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FlexPak 3000 OIM 4.2 - Rockwell Automation

1. drive J47 J28 J22 O O F2 O F1 ARM I GND IOGND2 lenn L 7 J18 S Z EPROM E 38 J3 J25 790 30 70 E 14 IE 0 J5 J2 J15 J20 J26 ovi2 H a G E Ho J16 J21 E Had E J30 J29 J27 Y Ai IE 0 0 aag E Pod N E J12 J10 J19 38 J9 2s F3 GND3 J8 J1 Ray o o O O Figure 3 1 Regulator Board Jumpers Connectors and Test Points Drive Setup and Adjustment 3 3 3 4 2 3 4 3 3 4 4 3 4 5 3 4 6 Setting Program Protection Jumper OIM PROGRAM J16 The OIM program jumper J16 determines whether or not parameter changes can be made through the keypad OIM Only programming options are affected by the setting of this jumper The OIM drive control keys such as RUN and JOG are not affected To allow keypad parameter changes place the jumper on pins 1 and 2 ENABLE To prevent parameter changes through the keypad place the jumper on pins 2 and 3 DISABLE Parameters cannot be modified through the keypad If an attempt to modify a parameter is made the message Hardware Password Protection is Enabled is displayed on the keypad Inspect the Field Loss Detection Jumper J20 The FIELD LOSS DETECT jumper J20 is not used with WebPak 3000 drives The position of this jumper has no effect on the drive Inspect the Fiel
2. 26 lad mo i SVN VEIAS ms Hit HI NI ES U L UUU 170 DO Do 45 r 45 CNI fI H Hn rn AYU L all UI JUL III UU L SHI gt TTT NNN HH ty c U JUUUUUUUUU UUU Toto E Si of ee ur EZ a J pe a se 3 gt Es C ea E N es Ee na J Ss J pr es rs C gt es we y 590 es 2 22 gle So Ea Ta G a ES cs A Z EE G Fa E 7 E Figure 2 4 Mounting Data for 800 A Drives Install and Wire the Drive Power connections Bus bars 50 x 10 Hole 13 5 mm AC Line 1U 1V 1W Protection earth PE Weight Cooling air Air flow direction Minimum clearances for air circulation Bus bars 40 x 10 Hole 13 5 mm Bolt M12 Torque 15 Nm 83 kg 814 m3 h from bottom to top 100 mm 2 5 455 975 905 60 400 T T nn 1 n Hn Pn dg MAMA k II MULA ifi Ann IK J JUUUUUL_S 7 I SUE ER H HI ANNAN UU UU UU UL Hi DU U UU U i T AA uu ol 515 a DC OUTPUT bus bars 100 x 10 drilling 4 x M12 bus bars 60 x 10 drilling 2 x 13 5 mm Bolt M12 Torque 25 Nm 195 kg 2000 m3 h from bottom to top We
3. 797 12 p E X ah i p 4 ig 4 RD 245 L 360 q Filter Part No 839 71 68 Power loss 50 W Weight 22 kg 797 62 Figure 5 10 340 A 440 500 V RFI Filter Dimensions mm 5 18 WebPak 3000 DC Drive Hardware Reference 440 V 1000 and 1600 A 900 250 Radio Interference Filter E E E E E E o E oe DE 0 wo z 250 2307225 460 380 230 149 260 200 285 120 100 705 24 500 878 31 680 500 250 154 000 836 733 840 650 400 204 PHHP A v P W kg CE 250 500 1000 and 1600 A 440 V RFI Filter Dimensions mm M12 M12 M12 Ground S T Bolt 250 24 30 g osj ros mo 18 18 500 15 30 30 on fore 1000 20 50 40 ote lore 100 20 50 40 ore ore Figure 5 11 5 19 Replacement Parts and Accessories Radio Interference Filter 600 1000 and 1600 A 500 690 V PE L41 L3 L2
4. Part Catalogue US Model Part Catalogue US Model Number Number Number Number Number Number 803 56 00 849 11 73 WP3000 S6R 800 AN FC 8310 79 70 920WK0011 849 13 43 WP3000 S6R 1200 60 AN FC 8108900 849 13 73 WP3000 S6R 1200 50 AN FC 813 39 00 E 849 15 43 WP3000 S6R 1600 60 AN FC 813 40 00 849 15 73 WP3000 S6R 1600 50 AN FC 813 41 00 849 17 43 WP3000 S6R F1600 60 AN FC 813 41 01 E 849 17 73 WP3000 S6R F 1600 50 AN FC 813 42 00 E 849 19 43 WP3000 S6R 2000 60 AN FC 8134201 849 19 73 WP3000 S6R 2000 50 AN FC 813 43 00 S 916 10 70 S 1LG1101 813 43 01 z 916 10 71 1LG1102 813 43 10 916 10 72 1LG1103 8134311 916 10 73 1LG1104 839 52 20 RFC X 916 10 74 1LG1105 839 70 20 RFB 150 916 10 80 1LG1201 839 70 66 RFB 270 916 10 81 1LG1202 839 71 53 RFB 100 916 10 82 1LG1203 839 71 68 RFB 340 916 10 83 1LG1204 839 72 05 RFB 25 916 10 84 1LG1205 8939 44 06 E 916 10 85 1LG1206 Essa OF REBO 916 10 86 1LG1207 839 72 09 RFB 80 916 10 87 _ 1LG1208 S OT IREB 260 916 10 88 1LG2401 ee 916 10 89 1LG2402 839 73 31 RFB 500 916 10 90 1LG2403 839 73 35 RFB 1000 ols Eeo 839 73 38 RFB 1600 839 73 92 RFC 600 get 220i 839 73 95 RFC 1000 921 90 00 __ 839 73 98 RFC 1600 921 91 00 839 74 22 RFB 180 921 91 11 849 01 73 WP3000 S6R 25 AN FC 922 58 10 849 03 73 WP3000 S6R 60 AN FC 922 95 01 OIM WEB 925WK010 84
5. y Pno a e o 844 65 Figure 5 12 600 1000 and 1600 A 500 690 V RFI Filter Dimensions mm 5 20 WebPak 3000 DC Drive Hardware Reference APPENDIX A Technical Specifications AC Line Considerations Requirement Measures 1 Limiting the AC line symmetrical fault Always adding an impedance in the line input current to 100 kA max for fuses or This can be a 3 phase line reactor with 2 values acc table below for UL cUL as voltage drop minimum refer to Table 5 6 or a well as limiting commutation notches at matched isolation transformer the line input terminals 1U 1V 1W 2 Limiting the AC line symmetrical fault Adding a 1 phase line reactor acc to Table 5 6 current RMS at the field rectifier input Exception No reactor is required when a terminals 3V 3W to 10 KA matched transformer is provided in the input to the converter on drives up to 450 A 3 Minimum supply system source Connecting to a source supply transformer with capacity kVA minimum kVA rating acc to the following table 4 and continuous undervoltage to 10 exceeds 4 or continuous undervoltage 5 Avoiding damage of drive components Providing additional input line conditioning on the due to overvoltage transients caused by drive e g Capacitance to ground medium voltage switching on supply Please Contact Rockwell Automation for transformers with primary rating gt 2300 V assistance when this is require
6. liei ss ses a dose cano pegos e Input Voltage asse Corie teers nna eee Input Impedance eee eee Signal COMMON sees eee Frequency Output Maximum Frequency Duty Cycle eee eee Output Voltage Maximum Output Offset Maximum Load sese eee eee eee Signal COMMON eee eee eee eee Signal Termination 24 VDC 9 mA at Vin 24 VDC All inputs share the same common 250 VAC maximum 30 VDC maximum 2 amps maximum resistive 1 amp maximum inductive 5 KQ minimum 10 VDC 4 20 mA 10 50 mA 5 KQ minimum 10 VDC maximum 10 VDC 4 mA 4 20 mA 5 32 VDC 0 1 3 KQ maximum load 10 VDC 4mA 250 kHz 25 at 250 kHz 20 at 100 kHz 2ms Differential A and A Not 50 V maximum differential 25 V to common 1 5 V minimum differential voltage swing 22 KQ differential 11 KQ to isolated 15 V common 100 Q to isolated 15 V common 250 kHz 50 5 V differential 0 4V 5mA 100 to isolated 15 V common 100 Q in series with 3900 pf WebPak 3000 DC Drive Hardware Reference APPENDIX B CE Conformity EMC Directive This converter device is a component intended for implementation in machines or systems for the capital goods industry They have been tested to meet Council Directive 89 336 Electromagnetic Compatibility EMC and all applicable standards listed in the technical construction file With the specified EMC
7. Cross Reference Cross Reference List Part Numbers Catalogue Numbers This appendix provides a cross reference lists for part numbers of the WebPak 3000 in numeric order and associated Rockwell Automation catalogue numbers and Reliance US Model Numbers Part numbers without catalogue numbers are spare parts Refer to Tables 5 1 to 5 6 Table C 1 Cross Reference List Part Number Catalogue Number US Model Number 122 04 02 Part Number Catalogue Number US Model Number 122 93 02 553 00 10 F F12 122 93 04 553 00 11 F F15 123 39 30 553 26 29 F SW2 123 43 04 553 26 30 F SW3 124 07 00 553 28 02 F 25 135 05 52 553 28 06 F 60 135 11 02 553 28 07 F 60A 135 12 02 553 28 08 F 150S 135 60 00 135 60 02 553 28 09 F 150AS 211 00 02 553 30 04 5953 30 05 F 150L F 150AL 211 00 05 553 30 06 F 250 211 36 05 553 31 13 F 250A 252 40 01 LL 25 553 31 14 F 450S 252 40 02 LL 40 553 32 16 F 450L 252 40 03 LL 62 553 32 18 F 450AL 252 40 04 LL 85 553 33 19 F 800S 252 40 05 LL 115 553 33 21 F 800L 252 40 06 LL 160 553 33 22 F 16S 252 40 07 LL 210 553 33 23 F 16M 252 40 08 LL 290 553 33 24 F 16XL 252 40 09 LL 392 553
8. Alarm Fault DC tachometer voltage polarity should be based on the polarity of the reference and the selection of the Over Under switch Reference Polarity Over Under Tachometer Voltage Polarity Positive Over Positive Positive Under Negative Negative Over Negative Negative Under Positive Figure 2 8b Sample Regulator Board Terminal Strip Connection Diagram Install and Wire the Drive 2 5 8 Wire the I O Expansion Board The I O Expansion board provides 8 inputs and 8 outputs These inputs and outputs are described briefly in the sections that follow Refer to the WebPak 3000 software reference manual D2 3444 for complete parameter descriptions Digital Inputs 64 p 5 63 62 lt 61 24 V 60 59 65 Analog Inputs 5 gl 5 kohm 50 52 53 Frequency Input 39 0 250 kHz i Digital Outputs CURRENT MEMORY DIG OUT 1 66 x ext supply TENSION ON DIG OUT 1 COM 67 DIAMETER RESET DIG OUT 2 68 x ext supply 24V DIG OUT 2 COM 69 DIAMETER SELECT B DIAMETER SELECT A 24 V 24 V COM 10 VDC Analog Outputs GND 10V or 4 20 mA 1 3 kohm max TENSION SETPOINT ANLG OUT 3 54 N V ext r 32 VDC max TENSION SETPOINT COM ANLG OUT 3 COM 55 TENSION DANCER FDBK ANLG OUT 4 56 TENSION DANCER FDBK COM ANLG OUT 4 COM 57 Frequency Output FREQ OUT A 42
9. FREQ INA Q 0 250 kHz FREQIN A FREQ OUT A 43 gt Cai COM 44 Figure 2 9 I O Expansion Board Terminal Strip Connection Diagram 2 18 WebPak 3000 DC Drive Hardware Reference Digital Inputs ATTENTION The user must read and understand the drive sequencing description and state diagram WebPak 3000 Software Reference chapter 3 before using the TENSION ON input Setting OCL SELECT NONE permits the TENSION ON input to start the drive Once the TENSION ON input is permitted to start the drive negating the TENSION ON input while in any other state than the stall tension state will not stop the drive Failure to observe this precaution could result in severe bodily injury or loss of life The I O Expansion board supports five digital inputs The function of each digital input is fixed and is shown in table 2 3 The drive will recognize a change in the state of a digital input signal e g Oto 24 VDC if it is applied for longer than 20 msec Table 2 3 I O Expansion Digital Inputs DIAMETER SELECTBTP P496 TT 60 lt es CC Terminals 58 and 61 24 VDC and 65 24 V COM are available for use with the digital inputs Digital Outputs The I O Expansion board supports two digital outputs Digital outputs can be sourced from various functions of the drive and hold their state for a minimum of 20 msec The digital output parameters are listed
10. Italian and Numeric Code is available Reference feedback and metering signals can be interfaced to the drive The drive can be controlled locally by the Operator Interface Module OIM Keypad or remotely by using the terminals at the regulator board terminal strip You can select one of the following active control sources using the CONTROL SOURCE SELECT key KEYPAD TERMBLK regulator board terminal strip NETWORK if an optional network communication board is installed SERIAL WebPakCS The built in Field Current Regulator adjustable for 4 10 or 15 A provides field economy as well as preweakening of the field using a fixed reference or field weakening for above base speed operation Refer to manual 49 1345 Publication FP3FCR UM003C EN The Input Output Expansion Board mounts on the WebPak 3000 chassis and gives additional analog frequency and digital I O capability OIM SERIAL NETWORK FIELD Regulator Board Al DRIVE CONTROL SIGNALS AND SEQUENCING z gt FIELD POWER erminal Strip CONTROL SUPPLY I O Expansion Board MOTOR FIELD DIGITAL SPEED ANALOG amp REFERENCE S6 S6R MOTOR ARMATURE FREQUENCY g gt SELECTION gt x gt POWER R INPUTS AND UNIT OUTPUTS SCALING ANALOG OR PULSE TACHOMETER Current Feedback Voltage Feedback Tachometer Feedback Figure 1 2 WebPak 3000 Functional Block Diagram 1 5 Related Publica
11. 220 800 108 125 160 so 365 2 2524011 aro 320 220 200 sa 120 230 do aro 2 25240 12 380 350 350 240 110 140 250 68 500 2 2524018 475 060 ass os 135 250 70 seo 2 22015 450 aol ae 5 e0o 2 252 40 16 460 380 450 m0 150 150 200 105 Ta 2 25244 12 510 450 450 65 TT 42 250 66 190 2 252 44 18 610 450 450 365 125 t65 210 100 600 2 252 44415 460 385 450 Lang 150 100 260 105 1100 2 n no co 4 a 50 low 1 2524206 Ta re 56 ar 60 lil 1 man 150 Tn La ro eo es 1 Figure 5 2 Line Reactor Dimensions mm Power Losses W and Weight kg Field Rectifier Input Replacement Parts and Accessories EMC Filters for WebPak 3000 General Description Power converters in general cause line disturbances over a wide frequency range Through the correct connection of the adapted filters HF filter or Radio Frequency Interference RFI filter according to the following Table 5 7 the conducted emissions in the frequency range 150 kHz to 30 MHz can be kept below the limits stated in product standard EN 61800 3 The radiated emissions in the frequency range 30 1000 MHz will stay below the limits if for the installation the same EMC measures are taken into account as for the conducted HF emissions NOTE On all WebPak drives a line input reac
12. FAULT F00065 SELF TUNING FAULT F00066 SELF TUNING FAULT F00067 SELF TUNING FAULT F00089 SELF TUNING to FAULT F00099 F00100 MAIN CONTACTOR 1 DID NOT OPEN Non zero speed feedback at self tune start Possible causes e ANALOG TACH ZERO ADJ P 202 not set properly e Incorrect speed feedback scaling or offset e Overhauling load causing motor shaft rotation Calculated armature inductance is out of range Possible causes e Motor armature winding not connected or open circuit Blown inverting fault DC fuse Inverting fault breaker tripped Armature inductance too high tune CML manually Maximum current with minimum rotation Possible causes e Motor cannot rotate freely e Motor load is too high e Motor field not at normal operating temperature Attached inertia is out of range Possible causes Maximum self tune speed reached Overhauling load present High mechanical friction present The speed loop cannot be self tuned Tune speed loop manually Speed unstable Possible causes e CML not properly tuned before speed loop e Tachometer or encoder feedback device connected incorrectly SELF TUNE STABILITY P 219 is too low Possible cause e Specified stability is less than that calculated by CML self tuning use 50 or more SELF TUNE STABILITY P 219 is too low Possible cause e Specified stability is less than that calculated by CML self tuning use 75 or more Fatal self tuning fault occurred P
13. Figure 5 6 100 A 500 V Filter Dimensions mm 5 14 WebPak 3000 DC Drive Hardware Reference Radio Interference Filter 150 A 460 V 194 17 160 17 IE 55 55 al 45 M10 a i o ALAS 12 13 amp E 180 95 N O A N N O LO LO a LO co o LOAD PE 111 1L2 1L3 a A FE E GIP ip OT E tae a amp 6 f Yo d E 55 Filter Part No 839 70 20 Power loss 12W Weight 14 kg Figure 5 7 150A 460 V Filter Dimensions mm Replacement Parts and Accessories 5 15 Radio Interference Filter 180 A 440 V and 280A 500 V L3 L2 L1 LINE LOAD L3 L2 L1 fe alo lo lelelo na efe La nai r aso 88 72 67 742 s o 103 159 660 31 so 260 220 700 62 28 70 150 Figure 5 8 180A 440 V and 280 A 500 V RFI Filter Dimensions mm 5 16 WebPak 3000 DC Drive Hardware Reference Radio Interference Filter 270 A 440 500 V 350 Filter Part No 839 70 66 Power loss 26 W Weight 48 kg Figure 5 9 270A 500 V RFI Filter Dimensions mm Replacement Parts and Accessories 5 17 Radio Interference Filter 340 A 440 500 V 420 873
14. WIO or zr i i i i i l j E E E y z E a E E x 7 E E L l na L SJox Ly FIX 12 LX CdA s a Va A f X ina 00 6 ELS OIL E E 1 hr NON 3OVANILNI HIMOd j T 9 1X tom i O 8 ou Ex H SIX ex l k 2 A E K j A amp zz 3 2 73 8 8 8 a Z Z aia RE al dre 1X 7N i 1 KN 9X ox a e i O pee 22 Sed Be Bebe O Ses x 2 xe se Tue 2s E v He ZE sr e z L z L xs L L j AS le O ant ae TA ra RD O A q ees Hp ae 19 Lt ale j oe DEDO ue _ o FZ AON Me eo gt L E gt T j P a EE i 4 sl Coa E 1 Ww N AS i a fg E ES mg j Ly L l 0 0 2972 7 Ec T OF JoyejnBey a LIND pIStd H 4 na C gel se ces MET cla amp l ASL XW 1 PR an Ze zg ney g Ts E mm poa l ES ESA Sd DES Sa Figure 2 7a Principle wiring diagram of WebPak 3000 four quadrant example S 6R 150 A 2 11 Install and Wire the Drive EEE oe S E Co ToS nia sA er ez gg 1 ay SE ar vr ZI 08 0L Z9L j E Er at A NOISNVdXI O I 2
15. conductors Always cross such conductors at 90 All reference signals should be wired with either twisted double or twisted triple conductor wire 40 twists per meter stranded copper 1 5 mm or screened 4 stranded 3 PE 0 5 mm PN 380 35 01 600 VAC rated insulation with a temperature range of 40 105 C Analog tachometer feedback should be run in a separate conduit isolated from all AC and DC power and logic control Wiring should be the same as for the reference signals but screened per pair if stranded cable 0 5 mm PN 380 33 00 is used Digital tachometer feedback Encoder wiring should be twisted per pair not screened and be run in a separate conduit isolated from all AC and DC power and logic control For mounting with external contacts and solenoids coils should be suppressed to reduce noise Important The maximum recommended wire length from the drive to the motor is 300 meter Ground the Drive and Enclosure the Motor and the Operator s Control Station for Grounding WebPak Drives in UL cUL Version refer Recommended Lugs next page You must ground both the control and power wiring 1 Locate the drive ground points as shown in figures 2 4 to 2 6 2 Run a suitable equipment grounding conductor unbroken from either drive ground point terminal PE or ground stud to the plant ground grounding electrode A ring lug is recommended at the ground point 3 Connect a suitable grounding conductor from each conduit to
16. i42 A A Power connections Terminals for 25 A Unit Motor 6 mm 1D 1C 1 4Nm AC Line 6 mm 1U 1V 1W 11 4 Nm Prot earth 6 mm 386 o PE 1 4 Nm Power connections Terminals for 60 A Unit 136 1 J Motor 16 mm 185 gt 1D 1C 2 5 Nm 107 AC Line 16 mm ON per 4 10 1V 1W 2 5Nm 7 25 219 z Prot earth 16 mm A 2 5 Nm MAX 250 a 287 WW U Weight 10 kg Minimum clearances Bs ate Sa ps for air circulation 100 mm HATH TTYL HT FUUU UU UU UU UU UU UU y J 200 Ne Y Figure 2 1 Mounting Data for 25 A and 60 A Drives 2 2 WebPak 3000 DC Drive Hardware Reference gl D o e ES 219 ae Pa 7 0 E amp amp diz 140 ES 7 S A Kal X 2 egege OOO S l J HHHH ai xx H 188 386 in 400 428 f 11130 136 J 107 bi E E HR PE Ea U 25 219 Misa MAX 250 La Ld Y URT JUL JUUL JUUL J 36 287 UUUUU UUUUU AANA AAA _JUUUUUUUUUUU UU UU UU UU 1 a 200 a se T Y Figure 2 2 Install and Wire the Drive Moun
17. the fault would be OIM COMMUNICATIONS TIMEOUT F00011 The two LEDs are labeled CPU OK and OIM COMM OK CPU OK will be on whenever the inputs and outputs are being scanned I O is not scanned during power up diagnostics and following certain faults OIM COMM OK will be on whenever the regulator board and the OIM are commu nicating properly The following table summarizes the possible states of the two LED indicators CPU OK LED OIM COMM OK LED Indication s and Action s Off Off e No power verify that the drive power is on Check for 24 volt at the regulator board terminals 1 and 15 COM e LED failure cycle power and verify that both LED s illuminate briefly lamp test e Power up diagnostics failed replace the Regulator board jon e Combination not used e Combination not used On e I O is being scanned regulator is not communicating with the OIM check OIM cable check voltages at the OIM e I O is being scanned the regulator is communicating with the OIM no faults this is a normal condition no action is required e I O is being scanned the regulator is communicating with the OIM diagnose correct the fault condition and reset the fault from the selected control source fault reset e Power up diagnostics in progress lamp test e Combination not used e I O is not being scanned Regulator board is not communicating with the OIM initialize card set P 010 P 306 P 307 and execute MEMORY SAVE pres
18. 0 positive adjust ARM VOLTAGE ZERO ADJ to a negative value If it was less than 0 negative adjust ARM VOLTAGE ZERO ADJ to a positive value 4 Repeat steps 2 and 3 until ARMATURE VOLTAGE is zero 5 Record the final value of ARM VOLTAGE ZERO ADJ in table 3 1 6 Check the value of output parameter ANALOG TACH FEEDBACK P 291 If the value is 0 Go to step 9 If the value is not zero Go to step 7 7 Adjust ANALOG TACH ZERO ADJ P 202 If analog tach feedback was more than 0 positive adjust ANALOG TACH ZERO ADJ to a negative value If it was less than 0 negative adjust ANALOG TACH ZERO ADJ to a positive value 8 Repeat steps 2 and 3 until ANALOG TACH FEEDBACK is zero 9 Record the final value of ANALOG TACH ZERO ADJ in table 3 1 Make Final Adjustments Set the Quick Start parameters and perform drive self tuning as described in the OIM or WebPakCsS instruction manuals When Quick Start and self tuning are complete adjust the nominal AC line frequency nominal AC line voltage and the field economy reference as follows See the OIM instruction manual for information on setting parameters 1 The default value of NOMINAL AC LINE FREQ P 306 is 60 Hz Adjust the frequency to the nominal value of the line frequency for your application 2 The default value of NOMINAL AC LINE VOLTS P 307 is 230 VAC Adjust the voltage to the nominal value of the line RMS voltage for your application ATTENTION Improper setting of
19. 1 environment residential as well as for the 2 environment industrial supply network b WebPak 3000 converters with AC line input currents above 100 A If the RFI filter is connected the HF emission limits of class A group 1 EN 55011 in the 2 environment industrial supply network are met as required in the past for the Generic Standard EN 50081 2 This is recommended if e g in industrial estates high power converters and offices with sensitive consumers are connected to the same supply transformer The filter must be connected into the three AC line input phases L1 L3 of the WebPak 3000 in front of the AC line reactor as shown in figure B 1 RFI Filter Selection The RFI Filters can be selected from Table 5 7 according to the permitted filter current and the maximum operating voltage The permitted filter current is dependent on the application specific maximum continuous DC current lag of the drive the DC current form factor FF and the ambient temperature T The ambient temperature T is the max temperature around the filter typical 50 C inside cabinets for a standard max cooling air temperature of 40 C Typical DC current form factor FF 1 05 For cabinet mounting with T 50 C and FF 1 05 Filter current maximum continuous DC current laa For other ambient temperatures T and form factors FF the continuous current of the filter can be calculated as follows 45 C 2 45 C FILTER ILine ms X4 s
20. 2 5 1 Ground the Drive the Motor and the Operator s Control Station 2 9 2 5 2 Recommended LUGS usas congecce edhe s des penio Cobnatlan ela da paira Gouna desen E nano 2 10 2 5 3 Wire AC Power to the Drive sss sese eee eee eee 2 13 2 5 4 Wire the DC Motor to the Drive errei 2 13 2 5 4 1 Motor Overload Protection sss sese 2 13 2 5 5 Wire Stopping Devices to the Drive sia 2 13 2 5 5 1 Description of Stop Modes and Drive States 2 13 2 5 5 2 Provide the Emergency Stop Function 2 14 2 5 5 3 COAST STOP Digital Input 2 15 2 5 5 4 SECTION OFF Digital Input iii 2 15 2 5 5 5 Customer Interlock Digital Input esse eee eee eee eee 2 15 2 5 6 Wire the Main Contactor to the DNS sss 2 15 2 5 7 Wire Optional Devices to the Drive sis 2 16 2 5 8 Wire the HO Expansion Board 2 18 Drive Setup and Adjustment 3 1 3 10 3 1 Perform a Power Off Inspection eee reererererererees 3 1 3 2 Test Equipment Needed essen 3 1 3 3 Perform a Motor Ground Check erre rererrarees 3 1 3 4 Set Jumpers on the Regulator Board rr 3 2 3 4 1 Set Regulator Type Jumper J15 25 0 002s0cacesastossasostissengstossecesicasen sicases 3 3 3 4 2 Setting Program Protection Jumper J16 3 4 3 4 3 Inspect the Field Loss Detection Jumper J20 3 4 3 4 4 Inspect th
21. 4 7 4 8 Adjusting the Tachometer or Encoder Loss Sensitivity Normally tachometer or encoder loss is reported when the SCR firing angle reaches 109 when armature current is present and the speed feedback is less than 5 of GEAR IN SPEED P 011 If you are getting nuisance trips associated with high inertia loads you can adjust the SCR angle at which tachometer or encoder loss is reported For a description of parameter TACH LOSS SCR ANGLE P 608 refer to the WebPak 3000 Software Reference manual T ATTENTION This equipment is at line voltage when AC power is connected to the drive Disconnect and lockout incoming power to the drive before proceeding After power is removed verify with a voltmeter at power terminals 1U 1V and 1W that no voltage exists before touching any internal parts of the drive Failure to observe these precautions could result in severe bodily injury or loss of life If you are getting nuisance tachometer or encoder loss trips 1 Lockout and tag power as necessary 2 Turn off power to the drive 3 Check all tachometer or encoder lead connections including polarity 4 If there is no problem with the connections increase TACH LOSS SCR ANGLE by 1 degree 5 Restart the drive 6 Ifa tachometer or encoder loss is reported and the angle is less than 127 repeat this procedure Phase Locked Loop PLL Maximum Error If your drive power is supplied by a source that cannot maintain a suitable fixe
22. 450 A 2 4 Figure 2 4 Mounting Dimensions for WebPak 3000 800 A 2 5 Figure 2 5 Mounting Dimensions for WebPak 3000 1200 and 1600 A 2 6 Figure 2 6 Mounting Dimensions for WebPak 3000 2000 A sese esse ee 2 7 Figure 2 7a Principle Wiring Diagram 150 A 2 11 Figure 2 7b Principle Wiring Diagram 1600 A 2 12 Figure 2 8a Main Contactor Connection Diagram Example eee eee 2 15 Figure 2 8b CTB Connection Diagram Example era 2 17 Figure 2 9 I O Expansion Board Terminal Strip Connection Diagram see eee 2 18 Figure 3 1 Regulator Board Jumper Positions aerea 3 3 Figure 3 2 AUTO REF JUMmpers ws sese eee 3 5 Figure 3 3 I O Expansion Board Jumper Locations ee 3 7 Figure 3 4 Jumper Settings on the I O Expansion board 3 8 Figure 4 1 SCR Armature Current During Normal Operation 4 13 Figure 4 2 Load SCRs Fail to Turn On sss eee 4 14 Figure 4 3 Thyristors Fail to Contact sese eee 4 15 Figure 5 2 AC Line Choke Dimensions esse eee eee eee 5 9 Figure e AF Filler DIMENSIONS iriri gs teers onda Aes deere Toni dad ee nada ee 5 10 Figure 5 4 to 5 12 RFlI Filter Dimensions sees eee eee eee 5 12 Figure B 1 Cabinet Configuration eee eee B 2 Figure B 2 Specification for screened Cable essere B 3 Table fiti iDrive Selection snes ducado HHT
23. 5 Fuse Holder Dimensions Part number 511 23 00 for fuses DIN 80 Size 00 553 2 up to 125 A Part number 511 24 00 for fuses DIN 80 1K 2K 553 30 31 32 160 550 A 5 6 WebPak 3000 DC Drive Hardware Reference Fuse Holder Dimensions continued 0 85 Part number 511 26 01 for fuses DIN 80 3K 660 V 800 1250 A 553 33 xx spacing 80 mm Part number 511 26 03 for fuses DIN 80 3K 800 V 800 1250 A 553 34 xx spacing 110 mm Bus bars To guarantee free air circulation the fuses must be mounted between the input output bus bars as shown with enough space to the next fuse Cooling air per fuse 130 m h curent A Te elfo e TE TS TTS 60 553 72 00 2000 A 230 100 15 105 M12 31 25 100 340 W 553 72 01 2500 A 60 230 100 15 105 M12 31 25 100 390 W Fuses for WebPak 3000 type 2000 A non UL cUL Replacement Parts and Accessories 5 7 Table 5 6 Iron Core Choke Selection The AC line input chokes 252 40 xx produce 2 voltage drop at 400 V and rated current The AC line input chokes 252 44 xx produce 2 voltage drop at 690 V and rated current Note that for applications with radio frequency interference filters RFI chokes for 2 voltage drop at rated input voltage up to 500 V and 4 voltage drop at 690 V are mandatory If on applications with RFI filters the drive is connected to a supply with nomina
24. 89 00 1 Field Current Regul 762 70 60 1 I O Expansion 762 70 80 1 MOV Module 123 43 04 Table 5 2 Urgent recommended spare parts for 4 Quadrant units S 6R 250 450 and 800 A Thyristor Thyristor Module 849 07 03 73 6 Modules 135 11 02 Power Unit Type 1 Module 124 07 00 1 MOV 849 09 03 73 6 Modules 123 39 30 135 12 02 849 11 03 73 12 Thyristors 122 04 02 Further spare parts Field Rectifier Module with MOV P C Boards MOV Module Cooling Fan 1 Regulator 810 79 70 1 Fan with Firmware EPROM 921 90 00 1 Interface TIE 1 Power Supply FPP 89 1 Field Current Regul TO 1 I O Expansion TO 1 MOV Module 43 1 Regulator with Firmware EPROM 1 Interface TIE 813 42 00 1 Power Supply FPP 810 89 00 1 Field Current Regul 762 70 70 1 I O Expansion TO 1 MOV Module 43 Unite o TT 250 450 A 1 Capacitor 211 00 05 1 Resistor 425 18 18 800 A 1 Capacitor 211 36 05 2 Resistor 425 18 18 Replacement Parts and Accessories 5 3 Table 5 3 Urgently recommended spare parts for 4 Quadrant Units S 6R 1200 2000 A S 6R Thyristors Fan P C Boards Unit Type Part No 12 Pieces MOV Module 1200A 50Hz 1 Interface TIG 1 Regulator 810 79 70 500 V 849 13 73 122 93 02 921 91 00 813 43 00 with Firmware EPROM 1200A 60Hz EE Ea aa 1 E eae 1 Field Current Regul 762 70 70 500 V 849 13 43 122 93 02 921 91 11 49 1P lyFPP 810 89 1600A 50Hz ower SO 0 89 00 500 V 849 15 73 122 93 02 92
25. E Oe sec da 1 2 Table 1 2 Drive Modification Kits T 1 4 Table 2 1 Recommended Lugs for Grounding WebPak Drives in UL cUL Version 2 10 Table 2 2 User Device Connections to the Control Terminal Board sse eee 2 16 Table 2 3 to 2 8 Input Output Connections to the I O Expansion Terminal Board 2 19 Table 3 1 Jumper and Adjustment Settings on the Regulator Board sese 3 2 Table 4 1 Fault Codesi s dawns iw Ari aversive A r an hata Gas ied a ee ee 4 3 Tabl 4 2 Alarm Codes uia cece cats perito E aa inatas nda 4 8 Table 5 1 Replacement Parts for WebPak 3000 25100 Anti ode tele ee kate 5 3 Table 5 2 Replacement Parts for WebPak 3000 250 800 A 5 3 Table 5 3 Replacement Parts for WebPak 3000 1200 2000 A i nn 5 4 Table 5 4 to 5 7 ACCEOSSOTIOS seve cde a a a naa aa a A r Eaa rra AAE oa Ea Fananie Eri 5 5 TableA T Armature Voltage 25 nirani deiarna aa aaa aaa aaa ia iaaa ia iaa aa aaike ia A 3 Table A 2 Tachometer Speed Regulation sss eee A 3 Table As Drive Specifiati nS eaoin merireitin E E EE herons E E E A A 4 Table C 1 Cross Reference Part Numbers Catalogue Numbers sse eee eee eee C 1 Contents III WebPak 3000 DC Drive Hardware Reference GENERAL NOTES Safety Instructions ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Important Identifies information t
26. FAULT e Electrical noise due to improper wiring practices or unsuppressed to brake coils relays contactors F03999 e Defective Regulator board Troubleshooting Diagnostics 4 7 Table 4 2 Alarm Codes CODE DISPLAY DESCRIPTION A00002 AC LINE VOLTAGE A00003 AC LINE VOLTAGE HIGH A00004 NETWORK COMMUNICATION TIMEOUT A00005 INVERTING FAULT AVOIDED A00030 MAIN CONTACTOR 1 DID NOT OPEN A00031 MAINCONTACTOR 2 DID NOT CLOSE The AC line voltage fell below 90 of NOMINAL AC LINE VOLTS P 307 Possible causes e Low AC line voltage e Incorrect value entered for NOMINAL AC LINE VOLTS P 307 e Blown AC line fuse s The AC line voltage rose above 115 of NOMINAL AC LINE VOLTS P 307 Possible causes e High AC line voltage e Incorrect value entered for NOMINAL AC LINE VOLTS P 307 Network Communications is missing or failed to communicate with master CONTROL SOURCE SELECT set to NETWORK Possible causes e NETW CONNECT TYPE P 910 was changed from BASIC to FULL NETW DROP NUMBER P 900 was changed Network Option cable connections are loose or not connected Network Option device failed or master communications failed The inverting fault avoidance logic has detected conditions that could have caused an inverting fault The drive took action to avoid an actual inverting fault The main contactor K1M did not open following a stop Possible causes e Disconnected loosely connected or
27. OUTPUT 0 600 VDC 1600 A SHORT CIRCUIT SYM RMS RATING 85 kA ENCLOSURE IP00 CHARACTER OF LOAD M MADE IN SWITZERLAND BY ROCKWELL AUTOMATION AG DIERIKON CE UL CUL Figure 1 1 Sample WebPak 3000 Nameplate Introduction to the WebPak3000 Drive 1 1 1 3 Drive Selection The following table lists the part numbers for ordering a specific drive type For Drive Modification Kits refer to Table 1 2 sheet 1 4 Table 1 1 Drive Selection Unit Type Power Unit Basic 1 S 6R with Nominal Max AC Line Field Current Current Voltage Regulator 25A 500 V 50 Hz 849 01 73 460 V 60 Hz 460 V 60 Hz 460 V 60 Hz 1600 A 690 V 50 Hz 849 17 73 1600 A 575 V 60 Hz 849 17 43 1 The Keypad Operator Interface Module OIM WEB is not included in the basic unit 849 xx xx 1 2 WebPak 3000 DC Drive Hardware Reference 1 4 Drive Description The drive is a full wave power converter without back rectifier complete with a digital current minor loop and a digital major loop for armature voltage or speed regulation by tachometer or encoder feedback The drive provides functions specifically for web handling applications Figure 1 2 shows a block diagram of the drive The drive employs a wireless construction and uses a keypad or dedicated configuration software WebPakCS for drive setup including parameter adjustments and unit selection monitoring and diagnostics Multiple language capability in English French German Spanish
28. a megohmmeter for continuity checks in the drive The A volt ohmmeter having a sensitivity of 20 000 ohms per volt may be used 3 3 Perform a Motor Ground Check conductors between the motor and the drive must be disconnected The T ATTENTION A megohmmeter can be used for this motor ground check but all megohmmeter s high voltage can damage the drive s electronic circuits Disconnect all conductors between the motor and the drive before using a megohmmeter for this motor ground check Failure to observe this precaution could result in damage to or destruction of the equipment The DC Motor frame and conduit box should be connected to a good earth ground per the motor instruction manual Verify that there is no path to ground in either the DC Motor armature circuit the shunt field circuit or the thermostat circuit Connect one lead of a standard ohm reading meter to the motor frame and the other lead to the two armature leads then to the two field leads and to the two thermostat leads If a reading of less than 100 000 ohms is observed a ground condition exists and MUST be corrected before power is applied Drive Setup and Adjustment 3 1 3 4 Set Jumpers on the Regulator Board ATTENTION This equipment is at line voltage when AC power is connected to the drive Disconnect and lockout incoming power to the drive before proceeding After power is removed verify with a voltmeter at power terminals 1U 1V and 1W that no voltage
29. braid or tinned steel braid It must be solidly connected to the control cabinet ground busbar or ground stud of the converter with large connection area and good conductivity The screen on the motor side must be solidly connected to the motor housing providing large connection area with good conductivity If screened cables are not available limited by the obtainable cross sections the individual conductors and protective conductors must be run in steel conduits or enclosed metal cable ducts also connected to ground at both ends All leads shall have the same cross section earth conductors with cross section gt 16 min 16 or 50 of armature lead The connections between filter and converter should be as short as possible These conductors must be bound together with tie wrap forming a triangle in cross section z Power and signal leads inside the cabinet must be distanced Analog or Digital Signals e g reference feedback signals Control Signals Relays These signal leads must be screened cable as specified in Figure B 2 The individual conductors must be stranded but twisted pairs are not required The screen must be grounded at both ends Stranded copper wire Plastic insulation Inner plastic sheath Compact screen of galvanised tinned copper or steel braid Outer plastic jacket Figure B 2 Specification for screened cable B 4 WebPak 3000 DC Drive Hardware Reference APPENDIX C
30. common The signals for both analog outputs can be utputs Analog Output 2 25 common and 26 averaged filtered over 100 ms Logic Running Indicator 27 and 28 The logic output circuits are normally open Outputs Alarm Indicator 29 and 30 when de energized relay contacts No Fault Indicator 31 and 32 1 Analog tachometer must be rated between 18 and 200 Volts 1000 RPM The output voltage must not exceed 250 V when the motor is rotating at the value set for the GEAR IN SPEED parameter To calculate the output voltage 5 Tachometer voltage at GEAR IN SPEED GEAR IN SPEED 1000 x ANALOG TACH VOLTS 1000 When the maximum tach voltage is 62 VDC or lower use terminals 22 and 23 to connect the analog tachometer When the maximum tach voltage is between 63 and 250 VDC use terminals 21 and 23 to connect the analog tachometer 2 16 WebPak 3000 DC Drive Hardware Reference Start Stop by User Contact 5k Auto Reference Analog Tachometer Analog Manual Reference i Section Run i Section Off Jog Fwd we Underwind Enable 27 24V i Coast Stop Vim i i Customer Interlock 129 i Fault Alarm Reset i 30 24V Slack Take up Motor Thermostat 24V 24 V COM i 10V Isolated i COM wii Diameter Taper Range i or Trim Reference 19 i i i 20 com HI Range LO Range Common 25 Analog Out Com i 26 Analog Out2 Jog Rev T i Running
31. exists before touching any internal parts of the drive Failure to observe these precautions could result in severe bodily injury or loss of life ATTENTION Unless explicitly stated otherwise power must be removed before changing any jumper connection Failure to observe this precaution could result in damage to or destruction of the equipment The jumper settings for the WebPak 3000 Regulator Board determine the regulator type program protection field settings references for automatic and manual modes tachometer voltage range and armature feedback scaling There are a few guidelines for setting jumpers e Using the OIM check the current jumper settings for J11 J14 and J18 in the Correct Scaling Jumper Positions menu under Drive Information Write down these settings as displayed and make sure the actual settings match e Using the OIM check the current setting for J15 in the Drive Information menu If this setting is correct for your system you do not need to change it Jumpers are read only on power up so power must be cycled for a change to a jumper setting to be recognized by the drive To set the jumpers 1 Remove power from the drive 2 Remove the cover and the keypad 3 The jumpers are located on the regulator board See Figure 3 1 for jumper locations 4 Set the jumpers as described in the following paragraphs per the requirements of your application Record final settings in Table 3 1 Table 3 1 J
32. filters and the measures as described in this guidelines the WebPak 3000 can be operated CE conform according to product standard EN 61800 3 ATTENTION The conformity of the drive and filter to any standard does not guarantee that the entire installation will conform Many other factors can influence the total installation and only direct measurements can verify total conformity It is therefore the responsibility of the machine manufacturer to ensure that the EC conformity is met Disturbances Conducted High Frequency Disturbances 0 15 30 MHz Depending on location first environment residential or public low voltage supply network second environment industrial supply network and converter rating different limits are permitted whereas the practical limit for the first environment is 100 A For converters with AC line input current below 100 A which are located in the first as well as in the second environment lower limits are required than for converters above 100 A in the second environment Radiated High Frequency Disturbances 30 1000 MHz The radiated disturbances of the converter will be kept below the limits if for the installation the same EMV Measures are taken into account as for the conducted disturbances Conducted Low Frequency Disturbances Harmonics 0 1 2 5 kHz Converters with non sinusoidal AC line input current always generate current harmonics The degree of disturbances caused by harmonics dep
33. parameter FIELD ECONOMY REF P 511 can cause a motor overvoltage condition Set parameter MOTOR HOT FLD AMPS P 510 to the motor s nameplate value Make sure FIELD ECONOMY REF P 511 and or FIELD REF REGISTER P 513 are above parameter FIELD LOSS THRESHOLD P 512 Failure to observe this precaution could result in bodily injury and damage to the equipment 4 The default value of FIELD ECONOMY REF P 511 is 0 Adjust the percentage to a value higher than that of FIELD LOSS THRESHOLD P 512 3 10 WebPak 3000 DC Drive Hardware Reference CHAPTER 4 Troubleshooting Diagnostics ATTENTION 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 section in its entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION This equipment is at line voltage when AC power is connected to the drive Disconnect and lockout incoming power to the drive before proceeding After power is removed verify with a voltmeter at power terminals 1U 1V and 1W that no voltage exists before touching any internal parts of the drive Failure to observe these precautions could result in severe bodily injury or loss of life This chapter provides troubleshooting and diagnostics information for the WebPak 3000 drive It lists faul
34. this drive ground point 4 Connect a suitable equipment grounding conductor to the motor frame the transformer enclosure if used and the drive enclosure Run this conductor unbroken to the grounding electrode 5 Connect the PE green yellow wire brought in with the incoming AC power line to the drive ground point 6 Tighten chassis ground connections per tables in figures 2 1 to 2 6 Install and Wire the Drive 2 9 2 5 2 Recommended Lugs for Grounding WebPak 3000 Drives in UL cUL Version The following describes how to interpret Reliance USA lug model numbers used in grounding the WebPak 3000 drive The lugs are non insulated screw type solderless for use with solid and stranded wire 1LG 1203 Basic Catalog Number Number of Conductors WW _ 1 one conductor 2 two conductors 3 three conductors Mounting Hole and Lug Material 1 one mounting hole copper 2 one mounting hole aluminum 3 two mounting holes copper 4 two mounting holes aluminum 5 four mounting holes copper 6 four mounting holes aluminum Lug Version Number 01 to 99 Table 2 1 Recommended Lugs for different Wire Sizes RA Dierikon Reliance USA Reliance USA Wire Size Mounting Material Part Number Model Number Part Number Hole 916 10 70 1LG1101 68321 38AA 14 8 AWG M5 copper 916 10 71 1LG1102 68321 38AB 14 8 AWG M6 copper 916 10 72 1LG1103 68321 38AC 4 1 0 AWG M1
35. 0 DC Drive Hardware Reference CHAPTER 1 Introduction to the WebPak 3000 Drive This section provides specifications and a description of the WebPak 3000 Drive 1 1 Store the Drive After receipt inspection repack the drive in its original shipping container until ready for installation To ensure satisfactory operation at startup and to maintain warranty coverage store the drive as follows e In its original shipping container in a clean dry safe place e In an ambient temperature that does not exceed 65 C 149 F or go below 30 C 22 F e Within a relative humidity range of 5 to 95 without condensation e Away from a corrosive atmosphere In harsh environments cover the shipping storage container e Atan altitude of less than 3 000 meters 10 000 ft above sea level 1 2 Drive Identification Nameplate The WebPak 3000 drive has a nameplate on the right side of the carrier that identifies the drive by its specific Hardware and Software Part Numbers and applicable AC input power and DC output power data Refer to this nameplate example All communication concerning this product should refer to the appropriate Part Number information The technical power information should be referenced to verify proper power application RELIANCE ELECTRIC ME P N EQUIPMENT 849 17 43 A SER NO P N VERSION EU IM 491359 TYPE WP3000 S6R F1600 60 AN FC SAW VERSION 1 0 US MIN US I M HW US I M S W INPUT 575 VAC 3PH 60 Hz 1360 A
36. 0 copper 916 10 73 1LG1104 68321 38AD 1 0 4 0 AWG M12 copper 916 10 74 1LG1105 68321 38AE 4 0 500 MCM M10 copper 916 10 80 1LG1201 68321 38BA 14 1 0 AWG M6 aluminum 916 10 81 1LG1202 68321 38BB 14 2 0 AWG M6 aluminum 916 10 82 1LG1203 68321 38BC 6 250 MCM M8 aluminum 916 10 83 1LG1204 68321 38BD 6 300 MCM M6 aluminum 916 10 84 1LG1205 68321 38BE 6 350 MCM M10 aluminum 916 10 85 1LG1206 68321 38BF 4 500 MCM M10 aluminum 916 10 86 1LG1207 68321 38BG 300 800 MCM M12 aluminum 916 10 87 1LG1208 68321 38BH 500 1000 MCM M12 aluminum 916 10 88 1LG2401 68321 39BA 2 600 MCM M10 aluminum 916 10 89 1LG2402 68321 39BB 350 800 MCM M10 aluminum 916 10 90 1LG2403 68321 39BC 500 1000 MCM M12 aluminum 916 10 91 1LG3601 68321 40BA 2 600 MCM M12 aluminum 2 10 WebPak 3000 DC Drive Hardware Reference E eS a Se ee ee ee 1 j EEE L er er ze or gr j Lr sr i or DR Er Tr Ir 08 07 292 NOISNVdXI O I ar a j Ov 62 018 00 68 0L8 dd4 i 7 er HOLVINDIA dans HIMOd j i L0 96 226 RE uondo
37. 1 91 00 1 I O Expansion 762 70 80 1600A 60Hz 500 V 849 15 43 122 93 02 921 91 11 pa Pp 500 V 849 19 73 122 93 02 921 91 00 nar Pe PE tie 500 V 849 19 43 122 93 02 921 91 11 ar PA a 690 V 849 17 73 122 93 04 921 91 00 813 43 10 1600A 60Hz 1 Interface TIG 575 V 849 17 43 122 93 04 921 91 11 813 43 10 1 MOV Module 123 43 04 Further spare parts for 1200 2000 A units Suppression print SBA 803 56 00 RC Suppression module for 690V only 922 58 10 5 4 WebPak 3000 DC Drive Hardware Reference 5 2 Accessories Semiconductor protection fuses in the AC line input of the converter and field circuit and in the motor armature circuit are to be selected from the following tables 5 4 and 5 5 Chokes in the AC line input of the converter and field circuit are to be selected from the table 5 6 The fuses and chokes are externally mounted and not supplied with the power module Table 5 4 Semiconductor Protection Fuses Motor Armature 4 Qd AC Line input Fuse e Fuses Fuses per Fuse lad 2 2 pieces 3 3 pieces Indicator Holder alal gz 2 as ee lize 50A 60A 80A 553 28 07 63A 553 28 06 553 29 00 511 23 00 150A 75A 90A 125A 553 28 09 100A 553 28 08 553 29 00 511 23 00 108A 130A 200A 553 30 05 160A 553 30 04 553 29 00 511 24 00 125A 150A 200A 553 30 05 160A 553 30 04 553 29 00 511 24 00 208A 250A 315A 553 31 13 250A 553 30 06 553 29 00 511 24 00 375A 450A 550A 553 32 18 450A 553 32 16 553
38. 10 VDC and 34 GND are available for use with up to two 5 kQ potentiometers Analog Outputs The I O Expansion board supports two analog outputs Analog output 2 can generate a bipolar DC voltage only The other can be configured to generate one of the following signals DC voltage 0 to 10 VDC or 4 20 mA Both outputs are unfiltered whereas standard meter outputs are averaged Analog outputs can be scaled to generate DC voltage signals as low as 5 V but maximum resolution 0 025 is obtained when the full scale output signal is used The full scale value is determined based on the selected parameter group load speed voltage power field or other Analog output signals are updated every I O scan typically 20 msec Table 2 6 lists the analog outputs and related parameters Figure 2 9 provides an example of how to wire an external supply for 4 20 mA output Table 2 6 I O Expansion Analog Outputs ANLGOUT3SIGTYPE TA P49 o ANLGOUT3GAINADJ T P40 o ANLGOUT4GAINADJ P42 0 oo Frequency Input The I O Expansion board supports one unipolar frequency input FREQ IN P 491 The freq input signal is read every 20 msec Table 2 7 lists the frequency input and related parameters Table 2 7 I O Expansion Frequency Input FREQINZERO A PAB o FREQ IN FULL SCALE P424 oo Frequency Output The I O Expansion board supports one unipolar frequency output The output is unfiltered The full scale value is determined based o
39. 29 00 511 24 00 800A 525A 630A 800A 553 33 21 630A 553 33 19 553 29 00 511 26 01 666A 800A 1000A 553 33 22 800A 553 33 21 553 29 00 511 26 01 1200A 833A 1000A 1250A 553 33 23 1000A 553 33 22 553 29 00 511 26 01 500V 1000A 1200A 2 800A 553 33 21 1250A 553 33 23 553 29 00 511 26 01 1600A 1167A 1400A 2 1000A 553 33 22 2 900A 553 33 24 553 29 00 511 26 01 500V 1334A 1600A 2 1000A 553 33 22 21 900A 553 33 24 553 29 00 511 26 01 2000A 1667A 2000A 2500A 553 72 01 2000A 553 72 00 553 26 30 500V 2 1250A_ 553 33 23 2 1000A 553 33 22 553 29 00 511 26 01 2 700A 34 2 630A 553 34 34 553 26 30 511 26 03 2 900A 34 2 800A 553 34 36 553 26 30 511 26 03 2 900A 34 2 800A 553 34 36 553 26 30 511 26 03 2 800A 553 33 21 1250A 553 33 23 553 29 00 511 26 01 2 900A 553 33 24 2 800A 553 33 21 553 29 00 511 26 01 2 900A 553 33 24 2 800A 553 33 21 553 29 00 511 26 01 Fuses and accessories marked in grey are not UL cUL Fuse trip indicator 553 29 00 included in fuse package For selection and dimensions see also following pages Table 5 5 Field Supply Input Fuse Max Field AC Input Fuse Holder Dimensions Field Current Fuse Fuse Fuse Fuse Holder Size 11 Rating Type Part No Part No 2 pieces ER ea ak osso smao RA ea 5580010 smao Con oa on marco Replacement Parts and Accessories 5
40. 3000 DC Drive Hardware Reference CHAPTER 2 Install and Wire the Drive ATTENTION The user is responsible for conforming to all other applicable standards Wiring practices grounding disconnects and overcurrent protection are of particular importance Size and install all wiring in conformance with the applicable standards Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION This equipment must be connected to a power source for which it was designed Compare available power with the requirements listed on the nameplate to insure that voltage frequency phase current capacity and interrupting capacity are adequate Failure to observe this precaution could result in severe bodily injury or loss of life 2 0 Recommended AC Line and DC Armature Fuses The user must select the correct fuse type ultra fast semiconductor protection for drive AC line and DC armature fuses from the table 5 4 in chapter 5 The armature fuse is only for four quadrant drives S 6R 2 1 Install the Drive Install the drive s in the cabinet Refer to figures 2 1 to 2 6 for mounting dimensions Minimum clearances of 100 mm must be maintained when the drive is mounted within a cabinet This allows adequate ventilation for the drive The user must ensure that the drive s ambient temperature specification is met For more information refer to page 1 of Appendix A Install and Wire the Drive 2 1
41. 34 34 F 14S 252 40 10 LL 530 5593 34 35 F 14M 252 40 11 LL 660 553 34 36 F 14L 252 40 12 LL 850 553 34 37 F 14AL 252 40 13 LL 1100 553 72 00 F 2000 252 40 14 LL 1300 553 72 01 F 2500 252 40 15 LL 1360 610 11 05 140M C2E1316 252 40 16 LL 1700 1750 70 04 2952 42 01 LF 15 1762 70 00 PTK 907FK0101 2952 42 05 LF 6 1762 70 29 SCK 252 42 06 LF 12 1762 70 30 DMK 2952 44 12 LL 850 A 1762 70 40 AMXF 915FK0101 2592 44 13 LL 1100 A 1762 70 45 IBSF 915FK3101 252 44 14 LL 1300 A 1762 70 50 FCU4 911FK0041 2592 44 15 LL 1360 A 1762 70 60 FCU10 911FK0101 511 21 00 F FH 1762 70 70 FCU15 911FK0151 511 23 00 F H1 1762 70 80 IOE 914FK0101 511 24 00 F H2 762 70 90 DNC 914FK1100 511 26 01 F H4 762 70 95 PDPF 915FK4101 511 26 03 F H5 762 70 96 CONF 915FK2101 553 00 09 F F6 772 27 00 61C127 61C127 Cross Reference 1172 27 20 2CA3001 2CA3001 C 1 Table C 1 Cross Reference List continued
42. 3PDP UM002B EN ControlNet Allows a WebPak to communicate over the 762 70 96 D2 3425 Communication open protocol ControlNet network CONF D2 3425 Board Mounts inside the WebPak and includes terminals for network connections The AMX Network Comm board cannot be used when using the ControlNet Drive Control Windows based software that allows the user D2 3447 Configuration to connect any personal computer running D2 3447 Software Micro soft Windows version 3 1 or later to a WebPakCS WebPak 3000 drive Allows you to create store upload and download drive configurations You can also monitor and change parameters through the PC and read and reset the drive s fault log Interface Cable for connecting the drive to PC 25 pin to 9 pin 772 27 00 610127 Keypad Operator Allows you to control e g Start Stop Jog 922 95 01 D2 3445 Interface Module the drive You can also monitor and change OIM WEB D2 3445 parameters read and clear the drive s alarm and fault log OIM Remote Provides for remote mounting of the OIM up 762 70 30 D2 3294 Mounting kit to 5 meters away from the drive Contains DMK D2 3294 1 also the cover plate 762 70 31 for the regulator unit Description 1 Manuals with Publication Number FP3xxx or D2 xxxx can be ordered in the Automation Bookstore or downloaded via www theautomationbookstore com than Public Item search Go Item Number begins with e g FP3 or D2 3445 search 1 4 WebPak
43. 50mA J12 J10 J12 J10 J12 J10 VOLTS 10 50 mm voLTs E volts 10 50 EE VOLTS E volts 10 50 Ei BOTH EH 4 20 BOTH mm 4 20 BOTH 4 20 E MAMPS PARK HE MAMPS PARK HH MAMPS PARK EE Figure 3 2 AUTO REF Jumpers J12 and J10 3 4 8 Scale the Armature Current Feedback Jumper J18 ATTENTION The drive will not run at the correct speed if this jumper is not set to the correct position Failure to observe this precaution could result in damage to or destruction of the equipment The ARM FB RB Jumper J18 scales the armature current feedback signal The drive calculates the value of the burden resistor needed to scale the armature current feedback signal The calculations are based on the values of MOTOR RATED ARM AMPS P 008 and MAXIMUM CURRENT P 007 The OIM displays the correct position of this jumper during the Quick Start procedure Verify this setting before performing the Self Tuning procedure 3 4 9 Inspect Jumper J26 This jumper determines whether or not a fault is generated when a tacho loss occurs or the armature is open ATTENTION Jumper J26 is for factory personnel use only The user must not change the status of this jumper Misapplication of this jumper can cause the motor to run at dangerously high speeds Failure to observe this precaution could result in bodily injury or loss of life J26 is intended for use by Rockwell Automation factory personnel only Veri
44. 6 Fault and Alarm Messages Descriptions and Code Numbers 4 3 4 7 Adjusting the Tachometer or Encoder Loss Sensitivity eee eee 4 10 4 8 Phase Locked Loop PLL Maximum Error eee 4 10 4 9 SCR Diagnostics and Adjusting Open SCR Sensitivity cee 4 11 4 10 Armature Phase Fire Test eee 4 13 4 11 Setting Reversed Tachometer or Reversed Encoder Lead Detection 4 15 4 12 Setting Up Inverting Fault Avoidance a 4 15 4 13 Checking the AC Line Period and Voltage cceccceeeeeeeeeeeteeeeeeeeeeeeeeenees 4 16 4 14 Checking Drive 1nformation ss sees eee eee 4 16 4 15 Power Supply Test Pin Identification eee eee 4 15 Replacement Parts and Accessories 5 1 5 20 5 0 Replacement of Components sss eee eee 5 1 5 1 Recommended Spare arie 10747 T za cT c c erre eras Oa Za Rar 2 5 3 Didi CACCOSSONOS rs nites nana Haste sie eee ene ee en eae La eee ts 5 5 Technical Specifications A 1 A 6 CE Conformity B 1 B 4 Cross Reference Part Numbers Catalogue Numbers C 1 C 2 WebPak 3000 DC Drive Hardware Reference List of Figures Figure 1 1 Sample WebPak 3000 Nameplate errei 1 1 Figure 1 2 WebPak 3000 Functional Block Diagram eee 1 3 Figure 2 1 Mounting Dimensions for WebPak 3000 25 and 60 A 2 2 Figure 2 2 Mounting Dimensions for WebPak 3000 150 A 2 3 Figure 2 3 Mounting Dimensions for WebPak 3000 250 and
45. 9 05 73 WP3000 S6R 150 AN FC 1 849 07 73 WP3000 S6R 250 AN FC 849 09 73 WP3000 S6R 450 AN FC C 2 WebPak 3000 DC Drive Hardware Reference Reach us now at Www rockwellautomation com Wherever you need us Rockwell Automation brings together leading brands in industrial automation including Allen Bradley controls Reliance Electric power transmission products Dodge mechanical power transmission components and Rockwell Software Rockwell Automation s unique flexible approach to helping customers achieve a competitive advantage is supported by thousands of authorized partners distributors and system integrators around the world Americas Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 01 414 382 2000 Fax 01 414 382 4444 Rockwell European Headquarters SA NV Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 06 00 Fax 32 2 663 06 40 p Asia Pacific Headquarters 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication WP3000 UMO10B EN Aug 2001 O 2001 Copyright Rockwell International Corporation
46. ETER Tachometer or encoder feedback signal missing Possible causes e Tachometer or encoder coupling failure e Disconnected loosely connected or damaged tachometer or encoder wires Pulse encoder supply voltage low Incorrect analog tachometer scaling Incorrect pulse encoder configuration Motor armature winding not connected or open circuit Blown inverting fault DC fuse Inverting fault breaker tripped Tachometer or encoder failure High inertia loads and high inductance armature circuits To reduce nuisance faults increase the firing angle threshold see section 4 7 F00003 OVERSPEED Motor speed exceeded the 110 of GEAR IN SPEED Possible causes e Incorrect tachometer or encoder scaling e Blown field supply fuse s e Improper speed loop tuning e Incorrect pulse encoder wiring F00004 FIELD CURRENT Field Current Regulator kit field supply FIELD FEEDBACK P 589 fell below the FIELD LOSS THRESHOLD P 512 Possible causes Motor field winding not connected or open circuit Blown field supply fuse s Blown AC line fuse s Field supply failure Disconnected loosely connected or damaged wiring harness Improper field loop tuning Troubleshooting Diagnostics 4 3 Table 4 1 Fault Codes Bear DE F00005 FO DISPLAY SUSTAINED OVERLOAD DESCRIPTION Inverse time overload circuit trip Possible causes e Incorrect armature current feedback scaling MOTOR RATED ARM AMPS MAXIMUM CURRENT C
47. OAST STOP Digital Input The WebPak 3000 drive can be configured to provide a coast to rest operational stop without physical separation of the power source from the motor A coast to rest stop turns off the transistor power device drivers Opening of the digital input COAST STOP terminal 8 during operation causes blocking of the regulator and the drive to Coast to rest This input may be used for the Emergency Stop control circuit if the main contactor drop out is forced by electro mechanic device otherwise this Stop function corresponds with Category 2 NOTE If this digital input is not used a jumper must be wired between drive terminals 7 and 8 otherwise the drive will not start SECTION OFF Digital Input Opening the SECTION OFF input terminal 3 with the drive running causes the drive to stop in the selected Stop Mode Coast to rest Ramp to rest or Current limit Stop This STOP function corresponds with Category 2 if the main contactor drop out is not forced by electro mechanic device The function is active at all times regardless of the selection of AUTO MANUAL or the CSS setting KEYPAD TERMBLK Customer Interlock Digital Input Opening the control input at terminal 9 during operation is the fastest way to disable the drive output By software it directly ramps down armature current to zero and then opens the main contactor The motor will coast to rest Because this is a software function it must not be used
48. RELIANCE ELECTRICS WebPak 3000 DC Drives Hardware Reference Installation and Troubleshooting Instruction Manual Ce DO Manual P N 899 07 86 User Manual 49 1359e 02 Publication WP3000 UM010B EN Rockwell Automation CONTENTS Chapter 1 Chapter 2 Chapter 3 Contents General Notes Safety Instruccions Gli c vee ceeds Gac a ORAR Na dada foda Lea a Cor tats caia V General MODS sua essa enaa eT do r ESA e pe FO de sou a Ga poa dep VI Introduction to the Drive 1 1 1 4 1f Store AMG NING asarira daundandtal E DEDO NUR RE PES RUE DOE NOR ORE q ai 1 1 1 2 Drive Identification Nameplate ee eereeeesaaaaaaaaaaaaaaaea 1 1 13 MORE Tele n 1 2 1 4 Drive Description erica eae aeaa e aea TEA 1 3 1 5 Related Publications e eeeeeeeeaaeea aeee rerenaaaaaaanananas 1 3 1 60 Optional RAS start drenados a 6 q A 6 OS 6 a Mr 1 4 Install and Wire the Drive 2 1 2 20 2 0 Recommended AC Line and DC Armature FUSES eee 2 1 2 1 Install the Drive Dimensions eee 2 1 2 2 Install a Line Reactor or Transformer for Input Power Conditioning 2 8 2 3 Install an Input Disconnect Guidelines eee ee 2 8 2 4 Install the Moor sees 2 9 2 97 NWS ANE DIIVO es is rasas giv ocus dsruadaseaeverdccebnaens sag exaeaetn clas cagVenweaets cate e ASE neer En 2 9 2 5 0 General Wiring Practices sacras soraia spas SE tele oh ur eg els ng asa 2 9
49. Ratings Nominal voltage for three phase at terminals 1U 1V 1W and 2U 2V 2W On units 25 60 150 A 200 500 VAC at 50 Hz 200 460 VAC at 60 Hz On units 500 V 250 450 800 1200 1600 and 2000 A 200 500 VAC On units 575 V 60 Hz 1600 A 300 575 VAC On units 690 V DO Hz 1600 A 300 690 VAC Input voltage for Field Controller Supply on WebPak 25 800 A max 415 VAC Input voltage for Field Current Regulator Kit Option max 460 VAC VOMAGS VANIA casa inire natesatdeder Osage sive sie sangen tates asus dent sa derrass 10 and 10 of Nominal Nominal line frequency eee eee 50 or 60 Hz Frequency variation TT 2 Hz Fan Supply Voltage and Current Consumption on Units 1200 2000 A Three phase input voltage at terminals 5U 5W SW eee eee eee 400 V 50 Hz or 460 V 60 Hz 1A NOTE On units 60 Hz 1200 2000 A in UL cUL version the fan must be external protected by the following thermal magnetic circuit breaker Dierikon part No 610 11 05 RA catalog No 140M C2E1316 Regulator Supply Voltage and Power Consumption Single phase input voltage via autotransformer 230 VAC at terminals 0 230 or 115 VAC at terminals 0 115 Power Consumption including fan on type 150 800 A sees eee eee max 120 VA Thermal magnetic protection by external circuit breaker NOTE On units with terminals 4U 4V without autotransformer i
50. T TURNS RATIO and or J18 not set properly e Blown field supply fuse s e Mechanical binding preventing the motor shaft from rotating freely 0006 BLOWER MOTOR This fault is not applicable on European versions WebPak 3000 STARTER OPEN Possible causes e Motor armature winding not connected or open circuit e Blown inverting fault DC fuse F00007 OPEN ARMATURE The motor armature circuit is open e Inverting fault breaker tripped F00008 F00009 F00010 F00011 THERMOSTAT TRIP CONTROLLER THERMOSTAT TRIP AC LINE SYNCHRONIZATION FAULT OIM COMMUNICATIONS TIMEOUT Motor thermostat indicates high temperature If a motor thermostat is not used customer terminal board pins 13 and 14 must be jumpered to inhibit this fault Possible causes Damaged or disconnected motor thermostat wiring Inadequate ventilation Blower motor failure Incorrect blower rotation Blocked ventilation slots Clogged filters Excessive armature current One or more thyristors not operating Drive thermostat indicates high temperature Possible causes e Inadequate heat sink ventilation e Inadequate cabinet ventilation e Heat sink fan failure e Damaged or disconnected drive thermostat wiring Three phase AC line synchronization circuit failure Possible causes e Blown AC line fuse s e AC line frequency not within required range of 48 to 62Hz e Excessive AC line noise or distortion e Unstable AC line freq
51. armature and field power wiring NOTE The Drive will not start if the circuit between terminals 13 and 14 is not made See Figure 2 8b Wiring Stopping Devices to the Drive Description of Stop Modes and Drive States The WebPak 3000 drive can be stopped by the assertion of a stop input which can be configured as a ramp stop a current limit stop or a coast DB stop opening a permissive input coast DB interlock or customer interlock deassertion of the JOG FWD or JOG REV input or in the event of a fault Depending on the type of stop one of two different stop sequences are executed to provide an orderly method of deactivating the armature To the internal sequencing algorithm the drive is always in one of three states armature not active main contactor open run mode or jog mode The armature is not active while in the NOT READY and READY states The drive is considered to be in RUN mode if it was started by the SECTION RUN input or the TENSION ON input Install and Wire the Drive 2 13 2 5 5 2 The following three states are considered to be permutations of RUN mode SPEED RUN TENSION and JOG TENSION The drive will remain in RUN mode until the completion of a stop sequence and the main contactor is opened The drive is considered to be in the JOG mode if the drive was started via the JOG input Note that the drive can enter the SPEED state from the JOG state if the SECTION RUN input is asserted while in JOG mode The drive
52. conductors for the specific drive rating see figures 2 1 to 2 6 and according to all applicable standards 2 Connect the AC line supply via disconnect if used and line reactor or matched transformer to the terminal strips or bus bars at the top of the converter or to the disconnect 3 Tighten incoming AC line connections per tables in figures 2 1 to 2 6 Important The tightening torque in the table applies to the wiring device stud or terminal board provided When an input or an output device breaker or lug kit is added refer to the kit instructions for tightening specifications Wire the DC Motor to the Drive 1 Size the motor armature circuit conductors for the specific drive rating see figures 2 1 to 2 6 and according to applicable standards Use only copper wire rated 60 70 C or higher 2 Locate the DC motor armature and field supply leads on the drive 4 Connect the DC motor armature leads and the shunt field supply leads to the drive 5 Tighten armature connections per tables in figures 2 1 to 2 6 Motor Overload Protection A software internal static overload is provided In addition to the software internal overload function a DC motor thermostat can be used for motor thermal overload protection The thermostat leads are brought out through the motor terminal box as leads P1 and P2 These two leads must be wired to the regulator board control terminals 13 and 14 The thermostat leads can be run with the motor
53. ct e Recheck all motor connections for tightness and correct identification e Verify that there is no path to ground in either the DC motor armature circuit the shunt field circuit or the thermostat circuit Connect one lead of a standard ohm meter to the motor frame and the other lead to the two armature leads then connect to the two thermostat leads and then to the two field leads If a reading of less than 100 000 ohms is observed a ground condition exists and MUST be corrected before power is applied Check that the field winding is not open or shorted e Verify the continuity of the motor thermostat and its proper connection to regulator board terminals 13 and 14 If a motor thermostat has been installed verify that it s circuit maintains continuity in the terminal 13 and 14 circuit Troubleshooting Diagnostics 4 1 4 4 Verifying Optional Kits Verify that each optional kit has been installed correctly according the appropriate instructions Refer to the appropriate instruction manuals See section 1 5 and 1 6 4 5 Checking the Regulator Led Status Two LEDs are located on the Regulator board to indicate the operating status of the Regulator board The cover on the OIM must be removed to observe these LEDs Check and observe these LEDs when the OIM is not communicating with the regulator Typically there will be no fault indication on the display when the OIM is not communicating with the regulator board If a fault can be displayed
54. d Full Load Minimum Source Capacity kVA Max Source Capacity Rated DC for different AC line voltages at 50 Hz Symmetr fault current rms Current 400V 460V 500V 575v 690V for UL cUL 25 15 18 20 18 kA 60 36 41 45 18 kA 150 90 102 111 18 kA 250 150 175 188 30 kA 450 270 306 333 30 kA 800 480 545 592 30 kA 1200 720 818 888 85 kA 1600 960 1100 1190 1400 1630 85 kA 2000 1200 1373 1486 85 kA Service Conditions SLANG Ia GUS creia anta gesso sas ga Sa A scale e Need ee Sout up to 1000 meters Above 1000 m the output current must be reduced by 1 per 100m Standard ambient temperature at Operation with nominal current e rererreeaereaararararararen a 0 C to 40 C eee nr a EE er rrr rrr eee 25 C to 55 C Transportations a a a a 25 C to 70 C Max ambient temperature eee eee 55 C Above 40 C output current must be reduced by 1 5 per C Relative h mMidity inss rs r reesi max 50 at 40 C unlimited time Non Condensating max 90 at 20 C 30 days year max 75 average per year Environment The drive should be located in an area that is free of dust dirt acidic vapors vibration and shock temperature extremes and electrical or electromagnetic noise interference Degree Of protection 2 ete ranea S592792 NaN Ea E ENE AN EAN IPOO Technical Specifications A 1 Input Voltage and Frequency
55. d contacts closed the three circuits indicate the following drive conditions Running 27 to 28 Alarm 29 to 30 No Fault 31 to 32 Electrical Specifications Operating Voltage sse eee eee 250 V AC maximum 30 V DC maximum Switching Le u 2 A maximum resistive 1 A maximum inductive Analog Inputs The three customer analog inputs are e Manual Mode Reference e Automatic Mode Reference e DC Tachometer Feedback These inputs are converted at 12 bits plus sign at their full range The electrical specifications for each of these is listed below Electrical Specifications Current loading as zadig aczsg2y irinin daiten SL ESA Dada LE aa SAE LESS La del nda cad 2 5 mA maximum Manual Mode Reference Jumper J19 Potentiometer 5 kohm minimum OT External Voltage Source 10 VDC when used for Analog Trim Ref EXT O 10 VDC when used for Manual Mode Speed Ref Automatic Mode Reference A 4 WebPak 3000 DC Drive Hardware Reference Analog Tachometer Feedback Tach Voltage at Gear in Speed sse eee eee eee 10 250 VDC NOTE J14 Jumper position and connection of DC Tachometer must correspond Gear in Speed Tach Volts EE ew Analog Outputs The two metering analog outputs are available at regulator board terminals 24 25 and 26 Terminal 25 is the common connection for both output signals The selected signals for both meter outputs are averaged filtered over 100 msec to reduce meter fluctuati
56. d Supply Jumper J21 The FIELD SUPPLY jumper J21 is not used with WebPak 3000 drives The position of this jumper has no effect on the drive Set the Source of Manual Mode Reference MANUAL REF J19 Jumper T ATTENTION The drive will not run at the correct speed if this jumper is not set to the correct position Failure to observe this precaution could result in damage to or destruction of the equipment The MANUAL REF jumper J19 determines whether the internal 10 V isolated power supply or an external 10 V source is used for the Diameter Taper Range or Trim Reference To use the 10 V power supply for the manual reference potentiometer place the jumper on pins 2 and 3 POT The supply at terminal 16 of the regulator board terminal strip is used To use an external 10 V source place the jumper on pins 1 and 2 EXT The external reference is connected at terminals 17 and 18 of the regulator board terminal strip NOTE This input can be used as a trim on the Line Speed reference by setting the jumper on pins 1 and 2 EXT Set the Voltage Range and Scale of an Analog Tachometer Jumpers J11 and J14 The TACH V RANGE J14 and TACH V SCALE J11 jumpers set the voltage range and scale of the analog tachometer NOTE These jumpers are ignored if an analog tachometer is not used and if FEEDBACK SELECT P 200 is not set to DC TACH T ATTENTION The drive will not run at the correct speed if these jumpers are not set to th
57. d frequency output such as an alternator you can adjust PLL MAXIMUM ERROR P 308 to prevent faults related to line synchronization For a description of parameter PLL MAXIMUM ERROR refer to the WebPak 3000 Software Reference manual 4 10 WebPak 3000 DC Drive Hardware Reference 4 9 SCR Diagnostics and Adjusting Open SCR Sensitivity Under normal drive operation the load carried by each SCR is relatively equal as shown in figure 4 1 Figure 4 1 SCR Armature Current During Normal Operation If one or more SCRs fail to turn to on a unique pattern of insufficient or missing current pulses results as shown in figure 4 2 Open SCR diagnostics detects SCRs that are not conducting by analyzing the level of current produced by each SCR pair firing If one or more SCR consistently fails to produce current at a level approximately equal to other SCRs that fired the drive concludes that an open SCR has occurred The open SCR diagnostic calculates the percentage deviation of current feedback for each pair of SCRs from the average current feedback The percent deviation must exceed the value set for OPEN SCR SENSITIVITY P 600 before the diagnostic proceeds to the next part of the diagnostic In the next part of the diagnostic deviations from the average current are integrated over time to eliminate transient effects from the calculation When the integration reaches the value of OPEN SCR TRIP THRESH P 601 an open SCR fault is g
58. damaged main contactor K1M or Aux contactor K1 wiring e Main contactor or Aux Main contactor failure e Disconnected loosely connected or damaged main contactor control wiring MCR The main contactor K1M did not close following a run or jog command Possible causes e Disconnected loosely connected or damaged main contactor K1M or Aux contactor K1 wiring e Main contactor or Aux Main contactor failure e Disconnected loosely connected or damaged main contactor control wiring MCR 1 When after stop command the auxiliary contactor does not indicate that the main contactor opened this alarm indication is 1000 msec time delayed 2 When after start command the auxiliary contactor does not indicate that the main contactor closed this alarm indication is 1000 msec time delayed 4 8 WebPak 3000 DC Drive Hardware Reference Table 4 2 Alarm Codes Continued CODE DISPLAY DESCRIPTION A00032 SUSTAINED SPEED A00033 SUSTAINED ARMATURE CURRENT A00050 CML FEEDBACK SCALING ERROR A00051 LOW MINIMUM SPEED A00052 no message A00700 RETENTIVE MEMORY SAVE ERROR Troubleshooting Diagnostics Motor speed did not fall below STOP SPEED THRESHOLD P 113 in the required amount of time during a stop this time is automatically set to two times the DECELERATION RATE P 002 time Possible causes e DECELERATION RATE P 002 not set properly e STOP SPEED THRESHOLD P 113 no
59. ds are reversed There is an overhauling load The drive was not tuned properly F00015 INVERTING FAULT AVOIDED F00016 PHASE LOSS F00017 kit missing or unsupported kit installed F00030 SCR No n NOT OPERATING F00042 MULTIPLE SCRS NOT OPERATING F00060 SELF TUNING FAULT Troubleshooting Diagnostics The inverting fault avoidance logic has detected conditions that could have caused an inverting fault The drive took action to avoid an actual inverting fault PHASE LOSS DETECT EN P 609 is set to ENABLE and the measured AC line voltage fell below 75 of the value specified by NOMINAL AC LINE VOLTS P 307 The I O Expansion board and Field Current Regulator are standard equipment and are required The drive does not support the DeviceNet kit The value of n indicates the SCR that is not operating n 1 6 11 16 One or more thyristor SCR is not carrying an equal load Possible causes e Disconnected loosely connected or damaged thyristor gating circuit Blown AC line fuse s Improper current minor loop tuning Improper speed voltage loop tuning Failed thyristor Self Tune aborted by external input Possible causes e Operator stop asserted e Drive interlock s open e Drive fault became active 4 5 Table 4 1 Fault Codes Continued CODE DISPLAY DESCRIPTION F00061 SELF TUNING FAULT F00062 SELF TUNING FAULT F00063 SELF TUNING FAULT F00064 SELF TUNING
60. e Field Supply Jumper J21 iara 3 4 3 4 5 Set the Source of Manual Mode Reference Jumper J19 sss 3 4 3 4 6 Set the Voltage Range and Scale of Analog Tacho Jumpers J14 J11 3 4 3 4 7 Set the Line Speed Reference Jumper J12 and J10 sss 3 5 3 4 8 Scale the Armature Current Feedback Jumper J18 sse 3 5 3 4 9 Inspect Jumper J26 e 29 LESTARI eE A 3 5 3 4 10 Inspect the Spare 1 and Spare 2 Jumper J27 ia 3 6 3 4 11 Inspect the Filter Select Jumper J28 0 0 0 cece eeeeeeseeeeseeeeeeeeeeeeseeeeeeeeeees 3 6 3 4 12 Inspect the Spare 2 Jumper J29 eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeea 3 6 3 4 13 Inspect the Power Interface Jumper J30 see 3 6 Chapter 4 Chapter 5 Appendix A Appendix B Appendix C 3 5 Set the Jumpers on the I O Expansion Board iii 3 7 3 6 Verify the Correct Direction of Motor Rotation i 3 9 3 7 Determine the DC Tachometer Lead Polarity nn 3 9 3 8 Make Tachometer and Armature Feedback Adjustments 3 10 3 9 Make Final Adjustment sss 3 10 Troubleshooting Diagnostics 4 1 4 16 4 1 Checking for Wiring Errors sss sese eee eee eee eee 4 1 4 2 Verify AC Line and Power Input renan 4 1 4 3 Verify DC Motor Connections sees eee eee 4 1 4 4 Verfying Optional KAS ins ee cache es eee our r a ent ie ae oes 4 2 4 5 Check the Regulator LED Status rrenan 4 2 4
61. e correct position Failure to observe this precaution could result in damage to or destruction of the equipment During Quick Start procedure the drive calculates the value of the tachometer voltage range based on the values of GEAR IN SPEED and ANLG TACH VOLTS 1000 and the setting of FEEDBACK SELECT The correct values are displayed on the Correct Scaling Jumper Positions screen Verify these settings before performing the Self Tuning procedure 3 4 WebPak 3000 DC Drive Hardware Reference The expected analog tachometer voltage range can be set to a maximum of 250 or 62 VDC J11 selects the hardware circuitry to maximize the resolution over the entire speed range Do Jumper 14 Jumper J11 Gear In Speed Tach Volts lt 16 volts Gear In Speed Tach Volts lt 31 volts 31 125 Gear In Speed Tach Volts lt 62 volts 62 250 Gear In Speed Tach Volts lt 125 volts HIGH 31 125 Gear In Speed Tach Volts lt 250 volts HIGH 62 250 Note that the output voltage of the tachometer must not exceed 250 VDC when the motor is rotating at GEAR IN SPEED To calculate the output voltage multiply the two parameter values Tach Voltage at GEAR IN SPEED GEAR IN SPEED x ANALOG TACH VOLTS 1000 1000 3 4 7 Set the Line Speed Reference Jumpers J12 and J10 The AUTO REF Jumpers J12 and J10 select the type of Line Speed reference J12 selects the type of signal VOLTS Voltage or MAMPS milli amps J10 selects the range 10 VOLTS MAX 10
62. ed by situations such as a line voltage dip a poorly tuned field regulator or an overhauling load Inverting faults can also be caused by thyristor misfiring induced by noise or a current minor loop rate limit that is set too fast Inverting faults can cause e clearing of the AC line fuses that protect the armature thyristors e tripping of an inverting fault circuit breaker e clearing of an armature DC fuse e loss of thyristors e degradation of commutator due to high current e flashover in the motor or power unit Inverting faults are only a concern in regenerative DC drive applications Typically a regenerative drive application uses a regenerative power unit S6R Inverting fault avoidance can be used in regenerative drive applications to prevent the occurrence of an inverting fault If inverting fault avoidance is used the drive recognizes conditions that could lead to an inverting fault and dynamically adjusts drive operation to prevent an inverting fault For a description of parameter INV FAULT AVOID SEL P 312 refer to the WebPak 3000 Software Reference manual Troubleshooting Diagnostics 4 15 4 13 4 14 4 15 Checking the AC Line Period and Voltage For a description of parameters AC LINE PERIOD P 393 AC LINE VOLTAGE P 392 and PHASE LOSS DETECTION EN P 609 refer to the WebPak 3000 Software Reference manual You can use these parameters to determine the AC line period AC line voltage and enable phase
63. ends not only on the supply network total Impedance but also on the relative converter power Voltage harmonics may cause disturbances e g in centralized telecontrol systems or other electrical consumers If high power converters are connected to low voltage distribution networks with low fault levels the resulting voltage harmonic content could be claimed by the power supply authority to exceed the permitted values stated in their regulations If the limits of the individual harmonic voltage portions are exceeded the harmonic currents must be reduced in the supply network e g by means of active or passive harmonic filters On request Rockwell Automation will provide the harmonics current spectrum generated by each WebPak 3000 or perform a harmonics analysis for the complete installation based on delivered data Immunity Immunity against Conducted and Radiated High Frequency Disturbances The WebPak DC converters have been tested to fulfill the Immunity requirement in the first as well as in the second environment CE Conformity B 1 Essential Requirements for Conforming Installation The following items are required for CE conformance 1 Connection of EMC filter RFI Filter on drives lt 100 A or HF filter on drives gt 100 A as specified in Chapter 5 Accessories 2 Because WebPak 3000 and filter have protection class IPOO they must be built in a cabinet Both units must be mounted on a blank not painted panel with good conduc
64. enerated If you are experiencing nuisance SCR faults you can use these parameters to increase the tolerance to conditions that could trigger an open SCR fault For a description of parameters OPEN SCR SENSITIVITY P 600 and OPEN SCR TRIP THRESH P 601 refer to the WebPak Software Reference manual Troubleshooting Diagnostics 4 11 Figure 4 2 Load SCRs Fail to Turn On 4 12 WebPak 3000 DC Drive Hardware Reference 4 10 Armature Phase Fire Test ATTENTION 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 section in its entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION This is an open loop test To prevent excess motor speed and current lock the motor shaft or disconnect the motor armature leads from the drive and replace them with a dummy load e g bulbs in series Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION If the field is disconnected the armature must be locked to prevent rotation Failure to observe this precaution could result in bodily injury ATTENTION This equipment is at line voltage when AC power is connected to the drive Disconnect and lockout incoming power to the drive before proceeding After power is removed veri
65. es requires always adding an impedance at line input terminals 1U 1V 1W You can use a 3 phase line reactor with 2 voltage drop minimum refer to Table 5 6 or other means of adding similar impedance e g matched isolation or auto transformer If an input transformer is installed ahead of the drive a power disconnecting device must be installed between the power line and the primary of the transformer If this power disconnecting device is a circuit breaker the circuit breaker trip rating must be coordinated with the inrush current 10 to 12 times full load current of the input transformer Failure to observe these precautions could result in damage to or destruction of the equipment ATTENTION Connection of a drive to a transformer with a primary rating of 2300 VAC or more may require additional input line conditioning Contact your local Rockwell Automation sales service office for assistance when this is required Failure to observe this precaution could result in damage to or destruction of the equipment The star point of the external AC line transformer must always be grounded Zero potential and connected to the drive ground point terminal PE or ground stud Input transformers step up or step down input voltage and can be either auto or isolation transformer types Users should consider using an isolation transformer instead of an auto transformer for the following advantages e AC power line disturbances and transie
66. for safety relevant stopping For emergency stop use the COAST STOP input NOTE If this digital input is not used a jumper must be wired between terminal 9 and 11 otherwise the drive will not start Wire the Main Contactor to the Drive Refer to connection diagram example Figures 2 8a and 2 8b A main contactor in the AC line input or armature circuit is not built in and must be externally provided It allows Coast to rest Category 0 or Ramp to rest Category 1 according to EN60204 1 Chap 9 2 2 each with disconnection of the power source from the motor The sequencing of the M contactor must be controlled by the drive MCR contact of the WebPak 3000 which is wired to terminal strip X1 5 and X1 6 located at top of the power unit On drives where the inrush current of the M contactor coil exceeds the MCR contact rating 330 VA at AC 230V cos phi 0 5 a pilot relay is required between the MCR contact output and the M contactor coil A normally open auxiliary contact from the main contactor must be wired to terminals X1 3 and X1 4 to provide contactor status feedback to the drive K10 K10T K1 K1M Figure 2 8a Main Contactor Sequencing Connection Diagram Example Install and Wire the Drive 2 15 2 5 7 Wire Optional Devices to the Drive ATTENTION Do not route signal wiring with power wiring in the same conduit This might cause interference with drive operation Route signal wiring and power wiring in separate cond
67. from the motor This circuit must be hardwired with electro mechanic components and shall not depend on electronic logic or software The stopping device e g mushroom head pushbutton with lock must be accessible to the operator Failure to observe this precaution could result in bodily injury or loss of life Electromagnetic Compatibility EMC Directive General Notes ATTENTION The operating of inverters in the European market is only permitted if the Council Directive Electromagnetic Compatibility 89 336 EWG has been observed It is the responsibility of the manufacturer of the machine or system to observe the immunity and emission limits requested by the Council Directive EMC in the European market Guidelines for the installation according EMC regulations for shielding grounding filter arrangement as well as wiring instructions are summarized in Appendix B CE Conformance of this Instruction manual General Notes Copyright 2001 Rockwell International Corporation Each reproduction of this manual may be prosecuted The copyright of the user s manual remains at Rockwell Automation AG CH 6036 Dierikon Trade mark WebPak and Reliance are registered trade marks of Rockwell Automation Manual Scope This manual contains information on drive installation drive startup and troubleshooting procedures Measures for CE Conformity on Electro Magnetic Compatibility EMC are shown in Appendix B Vi WebPak 300
68. fy that it is set as listed in table 3 1 Drive Setup and Adjustment 3 5 3 4 10 3 4 11 3 4 12 3 4 13 Inspect the Spare 1 Jumper J27 J27 is not used The position of this jumper has no effect on the drive Do not install a jumper block on this jumper Inspect the Filter Select Jumper J28 J28 is not used Do not install a jumper block on this jumper Inspect the Spare 2 Jumper J29 J29 is not used The position of this jumper has no effect on the drive Do not install a jumper block on this jumper Inspect the POWER INTERFACE Jumper J30 J30 is improperly set to the LOW position when it should be set to HI T ATTENTION The drive can operate at excessive armature voltage and speed if This jumper is factory set according to the type of Power Interface module installed in the drive jumper positions are labeled LOW and HIGH For WebPak 3000 drives with a nominal voltage rating AC 575 V 60 Hz and 690 V 50 Hz the jumper J30 must be set to HIGH for all other drives this jumper must stay in position LOW Please refer to the AC Input data on the nameplate If this jumper is not set to the correct position nuisance AC line voltage high low alarms may occur or if configured as a voltage regulator the drive will not operate at the correct speed 3 6 WebPak 3000 DC Drive Hardware Reference 3 5 Set the Jumpers on the I O Expansion Board The jumper settings for the I O Extension Board determine the Ana
69. fy with a voltmeter at power terminals 1U 1V and 1W that no voltage exists before touching any internal parts of the drive Failure to observe these precautions could result in severe bodily injury or loss of life An armature phase fire test mode is available to verify the operation of the S6R rectifier bridge This test should only be performed by qualified personnel For a description of parameters PHASE FIRE TEST DELTA P 309 and PHASE FIRE TST BRIDGE P 310 refer to the WebPak 3000 Software Reference manual To perform an armature phase fire test 1 Lockout and tag power as necessary 2 Turn off power to the drive 3 Either lock the motor armature to prevent rotation or disconnect the motor armature leads from the drive and replace with bulbs in series When locking the motor armature the motor field winding can be disconnected to prevent excessive torque If the motor field winding is disconnected field current loss faults must be inhibited by setting Parameter FIELD LOSS THRESHOLD P 512 4 Turn on power to the drive The drive must be stopped and the Drive Ready Indicator must be ON Set CONTROL SOURCE SELECT to KEYPAD On the OIM select CURRENT MINOR LOOP CML SCR Diagnostics Armature Phase Fire Test 7 Set PHASE FIRE TST BRIDGE P 310 This parameter must be set to the appropriate value before activating the armature phase fire test mode oO o oo Attach an oscilloscope to the armature curren
70. h with provisions for a padlock is recommended 2 Wire this disconnect in the primary circuit of the drive isolation transformer if used 2 8 WebPak 3000 DC Drive Hardware Reference 2 4 2 5 2 5 0 2 5 1 Install the Motor 1 Verify that the motor is the appropriate rating to use with the drive 2 Install the DC motor in accordance with its installation instructions 3 Make sure that coupled applications have proper shaft alignment with the driven machine or that belted applications have proper sheave belt alignment to minimize unnecessary motor loading 4 If the motor is accessible while it is running install a protective guard around all exposed rotating parts 5 Wire the motor to the drive Refer to Wire the DC Motor to the Drive Wiring Wiring grounding disconnects and overcurrent protection are of particular importance Size and install all wiring in conformance with all other applicable standards Failure to observe this precaution could result in severe bodily injury or loss of life T ATTENTION The user is responsible for conforming to all applicable standards General Wiring Practices The Drive is designed for AC entry and DC power exiting at the top and control and signal wiring entering from the bottom Reference signal wiring should be run in a separate conduit isolated from all AC and DC power and control Signal wires should not be run in parallel with high voltage or electrically noisy
71. hat is critical for successful application and understanding of the product ATTENTION Before installing and or operating this device this manual must be understood by the qualified electrical maintenance person who is familiar with this type of equipment and the hazards involved Failure to observe this precaution could result in bodily inj ATTENTION Earth fault detection devices must not be used on this converter as the sole protection measure against unintentional touching The DC component in the earth fault current may inhibit the correct function of the fault detector ATTENTION Electronic converters cause disturbances to the supply network The basic version of this converter does not include any harmonic filters and may not fulfil the limits of the national recommendations The harmonic voltage disturbances produced by the converter are dependent on the supply network impedance ATTENTION This inverter device is a component intended for implementation in machines or systems for the capital goods industry The start up of the inverter in the European market is not permitted until it has been confirmed that the machine into which the inverters are built is in conformance with the regulations of the Council Directive Machinery 98 37 EWG ATTENTION To inhibit uncontrolled machine operation in case of the malfunction of the drive the user must provide an external emergency stop circuit which ensures disconnection of the power source
72. ight Cooling air Air flow direction Minimum clearances for free air circulation 100 mm Figure 2 5 Mounting Data for WebPak 1200 1600 A 500V and 1600A 575 690V 2 6 WebPak 3000 DC Drive Hardware Reference Figure 2 6 Mounting Data for WebPak 2000A 500V Install and Wire the Drive N L 975 LL 9 amp ME 4 85 _ 38 B 14 50 1 7 O C S 40 27 O r O O O O l 96 26 le 3 131 5 96 a a mn N n nnn dg MAMA x Se S RA 1 l EI El E GC 5 200 t aes i 240 21 90 gt a 49 50 a 1 I i O O 40 120 O O E T S N i C OUTPUT M12 dal c 19 20 a S2 SO 12 l i y 120 40 v S O DC OUTPUT 418 PE AC INPUT Ss TN A TT op 1 LN 47 ra 160 m 4 Weight Cooling air Air flow direction bus bars 120 x 10 drilling 4 x M12 Torque 25 Nm bus bars 96 x 10 drilling 4 x 14 mm bus bar 60 x 10 drilling 2 x 14 mm 196 kg 2000 m3 h from bottom to top Minimum clearances for free air circulation 100 mm 2 7 2 2 2 3 Install a Line Reactor or Transformer for Input Power Conditioning ATTENTION Distribution system capacity above the maximum permitted system kVA as well as limitation of commutation notch
73. in table 2 4 Table 2 4 I O Expansion Digital Outputs DIG OUT 1 SELECT DIG OUT 2 SELECT DIG OUT 1 CONTACT TYP EBIC ap 27 DIG OUT 2 CONTACT TYP E a Important If digital output 1 or 2 is configured as normally closed it will act as normally open during a power cycle until the software contact type is read This should be accounted for in your application program Analog Inputs T ATTENTION At very low input levels noise or drift could cause analog input polarity to change This could result in damage to or destruction of the equipment The I O Expansion board supports two analog inputs TENSION SETPOINT IN P 492 and TENSION DANCER FDBK P 493 TENSION DANCER FDBK accepts a bipolar DC voltage only TENSION SETPOINT IN can be configured to accept any of the following signals bipolar DC voltage unipolar DC voltage 4 20 mA or 10 50 mA Analog inputs can be scaled to use DC voltage signals as low as 4 5 V 5V 10 but maximum resolution 0 024 is obtained when the full scale input signal is used Analog input signals are read every 20 msec Table 2 5 lists the analog inputs and related parameters Figure 2 9 provides wiring diagram for connecting 5 kQ potentiometers Install and Wire the Drive 2 19 Table 2 5 I O Expansion Analog Inputs TENSIONSETPTSIGTYPE P43 TENSION SETPOINT ZERO P 414 Pod TENSION SETPOINT GAIN TENSION DANCER ZERO P 416 T TENSION DANCER GAIN P 417 en Terminals 33
74. ion The WebPak 3000 drive includes an algorithm for detecting reversed speed feedback wiring The logic verifies that the difference between the speed reference and the speed feedback is greater than the threshold set by TACH LEAD FLT THRESH P 227 for the amount of time set by TACH LEAD FLT DELAY P 228 When the threshold is greater than the difference for the specified delay and the speed reference and speed feedback are opposite in polarity a REVERSED TACH LEADS fault is generated fault F00014 For a description of TACH LEAD FLT THRESH P 227 and TACH LEAD FLT DELAY P 228 refer to the WebPak 3000 Software Reference manual Fault F00014 can also be caused by an overhauling load improper drive tuning or a tachometer or encoder loss The tachometer lead fault parameters have default values that are set so that reversed tachometer lead detection is effectively disabled You must empirically determine values for these parameters so that reversed tachometer or encoder wiring can be detected without generating nuisance faults The ability to check for reversed tachometer lead faults is useful for machine manufacturers that require their equipment to be disassembled for shipping and reassembled and rewired at a customer site Setting Up Inverting Fault Avoidance An inverting fault is an uncontrollable high current resulting from commutation failure It is typically caused by an excessive armature to line voltage ratio which can be caus
75. l voltage gt 400V lt 690V two 2 chokes 252 40 xx in series will be required for nom voltage 690 V two 2 chokes 252 44 xx AC Line Input Field AC Input 3 Phase 1 Phase Drive Motor Current Rating Choke 1 Rating Choke Type Irom lad lioi Part No liom Part No A 5A i 60A 33A 40A 40A 252 40 02 6 252 42 05 50A 60A 62A 252 40 03 150A 75A 90A 85A 252 40 04 108A 130A 115A 252 40 05 6A 252 42 05 125A 150A 160A 252 40 06 208A 250A 210A 252 40 07 375A 450A 392A 252 40 09 666A 800A 660A 252 40 11 252 42 01 252 42 01 252 42 06 12A 12A 252 42 06 2A 252 42 06 AC Line AC Line L1 L2 13 PE L2 L3 PE UM vi Wi 1 4 Peake rs S S i i i e i RE e a MRS S ENE EER j u2 v2 w2 2 B 1U 1V 1W 3V 3W Converter Input Field Rectifier Input Fig 5 1 Line Reactor Wiring Diagram 5 8 WebPak 3000 DC Drive Hardware Reference W2 W1 V2 V1 U2 U1 B A U2 V23 E D C 40 A 1 2524002 165 150 180 170 75 60 72 65 65 eo 1 2524008 210 180 240 210 o0 52 12 so 7a 70 1 2524004 160 180 240 210 60 52 12 os rel eo 2 2524005 160 180 240 210 120 72 65 ms 11 00 2 2524006 240 260 260 24 75 or 170 18 130 2 252 40 07 2524008 240 260 200 240 100 146 160 26 aro 2 2524006 20 320 220 00 60 tio 230 35 205 2 2524010 260 270
76. log Input 1 and Analog Output 1 settings as shown in the following figures 3 3 and 3 4 The procedure is the same as for the Regulator board described in Section 3 4 on page 3 2 33 ND 34 J10 e e e J15 ee 1 ee ee J11 000 ee J5 J6 J7 J8 J9 a 38 39 40 41 42 43 44 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Z Figure 3 3 I O Board Layout with Jumper Locations Drive Setup and Adjustment 3 7 Jumper Settings on I O Board Analog Input 1 Jumpers Voltage Input default 4 20 mA Input 10 50 mA Input Analog Output 1 Jumpers Voltage Output default 4 20mA Output 4 20mA Output internal source default 4 20 mA Output external source J11 J12 10 50 both 12 3 1 E 5 LoL 2 m m m 6 V mA VOLT PARK 4 20 10 50 both 12 3 nn V mA VOLT PARK 4 20 10 50 M both 12 3 1181818 5 ILE 2181818 6 V mA VOLT PARK 4 20 J14 8 EH mA 6 EE J 4 jm RIT 2 E B Egr 6 m m 4 EE T 2 HH J15 EXT m 3 2 INT 1 EXT 3 2 INTE 1 Figure 3 4 Jumper Settings on the I O Expansion board 3 8 WebPak 3000 DC Drive Hardware Reference 3 6 3 7 Verify the Correct Direction of Motor Rotation ATTENTION If tachometer and or rotation is incorrect sudden and rapid acceleration may result which can cause overspeed of the drive Failure to ob
77. loss detection Checking Drive Information For a description of parameters J15 REGULATOR TYPE P 799 POWER UNIT TYPE P 795 and REGULATOR SW VERSION P 794 refer to the WebPak 3000 Software Reference manual You can use these parameters to determine the AC line period AC line voltage and enable phase loss detection Power Supply Test Pin Identification The following table lists the power supply PC board test pins and their respective voltage levels Since it is a switching power supply all checks need to be made while load is connected to the power supply card J4 to J5 J6 to J7 J8 to J7 J9 to J10 J11 to J12 J13 to J12 J14 to J16 J15 to J16 J3 to J16 4 16 WebPak 3000 DC Drive Hardware Reference CHAPTER 5 Replacement Parts and Accessories 5 0 Replacement of components Use original spare parts only Selection according to Tables 5 1 to 5 6 The location of the parts is shown on the layout label inside the U frame i 1 Screws 2 Steel plate 3 Housing 4a Flat washer 4 Plate springs 5 Stamp 6 Semiconductor 7 Centering bolt 8 Heatsink Replacement Parts and Accessories Replacement of a thyristor or thyristor module Type 25 800 A e Loosen and swing out regulator and Interface assembly e Remove bus bars above the thyristors e Remove gate leads of the thyristor concerned e Unscrew thyristor or thyristor module e Before mounting the new thyristor or thy
78. more information on changing parameter values 3 Initiate a JOG Fwd command 4 Use a voltmeter on the tachometer leads to determine the lead polarity for the Forward direction of rotation Label the tachometer leads accordingly and 5 Verify that the tachometer lead is connected to terminal 21 or 22 and that the tachometer lead is connected to terminal 23 If the tachometer lead is not connected to terminal 21 or 22 stop the drive Disconnect and lockout or tag power to the drive Reverse the connection of the tachometer leads Drive Setup and Adjustment 3 9 3 8 3 9 Make Tachometer and Armature Feedback Zero Adjustments This section describes Zero adjustments to compensate for signal drift when tachometer or armature feedback is used See the OIM instruction manual for instructions on changing these parameter values an overspeed condition These parameters must be set by a qualified person who understands the significance of setting them accurately Verify that the value of these parameters is accurate for your application Failure to observe this precaution could result in bodily injury T ATTENTION The incorrect setting of the parameters described below can cause 1 Stop the drive 2 Check the value of the output parameter ARMATURE VOLTAGE P 289 If the value is 0 Go to step 5 If the value is not ZERO Go to step 3 3 Adjust ARM VOLTAGE ZERO ADJ P 205 If ARMATURE VOLTAGE was more than
79. motor field Technical Specifications A 3 Drive Input Output Specifications The following sections describe drive inputs and outputs Refer to section 2 for terminal strip connections and wiring diagrams Logic Inputs ATTENTION Connecting an external power source to any of the 24 volt connections terminals 1 7 11 and 14 on the regulator board terminal strip will damage the drive DO NOT connect the external power source to the 24 volt connections on the regulator board terminal strip Failure to observe this precaution could result in damage to or destruction of the equipment The logic input circuits can be powered either from the internal 24 V DC power supply or from an external 24 V DC power source The internal 24 V DC power supply is available at the regulator board terminal strip see Figure 2 8b If an external power source is used only its COMMON must be connected to 24V COM on the regulator board terminal 15 24V COM is internally not grounded but may be externally grounded if required by the users control wiring Electrical Specifications MPU VOADOR Me Silos ON a See Si ok as a 24 V DC Jur Or MONG CS cei secient se EE Se SRU deca na ipa e a Sr N DS 8V TURNO CURCNE us raspadas sa eae AU E e R Yoe 0 5 mA COMMON aorta iiaia inke ar aniei Eua nad ban All input circuits have the same common Logic Outputs The logic output circuits are normally open when de energized relay contacts When energize
80. n the selected parameter group load speed voltage power field or other The frequency output signal is updated every 20 msec Table 2 8 lists the frequency output and related parameters Table 2 8 I O Expansion Frequency Output Parameter Number Terminal Strip Location FREQ OUT SELECT P 425 42 43 44 ss FREQ OUT ZERO P 426 FREQ OUT FULL SCALE P 427 Do 2 20 WebPak 3000 DC Drive Hardware Reference CHAPTER 3 Drive Setup and Adjustment operation of this equipment and the hazards involved should install adjust operate and or service this equipment Read and understand this section in its entirety before proceeding Failure to observe this precaution could result in bodily injury or loss of life T ATTENTION Only qualified electrical personnel familiar with the construction and 3 1 Perform a Power Off Inspection Inspect the Drive and modification kits for possible physical damage or improper connections Verify that the wiring of the operator s station and the wiring to the Drive is made with sufficient bare wire to make a good electrical connection The removal of an excessive length of insulation may needlessly expose conductors resulting in the possibility of shorts or safety hazards 3 2 Test Equipment Needed high voltage of the megohmmeter can damage the drive s electronic circuits Failure to observe this precaution could result in damage to or destruction of the equipment T ATTENTION Do not use
81. nd tachometer Drive Efficiency DRIVE OMY arcs ta patties ved eect a a E DEAR GR AD cect 98 6 rated load and speed Driye and MOOR sans ceacash Got ee ate oe eee haa ot atic ot ce tien aa Aa aeaa ade 85 typical Displacement Power Factor Power Loss Pv and Output Current Power Factor 88 typical rated load amp speed decreasing linearly with speed Typical percent speed depends on motor operating speed and motor frame size Power Consumption at no load see Pag in Table A 3 Table A 3 Drive Specifications ie ac aa 25A 25A 20 A 30 A 60 VA 120W 60 A 60 A 50 A 75A 4A 60 VA 210W 150 A 150 A 125 A 187 A 10 A 85 VA 460W 250 A 250 A 208A 312 A 10 A 90 VA 715W 450 A 450A 375A 562 A 10A 90 VA 1215 W 800 A 800 A 667A 1000A 12A 120 VA 2120 W 1200 A 500V 1500A 15A 400 VA 2680 W 1600 A 500V 2000A 15A 400 VA 3750 W 2000 A 500V 2000 A 2500A 15A 400 VA 4600 W 1600 A 575V 1600 A 1334 A 2000A 15A 400 VA 3900 W 1600 A 690V 1600 A 1334 A 2000A 15A 400 VA 4100 W la Maximum continuous current without overload capability I ad 1 2 X lanom lanom Nominal continuous current with overload capability 50 during 1 minute every 10 minutes la max Maximum current during 1 minute after 9 minutes operation with la nom la max 1 5 X la Hom lc Field current without overload capability A maximum field current of 20 A is permitted if the power unit blower is switched on together with the
82. ne MOY Orel 018 0068018 ddd ITA wT l A YOIVINGAY AlddNS YaMOd kL ASY TO U er UI LO LO S6 cz6 xp 3 uondo WIO ar L on d E dat Es EE E L SE E oo par ae 45 66 ES L I Lx LS 7 od 1 ES LOSPELS OU ES j OW SOVIYSIN YAMOd A Z 7 LO X 1 1 1 1 1 7 J ES a T A Gl T AA LT l 02 02 Z92 er or F EA JoyeinBay E pices IND piad 1 e E AOI XVIN xt 7 Figure 2 7b Principle wiring diagram of WebPak 3000 four quadrant S 6R 1600 A 575 V WebPak 3000 DC Drive Hardware Reference 2 12 2 5 3 2 5 4 2 5 4 1 2 5 5 2 5 5 1 Wire AC Power to the Drive ATTENTION The user is responsible for conforming to all applicable standards Wiring grounding disconnects and overcurrent protection are of particular importance Size and install all wiring in conformance with all applicable standards Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION The drive requires a three phase power source of ether 200 500 or 300 575 690 V 50 60 Hz see A 2 If the correct voltage is not available a transformer must be installed between power source and drive Do not connect the drive to a power source with available short circuit capacity in excess of the max symmetrical fault current listed in Appendix A page A 1 Failure to observe this precaution could result in bodily injury or equipment damage 1 Size the AC line supply
83. nput voltage 230 VAC is required Relay Output for Main Contactor Relay MCR at terminals X1 5 and X1 6 Nominal contact rating at AC 230 V cos phi 0 5 330 VA Maximum CUreNLS sesta seiesenesidccaudotieus e aa dos gaba dna esa et nl aaa aa CU au 3A DC Voltage Ratings Maximum permissible armature voltage Ua max at inductive voltage drop of Uk lt 4 per phase and max 10 line undervoltage At Uk 4 to 7 Ug max must be derated per 5 Ua nom is the recommended standard motor armature voltage for the selected line voltage and operation mode Table A 1 Armature voltage for various line voltages AC Line Motoring operation Regenerating operation Voltage Armature Voltage Armature Voltage UN Ua nom Ua max Ua nom Ua max Field VONAGE PRP RR ER A ane tally max 90 of line input voltage Protection by external fuses according to table 5 5 WebPak 3000 DC Drive Hardware Reference Regulation with 95 load change Table A 2 Tachometer Speed Regulation Speed Change with Speed Change from Part Number Regulation Arrangement 95 Load Change All other Variables Armature Voltage Regulation 2 3 15 Not applicable with IR Comp Closed Loop with Pulse tach 1 0 01 0 01 762 70 00 1 Optional Pulse Tachometer Feedback kit required See instruction manual 49 1343 Speed Range Operator s Speed Adjustment e 0 to rated speed Specification Speed Range sse eee eee 100 1 based on Gear In Speed a
84. nts are minimized by an isolation transformer thus reducing or eliminating possible damage to solid state components e An isolation transformer provides electrical isolation for the drive from plant power system grounds Damaging currents may be avoided in instances where the DC output is accidentally grounded or where the DC motor circuits are grounded Rockwell Automation offers a series of isolation transformers suitable for use with the drive Install an Input Disconnect ATTENTION The standard EN 60204 1 requires that an input disconnect must be provided in the incoming power line and either be located within sight of the drive or have provisions for a padlock Install an input disconnect in the incoming power line that is located in sight of the drive or one that has provisions for a padlock Failure to observe this precaution could result in severe bodily injury or loss of life Any fused disconnect or circuit breaker in the incoming AC line must accommodate a maximum symmetrical AC fault current as indicated in A 1 of this instruction manual Size the disconnect to handle the transformer primary current as well as any additional loads the disconnect may supply 1 Install an input disconnect in the incoming power line according to the standard EN 60204 1 if not provided with the drive The disconnect switch should be within clear view of machine operator and maintenance personnel for easy access and safety An open type switc
85. nvalid the fault log has been cleared Possible causes e Power loss during a prior fault log save e Defective regulator board F00702 KEYPAD REF The keypad reference value stored in retentive memory was RESTORE determined to be invalid The keypad reference has been set to the FAILURE MINIMUM SPEED P 003 value Possible causes e Power loss during a previous keypad reference save e Defective Regulator board F00800 INVALID FIELD Installed field supply is not supported by the regulator INSTALLED Possible causes e Disconnected loosely connected or damaged field supply wires e Regulated field supply failure e Defective regulator board F00801 FIELD FEEDBACK Regulated field supply feedback offset is too high OFFSET TOO HIGH possible causes e Disconnected loosely connected or damaged field supply wiring e Regulated field supply failure e Defective regulator board F01000 MICROBUS FAULT An error occurred on the Microbus to Possible causes F01999 e Electrical noise due to improper wiring practices or unsuppressed brake coils relays or contactors Disconnected loosely connected or damaged Microbus ribbon cable Defective Regulator board F01000 F01799 Defective Microbus peripheral or Regulator board F01810 F01816 A Microbus peripheral was found that is not supported by the regulator software F00999 MICRO A microprocessor hardware or software fault occurred and PROCESSOR Possible causes 02000 MSW
86. of the screen ground connection is ensured by laying the braid over a plastic cone which will press it to the inner side of the gland when mounted It is important that the connection area is 360 degree around the cone The cable glands provide pull relief through the cable jacket B 2 WebPak 3000 DC Drive Hardware Reference Configuration 1C 1D 3C 3D D 1U 1V 1W Led se a mm Figure B 1 Example for control cabinet configuration Cabinet Panel AC reactor Converter AC Input contactor SCR protecting fuses RFI Filter or HF Filter Circuit breaker Terminals for 4 wire AC Input cable L1 L2 L3 PE Cabinet protection ground busbar OD Cable bracket Screen 3 Screened 3 wire motor armature cable Shielded 2 wire motor field cable Shielded signal conductor cable feedback reference EMC tested armoured cable gland at terminal box CE Conformity B 3 Wiring Instruction Motor Cable The cables between cabinet armature output and DC motor armature shall be 3 wire screened cable and earth conductor green yellow as specified in Figure B 2 The cables between field supply output and DC motor field shall be 2 wire screened cable The screen must be tinned copper
87. ons METER OUT 1 SELECT P 404 corresponds to terminals 24 and 25 default CML FEEDBACK METER OUT 2 SELECT P 405 corresponds to terminals 25 and 26 default SPD LOOP FEEDBACK Refer to Appendix B METER OUT 1 SELECT P 404 and METER OUT 2 SELECT P 405 parameters for additional drive test points that can be configured to source Meter Outputs 1 and 2 Electrical Specifications Output MOM AG RPA IR ett PORRA RR ais UR OR adh eS tot ai ce DE PN 10 VDC Maximum Load 4 milliamps Drive Current Transformer Turns Ratio 25 60 A 416 150 A 250 A 2000 450 A 3000 800 A 5230 1200 A 8000 1600 2000 A 10500 Technical Specifications A 5 Technical Specifications of the I O Expansion Board Digital Inputs Input Voltage sss sese eee Input Current Draw sss eee eee COMMON T Digital Outputs Operating Voltage Switching Current Analog Inputs Analog Input 1 Potentiometer Input Voltage sse eee eee eee Input Current Reference Analog Input 2 Potentiometer Input Voltage sse eee eee eee Analog Outputs Analog Output 1 Output Voltage Maximum Load Current Output External Supply for 4 20 mA Output Analog Output 2 Output Voltage Maximum Load sees Frequency Input Maximum Frequency Minimum Duty Cycle time on to time off Minimum Pulse Width
88. ossible cause e Self tuning was unable to complete tune manually The main contactor was not open following a run or jog request Possible causes e Disconnected loosely connected or damaged main contactor K1M or Aux contactor K1 wiring e Main contactor or Aux Main contactor failure e Disconnected loosely connected or damaged main contactor control wiring MCR 1 When after stop command the auxiliary contactor does not indicate that the main contactor opened this fault indication is 1000 msec time delayed 4 6 WebPak 3000 DC Drive Hardware Reference Table 4 1 Fault Codes Continued CODE DISPLAY DESCRIPTION F00200 POWER FAILURE The power supply input voltage momentarily went below tolerance Possible causes e AC line voltage dip e Disconnected loosely connected or damaged J7 ribbon cable or power supply input wiring F00700 FACTORY The stored parameter values were determined to be invalid Factory DEFAULTS default values have been restored All parameter values including any RESTORED factory set parameters must be re adjusted based on your application before operating the drive is After all parameters have been set properly a memory save must be performed followed by a fault reset Possible causes e Power loss during a prior memory save e New or defective regulator board F00701 FAULT LOG The fault log information stored in retentive memory was determined to RESTORE FAILURE be i
89. ristor module coat the side which is in contact with the heat sink with a thin layer of heat conducting paste For units 800 A NOTE for safe and easy mounting of thyristors on 800 A units we recommend the tool PN 050 00 00 e Insert thyristor into box clamp and put the package on the centering bolt on the heatsink e Fasten the four hexagon bolts by hand until all slack is taken out and take care that the clamp housing stays parallel to the heatsink e Tighten each bolt by half a revolution at one time with hexagonal torque socket spanner 8 mm 10 mm diagonally NOTE Observe recommended torque e Repeat the procedure until the clamp is held down firmly to the heatsink on each side e Re connect gate leads e Screw on bus bars NOTE Before replacing a thyristor or thyristor module the gate and cathode faston connectors must be checked for conductivity 5 1 Replacement of a thyristor on power unit Type 1200 2000 A Write protocol about the following procedure Open controller and protection unit by tilting forwards Layout of thyristor assembly is visible now on side wall Remove bus bars on front heat sink Unscrew the upper cooling air deflector Unscrew the hexagon screws for the bus bar mounting Unscrew the lower cooling air deflector Loosen the two screws 13 mm on the clamp by quarter turns Caution the center clamp screw 24 mm must not be turned Withdraw clamp and heat sink Clean hea
90. s the OIM fault reset key check the OIM cable or cycle power e I O is not being scanned the regulator board is communicating with the OIM initialize card set P 010 P 306 P 307 and execute MEMORY SAVE press OIM fault reset key record information on the fault e I O is not being scanned regulator board is not communicating with the OIM initialize card set P 010 P 306 P 307 and execute M S press the OIM fault reset key record any information about the fault and cycle power 4 2 WebPak 3000 DC Drive Hardware Reference 4 6 Fault and Alarm Messages Descriptions and Code Numbers Table 4 1 lists all possible OIM error messages generated by the drive and fault alarm codes The error messages appear on the OIM display when certain drive conditions exist Table 4 1 lists fault codes and Table 4 2 lists alarm codes Tables 4 1 and 4 2 list fault and alarm codes by number Fxxxxx Fault Axxxxx Alarm associated message visible at the OIM display and a description along with possible causes Table 4 1 Fault Codes CODE DISPLAY DESCRIPTION F00001 IET Armature current instantaneously exceeded 180 of MAXIMUM OVERCURRENT CURRENT Possible causes e Incorrect armature current feedback scaling MOTOR RATED ARM AMPS MAXIMUM CURRENT CT TURNS RATIO or J18 not set properly e One or more thyristors not operating e Improper Current Minor Loop tuning e Motor armature winding damaged F00002 TACHOM
91. serve this precaution could result in bodily injury Power up the Drive 1 Apply AC power to the drive after you complete the Power Off Inspection Motor Ground Check and Drive Setup procedures 2 See the OIM instruction manual for the displays during power up Turn power to the drive OFF 1 Verify the operation of the Coast Stop pushbutton using an ohmmeter When pressed the ohmmeter should read infinite ohms open when released the reading should be O short 2 Turn power to the drive ON 3 After power up select ARMATURE VOLT for FEEDBACK SELECT P 200 by taking the following path from the main menu to access this parameter Re Loop SPD Speed Voltage Loop SPD Feedback 4 Initiate a JOG Fwd command to verify that the motor is rotating in the desired direction 5 If the direction of rotation is incorrect stop the drive and then disconnect and lockout or tag power to the drive 6 To change the direction of motor rotation reverse the connection of the motor armature leads 1C and 1D Important Wrong rotation direction can be caused by incorrect wiring of the field 3C and 3D Determine the DC Tachometer Lead Polarity 1 Turn power to the drive ON 2 After power up select ARMATURE VOLT for FEEDBACK SELECT P 200 by using the following path from the main menu to access this parameter en ee Loop SPD Speed Voltage Loop SPD Feedback Refer to the WebPak 3000 Software Reference Manual D2 3444 for
92. shbutton must be accessible to the operator Failure to observe this precaution could result in bodily injury or loss of life It is the responsibility of the user to decide how the Emergency Stop Function is fulfilled depending on the requirements of the application and based on a risk assessment of the machine Disconnection of the power source from the motor may be reached e g by one of the following measures a Circuit breaker used as Emergency Stopping Device easy accessible to the operator hand operated or remote operated e g undervoltage trip coil released by mushroom head pushbutton b Circuit breaker not used as Emergency Stopping Device Emergency Stopping Device mushroom head pushbutton interrupts control circuit and releases Coast Stop according to Category 0 A Connection Diagram Example for case b is shown in Figures 3 8a and 3 8b FUNCTION Actuating of the Emergency Stop pushbutton during operation causes immediate drop out of relay K10 opening the n o contact at input terminal 8 and blocking of the regulator At zero current opening of contact output MCR will drop out the main contactor via auxiliary contactor K1 The time delayed normally open contact of timer relay K10T ensures that in case of malfunction of the internal control circuit MCR does not open the main contactor drops out after 1 second 2 14 WebPak 3000 DC Drive Hardware Reference 2 5 5 3 2 5 5 4 2 5 5 5 2 5 6 C
93. ss Per XTad X gs c T Table 5 7 RFI Filter Selection RFlI Filter 460 500 V 690 V Application Filter 380 440 V 839 72 05 839 72 06 839 72 07 839 72 09 839 71 53 839 70 20 839 74 22 839 73 25 839 70 66 839 72 67 839 71 68 839 73 31 839 73 35 839 73 38 on request on request on request on request 839 71 53 on request on request 839 70 66 839 72 67 839 71 68 on request 839 73 92 839 73 95 839 73 98 according to a 5 14 according to b 839 73 92 839 73 95 839 73 98 Replacement Parts and Accessories Radio Interference Filters 25 36 and 50 A 440 V M6 150 L3 L2 L1 LINE O q LOAD L3 12 L1 1 L 135 J Filter Part No 839 72 05 839 72 06 839 72 07 Rated Current 25A 36 A 50 A Power loss 8 W 9 W 11 W Weight 3 kg 3 1 kg 3 5 kg Figure 5 4 25 36 and 50 A 440 V Filter Dimensions mm 5 12 WebPak 3000 DC Drive Hardware Reference Radio Interference Filter 80 A 440 V 427 LOAD LS L2 Filter Part No Power loss Weight 839 72 09 23 W 9 5 kg Figure 5 5 80 A 440 V Filter Dimensions mm Replacement Parts and Accessories 5 13 Radio Interference Filter 100 A 500 V 275 30 215 30 22 U 4xM6 22 axes 785 741 741 Y 22 22 i _ 62 50 50 50 63 18 47 15 E Filter Part No 839 71 53 Power loss 75 W Weight 9 5 kg
94. t feedback test point J17 J22 on the Regulator board Note that the WebPakCS software oscilloscope mode does not have sufficient bandwidth for this test 9 Press RUN The armature phase fire test mode is now active The OIM Running indicator will be on 10 Set PHASE FIRE TEST DELTA P 309 to 55 degrees Slowly increase PHASE FIRE TEST DELTA until a steady pattern of bumps appears on the oscilloscope If all thyristors in the selected bridge are operating there will be six bumps per AC line cycle similar to the example in figure 4 2 If any bumps are missing one or more thyristors are not conducting similar to the example in figure 4 3 Troubleshooting Diagnostics 4 13 Note that conduction will not begin until the firing angle is sufficiently advanced PHASE FIRE TEST DELTA P 309 more than 60 degrees A rate limit block limits the rate of change of firing angle advances to prevent sudden increases in current To prevent the drive from entering continuous conduction during this test PHASE FIRE TEST DELTA P 309 should not exceed 89 degrees Figure 4 3 Thyristors Fail to contact 11 Press STOP RESET to stop the armature phase fire test 12 Turn off power to the drive lockout and tag as necessary 13 Either unlock the motor armature or remove the bulbs and reconnect the motor armature leads WebPak 3000 DC Drive Hardware Reference 4 11 4 12 Setting Reversed Tachometer or Reversed Encoder Lead Detect
95. t set properly e Overhauling load maintaining motor speed higher than the STOP SPEED THRESHOLD e Incorrect speed voltage feedback scaling Armature current was unable to reach discontinuous conduction while stopping the drive Possible causes e Motor CEMF too high or line voltage too low for proper commutation Armature current feedback could not be scaled properly based on the values entered for MOTOR RATED ARM AMPS and MAXIMUM CURRENT Verify that these parameter values are correct for your application Verify that CT TURNS RATIO has been set to the correct value for your drive see parameter description The MINIMUM SPEED value is less than 10 of the MAXIMUM SPEED value This alarm will not be triggered on power up It only occurs when maximum or minimum speed has changed Verify that these parameter values are correct for your application NEG CUR LIM INV EN P 226 has changed state either enabling or disabling the negative current limit inverters The parameters POS CURRENT LIMIT SEL P 223 and NEG CURRENT LIMIT SEL P 224 have been set to REGISTER Carefully check your current limit scheme and the values of POSITIVE CURRENT LIM P 005 and NEGATIVE CURRENT LIM P 006 to avoid unintended drive operation An attempt to save information parameter values fault log data or the keypad reverence value to retentive memory failed The drive may continue to be operated Possible cause Regulator board failure 4 9
96. t sink from thermo conductive paste Coat both sides of the new thyristor with an thin film of thermo conductive paste a Mount the thyristor on the centering pin in the rear heatsink Observe correct polarity of cathode and anode according to layout Insert clamp in front heatsink and attach to thyristor with centering pin NOTE b Tighten the two clamp screws 13 mm alternately by one quarter turn until the control ring under the center clamp nut can be turned through 360 degree by hand Keep clearance to a minimum Proceed installation in the reverse order of removal 5 2 WebPak 3000 DC Drive Hardware Reference 5 1 Recommended Spare Parts Table 5 1 Urgent recommended spare parts for 4 Quadrant units S 6R 25 60 and 150 A Thyristor Power Unit Type Module 849 01 03 73 2 Module 135 60 00 1 Module 124 07 00 1 MOV 849 03 03 73 2 Module 123 39 30 135 60 02 849 05 03 73 6 Modules 135 05 52 Further spare parts for Unit Type 150 A 1 Capacitor 211 00 02 1 Resistor 750 70 04 Field Rectifier Module with MOV P C Boards MOV Module Cooling Fan 1 Regulator 810 79 70 with Firmware EPROM 1 Interface TIA 813 41 00 1 Power Supply FPP 810 89 00 1 Field Current Regul 762 70 50 1 I O Expansion 762 70 80 1 Regulator 810 79 70 1 Fan with Firmware EPROM 921 22 01 1 Interface TIC 813 39 00 1 Power Supply FPP 810
97. ting Data for 150 A Drives 69 5 32 5 32 5 32 5 32 5 69 5 SN eos T i T 7 1U 1C 1V 1D 1W p Power Connections on 1 Quadrant Units S 6 69 5 36 29 29 36 69 5 reas j 1C 1U 1V 1W 1D Power Connections on 4 Quadrant Units S 6R Power Connections Bus bars 90 mm Motor 1D 1C AC Line Bus bars 1U 1V 1W 60 mm Prot Earth Terminals 35 mm PE Torque 2 5 Nm Weight 14 kg Cooling air 187 m3 h Air flow direction from bottom to top Minimum clearances for air circulation 100 mm 2 3 rf fi dq l l mnr nn lrn H HEL uUUUUUUUUUU NANA fs ss s lU KERL UUU UUUUUUUUUUU TIS EE DH RR aa nannannnnnn Figure 2 3 Mounting Data for 250 A and 450 A Drives Power connections for 250 A Unit Motor Bus bars 25 x 5 1D 1C Hole 11 mm AC Line Bus bars 20 x 5 1U 1V 1W Hole 11 mm Prot earth Bolt M10 PE Torque 15 Nm Power connections for 450 A Unit Motor Bus bars 40 x 5 1D 1C Hole 14 mm AC Line Bus bars 30 x 5 1U 1V 1W Hole 14 mm Prot earth Bolt M10 PE Torque 15 Nm Weight 40 kg Cooling air 407 m3 h Air flow direction from bottom to top Minimum clearances for air circulation 100 mm 2 4 WebPak 3000 DC Drive Hardware Reference
98. tions Refer to the following publications as necessary for more information s D2 3444 WebPak 3000 DC Drive Software Reference Manual D2 3445 WebPak 3000 Operator Interface Module OIM User Guide s D2 3446 WebPak 3000 Application Workbook s D2 3447 WebPakCsS Software These manuals can be ordered in the Automation Bookstore or downloaded via www theautomationbookstore com than Public Item search Go Item Number begins with e g D2 3445 search Introduction to the WebPak3000 Drive 1 3 1 6 Optional Kits Rockwell Automation offers modification kits that broaden the application range of the drive A summary of these kits is presented in Table 1 2 For US Model No s refer to Appendix C Table 1 2 Drive Modification Kits Part Number Instruct Manual Catalog No Manual No Publication No 1 Pulse Encoder Allows for digital pulse Encoder speed 762 70 00 491343 Feedback Kit feedback PTK FP3TIF UM002B EN incl cable AutoMax Network Allows the WebPak 3000 to communicate on 762 70 40 D2 3318 Communication the Reliance AutoMax Distributed Control AMXF D2 3318 kit board amp System DCS cable IBSF Communic Allows the WebPak 3000 to communicate 762 70 45 49 1339 kit board amp cable over the standardized field bus system IBSF FP3IBS UM003C EN INTERBUS PDPF Communic Allows the WebPak 3000 to communicate 762 70 95 49 1348 kit board amp cable over the standardized Profibus DP system PDPF FP
99. tivity Correct grounding of the equipment and the cable screens as shown in example Figure B 1 Output power wiring drive to motor must be screened cable or run in a separate steel conduit All control I O and signal wiring must be screened cable Oo oa E WwW The braid of screened cables must be connected to the terminal box of the motor by the use of suitable EMC tested cable glands 7 For all DC converters a minimum line reactor of 2 voltage drop will be required The line reactors must be linked between filter Output and DC Converter Input For line reactor selection refer to Table 5 6 Mounting Instructions Refer to Figure B 1 e The filters must be screwed directly to the panel with the largest possible contact area e The support panel for the converters and filters must be a conducting steel sheet with a common ground busbar at the bottom This ground busbar mounted in front of the terminals must be solidly connected to the panel ensuring good conductivity e All cable screens entering the cabinet must be connected to the control cabinets ground busbar To ensure that the screen of the individual cable is connected solidly and with good conductivity to the ground busbar galvanised cable brackets as shown in Figure B 1 are recommended This applies also for coaxial cable at which only the outer insulation should be removed Cable Glands e Use suitable EMC tested cable glands only e The conductivity
100. tor must be connected between filter output and converter input This line reactor should be rated for minimum 2 voltage drop on drives up to 500 V and 4 for 690 V drives selection according to Table 5 6 The drives AC line input semiconductor protection fuses as per Table 5 4 must be mounted between filter output and line reactor Otherwise the filter inrush current may damage the fuses For installation instructions refer to Appendix B HF Filter If this filter is used on WebPak 3000 converters with AC line input currents above 100 A the HF emission limits for class A group 2 EN 55011 in the 2 environment industrial supply network according to the product standard EN 61800 3 are met and the drive fulfills CE conformity The HF filter is connected in front of the AC line reactor between the three AC line input phases and the protection earth conductor PE 1 S PE Leio e ma 2 fok l His jr Dt cal Fo Filter part no 839 52 20 Nominal voltage L L 690 V Figure 5 3 HF Filter dimensions mm 5 10 WebPak 3000 DC Drive Hardware Reference Radio Frequency Interference Filter a WebPak 3000 converters with AC line input currents below 100 A If the RFI filter is connected the HF emission limits for class A group 1 EN 55011 according to the product standard EN 61800 3 are met and the drive is CE conform This applies for the
101. ts and alarms that can occur and the possible causes It also references parameters that can be helpful when troubleshooting For instruction on how to clear faults and alarms see your OIM manual D2 3445 WebPak 3000 Operator Interface Module OM User s Guide 4 1 Checking for Wiring Errors Wiring errors and loose or grounded wiring are common problems that can inhibit operation of a drive Verify that the wiring has been correctly installed and that the drive is free of loose terminations and grounded conductors 4 2 Verifying AC Line and Power Input Verify that the applied AC power is correct for the specific drive If an isolation transformer has been installed on the incoming AC power verify its output voltage and that it has been properly connected Verify that the AC line fuses are semiconductor protection type and have been correctly sized per Table 5 4 The AC and DC power conductors should have been sized per local standards 4 3 Verifying DC Motor Connections ATTENTION A megohmmeter can be used for this motor ground check but all conductors between the motor and the drive must be disconnected The megohm meters high voltage can damage the drive s electronic circuits Disconnect all conductors between the motor and the drive before using a megohmmeter for this motor ground check Failure to observe this precaution could result in damage to or destruction of the equipment Verify that all DC motor connections are corre
102. uency See PLL MAXIMUM ERROR P 308 e Disconnected loosely connected or damaged J6 ribbon cable The regulator board was unable to communicate with the Operator Interface Module OIM See the previous section 4 5 for a description of the regulator status LEDs that can pinpoint whether or not the OIM is communicating Possible causes e Disconnected loosely connected or damaged interface module serial cable e Regulator board failure 4 4 WebPak 3000 DC Drive Hardware Reference Table 4 1 Fault Codes Continued CODE DISPLAY DESCRIPTION F00012 ARMATURE OVER F00013 NETWORK COMMUNICATION TIMEOUT F00014 REVERSED TACH LEADS Armature voltage exceeded 130 of MOTOR RATED ARM VOLTS P 009 Possible causes e MOTOR RATED ARM VOLTS not set properly e Improper voltage loop tuning Network Communications is missing or failed to communicate with master CONTROL SOURCE SELECT set to NETWORK Possible causes e NETW CONNECT TYPE P 910 was changed from BASIC to FULL e NETW DROP NUMBER P 900 was changed e Network Option cable connections are loose or not connected e Network Option board failed or master communications failed The difference between the speed reference and speed feedback was greater than TACH LEAD FLT THRESH P 227 for the time specified in TACH LEAD FLT DELAY P 228 Possible causes Tachometer or encoder leads are reversed The motor armature leads are reversed The motor field lea
103. uits Failure to observe this precaution could result in damage to or destruction of the equipment ATTENTION Connecting an external power source to any of the 24 volt connections terminals 1 7 11 and 14 on the Regulator board terminal strip will damage the drive DO NOT connect the external power source on the 24 volt connections on the Regulator board terminal strip Failure to observe this precaution could result in damage to or destruction of the equipment ATTENTION At very low input levels noise or drift could cause analog input polarity to change This could result in damage to or destruction of the equipment Refer to Figure 2 8b and the following Table 2 2 when wiring user devices to the drive Size and install all wiring in accordance with all applicable standards Table 2 2 User Device Connections to the Regulator Board Terminal Strip Type Terminal Connections Logic The logic input circuits can be powered Inputs o om the N LARA S E SU or from an externa vo power source The intemal 24 volt DC power supply is available at the Regulator 1 24V and 6 board terminal strip see figure 2 8b If an external power source is used only the common must be connected to ere o Analog Diameter Taper Range These inputs are converted at 12 bits plus Inputs or Trim Reference High Side 10V Isol 16 Wiper Low Side High Range Low Range 22 Common 23 Analog Analog Output 1 24 and 25
104. umper and Adjustment Settings on the Regulator Board 310 AUTO REP VOLTS S o O JM TACH V SCALE 16 o O 312 AUTO REF VOLTS S o O 4 1 0 1 J12 MMA TACHV RANGE e TT 15 REGULATOR TYPE semo TT J16 OIM PROGRAM ENABIE TT 8 ARMIFBRB Posting TT NS MANUALREF pOr TT J21 6 21 FIELD SUPPLY not used DO NOT USE J27 J29 SPARE 1 2 J28 FILTER SELECT red J30 POWER INTERFACE LOW Pe ANALOG TACH ZERO ADJ J0 S o O ARM VOLTAGE ZERO ADJ o T 3 2 WebPak 3000 DC Drive Hardware Reference 3 4 1 Set the Regulator Type Jumper J15 ATTENTION The J15 jumper must be set to the TORQUE CURRENT position when using the WebPak 3000 drive s feature to switch on the fly from speed voltage control to torque current control Applying a drive as a direct current regulator has safety issues that must be considered Refer to the WebPak 3000 Software Reference D2 3444 for proper setup of this function Failure to observe these precautions could result in severe bodily injury or loss of life J15 determines whether the drive uses Speed Voltage or Torque Current regulation J15 must be set to CURRENT in order to be able to switch from a speed regulator to a current regulator over the network When CURRENT is selected only the terminal strip or a Communication Board can be used as the control source Also note that speed voltage parameters must be set to provide overspeed protection for the
105. will remain in JOG mode until the completion of a stop sequence or until the RUN input is asserted causing the drive to switch from JOG mode to RUN mode Note that the drive will only enter RUN mode on a rising transition of JOG SECTION RUN or TENSION ON This is to prevent unintentional starts when changing control sources For example changing the control source from KEYPAD to TERMBLK will not start the drive while the terminal block SECTION RUN is asserted SECTION RUN must be deasserted then reasserted to start the drive The addition of the TENSION ON input represents an additional start mechanism to the drive A rising transition on TENSION ON from the READY state will cause the drive to enter the RUN mode with the tension major loop active in stall tension If the drive is in not ready when a rising edge is generated on TENSION ON the same drive not ready message will appear on the OIM Once the drive is in the STALL TENSION state a rising transition on the SECTION RUN input will cause the drive to switch to the RUN TENSION state Provide the Emergency Stop Function WARNING To inhibit uncontrolled machine operation in case of the malfunction of the drive the user must provide an external emergency stop circuit which ensures disconnection of the power source from the motor This circuit must be hardwired with electro mechanic components and shall not depend on electronic logic or software The stopping device e g mushroom head pu

FlexPak 3000 OIM 4.2 - Rockwell Automation

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