Blower Motor Starter Kit for FlexPak 3000 and WebPak 3000 Digital

Blower Motor Starter Kit
for FlexPak 3000 and WebPak 3000 Digital DC Drives
Model Number 902FKxxxx
Instruction Manual D2-3295-4
!
ATTENTION: Only qualified personnel familiar with the construction and operation of this
equipment and the hazards involved should install, adjust, operate and/or service this equipment.
Read and understand this manual in its entirety before proceeding. Failure to observe this
precaution could result in severe bodily injury or loss of life.
ATTENTION: All interconnecting wiring must be sized and installed in conformance with
applicable local, national, and international codes. Failure to observe this precaution could result
in damage to, or destruction of, the equipment.
Product Description
This instruction manual describes the installation procedure for the blower motor starter kit used with
FlexPak™ 3000 and WebPak™ 3000 drives. The kit includes a fused three-phase motor starter with an
adjustable overload and interlock, wire harness, and in-line fuses.
Verifying That the Kit Rating Matches the Blower Motor
Before installation, make sure the kit you are installing is rated for the blower motor being connected. Also
make sure that the blower motor rated voltage matches the drive AC line voltage. See table 1 for ratings and kit
model numbers.
Table 1 – Blower Motor Starter Kit Model Numbers1
Blower Motor Starter Full Load Amp Range
0.4 - 0.63 Amps
0.63 - 1.0 Amps
1.0 - 1.4 Amps
1.4 - 1.8 Amps
1.7 - 2.4 Amps
2.2 - 3.1 Amps
2.8 - 4.0 Amps
3.5 - 5.0 Amps
4.5 - 6.5 Amps
6.0 - 8.5 Amps
7.5 - 11.0 Amps
1.
Model Number
902FK0101
902FK0201
902FK0301
902FK0401
902FK0501
902FK0601
902FK0701
902FK0801
902FK0901
902FK0111
902FK0121
Model numbers apply to 1.5 HP through 150 HP @ 230 VAC and 3 HP through 600 HP @ 460 VAC.
Reliance, FlexPak and WebPak are trademarks of Rockwell Automation.
© 2000 Rockwell International Corporation
Checking the Contents of the Kit
Verify the contents of the kit. Each kit consists of the following:
Description
Prewired starter assembly on a mounting bracket (blower motor starter, controls, fuse block,
installed fuses, short wire harness)
Long wire harness
Wire ties
Qty
1
1
2
Important: Drives rated at 400 HP to 600 HP @ 460 VAC may require 2 identical blower motor starter kits.
Important: Replacement in-line fuses are not supplied with the kit. See table 2 for the correct replacement
fuse rating and part number.
Table 2 – Blower Motor Starter Kit Replacement Fuses
For Kit Model Number:
902FK0101
902FK0201
902FK0301
902FK0401
902FK0501
902FK0601
902FK0701
902FK0801
902FK0901
902FK0111
902FK0121
Order Reliance Fuse Part Number:
64676-72C
64676-72E
64676-72H
64676-73J
64676-73L
64676-73N
64676-73R
64676-73U
64676-73W
64676-73Y
64676-73Z
Fuse Amperage
0.8
1.25
2.0
2.5
3.5
4.5
6.0
7.5
9.0
12.0
15.0
Installation
!
ATTENTION: Do not install modification kits with power applied to the drive. Disconnect and lock
out incoming power before attempting such installation. Failure to observe this precaution could
result in severe bodily injury or loss of life.
Important: The following procedures assume the drive is wired and operational. See your FlexPak 3000 or
WebPak 3000 hardware instruction manual for more information.
Mounting the Blower Motor Starter on the Drive Chassis
Make sure you are referring to the correct figures when installing your blower motor starter kit.
Drive
1.5 HP to 30 HP @ 230 VAC / 3 HP to 60 HP @ 460 VAC
40 HP to 75 HP @ 230 VAC / 75 HP to 150 HP @ 460 VAC
100 HP to 150 HP @ 230 VAC / 200 HP to 300 HP @ 460 VAC
400 HP to 600 HP @ 460 VAC
2
See figures
1 and 2
1 and 3
1 and 4
5 and 6
Blower Motor Starter Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives
Step 1. Turn off, lockout, and tag power to the drive.
Step 2. Remove the cover from the drive or drive’s line fuse panel, if necessary.
Step 3. Remove the jumper plug from drive connector P8. Connector P8 is accessed through the opening in
the fuse/terminal panel. For 460 VAC drives rated 400 HP to 600 HP: If you are using two blower
motor starter kits, remove the jumper plugs from connectors P8A and P8B. If you are using only one
blower motor starter kit, remove the jumper plug from connector P8A only.
Step 4. Loosen the two screws securing the left side of the line fuse/terminal panel to the drive. See figure 2,
3, 4, or 6.
Step 5. Slide the keyhole slots on the left side of the blower motor starter’s mounting bracket over the
loosened screws.
Step 6. Slide the mounting bracket down until the narrow ends of the keyhole slots are under the screw
heads.
Step 7. Tighten the screws (torque to 55 in-lb/6.21 Nm) to secure the starter to the drive. See figure 2, 3, 4, or
6.
Wiring the Blower Motor Starter
Step 1. Plug connector P8 into the drive’s mating plug (P8). See figure 2, 3, 4, or 6. For drives with two
starters, plug connectors P8A and P8B into their respective mating plugs.
Step 2. For 230 VAC drives rated through 30 HP and 460 VAC drives rated through 60 HP:
Connect the spade receptacles attached to the blower motor starter’s 181, 182, and 183 fuses to the
spade tabs on A-C input fuses 181, 182, and 183, respectively. See figure 2.
Step 3. For 230 VAC drives rated 40 HP through 150 HP and 460 VAC drives rated 75 HP through 300
HP:
a. Disconnect wires 181, 182, and 183 from the blower motor starter’s fuse block and discard them.
These wires are connected to the back of the fuse block (the end closest to the drive chassis).
b.
Attach the 181, 182, and 183 connectors on the long wire harness to the 13FU, 14FU, and 15FU
spade terminals at the rear of the blower motor starter’s fuse block.
c.
Route the wire harness to the 181, 182, and 183 spade connectors on the drive’s line fuse panel.
These connectors are on the underside of the top end of the line fuse connectors.
d. Secure the wire harness to the drive chassis with the wire ties as illustrated in figure 3 or 4.
Step 4. For 460 VAC drives rated 400 HP through 600 HP, perform steps 4a - 4d for both starter kits:
a. Disconnect wires 181, 182, and 183 from the blower motor starter’s fuse block and discard them.
These wires are connected to the back of the fuse block (the end closest to the drive chassis).
b.
Attach the 181, 182, and 183 connectors on the long wire harness to the 13FU, 14FU, and 15FU
spade terminals at the rear of the blower motor starter’s fuse block.
c.
Route the wire harness to the 181, 182, and 183 spade connectors on the drive’s line fuse panel.
These connectors are directly above the rear set of line fuses.
d. Secure the wire harness to the drive chassis with the wire ties as illustrated in figure 6.
Blower Motor Starter Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives
3
Step 5. Turn the overload relay potentiometer to the blower motor’s rated full load current. Set the overload
relay to A (Auto). See figure 1 or figure 5.
Step 6. Connect the blower motor leads to the blower motor starter’s T1, T2, and T3 terminals.
Step 7. Turn on power to the drive.
Step 8. Check for proper blower motor rotation. If the blower motor is rotating in the wrong direction;
a. Turn off, lockout, and tag power to the drive.
b.
Swap the blower motor leads connected to the blower motor starter’s T1 and T2 terminals.
c.
Turn on power to the drive.
d. Repeat the check for proper blower motor rotation.
Step 9. Turn off and lockout power to the drive.
Step 10. Install the cover on the drive or drive's line fuse panel, if necessary.
Step 11. Turn on power to the drive.
Kit installation is now complete.
T3
T2
T1
Set to "A"
(AUTO)
95
98
97
96
P8 Connector
Set to rated blower
motor amps (FLA)
TEST TRIPPED
181/L1
2
4
6
14
182/L2
13FU
5
N
OL
6
T3
14FU
3
N
OL
4
T2
A12
183/L3
15FU
1
N
P8-3
N AUX
13
14
P8-4
P8-1
A1
95
OL
N
1
3
5
13
SUP
182
183
2
T1
13FU 14FU 15FU
181
OL
A2
96
P8-2
OL
97
98
Wiring Diagram
At rear of fuse holder
Figure 1 – Typical Blower Motor Starter (1.5 HP to 300 HP Drives)
4
Blower Motor Starter Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives
Loosen screw
81
82
83
Remove P8
ON
Loosen screw
OFF
181
182
183
181
182
183
Short harness
Figure 2 – Mounting the Starter on the Drive Line-Fuse Panel (1.5 HP to 30 HP @ 230 VAC / 3 HP to 60 HP @ 460 VAC)
Blower Motor Starter Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives
5
Loosen screw
A1
45
Remove P8
Loosen screw
GRD
Blower Motor
Starter kit
181
(11FU)
ARM. FUSE
(S6R) ONLY
182
183
Insert harness anchors
into panel
Wire
Ties
Route long harness under
fuse panel and connect to
terminals under fuses
181
182
183
LCD DISPLAY
Figure 3 – Mounting the Starter on the Drive Line-Fuse Panel (40 HP to 75 HP @ 230 VAC / 75 HP to 150 HP @ 460 VAC)
6
Blower Motor Starter Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives
Route long harness
under fuse panel and
connect to terminals
under fuses
181
182
183
1FU
2FU
3FU
281
282
283
Wire Ties
Loosen screw
Remove P8
jumper plug
Blower Motor
Starter kit
Loosen screw
183
182
181
4FU 5FU 6FU 7FU 8FU
Figure 4 – Mounting the Starter to the Drive Line-Fuse Panel (100 HP to 150 HP @ 230 VAC / 200 HP to 300 HP @ 460 VAC)
Blower Motor Starter Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives
7
Set to rated blower
motor amps (FLA)
Set to rated blower
motor amps (FLA)
T3 T2 T1
T3
T2
T1
Set to "A"
(AUTO)
97
98
95
TEST TRIPPED
6
4
5
3
98
TEST TRIPPED
14
2
4
6
14
A12
A12
1
13
3
5 13
182/L2
183/L3
1
97
13FU 14FU 15FU
13FU 14FU 15FU
181 182 183
181
13FU
5
N1
OL
181/L1
2
13FU
5
T1
14FU
3
N1
OL
1
N1
OL
182/L2
4
3
A1
A2
183/L3
6
OL1
95
96
1
P8B-1
P8A-2
N2
6
4
OL
2
A2
(13)
N1 AUX
OL2
95
96
P8B-2
N2
SUP
(14)
OL
N2
A1
OL1
97
98
P8A-4
OL
T1
N1
SUP
N2
T2
15FU
T3
P8A-1
183
T3
14FU
T2
15FU
182
At rear of fuse holder
At rear of fuse hoder
181/L1
2
96
P8B Connector
P8A Connector
96
(AUTO)
95
Set to "A"
P8A-3
P8B-4
(14)
(13)
OL2
97
98
P8B-3
N2 AUX
RRB1-8
RRB1-7
Wiring Diagram
Figure 5 – Typical Blower Motor Starter (400 HP to 600 HP @ 460 VAC Drives)
8
Blower Motor Starter Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives
Route long harnesses
on fuse panel and
connect to terminals
above fuses
181
182
183
281
282
283
Loosen screws.
Mount harnesses
under fasteners
and tighten screws.
Loosen screws.
Remove P8
jumper plugs.
183
181
182
183
181
182
Loosen screws.
4FU 5FU
288
289
Blower Motor
Starter kits
Figure 6 – Mounting the Starters on the Drive Line-Fuse Panel (400 HP to 600 HP @ 460 VAC)
Blower Motor Starter Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives
9
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: (1) 414 382-2000, Fax: (1) 414 382 4444
European Headquarters SA/NV, avenue Herrmann Debroux, 46, 1160 Brussels, Belgium, Tel: (32) 2 663 06 00, Fax: (32) 2 663 06 40
Asia Pacific Headquarters, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846
Reliance Electric Standard Drives Business, 24800 Tungsten Road, Cleveland, OH 44117, USA, Tel: (1) 888 374 8370, Fax: (216) 266 7095
Publication D2-3295-4 - August 2000
 2000 Rockwell International Corporation. All rights reserved. Printed in USA.
1999 Rockwell Automation Corporation. All Rights Reserved