Minarik RG500 Series User manual

RG500 SERIES
SCR, Dual Voltage, Adjustable-Speed
Regenerative Drives for DC Brush Motors

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.

i
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 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.

ii
Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Drive option description (by suffix) . . . . . . . . . . . . . . . . . . . . . . . 2
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Regenerative Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting chassis drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting cased drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AC line and motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cage-clamp terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Field output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tachogenerator feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Speed adjust potentiometer installation . . . . . . . . . . . . . . . . . . . 13
Speed adjust potentiometer connections . . . . . . . . . . . . . . . . . . 14
+15 and –15 terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Line Fusing for RG Series Drives . . . . . . . . . . . . . . . . . . . . . . . 16
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Selector switch settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Chassis drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cased drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . 22
Automatic restart upon power restoration . . . . . . . . . . . . . . 22
Regenerative deceleration . . . . . . . . . . . . . . . . . . . . . . . . . 22
Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . . 22
Regenerative brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Coast to a stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Decelerate to zero speed . . . . . . . . . . . . . . . . . . . . . . . . . 26

iii
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . 29
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . 29
FORWARD TORQUE (FWD TQ). . . . . . . . . . . . . . . . . . . . . . . . 30
REVERSE TORQUE (REV TQ). . . . . . . . . . . . . . . . . . . . . . . . . 31
IR COMPENSATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . 32
FORWARD ACCELERATION (FWD ACC) . . . . . . . . . . . . . . . . 33
REVERSE ACCELERATION (REV ACC) . . . . . . . . . . . . . . . . . 33
DEADBAND (DB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
TACHOGENERATOR (TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Application Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Connection to other Minarik devices. . . . . . . . . . . . . . . . . . . . . . 38
Optional speed adjust potentiometer connections. . . . . . . . . . . . 40
Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Forward-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Independent Adjustable Speeds (Forward Direction Only) . . . . . 41
Independent Forward and Reverse Speeds . . . . . . . . . . . . . . . . 42
Independent Forward and Reverse Speeds with
FWD-STOP-REV Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Factory Prewired Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Certificate of Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 6. Cage-Clamp Terminal Block. . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 7. Speed Adjust Potentiometer. . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 8. Speed Adjust Potentiometer Connections . . . . . . . . . . . . . 14
Figure 9. TB502 Terminal Assignments. . . . . . . . . . . . . . . . . . . . . . . 15
Figure 10. Voltage Follower Connection . . . . . . . . . . . . . . . . . . . . . . 17
Figure 11. Selector Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 12. Regenerative Deceleration Switch Connection . . . . . . . . . 22
Figure 13. INHIBIT Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 14. Inhibit - Run Jumper Settings. . . . . . . . . . . . . . . . . . . . . . 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 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

v
Figure 26. Prewired Connections to L1, L2(115) and L2(230) . . . . . . 48
Figure 27. Prewired Speed Adjust Potentiometer Connections . . . . . 49
Figure 28. RG500 Series Block Diagram . . . . . . . . . . . . . . . . . . . . . . 56

vi
Tables
Table 1. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Table 2. Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table 3. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Table 4. Corcom® Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Table 5. Minarik Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

1
Specifications
Max.
Armature HP Range HP Range
Current with 115 VAC with 230 VAC
Model (Amps DC) Applied Applied
* RG500A, RG500UA 10.0 † 1/4–1 † 1/2–2 †
* RG510A, RG510UA 3.0 1/20–1/8 1/10–1/4
† 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; S1 to S2) 0–10 VDC
Input Impedance (S0 to S2) 32K ohms
Load Regulation
with Armature Feedback 1% of base speed or better
with Tachogenerator Feedback 0.1% of base speed
Ambient Temp. Range (chassis drives) 10°C–55°C
Ambient Temp. Range (cased drives) 10°C–40°C
Vibration 0.5g max (0 – 50 Hz)
0.1g max (above 50 Hz)

2Specifications
Drive option description (by suffix)
Terminal
Suffix Style Block Type
ANEMA 4X Cage-Clamp
UA Chassis Cage-Clamp

3
Dimensions
Figure 1. RG500UA and RG510UA Dimensions
FU501 FU502
0.93 [24]
3.50 [89]0.64 [16]
8.90 [226]
.70 [18]
8.40 [213]
1.85 [47]
0.125 [3] REF
4.78 [121]
4.000 [102]0.28 [7]
IC501
IC502
S3 S2
C505
TB502
S0S1 RB1 -15RB2 +15
P501
MIN SPD
T2T1
INHIBIT
FWD TQ REV TQ
INV
P502 P503
230V
C502
SW502
C503
A2 A1
TB501
F2
SW501
GND F1115V
L2
115 230230 115
SO502
SO501
INH-RUN T505
T501
FU504
R501
T502
C504
L2
L1
FAST ACTING
FUSES ONLY L2L1
SCR501 SCR502 SCR504
C501
SCR503
P509
TACHFWD ACCMAX SPDIR COMP
P505P504 P506
REV ACC DB
P507 P508
SW504
T503
T504
SW503
ARM TACH
FEEDBACK
R503
90 180
ARMATURE
R502
R505R504
SCR505 SCR506
R506
SCR507 SCR508 C510
0.188 [5]
4.78 [121]
4.000 [102] 0.70 [18]
8.90 [228]
3.50 [89]
0.84 [18]
0.93 [24]
1.85 [47]
0.125 [3] REF
8.40 [213]
0.28 [7]
0.188 [5]

4Dimensions
Figure 2. RG500A and RG510A Cased Drive Dimensions
6.90 [175]
6.30 [160]
1.40 [36]
10.20 [259]
9.80 [249]
5.50 [140]
4.78 [121]
2.30 [58]
1.50 [38]
THREE 0.88 [22] KNOCKOUTS
ALL DIMENSIONS IN INCHES [MILLIMETERS]
1.50 [38]
0.12 [3]
1.45 [37]
FOUR (4) EACH MOUNTING SLOTS.
6.3 [160] x 7.0 [178]
ON CENTERS

5
Regenerative Drives
In most non-regenerative, variable speed, 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.

6Regenerative Drives
Figure 3. Four Quadrant Operation

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 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.
7
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 slotted screw clockwise until tight to secure the
front cover.
8Installation

9
S3
S2
C505
TB502
230V
A2 A1
TB501
F2GND F1
115V
L2
C504
L2
L1
A
ARMATURE
OUTPUT
FIELD
OUTPUT
FOR SHUNT WOUND
MOTORS ONLY.
See field output section
for connections.
230 VAC
115 VAC
AC LINE
INPUT
115 OR 230 VAC
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.
Figure 4. Chassis Drive Connections
Installation
AC LINE
INPUT
115 OR 230 VAC
115 VAC 230 VAC
ARMATURE
OUTPUT
A
FIELDOUTPUT
For Shunt Wound
Motors Only.
See field output section
for connections

10
IC501
IC502
S3 S2
C505
TB502
S0S1 RB1 -15RB2 +15
P501
MIN SPD
T2T1
INHIBIT
FWD TQ
REV TQ
P502
P503
230V
C502
SW502
C503
A2 A1
TB501
F2
SW501
GND F1
115V
L2
115 230230 115
SO502
SO501
INH-RUN
T502
C504
L2
L1
FAST ACTING
FUSES ONLY
L2
FU502
L1
FU501
SCR504
C501
12 3
A
Figure 5. Cased Drive Connections
Installation
ARMATURE
OUTPUT
115
VAC
230 VAC
AC LINE INPUT
115 OR 230 VAC
FIELD OUTPUT
For shunt wound motors
only. See field output
section for connections.

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.
Figure 6. Cage-Clamp Terminal Block
Installation
Wire Clamp
Lever Arm

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 1 lists the field output connections.
Table 1. Field Output Connections
Line Voltage Approximate Connect Motor
(VAC) Field Voltage (VDC) Field To
115 50 F1 and L1
115 100 F1 and F2
230 100 F1 and L1
230 200 F1 and F2
Tachogenerator feedback
Using tachogenerator feedback improves speed regulation
from approximately 1% of motor base speed to approximately
0.1% of motor base speed. Use tachogenerators rated from
7 VDC per 1000 RPM to 50 VDC per 1000 RPM. Connect
the tachogenerator to terminals T1 and T2 of terminal block
TB502. The polarity is + for T1 and – for T2 when the motor
running in the forward direction. The polarity is reversed
when the motor is running in the reverse direction.