User Manual - Galco Industrial Electronics
Contents
1. 3 m CS 3 Ee Pa 3 70 94 Sl A 2 55 65 8 p ez e Ile T S a 5 orina 11 HEATSINK DIMENSIONS optional 69 x 44x 10 1 d am gt 2 0 19 5 1 96 50 A Lap AU 1 66 42 IE 3 80 97 4 30 109 _ ALL DIMENSIONS IN INCHES MILLIMETERS Figure 3 RG60U PCM RG61U PCM Dimensions 4 Installation Mounting AN Warning Do not install rewire or remove this control with input power applied Doing so may cause fire or serious injury Make sure you have read and understood the Safety Warnings on page i before attempting installation Drive components are sensitive to electrostatic fields Avoid direct contact with the circuit board Hold drive by the chassis only Protect the drive from dirt moisture and accidental contact Provide sufficient room for access to the terminal block and calibration trimpots Mount the drive away from heat sources Operate the drive within the specified ambient operating temperature range Prevent loose connections by avoiding excessive vibration of the drive Mount driv2. NOTE ONLY ONE FEEDBACK DEVICE TE 1 RBI 38 282 31 590 MAGNETIC PICKUP OR OPTICAL ENCODER MAY BE USED AT A TIME Figure 21 RG60U Connections to DLC600 Application Notes 43 FWD REV switch Use a single pole two position switch with a single speed adjust potentiometer to plug reverse the motor Figure 22 18504 5 r T2 2 DOOD 82 P ENABLE TB50 10K OHM SPEED ADJUST POTENTIOMETER n 8 Figure 22 Forward Reverse Switch 44 Application Notes FWD STOP REV switch Use a single pole three position switch with a single speed adjust potentiometer to stop a motor between reversal Figure 23 Set the Switch to the center position to decelerate the motor to a stop ENABLE TB5 10K OHM T J SPEED ADJUST g POTENTIOMETER 3 co INHIBIT n t Figure 23 Forward Stop Reverse Switch Application Notes 45 Independent Adjustable Speeds Connect two speed adjust potentiometers with a single pole two position switch to select between two independent speeds shown in the forward direction Figure 24 The speed adjust potentiometers can be mounted at two separate operating stations Total parallel resistance must
3. 21 Warning Dangerous voltages exist on the drive when it is powered BE ALERT High voltages can cause serious or fatal injury For your safety use personal protective equipment PPE when operating this drive Before applying power 1 Verify that no conductive material is present on the printed circuit board 2 Ensure that all switches and jumpers are properly set 22 Operation Startup and shutdown To start the drive 1 Set the speed adjust potentiometer or reference voltage to zero speed 2 Apply AC line voltage 3 Slowly turn the speed adjust potentiometer clockwise or counterclockwise to rotate the motor in the forward or reverse direction If in a voltage follower mode slowly increase the voltage in either the positive or negative direction to rotate the motor in the forward or reverse direction Continue until the desired speed is reached 4 To decelerate the motor from set speed to a stop reset the speed adjust potentiometer to zero speed or reference voltage to zero To coast the motor from set speed to a stop remove AC line voltage from the drive If the motor or drive does not perform as described disconnect the AC line voltage immediately Refer to the Troubleshooting section for further assistance 23 Starting and Stopping Methods A Warning Decelerating to minimum speed regenerative braking or coasting to a stop is recom
4. 16 Figure 10 Line Voltage Switches bottom board 17 Figure 11 Armature Voltage and Feedback Selector Switch Locations top 18 Figure 12 RG 60U PCM connections and jumper settings 20 Figure 13 RUN STOP Switch 24 Figure 14 INHIBIT ENABLE Terminal TB503 and JP502 27 Figure 15 INHIBIT Settings 28 Figure 16 ENABLE Settings 29 Figure 17 RG60U Calibration Trimpot Locations 31 Figure 18 Deadband Settings 37 Figure 19 Typical FWD TQ REV TQ and IR COMP Trimpot Settings 39 Figure 20 PCM Calibration Trimpot Locations 40 Figure 21 RG60U Connections to DLC600 42 Figure 22 Forward Reverse Switch 43 Figure 23 Forward Stop Reverse Switch 44 Figure 24 Independent Adjustable Speeds Forward Direction 45 Figure 25 Independent Forward and Reverse Speeds 46 Figure 26 Independent Forward and Reverse Speeds with a Forward Stop Reverse Switch 47 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 th
5. 14 Installation Speed adjust potentiometer connections The motor can operate in one direction unidirectional or two directions bidirectional depending on how the speed adjust potentiometer is connected to the drive Connect the speed adjust potentiometer as shown in Figure 8 a page 15 for bidirectional operation The motor does not operate when the wiper is in the center position Turning the wiper clockwise CW from the center position causes the motor to rotate in one direction while turning the wiper counterclockwise CCW causes rotation in the opposite direction Connect the speed adjust potentiometer as shown in Figure 8 b page 15 for unidirectional operation in the forward direction Connect the speed adjust potentiometer as shown in Figure 8 c page 15 for unidirectional operation in the reverse direction Refer to the Application Notes section for additional speed adjust potentiometer connections Installation 15 T2 T1 RB1 RB2 10K OHM ziv REV SPEED POT 15V A 53 52 Y 51 FWD 50 501 a Bidirectional Operation T2 T2 n n RB1 RB1 RB2 10K OHM RB2 SPEED POT 15V 15V 53 52 51 50 10 SPEED b Unidirectional Operation Forward Direction REV cw TB501 15V 15V 53 52 51 50 Unidirectional Operation Reverse Direction Figure 8 Speed Adjust Potentiometer Connections 16 Installation Volta
6. 18 Feedback selector switch 18 Voltage or Current Follower non isolated signal PCM models 19 Polarity reversal switch PCM models 19 Operation ville a es N X RN NR 21 Before applying power 21 Startup and shutdown 22 To start the drive i onere ehe meer 22 Starting and Stopping Methods 23 Automatic restart upon power restoration 23 Decelerate to a stop 24 Coastto a stop iue o E CERT RE ERE 25 Regenerative brake 25 Invert Inhibit and Invert Enable 26 Calibration 30 MINIMUM SPEED MIN 32 MAXIMUM SPEED MAX SPD 32 FORWARD TORQUE FWD 33 REVERSE TORQUE REV 34 IR COMPENSATION IR COMP 35 FORWARD ACCELERATION FWD ACC 36 REVERSE ACCELERATION REV ACC 36 DEADBAND DB 37 TACH GENERATOR 38 RG60U POM isolation card 40 OFFSET RG60U POM isola
7. 50 60 Hz single phase Form Factor 1 37 at base speed Acceleration Time Range 0 5 6 seconds Deceleration Time Range 0 5 6 seconds Analog Input Voltage Range without PCM option signal must be isolated SO to S2 0 to 10 VDC Input Impedance 0 to 2 30 kohms Load Regulation with Armature Feedback with Tachogenerator Feedback 196 base speed 0 196 base speed Vibration 0 5G max 20 50 Hz 0 1G max 50 Hz Ambient Temperature Range 10 55 Weight 1 1 Ib 2 Dimensions gt et Olle cje zi m 3 70 94 n pee eJ 0 19 5 039 4 8 9 2 55 65 Ce Gris L Q lt K 0 80 20 0 71 18 11 i HEATSINK DIMENSIONS optional 6 9 x 44 x 1 0 gt Mp O 1 96 50 0 19 5 el 3 80 97 4 30 109 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 2 RG60U RG61U Dimensions Dimensions 3
8. attempting adjustment The RG60U PCM has a factory set offset to guarantee stability in a stopped motor To calibrate the OFFSET trimpot 1 2 3 Ensure that the input power is turned OFF Set the input signal to zero Set the OFFSET trimpot to the approximate midrange or 50 Note This is a 25 turn potentiometer After setting the trimpot to zero full CCW make 5 full rotations to reach midrange or 50 Apply power and observe the motor If the motor shaft drifts or slowly rotates with no signal applied adjust the OFFSET trimpot until the motor shaft stops The direction and amount of trimpot adjustment depends on the direction of the shaft rotation and connection of the motor leads See Figure 20 on page 40 for OFFSET trimpot location 42 Application Notes Connections to Minarik DLC600 MODEL DLC600 INPUT 115 230 VAC 50 60 HZ 50 mA MINARIK CORPORATION GLENDALE CA 91201 www minarikcorp com G L1 L2 S1 S2 FN IN C INH INHIBIT SWITCH OPEN to RUN CLOSE to INHIBIT 115 LE 230 VAC NU AC VOLTAGE MAGNETIC PICKUP NON POLARIZED SIGNAL COMMON 5 VDC OR 12 VDC OPTICAL ENCODER TB501 ON RG60U
9. it is powered When possible disconnect the voltage input from the drive before adjusting the trimpots If the trimpots must be adjusted with power applied use insulated tools and the appropriate personal protection equipment BE ALERT High voltages can cause serious or fatal injury The RG60U has nine user adjustable trimpots FWD ACC REV ACC MAX SPD IR COMP REV TQ FWD TQ DB MIN SPD and TACH Each drive is factory calibrated to its maximum current rating Readjust the calibration trimpot settings to accommodate lower current rated motors All adjustments increase with clockwise rotation CW and decrease with counterclockwise CCW rotation Use a non metallic screwdriver for calibration Each trimpot is identified on the printed circuit board See Figure 17 page 31 for RG60U calibration trimpot locations Calibration 31 FWD ACC ARMATURE 90 180 FEEDBACK ARM TACH REV ACC ACE MAX SPD Lil 7 0503 5 77 72 INVERT 16501 2 a ZOL IR COMP Coup zi e Lel 3 N REV S REV ME 3 Bp z 4 T m FWD K DB 2 IE 222222 MIN SPD TACH Figure 17 RG60U Calibration Trimpot Locations 32 Calibration MINIMUM SPEED MIN SPD The MIN SPD trimpot setting determines the minimum speed when the speed adjust potentiometer is turned full CCW It is fac
10. power The motor should be stopped 6 Slowly adjust the REV TQ trimpot CW slowly until the armature current is 120 of motor rated armature current 7 Set the speed adjust potentiometer to minimum 8 Remove the power from the drive 9 Unlock the motor shaft 10 Remove the ammeter in series with the motor armature if it is no longer needed and re apply power to the drive Calibration 35 IR COMPENSATION 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 See Figure 19 page 39 for typical IR COMP calibration settings or use the following procedure to recalibrate the IR COMP setting 1 Set the IR COMP trimpot to minimum full CCW 2 Rotate the speed adjust potentiometer until the motor runs at mid speed without load for example 900 RPM for an 1800 RPM motor A hand held tachometer may be used to measure motor speed 3 Load the motor armature to its full load armature current rating The motor should slow down 4 While keeping the load on the motor rotate the IR COMP trimpot until the motor runs at the speed measured in step 2 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 5 Unload the motor 36 Calibration FORWARD ACCELERATION FWD ACC The FWD ACC setting determines the time the motor t
11. 1 2 HP 2 Os O 5 ADC FWD TQ REV TQ IR COMP 1 4 HP 6 5 4 4 2 7 ADC FWD TQ REV TQ IR COMP e e z o 5 A o gt 9 5 A o x o gt 10 Q 4 o gt 2 lt 2 2 o o o 59 2 2 lt lt 2 m lt o Q OMI 2HP 180 VDC 9 2 ADC 1HP 180 VDC 5ADC 3 4 HP 180 VDC 3 8 ADC 1 2 HP 180 VDC 2 5 ADC Figure 19 Typical FWD TQ REV TQ and IR COMP Trimpot Settings 40 Calibration MAX PCM isolation card Determines the motor speed when the speed adjust potentiometer is turned to full CW or voltage signal is set to maximum It is factory set for maximum rated speed To calibrate set the MAX trimpot to full CCW or voltage signal to maximum Turn the main speed adjust potentiometer to full CW Adjust the MAX trimpot until the desired maximum motor speed is reached See Figure 20 for MAX trimpot location MAX amp OFFSET TRIMPOTS ON PCM BOARD D 2 2D TB501 Figure 20 PCM Calibration Trimpot Locations Calibration 41 OFFSET PCM isolation card A Warning This trimpot is set at the factory and should not need adjustment Do not adjust this trimpot unless you are experiencing drift problems Contact your Minarik representative before
12. 3 53 NOTES 54 NOTES Unconditional Warranty A Warranty Minarik Drives warrants that its products will be free from defects in workmanship and material for twelve 12 months or 3 000 hours whichever comes first from date of manufacture thereof Within this warranty period Minarik Drives will repair or replace at its sole discretion such products that are returned to Minarik Drives 14300 De La Tour Drive South Beloit IL 61080 3006 USA This warranty applies only to standard catalog products and does not apply to specials Any returns for special controls will be evaluated on a case by case basis Minarik Drives 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 Minarik Drives sole obligation and exclude all other warranties of merchantability for use express or implied Minarik Drives 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 Minarik Drives obligations whether express or implied and particularly of any other claim or breech of warranty containe
13. 3N340 gt m STVNINYAL LIBIHNI NAHM ooon o SAVY AT3ALLVH3N3933 HOLONN MN 435070 IQON LYSANI INI 20981 coSdr 435010 S VNIWH3LL ae LIGIHNI NAHM ol SSVUE YOLOW 3 o lt LISIHNI 9 20981 09 3SNOdS33 NOILVYNSIANOD S NILLAS 29 Operation q18VN3 79 pesop Ajsnoaueynwis sjeuiuue pue sjeduunf ueuw Buruuni euuou e3e1edo esiwexr peuedo 20581 uo pue uo ueuw jeuuou eje1edo 10993 1 ILON N3dO GANIVLNIV Nado 1 318VN3 2 savna 401 OL 995019 SLSYO HOLOW 5 N3dO H 3GOW LYSANI 20581 Q3NIVLNIVIA ae 318VN3 a 2 N3HM 4016 OL 5 90 5 S1SVOO HOLOW G3NIVLNIV I DDD 3dOW 318vN3 50984 3SNOdS3 NOILVYNSIANOD S NILAS 30 Calibration A Warning Dangerous voltages exist on the drive when
14. Copyright 2009 by Minarik Drives All rights reserved No part of this manual may be reproduced or transmitted in any form without written permission from Minarik Drives The information and technical data in this manual are subject to change without notice Minarik Drives makes 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 Drives assumes no responsibility for any errors that may appear in this manual and makes no commitment to update or to keep current the information in this manual Printed in the United States of America Safety Warnings X X 2 amp SHOCK AVOID KEEP AVOID HAZARD HEAT DRY VIBRATION This symbol A denotes an important safety tip or warning Please read these instructions carefully before performing any of the procedures contained in this manual DO NOT INSTALL REMOVE OR REWIRE THIS EQUIPMENT WITH POWER APPLIED Have a qualified electrical 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 dr
15. RT INHIBIT mode jumper locations 1 and 2 of JP502 see Figure 15 page 28 In INVERT INHIBIT mode the motor will regeneratively brake when inhibit terminals are open To accelerate the motor to set speed close the inhibit terminals To activate the INVERT ENABLE mode jumper locations 3 and 4 see Figure 16 page 29 In INVERT ENABLE mode the motor will coast to a stop when the enable terminals are open To accelerate the motor to set speed close the enable terminals Operation 27 INVERT INHIBIT amp INVERT ENABLE Jumper Settings JP502 ARMATURE FEEDBACK 90 180 sua INHIBIT TERMINALS ENABLE TERMINALS Figure 14 INHIBIT ENABLE Terminal TB503 and JP502 Locations Operation 28 LIGIHNI 6 94nBi4 pesop pue sjeduunf euuou esiwexr peuedo 0Sg pue 205 uo sjeduinf ueuw Buruuni euuou NOQOY 941 ILON N3dO Q
16. _ ft LOO f 1 l Figure 13 RUN STOP Switch Operation 25 Regenerative brake To regeneratively brake the motor short the INHIBIT terminals on TB503 Reopening the INHIBIT terminals causes the motor to accelerate to set speed see Figure 14 page 27 for INHIBIT terminal locations and Figure 15 page 28 for INHIBIT settings Twist inhibit wires and separate them from other power carrying wires or sources of electrical noise Use shielded cable if the inhibit wires are longer than 18 in 46 cm If shielded cable is used ground only one end of the shield to earth ground Do not ground both ends of the shield Coast to a stop To coast the motor to a stop without removing power to the drive short the ENABLE terminals on TB503 see Figure 14 page 27 for ENABLE terminal locations and Figure 16 page 29 for ENABLE settings Momentarily shorting the ENABLE terminals will coast the motor to zero speed then accelerate back to set speed Completely shorting the ENABLE terminals will coast the motor to a complete stop Reopening the ENABLE terminals causes the motor to accelerate to set speed 26 Operation Invert Inhibit and Invert Enable INVERT modes reverse the function of the INHIBIT and ENABLE terminals Each drive is assembled with the INVERT INHIBIT and INVERT ENABLE jumper settings open jumpers on location 1 and 4 of JP502 See Figure 14 page 27 for JP502 location To activate the INVE
17. akes 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 The FWD ACC setting is factory set for its fastest forward acceleration time Turn the FWD ACC trimpot CW to increase the forward acceleration time and CCW to decrease the forward acceleration time REVERSE ACCELERATION REV ACC The REV ACC 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 The REV ACC setting is factory set for its fastest reverse acceleration time Turn the REV ACC trimpot CW to increase the reverse acceleration time and CCW to decrease the reverse acceleration time Calibration 37 DEADBAND DB The deadband trimmer potentiometer determines the time that will elapse between the application of current in one direction before current is applied in the opposite direction The deadband trimmer potentiometer affects the resistance that a motor has to changes in shaft position at zero speed It does this by applying AC voltage to the motor armature Deadband is factory calibrated with the notch at approximately the 3 o clock position for 60 Hz AC line operation Recalibrate the deadband with the notch at the 9 o clock position for 50 Hz AC line operation If you hear motor noise humming the deadband might be set too high Turn the deadba
18. d in Paragraph A or of any other warranties express or implied or claim of liability that might despite Paragraph B be decided against Minarik Drives by lawful authority Minarik Drives shall under no circumstances be liable for any consequential damages losses or expense arising in connection with the use of or inability to use Minarik Drives product for any purpose whatsoever An adjustment made under warranty does not void the warranty nor does it imply an extension of the original 12 month 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 Minarik Drives 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 Minarik Drives 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 14300 De La Tour Drive South Beloit IL 61080 Phone 1 800 MINARIK 646 2745 Fax 815 624 6960 www minarikdrives com Document Number 250 0324 Rev 6 Printed in the U S A 11 09
19. e motor rotation Non regenerative drives operate in Quadrant 1 and also in Quadrant 3 if the drive is reversible see Figure 1 page Motors must stop before reversing direction Unless dynamic braking is used non regenerative drives 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 This allows regenerative drives to reverse a motor without contactors or switches to control an overhauling load and to decelerate a load faster than it would take to coast to a lower speed vi Regenerative Drives Quadrant II Quadrant Quadrant III Quadrant IV MOTOR ROTATION E TORGU TORQUE NOTE ARROWS IN SAME DIRECTION MOTOR ACTION ARROWS IN OPPOSITE DIRECTION REGENERATIVE ACTION Figure 1 Four Quadrant Operation Specifications Armature Armature Voltage Model Current Range Horsepower Range ADC VDC RG60U RG60U PCM 5 0 1 4 1 2 0 90 5 0 1 4 1 0 180 RG61U RG61U PCM 1 5 1 20 1 8 0 90 1 5 1 10 1 4 0 180 Max Armature Current 10 ADC and Max Horsepower 1 hp when mounted to heat sink kit part number 223 0159 Max Armature Current 10 ADC and Max Horsepower 2 hp when mounted to heat sink kit part number 223 0159 AC Line Voltage 115 VAC 230 VAC 10
20. e with its board in either a horizontal or vertical plane Six 0 19 in 5 mm wide slots in the chassis accept 8 pan head Screws Fasten either the large base or the narrow flange of the chassis to the subplate The chassis should be earth grounded Use a star washer beneath the head of at least one of the mounting screws to penetrate the anodized chassis surface and to reach bare metal Installation 5 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 Circuit potentials are at 115 or 230 VAC above ground To prevent the risk of injury or fatality avoid direct contact with the printed circuit board or 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 drive Use 18 AWG wire for speed adjust potentiometer wiring Use 14 AWG wire for AC line L1 L2 and motor A1 A2 wiring 6 Installation Shielding guidelines A Warning Under no circumstances should power and logic leads be bundled together Induced voltage can cause unpredictable behavior in any electronic device including motor controls As a general rule Minarik recommends shielding of all conductors If it is not practical to shield power conductors Minarik recommends shielding all logic level leads If shi
21. elding of all logic level leads is not practical the user should twist all logic leads with themselves to minimize induced 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 If the drive continues to pick up noise after grounding the shield it may be necessary to add AC line filtering devices or to mount the drive in a less noisy environment Logic wires from other input devices such as motion controllers and PLL velocity controllers must be separated from power lines in the same manner as the logic I O on this drive Installation 7 Heat sinking The RG60U drive requires an additional heat sink when the continuous armature current is above 5 ADC Use Minarik heat sink kit part number 223 0159 Use a thermally conductive heat sink compound such as Dow Corning 340 Heat Sink compound between the drive chassis and the heat sink surface for optimum heat transfer Line fusing Minarik drives should be used with fuses for protection Use fast acting fuses rated for 250 VAC or higher Fuse L1 only when the line voltage is 115 VAC Fuse both L1 and L2 when the line voltage is 230 VAC Table 1 on page 8 lists the recommended line fuse sizes 8 Installation Table 1 Recommended Line Fuse S
22. equal 10 kohms ODE TB501 oz c 3 8 T2 TA RB1 RB2 15V 15V 0 5 8 52 5 2 1 Figure 24 Independent Adjustable Speeds Forward Direction 46 Application Notes Independent forward and reverse speeds Connect two speed adjust potentiometers as shown in Figure 25 to select between independent forward and reverse speeds FWD REV 10K OHM 10K OHM 4 a Figure 25 Independent Forward and Reverse Speeds Application Notes 47 Independent forward and reverse speeds with FWD STOP REV switch Use a single pole three position switch to stop the motor when the Switch is in the center position Figure 26 FWD REV 10K OHM 10K OHM Figure 26 Independent Forward and Reverse Speeds with a Forward Stop Reverse Switch 48 Troubleshooting Warning 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 Before applying power Check the following steps before proceeding 1 The AC line voltage must be connected to the proper terminals 2 Check that the voltage switches and jumpers are set correctly 3 The motor must be rated for the drive s rated armature voltage and current 4 Chec
23. ge follower isolated signal The drive may be wired to follow a floating isolated 0 to 10VDC signal that is isolated from earth ground instead of using a speed adjust potentiometer Connect the signal input to S2 and the signal common to SO see Figure 9 T2 T1 RB1 RB2 15V 15V 53 52 51 SIGNAL COMMON 50 10 VDC SIGNAL 501 Figure 9 Voltage Follower Connection NOTE For configuration of a non isolated voltage or current signal please refer to the PCM option page 19 Installation 17 Line voltage switches SW501 and SW502 on the bottom board are the line voltage Switches see Figure 10 Set the switches to 115 VAC if the line voltage is 115 VAC or to 230 VAC if the line voltage is 230 VAC U 510 12 0 Q T502 SCRS03 5 504 SCR508 SCR507 5 506 SCR505 C506 T504 T505 SCRS0 SCR502 R18 T503 L1 GND A2 C509 J 0 MOV501 C501 C502 C 115 230 230 115 501 Line Voltage Switches SW501 amp SW502 115 VAC or 230 VAC Figure 10 Line Voltage Switches bottom board 18 Installation Armature voltage switch SW504 on
24. ive to run at full speed as a result of a component failure Minarik strongly recommends the installation of a master switch in the main power input to stop the drive in an emergency 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 approved personal protective equipment and insulated tools if working on this drive with power applied Contents Regenerative Drives Specificatlons ul ue Re x RE EIE RIDES 1 2 Installation x oe EE eR E 4 Mounting ie a ee tas See ea A ee eee 4 VI TITO ete ade a 5 Shielding guidelines 6 Heat sinking eerte cer Ae etes 7 Line f sirig n 7 Speed adjust potentiometer 9 5 soera edocet eh a ese eli tet nca 10 Power fuse and motor connections 11 Voltage follower isolated signal 16 Line voltage switches 17 Armature voltage switch
25. izes 90 VDC Motor 180 VDC Motor Max DC Armature AC Line Fuse Horsepower Horsepower Current amps Size amps 1 20 1 10 0 5 3 1 15 1 8 0 8 3 1 8 1 4 1 5 5 1 6 1 3 1 75 5 1 4 1 2 2 5 8 1 3 3 4 3 5 8 1 2 1 5 0 10 3 4 11 2 7 5 15 1 2 10 20 Minarik Corporation offers two fuse kits part number 050 0069 8 8A Fuse Kit 050 0073 5 20 Fuse Kit Installation 9 Speed adjust potentiometer A Warning Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure Grounding the input will cause damage to the drive Mount the speed adjust potentiometer through a 0 38 in 10 mm hole with the hardware provided Figure 4 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 speed adjust potentiometer wires are longer than 18 in 46 cm use shielded cable Keep speed adjust potentiometer wires separate from power leads L1 L2 A1 A2 MOUNT THROUGH A 0 38 IN 10 MM HOLE NUT STAR WASHER SPEED ADJUST POTENTIOMETER INSULATING DISK POT TAB ASSIGNMENTS PANEL Figure 4 Speed Adjust Potentiometer 10 Installation Connections Screw terminal block Most connections to the RG60U drive are made to a screw terminal block part number 160 0171 Using a screwdriver turn the termina
26. k that all terminal block connections are correct For additional assistance contact your local Minarik distributor or the factory direct 1 800 MINARIK 646 2745 or Fax 1 800 394 6334 Troubleshooting 49 Line fuse blows Possible Causes 1 Line fuse is the wrong size 2 Motor cable or armature is shorted to ground Nuisance tripping caused by a combination of ambient conditions and high current spikes i e reversing 3 Suggested Solutions Check that the line fuse is correct for the motor size Check motor cable and armature for shorts Add a blower to cool the drive components decrease FWD TQ and REV TQ settings or resize motor and drive for actual load demand or check for incorrectly aligned mechanical components or jams 50 Troubleshooting Problem Line fuse does not blow but the motor does not run Possible Causes 1 Speed adjust potentiometer or speed reference voltage is set to zero speed Speed adjust potentiometer or speed reference voltage is not connected to drive input properly connections are open INHIBIT terminals are shorted 52 is shorted to SO Drive is in current limit Drive is not receiving AC line voltage Motor is not connected Suggested Solutions Increase the speed adjust potentiometer setting or speed reference voltage Check connections to input Verify that c
27. l block screw counterclockwise to open the wire clamp Insert 18 AWG stripped wire into the wire clamp Turn the terminal block screw clockwise to clamp the wire Cage clamp terminal block Inhibit and enable connections are made to a cage clamp terminal block To insert a wire into the terminal block press down on the lever arm using a small screwdriver Insert 20 AWG stripped wire into the wire clamp in front of the terminal block Release the lever arm to clamp the wire Wire Clamp Screw Figure 6 Lever Arm Wire Clamp Cage Clamp Terminal Block Installation 11 A Warning Do not connect this equipment with power applied Failure to heed this directive may result in fire or serious injury Minarik strongly recommends the installation of a master power switch in the voltage input line as shown in Figure 7 page 13 The switch contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts Power fuse and motor connections Connect the power input leads an external line fuse and a DC motor to the drive s printed circuit board PCB as shown in Figure 7 page 13 Motor Minarik drives supply motor voltage from A1 and A2 terminals It is assumed throughout this manual that when 1 is positive with respect to A2 the motor will rotate clockwise CW while looking at the output shaft protruding from the front of the motor If thi
28. mended for frequent starts and stops Do not use any of these methods for emergency stopping They may not stop a drive that is malfunctioning Removing AC line power both L1 and L2 is the only acceptable method for emergency stopping For this reason Minarik strongly recommends installing an emergency stop switch on both the L1 and L2 inputs see Figure 7 page 13 Frequent decelerating to minimum speed or regenerative braking produces high torque This may cause damage to motors especially gearmotors that are not properly sized for the application Automatic restart upon power restoration All drives automatically run to set speed when power is applied and enabled 24 Operation Decelerate to a stop The RUN STOP switch in Figure 13 may be used to decelerate a motor to a stop Closing the switch between RB1 and RB2 decelerates the motor from set speed to a stop The FWD ACC and REV ACC trimpot settings determine the rate at which the will drive decelerate to a stop and accelerate back to set speed Set the switch to the RUN position to accelerate the motor to set speed TB501 EN Ti TBSOT RB1 STOP RB2 RUN 15V 15 53 52 51
29. mpot to minimum full CCW 3 Set the speed adjust potentiometer to maximum full CW 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 trimpot CW slowly until the armature current is 12096 of motor rated armature current 7 Set the speed adjust potentiometer to minimum 8 Remove the power from the drive 9 Unlock the motor shaft 10 Remove the ammeter in series with the motor armature if it is no longer needed and re apply power to the drive 34 Calibration REVERSE TORQUE REV TQ A Warning Although REV TQ can be set to 120 of motor nameplate curren rating continuous operation beyond this rating may damage the motor If you intend to operate beyond this rating contact your Minarik representative for assistance The REV TQ setting determines the maximum current limit for accelerating and driving the motor in the reverse direction It is factory set at 12096 of maximum rated drive current See Figure 19 page 39 for typical REV TQ calibration settings or use the following procedure to recalibrate REV TQ 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 Set the speed adjust potentiometer to maximum full CW 4 Carefully lock the motor armature Be sure that the motor is firmly mounted 5 Apply line
30. nd trimpot CCW until the motor noise ceases 60 Hz 50 Hz Applications Applications C T O 2 T O Figure 18 Deadband Settings 38 Calibration TACH GENERATOR TACH Calibrate the TACH 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 trimpot 1 Connect the tachogenerator to T1 and T2 The polarity is positive for T1 and negative for T2 with the motor running in forward direction Set SW503 to ARM for armature feedback 3 Set the speed adjust potentiometer full CW Measure the armature voltage across A1 and A2 using a voltmeter Set the speed adjust potentiometer to 0 zero speed Set SW503 to TACH for tachogenerator feedback the IR COMP trimpot to full CCW Set the TACH trimpot to full CW Apply line power Set the speed adjust potentiometer to full CW 0 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 speed when SW503 is set to either armature or tachogenerator feedback Calibration 39 1HP 90 VDC 4 2 5 9 10ADC FWD REV TQ IR COMP 3 4 HP X 90 VDC 7 6ADC FWD TQ REV TQ IR COMP
31. onnections are not open Remove the short from the INHIBIT terminals Remove short Verify that motor is not jammed Increase FWD TQ or REV TQ setting if they are set too low Apply AC line voltage to L1 and L2 Connect motor to A1 and A2 Troubleshooting 51 Problem Motor runs too fast Possible Causes MAX SPD not calibrated Suggested Solutions Calibrate MAX SPD Motor will not reach the desired speed 1 MAX SPD setting is too low IR COMP setting is too low Motor is overloaded Drive is in current limit Increase MAX SPD setting Increase IR COMP setting Check motor load Resize the motor if necessary 4 Verify torque settings Motor pulsates or surges under load IR COMP is set too high Motor bouncing in and out of current limit Adjust the IR COMP setting slightly CCW until the motor speed stabilizes Make sure motor is not undersized for load adjust FWD TQ and REV TQ trimpot 52 Troubleshooting Replacement Parts Replacement parts are available form Minarik Corporation and its distributors for this drive series Table 2 Replacement Parts Model No Symbol Description Minarik P N RG60U RG61U SCR501 508 800 V 25 SCR 072 0067 T501 DST 336 Transformer 230 0104 10K Ohm Potentiometer Kit 202 0104 2 Pin Jumper 164 0292 Fuse Kits 3 8A Fuse Kit 050 0069 5 20A Fuse Kit 050 007
32. s is opposite of the desired rotation simply reverse the wiring of A1 and A2 with each other A1 and A2 Connect a DC motor to PCB terminals A1 and A2 as shown in Figure 7 page 13 Ensure that the motor voltage rating is consistent with the drive s output voltage 12 Installation Power input Connect the AC line power leads to terminals L1 and L2 or to a double throw single pole master power switch recommended Line fuse Wire an external line fuse between the stop switch if installed and the terminal board Figure 7 page 13 An additional line fuse should be installed on L2 if the input voltage is 230 VAC Refer to the line fuse table Table 1 on page 8 for fuse ratings 13 Installation suonoeuuo pue OVA OEZ 10 911 lt oio S m sae S 8 sna Lar a LNdNI OVA OEZ mcs MSS dudes doce aaa CERE Ge1vog WOLLOS
33. the 5V terminal on TB501 of the PCM board A single pole single throw switch can be used as a polarity reversal switch Close the switch to reverse the output voltage polarity Open the switch to return the output voltage back to its original polarity See Figure 12 page 20 for polarity reversal Switch connections Installation 20 pue suonoeuuoo WOd N09 ON Z 91nB14 W313WOlLN31Od ASnrav daaads WHO YOL zs is 10881 YALSWOILNALOd isnrdv 9334 WHO 0 ts zs es 10981 NOlLV3H3dO IVNOILO3IIQ IS SNOILO3NNOOD M313WOILN310d 03345 WOd no9ou Bulsn uo eq jou 3 u eyov YMS dois oj jseoo 0 ejqeue dojs 0 10joui exeiq 2501 SSNILL3S HOLIMS AISIHNI NOILLO33IQ TWNOIS 15 03395 02 01 20 01 OF 01 ndu 109 jeubis vost 9 OCA 01 01 01 405 28 sud uedo indu jeubis 02 40 sud jedunr indui subs 02 0 p 10 L sud indui yod 10 jeubis OG 0 01 0 10 z suid jedunr SONILLAS 0521
34. the top board is the armature voltage selector switch Set SW504 to 90 if using a 90 VDC motor or to 180 if using a 180 VDC motor See Figure 11 for SW504 location Feedback selector switch SW503 on the top board is the feedback selector switch Set SW503 to TACH if using a tachogenerator otherwise set it to ARM for armature feedback See Figure 11 for SW503 location Armature Feedback Voltage Switch Selector Switch 90 VDC or 180 VDC ARM or TACH FEEDBACK ARMATURE MAX Qs Y 4 Figure 11 Armature Voltage and Feedback Selector Switch Locations top board Installation 19 Voltage or Current Follower non isolated signal PCM models PCM series drives can be configured to follow a grounded non isolated voltage or current signal To configure the drive to follow a voltage or current signal connect the signal leads to the YIN and IN terminals on TB501 observing proper polarity Ensure that the following jumper terminals are properly set J501 Settings Open pins 1 amp 2 for 10 to 10 VDC signal or pot input Jumper pins 1 amp 2 for 4 to 20 mA signal input J502 Settings Jumper pins 2 amp 3 for 10 to 10 VDC signal or pot input Jumper pins 1 amp 2 for 4 to 20 mA signal input See Figure 12 page 20 for jumper and terminal locations Polarity reversal switch PCM models To reverse the output voltage polarity without changing the input polarity connect the DIR terminal to
35. tion card 41 Application Notes 42 Connections to Minarik DLC600 42 EWD REV sWitch ade ki is ee 43 FWD STOP REV switch 44 Independent Adjustable Speeds 45 Independent forward and reverse speeds 46 Independent forward and reverse speeds with FWD STOP REV SWilch cie Rc Ee ore lec Re Ro oa 47 Troubleshootirig uem ule ete ah eae tine Benen 48 Before applying power 48 Replacement Parts 52 Unconditional Warranty inside back cover Tables Table 1 Recommended Line Fuse Sizes 8 Table 2 Replacement Parts 52 iv Illustrations Figure 1 Four Quadrant Operation vi Figure 2 RG60U RG61U Dimensions 2 Figure 3 RG60U PCM RG61U PCM Dimensions 3 Figure 4 Speed Adjust Potentiometer 9 Figure 5 Screw Terminal Block 10 Figure 6 Cage Clamp Terminal Block 10 Figure 7 Power and Motor Connections Bottom Board 13 Figure 8 Speed Adjust Potentiometer Connections 15 Figure 9 Voltage Follower Connection
36. tory set to zero speed The minimum speed feature applies only when the drive is operating in unidirectional mode To calibrate MIN SPD 1 Set the speed adjust potentiometer to full CCW 2 Adjust the MIN SPD trimpot until the desired minimum motor speed is reached MAXIMUM SPEED MAX SPD The MAX SPD trimpot setting determines the maximum forward and reverse speed It is factory set for maximum rated motor speed To calibrate MAX SPD 1 Set the MAX SPD trimpot full CCW 2 Turn the speed adjust potentiometer CW so that the motor is running at full speed 3 Adjust the MAX SPD trimpot until the desired maximum motor speed is reached Caution Do not attempt to run motor above 90 VDC on 115 VAC or above 180 VDC on 230 VAC Calibration 33 FORWARD TORQUE FWD TQ A Warning Although FWD TQ can be set to 120 of motor nameplate current rating continuous operation beyond this rating may damage the motor If you intend to operate beyond this rating contact your Minarik representative for assistance The FWD setting determines the maximum current limit for accelerating and driving the motor in the forward direction It is factory set at 12096 of maximum rated drive current See Figure 19 page 39 for typical FWD TQ calibration settings or use the following procedure to recalibrate FWD TQ 1 With the power disconnected from the drive connect a DC ammeter in series with the armature 2 Set the FWD TQ tri
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