Reliance electric FlexPak 3000 User manual

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: 790.30.72
Publication: FP3OIM-UM043M-EN

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TABLE OF CONTENTS
49’1340 e FlexPak 3000
I
Table of Contents
1.0 General Notes
1.1 Safety Instructions....................................................................................................... 1-1
1.2 General Notes............................................................................................................. 1-2
1.3 Manual Scope..............................................................................................................1.2
1.4 Related Documentation................................................................................................1-2
2.0 Introduction to the Drive 2-1..2-15
2.1 Drive Identification ...................................................................................................... 2-1
2.1.1 Nameplate ....................................................................................................... 2-1
2.1.2 Drive Selection ................................................................................................ 2-1
2.2 Drive Specifications..................................................................................................... 2-2
2.2.1 AC-Line Considerations................................................................................... 2-2
2.2.2 Service Conditions........................................................................................... 2-2
2.2.3 Input Voltage and Frequency Ratings ............................................................. 2-3
2.2.4 Regulator Supply ............................................................................................ 2-3
2.2.5 Relay Output.................................................................................................... 2-3
2.2.6 DC Voltage Ratings......................................................................................... 2-3
2.2.7 Regulation (with 95% load change)................................................................. 2-4
2.2.8 Speed Range................................................................................................... 2-4
2.2.9 Drive Efficiency................................................................................................ 2-4
2.2.10 Displacement Power Factor, Power Loss, Output Current.............................. 2-4
2.3 Drive Input/Output Specifications................................................................................ 2-5
2.3.1 Logic Inputs..................................................................................................... 2-5
2.3.2 Logic Outputs .................................................................................................. 2-5
2.3.3 Analog Inputs................................................................................................... 2-5
2.3.4 Analog Outputs................................................................................................ 2-6
2.4 Drive Description......................................................................................................... 2-7
2.5 Controls/Indicators...................................................................................................... 2-9
2.5.1 Indicators......................................................................................................... 2-9
2.5.2 Controls......................................................................................................... 2-10
3.0 Install and Wire the Drive 3-1...3-18
3.1 General ....................................................................................................................... 3-1
3.2 Recommended AC Line and DC Armature Fuses ...................................................... 3-1
3.3 Install the Drive, Dimensions....................................................................................... 3-1
3.4 Install a Transformer (If needed)................................................................................. 3-8
3.5 Install an Input Disconnect - Guidelines...................................................................... 3-8
3.6 Install the Motor........................................................................................................... 3-9
3.7 General Wiring Practices ............................................................................................ 3-9
3.8 Wire the Drive ........................................................................................................... 3-10
3.8.1 Ground the Drive, the Motor and the Operator's Control Station................... 3-10
3.8.2 Wire AC Power to the Drive........................................................................... 3-10
3.8.3 Wire the DC Motor to the Drive...................................................................... 3-10
3.8.3.1 Motor Overload Protection ............................................................ 3-10
3.8.4 Main Contactor ............................................................................................. 3-10
3.8.5 Emergency Stop Function ............................................................................. 3-11
3.8.6 Stopping Modes............................................................................................. 3-11
3.8.6.1 COAST-STOP Digital Input........................................................... 3-11
3.8.6.2 STOP Digital Input......................................................................... 3-11
3.8.6.3 Interlock Digital Input..................................................................... 3-11
3.8.7 Wire User Devices to the Drive ..................................................................... 3-11

TABLE OF CONTENTS
FlexPak 3000 49’1340 e
II
4.0 Drive Setup and Adjustment 4-1...4-16
4.1 General....................................................................................................................... 4-1
4.2 Test Equipment Needed............................................................................................. 4-1
4.3 Power Off Inspection................................................................................................... 4-1
4.4 Motor Ground Check................................................................................................... 4-1
4.5 Jumper Settings.......................................................................................................... 4-2
4.5.1 Set Regulator Type - J15 Jumper ................................................................... 4-3
4.5.2 Set Program Disable/Enable (OIM PROGRAM) - J16 Jumper ....................... 4-4
4.5.3 Set Field Loss Enable/Disable (FIELD LOSS DETECT) - J20........................ 4-4
4.5.4 Set Tacho Loss / Open Arm. Enable/Disable (TACHO LOSS DET) - J26 ..... 4-4
4.5.5 Field Supply Jumper Connection (FIELD SUPPLY) - J21............................... 4-5
4.5.6 Manual Reference (MANUAL REF) - J19 Jumper .......................................... 4-5
4.5.7 Tachometer Voltage Range/Scale (TACH V RANGE/SCALE) - J14 / J11...... 4-5
4.5.8 Analog Auto Reference (AUTO REF) - J12 and J10 Jumpers........................ 4-6
4.5.9 Armature Current Feedback Scaling (ARM I FB RB) - J18 Jumper................ 4-6
4.5.10 Check position of the FILTER SELECT - J28 Jumper ................................... 4-6
4.5.11 Check position of the POWER INTERFACE- J30 Jumper.............................. 4-6
4.6 Powering Up the Drive................................................................................................ 4-7
4.7 OIM Screen Contrast Adjustment............................................................................... 4-7
4.8 About the Main Menu.................................................................................................. 4-8
4.9 How to Access the Menus/Parameters....................................................................... 4-8
4.10 Verify the Correct Direction of Motor Rotation .......................................................... 4-10
4.11 Determination of DC Tachometer Lead Polarity ....................................................... 4-10
4.12 Adjustments.............................................................................................................. 4-10
4.12.1 Perform Armature Voltage Zero Adjust....................................................... 4-11
4.12.2 Perform Analog Tachometer Zero Adjust.................................................... 4-11
4.13 Language Selection.................................................................................................. 4-11
4.14 Programming Features............................................................................................. 4-12
4.14.1 Password (PASSWORD).............................................................................. 4-12
4.14.2 How to Enable/Disable Program Protection.................................................. 4-13
4.14.3 Memory Operations....................................................................................... 4-13
4.14.4 Reset Clock................................................................................................... 4-14
4.14.5 Define User Units.......................................................................................... 4-14
4.14.5.1 Define Speed Units....................................................................... 4-14
4.14.5.2 Define Load Units.......................................................................... 4-16
5.0 How to Change Parameter Values 5-1..5-4
5.1 Introduction................................................................................................................. 5-1
5.2 Integer Value Entry Screen......................................................................................... 5-1
5.3 Standard Choice Integer Value Entry Screen............................................................. 5-2
5.4 Selector Switch or Boolean Value Entry Screen......................................................... 5-4
6.0 Quick Start 6-1..6-10
6.1 Introduction................................................................................................................. 6-1
6.2 About the Quick Start Exit Menu................................................................................. 6-1
6.3 How to Step through Quick Start................................................................................. 6-1
6.4 Self Tuning.................................................................................................................. 6-7
6.4.1 Self Tune Setup ............................................................................................ 6-7
6.4.2 Execute Self Tuning...................................................................................... 6-8
6.5 Final Adjustments...................................................................................................... 6-10
6.5.1 Nominal A-C Line Adjustments...................................................................... 6-10
6.5.1.1 Perform Nominal AC-Line Frequency Adjust................................... 6-10
6.5.1.2 Perform Nominal AC-Line Volts Adjust............................................ 6-10

TABLE OF CONTENTS
49’1340 e FlexPak 3000
III
7.0 Troubleshooting/Diagnostics 7-1..7-8
7.1 General ....................................................................................................................... 7-1
7.2 Wiring Errors............................................................................................................... 7-1
7.3 AC Line and Power Input ............................................................................................ 7-1
7.4 DC Motor..................................................................................................................... 7-1
7.5 Remote M Contactor................................................................................................... 7-2
7.6 Optional Kits................................................................................................................ 7-2
7.7 Fault/Alarm/Diagnostic (FAD) Menus.......................................................................... 7-2
7.7.1 About The Fault Menu..................................................................................... 7-2
7.7.1.1 Review Log........................................................................................ 7-2
7.7.1.2 Reset Faults....................................................................................... 7-3
7.7.1.3 Clear Fault Log and Reset Faults...................................................... 7-3
7.7.2 About the Alarm Menu..................................................................................... 7-3
7.7.2.1 Review Log........................................................................................ 7-4
7.7.2.2 Reset Alarm Indicator........................................................................ 7-4
7.7.2.3 Clear Alarm Log and Reset Alarms................................................... 7-4
7.7.3 Diagnostics Menu............................................................................................ 7-5
7.7.4 Diagnostics Configure ..................................................................................... 7-5
7.7.5 Regulator LED Status Information................................................................... 7-6
7.7.6 Phase Firing Test Mode .................................................................................. 7-7
7.7.7 Power Supply Test Pin Identification............................................................... 7-8
8.0 Replacement Parts and Accessories 8-1..8-21
8.0 Replacement of Components...................................................................................... 8-1
8.1 Recommended Spare Parts........................................................................................ 8-3
8.2 Accessories................................................................................................................. 8-6
Appendices
Appendix A
Glossary of Terms ................................................................................................................ A-1...A-2
Appendix B
FlexPak 3000 User Input Parameters ................................................................................. B-1..B-52
Appendix C
FlexPak 3000 User Output Parameters ............................................................................ C-1...C-12
Appendix D
Index Block Diagrams.................................................................................................................... D-I
Block Diagrams................................................................................................................... D-1..D-14
Appendix E
Program Error Messages and Fault and Alarm Codes......................................................... E-1...E-8
Appendix F
OIM Parameter Menu Tree................................................................................................... F-1...F-8
Appendix G
User Quick Reference Table ............................................................................................... G-1...G-8
Appendix H
CE-Conformity..................................................................................................................... H-1...H-4
Appendix J
Cross Reference Part Numbers – Catalogue Numbers........................................................ J-1...J-2

TABLE OF CONTENTS
FlexPak 3000 49’1340 e
IV
List of Figures
Figure 2.1 - FlexPak 3000 Functional Block Diagram ............................................................... 2-7
Figure 2.2 - Operator Interface Module (OIM)........................................................................... 2-9
Figure 3.1 - Mounting Dimensions for FlexPak 3000, 25 and 60 A........................................ 3-2
Figure 3.2 - Mounting Dimensions for FlexPak 3000, 150 A.................................................... 3-3
Figure 3.3 - Mounting Dimensions for FlexPak 3000, 250 and 450 A...................................... 3-4
Figure 3.4 - Mounting Dimensions for FlexPak 3000, 800 A.................................................... 3-5
Figure 3.5 - Mounting Dimensions for FlexPak 3000, 1200 and 1600 A.................................. 3-6
Figure 3.6 - Mounting Dimensions for FlexPak 3000, 2000 A.................................................. 3-7
Figure 3.8a - CTB Connection Diagram - Example................................................................... 3-12
Figure 3.8b - Main Contactor Connection Diagram - Example.................................................. 3-13
Figure 3.9/10 - Principle Wiring Diagram, 150 A..................................................................... 3-14
Figure 3.11/12 - Principle Wiring Diagram, 1600 A.................................................................... 3-16
Figure 4.1 - Regulator Board Jumpers ...................................................................................... 4-3
Figure 4.2 - AUTO REF Jumpers .............................................................................................. 4-6
Figure 5.1 - Integer Value Entry Screen................................................................................... 5-1
Figure 8.2 - AC-Line Choke Dimensions................................................................................ 8-10
Figure 8.3 - HF Filter Dimensions........................................................................................... 8-11
Figure 8.4 to 8.12 - RFI-Filter Dimensions ................................................................................ 8-13
Figure D.1 - Drive Control Signals............................................................................................. D-1
Figure D.2 - Speed Reference Overview .................................................................................. D-2
Figure D.3 - Speed Reference Source Select........................................................................... D-3
Figure D.4 - Speed Reference Ramp........................................................................................ D-4
Figure D.5 - Speed Reference Mode Select ............................................................................. D-5
Figure D.6 - Speed Loop........................................................................................................... D-6
Figure D.7 - Digital and Analog Outputs.................................................................................... D-7
Figure D.8 - Meter Outputs........................................................................................................ D-8
Figure D.9 - Current Minor Loop Reference.............................................................................. D-9
Figure D.10 - Current Minor Loop ............................................................................................. D-10
Figure D.11 - Field Block........................................................................................................... D-11
Figure D.12 - Outer Control Loop.............................................................................................. D-12
Figure D.13 - I/O Expansion Board Inputs ................................................................................ D-13
Figure D.14 - Level Detectors ................................................................................................... D-14
Figure H.1 - Cabinet Configuration............................................................................................ H-3
Figure H.2 - Specification for screened cable........................................................................... H-4
List of Tables
Table 1.1 - Related Documentation.......................................................................................... 1-2
Table 2.1 - Armature Voltage ................................................................................................... 2-3
Table 2.2 - Tachometer Speed Regulation .............................................................................. 2-4
Table 2.3 - Drive Specifications................................................................................................ 2-4
Table 2.4 - Drive Modification Kits............................................................................................ 2-8
Table 2.5 - OIM Drive Fault and Status Indicators ................................................................ 2-10
Table 2.6 - Drive Monitor Capabilities .................................................................................... 2-11
Table 3.6 - User Device Connections to the Control Terminal Board..................................... 3-13
Table 3.7 - Recommended Lugs for Grounding FlexPak Drives in UL / cUL Version............ 3-18
Table 4.1 - Jumper and Adjustment Settings. .......................................................................... 4-2
Table 6.1 - Quick Start Jumper Settings....................................................................................6-2
Table 6.2 - Quick Start Parameter Modification Sequence. ..................................................... 6-3
Table 8.1/2 - Replacement Parts for FlexPak 3000 25-150 A.................................................. 8-3
Table 8.3/4 - Replacement Parts for FlexPak 3000 250-800 A.................................................. 8-4
Table 8.5/6 - Replacement Parts for FlexPak 3000 1200-2000 A.............................................. 8-5
Table 8.7 to 8.10 - Accessories..................................................................................................... 8-6
Table 8.10 - RFI Filter Selection............................................................................................... 8-12
Table E.1 - Fault Codes........................................................................................................... E-2
Table E.2 - Alarm Codes.......................................................................................................... E-7
Table G.1 - Quick Reference.................................................................................................... G-1
Table J.1 - Cross Reference Part Numbers – Catalogue Numbers.........................................J-1

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 Instructions
DANGER, WARNING, and CAUTION point out potential trouble areas.
• A DANGER alerts a person that high voltage is present which could result in severe bodily
injury or loss of life.
• A WARNING alerts a person to potential bodily injury if procedures are not followed.
• A CAUTION alerts a person that, if procedures are not followed, damage to, or destruction
of equipment could result.
DANGER:
Before installing and/or operating this device, this manual must be understood by the
qualified electrical maintenance person who is familiar with this type of equipment and
the hazards involved. Failure to observe this precaution could result in bodily injury.
WARNING:
Earth fault detection devices must not be used on this converter as the sole protection
measure against unintentional touching. The DC-component in the earth fault current
may inhibit the correct function of the fault detector.
CAUTION:
Electronic converters cause disturbances to the supply network. The basic version of
this converter does not include any harmonic filters and may not fulfil the limits of the
national recommendations. The harmonic voltage disturbances produced by the
converter are dependent on the supply network impedance.
Machinery Directive
CAUTION:
This inverter device is a component intended for implementation in machines or
systems for the capital goods industry.
The start-up of the inverter in the European market is not permitted until it has been
confirmed that the machine into which the inverters are built is in conformance with the
regulations of the Council Directive Machinery 98/37/EWG.
WARNING:
To inhibit uncontrolled machine operation in case of the malfunction of the drive, the
user must provide an external emergency stop circuit, which ensures disconnection of
the power source from the motor.
This circuit must be hardwired with electro-mechanic components and shall not depend
on electronic logic or software.The stopping device (e.g. mushroom head pushbutton
with lock) must be accessible to the operator.
Failure to observe this precaution could result in bodily injury or loss of life.
Electromagnetic Compatibility (EMC-Directive)
CAUTION :
The operating of inverters in the European market is only permitted if the Council
Directive Electromagnetic Compatibility 89/336/EWG has been observed.
It is the responsibility of the manufacturer of the machine or system to observe the
immunity and emission limits, requested by the Council Directive EMC in the European
market. Guidelines for the installation according EMC-regulations - for shielding,
grounding, filter arrangement as well as wiring instructions - are summarized in
Appendix H, ‘CE-Conformance’ of this Instruction manual.

GENERAL NOTES
FlexPak 3000 49’1340 e
1-2
1.2 General Notes
Copyright © Copyright Rockwell Automation AG, 2002
Each reproduction of this manual may be prosecuted. The copyright of the user's
manual remains at Rockwell Automation AG, CH-6036 Dierikon.
Trade mark Reliance® is a registered trade mark of Rockwell Automation AG.
SW-Version This manual is valid for Regulator Software Version 4.3.
Regulator SW Versions can be read in Parameter 794.
1.3 Manual Scope
This manual contains information on drive installation, drive startup, parameter descriptions,
and troubleshooting procedures. It also describes the controller and how to use the Keypad OIM
to configure the drive.
Specific terms used in this manual are described in Appendix A.
Measures for CE Conformity on Electro Magnetic Compatibility (EMC) are shown in Appendix H.
1.4 Related User Manuals
Table 1-1: Available User Manuals
Item Publication No. Language (-xx) Access
FlexPak3000 Power Module (this manual) FP3OIM-UM043M-xx EN, DE, FR, IT, ES (1)
Pulse Tacho Feedback Kit FP3TIF-UMyyyy-xx EN, DE, FR, IT, ES (1)
Field Current Regulator Kit FP3FCR-UMyyyy-xx EN, DE, FR, IT, ES (1)
I/O Expansion Board FP3IOE-UMyyyy-xx EN, DE, FR, IT, ES (1)
IBSF Communication Kit FP3IBS-UMyyyy-xx EN (1)
PDPF Communication Kit FP3PDP-UMyyyy-xx EN (1)
CS3000 Drive Control Configuration Software CS3000-UMyyyy-xx EN (1)
Lifting Instructions D2-3414 EN (2)
OIM Remote Mounting kit D2-3294 EN (2)
Enhanced Field Supply Kit D2-3413 EN (2)
AutoMax Network Communication Kit D2-3318 EN (2)
ControlNet Communication Board D2-3425 EN (2)
DeviceNet Communication Board HEC-FP3-DN EN (3)
xx: EN = English, DE = German, FR = French, IT = Italian, ES = Spanish
yyyy: Manual Index
(1) You can order hardcopies of these manuals or download files from the Automation Bookstore via
www.theautomationbookstore.com, then Public – search - Item Number: begins with FP3.
(2) You can order hardcopies of D2-xxxx using the U.S. Manual Ordering Form D-203 (D-202)
or download PDF-files of the manuals. Both are available at the following internet page:
www.reliance.com/docs_onl/online_stdrv.htm, then Manual Ordering or Listing User Manuals.
(3) This Horner Electric Manual can be downloaded from the Internet via:
www.heapg.com/devicenet.htm, then Manuals.

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 FlexPak 3000 Drive.
2.1 Drive Identification
2.1.1 Nameplate
The FlexPak 3000 drive has a name-
plate on the right side of the carrier that
identifies the drive by its specific
Hardware and Software Part Numbers
and applicable AC input power and DC
output power data. Refer to this
nameplate example.
All communication concerning this
product should refer to the appropriate
Part Number information.
The technical power information should
be referenced to verify proper power
application.
P.N. -EQUIPMENT 848.11.73 A SER. No.
P.N. -VERSION 790.30.72 A EU I/M 49‘1340
TYPE FP3000-S6R-800-AN-FC
S/W VERSION 4.3
US M/N 650FR8742 I/M US P.N. D2-3475
INPUT 500 VAC 3PH 50/60 Hz, 700 A
OUTPUT 0 -520 VDC , 800 A
SHORT CIRCUIT SYM RMS RATING 30 k A
ENCLOSURE IP00 CHARACTER OF LOAD M
MADE IN SWITZERLAND BY ROCKWELL AUTOMATION AG, DIERIKON
CE, UL, CUL
Sample FlexPak 3000 Nameplate
2.1.2 Drive Selection
The following table lists the European part numbers and North America Model No’s (where
available) for ordering a specific drive type. For options refer to Table 2-4, sheet 2-8.
Unit Type Power Unit (Basic) 1)
Nominal
Current
Max. AC-Line
Voltage
S-6
with Field
Rectifier
S-6 with
Field Current Regulator
U.S. Model No
S-6R
with Field
Rectifier
S-6R with
Field Current Regulator
U.S. Model No
25 A 500 V, 50 Hz
460 V, 60 Hz 848.00.03 848.00.73 20FN8742 848.01.03 848.01.73 20FR8742
60 A 500 V, 50 Hz
460 V, 60 Hz 848.02.03 848.02.73 50FN8742 848.03.03 848.03.73 50FR8742
150 A 500 V, 50 Hz
460 V, 60 Hz 848.04.03 848.04.73 125FN8742 848.05.03 848.05.73 125FR8742
250 A 500 V 848.06.03 848.06.73 200FN8742 848.07.03 848.07.73 200FR8742
450 A 500 V 848.08.03 848.08.73 375FN8742 848.09.03 848.09.73 375FR8742
800 A 500 V 848.10.03 848.10.73 650FN8742 848.11.03 848.11.73 650FR8742
1200 A 500 V, 50 Hz - 848.12.73* - - 848.13.73* -
1200 A 500 V, 60 Hz - 848.12.43 - - 848.13.43 -
1600 A 500 V, 50 Hz - 848.14.73* - - 848.15.73* -
1600 A 500 V, 60 Hz - 848.14.43 - - 848.15.43 -
2000 A 500 V, 50 Hz - 848.18.73* - - 848.19.73* -
2000 A 500 V, 60 Hz - 848.18.43 - - 848.19.43 -
1600 A 690 V, 50 Hz - 848.16.73* - - 848.17.73* -
1600 A 575 V, 60 Hz - 848.16.43 - - 848.17.43 -
* FlexPak 3000 converters 1200 A to 2000 A for 50 Hz are not UL, cUL.
1) The Keypad Operator Interface Module (OIM) is not included in the basic unit 848.xx.xx.

INTRODUCTION TO THE DRIVE
FlexPak 3000 49’1340 e
2-2
2.2 Drive Specifications
2.2.1 AC-Line Considerations
Requirement Measures
1) Limiting the AC line symmetrical fault
current to 100 kA (max. for fuses) or
values acc. table below for UL, cUL, as
well as limiting commutation notches at
the line input (terminals 1U, 1V, 1W).
Always adding an impedance in the line input.
This can be a 3-phase line reactor with 2%
voltage drop minimum (refer to Table 8-6) or a
matched isolation transformer.
2) Limiting the A-C line symmetrical fault
current (RMS) at the field rectifier input
(terminals 3V, 3W) to 10 kA.
Adding a 1-phase line reactor acc. to Table 8-6.
Exception: No reactor is required when a
matched transformer is provided in the input to
the converter on drives up-to 450 A.
3) Minimum supply system (source)
capacity kVA. Connecting to a source (supply transformer) with minimum kVA rating acc. to the following table.
4) Limiting line transformer impedance to 4%
and continuous undervoltage to 10%. Derating of armature voltage if impedance exceeds 4% or continuous undervoltage.
5) Avoiding damage of drive components
due to overvoltage transients caused by
medium voltage switching on supply
transformers with a primary rating of 2300
VAC or more.
Providing additional input line conditioning on the
drive (e.g. Capacitance to ground).
Please Contact Rockwell Automation for
assistance when this is required.
Minimum Source Capacity (kVA)
for different AC line voltages at 50 Hz
Full Load
Rated DC
Current 400 V 460 V 500 V 575 V 690 V
Max. Source Capacity
Symmetr. fault current (rms)
(for UL, cUL)
25 15 18 20 - - 18 kA
60 36 41 45 - - 18 kA
150 90 102 111 - - 18 kA
250 150 175 188 - - 30 kA
450 270 306 333 - - 30 kA
800 480 545 592 - - 30 kA
1200 720 818 888 - - 85 kA
1600 960 1100 1190 1400 1630 85 kA
2000 1200 1373 1486 - - 85 kA
2.2.2 Service Conditions
Standard altitude ......................................................................................up to 1000 meters
(Above 1000 m the output current must be reduced by 1% per 100m)
Standard ambient temperature at:
Operation with nominal current......................................................................0°C to 40°C
Storage ...................................................................................................... -25°C to 55°C
Transportation............................................................................................ -25°C to 70°C
Max. ambient temperature .......................................................................................... 55°C
(Above 40°C output current must be reduced by 1.5% per °C)
Relative humidity ........................................................ max 50% at 40°C unlimited time
Non-Condensating max 90% at 20°C (30 days/year)
max 75% average per year
Environment: The drive should be located in an area that is free of dust, dirt, acidic vapors,
vibration and shock, temperature extremes, and electrical or electromagnetic noise interference.
Degree of protection...................................................................................................... IP00

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, 1W and 2U, 2V, 2W
On units 25, 60, 150 A........................................................200 - 500 VAC at 50 Hz
200 - 460 VAC at 60 Hz
On units 500 V, 250, 450, 800, 1200, 1600 and 2000 A ..................... 200 - 500 VAC
On units 575 V, 60 Hz, 1600 A............................................................ 300 - 575 VAC
On units 690 V, 50 Hz, 1600 A............................................................ 300 - 690 VAC
Input voltage for Field Controller Supply (on FlexPak 25 - 800 A)................. max. 415 VAC
Input voltage for Field Current Regulator Kit (Option).................................... max. 460 VAC
Voltage variation .......................................................................+10% and -10% of Nominal
Nominal line frequency .......................................................................................50 or 60 Hz
Frequency variation ................................................................................................... ±2 Hz
Fan Supply Voltage and Current Consumption on Units 1200 - 2000 A
Three-phase input voltage
at terminals 5U, 5W, 5W ................................ ... 400 V, 50 Hz or. 460 V, 60 Hz, 1A
NOTE: On units 60 Hz, 1200 -2000 A in UL, cUL version the fan must be external protected
by the following, thermal magnetic circuit breaker:
Dierikon part No. 610.11.05, RA catalog No. 140M-C2E1316.
2.2.4 Regulator Supply Voltage and Power Consumption
Single-phase input voltage, via autotransformer.......................230 VAC at terminals 0, 230
or 115 VAC at terminals 0, 115
Power Consumption (including fan on type 150 - 800 A)..................................max. 120 VA
Thermal magnetic protection by external circuit breaker
NOTE: On units with terminals 4U, 4V (without autotransformer) input voltage 230 VAC is
required.
2.2.5 Relay Output for Main Contactor
Relay MCR at terminals X1:5 and X1:6
Nominal contact rating at AC 230 V, cos phi = 0.5 ...................................................330 VA
Maximum current............................................................................................................. 3 A
2.2.6 DC Voltage Ratings:
Maximum permissible armature voltage Ua max at inductive voltage drop of Uk ≤4% per phase
and max. 10% line undervoltage. At Uk = 4 to 7% Ua max must be derated per 5%.
Ua nom is the recommended standard motor armature voltage for the selected line
voltage and operation mode.
Table 2-1: Armature voltage for various line voltages
AC Line Motoring operation (S-6 / S-6R) Regenerating operation (S-6R)
Voltage Armature Voltage Armature Voltage
UNU
a nom U a max U a nom U a max
200 V 200 V 230 V 200 V 214 V
400 V 460 V 490 V 400 V 440 V
460 V 520 V 570 V 500 V 500 V
500 V 600 V 620 V 520 V 535 V
575 V 700 V 710 V 600 V 615 V
660 V 800 V 810 V 700 V 706 V
690 V 800 V 850 V 700 V 738 V
Field voltage ..........................................................................max. 90% of line input voltage
Protection by external fuses according to table 8-8.

INTRODUCTION TO THE DRIVE
FlexPak 3000 49’1340 e
2-4
2.2.7 Regulation (with 95% load change):
Table 2-2 - Tachometer Speed Regulation
Regulation Arrangement Speed Change with 95% Load Change Speed Change from All other Variables Part Number
Armature Voltage Regulation
with IR Comp. 2-3 % 15% Not applicable.
Closed Loop
with Analog tach 1% 2% -
with Pulse tach 1) 0.01% 0.01% 762.70.00
1) Optional Pulse Tachometer Feedback kit required (See instruction manual 49’1343).
2.2.8 Speed Range:
Operator's Speed Adjustment............................................................................... 0 to rated speed
Specification Speed Range ........................................100:1 based on top speed and tachometer
2.2.9 Drive Efficiency:
Drive Only........................................................................................98.6% (rated load and speed)
Drive and Motor............................................................................................................85% typical
2.2.10 Displacement Power Factor, Power Loss PV and Output Current:
Power Factor: 88% typical (rated load & speed, decreasing linearly with speed)
Typical percent speed depends on motor operating speed and motor frame size.
Power Consumption at no load: see PA in Table 2-3.
Table 2-3 - Drive Specifications
Unit-Type Iad I
anom I amax I F (-73/43) I F (-03) P AP v (at Ia nom)
25 A 25 A 20 A 30 A 4 A 6 A 60 VA 120 W
60 A 60 A 50 A 75 A 4 A 6 A 60 VA 210 W
150 A 150 A 125 A 187 A 10 A 6 A 85 VA 460 W
250 A 250 A 208 A 312 A 10 A 12 A 90 VA 715 W
450 A 450 A 375 A 562 A 10 A 12 A 90 VA 1215 W
800 A 800 A 667 A 1000 A 12 A 12 A 120 VA 2120 W
1200 A, 500V 1200 A 1000 A 1500 A 15 A * - 400 VA 2680 W
1600 A, 500V 1600 A 1334 A 2000 A 15 A * - 400 VA 3750 W
2000 A, 500V 2000 A 1667 A 2500 A 15 A * 400 VA 4600 W
1600 A, 575V 1600 A 1334 A 2000 A 15 A * - 400 VA 3900 W
1600 A, 690V 1600 A 1334 A 2000 A 15 A * - 400 VA 4100 W
Iad = Maximum continuous current without overload capability (Iad = 1.2 x Ia nom)
Ia nom = Nominal continuous current with overload capability 50% during 1 minute
every 10 minutes
Ia max = Maximum current during 1 minute after 9 minutes operation with Ia nom
(Ia max = 1.5 x Ia nom)
IF= Field current without overload capability
* A maximum field current of 20 A is permitted, if the power unit blower is switched on
together with the motor field.

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. Refer to section 3.8 for terminal strip
connections and wiring diagrams.
2.3.1 Logic Inputs:
CAUTION:
Connecting an external power source to any of the +24 volt connections (terminals 1, 7, 11, and 14)
on the regulator board terminal strip will damage the drive. DO NOT connect the external power
source to the +24 volt connections on the regulator board terminal strip. Failure to observe this
precaution could result in damage to, or destruction of, the equipment.
The logic input circuits can be powered either from the internal +24 V DC power supply or from
an external +24 V DC power source. The internal +24 V DC power supply is available at the
regulator board terminal strip (see Figure 3-8). If an external power source is used, only its
COMMON must be connected to 24V COM on the regulator board (terminal 15). 24V COM is
internally not grounded, but may be externally grounded if required by the users control wiring.
Electrical Specifications:
Input Voltage .........................................................................................................+24 V DC
Turn On Voltage ............................................................................................................ 8 V
Turn Off Current ....................................................................................................... 0.5 mA
Common ............................................................. All input circuits have the same common.
2.3.2 Logic Outputs:
The logic output circuits are normally open (when de-energized) relay contacts. When
energized (contacts closed), the three circuits indicate the following drive conditions:
Running 27 to 28, Alarm 29 to 30, No Fault 31 to 32
Electrical Specifications:
Operating Voltage .................................................................. 250 V AC maximum
30 V DC maximum
Switching Current .............................................................. 2 A maximum resistive
1 A maximum inductive
2.3.3 Analog Inputs:
The three customer analog inputs are
• Manual Mode Reference
• Automatic Mode Reference
• D-C Tachometer Feedback.
These inputs are converted at 12 bits plus sign at their full range. The electrical specifications
for each of these is listed below.
Electrical Specifications:
Current loading ......................................................................................... 2.5 mA maximum
Manual Mode Reference: Jumper J19
Potentiometer 5 kohm minimum POT
External Voltage Source: +/- 10 VDC (when used for Analog Trim Ref. )
0 - 10 VDC (when used for Manual Mode Speed Ref.) EXT
Automatic Mode Reference: Jumper J12 Jumper J10
Voltage Reference +/- 10 V DC VOLTS VOLTS & PARK
Milliamp Reference 4-20 milliamps MAMPS 4-20 & PARK
10-50 milliamps MAMPS 10-50 & 4-20

INTRODUCTION TO THE DRIVE
FlexPak 3000 49’1340 e
2-6
Analog Tachometer Feedback
Tach Voltage at Top Speed ........................................................................... 10 - 250 V DC
NOTE: J14 Jumper position and connection of DC-Tachometer must correspond.
Jumper J14 Jumper J11
Top Speed Tach Volts < 16 V LOW 16
< 31 V LOW 31/125
< 62 V LOW 62/250
< 125 V HI 31/125
< 250 V HI 62/250
2.3.4 Analog Outputs:
The two metering analog outputs are available at regulator board terminals 24, 25 and 26.
Terminal 25 is the common connection for both output signals. The selected signals for both
meter outputs are averaged (filtered) over 100 msec to reduce meter fluctuations.
METER OUT 1 SELECT (P.404) corresponds to terminals 24 and 25 (default: CML
FEEDBACK). METER OUT 2 SELECT (P.405) corresponds to terminals 25 and 26 (default:
SPD LOOP FEEDBACK).
Refer to Appendix B, METER OUT 1 SELECT (P.404) and METER OUT 2 SELECT (P.405)
parameters, for additional drive test points that can be configured to source Meter Outputs 1
and 2.
Electrical Specifications:
Output Voltage.................................................................................................... +/- 10 V DC
Maximum Load ...................................................................................................4 milliamps

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 with a digital current
minor loop and a digital major loop for armature voltage or speed regulation by tachometer
feedback. Figure 2-1 shows a block diagram of the Drive.
The Drive employs a wireless construction and uses a keypad for drive setup, including
parameter adjustments and unit selection, monitoring and diagnostics. Multiple language
capability in English, French, German, Spanish, Italian and ‘Code’ is available. Reference,
feedback, and metering signals can be interfaced to the drive. The drive can be controlled
locally by the Operator Interface Module (OIM) Keypad or remotely by using the terminals at the
regulator board terminal strip (see Section 3 for terminal connections). Based on the active
control source selected using the CONTROL SOURCE SELECT key, the OIM displays the
control source as "KEYPAD" or "TERMBLK" (regulator board terminal strip), or "NETWORK"
(if an optional network communication board is installed).
DRIVE CONTROL SIGNALS AND SEQUENCING
OIM SERIAL NETWORK
SPEED
LOOP CURRENT
MINOR
LOOP
(CML)
FIELD
CONTROL
S6/S6R
POWER
UNIT
FIELD
POWER
SUPPLY
SPEED
REFERENCE
SELECTION
AND
SCALING
OUTER
CONTROL
LOOP
(OCL)
Regulator Board
Terminal Strip
I/O Expansion
Board
Current Feedback
Voltage Feedback
Tachometer Feedback
MOTOR ARMATURE
ANALOG OR PULSE
TACHOMETER
MOTOR FIELD
DIGITAL,
ANALOG, &
FREQUENCY
INPUTS/
OUTPUTS
Figure 2-1 - FlexPak 3000 Functional Block Diagram

INTRODUCTION TO THE DRIVE
FlexPak 3000 49’1340 e
2-8
Rockwell Automation offers modification kits that broaden the application range of the drive.
A summary of these kits is presented in the following Table 2-4.
Related Instruction Manuals are listed in Table 1-1, Section 1.4.
Table 2-4 - Drive Modification Kits
Name Description Part
Number
Pulse Tacho
Feedback Kit PTK Allows for digital pulse tachometer speed feedback on high performance regulation applications. (Kit includes cable). 762.70.00
Enhanced Field
Supply kit FVR Provides electronic field voltage trim and field economy. It replaces the standard field supply. 762.70.10
Field Current
Regulator kit
FCU4
FCU10
FCU15
Provides field economy, as well as pre-weakening of the field using
a fixed reference or field weakening for above base speed
operation. Tachometer feedback is required with this kit.
This kit replaces the standard field supply.
762.70.50
762.70.60
762.70.70
(4,10,15A)
I/O Expansion
Board IOE Mounts on the FlexPak 3000 chassis and gives the FlexPak 3000 additional analog, frequency, and digital I/O capability. 762.70.80
AutoMax Network
Communic. kit
AMXF
A
llows the FlexPak 3000 to communicate on the Reliance AutoMax
Distributed Control System (DCS). (Kit contains board & cable). 762.70.40
Interbus Communi-
cation kit IBSF Allows the FlexPak 3000 to communicate over the standardized field bus system INTERBUS. (Kit contains board & cable). 762.70.45
Profibus Communi-
cation kit PDPF Allows the FlexPak 3000 to communicate over the standardized Profibus-DP system. (Kit contains board & cable) 762.70.95
ControlNet
Communication
Board CONF
Allows a FlexPak to communicate over the open protocol
ControlNet network. Mounts inside the FlexPak and includes
terminals for network connections. The AMX Network Comm.
board cannot be used when using the ControlNet.
762.70.96
DeviceNet
Communication
Board DNC
Allows a FlexPak to communicate over the open protocol
DeviceNet network. Mounts inside the FlexPak and includes
terminals for network connections. The AMX Network Comm.
board cannot be used when using the DeviceNet board.
762.70.90
Drive Control
Configuration
Software
CS3000-V6
Windows-based software that allows the user to connect any
personal computer running Micro-soft Windows version 3.1 or later
to a FlexPak 3000 drive. Allows you to create, store, upload, and
download drive configurations. You can also monitor and change
parameters through the PC and read and reset the drive’s fault log.
788.05.30
Interface Cable for connecting the drive to PC (25-pin to 9-pin) 772.27.00
Keypad Drive
Configuration
Module KDCM
Operator Interface that allows you to access and change drive
parameters, read and clear the drive’s alarm and fault log.
The DCM cannot control the drive.
922.95.10
Keypad Operator
Interface Module
KOIM
(M/N 317C160D)
Allows you to control (e.g. Start, Stop, Jog) the drive.
You can also monitor and change parameters, read and clear the
drive's alarm and fault log.
922.95.00
OIM Remote
Mounting kit DMK
(M/N 905FK0101)
Provides for remote mounting of the OIM up to 5 meters away from
the drive. Contains also the cover plate (762.70.31) for the
regulator unit.
762.70.30

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 Keypad OIM.
Drive fault and status indicators are listed in Table 2-5.
LCD Display LCD-Indicators
Control Key
LCD-Indicators
OIM Programming
Keys
Fault
Alarm
Interlock OK
Drive Ready
Running
Current Limit
Torque Limit
PROGRAM
MONITOR
STOP
FAULT JOG
FORWARD
REVERSE
CONTROL
SOURCE
SELECT
AUTO
MANUAL
PROGRAM KEYPAD MANUAL FORWARD
RESET
+RUN
HELP
?
CANCEL ENTER
Drive Control
Keys
Figure 2-2: Operator Interface Module OIM
2.5.1 Indicators
LCD (Liquid Crystal Display) and LED (Light Emitted Diode) displays are used to indicate the
status of the drive. LCD indicators are located on the OIM to the left of the text for the indicator.
LED indicators are located on the regulator board which is located behind the OIM.
LCD Indicators
An LCD indicator is on when a field is present !! ; off when extinguished. In Figure 2-2, the
Interlocks OK and the Drive Ready indicators are on. Table 2-5 contains a list of drive and fault
status indicators with their associated description.

INTRODUCTION TO THE DRIVE
FlexPak 3000 49’1340 e
2-10
Table 2-5 - OIM Drive Fault and Status Indicators
Indicators Description
Fault A condition or conditions exists in the drive which stopped it or prevents it from
running. When a fault occurs, the type of fault and further instructions are
displayed on the OIM display.
Alarm An alarm does not prevent the drive from running but alerts the user that a
condition exists that could cause a fault in the future. When an alarm occurs,
the type of alarm and further instructions are displayed (unless a subsequent
fault occurs which will overwrite the alarm text display).
Interlock OK This indicator is on when all customer interlocks (terminal 9) and the Coast/DB
contact (terminal 8) are closed. Off = 1 or more are open.
Drive Ready This indicator in on when all customer interlocks are closed, the Coast/DB
contact is closed and there are no drive faults present. Pressing the RUN or
JOG key will cause the drive to start if this indicator on. Off = not ready.
Running When on, this indicates that the contactor is closed and the motor armature is
energized. Off = contactor is open and drive is not running.
Current Limit
Torque Limit This is a real time indication of the motor operating in current limit. On = current limit
Off = not in current limit.
LED Indicators
Two LED indicators are located on the regulator board for status and service use: (LED1) CPU
OK and (LED2) OIM COMM OK. See Section 7 of this instruction manual for further details
regarding the use of these indicators for status and troubleshooting purposes.
2.5.2 Controls
The OIM keys can be categorized into two general functions:
1) OIM Programming Keys (program/monitor, fault, help, cancel, enter, and arrow keys)
2) Drive Control Keys (control source select, auto/manual, forward/reverse, jog, run, and
stop/reset.)
2.5.2.1 OIM Programming Keys
These keys provide the ability to tune the drive, scale inputs/outputs, save user configurations
or restore to/from non-volatile memory, set drive limits, access fault/alarm logs and monitor
several drive signals. The PROGRAM mode is used for menu and parameter selection. The
MONITOR mode displays standard drive output data values. See section 4 for further details on
menu and parameter selection.
PROGRAM
---------------
MONITOR
This key cycles the OIM display between Program screens and two Monitor
screens. The state of this key (PROGRAM or MONITOR) is shown on the LCD
directly above the key. The active OIM display mode is retained through drive
power cycles. For example, if the OIM was in MONITOR mode and power was
removed, the OIM would power up in the MONITOR display mode.
See the following example for more information.
NOTE: The PROGRAM mode is used for menu and parameter selection.

INTRODUCTION TO THE DRIVE
49’1340 e FlexPak 3000 2-11
FlexPak 3000 Main Menu
!!
"Quick Start
Drive Reference
Speed/Voltage Loop (SPD)
#Current Minor Loop (CML)
PROGRAM KEYPAD MANUAL FORWARD
• Pressing this key will display the following screen:
MOTOR SPEED 0 RPM
ARM VOLTS 0 VOLTS
MOTOR LOAD 0 %FLA
KEYPAD REF: 0 RPM
!!
MONITOR KEYPAD MANUAL FORWARD
This screen allows the user to change the drive's setpoint (KEYPAD REF) when the CONTROL
SOURCE SELECT is set to KEYPAD and the drive is in manual mode. Use the up/down arrow
keys to change the drive's setpoint. Pressing the ENTER key will save the setpoint to non-volatile
memory.
• Pressing the PROGRAM/MONITOR key a second time will display motor speed (RPM) and
motor load (FLA):
0 RPM
0 %FLA
!!
MONITOR KEYPAD MANUAL FORWARD
This screen does not allow the user to change the drive's setpoint (KEYPAD REF).
• Pressing the PROGRAM/MONITOR key after the second time will re-display the previous
PROGRAM display (the first screen in this example).
Pressing the ENTER key will save the setpoint to non-volatile memory.
Pressing the CANCEL key when in monitor mode will return the OIM to the PROGRAM mode.
Table 2.6 lists drive parameters monitored and reported to the OIM.
Table 2.6 - Drive Monitor Capabilities
Monitor List Selectable Engineering Units
Motor Speed Percent, RPM, Units*
Arm Volts (Armature Voltage) Volts
Motor Load (Armature Current) Percent Full Load Amps (%FLA), Amps
TERMBLK REF, KEYPAD REF
or TORQUE REF**, NETWORK REF*** Percent, RPM, Units*
* Units: Indicates the user's option to select an engineering unit (6 characters maximum) for readout to display. A number
from 1 to 10,000 full scale can be assigned a meaningful value (e.g. FPM, Feet Per Minute, etc.). See "Define User
Units" in Section 4.
** When the drive is configured as a current (torque) regulator (J15 Hardware Jumper = CURRENT), the Control Source
Select (CSS) can only be set to TERMBLK or NETWORK (if option is installed). In this case, TORQUE REF or
NETWORK REF is displayed. The units are the same as displayed for MOTOR LOAD.
** When the drive is configured as a speed or armature voltage regulator (J15 Hardware Jumper = SPEED),
the selected control source determines the reference source (TERMBLK REF or KEYPAD REF, or NETWORK REF).
*** Available with an optional Network Communication Board.

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,
clear the alarm indicator and display fault history and diagnostic information for
servicing the drive. The state of this key (FAULT, ALARM or DIAGS) is shown on
the LCD directly above the key.
• Pressing the FAULT key once will display the fault menu:
Fault Menu
"Review Log
Reset Faults
Clear Fault Log and Reset Faults
!!
!!
FAULT KEYPAD MANUAL FORWARD
• Pressing the FAULT key a second time will display the alarm menu.
Pressing the CANCEL key will return the OIM to the previous display mode (PROGRAM or
MONITOR).
Alarm Menu
"Review Log
Reset Alarms
Clear Alarm Log and Reset Alarms
!!
!!
ALARM KEYPAD MANUAL FORWARD
• Pressing the FAULT key a third time will display the diagnostics menu.
Pressing the CANCEL key will return the OIM to the previous display mode (PROGRAM or
MONITOR).
Diagnostics Menu
"Why is the drive not ready?
Why did the drive stop?
!!
!!
DIAGS KEYPAD MANUAL FORWARD
• Pressing the FAULT key after the third time will re-display the fault menu.
To exit this mode, press PROGRAM/MONITOR. This returns the OIM display to the previous
display mode (PROGRAM or MONITOR).
See Section 7 of this instruction manual for further details on the FAULT, ALARM, and DIAGS
menus.
HELP
? Menu and Parameter HELP are available. Access Menu or Parameter HELP by
pressing the HELP key when the cursor is at the particular menu or parameter of
interest. In the MONITOR mode, pressing HELP displays status indicators in the
selected language. Pressing CANCEL at anytime will return to the display
from the previous screen.
MENU HELP
Menu HELP provides the user with information regarding the general purpose of the menu and
some details of related parameter selections.
For example: If English is the selected Language, the following is displayed when HELP is
pressed when at the Main Menu.