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SECTION 1 INTRODUCTION 1.
DANGER CONTROLLER EQUIPMENT IS AT LINE VOLTĆ AGE WHEN AĆC POWER IS CONNECTED TO THE POWER UNIT IN THE FLEXPAK PLUS CONTROLLER. THUS AĆC POWER MUST BE REMOVED FROM THE UNIT BEFORE IT IS SAFE TO TOUCH INTERNAL PARTS OF THE CONĆ TROLLER. PERSONAL INJURY MAY RESULT UNLESS POWER IS REMOVED. WARNING DO NOT OPERATE THE FLEXPAK PLUS CONĆ TROLLER ON POWER SUPPLIES WITH AVAILĆ ABLE SHORTĆCIRCUIT CURRENTS IN EXCESS OF 5000 AMPERES. DAMAGE TO EQUIPMENT AND PERSONAL INJURY MAY OCCUR.
SECTION 2 GENERAL CONTROLLER INFORMATION 2.0 General - The FlexPak Plus DĆC VKS drive conĆ The FlexPak Plus controller is provided, as standard, in a chassis type configuration for panel mounting within a larger electrical enclosure. The Remote Operator Controls may then be placed on the larger enclosures face or some distance away.
Table 2.A - FlexPak Plus Features Summary Feature Category Controller Functions D D D D D D D D D D START/STOP RUN/JOG FORWARD/REVERSE Speed selection (5 to 100%) Unidirection operation with coastĆtoĆrest on stop command standard. (Dynamic braking and reversing available as options.) 20:1 controlledĆspeed range by means of armature voltage control. Auxiliary Panel armature loop contactor removes power to drive motor.
2.
Table 2.B - Specifications AĆC Line input Voltage 230/460 VAC (nominal, 60 HZ) 220/440 VAC (nominal, 50 Hz) three phase only Line Voltage Variation 10% of nominal AĆC Line Frequency Three Phase, 50/60 Hz Line Frequency Range 48Ć62 Hz Output Voltages (armature and field) See Table 2.
Table 2.C - Fuse Requirements WARNING IN THE OPTIONAL BASIC DRIVE, THE USER MUST INSTALL AN M CONTACTOR THAT HAS A 115 VAC COIL WITH A MAXIMUM CURRENT DRAW OF 440 MILLIAMPS. THE CONTACTOR ADAPTER KIT MUST BE INSTALLED WITH THE USER'S M CONTACTOR. (REFER TO DĆ3955) PERSONAL INJURY MAY OCCUR IF THIS IS NOT INSTALLED. HP 3Ć10 15 20 3Ć20 25Ć30 40 2.4.5 AĆC Line Fuse Requirements - AĆC line protecĆ tion is provided with the Auxiliary Panel.
SECTION 3 INSTALLATION 3.0 General - This Section outlines the procedures that are to be followed in order to properly install a FlexĆ Pak Plus controller. WARNING THE USER IS RESPONSIBLE FOR CONFORMĆ ING WITH THE NATIONAL ELECTRICAL CODE WITH RESPECT TO MOTOR, CONTROLLER AND OPERATOR DEVICE INSTALLATION, WIRĆ ING AND STARTĆUP.
Guideline 3 - Regardless of the above placement guidelines, the user is responsible for providing ambiĆ ent temperatures that meet the controllers specificaĆ tions of 0° to 55°C (32° to 131°F). This must be given careful consideration especially to units located near the very top of the supplied enclosure. Relative humidity must be kept between 5 and 95% without condensaĆ tion. D Personal injury is guarded against should accidental contact be made with an electrical conductor from the drive.
3.3 Power Wiring % $ $ # $ + "'& ! % Guideline 11 # $ & "! & &' "( % ( + !"& * & $ & "$% #") $ "$ & "( & % & &' & #$" '$ % &" " ") ) ! ) $ ! , #") $ %'#, # + ! % &" & "!&$" $ ! , "!&$" $ ' &% &" & $ ( % "!! & "! $ % ( ! & '$ 3.
#)' - + 2 +$/ )-)+ 3ĆPHASE PLANT POWER )- ) .' + )- ,0$- # (,-+.' (- (- +! )+ )&- " )&&)0 + $- ,0$- # #)' - + ,0$- # % $- ) .' + +) ,, )(-+)& )+ .-) ! + ( (*.-, ,0$- # Notes: 1> These signals must be run in a separate magnetic conduit to minimize the possibility of noise pickup. (Refer to Table 7.B for wire specifications.
WARNING IN THE OPTIONAL BASIC DRIVE, THE USER MUST INSTALL AN M CONTACTOR THAT HAS A 115 VAC COIL WITH A MAXIMUM CURRENT DRAW OF 440 MILLIAMPS. THE CONTACTOR ADAPTER KIT MUST BE INSTALLED WITH THE USER'S M CONTACTOR. (REFER TO DĆ3955) PERSONAL INJURY MAY OCCUR IF THIS IS NOT INSTALLED. All interconnecting wire should primarily be sized and installed in conformance with N.E.C., C.E.C. or local codes. Refer to the controller and motor nameplates for electrical data.
HP/SCALING PINS Figure 3.6 - Regulator Module, HP/Current Scaling Pins Step 3 - On the Regulator Module, locate the scaling pins. (Refer to Figure 3.6.) Near them, locate the black pigĆtail type jumper. Do not move it if it is connected to the proper pin. If it must be reconnected, carefully lift connector housing straight up and off the pin. Slide the connector straight down over the proper pin. nently fixed to the Regulator Module, must be moved to one of two positions.
WARNING armature voltage relays or a motor overspeed switch. (Assuming the drive equipment is operated on three phase power supplies listed below.) DANGER THE MACHINERY BUILDER IS RESPONSIBLE FOR INSURING THAT DRIVEN MACHINERY, ALL DRIVETRAIN MECHANISMS NOT SUPPLIED BY RELIANCE ELECTRIC AND PROCESS LINE MAĆ TERIAL ARE CAPABLE OF SAFE OPERATION AT MAXIMUM SPEEDS. FAILURE TO DO SO CAN RESULT IN DESTRUCTION OF MECHANISM OR MATERIAL AND FLYING FRAGMENTS, ENĆ DANGERING OPERATING PERSONNEL.
SECTION 4 STARTĆUP AND ADJUSTMENT 4.
DANGER IF CIRCUIT BREAKER HAS TRIPPED OR FUSES HAVE CLEARED THE FIELD SUPPLY, ITS WIRĆ ING MUST BE INSPECTED FOR DAMAGE. REAPPLYING POWER TO THE DRIVE, THE FIELD VOLTAGE MUST BE REĆCHECKED FOR PROPER VOLTAGE AT MOTOR TERMINALS F1, F2. IF THIS VOLTAGE IS BELOW 90% OF THE FIELD VOLTAGE SPECIFIED ON THE MOTOR NAMEPLATE, THE DRIVE MUST NOT BE STARTED UNTIL PROPER VOLTAGE IS OBĆ TAINED.
& " ! % - The Minimum Speed Potentiometer on the regulator has been factory preset for drive minimum speed, 5%. By means of adĆ justment, this speed may be raised or lowered. The reĆ sult is the lowest moving speed the operator can set on the SPEED dial. The control range is 5% to 30% of rated speed.
SECTION 5 TROUBLESHOOTING 5.0 General - This Section details troubleshooting information for the FlexPak Plus controller. Its organizaĆ tion is as follows: D General troubleshooting concepts (Paragraphs 5.1, 5.2, 5.3 and 5.4) D Specific symptom/probable cause/recommended procedures (Paragraph 5.5) D Reference schematics, photos and diagrams of the controller (Paragraph 5.6) D The Diagnostor which is a portable device about the size of a digital voltmeter.
5.3 Motor Problems - Do not overlook the possiĆ bility that the malfunction may be located in the drive motor. The following steps should become part of a troubleshooting routine: D Recheck all motor connections for firmness and correct identification. D Check that no obvious grounds have occurred on any of the wires. However, do not use a megger when checking for grounds unless the motor wiring to the FlexPak Plus controller is completely disconĆ nected.
TABLE 5.A - TROUBLESHOOTING SUGGESTIONS FOR THE COMPLETE CONTROLLER Symptom 1. POWER ON/OFF circuit breaker trips or fuses clear when power is apĆ plied. Probable Cause Recommended Procedures Incorrect wiring conĆ nections to controller; from controller to moĆ tor; in motor. DANGER IF CIRCUIT BREAKER HAS TRIPPED OR FUSES HAVE CLEARED,THE FIELD SUPPLY AND ITS WIRING MUST BE INSPECTED FOR DAMAGE.
TABLE 5.A - TROUBLESHOOTING SUGGESTIONS FOR THE COMPLETE CONTROLLER (Continued) Symptom 4. 5. 6. Probable Cause In reversing conĆ trollers only . . . Controller's M contactor not picking up when START switch is pressed (closed). FORWARD/REVERSE switch malfunction, V Examine Remote Operator Adapter on Regulator Module for firm seating and proper wiring and pin connections. V Test FORWARD/REVERSE switch. Use basic technique outlined above for the START/STOP switch. M contactor malfuncĆ tioning.
TABLE 5.A - TROUBLESHOOTING SUGGESTIONS FOR THE COMPLETE CONTROLLER (Continued) Symptom 8. Drive motor does not run with M contactor picked up. Potentiometer properly operatĆ ing. Probable Cause No output from Power Cubes, 45Ć47. Recommended Procedures V Examine armature wiring. First, open the power disconnect switch. V Check armature wiring for loose connections. V Turn aĆc power on again. DANGER THE PROCEDURE DESCRIBED HERE IS PERFORMED WITH LIVE AĆC VOLTAGE APPLIED TO THE CONTROLLER.
4FU, 5FU, 6FU OPTIONAL INCOMING LINE INCOMING CIRCUIT BREAKER LINE FUSES 1FU, 2FU FIELD SUPPLY FUSES 3FU, 7FU 8FU, 9FU CONTROL FUSES Figure 5.
M CONTACTOR PILOT RELAY DV/DT MODULE INCOMING LINE FUSES Figure 5.6 - Top View of Controller STATUS/DIAGNOSTICS INDICATOR & DIAGNOSTOR INPUT CONNECTOR REGULATOR/ DRIVE ASSEMBLY MOUNTING SCREWS REGULATOR/ DRIVE ASSEMBLY MOUNT SCREWS DIGITAL DRIVER MODULE RIBBON CABLE GATE LEADS FIELD SUPPLY BRIDGE Figure 5.
Figure 5.
Figure 5.
Figure 5.
Figure 5.
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Figure 5.
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Figure 5.
Figure 5.
NOTE SHEET 1> Function of panel rating, see Sh. 8. 2> If motor has series field, wire between 45/52 and FM contact is removed, and series field kit installed. 3> This contact is present only on Assy. No. 802220–RB & SB. 4> For Current Scaling, see table on Sh. 9. 5> For Feedback select, see table on Sh. 9. 6> Remove jumper (J4) if Auto/Manual switch is used. 7> Remove jumper (J9) if Reverse Contactor kit is used.
DANGER 15> A.) AN EXTERNAL, U/L LISTED, FUSED DISCONNECT OR CIRCUIT BREAKER IS REQUIRED TO PROVIDE NEC OR CEC DISCONNECT AND OVERCURRENT PROTECTION. B.) MAXIMUM PERMISSIBLE AVAILABLE SYMMETRICAL RMS SHORT CIRCUIT POWER SUPPLY CAPACITY: 5000A. 16> When installing replacement power cubes, apply a very thin, uniform thickness film of DOW #111 to mounting surface. Film is too thick if it squeezes out around power cube after power cube is torqued down.
DANGER EQUIPMENT IS AT LINE VOLTAGE WHEN AC POWER IS CONNECTED TO THE POWER UNIT. 3 PHASE AC POWER LINE MUST BE DISCONNECTED FROM THE POWER UNIT BEFORE IT IS SAFE TO TOUCH ANY INTERNAL PARTS OF THIS EQUIPMENT. START UP CHECK LIST A. B. BEFORE AC POWER IS APPLIED: 1. DRIVE IS SUPPLIED AS A VOLTAGE REGULATOR. IF USED AS A VOLTAGE REGULATOR, CHECK THAT JUMPER AT L51 ON THE REGULATOR CARD IS CONNECTED TO PIN “A” (ARMATURE FDBK)AT l52 SEE W/D SHEET 2 OR I/M. 2.
1. 2. 3. 4. 5. 6. CURRENT LIMIT: a) FACTORY PRESET TO 150%. ADJUST AS DESIRED FOR MAX. CURRENT 150%. (CCW DECREASES CURRENT). b) DOT #4 IS APPROXIMATELY 100%. MAX SPEED: a) SET MAX. SPEED AND MIN SPEED POTS CCW. b) SET SPEED (OR VOLTAGE) CONTROL POT TO MINIMUM. c) START DRIVE AND GRADUALLY INCREASE SPEED (OR VOLTAGE) CONTROL POT TO MAXIMUM. WAIT UNTIL SPEED STABILIZES. d) INCREASE MAX. SPEED POT UNTIL DESIRED MAX. SPEED (SPEED REGULATOR) OR MAX. VOLTAGE (VOLTAGE REGULATOR) IS ATTAINED.
SECTION 6 REPLACEMENT PARTS 6.0 General , +, ,"(.% (',# + & #'- #'#'! ,-( $ %('! /#-" ) +- '.& +, ' *. '-#-# , -. %%0 ., #' ( ,) + ) +-, % %#,-, -" &(+ (&&(' ) +-, -" ('-+(%% + Table 6.
Table 6.
SECTION 7 THREE PHASE FLEXPAK PLUS MODIFICATION KIT INSTRUCTION MANUALS 7.0 General - A number of optional features in the form of Modification Kits are offered with the three phase, FlexPak Plus controller. Each of these Kits exĆ tends the control of the unit and tailors its operation to specific application needs. This Section describes the procedures that must be folĆ lowed to install the Kits. Refer to Table 7.A for an informaĆ tional listing.
Table 7.A - Modification Kit Quick Reference List (Continued) Kit Instruction Manual Number Model No.
Table 7.B - Wire Specifications Use in Controller Type Conductor Required Characteristics Acceptable Types CONTROL WIRES D D D D Remote Operator Control Station: AUTO/MANUAL JOG/RUN FORWARD/REVERSE START/STOP D Single conductor and/or multiĆconductor D D D D Stranded copper AWG No. 16 600 VAC rating Insulation: polyvinyl chloride (PVC) D Temperature range: 40°-105°C (104°-221°F) D Unshielded D Any single conductor meeting N.E.C.
J9 J8 J4 J10 Figure 7.
TABLE OF CONTENTS Section Title Page 1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX OF FIGURES Figure Title Page Figure 1.1 - FlexPak Plus Complete w/Optional Status Diagnostic Indicator and Super RPM Motor . . . . 1 Figure 2.1 - Basic Controller and Auxiliary Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Figure 2.2 - FlexPak Plus DĆC VKS Drive 3 Ć40 HP Complete Controller Open Cover of Basic Drive . . . . 5 Figure 3.1 - Enclosure Mounting Minimum Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX OF TABLES Table Title Page Table 2.A - FlexPak Plus Features Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Table 2.B - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Table 2.C - Fuse Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
U.S. Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication D-3938-2– December 1991 Copyright © 1991 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
