8). If an external power source is used, only its COMMON must be connected to 24V COM on the regulator board (terminal 15). 24V COM is internally not grounded, but may be externally grounded if required by the users control wiring.

Electrical Specifications:

Input Voltage .........................................................................................................+24 V DC

Turn On Voltage ............................................................................................................ 8 V

Turn Off Current ....................................................................................................... 0.5 mA

Common ............................................................. All input circuits have the same common.

2.3.2 Logic Outputs:

The logic output circuits are normally open (when de-energized) relay contacts. When energized (contacts closed), the three circuits indicate the following drive conditions:

Running 27 to 28, Alarm 29 to 30, No Fault 31 to 32

Electrical Specifications:

Operating Voltage .................................................................. 250 V AC maximum

30 V DC maximum

Switching Current .............................................................. 2 A maximum resistive

1 A maximum inductive

2.3.3 Analog Inputs:

The three customer analog inputs are

• Manual Mode Reference

• Automatic Mode Reference

• D-C Tachometer Feedback.

These inputs are converted at 12 bits plus sign at their full range. The electrical specifications for each of these is listed below.

Electrical Specifications:

Current loading ......................................................................................... 2.5 mA maximum

Manual Mode Reference: Jumper J19 Potentiometer 5 kohm minimum POT External Voltage Source: +/- 10 VDC (when used for Analog Trim Ref. )

0 - 10 VDC (when used for Manual Mode Speed Ref.)

Automatic Mode Reference: Jumper J12 Jumper J10 Voltage Reference +/- 10 V DC VOLTS VOLTS & PARK Milliamp Reference 4-20 milliamps MAMPS 4-20 & PARK 10-50 milliamps MAMPS 10-50 & 4-20

49’1340 e FlexPak 3000 2-5

EXT

Analog Tachometer Feedback

Tach Voltage at Top Speed ........................................................................... 10 - 250 V DC

NOTE: J14 Jumper position and connection of DC-Tachometer must correspond.

Jumper J14 Jumper J11 Top Speed Tach Volts < 16 V LOW 16 < 31 V LOW 31/125 < 62 V LOW 62/250 < 125 V HI 31/125 < 250 V HI 62/250

2.3.4 Analog Outputs:

The two metering analog outputs are available at regulator board terminals 24, 25 and 26. Terminal 25 is the common connection for both output signals. The selected signals for both meter outputs are averaged (filtered) over 100 msec to reduce meter fluctuations. METER OUT 1 SELECT (P.404) corresponds to terminals 24 and 25 (default: CML FEEDBACK). METER OUT 2 SELECT (P.405) corresponds to terminals 25 and 26 (default: SPD LOOP FEEDBACK). Refer to Appendix B, METER OUT 1 SELECT (P.404) and METER OUT 2 SELECT (P.405) parameters, for additional drive test points that can be configured to source Meter Outputs 1 and 2.

INTRODUCTION TO THE DRIVE

Electrical Specifications:

Output Voltage.................................................................................................... +/- 10 V DC

Maximum Load ...................................................................................................4 milliamps

2-6

FlexPak 3000 49’1340 e

2.4 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 2-1 shows a block diagram of the Drive.

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 ‘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 (see Section 3 for terminal connections). Based on the active control source selected using the CONTROL SOURCE SELECT key, the OIM displays the control source as "KEYPAD" or "TERMBLK" (regulator board terminal strip), or "NETWORK" (if an optional network communication board is installed).

INTRODUCTION TO THE DRIVE

I/O Expansion

Board

DIGITAL,

ANALOG, &

FREQUENCY

INPUTS/

OUTPUTS

OIM SERIAL NETWORK

Regulator Board

Terminal Strip

OUTER

CONTROL

LOOP (OCL)

DRIVE CONTROL SIGNALS AND SEQUENCING

SPEED

REFERENCE

SELECTION

AND

SCALING

SPEED

LOOP

CURRENT

MINOR

LOOP (CML)

Figure 2-1 - FlexPak 3000 Functional Block Diagram

FIELD

CONTROL

S6/S6R

POWER

UNIT

Current Feedback

Voltage Feedback

Tachometer Feedback

FIELD POWER SUPPLY

MOTOR FIEL D

MOTOR ARMATURE

ANALOG OR PULSE

TACHOMETER

49’1340 e FlexPak 3000 2-7

INTRODUCTION TO THE DRIVE

Rockwell Automation offers modification kits that broaden the application range of the drive. A summary of these kits is presented in the following Table 2-4.

Related Instruction Manuals are listed in Table 1-1, Section 1.4. Table 2-4 - Drive Modification Kits

Name Description Part

Number

Pulse Tacho Feedback Kit PTK

Allows for digital pulse tachometer speed feedback on high performance regulation applications. (Kit includes cable).

762.70.00

Enhanced Field Supply kit FVR

Field Current Regulator kit FCU4 FCU10 FCU15

I/O Expansion Board IOE

AutoMax Network Communic. kit AMXF

Interbus Communication kit IBSF

Profibus Communication kit PDPF

ControlNet Communication Board CONF

DeviceNet Communication Board DNC

Provides electronic field voltage trim and field economy. It replaces the standard field supply.

Provides field economy, as well as pre-weakening 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.

Mounts on the FlexPak 3000 chassis and gives the FlexPak 3000 additional analog, frequency, and digital I/O capability.

llows the FlexPak 3000 to communicate on the Reliance AutoMax

Distributed Control System (DCS). (Kit contains board & cable).

Allows the FlexPak 3000 to communicate over the standardized field bus system INTERBUS. (Kit contains board & cable).

Allows the FlexPak 3000 to communicate over the standardized Profibus-DP system. (Kit contains board & cable)

Allows a FlexPak to communicate over the open protocol ControlNet network. Mounts inside the FlexPak and includes terminals for network connections. The AMX Network Comm. board cannot be used when using the ControlNet.

Allows a FlexPak to communicate over the open protocol DeviceNet network. Mounts inside the FlexPak and includes terminals for network connections. The AMX Network Comm. board cannot be used when using the DeviceNet board.

762.70.10

762.70.50

762.70.60

762.70.70 (4,10,15A)

762.70.80

762.70.40

762.70.45

762.70.95

762.70.96

762.70.90

Drive Control Configuration Software CS3000-V6

Windows-based software that allows the user to connect any personal computer running Micro-soft Windows version 3.1 or later to a FlexPak 3000 drive. Allows you to create, store, upload, and download drive configurations. You can also monitor and change

788.05.30

parameters through the PC and read and reset the drive’s fault log.

Interface Cable for connecting the drive to PC (25-pin to 9-pin) 772.27.00

Keypad Drive Configuration Module KDCM

Keypad Operator Interface Module KOIM

(M/N 317C160D)

OIM Remote Mounting kit DMK

(M/N 905FK0101)

Operator Interface that allows you to access and change drive parameters, read and clear the drive’s alarm and fault log. The DCM cannot control the drive.

Allows you to control (e.g. Start, Stop, Jog) the drive. You can also monitor and change parameters, read and clear the drive's alarm and fault log.

Provides for remote mounting of the OIM up to 5 meters away from the drive. Contains also the cover plate (762.70.31) for the regulator unit.

922.95.10

922.95.00

762.70.30

2-8

FlexPak 3000 49’1340 e

INTRODUCTION TO THE DRIVE

2.5 Controls/Indicators

See Figure 2-2 for location of the controls and indicators for the Keypad OIM. Drive fault and status indicators are listed in Table 2-5.

LCD Display LCD-Indicators

Control Key

LCD-Indicators

PROGR AM

PROGRAM

MONITOR

FAULT

OIM Programming

Keys

HELP

CANCEL

ENTER

Figure 2-2: Operator Interface Module OIM

2.5.1 Indicators

KEYPAD

CONTROL SOURCE SELECT

MANUAL

AUTO

MANUAL

FORW ARD

FORWARD

REVERSE

RUN

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

JOG

STOP

RESET

Drive Control Keys

LCD (Liquid Crystal Display) and LED (Light Emitted Diode) displays are used to indicate the status of the drive. LCD indicators are located on the OIM to the left of the text for the indicator. LED indicators are located on the regulator board which is located behind the OIM.

LCD Indicators

An LCD indicator is on when a field is present Interlocks OK and the Drive Ready indicators are on. Table 2-5 contains a list of drive and fault status indicators with their associated description.

; off when extinguished. In Figure 2-2, the

49’1340 e FlexPak 3000 2-9

INTRODUCTION TO THE DRIVE

Table 2-5 - OIM Drive Fault and Status Indicators

Indicators Description

Fault A condition or conditions exists in the drive which stopped it or prevents it from

running. When a fault occurs, the type of fault and further instructions are displayed on the OIM display.

Alarm An alarm does not prevent the drive from running but alerts the user that a

condition exists that could cause a fault in the future. When an alarm occurs, the type of alarm and further instructions are displayed (unless a subsequent fault occurs which will overwrite the alarm text display).

Interlock OK This indicator is on when all customer interlocks (terminal 9) and the Coast/DB

contact (terminal 8) are closed. Off = 1 or more are open.

Drive Ready This indicator in on when all customer interlocks are closed, the Coast/DB

contact is closed and there are no drive faults present. Pressing the RUN or JOG key will cause the drive to start if this indicator on. Off = not ready.

Running When on, this indicates that the contactor is closed and the motor armature is

energized. Off = contactor is open and drive is not running.

Current Limit Torque Limit

LED Indicators

Two LED indicators are located on the regulator board for status and service use: (LED1) CPU OK and (LED2) OIM COMM OK. See Section 7 of this instruction manual for further details regarding the use of these indicators for status and troubleshooting purposes.

This is a real time indication of the motor operating in current limit. On = current limit Off = not in current limit.

2.5.2 Controls

The OIM keys can be categorized into two general functions:

1) OIM Programming Keys (program/monitor, fault, help, cancel, enter, and arrow keys)

2) Drive Control Keys (control source select, auto/manual, forward/reverse, jog, run, and stop/reset.)

2.5.2.1 OIM Programming Keys

These keys provide the ability to tune the drive, scale inputs/outputs, save user configurations or restore to/from non-volatile memory, set drive limits, access fault/alarm logs and monitor several drive signals. The PROGRAM mode is used for menu and parameter selection. The MONITOR mode displays standard drive output data values. See section 4 for further details on menu and parameter selection.

PROGRAM

--------------MONITOR

NOTE: The PROGRAM mode is used for menu and parameter selection.

2-10

FlexPak 3000 49’1340 e

This key cycles the OIM display between Program screens and two Monitor screens. The state of this key (PROGRAM or MONITOR) is shown on the LCD directly above the key. The active OIM display mode is retained through drive power cycles. For example, if the OIM was in MONITOR mode and power was

removed, the OIM would power up in the MONITOR display mode. See the following example for more information.

INTRODUCTION TO THE DRIVE

FlexPak 3000 Main Menu

"Quick Start

Drive Reference Speed/Voltage Loop (SPD)

#Current Minor Loop (CML)

PROGRAM KEYPAD MANUAL FORWARD

• Pressing this key will display the following screen:

MOTOR SPEED 0 RPM ARM VOLTS 0 VOLTS

MOTOR LOAD 0 %FLA KEYPAD REF: 0 RPM

MONITOR KEYPAD MANUAL FORWARD

This screen allows the user to change the drive's setpoint (KEYPAD REF) when the CONTROL SOURCE SELECT is set to KEYPAD and the drive is in manual mode. Use the up/down arrow keys to change the drive's setpoint. Pressing the ENTER key will save the setpoint to non-volatile memory.

• Pressing the PROGRAM/MONITOR key a second time will display motor speed (RPM) and

motor load (FLA):

0 RPM 0 %FLA

MONITOR KEYPAD MANUAL FORWARD

This screen does not allow the user to change the drive's setpoint (KEYPAD REF).

• Pressing the PROGRAM/MONITOR key after the second time will re-display the previous

PROGRAM display (the first screen in this example). Pressing the ENTER key will save the setpoint to non-volatile memory. Pressing the CANCEL key when in monitor mode will return the OIM to the PROGRAM mode. Table 2.6 lists drive parameters monitored and reported to the OIM.

Table 2.6 - Drive Monitor Capabilities

Monitor List Selectable Engineering Units

Motor Speed Percent, RPM, Units* Arm Volts (Armature Voltage) Volts Motor Load (Armature Current) Percent Full Load Amps (%FLA), Amps TERMBLK REF, KEYPAD REF

Percent, RPM, Units*

or TORQUE REF**, NETWORK REF***

* Units: Indicates the user's option to select an engineering unit (6 characters maximum) for readout to display. A number

from 1 to 10,000 full scale can be assigned a meaningful value (e.g. FPM, Feet Per Minute, etc.). See "Define User Units" in Section 4.

** When the drive is configured as a current (torque) regulator (J15 Hardware Jumper = CURRENT), the Control Source

Select (CSS) can only be set NETWORK REF is displayed. The units are the same as displayed for MOTOR LOAD.

** When the drive is configured as a speed or armature voltage regulator (J15 Hardware Jumper = SPEED),

the selected control source determines the reference source (TERMBLK REF or KEYPAD REF, or NETWORK REF).

*** Available with an optional Network Communication Board.

to TERMBLK or NETWORK (if option is installed). In this case, TORQUE REF or

49’1340 e FlexPak 3000 2-11

INTRODUCTION TO THE DRIVE

FAULT

This key allows the operator to review and clear logs (fault and alarm), reset faults, clear the alarm indicator and display fault history and diagnostic information for servicing the drive. The state of this key (FAULT, ALARM or DIAGS) is shown on

the LCD directly above the key.

• Pressing the FAULT key once will display the fault menu:

Fault Menu " Review Log

Reset Faults Clear Fault Log and Reset Faults

FAULT KEYPAD MANUAL FORWARD

• Pressing the FAULT key a second time will display the alarm menu. Pressing the CANCEL key will return the OIM to the previous display mode (PROGRAM or

MONITOR).

Alarm Menu " Review Log

Reset Alarms Clear Alarm Log and Reset Alarms

ALARM KEYPAD MANUAL FORWARD

• Pressing the FAULT key a third time will display the diagnostics menu. Pressing the CANCEL key will return the OIM to the previous display mode (PROGRAM or

MONITOR).

Diagnostics Menu " Why is the drive not ready?

Why did the drive stop?

DIAGS KEYPAD MANUAL FORWARD

• Pressing the FAULT key after the third time will re-display the fault menu. To exit this mode, press PROGRAM/MONITOR. This returns the OIM display to the previous

display mode (PROGRAM or MONITOR). See Section 7 of this instruction manual for further details on the FAULT, ALARM, and DIAGS

menus.

HELP

Menu and Parameter HELP are available. Access Menu or Parameter HELP by pressing the HELP key when the cursor is at the particular menu or parameter of interest. In the MONITOR mode, pressing HELP displays status indicators in the

selected language. Pressing CANCEL at anytime will return to the display from the previous screen.

MENU HELP

Menu HELP provides the user with information regarding the general purpose of the menu and some details of related parameter selections.

For example: If English is the selected Language, the following is displayed when HELP is pressed when at the Main Menu.

2-12

FlexPak 3000 49’1340 e

INTRODUCTION TO THE DRIVE

MENU HELP FlexPak 3000 Main Menu

Select the appropriate menu item with the UP/DOWN arrow keys and the ENTER key.

You can use CANCEL at any time to return to the previous menu level.

PROGRAM KEYPAD MANUAL FORWARD

A # displayed at the bottom left of the text indicates that more text is available. Press the down

! key to scroll up the remaining text for viewing. Similarly, if a $ is displayed at the upper left

of the text, use the Press CANCEL to exit MENU HELP. PARAMETER HELP Parameter HELP displays the following information:

• Parameter name

• Code (parameter No.)

• Input

• Retentive or Non-retentive

• Units

" key to scroll down the previous text for viewing.

To obtain parameter help, the OIM must be at a value entry screen. See Section:5 "How to Make Parameter Adjustments" for examples of value entry screens.

For example: The following is displayed when HELP is pressed while at the value entry screen for the TOP SPEED parameter.

PARAMETER HELP P.011 TOP SPEED

INPUT RETENTIVE

RPM Press CANCEL to continue.

PROGRAM KEYPAD MANUAL FORWARD

Press CANCEL to exit PARAMETER HELP.

.CANCEL

The CANCEL key is used to return to a previous menu, exit a parameter modification (value entry) screen, clear a fault or an alarm message, etc.

ENTER

Displays the menu selected, accepts a change made to a parameter value, or selects an item from a pick list.

<-------

In the MONITOR mode, ENTER saves the KEYPAD REF setpoint. See Section 4 and Section 5 of this instruction manual for the specifics of using this key.

Scrolls up or down through the menu and parameter listings and changes parameter values. Increases or Decreases speed reference when in the first MONITOR display screen and CONTROL SOURCE SELECT is set to KEYPAD. When in the second MONITOR display screen (RPM and FLA), these keys will not change the speed reference. NOTE: Holding either of these keys down will cause the selected value to change rapidly

49’1340 e FlexPak 3000 2-13

Moves the cursor left or right in parameter modification (value entry) screens

to allow digit selection for parameter value setting. Left (⇐) accesses the Language Selection menu at any menu level but not

at parameter modification screens. See section 4.13 of this instruction manual for further details on the Language Selection menu.

Right (⇒) accesses the Contrast Adjustment screen at any menu level but not at parameter modification screens. See section 4.7 of this instruction manual for further details on the Contrast Adjustment screen.

2.5.2.2 Drive Control Keys

These keys can be used to control the motor. They provide the user with the ability to start, jog, select direction, select reference and control source. See figure 2.2

INTRODUCTION TO THE DRIVE

CONTROL

SOURCE

SELECT

Selects where the control signals for the drive originate. "KEYPAD" (OIM control), "TERMBLK" (terminal strip control) or "NETWORK" (network communication board). The selection can only be changed when the drive is not running. The state of this key (TERMBLK or KEYPAD, SERIAL or NETWORK) is shown on the LCD directly above the key.

• Keypad control uses the OIM buttons to control drive operations. The KEYPAD REF value (displayed in MONITOR mode) is used as the drive reference.

• Termblk control uses the reference at regulator board terminals (17-18 for Manual Reference or 19-20 for Auto Reference) for the setpoint. It also uses the controls connected to the terminal strip for control of drive operations. Reference Figure 3-8 for more details.

Network control can only be selected with a network communication board installed and when the control signals and reference originate from the network board. When the drive is configured as a current regulator (J15 = CURRENT), the control source can only be set to TERMBLK.

AUTO

--------

MANUAL

The AUTO/MANUAL key determines which drive reference source will be used when the CONTROL SOURCE SELECT is set to KEYPAD. The state of this key (AUTO or MANUAL) is shown on the LCD directly above the key.

• AUTO will use the signal at regulator board terminals 19 and 20 (see figure 3.8). The type of signal accepted at these terminals is determined by the position of hardware jumpers J10 and J12 (see Figure 4-1).

• MANUAL will use the KEYPAD REF from the OIM as the drive reference. When CONTROL SOURCE SELECT is not set to KEYPAD REF, the preset state of the reference mode is shown above the key (determined from the selected control source). When the drive is configured as a current regulator (J15 = CURRENT), AUTO/MANUAL is fixed in the AUTO mode.

FORWARD

--------------

REVERSE

Selects the direction of rotation when the drive at rest, or dynamically changes the direction of rotation (regenerative drives only) when the drive in operation. This key is active only when in KEYPAD control. This key also affects the direction of rotation for JOG. The FORWARD/REVERSE key is fixed to forward for any of these conditions: when the REVERSE DISABLE parameter is set to ON (for regenerative drives); when the drive is nonregenerative; when an A-C tach is used; and when a pulse tach with quadrature disabled is being used. The state of the controlling input is shown on the LCD directly above the key.

2-14

FlexPak 3000 49’1340 e

INTRODUCTION TO THE DRIVE

.JOG

-------- indicators show that the drive is "not ready", this request will be ignored.

Active only when in KEYPAD control mode. This key causes the drive reference to ramp up at the JOG ACCEL/DECEL rate to jog speed. When this key is released, the drive reference ramps to zero at the same rate. If the drive status

RUN



STOP

------

RESET

Active only when in KEYPAD control mode. This key allows the motor to accelerate to the speed reference setpoint.

STOP is active at all times regardless of the CONTROL SOURCE SELECT setting. Pressing the key with the drive running causes the drive to stop in the selected stop mode. RESET is active only if the drive is not running and CONTROL SOURCE SELECT is set to KEYPAD. When the RESET key is pressed, drive faults and alarms will be reset (see section 7 for more information.)

49’1340 e FlexPak 3000 2-15

2-16

FlexPak 3000 49’1340 e

INSTALLATION AND WIRING

3.0 Install and Wire the Drive

DANGER The user is responsible for conforming to all other applicable standards. Wiring practices, grounding, disconnects, and overcurrent protection are of particular importance. Size and install all wiring in conformance with the applicable standards. Failure to observe this precaution could result in severe bodily injury or loss of life.

DANGER This equipment must be connected to a power source for which it was designed. Compare available power with the requirements listed on the nameplate to insure that voltage, frequency, phase, current capacity and interrupting capacity are adequate. Failure to observe this precaution could result in severe bodily injury or loss of life.

3.1 General

This Section outlines the procedures that are to be followed to properly install the FlexPak 3000 Drive.

3.2 Recommended AC Line and DC Armature Fuses

The user must select the correct fuse type (ultra fast, semiconductor protection) for drive AC line and DC armature fuses from the table 8-7 in chapter 8. The armature fuse is only for four quadrant drives (S-6R).

3.3 Install the Drive

Minimum clearances of 100 mm must be maintained when the drive is mounted within a cabinet. This allows adequate ventilation around and through the drive.

Regardless of these placement guidelines, the user is responsible for ensuring that the Drive's ambient temperature specification of 0 to 40°C is met and its relative humidity is kept within 5% to 95% without condensation. Install the drive(s) in the cabinet. Refer to Figures 3-1 to 3-6 for mounting dimensions.

49’1340 e FlexPak 3000 3-1

INSTALLATION AND WIRING

386

136

130

269 219

14.0

7.0

Power connections Terminals for 25 A Unit

400

Motor 1D, 1C

AC-Line 1U, 1V, 1W

Prot. earth PE

6 mm2

1.4 Nm 6 mm2

1.4 Nm

Power connections Terminals for 60 A Unit

185

107

Motor 1D, 1C

AC-Line

219

1U, 1V, 1W Prot. earth

16 mm2

2.5 Nm 16 mm2

2.5 Nm

MAX. 250

287

200

Weight: 10 kg Minimum clearances

for air circulation: 100 mm

Figure 3-1: Mounting Data for 25 A and 60 A Drives.

3-2

FlexPak 3000 49’1340 e

INSTALLATION AND WIRING

269 219

7.0

69.5 32.5 32.5 32.5 32.5 69.5

ø8.5

MAX. 250

386

14.0

1U 1C 1V 1D 1W

Power Connections on 1-Quadrant Units S-6

185

400

428

130

69.5 36 29 29 36 69.5

ø8.5

1C 1U 1V 1W 1D

Power Connections on

136

107

4-Quadrant Units S-6R

Power Connections

219

Motor 1D, 1C

AC-Line 1U,1V,1W

Prot. Earth PE

Bus bars 90 mm

Bus bars 60 mm

Terminals 35 mm Torque 2.5 Nm

287

Weight: 14 kg Cooling air: 187 m3/h

Air flow direction: from bottom to top

200

Minimum clearances for air circulation: 100 mm

Figure 3-2: Mounting Data for 150 A Drives.

49’1340 e FlexPak 3000 3-3

INSTALLATION AND WIRING

Power connections for 250 A Unit

Motor 1D, 1C

AC-Line 1U, 1V, 1W

Prot. earth PE

Power connections for 450 A Unit

Motor 1D, 1C

AC-Line 1U, 1V, 1W

Prot. earth PE

Bus bars 25 x 5, Hole 11 mm

Bus bars 20 x 5, Hole 11 mm

Bolt M10, Torque 15 Nm

Bus bars 40 x 5, Hole 14 mm

Bus bars 30 x 5, Hole 14 mm

Bolt M10 Torque 15 Nm

Weight: 40 kg Cooling air: 407 m3/h

Air flow direction:

from bottom to top

Minimum clearances for air circulation: 100 mm

Figure 3-3: Mounting Data for 250 A and 450 A Drives.

3-4

FlexPak 3000 49’1340 e

INSTALLATION AND WIRING

25 Ø 1)

1) Holes for lifting hooks

Power connections Motor

1D, 1C AC-Line

1U, 1V, 1W Protection earth

Bus bars 50 x 10, Hole 13.5 mm

Bus bars 40 x 10, Hole 13.5 mm

Bolt M12 Torque 15 Nm

Weight: 83 kg Cooling air: 814 m3/h

Air flow direction: from bottom to top Minimum clearances

for air circulation: 100 mm

Figure 3-4: Mounting Data for 800 A Drives.

49’1340 e FlexPak 3000 3-5

INSTALLATION AND WIRING

975

905

455

400

240

185

138

317

49 50

DC OUTPUT

197

100 40

25 Ø 1)

190

515

100

M12

200

M12

DC OUTPUT

130

154

6089.56089.560

418

160

1) Holes for lifting hooks

Power connections Motor

1D, 1C AC-Line

1U, 1V, 1W

Bus bars 100 x 10, Drilling 4 x M12

Bus bars 60 x 10, Drilling 2 x 13,5 mm

Prot. earth PE Bolt M12, Torque 25 Nm

Weight: Cooling air:

195 kg

2000 m3/h Air flow direction: from bottom to top Minimum clearances

200

for free air circulation: 100 mm

Figure 3-5: Mounting Data for FlexPak 1200/1600 A, 500V and 1600A, 575/690V

3-6

FlexPak 3000 49’1340 e

+ 186 hidden pages