US drives AC Regen User manual

AC LINE
REGENERATIVE MODULE
15 HP TO 1750 HP
INSTRUCTION MANUAL

Thank You
We at US Drives would like to say thank
you for purchasing our product. We
believe the Regenerative Module Series
is the most problem free product in the
market today. If you have any questions
or comments please feel free to call us.
On behalf of all of us here once again
thank you.
Recording Drive Information
It is a good idea to record all product
nameplate information for future reference.
The nameplate is usually mounted on the
side of the unit. The following tables should
be filled in during starting or prior to starting
the module.
Part Number
P/N
Serial Number
S/N
Software Revision Level
SRL
Branch Circuit Protection
Branch circuit protection must be provided
by the end user. In this manual you will find
recommended fuse sizes and types for
each module size.
Mounting Location
The unit should be installed in a well
ventilated, moisture free area. If there are:
fumes; vapors; dirt; lint;, liquids or gases
that can interact with the module, then a
clean air supply must be provided. The
ambient temperature should not exceed the
range of 14 F to 131 F (-10 C to 55 C). If
the unit will be subject to vibration then the
enclosure should be shock mounted.
Safety Warnings
Regenerative modules, like all electrical
equipment in industry, if not properly
installed and operated can cause personal
injury. Always use common sense when
working around electrical equipment. Make
sure you read this manual before any work
on the unit begins. Never work on this
product if you are tired or under the
influence of any drug. The unit must be
grounded and installed in accordance with
National Electrical Codes (NEC) and any
local codes. Make sure that all power is
disconnected, before working on the
module. Always measure the incoming
voltage at the unit to make sure it is zero
after disconnecting the power. Make sure
all air passages are clear for proper cooling.
After the unit is energized lethal voltages
are present. Wait at least 5 minutes after
disconnecting power before working on
the module, since high voltages will still be
present. Call us if you have any questions.
Maintenance
If the enclosure is subject to foreign
material, clean the enclosure and check
any filters for build up of debris. If the
inside of the enclosure needs cleaning, a
low pressure vacuum cleaner is
recommended. Do not use an air hose
because of the possible oil vapor in the
compressed air and its high pressure.

AC REGEN 1
OBJECTIVES
The purpose of this manual is to provide the user with
the necessary information to install, start-up and
maintain the
AC REGEN . This manual should be read
thoroughly before operating, servicing or setting up
the AC REGEN.
This manual is intended for qualified service personnel
responsible for setting up and servicing the
AC
REGEN
. You must have previous experience with and
a basic understanding of electrical terminology,
programming procedures, and required equipment and
safety precautions before attempting service on the
AC REGEN.
SAFETY
WARNING
Only personnel familiar with motor drives and the
associated machinery should plan or implement the
installation, start-up, and subsequent maintenance of
the
AC REGEN . Failure to comply may result in
personnel injury and/or equipment damage.
WARNING
An incorrectly applied or installed AC REGEN can
result in component damage or a reduction in product
life. Wiring or application errors such as under sizing
the motor, incorrect or inadequate AC supply or
excessive ambient temperatures may result in damage
to the Drive or motor.
WARNING
This AC REGEN contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control
precautions are required when servicing or repairing
this assembly. Component damage may result if ESD
control procedures are not followed. If you are not
familiar with static control procedures, please consult
with the factory.
WARNING
TO AVOID A HAZARD OF ELECTRIC SHOCK,
AFTER THE INPUT AND CONTROL POWER IS
REMOVED FROM THE AC REGEN AND THE
DRIVE CONNECTED TO IT, WAIT FIVE (5)
MINUTES FOR BUS CAPACITORS TO FULLY
DISCHARGE.
MODEL RATINGS
Tables 1 through 3 show the
AC REGEN model ratings
for class 200, class 400 and class 500 units.

AC REGEN 2
SPECIFICATIONS AND FEATURES
Electrical Specifications:
Rated Input Voltage: 200-250Vac, 380-500Vac, 500-600Vac
-10% of minimum, +10% of maximum.
Frequency Tolerance: 47-63 Hz
Number of Phases: 3
Efficiency: 99% or greater
Max. Short Circuit Current Rating: 200,000A rms symmetrical, 600 volts (when used with AC input line fuses
specified in tables 1 to 3).
Noise Immunity: IEEE C62.41-1991 Category B (Formerly known as IEEE 587) - 6000V tests
EN50082-1, 2 Generic Immunity Standards
IEC 1000-4-2 ( IEC 801-2 )
IEC 1000-4-3 ( IEC 801-3 )
IEC 1000-4-4 ( IEC 801-4 )
IEC 1000-4-5 ( IEC 801-5 )
IEC 1000-4-6 ( IEC 801-6 )
IEC 1000-4-8 ( IEC 801-8 )
Environmental Specifications:
Ambient Temperature: -10C to 55C (14F to 131F) Nema type 1 enclosed.
Storage Temperature: -40C to 70C (-40F to 158F) Nema type 1 enclosed.
Altitude: Sea level to 3000 Feet [1000m] without derating.
Humidity: 95% relative humidity non-condensing.
Vibration: 9.8m/sec2 (1.0G) peak.
Physical attributes:
Mounting: Though hole or panel mount.
Nema Rating: Type 1 (IP20) as standard, Type 12 (IP54) optional.
Construction: Steel construction (reduces E.M.I.)
Control I/O:
 2 Digital Inputs: Regen Enable & Regen Reset
 2 Digital Outputs: Form C dry contacts rated 115Vac @ 5A; 30Vdc @ 3.5A.
 1 meter output: Use with 100A movement analog meter.
 24Vdc source: Use to power operator pushbuttons and US Drives option boards: 24Vdc @ 100 mA
max.
Protective Features:
 Peak output current monitoring to protect against line-to-line shorts and line-to-ground shorts.
 Ground fault monitoring.
 Heatsink over-temperature monitoring.
 AC line & DC bus over-voltage protection.
 AC line & DC bus under-voltage protection.
 Control power supply power ride-thru.
 Internal power supply monitoring.
 AC phase loss detection.
Standard Regen Features
 Latest generation IBGT.
 Nema type 1 (IP20) as standard for all models.
 55C ambient with standard Nema type 1 (IP20) enclosure.
 High voltage ratings: 250Vac+10% , 500Vac+10% models, and 600Vac+10% models
 Input line suppression: Metal oxide varistors for line-to-line and line-to-ground voltage surge protection.
 No programming or hardware jumper for all voltages.

AC REGEN 3
Table 1
Class 200 AC Regen Models (Typical Voltage 208/230/240 VAC)
200-250VAC (-10% to +10%)
Frame
Designation
NEMA 1
(IP20)
Catalog Number
Continuous
DC Bus
Current
(Amps)
Continuous
Regen
Power1
KW
Drive HP2
AC Current
(Amps)
Maximum
Recommended
AC Line Fuses3
(Amps)
Total Power
Losses4
(W)
SIZE 1 RG-0200-0030-N1 30 11 15 29 40 176
RG-0200-0045-N1 45 16 20 44 60 239
RG-0200-0060-N1 60 21 30 58 90 302
RG-0200-0090-N1 90 32 40 85 125 428
RG-0200-0120-N1 120 42 60 116 175 554
RG-0200-0180-N1 180 63 75 175 250 806
SIZE 2 RG-0200-0240-N1 240 84 100 233 350 1058
RG-0200-0300-N1 300 105 125 291 450 1300
RG-0200-0360-N1 360 126 150 349 600 1562
SIZE 3 RG-0200-0480-N1 480 168 200 466 700 2066
RG-0200-0540-N1 540 189 250 524 900 2318
RG-0200-0600-N1 600 210 300 582 900 2570
RG-0200-0720-N1 720 252 350 698 1000 3074
RG-0200-0840-N1 840 294 400 815 1200 3578
RG-0200-0960-N1 960 336 450 931 1200 4082
RG-0200-1080-N1 1080 378 500 1048 1500 4586
RG-0200-1440-N1 1440 504 700 1397 2000 6098
1 KW based on 240Vac AC Power line.
2 Drive HP ratings are calculated for 230 VAC Motors based on 100% Continuous Regeneration and 150% Regeneration for 1 Minute or Less.
Consult Factory for Module sizing when Regeneration requirements are less than or greater than these values.
3 Semiconductor Fuses: Ferraz Shawmut A50P, A60X, Bussmann FWH.
4 Total Power Loss shown is for continuous operation at full regeneration.
Table 2
Class 400 AC Regen Models (Typical Voltage 380/415/480 VAC)
380-500VAC (-10% to +10%)
Frame
Designation
NEMA 1
(IP20)
Catalog Number
Continuous
DC Bus
Current
(Amps)
Continuous
Regen
Power1
KW
Drive HP2
AC Current
(Amps)
Maximum
Recommended
AC Line Fuses3
(Amps)
Total Power
Losses4
(W)
SIZE 1 RG-0400-0030-N1 30 21 30 29 40 200
RG-0400-0045-N1 45 32 40 44 60 275
RG-0400-0060-N1 60 42 60 58 90 350
RG-0400-0090-N1 90 63 75 85 125 500
RG-0400-0120-N1 120 84 100 116 175 650
RG-0400-0180-N1 180 126 150 175 250 950
SIZE 2 RG-0400-0240-N1 240 168 200 233 350 1250
RG-0400-0300-N1 300 210 300 291 450 1525
RG-0400-0360-N1 360 252 350 349 600 1850
SIZE 3 RG-0400-0480-N1 480 336 450 466 700 2450
RG-0400-0540-N1 540 378 500 524 900 2750
RG-0400-0600-N1 600 420 600 582 900 3050
RG-0400-0720-N1 720 504 700 698 1000 3650
RG-0400-0840-N1 840 588 800 815 1200 4250
RG-0400-0960-N1 960 672 900 931 1200 4850
RG-0400-1080-N1 1080 756 1000 1048 1500 5450
RG-0400-1440-N1 1440 1008 1400 1397 2000 7250
1 KW based on 480Vac AC Power line.
2 Drive HP ratings are calculated for 460 VAC Motors based on 100% Continuous Regeneration and 150% Regeneration for 1 Minute or Less.
Consult Factory for Module sizing when Regeneration requirements are less than or greater than these values.
3 Semiconductor Fuses: Ferraz Shawmut A50P, A60X, Bussmann FWH.
4 Total Power Loss shown is for continuous operation at full regeneration.

AC REGEN 4
Table 3
Class 500 AC Regen Models (Typical Voltage 525/575/600 VAC)
525-600VAC (-10% to +10%)
Frame
Designation
NEMA 1
(IP20)
Catalog Number
Continuous
DC Bus
Current
(Amps)
Continuous
Regen
Power1
KW
Drive HP2
AC Current
(Amps)
Maximum
Recommended
AC Line Fuses3
(Amps)
Total Power
Losses4
(W)
SIZE 1 RG-0500-0030-N1 30 26 30 29 40 236
RG-0500-0045-N1 45 39 50 44 60 329
RG-0500-0060-N1 60 53 75 58 90 422
RG-0500-0090-N1 90 79 100 85 125 608
RG-0500-0120-N1 120 105 125 116 175 794
RG-0500-0180-N1 180 158 200 175 250 1166
SIZE 2 RG-0500-0240-N1 240 210 250 233 350 1538
RG-0500-0300-N1 300 263 350 291 450 1900
RG-0500-0360-N1 360 315 400 349 600 2282
SIZE 3 RG-0500-0480-N1 480 420 500 466 700 3026
RG-0500-0540-N1 540 473 600 524 900 3390
RG-0500-0600-N1 600 525 700 582 900 3770
RG-0500-0720-N1 720 630 800 698 1000 4514
RG-0500-0840-N1 840 735 900 815 1200 5250
RG-0500-0960-N1 960 840 1000 931 1200 6002
RG-0500-1080-N1 1080 945 1300 1048 1500 6746
RG-0500-1440-N1 1440 1260 1750 1397 2000 8978
1 KW based on 600Vac AC Power line.
2 Drive HP ratings are calculated for 575 VAC Motors based on 100% Continuous Regeneration and 150% Regeneration for 1 Minute or Less.
Consult Factory for Module sizing when Regeneration requirements are less than or greater than these values.
3 Semiconductor Fuses: Ferraz Shawmut A70P, A60X, Bussmann FWP.
4 Total Power Loss shown is for continuous operation at full regeneration.

AC REGEN 5
INSTALLATION AND WIRING
This Section provides the information needed to
properly mount and wire the
AC REGEN . Since most
start-up difficulties are the result of incorrect wiring, it
is essential that the wiring is done as instructed. Read
and understand this section in its entirety before
actual installation begins.
WARNINGS
WARNING
Only qualified electrical personnel familiar with the
construction and operation of this equipment and the
hazards involved should install, adjust, operate or
service this equipment.
WARNING
The control and its associated motors and operator
control devices must be installed and grounded in
accordance with all national and local codes (NEC,
VDE 0160, BSI, etc.). To reduce the potential for
electric shock, disconnect all power sources before
initiating any maintenance or repairs. Keep fingers
and foreign objects away from ventilation and other
openings. Keep air passages clear. Potentially lethal
voltages exist within the
AC REGEN enclosure and
connections. Use extreme caution during installation
and start-up.
WARNING
The following information is only a guide for proper
installation. US Drives cannot assume responsibility
for the compliance or noncompliance to any code,
national, local or otherwise for the proper installation
of this
AC REGEN or associated equipment. A hazard
of personal injury and/or equipment damage exists if
codes are ignored during the installation.
INITIAL CHECKS
Before installing the AC REGEN , check the unit for
physical damage sustained during shipment. If
damaged, file a claim with the shipper and return for
repair following the procedures outlined on the back
cover. If no damage is observed, remove all shipping
restraints and padding. Check
AC REGEN nameplate
data for conformance with the AC power source and
motor.
DETERMINING CONTROL LOCATION
The AC REGEN is suitable for most well-ventilated
factory areas where industrial equipment is installed.
Locations subject to steam vapors or excessive
moisture, oil vapors, flammable or combustible
vapors, chemical fumes, corrosive gases or liquids, or
excessive dirt, dust or lint should be avoided unless an
appropriate enclosure has been supplied or a source
of clean air is supplied to the enclosure. The location
should be dry and the ambient temperature should not
exceed 131F (55C). If the mounting location is
subject to vibration, the unit should be shock
mounted.
MOUNTING
Figure 1 shows the minimum required surrounding air
space for panel mounted AC REGEN . Note that the
panel mounted units must be mounted in an upright
position. Figure 2 shows dimensional information for
size 1. If through panel mounting is chosen, a suitable
sealant should be applied to the mounting faces of the
AC REGEN and the panel to prevent leakage.
Figure 1
Minimum Required Surrounding Air Space
AC SUPPLY SOURCE
AC REGEN is suitable for use on a power system
capable of delivering up to a maximum of 200,000
rms symmetrical amperes, 250/500/600 +10% volts
maximum when used with AC input line fuses
specified in tables 1, 2 and 3 respectively.
WARNING
To guard against personal injury and/or equipment
damage caused by improper fusing, use only the
recommended line fuses specified in tables 1, 2 and 3.

AC REGEN 6
Unbalanced Distribution Systems
The AC REGEN is designed to operate on three-phase
supply systems whose line voltages are symmetrical.
Surge suppression devices are included to protect the
AC REGEN from lightning induced over-voltages
between line and ground. Where the potential exists
for abnormally high phase-to-ground voltages (in
excess of 125% of nominal), or where the supply
ground is tied to another system or equipment that
could cause the ground potential to vary with
operation, suitable isolation is required for the
AC
REGEN . Where this condition exists, an isolation
transformer is strongly recommended.
Ungrounded Distribution Systems
All AC Regen are equipped with MOVs that provides
voltage surge protection and phase-to-phase plus
phase-to-ground protection which is designed to meet
IEEE 587. Where the potential exists for abnormally
high phase-to-ground voltages (in excess of 125% of
nominal), an isolation transformer is strongly
recommended. The MOV circuit is designed for surge
suppression only (transient line protection), not
continuous operation. With ungrounded distribution
systems, the phase-to-ground MOV connection could
become a continuous current path to ground.
If the AC source for the AC Regen does not have a
ground reference (neutral or phase ground), an
isolation transformer with the neutral of the secondary
grounded is highly recommended. These AC Regen’s
contain PE referenced MOV devices for input transient
voltage limiting. Transients occurring on a non-ground
referenced voltage source may generate excessive line
to ground voltages which could exceed the limits of
the insulation system of the AC Regen. Under these
conditions, it is highly recommended that a system
level transient voltage suppression device be
employed in order to limit the potential line to ground
voltage. Contact factory if the AC Regen must be
operated on an ungrounded voltage source.
Input Power Conditioning
The basic guidelines for determining if an isolation
transformer is required are as follows:
1. If the AC input power system does not have a
neutral or one phase referenced to ground, an
isolation transformer with the neutral of the
secondary grounded is highly recommended.
If the line-to-ground voltages on any phase can
exceed 125% of the nominal line-to-line
voltage, an isolation transformer with the
neutral of the secondary grounded, is always
required.
2. If the AC line supplying the AC REGEN has
power factor correction capacitors that are
switched in and out, an isolation transformer is
recommended between the AC REGEN and the
capacitors.
3. If the AC line frequency experiences transient
power interruptions or significant voltage
spikes, an isolation transformer or a three
percent (3%) reactor is recommended.
Input Fusing
WARNING
AC REGEN does not provide input power short circuit
fusing. Maximum Recommended AC Line Fuses are
shown in tables 1, 2 and 3. Note that branch circuit
breakers or disconnect switches can not respond fast
enough to provide the level of protection that the
AC
REGEN components require.
Input Devices
WARNING
Hardwired Stop Circuit
The AC REGEN “ENABLE” control input circuitry
includes solid-state components. If hazards
due to accidental contact with moving
machinery or unintentional flow of liquid, gas
or solids exist, an additional hardwired stop
circuit is required to remove AC line power to
the
AC REGEN . When AC power is removed, the
motor will coast to a stop. Consequently, an
auxiliary braking method may be required.
ELECTRICAL INTERFERENCE (EMI/RFI)
AC REGEN Immunity
The immunity of the AC REGEN’S to externally
generated interference is outstanding. No special
precautions other than following the procedures
outlined in this manual are required.
It is recommended that the coils of AC and DC
energized contactors interfaced with the AC REGEN be
suppressed with RC networks and diodes respectively
or with similar devices. This is because non-
suppressed coils (inductors) can generate high
electrical transients.
In areas prone to frequent lightning strikes, the
standard MOV’s (Metal Oxide Varistors) supplied with
the drive may need to be supplemented with
additional surge suppression MOV’s on the AC line
feeding the drive.

AC REGEN 7
AC REGEN Emissions
Care must be used in the routing of power and ground
connections to the
AC REGEN to avoid interference
with sensitive equipment that may be nearby. The
cable from the drive to the AC REGEN carries switched
voltages and should be routed well clear of sensitive
equipment. The ground conductor of the motor cable
should be connected to the drive ground stud directly.
Connecting this ground conductor to a cabinet ground
point or ground bus bar may cause high frequency
current to circulate in the ground system of
AC REGEN
enclosure.
GROUNDING
Refer to the “Recommended Power Wiring” diagram in
figure 3 for grounding instructions. The
AC REGEN
must be connected to AC system ground using the
power ground stud(s) provided. Ground
impedance must conform to requirements of national
and local industrial codes (NEC, VDE 0160, BSI, etc.)
and should be inspected and tested at regular
intervals. These ground wires must have a
current rating in compliance with the above
mentioned national and local codes.
Note that the
AC REGEN signal common (COM)
should not be connected to the power ground stud
directly. If desired, one of these commons may be
connected to earth ground at a single point outside
the drive enclosure.
For multiple
AC REGEN systems, if the signal common
on each AC REGEN is to be grounded, they can be
“daisy-chained” connected, using a single COM point
on each AC REGEN . Note that this AC REGEN COM
“bus” should only tie to earth ground at only one
point.
Grounding Sensitive Circuits
It is critical to control the paths through which high
frequency ground currents flow. Sensitive circuits
should not share a path with such currents. Control
and signal conductors should not be run near or
parallel to power conductors.
Power Cabling
Input and Output power connections are made
through the power terminal block and power ground
stud. The actual
AC REGEN label markings are shown
in Table 4. Maximum torque values for terminal
connections are also indicated on labels next to the
connection points.
Table 4
Power Signal Description
Terminal Description
GND Power Earth Ground Stud
L1 L2 L3
AC LINE INPUT AC Line Input Terminals
DC- DC+ DC Bus Terminals
Control and Signal Wiring
Terminal blocks TB1 and TB2 on the AC REGEN main
control board are used for connecting control and
signal wiring. See Figure 4 for terminal block physical
location A brief summary of the terminal block
assignments are shown in Table 5.
Before proceeding with any signal wiring, the
following precautions for the signal conduit and wire
must be followed:
Signal Conduit Requirements
 Use either rigid steel or flexible armored steel
cable.
 The signal conduit must cross non-signal conduit
at an angle of between 45 and 90.
 Do not route the conduit through junction or
terminal boxes that have non-signal wiring.
Signal Wire Requirements
 Size and install all wiring in conformance with the
requirements of national and local industrial safety
regulations (NEC, VDE 0160, BSI, etc.)
 Use shielded wire for signal wire connections.
 Route all signal wiring away from high current
lines such as AC lines.
Always run the signal wire in steel conduit. Never run
the signal wire with non-signal wire.

AC REGEN 8
Approximate Weight: 35 Lbs. [16 Kgs]
Notes:
- Top and bottom endplates are removable to gain access inside the drive and to punch holes for conduits.
- Endplates must be removed from the drive before drilling and punching holes to avoid metal dust inside the drive enclosure. Failure to
do so will cause damage to the drive.
- For through-panel mounting, customer is to seal for gap on all side of cutout. Provided by customer, aluminum angle 1” x 1” x 0.050”
can be used to attach to all sides of drive to help seal and secure the drive.
Figure 2
AC Regen Mounting Information:
Size 1 (Nema Type 1)

AC REGEN 9
Approximate Weight: 150 Lbs. [68 Kgs]
Notes:
- Top and bottom endplates are removable to gain access inside the drive and to punch holes for conduits.
- Endplates must be removed from the drive before drilling and punching holes to avoid metal dust inside the drive enclosure. Failure to
do so will cause damage to the drive.
- For through-panel mounting, customer is to seal for gap on all side of cutout. Provided by customer, aluminum angle 1” x 1” x 0.050”
can be used to attach to all sides of drive to help seal and secure the drive.
Figure 2-2a
AC Regen Mounting Information:
Size 2 (Nema Type 1)

AC REGEN 10
Approximate Weight: 450 Lbs. [204 Kgs]
Notes:
- Top and bottom endplates are removable to gain access inside the drive and to punch holes for conduits.
- Endplates must be removed from the drive before drilling and punching holes to avoid metal dust inside the drive enclosure. Failure to
do so will cause damage to the drive.
- For through-panel mounting, customer is to seal for gap on all side of cutout. Provided by customer, aluminum angle 1” x 1” x 0.050”
can be used to attach to all sides of drive to help seal and secure the drive.
- Size 3 enclosure can also be free-standing with optional floor stand kit from US Drives, Inc.
Figure 2-2b
AC Regen Mounting Information:
Size 3 (Nema Type 1)

AC REGEN 11
Figure 3
Size 1 (Only)
Recommended Power Wiring

AC REGEN 12
Figure 3-3a
Size 2 & 3
Recommended Power Wiring

AC REGEN 13
Figure 3-3b
Size 1, 2 & 3
AC Regen Connection in a Common Bus System

AC REGEN 14
TERMINAL BLOCK DESCRIPTION
TB1 TERM 1 24 Vdc @ 100mA Max.
TB1 TERM 2 Regen Enable ( 24 Vdc logic )
TB1 TERM 3 Regen Reset ( 24 Vdc logic )
TB1 TERM 4 Meter Out for 100 A movement analog meter proportional to DC bus current
TB1 TERM 5 Control circuit common
TB2 TERM 1 Normally open contact energized when “REGEN ACTIVE”
TB2 TERM 2 Normally close contact energized when “REGEN ACTIVE”
TB2 TERM 3 Form “C” contact common
Figure 4
Main Control Board Terminal Block Layout
Table 5
Terminal Blocks Description for Control Board

AC REGEN 15
LED DESCRIPTIONS
Regen Active LED
This LED indicates when the AC Regen is active
Under-voltage LED
The under-voltage LED becomes lit when the DC
bus voltage or AC line voltage drop below the
minimum level. This fault is automatically cleared
after the under-voltage condition disappears and the
voltages stabilize.
Over-voltage LED
The over-voltage LED becomes lit when the DC bus
voltage or AC line voltage exceed the maximum
level. This fault is automatically cleared after the
over-voltage condition disappears and the voltages
stabilize.
Phase-loss LED
The phase-loss LED becomes lit when a phase-loss
condition is detected or the AC line voltage drops
below the minimum value. This fault is
automatically cleared after the AC line voltage and
phase stabilize.
Current Limit LED
This LED is lit whenever the DC current is over the
rated level.
Over-temperature
The over-temperature LED becomes lit when the
heatsink temperature exceeds the maximum level.
The first fault is automatically cleared after the
temperature drops to an acceptable level. If a
second fault occurs within a minute, the fault is
latched and clearing it requires a Regen reset.
Over-current LED
This fault is latched and clearing it requires a Regen
reset after a 60 second timeout period.
SMPS LED
The SMPS LED becomes lit when the control supply
drops below normal. The first fault is automatically
cleared after the control power supply stabilizes. If a
second fault occurs within a minute, the fault is
latched and clearing it requires a Regen reset.
LEDs: at Start and Reset
* While the AC Regen is detecting the line frequency
all LEDs except the Regen Active LED will be lit.
* If the
AC Regen reset line is held active the drive
will rapidly flash (every 100msec) all LEDs (except
LED 1) to indicate that it is waiting for the reset
line to be released.
LED 1
LED1 becomes lit when there is charge at the DC
bus -Regen bus or drive bus. To avoid a hazard of
electric shock, after the input and control
power is removed from the
AC REGEN and the
drive connected to it, wait five (5) minutes for
bus capacitors to fully discharge.
Kernel LED
The flashing Kernel LED is the microcontroller
"heartbeat" indicating the CPU is operating properly.
SIZING THE AC REGEN
The following calculations can be used to size the
AC REGEN.
Step 1: Determine the Total Inertia
wk wk [wk L(GR) ]
2TM2 2
  
2 in (lb-ft2)
wk M
2Motor inertia in (lb-ft2)
wk L
2Load inertia in (lb-ft2)
GR
Speed reduction ratio: Output RPM
Input RPM
Step 2: Determine the Required Braking
Torque
TQ wk N N
t
B
T
d
 

22 1
308
[ ] in (lb-ft)
wk T
2Total inertia in (lb-ft2)
N1Motor minimum speed in (RPM)
N2Motor maximum speed in (RPM)
tdMotor deceleration time in (Sec)
Step 3: Determine the Required AC REGEN
HP TQ N
BB
2
5250 in (Hp)
HPBMaximum horsepower at maximum motor speed
Regen DC current = 0.2HPB for 240Vac drives
Regen DC current = 0.1HPB for 480Vac drives
Regen DC current = 8.0HPB for 575Vac drives

AC REGEN 16
AC REGEN POWER CIRCUIT TABLE
WARNING
To avoid an electric shock hazard, after the input and control power is removed from the drive and
the AC Regen, wait five (5) minutes for Bus capacitors to fully discharge (DC Bus capacitors of the
drive and the AC Regen). Verify that the voltage on the bus capacitors has discharged by
measuring the DC bus voltage at the +DC & –DC terminals of the drive. The voltage must be zero.
Fuse Check:
Check all fuses. Do not replace any fuse before performing the following checks. Please note if an on-board
fuse (soldered to the control board) is open, do not attempt to replace it. An open on-board fuse indicates a
damaged board.
Visual Check:
Check all fuses, boards, wire harnesses, connectors, bus bars and enclosure walls for discoloration
Ohmic Check:
Check IGBT personality boards for the following:
- Burnt or discolored resistors R1, R2, & R3 (6 sets per Regen)
- Shorted D1 & D2 using meter set for diode check (6 sets per Regen).
These personality boards are either soldered or screwed on the IGBT’s (power transistors).
+ Lead  Lead Meter setting Reading
L1, L2, L3 VC+ @ PCB Connector P2 DIODE 0.3 - 0.5
VC- @ PCB Connector P2 L1, L2, L3 DIODE 0.3 - 0.5
DC+ @ User Connection VC+ @ Connector P2 DIODE 0.3 - 0.5
VC- @ PCB Connector P2 DC- @ User Connection DIODE 0.3 - 0.5
VC+ @ Connector P2 DC+ @ User Connection DIODE OL
DC- @ User Connection VC- @ PCB Connector P2 DIODE OL
VC+ @ PCB Connector P2 L1, L2, L3 DIODE OL
L1, L2, L3 VC- @ PCB Connector P2 DIODE OL
L1, L2, L3 CHASSIS GND 200k ohms OL
DC+ @ User Connection CHASSIS GND 200k ohms OL
DC- @ User Connection CHASSIS GND 200k ohms OL
VC+ @ PCB Connector P2 CHASSIS GND 200k ohms OL
VC- @ PCB Connector P2 CHASSIS GND 200k ohms OL

WARRANTY
US Drives, Inc. warrants the equipment described in this manual for thirty-six (36) months from
the day of purchase, not to exceed forty (40) months from date of manufacture. US Drives
further warrants that such goods are free of defects in materials and workmanship.
If the goods fail to perform to US Drives published specifications, then the Buyer must contact
US Drives to obtain a Material Return Authorization (MRA), prepare the goods for shipment,
and return the goods to US Drives for repair or replacement at US Drives Option. The buyer
will bear all costs of transportation to and from US Drives factory, risk of loss for goods not at
US Drives factory, and any cost required to remove or prepare the goods for shipment to US
Drives factory and to reinstall equipment subsequent to repair.
In no event and under no circumstances shall the manufacturer be liable for: (a) damages and
failures due to improper use or installation; (b) damage in shipment; (c) damage to abnormal
conditions of temperature, dust, or corrosives, or failures due to operation above rated
capacities, whether intentional or unintentional; (d) non-authorized service, repair, modification,
transportation or installation. Nor shall the manufacturer ever be liable for consequential or
incidental damages including any lost profits or lost savings.
There are no other warranties, expressed or implied, which extend beyond that described
herein. The warranty set forth is exclusive and no other warranty, whether written or oral, is
expressed or implied. US Drives specifically disclaims the implied warranties of
merchantability and fitness for a particular purpose.
The warranty is effective only if a written notification of any claim under this warranty is
received by US Drives at the address indicated below within thirty (30) days of recognition of
defect by buyer.
US Drives reserves the right to make changes and improvements in its goods without incurring
any obligation to similarly alter goods previously purchased. US Drives neither assumes nor
authorizes any representative or any other person to assume for US Drives any other liability in
connection with the sale or any shipment of its goods.
US DRIVES INC.
2221 Niagara Falls Boulevard
P.O. Box 281
Niagara Falls, NY 14304-0281
Tel: [phone] Fax: [phone]
Visit us at www.usdrivesinc.com

Data Subject to Change Without Notice
RGIM091919 Printed in U.S.A.
"THE HIGH HORSEPOWER DESIGN EXPERTS"
US D
rives
,
Inc.
2221 Niagara Falls Boulevard
P.O. Box 281
Niagara Falls, NY 14304-0281
Tel: [phone] Fax: [phone]
Visit us at www.usdrivesinc.com
Products Designed and Manufactured
In The United States of America