User`s Manual - Minarik Drives

User`s Manual - Minarik Drives
A n A merican Cont rol Elect ronics Brand
P CM 2 3 0 0 0 A Seri es
USER MANUAL
PC M23001A
PC M23411A
PC M23401A
www.minarikdrives.com
Dear Valued Consumer:
Congratulations on your purchase of the PCM23000A Series
drive. This User Manual was created for you to get the most out
of your new device and assist with the initial setup. Please visit
www.minarikdrives.com to learn more about our other drives.
Thank you for choosing Minarik Drives!
No part of this document may be reproduced or transmitted in any form without written permission
from American Control Electronics®. The information and technical data in this document are
subject to change without notice. American Control Electronics® makes no warranty of any kind with
respect to this material, including, but not limited to, the implied warranties of its merchantability
and fitness for a given purpose. American Control Electronics® assumes no responsibility for any
errors that may appear in this document and makes no commitment to update or to keep current
the information in this document.
PCM23000A Series
Safety First!
SAFETY WARNINGS

!
WARNING!
Text in gray boxes denote important safety tips or warnings.
Please read these instructions carefully before performing any of
the procedures contained in this manual.
• DO NOT INSTALL, REMOVE, OR REWIRE THIS EQUIPMENT WITH
POWER APPLIED. Have a qualified electrical technician install, adjust
and service this equipment. Follow the National Electrical Code
and all other applicable electrical and safety codes, including the
provisions of the Occupational Safety and Health Act (OSHA), when
installing equipment.
• Reduce the chance of an electrical fire, shock, or explosion by using
proper grounding techniques, over-current protection, thermal
protection, and enclosure. Follow sound maintenance procedures.

!
WARNING!
It is possible for a drive to run at full speed as a result of a
component failure. Minarik Drives strongly recommends the
installation of a master switch in the main power input to stop
the drive in an emergency.
Circuit potentials are at 115 VAC 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 trim pots.
Use approved personal protective equipment and insulated tools
if working on this drive with power applied.
i
PCM23000A Series
Table of Contents
Section 1. Specifications...................................................... 1
Section 2. Dimensions.. ........................................................ 2
Section 3. Installation. . ........................................................ 4
Mounting...................................................................................... 4
Chassis.................................................................................. 4
Speed Adjust Potentiometer............................................... 5
NEMA 4X............................................................................... 6
Wiring........................................................................................... 7
Shielding Guidelines.............................................................. 8
Line Fusing............................................................................ 9
Connections.................................................................................11
Power Inputs........................................................................11
Motor.. .................................................................................11
Field Output Connections. . ....................................................12
Speed Adjust Potentiometer. . ................................................13
Analog Input Signal...............................................................13
Section 4. Operation. . ........................................................ 16
Before Applying Power..................................................................16
Select Switches.............................................................................17
Input Voltage Select (SW501)................................................17
Armature Voltage Select (SW502)..........................................17
Operation Modes..........................................................................18
Manual Mode.......................................................................18
Signal Mode.........................................................................18
Ratio Mode .. .........................................................................18
Startup.........................................................................................19
PCM23001A..........................................................................19
PCM23401A and PCM23411A ...............................................19
Starting and Stopping Methods.....................................................20
Line Starting and Stopping....................................................20
ii
PCM23000A Series
Dynamic Braking...................................................................21
Decelerating to Minimum Speed. . ..........................................23
Section 5. Calibration........................................................ 24
Minimum Speed (MIN SPD)...........................................................25
Maximum Speed (MAX SPD)..........................................................25
Signal Minimum Speed (SIG MIN)..................................................26
Signal Maximum Speed (SIG MAX).................................................26
Torque (TORQUE)..........................................................................27
IR Compensation (IR COMP)..........................................................28
Section 6.Application Notes................................................ 30
Multiple Fixed Speeds...................................................................30
Adjustable Speeds Using Potentiometers In Series . . ........................31
Independent Adjustable Speeds.. ...................................................32
RUN/JOG Switch...........................................................................33
Leader-Follower Application..........................................................34
Single Speed Potentiometer Control Of Multiple Drives..................35
Reversing.. ....................................................................................36
Section 7. Troubleshooting. . ............................................... 37
Before Troubleshooting.................................................................37
Section 8. Accessories & Replacement Parts........................ 40
Unconditional Warranty.. .................................................... 41
iii
PCM23000A Series
List of Tables
Table 1
Table 2
Table 3
Recommended Line Fuse Sizes...........................................10
Field Output Connections..................................................12
Minimum Recommended Dynamic Brake Resistor Values....22
List of Figures
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
iv
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
PCM23001A Dimensions..................................................... 2
PCM23401A and PCM23411A Dimensions........................... 3
Speed Adjust Potentiometer..............................................11
Chassis Drive Connections.................................................14
Cased Drive Connections...................................................15
Select Switches.................................................................17
Operation Modes..............................................................18
Dynamic Brake Wiring.......................................................22
Run/Decelerate to Minimum Speed Switch. . .......................23
Recommended TORQUE and IR COMP Settings...................29
Multiple Fixed Speeds.......................................................30
Adjustable Speeds Using Potentiometers in Series..............31
Independent Adjustable Speeds. . .......................................32
RUN/JOG Switch . . ..............................................................33
Leader-Follower Application..............................................34
Single Speed Potentiometer Control of Multiple Drives. . .....35
Reversing Circuit Wiring....................................................36
PCM23000A Series
Section 1. Specifications
Maximum
Armature
Current (ADC)
HP Range
with 90 VDC
Motor
HP Range
with 180 VDC
Motor
Enclosure
PCM23411A
1.5
1/20 - 1/8
1/10 - 1/4
NEMA 4X
PCM23001A
PCM23401D
10.0
1/8 - 1
1/4 - 2
Chassis
NEMA 4X
Model
AC Line Voltage
115/230 VAC ± 10%, 50/60 Hz, single phase
DC Armature Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
0 - 90 VDC
0 - 180 VDC
Field Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
50 VDC (F1 to L1); 100 VDC (F1 to F2)
100 VDC (F1 to L1); 200 VDC (F1 to F2)
Maximum Field Current
1 ADC
Acceleration & Deceleration Time
Analog Input Range
Input Impedance (S1 to S2)
1K ohms
Form Factor
1.37 at base speed
Load Regulation
1% base speed or better
Speed Range
60:1
Vibration
Safety Certifications
1 second
0 - 10 VDC, 4 - 20 mA
0.5G maximum (0 - 50 Hz)
0.1G maximum (> 50 Hz)
UL/cUL Recognized Equipment, File # E132235 (not PCM23411A)
CSA Certified Component, File # LR41380
Ambient Temperature Range
Chassis Drive
Cased Drive
10°C - 55°C
10°C - 40°C
1
PCM23000A Series
Section 2. Dimensions
6.90 [175]
0.70 [18]
6.30 [160]
SCR501
D508
D506
SCR502
A2
T501
L2
115 230
C501
SW501
NEG
3.00 [76]
C516
R531
L1
4.40 [112]
MOV502
R525
MOV501
F2
F1
T502
IC502
MOV503
D502
D501
IC501
RSH
SIGNAL INPUT
C502
S2
SIG MIN
1
C518
S3
POS
S1
SIG MAX
2
3
SO501
4
5
MAX SPD
MIN SPD
TORQUE
IR COMP
2.30 [58]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 1. PCM23001A Dimensions
2
A1
PCM23000A Series
6.90 [175]
6.30 [160]
1.40
[36]
10.22
[260]
9.80
[249]
7.00
[178]
0.22
[6]
1.45 [37]
5.51
[140]
4.78
[121]
2.31
[59]
0.12
[3]
1.50 [38]
1.50 [38]
THREE 0.88 IN
[22]INCHES
KNOCKOUTS
ALL DIMENSIONS
[MILLIMETERS]
Figure 2. PCM23401A and PCM23411A Dimensions
3
PCM23000A Series
Section 3. Installation

!
WARNING!
Do not install, rewire, or remove this control with input power
applied. Failure to heed this warning may result in fire, explosion,
or serious injury. Make sure you read and understand the Safety
Precautions on page i before attempting to install this product.
Mounting
Chassis
• Drive components are sensitive to electrostatic discharge. Avoid
direct contact with the circuit board. Hold the drive by the heat sink
only.
• Protect the drive from dirt, moisture, and accidental contact.
• Provide sufficient room for access to the terminals and calibration
trim pots.
• Mount the drive away from heat sources. Operate the drive within
the specified ambient operating temperature range.
• Prevent loose connections by avoiding excessive vibration of the
drive.
• Mount the drive with its board in either a horizontal or vertical
plane. Four 0.19” (5 mm) wide slots in the heat sink accept #8 pan
head screws.
• The heat sink should be earth grounded. Use a star washer beneath
the head of at least one of the mounting screws to penetrate the
anodized surface and to reach bare metal.
4
PCM23000A Series
Speed Adjust Potentiometer

!
WARNING!
Be sure that the potentiometer tabs do not make contact with the
potentiometer’s body. Grounding the input will cause damage to
the drive.
If using a remote potentiometer with a chassis drive, mount the speed
adjust potentiometer through a 0.38 in. (10 mm) hole with the hardware
provided (Figure 3). Install the circular insulating disk between the panel
and the 10K ohm speed adjust potentiometer.
Twist the speed adjust potentiometer wire to avoid picking up unwanted
electrical noise. If the speed adjust potentiometer wires are longer than
18 in. (46 cm), use shielded cable. Keep the speed adjust potentiometer
wires separate from power leads (L1, L2, A1, A2, F1, F2).
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
CW
WIPER
CCW
NUT
STAR
WASHER
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
POT TAB ASSIGNMENTS
PANEL
Figure 3. Speed Adjust Potentiometer
5
PCM23000A Series
Mounting (NEMA 4X Enclosures)
NEMA 4X 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.
Set the POWER switch to the OFF position before applying the
AC line voltage.
5. Install conduit hardware through the 0.88 inch (22 mm)
knockout holes. Connect external wiring to the terminal block.
6. Grasp the slotted screw and tilt the front cover back into place.
Avoid pinching any wires between the front cover and the case.
7. Turn the slotted screw clockwise until tight to secure the front
cover.
6
PCM23000A Series
Wiring

!
WARNING!
Do not install, rewire, or remove this control with input power
applied. Failure to heed this warning may result in fire, explosion,
or serious injury.
Circuit potentials are at 115 or 230 VAC above ground. To prevent
the risk of injury or fatality, avoid direct contact with the printed
circuit board or with circuit elements.
Do not disconnect any of the motor leads from the drive unless
power is removed or the drive is disabled. Opening any one
motor lead while the drive is running may destroy the drive.
This product does not have internal solid state motor overload
protection. It does not contain speed-sensitive overload
protection, thermal memory retention or provisions to receive
and act upon signal from remote devices for over temperature
protection. If motor over protection is needed in the end-use
product, it needs to be provided by additional equipment in
accordance with NEC standards.
• Use 18 - 24 AWG wire for logic wiring. Use 14 - 16 AWG wire for
AC line and motor wiring.
7
PCM23000A Series
Shielding Guidelines

!
WARNING!
Under no circumstances should power and logic level leads be
bundled together. Induced voltage can cause unpredictable
behavior in any electronic device, including motor controls.
As a general rule, Minarik Drives recommends shielding of all conductors.
If it is not practical to shield power conductors, it is recommended
to shield all logic-level leads. If shielding of all logic-level leads is not
practical, the user should twist all logic leads with themselves to
minimize induced noise.
It may be necessary to earth ground the shielded cable. If noise is
produced by devices other than the drive, ground the shield at the drive
end. If noise is generated by a device on the drive, ground the shield at
the end away from the drive. Do not ground both ends of the shield.
If the drive continues to pick up noise after grounding the shield, it may
be necessary to add AC line filtering devices, or to mount the drive in a
less noisy environment.
Logic wires from other input devices, such as motion controllers and PLL
velocity controllers, must be separated from power lines in the same
manner as the logic I/O on this drive.
8
PCM23000A Series
Line Fusing
Chassis drives should be fused for protection. Use fast acting fuses rated
for 250 VAC or higher and 150% of maximum armature current. Fuse
HOT L1 only when the line voltage is 115 VAC. Fuse both L1 and L2 when
the line voltage is 230 VAC. Table 1 on page 10 lists the recommended
line fuse sizes.
Cased models come with preinstalled fuses. Model PCM23411A is
preinstalled with 5 amp fuses. Model PCM23401A is preinstalled with
15 amp fuses.
Preinstalled line fuses are rated for maximum horsepower. If the
horsepower rating of the motor being used is less than the maximum
horsepower rating of the drive, the line fuse may have to be replaced
with a lower rated one. Fuses should be rated for 250 VAC or higher and
approximately 150% of the maximum armature current. Refer to Table 1
on page 10 to install a lower rated fuse.
9
PCM23000A Series
Table 1. Recommended Line Fuse Sizes
90 VDC
Motor
Horsepower
180 VDC
Motor
Horsepower
Maximum DC
Armature Current
(amps)
AC Line
Fuse Size
(amps)
1/20
1/15
1/8
1/6
1/10
1/8
1/4
1/3
0.5
0.8
1.5
1.7
1
1.5
3
3
1/4
1/2
2.5
5
1/3
1/2
3/4
1
3/4
1
1 1/2
2
3.5
5.0
7.5
10
8
10
15
15
Minarik Drives offers fuse kits. See Section 10: Accessories and
Replacement Parts for fuse kit part numbers.
10
PCM23000A Series
Connections

!
WARNING!
Do not connect this equipment with power applied. Failure to
heed this warning may result in fire, explosion, or serious injury.
Minarik Drives strongly recommends the installation of a
master power switch in the voltage input line, as shown in
Figure 4 (page 15). The switch contacts should be rated at a
minimum of 200% of motor nameplate current and 250 volts.
This power switch is provided with NEMA 1 and NEMA 4X models.
Power Input
For chassis models, connect the AC line power leads to terminals L1 and
L2. Minarik Drives recommends the use of a single-throw, double-pole
master power switch. The switch should be rated at a minimum of 250
volts and 200% of motor current. Refer to Figure 4 on page 14.
For enclosed models, connect the AC line power leads to screw terminals
1 (L1) and 2 (L2 115) if using a 115 VAC line or to terminals 1 (L1) and 3 (L2
230) if using a 230 VAC line. Refer to Figure 5 on page 15.
Motor
Drives supply motor armature voltage from A1 and A2 terminals. It is
assumed throughout this manual that, when A1 is positive with respect
to A2, the motor will rotate clockwise (CW) while looking at the output
shaft protruding from the front of the motor. If the motor does not
spin in the desired direction, remove power and reverse the A1 and A2
connections.
For chassis models, connect a DC motor to terminals A1 and A2 as shown
in Figure 4 on page 14. For enclosed models, connect a DC motor to
terminals 4 (A1) and 5 (A2) as shown in Figure 5 on page 15. Ensure that
the motor voltage rating is consistent with the drive’s output voltage.
11
PCM23000A Series
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
12
Line Voltage (VAC)
Approximate Field
Voltage (VDC)
Connect Motor
Field To
115
115
230
230
50
100
100
200
F1 (6) and L1 (1)
F1 (6) and F2 (7)
F1 (6) and L1 (1)
F1 (6) and F2 (7)
PCM23000A Series
Speed Adjust Potentiometer
For chassis models, use a 10K ohm, 1/4 W potentiometer for speed
control. Connect the counter-clockwise end of the potentiometer to S1,
the wiper to S2, and the clockwise end to S3. If the potentiometer works
inversely of the desired functionality (e.g. to increase motor speed you
must turn the potentiometer counterclockwise), power off the drive and
swap the S1 and S3 connections. Refer to Figure 4 on page 14.
For enclosed models, the speed adjust potentiometer is factory installed
and prewired.
Analog Input Signal
Instead of using a speed adjust potentiometer, the drive may be wired to
follow an analog input voltage or current signal that is either isolated or
non-isolated from earth ground. For chassis models, connect the signal
common (-) to NEG. Connect the signal reference (+) to POS. Refer to
Figure 4 on page 14. For enclosed models, connect the signal common
(-) to terminal 9. Connect the signal reference (+) to terminal 8. Refer to
Figure 5 on page 15.
An analog input signal range of 0–10 VDC or 4–20 mA is required to
produce an armature voltage range of 0–90 VDC with 115 VAC line
voltage or 0-180 VDC with 230 VAC line voltage.
If using an analog input current signal range of 4-20 mA, a 1000 ohm
resistor must be placed across RSH. Refer to Figure 4 on page 14.
13
SCR502
A1
MOTOR
PCM23000A Series
IR COMP
IC501
D508
C501
TORQUE
C502
C516
IC502
R531
SO501
4
C518
5
T501
MAX SPD
MOV502
MIN SPD
R525
1
SIG MIN
S1
F2
10K OHM
SPEED ADJUST
POTENTIOMETER
D502
SIG MAX
D501
F1
MOV503
SW501
T502
MOV501
115 230
L1
SCR501
D506
S2
L2
2
S3
3
A2
CW
NEG
POS
RSH
SIGNAL INPUT
FUSE
*FUSE
* NOTE: Do not add fuse to L2
unless input voltage is 230 VAC.
FIELD
SIGNAL REFERENCE (+)
STOP
SWITCH
SIGNAL COMMON (-)
AC LINE
VOLTAGE
115/230 VAC
RSH
Terminals
NOTE: DO NOT make
any connections to
F1 and F2 if using a
permanent magnet motor.
Figure 4. Chassis Drive Connections
14
PCM23000A Series
1
2
115 VAC
INPUT
3
4
5
6
7
8
9
POS
(+)
COM
(-)
+
230 VAC
INPUT
AC LINE
VOLTAGE
115/230 VAC
MOTOR
MOTOR
FIELD
COILS
SIGNAL
INPUT
NOTE: DO NOT make
any connections to
F1 and F2 if using a
permanent magnet motor.
Figure 5. Cased Drive Connections
15
PCM23000A Series
Section 4. Operation

!
WARNING!
Change voltage switch settings only when the drive is
disconnected from AC line voltage. Make sure both switches are
set to their correct position. If the switches are improperly set
to a lower voltage position, the motor will not run at full voltage
and may cause damage to the transformer. If the switches are
improperly set to a higher voltage position, the motor will
overspeed, which may cause motor damage, or result in bodily
injury or loss of life.
Dangerous voltages exist on the drive when it is powered. BE
ALERT. High voltages can cause serious or fatal injury. For your
safety, use personal protective equipment (PPE) when operating
this drive.
If the motor or drive does not perform as described, disconnect
the AC line voltage immediately. Refer to the Troubleshooting
section, page 37, for further assistance.
Before Applying Power
1. Verify that no foreign conductive material is present on the
printed circuit board.
2. Ensure that all switches and jumpers are properly set.
16
PCM23000A Series
Select Switches
Input Voltage Select (SW501)
Set the input voltage select switch SW501 to either 115 or 230 to match
the AC line voltage. See Figure 6.
Armature Voltage Select (SW502)
Set the armature voltage select switch SW502 to either 90 or 180 to
match the maximum armature voltage. See Figure 6.
SCR501
D508
D506
SCR502
A2
MOV502
C516
C501
SW501
NEG
Input Voltage
Select
(SW501)
T501
L2
115 230
R531
L1
R525
MOV501
F2
F1
T502
IC502
MOV503
D502
D501
IC501
RSH
SIGNAL INPUT
C502
S2
SIG MIN
1
A1
C518
S3
POS
S1
SIG MAX
2
3
SO501
4
5
Armature Voltage
Select (SW502)
MAX SPD
MIN SPD
TORQUE
IR COMP
Figure 6. Select Switches
17
PCM23000A Series
Operation Modes
Manual Mode
In this mode, the control will ignore any signal input and will respond
only to the speed adjust potentiometer setting. To operate in Manual
Mode, shorts pins 1 and 2 and pins 4 and 5.
Signal Mode
In this mode, the control will ignore the speed adjust potentiometer
setting and will respond only to the signal input. To operate in Signal
Mode, shorts pins 3 and 4.
Ratio Mode
In this mode, the signal input determines the maximum speed while the
speed adjust potentiometer sets a ratio. This feature is useful in multiple
motor applications, where it may be necessary to adjust the speed ratio
between two or more motors. To operate in Ratio mode, short pins 2 and
3 and pins 4 and 5. When enclosed models are set to Auto mode, they
are in Ratio mode.
MANUAL MODE
1
2
3
5
4
MANUAL / SIGNAL
SWITCH
1
2
3
4
MAN
MAN
1
2
3
4
5
1
MANUAL / RATIO
SWITCH
1
SIG
SIG
18
5
RATIO MODE
SIGNAL MODE
MAN
2
3
4
2
3
4
5
SIGNAL / RATIO
SWITCH
5
1
2
3
RATIO
SIG
Figure 7. Operation Modes
RATIO
4
SIG
5
RATIO
PCM23000A Series
Startup
PCM23001A
1.
Turn the speed adjust potentiometer full counterclockwise
(CCW) or set the input voltage or current signal to minimum.
2. Apply AC line voltage.
3. Slowly advance the speed adjust potentiometer clockwise
(CW) or increase the input voltage or current signal. The motor
slowly accelerates as the potentiometer is turned CW or as the
input signal is increased. Continue until the desired speed is
reached.
4.
Remove AC line voltage from the drive to coast the motor to a
stop.
PCM23401A and PCM23411A
1.
Turn the speed adjust potentiometer to “0” (full CCW) or set
the input voltage or current signal to minimum.
2. Set the POWER switch to the ON position.
3. Slowly advance the speed adjust potentiometer clockwise
(CW) or increase the input voltage signal. The motor slowly
accelerates as the potentiometer is turned CW or as the input
voltage or current signal is increased. Continue until the desired
speed is reached.
4. Set the POWER switch to the OFF position to coast the motor to
a stop.
19
PCM23000A Series
Starting and Stopping Methods

!
WARNING!
Dynamic braking, coasting to a stop, or decelerating to minimum
speed is recommended for frequent starts and stops. Do not use
any of these methods for emergency stopping. They may not stop
a drive that is malfunctioning. Removing AC line power (both
lines) is the only acceptable method for emergency stopping.
For this reason, Minarik Drives strongly recommends installing
an emergency stop switch on both AC line inputs (see Figure 4
on page 14).
Frequent starting and stopping can produce high torque. This
may cause damage to motors, especially gearmotors that are not
properly sized for the application.
Automatic Restart Upon Power Restoration
All drives automatically run to set speed when power is applied and the
inhibit is not active.
Line Starting and Stopping
Line starting and stopping (applying and removing AC line voltage) is
recommended for infrequent starting and stopping of a drive only. When
AC line voltage is applied to the drive, the motor accelerates to the speed
set by the speed adjust potentiometer or analog signal. When AC line
voltage is removed, the motor coasts to a stop.
20
PCM23000A Series
Dynamic Braking

!
WARNING!
Wait for the motor to completely stop before switching back to
RUN. This will prevent high armature currents from damaging
the motor or drive.
Dynamic braking may be used to rapidly stop a motor (Figure 8 on page
22). For the RUN/BRAKE switch, use a two pole, two position switch
rated for at least the armature voltage rating and 150% of the armature
current rating. For the dynamic brake resistor, use a 40 watt minimum,
high power, wirewound resistor.
Sizing the dynamic brake resistor depends on load inertia, motor voltage,
and braking time. Use a lower-value, higher-wattage dynamic brake
resistor to stop a motor more rapidly. Refer to Table 3 on page 22 for
recommended dynamic brake resistor sizes.
21
PCM23000A Series
Table 3. Minimum Recommended Dynamic Brake Resistor Values
Motor Armature Voltage
Dynamic Brake Resistor Value
90 VDC
180 VDC
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
A1
RUN
A2
RUN
MOTOR
MOTOR
DYNAMIC BRAKE
RESISTOR
DYNAMIC BRAKE
RESISTOR
BRAKE
S2
S1
BRAKE
Wiper of
Speed Adjust
Potentiometer
POS
Figure 8. Dynamic Brake Wiring
22
Signal Reference
PCM23000A Series
Decelerating to Minimum Speed
The switches shown in Figure 9 may be used to decelerate a motor to
a minimum speed. If using a speed adjust potentiometer, closing the
switch between S1 and S2 decelerates the motor to minimum speed. If
using an analog input signal, opening the switch in line with the signal
input will decelerate the motor to minimum speed. If the MIN SPD trim
pot is set full CCW, the motor decelerates to zero speed.
CW
S3
10K OHM
SPEED ADJUST
POTENTIOMETER
S2
S1
RUN
DECEL TO
MIN SPEED
DECEL TO
MIN SPEED
POS
SIGNAL INPUT REFERENCE
RUN
Figure 9. Run/Decelerate to Minimum Speed Switch
23
PCM23000A Series
Section 5. Calibration

!
WARNING!
Dangerous voltages exist on the drive when it is powered. When
possible, disconnect the voltage input from the drive before
adjusting the trim pots. If the trim pots must be adjusted with
power applied, use insulated tools and the appropriate personal
protection equipment. BE ALERT. High voltages can cause serious
or fatal injury.
PCM23000A series drives have user-adjustable trim pots. Each drive is
factory calibrated to its maximum current rating. Readjust the calibration
trim pot settings to accommodate lower current rated motors.
All adjustments increase with CW rotation, and decrease with CCW
rotation. Use a non-metallic screwdriver for calibration. Each trim pot is
identified on the printed circuit board.
24
PCM23000A Series
Minimum Speed (MIN SPD)
The MIN SPD setting determines the minimum motor speed when the
speed adjust potentiometer is set for minimum speed. It is factory set
for zero speed.
To calibrate the MIN SPD:
1.
Set the MIN SPD trim pot full CCW.
2. Set the speed adjust potentiometer for minimum speed.
3.
Adjust MIN SPD until the desired minimum speed is reached or
is just at the threshold of rotation.
Maximum Speed (MAX SPD)
The MAX SPD setting determines the maximum motor speed when the
speed adjust potentiometer is set for maximum speed.
To calibrate MAX SPD:
1.
Set the MAX SPD trim pot full CCW.
2.
Set the speed adjust potentiometer for maximum speed.
3. Adjust MAX SPD until the desired maximum 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.
25
PCM23000A Series
Signal Minimum Speed (SIG MIN)
The SIG MIN setting determines the minimum motor speed when the
input voltage or current signal is set for minimum speed. It is factory set
for zero speed.
To calibrate the SIG MIN:
1.
Set the SIG MIN trim pot full CCW.
2. Set the input voltage or current signal for minimum speed.
3.
Adjust SIG MIN until the desired minimum speed is reached or
is just at the threshold of rotation.
Signal Maximum Speed (SIG MAX)
The SIG MAX setting determines the maximum motor speed when the
input voltage or current signal is set for maximum speed.
To calibrate SIG MAX:
1.
Set the SIG MAX trim pot full CCW.
2.
Set the input voltage or current signal for maximum speed.
3. Adjust SIG MAX until the desired maximum speed is reached.
Note: Check the SIG MIN and SIG MAX adjustments after recalibrating
to verify that the motor runs at the desired minimum and maximum
speed.
26
PCM23000A Series
Torque (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 Drives 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 10 on page 29 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 trim pot to minimum (full CCW).
3. Set the speed adjust potentiometer full CW or input voltage
signal to maximum speed.
4. Carefully lock the motor armature. Be sure that the motor is
firmly mounted.
5. Apply line power. The motor should be stopped.
6. Slowly adjust the TORQUE trim pot CW until the armature
current is 150% of motor rated armature current.
7. Turn the speed adjust potentiometer CCW or decrease the
input voltage signal.
8. Remove line power.
9. Remove the stall from the motor.
10. Remove the ammeter in series with the motor armature if it is
no longer needed.
27
PCM23000A Series
IR Compensation (IR COMP)
The IR COMP setting determines the degree to which motor speed is held
constant as the motor load changes.
Use the following procedure to recalibrate the IR COMP setting:
1.
Set the IR COMP trim pot to minimum (full CCW).
2. Increase the speed adjust potentiometer or input voltage signal
until the motor runs at midspeed without load (for example,
900 RPM for an 1800 RPM motor). A handheld tachometer may
be used to measure motor speed.
3. Load the motor armature to its full load armature current rating.
The motor should slow down.
4. While keeping the load on the motor, rotate the IR COMP trim
pot until the motor runs at the speed measured in step 2. If
the motor oscillates (overcompensation), the IR COMP trim pot
may be set too high (CW). Turn the IR COMP trim pot CCW to
stabilize the motor.
5. Unload the motor.
See Figure 10 on page 29 for recommended IR COMP settings.
28
PCM23000A Series
MODELS PCM23001A, PCM23401A
TORQUE
TORQUE
TORQUE
IR COMP
IR COMP
IR COMP
1 HP
90 VDC
10 AMPS
1/2 HP
90 VDC
5 AMPS
1/8 HP
90 VDC
1.25 AMPS
TORQUE
TORQUE
TORQUE
IR COMP
IR COMP
IR COMP
2 HP
180 VDC
10 AMPS
1 HP
180 VDC
5 AMPS
1/4 HP
180 VDC
1.25 AMPS
MODELS PCM23411A
TORQUE
TORQUE
TORQUE
IR COMP
IR COMP
IR COMP
1/4 HP
90 VDC
2.50 AMPS
1/8 HP
90 VDC
1.25 AMPS
1/10 HP
90 VDC
1.00 AMP
TORQUE
TORQUE
TORQUE
IR COMP
IR COMP
IR COMP
1/2 HP
180 VDC
2.50 AMPS
1/4 HP
180 VDC
1.25 AMPS
1/6 HP
180 VDC
1.67 AMP
Figure 10. Recommended TORQUE and IR COMP Settings
(actual settings may vary with each application)
29
PCM23000A Series
Section 6.Application Notes
Multiple Fixed Speeds
Replace the speed adjust potentiometer with a series of resistors with a
total series resistance of 10K ohms (Figure 11). Add a single pole, multiposition switch with the correct number of positions for the desired
number of fixed speeds.
R1
S3
R2
S2
R3
S1
TOTAL SERIES
RESISTANCE
10K OHMS
R4
Figure 11. Multiple Fixed Speeds
30
PCM23000A Series
Adjustable Speeds Using Potentiometers In Series
Replace the speed adjust potentiometer with a series of resistors with a
total series resistance of 10K ohms (Figure 12). Add a single pole, multiposition switch with the correct number of positions for the desired
number of fixed speeds.
CW
S3
HIGH
SPEED
5K
OHM
LOW
SPEED
CW
S2
S1
5K
OHM
Figure 12. Adjustable Speeds Using Potentiometers In Series
31
PCM23000A Series
Independent Adjustable Speeds
Replace the speed adjust potentiometer with a single pole, multiposition switch, and two or more potentiometers in parallel, with a total
parallel resistance of 10K ohms. Figure 13 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 13. Independent Adjustable Speeds
32
PCM23000A Series
RUN/JOG Switch
Connect the RUN/JOG switch and the JOG pushbutton as shown in Figure
14. When the RUN/JOG switch is set to JOG, the motor decelerates to
minimum speed (minimum speed is determined by the MIN SPD trim pot
setting). Press the JOG pushbutton to jog the motor. Return the RUN/JOG
switch to RUN for normal operation.
S3
CW
S2
10K OHM
SPEED ADJUST
POTENTIOMETER
S1
RUN
JOG
NORMALLY CLOSED
JOG PUSHBUTTON
NORMALLY OPEN
JOG PUSHBUTTON
JOG
POS
RUN
NEG
Figure 14. RUN/JOG Switch
33
PCM23000A Series
Leader-Follower Application
In this application, use a PCM4 to monitor the speed of the leader motor
(Figure 15). The PCM4 isolates the leader motor from the follower
drive, and outputs a voltage proportional to the leader motor armature
voltage. The follower drive uses this voltage reference to set the speed of
the follower motor. An optional ratio potentiometer may be used to scale
the PCM4 output voltage.
MOTOR
A2
(+) 2
9 (+)
A1
Leader
Drive
PCM4
8
7 (-)
TB501
POS
(-) 1
TB502
NEG
10K Ohm
(optional)
Figure 15. Leader-Follower Application
34
Follower
Drive
PCM23000A Series
Single Speed Potentiometer Control Of Multiple Drives
Multiple drives can be controlled with a single speed adjust potentiometer
using a USIM-8 at the input of each drive to provide isolation (Figure 16).
Optional ratio potentiometers can be used to scale the USIM-8 output
voltage, allowing independent control of each drive.
10K Ohms
ratio pot A
(optional)
10K Ohms
S3
+
S2
1
POS
S1
-
NEG
+
Drive
A
A1
ratio pot B
(optional)
10K Ohms
A1
2
POS
-
NEG
Motor
A
A2
Drive
B
Motor
B
A2
USIM-8
+
ratio pot H
(optional)
10K Ohms
A1
8
POS
-
NEG
Drive
H
Motor
H
A2
Figure 16. Single Speed Potentiometer Control of Multiple Drives
35
PCM23000A Series
Reversing
A dynamic brake may be used when reversing the motor direction
(Figure 17). Use a three pole, three position switch rated for at least the
maximum DC armature voltage and maximum braking current. Wait for
the motor to stop completely before switching it to either the forward
or reverse direction. See the Dynamic braking section on page 31 for
recommended dynamic brake resistor sizes.
A1
MOTOR
S2
FWD
A2
DYNAMIC
BRAKE
RESISTOR
A1
MOTOR
BRAKE
BRAKE
REV
REV
S1
POS
Figure 17. Reversing Circuit Wiring
36
FWD
A2
DYNAMIC
BRAKE
RESISTOR
SIGNAL INPUT
REFERENCE
PCM23000A Series
Section 7. Troubleshooting

!
WARNING!
Dangerous voltages exist on the drive when it is powered. When
possible, disconnect the drive while troubleshooting. High
voltages can cause seroius or fatal injury.
Before Troubleshooting
Perform the following steps before starting any procedure in this
section:
1.
Disconnect AC line voltage from the drive.
2. Check the drive closely for damaged components.
3. Check that no conductive or other foreign material has become
lodged on the printed circuit board.
4. Verify that every connection is correct and in good condition.
5. Verify that there are no short circuits or grounded
connections.
6. Check that the selection switch settings are correctly set.
7. Check that the drive’s rated armature is consistent with the
motor ratings.
For additional assistance, contact your local Minarik Drives distributor
or the factory direct:
(800) MINARIK or FAX: (800) 394-6334
37
PCM23000A Series
PROBLEM
Line fuse
blows.
Line fuse does
not blow, but
the motor does
not run.
Motor does not
stop when the
speed adjust
potentiometer
is full CCW.
38
POSSIBLE CAUSE
SUGGESTED SOLUTIONS
1. Line fuse is the wrong size.
1. Check that the line fuse is
correct for the motor size.
2. Motor cable or armature is
shorted to ground.
2. Check motor cable and
armature for shorts.
3. Nuisance tripping caused by
a combination of ambient
conditions and high-current
spikes (i.e. reversing).
3. Add a blower to cool the drive
components, decrease TORQUE
settings, resize motor and drive
for actual load demand, or
check for incorrectly aligned
mechanical components
or “jams”. See page 27 for
information on adjusting the
TORQUE trim pot.
1. Speed adjust potentiometer
or input signal is set to zero
speed.
1. Increase the speed adjust
potentiometer setting or input
signal.
2. S2 is shorted to S1.
3. Remove the short.
3. Drive is in current limit.
4. Verify that the motor is not
jammed. Increase TORQUE
setting if set too low.
4. Drive is not receiving AC line
voltage.
5. Apply AC line voltage.
5. Motor is not connected.
6. Remove power. Connect the
motor to A1 and A2. Reapply
power.
1. MIN SPD is set too high.
1. Calibrate MIN SPD.
PCM23000A Series
PROBLEM
POSSIBLE CAUSE
SUGGESTED SOLUTIONS
Motor runs in
the opposite
direction
1. Motor connections to A1
and A2 are reversed.
1. Remove power. Reverse
connections to A1 and A2.
Reapply power.
Motor runs too
fast.
1. MAX SPD is set too high.
1. Calibrate MAX SPD.
Motor will
not reach the
desired speed.
1. MAX SPD setting is too low.
1. Increase MAX SPD setting.
2. IR COMP setting is too low.
2. Increase IR COMP setting.
3. TORQUE setting is too low.
3. Increase TORQUE setting.
4. Motor is overloaded.
4. Check motor load. Resize the
motor and drive if necessary.
1. IR COMP is set too high.
1. Adjust the IR COMP setting
slightly CCW until the motor
speed stabilizes.
2. Motor bouncing in and out
of current limit.
2. Make sure motor is not
undersized for load; adjust
TORQUE trim pot CW.
Motor pulsates
or surges under
load.
39
PCM23000A Series
Section 8. Accessories & Replacement Parts
Displays
Closed Loop................................................................................. DLC600
Open Loop....................................................................................... VT-8
Kits
Potentiometer & Connector
Pot Kit.................................................................................. 202-0039
Fuse
1.5 - 5 Amp Fuse Kit............................................................. 050-0066
1 - 8 Amp Fuse Kit with Pico Fuse........................................ 050-0068
3 - 8 Amp Fuse Kit with Pico Fuse........................................ 050-0069
5 - 15 Amp Fuse Kit.............................................................. 050-0071
Wiring
SO501 Plug (18 in. leads)..................................................... 201-0038
Logic Cards
Current Sensing
5 Amps..................................................................................... CSC1-5
20 amps................................................................................. CSC1-20
40
PCM23000A Series
Unconditional Warranty
A. Warranty
American Control Electronics warrants that its products will be free from defects in workmanship
and material for twelve (12) months or 3000 hours, whichever comes first, from date of
manufacture thereof. Within this warranty period, American Control Electronics will repair or
replace, at its sole discretion, such products that are returned to American Control Electronics,
14300 De La Tour Drive, South Beloit, Illinois 61080 USA.
This warranty applies only to standard catalog products, and does not apply to specials. Any
returns of special controls will be evaluated on a case-by-case basis. American Control Electronics
is not responsible for removal, installation, or any other incidental expenses incurred in shipping
the product to and from the repair point.
B. Disclaimer
The provisions of Paragraph A are American Control Electronics’s sole obligation and exclude all
other warranties of merchantability for use, expressed or implied. American Control Electronics
further disclaims any responsibility whatsoever to the customer or to any other person for
injury to the person or damage or loss of property of value caused by any product that has been
subject to misuse, negligence, or accident, or misapplied or modified by unauthorized persons
or improperly installed.
C. Limitations of Liability
In the event of any claim for breach of any of Americn Control Electronics’s obligations, whether
expressed or implied, and particularly of any other claim or breach of warranty contained in
Paragraph A, or of any other warranties, expressed or implied, or claim of liability that might,
despite Paragraph B, be decided against American Control Electronics by lawful authority,
American Control Electronics shall under no circumstances be liable for any consequential
damages, losses, or expenses arising in connection with the use of, or inability to use, American
Control Electronics’s product for any purpose whatsoever.
An adjustment made under warranty does not void the warranty, nor does it imply an extension
of the original 12-month warranty period. Products serviced and/or parts replaced on a
no-charge basis during the warranty period carry the unexpired portion of the original warranty
only.
If for any reason any of the foregoing provisions shall be ineffective, American Control Electronics’s
liability for damages arising out of its manufacture or sale of equipment, or use thereof, whether
such liability is based on warranty, contract, negligence, strict liability in tort, or otherwise, shall
not in any event exceed the full purchase price of such equipment.
Any action against American Control Electronics based upon any liability or obligation arising
hereunder or under any law applicable to the sale of equipment or the use thereof, must be
commenced within one year after the cause of such action arises.
41
PC M 23001A
PCM23401A
An Amer i ca n C o nt ro l E l e c t ro n i c s B ra n d
w w w.minarikdrives.com
1430 0 DE LA TOUR DRIV E
SO U TH BELOIT, IL 61080
(800) MINA RIK
250-0104 Rev 10
PCM23411A
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