Reliance electric MinPak Plus User manual

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  

1
SECTION 1
INTRODUCTION
1.0 General - This ma ual familiarizes the user with
the three phase, Mi PakPlus DĆC VSdrive co trolĆ
ler. (Refer to Figure 1.1.) It describes assembly a d
PO ER
ON/OFF
CIRCUIT
BREAKER
LOCAL OPERATORS
CONTROL SUPER
RPM
DĆC MOTOR
Figure 1.1 Ć MinPak Plus Controller and Super
RPM Motor
i stallatio procedures, gives a ge eral overview of opĆ
eratio s, a d co tai s i formatio o troubleshooti g,
mai te a ce, the orderi g of spare parts, a d specifiĆ
catio s.
The ma ual should be read before performi g i stallaĆ
tio or startĆup activities. Also, there are certai fu daĆ
me tal war i gs which must be kept i mi d at all
times. These are:
DANGER
THE DRIVE SYSTEM SHOULD BE INSTALLED,
ADJUSTED AND SERVICED BY QUALIFIED
ELECTRICAL MAINTENANCE PERSONNEL FAĆ
MILIAR ITH THE CONSTRUCTION AND OPĆ
ERATION OF ALL EQUIPMENT IN THE SYSTEM.
PERSONAL INJURY AND/OR EQUIPMENT
DAMAGE MAY OCCUR IF INDIVIDUALS ARE
NOT FAMILIAR ITH THE HAZARDS RESULTĆ
ING FROM IMPROPER OPERATION.
DANGER
CONTROLLER EQUIPMENT IS AT LINE VOLTĆ
AGE HEN AĆC PO ER IS CONNECTED TO
THE PO ER UNIT IN THE MINPAK PLUS CONĆ
TROLLER. THUS AĆC PO ER MUST BE REĆ
MOVED FROM THE UNIT BEFORE IT IS SAFE
TO TOUCH INTERNAL PARTS OF THE CONĆ
TROLLER. PERSONAL INJURY MAY RESULT
UNLESS PO ER IS REMOVED.
ARNING
THE NATIONAL ELECTRICAL CODE REQUIRES
THAT AN N.E.C. APPROVED CLASS KĆ5 FUSED
DISCONNECT S ITCH BE USED AHEAD OF
THE CONTROLLER AND PO ER TRANSFORMĆ
ER (IF USED) ON THE INCOMING AĆC LINE.
PERSONAL INJURY MAY RESULT IF AN EASILY
ACCESSIBLE MEANS OF LINE VOLTAGE DISĆ
CONNECTION IS NOT PROVIDED.
ARNING
DO NOT OPERATE THE MINPAK PLUS CONĆ
TROLLER ON PO ER SUPPLIES ITH AVAILĆ
ABLE SHORTĆCIRCUIT CURRENTS IN EXCESS
OF 5000 AMPERES. DAMAGE TO EQUIPMENT
AND PERSONAL INJURY MAY OCCUR.



3
 
  
 ! - The Minpak Plus DĆC VS drive conĆ
troller may be applied to three phase dĆc drive applicaĆ
tions with ratings within the following ranges:
From 3 to 20 hp with a 230 VAC, 50/60 Hz input
voltage
From 3 to 40 hp with a 460 VAC, 50/60 Hz input
voltage
The controller provides powerĆconversion and control
circuits which convert the aĆc line voltage into adjustĆ
able dĆc voltage in order to effectively control the drive
motor.
The Minpak Plus controller is provided, as standard, in
a EMA 12 enclosure intended for wall or panel mountĆ
ing. A three pole power on/off circuit breaker is standard
with a door interlock.
The operators controls can either be local and door
mounted or a remote control station is also available.
The three phase MinPak Plus is Underwriters LaboratoĆ
ries (U.L.) listed and Canadian Standards Association,
(C.S.A.) certified.
Optional Modification Kits conveniently expand the caĆ
pability of the three phase Minpak Plus.
The controller's features are summarized in Table 2.A.
  !#!" #! ## - For proper opĆ
eration of the Minpak Plus controller, it is necessary to
use an Operator's Control Station. (Refer to Figure 2.1.)
The Operator Stations allow the tailoring of control funcĆ
tions for the application. These may include:
SPEED control potentiometer
TORQUE control potentiometer
AUTO/MA UAL selector switch
RU /JOG selector switch
FORWARD/REVERSE selector switch
START/STOP selector switch
There are two basic configurations that may be selected:
Station mounted on controller cover
Station mounted remotely as a separate unit
  ## - When the Station is mounted loĆ
cally on the Cover, users may select from 8 standard
Facplates (Model o. 14C201 thru 14C208) in order to
configure a controller to a specific drive application. ReĆ
fer to I/M D3977 which includes an inclusive listing of
Faceplate types, Model umbers and functions. AsĆ
suming the Cover is properly installed, the Faceplate
design maintains the EMA Type 12 rating.
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4
STANDARD
BLANK
OPERATOR
STATION
COVER
Fi ure 2.2 - MinPak Plus with
Standard Blank Operator Station Cover
Fi ure 2.3 - MinPak Plus with
Optional Status/Dia nostic Indicator Kit
2.1.2 Remote Stations - ome applications may reĆ
quire that the Operator's Control tation be remotely loĆ
cated. Briefly, the following three steps describe what
must be done:
Maintain the standard blank Remote Operator taĆ
tion Cover Faceplate (Refer to Figure 2.2)
Order a Remote Operator Adapter Kit, Model
14C220. (This unit provides a connection point for
the Remote tation.)
pecify a Reliance Remote Operator Control tation.
Connect it to the controller.
Reliance offers a variety of Remote Operator tations
that are compatible with the MinPak Plus controller. (ReĆ
fer to Table 2.B.)
2.2 DĆC Drive Motors - Reliance Electric offers a
complete powerĆmatched drive system for the controlĆ
ler and the application. Thus, the choice of Reliance
Electric motors assures optimum performance and unĆ
matched singleĆsource responsibility.
2.3 Modification Kits - The basic capability of the
controller can be quickly and conveniently extended
with the use of a variety of optional Modification Kits. The
Basic Controller modifications are:
Tachometer Feedback
Voltage/Tachometer Follower
Instrument Interface/Preset peed
Test Meter Adapter
tatus/Diagnostic Indicator
Dancer Follower
Master Isolated Reference Receiver
The Auxiliary Panel modifications are:
Blower Motor tarter
Reversing Contactor
Circuit Breaker
Auxiliary M Contact
Dynamic Braking (Kit is mounted on top of NEMA 12
enclosure)
Complete descriptions of each Kit are given in ection 7.
Refer also to Table 7.A.
2.4 Specifications - The more important specifiĆ
cations for the MinPak Plus controller are listed in Table
2.C. Refer also to Table 2.D where other ratings are indiĆ
cated in relation to dĆc motors of specific horsepower.
2.4.1 Line Frequency - The MinPak Plus controller is
to operate without modification from a threeĆphase
power source having a frequency range from 48 to 62
Hz.
2.4.2 Volta e Tolerance - The MinPak Plus controller
delivers output current and voltage, as listed in Table
2.D. It will also operate within these regulation specificaĆ
tions even with incoming line voltage at ±10% of nomiĆ
nal.
2.4.3 Line Impedance Requirements - The MinPak

5
T ble 2.A - MinP k Plus Fe tures Summ ry
C tegory Fe ture
Controller Functions START/STOP
RU /JOG
FORWARD/REVERSE
Speed selection (5 to 100%)
Torque selection (10 to 150%)
Unidirection operation with coastĆtoĆrest on stop command standard. (Dynamic
braking and reversing available as options.)
20:1 controlledĆspeed range by means of armature voltage control.
Armature loop contactor removes power to drive motor.
Isolated armature voltage and current feedback decouples armature power from
operator devices and provides additional noise immunity.
With tachometers specified, 0.5% or 1.0% speed regulation with a 95% load
change.
Operates and delivers rated output speed with specified regulation tolerance limits
even with aĆc Line variations of ±10% of nominal rated input voltage.
Speed Regulation Jumper reconnectable regulator circuits which allow armature (A) or tachometer
feedback (T) regulation.
With voltage regulation, 3 to 5% speed regulation with 95% load change.
With tachometer specified, 1% speed regulation with a 95% load change.
(Tachometers are: REĆ045 aĆc tachometer; also 5PY or REĆ020 dĆc tachometer.)
With tachometer specified, 0.5% speed regulation with 95% load change.
(Tachometer is BC42.)
User Adjustments Adjustable IR drop compensation (0 to 12% of rated load).
Adjustable maximum speed (70 to 100% of base motor speed).
Adjustable minimum speed (5 to 30% of base motor speed).
Adjustable current limit (10 to 150% of fullĆload current).
Adjustable, separately set linear acceleration and deceleration rates (0.5 to 30 sec.)
Safety Control circuitry guards against automatic restarting of equipment after resumption
of interrupted aĆc incoming power.
Regulator and Operator's Controls isolated from aĆc line for personnel protection.
Armature voltage and current feedback isolated to assure separation of power and
regulator circuits.
Hardware Conveniently located screw terminal connections for incoming aĆc and outgoing
dĆc power allow easy cable entry and connection.
Circuit Breaker causes positive opening of aĆc line circuit in order to help protect
Power Cube from armature short circuit.
Protection from momentary surges on aĆc line and from dĆc load transients.
Pluscontroller must be connected to a shortĆcircuit sysĆ
tem designed to operate on plant power supplies with
maximum permissible available symmetrical RMS fault
currents of 5000 amperes. (Refer to Table 2.D.)
WARNING
DO NOT OPERATE THE MINPAK PLUS CONĆ
TROLLER ON POWER SUPPLIES WITH AVAILĆ
ABLE SHORTĆCIRCUIT CURRENTS IN EXCESS
OF 5000 AMPERES. DAMAGE TO EQUIPMENT
AND PERSONAL INJURY MAY OCCUR. EXTERĆ
NAL DISCONNECT MEANS MUST HAVE ABILĆ
ITY TO INTERRUPT A 5000 AMP RMS CURRENT
FAULT.
2.5 Enclosure - EMA Type 12 is generally defined
as an indoor enclosure that is dusttight and oiltight. It is
designed to resist fibers, flyings, dust, dirt and light oil
splashings.

6
T ble 2.B - Remote Oper tor Control St tions
When Using
MinP k Plus
Specify
Oper tor
'
s
Functions Provided
Mi
n
P
kPl
us
Controller
With:
O
per
t
or
'
s
St tion
Model
St r/Stop
Rocker Switch
Speed Setting
Potentiometer
Run/Jog
Selector
Forw rd/Reverse
Selector
Basic features
(standard unidirecĆ
tional Station)
NEMA Type 4
Station with basic
features
ExplosionĆproof
Station with basic
Features
Basic features plus
armature reversing
(standard reversing
Station)
NEMA Type 4
Station for reversĆ
ing
ExplosionĆproof
Station for
reversing
9C45
9C18
9C17
9C46
9C19
9C16
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
Yes
Yes
Yes
T ble 2.C - Specific tions
AĆC Line input Volt ge
230/460 VAC (nominal, 60 HZ)
220/440 VAC (nominal, 50 Hz)
three phase only
Line Volt ge V ri tion
10% of nominal
AĆC Line Frequency
Three Phase, 50/60 Hz
Line Frequency R nge
48Ć62 Hz
Output Volt ges
( rm ture nd field)
See Table 2.D
ControllerĆDrive HP R nge
3Ć20 (with 230 VAC input)
3Ć40 (with 460 VAC input)
Direction Control
Standard: Unidirection
ptionally: Forward/Reverse
M ximum Speed Adjustment
70 to 100% of base motor speed
(user adjustable)
Minimum Speed Adjustment
up to 30% of base motor speed
(user adjustable)
Oper tor Speed Adjustment
Infinitely adjustable with
optional control pot
(up to 100% of base speed)
Oper tor Torque Adjustment
Infinitely adjustable at
optional control pot
(10 to 150% of rated load)
IR Drop Compens tion
0 to 12% of rated load
(user adjustable)
Controll ble Speed R nge
20:1
Current Limit
Factory shipped: 150% of full load
User adjustable: 10 to 150% of full load
Regul tor (with 95% lo d ch nge)
3 to 5% with voltage feedback
1.0% with specified tachometer feedback
0.5% with specified tachometer feedback
Minimum Lo d for St ble Oper tion
5%
Acceler tion/Deceler tion R tes
0.5 to 30 sec. linear time
(userĆadjusted separately)
Arm ture Circuit Overlo d C p city
150% of armature current rating
for 1 minute (max.)
Efficiency (r ted speed/r ted lo d)
Controller only: 97%
Complete drive including
motor 85% (typical) ➀
Displ cement Power F ctor
68% (typical) ➀
Circuit Bre ker R ting
3Ć10 HP @ 230 VAC - 50 AMP
320HP@460VAC-50AMP
15Ć20 HP @ 230 VAC - 100 AMP
25Ć40 HP @ 460 VAC - 100 AMP
Tr nsient Protection
M V and utput RC Circuit
Controller Service F ctor
1.0
Duty
Continuous
Ambient Temper ture
Storage: 0 55°C (32°to 131°F)
peration: 0Ć40°C (32°to 104°F)
Rel tive Humidity
(stor ge nd oper tion l)
5 to 95% (without condensation)
Oper tion l Altitude
To 3300 ft (1000 m) above
sea level without derating
Controller Weight ( pprox.)
80 lb (36.3 Kg)
Controller Dimensions (LWD)
26.75 x 14.00 x 13.00 Inch
(679.4 x 355.6 x 330.2 MM)
Front l Swing Projection
14.00 Inch (355.6 MM)
➀Typical percent shown. Exact figure dependent on motor base speed and frame size.
➁Assumes proper installation procedures.

7
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14C310 3
5
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230
230
230
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20
28
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240
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14C312 20 230 66 240 72 150 5 5000 145 30
14C315 3
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10
15
20
460
460
460
460
460
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30
460
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47
500
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43
51
300
300
5
5
5000
5000
175
205
35
41
30
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➀Because o nature o ield loss protective circuitry, this supply must only be used or motor ield excitation.
➁Maximum permissible available symmetrical RMS ault current with NEC or CEC external approved disconnect
and Class KĆ5 Fuses ahead o the controller.
➂Drives have been designed or maximum o three units per maximum trans ormer rating.
➃Minimum required KVA size is 15 KVA or proper operation.



9
SEC ION 3
INS ALLA ION
3.0 General - This Secti n utlines the pr cedures
that are t be f ll wed in rder t pr perly install a MinĆ
Pak Plus c ntr ller.
The dĆc m t r sh uld be installed and wired in acc rĆ
dance with installati n instructi ns supplied with each
drive.
There are certain general warnings and cauti ns that
sh uld be kept in mind before planning begins. They
sh uld be c nsidered a general checklist which, if f lĆ
l wed, will minimize installati n pr blems and decrease
assembly time. As a user aid, they are listed here.
DANGER
HIS UNI SHOULD BE INS ALLED, ADJUS ED
AND SERVICED BY QUALIFIED ELEC RICAL
MAIN ENANCE PERSONNEL FAMILIAR WI H
HE CONS RUC ION AND OPERA ION OF
HIS YPE OF EQUIPMEN . HEY SHOULD
ALSO BE FAMILIAR WI H HE PO EN IAL
HAZARDS INVOLVED. IF HIS WARNING IS NO
OBSERVED. PERSONAL INJURY OR EQUIPĆ
MEN DAMAGE MAY RESUL .
DANGER
BE ABSOLU ELY CER AIN HA A GROUND
WIRE FROM HE INCOMING AĆC POWER LINE
IS PROPERLY CONNEC ED O HE CHASSIS
GROUND ERMINAL PROVIDED. WI HOU
PROPER GROUNDING, PERSONAL INJURY
MAY OCCUR.
WARNING
HE CON ROLLER REQUIRES A HREEĆ
PHASE POWER SUPPLY HA PROVIDES EIĆ
HER 230 VAC OR 460 VAC A 60 HZ, OR 220
VAC OR 440 VAC A 50 HZ. IF CORREC
VOL AGE IS NO AVAILABLE, I WILL BE
NECESSARY O INS ALL A RANSFORMER
BE WEEN HE POWER SUPPLY AND HE
CON ROLLER. DO NO OPERA E HE MINĆ
PAK PLUS CON ROLLER ON POWER SUPĆ
PLIES WI H AVAILABLE SHOR ĆCIRCUI CURĆ
REN S IN EXCESS OF 5000 AMPERES. DAMĆ
AGE O EQUIPMEN AND PERSONAL INJURY
MAY OCCUR.
WARNING
HE USER IS RESPONSIBLE FOR CONFORMĆ
ING WI H HE NA IONAL ELEC RICAL CODE
WI H RESPEC O MO OR, CON ROLLER
AND OPERA OR DEVICE INS ALLA ION, WIRĆ
ING AND S AR ĆUP. HE USER IS ALSO REĆ
SPONSIBLE FOR UNDERS ANDING AND APĆ
PLYING ALL O HER APPLICABLE LOCAL
CODES WHICH GOVERN SUCH PRAC ICES AS
WIRING PRO EC ION, GROUNDING, DISCONĆ
NEC S AND OVERCURREN PRO EC ION.
3.1 Layout Guidelines - This Paragraph lists recĆ
mmended lay ut pr cedures c mm n t all MinPak
Plus c ntr llers.
Guideline 1 - The MinPak Plus c ntr ller is designed
as a wall m unt r panelĆm unted unit. It is t be hung
within 10f vertical with the rear f the Cabinet m untĆ
ing brackets firmly resting against the m unting surĆ
face. (Do not p siti n the Cabinet n a h riz ntal surĆ
face.)
Guideline 2 - It is necessary t leave at least a 6 inch
(150 mm) clearance between c ntr llers including t p,
Figure 3.1 - Wall or Open Panel Minimum
Mounting Distances