Minarik RG501A User Manual

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User’s Manual
RG501A/RG511A
Cased, Regenerative, Variable Speed DC Drives
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Page II
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.
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m Safety 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.
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Contents
Introduction
1
Specifications
2
Dimensions
3
Regenerative Drives
4
Installation
5
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Field fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Cage-clamp terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Field output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Limit switch connections (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Remote pushbuttons (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Slide switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Mode select switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Operation
12
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Jogging the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Limit switch operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Calibration
17
Power board trimpots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
MIN SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
MAX SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
FWD ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
REV ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
IR COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
FWD TQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
REV TQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
DB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Logic board trimpots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
FWD JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
REV JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
DWELL TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
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Troubleshooting
24
Block Diagram
28
Prewired Connections
29
Replacement Parts
30
Cerificate of Compliance
31
Limited Warranty
inside back cover
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Illustrations
Fig. Description
Page
1. RG501A and RG511A Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2. Four-Quadrant Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3. Line and Field Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4. Cage-clamp terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
5. Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
6. Limit switch connections (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
7. Remote pushbuttons (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
8. Slide switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
9. Mode select switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
10. Typical FWD TQ, REV TQ and IR COMP Settings for RG501A . . . . . . . . . . . . . . .19
11. Typical FWD TQ, REV TQ and IR COMP Settings for RG511A . . . . . . . . . . . . . . .20
12. Deadband Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
13. Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
14. Prewired Connections (Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
17. Prewired Connections (Signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
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Tables
Fig. Description
Page
1. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4. AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
5. Armature Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
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1
Specifications
Model
RG501A
RG511A
Max.
Armature
Current
(Amps DC)
10.0
3.0
HP Range
with 115 VAC
Applied
1/4–1
1/20–1/8
HP Range
with 230 VAC
Applied
1/2–2
1/10–1/4
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)
Maximum Field Current
1 ADC
Acceleration Time Range (with no load)
0.5–15 seconds
Deceleration Time Range (with no load)
0.5–15 seconds
Analog Input Voltage Range (isolated; RB1 to S2)
–10 to +10 VDC
Input Impedance (RB1 to S2)
32K ohms
Load Regulation
with Armature Feedback
1% of base speed or better
with Tachogenerator Feedback
0.1% of base speed
Dwell Time
0.1 – 1 second (0.1 second increments)
Vibration
0.5G max. (0–50 Hz)
0.1G max. (>50 Hz)
Ambient Temperature Range
10°C–40°C
Weight
8.3 lb
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Dimensions
Figure 1. RG501A and RG511A Dimensions
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3
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 2).
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, or inhibit plugs. They can also control an overhauling load
and decelerate a load faster than it would take to coast to a lower speed.
Figure 2. Four Quadrant Operation
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Installation
Mounting
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. 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 to the 0 (OFF) position before applying the AC
line voltage.
Wiring
Use 14 AWG wire for AC line voltage (L1 and L2) and motor armature
(A1 and A2) wiring. Use 16 AWG wire for motor field (F1 and F2) and
tachogenerator (T1 and T2) wiring.
(continued)
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Installation
5
Use shielded cable if wires are longer than 12 inches (30 cm) to avoid
picking up unwanted electrical noise.
It may be necessary to earth ground the shielded cable. If noise is
produced by devices other than the drive, ground the shield at the 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.
m Do not bundle logic wires with power carrying wires that can cause
erratic operation. Keep logic wires in a conduit separated by at least 2
inches from power carrying wires. Do not allow logic wires to travel in
parallel to power carrying wires for more than 1 inch.
m Line fusing
RG501A and RG511A drives have line fuses preinstalled to fuseholders
FU501 and FU502 (see Figure 3 for location). Factory installed line fuses
are rated for maximum rated horsepower. Resize line fuses if a lower rated
horsepower motor is used. Table 1 lists the recommended line fuse sizes.
Use fast acting fuses rated for 250 VAC or higher, and approximately
150% of the maximum armature current.
Table 1. Recommended Line Fuse Sizes
90 VDC Motor
180 VDC Motor
Horsepower
Horsepower
1/20
1/10
1/15
1/8
1/8
1/4
1/6
1/3
1/4
1/2
1/3
3/4
1/2
1
3/4
1 1/2
1
2
Max. DC Armature
Current (amps)
0.5
0.8
1.5
1.7
2.6
3.5
5.0
7.6
10
AC Line Fuse
Size (amps)
3
3
5
5
8
8
10
15
20
Minarik Corporation offers two fuse kits: part number 050–0069 (3–8A
Fuse Kit) and 050–0073 (5–20A Fuse Kit). Both fuse kits include a 1/2A
pico fuse (part number 050–0074) which protects the transformer and
logic.
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Installation
Field fusing
To protect the motor field of shunt wound motors, all RG501A and
RG511A drives have 1.5A 3AG field fuses installed to fuseholder FU503
(see Figure 3). If this fuse needs to be replaced, use a fuse of the same
rating.
Line and Field Fuses
Figure 3. Line and Field Fuses
Cage-clamp terminals
RG Series drive connections are made to cage-clamp terminals. To insert a
wire into a terminal, see Figure 4.
1. Press down on the lever arm using a
small screwdriver.
2. Insert wire into the wire clamp.
3. Release the lever arm to clamp wire.
Figure 4. Cage-Clamp Terminal
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Installation
Connections
Prewired
Figure 5. Connections
Assumptions: Minarik® drives supply motor voltage from the A1
and A2 terminals. It is assumed throughout this manual that, when A1
is positive with respect to A2, the driven motor will rotate clockwise
(CW) while looking at the output shaft protruding from the front of
the motor. If the opposite is desired, simply reverse the wiring of A1
and A2 with each other.
m Minarik® assumes that the user has selected proper linebalancing and/or power factor correction circuitry.
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8
Installation
Field output
The field output is for shunt wound motors only. Do not make any
connections to the field output when using a permanent magnet motor.
See Table 2 for field output connections.
Table 2. Field Output Connections
Line Voltage
Approximate Field
(VAC)
Voltage (VDC)
115
50
115
100
230
100
230
200
Field
Connections
F1 and L1
F1 and F2
F1 and L1
F1 and F2
Limit switch connections (optional)
All connections to the logic
board are prewired (see prewired
connections on page 29). If your
application requires the use of limit
switches, connect the limit switches
Figure 6. Optional limit switch
to the logic board as shown in
connections
Figure 6. If only the forward limit
switch is used, remove the reverse limit switch and jumper terminal 21 to
22. If only the reverse limit switch is used, remove the forward limit
switch and jumper terminal 20 to 22.
Remote pushbuttons
(optional)
Add external jog, stop, reverse
and forward pushbuttons to control
the drive from a remote location.
Connect normally open pushbuttons
to top board terminals 15 through 19
(see Figure 7). Case pushbuttons
Figure 7. Optional remote pushbutton
may still be used if external
connections
pushbuttons are connected.
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9
Installation
Slide switches
Set all slide switches to their proper setting before applying power (see
Figure 8 ).
Feedback Switch
Set to ARM for armature feedback,
or TACH for tachogenerator feedback.
Armature Voltage Switch
Set to 90 for 90 VDC motor, or
180 for 180 VDC motor.
Line Voltage Switches
Set to 115 for 115 VAC line voltage, or
230 for 230 VAC line voltage.
Figure 8. Slide Switches
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Installation
Mode select switches
Mode select switches, located on the logic board (see Figure 9), are preset
with switch 1 OFF and switch 2 ON. This allows you to operate the drive
without the use of limit switches. Change mode select switch settings
when power is off. Make sure that terminals 20, 21, and 22 are jumpered if
limit switches are not used. If limit switches are used, set the mode select
switches to one of the four operating modes:
Mode 1 (1 and 2 OFF) – Half cycle between forward and
reverse limit switches.
Mode 2 (1 ON and 2 OFF) – Single cycle between forward
and reverse limit switches.
Mode 3 (1 OFF and 2 ON) – Continuous cycle between
forward and reverse limit switches.
Mode 4 (1 and 2 ON) – Single cycle with one limit switch.
See page 14 for more information on limit switch operating modes.
Mode Select Switches
Figure 9. Mode Select Switches
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Operation
m Before applying power
• Verify that no conductive material is present on the printed circuit
board.
• Set all switches to their proper settings.
• Verify that the AC supply is properly balanced.
Startup
1. Set the power switch to 0 (off); set forward and reverse speed adjust
potentiometers to 0; set FWD JOG and REV JOG trimpots to 50%
(12 o’clock).
2. Apply AC line voltage.
3. Set the power switch to I (on). The LED above STOP is lit.
3. To rotate the motor in the forward direction:
a. Press FWD . The LED above it lights.
b. Set the forward speed adjust potentiometer until the motor rotates
at the desired forward speed.
To rotate the motor in the reverse direction:
a. Press REV . The LED above it lights.
b. Set the reverse speed adjust potentiometer until the motor rotates at
the desired reverse speed.
5. To switch the direction of motor rotation, press the pushbutton of the
opposite direction.
6. Press STOP to stop the motor.
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12
Operation
Jogging the motor
The RG501A and RG511A has a jog option, allowing you to jog the
motor in the forward or reverse direction as long as the forward or reverse
pushbutton is pressed. The drive can be switched to the jog mode while the
motor is stopped, or is running in either the forward or reverse direction.
To jog the motor:
1. Press
JOG
to enter the jog mode.
2. To jog the motor in the forward direction:
a. Press and hold the FWD pushbutton. The motor jogs in
the forward direction. The motor speed is set by the FWD JOG
trimpot.
b. Release FWD to stop the motor.
To jog the motor in the reverse direction:
a. Press and hold the REV pushbutton. The motor jogs in
the reverse direction. The motor speed is set by the REV JOG
trimpot.
b. Release REV to stop the motor.
3. To exit the jog mode, press STOP .
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Operation
Limit switch operating modes
The following is a description of the four limit switch operating modes.
Mode 1 – Half cycle between forward and reverse limit switches
1. Press the forward pushbutton for
forward motor rotation.
2. Motor rotates in the forward direction
until the forward limit switch opens.
Press FWD to go forward.
Reverse
Limit
Switch
Forward
Limit
Switch
Forward Direction
3. The motor stops when the forward
limit switch opens.
STOP
4. Press the reverse pushbutton for
reverse motor rotation
Press
5. Motor rotates in the reverse direction
until the reverse limit switch opens.
REV
to go reverse.
Reverse Direction
6. The motor stops when the reverse
limit switch opens. Return to step 1
to repeat the process
STOP
1. Press the forward pushbutton for
forward motor rotation.
Press FWD to go forward.
2. Motor rotates in the forward
direction until the forward limit
switch opens.
Reverse
Limit
Switch
Forward Direction
3. The motor stops and dwells when the
forward limit switch opens. Set the
dwell time by calibrating the DWELL
TIME trimpot (see page 23).
STOP
AND
DWELL
4. Motor rotates in the reverse
direction until the reverse limit
switch opens.
5. The motor stops when the reverse
limit switch opens. Return to step 1
to repeat the process.
Forward
Limit
Switch
Reverse Direction
STOP
• Single cycle automatically returns travel to the reverse limit
switch location.
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14
Operation
Mode 3 – Continuous cycle between forward and reverse limit switches
1. Press the forward pushbutton for
forward motor rotation.
2. Motor rotates in the forward
direction until the forward limit
switch opens.
Press FWD to go forward.
Reverse
Limit
Switch
Forward Direction
3. The motor stops and dwells when
the forward limit switch opens.
Set the dwell time by calibrating
the DWELL TIME trimpot (see
page 23).
STOP
AND
DWELL
4. Motor rotates in the reverse
direction until the reverse limit
switch opens.
5. The motor stops and dwells
when the reverse limit switch
opens. The process repeats
steps 2-5 until you press the
STOP pushbutton.
Forward
Limit
Switch
Reverse Direction
STOP
AND
DWELL
Mode 4 – Single cycle with one limit switch
1. Press the forward pushbutton for
forward motor rotation.
Press FWD to go forward,
OR
OR
Press the reverse pushbutton for
reverse motor rotation.
Press
REV
to go reverse.
Limit Switch
2. Motor rotates until the limit
switch opens.
3. The motor stops when the limit
switch is open. Return to step 1 to
restart the motor.
STOP
Note:
For all operating modes, press the STOP pushbutton to stop a rotating
motor before a limit switch is activated. Resume operation
by pressing the FORWARD or REVERSE pushbuttons.
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Operation
15
m Warnings
Regenerative braking (by pressing the STOP pushbutton) is recommended
for frequent stops. Do not use this method for emergency stopping. It may
not stop a drive that is malfunctioning. Removing AC line power (both
L1 and L2) is the only acceptable method for emergency stopping.
Frequent regenerative braking produces high torque. This may cause
damage to motors, especially gearmotors, that are not properly sized for
the application.
If 230 VAC line voltage is used, it must be balanced. Contact your local
distributor for power factor correction circuitry and line balancing circuitry.
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16
Calibration
Each drive is factory calibrated to its maximum horsepower rating.
Readjust the calibration trimpot settings to accommodate lower
horsepower motors.
All adjustments increase with clockwise (CW) rotation, and decrease with
counterclockwise CCW rotation. Use a non-metallic screwdriver for
calibration. Each trimpot is identified on the printed circuit board.
Power board trimpots
MIN SPD
MIN SPD may be calibrated if the CCW side of the speed adjust
potentiometer is connected to S0 (S0 is in series with the MIN SPD
trimpot). Since the forward and reverse speed adjust potentiometers are
not connected to S0, MIN SPD cannot be calibrated.
MAX SPD
The MAX SPD trimpot setting determines the motor speed when the
forward (or reverse) speed adjust potentiometer is turned full CW. It is
factory set for maximum rated speed.
To calibrate MAX SPD:
1. Set the MAX SPD trimpot full CCW.
2. Press FWD (or REV ).
3. Turn the forward (or reverse) speed adjust potentiometer full CW.
4. Adjust the MAX SPD trimpot until the desired maximum motor speed
is reached.
The calibrated maximum speed is the same for both forward and reverse
directions.
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Calibration
17
FWD ACC
The FWD ACC trimpot setting determines the time the motor takes to
ramp to either a higher speed in the forward direction or a lower speed in
the reverse direction, within the limits of available torque. FWD ACC is
factory set for its fastest forward acceleration time.
Turn the FWD ACC trimpot CW to increase the forward acceleration
time and reverse deceleration time, and CCW to decrease the forward
acceleration time and reverse deceleration time.
REV ACC
The REV ACC trimpot setting determines the time the motor takes to
ramp to either a higher speed in the reverse direction or a lower speed in
the forward direction, within the limits of available torque. REV ACC is
factory set for its fastest reverse acceleration time.
Turn the REV ACC trimpot CW to increase the reverse acceleration
time and forward deceleration time, and CCW to decrease the reverse
acceleration time and forward deceleration time.
IR COMP
The IR COMP trimpot setting determines the degree to which motor
speed is held constant as the motor load changes. It is factory set for
optimum motor regulation.
To calibrate IR COMP (exact calibration):
1. With the motor rotating in the forward direction, set the forward speed
adjust potentiometer until the motor runs at midspeed (for example,
900 RPM for an 1800 RPM motor).
2. Load the motor armature to its full load armature current rating. The
motor should slow down.
3. While keeping the load on the motor, rotate the IR COMP trimpot until
the motor runs at the speed measured in step 1.
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18
Calibration
Approximate calibration:
If the motor does not maintain set speed as the load changes,
gradually rotate the IR COMP trimpot CW. If the motor oscillates
(overcompensation), the IR COMP trimpot may be set too high (CW).
Turn the IR COMP trimpot CCW to stabilize the motor speed.
See Figures 10 and 11 for recommended IR COMP trimpot settings.
FWD TQ
The FWD TQ setting determines the maximum torque for accelerating and
driving the motor in the forward direction. It also sets the maximum torque
for decelerating the motor from the reverse direction. FWD TQ is factory
set at 120% of rated motor current.
To recalibrate FWD TQ, refer to the recommended FWD TQ settings on
Figures 10 and 11, or recalibrate using the following procedure:
1. With the power disconnected from the drive, connect a DC ammeter in
series with the armature.
2. Set the FWD TQ trimpot to minimum (full CCW).
3. Lock the motor armature. Be sure that the motor is firmly mounted.
4. Connect power to the drive. The motor should remain stopped.
5. Press FWD .
6. Set the forward speed adjust potentiometer for maximum forward speed.
7. Adjust the FWD TQ trimpot CW until the armature current is 120% of
motor rated current.
8. Set the forward speed adjust potentiometer to minimum and remove the
stall from the motor.
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Calibration
19
REV TQ
The REV TQ trimpot setting determines the maximum torque for
accelerating and driving the motor in the reverse direction. It also sets the
maximum torque for decelerating the motor from the forward direction.
REV TQ is factory set at 120% of rated motor current.
To recalibrate REV TQ, refer to the recommended REV TQ settings on
Figures 10 and 11, or recalibrate using the following procedure:
1. With the power disconnected from the drive, connect a DC ammeter in
series with the armature.
2. Set the REV TQ trimpot to minimum (full CCW).
3. Lock the motor armature. Be sure that the motor is firmly mounted.
4. Connect power to the drive. The motor should remain stopped.
5. Press REV .
5. Set the reverse speed adjust potentiometer for maximum reverse speed.
6. Adjust the REV TQ trimpot CW until the armature current is 120% of
motor rated current.
7. Set the reverse speed adjust potentiometer to minimum and remove the
stall from the motor.
Figure 10. Recommended FWD TQ, REV TQ, and IR COMP Settings
for RG501A (actual settings may vary with each application)
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20
Calibration
Figure 11. Recommended FWD TQ, REV TQ, and IR COMP Settings
for RG511A
(actual settings may vary with each application)
DB
The deadband trimpot setting determines the time that will elapse between
the application of current in one direction before current is applied in the
opposite direction. It also affects the resistance that a motor has to changes
in shaft position at zero speed by applying AC voltage to the motor
armature.
Deadband is factory calibrated to approximately the 3 o’clock position
for 60 Hz AC line operation. Recalibrate the deadband to the 9 o’clock
position for 50 Hz AC line operation. If you hear motor noise (a humming
or buzzing sound), the deadband might be set too high. Turn the deadband
trimpot CCW until the motor noise ceases. See Figure 12 for
recommended deadband settings.
Figure 12. Deadband Settings
m Warning Do not turn DB past the 60 HZ setting. This could cause
shoot thru, which may blow fuses and cause the drive to fail.
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Calibration
21
TACH (for use with tachogenerator feedback only)
Calibrate the TACH trimpot setting only when a tachogenerator is used.
The TACH setting, like the IR COMP setting, determines the degree to
which motor speed is held constant as the motor load changes.
To calibrate the TACH:
1. Connect the tachogenerator to T1 and T2. The polarity is “+” for T1 and
“–” for T2 when the motor is running in the forward direction.
2. Set switch 504 (SW504) to ARM for armature feedback.
3. Set the power switch to I (on).
4. Press FWD .
3. Set the forward speed adjust potentiometer full CW. Measure the
armature voltage across A1 and A2 using a voltmeter.
4. Set the speed adjust potentiometer to 0 (zero speed).
5. Set SW504 to TACH for tachogenerator feedback.
6. Set the IR COMP trimpot full CCW.
7. Set the TACH trimpot full CW.
8. Set the speed adjust potentiometer full CW.
9. Adjust the TACH trimpot until the armature voltage is the same value as
the voltage measured in step 3.
Check that the tachogenerator is properly calibrated. The motor should run
at the same set speed when SW504 is set to either armature or
tachogenerator feedback.
Logic board trimpots
FWD JOG
The FWD JOG trimpot setting determines the motor speed when it rotates
in the forward direction in the jog mode. To calibrate FWD JOG:
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22
Calibration
1. Press
JOG .
2. Press and hold the FWD pushbutton. The motor jogs in
the forward direction.
3. Adjust the FWD JOG trimpot until the motor rotates at the desired
forward jog speed.
4. Release FWD to stop the motor.
REV JOG
The REV JOG trimpot setting determines the motor speed when it rotates
in the reverse direction in the jog mode. To calibrate REV JOG:
1. Press
JOG .
2. Press and hold the REV pushbutton. The motor jogs in
the reverse direction.
3. Adjust the REV JOG trimpot until the motor rotates at the desired
reverse jog speed.
4. Release REV to stop the motor.
DWELL TIME
The DWELL TIME trimpot setting determines the length of time the
motor stops before rotating in the opposite direction. DWELL TIME only
works when the drive is set for Mode 2 and Mode 3 (see page 14 for limit
switch operating modes).
There are 10 DWELL TIME settings (0 thru 9). Set the DWELL TIME
to 0 (the factory setting) for 0.1 second delay. Increasing the setting one
increment higher adds 0.1 second to the dwell time. Set the DWELL TIME
trimpot to 9 for approximately 1 second delay.
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23
Troubleshooting
m Warning
c Dangerous voltages exist on the drive when it is powered. When possible,
disconnect the drive while troubleshooting. High voltages can cause
serious or fatal injury.
Check the following steps before proceeding:
1. The AC line voltage must be balanced, and match the voltage on the
drive nameplate.
2. Check that all switches are set to the correct positions.
3. The deadband (DB) trimpot must be set approximately at the 3 o’clock
position for 60 Hz AC line frequency or at 9 o’clock for 50 Hz AC line
frequency.
4. The motor must be rated for the drive’s rated armature (all motors) and
field outputs (shunt wound motors only).
5. Do not make any connections to F1 and F2 if using a permanent
magnet motor.
6. Terminal block connections should be consistent with the connections
shown in this manual.
7. Check that line fuses FU501 and FU502 are properly sized and not
blown.
8. Check that field fuse FU503 is 1.5 A and not blown.
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24
Troubleshooting
Problem
Possible
Causes
Suggested
Solutions
Field fuse blows
1. Field fuse is the wrong
size.
1. Verify that the fuse
is 1.5 A.
2. Motor field is shorted
to ground.
2. Check if the motor
field is shorted to ground.
Replace motor if
necessary.
3. F1 is shorted to F2.
3. Check that F1 and F2
are not shorted together.
4. Motor cable is shorted
to ground.
4. Check that the motor
cable is not shorted to
ground. Replace cable if
necessary.
5. Motor field leads are
reversed with motor
armature.
5. Wire motor armature to
A1 and A2; wire motor
field to F1 and F2.
1. Line fuses are the
wrong size.
1. Check that line fuses
are properly sized.
2. Motor cable or armature
is shorted to ground.
2. Check motor cable and
armature for shorts.
3. Nuisance tripping
caused by a combination
of ambient conditions and
high-current spikes
(i.e. reversing).
3. Add a blower to cool
the drive components;
decrease FWD TQ and
REV TQ settings; check
wiring to be sure noise is
reduced or eliminated.
4. Field circuit is open.
4. Send in drive to
Minarik repair department.
1. MAX SPD setting is
too high.
1. Recalibrate MAX SPD.
2. Motor field connections
are loose (shunt wound
motors only).
2. Check motor field
connections.
Line fuse blows
Motor runs too fast at
maximum speed setting
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25
Troubleshooting
Problem
Possible
Causes
Suggested
Solutions
Line fuse does not blow,
but the motor does not run
when the forward or
reverse pushbutton is
pressed
1. Forward or reverse
speed adjust potentiometer
is set to zero speed.
1. Increase the forward or
reverse speed adjust
potentiometer setting
2. Forward or reverse
speed adjust potentiometer
is not connected to drive
input properly;
connections are open.
2. Check connections
to input. Verify that
connections are not open.
3. Middle and right
INH-RUN terminals are
not jumpered.
3. Jumper middle and
right INH-RUN terminals.
4. INHIBIT terminals are
jumpered.
4. Remove jumper
from INHIBIT terminal.
5. S2 is shorted to S0.
5. Remove short.
6. Drive is in current limit.
6. Verify if motor is
jammed. Increase FWD
TQ or REV TQ setting if
they are set too low.
7. Drive is not receiving
AC line voltage.
7. Apply AC line voltage
to L1 and L2.
8. Motor is not connected.
8. Connect motor to A1
and A2.
9. Touch panel, logic
board, or power board
connections might be
loose.
9. Check all connections.
1. Switches set incorrectly.
1. Verify all switch
settings.
2. MAX SPD is not
calibrated.
2. Calibrate MAX SPD.
3. Motor field not properly
connected (shunt wound
motors only)
3. Verify motor field
connections.
Motor runs too slow or too
fast
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26
Troubleshooting
Problem
Possible
Causes
Suggested
Solutions
Motor will not reach the
desired speed
1. MAX SPD setting is
too low.
1. Increase MAX SPD
setting.
2. IR COMP setting is
too low.
2. Increase the IR COMP
setting.
3. Motor is overloaded.
3. Check motor load.
Resize the motor if
necessary.
1. IR COMP is set too
high.
1. Adjust the IR COMP
setting slightly CCW until
the motor speed stabilizes.
2. Motor “bouncing” in
and out of torque limit.
2. Make sure motor is not
undersized for load; adjust
FWD TQ and
REV TQ trimpots.
Motor does not reverse
Touch panel, logic board,
or power board
connections might be
loose.
Check all connections.
Motor makes a humming
or buzzing noise
Deadband setting is
too high.
Turn deadband (DB)
trimpot CCW until the
noise stops.
FWD or REV JOG speed
is too slow or too fast
FWD or REV JOG speed
not calibrated.
Calibrate FWD JOG and
REV JOG trimpots (see
Calibration section).
Motor pulsates or surges
under load
For additional assistance, contact your local Minarik® Distributor, or the
factory direct: phone (818) 502-1528; fax (818) 502-0716.
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27
Figure 13. RG501A and RG511A Block Diagram
Block Diagram
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28
Prewired Connections
Figure 14. Prewired Connections to L1, L2 (115) and L2 (230)
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Prewired Connections
Figure 15. Touch Panel, Logic Board, and Power Board Connections
29
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30
Replacement Parts
Replacement parts are available from Minarik Corporation and its distributors
for this drive series.
Table 3. Replacement Parts
Model No.
RG501A
Symbol
R501
SCR501-508
T505
Description
0.01Ω, 5 W Resistor
800 V, 25 A SCR
3FD-436 Transformer
20 A, 3AB Line Fuse
1.5 A, 3AG Field Fuse
10KΩ, 1/2 W Potentiometer
Potentiometer Knob
Case
Power Switch
Toggle Switch Boot
Chassis
Heat Sink
Ribbon Cable
Minarik P/N
032-0129
072-0042
230-0072
050-0019
050-0026
120-0047
140-0013
223-0297
080-0003
155-0078
223-0260
223-0232
134-0037
RG511A
R501
SCR501-508
T505
0.1Ω, 5 W Resistor
800 V, 25 A SCR
3FD-436 Transformer
8 A, 3AB Line Fuse
10KΩ, 1/2 W Potentiometer
1.5 A, 3AG Field Fuse
Potentiometer Knob
Case
Power Switch
Toggle Switch Boot
Chassis
Heat Sink
Ribbon Cable
032-0100
072-0042
230-0072
050-0023
120-0047
050-0026
140-0013
223-0297
080-0003
155-0078
223-0260
223-0232
134-0037
Fuse Kits
F504
3–8A Fuse Kit (with 1/2A pico fuse) 050-0069
5–20A Fuse Kit (with 1/2A pico fuse) 050-0073
1/2A Pico Fuse
050-0074
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31
Certificate of Compliance
Minarik Corporation hereby certifies that its RG501A drive has been
approved to bear the “CE” mark provided the conditions of approval have
been met by the end user.
The RG501A has been tested to the following test specifications:
EN55011:1991 (emissions), and
EN50082-1:1992 (immunity)
Compliance allows the RG501A to bear the CE mark.
The end user, as described herein, falls into one of two categories:
1. The Consumer will deploy a stand-alone unit as an integral, yet external,
portion of the machine being operated.
2. The Original Equipment Manufacturer (OEM) will implement the product
as a component of the machine being manufactured.
AC Line Filters
In addition to EMI/RFI safeguards inherent in the RG501A design, external
filtering is required.
Minarik requires the Corcom® AC line filters listed in Table 4. Use model
5VR1 with drives rated for 3 ADC or below, and model 20VV1 with drives
rated for 10 ADC or below.
Table 4. AC Line Filters
Corcom® Model Number
Rated Current
Inductance
Capacitance
Line to Line
Line to Ground
Discharge Resistor
5VR1
5A
1.032 mH
20VV1
20 A
0.88 mH
0.303 µF
0.011 µF
680 KΩ
0.303 µF
0.011 µF
680 KΩ
Wire the AC line filter within 0.25 meters of the drive. The ground
connection from the filter must be wired to solid earth ground
(resistance less than 500 ohms); not machine ground. This is very
important!
If the end-user is using a CE-approved motor, the correct filter from Table 4
is all that is necessary to meet the EMC directives listed herein.
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32
Armature Filters
If the end-user is not using a CE-approved motor, a filter on the armature
must also be used. See Table 5 for recommended armature filters. Use
model CE04RG with drives rated for 3 ADC or below, and model CE10RG
with drives rated for 10 ADC or below.
Table 5. Armature Filters
Minarik® Model Number
Rated Current
Inductance
Capacitance (C1 and C2)
Discharge Resistor
CE04RG
CE10RG
4A
10 A
1200 mH
0.1 µF @ 400W VDC
680KΩ
Wire the armature filter to the DC output of the drive, as close to
the drive as possible. The ground connection from the filter must
be wired to solid earth ground (resistance less than 500 ohms);
not machine ground. This is very important!
The end user must use the filtration listed in this addendum to comply with
CE. The OEM may choose to provide alternative filtering that encompasses
the Minarik drive and other electronics within the same panel.The OEM
has this liberty because CE is a machinery directive.
Whether or not every component in the OEM’s machinery meets CE, the
OEM must still submit his machine for CE approval. Thus, no component
must necessarily meet CE within the machine, as long as the OEM takes
the necessary steps to guarantee the machine does meet CE. By the same
token, even if every component in the OEM’s machine does meet CE, the
machine will not necessarily meet CE as a machine.
Using CE-approved wiring practices (like proper shielding) and the filters
should assure the drive will meet EN55014 (1993 emissions standard) and
EN50082-1 (1992 immunity standard).
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33
Notes
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Notes
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Page 34
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35
Limited Warranty
A. Warranty - Minarik Corporation (referred to as “the Corporation”) warrants that its
products will be free from defects in workmanship and material for two (2) years from date
of shipment thereof, or 6,000 hours, whichever comes first. Within this warranty period, the
Corporation will repair or replace such products that are: (1) returned to Minarik Corporation,
901 East Thompson Avenue, Glendale, CA 91201-2011 U.S.A.; and, (2) determined by the
Corporation to be defective.
This warranty shall not apply to any product that has been subject to misuse, negligence, or
accident; or misapplied; or repaired by unauthorized persons; or improperly installed. The
Corporation is not responsible for removal, installation, or any other incidental expenses
incurred in shipping the product to and from the repair point.
B. Disclaimer - The provisions of Paragraph A are the Corporation’s sole obligation and
exclude all other warranties of merchantability for use, express or implied. The Corporation
further disclaims any responsibility whatsoever to the customer or to any other person for
injury to the person or damage or loss of property of value caused by any product that has
been subject to misuse, negligence, or accident, or misapplied or modified by unauthorized
persons or improperly installed.
C. Limitations of Liability - In the event of any claim for breech of any of the Corporation’s
obligations, whether express or implied, and particularly of any other claim or breech of
warranty contained in Paragraph A, or of any other warranties, express or implied, or claim
of liability that might, despite Paragraph B, be decided against the Corporation by lawful
authority, the Corporation shall under no circumstances be liable for any consequential
damages, losses, or expense arising in connection with the use of, or inability to use, the
Corporation’s product for any purpose whatsoever.
An adjustment made under warranty does not void the warranty, nor does it imply an
extension of the original two (2) year or 6,000 hour warranty period. Products serviced
and/or parts replaced on a no-charge basis during the warranty period carry the unexpired
portion of the original warranty only.
If for any reason any of the foregoing provisions shall be ineffective, the Corporation’s
liability for damages arising out of its manufacture or sale of equipment, or use thereof,
whether such liability is based on warranty, contract, negligence, strict liability in tort, or
otherwise, shall not in any event exceed the full purchase price of such equipment.
Any action against the Corporation based upon any liability or obligation arising hereunder
or under any law applicable to the sale of equipment or the use thereof, must be
commenced within one year after the cause of such action arises.
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Page 36
Other drives from Minarik Corporation:
RGT Series
RG5500U
MMRG Series
BOSS Series
901 East Thompson Avenue
Glendale, California 91201-2011
Phone: (818) 502-1528
Fax: (818) 502-0716
www.minarikcorp.com
Document number 250–0234, Revision 1
Printed in the U.S.A – 1/98
$11.00 North America – $12.00 Outside North America