USER`S MANUAL - Minarik Drives

USER`S MANUAL - Minarik Drives
USER’S MANUAL
MM23000 Series
SCR, Dual Voltage,
Adjustable Speed Drives
for DC Brush Motors
Model
MM23021C
Copyright  2001 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.
i
Safety Warnings
•
This symbol
denotes an important safety tip or warning.
Please read these sections carefully prior to performing any of
the instructions contained in that section.
•
Have a qualified electrical maintenance 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.
This drive is isolated from earth ground. 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 nonmetallic screwdriver for adjusting the calibration trimpots.
Use approved personal protective equipment and insulated
tools if working on this drive with power applied.
ii
Contents
Safety Warnings
i
Specifications
1
Dimensions
2
Installation
3
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Field output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Speed adjust potentiometer installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Operation
9
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Inhibit terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Decelerating to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Calibration
15
MINIMUM SPEED (MIN SPD)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
IR COMPENSATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
ACCELERATION (ACCEL)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
DECELERATION (DECEL)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
iii
Application Notes
23
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . .24
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Single speed potentiometer control of multiple drives . . . . . . . . . . . . . . . .29
Reversing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Reversing with a DIGI-LOK® controller, model DLC600 . . . . . . . . . . . . . .31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
CE Compliance
36
Line filters
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Armature filters
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Functional Diagrams
40
Replacement Parts
41
Limited Warranty
inside back cover
Tables
Table 1. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Table 2. Corcom® Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Table 3. Minarik Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
iv
Illustrations
Figure 1. MM23021C Dimensions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Figure 2. Chassis Drive Connections to Heat Sink Terminal Boards . . . . . . . . . . .5
Figure 3. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Figure 4. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 5. Voltage Follower Connections With Signal Greater than 3.5VDC . . . . .8
Figure 6. Voltage Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 7. INHIBIT Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Figure 8. Run/Decelerate to Minimum Speed Switch . . . . . . . . . . . . . . . . . . . . .12
Figure 9. Dynamic Brake Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 10. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 11. Typical TORQUE and IR COMP Settings . . . . . . . . . . . . . . . . . . . . .22
Figure 12. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Figure 13. Adjustable Fixed Speeds Using Potentiometers in Series . . . . . . . . .24
Figure 14. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Figure 15. RUN/JOG Switch Connection to Inhibit Plug . . . . . . . . . . . . . . . . . . .27
Figure 16. RUN/JOG Switch Connection to Speed Adjust Potentiometer . . . . . .27
Figure 17. Leader-Follower Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Figure 18. Single Speed Potentiometer Control of Multiple Drives . . . . . . . . . . .29
Figure 19. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Figure 20. Reversing with a DLC600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Figure 21. MM23000 Series Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .40
1
Specifications
Model
MM23021C
Max.
Armature
Current
(Amps DC)
18
AC Line Voltage
Max HP
with 115 VAC
Applied
1½
Max HP
with 230 VAC
Applied
3
Style
Chassis
115 VAC or 230 VAC ±10%, 50/60 Hz, single phase
Armature Voltage (115 VAC Input)
0–90 VDC
Armature Voltage (230 VAC Input)
0–180 VDC
Form Factor
Analog Input Voltage Range (signal must be isolated)
1.37 at base speed
0 – 3.5 VDC
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
Input Impedance (S1 to S2)
Load Regulation
Vibration
1 ADC
100K ohms
1% base speed or better
0.5g max (0–50 Hz)
0.1g max (>50 Hz)
Safety Certification
UL Recognized Component, file # E132235
CSA Certified Component, file # LR41380
CE Certificate of Compliance
Ambient Temp. Range (chassis drive)
Weight
10°C–55°C
1.5 lb.
2
Dimensions
D501
D503
MOV502
D502
A2
L1
MO
V5
F2
SCR502
C503
R501
01
R502
SCR501
T501
F1
C501
1
MOV503
L2
SO502
SW501
IC502
A1
115
S2
S3
230
+ METER
SO501
C504
INHIBIT
DECEL
IL501
P503
P504
MAX SPD
S1
P505
MIN SPD
P506
TORQUE
IR COMP
7.000"
9.800"
1
2
3
4
5
ACCEL
IC501
CL
180
90
SW502
P502
P501
C502
A1
110V
A2
1.375
230V
6.300"
6.900"
2.455"
0.125"
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 1. MM23021C Dimensions
3
Installation
Mounting
•
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. Four 0.19 inch (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. To ground the chassis, 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.
Heat sinking
The MM23021 has sufficient heat sinking in its basic
configuration. No additional heat sinking is necessary.
4
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. See Table 1 for field output connections.
Table 1. Field Output Connections
Line Voltage
(VAC)
115
115
230
230
Approximate
Field Voltage (VDC)
50
100
100
200
Connect Motor
Field To
F1 and L1
F1 and F2
F1 and L1
F1 and F2
Use 18 AWG wire to connect the field output to a shunt wound
motor.
5
Installation
Connections
ACCEL
DECEL
MAX SPD
MIN SPD
TORQUE
IR COMP
CW
1
2
3
4
5
SPEED
ADJUST
POT
10KΩ
FIELD
COILS
+
A1
A2
115 VAC INPUT
MOTOR
+
EMERGENCY
STOP SWITCHES
NOTE:
Do not connect
field coils if using a
permanent-magnet
motor.
230 VAC INPUT
Figure 2. Chassis Drive Connections to Heat Sink Terminal Boards
6
Installation
Speed adjust potentiometer installation
Warning
Be sure that the potentiometer tabs do not make contact with
the potentiometer enclosure. Grounding the input will cause
damage to the drive.
Install the circular insulating disk between the panel and the 10K
ohm speed adjust potentiometer. Mount the speed adjust
potentiometer through a 0.38 inch (10 mm) hole with the
hardware provided (Figure 3). Twist the speed adjust
potentiometer wire to avoid picking up unwanted electrical noise.
If potentiometer leads are longer than 18 inch (457 mm), use
shielded cable.
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
CW
WIPER
CCW
NUT
STAR
WASHER
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
POT TAB ASSIGNMENTS
PANEL
Figure 3. Speed Adjust Potentiometer
Installation
7
Shielding guidelines
Warning
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 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.
8
Installation
Voltage follower
Instead of using a speed adjust potentiometer, the drive may be
wired to follow an analog input voltage signal (0 – 3.5 VDC) that
is isolated from earth ground (Figure 4). Connect the signal input
(+) to terminal 4. Connect the signal common (–) to terminal 3.
Make no connection to 5.
If the maximum signal is greater than 3.5V, use the speed adjust
pot as a trimmer. See Figure 5 for connections. With the signal at
maximum, use the speed adjust pot to set the motor to the desired
maximum speed. It is advised that the speed adjust pot be
secured to preclude inadvertent tampering with this important
setting.
SIGNAL INPUT
NEG POS
(-) (+)
1
5
4
+ (POS)
2
3
3
- (NEG)
4
SPEED
ADJUST
POT
10KΩ
5
TERMINAL
BOARD
Figure 4. Voltage Follower
Connections
Figure 5. Voltage Follower
Connections With Signal
Greater than 3.5VDC
9
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.
Before applying power
• Set voltage switch SW501 to either 115V or 230V to match the
AC line voltage. Set voltage switch SW502 to either 90V or
180V to match the maximum armature voltage (see Figure 6).
L2
INPUT VOLTAGE
SELECT SWITCH
(SW501)
ARMATURE VOLTAGE
SELECT SWITCH
(SW502)
SW501
115
S2
S3
230
SO501
INHIBIT
P501
ACCEL
Figure 6. Voltage Switches
C504
90
180
SW502
P502
DECEL
P503
MAX SPD
P504
MIN S
10
Operation
Startup
1. Turn the speed adjust potentiometer full counterclockwise
(CCW).
2. Apply AC line voltage.
3. Slowly advance the speed adjust potentiometer clockwise
(CW). The motor slowly accelerates as the potentiometer is
turned CW. Continue until the desired speed is reached.
4. Remove AC line voltage from the drive to coast the motor to a
stop.
Line starting and line stopping
Line starting and line 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. When AC line voltage is removed, the motor
coasts to a stop.
11
Operation
Inhibit terminals
Short the INHIBIT terminals to coast the motor to minimum
speed (see Figure 7 for INHIBIT terminal location). Reopen the
INHIBIT terminals to accelerate the motor to set speed.
Twist inhibit wires and separate them from other power-carrying
wires or sources of electrical noise. Use shielded cable if the
inhibit wires are longer than 18 inches (46 cm). If shielded cable
is used, ground only one end of the shield to earth ground. Do not
ground both ends of the shield.
Minarik Corporation 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].
L2
115
S2
INHIBIT
Terminals
S3
SO502
SW501
230
+
METER
SO501
INHIBIT
P501
ACCEL
C504
DECEL
P503
MAX SPD
Figure 7. INHIBIT Terminals
IC50
CL
90
180
SW502
P502
C502
IL501
P504
MIN SPD
P505
TORQUE
P506
IR COMP
12
Operation
Decelerating to minimum speed
The switch shown in Figure 8 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 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.
Figure 8. Run/Decelerate to Minimum Speed Switch
Operation
13
Dynamic braking
Warning
For frequent starts and stops, short the inhibit terminals,
decelerate to a minimum speed, or apply a dynamic brake to
the motor. 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.
Frequent starting and stopping can produce high torque. This
may cause damage to motors, especially gearmotors that are
not properly sized for the application.
Dynamic braking may be used to rapidly stop a motor (Figure 9).
For the RUN/BRAKE switch, use a two pole, two position switch
rated for at least 15 amps at 180 VDC. For the dynamic brake
resistor, use a 40 watt minimum, high-power, wire-wound
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.
14
Operation
INHIBIT
PINS
RUN
A2
20Ω
40W
A1
MOTOR
Figure 9. Dynamic Brake Connections
BRAKE
15
Calibration
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.
MM23000 Series drives have six user adjustable trimpots: MIN
SPD, MAX SPD, TORQUE, IR COMP, ACCEL, and DECEL.
Refer to Figure 10, page 16 for trimpot layouts. Each drive is
factory calibrated to its maximum current rating. Readjust the
calibration trimpot settings to accommodate lower current rated
motors.
All trimpot settings increase with clockwise (CW) rotation, and
decrease with counterclockwise (CCW) rotation. Use a nonmetallic screwdriver for calibration. Each trimpot is identified
on the printed circuit board.
Calibration
D501
SCR501
D503
D502
MOV502
A2
L1
MO
SCR502
C503
R501
V5
F2
01
R502
16
T501
F1
C501
1
MOV503
L2
SO502
SW501
IC502
A1
115
S2
S3
230
+
METER
SO501
INHIBIT
P501
ACCEL
ACCEL
C504
DECEL
P503
IL501
P504
MAX SPD
MIN SPD
MAX SPEED
DECEL
IC501
CL
90
180
SW502
P502
C502
S1
P505
P506
TORQUE
IR COMP
TORQUE
MIN SPEED
Figure 10. Calibration Trimpot Layout
IR COMP
Calibration
17
MINIMUM SPEED (MIN SPD)
The MIN SPD setting determines the motor speed when the speed
adjust potentiometer is turned full CCW. It is factory set to zero
speed.
To calibrate, turn the speed adjust potentiometer full CCW. Adjust
the MIN SPD trimpot until the motor has stopped (for zero speed
setting), or is running at the desired minimum speed.
MAXIMUM SPEED (MAX SPD)
The MAX SPD setting determines the motor speed when the
speed adjust potentiometer is turned full CW. It is factory set for
maximum rated speed.
To calibrate, set the MAX SPD trimpot full CCW. Turn the speed
adjust potentiometer full CW. 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..
18
Calibration
TORQUE
Warning
Although TORQUE LIMIT is set to 120% of drive
nameplate current rating, continuous operation beyond this
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. To calibrate TORQUE refer to
the recommended TORQUE settings in Figure 11, page 22, 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 TORQUE trimpot to minimum (full CCW).
3. Set the speed adjust potentiometer to maximum speed (full CW).
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 TORQUE trimpot CW until the armature
current is 120% of motor rated armature current.
7. Turn the speed adjust potentiometer CCW until the motor stops.
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.
Calibration
19
IR COMPENSATION (IR COMP)
The IR COMP trimpot setting determines the degree to which
motor speed is held constant as the motor load changes. It is
factory set for optimum motor regulation.
To calibrate IR COMP refer to the recommended IR COMP settings
in Figure 11, page 22, or use the following procedure:
1. Set the IR COMP trimpot to minimum (full CCW).
2. Rotate the speed adjust potentiometer until the motor runs at
midspeed without load (for example, 900 RPM for an 1800 RPM
motor). A hand held tachmoter may be used to measure motor
speed.
3. Load the motor armature to its full 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. 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.
5. Unload the motor.
20
Calibration
ACCELERATION (ACCEL)
The ACCEL setting determines the time the motor takes
to ramp to a higher speed. See Specifications on page 1 for
approximate acceleration times. ACCEL is factory set for the
fastest acceleration time (full CCW).
To set the acceleration time:
1. Set the speed adjust potentiometer full CCW. The motor should
run at minimum speed.
2. Turn the speed adjust potentiometer full CW 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.
Calibration
21
DECELERATION (DECEL)
The DECEL setting determines the time the motor takes to ramp
to a lower speed. See Specifications on page 1 for approximate
deceleration times. DECEL is factory set for the fastest
deceleration time (full CCW).
To set the deceleration time:
1. Set the speed adjust potentiometer full CW. The motor should
run at maximum speed.
2. Turn the speed adjust potentiometer full CCW 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.
22
Calibration
90 VDC MOTORS
1 HP
1800 RPM
10 AMPS
3/4 HP
1800 RPM
7.5 AMPS
TQ
IR COMP
TQ
IR COMP
TQ
IR COMP
TQ
IR COMP
180 VDC MOTORS
3 HP
1800 RPM
14 AMPS
1 1/2 HP
1800 RPM
7.5 AMPS
TQ
IR COMP
2 HP
1800 RPM
10 AMPS
1 HP
1800 RPM
5 AMPS
TQ
IR COMP
Figure 11. Typical TORQUE and IR COMP Settings
23
Application Notes
Multiple fixed speeds
Replace the speed adjust potentiometer with series resistors
with a total series resistance of 10K ohms (Figure 12). Add a
single pole, multi-position switch with the correct number of
positions for the desired number of fixed speeds.
R1
S3
R2
S2
R3
S1
R4
Figure 12. Multiple Fixed Speeds
Total Series
Resistance
10K Ohm
24
Application Notes
Adjustable speeds using potentiometers in
series
Replace the speed adjust potentiometer with a single pole,
multi-position switch, and two or more potentiometers in series,
with a total series resistance of 10K ohms. Figure 13 shows a
connection for high and low speed adjust potentiometers.
CW
S3
HIGH
SPEED
5K Ω
LOW
SPEED
CW
S2
S1
5K Ω
Figure 13. Adjustable Fixed Speeds Using Potentiometers in Series
Application Notes
25
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 14 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 Ω
20K Ω
S2
S1
Figure 14. Independent Adjustable Speeds
26
Application Notes
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.
In the first wiring option, connect the RUN/JOG switch and JOG
pushbutton to the inhibit plug as shown in Figure 15. 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.
In the second wiring option, connect the RUN/JOG switch and
the JOG pushbutton as shown in the Figure 16. 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.
Application Notes
JOG
PUSHBUTTON
RUN
JOG
INHIBIT
Figure 15. RUN/JOG Switch Connection to Inhibit Plug
S3
S2
10K Ω
S1
RUN
JOG
JOG
PUSH BUTTON
Figure 16. RUN/JOG Switch Connection to Speed Adjust
Potentiometer
27
28
Application Notes
Leader-follower application
In this application, use a PCM4 to monitor the speed of the
leader motor (Figure 17). 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.
A1
Leader
Drive
9 (+)
Motor
A2
(+) 2
PCM4
8
7 (-)
TB501
S2
Follower
Drive
(-) 1
TB502
S1
10K Ohm
(optional)
Figure 17. Leader-Follower Application
Application Notes
29
Single speed potentiometer control of
multiple drives
Multiple drives can be controlled with a single speed adjust
potentiometer using a PCM4 at the input of each drive to provide
isolation (Figure 18). Optional ratio potentiometers can be used to
scale the PCM4 output voltage, allowing independent control of
each drive.
6
8
10K Ω
2
1
TB501
TB501
Drive A
S1
Motor
A
A2
TB502
6
7
A1
S2
PCM4
7
8
ratio pot A
(optional)
10K Ω
2
PCM4
1
ratio pot B
(optional)
10K Ω
A1
S2
S1
Drive B
Motor
B
A2
TB502
Figure 18. Single Speed Potentiometer Control of Multiple Drives
30
Application Notes
Reversing
A dynamic brake may be used when reversing the motor direction
(Figure 19). 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, page 13, for recommended dynamic brake
resistor sizes.
A1
A2
FWD
BRAKE
Dynamic Brake Resistor
REV
MOTOR
INHIBIT
Figure 19. Reversing Circuit Connection
Application Notes
31
Reversing with a DIGI-LOK® controller,
model DLC600
A DIGI-LOK® controller, model DLC600 can be used in a
reversing application. The DIGI-LOK® must be inhibited while
braking. Without the inhibit feature, the DIGI-LOK® will
continue to regulate. This will cause overshoot when the DIGILOK® is switched back to the drive. Figure 20 shows the
connection of the reversing circuit to a MM23000 series drive and
to a DLC600. Note: Only one DLC option (Optical Encoder or
Magnetic Pickup) may be used at a time.
S3
S2
MM23021C Drive
A1
S1
A2
S1
Dynamic
Brake Resistor
BRAKE
FWD
BRAKE
REV
FWD
S2
BRAKE
REV
FWD
REV
DLC 600
Inhibit Leads
C
MOTOR
Optical
Encoder
Common
Signal
+5 VDC
Magnetic
Pickup
Figure 20. Reversing with a DLC600
IN
+
32
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 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 voltage selection switch settings match the AC
line and output voltages.
7. Check that the drive’s rated armature and field outputs are
consistent with the motor ratings.
For additional assistance, contact your local Minarik distributor,
or the factory direct:
(800) MINARIK (phone) or (800) 394-6334 (fax).
Troubleshooting
33
Problem
Possible
Causes
Suggested
Solutions
Line fuse blows.
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 TORQUE
settings, or resize motor
and drive for actual load
demand, or check for
incorrectly aligned
mechanical components
or “jams”.
34
Troubleshooting
Problem
Possible
Causes
Suggested
Solutions
Line fuse does not blow,
but the motor does not run.
1. Speed adjust pot or
reference voltage is set
to zero speed.
1. Increase the speed adjust
potentiometer setting or
reference voltage.
2. INHIBIT terminals are
jumpered.
2. Remove jumper from
the INHIBIT terminals.
3. S2 is shorted to S1.
3. Remove short.
4. Drive is in current limit.
4. Verify that motor is
not jammed. Increase
TORQUE setting if they
are set too low.
5. Drive is not receiving
AC line voltage.
5. Apply AC line voltage
to L1 and L2.
6. Motor is not connected.
6. Connect motor to A1
and A2.
Motor does not stop
when the speed adjust
potentiometer is full CCW.
MIN SPD setting is too
high.
Calibrate MIN SPD.
Motor runs in the opposite
direction (non-reversing
drives).
Motor connections to A1
and A2 are reversed.
Reverse connections to A1
and A2.
Troubleshooting
Problem
Possible
Causes
Suggested
Solutions
Motor runs too fast.
1. MAX SPD and MIN
SPD are set too high.
1. Calibrate MAX SPD
and MIN SPD.
2. Motor field connections
are loose (shunt wound
motors only).
2. Check motor field
connections.
1. MAX SPD setting is too
low.
1. Increase MAX SPD
setting.
2. IR COMP setting is too
low.
2. Increase IR COMP
setting.
3. TORQUE setting is too
low.
3. Increase TORQUE
setting.
4. Motor is overloaded.
4. 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.
Motor will not reach the
desired speed.
Motor pulsates or surges
under load.
2. Motor bouncing in and
out of current limit.
35
2. Make sure motor is not
undersized for load;
adjust TORQUE trimpot
CW.
36
CE Compliance
Minarik Corporation hereby certifies that its MM23000C series
drives have been approved to bear the “CE” mark provided the
conditions of approval have been met by the end user.
The MM23000C series has been tested to the following
specifications:
EN55011:1991 (emissions), and
EN50082-1:1992 (immunity)
Compliance allows Minarik’s MM23000C series to bear the
CE mark.
The end user, as described herein, falls into one of two categories:
1. The Consumer will deploy a stand-alone unit as an
integral, yet external, portion of the machine being
operated.
2. The Original Equipment Manufacturer (OEM) will
implement the product as a component of the machine
being manufactured.
In addition to EMI/RFI safeguards inherent in the MM23000C
series’ design, external filtering is required.
CE Compliance
37
Line filters
Minarik requires the Corcom® line filters listed below.
Table 2. Corcom® Filters
Nameplate Current of
Motor Wired to the Drive
0 to 4 amps
4.1 to 13 amps
Corcom® Filter
Part Number
6VV1
20VV1
If the exact line filter is not available, the specifications are as
follows:
L = 1.8 milliHenries.
C = 0.01 microFarads (line-to-ground); 1.1 microFarads (lineto-line).
R = 330Kohms.
Rated current: 1.4 times maximum DC motor current.
Filter type: Balanced 2-section.
The line filters should be wired to the AC line within 0.25 meters
of the drive. The ground connection from the line filter must be
wired to solid earth ground (resistance less than 500 ohms); not
machine ground. This is very important!
If the end-user is using a CE-approved motor, the correct line
filter listed above is all that is necessary to meet the EMC
directives listed herein.
38
CE Compliance
Armature filters
If the end-user is not using a CE-approved motor, a second filter,
part no. CExxMM, must be used on the armature. XX = rated
current of the filter. Minarik Filters are listed below.
Table 3. Minarik Filters
Nameplate Current of
Motor Wired to the Drive
0 to 4 amps
4.1 to 13 amps
Minarik Filter
Part Number
CE4MM
CE20MM
The filters listed above are Real-Pole Balanced-Pi 3-pole
filters. If the exact filter is not available, the specifications are
as follows:
L & L1 = 2 x (0.8) milliHenries.
C & C1 = 2 x (0.1) microFarads @ 400W VDC.
Rin = 0.1 ohm; Rout = 1.2 ohm.
The filters listed above must be wired to the DC output of the
drive, as close to the drive as possible.
CE Compliance
39
The end user must use the filters listed in this section to comply
with CE. The OEM may choose to provide alternative filtering
that encompasses the Minarik drive and other electronics within
the same panel.
The OEM has this liberty because CE is a machinery directive.
Whether or not every component in the OEM’s machinery meets
CE, the OEM must still submit his machine for CE approval.
Thus, no component must necessarily meet CE within the
machine, as long as the OEM takes the necessary steps to
guarantee the machine does meet CE. By the same token, even if
every component in the OEM’s machine does meet CE, the
machine will not necessarily meet CE as a machine.
Using CE-approved wiring practices (like proper shielding) and
the filters listed in this section help the drive meet EN55011
(1991 emissions standard) and EN50082-1 (1992 immunity
standard).
40
Functional Diagrams
41
Replacement Parts
Replacement parts are available from Minarik Corporation and its
distributors for this drive series.
Table 3. Replacement Parts
Model No.
MM23021C
Symbol
SCR501, 502
D501-503
R501
T501
Description
S8025L SCR
800 V, 20 A Diode
0.01Ω, 5 W Resistor
3FD-224-001 Transformer
10KΩ potentiometer kit
Minarik P/N
072-0042
071-0041
032-0129
230-0083
202-0031
42
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 Corporation, 901 East Thompson Avenue, Glendale, CA 91201-2011
USA.
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.
901 East Thompson Avenue
Glendale, California 91201-2011
Phone: (800) MINARIK or (800) 646-2745
Fax: (800) 394-6334
www.minarikcorp.com
Document number 250–0086, Revision 3
Printed in the U.S.A – 3/01
U.S.A. $12.00, Canada $13.00
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