Reliance flexpak plus Wiring diagram

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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
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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
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~Copyrigh t Reliance Electric Company June 1981
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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
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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

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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