Section 6
TROUBLESHOOTING
6.0 General - This Section details troubleshooting infor-
mation for the Flex Pak Plus controller. Its organization is as
follows:
• General troubleshooting concepts (Paragraphs 6.1,
6.2, 6.3 and 6.4)
• Specific symptom / probable cause / recommended pro-
cedures (Paragraph 6.5)
• Reference schematics of the controller (Paragraph 6.6)
DANGER
CONTROLLER EQUIPMENT IS AT LINE
VOLTAGE .
WHEN A-C POWER IS CONNECTED TO THE
POWER UNIT IN THE FLEXPAK PLUS CONTROL -
LER. THUS , A-C POWER MUST BE REMOVED
FROM THE UNIT BEFORE IT IS SAFE TO TOUCH
THE INTERNAL PARTS OF THE FLEXPAK PLUS.
PERSONAL INJURY MAY RESULT UNLESS
t POWER-IS REMOVED.
DANGER
THE FLEXPAK PLUS CONTROLLER SHOULD BE
SERVICED ONLY BY QUALIFIED ELECTRICAL
MAINTENANCE PERSONNEL FAMILIAR WITH
THE CONSTRUCTION AND OPERATION OF ALL
APPLICATION EQUIPMENT IN THE SYSTEM .
PERSONALINJURY AND / OR EQUIPMENT DAM-
AGE MAY OCCUR IF INDIVIDUALS ARE NOT
FAMILIAR WITH THE HAZARDS RESULTING
FROM IMPROPER OPERATION.
In addition to step-by-step troubleshooting procedures,
there are some generalized comments that should be kept
in mind at all times. These may be divided into wiring errors
(Paragraph 6.1 ). incoming a-c line problems (Paragraph
6.2). motor problems (Paragraph 6.3) and mechanical prob-
lems (Paragraph 6.4).
6.1 Wiring Errors - The single most common problem
preventing normal d-c drive operation is incorrect wiring
within a system. A maintenance person should spend at
least five minutes carefully looking over the wiring before
taking active steps involving tests and replacement. Re-
member that a loose or grounded wire can occur in a
controller that had previously been functioning correctly if
initial wiring techniques were poorly performed .
For those not familiar with proper FlexPak Plus controller
wiring , other Sections in this manual may be consulted. For
more complex problems , Section 5 may be used to uncover
wiring problems in the optional Modification
Kits.
6.2 A-C Line Problems - The following are typical prob-
lems located on the incoming a-c line :
• A-c line voltage incorrect for the specific controller ,
which may operate on 115
or 230 VAC.
• Main disconnect switch contains fuses improperly
rated for the drive . (The fuses must be large enough to
prevent nuisance tripping yet small enough to protect
the circuit and equipment on the circuit.) Refer to Table
3.A.
33
• A-c conductors must be of adequate size for the appli-
cation. Refer to Table 3.A.
• If an isolation transformer is used, it must be sized
according to the requirements of the drive system. The
transformer itself must be wired for the correct output
voltage (115 / 230 VAC) in relation to the FlexPak Plus
controller.
6.3 Motor Problems - Do not overlook the possibility that
the malfunction may be located in the dr ive motor. The
following steps should become part of a troubleshooting
routine:
• Recheck all motor connections for firmness and cor-
rect identification .
• Check that no obvious grounds have occurred on any
of the wires . However , do not use a megger when
checking for grounds unless the motor wi ring to the
FlexPak Plus controller is completely disconnected .
• A volt-ohmmeter (VOM) may be used for ground check-
ing without disconnecting conductors to the FlexPak
Plus controller .
• Check the field windings for open or short conditions .
• Check continuity through the armature and brushes .
Use terminals A 1 and A2 at the Complete Controller
(terminals 45 and 47 at the Basic Controller) as test
points .
6.4 Mechanical - It may be that the malfun ction is a
simple mechanical problem. The load on the drive motor
may be too large , or it may have too high an inertia. The
results are long stopping times and current -lim it start ing
demands. Thus, the freedom of motion of the load device
should be considered.
6.5 Controller Malfunctions - Tables 6.8 and 6.C pre -
sent an organized troubleshoot ing sequence based on a
symptom / probable cause/ suggested procedure approach.
They develop from the most simple , obvious malfunction to
more complex ones.
Note that Reliance Electric color codes the wires to aid the
identification of pin numbers, that is, locations . Table 6.A is
a listing of these number-color combinations . These colors
will be helpful in the following troubleshooting procedures.
6.6 Schematics, Diagrams - In order to aid with the
troubleshooting process , various schemat ics and diagrams
are included . Note that these drawings are the late st revi-
sions as of the date of publication of this manual. The
manufacturer cannot guarantee that subsequent changes
will not occur ; although , if any do, they should be min or. In
cases of doubt, contact your local Reliance Electric Sales
Off ice or Distributor .
Included are the following drawings :
• Figure 6.1 which is a simplified control circuit sche -
matic for a unidirectional (forward only) controller .
• Figure 6.2 which is a simplified control circuit sche-
matic for a bidirectional (forward / reverse) controller.
• Figure 6.3 which is a timing chart for the relay control
sequencing used with this controller .
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