American Control Electronics Minarik DRIVES RG500 Series User manual

RG500UA
RG500UA-PCM
RG500A
RG510UA
RG510UA-PCM
RG510A
USER MANUAL
www.minarikdrives.com
RG500 SERIES
An American Control Electronics Brand

Dear Valued Consumer:
Congratulaons on your purchase of the RG500 Series drive.
This User Manual was created for you to get the most out of
your new device and assist with the inial setup. Please visit
www.minarikdrives.com to learn more about our other drives.
Thank you for choosing Minarik Drives!
No part of this document may be reproduced or transmied in any form without wrien permission
from American Control Electronics®. The informaon and technical data in this document are
subject to change without noce. American Control Electronics® makes no warranty of any kind with
respect to this material, including, but not limited to, the implied warranes of its merchantability
and tness 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 informaon in this document.

i
RG500 Series
Safety First!
• DO NOT INSTALL, REMOVE, OR REWIRE THIS EQUIPMENT WITH
POWER APPLIED. Have a qualified electrical 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 using
proper grounding techniques, over-current protection, thermal
protection, and enclosure. Follow sound maintenance procedures.
SAFETY WARNINGS
Text in gray boxes denote important safety ps or warnings.
Please read these instrucons carefully before performing any of
the procedures contained in this manual.
It is possible for a drive to run at full speed as a result of a
component failure. Minarik Drives strongly recommends the
installaon of a master switch in the main power input to stop
the drive in an emergency.
Circuit potenals 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 adjusng the calibraon trim pots.
Use approved personal protecve equipment and insulated tools
if working on this drive with power applied.

!
WARNING!

!
WARNING!

ii
RG500 Series
Table of Contents
Section 1. Regenerative Drives ............................................ 1
Section 2. Specifications ..................................................... 2
Section 3. Dimensions......................................................... 4
Section 4. Installation......................................................... 8
Heat Sinking ................................................................................. 8
Chassis.................................................................................. 8
NEMA 4X .............................................................................. 8
Mounting ..................................................................................... 9
Chassis................................................................................. 9
Speed Adjust Potentiometer.........................................10
NEMA 4X .............................................................................11
Wiring .........................................................................................12
Shielding Guidelines.............................................................13
Line Fusing ..........................................................................14
Connections.................................................................................16
Power Inputs .......................................................................16
Motor..................................................................................16
Field Output Connections.....................................................17
Speed Adjust Potentiometer.................................................18
Speed Adjust Potentiometer (-PCM models) ..........................19
Analog Input Signal ..............................................................20
Analog Input Signal (-PCM models) .......................................21
+15 and -15 .........................................................................22
Enable, Regen Brake, Inhibit .................................................22
Direction Switch ..................................................................22
Tachogenerator Feedback.....................................................23

iii
RG500 Series
Section 5. Operation......................................................... 27
Before Applying Power .................................................................27
Select Switches............................................................................28
Input Voltage Select (SW501, SW502) ...................................28
Armature Voltage Select (SW503) .........................................28
Feedback Select (SW504) .....................................................28
Signal Select (SW501) (-PCM models)....................................29
Input Voltage Select (SW502) (-PCM models) ........................29
Startup (Chassis models) ..............................................................30
Startup (NEMA 4X models) ...........................................................31
Starting and Stopping Methods ....................................................32
Automatic Restart Upon Power Restoration ..........................32
Line Starting and Stopping ...................................................32
Regenerative Brake to Zero Speed (INHIBIT Terminals)...........33
Regenerative Decel to Zero Speed (RB1 and RB2 Terminals) ...34
Regenerative Decel to Minimum Speed .................................35
Coast to Zero Speed (INHIBIT-RUN) .......................................36
Section 6. Calibration ....................................................... 37
Minimum Speed (MIN SPD) ..........................................................37
Maximum Speed (MAX SPD) .........................................................38
Forward Torque (FWD TQ) ............................................................39
Reverse Torque (REV TQ) ..............................................................40
IR Compensation (IR COMP) .........................................................41
Forward Acceleration (FWD ACC) ..................................................43
Reverse Acceleration (REV ACC)....................................................43
Deadband....................................................................................44
Tachogenerator (TACH).................................................................45
-MIN OUT, MAX OUT, and SIGNAL INPUT ADJUST (-PCM models) ....46

iv
RG500 Series
Section 7.Application Notes ............................................... 48
Direction Switch ..........................................................................48
Multiple Fixed Speeds ..................................................................49
Adjustable Speeds Using Potentiometers In Series.........................50
Independent Adjustable Speeds....................................................51
Independent Adjustable Forward and Reverse Speeds ...................52
RUN/JOG Switch - Inhibit Connection............................................53
RUN/JOG Switch - Potentiometer Connection ................................54
Leader-Follower Application .........................................................55
Single Speed Potentiometer Control Of Multiple Drives .................56
Section 8. Troubleshooting................................................ 57
Before Troubleshooting ................................................................57
Section 9. Accessories & Replacement Parts ....................... 60
Notes ............................................................................... 61
Unconditional Warranty..................................................... 62

v
RG500 Series
List of Tables
Table 1 Recommended Line Fuse Sizes ..........................................15
Table 2 Short Circuit Current Ratings ............................................15
Table 3 Field Output Connections .................................................17
List of Figures
Figure 1 Four Quadrant Operation .................................................. 1
Figure 2 RG500UA and RG510UA Dimensions................................... 4
Figure 3 RG500UA-PCM and RG510UA-PCM Dimensions................... 5
Figure 4 RG500A and RG510A Dimensions ....................................... 6
Figure 5 223-0235 Dimensions........................................................ 7
Figure 6 Speed Adjust Potentiometer .............................................10
Figure 7 Speed Adjust Potentiometer Connections..........................18
Figure 8 -PCM Speed Adjust Potentiometer Connections.................19
Figure 9 Analog Input Signal Connections.......................................20
Figure 10 -PCM Analog Input Signal Connections ..............................21
Figure 11 RG500UA and RG510UA Connections ................................24
Figure 12 RG500UA-PCM and RG510UA-PCM Connections.................25
Figure 13 RG500A and RG510A Connections .....................................26
Figure 14 Select Switches ................................................................28
Figure 15 SW501 Settings................................................................29
Figure 16 -PCM Select Switches .......................................................29
Figure 17 Inhibit Terminals ..............................................................33
Figure 18 Run/Decelerate to Minimum Speed Switch........................35
Figure 19 Inhibit-Run Terminal Location and Run/Coast Switch .........36

vi
RG500 Series
List of Figures
Figure 1 Four Quadrant Operation .................................................. 1
Figure 2 RG500UA and RG510UA Dimensions................................... 4
Figure 3 RG500UA-PCM and RG510UA-PCM Dimensions................... 5
Figure 4 RG500A and RG510A Dimensions ....................................... 6
Figure 5 223-0235 Dimensions........................................................ 7
Figure 6 Speed Adjust Potentiometer .............................................10
Figure 7 Speed Adjust Potentiometer Connections..........................18
Figure 8 -PCM Speed Adjust Potentiometer Connections.................19
Figure 9 Analog Input Signal Connections.......................................20
Figure 10 -PCM Analog Input Signal Connections ..............................21
Figure 11 RG500UA and RG510UA Connections ................................24
Figure 12 RG500UA-PCM and RG510UA-PCM Connections.................25
Figure 13 RG500A and RG510A Connections .....................................26
Figure 14 Select Switches ................................................................28
Figure 15 SW501 Settings................................................................29
Figure 16 -PCM Select Switches .......................................................29
Figure 17 Inhibit Terminals ..............................................................33
Figure 18 Run/Decelerate to Minimum Speed Switch........................35
Figure 19 Inhibit-Run Terminal Location and Run/Coast Switch .........36
Figure 20 Recommended FWD TQ, REV TQ, and IR COMP Settings .....42
Figure 21 Deadband Settings ...........................................................44
Figure 22 Forward-Reverse Switch ...................................................48
Figure 23 Forward-Stop-Reverse Switch ...........................................48
Figure 24 Multiple Fixed Speeds ......................................................49
Figure 25 Adjustable Speeds Using Potentiometers in Series .............50
Figure 26 Independent Adjustable Speeds........................................51
Figure 27 Independent Adjustable Forward and Reverse Speeds........52
Figure 28 Independent Adjustable Forward and Reverse Speeds with
Stop ................................................................................52

vii
RG500 Series
Figure 29 RUN/JOG Switch - Inhibit Connection ...............................53
Figure 30 RUN/JOG Switch - Speed Adjust Potentiometer Connection. 54
Figure 31 Leader-Follower Application .............................................55
Figure 32 Single Speed Potentiometer Control of Multiple Drives......56

1
RG500 Series
Most non-regenerave,
variable speed, DC drives
control current ow to a
motor in one direcon.
The direcon of current
ow is the same direcon
as the motor rotaon.
Non-regenerave drives
operate in Quadrant I,
and also in Quadrant III if
the drive is reversible (see
Figure 1). Motors must stop
before reversing direcon.
Unless dynamic braking
is used, non regenerave
drives cannot decelerate a
load faster than coasng to a
lower speed.
Regenerative drives operate
in two addional quadrants:
Quadrant II and Quadrant
IV. In these quadrants,
motor torque is in the
opposite direcon of motor rotaon.
This allows regenerave drives to reverse a motor without contactors
or switches, to control an overhauling load, and to decelerate a load
faster than it would to coast to a lower speed.
Section 1. Regenerative Drives
ARROWS IN OPPOSITE DIRECTION = REGENERATIVE ACTION
NOTE: ARROWS IN SAME DIRECTION = MOTOR ACTION
MOTOR
TORQUE
ROTATION
MOTOR
Quadrant III
Quadrant II
Quadrant IV
Quadrant I
Figure 1. Four Quadrant Operaon

2
RG500 Series
Section 2. Specifications
Model
Maximum
Armature
Current (ADC)
HP Range
with 90 VDC
Motor
HP Range
with 180 VDC
Motor Enclosure
RG510UA
RG510UA-PCM
RG510A
3.0 1/20 - 1/4 1/10 - 1/2 Chassis
Chassis
NEMA 4X
RG500UA*
RG500UA-PCM*
RG500A
10.0 1/8 - 1 1/4 - 2 Chassis
Chassis
NEMA 4X
* Heat sink kit part number 223-0235 must be used when the connuous
current output is over 7 amps.
AC Line Voltage 11 5/23 0 VAC ± 10 % 50/60 Hz, single phase
DC Armature Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
0 - 90 VDC
0 - 180 VDC
Field Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
50 VDC (F1 to L1); 100 VDC (F1 to F2)
100 VDC (F1 to L1); 200 VDC (F1 to F2)
Maximum Field Current 1 ADC
Acceleraon Time Range 0.5 - 15 seconds
Deceleraon Time Range 0.5 - 15 seconds
Analog Input Range
Non -PCM models
(signal must be isolated; RB1 to S2)
Voltage Signal Range
PCM models
Voltage Signal Range
Current Signal Range
0 to ± 10 VDC
0 to ± 250 VDC
4 - 20 mA

3
RG500 Series
Input Impedance
Non -PCM models (RB1 to S2)
-PCM models (Voltage Signal)
-PCM models (1-5 mA Signal)
-PCM models (4-20 mA Signal)
-PCM models (10-50 mA Signal)
32K ohms
>25K ohms
1K ohms
235 ohms
100 ohms
Form Factor 1.37 at base speed
Load Regulaon
with Armature Feedback
with Tachogenerator Feedback
1% base speed or beer
0.1% base speed
Vibraon 0.5G maximum (0 - 50 Hz)
0.1G maximum (> 50 Hz)
Safety Cercaon UL Recognized Component, File # E132235
CSA Cered Component, File # LR41380
Ambient Temperature Range
Chassis models
Enclosed models
10°C - 55°C
10°C - 40°C

4
RG500 Series
Section 3. Dimensions
Figure 2. RG500UA and RG510UA Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
L1 L2
230V
L2
115V GND F1 F2 A2 A1
SW501
C504
TB501
C503
C505
TB502
IC502
IC501
C502
115 230 230 115
SW502
L1 L2
FU502FU501
FAST ACTING
FUSES ONLY
S3 S2 S1 S0 RB1 RB2 -15 +15 T1 T2
INHIBIT
SO501
INH-RUN
T505
SO502
T501
R501
C501
SCR501 SCR502 SCR503 SCR504
T502
T503
SCR505 SCR506
R504 R505 R506
T504
SCR507 SCR508
C509
C508
C507
C506
C510
SW504SW503
ARMATURE FEEDBACK
90 180 ARM TACH
R502 R503
MIN SPD FWD TQ REV TQ IR COMP MAX SPD FWD ACC REV ACC DB TACH
P501 P502 P503 P504 P505 P506 P507 P508 P509
0.19 [5]
8.90 [228]
8.40 [213]
3.50 [89]
4.78 [121]
1.85 [47]
0.92 [23]

5
RG500 Series
Figure 3. RG500UA-PCM and RG510UA-PCM Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
L1 L2
230V
L2
115V GND F1 F2 A2 A1
SW501
C504
TB501
C503
C505
TB502
IC502
IC501
C502
115 230 230 115
SW502
L1 L2
FU502FU501
FAST ACTING
FUSES ONLY
S3 S2 S1 S0 RB1 RB2 -15 +15 T1 T2
T505
SCR501
MIN SPD FWD TQ REV TQ IR COMP MAX SPD FWD ACC REV ACC DB TACH
0.19 [5]
8.90 [226]
8.40 [213]
3.50 [89]
4.78 [121]
INH
COMPOL REVTPINPUT 2INPUT 1COM+15-15L2L1OUT 2OUT1
115 230
INPUT VOLTAGE SELECT
T501
SIGNAL INPUT ADJUST
SW501
R501
IC505
1-5mA
4-20mA
10-50mA
P502
P503
MAX
OUT
MIN
OUT
C501
C502
C503
C504
IC501
IC502
IC503
IC504 1 2 3
P501
SW502
C506 C505 C508 C507
3.07 [78]
1.85 [47]
0.92 [23]

6
RG500 Series
Figure 4. RG500A and RG510A Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
1.45 [37]
1.50 [38]
0.12
[3] 1.50 [38]
5.51
[140]
4.78
[121]
2.31
[59]
REVERSE
POWER
I
O
SPEED
FORWARD
BRAKE
40
30
20
10
0
50 60
70
80
90
100
1.40
[36]
0.22
[6]
6.30 [160]
6.90 [175]
10.22
[260]
9.80
[249]
7.00
[178]

7
RG500 Series
6.90 [175]
6.60 [168]
0.3 [8]
1.375 [35]
8.375 [213]
9.78 [249]
Figure 5. 223-0235 Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]

8
RG500 Series
Section 4. Installation
Do not install, rewire, or remove this control with input power
applied. Failure to heed this warning may result in re, explosion,
or serious injury. Make sure you read and understand the Safety
Precauons on page i before aempng to install this product.

!
WARNING!
Heat Sinking
Chassis
Models RG500UA and RG500UA-PCM require an addional heat sink
when the connuous armature current is above 7 amps. Use Minarik
Drives heat sink kit part number 223-0235. All other chassis drives
have sucient heat sinking in their basic conguraon. Use a thermally
conducve heat sink compound (such as Dow Corning® 340 Heat Sink
Compound) between the chassis and the heat sink surface for opmum
heat transfer.
All NEMA 4X models come with the heat sink already aached.
Therefore, all NEMA 4X drives have sucient heat sinking in their basic
conguraon.
NEMA 4X

9
RG500 Series
• Drive components are sensitive to electrostatic discharge. Avoid
direct contact with the circuit board. Hold 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.
Mounng
Chassis

10
RG500 Series
POT TAB ASSIGNMENTS
WIPER
CW
CCW
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
PANEL
STAR
WASHER
NUT
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
Figure 6. Speed Adjust Potenometer
If using a remote potenometer with a chassis drive, mount the speed
adjust potenometer through a 0.38 in. (10 mm) hole with the hardware
provided (Figure 6). Install the circular insulang disk between the panel
and the 10K ohm speed adjust potenometer.
Twist the speed adjust potenometer wire to avoid picking up unwanted
electrical noise. If the speed adjust potenometer wires are longer than
18 in. (46 cm), use shielded cable. Keep the speed adjust potenometer
wires separate from power leads (L1, L2, A1, A2, F1, F2).
Speed Adjust Potenometer
Be sure that the potenometer tabs do not make contact with the
potenometer’s body. Grounding the input will cause damage to
the drive.

!
WARNING!

11
RG500 Series
NEMA 4X cased drives come with two 0.88 inch (22 mm) conduit
knockout holes at the boom of the case. The units may be vercally wall
mounted using the four 0.19 inch (5 mm) sloed holes on the aached
heat sink. For motor loads less than 5 ADC, the drive may be bench
mounted horizontally or operated without mounng.
1. Install the mounting screws.
2. 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.
3. Carefully remove the conduit knockouts by tapping them into
the case and twisting them off with pliers.
4. Set the POWER switch to the OFF position before applying the
AC line voltage.
5. Install conduit hardware through the 0.88 inch (22 mm)
knockout 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 slotted screw clockwise until tight to secure the front
co ver.
Mounng (NEMA 4X Enclosures)