Rockwell Automation Reliance electric FlexPak 3000 Installation Instructions Manual
Enhanced field supply kit
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Summary of Contents for Rockwell Automation Reliance electric FlexPak 3000
- Page 1 FlexPak 3000 Enhanced Field Supply Kit Installation Instructions M/N 923FK0101 and 923FK0201 Instruction Manual D2-3413-1...
- Page 2 ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment. FlexPak 3000 and Reliance are trademarks of Rockwell Automation. ©2000 Rockwell International Corporation...
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Page 3: Table Of Contents
ONTENTS Chapter 1 Introduction Related Publications ..................1-2 Getting Assistance from Reliance Electric............1-2 Chapter 2 Installing the Enhanced Field Supply Kit on 3.0 HP to 60 HP @ 460 VAC (1.5 HP to 30 HP @ 230 VAC) Drives Removing the OIM Cover and Opening the Carrier ........ - Page 4 Resecuring the Hinged OIM Mounting Plate............5-5 Replacing the Drive Fuses ................5-6 Reinstalling the Plastic Drive Cover and Reclosing the Steel Door ....5-6 Modifying the Drive Configuration ..............5-6 Chapter 6 Setting the Field Voltage Trim Jumpers Chapter 7 Modifying the Drive Configuration Parameter 306 (NOMINAL AC LINE FREQUENCY) ........7-1 Parameter 500 (ENHANCED FLD VOLT ADJ)..........7-1 Examples for Setting Parameters 306 and 500 ..........7-2...
- Page 5 List of Figures Figure 1.1 – Enhanced Field Supply Board .............. 1-2 Figure 2.1 – Removing the Standard Field Supply Board (3 HP to 60 HP @ 460 VAC Drives) ................2-2 Figure 2.2 – Setting the Jumpers on the Enhanced Field Supply Board ....2-3 Figure 2.3 –...
- Page 6 FlexPak 3000 Enhanced Field Supply Installation Instructions...
- Page 7 List of Tables Table 1.1 – Current Ratings and Model Numbers for the Enhanced Field Supply Kit......................1-1 Table 6.1 – Setting the Enhanced Field Supply Board and the Regulator Board Jumpers ....................6-1 Table 7.1 – Parameter 500 Values When Jumpers are Set to B–C ......7-3 Table 7.2 –...
- Page 8 FlexPak 3000 Enhanced Field Supply Installation Instructions...
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Page 9: Chapter 1 Introduction
HAPTER Introduction This instruction manual describes how to install and configure the optional Enhanced Field Supply kit used by FlexPak 3000 DC Drives. The kit can be installed in FlexPak 3000 drives rated at 3 HP to 600 HP @ 460 VAC (1.5 HP to 150 HP @ 230 VAC). It replaces the Standard Field Supply (P/N 610273-14R) already installed on 3 HP to 125 HP @ 460 VAC (1.5 HP to 60 HP @ 230 VAC) drives and the Field Current Regulator (P/N 707973-10R, S, or T on 150 HP to 600 HP @ 460 VAC (75 HP to 150... -
Page 10: Related Publications
Side View Connect to wire harness Connect to P4 on the Power Interface Board Top View Figure 1.1 – Enhanced Field Supply Board 1.1 Related Publications This manual describes the Enhanced Field Supply kit and its associated FlexPak 3000 software parameters. You will also need the FlexPak 3000 DC Drive instruction manuals, which describes the drive hardware and software. -
Page 11: Removing The Oim Cover And Opening The Carrier
HAPTER Installing the Enhanced Field Supply Kit on 3.0 HP to 60 HP @ 460 VAC (1.5 HP to 30 HP @ 230 VAC) Drives ATTENTION: Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, operate, and/or service this equipment. -
Page 12: Removing The Standard Field Supply Board
Step 2. Loosen the OIM cover retaining screws and remove the cover. Step 3. Loosen the captive screw at the upper right corner of the drive’s Regulator board carrier and swing it open. 2.2 Removing the Standard Field Supply Board Step 1. -
Page 13: Figure 2.2 - Setting The Jumpers On The Enhanced Field Supply Board
Important: All Enhanced Field Supply boards are shipped with the wire jumper connecting pins ”B” and ”C”. The actual field output voltage, once the range is jumper selected, is adjusted through the drive’s OIM (Operator Interface Module). Step 2. If necessary, move the Enhanced Field Supply board’s wire jumper to select an output voltage range. -
Page 14: Installing The Enhanced Field Supply Board
2.4 Installing the Enhanced Field Supply Board Step 1. Remove the four mounting screws from the back of the Enhanced Field Supply board. Step 2. Working from the inside of the drive, align the Enhanced Field Supply board’s mounting holes with the mounting holes on the drive’s right side panel. See figure 2.4. -
Page 15: Replacing The Drive Fuses
2.5 Replacing the Drive Fuses Step 1. Remove the three fuses labeled 6FU, 7FU, and 8FU from the drive’s fuse block. See figure 2.5. Step 2. Install the three provided 25 A, 600 V fuses (P/N 64676–30M) in the fuse block in positions 6FU, 7FU, and 8FU. -
Page 16: Closing The Carrier And Reinstalling The Oim Cover
2.6 Closing the Carrier and Reinstalling the OIM Cover Step 1. Close the Regulator board carrier and secure it in place with its captive screw. Step 2. Reinstall the OIM cover and secure it in place with its screws. Step 3. Reconnect power to the drive. Hardware installation is complete. Step 4. -
Page 17: (40 Hp To 75 Hp @ 230 Vac) Drives
HAPTER Installing the Enhanced Field Supply Kit on 75 HP to 150 HP @ 460 VAC (40 HP to 75 HP @ 230 VAC) Drives ATTENTION: Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, operate, and/or service this equipment. -
Page 18: Accessing The Field Supply Board
3.1 Accessing the Field Supply Board ATTENTION: The drive contains printed circuit boards that are static sensitive. An anti-static wrist band should be worn by any person who touches the drive's components, connectors or leads. Erratic machine operation and damage to , or destruction of, equipment may result if this procedure is not followed. -
Page 19: Removing The Field Current Regulator Board (150 Hp @ 460 Vac / 40 Hp To 75 Hp @ 230 Vac Drives)
Motor Terminal Panel Loosen screws Loosen screws Remove 4 screws Remove top and Remove top and bottom screws; bottom screws; loosen middle screw loosen middle screw Drive without AC Disconnect Drive with AC Disconnect Field Supply Drive with Aux. Chassis Cover Removed Figure 3.1 –... -
Page 20: Adjusting The Jumpers On The Enhanced Field Supply Board And The Regulator Board
3.4 Adjusting the Jumpers on the Enhanced Field Supply Board and the Regulator Board Step 1. Refer to chapter 6 to determine the correct field output range jumpering for your application. Important: All Enhanced Field Supply boards are shipped with the wire jumper connecting ”B”... -
Page 21: Replacing The Drive Fuses
Field Supply Mounting Screws (Qty 4) Figure 3.2 – Installing the Enhanced Field Supply Board (75 HP to 150 HP @ 460 VAC Drives) 3.6 Replacing the Drive Fuses Step 1. Locate the three fuses labeled 6FU, 7FU, and 8FU. See figure 3.3. Step 2. -
Page 22: Figure 3.3 - Field Fuse Location (75 Hp To 150 Hp @ 460 Vac Drives)
Top View Fuse Block Field Supply Drive With Aux. Chassis Cover Removed Figure 3.3 – Field Fuse Location (75 HP to 150 HP @ 460 VAC Drives) FlexPak 3000 Enhanced Field Supply Installation Instructions... -
Page 23: Reinstalling The Auxiliary Chassis Cover
600V 25A 600V 25A Figure 3.4 – Attaching Replacement Drive Fuse Labels (75 HP to 150 HP @ 460 VAC Drives) 3.7 Reinstalling the Auxiliary Chassis Cover These steps apply if your drive does not have an AC disconnect. If your drive has an AC disconnect, skip this section and go to section 3.8. -
Page 24: Reinstalling The Ac Disconnect
3.8 Reinstalling the AC Disconnect If your drive has an AC disconnect that was removed, refer to instruction manual D2-3395 (CE-compliant drives) or D2-3315 (non-CE-compliant drives) for the procedue to reinstall it. 3.9 Modifying the Drive Configuration Go to chapter 7 and follow the procdures described there to set the parameters for the Enhanced Field Supply kit. -
Page 25: To 150 Hp @ 230 Vac) Drives
HAPTER Installing the Enhanced Field Supply Kit on 200 HP to 300 HP @ 460 VAC (100 HP to 150 HP @ 230 VAC) Drives ATTENTION: Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, operate, and/or service this equipment. -
Page 26: Adjusting The Jumpers On The Enhanced Field Supply Board And The Regulator Board
Step 2. Locate the Field Current Regulator board. It is attached to the lower right side of the drive, behind the line fuse panel, and can be accessed through the bottom of the drive. See figure 4.1. Step 3. Remove the four field supply mounting screws from the outside of the drive’s right side panel and remove the field supply. -
Page 27: Installing The Enhanced Field Supply Board
Step 4. Remove the four (4) screws securing the OIM to the Regulator board carrier and move the OIM to gain access to the drive’s Regulator board. It is not necessary to remove the OIM completely, though it can be by disconnecting the ribbon and ground connectors from the underside of the OIM. -
Page 28: Modifying The Drive Configuration
4.6 Modifying the Drive Configuration Go to chapter 7 and follow the procedures described there to set the parameters for the Enhanced Field Supply kit. FlexPak 3000 Enhanced Field Supply Installation Instructions... - Page 29 HAPTER Installing the Enhanced Field Supply Kit on 400 HP to 600 HP @ 460 VAC Drives ATTENTION: Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, operate, and/or service this equipment. Read and understand this instruction manual in its entirety before proceeding.
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Page 30: Removing The Drive Cover And Opening The Carrier
5.1 Removing the Drive Cover and Opening the Carrier ATTENTION: The drive contains printed circuit boards that are static sensitive. An anti-static wrist band should be worn by any person who touches the drive's components, connectors or leads. Erratic machine operation and damage to, or destruction of, equipment may result if this procedure is not followed. -
Page 31: Adjusting The Jumpers On The Enhanced Field Supply Board And The Regulator Board
Mounting Screws Rt. Extender Panel Standoff/Mtg. Acceptor (4 Pls) Field Supply Location of the Field Current Regulator or Enhanced Field Supply Figure 5.1 – Removing the Field Current Regulator Board (400 HP to 600 HP @ 460 VAC Drives) Fuse Block Disconnect in step 4, section 5.2 Figure 5.2 –... -
Page 32: Reinstalling The Oim And Cover
Step 2. If necessary, move the Enhanced Field Supply board’s wire jumper to select an output voltage range. (pin ”A” connected to pin ”C” or pin ”B” connected to pin ”C”.) See figure 2.2. Step 3. Remove the four screws that secure the OIM (control and display panel) to the carrier. -
Page 33: Resecuring The Hinged Oim Mounting Plate
Step 7. Tie-wrap or otherwise secure the cables that were disconnected in step 4, section 5.2 above. Secure or tie-wrap these cables to other wrapped cables or on cables under the hinged OIM mounting plate which swings out of the way. -
Page 34: Replacing The Drive Fuses
5.7 Replacing the Drive Fuses Step 1. Locate the fuse block, labeled 6FU, 7FU, and 8FU, on the drive’s line fuse panel. See figure 2.2. Step 2. If the installed fuses are different from the ones provided with this kit, replace them with the ones provided (25 A, 600 V (P/N 64676–30M). -
Page 35: Chapter 6 Setting The Field Voltage Trim Jumpers
HAPTER Setting the Field Voltage Trim Jumpers Given a supplied line voltage, field voltage trimming is used to match the drive’s field output to the rated field voltage of different DC motors. In general, a field voltage below the motor’s rated field voltage could operate the motor above rated (base) speed with reduced torque. - Page 36 FlexPak 3000 Enhanced Field Supply Installation Instructions...
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Page 37: Chapter 7 Modifying The Drive Configuration
HAPTER Modifying the Drive Configuration Proper operation of the Enhanced Field Supply requires the verification and adjustment of three drive parameters: • Parameter 306 (NOMINAL AC LINE FREQUENCY) • Parameter 500 (ENHANCED FLD VOLT ADJ) • Parameter 501 (FIELD ECONOMY DELAY) These parameters are accessed through the CURRENT MINOR LOOP and FIELD menus. -
Page 38: Examples For Setting Parameters 306 And 500
Important: This value is intended to give you a starting pointing for adjusting the drive’s field output voltage. Use an external voltmeter to measure actual field voltage in order to make an accurate adjustment of the field voltage. Step 3. Check the drive’s field output voltage. If necessary, readjust parameter 500 to obtain the motor’s rated field voltage. - Page 39 Table 7.1 – Parameter 500 Values When Jumpers are Set to B–C 0.4502 0.4502 0.4503 0.4505 0.4507 0.4510 0.4514 0.4518 0.4523 0.4529 0.4536 0.4543 0.4551 0.4559 0.4568 0.4578 0.4589 0.4600 0.4612 0.4624 0.4637 0.4651 0.4665 0.4681 0.4696 0.4712 0.4729 0.4747 0.4765 0.4784 0.4803...
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Page 40: Parameter 501 (Field Economy Delay)
7.4 Parameter 501 (FIELD ECONOMY DELAY) Parameter 501 is used to adjust the field economy time delay for those motors that may not be able to withstand the power dissipation under full field voltage with the motor at rest. After a user–specified time delay (0 to 27 minutes), FlexPak 3000 drives provide an automatic fixed reduction of field voltage, known as field economy, during motor rest periods. - Page 42 U.S. Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication D2-3413-1- November 2000 Copyright © 2000 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.