Minarik Drives RG500 SERIES Users Manual

RG500 SERIES

SCR, Dual Voltage, Adjustable-Speed

Regenerative Drives for DC Brush Motors

USER’S MANUAL

Copyright © 2001 by

Minarik Corporation

All rights reserved. No part of this manual may be reproduced or transmitted in
any form without written permission from Minarik Corporation. The information
and technical data in this manual are subject to change without notice. Minarik
Corporation and its Divisions make no warranty of any kind with respect to this
material, including, but not limited to, the implied warranties of its merchantability
and fitness for a given purpose. Minarik Corporation and its Divisions assume no
responsibility for any errors that may appear in this manual and make no
commitment to update or to keep current the information in this manual.

Printed in the United States of America.

 Safety Warnings

• This symbol  denotes an important safety tip or warning.

Please read these sections carefully prior to performing any of
the instructions contained in that section.

• Have a qualified electrical maintenance technician install,

adjust and service this equipment. Follow the National
Electrical Code and all other applicable electrical and safety
codes, including the provisions of the Occupational Safety
and Health Act (OSHA), when installing equipment.

• Reduce the chance of an electrical fire, shock, or explosion by

proper grounding, over-current protection, thermal protection,
and enclosure. Follow sound maintenance procedures.

• It is possible for a drive to run at full speed as a result of a

component failure. Please ensure that a master switch has
been placed in the AC line to stop the drive in an emergency.

• This drive is not isolated from earth ground. Circuit

potentials are at 115 VAC or 230 VAC above earth ground.
Avoid direct contact with the printed circuit board or with
circuit elements to prevent the risk of serious injury or fatality.
Use a non-metallic screwdriver for adjusting the calibration
trimpots.

i

PLEASE NOTE: A MAXIMUM OF 10 mA DC MAY BE SOURCED
FROM THE S1 AND/OR S2 TERMI NALS TO A I SOLATED L OAD OR
15mADCMAYBESOURCEDFROMTHE +15AND-15TERMINALS
TOAISOLATEDLOAD.

ii

Contents

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Drive option description (by suffix) . . . . . . . . . . . . . . . . . . . . . . . . . 2

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Regenerative Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mounting chassis drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mounting cased drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

AC line and motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cage-clamp terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Field output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Tachogenerator feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Speed adjust potentiometer installation . . . . . . . . . . . . . . . . . . . . 13

Speed adjust potentiometer connections . . . . . . . . . . . . . . . . . . . 14

+15 and –15 terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Line Fusing for RG Series Drives . . . . . . . . . . . . . . . . . . . . . . . . 16

Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Selector switch settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Chassis drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cased drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . 22

Automatic restart upon power restoration . . . . . . . . . . . . . . 22

Regenerative deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Regenerative brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Coast to a stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Decelerate to zero speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . 29

FORWARD TORQUE (FWD TQ) . . . . . . . . . . . . . . . . . . . . . . . . . 30

REVERSE TORQUE (REV TQ) . . . . . . . . . . . . . . . . . . . . . . . . . . 31

IR COMPENSATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . 32

FORWARD ACCELERATION (FWD ACC) . . . . . . . . . . . . . . . . . 33

REVERSE ACCELERATION (REV ACC) . . . . . . . . . . . . . . . . . . 33

DEADBAND (DB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

TACHOGENERATOR (TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Application Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Connection to other Minarik devices. . . . . . . . . . . . . . . . . . . . . . . 38

Optional speed adjust potentiometer connections . . . . . . . . . . . . 40

Forward-Stop-Reverse Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Forward-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Independent Adjustable Speeds (Forward Direction Only) . . . . . . 41

Independent Forward and Reverse Speeds . . . . . . . . . . . . . . . . . 42

Independent Forward and Reverse Speeds with

FWD-STOP-REV Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Factory Prewired Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Certificate of Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Unconditional Warranty . . . . . . . . . . . . . . . . . . . . . . . . inside back cover

iii

iv

Illustrations

Figure 1. RG500UA and RG510UA Dimensions . . . . . . . . . . . . . . . . . . 3

Figure 2. RG500A and RG510A Cased Drive Dimensions . . . . . . . . . . 4

Figure 3. Four Quadrant Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 4. Chassis Drive Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 5. Cased Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Figure 6. Cage-Clamp Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 7. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 8. Speed Adjust Potentiometer Connections . . . . . . . . . . . . . . 14

Figure 9. TB502 Terminal Assignments . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 10. Voltage Follower Connection . . . . . . . . . . . . . . . . . . . . . . . 17

Figure 11. Selector Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Figure 12. Regenerative Deceleration Switch Connection . . . . . . . . . 22

Figure 13. INHIBIT Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Figure 14. Inhibit - Run Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . 24

Figure 15. Inhibit - Run Terminals Location

and Run / Coast Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Figure 16. Run/Decelerate to Zero Speed Switch . . . . . . . . . . . . . . . 26

Figure 17. Typical FWD TQ, REV TQ, and IR COMP Settings . . . . . 34

Figure 18. Deadband Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Figure 19. RG500 Connections to DLC600 and PCM4 . . . . . . . . . . . . 38

Figure 20. RG500 connection to 200-0386A

Limit Switch Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Figure 21. Forward-Reverse Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 22. Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . 40

Figure 23. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . 41

Figure 24. Independent Forward and Reverse Speeds . . . . . . . . . . . . 42

Figure 25. Independent Forward and Reverse Speeds with a

Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . 43

Figure 26. Prewired Connections to L1, L2(115) and L2(230). . . . . . . 48

Figure 27. Prewired Speed Adjust Potentiometer Connections . . . . . . 49

Figure 28. RG500 Series Block Diagram. . . . . . . . . . . . . . . . . . . . . . . 56

v

vi

Tables

Table 1. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Table 2. Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Table 3. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Table 4. Corcom® Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Table 5. Minarik Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Specifications

Max.

Armature HP Range HP Range

Model (Amps DC) Applied Applied

* RG500A, RG500UA 10.0 † 1/4–1 † 1/2–2 †

* RG510A, RG510UA 3.0 1/20–1/8 1/10–1/4

† Maximum armature current and horsepower range apply when drive is attached to

additional heat sink: Minarik part number 223-0235. Use heat sink when armature
current is above 7 ADC. Heat sinks are pre-mounted on RG500 cased drives.

* See page 2 for suffix descriptions.

AC Line Voltage 115/230 VAC, ±10%, 50/60 Hz, single phase

Armature Voltage (115 VAC Input) 0–90 VDC

Armature Voltage (230 VAC Input) 0–180 VDC

Form Factor 1.37 at base speed

Field Voltage (115 VAC Input) 50 VDC (F1 to L1); 100 VDC (F1 to F2)

Field Voltage (230 VAC Input) 100 VDC (F1 to L1); 200 VDC (F1 to F2)

Max. Field Current 1 ADC

Accel. Time Range (with no load) 0.5 – 15 seconds

Decel. Time Range (with no load) 0.5 – 15 seconds

Analog Input Voltage Range (signal must be isolated; S0 to S2) 0–10 VDC

Input Impedance (S0 to S2) 32K ohms

Load Regulation

with Armature Feedback 1% of base speed or better

with Tachogenerator Feedback 0.1% of base speed

Ambient Temp. Range (chassis drives) 10°C–55°C

Ambient Temp. Range (cased drives) 10°C–40°C

Vibration 0.5g max (0 – 50 Hz)

Current with 115 VAC with 230 VAC

0.1g max (above 50 Hz)

1

2

Specifications

Drive option description (by suffix)

Terminal

Suffix Style Block Type

A NEMA 4X Cage-Clamp
UA Chassis Cage-Clamp

Dimensions

FU501

FU502

0.93 [24]

3.50 [89]

0.64 [16]

8.90 [226]

.70 [18]

8.40 [213]

1.85 [47]

0.125 [3] REF

4.78 [121]

4.000 [102]

0.28 [7]

IC501

IC502

S3 S2

C505

TB502

S0S1 RB1 -15RB2 +15

P501

MIN SPD

T2T1

INHIBIT

FWD TQ REV TQ

INV

P502 P503

230V

C502

SW502

C503

A2 A1

TB501

F2

SW501

GND F1

115V

L2

115 230230 115

SO502

SO501

INH-RU N

T505

T501

FU504

R501

T502

C504

L2

L1

FAST ACTING

FUSES ONLY

L2L1

SCR501 SCR502 SCR504

C501

SCR503

P509

TACHFWD ACCMAX SPDIR COMP

P505P504 P506

REV ACC DB

P507 P508

SW504

T503

T504

SW503

ARM TACH

FEEDBACK

R503

90 180

ARMATURE

R502

R505R504

SCR505 SCR506

R506

SCR507 SCR508

C510

0.188 [5]

3

4.78 [121]

0.28 [7]

0.93 [24]

0.84 [18]

0.125 [3] REF

8.40 [213]

4.000 [102]

0.70 [18]

8.90 [228]

3.50 [89]

0.188 [5]

1.85 [47]

Figure 1. RG500UA and RG510UA Dimensions

Optional 223-0235 Heatsink Dimensions: 9.8" x 6.9" x 1"

S0

S1

S2

S3

grey

grey/white

green

blue

REV

FWD

BRAKE

CW

10K

W

blue/
white

4

Dimensions

6.90 [175]

6.30 [160]

10.20 [259]

9.80 [249]

FOUR (4) EACH MOUNTING SLOTS.

6.3 [160] x 7.0 [178]
ON CENTERS

5.50 [140]

4.78 [121]

2.30 [58]

1.50 [38]

Figure 2. RG500A and RG510A Cased Drive Dimensions

THREE 0.88 [22] KNOCKOUTS

ALL DIMENSIONS IN INCHES [MILLIMETERS]

1.45 [37]

1.50 [38]

1.40 [36]

0.12 [3]

Regenerative Drives

In most non-regenerative, variable speed, DC drives control
current flows to a motor in one direction. The direction of
current flow is the same direction as the motor rotation.
Non-regenerative drives operate in Quadrant 1, and also in
Quadrant 3 if the drive is reversible (see Figure 3, page 6).
Motors must stop before reversing direction. Non-regenerative
drives cannot oppose an overhauling load, and cannot
decelerate a load faster than coasting to a lower speed.

Regenerative drives operate in two additional quadrants:
Quadrant 2 and Quadrant 4. In these quadrants, motor torque
is in the opposite direction of motor rotation.

Regenerative drives can reverse a motor without contactors,
switches, brake resistors, and inhibit plugs. They can also
control an overhauling load and decelerate a load faster than it
would take to coast to a lower speed.

5

6

Regenerative Drives

Figure 3. Four Quadrant Operation

Installation

Mounting chassis drives

Drive components are sensitive to electrostatic fields. Avoid
contact with the circuit board directly. Hold the drive by the
chassis only.

Protect the drive from dirt, moisture, and accidental contact.
Provide sufficient room for access to the terminal block and
calibration trimpots.

Mount the drive away from other heat sources. Operate
the drive within the specified ambient operating temperature
range.

Prevent loose connections by avoiding excessive vibration
of the drive.

Mount the drive with its board in either a horizontal or
vertical plane. Six 0.18 inch (4.57 mm) wide slots in the
chassis accept #8 pan head screws. Fasten either the large
base or the narrow flange of the chassis to the subplate.

7

The chassis must be earth grounded for noise suppression. To
ground the chassis, connect earth ground to the GND terminal
on terminal block TB501.

8

Installation

Mounting cased drives

NEMA 4X cased drives come with three 0.88 inch (22 mm)
conduit knockout holes at the bottom of the case. The units
may be vertically wall mounted using the four 0.25 inch
(6 mm) slotted holes on the attached heat sink. For motor
loads less than 5 ADC, the drive may be bench mounted
horizontally, or operated without mounting.

1. Set the POWER switch to the “0” or OFF position before
applying the AC line voltage.

2. Install the mounting screws.

3. For access to the terminal strip, turn the slotted screw on
the front cover counterclockwise until it is free from the
case. The right side of the cover is hinged to the case. Lift
or pull the slotted screw to open the case.

4. Carefully remove the conduit knockouts by tapping them
into the case and twisting them off with pliers.

5. Install conduit hardware through the 0.88 inch (22 mm)
conduit holes. Connect external wiring to the terminal
block.

6. Grasp the slotted screw and tilt the front cover back into
place. Avoid pinching any wires between the front cover
and the case.

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

S3 S2

C505

TB502

230V

A2 A1

TB501

F2GND F1

115V

L2

C504

L2

L1

A

ARMATURE

OUTPUT

FIELD

OUTPUT

FOR SHUN T WOUND

MOTORS ONL Y.

See f ield output section

for connections.

230 VAC

115 VAC

AC LINE

INP U T

115 OR 230 VAC

Installation

Heat sinking

Chassis RG500 models require an additional heat sink
when the continuous armature current is above 7 ADC. Use

®

Minarik

part number 223-0235. All cased drives have
sufficient heat sinking in their basic configurations. Use a
thermally conductive heat sink compound (such as Dow

®

Corning

340 Heat Sink compound) between the drive chassis
and the heat sink surface for optimum heat transfer.

AC line and motor connections

Use 14 AWG or 16 AWG standard wire for connecting the
line and the armature. Use 16 AWG or 18 AWG standard wire
when connecting the field of a shunt wound motor. Strip the
wire insulation 0.25 inches (6 mm). See Figures 4 and 5
(page 10) for AC line and motor connections to chassis and
cased drives.

9

AC LINE

115 OR 230 VAC

INPUT

Figure 4. Chassis Drive Connections

115 VAC

230 VAC

FIELD OUTPUT

For Shunt Wound

Motors Only.

See field output section

for connections

A

ARMATURE

OUTPUT

10

IC50 1

IC50 2

S3 S2

C505

TB502

S0S1 RB1 -15RB2 +15

P501

MIN SPD

T2T1

INHIB IT

FWD TQ REV

P502 P50

230V

C502

SW502

C503

A2 A1

TB501

F2

SW501

GND F1

115V

L2

115 230 230 115

SO502

SO501

INH- RUN

T502

C504

L2

L1

FAST ACTING

FUSES ONLY

L2

FU502

L1

FU501

SCR504

C501

123

A

115

VAC

230 VAC

AC LINE INPUT

115 OR 230 VAC

Installation

FIELD OUTPUT

For shunt wound motors

only. See field output

section for connections.

Figure 5. Cased Drive Connections

ARMATURE

OUTPUT

Installation

Cage-clamp terminal block

Connections to RG500 Series drives are made to a cage-clamp
terminal block (see Figure 6). To insert a wire into the
terminal block, press down on the lever arm using a small
screwdriver. Insert stripped wire into the large opening in front
of the terminal block. Release the lever arm to clamp the wire.

Lever Arm

Wire Clamp

11

Figure 6. Cage-Clamp Terminal Block

12

Installation

Field output

The field output is for shunt wound motors only. Do not
make any connections to F1 and F2 when using a
permanent magnet motor.

Use 18 AWG wire to connect the field output to a shunt
wound motor. Table 1 lists the field output connections.

Table 1. Field Output Connections

Line Voltage Approximate Connect Motor

(VAC) Field Voltage (VDC) Field To

115 50 F1 and L1
115 100 F1 and F2
230 100 F1 and L1
230 200 F1 and F2

Tachogenerator feedback

Using tachogenerator feedback improves speed regulation
from approximately 1% of motor base speed to approximately

0.1% of motor base speed. Use tachogenerators rated from
7 VDC per 1000 RPM to 50 VDC per 1000 RPM. Connect the
tachogenerator to terminals T1 and T2 of terminal block
TB502. The polarity is + for T1 and – for T2 when the motor
running in the forward direction. The polarity is reversed
when the motor is running in the reverse direction.

Speed adjust potentiometer installation

POT TAB ASSIGNMENTS

WIPER

CW

CCW

SPEED ADJUST

POTENTIOMETER

INSULATING DISK

PANEL

STAR

WASHER

NUT

MOUNT THROUGH A 0.38 IN. (10 MM) HOLE

Warning



Be sure that the potentiometer tabs do not make contact with
the potentiometer enclosure. Grounding the input will cause
damage to the drive.

On chassis drives, install the circular insulating disk between
the panel and the 10KΩ speed adjust potentiometer. Mount the
speed adjust potentiometer through a 0.38 in. (0.96 cm) hole
with the hardware provided (see Figure 7). Twist the speed
adjust potentiometer wire to avoid picking up unwanted
electrical noise. If potentiometer leads are longer than 18 in.
(46 cm), use shielded cable. Speed adjust potentiometers are
installed on all cased drives.

MOUNT THROUGH A 0.38 IN. (10 MM) HOLE

NUT

STAR

WASHER

SPEED ADJUST

POTENTIOMETER

INSULATING DISK

PANEL

Figure 7. Speed Adjust Potentiometer

POT TAB ASSIGNMENTS

Installation

WIPER

CW

13

CCW

FU501

FU502

IC501

IC502

S3 S2

C505

TB502

S0S1 RB1 -15RB2 +15

P501

MIN SPD

T2T1

INHIBIT

INV

230V

C502

SW502

C503

A2 A1

TB501

F2

SW501

GND F1

115V

L2

115 230 230 115

SO502

SO501

INH-RUN

T505

T501

FU504

R501

C504

L2

L1

FAST ACTING

FUSES ONLY

L2L1

SCR501 SCR502 SCR5

DS501

17 18

K502

14 16151312

K501

IC502

10 11

IL501

POWER

123456

21

200-0386A

LIMIT SWITCH

LOGIC BOARD

TB502 ON

RG500
SERIES

DRIVE

14

S0

S1

S2

TB502

10K OHM

SPEED ADJUST

POTENTIOMETER

CCW

S1

S2

S3

CW

10K OHM, 2W

SPEED ADJUST

POTENTIOMETER

TB502

REV

FWD

Installation

Speed adjust potentiometer connections

The motor can operate in one direction (unidirectional) or in
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) for speed control in one direction.

Connect the speed adjust potentiometer as shown in Figure
8(b) for speed control in two directions. The motor does not
rotate when the wiper is in the center position. Turning the
wiper CW from the center position causes the motor to rotate
in one direction, while turning the wiper CCW from the center
position causes the motor to rotate in the opposite direction.

10K OHM, 2W

SPEED ADJUST

POTENTIOMETER

REV

FWD

CW

Refer to the Application Notes section for additional speed
adjust potentiometer connections.

10K OHM

SPEED ADJUST

POTENTIOMETER

Figure 8. Speed Adjust Potentiometer Connections

for (a) Unidirectional Operation and (b) Bidirectional Operation

CCW

(a) (b)

TB502

S2

S1

S0

TB502

S3

S2

S1

Installation

S3 S2

TB502

S0S1 RB 1 -15RB2 +15 T2T1

+15 and –15 terminals

Warning



Do not short the +15 and -15 terminals for any reason.
Shorting these terminals may damage the drive.

RG500 Series drives can supply a regulated +15 and –15 VDC
signal (each sourcing 15 mA maximum) to isolated, external
devices. These voltage supply terminals are located on
terminal block TB502 (see figure 9).

TB502

S3 S2 S1 S0 RB1 RB2 -15 +15 T1 T2

Figure 9. TB502 Terminal Assignments

15

16

Installation

Line Fusing for RG Series Drives

Minarik drives require fuses for protection. Use fast acting fuses
rated for 250 VAC or higher, and approximately 150% of the
maximum armature current. Fuse L1 when using 115 VAC line
voltage. Fuse both L1 and L2 when the line voltage is 230 VAC.

The fuse chart below lists the recommended line fuse sizes.

Table 2. Fuse Chart

90 VDC Motor 180 VDC AC Line Fuse

Horsepower Horsepower Size (amps)

1/20 1/10 3
1/15 1/8 3

1/8 1/4 5
1/6 1/3 5
1/4 1/2 8
1/3 3/4 8
1/2 1 10
3/4 1 1/2 15

1220

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 050–0064) which protects the
transformer and logic.

Installation

RB1

S1

S2±10VDC

COMMON

All drives have line fuses installed (see Replacement Parts
section for installed line fuse size). Line fuses are rated for
maximum rated curent. Use line fuses rated for 20 A or less on
RG500 drives (8 A or less on RG501 drives).

Voltage follower

The drive may be wired to follow a floating (isolated)
0 to ±10V 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 RB1 (see Figure 10).

17

±10 VDC

COMMON

Figure 10. Voltage Follower Connection

S2

S1

RB1

DB DB

60 Hz

Applications

50 Hz

Ap p licat io n s

18

Operation



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. Check connections before applying AC line voltage to the

drive.

2. Check that no conductive material is present on the printed

circuit board.

3. Verify that all selector switches are set correctly (see the

following section for selector switch settings).

Operation

Selector switch settings

1. Set the line voltage selector switches (SW501 and SW502)

to 115 if using 115 VAC line voltage, or to 230 if using
230 VAC line voltage.

2. Set the armature voltage selector switch (SW503) to 90 if

using a 90 VDC motor, or to 180 if using a 180 VDC
motor.

3. Set the feedback selector switch (SW504) to TACH if

using a tachogenerator; otherwise set to ARM for armature
feedback.

Note: You may be required to derate a 90 VDC motor

when 230 VAC is applied to the drive. Contact the
factory for details.

See Figure 11 (page 21) for all switch locations.

Startup

Chassis drives

1. Set the speed adjust potentiometer for zero speed.

2. Apply AC line voltage.

3. Slowly advance the speed adjust potentiometer clockwise

(CW). The motor slowly accelerates as the potentiometer is
turned CW. Continue until the desired speed is reached.

4. Remove AC line voltage from the drive to coast the motor

to a stop.

19

20

Operation

Cased drives

1. Set the FORWARD/BRAKE/REVERSE switch to the

BRAKE position.

2. Set the speed adjust potentiometer to “0” (full CCW).

3. Apply AC line voltage.

4. Set the POWER switch to the “I” (ON) position.

5. Set the FORWARD/BRAKE/REVERSE switch to the

desired direction of rotation.

7. Slowly advance the speed adjust potentiometer clockwise

(CW). The motor slowly accelerates as the potentiometer is
turned CW. Continue until the desired speed is reached.

8. To brake the motor, set the FORWARD/BRAKE/REVERSE

switch to the BRAKE position. To coast the motor to a stop,
set the POWER switch to the “O” (OFF) position.

9. To reverse direction:

a. Set the FORWARD/BRAKE/REVERSE switch to the

BRAKE position.

b. After the motor comes to a complete stop, set the

FORWARD/BRAKE/REVERSE switch to the desired
direction of rotation.

10. Set the POWER switch to “O” (OFF) to remove power

from the drive.

Operation

FU501

FU502

IC501

IC502

S3 S2

C505

TB502

S0S1 RB1 -15RB2 +15

P501

MIN SPD

T2T1

INHIBIT

FWD TQ REV TQ

INV

P502 P503

230V

C502

SW502

C503

A2 A1

TB501

F2

SW501

GND F1

115V

L2

115 230 230 115

SO502

SO501

INH-R U N

T505

T501

FU504

R501

T502

C504

L2

L1

FAST ACTING

FUSES ONLY

L2L1

SCR501 SCR502 SCR504

C501

SCR503

P509

TACHFWD AC CMAX SPDIR COM P

P505P504 P506

REV ACC DB

P507 P508

SW504

T503

T504

SW503

ARM TACH

FEEDBACK

R503

90 180

ARMATURE

R502

R505R504

SCR505 SCR506

R506

SCR507 SCR508

C510

21

Figure 11. Selector Switch Locations

Selector Switch

Armature Voltage

Selector Switch

Line Voltage

Selector Switches

Feedback

22

Starting and Stopping Methods

Line starting and line stopping

Line starting and line stopping (applying and removing
AC line voltage) is recommended for infrequent starting and
stopping of a drive only. When AC line voltage is applied to
the drive, the motor accelerates to the speed set by the speed
adjust potentiometer. When AC line voltage is removed, the
motor coasts to a stop.

Automatic restart upon power restoration

All drives automatically run to set speed when power is
applied. Wiring a latching relay into the AC line is one way
to prevent automatic restarting following a power outage.

Regenerative deceleration

Short terminals RB1 and RB2
to regeneratively decelerate a
motor to a stop (Figure 12).
Since terminal RB1 bypasses
the MIN SPD circuit, shorting
RB1 and RB2 will decelerate a
motor to a stop instead of
minimum speed. Calibrate the
deceleration time
by adjusting the opposite­direction acceleration trimpot.

STOP

RUN

Figure 12. Regenerative

Deceleration Switch

Connection

RB1

RB2

Starting and Stopping Methods

FU501

FU502

IC501

IC502

S3 S2

C505

TB502

S0S1 RB1 - 15RB2 +15

P501

MIN SPD

T2T1

INHIBIT

FWD

INV

P502

230V

C502

SW502

C503

A2 A1

TB501

F2

SW501

GND F1

115V

L2

115 230 230 115

SO502

SO501

INH-R U N

T505

T501

FU504

R501

C504

L2

L1

FAST ACTING
FUSES ONLY

L2L1

SCR501 SCR502 S

C501

SCR503

Regenerative brake

Short the INHIBIT terminals to regeneratively brake the motor
(see Figure 13 for INHIBIT terminal location). Reopening the
INHIBIT terminals causes the motor to accelerate to set speed.

The INHIBIT terminals bypass both the MIN SPD circuit
and the deceleration circuit. This causes the motor to stop
rapidly when the INHIBIT terminals are shorted. Braking
torque is determined by the opposite-direction torque setting.

23

Figure 13. INHIBIT Terminals

INHIBIT

Terminals

24

Starting and Stopping Methods

Minarik Corporation offers two accessory plug harnesses for
the INHIBIT terminals:

Minarik

®

Part Number Description

201-0024 Inhibit plug with 18 in. (46 cm) wires
201-0079 Inhibit plug with 36 in. (91 cm) wires

Twist inhibit wires and separate them from other power­carrying 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, jumper
INHIBIT–RUN terminals 1 and 2
(see Figure 14, page 25). To restart
the motor, jumper INHIBIT–RUN
terminals 2 and 3. A single-pole,
double-throw switch may be used as
a COAST/RUN switch (see Figure
15, page 25).

Each drive is assembled with
INHIBIT–RUN terminals 2 and 3
jumpered. These terminals must
be connected for the motor to run.

1 2 3 1 2 3

INHIBIT RUN

Figure 14. Inhibit -

Run Jumper

Settings

IC501

IC502

S3 S2

C505

TB502

S0S1 RB1 -15RB2 +15

P501

MIN SPD

T2T1

INHIB IT

FW

INV

P

230V

C502

SW502

C503

A2 A1

TB501

F2

SW501

GND F1

115V

L2

115 230 230 115

SO502

SO501

INH- RUN

T505

T501

FU504

R501

L2

123

Starting and Stopping Methods

SO502

IN H -R U N

123

RUN

COAST

TO STOP

25

COAST TO

STOP

COAST / RUN

SWITCH

1 2 3

INH-RUN

Figure 15. Inhibit - Run Terminals Location

and Run / Coast Switch

RUN

S0502

INHIBIT- RUN

TERMINALS

26

S3

S2

S1

S0

DECEL TO

ZERO SPEED

RUN

CW

10K OHM

SPEED ADJUST

POTENTIOMETER

REV

FWD

Starting and Stopping Methods

Decelerate to zero speed

The circuit shown in Figure 16 may be used to decelerate a
motor to a zero speed. Closing the switch between S2 and S0
decelerates the motor from set speed to zero speed. The
DECEL trimpot setting determines the rate at which the drive
decelerates. Set the switch to the RUN position to accelerate
the motor to set speed at a rate determined by the ACCEL
trimpot setting.

10K OHM

SPEED ADJUST

POTENTIOMETER

REV

CW

(shown with bidirectional speed adjust

potentiometer connection)

FWD

Figure 16. Run/Decelerate to Zero Speed Switch

RUN

DECEL TO

ZERO SPEED

S3

S2

S1

S0

Starting and Stopping Methods

Warning



For frequent starts and stops, use regenerative deceleration
(shorting RB1 and RB2), regenerative braking (shorting
INHIBIT terminals to each other), coasting to a stop
(shorting INHIBIT–RUN terminals 1 and 2), or
decelerating to minimum speed (shorting S2 to S0). 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.

CURRENT LIMIT (FWD TQ and REV TQ on regenerative
drives) is still active while the drive is regeneratively braking.

Frequent regenerative deceleration, regenerative braking,
coasting to a stop, or decelerating to minimum speed produces
high torque. This may cause damage to motors, especially
gearmotors that are not properly sized for the application.

27

IC501

IC502

S3 S2

C505

TB502

S0S1 RB1 -15RB2 +15

P501

MIN SPD

T2T1

INHIB IT

FW

INV

P

230V

C502

SW502

C503

A2 A1

TB501

F2

SW501

GND F1

115V

L2

115 230 230 115

SO502

SO501

INH- RUN

T505

T501

FU504

R501

L2

123

SO502

IN H -R U N

123

RUN

COAST

TO STOP

28

Calibration



Warning

Dangerous voltages exist on the drive when 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.

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 CW rotation, and decrease with
CCW rotation. Use a non-metallic screwdriver for calibration.
Each trimpot is identified on the printed circuit board.

Calibration

MINIMUM SPEED (MIN SPD)

The MIN SPD trimpot setting determines the motor speed
when the speed adjust potentiometer is turned full CCW. It is
factory set to zero speed. The minimum speed feature

applies only when the drive is operating in unidirectional
mode.

To calibrate, set the speed adjust potentiometer full CCW.
Adjust the MIN SPD trimpot until the motor turns at the
desired minimum speed.

MAXIMUM SPEED (MAX SPD)

The MAX SPD setting determines the maximum motor speed
when the speed adjust potentiometer is turned full CW. It is
factory set for maximum rated motor speed.

To calibrate, set the speed adjust potentiometer full CW.
Adjust the MAX SPD trimpot until the motor turns at the
desired maximum speed.

29

FU501

FU502

IC501

IC502

S3 S2

C505

TB502

S0S1 RB1 - 15RB2 +15

P501

MIN SPD

T2T1

INHIBIT

FWD

INV

P502

230V

C502

SW502

C503

A2 A1

TB501

F2

SW501

GND F1

115V

L2

115 230 230 115

SO502

SO501

INH-R U N

T505

T501

FU504

R501

C504

L2

L1

FAST ACTING
FUSES ONLY

L2L1

SCR501 SCR502 S

C501

SCR503

30

Calibration

FORWARD TORQUE (FWD TQ)



FWD TQ should be set to 120% of drive nameplate current
rating. Continuous operation beyond this rating may
damage the motor. If you intend to operate beyond the
rating, contact your Minarik representative for assistance.

The FWD TQ trimpot 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 in the
reverse direction. Refer to Figure 17 (page 34) for
recommended FWD TQ trimpot settings 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. Set the speed adjust potentiometer to maximum forward

4. Lock the motor shaft. Be sure that the motor is firmly

5. Apply line power. The motor should be stopped.

6. Slowly adjust the FWD TQ trimpot CW until the armature

7. Set the speed adjust potentiometer to minimum.

8. Remove the power from the drive and unlock the motor shaft.

9. Remove the ammeter in series with the motor armature if it is

speed.

mounted to withstand maximum torque generated by the
motor.

current is 120% of rated drive current.

no longer needed and re-apply power to the drive.

Warning

REVERSE TORQUE (REV TQ)

Calibration

31



REV TQ should be set to 120% of drive nameplate current
rating. Continuous operation beyond this rating may
damage the motor. If you intend to operate beyond the
rating, contact your Minarik representative for assistance.

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 in the
forward direction. Refer to Figure 17 (page 34) for
recommended REV TQ trimpot settings 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. Set the speed adjust potentiometer to maximum reverse

speed.

4. Lock the motor shaft. Be sure that the motor is firmly

mounted to withstand maximum torque generated by the
motor.

5. Apply line power. The motor should be stopped.

6. Slowly adjust the REV TQ trimpot CW until the armature

current is 120% of rated drive current.

7. Set the speed adjust potentiometer to minimum.

8. Remove the power from the drive and unlock the motor shaft.

9. Remove the ammeter in series with the motor armature if it is

no longer needed and re-apply power to the drive.

Warning

FU501

FU502

IC501

IC502

S3 S2

C505

TB502

S0S1 RB1 -15RB2 +15

P501

MIN SPD

T2T1

INHIBIT

FWD TQ REV TQ

INV

P502 P503

230V

C502

SW502

C503

A2 A1

TB501

F2

SW501

GND F1

115V

L2

115 230 230 115

SO502

SO501

INH-R U N

T505

T501

FU504

R501

T502

C504

L2

L1

FAST ACTING

FUSES ONLY

L2L1

SCR501 SCR502 SCR504

C501

SCR503

P509

TACHFWD AC CMAX SPDIR COM P

P505P504 P506

REV ACC DB

P507 P508

SW504

T503

T504

SW503

ARM TACH

FEEDBACK

R503

90 180

ARMATURE

R502

R505R504

SCR505 SCR506

R506

SCR507 SCR508

C510

32

Calibration

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.

Recalibrate the IR COMP setting when using a lower curernt
rated motor. See Figure 17 (page 34), for typical IR COMP
trimpot settings, or recalibrate using the following procedure:

1. Set the IR COMP trimpot to minimum (full CCW).

2. Rotate the speed adjust potentiometer until the motor runs

3. Load the motor armature to its full load armature current

4. While keeping the load on the motor, rotate the IR COMP

5. Unload the motor.

at midspeed without load (for example, 900 RPM for an
1800 RPM motor). A hand held tachometer may be used to
measure motor speed.

rating. The motor should slow down.

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.

Calibration

FORWARD ACCELERATION (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. 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 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. 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.

33

34

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

1HP
90 VDC
10 AD C

3/4 HP
90 VDC

7.6 ADC

1/2 HP
90 VDC
5ADC

1/4 HP
90 VDC

2.7 ADC

1/2 HP
180 VDC

2.5 ADC

3/4 HP
180 VDC

3.8 ADC

1HP
180 VDC
5ADC

2HP
180 VDC

9.2 ADC

FWD TQ REV TQ IR COMP FWD TQ REV TQ IR COMP

1/8 HP
90 VDC

1.3 ADC

1/4 HP
180 VDC

1.4 ADC

FWD TQ REV TQ IR COMP FWD TQ REV TQ IR COMP

1/10 HP
90 VDC

1.1 ADC

1/8 HP
180 VDC

0.67 ADC

FWD TQ REV TQ IR COMP

1/20 HP
90 VDC

0.56 ADC

Calibration

FWD TQ REV TQ IR COMP

RG500 Models

1 HP
90 VDC
10 ADC

FWD TQ REV TQ IR COMP

2 HP
180 VDC

9.2 ADC

3/4 HP
90 VDC

FWD TQ REV TQ IR COMP

FWD TQ REV TQ IR COMP

FWD TQ REV TQ IR COMP

FWD TQ REV TQ IR COMP

7.6 ADC

1/2 HP
90 VDC
5 ADC

1/4 HP
90 VDC

2.7 ADC

RG510 Models

1/8 HP
90 VDC

1.3 ADC

FWD TQ REV TQ IR COMP

FWD TQ REV TQ IR COMP

FWD TQ REV TQ IR COMP

FWD TQ REV TQ IR COMP

1/10 HP
90 VDC

FWD TQ REV TQ IR COMP

FWD TQ REV TQ IR COMP

Figure 17. Typical FWD TQ, REV TQ, and IR COMP Settings

1.1 ADC

1/20 HP
90 VDC

0.56 ADC

FWD TQ REV TQ IR COMP

1 HP
180 VDC
5 ADC

3/4 HP
180 VDC

3.8 ADC

1/2 HP
180 VDC

2.5 ADC

1/4 HP
180 VDC

1.4 ADC

1/8 HP
180 VDC

0.67 ADC

(actual settings may vary with each application)

DB DB

60 Hz

Applications

50 Hz

Ap p licat io n s

Calibration

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 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. See Figure 18, for recommended deadband settings.

35

60 Hz

APPLICATIONS

Figure 18. Deadband Settings

50 Hz

APPLICATIONS

DBDB

RB1

S1

S2±10VDC

COMMON

36

Calibration

TACHOGENERATOR (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. Remove power from the drive.

2. Rotate the TACH trimmer pot to full clockwise (full CW),

3. Rotate the MAX SPD trimmer pot to full counterclockwise

(full CCW).

4. Rotate the IR COMP trimmer pot to full CCW.

5. Place the feedback selector switch (SW504) to the

ARMATURE (ARM) position.

6. Rotate the main speed potentiometer to midrange.

7. Wire the DC tach to the RG500UA. Note: The polarity of

the Tach voltage input to the RG500UA should be T1 (+)
and T2 (-). This polarity may be measured with a DC
voltmeter. If the polarity is incorrect, swap the two tach
input leads to the T1 and T2 terminals on TB502.

8. Apply power to the drive. The motor should be running at

minimum speed.

9. Rotate the main speed potentiometer to full speed in the

forward direction.

10. Turn the maximum speed trimmer pot clockwise until the

desired maximum speed is reached.

11. Remove all power from the drive. The motor should stop.

Calibration

12. Place the Feedback selector switch (SW504) to the

Tachogenerator (TACH) position.

13. Apply power to the drive. The motor should run in the

forward direction.

14. Rotate the TACH trimmer pot CCW so that the maximum

speed is reached. this is the same speed as was obtained
in step 10.

15. Rotate the main speed potentiometer to the reverse

direction (S2 should be negative with respect to S1). The
motor speed should follow the speed potentiometer
position.

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

37

S3 S2

TB502

S0S1 RB 1 -15RB2 +15 T2T1

38

S2

RB1

S2

S1

RG500 SERIES

DRIVE

RG500 SERIES

DRIVE

RB1 1

S2 2

DLC600

DIGI-LOC CONTROLS

PCM4

SIGNAL ISOLATOR

TB502

TB502 TB501

Application Notes

Connection to other Minarik devices

TB502

S2

RG500 SERIES

DRIVE

RB1

TB502 TB501

RG500 SERIES

DRIVE

Figure 19. RG500 Connections to DLC600 and PCM4

S2

RB1

S2

DIGI-LOC CONTROL

S1

2

SIGNAL ISOLATOR

1

DLC600

PCM4

Application Notes

FU501

FU502

IC501

IC502

S3 S2

C505

TB502

S0S1 RB1 -15RB2 +15

P501

MIN SPD

T2T1

INHIBIT

INV

230V

C502

SW502

C503

A2 A1

TB501

F2

SW501

GND F1

115V

L2

115 230 230 115

SO502

SO501

INH-RUN

T505

T501

FU504

R501

C504

L2

L1

FAST ACTING

FUSES ONLY

L2L1

SCR501 SCR502 SCR5

DS501

17 18

K502

14 16151312

K501

IC502

10 11

IL501

POWER

123456

21

200-0386A

LIMIT SWITCH

LOGIC BOARD

TB502 ON

RG500
SERIES

DRIVE

The RG500 can be connected to an optional 200-0386A limit
switch logic board. The 200-0386A provides the logic
interface between the regenerative drive and pushbutton
stations, foot switches, or programmable controls. See Figure
20 for RG500 connections to the 200-00386A limit switch
logic board. For more information on Minarik’s limit switch
logic board, refer to User’s Manual 250-0222 or the Minarik
Product Catalog.

39

200-0386A
LIMIT SWITCH
LOGIC BOARD

Figure 20. RG500 connection to 200-0386A

Limit Switch Logic Board

TB502 ON

RG500 SERIES

DRIVE

POT TAB ASSIGNMENTS

WIPER

CW

CCW

SPEED ADJUST

POTENTIOMETER

INSULATING DISK

PANEL

STAR

WASHER

NUT

MOUNT THROUGH A 0.38 IN. (10 MM) HOLE

40

Application Notes

Optional speed adjust potentiometer
connections

Forward-Reverse Switch

Use a single-pole, two­position switch with a
single speed adjust
potentiometer to plug
reverse the motor (Figure

21). The MIN SPD setting
is in effect for either
direction.

Figure 21. Forward-Reverse Switch

Forward-Stop-Reverse Switch

Use a single-pole, three­position switch with a
single speed adjust
potentiometer to stop a
motor between reversals
(Figure 22). Set the switch
to the center position to
decelerate the motor to a
stop.

Figure 22. Forward-Stop-Reverse Switch

S0

S1

S2

S3

REV

FWD

S0

S1

S2

REV

S3

STOP

FWD

10K

OHM

CW

10K

OHM

CW

Application Notes

Independent Adjustable Speeds (Forward
Direction Only)

Connect two speed adjust potentiometers with a single-pole
two-position switch to select between two independent speeds
shown in the forward direction (Figure 23). The speed adjust
potentiometers can be mounted at two separate operating
stations.

41

S0

S1

S2

SPEED 1

SPEED 2

P1

20K OHM

P2

20K OHM

CWCW

Figure 23. Independent Adjustable Speeds

(Forward Direction)

42

Application Notes

Independent Forward and Reverse Speeds

Connect two speed adjust potentiometers as shown in Figure
24 to select between independent forward and reverse speeds.

S0

S1

S2

S3

FORWARD

REVERSE

FWD
10K OHM

CW CW

REV
10K OHM

Figure 24. Independent Forward and Reverse Speeds

Application Notes

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 25).

43

S0

S1

S2

S3

FORWARD

STOP

REVERSE

FWD
10K OHM

CW CW

REV
10K OHM

Figure 25. Independent Forward and Reverse Speeds

with a Forward-Stop-Reverse Switch

S3 S2

C505

TB502

230V

A2 A1

TB501

F2GND F1

115V

L2

C504

L2

L1

A

ARMATURE

OUTPUT

FIELD

OUTPUT

FOR SHUN T WOUND

MOTORS ONL Y.

See f ield output section

for connections.

230 VAC

115 VAC

AC LINE

INP U T

115 OR 230 VAC

44

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.

Check the following steps before proceeding:

1. The AC line voltage must match the voltage on the drive
nameplate.

2. On dual voltage drives, check that the voltage switches are
set to the correct position.

3. The deadband (DB) 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 fuse FU501 (and FU502 for 230 VAC line
voltage) is properly sized and not blown.

8. Check that field fuse FU503 is 1.5 A and not blown.

Troubleshooting

Field fuse blows

1. Disconnect AC line voltage from the drive.

2. Verify that the fuse is 1.5 A.

3. Check motor cable for shorts.

4. Check motor field for shorts.

a. Disconnect field leads from terminals F1 and F2
b. Motor field resistance should measure approximately

100 to 1000 ohms, depending on motor horsepower.

c. A resistance reading from the motor frame to either

side of the field should show open when an ohmmeter
is used on its high resistance scale.

5. Reconnect field leads to the drive.

6. Reconnect AC line voltage to the drive.

7. Advance the speed adjust potentiometer to the desired
speed.

Line fuse blows

1. Disconnect AC line voltage from the drive.

2. Check that the motor cable and armature is not shorted or
grounded.

a. The motor’s armature resistance should measure

approximately 1 to 100 ohms, depending on motor
horsepower.

b. A resistance reading from the motor frame to either

armature side should show open when an ohmmeter is
used on its high resistance scale.

3. Check that the field circuit is not open.

45

46

Troubleshooting

Motor pulsates or surges under load

1. Readjust the IR COMP setting slightly CCW until the
motor speed is stabilized.

2. Verify that the motor is not going in and out of current
limit. If so, re-adjust FWD TQ and REV TQ pots.

Line fuse does not blow, but the motor does not run

1. Verify that the speed adjust potentiometer is not set to its
zero speed position. If in voltage follower mode, verify
that reference voltage is not set to zero.

2. Check the speed adjust potentiometer for continuity.

3. Verify that the inhibit pins are not shorted together.

4. Check that INHIBIT–RUN terminals 2 and 3 are
connected.

5. Verify that the drive is receiving AC line voltage.

6. Check that the drive is not in current limit. If the drive is in
current limit, verify that the motor is not jammed. It may
be necessary to increase the FWD TQ or REV TQ setting if
it is set lower than the current rating of the motor.

7. Check that the speed adjust potentiometer connections to
the terminal block are correct and not open.

Motor runs too fast at the maximum speed setting

1. Check that the MIN SPD and MAX SPD setting are not set
too high.

2. Check that the field output connections are secure if you
are using a shunt wound motor.

Troubleshooting

Motor will not reach the desired speed

1. Check the MAX SPD setting and increase if necessary.

2. Check that the IR COMP setting is not set too low.

3. Check that the motor is not overloaded.

For additional assistance, contact your local Minarik® distributor,
or the factory direct at: PHONE: (800) MINARIK

FAX: [phone]

47

48

Factory Prewired Connections

(for Cased Drives)

1 2 3

WHITE

BLACK

BLACK

BLACK

WHITE/BLACK

POWER

LIGHT

BLACK/WHITE

L2 (230)

L1

WHITE/BLACK

L2 (115)

Figure 26. Prewired Connections to L1, L2(115) and L2(230)

S0

S1

S2

S3

grey

grey/white

green

blue

REV

FWD

BRAKE

CW

10K

W

blue/
white

Factory Prewired Connections

GREY

S0

S1

S2

S3

GREY/WHITE

GREEN

BLUE

FWD

REV

BRAKE

BLUE/
WHITE

Figure 27. Prewired Speed Adjust Potentiometer

Connections

CW

49

10K

OHM

FU501

FU502

0.93 [24]

3.50 [89]

0.64 [16]

8.90 [226]

.70 [18]

8.40 [213]

1.85 [47]

0.125 [3] REF

4.78 [121]

4.000 [102]

0.28 [7]

IC501

IC502

S3 S2

C505

TB502

S0S1 RB1 -15RB2 +15

P501

MIN SPD

T2T1

INHIBIT

FWD TQ REV TQ

INV

P502 P503

230V

C502

SW502

C503

A2 A1

TB501

F2

SW501

GND F1

115V

L2

115 230230 115

SO502

SO501

INH-RU N

T505

T501

FU504

R501

T502

C504

L2

L1

FAST ACTING

FUSES ONLY

L2L1

SCR501 SCR502 SCR504

C501

SCR503

P509

TACHFWD ACCMAX SPDIR COMP

P505P504 P506

REV ACC DB

P507 P508

SW504

T503

T504

SW503

ARM TACH

FEEDBACK

R503

90 180

ARMATURE

R502

R505R504

SCR505 SCR506

R506

SCR507 SCR508

C510

0.188 [5]

50

Replacement Parts

Replacement parts are available form Minarik Corporation and its
distributors for this drive series.

Table 3. Replacement Parts

Model No. Symbol Description Minarik®P/N

RG500UA R501 0.01Ω, 5 W Resistor 032-0129

RG500A Same parts as RG500UA except 202-0003 and 223-0258.

SCR501-508 800 V, 25 A SCR 072-0042
T505 3FD-436 Transformer 230-0072

10KΩ Potentiometer Kit 202-0003
Chassis 223-0258
20 A, 3AB Line Fuse 050-0019

Include:

Line Fuse Kit (5 – 20A) 050-0073
Pico fuse, 63mA 050-0081

10KΩ, 2W Potentiometer 120-0047
Potentiometer Knob 140-0013
Case 223-0209
240 V Pilot Light 040-0043
FWD/BRAKE/REV Switch 080-0031
Power Switch 080-0022
Toggle Switch Boot 155-0078
Chassis 223-0260
Heat Sink 223-0232

Replacement Parts

Table 3. Replacement Parts (Continued)

Model No. Symbol Description Minarik®P/N

RG510UA R501 0.05Ω, 5 W Resistor 032-0146

SCR501-508 800 V, 25 A SCR 072-0042
T505 3FD-436 Transformer 230-0072

10KΩ Potentiometer Kit 202-0003
Chassis 223-0258
8 A, 3AB Line Fuse 050-0023
Line Fuse Kit (3 – 8A) 050-0069
Line Fuse Kit (5 – 20A) 050-0073
Pico fuse, 1/2A 050-0074

51

RG510A Same parts as RG500UA except 202-0003 and 223-0258.

Include:

10KΩ, 2W Potentiometer 120-0047
Potentiometer Knob 140-0013
Case 223-0209
240 V Pilot Light 040-0043
FWD/BRAKE/REV Switch 080-0004
Power Switch 080-0031
Toggle Switch Boot 155-0078
Chassis 223-0260
Heat Sink 223-0232

52

Certificate of Compliance

Minarik Corporation hereby certifies that its RG500 series
drives have been approved to bear the “CE” mark provided the
conditions of approval (listed in Exhibit “A”) have been met by
the end user.

The RG500 series has been tested to the following test
specifications: EN55011:1991 (emissions), and EN50082-1:1992
(immunity).

Compliance allows Minarik’s RG500 series 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 he/she is
operating.

2. The Original Equipment Manufacturer (OEM) will

implement the product as a component of the machine
being manufactured.

CE Addendum

Exhibit “A”

In addition to EMI/RFI safeguards inherent in the RG500 series’
design, external filtering is required.

®

Minarik requires the Corcom
filter is not available, the specifications are as follows:

L = 1.8 milliHenries.
C = 0.01 microFarad (Line to Ground); 1.1 microFarads
(Line to Line).
Discharge Resistor = 330Kohms.
Rated current: 1.4 times maximum DC motor current.
Filter type: Balanced 2-section.

Table 4. Corcom

Nameplate Current of

Motor Wired to the Drive Corcom®Filter Part Number

0 to 4 amps 6VV1

4.1 to 13 amps 20VV1

The filters in Table 4 should be wired to the AC line 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);

machine ground. This is very important!

not

filters listed in Table 4. If the exact

®

Filters

53

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.

54

CE Addendum

If the end-user is not using a CE-approved motor, a second
filter, part number CEXXRG, must be deployed on the output.
XX = rated current of the filter.

The CEXXRG is a Real-Pole Balanced-Pi 3-pole filter. If the
exact filter is not available, the specifications are as follows:

L & L1 = 2 x (0.8) milliHenries.
C & C1 = 2 x (0.1) microFarads @ 400W VDC.
Rin = 0.1 ohm; Rout = 1.2 ohm.

Table 5. Minarik Filters

Nameplate Current of

Motor Wired to the Drive Minarik Filter Part Number

0 to 4 amps CE04RG

4.1 to 13 amps CE20RG

The filters in Table 5 must be wired 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 Exhibit A 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.
meet CE, the machine will not necessarily meet CE as a
machine.

CE Addendum

55

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.

Use of CE-approved wiring practices, such as proper shielding,
and the filters listed in Exhibit A guarantee the drive will meet
EN55011 (1991 emissions standard) and EN50082-1 (1992
immunity standard).

56

Block Diagram

Figure 28. RG500 Series Block Diagram

Block Diagram

PLEASE NOTE: A MAXI M UM OF 10 mA DC MAY BE SOURCED
FROM THE S1 AND/OR S2 TERMI NALS TO A I SOLATED L OAD OR
15mADCMAYBESOURCEDFROMTHE +15AND-15TERMINALS
TOAISOLATEDLOAD.

PPLLEE AASSEE NNOOTT EE:: AA MMAAXXIIMMUUMM OOFF 1100 mmAA MMAAYY BB EE SSOOUURR CCEE DD
FFRROOMM TTHHEE SS11 AANNDD//OORR SS22 TTEERRMMIINNAALLSS TTOO AA IISSOOLLAATTEEDD LLOOAADD
OORR 1155 mmAA DDCC MMAAYY BB EE SSOOUURRCC EEDD FFRROOMM TTHHEE ++11 55 AANNDD --11 55
TTEERRMMIINNAALLSS TTOO AA IISSOOLLAATTEE DD LLOOAADD..

57

58

Notes

Unconditional Warranty

A. Warranty

Minarik Corporation (referred to as "the Corporation") 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,
the Corporation will repair or replace, at its sole discretion, such products that are
returned to Minarik Corporation, 901 East Thompson Avenue, Glendale, CA 91201­2011 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.
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 breach 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 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, 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.

Minarik Drives

www.minarikdrives.com

14300 De La Tour Drive, South Beloit, IL 61080

Phone: (800) MINARIK or 646-2745;

Fax: [phone] or [phone]

Document number 250–0210, Revision 4

Printed in the U.S.A. -- March 2006