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Reliance electric FlexPak 3000 Instruction Manual

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FlexPak 3000 Power Module
SW-Version 4.3
Instruction Manual
Manual Part No:
Firmware Part No: 790.30.72
Europe
North America
899.07.41
D2-3475-1
Publication: FP3OIM-UM043M-EN

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Summary of Contents for Reliance electric FlexPak 3000

  • Page 1 FlexPak 3000 Power Module SW-Version 4.3 Instruction Manual Europe North America Manual Part No: 899.07.41 D2-3475-1 Publication: FP3OIM-UM043M-EN Firmware Part No: 790.30.72...

  • Page 3: Table Of Contents

    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...
  • Page 4 Self Tune Setup .................... 6-7 6.4.2 Execute Self Tuning ..................6-8 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...
  • Page 5 Recommended Spare Parts ..................8-3 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 ............
  • Page 6 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 -...

  • Page 7: General Notes

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

  • Page 8: General Notes

    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. FlexPak 3000 49’1340 e...

  • Page 9: Introduction To The Drive

    575 V, 60 Hz 848.16.43 848.17.43 * 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...

  • Page 10: Drive Specifications

    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 FlexPak 3000 49’1340 e...

  • Page 11: Input Voltage And Frequency Ratings

    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...

  • Page 12: Regulation (With 95% Load Change)

    = 1.5 x I a max a nom = Field current without overload capability * A maximum field current of 20 A is permitted, if the power unit blower is switched on together with the motor field. FlexPak 3000 49’1340 e...

  • Page 13: Drive Input/Output Specifications

    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...

  • Page 14: Analog Outputs

    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. Electrical Specifications: Output Voltage....................+/- 10 V DC Maximum Load ....................4 milliamps FlexPak 3000 49’1340 e...

  • Page 15: Drive Description

    CURRENT S6/S6R SPEED SELECTION FREQUENCY MINOR POWER LOOP INPUTS/ LOOP UNIT SCALING OUTPUTS (CML) ANALOG OR PULSE TACHOMETER Current Feedback Voltage Feedback OUTER Tachometer Feedback CONTROL LOOP (OCL) Figure 2-1 - FlexPak 3000 Functional Block Diagram 49’1340 e FlexPak 3000...

  • Page 16: Table 2.4 - Drive Modification Kits

    Windows-based software that allows the user to connect any 788.05.30 Configuration personal computer running Micro-soft Windows version 3.1 or later to a FlexPak 3000 drive. Allows you to create, store, upload, and Software CS3000-V6 download drive configurations. You can also monitor and change parameters through the PC and read and reset the drive’s fault log.

  • Page 17: Controls/Indicators

    An LCD indicator is on when a field is present ; off when extinguished. In Figure 2-2, the 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. 49’1340 e FlexPak 3000...

  • Page 18: Controls

    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. NOTE: The PROGRAM mode is used for menu and parameter selection. 2-10 FlexPak 3000 49’1340 e...

  • Page 19: Table 2.6 - Drive Monitor Capabilities

    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 ARM VOLTS VOLTS MOTOR LOAD %FLA...
  • Page 20 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...
  • Page 21 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...
  • Page 22 ON (for regenerative drives); when the drive is non- regenerative; 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...
  • Page 23 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...
  • Page 24 2-16 FlexPak 3000 49’1340 e...

  • Page 25: Install And Wire The Drive 3-1

    Failure to observe this precaution could result in severe bodily injury or loss of life. General This Section outlines the procedures that are to be followed to properly install the FlexPak 3000 Drive. 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.
  • Page 26 16 mm 1U, 1V, 1W 2.5 Nm Prot. earth 16 mm 2.5 Nm MAX. 250 Weight: 10 kg Minimum clearances for air circulation: 100 mm Figure 3-1: Mounting Data for 25 A and 60 A Drives. FlexPak 3000 49’1340 e...
  • Page 27 Terminals 35 mm Torque 2.5 Nm Weight: 14 kg 187 m 3 /h Cooling air: Air flow direction: from bottom to top Minimum clearances for air circulation: 100 mm Figure 3-2: Mounting Data for 150 A Drives. 49’1340 e FlexPak 3000...
  • Page 28 Torque 15 Nm Weight: 40 kg 407 m 3 /h Cooling air: 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. FlexPak 3000 49’1340 e...
  • Page 29 Bolt M12 Torque 15 Nm Weight: 83 kg 814 m 3 /h Cooling air: 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...
  • Page 30 Weight: 195 kg 2000 m 3 /h Cooling air: Air flow direction: from bottom to top Minimum clearances for free air circulation: 100 mm Figure 3-5: Mounting Data for FlexPak 1200/1600 A, 500V and 1600A, 575/690V FlexPak 3000 49’1340 e...
  • Page 31 Drilling 2 x 14 mm, Weight: 196 kg 2000 m 3 /h Cooling air: Air flow direction: from bottom to top Minimum clearances for free air circulation: 100 mm Figure 3-6: Mounting Data for FlexPak 2000A, 500V. 49’1340 e FlexPak 3000...

  • Page 32: Install An Input Disconnect - Guidelines

    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). FlexPak 3000 49’1340 e...

  • Page 33: Install The Motor

    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...

  • Page 34: Wire The Drive

    (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...

  • Page 35: Emergency Stop Function

    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...
  • Page 36 THERMOSTAT + 24 V 24 V COM MANUAL REFERENCE + 10 V (ISOLATED) + MAN REF AUTO REFERENCE HI RANGE LO RANGE COMMON ANALOG TACH Figure 3-8a - Sample Regulator Board Terminal Strip Connection Diagram 3-12 FlexPak 3000 49’1340 e...
  • Page 37 ANALOG OUT2 (Metering) 25 (common) and 26 RUNNING (Indicator) 27 and 28 ALARM (Indicator) 29 and 30 NO FAULT (Indicator) 31 and 32 K10T K10T Figure 3-8b – Main Contactor Sequencing Connection Diagram - Example 49’1340 e FlexPak 3000 3-13...
  • Page 38 INSTALLATION AND WIRING Figure 3-9: Principle wiring diagram of FlexPak 3000, single quadrant (example S-6 150 A) 3-14 FlexPak 3000 49’1340 e...
  • Page 39 INSTALLATION AND WIRING Figure 3-10: Principle wiring diagram of FlexPak 3000, four quadrant (example S-6R 150 A) 49’1340 e FlexPak 3000 3-15...
  • Page 40 INSTALLATION AND WIRING 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...
  • Page 41 INSTALLATION AND WIRING 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...
  • Page 42 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.

  • Page 43: Drive Setup And Adjustment

    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...

  • Page 44: Jumper Settings

    DRIVE SETUP AND ADJUSTMENT 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.

  • Page 45: Figure 4.1 - Regulator Board Jumpers

    Also note that speed/voltage parameters must be set to provide overspeed protection for the drive. J28 J22 ARM I IOGND2 GND1 EPROM 790.30.70 J15 J20 J26 0VI2 J16 J21 J14 J11 J30 J29 J27 J12 J10 J19 GND3 GND4 Figure 4.1 - Regulator Board Jumpers, Connectors and Test Points 49’1340 e FlexPak 3000...

  • Page 46: Set Program Disable/Enable (Oim Program) - J16 Jumper

    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). FlexPak 3000 49’1340 e...

  • Page 47: Field Supply Jumper Connection (Field Supply) - J21

    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 x ANALOG TACH VOLTS 1000 1000 49’1340 e FlexPak 3000...

  • Page 48: Analog Auto Reference (Auto Ref) - J12 And J10 Jumpers

    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.

  • Page 49: 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. (c) Copyright Reliance Electric...

  • Page 50: How To Access The Menus/Parameters

    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 ...
  • Page 51 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...

  • Page 52: Verify The Correct Direction Of Motor Rotation

    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...

  • Page 53: 4.12.1 Perform Armature Voltage Zero Adjust

    • 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...

  • Page 54: Programming Features

    These features are accessible from the Operator Interface menu. FlexPak 3000 Main Menu   Operator Interface* Select Operator Interface from the FlexPak 3000 Main Menu. The following menu will appear. Operator Interface Fault Alarm " PASSWORD...

  • Page 55: 4.14.2 How To Enable/Disable Program Protection

    Select Memory Operations from the Operator Interface menu to perform any of these operations. FlexPak 3000 Main Menu Operator Interface* MEMORY SAVE - This choice saves the current changes ("runtime" RAM memory) of parameter values to retentive memory.

  • Page 56: 4.14.4 Reset Clock

    DRIVE SETUP AND ADJUSTMENT 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.
  • Page 57 Enter the number of decimal places: Interlock OK NONE Drive Ready Running Current Limit Torque Limit 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...

  • Page 58: Define Load Units

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

  • Page 59: How To Change Parameter Values

    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...

  • Page 60: Standard Choice Integer Value Entry Screen

    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. FlexPak 3000 49’1340 e...
  • Page 61 (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. HELP Provides help text on the particular parameter. 49’1340 e FlexPak 3000...

  • Page 62: Selector Switch Or Boolean Value Entry Screen

    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 keys. Pressing ENTER stores the new reference value. FlexPak 3000 49’1340 e...

  • Page 63: Quick Start

    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...

  • Page 64: Table 6.1 - Quick Start Jumper Settings

    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.

  • Page 65: Table 6.2 - Quick Start Parameter Modification Sequence

    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. The rated armature current from the motor nameplate. 49’1340 e FlexPak 3000...
  • Page 66 Set OFF for a unidirectional pulse encoder. is set to PULSE TACH QUADRATURE while is the selected PULSE TACH FEEDBACK type, NEGATIVE will SELECT CURRENT LIM be set to 0 and set to ON REVERSE DISABLE (preventing reverse direction). FlexPak 3000 49’1340 e...
  • Page 67 JOG ACCEL/ 3 SEC. The time it takes the Jog reference circuit to DECEL RATE reach from zero. The TOP SPEED (P.011) parameter does not CURVE ROUNDING (P.014) affect the setting of this parameter. 49’1340 e FlexPak 3000...
  • Page 68 This parameter is not available for current/torque regulated drives. Table 6.2 - Quick Start Parameter Modification Sequence. – continued FlexPak 3000 49’1340 e...

  • Page 69: Self Tuning

    Tune? Perform a memory save to store values to quired 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. 49’1340 e FlexPak 3000...

  • Page 70: Self Tune Setup

    - 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. FlexPak 3000 49’1340 e...

  • Page 71: Execute Self Tuning

    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...

  • Page 72: Final Adjustments

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

  • Page 73: Troubleshooting/Diagnostics

    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. This section details troubleshooting and diagnostics information for the FlexPak 3000 Drive. Wiring Errors DANGER This equipment is at line voltage when AC power is connected.

  • Page 74: Remote M Contactor

    Review Log Fault Alarm " 05 CONTROLLER THERMOSTAT TRIP Interlock OK 04 FIELD CURRENT LOSS Drive Ready 03 A-C LINE SYNCHRONIZATION FAULT Running 02 OIM COMMUNICATIONS TIMEOUT Current Limit Torque Limit FAULT KEYPAD MANUAL FORWARD FlexPak 3000 49’1340 e...

  • Page 75: Reset Faults

    FAULT key. The following will be displayed. Alarm Menu Fault " Review Log Alarm Reset Alarms Interlock OK Clear Alarm Log and Reset Alarms Drive Ready Running Current Limit Torque Limit ALARM KEYPAD MANUAL FORWARD 49’1340 e FlexPak 3000...

  • Page 76: Review Log

    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. FlexPak 3000 49’1340 e...

  • Page 77: Diagnostics Menu

    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.

  • Page 78: Regulator Led Status Information

    • I/O is not being scanned, regulator board is not Blink 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. FlexPak 3000 49’1340 e...
  • Page 79 If the motor field winding was disconnected, reconnect it and return jumper J20 to its original position (typically on FlexPak with field rectifier) or (on FlexPak with field current ENABLE regulator) set parameter (P.512) to its original value. FIELD LOSS THRESHOLD 49’1340 e FlexPak 3000...

  • Page 80: Power Supply Test Pin Identification

    + 18 V J9 to J10 + 15 VI J11 to J12 - 15 VI J13 to J12 + 15 V J14 to J16 + 5 V J15 to J16 - 15 V J3 to J16 FlexPak 3000 49’1340 e...

  • Page 81: Replacement Parts And Accessories

    NOTE: Before replacing a thyristor or thyristor module the gate and cathode faston (1) Screws connectors must be checked for (2) Steel plate conductivity. (3) Housing (4a) Flat washer (4) Plate springs (5) Stamp (6) Semiconductor (7) Centering bolt (8) Heatsink 49’1340 e FlexPak 3000...
  • Page 82 360 degree by hand. Keep clearance to a minimum. • Proceed installation in the reverse order of removal. FlexPak 3000 49’1340 e...

  • Page 83: Recommended Spare Parts

    1 Power Supply FPP 810.89.00 1 Field Current Regul. 762.70.60* 1 MOV-Module 123.43.04 * The Field Current Regulator is only included n FlexPak types 848.xx.73. Further spare parts for Unit Type 150 A: 1 Capacitor 211.00.02 1 Resistor 750.70.04 49’1340 e FlexPak 3000...
  • Page 84 123.43.04 * The Field Current Regulator is only included n FlexPak types 848.xx.73 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 FlexPak 3000 49’1340 e...
  • Page 85 690 V 848.17.73 122.93.04 921.91.00 1600A, 60Hz 1 Interface TIG 575 V 848.17.43 122.93.04 921.91.11 813.43.10 1 MOV-Module 123.43.04 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...

  • Page 86: 8.2 Accessories

    Fuse Holder Dimensions Field Fuse Fuse Fuse Fuse Holder Size 11 Current Rating Type Part No. Part No. (2 pieces) 12 A 553.00.09 511.21.00 12 A 16 A 553.00.10 511.21.00 20 A 30 A 553.00.11 511.21.00 FlexPak 3000 49’1340 e...
  • Page 87 REPLACEMENT PARTS and ACCESSORIES Fuse Holder Dimensions 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...
  • Page 88 Cooling air per fuse: 130 m Fuse Nominal Fuse Dimensions Part Number Current 2000 A: 105 M12 31,25 100 340 W 553.72.00 553.72.01 2500 A: 105 M12 31,25 100 390 W Fuses for FlexPak 3000 type 2000 A (non UL, cUL) FlexPak 3000 49’1340 e...
  • Page 89 500V 1600A 800A 1000A 850A 252.44.12 252.42.01 575V 1000A 1200A 1100A 252.44.13 1334A 1600A 1360A 690V 252.44.15 AC Line AC Line 1U 1V 3V 3W Converter Input Field Rectifier Input Fig. 8-1: Line Reactor Wiring Diagram 49’1340 e FlexPak 3000...
  • Page 90 252.40.04 252.40.05 252.40.06 252.40.07 252.40.08 252.40.09 252.40.10 252.40.11 252.40.12 252.40.13 252.40.15 252.40.16 252.44.12 252.44.13 252.44.15 1100 252.42.05 0.48 Field Rectifier 252.42.06 Input 252.42.01 Figure 8-2: Line Reactor Dimensions (mm), Power Losses (W) and Weight (kg): 8-10 FlexPak 3000 49’1340 e...

  • Page 91: Figure 8.3 - Hf Filter Dimensions

    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.

  • Page 92: Table 8-10: Rfi Filter Selection

    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.
  • Page 93 Filter Part No.: 839.72-05 839.72-06 839.72-07 Rated Current 25 A 36 A 50 A Power loss: 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...
  • Page 94 REPLACEMENT PARTS and ACCESSORIES Radio Interference Filter 80 A, 440 V LINE LOAD Filter Part No.: 839.72-09 Power loss: 23 W Weight: 9.5 kg Figure 8-5: 80 A, 440 V Filter Dimensions (mm) 8-14 FlexPak 3000 49’1340 e...
  • Page 95 Radio Interference Filter 100 A, 500 V 4 x M6 4 x M8 LINE LOAD Filter Part No.: 839.71-53 Power loss: 75 W Weight: 9.5 kg Figure 8-6: 100 A, 500 V Filter Dimensions (mm) 49’1340 e FlexPak 3000 8-15...
  • Page 96 REPLACEMENT PARTS and ACCESSORIES Radio Interference Filter 150 A, 460 V 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...
  • Page 97 Part No. [kg] 180 839.74-22 537 360 132 470 180 156 510 280 839.72-67 742 530 103 153 660 260 220 700 Figure 8-8: 180 A, 440 V and 280 A, 500 V RFI-Filter Dimensions (mm) 49’1340 e FlexPak 3000 8-17...
  • Page 98 REPLACEMENT PARTS and ACCESSORIES Radio Interference Filter 270 A, 440/500 V LINE LOAD 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...
  • Page 99 REPLACEMENT PARTS and ACCESSORIES Radio Interference Filter 340 A, 440/500 V 24.5 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...
  • Page 100 Ground Bolt [kg] ∅ 10.5 ∅ 10.5 ∅ 11 ∅ 12 ∅ 14 ∅ 12 1000 2x ∅ 14 ∅ 12 1600 Figure 8-11 250, 500, 1000 and 1600 A, 440 V RFI-Filter Dimensions (mm) 8-20 FlexPak 3000 49’1340 e...
  • Page 101 61.5 1000 839.73-95 1600 839.73-98 Ground Bolt [kg] ∅ 11 ∅ 12 ∅ 11 ∅ 12 1000 2x ∅ 14 ∅ 12 1600 Figure 8-12 600, 1000 and 1600 A, 500/690 V RFI-Filter Dimensions (mm) 49’1340 e FlexPak 3000 8-21...
  • Page 102 8-22 FlexPak 3000 49’1340 e...

  • Page 103: Appendix A Glossary Of Terms

    Inertia is measured in kg m   load RPM   Inertia reflected to the shaft of the motor = load Inertia   motor RPM LCD : Liquid Crystal Display. LED : Light Emitted Diode. 49’1340 e FlexPak 3000...
  • Page 104 Top Speed : The highest speed a drive can achieve. Top Speed equals Base Speed when there is no field weakening. Torque: Turning force delivered by a motor or gear motor shaft, usually expressed in Nm: M [Nm] = P [kW] x 9550 / n [RPM] = full load torque FlexPak 3000 49’1340 e...

  • Page 105: Flexpak 3000 User Input Parameters

    APPENDIX B FlexPak 3000 User Input Parameters This appendix provides an alphabetized list of input parameters with their associated default values, description and the OIM Menu path(s) for access. Partial control block diagrams are provided for some parameters. Refer to Appendix D for full block diagrams.
  • Page 106 Used to remove any hardware introduced offset from the analog auto reference signal. Typically, it will be 0. Parameter Range: -200 to + 200 Default Setting: Parameter Type: Tuneable OIM Menu Path(s): Drive Reference - Drive Reference Scaling FlexPak 3000 49’1340 e...
  • Page 107 To adjust the zero point, make small changes to this parameter until ANLG IN 1 equals zero when the signal at terminals 50 and 51 is at its zero value (0 V, 4 mA, or 10 mA). See ANLG IN 1 GAIN ADJ for block diagram. 49’1340 e FlexPak 3000...
  • Page 108 ANLG MAN REF ZERO ADJ (P.105) Removes any hardware introduced offset from the analog reference signal. Typically, it will be 0. Parameter Range: -200 to +200 Default Setting: Parameter Type: Tuneable OIM Menu Path(s): Drive Reference - Drive Reference Scaling FlexPak 3000 49’1340 e...

  • Page 109: Armature Voltage

    MOTOR HOT FLD AMPS FIELD FEEDBACK (P.589) ± 4095 OCL REFERENCE (P.845) OCL RAMP OUTPUT (P.846) OCL FEEDBACK (P.847) NETW IN REG 1 (P.905) NETW IN REG 2 (P.906) NETW IN REG 3 (P.907) FULL SCALE ZERO 49’1340 e FlexPak 3000...
  • Page 110 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. Set the value of this parameter accurately per your application requirements. Failure to observe this precaution could result in bodily injury. FlexPak 3000 49’1340 e...
  • Page 111 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. Set the value of this parameter accurately per your application requirements. Failure to observe this precaution could result in bodily injury. 49’1340 e FlexPak 3000...
  • Page 112 TERMBLK. Parameter Range: ANALOG, FREQUENCY IN Default Setting: ANALOG Parameter Type: Configurable OIM Menu Path(s): Drive Reference -Drive Reference Configure Refer also to Parameters: CONTROL SOURCE SELECT (P.000), SPD SOURCE SELECT OUT (P.193), TORQUE REFERENCE (P.189) FlexPak 3000 49’1340 e...
  • Page 113 Current Minor Loop (CML) - CML Tuning CML PI PROP GAIN (P.301) Proportional gain for the CML PI block. Parameter Range: 0.000 to 4.000 Default Setting: 0.250 Parameter Type: Tuneable OIM Menu Path(s): Current Minor Loop (CML) - CML Tuning 49’1340 e FlexPak 3000...
  • Page 114 PLC while it is in program mode. The drive will not be ready while in the program mode if this parameter is set to STOP . Parameter Range: 1 = STOP, 2 = NOT STOP Default Setting: 1 = STOP Parameter Type: Configurable OIM Menu Path(s): Additional Parameters B-10 FlexPak 3000 49’1340 e...
  • Page 115 Sets the level of current compounding to be used during any mode of drive operation. Parameter Range: -50% to + 50% Default Setting: Parameter Type: Tuneable OIM Menu Path(s): Speed/Voltage Loop (SPD) - Speed Voltage Loop (SPD) Tuning 49’1340 e FlexPak 3000 B-11...
  • Page 116 Regulator board P.499 Not Running Not Installed SERIAL Digital Input (term. 12) OCL enable OCL ENABLE I/O Expansion Kit (DIG IN 0) * BRUSH WEAR P.490 JOG SPEED SELECT disable DIG IN 0 SELECT P.428 B-12 FlexPak 3000 49’1340 e...
  • Page 117 On a power cycle or reset, the contact is held at normally open until the drive software is initialized. Make sure that this condition does not result in a dangerous situation for your application. Failure to observe this precaution can result in severe bodily injury or loss of life. 49’1340 e FlexPak 3000 B-13...
  • Page 118 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. Set the value of this parameter accurately per your application requirements. Failure to observe this precaution could result in bodily injury. B-14 FlexPak 3000 49’1340 e...
  • Page 119 PI block. This in turn lowers the armature voltage, lowering the input to the first PI block so that it is closer to zero. The field control loop only affects armature voltage control if a tachometer is used and if FIELD AUTO WEAKEN is set to ENABLED. 49’1340 e FlexPak 3000 B-15...
  • Page 120 Set MOTOR HOT FLD AMPS to the motor's nameplate value. Make sure FIELD ECONOMY REF and/or FIELD REF REGISTER (P.513) is above FIELD LOSS THRESHOLD (P.512). Failure to observe this precaution can result in bodily injury and damage to the equipment. B-16 FlexPak 3000 49’1340 e...
  • Page 121 Proportional gain setting for the field current PI block. See FIELD PI LEAD FREQ for block diagram. Parameter Range: 0.01 to 128.00 Default Setting: 0.50 Parameter Type: Tuneable OIM Menu Path(s): Field - Field Current Regulator - Field Loop Tuning Refer also to Parameters: FIELD PI LEAD FREQ (P.515) 49’1340 e FlexPak 3000 B-17...
  • Page 122 0.01 to 56.50 rad/s Default Setting: 0.50 rad/s Parameter Type: Tuneable OIM Menu Path(s): Field - Field Current Regulator - Field Loop Tuning Refer also to Parameters: FIELD AUTO WEAKEN (P.517) FLD WEAKEN PROP GAIN (P.519) B-18 FlexPak 3000 49’1340 e...
  • Page 123 (it will not go negative). Parameter Range: 2.0 to FREQ IN FULL SCALE kHz Default Setting: 2.0 kHz Parameter Type: Configurable OIM Menu Path(s): Input/Output - Frequency I/O Refer also to Parameters: FREQ IN FULL SCALE (P.424) 49’1340 e FlexPak 3000 B-19...
  • Page 124 MOTOR HOT FLD AMPS FIELD FEEDBACK (P.589) ± 4095 OCL REFERENCE (P.845) OCL RAMP OUTPUT (P.846) OCL FEEDBACK (P.847) NETW IN REG 1 (P.905) NETW IN REG 2 (P.906) NETW IN REG 3 (P.907) FULL SCALE ZERO B-20 FlexPak 3000 49’1340 e...
  • Page 125 ATTENTION: Enabling the inverting fault avoidance logic does not guarantee that an inverting fault is prevented in all instances. Therefore on regenerating drives super fast armature fuses (according to chapter 8) must be provided. 49’1340 e FlexPak 3000 B-21...
  • Page 126 0 to 50% of MOTOR RATED ARM AMPS (P.008) Default Setting: Parameter Type: Tuneable OIM Menu Path(s): Speed/Voltage Loop (SPD) - Spd/Volt Loop (SPD) Tuning - Quick Start Field - Field Current Regulator - Field Loop Tuning B-22 FlexPak 3000 49’1340 e...
  • Page 127 0 to MAXIMUM SPEED (RPM or user-defined units) Default Setting: 250 (RPM or user-defined units) Parameter Type: Tuneable OIM Menu Path(s): Additional Parameters Refer also to Parameter: DIG IN 0 SELECT(P.428), JOG SPEED 1 (P.012) 49’1340 e FlexPak 3000 B-23...
  • Page 128 10.0 seconds Parameter Type: Tuneable OIM Menu Path(s): Input/Output - Level Detectors Refer also to Parameters: LEVEL DETECT 1 SELECT (P.602), LEVEL DETECT 2 OUTPUT (P.649) LEVEL DETECT 2 SELECT (P.605), LEVEL DETECT 2 THRESH (P.606) B-24 FlexPak 3000 49’1340 e...
  • Page 129 MAXIMUM CURRENT is limited to 200% of MOTOR RATED ARM AMPS (P.008). Parameter Range: 25 to 200% of P.008 Default Setting: 150% Parameter Type: Configurable OIM Menu Path(s): Current Minor Loop (CML) - CML Feedback Scaling Refer also to Parameters: MOTOR RATED ARM AMPS (P.008) 49’1340 e FlexPak 3000 B-25...
  • Page 130 1.000 Parameter Type: Tuneable OIM Menu Path(s): Input/Output - Meter Outputs NOTE: Testpoint METER OUT FULL SCALE must source METER OUT 1 SELECT for an accurate adjustment. See Appendix D, figure D.8, for further details. B-26 FlexPak 3000 49’1340 e...
  • Page 131 Default Setting: Parameter Type: Tuneable OIM Menu Path(s): Input/Output - Meter Outputs NOTE: Testpoint METER OUT ZERO must source METER OUT 1 SELECT for an accurate adjustment. See Appendix D, figure D.8, for further details. 49’1340 e FlexPak 3000 B-27...
  • Page 132 Default Setting: Parameter Type: Tuneable OIM Menu Path(s): Input/Output - Meter Outputs NOTE: Testpoint METER OUT ZERO must source METER OUT 2 SELECT for an accurate adjustment. See Appendix D, figure D-7, for further details. B-28 FlexPak 3000 49’1340 e...
  • Page 133 SELECT MOP Decrement (MOP OUTPUT) terminal 62 MAXIMUM SPEED P.004 *ANALOG MINIMUM SPEED P.003 ACCEL DECEL P.115 MOP ACCEL TIME MOP DECEL TIME P.120 P.192 (ANALOG MAN REFERENCE) To Speed Reference Source Select Block Diagram 49’1340 e FlexPak 3000 B-29...
  • Page 134 Set MOTOR HOT FLD AMPS to the motor's nameplate value. Make sure FIELD ECONOMY REF and/or FIELD REF REGISTER (P.513) is above FIELD LOSS THRESHOLD (P.512). Failure to observe this precaution can result in bodily injury and damage to the equipment. B-30 FlexPak 3000 49’1340 e...
  • Page 135 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. Set the value of this parameter accurately per your application requirements. Failure to observe this precaution could result in bodily injury. 49’1340 e FlexPak 3000 B-31...
  • Page 136 The purpose of the negative current limit inverter is to add flexibility to applications such as web processes which primarily use either an analog input or network register to dynamically control the drive's current limits while running as a speed regulator. B-32 FlexPak 3000 49’1340 e...
  • Page 137 ANALOG IN 1 * SPD LOOP CUR LIM From I/O Expansion ANALOG IN 2 Inputs Block Diagram REGISTER NETW IN REG 1, 2, 3 From Network NEG CURRENT LIM INV EN 3) P.006 NEG CURRENT LIM 49’1340 e FlexPak 3000 B-33...
  • Page 138 Once the drive is stopped, it cannot be restarted until network communication is re- established or CONTROL SOURCE SELECT is changed to something other than NETWORK. B-34 FlexPak 3000 49’1340 e...
  • Page 139 As of FlexPak 3000 regulator software version 2.01, drop depth is 4 when NETW CONNECT TYPE is set to FULL.
  • Page 140 1.00 second Default Setting: Parameter Type: Tuneable OIM Menu Path(s): Speed/Voltage Loop (SPD) - Speed/Voltage Loop (SPD) Tuning Refer also to Parameters: INERTIA COMP SELECT (P.221), MOTOR HOT FLD AMPS (P.510), MOTOR RATED ARM AMPS (P.008) B-36 FlexPak 3000 49’1340 e...
  • Page 141 See OCL LEADLAG LOW FREQ for discussion and block diagram. Parameter Range: 2 to 20 Default Setting: Parameter Type: Tuneable OIM Menu Path(s): Outer Control Loop (OCL) - OCL Tuning Refer also to Parameters: OCL LEADLAG LOW FREQ (P.806), OCL LEADLAG SELECT (P.805) 49’1340 e FlexPak 3000 B-37...
  • Page 142 Outer Control Loop (OCL) - OCL Tuning Refer also to Parameters: OCL OUTPUT (P.848), OCL PI LEAD FREQ (P.809), OCL PI POSITIVE LIMIT (P.810), OCL PI PROP GAIN (P.808), OCL RAMP OUTPUT (P.846), TOP SPEED (P.011) B-38 FlexPak 3000 49’1340 e...
  • Page 143 10.0 seconds Parameter Type: Tuneable OIM Menu Path(s): Outer Control Loop (OCL) - OCL Tuning Refer also to Parameters: OCL RAMP OUTPUT (P.846), OCL REFERENCE (P.845), OCL REF RAMP TIME (P.802), OCL REF ROUNDING (P.803) 49’1340 e FlexPak 3000 B-39...
  • Page 144 Outer Control Loop (OCL) - OCL Tuning Refer also to Parameters: OCL OUTPUT (P.848), OCL PI LEAD FREQ (P.809), OCL PI NEGATIVE LIMIT (P.811), OCL PI POSITIVE LIMIT (P.810), OCL PI PROP GAIN (P.808), TOP SPEED (P.011) B-40 FlexPak 3000 49’1340 e...
  • Page 145 Lock the motor armature shaft securely to prevent rotation in either direction prior to selecting this test. Failure to observe these precautions could result in bodily injury. 49’1340 e FlexPak 3000 B-41...
  • Page 146 REGISTER Parameter Type: Configurable OIM Menu Path(s): Speed/Voltage Loop (SPD) - Speed/Voltage Loop (SPD) Tuning or Current Minor Loop (CML) - CML Tuning Refer also to Parameters: CONTROL SOURCE SELECT (P.000), POSITIVE CURRENT LIM (P.005) B-42 FlexPak 3000 49’1340 e...
  • Page 147 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. Set the value of this parameter accurately per your application requirements. Failure to observe this precaution could result in bodily injury. 49’1340 e FlexPak 3000 B-43...
  • Page 148 *The default is ON when: • The drive has a non-regenerative (S6) power unit. • FEEDBACK SELECT is set to AC TACH • FEEDBACK SELECT is set to PULSE TACH and PULSE TACH QUADRATURE is OFF. B-44 FlexPak 3000 49’1340 e...
  • Page 149 The typical value is 25. Applies to speed loop tuning only. Parameter Range: 10 to 100 Default Setting: Parameter Type: Tuneable OIM Menu Path(s): Current Minor Loop (CML) - CML Tuning - Self Tuning Setup Speed/Voltage Loop (SPD) - SPD Tuning - Self Tuning Setup 49’1340 e FlexPak 3000 B-45...
  • Page 150 LOW FREQ). If SPD LEADLAG SELECT is set to BYPASS, this parameter has no effect. Parameter Range: 2 to 20 Default Setting: Parameter Type: Tuneable OIM Menu Path(s): Speed/Voltage Loop (SPD) - Speed/Voltage Loop (SPD) Tuning Refer also to Parameters: SPD LEADLAG LOW FREQ (P.214), SPD LEADLAG SELECT (P.216) B-46 FlexPak 3000 49’1340 e...
  • Page 151 0.00 to 327.67 rad/s when • FEEDBACK SELECT (P.200) ≠ ARMATURE VOLT • SPD LOOP SCAN TIME (P.019) = 5 ms Default Setting: 3.00 rad/s Tuneable Parameter Type: OIM Menu Path(s): Speed/Voltage Loop (SPD) - Speed/Voltage Loop (SPD) Tuning 49’1340 e FlexPak 3000 B-47...
  • Page 152 OIM Menu Path(s): N/A, network only Refer also to Parameters: CONTROL SOURCE SELECT (P.000) SPD LOOP PI INIT SEL (Alternate network map, Drop_2, register 32) SPD LOOP PI INIT VAL (Alternate network map, Drop_1, register 39) B-48 FlexPak 3000 49’1340 e...
  • Page 153 If the drive is configured as a current regulator, only COAST/DB can be selected. Parameter Range: RAMP, COAST/DB, CURRENT LIMIT Default Setting: RAMP Parameter Type: Tuneable OIM Menu Path(s): Drive Reference - Drive Reference Configure STOP SPEED THRESHOLD (P.113) 49’1340 e FlexPak 3000 B-49...
  • Page 154 The incorrect setting of this parameter can cause an overspeed condition. Set the value of this parameter only as high as necessary to stop incorrect tach loss faults. Failure to observe this precaution could result in bodily injury. TOP SPEED (P.011) B-50 FlexPak 3000 49’1340 e...
  • Page 155 TRIM REFERENCE SELECT (P.108) Trim reference selection. Parameter Range: ANALOG MANUAL, REGISTER, ANALOG IN 1, NETW IN REG 1, NETW IN REG 2, NETW IN REG 3, ANALOG IN 2 Default Setting: REGISTER Parameter Type: Tuneable 49’1340 e FlexPak 3000 B-51...
  • Page 156 WLD LO Netw. Drop 1, Reg. 32, Bit 5 (SPD LOOP LAG OUTPUT) (SPD LOOP OUTPUT) SPEED FEEDBACK GAIN 1) A * B Netw. Drop 1, Reg. 38 1000 KEYPAD, TERMBLK P.000 CSS or SERIAL NETWORK B-52 FlexPak 3000 49’1340 e...
  • Page 157 APPENDIX C FlexPak 3000 User Output Parameter Records This appendix provides an alphabetized list of output parameters with their associated description and the menu path(s) for access. Reference Appendix D, Speed Loop & CML Block Diagrams, for the relation of these parameters in the signal flow of their associated loops.
  • Page 158 The CML feedback signal prior to the summing junction. OIM Menu Path(s): Current Minor Loop (CML) - SCR Diagnostics - Armature Phase Fire Test Current Minor Loop (CML) - CML Feedback Scaling Current Minor Loop (CML) - CML Test Points CML REFERENCE (P.396) FlexPak 3000 49’1340 e...
  • Page 159 See PRESET SPEED 1, 2, and 3 for more information. Parameter Range: OIM Menu Path(s): Input/Output - Digital I/O Refer also to Parameters: PRESET SPEED 1 (P.117), PRESET SPEED 2 (P.118) PRESET SPEED 3 (P.119) 49’1340 e FlexPak 3000...
  • Page 160 Determined by the selected trim reference signal and TRIM RANGE value. DRAW PERCENTAGE is used as a multiplier in the proportional trim mode for accelerate and decelerate rates. It is also used to generate the TRIM OUTPUT value. OIM Menu Path(s): Drive Reference - Drive Reference Test Points FlexPak 3000 49’1340 e...
  • Page 161 FREQ IN FULL SCALE (P.424), FREQ IN ZERO (P.423) FREQ IN is zero when the frequency at the input is less than or equal to FREQ IN ZERO. It is 4095 when the frequency equals FREQ IN FULL SCALE. 49’1340 e FlexPak 3000...
  • Page 162 OIM Menu Path(s): Drive Information - Correct Scaling Jumper Positions Current Minor Loop (CML) - CML Feedback Scaling Quick Start Refer also to Parameters: CT TURNS RATIO (P.010), MAXIMUM CURRENT (P.007) MOTOR RATED ARM AMPS (P.008) FlexPak 3000 49’1340 e...
  • Page 163 ON when the input signal is greater than or equal to LEVEL DETECT 2 THRESH for longer than LEVEL DETECT 2 DELAY. OFF whenever the input signal is less than LEVEL DETECT 2 THRESH. See LEVEL DETECT 1 SELECT for block diagram. 49’1340 e FlexPak 3000...
  • Page 164 V = Network card software version: 1 for AutoMax SW, 7 for Profibus SW, 8 for Interbus SW .xx = Network card software version subindex. OIM Menu Path(s): Network Communications NETWORK KIT (P.796) Indicates the status of the network option board. OIM Menu Path(s): Network Communications Drive Information FlexPak 3000 49’1340 e...
  • Page 165 Indicates if the drives employs an S6R (regenerative) or an S6 (non-regenerative) power unit. If the power unit type is S6 (non-regenerative), NEGATIVE CURRENT LIM will be automatically fixed to 0, and REVERSE DISABLE fixed to ON (preventing reverse direction). OIM Menu Path(s): Drive Information 49’1340 e FlexPak 3000...
  • Page 166 Drive Reference - Drive Reference Test Points SPD SOURCE SELECT OUT (P.193) The user selected speed reference source value. It is an input to the speed reference ramp section. OIM Menu Path(s): Drive Reference - Drive Reference Test Points C-10 FlexPak 3000 49’1340 e...
  • Page 167 OIM Menu Path(s): Current Minor Loop (CML) - CML Test Points TRIM OUTPUT (P.197) Actual signal used to trim (add to) the selected speed loop reference signal. OIM Menu Path(s): Drive Reference - Drive Reference Test Points 49’1340 e FlexPak 3000 C-11...
  • Page 168 C-12 FlexPak 3000 49’1340 e...
  • Page 169 • All capitalized signals = Input Parameters [ e.g. MAXIMUM SPEED] • All capitalized signal with parenthesis = Output Parameters [e.g. (TORQUE REFERENCE)] • All capitalized with italic type = switch position [e.g. KEYPAD ] • An asterisk (*) - default selection 49’1340 e FlexPak 3000...
  • Page 170 APPENDIX D D-II FlexPak 3000 49’1340 e...

  • Page 171: Figure D.1 - Drive Control Signals

    APPENDIX D Figure D.1 - Drive Control Signals 49’1340 e FlexPak 3000...

  • Page 172: Figure D.2 - Speed Reference Overview

    APPENDIX D Figure D.2 - Speed Reference Overview FlexPak 3000 49’1340 e...

  • Page 173: Figure D.3 - Speed Reference Source Select

    APPENDIX D Figure D.3 - Speed Reference Source Select 49’1340 e FlexPak 3000...

  • Page 174: Figure D.4 - Speed Reference Ramp

    APPENDIX D Figure D.4 - Speed Reference Ramp FlexPak 3000 49’1340 e...

  • Page 175: Figure D.5 - Speed Reference Mode Select

    APPENDIX D Figure D.5 - Speed Reference Mode Select 49’1340 e FlexPak 3000...

  • Page 176: Figure D.6 - Speed Loop

    APPENDIX D Figure D.6 - Speed Loop FlexPak 3000 49’1340 e...
  • Page 177 APPENDIX D Figure D.7 - Digital Outputs, Analog and Frequency Outputs 49’1340 e FlexPak 3000...
  • Page 178 APPENDIX D Figure D.8 - Metering Outputs FlexPak 3000 49’1340 e...

  • Page 179: Figure D.9 - Current Minor Loop Reference

    APPENDIX D Figure D.9 - Current Minor Loop Reference 49’1340 e FlexPak 3000...

  • Page 180: Figure D.10 - Current Minor Loop

    APPENDIX D Figure D.10 - Current Minor Loop D-10 FlexPak 3000 49’1340 e...

  • Page 181: Figure D.11 - Field Block

    APPENDIX D Figure D.11 - Field Block 49’1340 e FlexPak 3000 D-11...
  • Page 182 APPENDIX D Figure D.12 - I/O Expansion Board Outer Control Loop D-12 FlexPak 3000 49’1340 e...

  • Page 183: Figure D.13 - I/O Expansion Board Inputs

    APPENDIX D Figure D.13 - I/O Expansion Board Inputs 49’1340 e FlexPak 3000 D-13...

  • Page 184: Figure D.14 - Level Detectors

    APPENDIX D Figure D.14 - Level Detectors D-14 FlexPak 3000 49’1340 e...
  • Page 185 Table E-2 lists alarm codes. Tables E-1 and E-2 list fault and alarm codes by number (Fxxxxx = Fault; Axxxxx = Alarm), associated message visible at the OIM display and a description along with possible causes. 49’1340 e FlexPak 3000...

  • Page 186: Table E.1 - Fault Codes

    Possible causes: • Incorrect armature current feedback scaling (MOTOR RATED ARM and/or J18 not set AMPS, MAXIMUM CURRENT, CT TURNS RATIO properly). • Blown field supply fuse(s). • Mechanical binding preventing the motor shaft from rotating freely. FlexPak 3000 49’1340 e...
  • Page 187 Table E.1 - Fault Codes (Continued) CODE DISPLAY DESCRIPTION F00006 BLOWER MOTOR This fault is not applicable on European versions FlexPak 3000. STARTER OPEN F00007 OPEN ARMATURE The motor armature circuit is open. Possible causes: • Motor armature winding not connected or open circuit.
  • Page 188 Calculated armature inductance is out of range. FAULT Possible causes: • Motor armature winding not connected or open circuit. • Blown inverting fault (DC) fuse. • Inverting fault breaker tripped. • Armature inductance too high, tune CML manually. FlexPak 3000 49’1340 e...
  • Page 189 • Disconnected, loosely connected, or damaged J7 ribbon cable or power supply input wiring 1) When after stop command, the auxiliary contactor does not indicate that the main contactor opened, this fault indication is 1000 msec time delayed. 49’1340 e FlexPak 3000...
  • Page 190 F00999 MICRO- A microprocessor hardware or software fault occurred. PROCESSOR Possible causes: • Electrical noise due to improper wiring practices or unsuppressed F02000 HW/SW FAULT brake coils, relays, contactors. F03999 • Defective regulator board. FlexPak 3000 49’1340 e...

  • Page 191: Table E.2 - Alarm Codes

    1) When after stop command, the auxiliary contactor does not indicate that the main contactor opened, this alarm indication is 1000 msec time delayed. 2) When after start command, the auxiliary contactor does not indicate that the main contactor closed, this alarm indication is 1000 msec time delayed. 49’1340 e FlexPak 3000...
  • Page 192 A00700 RETENTIVE An attempt to save information (parameter values, fault log data or the MEMORY SAVE keypad reverence value) to retentive memory failed. The drive may ERROR continue to be operated. Possible cause: Regulator board failure. FlexPak 3000 49’1340 e...
  • Page 193 Why is the drive not ready? Why did the drive stop? To access the Main Menu, press CANCEL until FlexPak 3000 Main Menu is displayed at the top of the screen. Each menu shown below is expanded on the pages that follow.
  • Page 194 APPENDIX F FlexPak 3000 Main Menu Quick Start MOTOR BASE SPEED/TOP SPEED (P.011) MOTOR RATED ARM AMPS (P.008) MOTOR RATED ARM VOLTS (P.009) REVERSE DISABLE (P.015) FEEDBACK SELECT (P.200) ANLG TACH VOLTS/1000 (P.203) ACCELERATION TIME (P.001) DECELERATION TIME (P.002) MINIMUM SPEED (P.003) MAXIMUM SPEED (P.004)
  • Page 195 APPENDIX F FlexPak 3000 Main Menu Drive Reference Configure JOG SPEED (P.012) ANLG AUTO SIGNAL TYPE (P.100) STOP MODE SELECT (P.114) STOP SPEED THRESHOLD (P.113) AUTO REFERENCE SELECT (P.103) MANUAL REF SELECT (P.106) JOG OFF DELAY TIME (P.121) PRESET SPEED 1 (P.117) PRESET SPEED 2 (P.118)
  • Page 196 APPENDIX F FlexPak 3000 Main Menu Speed/Voltage Loop (SPD) Feedback FEEDBACK SELECT (P.200) MOTOR RATED ARM VOLTS (P.009) ARM VOLTAGE ZERO ADJ (P.205) ARM VOLTAGE GAIN ADJ (P.204) ARMATURE VOLTAGE (P.289) ANALOG TACH ZERO ADJ (P.202) ANALOG TACH GAIN ADJ (P.201) ANALOG TACH FEEDBACK (P.291)
  • Page 197 APPENDIX F FlexPak 3000 Main Menu Three Phase AC Line NOMINAL AC LINE FREQ (P.306) NOMINAL AC LINE VOLTS (P.307) AC LINE PERIOD (P.393) AC LINE VOLTAGE (P.392) PLL MAXIMUM ERROR (P.308) SCR Diagnostics OPEN SCR SENSITIVITY (P.600) OPEN SCR TRIP THRESH (P.601) Armature Phase Fire Test PHASE FIRE TEST DELTA (P.309)
  • Page 198 APPENDIX F FlexPak 3000 Main Menu Input/Output Meter Outputs METER OUT 1 SELECT (P.404) METER OUT 1 ZERO ADJ (P.402) METER OUT 1 GAIN ADJ (P.400) METER OUT 2 SELECT (P.405) METER OUT 2 ZERO ADJ (P.403) METER OUT 2 GAIN ADJ (P.401) Analog I/O I/O EXPANSION KIT (P.797)
  • Page 199 APPENDIX F FlexPak 3000 Main Menu Network Communications NETWORK KIT (P.796) NETW TYPE & VERSION (P.909) NETW COMM STATUS (P.908) NETW DROP NUMBER (P.900) NETW COMM LOSS SELECT (P.901) NETW CONNECT TYPE (P.910) AMX NETW REF SELECT (P.911) NETW OUT REG 1 SELECT (P.902) NETW OUT REG 2 SELECT (P.903)
  • Page 200 APPENDIX F FlexPak 3000 Main Menu Drive Information Correct Scaling Jumper Positions J11 ANLG TACH VLT SCL (P.792) J14 ANLG TACH VLT RNG (P.793) J18 ARM I FB RESISTOR (P.395) PULSE TACHOMETER KIT (P.798) NETWORK KIT (P.796) I/O EXPANSION KIT (P.797) FLD CURRENT REGULATOR (P.586)
  • Page 201 AUTO REFERENCE SELECT ANALOG • FREQUENCY IN ANLG MAN REF GAIN ADJ 0.750 - 1.250 1.000 (*) Or user defined unit. (2) Jumpers J10 and J12 must be set for the type of auto reference selected. 49’1340 e FlexPak 3000...
  • Page 202 1.000 ARM VOLTAGE ZERO ADJ -200 - +200 V IR COMPENSATION 0 - 50 %FLA 0% FLA (*) Or user defined unit. (3) If drive is configured as a current regulator, only COAST/DB can be selected. FlexPak 3000 49’1340 e...
  • Page 203 • NETW IN REG 3 • 1 = DISABLE NEG CUR LIM INV EN • 2 = ENABLE TACH LEAD FLT THRESH 0.0 to 250 % (of TOP SPEED) 200.0 TACH LEAD FLT DELAY 0 to 32767 (msec) 10 000 49’1340 e FlexPak 3000...
  • Page 204 • OCL OUTPUT • FIELD REFERENCE • FIELD FEEDBACK • NETW IN REG 1 • NETW IN REG 2 • NETW IN REG 3 same as above for P.404 METER OUT 2 SELECT SPD LOOP FEEDBACK FlexPak 3000 49’1340 e...
  • Page 205 • POWER OUTPUT • OCL REFERENCE • OCL RAMP OUTPUT • OCL FEEDBACK • OCL OUTPUT • FIELD REFERENCE • FIELD FEEDBACK • NETW IN REG 1 • NETW IN REG 2 • NETW IN REG 3 49’1340 e FlexPak 3000...
  • Page 206 • 3 = ANALOG IN 1 • 4 = ANALOG IN 2. FIELD DELTA HIGH LIM 0 - 180 degree 130 degree Thyristor Firing check OPEN SCR SENSITIVITY 0 - 100% OPEN SCR TRIP THRESH 800 - 4000 1600 FlexPak 3000 49’1340 e...
  • Page 207 • 8= NETW IN REG 2 • 9= NETW IN REG 3 OCL LEADLAG SELECT • LEAD/LAG BYPASS • BYPASS • LAG/LEAD OCL LEADLAG LOW FREQ 0.01 - 34.90 rad/s 1.00 rad/s OCL LEADLAG RATIO 2 - 20 49’1340 e FlexPak 3000...
  • Page 208 • 0 = DISABLED (overwind) Alternate network map, • 1 = ENABLED (underwind) Drop_1, reg. 32, bit 5) (1) Parameter is only available or displayed on the OIM if an optional Network Communications board is installed. FlexPak 3000 49’1340 e...
  • Page 209 They have been tested to meet Council Directive 89/336 Electromagnetic Compatibility (EMC) and all applicable standards (listed in the technical construction file). With the specified EMC filters and the measures as described in this guidelines the FlexPak 3000 can be operated CE-conform according to product standard EN 61800-3 .
  • Page 210 1. Connection of EMC filter (RFI-Filter on drives <100 A or HF filter on drives >100 A) as specified in Chapter 8, Accessories. 2. Because FlexPak 3000 and filter have protection class IP00 they must be built in a cabinet. Both units must be mounted on a blank (not painted) panel with good conductivity.
  • Page 211 Cabinet protection ground busbar Cable bracket Screen Screened 3-wire motor armature cable Shielded 2-wire motor field cable Shielded signal conductor cable (feedback, reference) EMC-tested armoured cable gland at terminal box Figure H-1: Example for control cabinet configuration 49'1340 e FlexPak 3000...

  • Page 212: Figure H-2: Specification For Screened Cable

    The individual conductors must be stranded, but twisted pairs are not required. The screen must be grounded at both ends. Stranded copper wire Plastic insulation Inner plastic sheath Compact screen of galvanised (tinned) copper or steel braid Outer plastic jacket Figure H-2: Specification for screened cable FlexPak 3000 49'1340 e...
  • Page 213 Cross Reference List Part Numbers - Catalogue Numbers This appendix provides a cross reference lists for part numbers of the FlexPak 3000 in numeric order and associated Rockwell Automation catalogue numbers and Reliance US-Model Numbers. Part numbers without catalogue numbers are spare parts. (Refer to Tables 8-1 to 8-6).
  • Page 214 20FN8742 848.00.73 FP3000-S6-25-AN-FC 20FR8742 848.01.73 FP3000-S6R-25-AN-FC 50FN8742 848.02.73 FP3000-S6-60-AN-FC 50FR8742 848.03.73 FP3000-S6R-60-AN-FC 125FN8742 848.04.73 FP3000-S6-150-AN-FC 125FR8742 848.05.73 FP3000-S6R-150-AN-FC 200FN8742 848.06.73 FP3000-S6-250-AN-FC 200FR8742 848.07.73 FP3000-S6R-250-AN-FC 375FN8742 848.08.73 FP3000-S6-450-AN-FC 375FR8742 848.09.73 FP3000-S6R-450-AN-FC 650FN8742 848.10.73 FP3000-S6-800-AN-FC 650FR8742 848.11.73 FP3000-S6R-800-AN-FC FlexPak 3000 49’1340 e...
  • Page 216 Asia Pacific: Rockwell Automation, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433 Europe/Middle East/Africa: Rockwell Automation, Brühlstraße 22, D-74834 Elztal-Dallau, Germany, Tel: (49) 6261 9410, Fax: (49) 6261 17741...

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