Boston Gear®
Ratiotrol®
DC Motor Speed Control
Installation and Operation
Doc. No. 86986
VEL-RG Series 1/6 – 1 HP
VEH-RG Series 1 – 5 HP
Table of Contents
Section I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Description . . . . . . . . . . . . . . . . . . 3
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operator Controls. . . . . . . . . . . . . . . . . . . . . 3
Model Types . . . . . . . . . . . . . . . . . . . . . . . . 3
Controller Identification . . . . . . . . . . . . . . . . 3
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation Conditions . . . . . . . . . . . . . . . . . 4
Performance Characteristics . . . . . . . . . . . . 4
Standard Features . . . . . . . . . . . . . . . . . . . . 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 5
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Principles Of Operation . . . . . . . . . . . . . . . . 5
Section II
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting Instructions . . . . . . . . . . . . . . . . . 6
Wiring Instructions . . . . . . . . . . . . . . . . . . . . 7
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . 8
Section III
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power On/Off . . . . . . . . . . . . . . . . . . . . . . . 10
Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Speed Control . . . . . . . . . . . . . . . . . . . . . . 10
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . 10
Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inoperative Controller . . . . . . . . . . . . . . . . 11
Section IV
Maintenance . . . . . . . . . . . . . . . . . . . . . . . 12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjustment Instructions . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 14
Section V
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Section VI
Option Combinations . . . . . . . . . . . . . . . . . 18
Section VII
List of Illustrations
Figure No. 1 Four-Quadrant
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure No.2 Enclosure
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure No.3 Chassis
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure No.4 Dimensions
Operator Control Station . . . . . . . . . . . . . . 7
Figure No.5 Connection
Diagram Run/Stop . . . . . . . . . . . . . . . . . 19
Figure No.6 Connection Diagram
Run/Stop/Jog Selection
with Jog Speed Pot . . . . . . . . . . . . . . . . . 20
Figure No. 7 Connection Diagram
Run/Stop/Forward, Reverse Selection . . 21
Figure No. 8 Schematic, Control
Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure No. 9 Schematic, Power Board
1/6 - 2 HP . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure No. 10 Schematic Power Board
3 & 5 HP . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure No. 11 Internal View,
Standard Controller . . . . . . . . . . . . . . . . . 25
Figure No. 12 Internal View
1/6 - 2 HP Chassis . . . . . . . . . . . . . . . . . 26
Figure No. 13 Internal View,
3 & 5 HP Chassis . . . . . . . . . . . . . . . . . . 27
List of Tables
Table No. 1
Operator Control Stations . . . . . . . . . . . . . 3
Table No. 2
Typical Application Data . . . . . . . . . . . . . . 4
Table No. 3
Speed Regulation Characteristics . . . . . . . 4
Table No. 4
Dynamic Braking Characteristics. . . . . . . 10
Table No. 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . 14
Table No. 6
Parts List, Controllers . . . . . . . . . . . . . . . 17
Table No. 7
Option Combinations . . . . . . . . . . . . . . . . 18
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . 19
2
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
Section I
General Information
Introduction
Model Types
This equipment manual contains installation,
operation, and maintenance instructions for
VEL/HRG Single-phase Adjustable Speed
Regenerative DC Motor Controllers. A parts list
and illustrations are also included.
Regenerative controllers are supplied in one of
two basic model types, as follows:
General Description
Regenerative Controllers are high performance
units which statically rectify single-phase AC
line power to regulated DC for adjustable speed
four quadrant armature control of DC motors.
Applications include those requiring controllable
bidirectional torque for overhauling loads,
contactorless reversing or precise position
control.
These controllers comply with applicable
standards established by the National Electrical
Code and NEMA for industrial motor and
control equipment
Motors
VEL/H RG controls 1/6 through 3 HP have been
factory-adjusted to run with permanent magnet
motors supplied by Boston Gear. The
VEHRG500CM, 5 HP control has been
adjusted to operate with 18500A-B or
18500ATF-B motors
Operator’s Control
The operator controls may be customer
supplied or supplied by Boston Gear as a
companion to the controller. Boston Gear’s
standard operator control stations contain
industrial rated components in a NEMA Type 1
TENV enclosure, as listed in Table 1.
Table 1. Operator Control Stations
Catalog
Number
66953RS
PushButtons
Run-Stop
Emerg. Stop
Toggle
Switch
-----
66954RS
Run-Stop
Emerg. Stop
Run-Jog
66955RS
Run-Stop
Emerg. Stop
Fwd-Rev
1.Standard-Packaged functional controller
supplied in a rugged die-cast aluminum
NEMA Type 12 enclosure in ratings from
1/6 through 2 HP.
2.-CM-Basic chassis-mount controller,
supplied in ratings from 1/6 through 5 HP,
for those who want to build their own drive
system by the addition of special logic or
auxiliary control devices. This model is a
complete self-contained functional controller
which includes a power conversion and
regulator module, AC line and DC loop
protection, and a motor contactor. Various
pre-engineered options are available.
Controller Identification
Each controller contains a data label. This label
identifies the controller, user connection
terminals and maximum wire size, controller
ratings, operation notes, and applicable options.
Ratings
1. Horsepower Range . . . . . . .1/6 – 5 HP
2. Power Source
. . . . . . 115 VAC, 1-phase, 50 or 60 Hz.
3. 115VAC Unit Output Voltages (1/6-1HP)
Armature . . . . . . . . . . . . . . . .0-90 VDC
Field . . . . . . . . . . . . . . . . . . . .100 VDC
4. 230VAC Unit Output Voltages (1-5HP)
Armature . . . . . . . . . . . . . . .0-180 VDC
Field . . . . . . . . . . . . . . . . . . . .200 VDC
5. Service Factor . . . . . . . . . . . . . . . . .1.0
6. Duty . . . . . . . . . . . . . . . . . . .Continuous
7. Overload Capacity
(Armature Circuit) . . .150% for 1 minute
8. Reference Power Supply . . . . .±10 VDC
Potentiometer (2)
Motor Speed
100-0-100
Motor Speed
100-0-100
Jog Speed
30-0-30
Motor Speed
0-100
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
3
Section I
General Information
Table 2 Typical Application Data
Component
Line
1-Phase Ac
Input
(Full Load)
DC
Output
(Full Load)
115V Unit
Amps
230V Unit
Rated Horsepower
1/2 3/4
1 1 1/2
1/6 1/4
1/3
3.9
6.0 8.7 12.4 15.8
5.0
---
2
3
5
---
---
---
---
---
---
---
---
8.8 12.6 17.0 22.0 35.0
.48
.58
.71 1.0
1.4
2.0
Motor Armature 90V
2.0
2.8
3.5 5.4
8.1 10.5
---
Amps
Motor Field
Amps (max)
--2.0
---
--2.0
---
--- --2.0 2.0
--- ---
--2.0
---
5.5
2.0
2.0
8.2
--2.0
11.6 15.1 24.0
------2.0 2.0 2.0
0.5 0.75 1.0 1.5
2.2
3.0
4.5
6.0
KVA
180V
100V
200V
Full-Load Torque
(lb. ft.) with 1750 RPM Base Speed Motors
Std.
Ch. (1/6-2HP)
Controller Weights
Ch. (3-5HP)
3.0
4.0
5.0
8.0
---
---
---
9.0 15.0
11.5 lbs (5.2 kg)
12.5 lbs (5.7 kg)
17.0 lbs (7.7 kg)
Operating Conditions
Performance Characteristics
1. Line Voltage Variation — ±10% of rated
2. Line Frequency Variation — ±2 Hertz of rated
3. Ambient Temperature*
Standard Model Controller
. . . . . . . . . . . . . .0 to 40ºC (32 to 104ºF)
Chassis Model Controller*
. . . . . . . . . . . . . .0 to 55°C (32 to 131°F)
4. Altitude (standard)
. . . . .1000 meters (3300 feet) maximum
1. Speed Range (controlled) – 0 to motor
base speed
2. Efficiency (maximum speed)
a. Controller SCR regulator - 99%
b. Complete drive (controller with motor,
typical) - 85%
3. Displacement Power Factor (at rated speed
with rated load)- 87%
4. Acceleration (standard) – By current limit
5. Speed Regulation (see Table 3) – Regulation
percentages are of motor base speed
under steady-state conditions.
6. Ripple Frequency - 120 Hz w/60 Hz line
- 100 Hz w/50 Hz line
* Temperature within the enclosure in which the Chassis is
mounted.
Table 3 Speed Regulation Characteristics
Variable
Regulation
Method
Standard Voltage
Feedback with IR
Compensation
Optional Speed
(Tach) Feedback
Speed
Range
Load
Change
95%
Line
Voltage
±10%
Field
Heating (1)
Cold/Normal
Temperature
±1.5%
±1.5%
±7.0%
±0.5%
30:1
±0.2%
±0.2%
±0.2%
±0.2%
100:1
±10ºC
(1)Does Not Apply to Permanent Magnet Motors.
Standard Features
1. Power Conversion --– Dual full-wave converter
consisting of two back-to-back bridges of four
silicon controlled rectifiers (SCR’s) each.
Power bridges are integrated, encapsulated
components.
4
2. Static Reversing--Solid-state reversal of motor
armature.
3. Static Braking--Smooth regenerative braking
under the following conditions:
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
Section I
General Information
Standard Features
a. Overhauling load-whenever the driven load
attempts to exceed the speed reference
signal
b. Speed reference change (signal reduction
or change in polarity).
c. Stop function-motor brakes to minimum
speed before motor contactor opens.
4. Feedback-Counter EMF voltage with
adjustable IR compensation.
5. AC Line Protection-AC line fuse(s) provide
instantaneous protection from peak loads
and fault currents.
6. DC Loop Protection-Current limit fuse
provides protection from inverting faults.
7. Voltage Transient Protection-Metal oxide
suppressor (varistor) across the AC line, and
RC networks across the power bridges,
minimize effects of high voltage spikes from
the AC power source.
8. Isolated Regulator-Internal DC circuits are
isolated from the AC power circuitry for
operator and equipment safety and simplified
application. The control reference input
common may be grounded or connected
without additional isolation to other drive
controllers or grounded output process
controllers or grounded output process
controllers. Isolation eliminates line voltage to
ground potentials on the MOTOR SPEED
potentiometer
9. Control Transformer-24-volt secondary
isolates operator controls and magnetic
control logic from the AC power source for
operator protection.
10. Motor Contactor-Provides positive
disconnection of motor armature from the
controller output, and undervoltage
protection. Contactor is sequenced with the
regulator so that the controller is turned off
before the contactor makes or breaks,
thereby providing contact longevity.
Adjustments
The following potentiometers are located on the
standard control circuit boards in the controller:
1. Current Limit (common forward and reverse
circuits)--50 to 150% of full-load torque
2. Gain (motor stability, factory set)--Adjustable
3.
4.
5.
6.
for individual motor characteristics
IR (load) Compensation – 0 to 100% of
rated load
Maximum Speed (common forward and
reverse circuits) 60 to 100% of motor base
speed
Phase Shift (factory set)--Adjustable for
individual motor characteristics
Error (factory set)--Line frequency calibration
Options
Standardized pre-engineered optional
equipment can be supplied with controllers at
additional costs. See Section VI for option
listing.
Principles of Operation
VEL/H RG Regenerative Controllers, also
known as four quadrant controllers, not only
control motor speed and direction of rotation,
but also the direction or motor torque. See
Figure 1.
Figure 1. Four-Quadrant Operation
QUADRANT II
QUADRANT I
MOTOR ROTATION
TORQUE
QUADRANT III
QUADRANT IV
NOTE:
Arrows
Same Direction
Motoring (Pulling)
Arrows
Opposite Direction
Braking (Holding)
Under braking conditions, controllers convert
the mechanical energy of the motor and
connected load into electrical energy, which is
returned (regenerated) to the AC power source.
With reference to Figure 1, page 5, when the
drive (controller and motor) is operating in
Quadrants I and III, motor rotation and torque
are in the same direction, and the drive
functions as a conventional nonregenerative
unit. In Quadrants II IV, motor torque opposes
the direction of motor rotation, which results in
controlled braking. The drive can switch rapidly
from motoring to braking modes while
simultaneously controlling the direction of motor
rotation.
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
5
Section II
Installation
3. Shock-mount the controller if it is subjected
to external vibrations. Shock and excessive
vibrations are detrimental to controller
performance and life. Vibration can cause
general deterioration of connections, and
component damage.
4. Standard operator control stations can be
wall-mounted using the two holes in the back
of the enclosure. See Figure 4.
5. If the motor is to be foot-mounted, bolt the
motor to a firm, flat foundation. If the
foundation is not flat, use shims to prevent
strain when tightening the bolts. If the motor
is to be connected directly to a machine, be
sure of correct alignment. Pulleys and
couplings must slip freely onto the motor
shaft.
Mounting Instructions
1. Surface mount the controller in a dry location
with the mounting holes (or tabs) provided.
The standard enclosure should not be used
where a watertight, weatherproof, or
explosion proof enclosure is required. See
Figure 2 or 3 for mounting dimensions.
Caution
Never Mount The Controller
Immediately Beside Or Above HeatGenerating Equipment, Or Directly
Below Water And Steam Pipes.
2. Allow for free air circulation around the
controller-four inches minimum clearance on
all sides, for maximum cooling efficiency. If
the controller is user-mounted in an
enclosure, allow for adequate ventilation. Air
passages into the bottom, with exit openings
near the top, form an adequate configuration.
If a small enclosure is used, a ventilation fan
may be required.
Max. Control Proj.
1.33
.65 (34)
(17)
Control
Panel
9.34
(237)
6.00
(152)
Never hammer the pulleys, couplings,
or motor shaft, nor overtighten drive
belts or timing chains. Bearing damage
could result.
1.35 (34)
12.00
(305)
1.75 (44)
Caution
D
Mounting
Slots
Width
.25 (6)
W
M2
M3
M4
D
8.59
(218)
1.20 (30)
Conduit
Entrance
¾-14 N.P.T.
(4) Places
10.55
(268)
6.0156
(153)
9.06
(230)
16.81
(427)
.25 (6)
Figure 2. Enclosure Dimensions
Model
HP
VEL/H RG16-200CM
VEH RG300/500CM
Dimensions (Inches)
W
H
1/6-2
9 7/8
13
3-5
12 3/4
13
M1
D
12 1/4 6 9/16
12
M4
M3
Holes
5
3/8
2 7/16
3/16
1/2
7/16
9/32
6 1/4 11 3/8
Figure 3. Chassis Dimensions
6
M2
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
Section II
Installation
Wiring Instructions
1. Refer to the nameplate in the controller and
be sure the input voltage and frequency to
the controller complies with its rating.
2. The controller is protected from normal line
transients and surges. However, to prevent
problems from high-energy transients and
large surges, observe the following:
a. Place the controller on a feeder line
separate from that supplying large
inductive loads.
b. If the input to the controller comes directly
from a transformer, always switch power
ON and OFF between the transformer
secondary and the controller.
Caution
Never make or break power in the
transformer primary. Transients could
be generated which could damage the
controller.
c. If the controller must be fed from an AC
feeder which also feeds highly inductive
loads, supply additional suppression to
limit transients or surges to 150% of peak
line voltage.
2.06 (52)
3.00
(76)
1.12 (28) Dia.
One
End
1.50 (38)
.88 (22) Max.
Control
Proj.
3.00
(76)
.19 (5) Dia.
(2) Holes
Caution
1. Oversize or solid wire, as well as
large screwdrivers for electrical
connections, can break terminal
board barriers.
2. All wiring must comply with the
national and local electrical codes
4.Use the 3/4-14 NPT tapped conduit holes in
the enclosure of standard controllers to
facilitate wiring.
5. All external wiring for low voltage signal
sources; e.g., potentiometers, tachometer
generators, transducers, should be run in
separate conduit from all other wiring.
Use twisted shielded cable. Maintain the
separation of power and signal wiring
within an enclosure by two inches
minimum.
Caution
Pickup from unwanted signals can
cause erratic operation and / or
controller damage.
6. Since the DC circuits are isolated from the
AC input power, the reference input common
can be grounded, or connected without
additional isolation to other drive controllers
or grounded output process controllers.
7. Interconnection wiring is required between
the controller, AC input power, operator
controls, and applicable optional equipment.
7.50
(191)
1.62
(41)
3. The wire size of the input power and motor
wiring can be determined from Table 2 and
the controller data label. Stranded wire is
recommended for all external wiring.
9.00
(229)
.69
(18)
AC Power Connections
Caution
.75 (19)
Figure 4. Operator Control Station Dimensions
Caution
Never Use The Power Factor
Correction Capacitors On The Input
Line To The Controller. These
Capacitors May Damage The SolidState Components
Be sure metal chips from drilled
conduit holes in a n enclosure do not
enter the controller.
Metal chips can cause short circuits
and/or grounds which can damage
the controller.
Connect the AC input power wires to controller
Terminals L1 and L2. See Figure 11, 12 or 13,
as applicable. If one of the power wires is a
neutral wire (grounded potential), connect it to
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
7
Section II
Installation
Terminal L2 and connect the hot wire (H) to
Terminal L1.
Connect the controller enclosure to an earth
ground according to applicable electrical codes.
A Ground Connection Screw (GND) is provided
for this purpose in enclosed controllers. (See
Figure 11)
operating conditions. Therefore, startup
adjustments should not be needed. However,
the following startup procedure should be
performed for proper operation, system
compatibility, and safety.
Motor Connections
1. Be sure all interconnection wiring is correct,
and all wiring terminations are tightened
securely. Wiring errors and accidental
grounds can cause controller and/or
motor damage.
2. Check the factory sealed potentiometers on
the control board and be sure they are at their
factory settings. See Figure 11, 12 or 13 for
potentiometer locations. If any potentiometer
has been moved, return it to its factory
setting.
NOTE: The MAX SPD (R52) and GAIN NO. 1
(R6) potentiometers are not sealed.
3. Turn the MOTOR SPEED potentiometer to
zero on its dial.
4. If used, place the RUN/JOG switch in RUN
position.
5. Couple the motor to the machine (load).
6. Turn on the AC power.
7. Depress the RUN button, and slowly turn the
MOTOR SPEED potentiometer until the
motor rotates. If motor rotation is opposite to
that desired, stop the motor with the STOP
button, turn off the AC input power, and
interchange the motor armature leads at the
motor connection box
8.Turn the MOTOR SPEED potentiometer to
100 on its dial. The motor should run at top
speed. Top speed is rated (base) speed. If top
speed cannot be reached, check motor
armature voltage. If armature voltage is below
rated, proceed as follows:
Controller
Minimum
Rating
Line Voltage
115 VAC
103 VAC
230 VAC
207 VAC
a. Check for insufficient line voltage on
controller Terminals L1 and L2. Minimum
requirements are as follows:
b. If the motor has a shunt field, check the
voltage on Terminals F+ and F-. If rated
line voltage is 115 VAC, the shunt Field
Check the motor data plate and be sure the HP,
voltage, and current ratings are compatible with
ratings listed on the controller data label.
Connect the motor field and armature terminals
(or leads) to controller Terminals F+, F-, A+ and
A-, respectively.* (See Figures 11, 12, or 13)
Caution
Do not ground the motor wiring.
Grounded wiring can cause controller
damage.
NOTE* Terminals F+ and F- are not used with
permanent-magnet motors
Connect the motor thermal switch, if used, in
series with Terminal 1 (Terminal Board TB1) on
the controller power board.
Operator Control Station Connections
Connect the operator control station as shown
in Figure 5, 6 or 7 (as applicable)
Each standard operator control station contains
two stop push-buttons-STOP and EMER STOP.
A Stop function provides controlled regenerative
braking, and an Emergency Stop function drops
out the motor contactor immediately, applies
dynamic braking and prevents a restart until the
motor stops. If dynamic braking is impractical
(due to load inertia) or is not desired,
disconnect DB resistor(s). If one of the stop
functions is not used, be sure to series connect
the two stop buttons so that each button will
stop the motor.
The MOTOR SPEED potentiometer must be
10,000 ohms with a 1/2 watt minimum rating.
Initial Startup
Before energizing the controller for the first
time, be familiar with any installed options.
See the option selection table in Section VI.
The controller has been factory tested and
adjusted with a motor under simulated
8
Startup Procedure
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
Section II
Installation
voltage should be 100 VDC, ±10 VDC. If
rated line voltage is 230 VAC, the shunt
filed voltage should be 200 VDC, ±20 VDC
c. Depress a RUN button, and turn the
MOTOR SPEED potentiometer to 100 on
its dial.
d. Turn the MAX SPD potentiometer (R52)
Caution
Do not exceed rated armature voltage.
Excessive armature voltage may cause
the controller fuses to blow when motor
speed is decreased rapidly from top
speed or when a Stop function is
initiated.
until rated armature voltage is recorded.
See Figure 11, 12 or 13 for the location of
R52.
e. If desired, maximum speed can be
decreased to 60% of motor base speed.
f. If the adjustment of Potentiometer R52
does not increase top speed, see Indication
#7 in the troubleshooting table (Table 5).
Also see Step 2 of this Startup Procedure.
9. If the MOTOR SPEED potentiometer has a
“zero-center” for bidirectional operation, turn
it fully counterclockwise to 100. The motor
should run in the reverse direction at rated
speed Forward and reverse maximum
speeds should be identical.
10. If motor speed is unstable, proceed as
follows:
a.Run the motor at half speed and slowly turn
the GAIN NO. 1 potentiometer (R6)
clockwise until motor speed stabilizes. See
Figure 11, 12 or 13 for the location of R6. If
instability increases, turn potentiometer R6
counterclockwise until motor speed
stabilizes.
b.If the adjustment of potentiometer R6 does
not stabilize motor speed, adjust R6 for
minimum instability, then turn the IR COMP
potentiometer (R63) counterclockwise until
motor speed stabilizes. See Figure 11, 12
or 13 for the location of R63. If motor speed
does not stabilize, see Indication #9 in the
troubleshooting table (Table 5). Also see
“Adjustment Instructions” in Section IV.
11. If the rate or acceleration of braking
response is too slow, if top speed cannot
be reached after performing Step 8, or if
there is a probability of armature current
being limited, proceed as follows:
a.Turn off the AC power and connect a zero
center DC ammeter in series with the motor
armature. Suggested ammeters are as
follows:
HP
Ammeter
Rating
Scale
1/6-2
30-0-30
3-5
50-0-50
b.Apply AC power, set the MOTOR SPEED
potentiometer at 50%, and depress the
RUN button. During acceleration, the
ammeter should read 150% or rated
armature current. Depress the STOP
button, and the ammeter should again
record 150% armature current.
c. If 150% of rated armature current is not
recorded, refer to Stop 9 of “Adjustment
Instruction” in Section IV.
12. Turn the MOTOR SPEED potentiometer to
0 and depress the STOP button.
13. Close and latch the enclosure door.
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
9
Section III
Operation
Stop
General
Depress the STOP button or the EMER STOP
button to stop the motor.
VEL/H-RG Controllers provide the following
operation functions: Run, Stop, Emergency
Stop, Speed Control, and Reversing. The actual
operator controls and location of same will vary
according to the model controller and the
options selected.
When the STOP button is depressed, the
controller provides controlled regenerative
braking
When the EMER STOP button is depressed,
power is removed immediately from the motor
armature, and the motor dynamically brakes to a
stop. An Antiplug Relay (APR) prevents the
motor from being restarted until it stops. Relay
APR picks up immediately after the motor starts
and drops out immediately before the motor
stops. APR contacts, connected in the run/stop
logic, prevent an operation function until a safe
minimum speed is attained.
Power ON/OFF
Controllers are energized when AC power is
applied to the controller. Normally, this occurs
when the user supplied input line disconnect
switch or circuit breaker is turn on.
Run
NOTE: If the dynamic braking is disconnected,
depressing the EMER STOP button will
cause the motor to stop at a rate
proportional to the deceleration (coast)
rate of the driven load.
To start the motor, depress the RUN button, and
the motor will accelerate to the setting of the
MOTOR SPEED potentiometer.
Speed Control
Dynamic braking provides exponential rate
braking of the motor armature, which occurs
when the circuit opens between the controller
and the motor armature, and a Resistor (DB)
connects across the armature.
Motor speed is directly proportional to the
setting of the MOTOR SPEED potentiometer.
This potentiometer may be adjusted while the
motor runs or may be preset at any position
before the motor is started.
When an Emergency Stop (dynamic braking)
function is initiated, the motor functions as a DC
generator and feeds the kinetic energy of its
armature and connected load through Resistor
DB where it is dissipated as heat. This opposes
motor rotation, thereby stopping the motor.
Reverse
When a zero-center MOTOR SPEED
potentiometer is used, turning it one direction
rotates the motor in a particular rotating direction
at a speed directly proportional to the
potentiometer setting. Turning the potentiometer
in the opposite direction, rotates the motor in the
opposite direction at a speed directly
proportional to the potentiometer setting. When
the potentiometer is in center position, motor
speed is zero.
Resistor DB is rated to provide initial braking
torque as shown in Table 4.
Caution
High inertia loads and / or armature
voltage higher than rated may extend
braking time beyond the wattage rating
of the resistor.
Table 4. Dynamic Braking Characteristics
Component
Braking Torque %
Stops Per Minute
10
Unit
115V
Rated Horsepower
1/6
1/4 1/3 1/2
3/4
1
1 1/2
2
3
5
300 215 170 110
75
60
---
---
---
---
230V
---
---
---
---
---
220
115V
9
6
5
5
4
4
---
---
---
---
230V
---
---
---
---
---
4
3
3
4
4
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
145 105 170 100
Section III
Operation
Jog
Controller are capable of jogging, but Option 9 must
be selected for the function.
If jogging is installed, place the RUN/JOG toggle
switch in JOG position and jog the motor with the
RUN button. Jog is momentary, causing motor
rotation only while the RUN button is depressed.
Release the RUN button to stop the motor. Jog
speed is controlled by a separate JOG SPEED
potentiometer, adjustable from 0 to 30% of motor
base speed.
Inoperable Motor
If the motor stops and/or won’t start, check the
controller for a blown fuse. See Figure 11, 12 or 13
for fuse locations. The fuses provide instantaneous
protection for the solid-state components from fault
currents and peak loads. Therefore, if a fuse blows
replace it with an exact replacement.
Caution
Do not substitute fuses.
Substitute fuses can cause controller and/or
motor damage.
If the replacement fuse blows, turn off the AC power
and refer to the troubleshooting table in Section IV of
this manual.
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
11
Section IV
Maintenance
Maintenance
WARNING
1. CONTROLLERS CONTAIN HIGH VOLTAGE
WHICH CAN CAUSE ELECTRIC SHOCK
RESULTING IN PERSONAL INJURY OR
LOSS OF LIFE.
2. NEVER CLEAN, REPAIR OR ADJUST THE
CONTROLLER WITH THE AC POWER ON.
General
Controllers require very little maintenance,
other than occasional visual inspection and, if
necessary, external cleaning. They must be
kept dry and reasonably free from dust, dirt,
and debris. No parts require periodic
replacement.
Maintain the motor according to maintenance
instructions supplied by the motor
manufacturer.
Visual Inspections
1. Be sure all wires are fastened securely.
2. Check components for damage due to
overheating or breakage. All damaged
and/or faulty components must be replaced
satisfactory operation.
Adjustment Instructions
Controllers are factory adjusted with a motor
under simulated operating conditions.
Therefore, except for initial startup adjustments
(see Section II), readjustments should not
normally be needed. However, if circuit boards
are replaced, or to make the controller
compatible with another type motor, the
following adjustments can be made. All
adjustments must be made in strict
conformance to the following instructions.
Refer to Figure 11, 12 or 13 when performing
the adjustment instructions.
Equipment Required
1.Ungrounded oscilloscope or an
oscilloscope isolated from the AC supply.
2.A zero center DC ammeter (1/6-2 HP 30-030 scale; 3-5 HP, 50-0-50 scale).
3.Digital voltmeter or a multimeter with
minimum input impedances of 20,000
ohms/volt DC and 5,000 ohms/volt AC.
4.Tachometer (useful, but not required).
12
Power on Adjustments
1.Turn on the AC power.
2.Connect the oscilloscope probe to Pin #1 of
Integrated Circuit U9 (or Test Point TP5, if
provided), located on the control board. Be
careful not to short circuit the pins on U9.
3. Adjust the POS ERROR (FWD RAMP)
potentiometer (R81) until the negative
peaks of the waveform on the oscilloscope
are at zero volts, as shown below.
+10V
0
Positive Peaks
Negative Peaks
NOTE: If negative peaks are less than zero
volts, unstable operation and/or fuse
blowing will occur.
4.Connect the oscilloscope probe to Pin #7 of
U9 (or Test Point TP6, if provided).
5.Adjust the NEG ERROR (REV RAMP)
potentiometer (R89) for the results described
in Step 3.
6.Uncouple the motor from the load (machine).
7.Set the MOTOR SPEED potentiometer at
zero.
8.Depress the RUN button and slowly turn the
MOTOR SPEED potentiometer to 50% in
either direction. Check for stable motor
speed. If motor speed is unstable, see
Indication #9 in the troubleshooting table
(Table 5).
9.With the MOTOR SPEED potentiometer set
at 50%, alternately depress the STOP and
RUN buttons while observing the ammeter.
During acceleration and braking, armature
current should reach 150% of rated. If
necessary, adjust the CUR LIMIT
potentiometer (R16) to attain 150% rated
armature current immediately after a RUN or
STOP button is depressed.
NOTE: If the controller contains bidirectional
linear acceleration or “soft”
acceleration/deceleration, the rate of
acceleration must be set at minimum to
attain the correct results when
performing Step 9.
10. Turn the MOTOR SPEED potentiometer
toward zero until the motor is running
approximately 50 RPM.
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
Section IV
Maintenance
11. Connect the oscilloscope probe to Test
Point TP2 on the control board.
12. Turn the CUR STBLY potentiometer (R28)
clockwise until the waveform frequency is 60
Hertz. Then turn Potentiometer R28
counterclockwise until the waveform frequency is
120 Hertz.
13. Stop the motor and recouple it to the load
(machine).
14. Depress the RUN button and run the motor at
half speed in the rotating direction so that
Terminal 2 on the input board is positive, with
respect to Terminal 4. This is normally the
forward rotating direction.
15. Connect the oscilloscope probe to Test Point
TP1 on the control board.
16. a. Slowly turn the GAIN NO. 2 Potentiometer
(R11) clockwise until the peaks of the
waveform become unequal in voltage (height)
as shown below.
16ms
Unequal
Peaks
b. Slowly turn GAIN NO. 2 Potentiometer (R11)
counterclockwise until the waveform peaks
are equal, as shown below.
16 ms
Equal
Peaks
17. With the motor running at half speed, turn the
GAIN NO. 1 Potentiometer (R6)
counterclockwise until the waveform becomes
unstable. Then turn potentiometer R6 clockwise
until the waveform stabilizes.
18. Connect the oscilloscope probe to Test Point
TP3 on the control board.
19. Slowly turn the IR COMP potentiometer (R63)
counterclockwise until the oscilloscope displays
minimum AC ripple. If motor speed is unstable,
turn potentiometer R63 counterclockwise until
motor speed stabilizes.
20. Adjust the 0 SHIFT Potentiometer (R47) for
minimum AC ripple at Test Point TP3. If motor is
unstable, turn IR COMP Potentiometer R63
counterclockwise until motor speed stabilizes.
21. Set maximum speed as described in Steps 8d
through 8g under “Initial Startup” in Section II.
22. Stop the motor, turn off the AC power and
disconnect all test equipment.
Troubleshooting
Most electrical failures are caused by incorrect
connections, overload, or the accumulation of dirt,
dust or moisture. Dirt and dust deposits limit the
transfer of heat from the solid-state components.
Moisture, usually caused by either “wash-down” or
condensation, can cause insulation failures and short
circuits. Be sure the controller is clean and dry
before doing troubleshooting.
WARNING
BE SURE THE AC POWER IS TURNED OFF
BEFORE WORKING ON THE CONTROLLER.
If repeated fuse blowing and/or power bridge failures
occur, turn off the AC power and protect the Power
Bridge (BR1) by connecting a 4 ohm, 300 watt
resistor in series with the Current Transformer (CT1)
primary, as follows:
HP
Rating
1/6-2
3-5
Installation Instructions
Remove the wire from Tab E1 on the
power board, and connect the resistor
between the wire and Tab E1.
Remove the wire from Terminal 10 at
Terminal Board TB-2 on the power
board and connect the resistor
between the wire and Terminal 10.
Then, check the AC input power for transients (high
level spikes) or rapid power fluctuations. Remove the
resistor after the cause of failure has been corrected.
If a circuit board fails, check all inputs to the board
for proper values before replacing the board. Install a
resistor, as described above, before applying power
to a new circuit board. If the controller operates
correctly, turn off the AC power and remove the
resistor.
Use standard troubleshooting procedures; e.g.,
continuity checks, to detect faults in relay and
switching logic and operator controls.
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
13
Section IV
Maintenance
Maintenance
Table 5. Troubleshooting
Indication
1. AC Line Fuse (F1, F3) blows when
power is applied to controller
2. AC Line Fuse (F1, F3) blows when
motor starts to turn
3. AC Line Fuse (F1, F3) blows while
motor is running
Possible Cause
Wiring faulty or incorrect
Circuit, component, or wiring grounded
Power Bridge (BR1, BR2) shorted
Power board failure
Control board failure
Shunt field shorted or grounded
Power Bridge (BR1, BR2) shorted
Motor shorted or grounded
Control board failure causing SCR’s
to turn on fully
Low line voltage
Overload
Loose or corroded connection. Wiring
faulty, incorrect or grounded
Top speed set too high
4. Armature Fuse (F2) blown
Motor shorted or grounded
SCR breaking down (intermittently shorting) in Power Bridge (BR1, BR2)
Control board failure causing SCR false
firing or misfiring
Overload
5. Fuses not blown, but motor won’t run
Wiring faulty, incorrect, or grounded
between the controller and motor.
Armature shorted or grounded
AC line open
6. Motor rotates when speed
reference is zero
Operator controls or relay logic inoperable
MOTOR SPEED potentiometer failure
Motor Failure
Control, input or power board failure
High line voltage
Power Bridge (BR1, BR2) shorted
Control or input board failure
14
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
Corrective Action
Check all external wiring terminating
in the controller.
Remove unwanted ground.
Replace shorted power bridge
Replace power board.
Replace control board.
Repair or replace motor.
Replace shorted power bridge.
Repair or replace motor.
Replace control board
Check for rated line voltage, ±10%,
controller AC line terminals.
Check shunt field current. Insufficient
shunt field current causes excessive
armature current. If field current is
OK, check for mechanical overload. I
If the unloaded motor shaft does not
rotate freely, replace motor bearings.
Also check for shorted armature.
Check fuse terminals and all
terminals, connections and wiring
between the line, controller and
motor.
See Steps 8d through 8g under
“Initial Startup” in Section II.
Repair or replace motor.
Replace faulty power bridge.
Replace control board.
Check shunt field current. Insufficient
shunt field current causes excessive
armature current. If field current is O
OK, check for mechanical overload.
If the unloaded motor shaft does not
rotate freely, replace motor bearings.
Check wiring and connections
Repair or replace motor.
Be sure external disconnect switch
or circuit breaker is turned on and ra
rated AC power is applied to
controller.
Repair accordingly.
Replace potentiometer.
Repair or replace motor.
Replace faulty board.
Check for rated line voltage, ±10%, on
controller AC line terminals.
Replace shorted power bridge.
Replace faulty board.
Section IV
Maintenance
Maintenance
Table 5. Troubleshooting
Indication
7. Motor does not attain top speed
Possible Cause
Low line voltage
Overload
8. Motor runs at fast speed only
9. Unstable speed
MOTOR SPEED potentiometer failure
MAX SPEED potentiometer (R52)
misadjusted
Control or input board failure
Power Bridge (BR1, BR2) failure
Power Bridge (BR1, BR2) failure
Control board failure
Feedback circuit open
AC line voltage oscillating
Oscillating load connected to the motor
Motor failure
SCR’s misfiring or false firing
10. High, unstable speed, low torque
11. Top speed only 1/2 (approximately)
of motor base speed and motor
noisy (possible half-waving)
12. Motor surges when starting
13. Line and armature current excessive
14. Shunt field current insufficient
Armature and field connections
interchanged
Power Bridge (BR1, BR2) failure
Power Bridge (BR1, BR2) breaking down
Faulty control board
Power Bridge (BR1, BR2) breaking down
(shorting intermittently)
Faulty control board
Overload
Open shunt field winding or wiring to the
shunt field
Field bridge failure
15. Shunt field current excessive
Field bridge failure
Shunt field windings shorted
Corrective Action
Check for rated line voltage, ±10%, on
controller AC line terminals.
Check shunt filed current. Insufficient
shunt field current causes excessive
armature current. If filed current is OK,
check for mechanical overload. If Unloaded motor shaft does not rotate
freely, replace motor bearings. Also
check for shorted armature.
Replace potentiometer.
See Steps 8d through 8g under “Initial
Startup” in Section II.
Replace faulty board.
Replace faulty power bridge.
Replace faulty power bridge.
Replace faulty board.
Check for open Resistor (R5-R8) and
feedback board.
Observe line voltage with voltmeter or
oscilloscope. If oscillations occur, contact electrical or local utility company.
Correct condition accordingly.
Check motor brushes and replace if
needed. Repair or replace motor.
Replace Power Bridge (BR1, BR2)
and/or control board.
Check controller-to-motor wiring.
Replace faulty power bridge.
Replace faulty power bridge
Replace control board.
Replace faulty power bridge.
Replace control board.
Check shunt field current. Insufficient
shunt field current causes excessive
armature current. If field current is OK,
check for mechanical overload. If
unloaded motor shaft does not rotate
freely, replace motor bearings. Also
check for shorted armature.
Check motor shunt field and associated circuitry for loose connection
or broken wire.
Replace field bridge (Diodes D1, D2,
D3, D4) or power board.
Replace field bridge (Diodes D1, D2,
D3, D4) or power board.
Check shunt field current and/or
measure shunt field resistance and
compare with motor data plate. Repair
or replace motor.
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
15
Section IV
Parts List
Maintenance
Table 5. Troubleshooting
Indication
16. Motor thermal switch open (if so
equipped)
Possible Cause
Ventilation insufficient
Motor armature drawing excessive
current
Motor overheating from friction
Shorted motor windings faulty bearings
16
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
Corrective Action
Free the motor intake and exhaust
screens from dirt, dust and debris.
Check shunt field current. Insufficient
shunt field current causes excessive
armature current. If field current is OK,
check for a mechanical overload.
Check for misalignment. Realign motor.
Repair motor.
Section V
Options
Parts List
Table 6. Parts List
Boston Part Number
Drawing
Designation
APR
BR1, BR2
--------F1
F2
F3
------------RV1
DB
Description
Relay, Antiplug
Power Bridge
Control Board
Latch
Fuse, Line
Fuse, Armature
Fuse, Line
Feedback Board
Input Board
Power Board
Varistor
Resistor, Dyn. Brake
115 VAC
230 VAC
1/6-1 HP
1-2 HP
3-5 HP
60263
66940
66936
63817
66946
66946
66952
66945
66943
66937*
60878
66920
60263
66940
66936
63817
66946
66946
66947
66945
66943
66937*
60878
66920
60263
66942
66936
63817
66949
66949
66951
66945
66943
66938*
60878
66924
NOTE: *Specify horsepower when ordering.
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
17
Section VI
Option Combinations
Illustrations
Table 7. Option Combinations
All VEL/H RG Controllers are supplied, as standard, with Dynamic Braking. Other options are listed
below. Only one option from Group “C” can be utilized in a single control.
Group
No.
A
18
Description
Remarks
4
--
Dynamic Braking
Unidirectional Operation
-21
Direction by Selector Switch
10-Turn Speed Pot
Standard
Standard, by reconnection of of remote
station to input board
Specify Remote Station Item No. 66955
Specify Kit No. 66929, for installation in
remote station-unidirectional only
B
9
Jog by Selector Switch, Adjustable
Specify Remote Station Item No. 66954
C
17
17S
22
25
Adj. Bidirectional Linear Accel.
“Soft” Accel/Decel
DC Tach. Follower
DC Signal (ma) Follower
Specify
Specify
Specify
Specify
D
24
DC Tach. Feedback
Specify Item No. 66932
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
Item
Item
Item
Item
No.
No.
No.
No.
66925
66926
66930
66935
Run
Emer. Stop
Stop
Motor
100
Speed
0
10K, 1/2W
100
GND
Station
4
3
2
1
7
6
5
8
12
11
10
9
Notes:
1
6
5
4
2
3
TB1
1
2
3
4
5
6
Controller
Power Board
1. Add wires 1 thru 9 from operator control station to TB1 and
TB3 in the controller.
2. Wires 7, 8 and 9 must be 3-conductor twisted and shielded
cable-such as Alpha No. 2258/3.
3. Connect shield of wires 7, 8 and 9 to controller or enclosure
ground.
4. For unidirectional operation move wire 7 to TB3-3 and
remove the 100-0-100 label on the run speed dial. Beneath
this label is the 0-100 legend.
1
2
3
4
5
TB3
9
8
7
Part #66953
Figure 5. Connection Diagram, Run/Stop, Remote Control Station,
7
8
9
TB1
13
Input Board
Section VII
Illustrations
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
19
20
Jog
Run
Emer. Stop
Stop
Motor
100
Speed
0
10K, 1/2W
100
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
GND
Station
4
3
2
1
7
6
5
8
12
11
10
9
Notes:
1
6
5
4
2
3
1
2
3
4
5
6
TB1
Controller
Power Board
1. Add wires 1 thru 9 from operator control station to TB1 and
TB3 in the controller.
2. Wires 7, 8 and 9 must be 3-conductor twisted and shielded
cable-such as Alpha No. 2258/3.
3. Connect shield of wires 7, 8 and 9 to controller or enclosure
ground.
4. For unidirectional operation move wire 7 to TB3-3-4 and
remove the 100-0-100 label on the run and jog dials. Beneath
this label is the 0-100 legend.
9
1 8
2 7
3
4
5
TB3
Figure 6. Connection Diagram, Run/Stop/Jog Selection with .
Remote Control Station, Part #66954
7
8
9
TB1
13
Input Board
Section VII
Illustrations
EMER
STOP
STOP
RUN
FWD
REV
11
8
10
6
3
2
5
0
100
2
1
4
3
6
9
7
11
Remote
Station
66955
5
4
3
2
1
TB1
9
8
7
6
10
10 13
9 12
11 11
NOTES:
9
1
8
2
7
3
10
4
5
TB3
1
6
5
4
2
3
TB1
1
2
3
4
5
6
Controller
Power Board
1. Add Wires 1 thru 10 from operator control station to TB1 and
TB3 in the controller.
2. Wires 7, 8 and 9 must be 4-conductor twisted and shielded
cable-such as Alpha No. 2258/4.
3. Connect shield of wires 7, 8 and 9 to controller or enclosure
ground.
Input Board
Figure 7. Connection Diagram, Run/Stop/Forward-Reverse Selection, Remote Control
Station Part # 66955
1
4
Motor Speed
Section VII
Illustrations
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
21
22
4
R5
47
27k
R3
R1
47
+24v
+12v
8
6
-12v
Sum
7
10
R1
1k
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
J5
Power
XFMR
Off
Regen.
To Stop
20 VAC
Sync XFMR
P5 To Power BD
Current
XFMR
Arm
Feedback
21
22
20
19
+12v
16
17
82.5k
1%
R4
1k
R3
D2
D1
14
15
13
5
9
12
11
10
6
1
4
D8
R134
D30
IN5393
(2 PL)
D31
C9
.47
100k
C36
+
50/
50v
D34
D35
R150
100
R71
R70
22k
R69
22k
R52
10k
68k
Q22
R151
220
Q24
10k 1%
G
R19
100k
R53
10k
10
R153
Q25
Q23
4.7
R152
Q27
MJE234
D39
D38
D36
D37
Q26
+
47k
R145
47k
.01
C12
C41
.1
Q20
.01 +12v
C13
C42
.1
14
Q21
13 U22
3146
C43
.1
R147 +12v
22k
+12v
27k
R78
R79
27k
2.2m
+12v
27k
R80
C14
.01
.01
C15
3 2 1611 76
10 74C 12
1 221 4
9 8 1514
R65
2.2k
14
3
-12v
100k
1%
R86
R87
100k
R84
10
R88
C17
.1
+6v
+12v
TP5
C18
3.3k
R85
4.7
C19
6.8/35v
TP6
C22
.1
C20
.1
R92
9
8
+12v
U2F
-12v
2.2k
+12v
Ramp Reset
Ramp Reset
10
13
R94
U11D
C21 10
.1 R93
Alt Cycling
Alt Cycling
Alt Cycling
R83
2 - .047
9 22k
1
+ 14 11 74C 10
3 324
+ U9B
8 339
- U11C 914
U2E
Alt Cycling
C16
Ramp Reset
Ramp Reset
Direction
Direction
Phase Control
+12v
+12v
Rev 1
Fwd 1
Phase Control
+12v
4011 4
5
U3B
U3A
13
4011 11
12
.047
6
5 324
+ 4
R91
14 1
4011 2
7 U14A
9 - 100k
1% 8
324
+ U9C
11
-12v
W1
U4B
6
14 1
4011 2
7 U18A
W2
4023
Neg. Error
U14C
R89 100
R90
6
4 4 - 100k 150k
5 4011
339
5+
U14D
U10D
4011
U14B
4011
13
11
12 4011
U8C
9
10
8 4011
U8D
3
4
3
5
11
10
4023
U4A
12
R81 100 R82
4 +12v
6
100k 50k
4011
339
U8B +6v 7 + U9C
U6D
4011 3
27
1
W4
+12v
8 14
4011 10
7
9
U3D
W3
Pos. Error
6 - U7D
U2B
1
5 +324 7 74C
914
R66
22k
12
11
4011
13
6
4 4011
5
U6B
9
Q7
R36 10 4011
8
R35 100k
U6C
C5
.1
10
+12v
14
U2A
74C
914
4
+12v 7
+12v
R95
1k
8
64 1
2
3
R155
D14
1k
R154
5
7
C27
.01
C24
.01
8
U17 7
455
6 4 1 5
2
3
R97
TP7
1
7 4023 9
8
+12v
D22
R124
3 8
10k
U21
12
2 455 7
R125
13
10
2.2k
9 4012
64 1 5
1
C31
C32
U19B 1 .01
.01
3
R157
Inhibit 2 4001
U16D 1k
Start Up
R116
+12v
10
R114
D18
+12v
3 8
10k
U20
2
2 455 7
R115
1
4
2.2k
5 4012
64 1 5
3
C28
7 U19A 5 .01
R156
4
C29
Inhibit
6 4001
U16C 1k
.01
Start Up
10k
R106
22k
C26
13 .01
Inhibit 12 4001 11
Start Up
U16B
11
13
9
10 4012
12
U15B
R105
10k
3 14
R96
4
1
2.2k
5 4012
2
U15A +12v C23
.01
9
Inhibit
8 4001 10
U16A
Start Up
+12v
U5D
+12v
8
10
9 4011
U5D
+12v
10
D10
W5
1 14 3
2 4011
U3C
1
3
2 4011
13
5
11
4 12 4011
6 4011
U5C
U5B
Figure
8. Schematic
Control
RG,
Figure
8. Schematic
ControlBoard
Baord VEL/H
VEL/H RG,
Part #66936 Part #66936
-12v
C39
4/50v
C44
.1
R77
27k
R64
100k
+12v
R56
-12v
10
C8
.1
100k
R22
47k
R33
R34
220k
+12v
Q6
R27
100k
3 2 1611 7 6
10
74C 12
4
1 221 14
9 8 15
+12v
Q19
U22 R146
3146 10k
+6v
R143
47k
R144
47k
+6v
C38
4/50v
R142
100k
R141
100k
R140
10k
Q3
R21
22k
R24
R55
2 49.9k1%
- U7C
324
1
+
3
R26
100k
47k
R23
R20
220k
R75
10k
13 74C 12 +12v
914
U2C
R76
+12v
10k
5 74C 6
914 U2D
+24v
R139
47k
220k .01
+
339
- U11B
R74
R73 C11
R72 C10
5 + 220k .01
2
4 339
- U11A
U22
R137 Q18 5 C34
10k
4
6.8/
35v
R138
3146 3
4.7k
R136
10k
+24v
10k 1%
U22
Q171
2
3146
+
R135 3 C33
10k
68/
35v
-24v
D33
C35
250/
50v
R149
22k
D32
+24v
IN5393
(2 PL)
D29
D28
R61
R50
R25
22k
3
D
200k1%
- U78 TP3 R54
324
+ 14
100k1%
R51
100
Q2
Q4
+24v
2
324
+
U1C
3
1
R18
250k
100k
22k
100k
G
+12v
R30
2.2M
C40
C4
R28
Cur
05k
Stabl
.001
.22 100
R31
- TP2
10
U1C
+
5 324
7
8
+
9 -324
U1B
4 R32
D
Cur
Lmt
R15 100 R16 R17
0
D5
D4
R58
100k 1%
IR
49.9k 1% R60 13
- 14 TP4
100 R630 Comp
R59 49.9k 1%12324
+
100k
+12v
100k
R62
D40 1%
3
49.9k 14
+
12v
1%
339 8
10
+6v
U10A
12
13 339 11
U10B + +6v
IN5393 (2 PL)
D27
D26
To Input
Board
J6-2
6.49 k%
R68
1k 1%
R67
D9
D7
8 IN5593
2 PL R57
100
7
D6
3 R42
Max
Spd
Q5
Q1 G
100k
3
D
R6
Gain #1
0
C1 0 100
R11
6AW #2
2M
.022
100 10k
C2
R12
150 pf
100k
13 R13
R8
324
12 +
100k
2.2k
D3 R9
-12v
R14
C5
10
.1
47k
R43
Shift
R41
1%
R47
2 1M 1% 73.2k
9 - U7A R46 25k R48
324 8
+
100 82.5k1%
3.7k
4 R45
10
C7 R49
1M 1%
+12v
1.0 330k
R44
10
73.2k
C6
1%
.1
Max Spd Pot
Arm Current
-12v
+24v
Fdbk
Sum
J5-6
18
15
12
13
2
820, 1/2W 9
D1
10v R4
Spd Ref R2
11
100k
C1
73.2k
1%
.01
1%
R6
3
R5
-24v
56k
820, 1/2W
D2
4
10v
Spd. Error
5
Cur. Input
R2
Feedback Board
Comm
Fwd
+10
1
Spd
Input
2
Rev
-10
3
External
Input Board
J6
1 Reset
C25
.1
R99
1k
.47
R126
10k
Q13
R111
47
Q11
R102
47
Q9
R130
47
R129
100
D23
Q15
R119 R121
10K 47
D19
R120
100
R109
10k
D15
R110
100
R100
10k
D11
R101
100
1k
R128
10k
R127
R107
10k
1k
R118
C30
.1
R107
10k
1k
R108
R98
10k
Q8
R39
220k
+24v
R148
100 2w
C37
100k
R38
2.2k
R37
+24v
R103
J1
220
R131
220
Q16
220
R132
D25 IN4933
220
T4 D24
IN4933
Q14
D21 IN4933
R123 3
R122
220 4J3
T3 D20
IN4933 1
Q12
220
D17 IN4933
R113 3
R112
J2
220 4
T2 D16
IN4933 1
Q10
D13 IN4933
R104 3
T1 D12 220 4
IN4933 1
G2
+
G3
AC1
G1
+
G4
AC2
AC1
G2
+
G3
AC2
G1
+
G4
P4 To BR2 (Rev)
P3 To BR2 (Rev)
P2 To BR1 (Fwd)
P1 To BR1 (Fwd)
Notes: (Unless Otherwise Specified)
1. All Resistor Values Are in Ohms
2. All Capacitor Values are in Microfarads
3. All REsistors Are ¼ W 5%
4. All Capacitors Are 100v 10%
5. All Pots Are ½ W 10%
6. All Diodes Are IN4148
7. All RET's Are 2N5462
8. All NPN's Are 2N5462
9. All PNP's Are MP56517
10. Last Ref Designations used-R157, C40, D40, U22
11. Ref. Designations not used-R40, R133, R7
12. Jumpers-W1 thru W5 may be removed to
isolate IC's (U3, U5, U8 & U14) From +12v
Power Supply
Section VII
Illustrations
To Speed Circuit
L2
115V
230V
Supply
L1
11
T1
Emerg.
Stop
5
60S6
4PL
6
E9
3
4
Com.
Off
BR2
1
10
+
G2
.1uf
50V
AC2
E15
D15
IN5393
K1
P5
G1
.1uf
50V
G3
.1uf
50V
AC1
10
R11
C6
+
50uf
50V
M
D13 R10
IN5393
D14
IN5393
K2
6
Regen To Stop
E14
E16
3 K1
2
4 P5
Run
Jog
Run
K1
K2
20V
T2 7
E3
E4
G4
.1uf
50V
-
Main
Contactor
Emerg. Stop
Relay
Pilot Relay
BR1
.1 uf
50V
G3
G1
AC1
.1uf
50V
-
+
E3
E4
R1
22
C4
.1uf
500V
R4
22
P5
1%
1/3HP
1/4HP
1/6HP
115V
1HP
3/4HP
1/2HP
230V
2HP
1 1/2HP
1HP
E7
M1
M1
D7
3.4
2.9
2.0
3
3
4
AMPS No. Turns
9.4
1
7.6
1 1/2
5.2
2
M1
A1
Remove 56K Res.
For 180V Arm.
A2
56K
2W
D6 IN5397
4 PL
D8
Arm.
90V/180V
2HP Max.
R9
68K
2W
APR
D5
D8 Opt.
15 1039
50W
E8
Current Transformer Turn Data
TB1
TB2
R8
1M 1/4W
1%
M1
R7
2M
1/2W
1%
3 1/2W
E11
2 E12
NOTES:
1. Terminal Identification -
E6
R3
22
.1uf C3
50V .1uf
G4 500V
AC2
G2
.1uf
50V
E5
Figure 9. Schematic, Power Board, 1/6-2 HP
Part #66937
Stop
4
115V
E10
NC
6 E13
8
5
8 7
P5
2.2K
R12
E1 CT1 E2
P1
P5 115V
2
C5 10uf
+ 50V
D11
APR K2
K2
APR
D9
D10 D12
24V
AC
E17 AC
D3
D4
F-
20V E18 COM
20V E19
IN5393
4 PL
Blk/Wht
115V
115V
Blk
D1
D2
Motor
Thermal Switch
Blk/Red
Wht
Jumper
For 115V
(Typ)
25A
F3
Jumper
For 115V
RV1
25A
F1
F+
100V/200V
Shunt Field
Remove
Jumpers For
F2
180V Arm
25A
(Typ)
C2
R5
.1uf
1M
500V
1%
R2
R6
22
2M
Section VII
Illustrations
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
23
24
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
1
60A
F3
3
1
APR
K2
CT1
K2
K1
K2
4
RUN
RUN
D11
P5
D12
E18 9
E19 12
E17 11
E16 10
E15 6
E14 1
C5 10
+
6 STOP
D9
24V D10
20V
20V
8
20V
E9 8
E10 7
E13 4
JOG
SEE CHART
10
11
60S6 R12
4 PL
2.2K
T1
APR
BLK/WHT
115V
BLK/RED
WHT
115V
BLK
1 115V
4
2
D3
D4
F-
2 1 T2 5
115V2
20V
D1
D2
Emerg 5
Stop
6
RV1
70A
Motor
Thermal
Switch
L2
L1
F1
F+
200V
SHUNT FIELD
3
2
2
D14
K1
D13
+
C7
0.1
G3
C10
0.1
G1
+
G2
C11
0.1
G4
2
1
R3
22
1W
9
C3
0.1
500V
C1
0.1
500V
R1
22
1W
8
R5
IM
1%
R7
2M
1/2W
1%
R4
22
1W
C4
0.1
500V
C2
0.1
500V
R2
22
1W
4
P5
2
E11 E12
3
M1
5 M1
R8
IM
1%
R7
2M
1/2W
1%
M1
M1
9
OPT. 1039
8
DB
15
50W
2 PL
70A
F2
Unless Otherwise Specified-All Resistor Values In Ohms
All Capacitor Values In Microfarads
All Diodes IN5393
All Resistor 1/4w 5%
All Capacitors 50v 10%
TB1
TB2
Indicates Components Not Mounted
On Printed Wiring Board
BR1 -
G3
AC2
C13
C12
0.1
0.1
AC1
Emerg
Stop
Relay
Main
Contactor
Pilot
Relay
4
2
1
3
Figure 10. Schematic Power Board, 3 & 5 HP
Part #66938
11
K2
2.2K
R10
K1
C9
0.1
G1
AC1
M1
1/2W
R11
1.5K
10
BR2
C8
0.1
G2
AC2
C6
0.1
G4
-
HP
3
5
7
D7
D5
6
D8
D6
A2
AMPS
14.5
24
3
R9
68K
2W
IN5397
4 PL
APR
4 A1
TURNS
2
1
ARM
180V
MAX
Section VII
Illustrations
230V
Neg
Error
Pot
J5
R81
Control BD
Wire
Harness
TP7
J1
Line
Connection
Terminals
+
Resistor DB
(Option 1039)
D.B
Res.
(Option)
Line
Fuse
Line
Fuse
E13 E14
T1
Ground
Connection
Screw
Gnd
+
Figure 11. Internal View, Standard Controller, 1/8-2 HP
Pos
Error
Pot
1
U9 R89
L1
TP4
R63
+
J2
J3
TB2
APR
Power
Board
+
IR
Comp
Pot
R28
L2
TP5 TP6 TP2
7
R16
J4
A2 F+ F-
TP3
R47
A1
Max Spd
Pot
R52
6
Shift
Pot
R6
5
R11
J6
4
TP1
TB1
Motor
Connection
Terminals
3
Input Bd
TB3
Data Label
2
Feedback BD
Gain No. 1 Pot
Gain No. 2 Pot
BR2
BR1
T2
+
Arm
Fuse
1
Cur Limit
Pot
Cur
Stbly
Pot
P2
25A
Power
Bridge
Power
Bridge
Latch
Section VII
Illustrations
+
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
25
1
2
3
4
5
D6
D5
R9
D4
6
D2
A1 A2 F+ F-
D3
L2
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
L1
R2
R8
E12
R5
C4
C3
BR1
-
2
E6
4
5
BR2
BR1
Blk
C1
C2
BR2
E8
D8
E7
D8
A
115V
115V
B
230V
Blk Red
Blk Wht
T2 Wht
E9 E10 CT
R3
R4
3
7 6
Resistor DB
(Option 1039)
Arm
Fdbk E11
CT
R1
R7
(Option)
E2
BR1
AC2
R6
D.B.
Res.
D1
Line
Fuse
M1
BR2
AC2
1
8
BR1
+
BR2
-
AC Line
Voltage
115
115
115
115
115
115
230
230
230
230
230
AC Line DC ARM
AMPS
AMPS
3.9
2.0
5.0
2.8
6.0
3.5
8.7
5.4
12.4
5.4
15.8
10.5
4.2
2.6
5.9
3.8
8.8
5.5
12.8
8.2
17.0
11.6
Unit is Calibrated For
Horsepower Checked
180
VDC
200
VDC
90
VDC
100
VDC
Line Voltage
115V
230V
Power
Bridges
*Option Wiring Information
Maximum Input 100 VDC at 50 VA
Indicates Options
Installed In Unit
10340D "S" Curve Accel
1036 Linear Accel/Decel
1039 Dynamic Braking
1049A Process Control
Follower
*1055A DC Tach Follower
*1061D DC Tach Feedback
Armature
Voltage
(Max)
Field
Voltage
(2 Amps Max)
Replacement Fuses
F1 & F2 - Shawmut A25X25
F3 - BUS NON25
Motor Thermal Button Or Other Motor Overcurrent
Protection Must Be Provided.
Drive
HP
1/6
1/4
1/3
1/2
3/4
1
1/2
3/4
1
1-1/2
2
MODEL 2200
Instruction Manual
Data
Label
Hinge
Hinge
TP4
TP3
J5
U9
R89
1
7
Max Spd
Pot
Control Bd
R81
TP5 TP6 TP2
R28
R11
TP1
R6
Neg
Error
Pot
TP7
J6
TB3
J1
J2
J3
J4
Gain No. 1 Pot
Gain No. 2 Pot
Feedback Bd. Input Bd.
R16
IR Comp
Pot
R63
R52
R47
o Shift
Pot
Cur
Limit
Pot
Figure 12. Internal View, 1/6-2 HP Chassis, Controller
CT1
E5
F2
25A
D
C
E19 E18
E17
Listed
Industrial Control
Equipment
+
Ground
Connection
Screw
D8
D7
BR2 AC1
E4
BR1 AC2
F1 25A
K2
D9
D11
D13
Line
Fuse
R10
F3 25A
D14
APR
T1
UL
®
E15 E16
E13 E14
C6
RV1
K1
C5
R11
Line
Connection
Terminals
Motor
Connection
Terminals
TB2
TB1
Power Bd
D10
D12
D15
Arm
Fuse
26
Power Board
.188 Dia. Mounting Hole
Ref. 4 - PL.
Pos Error
Pot
Cur
Stbly
Pot
Wire
Harness
Section VII
Illustrations
TB1
K1
1
3
4
5
6
1
7
APR
K2
2
3
8
F1
9
4
F+
5
RV1
7
T2
F-
1
4
Blk
Whit Blk
6
8
CT1
F3
Line
Fuse
10
Arm
Fdbk
11
TB2
F2
M1
Motor
Connection
Terminals
Power
Bridge
Line
Connection
Terminals
BR2
D.B.
Res
L1 A2 A1 L2
D.B.
Res
Ground
Connection
Screw
Resistors DB
(Option 1039)
Hinge
Hinge
TP3
J5
U9
TP2
Figure 13. Internal, 3 & 5 HP Chassis, Controller
R11
TP1
R6
Neg
Error
Pot
TP7
J6
TB3
J1
J2
J3
J4
Gain No. 1 Pot
Gain No. 2 Pot
Input Board
Max Spt
Pot
R28
1
R89 R81
TP5
7
TP6
R16
Feedback Board
IR Comp
Pot
R63
R52
R47
O Shaft
Pot
Cur
Limit
Pot
Figure 13. Internal, 3 & 5 HP Chassis, Controller
Main
Contactor
9
Line
Fuse
Armature
Fuse
Model VEL/H RG
Pos Error
Pot
Instruction Manual
Book 0439
Cur
Stbly
Pot
Data
Label
Wire
Harness
Illustrations
Power Board
2
BR1
Power Bridge
.188 Dia. Mounting Hole
Ref. 4-PL.
Section VII
Illustrations
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
27
Warranty
Warranty
Boston Gear warrants that products manufactured or sold by it shall be free
from defects in material and workmanship. Any products which shall within
two (2) years of delivery, be proved to the Company’s satisfaction to have been
defective at the time of delivery in these respects will be replaced or repaired
by the Company at its option. Freight is the responsibility of the customer. The
Company’s liability under this limited warranty is limited to such replacement
or repair and it shall not be held liable in any form of action for direct or
consequential damages to property or person. The foregoing limited warranty
is expressly made in lieu of all other warranties whatsoever, express, implied
and statutory and including without limitation the implied warranties of
merchantability and fitness.
No employee, agent, distributor, or other person is authorized to give
additional warranties on behalf of Boston Gear, nor to assume for Boston Gear
any other liability in connection with any of its products, except an officer of
Boston Gear by a signed writing.
Boston Gear, Inc.
14 Hayward Street • Quincy, MA 02171
617-328-3300 • Fax: 617-479-6238
www.bostongear.com
28
Doc. No. 86986 • Boston Gear® Ratiotrol® DC Motor Speed Control
Printed In The USA