DC Drives

 

 A three-phase digital DC drive for regenerative and non-regenerative applications from 1.5-600 HP

| Standard Features | Operator Features | Optional Features | Dimensions | Selection | Ratings & Info. |

The FlexPak 3000 digital DC drive features a unique ergonomic user interface that makes for easy application, installation, start-up, operation, maintenance and service. The use of the latest in digital, micro-integrated semiconductor and circuit technology combines simplicity, flexibility and reliability in a compact package.

Simple: All control, signal and power field wiring is readily accessible through supplied terminal boards to streamline installation.

Setup and operation is coordinated with a large graphics display and keypad using plain text. Diagnostic and status information as well as help text are displayed and entered in one of five languages easily selected through the keypad. A "Quick-Start" menu combines with self tuning of the speed and current loops to ensure straightforward drive setup and startup.

Flexible: While most applications are handled through standard drive software, many standard hardware kits and options are available allowing the drive's capability to be expanded with ease. The FlexPak 3000 is easily modified for input line voltages and frequencies used in many countries and displays setup, operating, status and diagnostic information in five different languages.

Reliable: The FlexPak 3000 uses the latest in high density power semiconductor devices, surface mount and sub micron ASIC technology. A power interface board circuit provides the noise suppression and firing circuits and connects to the digital regulator with only a single ribbon cable.

Compact: Extensive use of molded parts allows for a high density power module without compromising the accessibility of options and circuits. The packaging is compact yet allows for easy field wiring, mounting, modification or service. The basic chassis design can be easily converted to a NEMA 1 enclosure using available NEMA I conversion kits or floor mount NEMA I enclosures for high HP controllers.

Standard Features

AC Supply

  • 50/60 Hz AC line frequency input
  • Phase insensitive AC line input
  • Semi-conductor fuse protection
  • AC "N" contactor

Power Section

  • Full-wave, full control 6-SCR 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 1-minute
  • DC inverting fault fuse protection on Regenerative controllers (optional inverting fault circuit breaker)

User/Adjustments
(All adjustable in Quick Start Menu)

  • 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

Analog Signals (12 bit resolution)

  • 10 VDC manual speed reference
  • User selectable +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)

Digital Signals

  • Coast stop, auto/manual, forward/reverse, jog, run 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

Other Significant Standard Features

  • Self-tuning of speed and current loops without disconnecting the fields
  • Field (current) loss protection
  • User selectable stop modes
    • Coast
    • Current limit
    • Ramp
  • Local controls with interactive keypad and display for drive set up, drive operation, metering and diagnostics (including fault and alarm logs)

Standard Operator Interface Features

  • Complete operator controls for run, stop, forward/reverse, auto/manual, control source select and fault log
  • "Quick Start", sequence for easy, complete drive set up
  • Large, Easy-to-Read LCD display provides the following:
  • Built-in digital metering which are selectable in units proportional to speed or current such as FPM (feet per minute), percent load, or other user defined units
  • Display text in any of the following languages:
    • - English, German, French, Spanish, Italian
  • Monitor of multiple parameter values in a single display such as speed and load
  • Adjustments and monitoring using on-screen menus and full, non-abbreviated text
  • Drive status display indicators:
    • Drive Running Drive Running
    • Drive Alarm Current/torque limit
    • Interlocks are OK Drive ready
  • Extensive Diagnostics (with displayed recommended corrective action)
    • AC line voltage high/low alarm
    • Motor brush wear alarm
    • Loss of AC line synchronization fault
    • Failed SCR fault
    • Motor thermostat fault
    • Control 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

Optional Features

  • Incoming AC line disconnect
  • Fused blower motor starter with adjustable overload
  • NEMA I conversion kits and floor mount
    NEMA 1 and NEMA 12 enclosures
  • Remote mountable OIM kit for mounting in cabinet doors
  • Dynamic braking kits available for customer panel mount or NEMA 1 enclosed
  • Enhanced field supply kit provides for the following:
    • Electronic field trim
    • Field economy
    • 240 VDC field on 230 VAC controllers
    • 230 VAC controllers can be set for field voltages 103 VDC-259VDC
    • 460 VAC controller can be set for field voltages 207 VDC-515 VDC
  • Field Current regulators for above base speed operation and field economy
  • Pulse tachometer feedback kit provides .01% speed regulation via digital pulse tach speed feedback
  • AC tachometer feedback kit for use with existing motor mounted AC tachometers
  • I/O expansion cards expands drive capability to do dancer follower functions, outer control loops, external MOP, preset speeds, analog or frequency output signals, HP/KW output signals, speed or current level detector outputs
  • 115 VAC control circuit interface for separate mounting on chassis drives or mounted on enclosed drives
  • AutoMax network interface option card
  • DeviceNet communication option card
  • CS3000 WINDOWS-based configuration executive for upload/download, monitor and drive control capability.

Dimension Drawings of FlexPak 3000 Chassis / NEMA Conversion Kit

Controller Selection

HP

Non-Regenerative

Regenerative

 

230 VAC

460 VAC

230 VAC

460 VAC

1.5

1FN2032(2)

-

1FR2032(2)

-

2

2FN2032(2)

-

2FR2032(2)

-

3

3FN2032(2)

3FN4032(2)

3FR2032(2)

3FR4032(2)

5

5FN2032(2)

5FN4032(2)

5FR2032(2)

5FR4032(2)

7.5

7FN2032(2)

7FN4032(2)

7FR2032(2)

7FR4032(2)

10

10FN2032(2)

10FN4032(2)

10FR2032(2)

10FR4032(2)

15

15FN2032(2)

15FN4032(2)

15FR2032(2)

15FR4032(2)

20

20FN2032(2)

20FN4032(2)

20FR2032(2)

20FR4032(2)

25

25FB2032(2)

25FN4032(2)

25FR2032(2)

25FR4032(2)

30

30FN2032(2)

30FN4032(2)

30FR2032(2)

30FR4032(2)

40

40FN2032(2)

40FN4032(2)

40FR2032(2)

40FR4032(2)

50

50FN2032(2)

50FN4032(2)

50FR2032(2)

50FR4032(2)

60

60FN2032(2)

60FN4032(2)

60FR2032(2)

60FR4032(2)

75

75FN2031

75FN4031

75FR2031

75FR4031

100

100FN2031

100FN4031

100FR2031

100FR4031

125

125FN2031

125FN4031

125FR2031

125FR4031

150

150FN2031

150FN4031

150FR2031

150FR4031

200

-

200FN4031

-

200FB4031

250

-

250FN4031

-

250FB4031

300

-

300FN4031

-

300FB4031

400

-

(1)

-

(1)

500

-

(1)

-

(1)

600

-

(1)

-

(1)

(1) Available September 1997

(2) Drive will meet CE compliance if installed, wired, and grounded for compliance.

Controller Ratings (1)

HP
Ratings

Full Load Rated RMS
AC Line Current
(Amperes)

Full Load Rated RMS
DC Armature
Current
(Amperes)

Rated Field Current
(Amperes)

 

230 VAC

460 VAC

240 VDC

500 VDC

150 VDC

300 VDC

1.5

10

-

7

-

10

-

2

11

-

9

-

10

-

3

13

10

12

6

10

10

5

19

12

20

10

10

10

7.5

26

15

29

14

10

10

10

33

18

38

19

10

10

15

48

24

55

27

10

10

20

63

31

73

35

15

10

25

80

39

93

45

15

10

30

94

45

110

52

15

10

40

125

63

146

73

15

15

50

154

74

180

86

15

15

60

186

86

218

100

15

15

75

226

110

265

129

20

15

100

307

143

360

167

20

15

125

370

177

434

207

20

15

150

443

213

521

250

20

20

200

-

281

-

330

-

20

250

-

351

-

412

-

20

300

-

421

-

495

-

20

400 (1)

-

550

-

640

-

20

500 (1)

-

689

-

800

-

20

600 (1)

-

833

-

960

-

20

(1) Available up to 575 VAC.

Service Conditions

Standard Altitude

to 3300 feet (1000 meters)

Standard Ambient Temperature

 

Cabinet Units

0-40ƒC (32ƒF to 104ƒF)

Chassis Units

0-55ƒC (32ƒF to 131ƒF)

AC Line Voltage Variation

+/- 10%

AC Line Frequency

48/62 Hz

AC Line Distribution System KVA Capacity (1)

 

Maximum 3 drives per transformer (1) FlexPak 3000 drives are 50/60Hz.

 

Atmosphere Non-condensing

 

Relative Humidity 5 to 95%

 

Efficiency and Power Factor

Displacement Power Factor at Maximum Speed

88%

Efficiency of Power Module at:

 

100% Speed and 100% Load

99.3%

100% Speed and 25% Load

98.5%

25% Speed and 100% Load

96.8%

25% Speed and 25% Load

94.0%

Efficiency of drive including motor is typically 87%.

 

Capacities

Service Factor

1.0

Maximum Load

150% for one minute

Speed Range

Operating Range

1% to rated speed(2)

Range for quoted Regulation (Typical)

200:1(2)

Continuous Speed Range for Force-Ventilated Motors:

100% rated torque down to 5% base speed.

Speed Regulation

Speed Regulated with Digital Tachometer .01%

Speed Regulated with Analog Tachometer 1.0%

Speed Regulated with Armature Voltage Feedback 2.0%

(1) When applying FlexPak 3000 drives to power distribution systems with KVA capacity in excess of five times
the smallest drive rating use of an isolation transformer or line reactors of similar impedance is required.

(2)Dependent of top speed and pulse tachometer used.
5PY = 30:1
RD120 = 70:1
RL1024 = 200:1

Note: This material is not intended to provide operational instructions.

 Appropriate Reliance Electric Industrial Company instruction manuals
and precautions should be studied prior to installation, operation, or
maintenance of equipment.

Copyright 1997 Rockwell International, Inc.