RGA SERIES - American Control Electronics
Contents
1. any connections to T1 and T2 unless using a tachogenerator FWOTQ REVTO 18 MAXSPO REV ACC OPTIONAL REGENERATIVE BRAKE SWITCH OPTIONAL ARMATURE OUTPUT LJ L FIELD OUTPUT For shunt wound motors LINE only See field output VOLTAGE section for connections Figure 11 RGA400 Connections RGA Series POLARITY REVERSAL SWITCH 0 250 VDC 0 25 VDC 1 5 mADC 4 20 10 50 mADC d OPTIONAL REGENERATIVE BRAKE SWITCH OPTIONAL POWER SWITCH 9 9 L2. 52 Signal Reference Figure 9 Analog Input Signal Connections RGA Series Analog Input Signal RGA403 models Instead of using a speed adjust potentiometer the drive may be wired to follow an analog input voltage or current signal that is either isolated or non isolated from earth ground Connect the signal common to terminal 7 COM If using an input current signal or an input voltage signal of 0 to 25 VDC or less connect the signal reference to terminal 8 INPUT 1 or if using an input voltage signal greater than 0 to 25 VDC connect the signal reference to terminal 9 INPUT 2 Refer to Figures 15 and 16 on page 29 for switch SW501 settings and location If using an input current signal the signal may be used to determine motor speed only To change direction a direction switch must be used POLARITY REVERSAL SWITCH 0 25 0 i 1 5mADC EN PREWIRED TO RGA BOTTOM BOARD 4 20mapc 9 20 0 10 50 mADC Figure 10 RGA403 Analog Input Signal Connections RGA Series 15 and 15 Do not short the 15 and 15 terminals for any reason Shorting these terminals will damage the drive RGA series drives can supply a regulated 15 and
3. 1 50 38 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 4 RGA440 Dimensions RGA Series _______ 6 90 175 uw 6 60 168 4 1 375 35 8 375 21 78 249 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 5 HSK 0003 Dimensions RGA Series Section 4 Installation Do not install rewire or remove this control with input power applied Failure to heed this warning may result in fire explosion or serious injury Make sure you read and understand the Safety Precautions on page i before attempting to install this product Heat Sinking Chassis Models RGA400 10 and RGA403 10 require an additional heat sink when the continuous armature current is above 7 amps Use heat sink kit part number HSK 0001 All other chassis drives have sufficient heat sinking in their basic configuration Use a thermally conductive heat sink compound such as Dow Corning 340 Heat Sink Compound between the chassis and the heat sink surface for optimum heat transfer NEMA 4X All NEMA 4X models come with the heat sink already attached Therefore all NEMA 4X drives have sufficient heat sinking in their basic configuration RGA Series Mounting Chassis Drive components are sensitive to electrostatic discharge Avoid direct contact with the circuit board Hol
4. Figure 32 Single Speed Potentiometer Control of Multiple Drives RGA Series Section 8 Troubleshooting Dangerous voltages exist on the drive when it is powered When possible disconnect the drive while troubleshooting High voltages can cause seroius or fatal injury Before Troubleshooting Perform the following steps before starting any procedure in this section Disconnect AC line voltage from the drive Check the drive closely for damaged components Check that no conductive or other foreign material has become lodged on the printed circuit board Verify that every connection is correct and in good condition Verify that there are no short circuits grounded connections Check that the drive s rated armature is consistent with the motor ratings For additional assistance contact your local American Control Electronics distributor or the factory direct 800 AMCNTRL or FAX 800 394 6334 PROBLEM i Line fuse blows Line fuse does i not blow but the motor does i not run Motor cable or armature is shorted to ground Nuisance tripping caused by a combination of ambient conditions and high current spikes i e reversing Speed adjust potentiometer or speed reference voltage is set to zero speed INHIBIT mode is active Drive is not receiving AC line voltage Motor is not connected Drive is not enabled RGA Series SUGGESTED
5. Inhibit Terminals Figure 17 Inhibit Terminals RGA Series Regenerative Decel to Zero Speed RB1 and RB2 Terminals Short the RB1 and RB2 terminals to regeneratively brake the motor to zero speed See Figures 11 12 and 13 on pages 24 25 and 26 The RB1 and RB2 circuit follows the deceleration rate set by the FWD ACC and REV ACC trim pots Open the RB1 and RB2 terminals to accelerate the motor to set speed RGA Series Regenerative Decel to Minimum Speed The switch shown in Figure 18 may be used to decelerate a motor to minimum speed Closing the switch between 50 and 52 decelerates the motor from set speed to a minimum speed determined by the MIN SPD trim pot setting If the MIN SPD trim pot is set full CCW the motor decelerates to zero speed The REV ACC or FWD ACC trim pot setting determines the rate at which the drive decelerates depending on the direction of deceleration By opening the switch the motor accelerates to set speed 10K OHM SPEED ADJUST POTENTIOMETER DECEL TO MIN SPEED Figure 18 Run Decelerate to Minimum Speed Switch RGA Series Coast to Zero Speed INHIBIT RUN To coast the motor to a stop without removing power to the drive jumper INHIBIT RUN terminals 1 and 2 To restart the motor jumper INHIBIT RUN terminals 2 and 3 A single pole double throw switch may be used as a COAST
6. 40 C RGA Series Section 3 Dimensions ec din f 3 50 89 mes 4 78 121 1 85 47 og bo 0 92 23 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 2 RGA400 Dimensions RGA Series 019 B U EF 2 6 9 TE S GND AL fi I 3 50 89 4 78 121 3 07 78 1 85 47 0 92 23 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 3 RGA403 Dimensions RGA Series 6 90 175 6 30 160 FORWARD AMERICAN K CONTROL FX ELECTRONICS
7. 15 VDC signal each sourcing 15 mA maximum with respect to RB1 to isolated external devices See Figure 10 for voltage supply terminal locations Enable Regen Brake and Inhibit See the Starting and Stopping Methods section on pages 32 through 36 for a detailed description of the Enable Inhibit and Regen Braking RB1 RB2 connections Direction Switch For RGA400 and RGA440 models refer to Figures 22 and 23 on page 50 For RGA403 models a single pole single throw switch can be used as a reversal switch Connect the switch to terminals COM and DIR Close the switch to reverse the motor Open the switch to return the motor back to it s original direction Refer to Figure 12 on page 25 RGA Series Tachogenerator Feedback Using tachogenerator feedback improves speed regulation from approximately 1 of motor base speed to approximately 0 1 of motor base speed Use tachogenerators rated from 7 VDC per 1000 RPM to 50 VDC per 1000 RPM Connect the tachogenerator to terminals T1 and 2 of terminal block TB502 The polarity is positive for 1 and negative for T2 when the motor is running in the forward direction Place SW504 in the TACH position See Figures 11 12 and 13 on pages 24 25 and 26 for tachogenerator connections The TACH trim pot must be adjusted prior to operating with tachogenerator feedback Refer to the Calibration section for instructions on calibrating the TACH trim pot RGA Series
8. SOLUTIONS Check that the line fuse is correct for the motor size Check motor cable and armature shorts Add a blower to cool the drive components decrease FWD or REV TQ settings or resize motor and drive for actual load demand or check for incorrectly aligned mechanical components or jams See pages 38 and 39 for information on adjusting the FWD and REV trim pots Increase the speed adjust potentiometer setting or speed reference signal Remove the short from the INHIBIT Verify that the motor is not jammed Increase FWD TQ or REV setting if set too low See pages 39 and 40 Apply AC line voltage to L1 and 12 Connect the motor to A1 and A2 7 Make sure jumper SO502 is set RGA Series PROBLEM Motor runs in i the opposite direction i non reversing i drives Motor runs too fast Motor will not reach the desired speed Motor pulsates i or surges under i i load Motor connections to A1 and A2 are reversed MAX SPD and MIN SPD are set too high Motor is overloaded IR COMP is set too high Motor bouncing in and out of current limit SUGGESTED SOLUTIONS Reverse connections to A1 and A2 Calibrate MAX SPD and MIN SPD See page 38 Increase FWD TQ or REV TQ setting See pages 39 and 40 Check motor load Resize the motor and drive if necessar Adju
9. heed this warning may result in fire explosion or serious injury Circuit potentials are at 115 or 230 VAC above ground To prevent the risk of injury or fatality avoid direct contact with the printed circuit board or with circuit elements Do not disconnect any of the motor leads from the drive unless power is removed or the drive is disabled Opening any one motor lead while the drive is running may destroy the drive This product does not have internal solid state motor overload protection It does not contain speed sensitive overload protection thermal memory retention or provisions to receive and act upon signal from remote devices for over temperature protection If motor over protection is needed in the end use product it needs to be provided by additional equipment in accordance with NEC standards Use 18 24 AWG wire for logic wiring Use 14 16 AWG wire for AC line and motor wiring RGA Series Shielding Guidelines Under no circumstances should power and logic level leads be bundled together Induced voltage can cause unpredictable behavior in any electronic device including motor controls As a general rule it is recommended to shield all conductors If it is not practical to shield power conductors it is recommended to shield all logic level leads If shielding of all logic level leads is not practical the user should twist all logic leads with themselves to minimize induced noise I
10. loss of life Dangerous voltages exist on the drive when it is powered BE ALERT High voltages can cause serious or fatal injury For your safety use personal protective equipment PPE when operating this drive If the motor or drive does not perform as described disconnect the AC line voltage immediately Refer to the Troubleshooting section page 59 for further assistance Before Applying Power 1 Verify that no foreign conductive material is present on the printed circuit board Ensure that all switches are properly set RGA Series Select Switches Input Voltage Select SW501 SW502 Set the input voltage select switches SW501 and SW502 to either 115 or 230 to match the AC line voltage See Figure 14 Armature Voltage Select SW503 Set the armature voltage select switch SW503 to either 90 or 180 to match the maximum armature voltage See Figure 14 Feedback Select SW504 Set the feedback select switch SW504 to either ARM for armature feedback or TACH for tachogenerator feedback See Figure 14 Armature Voltage Select SW503 Input Voltage Feedback Select Select SW504 SW501 SW502 Figure 14 Select Switches RGA Series Signal Select SW501 RGA403 models Set the signal s
11. power leads L1 L2 A1 A2 F1 F2 MOUNT THROUGH A 0 38 IN 10 MM HOLE NUT STAR WASHER SPEED ADJUST POTENTIOMETER INSULATING DISK POT TAB ASSIGNMENTS PANEL Figure 6 Speed Adjust Potentiometer RGA Series Mounting NEMA 4X Enclosures NEMA 4X cased drives come with two 0 88 inch 22 mm conduit knockout holes at the bottom of the case The units may be vertically wall mounted using the four 0 19 inch 5 mm slotted holes on the attached heat sink For motor loads less than 5 ADC the drive may be bench mounted horizontally or operated without mounting 1 2 Install the mounting screws For access to the terminal strip turn the slotted screw on the front cover counterclockwise until it is free from the case The right side of the cover is hinged to the case Pull the slotted screw to open the case Carefully remove the conduit knockouts by tapping them into the case and twisting them off with pliers Set the POWER switch to the OFF position before applying the AC line voltage Install conduit hardware through the 0 88 inch 22 mm knockout holes Connect external wiring to the terminal block Grasp the slotted screw and tilt the front cover back into place Avoid pinching any wires between the front cover and the case Turn the slotted screw clockwise until tight to secure the front cover RGA Series Do not install rewire or remove this control with input power applied Failure to
12. speed adjust potentiometer as shown in Figure 7 c The motor does not operate when the potentiometer is in the center position Turning the potentiometer clockwise CW from the center position causes the motor to rotate in the forward direction while turning the potentiometer counterclockwise CCW causes rotation in the reverse direction 10 OHM SPEED POT Y cw FWD FWD a Unidirectional Forward 10K OHM SPEED POT cw REV 10K OHM P er SPEED POT Bidirectional cw REV b Unidirectional Reverse Figure 7 Speed Adjust Potentiometer Connections RGA Series Speed Adjust Potentiometer RGA403 models Use a 10K ohm 1 4 W potentiometer for speed control The motor can operate in one direction unidirectional or two directions bidirectional depending on how the speed adjust potentiometer is connected to the drive For unidirectional operation in the foward direction connect the speed adjust potentiometer as shown in Figure 8 a For unidirectional operation in the reverse direction connect the speed adjust potentiometer as shown in Figure 8 b For bidirectional operation connect the speed adjust potentiometer as shown in Figure 8 c The motor does not operate when the po
13. AMERICAN CONTROL ELECTRONICS RGA SERIES USER MANUAL RGA400 3 RGA400 10 RGA403 3 RGA403 10 RGA440 3 RGA440 10 www americancontrolelectronics com Dear Valued Consumer Congratulations on your purchase of the RGA Series drive This User Manual was created for you to get the most out of your new device and assist with the initial setup Please visit www americancontrolelectronics com to learn more about our other drives Thank you for choosing American Control Electronics No part of this document may be reproduced or transmitted in any form without written permission from American Control Electronics The information and technical data in this document are subject to change without notice American Control Electronics makes no warranty of any kind with respect to this material including but not limited to the implied warranties of its merchantability and fitness for a given purpose American Control Electronics assumes no responsibility for any errors that may appear in this document and makes no commitment to update or to keep current the information in this document RGA Series Safety First SAFETY WARNINGS Text in gray boxes denote important safety tips or warnings Please read these instructions carefully before performing any of the procedures contained in this manual DO NOT INSTALL REMOVE OR REWIRE THIS EQUIPMENT WITH POWER APPLIED Have a qualified electrical technician
14. Analog Input Signal RGA403 models 15 and 15 Enable Regen Brake Inhibit Direction Switch Tachogenerator Feedback RGA Series Section 5 Operation Before Applying Power Select Switches Input Voltage Select SW501 SW502 Armature Voltage Select SW503 Feedback Select SW504 Signal Select SW501 RGA403 models Input Voltage Select SW502 RGA403 models Startup Chassis models Startup NEMA 4X models Starting and Stopping Methods Automatic Restart Upon Power Restoration Line Starting and Stopping Regenerative Brake to Zero Speed INHIBIT Terminals Regenerative Decel to Zero Speed RB1 and RB2 Terminals Regenerative Decel to Minimum Speed Coast to Zero Speed INHIBIT RUN Section 6 Calibration Minimum Speed MIN SPD Maximum Speed MAX SPD Forward Torque FWD TQ Reverse Torque REV TQ IR Compensation IR COMP Forward Acceleration FWD ACC Reverse Acceleration REV ACC Deadband Tachogenerator TACH MIN OUT MAX OUT and SIGNAL INPUT ADJUST RGA403 models RGA Series Section 7 Application Notes Direction Switch Multiple Fixed Speeds Adjustable Speeds Using Potentiometers In Series Independent Adjustable Speeds Independent Adjustable Forward and Reverse Speeds RUN JOG Switch Inhibit Connection RUN JOG Switch Potentiometer Connection Leader Follower Application Single Speed Potentiometer Control Of Multiple Drives Section 8 Troubleshooting Before Trou
15. Figure 32 RGA Series RUN JOG Switch Inhibit Connection RUN JOG Switch Speed Adjust Potentiometer Connection 54 Leader Follower Application Single Speed Potentiometer Control of Multiple Drives RGA Series Section 1 Regenerative Drives Most Jnon regenerative variable speed DC drives control current flow to a motor in one direction The direction of current flow is the same direction as the motor rotation Non regenerative drives Quadrant II Quadrant I operate in Quadrant l Quadrant III Quadrant IV and also in Quadrant III if the drive is reversible see Figure 1 Motors must stop before reversing direction Unless dynamic braking is used non regenerative drives cannot decelerate a load faster than coasting to a MOTOR gt MOTOR ROTATION TORQUE lower speed NOTE ARROWS IN SAME DIRECTION MOTOR ACTION Regenerative drives operate ARROWS IN OPPOSITE DIRECTION REGENERATIVE ACTION in two additional quadrants Quadrant II and Quadrant IV In these quadrants motor torque is in the opposite direction of motor rotation Figure 1 Four Quadrant Operation This allows regenerative drives to reverse a motor without contractors or switches to control an overhauling load and to decelerate a load faster than it would to coast to a lower speed RGA Series Section 2 Specifications Maximum HP Range HP Range Armature with 90 VDC with 180 VDC Current ADC Motor E
16. LINE VOLTAGE any connections to ARMATURE T1 and T2 unless using OUTPUT a tachogenerator FIELD OUTPUT For shunt wound motors only See field output section for connections Figure 12 RGA403 Connections RGA Series NOTE DO NOT make any connections to T1 and T2 unless using a tachogenerator OPTIONAL e ejejejleejlejeje 115 VAC t 230 VAC PREWIREDTO POT AND SWITCH ON COVER ARMATURE OUTPUT FIELD OUTPUT For shunt wound motors only See field output section for connections Figure 13 RGA440 Connections RGA Series Section 5 Operation Change voltage switch settings only when the drive is disconnected from AC line voltage Make sure both switches are set to their correct position If the switches are improperly set to a lower voltage position the motor will not run at full voltage and may cause damage to the transformer If the switches are improperly set to a higher voltage position the motor will overspeed which may cause motor damage or result in bodily injury or
17. NG The TACH setting like IR COMP setting determines the degree to which motor speed is held constant as the motor load changes To calibrate the TACH trim pot 1 Connect the tachogenerator to 1 and T2 The polarity is positive for T1 and negative for T2 when the motor is running in the forward direction Set the feedback select switch SW504 to ARM for armature feedback Set the speed adjust potentiometer or input voltage or current signal to maximum speed Measure the armature voltage across A1 and A2 using a voltmeter Set the speed adjust potentiometer or input voltage or current signal to zero speed Set SW504 to TACH for tachogenerator feedback Set the IR COMP trim pot to full CCW Set the TACH trim pot to full CW Set the speed adjust potentiometer or input voltage or current signal to maximum speed Adjust the TACH trim pot until the armature voltage is the same value as the voltage measured in step 3 Check that the TACH is properly calibrated The motor should run at the same set speed when SW504 is set to either armature or tachogenerator feedback RGA Series Minimum Speed MIN OUT Maximum Speed MAX OUT amp Signal Input Adjust RGA403 models The following minimum and maximum values should be known INmin Minimum analog input signal INmax Maximum analog input signal OUTmin Minimum analog output signal OUTmax Maximum analog output signal INmin and INmax is the voltage appl
18. RUN switch Each drive is assembled with INHIBIT RUN terminals 2 and 3 jumpered These terminals must be connected for the motor to run See Figure 19 American Control Electronics offers an accessory plug harness for connecting to the INHIBIT RUN terminals part number KTW 0197 plug with 18 in 46 cm leads COAST RUN SWITCH INH RUN IV IV 1i J EEEEEE EDER m J rem Figure 19 Inhibit Run Terminal Location and Run Coast Switch RGA Series Section 6 Calibration possible disconnect the voltage input from the drive before adjusting the trim pots If the trim pots must be adjusted with power applied use insulated tools and the appropriate personal protection equipment BE ALERT High voltages can cause serious or fatal injury f Dangerous voltages exist on the drive when it is powered When RGA series drives have user adjustable trim pots Each drive is factory calibrated to its maximum current rating Readjust the calibration trim pot settings to accommodate lower current rated motors All adjustments increase with CW rotation and decrease with CCW rotation Use a non metallic screwdriver for calibration Each trim pot is identified on the printed circuit board RGA Series Minimum Speed MIN SPD The MIN SPD setting determines the minimum motor speed in unidirectional operation when the speed ad
19. arranty nor does it imply an extension of the original 12 month warranty period Products serviced and or parts replaced on a no charge basis during the warranty period carry the unexpired portion of the original warranty only If for any reason any of the foregoing provisions shall be ineffective American Control Electronics s liability for damages arising out of its manufacture or sale of equipment or use thereof whether such liability is based on warranty contract negligence strict liability in tort or otherwise shall not in any event exceed the full purchase price of such equipment Any action against American Control Electronics based upon any liability or obligation arising hereunder or under any law applicable to the sale of equipment or the use thereof must be commenced within one year after the cause of such action arises RGA400 3 ORAID S RGA400 10 EE RGA403 3 FIE ER RGA403 10 AMERICAN CONTROL ELECTRONICS RGA440 3 em Es RGA440 10 www americancontrolelectronics com 14300 DE LA TOUR DRIVE SOUTH BELOIT IL 61080 844 AMCNTRL 0010 Rev 1
20. ation time full CCW Turn the FWD ACC trim pot CW to increase the foward acceleration time and CCW to decrease the foward acceleration time Reverse Acceleration REV ACC The REV ACC setting determines the time the motor takes to ramp to a lower speed in the forward direction or to a higher speed in the reverse direction See Specifications on page 2 for approximate acceleration times REV ACC is factory set for the fastest acceleration time full CCW Turn the REV ACC trim pot CW to increase the reverse acceleration time and CCW to decrease the reverse acceleration time RGA Series Deadband DB The DB setting determines the time that will elapse between the application of current in one direction before current is applied in the opposite direction The DB affects the resistance that a motor has to changes in the shaft position at zero speed It does this by applying an AC voltage to the motor armature The deadband is factory calibrated to approximately 3 4 of a turn position for 60 Hz AC line operation Recalibrate the trim pot to approximately the 1 4 of a turn position for 50 Hz AC line operation If you hear motor noise humming the deadband might be set too high Turn the DB trim pot CCW until the motor noise ceases 50 Hz 60 Hz Applications Applications DB DB Figure 21 Deadband settings RGA Series Tachogenerator TACH Calibrate the TACH setting only when a tachogenerator is used WARNI
21. bleshooting Section 9 Accessories amp Replacement Parts RGA Series List of Tables Table 1 Recommended Line Fuse Sizes Table 2 Short Circuit Current Ratings Table 3 Field Output Connections RGA Series List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 O DUN Four Quadrant Operation RGA400 Dimensions RGA403 Dimensions RGA440 Dimensions HSK 0003 Dimensions Speed Adjust Potentiometer Speed Adjust Potentiometer Connections RGA403 Speed Adjust Potentiometer Connections Analog Input Signal Connections RGA403 Analog Input Signal Connections RGA400 Connections RGA403 Connections RGA440 Connections Select Switches SW501 Settings RGA403 Select Switches Inhibit Terminals Run Decelerate to Minimum Speed Switch Inhibit Run Terminal Location and Run Coast Switch Recommended FWD TQ REV TQ and IR COMP Settings Deadband Settings Forward Reverse Switch Forward Stop Reverse Switch Multiple Fixed Speeds Adjustable Speeds Using Potentiometers in Series Independent Adjustable Speeds Independent Adjustable Forward and Reverse Speeds Independent Adjustable Forward and Reverse Speeds with Figure 29 Figure 30 Figure 31
22. ction To calibrate REV TQ refer to the recommended REV TQ settings in Figure 20 page 42 or use the following procedure With the power disconnected from the drive connect a DC ammeter in series with the armature Set the REV TQ trim pot to minimum full CCW Set the speed adjust potentiometer or input voltage or current signal to maximum speed Carefully lock the motor armature Be sure that the motor is firmly mounted Apply line power The motor should be stopped Slowly adjust the REV TQ trim pot CW until the armature current is 150 of motor rated armature current Set the speed adjust potentiometer CCW or decrease the input voltage or current signal to minimum speed Remove line power Remove the stall from the motor Remove the ammeter in series with the motor armature if it is no longer needed RGA Series IR Compensation IR COMP The IR COMP setting determines the degree to which motor speed is held constant as the motor load changes Use the following procedure to recalibrate the IR COMP setting 1 Set the IR COMP trim pot to minimum full CCW 2 Increase the speed adjust potentiometer or input voltage or current signal until the motor runs at midspeed without load for example 900 RPM for an 1800 RPM motor A handheld tachometer may be used to measure motor speed Load the motor armature to its full load armature current rating The motor should slow down While keeping the load on the mot
23. d the drive by the heat sink only Protect the drive from dirt moisture and accidental contact Provide sufficient room for access to the terminals and calibration trim pots Mount the drive away from heat sources Operate the drive within the specified ambient operating temperature range Prevent loose connections by avoiding excessive vibration of the drive Mount the drive with its board in either a horizontal or vertical plane Six 0 19 5 mm wide slots in the chassis accept 8 pan head screws Fasten either the large base or the narrow flange of the chassis to the subplate The chassis should be earth grounded Use a star washer beneath the head of at least one of the mounting screws to penetrate the anodized surface and to reach bare metal RGA Series Speed Adjust Potentiometer Be sure that the potentiometer tabs do not make contact with the potentiometer s body Grounding the input will cause damage to the drive If using a remote potentiometer with a chassis drive mount the speed adjust potentiometer through a 0 38 in 10 mm hole with the hardware provided Figure 6 Install the circular insulating disk between the panel and the 10K ohm speed adjust potentiometer Twist the speed adjust potentiometer wire to avoid picking up unwanted electrical noise If the speed adjust potentiometer wires are longer than 18 in 46 cm use shielded cable Keep the speed adjust potentiometer wires separate from
24. g Line starting and stopping applying and removing AC line voltage is recommended for infrequent starting and stopping of a drive only When AC line voltage is applied to the drive the motor accelerates to the speed set by the speed adjust potentiometer or analog signal When AC line voltage is removed the motor coasts to a stop RGA Series Regenerative Brake to Zero Speed INHIBIT Terminals Short the INHIBIT terminals to regeneratively brake the motor to zero speed see Figure 17 The inhibit bypasses both the MIN SPD trim pot and the deceleration rate set by the FWD ACC or REV ACC trim pots Open the INHIBIT terminals to accelerate the motor to set speed Twist inhibit wires and separate them from power carrying wires or sources of electrical noise Use shielded cable if the inhibit wires are longer than 18 inches 46 cm If shielded cable is used ground only one end of the shield to earth ground Do not ground both ends of the shield American Control Electronics offers two accessory plug harnesses for connecting to the INHIBIT terminals part number KTW 0001 plug with 18 in 46 cm leads and part number KTW 0002 plug with 36 in 91 cm leads prp lv y Zi
25. ied across terminals 7 and 8 INPUT 1 or 9 INPUT 2 OUTmin and OUTmax is the voltage across terminals 1 OUT 1 and 2 OUT 2 that connect to the lower board Calibration Procedure 1 Ensure that switch SW501 on the top board is properly set See page 29 for switch settings 2 Connect but do not power the analog input signal as follows Connect the signal negative to terminal 7 COM For a current signal or a 0 25 VDC voltage signal connect the signal positive to terminal 8 INPUT 1 Fora 0 250 VDC voltage signal connect the signal positive to terminal 9 INPUT 2 RGA Series 3 Calibrate the regenerative drive s MIN SPD trim pot full CCW and the MAX SPD trim pot full CW 4 Apply AC line voltage and the analog input signal 5 Set the input signal to INmin 6 Adjust the MIN OUT trim pot P503 so that the output voltage is OUTmin 7 Set the analog input signal to INmax 8 Calculate the test point voltage _ 1 OUTmax OUTmin gt V where INmax INmin 9 Adjust the SIGNAL INPUT ADJ trim pot P501 so that the voltage between terminals 7 COM and 10 TP is Vip 10 Adjust the MAX OUT trim pot P502 so that the voltage output signal is OUTmax 11 Repeat steps 4 5 6 7 9 and 10 using the same values RGA Series Section 7 Application Notes Direction Switch For a Forward Reverse switch use a single pole
26. independent speed adjust potentiometers that can be mounted at two separate operating stations SPEED 1 Figure 26 Independent Adjustable Speeds RGA Series Independent Adjustable Forward and Reverse Speeds Replace the speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in parallel with a total parallel resistance of 10K ohms Figures 27 and 28 show the connection of two independent forward and reverse speed adjust potentiometers that can be mounted at two separate operating stations REV FWD 10K OHM 10K OHM Figure 27 Independent Adjustable Forward and Reverse Speeds REV FWD 10K OHM 10K OHM Figure 28 Independent Adjustable Forward and Reverse Speeds with Stop RGA Series RUN JOG Switch Inhibit Connection Use a single pole two position switch for the RUN JOG switch and a single pole normally closed momentary operated pushbutton for the JOG pushbutton Connect the RUN JOG switch and JOG pushbutton to the inhibit terminals as shown in Figure 29 The motor coasts to a stop when the RUN JOG switch is set to JOG Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation JOG PUSHBUTTON RUN Figure 29 RUN JOG Switch Inhibit Connection RGA Series RUN JOG Switch Potentiometer Connection Connect the RUN JOG switch and the JOG pushbut
27. install adjust and service this equipment Follow the National Electrical Code and all other applicable electrical and safety codes including the provisions of the Occupational Safety and Health Act OSHA when installing equipment Reduce the chance of an electrical fire shock or explosion by using proper grounding techniques over current protection thermal protection and enclosure Follow sound maintenance procedures It is possible for a drive to run at full speed as a result of a AN component failure American Control Electronics ACE strongly recommends the installation of a master switch in the main power input to stop the drive in an emergency Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Use a non metallic screwdriver for adjusting the calibration trim pots Use approved personal protective equipment and insulated tools if working on this drive with power applied RGA Series Table of Contents Section 1 Regenerative Drives Section 2 Specifications Section 3 Dimensions Section 4 Installation Heat Sinking Chassis NEMA 4X Mounting Chassis Speed Adjust Potentiometer NEMA 4X Shielding Guidelines Line Fusing Connections Field Output Connections Speed Adjust Potentiometer Speed Adjust Potentiometer RGA403 models Analog Input Signal
28. just potentiometer or input voltage signal is set for minimum speed To calibrate the MIN SPD 1 Setthe speed adjust potentiometer or input voltage signal for minimum speed 2 Adjust MIN SPD until the desired minimum speed is reached or is just at the threshold of rotation Maximum Speed MAX SPD The MAX SPD setting determines the maximum motor speed in the forward and reverse direction when the speed adjust potentiometer or input voltage signal is set for maximum speed To calibrate MAX SPD 1 Setthe speed adjust potentiometer or input voltage signal for maximum speed 2 Adjust MAX SPD until the desired maximum speed is reached Note Check the MIN SPD and MAX SPD adjustments after recalibrating to verify that the motor runs at the desired minimum and maximum speed Note If using models RGA403 3 or RGA403 10 set the MIN SPD to full CCW and the MAX SPD to full CW Use the MIN OUT and MAX SPD trim pots located on the top board for minimum and maximum speed calibration See page 45 for calibration of those trim pots RGA Series Forward Torque FWD TQ FWD TQ should be set to 150 of motor nameplate current rating Continuous operation beyond this rating may damage the motor If you intend to operate beyond the rating contact your WARNING 2 e MAKE American Control Electronics representative for assistance The FWD setting determines the maximum torque for accelerating and driving the m
29. ment Parts for fuse kit part numbers Table 2 Short Circuit Current Ratings Short Circuit Current Rating Maximum Drive Model Meximum Types of Branch Rating of Circuit Protection Overcurrent Current kA Voltage V Protection Inverse Non time 10 000 Delay K5 Fuse Time Circuit Breaker RGA Series Connections Do not connect this equipment with power applied Failure to heed this warning may result in fire explosion or serious injury American Control Electronics strongly recommends the installation of a master power switch in the voltage input line as shown in Figures 11 and 12 on pages 24 and 25 The switch contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts Power Input For chassis models connect the AC line power leads to terminals L1 and L2 115 if using a 115 VAC line or to terminals L1 and L2 230 if using a 230 VAC line American Control Electronics recommends the use of a single throw double pole master power switch The switch should be rated at a minimum of 250 volts and 200 of motor current Refer to Figures 11 and 12 on page 24 and 25 For NEMA 4X models the connect the AC line power leads to terminals 1 and 2 if using a 115 VAC line or to terminals 1 and 3 if using a 230 VAC line Refer to Figure 13 on page 26 Motor Drives supply motor armature voltage from A1 and A2 terminals It is assumed throughout this manual that when A1 is
30. nclosure RGA400 3 1 20 1 4 1 10 1 2 Chassis RGA403 3 Chassis RGA440 3 NEMA 4X RGA400 10 Chassis RGA403 10 Chassis RGA440 10 NEMA 4X Heat sink kit part number HSK 0003 must be used when the continuous current output is over 7 amps AC Line Voltage 115 230 VAC 10 50 60 Hz single phase DC Armature Voltage with 115 VAC Line Voltage 0 90 VDC with 230 VAC Line Voltage 0 180 VDC Field Voltage with 115 VAC Line Voltage 50 VDC F1 to L1 100 VDC F1 to F2 with 230 VAC Line Voltage 100 VDC F1 to L1 200 VDC F1 to F2 Acceleration Time Range 0 5 15 seconds Deceleration Time Range 0 5 15 seconds Analog Input Range RGA400 RGA440 models signal must be isolated RB1 to S2 Voltage Signal Range Oto 10 VDC RGA403 models Voltage Signal Range Oto 250 VDC Current Signal Range RGA Series Input Impedance RGA400 RGA440 models RB1 to 52 RGA403 models Voltage Signal RGA403 models 1 5 mA Signal RGA403 models 4 20 mA Signal RGA403 models 10 50 mA Signal Form Factor Load Regulation with Armature Feedback with Tachogenerator Feedback Safety Certification Ambient Temperature Range Chassis models Enclosed models 32K ohms gt 25 ohms 1K ohms 235 ohms 100 ohms 1 37 at base speed 196 base speed or better 0 196 base speed 0 5G maximum 0 50 Hz 0 1G maximum 50 Hz UL Recognized Component File E132235 CSA Certified Component File LRA1380 10 C 55 C 10 C
31. on Slowly advance the speed adjust potentiometer clockwise CW or increase the input voltage signal The motor slowly accelerates as the potentiometer is turned CW or as the input voltage signal is increased Continue until the desired speed is reached To brake the motor to a stop set the FORWARD BRAKE REVERSE switch to the BRAKE position To coast the motor to a stop set the POWER switch to the O OFF position To reverse direction set the FOWARD BRAKE REVERSE switch to the desired direction Set the POWER switch to the OFF position RGA Series Starting and Stopping Methods Regenerative braking coasting to a stop or decelerating to minimum speed is recommended for frequent starts and stops Do not use any of these methods for emergency stopping They may not stop a drive that is malfunctioning Removing AC line power both lines is the only acceptable method for emergency stopping For this reason American Control Electronics strongly recommends installing an emergency stop switch on both AC line inputs see Figures 11 and 12 on pages 23 and 24 WARNING Frequent starting and stopping can produce high torque This may cause damage to motors especially gearmotors that are not properly sized for the application Automatic Restart Upon Power Restoration All drives automatically run to set speed when power is applied the drive is enabled and the inhibit is open Line Starting and Stoppin
32. or rotate the IR COMP trim pot until the motor runs at the speed measured in step 2 If the motor oscillates overcompensation the IR COMP trim pot may be set too high CW Turn the IR COMP trim pot CCW to stabilize the motor 5 Unload the motor See Figure 20 on page 42 for recommended IR COMP settings RGA Series RGA4xx 10 Models 1 HP 2 HP so voc 480 voc cow 10 ADC 9 2 ADC 3 4 HP 1 HP amp 30 voc SILS 8 sso voc cow 7 6 ADC 5 ADC 1 2 HP 3 4 HP 90 VDC 8 8 180 VDC income 5 ADC 3 8 ADC 1 4 HP 1 2 HP 68 90 68 180 voc 2 7 ADC 2 5 ADC IR COMP FWD IR COMP RGA4xx 3 Models 1 8 HP 1 4 HP so voc e GG 180 VDC mcow 1 3 ADC 1 4 ADC 1 10 HP 1 8 HP 180 VDC Rcomp 1 1 ADC rwora Revta Rcomp 0 67 ADC 1 20 HP 8 90 VDC come 0 56 ADC Figure 20 Recommended FWD REV and IR COMP settings actual settings may vary with each application RGA Series Forward Acceleration FWD ACC The FWD ACC setting determines the time the motor takes to ramp to a higher speed in the forward direction or to a lower speed in the reverse direction See Specifications on page 2 for approximate acceleration times ACCEL is factory set for the fastest acceler
33. otor in the forward direction It also sets the maximum torque for decelerating the motor in the reverse direction To calibrate FWD refer to the recommended FWD settings in Figure 20 page 42 or use the following procedure With the power disconnected from the drive connect a DC ammeter in series with the armature Set the FWD trim pot to minimum full CCW Set the speed adjust potentiometer or input voltage or current signal to maximum speed Carefully lock the motor armature Be sure that the motor is firmly mounted Apply line power The motor should be stopped Slowly adjust the FWD TQ trim pot CW until the armature current is 15096 of motor rated armature current Set the speed adjust potentiometer CCW or decrease the input voltage or current signal to minimum speed Remove line power Remove the stall from the motor Remove the ammeter in series with the motor armature if it is no longer needed RGA Series Reverse Torque REV TQ REV TQ should be set to 150 of motor nameplate current rating Continuous operation beyond this rating may damage the motor If you intend to operate beyond the rating contact your WARNING z e MAMI American Control Electronics representative for assistance The REV TQ setting determines the maximum torque for decelerating the motor in the forward direction It also sets the maximum torque for accelerating and driving the motor in the reverse dire
34. positive with respect to A2 the motor will rotate clockwise CW while looking at the output shaft protruding from the front of the motor If the motor does not spin in the desired direction remove power and reverse the 1 and 2 connections Connect a DC motor to terminals A1 and A2 as shown in Figures 11 12 and 13 on pages 24 25 and 26 Ensure that the motor voltage rating is consistent with the drive s output voltage RGA Series Field Output Connections The field output is for shunt wound motors only Do not make any connections to 1 and F2 when using permanent magnet moio See Table 3 for field output connections Use 14 16 AWG wire to connect the field output to a field shunt wound motor Table 3 Field Output Connections Voltage VDC Field To 1 11 F1 F2 F1 and L1 F1 and F2 RGA Series Speed Adjust Potentiometer Use a 10K ohm 1 4 W potentiometer for speed control The motor can operate in one direction unidirectional or two directions bidirectional depending on how the speed adjust potentiometer is connected to the drive For unidirectional operation in the foward direction connect the speed adjust potentiometer as shown in Figure 7 a For unidirectional operation in the reverse direction connect the speed adjust potentiometer as shown in Figure 7 b For bidirectional operation connect the
35. st the IR COMP setting slightly CCW until the motor speed stabilizes See page 41 Make sure motor is not unddersized for load adjust FWD or REV trim pot CW See pages 39 and 40 RGA Series Section 9 Accessories amp Replacement Parts Displays Closed Loop OLD100 1 Open Loop CLD100 1 Heat Sinks HSK 0001 HSK 0001 Kits Potentiometer amp Connector RGA400 Pot 0001 Fuse 2 1 5 Amp 250V Fast blow Glass Fuses KTF 0001 2 3 Amp 250V Fast blow Glass Fuses KTF 0002 2 5 Amp 250V 3AG Fast blow Glass Fuses KTF 0003 2 8 Amp 250V 3AG Fast blow Glass Fuses KTF 0004 2 10 Amp 250V 3AB Normal blow Ceramic Fuses KTF 0005 2 15 Amp 250V 3AB Normal blow Ceramic Fuses KTF 0006 Logic Cards Current Sensing 100 5 CMC100 20 Isolation Cards Adder Board 150401 1 Unidirectional 8 outputs 150101 8 RGA Series RGA Series Unconditional Warranty A Warranty American Control Electronics warrants that its products will be free from defects in workmanship and material for twelve 12 months or 3000 hours whichever comes first from date of manufacture thereof Within this warranty period American Control Electronics will repair or replace at its sole discretion such products that are returned to American Control Electronics 14300 De La Tour Drive South Beloit Illinois 61080 USA This warranty applies only to standard catalog products and does not apply to specials An
36. t may be necessary to earth ground the shielded cable If noise is produced by devices other than the drive ground the shield at the drive end If noise is generated by a device on the drive ground the shield at the end away from the drive Do not ground both ends of the shield If the drive continues to pick up noise after grounding the shield it may be necessary to add AC line filtering devices or to mount the drive in a less noisy environment Logic wires from other input devices such as motion controllers and PLL velocity controllers must be separated from power lines in the same manner as the logic on this drive RGA Series Line Fusing Models RGA400 10 RGA403 10 and RGA440 10 are preinstalled with 20 amp fuses Models RGA400 3 RGA403 3 and RGA440 3 are preinstalled with 8 amp fuses Preinstalled line fuses are rated for maximum horsepower If the horsepower rating of the motor being used is less than the maximum horsepower rating of the drive the line fuse may have to be replaced with a lower rated one Fuses should be rated for 250 VAC or higher and approximately 150 of the maximum armature current Refer to Table 1 on page 15 to install a lower rated fuse Refer to Table 2 on page 15 for Short Circuit Current Ratings SCCR RGA Series Table 1 Recommended Line Fuse Sizes 180 VDC Maximum DC Motor Armature Current Fuse Size Horsepower Horsepower amps amps See Section 9 Accessories and Replace
37. tentiometer is in the center position Turning the potentiometer clockwise CW from the center position causes the motor to rotate in the forward direction while turning the potentiometer counterclockwise CCW causes rotation in the reverse direction 10 OHM SPEED POT FWD 15 COM INPUT1 cw FWD 10K OHM SPEED REV 10K OHM SPEED REV 15 a Unidirectional Forward 15 COM INPUT 1 15 COM INPUT 1 15 b Unidirectional Reverse Figure 8 RGA403 Speed Adjust Potentiometer Connections RGA Series Analog Input Signal Instead of using a speed adjust potentiometer the drive may be wired to follow an analog input voltage signal that is isolated from earth ground Figure 9 Connect the signal common RB1 Connect the signal input to S2 A potentiometer can be used to scale the analog input voltage An interface device such as American Control Electronics model 150401 1 may be used to scale and isolate an analog input voltage An isolated analog input voltage range of 10 to 10 VDC is required to produce an armature voltage range of 90 to 90 VDC with 115 VAC line voltage or 180 to 180 VDC with 230 VAC line voltage RB1 _ m Signal Common
38. ton as shown in Figure 30 When the RUN JOG switch is set to JOG the motor decelerates to zero speed Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation 10K OHM SPEED ADJUST POTENTIOMETER RUN I PUSHBUTTON Figure 30 RUN JOG Switch Speed Adjust Potentiometer Connection RGA Series Leader Follower Application In this application use 150202 1 to monitor the speed of the leader motor Figure 31 The 150202 1 isolates the leader motor from the follower drive and outputs a voltage proportional to the leader motor armature voltage The follower drive uses this voltage reference to set the speed of the follower motor An optional ratio potentiometer may be used to scale the 150202 1 output voltage 9 52 1 0202 1 1 Follower TB502 50 10K Ohm optional Figure 31 Leader Follower Application RGA Series Single Speed Potentiometer Control Of Multiple Drives Multiple drives can be controlled with a single speed adjust potentiometer using 150101 8 at the input of each drive to provide isolation Figure 32 Optional ratio potentiometers can be used to scale the 150101 8 output voltage allowing independent control of each drive ratio pot A optional 10K Ohms 10K Ohms ratio pot B optional 10K Ohms 180101 8 ratio pot H optional 10K Ohms
39. two position switch with a single speed adjust potentiometer to regeneratively reverse the motor Figure 22 If a Forward Stop Reverse switch is desired use a single pole three position switch Figure 23 The MIN SPD setting is in effect for either direction 10K OHM SPEED ADJUST POTENTIOMETER Figure 22 Forward Reverse Switch 10K OHM SPEED ADJUST POTENTIOMETER Figure 23 Forward Stop Reverse Switch RGA Series Multiple Fixed Speeds Replace the speed adjust potentiometer with a series of resistors with a total series resistance of 10K ohms Figure 24 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds S1 or S3 E TOTAL SERIES e RESISTANCE i6 R3 10K OHMS R4 Figure 24 Multiple Fixed Speeds RGA Series Adjustable Speeds Using Potentiometers In Series Replace the speed adjust potentiometer with a series of resistors with a total series resistance of 10K ohms Figure 25 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds S1 CW 5K OHM Figure 25 Adjustable Speeds Using Potentiometers In Series RGA Series Independent Adjustable Speeds Replace the speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in parallel with a total parallel resistance of 10K ohms Figure 26 shows the connection of two
40. witch SW501 based on the type of input signal to be used See Figure 15 for settings and Figure 16 for location DIP SWITCH SETTING 2 OFF OFF 4 20 ON 10 50 OFF Figure 15 SW501 Settings Input Voltage Select SW502 RGA403 models Set the input voltage select switch SW502 to either 115 or 230 to match the AC line voltage See Figure 16 Signal Select 501 Input Voltage Select SW502 Figure 16 RGA403 Select Switches RGA Series Startup RGA400 and RGA403 Turn the speed adjust potentiometer full counterclockwise CCW or set the input voltage or current signal to minimum Apply AC line voltage Slowly advance the speed adjust potentiometer clockwise CW or increase the input voltage or current signal The motor slowly accelerates as the potentiometer is turned CW or as the input voltage or current signal is increased Continue until the desired speed is reached Remove AC line voltage from the drive to coast the motor to a stop RGA Seri RGA440 1 es Set the FORWARD BRAKE REVERSE switch to the BRAKE position Turn the speed adjust potentiometer to 0 full CCW or set the input voltage signal to minimum Set the POWER switch to the ON position Set the FORWARD BRAKE REVERSE switch to the desired direction of rotati
41. y returns of special controls will be evaluated on a case by case basis American Control Electronics is not responsible for removal installation or any other incidental expenses incurred in shipping the product to and from the repair point B Disclaimer The provisions of Paragraph A are American Control Electronics s sole obligation and exclude all other warranties of merchantability for use expressed or implied American Control Electronics further disclaims any responsibility whatsoever to the customer or to any other person for injury to the person or damage or loss of property of value caused by any product that has been subject to misuse negligence or accident or misapplied or modified by unauthorized persons or improperly installed C Limitations of Liability In the event of any claim for breach of any of Americn Control Electronics s obligations whether expressed or implied and particularly of any other claim or breach of warranty contained in Paragraph A or of any other warranties expressed or implied or claim of liability that might despite Paragraph B be decided against American Control Electronics by lawful authority American Control Electronics shall under no circumstances be liable for any consequential damages losses or expenses arising in connection with the use of or inability to use American Control Electronics s product for any purpose whatsoever An adjustment made under warranty does not void the w
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