Rockwell-automation FlexPak 3000 Power Module Version 4.2 Manual de usuario

FlexPak 3000 Power ModuleSW-Version 4.2Instruction ManualULCRULREurope North AmericaManual Part No: 899.07.41 D2-3475Firmware Part No: 790.30.71Pub

INTRODUCTION TO THE DRIVEFlexPak 3000 49’1340 e2-22.2 Drive Specifications2.2.1 AC-Line ConsiderationsRequirement Measures1) Limiting the AC line symm

REPLACEMENT PARTS and ACCESSORIESFlexPak 3000 49’1340 e8-20Radio Interference Filter 250, 500, 1000 and 1600 A, 440 VL3 L2 L1

REPLACEMENT PARTS and ACCESSORIES49’1340 e FlexPak 3000 8-21Radio Interference Filter 600 ,1000 and 1600 A, 500/690 VL3 L2 L1

FlexPak 3000 49’1340 e8-22

APPENDIX A49’1340 e FlexPak 3000 A-1Glossary of TermsAltitude: The atmospheric altitude (height above sea level) at which the motor or drive will be o

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

APPENDIX B49’1340 e FlexPak 3000 B-1FlexPak 3000 User Input ParametersThis appendix provides an alphabetized list of input parameters with their assoc

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

APPENDIX B49’1340 e FlexPak 3000 B-3ANLG IN 1 GAIN ADJ (P.415)Only available if the I/O Expansion kit is installed.Gain adjustment for analog input 1

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

APPENDIX B49’1340 e FlexPak 3000 B-5ANLG OUT 1 GAIN ADJ (P.420)Only available if the I/O Expansion kit is installed. Adjusts analog output 1 (terminal

INTRODUCTION TO THE DRIVE49’1340 e FlexPak 3000 2-32.2.3 Input Voltage and Frequency Ratings:Nominal voltage for three-phase at terminals 1U, 1V, 1W a

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

APPENDIX B49’1340 e FlexPak 3000 B-7ANLG OUT 2 SELECT (P.421)Only available if the I/O Expansion Kit is installed.Selects the signal used to drive ana

APPENDIX BFlexPak 3000 49’1340 eB-8ARM VOLTAGE ZERO ADJ (P.205)Used to remove any hardware-introduced offset from the armature voltage signal.In most

APPENDIX B49’1340 e FlexPak 3000 B-9When the reference source is set to ANALOG, the analog auto input (terminals 19 and 20 on theregulator board) is u

APPENDIX BFlexPak 3000 49’1340 eB-10CML REF LIMIT SELECT (P.311)Selects the source for the CML positive and negative current limits.Parameter Range: 1

APPENDIX B49’1340 e FlexPak 3000 B-11CONTROL SOURCE SELECT (P.000)This parameter is only available on the Drive Configuration Module (DCM). It is a ke

APPENDIX BFlexPak 3000 49’1340 eB-12DECELERATION TIME (P.002)Selects the time it takes to decelerate from TOP SPEED to 0. Smaller changes in speed tak

APPENDIX B49’1340 e FlexPak 3000 B-13DIG OUT 1 CONTACT TYP (P.410)Only available if the I/O Expansion Kit is installed. Selects whether digital output

APPENDIX BFlexPak 3000 49’1340 eB-14DIG OUT 2 SELECT (P.411)Only available if the I/O Expansion Kit is installed. Selects the signal used to drive dig

APPENDIX B49’1340 e FlexPak 3000 B-15FIELD AUTO WEAKEN (P.517)Only available if the Field Current Regulator Kit is installed.Enables or disables field

INTRODUCTION TO THE DRIVEFlexPak 3000 49’1340 e2-42.2.7 Regulation (with 95% load change):Table 2-2 - Tachometer Speed RegulationRegulation Arrangemen

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

APPENDIX B49’1340 e FlexPak 3000 B-17FIELD LOSS THRESHOLD (P.512)Only available if the Field Current Regulator kit is installed.The value that is comp

APPENDIX BFlexPak 3000 49’1340 eB-18FIELD REF REGISTER (P.513)Only available if the Field Current Regulator kit is installed.Current reference for the

APPENDIX B49’1340 e FlexPak 3000 B-19FLD WEAKEN PROP GAIN (P.519)Only available if the Field Current Regulator kit is installed.The proportional gain

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

APPENDIX B49’1340 e FlexPak 3000 B-21FREQ OUT ZERO (P.426)Only available if the I/O Expansion kit is installed.The frequency generated when the signal

APPENDIX BFlexPak 3000 49’1340 eB-22INV FAULT AVOID SEL (P.312) settings and action taken when drive detects conditions that could lead toan inverting

APPENDIX B49’1340 e FlexPak 3000 B-23JOG ACCEL/DECEL TIME (P.013)Sets the time it takes the jog reference circuit to reach TOP SPEED from zero.The S-C

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

APPENDIX B49’1340 e FlexPak 3000 B-25LEVEL DETECT 2 SELECT (P.605)Selects the signal that drives level detector 2. See LEVEL DETECT 1 SELECT for discu

INTRODUCTION TO THE DRIVE49’1340 e FlexPak 3000 2-52.3 Drive Input/Output SpecificationsThe following sections describe drive inputs and outputs. Refe

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

APPENDIX B49’1340 e FlexPak 3000 B-27METER OUT 1 SELECT (P.404)Selects the drive testpoint that will source meter output 1 (terminals 24 and 25 on the

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

APPENDIX B49’1340 e FlexPak 3000 B-29MINIMUM SPEED (P.003)Selects the minimum speed of the drive without being stopped. It is typically greater than z

APPENDIX BFlexPak 3000 49’1340 eB-30MOP DECEL TIME (P.120)Only available if the I/O Expansion kit is installed. Minimum time in which the MOP OUTPUT c

APPENDIX B49’1340 e FlexPak 3000 B-31(FIELD FEEDBACK) ScalingSoftwareMOTOR HOT FLD AMPSA/DFIELD ECONOMY REF100MOTOR HOT FLD AMPSMOTOR HOT FLD AMPSFIEL

APPENDIX BFlexPak 3000 49’1340 eB-32NEG CURRENT LIM SEL (P.224)Selects the source for the negative current limit. If REGISTER is selected, NEGATIVE CU

APPENDIX B49’1340 e FlexPak 3000 B-33WARNING:When analog inputs or network registers are used to control current limits, bipolar values arepermitted f

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

APPENDIX B49’1340 e FlexPak 3000 B-35NETW CONNECT TYPE (P.910)AutoMax Network Connection type. When NETW CONNECT TYPE is set to BASIC, only the mostes

INTRODUCTION TO THE DRIVEFlexPak 3000 49’1340 e2-6Analog Tachometer FeedbackTach Voltage at Top Speed ...

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

APPENDIX B49’1340 e FlexPak 3000 B-37OCL FEEDBACK SELECT (P.804)Selects the source for the outer control loop (OCL) feedback signal. The I/O Expansion

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

APPENDIX B49’1340 e FlexPak 3000 B-39OCL PI POSITIVE LIMIT (P.810)Outer Control Loop PI block positive limit. The output of OCL PI block is never abov

APPENDIX BFlexPak 3000 49’1340 eB-40OCL REF REGISTER (P.801)The reference for the outer control loop that is used when OCL REFERENCE SELECT is set toR

APPENDIX B49’1340 e FlexPak 3000 B-41OCL TYPE3 POSN REG EN (P.814) (not available in SW-version 4.1)Selects the source of the Current Minor Loop refer

APPENDIX BFlexPak 3000 49’1340 eB-42PHASE FIRE TST BRIDGE (P.310)Armature phase fire test mode bridge select. This input can only be changed while the

APPENDIX B49’1340 e FlexPak 3000 B-43POSITIVE CURRENT LIM (P.005)Selects the highest amount of current (% motor rated armature amps) for the forward

APPENDIX BFlexPak 3000 49’1340 eB-44PULSE TACH QUADRATURE (P.208)Enables or disables pulse tachometer quadrature. Set ON for a bi-directional pulse ta

APPENDIX B49’1340 e FlexPak 3000 B-45S-CURVE ROUNDING (P.014)Rate of change (positive or negative) of acceleration and deceleration to smooth the SPEE

INTRODUCTION TO THE DRIVE49’1340 e FlexPak 3000 2-72.4 Drive DescriptionThe drive is a full-wave power converter without back rectifier, complete with

APPENDIX BFlexPak 3000 49’1340 eB-46SPEED FEEDBACK GAIN (Alternate network map, drop_1, register 38)Only available if the AutoMax Network Communicati

APPENDIX B49’1340 e FlexPak 3000 B-47SPD LEADLAG SELECT (P.216)Determines if the lead/lag block will act upon the speed loop feedback signal. If set t

APPENDIX BFlexPak 3000 49’1340 eB-48SPD LOOP PI INIT VAL (Alternate network map, Drop_1, register 39)Only available if the AutoMax Network Communicat

APPENDIX B49’1340 e FlexPak 3000 B-49Ramp StopCommand0OnOffDECACCSCURVESMOOTHINGDECELERATION TIMETRIM MODE SELECTPROPORTIONALINCREMENTAL* NO TRIM DE

APPENDIX BFlexPak 3000 49’1340 eB-50TACH LEAD FLT THRESH (P.227)The Threshold after which a REVERSED TACH LEADS fault (F00014) is generated.A REVERSED

APPENDIX B49’1340 e FlexPak 3000 B-51TRIM MODE SELECT (P.110)Parameter Range: NO TRIM, INCREMENTAL, PROPORTIONALDefault Setting: NO TRIMParameter Type

APPENDIX BFlexPak 3000 49’1340 eB-52UNDERWIND ENABLE (Alternate network map, Drop_1, register 32, Bit 5)Setting this bit to 1 enables two inverter blo

APPENDIX C49’1340 e FlexPak 3000 C-1FlexPak 3000 User Output Parameter RecordsThis appendix provides an alphabetized list of output parameters with th

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

APPENDIX C49’1340 e FlexPak 3000 C-3CML REFERENCE (P.396)The amplitude and rate limited value of the selected CML reference.OIM Menu Path(s): Current

INTRODUCTION TO THE DRIVEFlexPak 3000 49’1340 e2-8Rockwell Automation offers modification kits that broaden the application range of the drive.A summa

APPENDIX CFlexPak 3000 49’1340 eC-4DIG IN 2 (P.496)Only available if the I/O Expansion kit is installed.Shows the state of digital input 2 (terminal 6

APPENDIX C49’1340 e FlexPak 3000 C-5FIELD DELTA (P.588)The angle of the output of the field current regulator to the regulated field supply gate firin

APPENDIX CFlexPak 3000 49’1340 eC-6I/O EXPANSION KIT (P.797)Indicates whether or not the I/O Expansion kit is installed in the drive and if it has pas

APPENDIX C49’1340 e FlexPak 3000 C-7J20 FIELD LOSS DETECT (P.597)Indicates the position of hardware jumper FIELD LOSS DETECT, which enables or disable

APPENDIX CFlexPak 3000 49’1340 eC-8MOP OUTPUT (P.191)The output of the motor operated potentiometer (MOP). If the I/O Expansion Kit is not installed,t

APPENDIX C49’1340 e FlexPak 3000 C-9OCL ENABLE (P.849)The status of the outer control loop (OCL). OFF indicates the OCL is disabled or held in reset (

APPENDIX CFlexPak 3000 49’1340 eC-10PULSE TACH FEEDBACK (P.292)The digital value from the pulse tachometer after all hardware and software scaling.For

APPENDIX C49’1340 e FlexPak 3000 C-11SPEED RAMP INPUT TP (P.198)An output that represents the test point value immediately before the speed loop ramp

FlexPak 3000 49’1340 eC-12

APPENDIX D49’1340 e FlexPak 3000 D-ISpeed Loop and CML Block DiagramsThe following block diagrams for the speed loop and current minor loop (CML) are

INTRODUCTION TO THE DRIVE49’1340 e FlexPak 3000 2-92.5 Controls/IndicatorsSee Figure 2-2 for location of the controls and indicators for the Keypad OI

APPENDIX DD-II FlexPak 3000 49’1340 e

APPENDIX D49’1340 e FlexPak 3000 D-1KEYPAD*TERMBLKNETWORKKeypad Stop SignalTerminal Block Stop SignalNetwork Stop SignalOIM Run SignalTerminal Strip R

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

APPENDIX D49’1340 e FlexPak 3000 D-3From I/O ExpansionInput Block DiagramKeypad Reference(OIM/DCM)MOP Incrementterminal 63MOP Decrementterminal 62MAXI

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

APPENDIX D49’1340 e FlexPak 3000 D-5-DIG IN 0INVForward/Reverse Command0JOG SPEED 2OFFONDebouncedJog RequestCURRENT COMPOUNDING(CML FEEDBACK)8 sample

APPENDIX DFlexPak 3000 49’1340 eD-6From Speed ReferenceMode Select Block Diagram(SPD LOOP REFERENCE)SPD LOOP LAG FREQSPD LOOP PI PROP GAIN(SPD LOOP OU

APPENDIX D49’1340 e FlexPak 3000 D-7Digital Outputs 1 and 2From Level Detector Block DiagramFrom internal drive signalsFrom NetworkLEVEL DETECT 1 OUTP

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

APPENDIX D49’1340 e FlexPak 3000 D-9From Speed Ref SourceSelect Block DiagramFrom Speed LoopBlock Diagram(TORQUE REFERENCE)(SPD LOOP OUTPUT)MAXIMUM CU

INTRODUCTION TO THE DRIVEFlexPak 3000 49’1340 e2-10Table 2-5 - OIM Drive Fault and Status IndicatorsIndicators DescriptionFault A condition or conditi

APPENDIX DFlexPak 3000 49’1340 eD-10OUTMULGAINConverterDigitalAnalog to15 ohm20 ohm30 ohm+-LogicGainAdaptiveRATE LIM39 ohmRectifierMOTORLogicFiringPha

APPENDIX D49’1340 e FlexPak 3000 D-11FLD WEAKEN PROP GAIN(FIELD FEEDBACK)Note 1: FIELD AUTO WEAKEN is clamped to DISABLED when FEEDBACK SELECT

APPENDIX DFlexPak 3000 49’1340 eD-12OCL REF REGISTER*REGISTERANALOG IN 1ANALOG IN 2FREQUENCY INNETW IN REG 1, 2, 3From NetworkFrom I/O ExpansionInputs

APPENDIX D49’1340 e FlexPak 3000 D-13Digital Inputs (n = 1 through 5) n=1: terminal 59 (Preset Speed Select) n=2: terminal 60 (Preset Speed Select) n=

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

APPENDIX E49’1340 e FlexPak 3000 E-1Program Error Messages and Fault and Alarm CodesThis appendix lists all possible OIM error messages generated by t

APPENDIX EFlexPak 3000 49’1340 eE-2Table E.1 - Fault CodesCODE DISPLAY DESCRIPTIONF00001 IET(OVERCURRENT)Armature current instantaneously exceeded 180

APPENDIX E49’1340 e FlexPak 3000 E-3Table E.1 - Fault Codes (Continued)CODE DISPLAY DESCRIPTIONF00006 BLOWER MOTORSTARTER OPENThis fault is not applic

APPENDIX EFlexPak 3000 49’1340 eE-4Table E.1 - Fault Codes (Continued)CODE DISPLAY DESCRIPTIONF00013 NETWORKCOMMUNICATIONTIMEOUTNetwork Communications

APPENDIX E49’1340 e FlexPak 3000 E-5Table E.1 - Fault Codes (Continued)CODE DISPLAY DESCRIPTIONF00063SELF TUNINGFAULTMaximum current with minimum rota

INTRODUCTION TO THE DRIVE49’1340 e FlexPak 3000 2-11FlexPak 3000 Main Menu!!➤Quick Start Drive Reference Speed/Voltage Loop (SPD)#Current Minor Loop (

APPENDIX EFlexPak 3000 49’1340 eE-6Table E.1 - Fault Codes (Continued)CODE DISPLAY DESCRIPTIONF00700FACTORYDEFAULTSRESTOREDThe parameter values stored

APPENDIX E49’1340 e FlexPak 3000 E-7Table E.2 - Alarm CodesCODE DISPLAY DESCRIPTIONA00001 MOTOR BRUSHWEAR LOWThe motor brush wear detector indicates t

APPENDIX EFlexPak 3000 49’1340 eE-8Table E.2 - Alarm Codes (Continued)CODE DISPLAY DESCRIPTIONA00032 SUSTAINEDSPEEDMotor speed did not fall below the

APPENDIX F49'1340 e FlexPak 3000 F-1OIM Parameter Menu TreeThis appendix shows the FlexPak 3000 menu structures as they are displayed on the OIM.

APPENDIX FF-2 FlexPak 3000 49'1340 eFlexPak 3000 Main MenuQuick StartMOTOR BASE SPEED/TOP SPEED (P.011)MOTOR RATED ARM AMPS (P.008)MOTOR RATED AR

APPENDIX F49'1340 e FlexPak 3000 F-3FlexPak 3000 Main MenuDrive Reference ConfigureJOG SPEED (P.012)ANLG AUTO SIGNAL TYPE (P.100)STOP MODE SELECT

APPENDIX FF-4 FlexPak 3000 49'1340 eFlexPak 3000 Main Menu~Speed/Voltage Loop (SPD) FeedbackFEEDBACK SELECT (P.200)MOTOR RATED ARM VOLTS (P.009)

APPENDIX F49'1340 e FlexPak 3000 F-5FlexPak 3000 Main Menu ~Three Phase AC LineNOMINAL AC LINE FREQ (P.306)NOMINAL AC LINE VOLTS (P.307)AC LINE

APPENDIX FF-6 FlexPak 3000 49'1340 eFlexPak 3000 Main Menu ~Input/OutputMeter OutputsMETER OUT 1 SELECT (P.404)METER OUT 1 ZERO ADJ (P.402)METER

APPENDIX F49'1340 e FlexPak 3000 F-7FlexPak 3000 Main Menu ~Network CommunicationsNETWORK KIT (P.796)NETW TYPE & VERSION (P.909)NETW COMM ST

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INTRODUCTION TO THE DRIVEFlexPak 3000 49’1340 e2-12FAULTThis key allows the operator to review and clear logs (fault and alarm), reset faults,clear th

APPENDIX FF-8 FlexPak 3000 49'1340 eFlexPak 3000 Main Menu ~Drive InformationCorrect Scaling Jumper PositionsJ11 ANLG TACH VLT SCL (P.792)J14 AN

APPENDIX G49’1340 e FlexPak 3000 G-1User Quick Reference TableTable G.1 - User Quick Reference Table for Input ParametersPar.Parameter Parameter Selec

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

APPENDIX G49’1340 e FlexPak 3000 G-3Table G.1 - User Quick Reference Table for Input Parameters (continued)Par.Parameter Parameter Selection / Pg Init

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

APPENDIX G49’1340 e FlexPak 3000 G-5Table G.1 - User Quick Reference Table for Input Parameters (continued)Par.Parameter Parameter Selection / Pg Init

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

APPENDIX G49’1340 e FlexPak 3000 G-7Table G.1 - User Quick Reference Table for Input Parameters (continued)Par.Parameter Parameter Selection / Pg Init

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

H - CE-CONFORMITY49'1340 e FlexPak 3000 H-1EMC DirectiveThis converter device is a component intended for implementation in machines or systems f

INTRODUCTION TO THE DRIVE49’1340 e FlexPak 3000 2-13MENU HELPFlexPak 3000 Main MenuSelect the appropriate menu item with theUP/DOWN arrow keys and the

H - CE-CONFORMITYH-2 FlexPak 3000 49'1340 eEssential Requirements for Conforming InstallationThe following items are required for CE conformance:

H - CE-CONFORMITY49'1340 e FlexPak 3000 H-3Configuration1U, 1V, 1WMPEPE216345G1C, 1D 3C, 3D-K1CabinetPanelAC-reactorConverterAC-Input contacto

H - CE-CONFORMITYH-4 FlexPak 3000 49'1340 eWiring InstructionMotor Cable• The cables between cabinet / armature output and DC-motor armature sha

APPENDIX J49’1340 e FlexPak 3000 J-1Cross Reference ListPart Numbers - Catalogue NumbersThis appendix provides a cross reference lists for part number

APPENDIX JFlexPak 3000 49’1340 eJ-2Table J.1 - Cross Reference List (continued)PartNumberCatalogueNumberUS-Model-Number810.89.00 -813.39.00 -813.40.00

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U.S. Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives

INTRODUCTION TO THE DRIVEFlexPak 3000 49’1340 e2-14Moves the cursor left or right in parameter modification (value entry) screensto allow digit select

INTRODUCTION TO THE DRIVE49’1340 e FlexPak 3000 2-15.JOG---------Active only when in KEYPAD control mode. This key causes the drive referenceto ramp u

FlexPak 3000 49’1340 e2-16.

INSTALLATION AND WIRING49’1340 e FlexPak 3000 3-13.0 Install and Wire the DriveDANGERThe user is responsible for conforming to all other applicable st

INSTALLATION AND WIRINGFlexPak 3000 49’1340 e3-2Power connectionsTerminals for 25 A UnitMotor1D, 1C6 mm21.4 NmAC-Line1U, 1V, 1W6 mm21.4 NmProt. earthP

INSTALLATION AND WIRING49’1340 e FlexPak 3000 3-3Power Connections on1-Quadrant Units S-6Power Connections on4-Quadrant Units S-6RPower ConnectionsMot

INSTALLATION AND WIRINGFlexPak 3000 49’1340 e3-4Power connectionsfor 250 A UnitMotor1D, 1CBus bars 25 x 5,Hole 11 mmAC-Line1U, 1V, 1WBus bars 20 x 5,H

INSTALLATION AND WIRING49’1340 e FlexPak 3000 3-525 Ø 1)1) Holes for lifting hooksPower connectionsMotor1D, 1CBus bars 50 x 10,Hole 13.5 mmAC-Line1U

TABLE OF CONTENTS49’1340 e FlexPak 3000ITable of Contents1.0 General Notes1.1 Safety Instructions...

INSTALLATION AND WIRINGFlexPak 3000 49’1340 e3-6M12160619721======49 505052200418317240515400905604556089.56089.5602626M12100 4010040190138185130154DC

INSTALLATION AND WIRING49’1340 e FlexPak 3000 3-725 Ø 1)1) Holes for lifting hooksPower connectionsMotor1D, 1CBus bars 120 x 10,Drilling 4 x M12Torq

INSTALLATION AND WIRINGFlexPak 3000 49’1340 e3-83.4 Install a Line Reactor or TransformerCAUTIONDistribution system capacity above the maximum permitt

INSTALLATION AND WIRING49’1340 e FlexPak 3000 3-93.6 Install the Motor1. Verify that the motor is the appropriate rating to use with the drive.2. In

INSTALLATION AND WIRINGFlexPak 3000 49’1340 e3-103.8 Wire the Drive3.8.1 Ground the Drive and Enclosure, the Motor and the Operator's Control St

INSTALLATION AND WIRING49’1340 e FlexPak 3000 3-113.8.5 Emergency Stop-FunctionWARNING:To inhibit uncontrolled machine operation in case of the malfun

INSTALLATION AND WIRINGFlexPak 3000 49’1340 e3-122123192022+/-1817165k151413121110987654321AUTO REFERENCEMANUAL REFERENCECUSTOMER INTERLOCKFAULT/ALARM

INSTALLATION AND WIRING49’1340 e FlexPak 3000 3-13Table 3.6 - User Device Connections to the Regulator Board Terminal StripUser Device Regulator Board

INSTALLATION AND WIRINGFlexPak 3000 49’1340 e3-14K1K1K1L3L2L1PEX678119X1:4X1:3X1:6X1:5X3MCRM47GTID 813.40.00POWER INTERFACE~~-+M1MOV1483G382G481G47 45

INSTALLATION AND WIRING49’1340 e FlexPak 3000 3-15K1K1K1L3L2L1PEX678119X1:4X1:3X1:6X1:5X3MCRMTIC 813.39.00POWER INTERFACE~~-+M1MOV1483G382G481G473V3W1

TABLE OF CONTENTSFlexPak 3000 49’1340 eII4.0 Drive Setup and Adjustment4-1...4-164.1 General...

INSTALLATION AND WIRINGFlexPak 3000 49’1340 e3-16~~-+5825833735J3J6Field Curr.Regulator762.70.70810.79.401 24 32301150MOV 2-4460

INSTALLATION AND WIRING49’1340 e FlexPak 3000 3-17810.79.40~~-+5825833735J3J6Field Curr.Regulator762.70.701 24 32301150MOV 2-446

INSTALLATION AND WIRINGFlexPak 3000 49’1340 e3-18.Recommended Lugs for Grounding FlexPak 3000 Drives in UL / cUL VersionThe following describes how to

DRIVE SETUP AND ADJUSTMENT49’1340 e FlexPak 3000 4-14.0 Drive Setup and AdjustmentDANGEROnly qualified electrical personnel familiar with the construc

DRIVE SETUP AND ADJUSTMENTFlexPak 3000 49’1340 e4-24.5 Jumper SettingsThe jumper settings for the FlexPak 3000 drive determine the regulator type, pro

DRIVE SETUP AND ADJUSTMENT49’1340 e FlexPak 3000 4-34.5.1 Set the Regulator Type - J15 JumperJ15 determines whether the drive uses Speed/Voltage (SPEE

DRIVE SETUP AND ADJUSTMENTFlexPak 3000 49’1340 e4-44.5.2 Set Program Disable/Enable (OIM PROGRAM) - J16 JumperThe OIM program jumper (J16) determines

DRIVE SETUP AND ADJUSTMENT49’1340 e FlexPak 3000 4-54.5.5 Field Supply Jumper Connection (FIELD SUPPLY) - J21 JumperNOTE: This jumper has no affect on

DRIVE SETUP AND ADJUSTMENTFlexPak 3000 49’1340 e4-64.5.8 Analog Auto Reference (AUTO REF) - J12 and J10 JumpersThe AUTOREF Jumpers J12 and J10 select

DRIVE SETUP AND ADJUSTMENT49’1340 e FlexPak 3000 4-74.6 Powering Up the DriveApply A-C power to the drive after the Power Off Inspection, Motor Ground

TABLE OF CONTENTS49’1340 e FlexPak 3000III7.0 Troubleshooting/Diagnostics7-1..7-87.1 General ...

DRIVE SETUP AND ADJUSTMENTFlexPak 3000 49’1340 e4-84.8 Accessing the Main MenuThe Main Menu is accessed by pressing the PROGRAM/MONITOR key until &quo

DRIVE SETUP AND ADJUSTMENT49’1340 e FlexPak 3000 4-9Current Minor Loop(CML) CML Test Points  CML Tuning*  Self Tuning Setup*  Self Tuning  C

DRIVE SETUP AND ADJUSTMENTFlexPak 3000 49’1340 e4-104.10 Verify the Correct Direction of Motor RotationWARNINGIf tachometer and/or rotation is incorre

DRIVE SETUP AND ADJUSTMENT49’1340 e FlexPak 3000 4-114.12.1 Perform Armature Voltage Zero AdjustWARNINGThe incorrect setting of this parameter can cau

DRIVE SETUP AND ADJUSTMENTFlexPak 3000 49’1340 e4-122. Press CANCEL if the current selected language is the one of your choice. The display nowreturns

DRIVE SETUP AND ADJUSTMENT49’1340 e FlexPak 3000 4-134.14.2 How to Enable/Disable Program ProtectionTo enable or disable program protection, PASSWORD

DRIVE SETUP AND ADJUSTMENTFlexPak 3000 49’1340 e4-144.14.4 Reset ClockThis feature of the Operator Interface menu resets the elapsed time clock.FlexPa

DRIVE SETUP AND ADJUSTMENT49’1340 e FlexPak 3000 4-153. OTHER - Customize a User Unit Label:This choice allows the user to define a 1 to 6 character

DRIVE SETUP AND ADJUSTMENTFlexPak 3000 49’1340 e4-164.14.5.2 Define Load UnitsDefine User Units➤ Define Speed UnitsDefine Load Units$$$$FaultAlarmInte

CHANGING PARAMETER VALUES49’1340 e FlexPak 3000 5-15.0 How to Change Parameter Values5.1 IntroductionDANGEROnly qualified electrical personnel familia

TABLE OF CONTENTSFlexPak 3000 49’1340 eIVList of FiguresFigure 2.1 - FlexPak 3000 Functional Block Diagram ...

CHANGING PARAMETER VALUESFlexPak 3000 49’1340 e5-2The programmer cannot enter a number out of a parameter's valid range.1) Use ⇐ and ⇒ keys to s

CHANGING PARAMETER VALUES49’1340 e FlexPak 3000 5-32) Press ENTER to accept the current selection or press CANCEL to restore the originalvalue/selecti

CHANGING PARAMETER VALUESFlexPak 3000 49’1340 e5-45.4 Selector Switch or Boolean Value Entry ScreenThis screen allows the user to select one of two or

QUICK START49’1340 e FlexPak 3000 6-16.0 Quick StartATTENTION:Only qualified electrical personnel familiar with the construction and operation of this

QUICK STARTFlexPak 3000 49’1340 e6-2Table 6.1 - Quick Start Jumper SettingsHardware Jumper No. Initial Setting Final SettingJ11 (TACH V SCALE)J14 (TAC

QUICK START49’1340 e FlexPak 3000 6-3ATTENTION:The incorrect setting of the Quick Start parameters can cause an overspeed condition.These parameters m

QUICK STARTFlexPak 3000 49’1340 e6-4Table 6.2 - Quick Start Parameter Modification Sequence. - continuedStepNo.ParameterNameCodeNo.Default Description

QUICK START49’1340 e FlexPak 3000 6-5Table 6.2 - Quick Start Parameter Modification Sequence. - continuedStepNo.ParameterNameCodeNo.Default Descriptio

QUICK STARTFlexPak 3000 49’1340 e6-6Table 6.2 - Quick Start Parameter Modification Sequence. – continuedStepNo.ParameterNameCodeNo.Default Description

QUICK START49’1340 e FlexPak 3000 6-7StepNo.ParameterNameCodeNo.Default Description UserSetting18 MOTOR HOTFLD AMPS510 0.01ampsThis parameter only nee

GENERAL NOTES49’1340 e FlexPak 3000 1-1NOTE: The term converter is used throughout this manual for the FlexPak 3000 Power Module.1.1 Safety Instructio

QUICK STARTFlexPak 3000 49’1340 e6-86.4 Self-Tuning the Current Minor and Speed LoopsATTENTION: Before starting self-tuning, it must be verified that

QUICK START49’1340 e FlexPak 3000 6-96.4.2 Execute Self-tuningNOTE: CML self-tuning takes approximately 3-4 seconds to complete. Speed Loop self-tunin

QUICK STARTFlexPak 3000 49’1340 e6-10The following screen shows how the display will look after self-tuning has completedsuccessfully for both the CML

TROUBLESHOOTING/DIAGNOSTICS49’1340 e FlexPak 3000 7-17.0 Troubleshooting/Diagnostics7.1 GeneralDANGEROnly qualified electrical personnel familiar with

TROUBLESHOOTING/DIAGNOSTICSFlexPak 3000 49’1340 e7-27.5 Remote M ContactorIf an M Contactor has been supplied by others, verify that it has been prope

TROUBLESHOOTING/DIAGNOSTICS49’1340 e FlexPak 3000 7-3Pressing ENTER will display details and possible causes of the specific fault log entry.F00009: C

TROUBLESHOOTING/DIAGNOSTICSFlexPak 3000 49’1340 e7-47.7.2.1 Review LogThe Review Log selection displays the contents of the alarm log. Entries are lis

TROUBLESHOOTING/DIAGNOSTICS49’1340 e FlexPak 3000 7-57.7.3 Diagnostics MenuThis menu provides information regarding drive status for diagnostics menu

TROUBLESHOOTING/DIAGNOSTICSFlexPak 3000 49’1340 e7-67.7.5 Regulator Led Status InformationTwo LEDs are located on the Regulator board to indicate the

TROUBLESHOOTING/DIAGNOSTICS49’1340 e FlexPak 3000 7-77.7.6 Armature Phase Fire TestATTENTION: Only qualified electrical personnel familiar with the c

GENERAL NOTESFlexPak 3000 49’1340 e1-21.2 General NotesCopyright © Copyright Rockwell Automation AG, 2000Each reproduction of this manual may be prose

TROUBLESHOOTING/DIAGNOSTICSFlexPak 3000 49’1340 e7-87.7.7 Power Supply Test Pin IdentificationThe following table lists the power supply PC board test

REPLACEMENT PARTS and ACCESSORIES49’1340 e FlexPak 3000 8-18.0 Replacement of componentsUse original spare parts only.Selection according to Tables 8-

REPLACEMENT PARTS and ACCESSORIESFlexPak 3000 49’1340 e8-2Replacement of a thyristoron power unit Type 1200 - 2000 A• Write protocol about the followi

REPLACEMENT PARTS and ACCESSORIES49’1340 e FlexPak 3000 8-38.1 Recommended Spare PartsTable 8-1: Urgent recommended spare parts for 1-Quadrant units

REPLACEMENT PARTS and ACCESSORIESFlexPak 3000 49’1340 e8-4Table 8-3: Urgent recommended spare parts for 1-Quadrant units S-6 250 / 450 and 800 AThyri

REPLACEMENT PARTS and ACCESSORIES49’1340 e FlexPak 3000 8-5Table 8-5: Urgently recommended spare parts for 1-Quadrant Units S-6 1200-2000 AS-6 Thyri

REPLACEMENT PARTS and ACCESSORIESFlexPak 3000 49’1340 e8-68.2 AccessoriesSemiconductor protection fuses in the AC-line input of the converter and fiel

REPLACEMENT PARTS and ACCESSORIES49’1340 e FlexPak 3000 8-7Fuse Holder DimensionsPart number 511.23.00for fuses DIN 80/ Size 00 (553.2...) up to 125

REPLACEMENT PARTS and ACCESSORIESFlexPak 3000 49’1340 e8-8Fuse Holder Dimensions (continued)80 (110)Part number 511.26.01for fuses DIN 80/ 3K, 660 V,

REPLACEMENT PARTS and ACCESSORIES49’1340 e FlexPak 3000 8-9Table 8-9: Iron Core Choke SelectionThe AC-line input chokes 252.40.xx produce 2% voltage d

INTRODUCTION TO THE DRIVE49’1340 e FlexPak 3000 2-12.0 Introduction to the DriveThis section provides specifications and a description of the FlexPak

REPLACEMENT PARTS and ACCESSORIESFlexPak 3000 49’1340 e8-10U1 V1 W1W2V2U2ABEDCFHGBEDFGH==AW 2 W 1 V 2 V 1 U 2 U 1(1) (2)∆ Protection earth connec

REPLACEMENT PARTS and ACCESSORIES49’1340 e FlexPak 3000 8-11EMC Filters for FlexPak 3000General DescriptionPower converters in general cause line dist

REPLACEMENT PARTS and ACCESSORIESFlexPak 3000 49’1340 e8-12Radio Frequency Interference Filtera) FlexPak 3000 converters with AC line input currents b

REPLACEMENT PARTS and ACCESSORIES49’1340 e FlexPak 3000 8-13Radio Interference Filters 25, 36 and 50 A, 440 VM6E L3 L2 L1LINELOAD E'

REPLACEMENT PARTS and ACCESSORIESFlexPak 3000 49’1340 e8-14Radio Interference Filter 80 A, 440 V6.5E L3 L2 L1LINE150M10LOAD E'

REPLACEMENT PARTS and ACCESSORIES49’1340 e FlexPak 3000 8-15Radio Interference Filter 100 A, 500 V27521574130223022E L1 L2 L3LINELOADE

REPLACEMENT PARTS and ACCESSORIESFlexPak 3000 49’1340 e8-16Radio Interference Filter 150 A, 460 V19416025 55 5517M101L1 1L2 1L325171807

REPLACEMENT PARTS and ACCESSORIES49’1340 e FlexPak 3000 8-17Radio Interference Filter 180 A, 440 Vand 280 A, 500 V LOAD E' L3'

REPLACEMENT PARTS and ACCESSORIESFlexPak 3000 49’1340 e8-18Radio Interference Filter 270 A, 440/500 V13513511011055030 3065 653503355.1M12320160504080

REPLACEMENT PARTS and ACCESSORIES49’1340 e FlexPak 3000 8-19Radio Interference Filter 340 A, 440/500 V873797420 1107971224.562360Filter Part No.: 83