DC Drives

The easy to use three-phase
digital DC drive for regenerative
and non-regenerative applications from 1.5-600 HP

| Standard Features | Standard Operator Features | Optional Features |
| Dimensions | Controller Selection | Controller Ratings | Service Conditions |
| Efficiency and Power Factor | Capacities | Speed Regulation |

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

  • Simple: All control, signal and power field wiring is readily accessible through supplied terminal boards to streamline installation. Setup and operation is coordinated with a large graphics display and keypad using plain text. Diagnostic and status information as well as help text are displayed and entered in one of five languages easily selected through the keypad. A "Quick-Start" menu combines with self tuning of the speed and current loops to ensure straightforward drive setup and startup.
  • Flexible: While most applications are handled through standard drive software, many standard hardware kits and options are available allowing the drive's capability to be expanded with ease. The FlexPak 3000 is easily modified for input line voltages and frequencies used in many countries and displays setup, operating, status and diagnostic information in five different languages.
  • Reliable: The FlexPak 3000 uses the latest in high density power semiconductor devices, surface mount and sub micron ASIC technology. A power interface board circuit provides the noise suppression and firing circuits and connects to the digital regulator with only a single ribbon cable.
  • Compact: Extensive use of molded parts allows for a high density power module without compromising the accessibility of options and circuits. The packaging is compact yet allows for easy field wiring, mounting, modification or service. The basic chassis design can be easily converted to a NEMA I enclosure using available NEMA I conversion kits or floor mount NEMA I enclosures for high HP controllers.

Standard Features

AC Supply

  • 50/60 Hz AC line frequency input
  • Phase insensitive AC line input
  • Semi-conductor fuse protection
  • AC "N" contactor (3-300 HP)
  • DC "M" contactor (400-600 HP)

Power Section

  • Full-wave, full control 6-SCR power conversion for smooth efficient operation and high performance
  • Burst firing of SCRs
  • Non-regenerative or regenerative (required for reversing) controller
  • Capable of 150% full-load current for 1-minute & 200% for 5 sec.

User/Adjustments (All adjustable in Quick Start Menu)

  • Maximum speed
  • Minimum speed
  • Linear acceleration
  • Linear deceleration
  • Current limit (positive and negative on regenerative modules)
  • I/R compensation (voltage regulated drives)
  • Jog speed
  • Jog acceleration/deceleration rate
  • Reverse disable on regenerative drives

Analog Signals (12 bit resolution)

  • 0-10 VDC manual speed reference
  • User selectable +10 volt or 4-20 mA auto speed reference
  • (2) 0-10 VDC analog outputs that are user steerable
  • Speed feedback from analog tachometer (250 VDC maximum input)

Digital Signals

  • Coast stop, auto/manual, forward/reverse, jog, run and stop inputs
  • Motor thermostat diagnostic input
  • Brush wear diagnostic input or OCL enable
  • Customer interlock diagnostic input
  • Drive running contact output
  • Drive alarm contact output
  • Drive fault contact output

Other Significant Standard Features

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

Standard Operator Interface Features

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

Optional Features

  • Incoming AC line disconnect
  • Fused blower motor starter with adjustable overload
  • NEMA I conversion kits and floor mount NEMA 1 and NEMA 12 enclosures
  • Remote mountable OIM kit for mounting in cabinet doors
  • Dynamic braking kits available for customer panel mount or NEMA 1 enclosed
  • Enhanced field supply kit provides for the following:
    • Electronic field trim
    • Field economy
    • 240 VDC field on 230 VAC controllers
    • 230 VAC controllers can be set for field voltages 103 VDC-259VDC
    • 460 VAC controller can be set for field voltages 207 VDC-515 VDC
  • Field Current regulators for above base speed operation and field economy
  • Pulse encoder feedback kit provides .01% speed regulation via digital pulse encoder speed feedback
  • AC tachometer feedback kit for use with existing motor mounted AC tachometers
  • I/O expansion cards expands drive capability to do dancer follower functions, outer control loops, external MOP, preset speeds, analog or frequency output signals, HP/KW output signals, speed or current level detector outputs
  • 115 VAC control circuit interface for separate mounting on chassis drives or mounted on enclosed drives
  • AutoMax network interface option card
  • DeviceNet communication option card
  • ControlNet communication option card(1)
  • CS3000 WINDOWS-based configuration executive for upload/download, compare, monitor and drive control capability. PC-Scope feature available on V4 and higher drives.

(1) Contact Reliance for availability.


The 600 HP
FlexPak 3000

 

The 300 HP
FlexPak 3000

The FlexPak 3000 family of drives for 1-1/2-600 HP applications

Dimensions of FlexPak 3000 Chassis

Dimensions with NEMA I Conversion Kit Installed

Dimensions of FlexPak 3000 Chassis

Controller Selection

Horsepower

Non-Regenerative

Regenerative

230 VAC

460 VAC

230 VAC

460 VAC

1.5

1FN2042

-

1FR2042

-

2

2FN2042

-

2FR2042

-

3

3FN2042

3FN4042

3FR2042

3FR4042

5

5FN2042

5FN4042

5FR2042

5FR4042

7.5

7FN2042

7FN4042

7FR2042

7FR4042

10

10FN2042

10FN4042

10FR2042

10FR4042

15

15FN2042

15FN4042

15FR2042

15FR4042

20

20FN2042

20FN4042

20FR2042

20FR4042

25

25FB2042

25FN4042

25FR2042

25FR4042

30

30FN2042

30FN4042

30FR2042

30FR4042

40

40FN2042

40FN4042

40FR2042

40FR4042

50

50FN2042

50FN4042

50FR2042

50FR4042

60

60FN2042

60FN4042

60FR2042

60FR4042

75

75FN2042

75FN4042

75FR2042

75FR4042

100

-

100FN4042

-

100FR4042

125

-

125FN4042

-

125FR4042

150

-

150FN4042

-

150FR4042

200

-

200FN4042

-

200FR4042

250

-

250FN4042

-

250FB4042

300

-

300FN4042

-

300FB4042

400

-

400FN4041

-

400FR4041

500

-

500FN4041

-

500FR4041

600

-

600FN4041

-

600FR4041

Controller Ratings(1)

HP Ratings
Full Load Rated RMS AC Line Current (Amperes)

Full Load Rated RMS DC Armature Current (Amperes)

Rated Field Current (Amperes)

230 VAC
460 VAC

240 VDC

500 VDC

150 VDC

300 VDC

1.5

10

-

7

-

10

-

2

11

-

9

-

10

-

3

13

10

12

6

10

10

5

19

12

20

10

10

10

7.5

26

15

29

14

10

10

10

33

18

38

19

10

10

15

48

24

55

27

10

10

20

63

31

73

35

15

10

25

80

39

93

45

15

10

30

94

45

110

52

15

10

40

125

63

146

73

15

15

50

154

74

180

86

15

15

60

186

86

218

100

15

15

75

226

110

265

129

15

15

100

307

143

360

167

15

15

125

370

177

434

207

15

15

150

443

213

521

250

15

15

200

-

281

-

330

-

15

250

-

351

-

412

-

15

300

-

421

-

495

-

15

400

-

567

-

667

-

15

500

-

680

-

800

-

15

600

-

816

-

960

-

15

Service Conditions

  • Standard altitude: to 3300 feet (1000 meters)
  • Standard ambient temperature
  • Cabinet units: 0-40C (32 degrees F to 104 degrees F)
  • Chassis units: 0-55C (32 degrees F to 131 degrees F)
  • AC line voltage variation: +/- 10%
  • AC line frequency: 48/62 Hz
  • AC line distribution system KVA capacity(1)
  • Maximum 3 drives per transformer(1)
  • FlexPak 3000 drives are 50/60 Hz
  • Atmosphere: non-condensing relative humidity 5 to 95%

Efficiency and Power Factor

  • Displacement power factor at maximum speed: 88%
  • Efficiency of power module at:
  • 100% speed and 100% load: 99.3%
  • 100% speed and 25% load: 98.5%
  • 25% speed and 100% load: 96.8%
  • 25% speed and 25% load: 94.0%
  • Efficiency of drive including motor is typically 87%

Capacities

  • Service factor: 1.0
  • Maximum load: 150% for one minute, 200% for 5 seconds

Speed Range(2)

  • Operator's speed adjustment: 0 to rated speed
  • Specification speed range: 100:1 based on top speed and tachometer
(1) When applying FlexPak 3000 drives to power distribution systems with KVA capacity in excess of five times the smallest drive rating use of an isolation transformer or line reactors of similar impedance is required.
(2) Dependent of top speed and pulse tachometer used.
5PY = 30:1
RD120 = 70:1
RL1024 =100:1

Speed Regulation

Regulation
Arrangement

Speed Change with 95% Load Change

Speed Change from All Other Variables


Kit Model Number

Armature Voltage w/ IR Compensation
 2-3% 15% Not applicable
Closed Loop
      

w/ RE-045 tach(3)
w/ 5PY tach(4)
w/ RD-120-1 tach(5)
w/ RD-120-2 tach(5)
w/ RD-62 tach(5)

 1%
1%
0.01%
0.01%
0.01%		 2%
2%
0.01%
0.01%
0.01%		 907FK0301

907FK0101 907FK0101 907FK0101

(3) Standard DC Tachometer
(4) Optional AC Tachometer Feedback kit required
(5) Optional Pulse Encoder Feedback kit required


Document D-2882-4

Note:

This material is not intended to provide operational instructions. Appropriate Reliance Industrial Company instruction manuals and precautions should be studied prior to installation, operation, or maintenance of equipment.