User`s Manual

User`s Manual
SCR, Adjustable Speed Drives
for DC Brush Motors
User’s Manual
M1 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.
Printed in the United States of America.
i
Safety Warnings
SHOCK
HAZARD
AVOID
HEAT
KEE
DR
OID
ATION
• 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
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Power, fuse and motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Horsepower Jumper Terminal (J502) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Starting and stopping methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Inhibit terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
iii
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
IR COMPENSATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
ACCELERATION (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
DECELERATION (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
RUN/JOG switch option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
RUN/JOG switch option #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Reversing with a DIGI-LOK controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Unconditional Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inside back cover
Tables
Table 1. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 2. Minimum Recommended Dynamic Brake Resistor Values . . . . . . .20
Table 3. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
iv
Illustrations
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1. M1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3. M1 Series Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4. J502 Jumper Location and Settings . . . . . . . . . . . . . . . . . . . . . . .14
5. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6. INHIBIT Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
8. Recommended Torque and IR COMP Settings . . . . . . . . . . . . . . .26
9. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
10. Adjustable Fixed Speeds Using Potentiometers in Series . . . . . .30
11. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . .31
12. RUN/JOG Switch Connection to Inhibit Plug (Option #1) . . . . . . .32
13. RUN/JOG Switch Connection to Speed Adjust Potentiometer
(Option #2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 14. Leader-Follower Application . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Figure 15. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Figure 16. Reversing with a DLC600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
1
Specifications
Model
M1
M1 (w/ heatsink)*
Max Armature
Current
(Amps DC)
5.0
10.0
AC Line Voltage
HP Range
with 115 VAC
Applied
1/15 - 1/2
1/2 - 1
Style
Chassis
Chassis
115 VAC ±10%, 50/60 Hz, Single Phase
Armature Voltage (115 VAC Input)
0–90 VDC
Form Factor
1.37 at base speed
Accel. Time Range (for 0 - 90 Armature Voltage)
0.5 - 25 Seconds
Decel. Time Range (for 0 - 90 Armature Voltage)
0.5 - 25 Seconds
Analog Input Voltage Range (isolated; S1 to S2)
for 0 - 90 Armature Voltage
0 - 4.5 VDC
Input Impedence (S1 to S2)
Load Regulation
100K Ohms
1% base speed or better
Vibration
Ambient Temp. Range
* M1 Series drives require an additional heat sink (p/n 223-0159) when continuous armature
current is above 5ADC (see page 7).
1G max (0 - 50 Hz)
10°C - 55°C
2
Features and Benefits
• Speed Range and Regulation: 1% over 60:1 Speed Range.
• Six (6) User Adjustable Calibration Pots:
ACCEL, DECEL, TORQUE, IR COMP, MIN SPEED, and MAX SPEED
• Stopping Modes: Coast to stop with inhibit terminals (N.O.). Choice of header plug or spade
lug connections.
• Spade Terminals: Easy to use, low cost, and able to fit in a smaller package.
SPADE LUG CONNECTIONS
J502
L1 & L2 TO AC LINE VOLTAGE (115 VAC)
(see page 10)
JUMPER ON FOR MOTORS 1/8 HP OR LOWER
(see page 14)
SCR501
D502
C501
D503
SCR502
D501
MOV502
R501
L1
R502
T501
SPADE LUG
CONNECTIONS
A1
L2
TO MOTOR
(see page 9)
A2
C502
S1
Y501
1/8
HP-
TO SPEED ADJUST
POTENTIOMETER
(see page 7)
S2
S3
IC1
J501
J2
INHIBIT
Coast to stop using either Header
Plug or Spade Lug Connections
(see page 18)
INHIBIT
ACCEL
DECEL
IR COMP
TORQUE
MIN SPD
MAX SPD
(see page 22)
USER ADJUSTABLE CALIBRATION TRIMPOTS
Dimensions
0.188 [5]
SCR501
C501
D501
SCR502
MOV502
A1
R501
L1
D502
D503
QC502
QC503
A2
R502
2.64 [67]
1.75 [44]
L2
QC504
QC501
INHIBIT
QC508
C502
J502
T501
S1
Y501
1/8
HP-
QC507
QC509
QC506
IC1
J501
QC505
J2
INHIBIT
1.45 [37]
1.28 [33]
0.96 [24]
3.80 [97]
4.30 [109]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 1. M1 Dimensions
3
4
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 before attempting installation.
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 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.
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.
5
6
Installation
Shielding guidelines
Warning
Under no circumstances should power and logic leads be bundled together.
Induced voltage can cause unpredicatble 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.
Installation
7
Heat sinking
M1 Series drives 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.
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 2, page 8). 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).
8
Installation
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
CW
WIPER
W
NUT
STAR
WASHER
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
PANEL
Figure 2. Speed Adjust Potentiometer
Installation
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 3 (page 12). 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 the drive’s
printed circuit board (PCB) as shown in Figure 3, page 12.
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.
9
10
Installation
Connect a DC motor to PCB terminals A1 and A2 as shown in Figure 3, page 12.
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, singlepole master power switch (recommended). The switch should be rated at a minimum
of 250 volts and 200% of motor current. Refer to Figure 3, page 12.
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. Table 1
(page 11) lists the recommended line fuse sizes.
Wire an external line fuse between the stop switch (if installed) and L1 terminal. The
line fuse(s) should be rated at 250 volts and 150 - 200% of maximum motor
nameplate current.
Installation
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).
11
12
Installation
STOP
SWITCH
FUSE
HOT
AC LINE
VOLTAGE
(115 VAC)
NEUTRAL
L1
L2
SCR501
0
D502
C501
D503
D501
MOV502
A1
R501
L1
R502
L2
INHIBIT
A2
+
MOTOR
C502
J502
T501
SCR502
Y501
S1
1/8
HP-
S2
IC1
J501
S3
J2
CW
10K OHM
SPEED ADJUST
POTENTIOMETER
INHIBIT
(5K OHM Potentiometer
is also supported)
Figure 3. M1 Series Drive Connections
Installation
Horsepower Jumper Terminal (J502)
Jumper both header pins on J502 for 1/8 HP motors and lower. Jumper only 1
header pin for all other motors. The factory (default) setting is set to only 1 pin
jumpered.
For J502 jumper location and settings, refer to Figure 4 (page 14).
13
Installation
SCR501
D502
C501
D503
D501
SCR502
MOV502
A1
R501
L1
R502
T501
A2
L2
C502
S1
1/8
HP-
S2
S3
IC1
J2
J502
INHIBIT
J502
1/8
HP-
1/8
HP-
Jumper BOTH header pins for motors
1/8 HP and lower.
J502
14
1/8
HP-
Jumper one header pin only for motors
over 1/8 HP. (FACTORY DEFAULT)
Figure 4. J502 Jumper Location and Settings
Installation
15
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 5). 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.
An analog input voltage range of approximately 0 – 4.3 VDC is required to produce
an armature voltage range of 0–90 VDC.
M1
SERIES
DRIVE
S1
S2
Signal Common
+
Signal Input
Figure 5. Voltage Follower Connections
16
Operation
Warning
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 37, for further assistance.
Before applying power
• Verify that no conductive material is present on the printed circuit board.
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.
Operation
17
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 (see connection diagram on page 12).
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.
18
Operation
Inhibit terminals
M1 series drives offer two ways to INHIBIT:
1. Header Plug
2. Spade Lugs (Q508 and Q509)
Short the INHIBIT terminals to coast the motor to stop (see Figure 6 on page 19 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 header plug: 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].
Operation
SCR501
D502
C501
D503
D501
MOV502
SCR502
R501
A1
L1
A2
R502
L2
C502
S1
1/8
HPS2
S3
IC1
J2
INHIBIT
IT
HEADER PLUG
Figure 6. INHIBIT Terminals
SPADE LUGS
19
20
Operation
Table 2. Minimum Recommended Dynamic Brake Resistor Values
Motor Armature
Voltage
90 VDC
Dynamic Brake
Resistor Value
15 ohms
For motors rated 1/17 horsepower and lower, a brake resistor is not necessary since
the armature resistance is high enough to stop the motor without demagnetization.
Replace the dynamic brake with 12-gauge wire.
A1
DYNAMIC BRAKE
RESISTOR
MOTOR
BRAKE
RUN
A2
INHIBIT
Figure 7. Dynamic Brake Connection
Operation
21
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.
Remove 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 7, page 20). 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 2 (page 20) for recommended dynamic brake resistor sizes.
22
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.
M1 Series drives have six user-adjustable trimpots: Accel, Decel, IR Comp, Torque,
Min Spd, and Max Spd. Each drive is factory calibrated to its maximum current rating.
Re-adjust 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
23
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.
24
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 8 (page 26) 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 150% 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
25
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 hand held 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 8 (page 26), for recommended IR COMP settings.
26
Calibration
1 HP
1750 RPM
90 VDC
10 AMPS
1/4 HP
1750 RPM
90 VDC
2.5 AMPS
3/4 HP
1750 RPM
90 VDC
7.6 AMPS
1/8 HP
1800 RPM
90 VDC
1.3 AMPS
1/2 HP
1750 RPM
90 VDC
5 AMPS
1/15 HP
1800 RPM
90 VDC
0.75 AMPS
Figure 8. Recommended Torque and IR COMP Settings
(actual settings may vary with each application)
Calibration
27
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 shorter acceleration time, or CCW for a longer acceleration time.
Repeat steps 1 through 3 until the acceleration time is correct.
28
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.
29
Application Notes
Multiple fixed speeds
Replace the speed adjust potentiometer with series resistors with a total series
resistance of 10K ohms (Figure 9). 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
TOTAL SERIES
RESISTANCE
10K OHMS
S1
R4
Figure 9. Multiple Fixed Speeds
30
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 10 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 10. Adjustable Fixed Speeds Using Potentiometers in Series
Application Notes
31
Independent adjustable speeds
Replace the speed adjust potentiometer with a single pole, multi-position switch, and
two or more potentiometers in parallel, with a total parallel resistance of 10K ohms.
Figure 11 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 11. Independent Adjustable Speeds
32
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 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 12. The motor coasts to minimum speed (as
determined by the MIN SPD trimpot setting) 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 12. RUN/JOG Switch Connection to Inhibit Plug (Option #1)
Application Notes
33
RUN/JOG switch option #2
In the second wiring option, connect the RUN/JOG switch and the JOG pushbutton
as shown in Figure 13. 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 POT
S1
RUN
JOG
JOG
PUSHBUTTON
Figure 13. RUN/JOG Switch Connection to Speed Adjust Potentiometer
(Option #2)
34
Application Notes
Leader-follower application
In this application, use a PCM4 to monitor the speed of the leader motor (Figure 14).
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 14. Leader-Follower Application
Follower
Drive
Application Notes
35
Reversing
A dynamic brake may be
used when reversing the
motor direction (Figure 15).
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 21, for recommended
dynamic brake resistor
sizes.
A1
A2
DYNAMIC
BRAKE
RESISTOR
MOTOR
FWD
BRAKE
REV
INHIBIT
Figure 15. Reversing Circuit Connection
36
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.
S3
Figure 16 shows
the connection of
the reversing
circuit to a M1
Series drive and
DLC600.
MINARIK
DRIVE
A1
S1
A2
Dynamic
Brake
Resistor
S1
S2
BRAKE
FWD
NOTE: Only one
DLC option
(Optical Encoder
or Magnetic
Pickup) may be
simultaneously.
S2
RE
DLC600
Inhibit
Leads
C
Motor
Common
Optical
Encoder
Signal
+5 VDC
Magnetic
Pickup
Figure 16. Reversing with a DLC600
IN
+
37
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 the 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 drive’s rated armature is consistent with the motor rating.
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
38
Troubleshooting
Problem
Line fuse blows.
Possible
Causes
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.
Troubleshooting
Problem
Line fuse does not blow,
but the motor does not run.
Possible
Causes
39
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 the motor is
not jammed. Increase
TORQUE setting if they
are set too low. See
page 24.
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.
40
Troubleshooting
Problem
Possible
Causes
Suggested
Solutions
Motor does not stop when
the speed adjust
potentiometer is full CCW
1. MIN SPD setting is too
high.
1. Calibrate MIN SPD. See
page 23.
Motor runs in the opposite
direction (non-reversing
drives)
1. Motor connections to
A1 and A2 are
reversed.
1. Reverse connections to
A1 and A2.
Motor runs too fast
1. MAX SPD and MIN
SPD are set too high.
1. Calibrate MAX SPD and
MIN SPD. See page 23.
Troubleshooting
Problem
Motor will not reach the
desired speed
Motor pulsates or surges
under load.
Possible
Causes
Suggested
Solutions
1. MAX SPD setting is too
low.
1. Increase MAX SPD
setting. See page 23.
2. IR COMP setting is too
low.
2. Increase IR COMP
setting. See page 27.
3. TORQUE setting is too
low.
3. Increase TORQUE
setting. See page 24.
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 27.
2. Motor bouncing in and
out of current limit.
2. Make sure motor is not
undersized for load;
adjust TORQUE trimpot
CW. See page 24.
41
42
Replacement Parts
Replacement parts are available from Minarik Corporation and its distributors for this
drive series.
Table 3. Replacement Parts
Model No.
M1
Symbol
SCR501, 502
D501-503
R501
T501
Description
800 V, 20 A SCR
800 V, 20 A Diode
0.01 Ohm, 5W Resistor
13Z1300 SCR Transformer
10K OHM, 5W Potentiometer
Minarik P/N
072-0043
071-0039
032-0129
230-0123
120-0009
43
NOTES
44
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 12month 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 E Thompson Avenue
Glendale, CA 91201-2011
Tel.: 1-800-MINARIK (646-2745) Fax: 1-800-394-6334
www.minarikcorp.com
Document number 250–0342, Revision 0
Printed in the U.S.A – January 2002
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