Boston gear BETA II User manual
RBA2C-A
Rev. 04/97
ANGLE BRACKET CHASSIS
SINGLE-PHASE
ADJUSTABLE-SPEED
DC MOTOR CONTROLLERS
(1/6 - 2 HP)
RBA2C-A
iii
TABLE OF CONTENTS
SECTION TITLE PAGE
IGENERAL INFORMATION 1
Introduction 1
General Description 1
Model Types 1
Motor Selection 1
II INSTALLATION 3
Installation Guidelines 3
Installing The Controller 4
Initial Startup 13
III OPERATION 15
Power On/Off 15
Run 15
Stop 15
Speed Control 16
Jog 16
Reverse 16
Inoperative Motor 16
IV MAINTENANCE AND REPAIR 17
General 17
Adjustment Instructions 17
Troubleshooting 19
VPARTS LIST 23
VI RATINGS AND SPECIFICATIONS 25
Ratings 25
Operating Conditions 26
Performance Characteristics 26
Adjustments 27
Specifications 27
VII DRAWINGS 29
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LIST OF TABLES
TABLE TITLE PAGE
1Model Matrix 1
2Recommended Control And Signal Wiring Fuses 4
3Horsepower Calibration 5
4Initial Potentiometer Settings 12
5Dynamic Braking Characteristics 15
6Troubleshooting 19-22
7Parts List, RBA2C Controllers 23
8Typical Application Data 25
9Operating Voltages And Signals 26
10 Controller Weights 26
11 Speed Regulation Characteristics 27
12 Shunt Field Data 28
13 Tachometer Feedback Voltage Selection 28
LIST OF ILLUSTRATIONS
FIGURE TITLE PAGE
1Controller Mounting Dimensions 6
2Logic Connection Diagram, Using Run-Stop-Jog 7
Switch
3Logic Connection Diagram, Using Forward-Reverse 7
Switch And Run-Stop-Jog Switch
4Logic Connection Diagram, Using Run-Stop 8
Pushbuttons And Run-Jog Switch
5Logic Connection Diagram, Unidirectional Armature 8
Contactor Using Switches
6Logic Connection Diagram, Unidirectional Armature 9
Contactor Using Pushbuttons And Run-Jog Switch
7Logic Connection Diagram, Armature Contactor 9
Reversing Using Switches
8Logic Connection Diagram, Armature Contactor 10
Reversing Using Pushbuttons And Run-Jog Switch
9Logic Connection Diagram, Line Starting With 10
Motor Speed Potentiometer
10 Signal Connection Diagram, Motor Speed 11
Potentiometer
11 Signal Connection Diagram, Tachometer Feedback 11
12 Signal Connection Diagram, Current (Torque) 11
Reference Potentiometer
13 Signal Connection Diagram, Line Starting Without 12
A Motor Speed Potentiometer
14 Signal Connection Diagram, 0 - 10 VDC External 12
Speed Reference Signal
15 Functional Schematic, RBA2C 30
16 Schematic, RBA2C 31
17 Schematic, Reversing Board 32
18 RBA2C Control Board 33
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WARNING
The following must be strictly adhered to at all times.
1. YOU AS THE OWNER OR OPERATOR OF BOSTON GEAR EQUIPMENT HAVE THE
RESPONSIBILITY TO HAVE THE USERS OF THIS EQUIPMENT TRAINED IN ITS
OPERATIONS AND WARNED OF ANY POTENTIAL HAZARDS OF SERIOUS INJURY.
2. THE DRIVE EQUIPMENT SHOULD BE INSTALLED, OPERATED, ADJUSTED, AND
SERVICED ONLY BY QUALIFIED PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND
OPERATION OF THE EQUIPMENT AND THE HAZARDS INVOLVED INCLUDING THOSE
DESCRIBED BELOW. FAILURE TO OBSERVE THIS WARNING CAN RESULT IN PERSONAL
INJURY, LOSS OF LIFE, AND PROPERTY DAMAGE.
3. THE NATIONAL ELECTRICAL CODE REQUIRES THAT AN AC LINE FUSED DISCONNECT
OR CIRCUIT BREAKER BE PROVIDED IN THE AC INPUT POWER LINES TO THE
CONTROLLER. THIS DISCONNECT MUST BE LOCATED WITHIN SIGHT OF THE
CONTROLLER. DO NOT OPERATE THE CONTROLLER UNTIL THIS CODE REQUIREMENT
HAS BEEN MET.
4. THE DRIVE EQUIPMENT IS AT AC LINE VOLTAGE POTENTIAL WHENEVER AC POWER IS
CONNECTED TO THE DRIVE EQUIPMENT. CONTACT WITH AN ELECTRICAL
CONDUCTOR INSIDE THE DRIVE EQUIPMENT OR AC LINE DISCONNECT CAN CAUSE
ELECTRIC SHOCK RESULTING IN PERSONAL INJURY OR LOSS OF LIFE.
5. BE SURE ALL AC POWER IS DISCONNECTED FROM THE DRIVE EQUIPMENT BEFORE
TOUCHING ANY COMPONENT, WIRING, TERMINAL, OR ELECTRICAL CONNECTION IN
THE DRIVE EQUIPMENT.
6. ALWAYS WEAR SAFETY GLASSES WHEN WORKING ON THE DRIVE EQUIPMENT.
7. DO NOT REMOVE OR INSERT CIRCUIT BOARDS, WIRES, OR CABLES WHILE AC POWER
IS APPLIED TO THE DRIVE EQUIPMENT. FAILURE TO OBSERVE THIS WARNING CAN
CAUSE DRIVE DAMAGE AND PERSONAL INJURY.
8. ALL DRIVE EQUIPMENT ENCLOSURES, MOTOR FRAMES, AND REMOTE OPERATOR
STATIONS MUST BE CONNECTED TO AN UNBROKEN COMMON GROUND CONDUCTOR.
AN UNBROKEN GROUNDING CONDUCTOR MUST BE RUN FROM THE COMMON
GROUND CONDUCTOR TO A GROUNDING ELECTRODE BURIED IN THE EARTH OR
ATTACHED TO A PLANT GROUND. REFER TO THE NATIONAL ELECTRICAL CODE AND
LOCAL CODES FOR GROUNDING REQUIREMENTS.
9. THE ATMOSPHERE SURROUNDING THE DRIVE EQUIPMENT MUST BE FREE OF
COMBUSTIVE VAPORS, CHEMICAL FUMES, OIL VAPOR, AND ELECTRICALLY
CONDUCTIVE OR CORROSIVE MATERIALS.
10. SOLID-STATE COMPONENTS IN THE CONTROLLER CAN BE DESTROYED OR SEVERELY
DAMAGED BY STATIC ELECTRICITY. THEREFORE, PERSONNEL WORKING NEAR THESE
STATIC-SENSITIVE COMPONENTS MUST BE APPROPRIATELY GROUNDED.
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SECTION I
GENERAL INFORMATION
INTRODUCTION
This manual contains installation, operation, and maintenance and repair instructions for Boston Gear BETA
II Angle-Bracket-Chassis Single-Phase Adjustable-Speed DC Motor Controllers. A parts list, ratings and specifica-
tions, and drawings are also included.
GENERAL DESCRIPTION
BETA II Controllers statically convert AC line power to regulated DC for nonregenerative, adjustable-speed
armature control of shunt-wound and permanent-magnet motors.
These controllers comply with applicable standards established by the National Electrical Code and NEMA
for motor and industrial control equipment. The controllers are Underwriters Laboratories Listed (File No.
E60207) and CUL approved (File No. LR19781).
MODEL TYPES
TABLE 1. MODEL MATRIX
MOTOR SELECTION
These controllers control the operation of general purpose DC motors designed for use with solid-state recti-
fied power supplies. The motor may be shunt-wound, stabilized shunt-wound, or permanent magnet. For maximum
efficiency, the motor should be rated for operation from a NEMA Code K power supply.
MODEL
FUNCTION CONFIGURATION OPERATOR
CONTROLS
POWER
SOURCEa&
HP RANGE
a. Units are reconnectable
RUN-STOPb
b. No armature contactor
ARMATURE
CONTACTOR
UNIDIRECTIONAL
RUN AND DBc
c. Includes armature contactor
ARMATURE
CONTACTOR
REVERSE
AND DBc
ANGLE BRACKET
CHASSIS LOCAL
INTEGRAL REMOTE 115V 230V
RBA2C X X NA X1/6 - 1 1/2 - 2RBA2CU X X NA X
RBA2CM X X NA X
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SECTION II
INSTALLATION
Before starting the installation, read this section thoroughly. In addition, a through review of the Ratings And
Specifications (Section VI) is recommended. The following installation guidelines should be kept in mind when
installing the controller.
INSTALLATION GUIDELINES
1. CONTROLLER MOUNTING - The controller must be surface-mounted vertically. Never mount the
controller upside down, immediately beside or above heat generating equipment, or directly below water
or steam pipes.
The controller must be mounted in a location free of vibration.
Multiple controllers may be mounted side by side, but allow at least 2 inches (5.08 cm) between controllers
for cooling efficiency
2. ATMOSPHERE - The atmosphere surrounding the controller must be free of combustible vapors, chem-
ical fumes, oil vapor, and electrically conductive or corrosive materials.
The air surrounding the controller must not exceed 55 degrees C (131 degrees F). Minimum allowable air
temperature is 0 degree C (32 degrees F).
3. LINE SUPPLY - The controller should not be connected to a line supply capable of supplying more than
100,000 amperes short-circuit current. Short-circuit current can be limited by using an input supply trans-
former of 50 KVA or less, or by using correctly sized current limiting fuses in the supply line ahead of the
controller. Do not use a transformer with less than the minimum transformer KVA listed in Table 8, page
25.
If rated line voltage is not available, a line transformer will be required. If the line supply comes directly
from a transformer, place a circuit breaker or disconnect between the transformer secondary and the con-
troller. If power is switched in the transformer primary, transients may be generated which can damage the
controller. See Table 8 (page 25) for minimum transformer KVA.
Do not use power factor correction capacitors on the supply line to the controller.
A 12-joule metal oxide varistor (MOV) is connected across the controller terminals. If higher energy tran-
sients are present on the line supply, additional transient suppression will be required to limit transients to
150% of peak line voltage.
When a 115 VAC line supply is used, connect the white (common) wire to Terminal L2 and connect the
remaining (hot) wire to Terminal L1.
4. ISOLATION TRANSFORMER - While not required, an isolation transformer can provide the following
advantages:
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a. Reduce the risk of personal injury if high voltage drive circuits are accidently touched.
b. Provide a barrier to externally generated AC supply transients. This can prevent controller damage from
abnormal line occurrences.
c. Reduce the potential for damaging current if the motor armature, motor field, or motor wiring become
grounded.
5. GROUNDING - Connect the green or bare (ground) wire of the line supply to one of the controller mount-
ing bracket screws. Then ground the controller by connecting one of the mounting bracket screws to earth
ground.
The motor frame and operator control stations must also be grounded.
Personal injury may occur if the controller, motor, and operator stations are not properly grounded.
6. WIRING PRACTICES - The power wiring must be sized to comply with the National Electrical Code,
CUL, or local codes. Refer to the controller data label for line and motor current ratings.
Do not use solid wire.
Signal wiring refers to wiring for potentiometers, tachometer generators, and transducers. Control wiring
refers to wiring for operator controls, e.g., switches and pushbuttons. Signal and control wiring may be run
in a common conduit, but not in the same conduit as the power wiring. In an enclosure, signal and control
wiring must be kept separated from power wiring and only cross at a 90 degree angle.
Multiconductor twisted cable (Alpha 5630B1801 or equal) is recommended for signal and control wiring.
Since the use of shielded wire may cause electrical noise to be induced into the controller, causing erratic
controller operation, shielded wire is not recommended.
Since the controller DC circuits are notisolated from the AC power source, all external signal and control
wiring should be fused for operator and equipment safety. A ground fault, unisolated external speed refer-
ence, or an unisolated enable input will damage the controller. Refer to Table 2 for recommended fuses.
TABLE 2. RECOMMENDED CONTROL AND SIGNAL WIRING FUSES
7. OPTIONS - This equipment manual is for use with the basic controller. If options are installed in the con-
troller, they will be identified on the controller data label. The instruction sheets supplied with the options
should be reviewed before the controller is installed.
INSTALLING THE CONTROLLER
1. Check components in the controller for shipping damage. Report shipping damage to the carrier.
AC POWER SOURCE
(VAC) FUSE RATING BUSSMANN
PART
NUMBER
115 1/2A, 250V ABC-1/2
230 1/2A, 600V ATM-1/2
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2. Check the controller and motor data labels to be sure the units are electrically compatible.
3. Calibrate the controller for the motor being used by removing (clipping with a wire cutter) shunt wires
from the controller control board to comply with Table 3, below. For the location of the shunt wires, refer
to Figure 18, page 33. TABLE 3. HORSEPOWER CALIBRATION
4. Check the positions of Jumpers J1 and J2 on the control board. For the locations of J1 and J2, see Figure
18, page 33. For a 230 VAC line supply and a 180V armature motor, Jumper J1 must be in the 230V posi-
tion, and Jumper J2 must be in the 180V position. For a 115 VAC line supply and a 90V armature motor, J1
must be in the 115V position, and J2 must be in the 90V position. To change the position of J1 or J2, pull
the jumper from the control board and then push it onto the appropriate pins on the board.
5. Mount the controller on a panel using the two holes in the controller mounting bracket. Mounting dimen-
sions are shown in Figure 1, page 6.
6. Connect the power wiring to Terminals L1, L2, A1 (+), A2 (-), F+ and F-. Be sure to observe Installation
Guidelines 3 and 6 on pages 3 and 4. If half-wave shunt field voltage is desired, connect one of the motor
shunt field leads to Terminal F/2.
NOTE: Low inductance motors require a full-wave field to prevent current instability.
7. If the controller contains any options that require external wiring, follow the wiring instructions in the
instruction sheet supplied with the option.
8. Connect the controller as shown in the appropriate connection diagram (Figures 2 through 14). Figures 2
through 9 show operator control connections, and Figures 10 through 14 show signal connections.
9. The controller can be programmed for various applications by the removal (clipping with a wire cutter) of
wire Jumpers (W1 - W6). For line starting, clip Jumper W1. To use an external Current (Torque) Reference
potentiometer, clip Jumper W6. If jumpers need to be removed, it is noted in the appropriate signal connec-
tion diagram (Figures 10 through 14). Refer to Figure 18 (page 33) for the location of Jumpers W1 - W6.
MOTOR CURRENT RATING
(AMPS)a
a. Select the motor current rating in the table that is closest to the motor nameplate armature current
rating.
REMOVE SHUNT WIRES NUMBER OF SHUNT
WIRES REMAINING
10.5 NONE 7
9.0 R1 6
7.5 R1 & R2 5
6.0 R1 - R3 4
4.5 R1 - R4 3
3.0 R1 - R5 2
1.5 R1 - R6 1
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Reversing board, shown in broken lines, supplied with Models RBA2CU and RBA2CM.
FIGURE 1. CONTROLLER MOUNTING DIMENSIONS
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FIGURE 2. LOGIC CONNECTION DIAGRAM, USING RUN-STOP-JOG SWITCH
FIGURE 3. LOGIC CONNECTION DIAGRAM, USING FORWARD-REVERSE SWITCH AND RUN-
STOP-JOG SWITCH
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FIGURE 4. LOGIC CONNECTION DIAGRAM, USING RUN-STOP PUSHBUTTONS AND RUN-JOG
SWITCH
FIGURE 5. LOGIC CONNECTION DIAGRAM, UNIDIRECTIONAL ARMATURE CONTACTOR USING
SWITCHES
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FIGURE 7. LOGIC CONNECTION DIAGRAM, ARMATURE CONTACTOR REVERSING USING
SWITCHES
FIGURE 6. LOGIC CONNECTION DIAGRAM, UNIDIRECTIONAL ARMATURE CONTACTOR USING
PUSHBUTTONS AND RUN-JOG SWITCH
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FIGURE 8. LOGIC CONNECTION DIAGRAM, ARMATURE CONTACTOR REVERSING USING PUSH-
BUTTONS AND RUN-JOG SWITCH
FIGURE 9. LOGIC CONNECTION DIAGRAM, LINE STARTING WITH MOTOR SPEED POTENTIOME-
TER
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FIGURE 11. SIGNAL CONNECTION DIAGRAM, TACHOMETER FEEDBACK
FIGURE 12. SIGNAL CONNECTION DIAGRAM, CURRENT (TORQUE) REFERENCE POTENTIOME-
TER
FIGURE 10. SIGNAL CONNECTION DIAGRAM, MOTOR SPEED POTENTIOMETER
ADD W4 FOR
25V - 55V TACH
AT FULL SPEED
(55V - 120V)
(5V - 25V)
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FIGURE 13. SIGNAL CONNECTION DIAGRAM, LINE STARTING WITHOUT A MOTOR SPEED
POTENTIOMETER
FIGURE 14. SIGNAL CONNECTION DIAGRAM, 0 - 10 VDC EXTERNAL SPEED REFERENCE SIG-
NAL
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INITIAL STARTUP
1. Be familiar with all options installed in the controller by reviewing the instruction sheets supplied with the
options.
2. Be sure all wiring is correct and all wiring terminations are tightened securely.
3. Be sure the controller is calibrated correctly. See steps 3 and 4 under “Installing The Controller” on page 5.
4. Be sure the AC supply voltage to the controller agrees with the controller data label.
5. The potentiometers in the controller are factory adjusted as shown in Table 4. These settings will provide
satisfactory operation for most applications. If different settings are required, refer to “Adjustment Instruc-
tions” starting on page 17.
6. Turn-on the AC supply to the controller.
7. Check motor rotation, as follows:
a. If a MOTOR SPEED potentiometer is used, turn it fully counterclockwise. If an external signal is used
for the speed reference, set it at minimum.
b. If a RUN-STOP-JOG switch is used, place it in RUN position. Otherwise, initiate a Run command.
c. Turn the MOTOR SPEED potentiometer clockwise or increase the speed reference signal, as applica-
ble. To stop the motor, place the switch in STOP position or initiate a Stop command, as applicable.
If the motor rotates in the wrong direction, turn-off the AC supply to the controller, and then interchange
the motor armature leads at the motor connection box or at the controller terminal board.
8. Refer to Section III, “Operation” for operating instructions.
TABLE 4. INITIAL POTENTIOMETER SETTINGS
POTENTIOMETER SETTING DESCRIPTION
ACCEL 2/3 Turn Clockwise 10 Seconds
CUR LMT Fully Clockwise (100%) 150% Load
DECEL 2/3 Turn Clockwise 10 Seconds
IR/COMP Fully Counterclockwise (0%) 0% Boost
MAX SPD 3/4 Turn Clockwise 100% Speed
MIN SPD Fully Counterclockwise (0%) 0% Speed
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SECTION III
OPERATION
POWER ON/OFF
The controller energizes when the AC supply voltage is turned-on to the controller.
NOTE: Whenever the AC supply voltage is applied to the controller, the motor shunt field is energized with
rated voltage, and potentially hazardous voltage is present at the motor armature terminals. These voltages
can cause electric shock resulting in personal injury or loss of life.
RUN
If a RUN-STOP-JOG switch is used, place the switch in RUN position. Otherwise, initiate a Run command.
A Run command will accelerate the motor to the setting of the MOTOR SPEED potentiometer or external speed
reference signal, as applicable. The rate of acceleration is preset by the ACCEL potentiometer on the controller
control board.
STOP
If a RUN-STOP-JOG switch is used, place the switch in STOP position. Otherwise, initiate a Stop command.
A Stop command will stop the motor at a rate proportional to the stopping rate of the motor load.
If the controller has dynamic braking, the motor stopping time will be reduced. Dynamic braking provides
exponential rate braking of the motor armature, which occurs when the circuit is opened between the controller and
the motor armature, and one or more resistors connect across the motor armature.
The dynamic braking resistors provide initial braking torque and stops per minute as shown in Table 5.
An antiplug feature is included with Models RBA2CU and RBA2CM. This feature prevents restarting the
motor before the motor has braked to a stop.
TABLE 5. DYNAMIC BRAKING CHARACTERISTICSa
a. HIGH INERTIA LOADS MAY EXTEND BRAKING TIME AND CAUSE THE WATT-
AGE RATING OF THE DYNAMIC BRAKING RESISTORS TO BE EXCEEDED.
COMPONENT RATED
VOLTAGE
RATED HORSEPOWER
1/6 1/4 1/3 1/2 3/4 11-1/2 2
BRAKING TORQUE (%) 115V 180 129 103 66 44 34 NA NA
230V NA NA NA 278 190 130 88 62
STOPS PER MINUTE 115V 15 12 11 8 6 2 NA NA
230V NA NA NA 8 6 1 1 1
This manual suits for next models
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