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SEPTEMBER, 1987 INSTRUCTION MANUAL D-3938-1

INSTALLING, OPERATING, and MAINTAINING

FlexPak
D-C\S8DRIVES
and MODIFICATION KITS

RELIANCE ELECTRIC MS
TABLE OF CONTENTS

SECTION 1. SECTION 5.
INTRODUCTION TROUBLESHOOTING
1.0 General 5.0 General 21
5.1 Wiring Errors 21
5.2 A-C Line Problems 21
5.3 Motor Problems 22
SECTION 2. 5.4 Mechanical 22
GENERAL CONTROLLER 5.5 Controller Malfunctions 22
INFORMATION 5.6 Schematics, Diagrams 22
2.0 General 3
2.1 Operator's Controls 4
2.2 D-C Drive Motors 4 SECTION 6.
2.3 Modification Kits 5
REPLACEMENT PARTS
2.4 Specifications 6
2.4.1 Line Frequency 6 6.0 General 47
2.4.2 Voltage Tolerance 6
2.4.3 Line Impedance Requirements 6
2.4.4 Relay Control Circuit 6
2.4.5 A-C Line Fuse Requirements 7 SECTION 7.
MODIFICATION KIT
INSTRUCTION MANUALS
SECTION 3. 7.0 General 49
INSTALLATION D-3956 Circuit Breaker
D-3957 Dynamic Braking
3.0 General 9 D-3959 Reversing Contactor
3.1 Layout Guidelines 9 D-3960 Auxiliary M Contact
3.2 Mounting 11 D-3961 Blower Motor Starter
3.3 Power Wiring 11 D-3962 Fan Kit
3.4 Isolation Transformers 13 D-3963 Status/Diagnostic Indicator
3.5 HP/Current Jumper 13 D-3965 Series Field Kit
3.6 Regulation Mode Jumper 14 D-3966 Dancer Follower
3.7 Overspeed Warning 14 D-3967 Instrument Interface/Preset Speed
D-3968 Master Isolated Reference/Receiver
D-3969 Tachometer Feedback
D-3970 Test Meter Adapter
SECTION 4. D-3971 Voltage/Tachometer Follower
START-UP AND ADJUSTMENTS D-3955 M Contactor Adapter
D-3958 Auxiliary Panel
4.0 General 17
4.1 Power Off Inspection 17
4.2 Motor Ground Check 17
4.3 Power On Adjustments 17
4.3.1 Regulator Module Pots 18
4.3.2 Maximum Speed (Voltage) 18
4.3.3 Minimum Speed (Voltage) 19
4.3.4 Acceleration and Deceleration Rates 19
4.3.5 Current Limit 19
/^^\
4.3.6 IR Compensation 19
INDEX OF FIGURES

s?
Figure Title Page Figure Title Page
1.1 FlexPak Plus Complete Controller 5.8 230 VAC Controller Power
w/Optional Status Diagnostic Indicator Bridge Schematic 29
and Super RPM Motor 1 5.9 460 VAC Controller Power
2.1 Basic Controller and Auxiliary Panel 3 Bridge Schematic 30
2.2 FlexPak Plus D-C V*S Drive 3-40 HP 5.10 Controller Regulator Module &
Complete Controller Open Cover Digital Driver Schematic 31
of Basic Drive 5 5.11 230 VAC Auxiliary Panel Assembly
3.1 Enclosure Mounting Minimum Distances 9 Schematic 32
3.2 Mounting and Wiring Orientations 10 5.12 460 VAC Auxiliary Panel Assembly
3.3 Mounting Dimensions 11 Schematic 33
3.4 System Connection Diagram 12 5.13 Modification Kit Schematics 34
3.5 Remote Operators Buffer 5.14 Status/Diagnostic Indicator
Terminal Markings 13 Kit Schematic 37
3.6 Regulator Module, HP/Current 5.15 Technical Data 230 VAC Three
Scaling Parts 14 Phase FlexPak Plus 38
4.1 Regulator Module Potentiometers 18 5.16 Technical Data 460 VAC Three
5.1 Unidirectional Control Circuit 22 Phase FlexPak Plus 39
5.2 Bidirectional Control Circuit 22 5.17 Technical Notes 42
5.3 Regulator Module 26 7.1 Pin Alignment 49
5.4 Digital Driver Module ^ 26 7.2 Regulator Module with
5.5 Drive Breaker and Fuse Location 27 Typical Kit Installation 51 ^
5.6 TopView of Controller ...1..^. 28 7.3 Three Phase FlexPak Plus, Regulator
5.7 Bottom View of Controller .. A.. 28 Board Jumper Location 52

INDEX OF TABLES

Table Title Page Table Title Page


2.A FlexPak Plus Features Summary 4 5.A Troubleshooting Suggestions for
2.B Specifications 6 the Basic Controller 23
2.C Fuse Requirements 7 6.A Replacement Modules 47
2.D D-C Motor/Controller/Transformer 7.A Modification Kit Quick Reference Lift 49
Specifications 7 7.B Wiring Specifications 51
3.A Horsepower Calibration 13
SECTION 1
INTRODUCTION

1.0 General This manual familiarizes the user with the


DANGER
three phase, FlexPak Plus D-C V*S drive controller.
THE DRIVE SYSTEM SHOULD BE INSTALLED,
(Refer to Figure 1.1.) It describes assembly and installa
ADJUSTED AND SERVICED BY QUALIFIED ELEC
tion procedures, gives a general overview of operations,
TRICAL MAINTENANCE PERSONNEL FAMILIAR
and contains information on troubleshooting, mainte
WITH THE CONSTRUCTION AND OPERATION
nance, the ordering of spare parts, and specifications.
OF ALL EQUIPMENT IN THE SYSTEM. PERSONAL
The manual should be read before performing installation INJURY AND/OR EQUIPMENT DAMAGE MAY
or start-up activities. Also, there are certain fundamental OCCUR IF INDIVIDUALS ARE NOT FAMILIAR
warnings which must be kept in mind at all times. These WITH THE HAZARDS RESULTING FROM IM
are: PROPER OPERATION.

Figure 1.1 FlexPak Plus Complete Controller w/Optional Status Diagnostic Indicator and Super RPM Motor

1
DANGER
WARNING
CONTROLLER EQUIPMENT IS AT LINE VOLTAGE
DO NOT OPERATE THE FLEXPAK PLUS CON
WHEN A-C POWER IS CONNECTED TO THE
TROLLER ON POWER SUPPLIES WITH AVAIL
POWER UNIT IN THE FLEXPAK PLUS CON
ABLE SHORT-CIRCUIT CURRENTS IN EXCESS
TROLLER. THUS A-C POWER MUST BE REMOVED
OF 5000 AMPERES. DAMAGE TO EQUIPMENT
FROM THE UNIT BEFORE IT IS SAFE TO TOUCH
AND PERSONAL INJURY MAY OCCUR.
INTERNAL PARTS OF THE CONTROLLER. PER
SONAL INJURY 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 VOLTAGE
DISCONNECTION IS NOT PROVIDED.
SECTION 2
.y GENERAL CONTROLLER INFORMATION

2.0 General The FlexPak Plus D-C V*S drive controller larger electrical enclosure. The Remote Operator Con
may be applied to three phase d-c drive applications with trols may then be placed on the larger enclosure's face or
ratings within the following ranges: some distance away.

From 3 to 20 hp with a 230 VAC, 50/60 Hz input voltage The three phase FlexPak Plus is available as a Complete
From 3 to 40 hp with a 460 VAC, 50/60 Hz input voltage Controller with Auxiliary Panel. The Complete Controller
and the Auxiliary Panel (Figure 2.1) are Underwriters
The controller provides power-conversion and control
Laboratories (U.L.) listed.
circuits which convert the a-c line voltage into adjustable
d-c voltage in order to effectively control the drive motor. Optional Modification Kits conveniently expand the cap
ability of the Basic Controller and Auxiliary Panel.
The FlexPak Plus controller is provided, as standard, in a
chassis type configuration for panel mounting within a The controller's features are summarized in Table 2.A.

. ilia i

=i ecTRICm

FlexBw \55WJVE

Figure 2.1 Basic Controller and Auxiliary Panel

3
Table 2.A FlexPak Plus Features Summary

Category Feature

Controller Functions START/STOP


RUN/JOG
FORWARD/REVERSE
Speed selection (5 to 100%)
Torque selection (10 to 150%)
Unidirection operation with coast-to-rest on stop command standard. (Dynamic braking
and reversing available as options.)
20:1 controlled-speed range by means of armature voltage control.
Auxiliary Panel armature loop contactor removes power to drive motor.
Isolated armature voltage and current feedback decouples armature power from opera
tor devices and provides additional noise immunity.
With specified tachometers 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) 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: RE-045 a-c tachometer; also 5PY or RE-020 d-c 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 (5to 30% of base motor speed).
Adjustable current limit (10 to 150% of full-load current). y/'^WfcV

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 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 separation of power and regu
lator circuits.
Hardware Conveniently located screw terminal connections for incoming a-c and outgoing d-c
power allow easy cable entry and connection.
Auxiliary Panel a-c line fuses protect Power Cube from armature shortcircuit
and power relays provide positive power disconnect.
Protection from momentary surges on a-c line and from d-c load transients.

2.1 Operator's Controls For proper operation of the FORWARD/REVERSE selector switch (DPDT)
FlexPak Plus controller, it is necessary to provide Remote START/STOP selector switch (pushbuttons or
Operator's Controls. Reliance Electric offers a wide var special)
iety of operator control stations which may include the
following devices: 2.2 P-C Drive Motors Reliance Electric offers a com
SPEED control potetiometer (5K) plete power-matched drive system for the controller and
TORQUE control potentiometer (1OK) the application. Thus, the choice of Reliance Electric
AUTO/MANUAL selector switch (SPDT) motors assures optimum performance and unmatched
RUN/JOG selector switch (SPST) single-source responsibility.
2.3 Modification Kits The basic capability of the con Master Isolated Reference Receiver
troller can be quickly and conveniently extended with the Contactor Adapter
use of a variety of optional Modification Kits. The Basic
Controller modifications are: The Auxiliary Panel modifications are:
Blower Motor Starter
Tachometer Feedback
Reversing Contactor
Voltage/Tachometer Follower
Circuit Breaker
Instrument Interface/Preset Speed
Auxiliary M Contact
Test Meter Adapter
Status/Diagnostic Indicator Remote Dynamic Braking Kits are also available.
Dancer Follower Complete descriptions of each Kit are given in Section 7.

REVERSING
CONTACTOR OR
"M" CONTACTOR MOUNTING BLOWER MOTOR
LOCATION / STARTER MOUNTING
Mi <-2> L3 LOCATION
INCOMING LINE
CONNECTIONS

THREE-PHASE
INCOMING
MOUNTING
LINE FUSES
LOCATION FOR
OPTIONAL CIRCUIT
BREAKER OR
BLOWER MOTOR
STARTER

47 45 (A-, A 2) INCOMING
ARMATURE TERMINALS
PROTECTIVE
CIRCUITRY
WIRING (MOTOR
THERMOSTAT,
ETC.)
CONTROL CIRCUIT
FUSE
F1-F2
TERMINALS
REMOTE OPERATOR'S
CONTROL BUFFER
SHUNT FIELD
EXITATION FUSES

CONTROL REFERENCE
INPUT TERMINALS

LSI REGULATOR
CHIP
RIBBON CABLE CONNECTOR
TO DIGITAL DRIVER
MODULE
DRIVE
ALIGNMENT
POTENTIOMETERS

DIAGNOSTOR
CONNECTOR

REGULATOR PRINTED
CIRCUIT CARD

COVER
PLATE

Figure 2.2 FlexPak Plus D-C V*S Drive 3 - 40 HP Complete Controller Open Cover of Basic Drive

5
Table 2.B Specifications

A-C Line Input Voltage Operator Torque Adjustment Displacement Power Factor
230/460 VAC (nominal, 60 Hz) Infinitely adjustable at 68% (typical)
220/440 VAC (nominal, 50 Hz) optional control pot Transient Protection
three phase only (10 to 150% of rated load) MOV and Output RC Circuit
Line Voltage Variation IR Drop Compensation Controller Service Factor
10% of nominal Oto 12% of rated load 1.0
A-C Line Frequency (user adjustable)
Duty
Three Phase, 50/60 Hz Controllable Speed Range Continuous
20:1
Line Frequency Range Ambient Temperature
48-62 Hz Current Limit (storage and operational)
Output Voltages Factory shipped: 150% of full load 0 to55C (32 to131F)
(armature and field) User adjustable: 10 to 150% of full load
Relative Humidity
See Table 2.D Regulator (with 95% load change) (storage and operational)
Controller-Drive HP Range 3 to 5% with voltage feedback 5 to 95% (without condensation)
3-20 (with 230 VAC input) 1.0% with specified tachometer feedback
Operational Altitude
3-40 (with 460 VAC input) 0.5% with specified tachometer feedback
To 3300 ft (1000 m) above
Direction Control
Minimum Load for Stable Operation sea level without derating
5%
Standard: Unidirection Controller Weight (approx.)
Optionally: Forward/Reverse Acceleration/Deceleration Rates 37 lb (87.8 Kg)
0.5 to 30 sec. linear time
Maximum Speed Adjustment Controller Dimensions (LWD)
70 to 100% of base motor speed (user-adjusted separately) (A) = 18.75x10.62x8.00 in.
(user adjustable) Armature Circuit Overload Capacity (476x270x203 mm)
Minimum Speed Adjustment 150% of armature current rating (B) = 18.75x10.62x9.50 in.
up to 30% of base motor speed for 1 minute (max.) (476x370x241 mm)
(user adjustable) Efficiency (rated speed/rated load) A 3-10 HP/230V, 3-20 HP 460V
Controller only: 97% B 15-20 HP/230V, 25-40 HP 460V
Operator Speed Adjustment /^fev

Infinitely adjustable with Complete drive including


optional control pot motor 85% (typical)
(up to 100% of base speed)

Typical percent shown. Exact figure dependent on motor base speed and frame size.

WARNING
2.4 Specifications The more important specifications DO NOT OPERATE THE FLEXPAK PLUS CON
for the FlexPak Plus controller are listed in Table 2.B. TROLLER ON POWER SUPPLIES WITH AVAIL
Refer also to Table 2.D where other ratings are indicated ABLE SHORT-CIRCUIT CURRENTS IN EXCESS
in relation to d-c motors of specific horsepower. OF 5000 AMPERES. DAMAGE TO EQUIPMENT
AND PERSONAL INJURY MAY OCCUR. EXTER
NAL DISCONNECT MEANS MUST HAVE ABILITY
2.4.1 Line Frequency The FlexPak Plus controller is TO INTERRUPT A 5000 AMP RMS CURRENT
able to operate without modification from a three-phase FAULT.
power source having a frequency range from 48 to 62 Hz.
2.4.4 Relay Control Circuit The regulator board is set
up for use with 24 VDC main contactors having a coil
2.4.2 Voltage Tolerance The FlexPak Plus controller resistance greater than or equal to 100 ohms, 14C300
delivers output current and voltage, as listed in Table 2.D. only; 14C301 to 14C305 is 1000 ohms. The control logic
It will also operate within these regulation specifications
sequences the contractor and the control relay on the
even with incoming line voltage at 10% of nominal.
regulator so that current flow thru the main contactor is
never broken in normal operation by the contracts. Refer
to Figures 5.1, and 5.2.
2.4.3 Line Impedance Requirements The FlexPak Plus
controller must be connected to a plant power supply with The standard controller includes an M contactor. How
maximum permissible available symmetrical RMS fault ever, the Optional Basic Controller does not have an M
current no greater than 5000 amperes. (Refer to Table contactor. An M contactor is required to provide positive
2.D.) power disconnect in all applications.
Table 2.C Fuse Requirements
WARNING
IN THE OPTIONAL BASIC DRIVE, THE USER
MUST INSTALL AN M CONTACTOR THAT HAS A
Fuse Specification
115 VAC COIL WITH A MAXIMUM CURRENT A-C
(one per Phase)
DRAW OF 440 MILLIAMPS. THE CONTACTOR HP Line
ADAPTER KIT MUST BE INSTALLED WITH THE Volts Reliance
Rating
USER'S M CONTACTOR. (REFER TO D-3955) Part No.
PERSONAL INJURY MAY OCCUR IF THIS IS NOT
3-10 230 64676-12BX 70A, 500V
INSTALLED.
15 230 64676-12CC 125A, 500V
20 230 64676-12CC 125A, 500V
2.4.5 A-C Line Fuse Requirements A-C line protection
3-20 460 64676-12BX 70A, 500V
is provided with the Auxiliary Panel. The Optional Basic
25-30 460 64676-12CC 125A, 500V
FlexPak Controller, however, does not include a-c line
40 460 64676-12CC 125A, 500V
protection. Fused a-c line protection must be used. Refer
to Table 2.C for proper fuse sizing. (Note: Semiconductor
current limiting fuses must be used.)

Table 2.D D-C Motor/Controller/Transformer Specifications

D-C Power Transformer


VAC A-C D-C D-C Amp.
Controller Arm. Supply
HP Amps Maximum
Model Numbers @ Arm. Field Max. Rated
Amps Capacity kVA
60 Hz (RMS) (Volts) Volts kVA
(avg.)
14C300 3 230 12 240 12 150 5 5000 30 6
5 230 20 240 20 150 5 5000 50 10
7% 230 28 240 29 150 5 5000 63 12%
10 230 36 240 38 150 5 5000 80 16
14C301 15 230 51 240 55 150 5 5000 115 23
14C302 20 230 66 240 72 150 5 5000 145 30
14C303 3 460 7 500 6 300 5 5000 30 6
5 460 11 500 10 300 5 5000 50 10
7% 460 14 500 14 300 5 5000 63 12%
10 460 18 500 18 300 5 5000 80 16
15 460 26 500 27 300 5 5000 115 23
20 460 34 500 36 300 5 5000 145 30
14C304 25 460 40 500 43 300 5 5000 175 35
30 460 47 500 51 300 5 5000 205 41
14C305 40 460 63 500 69 300 5 5000 250 55
Because of nature of field l<dss orot ective c.'ir nuitrv/ thiiq ci m n l v/ m n e t r
^

excitation.

Maximum permissible available symmetrical RMS fault current with NEC or CEC external approved disconnect.
Drives have been designed for maximum of three units per maximum transformer rating.
Minimum required KVA size is 15 KVA for proper operation.
r
SECTION 3
INSTALLATION
3.0 General This Section outlines the procedures that
WARNING
are to be followed in order to properly install a FlexPak
THE USER IS RESPONSIBLE FOR CONFORMING
Plus controller.
WITH THE NATIONAL ELECTRICAL CODE WITH
The d-c motor should be installed and wired in accor RESPECTTO MOTOR, CONTROLLER AND OPER
dance with installation instructions supplied with each ATOR DEVICE INSTALLATION, WIRING AND
drive. START-UP. THE USER IS ALSO RESPONSIBLE
FOR UNDERSTANDING AND APPLYING ALL
There are certain general warnings and cautions that
OTHER APPLICABLE LOCAL CODES WHICH
should be kept in mind before planning begins. They
GOVERN SUCH PRACTICES AS WIRING PRO
should be considered a general checklist which, if fol
TECTION, GROUNDING, DISCONNECTS AND
lowed, will minimize installation problems and decrease
OVERCURRENT PROTECTION.
assembly time. As a user aid, they are listed here.

3.1 Layout Guidelines This Paragraph lists recom


DANGER mended layout procedures common to all FlexPak Plus
THIS UNIT SHOULD BE INSTALLED, ADJUSTED controllers.
AND SERVICED BY QUALIFIED ELECTRICAL
MAINTENANCE . PERSONNEL FAMILIAR WITH Guideline 1 The FlexPak Plus controller is designed as
THE CONSTRUCTION AND OPERATION OFTHIS
a panel-mounted unit. It is to be hung within 10 of vertical
TYPE OF EQUIPMENT. THEY SHOULD ALSO BE
with the rear of the Chassis firmly resting against the
FAMILIAR WITH THE POTENTIAL HAZARDS IN
mounting surface. (Do not position the Chassis on a
VOLVED. IF THIS WARNING IS NOT OBSERVED, horizontal surface.)
PERSONAL INJURY OR EQUIPMENT DAMAGE Guideline 2 It is necessary to leave at least a 4 inch (102
MAY RESULT. mm) clearance between controllers including top, bottom
and side. This unobstructed area allows for proper air
circulation through the heat sink. Do not place the con
DANGER troller directly in a corner. Leave at least 8 inches (200
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 THREE-PHASE
POWER SUPPLY THAT PROVIDES EITHER 230
VAC OR 460 VAC AT 60 HZ, OR 220 VAC OR 440
VAC AT 50 HZ. IF CORRECT VOLTAGE IS NOT
AVAILABLE, IT WILL BE NECESSARYTO INSTALL
A TRANSFORMER BETWEEN THE POWER SUP
PLY AND THE CONTROLLER. DO NOT OPERATE
THE FLEXPAK PLUS CONTROLLER ON POWER
SUPPLIES WITH AVAILABLE SHORT-CIRCUIT
CURRENTS IN EXCESS OF 5000 AMPERES. DAM
AGE TO EQUIPMENT AND PERSONAL INJURY
MAY OCCUR.
Figure 3.1 Enclosure Mounting Minimum Distances
mm) from the top or 6 inches (150 mm) from the bottom of An isolation transformer is not necessary unless the
the enclosure. (Refer to Figure 3.1.) Heat builds up at the application conditions require one. However, its use pro
cabinet's top and may exceed the permissible inside vides distinct advantages. With an isolation transformer:
ambient temperature upper limit. At the cabinet's bottom,
the unit must be high enough to allow air to flow upwards. Personal injury is guarded against should accidental
contact be made with an electrical conductorfrom the
Guideline 3 Regardless of the above placement guide drive.
lines, the user is responsible for providing ambient
temperatures that meet the controller's specifications of A-c power line disturbances, or transients, are minim
0 to 55C (32 to 131F). This must be given careful ized by an isolation transformer, thereby reducing or
consideration especially to units located near the very top eliminating damage to other solid-state equipment
of the supplied enclosure. Relative humidity must be kept power-conversion components in the controller and
between 5 and 95% without condensation.
other user-equipment on the same a-c line.
The transformer provides electrical isolation bet
Guideline 4 Due to the U-shaped panel design of the
ween the a-c power lines and the drive motor. Damag
FlexPak Plus, the controller must be mounted in the verti
ing currents may be eliminted in instances where a
cal position to allow for proper cooling.
d-c output accidentally becomes grounded in a unit
The controller is also designed to allow for power wiring where the a-c electrical system is grounded.
to enter from the top and for control and signal wiring to
For detailed information, refer to Paragraph 3.4.
be routed in thru the openings in the sides of the con
troller or from the bottom. (Refer to Figure 3.2.)
Guideline 7 The National Electrical Code requires that
a three-pole, fused disconnect switch be installed on the
incoming a-c line ahead of the controller to provide
POWER
WIRING
branch circuit protection. The fuse should be Class K5.
A I L 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 connec
tors 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


.CONTROL AND
LEFT SIDE VIEW SIGNAL WIRING FRONT VIEW it is adequate to use a screw in the conduit box near the
motor.

Figure 3.2 Mounting and Wiring Orientations Guideline 9 A thermostat is used to guard against
motor overload protection, It is essential to properly con
nect the motor thermostat to connections 34 and 132.

Guideline 5 Do not route the tachometer feedback


signal cable, if used, with a-c or d-c control or power CAUTION: External overload devices must be con
wiring. Also use the specified wire for this funtion. nected between terminals 32, 33, 34 and 132. The
Guideline 6 Although auto-transformers may step up drive will not start without them.

and step down a-c power supply voltage, they do not


isolate the driven system from the a-c line. Users should
Refer to Figure 3.4 where a typical Operator's Station
consider using an isolation transformer if the application
schematic is shown.
conditions warrant it.
Guideline 10 When planning signal or control wire
If an isolation or auto-transformer is used ahead of the
runs, follow these practices:
controller, the disconnect switch should be placed on the
a-c power line between the power source and the trans Conduits should be steel.
former primary. Again, use a fused disconnect switch. (Do If these conduits cross 460 VAC conductors, make
not use a circuit breaker type switch because of the high sure the cross is at 90
inrush of transformer equipment.). Do not route signal wires through junctions or ter-

10
minal boxes that contain non-signal a-c or d-c 3.3 Power Wiring This Paragraph briefly outlines the
(115/230/460V) wires. procedures to be followed when wiring a-c power supply
lines to the controller and d-c control circuits to the drive.
Guideline 11 Operational altitude above sea level may
A basic connection diagram is given at Figure 3.4.
not exceed 3300 ft (1000 m). Derate horsepower 3% for
each 1000 ft (300 m) above this altitude.
DANGER
3.2 Mounting This Paragraph outlines the procedures BERORB WIRING, MAKE SURE THAT A-C LINE
to be followed to mount the FlexPak Plus controller. DISCONNECT SWITCH IS LOCKED OPEN. EVEN
IF POWER HAS NOT BEEN APPLIED TO THE
Determine the exact placement of the Chassis on the
Panel. (Refer to Figure 3.3 for mounting dimensions.) INCOMING LINE, THIS PRACTICE ASSURES
PERSONAL SAFETY. IF NO LOCKOUT DEVICE
Scribe the panel. Drill three holes large enough to accept
EXISTS, REMOVE THE FUSES WITH AN INSU
#10 mounting bolts. Scrape the paint around the holes to
allow washers and bolts to make a ground contact.
LATED TOOL AND PLACE. A WARNING TAQ, ON
THE BOX.

0.31 in. 5.44 in.


(7.8 mm) "1 (138.1 mm)
1
w
18.75 in.
(467.2 mm)
T

12.00 in.
(304.7 mm)

Ft -f\=t
0.31 in. (7.9 mm) J 7.00 in. 1.75 in.
(177.8 mm) (4.44 mm)
_ 10.62 in.
(269.9 mm)
FRONT VIEW

.3.5 in.. .3.5 in.


(88.9 mm) (88.9 mm)

maximum swing
projection 9.50 in
(241.3 mm)

11.38 in. SIDE VIEW


"X"
(288.9 mm)
3-10 HP

0.218 in. (5.53 mm) dia. mounting 8.00 in. @ 230VAC


holes (4) for hardware 0.19 in. (203.2 mm) 3-20 HP
(4.83 mm). Scrape point around holes @ 460VAC
to assure grounding.
-- 15-20 HP
9.50 in. @ 230VAC
(241.3 mm) 25-40 HP
MOUNTING HOLE DRILL PLAN
@ 460VAC

Avoid exposed electrical connections in this area below drive. Hinged door is conductive metal.

Figure 3.3 Mounting Dimensions

11
fftar

Notes:

1>These signals must be run in a separate magnetic conduit to


minimize the possibilityof noise pickup. (Referto Table 7.B for
wire specifications.)
2>Remove the connection between SPEED pot and terminal 426
when AUTO/MANUAL switch is used.
3>Motors with dual voltage shunt fields should be connected for
the rated controller voltage.
4>Remove jumper J9 from Regulator Module when Reversing
Contactor is installed.
Process Control 5>Use convenience terminals for #14 AWG maximum wire size.

Auto Reference 6>lf Auxiliary Panel is not used, user must supply an appropriate
Inputs M contactor. Refer to Paragraphs 2.4.4 and l/M D3955.

FIGURE 3.4 SYSTEM CONNECTION DIAGRAM

j j
WARNING
IN THE OPTIONAL BASIC DRIVE, THE USER
MUST INSTALL AN M CONTACTOR THAT HAS A
115 VAC COIL WITH A MAXIMUM CURRENT
DRAW OF 440 MILLIAMPS. THE CONTACTOR
ADAPTER KIT MUST BE INSTALLED WITH THE
USER'S M CONTACTOR. (REFER TO D-3955)
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. 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 recom
mended. 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.
USER
For applications using the 230V, 3-10 HP FlexPak Plus, CONVIENCE,
BLANK - .-* -^*
wires to the motor armature (A1 and A2) must be lugged TERMINALS
with the provided lugs, or equivalent, before connection RErtOTE-OPEft. BUFFE,
to the appropriate relay terminals.

WARNING Figure 3.5 Remote Operators


DO NOT ALLOW CONDUCTORS TO GROUND ON Buffer Terminal Markings
THE CHASSIS. CHECK INTEGRITY OF ALL WIRE
INSULATION BEFORE DRAWING. REMOVE ONLY 3.5 HP/Current Jumper It is necessary to inspect the
ENOUGH INSULATION TO MAKE A FIRM TERMI Current Scaling/Horsepower Jumper on the Regulator
NAL CONNECTION. PERSONAL INJURY COULD Module to be sure that it is connected correctly for a
RESULT IF A BARE WIRE TOUCHES THE specific drive motor.
CHASSIS.
Step 1 On the drive motor, locate the nameplate. Note
the full-load current.

3.4 Isolation Transformers Although an auto-trans Step 2 Or, if current is not shown on the nameplate,
former may be required because of a-c line voltage levels, refer to Table 3.A. Relate the columns in the table with
it is unable to provide a number of benefits standard with known motor data. Read across to the right column
an isolation transformer.
marked "Motor Current." This figure indicates the proper
The general requirements for an isolation transformer jumper connection to make on the Module where a cor
are: responding number is etched.

Three phase Table 3.A Horsepower Calibration


3 to 8% impedance
230 VAC Motor Current 460 VAC Motor Current
Nonregulated
HP Pin Connection HP Pin Connection
Sinusoidal output
50/60 Hz, as required 3 13 3 5.7
150% overload for 1 minute (max.) 5 19 5 10
7.5 27 7.5 13
Refer also to Table 2.D for specific information on trans 36 10 19
former sizing requirements. In the "Transformer" column
10
15 54 15 27
at the right, maximum kVA and rated kVA figures are listed 20 72 20 36
in relation to specific d-c motor hp/VAC ratings. 25 45-
30 54
Reliance Electric offers a number of isolation trans
40 72
formers suitable for use with the FlexPak Plus controller.
High HP units cannot be directly scaled to the lower HP units, above line,
due to current transformers ratios used in feedback loop.
13
|rn^y_,yiy<!^;y;Y-yjyLlW~^-T-'y-'*^'i

HP/SCALING PINS

Figure 3.6 Regulator Module, HP/Current Scaling Pins

Step 3 On the Regulator Module, locate the scaling Regulation Mode Jumper, one end of which is perman
pins. (Refer to Figure 3.6.) Near them, locate the black ently fixed to the Regulator Module, must be moved to one
pig-tail type jumper. Do not move it ifit is connected to the of two positions. Detailsof jumper placement are noted in
proper pin. Ifit must be reconnected, carefully liftconnec Section 7, D-3969.
tor housing straight up and off the pin. Slide the connec
tor straight down over the proper pin.
DANGER
IF YOU ARE UNSURE WHICH REGULATION
3.6 Regulation Mode Jumper The FlexPak Plus con
MODE A CONTROLLER SHOULD HAVE, IT IS
troller offers two types of drive regulation. The first, which
IMPORTANT YOU FIND OUT. IF THE JUMPER IS
is factory shipped, is armature voltage feedback (A).
NOT PROPERLY CONNECTED, PERSONAL IN
Optionally, the user may also use tachometer feedback JURY MAY RESULT.
(T) regulation. In order to use this modes, however, the

14
WARNING

DANGER equipped with a speed limiting device such as tachometer


loss and overspeed protection, armature voltage relays or
THE MACHINERY BUILDER IS RESPONSIBLE
a motor overspeed switch. (Assuming the drive equip
FOR INSURING THAT DRIVEN MACHINERY, ALL ment is operated on three phase power supplies listed
DRIVETRAIN MECHANISMS NOT SUPPLIED BY below.)
RELIANCE ELECTRIC AND PROCESS LINE
MATERIAL ARE CAPABLE OF SAFE OPERATION Rated Rated A-C Maximum A-C

AT MAXIMUM SPEEDS. FAILURE TO DO SO CAN Armature Line Line

RESULT IN DESTRUCTION OF MECHANISM OR Voltage Voltage Voltage


MATERIAL AND FLYING FRAGMENTS, ENDAN
240 volts D-C 230 volts A-C 253 volts A-C
GERING OPERATING PERSONNEL.
500 volts D-C 460 volts A-C 506 volts A-C
600 volts D-C 550 volts A-C 605 volts A-C
3.7 Overspeed The D-C motor is performance rated to
develop nameplate horsepower when operated at rated Ifthe above A-C and D-C voltage conditions are not appli
base speed. The base speed of the D-C motor is defined as cable to the installation in question, then it becomes the
the speed at which the motor will operate when excited responsibility of the user to calculate attainable motor
with rated armature terminal voltage, rated shunt field speed underthesinglecomponentfailurecondition using
current and when coupled to a driven load requiring rated the procedure outlined below and to verify that this speed
torque. The actual speed at which the motor will run under does not exceed the M.S.S. of the motor.
these conditions will fall within a range of +7.5% from
CHART I
nameplate base speed. Typical base speeds for industrial
D-C machines include 650, 850,1150,1750 and 2500 RPM. VAC = Nominal RMS line-to-line voltage
Sg = Base speed at full field and rated armature
Many D-C machines are also performance rated to oper
voltage
ate above base speed in a "constant horsepower" or "field
Eg (NL) = Armature voltage no load
weakened" mode. These D-C machines may be incorpo
MSS = Max safe operating speed
rated into adjustable speed drive systems which allow
S VAC q
controlled reduction in shuntfield current while maintain
MAX =1.49x Eg (NL) X B
ing rated armature terminal voltage. When so operated
The motor Maximum Safe Speed, which varies as a func
most of these motors will deliver it's rated horsepower at
tion of motor frame diameter, are listed below. Examina
any speed between base speed and the indicated maxi
tion of the motor nameplate may indicate a M.S.S. slightly
mum field weakened speed. A D-C machine with an 1150
different for that specific machine. In that case, motor
RPM base speed and the capability to be operated to 1950
nameplate M.S.S. takes precedence.
RPM in a field weakened mode will be nameplated
1150/1950 RPM. Reliance Maximum Reliance Maximum

Although rarely encountered, a single component failure


Motor Operating Motor Operating
Frame Speed, Frame Speed,
may occur within the drive controller that can apply arma
Size RPM Size RPM
ture voltages in excess of 100% rated armature voltage to
the motor, causing the motor speed to significantly 56 5500 B400ATZ 2760
exceed either base speed or rated field weakened speed. B160 5000 5200 B500ATZ 2650
Under these conditions, motor speed may be unrespon B180ATZ 5000 B580ATZ 2475
sive to the operators speed potentiometer and/or other B210ATZ 4500 B680ATZ 2100
speed references. Should such a condition occur, the B250ATZ 4500 B840ATZ 1720
drive must be quickly stopped using the appropriate B280ATZ 4500 B960ATZ 1600
"stop" pushbutton, and the fault condition located and B320ATZ 3600 B1200 1600
corrected before returning the drive to operation. B360ATZ 3400 B1400 1440
B1600 1200
During such a condition, the D-C motor, associated drive-
train equipment, driven machinery and the driven process
itself may be subjected to operating speeds well in excess CAUTION: Motor frames not listed in the above
of normal rated speeds. As such, the following considera tabulation, or motors manufactured by others, may
tions are necessary: not operate within their maximum safe speeds, when
a single point failure occurs. In these cases, it
All Reliance Electric Drive packages manufactured after
becomes the responsibility of the user to verify the
February 1,1982 (where the motor and controller are both
motor maximum safe operating speed and confirm
manufactured by Reliance Electric and furnished together
(using the procedure above) that attainable motor
on the same Reliance Sales Order) have a maximum safe
speed undera single point fault condition falls below
speed (M.S.S.) in excess of the speed that would occur
the maximum safe operating speed.
under the single point failure discussed above or are

15
SECTION 4
START-UP AND ADJUSTMENT
4.0 General This Section provides start-up and adjust Inspect the signal wiring from the Operator Control Sta
ment procedures to be followed after the assembly and tion. A series of wires will connect to individual terminals
installation of the controller is complete. All initial opera on a strip mounted on the Remote Operator Interface
tion checks and final adjustments to the controller must Module. (This Module is mounted on the Regulator
be made in conformance to the procedures, warnings and Module.) Determine that all wires are firmly seated in the
recommendations listed here. terminal strip. Make sure all wires are connected.

DANGER 4.2 Motor Ground Check It may be necessary to make a


THE FLEXPAK PLUS CONTROLLER IS AT LINE check of the drive motor to assure that no damaging
VOLTAGE WHEN A-C LINE POWER IS CON grounds other than earth ground exist within the
NECTED TO THE POWER UNIT INSIDE THE motor.
CONTROLLER. BEFORE WORKING ON, OR
TOUCHING ANY INTERNAL PARTS OF, THE CAUTION:Although a megger may be used for this
CONTROLLER, REMOVE INCOMING A-C LINE test, if one is used, all conductors between the drive
POWER AT THE MAIN DISCONNECT SWITCH. motor and the FlexPak Plus controller are to be dis
PERSONAL INJURY MAY RESULT IF THIS WARN connected and moved aside. The megger's high vol
ING IS NOT FOLLOWED. tage can cause damage to the controller's circuits.

DANGER
DURING INITIAL START-UP, THE CONTROLLER Step 1 Attach one lead from the ohm meter to the motor
AND ITS ASSOCIATED EQUIPMENT MUST BE frame to make a simple resistance check.
OPERATED AND/OR ADJUSTED ONLY BY QUAL
Step 2 Touch the test probe to each of the two power,
IFIED ELECTRICAL MAINTENANCE PERSONNEL.
two thermostat, and two field leads to the motor.
THESE INDIVIDUALS SHOULD BE FAMILIAR
WITH THE DESIGN AND OPERATION OF THIS If the reading to ground on any terminal is less than
EQUIPMENT AND WITH THE HAZARDS IN 100,000 ohms, a ground condition exists.
VOLVED. PERSONAL INJURY AND/OR DAMAGE
Step 3 If a ground condition exists, inspect the motor
TO THE CONTROLLER COULD RESULT FROM thoroughly for internal shorts.
UNFAMILIARITY.
Step 4 When the grounding condition is corrected,
4.1 Power Off Inspection It is necessary to make a reconnect the conductors from the FlexPak Plus con
superficial inspection of the FlexPak Plus controller and troller.
its associated units. The purpose of this check is to look
for possible physical damage or improper connections. 4.3 Power On Adjustments Once all the preliminary
Inspect all plug-in Modification Kits. Test each for a firm power-off static adjustments have been performed with
mounting condition. acceptable results, the a-c line power is to be applied to
the controller, but the load is not connected. It is impor
Each should be mechanically connected to the Regulator tant to follow these steps closely. Observe all cautions
Module by means of a mounting post screw. Each should and warnings.
be electrically connected to the Module by a series of
parallel pins. Ifany of the pins are bent, improper opera
tion results. Examine the pins to make sure thay are per DANGER
fectly parallel. Only one pin may fit through a hole in the WITH A-C POWER APPLIED AND WITH THE
Kit. POWER ON/OFF SWITCH IN THE ON POSITION,
Inspect all screw terminal connections on the Modifica HAZARDOUS VOLTAGE EXISTS IN THE CON
tion Kits. Make sure the wires are firmly connected. Also TROLLER. EXERCISE EXTREME CAUTION WHEN
make sure that there is enough insulation on the wires to PERFORMING THESE TESTS. PERSONAL IN
JURY CAN RESULT.
prevent a short between the conductors.

17
DANGER DANGER
IF CIRCUIT BREAKER HAS TRIPPED OR FUSES USE ONLY ONE HAND TO HOLD THE SCREW
HAVE CLEARNED THE FIELD SUPPLY, ITS WIR DRIVER. KEEP YOUR OTHER HAND BEHIND
ING MUST BE INSPECTED FOR DAMAGE. RE YOU. DO NOT USE YOUR OTHER HANO TO
APPLYING POWER TO THE DRIVE, THE FIELD BRACE YOURSELF AGAINST THE CONTROLLER,
VOLTAGE MUST BE RE-CHECKED FOR PROPER PANEL OR ENCLOSURE. PERSONAL INJURY
VOLTAGE AT MOTOR TERMINALS F1.F2. IFTHIS COULD RESULT IF YOU ACCIDENTALLY TOUCH
VOLTAGE IS BELOW 90% OF THE FIELD VOL A COMPONENT AT LINE VOLTAGE.
TAGE SPECIFIED ON THE MOTOR NAMEPLATE,
THE DRIVE MUST NOT BE STARTED UNTIL
PROPER VOLTAGE IS OBTAINED. FAILURE TO
FOLLOW THIS PROCEDURE COULD RESULT IN 4.3.2 Maximum Speed (Voltage) The Maximum Speed
OVERSPEEDiNG THE MOTOR AND/OR THE Potentiometer on the Regulator Module has been factory
MACHINERY COUPLED TO THE MOTOR SHAFT preset for 70% of a typical motor base speed of about 1750
AND POSSIBLE FATAL INJURY. 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 70 to 100% of rated speed.
4.3.1 Regulator Module Pots The Regulator Module has
six adjustable potentiometers mounted on it. (Refer to The method for determining if the motor and driven
Figure 4.1.) They control the following functions: equipment are operating at an acceptable maximum
speed for the application is measure speed with a
Maximum speed (full CCW: 50 - 70% speed)
tachometer.
Minimum speed (full CCW: Drive Min. Speed 5%)
Acceleration rate (full CCW) Locate the Maximum Speed Potentiometer on the Regula
Deceleration rate (full CCW) tor Module. (Refer to Figure 4.1.) The letters MAX SPD are
Current limit (factory-set at 150%) printed on the Module. Note that CW rotation represents
IR comp (full CCW) an increase in speed. CCW represents a decrease.

The potentiometers are factory preset for the safest or


most conservative operation.
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
MAX SPEED DAMAGE AND SERIOUS PERSONAL INJURY
COULD RESULT.

MIN SPEED
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
ACC RATE exceeds the maximum acceptable speed, immediately
decrease the maximum speed on the SPEED dial. Use a
small insulated slot screwdriver.
DECL RATE
In some cases, to avoid exceeding the maximum operat
ing speed, it may be necessary to turn the Maximum
Speed Potentiometer completely CCW before turning the
CURRENT LIMIT SPEED dial completely CW.

If the 10 setting on the SPEED dial is lower than the


desired speed, increase the setting on the Maximum
IRCOMP
Speed Potentiometer to the necessary speed. To increase
the maximum speed, turn the potentiometer CW.

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
Figure 4.1 Regulator Module Potentiometers active; a change in one affects the other.

18
4.3.3. Minimum Speed (Voitage) The Minimum Speed 4.3.5 Current Limit Although it will probably not be
Potentiometer on the regulator has been factory preset necessary to make any adjustment in the factory-set cur
for drive minimum speed, 5%. By means of adjustment, rent limit value of 150% of rated load, it is possible to
this speed may be raised or lowered. The result is the change this governing value. (Individual application
lowest moving speed the operator can set on the SPEED speed changes or load changes on sustained overloads
dial. The control range is 5% to 30% of rated speed. may require readjustment. Also, applications requiring
torque limiting or accelerating of high inertia loads may
Again, the motor speed can be determined with a
tachometer.
require a change from this value.)
To reduce the torque output of the drive, turn the Current
With the SPEED dial at zero postion and using a small,
insulated slot screwdriver, carefully turn the Minimum
Limit Potentiometer CCW. Note, however, that turning
Speed Potentiometer until the desired minimum is
CCW too far may prevent the drive accelerating to the
desired speed.
reached. Note that CW represents an increase; CCW
represents a decrease.
4.3.6 IR Compensation IR (voltage) Compensation is a
NOTE: Carefully recheck the maximum speed adjust feature which makes up for the armature resistance of a
ment for desired setting. Since the maximum and min motor that causes a drop in speed as the load is increased.
imum speed adjustments are interactive, a change in one The IR Compensation Potentiometer is factory-set at
affects the other. At times, it may be necessary to work zero. The IR compensation feature can be adjusted
back and forth for precise adjustments. between O and 12% of rated load and is used only for a
voltage regulation mode. When using a tachometer feed
back, the IR Compensation Potentiometer must be turned
4.3.4 Acceleration and Deceleration Rates The Accel completely CCW.
eration and Deceleration Rate Potentiometers on the
Regulator Module have been factory preset for a typical CAUTION: Ifthe IR Compensation Potentiometer is
linear acceleration rate of six seconds to maximum and set too high, motor speed rising characteristics may
minimum speed. This time can be adjusted over a range of result. Instability and oscillation in motor speed will
0.5 to 30 seconds from a fully stopped condition. result.

19
SECTION 5
TROUBLESHOOTING
5.0 General This Section details troubleshooting size of a digital voltmeter. The Diagnostor will exer
information for the FlexPak Plus controller. Its organiza cise the regulator module and the digital driver board
tion is as follows: and logically determine the operating conditions of
these modules. It also has the ability to analyze the
General troubleshooting concepts (Paragraphs 5.1,
5.2, 5.3 and 5.4) power bridge circuitry while the drive is operating and
determine if a problem exists within the power bridge
Specific symptom/probable cause/recommended
procedures (Paragraph 5.5)
area. The diagnostor uses a LCD to visually enunciate
the logic output condition of its test. Two terminals
Reference schematics, photos and diagrams of the
coupled with specified pushbutton positions on the
controller (Paragraph 5.6)
Diagnostor faceplate allow access to various wave
DANGER
forms and voltages within the controller via a scope or
meter to assist in troubleshooting the drive.
CONTROLLER EQUIPMENT IS AT LINE VOLTAGE
WHEN A-C POWER IS CONNECTED TO THE The test meter adapter kit provides a convenient
POWER UNIT IN THE FLEXPAK PLUS CON means of monitoring voltage on the regulator module
TROLLER. THUS, A-C POWER MUST BE RE with an external user supplied voltmeter (Refer to
MOVED FROM THE UNIT BEFORE IT IS SAFE TO Instruction Manual D-3970)
TOUCH THE INTERNAL PARTS OFTHE FLEXPAK
PLUS. PERSONAL INJURY MAY RESULT UNLESS
POWER IS REMOVED. 5.1 Wiring Errors The single most common problem
preventing normal d-c drive operation is incorrect wiring
within a system. A maintenance person should spend at
DANGER least five minutes carefully looking over the wiring before
THE FLEXPAK PLUS CONTROLLER SHOULD BE taking active steps involving tests and replacement.
SERVICED ONLY BY QUALIFIED ELECTRICAL Remember that a loose or grounded wire can occur in a
MAINTENANCE PERSONNEL FAMILIAR WITH controller that had previously been functioning correctly
THE CONSTRUCTION AND OPERATION OF ALL if initial wiring techniques were poorly performed.
APPLICATION EQUIPMENT IN THE SYSTEM.
PERSONAL INJURY AND/OR EQUIPMENT DAM
Forthosenotfamiliarwith proper FlexPak Plus controller
wiring, other Sections in this manual may be consulted.
AGE MAY OCCUR IF INDIVIDUALS ARE NOT
For more complex problems, Section 7 may be used to
FAMILIAR WITH THE HAZARDS RESULTING
uncover wiring problems in the optional Modification
FROM IMPROPER OPERATION.
Kits.

In addition to step-by-step troubleshooting procedures, 5.2 A-C Line Problems The following are typical prob
lems located on the incoming a-c line:
there are some generalized comments that should be kept
in mind at all times. These may be divided into wiring A-c line voltage incorrect for the specific controller,
errors (Paragraph 5.1), incoming a-c line problems (Para which may operate on 230 or 460 VAC @ 60 Hz.
graph 5.2), motor problems (Paragraph 5.3) and mechan Main disconnect switch contains fuses improperly
ical problems (Paragraph 5.4). rated for the drive. (The fuses must be large enough to
A number of optional kits have also been developed to prevent nuisance tripping yet small enough to protect
the circuit and equipment on the circuit.)
assist in troubleshooting the drive. These are:
A-c conductors must be of adequate size for the
Status/Diagnostic indicator kit which installs on the application.
faceplate of the drive & utilizes a LCD to visually If an isolation transformer is used, it must be sized
enunciate 13 critical drive functions in regards to their according to the requirements of the drive system.
status as well as indicating the specific fault area. The transformer itself must be wired for the correct
(Refer to Instruction Manual D-3963). output voltage (230/460 VAC) in relation to the Flex
The Diagnostor which is a portable device about the Pak Plus controller.

21
5.3 Motor Problems Do not overlook the possiblity that 5.4 Mechanical It may be that the malfunction is a
the malfunction may be located in the drive motor. The simple mechanical problem. The load on the drive motor
following steps should become part of a troubleshooting may be too large, or it may have too high an inertia. The
routine: results are long stopping times and current-limit starting
demands. Thus, the freedom of motion of the load device
Recheck all motor connections for firmness and cor should be considered.
rect identification.
5.5 Controller Malfunctions Table 5.A presents an
Check that no obvious grounds have occurred on any organized troubleshooting sequence based on a symp
of the wires. However, do not use a megger when tom/probable cause/suggested procedure approach.
checking for grounds unless the motor wiring to the They develop from the most simple, obvious malfunction
FlexPak Plus controller is completely disconnected. to more complex ones.
A volt-ohmmeter (VOM) may be used for ground 5.6 Schematics, Diagrams In order to aid with the trou
checking without disconnecting conductors to the bleshooting process, various schematics and diagrams
FlexPak Plus controller. are included. Note that these drawings are the latest revi
sions as of the date of publication of this manual. The
Check the field windings for open or short conditions.
manufacturer cannot guarantee that subsequent changes
Check continuity through the armature and brushes. will not occur; although, if any do, they should be minor.
Use terminals A1 and A2 at the Controller as test In cases of doubt, contact your local Reliance Electric
points. Sales Office.

BIDIRECTIONAL CONTROL CIRCIKT


(SMUFIEO) -CONTROL
POWER

unidirectional control circuit


csovufied)
DRIVE
THERMOSTAT

THERMOSTAT
pn norm s%x
*\j' THERMOSTAT V
D*--
-x. BLOWER MOTOR/*
r THERMOSTAT^
*J\*~ WWW- <m -r- INTERLOCK V
W
flQ 0**
.. BLOWER MOTOR/,,
-v. OPERATOR'S^.
t- INTERLOCK *v*
*Y INTERLOCK %?'
iiD t>
jf- INTERLOCK x^'
12D6 3<-

JOGO * COILS ARE EITHER


* COIL IS EITHER FH OR FPR
RH.FftORRPR.Fffl.
DEPENDING ON ASSEMLV DEPENDING ON ASSYB
JOGO
O TERMINAL
D WIRE WRAP PM

Figure 5.1 Unidirectional Control Circuit (simplified) Figure 5.2 Bidirectional Control Circuit (simplified)

22
TABLE 5.A TROUBLESHOOTING SUGGESTIONS FOR THE COMPLETE CONTROLLER

Symptom Probable Cause Recommended Procedures

POWER ON/OFF Incorrect wiring con .,. DANGER- ..


circuit breaker nections to controller; IF CIRCUIT BREAKER HAS TRIPPED OR FUSES HAVE CLEAR ED, THE FIELD SUP
trips or fuses from controller to PLY AND ITS WIRING MUST BE INSPECTED FOR DAMAGE. AFTER RE-APPLYING
clear when power motor; in motor. POWER TO THE DRIVE, THE FIELD VOLTAGE MUST BE RE-CHECKED FOR
is applied. PROPER VOLTAGE AT MOTOR TERMINALS F1, F2. IF THIS VOLTAGE IS BELOW
90% OF THE FIELD VOLTAGE SPECIFIED ON THE MOTOR NAMEPLATE, THE
DRIVE MUST NOT BE STARTED UNTIL PROPER VOLTAGE IS OBTAINED.
FAILURE TO FOLLOW THIS PROCEDURE COULD RESULT IN OVERSPEEDING
THE MOTOR AND/OR THE MACHINERY COUPLED TO THE MOTOR SHAFT AND
POSSIBLE FATAL INJURY.

Remove a-c power at the disconnect.


Remove leads to L1, L2, L3, A1, A2 and F1, F2, on incoming side of controller's
respective location.
O Open the power disconnect switch.
Check for a ground condition at L1/181, L2/182, L3/183, A1, A2, F1 and F2. Do this at
controller (internal) side of 1TB. If a ground is discovered, check wiring
connections on Power Cube and motor field terminals F1 and F2.
O If no ground exists, examine the controller chassis for loose wires and/or foreign
objects.
D If no ground exists and if no foreign objects are discovered, reconnect the incoming
conductors A1, A2 and F1 and F2. Then check for grounds at these terminals.
D If a ground is found, it is in the conductors to the motor or in the motor itself.
Disconnect the motor from the conductors at the drive motor.
D Test A1, A2, F1 and F2 conductors for a ground. (If one exists, examine connections and
insulation for areas where shorts could occur.)
Ifno grounds are found in the conductors, check the motor for a ground condition. If a
ground is located here, examine and/or replace the motor, as necessary.
Short in Power Cube. D Replace Power Cube.
Short in Field Supply. D Replace Field Supply.
2. Drive motor does Main a-c line discon Check disconnect switch, fuses in it, and voltage on line.
not start. nect not closed; or fuse
blown; or no power
applied ahead of
disconnect.

Drive interlocks pre D Verify that all user-installed interlocks are in a state (physical condition and wiring
venting operation. connections) to allow a start.
32 to 33 on TB

Drive motor thermostat a Check connections to thermostat: at drive motor P1, P2; at controller 34. 132.
wires not connected Check for open thermostat inside motor. Make a resistance check of thermostat. (It
on FlexPak Plus control should read a short, or low resistance, if it is closed.
ler terminals 34 and
132onTB.

External overload Check connections to external overload. (Blower Motor Starter O/L)
wires not connected on Checkforopenoverload. Make a resistance check to overload. (Itshould reada short,or
FlexPak Plus controller low resistance, if it is closed.)
terminals 34 and 33
on TB.

Drive thermostat Check connections to thermostat at drive power bridge heat sink at controller
wires not connected on 132 or 232.
on FlexPak Plus Check foropenthermostat. Make a resistance checkto the thermostat. (Itshould read a
controller terminals short, or low resistance, if it is closed.
132 to 232

3. In non-reversing Faulty M Open the power disconnect switch.


controllers only . . . contactor. Q Examine M contactor for firm seating.
Controller's M P On the M contactor, connect an ohmmeter on 139 and 39 Wires.
contactor not picking The reading should be 150 to 1000 ohms
up when START Ifthese readings cannot be obtained, replace the Mcontactor. (Refer to Table 6.A.1
switch is pressed
(closed).

Faulty start/ D Check START/STOP switch, but first remove a-c line power at main disconnect.
Stop switch. Connect ohmmeter to terminal 32 on the Remote Operator Adapter.
D Touch probe to terminal 38 on the Remote Operator Adapter.
Place switch in the START (closed) position.
D If the switch is properly functioning, a short will be seen on the meter.
Check thee STOP function. Place the RUN/JOG switch in the RUN position. Connect the
ohmmeter to terminals 32 and 35. Place the switch in the STOP position, which should
open it ifit is functioning correctly. Ifthere is a short, it willbe seen on the meter. Ifthere is
no short, the circuit is opened, and the switch is functioning correctly.
a Using similar techniques, test the RUN/JOG switch in the RUN position at terminals 32
and 35. When the switch is in the RUN position, a short should be read.

23
TABLE 5.A TROUBLESHOOTING SUGGESTIONS FOR THE COMPLETE CONTROLLER (Continued)

Symptom Probable Cause Recommended Procedures

4. In reversing con FORWARD/REVERSE D Examine Remote Operator Adapter on Regulator Module for firm seating and proper
trollers only... switch malfunction. wiring and pin connections.
Controller's M Test FORWARD/REVERSE switch. Use basic technique outlined above for the
contactor not START/STOP switch.
picking up when
START switch is
M contactor On the Auxiliary M pins located on the Regulator Module, connect an ohmmeter. Place it
pressed (closed).
malfunctioning. on the pin 39 and pin 67.
Place the FORWARD/REVERSE switch in the FORWARD position. The reading should
be approximately 150 to 1000 ohms if it is operating properly.
Without changing test points, place the switch in the REVERSE position. The reading
should be .between 150 to 1000 ohms, if it is operating properly. If a short is observed,
remove jumper J9 and repeat the test.
Ifa 150-1000 ohm resistance reading cannot be obtained when the switches are open, the
M contactor is malfunctioning and must be replaced.

5. M contactor picks RUN/JOG switch is Place the RUN/JOG switch in the RUN position.
up but remains in JOG position.
in only when
CR relay not picking up. Connect a volt-ohmmeter on the Remote Operator Adapter. Place it on terminal 35.
START push Connect the second probe to conection 139 connected to the FlexPak Plus M
button is pressed
contactor.
and held in.
The reading should be +24 VDC for normal operation.
D Next, shift the probe from terminal 35 to terminal 38 on the same terminal board. However,
leave the second probe where it is.
D Press the START switch. The reading should be approximately 24 VDC for normal
operation.
D Press the START/STOP switch to STOP, and then START. A 24 VDC (approximately)
reading should continue to appear. If it does not, the CR relay is not picking up. In this
case, replace the Regulator Module.
Drive motor does No input signal from If the controller does not have an optional AUTO/MANUAL switch, inspect the Regulator
not run, but M SPEED potentiometer Module to determine that jumper J4 is In place. (The jumper is removed when the AUTO/
contactor and on Control Station. MANUAL switch is installed.)
CR pull up. Check the SPEED potentiometer on the Control Station. First, open the power
disconnect switch.
(Use this proce Connect a volt-ohmmeter to the Regulator Module Remote Operator Adapter inputs.
dure only if con Connect one lead to terminal 28. Connect the other to terminal 20. (Refer to Figure 3.4
troller does not for a Remote Station.)
have optional Test D For proper operation, the reading should be 5K ohms.
Meter Adapter D Disconnect the VOM lead from terminal 20. Connect it to terminal 426.
Kit.) Turn the SPEED potentiometer from 10 to 0. The resistance should vary from 5K to 0
ohms. If it does not, replace the potentiometer.
7. Drive motor does No input signal from First check the main power supplies. This must be done with power applied to the FlexPak
not run, but M SPEED pot. Plus controller.
contactor and
DANGER
CR pull up.
THE PROCEDURE DESCRIBED HERE IS PERFORMED WITH LIVE A-C VOLTAGE
(Use this proce APPLIED TO THE CONTROLLER. USE ONLY ONE HAND TO APPLY VOM LEADS/
dure only if PROBES. KEEP YOUR OTHER HAND BEHIND YOU AT ALL TIMES. DO NOT HOLD
controller has ONTO THE CONTROLLER FOR SUPPORT. PERSONAL INJURY MAY RESULT
optional Test IF THESE PRECAUTIONS ARE NOT TAKEN.
Meter Adapter
Kit.) D Connect one lead of volt-ohmmeter to test pin 357 on the Test Meter Adapter Module,
a Connect the second lead to test pin 356 on the Module.
The reading should be within the range of 10.8to 11.5VDC for normal operation.
D Next, remove the lead from pin 356. Place it on pin 456.
D The readingshould be within the range of +16to +28 VDC for normal operation.
D Next, remove the lead from pin 456. Place it on pin 471.
D The reading should be within the range of -16 to -28 VDC for normal operation.
D Ifthe proper readings are obtained, the powersupplies may be assumed to be operating
correctly.
If incorrect reading are obtained, replace the Regulator Module.
Next, check the reference voltage input signal. (This changes in direct proportion to an
increase of SPEED potentiometer voltage caused by a turning of the dial.)
Connect one lead of a volt-ohmmeter to pin 357 on the Test Meter Adapter Module.
D Connect the other lead to pin 826. Readings vary from 0 to +8.2 VDC, depending on the
set point of the SPEED potentiometer dial.
D If no voltage is noted between pins 357 and 826, check to see if jumper J4 on the
Regulator Module is properly placed/removed for the specific controller. (It is to be in
place, as factory-shipped, if there is no AUTO/MANUAL switch. It is to be
removed if there is an AUTO/MANUAL switch.)
D If the SPEED potentiometer is functioning normally, and if the J4 jumper is
placed/removed, as necessary, replace the Regulator Module.

24
TABLE 5.A TROUBLESHOOTING SUGGESTIONS FOR THE COMPLETE CONTROLLER (Continued)

Symptom Probable Cause Recommended Procedures

8. Drive motor does No output from Examine armature wiring. First, open the power disconnect switch.
not run with M Power Cubes, Check armature wiring for loose connections.
contactor picked up. 45-47. D Turn a-c power on again. ^
Potentiometer DANGER
properly operating. THE PRECEDURE DESCRIBED HERE IS PERFORMED WITH LIVE A-C VOLTAGE
APPLIED TO THE CONTROLLER. USE ONLY ONE HAND TO APPLY VOM LEADS/
PROBES. KEEP YOUR OTHER HAND BEHIND YOU AT ALL TIMES. DO NOT
HOLD ONTO THE CONTROLLER FOR SUPPORT. PERSONAL INJURY MAY
RESULT IF THESE PRECAUTIONS ARE NOT TAKEN.

a Connect a volt-ohmmeter to terminals 47 and 45 on TB.


Place the START/STOP switch in the START position.
D Increase the speed reference by turning the SPEED dial in the direction of 10.
The reading across 47 and 45, it may be 0 to 240 VDC for 230 VAC controllers. It
Continue this should be 0 to 500 for 460 VAC controllers.
symptom on next D If no reading is obtained across 47 and 45, it may be necessary to replace the Power
page Cubes and/or the Regulator Module, digital driver module. In order to determine which,
read on.

Regulator D Test the regulator module for output to digital driver module (PREF).
module suspected Turn power off. Open main disconnect.
because no output Connect a VOM, careful not to short pins together to terminals 280 (PREF) & 57 (OV)
reading at 45-47. on the regulator module.
Restore power to controller.
Place the start/stop switch in start position,
a Turn the speed pot to full on position.
D Voltage on VOM should be +5 volts.
D If this reading cannot be obtained replace regulator module.
Digital driver module D Test the digital driver for firing pulses. (Note: Make sure above test on regulator
suspected because no module has been completed first.)
output reading a Turn power off. Open main disconnect.
at 45-47. Loosen regulator/digital drive module assembly (four screws in each corner. So that
access to digital driver module on back side of assembly is possible. (Refer to
Figure 5.7.)
Connect scope common to Pin 57 on regulator module.
Connect scope probe to resistor on primary side of pulse transformer located at 7A or
Digital Driver Board (Refer to Figure 5.4.)
D Restore power to controller.
D Place the start/stop switch in start position.
D Turn SPEED POT to full on position.
A firing pulse waveform (+11.2V) should be seen at this point. If pulse is
measured continue this test from beginning but connect scope across the following
resistors to look at other five firing pulses. (14A, 10A, 11 A, 13A, 8A).
a If these readings cannot be obtained, replace digital drive module.
Power cubes a Establish that power cube is receiving pulse inputs from digital drive module. (Refer to
suspected because no above previous test.)
output reading D If power cubes are receiving pulses, yet no reading across 45 - 47, determine that
at 45-47. the contacts on M are closing.
D Replace drive motor wiring with light bulbs (2 light bulbs for 240 volt, 4 light bulbs for
500 volt armatures, series connection.)
a Run drive and look at waveform across light bulbs. (Should be six pulse/16.7 MSEC)
If pulse is missing indicates bad power cube.
Q Check individual power cubes.
D Connect scope across 51 & 47 on terminal strip look to see if SCR is switching if not
replace power cube.
D Repeat for 51 & 45, 52 & 47, 52 & 45, 53 & 47 & 53 & 45 if necessary.
9. Remote Operator Malfunctioning D Check START/STOP switch, but first remove a-c line power at main disconnect.
Control Station switches. D Connect ohmmeter to terminal 32 on the Remote Operator Adapter.
functions not a Touch probe to terminal 38 on the Remote Operator Adapter.
operating. Place switch in the START (closed) position.
a If the switch is properly functioning, a short will be seen on the meter.
Check the STOP function. Place the RUN/JOG switch in the RUN position. Connect the
ohmmeter to terminals 32 and 35. Place the switch in the STOP position, which should
open it if it is functioning correctly. If there is a short, it will be seen on the meter. If
there is no short, the circuit is opened, and the switch is functioning correctly.
D Using similar techniques, test the RUN/JOG switch in the RUN position at terminals 32
and 35. When the switch is in the RUN position, a short should be read.

25
MhV

"*rt inrewcwt.

Figure 5.3 Regulator Module

RESISTORS
ON PRIMARY SIDE
OF PULSE TRANSFORMERS

Figure 5.4 Digital Driver Module

26
4FU, 5FU, 6FU OPTIONAL INCOMING LINE
INCOMING -CIRCUIT BREAKER
LINE FUSES

Figure 5.5 CB/Fuse Locations

27
M CONTACTOR

PILOT
RELAY

DV/DT
MODULE

INCOMING
LINE FUSES

Figure 5.6 Top View of Controller

REGULATOR MODULE
STATUS/DIAGNOSTICS INDICATOR
&
DIAGNOSTOR INPUT CONNECTOR

REGULATOR/
DRIVE
ASSEMBLY
MOUNTING
REGULATOR/ SCREWS
DRIVE
ASSEMBLY
MOUNT
SCREWS

FIELD
SUPPLY
BRIDGE

Figure 5.7 Bottom View of Controller

28
'HI "") ^

DANGER
DISCONNECT ANP 0VERCUB3ENT
PROTECTION REQUIREO PER
CEC AND SEC.SEE SH.9 FOR
DETAILS. <B

TO PTLCT fELMT
CAJttXS) SH.1

BONDED
10
PANEL

^>FOR NOTES SEE SHEET 10& l|.


J WIIGMT-
1 to:, ru 04UJ4. B FASTON y WIRE WRAP CONNECTOR >- RIBBON CABLE SOCKET
J no* 3iawii:o.
ffi TALL WIRE WRAP PIN O TERMINAL CONNECTOR -^ RIBBON CABLE PLUG
d; O STa WIRE WRAP PIN

W/D 30070-1 (Sheet 1 of 13)

Figure 5.8 230 VAC Controller, Power Bridge Schematic


168,^ TO PILOT RELAT
^ CARDCS) SH.1
A

BONDED
10
PANEL

> FOR NOTES SEE SH.IO& II.


B FASTON ~}- WIRE WRAP CONNECTOR >- RIBBON CABLE SOCKET
J MOM OIAWIMC.
S TALL WIRE WRAP PIN O TERMINAL CONNECTOR -> RIBBON CABLE PLUG
O STa WIRE WRAP PIN

W/D 30070-2 (Sheet 1 off 13)

Figure 5.9 460 VAC Controller, Power Bridge Schematic

j j
o

CO

^> FOR NOTES SEE SHEET 10 4 II.

TO OPTIONAL STATUS CARD SH.7

W/D 30070-2 (Sheet 2 of 13)

Figure 5.10 Controller Regulator Module & Digital Driver Module Schematics
MO. fWCL CONTACTOR WRIHG
FORASSCKfL* f'S eOI5M-SE.SK
UNIDIRECTIONAL CONTROL CIRCUIT
AUX. PANEL CONTACTOR WRING (SIMPLIFIED)
FOR ASSEMBLY f S 6M566- SB 4 CONTROL -CONTROL
"' POWER POWER

-n2-
TO
CONTROL J
pM I
j f 0- 232 _= DRIVE

I39CORG3
S_f-"t_- 1 THERMOSTAT

-&- 112

TO
REGULATOR
CARD - Fit
-*f-
,

fn=|:<io Ch'TIONAL
AUX.
CONTACT T
112
tk O MOTOR
/lr- THERMOSTAT^'
Xi, "
SH.2 Hl- I FN 16
FN I Oil
-if-
-J-AUX.
!2___ _0R6
J____L
-&I \I YEL FN .T. BLOWER MOTOR^-j
I- INTERLOCK ^
TO
II-
REGULATOR BLUI I BLU :% OPERATOR*
"
AD
^3,
,|- INTERLOCK ^-w
rjiAUX. FN

r-fi
L^ORGji_.^RM;._1J
t. -<.M2
OPTIONAL
AUX. M KIT
sm-
PILOT RELAY CARD
8/M 0-54115-1
12

12
h_iwrL>^_g^M 9 J.
STOP, L@_] ril.,9
(705385-75)
zxe^ r4
(705388-3)
(SEESH.5)
Wli 15 * COIL IS EITHER
EITHER FN
FN (OR FPR
TO ^O DI \' DEPENDING ON ASSG
DEPENDING ON ASSEMBLY
REGULATOR _, !r__-_>!--.. JOG O
CARD
!*_*- jj. j
SH.2
4-4--'> _^
Lj?--_, I ______
66-GRV J 168 BIDIRECTIONAL CONTROL CIRCUIT
OPTIONAL ( SIMPLIFIED)
__,-.2M
REVERSING KIT 189
J *' OPTIONAL Y POWER
(705185-75)
AUX. PANEL WIRING WITH
OPTIONAL REVERSING KIT (705385-75) ^rV8 CONTACT KIT
r ir- I (705188-1)
i DRIVE
I C5260 THERMOSTAT
ORG _ -"N i
-*--( RPR J---9

'5_-
*__* RM
_tEL _*_:_.
TO
REGULATOR JtirV. BLU _ 2Q O---
CARD
RM O MOTOR ^,
SH_2
viol 10 . rlj- THERMOSTAT^'
14 0
_6R_M CRY
CRY mD-
.1. BLOWER MOTOR/
'* INTERLOCK ^
iiD 0"
DYNAMIC BRAKING RESISTOR KIT (80W55-4)
(INITIAL CURRENT OF ISO* DERATED IA)

HP

1
5
RE. VALUE
(OHMS)
9.420
5.930
RELIANCE
PART NO
H8267-L
48267-J
QUA
WAn-SECONDS
S 175 C
2.466
1.937
T2
12D C_i_>

7.5 3.819 48267-6 6,212


10 1.044 48267-F 7.98i
48267-D 12.981 * COILS ARE EITHER
IS 1.912
RM.FM.OR RPR.FPR.
20 1.521 HB267-C 16.355 DEPENDING ON ASSVi

O TERMINAL
D WIRE WRAP PIN

>F0R NOTES SEE SH.D&II.

W/D 30070-1 (Sheet 3 of 13)

Figure 5.11 230 VAC Auxiliary Panel Assembly Schematic


^) "1 ")

AUX. PANEL CONTACTOR WIRING

UNIDIRECTIONAL CONTROL CIRCUIT

TO
FPR
r^_=H__i CONTROL
" POWER
(SIMPLIFIED)
CONTROL
POWER

-ir- 0-
-c
CONTROL 212
XFMR. DRIVE
SH.I THERMOSTAT

2Z_f 112

I
r-,* -*-
FHzj=<30 112
P MOTOR /3|
_/t_r- THERMOSTAT^
139. XJ I

FH
14 JP
.1. BLOWER t-OTOR.
FN 16

' yelI "- INTERLOCK <*


TO IH
REGULATOR I BLul 11D 6"
CARD
FN ._. OPERATORV.i
SH.2 ,'- INTERLOCK V?'
-yf- 12I
65 I I 6RY1 I START
PILOT RELAY CARD ^ -*
B/N 0-54315-1
^-i_> QI39
RUN ,5 CR

L. |_j JOG O

__l : __!! -4~


.____-. J
BIDIRECnONAL CONTROL CIRCUIT
OPTIONAL .-261 ( SIMPLIFIED)
REVERSING KIT
(705385-76) J 'OPTIONAL -CONTROL

232 z
CO AUX. PANEL WIRING WITH
CO OPTIONAL REVERSING KIT (705385-76) RNJ-<<_0
"N-^-V* AUJL KIT
CONTACT V POWER
D-
I (705388-1)
,FM AJfr) DRIVE
G260
-70U-1 r--Q- ORG
-A--HRPR/---9
THERMOSTAT

RM
67 .YJ-L A._
TO 132
_rm REGULATOR
^FN CARD % 8i D (
O MOTOR ,
SH.2
19 yioj ru- THERMOSTAT^'1
(Sdbi
r'rT
N, MOTOR 66 GRyI 14 Q- Hf-iw"'
OPTIONALVWURE PILOT RaAY CARD

X
.1. BLOWER MOTOR/,,
B/M 0-54335-1 ** INTERLOCK V*
J! RESISTOR
-<*)13
ID82~|
<J)D82~ .J*. OPERATOR'S^.,
rt- INTERLOCK V?1
J9 MUST BE OPEN . -_|( .
DYNAMIC BRAKING RESISTOR KIT (801455-
32U 6 FWD W 66 f 39 39 ^v
_RM I (INITIAL CURRENT OF ISO* DERATED IA> - CO-* *(fprV-*--
I START
RES VALUE RELIANCE TOTAL WATT-SECONDS
HP QUA CONNECTION
(OHMS) PART NO OHMS 9 375C
45/S2
1 20.87 48267-P SERIES 41.74 4.090
-9 HI- A-fv)""AUX.PANELr""
AUX.PANELl 5 12.06 48267-M SERIES 24.10 3.894
7.5 5.930 48267-J SERIES I7J9 11.811
10 4.698 48267 -H SERIES 14.09 14.985
DC MOTOR
!sei
--RIES 15 3.044 48267-F SERIES 9.132 23.763
.: 20 2.370 48267 -E SERIES 7.110 30.426
25 1.912 48267-D SERIES 5.736 38,941 O TERMINAL
10 1.523 48267-C SERIES 4.569 49.065 D WIRE WRAP PIN
40 1.212 48267 -B SERIES 3.636 62.676

>FOR NOTES SEE SH.MII.

W/D 30070-2 (Sheet 3 of 13)

Figure 5.12 460 VAC Auxiliary Panel Assembly Schematics


OPTIONAL SERIES FIELD KIT
(70*385-76)

OPTIONAL CIRCUIT BREAKER KIT


(70S390-S)
(MTG.ON AUK.PNL.)
Al
H7

.181
LlO

TO AC INPUT
.182 -r\ oc
AC INPUT L20 LINE FUSES FROM
(SEE SHEET I) POWER BRIDGE S MOTOR
(SEE SHEET I) v ,' ARMATURE

LIO

1 1
i SERIES i
,FIELD KIT
HS/S2 j SI ; FM

-9 , <? j Hh-

OC MOTOR
SERIES HELD
L
OPTIONAL BLOWER S2
MOTOR STARTER
KIT(705391-2)

FROM AC INPUT
LINE FUSES
(SEE SHEET I)
CO

188 O- -om
TO TERM. 13 ft 1H
SHEET 2 BLOWER
MOTOR INTERLOCK
-OTi

TO ?,,?<>
(SEE SHEET D -097

B90- -098

Tl 6T2 6T3
I I

N I 4

0 BLOWER
MOTOR

W/D 30070-1 (Sheet 4 off 13)

Figure 5.13A Modification Kit Schematics

j j
f v

T ' "" 1 1

OPTIONAL CIRCUITS

DANGER 1 _n_ r>>,-->>>a I


APPLICATION MUST NOT RELY
1 >> ^LR^SSiCE lOOaj VOLTAGE AT AC ADC CONNECTION |
ON ZERO SPEEO SETTING FOR
9999999 ^,I , -t /-" 19>Ji____^.
SAFETY. SERIOUS OR FATAL
INJURY MAY RESULT.
719)- DIVIDER
""T.J CM_^H
|
_-* t-ntnnr AC =o]th I19]h
<J>4_
AUX.I

67>

CO | AUX. M KB B/M0-54179-I
en TCM fEEOMCK KIT B/H0-S70OS
AUX. H KIT(705388-3R)

>FOR NOTES SEE SH.IOA II

W/D 30070-1 (Sheet 5 off 13)

Figure 5.13B Modification Kit Schematics


OPTIONAL CIRCUITS

Hoy "- -D212_


n
r> -D56
> -057 *
99> ORG -099
BRN
i *> -07I
|20>
2fc}
L26> GRN
-0128

200K (1 V L__---7SMIN. SPD. >


> v>cV
AUTO MAX.
AUTO MAX. SPD.
\J,' -
SPD. *I0K
MOK V
I26> ML.
20
-OI26

PRESET SPEED AND +H.2V


INSTRUMENT INTERFACE (REFERENCE KIT) B/N 0-57002
*?> -065
BLU
66> -Ofcs,
22>(J8)19> VIO
-Q 19(18) <22
C18)67> -367(38)

ZERO SPO. SET.


-OI35 I
--II.2V AS50K
56> - +II.2V U BRN RR^|RI Jl^l4318
RED
26}-
>J -C312

126>- n DEMODULATION -^CTL-o,"| PWM -D12


nilERING * _-__> I" Jgfr
_I_^_i -, KC-O

REFERENCE RECEIVER (REFERENCE KIT) B/M 0-57007

288
SWITCH RECEIVER KIT
DANGER B/H 0-57008
APPLICATION MUST NOT RELY
ON ZERO SPEED SETTING FOR
SAFETY.SERIOUS OR FATAL
INJURY MAY RESULT.

>FOR NOTES SEE SH.IOA II.

D !_.- _A% IMe,


iiNuii otMii J "j* NOt ICAll
mom ciAwmo.
MATIIIM ! n
LJ 41014.
W/D 30070-1 (Sheet 6 of 13)

Figure 5.13C Modification Kit Schematics

j -l r/
1

OfTJQNA croups.

-^56_
I 57 "X
-N
1 JJLL
I N
I
s__Z]
"4?^r
26 < I LFL
-"__[>
HIGH IF FIELD LOSS
LIQUID CRYSTAL DISPLAY

I LIEF ;=>

I ^ -LHQ-
I LSOL
-T47~T HIGH IF O/L
^r
I LPHL HIGH IF PHASE LOSS
* A H__!__r
I pTl HIGH IF PLL UNLOCKED
H_5__E_r
UNDERVOLTAGE
28<-
1 SBY OV IN STANDBY/ -H.2V IN RUM _J STANDBY/ DRIVE
< -* RUN THtRMOSTAT
19 <-
I +VG DETECTOR
MOTOR
JCDIS THERMOSTAT
21 <- BLOWER
20V UNRE6.
I 20<- I 256
UNDER- MOTOR
VOLTAGE
27<-
IN.C. COMPARATOR
FROM
REGULATOR
I L1-I CURRENT
CARD SH.2 L__T_ MAJOR LOOP REF. CURRENT LIHI1
I 419 NAJOR LOOP FDBK LIMIT
DETECTOR
CO I L1-2 -^s
+IL2V-
^1 REGULATOR ON
PH

DRIVE
19 < L___
THERMOSTAT
40 HZ
OPTO-
OSC.
<- -* COUPLER
Iacfb
9- MOTOR
THERMOSTAT
29 ______

-*N
I<-
______
6LVR MOTOR
I 11 INTERLOCK
II
I MNL -^
1
I 1219
I 12
I 40 ^ NE6. CONTROL VOLTAGE
OPTO-
11* COUPLER STATUS BOARD
-^ 0-55111

DIAGNOSTIC
ICONNECTOR

>FOR NOTES SEE SH.IOAII

W/D 30070-1 (Sheet 7 of 13)

Figure 5.14 Status/Diagnostic Indicator Kit Schematic


PANEL RATING IHFORNATION BASIC POWER UNIT REPLACEHENT PARTS TABLE
<
AC OC FUSES FIELD REMOTE SUPPRESSOR SUPPRESSOR
ae go k MAX
RAT
INPUT OUTPUT
ARMATURE FIELD
CONTROL
TRANSF.
CURRENT
TRANSF.
FIELD
CURRENT '.9
115 VAC LOW VOLT
Flt'-O
OVOT
RESISTOR
DVOT
PC
REGULATOR DRIVER
PC PC
LOSS
PC
OPERATOR
PC
LED
ASSY.
ASSY. ASSY. FIELD
BRIDGE
POWER
CUBE
THERMO
STAT
to. I_I40
ED TRANSF. CONTROL CONTROL CARD 4SSR ISSR.2SSR
CARD CARD
88 oe
HP
VOLTS AMPS
VOLTSAMPS nous AMPS CCT ICT, 1CT FCT 1FU 7FLV8FU.9FU IFU.2FU
ASSY. CARO CARD
1SSR
FD

NONE 4II026-6R
RB RB 10 210 16 240 18 150 5 41102? 70S 6467D-22R 0-55110 4II026-9R 70I8I9-I5AC
6MCI REO'D

230 240 55 150 5 4II027-68S 64670-21R OPTIONAL NONE 0-5rtl0 4II026-9R 411026-6R 70I8I9-I9AC
RC RC 15 51 (705326-6S} REO'O
1320X1
. NONE 0-55110 4II026-9R 4II026-6R 70I8I9-I9AC
RO RD 20 210 66 240 72 150 5 411027-685 70S128-6R REO'D

<

e
l 1 5 r
o IT
o o O l 8
_e
*
3_ >
e
s k
RB RB 10 210 16 240 18 150 5 411027-70S
64670-Z2R
66031
W
1
?s NONE
REO'D
0-55110 ir

V*
1
IT
i 4II026-9R 4II026-6R
*>
s 7018I9-I9AC
m
m
i
e s
SC SC 15 210 51 240 55 150 5 4II027-68S 64670-21R
OPTIONAL
(705328-6S)
si *__
NONE
REO'D
0-55110
o e O o
4II026-9R 4I1026-6R 70tP*>-l9AC
4D
H20:i
*

\r
-- 53
210 66 411027-68$
NONE
0-55110 4II026-9R 4il026-6R 70I8I9-I9AC
SD SD 20 240 72 150 5 705328-6R REO'O

ss
<

CO
00
AUX. PANEL - REPLACEMENT PARTS TABLE

i Wo
AUX.
CONTACTOR
PILOT
RELAY CAPACITOR LINE
SPECIAL
CONNECTOR
5.
3
U.
n "J
u.*g
III"
PAWL
CONTACTOR AUX.
CONTACT
SUPPRESSOR
ASSY.
PC
CARD
SUBASSV. FUSE HARDWARE
(500V) CFORFUSES)
is SC

NONE NONE NONE 64676-I2BX


RB RB 801566-SB 411029-11R 608870-51R
REO'D REO'D REO'O 70 AMP
801566-SF 78001-SOB 7Rrt95-T M)0Mf-91$ rt-(;iiW-l NONE _i.A-*-i-rC
PC RC
nct-'w
125 AMP
600686-IIS 0-541.15-1 NONE
RD RD 601566-SE 7809I-50R 78095-T
REO'D d
M

801566-SB 411029-HR NONE NONE* N6bC 608870-51R


04676* I20X
RB RB
REO'D REO'D REO'D 70 AMP
NONE 64676-I2CC
SC SC B0I566-SK 7009I-5IR 78095-T 600686 -l' 0-54115-1 REO'D
125 AMP
801566-SK 78091-5IR 78095-T 600686-ltS 0-54H5-I NONE
2 SD SD
REO'D

I
>F0R NOTES SEE SH. 10* II.

W/D 30070-1 (Sheet 8 off 13)

Figure 5.15A Technical Data 230 VAC Three Phase FlexPak Plus

j j j
""") "1-

MOUI.T-.fi DATA
OETAft."D"
(AUX. PNL. WITH FUSE
MTG. PLATE REMOVED)
FRONT VIEW WITH COVER ROMWFP
5*4(138.1)H
PHOT RELAY _2_______i_______
B/HO-54335-^ .SUPPRESSW-600686-33S I
I
1

I
(FROM FiaD
LOSS TRANSF.) (Va)(RED)
PCTAIL"F"
_i

67
COO)

j
19
CYEL)
65
(GRY)
L75
(4.44] J- 100(1718) __J
10.62 (2.9.9)

CAUTION:UNMATE CONNECTORS ONLY BT PULLING


CONNEaORS.OO NOT PJLL WIRES. TYPICAL WHERE WEIGHT-17 t>s(81.77kg)
15E0. MAX. PROJ.= GR*S RB.SB= ai(203L2)
GR3 RC.RO_C.SDs9.50 (241.3)
MAX. SWING PR0J.s9.50(24L1)
W/D OPTIONS': SEE NOTES.
HTG.H0LES-.2I8(S.53) DIA.(4) HOLES
HTG. HARDWARE = .190(4033)
NOTE:DIMENSIONS IN PARENTHESES ARE
IN MILLIMETERS.

CURRENT FE.DCACK VOLTAGE FEEDBACK


CURRENT SCALlNGtCONNECT JUMPER FROM COM TO JUMPER FUNCTION
MOTOR CURRENT RATINGS PER HP RATINGS STANDARD CONNECTION FOR
A-COM
SPECIFIED 8ELGW. ARMATURE FEEDBACK
CURRENT TAP SETTING CONNECTION FOR TACH FEEDBACK
T-COM IF TACH FEEDBACK KIT IS
INSTALLED.

54 6R.mRC"-SC"
72 GR.*RD-A*SD'

>FOR NOTES SEE SH.I04II.

* NOTE:FOR 3HP RATING SEE INSTRUCTION MfcNUAL.

W/D 30070-1 (Sheet 9 off 13)

Figure 5.15B Technical Data 230 VAC Three Phase FlexPak Plus
0
PA NEL A1 riNG INFORMATION
_C
o AC DC FUSES FIELD REMOTE SUPPRESSOR SUPPRESSOf
<
00T REGULATOR
v
_e
h MAX
RAT-
INPUT OUTPUT
ARMATURE FIELD
CONTROL
TRANSF.
CURRENT
TRANSF.
FIELD
CURRENT VN
115 VAC LOW VOLT
OVOT
RESISTOR PC "
ORIVER
PC
LOSS
PC
OPERATOR
PC
LED
ASSY.
ASSY.
USSR
ASSY.
ISSR.2SSR
FIELD
BRIDGE
FD
POWER
CUBE
THERMO
STAT
Firto
If
9
TRANSF. CONTROL CONTROL CARD CARP CARD
_. iu_>
JOLTS AMPS IOLTS AMPS VOLTS AMPS
ASSY. CARD CARD 1SSR
ae CCT ICT, ICT FCT 1FU 7rU.8FU.9F. IFU.2FU

_ 41I026-9S 411026-9? 70I8I9-I9AW


64670-22R 78089-6R 0-55120
RE RE 20 460 14 500 16 300 5 4II027-69V
660:1
<
m OPnONAL 0-55120 4II026-9S 4II026-9V 70I6I9-I9AW
780B9-6R
RF RF 30 460 47 500 51 ?Ci 5 4II027-69V 64670-21R
1120:1
(705326-6S1
e
i 1 4II026-9S 411026-9V 1 70I8I9-I9AW
S l
RG RG 40 460 61 500 69 100 5 4II027-69V me
705128-6R 7B08*-6R 0-55920 i
e
k
9
M _* a*
t 1
_r
V-
i i
42

e o
e
si
m
a
5* 5S 5s ft
m
411026-9S 4I026-9V 70I8I9-I9AW
4II027-69V
64670-22R 7B089-6R 0-55120
\j
SE SE 20 460 14 500 16 100 5 660:i
OPtlONAL 4II026-9S 4II026-9V 70I8I9H9AW
2 SF SF 10 460 47 500 51 100 5 4II027-69V 64670-21R 76089-6R 0-55120
(705328-6S)
I120:i 4II026-9S 4II026-9V T0I8I9-I9AW
500 69 100 4II027-69V 70512B-6R 7B089-6R 0-55120
SG SG 40 460 61 5

4-
O

-40I15E9 12OTY. I/H-20KEPSNUT


ITL6O0NRB-UE.*
AUX. PANEL - REPLACEHENT PAPTS TABLE
1
_s
<
g IflO . PILOT SPECIAL
CONTACTOf
1 AU*. RELAY LINE CONNECTOR
_.
op

(CO
"J PANEL
CONTACTOR AUX.
CONTACT
SUPPRESSOR
ASSY.
PC
CARD
FUSE
(500V)
HARDWARE
[FOR FUSES)
ae

64676 -I2BX
RE RE 801566-SC 78090-50R 76095-1 .00686-71S 0-54115-1 70 AMP
2
RF RF 801566-SE 76091-50R 78095-T 600666-IIS 0-54115-1 64676-I2CC
125 AMP
RG RG 801566-SE 76091-50R 78095-T 6006*6-335 0-54115-1

S
64676-I2BX
SE SE 801566-SG 78090-5IR 78095-T 600666-11S 0-54115-1
WAMp
SF SF 801566-SK 76091-SIR 78095-T 600686-HS 0-54115-1 64676-I2CC
125 AMP
SG SG 801566-SK 78091-5IR 78095-T .00666-IIS 0-54115-1 >FOR NOTES SEE SH.I0AII

W/D 30070-2 (Sheet 8 off 13)

Figure 5.16A Technical Data 460 VAC Three Phase FlexPak Plus

j
MQVNT.1Q PATA
,DETAIL"0"
CAUX. PNL. WITH FUSE
HTG. PLATE REMOVED)
FRONT YEW WITH COVER REMOVED
PHOT RELAY GR."RCVSE" FOOT RELAY GR."Rr .SFVRG'A'SG*
B/MO-54335-U^ tSUPPRESSOR-6X686T3S B/HO-54335-l^ gSUPPRESSOR-60-686-33S

PHAIL"*'

76 715b 57
*__^
F1ELO
LOSS
PC

19?
OETAIL-F"

36 67
(BUI) CWO)

DETAIL"?"

B8.GRYH 3F01i83(6RY)
t~_|<l9)
6B2(BRN{W|282(BRN) 19 (5
(YEL) (GRY)
681 (jlED)[W|28URE0)
58i (qcoEWI^eKGRN)
CAUTION :UNMATE CONNECTORS ONLY RY PULLING WEIGHT=371 (84J7kg)
CONNECTORS.00 NOT PULL WIRES.TYPICAL WHERE MAX. PROJ. s 6R*S RE.SE = aCO (203.2)
U_0. GfTS RF,RG,SF.SG=9.S0 (241.3)

MAX. SWING PROJ.= 9.50(24I.3)


W/D OPTIONS s SEE NOTES.
H1G. H0LES-2e(5.53) 0IA.(4) HOLES
f gePFROM 3CT HTG. HARDWARES .190(4.83)
__W NOTEPENSIONS IN PARENTHESES ARE
Ig^FROMKT FAN 705328-faR
HILL-METERS.
U5E0 ON GR."RG.SG*

CURRENT FEEDBACK HLIAQE f EQ8A<a


jds_l___*_ MAXIMUM WIRE SIZE CURRENT SCALING: CONNECT JUMPER FROM COM TO JUMPER FUNCTION
AC INPUT 2AWG
DC OUTPUT 2 AUG MOTOR CURRENT RATINGS PER HP RATINGS STANDARD CONNECTION FOR

_/ .____
FIELD
MOTOR THERMOSTAT
8I2AWG SPECIFIED BELOW.
HP CURRENT TAP SETTING
A-COM
ARMATURE FEEDBACK
CONNECTION FOR TACH FEEDBACK
OPERATOR I2AWG
INTERLOCK I2AWG 1* 5.7 T-COM IF TACH FEEDBACK KIT IS
Ygw -B-r 5 INSTALLED.
7.5 B
-GR-'RE't-SE'
10 19

FIELD LOSS 8/MO54350-3 15 27


^RG.PC B/M 0-57160 20 36
^-DRIVER PC B/MO-57170 25 45
GR.'RF'4-SF- > FOR NOTES SEE SH.DAII.
30 54.
THIS CONFIGURATION E 40 72 GRrWA-SG*
OF CURRENT TRANSF.^
ASSY. USED ON GR,S___J
3MRI.<_9

* NOTE: FOR 3HP RATING SEE INSTRUCTION MANUAL.

W/D 30070-2 (Sheet 9 off 13)

Figure 5.16B Technical Data 460 VAC Three Phase FlexPak Plus
NOTE SHEET

>r> Function of panel rating, see Sh. &.


>lf motor has series field, wire between 45/S2 and PM contact Is removed*
and series field kit Installed.

3^ This contact Is present only on Assy. No. 802220-R8 aSB.


k^ For Current Scaling, see table on Sh. %.
5^ For Feedback select, see table on Sh. ^.
6^ Remove Jumper (J*) If Auto/Hanual switch Is used.
7^> Remove Jumper (J9) If Reverse Contactor kit Is used.
> Wiring for tachometer Input leads must be tightly twisted with two
full turns per Inch, minimum. Leads must be run physically separated
from all power circuit wiring. (See note 14 for Insulation temp, rating.)

> For OC tach. Jumper Is connected In this location.

1001 Motor
Voltaae Tach (RPM)
23V 20VDC/1666 Mm1 Ji56
3SV 20V0C/1000 RPM 1750
58V 50VDC/1000 RPM 1150
69V 20VOC/1000 RPM 3*50
88V 50VDC/1000 RPM 1750
115V 100VDC/1000 RPM 1150
175V 50VOC/1000 RPM 3450
175V 100V0C/1000 RPM 1750 1

>
10^ For AC tach. Jumper is connected In this location.
100t Motor
Voltage Tach (RPM)
52V 45VAC/1000 RPM "iTsT
79V 45VAC/1000 RPM 1750
155V 45VAC/1000 RPM 3450

lT> Aux. Contact rating: 1Amp *30 VDC or 0.5 Amp 120 VAC (Resistive).
12^ User convenience terminal for #14 AVG max. wire size.

13^> All wiring for remote Speed Pot. and Torque Pot- must utilize tightly
y^ twisted wire with two full turns per Inch, minimum. All wiring for
remote operators must be run in separate conduit, Isolated from all
power wiring. (See note 14 for insulation temp, rating.) See i/M for
details.

>1*^ Recommended Insulation Temp. Rating: 75C.

W/D 30070-1 (Sheet 10 of 13)

Figure 5.17A Technical Notes

42
DANGER
A.) AN EXTERNAL. U/L LISTED. FUSED DISCONNECT OR CIRCUIT BREAKER
o IS RE0UIRED TO PROVIDE NEC OR CEC DISCONNECT AND OVERCURRENT
PROTECTION.

B.) MAXIMUM PERMISSIBLE AVAILABLE SYMMETRICAL RMS SHORT CIRCUIT


POWER SUPPLY CAPACITY: 5000A.

o When Installing replacement power cubes, apply a very thin,


uniform thickness film of DOW #111 to mounting surface. Film
Is to thick If It squeezes out around power cube after power
cube is torqued down. Start the mounting screws carefully Into
existing threads, and then torque to 25 to 30 In*lbs.

17^^ Set Auto Min. Speed with Input an minimum, then set Auto Maximum
^ Speed with Input at maximum. Motor must not exceed Its speed or
voltage rating.

18^> Jumper for various process controllers.


IS^S Remove.Jumper If Auto/Manual switch Is used.

20^S Clip resistor (26.7K) and Jumper (J2) when optional Dancer
^ Position Adjust Pot. Is Installed.

21^> Not associated with 232 Drive Thermostat circuit on Sh. 2.


^ 232 Is open In auto mode ("A" not energized.)

22^> Numbers parenthesized are shown when different from original


^ Identification marking on kit.

Cut Jumpers (JI 6 J2) If Remote Operator Is Iretailed.


>
DANGER

*> EACH DRIVE MUST BE GR0UN0ED ACCORDING TO C00E REQUIREMENTS. USING


THE PRJVF, "MD." Tl-RMINAV,

The nominal Overload Threshold Is 11It of rated current. With circuit


> tolerances, the threshold can vary from 103* to 119** The Overload Trlr<
time Is nominally 60 seconds with a lead current of 150* of rated current.

26^> The IET (Instantaneous Electronic Trip) threshold Is s*t for apeak load
^ current of 300*.

For proper hardware and torque spec.'see replacement parts table (special
> connector hardware) sheet &.

WARNING
DRIVES ARE SHIPPED WITH 57 (0V) FLOATING. DEPENDING ON THE APPLICATION,
> 57 MAY BE LEFT FLOATING, OR TIED TO EARTH GROUND. IF LEFT FLOATING, THE
REGULATOR CIRCUITS MAY RISE TO A HIGH POTENTIAL.

If using an AC Tach, remove JI % J2.


>
30^ Contact Railng: 125 VAC, 3AMPS.
31^ Contact imr-t*be capable of breaking a0.5 AMP, Inductive load.

W/D 30070-1 (Sheet 11 of 13)

Figure 5.17B Technical Notes

43
PANGEA
EQUIPMENT IS AT LINE VOLTAGE WHEN AC POWER
IS CONNECTED TO THE "QWER UNIT. 3 PHASE AC
POWER LINE MUST S~5>SCONNECTED FROM THE POWER
UNIT BEFORE IT IS SAI'E TO TOUCH ANY INTERNAL
PARTS Of THIS EQUIPMENT.

START UP CHECK LIST

A. BEFORE AC POWER IS APPLIED:

1. DRIVE IS SUPPLIED AS A VOLTAGE REGULATOR. IF USED AS A VOLTAGE REGULATOR,


CHECK THAT JUMPER AT LSI ON THE REGUUTOR CARO IS CONNECTED TO PIN "A"
(ARMATURE FDBK) AT L52 SEE W/D SHEET 2 OR l/M.

2. IF ORIVE IS TO BE A SPEED REGUUTOR, CHECK THAT JUMPER AT L51 ON THE REGUUTOR CARO
IS CONNECTEO TO PIN "T" (TACH FDBK) AT Lk$. BE SURE TACHOMETER IS CONNECTED TO
TACHOMETER FEEDBACK KIT AND SCALED PROPERLY. SEE TABLES IN NOTES OR 10
FOR TACH SCALING. SEE l/M.

3. CHECK THAT THE CURRENT FEEDBACK JUMPER AT H63 ON THE REGUUTOR CARD IS SET TO THE
PROPER TAP. REFER TO TABLE ON SH. 1 OF W/D, AND l/M.

a. CHECK POURITY OF ARMATURE AND FIELD WIRING.

5. RECOMMENDED INITIAL POT SETTINGS.

(1) CURRENT LIMIT POT FACTORY PRESET TO 150*.


DOT 7. DO NOT DISTURB.
(2) IR COUP. POT FULLY CCW DOT 1
(3) MAX. SPEED POT FULLY CCW DOT 1
(k) MIN. LPEED POT FULLY CCW DOT 1
(5) ACCEL. POT FULLY CCW DOT 1
(6) OECEL. POT FULLY CCW DOT 1

B. AFTER AC POWER IS APPLIED (BEFORE STARTING DRIVE)

DANGER
DANGEROUS VOLTAGES ARE PRESENT IN DRIVE WHENEVER AC VOLTAGE
IS PRErgNT, WHETHERTR NOT ORIVE IS STARTED. P6 h6t TOUCH
ANY PO/ER CIRCUITS OR WIRING WHEN lINE VOLTAGE IS ON.

1. CHECK THAT AC LINE VOLTAGE IS WITHIN 10* OF RATED INPUT VOLTAGE. SEE SHEET 8.
/*tK
2. CHECK THAT FIELD VOLTAGE IS PRESENT AT MOTOR TERMINALS (F1, F2).

3. TURN THE SSEED OR VOL~AGE REFERENCE INITIALLY TO "0".

DURING THE INITIAL START-UP AND ADJUSTMENTS, BE PREPAREO TO STOP 0P1VE


IN CASJlNCORRECT SET-UP IN FIELD OR TACHOMETER SHOULD CAUSE'
UNCONTROLLED ACCELERATION OF THE MOTOR. IF THE DRIVE IS NOT SHUT
DOWN IJmTdIATELY UNDER SUCH CIRCUMSTANCSS7"P*EKS0NAL INJURY AND7oT
MACHINE OAMAGE MAY RESULT.

CAUTION: NEVER STOP DRIVE EXCEPT UNDER EMERGENCY BY INTERRUPTING INCOMING


POWER. DAMAGE TO THE DRIVE MAY RESULT.

DRIVE ADJUSTMENT PROCEDURE

CAUTICM: DO NOT PLUG A KIT PCB INTO (OK REMOVE IT FROM)


THE DBIVE WITHOUT FIRST TURNING CIRCUIT BREAKER TO "OFF"
POSITION. DO NOT USE AN OHMMETER TO CHECK TRANSISTORS OR
ASSOCIATED CIRCUITS. A TEST METER ADAPTOR KIT IS AVAILABLE
TO TE!T REGULATOR CIRCUITS.

NOTE: ADJUSTMENTS BELOW REFER ONLY TO STANDARD DRIVES. FOR CUSTOM


DRIVE SYSTEM SETTINGS REFER TO SYSTEM'S DOCUMENTATION.

PRINTED CIRCUIT POTENTIOMETER

<ytf-f~SftSfc

W/D 30070-1 (Sheet 12 of 13)

Figure 5.17C Technical Notes

44
1. CURRENT LIMITt

a) FACTORY PRESET TO 150*. AOJUST AS DESIRED FOR MAX. CURRENT


150*. (CCW DECREASES CURRENT).
b) DOT #4 IS APPROXIMATELY 100*.

2. MAX SPEEO:

a) SET MAX. SPEED AND MIN SPEEO POTS CCW.


b) SET SPEED (IR VOLTAGE) CONTROL POT TO MINIMUM.
c) START DRIVE AND GRADUALLY INCREASE SPEEO (OR VOLTAGE) CONTROL POT
TO MAXIMUM. WAIT UNTIL SPEED STABILIZES.
d) INCREASE MAX. SPEED POT UNTIL OESIREO MAX. SPEED (SPEED REGUUTOR) OR
MAX. VOLTAGI (VOLTAGE REGULATOR)IS ATTAINED. MOTOR MUST NOT EXCEED
ITS SPEEO OF. VOLTAGE RATING.
FOR REFERENCE DOT #1 CORRESPONDS TO MAX. SPEED APPROXIMATELY 70* RATED
SPEED, AND EACH SUCCEEDING DOT ADDS 5* UNTIL DOT #7 CORRESPONDS TO 100*
RATED SPEED (VOLTAGE). DOT #8 & #9 LOCATIONS INSURE 100* CAN BE
OBTAINED IN ALL DRIVES.

3. NIN. SPEED:

a) SET SPEED (OR VOLTAGE) CONTROL POT WO".


b) START ORIVE AND INCREASE MIN. SPEED POT CW UNTIL DESIRED MIN. SPEED (SPEED
REGUUTOR) OR MIN. VOLTS (VOLTAGE REGUUTOR) IS ATTAINED. WAIT UNTIL SPEED
STABILIZES.
c) FOR REFERENCE, DOT #1 NORMALLY CORRESPONDS TO MIN. SPEED OF APPROXIMATELY 3* AND
EACH SUCCEEDING DOT ADOS 5* TILL DOT #9 CORRESPONDS TO APPROXIMATELY 40*
RATEO SPEED. SEE l/M.

IR COMP: ONLY USED ON VOLTAGE REGULATOR SYSTEMS.


ALL OTHER SYSTEMS MUST HAVE IR COMP
POT FILLY CCW (SET TO DOT #1).

a) RUN DRIVE UNLOADED AT MAX. RATED SPEED.


b) LOAD DRIVE 10 FULL LOAD.
c) AOJUST IR CCMP CW UNTIL SPEED IS AT THE DESIREO LEVEL. (DO NOT EXCEED RATED
SPEEO).
d) TYPICAL MOTCRS WILL HAVE AN IR COMP SETTING OF ABOUT DOT #3.
5. ACCEL:

a) SET ACCEL. POT CCW (DOT 1).


b) START DRIVE AND TURN ACCEL. POT CW TO INCREASE ACCEL. RATE. ADJUST TO
DESIRED RATE. TO SET FAST ACCEL. RATES ACCURATELY, A CHART RECORDER OR A
STORAGE SCOPE MAY BE REQUIRED TO MONITOR THE SPEED (ARMATURE VOLTS OR TACH).
c) FOR REFERENCE, DOT #9 CORRESPONDS TO AN ACCEL. RAMP RATE OF ABOUT (0 TO 100*
REFERENCE)/C.3 SEC. AMD EACH DOT ADOS ABOUT 5 SECONDS, SO DOT #1 CORRESPONDS
TO RAMP RATE OF ABOUT (0 TO 100* REFERENCE)/kS SEC.

6. DECEL:

a) SET DECEL. POT CCW (DOT 1).


b) START DRIVE AND RUN AT MAXIMUM SPEED.
c) QUICKLY SET THE REFERENCE TO ZERO ANO TURN OECEL. POT O. TO INCREASE DECEL.
RATE. ADJUST TO DESIRED RATE. TO SET F..ST DECEL. RATES ACCURATELY A CHART
RECOROER OR A STORAGE SCOPE MAY BE REQUIRED TO MONITOR THE SPEED (ARMATURE
VOLTS OR TACH). THIS ADJUSTMENT MAY REQUIRE THE MOTOR TO BE LOAOEO IF THE
DESIRED DECEL. RATE IS FASTER THAN THE COAST-TO-REST RATE OF THE UNLOADED
MOTOR.

NOTE: THE CECEL. CIRCUITS ARE NOT USED DURING A STANDARD STOP SEQUENCE
UTILIZING TfcE STOP SWITCH.

d) FOR REFERENCE, DOT #9 CORRESPONDS TO A DECEL. RAMP RATE OF ABOUT (100*


TO 0 REFERENCE)/0.3 SEC. AND EACH DOT ADDS ABOUT 5 SECONDS, SO THAT DOT #1
CORRESPONDS TO RAMP RATE OF ABOUT (100* TO 0 REFERENCE)A5 SECONDS.

MAINTENANCE AND SERVICE SUGGESTIONS

THE OPTIONAL METER AOAPTOR KIT, STATUS INDICATOR AND/OR DIAGNOSTOR WILL ASSIST IN
DETERMINING WHETHER MAIN PCB'S ARE FUNCTIONALLY OPERATIONAL. AN UNDERSTANDING OF
THE WAVEFORMS INVOLVED WILL ISOUTE TROUBLE AREAS. IT IS SUGGESTED THAT THE USER
BECOME FAMILIAR WITH DRIVE VOLTAGE LEVELS WHEN EQUIPMENT IS OPERATING NORMALLY.
ALL VOLTAGE LEVELS ARE NOMINAL AND MAY INDICATE 10* OF STATED VALUE DEPENDING
ON METER ACCURACY AND ACTUAL VALUE OF AC SUPPLY VOLTAGES. SEE l/M FOR DETAILS.

W/D 30070-1 (Sheet 13 of 13)

Figure 5.17D Technical Notes

45
r
SECTION 6
REPLACEMENT PARTS
6.0 General Users should consider maintaining a stock along with part numbers and quantities actually used in
of spare parts. Table 6.A lists the more common parts the controller.

Table 6.A Replacement Modules

Quantity Per
Part Description Model Number Part Number
Controller

Regulator Module 1 14C650 0-57160

Digital Driver Module 1 14C651 0-57170

Field Loss PC 1 14C652 0-54350-3

Current Transformer (1CT, 3CT)


3to10HP230VAC 2 14C653 64670-22R
3 to 20 HP 460 VAC 2 14C653 64670-22R
15 to 20 HP 230 VAC 2 14C654 64670-23R
25 to 40 HP 460 VAC 2 14C654 64670-23R
Field Current Transformer 14C655 64670-24R

Power Cubes
3 - 20 HP 230 VAC 3 14C656 701819-19AC
3-40 HP 460 VAC 3 14C657 701819-19AW
M Contactor (Optional)
3-10 HP 230 VAC 1 14C242 i 69326-30R ;
15-20 HP 230 VAC 1 14C659 78091-50R
3-40 HP 460 VAC 1 14C659 78091-50R
Pilot Relay PC Card
10 HP-20 HP 230 VAC 1 14C668 0-54335-1
3-40 HP 460 VAC 1 14C668 0-54335-1
MOV Surge Suppressor
3 - 20 HP 230 VAC 3 14C660 411026-6R
3 - 40 HP 460 VAC 3 14C661 411026-9R
DV/DT PC Card
3 - 20 HP 230 VAC 1 14C662 0-55310
3 - 40 HP 460 VAC 1 14C663 0-55320
DV/DT Resistor Assembly
3-40 HP 460 VAC 14C664 78089-6R

Line Fuses 4FU, 5FU, 6FU


3-10 HP 230 VAC 3 64676-12BX
3-20 HP 460 VAC 3 64676-12BX
15-20 HP 230 VAC 3 64676-12CC
25-40 HP 460 VAC 3 64676-12CC
115 VAC Control Fuse, 3 FU 1 14C670 64676-23V

47
Table 6.A Replacement Modules

Quantity Per
Part Description Model Number Part Number
Controller

Low Voltage Control Fuses


7FU.8FU.9FU 3 14C671 64676-23V

Control Transformer
3-10 HP 230 VAC 14C665 411027-70S

15-20 HP 230 VAC 14C666 411027-68S

3 - 40 HP 460 VAC 14C667 411027-69V

Remote Operator PC Card 14C220 0-57005

14C672 608868-25R
Field Supply
MOV Surge Suppressor Field Supply
3 - 20 HP 230 VAC 14C673 411026-9R

3 - 40 HP 460 VAC 14C674 411026-9S

Fan
20 HP 230 VAC 14C669 705328-6R
14C669 705328-6R
40 HP 460 VAC

Field Supply Fuses


| 1FU,2FU 2 14C675 64676-30F

48
SECTION 7
THREE PHASE FLEXPAK PLUS MODIFICATION KIT
INSTRUCTION MANUALS
7.0 General A number of optional features in the form of
Modification Kits are offered with the three phase, Flex
Pak Plus controller. 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 7. A for an informa
tional listing.

DANGER
INSTALLATION OF MODIFICAITON KITS IS TO
BE DONE ONLY AFTER A-C LINE VOLTAGE IS
DISCONNECTED AND LOCKED OUT AT THE
MAIN DISCONNECT SWITCH. DO NOT INSTALL Figure 7.1 Pin Alignment
KITS WHEN POWER IS APPLIED TO THE FLEX
PAK PLUS CONTROLLER. SERIOUS PERSONAL
INJURY AND EQUIPMENT DAMAGE COULD A common installation problem is caused by bent, broken
RESULT. or incorrectly placed pins. Since improper operation
results, care must be taken. Exact alignment is critical.
Visually check that only one pin extends to the top of each
CAUTION: Installation of the Modification Kits slot once the connection is made.
should be performed only by qualified electrical
maintenance personnel familiar with the design and Many of the Modification Kits require the removal of one
operation of this equipment. Damage could result or more jumpers from the Regulator Module. In such
cases, carefully clip the leads on both sides of each
thru unfamiliarity.
jumper and discard it. Use a sharp pair of dykes (diagonal
Many of the Modification Kits are designed to make elec cutters) to assure a quick, clean cut. Do not twist the tool,
since damage may result.
trical connection with the Regulator Module by means of
pin-type connectors. These slide up through matching In cases where the Kit issecured by a mounting screw, be
holes in the Modules that form part of the Kit. (Refer to sure to tighten it firmly but do not overtighten. Excessive
Figure 7.1.) force can strip the threads.

Table 7.A Modification Kit Quick Reference List

Additional Additional
Instruction Controller
Model Options User-
Kit Manual Modification Options Required
No. Required Supplied
Number ? ?
Parts?

Circuit D-3956 14C610 Yes No None No


Breaker 14C611
14C612

Dynamic D-3957 14C630 Yes No None Wire


Braking thru
14C642

49
Table 7.A Modification Kit Quick Reference List (Continued)

Additional Additional
Instruction Controller
Model Options User-
Kit Manual Modification Options Required
No. Required Supplied
Number
? Parts?

Reversing D-3959 14C241 Yes Yes


Contactor 14C401 Fwd/Rev Selector No
14C402 Switch on OP
Station.

Auxiliary D-3960 14C480 No No None Wire


M Contact thru
14C484

Blower D-3961 14C510 Yes No None Wire


Motor Starter 14C520

Fan D-3962 14C560 Yes No None None


Kit

Status/ D-3963 14C570 Yes No None None


Diagnostic
Indicator

Series Field D-3965 14C620 Yes No None Wire


Kit 14C621
14C622

Dancer D-3966 14C230 Yes Yes Dancer Wire


Follower Potentiometer

Instrument D-3967 14C222 Yes No/Yes If Preset Speed No


Interface/ only, may need
Preset Speed Auto/Manual
Switch.

No/Yes If follows process Wire


controller, may
need Auto/
Manual Switch

Master D-3968 14C229 Yes Yes Master Isolated Wire


Isolated Reference
Reference Transmitter
Receiver

Tachometer D-3969 14C221 Yes No None Wire


Feedback

Test Meter D-3970 14C225 No No None No


Adapter

Voltage/ D-3971 14C223 Yes No/Yes May need Auto/ Wire


Tachometer Manual Selector
Follower Switch

M Contactor D-3955 14C470 Yes Yes 3 Phase Line M Contactor


Adapter Kit Input Fuses Wire NEC/CEC
Fuses

Auxiliary D-3958 14C240 Yes No None No


Panel 14C331
14C332

Modification here means that some work such as jumper placement, resistor clipping or wiring reconnection must be performed,
No options required in standard product offering optional basic controller would require specific auxiliary panel for required option.

50
Table 7.B Wire Specifications

Use in Type Required Acceptable


Controller Conductor Characteristics Types
CONTROL WIRES

Remote Operator Single conductor and/ Stranded copper Any single conductor
Control Station: or multi-conductor AWG No. 16 meeting N.E.C
AUTO/MANUAL 600 VAC rating required characteristics
JOG/RUN Insulation: polyvinyl
FORWARD/REVERSE chloride (PVC)
START/STOP Temperature range:
40-105C (104-221F)
Unshielded

SIGNAL WIRE

Remote Operator Three-conductor Stranded copper User may twist single


Control Station: Twisted with two (19x29) conductors of re
SPEED pot twists per inch AWG No. 16 quired specifications
TORQUE Pot 600 VAC rating Reliance Part No.
Twist per foot: 417900-79X
Tachometer Two-conductor 24 (y2-inch lay) User may twist single
Feedback Twisted pair with two Insualtion: polyvinyl conductors of re
Instrument Interface twists per inch chloride (PVC) quired specifications.
Voltage/Tachometer Temperature range: Reliance Part No.
Follower 40-105C (104-221F) 417900-76EAD

INSTRUMENT INTERFACE/PRESET
SPEED KIT (OPTIONAL)

TEST
METER
ADAPTER
KIT
(OPTIONAL)

REMOTE OPERATORS TACH FEEDBACK KIT (OPTIONAL)


BUFFER KIT (STANDARD)

Figure 7.2 Three Phase FlexPak Plus Regulator Board with Some Typical Kits Installed

51
n
<5*
c

<D

fO
<D

U)

Tl

X
TJ
Bl

en
C
V)

33
<T>
(Q
c

00
o
B)

3
o
fl>

O
o
Q)

5'
3
FlexPak INSTRUCTION MANUAL D-3956

ACCESSORY

INCOMING LINE CIRCUIT BREAKER KITS


MODEL NUMBERS 14C610, 14C611, 14C612
ASSEMBLY DRAWINGS 705390-5

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION

Circuit Breaker Kits provide an a-c input line circuit


breaker into low and medium horsepower three phase
FlexPak Plus controllers.

The circuit breaker provides additional fault protection


for the drive by means of its magnetic trip devices. It also
serves as a means to disconnect and lock out incoming
a-c power. Each kit is supplied complete with its circuit
breaker and necessary mounting hardware for installa
tion on the front panel of the auxiliary panel.

SPECIFICATION

The appropriate Circuit Breaker Kit should be selected on


the basis of controller horsepower and voltage per Table
1.
Figure 1 Three Phase FlexPak Plus Circuit Breaker Kit
Table 1 Circuit Breaker Kit Specifications

Controller Horsepower Circuit Breaker


Kit
Current
Model Incoming Line Voltage
Number
Rating
230 VAC 460 VAC (Amperes)
14C610 3-10
50

14C611 3-20 50
53*
14C612 15-20 25-40 100
Kff
*

RELIANCE**
ELECTRIC 1
ALLOWABLE AVAILABLE FAULT CURRENT , 1;!
The standard three phase, FlexPak Plus controller, fur
nished without an input circuit breaker, has a short circuit I
protection system designed to operate on plant power
supplies with maximum allowable available symmetrical
RMS fault current of 5000 amps. Do not attempt to operate
the three phase FlexPak Plus controller on plant power
supplies with available short circuit current in excess of IS

this maximum. The addition of these incoming line circuit


breaker kits do not increase the allowable available short
Figure 2 Three Phase FlexPak Plus Controller
circuit current.
With Circuit Breaker Kit Installed
INSTALLATION 3. Mount Circuit Breaker Kit to fuse/circuit breaker plate
using the 4 taptite screws and mounting bracket.
WARNING 4. Mount circuit breaker to mounting bracket with
BEFORE ATTEMPTING TO INSTALL THIS FLEX screws provided. (Figure 4).
PAK PLUS MODIFICATION KIT DISCONNECT
AND LOCK OUT ALL SOURCES OF INCOMING 5. Remount fuse/circuit breaker mounting plate to auxil
POWER TO THE CONTROLLER. iary panel using same screws removed previously.
6. Route wires from bottom of circuit breaker under cir
cuit breaker and connect to top of fuses as shown in
1. Open face plate of three phase FlexPak Plus and let it
Figure 3 and Figure 4.
hang open.
7. Tighten all connectors that may have been loosened
2. Remove fuse/circuit breaker mounting plate from
during kit installation.
auxiliary chassis by removing three existing screws
(Figure 3). 8. Close face plate and tighten screws.

. LI LI L3

MOUNTING
MOUNTING
SCREWS uj SCREWS

AUX. CHASSIS
IT r j
FUSE & CB. MTG. PLATE

^
Figure 3 Fuse/Circuit Breaker Mounting Plate

OPTIMAL aUCUIT BREAKER KIT


r (105)90-5)
CHT6.0N AUX.PH..)

AC OfffT -
10 AC INPUT
-UK FUSES

FUSE & CB
I MTG. PLATE

Figure 4 Fuse/Circuit Breaker Figure 5 Optional Circuit Breaker Kit Schematic


Mounting Plate Side View

Reliance Electric Company / 24703 Euclid Avenue / Cleveland, Ohio 44117

RELIANCE ELECTRIC MS

8821M
Printed in U.S.A. D-3956
FuxRakh/ INSTRUCTION MANUAL D-3957

MinPak i ACCESSORY

DYNAMIC BRAKING KIT


MODEL NUMBERS 14C630-14C644,14C420-14C434
ASSEMBLY DRAWINGS 801455-4

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION

The standard three phase FlexPak Plus and MinPak Plus


controllers allow a drive motor to coast to rest after the
stop switch is pressed. Optionally, a user may install a
Dynamic Braking kit. (Refer to Figure 1 and Figure 2)
Dynamic Braking is not a mechanical holding brake. It will
not hold the shaft in place nor will it prevent the motor
from turning once motion has stopped.

Figure 2 -Three Phase FlexPak Plus Dynamic Braking Kit


The Dynamic Braking option is actually a resistor con
nected across the motor armature. Itallowsamotortoact
as a generator; the rotating mechanical (kinetic) energy is
converted into electrical energy that is dissipated in the
form of heat by the Dynamic Braking resistor.
Note that the resistor is sized for infrequent stops. Thus,
users must allow time between stops for heat dissipation.
Figure 1 Three Phase MinPak Plus
Dynamic Braking Kit When ordering the Kit, it is necessary to specify Model
SPECIFICATIONS Numbers according to horsepower and voltage ratings.

Table 1 230VAC, 3 Phase, 50/60 Hz 240VDC Armature

MinPak Plus FlexPak Plus RES Value Reliance Watt-Seconds


HP QUA
Model No. Model No. (OHMS) Part No. @ 375 C
14C433 14C643 3 9.420 48267-L 2,466

14C420 14C630 5 5.930 48267-J 3,937


14C421 14C631 7.5 3.891 48267-G 6,212
14C422 14C632 10 3.044 48267-F 7,981
14C423 14C633 15 1.912 48267-D 12,981
14C424 14C634 20 1.523 48267-C 16,355
Table 2 460VAC, 3 Phase, 50/60 Hz 500VDC Armature

MinPak Plus FlexPak Plus RES Value Reliance Total Watt-Seconds


HP QUA Connection
Model No. Model No. (OHMS) Part No. OHMS @375C

14C434 14C644 3 20.87 48267-P 2 Series 41.74 4,090

14C425 14C635 5 12.06 48267-M 2 Series 24.10 3,894

14C426 14C636 7.5 5.930 48267-J 3 Series 17.79 11,811

14C427 14C637 10 4.698 48267-H 3 Series 14.09 14,985

14C428 14C638 15 3.044 48267-F 3 Series 9.132 23,763

14C429 14C639 20 2.370 48267-E 3 Series 7.110 30,426

14C430 14C640 25 1.912 48267-D 3 Series 5.736 38,943

14C431 14C641 . 30 1.523 48267-C 3 Series 4.569 49,065

14C432 14C642 40 1.212 48267-B 3 Series 3.636 62,676

(Note: Initial Current of 150% Derated lA)

INSTALLATION
MOUNTING TABS

.DB COVER
WARNING
BEFORE ATTEMPTING TO INSTALL THIS MIN .GROMMET

PAK PLUS/FLEXPAK PLUS MODIFICATION KIT ASSEMBLED MTG.


PANEL
DISCONNECT AND LOCK OUT ALL SOURCES OF -HEX HEAD CAP SCREW
INCOMING POWER TO THE CONTROLLER.
WASHER
JSVlat WASHER ^
MINPAK PLUS: VSPLIT WASHER
HEX NUT
Remove 5 knockouts in top of cabinet (Figure 3).
AUX. CHASSIS WITH
FUSE &CB MTG.
PLATE REMOVED.

^-MINPAK CABINET
WITHOUT DOOR
1 "-KNOCKOUT
1
1

1_ Figure 4 Front View of Three Phase MinPak
KNOCKOUT Plus Cabinet
o< -1- >o
V
VDB COVER into slots on mounting panel and using taptite screw
provided.
TAPTITE
SCREW
5. Open cabinet door and open controller face plate and
let hang open.

6. Remove fuse/circuit breaker mounting plate from


Figure 3 Top View of Three Phase MinPak Plus Cabinet auxiliary chassis by removing three screws.

1. Insert grommet into 1.75 diameter hole. 7. Connect lead DB1 to toward contactor and lead
DB2/A2 to other side of toward contactor. For revers
2. Place assembled mtg. panel on top of cabinet and ing applications connect DB2/A2to reversing contac
feed leads DB1 and DB2/A2 through the grommet. tor. (Refer to Figures 4 and 5).
3. Secure assembled mounting panel to cabinet using 8. Remount fuse/circuit breaker plate to auxiliary chas
four hex head cap screws, washers, flatwashers, split sis using three existing screws.
washers and hex nut mounting hardware (Figure 8). ^
(NOTE: Hardware must be used as shown in Figure 4 9. Tighten all connectors that may have loosened during
to Insure NEMA 12 rating.) kit installation.

4. Mount DB cover to mounting panel by inserting tabs 10. Close controller face plate and tighten screws.
tfc\

MTG. SURFACE
r 1
,rwr" two conmcio* *\XM COmfcOOvT
i COWKOO*
REV. BUS BAR
I <=
| C^ KM .*>
IF USED
era era

LUG DB2/A2
, ca a era
USER'S A2 OR LUG - DB2/A2
" v^r --^rrs rt-.^-
A2 TO TERM.
BOARD (ON P.M.)
3-10 HP < i 230 VAC
3-20 HP @ 460 VAC.

MTG. SURFACE
._y
FWD CONTACTOR REV. CONTACTOR

L.i

/
REV. BUS BAR (TYP)

15-20 HP @ 230 VAC


&
25-40 HP @ 460 VAC

Figure 5 Contactor Configurations For Dynamic Braking Kit Wiring


FLEXPAK PLUS: DB2/A2 to other side of toward contactor. For revers
Mount assembled panel into user supplied enclosure. ing applications connect DB2/A2to reversing contac
tor. (Refer to Figure 5).
1. Connect leads DB1 and DB2/A2to resistors (Refer to
Figures 2, 6 & 7). 5. Remount fuse/circuit breaker plate to auxiliary chas
sis using three existing screws.
2. Open controller face plate and let hang open.
6. Tighten all connectors that may have loosened during
3. Remove fuse/circuit breaker mounting plate from kit installation.
auxiliary chassis by removing three screws.
7. Close controller face plate and tighten screws.
4. Connect lead DB1 to forward contactor and lead

h?CH V-(->- OT-


'H

^m

^0 /
^ \ DC
N. MOTOR I
&rn I
r\ optional^' ARMATURE
X . . oe

'Xi
r
i t: resistor;

;oei
i

i
i
\DC MOTOR
/ARMATURE

I OPTIONAL

HS/S2 FH ,-_j
-9 (-) AUX.panel!

* *.0C MOTOR
I *. SERIES MS/S2 F>1
i. J f ICL0 >. .> -i-i
*^
A2|

Figure 6 Dynamic Braking Kit With Optional Figure 7 Dynamic Braking Kit For Unidirectional
Reversing Kit Schematic Application Schematic
FlexPak /
INSTRUCTION MANUAL D-3959

' MinPak ACCESSORY

REVERSING CONTACTOR KIT


MODEL NUMBERS 14C400, 14C401, 14C402
ASSEMBLY DRAWINGS 705385-75

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION

The standard three phase FlexPak Plus/MinPak Plus con


troller offers unidirectional control. With an optional
reversing contactor kit mounted on the auxiliary panel,
bidirectional operation (both forward and reverse) is pos
sible. Motor direction is manually selected.

Figure 1 Three Phase MinPak Plus/FlexPak Plus


Reversing Kit

CAUTION
The FlexPak Plus/MinPak Plus controllers were
designed for motoring operation only. In reversing
applications the drive must be assured to come to a
rest before the reversing contactor is pulled in. If not,
the possibility of transient regenerative currents can
occur with the result being significant damage to the
controller.

INSTALLATION

WARNING Figure 2 Reversing Kit Installed On Auxiliary Panel


BEFORE ATTEMPTING TO INSTALLTHE MINPAK
PLUS/FLEXPAK PLUS MODIFICATION KIT, DIS
CONNECT AND LOCK OUT ALL SOURCES OF 2. Remove fuse/circuit breaker mounting plate from
INCOMING POWER TO THE CONTROLLER. auxiliary panel by removing three screws.

3. Mount contactor to aux. chassis 3-10 hp 230VAC


1. Open face plate and let it hang down. units. Usetwotaptites provided. 15-20 hp @ 230 VAC
and 3-40 hp @ 460VAC use four taptites and 4 flat 4. 3-1 Ohp 230VAC only. Connect jumpers S1,47, A1 and
washers (Refer to Figure 3 and 4). A2 from forward contactor to rev contactor as shown
(Refer to Figure 5). (Skip to step no. 7).

5. All other ratings - Connect bus bar S1, 47, A1 and A2


from forward contactor to reversing contactor as
shown (Refer to Figure 4).
tM 6. Mount pilot relay printed circuit card to auxiliary
TAPTITE
Tvra.
i MOUNTING chassis using two binding HMS and star washers
SCREWS (Figure 4). Connect leads 188-189 from pilot relay
\ REVERSING card to terminal board on forward pilot relay card
S1 CONTACTOR
mounted on left side of auxiliary panel.
LEAD
FROM iSl SM. 7. Mount label in corresponding position, see Figures 3
zrr-JjjU_
TERMINAL BOARD^ LABEL
and 4.
HARNESS TO REGULATOR
PRINTED CIRCUIT MODULE
8. Connect harness from contactor, 3-10 hp @ 230VAC
or pilot relay, 139 to regulator printed circuit card
terminals 139.
Figure 3 3-10 HP @ 230VAC Reversing Kit Mounting
Locations 9. Disconnect lead 45 at contactor.

10. FlexPak Plus only - Install terminal block S1 between


existing terminals 53 and 45. Add marking tag S2 to
LABEL PILOT
RELAY PC top of existing terminal 45. Disconnect lead 45 at
BINDING terminal block and remove this lead totally from
HMS controller.

MinPak Plus only - Install terminal blocks S1 and


REVERSING 45-S2 between exisitng terminal blocks A2 and F1.
CONTACTOR
Reconnect lead 45 to terminal block 45.
TAPTITE
.MOUNTING 11. Connect lead S1 to contactor. Lead must be routed
SCREWS under terminal board mounting bracket (Figure 6).

HARNESS TO
S1 REGULATOR
LEAD PRINTED
FROM CIRCUIT
TERMINAL MODULE
BOARD

Figure 4 Reversing Kit Mounting Location 15-20 HP


@ 230VAC/3-40 HP @ 460VAC
FILTER
CAPACITOR

JUMPER,
47 A2
JUMPER HARNESS

A1 TO BpriTiATOR REVERSING Figure 6 Series Field Terminal Connection


JUMPER TERMINAL MODULE C0NTACT0R
BOARD

13. Cut jumper J9 on regulator PC Module.

Figure 5 Internal Jumper Connection for 3-10 HP 14. Remount fuse/circuit breaker mounting plate to auxil
@ 230VAC Reversing Application iary chassis using existing three screws.
15. Tighten all connectors that may have loosened during
kit installation.

16. Close face plate and tighten screws.

1
1

TO
CONTROL
XTMR. -
SH.I
p88
I 189 1
R
it

" | '
ff\V^r-
J

ORIVE
THERMOSTAT
- CONTROL
POWER

OPTIONAL fi MOTOR
\t*
' "=!=| AUX.
CONTACT KIT -Hj- THERMOSTAT
~19 1 1 org!
1 1 rl160nww8-t mQ Jp_J
BLOWER MOTOR
: : mi ^ i n. INTERLOCK
TO
REGULATOR
CARO _
16 ! ! *J 1 !l 1
SH.2
! ! wiol 1 w
67

65
1 1
1

1 GRVI
,
I
jrt J-^vi TjlW

PILOT RELAY CARO

ii 1 6/ri0-5<*114-l

RPR
frtvSl'c?*
-l- = - M
** 67 67
-Levi
/rprV- Ol19

L-L- T
ll_

1
1 -'1
188 O TERMINAL
0 PTIONAL
R EVERS1NC KIT 189
D WIRE WRAP PtN
( rasies-76) O" - - J f ' OPTIONAL
BMJ_ AUX.
r "n-T CONTACT KIT
i 1
(70S1881)
"ll9 ORG -C5260
J ^ --9
-HRPR/-

TO
*7__ tEL
RM
Figure 8 Typical Bidirectional Control Scheme
REGUUTOR
CARO
16
Qrtt ;;";;;r ",r"!
SU
19 woi i *
**-. r' J J
PILOT RELAY CARD
B/rio-smis-i

1
Figure 7 15-20 HP @ 230VAC/3-40 HP @ 460VAC
Installed Reversing Kit Schematic
FlexPak i / INSTRUCTION MANUAL D-3960

MwRrk i ACCESSORY
:W&?1
^."j\^'

'A^r ::Jr
sr'._.. vl-2 ^i_tjKf? i jisLxi;

CONTACTOR AUXILIARY CONTACT KITS


MODEL NUMBERS 14C480-14C484
ASSEMBLY DRAWINGS 705388-3

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION appropriate local codes. Under no circumstances should


With the optional auxiliary M Contactor Kit, the run status these contacts be used to control brakes or power loads.
of the three phase MinPak Plus and FtexPak Plus can be Recommended wire size is AWG No. 14 max.
interlocked with user supplied devices. Typical applica
tions include pilot/indicator lights, alarms, and interlock
SPECIFICATIONS:
ing with other control circuits dependent on the drive
system. (Figure 1).
Model Current
Voltage Load
Number Rating

14C480&
115 VAC 3 Amps Inductive
14C481

115 VAC 10 Amps Resistive


14C482 &
28 VDC 1 Amp Inductive
Controller Rating Kit Model Number

3-10 hp@ 230VAC 14C482


15-20 hp@230VAC/
14C480
3-40 hp @ 460VAC

15-20 hp@ 230VAC


14C481
3-40 hp @ 460VAC
For use with Bidirectional Applications.
For use with Unidirectional & Bidirectional
Applications.

Figure 1 Contactor Auxiliary Contact Kit INSTALLATION:

WARNING
BEFORE ATTEMPTING TO INSTALL THIS MIN
The Kit provides a single pair of Form C Contacts, one
PAK PLUS/FLEXPAK PLUS MODIFICATION KIT,
normally open (NO) and one normally closed (NC). These
DISCONNECT AND LOCK OUT ALL SOURCES OF
contacts function whether the controller is unidirectional
INCOMING POWER TO THE CONTROLLER
(forward only) or bidirectional (forward/reverse). Users CABINET.
supply the wiring to external devices and should meet
3. 3-10 hp @ 230VAC - ONLY Mount PC board to
terminal mounting bracket by pressing stand offs into
holes on mounting bracket.
(NOTE: Terminal Board on PC to face into power
module). (Refer to Figures 2, 5 & 6) skip to step 5.
Mix. CHffift 4. Mount auxiliary contacts to contact or contactors as
shown in Figure 3 & 4 with hardware supplied.

5. Mount terminal sections to right end of terminal


PRINTED
CIRCUIT.
board. (Refer to Figures 2, 3, 4 & 6).
MODULE
ST*i
j i '. 6. Route wire harness('s) under terminal board mount
ing bracket and connect to terminal sections. On 3-10
WIRE _
jgzs
"Lu-IJ
rag:
EgHKTERMINAL hp 230VAC kit route 139 orange harness to regulator
HARNESS SECTIONS
PC module #139 pins on top of card.

TOP VIEW 7. Remount fuse/circuit breaker mounting plate to auxil


iary chassis using existing screws.

.iTTTTlsrtE'
PRINTED MiX. D\M.S\S
CIRCUIT 7^ -f REVERSE
MODULE. WIRE HARNESS
-AUXILIARY
n=TT / CONTACT
vw\>
3fcO zu>
Figure 2 Mounting Location FORWARD H ~rx XT
AUXILIARY'
of Auxiliary Contact Kit 3-1^ hp @ 230VAC CONTACT
OQ
WIRE
1. Open face plate and let hand down. HARNESS

2. Remove fuse/circuit breaker mounting plate from


auxiliary chassis by removing three screws. 1 \ TERMINAL
SECTIONS

WIRE
HARNESS

MIX. 0M.S
Figure 4 3-40 hp @ 460VAC, 15-20 hp @ 230VAC
* Bidirectional Auxiliary Contact Kit Installation

fWO
3fc0
AUXILIARY/ XT
CONTACT

WIRE U
HARNESS
m
1 ^5; TERMINAL
V.IA. ' SECTION

Figure 3 3-40 hp @ 460VAC, 15-20 hp @ 230VAC


Unidirectional Auxiliary Contact Kit Installation

Figure 5 3-10 hp @ 230VAC Auxiliary Contact Kit


AUXCONTACT
PC CARD

AUX CONTACT
TERMINALS

Figure 6 3-10 hp @ 230VAC Auxiliary Contact Kit Installed

8. Tighten all connectors that may have been loosened


during kit installation.
2.50
9. Close face plate and tighten screws.
10. Mount warning name plate to power module face WARNING
NAME PLATE
plate per Figure 7. --i.58-J

CONTROLLER
' FACEPLATE

Figure 7 Auxiliary Kit Warning Plate Location


RexRakh/ INSTRUCTION MANUAL D-3961

' MinPak
ACCESSORY

BLOWER MOTOR STARTER KITS


MODEL NUMBERS 14C510, 14C520
ASSEMBLY DRAWINGS 705393-2

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION Short circuit protection is provided by means of three 15


ampere dual elements NEC fuses wired in series with
These Kits provide starters to control, protect and inter power feed to the a-c motor and mounted as part of the
lock the 3-phase a-c motor used for cooling a forced starter assembly.
ventilated d-c motor.
A normally open auxiliary contact on the starter (termi
Each Starter Kit provides a 3-pole magnetic starter, nals 33 and 34) allows interlocking with the drive to stop
inverse-time thermal overload heaters, 3-phase NEC the drive motor upon an a-c motor overload trip. A nor
fuses, a wiring harness and mounting hardware. Figure 1 mally open auxiliary contact on the starter (terminals 97
provides a schematic of the starter. and 98) allows the user to monitor the status of the blower
motor starter and to alarm a "blower motor starter open"
condition.

SPECIFICATIONS
Starter Size Size 1
Coil Voltage 115 volts a-c, 50/60 Hz.
IOQ JO! JOC JO_>
Power Contact Rating 30 amperes full load,
o-ipM*" u~~of" &~_^2- -034- at up to 600 volts a-c
033 Fuse Rating 15 ampere, NEC, for short circuit
protection of the a-c motor and wiring
Overload Heater Data:
-or? 14C520- Adjustable Heater Setting 1.0 to 1.6 amps
14C510- Adjustable Heater Setting .6 to 1.0 amps
<n8

It TZ 13,

Figure 1 Blower Motor Starter Kit Schematic


OPERATION
Blower motor control is provided by means of a magnetically
operated 3-phase motor contactor. The contactor coil
receives power from the MinPak Plus/FlexPak Plus control
circuit transformer and, as such, the contactor closes with
application of plant powerto the input of the drive and drops
out upon removal of plant power.

Thermal overload protection for the a-c motor is provided by


means of three thermal overload heaters mounted within the
starter. Thermal overload trip will cause the blower motor
starter to open. Figure 2 Blower Motor Starter Kit
SELECTING THE CORRECT
BLOWER MOTOR STARTER KIT TAPTITE HARNESS
SCREW
The following table is provided for the recommended FUSE & CB MTG. PLATE

matching of Blower Motor Starter Kits to Motor Blower AUX. CHASSIS

Kits. 4
Table 1 Blower Motor Kit / Blower Motor Selection "Illi
Super RPM Blower Kit Recommended Starter Kit
Dripproof Model 30 Power, 60 Hz S
Frame Size Number 230 Volt A-C 460 Volt A-C
St
B180ATZ 417077-51 14C520 14C510
ri.ij-.oi!*1-'
B210ATZ 417077-52 14C520 14C510 fTTI

B250ATZ 417077-53 14C520 14C510

B280ATZ 417077-54 14C520 14C510

B320ATZ 417077-55 14C520 14C510


or- ^.in

MOUNTING POSITIONS:
MinPak Plus-Therearetwo alternate mounting locations
for the Blower Motor Starter Kit on the MinPak Plus: Figure 4 Blower Motor Starter Kit MinPak Plus
Front Mounting Location
Front location to left of circuit breaker on the auxiliary
chassis circuit breaker mounting plate (Figure 4). FlexPak Plus - There are two alternate mounting locations
for the Blower Motor Starter Kit on the FlexPak Plus:
Rear location on auxiliary chassis to right hand side of
Front location to right of incoming a-c line fuses on
M-contactor (Figure 5).
the auxiliary chassis fuse/circuit breaker mounting
Choose the location most convenient to you. plate. Referto Figure 3 &6. NOTE: Ifcircuit breaker kit
is used, the Blower Motor Starter Kit must be mounted
on the rear location.

Rear location on auxiliary chassis to right hand side of


M-contactor (Figure 5) NOTE: If reversing kit is used,
the Blower Motor Starter Kit should be mounted on
front location. If this is not possible because Circuit

AUX. CHASSIS WITH HARNESS


FUSE & CB MTG. PLATE
TAPTITE
REMOVED
X
t-R '

II II

TO 51.52
FUSE TERMINALS
fJUMPER
'

P.M.

rT

Figure 3 FlexPak Plus With Blower Motor Starter Kit Figure 5 Blower Motor Starter Kit Mounted In Rear
Mounted In Front Location Location On Auxiliary Chassis

2
Breaker Kit Is present then Blower Motor Starter Kit
must be remotely mounted from FlexPak Plus auxil
iary chassis.

INSTALLATION INSTRUCTIONS

WARNING
BEFORE ATTEMPTING TO INSTALL THIS MIN TAPTITE
SCREW
PAK PLUS/FLEXPAK PLUS MODIFICATION KIT,
DISCONNECT AND LOCK OUT ALL SOURCES OF
INCOMING POWER TO THE CONTROLLER UNIT
AND CABINET.

HARNESS FUSE & CB MTG. PLATE

FUSE & CB MTG. PLATE


TAPTITE Figure 7 Side View Of Blower Motor Starter
AUX. CHASSSIS
SCREW
Mounted To Fuse/Circuit Breaker
Panel

6. Connect jumpers 51, 52, 53 to respective fuse


S2S2 mm
block terminals on Blower Motor Starter Kit.
Connect the other side of these jumpers to the
respective connectors/terminals of the fuse con
nectors on the FlexPak Plus or terminals of the
circuit breaker on the MinPak Plus.

7. With screwdriver adjust blower starter current trip


setting to correspond with name plate data of
blower motor.

JUMPERS" .P.M. 8. Tighten all connections that may have been loo
sened during kit installation.

9. Close faceplate and tighten screws.

Figure 6 Blower Motor Starter Kit FlexPak Plus Rear Location


Front Mounting Location
1. Open face plate cover and let it hang down.
Front location - (Figures 4 & 6) 2. Remove fuse/circuit breaker mounting plate from
auxiliary chassis by removing three screws.
1. Open face plate cover and let it hang down.
3. Mount Blower Motor Kit to auxiliary chassis using
2. Remove fuse/circuit breaker mounting plate from
two taptite screws (Refer to Figure 5).
auxiliary chassis by removing three screws.
3. Mount Blower Motor Kit to fuse/circuit breaker
4. Connect wire harness (188,189,33,34) to respec
tive terminals on blower Motor Starter Kit termi
mounting plate using four taptite screws pro
nal board. Connect other side of harness to
vided. Screws enter from rear of mtg. plate. (Ref
respective terminals on controller power module.
erence Figure 7). NOTE: Kit is mounted on left
hand side for MinPak Plus and righthand side for 5. Connect jumpers 51, 52, 53 to respective fuse
FlexPak Plus. (Reference Figures 4 & 6). block terminals on blower motor starter kit.

4. Remount fuse/circuit breaker mounting plate to 6. Remount fuse/circuit breaker mounting plate to
auxiliary panel using same screws previously auxiliary chassis using previously removed
removed. screws.

5. Connect wire harness to terminal board on 7. Connect loose end of jumpers 51, 52, 53 to
Blower Motor Starter Kit. (188,189,33 &34) route respective terminals on circuit breaker for Min
wire as shown, (Figure 4 & 6). To left for FlexPak Pak Plus or fuse connectors for FlexPak Plus.
Plus and to the right for MinPak Plus. Connect
8. With screwdriver adjust blower starter current trip
other side of harness to terminal board on con
setting to correspond with name plate data of
troller power module (188, 189, 33 & 34).
blower motor.
9. Tighten ail connections that may have been loo- for a Manual Reset Operation which is accomplished by
sened during kit installation. pushing in the blue button on the starter. If automatic
10. Close faceplate and tighten screws. reset js desired move the 8raV ,ever with a sma" sxcrew"
- driver in the slot to the right 90 (located right of blue /tm^
HEATER TRIP RESET pushbutton.) This will result in anautomatic resetcapabil- )
ity on trip.
The Blower Motor Starter Kit is shipped from the factory

X*S*J!!v

Reliance Electric Company / 24703 Euclid Avenue / Cleveland, Ohio 44117

RELIANCE ELECTRIC MS

Printed in U.S.A.
RexRakx/ INSTRUCTION MANUAL D-3962

MmRmc i ACCESSORY

FAN KIT
MODEL NUMBER 14C560
ASSEMBLY DRAWINGS 705328-6

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION Table 1 Specification of FlexPak Plus/MinPak


The Power Module Fan Kit can optionally be added to Plus Units That Can Incorporate The Fan Kit
specific FlexPak Plus and MinPak Plus controller power
FlexPak Plus MinPak Plus
modules to increase the flow and circulation of the air.
The Kit consists of the fan, mounting bracket and hard Model Model
Rating Rating
ware along with the wire harness. (Figure 1) Numbers Numbers

15 HP/ 3 HP/
14C301 14C310
230VAC 230VAC

25 HP/ 5 HP/
14C304 14C310
460VAC 230VAC

30 HP/ 7.5 HP/


14C304 14C310
460VAC 230VAC

10 HP/
14C310
230VAC

3 HP/
14C312
460VAC

5 HP/
14C312
460VAC

7.5 HP/
14C312
460VAC

10 HP/
14C312
460VAC

Even though the 3 hp, 5 hp, 7.5 hp & 10 hp 230VAC


FlexPak Plus, 14C300, doesn't incorporate a power
module fan; the optional fan can not be ulitized with
these ratings because of mechanical constraints.

Figure 1 Fan Kit


INSTALLATION INSTRUCTION
WARNING
BEFORE ATTEMPTING TO INSTALL THIS MIN
SPECIFICATION PAK PLUS/FLEXPAK PLUS MODIFICATION KIT,
115VAC, Single Phase, 50/60 Hz DISCONNECT AND LOCK OUT ALL SOURCES OF
105 CFM INCOMING POWER TO THE CONTROLLER UNIT
AND CABINET.
3200 RPM
1. Open face plate cover and let it hang down. and connect to respective terminals, 188-189 on
power module terminal strip.
2. Mount Fan Kit to chassis using two taptites. Refer to
Figure 2. NOTE: Direction of air fiow is from bottom to 4. Dress all wires away from fan blades
top of chassis controller and fan shall be oriented in 5. Tighten all connectors that may have loosened during
this manner. kit installation.

3. Route harness, 188-189 behind printed circuit boards 6. Close face plate and tighten screens.

/ i 1 r
c -, L

CVU5S15

OMCttON
OffWW

4
~^B nmr

Figure 2 Fan Kit Mounted In Controller Chassis With Air Flow From Bottom To Top

Reliance Electric Company / 24703 Euclid Avenue / Cleveland, Ohio 44117

RELIANCE ELECTRIC MS
^

Printed in U.S.A. 8821M


/{6i$i^
FlexPak i / INSTRUCTION MANUAL D-3963

MinPak i ACCESSORY > ...-.V.A.,!;,


^^'"Lv1^'' f ~"w

STATUS/DIAGNOSTIC INDICATOR KIT


MODEL NUMBERS 14C570,14C571
ASSEMBLY DRAWINGS 705385-74

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION appears. A smaller indicating bar simultaneously appears


next to that function that caused the fault. The fault condi
The Status/Diagnostic Indicator Kit provides a unique
means of monitoring and visually enunciating the status tion can then be corrected. The drive is reset via the
of thirteen, critical control points within the FlexPak Plus/ pushbutton or a power down-up reset. Three of the moni
MinPak Plus Controller. (Figure 1) The Kit contains the tored functions are not fault driven, but provide key status
Status/Diagnostics Indicator mounted to a controller indications of drive performance. Table 1 summarizes the
cover plate and a ribbon cable to connect the kit to the
functions of the Status/Diagnostics Indicator Kit and the
required action.
drive regulator output connector. Besides providing vis
ual status of the controller via an LCD, a fault reset push
button and an output connector for the portable drive WARNING
Diagnostor option is also provided. THISEQUIPMENTSHOULDBEINSTALLED,ADJUST-
ED AND SERVICED BY QUALIFIED ELECTRICAL
OPERATION MAINTENANCE PERSONNEL FAMILIAR WITH
THE CONSTRUCTION AND OPERATION OF THE
The Status/Diagnostic Indicator Kit is connected to the EQUIPMENT AND THE HAZARDS INVOLVED.
drive regulator thru a ribbon cable. Thirteen key drive THIS EQUIPMENT IS AT LINE VOLTAGE ANY
points are monitored and their status is indicated by a TIME THE INCOMING LINE CIRCUIT BREAKER IS
LCD (Liquid Crystal Device) which has the key function CLOSED, WHETHER THE UNIT IS IN OPERATION
shown next to the specific LCD indicating bar. When a OR NOT.
specific fault occurs, a flashing bar, the height of the LCD
Table 1 Status/Diagnostics Indicator Kit Function Indicated - Corrective Action

Function Cause Action


Field Loss Loss of field Excitation Replace Field Bridge
Open field in motor Repair motor
Open/shorted field circuit wiring Correct wiring problem
Blown fuse in field supply Check for short in field wiring
or motor. Replace fuse.

IET Excessive load conditions in Reset pushbutton


armature circuit

Continuous tripping of IET & Look for short or low impedance in


blowing of incoming line fuses armature circuit. Correct problem
and reset drive.

Static overload Excessive loads for periods Limit loading to rating - reset
above drive specifications pushbutton
Table 1 Status/Diagnostics Indicator Kit Function Indicated - Corrective Action (Continued)

| Function | Cause Action

Phase loss Loss of a phase on the Check incoming line conditions.


three phase incoming line Take corrective action.

Line sync Phase relationship on the incom Check incoming line conditions.
ing line is out of specification. Take corrective action.

Excessive incoming line notching Correct line conditions by adding


line filters, isolation transformers etc!

Undervoltage Incoming line potential has Check incoming line conditions.


dipped to an insufficient level. Take corrective action.

Drive thermostat Excessive drive heating Check ventilation systems for drive
enclosure. Check drive ambient
conditions against specifications.
Review loading conditions on drive
and take corrective action.

Open thermostat in drive Replace thermostat

Motor thermostat Excessive motor heating Check motor ventilation system.


Check for dirty filter on blower.
Check motor ambient conditions.
Review loading conditions on
motor and take corrective action.

Open thermostat in motor Replace thermostat


-^
Blower Motor Blower motor interlock has Check ventilation system of motor,
dropped out overloads especially filter conditions

Fuses blown on starter Check out condition of blower


motor replace fuse and correct
condition on motor.

Interlock Fault or emergency condition Correct condition on machine.


(This function is for an exists on machine being driven
interconnection of a machine by controller
interlock to shut down the
drive under an emergency situation)

Current Limit Drive is operating within None necessary


current limit setting

Run Control circuitry in run None necessary


mode condition

Regulator on +11.2 Volt power present on the None necessary


Regulator Module
INSTALLATION INSTRUCTIONS

WARNING
BEFORE ATTEMPTING TO INSTALL THIS MIN
PAK PLUS/FLEXPAK PLUS MODIFICATION KIT
DISCONNECT AND LOCK OUT ALL SOURCES OF
INCOMING POWER TO THE CONTROLLER UNIT
AND CABINET.

1. Open face plate cover and let it hang down.


2. Disconnect the two (2) LED wires, #40 from the regu
lator and #32 from the terminal block.

3. Remove the two screws used to hinge the face plate


and remove face plate (Figure 3)

4. Using previously removed hinge screws, mount the


Status/Diagnostics Kit face plate in same manner as
the previously removed face plate.

5. Connect ribbon cable from Status/Diagnostics Indi


cator kit to regulator module connector. NOTE: Posi
tion of center key on connectors. (Figures 3 & 4)

6. Tighten ail connectors that may have loosened during


kit installation.

7. Close status/diagnostic indicator face plate and


tighten screws (Figure 5). Figure 1 Status/Diagnostics Indicator Kit

MOM
tCCULATOft

r-|4~-H mmum
16 17 IS H 20 21 Zl 21 2H !> U 27 28 21 10 II K 11 1**
^diagnostic!
kONNECTOB

Figure 2 Status/Diagnostics Indicator Kit Schematic

3
Figure 4 Status/Diagnostics Indicator Kit
Connected to Regulator Module

Reliance Electric Company / 24703 Euclid Avenue / Cleveland, Ohio 44117

MS

Printed in U.S.A.
FlexRwcj]/ INSTRUCTION MANUAL D-3965

MwFwcn ACCESSORY

SERIES FIELD KIT


MODEL NUMBERS 14C620,14C621,14C622
ASSEMBLY DRAWINGS 705385-76

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION INSTALLATION INSTRUCTION


The Series Field Kit provides a means of accomplishing
dynamic braking or armature contactor reversing without WARNING

having the interaction and time constant of the sereis field BEFORE ATTEMPTING TO INSTALL THIS MIN
within these functions. The kit consists of additional ter PAK PLUS/FLEXPAK PLUS MODIFICATION KIT,
minals added to the power module terminal board, related DISCONNECT AND LOCK OUT ALL SOURCES OF
harnessing and terminal markers. (Figure 1) INCOMING POWER TO THE CONTROLLER.

1. Open the face plate and let it hang down.


2. Remove fuse/circuit breaker mounting plate from
auxiliary panel by removing three screws.
3. Discount lead #45 at contactor (Refer to Figures 6 &7)
4. FlexPak Plus only Install terminal block S1
between existing terminals 53 & 45.
Add marking tag, S2 to top of existing terminal 45.
(Figure 4) disconnect lead 45 at terminal block and
remove this lead totally from controller.
Figure 1 Series Field Kit MinPak Plus only - Install terminal blocks S1 & 45-S2
between existing terminal blocks A2 and F1. Recon
nect lead 45 to terminal block 45.
Table 1
5. Connect lead S1 to contactor. Lead must be routed
underterminal board mounting bracket (Referto Fig
Kit Model Number Controller Rating ures 4-7).
14C620 3-10hp@230VAC
6. Remount fuse/circuit breaker plate to auxiliary chas
14C622 3-20 hp @ 460VAC sis using screws previously removed.

15-20 hp@230VAC 7. Tighten all connectors that may have been loosened
14C621 and during kit installation.
25-40 hp @ 460VAC
8. Close face plate and tighten screws.
Al
Fr

FROM .'K DC
POWER BRIDGE S MOTOR
..' armature
Vai
a
t

1
1

1 1 1
i SERIES | 1
1 FIELD KIT
MVS2 ; s. J FM

:L_-J? ;. A2
9
J
: DC MOTOR
^ SERIES FIELD
52

Figure 2 Series Field Kit Schematic

SERIES
FIELD KIT
TERMINAL
BLOCKS

1Ipif'^^:^%j^:M- r":

Figure 3 Series Field Kit Installed in FlexPak Plus


REMOVE
LEAD #45
FROM CONTROLLER

LOOSEN SET SCREW


ON LEFT HAND BRACKET
AND SLIDE DOWN TO
INSERT TERMINAL
S1
ADD MARKER S2 AT
THIS LOCATION

Figure 4 Series Field Kit Installation FlexPak Plus

LOOSEN SET SCREW


ON LEFT HAND BRACKET
AND SLIDE DOWN TO
INSERT TERMINALS
S1-51 & S2-45.

RECONNECT
LEAD #45
TO TERMINAL 45.

Figure 5 Series Field Kit Installation MinPak Plus

3
FRONT VIEW OF
AUXILIARY CHASSIS

TOP VIEW
OF CONTACTOR

s\

SAME TERMINAL
LOCATION FOR LEAD
S1 AS THAT OF
REMOVED LEAD #45

Figure 6 Series Field Kit Installation Wiring To Contactor On Model Number Kit 14C620
/'1^Wf!!V

SAME TERMINAL
LOCATION FOR LEAD
S1 AS THAT OF
REMOVED LEAD #45.

Figure 7 Series Field Kit Installation Wiring To Contactor On Model Numbers 14C621 & 14C622

Reliance Electric Company / 24703 Euclid Avenue / Cleveland, Ohio 44117

RELIANCE ELECTRIC MS

Printed in U.S.A. 8821M


FlexRrk'i/ INSTRUCTION MANUAL D-3966

MmRrkhs ACCESSORY
:**--*

DANCER FOLLOWER KIT


MODEL NUMBER 14C230

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION INSTALLATION INSTRUCTIONS


The Dancer Follower Kit allows the MinPak Plus/FlexPak
WARNING
Plus to be controlled automatically in response to a speed
BEFORE ATTEMPTING TO INSTALL THIS MIN
reference generated by a line speed signal and trimmed
PAK PLUS/FLEXPAK PLUS MODIFICATION KIT
by a dancer potentiometer. Applications include web pro
DISCONNECT AND LOCK OUT ALL SOURCES OF
cess lines where a drive must closely follow or maintain
the position of a dancer. INCOMING POWER TO THE CONTROLLER UNIT
AND CABINET.
The Kit contains the Dancer Follower Module and a
mounting screw (Figure 1). Although the MinPak Plus-
1. Open the face plate cover and let it hang down.
/FlexPak Plus can use the Kit for exclusive automatic
speed control, if manual override control is needed, an 2. On the regulator module board locate the area of the
AUTO/MANUAL selector switch must be used on the board marked reference. This is where the Dancer
Local or Remote Operator Control Station. In the MAN Follower Module is to be mounted. Figure 2 shows
UAL position, the drive responds to the SPEED Potenti this area. Place the Dancer Follower Module in the
ometer setting. In AUTO, it follows only the external sig proper orientation so the pin guides on the module
nals and does not respond to manually input speed are aligned over the set of five pins on the Regulator
change commands. Module. Lower the Dancer Follower Module so the
pins pass through the pin guides and the mounting
spacer seats in the mounting hole. (It may be neces
nwm '1S 'vsd-^SPj^TTiMifrr*>jjEi i< sary to remove a protective plastic cap from the pins.)
3 *L'^lf E&jm&sSjSfc;
HigpSfrEly.*?
Secure the module with the supplied screw. Refer to
lill Figure 3.

3 *ii t^^B^ j& 3. Connect the black pig-tail jumper of the Dancer Fol
3 siliiiSa
x&OiQ-S'mr&m^
E#N\
?-' '-" ^
&r lower Module to pin 319 on the regulator module (Pin
319 is the third pin down in it's group) refer to Figure 3.
fOflNCER-, fiOtLUWERiK* i ^^^^^^r
4. Using a twisted pair, connect the external line speed
input to the terminal strip of the Dancer Follower
Module. The plus (+) wire is connected to terminal
Figure 1 Dancer Follower Kit Module
726 and the minus (-) wire is connected to terminal 57.
The Kit is designed to accept a line speed input signal of 4
to 10 VDC to obtain maximum speed. The input impe NOTE: Do not strip more than 1/8 Inch (3 mm) of
dance between the line speed input terminals 57 and 726 insulation off the ends of the wires because a short
is approximately 25,000 ohms. The dancer potentiometer circuit could occur at any point where the bare wire is
will provide up to 20% trim to the line speed signal. exposed. Maintain the twisted configuration of the
two wires as much as possible.
The user must supply the required lengths of the specified
signal wire. A dancer potentiometer and an optional 5. Using three twisted wires, connect the user supplied
dancer position potentiometer are also to be supplied by 5K ohm dancer potentiometer to the terminal strip of
the user. the Dancer Follower Module. The speed increase side
REFERENCE
AREA

REMOTE OPERATOR
ADAPTER MODULE
&
SWITCH
RECEIVER
MODULE
AREA

Figure 2 Regulator Module Kit Locations

PIG
TAIL TO
PIN 319

Figure 3 Dancer Follower Kit Mounted to Regulator Module

of the potentiometer connects to terminal 556 and the 6. If an optional dancer position potentiometer is used
speed decrease side connects to terminal 571. The (supplied by user), connect the "up" side of the poten
potentiometer wiper is connected to terminal 919. tiometer to terminal 726 of the Dancer Follower
Module and the "down" side to terminal 557. Connect is installed, place it in the mid-range.
the potentiometer wiper to terminal 926. Also cut and
Turn the GAIN Potentiometer of the Dancer Follower
remove jumper J2 and the 26.7 K resistor (R6) on the
Module fully counterclockwise for minimum dancer
Dancer Follower Module. Refer to Figure 4.
potentiometer response. Turn the GAIN Potentiome
ter clockwise in small increments to increase the
M W M dancer potentiometer response.
fii r;

POTS NOT SUPPLIED


**BI KITH KIT
\

DANCER
^S6,| p0'
buffering] ' | RIO*' SK*
^saGui *
FILTERING S",- "J
J( {*., TRIM
2!>
2<ji
JUMPER J2 RESISTOR (R6) JUMPER J1
11.2 VDC:
BUFFERING 72e_ () SPEED
St,) - II.? VDC ^ 4 I <J INPUT
FILTERING [__,
S7 -a vdc
72b

Figure 4 Jumpers J1, J2 and Resistor (R6) on Dancer


Follower Module . J? I SS7
L7<-J2fa.7R]-J<*,*-< G '
V, >Z I OPTIONAL
I " DANCER
POSITION
7. If an AUTO/MANUAL selector switch is used on the ADJUST

Operator Control Station, remove jumper J1 of the DANCER FOLLOWER KIT(REFERENCE KIT) e/n 0-S70I0

Dancer Follower Module. Refer to Figure 4. If. how 2t> remove JUMPER IF AUTO/MANUAL SWITCH' IS INSTALLED

ever, the controller is to run automatically without 22> CLIP 2b.7K AND JI WHEN OP'IONAL DANCER POSITION ADJUST POT INSTALLED

manual speed control, leave J1 in place.


Figure 5 Schematic Diagram
8. This Step assumes that the complete drive system,
including the controller, has been successfully 9. Stop drive and disconnect and lock out incoming
started and debugged. (Refer to your Controller power.
Instruction Manual start up section, if this has not
been accomplished.) 10. Tighten all connections that may have come loose
during the kit installation.

It is now necessary to conduct a power-on test. Start 11. Close face plate and tighten screws.
the drive and place it in the AUTO mode, if so
equipped. With the line speed reference at maximum DANGER '
value, adjust the MAX SPEED TRIM Potentiometer on APPLICATION MUST NOT RELY ON ZERO SET/
the Dancer Follower Module for maximum motor INPUT SETTING FOR SAFETY. SERIOUS OR
speed. If the optional dancer position potentiometer FATAL INJURY MAY RESULT.
FiexRakk/ INSTRUCTION MANUAL D-3967

MinPak
ACCESSORY

INSTRUMENT INTERFACE/PRESET SPEED KIT


MODEL NUMBER 14C222

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION The Kit contains a Module that has a jumperthat must be


connected by the user to select one of two maximum input
The MinPak Plus/FlexPak Plus can automatically follow a
signals: 5 mA or 50 mA. There is also a mounting screw.
milliampere signal from a process control instrument if
The Kit may be used aloneto provide full, automatic drive
the optional Instrument Interface/Preset Speed Kit is
control, or it may be used with an optional AUTO/MAN
installed. (Referto Figure 1). Alternately, the Kit also per
UAL selector switch on the Operator Control Station. This
mits the drive to run continuously at a preselected speed.
switch may be used to manually override the external d-c
The Instrument Interface Module accepts a 0 to 5,1 to 5, 4 signal. (In the MANUAL position, the drive follows the
to 20 or 10 to 50 mA signal, which may be grounded or SPEED Potentiometer on the Station.) The user supplies
ungrounded. The maximum input is 50 mA. the required lengths of specified signal wire.
A process instrument controller, or other transducer with
a d-c milliampere output, is also required.
NO TE: If the Operator Control Station contains an A UTOI
MANUAL selector switch, it is necessary to remove
jumper J1 from the Instrument Interface Module and J4
on the Regulator Module. (Refer to Figures 1 & 3. Do this
before placing the Module on the Regulator Module.)

INSTALLATION INSTRUCTIONS

WARNING
BEFORE ATTEMPTING TO INSTALL THIS MIN
PAK PLUS/FLEXPAK PLUS MODIFICATION KIT
DISCONNECT AND LOCK OUT ALL SOURCES OF
Figure 1 Instrument Interface Kit
INCOMING POWER TO THE CONTROLLER UNIT
AND CABINET.
Typical applications include cases where the drive
motor's speed must be controlled and varied as a function
of such process variables as temperature, weight, fluid 1. Open face plate cover and let it hang down.
flow and pressure. 2. Orient the Module over the dedicated area marked
The Auto Minimum Speed Potentiometer on the Module REFERENCE on the Regulator Module, just over the
can be set so that the drive runs at a preset minimum five pins. (Refer to Figure 2.) Lower it so that the pins
speed (up to 50%) with a minimum output signal from the pass through the guides on the Module. Use the screw
to secure it.
process instrument. The Auto Maximum Speed Potenti
ometer on the Module can be set so that the drive runs at 3. Connect the external reference signal wires to the
50% to base speed with a maximum output signal from the terminal strip on the Module. Plus (+) is on the left,
instrument. Other relationships within these parameters minus () on the right. Do notstrip morethan % inch
are also possible, and they allow operation over a larger (3 mm) of insulation off since shorts could occur at
speed range than the 5:1 range provided by the process exposed points. Maintain the twisted character as
controller. long as possible.

1
REFERENCE
AREA

REMOTE OPERATOR
ADAPTER MODULE
&
SWITCH
RECEIVER
MODULE
AREA

Figure 2 Regulator Module Kit Locations

Instrument Interface Installation Only Step 4 Since there is some interaction between these
two potentiometers, at times it may be necessary to work
When the Kit is to be used as an instrument interface,
back and forth to achieve precise adjustments.
follow these Steps.

Stepl Determine whether the maximum input signal is Preset Speed Installation Only
between 0 to 5 mA or 5 to 50 mA. Locate the black pig-tail When the Kit is to be used as a simple preset speed device,
jumperon the Module. (Referto Figure3). Carefully place follow these Steps.
it on the directly corresponding pin, both of which are
Step 1 This Step assumes that the complete drive sys
clearly marked. tem, including the controller, has been successfully
Step 2 This Step assumes that the complete drive sys started up and debugged. (Refer to your Controller
tem, including the controller, has been successfully Instruction Manual, start up section if this has not been
started up and debugged. (Refer to your Controller accomplished.)
Instruction Manual, start up section, if this has not been
accomplished). It is now necessary to carry out a power-
on test. Place the controller in the AUTO mode, if it is so
equipped. Set the process instrument controller for min
imum output. Locate the Auto Minimum Speed Potenti
ometer on the Interface Module. Using a small insulated
screwdriver, adjust it for the desired minimum motor
speed. (CCW decreases speed.)

Step 3 Set tne process instrument controller for maxi


mum output Locate the Auto Maximum Speed Potenti Jumper J1
mA pins
ometer. Adjust it for the desired maximum motor speed.
(CW increases speed.) Figure 3 Jumper J1, mA Pins

2
'*^y^^S^i^^^m^S3l^^]rf^rm
INSTRUMENT
INTERFACE/
PRESET
SPEED
KIT

Figure 4 Instrument Interface/Preset Speed Kit Mounted to Regulator Module

Step 2 Connect the black, pig-tail jumper on the Inter


face Module to the 50 mA pin. (Refer to Figure 3).
,e> . < E
E O
Step 3 Locate the Auto Minimum Speed Potentiometer RANGE
SELECT

on the Interface Module. Turn it CW to the third dot which 1


represents a one-third turn. 32bb }I
ISOLATION
I
FILTERING
Step 4 Place the controller in the AUTO mode, if so 71 ] 1- - 11.2V
Sb} ^- +II.2V
equipped. Locate the Auto Maximum Speed Potentiome
ter. Adjust it to obtain the desired preset speed. (CW
S7 ov
2O0K _bV AUTO
N.SPO.

increases speed, CCW decreases it.) AUTO HAX.SPO. L/ V'


' I0K
PRESET SPEED ANO + 11.JY
IhSTRUr-ENT INTERFACE (REFERENCE KIT ) B/M 0-S70C2
Step 5 Tighten all connections that may have come
loose during kit installation.

Step 6 Close face plate and tighten screws. 17> Set Auto Min. Speed with input an minimum, then set Auto
Maximum Speed with input at maximum. Motor must not
exceed its speed or voltage rating.

18> Jumper for various process controllers.

19> Remove jumper it Auto/Manual switch is used.

Figure 5 Instrument Interface/Preset Kit Schematic


FlexPak /
INSTRUCTION MANUAL D-3968

' MinPak ACCESSORY

MASTER ISOLATED REFERENCE RECEIVER KIT


MODEL NUMBER 14C229

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION

The addition of the optional Master Isolated Reference


Receiver Kit allows the MinPak Plus/FlexPak Plus to
receive and decode a PWM speed reference signal from
the Master Isolated Reference Transmitter. The Receiver
Kit consists of two printed circuit boards: a Switch
Receiver Module and a Reference Receiver Module which
are mounted on the MinPak Plus/FlexPak Plus Regulator
Module. (Refer to Figure 1).
XT w fr\
The Operator Control Station AUTO/MANUAL selector
switch is used to obtain local control or master reference
control of the individual drive. When the selector switch is
placed in the automatic mode, the individual drive speed Reference
potentiometer automatically is converted into a draw pot Receiver Module
adjustment for precise trim control between drives. The Switch Receiver Module
only adjustment requirement is a zero set adjustment on
the Reference Receiver Module. Should the speed refer- Figure 1 Master Isolated Reference Receiver Kit

sf" REFERENCE
AREA

REMOTE OPERATOR
ADAPTER MODULE
& SWITCH RECEIVER
MODULE AREA

Figure 2 Regulator Module Kit Locations


ence wires become disconnected, the MinPak Plus/
FlexPak Plus will go to zero speed.
Master Isolated Reference controlled MinPak Plus's &
FlexPak Plus's are ideally suited for non-reversing multi
ple conveyor drives, proportional pumps, feeder drives,
web lines or other similar operations which require multi
ple drives to follow a common reference signal.

INSTALLATION INSTRUCTIONS

WARNING
BEFORE ATTEMPTING TO INSTALL THIS MIN
PAK PLUS/FLEXPAK PLUS MODIFICATION KIT
DISCONNECT AND LOCK OUT ALL SOURCES OF
INCOMING POWER TO THE CONTROLLER UNIT
AND CABINET. JUMPER J1

1. Open face plate cover and let it hang down. Figure 3 Jumpers J1 and J2
on Switch Receiver Module
2. Refer to Figure 2 and note the heavy border area at the
extreme left-hand side of the Regulator Module. This 5. Refer to Figure 2 and note the heavy border area in the
is the area where the Switch Receiver Module is to be
center of the Regulator Module marked REFERENCE.
mounted. First, remove the Remote Operator Adapter This is the area where the Reference Receiver Module
is to be mounted. Place the Reference Receiver
Module. Then, place the Switch Receiver Module in
the proper orientation so the two connectors are Module in the proper orientation so the pin guides on
aligned over the two sets of pins (marked GRN 28 and the module are aligned over the set of five pins on the
RED 32). Carefully, slowly and gently press the con Regulator Module. Lower the Reference Receiver
nectors down on the pins until they bottom. Then, Module so the pins pass through the pin guides and
connect the black pig-tail jumper of the Switch the mounting spacer seats in the mounting hole. (It
Receiver Module to pin 40 on the Regulator Module. may be necessary to remove a protective plastic cap ^/<5S^v
from the pins.) Secure the module with the supplied
(NOTE: Pin 40 is located at top of Regulator Module screw.
just above board metal heat sink.) If drive incorpo
rates the front panel green LED indicator, remove 6. Connect the external start-stop wires (wires 189 and
white wire on Pin 40 and connect black pig-tail jumper 288) from the external Master Isolated Reference
Transmitter to the terminal block on the Switch
from Switch Receiver Module to Pin 40. Connect
Receiver Module in the controller cabinet.
white wire to Pin 139 near Pin 40.

3. Fold the PC board over the top of the two connectors NOTE: If remote operator devices are used, this step
so the mounting spacers fit into the mounting holes. must be completed before installing the Remote
Operator Adapter Module.
4. Mount the Remote Operator Adapter Module on top
of the Switch Receiver Module and secure the two PC
7. Using a twisted pair, connect the external reference
boards with the two long screws provided. wires (wires 1 and 2) from the external Master Isolated
Reference Transmitter to the terminal block on the
If a Local Operator Station is being used, secure the Reference Receiver Module in the controller cabinet.
Switch Receiver Module with the two short screws Connect wire 1 to terminal 1 and wire 2 to terminal 2.
provided. The Local Operator Station is then mounted
and connected to the two sets of pins on the Switch NOTE: Do not strip more than 1/8 inch (3 mm) of
Receiver Module.
insulation off the ends of the wires because a short
circuit could occur at any point where the bare wire is
NOTE: The external start-stop wires from the Master exposed. Maintain the twisted configuration of the
Isolated Reference Transmitter (wires 189 and 288) two wires as much as possible.
must be connected to the Switch Receiver Module
(Refer to Step 6.) before mounting the Remote Opera 8. If an AUTO/MANUAL selector switch is included in

tor Adapter Module on the Switch Receiver Module. the Operator Control Station, cut jumper J1 on the
Jumpers J1 and J2 on the Switch Receiver Module Reference Receiver Module. Refer to Figure 4. Also
(Refer to Figure 3) must be cut when Local or Remote cut jumper J4 at Regulator Module. ^
Operator Stations are used. These jumpers are left 9. With the MASTER Speed Potentiometer on the Mas
connected when only control from the Master Iso ter Isolated Reference Transmitter set at zero,
lated Reference Transmitter is desired. depress the START pushbutton on the Master Iso-
AU
DANGER .
ALTHOUGH ZERO SET ADJUSTMENT ON THIS;
KIT ALLOWS FOR ADJUSTMENT DOWN TO ZERO
SPEED, THIS ZERO SPEED SETTING MUST NOT
BE USED WHERE THE OPERATOR MAY RELY ON
A MAINTAINED ZERO SPEED. ELECTRICAL
NOISE, IMPROPER WIRING, POWER LINE, OR
MALFUNCTIONING COMPONENTS MAY CAUSE:
THE DRIVE TO TURN ON WHILE AT THE ZERO
Jumper J1
SPEED SETTING. :
Figure 4 Jumper J1 on Reference Receiver Module
lated Reference Transmitter. Adjust the ZERO SET
Potentiometer on the Reference Receiver Module to
obtain zero speed of the drive motor.

BLACK PIGTAIL
JUMPER
SWITCH
RECEIVER
KIT

REFERENCE
RECEIVER

Figure 5 Master Isolated Reference Receiver Kit Mounted on Regulator Module


-0232
-TTTCRay
-0-
PS \nto -Q56
"} -OS7
-Q99
-.-Jbrm
-DTI
TCL
I 20} -O20
! 2t}
CRN
Li* -QI28
r-r-Q6RN
6>
Jul. J2*
-Ol26
81R
I2*
-06S
* -O66
-O 39(38) <22
<38)67> -Otitis)
ORG
- a i35
Jl^3
ho Ibrn RED
auc 018
032
L'iS
a i2
jic-a

INPUT

288 J
SWnCH RECEIVER KIT
VH 0-57008

Figure 6 Master Isolated Reference Receiver Kit Schematic Diagrams

Reliance Electric Company / 24703 Euclid Avenue / Cleveland, Ohio 44117

v
RELIANCE ELECTRIC MS

Printed in U.S.A.
D-3968
FlexPak / INSTRUCTION MANUAL D-3969

' MinPak ACCESSORY

TACHOMETER FEEDBACK KIT


MODEL NUMBER 14C221

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION Table 1 Tachometer Voltage Scaling

The FlexPak Plus/MinPak Plus Controller is supplied as


Motor Base 100%
standard as a d-c armature voltage feedback controller. Tachometer
Speed Voltage
With the addition of the optional Tachometer Feedback (volts/1000 rpm)
(rpm) Connection
Kit, it can operate as a speed-regulated unit, thereby
improving regulation to as little as 0.5% with specified 1150 20 VDC 23
tachometers. (Refer to Figure 1). Either an a-c or d-c 1750 20 VDC 35
tachometer may be used. The maximum allowable input 1150 50 VDC 58
voltage is 175 volts. 3450 20 VDC 69

1750 50 VDC 88
1150 100 VDC 115
3450 50 VDC 175
1750 100 VDC 175

1150 45 VAC 52
1750 45 VAC 79
3450 45 VAC 155

INSTALLATION INSTRUCTIONS

WARNING
BEFORE ATTEMPTING TO INSTALL THIS MIN
PAK PLUS/FLEXPAK PLUS MODIFICATION KIT
Figure 1 Tachometer Feedback Kit DISCONNECT AND LOCK OUT ALL SOURCES OF
INCOMING POWER TO THE CONTROLLER UNIT
AND CABINET.
A 1% speed regulation with 95% load change can be
obtained when using a Reliance Electric a-c tachometer To install the Kit, follow these procedures. Check the
(RE-045) or d-c tachometer (5 PY or RE-020). A 0.5% tachometer to determine which wires areT1 (+) and T2().
speed regulation with a 95% load change can be obtained
1. Orient the Tachometer Module over the designated
when using a Reliance Electric d-c tachometer (BC-42).
area of the Regulator Module, just over the two pins.
Equivalent tachometers are acceptable.
(Refer to Figure 2.) Lower it so that the pins pass
through the guides in the Module. Use the screw to
The Kit contains a Module that has a jumper that must be
secure it.
connected by the user to provide proper scaling of the
feedback into the regulator. There is also a mounting 2. Connect the tachometer wires to the terminal strip on
;crew. The user must supply the tachometer and the the Module. Plus (+) is the left side, minus () the
required lengths of specified signal wire. (Refer to Table right. Do not strip off more than 1/8 inch (3 mm) of
1). No other equipment is necessary although certain insulation since shorts occur at exposed points. Main
adjustments must be made on the Regulator Module. tain the twist as long as possible.
REFERENCE
AREA

REMOTE OPERATOR
ADAPTER MODULE
& SWITCH RECEIVER
MODULE AREA
TEST
'AREA

TACHOMETER FEEDBACK
AREA

Figure 2 Regulator Module Kit Locations

3. Locate the black pig-tail jumper on the Tachometer


Module. It is to be placed on one of ten pins on the
Module. Exactly which depends on the voltage scal
ing factor. On the motor's nameplate, find the base JUMPER J2
speed (rpm). On the tachometer's nameplate, find the
output voltage per 1000 rpm.

Take these two figures and relate them to Table 1.


Read across to the right column, where the 100% volt
age figure is indicated. Place the jumper on the
Module's pin that corresponds to the figure.

tessSSS -..'
DANGER
WHEN A REVERSING CONTACTOR IS INSTALLED JUMPER J1

OR FOR ANY REASON THE TACHOMETER OUT


PUT VOLTAGE IS REVERSED, JUMPERS J1 and J2 Figure 3 Jumpers J1, J2
ON THE TACHOMETER FEEDBACK KIT MUST BE
REMOVED REGARDLESS OF THE TYPE
TACHOMETER USED. PERSONAL INJURY MAY
RESULT IF THIS PROCEDURE IS NOT
FOLLOWED.

4. Follow this Step only if an a-c tachometer is being


used. Skip to Step 5 if a d-c device is used.
On the Tachometer Module, locate jumpers J1 and J2
on the right of the terminal strip. (Refer to Figure 3).
Clip out and discard these jumpers for a-c operation.

5. Since the IR compensation is not used with tachom Figure 4 Feedback Connection on Regulator Module
eter feedback, it is necessary to turn the IR Potentio
meter fully CCW. If IR compensation is left in the ure 4.) Place the Regulator Module's fixed black
circuit, erratic operation may result. jumper on the pin marked T.

6. The Feedback Jumper on the Regulator Module must 7. This Step assumes that the complete drive system,
be connected fortachometerfeedback. (Referto Fig- including the controller, has been successfully
Figure 5 Tachometer Feedback Kit Mounted on Regulator Module

started and debugged. (Refer to your Controller test with power on in order to confirm that proper
Instruction Manual, start up section to accomplish feedback signals are being received by the regulator.
this.)
If erratic behavior continues, check the placement of
It is necessary to carry out a power-on test. Set the the two pig-tail jumpers against Steps 3 and 5.
SPEED Potentiometer at approximately 25% of full
8. The maximum and minimum speed potentiometers
rotation. Start the drive. It should run as set. If it
should now be adjusted per the start up instructions
accelerates to full speed, the tachometer is not provid
in your Controller Inst ruction Manual. DO NOT make
ing a signal.
any adjustments to the IR compensation potentiome
Stop the drive, turn off all power, and reverse the leads ter. It must be set fully CCW.
to the Tachometer Module's terminal strip. Repeatthe

I V> OC-| 22^ W VOLTAGE AT AC ft DC CONNECTION I 8> Wiring for tachometer input leads must be tightly twisted
9999999* .. ,a with two full turns per inch, minimum. Leads must be run
physically separated from all power circuit wiring.
719)- DIVIDER

"1- NETWORK
I DIODE
DIODE ACJ
AC =oItach
_to INPUT 9> For DC tach, jumper is connected in this location.
"J ro66
>j r* > >
BRIDGE

AC-I w*~
10> For AC tach, jumper is connected in this location.
1

29> If using an AC Tach, remove J1 & J2


TACH FEEDBACK KIT 1/H0-S700H
I

Figure 6 Tachometer Feedback Kit Schematic


FlexPak /
INSTRUCTION MANUAL D-3971

MinPak ACCESSORY

VOLTAGE/TACHOMETER FOLLOWER KIT


MODEL NUMBER 14C223

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION The user must also supply required lengths of the speci
fied signal wire. No other equipment is necessary
The Voltage/Tachometer Follower Kit allows the FlexPak
although some changes may be necessary on the Module.
Plus and MinPak Plus to be controlled automatically in
response to a speed reference generated by a tachometer
connected to an entirely separate machine unit. Ideal INSTALLATION INSTRUCTIONS
applications include automatic control systems where a
"second" slave drive must closely follow the speed of a WARNING

master drive, or machine. (Refer to Figure 1). BEFORE ATTEMPTING TO INSTALL THIS MIN
PAK PLUS/FLEXPAK PLUS MODIFICATION KIT
DISCONNECT AND LOCK OUT ALL SOURCES OF
INCOMING POWER TO THE CONTROLLER UNIT
AND CABINET.
IS MRX.
AUTO
MAX. SPG.
0-57003 S?'
1. Orient the Voltage/ Tachometer Follower Module
Kfti over the REFERENCE area on the Regulator Module,
just over the five pins. (Refer to Figure 2.) Lower it so
that the pins pass through the guides on the Module.
. . '"-' " ut
(It may be necessary to remove a protective plastic
cap from the pins.) Secure the Module with the screw.

e -i 2. Connect the wires from the tachometer to the termi


nal strip on the Module. Plus (+) is on the left, minus
(-) on the right. Do not strip more than % inch (3 mm)
of insulation off since shorts occur at exposed points.
Figure 1 Voltage/Tachometer Follower Maintain the twisted character as long as possible.
3. If an AUTO/MANUAL selector switch is used, it is
The Kit is designed to accept an input signal of 25 to 250
necessary to remove jumper J1 on the Module. (Refer
VDC to obtain maximum speed. (The maximum permissi
to Figure 3.) If, however, the controller is designed to
ble input voltage is 250 VDC.) The input impedance
run automatically without manual speed control, J1
between terminals is approximately 80,000 ohms. There
remains in place. In addition, remove jumper J4on the
fore, 100 VDC draw approximatley 1.25 mA current from
Regulator Module if an AUTO/MANUAL selector
the voltage source.
switch is used.
The Kit contains the Module and a mounting screw.
4. This Step assumes that the the complete drive sys
Although the FlexPak Plus and MinPak Plus can use the
tem, including the controller, has been successfully
Kit for exclusive automatic speed control, if manual over
started up and debugged. (If this has not been
ride control is needed, an AUTO/MANUAL selector
accomplished, referto the start up instruction section
switch must be used on the Operator Control Station. In
of your Controller Instruction Manual.)
the MANUAL position, the drive responds to the SPEED
Potentiometer setting. In AUTO, it follows only the exter It is now necessary to carry out a power-on test. Start
nal signal and does not respond to manually input speed the drive and place it in the AUTO mode, if so
change commands. equipped.
REFERENCE
AREA

REMOTE OPERATOR
ADAPTER MODULE
&
SWITCH
RECEIVER
MODULE
AREA

Figure 2 Regulator Module Kit Locations

With a small, insulated screwdriver, adjust the Auto


Speed Calibration Potentiometer on the Tachometer/
Follower Module until the drive reaches the desired
speed in relation to the reference input signal being
received.

DANGER
APPLICATION MUST NOT RELY ON ZERO
SPEED/INPUT SETTING FOR SAFETY. SERIOUS
OR FATAL INJURY MAY RESULT.
Figure 3 Jumper J1

AUTO.SPD.CAL.
8> Wiring for tachometer input leads must be tightly twisted
with two full turns per inch, minimum. Leads must be run
physically separated from all power circuit wiring. (See
,2>y DC TACH note 14 for insulation temp, rating.)
INPUT

19> Remove jumper if Auto/Manual switch used.


VOLTtSE TACH FOLLOWER (REFERENCE KIT! /n 0-57003

Figure 5 Voltage/Tachometer Follower Kit Schematic


VOLTAGE/TACHOMETER
FOLLOWER KIT

Figure 4 Voltage/Tachometer Follower Kit Mounted To Regulator Module


FlexPak / INSTRUCTION MANUAL D-3970

r MinPak ACCESSORY

TEST METER ADAPTER KIT


MODEL NUMBERS 14C225
The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

Table 1 Test Adapter Terminals, Readings


CAUTION: Under no circumstances should the
probes of a meter be connected directly to the pins Normal
Use
on the regulator module. Permanent damage to the For Function: Indication
Terminals:
solid state components can occur. (VDC):

Unregulated +456 16-28


+20 VDC -357
DESCRIPTION
Power Supply
Measuring and Monitoring of the MinPak Plus and Flex
Unregulated -471 16-28
Pak Plus regulator voltages can be safely and conve
20 VDC +357
niently carried out with the optional test meter adapter kit.
Power Supply
(Refer to Figure 1) it acts as an interface between the
regulator module and a user's voltmeter. Regulated +356 10.8-11.5
+11.2 VDC -357
The Kit contains a Module and a mounting screw. Except
Power Supply
for the voltmeter, no other equipment is necessary. The
meter should be a multimeter having a sensitivity of Regulated -371 10.8-11.5
20,000 ohms per volt, minimum. (Simpson Model 260, 11.2 VDC +357
Triplett Model 630, or equivalents are acceptable.) Power Supply

Drive Reference +826 0-9.6V


Signal -357

Major Loop -819 0-4.0


Feedback +357

Armature -816,* 0-4.0


Voltage +357
Feedback

Current -817,* 0-1.0


Feedback +357

* Early Production Boards, this signal is PREF, Analog


Signal into Digital Driver Board 5V = 100%.

INSTALLATION INSTRUCTIONS

WARNING
BEFORE ATTEMPTING TO INSTALL THIS MIN
PAK PLUS/FLEXPAK PLUS MODIFICATION KIT
DISCONNECT AND LOCK OUT ALL SOURCES OF
INCOMING POWER TO THE CONTROLLER UNIT
AND CABINET.
Figure 1 Test Meter Adapter
1. Orient the Test Meter Adapter Module over the area 2. For use, refer to Table 1 where the function is shown
on the Regulator Module marked TEST, just over the in relation to the test terminals to be used. The normal
ninepins. (Referto Figure2). Lower it so that the pins operating voltages are also shown.
pass through the guides on the Module. Use the screw
to secure it.

REFERENCE
AREA

H%$$

REMOTE OPERATOR
ADAPTER MODULE
&
SWITCH
RECEIVER ^-i
MODULE
AREA

Figure 2 Regulator Module Kit Locations

TEST
METER
^ADAPTER
KIT

Figure 3 Test Meter Adapter Kit Mounted To Regulator Module

13.0-

"3- -Or;

*> -Dl5t
I 7t> -CJjQ-0 17
I ,7> -i l IDm I
-no-DHst
27,>
TEST METES ADAPTER KIT 8/H 0 J 7Oi.

Figure 4 Test Meter Adapter Kit Schematic


Reliance Electric Company / 24703 Euclid Avenue / Cleveland, Ohio 44117

RELIANCE ELECTRIC MS
Printed in USA
FlexPak INSTRUCTION MANUAL D-3955

ACCESSORY

M-CONTACTOR ADAPTER KIT


MODEL NUMBER 14C470
ASSEMBLY DRAWINGS 705388-4

The equipment described below should beinstalled only byqualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION 1. Orient the Auxiliary Mounting Bracket (Refer to Fig


The Contactor Adapter Kit provides a means of connect ure 1) overthe Basic Controlleraligning the mounting
ing the optional user-supplied Mcontactor (and optional holes. Secure the Bracket with the provided washers
user-supplied reversing M contactor) to the optional and screws. Make sure the washer teeth are firmly
Basic FlexPak Plus Controller 14C320 thru 14C325 which
embedded in the Chassis to provide proper ground.
is supplied without the auxiliary panel. 2. Connect user supplied 115VAC, 3 amp max power to
The Kit is an assembly consisting of an Auxiliary Mount
188-189 on pilot relay PC. Now connect the orange
lead (139) from the pilot relay harness to the con
ing Bracket, a power terminal strip, two wire harnesses
and four screws and a pilot relay. troller regulator printed circuit card (refer to Figure 1.)
3. Wire the optional user-supplied M contactor (and
INSTALLATION
optional user-supplied reversing contactor) to the kit
terminal strip according to Figure 2A or 2B. Also, refer
WARNING
to Figures 5.8, 5.9, 5.11 and 5.12 of D-3938 for addi
BEFORE ATTEMPTING TO INSTALL THIS FLEX
tional wiring diagram information.
PAK PLUS MODIFICATION KIT, DISCONNECT
AND LOCK OUT ALL SOURCES OF INCOMING
POWER TO THE CONTROLLER.

M-CONTACTOR
ADAPTOR KIT

188
189

PILOT
RELAY PC CARD

BASIC CONTROLLER
j POWER MODULE

P.tt.

W.d. ?c

Figure 1 M-Contactor Adapter Kit Mounted To Basic Controller


.f?fc
/^HfSV
o -1
USER SUPPLIED 115 VAC
3 AMPS MAX.
INDUCTIVE LOAD { jJJ I
I

I FP*o-
"\o?tt.?c.

IPMCfl ?VNVK

Figure 2A M-Contactor Adapter Kit Wiring Diagram Forward Only Application

x ;;-.
L:>-
!Y?* I *&& o-*--tiv- -f
I \tn
USER SUPPLIED \as i.
115 VAC
t&<* r
3 AMPS MAX.
INDUCTIVE LOAD

vhnsO
i ??* O h P-lr-*
l&ttfc.PC
C7 onov p-jrr-i
IVESM^ ^
I P\IQT ESlftf PC

|\&& *?*

l*lo~ _-!'_-.

w* o-
l3UgU') j
^ tt& YL
131 CV)0) ^-
I P/iar flrtir PC
U(gk/
tf.::

Figure 2B M-Contactor Adapter Kit Wiring Diagram Forward and Reversing Applications

Reliance Electric Company / 24703 Euclid Avenue / Cleveland, Ohio 44117


>

RELIANCE ELECTRIC MS

Printed in U.S.A. 8821M


FuxRug INSTRUCTION MANUAL D-3958

ACCESSORY

AUXILIARY PANEL
MODEL NUMBERS 14C330,14C331,14C332
ASSEMBLY DRAWINGS 801566

The equipment described below should be installed only by qualified electrical maintenance personnel familiar
with the construction and operation of the equipment and the hazards involved.

DESCRIPTION 8. Remount fuse/circuit breaker mounting plate to auxil


The Auxiliary Panel Kit contains a-c line fuses, an M- iary panel using same screws removed previously.
contactor, a fuse/circuit breaker mounting plate and four 9. Tighten all connectors that may have been loosened
screws for use with the basic FlexPak Plus Controller. The during kit installation.
Auxiliary Mounting Panel is used to mount the incoming
line fuses, the Optional Circuit Breaker Kit and the Blower 10. Close face plate and tighten screws.
Motor Starter Kit which can also be mounted on the rear
mounting location, next to the M-contactor. The Revers
ing Kit is also mounted on the rear location next to the
M-contactor. (NOTE: The Blower Motor Starter Kit,
Reversing Contactor Kit, and Circuit Breaker Kit can be
used in any combination of two. However, all three CAN
NOT be used at the same time.) cx^Wokv cfor cowuaoR
SEC OETAIL-D")

The Auxiliary Panel is standard on model numbers Oj&OUfr


14C300 thru 14C305. This manual is for combining the AUXILIARY
PANEL
Auxiliary Panel with the optional basic controller model
numbers 14C320 thru 14C325 only. o<? <7

oLo
INSTALLATION llnll

1. Align the side mounting brackets with the holes in the


basic chassis.

2. Using screws provided mount the auxiliary panel to


the basic controller.
: s@Hfc:
3. Connect wires from terminal connectors 51, 52, 53 to BASIC
line fuse holders marked 51, 52, 53 correspondingly. CONTROLLER

(Refer to Figure 2). OPCKATOR Bma?SPD


B/M BnlN spo
o-sxos
J*I Qacc
4. Open face plate cover and let hang down. Gogc
REG. PC B LIMIT tLU
B/*Q.S7ttO BlBC0K>7l
5. Remove fuse/circuit breaker mounting plate from
auxiliary chassis by removing three existing screws.
M. M.
6. Connect wires from terminals 45 and 45 to corres
ponding terminals located on M-contactor. (Refer to
Figure 2).

7. Connect harness from pilot relay, if supplied, to regu


lator printed circuit card in controller, orange lead
harness to 139 to pin 139 on printed circuit card.
Connect 188-189 of pilot relay to terminals 188-189 on Figure 1 Three Phase FlexPak Plus Auxiliary Panel
controller. and Basic Controller
CONNECTION
TO INCOMING
LINE FUSES
51,52,53

M-CONTACTOR
45-47
WIRE
CONNECTIONS

Figure 2 Auxiliary Panel Wiring

Reliance Electric Company / 24703 Euclid Avenue / Cleveland, Ohio 44117

RELIANCE ELECTRIC MS

Printed in U.S.A