FlexPakr 3000 Field Current Regulator Kit Installation Instructions
Contents
1. o S om le o o o o o e e e O 3 181 182 1183 FlexPak 3000 Drive with AC Disconnect Field Supply FlexPak 3000 with Aux Chassis Cover Removed Remove 4 screws Remove top and bottom screws loosen middle screw Figure 3 1 Removing the Standard Enhanced Field Supply 75 150 HP Drives Field Current Regulator Cable Assembly Field Current Regulator Cable Assembly FRONT VIEW Field Current Regulator Figure 3 2 Cable Routing 75 150 HP Drives 4 0 INSTALLING THE FIELD CURRENT REGULATOR KIT ON 100 150 HP 230 VAC AND 200 300 HP 460 VAC DRIVES DANGER ONLY QUALIFIED PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL ADJUST 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 DANGER THE DRIVE IS AT LINE VOLTAGE WHEN CONNECTED TO INCOMING AC POWER DISCONNECT TAG AND2. Figure 4 1 Removing the Standard Enhanced Field Supply 200 300 HP Drives is 4 bp N f 288 289 581 582 585 CONTROL HARNESS G CURR CABLE Figure 4 2 Cable Routing 200 300 HP Drives 5 0 MODIFYING THE DRIVE CONFIGURATION Before you can use the Field Current Regulator kit you must set the parameters listed below in the FlexPak 3000 drive These parameters are described in sections 5 1 and 5 2 9 Parameter 510 MOTOR HOT FLD AMPS 9 Parameter 511 FIELD ECONOMY REF In addition the input parameters listed below may need to be adjusted in order to tune the field control loop Refer to your drive s instruction manual for a complete description of these parameters FIELD ECONOMY DELAY FIELD LOSS THRESHOLD FIELD REF REGISTER FIELD PI PROP GAIN FIELD PI LEAD FREQ FLD FEEDBACK GAIN ADJ FIELD AUTO WEAKEN FLD WEA
3. 38 1 8 NIVI dOdd N3XV3 NOILVSN3dWO3 at 8383 3 N3 V3 DN VOS SdWV Wav 38 4 495 034 8 8818 T 2300 ONT IH 17130 01 13 1C 780577 d Q 538 1 727 7 N3XV3 114 N3 w3 Di1nv 3 4 WI1 IH V113 ray NIVO 3 80333 114 SdWV 4 10H 804184 3s NIVO Bunos 380334 4 88 1313 80334 01312 j 338 AWONOD3 1314 001 AIT NIJD SdWv 4 LOH SOLOW 31907 AddNS 9 8 4 UA DINN bi 01314 pod Id Ozz W31SI038 438 314 1130 0314 ON333438 073135 di GAIL2V AWONODS 7314 C14 10H X0LOW 8384 V3 Id 7314 NIV9 dO amp d Id 1313 8 1 3 88 3 13 Figure 1 Field Control Loop A 2 NSTANT T E NSTANT P c c VOLTAGE H uJ a SC LL ARMATURE RCEN CEN PER Figure A 2 Drive Operation Over the Constant Torque and Constant Power Range Field Curre
4. Step 8 Step 9 Step 10 Insert the tabs on the left side of the auxiliary chassis cover into the slots on the right side of the drive s motor terminal panel Align the auxiliary chassis cover over the middle screw on the drive s right side panel and over the top and bottom mounting holes Insert the top and bottom screws into the mounting screw holes and then tighten all three mounting screws top bottom and middle Tighten the two screws on the right side of the motor terminal panel to secure the auxiliary chassis cover s tabs in place Drives with an AC line disconnect only Align the AC line disconnect over the mounting holes on the auxiliary chassis cover then secure it in place with the four screws removed earlier Close the OIM carrier and secure it in place with its captive screw Reinstall the drive cover and secure it in place with its screws Hardware installation is complete Reconnect power to the drive Remove the lockout and tag Turn on power to the drive Modifying the Drive Configuration Go to chapter 5 for information on setting parameters for the Field Current Regulator kit 3 3 Motor Termina 650 oe y AUXILIARY 9 1 CHASS COVER FlexPak 3000 Drive without AC Disconnect Loosen screws Loosen screws Remove top and bottom screws loosen middle screw
5. Set MOTOR HOT FLD AMPS to the value printed on the motor nameplate Select MEMORY SAVE by taking the following path from the main menu Operator Interface L Memory Operations Perform the Memory Save operation If the motor field winding was disconnected in step 2 above perform steps 13 17 Otherwise go to step 18 Step 13 Step 14 Step 15 Step 16 Step 17 Step 18 Step 19 Disconnect tag and lockout power to the drive Reconnect the motor field winding to the drive Reconnect power to the drive Remove the lockout and tag Turn on power to the drive Access the Fault menu by pressing the FAULT key until FAULT appears on the OIM directly above the FAULT key Select Clear Fault Log and Reset Faults and then press ENTER The fault log will be cleared and all drive faults will be reset If you have an OIM you are done with setting parameter 510 Go to section 5 1 to set parameter 511 FIELD ECOMOMY REF NOTE Performing a Restore Defaults operation will cause the Field Current Regulator to re enter the fixed voltage mode of operation and require the re execution of the above steps If the drive is equipped with a DCM use the following steps to set MOTOR HOT FLD AMPS Step 20 Step 21 Step 22 Step 23 Step 24 From the main menu scroll to Input Parameters and press ENTER Scroll to HOT FLD AMPS Set HOT FLD AMPS to the value printed on the motor nameplate From the main menu scroll to Memory Operatio
6. 1 Removing the Standard Enhanced Field Supply 200 300 HP Drives 4 4 Figure 4 2 Cable Routing 200 300 HP Drives 4 4 Figure A 1 Field Control Loop cc cdsnees d prati RN Ek E rx E EE E RR o ERE REG ER RE RUE A 2 Figure A 2 Drive Operation Over the Constant Torque and Constant Power Range A 3 List of Tables Table 1 1 Verifying the Field Current Regulator Kit Matches the Drive 1 1 Table 1 2 Field Current Regulator Kit Content 1 1 Table A 1 Field Current Feedback Scaling sssssssssssssssses ee en A 3 1 0 INTRODUCTION The products described in this instruction manual are manufactured or distributed by Reliance Electric Industrial Company This instruction manual describes how to install and configure the optional Field Current Regulator kits used by FlexPak 3000 drives The Field Current Regulator which includes a field regulator and a field supply can be used only in drives that have software version 3 00 REGULATOR SW VERSION parameter 3 00 or later When the kit is installed a field control loop is enabled allowing the user to adjust field control functions The field control loop operates in both the constant torque armature control range and the constant power field control range See Appendix A for a description of the field control loop There are three Field Current Regulator kits available for use in FlexPak 3000 drives They differ according to
7. Field Current Regulator cable assembly with the REG P25 connector through the opening in the carrier above the ribbon cable Connect the REG P25 connector to the J25 terminal on the Regulator board See figure 2 3 Slide the Regulator board back into place and secure it with its mounting screws Reinstall the OIM DCM 4 5 4 6 4 7 4 8 Reinstalling the OIM Carrier and Cover Step 1 Swing the mounting panel back into the closed position and secure it by twisting the notches on the two plastic anchors into a horizontal position Step 2 Close the OIM carrier and secure it in place with its captive screw Step 3 Reinstall the OIM DCM cover Replacing the Drive Fuses Step 1 Locate the fuse block on the drive s line fuse panel See figure 4 2 Step 2 Remove the three fuses labeled 6FU 7FU and 8FU from the fuse block Step 3 Install the three provided 25 Amp 600 Volt fuses P N 65676 30M in the fuse block in positions 6FU 7FU and 8FU Reinstalling the Drive Cover Step 1 Reinstall the cover over the right side of the drive Step 2 Reinstall the plastic cover over the drive s line fuse panel Hardware installation is complete Step 3 Reconnect power to the drive Step 4 Remove the lockout and tag Step 5 Turn on power to the drive Modifying the Drive Configuration Go to chapter 5 for information on setting parameters for the Field Current Regulator kit 4 8
8. Interface board s P4 connector See figure 2 1 Remove the four 4 mounting screws from the outside of the drive s right side panel and remove the field supply board Installing the Field Current Regulator Board Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Remove the four 4 mounting screws from the back of the Field Current Regulator board Connect the drive s wire harness connectors labeled 581 582 583 F2 35 and F1 37 to the corresponding terminals on the Field Current Regulator board See figure 1 1 for the location of the terminals Attach the Field Current Regulator cable assembly P N 707973 12S FLD P6 and FLD P3 connectors to the corresponding terminals on the Field Current Regulator See figure 1 1 Route the free end of the Field Current Regulator cable assembly under the fuse block through the grommet and across the heat sink to the left side of the drive following the same path as the red and blue control wiring harness Then run the cable assembly inside the front of the drive to the OIM carrier See figure 3 2 Working from the inside of the drive align the Field Current Regulator board s mounting holes with the mounting holes on the drive s right side panel Working from the outside of the drive insert one of the mounting screws removed in step 13 through one of the mounting holes on the drive s right side panel and into the corresponding mounting hole on the Field Current
9. 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 Installing the Field Current Regulator kit on 200 300 HP drives requires completing the following steps When you have finished installing the kit adjust the required drive parameters as described in chapter 5 before using the drive 9 Opening the cover and carrier e Removing the Enhanced Field Supply board e Installing the Field Current Regulator board e Wiring the Field Current Regulator board e Replacing the drive fuses e Reinstalling the drive carrier and cover e Modifying the drive configuration These steps are described in detail below 4 14 Opening the Cover and Carrier THEDRIVE 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 Step 1 Turn off lockout and tag power to the drive Step 2 Remove the plastic cover from the right side of the drive Step 3 Loosen the two screws holding the OIM cover in place and remove the OIM cover Step 4 Loosen the captive screw at the upper right corner of the OIM carrier and then swing the carrier open Note that t
10. Regulator board See figure 1 1 for the location of the terminals Attach the Field Current Regulator cable assembly P N 707973 12S connectors FLD P6 and FLD P3 to the corresponding terminals on the Field Current Regulator Route the free end of the Field Current Regulator cable assembly to the left side of the drive and into the OIM carrier Follow the path illustrated in figure 4 2 This is the same path used by the control wiring harness Working from the inside of the bottom of the drive align the Field Current Regulator board s mounting holes with the mounting holes on the drive s right side panel See figure 4 2 Working from the outside of the drive insert one of the mounting screws removed in step 11 through one of the mounting holes on the drive s right side panel and into the corresponding mounting hole on the Field Current Regulator board Tighten the screw to hold the board in place Repeat step 6 for the remaining three mounting screws Wiring the Field Current Regulator Board Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 The Operator Interface Module OIM or Drive Configuration Module DCM must be removed to provide access to the Regulator board Remove the screws that hold the OIM or DCM to the carrier and remove the OIM DCM Remove the three screws that hold the Regulator board in place then slide the Regulator board slightly to the right From the back of the OIM carrier push the end of the
11. Regulator board Tighten the screw to hold the board in place Repeat step 6 for the remaining three mounting screws Wiring the Field Current Regulator Board Step 1 Step 2 The Operator Interface Module OIM or Drive Configuration Module DCM must be removed to provide access to the Regulator board Remove the screws that hold the OIM or DCM to the carrier and remove the OIM DCM Remove the three screws that hold the Regulator board in place and slide the Regulator board slightly to the right 3 5 3 6 3 7 Step 3 Step 4 Step 5 Step 6 Step 7 From the back of the carrier push the end of the Field Current Regulator cable assembly with the REG P25 connector through the opening in the carrier above the ribbon cable See figure 3 2 Connect the REG P25 connector to the J25 terminal on the Regulator board See figure 2 3 Slide the Regulator board back into place and secure it with its mounting screws Reinstall the OIM DCM Use the supplied cable ties to fasten the Field Current Regulator cable assembly to the drive s fan or support bar Replacing the Drive Fuses Step 1 Step 2 Remove the three fuses labeled 6FU 7FU and 8FU from the drive s fuse block Install the three provided 25 A 600 V fuses P N 64676 30M in the fuse block in positions 6FU 7FU and 8FU Reinstalling the Auxiliary Chassis Cover Carrier and Drive Cover Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7
12. 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 Step 1 Turn off lockout and tag power to the drive Step 2 Loosen the cover retaining screws and remove the cover Step 3 Loosen the captive screw at the upper right corner of the drive s Operator Interface Module OIM carrier and swing open the carrier 2 2 2 2 2 3 2 4 2 5 Removing the Standard or Enhanced Field Supply Board Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Locate the Standard or Enhanced Field Supply board in the drive See figure 2 1 Disconnect the drive s wire harness connections from the existing field supply board s 581 582 583 F2 35 and F1 37 spade connectors Follow the field supply board s wire harness to the P4 connector on the Power Interface board Unplug the harness from the P4 connector Install the plug cap P N 69752 146D on the Power Interface board s P4 connector See figure 2 1 Locate the field supply s four mounting screws on the outside of the drive s right side panel Remove the four mounting screws from the outside of the dive and remove the field supply board Installing the Field Current Regulator Board Step 1 Step 2 Step 3 St
13. regardless of the state of FIELD ECONOMY ACTIVE The Field Current Regulator will provide field economy with a user adjustable field current reference FIELD ECONOMY REF This parameter is entered as a percentage of MOTOR HOT FLD AMPS FIELD ECONOMY REF must be set above FIELD LOSS THRESHOLD to avoid nuisance field loss faults Overspeed Protection Overspeed detection is active only when a tachometer is being used FEEDBACK SELECT ARMATURE VOLT Because of this the amount of field weakening is limited when the drive is configured as a voltage regulator FEEDBACK SELECT ARMATURE VOLT Overvoltage Protection Armature overvoltage protection is always active regardless of the type of feedback This will reduce the chance of overvoltaging the armature due to a weakened field An overvoltage fault will occur when the arma ture terminal voltage exceeds 130 percent of MOTOR RATED ARM VOLTS Reliance Electric 24703 Euclid Avenue Cleveland Ohio 44117 216 266 7000 RELIANCE ELECTRIC E Printed in U S A D2 3336 1 January 1997
14. the maximum motor field current they support Use the kit that provides the maximum motor field current including that necessary for field forcing required for your application Note that using a Field Current Regulator with a higher amperage rating than is needed will decrease control resolution Refer to table 1 1 to ensure you have the correct kit for your application and to table 1 2 for a list of the kit contents See figures 1 1 and 1 2 for illustrations of the Field Current Regulator board and cable assemblies Table 1 1 Verifying the Field Current Regulator Kit Matches the Drive Field Current Regulator Model Number Maximum Motor Field Current 911FK0041 4A 911FK0101 10A 911FK0151 15A Table 1 2 Field Current Regulator Kit Contents Kit Model Number Part Number Description Quantity 911FK0041 707973 10R Printed Circuit Board Assembly 1 64676 30M 25 A Fuse UL Class CC 600 V 3 707973 12R Cable Assembly 1 707973 125 Cable Assembly 1 69306 3D Cable Tie Wrap 8 69752 146D Plug Cap 1 D2 3336 Instruction Manual 1 911FK0101 707973 105 Printed Circuit Board Assembly 1 64676 30M 25 A Fuse UL Class CC 600 V 3 707973 12R Cable Assembly 1 707973 12S Cable Assembly 1 69306 3D Cable Tie Wrap 8 69752 146D Plug Cap 1 D2 3336 Instruction Manual 1 911FK0151 707973 10T Printed Circuit Board Assembly 1 64676 30M 25 A Fuse UL Class CC 600 V 3 707973 12R Cable A
15. FlexPak 3000 Field Current Regulator Kit Installation Instructions MIN 911FK0041 911FK0101 and 911FK0151 Instruction Manual D2 3336 1 ELECTRIC IW The information in the user s manual is subject to change without notice Read this manual in its entirety before installing and powering the drive Observe all DANGER WARNING and CAUTION advisories these advisories point out potentially hazardous procedures and conditions All three types of advisories are enclosed in a box to call attention to them e A DANGER alerts a person that severe bodily injury or loss of life could occur if procedures are not followed e A WARNING alerts a person to potential bodily injury if procedures are not followed 9 A CAUTION alerts a person that if procedures are not followed damage to or destruction of equipment could result DANGER ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL ADJUST OPERATE AND OR SERVICE THIS EQUIPMENT READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY BEFORE PROCEEDING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE CAUTION 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 FlexPak 3000 and Reliance are registered trade
16. KEN THRESHOLD FLD WEAKEN PROP GAIN e Parameter 520 FLD WEAKEN LEAD FREQ e Parameter 587 FIELD DELTA HIGH LIM Once the Field Current Regulator kit is installed and the drive is configured the following output parameters can be used Refer to your drive instruction manual for complete descriptions of these output parameters e Parameter 586 FLD CURRENT REGULATOR e Parameter 588 FIELD DELTA e Parameter 589 FIELD FEEDBACK e Parameter 590 FIELD REFERENCE If you are installing and setting up the Field Current Regulator kit as part of your initial drive setup and are using the quick start procedure described in the drive s instruction manual you will be prompted for parameter 510 MOTOR HOT FLD AMPS In this case after you finish with the quick start procedure make sure that you set parameter 511 FIELD ECONOMY REF If you are installing and setting up the Field Current Regulator kit after you have already set up the drive you do not need to rerun the quick start procedure Simply access the parameters and set the values as described in sections 5 1 and 5 2 e Parameter 501 e Parameter 512 e Parameter 513 e Parameter 514 e Parameter 515 e Parameter 516 e Parameter 517 e Parameter 518 e Parameter 519 5 1 Setting Parameter 510 MOTOR HOT FLD AMPS When the drive is first powered up after installing the Field Current Regulator the Field Current Regulator will o
17. OSS OF LIFE DANGER 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 Installing the Field Current Regulator kit on 75 150 HP drives requires completing the following steps When you have finished installing the kit adjust the required drive parameters as described in chapter 5 before using the drive 9 Opening the cover and carrier 9 Removing the Standard or Enhanced Field Supply board e Installing the Field Current Regulator board e Wiring the Field Current Regulator board e Replacing the drive fuses 9 Reinstalling the drive carrier and cover e Modifying the drive configuration These steps are described in detail below 3 4 Opening the Drive Cover and Carrier and Removing the AC Disconnect THEDRIVE 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 Step 1 Turn off lockout and tag power to the drive Step 2 Loosen the drive cover retaining screws and remove the cover Step 3 Loosen the captive screw at the upper r
18. VIEW 81 0 82 ss Field Supply Attaching Screws Qty 4 FlexPak Wire Harness Field Current Regulator Field Current Regulator Field Current Regulator Cable Assembly Cable Assembly Figure 2 2 Cable Routing 3 60 HP Drives j r4 Connector Cw Ja 9 Connector 5525955699 2229299995 0000000000 TL TL JL JL JL JL J Figure 2 3 Regulator Board Cable Connectors 3 0 INSTALLING THE FIELD CURRENT REGULATOR KIT ON 40 75 HP 230 VAC AND 75 150 HP 460 VAC DRIVES DANGER ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL ADJUST OPERATE AND OR SERVICE THIS EQUIPMENT READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY BEFORE PROCEEDING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR L
19. eld Current Regulator kit is now complete Appendix Field Current Regulator Description Description of the Field Control Loop The FlexPak 3000 version 3 regulator will detect the presence of the Field Current Regulator kit at power up The output parameter FLD CURRENT REGULATOR indicates whether or not the Field Current Regulator kit is installed When the Field Current Regulator kit is installed the field current control loop operates and drive parameters ENHANCED FLD VOLT ADJ and J21 FLD SUPPLY JUMPER are ignored The regulated field loss and field economy circuits become active in place of those used by the standard and enhanced field sup plies See figure A 1 for a block diagram of the field control loop NOTE The regulator board jumper J20 Field Loss Detect is ignored when the Field Current Regulator is installed Therefore setting J20 to the DISABLE position will NOT disable field loss detection The field control loop contains two regulators a field current regulator and an armature voltage counter EMF or CEMF regulator The field control loop can be configured to decrease armature voltage when the arma ture voltage feedback ARMATURE VOLTAGE exceeds the FLD WEAKEN THRESHOLD voltage and the field begins to weaken see figures A 1 and A 2 The armature IR drop can be compensated for by using the IR COMPENSATION parameter P206 The output of the Field Current Regulator determines the firing angle of the regulated field sup
20. ep 4 Step 5 Step 6 Remove the four mounting screws from the back of the Field Current Regulator board Connect the wire harness connectors labeled 581 582 583 F2 35 and F1 37 to the corresponding terminals on the Field Current Regulator board See figure 1 1 Attach the Field Current Regulator cable assembly s P N 707973 12R FLD P6 and FLD P3 connectors to the corresponding terminals on the Field Current Regulator board See figure 1 1 Working from the inside of the drive align the Field Current Regulator board s mounting holes with the mounting holes on the drive s right side panel See figure 2 2 Working from the outside of the drive insert one of the mounting screws removed in step 10 through one of the mounting holes on the drive s right side panel and into the corresponding mounting hole on the Field Current Regulator board Repeat step 5 for the remaining three mounting holes Wiring the Field Current Regulator Board Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 The Operator Interface Module OIM or Drive Configuration Module DCM must be removed to provide access to the Regulator board Remove the screws that hold the OIM or DCM to the carrier and remove the OIM DCM Remove the three screws that hold the Regulator board in place and slide the Regulator board slightly to the right From the back of the carrier push the end of the Field Current Regulator cable assembly with
21. he screw is designed to stay attached to the carrier when it is loosened do not attempt to remove it 4 2 4 2 4 3 4 4 Step 5 Locate the two plastic anchors holding the hinged mounting panel in place Release the anchors by inserting the tip of a flat bladed screwdriver into the notch on the anchors and twist so the notch is vertical Then swing the panel open Removing the Enhanced Field Supply Board Step 1 Step 2 Step 3 Step 4 Step 5 Locate the Enhanced Field Supply board It is attached to the right side of the drive behind the line fuse panel and can be accessed through the bottom of the drive See figure 4 1 Remove the four field supply mounting screws from the outside of the drive s right side panel and remove the field supply Disconnect the drive s wire harness from the field supply board s 581 582 583 F2 35 and F1 37 connectors Follow the field supply board s wire harness to the P4 connector on the Power Interface board Unplug the harness from the P4 connector Install the plug cap P N 69752 146D on the Power Interface board s P4 connector Installing the Field Current Regulator Board Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Remove the four 4 mounting screws from the back of the Field Current Regulator board Connect the drive s wire harness connectors labeled 582 582 583 F2 35 and F1 37 to the corresponding terminals on the Field Current
22. ight corner of the drive s Operator Interface Module OIM carrier and swing open the carrier If the drive is equipped with an AC line disconnect go to step 4 Otherwise go to step 5 3 2 3 2 3 3 3 4 Step 4 Step 5 Step 6 Step 7 Drives with an AC line disconnect only Remove the four screws that fasten the AC line disconnect to the auxiliary chassis cover Then lift and remove the AC line disconnect from the auxiliary chassis cover See figure 3 1 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 Remove the top and bottom screws fastening the auxiliary chassis cover to the drive s right side panel Loosen the middle screw that fastens the auxiliary chassis cover circuit breaker panel to the drive s right side panel Slightly swing out the auxiliary chassis cover and remove it Removing the Standard or Enhanced Field Supply Board Step 1 Step 2 Step 3 Step 4 Step 5 Locate the Standard or Enhanced Field Supply board in the drive See figure 3 1 Disconnect the drive s wire harness connections from the existing field supply board s 581 582 583 F2 35 and F1 37 spade connectors Follow the field supply board s wire harness to the P4 connector on the Power Interface board Unplug the harness from the P4 connector Install the plug cap P N 69752 146D on the Power
23. lectric sales office For technical assistance call 1 800 RELIANCE 2 0 INSTALLING THE FIELD CURRENT REGULATOR KIT ON 1 5 30 HP 230 VAC AND 3 60 HP 460 VAC DRIVES DANGER ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL ADJUST OPERATE AND OR SERVICE THIS EQUIPMENT READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY BEFORE PROCEEDING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE DANGER 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 Installing the Field Current Regulator kit on 3 60 HP drives requires completing the following steps When you have finished installing the kit adjust the required drive parameters as described in chapter 5 before using the drive e Opening the cover and carrier 9 Removing the Standard or Enhanced Field Supply board e Installing the Field Current Regulator board e Wiring the Field Current Regulator board e Replacing the drive fuses e Reinstalling the drive carrier and cover e Modifying the drive configuration These steps are described in detail below 2 4 Opening the Drive Cover and Carrier THE DRIVE CONTAINS PRINTED CIRCUIT BOARDS THAT ARE STATIC
24. marks of Reliance Electric Company or its subsidiaries Copyright Reliance Electric Industrial Company 1997 1 0 2 0 3 0 4 0 5 0 Table of Contents INGTFOGUCHION mr 1 1 1 1 Related Publications ANEN ENNEN cheek da EG dank a dr dd d IR d 1 3 1 2 Getting Assistance from Reliance Eech 1 3 Installing the Field Current Regulator Kit on 1 5 30 HP 2 230 VAC and 3 60 HP 460 VAC Drives 000 c cece cece cece eee hh hh nnn 2 1 2 1 Opening the Drive Cover and Carrier 2 1 2 2 Removing the Standard or Enhanced Field Supply Board 2 2 2 3 Installing the Field Current Regulator Board 2 2 2 4 Wiring the Field Current Regulator Board 2 2 2 5 Replacing the Drive FUSES d et dE del y edam EEG RE REY REPA EE X RC RR a eh anita 2 2 2 6 Replacing the Carrier and Drive Cover 2 3 2 7 Modifying the Drive Configuration 0 0 ee en 2 3 Installing the Field Current Regulator Kit on 40 75 HP 230 VAC and 75 150 HP 460 VAC Drives 3 1 3 1 Opening the Drive Cover and Carrier and Removing the AC Disconnect 3 1 3 2 Removing the Standard or Enhanced Field Supply Board 3 2 3 3 Installing the Field Current Regulator Board 3 2 3 4 Wiring the Field Current Regulator Board 3 2 3 5 Replacing the Drive FUSES EEN 3 3 3 6 Reinstalling the Auxiliary Chassis Cover Carrier and Drive Cover 3 3 3 7 Modifying the Drive Configuration sssssssssse
25. nfigurable low limit parameter associated with these PI blocks The low limit is always fixed at zero The high limit FIELD DELTA HI LIM is user configurable up to 180 degrees allowing full on field voltage of 207 VDC 230 VAC and 414 VDC 460 VAC To regulate greater field voltages a step up transformer must be used to supply the AC side of the Field Current Regulator As the motor speed increases beyond base speed the armature voltage will increase above rated voltage The PI block monitoring armature voltage will reduce the high limit of the PI block controlling field current As field current decreases field flux and armature voltage will also decrease Field current continues to decrease until armature voltage is reduced to FLD WEAKEN THRESHOLD volts Control of armature voltage during field weakening is only permitted when a tachometer is used FEEDBACK SELECT z ARMATURE VOLTS Automatic field weakening can be disabled by setting FIELD AUTO WEAKEN DISABLED The drive can also be operated in the constant power field control range by controlling the field current reference exclu sively FIELD REF REGISTER A 1 3 5 8344 uMous aud 548 8 6 45 4nda4n j 28 38344 u ous auo Suazawound ndur NOILVSN3dWO9 81 1 38 1 8 123135 3980334 usum ee 3 8 810 63 Peaduo S N3 wV3 1 314 939N CGDOV1TDA 3anivWaw LV 10538 WJD 39VL
26. ns and press ENTER Scroll to Memory Save and then perform the memory save operation If the motor field winding was disconnected in step 2 above perform steps 25 29 Otherwise proceed to step 30 Step 25 Disconnect tag and lockout power to the drive Step 26 Reconnect the motor field winding to the drive Step 27 Reconnect power to the drive Step 28 Remove the lockout and tag Step 29 Turn on power the drive Step 30 Access the Fault menu and press ENTER Step 31 Scroll to Clear Fault Log and Reset Faults and then press ENTER The fault log will be cleared and all drive faults will be reset NOTE Performing a Restore Defaults operation will cause the Field Current Regulator to re enter the fixed voltage mode of operation and require the re execution of the above steps 5 2 Setting Parameter 511 FIELD ECONOMY REF IMPROPER SETTING OF THE FIELD ECONOMY REF PARAMETER CAN CAUSE A MOTOR OVERVOLTAGE CONDITION SET THE MOTOR HOT FLD AMPS PARAMETER TO THE MOTOR S NAMEPLATE VALUE MAKE SURE THE FIELD ECONOMY REF PARAMETER AND OR FIELD REF PARAMETER P513 ARE ABOVE THE FIELD LOSS THRESHOLD PARAMETER P 512 FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY AND DAMAGE TO THE EQUIPMENT For proper drive operation the value for parameter 511 FIELD ECONOMY REF must be set above the value for parameter 512 FIELD LOSS THRESHOLD Note that the default value for FIELD ECONOMY REF is 0 and that the defa
27. nt Feedback Scaling There are three Field Current Regulator ratings 4 amps 10 amps and 15 amps The Regulator board hard ware provides three different gains for the field current feedback signal 1 2 and 5 The user must enter the motor nameplate value for rated field amps MOTOR HOT FLD AMPS to properly scale the feedback signal The software will automatically select the feedback gain in hardware which produces the largest full scale digital value in the analog to digital converter MOTOR HOT FLD AMPS will be limited based on the rating of the Field Current Regulator kit installed Table A 1 shows what the software will select as the feedback gain depending on motor hot field amps Table A 1 Field Current Feedback Scaling Field Current Field Current Rated Output Resolution Rating Amps Motor Hot FLD Amps Gain Amps milliamps 4 0 11 to 0 8 5 0 8 4 0 81 to 2 00 2 2 10 2 01 to 4 00 1 4 20 10 0 28 to 2 00 5 2 10 2 01 to 5 00 2 5 25 5 01 to 10 00 1 10 50 15 0 55 to 4 00 5 4 20 4 01 to 10 00 2 10 50 10 01 to 20 00 1 15 100 A 3 A 4 Field Loss When the Field Current Regulator is operating in fixed voltage mode a field current loss fault will be gener ated only when there is a complete loss of field current When the Field Current Regulator is regulating field current that is not in fixed voltage mode a field current loss fault will be generated when the field current drops below the user
28. perate in a fixed voltage mode until a valid value is entered for MOTOR HOT FLD AMPS This fixed voltage will produce 150 VDC on a 230 VAC line or 300 VDC on a 460 VAC line If your motor field voltage is significantly less than this begin with step 1 Otherwise begin with step 7 if your drive is equipped with an OIM or step 18 if your drive is equipped with a DCM If the motor field voltage is less than 150 VDC on a 230 VAC line or less than 300 VDC on a 460 VAC line complete steps 1 6 first Otherwise go to step 9 Step 1 Disconnect tag and lockout power to the drive Step 2 Disconnect the motor field winding from the drive 5 1 5 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Reconnect power to the drive Remove the lockout and tag Turn on power to the drive After completing power up diagnostics the drive will generate a field current loss fault Ignore this fault Access the Fault menu by pressing the FAULT key until FAULT appears on the OIM directly above the FAULT key Select Clear Fault Log and Reset Faults and then press ENTER The fault log will be cleared and all drive faults will be reset If the drive is equipped with an OIM complete the following steps to set MOTOR HOT FLD AMPS Otherwise go to step 18 Step 9 Step 10 Step 11 Step 12 Select MOTOR HOT FLD AMPS by taking the following path from the main menu Field Field Current Regulator L Field Loop Feedback Scaling
29. ply gate firing circuit The output parameter FIELD DELTA represents the angle in degrees If the factory defaults for the Field Current Regulator are in effect it will operate in a fixed voltage mode by firing the field SCRs at a fixed angle of 117 This will produce a field voltage of 150 VDC at 230 VAC line input or 300 VDC at 460 VAC line input For other motor field voltages MOTOR HOT FLD AMPS must be set properly before the motor field is connected While the Field Current Regulator is producing fixed voltage the value for MOTOR HOT FLD AMPS will be set to 0 01 amps After a valid value is entered for MOTOR HOT FLD AMPS the user assigned value for FIELD LOSS THRESHOLD becomes effective The Field Current Regulator will NOT regulate field current until a valid value for MOTOR HOT FLD AMPS is entered While in fixed voltage mode a field loss fault will only occur if there is a complete loss of field current This is similar to having a standard or enhanced field supply installed CAUTION If the factory defaults for the Field Current Regulator are not in effect e g MOTOR HOT FLD AMPS was modified via the network or CS3000 extreme care must be exercised to ensure the correct value for MOTOR HOT FLD AMPS is present when power is applied to the drive Failure to observe this precaution could result in damage to or destruction of the equipment Both field loop regulators contain proportional plus integral PI control There is no user co
30. set FIELD LOSS THRESHOLD The same field feedback signal used by the Field Current Regulator is used by the field loss detection circuit The field current feedback will be compared against a user entered FIELD LOSS THRESHOLD If the feed back is less than the threshold value a fault will be generated FIELD LOSS THRESHOLD is entered as a per centage of MOTOR HOT FLD AMPS 0 100 speed regulator 50 100 armature voltage regulator FIELD ECON OMY REF must be set above FIELD LOSS THRESHOLD to avoid field loss faults when the drive enters field economy A field loss fault will also occur if the digital value on the A D converter reaches full scale approximately 28 above the rated field output The regulator board hardware jumper J20 Field Loss Detect is designed to allow the user to separately ex cite the motor field winding and is not intended as a means of bypassing field loss detection when using an internal field supply Therefore when the Field Current Regulator kit is installed this jumper is ignored Note that leaving J20 in the DISABLE position will NOT disable field loss detection Field Economy The output parameter FIELD ECONOMY ACTIVE indicates when field economy is active Field economy be comes active after a user defined time delay FIELD ECONOMY DELAY from the time the motor stops or the drive is powered up When the Field Current Regulator is operating in fixed voltage mode a constant field voltage is generated
31. ssembly 1 707973 125 Cable Assembly 1 69306 3D Cable Tie Wrap 8 69752 146D Plug Cap 1 D2 3336 Instruction Manual 1 1 2 lop View 587 0000000000 FLD P3 comector Figure 1 1 Field Current Regulator Board 4 pin Square Connector FLD P3 Number Label lo oo 12 pin PCB Connector 10 pin PCB Connector REG P25 FLD P6 4 pin Square Connector FLD P3 12 pin PCB Connector 10 pin PCB Connector REG P25 FLD P6 Figure 1 2 Cable Assemblies 1 1 Related Publications This manual describes the Field Current Regulator kit and its associated FlexPak 3000 software parameters You will also need the FlexPak 3000 DC Drive instruction manual 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 E
32. sssee een 3 3 Installing the Field Current Regulator Kit on 100 150 HP 230 VAC and 200 300 HP 460 VAC Drives sseeeeeeeeRRI I Inn nnn 4 1 4 1 Opening the Cover and Carrier 6446666 4 1 4 2 Removing the Enhanced Field Supply Board 4 2 4 3 Installing the Field Current Regulator Board 4 2 4 4 Wiring the Field Current Regulator Board 4 2 4 5 Reinstalling the OIM Carrier and Cover sssssssssssese en 4 3 4 6 Replacing the Drive Fuses 4 3 4 7 Reinstalling the Drive Cover 4 3 4 8 Modifying the Drive Configuration isssssssseesssee e nn 4 3 Modifying the Drive Configuration 5 1 5 1 Setting Parameter 510 MOTOR HOT FLD AMPS 4 65656 5 1 5 2 Setting Parameter 511 FIELD ECONOMY RER 5 3 Appendices Appendix A Field Current Regulator Description A 1 List of Figures Figure 1 1 Field Current Regulator Board 1 2 Figure 1 2 Cable Assemblies 1 3 Figure 2 1 Removing the Standard Enhanced Field Supply 3 60 HP Drives Lsusue 2 3 Figure 2 2 Cable Routing 3 60 HP Drives 2 4 Figure 2 3 Regulator Board Cable Connectors 0 060 tte eee ees 2 4 Figure 3 1 Removing the Standard Enhanced Field Supply 75 150 HP Drives 3 4 Figure 3 2 Cable Routing 75 150 HP Drives sssssssssssssee n 3 4 Figure 4
33. the REG P25 connector through the opening in the carrier above the ribbon cable See figure 2 2 Connect the REG P25 connector to the J25 terminal on the Regulator board See figure 2 3 Slide the Regulator board back into place and secure it with its mounting screws Reinstall the OIM DCM Use the supplied cable ties to fasten the Field Current Regulator cable assembly to the drive s fan or support bar Replacing the Drive Fuses Step 1 Step 2 Remove the three fuses labeled 6FU 7FU and 8FU from the drive s fuse block Install the three provided 25 A 600 V fuses P N 64676 30M in the fuse block in positions 6FU 7FU and 8FU 2 6 Replacing the Carrier and Drive Cover Step 1 Close the carrier and secure it in place with its captive screw Step 2 Reinstall the drive 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 5 for information on setting parameters for the Field Current Regulator kit 81 0 5 0 5 e lee 0 91 eo Power I F Board P4 Connector FlexPak Wire Harness Standard or Enhanced Field Supply Carrier Figure 2 1 Removing the Standard Enhanced Field Supply 3 60 HP Drives 2 3 2 4 FRONI Lee e e Carrier J25 Connector J6 Connector
34. ult value for FIELD LOSS THRESHOLD is 60 of MOTOR HOT FLD AMPS Using the defaults for parameters 511 and 512 will result in a drive default See your drive s manual for more information on setting the FIELD LOSS THRESHOLD parameter properly Then complete the following steps If the drive is equipped with an OIM complete steps 1 6 If the drive is equipped with a DCM skip to step 7 Step 1 Select FIELD LOSS THRESHOLD by taking the following path form the main menu Field Field Current Regulator Field Loop Configure Step 2 Note the value of FIELD LOSS THRESHOLD Step 3 Back up to the Field Loop Configure menu and select FIELD ECONOMY REF Step 4 Setthe value of FIELD ECONOMY REF to a value higher than that of FIELD LOSS THRESHOLD Step 5 Select MEMORY SAVE by taking the following path from the main menu Operator Interface Memory Operations Step 6 Perform the Memory Save operation If the drive is equipped with a DCM complete the following steps Step 7 From the main menu scroll to Input Parameters and press ENTER Step 8 Scroll to FIELD LOSS THRESHOLD and note its value Step 9 Scroll to FIELD ECONOMY REF 5 8 5 4 Step 10 Set the value of FIELD ECONOMY REF to a value higher than that of FIELD LOSS THRESHOLD Step 11 From the main menu scroll to Memory Operations and press ENTER Step 12 Scroll to Memory Save and then perform the memory save operation The installation procedure for the Fi
Download Pdf Manuals
Related Search