Reliance flexpak plus Wiring diagram

"
/
I ., ...
.•·
:: :::.' ··
. .
JUNE 1981 INSTRUCTI.ONMANUAL0-3900~
INSTALLING, OPERATING, ~nd MAINTAINING
FLExPAKD
·, ' . .
D-C\Y*JD,RIVE
and MODIFICATION KITS .
RE 17-1-ri ~1;;1-...w._ _ . ) TRJC
~
I•
•
,....
•
-·
~/. , -
Ii
..r'

..,....
TABLE OF CONTENTS
Sec.I Par. Title Page Sec.I Par. Title Page
1
1.0
2
2.0
2.1
2.2
.2.3
2.4
2.4.1
2.4.2
2.4.3
4.il.4
2.4.5
3
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4
a.a
4. 1
4.2
4.3
4.3.1
4.3.2
4.3.3
4.3.4
Introduction ... . ............ . ... . ... . ... 1
General ....... .. ............ . ........... 1
General Cont roller Information . . . . . . .. . . 3
General ...... . ..... . ......... . . . . ..... .. 3
Operator 's Controls .. . . ..... . ............ 3
D-C Drive Moto rs ......... . ......... .. . .. 3
Modificat ion Kits . . .. . . . . .. . . . . . . . . . . . . . . . 4
Specifications . . . . .. . . . . .. . . . . . . . . . . . . . . . 5
Line Frequency .... ....... . ........... . .. 5
Voltage Tolerance ............ . . .. ... . .... 5
Line Impedance Requirements ............ 6
Relay Contr ol Circu it ... . ........... ..... . 6
A-C Line Fuse Requirem ents .... . ......... 6
Installation .... . .. . ........ . .......... . . 9
General ..... . ...................... . .... 9
Layout Guidel ines .. . . . ... .. . . . . ......... 9
Mounting .......... .. .................. 11
Power Wiring . .. . ......... .. ......... .. . 11
Isolation Transform ers .......... . ....... 13
50-Hz Operation . .... .. ............. ... . 13
HP/ Current Jumper ...... . .. . ........... 14
Regulat ion Mode Jumper . ........... . ... 14
Start-Up and Adjustment .. . ... .. ....... 15
General ..... .. . . . . . . . . .......... . .. .... 15
Power Off Inspect ion . .... . .... . .. . ..... . 15
Motor Ground Check .... . .. . . .. . . . . ..... 15
Power On Adjustments .. . .... .. ... ... ... 15
Regulator Module Pots·....... .. ...... . .. 16
Maximum Speed (Voltage) . . . ....... .. .. . 16
Min imum Speed (Voltage) ......... ...... 16
Acceleration and Deceleration Rates ..... 16
4.3.5
4.3.6
5
5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.7.1
5.7.2
5.8
5.9
5.10
5.11
5.12
5.13
5.14
6
6.0
6.1
6.2
6.3
6.4
6.5
6.6
7
7.0
Current Limit ...................... . .. . . 17
IR Compensation .. . . . ..... . ......... .. . 17
Modification Kits ...... . . . .... . ..... . ... 19
General .. ·... ... .. ...... . . . ..... . ....... 19
Auxiliary Panel . ................. . .... . . 19
Dynamic Braking ...... ... ..... . ..... . .. 20
Reversing Contactor ... . ................ 21
Automa tic Reversing ...... .. ... .. ... . ... 21
Tachometer Feedback ... .. ......... ... .. 22
Voltage/ Tachometer Follower ............ 24
Instr ument Interface/ Preset Speed ... ... . 24
Installing Instrum ent Interface ........... 25
Installin g Preset Speed ... . . . ....... . .... 25
Field Supply .. ... ..................... . . 26
Torque Taper ...... .... ...... . . .. ....... 26
Auxiliary M Contacts .... .. ........ ... .. . 27
Test Meter Adapt er ........... . ........ . 28
Dancer Follower ....... . ................ 28
Master Isolated Reference Receiver ..... . 29
Contactor Adapter ...... . ... ....... .. ... 31
Troubleshooting ....... .. ........ . ...... 33
General . . ..... . ........................ 33
Wiring Errors . ... .... ................... 33
A-C Line Problems ..... .. ............... 33
Motor Problems . . . .... .. ........ . ...... 33
Mechanical . .... . .... ..... . ...... . ..... 33
Contr oller Malfunc tions . .. . ..... . ....... 33
Schematics, Diagrams ..... . . .. ..... . . . . 33
Replacement Parts .... . ..... .. ........ . 47
General . . ... .. . . ...... . .... ... ... ... ... 47
.~
~Copyrigh t Reliance Electric Company June 1981
ii
..
..

•
•
Figure
1.1
2.1
2.2
3.1
3.2
3.3
3.4
3.5
3.6
4.1
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
Table
2.A
2.B
2.C
2.0
3.A
3.B
3.C
5.A
LIST OF FIGURES
Title Page
FlexPak Plus Complete Controller
and Typical Motor. . . . . . . . . . . . . . . . . . . . . . 1
Basic Controller and Auxiliary Panel ...... . 3
FlexPak Plus Complete Controller
with Modification Kits ... .. . ... .. .. ... .. 4
Enclosure Mounting Minimum
Distances .................. . ... . . ... .. 9
Mounting and Wiring Orientations . . ..... 10
Mounting Dimens ions ................... 11
System Connection Diagram . ..... . ...... 12
50-Hz Resistor Removal ................. 13
HP/ Current Scaling Pins ................ 14
Regulator Module Pots ..... . .. . .. . ...... 16
Pin Alignment .... ........ .. . ........... 19
Auxiliary Panel Mounting ................ 19
Dynamic Braking Kit .... . ...... .. ... . .. . 20
Dynamic Braking Kit Installed ............ 21
Dynamic Braking Connections ........... 21
Reversing Contactor Connections ........ 21
Automatic Reversing Kit ............. .... 21
Tachometer Feedback Kit .. ... .. .. .... ... 22
Jumpers J1, J2 ......... .. ... ... .. .... . . 23
Feedback Connection on
Regulator Module . .. .......... ........ 23
Voltage/ Tachometer Follower ............ 24
Jumper J1 ............................. 24
Figure
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
5.22
5.23
5.24
5.25
5.26
5.27
6.1
6.2
6.3
6.4
6.5
6.6
6.7
LIST OF TABLES
Title Page
FlexPak Plus Features Summary . . ........ 5
Specifications ... ....... . .. ........ . . . .. . 6
Fuse Requirements ...... .. . .. ........... 7
0-C Motor / Controller / Transformer
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Wire, Fuse Sizes ................. 10
Reliance Electric Isolation Transformers .. 13
Horsepower Calibration .... .... ......... 14
Modification Kit Quick Reference List ..... 20
iii
Table
5.B
5.C
5.0
6.A
6.8
6.C
7.A
Title Page
Instrument Interface Kit ................. 25
Jumper Jl , mA Pins . .... ............... 25
Field Supp ly Kit ......................... 26
Connecting Field Supply ............... . . 26
Torque Taper Kit ... .. ... . ... ............ 26
Torque Curves .... . .... .. ............... 26
Auxiliary M Contactor Kit . ... ... ....... . . 27
External Wiring, Auxiliary M .. . .......... 27
Test Meter Adapter .......... . . . . .. ...... 28
Dancer Follower Module ................ 28
Jumpers J1, J2 and Resistor (R6) .... ... . 29
Master Isolated Reference
Receiver Kit ............... . . . ........ 29
Jumpers J1 and J2 on Switc h
Receiver Module ........ .. ............ 30
Jumper J1 on Reference
Receiver Module ... .. .. . .............. 30
Connecting User-supplied
FM and RM Contactors .... . ... .. .. .. . . 31
Unidirectional Control Circuit ............ 34
Bidirectiona l Control Circuit ..... .. ....... 35
Relay Control Sequencing . .. ........ . ... 35
Regulation Module Screen ............... 36
Controller Schematic .................... 43
Modification Kits Schemati cs ......... 44, 45
Controller Technical Data .. . ... .. ........ 46
Title Page
Tachometer Voltage Scaling ..... .. ....... 22
Wire Specifications ..................... 23
Test Adapter Terminals, Readings ...... .. 28
Color Coding System ........... ... ...... 34
Troubleshooting Suggestions for
the Basic Controller . ..... ............. 37
Troubleshooting Suggestions for
the Complete Controlle r ............... 40
Replacemen t Modules ..... .. ....... .. ... 47

'
Ii

•
i
Section 1
INTRODUCTION
1.0 General -This manual familiarizes the user with the
FlexPak™ Plus D-C V*S ® drive controller. (Refer to Figure
1.1.) It describes assembly and installat ion procedures ,
gives a general overview of operation , and contains infor-
mation on troubleshooting , maintenance , the ordering of
spare parts , and specifications .
The manual should be read before performing installat ion
or start-up activities. Also , there are certain fundamental
warnings which must be kept in mind at all times . These
are:
DANGER
THE DRIVE SYSTEM SHOULD BE INSTALLED,
ADJUSTED AND SERVICED BY QUALIFIED ELEC-
TRICAL MAINTENANCE PERSONNEL FAMILIAR
WITH THE CONSTRUCTION AND OPERATION OF
ALL EQUIPMENT' IN THI:- SYSTEM :· PERSONAL
INJURY AND / OR EQUIPMENT DAMAGE MAY
OCCUR IF INDIVIDUALS ARE NOT FAMILIAR
WITH THE HAZARDS RESULTING FROM IM-
PROPER OPERATION.
Complete Controller
DANGER
CONTROLLER EQUIPMENT IS0AT LINE VOLTAGE
WHEN A-C POWER IS CONNECTED TO THE
POWER UNIT IN THE FLEXPAK PLUS CONTROL-
LER. THUS A-C POWER MUST BE REMOVED
FROM THE UNIT BEFORE IT IS SAFE TO TOUCH
INTERNAL PARTS OF THE CONTROLLER. PER-
SONALINJURY MAY RESULT UNLESS POWER IS
REMOVED.
WARNING
THE NATIONAL ELECTRICAL CODE REQUIRES
THAT AN N.E.C. APPROVED FUSED DISCON-
NECT SWITCH OR CIRCUIT BREAKER BE USED
AHEAD OF THE CONTROLLER AND POWER
TRANSFORMER (IF USED) ON THE INCOMING
A-C LINE . PERSONAL INJURY MAY RESULT IF
AN EASILY ACCESSIBLE MEANS OF LINE VOLT-
AGE DISCONNECTION IS NOT PROVIDED.
WARNING
DO NOT OPERATE THE FLEXPAK PLUS CON-
TROLLER ON POWER SUPPLIES WITH AVAIL-
ABLE SHORT-CIRCUIT CURRENTS IN EXCESS
OF 5000 AMPERES. DAMAGE TO EQUIPMENT
AND PERSONAL INJURY MAY OCCUR .
D-c Motor
Figure 1.1 - FlexPak Plus Complete Controller and Typical Motor

i
•
Section 2
GENERAL CONTROLLER INFORMATION
2.0 General -The FlexPak Plus 0-C V*S drive controller
may be applied to single-phase d-c drive applications with
ratings within the following ranges :
• From 1/
4 to :Y 4 hp with a 115 VAC, 50/ 60 Hz input
voltage
• From 1/
2 to 5 hp with a 230 VAC, 50/ 60 Hz input
voltage
Reliance Electric d-c motors, which may be used with the
controller, may be either permanent magnetic motors up to
11
/2 hp or wound field (excited) motors up to 5 hp.
The controller provides power-conversion and control cir-
cuits which convert the a-c line voltage into adjustable d-c
voltage in order to effectively control the drive motor .
The FlexPak Plus controller is provided , as standard , in a
chassis type configuration for panel mounting within a
larger electrical enclosure . The Remote Operator Controls
may then be placed on the larger enclosure 's face or some
distance away .
The FlexPak Plus is available in two basic configurations :
the Basic Controller and the Complete Controller (Basic
Controller with Auxiliary Panel). Both the Basic Controller
and the Auxil iary Panel (Figure 2.1) are Underwriters
I
l~~--rr:r::r:::t L::~~~::::;:;;=- 1J
Basic Controller
Laboratories (U.L.) recognized . Both units when used
together (Complete Controller) are U.L. Listed .
Optional Modification Kits conveniently expand the capa-
bility of the Basic Controller and Au xiliary Panel.
The controller's features are summarized in Table 2.A.
2.1 Operator 's Controls -For proper operation of the
FlexPak Plus controller, it is necessary to provide Remote
Operator 's Controls . Reliance Electric offers a wide variety
of operator control stations which may include the follow-
ing devices :
• SPEED control potentiometer (5K)
• TORQUE control potentiometer (10K)
• AUTO/ MANUAL selector switch (SPOT)
• RUN/ JOG selector switch (SPST)
• FORWARD/ REVERSE selector switch (DPDT)
• START/ STOP selector switch (pushbuttons or special)
2.2 D-C Drive Motors -Reliance Electric offers a com-
plete power-matched drive system for the controller and
the· application . Thus . the choice of Reliance Electric
motors assures optimum performance and unmatched
single-source responsib ility .
."
L._
••
,,. ..--
Auxiliary Panel
"\
C
C C
,)
Figure 2.1 - Basic Controller and Auxiliary Panel
3
I

2.3 Modification Kits -The basic capability of the con-
troller can be quickly and conveniently extended with the
use of a variety of optional Modification Kits. (Refer to
Figure 2.2.) The Basic Controller modifications are:
• Tachometer Feedback
• Voltage/ Tachometer Follower
• Instrument Interface / Preset Speed
• Field Supply (Standard on 2. 3 and 5 hp controllers)
• Torque Taper
• Test Meter Adapter
Remote Operator
Adapter Module
and/ or
Master Reference Switch
Receiver Module
Tachometer Feedback
• Dancer Follower
• Master Isolated Reference Receiver
• Contactor Adapter
The Auxiliary Panel modifications are:
• Dynamic Braking
• Reversing Contactor
• Automatic Reversing
• Auxiliary M Contact
Complete descriptions of each Kit are given in Section 5.
Refer also to Table 5.A.
Reversing Contactor
Auxiliary M Contact
Voltage / Tachometer
Follower
or
Instrument Interface /
Preset Speed
or
Dancer Follower
or
Master Reference
Receiver
Test Meter Adapter
Figure 2.2 - FlexPak Plus Complete Controller with Modification Kits
4

i
i
'--.
2.4 Specifications -The more important specifications
for the FlexPak Plus controller are listed in Table 2.8. Refer
also to Table 2.D where other ratings are indicated in rela-
tion to d-c motors of specific horsepower.
However , for optimum 50-Hz operation. it is recommended
that two resistors be removed from the Regulator Module .
(Complete details are given at Paragraph 3.5.) If the resis -
tors are not removed , there is a slight loss of performance .
2.4.1 Line Frequency -The FlexPak Plus controller is
able to operate without modification from a single-phase
power source having a frequency range from 48 to 62 Hz.
2.4.2 Voltage Tolerance - The FlexPak Plus controller
delivers output current and voltage, as listed in Table 2.D. It
will also operate within these regulation specifications
even with incoming line voltag e at ±10% of nominal.
Table 2.A
FLEXPAK PLUS FEATURES SUMMARY
CATEGORY FEATURE
Controller Functions • START/ STOP
• RUN/ JOG
• FOR\NARD/ REVERSE
• Speed selection (0 to 100%)
• Torque selection (10 to 150%)
• Unidirection operat ion with coast-to -rest or. stop command standard . (Dynamic braking
and reversing available as options .)
• 20:1 controlled-speed range by means of armat ure voltage control.
• \Nith Auxiliary Panel specified , armature loop contactor removes power to drive motor .
• Isolated armature voltage and current feedback decouples armatu re power from opera-
tor devices and provides additional noise immunity .
• \Nith tachometers specified in this manual, 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 a-c line variations of± 10% of nominal rated input voltage .
Speed Regulation • Jumper reconnectable regulator circuits which allow armature (A), counte r EMF (C) or
tachometer feedback (T) regulation .
• \Nith voltage regulation, 3 to 5% speed regulation with 95% load change .
• \Nith counter EMF (CEMF) regulation , 2 to 3% speed regulation with a 95% load change .
• \Nith tachometer specified, 1% speed regulation with a 95% load change . (Tachometer s
are: RE-045 a-c tachometer; also SPYor RE-020 d-c tachometer .)
• \Nith 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 (50 to 100 % of base motor speed).
• Adjustable minimum speed (up to 50% of base motor speed).
• Adjustable current limit (10 to 150 % of full-load current).
• Adjustable, separately set linear acceleration and deceleration rates (0.5 to 30 sec.).
Safety • Control circuitry guards against automatic restarting of equipme nt after resumption of
interrupted a-c incoming power.
• Regulator and Operator's Controls isolated from a-c line for personnel protection .
• Armature voltage and current feedback isolated to assure separat ion of power and regula-
tor circuits.
Hardware -:- Conveniently located screw terminal connections for incoming a-c and outgoing d-c power
allow easy cable entry and connection.
• \Nith · Auxiliary Panel specified, a-c line fuses protect Power Cube from armature short
circuit and power relays provide positive power disconnect .
• Protection from momentary surges on a-c line and from d-c load transients.
5

2.4 .3 Line Impedance Requirements - The FlexPak Plus
controller must be connected to a short-circuit protec tion
syste m design ed to operat e on plant power supplies with
maximum permissible available symmetrical RMS fault
curren ts of 5000 amperes. (Refer to Table 2.D.)
The Basic Contro lle r does not have an M contactor. An M
contactor is requ ired to provide positive power disconnect.
WARNING
THE USER MUST INSTALL AN M CONTACTOR
THAT HAS A 24 voe COIL WITH A MAXIMUM
CURRENT DRAW OF 150 MILLIAMPS . FOR TIM-
ING, A 200 MICROFARAD CAPACITOR MUST BE
INSTALLED WITH CORRECT POLARITY ACROSS
THE RELAY COIL. THE CONTACTOR ADAPTER
KIT MUST BE INSTALLED WITH THE USER'S M
CONTACTOR . (REFER TO TABLE 5 .A AND
PARAGRAPH 5. 14 .) PERSONAL INJURY MAY
OCCUR IF THIS IS NOT INSTALLED.
WARNING
DO NOT OPERATE THE FLEXPAK PLUS CON-
TROLLER ON POWER SUPPLIES WITH AVAIL-
ABLE SHORT -CIRCUIT CURRENTS IN EXCESS
OF 5000 AMPERES . DAMAGE TO EQUIPMENT
AND PERSONAL INJURY MAY OCCUR.
2.4 .4 Relay Control Circuit -The regulator board is set
up for use w ith main cont actors having a coil resistance
greater tha n or equal to 100 ohms . The control logic
sequences the contacto r and the control relay on the regu-
lator so that current flow thru the main contactor is never
broken in normal operation by the contacts. Refer to Fig-
ures 6.1, 6.2 and 6.3.
2.4.5 A-C Line Fuse Requirements - A-c line protection
is provided when the Auxiliary Panel is specified. The Basic
FlexPak Controller , however , does not include a-c line pro-
tection . Fused a-c line protection mu st be used . Refer to
Table 2.C for proper fuse sizing.
Table 2.B
SPECIFICATIONS
A-C Line Input Voltage Operator Torque Adjustment Displacement Power Factor
115/230 VAC (nominal) Infinitely adjustable at 68% (typical) CD
single-phase only optional control pot Transient Protect ion
Line Voltage Variation (10 to 150% of rated load) MOV and Output RC Circuit
±10% of nominal IR Drop Compensation Controller Service Factor
A-C Line Frequency 0 to 12% of rated load 1.0
Single Phase, 50/ 60 Hz (user adjustable) Duty
(Jumper selectable) CD Controllable Speed Range Continuous
Line F:·equency Range 20:1 Ambient Temperature
48-62 Hz Current Limit (storage and operational)
Output Voltages Factory shipped : 150% of full load 00 to 55°C (32° to 131° F)
(armature and field) User adjustable: 10 to 150% of full load
See Table 2.D Regulation (with 95% load change) Relative Humidity
(storage and operational)
Controller -Drive HP Range 3 to 5% with voltage feedback 5 to 95% (without conde nsation)
Yd'4hp (with 115 VAC input) 2 to 3% with CEMF feedback
1/
2-5 hp (with 230 VAC input) 1.0% with specified tachometer feedback Operational Altitude
0.5% wit h specified tachometer feedback To 3300 ft (100 0 m) above
Direction Control sea level w ithout derating
Standard : Unidirection Minimum Load for Stable Operation
Optionally: Forward / Reverse 5% Controller Weight (approx.)
Basic= 9.0 lb (4.08 kg)
Maximum Speed Adjustment Acceleration / Deceleration Rates Complete= 11.0 lb (4.99 kg)
50 to 100% of base motor speed 0.5 to 30 sec. linear time
(user adjustable) (user-adjusted separately) Controller Dimensions (LWD)
Basic= 7.22 x 8.37 x 5.95 inches
Minimum Speed Adjustment Armature Circuit Overload Capacity (184 x 213 x 152mm )
up to 50% of base motor speed 150% of armature current rating Complete= 11.97 x 8.37 x 5.95 inches
(user adjustable) for 1 minute (max.) (305 x 213 x 152 mm )
Operator Speed Adjustment Efficiency (rated speed/ rated load) © SeeParagraph3.5.
Infini tely adjustable with Controller only: 97% CDTypical percent shown. Exactfigure
optional control pot Complete drive including dependent on motor base speedand
(up to 100% of base speed) motor: 85% (typical) CD frame size.
6

Table 2.C
FUSE REQUIREMENTS
Dual Element Class
HP A-C Line K5, 250 VAC Fuse
Volts Quantity Amp
FOR BASIC MOTOR PROTECTION
1/4-7'4 115 1(D 15
1/2-11/2 230 2 15
2-3 230 2 25
5 230 2 45
le FOR SUPERIOR MOTOR PROTECTION
1/4 115 1(D 6.25
1/3 115 1(D 10
1/2 115 1(D 10
7'4 115 1(D 15
1/2 230 2 6.25
:y4 230 2 10
1 230 2 10
11/2 230 2 15
2 230 2 20
3 230 2 25
5 230 2 45
(!)Install fuse in input line Ll (hot line ).
Table 2.D
D-C MOTOR / CONTROLLER / TRANSFORMER SPECIFICATIONS
CONTROLLER OPTIONAL TRANSFORMER
MODEL NUMBERS D-C POWER
A-C D-C ARM. D-C AMP. SUPPLY MAXIMUM FULL
AMPS ARM. AMPS FIELD MAX. CAPACITY kVA LOAD
BASIC COMPLETE HP VAC (RMS) (VOLTS) (avg.) VOLTS (optional) CD Per Phase kVA
1/4 115 3.5 90 2.5 100 3.0 5000 40 0.75
14C50 14C50/ 14C80 % 115 5.2 90 3.7 100 3.0 5000 40 0.75
1/2 115 7.0 90 5.0 100 3.0 5000 40 1.0
% 115 10.5 90 7.5 100 3.0 5000 40 1.5
112 230 3.5 180 2.5 200 3.0 5000 40 1.0
14C51 14C51/ 14C81 % 230 5.2 180 3.7 200 3.0 5000 40 1.5
1 230 7.0 180 5.0 200 3.0 5000 40 2.0
11/2 230 10.5 180 7.5 200 3.0 5000 40 3.0
14C52 14C52/ 14C82 2 230 14.0 180 10.0 200 3.0(D 5000 40 5.0
3 230 21.0 180 15.0 200 3.0(D 5000 40 5.0
14C53 14C53/ 14C83 5 230 35.0 180 25.0 200 3.0(D 5000 40 10.0
CDStandard
CDMaximum permissible availabl e symm etri cal RMS fault current with NEC or CEC external approved disconnect .
7