User Manual - Galco Industrial Electronics
Contents
1. S LO 4 0 3 8 3 E a am mp 200 0386 502 LIMIT SWITCH RG500 SERIES LOGIC BOARD DRIVE Figure 20 RG500 connection to 200 0386A Limit Switch Logic Board 40 Application Notes Optional speed adjust potentiometer connections Forward Reverse Switch Use a single pole two position switch with a single speed adjust 51 potentiometer to plug 50 10K reverse the motor Figure 52 eX OHM 21 The MIN SPD setting S3 ES is in effect for either direction FWD Figure 21 Forward Reverse Switch Forward Stop Reverse Switch Use a single pole three position switch with a 50 single speed adjust 81 potentiometer to stop 10K motor between reversals 52 OHM Figure 22 Set the switch S3 REV cw to the center position to STOP decelerate the motor to a FWD stop Figure 22 For2. 230 VAC AC LINE INPUT 115 OR 230 VAC 77 ARMATURE OUTPUT FIELD OUTPUT For shunt wound motors only See field output section for connections Figure 5 Cased Drive Connections Installation 11 Cage clamp terminal block Connections to RG500 Series drives are made to a cage clamp terminal block see Figure 6 To insert a wire into the terminal block press down on the lever arm using a small screwdriver Insert stripped wire into the large opening in front of the terminal block Release the lever arm to clamp the wire Lever Arm Wire Clamp Figure 6 Cage Clamp Terminal Block 12 Installation Field output The field output is for shunt wound motors only Do not make any connections to F1 and F2 when using a permanent magnet motor Use 18 AWG wire to connect the field output to a shunt wound motor Table lists the field output connections Table 1 Field Output Connections Line Voltage Approximate Connect Motor VAC Field Voltage VDC Field To 115 50 1 and L1 115 100 F1 and F2 230 100 and L1 230 200 F1 and F2 Tachogenerator feedback Using tachogenerator feedback improves speed regulation from approximat
3. A Warning 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 Before applying power 1 Check connections before applying AC line voltage to the drive 2 Check that no conductive material is present on the printed circuit board 3 Verify that all selector switches are set correctly see the following section for selector switch settings Operation 19 Selector switch settings 1 Set the line voltage selector switches SW501 and SW502 to 115 if using 115 VAC line voltage or to 230 if using 230 VAC line voltage 2 Set the armature voltage selector switch SW503 to 90 if using a 90 VDC motor or to 180 if using a 180 VDC motor 3 Set the feedback selector switch SW504 to TACH if using a tachogenerator otherwise set to ARM for armature feedback Note You may be required to derate a 90 VDC motor when 230 VAC is applied to the drive Contact the factory for details See Figure 11 page 21 for all switch locations Startup Chassis drives 1 Set the speed adjust potentiometer for zero speed 2 Apply AC line voltage 3 Slowly advance the speed adjust potentiometer clockwise CW The motor slowly accelerates as the potentiometer is turned CW Continue until the desired speed is reached 4 Remove AC line voltage from the drive to coas
4. QR of Feedback Selector Switch Armature Voltage Selector Switch Line Voltage Selector Switches Figure 11 Selector Switch Locations 22 Starting and Stopping Methods Line starting and line stopping Line starting and line 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 When AC line voltage is removed the motor coasts to a stop Automatic restart upon power restoration All drives automatically run to set speed when power is applied Wiring a latching relay into the AC line is one way to prevent automatic restarting following a power outage Regenerative deceleration Short terminals RB1 and RB2 to regeneratively decelerate a RB1 motor to a stop Figure 12 Since terminal RB1 bypasses STOP the MIN SPD circuit shorting RB2 and RB2 will decelerate a motor to a stop instead of RUN minimum speed Calibrate the deceleration time Figure 12 Regenerative by adjusting the opposite Deceleration Switch
5. 16 Voltage follower 17 Operation nes as Een Abe ee INR REA ete RR 18 Before applying power 18 Selector switch settings 19 eres nett satu oud RU Re beet ec ing 19 Chassis drives inir menaa Ree o b pace eh Ga ee 19 Cased drives iii viele cede Ea pie 20 Line starting and line stopping 22 Automatic restart upon power restoration 22 Regenerative deceleration 22 Starting and Stopping 5 22 Regenerative brake 23 Coast toa 50 isi ee idm RR tp dare de Pe 24 Decelerate to zero speed 26 Calibration i se Re tac 28 MINIMUM SPEED MIN 29 MAXIMUM SPEED MAX SPD 29 FORWARD TORQUE FWD 30 REVERSE TORQUE REV TQ 31 IR COMPENSATION IR COMP 32 FORWARD ACCELERATION FWD ACC 33 REVERSE ACCELERATION REV ACC 33 DEADBAND 35 TACHOGENERATOR TACH 36 Application 38 Connection to other Minarik
6. 12 13 14 15 Place the Feedback selector switch SW504 to the Tachogenerator TACH position Apply power to the drive The motor should run in the forward direction Rotate the TACH trimmer pot CCW so that the maximum speed is reached this is the same speed as was obtained in step 10 Rotate the main speed potentiometer to the reverse direction S2 should be negative with respect to S1 The motor speed should follow the speed potentiometer position Check that the tachogenerator is properly calibrated The motor should run at the same set speed when SW504 is set to either armature or tachogenerator feedback 38 Application Notes Connection to other Minarik devices TB502 52 52 RG500 SERIES DRIVE DLC600 DIGI LOC CONTROL RB1 51 502 501 52 RG500 SERIES DRIVE PCM4 SIGNAL ISOLATOR RB1 Figure 19 RG500 Connections to DLC600 and PCM4 Application Notes 39 The RG500 can be connected to an optional 200 0386A limit switch logic board The 200 0386A provides the logic interface between the regenerative drive and pushbutton stations foot switches or programmable controls See Figure 20 for RG500 connections to the 200 00386A limit switch logic board For more information on Minarik s limit switch logic board refer to User s Manual 250 0222 or the Minarik Product Catalog
7. SCR Dual Voltage Adjustable Speed Regenerative Drives for DC Brush Motors TVWANVIN Copyright 2001 by Minarik Corporation All rights reserved No part of this manual may be reproduced or transmitted in any form without written permission from Minarik Corporation The information and technical data in this manual are subject to change without notice Minarik Corporation and its Divisions make 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 Minarik Corporation and its Divisions assume no responsibility for any errors that may appear in this manual and make no commitment to update or to keep current the information in this manual Printed in the United States of America Safety Warnings This symbol A denotes an important safety tip or warning Please read these sections carefully prior to performing any of the instructions contained in that section Have a qualified electrical maintenance technician 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 proper grounding over current protection thermal protection and enclosure Follow sound maintenance pr
8. 5 38 Optional speed adjust potentiometer connections 40 Forward Stop Reverse 40 Forward Reverse 40 Independent Adjustable Speeds Forward Direction Only 41 Independent Forward and Reverse lt 42 Independent Forward and Reverse Speeds with FWD STOP REV Switch 43 Troubleshooting 00000 eee eee 44 Factory Prewired Connections 48 Replacement Parts 5 0 gees bowed toed we 50 Certificate of Compliance 52 Block Diagram ded 56 Unconditional Warranty inside back cover iv Illustrations Figure 1 RG500UA and RG510UA Dimensions 3 Figure 2 RG500A and RG510A Cased Drive Dimensions 4 Figure 3 Four Quadrant Operation 6 Figure 4 Chassis Drive Connections 9 Figure 5 Cased Drive 10 Figure 6 Cage Clamp Terminal 11 Figure 7 Speed Adjust 13 Figure 8 Speed Adjust Potentiometer Connections 14 Figure 9 TB502 Terminal Assignments 15 Figure
9. Pico fuse 63mA 050 0081 500 Same parts as RG500UA except 202 0003 and 223 0258 Include 10KQ 2W Potentiometer 120 0047 Potentiometer Knob 140 0013 Case 223 0209 240 V Pilot Light 040 0043 FWD BRAKE REV Switch 080 0031 Power Switch 080 0022 Toggle Switch Boot 155 0078 Chassis 223 0260 Heat Sink 223 0232 Replacement Parts 51 Table 3 Replacement Parts Continued Model No Symbol Description Minarik P N RGS510UA R501 0 050 5 Resistor 032 0146 SCR501 508 800 25 A SCR 072 0042 T505 3FD 436 Transformer 230 0072 10KQ Potentiometer Kit 202 0003 Chassis 223 0258 8 A 3AB Line Fuse 050 0023 Line Fuse Kit 3 8A 050 0069 Line Fuse Kit 5 20A 050 0073 Pico fuse 1 2A 050 0074 510 Same parts as RG500UA except 202 0003 223 0258 Include 10KQ 2W Potentiometer 120 0047 Potentiometer Knob 140 0013 Case 223 0209 240 V Pilot Light 040 0043 FWD BRAKE REV Switch 080 0004 Power Switch 080 0031 Toggle Switch Boot 155 0078 Chassis 223 0260 Heat Sink 223 0232 52 Certificate of Compliance Minarik Corporation hereby certifies that its RG500 series drives have been approved to bear the CE mark provided the conditions of approval listed in Exhibit have been met by the end user The RG500 series has been tested to the following test specifications EN55011 1991 emissions and EN50082 1 1992 immunity Compliance allows Minarik s RG500 series to bear the CE mark The end
10. direction acceleration trimpot Connection Starting and Stopping Methods 23 Regenerative brake Short the INHIBIT terminals to regeneratively brake the motor see Figure 13 for INHIBIT terminal location Reopening the INHIBIT terminals causes the motor to accelerate to set speed The INHIBIT terminals bypass both the MIN SPD circuit and the deceleration circuit This causes the motor to stop rapidly when the INHIBIT terminals are shorted Braking torque is determined by the opposite direction torque setting am Y INHIBIT Terminals S gt 18 15 T 12 d d d d A d a aS Figure 13 INHIBIT Terminals 24 Starting and Stopping Methods Minarik Corporation offers two accessory plug harnesses for the INHIBIT terminals Minarik Part Number Description 201 0024 Inhibit plug with 18 in 46 cm wires 201 0079 Inhibit plug with 36 in 91 cm wires Twist inhibit wires and separate them from other power carrying wires or sources of ele
11. forward direction within the limits of available torque The REV ACC setting is factory set for its fastest reverse acceleration time Turn the REV ACC trimpot CW to increase the reverse acceleration time and CCW to decrease the reverse acceleration time 34 Calibration RG500 Models COC ke Qi OBS ae me 2 5 o 2 E Q FWD o a o Q 5 RG510 Models 60 VD QAQA Hr 90 VDC 180 VDC FwoTa mcowe 1 3ADC mcow 1 4 ADC 1 10 HP 1 8 HP 90 VDC 180 VDC FwoTa Rcomp 1 1 ADC REvra ircomp 0 67 ADC Q 1 20 HP 90 VDC ER E X I comp 0 56 ADC 3 gt a o 2 lt a o Figure 17 Typical FWD TQ REV TQ and IR COMP Settings actual settings may vary with each application Calibration 35 DEADBAND DB The deadband trimmer potentiometer determines the time that will elapse between the application of current in one direction before current is applied in the opposite direction The deadband trimmer potentiometer affects the resistance that a motor has to changes in shaft position at zero speed It does this by applying AC voltage to the motor armature Deadband is factory calibrated to approximately the 3 o clock position for 60 Hz AC
12. slotted screw clockwise until tight to secure the front cover Installation 9 Heat sinking Chassis RG500 models require an additional heat sink when the continuous armature current is above 7 ADC Use Minarik part number 223 0235 All cased drives have sufficient heat sinking in their basic configurations Use a thermally conductive heat sink compound such as Dow Corning 340 Heat Sink compound between the drive chassis and the heat sink surface for optimum heat transfer AC line and motor connections Use 14 AWG or 16 AWG standard wire for connecting the line and the armature Use 16 AWG or 18 AWG standard wire when connecting the field of a shunt wound motor Strip the wire insulation 0 25 inches 6 mm See Figures 4 and 5 page 10 for AC line and motor connections to chassis and cased drives Ore SEEE RERE f ARMATURE OUTPUT AC LINE 230 VAC i INPUT 115 VAC FIELD OUTPUT For Shunt Wound 115 OR 230 VAC Motors Only c See field output section for connections Figure 4 Chassis Drive Connections 10 Installation
13. the drive Check that the motor cable and armature is not shorted or grounded a The motor s armature resistance should measure approximately 1 to 100 ohms depending on motor horsepower b A resistance reading from the motor frame to either armature side should show open when an ohmmeter is used on its high resistance scale Check that the field circuit is not open 46 Troubleshooting Motor pulsates or surges under load 1 2 Readjust the IR COMP setting slightly CCW until the motor speed is stabilized Verify that the motor is not going in and out of current limit If so re adjust FWD TQ and REV TQ pots Line fuse does not blow but the motor does not run 1 Verify that the speed adjust potentiometer is not set to its zero speed position If in voltage follower mode verify that reference voltage is not set to zero Check the speed adjust potentiometer for continuity Verify that the inhibit pins are not shorted together Check that INHIBIT RUN terminals 2 and 3 are connected Verify that the drive is receiving AC line voltage Check that the drive is not in current limit If the drive is in current limit verify that the motor is not jammed It may be necessary to increase the FWD TQ or REV TQ setting if it is set lower than the current rating of the motor Check that the speed adjust potentiometer connections to the terminal block are correct and not open Motor runs too fast at the ma
14. 10 Voltage Follower Connection 17 Figure 11 Selector Switch 21 Figure 12 Regenerative Deceleration Switch Connection 22 Figure 13 INHIBIT 23 Figure 14 Inhibit Run Jumper 5 24 Figure 15 Inhibit Run Terminals Location and Run Coast Switch 25 Figure 16 Run Decelerate to Zero Speed Switch 26 Figure 17 Typical FWD TQ REV TQ and IR COMP Settings 34 Figure 18 Deadband 5 5 35 Figure 19 RG500 Connections to DLC600 and PCM4 38 Figure 20 RG500 connection to 200 0386A Limit Switch Logic Board 39 Figure 21 Forward Reverse Switch 40 Figure 22 Forward Stop Reverse Switch 40 Figure 23 Independent Adjustable Speeds 41 Figure 24 Independent Forward and Reverse Speeds 42 Figure 25 Independent Forward and Reverse Speeds with a Forward Stop Reverse Switch 43 Figure 26 Prewired Connections to L1 L2 115 L2 230 Figure 27 Prewired Speed Adjust Potentiometer Connections Figure 28 RG500 Series Block Diagram vi Tables Table 1 Table 2 Table 3 Table 4 Table 5 Field Output Connections 12 Fu
15. AC line voltage must match the voltage on the drive nameplate On dual voltage drives check that the voltage switches are set to the correct position The deadband DB must be set approximately at the 3 o clock position for 60 Hz AC line frequency or at 9 o clock for 50 Hz AC line frequency The motor must be rated for the drive s rated armature all motors and field outputs shunt wound motors only Do not make any connections to F1 and F2 if using a permanent magnet motor Terminal block connections should be consistent with the connections shown in this manual Check that line fuse FUS01 and FU502 for 230 VAC line voltage is properly sized and not blown Check that field fuse FU503 is 1 5 A and not blown Troubleshooting 45 Field fuse blows 1 2 3 4 ON Disconnect AC line voltage from the drive Verify that the fuse is 1 5 A Check motor cable for shorts Check motor field for shorts a Disconnect field leads from terminals F1 and F2 b Motor field resistance should measure approximately 100 to 1000 ohms depending on motor horsepower A resistance reading from the motor frame to either side of the field should show open when an ohmmeter is used on its high resistance scale Reconnect field leads to the drive Reconnect AC line voltage to the drive Advance the speed adjust potentiometer to the desired speed Line fuse blows 1 2 3t Disconnect AC line voltage from
16. IGGERING CIRCUIT ES a SUMMING DEADBAND DB POWER BRIDGE FEEDBACK l M CIRCUIT CIRCUIT RECTIFIERS CIRCUIT 0 90 VDC OUTPUT WITH 115 voc INPUT 0 180 VDC OUTPUT WITH 230 vac INPUT REV TRIGGERING CIRCUIT THE POLARITY OF THE ARMATURE OUTPUT 15 VOLTAGE IS AT AND AT A2 cw WHEN CEERATNG Ne DIRECTION AS SHOWN ABOVE THE CURRENT POLARITY IS REVERSED WHEN OPERATING CIRCUIT IN THE REVERSE DIRECTION REV TO Tesi FELD m FIELD OUTPUT VOLTAGE vac i a Fi f 0001 200 VDC FIELD OUTPUT VOLTAGE 13 WITH 230 vac APPLIED F2 1 MAX THE AND F2 ENABLE THE DRIVE INHIBIT THE DRIVE TO STOP 10 VDC NAL SUPPLY 15 TB502 VOLTAGES MEASURED WITH RESPECT TO CIRCUIT COMMON TERMINAL RB1 PM MOTOR TERMINALS SHOULD BE LEFT OPEN WHEN USING A PERMANENT MAGNET PLEASEDNOTE 00 AUMAXIMUMOOFO100mA0MAYOBEDSOURC ED FROMO THEOS10AND OROS20 TERMINALSO ADISOLATEDOLOAD ORD 150mA0DCOMAYUB EUSOURC 15 15 TERMINALSO TOU ADISOLATEDOLOAD Notes Unconditional Warranty A Warranty Minarik Corporation referred to as the Corporation warrants that its products will be free from defects in workmanship and material for twelve 12 months or 3 000 hours whichever comes first from date of manufacture thereof Within this warranty period the Corporation will repair or repla
17. OT SETTINGS 5K MN SPD RECONNECT THIS LEAD CURRI TO THE TERMINAL MARKED a 50 FOR UNIDIRECTIONAL FWD TO a OPERATION MODELS RG500UA AND RG500A USE 20 ANP FAST ACTING LINE FUSES FUBO FU502 REF PART NUMBER 060 0019 MODELS RGB10A AND RGS QUA USE AMP FAST ACTING LINE FUSES 501 FU502 REF PART NUMBER 050 0023 ALL RG500 SERIES MODELS USE A 1 6 FAST ACTING FIELD FUSE FU503 REF PART NUMBER 050 0026 pS FIELD CIRCUIT 14 LINE VOLTAGE INPUT 9 JUMPER TERMINALS 2 AND 3 TO ENAE CONNECT THE LINE ACROSS THE 999 9 JUMPER TERMINALS 1 AND 2 TO INHIB RMINALS MARKED L AND L2 115 2 5 CAUSING THE MOTOR TO COAST TO A IF 115 voc IS BEING USED INH RUN CONNECT THE LINE ACROSS THE TERMINALS MARKED 11 AND L2 230 10 IF 230 voc 15 BEING USED INTERNAL 51 Ny 115 vac POWER DOWN 230 vac dis POWER DISCHARGE 415 SUPPLY CIRCUIT 7 FU502 230 a E TES TT 115 250 230 115 W50 SWs02 SWsot Figure 28 RG500 Series Block Diagram Block Diagram 57 TOR ATURE ARMATURE FEEDBACK SW504 m TACH ARM TU 1 VOLTAGE FEEDBACK CIRCUIT IR COMP cw IR COMPENSATION REGULATION ZACH CIRCUIT AND GEN FWD TR
18. Terminal Assignments 16 Installation Line Fusing for RG Series Drives Minarik drives require fuses for protection Use fast acting fuses rated for 250 VAC or higher and approximately 150 of the maximum armature current Fuse L1 when using 115 VAC line voltage Fuse both L1 and L2 when the line voltage is 230 VAC The fuse chart below lists the recommended line fuse sizes Table 2 Fuse Chart 90 VDC Motor 180 VDC AC Line Fuse Horsepower Horsepower Size amps 1 20 1 10 3 1 15 1 8 3 1 8 1 4 5 1 6 1 3 5 1 4 1 2 8 1 3 3 4 8 1 2 1 10 3 4 1 1 2 15 1 2 20 Minarik Corporation offers two fuse kits part number 050 0069 3 8A Fuse Kit and 050 0073 5 20A Fuse Kit Both fuse kits include a 1 2A pico fuse part number 050 0064 which protects the transformer and logic Installation 17 All drives have line fuses installed see Replacement Parts section for installed line fuse size Line fuses are rated for maximum rated curent Use line fuses rated for 20 A or less on RG500 drives 8 A or less on RG501 drives Voltage follower The drive may be wired to follow a floating isolated 0 to 10V signal that is isolated from earth ground instead of using a speed adjust potentiometer Connect the signal input to 52 and the signal common to see Figure 10 10 VDC _ 52 51 COMMON 4 RB1 Figure 10 Voltage Follower Connection 18
19. ce at its sole discretion such products that are returned to Minarik Corporation 901 East Thompson Avenue Glendale CA 91201 2011 USA This warranty applies only to standard catalog products and does not apply to specials Any returns for special controls will be evaluated on a case by case basis The Corporation 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 the Corporation s sole obligation and exclude all other warranties of merchantability for use express or implied The Corporation 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 the Corporation s obligations whether express or implied and particularly of any other claim or breech of warranty contained in Paragraph A or of any other warranties express or implied or claim of liability that might despite Paragraph B be decided against the Corporation by lawful authority the Corporation shall under no circumstances be liable for any consequential damages losses or expense arising in connection with the use of or
20. ctrical noise Use shielded cable if the inhibit wires are longer than 18 in 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 Coast to a stop To coast the motor to a stop without removing power to the drive jumper INHIBIT RUN terminals 1 and 2 see Figure 14 page 25 To restart the motor jumper INHIBIT RUN terminals 2 and 3 A single pole double throw switch may be used as a COAST RUN switch see Figure 15 page 25 Ez egg INHIBIT RUN Each drive is assembled with INHIBIT RUN terminals 2 and 3 Figure 14 Inhibit jumpered These terminals must Run Jumper be connected for the motor to run Settings Starting and Stopping Methods 25 COAST TO RUN COAST RUN SWITCH STOP J O 1 2 3 INH RUN 1 3 INHIBIT RUN TERMINALS MI LIII UE amp Figure 15 Inhibit Run Terminals Location and Run Coast Switch 26 Starting an
21. d Stopping Methods Decelerate to zero speed The circuit shown in Figure 16 may be used to decelerate a motor to a zero speed Closing the switch between S2 and SO decelerates the motor from set speed to zero speed The DECEL trimpot setting determines the rate at which the drive decelerates Set the switch to the RUN position to accelerate the motor to set speed at a rate determined by the ACCEL trimpot setting 10K OHM SPEED ADJUST POTENTIOMETER REV S3 i a RUN 2 5 g 9 3 52 DECEL TO ZERO SPEED i FWD CW 50 Figure 16 Run Decelerate to Zero Speed Switch shown with bidirectional speed adjust potentiometer connection Starting and Stopping Methods 27 A Warning For frequent starts and stops use regenerative deceleration shorting RB1 and RB2 regenerative braking shorting INHIBIT terminals to each other coasting to a stop shorting INHIBIT RUN terminals 1 and 2 or decelerating to minimum speed shorting S2 to 50 Do not use any of these methods for emergency stopping They may not stop a drive that is malfunctioning Removing AC line power both L1 and L2 is the only acceptable method for emergency stopping CURRENT LIMIT FWD TQ and REV TQ on regenerative drives is still active while the drive is regeneratively braking Frequent regenerative deceleration regenerative braking coasting to a stop or decelerating to minimum speed produces high torq
22. e of CE approved wiring practices such as proper shielding and the filters listed in Exhibit A guarantee the drive will meet EN55011 1991 emissions standard and EN50082 1 1992 immunity standard 56 Block Diagram THE POLARITY OF THE TACHOMETER INPUT IF USED SHOULD BE AT Tf AND AT T2 WHEN OPERATING IN THE FORWARD DIRECTION AS SHOWN FEE THE POLARITY 15 REVERSED WHEN OPERATING IN THE 5 REVERSE DIRECTION cw TAC TACH FEEDBACK FEEDBACK 2 CIRCUIT INPUT OPTIONAL rt FUR 78502 PLEASE NOTE A MAXIMUM OF 10 DC MAY BE SOURCED FROM THE 51 AND OR S2 TERMINALS TO ISOLATED LOAD OR 25 DC MAY SOURCED FROM THE 15 AND 15 TERMINALS 50801 SHORT THE INHIBIT PINS TO EACH TO A ISOLATED LOAD Oo OTHER TO INHIBIT THE DRIVE AND THE POLARITY AT 52 WITH RESPECT TO CIRCUIT COMMON OR RB1 TO CAUSE THE MOTOR TO REGEN IS FOR THE FORWARD DIRECTION AND FOR THE REVERSE DIRECTION Mgr BRAKE TB502 FWD REY ss L 10 FL Acc JA SPD ADJ POT R11 FWO ACC REV ACC 10K 52 CIRCUIT cw cw 51 REV 5 MAXIMUM SPEED OPTIONAL RUN STOP ee RINNE m THI U ZERO SPEED TO CAUSE THE MOTOR AO RB2 ULL CIRCUIT TO DECELERATE TO A STOP DEPENDENT UPON 50 THE FWD AND REV P501 15 ACC TRIMMER P
23. ely 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 1 and T2 of terminal block TB502 The polarity is for and for T2 when the motor running in the forward direction The polarity is reversed when the motor is running in the reverse direction Installation 13 Speed adjust potentiometer installation Warning Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure Grounding the input will cause damage to the drive On chassis drives install the circular insulating disk between the panel and the 10KO speed adjust potentiometer Mount the speed adjust potentiometer through a 0 38 in 0 96 cm hole with the hardware provided see Figure 7 Twist the speed adjust potentiometer wire to avoid picking up unwanted electrical noise If potentiometer leads are longer than 18 in 46 cm use shielded cable Speed adjust potentiometers are installed on all cased drives MOUNT THROUGH A 0 38 IN 10 MM HOLE STAR WASHER SPEED ADJUST POTENTIOMETER a INSULATING DISK POT TAB ASSIGNMENTS PANEL Figure 7 Speed Adjust Potentiometer 14 Installation Speed adjust potentiometer connections The motor can operate in one direction unidirectiona
24. eter full CW Adjust the MAX SPD trimpot until the motor turns at the desired maximum speed 30 Calibration FORWARD TORQUE FWD TQ Warning FWD TQ should be set to 120 of drive nameplate current rating Continuous operation beyond this rating may damage the motor If you intend to operate beyond the rating contact your Minarik representative for assistance The FWD TQ trimpot setting determines the maximum torque for accelerating and driving the motor in the forward direction It also sets the maximum torque for decelerating the motor in the reverse direction Refer to Figure 17 page 34 for recommended FWD TQ trimpot settings or recalibrate using the following procedure 1 With the power disconnected from the drive connect a DC ammeter in series with the armature 2 Set the FWD TQ trimpot to minimum full CCW 3 Set the speed adjust potentiometer to maximum forward speed 4 Lock the motor shaft Be sure that the motor is firmly mounted to withstand maximum torque generated by the motor 5 Apply line power The motor should be stopped 6 Slowly adjust the FWD TQ trimpot CW until the armature current is 120 of rated drive current 7 Set the speed adjust potentiometer to minimum 8 Remove the power from the drive and unlock the motor shaft 9 Remove the ammeter in series with the motor armature if it is no longer needed and re apply power to the drive Calibration 31 REVERSE TORQUE REV TQ Warnin
25. g REV TQ should be set to 120 of drive nameplate current rating Continuous operation beyond this rating may damage the motor If you intend to operate beyond the rating contact your Minarik representative for assistance The REV TQ trimpot setting determines the maximum torque for accelerating and driving the motor in the reverse direction It also sets the maximum torque for decelerating the motor in the forward direction Refer to Figure 17 page 34 for recommended REV TQ trimpot settings or recalibrate using the following procedure 1 With the power disconnected from the drive connect a DC ammeter in series with the armature 2 Set the REV TQ trimpot to minimum full CCW 3 Set the speed adjust potentiometer to maximum reverse speed 4 Lock the motor shaft Be sure that the motor is firmly mounted to withstand maximum torque generated by the motor 5 Apply line power The motor should be stopped 6 Slowly adjust the REV TQ trimpot CW until the armature current is 120 of rated drive current 7 Set the speed adjust potentiometer to minimum 8 Remove the power from the drive and unlock the motor shaft 9 Remove the ammeter in series with the motor armature if it is no longer needed and re apply power to the drive 32 Calibration IR COMPENSATION IR COMP The IR COMP trimpot setting determines the degree to which motor speed is held constant as the motor load changes It is factory set for optimum motor
26. ient Temp Range cased drives 10 C 40 C Vibration 0 5g max 0 50 Hz 0 1g max above 50 Hz 2 Specifications Drive option description by suffix Terminal Suffix Style Block Type A NEMA 4X Cage Clamp UA Chassis Cage Clamp Dimensions 4 78 121 4 000 102 18 4 0 188 5 0 28 7 4 Ir Aad 9 9 quenter v S 8 90 228 fl 4 0 93 24 0 84 3 50 89 1 85 47 0 125 B REF nir 1 Figure 1 RG500UA and RG510UA Dimensions Optional 223 0235 Heatsink Dimensions 9 8 x 6 9 x 1 4 Dimensions 6 90 175 6 30 160 H 1 40 36 mmi X i 10 20 259 9 80 249 FOUR 4 EACH MOUNTING SLOTS 6 3 160 x 7 0 178 ON CENTERS 5 50 140 4 78 121 3 L 145 37 2 30 58 a d 1 50 138 1 50 38 THREE 0 88 22 KNOCKOUTS ALL DIMENSIONS IN INCHES MILLIMETERS Figure 2 RG500A and RG510A Cased Drive Dimensions Regenerative Drives In most non regenerative variable s
27. inability to use the Corporation s product for any purpose whatsoever An adjustment made under warranty does not void the warranty 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 the Corporation 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 the Corporation 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 Minarik Drives www minarikdrives com 14300 De La Tour Drive South Beloit IL 61080 Phone 800 MINARIK or 646 2745 Fax 800 394 6334 or 815 624 6960 Document number 250 0210 Revision 4 Printed in the U S A March 2006
28. its board in either a horizontal or vertical plane Six 0 18 inch 4 57 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 must be earth grounded for noise suppression To ground the chassis connect earth ground to the GND terminal on terminal block TB501 8 Installation Mounting cased drives NEMA 4X cased drives come with three 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 25 inch 6 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 Set the POWER switch to the 0 or OFF position before applying the AC line voltage 2 Install the mounting screws 3 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 Lift or pull the slotted screw to open the case 4 Carefully remove the conduit knockouts by tapping them into the case and twisting them off with pliers 5 Install conduit hardware through the 0 88 inch 22 mm conduit holes Connect external wiring to the terminal block 6 Grasp the slotted screw and tilt the front cover back into place Avoid pinching any wires between the front cover and the case 7 Turn the
29. l or in two directions bidirectional depending on how the speed adjust potentiometer is connected to the drive Connect the speed adjust potentiometer as shown in Figure 8 a for speed control in one direction Connect the speed adjust potentiometer as shown in Figure 8 b for speed control in two directions The motor does not rotate when the wiper is in the center position Turning the wiper CW from the center position causes the motor to rotate in one direction while turning the wiper CCW from the center position causes the motor to rotate in the opposite direction Refer to the Application Notes section for additional speed adjust potentiometer connections 10K OHM 2W 10K OHM E907 SPEED ADJUST SPEED ADJUST POTENTIOMETER 78502 S2 REV S3 51 52 50 51 FWD cw CCW a b Figure 8 Speed Adjust Potentiometer Connections for a Unidirectional Operation and b Bidirectional Operation Installation 15 15 and 15 terminals Warning Do not short the 15 and 15 terminals for any reason Shorting these terminals may damage the drive RG500 Series drives can supply a regulated 15 and 15 VDC signal each sourcing 15 mA maximum to isolated external devices These voltage supply terminals are located on terminal block TB502 see figure 9 cosa S3 S2 S1 50 RB1 RB2 15 15 T1 T2 Figure 9 TB502
30. line operation Recalibrate the deadband to the 9 o clock position for 50 Hz AC line operation See Figure 18 for recommended deadband settings 60 Hz 50 Hz APPLICATIONS APPLICATIONS Figure 18 Deadband Settings 36 Calibration TACHOGENERATOR TACH Calibrate the TACH setting only when a tachogenerator is used The TACH setting like the IR COMP setting determines the degree to which motor speed is held constant as the motor load changes To calibrate the TACH trimpot 1 27 3 4 Place the feedback selector switch SW504 to the 8 9 Remove power from the drive Rotate the TACH trimmer pot to full clockwise full CW Rotate the MAX SPD trimmer pot to full counterclockwise full CCW Rotate the IR COMP trimmer pot to full CCW ARMATURE ARM position Rotate the main speed potentiometer to midrange Wire the DC tach to the RGSOOUA Note The polarity of the Tach voltage input to the RGSOOUA should be T1 and T2 This polarity may be measured with a DC voltmeter If the polarity is incorrect swap the two tach input leads to the 1 and T2 terminals on TB502 Apply power to the drive The motor should be running at minimum speed Rotate the main speed potentiometer to full speed in the forward direction 10 Turn the maximum speed trimmer pot clockwise until the desired maximum speed is reached 11 Remove all power from the drive The motor should stop Calibration 37
31. ocedures It is possible for a drive to run at full speed as a result of a component failure Please ensure that a master switch has been placed in the AC line to stop the drive in an emergency This drive is not isolated from earth ground 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 trimpots Contents Specifications a eter aa ee es 1 Drive option description by suffix 2 DIMENSIONS iei eee cene e bp mh ee e 3 Regenerative Drives 5 Installation irie retirer eb etm Rr e ce ene 7 Mounting chassis 7 Mounting cased drives 8 Heat sinkirng sr e eiue ne 9 AC line and motor connections 9 Cage clamp terminal block 11 Field output 2 fee illus d hte da be ob ale 12 Tachogenerator feedback 12 Speed adjust potentiometer installation 13 Speed adjust potentiometer connections 14 15 and 151 15 Line Fusing for RG Series Drives
32. peed DC drives control current flows to a motor in one direction The direction of current flow is the same direction as the motor rotation Non regenerative drives operate in Quadrant 1 and also in Quadrant 3 if the drive is reversible see Figure 3 page 6 Motors must stop before reversing direction Non regenerative drives cannot oppose an overhauling load and cannot decelerate a load faster than coasting to a lower speed Regenerative drives operate in two additional quadrants Quadrant 2 and Quadrant 4 In these quadrants motor torque is in the opposite direction of motor rotation Regenerative drives can reverse a motor without contactors switches brake resistors and inhibit plugs They can also control an overhauling load and decelerate a load faster than it would take to coast to a lower speed 6 Regenerative Drives 7 a Figure 3 Four Quadrant Operation Installation Mounting chassis drives Drive components are sensitive to electrostatic fields Avoid contact with the circuit board directly Hold the drive by the chassis only Protect the drive from dirt moisture and accidental contact Provide sufficient room for access to the terminal block and calibration trimpots Mount the drive away from other 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
33. regulation Recalibrate the IR COMP setting when using a lower curernt rated motor See Figure 17 page 34 for typical IR COMP trimpot settings or recalibrate using the following procedure 2 Set the IR COMP trimpot to minimum full CCW Rotate the speed adjust potentiometer until the motor runs at midspeed without load for example 900 RPM for an 1800 RPM motor A hand held 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 motor rotate the IR COMP trimpot until the motor runs at the speed measured in step 2 If the motor oscillates overcompensation the IR COMP trimpot may be set too high CW Turn the IR COMP trimpot CCW to stabilize the motor Unload the motor Calibration 33 FORWARD ACCELERATION FWD ACC The FWD ACC trimpot setting determines the time the motor takes to ramp to either a higher speed in the forward direction or a lower speed in the reverse direction within the limits of available torque The FWD ACC setting is factory set for its fastest forward acceleration time Turn the FWD ACC trimpot CW to increase the forward acceleration time and CCW to decrease the forward acceleration time REVERSE ACCELERATION REV ACC The REV ACC trimpot setting determines the time the motor takes to ramp to either a higher speed in the reverse direction or a lower speed in the
34. se Chattss 22 a ioe on NEA SA 16 Replacement Parts 50 Corcom Filters 53 Minarik Filters me ciui 54 Armature HP Range HP Range Current with 115 VAC with 230 VAC Model Amps DC Applied Applied RG500A RG500UA 10 0 f 1 4 1 t 1 2 2 t RG510A RG510UA 3 0 1 20 1 8 1 10 1 4 T Maximum armature current and horsepower range apply when drive is attached to additional heat sink Minarik part number 223 0235 Use heat sink when armature current is above 7 ADC Heat sinks are pre mounted on RG500 cased drives See page 2 for suffix descriptions AC Line Voltage 115 230 VAC 10 50 60 Hz single phase Armature Voltage 115 VAC Input 0 90 VDC Armature Voltage 230 VAC Input 0 180 VDC Form Factor 1 37 at base speed Field Voltage 115 VAC Input 50 VDC F1 to L1 100 VDC F1 to F2 Field Voltage 230 VAC Input 100 VDC F1 to L1 200 VDC F1 to F2 Max Field Current 1 ADC Accel Time Range with no load 0 5 15 seconds Decel Time Range with no load 0 5 15 seconds Analog Input Voltage Range signal must be isolated SO to S2 0 10 VDC Input Impedance 50 to 52 32K ohms Load Regulation with Armature Feedback 196 of base speed or better with Tachogenerator Feedback 0 196 of base speed Ambient Temp Range chassis drives 10 55 Amb
35. t the motor to a stop 20 Operation Cased drives 1 Set the FORWARD BRAKE REVERSE switch to the BRAKE position Set the speed adjust potentiometer to 0 full CCW Apply AC line voltage Set the POWER switch to the I ON position Set the FORWARD BRAKE REVERSE switch to the desired direction of rotation 7 Slowly advance the speed adjust potentiometer clockwise CW The motor slowly accelerates as the potentiometer is turned CW Continue until the desired speed is reached 8 To brake the motor set the FORWARD BRAKE REVERSE switch to the BRAKE position To coast the motor to a stop set the POWER switch to the OFF position 9 To reverse direction a Set the FORWARD BRAKE REVERSE switch to the BRAKE position b After the motor comes to a complete stop set the FORWARD BRAKE REVERSE switch to the desired direction of rotation 10 Set the POWER switch to OFF to remove power from the drive gt Operation 21 C m Y mo Y Ts IH Y IE Toor V I IH Y T V i mics 8 IH I i
36. the output XX rated current of the filter The CEXXRG is a Real Pole Balanced Pi 3 pole filter If the exact filter is not available the specifications are as follows L amp L1 2 x 0 8 milliHenries C amp C1 2 x 0 1 microFarads 400W VDC Rin 0 1 ohm Rout 1 2 ohm Table 5 Minarik Filters Nameplate Current of Motor Wired to the Drive Minarik Filter Part Number 0 to 4 amps CE04RG 4 1 to 13 amps CE20RG The filters in Table 5 must be wired to the DC output of the drive as close to the drive as possible The ground connection from the filter must be wired to solid earth ground resistance less than 500 ohms not machine ground This is very important The end user must use the filtration listed in Exhibit A to comply with CE The OEM may choose to provide alternative filtering that encompasses the Minarik drive and other electronics within the same panel The OEM has this liberty because CE is a machinery directive Whether or not every component in the OEM s machinery meets CE the OEM must still submit his machine for CE approval meet CE the machine will not necessarily meet CE as a machine CE Addendum 55 Thus no component must necessarily meet CE within the machine as long as the OEM takes the necessary steps to guarantee the machine does meet CE By the same token even if every component in the OEM s machine does meet CE the machine will not necessarily meet CE as a machine Us
37. ue This may cause damage to motors especially gearmotors that are not properly sized for the application 28 Calibration A Warning Dangerous voltages exist on the drive when it is powered When possible disconnect the voltage input from the drive before adjusting the trimpots If the trimpots 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 Each drive is factory calibrated to its maximum current rating Readjust the calibration trimpot 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 trimpot is identified on the printed circuit board Calibration 29 MINIMUM SPEED MIN SPD The MIN SPD trimpot setting determines the motor speed when the speed adjust potentiometer is turned full CCW It is factory set to zero speed The minimum speed feature applies only when the drive is operating in unidirectional mode To calibrate set the speed adjust potentiometer full CCW Adjust the MIN SPD trimpot until the motor turns at the desired minimum speed MAXIMUM SPEED MAX SPD The MAX SPD setting determines the maximum motor speed when the speed adjust potentiometer is turned full CW It is factory set for maximum rated motor speed To calibrate set the speed adjust potentiom
38. user as described herein falls into one of two categories 1 The Consumer will deploy a stand alone unit as an integral yet external portion of the machine he she is operating 2 The Original Equipment Manufacturer OEM will implement the product as a component of the machine being manufactured CE Addendum 53 Exhibit A In addition to EMI RFI safeguards inherent in the RG500 series design external filtering is required Minarik requires the Corcome filters listed in Table 4 If the exact filter is not available the specifications are as follows L 1 8 milliHenries C 0 01 microFarad Line to Ground 1 1 microFarads Line to Line Discharge Resistor 330Kohms Rated current 1 4 times maximum DC motor current Filter type Balanced 2 section Table 4 Corcom Filters Nameplate Current of Motor Wired to the Drive Corcom Filter Part Number 0 to 4 amps 6VV1 4 1 to 13 amps 20VV1 The filters in Table 4 should be wired to the AC line within 0 25 meters of the drive The ground connection from the filter must be wired to solid earth ground resistance less than 500 ohms not machine ground This is very important If the end user is using a CE approved motor the correct filter from Table 4 is all that is necessary to meet the EMC directives listed herein 54 CE Addendum If the end user is not using a CE approved motor a second filter part number CEXXRG must be deployed on
39. ward Stop Reverse Switch Application Notes 41 Independent Adjustable Speeds Forward Direction Only Connect two speed adjust potentiometers with a single pole two position switch to select between two independent speeds shown in the forward direction Figure 23 The speed adjust potentiometers can be mounted at two separate operating stations 50 1 2 20K OHM 20K OHM 1 SPEED 1 cw cw 52 B SPEED 2 Figure 23 Independent Adjustable Speeds Forward Direction 42 Application Notes Independent Forward and Reverse Speeds Connect two speed adjust potentiometers as shown in Figure 24 to select between independent forward and reverse speeds 50 FWD REV 10K OHM 10K OHM S1 FORWARD oy ew 52 REVERSE 53 Figure 24 Independent Forward and Reverse Speeds Application Notes 43 Independent Forward and Reverse Speeds with FWD STOP REV Switch Use a single pole three position switch to stop the motor when the switch is in the center position Figure 25 e S0 FWD REV 10K OHM 10K OHM 51 cW cw FORWARD 2 STOP REVERSE 53 Figure 25 Independent Forward and Reverse Speeds with a Forward Stop Reverse Switch 44 Troubleshooting A Warning Dangerous voltages exist on the drive when it is powered When possible disconnect the drive while troubleshooting High voltages can cause serious or fatal injury Check the following steps before proceeding 1 The
40. ximum speed setting 1 2 Check that the MIN SPD and MAX SPD setting are not set too high Check that the field output connections are secure if you are using a shunt wound motor Troubleshooting 47 Motor will not reach the desired speed 1 Check the MAX SPD setting and increase if necessary 2 Check that the IR COMP setting is not set too low 3 Check that the motor is not overloaded For additional assistance contact your local Minarik distributor or the factory direct PHONE 800 MINARIK FAX 800 394 6334 48 Factory Prewired Connections for Cased Drives WHITE wv WHITE BLACK 12 230 POWER LIGHT BLACK BLACK lt e BLACK WHITE WHITE BLACK 12 115 Figure 26 Prewired Connections to L1 L2 115 and L2 230 Factory Prewired Connections 49 50 51 52 53 GREY WHITE FWD GREEN REV BLUE Figure 27 Prewired Speed Adjust Potentiometer Connections 10K OHM 50 Replacement Parts Replacement parts are available form Minarik Corporation and its distributors for this drive series Table 3 Replacement Parts Model No Symbol Description Minarik P N RG500UA R501 0 010 5 W Resistor 032 0129 SCR501 508 800 25 A SCR 072 0042 T505 3FD 436 Transformer 230 0072 10KQ Potentiometer Kit 202 0003 Chassis 223 0258 20 A 3AB Line Fuse 050 0019 Line Fuse Kit 5 20A 050 0073
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