Flex Pak 3000

Reliance Electric FlexPak 3000 Digital DC Variable Speed Drives Product SummaryA three-phase digital DC drive for regenerative and non-regenerative applications The Reliance Family Of Variable Speed AC and DC Drives Note: This material is not intended to provide operational instructions. Appropriate Rockwell International Corporation instruction manuals and precautions should be studied prior to installation, operation, or maintenance of equipment. ® The Reliance® FlexPak 3000 is part of the Reliance Electric family of variable speed AC and DC drives. The FlexPak 3000 digital DC drive features a unique, ergonomic user interface for easy installation, start-up, application, and maintenance. Its unique design uses the latest digital, micro-semiconductor and circuit technology for an exceptional combination of simplicity, flexibility, and reliability in a compact package. Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Standard Features and Benefits . . . . . . . . . . . . . . . . . . 4 Drive Modification Kits With Block Diagrams . . . . 5-8 Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Operator Interface Module (OIM) . . . . . . . . . . . . 10-11 Quick Start Summary . . . . . . . . . . . . . . . . . . . . . . 12-13 Communications and Control Capabilities . . . . . 14-15 Control Block Diagram . . . . . . . . . . . . . . . . . . . . . . . 16 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Application Solutions. . . . . . . . . . . . . . . . . . . . . . . . . 18 Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . 19 Chassis and Conversion Kit Dimensions . . . . . . . 20-21 Minimum Mounting Clearance Distances. . . . . . . . . 22 Controller Selection/Controller Ratings . . . . . . . . . . 23 2 • Standard drive software accommodates a wide range of application requirements • Expanded capabilities available through drive modification kits and options • Easily modified to a full range of international input-line voltages and frequencies Reliable. Reliable. French.S. and sub-micron ASIC technology for exceptional dependability • Sophisticated design uses fewer parts for extended performance and reduced maintenance requirements ISO Certified. the display language of FlexPak 3000 DC drives can be changed to English. • Readily accessible control. and the rugged reliability required by rubber and plastic extrusion equipment. for displaying diagnostics. Spanish. CERTIFIED Reliance FlexPak 3000 digital DC drives are manufactured in the U. and field wiring for streamlined installation • User-friendly. modification. and maintenance • Standard chassis design converts easily to NEMA 1 enclosure using NEMA 1 conversion kits or. accessible with a single keystroke. and “help” text Compact. precise control. in compliance with ISO 9001 certification procedures for consistent.FlexPak 3000: Simple. German. 3 . signal. Flexible. or Italian. Flexible. • Extensive use of molded parts enable feature-rich power density with a small footprint • Space-saving package facilitates field wiring. graphical displays and a remote keypad using plain text instructions provide fast and easy set-up • Five languages.A. mounting. Simple. Our program of continuous quality improvement ensures that every FlexPak 3000 drive meets world-class standards of excellence with the ultimate goal of customer satisfaction. predictable performance. status information. With a single keystroke. Compact. • Advanced high-density power semiconductor devices. surface mount. floor-mount NEMA 1 enclosures FlexPak 3000 DC drives provide high breakaway torque. for high HP controllers. Metering and diagnostics (including fault and alarm logs) User-Friendly Quick Start Menu For Easy Set-Up and Application Adjustable parameters include: • Maximum speed • Minimum speed • Linear acceleration • Linear deceleration • Current limit (positive and negative on regenerative modules) • I/R compensation (voltage regulated drives) • Jog speed • Jog acceleration/deceleration rate • Reverse disable on regenerative drives 12-Bit Resolution Analog Signals For Exceptional Accuracy • 10 VDC manual speed reference • User selectable +/. auto/manual. jog.Standard Features and Benefits Dependable AC Supply For Optimum Reliability • • • • 50/60 Hz AC line frequency input Phase insensitive AC line input Semiconductor fuse protection AC “N” contactor (DC “M” above 300 HP) Expanded Offering of Digital Signals For Optimum Flexibility • Coast. stop. full control 6-Pulse power conversion for smooth efficient operation and high performance • Burst firing of SCRs • Non-regenerative or regenerative (required for reversing) controller • Capable of 150% full-load current for one minute • DC inverting fault protection on regenerative controllers Feature-Rich “Standard” Package For Exceptional Functionality • Self-tuning of speed and current loops without disconnecting the fields • Field (current) loss protection • User selectable stop modes .Ramp • Local controls with interactive keypad and display for: .Coast .Drive operation . and stop inputs • Motor thermostat diagnostic input • Brush wear diagnostic input • Customer interlock diagnostic input • Drive running contact output • Drive alarm contact output • Drive fault contact output Versatile Power Capabilities For Diverse Application Requirements • Full-wave.Current limit . forward/reverse.Drive set-up . run.10 Volt or 4-20 mA auto speed reference • 0-10 VDC analog output proportional to speed • 0-10 VDC analog output proportional to armature current • Speed feedback from analog tachometer (250 VDC maximum input) 4 . This kit is recommended when applying regenerative drives to high inertia loads or when drive is frequently in low power regenerative mode. Allows conversion of the 460 VAC to 230 VAC at 1/2 the 460 VAC horsepower rating. Allows the drive to communicate over the open protocol DeviceNet network. field economy. D2-3298 D2-3300 OR D2-3330 904FK series 905FK0101 D2-3299 OR D2-3331 D2-3294 Enables mounting of OIM up to five meters from the drive. Converts standard chassis to NEMA 1 enclosure. 901FK series 907FK0301 D2-3292 or D2-3315 D2-3297 915FK0101 D2-3318 Provides a fused AC starter with adjustable overload and interlocking for control of the three-phase blower motor used to cool the DC motor. 907FK0101 D2-3302 5 . Allows digital pulse tachometer or digital encoder speed feedback. 2CS3000 D2-3348 Provides the hardware. including braking grids. 908/9/ 12/13FK series 903FK series 906FK series D2-3313 Enhanced Field Supply Kit Inverting Fault Circuit Breaker NEMA 1 Conversion Kit OIM Remote Mounting Kit Pulse Tachometer Feedback Kit Provides electronic field trim. Allows the drive to communicate on the Reliance AutoMax Distributed Control System (DCS).Drive Modification Kits With Block Diagrams Name 115 VAC Control Interface 460 VAC to 230 VAC Fuse Conversion Kit AC Line Disconnect Kit AC Tachometer Feedback Kit AutoMax Network Communication Board Blower Motor Starter Kit Description Converts customer-supplied 115 VAC signals to 24 VDC. to provide dynamic braking on stop. (see page 14) 902FK series D2-3295 DeviceNet Communication Board Drive Control Configuration Software Dynamic Braking Kit 915FK1100 HE-FP3 Windows™ based software that connects any personal computer using Microsoft Windows V 3. and the ability to supply 240 Volts field voltage from a 230 VAC line.1 or higher to a FlexPak 3000 drive. Model Number 917FK0100 I/M Number D2-3338 916FK series D2-3329 Mounts on the FlexPak 3000 and allows the three-phase line to be disconnected at the drive. Allows the drive to accept feedback signals from AC tachometers to a maximum RMS of 275 VAC. Mounts separate from the drive. Mounts on the FlexPak 3000 chassis to provide additional analog. Model Number 911FK series 914FK0101 I/M Number D2-3336 D2-3301 Digital Inputs (n = 1 through 5) n=1:terminal 59 (PresetSpeed Select) n=2:terminal 60 (PresetSpeed Select) n=3:terminal 62 (MOP Decrement) n=4:terminal 63 (MOP Increment) n=5:terminal 64 (OCL Enable) +24 VDC available at terminal 14 on regular board and at terminal 58 or 61 on I/O Expansion board (DIG IN n) To function specified by digital input n Analog Inputs Analog Input 1 (+) terminal 50 (-) terminal 51 A/D ANLG IN 1 SIG TYPE ANLG IN 1 ZERO ADJ ANLG IN 1 GAIN ADJ (ANLG IN 1) HI SOFTWARE SCALING LIMIT LO To any switch selection labeled ANALOG IN 1 *+/-10 V 0-10 V 0 ANLG IN 1 SIG TYPE 4-20 mA 10-50 mA ANLG IN 2 ZERO ADJ Analog Input 2 (+) terminal 52 (-) terminal 51 A/D ANLG IN 2 GAIN ADJ (ANLG IN 2) To any switch selection labeled ANALOG IN 2 SOFTWARE SCALING Frequency Input FREQ IN ZERO Frequency Input (A) terminal 39 (A) terminal 40 (COM) terminal 41 F/D FREQ IN FULL SCALE (FREQ IN) SOFTWARE SCALING HI LIMIT LO To any switch selection labeled FREQUENCY IN * = Default Selection I/O Expansion Board Interconnections 6 . frequency.Drive Modification Kits With Block Diagrams Name Field Current Regulator Kit I/O Expansion Board Description Provides field economy. as well as pre-weakening of the field using a fixed reference or field weakening for above base speed operation. and digital I/O capabilities. Drive Modification Kits With Block Diagrams OCL REF REGISTER *REGISTER ANALOG IN 1 OCL REFERENCE SELECT (OCL REFERENCE) output of OCL enable logic OCL REF ROUNDING JERK OCL PI LEAD FREQ (OCL RAMP OUTPUT) KP INITV From I/O Expansion Inputs Block Diagram ANALOG IN 2 FREQUENCY IN NETW IN REG 1. 3 OCL PI NEGATIVE LIMIT OCL TRIM RANGE HI (OCL OUTPUT) MUL S-CURVE RST\ ACC INITV DCC output of OCL enable logic PI RST\ WLD LO GAIN To Speed Reference Mode Select Block Diagram From Network OCL REF RAMP TIME OCL PI LEAD FREQ OCL LEADLAG SELECT OCL PI NEGATIVE LIMIT *NONE (CML FEEDBACK) 8 sample average From I/O Expansion Inputs Block Diagram CML FEEDBACK ANALOG IN 1 ANALOG IN 2 OCL FEEDBACK SELECT INITV *BYPASS LEAD/LAG L/L LAG/LEAD RATIO (OCL FEEDBACK) WLD RST\ OCL LEADLAG LOWFREQ OCL LEADLAG RATIO output of OCL enable logic Outer Control Loop Enable Logic Network OCL Enable Digital Input OCL Enable terminal 64 NETWORK TERMBLK *KEYPAD CONTROL SOURCE SELECT Running OFF Drive Status (OCL ENABLE) OCL enable output Must be ON for OCL to execute Not Running I/O Expansion Board Block Diagram 7 . 2. Drive Modification Kits With Block Diagrams MOTOR HOT FIELD AMPS HI FIELD REF REGISTER LIMIT LO OFF ON (FIELD ECONOMY ACTIVE) (FIELD REFERENCE) FIELD PI PROP GAIN KP FIELD PI LEAD FREQ WLD (FIELD DELTA) PI LO HI 0 FIELD PHASE FIRING LOGIC FIELD REGULATOR SUPPLY MOTOR HOT FIELD AMPS GAIN MUL DIV (FIELD FEEDBACK) FIELD FEEDBACK GAIN ADJ MUL FIELD 100 ECONOMY REF MOTOR HOT FIELD AMPS Field Current Feedback A/D SOFTWARE SCALING GAIN 0° FIELD DELTA HIGH LIM LO HI FIELD WEAKEN THRESHOLD KP PI WLD ENABLED FIELD DELTA DISABLED HIGH LIM FIELD AUTO WEAKEN MOTOR RATED ARM AMPS SOFTWARE SCALING IR COMPENSATION FIELD WEAKEN PROP GAIN (Note 1) FIELD WEAKEN LEAD FREQ (ARMATURE VOLTAGE) (CML FEEDBACK) 8 Sample Average ABS SOFTWARE SCALING IR COMPENSATION Field Current Regulator Block Diagram 8 . Features and Benefits AC Line Fuses AC Line Disconnect Fused Blower Motor Starter Compact Chassis Design Operator Interface Module (OIM) Enhanced Field Supply or Field Regulator Kit Compact Package with Surface-Mount Regulator Board Digital Encoder or AC Tachometer. and other Circuit Kits mount inside drive chassis Terminal Strip for User Control 9 . AutoMax® Network or DeviceNet™. In addition to logging the time and description of each fault. adjust. stop. More complex set-up and adjustment information is also easily accessible through logically organized. the OIM allows quick access to the fault and alarm logs. using the drive and motor nameplate information. An ergonomic keypad layout and extensive full-text information presented on a large liquid crystal display make the OIM easy to understand and use. a motor thermostat trip fault might suggest checking for an overloaded motor. OIM Integer Value Entry Screen 10 . and in your choice of five languages: English. etc. “Help” in the language of your choice. Similar functions are grouped together on the keypad: • Control keys (start. clogged filters. German. or Spanish. The OIM allows you to startup. start-up. possible causes are identified. and cancel) grouped together on the left To promote ready identification of specific functions.Operator Interface Module (OIM) Unique Reliance OIM technology makes the FlexPak 3000 digital DC drive exceptionally easy to set-up. full-text menus that significantly reduce operator training since there’s no need to memorize cryptic names or parameter numbers. etc. and forward/reverse) on the lower right • Set-up keys (help. the OIM uses symbols as well as text descriptions and keys that vary in size and shape. Italian. For example. run. all information is displayed in easy to understand units such as RPM. operate. French. amps. is always only a keystroke away. volts. The end result of this sophisticated diagnostic process is reduced downtime. incorrect blower rotation. monitor. jog. The Quick Start routine makes set-up fast and easy through self-prompting of the drive. To promote international use.. and trouble-shoot. enter. and operate the drive through one simple interface. The drive can be started in minutes. If a fault should occur. Drive ready Helpful Diagnostics For Reduced Downtime Diagnostic displays recommending corrective action include: • AC line voltage high/low alarm • Motor brush wear alarm • Loss of AC line synchronization fault • Failed SCR fault • Motor thermostat fault • Drive thermostat fault • Drive (inverse time) overload fault • Drive IET (instantaneous electronic trip) fault • Tachometer loss fault • Overspeed fault • Field current loss fault • Network communication fault 11 .Run .Drive fault .Drive alarm .Current/torque limit .Operator Interface Module (OIM) Extensive Operator Control For Quick and Easy Use • Control keys include: . easy-to-read LCD provides: .Built-in digital metering. can be monitored in a single display • On-screen menus with non-abbreviated text for adjustments and monitoring • Drive status display indicators include: .Drive running . selectable in units proportional to speed or current such as feet/minute (FPM) or percent load .Stop .Italian .Single keystroke selects display text language: .French .Auto/Manual .Spanish .code • Multiple parameter values.Forward/Reverse . such as speed and load.German .English .Control Source Select • Quick Start sequence for fast and easy drive set-up • Large.Interlocks (OK) . REVERSE DISABLE prevents the drive from operating in reverse. 5 This selects the type of feedback signal used for the speed/voltage loop. 11 This parameter selects the drive’s minimum operational speed. 4 When on. 6 This is the analog tachometer scaling from the tachometer nameplate in volts per 1000 RPM. 3 This is the rated armature voltage from the motor nameplate. 8 9 10 This is the time it takes to decelerate from TOP SPEED to zero.Quick Start Summary The Quick Start function from the Main Menu will be used to start-up and tune the drive. This is the time it takes to accelerate to TOP SPEED. Refer to the FlexPak Instruction Manual for critical set-up information. This parameter enables or disables a QUADRATURE tachometer. CONTROL SOURCE SELECT must be set to KEYPAD for complete OIM control during the Quick Start procedure. Quick Start Parameter Modification Sequence This modification sequence is not intended to provide set-up instructions. 12 . Step Number 1 2 Parameter Name TOP SPEED MOTOR RATED ARM AMPS MOTOR RATED ARM VOLTS REVERSE DISABLE FEEDBACK SELECT ANLG TACH VOLTS/1000 PULSE TACH PPR PULSE TACH ACCELERATION TIME DECELERATION TIME MINIMUM SPEED MAXIMUM SPEED Description This is the highest normal running speed of the motor. This parameter MUST match the rated armature current from the motor nameplate. 12 This parameter is the maximum speed of the drive that can be supported by the application or process. 7 This parameter sets the pulse tachometer pulses per revolution (PPR) from the pulse tachometer nameplate. This parameter sets the motor rated hot field amps from the motor nameplate. 20 Allows user to self-tune the speed and/or current loops. This selects the maximum percent of motor rated armature current for the forward bridge. 17 18 19 Displays correct regulator jumper positions. 14 15 This is the operating speed when the drive is jogging.Quick Start Summary Step Number 13 Parameter Name JOG ACCEL/DECEL TIME JOG SPEED POSITIVE CURRENT LIM NEGATIVE CURRENT LIM IR COMPENSATION MOTOR HOT FLD AMPS JUMPER INFORMATION DISPLAY SELF TUNE? NO YES Description This is the time it takes the jog reference to reach TOP SPEED from zero. 13 . 16 This parameter selects the maximum percent of motor rated armature current for the reverse bridge. This parameter selects the armature voltage loss compensation value used when the drive is configured as a voltage regulator. The DeviceNet Communication Board enables drive configuration. control. monitoring. Ethernet® Communications to Host Computer IBM® PC Compatible Programming AutoMax Master Controller Ethernet Communications to Host Computer DCS-Net Communications PC3000 FlexPak 3000 DC Drive GV3000 AC Drive Inputs/Outputs 14 . PLC Scanner RS 232 Interface DC Power Supply Device Configuration Program Manager Software DeviceNet Communication Link GV3000 AC Drive Inputs/Outputs Motor Starters FlexPak 3000 DC Drive AutoMax DCS-Net FlexPak 3000 drives are also available with an interface card that allows an AutoMax real-time distributed controller to control their operations. Typically. the drive can receive reference. the capabilities of the FlexPak 3000 are extended to include high speed communications over the network that has become the industry standard for open communication.Communications and Control Capabilities DeviceNet When used in conjunction with the DeviceNet Communication Board. complex operations such as interlocking and sequencing can be easily configured with software from a single location. a host logic controller is used as the central manufacturing or process control center. Since all devices communicate through this single network. with nodes or drops used for all devices on the network. All data is pre-defined on the DCS-Net through fixed memory mapping to minimize programming. and diagnostics to be accessed from a remote location for optimum versatility. and tuning information and send monitoring and diagnostic information such as speed feedback and drive status through a high-speed network link. When connected to this network. control. FlexPak 3000 DC drives are ideal for use in connected production or processing applications where high-speed communications are required for exacting motor torque and/or speed control. Each device is individually addressed and connected to the network by a single cable to reduce the amount of wiring required. The DeviceNet protocol is supported by a wide array of industrial equipment manufacturers. output current.1 or higher Speed Reg. etc.0 P.005 = 150 P. Hardware Requirements File Management Opened files can be downloaded to the drive. or VGA monitor • RS-232 serial COM port 15 .0 0.0 0.0 0. and all configurations can be saved as files. stop.primary Minimum Speed limit Maximum Speed limit Current limit TB digital inputs config TB speed ref select TB analog input offset Drive Status A pop-up drive status window can be viewed whenever a drive connect is performed for convenient monitoring that includes fault/alarm status. and print drive configurations • Control drive (start.0 0 0.) • Monitor drive status (faults.0 Hz 60. P. ready.009 = 0 Sec Sec RPM RPM % Accel time .007 = 0 P. forward. Forward • IBM 286/386/486 Pentium or IBM-compatible PC • Windows 3.0 Hz Mode Auto Manual Run Jog 0 Output 60. store.5” floppy disk drive • Monochrome or color EGA. download. Drive Configuration Configurations can be easily downloaded from a PC office environment to a drive on the factory floor.) • Monitor and change drive parameters in English rather than codes • Compare drive and PC configurations • Read and reset the drive fault/alarm log Configuration Editor Assign OK Cancel Help Drive Control Set reference Min Max Control source Close Local Terminal block Serial 5.001 = 20. etc. Warnings and/or Cautions in the Drive Instruction Manual. and makes it easy to monitor drive status with a wide selection of controls and an extensive display of drive output conditions. alarms. etc.0 P. so it’s easy to duplicate configurations for drives on repeat applications. Drive Status No Faults No Alarms Stopped Drive ready Manual mode * Do not change parameters marked with * before reading and understanding the Dangers. reverse.002 = 20.) • Drive metering (output speed.008 = 20. CGA.primary Decel time .5 Volts 0 Output Power 230 KW Stop/Reset 0 90.0 Set Help Drive metering Reference Network 24.003 = 150 P. It can: • Create.0 Hertz 0 Motor Current 230 Amps Direction Forward Reverse 0 Motor Volts 8.00 Hz 0 Output Speed 60.Communications and Control Capabilities CS3000 Control and Configuration Software CS3000 is a Windows based software program that can be used to configure and operate FlexPak 3000 drives from a personal computer (PC).0 * * * P. • Hard drive with at least Connected 8 Mbytes of available space • Minimum of 640 Kbytes of conventional RAM plus 256 Kbytes of extended RAM • 1 3.0 24. upload. minimizes troubleshooting time.004 = 1722 P.0 Drive Control PC drive control facilitates start-ups. Predictable Performance The FlexPak 3000 is a full-wave. a position regulator.. There is also a third control loop for applications requiring an Outer Control Loop (OCL). FlexPak 3000 Drive Control Block Diagram OIM SERIAL NETWORK I/O Expansion Board Regulator Board DRIVE CONTROL SIGNALS AND SEQUENCING FIELD CONTROL FIELD POWER SUPPLY MOTOR FIELD DIGITAL ANALOG & FREQUENCY INPUTS/OUTPUTS SPEED REFERENCE SELECTION & SCALING CURRENT MINOR LOOP (CML) S6/S6R POWER UNIT MOTOR ARMATURE SPEED LOOP Current Feedback Voltage Feedback ANALOG TACHOMETER OR DIGITAL ENCODER OUTER CONTROL LOOP (OCL) Speed Feedback 16 .FlexPak 3000 Drive Control Block Diagram Proven DC Technology For Reliable. e. 6-pulse power converter that includes a digital current minor loop and a digital major loop for armature voltage or speed regulation by tachometer.g. FlexPak 3000 Digital Drive Wiring Diagram T (181) (182) (183) 1FU(281) 2FU(282) 3FU(283) S6/S6R 45(–) 45 S2 FN 47(+ 11FU(S6R ONLY) A1 A1 A2 SPEED FEEDBACK TO TERMINAL BLOCK M S1 4FU (781) 5FU (281)6FU (783) 37 /F1(+) (282)7FU (283)8FU 35 /F2(–) FUSES ON 115VAC SIDE FOR UNITS ABOVE 150HP (188) FN P6–9 (189) 12FU REGULATOR POWER 150VDC P6–1 (+) P6–4 (–) P10–1 P10–3 SUPPLY BOARD J1 TO TERMINAL BLOCK RELAY RECTIFIER ( ) = TERMINAL NUMBER (1) (2) (3) (4) +24V RUN STOP JOG REV/FWD AUTO/MAN +24V (24) METER OUT 1 (25) METER OUT COM (26) METER OUT 2 (27) (28) RUNNING COAST/STOP START/STOP by user 1 REV AUTO (5) FWD (6) MAN (7) (8) 2 3 CUSTOMER INTERLOCK (9) (10) (11) (12) (13) (14) (15) (16) CUSTOMER INTERLOCK FAULT/ALARM RESET +24V BRUSH WEAR MOTOR THERMOSTAT +24V 24V COM +10V + – + – HI RANGE LO RANGE COMMON (29) (30) ALARM (31) (32) FAULT MANUAL REFERENCE (17) (18) (19) AUTO REFERENCE (20) (21) FROM ANALOG TACHOMETER (22) (23) 17 . Application Solutions Stand-Alone FlexPak 3000 Configuration Stand Alone M T Recommended Applications • • • • Plastic or food extruders Mixers or agitators Line shafts Lead section for multiple drive MG set replacement Benefits • High break-away torque • Wide speed range • Excellent speed regulation when used with digital tachometer FLEXPAK 3000 Master/Follower FlexPak 3000 Configuration Recommended Applications M T M T Benefits • Exceptional resolution accuracy with I/O frequency • Reduced hardware • Wide speed range • High starting torque FLEXPAK 3000 FLEXPAK 3000 • • • • • Web handling Conveyors Wire drawing Multi-section process Fiber Drawing LINE SPEED Dancer Position Regulator FlexPak 3000 Configuration Recommended Applications M Position Feedback Position Reference OCL Benefits • • • • Less external hardware Simple set-up Precise control Full PI regulation • Textile • Web processing/handling FLEXPAK 3000 LINE SPEED 18 . . . . . . . . . . . . . . . . . E59092 C-UL Listed IEC Classified. 200:1(2) Continuous (for force-ventilated motors) . . . . . . . . . . +/-10% AC Line Frequency . . . . . .5% 25% Speed. . .3% 100% Speed. . . . . . . . . . . . . . . . . EN 50081-1 EN 50082-2 EN 60204 EN 1050 EN 292 EN 1037 Speed Range Operating . . . . . . 98. . . . . . . . . . . . . . .0 Maximum Load . . . . 0-55° C (32-131° F) AC Line Voltage Variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25% Load . . . . . . . . . .0% With Armature Voltage Feedback . . 96. . . . to 3300 feet (1000 meters) Above 3300 feet . . . .Technical Specifications Service Conditions Standard Altitude. . . . . . . . 87. . . . . . .8% 25% Speed. . . . . . 150% for one minute 19 . (1) Atmosphere (non-condensing relative humidity). 100% load. E123851 CE Approved(3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . temperature extremes. . . . . . 100% load . . . . . 88. 100% rated torque down to 5% base speed Speed Regulation With Digital Encoder. . . . . . . 25% load. 48/62 Hz AC Line Distribution System KVA Capacity (1 ) . . . . . . . . . . . . .01% With Analog Tachometer. . . . . . . . . .0% Applying FlexPak 3000 digital DC drives to power distribution systems with KVA capacity in excess of five times the smallest drive rating requires the use of an isolation transformer or line reactors of similar impedance. . . . . . . . . . . . . . . . 0-40° C (32-104° F) Chassis Units . . . . The drive should be located in an area that is free of dust. . . 1. . . . . . . . . . . . . . . . . . . . .0% Power Module Efficiency: 100% Speed. . . . . . . . . . . . . . . . . . . . 2. . . . . . . acidic or caustic vapors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) (3) Capacities Service Factor . . . vibration and shock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . 94. and electrical or electromagnetic noise interference Conformity to Standards UL Listed . . . . . . . . . . 5-95% Environment . . . . . . (1) Maximum Three Drives/Transformer (1 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000 ft Standard Ambient Temperature: Cabinet Units . . . . . . . . . . . 99. . . . . Dependent on top speed and digital encoder used: • 5PY = 30:1 • RD120 = 70:1 • RL1024 = 200:1 Contact Reliance for installation requirements. . . . . . . . . . . . . . .0% (1) Efficiency and Power Factor Displacement Power Factor At Maximum Speed . . . . . . . . dirt. . . . . . . . . . . 0. . . . . . . 1% to rated speed(2) Typical Quoted Regulation. . . . . . . . . . . Derate 3% for every 1000 ft above 3300 ft up to 10. . . . . . . . . . . . . . .0% Drive Efficiency With Motor (typically). . . . . . . . . . . . . . . . . . . . 60 HP @ 460 VAC in.FlexPak 3000 Chassis And Conversion Kit Dimensions 1.5-30 HP @ 230 VAC. 3-60 HP @ 460 VAC 30 HP @ 230 VAC./mm in./mm 40-75 HP @ 230 VAC./mm 20 . 75-150 HP @ 460 VAC 75 HP @ 230 VAC./mm in. 150 HP @ 460 VAC in. /mm 21 . 400-600 HP @ 460 VAC in./mm in./mm 200-300 HP @ 230 VAC. 200-300 HP @ 460 VAC 150 HP @ 230 VAC.FlexPak 3000 Chassis and Conversion Kit Dimensions 100-150 HP @ 230 VAC. 300 HP @ 460 VAC in. FlexPak 3000 Minimum Mounting Clearance Distances FlexPak 3000 Controller Ratings HP Ratings Full Load Rated RMS AC Line Current (Amperes) 230 VAC 460 VAC Full Load Rated RMS DC Armature Current (Amperes) 240 VAC 500 VAC Rated Field Current (Amperes) 150 VDC 300 VDC HP Ratings Full Load Rated RMS AC Line Current (Amperes) 230 VAC 460 VAC Full Load Rated RMS DC Armature Current (Amperes) 240 VAC 500 VAC Rated Field Current (Amperes) 150 VDC 300 VDC 1.5 2 3 5 7.5 10 15 20 25 30 10 11 13 19 26 33 48 63 80 94 – – 10 12 15 18 24 31 39 45 7 9 12 20 29 38 55 73 93 110 – – 6 10 14 19 27 35 45 52 10 10 10 10 10 10 10 15 15 15 – – 10 10 10 10 10 10 10 10 40 50 60 75 100 125 150 200 250 300 400 500 600 125 154 186 226 307 370 443 592 733 859 – – – 63 74 86 110 143 177 213 281 351 421 550 689 833 146 180 218 265 360 434 521 685 850 1000 – – – 73 86 100 129 167 207 250 330 412 495 640 800 960 15 15 15 20 20 20 20 20 20 20 – – – 15 15 15 15 15 15 20 20 20 20 20 20 20 22 . (2) 23 . the drives are designed for a maximum of three units per transformer. Maximum permissible available symmetrical RMS fault current. Source KVA Reference HP @ 460 VAC Input Model Number (Non-Regen) Model Number (Regen) 7A 29A 55A 110A 265A (1) 380/415 380/415 380/415 380/415 380/415 10 26 48 94 226 7 29 55 110 265 10 10 10 15 20 5000 5000 5000 10000 25000 4/5 16/18 33/36 62/68 145/157 3 15 30 60 150 7FN3031 29FN3031 55FN3031 110FN3031 265FN3031 7FR3031 29FR3031 55FR3031 110FR3031 265FR3031 When applying FlexPak 3000 drives to a power distribution system with KVA capacity in excess of five times the smallest drive rating the use of an isolation transformer or line reactors of similar impedance is required. Special AC Line Voltage Controllers (380/415 VAC) Unit Type Input Voltage VAC Full Load Rated RMS AC Line Current (Amperes) Full Load Rated DC Armature Current (Amperes) Rated Field Current (Amperes) Power Supply Capacity(2) Min. Also.FlexPak 3000 Controller FlexPak 3000 Controller Selection Non-Regenerative Horsepower 1.5 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 400 500 600 (1) Regenerative 460 VAC – – 3FN4032 5FN4032 7FN4032 10FN4032 15FN4032 20FN4032 25FN4032 30FN4032 40FN4032 50FN4032 60FN4032 230 VAC 1FR2032 2FR2032 3FR2032 5FR2032 7FR2032 10FR2032 15FR2032 20FR2032 25FR2032 30FR2032 40FR2032 60FR2032 (1) 230 VAC 1FN2032 2FN2032 3FN2032 5FN2032 7FN2032 10FN2032 15FN2032 20FN2032 25FN2032 30FN2032 40FN2032 60FN2032 (1) 460 VAC – – 3FR4032 5FR4032 7FR4032 10FR4032 15FR4032 20FR4032 25FR4032 30FR4032 40FR4032 50FR4032 60FR4032 75FR4032(1) 100FR4032(1) 125FR4032(1) 150FR4032(1) 200FB4031 250FB4031 300FB4031 400FR4031 500FR4031 600FR4031 50FN2032(1) (1) 50FR2032(1) (1) 75FN2032(1) 100FN2031 125FN2031 150FN2031 200FN2031 250FN2031 – – – (1) (1) 75FN4032(1) 100FN4032(1) 125FN4032 (1) 75FR2032(1) 100FR2031 125FR2031 150FR2031 200FR2031 250FR2031 – – – (1) (1) 150FN4032(1) 200FN4031 250FN4031 300FN4031 400FN4031 (1) 300FN2031(1) 300FR2031(1) 500FN4031(1) 600FN4031 (1) Contact Reliance for Availability. operation. And Support Rockwell Automation Global Technical Services provides comprehensive training for FlexPak 3000 and all Reliance products. Service. services. IBM® is a registered trademark of International Business Machines Corporation. D-509 19710M . Performance Driven To find out how Reliance can help you meet the productivity and performance demands of your application. and/or maintenance of equipment. career opportunities. CERTIFIED Reliance Electric / 24701 Euclid Avenue / Cleveland. DeviceNet™ is a trademark of Open Device Net Vendors Association. call 1-800-RELIANCE (1-800-735-4262). Inc. visit us on line at http://www.reliance.Worldwide Training. call or FAX today. OH 44117 Printed in the U. Appropriate Rockwell International Corporation instruction manuals and precautions attached to apparatus should be read carefully prior to installation.com IMPORTANT NOTICE This brochure is not intended to provide operating instructions.S. and contacts worldwide. ©1997 by Rockwell International Corporation Reliance® and AutoMax® are trademarks of Rockwell Automation.A. Windows™ is a trademark of Microsoft Corporation. For information on class availability and pricing. Toll Free 1-800-245-4501 FAX 1-216-266-7120 To obtain the latest information about Reliance products.