Rerplacement Guide
DCS800-EP replaces the Reliance FlexPak® 3000

Replacement Guide - ABB DCS800-EP replaces the Reliance FlexPak 3000

Product Differences and Remedies
Control/Interface & Features


  1. Coast/Stop and Customer Interlock Inputs
    The FlexPak 3000 supported a “coast/stop” and a “customer interlock” input, which resulted in the same reaction, to cutoff current to the motor causing it to coast to a stop.
    The DCS800 only supports one of these (“coast,” also called “Off2”).
    REMEDY: If two inputs are required, a RDIO-01 option board can be added to increase the number of digital inputs.
    “Customer interlock” would be configured as “external fault” (para. 30.31).
  2. Brush Wear Indicator
    The FlexPak 3000 supported a feature to monitor the wear of the DC motor brushes. The DCS800-EP does not support this feature.
    REMEDY: Discontinue use of the brush wear indicator
  3. Digital Inputs and Outputs
    FlexPak 3000 has 9 digital inputs; DCS800 only has 8 native to the drive.
    REMEDY: Use of the RDIO-01 digital I/O extension board adds 3 digital inputs (total 11). The RDIO-01 would be unnecessary if any of the following were done:

    • Combine “customer interlock” with “Coast/Stop” as above
    • Do not use “digital input 0” which could have been used as
      • “brush wear input”
      • “jog speed select” or
      • “outer control loop enable”
    • Do not use one of the other inputs DI-1 through DI-9
  4. Motor Thermal Switch
    The FlexPak 3000 accepted a signal from the motor thermal switch as standard.
    REMEDY: The DCS800 supports a motor thermal switch (KLIXON®) with an isolated digital input using the RDIO-01 expansion board. PT100 and PTC are also supported using analog input 2 or 3 (AI2, AI3) on the SDCS-I0B-3 or AI7 and AI8 of the RAIO-01 expansion board. See “Fault Tracing/Motor Protection„ in DCS800 Firmware Manual for more infomration.
  5. Field Power On/Off
    With the FlexPak 3000, the field power was energized whenever 3-phase AC power was connected to the drive. With the DCS800, the field turns on and off during the motor on-off sequence.
    REMEDY: If the field needs to be energized all the time, enable the “field heating” feature as described in “Field Excitation: Field Heating” section of the DCS800 Firmware Manual. NOTE: DCS800’s current controlled field exciter supplies constant field strength whether the motor is cold or hot, so field heating may not be required.
  6. AutoMax Interface
    The FlexPak 3000, when used with the AutoMax® Network Communication Board, could talk to the AutoMax Distributed Control System. DCS800-EP does not have this interface.
    REMEDY: Third party gateways are available to convert AutoMax to Ethernet IP. Consult with ABB for additional information.
  7. Motor On/Off with 2-Wire control
    The FlexPak 3000 only supported 3-wire (momentary) signals for motor on-off. In order to support maintained signals, the hardware needed to be wired in a specific configuration.
    The DCS800 can be configured to use 3-wire (momentary) or 2-wire (maintained) on-off inputs, but when 2-wire control is enabled, two inputs, ON and RUN, must be set and maintained to command motor rotation, not just one input.
    (1) Set up the DCS800 for 3-wire control and use the same hardware circuit as FlexPak 3000 to mimic 2-wire control.
    (2) Configure the drive for 2-wire control and wire in a second input. NOTE: ON and RUN can be set and cleared at the same time, or the auxiliary contact from the AC contactor can be used to energize the RUN signal. ON cannot be “tied high” because it must be cleared before a fault can be reset.


  1. Jog Button on Operator Interface Module (OIM)
    The DCS800-EP does not have a jog button on the drive’s control panel like the FlexPak 3000 OEM.
    REMEDY: The DCS800 drive can be commanded locally from the control panel using the panel’s start and stop buttons and speed selector.
  2. Direct Tension Control Winders
    Some versions of the FlexPak 3000 had the ability to control a winder, reading feedback from a tension-measuring device such as a dancer arm. The DCS800 does not have this functionality.
    An optional program is available, however, that provides winder functionality using indirect tension control (using an estimate of web tension). Contact ABB about the “Center Winder/Unwinder” application program for more information.
  3. Adaptive Programming
    FlexPak 3000 had no ability to add any additional programmability to the drive. The Adaptive Programming (AP) feature of the DCS800 gives the user the freedom to add programming blocks. Sixteen function blocks can be added utilizing a library of 31 blocks including logic blocks, math blocks and an event block that creates a user-defined alarm or fault. See section “Adaptive Programming” in the DCS800 Firmware Manual for more information.

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Specifications subject to change without notice.
DCS800-EP | Reliance FlexPak 3000 Replacement