Installing, Operating and Maintaining Reliance MaxPak Plus D-C VxS Drives and Modification Kits * DRIVES Instruction Manual D-3817-5 December, 1991 RELIANCE; ELECTRICEOIMPORTANT THIS EQUIPMENT SHOULD BE INSTALLED, ADJUSTED AND SERVICED BY QUALIFIED ELECTRICAL MAINTENANCE PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THE EQUIPMENT AND THE HAZARDS INVOLVED. It is important that these instructions be studied by the personnel installing and servicing the unit, Read thoroughly before making repairs. Keep these instructions for future use. © Copyright Reliance Electric Reliance and VS are Trademarks of Reliance ElectricTABLE OF CONTENTS Section Title RECEIVING AND HANDLING . SECTION 1 GENERAL INFORMATION ............. INTRODUCTION. REFERENCE LITERATURE BASIC DRIVE ELEMENTS ..... CONTROLLER IDENTIFICATION MAXPAK PLUS MODEL NUMBER ASSIGNMENTS DRIVE FUNCTIONS CONTROLLER FUNCTIONAL DESCRIPTION CONTROLLER SPECIFICATIONS DRIVE MODIFICATIONS TRANSFORMERS SECTION 2 DRIVE INSTALLATION .............006 INSTALLATION OF THE DRIVE MOTOR : INSTALLATION OF THE DRIVE CONTROLLER ... WIRING THE DRIVE BASIC DRIVE INTERCONNECTIONS. TRANSFORMERS .... WIRE SECTION 3 START-UP AND ADJUSTMENT PROCEDURES . TEST EQUIPMENT ....... TESTER CARD. MOTOR CHECKS «... - PHYSICAL INSPECTION OF EQUIPMENT. PRELIMINARY CHECKS WITH POWER OFF . FINAL CHECKS WITH POWER ON ..... START-UP AND ADJUSTMENT PROCEDURE. SECTION 4 DESCRIPTION OF OPERATION MOTOR........ ‘ARMATURE RECTIFIER GATING SEQUENCE AND CURRENT FLOW POWER CIRCUIT FAULT PROTECTION ‘SEMI-CONDUCTOR TRANSIENT PROTECTION, OTHER POWER UNIT HARDWARE . FIELD SUPPLY REGULATOR 2.02.0... Regulator Functions PHASE SEQUENCE, LINE AND FIELD SUPPLY MONITOR CONTROLLER REGULATOR CARD — CRCF CURRENT LOOP DRIVER - CLDK CURRENT AND VOLTAGE TRANSDUCTOR ~ CVTG STATIC SEQUENCING AND CONTROL CARD — SSCC. OVERLOAD AND VOLTAGE COMPARATOR ~ OLVC OPTIONAL TESTER CARD — TSTB . SECTIONS TROUBLESHOOTING ........ TROUBLESHOOTING NOTES ....- TROUBLESHOOTING SUGGESTIONS .. “47TABLE OF CONTENTS Section Title Page SECTION 6 REPLACEMENT PARTS 56 SECTION 7 WARRANTY 58 PRODUCT 58 REPAIR 58 SECTION 8 MAXPAK PLUS MODIFICATION KIT INSTRUCTION MANUALS 59INDEX OF PHOTOS AND DRAWINGS Title FIGURE 1 ~ RECEIVING THE MAXPAK PLUS CONTROLLER Figure FIGURE 2 ~ TYPICAL SUPER RPM D-C MOTOR . FIGURE 3 — 9C45 OPERATOR'S CONTROL STATION FIGURE 4 ~ MAXPAK PLUS CONTROLLER CABINET FIGURE 5 — CONTROLLER AND AUXILIARY PAI FIGURE 6 ~ CONTROLLER POWER UNIT .. FIGURE 7 — POWER UNIT FAN \NELS FIGURE 8 ~ CONTROLLER PANEL — TOP VIEW FIGURE 9 ~ OUTGOING POWER TERMINATIONS .... FIGURE 10 ~ MAXPAK PLUS BLOCK DIAGRAM FIGURE 11 ~ CONTROLLER EFFICIENCY . FIGURE 12 — DISPLACEMENT POWER FACTOR FIGURE 13 ~ OPEN PANEL DIMENSIONS AND WEIGHTS . FIGURE 14 — WALL MOUNTED CONTROLLER DIMENSIONS AND WEIGHTS FIGURE 15 ~ FD68 FLOOR MOUNTED CONTROLLER DIMENSIONS. FIGURE 16 ~ INTERCONNECTION DIAGRAM FOR NON-REVERSING DRIVES ... FIGURE 17 — INTERCONNECTION DIAGRAM FOR REVERSING DRIVES FIGURE 18 ~ REGULATOR ASSEMBLY . FIGURE 19 — FULL WAVE BRIDGE CONFIGURATION, FIGURE 20 ~ PHASE RECTIFIER MODULE . FIGURE 21 — CONTROLLER POWER UNIT FIGURE 22 ~ POWER UNIT ~ TOP VIEW ... FIGURE 23 — FIELD SUPPLY REMOVED FROM FIGURE 24 — FIELD SUPPLY SCHEMATIC UNIT FIGURE 25 ~ REGULATOR RACK ASSEMBLY .... FIGURE 26 ~ REGULATOR ARRANGEMENT FIGURE 27 ~ PHASE SEQUENCE, LINE AND FIELD SUPPLY MONITOR FIGURE 28 ~ PHASE SEQUENCE LINE AND FIELD SUPPLY MONITOR FIGURE 29 ~ CRCF CARD FIGURE 30 ~ CRCF BLOCK DIAGRAM . FIGURE 31 ~ CLDK CARD FIGURE 32 ~ CLDK BLOCK DIAGRAM . FIGURE 33 ~ CVTG CARD FIGURE 34 ~ CVTG BLOCK DIAGRAM . FIGURE 29 - SSCC CARD FIGURE 36 ~ SSCC BLOCK DIAGRAM . FIGURE 37 ~ OLVC CARD FIGURE 38 ~ OLVC BLOCK DIAGRAM FIGURE 39 - TSTB CARD Page " 12 18 18 18 19 20 24 30 31 32 32 32 32 33 34 36 36 37 38 39 40 a4 42 45 48 49INDEX OF TABLES Table Title TABLE 1 — REFERENCE LITERATURE TABLE 2 ~ OPERATOR CONTROL STATION FUNCTIONS TABLE 3 — MODEL NUMBER ENCLOSURE DESIGNATIONS ... TABLE 4 — MODEL NUMBER FEATURE DESIGNATIONS .... TABLE 5 — CONTROLLER CURRENT RATINGS: TABLE 6 ~ SPEED REGULATION .. TABLE 7 ~ CONTROLLER MODIFICATIONS. TABLE 8 — CONTROLLER ENCLOSURES TABLE 9 — TESTER FUNCTIONS TABLE 10 ~ STANDARD CONTROLLER CARD COMPLEMENT TABLE 11 — CURRENT FEEDBACK CALIBRATION TABLE 12 — MINIMUM ALLOWABLE MOTOR HORSEPOWER TABLE 13 ~ TACHOMETER VOLIAGE SCALING . TABLE 14 — INDICATOR LIGHTS TABLE 15 — THYRISTOR GATING SEQUENCE TABLE 16 ~ PHASE SEQUENCE LINE AND FIELD SUPPLY MONITOR CARDS. TABLE 17 ~ TROUBLESHOOTING SUGGESTIONS. TABLE 18 — HORSEPOWER-INDEPENDENT PARTS TABLE 19 - HORSEPOWER-DEPENDENT PARTS. 2 25 31 35 82 56 87RECEIVING AND HANDLING ACCEPTANCE Reliance terms of sale, in all instances, are FO.B. point of origin. Thoroughly inspect this equipment be- fore accepting shipment from the transportation com- pany. If any of the goods called for in the bill oflading or express receipt are damaged or the quantity is short, do notaccept them until the freight or express agent makes an appropriatenotation on your freightbill or express re- ceipt. if any concealed loss or damage's discovered lat- notify your freight or express agent within 15 days of receipt and request that he make an inspection. The Consignee should make claim for any shortage or dam- age in transit against the Carrier. Claims for loss or damage in shipment must not be deducted from the Reliance invoice, nor should pay- ment of the Reliance invoice be withheld awaiting ad- justment of such claims as the carrier guarantees safe delivery. If considerable damage has been incurred and the situation is urgent, contact the nearest Reliance Sales Office for assistance. Unpacking and Storing Store the equipment in a clean, dry area and do not unpack unit until ready for use. Under no conditions shouldthe equipment be stored where ambient temper- ature exceeds 60°C, where corrosive conditions exists, ‘or where high humidity is likely to cause condensation. Reliance publication 0-8079 provides further informa- tion on storage procedures and precautions. Proper storage is a must to insure satisfactory drive operation, FIGURE 1 — RECEIVING THE MAXPAK PLUS. at startup and to maintain warranty coverage. ‘CONTROLLER DANGER Rese aU aa ek UNL) Peel a Te eon aoa en Me UN Te eC es TION AND OPERATION OF THE EQUIPMENT AND THE CVC eo Rel ey eA CC AGN aI CON ORC LAM keg bral gene a ae en edge tesa ha ae eG alg INTERNAL PARTS OF THIS EQUIPMENT.SECTION 1 GENERAL INFORMATION INTRODUCTION This manual contains installation, setup, operating, maintenance and troubleshooting instructions for Re- liance MaxPak Plus D-C VaS Drives. It applies to drive ratings from five through 125 hp at an armature voltage of 240 volts d-c with 230 volts, 3-phase input power, from five through 250 hp at an armature voltage of 500, volts d-c with 460 volt, 3-phase input power and from 40, through 300 hp at an armature voltage of 600 volts with ‘550 volt, 3 phase input power. it applies as well to U.S. built MaxPak Plus drives operating from other incoming a-c voltage leads between 200 and 575 volts where the ratio of motor horsepower to incoming a-c line voltage. does not exceed 0.543. REFERENCE LITERATURE The users urged to refer to the publications listed in Table 1 to improve his understanding of the application and operation of MaxPak Plus VaS Drives and related Reliance equipment and services. These manuals are readily available from your Reliance Distributor or local Reliance Sales Office Publication Number Publication Contents D-8066 ‘Selection and Application Guide | This manual provides a discussion of the mechanical and for Reliance MaxPak Plus VxS_—_| electrical considerations involved in the selection and siz- Drives. ing of adjustable speed d-c drives. It also describes the many modifications that can be mado by the usor to the MaxPak Plus drive and offers typical examples of their use. C3076 Instruction Manual for Reliance _ | This manual provides complete instructions for the Re- ‘Super RPM D-C Motors lance Super RPM D-C Motor used with the MaxPak Plus controller. D-8078 Long Term storage for contro! __| This document provides information on proper storage cabinets procedures and precautions for MaxPak Plus drives and related equipment. ‘TABLE 1 — REFERENCE LITERATURE. BASIC DRIVE ELEMENTS Reliance MaxPak Plus VAS Drives consist ofthree ba- sic drive elements: A laminated frame Super RPM shunt wound d-c motor, a compact, remotely mounted opera- tor's control station and a MaxPak Plus controller, Motor The MaxPak Plus controller provides shunt field ex- citation and adjustable voltage armature power to drive shunt wound d-c machine with compatible voltage re- uirements and intended for adjustable speed service. MaxPak Plus drives are furnished with Reliance Super RPM laminated frame d-c motors. In this way, Reliance Electric offers a completely power matched drive sys- tem with the controller and motor power matched to ‘one another for optimum performance and undisputed single source responsibilty. The Super RPM motor is described by brochure C2519-1 as well as Instruction Manual C-3076-4. A typical Super RPM machine in a dripproof guarded enclosure is shown in Figure 2 FIGURE 2 - TYPICAL SUPER RPM D-C MOTOR,Operator's Control Station Operator's control devices must be connected tothe drive controller, As indicated in Table 2, standard Re- liance operator's control stations inciude a speed con- trol potentiometer, star-stop rocker switch and either a run-jog selector or pushbutton device for jog control. ‘The 9C46 and 9C52 operator'sstations, when usedwith armature reversing MaxPak Plus controllers provide a “forward/reverse", selector. A 9C45 station is illustrated in Figure 3. FIGURE 3 - 9C45 OPERATOR'S CONTROL STATION Specify Functions Provided When Using a MaxPak Plus | Operators | a= ; 7 9] Speed Seting | og | Forward Reverse Controle With: station Mode! | Soea : = + Basi atures 36a Yes Yes | Selector Swich No Basic features plus cst Yes Yes Pushbutton No dynamo braking © Basic Tealres pus 3046 Yes Yes | Selector Swish Yes ‘dynamic braking and 9c52 ‘Yes ‘Yes Pushbutton: ‘Yes armature reversing ‘TABLE 2 - OPERATOR CONTROL STATION FUNCTIONS: Controller ‘The MaxPak Plus controller provides adjustable volt- ‘age armature power to the d-c motor by phase con- trolled rectification of 3-phase plant power. The phase controlled rectifier, major and minor loop regulators, field exciter and all required sequencing controls and, protective circuits make up the drive controller. This controller is normally supplied mounted and wired with- in its own NEMA 1 enclosure. Standard enclosure di- ‘mensions are provided on pages 17 and 18. The con- troller may also be specified in larger NEMA 1 enclosures, NEMA 12 enclosures or in open panel construction MaxPak Plus controllers in Reliance cabinets are U.L. listed and may be C.S.A. approved. Open panel Max- Pak Plus drives are also ULL. listed. ‘The controller is functionally described on pages 4 through 9, CONTROLLER IDENTIFICATION MaxPak Plus controllers are manufactured as stan- dard model number units to a set of Reliance specifica- tions or as modified units to customer specifications. ‘The MaxPak Plus controller can be positively identified bby the nameplate mounted on the front face of the cabi- net door or, in the case of a panel mounted drive, on the controller itself If built to customer specifications, a Reliance sales ‘order number will be imprinted on the nameplate, ap- pearing as a six digit number following a 1GA, 2GA, GA, or TT, 10TT, 20TT prefix (such as 1GA-679042 or 40TT-896401) . Use this identification number whenever discussing this drive equipment with Reliance Electric personnel. It uniquely describes a controller manufac- tured to customer specifications. Alternately, if the controller was manufactured as a Reliance model number drive, its model number Uniquely describes the hardware furnished. MAXPAK PLUS MODEL NUMBER ASSIGNMENTS Ifthe MaxPak Plus controller was built to a Reliance model number specification, afour through eight char- acter alpha-numeric model number will be printed on the drive's identification nameplate. This model number will also be present on the shipping label on the outside ofthe controller shipping container. The model number provides a complete controller specification as noted in ‘Tables 3 and 4 A typical MaxPak Plus model number would be 20C58S, and signify the following: 20 © 58.8 Finals" inModel amber May or sy ontroterHorsepower —/ /\ \ wer rece pao 7) a Single Digt Enclosure Designation is Aero is Not Features per Table 420058 controller is rated at20 hp (20preceding the *C’), furnished in a NEMA 1 wall mounted enclosure (a zero, not printed, following the “C", see Table 3) and Provides basic features plus dynamic braking at 230 volts a-c input power, 240 volts d-c armature and 150 Volts d-c field (68 suffix, per Table 4) . A20C158S would describe the same drive controller when furnished in an FD68 NEMA 1 floor mounted enclosure.Digit immediately Following “C” Controller Enclosure 0 2 ‘NEMA wall mounted enciosure (Zero may be ‘omitted in printing the controller MIN), 1 FD 86U NEMA 1 floor mounted enclosure (Open panel supplied without enclosure ‘TABLE 3 - MODEL NUMBER ENCLOSURE DESIGNATIONS. Last Two Digits Of ac Armature Feld ‘Model Input Voltage Voltage Features Number Voltage (PC Volts) | (0-C Volts) a7 230 220 10 Basic Features 38 230 200 10 Basic Features Plus Dynamic Braking 59 230 240 160 Basic Features Plus Dynamic Braking and Reversing 60 460 500 3c0 Basic Features 61 460 500 3c0 Basic Features Plus Dynamic Braking 62 460 500 300 Basic Features Plus Dynamic Braking and Reversing 63 230 240 10 Basic Plus Extruder Features 64 460 500 30 Basic Plus Extruder Features ‘TABLE 4 — MODEL NUMBER FEATURE DESIGNATIONS DRIVE FUNCTIONS Basic MaxPak Plus Controllers The following standard features are built into every MaxPak Plus drive controller. Together, they define the functions provided by the basic MaxPak Plus. 1 2, 3 10. " 12, Start-stop and speed selection. Unidirectional Operation, coast-to-rest. ‘Twenty to one (20:1) controlled speed range by ar- mature voltage control. Separately adjustable rates of linear acceleration and, deceleration. Adjustable from 0.5 to 30 seconds. Jumper reconnectable regulator circuits to allow ei- ther armature voltage regulation or closed loop speed regulation with tachometer feedback. Provides: © 5% speed change with 95% load change by Voltage regulation. © 1% speed change with 95% load change by ‘speed regulation using an RE045 a-c tachome- ter or SPY dec tachometer. © 0.5% speed change with 95% load change by speed regulation using a BC42 tachometer Jog at adjustable preset speed (0-50%) by push- button or selector switch depending on selection of operator's station. Adjustable IR drop compensation (0 to 10%) by, jumper connection ‘Adjustable minimum speed (2% to 40%). ‘Adjustable maximum speed (80 to 120%) 450% one minute current rating. 50/60 Hz compatibility without modification. Ability to deliver rated output and operate within specified regulation tolerance limits with a-c line 13. 14. 16. 16. 17. 18. 19. 20. 21 22. 23, 24, variations of +:10% of nominal. Capable of opera- tion without power unit damage to 25% low incom- ing line. Static sequencing to provide coordination of minor loop, major loop and armature contactor during start, stop and jog commands without the need for relays. Complete with major and minor loop status, lights on the face of the regulator. Isolated armature voltage and current feedback to assure complete isolation between armature and regulating circuits. Fused and isolated 115 volta-c supply for pushbut- ton and regulator control. Conveniently located incoming and outgoing pow- €r terminal locations to allow easy cable entry and connection. Full rated armature loop contactor. Complete with, blowouts, Phase sequence interlock to prevent drive opera- tion with incorrect incoming phase rotation. Com- plete with regulator face plate LED to indicate prop- ‘er rotation. Surge protection from a-cline and d-c load transients. Current limit, adjustable from 50% to 150% of drive full load current. Bolted fault protection by means of three pairs ofin- ‘coming line current limiting fuses. ‘Overcurrent IET (instantaneous electronic trip) with regulator faceplate indicating light. Solid state motor overload protection with regulator faceplate indicating light. Field excitation loss protection with regulator face- plate indicating light.MaxPak Plus Controllers with Basic Features and Dynamic Braking When specified to include “basic and dynamic brak- ing” functions, the MaxPak Plus controller will also pro- vide: ‘© Rapid stopping of the drive motor by means of dynamic braking upon a “stop” command. Com- plete with additional power pole on armature loop contactor and energy absorbing resistors. MaxPak Plus Controllers with Basic Features Plus Dynamic Braking and Reversing When specified to provide “basic plus dynamic brak- ing and reversing’, functions, the MaxPak Plus control- ler will contain: ‘© Asecond armature loop contactor to allow preselec- tion of desired motor rotation with direction of rotation determined by the forward/reverse toggle switch on the operator's control station MaxPak Plus Controllers with Extruder Features When specified to include extruder features. the Max- Pak Plus controller is furnished with the foliowing in addition to the "basic" features listed previously. Neither ‘dynamic braking nor armature reversing are provided. ‘© One normally open auxiliary contact on the motor armature contactor wired to terminals for user use. '® A blower motor starter to protect and control the de motor blower. ‘© A moter filter card providing buffered signals for remote metering of armature voltage and current. CONTROLLER FUNCTIONAL DESCRIPTION ‘The MaxPak Plus controller employs a full wave, full control phase controlled rectifier to provide adjustable voltage armature power for adjustable speed d-c motor drive service. The rectifier bridge, comprised of six SCR switches, operates directly from 3-phase plant power. ‘The firing angle of the phase controlled rectifier is deter- mined by the drive's regulator utilizing either armature voltage or motor speed as the major loop controlled variable. Speed is set by a potentiometer on the opera- tor's control station and start-stop-jog functions are controlled via conventional pushbutton devices. ‘A power unit cooling fan is furnished for forced ven- tilation of the power bridge when required. A fixed po- tential field supply provides shunt field excitation to the motor. Poweris delivered to the motor through an armature loop contactor and the controller is furnished with a ‘complete protection system for itself and the drive mo- tor, The block diagram of Figure 10 and photographs with component callouts in Figures 4 through 9 should, bbe used to gain a basic understanding of controller hardware and function. A detailed discussion of power bridge and regulator operation is provided in Section 4 ofthis manual. Functional hardware within the controller includes: 1. Controller enclosure. The MaxPak Plus controller may be furnished on an open panel or nits own wall or floor mounted NEMA 1 enclosure. Special encio- sures for operation in unusual environments are also available. Figure 4 shows a typical controller, complete with dynamic braking and reversing in a wall mounted NEMA 1 cabinet, The door is hinged and has provisions for padlocking. The cover plate near the center of the door is removable to allow mounting of the handle for the optional incoming circuit breaker kit. Note the controllers identifying nameplate. FIGURE 4 ~ MAXPAK PLUS CONTROLLER CABINET 2. Controller Panel. All controller hardware with the exception of the armature loop contactor and out put d-c terminations is mounted on the controller panel the left hand panel within the controller enclo- Sure as shown in Figure 5. The controller panel, when so specified, can be furnished alone -without the auxiliary panei or controller enclosure, where the customer desires to furnish his own armature magnetics and cabinet.3. Auxillary Panel. This panel, mounted tothe right of the controller panel, contains the armature loop Contactor(s) and armature output power termina- tions. The exact contactor and terminal configura- tion is dependent upon horsepower, voltage, and the presence of optional dynamic braking and ar- mature reversing features. Figure 5 and photos in this manual depict the exact auxiliary panel ar- rangement for controllers furnished with dynamic. braking and armature reversing at horsepowers from 40 through 150 at 460 volts a-c input or from 20 through 75 horsepower at 230 volts a-c input. ‘rniowt FIGURE 5 - CONTROLLER AND AUXILIARY PANELS, The auxiliary panel arrangement on drives of higher; horsepower is similar to that shown in the photographs of this manual but is accomplished ‘while using larger contactors and busbar. Drives of lower horsepower rating use a terminal board for customer armature connection. Drive controllers without the armature reversing function employ only one contactor. The absence of dynamic braking further simplifies the auxiliary pan- ol, armature wiring or bus work ‘The auxiliary panel also provides mounting space for many ofthe pre-packaged modification its. 4, Incoming Line Terminals. Three-phase incoming power terminals are provided as shown in Figure 6 and are arranged for easy top entry of power wiring. ‘As with most other power connections within the MaxPak Plus controller, these terminals are fitted with special fasteners, designedto provide superior electrical connection’ and even contact pressure over the entire contact area. They must be tight- ened properly in order to provide this function, and hardware tightening instructions are provided with- in the controller enclosure as shown in Figure 5. Incoming line fuses. Current limiting fuses 1FU, 2FU and 3FU provide bolted fault short circuit protection for the controller. See Figure 6. 6. Controller Power Unit. The controller power unit, houses the three phase rectifier modules and pro- ‘vides mounting surfaces for other power circult de- vices. It also houses the controller cooling fan where required. See Figures 5, 6 and 7 FIGURE 6 ~ CONTROLLER POWER UNITCONTROLLER IRCUIT ‘TRANSFORMER LINE. CURRENT TRANSFORMERS FIGURE 8 ~ CONTROLLER PANEL ~ TOP VIEW 7. Current Transformers. Current transformers 1CT and 3CT shown in Figure 8, provide load current feedback to the regulator. Since a-c line current is directly proportional to d-c armature current, these transformers provide an isolated current feedback signal usable as input for I compensation, current limit, motor thermal overload and overcurrent shut- down (IET) circuit functions. 8. Phase Rectifier Modules. Three identical rectifier modules, each containing two thyristors, dv/dt pro- tective networks, gate firing circuitry and heatsinks are visible in Figure 6. Each module's easily remov- able and replaced as a unit. Gate lead connections. are made by a quick-disconnect plug. Note the gate lead orientation diagram illustrating proper gate lead connections. Ferrite Reactors. A ferrite reactor assembly is pro- vided for each leg ofthe power rectifier. These reac- tors provide difdt protection forthe rectifier thyri tors, and function as part of the thyristor dv/at protective circuitry. They are mounted within the power unit. ‘Output Network. This circuit acts to provide an as- sured minimum load to the armature power unit to guarantee thyristor latching, minimizes armature voltage overshoot, and also provides a shunt path for high frequency generated by the d-cmotor com- mutator. It is mounted as a part of the controller power unit and shown in Figure 8." 12. 13. 14, ‘Armature Loop Contactor. This load-break-rated 48. device provides a positive disconnect between, the power unit and the motor armature. Although it is a load-break device and furnished with blow- Outs, its opening and closing is sequenced by the drive regulator so that it opens and closes only un- der no-load conditions for assured long life. An additional load pole is furnished for dynamic brak- ing applications. Two contactors are provided to al- low armature reversing as visible in figures § and 9. Outgoing Power Terminations. Armature power terminations have been arranged to allow easy cable routing and connection to the controller. Two sets of connections are provided to allow both top or bottom cable entry. On drives of 20 hp or greater at 230 volts a-c in- ut, or 40 hp or greater at 460 volts or 550 volts ac input, the arrangement is as shown in Figure 9. In this case, two alternate sets of bolted armature ter- minations are provided -one allowing top connec- tion and the other providing terminations when bot- tom entry is used. On smaller drives, armature terminations are made to a single power terminal board employing compression-type box connec- tors and located to allow easy connection for either top or bottom entry. ‘Two armature connections (1 and A2/S2) are provided on drives with “basic”, features. Three ar- mature terminations (1, A2/S1 and S2), provided Con drives with dynamic braking, allow removal of the stabilizing shunt field during db for maximum braking torque. Four terminations (A1, A2, $1 and 2) assure proper orientation of the stabilizing shunt field in either direction of rotation on drives, with armature reversing, Motor field connections are made to a terminal board mounted as shown on the auxiliary panel Field Supply. Shunt field excitation is provided by means of a fixed diode rectifier operating from in- coming a-c line power. Fuses 4FU and SFU provide short circuit protection. See Figure 6. Control Circuit Transformer. Along with second- ary fuse 6FU (Figure 6) , this isolation transformer, visible in Figure 8, provides the 115 volt a-c power forthe regulator, pushbutton control, armature con- tactor coils and ventilating fan. 16. 16. 17. 18. Phase Sequence, Line and Field Supply Monitor. ‘This printed circuit card receives incoming a-c line and field supply output voltage information and supplies, as its output, low level isolated signals to the reguiator indicating proper or improper phase rotation, loss of incoming a-c line and loss of field supply voltage. These signals are subsequently used by the regulator as fault inputs to shutdown the drive under incoming line or field loss condi- tions. See Figure 6. Regulator Assembly. The regulator assembly, Fig- ure’, contains the five plug-in 44-pin printed circuit, ‘cards which comprise the MaxPak Plus regulator and houses an isolation transformer (not visible in the photos) providing 34 volts a-c for subsequent ‘generation of +12 volt -c power within the regula- tor, The regulator accepts start, stop and other pushbutton commands and a speed reference sig- nal along with feedback signals proportional to ar- mature voltage and current. The output of the regu- lator controls fring angle of the thyristors to adjust armature voltage and motor speed, sequences the motor armature contactor(s) and provides a num- ber of drive protective functions. The function and ‘operation of the regulator as well as that of each of the regulator cards is discussed in greater detail in section 4 of this manual . Drive Tester. This plug in tester card, noted in Fig- ure 5 and available as an option, allows inservice monitoring of 11 internal voltage signals and allows. injection of an adjustable test signal into the drive for troubleshooting purposes. A pair of faceplate ‘connectors allow monitoring ofa number ofinternal rive signals with an external metering device (digi- tal voltmeter, oscilloscope, etc.) Complete instructions for use of this diagnostic toolare contained in section 8 of this manual. Acon- densed set of instructions are printed and mounted within the drive enclosure as shown. ‘Startup Instructions and Spare Parts List. Startup land adjustment procedures are discussed in Sec- tion 3 of this manual. The spare pars lists printed in Section 6. This information, in condensed form, is attached to the inside cabinet door for easy refer ‘ence as seen in Figure 5.FIGURE 9 ~ OUTGOING POWER TERMINATIONS, CONTROLLER SPECIFICATIONS Voltage and Current Ratings MaxPak Plus controllers are available from 5 through 125 HP for operation from 230 volt a-c line power’ from D through 250 HP from 460 volt ac operation and from 40 through 300 HP for 550 volta-c operation. Table 5 be- low lists armature, field and input a-c current ratings for each drive horsepower. ARMATURE CONNECTIONS. FoR TOP: CABINET Entry FIELD ‘CONNECTIONS ARMATURE. CONNECTIONS FOR BOTTOM. CABINET ENTRY ‘Available | Incoming | Armature | Field HP Ratings | Line Power | Voltage | Voltage 3 125 | 280 volts a-c | 240 volts dc | 150 vols Ge 5 — 250 | 460,volts a-c | 500 volts dc | 300 volts d-c 40 ~ 300 _| $60 votts a-c | 600 votts d-c | 240 volts d-cy | FIGURE 10 — MAXPAK PLUS BLOCK DIAGRAM 9Service Conditions Standard Altitude =... Up to 3300 feet (1000 meters) above sea level without derating, ‘Ambient Temperature =. Oto 40°C for "cabinet models. 0 to 55°C {for panel mounted drives Line Frequency . 48 — 62 Hz Line Voltage Variation .. £10% of nominal Ambient Humidity (010 95%, non-condensing Line Power Considerations Line Frequency MaxPak Plus controllers operate without modifica- tion from 3-phase plant power with a frequency within the range of 48 to 62 Hz. — Voltage Tolerance ‘The MaxPak Plus controller with deliver output cur- rentand voltage per Table and operate within the regu- lation specifications listed below with incoming line volt- ‘age at 10% above or below the normal. The drive will ‘operate without component damage under low incom- ing line conditions down to 25% below nominal. Line Impedance Requirements The standard MaxPak Plus controller, furnished with- outan input circuit breaker, has.ashort circuit protection system designed to operate on plant power supplies with maximum allowable available symmetrical RMS fault currents as listed in Table 5 below. ‘Do not attempt to operate the MaxPak Plus control- er on power supplies with available short circuit currents in excess of these allowable maximums. Further, note that the addition of an incoming line cit- cuit breaker may further reduce the allowable available fault current, depending upon the clearing capacity of the circuit breaker ise. Instruction Manual D-3818, de- scribing the incoming line circuit breaker kits often used, with MaxPak Plus controllers, lists the allowable avail- able fault current for each circuit breaker rating. Manual, 10-3818 is bound within this instruction manual. Operation From Unlisted Voltages 230 volt MaxPak Plus controllers will operate satis- factorily from 110 to 270 volt a-c plant power, delivering, armature voltage, field voltage and output horsepower proportional to ratings specified at 230 volt input, pro- Viding that the output from the control circuit transform- er (CCT) is maintained at 115 volt a-c.* In alike manner, 550 volt controllers can be operated from plant power within the range of 430t0575 volts a-c. 460 volt controllers can be operated from plant pow- er within the range of 270 to 430 volts a-c by replacing the 0-54349-2 Phase Sequence, Line and Field Supply Monitor printed circuit board with a 0-54349-1 board and observing the control transformer secondary volt- ‘age requirement noted above. ‘Kit model number 28672 provides a control circuit trans- ‘former with multiple taps for matching unusual ine voltages. Itis available either as a factory specified item or as a pre- packaged kit for fold installation. HP Full Load Rated Full Load Rated Field Supply ‘Maximum Allowable Ratings RMS A.C Line D.C Armature Current Capacity Available Symmetrical Current (Amperes) Current (Amperes) (Amperes) RMS Fault Current (AMP) 230V_| 460V | S80v | 240V | SOOV | Goo” | TSO | s0OV | 2a0v | 230V | a60V | S5OV 3 | 2 | 73 | 0 | — 5 3 | — | «800 | 4500 | — 75] 2 | 18 | — a | 1] — 5 5 | — | 4500 | 4500 | — to | a | a | — aa | we | — 5 5 | — | 4500 | 4500 | — 1s | se | ao | — se | 28 | — 5 5 | — | 4500 | 4500 | — 2 | 6 | 37 | — vm | 36 | — | 10 5 | — | 4500 | 4500 | — = | «| a) — 3 | = | — | =| — | 25000 | 4500 | — so | o9 | so | — | 10 | se | — | 15 5 | — | 25000 | 4500 | — 40 | 127 | 64 | sa | ta | 69 | 57 | 15 | 10 | 15 | 25000 | «500 | 25000 a} — | — a | — | — e | — | — | ts | — | — | 28000 so | tsa | 79 | 63 | 178 | a6 | 7 | 15 | 15 | 15 | 25000 | 25000 | 25000 0 | 6 | 91 | 79 | 22 | 100 |e | 15 | 15 | 18 | 25000 | 25000 | 25000 70 = oa | — | — | 1 | — | — | & | — | — | 25000 75 | 244 | 116 | 97 | 265 | 129 | 107 | 15 | 15 | 15 | 25000 | 25000 | 25000 vo | — | — J me | — | — | we | — | — | te | — | — | 25000 100 | 275 | 152 | 127 | 925 | t67 | 132 | 15 | 15 | 15 | 25000 | 25000 | 25000 wo | — | — |we|— |— |)om]—|— |s | — | — | 00 125 | 340 | 190 | 152 | 400 | 205 | 171 | 15 | 15 | 18 | 48000 | 25000 | 25000 150 | — | 219 | 10 | — | 260 | 206 | — | 18 | 18 | — | 25000 | 25000 io | — | — | 20 | — | — | ao | — | — | 1 | — | — | 25000 200 | — | 276 | os | — | oa | 270 | — | 18 | 18 | — | 45000 | 45000 zo | — | — | as | — | — | as | — | — | 8 | — | — | 45000 250 | — | sao | asa | — | aoo | 3x5 | — | 15 | 15 | — | 45000 | 45000 soo | — | — | a0 | — | — | ao | — | — | ts | — | — | 45000 ‘TABLE 5 ~ CONTROLLER CURRENT RATINGS. 10Load Specifications Capacity cessessese+ 180% of full load rated armature current for one minute. Controller Service Factor ees eereeeeeee 1.0 Minimum Load for Assured Stable Operation’... 5% Adjustments ‘Acceleration -.0.5~30 seconds Deceleration 05-30 seconds Minimum Speed 040% Maximum Speed ‘80-120%. Jog Speed 050% Current Limit 50-150%. IR Drop Compensation (Optional) . =. 010%. ‘Speed Regulation ‘As furnished from the factory, the MaxPak Plus con- troller is configured as a voltage regulator, using arma- ture voltage as the controlled parameter. The controller canbe converted to a speed regulator by jumper recon- nection as described on page 21, item 10, of this manu- al, with resulting speed regulation being a function of tachometer selection as noted in Table 7. ‘Speed Regulation With_] All Other Variables 98% Load Change (% of | (% of Motor Base | Tachometer Motor Base Speed) ‘Speed) Required o 15% None 1% 2% E045 or SPY 05% 05% 50-42 TABLE 6 — SPEED REGULATION Controlled Speed Range Atstandard 40°C ambientconditionsatthemotor, thedrive can be operated downto.60% of motorbase speed with 100% rated load without supplementary ‘motor ventilation. Ifthe load does not exceed 60% of rated, continuous operation down to one-twentieth of ‘motor base speed is possible without supplementary ‘motor ventilation; however, UNDER ALL LOAD CONDI- TIONS, WHEN OPERATING BELOW ONE TWENTIETH OF BASE SPEED, THE MOTOR MUST ALWAYS BE EQUIPPED WITH BLOWER VENTILATION OR A TENV MOTOR MUST BE SUPPLIED. Controller Dissipation When a panel mounted MaxPak Plus controllers fur- nished for mounting within a customer supplied enclo- ssure, the customer is responsible for assuring that the ‘maximum temperature within the enclosure remains at or below 55°C under worst case operating conditions. When designing the enclosure ventilating system or when sizing a non-ventilated enclosure in which the controllers to be mounted, the energy dissipation of all ‘components within that cabinet should be considered. 1" ‘MaxPak Plus controller dissipation can be expressed by the equation: Watts Loss = W; + (3 x Full Load Rated Armature Current) Where: ‘+ W;= 150 for controllers rated 5 through 75 hp 230 volts a-c input, 5 through 150 hp at ‘460 volts a-c input and 5 through 180 hp at 550 volts a-c input. ‘* W_= 350 for controllers with horsepower ratings in excess of those above ‘* Full Load Rated Armature Current is per Table 5. Efficiency and Power Factor Controller only - Figure 11 illustrates, typical controller-only efficiency vs speed and load Complete drive, including motor ........ Dependent ‘on motor selected. Typical drive efficiency will be in range of 85 to 93% operating at full speed, full load. Controtier Eten, ‘Speed, % of Rated FIGURE 11 — CONTROLLER EFFICIENCYDisplacement Power Factor Displacement power factor is almost entirely a function of operating ‘speed. Displacement power factor vs ‘speed is illustrated in Figure 12. e ; Foal i + + in — i | CoCr i + cat ||| 7 I | 2 60 2100 ‘Speed, % of Rated FIGURE 12 — DISPLACEMENT POWER FACTOR DRIVE MODIFICATIONS Factory Installed Modifications. A large number of factory installed modifications, such as armature reversing, dynamic braking, extruder features, special sequencing, etc., are available when specified at order entry. The most common of these have been previously referenced in this manual and will be further described in the paragraphs below. Jumper Reconnections Operation of the MaxPak Plus controller can bemodi- fied (either at the factory or by the user) in a number of ways by simple jumper reconnection. These possibili- {esate listen Table 7 and further described in Manual -9066. Prepackaged Kit Modifications In addition, a complete selection of pre-packaged ‘modifications is available in kit form for easy addition in the field. These kits are listed in Table 7 and further dis cussed in D-9066. Kit instruction manuals form section, 8 of this manual, User-installed Modifications Lastly, the MaxPak Plus can often be adapted tomeet special requirements by minor modifications using aux- lary components furnished by the customer. Anumber ofsuch modifications are lstedin Table 7 with these and other user-installed modifications discussed fully in D-9068. 12 Acceleration/Deceleration Times, Extended. The range of the linear timing circuit provided in the stan- dard MaxPak Plus controller is from 0.5 to 30 seconds with acceleration and deceleration rates individually ad- justable within this range. This overall range may bemo- ified by the addition of nonpolarized, 25 volt, paper or mylar capacitors between terminals 22 and 24 ofthe ter- minal board located along the bottom edge of the con- troller panel as indicated in Figure 18, page 24. Each 10 microfarads of capacitance so added will increase the timing range by an additional 30 secondstoamaximum of 200 seconds. Blower Motor Starter. The blower motor starter kit pro- Vides short circuit protection (via rejection type NEC fuses) and thermal overload protection for the three phase a-c motor used to drive the cooling fan on force Ventilated d-c drive motors. Italso provides ameans, via an auxiliary contact on the starter contactor, to stop the drive in the event of a blower motor overload. This fused motor starter, with a selection of overload heaters, mounts in any one of two locations within the MaxPak Plus controller depending upon other modifications provided with the drive. Circuit Breaker with Thru-the Door Handle. Wh specified as a factory-installed modification, the incom- ing line circuit breaker will be furnished mounted and. wired within the controller enclosure. Itis complete with, a thru-the-door handle to allow breaker operation from. outside the enclosure and to provide a door interlock. ‘The breaker serves as a means to disconnect the con- troller from incoming plant power and is furnished with. ‘magnetic trip elements. With this device installed (it ‘mounts on a sheet metal plate in front of the armature. loop contactor) customer incoming power connections, are to its line side terminals. When furnished as a kit, itis complete with mounting brackets, aload-side wiring hamess and operating han- dle. All MaxPak Plus controller cabinets have doors pr punched to accept this option without the need for on- site drilling Drive to Rest on Stop. In response to a “stop” com- ‘mand from the operator's stop pushbutton, the stan- dard MaxPak Plus controller will cause the armature contactor to open and the motor to coast to rest. Ifthe controller was furnished with dynamic braking, the mo- ‘or will dynamic brake to rest on a "stop" command. In either case, the stop mode is relay-actuated and, there- fore, positive. If desired, the drive can be modified to “drive-to-n set” onastop command. This wll cause the drive to de- celerate to zero speed at a rate determined by the set- ting of the deceleration rate control. Once near zero speed, the armature contactor will drop out. This stop- ping mode may be of benefit where slow and gradual speed changes are required to protect the process or where several drives are required to start and stop in Unison while maintaining coordinated speeds.TABLE 7 - CONTROLLER MODIFICATIONS ‘Availabilty an Factory ‘Jumper PrePackaged Kit | _Usernstalled Installed Reconnection MN (uM) Modification ‘Acceleration/deceleration Yes Yes times, extended Auxiliary armature Yes 23C100-236103 Yes contactor contacts (0-3824) Blower motor starter Yes 23040-23046 (03821) Circuit breaker with thru- Yes 2302-2306 the-door handle (0-3818) Control Circuit Transformer Yes 28C70, 2871 350 VA (03827) Control Gircult Transformer Yes 23072 23072 360 VA, mult-tapped (03827) Current Limit, remote adjustment Yes Yes Drive to Rest on Stop Yes Yes Dynamic Braking Yes Fan loss detector Yes 23080 (0-3828) Field current regulator with Yes 23090-23095" tachometer loss protection (0-382) Field Economy Function Yes Field trim resistors Yes Yes Follower, signal Yes Yes IR Drop Compensation Yes Yes Jog, extended speed range Yes Yes Jog, Remote Speed Adjustment Yes Yes Jog Reverse Yes Jog, “Sot” Yes Yes Load Meter Yes 280121, 230122 (0-3830) Meter Filter Yes 23030 (D-3819) Multiple Motor Operation Yes Yes Multiple Preset Speeds Yes Yes Response Improved Yes Reversing by Armature Contactor Yes ‘Shunt, 0 MV Yes 23023-23027 (0-3820) ‘Shunt, 100 MV Yes 23013-23017 (0-3820) ‘Speed Indicator Yes ‘Speed Regulation, 19 Yes Yes™ ‘Speed Regulation, 0.5% Yes Yes* ‘Speed Regulation, 0.25% Yes ‘Speed Regulation, 0.10% Yes Tester, Circuit Yes 8049 Voltmeter, Armature Yes 2a0131 2301682 (0-3830) * Also requires Motor Driven Tachometer. When supplied as a factory-installed option, a spe- buttons (one providing “drive-to-rest on stop" and the cial operator station with two alternate-mode stop push- other coast or dynamic braking action) will be provided. 13Revised jumper interconnections will also be provided and special wiring diagrams noting all the above changes will be furnished Instructions for user installation of this modifica- tion are provided on pages 18 and 19 of Application Manual D-9066. They must be carefully and com- pletely followed to maintain safe and positive drive stopping operation. Dynamic Braking. Drives with this modification will be equipped with a dynamic braking resistor. Braking is ac- complished by connecting this resistor directly across the motor armature and thereby dissipating its energy. Dynamic braking provides rapid, shockless stopping of the drive motor whenever the "Stop" pushbutton on the ‘operator's control is depressed. Dynamic braking will not hold the motor shaft and keep it from turning once it is stopped. The dynamic braking resistor is ‘mounted in a separate ventilated enclosure on top of the control unit enclosure as can be seen in Figure 4, page 4. Field Current Regulator with Tachometer Loss and ‘Overspeed Protection. This modification provides the ability to operate the d-c motor above base speed in the constant horsepower mode of operation by means of weakening the strength of the motor shunt field. Two printed circuit cards, furnished in their own card rack, ‘mountnear the bottom ofthe auxiliary panel and receive 415 volts a-c control power and a reference signal from the controller armature output voltage. When motor ar- ‘mature voltage is sensed to be at 100% and a further in- crease in speed reference occurs, the motor field is gradually weakened by regulating its current to allow motor operation above base speed with decreased torque capability. A TACHOMETER MUST BE MOUNTED ON THE DRIVE MOTOR WHEN THIS OP- TION IS USED. The tachometer monitor circuit pro- vides an interlock causing the drive to stop in the event of tachometer signal loss or motor overspeed. Field Economy Function. itis good operating practice to remove incoming a-c power to the MaxPak Plus con- troller between periods of operation. Ifthe drive is inop- erative overnight or over weekends, incoming power should be removed and locked out. Not only does this practice enhance personnel safety. but alsoremovesiin- coming power from the drive in the periods during which plant voltage levels tend to climb—often to well ‘over nominal values found during periods of normal plant activity. 14 Ifor some reason, however, incoming plant power is left on the equipment while idle for long periods of time as described above and plant line voltages tend to climb over 110% of nominal, the addition of Field Econ- ‘omy hardware can eliminate the possibilty of motor damage caused by overheating of the d-c motor field windings when subjected to these abnormally high volt- ‘ages without the benefit of the cooling provided by the armature shaft driven cooling fan. This function automatically reduces the voltage de- liveredto the motor shunt field during periods when the driveisinastandby mode. Fullfeld strength. isreturned automatically when the driveis once again requested to run. Ifthe d-c motor is equipped with an a-c motor driven blower for cooling, its operation during periods of standby will provide satisfactory motor cooling without the need for field economy. Field Trim Resistors. A need often exists to obtain a 5 to 10% speed increase above motor base speed. This, is used primarily to match a standard gear ratio with the motor and the driven machine. This “gear in” is ob- tained by weakening the motor field excitation (field trim) using a slidewire resistor in series with the motor field, Available as a factory-installed modification, the resistor mounts on the auxiliary panel. Follower, Signal. When so specified, the controller will be equipped with circuitry to control motor speed in re- sponse to an external voltage or current signal. Com- ‘monly, the drive is specified to follow 4-20 or 1 0-50 ma. signals as generated by conventional process control instruments. Also common isthe specification which re- Quires the drivetofollowazero-based voltage reference (0-5, 0-10 or 0-20 volt. In either case, the drive will con- trolmotor speed in direct proportion to the applied refer- tence with motor speed increasing with an increase in the value of the reference signal Reversing by Armature Contactor. Drives with arma- ture reversing will be equipped with a forward (FM) and reverse (RM) motor contactor. Both contactors and pro- Visions for four-terminal armature connection (A1, A2, S1 and S2) to allow proper orientation of the stabilizing field in either direction of rotation are mounted on the auxiliary panel. An operator's control station with a for- ward/reverse selector should be specified when order- ing an armature reversing drive as noted in Table 2, page 2. Photographs on pages 5 and 8 illustrate the hardware arrangement of a reversing controller ‘Speed Regulation. This modification is accomplished by addition of an appropriate tachometer to the drive motor and a minor jumper reconnection of the drive controller. The controller, otherwise, is unchanged Tachometer selection is based upon desired regulation accuracy as noted in Table 6.Tester, Circuit, Available factory installed or as a pre- packaged kit, this plug in 44-pin card installs into a slot inthe card rack and allows monitoring of 11 critical volt- ‘ages within the controller. also contains an adjustable voltage reference signal source which can be injected into the drive in either polarity for g diagnostic evalua- tion. Operation and use of he testeris describedin Sec- tion 3 of this manual. TRANSFORMERS Auto transformers step the a-c power supply voltage up or down, but these do not provide isolation from the line. Isolation transformers also provide voltage step-up or step-down. They also isolate the armature circuit fromthe line. Isolation transformershelptoeliminatethe possibilty of: 15 © Injury to personnel if contact is accidentally made with an electrical conducting component from the drive. © Voltage transients from the a-c line coming to the solid-state power conversion unit in the drive, which might result in damage to the equipment. © Damaging currents which can existifapointin the de output becomes grounded and the a-c electrical system contains a ground also. NOTE: IF AN AUTO ORISOLATION TRANSFORMERS. USED AHEAD OF THE DRIVE, A POWER DISCON- NECTING DEVICE SHOULD BE USED BETWEEN THE. POWER LINE AND THE TRANSFORMER PRIMARY. DUE TO THE HIGH INRUSH OF TRANSFORMER, EQUIPMENT, IT IS NOT RECOMMENDED THAT A CIR- CUIT BREAKER TYPE DISCONNECT BE USED. RATH- ER, A FUSED DISCONNECT SWITCH SHOULD BE INSTALLED.SECTION 2 DRIVE INSTALLATION DANGER RA OR etl ONO eae ea) FM oat oR UNDE ola ag TGR m ker aoa tN Kelas ee Rela ase aa va OOS ene BOATS NS ese ee Belen M omer sw) OPERATOR DEVICES 'IN CONFORMANCE PAREN Ue MR eke au aun al aga o Pre MUR ue ato Teatod Re Rn ae Loe) Pau men etn cma Pe Rel aa eeu INSTALLATION OF THE DRIVE MOTOR The d-c drive motor should be installed in accor- dance with its own installation instructions. Instructions, for the installation of Reliance Super RPM motors fur- nished in frames 8180ATZ through BEB0ATZ are fur- nished in instruction manual C-3076-3. INSTALLATION OF THE DRIVE CONTROLLER ‘The MaxPak Plus controller, most often supplied in its ‘own NEMA 1 enclosure, is also available in NEMA 4 and MENA 12 cabinets, in free standing floor mounted cabi- nets and in an open panel configuration for mounting in the customers enclosure. Table 8 and Figures 13thru 15 provide cabinet and open panel dimensions and weight asa function of controller horsepower and voltage. The dimensions apply to all model number MaxPak Plus controllers and are not affected by the addition of any ofthe kit or factory modifications described on pages 12 through 15. Cabinet Enclosed Wall Mounted Drives Wall mounted NEMA 1 cabinet controllers are con- vection cooled through 15 hp at 230 volts, through 30, hp at 460 volts and through 60 hp at 550 volts, They are force ventilated by means of their own internal cooling fan in most higher horsepower ratings. Ineither case, air is drawn into the enclosure through siots in the cabinet, bottom and in the lower portion of the cabinet sides. Air is exhausted through internally shielded slots near the top of the cabinet sides. Air intake and exhaust open- ings are unfitered. Wall mounted cabinet dimensions, weights, and mounting layout are illustrated in Figure 14, 16 NEMA 4 and MENA 12 cabinet enclosed controllers are unventiated. Although an internal circulating fan may be employed to more air around within the con- fines of the cabinet to better utilize the cabinet skin and eliminate the possibilty of internal hot spots, no air ex- change is present with the atmosphere outside of the enclosure Floor Mounted Drives ‘The MaxPak Plus controller may be specifiedin either NEMA 1 or NEMA 12 free standing floor mounted cabi- nets. Ventilated cabinets draw cooling alr from slots in the lower portion of the cabinet door and exhaust air through slots near the door stop. Ventilation openings are unfiltered and air flow is either by convection or fan. forcing depending upon drive horsepower. Refer tofig- ure 15 for dimensions, weights and mounting layout of all floor mounted MaxPak Plus drive cabinets. Panel Mounted Drives The MaxPak Plus controller is available as an open panel drive for installation where mounting of the con- troller within a customer furnished enclosure is desired. Dimensions are provided by Figure 13. In these instances, the customer is responsible for assuring that, the maximum temperature within his enclosure remains. at or below 85°C under worst case operating condi- tions. When designing the enclosure ventilating system or when sizing a non-ventilated enclosure in which the MaxPak Plus is to be mounted, the eneray dissipation of al components within that cabinet should be consid- ered. MaxPak Plus controller dissipation is defined by formula on page 11 General Requirements Unless designed for special environments, the drive controller should be installed in an area where the fol- lowing conditions exist: 1. Ambient temperature does not exceed 40°C (104°F) for cabinet models, or 85°C (181°F) for chassis models. ‘Ambient temperature is not less than 0°C. (82°F). Altitude above sea level does not exceed 3300 fest (1000 meters) 4. Ambient aris clean and dry and free of flammable or combustible vapors, chemical fumes, oil vapor, steam, excessive moisture and dirt 6. Clearances around the equipment must be large enough to: a. Provide accessibility to the controls within the control cabinet for inspection, maintenance and module replacement.. Provide non-restricted flow of ar to and from the intake and exhaust openings. 6. Airfor cooling in sufficient quality and flow to avoid recycling the heated exhaust air back into the drive air inlets. ‘The operator’s control station may be conveniently mounted and wired to the controller as described be- low. WIRING THE DRIVE Important: Make certain that the input power to the Grive cabinetis ofthe correct voltage and frequency and, that the plant supply is of sufficient ampacity to support input current requirements of the controller. Refer to the Grive cabinet nameplate for correct input power in- formation. Ifthe correct voltage is not available, it will be necessary to use a transformer between the power sup- ply and the drive. PR Re Re FURNISHED WITHOUT A CIRCUIT BREAKER, SGN a eee ell reas RGR en adm Rela iatd oe RA elena elo BTU tlds on BASIC DRIVE INTERCONNECTIONS The drive will require electrical interconnection be- tween the drive cabinet and the motor, between the op- ¢erator’s control station and the drive cabinet, and be- tween the tachometer (if used) and the drive cabinet. Refer to the cabling diagram supplied with your drive or refer to the Typical Interconnection Diagram of Figures Gand 17. Besure that the cabling diagram widnumber corresponds to that indicated on the drive cabinet nameplate. NOTE: Potentiometer wiring must be done with twisted three conductor wire with at least two twists per Inch (Reliance part number 413329-T ‘or equivalent). Tachometer feedback wiring (where used) much be done with twisted two con- ductor wire with at least two twists per Inch (Re- liance part number 413329-S or equivalent). ‘These signals must be run ina separate magnetic conduit fo eliminate the possibility of noise pick- up. TRANSFORMERS Transformers must be connected in accordance with the transformer nameplate connection data. WIRE Care should be taken to see that all interconnecting Wiring is sized and installed in conformance with the “National Electrical Code” published by National Fire Protection Association, and other applicable local codes, Refer to drive cabinet and motor nameplates for cur- rent ratings. Preis IF YOUR DRIVE CABINET IS MOUNTED SUCH MLN MM omc NDOeY GROUND WIRE SHOULD BE CONNECTED TO MN hm Mon ma and SE Oe a Uae iret a a aMe one TN ae Ree Le Caan a uly ear) ae NI Meuse eee (ey ERTS UMNO Gree Us rots Co SU e NEMA 12 Horsepower . Open 240 VoR Armature | 500 Vol Armature | 600 VOR Armature 240 Vor | 500 vor] 600 vor | Panel /NEMAT |“Witnout ] with | Without | with | Without | wih Armature | Armature | Armature Fed | Feld | Fed | Field | Fed | Feld Regulator | Regulator | Regulator | Regulator | Regulator | Regulator sre] 8-1 | — | x | wao | was | wos [was | was | — = 10 20 x | woo | was | wos | was | was * 25 = | x | Wao | was | was | was | was | — = 8 30 = | x | woo | wa | wis | was | roe | — = 20 40 x_| wo | Foes | Foes | Foss | Foes | — = Pa = [40-60 | vy | wa | Fos | Foss | Foes | Foes | Foes | —FD6e 30 60 7 | yy | was | —" | Foes | Foss | FDes | FOSS 40~50 | 75-100 |100~ 125] y | waz 60-75 |125~150|150- 180] y | wae | — = = = = = 100 — 125 [200 — 250 [200 soo] z | Foes | — = = = = = ‘TABLE 8 - CONTROLLER ENCLOSURES 74 (1.3) yatt.43) uc) 261%, (67.3) Nw (2.06) oS ee (es Srexoans i lI I |] | eee li | | | | | | : nT a comme" | Mawel") | i> c | | | ae bwmotwmet woop HI | 0) ‘amouts | yy iea0 pe a sue. S9tRB\, venation 4 19 (33) | Fe’ pr (1.2) re = BOTENDS, | EESEEEEE-7 LL -weso—_] |» — | BEEEEEES | nerenence:o' mesr Ld wx PROJECTION = 1205 MOUNTING HOLES: 76.4 Panel Inches (CM) ‘Weight ste inches (eM) Weight Size | = c D] Pounds (Ke) x E Tey |Peundls (a) X | 9 (229) |10 (25.4) |21 (63.3) }22 (65.9)| 90 (40.8) hey ar sre be Se 90 (40.8) + [8209 io esa) [ar 20 fas erry] tao.61-9 00617) Was | 28 13 lavas nod) a8 os Z _|15 (38.1) ]16 (40.6) [30 (76.2) |31 (78.7)|__ 218 (99) was sos an [soars 1253) saat 218 (99) FIGURE 13 — OPEN PANEL DIMENSIONS FIGURE 14 — WALL MOUNTED CONTROLLER AND WEIGHTS DIMENSIONS AND WEIGHTS 1.0 (2.54) ie 71 son F180 (08) max conour _ Cg RK Se wom]! vekuaTion 68.0 (172.7) od 4 Va wae wre, otha mH 4 4 ws t 7 Lasred |e vas corm 120 1-90 9g) max, conourT k Ee L zs SUES as) nerepence- 0/5 soso WEIGHT: 600 LBS. (272 KG) FIGURE 15 ~ FD68 FLOOR MOUNTED CONTROLLER DIMENSIONS. 18S-PHASE PLANT POWER, -—1t—_ SOGIRUN ‘SWITCH ‘STARTISTOP ‘SWITCH SPEED POT. ‘CONNECTIONS ’AS ABOVE ‘STARTISTOP. ‘swiTcH ‘CONTROLLER ypu "AUXILARY PANEL, 6 rover [] rer2[]° veoraf] wu] [aru] foru U U T 18 —hae REGULATOR ‘ASSEMBLY —r (La ‘OPERATOR'S, CONTROL STATION 0st 2) ~ motor NoTEs: 1. Potentiometer wiring must be done with twisted three conductor ‘wie with atleast two twits or inch. (Reliance part number 1#13020-1 or equivalnt. Tachometer feedback wing (where ‘sed) must be done with twisted two conductor wire wi) at least two twats per inch (Reliance part number 413929-8 or equal ‘hese signals must be run in separate magnetic condut to em ale the possibly of noise pickup, 2. Tachometer connections (whan used with non regenerative Max- Pak Pus controllers) ae polarty insensitive when connected to 419 and 519. 8. Armature terminations onthe atiiay pane! may be via bus bar ‘connection or a power terminal board depending Upon controller Rorsepower and voltage. 4. At, 2,81, 82, F1 and F2 connections within the motor conduit, bok mist Bo made according tothe Instructions of 3076-8 sup: piled with te drive motor 1 assure proper dracton of motor rola tion and proper pola ofthe stabazing el, FIGURE 16 — INTERCONNECTION DIAGRAM FOR NON-REVERSING DRIVES When using 9C45 or 9051 operator's contol stations 19PHASE PLANT POWER, —— ‘CONTROLLER PANEL. wenagCruraz pesr3)° su] [aru] [aru T 7 To oPERUTOR'S CONTROL 18 218 ‘STATION WITH WIRES a FROM TTB 329 [aot TE} REGULATOR "ASSEMBLY "AUXILIARY PANEL OPERATOR'S, ‘CONTROL STATION ‘SWITCH FORWARD/REVERSE ‘SWITCH STARTISTOP. ‘SWITCH OPERATOR'S (CONTROL STATION ‘5082 SPcED POT. __ | connecrions "AS ABOVE x 408, PUSHBUTTON FORWARD/BEVERSE ‘Switch STaRT/STOP ‘SWITCH Ral Fa Sra] bk i MoTOR NoTES: 1. Potentiometer wiring must be done with twisted three con- ‘ductor wire wih at bast two twists por inch. (elanee part number 418520" o° equivalen). Tachometer feedback wing {where usec) must be done wit twisted two conductor Wire ‘With at last wo twists per inch (Aelance pert number 1413020-6 or equivalen). These Signale must be un in a sep- {arate magnetic conduit io ebminae the possibilty of nolse pickup. 2. Tachometer connections (when used with non-egenerative MaxPak Plus controllers) ae polar insensitive when con ected to 419.and 819, 3. Armature terminations on the auxiliary panel may be via bus bar connection ora power terminal board depending upon ‘controler horsepower and voltage. 4.1, A2, St, 82, F1 and F2 connections within the motor con- ‘uit box must be made according tothe msvuctons of {€.3076'3 supplied wr th arive motor to assure proper region of motor eatin and proper polarity of he sa ing fel FIGURE 17 — INTERCONNECTION DIAGRAM FOR REVERSING DRIVES When using 9646 or 8C52 operator's control stations 20SECTION 3 START-UP AND ADJUSTMENT PROCEDURES DANGER Be UL aU NIL PU) Reem Mi mea eM Nel eae MGM yl ere aL oo) Cee gma ez oe EQUIPMENT IS AT LINE VOLTAGE WHEN A-C POWER IS ooo LRM aga A a el PORN MN Ae een ou ae mt eat Maa au ARIE ALN DU aise aid All operation and adjustments to the drive must be made in strict conformance to the instructions given in this manual ‘This equipment has been operated under actual mo- tor load al the factory to check performance and adjust- ments. The start up and adjustment procedure below will locate any shipping damage, verify proper installa- tion and field wiring and provide a second check of ad- just ments. Start-up will proceed in the following sequence: Motor Checks Physical inspection of equipment Preliminary electrical checks with power off Final electrical checks with power on Initial agiustments Sequencing and operational check Before attempting to perform this start up procedure, the reader should be familiar with the general arrange- ment and function of the drive equipment (Section 1, pages 4 thru 9) and should verify that it has been installed and wired per the instructions of Section 2. While proceeding with the start-up, the reader should reference Figure 18 for assistance in locating compo- nents, jumpers and controls. NOTE: If, during any of the checks or adjustments pro- ‘cedures given below, itis not possible to obtain the cor- rect meter reading or proper operation, do the follow- ing: 1. Stop the drive, turn off and lock out all a-c input power, 2. Checkthatall connections arein strict conformance to the wiring diagram. 3. Consultthe troubleshooting section of this manual 21 TEST EQUIPMENT Although an oscilloscope is referenced in the text for use in making certain adjustments to high performance custom drives, standard performance equipment re- quires only a multimeter having a sensitivity of 20,000, ohms per volt (such as Simpson Model 260, Triplett ‘Model 630 or equivalent) to complete the startup proce- dure. ‘Amegger may be used to reliably verify the absence of inadvertent grounding of the motor. Refer to step 12, page 25 for the proper procedure in making these ‘checks. Failure to follow proper procedure with the ‘Megger may cause damage to the controller. Pers Peete Prey Ve SGU a0 Pam Mu eee Dei eee Rel Ml oan MURINE cto Pret ar rl MT CoN TES 219 AND 57 WILL PRESENT THE CONTROLLER PR Maasai earch PRU eo Rt RCOy Rae leg cesta Ue Raa AU ease ON Uy Pra sewed Meet Ul BE EXTREMELY FAST. RESULTING ACCELERA- SUP U DEN Mees ets DINU et Ae Nol PN cme Re MRL) Base Nao te LNA Ua BUR ae Rel mee Ene en Motel oe ea Ley TERMINAL 219 IN SERIES WITH THE LEADS TO pre a aioeTESTER CARD ‘A. The armature should rotate freely and be clear of any obstructions. The optional Tester Card may be present in your el drive. Ifo, itis located in the right hand most card slot in the regulator rack (Figure 18). Its use during startup will be referenced in the following procedure. A com- ‘The brushes should move easily in their holders and should make proper contact on the commu- tator. plete description of the function and operation of the C. The interior of the motor should be clean and tester card Is provided in Section 4, page 44. Table 9 ary. presides a leting of circuits tested by the tester and D. Connections should be tight. Ifa tester card is not present in your drive, it may be aan added at any time, or You may choose to' make the checks as noted in the text and/or Table 9 with a separate aeRO Lele eal led voltmeter having a sensitivity of 20,000 ohms per volt by baat ES I aU making connections to the appropriate terminals. beau Daeg A ened as Cele eas ‘The following table shows the circuit being checked and cor- Maal "2 ssl pt rags endings bse eto nal (output commot) ere provided for Ob- [ering ne same cut points wits soperete netument lithe MaxPak Plus controlleris being used with amo- All voltages listed have a tolerance of = 10%. torotherthan a Reliance Super RPM machine, read and Test ‘comply with the instructions supplied with it before pro- Position | Terminat_| Scale Indication ceeding 1 | 86-57 | 15v [Positive Fower Supply 2. Couple the motor securely to its intended load. 2 | | Noone Peat Suey PHYSICAL INSPECTION OF EQUIPMENT ee 4+ SV io av (ar T00%) Before operating the equipment DISCONNECT AND poe pe pS LOCK OUT ALL INCOMING POWER and perform the Bea a eon following checks: 3 near Current Ln 1. Carefully inspect the controller for physical dam- Refrence Input age. Ascertain free operation ofall switches, relays, auxiliary contacts and contactors. o_[_ naw [a] Boa ig gO O10 2, Visually inspect intemal wiring for loose or broken tara Go ‘connections or damaged wires. 7 326-57 | 15V ‘Speed Relerence 3. Visually check for damaged components. 3 [ai a7 [av | Walort2op Foesback PRELIMINARY CHECKS WITH POWER OFF 9 ‘219-87 | 15v Current Feedback 1. Check to see that the plant power supply to the con- Oto +6.67V (At 100%) troller is of the correct voltage and frequency and 10 119 = 57 ev ‘Voltage Feedback that the plant supply branch from which the drive is Sto ~V to be operated is of sufficient ampere capacity to | =a |B | Tid pond Rferone supply drive input current requirements as listed in 10 +50 Table 5, page 10. Compare observed plant line pa- Of [a8 a7 a Tester Opt rameters against those specified on the cabinet Sav ea rarablates TABLE 9 — TESTER FUNCTIONS: 2. Check to see that the transformer (when used) is connected to give correct voltage to the input of the controller. MOTOR CHECKS 3. Verify that the controller has been properly installed 1. Carefully read and comply with the Operation and Interwired per the instructions of Section 2. Section of Instruction Manual C-3076-3 describ- 4. Inspect the regulator rack and check that each of ing the Super RPM d-c motor. In particular, note the five cards (six, ifthe optional tester has been fur- the following nished) is firmly Seated in its connector and com- pletely fastened into place by means of its two fas tening screws. From left to right, regulator cards should have alpha notation and bill of material (BIM) identifying numbers per Table 10. 22‘Alpha Regulator Card Notation | ByM Number Siatic Sequence 3800 | 0518742 Controller Overload and owe | 0526082 Voltage Comparator Current and Voltage cvra | ostest-s Transductor Current Loop Driver cuk | 051865-9 Controller Regulator cror | ostest-s Tester (Optional) tsta_ | _ostet-1 TABLE 10 ~ STANDARD CONTROLLER CARD COMPLEMENT Verification of the above card compliment identifies the drive regulator as.a “standard performance” regula- tor. As such, drive adjustment (beginning on page 26) as described for'standard drives” will apply and adjust- ‘ment can be completed with nothing more than a mutt meter as specified above. Hf, however, one or more of the above listed cards displays a “modified” bill of material number, differ- ent than those listed above and affixed to the card faceplate via a typed paper label, then the adjust- ment procedure for that modified card will be per this manual as modified or addended by specific instructions supplied with supplemental sales order documentation. 5. Loosen the two phillips screws securing the power module cover three or four turns, lift and drop the Power module cover into the service position. Check to see that all six gate cables are firmly at- tached to their respective gate coupling printed cir- cuit board. Check their orientation according to the connection diagram affixed to the inside of the pow- er module cover and be sure that the red and white color coding of each cable matches the color code lettering on the gate coupling boards. Close and re- secure the power module cover. 6. The CVTG card contains a jumper allowing one of nine possible current feedback scaling ratios. Since properly scaled current feedback is absolutely es- sential to assure proper coordination of motorther- mal overload protection, current limit, overcurrent shutdown (IET) and IR compensation (when used), this check should be made very carefully, especially when the controller is being used to operate a driv- enmotor of a lower horsepower than the nameplate horsepower rating of the controller. If not set prop- erly, all of the above drive controller and motor protective circuits will be rendered invalid. Remove the CVTG card from the rack and check the jumpered *M" value to that provided in Table 11. ‘The “M’ value must be set for the proper motor horsepower. 7. Replace and resecure the CVTG card. NOTE: The controller should never be used to ‘operate a motor of higher nameplate horsepow- er than the controller. Further, due to the charac- teristics of the current transformers and range of current feedback calibration allowed by the CVTG circuitry, there Is also a lower limit of mo- tor horsepower that can be reliably operated by the controller. Minimum allowable motor horse- power for each MaxPak Plus controller rating Is. listed In Table 12. Proper Vale one gy | ziOvoR | —sdvoR | oo VOR Amature | Armature 7 735 = 3 a | ate re ie | te ‘ to | bar 8 | 3m 3 : 99 2 te | its & tse | ise & ter : é Bs 2 & zx | igs & fe | 1s 4 a eZ 5 ao | 1 a a a i» a | ast ‘2 ss 5 ‘3 2 2a '@ = a ‘= = = mo = 2a ao = = a Zea 5. = = Dependent upon power unt supped. Foner un en) B0129-1RE or eO1420-4SE Using loge SONS Sete 1 —Powsrunt pt number (9) 60}420R@ or 01420188 using dlscype SCR’s: Set M = 1.00 TABLE 11 — CURRENT FEEDBACK CALIBRATION 8. Check that the armature voltage feedback connec- tions are made to the appropriate faceplate termi- nals of the CVTG card. Wire number 45 (black) should be attached to the COM terminal, with wire 47 (Orange) attached to match the armature output voltage of the controller.‘Controller | Minimum Allowable Motor Horsepower 9. If built as a Reliance model number controller, the Namepioto MaxPak Pluss shipped as a voltage regulator. so | 240 Volk ] 500 Voit | 600 Voit desired, it may be easily converted toa speed regu- Aamratize | EAccaatixe 9 | panTTaene) lator by the addition of a motor-driven tachometer 5 3 5 = and jumper reconnection within the controller itself. 72 3 5 - If built per customer specifications, the controller 2 @ 8 = may ship as either a voltage or a speed regulator. 2 6 2 = if operation as a voltage regulator is desired, 3 2 30 = ccheck for the presence ofa jumper between term a ie a = nals 157 and 919 on terminal board 278 (located at i 2 wy 5 the right hand end of the regulator assembly). Also. 50 2» 40 | verify presence of a jumper between terminals 119. % 2 * s and 619 of 2TB. 75 20 40 - If operation as a speed regulator is desired, the 0 — = 40 above referenced 2TB jumpers between 157 and 109 ‘00 “ a 919 and between 119 and 619 must be verified as + 00m) a a being removed. Tachometer feedback should be ie a rs a connected to 278 terminals 419 and 519. 9 = | wm | 2 In ether case, check for presence of factory 20 = es 22) installed jumpers betwoen terminals 57 and 12, 244 250 _ 200(2) — and 344, 24 and 667,18 and 118 and from 99 to 100. ES = S 2401 See Figure 18 for their locations. m ee 10 tp miairum 10. If the drive is ta be operated as a speed regulator, Power unit part number (P/N) 801429-1SE: 20 hp minimum determine, either from the sales order wiring dia —Power unit part number (P/N) 801429-RB: 20 hp minimum gram or tachometer nameplate information, the —Power unit part number (P/N) 801429-SB: 40 hp minimum poe ‘output voltage delivered oe peed ot minimum hp’ are eloweble. Consult the tctory tor speed, Connect jumpers on terminal board 2TB as (2) Lower minimum np’ oe allowable, Const the factory fo noted in Table 13 to provide proper scaling of the tachometer feedback voltage into the regulator. ‘TABLE 12 ~ MINIMUM ALLOWABLE MOTOR HORSEPOWER s o c a ie T 3° Le geo It ° Ro i 278 g ie | : y ; a GAIN, 8 wason | SMB! Sar] wars) (orrionaty = 0(18)| COMPARATOR ° suwon | pase 20 | Ovs)| Osea.| aaTe T _ eto I, a au. ei | 7 a Be] neser De] | nen [a O Ee wee | reansronwen| 79 ca zs fsoov]| ° to] cbs” ‘OVERLOAD faeov|| SAIN uM fal | 10 ° a Lo ee Tee $18 sm foster: came bene sists eames ° Te ° fo ° TDs] es| see] EF SERRE EPR ar JUMPERS SHOWN ARE SUPPLIED AS STANDARD ON MODEL NUMBER DRIVES FROM THE FACTORY FIGURE 18 — REGULATOR ASSEMBLY 24Tachometer Voliage Sealing ‘Nominal Tachometer Voltage (A-C oF D-C) | Jumpers Required (Remove Jumper 4 100% Motor Speed_| " From 157 % 919 and 6190 119) 226v — 250V | None 156 225V [Jumper 919 10 610 Toov—165V [Jumper 71910 619 sv 90 Jumper 81910 619) av ev Jumper 919 10 819 and 71910 619) ev — 46 Jumper 919 19 719 and 819 10 619) TABLE 13 - TACHOMETER VOLTAGE SCALING 11. Check for grounds in the magnetic control circuits. DO NOT USE A MEGGER TO PERFORM THIS CHECK SINCE SOME ELECTRONIC CIRCUITS, WHICH MAY BE CONNECTED TO THE TERMINAL BOARD WOULD BE DAMAGED. a. Connectoneohmmeterleadtothe metal control cabinet b. Set the ohmmeter scale on R x 100,000. ©. Touch the other chmmeter test probe to each terminal on terminal board number two (2TB) lo- cated on the right hand side of the regulator por- tion of the power conversion panel in the control unit. fa reading to ground on any terminalisless 4. Consultyour wiring diagram to analyze location of possible fault. Go overthe circuit, represented by the grounded terminal, to ascertain whether there exists any breaks in insulation of the wir- ing, or any grounded components. e. Always use an chmmeter for checking grounds in tachometer circuits. 12. Checkrotating equipment for grounds. fa megger Is used, make certain that all leads are discon- nected between the rotating equipment and the control cabinet. This will prevent damage to electronic circuitry (excites and their associated circuits, etc.) due to the high voltage ‘generated by the meg FINAL CHECKS WITH POWER ON ers =e A OR Ma et ADJUSTED AND SERVICED BY QUALIFIED ia rem NN a TIGR oa to Kel Ve Rg ae ae PSUR olan eae ee Ac AU d aN ou Ri al aks ALL PHASES OF THE A-C POWER LINE MUST PSPS cua anes Pag ay Gane EAD Ue Datta syia than 100,000 ohms, a ground condition exists in this circuit INDICATOR FUNCTIONS ‘Status Major Loop The major loop is enabled when this indicator is on (unless the jumper Is removed from Indicators |On (1S) 244 to $44 keeping the major loop in standby). The major loop is in standby when this, indicator is of Minor Loop — The minor loop is enabled when this indicator is on. The minor loop is in standby when On (2S) "this indicator is oft. ‘Arm. Voltage Armature voltage is present when this indicator is on. Armature voltage is zero when Comparator _ this indicator is oft. Phase Seq. Line phase sequence is correct when this indicator is on. Drive will not start unless ind Cator is on. Ifindicator is off phase sequence is incorrect, line voltages are unbalanced, or line fuses may be blown. (Reverse any two lines to reverse phase sequence: Check fuses and line to line voltages) Field Supply Field supply is working when indicator is on. Field supply not working, or field fuses blown when indicator is off Drive will not start unless indicator is on. Gain Limit Minor loop ampiifier is overloaded when this indicator is on. Occasional fickering of this light may occur during normal operation. If indicator is on continuously, current gain is too high, or minor fooa is not working properly. Fault [Overload Overload fault circuit is tipped when this indicator is on. Indicators | Fault Drive will not star if indicatoris on TET Fault IET fault circuits tripped when this Indicator is on. Drive will not start it indicator Is on. NOTE: Overioad IET indicators remain on until fault circuits are reset. In auto reset mode fault circuits and fault indicators reset automatically after approximately 3 se- Conds. In manual reset mode reset occurs when reset button is pressed TABLE 1 ~ INDICATOR LIGHTS. 251 DANGER SR UM eGR ome Ue} Ao MG aR GS eM AUP Cle ASC Ce) oa UG DUS a ete PM chn sar ase a ere DL PUN Verify Proper indicator Light Status With power now applied, verify the status of the regulator card faceplate lights as follows: Phase Sequence ‘The light marked “phase seq.” on the face of the OLVC card should be it. If itis not, remove power tothe drive cabinet and interchange any twoa-cline power wires feeding the drive controller input. Re- energize the drive and verify the “phase seq.” light asi. This indicates proper phase sequenceinto the controller. The drive controller will not respond to any of the operator controls unless proper phase sequence is provided. Field Supply The light market "Field Supply" on the face of the OLVC card should be lit, thus indicating the pres- ence of excitation voltage at the output of the field supply. This indicator, if extinguished, indicates a lack of field excitation voltage due to a field supply failure, or open fuses 4FU or SFU. It does not nec- essarily indicate a complete motor field circult. Major Loop On 1S Minor Loop On 28 ET Fault Armature Volt Comp Gain Limit ‘These indicator lights, located on the faceplates of the SSC, OLVC and CLDK cards should all be extinguished at this time, Table 14 provides alisting of each of the indicator lights, its operation and meaning, Verify Fan Rotation Ifthe drive is equipped with a power module fan, check to see that airis being forced up into, and out the top of the power module. Ifthe drive is equipped with a cabinet fan, check to see that air is drawn in the bottom louvers and forced out the top louvers. Verity Field Current Using a d-c clamp-on ammeter, verity that motor field current is flowing in the motor field circuit. This current should be within 20% of the field current stamped on the motor nameplate. Stop Remove power to the drive and read the adjust- ment procedure before attempting to adjust the drive. Overload Fault 26 START-UP AND ADJUSTMENT PROCEDURE Pwr ae aOR aR ty ADJUSTED AND SERVICED BY QUALIFIED Faso of MUNN laa a CRT mis Melo leg tele as ERATION OF THE EQUIPMENT AND THE HAZ- PCO SET eh wo ST Cig as Ce opie CER Cem Mase DRIVE CABINET BEFORE ITIS SAFE TO TOUCH UN at act Tua SS VANES NLR Aa) RAN aay RN Rel eT cae ae Aol a Sor CMR CUM SNe Coe AS GR Ske ond Read the entire adjustment procedure before at- tempting to ad just the drive. Also refer to wiring dia- grams supplied with your drive. Allow at least 30 mit Lutes warm-up time beforemaking theadjustments. With, incoming power to the drive, but the drive stopped, the ‘motor fieldis excited. During the 30 minute warm-up pe- riod, the motor field reaches operating temperature. All adjustments should be made with the motor coupled to, its intended load. fan adjustment reference source is not readily avail- able, the signal from the tester card (TSTB) may beused, as follows: a. Sot the selector switch on the tester to OFF. b. Set the range switch to the 18V position, c. Remove any wires connected to terminal 326 on. terminal board two (2TB) and connect a jumper between terminals 326 and 226, d. The test signal voltage is then the speed refer- ence. Whenever the test signal switch is de- Pressed in the (+) direction, the reference volt- age can be read on the 15V meter scale of the tester. CAUTION: Do not plug a card into (or remove it from) its socket without first removing power from the panel (except for tester card which may be removed while the drive is in operation provided the selector is In the OFF position (posi number 12). CURRENT RATE ADJUSTMENT On standard performance drives the Current Rate control must be set fully CCW. Onhigh performance custom drives the Current Rate setting is indicated by documentation supplied with the system,CURRENT GAIN ADJUSTMENT (On standard performance drives the Current Gain control must be set fully CCW. On high performance custom drives the Current Gain setting is indicated by documentation supplied with the system. ‘On custom drives where no prior information is avail- able, the Current Gain may be set by observing the step response of the current loop, according to the proce- dure below: NOTE: The digital firing circuithas dynamic characteris- tics different than analog driver circuits under condi- tions of excess gain. Excessive gain does not cause in- stability and uneven firing as is characteristic of analog firing circuits. Excessive gain will cause saturation and non-linear performance of the current loop, and should be avoided. The Current Gain control settings must be established by observing the step response of the cur- rent loop, DANGER page OCLs aa yg ager ed ees rane N I ata) Pe me ter ae ore eUEU ETE Aire ean me eens 4. Tumine power off, Lock the armature shaft. Dis- connect the motor field. (Do not disconnect the | field by removing the fied supply fuses, as this will cause a field loss indication, and lock out the start logic) 2. Remove the jumper between terminals 244 and 344 (See Figure 18) of the bottom terminal board on the Tegulator rack. This keeps the major loop regulator inthe standby mode. 3. Connect an oscilloscope from terminal 219 to 57 to monitor the current feedback signal (or connect the oscilloscope to the optional tester output pins, with the tester set to position 9 with a 18V range) 4, Connectaswitched adjustable testreference signal (Oto +12V) to the major loop test input, terminal 6. (The test reference from the optional tester card may be used by jumping terminal 226 to terminal 6) 5._ Initially set the Current Gain fully CCW. 6. Tum on line power. Start the drive and increase the test reference to a voltage corresponding to 100% ofrated current. (The test reference voltage fromthe optional ester can be read with the testerin the “oft” position.) NOTE: The gain rom the terminal 6testinputto cur- rent feedback voltage is unity with the major loop in standby. Standard scaling is 6.7 volts for 100% cur- rent. On custom drives consult system documenta tion to determine the current feedback scaling, a7 7. Step the reference from 0 to 100% while observing the current feedback waveform on the oscillo- ‘scope. Increase the Current Gain while continuing to observe the step response, until a slightly over- damped response is obtained. 8 Step the reference while observing the Gain Limit, indicator light on the faceplate of the CLDK card. If necessary, reduce the gain until the Gain Limit indi- cator stays off while the reference is stepped. (It is acceptable if the Gain Limit indicator flickers occa- sionally, but it should not be on continuously.) NOTE: Itis advisable notto set the Current Gain any higher than necessary o achieve the desired pa mance. 9. Stop the drive. Turn off the power. Remove the ar- mature lock. Reconnect the field. Replace thejump- er from 244 to 344, Disconnect he test reference, or jumper from terminal 6 to 226. CURRENT LIMIT ADJUSTMENT On standard performance drives a feedback scaling of 6.7 volts is used for 100% current. Current limit is set, at 150% at final test. The setting of the current limit po- tentiometer required to achieve 150% current limit is, noted under the "Panel Test” column of the potentiome- ter adjustment table. This table is mounted on the Con- troller's power module cover just above the regulator assembly. The current limit maybe reduced from this, standard setting if desired. On custom drives a different feedback scaling may bbe used. Consult system documentation to determine the scaling used, and the corresponding Current Limit, control setting, When desired, the Current Limit may be readjusted by the procedure below. In all cases, however, the Cur- rent Limit should not be set above a value correspond- ing to 10V of current feedback. The major loop regulator may saturate if-a higher current limit setting is at- tempted. Pes a gee eae a ee ered ees ta Ne actor) Dore re Moe arte mca UE ATS ies eee mae Een arc NOTE: The following adjustments must be made quickly enough to avoid tripping the overload cuits. Do not exceed 150% current or 10V for 1 ute (for standard OLVC trip characteristics.) 1. Turnline power off. Lock the armature shaft. Discon- rect the motor field. (Do not disconnect the field by removing the field supply fuses, as this will cause a field loss indication, and lock out the start logic.)10. Remove the jumper between terminals 244 and 344 of the bottom terminal board on the regulator rack. This keeps the major loop regulator in the standby mode. Connect a D-C ammeter in the armature circuit to measure armature current. (Armature current can also be determined by measuring the current feed- back voltage from terminal 219 to 57. The optional tester card may be used in position’9 with a 15V range. The standard scaling is 6.7 volts for 100% Current; 1Ovolts for 150% current. On custom drives consult system documentation to determine feed- back scaling, Connect an adjustable test reference signal (0 to +12) to the major loop test input terminal 6. (The test reference from this optional tester card may be used by jumpering terminal 226 to terminal 6.) Initially set the current limit control fully CCW. ‘Tum on line power. Start the drive and increase the testreference to a vollage corresponding to the de- siredlimit point. (The testreference voltage fromthe tester can be read withthe testerin the off position.) NOTE: The gain from the terminal 6 testinputto cur- rent feedback voltage is unity with the major loop in standby. Standard scaling is 6.7 volts for 100% cur- rent. On custom drives consult system documenta tion to determine the current feedback scaling ‘Tum the current limit control CW, noting that arma- ture current increases othe value corresponding to the test reference input. ‘Turn the current limit control CCW until the current just begins to decrease. The current limit threshold is now set at the test reference point. Check the adjustment by increasing the test refer- ence noting that the armature current limits at the desired value. Stop the drive. Tum off power. Remove the shatt lock. Reconnect the field. Replace the jumper from 24410344. Disconnect the test reference, orjumper from terminal 226 to terminal 6. ‘The actual current limit point during normal drive operation may vary slightly from that set by the pro- cedure above. The adjustment may be trimmed slightly during actual operation of the driveif greater precision is required. ‘STABILITY ADJUSTMENT per at On standard performance drives stable major loop formance is obtained by setting the Stability Control 3. Improved performance may be obtained in se- lected cases by an adjust ment above or below this set- ting 19. This may be determined by trial and error. Observe the major loop feedback signal with an oscilloscope fron ym terminal 319057 (or use optional tester in position 8 on 6V range and connect scope to tester output pins), while changing the major loop reference input, to deter- ine response characteristics. Onhigh performance custom drives, documentation supplied with the system will indicate the correct Stabil- ity setting. This setting depends on the nature of the driven load, and the optional components (if any) used, on the Controller card. IR COMPENSATION This control should only be used with voltage regula- tor systems, never with speed regulators. The control is, only active when a jumper is added between terminals 219 and 567 of the bottom terminal board of the rack. Standard controls are shipped without his jumper installe 1 2. 3. 4 Initially set the control fully COW. Start drive and run unloaded at rated speed. Load the drive to full load current. ‘Adjust the IR compensation clockwise until the de- sired compensation is achieved. Do not adjust for ‘speeds higher than the unloaded speed. NOTE: Setting the IR Comp. too high may cause it stability. Adjust control CCW if this occurs. MAX. & MIN. SPEED (VOLTAGE) ‘These controls interact and must be adjusted alter- nately n an iterative manner untilthe correct adjustment, is obtained. Initially set both controls fully CCW. ‘Max Speed (Voltage) 1 2 Set the speed or voltage reference fully CW. Start drive and increase reference slowly fully CW. CAUTION: Do not allow drive to exceed rated max. speed. Make sure no machine damage will result. With the reference control fully CW, increase the Max. Speed control untilthe driveis operating atthe desired maximum speed point. (if correct adjust- mentisnot obtained check majorloop feedback cir- ‘cults for proper scaling resistor, Engineered drives are shipped with a 301 ohm resis- tor jumpered between terminals 20 and 326. Min. Speed (Voltage) 1 2, Set the speed or voltage reference fully COW. Start drive and turn Min. Speed control CCW until the desired minimum speed point is reached. Repeat the adjustments ofboth Max. Speed and Min, ‘Speed controls untilboth controls are setfor the desired, speed characteristics. ACCEL. AND DECEL. RATE These controls are only enabled when a jumper is used betwoen terminals 24 and 667 on the bottom ter- minal board of the reguiatorrack. These controlsare set by tial and error, noting the resuitant performance, and adjusting as required.Initially set both controls fully CCW (slowest rate) 2. Start drive and turn the speed or voltage reference control slowly CW until drive is operating at rated speed. Note the reference control setting. Stop the drive, Accel. Rate Leave the reference control set for rated speed and start the drive. Adjust the Acceleration Rate Control CW nti the desired rate is obtained. The rate can be mea- sured conveniently with astop watch atthe slowerrates. ‘An oscilloscope or chart recorder will be required to set the faster rates accurately. Monitor the major loop feed- bback signal to determine the acceleration interval. (Use the tester card in position 8 with a 6V range). Decel. Rate Run the drive at rated speed. Tur the reference con- trol quickly CCW to initiate deceleration. Adjust the De- celeration Control CW until the desired deceleration, rate is obtained. Monitor the actual rate as described above for acceleration. NOTE: The motor must be loaded such that it does not, coast during the deceleration period. In cases where controlled deceleration is not significant to the applica tion, the Decel. Control should be set fully CW. The mo- tor will generally coast during the deceleration interval {or this setting, A slight interaction may occur between the Accel and Decel. Rate circuits. Trim both adjustments to final, value after readjustment of either control. JOG SPEED 1. Set the Jog Speed control fully CCW. 2, Jog the drive. 3. Adjust the Jog Speed control CW until the desired jog speed is obtained.SECTION 4 DESCRIPTION OF OPERATION MOTOR ‘The Super RPM d-c motors furnished for adjustable speed service as either a straight shunt or stabilized shunt machine which provides constant shaft torque capability from zero to base speed when provided with fixed shunt field excitation current and a source of ad- justable d-c voltage for armature power. The fixed shunt field provides aconstantstrength magnetictield against which the armature-induced field can react. Armature (and shaft) speed is then controlled by varying the ter- ‘minal voltage to the armature. Motor speed is nearly proportional to armature terminal voltage. Armature currents drawn as needed to provide mo- tor torque. It is approximately proportional to load torque at the motor shaft plus a small amount required to support motor losses. With the motor’s operational needs so described, the motor controller must consist of an adjustable voltage armature supply, a fixed potential shunt field exciter and aregulatorto control and adjust armature voltage under varying torque and speed requirements, Refer to manual D-3076-8 fora more detailed discus- sion of motor operation. ARMATURE RECTIFIER The armature rectifier (power unit) used in the Max- Pak Plus controller is a conventional three phase, full controlled, full wave bridge. Itis shown schematically in, Figure 19. Using six thyristors, the power unit provides adjustable d-c voltage for the motor armature circuit by phase-controlled-rectification of 3-phase a-c plant pow- fr. Each of the thyristors is “turned on” by pulsing its gate at a point in the a-c input power cycle when its anode potential is positive with respect to its cathode. Under these conditions, the application of alow pow- er gate pulse approximately 350 microseconds in dura- tion, will cause the thyristor to conduct for as long as its anode remains positive with respect to its cathode. ‘Anode-to-cathode polarity reversal, brought about by ‘the sinusoidal nature of the incoming plant line, will commutate or “tu off the thyristor. The relative timing ofthe gate pulse with respect o the a-c plant supply will dotermine the conduction angle (relative conduction time) ofthe thyristor (and of te bridge) thus controlling the average d-c output voltage from the bridge to the motor armature. Firing the thyristor gates early in the positive half of the incoming sinusoid wil allow itto con- duct for a relatively long time until commutated off by the line, thus producing relatively high average voltage 121 a jt Puabe c ott p28 recriricn Sse 282 MODULE?) Goi aes | te REGULATOR a FIGURE 19 — FULL WAVE BRIDGE CONFIGURATION 30to the motor armature. Firing thyristor gates late in the positive half cycle will allow only short periods of con- duction before commutation, thus producing low values, of average d-c output voltage to the motor armature. Each pair of bridge thyristors (the upper and lower thyristor connected together to the same input a-c line) are mounted along with their dv/dt RC network, metal oxide varistors and a gate coupling board into a heat- sink assembly referred to as a phase rectifier module. Removable as a unit, each of these interchangeable phase rectifiers forms one-third of the power rectifier. ‘The mechanical design of the phase rectifier modules allows utilization of the heatsinks as electrical as well as thermal conductors. Atypical phase rectifier module ut- lizing disc-type thyristors is shown in Figure 20. FIGURE 20 — PHASE RECTIFIER MODULE GATING SEQUENCE AND CURRENT FLOW Referring to Figure 18 of the basic full wave rectifier configuration; when phase C (183) is positive with re- spect to phase B (182), current will flow through thyris- tor #6, through the load and thyristor #2, when these thyristors are gated ON. When phase C (183) is positive with respect to phase A (181), current will flow through thyristor #6, through the load and thyristor #1. when these thyristors are gated ON. Note here that thyristor +#6is gated ON twice, 60 degrees apart, once with thy- ristor #2 and once with thyristor #1. 31 When phase B (182) is positive with respectto phase ‘A (181), current will flow through thyristor #5, through the load and through thyristor #1, when these thyristors are gated ON. When phase B (182) is positive with re- spect to phase C (183), current will flow through thyris- tor #5, through the load and through thyristor#3, when these are gated ON. Note here that thyristor #5 is gated ON twice, 60 degrees apart, once with thyristor #1 and once with thyristor #3. When phase A (181 )is positive with respectto phase (183), current will fow through thyristor #4, through the load and through thyristor #3, when these thyristors, are gated ON. When phase A (181) is positive with re- spect to phase B (182), current will flow through thyris- tor #4, through the load and through, thyristor #2, when these thyristors are gated ON. Note here that thyristor 4#41is gated ON twice, 60 degrees apart, once with thy- ristor #8 and once with thyristor #2. The above description of thyristor gating canbe sum- marized by the following table 15. Thyristor Gated Relative Line Conditions e82 $133 — 182 61 $183 — 181 Bat +182 — 181 5&3 +182 — 183 483 iat — 183 482 +181 ~ 182 TABLE 15 — THYRISTOR GATING SEQUENCE, POWER CIRCUIT FAULT PROTECTION Abalanced, coordinated fault protection system isin- corporated by the following: 1. Bolted fault protection is obtained through the use (of current limiting fuses in the a-c lines, having a fault current interrupting rating suitable for a-c ‘source capacity as noted on page 10 of this manu- al. 2. The functions of limited current fault protection and instantaneous peak overload conditions such as might arise from a regulator failure, a control se- ‘quencing failure or a mechanical jamming of the motor shaft, is coveredby ainstantaneous electron- ic trip (EM). ‘An optional a-c line breaker is recommended to provide branch circuit feeder protection to meet NEC requirements. 3. Themotoris protected against sustained overloads bya sold state overoad trp cuit within the regu: lator.4. Peak operating overloads such as those encoun- tered on acceleration, shock loading, etc. are han- dled by; a fast acting current limit circuit utilizing a minor current regulating loop which experience has proven to be the most stable and fast acting type of current limit circuit obtainable. Motor current is sensed for use with protective fea- tures2 through 4 by apa ofincoming line currenttrans- formers. Since only two thyristors (one upper, one low- er) are conducting at any given time, only two of the three input power lines are ever simultaneously con- ducting current. Thus, instantaneously, a-c line current in any conducting line is equal to d-c armature current. On an average basis, la.crms= -85 lec avg SEMI-CONDUCTOR TRANSIENT PROTECTION Each thyristor in the power bridge is individually pro- tected by an R-C circuit and a M.O.V. surge suppressor, connected directly across the thyristor on the same veatsin! The R-C networks also provide dv/dt protection for the bridge thyristors. Ferrite core reactors are provided in the legs of the power bridge. They provide di/dt limitation matched to thyristor di/dt capability, and, in conjunction with the R-Ccircuits across each thyristor, provide high frequen- cy line transient attenuation. OTHER POWER UNIT HARDWARE An R-C network is connected across the d-c output bus. This network allows thyristor holding current to flow at no load, and prevents “ringing” of the armature circuit under certain conditions. ‘Armature power is delivered to the motor through an armature loop contactor, Figures 21 and 22 illustrate the location of power unit ‘components. FIGURE 21 - CONTROLLER POWER UNIT 32 FIGURE 22 — POWER UNIT - TOP VIEW FIELD SUPPLY ‘The field supply is a constant potential rectifier, con- sisting of three diodes (two rectifiers and one back diode). This arrangement allows generation of 150 volts d-

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