USER`S MANUAL

USER`S MANUAL
USER’S MANUAL
XP-AC SERIES
Pulse-Width Modulated,
Adjustable Speed Drives
for DC Brush Motors
MODEL XP02-115AC-Q
Copyright © 2006 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.
Safety Warnings
• Have a qualified electrical maintenance technician install, adjust, and service this equipment. Follow the National
Electrical Code and all other applicable electrical and safety codes, including the provisions of the Occupational
Safety and Health Act (OSHA) when installing equipment.
• Reduce the chance of an electrical fire, shock, or explosion by proper grounding, over current protection, thermal
protection, and enclosure. Follow sound maintenance procedures.
• It is possible for a drive to run at full speed as a result of a component failure. Install a master switch in the AC
line for stopping the drive in an emergency.
• This drive is not isolated from Earth ground. Circuit potentials are at 115 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.
II
Table of Contents
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Line Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Quick-connect terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Voltage Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Line starting and line stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inhibit switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dynamic braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MIN SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MAX SPD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
IR COMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Application Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Multiple fixed speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjustable speeds using potentiometers in series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RUN/JOG switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connection to other Minarik devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Leader-follower application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Single speed potentiometer control of multiple drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Reversing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Unconditional Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inside back cover
III
Illustrations
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 10.
Figure 11.
Figure 12.
Figure 13.
Figure 14.
Figure 15.
Figure 16.
Figure 17.
Figure 18.
XP02-115AC-Q Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuseholder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Speed Adjust Potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Quick-Connect Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
XP02-115AC-Q Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Voltage Signal Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Diagnostic LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inhibit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dynamic Brake Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Typical TORQUE and IR COMP Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Multiple Fixed Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjustable Fixed Speeds Using Potentiometers in Series . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RUN/JOG Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
XP02-115AC-Q Connections to Minarik Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Leader-Follower Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Single Speed Potentiometer Control of Multiple Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Reversing Circuit Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Specifications
Model
AC Line Voltage
Horsepower Range (with 130 VDC motors)
Armature Voltage
Maximum Continuous Armature Current
Form Factor (at base speed)
Acceleration Time (with load)
Deceleration Time (with load)
Analog Input Voltage Range (isolated; S1 to S2)
Input Impedance (S1 to S2)
Speed Regulation
Ambient Temperature Range
Weight
XP02-115AC-Q
115 VAC, ±10%, 50/60 Hz, single phase
1/20 – 1/3 HP
0 – 130 VDC
2 ADC
1.05
1 second
2 seconds
0 – 5 VDC
> 100K ohms
1% of base speed or better
10° C – 40° C
0.6 lbs
Dimensions
0.19 [5]
3.58 [91]
1.75 [44]
MAX SPD
P501
TORQUE
P502
MIN SPD
P503
0.74 [19]
IR COMP
P504
0.65 [16]
3.80 [97]
4.30 [109]
0.19 [5]
2.15 [55]
1.28 [33]
0.97 [25]
Figure 1.
XP02-115AC-Q Dimensions
Installation
Mounting
• Drive components are sensitive to electrostatic fields. Avoid contact with the circuit board directly. Hold the
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 operation
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 in. (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. 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.
Wiring
• Use 18 AWG wire for speed adjust potentiometer wiring. Use 16 AWG wire for motor and AC line voltage
wiring.
• Twist logic wires (for speed adjust potentiometer and inhibit) to avoid picking up unwanted electrical noise.
Use shielded cable if wires are longer than 18 in. (46 cm).
• Keep logic wires away from power carrying lines or sources of electrical noise that can cause erratic operation. Never run speed adjust potentiometer or inhibit wires in the same conduit used for the motor and AC
line voltage wires.
• 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 drive.
Line Fuse
All XP02-115AC-Q drives are protected by a 5A, 250V AC line fuse. The fuse does not have to be
resized as long as the motor used is within the drive’s specified horsepower range.
The fuse is mounted in the fuseholder (see Figure 2). To replace a blown fuse, use a screwdriver to
turn the fuseholder knob counterclockwise. Remove the blown fuse and replace with a new fuse.
Fuseholder
Knob
Figure 2.
Fuseholder
Speed adjust potentiometer
Mount the speed adjust potentiometer through a 0.38 in. (10 mm) hole with the hardware provide (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 potentiometer leads are
longer than 18 in. (457 mm), use shielded cable (see Wiring section).
m 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 THROUGH A 0.38 IN. (10 MM) HOLE
CW
WIPER
CCW
NUT
STAR
WASHER
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
PANEL
Figure 3.
Speed Adjust Potentiometer
POT TAB ASSIGNMENTS
Quick-connect terminal block
The quick-connect terminal block has an 8-pin header block and 8-screw terminal plug (Figure 4). To use
the quick-connect 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.
6. Insert plug into header until securely fastened.
Terminal Plug
Header Block
Figure 4.
Quick-Connect Terminal Block
Connections
MAX SPD
P501
TORQUE
P502
MIN SPD
P503
L1
L2
A1
A2
S3
S2
H2
S1
IR COMP
P504
H1
CW
10K
SPD ADJ
POT
Line Voltage
115 Vac
Motor Armature
Figure 5.
RUN
STOP
Inhibit Switch
(optional)
XP02-115AC-Q Connections
ASSUMPTIONS: Minarik drives supply motor voltage from A1 and A2 terminals. It is assumed through 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.
Voltage Follower
Instead of using a speed adjust potentiometer, the drive may be wired to follow a 0 – 5 VDC voltage signal
that is isolated from Earth ground (Figure 6). 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.
To achieve greater linearity and control, use an interface device such as Minarik ® model PCM4 to scale the
analog input voltage.
L1
L2
A1
A2
S3
S2
H2
S1
H1
0 - 5 VDC
Isolated Voltage
Signal Input
Figure 6.
Voltage Signal Connections
Operation
Startup
Note:
Before applying power, verify that no foreign conductive material is placed on the printed circuit board.
To start the drive:
1. Turn the speed adjust potentiometer full counterclockwise (CCW). If the drive is following a voltage
signal, set the voltage signal to 0 VDC.
2. Apply AC line voltage.
3. Slowly advance the speed adjust potentiometer clockwise (CW). If the drive is following a voltage signal, slowly increase the voltage signal. The motor slowly accelerates as the potentiometer is turned
CW, or the voltage signal is increased. Continue until the desired speed is reached.
4. Remove AC line voltage form the drive to coast the motor to a stop.
If the motor or drive does not perform as described, disconnect the AC line voltage immediately. Refer to the
Troubleshooting section for further assistance.
Diagnostic LEDs
All XP02-115AC-Q drives are equipped with diagnostic LEDs. See Figure 7 for LED locations.
POWER (PWR): Green LED lights whenever AC line voltage is applied to drive.
CURRENT LIMIT (CUR LIM): Red LED lights whenever the drive reaches current limit.
L1
L2
A1
A2
S3
S2
H2
S1
H1
POWER
LED
(green)
Figure 7.
Diagnostic LEDs
CURRENT LIMIT
LED
(red)
10
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.
Inhibit switch
An inhibit switch allows the motor to decelerate to zero speed when the switch is closed. Connect a
single pole, single throw switch between H1 and H2 (see Figure 8). Close the switch to decelerate
to the motor to zero speed. Open the switch to accelerate the motor to set speed. An open-collector
output rated for at least 10 mA (ICE) may also be used as an inhibit switch. Wire the collector to H1,
and the emitter to H2.
L1
L2
A1
A2
S3
S2
H2
S1
H1
RUN
STOP
Inhibit Switch
(optional)
Figure 8.
Inhibit Switch
Dynamic braking
Dynamic braking may be used to rapidly stop a motor (Figure 9). For the RUN/BRAKE switch,
use a double pole, double throw switch rated for at least the maximum DC armature voltage and
maximum braking current.
11
A2
MOTOR
1Ω / 1W
Dynamic Brake
Resistor
RUN
A1
BRAKE
H2
H1
Figure 9.
Dynamic Brake Connection
A 1 Ω, 1W resistor is used as the dynamic brake resistor. For motors rated 1/17 horsepower and lower, a dynamic brake resistor is not necessary since the armature resistance is high enough to stop the motor without
demagnetization. In this case, replace the dynamic brake resistor with 12 gauge wire.
m Warning
Wait for the motor to completely stop before switching it back to RUN. This will prevent high armature
currents from damaging the motor or drive.
12
Calibration
Each drive is factory calibrated to its maximum horsepower rating. Readjust the calibration trimpot settings to
accommodate lower horsepower 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.
MIN SPD
The MIN SPD setting determines the motor speed when the speed adjust potentiometer is turned
full CCW. It is factory set for zero speed.
To calibrate turn the speed adjust potentiometer full CCW. Adjust the MIN SPD trimpot until the
motor has stopped, or is running at the desired minimum speed.
MAX SPD
The MAX SPD setting determines the motor speed when the speed adjust potentiometer is turned
full CW. It is factory set for maximum rated speed.
To calibrate, set the MAX SPD trimpot full CCW. Turn the speed adjust potentiometer full CW.
Adjust the MAX SPD trimpot until the desired maximum motor speed is reached.
Note:
Check the MIN SPD and MAX SPD adjustments after recalibrating to verify that the motor runs at
the desired minimum and maximum speed.
IR COMP
The IR COMP setting determines the degree to which motor speed is held constant as the motor
load changes. It is factory calibrated for a 1/8 HP, 90 VDC motor.
Recalibrate the IR COMP setting when using a lower horsepower motor. Refer to the recommended IR COMP settings in Figure 10, or recalibrate using the following procedure:
If the motor does not maintain set speed as the load changes, gradually rotate the IR COMP
trimpot CW. If the motor oscillates (overcompensation), the IR COMP trimpot may be set too high
(CW). Turn the IR COMP trimpot CCW to stabilize the drive.
13
TORQUE
The TORQUE setting determines the maximum armature current output of the drive. It is factory
calibrated for a 1/8 HP, 90 VDC motor.
Recalibrate the TORQUE setting when using a lower horsepower motor. Refer to the recommended TORQUE settings in Figure 10, or recalibrate using the following procedure:
1. With the power disconnected from the control, connect a DC ammeter (0 – 15 A minimum scale) in
series with the armature.
2. Set the TORQUE trimpot to minimum (full CCW).
3. Connect power to the drive. The motor should remain stopped.
4. Lock the motor armature. Be sure that the motor is firmly mounted.
5. Set the speed adjust potentiometer to maximum (full CW).
6. Adjust the TORQUE trimpot CW slowly until the armature current is 120% of motor rated armature
current.
7. Set the speed adjust potentiometer to minimum and remove the stall from the motor.
TORQUE
*
TORQUE
IR COMP
IR COMP
1/4 HP
130 VDC
2500 RPM
1.40 ADC
1/8 HP
90 VDC
1800 RPM
1.30 ADC
TORQUE
TORQUE
IR COMP
IR COMP
1/8 HP
130 VDC
2500 RPM
1.00 ADC
TORQUE
IR COMP
1/10 HP
90 VDC
1725 RPM
1.10 ADC
1/15 HP
90 VDC
1800 RPM
0.75 ADC
1/20 HP
90 VDC
1750 RPM
0.56 ADC
TORQUE
IR COMP
* factory settings
Figure 10. Typical TORQUE and IR COMP Settings
(Actual settings may vary with each application)
14
Application Notes
Multiple fixed speeds
Replace the speed adjust potentiometer with series resistors with a total series resistance of 10K
ohms (Figure 11). Add a single pole, multi-position switch with the correct number of positions for
the desired number of fixed speeds.
S3
Total Series
Resistance
10K Ohms
S2
S1
Figure 11.
Multiple Fixed Speeds
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 12 shows a connection
for fixed high and low speed adjust potentiometers.
CW
S3
High
Speed
5K Ohm
S2
S1
Low
Speed
CW
5K Ohm
Figure 12. Adjustable Fixed Speeds Using Potentiometers in Series
15
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 13 shows the connection of two
independant speed adjust potentiometers that can be mounted at two separate operating stations.
S3
SPEED 2
CW
CW
S2
SPEED 1
20K ohm
S1
Figure 13.
Independent Adjustable Speeds
20K ohm
16
RUN/JOG switch
Using a RUN/JOG switch is recommended in applications where quick stopping is not needed and
frequent jogging is required. Use a single pole, single throw switch for the RUN/JOG switch, and a
single pole, normally closed, momentary operated pushbutton for the JOG pushbutton (see Figure
14). When the RUN/JOG switch is set to JOG, the motor decelerates to zero speed. Press the JOG
pushbutton to jog the motor. Return the RUN/JOG switch to RUN for normal operation.
MAX SPD
P501
TORQUE
P502
MIN SPD
P503
L1
L2
A1
A2
S3
S2
H2
S1
CW
10K Ohm
H1
RUN
JOG
Figure 14.
IR COMP
P504
RUN/JOG Switch Connection
JOG
Pushbutton
17
Connection to other Minarik devices
S3
PCM4
2
S2
1
S1
XP02-115AC-Q
S3
DLC600
Figure 15.
S2
S2
S1
S1
XP02-115AC-Q
XP02-115AC-Q Connections to Minarik Devices
(PCM4, DLC100, and DLC300)
18
Leader-follower application
In this application, use a PCM4 to monitor the speed of the leader motor (Figure 16). The PCM4
isolates the leader motor from the follower drive, and outputs a voltage proportional to the leader
motor armature voltage. The follower drive uses this voltage reference to set the speed of the follower motor. An optional ratio potentiometer may be used to scale the PCM4 output voltage.
A1
Leader
Drive
9
MOTOR
A2
(+)
PCM4
8
7
(-)
TB501
Figure 16.
(+)
2
(-)
1
S2
Follower
Drive
TB502
S1
10K Ohm
(optional)
Leader-Follower Application
19
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 17). Optional ratio potentiometers can be used to scale the PCM4 output
voltage, allowing independent control of each drive.
6
8
2
ratio pot A
(optional)
10KΩ
PCM4
S1
A1
DRIVE A
7
TB501
MOTOR
A2
TB502
6
8
S2
1
2
PCM4
ratio pot B
(optional)
10KΩ
S1
A1
DRIVE B
7
TB501
Figure 17.
1
S2
TB502
Single Speed Potentiometer Control of Multiple Drives
MOTOR
A2
20
Reversing
A dynamic brake may be used when reversing the motor direction (Figure 18). 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.
A2
Forward
Brake
Reverse
MOTOR
A1
H2
H1
Figure 18.
Reversing Circuit Connection
1Ω / 1W
Dynamic
Brake
Resistor
21
Troubleshooting
m Warning
Dangerous voltages exist on the drive when it is powered. When possible, disconnect the AC line
voltage from the drive while troubleshooting. Be Alert. High voltages can cause serious or fatal injury.
Before troubleshooting
Perform the following steps before starting any procedure in this section:
• Disconnect AC line voltage from the drive.
• Check the drive closely for damaged components.
• Check that no conductive or other foreign material has become lodged on the printed circuit
board.
• Verify that every connection is correct and in good condition.
• Verify that there are no short circuits or grounded connections.
• Check that the voltage selection switch settings match the AC line and output voltages.
• Check that the drive’s rated armature and field outputs are consistent with the motor ratings.
22
Motor does not run
1. Check for blown fuses or tripped circuit breaker.
2. Verify that the speed adjust potentiometer is not set to zero speed position.
3. Verify that the inhibit terminals (H1 and H2) are not shorted together.
4. Verify that the drive is receiving AC line voltage.
5. Check that the drive is not in current limit. The red current limit (CUR LIM) LED must be off. If the
red current limit LED is on, verify that the motor is not jammed. It may be necessary to increase the
TORQUE setting if it is set to a value lower than the current rating of the motor.
Fuses or circuit breaker blows
1. Check all wiring for shorts, grounds, or misconnections.
2. Check that the drive is configured to match the motor rating.
3. Check that the motor is not jammed or restricted from movement.
4. Check that the fuse size is correct for the motor being driven.
Motor runs too fast at the maximum speed setting
1. Check that the MIN SPD and MAX SPD settings are not set too high.
2. Check that the field output connections are secure if you are using a shunt wound motor.
Motor will not stop when the speed adjust potentiometer is full CCW
1. Turn the MIN SPD trimpot CCW until the motor stops.
Motor runs in the opposite direction
1. Remove AC line voltage.
2. Reverse connections to the motor armature.
23
Motor slows under load
1. Check that the drive has been correctly calibrated for the motor.
2. Check that the motor is not overloaded.
3. Readjust the IR COMP slightly CW until motor runs at proper speed.
Motor is unstable under load
1. Readjust the IR COMP setting slightly CCW until motor speed is stabilized.
Motor only runs at full speed
1. Check that S2 and S3 are not shorted together.
For additional assistance, contact your local Minarik® distributor, or the factory direct:
Phone: (800) 646-2745
Fax: (815) 624-6960
24
Replacement Parts
Replacement parts are available from Minarik Corporation and its distributors for this drive series.
BR501
C503
D501
FU501
Q501
R501
R502
GBU8J Bridge
470 μF, 400 VDC Capacitor
16 A, 300V Diode
Fuse Holder
Power MOSFET
0.2 Ω, 5 W Resistor
6.8 KΩ, 10 W Resistor
5 A, 3 AG Fast-Acting Fuse
10 KΩ Potentiometer Kit (with Terminal Plug)
073-0006
011-0120
071-0054
050-0050
070-0043
032-0093
032-0103
050-0022
202-0074
25
Unconditional Warranty
A. Warranty
Minarik Drives 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, Minarik Drives will repair or replace, at its sole discretion, such products that
are returned to Minarik Drives, 14300 De La Tour Drive, South Beloit, IL 61080 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. Minarik Drives 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 Minarik Drives sole obligation and exclude all other warranties
of merchantability for use, express or implied. Minarik Drives 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 Minarik Drives 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 Minarik Drives by lawful authority, Minarik Drives shall under no circumstances be
liable for any consequential damages, losses, or expense arising in connection with the use of, or
inability to use, Minarik Drives 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, Minarik Drives 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 Minarik Drives based upon any liability or obligation arising hereunder or under
any law applicable to the sale of equipment or the use thereof, must be commenced within one
year after the cause of such action arises.
MINARIK DRIVES
www.minarikdrives.com
14300 De La Tour Drive, South Beloit, IL 61080
Phone: (800) MINARIK (646-2745); Fax: (800) 394-6334
Document Number: 250-0213, Revision 1; Printed in the U.S.A. - April 2006
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