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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14C315 3
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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

10
bottom and side. This unobstructed area allows for
proper air circulation through the heat sink. Do not
place the controller directly in a corner. Leave at least 8
inches (200 mm) from the top or 6 inches (150 mm) from
the bottom of the enclosure. ( efer to Figure 3.1.)
Guideline 3 - Since the controller's Cover is hinged,
additional clearance must be provided on the fourth
side of the Chassis. ( efer to Figure 3.1.)
Guideline 4 -If mounting the controller within a larger
enclosure, do not place it directly in a corner. Leave at
least 8 inches (200 mm) from the top or 6 inches
(150mm) from the bottom of the enclosure. Also leave
8 inches (200 mm) between the enclosure side wall and
the unhinged side of the controller. ( efer to Figure 3.2.)
Heat builds up at the cabinet's top and may exceed the
permissible inside ambient temperature upper limit. At
the cabinet's bottom, the unit must be high enough to
allow air to flow upwards.
Figure 3.2 - Enclosure Mounting Minimum Distances
Guideline 5 - egardless of the above placement
guidelines, the user is responsible for providing ambiĆ
ent temperatures that meet the controller's specificaĆ
tions. For units mounted on an open panel or wall this
range is 0°Ć40°C (32°Ć104°F).
Guideline 6 -Conduit knockouts ar provided on top
and bottom of this cabinet. Plan controller placement on
the wall or panel to allow for conduit runs. Proper care
should be taken when installing conduit to maintain
NEMA 12 type rating.
Guideline 7 -If the controller is placed in a larger encloĆ
sure, do not place it so that the Cover, if used, cannot
swing open at least 90°minimum. Allowing for a full
110°swing aids subsequent installation and trouble
shooting. (Note that the Cover will swing open to the
left).
Guideline 8 -Do not route the tachometer feedback
signal cable, if used, with aĆc or dĆc control or power wirĆ
ing. Also use the specified wire for this function.
Guideline 9 -The controller requires a threeĆphase
power supply that provides either 230 VAC or 460 VAC
at 50/60 Hz. If correct voltage is not available, it will be
necessary to install a transformer between the power
supply and the controller.
WA NING
DO NOT OPE ATE THE MINPAK PLUS CONĆ
T OLLE ON POWE SUPPLIES WITH AVAILĆ
ABLE SHO TĆCI CUIT CU ENTS IN EXCESS
OF 5000 AMPE ES. DAMAGE TO EQUIPMENT
AND PE SONAL INJU Y MAY OCCU .
Guideline 10 - Although autoĆtransformers may step
up and step down aĆc power supply voltage, they do
not isolate the driven system from the aĆc line. Users
should consider using an isolation transformer if the apĆ
plication conditions warrant it.
If an isolation or autoĆtransformer is used ahead of the
controller, the disconnect switch should be placed on
the aĆc power line between the power source and the
transformer primary. Again, use a f used disconnect
switch. (Do not use a circuit breaker type switch beĆ
cause of the high inrush of transformer equipment.).
An isolation transformer is not necessary unless the apĆ
plication conditions require one. However, its use proĆ
vides distinct advantages. With an isolation transformĆ
er:
Personal injury is guarded against should accidental
contact be made with an electrical conductor from
the drive.
AĆc power line disturbances, or transients, are
minimized by an isolation transformer, thereby reĆ
ducing or eliminating damage to other solidĆstate
equipment powerĆconversion components in the
controller and other userĆequipment on the same ac
line.
The transformer provides electrical isolation beĆ
tween the aĆc power lines and the drive motor.
Damaging currents may be eliminated in instances
where a dĆc output accidentally becomes grounded
in a unit where the aĆc electrical system is grounded.
For detailed information, refer to Paragraph 3.4.
Guideline 11 - The National Electrical Code requires
that a threeĆpole, fused disconnect switch be installed
on the incoming aĆc line ahead of the controller to proĆ
vide branch circuit protection. The fuse should be Class
K5.
It is recommended that the disconnect switch be placed
within easy reach of operating and maintenance perĆ
sonnel. Do not place it inside a surrounding enclosure
since cabinet doors may be locked. (Consult your local
codes.)
Note that the standard POWE ON/OFF circuit breaker
is a threeĆpole circuit breaker designed only to provide

11
overĆcurrent protection for the internal Power Cubes
containing the power semiconductors. It should not be
considered a proper main disconnect device.
Guideline 12 - It is necessary to connect the GND
(Green/ground) wire of the threeĆconductor incoming
aĆc line to the terminal provided on the Chassis. ing
type connectors are recommended. The user must be
sure that the ground wire is connected to the plant
ground at the source.
The motor frame should also be grounded. In many
cases it is adequate to use a screw in the conduit box
near the motor.
Guideline 13 - A thermostat is used to guard against
motor overload protection, It is essential to properly
connect the motor thermostat to connections 34 and
132.
CAUTION: External overload devices must be conĆ
nected between terminals 32, 33, 34 and 132. The
drive will not start without them.
efer to Figure 3.4 where a typical Operator's Station
schematic is shown.
Guideline 14 - When planning signal or control wire
runs, follow these practices:
Conduits should be steel.
If these conduits cross 460 VAC conductors, make
sure the cross is at 90°.
Do not route signal wires through junctions or
terminal boxes that contain nonĆsignal aĆc or dĆc
(115/230/460V) wires.
Guideline 15 - Operational altitude above sea level
may not exceed 3300 ft (1000 m). Derate horsepower
3% for each 1000 ft (300 m) above this altitude.
Figure 3.3 - Three Phase MinPak Plus Mounting
Dimensions
3.2 Mounting - This Paragraph outlines the proceĆ
dures to be followed to mount the MinPak Plus controlĆ
ler.
Determine the exact placement of the Chassis on the
Panel. ( efer to Figure 3.3 for mounting dimensions.)
Scribe the panel. Drill three holes large enough to acĆ
cept #10 mounting bolts. Scrape the paint around the
holes to allow washers and bolts to make a ground conĆ
tact.
Choose four 3/8 inch lug bolts. The length depends
upon the depth of the entire mounting surface. Mount
controller using lug bolts.
3.3 Power iring - This Paragraph briefly outlines
the procedures to be followed when wiring aĆc power supĆ
ply lines to the controller and dĆc control circuits to the
drive. A basic connection diagram is given at Figure 3.4.
DANGER
BEFORE IRING, MAKE SURE THAT AĆC LINE
DISCONNECT S ITCH IS LOCKED OPEN.
EVEN IF PO ER HAS NOT BEEN APPLIED TO
THE INCOMING LINE, THIS PRACTICE ASĆ
SURES PERSONAL SAFETY. IF NO LOCKOUT
DEVICE EXISTS, REMOVE THE FUSES ITH AN
INSULATED TOOL AND PLACE A ARNING
TAG ON THE BOX. IF THIS ARNING IS NOT
OBSERVED PERSONAL INJURY MAY RESULT.
All interconnecting wire should primarily be sized and
installed in conformance with N.E.C., C.E.C. or local
codes. efer to the controller and motor nameplates for
electrical data. Note that long cable runs may require
that a larger gauge be used to avoid excessive voltage
drop. Use of stranded wire, up to 19 strand, is also recĆ
ommended. Wire according to Figure 3.4.
After wiring, examine all terminals to determine that conĆ
nections are correctly made at both ends. Confirm wire
identification. Examine the firmness of the connections.
ARNING
DO NOT ALLO CONDUCTORS TO GROUND
ON THE CHASSIS. CHECK INTEGRITY OF ALL
IRE INSULATION BEFORE DRA ING. REĆ
MOVE ONLY ENOUGH INSULATION TO MAKE A
FIRM TERMINAL CONNECTION. PERSONAL
INJURY COULD RESULT IF A BARE IRE
TOUCHES THE CHASSIS.
3.4 Isolation Transformers - Although an autoĆ
transformer may be required because of aĆc line voltage
levels, it is unable to provide a number of benefits stanĆ
dard with an isolation transformer.


     

13
The general requirements for an isolation transformer
are:
Three phase
3 to 8% impedance
Nonregulated
Sinusoidal output
50/60 Hz, as required
150% overload for 1 minute (max.)
Refer also to Table 2.D for specific information on transĆ
former sizing requirements. In the Transformer" colĆ
umn at the right, maximum kVA and rated kVA figures
are listed in relation to specific dĆc motor hp/ VAC ratĆ
ings.
Reliance Electric offers a number of isolation transformĆ
ers suitable for use with the Min ak lus controller.
3.5 HP/Current Jumper - It is necessary to inĆ
spect the Current Scaling/Horsepower Jumper on the
Regulator Module to be sure that it is connected correctĆ
ly for a specific drive motor.
Step 1 - On the drive motor, locate the nameplate. Note
the fullĆload current.
Step 2 - Or, if current is not shown on the nameplate,
refer to Table 3.A. Relate the columns in the table with
known motor data. Read across to the right column
marked Motor Current." This figure indicates the propĆ
er jumper connection to make on the Module where a
corresponding number is etched.
able 3.A - Horsepower Calibration
230 VAC
HP
Motor Current
Pin Connection
460 VAC
HP
Motor Current
Pin Connection
3
5
7.5
10
13
19
27
36
3
5
7.5
10
15
5.7
10
13
19
27
➀15 54 20 36
20 72 ➀25
30
40
45
54
72
➀High H units cannot be directly scaled to the lower H units, above
line, due to current transformers ratios used in feedback loop
Step 3 - On the Regulator Module, locate the scaling
pins. (Refer to Figure 3.6.) Near them, locate the black
pigĆtail type jumper. Do not move it if it is connected to
the proper pin. If it must be reconnected, carefully lift
connector housing straight up and off the pin. Slide the
connector straight down over the proper pin.
3.6 Regulation Mode Jumper - The Min ak
lus controller of drive regulation. The first, which is facĆ
tory shipped, is armature voltage feedback (A).
Optionally, the user may also use tachometer feedback
(T) regulation. In order to use this modes, however, the
Regulation Mode Jumper, one end of which is permaĆ
nently fixed to the Regulator Module, must be moved to
one of two positions. Details of jumper placement are
noted in Section 7, DĆ3969.
DANGER
IF YOU ARE UNSURE WHICH REGULA ION
MODE A CON ROLLER SHOULD HAVE, I IS
IMPOR AN YOU FIND OU . IF HE JUMPER IS
NO PROPERLY CONNEC ED, PERSONAL INĆ
JURY MAY RESUL .
CHASSIS
GROUND
CONDUI KNOCKĆOU S
ERMINALS
A1-A2
MO OR
ARMA URE
CIRCUI
ERMINALS
132, 33, 34, 32
EX ERNAL IN ERLOCK
PRO EC IVE CIRCUI RY
(MO OR HERMOS A , E C.)
HREE PHASE
INCOMING
AĆC LINE
L1, L2, L3
ERMINALS
F1ĆF2
MO OR SHUN
FIELD
Figure 3.5 - hree Phase Minpak Plus Wiring
Locations

WARNING
14
DANGER
THE MACHINERY BUILDER IS RESPONSIBLE
FOR INSURING THAT DRIVEN MACHINERY, ALL
DRIVETRAIN MECHANISMS NOT SUPPLIED BY
RELIANCE ELECTRIC AND PROCESS LINE MAĆ
TERIAL ARE CAPABLE OF SAFE OPERATION AT
MAXIMUM SPEEDS. FAILURE TO DO SO CAN
RESULT IN DESTRUCTION OF MECHANISM OR
MATERIAL AND FLYING FRAGMENTS, ENĆ
DANGERING OPERATING PERSONNEL.
3.7 Ov rsp d - The DĆC motor is performance
rated to develop nameplate horsepower when operĆ
ated at rated base speed. The base speed of the DĆC
motor is defined as the speed at which the motor will opĆ
erate when excited with rated armature terminal voltĆ
age, rated shunt field. current and when coupled to a
driven load requiring rated torque. The actual speed at
which the motor will run under these conditions will fall
within a range of +7.5% from nameplate base speed.
Typical base speeds for industrial DC machines include
650, 850, 1150, 1750 and 2500 RP .
any DĆC machines are also performance rated to opĆ
erate above base speed in a constant horsepower" or
field weakened" mode. These DĆC machines may be
incorporated into adjustable speed drive systems
which allow controlled reduction in shunt field current
while maintaining rated armature terminal voltage.
When so operated most of these motors will deliver it's
rated horsepower at any speed between base speed
and the indicated maximum field weakened speed. A
DĆC machine with an 1150 RP base speed and the caĆ
pability to be operated to 1950 RP in a field weakened
mode will be nameplated 1150/1950 RP .
Although rarely encountered, a single component failure
may occur within the drive controller that can apply arĆ
mature voltages in excess of 100% rated armature voltĆ
age to the motor, causing the motor speed to significantĆ
ly exceed either base speed or rated field weakened
speed. Under these conditions, motor speed may be unĆ
responsive to the operators speed potentiometer and/or
other speed references. Should such a condition occur,
the drive must be quickly stopped using the appropriate
stop" pushbutton, and the fault condition located and
corrected before returning the drive to operation.
During such a condition, the DĆC motor, associated driĆ
vetrain equipment, driven machinery and the driven
process itself may be subjected to operating speeds
well in excess of normal rated speeds. As such, the folĆ
lowing considerations are necessary:
All Reliance Electric Drive packages manufactured after
February 1,1982 (where the motor and controller are
both manufactured by Reliance Electric and furnished
together on the same Reliance Sales Order) have a maxiĆ
mum safe speed ( .S.S.) in excess of the speed that
would occur under the single point failure discussed
above or are equipped with a speed limiting device
such as tachometer loss and overspeed protection,
armature voltage relays or a motor overspeed switch.
(Assuming the drive equipment is operated on three
phase power supplies listed below.)
Rat d
Armatur
Voltag
Rat d AĆC
Lin
Voltag
Maximum AĆC
Lin
Voltag
240 volts DĆC
500 volts DĆC
230 volts DĆC
460 volts DĆC
253 volts AĆC
506 volts AĆC
If the above AĆC and DĆC voltage conditions are not apĆ
plicable to the installation in question. then it becomes
the responsibility of the user to calculate attainable moĆ
tor speed under the single component failure condition
using the procedure outlined below and to verify that
this speed does not exceed the .S.S. of the motor.
CHART I
VAC = Nominal R S lineĆtoĆline voltage
SB= Base speed at full field and rated armature
voltage
Eg (NL) = Armature voltage no load
SS = ax safe operating speed
VAC
SAX = 1.49 x Eg (NL) x SB
The motor aximum Safe Speed, which varies as a
function of motor frame diameter, are listed below. ExĆ
amination of the motor nameplate may indicate a
.S.S. slightly different for that specific machine. In that
case, motor nameplate .S.S. takes precedence.
R lianc
Motor
Fram
Siz
Maximum
Op rating
Sp d,
RPM
R lianc
Motor
Fram
Siz
Maximum
Op rating
Sp d,
RPM
56
B160
B180ATZ
B210ATZ
B250ATZ
B280ATZ
B320ATZ
B360ATZ
5500
5000 5200
5000
4500
4500
4500
3600
3400
B400ATZ
B500ATZ
B580ATZ
B680ATZ
B840ATZ
B960ATZ
B1200
B1400
B1600
2760
2650
2475
2100
1720
1600
1600
1440
1200
CAUTION: otor frames not listed in the above tabĆ
ulation, or motors manufactured by others, may not
operate within their maximum safe speeds, when a
single point failure occurs. In these cases, it beĆ
comes the responsibility of the user to verify the moĆ
tor maximum safe operating speed and confirm
(using the procedure above) that attainable motor
speed under a single point fault condition falls beĆ
low the maximum safe operating speed.


USER
CONVENIENCE,
BLANK
TERMINALS
Figure 3.6 - Remote Operator's Buffer Terminal
Markings
HP/SCALING PINS
Figure 3.7 - Regulator Mo ule, HP/Current & Scaling Pins



17
SECTION 4
STARTĆUP AND ADJUSTMENT
4.0 General - This Section provi es startĆup an a Ć
justment proce ures to be followe after the assembly
an installation of the controller is complete. All initial
operation checks an final a justments to the controller
must be ma e in conformance to the proce ures, warnĆ
ings an recommen ations liste here.
DANGER
THE MINPAK PLUS CONTROLLER IS AT LINE
VOLTAGE HEN AĆC LINE PO ER IS CONĆ
NECTED TO THE PO ER UNIT INSIDE THE
CONTROLLER. BEFORE ORKING ON, OR
TOUCHING ANY INTERNAL PARTS OF, THE
CONTROLLER, REMOVE INCOMING AĆC LINE
PO ER AT THE MAIN DISCONNECT S ITCH.
PERSONAL INJURY MAY RESULT IF THIS
ARNING IS NOT FOLLO ED.
DANGER
DURING INITIAL STARTĆUP, THE CONTROLLER
AND ITS ASSOCIATED EQUIPMENT MUST BE
OPERATED AND/OR ADJUSTED ONLY BY
QUALIFIED ELECTRICAL MAINTENANCE PERĆ
SONNEL. THESE INDIVIDUALS SHOULD BE
FAMILIAR ITH THE DESIGN AND OPERATION
OF THIS EQUIPMENT AND ITH THE HAZARDS
INVOLVED. PERSONAL INJURY AND/OR DAMĆ
AGE TO THE CONTROLLER COULD RESULT
FROM UNFAMILIARITY.
4.1 Power Off Inspection - It is necessary to
make a superficial inspection of the MinPak Plus conĆ
troller an its associate units. The purpose of this
check is to look for possible physical amage or imĆ
proper connections.
Inspect all plugĆin Mo ification Kits. Test each for a firm
mounting con ition.
Each shoul be mechanically connecte to the RegulaĆ
tor Mo ule by means of a mounting post screw. Each
shoul be electrically connecte to the Mo ule by a seĆ
ries of parallel pins. If any of the pins are bent, improper
operation results. Examine the pins to make sure they
are perfectly parallel. Only one pin may fit through a hole
in the Kit.
Inspect all screw terminal connections on the Mo ificaĆ
tion Kits. Make sure the wires are firmly connecte . Also
make sure that there is enough insulation on the wires
to prevent a short between the con uctors.
Inspect the signal wiring from the Operator Control StaĆ
tion. If a Local Station is use on the Cover, there are 2
connectors that mate with the Regulator Mo ule at Pins
32 (RED) an 28 (GRN). (See Figure 4.2.)
If a Remote Station is use , a series of wires will connect
to in ivi ual terminals on a strip mounte on the ReĆ
mote Operator Interface Mo ule. (This Mo ule is
mounte on the Regulator Mo ule. Refer to Figure 4.1.)
Determine that all wires are firmly seate in the terminal
strip.
TEST
AREA
REFERENCE
AREA
REMOTE OPERATOR
ADAPTER MODULE
&
S ITCH
RECEIVER
MODULE
AREA
Figure 4.1 - Regulator Module Kit Locations

18
(%   # $ ' #""'#%&
Make ure all wire are connected.
 #'#% %#("  - It may be nece ary
to make a check of the drive motor to a ure that no
damaging ground - other than earth ground - exi t
within the motor.
 Although a megger may be u ed for thi
te t, if one i u ed, all conductor between the drive
motor and the MinPak Plu controller are to be di Ć
connected and moved a ide.  !%& 
)# ' " (& ! '# ' #"'%# %&
%('&
'$  - Attach one lead from the ohmmeter to the moĆ
tor frame to make a imple re i tance check.
'$  - Touch the te t probe to each of the two power,
two thermo tat, and two field lead to the motor.
If the reading to ground on any terminal i && '"
100,000 ohm , a ground condition exi t .
'$  - If a ground condition exi t , in pect the motor
thoroughly for internal hort .
'$  - When the grounding condition i corrected,
reconnect the conductor from the MinPak Plu controlĆ
ler.
 #*% " (&'!"'& - Once all the preĆ
liminary powerĆoff tatic adju tment have been perĆ
formed with acceptable re ult , the aĆc line power i to
(%   % & "  (& "'%" +#('

19
b appli d to th controll r, but th load is not conĆ
n ct d. It is important to follow th s st ps clos ly. ObĆ
s rv all cautions and warnings.
DANGER
WITH AĆC POWER APPLIED AND WITH THE
POWER ON/OFF WITCH IN THE ON PO IĆ
TION. HAZARDOU VOLTAGE EXI T IN THE
CONTROLLER. EXERCI E EXTREME CAUTION
WHEN PERFORMING THE E TE T . PERĆ
ONAL INJURY CAN RE ULT.
DANGER
IF CIRCUIT BREAKER HA TRIPPED OR FU E
HAVE CLEARED THE FIELD UPPLY, IT WIRĆ
ING MU T BE IN PECTED FOR DAMAGE.
REAPPLYING POWER TO THE DRIVE, THE
FIELD VOLTAGE MU T BE REĆCHECKED FOR
PROPER VOLTAGE AT MOTOR TERMINAL F1,
F2. IF THI VOLTAGE I BELOW 90% OF THE
FIELD VOLTAGE PECIFIED ON THE MOTOR
NAMEPLATE, THE DRIVE MU T NOT BE
TARTED UNTIL PROPER VOLTAGE I OBĆ
TAINED. FAILURE TO FOLLOW THI PROCEĆ
DURE COULD RE ULT IN OVER PEEDING THE
MOTOR AND/OR THE MACHINERY COUPLED
TO THE MOTOR HAFT AND PO IBLE FATAL
INJURY.
4.3.1 Regulator Module Pots - Th R gulator Modul
has six adjustabl pot ntiom t rs mount d on it. (R f r
to Figur 4.4.) Th y control th following functions:
Maximum sp d (full CCW: 50 Ć70% sp d)
Minimum sp d (full CCW: Driv Min. Sp d 5%)
Acc l ration rat (full CCW)
D c l ration rat (full CCW)
Curr nt limit (factoryĆs t at 150%)
IR comp (full CCW)
Th pot ntiom t rs ar factory pr s t for th saf st or
most cons rvativ op ration.
DANGER
U E ONLY ON HAND TO HOLD THE CREWĆ
DRIVER. KEEP YOUR OTHER HAND BEHIND
YOU. DO NOT U E YOUR OTHER HAND TO
BRACE YOUR ELF AGAIN T THE CONTROLĆ
LER, PANEL OR ENCLO URE. PER ONAL INĆ
JURY COULD RE ULT IF YOU ACCIDENTALLY
TOUCH A COMPONENT AT LINE VOLTAGE.
4.3.2 Maximum peed (Voltage) - Th Maximum
Sp d Pot ntiom t r on th R gulator Modul has
b n factory pr s t for 70% of a typical motor bas
sp d of about 1750 rpm. By m ans of adjustm nt, th
maximum sp d may b rais d to suit th application.
Th r sult is th high st sp d that can b s t by th
MAX PEED
MIN PEED
ACC RATE
DECL RATE
CURRENT LIMIT
IR COMP
Figure 4.4 - Regulator Module Pots