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

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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
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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 .
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Auxiliary Panel
"\
C
C C
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Figure 2.1 - Basic Controller and Auxiliary Panel
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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
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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.
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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.
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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

Section 3
INSTALLATION
3.0 General -This Section outlines the procedures that
are to befollowed in order to properly install aFlexPak Plus
controller .
The d-c motor should be installed and wired in accordance
with installation instructions supplied with each drive.
There are certain general warnings and cautions that
should be kept in mind before planning begins. They
should be considered a general checklist which, if followed,
will minimize installation problems and decrease assembly
time . As a user aid, they are listed here .
DANGER
THIS UNIT SHOULD BE INSTALLED, ADJUSTED
AND SERVICED BY QUALIFIED ELECTRICAL
MAINTENANCE PERSONNEL FAMILIAR WITH
THE CONSTRUCTION AND OPERATION OF THIS
TYPE.OF EQUIPMENT . THEY SHOULD ALSO BE
{' FAMILIAR ' WITH THE POTENTIAL HAZARDS IN-
VOLVED. IF THIS WARNING IS NOT OBSERVED,
PERSONAL INJURY OR EQUIPMENT DAMAGE
MAY RESULT.
DANGER
BE ABSOLUTELY CERTAIN THAT A GROUND
WIRE FROM THE INCOMING A-C POWER LINE IS
PROPERLY CONNECTED TO THE CHASSIS
GROUND TERMINAL PROVIDED . WITHOUT
PROPER GROUNDING, PERSONAL INJURY MAY
OCCUR.
WARNING
THE CONTROLLER REQUIRES A SINGLE-PHASE
POWER SUPPLY THAT PROVIDES EITHER 115
VAC OR 230 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 CON-
TROLLER . DO NOT OPERATE THE FLEXPAK PLUS
CONTROLLER ON POWER SUPPLIES WITH
AVAILABLE SHORT -CIRCUIT CURRENTS IN
EXCESS OF 5000 AMPERES . DAMAGE TO
EQUIPMENT AND PERSONAL INJURY MAY
OCCUR .
WARNING
THE USER IS RESPONSIBLE FOR CONFORMING
WITH THE NATIONAL ELECTRICAL CODE WITH
RESPECT TO MOTOR. CONTROLLER AND OPER-
ATOR DEVICE INSTALLATION, WIRING AND
START-UP. THE USER IS ALSO RESPONSIBLE
FOR UNDERSTANDING AND APPLYING ALL
OTHER APPLICABLE LOCAL CODES WHICH
GOVERN SUCH PRACTICES AS WIRING PRO-
TECTION, GROUNDING, DISCONNECTS AND
OVERCURRENT PROTECTION.
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3.1 Layout Guidelines -This Paragraph lists recom-
mended layout procedures common to all FlexPak Plus
controllers .
Guideline 1 -The FlexPak Plus controller is designed as a
panel-mounted unit. It is to be hung within 10° of vertical
with the rear of the Chassis firmly resting against the
mounting surface. (Do not position the Chassis on a hori-
zontal surface .)
Guideline 2 -It is necessary to leave at least a 2-inch (50
mm) clearance between the top of one controller and the
bottom of another controller .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 . (Refer to Figure 3.1.) Heat
builds up at the cabinet's top and may exceed the permissi-
ble inside ambient temperature upper limit .At the cabinet 's
bottom , the unit mus t be high enough to allow air to flow
upwards .
E:]__;;n. (200mm(
EJ--:}(50mm}
6 in. (150 mm)
Figure 3 .1 -Enclosure Mounting Minimum Distances
Guideline 3 -Regardless of the above placement guide-
lines , the user is responsible for providing ambient temper-
atures that meet the controller's specifications of 0° to
55°C (32° to 131°F). Relative humid ity must be kept
between 5 and 95% without condensation .
Guideline 4 -Due to the U-shaped panel design of the
FlexPak Plus, the controller must be mounted in the vertical
position to allow for proper cooling .

The controller is also designed to allow for power wiring to
enter from the top and for control and signal wiring to be
routed in thru the openings in the sides of the controller or
from the bottom . (Refer to Figure 3.2.)
POWER
WIRING-----
CONTROL AND ~
SIGNAL WIRING FRONT VIEW
Figure 3 .2 -Mounting and Wiring Orientations
Guideline 5 -Do not route the tachometer feedback sig-
nal cable, if used, with a-c or d-c control or power wiring.
Also use the specified wire for thi~ function .
Guideline 6 -Although auto -transform ers may step up
and step down a-c power supply voltage, they do not
isolate the drive system from the a-c line . Users should
consider using an isolation transformer if the application
conditions warrant it.
If an isolation or auto-transformer is used ahead of the
controller , the disconnect sw itch should be placed on the
a-c power line between the power source and the trans-
former primary .Again , use a fused disconnect switch. (Do
not use a circuit breaker type switch because of the high
inrush of transformer equipment.) Refer to Table 3.A for
sizes and types .
An isolation transformer is not necessary unless the appli-
cation conditions require one . However . its use provides
distinct advantages . With an isolation transformer :
• Personal injury is guarded against should accidental
contact be made with an electrical conductor from the
drive.
• A-c power line disturbances , or transients , are mini-
mized by an isolation transformer ,thereby reducing or
eliminating damage to other solid-state equipment
power-conversion components in the controller and
other user-equipment on the same a-c line.
• The transformer provides electrical isolation between
the a-c power lines and the drive motor . Damaging
currents may be eliminated in instances where a d-c
output accidentally becomes grounded in a unit where
the a-c electrical system is grounded.
For detailed information. refer to Paragraph 3.4 .
Guideline 7 -The National Electrical Code requires that a
two-pole, fused disconnect swit ch be installed on the
incoming a-c line ahead of the controller to provide branch
circuit protection . Fuses for this disconnect switch should
be chosen from Table 3.A. They should be dual-element,
slow blow type. or Class K5.
It is recommended that the disconnect switch be placed
within easy reach of operating and maintenance person-
nel. Do not place it inside a surrounding enclosure since
cabinet doors may be locked . (Consult your local codes .)
Guideline 8 -It is necessary to connect the GND (green /
ground) wire of the three-conductor incoming a-c line to
the terminal provided on the Chassis. Ring 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 .
Table 3.A
TYPICAL WIRE. FUSE SIZES (D
DISCONNECT
A-C POWER D-C ARMATURE D-C FIELD (D FUSE SIZE (D
HP VAC (min. size/ insul.) (min. size/ insul.) (min . size/ insul .) (amps)
1/4 115 No. 14 AWG 75°C No. 14 AWG 75°C No. 14 AWG 75°C 8
1/rY2 115 No. 14 AWG 75°C No. 14 AWG 75°C No. 14 AWG 75°C 15
% 115 No. 12AWG75°C No. 12 AWG 75°C No. 14 AWG 75°C 20
% 230 No. 14 AWG 75°C No. 14 AWG 75°C No. 14 AWG 75°C 8
%- 1 230 No. 14 AWG 75°C No. 14AWG 75°C No. 14 AWG 75°C 15
1% 230 No. 12 AWG 75°C No. 12 AWG 75°C No. 14 AWG 75°C 20
2 230 No. 12 AWG 75°C No. 12 AWG 75°C No. 14 AWG 75° C 25
3 230 No. 10 AWG 75°C No. 10 AWG 75°C No. 14 AWG 75°C 35
5 230 No. BAWG 90°C No. BAWG 90°C No. 12 AWG 90° C 60
CDCopperwire recommended.
CDPermanentmagnet motorsdonot require field supply.
0 Fuses must bedual-element, time-delay (slow-blow)type, or U.L. Class K5.
10

Guideline 9 -A thermostat is used to guard against motor
overload protection . It is essential to properly connect the
motor thermostat in series with the Operator's Control
Station STOP selector switch at connections 32 and 132 .
CAUTION: An external overload device must be con -
nected between terminals 32 and 132. The drive will
not start without it.
Refer to Figure 3.4 where a typical Operator 's Control Sta-
tion schematic is shown .
Guideline 10 -When planning signal or control wire runs.
as listed in Table 5.C, follow these practices:
• Conduits should be steel.
• If these conduits cross 440 VAC conductors , make
sure the cross is at 90°.
.....-------r-----------,
I I
I I
I I
I I
0.31 in.
(7.9mml I
I
11.97 in.
(305mm )
7.22 in.
(183 .4 mml
0.31 in. (7.9 mm)
FRONTVIEW
3.06 in -f-- 3.06 in.
(77.8 mm) I (77.8 mml
...,.----,----@----+--
6.60 in.
(167.6 mml
L~-
1
I
---- --
1
MOUNTINGHOLE DRILL PLAN
• Do not route signal wires through junctions or termi-
na I boxes that contain non-signal a-c or d-c
(115/230 / 460 V) wires .
Guideline 11 -Operational altitude above sea level may
not exceed 3300 ft (1000 m). Derate horsepower 3% for
each 1000 ft (300 m) above this altitude .
3.2 Mounting -This Paragraph outlines the procedures
to be followed to mount the FlexPak Plus controller.
Determine the exact placement of the Chassis on the panel.
(Refer to Figure 3.3 for mounting dimensions .) Scribe the
panel. Drill three holes large enough to accept 1
/4 -inch
mounting bolts . Scrape the paint around the holes to allow
washers and bolts to make a ground contact.
3.3 Power Wiring -This Paragraph briefly outlines the
procedures to be followed when wiring a-c power supply
lines to the controller and d-c control circu its to the drive. A
basic connection diagram is given at Figure 3.4 .
maximum swing
projec1ion 6.50 in .
(165.1 mml
0.218 in. (5.53 mml dia. mounting holes (3l
for hardwar e 0.19 in. (4.83 mml
Scrape point around holes
to assure grounding .
II
II
II
II
II
II
II
II
~----- -
.I.1800 SW~~:
5 in.
(151.1 mml
SIDE VIEW
Figure 3.3 - Mounting Dimensions
11

"
REMOTE OPERATOR CONTROLS
,--------------------------------,
No
Number
swirch
JOG/RUN
switch
FWD/REV
switch
No
Number
START/STOP
switch
426 326
35
67
65
39
32
38
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
L-------------------------------J
0 -C Drive Motor
51 52 32 132
REMOTE OPERATOR
INTERFACE
r----,
I 57
I
1-Phase
Ptant Power Pl P2
.--1-i 32
(RED)
Terminal
Instrument Interface
or
Voltage Follower Kit
132
(ORGI
STOP
RUN
JOG•
TYPICAL OPERATOR SCHEMATIC
24 VAC
+
40
START
_L r-----1
38 FM 36
~.=-.::.-41.,.._-+--I CR~ ------1 Stat ic
Logic
(BANII (GANI
35 CR I FM 65
(ORGI (BLKI
RM 66
(BLUEi
J9
/'.;\.
L
L_
REV
I
I
I
I
I
I
I
I
FWD
I
I
39
(YELi
67
(GRAY)
1
I
I
I
I
I
I
I
I
I
_J
~----
Notes:
Tachometer Feedback Kit
r------, I
Process Control
or
Auto Rtferenct
Inputs
Figure 3.4 - System Connection Diagram
1> These signals must be run in a separate magnetic condu it to
minimize the possibility of noise pickup. (Refer to Table 5.Cfor
wire specifications .)
2> Remove th e con nection between SPEED pot and terminal 426
when AUTO / MANUAL switch is used.
3> Motors with dual voltage shunt fields should be conn ected for
the higher voltage.
4> Remove jump er J9 from Regulator Module when Reversing
Contactor is installed.
S> Use convenienc e termina ls for #14 AWG maximum wire size.
6> 11Auxiliary Panel is not used, user must supply an appropriate
M con tactor . Refer to Paragraphs 2.4.4 and 5.14 .
/

DANGER
BEFORE WIRING, MAKE SURE THE A-C LINE
DISCONNECT SWITCH IS LOCKED OPEN. EVEN
IF POWER HAS NOT BEEN APPLIED TO THE
INCOMING LINE , THIS PRACTICE ASSURES
PERSONAL SAFETY . IF NO LOCKOUT DEVICE
EXISTS , REMOVE THE FUSES WITH AN INSU -
LATED TOOL AND PLACE A WARNING TAG ON
THE BOX.
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.
All interconnecting wire should primarily be sized and
installed in conformance with N.E.C., C.E.C. or local codes.
Refer to the controller and motor nameplates for electrical
data.Typical wire sizes and types are listed in Table 3.A as a
basic guideline. Note that long cable runs may require that
a larger gauge be used to avoid excessive voltage drop . Use
of stranded wire is also recommended . Wire according to
Figure 3.4.
After wiring, examine all terminals to determine that con -
nections are correctly made at both ends. Confirm wire
identification. Examine the firmness of the connections.
Ifthe Auxiliary Panel is employed ,wires to the motor arma -
tur e (A 1 and A2) must be lugged with the provided lugs , or
equivalent , before conn ection to the appropriate relay ter-
minals . Lugs provided will accommodate :
%to 1Y
2 hp - 12 AWG
1
Y
2 to 3 hp - 10 AWG
5 hp-8AWG
WARNING
DO NOT ALLOW CONDUCTORS TO GROUND ON
THE CHASSIS. CHECK INTEGRITY OF ALL WIRE
INSULATION BEFORE DRAWING. REMOVE
ONLY ENOUGH INSULATION TO MAKE A FIRM
TERMINAL CONNECTION. PERSONAL INJURY
COULD RESULT IF A BARE WIRE TOUCHES THE
CHASSIS.
3.4 Isolation Transformers -Although an auto-tran s-
former may be required becau seof a-c line voltage levels ,it
is unable to provide a number of benefits standard with an
isolat ion transformer .
The general requirements for an isolation tran sformer are:
• Single phase
• 3 to 8% impedance
• Nonregulated
13
• Sinusoidal output
• 50/ 60 Hz, as required
• 150% overload for 1 minute (max.)
Refer also to Table 2.D for specific information on trans-
former sizing requirements . In the 'Tr ansform er" column
at the right, maximum kVA and full -load kVA figures are
listed in relat ion to specific d-c motor hp/ VAC rating s.
Reliance Electr ic offers a number of isolation transformer s
suitable for use with th e FlexPak Plus controller. (Refer to
Table 3.8.)
Table 3.B
RELIANCE ELECTRIC ISOLATION TRANSFORMERS
PRIMARY SECONDARY ORDER
HP kVA VAC VAC NUMBER:
%·Y3 0.75 230 / 460 115 77530-10S
Y4·Y3 0.75 575 115 Special Order
Y2 1.0 230 / 460 230 Special Order
Yi 1.0 575 115 Special Order
% 1.5 115 115 77530 -12V
:y4 1.5 575 115 77530-1 lV
% 1.5 230 / 460 115 77530 -lOV
% 1.5 230 / 460 230 Special Order
% 1.5 575 230 Special Order
1 2.0 230 / 460 230 77530-BW
1 2.0 575 230 Special Order
,Yi 3.0 230 / 460 230 77530 -BX
1
Y2 3.0 575 230 Special Order
2-3 5.0 230 / 460 230 77530 -BY
2-3 5.0 575 230 77530-SY
5 10.0 230 / 460 230 77530 -BRC
5 10.0 575 230 77530 -SRC
3.5 50-Hz Operation -There may be cases wh en the
FlexPak Plus controll er is to be operat ed continuou sly on 50
Hz. If so, two resistor s should be remov ed from the Regul a-
tor Module for optimum performan ce.(Refer to Figure 3.5.)
Remove resistor Remove resistor
Figure 3.5 -50 -Hz Resistor Removal

3.6 HP/ Current Jumper -It is necessary to inspect the
Current Scaling / Horsepower Jumper on the Regulator
Module to be sure that it is connected correctly for a spe-
cific drive motor .
Step 1 -On the drive motor , locate the nameplate. Note
the full-load current .
Step 2 -Or, if current is not shown on the nameplate ,
refer to Table 3.C. Relate the left or center columns in the
table with known motor data . Read across to the right
cnlumn marked "Motor Current ." This figure indicates the
proper jumper connection to make on the Module where a
corresponding number is etched .
Table 3.C
HORSEPOWER CALIBRATION
MOTOR HP MOTOR CURRENT /
115 VAC 230 VAC PIN CONNECTIONS
1/4 1/2 2.5A
1/3 314 3.7A
Yi 1 5A
7'4 11/2 7.5A
-2 10A
-3 15A
-5 25A
Step 3 - On the Regulator Module , locate the scaling pins .
(Refer to Figure 3.6.) Near them, locate the black pig-tail
type jumper . Do not move it if it is connected to the proper
pin . If it must be reconnected, carefully lift it straight up and
off the pin. Slide the connector straight down over the
proper pin.
3. 7 Regulation Mode Jumper - The FlexPak Plus con-
troller offers three types of drive regulation. The first ,which
is factory shipped , is an armature voltage feedback (A).
14
Figure 3.6 -HP/ Current Scaling Pins
Optionally , the user may also use either tachometer feed-
back (T)regulation or counter EMF feedback (C). In order to
use these two modes , however, the Regulation Mode
Jumper, one end of which is permanently fixed to the
Regulator Module, must be moved to one of two positions .
(Refer to Figure 5.10.) Details of jumper placement are
noted in Section 5.
DANGER
IF YOU ARE UNSURE WHICH REGULATION
MODE A CONTROLLER SHOULD HAVE. IT IS
IMPORTANT YOU FIND OUT. IF THE JUMPER IS
NOT PROPERLY CONNECTED. PERSONAL
INJURY MAY RESULT.

Section 4
START-UP AND ADJUSTMENT
4.0 General - This Section provides start-up and adjust-
ment procedures to be followed after the assembly and
installation of the controller is complete. All initial opera-
tion checks and final adjustments to the controller must be
made in conformance to the procedures , warnings and
recommendations listed here.
DANGER
THE FLEXPAK PLUS CONTROLLER IS AT LINE
VOLTAGE WHEN A-C LINE POWER IS CON-
NECTED TO THE POWER UNIT INSIDE THc
CONTROLLER. BEFORE WORKING ON , OR
TOUCHING ANY INTERNAL PARTS OF, THE
CONTROLLER. REMOVE INCOMING A-C LINE
POWER AT THE MAIN DISCONNECT SWITCH.
PERSONAL INJURY MAY RESULT IFTHISWARN-
i ING IS;NOT. FOLLOWED; .
DANGER
DURING INITIAL START-UP, THE CONTROLLER
AND ITS ASSOCIATED EQUIPMENT MUST BE
OPERATED AND / OR ADJUSTED ONLY BY
QUALIFIED ELECTRICAL MAINTENANCE PER-
SONNEL. THESE INDIVIDUALS SHOULD BE
FAMILIAR WITH THE DESIGN AND OPERATION
OF THIS EQUIPMENT AND WITH THE HAZARDS
INVOLVED. PERSONAL INJURY AND / OR DAM-
AGE TO THE CONTROLLER COULD RESULT
FROM UNFAMILIARITY.
4.1 Power Off Inspection - It is necessary to make a
superfic ial inspection of the FlexPak Plus controller and its
associated units. The purpose of this check is to look for
possible physical damage or improper connections.
Inspect all plug-in Modification Kits. Test each for a firm
mounting condition .
Each should be mechanically connected to the Regulator
Module by means of a mounting post screw. Each should
be electrically connected to the Module bya series of paral-
lel 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 Modification
Kits. Make sure the wires are firmly connected. Also make
sure that there is enough insulation on thewires to prevent
a short between the conductors.
Inspect the signal wiring from the Operator Control Station.
A series of wires will connect to individual terminals on a
strip mounted on the Remote Operator Interface Module .
(This Modul e is mounted on the Regulator Module.) Deter-
mine that all wires are firmly seated in the terminal strip.
Make sure all wires are connected .
15
4.2 Motor Ground Check - It may be necessary to make
a check of the drive motor to assure that no damaging
grounds-other than earth ground-exist within the motor .
CAUTION: Although a megger may be used for th is
test, if one is used, all conductors between the drive
motor and the FlexPak Plus controller are to be discon-
nected and moved aside. The megger's high voltage
can cause damage to the controller's circuits .
Step 1 - Attach one lead from the ohmmeter to the motor
frame to make a simple resistance check.
Step 2 - Touch the test probe to each of the two power ,
two thermostat , and two field leads to the motor .
If the reading to ground on any terminal is less than
100,000 ohms , a ground condit ion exists.
Step 3 - If a ground condit ion exists, inspect the moto r
thoroughly for internal shorts.
Step 4 - When the ground ing condition is corrected ,
reconnect the conductors from the FlexPak Plus controller.
4.3 Power On Adjustments - Once all the preliminary
power-off static adjustments have been performed with
acceptable results, the a-c line power isto be applied to the
controller , but the load is not connected . It is important to
follow these steps closely. Observe all cautions and
warnings .
DANGER
WITH A-C POWER APPLIED AND WITH THE
POWER ON / OFF SWITCH IN THE ON POSITION,
HAZARDOUS VOLTAGE EXISTS IN THE CON-
TROLLER . EXERCISE EXTREME CAUTION WHEN
PERFORMING THESE TESTS. PERSONAL
INJURY CAN RESULT.
DANGER
IF CIRCUIT BREAKER HAS TRIPPED OR FUSES
HAVE CLEARED, USER MUST DETERMINE IF A
FIELD SUPPLY KIT IS PRESENT . (SEE FIGURE
5.15 .) IF FIELD SUPPLY KIT IS PRESENT . THE
FIELD SUPPLY KIT AND ITS WIRING MUST BE
INSPECTED FOR DAMAGE. RE - APPLYING
POWER TO THE DRIVE . THE FIELD VOLTAGE
MUST BE RE-CHECKED FOR PROPER VOLTAGE
AT MOTOR TERMINALS F1. F2. IFTHIS VOLTAGE
IS BELOW 90 % OF THE FIELD VOLTAGE SPECI -
FIED ON THE MOTOR NAMEPLATE . THE DRIVE
MUST NOT BE STARTED UNTIL PROPER VOLT-
AGE IS OBTAINED. FAILURE TO FOLLOW THIS
PROCEDURE COULD RESULT IN OVERSPEED-
ING THE MOTOR AND / OR THE MACHINERY
COUPLED TO THE MOTOR SHAFT AND POSSI -
BLE FATAL INJURY . REFER TO SYMPTOM 1 IN
TABLES 6.B AND 6.C.

4.3.1 Regulator Module Pots -The Regulator Module
has six adjustable potentiometers mounted on it. (Refer to
Figure 4 .1.) They control the following functions :
• Maximum speed (full CCW: 50% speed)
• Min imum speed (full CCW: zero speed)
• Acceleration rate (full CCW)
• Deceleration rate (full CCW)
• Current limit (factory-set at 150%)
• IR comp (full CCW)
The potentiometer s are factory preset for the safest or most
conservative operation .
4.3.2 Maximum Speed (Voltage) -The Maximum Speed
Potentiometer on the Regulator Module has been factory
preset for 50% of a typical motor base speed of about 1750
rpm. By means of adjustment, the maximum speed may be
raised to suit the application. The result is the highest
speed that can be set by the operator on the SPEED dial.
The control range is 50 to 100% of rated speed.
There are two methods for determining if the motor and
driven equipment are operating at an acceptable maximum
speed for the application.
• Tachometer
• Visual inspection of machine operation
Locate the Max imum Speed Potentiometer on the Regula-
tor Module .(Refer to Figure 4.1.)The latters MAX SPD are
printed on the Module . Note that CW rotat ion represents an
increase in speed. CCW represents adecrease.
Max Speed
Min Speed
Ace Rate
Deel Rate
Currant Limit
IR Comp
Figure 4.1 - Regulator Module Potentiometers
16
DANGER
WHEN PERFORMING THIS ADJUSTMENT PRO-
CEDURE , DO NOT ALLOW THE DRIVE MOTOR TO
EXCEED ITS RATED MAXIMUM SPEED, AS
LISTED ON THE NAMEPLATE . EQUIPMENT
DAMAGE AND SERIOUS PERSONAL INJURY
COULD RESULT.
On the Operator Station , increase the SPEED dial slowly in
the direction of 10, which is 100% of full travel. If, as the
SPEED dial is turned toward the 10 setting, the speed
exceeds the maximum acceptable speed, immediately
decrease the maximum speed on the SPEED dial. Use a
small insulated slot screwdriver.
In some cases, to avoid exceeding the maximum operating
speed, it may be necessary to turn the Maximum Speed
Potentiometer completely CCW before turning the SPEED
dial completely CW.
Ifthe 1Osetting on the SPEEDdial is lower than the desired
speed, increase the setting on the Maximum Speed Poten-
tiometer to the necessary speed.To increase the max imum
speed, turn the potentiometer CW.
DANGER
USE ONLY ONE HAND TO HOLD THE SCREW -
DRIVER. KEEP YOUR OTHER HAND BEHIND
YOU. DO NOT USE YOUR OTHER HAND TO
BRACE YOURSELF AGAINST THE CONTROLLER,
PANEL OR ENCLOSURE . PERSONAL INJURY
COULD RESULT IF YOU ACCIDENTALLY TOUCH
A COMPONENT AT LINE VOLTAGE .
NOTE:A further adjustment may be needed, but it should
be performed after completing Paragraph 4.3.3. Note that
the maximum and minimum speed adjustments are inter-
active; a change in one affects the other.
4.3 .3 Minimum Speed (Voltage) -The Minimum Speed
Potent iometer on the Regulator has been factory preset for
zero speed. By means of adjustment, this speed may be
raised or lowered . The result is the lowest moving speed
the operator can set on the SPEEDdial. The control range is
zero to 50% of rated speed.
Again , the motor speed can be determ ined by atachometer
or by visual inspection of machine operation .
With the SPEED dial at zero position and using a small,
insulated slot screwdriver, carefully turn the Minimum
Speed Potentiometer until the desired minimum is
reached . Note that CW represents an increase; CCW
represents a decrease.
NOTE: Carefully recheck the maximum speed adjustment
for desired setting . Since the maximum and minimum
speed adjustments are interactive , a change in one affects
the other . At times , it may be necessary to work back and
forth for precise adjustments.
4.3 .4 Acceleration and Deceleration Rates -The
Acceleration and Deceleration Rate Potentiometers on the
Regulator Modul e have been factory preset for a typical
linear acceleration rate of six seconds to maximum and
minimum speed. This time can be adjusted over a range of
0.5 to 30 seconds from a fully stopped condition.

•
4.3.5 Current Limit -Although it will probably not be
necessary to make any adjustment in the factory-set cur -
rent limit value of 150% of rated load, it is possible to
change this governing value. (Individual application speed
changes or load changes on sustained overloads may
require readjustment . Also, applications requiring torque
limiting or accelerating of high inertia loads may require a
change from this value .)
To reduce the torque output of the drive, turn the Current
Limit Potentiometer CCW. Note, however , that turning
CCW too far may prevent the drive accelerating to the
desired speed.
4.3.6 IR Compensation -IR(voltage)Compensation is a
feature which makes up for the armature resistance of a
17
motor that causes a drop in speed as the load is increased .
The IR Compensation Potentiometer is factory-set at zero.
The IR Compensation feature can be adjusted between 0
and 12% of rated load and is used only for avoltage regula-
tion mode. When using a tachometer or CEMF feedback,
the IR Compensation Potentiometer must be turned com-
pletely CCW.
CAUTION : If the IR Compensation Potentiometer is
set too high, motor speed rising characteristics may
result. Instab ility and oscillation in motor speed will
result.

Section 5
MODIFICATION KITS
5.0 General -A number of optional features in the form
of Modification Kits are offered with the FlexPak Plus con-
troller . Each of these Kits extends the control of the unit and
tailors its operation to specific application needs .
This Section describes the procedures that must be fol-
lowed to install the Kits. Refer to Table 5.A for an informa-
tional listing.
DANGER
INSTALLATION OF MODIFICATION KITS IS TO BE
DONE ONLY AFTER A-CLINE VOLTAGE IS DIS-
CONNECTED AND LOCKED OUT AT THE MAIN
DISCONNECT SWITCH. DO NOT INSTALL KITS
WHEN POWER IS APPLIED TO THE FLEXPAK
PLUSCONTROLLER. SERIOUS PERSONAL INJURY
AND EQUIPMENT DAMAGE COULD RESULT.
CAUTION: Installation of the Modification Kits should
be performed only by qualified electrical maintenance
personnel familiar with the design and operation of
this equipment. Damage could result thru unfamil-
iarity .
Many of the Modification Kits are designed to make electri-
cal connection with the Regulator Module hy means of
pin-type connectors. These slide up tr· r ,h matching
holes in the Modules that form part ti Kit. (Refer to
Figure 5.1.)
Figure 5 .1 -Pin Alignment
A common installation probl em is caused by bent, broken
or incorrectly placed pins . Since imprope r operation
result s, care must be taken . Exact alignment is critical.
Visually check that only one pin extends to the top of each
slot once the connection is made.
Many of the Modifi cation Kits require the removal of one or
more jumpers from the Regulator Module. In such cases,
carefully clip the leads on both sides of each jumper and
discard it. Use a sharp pair of dykes (diagonal cutters) to
assure a quick, clean cut. Do not twist the tool , since dam-
age may result.
In cases where the Kit is secured by a mounting screw, be
sure to tight en it firmly but do not overtighten . Excessive
force can strip the threads.
5.1 Auxiliary Panel -The Auxiliary Panel contains a-c
line fuses. an M contactor, an Auxiliary Mounting Bracket
19
and four screws for use with the Basic FlexPak Plus . The
Auxiliary Mounting Bracket provides a mounting surface
for the Automatic Reversing and Auxiliary M Contactor
Kits.
To install the Auxiliary Panel, follow these procedures .
Step 1 -Follow this Step only if the Contactor Adapter Kit
with a user-supplied M contactor isalready installed. If this
condition does not exist , proceed to Step 2.
Disconnect the user- supplied FM contactor (and user-
supplied RM contactor if applicable}. Remove the two har-
ness connectors from the Regulator Module . Remove and
discard the Contactor Adapter Kit (including the Auxiliary
Mounting Bracket} .
Step 2 -Orient the Auxiliary Panel over the Basic Con-
troller aligning the mounting holes. Secure the Panel with
the provided screws . (Refer to Figure 5.2 .)
Step 3 -Connect leads 51 and 52 to termina ls 51 and 52 .
respectively , on 1TB of the Basic FlexPak Plus. Connect
leads45 and 47 toterminals45 and 47,respectively , on the
Basic FlexPak Plus. Make sure connections are tight and
well made.
Step 4 -Place the relay control harness connector over
the Regulator pins marked FWD. (Refer to Figure 5.2.)
Orientat ion is important : connect the orange wire with the
pin called out as ORG 139.(Refer to Figure 6.4.)
Linefuse M contactor
Mounting screws
(2 each side)
Figure 5.2 -Auxiliary Panel Mounting