Rockwell Automation Reliance electric FlexPak 3000, Installation Instructions Manual

Page 1: ...Instruction Manual FlexPak 3000 Enhanced Field Supply Kit Installation Instructions M N 923FK0101 and 923FK0201 D2 3413 1 ...

Page 2: ...tices or circumstances that can lead to personal injury or death property damage or economic loss FlexPak 3000 and Reliance are trademarks of Rockwell Automation 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 be...

Page 3: ...HP to 75 HP 230 VAC Drives 3 3 3 4 Adjusting the Jumpers on the Enhanced Field Supply Board and the Regulator Board 3 4 3 5 Installing the Enhanced Field Supply Board 3 4 3 6 Replacing the Drive Fuses 3 5 3 7 Reinstalling the Auxiliary Chassis Cover 3 7 3 8 Reinstalling the AC Disconnect 3 8 3 9 Modifying the Drive Configuration 3 8 Chapter 4 Installing the Enhanced Field Supply Kit on 200 HP to 3...

Page 4: ...astic Drive Cover and Reclosing the Steel Door 5 6 5 9 Modifying the Drive Configuration 5 6 Chapter 6 Setting the Field Voltage Trim Jumpers Chapter 7 Modifying the Drive Configuration 7 1 Parameter 306 NOMINAL AC LINE FREQUENCY 7 1 7 2 Parameter 500 ENHANCED FLD VOLT ADJ 7 1 7 3 Examples for Setting Parameters 306 and 500 7 2 7 4 Parameter 501 FIELD ECONOMY DELAY 7 4 ...

Page 5: ...ment Drive Fuse Labels 3 HP to 60 HP 460 VAC Drives 2 5 Figure 3 1 Removing the Field Supply Board 75 HP to 125 HP 460 VAC Drives 3 3 Figure 3 2 Installing the Enhanced Field Supply Board 75 HP to 150 HP 460 VAC Drives 3 5 Figure 3 3 Field Fuse Location 75 HP to 150 HP 460 VAC Drives 3 6 Figure 3 4 Attaching Replacement Drive Fuse Labels 75 HP to 150 HP 460 VAC Drives 3 7 Figure 4 1 Removing the F...

Page 6: ...IV FlexPak 3000 Enhanced Field Supply Installation Instructions ...

Page 7: ...el 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 Parameter 500 Values When Jumpers are Set to A C 7 3 ...

Page 8: ...VI FlexPak 3000 Enhanced Field Supply Installation Instructions ...

Page 9: ...ve to provide a 240 volt field to a motor from a 230 volt line See chapter 6 Modifying the Drive Configuration for more information Two versions of the Enhanced Field Supply kit are available They differ according to the current rating Each kit is supplied as an assembly that includes the Enhanced Field Supply board and an attached wiring harness as well as replacement fuses fuse labels and mounti...

Page 10: ... DC Drive instruction manuals which describes the drive hardware and software 1 2 Getting Assistance from Reliance Electric If you have any questions or problems with the products described in this instruction manual contact your local Reliance Electric sales office For technical assistance call 1 800 726 8112 Figure 1 1 Enhanced Field Supply Board Connect to wire harness TopView Connect to P4onth...

Page 11: ...2 1 Removing the OIM Cover and Opening the Carrier Step 1 Turn off lockout and tag power to the drive 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 Failure to observe this precaution could res...

Page 12: ...ors Step 3 Follow the field supply board s wire harness to the P4 connector on the Power Interface board Unplug the harness from the P4 connector Step 4 Locate the field supply s four mounting screws on the outside of the drive s right side panel Step 5 Remove the four mounting screws from the outside of the drive and remove the field supply board 2 3 Adjusting the Jumpers on the Enhanced Field Su...

Page 13: ...n access to the drive s Regulator board Do not attempt to remove the OIM completely See figure 2 3 Step 4 Locate Regulator board jumper J21 FIELD SUPPLY JUMPER Step 5 Move regulator board jumper J21 so that it matches the jumper setting of the Enhanced Field Supply board A C or B C Step 6 Reinstall the OIM on the Regulator board carrier Figure 2 2 Setting the Jumpers on the Enhanced Field Supply B...

Page 14: ...ugh one of the mounting holes on the drive s right side panel and into the corresponding mounting hole in the Enhanced Field Supply s board Tighten the screw to hold the board in place Step 4 Repeat step 3 for the remaining three mounting screws Step 5 Connect the drive s wire harness to the Enhanced Field Supply board s 581 582 583 F2 35 and F1 37 spade connectors See figure 1 1 for the location ...

Page 15: ...all the three provided 25 A 600 V fuses P N 64676 30M in the fuse block in positions 6FU 7FU and 8FU Step 3 Locate the replacement fuse table on the back of the carrier Attach one of the adhesive fuse rating labels P N 179540 over each of the places indicated in figure 2 6 Figure 2 5 Field Fuse Location 3 HP to 60 HP 460 VAC Drives Figure 2 6 Attaching Replacement Drive Fuse Labels 3 HP to 60 HP 4...

Page 16: ...e 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 Remove the lockout and tag Step 5 Turn on power to the drive 2 7 Modifying the Drive Configuration Go to chapter 7 and follow the procedures described there to set the parameters for the Enhanced Field Supply kit ...

Page 17: ...is cover Reinstalling the AC Disconnect Modifying the drive configuration These steps are described in detail below When you have finished installing the kit adjust the required drive parameters as described in chapter 7 before using the drive ATTENTION Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install operate and or ser...

Page 18: ...t follow the steps in the next section If the AC disconnect must be removed for access to the field supply board refer to instruction manual D2 3395 for CE compliant drives or D2 3315 non CE compliant drives 3 2 Removing the Standard Field Supply Board 75 HP to 125 HP 460 VAC 40 HP to 75 HP 230 VAC Drives Step 1 Locate the Standard Field Supply board in the drive See figure 3 1 If you have an AC d...

Page 19: ...ble assembly P N 707973 12R S or T FLD P6 and FLD P3 connectors from the Field Current Regulator board Also disconnect the oppositie end of this cable from J25 Do not remove the cable Step 4 Remove the four 4 mounting screws from the outside of the drive s right side panel and remove the Field Current Regulator board Figure 3 1 Removing the Field Supply Board 75 HP to 125 HP 460 VAC Drives Drive w...

Page 20: ...the OIM on the Regulator board carrier Step 8 Reinstall the OIM cover 3 5 Installing the Enhanced Field Supply Board If you have an AC Disconnect and elected not to remove it do steps 5 and 6 first Then return to step 1 If the drive does not have an AC Disconnect begin with step 1 Step 1 Remove the four mounting screws from the back of the Enhanced Field Supply board Step 2 Working from the inside...

Page 21: ... If the fuses are different from the three provided 25 A 600 V fuses P N 64676 30M replace them with the ones provided Step 3 Locate the replacement fuse table on the back of the carrier Attach one of the adhesive fuse rating labels P N 179540 over each of the places indicated in figure 3 4 Figure 3 2 Installing the Enhanced Field Supply Board 75 HP to 150 HP 460 VAC Drives MountingScrews Qty 4 Fi...

Page 22: ... FlexPak 3000 Enhanced Field Supply Installation Instructions Figure 3 3 Field Fuse Location 75 HP to 150 HP 460 VAC Drives Cover Removed Drive With Aux Chassis Fuse Block Top View 6FU 8FU 7FU Field Supply ...

Page 23: ...nal panel Step 2 Align the auxiliary chassis cover over the middle screw on the drive s right side panel and over the top and bottom mounting holes Step 3 Insert the top and bottom screws into the mounting screw holes and then tighten all three mounting screws top bottom and middle Step 4 Tighten the two screws on the right side of the motor terminal panel to secure the auxiliary chassis cover s t...

Page 24: ...e 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: ...or Board Step 1 Turn off lockout and tag power to the drive 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 Failure to observe this precaution could result in severe bodily injury or loss of lif...

Page 26: ...4 2 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 If it is necessary to change jumper settings follow the remaining steps in this section Important All Enhanced Field Supply boards are shipped with the wire jumper connecting pins B and C The actual field output vo...

Page 27: ...nnector S4 Step 3 Remove the four mounting screw from the back of the Enhanced Field Supply board Step 4 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 4 1 Orient this board so that the end with the transformer points to the front of the drive Step 5 Working from the outside of the drive...

Page 28: ...xPak 3000 Enhanced Field Supply Installation Instructions 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 ...

Page 29: ...eel Door Modifying the Drive Configuration These steps are described in detail below When you have finished installing the kit adjust the required drive parameters as described in chapter 7 before using the drive 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 un...

Page 30: ...he cover from the carrier 5 2 Removing the Field Current Regulator Board Step 1 Locate the Field Current Regulator board It is attached to the left side of the extender panel See figure 5 1 Step 2 Remove the four field supply mounting screws from the right side of the extender panel and remove the Field Current Regulator board Step 3 Disconnect the drive s wire harness from the Field Current Regul...

Page 31: ... 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 Figure 5 1 Removing the Field Current Regulator Board 400 HP to 600 HP 460 VAC Drives Figure 5 2 Location of Field Current Regulator Connectors Rt Extender Panel Field Supply Location of theField Current Regulator or EnhancedF...

Page 32: ...n to the back of the OIM if you previously removed it Step 2 Reposition the OIM on the carrier Then replace and tighten the four mounting screws Step 3 Reconnect the horizontal ribbon connector between the OIM and the Regulator board Step 4 Reinstall the cover on the OIM and tighten its thumb screws 5 5 Installing the Enhanced Field Supply Board Step 1 Remove the four mounting screws from the back...

Page 33: ...ables under the hinged OIM mounting plate which swings out of the way Important Do not secure these cables to the gray power cables 5 6 Resecuring the Hinged OIM Mounting Plate If previously swung open to the left swing the OIM mounting plate back into position Replace and tighten its mounting screws Figure 5 3 Mounting the Enhanced Field Supply Right Side View Semiconductor Disconnect Field Suppl...

Page 34: ... 30M 5 8 Reinstalling the Plastic Drive Cover and Reclosing the Steel Door Step 1 Reinstall the plastic cover over the drive s line fuse panel Hardware installation is complete Step 2 Swing the steel door closed Then replace and tighten the two bolts in the right hand corners Step 3 Reconnect power to the drive Step 4 Remove the lockout and tag Step 5 Turn on power to the drive 5 9 Modifying the D...

Page 35: ... the following steps to determine the correct jumper setting for the Enhanced Field Supply board and the Regulator board Begin with your AC line input voltage and your motor s rated DC field voltage Step 1 Calculate the line multiplier according to the following formula Step 2 Use the resulting line multiplier to set the jumpers as indicated in the following table For example AC Line Input Voltage...

Page 36: ...6 2 FlexPak 3000 Enhanced Field Supply Installation Instructions ...

Page 37: ...to the AC input line voltage times a line multiplier As shown in tables 7 1 and 7 2 each value of parameter 500 is associated with a given line multiplier for a specified jumper selection You must determine the field voltage trim line multiplier as described in chapter 6 before proceeding Important If the drive is operating in the field economy mode this adjustment will have no effect on the outpu...

Page 38: ...ate the multiplier that determines Enhanced Field Supply board and Regulator board jumpering See chapter 6 for more information Determine the value for parameter ENHANCED FLD VOLT ADJ The equation for this example is Step 3 Refer to table 6 1 for the calculated multiplier In this example the calculated multiplier of 0 6522 falls between 0 45 and 0 9 so the correct jumpering for the Enhanced Field ...

Page 39: ...0 8344 0 8371 0 8398 0 8425 0 8451 140 0 8477 0 8502 0 8526 0 8550 0 8573 0 8596 0 8618 0 8640 0 8661 0 8682 150 0 8702 0 8721 0 8740 0 8758 0 8775 0 8792 0 8809 0 8824 0 8838 0 8854 160 0 8867 0 8881 0 8893 0 8905 0 8916 0 8926 0 8936 0 8945 0 8954 0 8962 170 0 8969 0 8975 0 8981 0 8986 0 8991 0 8995 0 8998 0 9000 0 9002 0 9003 180 0 9003 Table 7 2 Parameter 500 Values When Jumpers are Set to A C...

Page 40: ...er 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 When the drive restarts the FlexPak returns to its user adjusted full field output voltage level Access parameter 501 from the OIM s FIELD menu and adjust the value to an appropriate...

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Page 42: ...ail 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 ...