Minarik Drives RG60U Series Users Manual
RG60U Series
RG60U RG60U-PCM
RG61U RG61U-PCM
User’s Manual
Dual Voltage, Adjustable Speed,
SCR Regenerative Drive for
Permanent Magnet DC Brush Motors
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.
SHOCKAVOID
OID
ON
i
Safety Warnings
• This symbol 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 drive 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. Use approved personal protective
equipment and insulated tools if working on this drive with
power applied.
TI
ii
Contents
Regenerative Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Power, fuse and motor connections . . . . . . . . . . . . . . . . . . . . . . .11
Voltage follower (isolated signal) . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Line voltage switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Armature voltage switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Feedback selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Voltage or Current Follower (non-isolated signal, -PCM models) . .19
Polarity reversal switch (-PCM models) . . . . . . . . . . . . . . . . . . . . . .19
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Before applying power: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Startup and shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
To start the drive: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Automatic restart upon power restoration . . . . . . . . . . . . . . . . . .23
Decelerate to a stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Coast to a stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Regenerative brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Invert Inhibit and Invert Enable . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
FORWARD TORQUE (FWD TQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
REVERSE TORQUE (REV TQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
IR COMPENSATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . .35
FORWARD ACCELERATION (FWD ACC) . . . . . . . . . . . . . . . . . . . .36
REVERSE ACCELERATION (REV ACC) . . . . . . . . . . . . . . . . . . . . .36
DEADBAND (DB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
TACH GENERATOR (TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
MAX (RG60U-PCM isolation card) . . . . . . . . . . . . . . . . . . . . . . . . . .40
OFFSET (RG60U-PCM isolation card) . . . . . . . . . . . . . . . . . . . . . . .41
Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Connections to Minarik DLC600 . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
FWD-REV switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Unconditional Warranty . . . . . . . . . . . . . . . . . . . . . .inside back cover
iii
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 . . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 10. Line Voltage Switches (bottom board) . . . . . . . . . . . . . . . .17
Figure 11. Armature Voltage and Feedback
Selector Switch Locations (top board) . . . . . . . . . . . . . . . . .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 Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 the motor rotation. Non-regenerative drives
operate in Quadrant 1, and also in Quadrant 3 if the drive is
reversible (see Figure 1, page VI). 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.
v
vi
ON
OR
E
ON
OR
I
I
V
I
Regenerative Drives
uadrant I
uadrant II
T
TATI
ARROWS IN OPPOSITE DIRECTION = REGENERATIVE ACTI
uadrant
uadrant I
MOT
TORQU
Figure 1. Four Quadrant Operation
Specifications
1
Model Current Range Horsepower Range
RG60U, RG60U-PCM 5.0* 1/4 - 1/2* 0 - 90
RG61U, RG61U-PCM 1.5 1/20 - 1/8 0 - 90
* 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%, 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; S0 to S2) 0 to +/- 10 VDC
Input Impedance (S0 to S2) 30 kohms
Load Regulation
with Armature Feedback 1% base speed
with Tachogenerator Feedback 0.1% base speed
Vibration 0.5G max. (20–50 Hz)
Ambient Temperature Range 10°C – 55°C
Weight 1.1 lb
Armature Armature Voltage
(ADC) (VDC)
5.0** 1/4 – 1** 0 – 180
1.5 1/10 - 1/4 0 - 180
0.1G max. (> 50 Hz)
2
Dimensions
L2
3.70 [94]
2.55 [65]
0.80 [20]
L1
GND
FEEDBACKARMATURE
90-180 ARM-TACH
FWD
ACC
REV
ACC
MAX
SPD
IR
COMP
REV
TQ
FWD
TQ
DB
MIN
SPD
TACH
SW504
C504
JP502
C503
Y501
6.9
+15VS0S1S2S3
POWER
IC504
IC501
TB503
ENABLE
x
4.4
x
1.0
INVERT
INHIBIT
INVERT
ENABLE
LIMIT
FWD
REV
IL502IL501
TB502
IL503
RB1
-15V
RB2
T1
T2
TB501
HEATSINK DIMENSIONS (optional)
SW503
C502
C501
IC502
IC503
INHIBIT
T501
A1
A2
0.19 [5]
0.71 [18]
1.96 [50]
0.19 [5]
1.66 [42]
3.80 [97]
4.30 [109]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 2. RG60U/RG61U Dimensions
3.70 [94]
3.03 [77]
2.55 [65]
1.96 [50]
0.80 [20]
1.66 [42]
TB502
L2
L1
GND
INHENDIR
IC504
IC503
IC502
+5V
COMS3S2S1+IN
IC505
HEATSINK DIMENSIONS (optional)
6.9
MAX OFFSET
J502
C504
-IN
TB501
x 4.4 x 1.0
3Dimensions
A1
0.19 [5]
A2
C503
T503
J501
C502
C501
IC501
IC506
0.71 [18]
0.19 [5]
3.80 [97]
4.30 [109]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 3. RG60U-PCM/RG61U-PCM Dimensions
4
Installation
Mounting
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 drive 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.
Wiring
Warning
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.
5Installation
6
Installation
Shielding guidelines
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 shielding 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.
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.
7Installation
8
Installation
Table 1. Recommended Line Fuse Sizes
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 1 1/2 7.5 15
1 2 10 20
Minarik Corporation offers two fuse kits: part number 050–0069
(3–8A Fuse Kit) and 050–0073 (5–20A Fuse Kit).
S
JUST
R
SK
STAR
R
UT
E
Installation
Speed adjust potentiometer
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).
UNT THROUGH A 0.38 IN. (10 MM) HOL
W
9
N
WASHE
INSULATING DI
PEED AD
POTENTIOMETE
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 terminal
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 5. Screw Terminal Block
Lever Arm
Wire Clamp
Figure 6. Cage-Clamp
Terminal Block
Installation
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 A1 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 this is
opposite of the desired rotation, simply reverse the wiring of A1 and
A2 with each other (A1 - and A2 +).
11
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.
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