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