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RELIANCE ELECTRIC
AUGUST, 1982
INSTRUCTION MANUAL D 3937
RELIANCE ELECTRIC
INSTALLING, OPERATING, and MAINTAINING
and MODIFICATION KITS 1
SECTION 1
INTRODUCTION
1.0 General
- This manual familiarizes the user with
the three phase, MinPakt Plus D C VKSr drive control
ler. (Refer to Figure 1.1.) It describes assembly and
POWER
ON/OFF
CIRCUIT
BREAKER
LOCAL OPERATORS
CONTROL
SUPER
RPM
D C MOTOR
Figure 1.1 MinPak Plus Controller and Super
RPM Motor
installation procedures, gives a general overview of op
erations, and contains information on troubleshooting,
maintenance, the ordering of spare parts, and specifi
cations.
The manual should be read before performing installa
tionor start up activities. Also, there are certainfunda
mental warnings which must be kept in mind at all
times. These are:
DANGER
THE DRIVE SYSTEM SHOULD BE INSTALLED,
ADJUSTED AND SERVICED BY QUALIFIED
ELECTRICAL MAINTENANCE PERSONNEL FA
MILIAR WITH THE CONSTRUCTION AND OP
ERATION OF ALL EQUIPMENT IN THE SYSTEM.
PERSONAL INJURY AND/OR EQUIPMENT
DAMAGE MAY OCCUR IF INDIVIDUALS ARE
NOT FAMILIAR WITH THE HAZARDS RESULT
ING FROM IMPROPER OPERATION.
DANGER
CONTROLLER EQUIPMENT IS AT LINE VOLT
AGE WHEN A C POWER IS CONNECTED TO
THE POWER UNIT IN THE MINPAK PLUS CON
TROLLER. THUS A C POWER MUST BE RE
MOVED FROM THE UNIT BEFORE IT IS SAFE
TO TOUCH INTERNAL PARTS OF THE CON
TROLLER. PERSONAL INJURY MAY RESULT
UNLESS POWER IS REMOVED.
WARNING
THE NATIONAL ELECTRICAL CODE REQUIRES
THAT AN N.E.C. APPROVED CLASS K 5 FUSED
DISCONNECT SWITCH BE USED AHEAD OF
THE CONTROLLER AND POWER TRANSFORM
ER (IF USED) ON THE INCOMING A C LINE.
PERSONAL INJURY MAY RESULT IF AN EASILY
ACCESSIBLE MEANS OF LINE VOLTAGE DIS
CONNECTION IS NOT PROVIDED.
WARNING
DO NOT OPERATE THE MINPAK PLUS CON
TROLLER ON POWER SUPPLIES WITH AVAIL
ABLE SHORT CIRCUIT CURRENTS IN EXCESS
OF 5000 AMPERES. DAMAGE TO EQUIPMENT
AND PERSONAL INJURY MAY OCCUR. 2 3
SECTION 2
GENERAL CONTROLLER INFORMATION
2.0 General
- The Minpak Plus D C VKS drive con
troller may be applied to three phase d c drive applica
tions with ratings within the following ranges:
D From 3 to 20 hp with a 230 VAC, 50/60 Hz input
voltage
D From 3 to 40 hp with a 460 VAC, 50/60 Hz input
voltage
The controller provides power conversion and control
circuits which convert the a c line voltage into adjust
able d c voltage in order to effectively control the drive
motor.
The Minpak Plus controller is provided, as standard, in
a NEMA 12 enclosure intended for wall or panel mount
ing. A three pole power on/off circuit breaker is standard
with a door interlock.
The operators controls can either be local and door
mounted or a remote control station is also available.
The three phase MinPak Plus is Underwriters Laborato
ries (U.L.) listed and Canadian Standards Association,
(C.S.A.) certified.
Optional Modification Kits conveniently expand the ca
pability of the three phase Minpak Plus.
The controller's features are summarized in Table 2.A.
2.1 Operator's Control Station
- For proper op
eration of the Minpak Plus controller, it is necessary to
use an Operator's Control Station. (Refer to Figure 2.1.)
The Operator Stations allow the tailoring of control func
tions for the application. These may include:
D SPEED control potentiometer
D TORQUE control potentiometer
D AUTO/MANUAL selector switch
D RUN/JOG selector switch
D FORWARD/REVERSE selector switch
D START/STOP selector switch
There are two basic configurations that may be selected:
D Station mounted on controller cover
D Station mounted remotely as a separate unit
2.1.1 Local Station - When the Station is mounted lo
cally on the Cover, users may select from 8 standard
Facplates (Model No. 14C201 thru 14C208) in order to
configure a controller to a specific drive application. Re
fer to I/M D3977 which includes an inclusive listing of
Faceplate types, Model Numbers and functions. As
suming the Cover is properly installed, the Faceplate
design maintains the NEMA Type 12 rating.
REMOTE OPERATOR
CONTROL STATION
Figure 2.1 - Remote and Local Operator Control Stations 4
STANDARD
BLANK
OPERATOR
STATION
COVER
Figure 2.2 - MinPak Plus with
Standard Blank Operator Station Cover
Figure 2.3 - MinPak Plus with
Optional Status/Diagnostic Indicator Kit
2.1.2 Remote Stations - Some applications may re
quire that the Operator's Control Station be remotely lo
cated. Briefly, the following three steps describe what
must be done:
D Maintain the standard blank Remote Operator Sta
tion Cover Faceplate (Refer to Figure 2.2)
D Order a Remote Operator Adapter Kit, Model
14C220. (This unit provides a connection point for
the Remote Station.)
D Specify a Reliance Remote Operator Control Station.
Connect it to the controller.
Reliance offers a variety of Remote Operator Stations
that are compatible with the MinPak Plus controller. (Re
fer to Table 2.B.)
2.2 D C Drive Motors
- Reliance Electric offers a
complete power matched drive system for the control
ler and the application. Thus, the choice of Reliance
Electric motors assures optimum performance and un
matched single source responsibility.
2.3 Modification Kits
- The basic capability of the
controller can be quickly and conveniently extended
with the use of a variety of optional Modification Kits. The
Basic Controller modifications are:
D Tachometer Feedback
D Voltage/Tachometer Follower
D Instrument Interface/Preset Speed
D Test Meter Adapter
D Status/Diagnostic Indicator
D Dancer Follower
D Master Isolated Reference Receiver
The Auxiliary Panel modifications are:
D Blower Motor Starter
D Reversing Contactor
D Circuit Breaker
D Auxiliary M Contact
D Dynamic Braking (Kit is mounted on top of NEMA 12
enclosure)
Complete descriptions of each Kit are given in Section 7.
Refer also to Table 7.A.
2.4 Specifications
- The more important specifi
cations for the MinPak Plus controller are listed in Table
2.C. Refer also to Table 2.D where other ratings are indi
cated in relation to d c motors of specific horsepower.
2.4.1 Line Frequency - The MinPak Plus controller is
to operate without modification from a three phase
power source having a frequency range from 48 to 62
Hz.
2.4.2 Voltage Tolerance - The MinPak Plus controller
delivers output current and voltage, as listed in Table
2.D. It will also operate within these regulation specifica
tions even with incoming line voltage at
±
10% of nomi
nal.
2.4.3 Line Impedance Requirements - The MinPak 5
Table 2.A - MinPak Plus Features Summary
Category
Feature
Controller Functions
D START/STOP
D RUN/JOG
D FORWARD/REVERSE
D Speed selection (5 to 100%)
D Torque selection (10 to 150%)
D Unidirection operation with coast to rest on stop command standard. (Dynamic
braking and reversing available as options.)
D 20:1 controlled speed range by means of armature voltage control.
D Armature loop contactor removes power to drive motor.
D Isolated armature voltage and current feedback decouples armature power from
operator devices and provides additional noise immunity.
D With tachometers specified, 0.5% or 1.0% speed regulation with a 95% load
change.
D Operates and delivers rated output speed with specified regulation tolerance limits
even with a c Line variations of
±
10% of nominal rated input voltage.
Speed Regulation
D Jumper reconnectable regulator circuits which allow armature (A) or tachometer
feedback (T) regulation.
D With voltage regulation, 3 to 5% speed regulation with 95% load change.
D With tachometer specified, 1% speed regulation with a 95% load change.
(Tachometers are: RE 045 a c tachometer; also 5PY or RE 020 d c tachometer.)
D With tachometer specified, 0.5% speed regulation with 95% load change.
(Tachometer is BC42.)
User Adjustments
D Adjustable IR drop compensation (0 to 12% of rated load).
D Adjustable maximum speed (70 to 100% of base motor speed).
D Adjustable minimum speed (5 to 30% of base motor speed).
D Adjustable current limit (10 to 150% of full load current).
D Adjustable, separately set linear acceleration and deceleration rates (0.5 to 30 sec.)
Safety
D Control circuitry guards against automatic restarting of equipment after resumption
of interrupted a c incoming power.
D Regulator and Operator's Controls isolated from a c line for personnel protection.
D Armature voltage and current feedback isolated to assure separation of power and
regulator circuits.
Hardware
D Conveniently located screw terminal connections for incoming a c and outgoing
d c power allow easy cabl