FlexPak 3000 DC Drives and WebPak 3000 DC Drives Replacement Parts Instruction Manual D2-3438-4 Effective Date: July 22, 2005 ! ATTENTION: Only qualified electrical personnel familiar with the construction of this equipment and the hazards involved should install, adjust, operate, and/or service this equipment. Read and understand the applicable FlexPak 3000 hardware manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION: Equipment is at line voltage when AC power is connected. Disconnect and lock out all ungrounded conductors of the AC power line before checking wiring. Failure to observe this precaution could result in severe bodily injury or loss of life. ATTENTION: Replacing fuses with different ratings other than the ratings supplied with the original equipment can cause damage to the equipment. Replace fuses only with the same current, voltage, and class rating as supplied with the original equipment. Failure to observe this precaution could result in damage to, or destruction of, the equipment. The table that follows lists replacement parts for FlexPak™ 3000 DC drives and WebPak™ 3000 DC drives. Unless noted, the replacement parts are the same for both drives. Note: All parts are subject to change. Please call Reliance Electric for the latest part information. These parts are available from your local Reliance Electric Distributor or direct from Reliance Electric Company: Reliance Electric Company Cleveland Service Center 375 Alpha Drive Highland Heights, Ohio 44143 Order Entry Phone: 440-646-6650 Fax: 440-646-6618 This document is available as an electronic file for downloading only. Reliance, FlexPak, and WebPak are trademarks of Rockwell Automation. © 2005 Rockwell Automation. All rights reserved. FlexPak 3000 and WebPak 3000 DC Drive Replacement Parts Part Description Quantity Per Drive AC Line Fuse (1FU, 2FU, 3FU): (except as noted, Bussman series FWH) 1.5 thru 5 HP @ 230 VAC/3 thru 10 HP @ 460 VAC 7.5 thru 10 HP @ 230 VAC/15 thru 25 HP @ 460 VAC 15 HP @ 230 VAC/30 HP @ 460 VAC 20 thru 30 HP @ 230 VAC/40 thru 60 HP @ 460 VAC 40 thru 60 HP @ 230 VAC/75 thru 125 HP @ 460 VAC 75 HP @ 230 VAC/150 HP @ 460 VAC 100 HP @ 230 VAC/200 HP @ 460 VAC 125 thru 150 HP @ 230 VAC/250 thru 300 HP @ 460 VAC 400 thru 600 HP @ 460 VAC (Gould part # A70QS600-4K) 7 Amp Rated Output 29 Amp Rated Output 55 Amp Rated Output 110 Amp Rated Output 265 Amp Rated Output 3 3 3 3 3 3 3 3 6 3 3 3 3 3 64676-120AMX (40A, 500V) 64676-120ARX (80A, 500V) 64676-120ASX (90A, 500V) 64676-120AVX (150A, 500V) 64676-120AZX (300A, 500V) 64676-120BAX (350A, 500V) 64676-120BDX (600 A, 500 V) 64676-120BGX (800 A, 500V) 184972-Q07 (600 A, 700V) 64676-120AMX (40 A, 500 V) 64676-120ARX (80 A, 500 V) 64676-120ASX (90 A, 500 V) 64676-120AVX (150 A, 500 V) 64676-120BAX (350 A, 500 V) CCT Fuse (4FU, 5FU): 1.5 thru 30 HP @ 230 VAC 3 thru 60 HP @ 460 VAC 40 thru 75 HP @ 230 VAC 75 thru 150 HP @ 460 VAC 100 HP @ 230 VAC/200 HP @ 460 VAC 125 thru 150 HP @ 230 VAC/250 thru 500 HP @ 460 VAC 600 HP @ 460 VAC 7 thru 110 Amp Rated Output 265 Amp Rated Output 2 2 2 2 2 2 2 2 2 64676-64F (1.5A, 600V) 64676-64U (.6A, 600V) 64676-64AC (4.5A, 600V) 64676-64Z (2.25A, 600V) 64676-64L (5.0A, 600V) 64676-64N (7.5 A, 600 V) 64676-64AG (10 A, 600 V) 64676-64D (1.0 A, 600 V) 64676-64G (2.0 A, 600 V) Field Fuse (6FU, 7FU, 8FU): FlexPak 3000 with Standard Field Supply 1.5 thru 30 HP @ 230 VAC/3 thru 60 HP @ 460 VAC 40 thru 60 HP @ 230 VAC/75 thru 125 HP @ 460 VAC 75 HP @ 230 VAC/150 HP @ 460 VAC 100 thru 150 HP @ 230 VAC/200 thru 600 HP @ 460 VAC 7 thru 110 Amp Rated Output 265 Amp Rated Output 3 3 3 3 3 3 64676-30K (15A, 600V) 64676-30K (15A, 600V) 64676-30M (25A, 600V) 64676-30M (25 A, 600 V) 64676-30K (15 A, 600 V) 64676-30M (25 A, 600 V) FlexPak 3000 with Field Current Regulator All drives 3 64676-30M (25A, 600V) WebPak 3000 1.5 thru 75 HP @ 230 VAC/3 thru 150 HP @ 460 VAC 3 64676-30M (25A, 600V) Surge Suppressor Fuse (9FU, 10 FU): 1.5 thru 15 HP @ 230 VAC/3 thru 30 HP @ 460 VAC 20 thru 75 HP @ 230 VAC/40 thru 150 HP @ 460 VAC 7 thru 55 Amp Rated Output 110 thru 265 Amp Rated Output (9FU, 10FU, 11FU) 100 thru 150 HP @ 230 VAC/200 thru 600 HP @ 460 VAC 2 Part Number N/R 2 N/R 2 Not Required (N/R) 64676-68X (4.0A, 500V) Not Required (N/R) 64676-68X (4.0 A, 500 V) 3 64676-30K (15 A, 600 V) FlexPak 3000 DC Drives and WebPak 3000 DC Drives Replacement Parts FlexPak 3000 and WebPak 3000 DC Drive Replacement Parts Part Description Quantity Per Drive Armature Fuse (11FU, S6R ONLY) (Bussman series FWP up to 75 HP @ 230 VAC, 150 HP @ 460 VAC)): 1.5 HP @ 230 VAC/3 HP @ 460 VAC 2 HP @ 230 VAC/5 HP @ 460 VAC 3 HP @ 230 VAC/7.5 HP @ 460 VAC 5 HP @ 230 VAC/10 HP @ 460 VAC 7.5 HP @ 230 VAC/15 HP @ 460 VAC 10 HP @ 230 VAC/20 HP @ 460 VAC 25 HP @ 460 VAC 15 HP @ 230 VAC/30 HP @ 460 VAC 20 thru 25 HP @ 230 VAC/40 thru 50 HP @ 460 VAC 30 HP @ 230 VAC/60 HP @ 460 VAC 40 HP @ 230 VAC/75 HP @ 460 VAC 50 HP @ 230 VAC/100 HP @ 460 VAC 60 HP @ 230 VAC/125 HP @ 460 VAC 75 HP @ 230 VAC/150 HP @ 460 VAC 7 Amp Rated Output 29 Amp Rated Output 55 Amp Rated Output 110 Amp Rated Output 265 Amp Rated Output 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 64676-130AGX (15A, 700V) 64676-130AHX (20A, 700V) 64676-130AJX (25A, 700V) 64676-130ALX (35A, 700V) 64676-130AMX (40A, 700V) 64676-130ANX (50A, 700V) 64676-130APX (60A, 700V) 64676-130AQX (70A, 700V) 64676-130AUX (125A, 700V) 64676-130AVX (150A, 700V) 64676-130AXX (200A, 700V) 64676-130AYX (250A, 700V) 64676-130AZX (300A, 700V) 64676-130BAX (350A, 700V) 64676-130AGX (15 A, 700V) 64676-130AMX (40 A, 700V) 64676-130AQX (70 A, 700V) 64676-130AVX (150 A, 700V) 64676-130BAX (350 A, 700V) Power Supply Fuse (12FU) 1 64676-21AF (4.0A, 250 V) Current Transformer (1CT, 3CT): 1.5 HP @ 230 VAC/3 HP @ 460 VAC 2 thru 7.5 HP @ 230 VAC / 4 thru 15 HP @ 460 VAC 10 thru 15 HP @ 230 VAC/20 thru 30 HP @ 460 VAC 20 thru 30 HP @ 230 VAC/40 thru 60 HP @ 460 VAC 40 thru 75 HP @ 230 VAC/75 thru 150 HP @ 460 VAC 100 thru 150 HP @ 230 VAC/200 thru 300 HP @ 460 VAC 400 thru 600 HP @ 460 VAC 7 Amp Rated Output 29 Amp Rated Output 55 Amp Rated Output 110 Amp Rated Output 265 Amp Rated Output 2 2 2 2 2 2 2 2 2 2 2 2 (Tp/Tn) 610273-121V (833/6) 610273-121T (833/4) 610273-121S (833/2) 610273-121R (833/1) 610274-21R (2000/1) 610275-41R (5230/1) 610276-39R (7770/1) 610273-121V (833/6) 610273-121T (833/4) 610273-121S (833/2) 610273-121R (833/1) 610274-21R (2000/1) Armature Power Semiconductors: 1.5 thru 15 HP @ 230 VAC/3 thru 30 HP @ 460 VAC 20 thru 30 HP @ 230 VAC/40 thru 60 HP @ 460 VAC 40 thru 75 HP @ 230 VAC/75 thru 150 HP @ 460 VAC 100 thru 150 HP @ 230 VAC/200 thru 150 HP @ 460 VAC 400 thru 600 HP @ 460 VAC 7 thru 55 Amp Rated Output 110 Amp Rated Output 265 Amp Rated Output dV/dT and Gate Drivers: 400 thru 600 HP @ 460 VAC MOV Suppressor Assembly (4SSR): 100 thru 150 HP @ 230 VAC/200 thru 300 HP @ 460 VAC 400 thru 600 HP @ 460 VAC Part Number S6 S6R 1 2 701819-306AW (before Jan, 1999) 1 2 179128-Q01 (after Jan, 1999) 3 6 701819-209AW 3 6 701819-205AW 6 12 610275-40R 6 12 410403-79AZ 1 2 701819-306AW (before Jan, 1999) 1 2 179128-Q01(after Jan, 1999) 3 6 701819-209AW 3 6 701819-205AW S6 S6R O-58706-41 3 3 O-58706-40 1 1 FlexPak 3000 DC Drives and WebPak 3000 DC Drives Replacement Parts 610275-52R 802276-815R 3 FlexPak 3000 and WebPak 3000 DC Drive Replacement Parts Part Description Coil Surge Suppressor (2SSR) Quantity Per Drive 1 Part Number 600686-33A Surge Suppressor Resistor Assembly (R1): 1.5 thru 15 HP @ 230 VAC/3 thru 30 HP @ 460 VAC 20 thru 30 HP @ 230 VAC/40 thru 60 HP @ 460 VAC 40 thru 75 HP @ 230 VAC/75 thru 150 HP @ 460 VAC 100 thru 150 HP @ 230 VAC/200 thru 300 HP @ 460 VAC 400 thru 600 HP @ 460 VAC 7 thru 55 Amp Rated Output 110 Amp Rated Output 265 Amp Rated Output N/R 2 2 1 1 N/R 2 2 Not Required 63481-101TAA (two 10K, 40W in series) 63481-102TAA (two 10K, 90W in parallel) 802275-41R (six 10K, 100W in parallel) 802272-13T (six 7.5K, 200W in parallel) Not Required 63481-101TAA (two 10K, 40W in series) 63481-102TAA (two 10K, 90W in parallel) Surge Suppressor (C1): 1.5 thru 15 HP @ 230 VAC/3 thru 30 HP @ 460 VAC 20 HP thru 30 HP @ 230 VAC/40 thru 60 HP @ 460 VAC 40 thru 75 HP @ 230 VAC/75 thru 150 HP @ 460 VAC 100 thru 150 HP @ 230 VAC/200 thru 300 HP @ 460 VAC 400 thru 600 HP @ 460 VAC 7 thru 55 Amp Rated Output 110 Amp Rated Output 265 Amp Rated Output N/R 1 1 1 3 N/R 1 1 Not Required 66056-49PH (2µF, 1500VDC) 66056-49PQ (4µF, 1500VDC) 610275-42R (8µF, 1500 VDC) 802276-819R (8µF, 1500 VDC) Not Required 66056-49PH (2µF, 1500 VDC) 66056-49PQ (4µF, 1500VDC) Surge Suppressor Rectifier Heatsink Assembly: 100 thru 150 HP @ 230 VAC/200 thru 600 HP @ 460 VAC 1 802275-40R Power Unit Fan: 1.5 thru 5 HP @ 230 VAC/3 thru 10 HP @ 460 VAC 7.5 thru 30 HP @ 230 VAC/15 thru 60 HP @ 460 VAC 40 thru 50 HP @ 230 VAC/75 thru 100 HP @ 460 VAC 60 thru 75 HP @ 230 VAC/125 thru 150 HP @ 460 VAC 100 HP @ 230 VAC/200 HP @ 460 VAC 125 thru 150 HP @ 230 VAC/250 thru 500 HP @ 460 VAC 600 HP @ 460 VAC 7 Amp Rated Output 29 thru 110 Amp Rated Output 265 Amp Rated Output N/R 1 1 1 2 2 4 N/R 1 1 Not Required 69739-27X 69739-20R 69739-9R 69739-20R 69739-9R 69739-9R Not Required 69739-27X 69739-9R Field Supply Assembly: FlexPak 3000 1.5 thru 15 HP @ 230 VAC/3 thru 30 HP @ 460 VAC 20 thru 60 HP @ 230 VAC/40 thru 125 HP @ 460 VAC 75 thru 150 HP @ 230 VAC/150 thru 600 HP @ 460 VAC 7 thru 55 Amp Rated Output 110 Amp Rated Output 265 Amp Rated Output WebPak 3000 1.5 thru 15 HP @ 230 VAC/3 thru 30 HP @ 460 VAC 20 thru 75 HP @ 230 VAC/40 thru 150 HP @ 460 VAC Control Transformer CCT: 1.5 thru 30 HP @ 230 VAC/3 thru 60 HP @ 460 VAC 40 thru 75 HP @ 230 VAC/75 thru 150 HP @ 460 VAC 100 HP @ 230 VAC/200 HP @ 460 VAC 125 thru 150 HP @ 230 VAC/250 thru 300 HP @ 460 VAC 400 thru 500 HP @ 460 VAC 600 HP @ 460 VAC 7 thru 110 Amp Rated Output 265 Amp Rated Output 4 1 1 1 1 1 1 179537 179536 911FK0151 179537 179536 911FK0151 1 1 911FK0101 911FK0151 1 1 1 1 1 1 1 1 417155-6R (150VA) 417155-S (350VA) 417155-T (500VA) 417155-RB (750VA) 417155-SB (750VA) 417155-RV (1000VA) 411027-129A 411027-129B FlexPak 3000 DC Drives and WebPak 3000 DC Drives Replacement Parts FlexPak 3000 and WebPak 3000 DC Drive Replacement Parts Part Description “FN” Contactor: 1.5 thru 5 HP @ 230 VAC/3 thru 10 HP @ 460 VAC 7.5 thru 10 HP @ 230 VAC/15 thru 20 HP @ 460 VAC 15 thru 30 HP @ 230 VAC/25 thru 60 HP @ 460 VAC Quantity Per Drive Part Number 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 100-C12D10 100-C30D10 179517 (prior to June 2000) 100-C85D10 (after June 2000) 705310-68A or retrofit to 100-D180 with 374206-A01 (prior to September 2005) 705310-70A or retrofit to 100-D180 with 374206-A01 (prior to September 2005) 100-D180D00 plus 100-Ds1-B11 (after September 2005) 705310-71A or retrofit to 100-D180 with 374206-A01 (prior to September 2005) 705310-72A or retrofit to 100-D180 with 374206-A02 (prior to September 2005) 100-D420ED00 plus 100-DS1-B11 (after September 2005) 100-C12D10 100-C30D10 179517 (before June 2000) 100-C85D10 (after June 2000) 179517 (before June 2000) 100-C85D10 (after June 2000) 705310-70A or retrofit to 100-D180 with 374206-A01 (prior to September 2005) 100-D180D00 plus 100-DS1-B11 (after September 2005) “M” Contactor: 400 HP @ 460 VAC 500 to 600 HP @ 460 VAC 1 1 705310-191A 705310-211A AC Line Disconnect: 1.5 thru 25 HP @ 230 VAC/3 thru 50 HP @ 460 VAC 30 HP @ 230 VAC/60 HP @ 460 VAC 40 thru 60 HP @ 230 VAC/75 thru 125 HP @ 460 VAC 75 HP @ 230 VAC/150 HP @ 460 VAC 100 HP @ 230 VAC/200 HP @ 460 VAC 125 thru 150 HP @ 230 VAC/250 thru 300 HP @ 460 VAC 400 thru 500 HP @ 460 VAC 600 HP @ 460 VAC 7 thru 55 Amp Rated Output 110 Amp Rated Output 265 Amp Rated Output 1 1 1 1 1 1 1 1 1 1 1 65242-100NSX 65242-100SSX 65242-200ZSX 65242-300FSX 65242-300FSX 65242-400JSX 65242-500LSX 65242-500NSX 65242-100NSX 65242-100SSX 65242-300FSX Regulator PCB (FlexPak 3000) Regulator PCB (WebPak 3000) 1 1 M/N 920FK0042 M/N 920WK0011 Power Supply Board PCB 1 O-58771 OIM PCB (FlexPak 3000) OIM PCB (WebPak 3000) 1 1 180372-A01 180374-A01 OIM Assembly (Keypad/Display) (FlexPak 3000) OIM Assembly (Keypad/Display) (WebPak 3000) 1 1 M/N 317C160D M/N 925WK0101 DCM PCB 1 O-58777-300 DCM Assembly (Keypad/Display) 1 802273-90R Relay Rectifier PCB 1 O-58718 40 HP @ 230 VAC/75 HP @ 460 VAC 50 thru 75 HP @ 230 VAC/100 thru 150 HP @ 460 VAC 40 thru 75 HP @ 230 VAC/75 thru 150 HP @ 460 VAC 100 thru 125 HP @ 230 VAC/200 thru 250 HP @ 460 VAC 150 HP @ 230 VAC/300 HP @ 460 VAC 100 thru 150 HP @ 230 VAC/200 thru 300 HP @ 460 VAC 7 Amp Rated Output 29 Amp Rated Output 55 Amp Rated Output 110 Amp Rated Output 265 Amp Rated Output FlexPak 3000 DC Drives and WebPak 3000 DC Drives Replacement Parts 5 FlexPak 3000 and WebPak 3000 DC Drive Replacement Parts Part Description Power I/F PCB: 1.5 thru 5 HP @ 230 VAC/3 thru 10 HP @ 460 VAC Quantity Per Drive Part Number S6R O-58706-16 (before Jan 1999) 179124 (after Jan 1999) O-58706-17 (before Jan 1999) 179126 (after Jan 1999) 179679-A02 179978 O-58706-32 O-58706-42 O-58706-16 (before Jan 1999) 179124 (after Jan 1999) O-58706-17 (before Jan 1999) 179126 (after Jan 1999) O-58706-18 179978 1 1 1 1 1 1 1 1 1 1 1 1 1 1 S6 O-58706-19 (before Jan 1999) 179125 (after Jan 1999) O-58706-20 (before Jan 1999) 179127 (after Jan 1999) O-58706-21 180041-A01 O-58706-33 O-58706-43 O-58706-19 (before Jan 1999) 179125 (after Jan 1999) O-58706-20 (before Jan 1999) 179127 (after Jan 1999) O-58706-21 180041-A01 Inverting Fault Breaker: 1.5 thru 2 HP @ 230 VAC/3 thru 5 HP @ 460 VAC 3 thru 5 HP @ 230 VAC/7.5 thru 10 HP @ 460 VAC 7.5 thru 10 HP @ 230 VAC/15 thru 20 HP @ 460 VAC 15 thru 20 HP @ 230 VAC/25 thru 40 HP @ 460 VAC 25 thru 30 HP @ 230 VAC/50 thru 60 HP @ 460 VAC 40 thru 60 HP @ 230 VAC/75 thru 125 HP @ 460 VAC 75 HP @ 230 VAC/150 HP @ 460 VAC 100 HP @ 230 VAC/200 HP @ 460 VAC 125 HP @ 230 VAC/250 HP @ 460 VAC 150 HP @ 230 VAC/300 HP @ 460 VAC 400 HP @ 460 VAC 500 HP @ 460 VAC 600 HP @ 460 VAC 7 Amp Rated Output 29 Amp Rated Output 55 Amp Rated Output 110 Amp Rated Output 265 Amp Rated Output 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 77801-18DXA Set at A (40 A) 419035-100DSA Set at L (50 A) 419035-100HSA Set at 2 (90 A) 419035-100NSA Set at L (150 A) 419035-100SSA Set at L (450 A) 419035-200ZSA Set at 2 (470 A) 419035-300FSA Set at 2 (625 A) 419035-400JSA Set at 2 (800 A) 419035-400JSA Set at 4 (1100 A) 419035-400JSA Set at HI (1250 A) 419035-600QSA Set at 2 (1900 A) 419035-600QSA Set at 3 (2300 A) 419035-600QSA Set at 4 (2600 A) 77801-18DXA Set at A (40A) 419035-100HSA Set at 2 (90A) 419035-100NSA Set at L (150 A) 419035-100SSA Set at L (450 A) 419035-300FSA Set at 2 (625 A) Heat Sink Assembly: 1.5 thru 5 HP @ 230 VAC/3 thru 10 HP @ 460 HP 7.5 thru 10 HP @ 230 VAC/15 thru 20 HP @ 460 HP 25 HP @ 460 HP 15 HP @ 230 VAC/30 HP @ 460 HP 20 thru 30 HP @ 230 VAC/40 thru 60 HP @ 460 HP 40 thru 75 HP @ 230 VAC/75 thru 150 HP @ 460 HP 100 thru 150 HP @ 230 VAC/200 thru 300 HP @ 460 VAC 7 Amp Rated Output 29 Amp Rated Output 55 Amp Rated Output 110 Amp Rated Output 265 Amp Rated Output 1 1 1 1 1 1 1 3 1 1 1 1 1 S6 802273-308V 802273-308T 802273-308SA 802273-308S 802273-209R 802274-206R 802275-2R 802273-308V 802273-308T 802273-308S 802273-209R 802274-206R 7.5 thru 15 HP @ 230 VAC/15 thru 30 HP @ 460 VAC 20 thru 30 HP @ 230 VAC/40 thru 60 HP @ 460 VAC 40 thru 75 HP @ 230 VAC/75 thru 150 HP @ 460 VAC 100 thru 150 HP @ 230 VAC/200 thru 300 HP @ 460 VAC 400 thru 600 HP @ 460 VAC 7 Amp Rated Output 29 thru 55 Amp Rated Output 110 Amp Rated Output 265 Amp Rated Output 6 S6R 802273-307V 802273-307T 802273-307SA 802273-307S 802273-206S 802274-207R 802275-3R 802273-307V 802273-307T 802273-307S 802273-206S 802274-207R FlexPak 3000 DC Drives and WebPak 3000 DC Drives Replacement Parts