Reliance flexpak plus Installing, Operating & Maintaining

"

/

I

.,

...

. •·

:: :::.'··

. .

JUNE 1981 INSTRUCTI.ON MANUAL 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'

.. ,....

TABLE OF CONTENTS

Sec.I Par.

Title

Page

Sec.I Par.

Title

Page

1

1.0

2

2.0

2.1

2.2

.2.3

2.4

2.4.1

2.4.2

2.4.3

4.il.4

2.4.5

3

3.0

3.1

3.2

3.3

3.4

3.5

3.6

3.7

4

a.a

4. 1

4.2

4.3

4.3.1

4.3.2

4.3.3

4.3.4

Introduction ... . ............ . ... . ... .... 1

General ....... .. ............ . ........... 1

General Cont roller Information . . . . . . . . . . 3

General ...... . ..... . ......... . . .. ..... .. 3

Operator 's Controls .. . . ..... . ............ 3

D-C Drive Moto rs ......... . ......... .. . .. 3

Modificat ion Kits . . . . . . . . . . . . . . . . . . . . . . . . . 4

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Line Frequency .... ....... ............ . .. 5

Voltage Tolerance ............ . . .. ... . .... 5

Line Impedance Requi rements ............ 6

Relay Contr ol Circuit ... . ........... ..... . 6

A-C Line Fuse Requirem ents .... . ......... 6

Installation .... . .. . ........ . .......... . . 9

General ..... . ...................... . .... 9

Layout Guidel ines .. . . . ... .. . . . .......... 9

Mounting .......... .. .................. 11

Power Wiring . .. . ......... .. ......... .. . 11

Isolation Transform ers .......... . ....... 13

50-Hz Operation . .... .. ............. ... . 13

HP/ Current Jumper ...... . .. . ........... 14

Regulat ion Mode Jumper . ........... . ... 14

Start-Up and Adjustment .. . ... .. ....... 15

General ..... .. . . . . .. . . .......... . .. .... 15

Power Off Inspect ion ..... . .... . .. . ..... . 15

Motor Ground Check .... . .. . . .. . . . . ..... 15

Pow er On Adjustments .. . .... .. ... ... ... 1 5

Regulator Module Pots· ....... .. ...... . .. 16

Maximum Speed (Voltage) . .. ....... .. .. . 16

Min imum Speed (Voltage) ......... ...... 16

Acceleration and Deceleration Rates ..... 16

4.3.5

4.3.6

5

5.0

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.7.1

5.7.2

5.8

5.9

5.10

5.11

5.12

5.13

5.14

6

6.0

6.1

6.2

6.3

6.4

6.5

6.6

7

7.0

Current Limit ...................... . .. . . 17

IR Compensation .. . . . ..... .......... .. . 17

Modification Kits ...... . . . .... . ..... .... 1 9

General .. · ... ... .. . ..... .. . ..... ........ 19

Auxiliary Panel . ................. . .... . . 19

Dynamic Braking ...... ... ..... . ..... ... 20

Reversing Contactor ... . ................ 21

Automa tic Reversing ...... .. ... .. ... . ... 21

Tachometer Feedback ... .. ......... ... .. 22

Voltage/ Tachometer Follow er ............ 24

Instr ument Interface/ Preset Speed ... ... . 24

Installing Instrum ent Interface ........... 25

Installin g Preset Speed ... . . . ....... . .... 25

Field Supply .. ... ..................... . . 26

Torque Taper ...... .... ...... . . .. ....... 26

Auxiliary M Contacts .... .. ........ . .. .. . 27

Test Meter Adapt er ........... . ........ . 28

Dancer Follower ....... . ................ 28

Master Isolated Reference Receiver ..... . 29

Contactor Adapter ...... . ... ....... .. ... 31

Troubleshooting ....... .. ........ . ...... 33

General .. ..... . ........................ 33

Wiring Errors .... .... ................... 33

A-C Line Problems ..... .. ............... 33

Motor Problems . .. .... .. ........ . ...... 33

Mechanical . .... . .... ..... . ...... . ..... 33

Contr oller Malfunc tions . .. . ..... . ....... 33

Schematics, Diagr ams ..... . . .. ..... .. . . 33

Replacement Parts .... . ..... .. ........ . 4 7

General .. ... .. . . ...... . .... ... ... ... ... 47

. ~

~Copyrigh t Reliance Electric Company June 1981

ii

..

..

•

•

Figure

1.1

2.1

2.2

3.1

3.2

3.3

3.4

3.5

3.6

4.1

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

5.10

5.11

5.12

Table

2.A

2.B

2.C

2.0

3.A

3.B

3.C

5.A

LIST OF FIGURES

Title Page

FlexPak Plus Complete Controller

and Typical Motor. . . . . . . . . . . . . . . . . . . . . . 1

Basic Controller and Auxiliary Panel ...... . 3

FlexPak Plus Complete Controller

with Modification

Kits ... .. . ... .. .. ... .. 4

Enclosure Mounting M inimum

Distances .................. . ... . . ... .. 9

Mounting and Wiring Orientations .. ..... 10

Mounting Dimens ions ................... 11

System Connection Diagram . ..... . ...... 12

50-Hz Resistor Removal ................. 13

HP/ Current Scaling Pins ................ 14

Regulator Module Pots ..... ... . .. . ...... 16

Pin Alignment .... ........ .. . ........... 19

Auxiliary Panel Mounting ................ 19

Dynamic Braking Kit .... . ...... .. ... . .. . 20

Dynamic Braking Kit Installed ............ 21

Dynamic Braking Connections ........... 21

Reversing Contactor Connections ........ 21

Automatic Reversing Kit ............. .... 21

Tachometer Feedback Kit . . ... .. .. .... ... 22

Jumpers J1, J2 ......... .. ... ... .. .... . . 23

Feedback Connection on

Regulator Module . .. .......... ........ 23

Voltage/ Tachometer Follower ............ 24

Jumper

J1 ............................. 24

Figure

5.13

5.14

5.15

5.16

5.17

5.18

5.19

5.20

5.21

5.22

5.23

5.24

5.25

5.26

5.27

6.1

6.2

6.3

6.4

6.5

6.6

6.7

LIST OF TABLES

Title

Page

FlexPak Plus Features Summary . . ........ 5

Specifications ... ....... ... ........ . . ... . 6

Fuse Requirements ...... .. . .. ........... 7

0-C Motor / Controller / Transformer

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical Wire, Fuse Sizes ................. 10

Reliance Electric Isolation Transformers .. 13

Horsepower Calibration .... .... ......... 14

Modification Kit Quick Reference List ..... 20

iii

Table

5.B

5.C

5.0

6.A

6.8

6.C

7.A

Title

Page

Instrument Interface Kit ................. 25

Jumper Jl , mA Pins . .... ............... 25

Field Supp ly Kit ......................... 26

Connecting Field Supply ............... . . 26

Torque Taper Kit ... .. ... . ... ............ 26

Torque Curves .... . .... .. ............... 26

Auxiliary M Contactor Kit . ... ... ....... . . 27

External Wiring, Auxiliary M .. . .......... 27

Test Meter Adapter .......... . . . . .. ...... 28

Dancer Follower Module ................ 28

Jumpers

J1, J2 and Resisto r (R6) .... ... . 29

Master Isolated Reference

Receiver Kit ............... . . . ........ 29

Jumpers

J1 and J2 on Switc h

Receiver Module ........ .. ............ 30

Jumper

J1 on Reference

Receiver Module ... .. .. . .............. 30

Connecting User-supplied

FM and RM Contactors .... . ... .. .. .. . . 31

Unidirectional Control Circuit ............ 34

Bidirectiona l Control Circuit ..... .. ....... 35

Relay Control Sequencing . .. ........ . ... 35

Regulation Module Screen ............... 36

Controller Schematic .................... 43

Modification Kits Schemati cs ......... 44, 45

Controller Technical Data .. .... .. ........ 46

Title

Page

Tachometer Voltage Scaling ..... .. ....... 22

Wire Specifications ..................... 23

Test Adapter Terminals, Readings ...... .. 28

Color Coding System ........... ... ...... 34

Troubleshooting Suggestions for

the Basic Controller . ..... ............. 37

Troubleshooting Suggestions for

the Complete Controlle r ............... 40

Replacemen t Modules ..... .. ....... .. ... 47

'

Ii

•

i

Section 1

INTRODUCTION

1.0 General - This manual familiarizes the user with the

FlexPak™ Plus D-C

V*S ® drive controller. (Refer to Figure

1.1.) It describes assembly and installat ion procedures ,

gives a general overview of operation , and contains infor-

mation on troubleshooting , maintenance , the ordering of
spare parts , and specifications .

The manual should be read

before performing installat ion

or start-up activities. Also , there are certain fundamental
warnings which must be kept in mind

at all times . These

are:

DANGER
THE DRIVE SYSTEM SHOULD BE INSTALLED,
ADJUSTED AND SERVICED BY QUALIFIED ELEC­TRICAL MAINTENANCE PERSONNEL FAMILIAR
WITH THE CONSTRUCTION AND OPERATION OF
ALL

EQUIPMENT' IN THI:- SYSTEM :· PERSONAL

INJURY AND / OR EQUIPMENT DAMAGE MAY

OCCUR IF INDIVIDUALS ARE NOT FAMILIAR

WITH THE HAZARDS RESULTING FROM IM-

PROPER OPERATION.

Complete Controller

DANGER

CONTROLLER EQUIPMENT IS

0

AT LINE VOLTAGE
WHEN A-C POWER IS CONNECTED TO THE
POWER UNIT IN THE FLEXPAK PLUS CONTROL­LER. THUS A-C POWER MUST BE REMOVED
FROM THE UNIT BEFORE IT IS SAFE TO TOUCH
INTERNAL PARTS OF THE CONTROLLER. PER­SONALINJURY 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.

WARNING

DO NOT OPERATE THE FLEXPAK PLUS CON­TROLLER ON POWER SUPPLIES WITH AVAIL­ABLE SHORT-CIRCUIT CURRENTS IN EXCESS

OF 5000 AMPERES. DAMAGE TO EQUIPMENT

AND PERSONAL INJURY MAY OCCUR .

D-c Motor

Figure 1.1 - Flex Pak Plus Complete Controller and Typical Motor

i

•

Section 2

GENERAL CONTROLLER INFORMATION

2.0 General -The FlexPak Plus 0-C V*S drive controller

may be applied to single-phase d-c drive applications with
ratings within the following ranges :

• From

1/

4

to :Y4 hp with a 115 VAC, 50 / 60 Hz input

voltage

• From

1/

2

to 5 hp with a 230 VAC, 50/ 60 Hz input

voltage

Reliance Electric d-c motors, which may be used with the
controller, may be either permanent magnetic motors up to

1

1

/

2

hp or wound field (excited) motors up to 5 hp.

The controller provides power-conversion and control cir-

cuits which convert the a-c line voltage into adjustable d-c
voltage in order to effectively control the drive motor .

The FlexPak Plus controller is provided , as standard , in a
chassis type configuration for panel mounting within a
larger electrical enclosure . The Remote Operator Controls
may then be placed on the larger enclosure 's face or some
distance away .

The FlexPak Plus is available in two basic configurations :

the Basic Controller and the Complete Controller (Basic
Controller with Auxiliary Panel) . Both the Basic Controller
and the Auxil iary Panel (Figure 2.1) are Underwriters

I

l~~--rr:r::r:::t L::~~~::::;:;;=- 1 J

Basic Controller

Laboratories (U.L.) recognized . Both units when used
together (Complete Controller) are U.L. Listed .

Optional Modification Kits conveniently expand the capa­bility of the Basic Controller and Au xiliary Panel.

The controller's features are summarized in Table 2.A.

2.1 Operator 's Controls - For proper operation of the

FlexPak Plus controller, it is necessary to provide Remote
Operator 's Controls . Reliance Electric offers a wide variety
of operator control stations which may include the follow­ing devices :

• SPEED control potentiometer (5K)

• TORQUE control potentiometer (10K)

• AUTO/ MANUAL selector switch (SPOT)

• RUN/ JOG selector switch (SPST)

• FORWARD/ REVERSE selector switch (DPDT)

• START / STOP selector switch (pushbuttons or special)

2.2 D-C Drive Motors - Reliance Electric offers a com-

plete power-matched drive system for the contr oller and
the· application . Thus . the choice of Reliance Electric
motors assures optimum performance and unmatched
single-source responsib ility .

. "

L._

••

,,.

.. --

Auxiliary Panel

"\

C

C C

,)

Figure 2.1 - Basic Controller and Auxiliary Panel

3

I

2.3 Modification Kits - The basic capability of the con-

troller can be quickly and conveniently extended with the

use of a variety of optional Modification Kits. (Refer to
Figure 2.2.) The Basic Controller modifications are:

• Tachometer Feedback

• Voltage/ Tachometer Follower

• Instrument Interface / Preset Speed

• Field Supply (Standard on 2. 3 and 5 hp controllers)

• Torque Taper

• Test Meter Adapter

Remote Operator

Adapter Module

and/ or

Master Reference Switch

Receiver Module

Tachometer Feedback

• Dancer Follower

• Master Isolated Reference Receiver

• Contactor Adapter

The Auxiliary Panel modifications are:

• Dynamic Braking

• Reversing Contactor

• Automatic Reversing

• Auxiliary M Contact

Complete descriptions of each Kit are given in Section

5.

Refer also to Table 5.A.

Reversing Contactor

Auxiliary M Contact

Voltage / Tachometer

Follower

or

Instrument Interface /

Preset Speed

or

Dancer Follower

or

Master Reference

Receiver

Test Meter Adapter

Figure 2.2 - Flex Pak Plus Complete Controller with Modification Kits

4

i

i

'--.

2.4 Specifications - The more important specifications

for the FlexPak Plus controller are listed in Table 2.8. Refer
also to Table 2.D where other ratings are indicated in rela­tion to d-c motors of specific horsepower.

However , for optimum 50-Hz operation. it is recommended

that two resistors be removed from the Regulator Module .
(Complete deta ils are given at Paragraph 3.5.) If the resis ­tors are not removed , there is a slight loss of performance .

2.4.1 Line Frequency - The FlexPak Plus controller is

able to operate without modification from a single-phase
power source having a frequency range from 48 to 62 Hz.

2.4.2 Voltage Tolerance - The FlexPak Plus controller

delivers output current and voltage, as listed in Table 2.D. It
will also operate within these regulation specifications
even with incoming line voltag e at

± 10% of nominal.

Table 2.A

FLEXPAK PLUS FEATURES SUMMARY

CATEGORY FEATURE

Controller Functions

• ST ART / STOP

• RUN/ JOG

• FOR\NARD/ REVERSE

• Speed selection (0 to 100%)

• Torque selection ( 1 0 to 1 50%)

• Unidirection operat ion with coast-to -rest

or. stop command standard . (Dynamic braking

and reversing available as options .)

• 20 :1 controlled-speed range by means of armat ure voltage control.

•

\Nith Auxiliary Panel specified , armature loop contactor removes power to drive motor .

• Isolated armature voltage and current feedback decouples armatu re power from opera­tor devices and provides additional noise immunity .

•

\Nith tachometers specified in this manual, 0.5% or 1.0% speed regulation with a 95%
load change .

• Operates and delivers rated output speed with specified regulation tolerance limits even
with a-c line variations of± 10% of nominal rated input voltage .

Speed Regulation

• Jumper reconnectable regulator circuits which allow armature (A), counte r EMF (C) or
tachometer feedback (T) regulation .

•

\Nith voltage regulation, 3 to 5% speed regulation with 95% load change .

•

\Nith counter EMF (CEMF) regulation , 2 to 3% speed regulation with a 95 % load change .

•

\Nith tachometer specified, 1 % speed regulation with a 95% load change . (Tachometer s
are: RE-045 a-c tachometer; also

SPY or RE-020 d-c tachometer .)

•

\Nith tachometer specified, 0.5% speed regulation with 95% load change . (Tachometer is

BC42.)

User Adjustments

• Adjustable IR drop compensation (0 to 12% of rated load).

• Adjustable maximum speed (50 to 100 % of base motor speed).

• Adjustable minimum speed (up to 50% of base motor speed).

• Adjustable current limit (10 to 150% of full-load current).

• Adjustable, separately set linear acceleration and deceleration rates (0.5 to 30 sec.).

Safety

• Control circuitry guards against automatic restarting of equipme nt after resumption of
interrupted a-c incoming power.

• Regulator and Operator's Controls isolated from a-c line for personnel protection .

• Armature voltage and current feedback isolated to assure separat ion of power and regula-

tor circuits.

Hardware

-:- Conveniently located screw terminal connections for incoming a-c and outgoing d-c power
allow easy cable entry and connection.

•

\Nith · Auxiliary Panel specified, a-c line fuses protect Power Cube from armature short
circuit and power relays provide positive power disconnect .

• Protection from momentary surges on a-c line and from d-c load transients.

5

2.4 .3 Line Impedance Requirements - The FlexPak Plus
controller must be connected to a short-circuit protec tion
syste m design ed to operat e on plant power supplies with

maximum permissible available symmetrical RMS fault

curren ts of 5000 amperes. (Refer to Table 2.D.)

The Basic Contro ller does not have an M contactor. An M

contactor is required to provide positive power disconnect.

WARNING
THE USER MUST INSTALL AN M CONTACTOR
THAT HAS A 24

voe COIL WITH A MAXIMUM

CURRENT DRAW OF 150 MILLIAMPS . FOR TIM-

ING, A 200 MICROFARAD CAPACITOR MUST BE
INSTALLED WITH CORRECT POLARITY ACROSS

THE RELAY COIL. THE CONTACTOR ADAPTER

KIT MUST BE INSTALLED WITH THE USER'S M
CONTACTOR . (REFER TO TABLE 5 .A AND
PARAGRAPH 5. 14 .) PERSONAL INJURY MAY
OCCUR IF THIS IS NOT INSTALLED.

WARNING

DO NOT OPERATE

THE FLEXPAK PLUS CON-
TROLLER ON POWER SUPPLIES WITH AVAIL-
ABLE SHORT -CIRCUIT CURRENTS IN EXCESS

OF 5000 AMPERES . DAMAGE TO EQUIPMENT

AND PERSONAL INJURY MAY OCCUR.

2.4 .4 Relay Control Circuit -

The regulator board is set

up for use w ith main cont actors having a coil resistance
greater tha n or equal to 100 ohms . The control logic
sequences the contacto r and the control relay on the regu­lator so that current flow thru the main contactor is never
broken in normal operation by the contacts. Refer to Fig-

ures 6. 1, 6.2 and 6.3.

2.4 . 5 A-C Line Fuse Requirements - A-c line protection

is provided when the Auxi liary Panel is specified. The Basic
FlexPak Controller , however , does not include a-c line pro­tection . Fused a-c line protection mu st be used . Refer to

Table 2.C for proper fuse sizing.

Table 2.B

SPECIFICATIONS

A-C Line Input Voltage

Operator Torque Adjustment

Displacement Power Factor

115/230 VAC (nominal)

Infinitely adjustable at

68% (typical)

CD

single-phase only

optional control pot

Transient Protection

Line Voltage Variation

( 10 to 1 50% of rated load)

MOV and Output RC Circuit

± 10% of nominal

IR Drop Compensation

Controller Service Factor

A-C Line Frequency

0 to 12% of rated load

1 .0

Single Phase, 50/ 60 Hz

(user adjustable)

Duty

(Jumper selectable) CD

Controllable Speed Range

Continuous

Line F:·equency Range

20:1

Ambient Temperature

48-62 Hz

Current Limit

(storage and operational)

Output Voltages

Factory shipped : 150% of full load

00 to 55°C (32° to 131° F)

(armature and field)

User adjustable: 10 to 150% of full load

See Table 2.D

Regulation (with 95% load change)

Relative Humidity

(storage and operational)

Controller -Drive HP Range

3 to 5% with voltage feedback

5 to 95% (wit hout conde nsation)

Yd'4 hp (with 115 VAC input)

2 to 3% with CEMF feedback

1/

2

-5 hp (with 230 VAC input)

1 .0% with specified tachometer feedback

Operational Altitude

0.5% wit h specified tachometer feedback

To 3300 ft (100 0 m) above

Direction Control

sea level w ithout derating

Standard : Unidirection

Minimum Load for Stable Operation

Optionally: Forward / Reverse

5%

Controller Weight (approx.)

Basic= 9.0 lb (4.08 kg)

Maximum Speed Adjustment

Acceleration / Deceleration Rates

Complete= 1 1 .0 lb (4.99 kg)

50 to 1 00% of base motor speed

0.5 to 30 sec. linear time

(user adjustable)

(user-adjusted separately)

Controller Dimensions (LWD)

Basic= 7.22 x 8.37 x 5.95 inches

Minimum Speed Adjustment

Armature Circuit Overload Capacity

(184 x 213 x 152mm )

up to 50 % of base motor speed

150% of armature current rating

Complete= 11 .97 x 8.37 x 5.95 inches

(user adjustable)

for 1 minute (max.)

(305 x 213 x 152 mm)

Operator Speed Adjustment

Efficiency (rated speed/ rated load)

© See Paragraph 3.5.

Infini tely adjustable with

Controller only: 97%

CD Typical percent shown. Exact figure

optional control pot

Complete drive including

dependent on motor base speed and

(up to 100% of base speed)

motor: 85% (typical)

CD

frame size.

6

Table 2.C

FUSE REQUIREMENTS

Dual Element Class

HP

A-C Line K5, 250 VAC Fuse

Volts Quantity Amp

FOR BASIC MOTOR PROTECTION

1/4 -7'4

115 1(D

15

1/2-11/2

230 2

15

2-3

230 2

25

5

230 2

45

le

FOR SUPERIOR MOTOR PROTECTION

1/4

115 1(D 6.25

1/3

115 1(D

10

1/2

115 1(D 10

7'4

115 1(D 15

1/2

230 2 6.25

:y4

230 2

10

1 230 2

10

11/2

230 2 15

2

230 2 20

3

230

2 25

5

230 2 45

(!)Install fuse in input line Ll (hot line ).

Table 2.D

D-C MOTOR / CONTROLLER / TRANSFORMER SPECIFICATIONS

CONTROLLER

OPTIONAL

TRANSFORMER

MODEL NUMBERS

D-C

POWER

A-C D-C ARM.

D-C AMP.

SUPPLY

MAXIMUM

FULL

AMPS

ARM.

AMPS FIELD

MAX. CAPACITY

kVA LOAD

BASIC COMPLETE

HP

VAC (RMS) (VOLTS)

(avg.) VOLTS

(optional)

CD

Per Phase

kVA

1/4

115 3.5

90

2.5

100

3.0 5000

40 0.75

14C50 14C50/ 14C80

%

115 5.2 90

3.7 100

3.0 5000

40 0.75

1/2 115 7.0 90

5.0

100

3.0 5000

40 1.0

%

115 10.5 90

7.5

100

3.0

5000

40 1.5

112 230 3.5

180

2.5 200

3.0 5000

40

1.0

14C51

14C51/ 14C81

%

230

5.2 180

3.7

200

3.0

5000

40 1.5

1 230

7.0

180 5.0

200 3.0

5000

40

2.0

11/2

230 10.5

180 7.5

200

3.0

5000

40

3.0

14C52 14C52/ 14C82

2 230

14.0 180 10.0

200 3.0(D

5000

40

5.0

3

230

21.0

180 15.0

200

3.0(D

5000

40

5.0

14C53

14C53/ 14C83 5 230

35.0 180 25.0

200

3.0(D

5000

40 10.0

CD Standard
CD Maximum permissible availabl e symmetri cal RMS fault current with NEC or CEC external approved disconnect .

7

Section 3

INSTALLATION

3.0 General - This Section outlines the procedures that

are to be followed in order to properly install a FlexPak Plus
controller .

The d-c motor should be installed and wired in accordance
with installation instructions supplied with each drive.

There are certain general warnings and cautions that
should be kept in mind

before planning begins. They

should be considered a general checklist which, if followed,
will minimize installation problems and decrease assembly
time . As a user aid, they are listed here .

DANGER

THIS UNIT SHOULD BE INSTALLED, ADJUSTED

AND SERVICED BY QUALIFIED ELECTRICAL

MAINTENANCE PERSONNEL FAMILIAR WITH
THE CONSTRUCTION AND OPERATION OF THIS
TYPE.OF EQUIPMENT . THEY SHOULD ALSO BE

{' FAMILIAR ' WITH THE POTENTIAL HAZARDS IN-

VOLVED. IF THIS WARNING IS NOT OBSERVED,

PERSONAL INJURY OR EQUIPMENT DAMAGE

MAY RESULT.

DANGER

BE ABSOLUTELY CERTAIN THAT A GROUND

WIRE FROM THE INCOMING A-C POWER LINE IS

PROPERLY CONNECTED TO THE CHASSIS
GROUND TERMINAL PROVIDED . WITHOUT
PROPER GROUNDING, PERSONAL INJURY MAY
OCCUR.

WARNING

THE CONTROLLER REQUIRES A SINGLE-PHASE

POWER SUPPLY THAT PROVIDES EITHER 115

VAC OR

230 VAC AT 50 / 60 HZ. IF CORRECT

VOLTAGE IS NOT AVAILABLE, IT WILL BE

NECESSARY TO INSTALL A TRANSFORMER
BETWEEN THE POWER SUPPLY AND THE CON-

TROLLER . DO NOT OPERATE THE FLEXPAK PLUS

CONTROLLER ON POWER SUPPLIES WITH
AVAILABLE SHORT -CIRCUIT CURRENTS IN
EXCESS OF

5000 AMPERES . DAMAGE TO

EQUIPMENT AND PERSONAL INJURY MAY
OCCUR .

WARNING

THE USER IS RESPONSIBLE FOR CONFORMING

WITH THE NATIONAL ELECTRICAL CODE WITH
RESPECT TO MOTOR. CONTROLLER AND OPER­ATOR DEVICE INSTALLATION, WIRING AND

START-UP. THE USER IS ALSO RESPONSIBLE
FOR UNDERSTANDING AND APPLYING ALL
OTHER APPLICABLE LOCAL CODES WHICH
GOVERN SUCH PRACTICES AS WIRING PRO­TECTION, GROUNDING, DISCONNECTS AND
OVERCURRENT PROTECTION.

9

3.1 Layout Guidelines - This Paragraph lists recom-

mended layout procedures common to all FlexPak Plus

controllers .

Guideline 1 -The FlexPak Plus controller is designed as a

panel-mounted unit. It is to be hung within 10° of vertical

with the rear of the Chassis firmly resting against the

mounting surface.

(Do not position the Chassis on a hori-

zontal surface .)

Guideline 2 - It is necessary to leave at least a 2-inch (50

mm) clearance between the top of one controller and the
bottom of another controller . This unobstructed area allows
for proper air circulation through the heat sink .

Do not

place the controller directly in a corner . Leave at least 8
inches (200 mm) from the top or 6 inches (150 mm) from
the bottom of the enclosure . (Refer to Figure 3.1.) Heat
builds up at the cabinet's top and may exceed the permissi­ble inside ambient temperature upper limit . At the cabinet 's
bottom , the unit must be high enough to allow air to flow
upwards .

E:] __ ; ;n. (200 mm(

EJ--:}(50 mm}

6 in. (150 mm)

Figure 3.1 - Enclosure Mounting Minimum Distances

Guideline 3 -

Regardless of the above placement guide­lines , the user is responsible for providing ambient temper­atures that meet the

controller's specifications of 0° to
55°C (32° to 131°F). Relative humid ity must be kept
between 5 and 95%

without condensation .

Guideline 4 - Due to the U-shaped panel design of the

FlexPak Plus, the controller must be mounted in the vertical
position to allow for proper cooling .

The controller is also designed to allow for power wiring to
enter from the top and for control and signal wiring to be
routed in thru the openings in the sides of the controller or
from the bottom . (Refer to Figure 3.2.)

POWER
WIRING

-----

CONTROL AND

~

SIGNAL WIRING FRONT VIEW

Figure 3.2 - Mounting and Wiring Orientations

Guideline

5 - Do not route the tachometer feedback sig-

nal cable, if used, with a-c or d-c control or power wiring.

Also use the specified wire for

thi~ function .

Guideline 6 - Although auto -transform ers may step up

and step down a-c power supply voltage, they

do not

isolate the drive system from the a-c line . Users should
consider using an isolation transformer if the application
conditions warrant it.

If an isolation or auto-transformer is used ahead of the
controller , the disconnect sw itch should be placed on the
a-c power line between the power source and the trans­former primary . Again , use a fused disconnect switch.

(Do

not

use a circuit breaker type switch because of the high
inrush of transformer equipment.) Refer to Table 3.A for
sizes and types .

An isolation transformer is not necessary unless the appli­cation conditions require one. However . its use provides
distinct advantages . With an isolation transformer :

• Personal injury is guarded against should accidental
contact be made with an electrical conductor from the

drive.

• A-c power line disturbances , or transients , are mini­mized by an isolation transformer , thereby reducing or
eliminating damage to other solid-state equipment

power-conversion components in the controller and
other user-equipment on the same a-c line.

• The transformer provides electrical isolation between

the a-c power lines and the drive motor . Damaging
currents may be eliminated in instances where a d-c
output accidentally becomes grounded in a unit where
the a-c electrical system is grounded.

For detailed information. refer to Paragraph 3.4 .

Guideline 7 - The National Electrical Code requires that a

two-pole, fused disconnect swit ch be installed on the
incoming a-c line

ahead of the controller to provide branch

circuit protection . Fuses for this disconnect switch should
be chosen from Table 3.A. They should be dual-element,
slow blow type. or Class K5.

It is recommended that the disconnect switch be placed
within easy reach of operating and maintenance person­nel.

Do not place it inside a surrounding enclosure since

cabinet doors may be locked. (Consult your local codes.)

Guideline 8 - It is necessary to connect the GND (green /

ground) wire of the three-conductor incoming a-c line to

the terminal provided on the Chassis. Ring type connectors
are recommended . The user must be sure that the ground
wire is connected to the plant ground at the source.

The motor frame should also be grounded . In many cases it

is adequate to use a screw in the conduit box near the

motor .

Table 3.A

TYPICAL WIRE. FUSE SIZES

(D

DISCONNECT

A-C POWER

D-C ARMATURE

D-C FIELD

(D

FUSE SIZE (D

HP

VAC

(min. size/ insul.)

(min. size/ insul.) (min . size / insul .)

(amps)

1/4

115

No. 14 AWG 75°C

No. 14 AWG

75°C

No. 14 AWG 75°C

8

1/rY2

115

No. 14 AWG 75°C

No. 14 AWG 75°C No. 14 AWG 75 ° C

15

%

115

No. 12AWG75°C

No. 12 AWG 75°C

No. 14 AWG 75°C

20

%

230

No. 14 AWG 75°C

No. 14 AWG 75°C

No. 14 AWG 75°C

8

%- 1

230

No. 14 AWG 75°C

No. 14AWG 75°C

No. 14 AWG 75°C

15

1% 230

No. 12 AWG 75°C

No. 12 AWG

75°C

No. 14 AWG 75°C

20

2

230

No. 12 AWG

75°C

No. 12 AWG 75°C

No. 14 AWG 75°C

25

3

230

No. 10 AWG 75°C

No. 10 AWG 75°C

No. 14 AWG 75°C

35

5

230

No.

BAWG 90°C

No.

BAWG 90°C

No. 12 AWG 90°C

60

CD Copper wire recommended.
CD Permanent magnet motors do not require field supply.

0 Fuses must be dual-element, time-delay (slow-blow) type, or U.L. Class K5 .

10

Guideline 9 -A thermostat is used to guard against motor

overload protection . It is essential to properly connect the
motor thermostat

in series with the Operator's Control

Station

STOP selector switch at connections 32 and 132 .

CAUTION: An external overload device must be con -

nected between terminals 32 and 132. The drive will
not start without it.

Refer to Figure 3.4 where a typical Operator 's Control Sta­tion schematic is shown .

Guideline 10 - When planning signal or control wire runs.

as listed in Table 5.C, follow these practices:

• Conduits should be steel.

• If these conduits cross 440 VAC conductors , make
sure the cross is at 90 ° .

.....-------r-----------,

I I

I I
I I

I I

0.31 in.

(7.9mml

I

I

11.97 in.

(305mm )

7.22 in.

(183 .4

mml

0.31 in. (7.9 mm)

FRONT VIEW

3.06 in -f-- 3.06 in.

(77.8 mm)

I (77.8 mml

...,.----,----@----+--

6.60 in.

(167.6

mml

L~-

1

I

---- --

1

MOUNTING HOLE DRILL PLAN

• Do not route signal wires through junctions or termi­na 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 ( 1 000 m ). De rate horsepower 3% for

each 1000

ft (300 m) above this altitude .

3.2 Mounting - This Paragraph outlines the procedures

to be followed to mount the FlexPak Plus controller.

Determine the exact placement of the Chassis on the panel.
(Refer to Figure 3.3 for mounting dimensions .) Scribe the
panel. Drill three holes large enough to accept

1

/

4

-inch

mounting bolts . Scrape the paint around the holes to allow
washers and bolts to make a ground contact.

3.3 Power Wiring - This Paragraph briefly outlines the

procedures to be followed when wiring

a-c power supply

lines to the controller and

d-c control circu its to the drive. A

basic connection diagram is given at Figure 3.4 .

maximum swing

projec1ion 6.50 in.

(165.1

mml

0.218 in. (5.53 mml dia. mounting holes (3l
for hardwar e 0.19 in. (4.83 mml

Scrape point around holes
to assure grounding .

II

II

II
II

II

II
II

II

~----- -

. I. 1800 SW~~:

5

in .

(151.1

mml

SIDE VIEW

Figure 3.3 - Mounting Dimensions

11

"

REMOTE OPERATOR CONTROLS

,--------------------------------,

No
Number

swirch

JOG/RUN

switch

FWD/REV

switch

No
Number

START/STOP

switch

426

326

35

67

65

39

32

38

I

I

I

I
I

I

I

I
I

I

I
I
I

I
I

I

I

I

I
I
I
I

L-------------------------------J

0 -C Drive Motor

51 52 32 132

REMOTE OPERATOR

INTERFACE

r----,

I 57

I

1-Phase

Ptant

Power

Pl

P2

.--1-i

32

(RED)

Terminal

Instrume nt Interface

or

Voltage Follower Kit

132

(ORGI

STOP

RUN

JOG•

TYPICAL OPERATOR SCHEMATIC

24 VAC

+

40

START

_L

r-----1

38 FM 36

~.=-.::.-41.,.._-+--I CR~ ------1

Stat ic

Logic

(BANI I (GANI

35

CR

I FM

65

(ORGI

(BLKI

RM

66

(BLUEi

J9

/'.;\.

L

L_

REV

I

I

I

I

I
I

I

I

FWD

I

I

39

(YELi

67

(GRAY)

1

I
I

I

I

I
I

I
I

I

_J

~----

Notes:

Tachometer Feedback Kit

r------,

I

Process Control

or

Auto

Rtferenct

Inputs

Figure 3.4 - System Connection Diagram

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

minimize th e possibility of noise pickup. (Refer to Table 5.C for
wire specifications .)

2>Remove th e 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 higher voltage.

4>Remove jump er J9 from Regu lator Module when Reversing

Contactor is installed.

S>Use convenienc e termina ls for

#14 AWG maximum wire size.

6> 11 Auxiliary Panel is not used , user must supply an appropriate

M contactor . Refer to Paragraphs 2.4.4 and 5.14.

/

DANGER
BEFORE WIRING, MAKE SURE THE A-C LINE
DISCONNECT SWITCH IS LOCKED OPEN. EVEN
IF POWER HAS NOT BEEN APPLIED TO THE
INCOMING LINE , THIS PRACTICE ASSURES
PERSONAL SAFETY . IF NO LOCKOUT DEVICE
EXISTS , REMOVE THE FUSES WITH AN INSU ­LATED TOOL AND PLACE A WARNING TAG ON

THE BOX.

WARNING
THE USER MUST INSTALL AN M CONTACTOR
THAT HAS A 24

voe COIL WITH A MAXIMUM

CURRENT DRAW OF 150 MILLIAMPS. FOR TIM­ING, A 200 MICROFARAD CAPACITOR MUST

BE

INSTALLED WITH CORRECT POLARITY ACROSS
THE RELAY COIL. THE CONTACTOR ADAPTER
KIT MUST BE INSTALLED WITH THE USER'S M
CONTACTOR. (REFER TO TABLE 5.A AND

PARAGRAPH 5.14.) PERSONAL INJURY MAY
OCCUR IF THIS IS NOT INSTALLED.

All interconnecting wire should primarily be sized and
installed in conformance with N.E.C., C.E.C. or local codes .
Refer to the controller and motor nameplates for electrical
data. Typical wire sizes and types are listed in Table 3.A as a
basic guideline. Note that long cable runs may require that
a larger gauge be used to avoid excessive voltage drop . Use
of stranded wire is also recommended . Wire according to
Figure 3.4.

After wiring, examine all terminals to determine that con -

nections are correctly made at

both ends. Confirm wire

identification. Examine the firmness of the connections.

If the Auxiliary Panel is employed , wires to the motor arma ­ture (A 1 and A2) must be lugged with the provided lugs , or
equivalent , before conn ection to the appropriate relay ter-

minals . Lugs provided will accommodate :

% to 1 Y

2

hp - 12 AWG

1

Y

2

to 3 hp - 10 AWG

5 hp-8AWG

WARNING

DO NOT ALLOW CONDUCTORS TO GROUND ON

THE CHASSIS. CHECK INTEGRITY OF ALL WIRE

INSULATION BEFORE DRAWING. REMOVE
ONLY ENOUGH INSULATION TO MAKE A FIRM

TERMINAL CONNECTION. PERSONAL INJURY

COULD RESULT IF A BARE WIRE TOUCHES THE
CHASSIS.

3.4 Isolation Transformers -

Although an auto-tran s­former may be required becau se of a-c line voltage levels , it
is unable to provide a number of benefits standard with an
isolat ion transformer .

The general requirements for an isolation tran sformer are:

• Single phase

• 3 to 8% impedance

• Nonregulated

13

• Sinusoidal output

• 50/ 60 Hz, as required

• 150% overload for 1 minute (max.)

Refer also to Table 2.D for specific information on trans­former sizing requirements . In the 'Transform er" column
at the right, maximum kVA and full -load kVA figures are
listed in relat ion to spec ific d-c motor hp/ VAC rating s.

Reliance Electr ic offers a number of isolation transformer s
suitable for use with th e FlexPak Plus controller. (Refer to
Table 3.8.)

Table 3.B

RELIANCE ELECTRIC ISOLATION TRANSFORMERS

PRIMARY

SECONDARY ORDER

HP

kVA

VAC VAC NUMBER:

%·Y3

0.75 230 / 460 115

77530-10S

Y4·Y3

0.75 575 115

Special Order

Y2

1.0

230 / 4 60 230 Special Order

Yi

1.0 575 115 Special Order

%

1.5 115 115 77530 -12V

:y4 1.5 575

115 77530-1

lV

%

1.5 230 / 460

115 77530 -lOV

%

1.5 230 / 460

230 Special Ord er

%

1.5

575 230 Special Order

1

2.0 230 / 460

230 77530-BW

1

2.0 575 230 Special Order

, Yi

3.0 230 / 460

230 77530 -BX

1

Y2

3.0 575

230 Special Order

2-3 5.0 230 / 460

230

77530 -BY

2-3 5.0 575

230 77530-SY

5

10.0 230 / 460

230

77530 -BRC

5 10.0 575

230 77530 -SRC

3.5 50-Hz Operation - There may be cases wh en the

Flex Pak Plus controll er is to be operat ed continuou sly on 50
Hz. If so, two resistor s should be remov ed from the Regula­tor Module for optimum performan ce. (Refer to Figure 3.5.)

Remove resistor

Remove resistor

Figure 3.5 - 50 - Hz Resistor Removal

3.6 HP/ Current Jumper - It is necessary to inspect the

Current Scaling / Horsepower Jumper on the Regulator

Module to be sure that it is connected correctly for a spe-

cific drive motor .

Step 1 - On the drive motor , locate the nameplate. Note

the full-load current .

Step 2 - Or, if current is not shown on the nameplate ,

refer to Table 3.C. Relate the left or center columns in the
table with known motor data . Read across to the right
cnlumn marked "Motor Current ." This figure indicates the

proper jumper connection to make on the Module where a
corresponding number is etched .

Table 3.C

HORSEPOWER CALIBRATION

MOTOR HP

MOTOR CURRENT /

115 VAC 230 VAC

PIN CONNECTIONS

1/4

1/2

2.5A

1/3 314

3.7A

Yi

1 5A

7'4

11/2

7.5A

-

2

10A

- 3

15A

- 5

25A

Step

3 - On the Regulator Module , locate the scaling pins .

(Refer to Figure

3.6.) Near them, locate the black pig-tail

type jumper . Do not move it if it is connected to the proper
pin . If it must be reconnected, carefully lift it straight up and
off the pin. Slide the connector straight down over the
proper pin.

3. 7 Regulation Mode Jumper - The FlexPak Plus con-

troller offers three types of drive regulation. The first , which

is factory shipped , is an armature voltage feedback

(A).

14

Figure 3.6 - HP/ Current Scaling Pins

Optionally , the user may also use either tachometer feed-

back (T) regulation or counter EMF feedback

(C). In order to

use these two modes , however, the Regulation Mode
Jumper, one end of which is permanently fixed to the
Regulator Module, must be moved to one of two positions .
(Refer to Figure

5. 10.) Details of jumper placement are

noted in Section 5.

DANGER

IF YOU ARE UNSURE WHICH REGULATION

MODE A CONTROLLER SHOULD HAVE.

IT IS

IMPORTANT YOU FIND OUT. IF THE JUMPER IS
NOT PROPERLY CONNECTED. PERSONAL

INJURY MAY RESULT.

Section 4

START-UP AND ADJUSTMENT

4.0 General - This Section provides start-up and adjust-

ment procedures to be followed after the assembly and
installation of the controller is complete. All initial opera­tion checks and final adjustments to the controller must be
made in conformance to the procedures , warnings and
recommendations listed here.

DANGER
THE FLEXPAK PLUS CONTROLLER IS AT LINE
VOLTAGE WHEN A-C LINE POWER IS CON-

NECTED TO THE POWER

UNIT INSIDE THc

CONTROLLER. BEFORE WORKING ON , OR

TOUCHING ANY INTERNAL PARTS OF, THE
CONTROLLER. REMOVE INCOMING A-C LINE
POWER AT THE

MAIN DISCONNECT SWITCH.

PERSONAL INJURY MAY RESULT IFTHISWARN-

i ING IS; NOT. FOLLOWED; .

DANGER

DURING INITIAL START-UP, THE CONTROLLER

AND ITS ASSOCIATED EQUIPMENT MUST BE

OPERATED AND / OR ADJUSTED ONLY BY
QUALIFIED ELECTRICAL MAINTENANCE PER­SONNEL. THESE INDIVIDUALS SHOULD BE
FAMILIAR WITH THE DESIGN AND OPERATION
OF THIS EQUIPMENT AND WITH THE HAZARDS

INVOLVED. PERSONAL INJURY AND / OR DAM-

AGE TO THE CONTROLLER COULD RESULT

FROM UNFAMILIARITY.

4.1 Power Off Inspection - It is necessary to make a

superfic ial inspection of the FlexPak Plus controller and its
associated units. The purpose of this check is to look for
possible physical damage or improper connections.

Inspect all plug-in Modification Kits. Test each for a firm
mounting condition .

Each should be mechanically connected to the Regulator
Module by means of a mounting post screw. Each should
be electrically connected to the Module by a series of paral­lel pins . If any of the pins are bent, improper operation

results. Examine the pins to make sure they are perfectly

parallel. Only one pin may fit through a hole in the Kit.

Inspect all screw terminal connections on the Modification
Kits. Make sure the wires are firmly connected. Also make
sure that there is enough insulation on the wires to prevent
a short between the conductors.

Inspect the signal wiring from the Operator Control Station.
A series of wires will connect to individual terminals on a
strip mounted on the Remote Operator Interface Module .
(This Modul e is mounted on the Regulator Module.) Deter-

mine that all wires are firmly seated in the terminal strip.
Make sure all wires are connected .

15

4.2 Motor Ground Check - It may be necessary to make
a check of the drive motor to assure that no damaging

grounds-other than earth ground-exist within the motor .

CAUTION: Although a megger may be used for th is
test, if one is used, all conductors between the drive

motor and the FlexPak Plus controller are to be discon­nected and moved aside . The megger's high voltage
can cause damage to the controller's circuits .

Step 1 - Attach one lead from the ohmmeter to the motor
frame to make a simple resistance check.

Step 2 - Touch th e test probe to each of the two power ,

two thermostat , and two field leads to the motor .
If the reading to ground on any terminal is less than

100,000 ohms, a ground condit ion exists.

Step 3 - If a ground condit ion exists, inspect the moto r
thoroughly for internal shorts.

Step 4 - When the ground ing condition is corrected ,
reconnect the conductors from the FlexPak Plus controller.

4.3 Power On Adjustments - Once all the preliminary

power-off static adjustments have been performed with
acceptable results, the a-c line power is to be applied to the
controller , but the load is not connected . It is important to
follow these steps closely. Observe all cautions and
warnings .

DANGER
WITH A-C POWER APPLIED AND WITH THE
POWER ON / OFF SWITCH IN THE ON POSITION,
HAZARDOUS VOLTAGE EXISTS IN

THE CON-

TROLLER . EXERCISE EXTREME CAUTION WHEN

PERFORMING

THESE TESTS. PERSONAL

INJURY CAN

RESULT.

DANGER
IF CIRCUIT BREAKER HAS TRIPPED OR FUSES
HAVE CLEARED, USER MUST DETERMINE IF A
FIELD SUPPLY KIT IS PRESENT . (SEE FIGURE

5.15 .) IF FIELD SUPPLY KIT IS PRESENT . THE
FIELD SUPPLY KIT

AND ITS WIRING MUST BE

INSPECTED FOR DAMAGE. RE -APPLYING
POWER TO THE DRIVE . THE FIELD VOLTAGE
MUST BE RE-CHECKED FOR PROPER VOLTAGE
AT MOTOR TERMINALS F1. F2. IFTHIS VOLTAGE
IS BELOW 90 % OF THE FIELD VOLTAGE SPECI ­FIED ON THE MOTOR NAMEPLATE . THE DRIVE

MUST NOT BE STARTED UNTIL PROPER VOLT-

AGE IS OBTAINED. FAILURE TO FOLLOW THIS

PROCEDURE COULD RESULT IN OVERSPEED­ING THE MOTOR AND / OR THE MACHINERY
COUPLED TO THE MOTOR SHAFT AND POSSI -

BLE FATAL INJURY . REFER TO SYMPTOM 1 IN

TABLES 6.B AND 6.C.

4.3.1 Regulator Module Pots - The Regulator Module

has six adjustable potentiometers mounted on it. (Refer to
Figure 4.1 .) They control the following functions :

• Maximum speed (full CCW: 50% speed)

• Min imum speed (full CCW: zero speed)

• Acceleration rate (full CCW)

• Deceleration rate (full CCW)

• Current limit (factory-set at 150%)

• IR comp (full CCW)

The potentiometer s are factory preset for the safest or most

conservative operation .

4.3.2 Maximum Speed (Voltage) - The Maximum Speed

Potentiometer on the Regulator Module has been factory
preset for 50% of a typical motor base speed of about 1750
rpm. By means of adjustment, the maximum speed may be
raised to suit the application. The result is the highest
speed that can be set by the operator on the SPEED dial.
The control range is 50 to 100% of rated speed.

There are two methods for determining if the motor and
driven equipment are operating at an acceptable maximum
speed for the application.

• Tachometer

• Visual inspection of machine operation

Locate the Max imum Speed Potentiometer on the Regula­tor Module . (Refer to Figure 4.1.) The

latters MAX SPD are

printed on the Module . Note that CW rotat ion represents an

increase in speed. CCW represents a

decrease.

DANGER
WHEN PERFORMING THIS ADJUSTMENT PRO­CEDURE , DO NOT ALLOW

THE DRIVE MOTOR TO

EXCEED ITS RATED MAXIMUM SPEED, AS
LISTED ON

THE NAMEPLATE . EQUIPMENT

DAMAGE AND SERIOUS PERSONAL INJURY
COULD RESULT.

On the Operator Station , increase the SPEED dial slowly in

the direction of 10, which is 100% of full travel. If, as the
SPEED dial is turned toward the 10 setting, the speed
exceeds the maximum acceptable speed,

immediately

decrease the maximum speed on the SPEED dial. Use a

small insulated slot screwdriver.

some cases, to avoid exceeding the maximum operating

In

speed, it may be necessary to turn the Maximum Speed

Potentiometer completely CCW before turning the SPEED

dial completely CW.

If the 1 Osetting on the SPEED dial is lower than the desired

speed, increase the setting on the Maximum Speed Poten-

tiometer to the necessary speed. To increase the maximum

speed, turn the potentiometer CW.

DANGER

USE ONLY ONE HAND

DRIVER. KEEP YOUR

YOU. DO NOT

USE YOUR OTHER HAND TO

TO HOLD THE SCREW -

OTHER HAND BEHIND

BRACE YOURSELF AGAINST THE CONTROLLER,
PANEL OR

ENCLOSURE . PERSONAL INJURY

COULD RESULT IF YOU ACCIDENTALLY TOUCH

A COMPONENT AT LINE VOLTAGE .

Max Speed

Min Speed

Ace Rate

Deel Rate

Currant Limit

IR Comp

Figure 4.1 - Regulator Module Potentiometers

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 inter­active; a change in one affects the other .

4.3 .3 Minimum Speed (Voltage) - The Minimum Speed

Potent iometer on the Regulator has been factory preset for
zero speed. By means of adjustment, this speed may be
raised or lowered . The result is the lowest moving speed
the operator can set on the SPEED dial. The control range is
zero to 50 % of rated speed.

Again , the motor speed can be determ ined by a tachometer

or by visual inspection of machine operation .

With the SPEED dial at zero position and using a small,

insulated slot screwdriver, carefully turn the Minimum
Speed Potentiometer until the desired minimum is
reached . Note that CW represents an
represents a

decrease.

increase; CCW

NOTE: Carefully recheck the maximum speed adjustment

for desired setting . Since the maximum and minimum
speed adjustments are interactive , a change in one affects
the other . At times , it may be necessary to work back and
forth for precise adjustments.

4.3 .4 Acceleration and Deceleration Rates - The

Acceleration and Deceleration Rate Potentiometers on the

Regulator Modul e have been factory preset for a typical
linear acceleration rate of six seconds to maximum and
minimum speed . This time can be adjusted over a range of

0.5 to 30 seconds from a fully stopped condition.

16

•

4.3 .5 Current Limit - Although it will probably not be

necessary to make any adjustment in the factory-set cur ­rent limit value of 150% of rated load, it is possible to
change this governing value. (Individual application speed
changes or load changes on sustained overloads may
require readjustment . Also, applications requiring torque
limiting or accelerating of high inertia loads may require a
change from this value .)

To reduce the torque output of the drive, turn the Current

Limit Potentiometer CCW. Note, however , that turning
CCW too far may prevent the drive accelerating to the
desired speed.

4.3.6 IR Compensation - IR (voltage)Compensation is a

feature which makes up for the armature resistance of a

17

motor that causes a drop in speed as the load is increased .
The IR Compensation Potentiometer is factory-set at zero.
The IR Compensation feature can be adjusted between 0

and 12% of rated load and is used only for a voltage regula-

tion mode. When using a tachometer or CEMF feedback,

the IR Compensation Potentiometer must be turned com-

pletely CCW.

CAUTION : If the IR Compensation Potentiometer is

set too high, motor speed rising characteristics may

result. Instab ility and oscillation in motor speed will

result.

Section 5

MODIFICATION KITS

5.0 General - A number of optional features in the form
of Modification Kits are offered with the FlexPak Plus 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 5.A for an informa­tional listing.

DANGER
INSTALLATION OF MODIFICATION KITS IS TO BE
DONE ONLY AFTER A-CLINE VOLTAGE IS DIS-

CONNECTED AND LOCKED OUT AT THE MAIN

DISCONNECT SWITCH. DO NOT INSTALL KITS
WHEN POWER IS APPLIED TO THE FLEXPAK

PLUS CONTROLLER. SERIOUS PERSONAL INJURY

AND EQUIPMENT DAMAGE COULD RESULT.

CAUTION:

Installation of the Modification Kits should
be performed only by qualified electrical maintenance
personnel familiar with the design and operation of
this equipment. Damage could result thru unfamil­iarity .

Many of the Modification Kits are designed to make electri­cal connection with the Regulator Module hy means of
pin-type connectors. These slide up

tr· r ,h matching
holes in the Modules that form part ti Kit . (Refer to
Figure 5.1.)

Figure 5 .1 - Pin Alignment

A common installation probl em is caused by bent, broken
or incorrectly placed pins . Since imprope r operation

result s, care must be taken . Exact alignment is critical.

Visually check that only

one pin extends to the top of each

slot once the connection is made.
Many of the Modifi cation Kits require the removal of one or

more jumpers from the Regulator Module. In such cases,
carefully clip the leads on

both sides of each jumper and

discard it . Use a sharp pair of dykes (diagonal cutters) to
assure a quick, clean cut. Do not twist the tool, since dam­age may result.

In cases where the Kit is secured by a mounting screw, be

sure to tight en it firmly but

do not overtighten . Excess ive

force can strip the threads.

5.1 Auxiliary Panel - The Auxiliary Panel contains a-c

line fuses. an M contactor, an Auxiliary Mounting Bracket

19

and four screws for use with the Basic FlexPak Plus . The
Auxiliary Mounting Bracket provides a mounting surface
for the Automatic Reversing and Auxiliary M Contactor

Kits.

To install the Auxiliary Panel, follow these procedures .

Step 1 - Follow this Step only if the Contactor Adapter Kit

with a user-supplied M contactor is already installed. If this

condition does not exist , proceed to Step 2.
Disconnect the user- supp lied FM contactor (and user-

supplied RM contactor if applicable}. Remove the two har­ness connectors from the Regulator Module . Remove and

discard the Contactor Adapter Kit (including the Auxiliary

Mounting Bracket} .

Step 2 - Orient the Auxiliary Panel over the Basic Con-

troller aligning the mounting holes. Secure the Panel with
the provided screws . (Refer to Figure 5.2 .)

Step 3 - Connect leads 51 and 52 to termina ls 51 and 52 .

respectively , on 1 TB of the Basic FlexPak Plus. Connect
leads45 and 47 toterminals45 and 47 , respectively , on the
Basic FlexPak Plus. Make sure connections are tight and
well made.

Step 4 - Place the relay control harness connector over

the Regulator pins marked FWD. (Refer to Figure 5.2.)
Orientat ion is important : connect the orange wire with the
pin called out as ORG 139. (Refer to Figu re

6.4.)

Line fuse

M contactor

Mounting screws
(2 each side)

Figure 5.2 - Auxiliary Panel Mounting

5.2 Dynamic Braking - The standard FlexPak Plus con­troller allows 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 5.3 .) Its use allows a rapid,
shockless stopping of the drive motor .

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.

Table 5.A

Figure 5.3 - Dynamic Braking Kit

MODIFICATION KIT QUICK REFERENCE LIST

ADDITIONAL ADDITIONAL

MANUAL

CONTROLLER OPTIONS USER-

PARAGRAPH

MODEL

MODIFICATION REQUIRED SUPPLIED

KIT

NUMBER

NO.

7a) 7 OPTIONS REQUIRED PARTS?

Automatic

5.4

14C226 no

yes

• Auxiliary Panel no

Reversing

• Reversing Contactor Kit

Auxiliary

5.10

14C219

no

M Contact

yes

Auxiliary Panel

wire©

©

Auxiliary

5.1

14C80

yes no

None

no

Panel

thru 83

Contactor

5.14

14C276 no no None M Contactor

Adapter Kit

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/ yes • If preset speed only, may no

Interface /

need AUTO/ MANUAL

Preset Speed

switch .

no/ yes

• If follows process con-

wire ©

troffer, may need AUTO/

MANUAL switch.

Master Isolated

5.13

14C229 yes yes Master Isolated

wire©

Reference

Reference Transmitter

Receiver©
Reversing

5.3 14C218

yes

yes

• FORVVARD/ REVERSE

no

Contactor

selector switch on
Operator Station
(See Figure 3.4.)

• Auxiliary Panel no

Tachometer

5.5

14C221

yes

no

None

wire©

Feedback

Test

Meter

5.11

14C225

no no None no

Adapter
Torque Taper

5.9 14C224

yes

no

None

no

Voltage/

5.6

14C223

yes no/ yes

May need AUTO/ MANUAL

wire ©

Tachometer

selector switch

Follower

<D Modification here means that some work such as jumper placement, resistor clipping, or wiring reconnection. must be performed.
<D Refer to Table 5.C.

<D Supplied as standard with 2, 3 and 5 hp FlexPak Plus controllers.

© Not to exceed AWG No. 14.
© Refer to Paragraph 5.8 for specific sizes.
© Special order only.

20

The Dynamic Braking option is actually a resistor con-

nected across the motor armature. It allows a motor to act
as a generator; the rotating mechan ical (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 .
When ordering the Kit, it is necessary to specify Part

Numbers according to horsepower and voltage ratings .
(Refer to Table 7.A.)

The Dynamic Braking Kit contains the resistor and two
mounting screws. Mount the Kit in the upper right-hand
corner of the Auxiliary Panel as shown in Figure 5.4 . Wire
the Dynamic Braking Kit according to Figure 5.5.

DB Resistor

~\

Figure 5.4 - Dynamic Braking Kit Installed

first

row

FM only

FM or
RM(D

Non-reversing (FM) contactor

longer wire

D.B.

CD For Reversing Contactors this wire only is placed on

exactly corresponding term inal on RM.

Figure 5.5 - Dynamic Brak ing Connections

21

5.3 Reversing Contactor - The standard FlexPak Plus

controller offers unidirectional control. With an optional
Reversing Contactor Kit and Auxiliary Panel, bidirectional
operation (both forward and reverse) is possible. Motor
direction is manually selected. Install the Auxiliary Panel
onto the Basic Controller according to Paragraph 5.1.
Mount the Reversing Contactor Kit on the right-hand side
of the Auxil iary Panel with the three mounting screws
provided . Connect the two power wiring harn esses and the
control wiring harness as shown in Figure 5.6.

second

row

47

45

second

row

A1

66~

I I I I

BLUE REV. pin on Regulator Modul e

Figure 5.6 - Reversing Contactor Connections

5.4 Automatic Reversing - The optional Automatic Re-

versing Kit provides an

automatic reverse-direc tion capa-

bility to the FlexPak Plus. Functionally , the Kit allow s the
controller to sequence off, and then immediately sequence
on again, thereby providing a fast, automatic change of
direction . This respon se may be caused by either an exter ­nal switching signal or manually with a FORWARD /

REVERSE selector switch . (Refer to Figure 5.7.)

'*

~

Figure 5.7 - Automatic Reversing Kit

The Kit contains a single Module with a fixed wire harness.

However, its use requires that two other options also be

used:

• Auxiliary Panel

• Reversing Contactor

No other parts are required, and no modifications need be
made to the controller beyond those implied in the above

two options.

To install the Kit, follow these procedures.

Step 1 - Install the Auxiliary Panel and the Reversing

Contactor, as outlined in Paragraphs 5.1 and 5.3.

Step 2 - On the right-hand end of the Auxiliary Mounting

Bracket, orient the Automatic Reversing Module so that the
harness points toward the Regulator Module. (Refer to
Figure 2.2.) Press the four nylon pins firmly into the four
holes in the Auxiliary Mounting Bracket.

Step 3 - Place the harness connector over the Regulator

Module pins marked AUTO REV. (Refer to Figure 6.4.)
Orientation is important: connect the purple (40) wire with
the pin called out as PUR on the Regulator Module.

5.5 Tachometer Feedback - The FlexPak Plus is supplied

as standard as a d-c armature voltage feedback controller.

With the addition of the optional Tachometer Feedback Kit,

it can operate as a speed-regulated unit, thereby improving
regulation to as little as 0.5% with specifiAd tachometers.
(Refer to Figure 5.8.) Either an a-c or d-c tachometer may be

used. The maximum allowable input voltage is 175 volts.

Figure 5.8 - Tachometer Feedback Kit

A 1 % speed regulation with 95% load change can be
obtained when using a Reliance Electric a-c tachometer
(RE-045) or d-c tachometer (5 PY or RE-020). A 0.5% speed

regulation with a

95% load change can be obtained when
using a Reliance Electric d-c tachometer (BC-42). Equiva­lent tachometers are acceptable.

The Kit contains a Module that has a jumper that must be
connected by the user to provide proper scaling of the

feedback into the regulator. There is also a mounting
screw.· The user must supply the tachometer and 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 VOLTAGE SCALING

MOTOR

BASE

100%

SPEED

TACHOMETER

VOLTAGE

(rpm)

(volts/ 1000 rpm)

CONNECTION

1150

20VOC

23

1750

20VDC

35

1150

50VDC

58

3450

20VOC

69

1750

50VDC

88

1150

100VDC

115

3450

50VDC

175

1750

100VDC

175

1150

45VAC

52

1750

45VAC

79

3450

45VAC

155

To install the Kit, follow these procedures. Check the

tachometer to determine which wires are T1 (+) and T2 (-).

Step 1 - Orient the Tachometer Module over the desig-

nated area of the Regulator Module, just over the two pins.
(Refer to Figure 2.2.) Lower it so that the pins pass through
the guides in the Module. Use the screw to secure it.

Step 2 - Connect the tachometer wires to the terminal

strip on the Module. Plus(+) is the left side, minus(-) the
right. Do not strip off more than

Ya inch (3 mm) of insulation

since shorts occur at exposed points. Maintain the twist as

long as possible.

Step 3 - Locate the black pig-tail jumper on the Tachome-

ter Module. It is to be placed on one of ten pins on the

Module. Exactly which depends on the voltage scaling fac-

tor. On the motor's nameplate, find the base speed (rpm).

On the tachometer's nameplate, find the output voltage per

1000 rpm.

Take these two figures and relate them to Table 5.B. Read

across to the right column, where the 100% voltage figure

is indicated. Place the jumper on the Module's pin that

corresponds to this figure.

DANGER

WHEN A REVERSING CONTACTOR IS IN-

STALLED OR FOR ANY REASON THE TACHOME­TER OUTPUT VOLTAGE IS REVERSED.JUMPERS
J1 AND 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.

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

being used. Skip to Step 6 if a d-c device is used.
On the Tachometer Module, locate jumpers J 1 and J2 on

the right of the terminal strip. (Refer to Figure 5.9.) Clip out

and discard these jumpers for a-c operation.

V

V

V

JumperJ2

Jumper J1

Figure 5.9 - Jumpers J 1. J2

Step

5 - Since the IR compensation is not used with

tachometer feedback , it is necessary to turn the IR Potent i­ometer fully CCW. (Refer to Figure 4.1.) If IR compensation
is left in the circuit. erratic operation may result .

Step 6 - The Feedback Jumper on the Regulator Module

must be connected for tachometer feedback . (Refer to Fig­ure 5.10 .) Place the Regulator Module 's fixed black jumper
on the pin marked T.

Figure 5. 1 0 - Feedback Connection on

Regulator Module

Step

7 - This Step assumes that the complete drive sys-

tem, including the controller , has been successfully started

Table 5.C

USE IN CONTROLLER

Remote Operator Control

Station :

• AUTO/ MANUAL

• JOG / RUN

• FORWARD/ REVERSE

• START / STOP

Remote Operator

Control Station :

• SPEED pot

• TORQUE pot

• Tachometer
Feedback

• Instrument
Interface

• Voltage / Tachometer
Follower

WIRE SPECIFICATIONS

TYPE CONDUCTOR

REQUIRED

CHARACTERISTICS

CONTROL WIRES

• Single conductor and/ or
multi -conductor

• Stranded copper

• AWG No. 16

• 600 VAC rating

• Insulation : poly­vinyl chloride (PVC)

• Temperature range :
40°-105 ° C (104°- 221°F)

• Unshielded

SIGNAL WIRE

• Three -conductor • Stranded copper

• Twisted with two twis ts

(19

X 29)

per inch

• AWG No. 16

• 600 VAC rating

• Two -conductor

• Twist per foot :
24

(1/

2

-inch lay)

• Twisted pair with two

• Insulation : poly-

twists per inch

vinyl chloride (PVC)

• Temperature range :
40° -105°C (104°- 221

Of)

23

ACCEPTABLE TYPES

• Any single conductor
meeting N.E.C.

required characteristics

• User may twist single

conductors of re­qui red specifications

• Relianc e Part No.

417900 -79X

• User may twist single

conductors of re­quired specifications

• Reliance Part

No.

417900- 76EAD

up and debugged according to Section 4 thru Paragraph

4.3.1. It is necessary to carry out a power-on test . Set the
SPEED Potentiometer at approximately 25%of full rotation .
Start the drive . It should run as set. If it accelerates to full
speed, the tachometer is not providing a signal.

Stop the drive, turn off all power , and reverse the leads to

the Tachometer Module 's terminal strip . Repeat the test
with power on in order to confirm that proper feedback

signals are being received by the regulator .
If erratic behavior continues, check the placement of the

two pig-tail jumpers against Steps 3 and 5.

Step 8 - The Maximum and Minimum Speed Potentiome-

ters should now be adjusted to Paragraphs 4.3.2 and 4.3.3.
Be sure to follow 4.3.4 and 4.3.5 but

do not follow 4.3.6.

5.6

Voltage / Tachometer Follower - The Voltage /

Tachometer Follower Kit allows the FlexPak Plus to be
controlled

automatically in response to a speed reference

generated by a tachometer connected to an entirely sepa-

rate machine unit . Ideal appl ications include automatic
control systems where a "second" slave drive must closely
follow the speed of a master drive, or machine . (Refer to
Figure 5.11.)

Figure 5.11 - Voltage/Tachometer Follower

The Kit is designed to accept an input signal of 25 to 250
VDC to obtain maximum speed. (The maximum permissible

input voltage is 250 VDC.) The input impedance between
terminals is approximately 80,000 ohms . Therefore , 100
VDC draw approximately 1 .25 mA current from the voltage
source .

The Kit contains the Module and a mounting screw .
Although the FlexPak Plus can use the Kit for exclusive
automatic speed control, if manual override control is

needed, an AUTO/ MANUAL selector switch must be used
on the Operator Control Station. In the MANUAL position,
the drive responds to the SPEED Potentiometer setting. In
AUTO, it follows

only the external signal and does not

respond to manually input speed change commands .
The user must also supply required 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

over the REFERENCE area on the Regulator Module, just
over the five pins . (Refer to Figure 6.4.) Lower it so that the
pins pass through the guides on the Module. (It may be
necessary to remove a protective plastic cap from the pins.)
Secure the Module with the screw .

Step 2 - Connect the wires from the tachometer to the

terminal strip on the Modu le. Plus( + ) is on the left, minus
(-) on the right . Do not strip more than

1/

8

inch (3 mm) of

insulation off since shorts occur at exposed points. Main-

tain the twisted character as long as possible .

Step 3 - If an AUTO/ MANUAL selector switch is used, it

is necessary to remove jumper

Jl on the Module . (Refer to

Figure 5.12.) If, however , the controller is designed to run
automatically

without manual speed cont rol, Jl remains

in place . In addition , remove jumper J4 on the Regulator
Module if an AUTO / MANUAL selector switch is used.

JumperJ1

Figure 5.12 - Jumper J 1

Step 4 - This Step assumes that the complete drive sys-

tem, including the controller, has been successfully started
up and debugged according to Section 4. It is now neces­sary to carry out a power-on test. Start the drive and place it
in the AUTO mode , if so equipped .

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

RE LY ON ZERO

SPEED / INPUT SETTING FOR SAFETY. SERIOUS
OR FATAL INJURY MAY

RESULT.

5. 7 Instrument Interface / Preset Speed - The FlexPak

Plus can

automatically follow a milliampere signal from a

process control instrument if the optional Instrument Inter­face/ Preset Speed Kit is installed . (Refer to Figure 5.13.)
Alternately , the Kit also perm its the drive to run continu­ously at a preselected speed.

The Instrument Interface Module accepts a Oto 5, 1 to 5, 4

to 20 or 10 to 50 mA signal, which may be grounded or

ungrounded. The maximum input is 50 mA.

Figure 5.13 - Instrument Interface Kit

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 flow and
pressure .

The Auto Minimum Speed Potentiometer on the Module

can be set so that the drive runs at a preset minimum speed
( up to 50% ) with a minimum output signal from the pro­cess instrument. The Auto Maximum Speed Potentiometer
on the Module can be set so that the drive runs at 50% to
base speed with a maximum output signal from the instru­ment . Other relationships within these parameters are also
possible , and they allow operation over a larger speed
range than the 5:1 range proviaed by the process
controller .

The Kit contains a Module that has a jumper that must be

connected by the user to select one of two maximum input
signals : 5 mA or 50 mA. There is also a mounting screw .

The Kit may be used alone to provide full, automatic drive

control, or it may be used with an optional AUTO / MANUAL
selector switch on the Operator Control Station. This
switch may be used to manually override the external d-c
signal. (In the MANUAL position , the drive follows the
SPEED Potentiometer on the Station .) The user supplies
the required lengths of specified signal wire . (Refer to Table

5.C.) A process instrument controller, or other transducer
with a d-c mill iampere output , is also required.

NOTE: If the Operator Control Station contains an AUTO !

MANUAL selector

switch. it is necessary to remove jumper
J1 from the Instrument Interface Module and J4 on the
Regulator Module. (Refer to Figures 5. 14 and 6.4.) Do this
before placing the Module on the Regulator Module .

DANGER
APPLICATION MUST NOT RELY ON ZERO SPEED
SEITING FOR SAFETY. SERIOUS OR FATAL

INJURY MAY OCCUR .

To install the Kit, follow these procedures. The following
explanation assumes thatthe initial wiring was carried out.

Step 1 - Orient the Module over the dedicated area

marked REFERENCE on the Regulator Module, just over the
five pins. (Refer to Figure

6.4.) Lower it so that the pins 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 not strip more than

Ya inch (3 mm)

of insulation off since shorts could occur at exposed points.
Maintain the twisted character as long as possible.

Step 3 - At this point refer to Paragraph 5. 7 .1 if the

FlexPak Plus is to follow a

process instrument controller

signal. Refer to Paragraph

5. 7.2 if the FlexPak Plus is to be

set at a

preset speed for continuous operation. The proce-

dures differ.

5.7 .1 Installing Instrument Interface - When the Kit is

to be used as an instrument interface, follow these Steps.

Step 1 - Determine whether the maximum input signal is

between Oto 5 mA or 5 to 50 mA. Locate the black pig-tail
jumper on the Module . (Refer to Figure 5.14.) Carefully
place it on the directly corresponding pin , both of which are
clearly marked.

mA pins

Jumper J1

Figure 5. 14 - Jumper J 1, mA Pins

Step 2 -

This Step assumes that the complete drive sys-

tem, including the controller, has been successfully started

up and debugged according to Section 4 . It is now neces­sary to carryout a power-on test . Place the controller in the
AUTO mode, if it is so equipped. Set the process instrument
controller for minimum output . Locate the Auto Minimum
Speed Potentiometer on the Interface Module . Using a
small insulat ed screwdriver , adjust it for the desired min-

imum motor speed. (CCW decreases speed.)

Step 3 - Set the process instrument controller for maxi -

mum output. Locate the Auto Maximum Speed Potenti ­ometer. Adjust it for the desired maximum motor speed.
(CW increases speed.)

Step 4 - Since there is some interaction between these

two potentiometer s, at times it may be necessary to work
back and forth to achieve precise adjustments.

5. 7.2 Installing Preset Speed - When the Kit is to be

used as a simple preset speed device , follow the se Steps.

Step 1 - Make the same assumption as in Paragraph

5.7.1, Step

2.

Step 2 - Connectthe black pig-tail jumper on the Interface

Module to the 50 mA pin. (Refer to Figure 5.14.)

Step 3 - Locate the Auto Minimum Speed Potentiometer

on the Interfa ce Module . Turn it CW to the third dot which
represents a one-third turn .

Step 4 - Place the controller in the AUTO mode, if so

equipped . Locate the Auto Maximum Speed Potentiometer.

Adjust it to obtain the desired preset speed. (CW increases

speed, CCW decreases it.)

5.8 Field Supply - The Field Supply Kit provides full­wave field excitation for shunt -wound d-c motors . (Refer to
Figure 5.15.) It may be optionall y applied to controll ers from

% thru 11f2 hp. (It is a standa rd feature for 3 and 5 hp FlexPak

Plus controllers .)

Figure 5.15 - Field Supply Kit

D-c field supply voltage and maximum field amperes are

listed in Table 2.0 .

The Kit is an assembly consisting of a terminal block , a Field

Supply Power Cube, two wire harnesses , and two screws .

The user provides the F1 / F2 conductors to the drive motor .

No other equipment is required.

To install the

Kit. follow these procedures .

Step 1 - Mount the Field Supply Power Cube on the

right-hand edge of the terminal board bracket of the Basic
Controller . Use the long taptite screw and nylon washer
provided . Attach the F1, F2 terminal board to the terminal
board labeled 32, 132.

Step 2 -Wire from the Field Supply Power Cube to termi-

nals 51 and 52 on 1TB, as shown in Figure 5.16.

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 or Figure 5.16.

5.9 Torque Taper - The addit ion of the optional Torque

Taper Kit to the FlexPak Plus controller allows fine adjust­ment of the slope and break point of the drive 's speed­torque curve . (Refer to Figure 5.17.) It is ideal for cases
whe re simple , center-driven winders and similar applica­tions require a reciprocal speed-torque relat ionsh ip to

maintain constant tension as material builds up. In other

words , a higher current limit (here, torque) setting is

required for a decrease in motor speed due to a growing

diameter . This relation ship is shown in Figure 5.18.

26

51

G) Not e: The fie ld supply voltages liste d in Table 2.0

are full wave supplies. For half voltage or half wave

supply connect mo tor lead Fl , to terminal

51 o n

1 TB and motor lead F2 to term inal F2 on 2T B.

A·C LI NE

FIELD SUPPL Y VOLT AGE

VOLTAGE HALF WAVE FULL WAV E

115V so

100

230V 100 200

To

Fl, F2

on motor

~ 2TB

0

<D

52

Fl F2

Figure 5. 16 - Connecting Field Supply

Figure 5.17 - Torque Taper Kit

100%

base SPEED pot CORE TORQUE pot

~

41/_~===::::!~~ -------t-

N

(rpm)

0

\ ',, I

\ '' I

\ ..............

\

\

Torque ,
taper~

I (torque)

\

\

\

\

\

,

Current

Limit pot

or

Torqu e pot

100% current (torque)

Figure 5 .18 - Torque Curves

'

•

' .

The Kit consists of a Module and a mounting screw. No
other equipment is required . However, the SPEED Potenti­ometer and either the TORQUE Potentiometer or the Cur­rent Limit Potentiometer on the Regulator Module are used
in conjunction with the two potentiometers on the Module .

To install the Kit and to make initial adjustments , follow

these procedures .

Step 1 - Remove jumpers J7 and JS on the Regulator

Module . (Refer to Figure 6.4 .)

Step 2 - Orient the Module over the area marked TORQUE

TAPER on the Regulator Module , just over the seven pins.
(Refer to Figure 6.4.) Lower it so that the pins pass through

the guides in the Module. Use the mounting screw to
secure it.

Step 3 - On the Regulator Module , adjust the Current

Limit Potentiometer CCW to 100%, or lower. depending on

the application . Remember that it is factory-shipped at

150%. Dot No. 4 is approximately 100% . (Refer to Figure

4.1.)

Step 4 - On the Torque Taper Module, turn the CORE

TORQUE Potentio meter completely CCW. The core torque
setting provides a minimum winding torque, or minimum
strip tension, when the winding cycle begins .

Step 5 - On the Torque Taper Module, turn the Torque

Taper Potentiometer completely CW. This assures that
excessive tension will not develop as the first coil or pack­age is wound.

Step 6 - This Step assumes that the complete drive sys-

tem, including the controller, has been successfully started
up and debugged according to Section

4. It is now neces-

sary to carry out a power-on test . Thread the strip onto the
winder and securely fasten it to the core. Remove all strip
slack before the drive is restarted .

Step 7 - Set the SPEED Potentiometer for a safe maxi-

mum winder speed.

Step 8 - Start the drive . If the strip or web breaks imme-

diately , stop it. Reduce the Current Limit Potentiometer
setting on the Regulator Module . (CCW decreases current,
here torque .)

If the strip does not immediately break, start the process
and allow the winder to begin winding . Accelerate it to
normal running speed. On the Torque Taper Module, adjust
the CORE TORQUE Potentiometer to obtain the desired
strip tension at the beginning of the coil. (CCW decreases,
CW 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 cur­rent , here torque .) Adjust in small increments as the diam­eter grows.

An ammeter in the armature circuit is useful when adjust-

ing both potentiometers on the Module . Observing the
ammeter, which shows current, and the growing coil di­ameter gives visual confirmation that current (torque) is
increasing too fast or slow in relation to the build-up .

NOTE: Depending on the amount of torque taper desired

and the size of the coil or package being wound, the drive
may go into current limit. However.

at no time should the

Current Limi t Potentiometer on the Regulator Module be
set higher than 100% of the nameplate rating on the motor .

27

5.10 Auxiliary M Contacts - With the optional Auxiliary

M Contactor Kit, the ON/ OFF status of the FlexPak Plus is
able to be interlocked with user-supplied devices . (Refer to
Figure 5.19.) Typical applications include pilot /i ndicator
lights, alarms , and interlocking with other control circuits

dependent on the drive system.

Figure 5 .19 - Auxiliary M Contactor Kit

The Kit provides a single pair of Form C contacts , one

normally open

(NO) and one normally closed (NC). Both

share a common terminal. (Refer to Figure 5.20.) These
contacts function whether the controller is unidirectional
(forward only) or bidirectional (forward / reverse) .

41 COM

43

42 41

e

© 0

NO

NC COM

Figure 5.20 - External Wiring, Auxiliary M

The Kit contains only a Module that has a wire harness
attached. However , the Auxiliary Panel is also required .

Users supply the wiring to external devices. Size is depen­dent on the specific application . It should not exceed AWG
No. 14.

The maximum rating of each contact is 1 ampere at 30 VDC

(resistive) or 0 .5 ampere at 120 VAC (resistive).
Under

no circumstances should these contacts be used to

control brakes or other power loads.
To install the Kit. follow these procedures .

S!ep 1 - Fit the Auxiliary Panel onto the Basic Controller

according to Paragraph 5.1 .

Step 2 - Mount the Aux iliary M Contactor Module on the

center of the Auxiliary Mounting Bracket. (Refer to Figure

2.2.) Note that orientation is important. The overhanging
edge of the assembly

must hang over the Regulator

Module . Then snap the assembly into the Bracket.

Step 3 - Connect the three -wire harness to the Regulator

Module. Locate the letters AUX. M printed on the Module
near a three-pin connector. (Refer to Figure 6.4.) The con­nector fits on the bayonet pins. Note that -the yellow (39)
wire

must connect with the pin marked YEL 39 on the

Regulator Module .

Step 4 - Route external wiring to the Module 's terminal

block . Do not strip more than

% inch (6 mm) of insulation

from the wires since shorts could occur at exposed points .

5.11 Test Meter Adapter - Measuring and monitoring of

FlexPak Plus regulator voltages can be safely and con­veniently carried out with the optional Test Meter Adapter
Kit. (Refer to Figure 5.21.) It acts as an interface between
the Regulator Module and a user's voltmeter .

CAUTION : Undernocircumstancesshouldtheprobes

of a meter be connected directly to the pins on the

Regulator Module . Permanent damage to the solid
state components can occur .

Figure 5.21 -Test Meter Adapter

The Kit contains a Module and a mounting screw . Except

for the voltmeter , no other equipment is necessary. The
meter should be a multimeter having a sensitivity of 20,000
ohms per volt , minimum. (Simpson Model 260 , Triplett

Model 630, or equivalents are acceptable.)

To install and use the Kit, follow these procedures.

Step 1 - Orient the Test Meter Adapter Module over the

area on the Regulator Module marked TEST, just over the

nine pins . (Refer 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 terminals to be used. The

normal operating voltages are also shown .

5.12 Dancer Follower - The Dancer Follower Kit allows

the FlexPak Plus to be controlled

automatically in response

to a speed reference generated by a line speed signal and
trimmed by a Dancer Potentiometer . Applications include
web process lines where a drive must closely follow or
maintain the position of a dancer .

28

Table 5.0

TEST ADAPTER TERMINALS , READINGS

NORMAL

USE

INDICATION

FOR FUNCTION:

TERMINALS:

(VDC) :

Unregulated

+456

16-28

+20VDC

-357

Power Supply
Unregulated

-471

16-28

-20VDC

+ 357

Power Supply

Regulated

+356

10.8-11 .5

+ 11.2VDC

-357

Power Supply
Regulated

-371 10.8-11.5

-11 .2VDC

+ 357

Power Supply
LVTU (linear +826

0-8 .0

voltage time unit)

-357

Input
Major Loop

-819

0-4 .0

Feedback

+ 357

Two Driver

-816 , -817 On 10 VDC scal e,

Outputs

+ 356

increase of approx.

1

voe occurs when

drive is started .

The Kit contains the Dancer Follower Module and a mount-

ing screw . (Refer to Figure 5.22.)Although the Flex Pak Plus

can use the Kit for exclusive automatic speed control , if

manual override control is needed, an AUTO / MANUAL
selector switch must be used on the Remote Operator
Control Station. In the MANUAL pos ition, the drive
responds to the SPEED Potent iomete r setting . In AUTO, it
follows

only the external signa ls and does not respond to

manually input speed change commands .

Figure 5.22 - Dancer Follower Module

The Kit is designed to accept a line speed input signal of 4 to

10 VDC to obtain maximum speed. The input impedance

between the line speed input terminals 57 and 726 is
approximately 25,000 ohms. The Dancer Potentiometer
will provide up to a 20% trim to the line speed signal.

The user must supply the required lengths of the specified
signal wire. (Refer to Table 5.C.) A Dancer Potentiometer
and an optional Dancer Position Potentiometer are also to
be supplied by the user.

To install the Kit follow these procedures .

Step 1 - Refer to Figure 6.4 and note the heavy border

area in the center of the Regulator Module marked REFER-

ENCE. This is the area where the Dancer Follower Module
is to be mounted. Place the Dancer Follower Module in the

proper orientation so the pin guides on the Module are
aligned over the set of five pins on the Regulator 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 necessary to remove a protec ­tive plastic cap from the pins .) Secure the Module with the
supplied screw.

Step 2 - Connect the black pig-tail jumper of the Dancer

Follower Module to pin 319 on the Regulator Module. (Pin
319 is the third pin down in the group of pins marked

TORQUE TAPER.)

Step 3 - 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 726and

the minus (-) wire is connected to terminal 57.

NOTE : Do not strip more than 1/

8

inch (3 mm) of insulation
off the ends of the wires because a short circuit could occur
at any point where the bare wire is exposed. Maintain the
twisted configuration of the two wires as Jong as possible.

Step 4 - Using three twisted wires. connect the user

supplied 5K ohm Dancer Potentiometer to the terminal
strip of the Dancer Follower Module. The speed increase
side of the potentiometer connects to terminal 556 and the
speed decrease side connects to terminal 571. The potenti­ometer wiper is connected to terminal 919.

Step 5 - If an optional Dancer Position Potentiometer is

used (supplied by user), connectthe

"up " side of the poten­tiometer to terminal 726 of the Dancer Follower Module
and the

"down" side to terminal 557 . Connect the potenti­ometer wiper to terminal 926. Also cut and remove jumper
J2 and the 26.7K resistor (R6) on the Dancer Follower
Module . (Refer to Figure 5.23.)

Step 6 - If an AUTO / MANUAL selector switch is used on

the Operator Control Station, remove jumper J1 of the
Dancer Follower Module. (Refer to Figure 5.23 .) If, how-

ever, the controller is to run automaticallywithout manual
speed control, leave J1 in place.

Step 7 - This Step assumes that th e complete drive sys-

tem, including the controller , has been successfully started
and debugged according to Section

4. It is now necessary to

conduct a power-on test.
Start the drive and place it in the AUTO mode, if so

equipped. With the line speed reference at maximum
value, adjust the MAX SPEED TRIM Potentiometer on the
Dancer Follower Module for maximum motor speed. If the
optional Dancer Position Potentiometer is installed, place it
in the mid-range.

29

Resistor (R6)

Figure 5.23 - Jumpers J1. J2 and Resistor (R6)

Turn the GAIN Potentiometer of the Dancer Follower Mod-

ule fully counterclockwise for minimum Dancer Potent i­ometer response . Turn the GAIN Potentiometer clockwise
in small increments to increase the Dancer Potentiometer
response .

DANGER

APPLICATION MUST NOT

RELY ON ZERO SET/
INPUT SETTING FOR SAFETY. SERIOUS OR
FATAL INJURY MAY RESULT.

5. 13 Master Isolated Reference Receiver -

The Master

Isolated Reference Receiver Kit may be added to special

order FlexPak Plus controllers. This Kit allows the FlexPak

Plus to receive and decode a PWM speed reference signal
from the Master Isolat ed Reference Transmitter . The
Receiver Kit consists of two printed circuit boards: a Switch
Receiver Module and a Reference Receiver Mod ule which

are mounted on the FlexPak Plus Regulator Modul e. (Refer
to Figure 5.24.)

Switch Receiver

Module

Reference Receiver

Module

Figure 5.24 - Master Isolated Reference Receiver Kit

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 AUTO mode, the individual drive SPEED
Potentiometer automatically is converted into a draw pot
adjustment for precise tFim control between drives. The
only adjustment requirement is a zero set adjustment on
the Reference Receiver Module. Should the speed refer­ence wires become disconnected, the FlexPak Plus will go

to zero speed.
FlexPak Plus controllers controlled by Master Isolated Ref-

erence are ideally suited for non-reversing multiple con­veyor drives, proportional pumps, feeder drives, web lines
or other similar operations which require multiple drives to

follow a common reference signal .

To install the Kit, follow these procedures.

Step 1 - Refer to Figure 6.4 and note the heavy border

area atthe extreme left-hand side of the Regulator Module.
This is the area where the Switch Receiver Module is to be

mounted. First, remove the Remote Operator Adapter

Module. Then, place the Switch Receiver Module in the
proper orientation so the two connectors are aligned over
the two sets of pins (marked GRN 28 and RED 32). Care­fully, slowly and gently press the connectors down on the

pins until they bottom . Then, connect the black pig-tail
jumper of the Switch Receiver Module to pin 40 on the

Regulator Module. (Pin 40 is the left-hand pin of the group

marked AUTO REV.).

Step 2 - Fold the PC board over the top of the two connec-

tors so the mounting spacers fit into the mounting holes .

Step 3 - Connect the external start-stop wires (wires 189

and 288) from the external Master Isolated Reference

Transmitter to the terminal block on the Switch Receiver

Module in the controller cabinet.

Step 4 - Mount the Remote Operator Adapter Module on

top of the Switch Receiver Module and secure the two PC

boards with the two long screws provided.

NOTE : The external start -stop wires from the Master Iso­lated Reference Transmitter (wires 189 and 288) must be
connected to the Switch Receiver Module (Refer to Step 3.)
before mounting 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 jumpers
are left connected when only control from the Master Iso­lated Reference Transmitter is desired.

Step 5 - Refer to Figure 6.4 and note the heavy border

area in the center of the Regulator Module marked REFER­ENCE. This is the area where the Reference Receiver Mod­ule is to be mounted. Place the Reference Receiver Module
in the proper orientation so the pin guides on the Module
are aligned over the set of five pins on the Regulator

Module. Lower the Reference Receiver Module so the pins

pass through the pin guides and the mounting spacer seats

in the mounting hole. (It may be necessary to remove a
protective plastic cap from the pins.) Secure the Module
with the supplied screw.

Step 6 - Using a twisted pair, connect the external refer-

ence wires (wires 1 and 2) from the external Master Iso-

lated Reference Transmitter to the terminal block on the

Reference Receiver Module in the controller cabinet. Con­nect wire 1 to terminal 1 and wire 2 to terminal 2.

30

NOTE: Do not strip more than

1

/

8

inch (3 mm) of insulation
off the ends of the wires because a short circuit could occur
at any point where the bare wire is exposed. Maintain the

twisted configuration of the two wires as long as possible.

Step 7 - If an AUTO/ MANUAL selector switch is included

in the Operator Control Station, cut jumper

Jl on the Ref-

erence Receiver Module. (Refer to Figure 5.26.)

Step 8 - With the MASTER Speed Potentiometer on the

Master Isolated Reference Transmitter set at zero, depress
the START pushbutton on the Master Isolated Reference

Transmitter . Adjust the ZERO SET Potentiometer on the

Reference Receiver Module to obtain zero speed of the
drive motor.

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

ONtWHILEAT THE ZERO

SPEED SETTING.

JumperJ1

Figure 5.25 - Jumpers J1 and J2 on

Switch Receiver Module

Jumper J1

Figure 5.26 - Jumper J1 on Reference Receiver

Module

\

\

5.14 Contactor Adapter - The Contactor Adapter Kit
provides a means of connecting the user-supplied M con­tactor (and optional user-supplied reversing M contactor)to
the Basic Flex Pak Plus Controller . Refer to Paragraph 2.4.4
for M contactor specifications .

The Kit is an assembly consist ing of an Auxiliary Mounting
Bracket , a power terminal strip , two wire harnesses and
four screws .

To install the Kit, follow these procedures .

Step 1 - Orient the Auxiliary Mounting Bracket (Refer to

Figure 5.2.) over the Basic Controller aligning 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 connectors is impor ­tant . Place the left harness connector over the Regulator
pins marked FWD with the orange (139) wire with the pin
called out as ORG 139. Place the other harness connector
over the Regulator pins marked REV with the blue (66) wire
with the pin called out as BLU 66. (Refer to Figure 6.4.)

Step 3 - Wire the user-supplied M contactor (and optional
user-supplied reversing contactor) to the kit terminal strip
according to Figure 5.27.

31

AUXILIARY

MOUNTING

BRACKET

Figure 5 .27 - Connecting User-Supplied FM

and RM Contactors

Section 6

TROUBLESHOOTING

6.0 General - This Section details troubleshooting infor-

mation for the Flex Pak Plus controller. Its organization is as
follows:

• General troubleshooting concepts (Paragraphs 6.1,

6.2, 6.3 and 6.4)

• Specific symptom / probable cause / recommended pro­cedures (Paragraph 6.5)

• Reference schematics of the controller (Paragraph 6.6)

DANGER

CONTROLLER EQUIPMENT IS AT LINE

VOLTAGE .

WHEN A-C POWER IS CONNECTED TO THE
POWER UNIT IN THE FLEXPAK PLUS CONTROL ­LER. THUS , A-C POWER MUST BE REMOVED
FROM THE UNIT BEFORE IT IS SAFE TO TOUCH

THE INTERNAL PARTS OF THE FLEXPAK PLUS.

PERSONAL INJURY MAY RESULT UNLESS

t POWER-IS REMOVED.

DANGER
THE FLEXPAK PLUS CONTROLLER SHOULD BE
SERVICED ONLY BY QUALIFIED ELECTRICAL
MAINTENANCE PERSONNEL FAMILIAR WITH
THE CONSTRUCTION AND OPERATION OF ALL
APPLICATION EQUIPMENT IN THE SYSTEM .

PERSONALINJURY AND / OR EQUIPMENT DAM­AGE MAY OCCUR IF INDIVIDUALS ARE NOT
FAMILIAR WITH THE HAZARDS RESULTING
FROM IMPROPER OPERATION.

In addition to step-by-step troubleshooting procedures,
there are some generalized comments that should be kept

in mind at all times. These may be divided into wiring errors

(Paragraph 6.1 ). incoming a-c line problems (Paragraph

6.2). motor problems (Paragraph 6.3) and mechanical prob-

lems (Paragraph 6.4).

6.1 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
least five minutes carefully looking over the wiring before
taking active steps involving tests and replacement. Re­member that a loose or grounded wire can occur in a
controller that had previously been functioning correctly if
initial wiring techniques were poorly performed .

For those not familiar with proper FlexPak Plus controller

wiring , other Sections in this manual may be consulted. For

more complex problems , Section 5 may be used to uncover
wiring problems in the optional Modification

Kits.

6.2 A-C Line Problems - The following are typical prob-

lems located on the incoming a-c line :

• A-c line voltage incorrect for the specific controller ,

which may operate on 115

or 230 VAC.

• Main disconnect switch contains fuses improperly

rated for the drive . (The fuses must be large enough to
prevent nuisance tripping yet small enough to protect
the circuit and equipment on the circuit.) Refer to Table

3.A.

33

• A-c conductors must be of adequate size for the appli­cation. 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 (115 / 230 VAC) in relation to the FlexPak Plus
controller.

6.3 Motor Problems - Do not overlook the possibility that

the malfunction may be located in the dr ive motor. The
following steps should become part of a troubleshooting

routine:

• Recheck all motor connections for firmness and cor­rect identification .

• Check that no obvious grounds have occurred on any

of the wires . However , do not use a megger when
checking for grounds unless the motor wi ring to the

FlexPak Plus controller is completely disconnected .

• A volt-ohmmeter (VOM) may be used for ground check­ing without disconnecting conductors to the FlexPak
Plus controller .

• Check the field windings for open or short conditions .

• Check continuity through the armature and brushes .
Use terminals A 1 and A2 at the Complete Controller
(terminals 45 and 47 at the Basic Controller) as test
points .

6.4 Mechanical - It may be that the malfun ction is a

simple mechanical problem. The load on the drive motor

may be too large , or it may have too high an inertia. The

results are long stopping times and current -limit start ing
demands. Thus, the freedom of motion of the load device
should be considered.

6.5 Controller Malfunctions - Tables 6.8 and 6.C pre-

sent an organized troubleshoot ing sequence based on a
symptom / probable cause/ suggested procedure approach.
They develop from the most simple , obvious malfunction to
more complex ones.

Note that Reliance Electric color codes the wires to aid the

identification of pin numbers, that is, locations . Table 6.A is
a listing of these number-color combinations . These colors
will be helpful in the following troubleshooting procedures.

6.6 Schematics, Diagrams - In order to aid with the

troubleshooting process , various schemat ics and diagrams
are included . Note that these drawings are the latest revi-

sions as of the date of publication of this manual. The

manufacturer cannot guarantee that subsequent changes
will not occur ; although , if any do, they should be minor. In

cases of doubt, contact your local Reliance Electric Sales

Office or Distributor .

Included are the following drawings :

• Figure 6.1 which is a simplified control circuit sche­matic for a unidirectional (forward only) controller .

• Figure 6.2 which is a simplified control circuit sche­matic for a bidirectional (forward / reverse) controller.

• Figure 6.3 which is a timing chart for the relay control
sequencing used with this controller .

Table 6.A

• Figure 6.4 which is a copy of the screen used to mark

the Regulator Module. It is useful in identifying loca­tions on the board. Note that areas where optional

Modification Kits fit are marked with heavy lines.

COLOR CODING SYSTEM

• Figure 6.5 which is a schematic for the controller.

• Figure 6.6 which is a schematic for the Modification

Kits.

• Figure 6.7 which may be used to locate major assem-

blies in the controller. It also lists various technical
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

Auxiliary M

Control transformer secondary winding.

481

FM

., 1---- .......

FM

-i .... f---065

14----- approx. 24 voe

r-~OP- - START i :~;

NO.

139

36
65
39

38

66

67

38

139

36
32

132

47

45

40

39

I _I_, 38 J9 1-1

U----1-LWII-...... •---

1

-----------Q- ...... ( )-+- - -

132 32 L _ _ _ J 39 FM

RUN

L, 1K

D - Denotes wire wrap pin.

0 - Denotes wire terminal board.

38

Figure 6. 1 - Unidirectional Control Circuit (simplified)

34

Static

Logic

139

I

COLOR

V

ORANGE

GREEN

BLACK

YELLOW

BROWN

BLUE

GRAY

BROWN

ORANGE

GREEN

RED

ORANGE

BLACK

YELLOW

PURPLE

YELLOW

V

V

481

--- Control transformer secondary winding.
482

approx. 24

voe

~-------1-

RM

10µfd

+

200µfd

Static
Logic

40

139 (ORG)

r-------;:i

1

START

1

: STOP _j_ :

38

132 THERM. 32 I

I

BROWN

(RED)L_ --- ____ _J

FM

200µfd

RUN CR

D - Denotes wire 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-4PEN 1--f%-c-~-~-E -

STOPSwitch H ----

1 I I

I I

I 11-1--I ---

P~.'-L t I I I to;~;

FM or RM contactor ----'------'j I l I I

I I '1i' I

1 1 PULL

I

DROP 1

CR Relay I f IN I OUT I

(enables drive) 20 msec

1

~

I Jt~m~~~c r-

8 msec

~

~

8

Note: All times

± 50% msec

Figure 6.3 - Relay Control Sequencing

35

Place 5-wire connector from Remove Jg if using Route standard twisted pair
Reversing Contactor here. Reversing Contactor I FDBK. to right or RM.

---------~~

8f2"0000.QQ),~\D000QI

C~ooot oo=oolFMD.eL1('1i& REY. din. FiiiK. ~2L203 4 ~G4n:::; i, f!-2193

:f]s1

. . J XF~:~~~ooo'·OOo r , ' , " ' , '

Aux1hary M I~ YEt 39"'PlJll'J.~

so) • ~H1 , ,J~ ,, ,J5', 0 con

62

"" Remove J7 and JS if \

1

~

usingTorqueTaperKit. -\:---

00000' t~o_ p _oo /J 00, 00 REDOOIFJeK.

2

:~:.ects ~r -~rl ~~6;: - - • 100KO ~C~;:

aH,/ 0 .er A-

u- o ;

3 ·1, , I

11

•

~

, ...J1.. ,a

u

i

o

~~;~~u~o

Reversing 57 O

Module here. _ _

Remote
Operator

Adapter

connects
here.

Remove J4 if AUTO/MANUAL selector is installed. Feedback

___________ ,2s 30 35 40 45 o 55 60 65 10

28

ORN

8 ;

~

1§1:t 1 [ :d1P ;o: , §

~~

.... --TR-CH .FDBK. - .m:. t, I 8

~

'-+++ 6 I 1111 ii mT' iii~!: :.!! ~+!++++ AA~

jumpers Test at Test Meter

Figure 6.4 - Regulation Module Screen

~

/ \

I

~

SOHZ O

~

-]

h§ TEST ·§

Adapter-pins only.

V

L.

•

V

36

t

SYMPTOM

1. POWER ON/ OFF
circuit breaker
trips or fuses
clear when power
is applied .

2. Drive motor does
not start .

3. Drive motor does

not run, but CR

pulls up.

(Use this proce­dure only if con­troller does not
have optional Test
Meter Adapter
Kit.)

Table 6.8

TROUBLESHOOTING SUGGESTIONS FOR THE BASIC CONTROLLER

PROBABLE CAUSE

Incorrect wiring con­nections to controller ;

from controller to

motor ; in motor.

Short in Power Cube.

RECOMMENDED PROCEDURES

DANGER
IF CIRCUIT BREAKER HAS TRIPPED OR FUSES HAVE CLEARED . USER MUST
DETERMINE IF A FIELD SUPPLY KIT IS PRESENT. (SEE FIGURE 5. 15 .} IF FIELD
SUPPLY KIT IS PRESENT , THE FIELD SUPPLY KIT AND ITS WIRING MUST BE
INSPECTED FOR DAMAGE . AFTER RE-APPLYING POWER TO THE DRIVE, THE
FIELD VOLTAGE MUST BE RE-CHECKED FOR PROPER VOLTAGE AT MOTOR
TERMINALS Fl . 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 PROCE ­DURE COULD RESULT IN OVERSPEEDING THE MOTOR AND / OR THE MA -

CHINERY COUPLED TO THE MOTOR SHAFT AND POSSIBLE FATAL INJURY.

0 Remove

a-c power at the disconnect.

0 Remove leads to L 1, L2. 45, 47 and, if used, F1, F2, on incoming side of controller's 1TB and

2TB. (Refer to Figure 3.4.)

0 Open the power disconnect switch .

0 Check for a ground condition at ll / 181. L2/ 182, 45, 47, F1 and F2. Do this at controller

(internal) side of 1TB and 2TB. If a ground is discovered, check wiring connections on POWER
ON/ OFF circuit breaker or fuse block and power disconnect . Also check connection to Power
Cube and motor field terminals F1 and F2.

0 If no ground exists. examine the controller Chassis for loose wires and / or foreign objects .
0 If no ground exists and if no foreign objects are discovered, reconnect the incoming conductors

45, 4 7 and, if used, F 1 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 .
0 Disconnect the motor from the conductors at 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 the motor for a ground condition . If a ground is

located here , examine and/ or replace the motor , as necessary.

0 Replace Power Cube.

Short in Field Supply Kit.

0 Replace Diode Bridge in Field Supply Kit. Inspect wires and connections to Field Supply Kit .

Main

a-c line discon ­nect not closed; or fuse
blown ; or no power
applied ahead of
disconnect .

Drive interlock s pre­venting operation .

Drive motor thermostat
wires not connected

on FlexPak Plus control ­ler terminals 32 and

132 on 2TB.

External overload
wires not connected on
FlexPak Plus controller
terminals 32 and 132
on 2TB.

No input signal from
SPEED potentiometer
on Control Station .

Replace all damaged wires and connectors .

0 Check disconnect switch, fuses in it, and voltage on line.

0 Verify that all user -installed interlocks are in a state (physical condition and wiring connections)

to allow a

start.

0 Check connections to thermostat : at drive motor P1, P2; at controller 32. 132.
0 Check for open thermostat inside motor . Make a resistance check of thermostat. (It should read

a short. or low resistance, if it is closed.}

0 Check connections to external overload .
0 Check for open overload. Make a resistance check to overload . (It should read a short. or low

resistance , if it is closed.}

0 If the controller does not have an optional AUTO/ MANUAL switch . inspect the Regulator

Module to determine that jumper J4 is in place. (The jumper is removed when the AUTO/
MANUAL switch is installed .)

0 Check the SPEED potentiometer on the Control Station. First. open the power disconnect

switch.

0 Connect a volt-ohmmeter to the Regulator Module Remote Operator Adapter inputs . Connect one

lead to terminal 28 . Connect the other to terminal 20. (Refer to Figure 3.4 for a Remote Station .}

0 For proper operation , the reading should be SK ohms .
0 Disconnect the VOM lead from terminal 20. Connect it to terminal 426.

0 Turn the SPEED potentiometer from 10 to 0. The resistance should vary from SK to O ohms. If it

does not. replace the potentiometer .

37

Table 8.8

TROUBLESHOOTING SUGGESTIONS FOR THE BASIC CONTROLLER (continued)

SYMPTOM

4. Drive motor does
not run. but CR
pulls up.

(Use this proce­dure only if
controller has
optional Test
Meter Adapter
Kit.)

5. Drive motor does

not run with CR
relay picked up

and SPEED poten-

tiometer property
operating.

(Use this proce­dure only if con­troller does not
have optional Test
Meter Adapter
Kit)

PROBABLE CAUSE

No input signal from

SPEED pot.

No output from
Power Cube.

Regulator Module sus­pected because no out­put reading at 46, 47.

Power Cube suspected

because no output

reading at 46, 47.

RECOMMENDED PROCEDURES

a First check the main power supplies. This must be done with power applied to the FlexPak Plus

controller.

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 0TH ER HAND BEHIND YOU AT ALL TIMES. 00 NOT HOLD
ONTO THE CONTROLLER FOR SUPPORT. PERSONAL INJURY MAY
THESE PRECAUTIONS ARE NOT TAKEN.

DANGER

RESUL:r IF

a 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.
a The reading should be within the range of 10.8 to 11 .5 VOC for normal operation.
a Next, remove the lead from pin 356. Place it on pin 466.
a The reading should be within the range of+ 16 to +28 VOC for normal operation.

a Next, remove the lead from pin 466. Place it on pin 471.

a The reading should be within the range of -16 to -28 voe for normal operation.

a If the proper readings are obtained, the power supplies may be assumed to be operating correctly.
a If incorrect readings are obtained, replace the Regulator Module.
a 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.)

a Connect one lead of a volt-ohmmeter to pin 367 on the Test Meter Adapter Module.

a Connect the other lead to pin 826. Readings vary from Oto +8.2 voe, depending on the set point of

the

SPEED potentiometer dial.

a If no voltage is noted between pins 367 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.)

a If the SPEED potemiometer is functioning normally, and·if the J4 jumper is placed/removed, as

necessary, replace the Regulator Module.

a Examine armature wiring. First, open the power disconnect switch.
a Check armature wiring for loose connections.
a Turn a-c power on again.

THE PROCEDURE DESCRIBED HERE IS PERFORMED WITH LIVE
APPLIED TO THE CONTROLLER. USE ONLY ONE HAND TO APPLY VOM LEADS/
PROBES. KEEP YOUR OTHER HAND BEHIND YOU AT
ONTO THE CONTROLLER FOR SUPPORT. PERSONAL INJURY MAY RESULT IF
THESE PRECAUTIONS ARE NOT TAKEN.

DANGER

ALL TIMES. DO NOT HOLD

A·C VOL1,.\GE

a Connect a volt-ohmmeter to terminals 46 and 47 on 1TB. (Refer to Figure 3.4.)

0 Place the START/STOP switch in the START position.

a Increase the speed reference by turning the SPEED dial in the direction of 10.
a The reading across45 and 47 should be Oto 90 VOC for 115 VAC controllers. ltshould be Oto 180

for 230 VAC controllers.

a If no reading is obtained across 46 and 4 7, it may be necessary to replace the Power Cube and/ or

the Regulator Module. In order to determine which, read on.

------------------------

0 Test the Regulator Module for firing pulses.

a Open the power disconnect switch.
a Locate on the Regulator Module a connector near the edge directly above the Maximum Speed

potemiometer. (Refer to Figure 6.4.) This connector has four sets of twisted red and white wires

going into it.

a Gently lift the connector off the pins. Move it aside to a position where it cannot cause shorts or

grounds.

a Connectthe leads of the VOM to pins L1 and G1. (These pins are identified on the Module.) Refer

to Figure 6.4.

a Restore power to comroller.

0 Place the START/STOP switch in the START position.

a Turn the SPEED potentiometer to 10.

a The reading on the VOM should be 1/

a H this reading cannot be obtained, replace the Regulator Module.

VAC for proper operation.

2

a In turn, repeat this same test with pins L2/G2, 47 /G3, 47 /G4.

------

a Establish that the Power Cube is receiving pulse inputs at the connector on the Regulator Module.

(Refer to "Regulator Module

suspected," Symptom 6.)

a If the Power Cube is receiving pulses yet there is no reading across 45 and 47, determine that the

main contacts on the M contactor are closing.

a In order to check the contacts, replace the drive motor with a light bulb on the armature wiring at

1 TB. (On 230 VAC controllers

use two light bulbs in series.)

a H the light does not light, replace the Power Cube.

V

i

V

-·-·"""'""""'-··-~-

38

'

•

Table 6.B

TROUBLESHOOTING SUGGESTIONS FOR THE

BASIC CONTROLLER (continued)

SYMPTOM

6. Drive motor does
not run with CR
relay picked up
and SPEED pote n­tiometer properly
operating.

(Use this proce­dure only if
controller has
optional Test
Meter Adapter
Kit.)

7. Remote Operator
Control Station

function s not
operating.

PROBABLE CAUSE

No gate firing pulses.

Malfunctioning
switches .

RECOMMENDED PROCEDURES

D Turn off power to the controller at the main disconnect.
D Connect a volt-ohmmeter lead to test pin 356 on the Test Met er Module .

D Connect the second lead to test pin 817 .

D Restore power to the controller.

DANGER

THE PROCEDURE DES CRIBED 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 A TALL TIMES . DO NOT HOLD
ONTO THE CONTROLLER FOR SUPPORT . PERSONAL INJURY MAY RESULT IF

THESE PRECAUTIONS ARE

NOTTAK~N .

D Place the START/ STOP switch in the START posit ion.
D On the + 10 VDC scale of the volt-ohmmeter, an increase of approximately + 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 should be

noted.
D If voltage readings increase, the Power Cube is receiving pulses to ,ts SCRs.
D Make a last check of wiring to the Power Cube.
D If wiring is correct. replace the Power Cube.

D Check START / STOP switch, but

first remove a-c line power at main disconnect.

D Connect ohmmeter to terminal 32 on the Remote Operator Adapter.
D Touch probe to terminal 38 on the Remote Operator Adapter .
D Place switch in the START (closed) position.
D If the switch is properly functioning , a short will be seen on the meter.
D Check the STOP function . Place the RUN/ JOG switch in the RUN position . Connect the ohmmete r

to terminals 32 and 35. Place th e switch in the STOP position , wh ich shou ld open it if it is

functioning correctly. If there isa shon. it will be seen on the meter. If there is nos hon, the circui t is

opened, and the switch is functioning correctly.

D Using similar techn iques, test the RUN/ JOG switch in the RUN position at termina ls 32 and 35 .

When the switch is in the RUN position, a short should be read .

39

SYMPTOM

1. POWER ON/OFF

circuit breaker
trips or fuses
clear when power

is applied.

2. Drive motor does
not start.

3. In non-revers-

ing, controllers

only ••• ·

Controller's M
contactor not
picking up when

START switch is
pressed (closed,.

4.

In reversing con-

trollers

only . ..

Controller's M
contactor not

picking up when

$TART switch is
pressed

(closed,.

Table 6.C

TROUBLESHOOTING SUGGESTIONS FOR THE COMPLETE CONTROLLER

PROBABLE CAUSE

Incorrect wiring con­nections to controller;
from controller to
motor; in motor.

Short in Power Cube.
Short in Field Supply Kit.

Main a-c line discon­nect not closed; or fuse

blown; or no power

applied ahead of
disconnect.

Drive interlocks pre­venting operation.

Drive motor thermostat
wires not connected
on FlexPak Plus control­ler terminals 32 and
132on 2TB.

External overload
wires not connected on
FlexPak Plus controller
terminals 32 and 132
on 2TB.

FORVVARD/REVERSE

switch malfunction.

Mcontactor
malfunctioning.

RECOMMENDED PROCEDURES

DANGER
IF CIRCUIT BREAKER HAS TRIPPED OR FUSES HAVE CLEARED. USER MUST
DETERMINE IF A FIELD SUPPLY KIT IS PRESENT. (SEE FIGURE 5.15.) IF FIELD
SUPPLY KIT IS PRESENT. THE FIELD SUPPLY

KIT AND 1TS WIRING MUST OE
INSPECTED FOR DAMAGE. AFTER HE-APPLYING POWER TO THE DRIVE. THE
FIELD VOLTAGE MUST BE RE-CHECKED FOR 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 ANO/OR THE MA­CHINERY COUPLED TO THE MOTOR SHAFT ANO POSSIBLE FATAL INJURY.

a Remove a-c power at the disconnect.

a Remove leads to L1. L2. A1. A2 and, if used, F1, F2. on incoming side of controller's 1TB and

2TB. (Refer to Figure

3.4.,

a Open the power disconnect switch.

a Check for a ground condition at L1/181, L2/182. A1. A2. F1 and F2. Do this at controller

(internal, side of 1TB and 2TB. If a ground is discovered, check wiring connections on POWER
ON/OFF circuit breaker or fuse block and power disconnect. Also check connection to Power
Cube and motor field terminals F1 and F2.

a If no ground exists, examine the controller Chassis for loose wires and/or foreign objects.
a If no ground exists and if no foreign objects are discovered. reconnect the incoming conductors

A 1, A2 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 drive motor.
a Test A 1, A2, F1 and F2 conductors for a ground. (If one exists, examine connections and insula-

tion for areas where shorts could occur.,

a If no 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.

a Replace Power Cube.
a Replace Diode Bridge in Field Supply Kit. Inspect wires and connections to Field Supply Kit.

Replace all damaged wires and connectors.

a Check disconnect switch, fuses in it, and voltage on line.

0 Verify that all user-installed interlocks are in a state (physical condition and wiring connections,

to allow a start.

-------- ----------- --

a Check connections to thermostat: at drive motor P1, P2; at controller 32. 132.

0 Check for open thermostat inside motor. Make a resistance check of thermostat. (It should read

a short, or low resistance, if it is

closed.)

a Check connections to external overload.

0 Check for open overload. Make a resistance check to overload. (It should read a short, or low

resistance, if it is closed.)

a Open the power disconnect switch.

0 Examine M contactor for firm seating.
0 On the M contactor, connect an ohmmeter on the brown (location 38, and black (location 65, wires.

A short should be read.

0 Connect the ohmmeter on the orange (location 139, and yellow (39, wires. The reading should be

approximately 230 ohms.

a If these readings cannot be obtained, replace the M contactor. (Refer to Table 7.A.)

D Examine Remote Operator Adapter on Regulator Module for firm seating and proper wiring and pin

connections. (Refer to Figure 6.4.)

D Test FORVVARO/REVERSE switch. Use basic technique outlined above for the START /STOP

switch. Here test 39 (purple) against 66 (blue, and 65

(white, against 67 (gray,.

a On the Auxiliary M pins located on the Regulator Module, connect an ohmmeter. Place it on the pin

39 and pin 67.

0 Place the FORVVARD/REVERSE switch in the FORVVARD position. The reading should be

approximately 500 ohms if it is operating properly.

a Without changing test points. place the switch in the REVERSE position. The reading should be

about 500 ohms

if it is operating properly. If a short is observed, remove jumper J9 and repeat the

test.

0 If a 500-ohm resistance reading cannot be obtained when the switches are open, the M contactor

is malfunctioning and must be replaced.

40

V

r

V

'

Table 6.C

TROUBLESHOOTING SUGGESTIONS FOR THE COMPLETE CONTROLLER (continued)

SYMPTOM

5.

M contactor picks

up but remains
in only when
START pushbut­ton is pressed
and held in .

6. Drive motor does
not run, but M

contactor and

CR pull up.
(Use this proce-

dure only if con·
troller does not

have optional Test
Meter Adapter
Kit.)

7. Drive motor does
not run. but

M

contacto r and

CR pull up.
(Use this proce-

dure

only if

controller

has

optional Test

Meter Adapter
Kit.)

8. Drive motor does
not run with

M

contactor picked
up and SPEED
potentiometer
properly operat ing.

(Use this proce­dure only if con­troller does

not

have optional Test

Meter Adapter
Kit.)

Continue this
symptom on next
page

PROBABLE CAUSE

RUN/ JOG switch is
in JOG postion .

CR relay not picking up.

No input signal from
SPEED potentiom eter
on Control Station .

No input signal from
SPEED pot .

No output from
Power Cube.

RECOMMENDED PROCEDURES

D Place the RUN/ JOG switch in the RUN position.

D

Connec~olt -ohmm;;;;; on the Re~ Operator Adapt;:i;lac-;;Tt°on wminal 35. -- --

0 Connect th e second probe to connection 139 (orange wi re) connected to the FlexPak Plus M

contactor.

0 The reading should be +24 VDC for normal operation. (Refer to Figure 6.5 to see the logic of this

test.)

D

Next, shift the probe from terminal 35 to terminal 38 on the same termina l board. However , leave

the second probe where it is.

D Press the ST ART switc h. The reading should be approximately 24 VDC for normal operation . (Refer

to Figure 6.5 to see the logic of this test.)

D Press the START / STOP switch to STOP. and then START. A 24 VOC (approximate) reading should

conti nue to appear. If it does not. the CR relay is not picking up. In this case. replace the Regulator
Module.

D If the controller does not have an optional AUTO/ MANUAL switch , inspect the Regulator

Module to determine that jumper J4 i1 in

piece . (The jumper is removed when the AUTO/

MANUAL swi tch is installed.)

D Check the SPEED potentiometer on the Control Station.

First. open the power disconnect

switch .

D Connect a volt-ohmmeter to the Regulator Module Remote Operator Adapter inputs . Connect one

lead to terminal 28. Connect the other to terminal 20. (Refer to Figure 3.4 for a Remote Station .)
D For proper operation. the reading should be 5K ohms.
D Disconnect the VOM lead from terminal 20. Connect it to terminal 426 .

D Turn the SPEED potentiometer from 10 to 0. The resistance should vary from 5K to O ohms. If it

does not, replace the potentiomete r.

D First check the main

power supplie s. This must be done with power applied to the FlexPak 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 ALL TIMES. DO NOT HOLD
ONTO THE CONTROLLER FOR SUPPORT. PERSONAL INJURY MAY RESULT IF
THESE PRECAUTIONS ARE NOT TAKEN.

D Connect one lead of volt-ohmmeter to test pin 357 on the Test Meter Adapter Module.
D Connect the second lead to test pin 356 on the Module .
D The reading should be within the range of 10.8 to 11.5 VDC for normal operation .
D Next. remove the lead from pin 356. Place it on pin 456.
D The reading should be within the range of + 16 to + 28 VOC 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 VOC for normal operation.
D If the proper reading s are obtained. the power supplie s may be assumed to be operating correctly.
D

If iacorrect readings are obtained, replace the Regulator Module .

D

Next. check the reference voltage input signal. (This changes in direct proportio n to an increase of

SPEED potentiometer voltage caused

by a turning of the dial.)

D Connect one lead of a volt-ohmm eter to pin 357 on the Test Meter Adapter Module .
D Connect the other lead to pin 826 . Readings vary from Oto +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 jump er 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 A UTO/ MANUAL switch.)

D If the SPEED potentiometer is functioning normally , and if the J4 jumper is placed/ removed, as

necessary, replace the Regulator Module .

D Examine armatur e wiring . First. open the power disconnect switc h.
D Check armature wiring for loose connections.
D Turn a-c power on again.

DANGER
THE PROCEDURE DESCRIBED HERE IS PERFORMED WITH LIVE A-C VOLTAGE
APPLI ED 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.

D Connect a volt-ohmmeter to terminals A 1 and A2 on 1 TS. (Refer to Figure 3.4.)

0 Place the START/ STOP switch in the START position .

D Increase the speed reference by turning the SPEED dial in the direction of 10.
O The reading across A 1 andA2shouldbe Oto90VOCfor 115VAC contr ollers. It should be Oto 180

for 230 VAC controller s.

D

If no reading is obtained across A 1 and A2, it may be necessary to replace the Power Cube and / or

the Regulator Module. In order to determine which , read on.

41

Table 6.C

TROUBLESHOOTING SUGGESTIONS FOR THE COMPLETE CONTROLLER (continued)

SYMPTOM

8. Drive motor does
not run with

M

contactor picked

up and SPEED
potentiometer
properly operat­ing. (continued)

9. Drive motor does

not run with

M

contactor picked

up and SPEED
potentiometer
properly operat­ing.

(Use this proce­dure

only if

controller has
optional Test

Meter Adapter

Kit.)

1 0. Remote Operator

Control Station
functions not
operating.

PROBABLE CAUSE

Regulator Module sus­pected because no out­put reading at A 1, A2 .

Power Cube suspected
because no output
reading at A 1. A2.

No

gate firing pulses .

Malfunctioning
switches .

RECOMMENDED PROCEDURES

D Test the Regulator Module for fir ing pulses .

D Open the power disconnect switch.

D Locate on the Regulator Module a connector near the edge directly above the Ma ximum Speed

potentiometer . (Refer to Figure 6.4.) This connector has four sets of twi sted red and whi te wires
going into it .

D Gently I ift the connector off the pins. Move it aside to a position w here it cannot cause shorts or

grounds .

D Connect the leads of the VOM to pins L 1 and G 1. (These pins are identified on the Modu le.) Refer

to Figure 6.4 .

D Restore power to controller .
D Place the START / STOP switch in the START position.
D Turn the SPEED potentiometer to 10.

D The reading on the VOM should be \/

2

VAC for proper operation .

D If this reading cannot be obtained , replace the Regulator Module.

D In turn . repeat this same test with pins l2 / G2. 47/ G3. 47/ G4.

D Establish that the Power Cube is receiving pulse inputs at the conn ector on the Regul ator Module .

(Refer to "Regulator Module suspected," Symptom 8.)

D If the Power Cube is receiving pulses yet there is no reading across A 1 and A2. determin e that the

main contacts on the M contactor are closing .

D In order to check the contacts. replace the drive motor wi th a light bulb on the armat ure wiring 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 at the main disconnect .
D Connect a volt-ohmmeter lead to test pin 356 on the Test Meter Module .

D Connect the second lead to test pin 817.
D Restore power to the 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 ALL TIMES . DO NOT HOLD
ONTO THE CONTROLLER FOR SUPPORT . PERSONAL INJURY MAY RESULT IF
THESE PRECAUTIONS ARE NOT TAKEN.

D Place the START / STOP switch in the START position.

D On the + 10

voe scale of the volt-ohmmeter . an increase of approximatel y + 1 VOC should be

noted.

D Turn off

power to the controller .

D Reconnect the volt-ohmmeter to test pins 356 and 816.

D On the + 10

voe scale of the volt-ohmmeter . an increase of approximately +1 VDC should be

noted.
D If voltage readings increase, the Power Cube is receiving puls es to its SCRs.
D

Make a last check of wiring 10 the Power Cube.

D

If wiring is correct, replace the Power Cube.

D Check START / STOP switch, but

first remove a-c line power at main disconnect.

D Connect ohmmeter to terminal 32 on the Remote Operator Adapter .
D Touch probe to terminal 38 on the Remote Operator Adapter .
D Place switch in the START (closed) position.
D

If the switch is properly functioning , a short will be seen on the meter .

·o Check the STOP function . Place the RUN/ JOG sw itch in the RUN position. Connect the ohmmete r

to terminals 32 and 35. Place the switch in the STOP posit ion. whic h should open it if it is

functioning correctly . If there isa short. it will be seen on the meter .

If t here is no short. the circu it is

opened. and the switch is functioning correct ly.
D Using similar techniques , test the RUN/ JOG switch in the RUN position at termin als 32 and 35.

When the switch is in the RUN position , a short should be read.

42

i

>

.i,.

w

..

..

...

..

200C't

0

1~1~--- ------- ---- -------= =======================~

112

-+

~

co, -;

LI V

181/LI

i

o- -[ ]} ~

' "' I~

~

1

,.---I rXLt_ BRH~a.1!Z-

~

L2 182/l.2 I l I)"'.~ I -

1

'

I I I mo\ I I

tO:• -C:I!-~

WARNING

DISCONNECT AND OVER-

CURRENT PROTECTION

REQUIRED PER

filAND
NEC. SEE SH.It FOR
DETAILS.

TORQUE TAPER {

KIT sec S1t. l

H {'

it:DaA c• Kil '

SEE SH. l

--,---1 ,s,1

~

i

I

FRON RE FDBK. ••

STOP ARHATU

F - I '"ro ~•-,{

I

1

~ - ... ,

I _ -

- ' e I KIT SEE SH. ' lZ

I START I JRUN : l_ffi<>\;

~

l BE:. g ll i i•~

[

I t. -

L-~~

1--- ~~

---- ~-- -!~

,e-- - - .

I "_ .. REV. , r- _ =•z• ·~

r-;: -- - -~-17

1A10.,- t. ••r _

~~

.

I l _:=:::..t'_. fr- ~• ~I 12•

L: _J I I r '~Nlr~

- - J I I I RENOTE ,:;~~g-,,-1 ..

er

--- -

I 11

~~T~

::ii::•~

I I I BUR(UIT t"'"' I o.il

NUAL .J Cl

AU9 ';4-=._-_--= _J 8/PI o-57D05 i 11 I ~:~: ,;.

~

ENOTE OPERATOR

~

~NOT SUPPLIED)

~

RN :7

~· <--------=--== -

fl---- - _ __ _

,,_....-

SPEED ,< .- -=

POT f( ...__=_..'.

IOI(,,__ L____ __

TORQUE

POT

TEST

NETER ADAPTER KIT

SEE SH. l

t, 1.in:

IR CONP.

Pb

112

12 I RED

I

I AUX. N

J :·~;:·"

,. g:·-5:--.. ;

:t====-1l:ifE£Iff !j·U

~

:~

~.

J~~~

J FH

12 _ .J

-~ --- - --;;;;

lHERNOSTAT

--- ----,

, - - FIELD KIT l

t: c;1 IAC DlODE

~

o SI .. 52 -r.fA BRIDGE

~

r;z.--

7051es - 11R

- , j• - -

~~~R

e~::R 1

{

.. 7

( KT

Gl

Fl

FZ

'- - - <>-- ··

OC MOTOR

SHUNT FIEL D

l _______ -:i _RN

: --.. -, ~·

1

~:=--:--:--;iR N

HI HZ

• b Cr ·11iin'4. 1

1

1

, : REVERSE

t,,t,Cr~;-f J ~. l \ AN, i (OHTACTOR

---{ u : ~C.J J Kif

11",-.<CS,:Ofoi'~ - - --

,c ,c ,c c CC IQQ" L. - - - - - _ -

~

( ON. SGooooi;i

~

l ~~==~NTCI)

I
I

FRON DRIVER

CIRCUIT

•51"2

- ~,

f:,: 1:~ -~ Al

i I 1" 7- -( c 9

: I lw.21a: !

a: I I I I I I/ '

~

I I 1~11~ 1 I

~

1 I 'T'';' ' ..,./

~

:1 ro

~P OWER

, LOHT

i I 11:t I j!

f" , .... ~ --6 V

J.~ ~:f liri' A2 0

~

-~

PIAIN REGULATOR JJI I I

m, ,,,. . .,~

~

FEEDBACK SELECT SEE TABLE SH. • .

,) :~J tsU!1r~:T1i'.~~~ LOCAi. ~ TO/ MANUAL

5) JUIIPERS(J<; & Jbl ARE RENOYEO ON ZlOVOLT

o) : ~ ..fJNl'ERS ( J7 & J8) FOR TORQUE TAPER.

j) RENOVE JUNPER (.I'll -· REVERSE

>

CONlAC70R KIT IS ADDED.

8

5(£ E / H FOR US AG[.

V AENOVE Rcs rs,oR roA r;o H2.<2 PL ACES>

1g) i~:Ni~~

:

~~~?

ION l I( I T MANUALS FOR

1!) FOR CURRENT SCALING SEE TABLE SH."t.

Figure 6.5 - Controller Schematic

2000f. %

' ·~·II'~

t

VI '>

r- -- zl)

z9>

C

" E

E o

.,. .,.

I RANGE

I SELECT I

I

I

lZ•,

z• ~

FILTERING

ISOLATION

DANGER

APPLJC~T NQJ

RELY ON ZEAO SP£EP

SETTING FOR SAFETY.

SERIOUS OR FATAL I NJURY

t1!!...!lli!:!:

j INPUT

11 i---. -11.zv

~•}--. + 11.ZV

I ~,:i-- ov M

~

AUTO /.

J ~OOK N IN. s,o;,'( O

l;) \.

~

AUTO NAX. SPO. IOK '\!Z

PRESET SPEED AND +11.lf
INSTRUNEN!._ l.!!_TUFACE (ll[FERCNCE Kl~

'.!_N l)-\700Z

I

IDANCER POT,

I

- I

~o;.o-_l __ o' - ~(5K

I

... -'--•...- J

I

I 8UFF.ERING

~_!.. _ _., _..,...

I

I

1,i]

I

~

I

I

} LINE

I (Of'TIONALI

SPEED
INPUT

ra;g;~N

NOTES:

DANCER FOLLOWER
(REFERENCE KIT)

e111 o-57010

FOR DETAILED KIT INFORHAllON S EE INDIVIDUAL l lT' S
INSTRUCTION HANUAL.

tj> RENOVE JUIIPER IF AUT0/ 11ANUAL SWITCH IS INSTALLED.

zp SET AUTO 111N.S PD. WITH INPUT AT HINl11Ul1, THEN SET

AUTO H41 . SPO. WITH INPOT AT HAUN UH, NOTOR HUST

NOT EXCEED ITS SPEED OR VOLTAGE RATING.

zj:>J UNPER FOR VARIOUS PROCESS CONTROLLERS.
z5>cuP RES 1S T0R(Z6.7KI AND JUHPER(JZ) WHEN OPTIONAL

DANCER

POSITION ADJUST POT. IS INSTALLED.

ADJUST

_ -.--._.z5K

=-·--.. •)

1_ .. _

I

OPTIONAL CIRCUIT S

I J : - AUTO. SPD,CAL- -

-11.zv

~

•

~+11.ZW (

~

I Z NEG

I Z~ JI

I z• r--=,.-.=.:

1~~

~

, r

•}oci?'cH

"1 o- INPUT

Figure 6.6 - Mo dificat ion Kits Schematics (continued on next page )

SMIU

i% "30002

...

_,

..

2000l /1'1

U IMS

t-- - -uBlb

>----u,11

'-r-.--.-~

lSb
HI

~l IK ln I

25~ .. 5b

1

rn}--------{JD--0 ~;; I

TEST HETE!!_M1APTER I\JT B{MO:j~O~

t>

{

>>>>>>> -- - - ----,

21 O( ,.. ""m•., "'tr IOOXYOLTAGE AT AC I OC CONNECTION I

,..,,.. v-.om :!:: I

719

57

)> SEE SH.I

-DIODE AC + ~ TACH

+ Ml°" AC 1------,:i1 INPUT

I

~

SEE SH... I

TACH FEEDBACJt ••.! _!IH o-Hoo,

__ _J

100"

TACH

VOLTA(. [

HY

20YDC/ IOOO

l ~Y 20V OC/1000

58Y

SOY

DC/1000
b9Y 20V OC/ 1000
UY 50Y OC/1000
115Y IOOV OC/1000
175Y

50V

OC/1000
175V

IOOY OC/1000

HOTOR
(RPHl

1150

17'i0

1150

l~t;O

1750

1150

1,50

1150

PRINTED CIRCUIT IOARD
NOT ARRANc;ED IN ORDER
SHOWN,

OPTIONAL CIRCUITS

11

1

--~

"bai 1

9

;1-=YEL _..,..IJM

1

---.

AUl.t:r-°" :

I •ur.c)ux :~

10)11' !------+-------'

I bl>-----~

I

I

~K!_! _!IIH0-5•1H - I

29 AUX. CONTACT RATING : I AHP. 11 lOY DC OR .5 AHP, 11120 y AC RE SISTI VE.

1

~ ~~ts~~Ro

1

t~R~

0

~1~~"fJ~ f:i1.

~iN~~E~o~~~!

J1':.~H"uul1.~P~!~fNJ

1

~gJLY

REHOTE OPERATORS HUST BE RUN IN SEPARATE CONDUIT. ISOLATED FROH

ALL POWER WIRING .(SEE NOTE •2 SH.It FOR INSULATION T[r,P. RATING).

SEE 1/H FOR DETAILS,

1J>

NUH8ERS PARENTHESIZED ARE SHOWN WHEN DI FFERENT FROH HINP>• PLUS
ANO

ORIGINAL IDENTIFICATION HARKING ON KIT.

19 CUT J UHPERS (JI & J2) IF LOCAL OR REHOTE OPERATOR IS INSTALLED ,
l}> NOT ASSOCIATED WITH 212 IN HOTOR THERHOS TAT CIRCUIT ON SHEET I.

I

I

__ __J

Figure 6.6 - Modification Kits Schematics (continued from prior page)

. ,,.,.

(

.,..

(J)

2000f. 0/M

..

ON

.,

~

_,o

!g

,...,.

!!;~

~

>

AB RB

SB

S6

SC SC

SD so

.,,

fAONT VIEW (WlTH CQYEA R£HOY£Q)

J~

" "

)( )(

J6

u, uuToa

P.C . IOAAD

J•

;-:I X

co" 2S

-, ·~

<.-10

•Jllx 1.c;

CT Li2tt t/v

z.~

[ru,,AL Sl'Q. J 7

[fil" I N.Sro. • •

~

ACCEL. X t X

[fil OECEL. CL Ir FDa

[fil l LI". ~O

HZ

@ I RCO"P.

®

OPTIONAL FIELD SUPl'U

OIOOE IRIOQ'. Foa
GR."RI Ga SI" IS " TO.

OH SUPl'OIIT IRAOET.

L--- ---- l'n..MMl("-ll'iln >---- -

l\'"'c. "l1111 212..l nvnCLll!lln );"';::;,;::_.::_:.:.._ ________ _

PANEL RATING

-~

REPUCE"ENT PARTS TA8LE

NAX.

CURRENT CONTllOl REGL• •• UOR

FI ELD

AC INPUT DC OUTPUT

,OWCA

RATEO

TRANSFOR"ER

CUBE

TIAHSF.

,.,.

010Df.

(IT)

IOAaG

( ID)

HP

VOLTS

A"PS

VOLTS

AHPS ICT

~~

v•

115

,o.r;

40

7.~

6'670 ·17A

'101819-91

'tllOZl- Wa '

---

~

0
0

MOUNTING DATA

:i~ G.HIJo".im~· ~ /~L mm ,~.m,,

MAX. SWING PROJECTION: 11n.11M1(6.~ in)

W/0

OPTIONS: SEE NOTE.

=gi:m~ ~Ji~ats'l'it!~l't~t"° .. )

4V MA><. US£R'S WIRE S1ZE:t8AWG COPPER

"' .. T~·c INSULATION ,il HI' (U•s•a1.s1 • .s c• )

N&N. t0•c JNSULATION 'S "' ( Gl ' S •so•)

4

t> tiko~~~~!: ~YJM~Fr;r;~; ~c; ,~~N~ '~ (

TURNS PER INCH MINIMUM. LEADS MUST BE RUN
PHYSICALLY

SEPARATED FROM ALL POWEii CIRCUIT

WIIING. SEE NOTE 42 FOR INSULATION TEMP. RATING,

AND 1/M FOR INSTALLATION REQUIREMENT.

4

? Al

~

~,~f~f.Pi~tfK1,l-lfsT~Will~~g ~b~gJ,1E

NEC OR CEC DISCONNECT AND OVERCURRENT
PROTECTION ON UNITS RATED FOR

MORE THAN I HP.

Bl MAXIMUM PERMISSIBLE AVAILABLE SYMMETRICAL

RMS SHORT CIRCUIT POWER SUPPLY CAPACITY OH

UNITS WITH EXTERNAL U/L LISTED, DISCONNECT
DESCRIBED IN

(A) AND SET UP FOR MORE THAN

I HP1

5.000 A.

4V WHEN INSTALLING REPLACEMENT POWER CUBE(S),APPLY

A VERY THIN, UNIFORII THICKNESS FILM OF DOW 1111

TO MOUNTING SURFACE. FILM IS TOO THICK IF IT SQUEEZES
OUT AROUND POWER CU8E(SI AFTER POWER CUBE(S)
ARE TORQUED DOWN. START THE MOUNTING SCREWS
CAREFULLY INTO EXISTING TtlREAOS ANO THEN TORQUE

25 TO 35 IN/LBS.

•v::t~~ :UE/ifi~1T.'.:.,~ o ~TORi\.~':.'ir! ~E~~1H ......

CURRENT SCALINSii CONNECT JUNP£R FRON CON TO

SEE SHJ

NOTOR CUR~ENT RATUCGS PER VOC.TAGE & '"HP AAJlNGS

FOAIEF •

srECIFIEO IELOII. NOTE

noTOB CURRENT

~

filfil.

2.5A

11,

HP

1/Z HP

l . 7A 1/l HP 1/'tHP

~A

1/ZHP I HP

II

7 .5A V• HP

I 1/2HP

IOA

--

2 HP

l~A

--

l HP

2~A

--

~

HP

~Uffi!ESSao

AUi.

RC

PAN[l

(IS •~~

CUD

(OPTIONAL

• 1102• - ~x

IOl';9Z·l6R8

N

0

~

POWER CU8£(SI

DETAIL "A"

~ ·

(FRONT VIEW)

.. , (+)

GI

l~l!LO

a:.ll:

!!ll

"

L2 / H

l.!.ll

0

~

Ull

®

0

®

l!.11

©

JUHP[R FUHCTJON

,.

~~~fl~

1'r~l1tt~~L AUTO/ NAN.

J'i Jt.

JUHPEAS ARE REIIOVEO ON ZlDV UNITS.

J7 .J8

REHOVE JUMPERS FOR TOAOllE TAPER

J•

REHOVE J U"':~~

~:~~

. .."!.V. ~AY

\OLTAGE FEEDBACK

JUNPE R FUNCTION

A-COtt

1, ,_.. .,. .. ".., \.u,.,11:.{ TION FOR

ARHATURE FEEDBACK.

C-C ON

COHNECTIDff FOR CE" F, IF CEHF

TRANSFOAwrq IC: INfi:f.t Ir ,..

T - co "

f~m~Tmcf~JAirTFffDBA CK
INSTALLED.

~

...

,

SEE SH.I

F:frEf,

•

5

6

7

SEE SH.I
FDR REF.

NOTE

I

701819·9A(

..

..

I 1/2 210

10.~

110

7.~ b-.bl0-17 R

..

- - -

'f

80fli92· lbS9

'

0

..9 ::~g:~ ~~::.tl::~co~E~~a~NDS .18 lNCH

l 210 21 180 15 b'tt:al0· 17S

l01819·10AC

\ill02l-ti15

0

101119-llA,( 'tll02t. -..,AC

IIOl'i9Z·l6SC

5 210 15 180

25

b\tbl0· 17T

l01819· 19AC

70lllt - l7AC IOl'l'IM6SD

(Z R[Q•O)

SMUf'~f

;W/D 10002

Figure 6. 7 - Controller Tec hnical Data

-4'

)

Section 7

REPLACEMENT PARTS

7.0 Gr ) ral - Users should consider mainta ining a stock

of

s~E! parts . Table 7.A lists the more common parts along
with part numbers and quantities actually used in the
controller.

Table 7 .A

REPLACEMENT MODULES

PART DESCRIPTION

QUANTITY PER

CONTROLLER MODEL NUMBER

Regulator Module
Current Transformer (1 CT)

% and 1 Yz hp

2 and 3 hp
5 hp

Power Cube

1/.i to :Y

4

hp 115 VAC
1/2 to 11/z hp 230 VAC
2 and 3 hp 230 VAC
5 hp 230 VAC

M Contactor (Optional)
Fuse (K5 Dual Element)

1f4tO:Y4hp 115VAC
1/2 to 11/2 hp 230 VAC
2 and 3 hp 230 VAC
5 hp 230 VAC

MOV Surge Suppressor

115-volt drives
230-volt drives

Control Transformer

115-volt drives
230-volt drives

Output R-C Assembly
Dynamic Braking

1/.i to Yz hp 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

1 Kit

14C248

14C256
14C257
14C258

14C250
14C251
14C252
14C253

14C274

14C270

CD

14C271 CD

14C260

14C261

14C275

14C214
14C214
14C215
14C216

14C237

CD

'

PART NUMBER

0-57100

64670 -17R
64670-17S
64670-17T

701819 -SX
701819-SAC
701819 -lOAC
701819-1 SAC

69326-25R

64676 -lW
64676-lW
64676 -lY
64676-lAC

411026 -4X

CD

411026 -4AC CD

411027 -61R
411027 -61S

0-55302

705385 -61 R
705385-61R
705385 -61 S
705385-61T

701819 -17AC

CD

<D Model Number replacement modules are complete assembli es conta ining moun ting hardwar e and electrical connectors.

<D Part Num~ rs descr ibe the discrete component only and do not include mounting hardware .

47

Ii!

.....

'>ii

> -

'!!11'

,-

Reliance Electric Company / 24703 Euclid Avenu~ / Cleveland, Ohio 4411,

RELIANCE ELECTRIC,:

Printed In U.S.A.

lnslruclion Manual l).390()

2855M

~

~

~.'

4

~~

',

'"' '