Minarik Drives - MC10 Series

Minarik Drives - MC10 Series
USER’S MANUAL
MC10 SERIES
MODELS
MC10
MC10-R
MC10-PCM
NEMA 4X SCR MOTOR CONTROLS
Copyright © 2006 by
Minarik Drives
All rights reserved. No part of this manual may be reproduced or transmitted in any form
without written permission from Minarik Drives. The information and technical data in this
manual are subject to change without notice. Minarik 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.
m Safety Warnings
SHOCK
HAZARD
AVOID
HEAT
KEEP
DRY
AVOID
VIBRATION
m
• 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.
m WARNING
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 insulated tools if working on this drive with power applied.
ii
Table of Contents
Specifications
1
Dimensions
2
Installation
4
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removing the plastic cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Field Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Voltage Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Calibration
10
Calibration procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MINIMUM SPEED (MIN SPD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MAXIMUM SPEED (MAX SPD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REGULATION (IR COMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TORQUE LIMIT (TORQUE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ACCELERATION (ACCEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DECELERATION (DECEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Calibration procedure conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operation
17
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MC-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MC-10-R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
MC10-PCM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
iii
Application Notes
21
Inhibit circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Decelerating to minimum speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dynamic braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Multiple fixed speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Adjustable speeds using potentiometers in series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
RUN/JOG switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
RUN/JOG option #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
RUN/JOG option #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Single speed potentiometer control of multiple drives . . . . . . . . . . . . . . . . . . . . . . . . . 32
Reversing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Troubleshooting
34
Before troubleshooting
34
Power and current limit LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Limited Warranty
inside back cover
iv
Illustrations
Figure 1. MC10 Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2. Cover removal for terminal strip access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 3. Drive connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 4. Voltage Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 5. Calibration Trimpot Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 6. Recommended TORQUE and IR COMP Settings for MC10 Series Controls. . . . . 16
Figure 7. Inhibit Plug with Run/Coast to Minimum Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 8. Run/Decelerate to Minimum Speed Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 9. Dynamic Brake Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 10. Multiple Fixed Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 11. Adjustable Fixed Speeds using Potentiometers in Series. . . . . . . . . . . . . . . . . . . 27
Figure 12. Independent Adjustable Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 13. RUN/JOG Switch Option #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 14. RUN/JOG Switch Option #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 15. Leader-Follwer Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 16. Single Speed Potentiometer Control of Multiple Drives . . . . . . . . . . . . . . . . . . . 32
Figure 17. Reversing Circuit Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 18. Current Limit LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Tables
Table 1. Recommended Line Fuse Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2. Field Output Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 3. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Specifications
MODEL
MC10 SERIES
MAX Armature
Current (ADC)
10
AC Line Voltage
HP RANGE
WITH 115 VAC
APPLIED
1/8–1
HP RANGE
WITH 230 VAC
APPLIED
1/4–2
STYLE
NEMA 4X
115/230 VAC, ±10%, 50/60 Hz, single phase
0–90 VDC
Armature Voltage (115 VAC Input)
0–180 VDC
Armature Voltage (230 VAC Input)
1.37 at base speed
Form Factor
Field Voltage (115 VAC Input)
50 VDC (F1 to L1); 100 VDC (F1 to F2)
Field Voltage (230 VAC Input)
100 VDC (F1 to L1); 200 VDC (F1 to F2)
Max Field Current
1 ADC
Accel. Time Range:
for 0–90 VDC Armature Voltage
1 – 15 seconds
for 0–180 VDC Armature Voltage
1 – 15 seconds
**Analog Input Voltage Range (signal must be isolated; S1 to S2):
for 0–90 VDC Armature Voltage
0 – 1.4 VDC
for 0–180 VDC Armature Voltage
0 – 2.8 VDC
Decel. Time Range:
for 0–90 VDC Armature Voltage
1 – 15 seconds
for 0–180 VDC Armature Voltage
1 – 15 seconds
Current Limit Range:
for 0–90 VDC Armature Voltage
0 – 14 A
for 0–180 VDC Armature Voltage
0 – 13.5 A
Input Impedance (S1 to S2)
Load Regulation
Vibration
Ambient Temp. Range (cased drive)
** Not valid for the MC10-PCM
3M ohms
1% base speed or better
1G max (0–50 Hz)
10°C – 40°C
Dimensions
5.63 [143]
5.16 [ 131]
POWER
ON

0.19 [5.00]
SLOTTED HOLES
4 PLACES
OFF
5
6
3
4
2
7
1
8
9
0
1 0
7.50 [191]
SPEED
5.50 [140]
ADJUSTABLE SPEED
DC MOTOR CONTROL
BOTTOM PLATE
0.73 [18.5]
CONDUIT HOLES
2 PLACES
4.56 [116]
2.12 [53.8]
2.20
[55.9]
3.40
[86.4]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 1. MC10 Series Dimensions
Overview
The following is an overview of the steps taken to set up a MC10 Series control. For more
detailed installation information, read the Installation and Calibration sections of this
manual.
1. Mount the control using the 4 slotted holes on the heat sink. The slotted holes are
0.19 inches [5 mm] (see Figure 1).
2. Remove the plastic cover by unscrewing the 6 screws on the front cover and 5 screws
on the bottom plate. NOTE: Do not remove the 3 screws securing the bottom plate to
the heatsink.
3. Change the line fuse if necessary. If the horsepower rating of the motor being used is
less than the maximum HP rating of the drive, the line fuse may have to be replaced
with a lower rated one.
4. Wire the control through the conduit holes, or optional aluminum hardware. NOTE: Do
not connect the control while power is applied.
5. Assure that settings on voltage switches are correct (SW501 & SW502).
6. Apply power to the drive.
7. Calibrate the trimmer pots, if necessary.
8. Re-install the plastic cover.
Installation
Mounting
MC10 Series drives may be vertically wall mounted using the four 0.19 inch (5 mm) slotted
holes on the attached heat sink (see Figure 1, Page 2). For motor loads less than 5 ADC,
the drive may be bench mounted horizontally, or operated without mounting.
Removing the Plastic Cover
Connections, calibration, and other settings must be made internally. After mounting, use
the following procedure to remove the plastic cover and configure the control:
1. Remove the six (6) phillips screws on the front cover. NOTE: The two shorter screws (#6 - 32 x 2 ½) are for the two lower holes on the front of the cover (see Figure 2, page 6).
2. Remove the five (5) phillips screws on the bottom plate (see FIgure 2, page 6). NOTE:
DO NOT remove the 3 screws securing the bottom plate to the heatsink.
Line fusing
Line fuses are preinstalled on all MC10 Series drives. If the current rating of the motor being used is less than the maximum current rating of the drive, the line fuse may have to be
replaced with a lower rated one. Refer to Table 1 for recommended line fuse sizes.
Installation
Table 1. Recommended Line Fuse Sizes
MOTOR HP
FUSE SIZE (AMPS)
@ 115 VAC INPUT
FUSE SIZE (AMPS)
@ 230 VAC INPUT
1/4
1/3
1/2
3/4
1
1½
2
5
8
8
10
15
–
–
3
3
5
8
8
10
15
Connections
m WARNING
Do not connect this equipment with power applied. Failure to heed this directive may
result in fire or serious injury.
1. Install conduit hardware through the two 0.73 inch (18.5 mm) conduit holes or by
using optional aluminum cord connectors (Part # 155-0081) attached to the line seal
plate on the bottom of the case.
2. Connect external wiring to the terminal block as shown in Figure 3, page 7.
Installation
1
2
POWER
ON

OFF
1
7 8 9
2 3
4 5 6
0
3
4
SPEED
ADJUSTABLE SPEED
DC MOTOR CONTROL
STEP #1
REMOVE THE SIX (6)
PHILLIPS SCREWS ON
THE FRONT CASE.
NOTE: THE TWO SHORTER
SCREWS (#6 - 32 x 2 ½) ON
THE FRONT CASE ARE USED
AT HOLE LOCATIONS 5 & 6.
6
5
OPTIONAL
ALUMINUM CORD
CONNECTORS (2)
PART #: 155-0081
1
STEP #2
REMOVE THE FIVE (5)
PHILLIPS SCREWS ON
THE BOTTOM PLATE.
2
BOTTOM PLATE
3
OPTIONAL ALUMINUM
CORD CONNECTORS
4
5
DO NOT REMOVE
THE THREE (3) SCREWS SECURING
THE BOTTOM PLATE TO THE HEATSINK
Figure 2. Cover removal for terminal strip access
MOV502
R502
Installation
MOV501
F502
A2 TO SW A1
L2 TO SW L1
A2 FRM SW A1
F501
MOV503
A1
A2
L1
L2-230
L2-115
TB501
F2
F1
L2 FRM SW L1
+
230 VAC
D
115 VAC
EARTH GROUND
(GREEN SCREW)
FIELD
OUTPUT
D
LINE VOLTAGE INPUT
(115 or 230 VAC)
MOTOR
ARMATURE
FIELD OUTPUT CONNECTIONS
D
The field output is for shunt wound motors only. Do not make any
connections to F1 and F2 when using a permanent magnet motor.
For field connections, see Table 2 on Page 8.
Figure 3. Drive connections
Installation
Field Output
The field output is for shunt wound motors only. Do not make any connections to F1 and
F2 when using a permanent magnet motor. Use 18 AWG wire to connect the field output
to a shunt wound motor. Table 2 lists the field output connections.
Table 2. Field Output Connections
Line Voltage
(VAC)
Approx. Field
Voltage (VDC)
Connect Motor
Field To
115
115
230
230
50
100
100
200
F1 and L1
F1 and F2
F1 and L1
F1 and F2
Voltage Switches
• Set voltage switch SW501 to either 115 or 230 to match the AC line voltage (see Figure
4, page 9).
• Set voltage switch SW502 to either 90 or 180 to match the maximum motor armature
voltage (see Figure 4, page 9).
Installation
IL502
IC501
CURRENT
LIMIT
IL501
SO501
SW502 (90 or 180 VDC)
TQ LIMIT
ACCEL
DECEL
IR COMP
MIN SPD
MAX SPD
T501
R501
230 - 115
SO502
SW501
90 - 180 SW502 INHIBIT
IC502
MAX ARMATURE VOLTAGE SWITCH
S3 S2 S1
C501
C504
POWER
C502
AC LINE VOLTAGE SWITCH
MOV501
C503
MOV502
R502
SW501 (115 or 230 VAC)
F502
A2 TO SW A1
L2 TO SW L1
A2 FRM SW A1
F501
MOV503
F1
L2 FRM SW L1
TB501
F2
L2-115
Figure 4. Voltage Switches
L2-230
L1
A2
A1
10
Calibration
m WARNING
Dangerous voltages exist on the drive when it is powered. 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.
All drives have six user-adjustable trimpots: Torque Limit (TORQUE), Acceleration (ACCEL),
Deceleration (DECEL), Regulation (IR COMP), Minimum Speed (MIN SPD), and Maximum
Speed (MAX SPD). Each drive is factory calibrated to its maximum current rating. Readjust
the calibration trimpot settings to accommodate lower current rated motors.
All adjustments increase with CW rotation, and decrease with CCW rotation. Use a nonmetallic screwdriver for calibration. Each trimpot is identified on the printed circuit board.
Refer to Figure 5 (page 11) for trimpot locations and Figure 6 (page 16) for typical TORQUE
LIMIT and IR COMP settings.
11
IL502
IC501
CURRENT
LIMIT
IL501
ACCEL
DECEL
MOV502
MOV501
IR COMP
R502
R501
230-115
MIN SPD
MAX SPD
C503
SW501
SO502
T501
90 - 180 SW502 INHIBIT
TQ LIMIT
S3 S2 S1
IC502
SO501
C501
C504
POWER
C502
F502
A2 TO SW A1
L2 TO SW L1
A2 FRM SW A1
F501
MOV503
F1
L2 FRM SW L1
TB501
F2
L2-115 L2-230 L1
A2
A1
Figure 5. Calibration Trimpot Layout
TRIMMER POTS
TORQUE LIMIT (TQ LIMIT)
ACCELERATION (ACCEL)
DECELERATION (DECEL)
REGULATION (IR COMP)
MINIMUM SPEED (MIN SPD)
MAXIMUM SPEED (MAX SPD)
12
Calibration
Calibration procedure
Calibrate the drive using the following procedure:
1. Set the MIN SPD, IR COMP, ACCEL and DECEL trimpots to zero (full CCW).
2. Set the TORQUE trimpot to maximum (full CW).
3. Set the MAX SPD trimpot to midrange (approximate 12 o’clock position).
4. Turn the speed adjust potentiometer on front cover to zero.
5. Apply power to the drive.
6. Calibrate the trimpots as follows:
MINIMUM SPEED (MIN SPD)
The MIN SPD setting determines the motor speed when the speed adjust potentiometer is
turned full CCW or reference signal is at its minimum. It is factory set to zero speed.
To calibrate, turn the speed adjust potentiometer full CCW or reference signal is at its
minimum. Adjust the MIN SPD trimpot until the motor has stopped, or is running at the
desired minimum speed.
Note: When using MC10-PCM drives in signal mode, calibrate SIG MIN first. Refer to
page 20.
Calibration
13
MAXIMUM SPEED (MAX SPD)
The MAX SPD setting determines the motor speed when the speed adjust potentiometer
is turned full CW or reference signal is at its maximum. It is factory set for maximum rated
speed.
To calibrate, set the MAX SPD trimpot full CCW. Turn the speed adjust potentiometer full
CW or reference signal is at its maximum. Adjust the MAX SPD trimpot until the desired
maximum motor speed is reached.
Note: Check the MIN SPD and MAX SPD adjustments after recalibrating to verify that the
motor runs at the desired minimum and maximum speed. When using the MC10-PCM
drives in signal mode, calibrate SIG MAX first. Refer to page 20.
REGULATION (IR COMP)
The IR COMP setting determines the degree to which motor speed is held constant as the
motor load changes. It is factory set for optimum motor regulation.
Recalibrate the IR COMP setting when using a lower horsepower motor. Refer to the
recommended IR COMP settings in Figure 6 (page 16), or recalibrate using the following
procedure:
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. Turn the IR COMP trimpot CCW to stabilize the motor.
14
Calibration
TORQUE LIMIT (TORQUE)
m WARNING
Although TORQUE is set to 150% of drive 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 TORQUE setting determines the maximum torque for accelerating and driving the
motor. TORQUE is factory set at 150% of maximum drive current. You must recalibrate
the TORQUE setting if using a lower current rated motor. See Figure 6 (page 16) for typical
TORQUE and IR COMP settings.
1. With no power applied to the drive, connect a DC ammeter in series with the motor
armature.
2. Set the TORQUE trimpot to full CCW.
3. Carefully lock the motor armature. Ensure that the motor is firmly mounted.
4. Apply line power. The motor should be stopped.
5. Set the speed potentiometer or reference signal to maximum speed. The motor should
remain stopped.
6. Slowly rotate the TORQUE trimpot clockwise (CW) until the ammeter reads 150% of
maximum motor armature current.
7. Set the speed adjust potentiometer or reference signal to zero speed.
8. Remove power from the drive.
9. Remove the lock from the motor shaft.
10. Remove the ammeter in series with the motor armature.
Calibration
15
ACCELERATION (ACCEL)
The ACCEL setting determines the time the motor takes to ramp to a higher speed. See
Specifications on page 1 for approximate acceleration times. The ACCEL setting is factory
set to its minimum value (full CCW).
Turn the ACCEL trimpot CW to increase the acceleration time, and CCW to decrease the
acceleration time.
DECELERATION (DECEL)
The DECEL setting determines the time the motor takes to ramp to a lower speed. See
Specifications on page 1 for approximate decelerating times. The DECEL setting is factory
set to its minimum value (full CCW).
Turn the DECEL trimpot CW to increase the deceleration time, and CCW to decrease the
deceleration time.
Calibration procedure conclusion
This concludes the calibration procedure. The control should now be calibrated for
optimum operation.
16
Calibration
TORQUE
TORQUE
TORQUE
IR COMP
IR COMP
IR COMP
1 HP
90 VDC
1750 RPM
10 AMPS
1/2 HP
90 VDC
1750 RPM
5 AMPS
1/4 HP
90 VDC
1750 RPM
2.7 AMPS
TORQUE
TORQUE
TORQUE
IR COMP
IR COMP
IR COMP
2 HP
180 VDC
1750 RPM
9.2 AMPS
1 HP
180 VDC
1750 RPM
5 AMPS
1/2 HP
180 VDC
1750 RPM
1.3 AMPS
Figure 6. Recommended TORQUE and IR COMP Settings for MC10 Series Controls
17
Operation
m 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. If the
switches are improperly set to a higher voltage position, the motor will overspeed,
which may cause motor damage.
Before applying power
• Set voltage switch SW501 to either 115 or 230 to match the AC line voltage (see Figure 4, page 9).
• Set voltage switch SW502 to either 90 or 180 to match the maximum armature voltage
(see Figure 4, page 9).
• Verify that no conductive material is present on the printed circuit board.
• If using a 90 VDC or 130 VDC motor with 230 VAC line voltage, derate the nameplate
motor torque by at least 30%.
18
Operation
Startup
MC10
m WARNING
If the motor or drive does not perform as described in this section, disconnect the AC
line voltage immediately. Refer to the Troubleshooting section for further assistance.
1. Set the speed adjust potentiometer (SPEED dial) to “0”, or full CCW.
2. Apply AC line voltage.
3. Set the POWER switch to the ON position.
4. Slowly advance the speed adjust potentiometer CW. The motor slowly accelerates as
the potentiometer is turned CW. Likewise, the motor slowly decelerates as the potentiometer is turned CCW. Continue until the desired speed is reached.
5. To bring the motor to a stop, turn the speed adjust potentiometer to “0” or set the
POWER switch to the OFF position.
Operation
19
MC10-R
m WARNING
Do not change the motor direction while the motor is running. The motor must come to
a complete stop before reversing. Changing motor direction before allowing the motor
to completely stop will cause excessively high current to flow in the armature circuit,
and may damage the drive and/or motor.
1. Set the FORWARD/OFF/REVERSE switch to the OFF position.
2. Set the speed adjust potentiometer (SPEED dial) to “0”, or full CCW.
3. Apply AC line voltage.
4. Set the FORWARD/OFF/REVERSE switch to the desired direction of rotation.
5. Slowly advance the speed adjust potentiometer CW. The motor slowly accelerates as
the potentiometer is turned CW. Likewise, the motor slowly decelerates as the potentiometer is turned CCW. Continue until the desired speed is reached.
6. To bring the motor to a stop, turn the speed adjust potentiometer to “0” or set the
FORWARD/OFF/REVERSE switch to the OFF position.
7. To reverse direction:
a. Set the FORWARD/OFF/REVERSE switch to the OFF position.
b. After the motor comes to a complete stop, set the FORWARD/OFF/REVERSE
switch to the desired direction of rotation.
20
Operation
MC10-PCM
Manual Operation
1. Set the Signal/Manual Switch located on the enclosure to MANUAL position.
2. Set the speed adjust dial to “0” (full CCW).
3. Apply AC line voltage.
4. Set the POWER switch to the ON position.
5. Slowly advance the speed adjust dial CW. The motor slowly accelerates as the dial is
turned CW. Continue until the desired speed is reached.
6. To bring the motor to a stop, turn the speed adjust dial to “0” or set the POWER switch
to the OFF position.
Signal Operation Calibration
1. Set the Signal/Manual Switch located on the enclosure to the SIGNAL position.
2. Apply the AC line voltage.
3. Set the POWER switch to the ON position.
4. Apply minimum current or voltage signal. Adjust the SIG MIN trimpot to achieve the
desired minimum motor speed.
5. Apply the maximum current or voltage signal. Adjust the SIG MAX trimpot to achieve
the desired maximum motor speed.
21
Application Notes
m WARNING
Decelerating to minimum speed, inhibit operation, 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 the AC line
power (both L1 and L2) is the only acceptable method for emergency stopping.
Inhibit circuit
Maintianing a connection between the inhibit pins (Figure 7, page 22) causes the motor
to coast to minimum speed. Removing the connection between the inhibit pins allow the
motor to accelerate to the speed set by the speed adjust potentiometer.
Minarik offers two accessory plug harnesses for connecting to the INHIBIT terminals: part
number 201-0024 [inhibit plug with 18 inches (46 cm) leads]; and part number 201-0079
[inhibit plug with 36 inches (91 cm) leads].
Twist inhibit wires and separate them from other power-carrying wires or sources of
electrical noise. Use sheilded 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.
Application Notes
RUN
SO501 2-PIN HEADER
HI
BI
T
COAST TO
MIN SPEED
IN
22
Use accessory plug harness 201-0024 or
201-0079 to mate with 2-pin header
(SO501) on control board.
Figure 7. Inhibit Plug with Run/Coast to Minimum Speed
Application Notes
23
Decelerating to minimum speed
The switch shown in Figure 8 may be used to decelerate a motor to minimum speed.
Closing the switch between S1 and S2 decelerates the motor from set speed to minimum
speed determined by the MIN SPD trimpot setting. If the MIN SPD trimpot is set full CCW,
the motor decelerates to zero speed when the switch between S1 and S2 is closed. The
DECEL trimpot 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 trimpot
setting.
RUN
CLOSE TO
DECEL TO
MIN SPEED
10K OHM
SPEED ADJUST
POTENTIOMETER
S3
S2
S0
S1
50
2
CW
Figure 8. Run/Decelerate to Minimum Speed Switch
24
Application Notes
Dynamic Braking
m WARNING
Wait for the motor to completly stop before swtiching it back to the RUN position. This
will prevent high armature currents from damaging the motor or drive.
Dynamic braking may be used to rapidly stop a motor (Figure 9, page 25). For the
RUN/BRAKE switch, use a two-pole, two-position switch rated for at least the maximum DC
armature voltage and maximum braking current. 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.
Application Notes
A1
A2
RUN
MOTOR
DYNAMIC BRAKE
RESISTOR
BRAKE
DYNAMIC BRAKE RESISTOR
IN
HI
BI
T
15 ohm for 90 VDC motors
30 ohm for 180 VDC motors
SO501 2-PIN HEADER
Use accessory plug harness 201-0024 or
201-0079 to mate with 2-pin header
(SO501) on control board.
Figure 9. Dynamic Brake Connection
25
26
Application Notes
Multiple Fixed Speeds
Replace the speed adjust potentiometer with series resistors with a total series resistance
of 10K ohms (Figure 10). Add a single-pole, multi-position switch with the correct number
of positions for the desired number of fixed speeds.
R4
R3
R2
S3
S2
S0
S1
50
2
R1
Figure 10. Multiple Fixed Speeds
TOTAL SERIES
RESISTANCE
10K OHMS
Application Notes
27
Adjustable speeds using potentiometers in series
Replace the speed adjust ptentiometer with a single-pole, multi-position switch, and two or
more potentiometers in series, with a total series resistance of 10K ohms. Figure 11 shows
a connection for fixed high and low speed adjust potentiometers.
5K
OHM
CW
HIGH
SPEED
5K
OHM
CW
S3
S2
S1
S0
50
2
LOW
SPEED
Figure 11. Adjustable Fixed Speeds Using Potentiometers in Series
28
Application Notes
Independent adjustable speeds
Replace the speed adjust potentiometer with a single pole, multiposition switch, and two
or more potentiometers in parallel, with a total prallel resistance of 10K ohms. Figure
12 shows the connection of two independent speed adjust potentiometers that can be
mounted at two separate operating stations.
SPEED 1
S3
S2
S0
S1
50
2
SPEED 2
Figure 12. Independent Adjustable Speeds
20K
OHM
20K
OHM
CW
CW
Application Notes
29
RUN/JOG Switch
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.
RUN/JOG option #1
In the first wiring option, connect the RUN/JOG switch and JOG pushbutton to the inhibit
plug as shown in Figure 13. The motor coasts to minimum speed 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
JOG
PUSHBUTTON
JOG
IBIT
INH
SO501 2-PIN HEADER
Use accessory plug harness 201-0024 or
201-0079 to mate with 2-pin header
(SO501) on control board.
Figure 13. RUN/JOG Switch Option #1
30
Application Notes
RUN/JOG option #2
In the second wiring option, connect the RUN/JOG switch and the JOG pushbutton as
shown in Figure 14. When the RUN/JOG switch is set to JOG, the motor decelerates to
minimum speed (minimum speed is determined by the MIN SPD trimpot setting). Press the
JOG pushbutton to jog the motor. Return the RUN/JOG switch to RUN for normal operation.
JOG
PUSHBUTTON
RUN
JOG
S3
S2
S0
S1
50
2
CW
Figure 14. RUN/JOG Switch Option #2
10K OHM
SPEED ADJUST
POTENTIOMETER
Application Notes
31
Leader-follower application
In this application, use a Process Control Module (PCM4) to monitor the speed of the
leader motor (Figure 15). 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
potentiomter may be used to scale the PCM output voltage.
9 (+)
A1
Leader
Drive
MOTOR
A2
8
(+) 2
PCM4
7 (-)
TB501
S2
(-) 1
TB502
S1
10K Ohm
(optional)
Figure 15. Leader-Follower Application
Follower
Drive
32
Application Notes
Single speed potentiometer control of multiple drives
Multiple drives can be controlled with a single speed adjust potentiometer using a Process
Control Module (PCM4) at the input of each drive to provide isolation (Figure 16). Optional
ratio potentiometers can be used to scale the PCM output voltage, allowing independent
control of each drive.
6
10K Ohms
8
2
1
7
TB501
Drive
A
S1
A1
Motor
A
A2
TB502
6
8
S2
PCM4
7
TB501
ratio pot A
(optional)
10K Ohms
2
ratio pot B
(optional)
10K Ohms
A1
S2
PCM4
1
S1
Drive
B
A2
TB502
Figure 16. Single Speed Potentiometer Control of Multiple Drives
Motor
B
Application Notes
33
Reversing
A dynamic brake may be used when reversing the motor direction (Figure 17). Use a threepole, 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, page 24, for recommended
dynamic brake resistor sizes. NOTE: Model MC10-R is equipped with the reversing feature,
but not the dynamic brake feature.
A1
A2
DYNAMIC
BRAKE
RESISTOR
MOTOR
FWD
BRAKE
REV
SO501 2-PIN HEADER
IN
H
IB
IT
Use accessory plug harness 201-0024 or
201-0079 to mate with 2-pin header
(SO501) on control board.
Figure 17. Reversing Circuit Connection
34
Troubleshooting
m 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 troubleshooting
Perform the following steps before starting any procedure in this section:
• Disconnect AC line voltage from the drive.
• Check the drive closely for damaged components.
• Check that no conductive or other foreign material has become lodged on the printed
circuit board.
• Verify that every connection is correct and in good condition.
• Verify that there are no short circuits or grounded connections.
• Check that the voltage switch settings match the AC line and maximum armature
output voltages.
• Check that the drive’s rated armature outputs are consistent with the motor ratings.
Troubleshooting
35
Power and Current Limit LEDs
Patriot Series drives are equipped with a green, PCB-mounted power LED and a red, PCBmounted current limit LED.
POWER LED (IL502)
The green power LED turns on when AC line voltage is applied to the drive.
CURRENT LIMIT (IL501)
The red current limit LED turns on when the drive reaches current limit and turns off whenever the drive is not in current limit (normal operation).
POWER LED (IL502)
IL502
IC501
CURRENT
LIMIT
IL501
DECEL
IR COMP
MIN SPD
MAX SPD
90-180
ACCEL
230-115
R501
MOV502
R502
Figure 18. Current Limit LEDs
MOV501
F502
SO502
SW501
C503
T501
S3 S2 S1
TQ LIMIT
SW502 INHIBIT
IC502
SO501
C501
C504
POWER
C502
CURRENT LIMIT LED (IL501)
36
Troubleshooting
Symptom
Fuse blows or circuit breaker
trips
Possible Causes
1. Check that line fuses or
circuit breakers are the
proper 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.
Line fuse does not blow or
circuit breaker does not trip,
but the motor does not run
Suggested Solutions
1. Line fuses or circuit
breakers are the wrong
size.
3. Add a blower to cool
the drive components;
decrease TORQUE settings, or resize motor
and drive for actual
load demand, or check
for incorrectly aligned
mechanical components or “jams”. See
page 14 for information
on adjusting the
TORQUE trimpot.
1. Reference signal or
speed adjust pot is set
to zero speed.
1. Increase reference
signal or speed adjust
potentiometer setting.
2. Reference signal or
speed adjust potentiometer connections
are open.
2. Check that the reference signal or speed
adjust potentiometer
connections are not
open.
3. Drive is in current limit.
4. Drive is not receiving
AC line voltage.
5. Motor is not connected.
3. Verify that the motor is
not jammed. Increase
TORQUE setting (page
14).
4. Apply AC line voltage to
L1 and L2.
5. Connect motor to A1
and A2.
Troubleshooting
Symptom
Possible Causes
37
Suggested Solutions
Motor runs too fast at maximum speed setting.
1. MIN SPD and MAX SPD
settings are too high.
1. Recalibrate MIN SPD
(page 12) and MAX
SPD (page 13).
Motor runs too slow or too
fast.
1. MIN SPD and MAX SPD
are not calibrated.
1. Recalibrate MIN SPD
(page 12) and MAX
SPD (page 13).
Motor will not reach the
desired speed.
1. MAX SPD setting is
too low.
1. Increase MAX SPD
setting (page 13).
2. IR COMP setting is
too low.
2. Increase IR COMP setting (page 13).
3. Motor is overloaded.
3. Check motor load.
Resize the motor or
drive if necessary.
1. IR COMP is set too
high.
1. Adjust the IR COMP
setting slightly CCW
until the motor speed
stabilizes (page 13).
2. Control is in current
limit mode.
2. Check that motor is of
sufficient horsepower
and amperage.
On non-reversing drives,
motor runs in the opposite
direction.
1. Motor armature leads
are reversed.
1. Reverse connections to
the motor armature.
Motor will not stop when the
speed adjust potentiometer
or reference signal is set to
zero speed.
1. MIN SPD trimpot is not
adjusted properly.
1. Slowly rotate the MIN
SPD trimpot until the
motor stops.
Motor pulsates or surges
under load.
38
Troubleshooting
Replacement Parts
Replacement parts are available from Minarik Drives and its distributors for this drive
series.
m WARNING
Dangerous voltages exist on the drive when it is powered. Disconnect power from the
drive, use insulated tools and the appropriate personal protection equipment.
BE ALERT. High voltages can cause serious or fatal injury.
Table 3. Replacement Parts
MODEL NO.
SYMBOL
DESCRIPTION
MC10
SCR501, 502
D501-503
R501
800 V, 20 A SCR
800 V, 20 A Diode
0.01 OHM, 5 W Resistor
MC10-R
SCR501, 502
D501-503
R501
800 V, 20 A SCR
800 V, 20 A Diode
0.01 OHM, 5 W Resistor
MC10-PCM
SCR501, 502
D501-503
R501
800 V, 20 A SCR
800 V, 20 A Diode
0.01 OHM, 5 W Resistor
39
Notes
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 or 3,000
hours, whichever comes first, from date of manufacture thereof. Within this warranty period,
the Corporation will repair or replace, at its sole discretion, such products that are returned
to Minarik Drives, 14300 De La Tour Drive, South Beloit, IL 61080, U.S.A.
This warranty applies only to standard catalog products, and does not apply to specials. Any
returns for special controls will be evaluated on a case-by-case basis. 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 breech 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 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, 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.
MINARIK DRIVES
w w w. m i n a r i k d r i ve s . c o m
14300 De La Tour Drive, South Beloit, IL 61080
Phone: (800) MINARIK or (815) 624-5959; Fax: (815) 624-6960
Document Number: 250-0352; Revision 2. Printed in the U.S.A. -- August 2006
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