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American Control Electronics Minarik DRIVES RG500 Series, User Manual, Page: 17 / 72

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American Control Electronics Minarik DRIVES RG500 Series User Manual Download Page 17

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 fire, explosion, 

or serious injury.  Make sure you read and understand the Safety 

Precautions on page i before attempting to install this product.

!

WARNING!

Heat Sinking

Chassis

Models  RG500UA  and  RG500UA-PCM  require  an  additional  heat  sink 

when  the  continuous  armature  current  is  above  7  amps.  Use  Minarik 

Drives  heat  sink  kit  part  number  223-0235.  All  other  chassis  drives 

have sufficient heat sinking in their basic configuration. Use a thermally 

conductive heat sink compound (such as Dow Corning® 340 Heat Sink 

Compound) between the chassis and the heat sink surface for optimum 

heat transfer.

All  NEMA  4X  models  come  with  the  heat  sink  already  attached. 

Therefore, all NEMA 4X drives have sufficient heat sinking in their basic 

configuration.

NEMA 4X

Summary of Contents for Minarik DRIVES RG500 Series

Page 1: ...RG500UA RG500UA PCM RG500A RG510UA RG510UA PCM RG510A USER MANUAL w w w m i n a r i k d r i v e s c o m RG500 SERIES An American Control Electronics Brand...

Page 2: ...itted in any form without written permission from American Control Electronics The information and technical data in this document are subject to change without notice American Control Electronics mak...

Page 3: ...I N G S Text in gray boxes denote important safety tips or warnings Please read these instructions carefully before performing any of the procedures contained in this manual It is possible for a drive...

Page 4: ...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 S...

Page 5: ...tart 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 Minim...

Page 6: ...e 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 Potentiomet...

Page 7: ...iometer 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 Conne...

Page 8: ...A 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 D...

Page 9: ...gure 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...

Page 10: ...d faster than coasting to a lower speed Regenerative drives operate in two additional quadrants Quadrant II and Quadrant IV In these quadrants motor torque is in the opposite direction of motor rotati...

Page 11: ...ver 7 amps AC Line Voltage 115 230 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...

Page 12: ...ohms 235 ohms 100 ohms Form Factor 1 37 at base speed Load Regulation with Armature Feedback with Tachogenerator Feedback 1 base speed or better 0 1 base speed Vibration 0 5G maximum 0 50 Hz 0 1G maxi...

Page 13: ...1 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...

Page 14: ...S 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 COM POL REV TP INPUT 2 INPUT 1 COM 15 15...

Page 15: ...0A 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 1...

Page 16: ...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...

Page 17: ...0UA PCM require an additional heat sink when the continuous armature current is above 7 amps Use Minarik Drives heat sink kit part number 223 0235 All other chassis drives have sufficient heat sinking...

Page 18: ...he 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 vertic...

Page 19: ...re 6 Install the circular insulating disk between the panel and the 10K ohm speed adjust potentiometer Twist the speed adjust potentiometer wire to avoid picking up unwanted electrical noise If the sp...

Page 20: ...se 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 t...

Page 21: ...with circuit elements Do not disconnect any of the motor leads from the drive unless power is removed or the drive is disabled Opening any one motor lead while the drive is running may destroy the dr...

Page 22: ...drive end If noise is generated by a device on the drive ground the shield at the end away from the drive Do not ground both ends of the shield If the drive continues to pick up noise after grounding...

Page 23: ...epower If the horsepower rating of the motor being used is less than the maximum horsepower rating of the drive the line fuse may have to be replaced with a lower rated one Fuses should be rated for 2...

Page 24: ...10 15 15 Minarik Drives offers fuse kits See Section 9 Accessories and Replacement Parts for fuse kit part numbers Table 1 Recommended Line Fuse Sizes Table 2 Short Circuit Current Ratings Drive Mode...

Page 25: ...wer switch The switch should be rated at a minimum of 250 volts and 200 of motor current Refer to Figures 11 and 12 on page 24 and 25 For NEMA 4X models the connect the AC line power leads to terminal...

Page 26: ...0 100 200 F1 and L1 F1 and F2 F1 and L1 F1 and F2 Table 3 Field Output Connections The field output is for shunt wound motors only Do not make any connections to F1 and F2 when using a permanent magne...

Page 27: ...ust potentiometer as shown in Figure 7 b For bidirectional operation connect the speed adjust potentiometer as shown in Figure 7 c The motor does not operate when the potentiometer is in the center po...

Page 28: ...tentiometer as shown in Figure 8 b For bidirectional operation connect the speed adjust potentiometer as shown in Figure 8 c The motor does not operate when the potentiometer is in the center position...

Page 29: ...otentiometer can be used to scale the analog input voltage An interface device such as Minarik Drives model PCM4 may be used to scale and isolate an analog input voltage An isolated analog input volta...

Page 30: ...voltage signal of 0 to 25 VDC or less connect the signal reference to terminal 8 INPUT 1 or if using an input voltage signal greater than 0 to 25 VDC connect the signal reference to terminal 9 INPUT 2...

Page 31: ...G Enable Regen Brake and Inhibit Direction Switch For non PCM models refer to Figures 22 and 23 on page 50 For PCM models a single pole single throw switch can be used as a reversal switch Connect the...

Page 32: ...onnect the tachogenerator to terminals T1 and T2 of terminal block TB502 The polarity is positive for T1 and negative for T2 when the motor is running in the forward direction Place SW504 in the TACH...

Page 33: ...07 C506 C510 SW504 SW503 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 A ARMATURE OUTPUT FIELD...

Page 34: ...501 SCR501 MIN SPD FWD TQ REV TQ IR COMP MAX SPD FWD ACC REV ACC DB TACH A ARMATURE OUTPUT FIELD OUTPUT s r o t o m d n u o w t n u h s r o F t u p t u o d l e i f e e S y l n o s n o i t c e n n o c...

Page 35: ...8 C509 C508 C507 C506 C510 SW504 SW503 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 A ARMATURE...

Page 36: ...full voltage and may cause damage to the transformer If the switches are improperly set to a higher voltage position the motor will overspeed which may cause motor damage or result in bodily injury or...

Page 37: ...230 230 115 SW502 L1 L2 FU502 FU501 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 R50...

Page 38: ...location Signal Select SW501 PCM models Figure 16 PCM Select Switches Input Voltage Select SW502 Set the input voltage select switch SW502 to either 115 or 230 to match the AC line voltage See Figure...

Page 39: ...advance the speed adjust potentiometer clockwise CW or increase the input voltage or current signal The motor slowly accelerates as the potentiometer is turned CW or as the input voltage or current si...

Page 40: ...e the speed adjust potentiometer clockwise CW or increase the input voltage signal The motor slowly accelerates as the potentiometer is turned CW or as the input voltage signal is increased Continue u...

Page 41: ...on pages 23 and 24 Frequent starting and stopping can produce high torque This may cause damage to motors especially gearmotors that are not properly sized for the application WARNING All drives autom...

Page 42: ...offers two accessory plug harnesses for connecting to the INHIBIT terminals part number 201 0024 plug with 18 in 46 cm leads and part number 201 0079 plug with 36 in 91 cm leads Regenerative Brake to...

Page 43: ...r to zero speed See Figures 11 12 and 13 on pages 24 25 and 26 The RB1 and RB2 circuit follows the deceleration rate set by the FWD ACC and REV ACC trim pots Open the RB1 and RB2 terminals to accelera...

Page 44: ...ing If the MIN SPD trim pot is set full CCW the motor decelerates to zero speed The REV ACC or FWD ACC trim pot setting determines the rate at which the drive decelerates depending on the direction of...

Page 45: ...ory plug harness for connecting to the INHIBIT RUN terminals part number 201 0197 plug with 18 in 46 cm leads Coast to Zero Speed INHIBIT RUN Figure 19 Inhibit Run Terminal Location and Run Coast Swit...

Page 46: ...te personal protection equipment BE ALERT High voltages can cause serious or fatal injury WARNING RG500 series drives have user adjustable trim pots Each drive is factory calibrated to its maximum cur...

Page 47: ...mum speed Note If using models RG500UA PCM or RG510UA PCM set the MIN SPD to full CCW and the MAX SPD to full CW Use the MIN OUT and MAX SPD trim pots located on the top board for minimum and maximum...

Page 48: ...maximum speed 4 Carefully lock the motor armature Be sure that the motor is firmly mounted 5 Apply line power The motor should be stopped 6 Slowly adjust the FWD TQ trim pot CW until the armature cur...

Page 49: ...maximum speed 4 Carefully lock the motor armature Be sure that the motor is firmly mounted 5 Apply line power The motor should be stopped 6 Slowly adjust the REV TQ trim pot CW until the armature cur...

Page 50: ...at midspeed without load for example 900 RPM for an 1800 RPM motor A handheld tachometer may be used to measure motor speed 3 Load the motor armature to its full load armature current rating The moto...

Page 51: ...MP FWD TQ REV TQ IR COMP FWD TQ REV TQ IR COMP FWD TQ REV TQ IR COMP FWD TQ REV TQ IR COMP FWD TQ REV TQ IR COMP FWD TQ REV TQ IR COMP FWD TQ REV TQ IR COMP FWD TQ REV TQ IR COMP FWD TQ REV TQ IR COMP...

Page 52: ...ACC trim pot CW to increase the foward acceleration time and CCW to decrease the foward acceleration time Reverse Acceleration REV ACC The REV ACC setting determines the time the motor takes to ramp t...

Page 53: ...zero speed It does this by applying an AC voltage to the motor armature The deadband is factory calibrated to approximately 3 4 of a turn position for 60 Hz AC line operation Recalibrate the trim pot...

Page 54: ...ed Measure the armature voltage across A1 and A2 using a voltmeter 4 Set the speed adjust potentiometer or input voltage or current signal to zero speed 5 Set SW504 to TACH for tachogenerator feedback...

Page 55: ...ls 7 COM and 8 INPUT 1 or 9 INPUT 2 OUTmin and OUTmax is the voltage across terminals 1 OUT 1 and 2 OUT 2 that connect to the lower board Calibration Procedure 1 Ensure that switch SW501 on the PCM bo...

Page 56: ...trim pot P503 so that the output voltage is OUTmin 7 Set the analog input signal to INmax 8 Calculate the test point voltage Vtp 9 Adjust the SIGNAL INPUT ADJ trim pot P501 so that the voltage between...

Page 57: ...the motor Figure 22 If a Forward Stop Reverse switch is desired use a single pole three position switch Figure 23 The MIN SPD setting is in effect for either direction Direction Switch S3 S2 S1 S0 CW...

Page 58: ...with a total series resistance of 10K ohms Figure 24 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds Multiple Fixed Speeds R1 R2 R4...

Page 59: ...iometers In Series Replace the speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in series with a total series resistance of 10K ohms Figure 25 shows a...

Page 60: ...speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in parallel with a total parallel resistance of 10K ohms Figure 26 shows the connection of two indep...

Page 61: ...nection of two independent forward and reverse speed adjust potentiometers that can be mounted at two separate operating stations Independent Adjustable Forward and Reverse Speeds S0 S1 S2 S3 CW CW RE...

Page 62: ...e pole normally closed momentary operated pushbutton for the JOG pushbutton Connect the RUN JOG switch and JOG pushbutton to the inhibit terminals as shown in Figure 29 The motor coasts to a stop when...

Page 63: ...to JOG the motor decelerates to zero speed Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation RUN JOG Switch Potentiometer Connection S1 or S3 S2 S0 10K O...

Page 64: ...to monitor the speed of the leader motor Figure 31 The PCM4 isolates the leader motor from the follower drive and outputs a voltage proportional to the leader motor armature voltage The follower driv...

Page 65: ...t H optional 10K Ohms 8 Figure 32 Single Speed Potentiometer Control of Multiple Drives Multipledrivescanbecontrolledwithasinglespeedadjustpotentiometer using a USIM 8 at the input of each drive to pr...

Page 66: ...nect AC line voltage from the drive 2 Check the drive closely for damaged components 3 Check that no conductive or other foreign material has become lodged on the printed circuit board 4 Verify that e...

Page 67: ...or jams See pages 38 and 39 for information on adjusting the FWD TQ and REV TQ trim pots Line fuse does not blow but the motor does not run 1 Speed adjust potentiometer or speed reference voltage is...

Page 68: ...speed 1 MAX SPD setting is too low 1 Increase MAX SPD setting See page 38 2 IR COMP setting is too low 2 Increase IR COMP setting See page 41 3 Torque setting is too low 3 Increase FWD TQ or REV TQ se...

Page 69: ...ector Pot Kit 202 0003 Fuse 1 5 5 Amp Fuse Kit 050 0066 1 8 Amp Fuse Kit with Pico Fuse 050 0068 3 8 Amp Fuse Kit with Pico Fuse 050 0069 5 15 Amp Fuse Kit 050 0071 1 20 Amp Fuse 050 0019 Logic Cards...

Page 70: ...61 RG500 Series Notes...

Page 71: ...s of Liability In the event of any claim for breach of any of Americn Control Electronics s obligations whether expressed or implied and particularly of any other claim or breach of warranty contained...

Page 72: ...www minarikdrives com 14300 DE LA TOUR DRIVE SOUTH BELOIT IL 61080 800 MINARIK 250 0210 Rev 8 An American Control Electronics Brand RG510UA RG510UA PCM RG510A RG500UA RG500UA PCM RG500A...

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