Rockwell-automation FlexPak 3000 Power Module SW-Version 4.3 Manuel d'utilisateur

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:

INTRODUCTION TO THE DRIVE FlexPak 3000 49’1340 e 2-22.2 Drive Specifications 2.2.1 AC-Line Considerations Requirement Measures 1) Limiting the AC li

REPLACEMENT PARTS and ACCESSORIES FlexPak 3000 49’1340 e 8-20Radio Interference Filter 250, 500, 1000 and 1600 A, 440 V L3 L2

REPLACEMENT PARTS and ACCESSORIES 49’1340 e FlexPak 3000 8-21 Radio Interference Filter 600 ,1000 and 1600 A, 500/690 V L3 L2

FlexPak 3000 49’1340 e 8-22

APPENDIX A 49’1340 e FlexPak 3000 A-1 Glossary of Terms Altitude: The atmospheric altitude (height above sea level) at which the motor or drive wil

APPENDIX A FlexPak 3000 49’1340 e A-2Motor: A device that converts electrical energy to mechanical energy to turn a shaft. Motor Electrical Time

APPENDIX B 49’1340 e FlexPak 3000 B-1 FlexPak 3000 User Input Parameters This appendix provides an alphabetized list of input parameters with their

APPENDIX B FlexPak 3000 49’1340 e B-2ANALOG TACH ZERO ADJ (P.202) Used to remove any hardware-introduced offset from the analog tachometer feedback

APPENDIX B 49’1340 e FlexPak 3000 B-3 ANLG IN 1 GAIN ADJ (P.415) Only available if the I/O Expansion kit is installed. Gain adjustment for analog in

APPENDIX B FlexPak 3000 49’1340 e B-4ANLG IN 2 GAIN ADJ (P.417) Only available if the I/O Expansion kit is installed. Gain adjustment for analog inp

APPENDIX B 49’1340 e FlexPak 3000 B-5 ANLG OUT 1 GAIN ADJ (P.420) Only available if the I/O Expansion kit is installed. Adjusts analog output 1 (ter

INTRODUCTION TO THE DRIVE 49’1340 e FlexPak 3000 2-3 2.2.3 Input Voltage and Frequency Ratings: Nominal voltage for three-phase at terminals 1U, 1V

APPENDIX B FlexPak 3000 49’1340 e B-6ANLG OUT 1 SIG TYPE (P.419) Only available if the I/O Expansion Kit is installed. Selects the type of signal to

APPENDIX B 49’1340 e FlexPak 3000 B-7 ANLG OUT 2 SELECT (P.421) Only available if the I/O Expansion Kit is installed. Selects the signal used to dri

APPENDIX B FlexPak 3000 49’1340 e B-8ARM VOLTAGE ZERO ADJ (P.205) Used to remove any hardware-introduced offset from the armature voltage signal. I

APPENDIX B 49’1340 e FlexPak 3000 B-9 When the reference source is set to ANALOG, the analog auto input (terminals 19 and 20 on the regulator board)

APPENDIX B FlexPak 3000 49’1340 e B-10CML REF LIMIT SELECT (P.311) Selects the source for the CML positive and negative current limits. Parameter Ra

APPENDIX B 49’1340 e FlexPak 3000 B-11 CONTROL SOURCE SELECT (P.000) This parameter is only available on the Drive Configuration Module (DCM). It is

APPENDIX B FlexPak 3000 49’1340 e B-12DECELERATION TIME (P.002) Selects the time it takes to decelerate from TOP SPEED to 0. Smaller changes in spee

APPENDIX B 49’1340 e FlexPak 3000 B-13 DIG OUT 1 CONTACT TYP (P.410) Only available if the I/O Expansion Kit is installed. Selects whether digital o

APPENDIX B FlexPak 3000 49’1340 e B-14DIG OUT 2 SELECT (P.411) Only available if the I/O Expansion Kit is installed. NETW IN REG 1, 2, or 3: Bit 1 o

APPENDIX B 49’1340 e FlexPak 3000 B-15 FIELD AUTO WEAKEN (P.517) Only available if the Field Current Regulator Kit is installed. Enables or disables

INTRODUCTION TO THE DRIVE FlexPak 3000 49’1340 e 2-42.2.7 Regulation (with 95% load change): Table 2-2 - Tachometer Speed Regulation Regulation Ar

APPENDIX B FlexPak 3000 49’1340 e B-16FIELD DELTA HIGH LIM (P.587) High limit of the field current PI block. See FIELD AUTO WEAKEN for block diagram

APPENDIX B 49’1340 e FlexPak 3000 B-17 FIELD LOSS THRESHOLD (P.512) Only available if the Field Current Regulator kit is installed. The value that i

APPENDIX B FlexPak 3000 49’1340 e B-18FIELD REF REGISTER (P.513) Only available if the Field Current Regulator kit is installed. Current reference f

APPENDIX B 49’1340 e FlexPak 3000 B-19 FLD WEAKEN PROP GAIN (P.519) Only available if the Field Current Regulator kit is installed. The proportional

APPENDIX B FlexPak 3000 49’1340 e B-20FREQ OUT FULL SCALE (P.427) Only available if the I/O Expansion kit is installed. The frequency generated when

APPENDIX B 49’1340 e FlexPak 3000 B-21 FREQ OUT ZERO (P.426) Only available if the I/O Expansion kit is installed. The frequency generated when the

APPENDIX B FlexPak 3000 49’1340 e B-22INV FAULT AVOID SEL (P.312) settings and action taken when drive detects conditions that could lead to an inve

APPENDIX B 49’1340 e FlexPak 3000 B-23 JOG ACCEL/DECEL TIME (P.013) Sets the time it takes the jog reference circuit to reach TOP SPEED from zero. T

APPENDIX B FlexPak 3000 49’1340 e B-24LEVEL DETECT 1 DELAY (P.604) The delay time in seconds for the level detector 1 circuit. Sets the amount of ti

APPENDIX B 49’1340 e FlexPak 3000 B-25 LEVEL DETECT 2 SELECT (P.605) Selects the signal that drives level detector 2. See LEVEL DETECT 1 SELECT for

INTRODUCTION TO THE DRIVE 49’1340 e FlexPak 3000 2-5 2.3 Drive Input/Output Specifications The following sections describe drive inputs and outputs.

APPENDIX B FlexPak 3000 49’1340 e B-26MAXIMUM SPEED (P.004) The maximum speed of the drive that can be supported by the application or process. MAXI

APPENDIX B 49’1340 e FlexPak 3000 B-27 METER OUT 1 SELECT (P.404) Selects the drive testpoint that will source meter output 1 (terminals 24 and 25 o

APPENDIX B FlexPak 3000 49’1340 e B-28METER OUT 2 GAIN ADJ (P.401) Scales the Meter 2 output signal at the regulator board terminal strip. Parameter

APPENDIX B 49’1340 e FlexPak 3000 B-29 MINIMUM SPEED (P.003) Selects the minimum speed of the drive without being stopped. It is typically greater t

APPENDIX B FlexPak 3000 49’1340 e B-30MOP DECEL TIME (P.120) Only available if the I/O Expansion kit is installed. Minimum time in which the MOP OUT

APPENDIX B 49’1340 e FlexPak 3000 B-31 (FIELD FEEDBACK) ScalingSoftwareMOTOR HOT FLD AMPSA/DFIELD ECONOMY REF100MOTOR HOT FLD AMPSMOTOR HOT FLD AMP

APPENDIX B FlexPak 3000 49’1340 e B-32NEG CURRENT LIM SEL (P.224) Selects the source for the negative current limit. If REGISTER is selected, NEGATI

APPENDIX B 49’1340 e FlexPak 3000 B-33 WARNING: When analog inputs or network registers are used to control current limits, bipolar values are per

APPENDIX B FlexPak 3000 49’1340 e B-34NETW BAUD RATE (P.912) Sets the baud rate for the DeviceNet Network Communication board. The baud rate for the

APPENDIX B 49’1340 e FlexPak 3000 B-35 NETW CONNECT TYPE (P.910) AutoMax Network Connection type. When NETW CONNECT TYPE is set to BASIC, only the m

INTRODUCTION TO THE DRIVE FlexPak 3000 49’1340 e 2-6Analog Tachometer Feedback Tach Voltage at Top Speed ...

APPENDIX B FlexPak 3000 49’1340 e B-36NETW OUT REG 3 SELECT (P.904) Selects which parameter is to be monitored in drop_1, register 9. Select the par

APPENDIX B 49’1340 e FlexPak 3000 B-37 OCL FEEDBACK SELECT (P.804) Selects the source for the outer control loop (OCL) feedback signal.. To enable t

APPENDIX B FlexPak 3000 49’1340 e B-38OCL LEADLAG SELECT (P.805) Selects the outer control loop as lead/lag, lag/lead, or bypassed. If the OCL is co

APPENDIX B 49’1340 e FlexPak 3000 B-39 OCL PI POSITIVE LIMIT (P.810) Outer Control Loop PI block positive limit. The output of OCL PI block is never

APPENDIX B FlexPak 3000 49’1340 e B-40OCL REF REGISTER (P.801) The reference for the outer control loop that is used when OCL REFERENCE SELECT is se

APPENDIX B 49’1340 e FlexPak 3000 B-41 OCL TYPE3 POSN REG EN (P.814) Selects the source of the Current Minor Loop reference when the drive is config

APPENDIX B FlexPak 3000 49’1340 e B-42PHASE FIRE TST BRIDGE (P.310) Armature phase fire test mode bridge select. This input can only be changed whil

APPENDIX B 49’1340 e FlexPak 3000 B-43 POSITIVE CURRENT LIM (P.005) Selects the highest amount of current (% motor rated armature amps) for the for

APPENDIX B FlexPak 3000 49’1340 e B-44PULSE TACH QUADRATURE (P.208) Enables or disables pulse tachometer quadrature. Set ON for a bi-directional pul

APPENDIX B 49’1340 e FlexPak 3000 B-45 S-CURVE ROUNDING (P.014) Rate of change (positive or negative) of acceleration and deceleration to smooth the

INTRODUCTION TO THE DRIVE 49’1340 e FlexPak 3000 2-7 2.4 Drive Description The drive is a full-wave power converter without back rectifier, complete

APPENDIX B FlexPak 3000 49’1340 e B-46SPEED FEEDBACK GAIN (Alternate network map, drop_1, register 38) Only available if the AutoMax Network Commun

APPENDIX B 49’1340 e FlexPak 3000 B-47 SPD LEADLAG SELECT (P.216) Determines if the lead/lag block will act upon the speed loop feedback signal. If

APPENDIX B FlexPak 3000 49’1340 e B-48SPD LOOP PI INIT SEL (Alternate network map, Drop_2, register 32) Only available if the AutoMax Network Commun

APPENDIX B 49’1340 e FlexPak 3000 B-49 SPD LOOP SCAN TIME (P.019) Selects the speed loop scan time for closed loop operation The drive must be stopp

APPENDIX B FlexPak 3000 49’1340 e B-50Sets the threshold speed below which the main contactor will automatically open after a ramp stop or current l

APPENDIX B 49’1340 e FlexPak 3000 B-51 TOP SPEED is the highest normal running speed of the motor. This parameter scales the feedback device. TOP S

APPENDIX B FlexPak 3000 49’1340 e B-52OIM Menu Path(s): Drive Reference - Drive Reference Trim The choices are: • REGISTER: The reference is TR

APPENDIX C 49’1340 e FlexPak 3000 C-1 FlexPak 3000 User Output Parameter Records This appendix provides an alphabetized list of output parameters wi

APPENDIX C FlexPak 3000 49’1340 e C-2ANLG IN 1 (P.492) Only available if the I/O Expansion kit is installed. The value representing analog input 1 (

APPENDIX C 49’1340 e FlexPak 3000 C-3 The amplitude and rate limited value of the selected CML reference. OIM Menu Path(s): Current Minor Loop (CML

INTRODUCTION TO THE DRIVE FlexPak 3000 49’1340 e 2-8Rockwell Automation offers modification kits that broaden the application range of the drive. A

APPENDIX C FlexPak 3000 49’1340 e C-4DIG IN 2 (P.496) Only available if the I/O Expansion kit is installed. Shows the state of digital input 2 (term

APPENDIX C 49’1340 e FlexPak 3000 C-5 FIELD DELTA (P.588) The angle of the output of the field current regulator to the regulated field supply gate

APPENDIX C FlexPak 3000 49’1340 e C-6I/O EXPANSION KIT (P.797) Indicates whether or not the I/O Expansion kit is installed in the drive and if it ha

APPENDIX C 49’1340 e FlexPak 3000 C-7 J20 FIELD LOSS DETECT (P.597) Indicates the position of hardware jumper FIELD LOSS DETECT, which enables or di

APPENDIX C FlexPak 3000 49’1340 e C-8MOP OUTPUT (P.191) The output of the motor operated potentiometer (MOP). If the I/O Expansion Kit is not instal

APPENDIX C 49’1340 e FlexPak 3000 C-9 OCL ENABLE (P.849) The status of the outer control loop (OCL). OFF indicates the OCL is disabled or held in re

APPENDIX C FlexPak 3000 49’1340 e C-10PULSE TACH FEEDBACK (P.292) The digital value from the pulse tachometer after all hardware and software scalin

APPENDIX C 49’1340 e FlexPak 3000 C-11 SPEED RAMP INPUT TP (P.198) An output that represents the test point value immediately before the speed loop

FlexPak 3000 49’1340 e C-12

APPENDIX D 49’1340 e FlexPak 3000 D-I Speed Loop and CML Block Diagrams The following block diagrams for the speed loop and current minor loop (CML

INTRODUCTION TO THE DRIVE 49’1340 e FlexPak 3000 2-9 2.5 Controls/Indicators See Figure 2-2 for location of the controls and indicators for the Keyp

APPENDIX D D-II FlexPak 3000 49’1340 e

APPENDIX D 49’1340 e FlexPak 3000 D-1 KEYPAD*TERMBLKNETWORKKeypad Stop SignalTerminal Block Stop SignalNetwork Stop SignalOIM Run SignalTerminal St

APPENDIX D FlexPak 3000 49’1340 e D-2Speed ReferenceTrim ReferenceJOG SPEEDTo Speed LoopBlock Diagram(Fig.D.6)Torque Reference (current regulator)To

APPENDIX D 49’1340 e FlexPak 3000 D-3 From I/O ExpansionInput Block DiagramKeypad Reference(OIM/DCM)MOP Incrementterminal 63MOP Decrementterminal 62

APPENDIX D FlexPak 3000 49’1340 e D-4Forward/ReverseCommandINV* NO TRIMAUTO MODE MIN BYPASS (see Note 1)(DRAW PERCENTAGE OUT)0 ACCEL TIME1 + DRA

APPENDIX D 49’1340 e FlexPak 3000 D-5 -DIG IN 0INVForward/Reverse Command0JOG SPEED 2OFFONDebouncedJog RequestCURRENT COMPOUNDING(CML FEEDBACK)8 sam

APPENDIX D FlexPak 3000 49’1340 e D-6From Speed ReferenceMode Select Block Diagram(SPD LOOP REFERENCE)SPD LOOP PI PROP GAIN(SPD LOOP ERROR)(SPD LOOP

APPENDIX D 49’1340 e FlexPak 3000 D-7 Digital Outputs 1 and 2From Level Detector Block DiagramFrom internal drive signalsFrom NetworkLEVEL DETECT 1

APPENDIX D FlexPak 3000 49’1340 e D-8Meter Outputs (n = 1, 2)From Current Minor Loop Block DiagramFrom Speed Loop Block DiagramFrom Speed Reference

APPENDIX D 49’1340 e FlexPak 3000 D-9 From Speed Ref SourceSelect Block DiagramFrom Speed LoopBlock Diagram(TORQUE REFERENCE)(SPD LOOP OUTPUT)MAXIMU

INTRODUCTION TO THE DRIVE FlexPak 3000 49’1340 e 2-10Table 2-5 - OIM Drive Fault and Status Indicators Indicators Description Fault A condition or

APPENDIX D FlexPak 3000 49’1340 e D-10OUTMULGAINConverterDigitalAnalog to15 ohm20 ohm30 ohm+-LogicGainAdaptiveRATE LIM39 ohmRectifierMOTORLogicFirin

APPENDIX D 49’1340 e FlexPak 3000 D-11 FLD WEAKEN PROP GAIN(FIELD FEEDBACK)Note 1: FIELD AUTO WEAKEN is clamped to DISABLED when FEEDBACK SEL

APPENDIX D FlexPak 3000 49’1340 e D-12OCL REF REGISTER*REGISTERANALOG IN 1ANALOG IN 2FREQUENCY INNETW IN REG 1, 2, 3From NetworkFrom I/O ExpansionIn

APPENDIX D 49’1340 e FlexPak 3000 D-13 Digital Inputs (n = 1 through 5) n=1: terminal 59 (Preset Speed Select) n=2: terminal 60 (Preset Speed Select

APPENDIX D FlexPak 3000 49’1340 e D-14Level Detectors 1 and 2(CML FEEDBACK) 8 Sample AverageFrom Speed Loop Block DiagramFrom Speed ReferenceRamp Bl

APPENDIX E 49’1340 e FlexPak 3000 E-1 Program Error Messages and Fault and Alarm Codes This appendix lists all possible OIM error messages generate

APPENDIX E FlexPak 3000 49’1340 e E-2Table E.1 - Fault Codes CODE DISPLAY DESCRIPTION F00001 IET (OVERCURRENT) Armature current instantaneously exc

APPENDIX E 49’1340 e FlexPak 3000 E-3 Table E.1 - Fault Codes (Continued) CODE DISPLAY DESCRIPTION F00006 BLOWER MOTOR STARTER OPEN This fault is n

APPENDIX E FlexPak 3000 49’1340 e E-4Table E.1 - Fault Codes (Continued) CODE DISPLAY DESCRIPTION F00013 NETWORK COMMUNICATION TIMEOUT Network Comm

APPENDIX E 49’1340 e FlexPak 3000 E-5 Table E.1 - Fault Codes (Continued) CODE DISPLAY DESCRIPTION F00063 SELF TUNING FAULT Maximum current with m

INTRODUCTION TO THE DRIVE 49’1340 e FlexPak 3000 2-11 FlexPak 3000 Main Menu !! "Quick Start Drive Reference Speed/Voltage Loop (SPD) #Curr

APPENDIX E FlexPak 3000 49’1340 e E-6Table E.1 - Fault Codes (Continued) CODE DISPLAY DESCRIPTION F00700 FACTORY DEFAULTS RESTORED The parameter va

APPENDIX E 49’1340 e FlexPak 3000 E-7 Table E.2 - Alarm Codes CODE DISPLAY DESCRIPTION A00001 MOTOR BRUSH WEAR LOW The motor brush wear detector in

APPENDIX E FlexPak 3000 49’1340 e E-8Table E.2 - Alarm Codes (Continued) CODE DISPLAY DESCRIPTION A00032 SUSTAINED SPEED Motor speed did not fall

APPENDIX F 49'1340 e FlexPak 3000 F-1 OIM Parameter Menu Tree This appendix shows the FlexPak 3000 menu structures as they are displayed on the

APPENDIX F F-2 FlexPak 3000 49'1340 e FlexPak 3000 Main Menu Quick Start MOTOR BASE SPEED/TOP SPEED (P.011) MOTOR RATED ARM AMPS (P.008

APPENDIX F 49'1340 e FlexPak 3000 F-3 FlexPak 3000 Main Menu Drive Reference Configure JOG SPEED (P.012) ANLG AUTO SIGNAL TYPE (P.1

APPENDIX F F-4 FlexPak 3000 49'1340 e FlexPak 3000 Main Menu ~ Speed/Voltage Loop (SPD) Feedback FEEDBACK SELECT (P.200) MOTOR R

APPENDIX F 49'1340 e FlexPak 3000 F-5 FlexPak 3000 Main Menu ~ Three Phase AC Line NOMINAL AC LINE FREQ (P.306) NOMINAL AC

APPENDIX F F-6 FlexPak 3000 49'1340 e FlexPak 3000 Main Menu ~ Input/Output Meter Outputs METER OUT 1 SELECT (P.404) METER OUT

APPENDIX F 49'1340 e FlexPak 3000 F-7 FlexPak 3000 Main Menu ~ Network Communications NETWORK KIT (P.796) NETW TYPE & VERSION (P.9

.

INTRODUCTION TO THE DRIVE FlexPak 3000 49’1340 e 2-12 FAULT This key allows the operator to review and clear logs (fault and alarm), reset faults, c

APPENDIX F F-8 FlexPak 3000 49'1340 e FlexPak 3000 Main Menu ~ Drive Information Correct Scaling Jumper Positions J11 ANLG TACH VLT

APPENDIX G 49’1340 e FlexPak 3000 G-1 User Quick Reference Table Table G.1 - User Quick Reference Table for Input Parameters Par. Parameter Param

APPENDIX G FlexPak 3000 49’1340 e G-2 Table G.1 - User Quick Reference Table for Input Parameters (continued) Par. Parameter Parameter Selection /

APPENDIX G 49’1340 e FlexPak 3000 G-3 Table G.1 - User Quick Reference Table for Input Parameters (continued) Par. Parameter Parameter Selection /

APPENDIX G FlexPak 3000 49’1340 e G-4Table G.1 - User Quick Reference Table for Input Parameters (continued) Par. Parameter Parameter Selection /

APPENDIX G 49’1340 e FlexPak 3000 G-5 Table G.1 - User Quick Reference Table for Input Parameters (continued) Par. Parameter Parameter Selection /

APPENDIX G FlexPak 3000 49’1340 e G-6Table G.1 - User Quick Reference Table for Input Parameters (continued) Par. Parameter Parameter Selection /

APPENDIX G 49’1340 e FlexPak 3000 G-7 Table G.1 - User Quick Reference Table for Input Parameters (continued) Par. Parameter Parameter Selection /

APPENDIX G FlexPak 3000 49’1340 e G-8Table G.1 - User Quick Reference Table for Input Parameters (continued) Par. Parameter Parameter Selection /

H - CE-CONFORMITY 49'1340 e FlexPak 3000 H-1 EMC Directive This converter device is a component intended for implementation in machines or syste

INTRODUCTION TO THE DRIVE 49’1340 e FlexPak 3000 2-13 MENU HELP FlexPak 3000 Main Menu Select the appropriate menu item with the UP/DOWN arrow keys

H - CE-CONFORMITY H-2 FlexPak 3000 49'1340 e Essential Requirements for Conforming Installation The following items are required for CE conforma

H - CE-CONFORMITY 49'1340 e FlexPak 3000 H-3 Configuration 1U, 1V, 1WMPEPE216345G1C, 1D 3C, 3D-K1 Cabinet Panel AC-reactor Converter AC-I

H - CE-CONFORMITY H-4 FlexPak 3000 49'1340 e Wiring Instruction Motor Cable • The cables between cabinet / armature output and DC-motor armatur

APPENDIX J 49’1340 e FlexPak 3000 J-1 Cross Reference List Part Numbers - Catalogue Numbers This appendix provides a cross reference lists for part

APPENDIX J FlexPak 3000 49’1340 e J-2Table J.1 - Cross Reference List (continued) Part Number Catalogue Number US-Model-Number 810.89.00 - 813.39

.

www.rockwellautomation.com Corporate Headquarters Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, T

INTRODUCTION TO THE DRIVE FlexPak 3000 49’1340 e 2-14 Moves the cursor left or right in parameter modification (value entry) screens to allow digi

INTRODUCTION TO THE DRIVE 49’1340 e FlexPak 3000 2-15 .JOG --------- Active only when in KEYPAD control mode. This key causes the drive reference t

FlexPak 3000 49’1340 e 2-16 .

INSTALLATION AND WIRING 49’1340 e FlexPak 3000 3-1 3.0 Install and Wire the Drive DANGER The user is responsible for conforming to all other appl

INSTALLATION AND WIRING FlexPak 3000 49’1340 e 3-2 Power connections Terminals for 25 A Unit Motor 1D, 1C 6 mm2 1.4 Nm AC-Line 1U, 1V, 1W 6 mm

INSTALLATION AND WIRING 49’1340 e FlexPak 3000 3-3 Power Connections on 1-Quadrant Units S-6 Power Connections on 4-Quadrant Units S-6R Power Con

INSTALLATION AND WIRING FlexPak 3000 49’1340 e 3-4 Power connections for 250 A Unit Motor 1D, 1C Bus bars 25 x 5, Hole 11 mm AC-Line 1U, 1V, 1

INSTALLATION AND WIRING 49’1340 e FlexPak 3000 3-5 25 Ø 1) 1) Holes for lifting hooks Power connections Motor 1D, 1C Bus bars 50 x 10, Hole 13

TABLE OF CONTENTS 49’1340 e FlexPak 3000 I Table of Contents 1.0 General Notes 1.1 Safety Instructions...

INSTALLATION AND WIRING FlexPak 3000 49’1340 e 3-6M12160619721======49 505052200418317240515400905604556089.56089.5602626M12100 40100401901381851301

INSTALLATION AND WIRING 49’1340 e FlexPak 3000 3-7 25 Ø 1) 1) Holes for lifting hooks Power connections Motor 1D, 1C Bus bars 120 x 10, Drilling

INSTALLATION AND WIRING FlexPak 3000 49’1340 e 3-83.4 Install a Line Reactor or Transformer CAUTION Distribution system capacity above the maximu

INSTALLATION AND WIRING 49’1340 e FlexPak 3000 3-9 3.6 Install the Motor 1. Verify that the motor is the appropriate rating to use with the drive.

INSTALLATION AND WIRING FlexPak 3000 49’1340 e 3-103.8 Wire the Drive 3.8.1 Ground the Drive and Enclosure, the Motor and the Operator's Cont

INSTALLATION AND WIRING 49’1340 e FlexPak 3000 3-11 3.8.5 Emergency Stop-Function WARNING: To inhibit uncontrolled machine operation in case of t

INSTALLATION AND WIRING FlexPak 3000 49’1340 e 3-122123192022+/-1817165k151413121110987654321AUTO REFERENCEMANUAL REFERENCECUSTOMER INTERLOCKFAULT/A

INSTALLATION AND WIRING 49’1340 e FlexPak 3000 3-13 Table 3.6 - User Device Connections to the Regulator Board Terminal Strip User Device Regulato

INSTALLATION AND WIRING FlexPak 3000 49’1340 e 3-14K1K1K1L3L2L1PEX678119X1:4X1:3X1:6X1:5X3MCRM47GTID 813.40.00POWER INTERFACE~~-+M1MOV1483G382G481G4

INSTALLATION AND WIRING 49’1340 e FlexPak 3000 3-15 K1K1K1L3L2L1PEX678119X1:4X1:3X1:6X1:5X3MCRMTIC 813.39.00POWER INTERFACE~~-+M1MOV1483G382G481G473

TABLE OF CONTENTS FlexPak 3000 49’1340 e II4.0 Drive Setup and Adjustment 4-1...4-16 4.1 General ...

INSTALLATION AND WIRING FlexPak 3000 49’1340 e 3-16~~-+5825833735J3J6Field Curr.Regulator762.70.70810.79.401 24 32301150MOV 2-

INSTALLATION AND WIRING 49’1340 e FlexPak 3000 3-17 810.79.40~~-+5825833735J3J6Field Curr.Regulator762.70.701 24 32301150MOV 2

INSTALLATION AND WIRING FlexPak 3000 49’1340 e 3-18 .Recommended Lugs for Grounding FlexPak 3000 Drives in UL / cUL Version The following describes

DRIVE SETUP AND ADJUSTMENT 49’1340 e FlexPak 3000 4-1 4.0 Drive Setup and Adjustment DANGER Only qualified electrical personnel familiar with the

DRIVE SETUP AND ADJUSTMENT FlexPak 3000 49’1340 e 4-24.5 Jumper Settings The jumper settings for the FlexPak 3000 drive determine the regulator type

DRIVE SETUP AND ADJUSTMENT 49’1340 e FlexPak 3000 4-3 4.5.1 Set the Regulator Type - J15 Jumper J15 determines whether the drive uses Speed/Voltage

DRIVE SETUP AND ADJUSTMENT FlexPak 3000 49’1340 e 4-44.5.2 Set Program Disable/Enable (OIM PROGRAM) - J16 Jumper The OIM program jumper (J16) deter

DRIVE SETUP AND ADJUSTMENT 49’1340 e FlexPak 3000 4-5 4.5.5 Field Supply Jumper Connection (FIELD SUPPLY) - J21 Jumper NOTE: This jumper has no aff

DRIVE SETUP AND ADJUSTMENT FlexPak 3000 49’1340 e 4-64.5.8 Analog Auto Reference (AUTO REF) - J12 and J10 Jumpers The AUTOREF Jumpers J12 and J10 s

DRIVE SETUP AND ADJUSTMENT 49’1340 e FlexPak 3000 4-7 4.6 Powering Up the Drive Apply A-C power to the drive after the Power Off Inspection, Motor

TABLE OF CONTENTS 49’1340 e FlexPak 3000 III7.0 Troubleshooting/Diagnostics 7-1..7-8 7.1 General ...

DRIVE SETUP AND ADJUSTMENT FlexPak 3000 49’1340 e 4-84.8 Accessing the Main Menu The Main Menu is accessed by pressing the PROGRAM/MONITOR key unti

DRIVE SETUP AND ADJUSTMENT 49’1340 e FlexPak 3000 4-9 Current Minor Loop(CML)  CML Test Points   CML Tuning*   Self Tuning Setup*   Se

DRIVE SETUP AND ADJUSTMENT FlexPak 3000 49’1340 e 4-104.10 Verify the Correct Direction of Motor Rotation WARNING If tachometer and/or rotation is

DRIVE SETUP AND ADJUSTMENT 49’1340 e FlexPak 3000 4-11 4.12.1 Perform Armature Voltage Zero Adjust WARNING The incorrect setting of this paramete

DRIVE SETUP AND ADJUSTMENT FlexPak 3000 49’1340 e 4-122. Press CANCEL if the current selected language is the one of your choice. The display now r

DRIVE SETUP AND ADJUSTMENT 49’1340 e FlexPak 3000 4-13 4.14.2 How to Enable/Disable Program Protection To enable or disable program protection, PAS

DRIVE SETUP AND ADJUSTMENT FlexPak 3000 49’1340 e 4-144.14.4 Reset Clock This feature of the Operator Interface menu resets the elapsed time clock.

DRIVE SETUP AND ADJUSTMENT 49’1340 e FlexPak 3000 4-15 This choice allows the user to define a 1 to 6 character string for the units of a parameter

DRIVE SETUP AND ADJUSTMENT FlexPak 3000 49’1340 e 4-164.14.5.2 Define Load Units Define User Units " Define Speed Units Define Load Units !

CHANGING PARAMETER VALUES 49’1340 e FlexPak 3000 5-1 5.0 How to Change Parameter Values 5.1 Introduction DANGER Only qualified electrical personn

TABLE OF CONTENTS FlexPak 3000 49’1340 e IVList of Figures Figure 2.1 - FlexPak 3000 Functional Block Diagram ...

CHANGING PARAMETER VALUES FlexPak 3000 49’1340 e 5-2The programmer cannot enter a number out of a parameter's valid range. 1) Use ⇐ and ⇒ key

CHANGING PARAMETER VALUES 49’1340 e FlexPak 3000 5-3 3) If the selected choice (choice at cursor) is OTHER: a) Press ENTER. b) Use ⇐ and ⇒ keys

CHANGING PARAMETER VALUES FlexPak 3000 49’1340 e 5-45.4 Selector Switch or Boolean Value Entry Screen This screen allows the user to select one of

QUICK START 49’1340 e FlexPak 3000 6-1 6.0 Quick Start ATTENTION: Only qualified electrical personnel familiar with the construction and operation

QUICK START FlexPak 3000 49’1340 e 6-2Table 6.1 - Quick Start Jumper Settings Hardware Jumper No. Initial Setting Final Setting J11 (TACH V SCALE)

QUICK START 49’1340 e FlexPak 3000 6-3 ATTENTION: The incorrect setting of the Quick Start parameters can cause an overspeed condition. These par

QUICK START FlexPak 3000 49’1340 e 6-4Table 6.2 - Quick Start Parameter Modification Sequence. - continued Step No. Parameter Name Code No. Default

QUICK START 49’1340 e FlexPak 3000 6-5 Table 6.2 - Quick Start Parameter Modification Sequence. - continued Step No. Parameter Name Code No. Defaul

QUICK START FlexPak 3000 49’1340 e 6-6Table 6.2 - Quick Start Parameter Modification Sequence. – continued Step No. Parameter Name Code No. Default

QUICK START 49’1340 e FlexPak 3000 6-7 Step No. Parameter Name Code No. Default Description User Setting 18 MOTOR HOT FLD AMPS 510 0.01amps This pa

GENERAL NOTES 49’1340 e FlexPak 3000 1-1 NOTE: The term converter is used throughout this manual for the FlexPak 3000 Power Module. 1.1 Safety Instr

QUICK START FlexPak 3000 49’1340 e 6-86.4 Self-Tuning the Current Minor and Speed Loops NOTE: Self-tuning can only be performed if the OIM is conn

QUICK START 49’1340 e FlexPak 3000 6-9 6.4.2 Execute Self-tuning NOTE: CML self-tuning takes approximately 3-4 seconds to complete. Speed Loop self-

QUICK START FlexPak 3000 49’1340 e 6-10 The following screen shows how the display will look after self-tuning has completed successfully for both

TROUBLESHOOTING/DIAGNOSTICS 49’1340 e FlexPak 3000 7-1 7.0 Troubleshooting/Diagnostics 7.1 General DANGER Only qualified electrical personnel fami

TROUBLESHOOTING/DIAGNOSTICS FlexPak 3000 49’1340 e 7-27.5 Remote M Contactor If an M Contactor has been supplied by others, verify that it has been

TROUBLESHOOTING/DIAGNOSTICS 49’1340 e FlexPak 3000 7-3 Pressing ENTER will display details and possible causes of the specific fault log entry. F00

TROUBLESHOOTING/DIAGNOSTICS FlexPak 3000 49’1340 e 7-47.7.2.1 Review Log The Review Log selection displays the contents of the alarm log. Entries ar

TROUBLESHOOTING/DIAGNOSTICS 49’1340 e FlexPak 3000 7-5 7.7.3 Diagnostics Menu This menu provides information regarding drive status for diagnostics

TROUBLESHOOTING/DIAGNOSTICS FlexPak 3000 49’1340 e 7-67.7.5 Regulator Led Status Information Two LEDs are located on the Regulator board to indicat

TROUBLESHOOTING/DIAGNOSTICS 49’1340 e FlexPak 3000 7-7 7.7.6 Armature Phase Fire Test ATTENTION: Only qualified electrical personnel familiar with

GENERAL NOTES FlexPak 3000 49’1340 e 1-21.2 General Notes Copyright © Copyright Rockwell Automation AG, 2002 Each reproduction of this manual may

TROUBLESHOOTING/DIAGNOSTICS FlexPak 3000 49’1340 e 7-87.7.7 Power Supply Test Pin Identification The following table lists the power supply PC boar

REPLACEMENT PARTS and ACCESSORIES 49’1340 e FlexPak 3000 8-1 8.0 Replacement of components Use original spare parts only. Selection according to T

REPLACEMENT PARTS and ACCESSORIES FlexPak 3000 49’1340 e 8-2Replacement of a thyristor on power unit Type 1200 - 2000 A • Write protocol about the

REPLACEMENT PARTS and ACCESSORIES 49’1340 e FlexPak 3000 8-3 8.1 Recommended Spare Parts Table 8-1: Urgent recommended spare parts for 1-Quadrant

REPLACEMENT PARTS and ACCESSORIES FlexPak 3000 49’1340 e 8-4Table 8-3: Urgent recommended spare parts for 1-Quadrant units S-6 250 / 450 and 800 A

REPLACEMENT PARTS and ACCESSORIES 49’1340 e FlexPak 3000 8-5 Table 8-5: Urgently recommended spare parts for 1-Quadrant Units S-6 1200-2000 A S-

REPLACEMENT PARTS and ACCESSORIES FlexPak 3000 49’1340 e 8-68.2 Accessories Semiconductor protection fuses in the AC-line input of the converter an

REPLACEMENT PARTS and ACCESSORIES 49’1340 e FlexPak 3000 8-7 Fuse Holder Dimensions Part number 511.23.00 for fuses DIN 80/ Size 00 (553.2...) up

REPLACEMENT PARTS and ACCESSORIES FlexPak 3000 49’1340 e 8-8Fuse Holder Dimensions (continued) 80 (110) Part number 511.26.01 for fuses DIN 80/ 3K,

REPLACEMENT PARTS and ACCESSORIES 49’1340 e FlexPak 3000 8-9 Table 8-9: Iron Core Choke Selection The AC-line input chokes 252.40.xx produce 2% volt

INTRODUCTION TO THE DRIVE 49’1340 e FlexPak 3000 2-1 2.0 Introduction to the Drive This section provides specifications and a description of the F

REPLACEMENT PARTS and ACCESSORIES FlexPak 3000 49’1340 e 8-10 U1 V1 W1W2V2U2ABEDCFHGBEDFGH==AW 2 W 1 V 2 V 1 U 2 U 1 (1) (2) ∆ Protection ea

REPLACEMENT PARTS and ACCESSORIES 49’1340 e FlexPak 3000 8-11 EMC Filters for FlexPak 3000 General Description Power converters in general cause li

REPLACEMENT PARTS and ACCESSORIES FlexPak 3000 49’1340 e 8-12Radio Frequency Interference Filter a) FlexPak 3000 converters with AC line input curr

REPLACEMENT PARTS and ACCESSORIES 49’1340 e FlexPak 3000 8-13 Radio Interference Filters 25, 36 and 50 A, 440 V M6E L3 L2 L1LINELOAD E&ap

REPLACEMENT PARTS and ACCESSORIES FlexPak 3000 49’1340 e 8-14Radio Interference Filter 80 A, 440 V 6.5E L3 L2 L1LINE150M10LOAD E&apo

REPLACEMENT PARTS and ACCESSORIES 49’1340 e FlexPak 3000 8-15 Radio Interference Filter 100 A, 500 V 27521574130223022E L1 L2 L3LI

REPLACEMENT PARTS and ACCESSORIES FlexPak 3000 49’1340 e 8-16Radio Interference Filter 150 A, 460 V 19416025 55 5517M101L1 1L2 1L32

REPLACEMENT PARTS and ACCESSORIES 49’1340 e FlexPak 3000 8-17 Radio Interference Filter 180 A, 440 V and 280 A, 500 V LOAD E'

REPLACEMENT PARTS and ACCESSORIES FlexPak 3000 49’1340 e 8-18Radio Interference Filter 270 A, 440/500 V 13513511011055030 3065 653503355.1M12320160

REPLACEMENT PARTS and ACCESSORIES 49’1340 e FlexPak 3000 8-19 Radio Interference Filter 340 A, 440/500 V 873797420 1107971224.562360 Filter Part