Reliance flexpak plus Installing, Operating & Maintaining Download

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Summary of Contents for flexpak plus

Page 1: ...I JUNE 1981 INSTRUCTI ONMANUAL 0 3900 INSTALLING OPERATING nd MAINTAINING FLExPAKD D C Y J D RIVE and MODIFICATION KITS RE 17 1 ri 1 1 w _ _ TRJC I Ii r...

Page 2: ...Regulator Module Pots 16 Maximum Speed Voltage 16 Min imum Speed Voltage 16 Acceleration and Decelerati on Rates 16 4 3 5 4 3 6 5 5 0 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 7 1 5 7 2 5 8 5 9 5 10 5 1 1 5 12 5...

Page 3: ...5 Specifications 6 Fuse Requirements 7 0 C Motor Controller Transformer Specifications 7 Typical Wire Fuse Sizes 10 Reliance Electric Isolation Transformers 13 Horsepower Calibration 14 Modification...

Page 4: ...Ii...

Page 5: ...IF INDIVIDUALS ARE NOT FAMILIAR WITH THE HAZARDS RESULTING FROM IM PROPER OPERATION Complete Controller DANGER CONTROLLER EQUIPMENT IS0 AT LINE VOLTAGE WHEN A C POWER IS CONNECTED TO THE POWER UNIT IN...

Page 6: ...ler Basic Controller with Auxiliary Panel Both the Basic Controller and the Auxil iary Panel Figure 2 1 are Underwriters I l rr r r t L 1J Basic Controller Laboratories U L recognized Both units when...

Page 7: ...ator Adapter Module and or Master Reference Switch Receiver Module Tachometer Feedback Dancer Follower Master Isolated Reference Receiver Contactor Adapter The Auxiliary Panel modifications are Dynami...

Page 8: ...lation 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 Jum...

Page 9: ...djustable at 68 typical CD single phase only optional control pot Transient Protect ion Line Voltage Variation 10 to 150 of rated load MOV and Output RC Circuit 10 of nominal IR Drop Compensation Cont...

Page 10: ...UM FULL AMPS ARM AMPS FIELD MAX CAPACITY kVA LOAD BASIC COMPLETE HP VAC RMS VOLTS avg VOLTS optional CD Per Phase kVA 1 4 115 3 5 90 2 5 100 3 0 5000 40 0 75 14C50 14C50 14C80 115 5 2 90 3 7 100 3 0 5...

Page 11: ...AL ELECTRICAL CODE WITH RESPECT TO MOTOR CONTROLLER AND OPER ATOR DEVICE INSTALLATION WIRING AND START UP THE USER IS ALSO RESPONSIBLE FOR UNDERSTANDING AND APPLYING ALL OTHER APPLICABLE LOCAL CODES W...

Page 12: ...rrents may be eliminated in instances where a d c output accidentally becomes grounded in a unit where the a c electrical system is grounded For detailed information refer to Paragraph 3 4 Guideline 7...

Page 13: ...i na I boxes that contain non signal a c or d c 115 230 460 V wires Guideline 11 Operational altitude above sea level may not exceed 3300 ft 1000 m Derate horsepower 3 for each 1000 ft 300 m above thi...

Page 14: ...YELi 67 GRAY 1 I I I I I I I I I _J Notes Tachometer Feedback Kit r I Process Control or Auto Rtf erenct Inputs Figure 3 4 System Connection Diagram 1 These signals must be run in a separate magnetic...

Page 15: ...OF ALL WIRE INSULATION BEFORE DRAWING REMOVE ONLY ENOUGH INSULATION TO MAKE A FIRM TERMINAL CONNECTION PERSONAL INJURY COULD RESULT IF A BARE WIRE TOUCHES THE CHASSIS 3 4 Isolation Transformers Althou...

Page 16: ...g pins Refer to Figure 3 6 Near them locate the black pig tail type jumper Do not move it if it is connected to the proper pin If it must be reconnected carefully lift it straight up and off the pin S...

Page 17: ...ce Module This Modul e is mounted on the Regulator Module Deter mine that all wires are firmly seated in the terminal strip Make sure all wires are connected 15 4 2 Motor Ground Check It may be necess...

Page 18: ...xceeding the maximum operating speed it may be necessary to turn the Maximum Speed Potentiometer completely CCW before turning the SPEED dial completely CW If the 1Osetting on the SPEEDdial is lower t...

Page 19: ...ever that turning CCW too far may prevent the drive accelerating to the desired speed 4 3 6 IR Compensation IR voltage Compensation is a feature which makes up for the armature resistance of a 17 moto...

Page 20: ...on both sides of each jumper and discard it Use a sharp pair of dykes diagonal cutters to assure a quick clean cut Do not twist the tool since dam age may result In cases where th e Kit is secured by...

Page 21: ...wire Dancer 5 12 14C230 yes yes Dancer Potentiometer wire Follower Dynamic 5 2 14C214 no yes Auxiliary Panel no Braking thru 16 Field Supply CD 5 8 14C237 no no None wire Instrument 5 7 14C222 yes no...

Page 22: ...mic Brak ing Connections 21 5 3 Reversing Contactor The standard FlexPak Plus controller offers unidirectional control With an optional Reversi ng Contactor Kit and Auxiliary Panel bidirectional opera...

Page 23: ...nd the required lengths of specified signal wire Refer to Tables 5 B and 5 C No other equipment is necessary although certain adjustments must be made on the Regulator Module 22 Table 5 8 TACHOMETER V...

Page 24: ...SE START STOP Remote Operator Control Station SPEED pot TORQUE pot Tachometer Feedback Instrument Interface Voltage Tachometer Follower WIRE SPECIFICATIONS TYPE CONDUCTOR REQUIRED CHARACTERISTICS CONT...

Page 25: ...ed lengths of the specified signal wire Refer to Table 5 C No other equipment is necessary although some changes may be necessary on the Module 24 Step 1 Orient the Voltage Tachometer Follower Module...

Page 26: ...ins pass through the guides on the Module Use the screw to secure it 25 Step 2 Connect the external reference sig nal wires to the terminal strip on the Module Plus is on the leh minus on the right Do...

Page 27: ...6 Step 3 The user supplied field wir ing conductors should be drawn into the Chassis Route them as indicated in Figure 3 4 Move them to the upper screws on 2TB and connect F1 F2 according to the label...

Page 28: ...increases Step 9 As the coil or package increases in diameter adjust the TORQUE TAPER Potentiometer on the Torque Module to maintain proper tension CCW increases cur rent here torque Adjust in small i...

Page 29: ...r to Figure 6 4 Lower it so that the pins pass through the guides on the Module Use the screw to secure it Step 2 For use refer to Table 5 D where the function is shown in relat ion to the test termin...

Page 30: ...ease side connects to terminal 571 The potenti ometer wiper is connected to terminal 919 Step 5 If an optional Dancer Position Potentiometer is used supplied by user connectthe up side of the poten ti...

Page 31: ...unting the Remote Operator Adapter Module on the Switch Receiver Module Jumpers J1 and J2 on the Switch Receiver Module Refer to Figure 5 25 must be cut when Remote Operator Stations are used These ju...

Page 32: ...the mounting holes Secure the Bracket with the provided washers and screws Make sure the washer teeth are firmly embedded in the Chassis to provide proper ground Step 2 Orientation of the harness con...

Page 33: ...i cation Refer to Table 3 A If an isolation transformer is used it must be sized according to the requirements of the drive system The transformer itself must be wired for the correct output voltage 1...

Page 34: ...cal data although all of this information is included in other parts of the manual COMPONENTS Relay Wire Harness forward Relay Wire Harness Reverse Thermostat Harness Gate Harness Auto Reverse Auxilia...

Page 35: ...re wrap pin 0 Denotes wire terminal board 38 Figure 6 2 Bidirectional Control Circuit simplified START Switch CLOSE t I I minimum duration I I ___ 1 __o 4PEN1 f c E STOPSwitch H 1 I I I I I 11 1 I P L...

Page 36: ...203 4 G4n i f 2193 f s1 62so H1 J J5 0 con 2 J XF ooo OOo r Aux1hary M I YEt39 PlJll J ects r rl 6 100KO C aH 0 er A u o 11 o 3 1 I J1 a u o ORN288 1 1 t 1 d1P o Reversing 57 O SOHZ O Modulehere _ _ I...

Page 37: ...t the drive motor 0 Test 45 47 Fl and F2 conductors for a ground If one exists examine connections and insula tion for areas where shorts could occur 0 If no grounds are found in the conductors check...

Page 38: ...AUTO MANUAL switch It is to be removed if there is an AUTO MANUAL switch a If the SPEEDpotemiometer is functioning normally and if the J4 jumper is placed removed as necessary replace the Regulator Mo...

Page 39: ...ately 1 VDC should be noted D Turn off power to the controller D Reconnect the volt oh mmeter to test pins 356 and 816 D On the 10 VDC scale of the volt ohmmeter an increase of approximately 1 VDC sho...

Page 40: ...2 and if used Fl and F2 Then check for grounds at these terminals 0 If a ground is found it is in the conductors to the motor or in the motor itself a Disconnect the motor from the conductors at the d...

Page 41: ...exPak Plus controller DANGER THE PROCEDURE 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 AL...

Page 42: ...e motor wi th a light bulb on the armat ure wiri ng at 1TB On 230 VAC controllers use two light bulbs in series D If the light does not light replace the Power Cube D Turn off power to the controller...

Page 43: ...112 12 I RED I IAUX N J g 5 t 1l ifE Iff j U J J FH 1 2 _ J lHERNOSTAT FI ELD KIT l t c 1 IAC Dl ODE o SI 52 r fA BRIDGE r z 7051es 11R j R e R 1 7 KT Gl Fl FZ OC M OTOR SHUNT FI EL D l___ ____ i_ RN...

Page 44: ...ANCERFOLLOWER REFERENCE KIT e111o 57010 FOR DETAILED KIT I NFORHAllON SEE INDI VIDUA L l lT S INSTRUCTION HANUAL tj RENOVEJUIIPER IF AUT0 11ANUALSWITCH IS INSTALLED zpSET AUTO111N S PD WITH INPUT AT H...

Page 45: ...WN OPTIONAL CIRCUITS 111 bai19 1 YEL _ IJM 1 AUl t r I ur c u x 10 11 I bl I I K _ _ IIH0 5 1H I 29 AUX CONTACT RATING I AHP 11lOY DC OR 5 AHP 11120 y AC RE SISTI VE 1 ts Ro 1 t R 0 1 fJ f i1 iN E o J...

Page 46: ...D IN A AND SET UPFOR MORE THAN I HP1 5 000 A 4VWHEN INSTALLINGREPLACEMENTPOW ER CUBE S APPLY A VERY THIN UNIFORII THICKNESS FILM OF DOW 1111 TOMOUNTING SURFA CE FILM IS TOOTHICK IF IT SQUEEZES OUT ARO...

Page 47: ...rol Transformer 115 volt drives 230 volt drives Output R C Assembly Dynamic Braking 1 i to Yzhp 115 VAC 2 to 3 hp 230 VAC hp 115 VAC 1 z to 11 2 and 5 hp 230 VAC Field Supply 1 1 1 2 1 1 2 2 2 1 1 1 1...

Page 48: ...Ii ii 11 Reliance Electric Company 24703 Euclid Avenu Cleveland Ohio 4411 RELIANCE ELECTRIC PrintedIn U S A lnslruclion Manuall 390 2855M 4...

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