Minarik RG300 Series User manual

USER’S MANUAL
RG300 and RG400 Series
SCR, Adjustable Speed, Regenerative Drives
for DC Brush Motors

Copyright  1998 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.

mSafety Warnings
•This symbol m 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 procedures.
•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 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.

ii
Contents
Specifications 1
Dimensions 3
Regenerative Drives 6
Installation 8
Mounting chassis drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Mounting cased drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Cage-clamp terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Screw terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
AC line and motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Field output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Speed adjust potentiometer installation . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Speed adjust potentiometer connections . . . . . . . . . . . . . . . . . . . . . . . . . .17
Line fusing for RG300/400 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Operation 20
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Chassis drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Cased drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Automatic restart upon power restoration . . . . . . . . . . . . . . . . . . . . . . . . .21
Regenerative deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Regenerative brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Decelerate to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

iii
Contents
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Calibration 26
MIN SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
MAX SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
FWD TQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
REV TQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
IR COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
FWD ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
REV ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
DB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Application Notes 33
Connection to other Minarik devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Optional speed adjust potentiometer connections . . . . . . . . . . . . . . . . . . .35
Troubleshooting 38
Block Diagram 43
Factory Prewired Connections (for Cased Drives) 44
CE Compliance 46
Line filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Armature filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Replacement Parts 50
Limited Warranty inside back cover

iv
Illustrations
Fig. Description Page
1. RG300UA, RG310UA and RG400UA Dimensions . . . . . . . . . . . . . . . . . . . .3
2. RG300UA-S, RG310UA-S and RG400UA-S Dimensions . . . . . . . . . . . . . . .4
3. Cased Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4. Four-Quadrant Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5. Cage-Clamp Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6. Screw Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
7. Chassis Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
8. Cased Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
9. Speed Adjust Potentiometer Installation . . . . . . . . . . . . . . . . . . . . . . . . . .16
10. Speed Adjust Potentiometer Connections . . . . . . . . . . . . . . . . . . . . . . . . .17
11. Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
12. Regenerative Deceleration Switch connection . . . . . . . . . . . . . . . . . . . . . .22
13. Run/Decelerate to Minimum Speed Switch . . . . . . . . . . . . . . . . . . . . . . . .24
14. Typical FWD TQ, REV TQ and IR COMP Settings . . . . . . . . . . . . . . . . . . .30
15. Deadband Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
16. Connection to Other Minarik Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
17. RG300/400 Connection to 200-0386A Logic Board . . . . . . . . . . . . . . . . . .34
18. FWD-REV Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
19. FWD-STOP-REV Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
20. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
21. Independent Forward and Reverse Speeds . . . . . . . . . . . . . . . . . . . . . . . .36
22. Independent Forward and Reverse Speed with FWD-STOP-REV Switch . .37
23. RG300/400 Series Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
24. Prewired Power Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
25. Prewired Speed Adjust Potentiometer Connections . . . . . . . . . . . . . . . . . .45

v
Tables
Table Description Page
1. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2. Line Fusing for RG Series Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3. Corcom® Filters for CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4. Minarik® Filters for CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Specifications
Maximum
Armature Armature Horsepower
Model Current Voltage Range
RG310 3.0 ADC 0 – 90 VDC 1/20 – 1/8
RG300 10.0 ADC † 0 – 90 VDC 1/4 – 1 †
RG400 10.0 ADC † 0 – 180 VDC 1/2 – 2 †
† 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 5 ADC. Heat sinks are pre-mounted on RG300 and RG400 series
cased drives.
AC Line Voltage
RG300/RG310 115 VAC, ±10%, 50/60 Hz, single phase
RG400 230 VAC, ±10%, 50/60 Hz, single phase
Form Factor 1.37 at base speed
Field Voltage
115 VAC Input 50 VDC (F1 to L1); 100 VDC (F1 to F2)
230 VAC Input 100 VDC (F1 to L1); 200 VDC (F1 to F2)
Maximum Field Current 1 ADC
Acceleration Time Range 0.5 – 6 seconds
Deceleration Time Range 0.5 – 6 seconds
Analog Input Voltage Range (isolated; RB1 to S2) –10 VDC to +10 VDC
Input Impedance (RB1 to S2) 32KΩ
Load Regulation 1% of base speed or better
Vibration 0.5G max. (0 – 50 Hz)
0.1G max. (>50Hz)
Ambient Temperature Range (chassis drive) 10°C – 55°C
Ambient Temperature Range (cased drive) 10°C – 40°C
Safety Certification UL file # E132235
CSA file # LR41380
CE Certificate of Compliance
1

2Specifications
Drive option description - by suffix Terminal
Suffix Style Block Type
A NEMA 4 Cage-Clamp*
A–S NEMA 4 Screw
UA Chassis Cage-Clamp*
UA–S Chassis Screw
*Note: All cased regenerative drives in this series have a two slot
screw terminal block for connecting the AC line voltage
(see page 18).

3
Dimensions
Figure 1. RG300UA, RG310UA, and RG400UA Dimensions

4Dimensions
Figure 2. RG310UA–S, RG300UA–S, RG400UA–S,
Dimensions

5
Dimensions
Figure 3. RG310A, RG300A, RG400A
and RG310A–S, RG300A–S, RG400A–S
Cased Drive Dimensions

6
Regenerative Drives
Most non-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 operate in Quadrant 1, and also in
Quadrant 3 if the drive is reversible (see Figure 4). Motors
must stop before reversing direction. Unless dynamic braking
is used, 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.

7
Regenerative Drives
Figure 4. Four Quadrant Operation

Installation
ASSUMPTIONS: Minarik drives supply motor voltage from
A1 and A2 terminals. It is assumed throughout this manual
that, when A1 is 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 this is opposite of
the desired rotation, simply reverse the wiring of A1 and A2
with each other.
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.
8

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 0.188 inch
(5 mm) slotted holes on the attached heat sink. The cased
drives in this series may be bench mounted. For motor loads
greater than 8 ADC the heat sink fins must be in the vertical
direction. Detailed step by step instructions begin on the
page 14.
9
Installation
Mount the drive with its board in either a horizontal or
vertical plane. Six 0.188 inch (4.8 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 501 (TB501).

Mounting cased drives (continued)
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. Lift
or 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. Install conduit hardware through the 0.88 inch (22 mm)
conduit holes. Connect external wiring to the terminal
block.
5. Grasp the slotted screw and tilt the front cover back into
place. Avoid pinching any wires between the front cover
and the case.
6. Turn the slotted screw clockwise until tight to secure the
front cover.
7. Set the POWER switch OFF position before applying the
AC line voltage.
10 Installation

11
Installation
Figure 5. Cage-Clamp Terminal Block
Cage-clamp terminal block
Most connections to RG300 and RG400 Series drives (UA
and A versions) are made to a cage-clamp terminal block
(Figure 5). 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.
Note: All AC line voltage connections to cased regen drives
are made to screw terminals.

12 Installation
Screw terminal block
Connections to RG300 and RG400 Series drives (A-S version
and UA-S) are made to screw terminal blocks. The larger one
is shown in Figure 6.
Using a screwdriver, turn the terminal block screw counter-
clockwise to open the wire clamp. Insert stripped wire into the
wire clamp. Turn the terminal block screw clockwise to clamp
the wire.
Terminal Block Screw
Wire Clamp
Figure 6. Screw Terminal Block