Rockwell Automation Reliance electric FlexPak 3000 User manual

Instruction Manual
FlexPak 3000
Enhanced Field Supply Kit
Installation Instructions
M/N 923FK0101 and 923FK0201
D2-3413-1

©2000 Rockwell International Corporation
The information in this manual is subject to change without notice.
Throughout this manual, the following notes are used to alert you to safety considerations:
Important: Identifies information that is critical for successful application and understanding of the product.
The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to
signify new or revised text or figures.
!ATTENTION:Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
FlexPak 3000 and Reliance are trademarks of Rockwell Automation.
!ATTENTION:Only qualified personnel familiar with the construction and operation of this
equipment and the hazards involved should install, operate, and/or service this equipment. Read
and understand this instruction manual in its entirety before proceeding. Failure to observe this
precaution could result in severe bodily injury or loss of life.
ATTENTION: The user is responsible for conforming with all applicable local, national, and
international codes. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.

Contents I
CONTENTS
Chapter 1 Introduction
1.1 Related Publications........................................................................................1-2
1.2 Getting Assistance from Reliance Electric.......................................................1-2
Chapter 2 Installing the Enhanced Field Supply Kit on 3.0 HP to 60 HP @ 460 VAC
(1.5 HP to 30 HP @ 230 VAC) Drives
2.1 Removing the OIM Cover and Opening the Carrier ........................................2-1
2.2 Removing the Standard Field Supply Board ...................................................2-2
2.3 Adjusting the Jumpers on the Enhanced Field Supply Board
and the Regulator Board .................................................................................2-2
2.4 Installing the Enhanced Field Supply Board....................................................2-4
2.5 Replacing the Drive Fuses ..............................................................................2-5
2.6 Closing the Carrier and Reinstalling the OIM Cover........................................2-6
2.7 Modifying the Drive Configuration ...................................................................2-6
Chapter 3 Installing the Enhanced Field Supply Kit on 75 HP to 150 HP @ 460 VAC
(40 HP to 75 HP @ 230 VAC) Drives
3.1 Accessing the Field Supply Board...................................................................3-2
3.2 Removing the Standard Field Supply Board (75 HP to 125 HP @ 460 VAC /
40 HP to 75 HP @ 230 VAC Drives)...............................................................3-2
3.3 Removing the Field Current Regulator Board (150 HP @ 460 VAC /
40 HP to 75 HP @ 230 VAC Drives)...............................................................3-3
3.4 Adjusting the Jumpers on the Enhanced Field Supply Board
and the Regulator Board .................................................................................3-4
3.5 Installing the Enhanced Field Supply Board....................................................3-4
3.6 Replacing the Drive Fuses ..............................................................................3-5
3.7 Reinstalling the Auxiliary Chassis Cover.........................................................3-7
3.8 Reinstalling the AC Disconnect .......................................................................3-8
3.9 Modifying the Drive Configuration ...................................................................3-8
Chapter 4 Installing the Enhanced Field Supply Kit on 200 HP to 300 HP @ 460 VAC (100 HP
to 150 HP @ 230 VAC) Drives
4.1 Removing the Field Current Regulator Board .................................................4-1
4.2 Adjusting the Jumpers on the Enhanced Field Supply Board
and the Regulator Board .................................................................................4-2
4.3 Installing the Enhanced Field Supply Board....................................................4-3
4.4 Reinstalling the OIM and Its Cover..................................................................4-3
4.5 Replacing the Drive Fuses ..............................................................................4-3
4.6 Modifying the Drive Configuration ...................................................................4-4
Chapter 5 Installing the Enhanced Field Supply Kit on 400 HP to 600 HP @ 460 VAC Drives
5.1 Removing the Drive Cover and Opening the Carrier.......................................5-2
5.2 Removing the Field Current Regulator Board .................................................5-2
5.3 Adjusting the Jumpers on the Enhanced Field Supply Board
and the Regulator Board .................................................................................5-3
5.4 Reinstalling the OIM and Cover.......................................................................5-4
5.5 Installing the Enhanced Field Supply Board....................................................5-4

II FlexPak 3000 Enhanced Field Supply Installation Instructions
5.6 Resecuring the Hinged OIM Mounting Plate....................................................5-5
5.7 Replacing the Drive Fuses...............................................................................5-6
5.8 Reinstalling the Plastic Drive Cover and Reclosing the Steel Door .................5-6
5.9 Modifying the Drive Configuration....................................................................5-6
Chapter 6 Setting the Field Voltage Trim Jumpers
Chapter 7 Modifying the Drive Configuration
7.1 Parameter 306 (NOMINAL AC LINE FREQUENCY).......................................7-1
7.2 Parameter 500 (ENHANCED FLD VOLT ADJ)................................................7-1
7.3 Examples for Setting Parameters 306 and 500 ...............................................7-2
7.4 Parameter 501 (FIELD ECONOMY DELAY) ...................................................7-4

Contents III
List of Figures
Figure 1.1 – Enhanced Field Supply Board..............................................................1-2
Figure 2.1 – Removing the Standard Field Supply Board (3 HP to 60 HP
@ 460 VAC Drives)..............................................................................2-2
Figure 2.2 – Setting the Jumpers on the Enhanced Field Supply Board..................2-3
Figure 2.3 – Setting the Jumpers on the Regulator Board .......................................2-3
Figure 2.4 – Installing the Enhanced Field Supply Board (3 HP to 60 HP
@ 460 VAC Drives)..............................................................................2-4
Figure 2.5 – Field Fuse Location (3 HP to 60 HP @ 460 VAC Drives).....................2-5
Figure 2.6 – Attaching Replacement Drive Fuse Labels (3 HP to 60 HP @ 460 VAC
Drives)..................................................................................................2-5
Figure 3.1 – Removing the Field Supply Board (75 HP to 125 HP
@ 460 VAC Drives)..............................................................................3-3
Figure 3.2 – Installing the Enhanced Field Supply Board (75 HP to 150 HP
@ 460 VAC Drives)..............................................................................3-5
Figure 3.3 – Field Fuse Location (75 HP to 150 HP @ 460 VAC Drives).................3-6
Figure 3.4 – Attaching Replacement Drive Fuse Labels (75 HP to 150 HP @ 460 VAC
Drives)..................................................................................................3-7
Figure 4.1 – Removing the Field Current Regulator Board (200 HP to 300 HP
@ 460 VAC Drives)..............................................................................4-2
Figure 5.1 – Removing the Field Current Regulator Board (400 HP to 600 HP
@ 460 VAC Drives)..............................................................................5-3
Figure 5.2 – Location of Field Current Regulator Connectors..................................5-3
Figure 5.3 – Mounting the Enhanced Field Supply...................................................5-5

IV FlexPak 3000 Enhanced Field Supply Installation Instructions

Contents V
List of Tables
Table 1.1 – Current Ratings and Model Numbers for the Enhanced Field Supply
Kit..........................................................................................................1-1
Table 6.1 – Setting the Enhanced Field Supply Board and the Regulator Board
Jumpers ................................................................................................6-1
Table 7.1 – Parameter 500 Values When Jumpers are Set to B–C.........................7-3
Table 7.2 – Parameter 500 Values When Jumpers are Set to A–C.........................7-3

VI FlexPak 3000 Enhanced Field Supply Installation Instructions

Introduction 1-1
CHAPTER 1
Introduction
This instruction manual describes how to install and configure the optional Enhanced
Field Supply kit used by FlexPak 3000 DC Drives. The kit can be installed in FlexPak
3000 drives rated at 3 HP to 600 HP @ 460 VAC (1.5 HP to 150 HP @ 230 VAC). It
replaces the Standard Field Supply (P/N 610273-14R) already installed on 3 HP to
125 HP @ 460 VAC (1.5 HP to 60 HP @ 230 VAC) drives and the Field Current
Regulator (P/N 707973-10R, S, or T on 150 HP to 600 HP @ 460 VAC (75 HP to 150
HP @ 230 VAC) drives.
When installed in your drive, the Enhanced Field Supply kit provides you with greater
control over the drive’s field output, allowing you to match the rated field voltage of the
DC motor required for your application. For example, the Enhanced Field Supply
enables the drive to provide a 240 volt field to a motor from a 230 volt line. (See
chapter 6, Modifying the Drive Configuration, for more information.)
Two versions of the Enhanced Field Supply kit are available. They differ according to
the current rating. Each kit is supplied as an assembly that includes the Enhanced
Field Supply board and an attached wiring harness, as well as replacement fuses,
fuse labels, and mounting hardware. See figure 1.1 for an illustration of the Enhanced
Field Supply board. Enhanced Field Supply kit contents are shown in table 1.1.
Table 1.1 – Current Ratings and Model Numbers for the Enhanced Field Supply Kit
Kit Model
Number Current Rating Part Number Description Quantity
923FK0101 10 707973-15S Enhanced Field Supply Board 1
64676-30M Field Input Fuses (25 A, 600 V) 3
179540 Fuse Rating Label 4
D2-3413-1 Instruction Manual 1
923FK0201 20 707973-15R Enhanced Field Supply Board 1
64676-30M Field Input Fuses (25 A, 600 V) 3
179540 Fuse Rating Label 4
D2-3413-1 Instruction Manual 1

1-2 FlexPak 3000 Enhanced Field Supply Installation Instructions
1.1 Related Publications
This manual describes the Enhanced Field Supply kit and its associated FlexPak 3000
software parameters. You will also need the FlexPak 3000 DC Drive instruction
manuals, which describes the drive hardware and software.
1.2 Getting Assistance from Reliance Electric
If you have any questions or problems with the products described in this instruction
manual, contact your local Reliance Electric sales office. For technical assistance, call
1-800-726-8112.
Figure 1.1 – Enhanced Field Supply Board
Connect to
wireharness
Top View
Connect toP4onthe
Power InterfaceBoard
Side View

Installing the Enhanced Field Supply Kit on 3.0 HP to 60 HP @ 460 VAC (1.5 HP to 30 HP @ 230 VAC) Drives 2-1
CHAPTER 2
Installing the Enhanced Field Supply Kit
on 3.0 HP to 60 HP @ 460 VAC (1.5 HP to
30 HP @ 230 VAC) Drives
Installing the Enhanced Field Supply kit on 3.0 HP to 60 HP @ 460 VAC (1.5 HP to 30
HP @ 230 VAC) drives requires completing the following steps.Removing the OIM
cover and opening the carrier
•Removing the Standard Field Supply board
•Setting the jumpers on the Enhanced Field Supply board and the Regulator board
•Installing the Enhanced Field Supply board
•Replacing the drive fuses
•Closing the carrier and reinstalling the OIM cover
•Modifying the drive configuration
These steps are described in detail below.
When you have finished installing the kit, adjust the required drive parameters as
described in chapter 7 before using the drive.
2.1 Removing the OIM Cover and Opening the Carrier
Step 1. Turn off, lockout, and tag power to the drive.
!ATTENTION:Onlyqualified personnel familiarwith the construction and
operation of this equipment and the hazards involved should install,
operate, and/or service this equipment. Read and understand this
instruction manual in its entirety before proceeding. Failure to observe
this precaution could result in severe bodily injury or loss of life.
ATTENTION:Do not install modification kits with power applied to the
drive. Disconnect and lockout incoming power before attempting such
installation. Failure to observe this precaution could result in severe
bodily injury or loss of life.
!ATTENTION:The drive contains printed circuit boards that are static
sensitive. An anti-static wrist band should be worn by any person who
touches the drive’s components, connectors or leads. Erratic machine
operation and damage to, or destruction of, equipment may result if this
procedure is not followed. Failure to observe this precaution may result
in bodily injury.

2-2 FlexPak 3000 Enhanced Field Supply Installation Instructions
Step 2. Loosen the OIM cover retaining screws and remove the cover.
Step 3. Loosen the captive screw at the upper right corner of the drive’s Regulator
board carrier and swing it open.
2.2 Removing the Standard Field Supply Board
Step 1. Locate the Standard Field Supply board in the drive. See figure 2.1.
Step 2. Disconnect the drive’s wire harness connections from the existing field
supply board’s 581, 582, 583, F2/35 and F1/37 spade connectors.
Step 3. Follow the field supply board’s wire harness to the P4 connector on the
Power Interface board. Unplug the harness from the P4 connector.
Step 4. Locate the field supply’s four mounting screws on the outside of the drive’s
right side panel.
Step 5. Remove the four mounting screws from the outside of the drive and remove
the field supply board.
2.3 Adjusting the Jumpers on the Enhanced Field Supply
Board and the Regulator Board
Step 1. Refer to chapter 6 to determine the correct field output range jumpering for
your application.
Figure 2.1 – Removing the Standard Field Supply Board (3 HP to 60 HP @ 460 VAC Drives)
Carrier Field Supply
Harness
FlexPak Wire
P4 Connector
Power Interface Board
Standard

Installing the Enhanced Field Supply Kit on 3.0 HP to 60 HP @ 460 VAC (1.5 HP to 30 HP @ 230 VAC) Drives 2-3
Important: All Enhanced Field Supply boards are shipped with the wire jumper
connecting pins ”B” and ”C”. The actual field output voltage, once the
range is jumper selected, is adjusted through the drive’s OIM (Operator
Interface Module).
Step 2. If necessary, move the Enhanced Field Supply board’s wire jumper to select
an output voltage range. (pin “A” connected to pin “C” or pin “B” connected to
pin “C”.) See figure 2.2.
Step 3. Remove the four (4) screws securing the OIM to the Regulator board carrier
and move the OIM to gain access to the drive’s Regulator board. Do not
attempt to remove the OIM completely. See figure 2.3.
Step 4. Locate Regulator board jumper J21 (FIELD SUPPLY JUMPER).
Step 5. Move regulator board jumper J21 so that it matches the jumper setting of the
Enhanced Field Supply board (A–C or B–C).
Step 6. Reinstall the OIM on the Regulator board carrier.
Figure 2.2 – Setting the Jumpers on the Enhanced Field Supply Board
Figure 2.3 – Setting the Jumpers on the Regulator Board
Top View Jumper A-C for enhanced DC field voltage
between 0.90(VAC) and 1.12(VAC) **
** (VAC) = RMS Line to Line between
any two of 581 - 582 - 583.
Jumper B-C (as shown) for DC field voltage
between 0.45(VAC) and 0.90(VAC) **
Regulator Board Jumper J21 Location
Regulator Board
Regulator Board Carrier
Regulator Board
jumper J21
gain access to
Remove OIM to
(Qty4)
Remove Screws

2-4 FlexPak 3000 Enhanced Field Supply Installation Instructions
2.4 Installing the Enhanced Field Supply Board
Step 1. Remove the four mounting screws from the back of the Enhanced Field
Supply board.
Step 2. Working from the inside of the drive, align the Enhanced Field Supply board’s
mounting holes with the mounting holes on the drive’s right side panel. See
figure 2.4.
Step 3. Working from the ouutside of the drive, insert one of the mounting screws
(removed in step 1 through one of the mounting holes on the drive’s right side
panel and into the corresponding mounting hole in the Enhanced Field
Supply’s board. Tighten the screw to hold the board in place.
Step 4. Repeat step 3 for the remaining three mounting screws.
Step 5. Connect the drive’s wire harness to the Enhanced Field Supply board’s 581,
582, 583, F2/35, and F1/37 spade connectors. See figure 1.1 for the location
of the connectors.
Step 6. Plug the Enhanced Field Supply’s harness connector P4 into connector P4
on the drive’s Power Interface board. See figure 2.1.
Figure 2.4 – Installing the Enhanced Field Supply Board (3 HP to 60 HP @ 460 VAC Drives)
(Qty 4)
Mounting Screws
Field Supply
Side View

Installing the Enhanced Field Supply Kit on 3.0 HP to 60 HP @ 460 VAC (1.5 HP to 30 HP @ 230 VAC) Drives 2-5
2.5 Replacing the Drive Fuses
Step 1. Remove the three fuses labeled 6FU, 7FU, and 8FU from the drive’s fuse
block. See figure 2.5.
Step 2. Install the three provided 25 A, 600 V fuses (P/N 64676–30M) in the fuse
block in positions 6FU, 7FU, and 8FU.
Step 3. Locate the replacement fuse table on the back of the carrier. Attach one of
the adhesive fuse rating labels (P/N 179540) over each of the places
indicated in figure 2.6.
Figure 2.5 – Field Fuse Location (3 HP to 60 HP @ 460 VAC Drives)
Figure 2.6 – Attaching Replacement Drive Fuse Labels (3 HP to 60 HP @ 460 VAC Drives)
8FU
7FU
6FU
Top View
600V 25A

2-6 FlexPak 3000 Enhanced Field Supply Installation Instructions
2.6 Closing the Carrier and Reinstalling the OIM Cover
Step 1. Close the Regulator board carrier and secure it in place with its captive
screw.
Step 2. Reinstall the OIM cover and secure it in place with its screws.
Step 3. Reconnect power to the drive. Hardware installation is complete.
Step 4. Remove the lockout and tag.
Step 5. Turn on power to the drive.
2.7 Modifying the Drive Configuration
Go to chapter 7 and follow the procedures described there to set the parameters for
the Enhanced Field Supply kit.

Installing the Enhanced Field Supply Kit on 75 HP to 150 HP @ 460 VAC (40 HP to 75 HP @ 230 VAC) Drives 3-1
CHAPTER 3
Installing the Enhanced Field Supply Kit
on 75 HP to 150 HP @ 460 VAC
(40 HP to 75 HP @ 230 VAC) Drives
Installing the Enahnced Field Supply kit on 75 HP to 150 HP @ 460 VAC (40 HP to 75
HP @ 230 VAC) drives requires completing the following steps. Accessing the Field
Supply board
•Removing the Standard Field Supply board
•Removing the Field Current Regulator board
•Adjusting the Jumpers on the Enhanced Field Supply board and the Regulator
board
•Installing the Enhanced Field Supply board
•Replacing the drive fuses
•Reinstalling the auxiliary chassis cover
•Reinstalling the AC Disconnect
•Modifying the drive configuration
These steps are described in detail below.
When you have finished installing the kit, adjust the required drive parameters as
described in chapter 7 before using the drive.
!ATTENTION:Onlyqualified personnel familiarwith the construction and
operation of this equipment and the hazards involved should install,
operate, and/or service this equipment. Read and understand this
instruction manual in its entirety before proceeding . Failure to observe
this precaution could result in severe bodily injury or loss of life.
ATTENTION:The drive is at line voltage when connected to incoming
AC power. Disconnect, tag and lockout all incoming power to the drive
before performing the following procedure. Failure to observe this
precaution could result in severe bodily injury or loss of life.

3-2 FlexPak 3000 Enhanced Field Supply Installation Instructions
3.1 Accessing the Field Supply Board
Step 1. Turn off, lockout, and tag power to the drive.
If the drive is equipped with an AC line disconnect, go to step 5. Otherwise,
follow steps 2 through 4.
Step 2. Loosen the two screws at the right side of the motor terminal panel to free the
tabs on the auxiliary chassis cover. Do not to remove the screws completely.
See figure 3.1.
Step 3. Remove the top and bottom screws fastening the auxiliary chassis cover to
the drive’s right side panel.
Step 4. Loosen the middle screw that fastens the auxiliary chassis cover/circuit
breaker panel to the drive’s right side panel. Swing out the auxiliary chassis
cover and remove it.
Step 5. If there is enough clearance between the top of the AC disconnect and the
roof of the cabinet (drive enclosure), the field supply board can possibly be
removed and replaced from the top. This would bypass the procedure of
removing the AC disconnect. If you can remove and replace the field supply
board from the top and behind the AC disconnect, follow the steps in the next
section. If the AC disconnect must be removed for access to the field supply
board, refer to instruction manual D2-3395 (for CE-compliant drives) or
D2-3315 (non-CE-compliant drives).
3.2 Removing the Standard Field Supply Board (75 HP to
125 HP @ 460 VAC / 40 HP to 75 HP @ 230 VAC
Drives)
Step 1. Locate the Standard Field Supply board in the drive. See figure 3.1. If you
have an AC disconnect and elected not to remove it, skip to step 4, then
return to steps 2 and 3. Otherwise, continue with step 2.
Step 2. Disconnect the drive’s wire harness connections from the existing field
supply board’s 581, 582, 583, F2/35 and F1/37 spade connectors.
Step 3. Disconnect the Standard Field Supply board P4 connector from the S4.
Step 4. Remove the four (4) mounting screws from the outside of the drive’s right
side panel and remove the Standard Field Supply board from above and
behind the AC disconnect.
!ATTENTION:The drive contains printed circuit boards that are static
sensitive. An anti-static wrist band should be worn by any person who
touches the drive's components, connectors or leads. Erratic machine
operation and damage to , or destruction of,equipment may result if this
procedure is not followed. Failure to observe this precaution may result
in bodily injury.

Installing the Enhanced Field Supply Kit on 75 HP to 150 HP @ 460 VAC (40 HP to 75 HP @ 230 VAC) Drives 3-3
3.3 Removing the Field Current Regulator Board (150 HP
@ 460 VAC / 40 HP to 75 HP @ 230 VAC Drives)
Step 1. Locate the Field Current Regulator board in the drive. See figure 3.1.
Step 2. Disconnect the drive’s wire harness connections from the existing field
supply board’s 581, 582, 583, F2/35 and F1/37 spade connectors.
Step 3. Disconnect the Field Current Regulator cable assembly (P/N 707973–12R,
S, or T) FLD P6 and FLD P3 connectors from the Field Current Regulator
board. Also disconnect the oppositie end of this cable from J25. Do not
remove the cable.
Step 4. Remove the four (4) mounting screws from the outside of the drive’s right
side panel and remove the Field Current Regulator board.
Figure 3.1 – Removing the Field Supply Board (75 HP to 125 HP @ 460 VAC Drives)
Drive without AC Disconnect
Motor Terminal Panel
Drive with Aux. Chassis
Cover Removed
Drive with AC Disconnect
Field Supply
loosen middle screw
bottom screws;
Remove top and
Loosen screws Loosen screws
Remove top and
bottom screws;
loosen middle screw
Remove 4 screws

3-4 FlexPak 3000 Enhanced Field Supply Installation Instructions
3.4 Adjusting the Jumpers on the Enhanced Field Supply
Board and the Regulator Board
Step 1. Refer to chapter 6 to determine the correct field output range jumpering for
your application.
Important: All Enhanced Field Supply boards are shipped with the wire jumper
connecting ”B” and ”C”. The actual field output voltage, once the range is
jumper selected, is adjusted through the drive’s OIM (Operator Interface
Module).
Step 2. If necessary, move the Enhanced Field Supply board’s wire jumper to select
an output voltage range (pin ”A” connected to pin ”C” or pin ”B” connected to
pin ”C”). See figure 2.2.
Step 3. Loosen the OIM cover retaining screws and remove the cover.
Step 4. Remove the four (4) screws securing the OIM to the Regulator board carrier
and move the OIM to gain access to the drive’s Regulator board. See figure
2.3.
Step 5. Locate Regulator board jumper J21 (FIELD SUPPLY JUMPER). See figure
2.3.
Step 6. If necessary, move Regulator board jumper J21 so that it matches the jumper
setting of the Enhanced Field Supply board (A–C or B–C).
Step 7. Reinstall the OIM on the Regulator board carrier.
Step 8. Reinstall the OIM cover.
3.5 Installing the Enhanced Field Supply Board
If you have an AC Disconnect, and elected not to remove it, do steps 5 and 6 first.
Then return to step 1. If the drive does not have an AC Disconnect, begin with step 1.
Step 1. Remove the four mounting screws from the back of the Enhanced Field
Supply board.
Step 2. Working from the inside of the drive, align the Enhanced Field Supply board’s
mounting holes with the mounting holes on the drive’s right side panel. See
figure 3.2. Orient the Enhanced Field Supply board so that the end with the
transformer points to the front of the panel.
Step 3. Working from the outside of the drive, insert one of the mounting screws
(removed in step 1) through one of the mounting holes on the drive’s right
side panel and into the corresponding mounting hole on the Enhanced Field
Supply board. Tighten the screw only enough to hold the board in place.
Step 4. Repeat step 3 for the remaining three mounting screws. Tighten all four
screws.
Step 5. Connect the drive’s wire harness to the Enhanced Field Supply board’s 581,
582, 583, F2/35, and F1/37 spade connectors. See figure 1.1 for the location
of the connectors.
Step 6. Plug the Enhanced Field Supply’s harness connector P4 into the wire
harness with connector S4.