250 0219

250 0219
A n A merican Cont rol Elect ronics Brand
X P S erie s
USER MANUAL
PC MXP02-115AC
PC MXP05-115AC
PC MXP10-115AC
X P02- 115AC
X P02- 115AC -Q
X P05- 115AC
X P10- 115AC
www.minarikdrives.com
Dear Valued Consumer:
Congratulations on your purchase of the XP 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!
No part of this document may be reproduced or transmitted in any form without written permission
from American Control Electronics®. The information and technical data in this document are
subject to change without notice. American Control Electronics® 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. American Control Electronics® 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.
XP 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 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
XP Series
Table of Contents
Section 1. Specifications...................................................... 1
Section 2. Dimensions.. ........................................................ 3
Section 3. Installation. . ........................................................ 7
Heat Sinking.................................................................................. 7
Mounting...................................................................................... 8
Speed Adjust Potentiometer. . ................................................. 9
Wiring..........................................................................................10
Shielding Guidelines.............................................................11
Line Fusing...........................................................................12
Connections.................................................................................13
Quick-Disconnect Terminal Block...........................................13
Power Input. . ........................................................................15
Motor.. .................................................................................15
Speed Adjust Potentiometer. . ................................................15
Analog Input Signal (XP models)............................................16
Analog Input Signal (PCMXP models).....................................17
Section 4. Operation. . ........................................................ 20
Before Applying Power..................................................................20
Select Jumpers . . ............................................................................21
Manual/Signal Select (SW501) (PCMXP models only)..............21
Startup.........................................................................................22
Starting and Stopping Methods.....................................................23
Line Starting and Stopping....................................................23
Dynamic Braking...................................................................24
Inhibit Terminals (-Q models only).........................................26
Decelerating to Minimum Speed. . ..........................................27
Section 5. Calibration........................................................ 28
Minimum Speed (MIN SPD) (-Q and PCMXP models only). . ..............29
Maximum Speed (MAX SPEED / MAX SPD)......................................29
Signal Adjust (SIG ADJ) (PCMXP models only).................................30
Torque (CURRENT LIMIT, CUR LIMIT, or TORQUE)............................31
ii
XP Series
IR Compensation (IR COMP)..........................................................32
Acceleration/Deceleration (ACCEL/DECEL).. ....................................35
Section 6. Application Notes.............................................. 36
Multiple Fixed Speeds...................................................................36
Adjustable Speeds Using Potentiometers In Series . . ........................37
Independent Adjustable Speeds.. ...................................................38
RUN/JOG Switch - Inhibit Connection (-Q models only)...................39
RUN/JOG Switch - Potentiometer Connection. . ...............................39
Leader-Follower Application..........................................................41
Single Speed Potentiometer Control Of Multiple Drives..................42
Reversing.. ....................................................................................43
Section 7. Diagnostic LEDs.. ................................................ 44
Section 8. Troubleshooting. . ............................................... 45
Before Troubleshooting.................................................................45
Section 9. Accessories & Replacement Parts........................ 48
Unconditional Warranty.. .................................................... 49
iii
XP Series
List of Tables
Table 1
Table 2
Recommended Line Fuse Sizes...........................................12
Minimum Recommended Dynamic Brake Resistor Values....25
List of Figures
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
XP Series Dimensions......................................................... 3
XP02-115AC-Q Dimensions................................................. 4
PCMXP Series Dimensions.................................................. 5
223-0159 Dimensions......................................................... 6
Speed Adjust Potentiometer............................................... 9
Quick-Disconnect Terminal Block.......................................14
XP Series Analog Input Signal Connections.........................16
PCMXP Series Connections................................................17
XP Series Connections.......................................................18
XP02-115AC-Q Connections...............................................19
Manual/Signal Jumper. . .....................................................21
Dynamic Brake Wiring.......................................................25
Run/Decelerate to Minimum Speed Switch. . .......................27
Recommended CURRENT LIMIT and IR COMP Settings for 2
and 5 amp models. . ...........................................................33
Figure 15 Recommended CURRENT LIMIT and IR COMP Settings for 10
amp models......................................................................34
Figure 16 Multiple Fixed Speeds.......................................................36
Figure 17 Adjustable Speeds Using Potentiometers in Series..............37
Figure 18 Independent Adjustable Speeds. . .......................................38
Figure 19 RUN/JOG Switch - Connection to Inhibit ............................39
Figure 20 RUN/JOG Switch - Connection to Speed Adjust
Potentiometer..................................................................40
Figure 21 Leader-Follower Application..............................................41
Figure 22 Single Speed Potentiometer Control of Multiple Drives. . .....42
Figure 23 Reversing Circuit Wiring....................................................43
Figure 24 XP02-115AC-Q Diagnostic LED Locations............................44
iv
1
2
3
4
5
6
7
8
9
10
11
12
13
14
XP Series
Section 1. Specifications
Maximum
Armature
Current (ADC)
HP Range with
90/130 VDC
Motor
HP Range with
180/240 VDC
Motor
PCMXP02-115AC
XP02-115AC
XP02-115AC-Q
2.0
1/20 - 1/6
1/10 - 1/3
Chassis
Chassis
Chassis
PCMXP05-115AC
XP05-115AC
5.0
1/6 - 1/2
1/3 - 1
Chassis
Chassis
PCMXP10-115AC
XP10-115AC
10.0*
1/2 - 1
1-2
Chassis
Chassis
Model
Enclosure
* Heat sink kit part number 223-0159 must be used when the continuous
current output is over 5 amps.
AC Line Voltage
115 VAC ± 10%, 50/60 Hz, single phase
DC Armature Voltage
0 - 130 VDC
Acceleration Time Range
XP models
XP-Q & PCMXP models
Deceleration Time Range
XP models
XP-Q models
PCMXP models
0.5 - 6 seconds
1 second
coast to a stop - 6 seconds
2 seconds
1 second
Analog Input Range
XP models (Signal must be isolated; S1 to S2)
XP-Q models (Signal must be isolated; S1 to S2)
PCM models (Signal may be isolated or non-isolated; NEG to POS)
Input Impedance (S1 to S2)
XP models (S1 to S2)
XP-Q models (S1 to S2)
PCM models (NEG to POS)
Form Factor
0 - 10 VDC
0 - 5 VDC
0 - 10 VDC
~10K ohms
> 100K ohms
> 2K ohms
1.05
1
XP Series
Load Regulation
Speed Range
Vibration
Safety Certifications
Ambient Temperature Range
2
1% base speed or better
80:1
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
XP Series
Section 2. Dimensions
4.30 [109]
3.80 [97]
R502
R504
AA+
+ DC IN
CURRENT
LIMIT
ACCEL /
DECEL
3.64 [93]
1.75 [44]
0.19 [5]
C501
R501
- DC IN
L
S1
W
S2
H
S3
R503
IR COMP
0.73 [19]
MAX SPEED
0.19 [5]
A
1.35 [34]
1.03 [26]
MODEL
DIMENSION “A” HEIGHT
XP02-115AC
1.77 [45]
XP05-115AC
2.36 [60]
XP10-115AC
2.88 [73]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 1. XP Series Dimensions
3
XP Series
0.19 [5]
3.58 [91]
1.75 [44]
MAX SPD
P501
TORQUE
P502
MIN SPD
P503
0.74 [19]
IR COMP
P504
0.65 [16]
3.80 [97]
4.30 [109]
0.19 [5]
2.15 [55]
1.28 [33]
0.97 [25]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
4
Figure 2. XP02-115AC-Q Dimensions
XP Series
4.30 [109]
3.80 [97]
A1
C502
C505
C504
A2
R502
C501
0.19 [5]
T501
3.64 [93]
R501
POS
1.75 [44]
NEG
S3
BUS-
IR COMP
SIG ADJ
SW501
INPUT
MAN SIG
BUS+
S2
TH501
C503
S1
0.73 [19]
MAX SPD
MIN SPD
TQ LIMIT
MODEL
DIMENSION “A” HEIGHT
PCMXP02-115AC
1.77 [45]
PCMXP05-115AC
2.36 [60]
PCMXP10-115AC
2.88 [73]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 3. PCMXP Series Dimensions
5
XP Series
6.90 [175]
6.30 [160]
5.90 [150]
0.7 [18]
4.40 [112]
3.00 [76]
1.75 [44]
3.90 [100]
0.125 [3]
1.00 [26]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 4. 223-0159 Dimensions
6
XP 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
Models XP10-115AC and PCMXP10-115AC require an additional heat
sink when the continuous armature current is above 5 amps. Use Minarik
Drives heat sink kit part number 223-0159. 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.
7
XP 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.
8
XP 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).
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 5. Speed Adjust Potentiometer
9
XP 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.
10
XP 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.
11
XP 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. Table 1 lists the recommended line fuse sizes.
Model XP02-115AC-Q comes with a preinstalled 5 amp fuse.
Preinstalled line fuse is rated for maximum horsepower. If the
horsepower rating of the motor being used is less than the maximum
horsepower rating of the drive, the line fuse may have to be replaced
with a lower rated one. Fuses should be rated for 250 VAC or higher and
approximately 150% of the maximum armature current. Refer to Table 1
to install a lower rated fuse.
Table 1. Recommended Line Fuse Sizes
90 / 130 VDC
Motor Horsepower
Maximum DC Armature
Current (amps)
AC Line
Fuse Size
(amps)
1/20
1/15
1/8
1/6
0.5
0.8
1.5
1.7
1
1.5
3
3
1/4
2.5
5
1/3
1/2
3/4
1
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.
12
XP Series
Connections

!
WARNING!
Do not connect this equipment with power applied. Failure to
heed this warning may result in fire, explosion, or serious injury.
Minarik Drives strongly recommends the installation of a
master power switch in the voltage input line, as shown in
Figures 8, 9, and 10 (pages 17, 18, and 19). The switch contacts
should be rated at a minimum of 200% of motor nameplate
current and 250 volts.
Quick-Disconnect Terminal Block (-Q Models Only)
The quick-disconnect terminal block, found only on -Q drives, is
composed of a 8-pin header block and 8-screw terminal plug (Figure 6 on
page 14). To use the quick-disconnect terminal block:
1.
Carefully pull terminal plug from header block.
2. With a small flat-head screwdriver, turn terminal plug screw
counterclockwise to open wire clamp.
3. Insert stripped wire into the large opening in front of the plug.
4. Turn the terminal plug screw clockwise to clamp the wire.
5. Repeat steps 2–4 for each terminal until all connections are
made.
6. Insert plug into header until securely fastened.
13
XP Series
Header Block
(mounted on the drive)
Terminal Plug
Figure 6. Quick-Disconnect Terminal Block
14
XP Series
Power Input
For chassis models, 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 Figures 8, 9, and 19 on pages
17, 18, and 19.
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 Figures 8, 9,
and 10 on pages 17, 18, and 19. Ensure that the motor voltage rating is
consistent with the drive’s output voltage.
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 Figures 8, 9, and 10 on pages 17, 18, and 19.
15
XP Series
Analog Input Signal (XP models)
Instead of using a speed adjust potentiometer, non PCMXP models may
be wired to follow an analog input voltage signal that is isolated from
earth ground (Figure 7). 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 XP models, an analog input voltage range of 0–10 VDC is required to
produce an armature voltage range of 0–130 VDC. With XP-Q models, an
analog input voltage range of 0-5 VDC is required to produce an armature
voltage range of 0-130 VDC.
R502
R504
AA+
+ DC IN
CURRENT
LIMIT
SIGNAL INPUT (-)
S1
SIGNAL REFERENCE (+)
S2
ACCEL /
DECEL
L
S1
W
S2
H
S3
C501
R501
- DC IN
R503
IRCOMP
MAX SPEED
CONNECT TO HEADER BLOCK
L1
L2
A1
A2
S3
S2
SIGNAL
REFERENCE (+)
H2
S1
H1
SIGNAL
INPUT (-)
Figure 7. XP Series Analog Input Signal Connections
16
XP Series
Analog Input Signal (PCMXP models)
Instead of using a speed adjust potentiometer, PCM models may be
wired to follow an analog input voltage signal that is either isolated or
non-isolated from earth ground (Figure 8). Connect the signal common
(–) to NEG. Connect the signal reference (+) to POS. 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 an analog input
voltage.
An analog input voltage range of 0–10 VDC is required to produce an
armature voltage range of 0–130 VDC.
MOTOR
A1
C502
C505
C504
A2
R502
C501
T501
R501
POS
NEG
S3
IR COMP
SIG ADJ
SW501
INPUT
MAN SIG
BUS+
S2
BUS-
C503
S1
TH501
Signal Reference (+)
Signal Common (-)
FUSE
CW
MAX SPD
10K OHM
SPEED ADJUST
POTENTIOMETER
MIN SPD
TQ LIMIT
POWER
SWITCH
AC LINE
VOLTAGE
120 VAC
Figure 8. PCMXP Series Connections
17
XP Series
MOTOR
R502
R504
AA+
10K OHM
SPEED ADJUST
POTENTIOMETER
+ DC IN
CURRENT
LIMIT
ACCEL /
DECEL
C501
R501
- DC IN
L
S1
W
S2
H
S3
R503
IR COMP
CW
FUSE
MAX SPEED
POWER
SWITCH
AC LINE
VOLTAGE
120 VAC
Figure 9. XP Series Connections
18
XP Series
CONNECT TO HEADER BLOCK
L1
L2
A1
A2
S3
S2
H2
S1
H1
RUN
STOP
CW
POWER
SWITCH
MOTOR
ARMATURE
10K OHM
SPEED ADJUST
POTENTIOMETER
Figure 10. XP02-115AC-Q Connections
19
XP 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 45, for further assistance.
Before Applying Power
1. Verify that no foreign conductive material is present on the
printed circuit board.
2. Ensure that all jumpers are properly set.
20
XP Series
Select Jumpers
Manual/Signal Select (SW501) (PCMXP models only)
Place a jumper on the Manual/Signal select (SW501) to set the drive for
manual input (MAN) or signal input (SIG). See Figure 11 for settings and
location.
A1
C502
C505
C504
A2
R502
C501
T501
R501
POS
NEG
S3
BUS-
IR COMP
SIG ADJ
SW501
INPUT
MAN SIG
MAX SPD
BUS+
Manual/Signal
Jumper (SW501)
S2
TH501
C503
S1
MIN SPD
TQ LIMIT
Figure 11. Manual/Signal Jumper
21
XP 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.
22
Remove AC line voltage from the drive to coast the motor to a
stop.
XP 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 Figures 8, 9,
and 10 on pages 17, 18, and 19).
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.
23
XP 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 12 on page
25). 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 2 on page 25 for
recommended dynamic brake resistor sizes.
24
XP Series
Table 2. Minimum Recommended Dynamic Brake Resistor Values
Motor Armature Voltage
Dynamic Brake Resistor Value
90 or 130 VDC
15 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
CW
10K OHM
SPEED ADJUST
POTENTIOMETER
S3
S2
S1
Figure 12. Dynamic Brake Wiring
25
XP Series
Inhibit Terminals (-Q models only)
Close the INHIBIT to coast the motor to a stop (see Figure 10 on page 19
for INHIBIT H1 and H2 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.
26
XP Series
Decelerating to Minimum Speed
The switch shown in Figure 13 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.
For XP models, the ACCEL/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/DECEL trim
pot setting.
For XP-Q and PCMXP models, refer to the Specifications table on page 1
for the acceleration and deceleration time rates.
CW
S3
10K OHM
SPEED ADJUST
POTENTIOMETER
S2
S1
RUN
DECEL TO
MIN SPEED
Figure 13. Run/Decelerate to Minimum Speed Switch
27
XP 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.
XP 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.
28
XP Series
Minimum Speed (MIN SPD) (-Q and PCMXP models only)
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 SPEED / MAX SPD)
For XP models, the MAX SPEED setting determines the maximum motor
speed when the speed adjust potentiometer or input voltage signal is
set for maximum speed. For PCMXP models, the MAX SPEED settings
determines the maximum motor speed only when a speed adjust
potentiometer is used.
To calibrate MAX SPEED:
1.
Set the MAX SPEED trim pot full CCW.
2.
Set the speed adjust potentiometer or input voltage signal for
maximum speed.
3. Adjust MAX SPEED until the desired maximum speed is reached.
Note: Check the MIN SPD and MAX SPEED adjustments after
recalibrating to verify that the motor runs at the desired minimum and
maximum speed.
29
XP Series
Signal Adjust (SIG ADJ) (PCMXP models only)
The SIG ADJ setting determines the maximum motor speed when the
input voltage signal is set for maximum speed.
To calibrate SIG ADJ:
1.
Set the SIG ADJ trim pot full CCW.
2.
Set the input voltage signal for maximum speed.
3. Adjust SIG ADJ until the desired maximum speed is reached.
30
XP Series
Torque (CURRENT LIMIT, CUR LIMIT, or TORQUE)

!
WARNING!
CURRENT 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 CURRENT LIMIT setting determines the maximum torque for
accelerating and driving the motor. To calibrate CURRENT LIMIT, refer to
the recommended CURRENT LIMIT settings in Figures 14 and 15 on pages
33 and 34 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 CURRENT 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 CURRENT 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.
31
XP 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 14 and 15 on pages 33 and 34 for recommended IR COMP
settings.
32
XP Series
MODELS XP02-115AC, XP02-115AC-Q, PCMXP02-115AC
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
1/6 HP
90 VDC
1.67 AMPS
1/10 HP
90 VDC
1.00 AMP
1/20 HP
90 VDC
0.50 AMPS
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
1/6 HP
130 VDC
1.15 AMPS
1/10 HP
130 VDC
0.70 AMPS
1/20 HP
130 VDC
0.35 AMPS
MODELS XP05-115AC, PCMXP05-115AC
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
1/2 HP
90 VDC
5.00 AMPS
1/4 HP
90 VDC
2.50 AMPS
1/6 HP
90 VDC
1.67 AMPS
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
1/2 HP
130 VDC
3.50 AMPS
1/4 HP
130 VDC
1.75 AMP
1/6 HP
130 VDC
1.15 AMPS
Figure 14. Recommended CURRENT LIMIT and IR COMP Settings
for 2 and 5 amp models
(actual settings may vary with each application)
33
XP Series
MODELS XP10-115AC, PCMXP10-115AC
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
1 HP
90 VDC
10.0 AMPS
3/4 HP
90 VDC
7.50 AMPS
1/2 HP
90 VDC
5.00 AMPS
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
1 HP
130 VDC
7.00 AMPS
3/4 HP
130 VDC
5.20 AMP
1/2 HP
130 VDC
3.50 AMPS
Figure 15. Recommended CURRENT LIMIT and IR COMP Settings
for 10 amp models
(actual settings may vary with each application)
34
XP Series
Acceleration/Deceleration (ACCEL/DECEL) (XP models only)
The ACCEL/DECEL setting determines the time the motor takes to ramp
to a lower or higher speed. See Specifications on page 1 for approximate
acceleration and deceleration times. ACCEL/DECEL is factory set for the
shortest acceleration/deceleration 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/DECEL trim pot CW for a longer
acceleration time or CCW for a faster acceleration time. Repeat
steps 1 through 2 until the acceleration time is correct.2 until
the acceleration time is correct.
35
XP 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 16). 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 16. Multiple Fixed Speeds
36
XP 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 17). 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 17. Adjustable Speeds Using Potentiometers In Series
37
XP 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 18 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 18. Independent Adjustable Speeds
38
XP Series
RUN/JOG Switch - Inhibit Connection (-Q models only)
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 19. 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 19. RUN/JOG Switch - Connection to Inhibit Plug
39
XP Series
RUN/JOG Switch - Potentiometer Connection
Connect the RUN/JOG switch and the JOG pushbutton as shown in Figure
20. 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 20. RUN/JOG Switch - Connection to Speed Adjust Potentiometer
40
XP Series
Leader-Follower Application
In this application, use a PCM4 to monitor the speed of the leader motor
(Figure 21). 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
Follower
Drive
10K Ohm
(optional)
Figure 21. Leader-Follower Application
41
XP 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 22).
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 22. Single Speed Potentiometer Control of Multiple Drives
42
XP Series
Reversing
A dynamic brake may be used when reversing the motor direction
(Figure 23). 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 25 for
recommended dynamic brake resistor sizes.
A1
A2
DYNAMIC
BRAKE
RESISTOR
MOTOR
FWD
BRAKE
REV
INHIBIT
Figure 23. Reversing Circuit Wiring
43
XP Series
Section 7. Diagnostic LEDs
XP02-115AC-Q drives are equipped with two diagnostic LEDs:
•
Power (PWR): Green LED lights whenever AC line voltage is applied
to the drive.
•
Current Limit (CUR LIM): Red LED lights whenever the drive reaches
current limit.
MAX SPD
TORQUE
MIN SPD
Power LED
IR COMP
Current Limit
LED
Figure 24. XP02-115AC-Q Diagnostic LED Locations
44
XP 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
45
XP Series
PROBLEM
Line fuse
blows.
Line fuse does
not blow, but
the motor does
not run.
46
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
CURRENT LIMIT settings, resize
motor and drive for actual
load demand, or check for
incorrectly aligned mechanical
components or “jams”. See
page 31 for information on
adjusting the CURRENT 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 mode is active.
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 CURRENT
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.
XP Series
PROBLEM
POSSIBLE CAUSE
SUGGESTED SOLUTIONS
Motor does not
stop when the
speed adjust
potentiometer
is full CCW.
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. CURRENT LIMIT setting is
too low.
3. Increase CURRENT 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
CURRENT LIMIT trim pot CW.
Motor pulsates
or surges under
load.
47
XP Series
Section 9. Accessories & Replacement Parts
Displays
Closed Loop................................................................................. DLC600
Open Loop....................................................................................... VT-8
Heat Sinks
Chassis..................................................................................... 223-0159
Kits
Potentiometer & Connector
Pot Kit (XP & PCMXP models).............................................. 202-0066
Pot Kit (XP-Q models).......................................................... 202-0074
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
Logic Cards
Current Sensing
5 Amps..................................................................................... CSC1-5
20 amps................................................................................. CSC1-20
Isolation Cards
Unidirectional, 8 outputs........................................................ USIM-8
Bidirectional, 1 output............................................................... PCM4
48
XP Series
Unconditional Warranty
A. Warranty
American Control Electronics 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, American Control Electronics will repair or
replace, at its sole discretion, such products that are returned to American Control Electronics,
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. American Control Electronics
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 American Control Electronics’s sole obligation and exclude all
other warranties of merchantability for use, expressed or implied. American Control Electronics
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 Americn Control Electronics’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 American Control Electronics by lawful authority,
American Control Electronics shall under no circumstances be liable for any consequential
damages, losses, or expenses arising in connection with the use of, or inability to use, American
Control Electronics’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, American Control Electronics’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 American Control Electronics 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.
49
An Amer i ca n C o nt ro l E l e c t ro n i c s B ra n d
w w w.minarikdrives.com
1430 0 DE LA TOUR DRIV E
SO U TH BELOIT, IL 61080
(800) MINA RIK
250-0219 Rev 2
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