MaxPak Plus

DĆC VKS Drives

and Modification Kits

200Ć300 HP, 230 VAC, 50/60 HZ

400Ć600 HP, 460 VAC, 50/60 HZ
480Ć720 HP, 575 VAC, 50/60 HZ

Instruction Manual DĆ3919Ć1

February, 1993
 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.

Reliancer, MaxPakr, VKSr, and RPMt are Trademarks of Reliance Electric Company or its subsidiaries.
 TABLE OF CONTENTS
Section Title Page
RECEIVING AND HANDLING
SECTION 1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REFERENCE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BASIC DRIVE ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONTROLLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MAXPAK PLUS MODEL NUMBER ASSIGNMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DRIVE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CONTROLLER FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CONTROLLER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DRIVE MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TRANSFORMERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 2
DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION OF THE DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION OF THE DRIVE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WIRING THE DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BASIC DRIVE INTERCONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TRANSFORMERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 3
STARTĆUP AND ADJUSTMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TESTER CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MOTOR CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PHYSICAL INSPECTION OF EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PRELIMINARY CHECKS WITH POWER OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FINAL CHECKS WITH POWER ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
STARTĆUP AND ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 4
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ARMATURE RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GATING SEQUENCE AND CURRENT FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
POWER CIRCUIT FAULT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SEMIĆCONDUCTOR TRANSIENT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OTHER POWER UNIT HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FIELD SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Regulator Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Regulator Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PHASE SEQUENCE, LINE AND FIELD SUPPLY MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CONTROLLER REGULATOR CARD - CRCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CURRENT LOOP DRIVER - CLDK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CURRENT AND VOLTAGE TRANSDUCTOR - CVTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
STATIC SEQUENCING AND CONTROL CARD - SSCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
OVERLOAD AND VOLTAGE COMPARATOR - OLVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPTIONAL TESTER CARD - TSTB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SECTION 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
TROUBLESHOOTING NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

i
 TABLE OF CONTENTS
Section Title Page
TROUBLESHOOTING SUGGESTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SECTION 6
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

ii
 LIST OF PHOTOS AND DRAWINGS
Figure Title Page
FIGURE 1 - MAXPAK PLUS CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
FIGURE 2 - TYPICAL SUPER RPM DĆC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FIGURE 3 - 9C45 OPERATOR'S CONTROL STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FIGURE 4 - MAXPAK PLUS CONTROLLER CABINET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FIGURE 5 - MAJOR CONTROLLER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FIGURE 6 - POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FIGURE 7 - REMOVING PHASE RECTIFIER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FIGURE 8 - ARMATURE LOOP CONTACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIGURE 9 - FIELD SUPPLY WITH COVER REMOVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIGURE 10 - REGULATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIGURE 11 - MAXPAK PLUS BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FIGURE 12 - CONTROLLER EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FIGURE 13 - DISPLACEMENT POWER FACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FIGURE 14 - FLOOR MOUNTED CABINET, FD86U, BLOWER VENTILATED
POSITIVE PRESSURE, NEMA 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FIGURE 15 - INTERCONNECTION DIAGRAM FOR NONĆREVERSING DRIVES . . . . . . . . . . . . . . . . . . . . . 17
FIGURE 16 - REGULATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FIGURE 17 - MAXIMUM ALLOWABLE CURRENT RATE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FIGURE 18 - FULL WAVE POWER BRIDGE CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FIGURE 19 - PHASE RECTIFIER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
FIGURE 20 - REGULATOR BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FIGURE 21 - PHASE SEQUENCE, LINE AND FIELD SUPPLY MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FIGURE 22 - PHASE SEQUENCE LINE AND FIELD SUPPLY MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FIGURE 23 - CRCF CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
FIGURE 24 - CRCF BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
FIGURE 25 - CLDK CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FIGURE 26 - CLDK BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
FIGURE 27 - CVTG CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FIGURE 28 - CVTG BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FIGURE 29 - SSCC CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
FIGURE 30 - SSCC BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FIGURE 31 - OLVC CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
FIGURE 32 - OLVC BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
FIGURE 33 - TSTB CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

iii
 INDEX OF TABLES
Table Title Page
TABLE 1 - REFERENCE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TABLE 2 - OPERATOR CONTROL STATION FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TABLE 3 - MODEL NUMBER ENCLOSURE DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TABLE 4 - MODEL NUMBER FEATURE DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TABLE 5 - CONTROLLER RATING SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TABLE 6 - CONTROLLER CURRENT RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TABLE 7 - SPEED REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TABLE 8 - CONTROLLER MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TABLE 9 - STANDARD CONTROLLER CARD COMPLEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TABLE 10 - CURRENT FEEDBACK CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TABLE 11 - MINIMUM ALLOWABLE MOTOR HORSEPOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TABLE 12 - TACHOMETER VOLTAGE SCALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TABLE 13 - INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TABLE 14 - THYRISTOR GATING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TABLE 15 - PHASE SEQUENCE LINE AND FIELD SUPPLY MONITOR CARDS . . . . . . . . . . . . . . . . . . . . . 31
TABLE 16 - TESTER FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
TABLE 17 - TROUBLESHOOTING SUGGESTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
TABLE 18 - HORSEPOWERĆINDEPENDENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
TABLE 19 - HORSEPOWERĆDEPENDENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

iv
 RECEIVING AND HANDLING

ACCEPTANCE
Reliance terms of sale, in all instances, are F.O.B.
point of origin. Thoroughly inspect this equipment beĆ
fore accepting shipment from the transportation comĆ
pany. If any of the goods called for in the bill of lading or
express receipt are damaged or the quantity is short, do
not accept them until the freight or express agent makes
an appropriate notation on your freight bill or express reĆ
ceipt. If any concealed loss or damage is discovered latĆ
er, 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 damĆ
age in transit against the Carrier.
Claims for loss or damage in shipment must not be
deducted from the Reliance invoice, nor should payĆ
ment of the Reliance invoice be withheld awaiting adĆ
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 Storage

Store the equipment in a clean, dry area and do not
unpack unit ready for use. Under no conditions should
the equipment be stored where ambient temperature
exceeds 60°C, where corrosive conditions exists, or
where high humidity is likely to cause condensation. ReĆ
liance publication DĆ8079 provides further information
on storage procedures and precautions. Proper storĆ
age is a must to insure satisfactory drive operation at
startup and to maintain warranty coverage.

DANGER
THIS EQUIPMENT SHOULD BE INSTALLED,
ADJUSTED AND SERVICED BY QUALIFIED
ELECTRICAL MAINTENANCE PERSONNEL FAĆ
MILIAR WITH THE CONSTRUCTION AND OPĆ
ERATION OF THE EQUIPMENT AND THE HAZĆ
ARDS INVOLVED.
EQUIPMENT IS AT LINE VOLTAGE WHEN AĆC
POWER IS CONNECTED TO THE POWER UNIT.
ALL PHASES OF THE AĆC POWER LINE MUST
BE DISCONNECTED FROM THE POWER UNIT
BEFORE IT IS SAFE TO TOUCH ANY INTERNAL
PARTS OF THIS EQUIPMENT.
DANGER
THESE CONTROLLERS CONTAIN YELLOW
CONTROL CIRCUIT WIRES WHICH MAY REĆ
MAIN ENERGIZED AFTER THE MAIN DISCONĆ
NECT IS OPEN. TOUCHING THESE WIRES
WHEN ENERGIZED CAN RESULT IN SERIOUS
OR FATAL INJURY. TO DEĆENERGIZE THESE
WIRES, OPEN THE KNIFE SWITCH DISCONĆ
NECT FOR THE YELLOW WIRES ON 6TB.
FIGURE 1 - MAXPAK PLUS CONTROLLER
WARNING
THIS EQUIPMENT GENERATES, USES, AND
CAN RADIATE RADIO FREQUENCY ENERGY
AND IF NOT INSTALLED AND USED IN ACCORĆ
DANCE WITH THE INSTRUCTION MANUAL,
MAY CAUSE INTERFERENCE TO RADIO COMĆ
MUNICATIONS. AS TEMPORARILY PERMITTED
BY REGULATION IT HAS NOT BEEN TESTED
FOR COMPLIANCE WITH THE LIMITS FOR
CLASS A COMPUTING DEVICES PURSUANT
TO SUBPART J OF PART 15 OF FCC RULES,
WHICH ARE DESIGNED TO PROVIDE REASONĆ
ABLE PROTECTION AGAINST SUCH INTERĆ
FERENCE. OPERATION OF THIS EQUIPMENT
IN A RESIDENTIAL AREA IS LIKELY TO CAUSE
INTERFERENCE IN WHICH CASE THE USER AT
HIS OWN EXPENSE WILL BE REQUIRED TO
TAKE WHATEVER MEASURES MAY BE REĆ
QUIRED TO CORRECT THE INTERFERENCE.
 SECTION 1
GENERAL INFORMATION
INTRODUCTION
This manual contains installation, setup, operating,
maintenance and troubleshooting instructions of ReĆ
liance MaxPak Plus DĆC VKS Drives. It applies to drive
ratings from 200 through 300 hp at an armature voltage
of 240 volts dĆc with 230 volts, 3Ćphase input power,
from 400 through 600 hp at an armature voltage of 500
volts dĆc with 460 volts,3Ćphase input power and from
480 through 720 hp at an armature voltage of 600 volts
with 575 volts,3Ćphase input power. It applies as well
to U.S. built MaxPak Plus drives operating from other
TABLE 1 - REFERENCE LITERATURE
Publication
Number Publication
DĆ9C066 Selection and Application Guide
for Reliance MaxPak Plus VKS
Drives.
CĆ3076 Instruction Manual for Reliance
Super RPM DĆC Motors
DĆ8079 Long Term storage for control
cabinet
BASIC DRIVE ELEMENTS
Reliance MaxPak Plus VKS Drives consist of three baĆ
sic drive elements: A laminated frame Super RPM shunt
wound dĆc motor, a compact, remotely mounted operaĆ
tor's control station and a MaxPak Plus controller.
FIGURE 2 - TYPICAL SUPER RPM DĆC MOTOR
incoming aĆc voltage leads between 200 and 575 volts
where the motor horsepower divided by incoming aĆc
line voltage does not exceed 1.3.
REFERENCE LITERATURE
The user is urged to refer to the publications listed in
Table 1 to improve his understanding of the application
and operation of MaxPak VKS Drives and related ReĆ
liance equipment and services. These manuals are
readily available from your Reliance Distributor or local
Reliance Sales Office.
Contents
This manual provides a discussion of the mechanical and
electrical considerations involved in the selection and sizĆ
ing of adjustable speed dĆc drives. It also describes the
many modifications that can be made by the user to the
MaxPak Plus drive and offers typical examples of their
use.
This manual provides complete instructions for the ReĆ
liance Super RPM DĆC Motor used with the MaxPak Plus
controller.
This document provides information on proper storage
procedures and precautions for MaxPak Plus drives and
related equipment.
Motor
The MaxPak Plus controller provides shunt field exĆ
citation and adjustable voltage armature power to drive
a shunt wound dĆc machine with compatible voltage reĆ
quirements and intended for adjustable speed service.
MaxPak Plus drives are furnished with Reliance Super
RPM laminated frame dĆc motors. In this way, Reliance
Electric offers a completely power matched drive sysĆ
tem with the controller and motor power matched to one
another for optimum performance and undisputed
single source responsibility. The Super RPM motor is
described by brochure C2519Ć1 as well as Instruction
Manual CĆ3076. A typical Super RPM machine is a dripĆ
proof guarded forced ventilated enclosure is shown in
Figure 2.
Operator's Control Station
Operator's control devices must be connected to the
drive controller. As indicated in Table 2, standard ReĆ
liance operator's control stations include a speed conĆ
trol potentiometer, startĆstop rocker switch and either a
runĆjog selector or pushbutton device for jog control. A
9C45 station is illustrated in Figure 3.
1
 Controller
The MaxPak Plus controller provides adjustable voltĆ
age armature power to the dĆc motor by phase
controlled rectification of 3Ćphase plant power. The
FIGURE 3 - 9C45 OPERATOR'S phase controlled rectifier, major and minor loop regulaĆ
CONTROL STATION tors, field exciter and all required sequencing controls
and protective circuits make up the drive controller. This
controller is normally supplied mounted and wired withĆ
in its own NEMA 1 enclosure. Standard enclosure diĆ
mensions are provided on page 17. The controller may
also be specified in larger NEMA 1 enclosures, or in
open panel construction.
The controller is functionally described on pages 4
through 9.

TABLE 2 - OPERATOR CONTROL STATION FUNCTIONS

Specify Functions Provided
When Using a MaxPak Operator's
StartĆStop Speed Setting Jog ForwardĆReverse
Plus Controller With: Station Model
Rocker Switch Potentiometer Control Selector
D Basic features 9C45 Yes Yes Selector Switch No
D Basic features plus 9C51 Yes Yes Pushbutton No
dynamic braking.

CONTROLLER IDENTIFICATION A typical MaxPak Plus model number would be

600C161S, and signify the following:
MaxPak Plus controllers are manufactured as stanĆ
dard model number units to a set of Reliance specificaĆ 600 C 1 61 S Final S" in Model
tions or as modified units to customer specifications. Controller Horsepower
Number May or May
The MaxPak Plus controller can be positively identified Not Be Present
(600 HP)
by the nameplate mounted on the front face of the cabiĆ
Single Digit Enclosure Specified AĆC Input Voltage
net door or, in the case of a panel mounted drive, on the Designation. Output Armature and Field
controller itself. Voltages and Detail
Features per Table 4.
If built to customer specifications, a Reliance sales
order number will be imprinted on the nameplate, apĆ
pearing as a six digit number following a 1GA, 2GA, A 600C161 controller is rated at 600 hp (600 precedĆ
3GA, or TT, 10TT, 20TT prefix (such as 1GAĆ679042 or ing the C"), furnished in a NEMA 1 floor mounted enĆ
10TTĆ896401). Use this identification number whenever closure (a one following the C", see Table 3) and proĆ
discussing this drive equipment with Reliance Electric vides basic features plus dynamic braking at 460 volts
personnel. It uniquely describes a controller manufacĆ aĆc input power, 500 volts dĆc armature and 300 volts
tured to customer specifications. dĆc field (61 suffix, per Table 4).
Alternately, if the controller was manufactured as a
Reliance model number drive, its model number TABLE 3 - MODEL NUMBER ENCLOSURE
uniquely describes the hardware furnished. DESIGNATIONS

MAXPAK PLUS MODEL NUMBER Digit Immediately

ASSIGNMENTS Following C" Controller Enclosure
0 NEMA 1 wall mounted enclosure
If the MaxPak Plus controller was built to a Reliance
(Zero may be omitted in printĆ
model number specification, a four through eight charĆ
acter alphaĆnumeric model number will be printed on ing the controller M/N).
the drive's identification nameplate. This model number 1 FD 86U NEMA 1 floor mounted
will also be present on the shipping label on the outside enclosure
of the controller shipping container. The model number
2 Open panel supplied without
provides a complete controller specification as noted in
Tables 3 and 4. enclosure

2
 TABLE 4 - MODEL NUMBER FEATURE DESIGNATIONS
Last Two
Digits Of AĆC Armature Field
Model Input Voltage Voltage Features
Number Voltage (DĆC Volts) (DĆC Volts)
57 230 240 150 Basic Features
58 230 240 150 Basic Features Plus Dynamic Braking
60 460 500 300 Basic Features
61 460 500 300 Basic Features Plus Dynamic Braking
63 230 240 150 Basic Plus Extruder Features
64 460 500 300 Basic Plus Extruder Features

DRIVE FUNCTIONS 14. Isolated armature voltage and current feedback to

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. StartĆstop and speed selection.
2. Unidirectional Operation, coastĆtoĆrest.
3. Twenty to one (20:1) controlled speed range by arĆ
mature voltage control.
4. Separately adjustable rates of linear acceleration
and deceleration. Adjustable from 0.5 to 30 seĆ
conds.
5. Jumper reconnectable regulator circuits to allow eiĆ
ther armature voltage regulation or closed loop
speed regulation with tachometer feedback.
Provides:
D 5% speed change with 95% load change by
voltage regulation.
D 1% speed change with 95% load change by
speed regulation using an RE045 aĆc tachomeĆ
ter or 5PY dĆc tachometer.
D 0.5% speed change with 95% load change by
speed regulation using a BC42 tachometer.
6. Jog at adjustable preset speed (0Ć50%) by pushĆ
button or selector switch depending on selection of
operator's station.
7. Adjustable IR drop compensation (0 to 10%) by
jumper connection.
8. Adjustable minimum speed (2% to 40%).
9. Adjustable maximum speed (80 to 120%).
10. 150% one minute current rating.
11. 50/60 Hz compatibility without modification.
12. Ability to deliver rated output and operate within
specified regulation tolerance limits with aĆc line
variations of "10% of nominal. Capable of operaĆ
tion without power unit damage to 25% low incomĆ
ing line.
assure complete isolation between armature and
regulating circuits.
15. Fused and isolated 115 volt aĆc supply for pushbutĆ
ton and regulator control.
16. Conveniently located incoming and outgoing powĆ
er terminal locations to allow easy cable entry and
connection.
17. Full rated armature loop contactor. Complete with
blowouts.
18. Phase sequence interlock to prevent drive operaĆ
tion with incorrect incoming phase rotation. ComĆ
plete with regulator face plate LED to indicate propĆ
er rotation.
19. Surge protection from aĆc line and dĆc load tranĆ
sients.
20. Current limit, adjustable from 50% to 150% of drive
full load current.
21. Bolted fault protection by means of three pairs of inĆ
coming line current limiting fuses.
22. Overcurrent IET (instantaneous electronic trip) with
regulator faceplate indicating light.
23. Solid state motor overload protection with regulator
faceplate indicating light.
24. Field excitation loss protection with regulator faceĆ
plate indicating light.
25. Auxiliary NO or NC control contacts on the armature
loop contactor.
MaxPak Plus Controllers with Basic Features and
Dynamic Braking
When specified to include basic and dynamic braking"
functions, the MaxPak Plus controller will also provide:
D Rapid stopping of the drive motor by means of
dynamic braking upon a stop" command. A second
armature loop contactor connects energy absorbing
resistors across the motor armature. Note: Dynamic
braking is NOT a holding brake.

13. 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.
MaxPak Plus Controller with Extruder Features
When specified to include extruder features, the MaxĆ
Pak Plus controller is furnished with the following in
addition to the basic" features listed previously. Neither
dynamic braking nor armature reversing are provided.

3
D One normally open auxiliary contact on the motor
armature contactor wired to terminals for user use.
D A blower motor starter to protect and control the dĆc
motor blower.
D A meter 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 dĆc motor
drive service. The rectifier bridge, comprised of six SCR
switches, operates directly from 3Ćphase plant power.
The firing angle of the phase controlled rectifier is deterĆ
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 operaĆ
tor's control station and startĆstopĆjog functions are
controlled via conventional pushbutton devices.
A power unit cooling fan is furnished for forced venĆ
tilation of the power bridge. A fixed potential field supply
provides shunt field excitation to the motor.
Power is delivered to the motor through an armature
loop contactor and the controller is furnished with a
complete protection system for itself and the drive moĆ
tor.
PROVISION
FOR DYNAMIC
BRAKING GRIDS
WHEN SUPPLIED
IDENTIFYING
NAMEPLATE
DOOR HANDLE
WITH PROVISION
FOR PAD LOCK
INCOMING AIR
FILTER
FIGURE 4 - MAXPAK PLUS CONTROLLER
CABINET
4
The block diagram of Figure 11 (page 8) and
photographs with component callouts in Figures 4
through 10 should be used to gain a basic understandĆ
ing of controller hardware and function. detailed discusĆ
sion of power bridge and regulator operation is proĆ
vided in Section 4 of this manual Functional hardware
controller includes:
1. Controller enclosure. The MaxPak Plus controller
may be furnished on an open panel or in its own
floor mounted NEMA 1 enclosure. Special encloĆ
sures for operation in unusual environments are
also available. Figure 4 shows a typical controller,
in a floor mounted NEMA 1 cabinet. The door is
hinged and has provisions for padlocking. Note the
controllers identifying nameplate.
2. Incoming Line Terminals. ThreeĆphase incoming
power terminals are provided as shown in Figure 5
and are arranged for easy top or bottom entry of
power wiring. As with most other power connecĆ
tions within the MaxPak Plus controller, these termiĆ
nals are designed to provide superior electrical
connection and even contact pressure over the enĆ
tire contact area. They must be tightened properly
in order to provide this function.
Hardware tightening instructions are provided
within the controller enclosure as shown in Figure
5.
3. AĆC Line Capacitors. Six, 0.5 mfd. capacitors are
connected to the aĆc input immediately ahead of the
Power Module. These capacitors are intended to
suppress the transients generated when the feed
transformer is first energized.
Two capacitors are connected in series and the
three groups of two capacitors each are connected
in a wye configuration with the center of the wye
connected to cabinet ground. This cabinet ground
should be connected to earth ground.
4. Incoming line fuses. Current limiting fuses 1FU
through 6FU (three pairs of two fuses) provide
bolted fault short circuit protection for the controller.
See Figure 6.
5. Controller Power Unit. The controller power unit
houses the three phase rectifier modules. It also
houses the controller cooling fan. See Figures 5, 6
and 7.
6. Cabinet Ventilation. A single-phase 1/4Ćhp cabiĆ
net fan pulls outside air in through the doorĆ
mounted filter. This cooling air is forced up through
the heatĆsink assemblies and current limiting fuses,
past the incoming and outgoing power terminaĆ
tions, and out the louves in the top of the cabinet.
 INCOMING LINE
MOTOR TERMINALS
ARMATURE BEHIND COVER
CONNECTIONS

ARC BUS BAR COVER

SHIELD

MOTOR ARMATURE
FIELD CONTACTOR
CONNECTIONS
FIELD SUPPLY

RENEWAL CONTROL
PARTS LIST, CIRCUIT
CONNECTOR TRANSFORMER
TIGHTENING AND
TEST INSTRUCTION
AĆC LINE
FILTER
CAPACITORS
REGULATOR

FIGURE 5 - MAJOR CONTROLLER ASSEMBLIES

OUTPUT RĆC
NETWORK CURRENT TRANSFORMERS POWER
MODULE
WITH
COVER
REMOVED
INCOMING
LINE FUSES
1FU - 6FU
FERRITE
REACTORS

GATE LEAD
CONNECTION
DIAGRAM
INSIDE OF
POWER
MODULE
COVER

FIGURE 6 - POWER MODULE FIGURE 7 - REMOVING PHASE RECTIFIER

MODULE

5
 An airĆflow detector is mounted behind the fan to
shut down the drive if the airflow stops or is signifĆ
icantly reduced. Plus, a thermostat in the power
module will shut down the drive if the exhaust air
temperature in the power module exceeds design
limits.
7. Current Transformers. Current transformers 1 CT
and 3CT shown in Figure 6, provide load current
feedback to the regulator. Since aĆc line current is
directly proportional to dĆc armature current, these
transformers provide an isolated current feedback
signal usable as input for IR compensation, current
limit, motor thermal overload and overcurrent shutĆ
down (IET) circuit functions.
8. Phase Rectifier Modules. Three identical rectifier
modules, each containing two thyristors, dv/dt proĆ
tective networks with fusibleĆresistor assemblies,
gate firing circuitry and heatsinks are visible in FigĆ
ure 7. Each module is easily removable and reĆ
placed as a unit. Gate lead connections are made
by a quickĆdisconnect plug. Note the gate lead
orientation diagram illustrating proper gate lead
connections, see Figure 6.
9. Ferrite Reactors. A ferrite reactor assembly is proĆ
vided for each leg of the power rectifier. These reacĆ
tors provide di/dt protection for the thyristors, and
function as part of the thyristor dv/dt protective cirĆ
cuitry. They are mounted within the power unit. See
Figure 6.
10. Output Network. This circuit acts to provide an asĆ
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 current's generated by the dĆc
motor commutator. It is mounted as a part of the
controller power unit and shown in Figure 6.
11. Armature Loop Contactor. This loadĆbreakĆrated
device provides a positive disconnect between the
power unit and the motor armature. Although it is a
loadĆbreak device and furnished with blowĆouts, its
opening and closing is sequenced by the drive regĆ
ulator so that it opens and closes only under noĆ
load conditions for assured long life. An additional
contactor is furnished for dynamic braking applicaĆ
tions.
12. Outgoing Power Terminations. Armature power
terminations allow easy cable routing and connecĆ
tion to the controller. These cables can enter the
cabinet from either the top or bottom.
Two armature connections (A1 and A2/S2) are
provided on drives with basic" features. Three arĆ
mature terminations (A1, A2/S1 and S2), provided
on drives with dynamic braking, allow removal of
the stabilizing shunt field during db for maximum
braking torque.
Motor field connections are made to a terminal
board shown in Figure 5.
13. Field Supply. Shunt field excitation is provided by
means of a fixed diode rectifier operating from inĆ
coming aĆc line power. Fuses 7FU and 8FU provide
short circuit protection. See Figures 5 and 9.
14. Control Circuit Transformer. Along with secondĆ
ary fuse 13FU this isolation transformer, visible in
6
Figure 10 provides the 115 volt aĆc power for the
regulator, pushbutton control, armature contactor
coils and ventilating fan.
15. Phase Sequence, Line and Field Supply Monitor.
This printed circuit card receives incoming aĆc line
and field supply output voltage information and
supplies, as its output, low level isolated signals to
the regulator indicating proper or improper phase
rotation, loss of incoming aĆc 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 condiĆ
tions. See Figure 10.
16. Regulator Assembly. The regulator assembly, FigĆ
ure 10, contains the five plugĆin 44Ćpin printed cirĆ
cuit cards which comprise the MaxPak Plus regulaĆ
tor and houses an isolation transformer (not visible
in the photos) providing 34 volts aĆc for subsequent
generation of "12 volt dĆc power within the regulaĆ
tor. The regulator accepts start, stop and other
pushbutton commands and a speed reference sigĆ
nal along with feedback signals proportional to arĆ
mature voltage and current. The output of the reguĆ
lator controls firing angle of the thyristors to adjust
armature voltage and motor speed, sequences the
motor armature contractor(s) and provides a numĆ
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.
17. Drive Tester. This plug in tester card, noted in FigĆ
ure 10 and available as an option, allows inĆservice
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 of a number of internal
drive signals with an external metering device (digiĆ
tal voltmeter, oscilloscope, etc.).
Complete instructions for use of this diagnostic
tool are contained in section 3 of this manual. A conĆ
densed set of instructions are printed and mounted
within the drive enclosure as shown.
18. Startup Instructions and Spare Parts List. Start up
and adjustment procedures are discussed in SecĆ
tion 3 of this manual. The spare parts list is printed
in Section 6. This information, in condensed form,
is attached to the inside cabinet door for easy referĆ
ence as seen in Figure 5.
 DĆC MOTOR ARMATURE
CONNECTIONS

ARMATURE
(M)
CONTACTOR

DYNAMIC
BRAKING
CONTACTOR
(OPTIONAL)

FIGURE 8 - ARMATURE LOOP CONTACTORS

CONTROL CIRCUIT
13FU 9FU TRANSFORMER
PHASE
SEQUENCE,
LINE AND
FIELD
SUPPLY
MONITOR

GATE CABLE TESTER CARD

CONNECTOR (OPTIONAL)
FIGURE 9 - FIELD SUPPLY WITH COVER FIGURE 10 - REGULATOR ASSEMBLY
REMOVED
TABLE 5 - CONTROLLER RATING SUMMARY
CONTROLLER SPECIFICATIONS
Voltage and Current Ratings Available Incoming Armature Field VoltĆ
HP Ratings Line Power Voltage age
MaxPak Plus controllers are available from 200 200 - 300 230 volts aĆc 240 volts dĆc 150 volts dĆc
to 720 hp as listed Table 5. Table 6 lists armature, field 400 - 600 460 volts aĆc 500 volts dĆc 300 volts dĆc
and input aĆc current ratings for each drive horsepower 480 - 720 575 volts aĆc 600 volts dĆc 360 volts dĆc
rating.

7
 ARMATURE
LOOP
CONTACTOR

INPUT
POWER
230, 460, ARMATURE
OR 575v POWER
3f 0Ć240
0Ć500 OR 0Ć600 VOLTS DĆC
50/60 Hz
LOAD CURRENT
FEEDBACK TO
REGULATOR
(IA)
FERRITE
REACTOR

FIELD SUPPLY (1) FIELD

ARMATURE VOLTAGE EXCITATION
FEEDBACK TO 150 OR 300 VOLTS DĆC
REGULATOR (VA) FIXED POTENTIAL

REGULATOR
PHASE SEQUENCE LINE & ASSEMBLY
FIELD SUPPLY MONITOR (1)

COOLING
FAN (1)

SPEED
OPERATOR'S REFERENCE
PUSHBUTTON
DEVICES
➀ FusibleĆResistor is in series with each capacitor indicated.

FIGURE 11 - MAXPAK PLUS BLOCK DIAGRAM

8
 TABLE 6 - CONTROLLER CURRENT RATINGS
HP Full Load Rated Full Load Rated Field Supply Maximum Allowable
Ratings RMS AĆC LIne DĆC Armature Current Capacity Available Symmetrical
Current (Amperes) Current (Amperes) (Amperes) RMS Fault Current
(AMP)
230V 460V 575V 240V 500V 600V 150V 300V 360V 230V 460V 575V
200 592 Ċ Ċ ă685 Ċ Ċ 20 Ċ Ċ 85,000 Ċ Ċ
250 733 Ċ Ċ ă850 Ċ Ċ 20 Ċ Ċ 85,000 Ċ Ċ
300 859 Ċ Ċ 1000 Ċ Ċ 20 Ċ Ċ 85,000 Ċ Ċ
400 Ċ 553 Ċ Ċ 640 Ċ Ċ 20 Ċ Ċ 85,000 Ċ
480 Ċ Ċ 553 Ċ Ċ 640 Ċ Ċ 20 Ċ Ċ 85,000
500 Ċ 687 Ċ Ċ 800 Ċ Ċ 20 Ċ Ċ 85,000 Ċ
600 Ċ 825 689 Ċ 960 800 Ċ 20 20 Ċ 85,000 85,000
720 Ċ Ċ 825 Ċ Ċ 960 Ċ Ċ 20 Ċ Ċ 85,000

Service Conditions
Standard Altitude . . . . . . . . . . . . . . . . . . Up to 3300 feet
(1000 meters) above
sea level without derating.
Ambient Temperature . . . . . . . . . . . . . . . . 0 to 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 . . . . . . . 0 to 95%, nonĆcondensing
Line Power Considerations
- Line Frequency
MaxPak Plus controllers operate without modificaĆ
tion from 3Ćphase plant power with a frequency within
the range of 48 to 62 Hz.
- Voltage Tolerance
The MaxPak Plus controller with deliver output curĆ
rent and voltage per Table 6 and operate within the reguĆ
lation specifications listed below with incoming line voltĆ
age at 10% above or below the normal. The drive will
operate without component damage under low incomĆ
ing line conditions down to 25% below nominal.
- Line Impedance Requirements
The standard MaxPak Plus controller, furnished withĆ
out an input circuit breaker, has a short circuit protection
system designed to operate on plant power supplies
with maximum allowable available symmetrical RMS
fault currents as listed in Table 6. Do not attempt to opĆ
erate the MaxPak Plus controller on power supplies
with available short circuit currents in excess of
these allowable maximums.
- Operation From Unlisted Voltages
230 volt MaxPak Plus controllers will operate satisĆ
factorily from 110 to 270 volt aĆc plant power, delivering
armature voltage, field voltage and output horsepower
proportional to ratings specified at 230 volt input, proĆ
viding that the output from the control circuit transformĆ
er (CCT) is maintained at 115 volt aĆc.
In a like manner, 575 volt controllers can be operated
from plant power within the range of 430 to 575 volts aĆc.
460 volt controllers can be operated from plant powĆ
er within the range of 270 to 430 volts aĆc by replacing
the 0Ć543349Ć2 Phase Sequence, Line and Field Supply
Monitor printed circuit board with a 0Ć54349Ć1 board
and observing the control transformer secondary voltĆ
age requirement noted above.
Load Specifications
Capacity . . . . . . . . . . . . . . . . . . . . . . . . 150% of full load
rated armature current for one minute.
Controller Service Factor . . . . . . . . . . . . . . . . . . . . . . 1.0
Minimum Load for Assured Stable Operation . . . . 5%
Adjustments
Acceleration . . . . . . . . . . . . . . . . . . . . . 0.5-30 seconds
Deceleration . . . . . . . . . . . . . . . . . . . . . 0.5-30 seconds
Minimum Speed . . . . . . . . . . . . . . . . . . . . . . . . . 2-40%
Maximum Speed . . . . . . . . . . . . . . . . . . . . . . . 80-120%
Jog Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50%
Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150%
IR Drop Compensation (Optional) . . . . . . . . . . 0-10%
Speed Regulation
As furnished from the factory, the MaxPak Plus conĆ
troller is configured as a voltage regulator, using armaĆ
ture voltage as the controlled parameter. The controller
can be converted to a speed regulator by jumper reconĆ
nection as described on page 21, item 10, of this manuĆ
al, with resulting speed regulation being a function of
tachometer selection as noted in Table 7.
TABLE 7 - SPEED REGULATION
Speed Regulation
With 95% Load All Other Variables
Change (% of Motor (% of Motor Base Tachometer
Base Speed) Speed) Required
5% 15% None
1% 2% REĆ045 or 5PY
0.5% 0.5% BCĆ42
Controlled Speed Range
At standard 40_C ambient conditions at the motor,
the drive can be operated down to 60% of motor base
speed with 100% rated load without supplementary

9
motor ventilation. If the load does not exceed 60% of Complete drive, including motor . . . . . . . . Dependent
rated, continuous operation down to 5% of motor base on motor selected.
speed is possible without supplementary motor ventilaĆ Typical drive efficiency will be
tion; however, UNDER ALL LOAD CONDITIONS, WHEN in range of 85 to 93% operating
OPERATING BELOW 5% OF BASE SPEED, THE MOĆ at full speed, full load.
TOR MUST ALWAYS BE EQUIPPED WITH BLOWER
VENTILATION OR A TENV MOTOR MUST BE SUPĆ Displacement Power Factor . . . . . . . . . Displacement
PLIED. power factor is almost
entirely a function of operating
speed. Displacement power factor vs
Controller Dissipation speed is illustrated in Figure 13.
MaxPak Plus controller dissipation can be expressed
by the equation:

Watts Loss = 1000 + (3 x Full Load Rated

Armature Current)

Where:
• Full Load Rated Armature Current is per Table 6.

Efficiency and Power Factor

Controller only . . . . . . . . . . . . . . Figure 12 illustrates
typical controllerĆonly efficiency
vs speed and load

Speed, % of Rated

FIGURE 13 - DISPLACEMENT POWER FACTOR

DRIVE MODIFICATIONS
Factory Installed Modifications
100% LOAD
A large number of factory installed modifications,
75% LOAD
such as dynamic braking, extruder features, special seĆ
quencing, etc., are available when specified at order
50% LOAD entry. The most common of these have been previously
referenced in this manual and will be further described
in the paragraphs below.
Field Economy Function. It is good operating practice
to remove incoming aĆc power to the MaxPak Plus conĆ
troller between periods of operation. If the drive is inopĆ
erative overnight or over weekends, incoming power
25% LOAD should be removed and locked out. Not only does this
practice enhance personnel safety, but also removes inĆ
coming power from the drive in the periods during
which plant voltage levels tend to climb - often to well
over nominal value found during periods of normal
plant activity.
Speed, % of Rated If for some reason, however, incoming plant power
is left on the equipment while idle for long periods of
FIGURE 12 - CONTROLLER EFFICIENCY time as described above and plant line voltages tend to

10
climb over 110% of nominal, the addition of Field EconĆ
omy hardware can eliminate the possibility of motor
damage caused by overheating of the dĆc motor field
windings when subjected to these abnormally high voltĆ
ages without the benefit of the cooling provided by the
armature shaft driven cooling fan.
This function automatically reduces the voltage deĆ
livered to the motor shunt field during periods when the
drive is in a standby mode. Full field strength is returned
automatically when the drive is once again requested to
run.
If the dĆc motor is equipped with an aĆc motor driven
blower for cooling, its operation during periods of
standby will provide satisfactory motor cooling without
the need for field economy.
Jumper Reconnections
Operation of the MaxPak Plus controller can be modiĆ
fied (either at the factory or by the user) in a number of
ways by simple jumper reconnection. These possibiliĆ
ties are listed in Table 8 and further described in Manual
DĆ9066.
Prepackaged Kit Modifications
In addition, a complete selection of preĆpackaged
modifications is available in kit form for easy addition in
the field. These kits are listed in Table 8 and further disĆ
cussed in DĆ9066. Kit instruction manuals form section
8 of this manual.
UserĆInstalled Modifications
Lastly, the MaxPak Plus can often be adapted to meet
special requirements by minor modifications using auxĆ
iliary components furnished by the customer. A number
of such modifications are listed in Table 8 with these and
other userĆinstalled modifications discussed fully in
DĆ9066.
Acceleration/Deceleration Times, Extended. The
range of the linear timing circuit provided in the stanĆ
dard MaxPak Plus controller is from 0.5 to 30 seconds
with acceleration and deceleration rates individually adĆ
justable within this range. This overall range may be moĆ
dified by the addition of nonĆpolarized; 25 volt, paper or
mylar capacitors between terminals 22 and 24 of the terĆ
minal board located along the bottom edge of the conĆ
troller panel as indicated in Figure 16, page 22. Each 10
microfarads of capacitance so added will increase the
timing range by an additional 30 seconds to a maximum
of 200 seconds.
Blower Motor Starter. The blower motor starter kit proĆ
vides short circuit protection (via Class CC Type CCMR
fuses) and overload protection for the threeĆphase AĆC
motor used to drive the cooling fan on force ventilated
DĆC motors. It also provides a means via an auxiliary
contact on the starter coil, to stop the drive in the event
11
of a blower motor overload. This fused motor starter,
with a selection of overloads, mounts within the MaxPak
Plus Controller.
Circuit Breaker with ThruĆthe Door Handle. When
specified as a factoryĆinstalled modification, the incomĆ
ing line circuit breaker will be furnished mounted and
wired within the controller enclosure. It is complete with
a thruĆtheĆdoor handle to allow breaker operation from
outside the enclosure and to provide a door interlock.
The breaker serves as a means to disconnect the conĆ
troller from incoming plant power and is furnished with
magnetic trip elements.
When furnished as a kit, it is complete with mounting
hardware. a loadĆside bus bars and operating handle.
Drive to Rest on Stop. In response to a stop" comĆ
mand from the operator's stop pushbutton, the stanĆ
dard MaxPak Plus controller will cause the armature
contactor to open and the motor to coast to rest. If the
controller was furnished with dynamic braking, the moĆ
tor will dynamic brake to rest on a stop" command. In
either case, the stop mode is relayĆactuated and, thereĆ
fore, positive.
If desired, the drive can be modified to driveĆtoĆrest"
on a stop command. This will cause the drive to decelerĆ
ate to zero speed at a rate determined by the setting of
the deceleration rate control. Once near zero speed, the
armature contactor will drop out. This stopping 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.
When supplied as a factoryĆinstalled option, a speĆ
cial operator station with two alternateĆmode stop pushĆ
buttons (one providing driveĆtoĆrest on stop" and the
other coast or dynamic braking action) will be provided.
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 modificaĆ
tion are provided on pages 18 and 19 of Application
Manual DĆ9066. They must be carefully and comĆ
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 acĆ
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 the top of the controller enclosure.
Field Current Regulator with Tachometer Loss and
Overspeed Protection. This modification provides the
ability to operate the dĆc motor above base speed in the
 TABLE 8 - CONTROLLER MODIFICATIONS
Availability
Modification
Factory Jumper PreĆPackaged Kit UserĆInstalled
Installed Reconnection M/N (I/M) Modification
Acceleration/deceleration Std. Std.
times, extended
Auxiliary armature Std. 23C47 Std.
contactor contacts 23C48
Blower motor starter Yes 23C50
(DĆ3921)
Circuit breaker with thruĆ Yes 23C55, 23C56
theĆdoor handle (DĆ3920)
Current Limit, remote adjustment Yes Yes
Drive to Rest on Stop Yes Yes
Dynamic Braking Yes
Fan loss detector Std.
Field current regulator with Yes 23C96, 23C97
tachometer loss protection (DĆ3923)
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 Yes
Jog, Soft" Yes
Load Meter Yes 23C121, 23C122
(DĆ3830)
Meter Filter Yes 23C30
(DĆ3819)
Multiple Motor Operation Yes
Multiple Preset Speeds Yes Yes
Response Improved Yes
Shunt, 50 MV Yes 23C60Ć23C65
(DĆ3922)
Speed Indicator Yes
Speed Regulation, 1% Yes Yes*
Speed Regulation, 0.5% Yes Yes*
Speed Regulation, 0.25% Yes
Speed Regulation, 0.10% Yes
Tester, Circuit Yes 9C49
Voltmeter, Armature Yes 23C131Ć23C152
(DĆ3830)

* Also requires Motor Driven Tachometer.

Std." indicates controller has this item as a standard feature.

12
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,
mount beside the main regulator rack, and receive 115
volt aĆc control power and a reference signal from the
controller armature output voltage. When motor armaĆ
ture voltage is sensed to be at 100% and a further inĆ
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 OPĆ
TION IS USED. The tachometer monitor circuit proĆ
vides an interlock causing the drive to stop in the event
of tachometer signal loss or motor overspeed.
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 obĆ
tained by weakening the motor field excitation (field
trim) using a slidewire resistor in series with the motor
field. This is available as a factoryĆinstalled modification.
Follower, Signal. When so specified, the controller will
be equipped with circuitry to control motor speed in reĆ
sponse to an external voltage or current signal. ComĆ
monly, the drive is specified to follow 4Ć20 or 1050 ma.
signals as generated by conventional process control
instruments. Also common is the specification which reĆ
quires the drive to follow a zeroĆbased voltage reference
(0Ć5, 0Ć10 or 0Ć20 volt). In either case, the drive will conĆ
trol motor speed in direct proportion to the applied referĆ
ence with motor speed increasing with an increase in
the value of the reference signal.
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 7.
13
Tester, Circuit. Available factory installed or as a preĆ
packaged kit, this plug in 44Ćpin card installs into a slot
in the card rack and allows monitoring of 11 critical voltĆ
ages within the controller. It also contains an adjustable
voltage reference signal source which can be injected
into the drive in either polarity for diagnostic evaluation.
Operation and use of the tester is described in Section
3 of this manual.
TRANSFORMERS
Auto transformers step the aĆc power supply voltage
up or down, but these do not provide isolation from the
line.
Isolation transformer also provide voltage stepĆup or
stepĆdown. They also isolate the armature circuit from
the line. Isolation transformer help to eliminateĆthe posĆ
sibility of:
D Injury to personnel if contact is accidentally made
with an electrical conducting component from the
drive.
D Voltage transients from the aĆc line coming to the
solidĆstate power conversion unit in the drive, which
might result in damage to the equipment.
D Damaging currents which can exist if a point in the
dĆc output becomes grounded and the aĆc electrical
system contains a ground also.
NOTE: IF AN AUTO OR ISOLATION TRANSFORMER IS
USED AHEAD OF THE DRIVE, A POWER DISCONĆ
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 CIRĆ
CUIT BREAKER TYPE DISCONNECT BE USED. RATHĆ
ER, A FUSED DISCONNECT SWITCH SHOULD BE
INSTALLED.
 SECTION 2
DRIVE INSTALLATION
DANGER
THIS EQUIPMENT SHOULD BE INSTALLED,
ADJUSTED AND SERVICED BY QUALIFIED
ELECTRICAL MAINTENANCE PERSONNEL FAĆ
MILIAR WITH THE CONSTRUCTION AND OPĆ
ERATION OF THE EQUIPMENT AND THE HAZĆ
ARDS INVOLVED.
THE USER IS RESPONSIBLE FOR INSTALLAĆ
TION OF THE MOTOR, CONTROLLER AND
OPERATOR DEVICES IN CONFORMANCE
WITH THE ``NATIONAL ELECTRIC CODE" PUBĆ
LISHED BY THE NATIONAL FIRE PROTECTION
ASSOCIATION, AND OTHER APPLICABLE LOĆ
CAL CODES WHICH COVER SUCH ITEMS AS
WIRING PROTECTION, GROUNDING, DISCONĆ
NECTS AND OVERCURRENT PROTECTION.
INSTALLATION OF THE DRIVE MOTOR
The dĆc drive motor should be installed in accorĆ
dance with its own installation instructions. Instructions
for the installation of Reliance Super RPM motors furĆ
nished in frames B180ATZ through B680ATZ are furĆ
nished in instruction manual CĆ3076.
INSTALLATION OF THE DRIVE CONTROLLER
The MaxPak Plus controller, most often supplied in its
own NEMA 1 enclosure, is also available in a NEMA 12
cabinet. Figure 14 provides cabinet dimensions and
weight. The dimensions apply to all model number MaxĆ
Pak Plus controllers and are not affected by the addition
of any of the kit or factory modifications described on
pages 12 through 13.
General Requirements
Unless designed for special environments, the drive
controller should be installed in an area where the folĆ
lowing conditions exist:
1. Ambient temperature does not exceed 40°C
(104°F).
2. Ambient temperature is not less than 0°C (32°F).
3. Altitude above sea level does not exceed 3300 feet
(1000 meters).
4. Ambient air is clean and dry and free of flammable
or combustible vapors, chemical fumes, oil vapor,
steam, excessive moisture and dirt.
5. Clearances around the equipment must be large
enough to:
14
a. Provide accessibility to the controls within the
control cabinet for inspection, maintenance and
module replacement.
b. Provide nonĆrestricted flow of air to and from the
intake and exhaust openings.
6. Air for 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 beĆ
low.
WIRING THE DRIVE
Important: Make certain that the input power to the
drive cabinet is of the correct voltage and frequency and
that the plant supply is of sufficient ampacity to support
input current requirements of the controller. Refer to the
drive cabinet nameplate for correct input power inĆ
formation. If the correct voltage is not available, it will be
necessary to use a transformer between the power supĆ
ply and the drive.
NOTE: When the drive controller has been furĆ
nished without a circuit breaker, the user must
Install a circuit breaker or fused disconnect In orĆ
der to comply with the overcurrent protection reĆ
quirements of NEC.
BASIC DRIVE INTERCONNECTIONS
The drive will require electrical interconnection beĆ
tween the drive cabinet and the motor, between the opĆ
erator's control station and the drive cabinet, and beĆ
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, Figure
15. Be sure the cabling diagram W/D number correĆ
sponds to that indicated on the drive cabinet nameĆ
plate.
NOTE: Potentiometer wiring must be done with
twisted three conductor wire with at least two
twists per Inch (Reliance part number 413329ĆT
or equivalent). Tachometer feedback wiring
(where used) much be done with twisted two conĆ
ductor wire with at least two twists per Inch (ReĆ
liance part number 413329ĆS or equivalent).
These signals must be run In a separate magnetic
conduit to eliminate the possibility of noise pickĆ
up.
 Terminations for the power conductors, both AĆC and
DĆC, are located near the top of the cabinet. However.
the cabinet is also designed for easy wiring when the
cabinet is to be mounted over a floor wiring duct or other
bottom entry installation. The lower rear portion of the
cabinet provides access to a cabling area. Thus, cables
can be pulled out of a floor wiring duct, the wires placed
in the cabinet cabling area, the cabinet pushed back
over the floor duct, and the cables lugged and conĆ
nected to the controller terminations.
The terminations in the controller are designed to acĆ
cept the following maximum wire sizes when affixed
with standard Burndy Hylugs", style YAĆA or YAĆAĆTN
or equal:
AĆC Inputs (per line): Three, 500 MCM wires or
four, 350 MCM wires.
DĆC Armature Output (per line): Four, 500 MCM
wires or three, 750 MCM wires.
TRANSFORMERS
Transformers must be connected in accordance with
the transformer nameplate connection data.
15
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 nameplate for curĆ
rent ratings.
DANGER
If your drive cabinet is mounted such that the cabĆ
inet is not grounded, a ground wire should be
connected to the cabinet for personnel safety.
Also, the motor frame should be grounded by solĆ
idly connecting a ground wire to a screw in the
conduit box. If the motor is accessible while it is
running, a protective guard should be installed
around all exposed rotating parts.
 32.56 DOOR SWING
CAB. LIFTING 155°
EYEBOLTS

VENTILATION SLOTS

MAX CONDUIT
EXTENSION
HANDLE W/D N/P
PROJ. 1.88

MIN. MTG. MAX CONDUIT

STUD LENGTH FILTER EXTENSION
& FAN

FRONT VIEW

CONDUIT ENTRY AREA IN BOTTOM

APPROX. WEIGHT
WITH CONTROL: 725#
.75 DIA.
(4) MTG. HOLES

DIMENSIONS ARE IN INCHES

FRONT
SECTION AA

REFERENCE D/S 604592Ć3

FIGURE 14 - FLOOR MOUNTED CABINET, FD86U, BLOWER VENTILATED

POSITIVE PRESSURE, NEMA 1

16
 3ĆPHASE
PLANT POWER

REGULATOR
ASSEMBLY

TYPICAL MOTOR CONNECTIONS

FOR DRIVES WITH BASIC AND
DB FEATURES (3)

OPERATOR'S
CONTROL STATION
9C51

SPEED
POTENTIOMETER

TACH

JOG/RUN
SWITCH MOTOR

START/STOP
SWITCH NOTES:

1. Potentiometer wiring must be done with twisted three conductor

wire with at least two twists per inch. (Reliance part number
413329ĆT or equivalent). Tachometer feedback wiring (where
used) must be done with twisted two conductor wire with at least
OPERATOR'S two twists per inch (Reliance part number 413329ĆS or equivalent).
CONTROL STATION These signals must be run in a separate magnetic conduit to elimiĆ
9C51 nate the possibility of noise pickup.
SPEED POT 2. Tachometer connections (when used with nonĆregenerative MaxĆ
CONNECTIONS Pak Plus controllers) are polarity insensitive when connected to
AS ABOVE 419 and 519.
3. A1, A2, S1, S2, F1 and F2 connections within the motor conduit
JOG box must be made according to the instructions of CĆ3076Ć3 supĆ
PUSHBUTTON plied with the drive motor to assure proper direction of motor rotaĆ
tion and proper polarity of the stabilizing field.

FIGURE 15 -
START/STOP
SWITCH INTERCONNECTION DIAGRAM
FOR NONĆREVERSING DRIVES
When using 9C45 or 9C51 operator's control stations

17
 SECTION 3
STARTĆUP AND ADJUSTMENT PROCEDURES
DANGER
THIS EQUIPMENT SHOULD BE INSTALLED,
ADJUSTED AND SERVICED BY QUALIFIED
ELECTRICAL MAINTENANCE PERSONNEL FAĆ
MILIAR WITH THE CONSTRUCTION AND OPĆ
ERATION OF THE EQUIPMENT AND THE HAZĆ
ARDS INVOLVED.
EQUIPMENT IS AT LINE VOLTAGE WHEN AĆC
POWER IS CONNECTED TO THE POWER UNIT.
ALL PHASES OF THE AĆC POWER LINE MUST
BE DISCONNECTED FROM THE POWER UNIT
BEFORE IT IS SAFE TO TOUCH ANY INTERNAL
PARTS OF THIS EQUIPMENT.
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 moĆ
tor load at the factory to check performance and adjustĆ
ments. The start up and adjustment procedure below
will locate any shipping damage, verify proper installaĆ
tion and field wiring and provide a second check of adĆ
justments.
StartĆup will proceed in the following sequence:
1. Motor Checks
2. Physical inspection of equipment
3. Preliminary electrical checks with power off
4. Final electrical checks with power on
5. Initial adjustments
6. Sequencing and operational check
Before attempting to perform this start up procedure,
the reader should be familiar with the general arrangeĆ
ment and function of the drive equipment (Section 1,
pages 4 thru 7) and should verify that it has been
installed and wired per the instructions of Section 2.
While proceeding with the startĆup, the reader should
reference Figure 16 for assistance in locating compoĆ
nents, jumpers and controls.
NOTE: If, during any of the checks or adjustments proĆ
cedures given below, it is not possible to obtain the corĆ
rect meter reading or proper operation, do the followĆ
ing:
1. Stop the drive, turn off and lock out all aĆc input
power.
2. Check that all connections are in strict conformance
to the wiring diagram.
3. Consult the troubleshooting section of this manual.
TEST EQUIPMENT
Although an oscilloscope is referenced in the text for
use in making certain adjustments to high performance
18
custom drives, standard performance equipment reĆ
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 proceĆ
dure.
A megger may be used to reliably verify the absence
of inadvertent grounding of the motor. Refer to step 12,
page 22 for the proper procedure in making these
checks. Failure to follow proper procedure with the
Megger may cause damage to the controller.
DANGER
WHEN OBSERVING THE CURRENT FEEDBACK
SIGNAL WITH A SEPARATE INSTRUMENT Ć
WHETHER FROM THE FACEPLATE TERMIĆ
NALS OF THE TESTER CARD OR DIRECTLY
FROM REGULATOR TERMINALS Ć EXERCISE
EXTREME CAUTION. SHORTING TERMINALS
219 AND 57 WILL PRESENT THE CONTROLLER
WITH A ZERO CURRENT FEEDBACK SIGNAL
AND CAUSE THE MOTOR TO DRIVE TO A
SPEED WHICH MIGHT BE IN EXCESS OF THAT
SET BY THE MAXIMUM SPEED ADJUSTMENT
OF THE REGULATOR. ACCELERATION WILL
BE EXTREMELY FAST. RESULTING ACCELERAĆ
TION AND FINAL MOTOR SPEED MAY CAUSE
DAMAGE TO THE DRIVE MOTOR AND/OR
DRIVEN EQUIPMENT OR CAUSE INJURY TO
PERSONNEL.
TO REDUCE THE POSSIBILITY OF INADVERĆ
TENT SHORTING OF THE CURRENT FEEDĆ
BACK SIGNAL, CONNECT A 5K RESISTOR TO
TERMINAL 219 IN SERIES WITH THE LEADS TO
THE SEPARATE INSTRUMENT BEING USED.
TESTER CARD
The optional Tester Card may be present in your
drive. If so, it is located in the right hand most card slot
in the regulator rack (Figure 16). Its use during startup
will be referenced in the following procedure. A comĆ
plete description of the function and operation of the
tester card is provided in Section 4, page 44.
If a tester card is not present in your drive, it may be
added at any time, or you may choose to make the
checks as noted in the text and/or Table 16 with a sepaĆ
rate voltmeter having a sensitivity of 20,000 ohms per volt
by making connections to the appropriate terminals.
MOTOR CHECKS
1. Carefully read and comply with the Operation SecĆ
tion of Instruction Manual CĆ3076Ć3 describing the
Super RPM dĆc motor. In particular, note the followĆ
ing:
A. The armature should rotate freely and be clear
of any obstructions.
 B. The brushes should move easily in their holders
and should make proper contact on the commuĆ
tator.
C. The interior of the motor should be clean and
dry.
D. Connections should be tight.
DANGER
Before starting motor, remove all unused shaft
keys and loose rotating parts to prevent them
from flying off. Replace covers and protective
devices.
If the MaxPak Plus controller is being used with a moĆ
tor other than a Reliance Super RPM machine, read and
comply with the instructions supplied with it before proĆ
ceeding.
2. Couple the motor securely to its intended load.
PHYSICAL INSPECTION OF EQUIPMENT
Before operating the equipment DISCONNECT AND
LOCK OUT ALL INCOMING POWER and perform the
following checks:
1. Carefully inspect the controller for physical damĆ
age. Ascertain free operation of all switches, relays,
auxiliary contacts and contactors.
2. Visually inspect internal wiring for loose or broken
connections or damaged wires.
3. Visually check for damaged components.
PRELIMINARY CHECKS WITH POWER OFF
1. Check to see that the plant power supply to the conĆ
troller is of the correct voltage and frequency and
that the plant supply branch from which the drive is
to be operated is of sufficient ampere capacity to
supply drive input current requirements as listed in
Table 6, page 9. Compare observed plant line paĆ
rameters against those specified on the cabinet
nameplate.
2. Check to see that the transformer (when used) is
connected to give correct voltage to the input of the
controller.
3. Verify that the controller has been properly installed
and interwired per the instructions of Section 2.
4. Inspect the regulator rack and check that each of
the five cards (six, if the optional tester has been furĆ
nished) is firmly seated in its connector and comĆ
pletely fastened into place by means of its two fasĆ
tening screws. From left to right, regulator cards
should have alpha notation and bill of material
(B/M) identifying numbers per Table 9.
Verification of the above card compliment identifies
the drive regulator as a standard performance"
19
TABLE 9 - STANDARD CONTROLLER CARD
COMPLEMENT
Alpha
Regulator Card Notation B/M Number
Static Sequence SSCC 0Ć51874Ć2
Controller
Overload and OLVC 0Ć52808Ć2
Voltage Comparator
Current and Voltage CVTG 0Ć51831Ć6
Transductor
CLDK 0Ć51865Ć9
Current Loop Driver
CRCF 0Ć51851Ć5
Controller Regulator
TSTB 0Ć51811Ć1
Tester (Optional)
regulator. As such, drive adjustment (beginning on
page 23) as described for"standard drives" will apply
and adjustment can be completed with nothing more
than a multimeter as specified above.
If, however, one or more of the above listed cards
displays a modified" bill of material number, differĆ
ent than those listed above and affixed to the card
faceplate via a typed paper label, then the adjustĆ
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 four Phillips screws securing the power
module cover three or four turns, lift and remove the
power module cover. Check to see that all six gate
cables are firmly attached to their respective gate
coupling printed circuit board. Check their orientaĆ
tion according to the connection diagram affixed to
the inside of the power module cover and be sure
that the red and white color coding of each cable
matches the color code lettering on the gate couĆ
pling boards. Replace and resecure 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 esĆ
sential to assure proper coordination of motor therĆ
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 drivĆ
en motor of a lower horsepower than the nameplate
horsepower rating of the controller. If not set propĆ
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 10. The
M" value must be set for the proper motor horsepower.
7. Replace and resecure the CVTG card. If operation as a voltage regulator is desired,
check for the presence of a jumper between termiĆ
NOTE: The controller should never be used to nals 157 and 919 on terminal board 2TB (located at
operate a motor of higher nameplate horsepowĆ the right hand end of the regulator assembly). Also
er than the controller. Further, due to the characĆ verify presence of a jumper between terminals 119
teristics of the current transformers and range of and 619 of 2TB.
current feedback calibration allowed by the
CVTG circuitry, there is also a lower limit of moĆ If operation as a speed regulator is desired, the
tor horsepower that can be reliably operated by above referenced 2TB jumpers between 157 and
the controller. Minimum allowable motor horseĆ 919 and between 119 and 619 must be verified as
power for each MaxPak Plus controller rating is being removed. Tachometer feedback should be
listed in Table 11. connected to 2TB terminals 419 and 519.
In either case, check for presence of factory
TABLE 10 - CURRENT FEEDBACK CALIBRATION installed jumpers between terminals 57 and 12, 244
Proper M" Value and 344, 24 and 667,18 and 118 and from 99 to 100.
Motor
240 Volt 500 Volt 600 Volt
See Figure 16 for their locations.
Horsepower
Armature Armature Armature 10. If the drive is to be operated as a speed regulator,
200 2.31 Ċ Ċ determine, either from the sales order wiring diaĆ
250 2.82 Ċ Ċ gram or tachometer nameplate information, the
300 3.39 Ċ Ċ tachometer output voltage delivered at 100% motor
400 Ċ 2.31 Ċ speed. Connect jumpers on terminal board 2TB as
480 Ċ Ċ 2.31 noted in Table 12 to provide proper scaling of the
500 Ċ 2.82 Ċ tachometer feedback voltage into the regulator.
600 Ċ 3.39 2.82
720 Ċ Ċ 3.39 TABLE 12 - TACHOMETER VOLTAGE SCALING

Tachometer Voltage Scaling

TABLE 11 - MINIMUM ALLOWABLE MOTOR
HORSEPOWER Nominal Tachometer
Voltage (AĆC or DĆC) Jumpers Required (Remove
Controller Minimum Allowable Motor Horsepower at 100% Motor Speed Jumper From 619 to 119)
Nameplate
240 Volt 500 Volt 600 Volt 226V - 250V None
Horsepower
Armature Armature Armature 156V - 225V Jumper 919 to 819
200 200 Ċ Ċ 100V - 155V Jumper 719 to 619
250 Ċ Ċ Ċ
300 200 Ċ Ċ 65V - 99V Jumper 819 to 619

400 Ċ 300 Ċ 47V - 64V
480 Ċ Ċ 360
500 Ċ 300 Ċ
600 Ċ 300 360
720 Ċ Ċ 360
(1) Dependent upon power unit supplied.
ĊPower unit part number (P/N) 801429Ć1RE: 10 hp minimum
ĊPower unit part number (P/N) 801429Ć1SE: 20 hp minimum
ĊPower unit part number (P/N) 801429ĆRB: 20 hp minimum
ĊPower unit part number (P/N) 801429ĆSB: 40 hp minimum
(2) Lower minimum hp's are allowable. Consult the factory for
correct M" settings.
8. Check that the armature voltage feedback connecĆ
tions are made to the appropriate faceplate termiĆ
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.
9. If built as a Reliance model number controller, the
MaxPak Plus is shipped as a voltage regulator. If so
desired, it may be easily converted to a speed reguĆ
lator by the addition of a motorĆdriven tachometer
and jumper reconnection within the controller itself.
If built per customer specifications, the controller
may ship as either a voltage or a speed regulator.
Jumper 919 to 819 and 719 to 619
36V - 46V Jumper 919 to 719 and 819 to 619
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. Connect one ohmmeter lead to the metal control
cabinet.
b. Set the ohmmeter scale on R x 100,000.
c. Touch the other ohmmeter test probe to each
terminal on terminal board number two (2TB) loĆ
cated on the right hand side of the regulator porĆ
tion of the power conversion panel in the control
unit. If a reading to ground on any terminal is less
than 100,000 ohms, a ground condition exists in
this circuit.
d. Consult your wiring diagram to analyze location
of possible fault. Go over the circuit, represented
by the grounded terminal, to ascertain whether
there exists any breaks in insulation of the wirĆ
ing, or any grounded components.

20
 JUMPERS SHOWN ARE SUPPLIED AS STANDARD ON MODEL NUMBER DRIVES
FROM THE FACTORY
FIGURE 16 - REGULATOR ASSEMBLY
e. Always use an ohmmeter for checking grounds
in tachometer circuits.
12. Check rotating equipment for grounds. If a megger
Is used, make certain that all leads are disconĆ
nected between the rotating equipment and the
control cabinet. This will prevent damage to
electronic circuitry (exciters and their
associated circuits, etc.) due to the high voltage
generated by the megger.
FINAL CHECKS WITH POWER ON
1. Verify Proper indicator Light Status
DANGER
THIS EQUIPMENT SHOULD BE INSTALLED,
ADJUSTED AND SERVICED BY QUALIFIED
ELECTRICAL MAINTENANCE PERSONNEL FAĆ
MILIAR WITH THE CONSTRUCTION AND OPĆ
ERATION OF THE EQUIPMENT AND THE HAZĆ
ARDS INVOLVED. THIS EQUIPMENT IS AT LINE
VOLTAGE ANYTIME THE INCOMING LINE CIRĆ
CUIT BREAKER IS CLOSED, WHETHER THE
UNIT IS IN OPERATION OR NOT.
21
DANGER
BEFORE PROCEEDING, MAKE SURE THAT YOU
CAN QUICKLY STOP THE DRIVE IF NECESSARY.
IF THE INPUT POWER DISCONNECT AND/OR
STOP PUSHBUTTON ARE OUT OF YOUR
REACH, HAVE AN ASSOCIATE STATIONED TO
OPERATE THEM IN THE EVENT OF DRIVE
MISFUNCTION DURING THESE INITIAL POWER
ON CHECKS AND DRIVE ADJUSTMENT.
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 lit. If it is not, remove
power to the drive cabinet and interchange any
two aĆc line power wires feeding the drive controlĆ
ler input. Reenergize the drive and verify the
phase seq." light as lit. This indicates proper
phase sequence into the controller. The drive conĆ
troller will not respond to any of the operator conĆ
trols unless proper phase sequence is provided.
 TABLE 13 - INDICATOR LIGHTS
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 344 keeping the major loop in standby). The major loop is in standby when this
indicator is off.
Minor Loop The minor loop is enabled when this indicator is on. The minor loop is in standby when
On (2S) this indicator is off.
Arm. Voltage Armature voltage is present when this indicator is on. Armature voltage is zero when
Comparator this indicator is off.
Phase Seq. Line phase sequence is correct when this indicator is on. Drive will not start unless indiĆ
cator is on. If indicator 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 amplifier is overloaded when this indicator is on. Occasional flickering of
this light may occur during normal operation. If indicator is on continuously, current
gain is too high, or minor loop is not working properly.
Fault Overload Overload fault circuit is tripped when this indicator is on.
Indicators Fault Drive will not start if indicator is on.
IET Fault IET fault circuit is tripped when this indicator is on. Drive will not start if indicator is on.
NOTE: Overload IET indicators remain on until fault circuits are reset. In auto reset
mode fault circuits and fault indicators reset automatically after approximately 3 seĆ
conds. In manual reset mode reset occurs when reset button is pressed.

Field Supply STARTĆUP AND ADJUSTMENT PROCEDURE

The light market Field Supply" on the face of the
OLVC card should be lit, thus indicating the presĆ
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 7FU or 8FU. It does not necĆ
essarily indicate a complete motor field circuit.
Major Loop On 1S
Minor Loop On 2S
Armature Volt Comp
Overload Fault
IET Fault
Gain Limit
These indicator lights, located on the faceĆ
plates of the SSCC, OLVC and CLDK cards
should all be extinguished at this time.
Table 13 provides a listing of each of the indiĆ
cator lights, its operation and meaning.
2. Verify Fan Rotation
Check to see that air is drawn in the bottom
filtered opening and forced out the top louvers.
3. Verity Field Current
Using a dĆc clampĆon ammeter, verify that moĆ
tor field current is flowing in the motor field circuit.
This current should be within 20% of the field curĆ
rent stamped on the motor nameplate.
4. Stop
Remove power to the drive and read the adĆ
justment procedure before attempting to adjust
the drive.
DANGER
THIS EQUIPMENT SHOULD BE INSTALLED,
ADJUSTED AND SERVICED BY QUALIFIED
ELECTRICAL MAINTENANCE PERSONNEL FAĆ
MILIAR WITH THE CONSTRUCTION AND OPĆ
ERATION OF THE EQUIPMENT AND THE HAZĆ
ARDS INVOLVED. AĆC POWER MUST BE DISĆ
CONNECTED (ALL AĆC LINES) FROM THE
DRIVE CABINET BEFORE IT IS SAFE TO TOUCH
ANY INTERNAL PARTS OF THIS ENTIRE DRIVE
SYSTEM. ALL ADJUSTMENTS WILL BE MADE
WITH THE INPUT POWER TURNED ON. THIS
EQUIPMENT IS AT LINE VOLTAGE ANYTIME
THE INCOMING LINE CIRCUIT BREAKER IS
CLOSED, WHETHER THE UNIT IS ON OR NOT.
Read the entire adjustment procedure before atĆ
tempting to ad just the drive. Also refer to wiring diaĆ
grams supplied with your drive. Allow at least 30 minĆ
utes warmĆup time before making the adjustments. With
incoming power to the drive, but the drive stopped, the
motor field is excited. During the 30 minute warmĆup peĆ
riod, the motor field reaches operating temperature. All
adjustments should be made with the motor coupled to
its intended load.
If an adjustment reference source is not readily availĆ
able, the signal from the tester card (TSTB) may be used
as follows:
a. Set the selector switch on the tester to OFF.
b. Set the range switch to the 15V 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 referĆ
ence.

22
 Whenever the test signal switch is depressed in
the (+) direction, the reference voltage 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 switch is In the OFF position (position
number 12).
CURRENT RATE ADJUSTMENT
On standard performance drives the Current Rate
control must be set fully CCW.
On high performance custom drives the Current Rate
setting is indicated by documentation supplied with the
system.
The maximum Current Rate setting depends on the
motor armature electrical time constant, Te. The maxiĆ
mum setting is plotted as a function of Te in Figure 17.
This setting should never be exceeded.
NOTE: It is advisable not to set the Current Rate any
higher than necessary to achieve the desired perforĆ
mance.
MOTOR ELECTRICAL TIME CONSTANT
La/Ra IN MILLISECONDS
FIGURE 17 - MAXIMUM ALLOWABLE CURRENT
RATE ADJUSTMENT
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 availĆ
able, the Current Gain may be set by observing the step
response of the current loop, according to the proceĆ
dure below:
NOTE: The digital firing circuit has dynamic characterisĆ
tics different than analog driver circuits under condiĆ
tions of excess gain. Excessive gain does not cause inĆ
stability and uneven firing as is characteristic of analog
23
firing circuits. Excessive gain will cause saturation and
nonĆlinear performance of the current loop, and should
be avoided. The Current Gain control settings must be
established by observing the step response of the curĆ
rent loop.
DANGER
THE FOLLOWING PROCEDURE MUST BE FOLĆ
LOWED EXACTLY TO PREVENT UNEXPECTED
UNCONTROLLED SHAFT ACCELERATION AND
SUBSEQUENT POSSIBLE PERSONNEL INJUĆ
RY OR MACHINERY DAMAGE.
1. Disconnect all aĆc power from the drive. LOCK THE
ARMATURE SHAFT SECURELY WITH THE ABILĆ
ITY TO WITHSTAND AT LEAST THREE (3) TIMES
FULL LOAD MOTOR TORQUE. Disconnect the
motor field by removing the motor field leads conĆ
nected to F1 and F2 or 137 and 35 at the power unit.
Do not disconnect the field by removing the field
supply fuses, as this will cause a field loss indicaĆ
tion and lockout the start logic.
2. Remove jumper between terminals 244 and 344
(See Figure 16) of the bottom terminal board on the
regulator rack. This keeps the major loop regulator
in the standby mode.
3. Connect an oscilloscope from terminal 219 to 57
with a 5K ohm resistor between the oscilloscope
and terminal 219 to monitor the current feedback
signal or connect the oscilloscope to the optional
tester output pi ns with the tester set to position 9 on
the 15V range. The 5K ohm resistor between the osĆ
cilloscope and tester must also be used when monĆ
itoring this signal via the tester output pins. Refer to
the current feedback monitoring warning note
on page 19.
4. Connect a switched adjustable test reference signal
(0 to +12V) to the major loop test input, terminal 6.
(The test reference from the optional tester card
may be used to jumping terminal 226 to terminal 6).
5. Initially set the Current Gain fully CCW.
6. Turn on line power. Start the drive and increase the
test reference to a voltage corresponding to 100%
of rated current. (The test reference voltage from the
optional tester can be read with the tester in the off',
position.)
NOTE: The gain from the terminal 6 test input to
current feedback voltage is unity with the major
loop in standby. Standard scaling is 6.7 volts for
100% current. On custom drives consult system
documentation to determine the current feedback
scaling.
Due to the deadband" in the current loop, it may
require up to "1.2 volts of reference before curĆ
rent will flow.
7. Step the reference from 0 to 100% while observing
the current feedback waveform on the oscilloĆ
scope.
 Increase the Current Gain while continuing to obĆ
serve the step response, until a slightly overĆ
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 indiĆ
cator stays off while the reference is stepped. (It is
acceptable if the Gain Limit indicator flickers occaĆ
sionally, but it should not be on continuously).
NOTE: It is advisable not to set the Current Gain
any higher than necessary to achieve the desired
performance .
9. Stop the drive. Turn off the power. Remove the arĆ
mature lock. Reconnect the field. Replace the jumpĆ
er from 244 to 344. Disconnect the 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 poĆ
tentiometer required to achieve 150% current limit is
noted under the Panel Test" column of the potentiomeĆ
ter adjustment table. This table is mounted on the ConĆ
troller's power module cover just above the regulator
assembly. The current limit may be reduced from this
standard setting if desired.
On custom drives a different feedback scaling may
be 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 CurĆ
rent Limit should not be set above a value correspondĆ
ing to 10V of current feedback. The major loop regulator
may saturate if a higher current limit setting is atĆ
tempted.
NOTE: The following adjustments must be made
quickly enough to avoid tripping the overload cirĆ
cuits. Do not exceed 150% current or 10V for 1 minĆ
ute (for standard OLVC trip characteristics.)
DANGER
THE FOLLOWING PROCEDURE MUST BE FOLĆ
LOWED EXACTLY TO PREVENT UNEXPECTED
UNCONTROLLED SHAFT ACCELERATION AND
SUBSEQUENT POSSIBLE PERSONNEL INJUĆ
RY OR MACHINERY DAMAGE.
1. Disconnect all aĆc power from drive. LOCK THE
ARMATURE SHAFT SECURELY WITH THE ABILĆ
ITY TO WITHSTAND AT LEAST THREE (3) TIMES
FULL LOAD MOTOR TORQUE. Disconnect the
motor field by removing the motor field leads conĆ
nected to F1 and F2 or 137 and 35 at the power unit.
24
Do not disconnect the field by removing the field
supply fuses, as this will cause loss indication
and lockout the start logic.
2. Remove jumper between terminals 244 and 344
(See Figure 16) of the bottom terminal board on the
regulator rack. This keeps the major loop regulator
in the standby mode.
3. Connect a dĆc ammeter in the armature circuit to
measure armature current. Armature current can
also be determined by connecting a meter with a
20,000 ohm pr volt sensitivity from terminal 219 to
57 with a 5K ohm resistor between the meter and
terminal 219 to monitor the current feedback signal,
or by connecting the meter to the optional tester
output pins with the tester set to position 9 on the 15
volt range. The 5K ohm resistor between the meter
and tester must also be used within monitoring this
signal via the tester output pins. Refer to the curĆ
rent feedback monitoring warning note on page
19.
4. Connect an adjustable test reference signal (0 to
+12V) 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.)
5. Initially set the current limit control fully CCW.
6. Turn on line power. Start the drive and increase the
test reference to a voltage corresponding to the deĆ
sired limit point. (The test reference voltage from the
tester can be read with the tester in the off position.)
NOTE: The gain from the terminal 6 test input to
current feedback voltage is unity with the major
loop in standby. Standard scaling is 6.7 volts for
100% current. On custom drives consult system
documentation to determine the current feedback
scaling.
7. Turn the current limit control CW, noting that armaĆ
ture current increases to the value corresponding to
the test reference input.
8. 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.
9. Check the adjustment by increasing the test referĆ
ence noting that the armature current limits at the
desired value.
10. Stop the drive. Turn off power. Remove the shaft
lock. Reconnect the field. Replace the jumper from
244 to 344. Disconnect the test reference, or jumper
from terminal 226 to terminal 6.
The actual current limit point during normal drive opĆ
eration may vary slightly from that set by the procedure
above. The adjustment may be trimmed slightly during
actual operation of the drive if greater precision is reĆ
quired.
STABILITY ADJUSTMENT
On standard performance drives stable major loop
performance is obtained by setting the stability control
at 3. Improved performance may be obtained in seĆ
lected cases by an adjustment above or below this setĆ
ting. This may be determined by trial and error. Observe
the major loop feedback signal with an oscilloscope
from terminal 319 to 57 (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 deterĆ
mine response characteristics.
On high performance custom drives, documentation
supplied with the system will indicate the correct StabilĆ
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 regĆ
ulator systems, never with speed regulators. The
control is only active when a jumper is added beĆ
tween terminals 219 and 567 of the bottom terminal
board of the rack. Standard controllers are shipped
without this jumper installed.
1. Initially set the control fully CCW.
2. Start drive and run unloaded at rated speed.
3. Load the drive to full load current.
4. Adjust the IR compensation clockwise until the deĆ
sired compensation is achieved. Do not adjust for
speeds higher than the unloaded speed.
NOTE: Setting the IR comp. too high may cause inĆ
stability. Adjust control CCW if this occurs.
MAX. & MIN. SPEED (VOLTAGE)
These controls interact and must be adjusted alterĆ
nately in an iterative manner until the correct adjustment
is obtained. Initially set both controls fully CCW.
Max Speed (Voltage)
1. Set the speed or voltage reference fully CCW.
2. 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.
3. With the reference control fully CW, increase the
Max. Speed control until the drive is operating at the
desired maximum speed point. (If correct adjustĆ
ment is not obtained check major loop feedback cirĆ
cuits for proper scaling resistor.)
25
Min. Speed (Voltage)
1. Set the speed or voltage reference fully CCW.
2. Start drive and turn Min. Speed control CW until the
desired minimum speed point is reached.
Repeat the adjustments of both Max. Speed and Min.
speed controls until both controls are set for the desired
speed characteristics.
ACCEL. AND DECEL. RATE
These controls are only enabled when a jumper is
used between terminals 24 and 667 on the bottom terĆ
minal board of the regulator rack. These controls are set
by trail and error, noting the resultant performance and
adjusting as required.
1. 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 controls setting. Stop the
drive.
Accel. Rate
Leave the reference control set for rated speed and
start the drive. Adjust the Acceleration Rate Control CW
until the desired rate is obtained. The rate can be meaĆ
sured conveniently with a stop watch at the slower rates.
An oscilloscope or chart recorder will be required to set
the faster rates accurately. Monitor the major loop feedĆ
back 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. Turn the reference conĆ
trol quickly CCW to initiate deceleration. Adjust the DeĆ
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 applicaĆ
tion, the Decel. control should be set fully CW. The moĆ
tor will generally coast during the deceleration interval
for 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 dĆc motor is 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 adĆ
justable dĆc voltage for armature power. The fixed shunt
field provides a constant strength magnetic field against
which the armatureĆinduced field can react. Armature
(and shaft) speed is then controlled by varying the terĆ
minal voltage to the armature. Motor speed is nearly
proportional to armature terminal voltage.
Armature current is drawn as needed to provide moĆ
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
a regulator to control and adjust armature voltage under
varying torque and speed requirements.
Refer to manual DĆ3076Ć3 for a more detailed discusĆ
sion of motor operation.
ARMATURE RECTIFIER
The armature rectifier (power unit) used in the MaxĆ
Pak Plus controller is a conventional three phase, full
controlled, full wave bridge. It is shown schematically in
Figure 18. Using six thyristors, the power unit provides
adjustable dĆc voltage for the motor armature circuit by
phaseĆcontrolledĆrectification of 3Ćphase aĆc plant powĆ
AĆC
LINE
CURRENT
LIMITING
FUSES
LOAD CURRENT
FEEDBACK TO
REGULATOR
(IA)
FERRITE
REACTOR
➀ FusibleĆResistor is in series with each capacitor indicated.
FIGURE 18 - FULL WAVE POWER BRIDGE CONFIGURATION
26
er. Each of the thyristors is turned on" by pulsing its
gate at a point in the aĆc input power cycle when its
anode potential is positive with respect to its cathode.
Under these conditions, the application of a low powĆ
er gate pulse approximately 350 microseconds in duraĆ
tion, will cause the thyristor to conduct for as long as its
anode remains positive with respect to its cathode.
AnodeĆtoĆcathode polarity reversal, brought about by
the sinusoidal nature of the incoming plant line, will
commutate or turn off', the thyristor. The relative timing
of the gate pulse with respect to the aĆc plant supply will
determine the conduction angle (relative conduction
time) of the thyristor (and of the bridge) thus controlling
the average dĆc output voltage from the bridge to the
motor armature. Firing the thyristor gates early in the
positive half of the incoming sinusoid will allow it to conĆ
duct for a relatively long time until commutated off by
the line, thus producing relatively high average voltage
to the motor armature. Firing thyristor gates late in the
positive half cycle will allow only short periods of conĆ
duction before commutation, thus producing low values
of average dĆc output voltage to the motor armature.
Each pair of bridge thyristors (the upper and lower
thyristor connected together to the same input aĆc line)
are mounted along with their dv/dt RC network, metal
oxide varistors and a gate coupling board into a heatĆ
sink assembly referred to as a phase rectifier module.
Removable as a unit, each of these interchangeable
phase rectifiers forms oneĆthird of the power rectifier.
The mechanical design of the phase rectifier modules
allows utilization of the heatsinks as electrical as well as
thermal conductors. A typical phase rectifier module utiĆ
lizing discĆtype thyristors is shown in Figure 19.
ARMATURE
LOOP
CONTACTOR
OUTPUT
NETWORK
MOTOR
ARMATURE
ARMATURE VOLTAGE
FEEDBACK TO
REGULATOR (VA)

FIGURE 19 - 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 reĆ
spect to phase B (182), current will flow through thyrisĆ
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
#6 is gated ON twice, 60 degrees apart, once with thyĆ
ristor #2 and once with thyristor #1.
When phase B (182) is positive with respect to 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 reĆ
spect to phase C (183), current will flow through thyrisĆ
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 respect to phase
C (183), current will flow through thyristor #4, through
the load and through thyristor #3, when these thyristors
are gated ON. When phase A (181) is positive with reĆ
spect to phase B (182), current will flow through thyrisĆ
tor #4, through the load and through, thyristor #2, when
these thyristors are gated ON. Note here that thyristor
#4 is gated ON twice, 60 degrees apart, once with thyĆ
ristor #3 and once with thyristor #2.
The above description of thyristor gating can be sumĆ
marized by the following Table 14.
27
TABLE 14 - THYRISTOR GATING SEQUENCE
Thyristor Gated Relative Line CondiĆ
tions
6&2 +183 - 182
6&1 +183 - 181
5&1 +182 - 181
5&3 +182 - 183
4&3 +181 - 183
4&2 +181 - 182
POWER CIRCUIT FAULT PROTECTION
A balanced, coordinated fault protection system is inĆ
corporated by the following:
1. Bolted fault protection is obtained through the use
of current limiting fuses in the aĆc lines, having a
fault current interrupting rating suitable for aĆc
source capacity as noted on page 9 of this manual.
This is achieved by using three pairs of fuses
which is recognized by UL in this controller.
2. The functions of limited current fault protection and
instantaneous peak overload conditions such as
might arise from a regulator failure, a control seĆ
quencing failure or a mechanical jamming of the
motor shaft, is covered by an instantaneous elecĆ
tronic trip (IET).
An optional aĆc line breaker is recommended to
provide branch circuit feeder protection to meet
NEC requirements.
3. The motor is protected against sustained overloads
by a solid state overload trip circuit within the reguĆ
lator.
4. Peak operating overloads such as those encounĆ
tered on acceleration, shock loading, etc. are hanĆ
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 feaĆ
tures 2 through 4 by a pair of incoming line current transĆ
formers. Since only two thyristors (one upper, one lowĆ
er) are conducting at any given time, only two of the
three input power lines are ever simultaneously conĆ
ducting current. Thus, instantaneously, aĆc line current
in any conducting line is equal to dĆc armature current.
On an average basis, IaĆc rms = .85 IdĆc avg.
SEMIĆCONDUCTOR TRANSIENT
PROTECTION
Each thyristor in the power bridge is individually proĆ
tected by an RĆC circuit and a M.O.V. surge suppressor,
connected directly across the thyristor on the same
heatsink.
 The RĆC 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
RĆC circuits across each thyristor, provide high frequenĆ
cy line transient attenuation.
OTHER POWER UNIT HARDWARE
An RĆC network is connected across the dĆc 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 6 and 7 illustrate the location of power unit
components.
FIELD SUPPLY
The field supply, Figure 9, is a constant potential recĆ
tifier, consisting of three diodes (two rectifiers and one
back diode). This arrangement allows generation of 150
volts dĆc from a 230 volt aĆc plant line and 300 volts dĆc
from a 460 volt aĆc line, without the use of an anode
transformer. All of the diodes are protected by surge
suppressors. Both outputs F1 and F2 of the field supply
are fused . The field supply monitor detects field voltage
from the fused outputs.
The location of the field supply within the controller
is shown in Figure 5, page 5. The field supply is shown
schematically in Figure 11.
REGULATOR
Regulator Functions
The MaxPak Plus regulator provides major and minor
loop regulation, thyristor gate firing, static sequencing
and protective functions for a six pulse power unit. The
following basic functions are provided:
A. Major loop armature voltage or speed regulaĆ
tion.
B. Linear reference timing for controlled acceleraĆ
tion and deceleration.
C. Reference switching for selecting either jog or
run references.
D. Current minor loop regulator.
E. Digital gate driver circuits.
F. A transductor for isolated armature voltage feedĆ
back.
G. Rectifier and scaling resistors for isolated curĆ
rent transformer inputs to provide current feedĆ
back.
28
H. Rectifier, filter and scaling resistor network for
optional tachometer feedback.
I. Start, jog, and coast or dynamic brake stop seĆ
quencing.
J. Power up and power fail sequencing.
K. Protective circuits for overload, IET, incorrect
phase sequence or loss of field excitation.
In addition to the above features, the regulator proĆ
vides the ability to add a variety of optional features or
modifications not described in this manual. A number of
these regulatorĆbased modifications are listed in Table
8, page 12 and further described in manual DĆ9066.
Description
The regulator consists of a 10" wide, 44 pin card rack
and a separately mounted Phase Sequence, Line and
Field Supply Monitor printed circuit card. This separateĆ
ly mounted card is considered part of the regulator
since its function is associated primarily with the regulaĆ
tor protective circuits. This card is mounted in a sepaĆ
rate black enclosure located above the left end of the
card rack, Figure 10.
The card rack consists of a master interconnection
board, and five 44Ćpin plugĆin cards. An optional (6th)
tester card may be used in the right hand card position,
if called for. Figure 10 shows the regulator rack assemĆ
bly. The rack also includes a power transformer
mounted on the inside of the right hand side panel. This
transformer supplies isolated low voltage aĆc for the
regulator power supply. The transformer primary is exĆ
cited by the control power input terminals 188 and 189
(115 VAC).
All connections to the regulator for the commonly
used standard functions are accomplished with termiĆ
nal board connections. Control circuit (115 VAC) wiring
is grouped on the left hand terminal board (1TB). ReferĆ
ence and feedback wiring is grouped on the right hand
terminal board (2TB). The bottom terminal board inĆ
cludes various optional inputs, optional jumpers, and
optional components.
The terminal board arrangement is intended to
physically isolate the different types of circuits to miniĆ
mize electrical noise coupling. The control circuit wiring
to the left hand terminal board involves power and relay
circuits, and may be electrically noisy. The reference
and feedback wiring to the right hand terminal board are
low level signals which may be susceptible to noise. The
optional inputs to the bottom terminal board are also
low level signals. It is important to keep the control wirĆ
ing to the left hand terminal board physically isolated
from the wiring to the right hand and bottom terminal
boards.
 Status indicator lights on the regulator faceplates inĆ
dicate status and fault conditions. The functions of the
various faceplate indicators are listed in Table 13, page
23.
Regulator Arrangement
The block diagram of Figure 20 provides a simplified
schematic of the drive regulator. It contains all major cirĆ
cuits and, by means of the dottedĆline notation and alĆ
pha identifications, indicates the specific regulator card
which performs each function.
A more detailed discussion of the operation of each
of these regulator cards is presented on pages 32
through 44 of this manual.
Major Loop Regulator
The major loop regulator function is provided by the
CRCF card. It accepts a speed reference from the operĆ
ator's speed setting potentiometer, modifies this input
signal by adding adjustable linear acceleration and deĆ
celeration to it, and presents it, thus modified, to the inĆ
put of the speed (major loop) operational amplifier. A
separate jog speed reference may also be inputted to
the CRCF card.
The regulator will accept either armature voltage, isoĆ
lated by the CVTG card, or a tachometer feedback sigĆ
nal as the regulated major loop parameter. Although
shipped from the factory as a voltage regulator, converĆ
sion of this regulator into a speed regulator is accomĆ
plished by simple terminal jumper reconnection as deĆ
scribed on page 9. Either aĆc or dĆc tachometer
feedback is directly usable, since the tachometer signal
is fullĆwave rectified by the CRCF card before being furĆ
ther filtered and conditioned for use by the major loop
operational amplifier.
The outputs from the SSCC card will properly select
either the speed or jog reference, release or reĆzero the
timing capacitors in the acceleration/deceleration timĆ
ing circuits and either release or clamp the output from
the major loop operational amplifier in response to opĆ
erator's pushbutton commands.
Action of the major loop operational amplifier also
provides adjustable current limit protection to the drive
controller and its driven motor.
Minor (Current) Loop Regulator
The CLDK card provides the minor loop regulator
function by comparing the error output from the CRCF
card with an isolated current feedback signal derived
from the line current transformers and scaled by the
CVTG card scaling network. Output from the current opĆ
erational amplifier is fed to the digital gate driver circuits
whose outputs control the conduction angle of the powĆ
er unit thyristors.
29
Voltage and Current Transductors
Armature voltage feedback is isolated for use by the
regulator by the CVTG card. This card also provides
scaling of the already isolated armature current feedĆ
back signal and houses an isolated power supply for its
own use as well as the use of the rest of the driver regulaĆ
tor.
Drive Sequencing
Drive sequencing is achieved without the use of reĆ
lays through the action of the static sequencing card
(SSCC). It acts in response to inputs from the operator's
pushbutton controls to control major and minor loop
amplifier clamps, to select the proper speed reference
circuit and to operate the drive's armature loop (M) conĆ
tactor. An input to this card from the OLVC card coordiĆ
nates the above listed functions during drive fault condiĆ
tions as well.
Sensing Line and Field Supply Conditions
The Phase Sequence, Line and Field Supply Monitor
card constantly monitors the presence of incoming aĆc
power, incoming line phase sequence and field supply
output. Fault conditions sensed by this card are fed to
the OLVC card for fault signal processing.
Overload and Fault Sequencing
The OLVC card monitors the isolated and scaled arĆ
mature feedback signal derived on the CVTG card and
compares it with a fault current threshold level (at 200%
rated current). It initiates an instantaneous drive shutĆ
down (IET) if armature current reaches this fault threshĆ
old by acting to suppress gate pulses to the power unit
SCR's and then, through the action of the SSCC card,
causing the armature loop contactor to drop out and
placing the drive regulator in a standby state.
This card also used the armature current feedback
signal to sense low level motor overloads and, through
the action of a digital thermal overload" circuit, causes
the drive to undergo a normal stop if an overload perĆ
sists.
Fault signals from the Line and Field Supply Monitor
card are processed by the OLVC and also cause normal
drive stop.
FIGURE 20 - REGULATOR BLOCK DIAGRAM

30
 PHASE SEQUENCE, LINE AND FIELD SUPPLY MONITOR
0Ć54349ĄĄ
0Ć54349Ć1
0Ć54349Ć2
This printed circuit card, mounted in a separate enĆ Loss of incoming line or an incoming line supply eiĆ
closure above the left end of the regulator rack, detects ther low in value or with a single phase loss provides no
proper phase sequence, input line voltage, and field signal to drive the photo couple,, causing the photo
supply voltage. Three versions of this card exist deĆ transistor to turn off" and resulting in a logic high at
pending upon the value of incoming line voltage. With 166.
that exception, the boards perform the same function.
In a like manner, presence of field supply voltage proĆ
duces a logic zero at terminal 66 via a conducting phoĆ
TABLE 15 - PHASE SEQUENCE LINE AND FIELD toĆtransistor. Terminal 66 switches to a high state on loss
SUPPLY MONITOR CARDS of field power.
Incoming Line Monitor Board Comments
Voltage Used
Both outputs from this card are fed to the Overload
and Fault Logic card (OLVC), and form a portion of the
110 to 270 volts aĆc 0Ć54349ĄĄ Used on all 230 controller's overall protection network.
270 to 430 volts aĆc 0Ć54349Ć1 volt drives
430 to 550 volts aĆc 0Ć54349Ć2 Used on all 460 & There are no adjustments on this card.
575 volt drives

The phase sequence and line voltage monitoring

functions are both accomplished with the same circuit.
When phase rotation is correct, this circuit causes the
photoĆdiode portion of a photo isolator to conduct, satuĆ
rating the photoĆtransistor portion of the coupler isolator
and resulting in a zero volt condition (logic zero) at terĆ
minal 166. Incorrect phase sequence causes a logic
high at 166 with the phototransistor in a nonconductive
state.
FIGURE 21 - PHASE SEQUENCE, LINE AND
FIELD SUPPLY MONITOR

31
 PHOTO ISOLATOR

PHASE
SEQUENCE &
AĆC LINE LINE
INPUT MONITOR

PHASE
SEQUENCE &
LINE MONITOR
OUTPUT

PHOTO ISOLATOR

FIELD FIELD FIELD SUPPLY

SUPPLY SUPPLY MONITOR
INPUT MONITOR OUTPUT

FIGURE 22 - PHASE SEQUENCE LINE AND FIELD SUPPLY MONITOR

32
 CONTROLLER REGULATOR CARD - CRCF
0Ć51851Ć5
The CRCF card, whose simplified circuitry is illusĆ
trated in Figure 24 provides the major loop regulator
functions for the drive controller. Its circuits perform the
following operations:
1. The major loop regulating amplifier acts on the alĆ
gebraic sum of the drive major loop reference sigĆ
nal (normally a speed reference signal as set by the
operator's speed setting potentiometer) and major
loop feedback signal (normally armature voltage or
motor speed as derived from a motorĆdriven
tachometer). The output signal from this amplifier
stabilizes when the summation of the reference and
feedback signals is zero. For this to occur, the feedĆ
back level must equal the reference level and
steady state regulation is then achieved. This ampliĆ
fier output serves as the current reference signal to
the current minor loop of the MaxPak Plus controlĆ FIGURE 23 - CRCF CARD
ler.
6. Acceleration and deceleration rate circuits guaranĆ
2. The feedback amplifier and impedance elements tee smooth acceleration and deceleration of the
form a feedback path around the major loop amplifiĆ drive motor in response to a start" command or to
er, allow limited range stability adjustment of the changes in the setting of the reference potentiomeĆ
drive major loop, and provide terminals for optional ter.
addition of an engineered component arrangement
in the feedback path for applications where other A 10 microfarad timing capacitor is included on
drive performance characteristics are required. the CRCF card and allows acceleration and decelĆ
eration timing to 30 seconds maximum. An addiĆ
3. The current limit circuit allows adjustable limiting of tional 30 seconds of ramp timing can be achieved
delivered motor torque from the setting of either a for each 10 microfarads of additional capacitance
local or remotely located potentiometer. attached to the terminals noted up to a maximum of
4. The electronic switching of run and jog reference inĆ 200 seconds.
puts selects the correct drive reference signal in reĆ 7. Tachometer rectifier and filter circuit with programĆ
sponse to logic commands from the Static SeĆ mable resistors for tachometer voltage scaling allow
quencing card (SSCC). the controller to be easily converted for use as a
5. FET switches sequenced in response to a major speed regulator using a variety of aĆc or dĆc tachomĆ
loop standby" command from the SSCC card. a) eter generators with a wide range of output voltages.
discharge the linear reference timing circuit capaciĆ The CRCF card also includes faceplate controls to alĆ
tor, thus returning the timed run speed reference to low adjustment of maximum speed, minimum speed,
zero upon a stop command and maintaining this acceleration and deceleration rates, jog speed, IR comĆ
zero value for as long as the drive is in"standby". b) pensation (when connected), current limit and major
switch all but the test" input to the major loop amĆ loop stability.
plifier to zero, thus preventing amplifier drift during
standby, and, by means of adding a 2K ohm feedĆ The two terminals noted as A" on the block diagram
back resistor around the major loop amplifier, conĆ allow modifying components be added to the jog cirĆ
vert the amplifier to a proportional only circuit with cuit. The addition of a capacitor across these terminals
a fixed gain of 0.75 to allow specified CRCF card will cause exponential (soft) acceleration of the drive
testing to be performed while in standby. motor in response to a jog command, while wireĆwrapĆ
ping a resistor between these terminals will increase the
jog speed adjustment range from to 0 to 50% speed
range furnished as standard.

33
 FET SWITCH ADDITIONAL
CAPACITANCE
FOR EXTENDED
ACCEL/DECEL
TIMES
LOGIC INPUTS
FROM SSCC CARD
CONNECTIONS
ON TB2

MAX. SPEED
CLOSED IN
STANDBY

LINEAR
REFERENCE
SPEED TIMING
SETTING CIRCUIT
POTENTIOMETER
RUN REFERENCE
MIN. SPEED ENABLE

CURRENT
LIMIT

CLOSED IN
STANDBY

TIMED AND SWITCHED RUN SPEED REFERENCE CURRENT REFERENCE

TO CLDK CARD
JOG
REFERENCE
CLOSED IN
STANDBY
JOG
SPEED

IR COMP
OPTIONAL IR COMP REFERENCE
FEEDBACK AMPLIFIER
& IMPEDANCE ELEMENTS
ISOLATED
ARMATURE FEEDBACK
VOLTAGE
FEEDBACK
TACHOMETER
VOLTAGE STABILITY
SCALING

FET SWITCH DRIVE

LOGIC
TACHOMETER CONVERTER
OPTIONAL TACH FILTER
AĆC OR DĆC RECTIFIER
TACHOMETER
250 VOLTS
MAXIMUM

MAJOR LOOP (1S)

TEST INPUT
MAJOR LOOP (1S)
LOGIC INPUT
1. Factory installed jumper. See page 24. FROM SSCC
2. This Jumper, when installed, allows addition of IR compensaĆ CARD
tion. For use with voltage regulated drives only. See page 28.
3. Factory installed jumpers from 119 to 619, and 57 to 919
must be in place for operation as a voltage regulator. They must 4. See page 24 for a discussion of tachometer voltage scaling.
be removed for operation as a speed regulator when tach feed 5. Refer to Engineering Manual E/M 0Ć51851Ć5 for CRCF card
back is added. test procedures.

FIGURE 24 - CRCF BLOCK DIAGRAM

34
 CURRENT LOOP DRIVER - CLDK
0Ć51865Ć9
The primary function of the card is to regulate armaĆ
ture current in response to the current reference input
signal by phase angle firing control of the power unit.
The card receives a 50 or 60 Hertz line synchronizing
(line sync) input signal from the SSCC card, the current
loop reference signal generated as the output from the
major loop regulator on the CRCF card, an isolated and
scaled armature current feedback signal from the curĆ
rent transductor portion of the CVTG card, IET logic inĆ
put from the fault circuits of the OLVC card, and generĆ
ates, as its output, a set of 6 firing signals, one directed
to the gate of each of the power unit SCR's.
The line sync input signal developed by the SSCC
card provides input to a phase locked loop forming a
line synchronized clock whose output maintains synĆ
chronism between the gate pulse generator and incomĆ FIGURE 25 - CLDK CARD
ing line power. With synchronism thus developed, the
controller operates without modification on 50 or 60 errors where extremely high performance operation is
hertz line power. required. Current gain is normally set at zero, with an adĆ
The current reference signal generated by the CRCF justment away from this zero setting providing no imĆ
card is used as an input to the card where a rate of provement in drive performance in most cases. A gain
change limit is imposed upon it. The degree of rate limitĆ limit lamp mounted on the faceplate of the card indiĆ
ing is determined by the current rate potentiometer adĆ cates saturation of the error loop in cases where current
justed on the card faceplate. The purpose of this rate of gain has been set too high.
change limit is to guard against motor commutation failĆ The digitized current error signal, along with synĆ
ure or inverting faults when the controller is configured chronizing information from the phase controlled loop,
for operation in the regenerating mode. Since the MaxĆ is used as input to 6 digital gate drive circuits to fire the
Pak Plus drive, as described by this manual, is a nonĆreĆ thyristor gates. Since the gate firing circuit is totally digiĆ
generative drive, this current rate adjustment is immateĆ tal there is no need for current balance" adjustments
rial and is set at zero. (The only exception to this rule is nor any possibility for component tolerance or circuit
if the drive were specifically applied on an unwind type drift to effect the firing angle of the thyristors in relation
of application wherein the controller operates with arĆ to one another so as to cause a current imbalance.
mature voltage tending to drive the motor in one direcĆ
tion and web tension forcing the motor to operate in the An IET logic signal generated on the OLVC card acts,
other. In this condition, the motor acts as a brake and on an IET trip, to interrupt gate pulses to the power unit
operates in a regenerative mode of operation. If this is thyristors. Its action also opens the current reference
the case, engineering manual 0Ć51865Ć9 and systemĆ signal to the input of the CLDK
supplied documentation should be consulted for the
A standĆby logic command from the SSCC card asĆ
appropriate setting of the current rate adjustment.)
sures current loop zeroing when the drive is in a standĆ
The timed current reference signal is compared with by mode by providing a feedback signal proportional to
a signal proportional to actual armature current as genĆ the firing angle when the drive is in standĆby. Since, in
erated by the CVTG card. This reference and feedback standĆby, the current reference signal is zero (due to the
comparison is made by the current summing amplifier action of standĆby logic on the CRCF card), the current
whose outputĊcurrent errorĊis converted to a pulse loop regulator will maintain zero firing angle (generating
rate signal by the action of the error voltage controlled zero armature volts) during standby.
oscillator. A current gain adjustment acting on this voltĆ
This feature allows exercising the current loop reguĆ
age controlled oscillator provides the ability to increase
lator by means of a test input in the standĆby mode by
the sensitivity of the current regulating loop to current
allowing the test input signal to substitute for the current
reference signal for testing purposes.

35
FIGURE 26 - CLDK BLOCK DIAGRAM

36
 CURRENT AND VOLTAGE TRANSDUCTOR - CVTG
0Ć51831Ć6
The CVTG card performs three major functions.
1. The voltage transductor provides isolated, scaled
voltage feedback from the 240 volt, 500 volt, or 600
volt armature circuit.
2. A current transductor network, acting on load curĆ
rent signals from current feedback transformers,
provides a scaled current feedback signal.
3. This card also contains a plus and minus 12 volt
zener power supply for the regulator.
The voltage transductor receives 240, 500, or 600
volt dĆc armature voltage feedback information and,
with a resistor scaling network, provides a normalized
dĆc voltage to the input of the isolating circuit.
The isolating circuit is composed of an integrator,
comparator and clipper forming a pulse width moduĆ
lated oscillator. The aĆc output of this oscillator is fed
through a photoĆcoupler whose output is subsequently
rerectified and buffered. Thus, a low impedance isoĆ
lated dĆc signal proportional to perĆunit armature voltĆ
age is developed for use within the regulator. When the
MaxPak Plus controller is used as an armature voltage
regulator, this signal is used as armature voltage feedĆ FIGURE 27 - CVTG CARD
back to the major loop regulator on the CRCF card.
The current transductor receives armature current inĆ input to the current regulating minor loop on the CLDK
formation provided by incoming line current transformĆ card. It also serves as the source signal to provide IR
ers 1CT and 3CT. Their outputs are summed and rectiĆ compensation and provides overcurrent IET protection
fied and passed through a normalizing burden resistor via the fault circuits on the OLVC card.
network for scaling. Scaling is adjustable, with the scalĆ
ing factor (designated as M") chosen by means of a seĆ The CVTG also provides an isolated plus and minus
lector plug on the circuit board. The plug connects to 12 volt power supply for the voltage transductor and a
one of nine possible pins depending upon the full load separate plus and minus 12 volt supply for other regulaĆ
current rating of the panel/motor combination and seĆ tor loads. Load supplies are zener voltage regulated
lected to produce 6.67 volts at the scaling network's and current regulated to limit at 500 milliamps.
output at 100% rated current. A listing of the proper With the exception of the jumper connection used to
jumper position for standard drive panels is provided on scale armature current, and faceplate terminals to scale
page 21 of this manual. The output from the current armature voltage, there are no adjustments on this card.
transductor is used for current feedback, providing the

37
FIGURE 28 - CVTG BLOCK DIAGRAM

38
 STATIC SEQUENCING AND CONTROL CARD - SSCC
0Ć51874Ć2
The SSCC card provides the necessary control logic,
and timing functions to sequence and control the MaxĆ
Pak Plus regulator and M contactor. It also provides a
circuit which generates an isolated line sync signal for
phase reference to the phase locked loop on the current
loop driver (CLDK) card.

STATIC SEQUENCING FUNCTION

General
Inputs to the sequencing portion of the SSCC card
consist of a 110V aĆc control power reference, start, top,
and jog push buttons, and an auxiliary contact closure
from the motor armature loop contactor. Outputs inĆ
clude logic signals which enable the proper major loop
reference (run or jog), sequential logic signals to control
the major and minor loop standby witches, and relay
contacts to control the M contactor. The sequence card
interfaces directly with logic signals from the OLVC card
to provide overload, IET, field loss, line loss, incorrect
phase sequence, power up sequencing, and controlled
stop sequence.
With the exception of run relay (RR), the SSCC card
uses static logic to perform all sequencing functions.
The RR relay provides a nonelectronic mean of topping
the drive even in the event of a failure in any of the elecĆ FIGURE 29 - SSCC CARD
tronic circuits. An M control relay (MCR) is provided to
switch power to the M contactor coil. ternally generated drive stop" commands. For the purĆ
Push button control signals into the SSCC card operĆ poses of this discussion, SRR may be opened either by
ate from 110 volt aĆc power and photoĆisolators are an internally sensed drive controller fault or by the acĆ
used to couple their outputs to the low level logic eleĆ tion of the jog timer logic which will be discussed below.
ments within the card. In either case, the run relay (RR) is disabled for as long
as run relay switch remains open.
The following description provides a basic and brief
overview of the SSCC sequencing action as applied to The run relay contact closes, completing the circuit
standard MaxPak Plus controllers. A detailed analysis of through diode D4 and charging the M control relay caĆ
card sequencing is provided by engineering manual pacitor (CMCR)
0Ć51874Ć2. The M auxiliary contacts complete the circuit to phoĆ
tocoupler 4 and the photocoupler energizes the 1S (miĆ
Start Sequence nor loop) and 2S (major loop) sequencer. The sequencĆ
er enables the minor loop (current regulating loop) on
Depressing the start" pushbutton energizes photoĆ
the CLDK card with the 2S logic signal output. The major
coupler 1 . This photocoupler activates logic converter
loop (speed or voltage regulating loop on the CRCF
1, and, through the action of this logic converter and the
card) is then enabled with the 1S logic signal output.
mode and reference selector, the SSCC card enables
the run reference switch on the CRCF card. This will
cause the drive to follow the speed setting determined Jog Sequence
by the operator's speed control device. Operation of the control circuits during a jog seĆ
Simultaneously power is obtained through the start quence is the same as the start sequence described
button and diode D1 to charge the run relay capacitor above except that the run relay capacitor (CRR) is initialĆ
(CRR). When this capacitor is charged, the run relay ly charged by diode D2 and photocoupler 2 is activated
(RR) closes, provided that the run relay switch (SRR) is by the signal from the jog button.
closed. This run relay switch (SRR) is a normally closed In the jog mode, the jog reference is used for speed
FET switch which acts to open the RR relay under inĆ selection through the action of the mode in reference seĆ
lector and the FET jog enable switch on the CRCF card.

39
 With release of the jog push button, the jog reference
enable FET is opened on the CRCF card, the speed refĆ
erence to the drive's major loop is zero and SRR is
opened, dropping out RR and initiating a drive stop seĆ
quence.
Simultaneous Start and Jog Inputs
If start and jog inputs are received simultaneously,
the jog input is dominant and the drive runs at jog
speed. As soon as the jog input is released, the start inĆ
put becomes dominant and the drive completes a start
sequence.
Stop Sequence
Pressing the stop push button interrupts control
power to diode D3 and D4. The run relay capacitor
(CCRR) and the M control relay capacitor (CMCP)
therefore, begin discharging. After a delay of approxiĆ
mately 50 milliseconds, the run relay drops out. Since
the run relay contacts are in series with the control sigĆ
nal from the emergency stop input, this input becomes
latched when the run relay contacts open. Interrupting
the stop control signal turns off photocoupler 4, and seĆ
quences off first the major loop and then the minor loop.
FIGURE 30 - SSCC BLOCK DIAGRAM
40
Simultaneously, the M Control relay capacitor (CMCR)
discharges until the M control relay drops out. The M
control relay contacts open, the M contactor drops out,
and the capacitor discharge is such that the Contactor
drops out shortly after the sequencer is once again in
standby.
LINE SYNC GENERATOR
The control power input to the sequence card drives
the input diode to photocoupler 6. The photocoupler
output, therefore, switches in a half wave pattern in
phase with the control power supply voltage. This isoĆ
lated and line synchronized signal is buffered and proĆ
vided as a line sync signal for phase reference to the
phase locked loop on the current loop driver card.
ADJUSTMENTS
There are no adjustments on this card. There are,
however, optional functions and optional sequencing
routines including delayed contactor dropout on jog
and drive to rest on stop which this card may be proĆ
grammed to provide. Refer to application manual
DĆ9066 for details.
 OVERLOAD AND VOLTAGE COMPARATOR - OLVC
0Ć52808Ć2
The OLVC card, when interfaced with the static seĆ successive overloads. If the d rive is not restarted followĆ
quencing card (SSCC), will stop the drive when an overĆ ing an overload trip, it will take the counter approximateĆ
load or fault condition exists. These conditions include: ly 20 seconds to count back down to 0.
1. Incorrect phase sequence. Armature current signals for the overload and overĆ
current IET circuits are received from the output of the
2. Field loss. current transductor and scaling circuits on the CVTG
3. Current overload which causes a delay trip when card.
current exceeds 115% for a predetermined time.
INSTANTANEOUS TRIP
4. Instantaneous electronic trip (IET) when current
momentarily exceeds 200% of rated current. The instantaneous electronic trip circuit (IET) senses
an instantaneous fault output for any current overload
This card also contains a powerĆup timer which disĆ exceeding 200%. The I ET comparator sets the IET latch
ables the drive for approximately 3.5 seconds after powĆ when it switches. A reset timer on the latch insures that
er is first applied, allowing all logic states to be defined the output fault will last long enough to generate an
before starting is allowed. A gate power switch circuit inĆ emergency stop in the drive sequence circuits. The lET
hibits all gate signals during the powerĆup time delay inĆ trip also causes the lET logic output to phase the thyrisĆ
terval. tors back to zero degrees conduction through the opĆ
eration of the FET switches on the CLDK card. The drive
OVERLOAD CIRCUITRY then proceeds to shut down through the normal fault seĆ
The current overload circuit consists of a voltage quencing circuit.
controlled oscillator (VCO), a pulse counter, and a latch
circuit. The oscillator generates pulses at a frequency
controlled by input integration current of the circuit. The
oscillator's input is biased such that under conditions
where motor armature current is less than 115% of
rated, the oscillator will count down to 0. When motor arĆ
mature current exceeds 115%, the counter switches
from counting down to counting up at a count rate deterĆ
mined by the level of overload present. An overload trip
occurs after 960 pulses in the up direction.
An overload trip output from this up/down counter arĆ
rangement sets the overload latch, illuminating the
overload fault lamp on the face plate of the OLVC card,
and, through the action of the runĆrelay switch (SRR) on
the SSCC card, brings the drive to rest as if the stop
pushbutton had been depressed.
Before the drive can be restarted, the fault reset"
pushbutton on the face plate of the OLVC card must be
momentarily depressed. Although this action will reset
the drive start circuitry, and once again allow the drive
start pushbutton to be active, it does not rezero any
overload information in the overload counter. Hence, if
the drive is restarted into an overload condition, the
overload counter will not begin counting again from
zero, but will be prebiased from the previous overload
condition. The overload counter is reset to zero only
during control circuitry power up (as might occur if the
drive were shut off by means by its input disconnect deĆ
vice and then reconnected to the source of incoming
aĆc power.) This prevents power unit, motor, and wirĆ
ing damage due to the accumulative effect of several FIGURE 31 - OLVC CARD

41
 IET reset can be accomplished by means of the fault
reset push button on the face plate of the card. An IET
trip is indicated by an illuminated IET fault light on the
card face plate.
POWER UP TIMER AND GATE POWER SWITCH
Following a delay of approximately 3.5 seconds after
the controller is connected to incoming line power, the
action of the power up timer and gate power switch proĆ
vides power to the gate driver amplifiers on the current
loop driver card and completes its resetting action of the
fault circuits of the OLVC.
FIGURE 32 - OLVC BLOCK DIAGRAM
42
PHASE SEQUENCE, LINE AND FIELD SUPPLY
MONITOR INPUTS
The phase sequence and line monitor logic input and
the field supply monitor logic input are generated by the
Phase Sequence, Line and Field Supply Monitor card.
Any of these fault signals, through the action of circuitry
on the OLVC card, will inhibit drive starting through the
run relay switch (SRR) on the SSCC card and will illumiĆ
nate the appropriate LED indicator on the face plate of
the OLVC.
 OPTIONAL TESTER CARD - TSTB
0Ć51811Ć1
An optional circuit tester may be purchased with the The tester card is provided to check typical panel and
drive or added at any time. The optional circuit tester is circuit card voltage levels, and/or permit observation,
a plugĆin module containing a multiĆscale voltmeter and by an external oscilloscope, of circuit test points accordĆ
the following controls for circuit testing. ing to the position of the test switch. The test switch may
be set to any position while the drive is running. The tesĆ
1. A Range selector which determines the voltage ter card may be plugged into (or removed from) its sockĆ
scale on the indicating voltmeter. The smaller conĆ et without interfering with the operation of the drive
centric know\b on the Range and Circuit Selector when the test switch is in the OFF position.
determines the voltmeter scale used.
Table 16 shows the circuit being checked and correct
2. A Circuit Selector which is the larger concentric scale position for voltage readings at each test switch
knob. This determines which one of the twelve test position. Terminals (outputĆcommon) are provided for
points is to be monitored by the meter. observing the same circuit points by an oscilloscope.
3. A Test Signal Potentiometer which adjusts the test If an adjustment reference source is not readily availĆ
voltage signal (0 to 12 volts)which can be utilized for able, the signal from the tester card (TSTB) may be used
testing procedures in setting up the regulator. as follows:
4. A three position toggle switch which determines the a. Set the selector switch on the test or to OFF.
polarity of the test signal voltage as obtained from
the Test Signal Potentiometer. Center position is b. Set the range switch to the 15V position.
OFF. The "12 volts dĆc maximum output from the c. Remove any wires connected to terminal 326 on
potentiometer is brought out to terminal 226 on the terminal board two (2TB) and connect a jumper
terminal board for jumper connection to the apĆ between terminals 326 and 226.
propriate regulator terminal, when it is desired to inĆ
sert a test reference signal. This selector switch d. The test signal voltage is then the speed referĆ
makes it possible to step change the substitute refĆ ence. Whenever the test signal switch is deĆ
erence signal. pressed in the (+) direction, the reference voltĆ
age can be read on the 15V meter scale of the
TABLE 16 - TESTER FUNCTIONS tester.
The following table shows the circuit being checked and corĆ CAUTION: Do not plug a card into (or remove it
rect scale position for voltage readings at each test switch from) its socket without first removing power from
position. Terminals (output - common) are provided for obĆ the panel (except for tester card which may be reĆ
serving the same circuit points with a separate instrument.
All voltages listed have a tolerance of "10%.
moved while the drive is in operation provided the
selector switch is in the OFF position (position
Test
Position Terminal Scale Indication number 12).
1 56 - 57 15V Positive Power Supply
+2V
2 71 - 57 15V Negative Power Supply
012V
3 141 - 57 6V Current Reference
+.5V to -5V (At 100%)
4 241 - 57 6V Timed Current Reference
+.5V to 05V (At 100%)
5 99 - 57 15V Current Limit
Reference Input
0 to 09V
6 None 6V Digital Firing Test Output
0 to +6V Avg.
(Variable Duty
Pulse Waveform)
7 326 - 57 15V Speed Reference
0 to +10V
8 319 - 57 6V Major Loop Feedback
0 to 02V
9 219 - 57 15V Current Feedback
0 to +6.67V (At 100%)
10 119 - 57 6V Voltage Feedback
0 to 04V
11 24 - 57 6V Timed Speed Reference
0 to +5V
Off 226 - 57 15V Tester Output FIGURE 33 - TSTB CARD
-12V to +12V

43
 SECTION 5
TROUBLESHOOTING
DANGER
THE EQUIPMENT SHOULD BE INSTALLED,
ADJUSTED AND SERVICED BY QUALIFIED
ELECTRICAL MAINTENANCE PERSONNEL FAĆ
MILIAR WITH THE CONSTRUCTION AND OPĆ
ERATION OF EQUIPMENT AND THE HAZARDS
INVOLVED. DANGEROUS VOLTAGES ARE ALĆ
WAYS PRESENT WHEN THE INCOMING POWĆ
ER LINE IS CONNECTED, USE APPROPRIATE
HIGH VOLTAGE SAFETY TECHNIQUES FOR
ALL TROUBLESHOOTING PROCEDURES.
ACCIDENTAL SHORT CIRCUITS MAY RESULT
IN EXTREMELY HIGH CURRENTS AND SEĆ
RIOUS DAMAGE AND INJURY.
WEAR SAFETY CLOTHING AND EYE PROTECĆ
TION. MAKE ALL CHANGES WITH POWER OFF.
DOUBLE CHECK FOR POSSIBLE OFF. DOUBLE
CHECK FOR POSSIBLE SHORT CIRCUITS BEĆ
FORE APPLYING POWER. USE ISOLATED
INSTRUMENTS FOR ALL MEASUREMENTS.
TROUBLESHOOTING NOTES
Many circuit faults can be caused by either a faulty
power unit or by a malfunctioning regulator. It may be
necessary to disable the power unit to isolate the probĆ
lem area. Also, it may be very difficult to troubleshoot the
regulator electronics if the power unit is frequently misĆ
firing. The misfiring in the power unit may cause loss of
control or blowing of the line fuses, shutting down the
drive and making troubleshooting impossible.
Disabling the Power Unit
The power unit may be disabled to simplify troubleĆ
shooting. This can be accomplished by disconnecting
the six red and white twisted pair gate drive cables
which lead from the front of the GOAA card in the regulaĆ
tor rack to the thyristor assemblies in the power module.
These cables can be disconnected at the harness conĆ
nector on the front of the GOAA card.
DANGER
POWER REMAINS APPLIED TO THE POWER
UNIT EVEN THOUGH THE GATE CABLES ARE
DISCONNECTED.
CAUTION: The wiring harness connector is reĆ
leased by unscrewing the knurled locking screw
and gently pulling on the connector housing. AtĆ
tempting to remove the connector by pulling on
the wires will not release the connector, and may
damage the connector and wiring.
44
To avoid any possibility of the motor load being drivĆ
en if the power unit is defective or misfires it is recomĆ
mended that the armature leads (A1 and A2/S2) be disĆ
connected during testing and troubleshooting.
With the power unit disabled, troubleshooting can
proceed.
Incoming Power Considerations
The MaxPak Plus power unit will operate from typical
aĆc power lines. An abnormal line condition can reflect
itself as an intermittent power unit fault. The line should
be monitored with an oscilloscope to insure that tranĆ
sients do not exceed limitations as listed below:
1. Repetitive line spikes of less than 10 microseconds
must not exceed the following magnitude: E.G. 230
Volt DrivesĊ400 V. Peak.
230 Volts Drives Ċ 400 V. Peak
460 Volt Drives Ċ 800 V. Peak
575 Volt Drives Ċ 950 V. Peak
2. NonĆrepetitive transients must not exceed 25 watt
seconds of energy for any of the above ref. w/d's or
assemblies. Transients of excessive magnitude or
time duration can damage dv/dt networks or surge
suppressors.
3. Line notches must not exceed 300 microseconds in
duration.
Either high amplitude spikes or excessive notch
conditions in the applied power could reflect as a power
unit failure.
TroubleshootIng the Regulator
The first step in troubleshooting the regulator should
be to check all fault and status indicators for normal inĆ
dication. Refer to page 23 for a listing of LED functions.
Note that either Overload or IET faults can be reset
automatically without a permanent indication of these
conditions. If this is suspected, the regulator can be
temporarily reconnected for manual reset. Terminals 12
and 57 are jumpered for a local manual reset condition.
These terminals are located on the terminal strip directly
below the regulator rack. With the jumper in place, a
fault indication will be maintained until manually reset.
A momentary loss of power will cause the drive to
stop, and then power up in standby with no fault indicaĆ
tion. Monitor the power line to establish that this is no ocĆ
curring.
Malfunctions of the regulator may be caused by elecĆ
trical noise pickup. Check for sources of electrical noise
near the regulator, such as relay cabinets, motor startĆ
ers, welders, RF generating equipment, etc. remove
these sources to a different location, or shield these
sources.
 Many circuit faults can be located quickly by use of
the tester card. Most problems will 11 be indicated by
one more abnormal readings on the tester card. ReferĆ
ence to the wiring diagrams and table of tester functions
on page 44 will usually isolate the circuit section which
is malfunctioning.
Defective cards in the regulator rack can be most
easily isolated and verified by substitution of known
good cards. If a defective card is discovered it should be
replaced with a new card. Repair of defective cards is
not recommended.
Troubleshooting of the regulator electronics while
connected to the power unit may be very difficult if the
power unit frequently or consistently misfires. The misĆ
firing in the power unit may cause loss of control, or
slowing of the line fuses, shutting down the drive and
making troubleshooting impossible.
The power unit may be disabled to simplify troubleĆ
shooting of the regulator. See Power Unit section above
for this procedure.
The regulator can be powered up independently of
the power unit by applying 115 VAC to terminals 188
and 189 of 1TB, the left hand terminal board on the regĆ
ulator rack. Remove the control fuse 13FU to avoid
feed through in the control transformer wiring. AlternaĆ
tively, with the gate cables disconnected, the power
unit can be reĆenergized to power the regulator for
troubleshooting.
Tester Card
The optional tester card can be used to check typical
panel and circuit card voltage levels, and/or to permit
observation by an external oscilloscope of circuit test
points according to the position of the test switch. In
45
addition, an adjustable test signal is provided for test
and setĆup purposes. The test switch may be set to any
position while the drive is running. The tester card may
be plugged into (or removed from) its socket without inĆ
terfering with the operation of the drive when the test
switch is in the off position. The same tests may be perĆ
formed with separate voltmeter having a sensitivity of
20,000 ohms/v (such as Simpson Model 260, Triplett
Model 630 or similar) by making connections to apĆ
propriate terminals.
The tester card will assist in locating most circuit failĆ
ures which may occur. An understanding of the circuits
involved with each meter indication will help to isolate
trouble areas. It is suggested that the user become faĆ
miliar with drive voltage levels when equipment is operĆ
ating normally. All voltage levels are nominal and may
indicate "10% of stated value depending on meter acĆ
curacy and actual value of aĆc supply voltages. Routine
tester use is possible since the tester may be used any
time the motor is running.
See page 44 for a listing of tester functions and readĆ
ings.
TROUBLESHOOTING SUGGESTIONS
The following table has been constructed in order to
assist in the isolation of a faulty component. Many referĆ
ences in the table are made of tests involving the meaĆ
surements of voltages at regulator card pins. In order for
these pins to be accessible, a 44 pin card extender is
necessary.
This table may be used to determine which of the
components of the drive is most likely defective.
 TABLE 17 - TROUBLESHOOTING SUGGESTIONS
Possible
Symptom Fault Test Required Correction
Line fuses (1FU, 2FU, 3FU, 4FU, Power Unit Remove all power from the drive. Disable power unit Remove short
5FU, 6FU consistently blow when Short by disconnecting the six red and white twisted pair
power is applied to the drive. gate drive cables at the power unit. Reapply power. If
fuses blow immediately, the problem is one of the
following:
1. Shorted or grounded wiring between the fuses and
the power module.
2. Shorted or grounded wiring or components within
the power module. (Foreign objects).
3. One or more shorted thyristors.
Fault Regulator If the fuse do not blow with the power unit disabled, Replace CLDK
Output problem most likely lies within the regulator, card
specifically the CLDK card.
Line Fuses (1FU, 2FU, 3FU, 4FU, Short in Ohmmeter for shorts and/or grounds in armature Remove Short
5FU, 6FU) consistently blow armature circuit circuit. and/or ground.
when drive start pushbutton is
pressed.
Drive does not start. M" Drive interlocks Verify all user installed drive interlocks in a state which Reset
contactor will not pick up. preventing will allow drive start to occur. To initiate a start 115VAC interlocks as
operation. must be present at terminals 32, 33 and 44 on ITB. required.
Line fuses IFU Verify plant supply voltage at terminals 381Ć383 on Replace fuse
- 6FU blown. fuse block behind power module cover. (Zero volts pairs
equals open line fuse).
NOTE: Replace incoming line fuses in pairs only (e.g.
1FU and 2FU or 5FU and 6FU) using exact type/class
and ratings as originally supplied.
Control circuit Verify plant supply voltage at terminals 281Ć283 on Replace fuses
line fuse(s) fuse block located behind power module cover. (Zero
10FU and/or volts equals open control circuit line fuse on fuse
12FU blown. block)
Failed Control With plant supply voltage at 281Ć283, verify voltage Replace CCT
circuit from terminal 88 to 189 = 115VAC. Ohmmeter check
transformer windings for approx. zero ohms.
(CCT)
Control With 115VAC at 88Ć189 verify voltage from term. 188 to Replace fuse
transformer 189 = 115VAC (zero volts indicates open fuse)
fuse 13FU
blown
Cabinet fan not Check cabinet fan operation. If not operating, check Replace fuse
operating 9FU fuse above regulator rack.
Power module Remove power from drive. Check for continuity Correct fault
thermostat or between terminals 44 and 33A on 5TB. If open, check condition/repla
fan loss switch wires 44 and 44A for continuity. An open indicates a ce thermostat
open high temperature fault condition or a defective
thermostat.
Check wires 44A and 33A on fan TB for continuity. If Replace fan
open, faulty fan loss switch. loss switch or
NOTE: A clogged cabinet air filter can result in an air clean filter
flow loss and/or a high temperature fault indication.
Failed regulator With 115VAC at H1ĆH2, verify voltage from X1 to X2 = Replace 1T
Transformer 37 VAC. If not, ohmmeter primary and secondary for
(IT) approx. zero OHMS.
Failed power With 37VAC at X1ĆX2 verify voltage from terminal 56 to Replace CVTG
supply on 57 = +12VDC, and from 71 to 57 = 12VDC.
CVTG card NOTE: A zero volt reading could be a result of a
reflected short elsewhere (card or wiring). This card
has short circuit protection.

46
 TABLE 17 - TROUBLESHOOTING SUGGESTIONS
Possible
Symptom Fault Test Required Correction
Drive does not start. M" Failed OLVC Pin 21 of OLVC card to terminal 57 should be 0V DC Replace OLVC
contactor will not pick up. card with no faults indicated (phase sequence on, field
(Cont'd.) supply on, IET off and O/L off). A +12 VDC
measurement, with no fault, indicates card failure.
Failed SSCC Terminal 39 to 189 on ITB should be 115VAC after start Replace SSCC
is initiated. (115 VAC to terminals 33 and 44,
momentary or maintained 115 VAC to terminal 32).
Fault F" relay With 115 VAC from terminals 39Ć189, F" relay should Replace relay
be energized. Ohmmeter check F" coil for continuity.
Ohmmeter check F" contacts.
Failed rectifier Verify 115VAC at terminals 188Ć189 on rectifier and Replace P.C.
and suppressor suppressor board. (Behind 5TB, 6TB and 7TB board
board mounting bracket). If DB is supplied, M" board will be
(0Ć54341) upper board, DB" board lower. With 115VAC on
188Ć189, terminals 111Ć113 (wires 238Ć233) should
measure X63 VDC.
Open M" coil Ohmmeter check M" coil for continuity. Replace coil
Faulty DB" If DB" is supplied, ohmmeter check aux. contacts. Replace
aux. contacts contacts
M" contactor Verify ARC chute in closed or down position. Close ARC
ARC chute not chute
closed or in
down position
Phase sequence light Failed phase Verify plant supply voltage at terminals 281, 282, and Replace phase
extinguished. Unable to start. sequence, line 283 on 4TB. If not present check 10FU, 11FU and sequence line
and field 12FU behind power module cover. If present, measure and field
supply monitor the voltage from terminals 166 to 57 on 4TB. A supply
P.C. board. +12VDC reading, when the phase sequence is known
to be correct, indicates probably phase sequence
monitor failure.
Failed OLVC If 0V DC is measured in previous check (166Ć57), then Replace OLVC
probable OLVC card failure.
Field supply light not on. Fuse 7FU Verify plant supply voltage at terminal 281, 282 and Remove short.
Unable to start. and/or 8FU 283 on terminal lock behind VSX supply cover. Replace fuse(s)
blown. Measure terminal 137+ to 35- on fuse holder for
proper field voltage. If zero volts, check field leads (F1
and F2) for short, check field to ground for short.
Failed phase Measure 137+ to 35- on 4TB Replace phase
sequence, line (NOTE: 137 must be + with respect to 35). If proper sequence, line
and field field voltage is present, measure voltage from 66 to 57 and field
supply monitor on 4TB. +12VDC indicates a failed field supply supply monitor
board monitor. P.C. board.
Failed OLVC If 0V DC is measured in above check, then probable Replace OLVC
OLVC failure.
Monitor will not run. M" Open max. Verify that term, 28 to 57 on 2TB = from +6VDC to Replace CRCF
contactor energized. No speed pot on +12 VDC. Zero volts indicates open max. speed pot.
armature current. CRFC card
Failed CRFC The DĆC voltage present from pin 43 to 57 on CRCF Replace CRCF
card card should equal 1/2 of voltage from pin 8 to 57 of
CRCF card. The voltage from pin 20 to 57 should
equal 1/2 of voltage from pin 8 to 57 after acceleration
ramp time.
NOTE: Above test valid only when pin 10 and pin 21
are +12VDC with respect to term. 57. These enable
signals are generated by the SSCC card in response
to a run command.
Failed SSCC Pins 14, 15 and 18 to term. 57 on the SSCC card Replace SSCC
card should go to +12VDC when running. Zero or -12VDC
at these pins indicates card failure.

47
 TABLE 17 - TROUBLESHOOTING SUGGESTIONS
Possible
Symptom Fault Test Required Correction
Motor will not run. M" contactor Failed M" Assure that no armature voltage is present and Replace
energized. No armature current. contactor carefully determine if there is proper contact closure. contactor or
(Cont'd.) power contacts contacts
Failed OLVC With overload and IET lights off, pin 25 to term. 57 on Replace OLVC
card the OLVC card should be Ć12VDC. +12VDC indicate
card failure. Pin (6)+ to pin 8(Ć) should be 20 to
24VDC.
M" contactor picks up but not Faulty M" While holding in the start button with M" Contactor Replace
latch. contactor energized verify the presence of 115 VAC from pins 25 auxiliary
auxiliary and 2 of SSCC card to terminal 189. Zero volts at pin 2 contact
contact. when there is 115VAC at pin 25 indicates open M"
auxiliary contact. Remove all drive power and verify
failed contact with ohmmeter.
Faulty SSCC While holding in the start button with M" Contactor Replace SSCC
Card. energized verify the presence of 115VAC from pin 2 of
SSCC card to terminal 189.
Drive starts. M" contactor Open Min. Verify that term. 20 to 57 on 2TB = Zero to 6VDC. Replace CRCF
energizes. Drive runs at high speed pot on +12VDC indicates open min. speed pot.
speed with no control. CRCF card
If the drive is being operated as a voltage regulator,
make the following additional check:
Failed CVTG Term. 119 to 57 on 2TB should be 4VDC at 100% Replace CVTG
card armature voltage, and zero volts at zero armature
voltage.
If the drive is being operated as a speed regulator,
make the following additional checks:
Faulty Verify that the speed feedback signal, term. 419 to Repair or
Tachometer 519, complies with tachometer specifications. change tach.
feedback signal
Failed CRCF Speed feedback term. 619 to 57 on 2TB = 4VDC Replace CRCF
card "20% at max. speed. (when properly scaled per table
12
Drive runs but will not jog. Failed CRCF Verify presence of +12VDC (from SSCC) from pin 9 to Replace CRCF
card 57 on CRCF card. Verify presence of +12VDC (from
SSCC) from pin 21 to 57 on CRCF card. Check
reference voltage at terminal 118 (located on term.
strip below regulator rack) to be from zero to +12VDC.
If above voltages are present and drive refuses to jog,
CRCF is faulty.
Failed SSCC Verify that voltage from pin 19 to 57 on SSCC card Replace SSCC
card goes to +12VDC when jog pushbutton is pressed.
Intermittent fuse blowing, Improper CVTG Compare voltage from term. 219 to 57 for proper ratio Correct
instability; overload trip; IET trip. current to IA 6.7 VDC = 100% IA. calibration per
feedback Table 10.
calibration
Shorted phase Ohmmeter check of each phase rectifier module. Replace phase
rectifier module Check for shorted thyristor. rectifier module
Thyristor Ohmmeter check of thyristor gate to cathode Replace phase
doesn't fire resistance should show diode resistive action. rectifier module
Thyristor Ohmmeter check of primary and secondary of Replace gate
doesn't fire coupling transformer on gate coupling card. Check for coupling card
approx. zero ohms. or phase
rectifier module
Open current Check for approx. zero ohms. Replace
transformer current
(1CT, 3CT) transformer
Faulty SSCC Check pin 37 to term. 57 on SSCC card for 6VDC. Replace SSCC
card Zero or +12VDC indicates failure. If observing with an
oscilloscope, pin 37 will show a square wave with a
50% duty cycle going from zero to +12VDC.

48
 TABLE 17 - TROUBLESHOOTING SUGGESTIONS
Possible
Symptom Fault Test Required Correction
Intermittent fuse blowing, Faulty CLDK To effectively test the CLDK card, an oscilloscope is Replace CLDK
instability; overload trip; IET trip. card necessary. This allows monitoring of individual gate
(Con'td.) pulses with phase shifting. If the CLDK card is suspect,
the best test is substitution with a known good card.
Or, in the absence of an oscilloscope or replacement
card, a voltmeter will allow partial card test. The
following conditions must be met prior to the voltmeter
check. Set up conditions:
(1) Line sync. present at pin 15 to term 57
= 6VDC from SSCC card.
(2) -12VDC at pin 14 to 57 from OLVC card.
(3) Term. 141 to 57 = OVDC from CRCF card.
(4) Term. 219 to 57 = OVDC from CVTG card.
(5) Pin 21 to 57 = -12VDC from SSCC card.
(6) Pin 17 to 57 = -12VDC from CVTG card.
(7) Pin 16 to 57 = +12VDC from CVTG card.
(8) Pin 2 to Pin 21 = 20 to 24VDC from OLVC card.
With the above conditions met and a zero to -12VDC
signal applied to term. 526, the output at pin 37 to
term. 57 should read zero to +6VDC. This voltmeter
tests approx. 95% of the card. An oscilloscope
connected to monitor the individual pulse outputs
would test the card completely. There should be two
pulse per output in a 16.67 ms period. These pulses
should shift with respect to time as the input signal is
varied. The output at pin 37 is a square wave with a
variable duty cycle.
Misadjusted Refer to Section 3 page 24 for current gain adjustment. Perform
current gain adjustment
procedure
Open fusible Ohmmeter check fusible resistors. Replace
resistor in resistor(s)
DV/DT network
on thyristor
assembly
IET light on or overload light on. Failed OLVC Use check list for intermittent fuse blowing instability, Replace OLVC
card IET, overload" above. If all OK, replace OLVC card.
Fail to reset IET or overload Failed OLVC Push Fault reset on faceplate of OLVC card. If light(s) Replace OLVC
card do not go out, replace card.
Erratic performance of lights and Failed CVTG Verify power supply voltages. Term. 56 to 57 = Replace CVTG
drive. card +12VDC. Term. 71 to 57 = Ć12VDC
Drive unstable or doesn't Improper Verify proper operation of current minor loop. Insert Replace CRCF
regulate properly. CRCF test signal into term. 6 (zero to +6VDC). Calculate and
operation measure appropriate voltage values at wire wrap pins
151, 251, 351, 451, 551, 651 and 751 with respect to
term 57. If not proper, CRCF operation is improper.
Drive instability at light or no 1R, 2R, 11R or Ohmmeter check 1R, 2R, 11R and 1C. Check fusible Replace Faulty
load. Ringing on armature circuit 1C failure, resistor. component
at light or no load. open fusible
resistor
Armature current waveform is Load Check for loose couplings misaligned shafts uneven Repair
uneven. characteristics load characteristics. mechanical
malfunction
Thyristors not Check for imbalance in thyristor blocking resistance Replace faulty
firing properly with ohmmeter. Check drive CLDK for proper gate thyristor or
triggering. CLDK card.
Imbalance in Check AĆC power line to line voltage and isolation Repair and
AĆC power line. transformer. replace as
necessary.
Increase IA, probable overload Low field Perform ohmmeter, check on diodes in field supply. Replace
trip. supply voltage Diodes or field
supply as
necessary

49
 SECTION 6
REPLACEMENT PARTS

TABLE 18 - HORSEPOWERĆINDEPENDENT PARTS

Part
Part Description Quantity Number
Field Supply, VSX, 240, 500 and 600 VDC Armature 1 per drive 801463Ć2R
Control Circuit Suppressor, 1SSR 1 per drive 411026ĆX
Regulator Printed Circuit Cards
ĄStatic Logic, SSCC 1 per drive 0Ć51874Ć2
ĄFault & Overload Logic, OLVC 1 per drive 0Ć52808Ć2
ĄPower Supply & Transductor, CVTG 1 per drive 0Ć51831Ć6
ĄCurrent Loop Driver, CLDK 1 per drive 0Ć51865Ć9
ĄMajor Loop Regulator, CRCF 1 per drive 0Ć51851Ć5
ĄTester (Optional), TSTB Ċ 0Ć51811Ć1
Regulator Isolation Transformer, 1T 1 per drive 411027Ć32R
Phase Sequence, Line and Field Supply Monitor P.C. Board
Ą230VAC Input, 240VDC Armature 1 per drive 0Ć54349
Ą460VAC Input, 500VDC Armature 1 per drive 0Ć54349Ć2
Ą550VAC Input, 600 VDC Armature 1 per drive 0Ć54349Ć2
Special Fastener*
ĄBelleville Washer for Line Fuse* 2 per fuse 601748Ć7E
ĄHex Head Cap Screw for Line Fuse* 2 per fuse 601741Ć4B
ĄKeps Nut for Phase Rectifier Module* 6 per module 401599Ć11F
Belleville Washer for AĆC and DĆC Bus Bar Connections* 2 per connector 601748Ć7E
ĄHex Head Cap Screw for AĆC and DĆC Bus Bar Connections* 2 per connector 601741Ć4D
DĆC Armature Contactor 1 for basic drive 417690Ć3R
2 if drive has DB
Rectifier and Suppressor Card 1 per contactor 0Ć54341
Interlock Relay for DĆC Contactor 1 per drive 600434Ć6R
DĆC Contactor Auxiliary Contact (2ĆNO and 2ĆN.C.) 1 per contactor 608830Ć3A
DĆC Contactor Coil 1 per contactor 608831Ć6A
DĆC Contactor Contacts: Moveable 1 per contactor 608833Ć2A
Stationary 1 per contactor 608833Ć2B
DĆC Contactor, arc chute 1 per contactor 608834ĆA
Fan Motor 1 per drive 64960Ć27R
Air Flow Switch 1 per drive 604580Ć1R
Current Transformer (1CT, 3CT) 2 per drive 64670Ć11W
Control Transformer (750VA):
Ą230V and 460V AĆC Input 1 per drive 417155ĆRB
Ą575V AĆC Input 1 per drive 417155ĆSB
Gate Coupling Card 6 per drive 0Ć51378Ć19
Over Temperature Thermostat 1 per drive 66012Ć10A
Fuses except for aĆc line fuses listed on next page:
ĄField (7, 8FU) 2 per drive 64676Ć18BB
ĄFan (9FU) 1 per drive 64676Ć1R
ĄControl (10, 11, 12FU) 3 per drive 64676Ć30K
ĄControl (13FU) 1 per drive 64676Ć1T
Output Network
Ą230V AĆC Input Drives:
ĄĄCapacitor (1C) 2mf 1 per drive 69932Ć12R
ĄĄResistor (1R) 1K W 1 per drive 63481Ć6V
ĄĄResistor (2) 75 W 1 per drive 63481Ć6K
ĄĄFusible Resistor 1 per drive 705330Ć70RF
Ą460V and 575V AĆC Input Drives:
ĄĄCapacitor (1C) 2mf 1 per drive 69932Ć12R
ĄĄResistor (1R and 11R) 750 W 2 per drive 63481Ć6U
ĄĄResistor (2R) 50 W 1 per drive 63481Ć6J
ĄĄFusible Resistor 1 per drive 705330Ć70RG
AĆC Line Capacitors 6 per drive 69932Ć13R

50
 TABLE 19 - HORSEPOWERĆDEPENDENT PARTS
Phase Rectifier Modules
Horsepower Line Fuses 1 Thy - 6 Thy (3 per drive)
1FU 2FU,
1FU, 2FU 3FU,
3FU 4FU
230 Volt 460 Volt 575 Volt 5FU, 6FU (6 per drive)
AĆC Input AĆC Input AĆC Input 230 & 460V AĆC Input 575 AĆC Input
200 400 480 64676Ć12DD 86466Ć74RB 86466Ć74RE
250 500 600 64676Ć12DE 86466Ć74RC 86466Ć74RF
300 600 720 64676Ć12DE 86466Ć74RD 86466Ć74RF

51
Reliance Electric / 24703 Euclid Avenue / Cleveland, Ohio 44117 / (216) 266-7000

Printed in U.S.A. Instruction Manual D-3919-1 February 1993