250 0233

250 0233
X L S er ie s
USER MANUAL
X L3025A
X L3050A
X L3200A
www.minarikdrives.com
Dear Valued Consumer:
Congratulations on your purchase of the XL Series drive.
This User Manual was created for you to get the most out of
your new device and assist with the initial setup. Please visit
www.minarikdrives.com to learn more about our other drives.
Thank you for choosing Minarik Drives!
© 2014 Minarik Drives. All rights reserved.
No part of this document may be reproduced or transmitted in any form without written permission
from Minarik Drives. The information and technical data in this document 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 document
and makes no commitment to update or to keep current the information in this document.
XL Series
Safety First!
SAFETY WARNINGS

!
WARNING!
Text in gray boxes denote important safety tips or warnings.
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 using
proper grounding techniques, over-current protection, thermal
protection, and enclosure. Follow sound maintenance procedures.

!
WARNING!
It is possible for a drive to run at full speed as a result of a
component failure. Minarik Drives 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 trim pots.
Use approved personal protective equipment and insulated tools
if working on this drive with power applied.
i
XL Series
Table of Contents
Section 1. Specifications...................................................... 1
Section 2. Dimensions.. ........................................................ 3
Section 3. Installation. . ........................................................ 5
Heat Sinking.................................................................................. 5
Mounting...................................................................................... 6
Speed Adjust Potentiometer. . ................................................. 7
Wiring........................................................................................... 8
Shielding Guidelines.............................................................. 9
Line Fusing...........................................................................10
Connections.................................................................................11
Power Inputs........................................................................11
Motor.. .................................................................................11
Field Output Connections. . ....................................................12
Speed Adjust Potentiometer. . ................................................13
Analog Input Signal...............................................................14
Section 4. Operation. . ........................................................ 15
Before Applying Power..................................................................15
Select Switches.............................................................................16
Input Voltage Select (SW501, SW502)....................................16
Startup.........................................................................................17
Starting and Stopping Methods.....................................................18
Line Starting and Stopping....................................................18
Dynamic Braking...................................................................19
Decelerating to Zeo Speed (INHIBIT)......................................21
Decelerating to Minimum Speed. . ..........................................22
Section 5. Calibration........................................................ 23
Minimum Speed (MIN SPD)...........................................................24
Maximum Speed (MAX SPD)..........................................................24
Torque (CURR LIMIT).....................................................................25
IR Compensation (IR COMP)..........................................................26
ii
XL Series
Acceleration (ACCEL). . ...................................................................30
Deceleration (DECEL)....................................................................30
Section 6.Application Notes................................................ 31
Multiple Fixed Speeds...................................................................31
Adjustable Speeds Using Potentiometers In Series . . ........................32
Independent Adjustable Speeds.. ...................................................33
RUN/JOG Switch - Inhibit Connection. . ...........................................34
RUN/JOG Switch - Potentiometer Connection. . ...............................35
Leader-Follower Application..........................................................36
Single Speed Potentiometer Control Of Multiple Drives..................37
Reversing.. ....................................................................................38
Section 7. Diagnostic LEDs.. ................................................ 39
Section 8. Troubleshooting. . ............................................... 40
Before Troubleshooting.................................................................40
Section 9. Accessories & Replacement Parts........................ 43
Unconditional Warranty.. .................................................... 44
iii
XL Series
List of Tables
Table 1
Table 2
Table 3
iv
Recommended Line Fuse Sizes...........................................10
Field Ouput Connections...................................................12
Dynamic Brake Resistor Values.. .........................................20
XL Series
List of Figures
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1
2
3
4
5
6
7
8
9
10
Figure 11
Figure 12
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
13
14
15
16
17
18
19
20
21
XL Series Dimensions.. ........................................................ 3
223-0271 Dimensions......................................................... 4
Speed Adjust Potentiometer............................................... 7
Drive Connections.............................................................13
Analog Input Signal Connections. . ......................................14
Select Switches.................................................................16
Dynamic Brake Wiring.......................................................20
Inhibit Terminals...............................................................21
Run/Decelerate to Minimum Speed Switch. . .......................22
Recommended CURR LIMIT and IR COMP Settings for model
XL3025A...........................................................................27
Recommended CURR LIMIT and IR COMP Settings for model
XL3050A...........................................................................28
Recommended CURR LIMIT and IR COMP Settings for model
XL3200A...........................................................................29
Multiple Fixed Speeds.......................................................31
Adjustable Speeds Using Potentiometers in Series..............32
Independent Adjustable Speeds. . .......................................33
RUN/JOG Switch - Inhibit Connection.................................34
RUN/JOG Switch - Potentiometer Connection.....................35
Leader-Follower Application..............................................36
Single Speed Potentiometer Control of Multiple Drives. . .....37
Reversing Circuit Wiring....................................................38
Diagnostic LED Locations...................................................39
v
XL Series
Section 1. Specifications
Maximum
Armature
Current (ADC)
HP Range
with 130 VDC
Motor
HP Range
with 240 VDC
Motor
Enclosure
XL3025A
3.0
1/20 - 1/4
1/10 - 1/2
Chassis
XL3050A
5.0
1/8 - 1/2
1/4 - 1
Chassis
XL3200A*
10.0
1/4 - 1
1/2 - 2
Chassis
Model
* Heat sink kit part number 223-0271 must be used when the continuous
current output is over 5 amps.
AC Line Voltage
115/230 VAC ± 10%, 50/60 Hz, single phase
DC Armature Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
0 - 130 VDC
0 - 240 VDC
Field Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
50 VDC (F1 to L1); 100 VDC (F1 to F2)
100 VDC (F1 to L1); 200 VDC (F1 to F2)
Maximum Field Current
1 ADC
Acceleration Time Range
1 - 12 seconds
Deceleration Time Range
coast to a stop - 12 seconds
Analog Input Range (signal must be isolated; S1 to S2)
A
with 115 VAC Line Voltage
with 230 VAC Line Voltage
0 - 2.7 VDC
0 - 5.0 VDC
Input Impedance (S1 to S2)
100K ohms
Form Factor
Load Regulation
Speed Range
1.05
1% base speed or better
100:1
1
XL Series
Vibration
Safety Certifications
Ambient Temperature Range
2
0.5G maximum (0 - 50 Hz)
0.1G maximum (> 50 Hz)
UL/cUL Recognized Equipment, File # E132235
CSA Certified Component, File # LR41380
10°C - 40°C
XL Series
Section 2. Dimensions
BR501
Q501
Q502
D501
0.19"
TH501
B2
R503
AC1
A C2
BR+
BRB1
T501
C503
SW502
230
C505
230
SW501
4.97 [126]
R501
4.13 [105]
IC503
IC502
C501
IC501
R502
FU501
FAST-ACTING
C502
CURR
LIMIT
C504
INHIBIT
IL501
0.50"
IL502
TB501
L1
L2
S1
S2
S3
F1
F2
A1
0.25 [6]
5.38 [137]
A
1.75 [45]
MODEL
DIMENSION “A” HEIGHT
XL3025A
2.25 [57]
XL3050A
3.00 [76]
XL3200A
3.75 [95]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 1. XL Series Dimensions
3
XL Series
C
0.188 WIDE SLOT
(4 PLACES)
8-32 THD
(4 PLACES)
9.78 [248]
8.41 [214]
6.70 [170]
3.08 [78]
1.41 [35]
2.50 [64]
2.50 [64]
3.15 [80]
3.15 [80]
6.90 [175]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
1.00 [25]
Figure 2. 223-0271 Dimensions
4
XL Series
Section 3. Installation

!
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. Make sure you read and understand the Safety
Precautions on page i before attempting to install this product.
Heat Sinking
Model XL3200A requires an additional heat sink when the continuous
armature current is above 5 amps. Use Minarik Drives heat sink kit part
number 223-0271. All other chassis drives have sufficient heat sinking
in their basic configuration. Use a thermally conductive heat sink
compound (such as Dow Corning® 340 Heat Sink Compound) between
the chassis and the heat sink surface for optimum heat transfer.
5
XL Series
Mounting
• Drive components are sensitive to electrostatic discharge. Avoid
direct contact with the circuit board. Hold the drive by the chassis
or heat sink only.
• Protect the drive from dirt, moisture, and accidental contact.
• Provide sufficient room for access to the terminals and calibration
trim pots.
• 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 the drive with its board in either a horizontal or vertical
plane. Six 0.19” (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 surface and to reach bare metal.
6
XL Series
Speed Adjust Potentiometer

!
WARNING!
Be sure that the potentiometer tabs do not make contact with the
potentiometer’s body. Grounding the input will cause damage to
the drive.
If using a remote potentiometer with a chassis drive, mount the speed
adjust potentiometer through a 0.38 in. (10 mm) hole with the hardware
provided (Figure 3). 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 the speed adjust potentiometer wires are longer than
18 in. (46 cm), use shielded cable. Keep the speed adjust potentiometer
wires separate from power leads (L1, L2, A1, A2, F1, F2).
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
CW
WIPER
CCW
NUT
STAR
WASHER
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
POT TAB ASSIGNMENTS
PANEL
Figure 3. Speed Adjust Potentiometer
7
XL Series
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.
This product does not have internal solid state motor overload
protection. It does not contain speed-sensitive overload
protection, thermal memory retention or provisions to receive
and act upon signal from remote devices for over temperature
protection. If motor over protection is needed in the end-use
product, it needs to be provided by additional equipment in
accordance with NEC standards.
• Use 18 - 24 AWG wire for logic wiring. Use 14 - 16 AWG wire for
AC line and motor wiring.
8
XL Series
Shielding Guidelines

!
WARNING!
Under no circumstances should power and logic level leads be
bundled together. Induced voltage can cause unpredictable
behavior in any electronic device, including motor controls.
As a general rule, Minarik Drives recommends shielding of all conductors.
If it is not practical to shield power conductors, it is recommended
to shield 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.
9
XL Series
Line Fusing
Drives should be fused for protection. Use fast acting fuses rated for 250
VAC or higher and 150% of maximum armature current. Fuse HOT L1
only when the line voltage is 115 VAC. Fuse both L1 and L2 when the line
voltage is 230 VAC. Table 1 lists the recommended line fuse sizes.
Table 1. Recommended Line Fuse Sizes
130 VDC
Motor
Horsepower
240 VDC
Motor
Horsepower
Maximum DC
Armature Current
(amps)
AC Line
Fuse Size
(amps)
1/20
1/15
1/8
1/6
1/10
1/8
1/4
1/3
0.5
0.8
1.5
1.7
1
1.5
3
3
1/4
1/2
2.5
5
1/3
1/2
3/4
1
3/4
1
1 1/2
2
3.5
5.0
7.5
10
8
10
15
15
Minarik Drives offers fuse kits. See Section 9: Accessories and
Replacement Parts for fuse kit part numbers.
10
XL Series
Connections

!
Do not connect this equipment with power applied. Failure to
heed this warning may result in fire, explosion, or serious injury.
WARNING!
Minarik Drives strongly recommends the installation of a
master power switch in the voltage input line, as shown in
Figure 4 (page 13). The switch contacts should be rated at a
minimum of 200% of motor nameplate current and 250 volts.
Power Input
Connect the AC line power leads to terminals L1 and L2. Minarik Drives
recommends the use of a single-throw, double-pole master power
switch. The switch should be rated at a minimum of 250 volts and 200%
of motor current. Refer to Figure 4 on page 13.
Motor
Drives supply motor armature 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 the motor does not
spin in the desired direction, remove power and reverse the A1 and A2
connections.
Connect a DC motor to terminals A1 and A2 as shown in Figure 4 on page
13. Ensure that the motor voltage rating is consistent with the drive’s
output voltage.
11
XL Series
Field Output Connections

!
WARNING!
The field output is for shunt wound motors only. Do not make
any connections to F1 and F2 when using a permanent magnet
motor.
See Table 2 for field output connections. Use 18 AWG wire to connect
the field output to a shunt wound motor.
Table 2. Field Output Connections
12
Line Voltage (VAC)
Approximate Field
Voltage (VDC)
Connect Motor
Field To
115
115
230
230
50
100
100
200
F1 and L1
F1 and F2
F1 and L1
F1 and F2
XL Series
Speed Adjust Potentiometer
Use a 10K ohm, 1/4 W potentiometer for speed control. Connect the
counter-clockwise end of the potentiometer to S1, the wiper to S2, and
the clockwise end to S3. If the potentiometer works inversely of the
desired functionality (e.g. to increase motor speed you must turn the
potentiometer counterclockwise), power off the drive and swap the S1
and S3 connections. Refer to Figure 4.
TB501
L1
L2
S1
S2
S3
F1
F2
A1
+
CW
*FUSE
POWER
SWITCH
10K OHM
SPEED ADJUST
POTENTIOMETER
FIELD
OUTPUT
MOTOR
ARMATURE
NOTE: DO NOT make
any connections to
F1 and F2 if using a
permanent magnet motor.
AC LINE
VOLTAGE
120/240 VAC
Figure 4. Drive Connections
* NOTE: Do not add fuse to L2
unless input voltage is 230 VAC.
13
XL Series
Analog Input Signal
Instead of using a speed adjust potentiometer, the drive may be wired to
follow an analog input voltage signal that is isolated from earth ground
(Figure 5). Connect the signal common (–) to S1. Connect the signal
reference (+) to S2. Make no connection to S3. A potentiometer can
be used to scale the analog input voltage. An interface device, such as
Minarik Drives model PCM4, may be used to scale and isolate an analog
input voltage.
With 115 VAC line voltage, an analog input voltage range of 0–2.7 VDC is
required to produce an armature voltage range of 0–130 VDC. With 230
VAC line voltage, an analog input voltage range of 0–5 VDC is required to
produce an armature voltage range of 0–180 VDC.
SIGNAL
COMMON
S2 (+)
S1 (-)
TB501
SIGNAL
INPUT
Figure 5. Analog Input Signal Connections
14
XL Series
Section 4. Operation

!
WARNING!
Change voltage switch settings only when the drive is
disconnected from AC line voltage. Make sure both switches are
set to their correct position. If the switches are improperly set
to a lower voltage position, the motor will not run at full voltage
and may cause damage to the transformer. If the switches are
improperly set to a higher voltage position, the motor will
overspeed, which may cause motor damage, or result in bodily
injury or loss of life.
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.
If the motor or drive does not perform as described, disconnect
the AC line voltage immediately. Refer to the Troubleshooting
section, page 40, for further assistance.
Before Applying Power
1. Verify that no foreign conductive material is present on the
printed circuit board.
2. Ensure that all switches are properly set.
15
XL Series
Select Switches
Input Voltage Select (SW501, SW502)
Set the input voltage select switches SW501 and SW502 to either 115 or
230 to match the AC line voltage. See Figure 6.
BR501
Q502
D501
Q501
TH501
B2
R503
AC1
AC2
BR+
BRB1
T501
C503
SW502
230
C505
230
SW501
IC503
IC502
FU501
FAST-ACTING
Input Voltage
Select
(SW501, SW502)
R501
C501
IC501
R502
C502
CURR
LIMIT
C504
INHIBIT
TB501
L1
L2
S1
S2
S3
F1
F2
Figure 6. Select Switches
16
A1
IL501
IL502
XL Series
Startup
1.
Turn the speed adjust potentiometer full counterclockwise
(CCW) or set the input voltage signal to minimum.
2. Apply AC line voltage.
3. Slowly advance the speed adjust potentiometer clockwise
(CW) or increase the input voltage signal. The motor slowly
accelerates as the potentiometer is turned CW or as the input
voltage signal is increased. Continue until the desired speed is
reached.
4.
Remove AC line voltage from the drive to coast the motor to a
stop.
17
XL Series
Starting and Stopping Methods

!
WARNING!
Dynamic braking, coasting to a stop, or decelerating to minimum
speed is recommended for frequent starts and stops. Do not use
any of these methods for emergency stopping. They may not stop
a drive that is malfunctioning. Removing AC line power (both
lines) is the only acceptable method for emergency stopping.
For this reason, Minarik Drives strongly recommends installing
an emergency stop switch on both AC line inputs (see Figure 4
on page 13).
Frequent starting and stopping can produce high torque. This
may cause damage to motors, especially gearmotors that are not
properly sized for the application.
Automatic Restart Upon Power Restoration
All drives automatically run to set speed when power is applied and the
inhibit is not active.
Line Starting and Stopping
Line starting and 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 or analog signal. When AC line
voltage is removed, the motor coasts to a stop.
18
XL Series
Dynamic Braking

!
WARNING!
Wait for the motor to completely stop before switching back to
RUN. This will prevent high armature currents from damaging
the motor or drive.
Dynamic braking may be used to rapidly stop a motor (Figure 7 on page
20). For the RUN/BRAKE switch, use a two pole, two position switch
rated for at least the armature voltage rating and 150% of the armature
current rating. For the dynamic brake resistor, use a 40 watt minimum,
high power, wirewound resistor.
Sizing the dynamic brake resistor depends on load inertia, motor voltage,
and braking time. Use a lower-value, higher-wattage dynamic brake
resistor to stop a motor more rapidly. Refer to Table 3 on page 20 for
recommended dynamic brake resistor sizes.
19
XL Series
Table 3. Minimum Recommended Dynamic Brake Resistor Values
Motor Armature Voltage
Dynamic Brake Resistor Value
130 VDC
240 VDC
15 ohms
30 ohms
For motors rated 1/17 horsepower and lower, a brake resistor is not
necessary since the armature resistance is high enough to stop the
motor without demagnetization. Replace the dynamic brake with
12-gauge wire.
A1
A2
RUN
MOTOR
DYNAMIC BRAKE
RESISTOR
BRAKE
INHIBIT
Figure 7. Dynamic Brake Wiring
20
XL Series
Decelerating to Zero Speed (INHIBIT)
Short the INHIBIT terminals to coast the motor to minimum speed (see
Figure 8 for INHIBIT terminal location). Open the INHIBIT terminals to
accelerate the motor to set speed.
Twist inhibit wires and separate them from power-carrying wires or
sources of electrical noise. Use shielded cable if the inhibit wires are
longer than 18 inches (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.
Minarik Drives offers two accessory plug harnesses for connecting to
the INHIBIT terminals: part number 201-0024 [plug with 18 in. (46 cm)
leads]; and part number 201-0079 [plug with 36 in. (91 cm) leads].
BR501
Q501
Q502
D501
TH501
B2
R503
AC1
AC2
BR+
BRB1
T501
C503
C505
SW502
230 230
SW501
R501
IC503
IC502
FU501
FAST-ACTING
Inhibit
Terminals
C501
IC501
R502
C502
CURR
LIMIT
C504
INHIBIT
IL501
IL502
TB501
L1
L2
S1
S2
S3
F1
F2
A1
Figure 8. Inhibit Terminals
21
XL Series
Decelerating to Minimum Speed
The switch shown in Figure 9 may be used to decelerate a motor to a
minimum speed. Closing the switch between S1 and S2 decelerates
the motor from set speed to a minimum speed determined by the
MIN SPD trim pot setting. If the MIN SPD trim pot is set full CCW, the
motor decelerates to zero speed when the switch between S1 and S2 is
closed. The DECEL trim pot setting determines the rate at which the drive
decelerates. By opening the switch, the motor accelerates to set speed at
a rate determined by the ACCEL trim pot setting.
CW
S3
10K OHM
SPEED ADJUST
POTENTIOMETER
S2
S1
RUN
DECEL TO
MIN SPEED
Figure 9. Run/Decelerate to Minimum Speed Switch
22
XL Series
Section 5. Calibration

!
WARNING!
Dangerous voltages exist on the drive when it is powered. When
possible, disconnect the voltage input from the drive before
adjusting the trim pots. If the trim pots 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.
XL series drives have user-adjustable trim pots. Each drive is factory
calibrated to its maximum current rating. Readjust the calibration trim
pot 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 trim pot is
identified on the printed circuit board.
23
XL Series
Minimum Speed (MIN SPD)
The MIN SPD setting determines the minimum motor speed when the
speed adjust potentiometer or input voltage signal is set for minimum
speed. It is factory set for zero speed.
To calibrate the MIN SPD:
1.
Set the MIN SPD trim pot full CCW.
2. Set the speed adjust potentiometer or input voltage signal for
minimum speed.
3.
Adjust MIN SPD until the desired minimum speed is reached or
is just at the threshold of rotation.
Maximum Speed (MAX SPD)
The MAX SPD setting determines the maximum motor speed when the
speed adjust potentiometer or input voltage signal is set for maximum
speed.
To calibrate MAX SPD:
1.
Set the MAX SPD trim pot full CCW.
2.
Set the speed adjust potentiometer or input voltage signal for
maximum speed.
3. Adjust MAX SPD until the desired maximum speed is reached.
Note: Check the MIN SPD and MAX SPD adjustments after recalibrating
to verify that the motor runs at the desired minimum and maximum
speed.
24
XL Series
Torque (CURR LIMIT)

!
WARNING!
CURR LIMIT should be set to 150% of motor nameplate current
rating. Continuous operation beyond this rating may damage the
motor. If you intend to operate beyond the rating, contact your
Minarik Drives representative for assistance.
The CURR LIMIT setting determines the maximum torque for accelerating
and driving the motor. To calibrate CURR LIMIT, refer to the recommended
CURR LIMIT settings in Figures 10, 11, and 12 on pages 27 through 29 or
use the following procedure:
1. With the power disconnected from the drive, connect a DC
ammeter in series with the armature.
2. Set the CURR LIMIT trim pot to minimum (full CCW).
3. Set the speed adjust potentiometer full CW or input voltage
signal to maximum speed.
4. Carefully lock the motor armature. Be sure that the motor is
firmly mounted.
5. Apply line power. The motor should be stopped.
6. Slowly adjust the CURR LIMIT trim pot CW until the armature
current is 150% of motor rated armature current.
7. Turn the speed adjust potentiometer CCW or decrease the
input voltage signal.
8. Remove line power.
9. Remove the stall from the motor.
10. Remove the ammeter in series with the motor armature if it is
no longer needed.
25
XL Series
IR Compensation (IR COMP)
The IR COMP setting determines the degree to which motor speed is held
constant as the motor load changes.
Use the following procedure to recalibrate the IR COMP setting:
1.
Set the IR COMP trim pot to minimum (full CCW).
2. Increase the speed adjust potentiometer or input voltage signal
until the motor runs at midspeed without load (for example,
900 RPM for an 1800 RPM motor). A handheld tachometer may
be used to measure motor speed.
3. Load the motor armature to its full load armature current rating.
The motor should slow down.
4. While keeping the load on the motor, rotate the IR COMP trim
pot until the motor runs at the speed measured in step 2. If
the motor oscillates (overcompensation), the IR COMP trim pot
may be set too high (CW). Turn the IR COMP trim pot CCW to
stabilize the motor.
5. Unload the motor.
See Figures 10, 11, and 12 on pages 27 through 29 for recommended IR
COMP settings.
26
XL Series
MODEL XL3025A
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
1/4 HP
90 VDC
2.50 AMPS
1/8 HP
90 VDC
1.25 AMPS
1/20 HP
90 VDC
0.50 AMPS
1/4 HP
130 VDC
1.75 AMPS
1/8 HP
130 VDC
0.90 AMPS
1/20 HP
130 VDC
0.35 AMPS
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
1/2 HP
180 VDC
2.50 AMPS
1/4 HP
180 VDC
1.25 AMPS
1/10 HP
180 VDC
0.50 AMPS
1/2 HP
240 VDC
1.90 AMPS
1/4 HP
240 VDC
0.95 AMPS
1/10 HP
240 VDC
0.40 AMPS
Figure 10. Recommended CURR LIMIT and IR COMP Settings
for model XL3025A
(actual settings may vary with each application)
27
XL Series
MODEL XL3050A
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
1/2 HP
90 VDC
5.00 AMPS
1/4 HP
90 VDC
2.50 AMPS
1/8 HP
90 VDC
1.25 AMPS
1/2 HP
130 VDC
3.50 AMPS
1/4 HP
130 VDC
1.75 AMPS
1/8 HP
130 VDC
0.90 AMPS
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
1 HP
180 VDC
5.00 AMPS
1/2 HP
180 VDC
2.50 AMPS
1/4 HP
180 VDC
1.25 AMPS
1 HP
240 VDC
3.75 AMPS
1/2 HP
240 VDC
1.90 AMPS
1/4 HP
240 VDC
0.95 AMPS
Figure 11. Recommended CURR LIMIT and IR COMP Settings
for model XL3050A
(actual settings may vary with each application)
28
XL Series
MODEL XL3200A
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
1 HP
90 VDC
10.0 AMPS
1/2 HP
90 VDC
5.00 AMPS
1/4 HP
90 VDC
2.50 AMPS
1 HP
130 VDC
7.00 AMPS
1/2 HP
130 VDC
3.50 AMPS
1/4 HP
130 VDC
1.75 AMPS
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
2 HP
180 VDC
10.0 AMPS
1 HP
180 VDC
5.00 AMPS
1/2 HP
180 VDC
2.50 AMPS
2 HP
240 VDC
7.50 AMPS
1 HP
240 VDC
3.75 AMPS
1/2 HP
240 VDC
1.90 AMPS
Figure 12. Recommended CURR LIMIT and IR COMP Settings
for model XL3200A
(actual settings may vary with each application)
29
XL Series
Acceleration (ACCEL)
The ACCEL setting determines the time the motor takes to ramp to a
higher speed. See Specifications on page 1 for approximate acceleration
times. ACCEL is factory set for the shortest acceleration time (full CCW).
To set the acceleration time:
1.
Set the speed adjust potentiometer or input voltage signal for
minimum speed. The motor should run at minimum speed.
2.
Set the speed adjust potentiometer or input voltage signal for
maximum speed. Measure the time it takes the motor to go
from minimum to maximum speed.
3. If the time measured in step 2 is not the desired acceleration
time, turn the ACCEL trim pot CW for a longer acceleration time
or CCW for a shorter acceleration time. Repeat steps 1 through
2 until the acceleration time is correct.
Deceleration (DECEL)
The DECEL setting determines the time the motor takes to ramp to a
lower speed. See Specifications on page 1 for approximate deceleration
times. DECEL is factory set for the shortest deceleration time (full CCW).
To set the deceleration time:
1.
Set the speed adjust potentiometer or input voltage signal for
maximum speed. The motor should run at maximum speed.
2. Set the speed adjust potentiometer or input voltage signal for
minimum speed. Measure the time it takes the motor to go
from maximum to minimum speed.
3. If the time measured in step 2 is not the desired deceleration
time, turn the DECEL trim pot CW for a longer deceleration time
or CCW for a shorter deceleration time. Repeat steps 1 through
2 until the deceleration time is correct.
30
XL Series
Section 6.Application Notes
Multiple Fixed Speeds
Replace the speed adjust potentiometer with a series of resistors with a
total series resistance of 10K ohms (Figure 13). Add a single pole, multiposition switch with the correct number of positions for the desired
number of fixed speeds.
R1
S3
R2
S2
R3
S1
TOTAL SERIES
RESISTANCE
10K OHMS
R4
Figure 13. Multiple Fixed Speeds
31
XL Series
Adjustable Speeds Using Potentiometers In Series
Replace the speed adjust potentiometer with a series of resistors with a
total series resistance of 10K ohms (Figure 14). Add a single pole, multiposition switch with the correct number of positions for the desired
number of fixed speeds.
CW
S3
HIGH
SPEED
5K
OHM
LOW
SPEED
CW
S2
S1
5K
OHM
Figure 14. Adjustable Speeds Using Potentiometers In Series
32
XL Series
Independent Adjustable Speeds
Replace the speed adjust potentiometer with a single pole, multiposition switch, and two or more potentiometers in parallel, with a total
parallel resistance of 10K ohms. Figure 15 shows the connection of two
independent speed adjust potentiometers that can be mounted at two
separate operating stations.
S3
SPEED 2
CW
CW
SPEED 1
20K
OHM
20K
OHM
S2
S1
Figure 15. Independent Adjustable Speeds
33
XL Series
RUN/JOG Switch - Inhibit Connection
Using a RUN/JOG switch is recommended in applications where quick
stopping is not needed and frequent jogging is required. Use a single pole,
two position switch for the RUN/JOG switch, and a single pole, normally
closed, momentary operated pushbutton for the JOG pushbutton.
Connect the RUN/JOG switch and JOG pushbutton to the inhibit plug
as shown in Figure 16. The motor coasts to a stop when the RUN/JOG
switch is set to JOG. Press the JOG pushbutton to jog the motor. Return
the RUN/JOG switch to RUN for normal operation.
RUN
INHIBIT
JOG
PUSHBUTTON
JOG
Figure 16. RUN/JOG Switch - Inhibit Connection
34
XL Series
RUN/JOG Switch - Potentiometer Connection
Connect the RUN/JOG switch and the JOG pushbutton as shown in Figure
17. When the RUN/JOG switch is set to JOG, the motor decelerates to
minimum speed (minimum speed is determined by the MIN SPD trim pot
setting). Press the JOG pushbutton to jog the motor. Return the RUN/JOG
switch to RUN for normal operation.
S3
CW
S2
10K OHM
SPEED ADJUST
POTENTIOMETER
S1
RUN
JOG
JOG
PUSHBUTTON
Figure 17. RUN/JOG Switch - Potentiometer Connection
35
XL Series
Leader-Follower Application
In this application, use a PCM4 to monitor the speed of the leader motor
(Figure 18). The PCM4 isolates the leader motor from the follower
drive, and outputs a voltage proportional to the leader motor armature
voltage. The follower drive uses this voltage reference to set the speed of
the follower motor. An optional ratio potentiometer may be used to scale
the PCM4 output voltage.
MOTOR
A2
(+) 2
9 (+)
A1
Leader
Drive
PCM4
8
7 (-)
TB501
S2
(-) 1
TB502
S1
10K Ohm
(optional)
Figure 18. Leader-Follower Application
36
Follower
Drive
XL Series
Single Speed Potentiometer Control Of Multiple Drives
Multiple drives can be controlled with a single speed adjust potentiometer
using a USIM-8 at the input of each drive to provide isolation (Figure 19).
Optional ratio potentiometers can be used to scale the USIM-8 output
voltage, allowing independent control of each drive.
10K Ohms
ratio pot A
(optional)
10K Ohms
S3
+
S2
1
S2
S1
-
S1
+
Drive
A
A1
ratio pot B
(optional)
10K Ohms
A1
2
S2
-
S1
Motor
A
A2
Drive
B
Motor
B
A2
USIM-8
+
ratio pot H
(optional)
10K Ohms
A1
8
S2
-
S1
Drive
H
Motor
H
A2
Figure 19. Single Speed Potentiometer Control of Multiple Drives
37
XL Series
Reversing
A dynamic brake may be used when reversing the motor direction
(Figure 20). Use a three pole, three position switch rated for at least the
maximum DC armature voltage and maximum braking current. Wait for
the motor to stop completely before switching it to either the forward
or reverse direction. See the Dynamic braking section on page 20 for
recommended dynamic brake resistor sizes.
A1
A2
DYNAMIC
BRAKE
RESISTOR
MOTOR
FWD
BRAKE
REV
INHIBIT
Figure 20. Reversing Circuit Wiring
38
XL Series
Section 7. Diagnostic LEDs
XL series drives are equipped with two diagnostic LEDs:
•
Power (POWER ON): Green LED lights whenever AC line voltage is
applied to the drive.
•
Current Limit (CURR LIMIT): Red LED lights whenever the drive
reaches current limit.
BR501
Q501
Q502
D501
TH501
B2
R503
AC1
AC2
BR+
BRB1
T501
C503
SW502
230
C505
230
SW501
R501
CURR LIMIT
LED
IC503
IC502
C501
IC501
R502
FU501
FAST-ACTING
C502
C504
CURR
LIMIT
POWER ON
LED
INHIBIT
IL501
IL502
TB501
L1
L2
S1
S2
S3
F1
F2
A1
Figure 21. Diagnostic LED Locations
39
XL Series
Section 8. Troubleshooting

!
WARNING!
Dangerous voltages exist on the drive when it is powered. When
possible, disconnect the drive while troubleshooting. High
voltages can cause seroius or fatal injury.
Before Troubleshooting
Perform the following steps before starting any procedure in this
section:
1.
Disconnect AC line voltage from the drive.
2. Check the drive closely for damaged components.
3. Check that no conductive or other foreign material has become
lodged on the printed circuit board.
4. Verify that every connection is correct and in good condition.
5. Verify that there are no short circuits or grounded
connections.
6. Check that the selection switch settings are correctly set.
7. Check that the drive’s rated armature is consistent with the
motor ratings.
For additional assistance, contact your local Minarik Drives distributor
or the factory direct:
(800) MINARIK or FAX: (800) 394-6334
40
XL Series
PROBLEM
Line fuse
blows.
Line fuse does
not blow, but
the motor does
not run.
POSSIBLE CAUSE
SUGGESTED SOLUTIONS
1. Line fuse is the wrong size.
1. Check that the line fuse is
correct for the motor size.
2. Motor cable or armature is
shorted to ground.
2. Check motor cable and
armature for shorts.
3. Nuisance tripping caused by
a combination of ambient
conditions and high-current
spikes (i.e. reversing).
3. Add a blower to cool the
drive components, decrease
CURR LIMIT settings, resize
motor and drive for actual
load demand, or check for
incorrectly aligned mechanical
components or “jams”. See
page 25 for information on
adjusting the CURR LIMIT
trim pot.
1. Speed adjust potentiometer
or input voltage signal is set
to zero speed.
1. Increase the speed adjust
potentiometer setting or input
voltage signal.
2. INHIBIT is shorted.
2. Remove the short from the
INHIBIT terminals.
3. S2 is shorted to S1.
3. Remove the short.
4. Drive is in current limit.
4. Verify that the motor is not
jammed. Increase CURR LIMIT
setting if set too low.
5. Drive is not receiving AC line
voltage.
5. Apply AC line voltage.
6. Motor is not connected.
6. Remove power. Connect the
motor to A1 and A2. Reapply
power.
41
XL Series
PROBLEM
SUGGESTED SOLUTIONS
1. MIN SPD is set too high.
1. Calibrate MIN SPD.
Motor runs in
the opposite
direction
1. Motor connections to A1
and A2 are reversed.
1. Remove power. Reverse
connections to A1 and A2.
Reapply power.
Motor runs too
fast.
1. MAX SPD is set too high.
1. Calibrate MAX SPD.
Motor will
not reach the
desired speed.
1. MAX SPD setting is too low.
1. Increase MAX SPD setting.
2. IR COMP setting is too low.
2. Increase IR COMP setting.
3. TORQUE setting is too low.
3. Increase CURR LIMIT setting.
4. Motor is overloaded.
4. Check motor load. Resize the
motor and drive if necessary.
1. IR COMP is set too high.
1. Adjust the IR COMP setting
slightly CCW until the motor
speed stabilizes.
2. Motor bouncing in and out
of current limit.
2. Make sure motor is not
undersized for load; adjust
CURR LIMIT trim pot CW.
Motor pulsates
or surges under
load.
42
POSSIBLE CAUSE
Motor does not
stop when the
speed adjust
potentiometer
is full CCW.
XL Series
Section 9. Accessories & Replacement Parts
Displays
Closed Loop................................................................................. DLC600
Open Loop....................................................................................... VT-8
Heat Sinks
Chassis..................................................................................... 223-0159
Kits
Potentiometer & Connector
Pot Kit.................................................................................. 202-0003
Fuse
1.5 - 5 Amp Fuse Kit............................................................. 050-0066
1 - 8 Amp Fuse Kit with Pico Fuse........................................ 050-0068
3 - 8 Amp Fuse Kit with Pico Fuse........................................ 050-0069
5 - 15 Amp Fuse Kit.............................................................. 050-0071
Wiring
Inhibit Plug (18 in. leads)..................................................... 201-0024
Inhibit Plug (36 in. leads)..................................................... 201-0079
Logic Cards
Current Sensing
5 Amps..................................................................................... CSC1-5
20 amps................................................................................. CSC1-20
Isolation Cards
Unidirectional, 8 outputs........................................................ USIM-8
Bidirectional, 1 output............................................................... PCM4
43
XL Series
Unconditional Warranty
A. Warranty
Minarik Drives warrants that its products will be free from defects in workmanship and material
for twelve (12) months or 3000 hours, whichever comes first, from date of manufacture thereof.
Within this warranty period, Minarik Drives will repair or replace, at its sole discretion, such
products that are returned to Minarik Drives, 14300 De La Tour Drive, South Beloit, Illinois 61080
USA.
This warranty applies only to standard catalog products, and does not apply to specials. Any
returns of special controls will be evaluated on a case-by-case basis. Minarik Drives is not
responsible for removal, installation, or any other incidental expenses incurred in shipping the
product to and from the repair point.
B. Disclaimer
The provisions of Paragraph A are Minarik Drives’s sole obligation and exclude all other
warranties of merchantability for use, expressed or implied. Minarik Drives further disclaims
any responsibility whatsoever to the customer or to any other person for injury to the person
or damage or loss of property of value caused by any product that has been subject to misuse,
negligence, or accident, or misapplied or modified by unauthorized persons or improperly
installed.
C. Limitations of Liability
In the event of any claim for breach of any of Minarik Drives’s obligations, whether expressed
or implied, and particularly of any other claim or breach of warranty contained in Paragraph
A, or of any other warranties, expressed or implied, or claim of liability that might, despite
Paragraph B, be decided against Minarik Drives by lawful authority, Minarik Drives shall under no
circumstances be liable for any consequential damages, losses, or expenses arising in connection
with the use of, or inability to use, Minarik Drives’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, Minarik Drives’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 Minarik Drives based upon any liability or obligation arising hereunder or
under any law applicable to the sale of equipment or the use thereof, must be commenced within
one year after the cause of such action arises.
44
w w w.minarikdrives.com
1430 0 DE LA TOUR DRIV E
SO U TH BELOIT, IL 61080
(800) MINA RIK
250-0233 Rev 8
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