User manual | 250 0265

250-0265_rev2.qxd
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Page a
Model
NRGD02-D240AC-4Q
Digitally-Controlled, Four-Quadrant,
Regenerative PWM Drives
for DC Brush Motors
User’s Manual
NRGD–4Q
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Copyright  2000 by
Minarik Corporation
All rights reserved. No part of this manual may be reproduced or transmitted in any
form without written permission from Minarik Corporation. The information and
technical data in this manual are subject to change without notice. Minarik
Corporation and its Divisions make no warranty of any kind with respect to this
material, including, but not limited to, the implied warranties of its merchantability
and fitness for a given purpose. Minarik Corporation and its Divisions assume no
responsibility for any errors that may appear in this manual and make no
commitment to update or to keep current the information in this manual.
Printed in the United States of America.
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Page i
Safety Warnings
• This symbol denotes an important safety tip or warning.
Please read these instructions carefully before performing
any of the procedures contained in this manual.
•
DO NOT INSTALL, REMOVE, OR REWIRE THIS
EQUIPMENT WITH POWER APPLIED. Have a qualified
electrical technician install, adjust and service this equipment.
Follow the National Electrical Code and all other applicable
electrical and safety codes, including the provisions of the
Occupational Safety and Health Act (OSHA), when installing
equipment.
•
Reduce the chance of an electrical fire, shock, or explosion by
proper grounding, over-current protection, thermal protection,
and enclosure. Follow sound maintenance procedures.
It is possible for a drive to run at full speed as a result of
a component failure. Minarik strongly recommends the
installation of a master switch in the main power input to
stop the drive in an emergency.
Circuit potentials are at 115 VAC or 230 VAC above earth
ground. Avoid direct contact with the printed circuit board or
with circuit elements to prevent the risk of serious injury or
fatality. Use a non-metallic screwdriver for adjusting the
calibration trimpots. Use approved personal protective
equipment and insulated tools if working on this drive with
power applied.
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Page ii
ii
Contents
Specifications
1
Dimensions
3
Installation
5
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Power, fuse and motor connections . . . . . . . . . . . . . . . . . . . . . .11
Optional switch connections . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Optional speed adjust potentiometer connections . . . . . . . . . . .17
Regen dump circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Jumper terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Motor armature voltage select . . . . . . . . . . . . . . . . . . . . . . . . . .21
Feedback select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Tach-generator feedback voltage select . . . . . . . . . . . . . . . . . . .21
Jumper settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Operation
Before applying power: . . . . . . . . . . . . . . .
Startup and shutdown . . . . . . . . . . . . . . . .
To start the drive: . . . . . . . . . . . . . . . . .
Starting and Stopping Methods . . . . . . . . .
Automatic restart upon power restoration
INHIBIT switch . . . . . . . . . . . . . . . . . . .
ENABLE/DISABLE switch . . . . . . . . . . .
RUN/BRAKE switch . . . . . . . . . . . . . . .
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25
.25
.26
.26
.27
.27
.28
.28
.28
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iii
Calibration
CURRENT LIMIT . . . . . . . . . . . . . . . . . . . . . . . .
IR COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAX SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DECEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TACH (for use with tachogenerator feedback only)
To calibrate the TACH trimpot: . . . . . . . . . . . . .
LOOP GAIN (LOOP) . . . . . . . . . . . . . . . . . . . . . .
OFFSET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application Notes
Connection to other Minarik devices . . . .
FWD-REV switch . . . . . . . . . . . . . . . . .
FWD-STOP-REV switch . . . . . . . . . . . .
Independent adjustable speeds . . . . . . .
Independent forward and reverse speeds
Independent forward and reverse speeds
with FWD-STOP-REV switch . . . . . .
Troubleshooting
Before applying power
Diagnostic LEDs . . . .
Terminal assignments
Replacement Parts . .
...
...
..
...
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29
.31
.32
.33
.34
.35
.35
.36
.38
.39
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41
.41
.42
.43
.44
.45
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. . . . . . . . . . . . . . . . . .46
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47
.47
.48
.50
.56
Index
57
Unconditional Warranty
63
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iv
Illustrations
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Figure 18.
Figure 19.
Four Quadrant Operation . . . . . . . . . . . . . . . . . . . . . . .ix
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . .10
Power and Motor Connections . . . . . . . . . . . . . . . . . . .13
Signal and Optional Switch Connections . . . . . . . . . . .16
Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . .18
Voltage Follower Connections . . . . . . . . . . . . . . . . . . .20
Jumper Terminal Location . . . . . . . . . . . . . . . . . . . . . .22
Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . .30
Typical CURRENT LIMIT and IR COMP Settings . . . . .40
Connection to DLC600 and PCM4 . . . . . . . . . . . . . . . .41
Forward-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . .42
Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . .43
Independent Adjustable Speeds (Forward Direction) . .44
Independent Forward and Reverse Speeds . . . . . . . . .45
Independent Forward and Reverse Speeds
with a Forward-Stop-Reverse Switch . . . . . . . . . . . . . .46
Diagnostic LED Location . . . . . . . . . . . . . . . . . . . . . . .49
Terminal Assignments . . . . . . . . . . . . . . . . . . . . . . . . .51
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v
Tables
Table 1.
Table 2.
Table 3.
Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . .8
Regen Dump Circuit Part Numbers . . . . . . . . . . . . . . .19
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . .56
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vi
NRGD–4Q Drives
Minarik’s NRGD–4Q Series drives are four-quadrant, full wave,
regenerative PWM drives. These open-chassis drives come with
the following features:
Four-quadrant ACCEL/DECEL.
Allows the user to control acceleration and deceleration in
forward and reverse directions.
Pulse width modulation.
Lower form factor than SCR drives (1.10 versus 1.37) throughout
the motor speed range. Motor runs with greater efficiency and
less maintenance.
Four-quadrant regenerative operation.
see Regenerative drives section on the following pages.
Regenerative braking.
Active braking along user-adjusted deceleration profile. No
contactors required. No electromechanical components to
overheat or wear out.
Fast brake/inhibit.
Active braking as fast as user-adjusted current limit allows.
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NRGD-4Q Drives
vii
Enable/disable.
Turns off the output stage, allowing the motor to coast to a stop.
Cage-clamp terminals.
Quicker and easier wiring than screw terminals.
Plug reversing.
Quickly switch from forward to reverse.
Autoranging dual voltage input (D240AC models
only).
Power the drive with either 120 VAC or 240 VAC.
Tachogenerator feedback option.
Improve the speed regulation from approximately 1% (armature
feedback) to 0.1% with tachogenerator feedback.
Diagnostic LEDs.
Green POWER ON and red FAULT LEDs allow easy visual
inspection of the drive status:
User adjustable trimpots.
Calibrate the drive precisely to your application needs.
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viii
Regenerative Drives
Most non-regenerative, variable speed, DC drives control current
flow to a motor in one direction. The direction of current flow is
the same direction as the motor rotation. Non-regenerative drives
operate in Quadrant 1, and also in Quadrant 3 if the drive is
reversible (see Figure 1). Motors must stop before reversing
direction. Unless dynamic braking is used, non-regenerative
drives cannot oppose an overhauling load, and cannot decelerate a
load faster than coasting to a lower speed.
Regenerative drives operate in two additional quadrants: Quadrant
2 and Quadrant 4. In these quadrants, motor torque is in the
opposite direction of motor rotation.
This allows regenerative drives to reverse a motor without
contactors or switches, to control an overhauling load, and to
decelerate a load faster than it would take to coast to a lower
speed.
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Page ix
Regenerative Drives
Figure 1. Four Quadrant Operation
ix
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Page 1
1
Specifications
Type
Open Chassis
AC Line Voltage
120 VAC or 240 VAC, ±10%, 50Hz or 60 Hz, single phase
Maximum Continuous Armature Current
2 ADC
Horsepower Range @ 130 VDC Output
1/20 – 1/4
Horsepower Range @ 240 VDC Output
1/10 – 1/2
Maximum Armature Voltage Range @ 120 VAC Input
0–130 VDC
Maximum Armature Voltage Range @ 240 VAC Input
0–240 VDC
Form Factor
1.10
Acceleration Time Range
0.1 – 20 seconds
Deceleration Time Range
0.1 – 20 seconds
Floating Input Signal Range (signal must be isolated) – 10 to +10 VDC
Input Impedance
100 Kohm minimum
Speed Regulation (% of base speed)
1% open loop
0.1% in tachogenerator feedback mode
Vibration
0.5G max. (0–50 Hz); 0.1G max. (>50 Hz)
Weight
Ambient Operating Temperature Range
0.78 lb
10°C–40°C
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3
Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 2. Dimensions
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5
Installation
Mounting
Warning
Do not install, rewire, or remove this control with input
power applied. Doing so may cause fire or serious injury.
Make sure you have read and understood the Safety
Warnings on pg i before attempting installation.
• Drive components are sensitive to electrostatic fields. Avoid
direct contact with the circuit board. Hold drive by the chassis
only.
• Protect the drive from dirt, moisture, and accidental contact.
Provide sufficient room for access to the terminal block and
calibration trimpots.
• Mount the drive away from heat sources. Operate the drive
within the specified ambient operating temperature range.
• Prevent loose connections by avoiding excessive vibration of
the drive.
• Mount drive with its board in either a horizontal or vertical
plane. Six 0.19 in. (5 mm) wide slots in the chassis accept #8
pan head screws. Fasten either the large base or the narrow
flange of the chassis to the subplate.
• The chassis must be earth grounded. Use a star washer beneath
the head of at least one of the mounting screws to penetrate the
anodized chassis surface and to reach bare metal.
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Installation
Wiring
Warning
Do not install, remove, or rewire this equipment with 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 may destroy the drive.
• Use 18-24 AWG wire for speed adjust potentiometer wiring.
Use 14–16 AWG wire for AC line (L1, L2) and motor (A1 and
A2) wiring.
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Installation
7
Shielding guidelines
Under no circumstances should power and logic leads be
bundled together. Induced voltage can cause unpredictable
behavior any electronic device, including motor controls.
As a general rule, Minarik recommends shielding of all
conductors.
If it is not practical to shield power conductors, Minarik
recommends shielding all logic-level leads. If shielding 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.
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Installation
Heat sinking
The NRGD02–4Q has sufficient heat sinking in its basic
configuration. No additional heat sinking is necessary.
Line fusing
Protect all Minarik drives with AC line fuses. Use fast acting AC
line fuses rated for 250 volts, and approximately 150% – 200% of
the maximum armature current. Fuse only the “hot” side of the
AC line (L1) if using 115 VAC line voltage. See Table 1 for
recommended line fuse sizes:
Table 1. Recommended Line Fuse Sizes
90 VDC Motor 180 VDC Motor
Horsepower
Horsepower
1/20
1/15
1/8
1/6
1/4
1/3
1/2
3/4
1
1/10
1/8
1/4
1/3
1/2
3/4
1
1 1/2
2
Max. DC Armature AC Line
Current (amps) Size (amps)
0.5
0.8
1.5
1.7
2.6
3.5
5.0
7.6
10
3
3
5
5
8
8
10
15
20
Minarik Corporation offers two fuse kits: part number 050–0069
(3–8A Fuse Kit) and 050–0073 (5–20A Fuse Kit).
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Page 9
Installation
9
Speed adjust potentiometer
Warning
Be sure that the potentiometer tabs do not make contact with
the potentiometer enclosure. Grounding the input will cause
damage to the drive.
Mount the speed adjust potentiometer through a 0.38 in. (10 mm)
hole with the hardware provided (Figure 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 speed adjust potentiometer wires are
longer than 18 in. (457 mm), use shielded cable. Keep speed
adjust potentiometer wires separate from power leads (L1, L2,
A1, A2).
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Page 10
Installation
Figure 3. Speed Adjust Potentiometer
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Installation
11
Connections
Warning
Do not connect this equipment with power applied.
Failure to heed this directive may result in fire or serious
injury.
Minarik strongly recommends the installation of a master
power switch in the voltage input line, as shown in
Figure 4. The switch contacts should be rated at a minimum
of 200% of motor nameplate current and 250 volts.
Power, fuse and motor connections
Connect the power input leads, an external line fuse and a DC
motor to TB501 on the drive’s printed circuit board (PCB) as
shown in Figure 4, page 13.
Motor
Minarik drives supply motor voltage from A1 and A2 terminals.
It is assumed throughout this manual that, when A1 is positive
with respect to A2 , the motor will rotate clockwise (CW) while
looking at the output shaft protruding from the front of the motor.
If this is opposite of the desired rotation, simply reverse the
wiring of A1 and A2 with each other.
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Installation
Connect a DC motor to PCB terminals A1 and A2 as shown in
Figure 4. Ensure that the motor voltage rating is consistent
with the drive’s output voltage.
Power input
Connect the AC line power leads to TB501 terminals L1 and L2,
or to a double-throw, single-pole master power switch
(recommended).
Line fuse
Wire an external line fuse between the stop switch (if installed)
and the L1 terminal on terminal board TB501. An additional line
fuse should be installed on L2 if the input voltage is 230VAC.
The line fuse(s) should be rated at 250 volts and 150 - 200% of
maximum motor nameplate current. Refer to the line fuse chart
on page 8 for fuse ratings.
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Installation
Figure 4. Power and Motor Connections
13
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Installation
Optional switch connections
Connect the following switches or jumpers to terminal board
TB502 as shown in Figure 5, page 16.
ENABLE/DISABLE switch
Install a single-pole, single- throw switch between the ENABLE
and COM terminals. Close the switch to disable the drive and
coast the motor to a stop. Leave open to enable the drive and run
the motor.
RUN/BRAKE switch
Install a single-pole, single- throw switch between the RB and
COM terminals. Close the switch to regeneratively brake the
motor to a stop at a rate controlled by the DECEL trimpot. Open
the switch to accelerate the motor to set speed at a rate controlled
by the ACCEL trimpot.
DIRECTION switch
Install a single-pole, single- throw switch between the DIR and
COM terminals. Open or close the switch as required to change
direction. Refer to the Application Notes for additional direction
switch connections.
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Installation
15
INHIBIT switch
Shorting the INH and COM terminals on connector TB502 to
each other causes the motor to decelerate to minimum speed at a
rate controlled by the CURRENT LIMIT trimpot. Remove the
short to accelerate the motor to set speed.
An alternative is to install a single-pole, single- throw switch
between the INH and COM terminals. Close the switch to
decelerate to minimum speed at a rate controlled by the
CURRENT LIMIT trimpot. Open the switch to accelerate the
motor to set speed.
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Page 16
Installation
NOTE: SPEED ADJUST
POT SHOWN
CONNECTED FOR
BIDIRECTIONAL
OPERATION
Figure 5. Signal and Optional Switch Connections
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Installation
17
Optional speed adjust potentiometer connections
The motor can operate in one direction (unidirectional) or two
directions (bidirectional) depending on how the speed adjust
potentiometer is connected to the drive.
Connect the speed adjust potentiometer as shown in Figure 6(a)
for bidirectional operation. The motor does not operate when the
wiper is in the center position. Turning the wiper CW from
center causes the motor to rotate in one direction, while turning
the wiper CCW from center causes rotation in the opposite
direction.
Connect the speed adjust potentiometer as shown in Figure 6(b)
for unidirectional operation in the forward direction.
Connect the speed adjust potentiometer as shown in Figure 6(c)
for unidirectional operation in the reverse direction.
Refer to the Application Notes for additional speed adjust
potentiometer connections.
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Installation
(a)
(b)
(c)
Figure 6. Speed Adjust Potentiometer Connections for
(a) Bidirectional Operation; (b) Unidirectional Operation (Forward);
and (c) Unidirectional Operation (Reverse)
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Installation
19
Regen dump circuit
The regen dump circuit reduces the voltage across the bus
capacitor when it reaches a factory-set trip point. As the drive
regeneratively brakes, it returns excess voltage to the bus
capacitor, where it is stored until it can be discharged.
When the regen dump circuit detects this condition, it redirects or
“dumps” the excess voltage through a shunt resistor network,
safely discharging the bus capacitor. Bus capacitor maximum
voltage ratings are 200 VDC for 115 VAC drives and 400 VDC
for 240 VAC drives.
Please contact your Minarik representative for more information
on changing the drive’s regen dump trip setting.
Table 2. Regen Dump Circuit Part Numbers
Drive model number
NRGDxx-115AC-4Q
NRGDxx–D240AC–4Q
Regen dump circuit
input voltage
115 VAC
240 VAC
BOSS DB-115
N/A
BOSS DB-115
BOSS DB-230*
*Note: BOSS DB-230 regen dump circuit requires an input
voltage of 240 VAC. Use BOSS DB-115 if input voltage is 115
VAC.
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Installation
Voltage follower
Instead of using a speed adjust potentiometer to set motor speed,
the drive may follow a floating (isolated) –10 to +10 VDC signal.
Connect the signal input to S2, and signal common to S0. See
Figure 7.
Figure 7. Voltage Follower Connections
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InstallationInstallati
21
Jumper terminals
Motor armature voltage select
Jumper terminals 1 and 2 on J1 and J2 if the motor armature
voltage is 90 volts. Jumper terminals 2 and 3 if the motor
armature voltage is 180 volts. The factory (default) setting is 180
volts (terminals 2 and 3). See Figure 9 for settings.
Feedback select
Jumper terminals 1 and 2 on J5 and J6 as shown if the feedback
selected is from the motor armature. Jumper terminals 2 and 3 if
the feedback is from a tach-generator. The factory (default)
setting is motor armature feedback (terminals 1 and 2). See
Figure 9 for settings.
Tach-generator feedback voltage select
NOTE: This jumper setting is applicable only if J5 and J6 are
set for tach-generator feedback. It is otherwise inoperative.
Jumper terminals 1 and 2 on J3 as shown if the tach-generator
voltage range is 7.5 – 20 volts/1000 RPM. Jumper terminals
2 and 3 if the voltage range is 50 – 100 volts/1000 RPM. The
factory (default) setting is 7.5 – 20 volts/1000 RPM. See
Figure 9 for settings.
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Installation
ARMATURE
VOLTAGE
SELECT
(J1 AND J2)
ARM/TACH
FEEDBACK
SELECT
(J5 AND J6)
TACH
VOLTAGE
RANGE
SELECT
(J3)
Figure 8. Jumper Terminal Location
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Installation
Jumper Settings
J1/J2
MOTOR
ARMATURE
VOLTAGE
J5/J6
ARM/TACH
FEEDBACK
SELECT
ARM/TACH
FEEDBACK
JUMPERS SET TO
ARMATURE
J3
TACH
FEEDBACK
VOLTAGE
RANGE
1 - 2 = 7.5 - 20
2 - 3 = 50 - 100
ARM/TACH
FEEDBACK
JUMPERS SET TO
TACH
1 - 2 = 7.5 - 20
2 - 3 = 50 - 100
TACH FEEDBACK
VOLTAGE RANGE
JUMPER SET FOR
7.5 – 50V TACH
OUTPUT
TACH FEEDBACK
VOLTAGE RANGE
JUMPER SET FOR
50 – 100V TACH
OUTPUT
Figure 9. Jumper Settings
23
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25
Operation
Warning
Dangerous voltages exist on the drive when it is powered,
and up to 30 seconds after power is removed and the motor
stops. BE ALERT. High voltages can cause serious or fatal
injury. For your safety, use personal protective equipment
(PPE) when operating this drive.
Before applying power:
• Verify that no conductive material is present on the printed
circuit board.
• Ensure that all jumpers are properly set.
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Operation
Startup and shutdown
To start the drive:
1. Turn the speed adjust potentiometer full counterclockwise
(CCW). If the drive is following a voltage signal, set the
voltage signal to 0 VDC.
2. Apply AC line voltage.
3. Slowly advance the speed adjust potentiometer clockwise
(CW). If the drive is following a voltage signal, slowly increase
the voltage signal. The motor slowly accelerates as the
potentiometer is turned CW, or the 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.
If the motor or drive does not perform as described, disconnect
the AC line voltage immediately. Refer to the Troubleshooting
section for further assistance.
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Operation
27
Starting and Stopping Methods
Warning
Decelerating to minimum speed, regenerative braking, or
coasting to a stop 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 L1 and L2) is the only
acceptable method for emergency stopping.
For this reason, Minarik strongly recommends installing
an emergency stop switch on both the L1 and L2 inputs
(see Connections).
Note: After a one-second time delay, all drives
automatically run to set speed when power is applied and the
ENABLE input is jumpered.
Frequent decelerating to minimum speed or regenerative braking
produces high torque. This may cause damage to motors,
especially gearmotors that are not properly sized for the
application.
Automatic restart upon power restoration
After a one-second time delay, all drives automatically run to set
speed when power is applied and the ENABLE input is jumpered.
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Operation
INHIBIT switch
Shorting the INH and COM terminals on connector TB502 to
each other causes the motor to decelerate to minimum speed at a
rate controlled by the CURRENT LIMIT trimpot. Remove the
short to accelerate the motor to set speed.
An alternative is to install a single-pole, single- throw switch
between the INH and COM terminals. Close the switch to
decelerate to minimum speed at a rate controlled by the
CURRENT LIMIT trimpot. Open the switch to accelerate the
motor to set speed.
ENABLE/DISABLE switch
Install a single-pole, single- throw switch between the ENABLE
and COM terminals. Close the switch to disable the drive and
coast the motor to a stop. Leave open to enable the drive and run
the motor.
RUN/BRAKE switch
Install a single-pole, single- throw switch between the RB and
COM terminals. Close the switch to regeneratively brake the
motor to a stop at a rate controlled by the DECEL trimpot. Open
the switch to accelerate the motor to set speed at a rate controlled
by the ACCEL trimpot.
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29
Calibration
Warning
Dangerous voltages exist on the drive when it is powered,
and up to 30 seconds after power is removed and the motor
stops. When possible, disconnect the voltage input from the
drive before adjusting the trimpots. If the trimpots must be
adjusted with power applied, use insulated tools and the
appropriate personal protection equipment. BE ALERT.
High voltages can cause serious or fatal injury.
NRGD–4Q drives have eight user-adjustable trimpots. Each drive
is factory calibrated to its maximum horsepower rating. Readjust
the calibration trimpot settings to accommodate lower horsepower
motors.
All adjustments increase with CW rotation, and decrease with
CCW rotation. Use a non-metallic screwdriver for calibration.
Each trimpot is identified on the printed circuit board.
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Calibration
LOOP
CURRENT
LIMIT
DECEL
IR COMP
MAX SPD
ACCEL
OFFSET
BALANCE
TACH
Figure 10. Calibration Trimpot Layout
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Calibration
31
CURRENT LIMIT
Warning
Although CURRENT LIMIT is set to 120% of motor
nameplate current rating, continuous operation beyond that
rating may damage the motor. If you intend to operate
beyond the rating, contact your Minarik representative for
assistance.
The CURRENT LIMIT (CL) setting determines the maximum
current limit for accelerating and driving the motor. CL is factory
set at 120% of maximum rated motor current.
To calibrate CURRENT LIMIT:
1. With the power disconnected from the drive, connect a DC
ammeter in series with the armature.
2. Set the CL trimpot to minimum (full CCW).
3. Lock the motor shaft. Be sure that the motor is firmly
mounted.
4. Connect power to the drive. The motor should remain stopped.
5. Set the speed adjust potentiometer or voltage input signal for
maximum forward speed.
6. Slowly adjust the CL trimpot CW until the armature current is
120% of motor rated current.
7. Set the speed adjust potentiometer or voltage input signal for
zero speed and remove the stall from the motor.
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Calibration
IR COMP
The IR COMP (also known as regulation) setting determines the
degree to which motor speed is held constant as the motor load
changes. It is factory set for optimum motor regulation at
maximum rated horsepower.
To calibrate IR COMP (exact calibration):
1. Turn the IR COMP trimpot full CCW.
2. Set the speed adjust potentiometer or voltage input signal until
the motor runs at midspeed without load (for example, 900 RPM
for an 1800 RPM motor). Measure the motor speed with a hand
held tachometer.
3. Load the motor armature to its full load armature current
rating. The motor should slow down.
4. While keeping the load on the motor, rotate the IR COMP
trimpot until the motor runs at the speed measured in step 2.
Approximate calibration:
If the motor does not maintain set speed as the load changes,
gradually rotate the IR COMP trimpot CW. If the motor oscillates
(overcompensation), the IR COMP trimpot may be set too high
(CW). Turn the IR COMP trimpot CCW to stabilize the motor
speed.
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Calibration
33
MAX SPD
The MAX SPD setting determines the maximum motor speed
when the speed adjust potentiometer, or voltage input signal is set
for maximum forward speed. It is factory set for maximum rated
motor speed.
To calibrate MAX SPD:
1. Set the MAX SPD trimpot full CCW.
2. Set the speed adjust potentiometer or voltage input signal for
maximum forward speed.
3. Adjust MAX SPD until the desired maximum forward speed is
reached.
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Calibration
ACCEL
The ACCEL setting determines the time the motor takes to ramp
to a higher speed in the either direction. ACCEL is factory set for
the fastest acceleration time (full CCW).
To calibrate ACCEL:
1 . Set the speed adjust potentiometer or voltage input signal for
minimum speed. The motor should run at minimum speed.
2. Set the speed adjust potentiometer or voltage input signal to
maximum forward speed, and 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 trimpot CW for a slower acceleration time,
or CCW for a faster acceleration time. Repeat steps 1 through 3
until the acceleration time is correct.
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Calibration
35
DECEL
The DECEL setting determines the time the motor takes to ramp
to a lower speed in either direction. DECEL is factory set for the
shortest deceleration time (full CCW).
To calibrate DECEL:
1. Set the speed adjust potentiometer or voltage input signal for
maximum forward speed. The motor should run at maximum
speed.
2. Set the speed adjust potentiometer or voltage input signal for
minimum speed and 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 trimpot CW for a slower deceleration time,
or CCW for a faster deceleration time. Repeat steps 1 through 3
until the deceleration time is correct.
TACH (for use with tachogenerator feedback
only)
Calibrate the TACH setting only when a tachogenerator is used.
The TACH setting, like the IR COMP setting, determines the
degree to which motor speed is held constant as the motor load
changes.
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Calibration
To calibrate the TACH trimpot:
1. Disconnect power to the drive and motor.
2. Connect the tachogenerator to terminal SO502. The polarity is
“+” for T1 and “–” for T2 with the motor running in the forward
direction.
3. Set the ARM/TACH FEEDBACK jumpers for armature
feedback. Refer to Figure 9 (page 23).
4. Apply power to the drive.
5. Run the motor at full speed. Measure the armature voltage
across A1 and A2 using a voltmeter.
6. Run the motor at either minimum speed or zero speed.
7. Disconnect power to the drive and motor.
8. Set the ARM/TACH FEEDBACK jumpers for tachogenerator
feedback.
9. Set the TACH VOLTAGE jumper to the correct tachogenerator
voltage range.
10. Set the IR COMP trimpot full CCW.
11. Set the TACH trimpot full CW.
12. Apply power to the drive and motor. Run the motor at full
speed.
13. Adjust the TACH trimpot until the armature voltage is the
same value as the voltage measured in step 5.
Check that the tachogenerator is properly calibrated. The motor
should run at the same set speed when the ARM/TACH
FEEDBACK jumpers are set to either armature or tachogenerator
feedback.
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Calibration
37
BALANCE (BAL)
The balance setting corrects for a small offset voltage which
could be applied to the motor while the drive is in BRAKE mode.
This voltage may cause the motor shaft to continue to rotate even
after the drive and motor have been braked.
To calibrate BAL:
1. Set the BAL trimpot to the middle of its travel. Set the speed
adjust potentiometer to minimum speed (full CCW) and apply
input power.
2. Set the speed adjust potentiometer or voltage input signal for
maximum forward speed. The motor should run at maximum
speed.
3. Set the RUN/BRAKE switch to BRAKE. If no switch is
installed, short the COM and RB terminals of connector J501.
The motor should brake to a stop.
4. If the motor shaft does not stop, but slowly rotates after
braking, adjust the BAL trimpot either CW or CCW (depending
on the direction of motor shaft rotation) until the motor shaft
comes to a stop.
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Calibration
LOOP GAIN (LOOP)
The LOOP trimpot is used to provide additional regulation for
certain low-horsepower, high-inductance motors. It is unused in
most applications and is factory set to zero (full CCW).
Please consult your Minarik representative for more information
before adjusting this trimpot.
If calibration is necessary, perform the following procedure:
1. Apply input power and set the speed adjust pot to
approximately 50% of maximum motor speed. If an input signal
is used, set the signal to approximately 50% of maximum.
2. Adjust the LOOP trimpot slowly CW until the motor becomes
unsteady under load. A hum from the motor may be audible at
this point.
3. Slowly adjust the LOOP trimpot CCW until the motor
stabilizes and the hum (if any) is quieted. At this point, the
LOOP GAIN trimpot is calibrated and should need no further
adjustment.
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Calibration
39
OFFSET
Warning
This trimpot is set at the factory and should not need
adjustment. Do not adjust this trimpot unless you are
experiencing drift problems. Contact your Minarik
representative before attempting adjustment, as improper
calibration may have unpredictable results.
The NRGD series has a factory-set offset around zero speed to
guarantee stability in the stopped motor. Contact your Minarik
representative before attempting adjustment, as improper
calibration may have unpredictable results.
To calibrate OFFSET:
1. Ensure that input power is turned OFF.
2. Set the signal input to zero.
3. Set the OFFSET trimpot to the approximate midpoint of its
travel.
4. Apply power and observe the motor shaft.
5. If the motor shaft “creeps”, i.e., slowly rotates with no signal
applied, adjust the OFFSET trimpot until the motor shaft stops.
The direction and amount of trimpot adjustment depends on the
direction of shaft rotation and connection of the motor leads.
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Calibration
120 VAC INPUT
240 VAC INPUT
Figure 11. Typical CURRENT LIMIT and IR COMP Settings
(actual settings may vary with each application)
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41
Application Notes
Connection to other Minarik devices
NRGD
DRIVE
DLC600
S0
BIDIRECTIONAL
Figure 12. Connection to DLC600 and PCM4
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Application Notes
FWD-REV switch
Use a single-pole, two-position switch with a single speed adjust
potentiometer to reverse a motor (Figure 13). Brake the drive
before reversing by using a RUN/BRAKE switch as shown. This
will help prevent high reversing currents from damaging the drive
or motor.
Figure 13. Forward-Reverse Switch
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Application Notes
43
FWD-STOP-REV switch
Use a single-pole, three-position switch with a single speed adjust
potentiometer to stop a motor between reversals (Figure 14). Set
the switch to the center position to decelerate the motor to a stop.
TB502
Figure 14. Forward-Stop-Reverse Switch
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Application Notes
Independent adjustable speeds
Connect two speed adjust potentiometers with a single-pole,
two- position switch to select between two independent speeds in
the same direction. Refer to Figure 15.
TB502
Figure 15. Independent Adjustable Speeds
(Forward Direction)
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Application Notes
Independent forward and reverse speeds
Connect two speed adjust potentiometers as shown in
Figure 16 to select between independent forward and reverse
speeds.
TB502
Figure 16. Independent Forward and Reverse Speeds
45
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Application Notes
Independent forward and reverse speeds
with FWD-STOP-REV switch
Use a single-pole, three-position switch to stop the motor when
the switch is in the center position (Figure 17). Set the switch to
the center position to decelerate the motor to a stop.
TB502
Figure 17. Independent Forward and Reverse Speeds
with a Forward-Stop-Reverse Switch
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Troubleshooting
47
Troubleshooting
Warning
Dangerous voltages exist on the drive when it is powered.
When possible, disconnect the drive while troubleshooting.
High voltages can cause serious or fatal injury.
Before applying power
Check the following steps before proceeding:
1. The AC line voltage must be connected to the proper
terminals.
2. Check that the voltage switches and jumpers are set correctly.
3. The motor must be rated for the drive’s rated armature voltage
and current.
4. Check that all terminal block connections are correct.
For additional assistance, contact your local Minarik® distributor,
or the factory direct:
1-800-MINARIK (646-2745) or Fax: 1-800-394-6334
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Troubleshooting
Diagnostic LEDs
NRGD02 drives are equipped with the following diagnostic LEDs
to aid in troubleshooting or monitoring equipment status.
POWER
Green LED lights when AC line voltage is applied to the drive.
RUN
Red LED lights when the drive applies a signal to run the motor.
CURRENT LIMIT (CL/FLT)
Red LED lights when drive output current exceeds the threshold
set by the CURRENT LIMIT trimpot.
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Troubleshooting
CURRENT
LIMIT
RUN
POWER
Figure 18. Diagnostic LED Location
49
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Troubleshooting
Terminal assignments
DIR
Short the DIR and COM terminals to reverse the direction of
motor shaft rotation.
ENBL
Short the ENBL and COM terminals to enable the drive’s power
section. Removing the short will disable the drive and coast the
motor to a stop.
COM
Circuit common.
INHIBIT
Close the INHIBIT and COM terminals to brake the motor to a
stop at a rate controlled by the CURRENT LIMIT trimpot.
RB
Short RB to COM to decelerate the motor to a minimum speed
using regenerative braking. The braking rate is controlled by the
DECEL trimpot.
S3
+10 VDC reference for 10 KOHM speed adjust potentiometer.
Circuit common is S0.
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Troubleshooting
S2
Accepts 10 Kohm speed adjust potentiometer wiper or isolated
–10 VDC to +10 VDC reference.
S1
–10 VDC reference for 10 Kohm speed adjust potentiometer.
Circuit common is S0.
S0
Circuit common for 10 Kohm speed adjust potentiometer or
isolated voltage input signal.
Figure 19. Terminal Assignments
51
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Troubleshooting
Problem
Line fuse blows
Line fuse does not
blow, but the motor
does not run
Possible Cause
Suggested
Solution
1. Line fuses are the
wrong size.
1. Check that line
fuses are properly
sized for the motor
being used.
2. Motor cable or
armature is shorted
to ground.
2. Check motor
cable and armature
for shorts.
1. Speed adjust
potentiometer or
voltage input signal
set to zero speed.
1. Increase the
speed adjust
potentiometer
setting or voltage
input signal.
2. Speed adjust
potentiometer or
voltage input signal
not connected to
drive input properly;
connections are
open.
2. Check
connections
to input. Verify that
connections are not
open.
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Troubleshooting
Problem
Line fuse does not
blow, but the motor
does not run (cont.)
Possible Cause
53
Suggested
Solution
3. Inhibit terminals
are shorted to each
other; or S2 is
shorted to S0.
3. Remove short.
4. Drive is in current
limit. Check
diagnostic LEDs.
4. Verify that motor
is not jammed.
Increase CURRENT
LIMIT setting if it is
set too low.
5. Drive is not
receiving AC line
voltage. Check
diagnostic LEDs.
5. Apply AC line
voltage to L1 and
L2.
6. Motor is not
connected.
6. Connect motor to
A1 and A2.
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Troubleshooting
Problem
Motor runs too slow
or too fast at set
speed
Motor will not reach
the desired speed
Motor pulsates or
surges under load
Possible Cause
Suggested
Solution
1. Switches or
jumpers are set
incorrectly.
1. Verify all switch
and jumper settings.
2. MAX SPD is not
calibrated.
2. Calibrate MAX
SPD.
1. MAX SPD setting
is too low.
1. Increase MAX
SPD setting.
2. IR COMP setting
is too low.
2. Increase the IR
COMP setting.
3. Motor is
overloaded. Check
diagnostic LEDs.
3. Check motor load.
Resize the motor if
necessary.
1. IR COMP is set
too high.
1. Adjust the IR
COMP setting
slightly CCW until
the motor speed
stabilizes.
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Troubleshooting
Problem
Possible Cause
55
Suggested
Solution
Motor pulsates or
surges under load
(cont.)
2. Motor “bouncing”
in and out of torque
limit.
2. Make sure motor
is not undersized for
load.
Motor does not
reverse
1. Bad switch
connection to DIR
and COM.
1. Check switch
connection to DIR
and COM.
2. Reversing circuit
not working properly.
2. Check reversing
circuit by shorting
DIR to COM with
jumper wire.
1. BAL trimpot not
set for zero speed.
1. Calibrate BAL
trimpot. Refer to
page 37.
2. IR COMP set too
high.
2. Calibrate IR
COMP trimpot.
Refer to page 32.
3. OFFSET trimpot
not calibrated.
Calibrate OFFSET
trimpot. Refer to
page 39.
Motor creeps when
inhibit terminals are
shorted to each other
or RB and COM
terminals are shorted.
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Troubleshooting
Replacement Parts
Replacement parts are available from Minarik Corporation and its
distributors for this drive series.
Table 3. Replacement Parts
Model No.
Symbol
NRGD02-D240AC-4Q
C501
C503
C504
C505, 506
IC505
Q501–504
T501
T506
TB501
TB502
Description
Minarik® P/N
470 µF, 400 V Capacitor
1000 µF, 63 V Capacitor
120 µF, 25 V Capacitor
100 µF, 25 V Capacitor
Isolation Unit HCPL7840
IRG4BC30UD IGBT
POL-15204 Transformer
DST–2–36 Transformer
14 Terminal Block
Cage–Clamp Terminal Block
Speed Adj. Pot Kit
Pico Fuse
Fuse Kit (3 – 8A)
011-0120
011-0127
011-0122
011-0079
060-0121
070-0085
230-0111
230–0066
164-0320
164-0318
202-0096
050–0064
050-0069
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Index
Application Notes: 41
Connection to other Minarik devices: 41
FWD-REV switch: 42
FWD-STOP-REV switch: 43
Independent adjustable speeds: 44
Independent forward and reverse speeds: 45
Independent forward and reverse speeds
with FWD-STOP-REV switch: 46
Calibration
ACCEL: 11, 34
BALANCE (BAL): 37
CURRENT LIMIT: 31
DECEL: 35
IR COMP: 32
LOOP GAIN (LOOP): 38
MAX SPD: 33
OFFSET: 39
TACH: 35
Diagnostic LEDs: 48
Dimensions: 3-65
Illustrations
Figure 1. Four Quadrant Operation: ix
Figure 2. Dimensions: 3
Figure 3. Speed Adjust Potentiometer: 10
Figure 4. Power and Motor Connections: 13
Figure 5. Signal and Optional Switch Connections: 16
Figure 6. Speed Adjust Potentiometer Connections: 18
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Index
Figure 7. Voltage Follower Connections: 20
Figure 8. Jumper Terminal Location: 22
Figure 9. Jumper Settings: 23
Figure 10. Calibration Trimpot Layout: 30
Figure 11. Typical CURRENTLIMIT and IRCOMP Settings: 40
Figure 12. Connection to DLC600 and PCM4: 41
Figure 13. Forward-Reverse Switch: 42
Figure 14. Forward-Stop-Reverse Switch: 43
Figure 15. Independent Adjustable Speeds: 44
Figure 17. Independent Forward and Reverse Speeds
with a Forward-Stop-Reverse Switch: 46
Figure 18. Diagnostic LED Location: 49
Figure 19. Terminal Assignments: 51
Installation: 5
Heat sinking: 8
Jumper Settings: 23
Line fusing: 8
Optional speed adjust potentiometer connections: 17
Speed adjust potentiometer: 9
Terminal assignments: 50
Voltage follower: 20
NRGD–4Q Drives Overview: vi
Autoranging dual voltage input: vii
Cage-clamp terminals: vii
Enable/disable: vii
Fast brake/inhibit: vi
Four-quadrant ACCEL/DECEL: vi
Four-quadrant regenerative operation: vi
Plug reversing: vii
Pulse width modulation: vi
Regenerative braking: vi
Tachogenerator feedback option: vii
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Index
User adjustable trimpots: vii
Operation: 25
Before applying power: 25
Starting and Stopping Methods: 27
Automatic restart upon power restoration: 27
ENABLE/DISABLE switch: 28
INHIBIT switch: 28
RUN/BRAKE switch: 28
Startup and shutdown: 26
Safety Warnings: i
Specifications: 1-65
Tables
Table 1. Recommended Line Fuse Sizes: 8
Table 2. Regen Dump Circuit Part Numbers: 19
Table 3. Replacement Parts: 56
Troubleshooting: 47
Diagnostic LEDs: 48
CURRENT LIMIT (CL/FLT): 48
POWER: 48
RUN: 48
Replacement Parts: 56
Troubleshooting Tree: 52
Warning: 47
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Unconditional Warranty
A. Warranty
Minarik Corporation (referred to as “the Corporation”) warrants that its products will be free from
defects in workmanship and material for twelve (12) months from date of manufacture thereof.
Within this warranty period, the Corporation will repair or replace such products that are returned
to Minarik Corporation, 901 East Thompson Avenue, Glendale, CA 91201-2011 USA.
This warranty shall not apply to any product that has been repaired by unauthorized persons.
The Corporation is not responsible for removal, installation, or any other incidental expenses
incurred in shipping the product to and from the repair point.
B. Disclaimer
The provisions of Paragraph A are the Corporation’s sole obligation and exclude all other
warranties of merchantability for use, express or implied. The Corporation further disclaims any
responsibility whatsoever to the customer or to any other person for injury to the person or
damage or loss of property of value caused by any product that has been subject to misuse,
negligence, or accident, or misapplied or modified by unauthorized persons or improperly
installed.
C. Limitations of Liability
In the event of any claim for breach of any of the Corporation’s obligations, whether express or
implied, and particularly of any other claim or breech of warranty contained in Paragraph A, or of
any other warranties, express or implied, or claim of liability that might, despite Paragraph B, be
decided against the Corporation by lawful authority, the Corporation shall under no
circumstances be liable for any consequential damages, losses, or expense arising in
connection with the use of, or inability to use, the Corporation’s product for any purpose
whatsoever.
An adjustment made under warranty does not void the warranty, nor does it imply an extension
of the original 12-month warranty period. Products serviced and/or parts replaced on a nocharge basis during the warranty period carry the unexpired portion of the original warranty only.
If for any reason any of the foregoing provisions shall be ineffective, the Corporation’s liability for
damages arising out of its manufacture or sale of equipment, or use thereof, whether such
liability is based on warranty, contract, negligence, strict liability in tort, or otherwise, shall not in
any event exceed the full purchase price of such equipment.
Any action against the Corporation based upon any liability or obligation arising hereunder or
under any law applicable to the sale of equipment or the use thereof, must be commenced
within one year after the cause of such action arises.
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901 E Thompson Avenue
Glendale, CA 91201-2011
Tel.: 1-800-MINARIK (646-2745)
Fax: 1-800-394-6334
www.minarikcorp.com
Document number 250–0265, Revision 2
Printed in the U.S.A – 2/00
North America $12.00, Outside North America $15.00

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