Rockwell Automation FlexPak 3000 Power Module User Manual

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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

INSTALLATION AND WIRING

25 Ø 1)

200

Figure 3-6: Mounting Data for FlexPak 2000A, 500V.

1) Holes for lifting hooks

Power connections Motor

1D, 1C

Bus bars 120 x 10, Drilling 4 x M12 Torque 25 Nm

AC-Line 1U, 1V, 1W

Bus bars 96 x 10, Drilling 4 x 14 mm

Prot. earth PE Bus bar 60 x 10,

Drilling 2 x 14 mm,

Weight: Cooling air:

196 kg

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

for free air circulation: 100 mm

49’1340 e FlexPak 3000 3-7

INSTALLATION AND WIRING

3.4 Install a Line Reactor or Transformer

CAUTION Distribution system capacity above the maximum permitted system kVA, as well as limitation of commutation notches, requires always adding an impedance at line input (terminals 1U, 1V, 1W). You can use a 3-phase line reactor with 2% voltage drop minimum (refer to Table 8-6) or other means of adding similar impedance (e.g. matched isolation or auto transformer). If an input transformer is installed ahead of the drive, a power disconnecting device must be installed between the power line and the primary of the transformer. If this power disconnecting device is a circuit breaker, the circuit breaker trip rating must be coordinated with the inrush current (10 to 12 times full-load current) of the input transformer. Failure to observe these precautions could result in damage to, or destruction of, the equipment.

CAUTION The star point of the external AC-line transformer must always be grounded (Zero potential) and connected to the drive ground point (terminal PE or ground stud).

Connection of a drive to a transformer with a primary rating of 2300 VAC or more may require additional input line conditioning. Contact your local Rockwell Automation sales/service office for assistance when this is required. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Input transformers step up or step down input voltage and can be either auto or isolation transformer types. Users should consider using an isolation transformer instead of an auto transformer for the following advantages:

• AC power line disturbances and transients are minimized by an isolation transformer, thus reducing or eliminating possible damage to solid state components.

• An isolation transformer provides electrical isolation for the drive from plant power system grounds. Damaging currents may be avoided in instances where the DC output is accidentally grounded or where the DC motor circuits are grounded.

Rockwell Automation offers a series of isolation transformers suitable for use with the drive.

3.5 Install an Input Disconnect

DANGER The standard EN 60204-1 requires that an input disconnect must be provided in the incoming power line and either be located within sight of the drive or have provisions for a padlock. Install an input disconnect in the incoming power line that is located in sight of the drive or one that has provisions for a padlock. Failure to observe this precaution could result in severe bodily injury or loss of life.

Any fused disconnect or circuit breaker in the incoming AC line must accommodate a maximum symmetrical AC fault current as indicated in 2.2.1 of this instruction manual.Size the disconnect to handle the transformer primary current as well as any additional loads the disconnect may supply.

1. Install an input disconnect in the incoming power line according to the standard EN 60204-1 if not provided with the drive.

The disconnect switch should be within clear view of machine operator and maintenance personnel for easy access and safety. An open-type switch with provisions for a padlock is recommended.

2. Wire this disconnect in the primary circuit of the drive isolation transformer (if used).

3-8

FlexPak 3000 49’1340 e

INSTALLATION AND WIRING

3.6 Install the Motor

1. Verify that the motor is the appropriate rating to use with the drive.

2. Install the DC motor in accordance with its installation instructions.

3. Make sure that coupled applications have proper shaft alignment with the driven machine or that belted applications have proper sheave/belt alignment to minimize unnecessary motor loading.

4. If the motor is accessible while it is running, install a protective guard around all exposed rotating parts.

5. Wire the motor to the drive. Refer to "Wire the DC-Motor to the Drive".

3.7 General Wiring Practices

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

The Drive is designed for AC entry and DC power exiting at the top and control and signal wiring entering from the bottom.

Reference signal wiring should be run in a separate conduit isolated from all AC and DC power and control. Signal wires should not be run in parallel with high voltage or electrically noisy conductors. Always cross such conductors at 90°. All reference signals should be wired with either twisted double or twisted triple conductor wire, 40 twists per meter, stranded copper, 1.5 mm

, or screened 4-stranded (3, PE) 0.5 mm2 (PN

380.35.01), 600 VAC rated insulation, with a temperature range of 40 - 105°C.

Analog tachometer feedback should be run in a separate conduit isolated from all AC and DC power and logic control. Wiring should be the same as for the reference signals but screened per pair if stranded cable 0.5 mm

(PN 380.33.00) is used.

Digital tachometer feedback (Encoder) wiring should be twisted per pair, not screened and be run in a separate conduit isolated from all AC and DC power and logic control.

For mounting with external contacts and solenoids, coils should be suppressed to reduce noise.

NOTE: The maximum recommended wire length from the drive to the motor is 300 meter.

49’1340 e FlexPak 3000 3-9

INSTALLATION AND WIRING

3.8 Wire the Drive

3.8.1 Ground the Drive and Enclosure, the Motor and the Operator's Control Station

(Refer to page 18, Recommended Lugs for Grounding FlexPak Drives in UL / cUL Version)

1. Run a suitable equipment grounding conductor unbroken from either drive ground point (terminal PE or ground stud) to the plant ground (grounding electrode).

2. Connect a suitable grounding conductor from each conduit to this drive ground point. A ring lug is recommended at the ground point.

3. Connect a suitable equipment grounding conductor to the motor frame, the transformer enclosure if used, and the drive enclosure. Run this conductor unbroken to the grounding electrode.

4. Connect the PE (green/yellow) wire brought in with the incoming AC power line to the drive ground point. Tighten chassis ground connections.

3.8.2 Wire AC-Power to the Drive

WARNING

The drive requires a 3-phase power source of 200 - 500 (300 - 575/690 V), 50/60 Hz (see 2.2.2). If the correct voltage is not available, a transformer must be installed between power source and drive. Do not connect the drive to a power source with available short circuit capacity in excess of the max. symmetrical fault current. Failure to observe these precautions could result in bodily injury.

1. Size the AC line supply conductors for the specific drive rating and according to all applicable standards.

2. Connect the AC line supply via disconnect (if used) and line reactor or matched transformer to the terminal strips or bus bars at the top of the Converter or to the disconnect.

3.8.3 Wire the DC-Motor to the Drive

1. Size the motor armature circuit conductors for the specific drive rating (see Table 2-3) and according to applicable standards. Use only copper wire rated 60/70°C or higher.

2. Locate the DC-motor armature and field supply leads on the drive.

3. Connect the DC-motor armature leads and the shunt field supply leads to the drive.

3.8.3.1 Motor Overload Protection

A software (internal) static overload is provided. In addition to the software (internal) overload function, a DC-motor thermostat can be used for motor thermal overload protection. The thermostat leads are brought out through the motor terminal box as leads P1 and P2. These two leads must be wired to the regulator board control terminals 13 and 14. The thermostat leads can be run with the motor armature and field power wiring.

NOTE: The Drive will not start if the circuit between terminals 13 and 14 is not made. See Figure 3-8.

3.8.4 Main contactor (Refer to connection diagram example Figures 3-8a and 3-8b)

A main contactor in the AC-line input or armature circuit is not built-in and must be externally provided. It allows ‘Coast-to-rest’ (Category 0) or ‘Ramp-to-rest’ (Category 1, according to EN60204-1, Chap. 9.2.2.) each with disconnection of the power source from the motor. The sequencing of the M-contactor must be controlled by the drive MCR contact of the FlexPak 3000, which is wired to terminal strip X1:5 and X1:6 located at top of the power unit. On drives, where the inrush current of the M-contactor coil exceeds the MCR contact rating (330 VA at AC 230V, cos phi 0.5), a pilot relay is required between the MCR contact output and the M-contactor coil. A normally open auxiliary contact from the main contactor must be wired to terminals X1:3 and X1:4 to provide contactor status feedback to the drive.

3-10

FlexPak 3000 49’1340 e

INSTALLATION AND WIRING

3.8.5 Emergency Stop-Function

WARNING:

It is the responsibility of the user to decide, how the Emergency Stop Function is fulfilled, depending on the requirements of the application and based on a risk assessment of the machine. Disconnection of the power source from the motor may be reached e.g. by one of the following measures:

a) Circuit breaker used as Emergency Stopping Device:

b) Circuit breaker not used as Emergency Stopping Device:

A Connection Diagram - Example for case b) is shown in Figures 3-8a and 3-8b. FUNCTION: Actuating of the Emergency Stop pushbutton during operation, causes immediate

drop out of relay K10, opening the n.o. contact at input terminal 8 and blocking of the regulator. At zero current, opening of contact output MCR will drop out the main contactor via auxiliary contactor K1. The time delayed normally open contact of timer relay K10T ensures, that in case of malfunction of the internal control circuit (MCR does not open) the main contactor drops out after 1 second.

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) must be accessible to the operator. Failure to observe this precaution could result in bodily injury or loss of life.

- easy accessible to the operator, hand operated or

- remote operated, e. g. undervoltage trip coil released by mushroom head pushbutton.

- Emergency Stopping Device (mushroom head pushbutton) interrupts control circuit and releases Coast Stop according to Category 0.

3.8.6 Stopping the Drive

3.8.6.1 COAST-STOP Digital Input

Opening of the digital input COAST-STOP (drive terminal 8) during operation causes blocking of the regulator and the drive to Coast-to-rest. This input may be used for the Emergency Stop control circuit, if the main contactor drop out is forced by electro mechanic device, otherwise this Stop function corresponds with Category 2. NOTE: If this digital input is not used, a jumper must be wired between drive terminals 7 and 8, otherwise the drive will not start.

3.8.6.2 STOP Digital Input

Depressing the STOP key (between 1 and 3 of drive terminals ) with the drive running causes the drive to stop in the selected Stop-Mode (‘Coast-to-rest’, ‘Ramp-to-rest’ or ‘Current limit Stop’). This STOP-function corresponds with Category 2, if the main contactor drop out is not forced by electro-mechanic device. The function is active at all times regardless of the selection of AUTO/MANUAL or the CSS setting (KEYPAD/TERMBLK).

3.8.6.3 Customer Interlock

Opening the control input at terminal 9 during operation is the fastest way to disable the drive output. By software it directly ramps down armature current to zero and then opens the main contactor. The motor will coast to rest. Because this is a software function it must not be used for safety relevant stopping. For emergency stop use the coast to stop input as per 3.8.6.1. NOTE: If this digital input is not used, a jumper must be wired between terminal 9 and 11, otherwise the drive will not start.

3.8.7 Wire User Devices to the Drive (If Used)

Reference Figure 3-8a and Table 3-6 when wiring user devices to the drive. Size and install all wiring in accordance with all other applicable standards.

49’1340 e FlexPak 3000 3-11

INSTALLATION AND WIRING

+ 24 V

K10

RUN

STOP

JOG

REV/FWD

AUTO/MAN Reference select

+ 24 V

COAST STOP

CUSTOMER INTERLOCK

FAULT/ALARM RESET

+ 24 V

METERING OUTPUTS

24 ANALOG OUT1

25 ANALOG OUT

COM

ANALOG OUT2

RUNNING

ALARM

MANUAL REFERENCE

AUTO REFERENCE

DIGITAL INPUT 0

MOTOR THERMOSTAT

+ 24 V

24 V COM

+ 10 V (ISOLATED)

COM

+ MAN REF

+/-

COM

HI RANGE LO RANGE

FAULT

ANALOG TACH

COMMON

Figure 3-8a - Sample Regulator Board Terminal Strip Connection Diagram

3-12

FlexPak 3000 49’1340 e

INSTALLATION AND WIRING

Table 3.6 - User Device Connections to the Regulator Board Terminal Strip

User Device Regulator Board Terminal Strip Numbers

RUN 1 (+24V) and 2 STOP 1 (+24V) and 3 JOG 1 (+24V) and 4 REV/FWD 1 (+24V) and 5 AUTO/MAN reference select 1 (+24V) and 6 INTERLOCK 9 and 11 (+24V) FAULT/ALARM RESET 10 and 11 (+24V) DIGITAL INPUT 0 12 and 14 (+24V) MOTOR THERMOSTAT 13 and 14 (+24V) 24V SUPPLY COMMON 15 (+24V COM)

SPEED REFERENCE POTENTIOMETER:

■ High Side (+10 ISOL)

■ Wiper (+ MAN REF) 17

■ Low Side (COM) 18

AUTO REFERENCE: (+) 19

(-) 20 TACHOMETER (Analog): High Range (Jumper J14 in position HIGH)

Low Range (Jumper J14 in position LOW) 22 Common 23 ANALOG OUT1 (Metering) 24 and 25 (common) ANALOG OUT2 (Metering) 25 (common) and 26 RUNNING (Indicator) 27 and 28 ALARM (Indicator) 29 and 30 NO FAULT (Indicator) 31 and 32

K1M

5634 MCR

K10

K10 K10T K1 K1M

K10T

Figure 3-8b – Main Contactor Sequencing Connection Diagram - Example 49’1340 e FlexPak 3000 3-13

INSTALLATION AND WIRING

X1:6

X1:5

X1:4

X1:3

MCR

OIM 604.42.00

DCM 604.42.10

483G

382G

481G

47G

THY6

THY3

V6V5V4

V3V2V1

THY5

THY2

THY4 THY1

TID 813.40.00

POWER INTERFACE

J9 J1

J5J8

321

47 45

121187

MOV1

MOV 2-4

1 2

4 3

230 115

531

4321

X6X5

X2 531

2W2V2U

REGULATOR

POWER SUPPLY

J4J3J2J1

810.79.40

J7J1

FPP 810.89.00

MAX. 415V

Figure 3-9: Principle wiring diagram of FlexPak 3000, single quadrant (example S-6 150 A) 3-14

FlexPak 3000 49’1340 e

INSTALLATION AND WIRING

V13

V12V11

V6V5V4

45G

THY13 THY16

V16

V15

V14

V3V2V1

THY12 THY15

THY11

THY14

483G

382G

481G

47G

THY6 THY3

THY5

THY2

THY4 THY1

X1:6

X1:5

MCR

X1:4

X1:3

OIM 604.42.01

DCM 604.42.10

J9 J1

TIC 813.39.00

POWER INTERFACE

J5J8

321

J4J3J2J1

121187

MOV1

MOV 2-4

1 2

4 3

2W 2V

531

4321

X6X5

5 4

X2 531

230 115

-+ 75

810.79.40

REGULATOR

J7J1

FPP 810.89.00

POWER SUPPLY

MAX. 415V

Figure 3-10: Principle wiring diagram of FlexPak 3000, four quadrant (example S-6R 150 A) 49’1340 e FlexPak 3000 3-15

INSTALLATION AND WIRING

810.79.40

Field Curr.

Regulator

762.70.70

583

582

1 2

4 3

MOV 2-4

230 115

460 V

Figure 3-11: Principle wiring diagram of FlexPak 3000, single quadrant S-6, 1600 A, 575 V 3-16

FlexPak 3000 49’1340 e

INSTALLATION AND WIRING

810.79.40

Field Curr.

Regulator

762.70.70

583

582

1 2

4 3

MOV 2-4

230 115

460 V

Figure 3-12: Principle wiring diagram of FlexPak 3000, four quadrant S-6R, 1600 A, 575 V 49’1340 e FlexPak 3000 3-17

INSTALLATION AND WIRING

Recommended Lugs for Grounding FlexPak 3000 Drives in UL / cUL Version

The following describes how to interpret Reliance USA lug model numbers used in grounding the FlexPak 3000 drive. The lugs are non-insulated screw type (solderless) for use with solid and stranded wire.

1LG 1 2 03

Basic Catalog Number Number of Conductors

1 = one conductor 2 = two conductors 3 = three conductors

Mounting Hole and Lug Material

1 = one mounting hole, copper 2 = one mounting hole, aluminum 3 = two mounting holes, copper 4 = two mounting holes, aluminum 5 = four mounting holes, copper 6 = four mounting holes, aluminum

Lug Version Number

01 to 99

Table 3-7: Recommended Lugs for different Wire Sizes

RA Dierikon Part Number

916.10.70 1LG1101 68321-38AA 14 - 8 AWG M5 copper

Reliance USA Model Number

Reliance USA Part Number

Wire Size Mounting

Hole

Material

916.10.71 1LG1102 68321-38AB 14 - 8 AWG M6 copper

916.10.72 1LG1103 68321-38AC 4 - 1/0 AWG M10 copper

916.10.73 1LG1104 68321-38AD 1/0 - 4/0 AWG M12 copper

916.10.74 1LG1105 68321-38AE 4/0 - 500 MCM M10 copper

916.10.80 1LG1201 68321-38BA 14 - 1/0 AWG M6 aluminum

916.10.81 1LG1202 68321-38BB 14 - 2/0 AWG M6 aluminum

916.10.82 1LG1203 68321-38BC 6 - 250 MCM M8 aluminum

916.10.83 1LG1204 68321-38BD 6 - 300 MCM M6 aluminum

916.10.84 1LG1205 68321-38BE 6 - 350 MCM M10 aluminum

916.10.85 1LG1206 68321-38BF 4 - 500 MCM M10 aluminum

916.10.86 1LG1207 68321-38BG 300 - 800 MCM M12 aluminum

916.10.87 1LG1208 68321-38BH 500 - 1000 MCM M12 aluminum

916.10.88 1LG2401 68321-39BA 2 - 600 MCM M10 aluminum

916.10.89 1LG2402 68321-39BB 350 - 800 MCM M10 aluminum

916.10.90 1LG2403 68321-39BC 500 - 1000 MCM M12 aluminum

916.10.91 1LG3601 68321-40BA 2 - 600 MCM M12 aluminum

3-18

FlexPak 3000 49’1340 e

DRIVE SETUP AND ADJUSTMENT

4.0 Drive Setup and Adjustment

DANGER Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate and/or service this equipment. Read and understand this section in its entirety before proceeding. Failure to observe this precaution could result in bodily injury or loss of life.

4.1 Introduction

This section details the setup and adjustment of the drive. Record final settings in Table 4.1.

4.2 Test Equipment Needed

CAUTION Do not use a megohmmeter for continuity checks in the drive. The high voltage of the megohmmeter can damage the drive's electronic circuits. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

A volt-ohmmeter having a sensitivity of 20,000 ohms per volt may be used.

4.3 Power Off Inspection

Inspect the Drive and modification kits for possible physical damage or improper connections. Verify that the wiring of the operator's station and the wiring to the Drive is made with sufficient

bare wire to make a good electrical connection. The removal of an excessive length of insulation may needlessly expose conductors resulting in the possibility of shorts or safety hazards.

4.4 Motor Ground Check

CAUTION: A megohmmeter can be used for this motor ground check, but all conductors between the motor and the drive must be disconnected. The megohmmeter’s high voltage can damage the drive's electronic circuits. Disconnect all conductors between the motor and the drive before using a megohmmeter for this motor ground check. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

The DC Motor frame and conduit box should be connected to a good earth ground per the motor instruction manual.

Verify that there is no path to ground in either the D-C Motor armature circuit, the shunt field circuit or the thermostat circuit. Connect one lead of a standard ohm reading meter to the motor frame and the other lead to the two armature leads, then to the two field leads and to the two thermostat leads. If a reading of less than 100,000 ohms is observed, a ground condition exists and MUST be corrected before power is applied.

49’1340 e FlexPak 3000 4-1

DRIVE SETUP AND ADJUSTMENT

4.5 Jumper Settings

The jumper settings for the FlexPak 3000 drive determine the regulator type, program protection, field settings, references for automatic and manual modes, tachometer voltage range, and armature feedback scaling.

• Through the OIM, check the proper jumper settings for J11, J14, and J18 in the Correct Scaling Jumper Positions menu under Drive Information. Write down these settings as displayed and make sure the actual settings match.

• Through the OIM, check the current settings for J15, J20, and J21 in the Drive Information menu. If these settings are correct for your system, you do not need to change them.

DANGER This equipment is at line voltage when A-C power is connected to the drive. Disconnect and lockout incoming power to the drive before proceeding. After power is removed, verify with a voltmeter at power terminals 1U, 1V and 1W that no voltage exists before touching any internal parts of the drive. Failure to observe these precautions could result in severe bodily injury or loss of life.

CAUTION Unless explicitly stated otherwise, power must be removed before changing any jumper connection. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Jumpers are read only on power-up, so power must be cycled for a change to a jumper setting to be recognized by the drive.

1. Remove power from the drive.

2. Remove the cover and the keypad

3. The jumpers are located on the regulator board. See Figure 4.1 for jumper locations

4. Change the jumper settings as described in the following paragraphs per the requirements of your application. Record final settings in Table 4.1.

Table 4.1 - Jumper and Adjustment Settings

JUMPER/ADJUSTMENT DEFAULT SETTING FINAL SETTING

J10 (AUTO REF) VOLTS J11 (TACH V SCALE) 16 J12 (AUTO REF) VOLTS J14 (TACH V RANGE) 62 J15 (REGULATOR TYPE) SPEED J16 (OIM PROGRAM) ENABLE J18 (ARM I FB RB) Position 4 J19 (MANUAL REF) POT J20 (FIELD LOSS DETECT) DISABLE J21 (FIELD SUPPLY) NOT APPLICABLE 1) J26 (TACH LOSS DETECT) ENABLE J27, J29 for future selection needs J28 (FILTER SELECT) (red) FLDFBK (do not change) FLDFBK J30 (POWER INTERFACE) LOW ANALOG TACH ZERO ADJ 0 ARM VOLTAGE ZERO ADJ 0

(1) Only applicable when the optional Enhanced Field Supply kit is installed.

4-2

FlexPak 3000 49’1340 e

DRIVE SETUP AND ADJUSTMENT

4.5.1 Set the Regulator Type - J15 Jumper

J15 determines whether the drive uses Speed/Voltage (SPEED) or Torque/Current (CURRENT) regulation. When CURRENT is selected, only the terminal strip or the AutoMax Network Communication Board can be used as the control source. and the reference selection is automatically set to AUTO mode. Also note that speed/voltage parameters must be set to provide overspeed protection for the drive.

GND1

ARM I

J15 J20 J26

J17

J18

J28 J22

GND

J25

IOGND2

EPROM

790.30.70

0VI2

J16 J21

J30 J29 J27

J14 J11

J12 J10 J19

GND3

Figure 4.1 - Regulator Board Jumpers, Connectors and Test Points

GND4

49’1340 e FlexPak 3000 4-3

DRIVE SETUP AND ADJUSTMENT

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

The OIM program jumper (J16) determines whether or not parameter changes can be made through the keypad. Only programming options are affected by the setting of this jumper. The OIM drive control keys (such as RUN) and the manual speed reference are not affected. To allow keypad parameter changes, place the jumper on pins 1 and 2 (ENABLE). To prevent parameter changes through the keypad, place the jumper on pins 2 and 3 (DISABLE). Parameters cannot be modified through the keypad. If an attempt to modify a parameter is made, the message "Hardware Password Protection is Enabled" is displayed on the keypad.

PROGRAM ERROR E001

HARDWARE PASSWORD PROTECTION IS ENABLED.

Press CANCEL to continue.

PROGRAM KEYPAD MANUAL FORWARD

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

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

The FIELD LOSS DETECT jumper (J20) determines whether or not a fault is generated when a field loss occurs.

NOTE: Jumper J20 is ignored if the Field Current Regulator kit is installed. Therefore, placing

J20 in the DISABLE position will not disable field loss detection. See I/M 49’1345 for more information on the Field Current Regulator.

WARNING The user must provide external field current loss detection and inhibit drive operation via one of the drive interlocks when this jumper is positioned to disable. Misapplication of this jumper can cause the motor to run at dangerously high speeds. Failure to observe this precaution could result in bodily injury.

To detect complete loss of field current, place the jumper on pins 1 and 2 (ENABLE). When a complete loss is sensed, a fault is generated and the drive is stopped.

To ignore field loss, place the jumper on pins 2 and 3 (DISABLE). Any loss of field current is than ignored. Use the DISABLE option only when no field exists, such as with a permanent magnet or when a separate field supply is used.

4.5.4 Set Tacho Loss / Open Armature Enable/Disable (TACHO LOSS DETECT) - J26 Jumper

This jumper determines whether or not a fault is generated when a tacho loss occurs or the armature is open.

WARNING When this jumper is removed and pins 1 and 3 connected, the user must provide external tacho loss detection and inhibit drive operation via one of the drive interlocks. Misapplication of this jumper can cause the motor to run at dangerously high speeds. Failure to observe this precaution could result in bodily injury.

To detect tacho loss, place the jumper on pins 1 and 2 (ENABLE). When a loss is sensed, a fault is generated and the drive is stopped. To ignore tacho loss or open armature, the jumper must be removed and pins 1 and 3 connected (through wire-wrap connection).

4-4

FlexPak 3000 49’1340 e

DRIVE SETUP AND ADJUSTMENT

4.5.5 Field Supply Jumper Connection (FIELD SUPPLY) - J21 Jumper

NOTE: This jumper has no affect on the standard field supply or the field current regulator. The FIELD SUPPLY jumper (J21) determines the voltage range that the drive expects to see

from the optional Field voltage controller kit. Refer to I/M 49’1344 for more information on that kit. The position of this jumper must correspond with the voltage range selected via the jumper wire on the optional Field voltage controller.

Jumper Connection D-C Field Voltage Range (1)

B-C 45% of VAC to 90% of VAC

(1) VAC is the RMS Line to Line Voltage at 3V and 3W.

4.5.6 Setting the Source for the Manual Mode Reference (MANUAL REF) - J19 Jumper

CAUTION: The drive will not run at the correct speed if this jumper is not set to the correct position.

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

The MANUAL REF jumper (J19) determines whether the internal +10 V isolated power supply or an external +10 V source is used for the manual mode reference.

To use the +10V power supply for the manual reference potentiometer, place the jumper on pins 2 and 3 (POT). The supply at terminal 16 of the regulator board terminal strip is used.

To use an external +10 V source, place the jumper on pins 1 and 2 (EXT). The external reference is connected at terminals 17 and 18 of the regulator board terminal strip.

NOTE: This input can be used as a trim on auto mode speed reference by setting the jumper on

pins 1 and 2 (EXT). In this case a

10 V reference can be used.

4.5.7 Setting the Tachometer Voltage Range (TACH V RANGE) - J14 Jumper / and Tachometer Voltage Scale (TACH V SCALE) - J11 Jumper

The TACH V RANGE (J14) and TACH V SCALE (J11) jumpers set the voltage range and scale of the analog tachometer.

NOTE: This jumper is ignored if an analog tachometer is not used and if FEEDBACK SELECT

is not set to DC TACH or AC TACH.

CAUTION: The drive will not run at the correct speed if these jumpers are not set to the correct position. Failure to observe this precaution could result in damage to, or destruction of the equipment.

During "Quick Start", the drive calculates the value of the tachometer range based on the values of TOP SPEED and ANLG TACH VOLTS/1000 and the setting of FEEDBACK SELECT. The correct values are displayed on the Correct Scaling Jumper Positions screen. Verify these settings prior to performing the Self Tuning procedure.

The expected analog tachometer voltage range can be set to a maximum of 250 or 62 VDC. J11 selects the hardware circuitry to maximize the resolution over the entire speed range. Jumper J14 Jumper J11 Top Speed Tach Volts < 16 volts LOW 16 Top Speed Tach Volts < 31 volts LOW 31/125 Top Speed Tach Volts < 62 volts LOW 62/250 Top Speed Tach Volts < 125 volts HIGH 31/125 Top Speed Tach Volts < 250 volts HIGH 62/250

NOTE: The output voltage of the tachometer must not exceed 250 V for DC tachometers or 275 RMS for AC tachometers when the motor is rotating at TOP SPEED. To calculate the output voltage at top speed, multiply the two parameter values:

Tachometer Voltage at TOP SPEED = TOP SPEED

1000 1000

49’1340 e FlexPak 3000 4-5

x ANALOG TACH VOLTS

DRIVE SETUP AND ADJUSTMENT

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

The AUTOREF Jumpers J12 and J10 select the type of analog auto reference to be used when the AUTO mode is selected. J12 selects the type of signal - VOLTS (Voltage) or MAMPS (milliamps). J10 selects the range.

+ / - 10 VOLTS MAX 4 - 20 mA 10 - 50 mA

J12  J10

VOLTS  10 - 50

 (BOTH)

MAMPS  PARK 

! !

VOLTS

! !

4 - 20

! !

J12  J10

VOLTS  10 - 50

(BOTH)

MAMPS  PARK 

! ! ! ! ! !

VOLTS 4 - 20

J12  J10

VOLTS  10 - 50

(BOTH)

MAMPS  PARK 

Figure 4.2 - AUTO REF Jumpers (J12 and J10)

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

CAUTION: The drive will not operate at the correct speed if this jumper is not set to the correct position. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

The ARM I FB RB) Jumper J18 scales the armature current feedback signal. The drive calculates the value of the burden resistor needed to scale the armature current feedback signal. The calculations are based on the values of MOTOR RATED ARM AMPS and MAXIMUM CURRENT. The OIM displays the correct position of this jumper during the "Quick Start" procedure. Verify this setting prior to performing the Self Tuning procedure.

! !

VOLTS

! !

4 - 20

! !

4.5.10 Check the FILTER SELECT - J28 Jumper

NOTE: jumper J28 must always be set to position FLDFBK.

4.5.11 Check the POWER INTERFACE – J30 Jumper

This jumper is factory set according to the type of power interface module installed in the drive. jumper positions are labeled LOW and HIGH. For FlexPak 3000 drives with a nominal voltage rating AC 575 V, 60 Hz and 690 V, 50 Hz the jumper J30 must be set to HIGH, for all other drives this jumper must stay in position LOW. Please refer to the ‘AC Input’ data on the nameplate.

If this jumper is not set to the correct position. nuisance AC line voltage high/low alarms may occur or, if configured as a voltage regulator, the drive will not operate at the correct speed,

CAUTION: The drive will not operate at the correct speed if this jumper is not set to the correct position. Failure to observe this precaution could result in damage to the equipment or in bodily injury.

4-6

FlexPak 3000 49’1340 e

DRIVE SETUP AND ADJUSTMENT

4.6 Powering Up the Drive

Apply A-C power to the drive after the Power Off Inspection, Motor Ground Check and Drive Setup procedures are completed. During initial power-up, the drive displays the following three screens on the OIM.

WELCOME TO THE FLEXPAK 3000 DIGITAL D-C DRIVE.

Industrial Company 1994

Keypad Version: xxx

Running keypad/display diagnostics Please wait.

Link initialization in progress. Reading Regulator data. Please wait.

FlexPak 3000 Main Menu

" Quick Start

Drive Reference Speed/Voltage Loop (SPD)

# Current Minor Loop (CML)

PROGRAM TERMBLK MANUAL FORWARD

4.7 OIM Screen Contrast Adjustment

This function can be enabled at any program menu level but not at parameter value entry screens. To enable the contrast adjustment function, press the right arrow key. The Contrast Adjustment Screen appears as:

Contrast Adjustment A B C D E F G H I J K L M N O P Q R S Press RIGHT/LEFT to INC/DEC contrast.

PROGRAM KEYPAD MANUAL FORWARD

The left arrow key decreases the contrast setting and the right arrow key increases the contrast setting.

• Press ENTER to accept the new contrast setting.

Press CANCEL to return to the previous menu screen.

• A memory save must be performed in order to save the new contrast setting to non-volatile

memory.

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

49’1340 e FlexPak 3000 4-7

DRIVE SETUP AND ADJUSTMENT

4.8 Accessing the Main Menu

The Main Menu is accessed by pressing the PROGRAM/MONITOR key until "PROGRAM" appears above the key.

The Main Menu consists of sub-menus that can be used to quick start your drive, select drive reference, tune the speed/voltage loop and/or current minor loop, configure input/output terminals for metering, set up the field, configure SCR diagnostics, or display drive information and operator interface selections. The following tree provides the overview of the Main Menu at a glance.

FlexPak 3000 Main Menu

Quick Start  Drive Reference   Speed/Voltage Loop (SPD)   Current Minor Loop (CML)   Outer Control Loop (OCL)   Input/Output   Network Communication   Field   Drive Information   Operator Interface   Additional Parameters

The sub-menus in the Main Menu list contain lower level menu lists and/or parameter lists for configuring, tuning, setup, monitoring or troubleshooting the drive.

4.9 How to Access the Menus/Parameters

Position the cursor at the menu/parameter of your choice using the up/down arrow keys and then press the ENTER key to access. If a # character displayed at the bottom left of a menu/ parameter list indicates that more selections are available. Press the down arrow key to scroll up through the selections. Similarly, if a $ character is displayed at the top left of a menu/ parameter list, use the up arrow key to scroll down through the selections.

Using the following paths starting from the Main Menu, the user can access parameters to monitor, setup, adjust, configure and tune the drive using value entry screens.

Drive Reference Speed/Voltage Loop (SPD)

  Drive Reference   Drive Reference Test Points*   Drive Reference Trim*   Drive Reference Limits*   Drive Reference Ramp*   Drive Reference Configure*   Drive Reference Scaling*

  Speed/Voltage Loop (SPD) Test Points*   Speed/Voltage Loop (SPD) Tuning   Self Tuning Setup*   Self Tuning   Speed/Voltage Loop (SPD) Feedback*

4-8

FlexPak 3000 49’1340 e

DRIVE SETUP AND ADJUSTMENT

Current Minor Loop(CML)

 CML Test Points   CML Tuning*   Self Tuning Setup*  

  CML Feedback Scaling*   Three-Phase A-C Line*   SCR Diagnostics*  Armature Phase Fire Test

Outer Control Loop (OCL)

  OCL Test Points  OCL Tuning  OCL Configure

Network Communications

Input/Output

  Meter Outputs  Analog I/O*  Digital I/O*  Frequency I/O*

 Level Detectors*

Self Tuning

Drive Information*  Correct Scaling Jumper Positions*

Field*

 Standard/enhanced Field Supply  Field Current Regulator

 Field Loop Test Points  Field Loop Tuning  Field Loop Configure  Field Loop Feedback Scaling

Operator Interface*

  Memory Operations   Memory Save   Memory Restore   Restore Defaults   Reset Clock   Define User Units

 Define Speed Units  Define Load Units  Define Outer Control Loop Units

An asterisk (*) in these paths indicates that a parameter or a parameter list exists when ENTER is pressed at that menu selection. The * is not actually displayed when the menu selection is displayed on the OIM.

Refer to Appendices B and C for information regarding the menu access path(s) for individual parameters. Appendix B contains an alphabetized list of input parameters with their associated default values, code No., description and the menu path for access. Appendix C contains an alphabetized list of output parameters with a description, code No. and the menu path for access.

49’1340 e FlexPak 3000 4-9

DRIVE SETUP AND ADJUSTMENT

4.10 Verify the Correct Direction of Motor Rotation

WARNING

If tachometer and/or rotation is incorrect, sudden and rapid acceleration may result which can cause overspeed of the drive. Failure to observe this precaution could result in bodily injury.

1. Turn power to the drive OFF.

2. Verify the operation of the Coast/Stop pushbutton using an ohmmeter. When pressed, the ohmmeter should read infinite ohms (open); when released, the reading should be 0 (short).

3. Turn power to the drive ON.

4. After power-up, select ARMATURE VOLT for FEEDBACK SELECT by taking the following path from the main menu to access this parameter:

Speed/Voltage Loop (SPD)

  Speed/Voltage Loop (SPD) Feedback*

Refer to Section 5 on "How to Change Parameter Values".

5. Initiate a "JOG" command to verify that the motor is rotating in the desired direction for the "Forward" command.

6. If the direction of rotation is incorrect, Stop the drive and then disconnect and lockout or tag power to the drive.

7. To change the direction of motor rotation, reverse the connection of the motor armature leads 1C and 1D. NOTE: Wrong rotation direction can be caused by incorrect wiring of the field (3C and 3D).

4.11 Determination of D-C Tachometer Lead Polarity

1. Turn power to the drive ON.

2. After power-up, select ARMATURE VOLT for FEEDBACK SELECT by using the following path from the main menu to access this parameter:

Speed/Voltage Loop (SPD)

  Speed/Voltage Loop (SPD) Feedback*

Refer to Section 5 on "How to Change Parameter Values".

3. Select the forward direction (as indicated above the forward/reverse key) and verify that the (+) tachometer lead is connected to terminal 21 or 22 corresponding to J14 setting, and that the (-) tachometer lead is connected to terminal 23. If the (+) tachometer lead is not connected to terminal 21 or 22, stop the drive. Disconnect and lockout or tag power to the drive. Reverse the connection of the tachometer leads.

4. Initiate a JOG command.

5. Use a voltmeter on the tachometer leads to determine the lead polarity for the Forward direction of rotation. Label the tachometer leads accordingly, (+) and (-).

4.12 Adjustments

This section describes Zero adjustments to compensate for signal drift when tachometer or armature feedback is used. These adjustments are available by accessing the Speed/Voltage Loop (SPD) Feedback menu from the Speed/Voltage Loop (SPD) at the Main Menu.

Speed/Voltage Loop (SPD)

  Speed/Voltage Loop (SPD) Feedback*

4-10

FlexPak 3000 49’1340 e

DRIVE SETUP AND ADJUSTMENT

4.12.1 Perform Armature Voltage Zero Adjust

WARNING The incorrect setting of this parameter can cause an overspeed condition. This parameter must be set by a qualified person who understands the significance of setting it accurately. Verify that the value of this parameter is accurate per your application requirements. Failure to observe this precaution could result in bodily injury.

With the drive stopped, note the value of "ARMATURE VOLTAGE" (P.289). If the value is 0 then no further adjustments are required. If the value is other than 0 then adjust the ARM VOLTAGE ZERO ADJ (P. 205) with a more positive number if the reading is a minus value, or with a more negative value if the reading is positive. Note the value of ARMATURE VOLTAGE (P.289) and continue to adjust the zero adjust parameter accordingly until the feedback value reads 0. Record the final value in Table 4.1, section 4.5.

4.12.2 Perform Analog Tachometer Zero Adjust

With the drive stopped, note the value of "ANALOG TACH FEEDBACK" (P.291). If the value is 0 then no further adjustments are required. If the value is other than 0 then adjust the "ANALOG TACH ZERO ADJ" (P.202) with a more positive number if the reading is a minus value, or with a more negative value if the reading is positive. Note the value of "ANALOG TACH FEEDBACK" (P.291) and continue to adjust the zero adjust parameter accordingly until the feedback value reads 0. Record the final value in Table 4.1, section 4.5.

4.13 Language Selection

1. At any menu level, press the left arrow (⇐) key to access the Language Select menu. This menu cannot be accessed at any parameter modification (value entry) screens. This screen will allow you to select the language used on the display. The currently selected language is displayed in the upper right of the menu screen. In the MONITOR mode, pressing HELP displays status indicators in the selected language.

LANGUAGE SELECT ENGLISH

" ENGLISH

DEUTSCH FRANCAIS

# ESPANOL

PROGRAM KEYPAD MANUAL FORWARD

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

The following languages are available:

• ENGLISH (Default)

• DEUTSCH (German)

• FRANCAIS (French)

• ESPANOL (Spanish)

• ITALIANO (Italian)

• Code (Parameter Numbers)

"Code" allows the use of parameter numbers when interfacing with the OIM. See appendices B and C for a cross-reference of "Code No." to parameter names.

49’1340 e FlexPak 3000 4-11

DRIVE SETUP AND ADJUSTMENT

2. Press CANCEL if the current selected language is the one of your choice. The display now returns to the previous menu.

3. To choose another language other than the current selected language, move the cursor to the language of your choice using the Up/Down

The OIM responds in the new selected language with:

"Please wait."

The display now returns to the main menu using the newly selected language. All drive information (software parameters, fault/alarm messages and drive status) will subsequently be displayed in the selected language.

4.14 Programming Features

The OIM allows the user to customize the drive to define user units, reset the system clock, perform memory save operations and provide program protection. These features are accessible from the Operator Interface menu.

FlexPak 3000 Main Menu

  Operator Interface*

" ! keys and then press ENTER.

Select Operator Interface from the FlexPak 3000 Main Menu. The following menu will appear.

Operator Interface

" PASSWORD

Memory Operations Reset Clock Define User Units

PROGRAM KEYPAD MANUAL FORWARD

The features of this menu are explained in the following section.

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

4.14.1 Password (PASSWORD)

WARNING It is the user's responsibility to distribute the security password. Reliance is not responsible for unauthorized access violations within the user's organization. Failure to observe this precaution could result in bodily injury.

The PASSWORD parameter prevents modification of a password protected parameters from the OIM. It can be used to lock or write-protect all software parameters from the OIM keypad. The same holds true for certain menu choices (e.g. QUICK START); while locked, the user cannot select the choice.

The PASSWORD parameter only applies to OIM programming. The OIM's drive control keys (run, jog, etc.) are not regulated by the system password. Similarly, the KEYPAD-MANUAL speed reference (OIM MOP) will continue to function.

The system automatically detects the state of the PASSWORD parameter (Enabled or Disabled).

4-12

FlexPak 3000 49’1340 e

DRIVE SETUP AND ADJUSTMENT

4.14.2 How to Enable/Disable Program Protection

To enable or disable program protection, PASSWORD must be selected at the Operator Interface menu. After pressing ENTER to confirm this selection, one of the following two

screens will appear depending on the current state of program protection.

Do you wish to enter the password to ENABLE program protection?

" NO

YES

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

PROGRAM KEYPAD MANUAL FORWARD

-OR-

Do you wish to enter the password to DISABLE program protection?

" NO

YES

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

PROGRAM KEYPAD MANUAL FORWARD

NOTE: Pressing ENTER or CANCEL while at one of these screens will display the Operator Interface menu.

PASSWORD + 55

-10000 <-> 10000

PROGRAM KEYPAD MANUAL FORWARD

4.14.3 Memory Operations

The user can save current changes made to parameter values, restore the last saved parameter values, or restore all parameters to their factory default value. Select Memory Operations from the Operator Interface menu to perform any of these operations.

FlexPak 3000 Main Menu

Operator Interface*

Select YES. At the PASSWORD integer value screen: set the value to 55.

MEMORY SAVE parameter values to retentive memory. Changes to parameters effect the operation of the drive. However, these changes are lost if the drive is powered down without saving the changes.

- This choice saves the current changes ("runtime" RAM memory) of

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

MEMORY RESTORE

- This choice restores the last saved parameter values from retentive

memory to "runtime" memory. RESTORE DEFAULTS

- This choice restores factory default parameter values to "runtime"

memory.

49’1340 e FlexPak 3000 4-13

4.14.4 Reset Clock

This feature of the Operator Interface menu resets the elapsed time clock.

FlexPak 3000 Main Menu

  Operator Interface*

The elapsed time clock indicates the number of days, hours, minutes and seconds since the last powerup. This clock is only visible if a fault or an alarm exist when reviewing the fault and alarm logs. Pressing ENTER while the choice is at Reset Clock will reset the readouts of the elapsed time clock to "00" and display the following message:

DRIVE SETUP AND ADJUSTMENT

Reset Clock

DRIVE CLOCK HAS BEEN RESET. Press CANCEL to continue.

PROGRAM KEYPAD MANUAL FORWARD

4.14.5 Define User Units

1. Select "Define User Units" from the "Operator Interface" menu.

FlexPak 3000 Main Menu

  Operator Interface*

2. Move the cursor to "Define User Units" and then press ENTER. The following menu is now displayed:

Define User Units

" Define Speed Units

Define Load Units

PROGRAM KEYPAD MANUAL FORWARD

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

4.14.5.1 Define Speed Units

1. Move the cursor to Define Speed Units or Define Outer Control Loop Units, press ENTER. If you select speed units, the following modification screen appears:

Define Speed Units

SPEED UNITS SELECT RPM

" RPM

% OTHER

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

PROGRAM KEYPAD MANUAL FORWARD

The OCR loop units screen looks the same, except that AMPS is an option instead of RPM.

2. Select the unit of your choice (RPM, AMPS, or %) or use OTHER to customize a label for speed units. See Step 3. if OTHER is selected.

3. OTHER - Customize a User Unit Label:

4-14

FlexPak 3000 49’1340 e

DRIVE SETUP AND ADJUSTMENT

This choice allows the user to define a 1 to 6 character string for the units of a parameter in the speed parameter class. Thus, the user defines the units for a class and every parameter in that class will appear in those units i.e., user units. Parameters not in the class are not affected by the user unit definitions. Parameters for which user units may be defined will be subsequently displayed in terms of those units and will require value entry in such terms.

For example, suppose the user wants to define speed related parameters in terms of inches per second rather than the standard units of RPM. All parameters in the speed class (MAXIMUM SPEED, MINIMUM SPEED, etc.) will use this single set of units (unit label: "INCH/S"; scaling constant: 100 IN/SEC = 1750 RPM) defined for the speed class.

First, use the left and right arrow keys to select the column to be changed. Use the up arrow and down arrow keys to define the characters in the label. The label may be from 1 to 6 alphabetic characters in length. For example: "INCH/S".

Define Speed Units

Define Units Tag. INCH/S

PROGRAM KEYPAD MANUAL FORWARD

Second, enter the scaling constant at the following display which relates the user unit to the standard unit. The OIM will use this constant to translate between user and standard units.

Define Speed Units

FULL SCALE VALUE 100 + 100

1 <-> 10000

PROGRAM KEYPAD MANUAL FORWARD

In the previous example, the OIM would translate between user and standard units as follows:

user units standard units

100 INCH/S 1750 RPM 50 INCH/S 875 RPM

-20 INCH/S -350 RPM 0 INCH/S 0 RPM

The scaling constant may be in increments of 0.01 by entering the number of decimal places at the following screen. NOTE: this screen will appear only if the full scale value is less than 4094.

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

Define Speed Units Enter the number of decimal places:

NONE ONE TWO

PROGRAM KEYPAD MANUAL FORWARD

The OIM returns to the Define User Units menu after the number of decimal places has been entered.

49’1340 e FlexPak 3000 4-15

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

4.14.5.2 Define Load Units

DRIVE SETUP AND ADJUSTMENT

Define User Units

" Define Speed Units

Define Load Units

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

PROGRAM KEYPAD MANUAL FORWARD

1. Move the cursor to Define Load Units and then press ENTER. The following value entry

screen appears:

Define Load Units LOAD UNITS SELECT %FLA

" %FLA

AMPS

PROGRAM KEYPAD MANUAL FORWARD

2. Choose the units of your choice and then press ENTER.

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

3. Press CANCEL to return to the Define User Units menu. Press CANCEL a second time to

return to the Operator Interface menu.

4-16

FlexPak 3000 49’1340 e

CHANGING PARAMETER VALUES

5.0 How to Change Parameter Values

5.1 Introduction

Value entry screens (Integer, Standard Choice Integer, Selector Switch or Boolean) allow the user to modify a single parameter's value or selection. Value entry screens contain a cursor and an entry field area. Note that the cursor for value entry fields is a blinking underscore.

Generally, pressing ENTER while in a value entry screen has the following effects:

1) The current value/selection is accepted and the entry field is reset to the new value.

2) The display remains in the value entry screen.

5.2 Integer Value Entry Screen

This screen allows the user to enter a numeric value within the specified limits of the parameter's input range.

The entry field consists of 5 digit positions and a sign. A cursor marks the position of the digit to be adjusted. A sign indicator is positioned 1 character to the left of the left-most digit (MSD or most significant digit) as shown below:

Parameter-Name Parameter’s

Entry Sign Parameter’s

Input Range

Parameter’s Parameter Parameter- Parameter Main Menu Entry Field Present Value Units

DRIVE REF RAMP

CCELERATION RATE

10.0

0.1 < - > 300.0

PROGR AM

MONITOR

HELP

CANCEL

FAULT

ENTER

KEYPAD

CONTROL SOURCE SELECT

MANUAL

AUTO

MANUAL

SECOND10.0

FORW ARD

FORWA RD

REVERSE

RUN

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

JOG

STOP

RESET

Figure 5.1 - Integer Value Entry Screen Borrows and carries will be in effect for the right-most digit (LSD or least significant digit) only.

For example, pressing ⇑ with the cursor at the LSD would change the number 199 to 200. However if the cursor was positioned 1 to the left of the LSD then the number would change from 199 to 109.

49’1340 e FlexPak 3000 5-1

CHANGING PARAMETER VALUES

The programmer cannot enter a number out of a parameter's valid range.

1) Use ⇐ and ⇒ keys to select the digit position or the sign within the entry field.

No wrapping (i.e. from LSD to MSD and vice versa).

When ⇐ or ⇒ is pressed, before the cursor position changes to the new position,

the number at the old cursor position is first accepted.

ACTIVE KEYS:

ENTER

<-------

2) The display remains in the value entry screen.

1) The new value is accepted and the entry field is set to the new value (just accepted).

" UP ! DOWN  LEFT

& RIGHT

CANCEL

-OR-

HELP

Increments digit at cursor or toggles the sign plus "+" or minus "−"

when the cursor is positioned over the sign.

Decrements digit at cursor or toggles the sign plus "+" or minus "−"

when the cursor is positioned over the sign.

Moves the cursor left 1 position to select a digit position or a sign

within the entry field.

Moves the cursor right 1 position to select the digit position or the sign

within the entry field.

Restores the original value and the current value entry screen remains displayed

if an entry is in progress,

i.e. the value has been altered but not yet accepted (using ENTER).

The previous menu before entering the value entry screen is displayed if no entry is in progress, i.e. the value has not yet been altered.

Provides help text on the particular parameter.

5.3 Standard Choice Integer Value Entry Screen

This screen allows the user to enter a numeric value by selecting one of several "standard" values, or instead, by selecting the "OTHER" option. "OTHER" allows the user to enter a numeric value within the specified limits of the range similar to operations of the "Integer Value Entry Screen".

For example:

SETUP PARAMETER PARAMETER NAME 230 VAC

" 230

400 460

" OTHER

PROGRAM KEYPAD MANUAL FORWARD

1) Position the cursor to the line containing the desired "standard" choice (in this example, 230, 400, or 460). This will be performed using the ⇑ and ⇓ keys only. Scrolling will take place when applicable.

If the selected choice (choice at cursor) is the desired value:

2) Press ENTER to accept the current selection or press CANCEL to restore the original value/selection (230 VAC) and then display the previous menu before entering the value entry screen.

5-2

FlexPak 3000 49’1340 e

!! !!

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

CHANGING PARAMETER VALUES

3) If the selected choice (choice at cursor) is OTHER: a) Press ENTER. b) Use ⇐ and ⇒ keys to select the digit position or the sign within the entry field.

No wrapping (i.e. from LSD to MSD and vice versa).

When the ⇐ or ⇒ key is pressed, before the cursor position changes

to the new position, the number at the old cursor position is first accepted.

ACTIVE KEYS:

ENTER

<-------

2) The display remains in the value entry screen.

1) The new value/selection is accepted and the entry field is set to the new value/selection (just accepted).

" UP

! DOWN

 LEFT

& RIGHT

CANCEL

HELP

Moves the cursor up and/or scrolls down; when in a value entry screen,

it increments the digit at the cursor or toggles the sign plus "+" or minus "-" when the cursor is positioned over the sign.

Moves the cursor down and/or scrolls up; when in a value entry screen,

it decrements digit at cursor or toggles the sign plus "+" or minus "−" when the cursor is positioned over the sign.

Moves the cursor left 1 position to select a digit position or a sign within the entry

field.

Moves the cursor right 1 position to select the digit position or the sign within the

entry field of a value entry screen.

Restores the original value and the current value entry screen remains displayed

if an entry is in progress,

i.e. the value has been altered but not yet accepted (using ENTER).

-OR-

The previous menu before entering the value entry screen is displayed if no entry is in progress, i.e. the value has not yet been altered.

Provides help text on the particular parameter.

49’1340 e FlexPak 3000 5-3

CHANGING PARAMETER VALUES

5.4 Selector Switch or Boolean Value Entry Screen

This screen allows the user to select one of two or several possible switch positions. It is similar to a multi-position switch. The switch is changed by selecting a position from a list of selections.

For example:

Speed/Voltage Loop (SPD) Feedback

FEEDBACK SELECT DC TACH " ARMATURE VOLTS

DC TACHOMETER PULSE TACHOMETER AC TACHOMETER

PROGRAM KEYPAD MANUAL FORWARD

1) Position the cursor to the line containing the desired switch position. This will be performed using the

2) Press ENTER to accept the new value or press CANCEL to restore the original value and then display the current value entry screen.

" and ! keys only. Scrolling will take place when applicable.

5.5 Reference Selecting via Keypad OIM

To select the reference via Keypad OIM, Control source select must be set to Keypad The reference can then be altered using the

reference value.

" and ! keys. Pressing ENTER stores the new

!! !!

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

5-4

FlexPak 3000 49’1340 e

QUICK START

6.0 Quick Start

ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate and/or service this equipment. Read and understand this section in its entirety before proceeding. Failure to observe this precaution could result in bodily injury or loss of life.

6.1 Introduction

The Quick Start function from the Main Menu will be used to start up and tune the drive. NOTE: CONTROL SOURCE SELECT must be set to KEYPAD for complete OIM control during the Quick Start procedure.

6.2 About The Quick Start Exit Menu

Pressing CANCEL during the Quick Start procedure (except where noted) will cause the Quick Start Exit Menu to be displayed.

For example:

Quick Start Quick Start Exit Menu

" Return to previous step.

Exit Quick Start using changes. Exit Q.S. without using changes.

PROGRAM KEYPAD MANUAL FORWARD

The user must pick one of the options from the Quick Start Exit Menu. Repeatedly pressing CANCEL and selecting "Return to previous step" allows the user to go backward through the Quick Start procedure.

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

6.3 How To Step Through Quick Start

ATTENTION: The drive will not operate at the correct speed if hardware jumpers J11, J14 and J18 are not set as indicated on the OIM during Quick Start. Record and verify that these jumpers are set as indicated on the OIM during Quick Start. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Record the present values of J11, J14 and J18 in Table 6.1 before continuing with this procedure. The correct position of these jumper settings will be displayed during the "Quick Start" procedure. If the correct position of these jumpers are the same as the values recorded in Table 6.1, Self Tuning can be started without leaving the Quick Start screens. If they are not the same, refer to section 4.5, Jumper Settings.

49’1340 e FlexPak 3000 6-1

QUICK START

Table 6.1 - Quick Start Jumper Settings

Hardware Jumper No. Initial Setting Final Setting J11 (TACH V SCALE) J14 (TACH V RANGE) J18 (ARM I FB RB)

NOTE: The values entered in the Quick Start procedure are not automatically saved to retentive

memory. To save these values, the user must perform a memory save. Reference section 4 of this instruction manual for procedures regarding memory operations.

FlexPak 3000 Main Menu

" Quick Start

Drive Reference Speed/Voltage Loop (SPD)

# Current Minor Loop (CML)

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

PROGRAM KEYPAD MANUAL FORWARD

At the FlexPak 3000 Main Menu, position the cursor at Quick Start and then press ENTER to begin the Quick Start procedure.

ATTENTION: Some of the parameters set in the quick start procedure can cause the drive to operate improperly if the values are entered incorrectly. Incorrect values can cause the drive to operate outside of the recommended operating conditions. Verify that the values of these parameters are appropriate for your application before changing them. Failure to observe these precautions could result in bodily injury.

The MOTOR BASE SPEED/TOP SPEED standard choice integer value entry screen is now displayed.

Quick Start MOTOR BASE SPEED/

TOP SPEED 1750 RPM 1150 1750

2500

" OTHER

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

PROGRAM KEYPAD MANUAL FORWARD

Change the value of this parameter if required. Refer to the section on HOW TO CHANGE PARAMETER VALUES if needed.

The following table lists the sequence of the parameter value entry screens along with their associated parameter default values, parameter descriptions and provides a column to record the parameter value as entered (changed) by the user.

Pressing ENTER accepts the value and then moves to the next step in the sequence of screens presented in Table 6.2.

6-2

FlexPak 3000 49’1340 e

QUICK START

ATTENTION: The incorrect setting of the Quick Start parameters can cause an overspeed condition. These parameters must be set by a qualified person who understands the significance of setting. Verify that the value of these parameters is set accurately per your application requirements. Failure to observe this precaution could result in bodily injury.

ATTENTION: The parameter for the current transformer turns ratio (Tp/Tn) CT TURNS RATIO (P.010) is factory set depending on the power unit size. Do not adjust/change the value of this parameter from its factory default value unless you are replacing the regulator board without downloading of the parameter set. In that case refer to Appendix B for setting the ratio (Tp/Tn). Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Table 6.2 - Quick Start Parameter Modification Sequence

Step No.

Parameter Name

Code No.

Default Description User

1 TOP SPEED 011 500 RPM The highest running speed of the motor. It

scales the feedback device.

TOP SPEED depends on several factors:

• If there is no field weakening, the top speed is typically the same as the nameplate base speed.

• If there is field weakening, the Top Speed is the same as the field weakened speed. Top speed is typically more than the base speed when field weakening is applied.

ATTENTION: Before starting the drive, this parameter must be set to base speed or, if the Field Current Regulator kit is installed, the field weakened speed. You are responsible for assuring safe conditions for operating personnel by setting this parameter properly. Failure to observe this precaution could result in bodily injury.

Do not allow the motor to exceed the maximum safe speed of the motor or driven equipment as determined by the equipment manufacturer. Failure to observe this precaution can result in bodily injury

2 MOTOR

RATED ARM AMPS

008 8 AMPS

ATTENTION: The drive will not operate properly if this parameter value is wrong. This parameter must be less than the rated armature amps on the motor nameplate. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Setting

The rated armature current from the motor nameplate.

49’1340 e FlexPak 3000 6-3

QUICK START

Table 6.2 - Quick Start Parameter Modification Sequence. - continued

Step No.

3 MOTOR

Parameter Name

Code No.

009 400 VOLTS RATED ARM VOLTS

4 REVERSE

015 OFF* NOTE: This parameter might be affected by DISABLE

5 FEEDBACK

200 SELECT

6 ANLG TACH

203 60 V/1000 VOLTS/1000

7 PULSE TACH

207 1024 PPR PPR

8 PULSE TACH

208 ON QUADRATURE

Default Description User

Setting

The rated armature voltage from the motor nameplate.

FEEDBACK SELECT, step 5.

When

ON, REVERSE DISABLE prevents the

speed reference from dropping below zero. The reverse bridge cannot be activated.

When OFF, the speed reference can drop below zero and the drive can reverse. *The default is ON when:

• The drive has a non-regen. (S6) power unit.

•

FEEDBACK SELECT is set to AC TACH. FEEDBACK SELECT is set to PULSE TACH

•

and

PULSE TACH QUADRATURE is OFF.

ARMATURE VOLT

Determines the type of feedback signal that is used for the speed/voltage loop:

PULSE TACH can be selected only if a pulse

tachometer kit is installed.

FEEDBACK SELECT causes the NEGATIVE CURRENT LIM (step 16) to be set to 0 and REVERSE DISABLE to be set to ON if:

•

AC TACH is selected. PULSE TACH is selected and PULSE TACH

•

QUAD is set OFF.

RPM

Only needs to be set if FEEDBACK SELECT is set to

AC TACH or DC TACH.

This parameter is the analog tachometer scaling from the tachometer nameplate in volts per 1000 RPM.

It might be limited to less than 200.0 volts/1000 so that voltage from the tachometer will not be more than 250 V.

Only displayed if

PULSE TACH and a pulse tach interface is

FEEDBACK SELECT Is set to

installed. It sets the pulse encoder pulses per revolution

(PPR) from the pulse encoder nameplate. Only displayed if

PULSE TACH and a pulse tach interface is

FEEDBACK SELECT is set to

installed. Enables or disables pulse encoder quadrature. Set ON for a bi-directional pulse encoder. Set OFF for a unidirectional pulse encoder.

PULSE TACH QUADRATURE is set to OFF

while

PULSE TACH is the selected FEEDBACK

SELECT type, NEGATIVE CURRENT LIM will

be set to 0 and

REVERSE DISABLE set to ON

(preventing reverse direction).

6-4

FlexPak 3000 49’1340 e

QUICK START

Table 6.2 - Quick Start Parameter Modification Sequence. - continued

Step No.

Parameter Name

9 ACCELERA-

TION RATE

10 DECELERA-

TION RATE

11 MINIMUM

SPEED

Code

Default Description User

No.

001 5 SEC. The time it takes to accelerate from 0 to Top

speed. Smaller changes in speed take proportionately less time. If

SELECT is set to PROPORTIONAL, this time

value is modified by

OUT.

DRAW PERCENTAGE

TRIM MODE

002 5 SEC. DECELERATION TIME selects the time it takes

to decelerate from Top speed to 0. Smaller changes in speed take proportionately less

003 0 RPM

time. If

PROPORTIONAL, this time value is modified by DRAW PERCENTAGE OUT.

ATTENTION: This drive can operate at and

TRIM MODE SELECT is set to

maintaining zero speed when this parameter is set to zero. The user is responsible for assuring safe conditions for operating personnel by providing suitable guards, audible or visual alarms, or other devices to indicate that the drive is operating at or near zero speed. Failure to observe this precaution could result in severe bodily injury or loss of life.

Setting

12 MAXIMUM

SPEED

13 JOG ACCEL/

DECEL RATE

Selects the minimum speed of the drive without being stopped. It is typically greater than zero. If it is < 10% of MAXIMUM SPEED, an alarm is generated.

004 500 RPM

The maximum speed of the drive that can be supported by the application or process. If raising this value causes become less than 10% of an alarm is generated.

MINIMUM SPEED to

MAXIMUM SPEED,

This is typically set to base speed from the motor nameplate.

ATTENTION: Do not allow the motor to exceed the maximum safe speed as determined by the equipment manufacturer of the motor or the driven equipment. Failure to observe these precautions could result in bodily injury.

013 3 SEC. The time it takes the Jog reference circuit to

reach

TOP SPEED (P.011) from zero. The S-

CURVE ROUNDING (P.014)

parameter does not

affect the setting of this parameter.

49’1340 e FlexPak 3000 6-5

QUICK START

Table 6.2 - Quick Start Parameter Modification Sequence. – continued

Step No.

Parameter Name

Code

No.

Default Description User

Setting

14 JOG SPEED1 012 250 RPM The operating speed when the drive is jogging.

If DIG IN 0 SELECT (P.428) is set to

SPEED SELECT, this parameter is used when DIG IN 0 (terminal 12) is off.

JOG

ATTENTION: This drive can operate at and maintaining zero speed when this parameter is set to zero. The user is responsible for assuring safe conditions for operating personnel by providing suitable guards, audible or visual alarms, or other devices to indicate that the drive is operating at or near zero speed. Failure to observe this precaution could result in severe bodily injury or loss of life.

15 POSITIVE

CURRENT LIM

16 NEGATIVE

CURRENT LIM

005 150% FLA Sets the highest amount of current (% full load

amps) for the forward bridge. Used as a high

006 150%

FLA

limit for the speed loop PI block when

CURRENT LIM SEL (P.224)

is set to REGISTER.

This parameter only needs to be set for regenerative drives. Selects the highest

POS

amount of current (% full load amps) for the reverse bridge. Used as a low limit for the speed loop when

NEG CURRENT LIM SEL (P.224) is set to

PI block

The range is clamped to zero:

• For non-regenerative drives.

• If FEEDBACK SELECT is set to AC TACH.

• I

F FEEDBACK SELECT is set to PULSE TACH

and

PULSE TACH QUADRATURE (P.208) is set

OFF.

The range depends on the setting of

LIM INV EN

(P.226).

NEG CUR

17 IR COMPEN-

SATION

206 0% FLA Armature voltage loss compensation value

used when the drive is configured as a voltage regulator. This parameter is also used by the field current regulator to set the field weakened threshold.

IR COMPENSATION is normally determined from

the motor data sheet. It should be set to the percent

IR drop of the motor.

If this data is not available on the motor data sheet, you can set this empirically so that the no-load and full-load speeds are as close as possible when operating as a voltage regulator. This parameter is not available for

current/torque regulated drives.

Table 6.2 - Quick Start Parameter Modification Sequence. – continued

6-6

FlexPak 3000 49’1340 e

QUICK START

Step No.

18 MOTOR HOT

Parameter Name

Code No.

510 0.01amps

FLD AMPS

19 Jumper

Informat. Display

J11

J14

792

793

Default Description User

Setting

This parameter only needs to be set if a field current regulator is installed. Motor nameplate value of the rated hot field amps. This input is the basis of field current scaling. If the factory defaults are restored, or if a valid value has not yet been entered for this parameter, the DC field voltage is fixed at 150V on a 230VAC line, or at 300V on a 460VAC line.

ATTENTION You must configure this to the motor nameplate value. The incorrect configuration of this parameter can cause a motor overvoltage condition. Configure

MOTOR HOT FLD AMPS to the motor’s

nameplate value. Failure to observe this precaution can result in bodily injury and damage to the equipment

N/A

ATTENTION: The drive will not operate at the correct speed if these jumpers are not set to the correct positions. Set these

J11

jumpers to the positions as displayed in the "Quick Start" procedure for the drive to

J14

operate at the correct speed. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

J18 395 The OIM displays the correct jumper positions

for J11, J14 and J18. Record these positions in the space provided. Verify that the hardware for these jumpers is positioned the same before continuing with Quick Start.

20 Self

Tune? NO YES

N/A N/A N/A NO - Returns the display to the Main Menu.

Perform a memory save to store values to retentive memory. YES - Proceeds with the Self-Tuning procedure. Refer to the Self-Tuning section of this instruction manual before proceeding with self-tuning.

N/A = Not Applicable.

J18

Not Required

49’1340 e FlexPak 3000 6-7

QUICK START

6.4 Self-Tuning the Current Minor and Speed Loops

NOTE: Self-tuning can only be performed if the OIM is connected to the FlexPak.

ATTENTION: Before starting self-tuning, it must be verified that no overhauling or hanging loads are on the motor. self-tuning will not operate properly if overhauling loads exist. Failure to observe this precaution could result in bodily injury.

ATTENTION: The motor will rotate during self-tuning. Stay clear of rotating machinery to avoid contact with rotating machinery. Failure to observe this precaution could result in bodily injury.

ATTENTION: Self-tuning will not operate properly if prior adjustments in the Drive Setup and Adjustment are not performed. Perform all prior adjustment procedures contained in the "Drive Setup

and Adjustment" section before proceeding. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: Self-tuning must not be performed on drives operating in a process line which are mechanically coupled to one another through the process material. However, the drive may be selftuned with load applied and with inertia connected. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

NOTE: Speed Loop self-tuning can only be performed on drives with tachometer feedback

(analog or digital). In armature voltage-controlled drives, only the Current Minor Loop (CML) can be self-tuned.

6.4.1 Self Tune Setup

Speed Loop Self-tuning will tune the drive based on the current values of the following parameters:

SELF TUNE BRIDGE (P.220) - Determines the direction the motor shaft will rotate during the self tune process by selecting the SCR bridge. For non-regenerative (S6) drives, this is automatically set to FORWARD and cannot be changed.

SELF TUNE FIELD RANGE (P.218) - Sets the self-tune field range, which is the ratio of TOP SPEED to base speed. The typical value is 1.00: where top speed = base speed.

SELF TUNE STABILITY (P.219) - Determines the self-tune stability, which sets the performance of the speed loop. Low values increase the speed loop response. High values decrease the speed loop response. The typical value is 25. The following screen allows the user to change one or all of the self-tune setup values prior to self-tuning the drive.

Self tuning Setup

" SELF TUNE BRIDGE FORWARD

SELF TUNE FIELD RANGE 1.00 SELF TUNE STABILITY 25

PROGRAM KEYPAD MANUAL FORWARD

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

To access this screen outside of "Quick Start", follow one of the following menu level paths from the main menu:

Speed/Voltage Loop (SPD) Current Minor Loop (CML)

- Speed/Voltage Loop (SPD) Tuning - CML Tuning

- - Self tuning Setup* - Self tuning Setup*

- Self tuning - Self tuning

If the self-tune setup parameter values are acceptable, then continue to the EXECUTE SELF TUNING procedure to self-tune the drive.

6-8

FlexPak 3000 49’1340 e

6.4.2 Execute Self-tuning

NOTE: CML self-tuning takes approximately 3-4 seconds to complete. Speed Loop self-tuning takes approximately 1 minute to complete. If Self Tuning is not initiated by the Quick Start procedure, Self Tuning must be initiated via one the following menu level paths from the main menu:

Speed/Voltage Loop (SPD) Current Minor Loop (CML)

- Speed/Voltage Loop (SPD) Tuning - CML Tuning

- - Self tuning Setup* - Self tuning Setup*

- Self tuning - Self tuning

NOTE: The following screen will not appear if FEEDBACK SELECT is set to ARMATURE VOLT.

Self Tuning Select the type of Self Tuning:

" CML and SPEED Loop

CML only SPEED only

PROGRAM KEYPAD MANUAL FORWARD

QUICK START

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

CML and SPEED Loop - The system will perform tuning on the CML and then after completion, perform tuning on the SPEED Loop.

CML only - The system will perform tuning on the CML only. NOTE: If the FEEDBACK SELECT is set to ARMATURE VOLT, self-tuning assumes "CML only".

SPEED only - The system will perform tuning on the speed loop only. NOTE: If tuning the speed loop separately, the CML should have been previously tuned for best

results. NOTE: Most applications use 150% for the MAXIMUM CURRENT to achieve the most accurate results from self-tuning. The greater the difference between MAXIMUM CURRENT and 150% yields a corresponding greater error in the values self-tuning calculates.

To execute self-tuning, perform the following steps:

1. Select the type of self-tuning to perform and then press ENTER.

The following screen appears:

Self Tuning

Press RUN to begin self-tuning. Press CANCEL to abort.

PROGRAM KEYPAD MANUAL FORWARD

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

Pressing CANCEL returns the display to the previous screen.

2. Press RUN. NOTE: It is possible to display one of the monitor screens while self-tuning is active.

This allows the user to monitor the speed of the motor while self-tuning.

"Self-tuning is active." blinks on the display during self-tuning. The display updates as

indicated with the status of the loop being self tuned after it is complete. Once self-tuning is complete and the gains are updated, the display updates with "Self Tuning has updated the gains" and removes "Self Tuning is active."

49’1340 e FlexPak 3000 6-9

QUICK START

The following screen shows how the display will look after self-tuning has completed

successfully for both the CML and the SPD/Voltage Loop.

NOTE: The gains are not automatically saved to retentive memory. If the gain values are

acceptable, the user must perform a memory save.

Self Tuning CML Tuning complete.

SPD/VOLTAGE Loop Tuning complete. Self Tuning has updated the gains.

Press CANCEL to continue.

PROGRAM KEYPAD MANUAL FORWARD

Pressing CANCEL goes to the FlexPak 3000 Main Menu or to the previous screen if not initiated as part of the Quick Start menu.

6.5 Final Adjustments

These adjustments detail how to adjust the nominal AC Line frequency and A-C line volts parameters.

6.5.1 Nominal AC Line Adjustments

The frequency (NOMINAL A-C LINE FREQ, P.306) and the voltage (NOMINAL A-C LINE VOLTS, P.307) adjustments are accessed by selecting Current Minor Loop (CML) at the Main Menu and then selecting the Three-Phase AC Line at the CML menu level.

Current Minor Loop (CML)

- Three-Phase AC Line*

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

6.5.1.1 Perform Nominal AC Line Frequency Adjust

The default value is 50 Hz. Typically, the value is 50 or 60 Hz. Use the up/down arrow keys to adjust the value to the nominal value of the line frequency in use. Valid values are 48 to 62 Hz.

6.5.1.2 Perform Nominal AC Line Volts Adjust

The default value is 400 VAC. Use the up/down arrow keys to adjust the value to the nominal value of the AC line RMS voltage in use. Refer to Parameter description in Appendix B.

6-10

FlexPak 3000 49’1340 e

TROUBLESHOOTING/DIAGNOSTICS

7.0 Troubleshooting/Diagnostics

7.1 General

This section details troubleshooting and diagnostics information for the FlexPak 3000 Drive.

7.2 Wiring Errors

DANGER This equipment is at line voltage when AC power is connected. Disconnect and lockout all ungrounded conductors of the AC power line before checking wiring. Failure to observe this precaution could result in severe bodily injury or loss of life.

Wiring errors and loose or grounded wiring are common problems that can inhibit operation of a drive. Verify the installation wiring has been correctly executed and that the drive is free of loose terminations and grounded conductors.

7.3 AC Line and Power Input

DANGER This equipment is at line voltage when AC power is connected. Exercise extreme care when checking the AC line and power input. Failure to observe this precaution could result in bodily injury or loss of life.

Verify that the applied AC power is correct for the specific drive (refer to 2.1.2 and 2.2.3). If an isolation transformer has been installed on the incoming AC power, verify its output voltage and that it has been properly connected. Verify that the AC line fuses are semiconductor protection type and have been correctly sized per Table 8-7. The AC and DC power conductors should have been sized per local standards.

7.4 DC Motor

CAUTION A megohmmeter (megger) can be used for this motor ground check, but all conductors between the motor and the drive must be disconnected. The megger's high voltage can damage the drive's electronic circuits. Disconnect all conductors between the motor and the drive before using a megger for this motor ground check. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Recheck all motor connections for tightness and correct identification. Verify that there is no path to ground in either the DC motor armature circuit, the shunt field circuit or the thermostat circuit. Connect one lead of a standard ohm meter to the motor frame and the other lead to the two armature leads. then connect to the two thermostat leads and then to the two field leads. If a reading of less than 100,000 ohms is observed, a ground condition exists and MUST be corrected before power is applied. Check that the field winding is not open or shorted.

Verify the continuity of the motor thermostat and its proper connection to regulator board terminals 13 and 14. If a motor thermostat has been installed, verify that it's circuit maintains continuity in the terminal 13 and 14 circuit.

49’1340 e FlexPak 3000 7-1

TROUBLESHOOTING/DIAGNOSTICS

7.5 Remote M Contactor

If an M Contactor has been supplied by others, verify that it has been properly connected.

7.6 Optional Kits

Verify that each optional kit has been installed correctly according the appropriate instructions. Refer to the appropriate instruction manuals.

7.7 Fault/Alarm/Diagnostic (FAD) Menus

The OIM FAULT key toggles the FAD menus (see Section 2:). FAD menus are provided to assist in the analysis of drive operation problems. Refer to Appendix E for a complete guide to error and alarm codes. Faults prevent the drive from starting until the drive fault is corrected. In contrast, Alarms are drive conditions which could eventually result in the occurrence of a Fault, however, Alarms will not prevent the drive from starting.

7.7.1 About The Fault Menu

Access the Fault Menu by pressing the FAULT key until FAULT appears on the OIM directly above the FAULT key. The following will be displayed.

Fault Menu

" Review Log

Reset Faults Clear Fault Log and Reset Faults

FAULT KEYPAD MANUAL FORWARD

The following paragraphs will discuss these selections.

7.7.1.1 Review Log

Pressing ENTER with the cursor at Review Log displays the contents of the fault log. Entries are listed from most recent (higher numbered faults) to the oldest (lower numbered faults).

Review Log

" 05 CONTROLLER THERMOSTAT TRIP

04 FIELD CURRENT LOSS 03 A-C LINE SYNCHRONIZATION FAULT 02 OIM COMMUNICATIONS TIMEOUT

FAULT KEYPAD MANUAL FORWARD

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

7-2

FlexPak 3000 49’1340 e

TROUBLESHOOTING/DIAGNOSTICS

Pressing ENTER will display details and possible causes of the specific fault log entry.

F00009: CONTROLLER THERMOSTAT TRIP 028 days 14 hours 30 mins 00 secs

Controller thermostat indicates high temperat. Possible causes:

# Inadequate heat sink ventilation

FAULT KEYPAD MANUAL FORWARD

# Indicates that more information is available. To view this information, press the down arrow key. The remaining text for this specific fault will be displayed when scrolling takes place:

Inadequate cabinet ventilation. Heat sink failure. Damaged or disconnected controller thermostat wiring.

7.7.1.2 Reset Faults

Pressing ENTER with the cursor at Reset Faults extinguishes the Fault indicator and displays the following message on the OIM display:

ATTENTION! DRIVE FAULTS HAVE BEEN RESET. Press CANCEL to continue.

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

Resetting faults allows the user to try restarting the drive. NOTE: If proper steps were not taken to correct the fault before reset, another Fault will occur. Press CANCEL to continue.

Faults can also be reset by pressing the STOP/RESET key when the drive is stopped and CSS = KEYPAD.

7.7.1.3 Clear Fault Log and Reset Faults

Pressing ENTER with the cursor at Clear Fault and Reset Faults extinguishes the Fault indicator, resets drive faults and displays the following message on the OIM display:

ATTENTION! DRIVE FAULTS HAVE BEEN RESET. FAULT LOG HAS BEEN CLEARED. Press CANCEL to continue.

7.7.2 About The Alarm Menu

Access the Alarm Menu by pressing the FAULT key until ALARM appears on the OIM directly above the FAULT key. The following will be displayed.

Alarm Menu " Review Log

Reset Alarms Clear Alarm Log and Reset Alarms

ALARM KEYPAD MANUAL FORWARD

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

49’1340 e FlexPak 3000 7-3

7.7.2.1 Review Log

The Review Log selection displays the contents of the alarm log. Entries are listed from most recent (higher numbered alarms) to the oldest (lower numbered alarms).

TROUBLESHOOTING/DIAGNOSTICS

Review Log

" 04 LOW MINIMUM SPEED

03 LINE VOLTAGE LOW 02 MOTOR BRUSH WEAR LOW 01 LINE VOLTAGE LOW

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

ALARM KEYPAD MANUAL FORWARD

Pressing ENTER will display details and possible causes of that specific alarm log entry.

A00051: LOW MINIMUM SPEED 138 days 16 hours 23 mins 52 secs

The MINIMUM SPEED value is less than 10% of the MAXIMUM SPEED value. Verify that these parameter values are correct for your application.

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

ALARM KEYPAD MANUAL FORWARD

# Indicates that more information is available. To view this information, press the down arrow key. The remaining text for this specific alarm will be displayed when scrolling takes place.

Press the CANCEL key to exit this display.

7.7.2.2 Reset Alarm Indicator

Pressing ENTER with the cursor at Reset Alarms extinguishes the Alarm indicator and displays the following message on the OIM display:

ATTENTION! DRIVE ALARMS HAVE BEEN RESET. Press CANCEL to continue.

Press CANCEL to continue. NOTE: Alarms can also be reset by pressing the STOP/RESET key when the drive is stopped

and Control Source Select is set to KEYPAD.

7.7.2.3 Clear Alarm Log and Reset Alarms

Pressing ENTER with the cursor at Clear Alarm and Reset Alarms extinguishes the Alarm indicator, resets drive alarms and displays the following message on the OIM display:

ATTENTION! DRIVE ALARMS HAVE BEEN RESET. ALARM LOG HAS BEEN CLEARED. Press CANCEL to continue.

7-4

FlexPak 3000 49’1340 e

7.7.3 Diagnostics Menu

This menu provides information regarding drive status for diagnostics menu selections Why is the drive not ready? and Why did the drive stop?. Access the Diagnostics Menu by pressing the

FAULT key until DIAGS appears on the OIM directly above the FAULT key. The following will be displayed.

TROUBLESHOOTING/DIAGNOSTICS

Diagnostics Menu " Why is the drive not ready?

Why did the drive stop?

DIAGS KEYPAD MANUAL FORWARD

WHY IS THE DRIVE NOT READY? If the LCD indicator for Drive Ready is extinguished, the drive is not ready for one or more of the

following reasons:

• Drive faults are present.

• All interlocks, customer supplied and internal, are not closed.

Selecting the Why is the drive not ready? menu item will list on the display the reason(s) why the drive is not ready.

WHY DID THE DRIVE STOP? Selecting Why did the drive stop? will list on the display the reason(s) why the drive stopped.

This includes operator induced commands such as pushing the Coast/Stop pushbutton or the STOP key on the OIM.

7.7.4 Diagnostics Configure

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

If line disturbances occur, resulting in open SCR nuisance trips, a Diagnostics Configure menu can be accessed to help reduce the sensitivity to these disturbances. This menu is accessible directly from the Main Menu.

FlexPak 3000 Main Menu

Diagnostics Configure Use the up/down arrow keys to position the cursor next to Diagnostics Configure.

Press ENTER to access.

Diagnostics Configure " OPEN SCR SENSITIVITY 0%

OPEN SCR TRIP THRESH 800 Armature Phase Fire Test

Fault Alarm

Interlock OK Drive Ready Running Current Limit Torque Limit

PROGRAM KEYPAD MANUAL FORWARD

OPEN SCR SENSITIVITY - This parameter adjusts for load sharing differences due to unbalanced A-C lines. Increase its value to open the SCR diagnostic tolerance of load sharing differences.

OPEN SCR TRIP THRESH - This is the trip point for the SCR loss function. The default value should not be changed unless nuisance trips occur due to extremely unusual load conditions or severe instability in the CML. Raising this value will increase the diagnostic's tolerance of such disturbances. OPEN SCR TRIP THRESH should only be increased if raising OPEN SCR SENSITIVITY does not eliminate nuisance trips.

49’1340 e FlexPak 3000 7-5

TROUBLESHOOTING/DIAGNOSTICS

7.7.5 Regulator Led Status Information

Two LEDs are located on the Regulator board to indicate the operating status of the Regulator board. Check and observe these LEDs when the OIM is not communicating with the regulator. Typically, there will be no fault indication on the display when the OIM is not communicating with the regulator board, or the CPU is suspect. If, through "spurts" of communications, a fault can be displayed, the fault would be OIM COMMUNICATIONS TIMEOUT (F00011). The cover on the OIM must be removed to observe these LEDs.

The two LEDs are labeled CPU OK and OIM COMM OK. CPU OK will be on whenever the inputs and outputs are being scanned (I/O is not scanned during power-up diagnostics and following certain faults). OIM COMM OK will be on whenever the regulator board and the OIM are communicating properly. The following table summarizes the possible states of the two LED indicators.

CPU OK LED OIM COMM OK LED

Off Off

On Blink On Off

Blink Blink Off

Indication(s) and Action(s)

• No power - verify that the drive power is on. Check for 24 V at the regulator board terminals 1 and 15 (COM

• LED failure - cycle power and verify that both LED's illuminate briefly (lamp test).

• Power-up diagnostics failed - replace the regulator board.

• Combination not used.

• I/O is being scanned, regulator is not communicating with

the OIM - check OIM cable, check voltages at the OIM.

• I/O is being scanned, the regulator is communicating with the OIM, no faults - this is the normal condition, no action is required.

• I/O is being scanned, the regulator is communicating with the OIM, - diagnose/correct the fault condition and reset the fault from the selected control source fault reset.

• Power-up diagnostics in progress (lamp test).

• Combination not used.

• I/O is not being scanned, regulator board is not

communicating with the OIM,

- initialize card: set P.010, P.306, P.307 and execute MEMORY SAVE,

- press the OIM fault reset key

- check the OIM cable or cycle power.

Blink

7-6

FlexPak 3000 49’1340 e

• I/O is not being scanned, the regulator board is communicating with the OIM,

- initialize card: set P.010, P.306, P.307 and execute MEMORY SAVE,

- press the OIM fault reset key

- record information on the fault.

• I/O is not being scanned, regulator board is not communicating with the OIM,

- initialize card: set P.010, P.306, P.307 and execute MEMORY SAVE,

- press the OIM fault reset key

- record any information about the fault and cycle power.

TROUBLESHOOTING/DIAGNOSTICS

7.7.6 Armature Phase Fire Test

ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this

equipment and the hazards involved should perform this test. Read and understand this section in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: This is an open loop test. To prevent excess motor speed and current, lock the motor

shaft or disconnect the motor armature leads from the drive and replace them with a dummy load (e.g. bulbs in series). Failure to observe this precaution could result in severe bodily injury or loss of life.

An armature phase fire test mode is available to verify the operation of the S6 or S6R rectifier bridge. This test should only be performed by qualified personnel. Note that this test is not available through the

To perform an armature phase fire test:

1. Turn off power to the drive. (Lockout and tag power as necessary).

2. Either lock the motor armature to prevent rotation or disconnect the motor armature leads from the drive and replace with bulbs in series. When locking the motor armature, the motor field winding can be disconnected to prevent excessive torque. If the motor field winding is disconnected field current loss faults must be inhibited by either setting jumper J20 to Parameter

FIELD LOSS THRESHOLD (P.512) to 0 on FlexPak with field current regulator.

DCM.

DISABLE on FlexPak with field rectifier or setting

3. Turn on power to the drive. The drive must be stopped and the Drive Ready Indicator must be

ON.

4. Set

5. On the

6. Set

CONTROL SOURCE SELECT to KEYPAD.

OIM, select Current Minor Loop (CML) – SCR Diagnostics – Armature Phase Fire Test.

PHASE FIRE TST BRIDGE (P.310). This parameter must be set to the appropriate value

before activating the armature phase fire test mode.

7. Attach an oscilloscope to the armature current feedback test point (J17+, J22– on the Regulator board). Note that the CS3000 software oscilloscope mode does not have sufficient bandwidth for this test.

8. Press RUN. The armature phase fire test mode is now active. The

OIM Running indicator will

be on.

9. Set

PHASE FIRE TEST DELTA (P.309) to 55 degrees. Slowly increase PHASE FIRE TEST DELTA

until a steady pattern of “bumps” appears on the oscilloscope. If all thyristors in the selected bridge are operating, there will be six bumps per AC line cycle. If any bumps are missing, one or more thyristors are not conducting. Note that conduction will not begin until the firing angle is sufficiently advanced (

TEST DELTA (P.309) more than 60 degrees). A rate limit block limits the rate of change of

PHASE FIRE

firing angle advances to prevent sudden increases in current. To prevent the drive from entering continuous conduction during this test,

PHASE FIRE TEST DELTA (P.309) should not

exceed 89 degrees.

10. Press STOP to stop the armature phase fire test.

11. Turn off power to the drive (lockout and tag as necessary).

12. Either unlock the motor armature or remove the bulbs and reconnect the motor armature leads.

If the motor field winding was disconnected, reconnect it and return jumper J20 to its original position (typically regulator) set parameter

ENABLE on FlexPak with field rectifier) or (on FlexPak with field current

FIELD LOSS THRESHOLD (P.512) to its original value.

49’1340 e FlexPak 3000 7-7

TROUBLESHOOTING/DIAGNOSTICS

7.7.7 Power Supply Test Pin Identification

The following table lists the power supply PC board test pins and their respective voltage levels. Since it is a switching power supply, all checks need to be made while load is connected to the power supply card.

Test Pin Voltage Level

J4 to J5 J6 to J7 J8 to J7 J9 to J10 J11 to J12 J13 to J12 J14 to J16 J15 to J16 J3 to J16

+ 24 VDC + 12 VI

- 12 VI + 18 V + 15 VI

- 15 VI + 15 V

+ 5 V

- 15 V

7-8

FlexPak 3000 49’1340 e

REPLACEMENT PARTS and ACCESSORIES

8.0 Replacement of components

Use original spare parts only. Selection according to Tables 8-1 to 8-6. The location of the parts is shown on the layout label inside the U-frame.

Replacement of a thyristor or thyristor module Type 25 - 800 A

• Loosen and swing out regulator and Interface

assembly

• Remove bus bars above the thyristors

• Remove gate leads of the thyristor concerned

• Unscrew thyristor or thyristor module

• Before mounting the new thyristor or thyristor

module, coat the side, which is in contact with the heat sink, with a thin layer of heat conducting paste.

For units 800 A:

(1) Screws (2) Steel plate (3) Housing (4a) Flat washer (4) Plate springs (5) Stamp (6) Semiconductor (7) Centering bolt (8) Heatsink

NOTE: for safe and easy mounting of thyristors

on 800 A units we recommend the tool PN 050.00.00

• Insert thyristor into box-clamp and put the

package on the centering bolt on the heatsink

• Fasten the four hexagon bolts by hand until

all slack is taken out and take care that the clamp housing stays parallel to the heatsink.

• Tighten each bolt by half a revolution at one

time with hexagonal torque socket spanner 8 mm (10 mm), diagonally.

NOTE: Observe recommended torque!

• Repeat the procedure until the clamp is held

down firmly to the heatsink on each side.

• Re-connect gate leads

• Screw on bus bars.

NOTE: Before replacing a thyristor or thyristor

module the gate and cathode faston connectors must be checked for conductivity.

49’1340 e FlexPak 3000 8-1

REPLACEMENT PARTS and ACCESSORIES

Replacement of a thyristor on power unit Type 1200 - 2000 A

• Write protocol about the following procedure

• Open controller and protection unit by tilting

forwards. Layout of thyristor assembly is visible now on side wall.

• Remove bus bars on front heat sink

• Unscrew the upper cooling air deflector.

Unscrew the hexagon screws for the bus bar mounting.

• Unscrew the lower cooling air deflector

• Loosen the two screws (13 mm) on the clamp

by quarter turns. (Caution: the center clamp screw 24 mm must not be turned)

• Withdraw clamp and heat sink.

• Clean heat sink from thermo conductive

paste.

• Coat both sides of the new thyristor with an

thin film of thermo conductive paste /a

• Mount the thyristor on the centering pin in the

rear heatsink. Observe correct polarity of cathode and anode according to layout.

• Insert clamp in front heatsink and attach to

thyristor with centering pin.

NOTE /b Tighten the two clamp screws (13 mm)

alternately by one quarter turn until the control ring under the center clamp nut can be turned through 360 degree by hand. Keep clearance to a minimum.

• Proceed installation in the reverse order of

removal.

8-2

FlexPak 3000 49’1340 e

REPLACEMENT PARTS and ACCESSORIES

8.1 Recommended Spare Parts

Table 8-1: Urgent recommended spare parts for 1-Quadrant units S-6 25, 60 and 150 A

Thyristor- Field Rectifier P.C. Boards,

Power Unit Type Module Module with MOV

25 A 848.00.03/73 1 Module 1 Module 1 Regulator 810.79.40

135.60.00 124.07.00 with Firmware EPROM

1 MOV 60 A

135.60.02

150 A 848.04.03/73 3 Modules 1 Regulator 810.79.40 1 Fan

135.05.52 with Firmware EPROM 921.22.01

1 Field Current Regul. 762.70.60*

* The Field Current Regulator is only included in FlexPak types 848.xx.73

848.02.03/73

1 Module

123.39.30

MOV-Module

1 Interface TIB 813.41.01 1 Power Supply FPP 810.89.00

1 Field Current Regul. 762.70.50*

1 Interface TID 813.40.00 1 Power Supply FPP 810.89.00

1 MOV-Module 123.43.04

Cooling Fan

Table 8-2: Urgent recommended spare parts for 4-Quadrant units S-6R 25, 60 and 150 A

Thyristor- Field Rectifier P.C. Boards,

Power Unit Type Module Module with MOV

25 A 848.01.03/73 2 Module 1 Module 1 Regulator 810.79.40

135.60.00 124.07.00 with Firmware EPROM 1 Interface TIA 813.41.00 1 MOV

60 A 848.03.03/73 2 Module

135.60.02

150 A 848.05.03/73 6 Modules 1 Regulator 810.79.40 1 Fan

135.05.52 with Firmware EPROM 921.22.01

1 Field Current Regul. 762.70.60*

* The Field Current Regulator is only included in FlexPak types 848.xx.73.

123.39.30 1 Field Current Regul. 762.70.50*

MOV-Module

1 Power Supply FPP 810.89.00

1 Interface TIC 813.39.00 1 Power Supply FPP 810.89.00

1 MOV-Module 123.43.04

Cooling Fan

Further spare parts for Unit Type 150 A:

1 Capacitor 211.00.02 1 Resistor 750.70.04

49’1340 e FlexPak 3000 8-3

REPLACEMENT PARTS and ACCESSORIES

Table 8-3: Urgent recommended spare parts for 1-Quadrant units S-6 250 / 450 and 800 A

Thyristor/ Field Rectifier P.C. Boards,

Power Unit Type Thyristor- Module with MOV

Module

250 A 848.06.03/73 3 Modules 1 Module 1 Regulator 810.79.40 1 Fan

135.11.02 124.07.00 with Firmware EPROM 921.90.00

450 A 848.08.03/73 3 Modules

135.12.02 1 Field Current Regul. 762.70.60*

800 A 848.10.03/73 6 Thyristors 1 Regulator 810.79.40

122.04.02 with Firmware EPROM

1 Field Current Regul. 762.70.70*

* The Field Current Regulator is only included in FlexPak types 848.xx.73.

1 MOV 1 Interface TIF 813.42.01

123.39.30

MOV-Module

1 Power Supply FPP 810.89.00

1 MOV-Module 123.43.04

1 Interface TIF 813.42.01 1 Power Supply FPP 810.89.00

1 MOV-Module 123.43.04

Cooling Fan

Table 8-4: Urgent recommended spare parts for 4-Quadrant units S-6R 250 / 450 and 800 A

Thyristor/ Field Rectifier P.C. Boards,

Power Unit Type Thyristor- Module with MOV

Module

250 A 848.07.03/73 6 Modules 1 Module 1 Regulator 810.79.40 1 Fan

135.11.02 124.07.00 with Firmware EPROM 921.90.00

450 A 848.09.03/73 6 Modules

135.12.02 1 Field Current Regul. 762.70.60*

800 A 848.11.03/73 12 Thyristors

1 Field Current Regul. 762.70.70*

* The Field Current Regulator is only included in FlexPak types 848.xx.73

122.04.02 with Firmware EPROM

1 MOV 1 Interface TIE 813.42.00

123.39.30

MOV-Module

1 Power Supply FPP 810.89.00

1 MOV-Module 123.43.04 1 Regulator 810.79.40

1 Interface TIE 813.42.00 1 Power Supply FPP 810.89.00

1 MOV-Module 123.43.04

Cooling Fan

Further spare parts:

Unit Type 250 / 450 A 1 Capacitor 211.00.05 1 Resistor 425.18.18

800 A: 1 Capacitor 211.36.05 2 Resistor 425.18.18

8-4

FlexPak 3000 49’1340 e

REPLACEMENT PARTS and ACCESSORIES

Table 8-5: Urgently recommended spare parts for 1-Quadrant Units S-6 1200-2000 A

S-6 Thyristors Fan

Unit Type Part No. 6 Pieces

1200A, 50Hz

500 V 848.12.73 122.93.02 921.91.00

1200A, 60Hz

500 V 848.12.43 122.93.02 921.91.11

1600A, 50Hz

500 V 848.14.73 122.93.02 921.91.00

1600A, 60Hz

500 V 848.14.43 122.93.02 921.91.11

2000A, 50Hz

500 V 848.18.73 122.93.02 921.91.00

2000A, 60Hz

500 V 848.18.43 122.93.02 921.91.11

1600A, 50Hz

690 V 848.16.73 122.93.04 921.91.00

1600A, 60Hz 575 V 848.16.43 122.93.04 921.91.11

P.C. Boards,

MOV-Module

1 Interface TIG

813.43.01

1 Interface TIG

813.43.11

1 Interface TIG

813.43.11

1 MOV-Module

123.43.04

1 Regulator 810.79.40 with Firmware EPROM

1 Field Current Regul. 762.70.70 1 Power Supply FPP 810.89.00

Table 8-6: Urgently recommended spare parts for 4-Quadrant Units S-6R 1200-2000 A

S-6R Thyristors Fan

Unit Type Part No. 12 Pieces

1200A, 50Hz

500 V 848.13.73 122.93.02 921.91.00

1200A, 60Hz

500 V 848.13.43 122.93.02 921.91.11

1600A, 50Hz

500 V 848.15.73 122.93.02 921.91.00

1600A, 60Hz

500 V 848.15.43 122.93.02 921.91.11

2000A, 50Hz

500 V 848.19.73 122.93.02 921.91.00

2000A, 60Hz

500 V 848.19.43 122.93.02 921.91.11

1600A, 50Hz

690 V 848.17.73 122.93.04 921.91.00

1600A, 60Hz 575 V 848.17.43 122.93.04 921.91.11

P.C. Boards,

MOV-Module

1 Interface TIG

813.43.00

1 MOV-Module

123.43.04

1 Interface TIG

813.43.10

1 Interface TIG

813.43.10

1 MOV-Module

123.43.04

1 Regulator 810.79.40 with Firmware EPROM

1 Field Current Regul. 762.70.70 1 Power Supply FPP 810.89.00

Further spare parts for 1200-2000 A units: Suppression print SBA 803.56.00 RC-Suppression module (for 690V only) 922.58.10

49’1340 e FlexPak 3000 8-5

REPLACEMENT PARTS and ACCESSORIES

8.2 Accessories

Semiconductor protection fuses in the AC-line input of the converter and field circuit and in case of fourquadrant operation in the motor armature circuit are to be selected from the following tables 8-7 and 8-8. Chokes in the AC-line input of the converter and field circuit are to be selected from the table 8-9. The fuses and chokes are externally mounted and not supplied with the power module.

Table 8-7: Semiconductor Protection Fuses

Drive

Type

25A 21A 25A 32A 553.28.02 32A 553.28.02 553.29.00 511.23.00 60A 33A 40A 80A 553.28.07 63A 553.28.06 553.29.00 511.23.00

50A 60A 150A 75A 90A 125A 553.28.09 100A 553.28.08 553.29.00 511.23.00

108A 130A 125A 150A 200A 553.30.05* 160A 553.30.04* 553.29.00

250A 158A 190A 315A 553.31.13* 250A 553.30.06* 553.29.00 511.24.00 208A 250A 315A 553.31.13* 250A

450A 294A 350A 450A 553.32.16* 350A 553.31.14* 553.29.00 511.24.00 375A 450A 550A 553.32.18* 450A 553.32.16*

800A 525A 630A 800A 553.33.21* 630A 553.33.19* 553.29.00 511.26.01 666A 800A 1000A 553.33.22* 800A 553.33.21* 553.29.00 511.26.01

1200A 833A 1000A 1250A 553.33.23* 1000A 553.33.22* 553.29.00 511.26.01 500V

1600A 1167A 1400A 2 // 1000A 553.33.22* 2 // 900A 553.33.24* 553.29.00 511.26.01 500V

2000A 1667A 2000A 2500A 553.72.01 2000A 553.72.00 553.26.30 500V

1600A 833A 1000A 2 // 700A 553.34.35 2 // 630A 553.34.34 553.26.30 511.26.03 690V 50 Hz

1600A 833A 1000A 2 // 800A 553.33.21* 1250A 553.33.23* 553.29.00 511.26.01 575V 60 Hz

Motor

Current

nom

1000A 1200A 2 // 800A 553.33.21* 1250A 553.33.23* 553.29.00 511.26.01

1334A 1600A 2 // 1000A 553.33.22* 2 // 900A 553.33.24* 553.29.00 511.26.01

2 // 1250A 553.33.23* 2 // 1000A 553.33.22* 553.29.00 511.26.01

1167A 1400A 1334A 1600A

1167A 1400A 2 // 900A 553.33.24* 2 // 800A 553.33.21* 553.29.00 511.26.01 1334A 1600A 2 // 900A 553.33.24* 2 // 800A 553.33.21* 553.29.00 511.26.01

Motor Armature (4-Qd)

Fuses

Rating Part No.

80A 553.28.07 63A 553.28.06

200A 553.30.05* 160A 553.30.04* 553.29.00 511.24.00

2 // 900A 553.34.37 2 // 800A 553.34.36 553.26.30 511.26.03 2 // 900A 553.34.37 2 // 800A 553.34.36 553.26.30 511.26.03

(2 pieces)

AC-Line input

Fuses

Rating Part No.

(3 pieces)

553.30.06* 553.29.00

Fuse Accessory **)

(per Fuse)

Fuse Trip Indicator

553.29.00 511.23.00

553.29.00

Fuse Holder

511.24.00

Fuses and accessories marked in grey are not UL, cUL * Fuse trip indicator

553.29.00 included in fuse package

** For selection and dimensions see also following pages

Table 8-8: Field Supply Input Fuse

Max. Field Current

6 A 12 A aR 553.00.09 511.21.00 12 A 16 A aR 553.00.10 511.21.00 20 A 30 A aR 553.00.11 511.21.00

Fuse

Rating

Fuse Type

Field AC-Input Fuse Holder Dimensions

Fuse

Part No.

Fuse Holder Size 11

Part No. (2 pieces)

8-6

FlexPak 3000 49’1340 e

Fuse Holder Dimensions

REPLACEMENT PARTS and ACCESSORIES

Part number 511.23.00 for fuses DIN 80/ Size 00 (553.2...) up to 125 A

Part number

511.24.00

for fuses DIN 80/1K, 2K (553.30../31../32..) 160 - 550 A

49’1340 e FlexPak 3000 8-7

REPLACEMENT PARTS and ACCESSORIES

Fuse Holder Dimensions (continued)

80 (110)

Part number 511.26.01 for fuses DIN 80/ 3K, 660 V, 800 - 1250 A, (553.33.xx) spacing 80 mm

Part number 511.26.03 for fuses DIN 80/ 3K, 800 V, 800 - 1250 A, (553.34.xx) spacing 110 mm

Bus bars Fuse

To guarantee free air circulation, the fuses must be mounted between the input/output bus-bars as shown, with enough space to the next fuse.

Cooling air per fuse: 130 m

Fuse Part Number

Nominal Current

Fuse Dimensions

A B C D E F G H Pv

553.72.00

553.72.01

2000 A: 60 230 100 15 105 M12 31,25 100 340 W 2500 A: 60 230 100 15 105 M12 31,25 100 390 W

Fuses for FlexPak 3000 type 2000 A (non UL, cUL) 8-8

FlexPak 3000 49’1340 e

REPLACEMENT PARTS and ACCESSORIES

Table 8-9: Iron Core Choke Selection

The AC-line input chokes 252.40.xx produce 2% voltage drop at 400 V and rated current. The AC-line input chokes 252.44.xx produce 2% voltage drop at 690 V and rated current. Note, that for applications with radio frequency interference filters (RFI) chokes for 2% voltage drop at rated input voltage up-to 500 V and 4% voltage drop at 690 V are mandatory. If on applications with RFI filters the drive is connected to a supply with nominal voltage >400V < 690V two 2% chokes 252.40.xx in series will be required (for nom. voltage 690 V two 2% chokes 252.44.xx).

Drive

Type

25A 21A 25A 25A 252.40.01 6A 252.42.05 60A 33A 40A 40A 252.40.02 6A 252.42.05

50A 60A 62A 252.40.03 150A 75A 90A 85A 252.40.04

108A 130A 125A 150A

250A 158A 190A 160A 252.40.06 12A 252.42.06 208A 250A 210A 252.40.07

450A 294A 350A 290A 252.40.08 12A 252.42.06 375A 450A 392A 252.40.09

800A 525A 630A 530A 252.40.10 12A 252.42.06

Motor

nom

666A

Current

800A 660A 252.40.11

AC- Line Input

3-Phase

Rating

nom

115A 252.40.05 6A 252.42.05 160A 252.40.06

Choke 1)

Part No.

Field AC-Input

1-Phase

Rating

nom

Part No.

Choke

1200A 833A 1000A 850A 252.40.12 20A 252.42.01 500V

1600A 1334A 1600A 1360A 500V

2000A 1667A 2000A 1700A 252.40.16 500V

1600A 800A 1000A 850A 252.44.12 20A 252.42.01 575V

690V

1000A

1000A 1200A 1100A 252.44.13 1334A 1600A 1360A

1200A 1100A 252.40.13

252.40.15

252.44.15

AC Line AC Line

L1 L2 L3 PE

1U 1V 1W 3V 3W

L2 L3 PE

Converter Input Field Rectifier Input Fig. 8-1: Line Reactor Wiring Diagram

49’1340 e FlexPak 3000 8-9

REPLACEMENT PARTS and ACCESSORIES

W 2 W 1 V 2 V 1 U 2 U 1

U1 V1 W1

E D

W2V2

(1) (2)

∆ Protection earth connection stud

Line Reactor Part No.

H [kg]

[W]

Fig.

Used for

252.40.01 190 150 190 170 75 45 67 80 4.7 50 1 Converter

252.40.02 185 150 190 170 75 60 72 85 6.5 60 1

Input

252.40.03 210 180 240 210 90 52 72 90 7.8 70 1

252.40.04 160 180 240 210 90 52 72 95 7.8 80 2

252.40.05 160 180 240 210 120 72 93 115 11 90 2

252.40.06 240 260 260 -- 240 75 97 170 18 130 2

252.40.07 240 260 260 -- 240 75 96 170 26 150 2

252.40.08 240 290 260 -- 240 100 116 190 26 170 2

252.40.09 290 320 320 -- 300 80 116 220 35 225 2

252.40.10 280 270 320 300 108 123 180 50 365 2

252.40.11 310 320 320 -- 200 93 120 220 40 370 2

252.40.12 330 350 350 -- 240 110 140 250 55 590 2

252.40.13 475 -- 390 -- 355 95 135 250 70 580 2

252.40.15 450 410 280 95 800 2

252.40.16 460 380 450 410 150 190 290 105 950 2

252.44.12 510 450 450 395 117 142 250 88 790 2

252.44.13 510 450 450 395 125 165 310 100 900 2

252.44.15 460 385 450 410 150 190 280 105 1100 2

252.42.05 110 60 44 38 50 0.48 1 Field

252.42.06 124 78 56 47 60 1.2 1

252.42.01 150 105 84 70 89 3.8 1

Rectifier

Input

Figure 8-2: Line Reactor Dimensions (mm), Power Losses (W) and Weight (kg):

8-10

FlexPak 3000 49’1340 e

REPLACEMENT PARTS and ACCESSORIES

EMC Filters for FlexPak 3000

General Description

Power converters in general cause line disturbances over a wide frequency range. Through the correct connection of the adapted filters (HF filter or Radio Frequency Interference (RFI) filter according to the following Table 8-10), the conducted emissions in the frequency range 150 kHz to 30 MHz can be kept below the limits stated in product standard EN 61800-3.

The radiated emissions in the frequency range 30 -1000 MHz will stay below the limits, if for the installation the same EMC measures are taken into account as for the conducted HF emissions.

NOTE: On all FlexPak drives a line input reactor must be connected between filter output and converter input. This line reactor should be rated for minimum 2% voltage drop on drives up to 500 V and 4% for 690 V drives (selection according to Table 8-9). The drives AC-line input semiconductor protection fuses as per Table 8-7 must be mounted between filter output and line reactor. Otherwise the filter inrush current may damage the fuses. For installation instructions refer to Appendix H

HF Filter

If this filter is used on FlexPak 3000 converters with AC line input currents above 100 A the HF emission limits for class A, group 2* (EN 55011) in the 2

environment (industrial supply network) according to

the product standard EN 61800-3 are met and the drive fulfills CE conformity. The HF filter is connected in front of the AC line reactor between the three AC line input phases and the

protection earth conductor PE.

Filter part no.: 839.52.20 Nominal voltage L-L: 690 V

Figure 8-3: HF-Filter dimensions (mm)

49’1340 e FlexPak 3000 8-11

REPLACEMENT PARTS and ACCESSORIES

Radio Frequency Interference Filter

a) FlexPak 3000 converters with AC line input currents below 100 A:

If the RFI filter is connected, the HF emission limits for class A, group 1 (EN 55011) according to the

product standard EN 61800-3 are met and the drive is CE conform. This applies for the

environment (residential) as well as for the 2nd environment (industrial supply network).

b) FlexPak 3000 converters with AC line input currents above 100 A:

If the RFI filter is connected, the HF emission limits of class A, group 1 (EN 55011) in the 2

environment (industrial supply network) are met, as required in the past for the Generic Standard EN

50081-2. This is recommended if e.g. in industrial estates high power converters and offices with sensitive consumers are connected to the same supply transformer.

The filter must be connected into the three AC line input phases L1 - L3 of the FlexPak 3000 in front of the AC line reactor, as shown in figure H-1.

RFI Filter Selection

The RFI-Filters can be selected from Tab. 8-10 according to the permitted filter current and the maximum operating voltage. The permitted filter current is dependent on the application specific maximum continuous DC-current I of the drive, the DC-current form factor (FF) and the ambient temperature T.

The ambient temperature T is the max. temperature around the filter (typical 50°C inside cabinets for a standard max. cooling air temperature of 40°C). Typical DC-current form factor FF = 1.05

For cabinet mounting with T = 50°C and FF = 1.05:

Filter current = maximum continuous DC-current I

For other ambient temperatures (T) and form factors (FF) the continuous current of the filter can be calculated as follows:

Table 8-10:

Filter

Current

FILTER Line rms ad

=×

()

°−

=×××

FF I

RFI Filter Selection

RFI-Filter

380 - 440 V 460 - 500 V 690 V

Part No. see Page Part No. see Page Part No. see Page

°−

25A 839.72.05 8-13 on request 36A 839.72.06 8-13 on request 50A 839.72.07 8-13 on request 80A 839.72.09 8-14 on request 100A 839.71.53 8-15 839.71.53 8-15

150A 839.70.20 8-16 180A 839.74.22 8-17 on request 250A 839.73.25 8-20 on request 270A 839.70.66 8-18 839.70.66 8-18 280A 839.72.67 8-17 839.72.67 8-17 340A 839.71.68 8-19 839.71.68 8-19 500A 839.73.31 8-20 on request

600A -

839.73.92

8-21

839.73.92 1000A 839.73.35 8-21 839.73.95 8-21 839.73.95 8-21 1600A 839.73.38 8-20 839.73.98 8-21 839.73.98 8-21

Application

according

to a)

according

to b)

8-21

8-12

FlexPak 3000 49’1340 e

REPLACEMENT PARTS and ACCESSORIES

Radio Interference Filters 25, 36 and 50 A, 440 V

E L3 L2 L1

200

250

150

LINE

42.5

115

6.5

LOAD

E' L3' L2' L1'

21 20 20

120

135

42.5

Filter Part No.: 839.72-05 839.72-06 839.72-07 Rated Current 25 A 36 A 50 A

Power loss: 8 W 9 W 11 W Weight: 3 kg 3.1 kg 3.5 kg

Figure 8-4: 25, 36 and 50 A, 440 V Filter Dimensions (mm)

49’1340 e FlexPak 3000 8-13

REPLACEMENT PARTS and ACCESSORIES

Radio Interference Filter 80 A, 440 V

150

M10

E L3 L2 L1

LINE

400

427

375

350

LOAD

E' L3' L2' L1'

30 30

130

Filter Part No.: 839.72-09 Power loss: 23 W

Weight: 9.5 kg

Figure 8-5: 80 A, 440 V Filter Dimensions (mm)

6.5

8-14

FlexPak 3000 49’1340 e

REPLACEMENT PARTS and ACCESSORIES

Radio Interference Filter 100 A, 500 V

275

785

215

E L1 L2 L3

LINE

741

4 x M6

4 x M8

741

LOAD

E' L1' L2' L3'

62 50 50 50 63

Filter Part No.: 839.71-53 Power loss: 75 W

Weight: 9.5 kg

Figure 8-6: 100 A, 500 V Filter Dimensions (mm)

18 47 15

49’1340 e FlexPak 3000 8-15

REPLACEMENT PARTS and ACCESSORIES

Radio Interference Filter 150 A, 460 V

194

550

25 55 55

1L1 1L2 1L3

475

160

M10

180

292163.5 24

LOAD

PE 1L1 1L2 1L3

Filter Part No.: 839.70-20 Power loss: 12 W

Weight: 14 kg

Figure 8-7: 150 A, 460 V Filter Dimensions (mm)

8-16

FlexPak 3000 49’1340 e

REPLACEMENT PARTS and ACCESSORIES

Radio Interference Filter 180 A, 440 V

and 280 A, 500 V

M10

E L3 L2 L1

LINE

LOAD

E' L3' L2' L1'

H G G

6.5

C L

[A]

Filter Part No.

A B C E F G H J L P R [kg]

[W]

Terminal

max. mm

180 839.74-22 537 360 88 132 470 25 28 180 156 510 77 13 49 95 280 839.72-67 742 530 103 153 660 31 59 260 220 700 82 28 70 150

Figure 8-8: 180 A, 440 V and 280 A, 500 V RFI-Filter Dimensions (mm)

49’1340 e FlexPak 3000 8-17

REPLACEMENT PARTS and ACCESSORIES

Radio Interference Filter 270 A, 440/500 V

350

M12

E L3 L2 L1

LINE

110

135

550

135

110

30 30

LOAD

E' L3' L2' L1'

5.1

65 65

335

160

408080

320

Filter Part No.: 839.70-66 Power loss: 26 W

Weight: 48 kg

Figure 8-9: 270 A, 500 V RFI-Filter Dimensions (mm)

8-18

FlexPak 3000 49’1340 e

REPLACEMENT PARTS and ACCESSORIES

Radio Interference Filter 340 A, 440/500 V

420 110

873

24.5

797

360

Filter Part No.: 839.71-68 Power loss: 50 W

Weight: 22 kg

Figure 8-10: 340 A, 440/500 V RFI-Filter Dimensions (mm)

49’1340 e FlexPak 3000 8-19

REPLACEMENT PARTS and ACCESSORIES

Radio Interference Filter 250, 500, 1000 and 1600 A, 440 V

PE L1/L3 L2

L3 L2 L1

L3' L2' L1'

LINE

LOAD

PE' L1'/L3' L2'

Filter

[A]

Part No.

250

500 1000 1600

839.73-25 460 350 230 149 260 200 285 120 100 79.5 24

839.73-31 590 500 250 154 280 280 305 150 93 59.5 24

839.73-35 840 650 400 204 440 320 465 262 127 79 34

839.73-38 870 680 400 204 440 340 465 262 127 79 34

[A] P Q R

250

500 1000 1600

- 24 30 15 30 30 20 50 40 20 50 40

∅10.5 ∅10.5 ∅11 ∅12 ∅14 ∅12

∅14 ∅12

Ground

Bolt

[kg]

[W] M10 18 18 M12 49 45 M12 90 90 M12 130 144

Figure 8-11 250, 500, 1000 and 1600 A, 440 V RFI-Filter Dimensions (mm) 8-20

FlexPak 3000 49’1340 e

Rockwell Automation FlexPak 3000 Power Module User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

1.1 Safety Instructions

1.2 General Notes

1.3 Manual Scope

GENERAL NOTES

1.4 Related User Manuals

INTRODUCTION TO THE DRIVE

2.1 Drive Identification

2.2 Drive Specifications

2.3 Drive Input/Output Specifications

2.4 Drive Description

2.5 Controls/Indicators

3.1 General

3.2 Recommended AC Line and DC Armature Fuses

3.3 Install the Drive

3.4 Install a Line Reactor or Transformer

3.5 Install an Input Disconnect

3.6 Install the Motor

3.7 General Wiring Practices

3.8 Wire the Drive

DRIVE SETUP AND ADJUSTMENT

4.1 Introduction

4.2 Test Equipment Needed

4.3 Power Off Inspection

4.4 Motor Ground Check

4.5 Jumper Settings

4.7 OIM Screen Contrast Adjustment

4.8 Accessing the Main Menu

4.9 How to Access the Menus/Parameters

4.10 Verify the Correct Direction of Motor Rotation

4.11 Determination of D-C Tachometer Lead Polarity

4.12 Adjustments

4.13 Language Selection

4.14 Programming Features

5.0 How to Change Parameter Values

5.1 Introduction

5.2 Integer Value Entry Screen

5.3 Standard Choice Integer Value Entry Screen

5.5 Reference Selecting via Keypad OIM

QUICK START

6.1 Introduction

6.2 About The Quick Start Exit Menu

6.3 How To Step Through Quick Start

6.4 Self-Tuning the Current Minor and Speed Loops

6.5 Final Adjustments

TROUBLESHOOTING/DIAGNOSTICS

7.1 General

7.2 Wiring Errors

7.3 AC Line and Power Input

7.4 DC Motor

7.5 Remote M Contactor

7.6 Optional Kits

7.7 Fault/Alarm/Diagnostic (FAD) Menus

8.0 Replacement of components

8.1 Recommended Spare Parts

8.2 Accessories