Section 4
START-UP AND ADJUSTMENT
4.0 General - This Section provides start-up and adjust-
ment procedures to be followed after the assembly and
installation of the controller is complete. All initial opera-
tion checks and final adjustments to the controller must be
made in conformance to the procedures , warnings and
recommendations listed here.
DANGER
THE FLEXPAK PLUS CONTROLLER IS AT LINE
VOLTAGE WHEN A- C LINE POWER IS CON-
NECTED TO THE POWER
UNIT INSIDE THc
CONTROLLER. BEFORE WORKING ON , OR
TOUCHING ANY INTERNAL PARTS OF, THE
CONTROLLER. REMOVE INCOMING A-C LINE
POWER AT THE
MAIN DISCONNECT SWITCH.
PERSONAL INJURY MAY RESULT IFTHISWARN-
i ING IS; NOT. FOLLOWED; .
DANGER
DURING INITIAL START-UP, THE CONTROLLER
AND ITS ASSOCIATED EQUIPMENT MUST BE
OPERATED AND / OR ADJUSTED ONLY BY
QUALIFIED ELECTRICAL MAINTENANCE PER-
SONNEL. THESE INDIVIDUALS SHOULD BE
FAMILIAR WITH THE DESIGN AND OPERATION
OF THIS EQUIPMENT AND WITH THE HAZARDS
INVOLVED. PERSONAL INJURY AND / OR DAM-
AGE TO THE CONTROLLER COULD RESULT
FROM UNFAMILIARITY.
4.1 Power Off Inspection - It is necessary to make a
superfic ial inspection of the FlexPak Plus controller and its
associated units. The purpose of this check is to look for
possible physical damage or improper connections.
Inspect all plug-in Modification Kits. Test each for a firm
mounting condition .
Each should be mechanically connected to the Regulator
Module by means of a mounting post screw. Each should
be electrically connected to the Module by a series of paral-
lel pins . If any of the pins are bent, improper operation
results. Examine the pins to make sure they are perfectly
parallel. Only one pin may fit through a hole in the Kit.
Inspect all screw terminal connections on the Modification
Kits. Make sure the wires are firmly connected. Also make
sure that there is enough insulation on th e wires to prevent
a short between the conductors.
Inspect the signal wiring from the Operator Control Station.
A series of wires will connect to individual terminals on a
strip mounted on the Remote Operator Interface Module .
(This Modul e is mounted on the Regulator Module.) Deter-
mine that all wires are firmly seated in the terminal strip.
Make sure all wires are connected .
15
4 .2 Motor Ground Check - It may be necessary to make
a check of the drive motor to assure that no damaging
grounds-other than earth ground-exist within the motor .
CAUTION: Although a megger may be used for th is
test, if one is used, all conductors between the dr ive
motor and the FlexPak Plus controller are to be discon-
nected and moved aside. The megger's high voltage
can cause damage to the controller's circuits .
Step 1 - Attach one lead from the ohmmeter to the motor
frame to make a simple resistance check .
Step 2 - Touch the test probe to each of the two power ,
two thermostat , and two field leads to the motor .
If the reading to ground on any terminal is less than
100 ,000 ohms , a ground condit ion exists.
Step 3 - If a ground condit ion exists, inspect the moto r
thoroughly for internal shorts.
Step 4 - When the ground ing condition is corrected ,
reconnect the conductors from the FlexPak Plus controller.
4 .3 Power On Adjustments - Once all the preliminary
power-off static adjustments have been performed with
acceptable results, the a-c line power is to be applied to the
controller , but the load is not connected . It is important to
follow these steps closely. Observe all cautions and
warnings .
DANGER
WITH A-C POWER APPLIED AND WITH THE
POWER ON / OFF SWITCH IN THE ON POSITION,
HAZARDOUS VOLTAGE EXISTS IN
THE CON-
TROLLER . EXERCISE EXTREME CAUTION WHEN
PERFORMING
THESE TESTS. PERSONAL
INJURY CAN
RESULT.
DANGER
IF CIRCUIT BREAKER HAS TRIPPED OR FUSES
HAVE CLEARED, USER MUST DETERMINE IF A
FIELD SUPPLY KIT IS PRESENT . (SEE FIGURE
5.15 .) IF FIELD SUPPLY KIT IS PRESENT . THE
FIELD SUPPLY KIT
AND ITS WIRING MUST BE
INSPECTED FOR DAMAGE. RE - APPLYING
POWER TO THE DRIVE . THE FIELD VOLTAGE
MUST BE RE-CHECKED FOR PROPER VOLTAGE
AT MOTOR TERMINALS F1. F2 . IFTHIS VOLTAGE
IS BELOW 90 % OF THE FIELD VOLTAGE SPECI -
FIED ON THE MOTOR NAMEPLATE . THE DRIVE
MUST NOT BE STARTED UNTIL PROPER VOLT-
AGE IS OBTAINED. FAILURE TO FOLLOW THIS
PROCEDURE COULD RESULT IN OVERSPEED-
ING THE MOTOR AND / OR THE MACHINERY
COUPLED TO THE MOTOR SHAFT AND POSSI -
BLE FATAL INJURY . REFER TO SYMPTOM 1 IN
TABLES 6.B AND 6.C.
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