User`s Manual

User`s Manual
SCR, Adjustable Speed Drives
for DC Brush Motors
User’s Manual
MM23000
Series
Copyright © 2002 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. MVD032202
Printed in the United States of America.
i
Safety Warnings
• This symbol denotes an important safety tip or warning.
Please read these instructions carefully before performing
any of the procedures contained in this manual.
•
DO NOT INSTALL, REMOVE, OR REWIRE THIS EQUIPMENT
WITH POWER APPLIED. Have a qualified electrical technician
install, adjust and service this equipment. Follow the National
Electrical Code and all other applicable electrical and safety
codes, including the provisions of the Occupational Safety and
Health Act (OSHA), when installing equipment.
•
Reduce the chance of an electrical fire, shock, or explosion by
proper grounding, over-current protection, thermal protection,
and enclosure. Follow sound maintenance procedures.
It is possible for a drive to run at full speed as a result
of a component failure. Minarik strongly recommends the
installation of a master switch in the main power input to
stop the drive in an emergency.
Circuit potentials are at 115 VAC or 230 VAC above earth
ground. Avoid direct contact with the printed circuit board or
with circuit elements to prevent the risk of serious injury or
fatality. Use a non-metallic screwdriver for adjusting the
calibration trimpots. Use approved personal protective
equipment and insulated tools if working on this drive with
power applied.
ii
Contents
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Specifications (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Suffix Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Chassis drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Quick-disconnect terminal block (C-Q drives only) . . . . . . . . . . . . . . . . . .15
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Chassis drive connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Power, fuse and motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Cased drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Mounting (NEMA 1 enclosures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Mounting (NEMA 4X and NEMA 12 enclosures) . . . . . . . . . . . . . . . . . . . .25
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Current limit LED (C models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Meter header block (cased C models only) . . . . . . . . . . . . . . . . . . . . . . . . . .30
MM23001C-Q, MM23071, and MM23072 diagnostic LEDs . . . . . . . . . . . . .31
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Voltage select switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Input voltage select (SW501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Armature voltage select (SW502) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
MM23001, MM23011, MM23071, and MM23072 . . . . . . . . . . . . . . . . . . .34
iii
MM23101, MM23111, MM23401, and MM23411 . . . . . . . . . . . . . . . . . . .34
MM23201 and MM23211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
MM23501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Starting and stopping methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Inhibit terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Decelerating to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
IR COMPENSATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
ACCELERATION (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
DECELERATION (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . . . .50
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
RUN/JOG switch option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
RUN/JOG switch option #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Single speed potentiometer control of multiple drives . . . . . . . . . . . . . . . . . .55
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Reversing with a DIGI-LOK controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Line filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Armature filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Unconditional Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inside back cover
iv
Illustrations
Figure 1. MM23001 and MM23011 Dimensions . . . . . . . . . . . . . . . . .3
Figure 2. MM23001C-Q and MM23011C-Q Dimensions . . . . . . . . . . .4
Figure 3. MM23101 and MM23111 Dimensions . . . . . . . . . . . . . . . . . .5
Figure 4. MM23201 and MM23211 Dimensions . . . . . . . . . . . . . . . . .6
Figure 5. MM23401 and MM23411 Dimensions . . . . . . . . . . . . . . . . .7
Figure 6. MM23501 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 7. MM23071 and MM23072 Dimensions . . . . . . . . . . . . . . . . .9
Figure 8. Heat Sink Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Figure 9. Quick-Disconnect Terminal Block
. . . . . . . . . . . . . . . . . . .15
Figure 10. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . .16
Figure 11. Chassis Drive Connections . . . . . . . . . . . . . . . . . . . . . . . .21
Figure 12. MM23201C-Q and MM23011C-Q Connections . . . . . . . .22
Figure 13. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . .23
Figure 14. Cased Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . .29
Figure 15. Voltage Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 16. INHIBIT Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Figure 17. Run/Decelerate to Minimum Speed Switch . . . . . . . . . . .39
Figure 18. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . .41
Figure 19. Recommended Torque and IR COMP Settings . . . . . . . .46
Figure 20. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Figure 21. Adjustable Fixed Speeds Using
Potentiometers in Series . . . . . . . . . . . . . . . . . . . . . . . . . .50
Figure 22. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . .51
v
Figure 23. RUN/JOG Switch Connection to Inhibit Plug (Option #1) .52
Figure 24. RUN/JOG Switch Connection to
Speed Adjust Potentiometer (Option #2) . . . . . . . . . . . . .53
Figure 25. Leader-Follower Application . . . . . . . . . . . . . . . . . . . . . . .54
Figure 26. Single Speed Potentiometer Control of Multiple Drives . .55
Figure 27. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . .56
Figure 28. Reversing with a DLC600 . . . . . . . . . . . . . . . . . . . . . . . . .57
FIgure 29. MM23000 Series Block Diagram . . . . . . . . . . . . . . . . . . .62
FIgure 30. MM23101, MM23111, MM23401 and MM23411
Terminal Block Connections . . . . . . . . . . . . . . . . . . . . . . .63
FIgure 31. MM23201 and MM23211 Terminal Block Connections . .64
Figure 32. MM23501 Terminal Block Connections . . . . . . . . . . . . . . .65
vi
Tables
Table 1. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . . .19
Table 2. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . .20
Table 3. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . .28
Table 4. Minimum Recommended Dynamic Brake Resistor Values .41
Table 5. Replacement Parts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Table 6. Corcom® Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Table 7. Minarik Filters
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
1
Specifications
Model
MM23011
MM23111
MM23211
MM23411
MM23072
MM23001
MM23101
MM23201
MM23071
MM23401
MM23501
Max.
Armature
Current
(Amps DC)
1.5
HP Range
with 115 VAC
Applied
1/20–1/8
HP Range
with 230 VAC
Applied
1/10–1/4
5.0
1/8–1/2
1/4–1
10.0
1/8–1
1/4–2
†
‡
‡
†
Style
Chassis
NEMA 1
NEMA 1
NEMA 4/4X/ 12
Chassis
Chassis
NEMA 1
NEMA 1
Chassis
NEMA 4/4X/12
NEMA 4/4X/12
† Double maximum armature current and horsepower when drive is mounted on heat
sink part number 223-0159.
‡ Double maximum armature current and horsepower when drive is mounted on heat
sink part number 223-0174.
AC Line Voltage
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
1.37 at base speed
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
0.5–11 seconds
for 0–180 VDC Armature Voltage
0.5–22 seconds
Decel. Time Range:
for 0-90 VDC Armature Voltage
coast to a stop–13 seconds
for 0–180 VDC Armature Voltage
coast to a stop–25 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
2
Specifications
Specifications (Continued)
Input Impedance (S1 to S2)
100K ohms
Load Regulation
1% base speed or better
Vibration
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)
10°C–55°C
Ambient Temp. Range (cased drive)
10°C–40°C
Suffix Definitions
A:
C:
C-Q:
Basic drive
Basic drive with current limit LED
Basic drive with current limit LED, power LED, and quickdisconnect terminal block
Note:
•
C suffix applies to all models except MM23071 and MM23072.
•
MM23071A and MM23072A drives include a current limit and
power LED; trimmer potentiometers (trimpots) are
perpendicular to the PC board.
3
Dimensions
R502
MO
F2
D503
V5
01
SCR502
C503
D502
A2
0.19 [5]
R501
D501
L1
MOV502
SCR501
F1
C501
L2
3.58 [91]
IC502
MOV503
SW501
A1
1.75 [44]
115
230
SO502
+
METER
S2
C502
IC501
C504
90
S3
INHIBIT
CL
180
SW502
IL501
S1
0.74 [19]
0.64 [16]
ACCEL
DECEL
MAX SPD
MIN SPD
TORQUE
IR COMP
0.19 [5]
1.60 [41]
1.28 [33]
0.96 [24]
3.80 [97]
4.30 [109]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 1. MM23001 and MM23011 Dimensions
Dimensions
D502
R502
MOV502
MOV501
SCR502
D503
C503
D501
T501
3.95 [100]
R501
SCR501
C501
3.58 [91]
IC502
IC501
SW501
1.75 [44]
TQ LIMIT
MOV503
SO501
IL502
SO503
A1
A2
IR COMP
C502
SO502
4
L1
L2
F1
F2
S1
S2
S3
C504
0.74 [ 19]
SW502
1.80 [46]
3.80 [97]
4.30 [109]
1.55 [39]
0.96 [24]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 2. MM23001C-Q and MM23011C-Q Dimensions
Dimensions
6.00 [125]
CL
1.79
[45]
2.50
[64]
8.00
[203]
5.00
[127]
3.46
[88]
2.75
[70]
1.25 [32]
1.72
[44]
2.50
[64]
TWO 0.88 [22] CONDUIT HOLES
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 3. MM23101 and MM23111 Dimensions
2.50
[64]
5
6
Dimensions
6.00 [125]
C
L
1.79
[45]
2.50
[64]
8.00 [203]
2.50
[64]
5.00
[127]
3.46 [88]
2.75
[70]
1.25 [32]
1.72
[44]
2.50
[64]
FOUR MOUNTING SLOTS 0.19 INCHES [5 MILLIMETERS] WIDE
TWO 0.88 [22] KNOCKOUTS
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 4. MM23201 and MM23211 Dimensions
Dimensions
6.90 [175]
6.30 [160]
POWER
0.87 [22]
SPEED
8.20 [208]
7.76 [197]
6.00 [152]
4.50 [114]
3.70 [94]
2.25 [57]
0.13 [3]
2.50 [64]
FOUR MOUNTING SLOTS 0.19 INCHES [5 MILLIMETERS] WIDE
TWO 0.88 [22] KNOCKOUTS
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 5. MM23401 and MM23411 Dimensions
7
8
Dimensions
6.90 [175]
6.30 [160]
1.37 [35]
POWER
SPEED
BRAKE
10.20 [259]
REVERSE
9.76 [248]
FORWARD
7.00 [178]
5.49 [139]
4.78 [121]
2.37 [60]
0.13 [3]
2.50 [64]
FOUR MOUNTING SLOTS 0.19 INCHES [5 MILLIMETERS] WIDE
TWO 0.88 [22] KNOCKOUTS
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 6. MM23501 Dimensions
Dimensions
D502
A2
D501
MOV502
SCR501
01
F2
F1
SCR502
C503
R502
V5
3.58 [91]
D503
R501
MO
L1
C501
MOV503
T501
SW501
IC502
1.75 [44]
L2
115
9
0.19 [5]
230
A1
C502
S2
IC501
SW502
S1
INHIBIT
C504
90
180
S3
0.74 [19]
P501
P502
ACCEL
DECEL
P503
P504
P505
P506
IL502 IL501
MAX SPD
MIN SPD CL
PWR CUR LIM
0.64 [16]
IR COMP
1.60 [41]
1.28 [33]
0.96 [24]
0.19 [5]
3.80 [97]
4.30 [109]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 7. MM23071 and MM23072 Dimensions
10
Dimensions
6.90 [175]
6.30 [160]
5.90 [150]
C
A
D
B
E
MOUNTING SLOTS 0.19 X 0.34 [5 X 9]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
PART NO.
DIM “A”
DIM “B”
DIM “C”
DIM “D”
DIM “E”
223-0159
4.40 [112]
3.00 [76]
0.7 [18]
1.75 [44]
3.90 [100]
223-0174
7.78 [198]
6.00 [152]
0.89 [23]
6.00 [152]
5.35 [136]
Heat sinks sold separately.
Figure 8. Heat Sink Dimensions
11
Installation
Warning
Do not install, rewire, or remove this control with input
power applied. Doing so may cause fire or serious injury.
Make sure you have read and understood the Safety
Warnings on page i before attempting installation.
Chassis drives
Mounting
• Drive components are sensitive to electrostatic fields. Avoid
contact with the circuit board directly. 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 other heat sources. Operate the drive
within the specified ambient operating temperature range.
• Prevent loose connections by avoiding excessive vibration of the
drive.
• Mount drive with its board in either a horizontal or vertical plane.
Six 0.19 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.
12
Installation
Wiring
Warning
Do not install, remove, or rewire this equipment with power
applied. Failure to heed this warning may result in fire,
explosion, or serious injury.
Circuit potentials are at 115 or 230 VAC above ground. To
prevent the risk of injury or fatality, avoid direct contact with
the printed circuit board or with circuit elements.
Do not disconnect any of the motor leads from the drive
unless power is removed or the drive is disabled. Opening
any one motor lead may destroy the drive.
• Use 18-24 AWG wire for speed adjust potentiometer wiring. Use
14–16 AWG wire for AC line (L1, L2) and motor (A1 and A2)
wiring.
Installation
13
Shielding guidelines
Warning
Under no circumstances should power and logic leads be
bundled together. Induced voltage can cause unpredictable
behavior in 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 of logic
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.
14
Installation
Heat sinking
Models MM23001 and MM23071 require an additional heat
sink when the continuous armature current is above 5 ADC. Use
Minarik part number 223-0159. All other chassis drives have
sufficient heat sinking in their basic configurations. Use a thermally
conductive heat sink compound (such as Dow Corning ® 340 Heat
Sink Compound) between the drive chassis and heat sink surface
for optimum heat transfer.
Installation
15
Quick-disconnect terminal block (C-Q drives only)
The quick-disconnect terminal block, found only on C-Q drives, is
composed of a 9-pin header block and 9-screw terminal plug
(Figure 8). 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. Make no connections to F1 and F2 if using a permanent
magnet motor.
6. Insert plug into header until securely fastened.
Header Block
(mounted on the drive)
Terminal Plug
Figure 9. Quick-Disconnect Terminal Block
16
Installation
Speed adjust potentiometer
Warning
Be sure that the potentiometer tabs do not make contact with
the potentiometer enclosure. Grounding the input will cause
damage to the drive.
Mount the speed adjust potentiometer through a 0.38 in. (10 mm)
hole with the hardware provided (Figure 9). Install the circular
insulating disk between the panel and the 10K ohm speed adjust
potentiometer.
Twist the speed adjust potentiometer wire to avoid picking up
unwanted electrical noise. If speed adjust potentiometer wires are
longer than 18 in. (457 mm), use shielded cable. Keep speed
adjust potentiometer wires separate from power leads (L1, L2, A1,
A2).
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
CW
WIPER
W
NUT
STAR
WASHER
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
PANEL
Figure 10. Speed Adjust Potentiometer
Installation
17
Chassis drive connections
Warning
Do not connect this equipment with power applied.
Failure to heed this directive may result in fire or serious
injury.
Minarik strongly recommends the installation of a master
power switch in the voltage input line, as shown in
Figure 11 (page 21). The switch contacts should be rated at
a minimum of 200% of motor nameplate current and 250
volts.
Power, fuse and motor connections
Connect the power input leads, an external line fuse and a DC
motor to TB501 on the drive’s printed circuit board (PCB) as shown
in Figure 11, page 21.
Motor
Minarik 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 this is opposite of the desired rotation, simply reverse the
wiring of A1 and A2 with each other.
18
Installation
Connect a DC motor to PCB terminals A1 and A2 as shown in
Figure 11, page 21. Ensure that the motor voltage rating is
consistent with the drive’s output voltage.
Power input
Connect the AC line power leads to terminals L1 and L2, or to a
double-throw, single-pole master power switch (recommended).
The switch should be rated at a minimum of 250 volts and 200%
of motor current. Refer to Figure 11, page 21.
Line fuse
Minarik drives require an external fuse for protection. Use fast
acting fuses rated for 250 VAC or higher, and approximately 150%
of the maximum armature current. Fuse only the HOT leg of the
AC line that connects to L1 and leave L2 unfused when the AC line
voltage is 115 VAC. Table 1 (page 19) lists the recommended line
fuse sizes.
Wire an external line fuse between the stop switch (if installed) and
the L1 terminal on terminal board TB501. An additional line fuse
should be installed on L2 if the input voltage is 230VAC. The line
fuse(s) should be rated at 250 volts and 150 - 200% of maximum
motor nameplate current.
Installation
19
Table 1. Recommended Line Fuse Sizes
90 VDC Motor
180 VDC
Max. DC Armature
AC Line Fuse
Horsepower
Horsepower
Current (amps)
Size (amps)
1/20
1/10
0.5
1
1/15
1/8
0.8
1.5
1/8
1/4
1.5
3
1/6
1/3
1.7
3
1/4
1/2
2.5
5
1/3
3/4
3.5
8
1/2
1
5.0
10
3/4
1 1/2
7.5
15
1
2
10
15
Minarik Corporation offers two fuse kits: part number 050–0066
(1–5A Fuse Kit) and 050–0071 (5–15A Fuse Kit).
20
Installation
Field output connections
Warning
The field output is for shunt wound motors only. Do not
make any connections to F1 and F2 when using a
permanent magnet motor.
See Table 2 for field output connections. Use 18 AWG wire to
connect the field output to a shunt wound motor.
Table 2. Field Output Connections
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
Installation
FIELD COILS
(SEE FIELD OUTPUT
SECTION FOR
CONNECTIONS)
NOTE: DO NOT make
any connections to F1 & F2
terminals if using a
permanent magnet motor.
R502
MO
F2
D503
V5
01
SCR502
C503
D502
A2
R501
D501
L1
MOV502
SCR501
21
F1
C501
MOTOR
FUSE
IC502
MOV503
SW501
L2
A1
115
230
SO502
+
METER
S2
C502
IC501
C504
*FUSE
S3
ACCEL
CL
90
180
SW502
INHIBIT
DECEL
MAX SPD
IL501
MIN SPD
TORQUE
S1
IR COMP
STOP
SWITCH
CW
AC LINE
VOLTAGE
120/240 VAC
10K OHM
SPEED ADJUST
POTENTIOMETER
* NOTE: Do not add fuse to L2
unless input voltage is 230 VAC.
Figure 11. Chassis Drive Connections
22
Installation
CONNECT TO HEADER BLOCK
A1
A2
L1
L2
F1
F2
S1
S2
S3
*
MOTOR
ARMATURE
CW
STOP
SWITCH
10K OHM
SPEED ADJUST
POTENTIOMETER
* NOTE:
Do not add fuse to L2 unless
input voltage is 230 VAC.
NOTE: DO NOT make
any connections to F1 & F2
terminals if using a
permanent magnet motor.
FIELD OUTPUT
(SHUNT WOUND
MOTORS ONLY)
WITH 115 VAC INPUT
CONNECT TO L1 FOR 50 VOLT FIELD.
CONNECT TO F2 FOR 100 VOLT FIELD.
WITH 230 VAC INPUT
CONNECT TO L1 FOR 100 VOLT FIELD.
CONNECT TO F2 FOR 200 VOLT FIELD.
Figure 12. MM23001C-Q and MM23011C-Q Connections
Installation
23
Voltage follower
Instead of using a speed adjust potentiometer, the drive may be
wired to follow an analog input voltage signal that is isolated from
earth ground (Figure 13). Connect the signal input (+) to S2.
Connect the signal common (–) to S1. Make no connection to S3.
A potentiometer can be used to scale the analog input voltage. An
interface device, such as Minarik model PCM4, may be used to
scale and isolate an analog input voltage.
With either 115 VAC or 230 VAC line voltage, an analog
input voltage range of approximately 0–1.4 VDC is required to
produce an armature voltage range of 0–90 VDC. With 230 VAC
line voltage, an analog input voltage range of approximately 0–2.8
VDC is required to produce an armature voltage range of 0–180
VDC.
MM23000
SERIES DRIVE
01
SCR502
C503
V5
F2
D503
R502
MO
R501
D502
A2
D501
L1
MOV502
SCR501
F1
C501
L2
IC502
MOV503
SW501
A1
115
SIGNAL INPUT
S2 (+)
230
C502
IC501
C504
S3
INHIBIT
ACCEL
SIGNAL COMMON
SO502
+
METER
S2
CL
90
180
SW502
DECEL
MAX SPD
IL501
MIN SPD
TORQUE
S1
IR COMP
S1 (-)
Figure 13. Voltage Follower Connections
24
Installation
Cased drives
Warning
Do not install, rewire, or remove this control with input
power applied. Doing so may cause fire or serious injury.
Make sure you have read and understood the Safety
Warnings on page i before attempting installation.
Mounting (NEMA 1 enclosures)
NEMA 1 cased drives come with two 0.88 inch (22 mm) conduit
holes at the bottom of the case. The units may be vertically wall
mounted or horizontally bench mounted using the three keyholes
on the back of the case.
1. For access to the keyholes and the terminal strip, remove the
two screws from the front of the case by turning them
counterclockwise. Grasp the front cover and lift it straight out.
2. Install the mounting screws in the three keyholes.
3. Install conduit hardware through the conduit holes at the bottom
of the case. Connect external wiring to the terminal block.
4. Reinstall the front cover. Avoid pinching any wires between the
front cover and the case.
5. Replace the two screws to the front cover. Turn the screws
clockwise to tighten.
6. Set the POWER switch to the OFF position before applying the
AC line voltage.
Installation
25
Mounting (NEMA 4X and NEMA 12 enclosures)
NEMA 4X and NEMA 12 cased drives come with two 0.88 inch (22
mm) conduit knockout holes at the bottom of the case. The units
may be vertically wall mounted using the four 0.19 inch (5 mm)
slotted holes on the attached heat sink. For motor loads less than 5
ADC, the drive may be bench mounted horizontally, or operated
without mounting.
1. Install the mounting screws.
2. For access to the terminal strip, turn the slotted screw on the
front cover counterclockwise until it is free from the case. The
right side of the cover is hinged to the case. Pull the slotted
screw to open the case.
3. Carefully remove the conduit knockouts by tapping them into the
case and twisting them off with pliers.
4. Install conduit hardware through the 0.88 inch (22 mm)
knockout holes. Connect external wiring to the terminal block.
5. Grasp the slotted screw and tilt the front cover back into place.
Avoid pinching any wires between the front cover and the case.
6. Turn the slotted screw clockwise until tight to secure the front
cover.
7. Set the POWER switch to the OFF position before applying the
AC line voltage.
26
Installation
Heat sinking
Models MM23101 and MM23201 require additional heat sinking
when the continuous armature current is above 5 ADC. Use
Minarik part number 223-0174. All other cased drives have
sufficient heat sinking in their basic configurations. Use a thermally
conductive heat sink compound (such as Dow Corning® 340 Heat
Sink Compound) between the back of the drive case and heat sink
surface for optimum heat transfer.
Line fusing
15 amp line fuses are preinstalled on the cased models MM23101,
MM23201, MM23401, and MM23501. 3 amp line fuses are
preinstalled on the cased models MM23111, MM23211, and
MM23411.
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. Refer to the “Recommended
Line Fuse Sizes” table on page 18 to install a lower rated fuse.
Installation
27
Connections
Warning
Do not connect this equipment with power applied.
Failure to heed this directive may result in fire or serious
injury.
Minarik strongly recommends the installation of a master
power switch in the voltage input line. The switch contacts
should be rated at a minimum of 200% of motor nameplate
current and 250 volts.
Power and motor connections
Connect the power input leads and a DC motor to TB501 as shown
in Figure 14, page 29.
Motor
Minarik drives supply motor voltage from A1 and A2 terminals. It is
assumed throughout this manual that, when A1 is positive with
respect to A2 , the motor will rotate clockwise (CW) while looking
at the output shaft protruding from the front of the motor. If this is
opposite of the desired rotation, simply reverse the wiring of A1 and
A2 with each other.
Connect a DC motor to PCB terminals A1 and A2 as shown in
Figure 14. Ensure that the motor voltage rating is consistent with
the drive’s output voltage.
28
Installation
Power input
Connect the AC line power leads to TB501 terminals L1 and L2, or
to a double-throw, single-pole master power switch
(recommended).
Field output connections
Warning
The field output is for shunt wound motors only. Do not
make any connections to F1 and F2 when using a
permanent magnet motor.
See Table 3 for field output connections. Use 18 AWG wire to
connect the field output to a shunt wound motor.
Table 3. 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
Installation
1
2
3
4
5
6
29
7
+
115
VAC
MOTOR
ARMATURE
230
VAC
MOTOR FIELD
(SHUNT WOUND
MOTORS ONLY)
-
EARTH GROUND
(GREEN SCREW)
NOTE: DO NOT make
any connections to
terminal 7 if using a
permanent magnet motor.
WITH 115 VAC INPUT:
CONNECT TO TERMINAL 1 FOR 50 VOLT FIELD.
CONNECT TO TERMINAL 6 FOR 100 VOLT FIELD.
WITH 230 VAC INPUT:
CONNECT TO TERMINAL 1 FOR 100 VOLT FIELD.
CONNECT TO TERMINAL 6 FOR 200 VOLT FIELD.
Figure 14. Cased Drive Connections
30
Installation
Current limit LED (C models only)
MM23000C series drives are equipped with a red current limit LED.
The red current limit LED turns on whenever the drive reaches
current limit and turns off whenever the drive is not in current limit
(normal operation).
Meter header block (cased C models only)
To supply power to external devices, the Meter header block
can supply an unregulated +9 VDC (5 mA) signal when the motor
and the power supply of the drive are fully loaded. More current is
available with less motor loading. Meter can supply an unregulated
+15V (10 mA) signal in typical applications.
Installation
31
MM23001C-Q, MM23071, and MM23072
diagnostic LEDs
Models MM23001C-Q, MM23071, and MM23072 are equipped with
two diagnostic LEDs:
Power (PWR): Lights whenever the AC line voltage is applied to
the drive.
Current Limit (CURR LIMIT or CL): Lights whenever the drive
reaches current limit.
32
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 57, for further assistance.
Before applying power
• Verify that no conductive material is present on the printed circuit
board.
• Ensure that the voltage select switches switches are properly set.
Operation
33
Voltage select switches
Input voltage select (SW501)
Set the voltage switch SW501 to either 115V or 230V to
match the AC line voltage. See Figure 15.
Armature voltage select (SW502)
Set the voltage switch SW502 to either 90V or 180V to match the
maximum armature voltage. See Figure 15.
F1
MOV503
INPUT VOLTAGE
SELECT (SW501)
L2
SW501
115
230
S2
C504
ARMATURE
VOLTAGE SELECT
(SW502)
90
S3
INHIBIT
ACCEL
180
SW502
DECEL
Figure 15. Voltage Switches
MAX SPD
IL5
MIN SPD
T
34
Operation
Startup
MM23001, MM23011, MM23071, and MM23072
1. Turn the speed adjust potentiometer full counterclockwise
(CCW) or set the voltage signal to minimum.
2. Apply AC line voltage.
3. Slowly advance the speed adjust potentiometer clockwise (CW)
or increase the voltage signal. 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.
MM23101, MM23111, MM23401, and MM23411
1. Set the speed adjust potentiometer to “0” (full CCW).
2. Apply AC line voltage.
3. Set the POWER switch to the ON position.
4. 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.
5. Set the POWER switch to the OFF position to coast the motor to
a stop.
Operation
35
MM23201 and MM23211
Warning
Do not change the FORWARD / REVERSE switch 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 will damage the
drive and/or motor.
1. Set the RUN/BRAKE switch to the BRAKE position.
2. Set the speed adjust potentiometer to “0” (full CCW).
3. Apply AC line voltage.
4. Set the POWER switch to the ON position.
5. Set the FORWARD/REVERSE switch to the desired direction of
rotation.
6. Set the RUN/BRAKE switch to the RUN position.
7. 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.
8. To reverse direction:
a. Set the RUN/BRAKE switch to the BRAKE position.
b. Set the FORWARD/REVERSE switch to the desired
direction of rotation.
c. Set the RUN/BRAKE switch to the RUN position.
9. To brake the motor, set the RUN/BRAKE switch to the BRAKE
position. To coast the motor to a stop, set the POWER switch to
the OFF position.
36
Operation
MM23501
Warning
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 will damage the drive and/or motor.
1. Set the FORWARD/BRAKE/REVERSE switch to the BRAKE
position.
2. Set the speed adjust potentiometer to “0” (full CCW).
3. Apply AC line voltage.
4. Set the POWER switch to the ON position.
5. Set the FORWARD/BRAKE/REVERSE switch to the desired
direction of rotation.
7. 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.
8. To reverse direction:
a. Set the FORWARD/BRAKE/REVERSE switch to the
BRAKE position.
b. After the motor comes to a complete stop, set the
FORWARD/BRAKE/REVERSE switch to the desired
direction of rotation.
9. To brake the motor, set the FORWARD/BRAKE/REVERSE
switch to the BRAKE position. To coast the motor to a stop, set
the POWER switch to the OFF position.
Operation
37
Starting and stopping methods
Warning
Decelerating to minimum speed, dynamic braking, or coasting
to a stop is recommended for frequent starts and stops. Do
not use any of these methods for emergency stopping. They
may not stop a drive that is malfunctioning. Removing AC line
power (both L1 and L2) is the only acceptable method for
emergency stopping.
For this reason, Minarik strongly recommends installing
an emergency stop switch on both the L1 and L2 inputs
(see connection diagrams on pages 21 & 22).
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 or
voltage reference signal. When AC line voltage is removed, the
motor coasts to a stop.
38
Operation
Inhibit terminals
Short the INHIBIT terminals to coast the motor to minimum speed
(see Figure 16 for INHIBIT terminal location). Open the INHIBIT
terminals to accelerate the motor to set speed.
Twist inhibit wires and separate them from power-carrying wires or
sources of electrical noise. Use shielded cable if the inhibit wires
are longer than 18 inches (46 cm). If shielded cable is used,
ground only one end of the shield to earth ground. Do not ground
both ends of the shield.
Minarik 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].
115
230
SO50
+
MET
S2
C504
INHIBIT
TERMINALS
90
S3
INHIBIT
ACCEL
180
SW502
DECEL
Figure 16. INHIBIT Terminals
MAX SPD
IL501
MIN SPD
TORQ
Operation
39
Decelerating to minimum speed
The switch shown in Figure 16 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.
CW
S3
10K OHM
SPEED ADJUST
POTENTIOMETER
S2
S1
RUN
DECEL TO
MIN SPEED
Figure 17. Run/Decelerate to Minimum Speed Switch
40
Operation
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 18, page 41). For the RUN/BRAKE switch, use a two pole,
two position switch rated for at least 125 VDC, 6 amps. 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
4 (page 40) for recommended dynamic brake resistor sizes.
Note: Models MM23201, MM23211, and MM23501 incorporate
dynamic braking in their designs.
Operation
41
Table 4. Minimum Recommended Dynamic Brake
Resistor Values
Motor Armature
Voltage
90 VDC
180 VDC
Dynamic Brake
Resistor Value
15 ohms
30 ohms
For motors rated 1/17 horsepower and lower, a brake resistor is not
necessary since the armature resistance is high enough to stop the
motor without demagnetization. Replace the dynamic brake with
12-gauge wire.
A1
A2
RUN
MOTOR
DYNAMIC BRAKE
RESISTOR
BRAKE
INHIBIT
Figure 18. Dynamic Brake Connection
42
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 user-adjustable trimpots. 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 non-metallic screwdriver for calibration. Each
trimpot is identified on the printed circuit board.
Calibration
43
MINIMUM SPEED (MIN SPD)
The MIN SPD trimpot establishes the motor speed obtained in
response to the minimum input signal. It is factory set for zero
speed.
To calibrate the MIN SPD pot, apply the minimum signal. Adjust the
MIN SPD trimpot until the motor runs at the desired speed or is just
at the threshold of rotation.
MAXIMUM SPEED (MAX SPD)
The MAX SPD setting determines the maximum motor speed when
the speed adjust potentiometer, or voltage input signal is set for
maximum forward speed. It is factory set for maximum rated motor
speed.
To calibrate MAX SPD:
1. Set the MAX SPD trimpot full CCW.
2. Set the speed adjust potentiometer or voltage input signal for
maximum forward speed.
3. Adjust MAX SPD until the desired maximum forward speed is
reached.
Note: Check the MIN SPD and MAX SPD adjustments after
recalibrating to verify that the motor runs at the desired minimum
and maximum speed.
44
Calibration
TORQUE
Warning
TORQUE 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 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 19 (page 46) or us
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 or voltage reference signal
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 150% of motor rated armature current.
7. Turn the speed adjust potentiometer CCW.
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
45
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.
Use the following procedure to recalibrate the IR COMP setting:
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 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
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.
See Figure 19, for recommended IR COMP settings.
46
Calibration
MODELS MM23011, MM23111, MM23211, MM23072, and MM23411
1/8 HP
90 VDC
1800 RPM
TORQUE IR COMP 1.3 AMPS
1/15 HP
90 VDC
1800 RPM
TORQUE IR COMP 0.77 AMPS
TORQUE
TORQUE
IR COMP
1/4 HP
180 VDC
1800 RPM
1.4 AMPS
IR COMP
1/8 HP
180 VDC
1800 RPM
0.67 AMPS
MODELS MM23001, MM23071, MM23101, MM23201, MM23401, and MM23501
1 HP
90 VDC
1750 RPM
TORQUE IR COMP 10 AMPS
3/4 HP
90 VDC
1750 RPM
TORQUE IR COMP 7.6 AMPS
1/2 HP
90 VDC
1750 RPM
TORQUE IR COMP 5 AMPS
1/3 HP
90 VDC
1750 RPM
TORQUE IR COMP 3.5 AMPS
1/4 HP
90 VDC
1750 RPM
TORQUE IR COMP 2.7 AMPS
TORQUE
TORQUE
TORQUE
TORQUE
TORQUE
IR COMP
2 HP
180 VDC
1750 RPM
9.2 AMPS
IR COMP
1 1/2 HP
180 VDC
1800 RPM
7 AMPS
IR COMP
1 HP
180 VDC
1750 RPM
5 AMPS
IR COMP
3/4 HP
180 VDC
1750 RPM
3.8 AMPS
IR COMP
1/2 HP
180 VDC
1750 RPM
1.3 AMPS
Figure 19. Recommended Torque and IR COMP Settings
(actual settings may vary with each application)
Calibration
47
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.
48
Calibration
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.
49
Application Notes
Multiple fixed speeds
Replace the speed adjust potentiometer with series resistors
with a total series resistance of 10K ohms (Figure 20). 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
TOTAL SERIES
RESISTANCE
10K OHMS
R4
Figure 20. Multiple Fixed Speeds
50
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 21 shows a
connection for fixed high and low speed adjust potentiometers.
CW
S3
HIGH
SPEED
5K
OHM
LOW
SPEED
CW
S2
S1
5K
OHM
Figure 21. Adjustable Fixed Speeds Using
Potentiometers in Series
Application Notes
51
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 22 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 22. Independent Adjustable Speeds
52
Application Notes
RUN/JOG switch
RUN/JOG switch option #1
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 23. 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 23. RUN/JOG Switch Connection to Inhibit Plug (Option #1)
Application Notes
53
RUN/JOG switch option #2
In the second wiring option, connect the RUN/JOG switch and the
JOG pushbutton as shown in the Figure 24. 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.
S3
CW
S2
10K OHM
SPEED ADJUST
POTENTIOMETER
S1
RUN
JOG
JOG
PUSHBUTTON
Figure 24. RUN/JOG Switch Connection to
Speed Adjust Potentiometer (Option #2)
54
Application Notes
Leader-follower application
In this application, use a PCM4 to monitor the speed of the
leader motor (Figure 25). 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
8
PCM4
7 (-)
TB501
S2
(+) 2
9 (+)
A1
Leader
Drive
(-) 1
TB502
S1
10K Ohm
(optional)
Figure 25. Leader-Follower Application
Follower
Drive
Application Notes
55
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 26). Optional ratio potentiometers can be used to
scale the PCM4 output voltage, allowing independent control of
each drive.
6
10K Ohms
8
2
1
7
TB501
Motor
A
Drive
A
S1
A2
TB502
6
8
A1
S2
PCM4
7
TB501
ratio pot A
(optional)
10K Ohms
2
ratio pot B
(optional)
10K Ohms
A1
S2
PCM4
1
S1
Motor
B
Drive
B
A2
TB502
Figure 26. Single Speed Potentiometer Control of Multiple Drives
56
Application Notes
Reversing
A dynamic brake may be used when reversing the motor direction
(Figure 27). 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 41, for recommended dynamic brake resistor sizes
Note: Model MM23501 is equipped with this reversing feature.
A1
A2
DYNAMIC
BRAKE
RESISTOR
MOTOR
FWD
BRAKE
REV
INHIBIT
Figure 27. Reversing Circuit Connection
57
Application Notes
Reversing with a DIGI-LOK controller
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 DIGI-LOK is switched back to the drive.
Figure 28 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
MINARIK
DRIVE
A1
S2
S1
A2
Dynamic
Brake
Resistor
S1
S2
BRAKE
FWD
REV
DLC600
Inhibit
Leads
C
Motor
Common
Optical
Encoder
Signal
+5 VDC
Magnetic
Pickup
Figure 28. Reversing with a DLC600
IN
+
58
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 at:
Tel.: 1-800-MINARIK (646-2745) or
Fax: 1-800-394-6334
Troubleshooting
Problem
Line fuse blows.
Possible
Causes
59
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 highcurrent 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”.
See page 44 for
information on
adjusting the TORQUE
trimpot.
60
Troubleshooting
Problem
Line fuse does not blow,
but the motor does not
run.
Possible
Causes
Suggested
Solutions
1. Speed adjust pot or
speed reference
voltage is set to zero
speed.
1. Increase the speed
adjust pot or speed
reference voltage
setting.
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.
See page 44.
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. See
page 43.
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
Motor runs too fast.
Motor will not reach the
desired speed.
Motor pulsates or surges
under load.
Possible
Causes
61
Suggested
Solutions
1. MAX SPD and MIN
SPD are set too high.
1. Calibrate MAX SPD
and MIN SPD. See
page 43.
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. See page 43.
2. IR COMP setting is too
low.
2. Increase IR COMP
setting. See page 44.
3. TORQUE setting is too
low.
3. Increase TORQUE
setting. See page 44.
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. See page
45.
2. Motor bouncing in and
out of current limit.
2. Make sure motor is not
undersized for load;
adjust TORQUE
trimpot CW. See page
44.
L1
L2
FIELD
CIRCUIT
MOTOR
0.01 OHM
OR 0.05 OHM
FEEDBACK
RESISTOR
CURRENT
LIMIT
IR COMP
RAMP
GENERATOR
FIRING
CIRCUIT
+
-
S
-
+
+
+10 VDC
-10 VDC
+5 VDC
-5 VDC
MIN SPD
ACCEL/
DECEL
+
FIgure 29. MM23000 Series Block Diagram
SCR
POWER
BRIDGE
ARMATURE
FEEDBACK
POWER
SUPPLY
SPEED
INPUT
(MAX SPD)
+
L2
L1
S1
S2
S3
10K OHM
SPEED ADJUST
POTENTIOMETER
62
Troubleshooting
Troubleshooting
63
A1
A2
S3
CW
P1
S2
10 KOHM
SPEED ADJUST
POTENTIOMETER
S1
L1
L2
F1
F2
SW3
NLT
WITH 115 VAC INPUT:
CONNECT TO TERMINAL 1 FOR 50 VOLT FIELD.
CONNECT TO TERMINAL 6 FOR 100 VOLT FIELD.
WITH 230 VAC INPUT:
CONNECT TO TERMINAL 1 FOR 100 VOLT FIELD.
CONNECT TO TERMINAL 6 FOR 200 VOLT FIELD.
MOTOR FIELD
(SHUNT WOUND
MOTORS ONLY)
7
+
6
+
5
MOTOR
ARMATURE
90 VDC (180 VDC)
4
FU2
3
2
230 VAC
115 VAC
LINE VOLTAGE
INPUTS
1
FU1
EARTH GROUND
(GREEN SCREWS)
FIgure 30. MM23101, MM23111, MM23401 and MM23411
Terminal Block Connections
64
Troubleshooting
TO
INHIBIT
PINS
A1
A2
CW
S3
S2
P1
S1
10 KOHM
SPEED ADJUST
POTENTIOMETER
L1
L2
SW3
NLT
F1
F2
C19
.1µF
RUN
SW3
SW2
FWD
BRAKE
REV
R32
WITH 115 VAC INPUT:
CONNECT TO TERMINAL 1 FOR 50 VOLT FIELD.
CONNECT TO TERMINAL 6 FOR 100 VOLT FIELD.
MOTOR FIELD
(SHUNT WOUND
MOTORS ONLY)
7
WITH 230 VAC INPUT:
CONNECT TO TERMINAL 1 FOR 100 VOLT FIELD.
CONNECT TO TERMINAL 6 FOR 200 VOLT FIELD.
+
6
+
5
4
MOTOR
ARMATURE
90 VDC (180 VDC)
FU2
3
2
230 VAC
115 VAC
LINE VOLTAGE
INPUTS
1
FU1
EARTH GROUND
(GREEN SCREW)
FIgure 31. MM23201 and MM23211 Terminal Block Connections
Troubleshooting
TO
INHIBIT
PINS
A1
A2
CW
S3
10 KOHM
SPEED ADJUST
POTENTIOMETER
S2
S1
L1
L2
SW3
F1
NLT
F2
A
3
C19 .1µF
A = FWD
B = BRAKE
C = REV
B
1
2
C
6
R32
7
8
BRAKE
RESISTOR
SW4
9
10
WITH 115 VAC INPUT:
CONNECT TO TERMINAL 1 FOR 50 VOLT FIELD.
CONNECT TO TERMINAL 6 FOR 100 VOLT FIELD.
MOTOR FIELD
(SHUNT WOUND
7
6
WITH 230 VAC INPUT:
CONNECT TO TERMINAL 1 FOR 100 VOLT FIELD.
CONNECT TO TERMINAL 6 FOR 200 VOLT FIELD.
+
+
5
MOTOR
ARMATURE
90 VDC (180 VDC)
4
FU2
3
2
230 VAC
115 VAC
LINE VOLTAGE
INPUTS
1
FU1
EARTH GROUND
(GREEN SCREW)
Figure 32. MM23501 Terminal Block Connections
65
66
Troubleshooting
Replacement Parts
Replacement parts are available from Minarik Corporation and
its distributors for this drive series.
Table 5. Replacement Parts
Model No.
MM23001 and
MM23071
Symbol
SCR501, 502
D501-503
R501
T501
Description
800 V, 20 A SCR
800 V, 20 A Diode
0.01 OHM, 5 W Resistor
3FD-224-001 Transformer
10KW potentiometer kit
Minarik P/N
072-0043
071-0039
032-0129
230-0083
202-0031
MM23011
Same as MM23001 except:
SCR501, 502
600 V, 8 A SCR
D501-503
600 V, 3 A Diode
R501
0.05 OHM, 3W Resistor
072-0024
071-0007
032-0073
MM23101
Same as MM23001 except potentiometer kit, and
Case Bottom
Case Cover
240V Pilot Light
10K OHM, 2W Potentiometer
Knob
DPST Power Switch
15 A, 3AB Fuse
including:
223-0170
223-0169
040-0043
120-0047
140-0013
080-0037
050-0018
MM23111
Same as MM23011 except potentiometer kit. Same as
MM23101 except fuse. Include:
3 A, 3AG Fuse
050-0021
MM23201
Same as MM23101 except case cover, and including:
Case Cover
223-0168
40 OHM, 40W Resistor
032-0076
SW4
DPST Run/Brake Switch
080-0027
SW5
DPST FWD/REV Switch
080-0027
Troubleshooting
67
Table 5. Replacement Parts (continued)
Model No.
MM23211
Symbol
Description
Minarik P/N
Same as MM23011 except potentiometer kit. Same as
MM23201 except fuse. Include:
20KW, 10W Resistor
032-0043
3 A, 3AG Fuse
050-0021
MM23411
Same as MM23011 except potentiometer kit, and
Knob
240V Pilot Light
DPST Power Switch
Power Switch Boot
10K OHM, 2 W Potentiometer
3A 3AG Fuse
Heat Sink
Case
MM23401
Same as MM23001 except pot kit. Same parts as MM23411
(knob,...,case) except fuse, and including:
15 A, 3AB Fuse
050-0018
MM23501
Same as MM23401 except heat sink and case, and including:
Heat Sink
223-0183
Case
223-0106
20 OHM, 40 W Resistor
032-0062
FWD/BRAKE/REV Switch
081-0010
Knob
140-0014
MM23072
Same as MM23071 except:
R501
0.05 OHM, 5W Resistor
MM23001C-Q
including:
140-0013
040-0043
080-0037
155-0078
120-0047
050-0021
223-0182
223-0104
032-0089
Same as MM23001 including:
SO503
Quick-Disconnect Header Block 164-0211
Quick-Disconnect Plug
160-0095
68
CE Compliance
Minarik Corporation hereby certifies that its MM23000 series drives
have been approved to bear the “CE” mark provided the conditions
of approval have been met by the end user.
The MM23000 series has been tested to the following test
specifications:
EN55011:1991 (emissions), and
EN50082-1:1992 (immunity)
Compliance allows Minarik’s MM23000 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 MM23000 series’
design, external filtering is required.
CE Compliance
69
Line filters
Minarik requires the Corcom® line filters listed below.
Table 6. 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 = (1.73 + 0.03) milliHenries.
C = (0.27 + 0.54) microFarads (X); 0.0055 microFarads (Y).
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.
70
CE Compliance
Armature filters
If the end-user is not using a CE-approved motor, a second
filter on the armature must be used. It is Minarik’s CEXXMM. XX =
rated current of the filter. Minarik Filters are listed below.
Table 7. 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 * (0.8) milliHenries.
C & C1 = 2 * (0.1) microFarads @ 400 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
71
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).
72
NOTES
73
NOTES
74
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.
Other drives from Minarik Corporation:
DLC600
PCM20000 Series
MM-PCM Series
XP Series
(AC or DC Input)
14300 DeLaTour Dr, South Beloit IL 61080
PHONE: 800-646-2745, FAX: 800-394-6334
www.minarikdrives.com
Document number 250–0091, Revision 7
Printed in the U.S.A – 9/04
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