USER`S MANUAL - Minarik Drives
USER’S MANUAL
PROCESS CONTROL
MODULE PCM3
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. MVD061402
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
maintenance technician install, adjust, and service this
equipment. Follow the National Electrical Code (NEC) 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.

Although this process control module isolates a voltage or
current signal, its internal 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.
ii
Contents
Safety Warnings
i
Specifications
1
Dimensions
2
Introduction
3
Installation
4
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Screw terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
AC line connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Voltage follower connection . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Current follower connection . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Leader signal generator connections . . . . . . . . . . . . . . . . . . . . .12
Output Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Armature Voltage Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Multiple Follower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Voltage/Current Selector Slide Switch . . . . . . . . . . . . . . . . . . . .20
Calibration
21
Voltage Signal Follower Calibration . . . . . . . . . . . . . . . . . . . . . .22
Manual Leader Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Current Signal Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
1-5 mA DC current signal input range:
. . . . . . . . . . . . . . . . . . . . . . . .24
4-20 mA DC current signal input range:
. . . . . . . . . . . . . . . . . . . . . . .25
10-50 mA DC current signal input range:
. . . . . . . . . . . . . . . . . . . . . .26
iii
Troubleshooting
Certificate of Compliance
Unconditional Warranty
28
31
inside back cover
iv
Illustrations
Figure 1. Process Control Module Dimensions . . . . . . . . . . . . . . . . . .2
Figure 2. Screw Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Figure 3. 115VAC Power Connection . . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 4. 230VAC Power Connection . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 5. Connection – Following an External Voltage Signal . . . . . . .10
Figure 6. Connection – Following an External Current Signal . . . . . . .11
Figure 7. Connection – Unidirectional Manual Leader Signal Source .13
Figure 8. Connection – Output Voltage . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 9. Armature Voltage Follower Connections . . . . . . . . . . . . . . .17
Figure 10. Multiple Follower Motors Connection . . . . . . . . . . . . . . . .19
Figure 11. Voltage/Current Selectro Slide Switch . . . . . . . . . . . . . . . .20
Figure 12. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . .21
Figure 13. Shunt Resistor Installation . . . . . . . . . . . . . . . . . . . . . . . .27
1
Specifications
Power Requirements
Line input
115VAC/230 VAC, 50/60 Hz, single phase
Input Signal Ranges (input circuit is isolated)
Voltage signal, narrow range
0 to +25 VDC
Voltage signal, mid range
0 to +120 VDC
Voltage signal, wide range
0 to +550 VDC
Current signal
1–5 mADC, 4–20 mADC, 10–50 mADC
Input Impedance
Voltage signal
Current signal, 1–5 mADC
Current signal, 4–20 mADC
Current signal, 10–50 mADC
Output
Impedance
Voltage range, max
Linearity
Operating Temperature Range
>25K
1K
235
100
ohms
ohms
ohms
ohms
800 ohms
0 to +10 VDC
0.1%
0 – 50 °C
2
Dimensions
4.825 [123]
4.225 [107]
IC1
C1
C2
OC1
MINARIK
ELECTRIC
T1
SIGNAL
ISOLATOR
R1
C3
R2
MAXIMUM
OUTPUT
R3
TP
C4
2.700 [69]
CURRENT
IC2
P1
C5
P2
2.150 [55]
P3
REF OUT
MINIMUM
OUTPUT
TB1
1
2
3
4
5
6
7
8
9
10
1.280 [33]
MOUNTING HOLE (4 EA)
0.146 [4] DIAMETER
0.250 [6]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 1. Process Control Module Dimensions
3
Introduction
Minarik model PCM3 signal isolators produce a floating DC voltage
signal proportional to a variable DC current or voltage signal input.
It also can generate the floating DC voltage signal output controlled
by an external potentiometer. The output signal fed to a speed
controller allows a motor to be driven automatically at a speed
proportional to the signal, i.e., to follow the signal. The maximum
PCM3 output voltage is 10 VDC.
The PCM3 DC voltage output must be trimmed to not exceed the
reference voltage, i.e., the normal voltage drop across the speed
adjust potentiometer of the motor speed controller. For Minarik
MM20000 series controls, the reference voltage is approximately
3.5 VDC. Putting higher DC voltage into the control speed adjust
circuit will not produce correspondingly higher motor speeds. Such
an error can seriously degrade the linearity between the process
signal level and motor speed.
This manual contains specifications, installation procedures,
connections, and calibration procedures for the process control
module, model PCM3. Refer to your variable speed drive user’s
manual for additional installation, operation, and troubleshooting
procedures.
4
Installation
Mounting
 Warning
Do not install, rewire, or remove this control with input power
applied. Doing so may cause fire or serious injury. Make
sure you read and understand the Safety Warnings on page
i before attempting installation.
• PCM3 components are sensitive to electrostatic fields. Avoid
contact with the circuit board directly.
• Protect the PCM3 from dirt, moisture, and accidental contact.
• Provide sufficient room for access to the terminal block.
• Mount the PCM3 away from other heat sources. Operate within
the specified ambient operating temperature range. The
operating temperature range for the PCM3 is 0°C through 50°C.
• Prevent loose connections by avoiding excessive vibration of the
process control module board.
• Mount the PCM3 in either a horizontal or vertical plane. The
PCM3 is mounted using 4 ea. 0.25 inch [6mm] standoffs.
See Figure 1, page 2 for the physical locations of these
standoffs. Use #8 panhead screws to fasten the standoffs to the
mounting surface.
Installation
Wiring
 Warning
쇵
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.
This drive is isolated from earth ground. Circuit potentials
are at 115 or 230 VAC above ground. To prevent the risk of
injury or fatalisty, 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 unpredictable
behavior in any electronic device, including motor controls.
As a general rule, Minarik recommends shielding of all conductors.
If it is not practical to shield power conductors, Minarik
recommends shielding all logic-level leads. If shielding 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 PCM module, ground the
shield at the module end. If noise is generated by a device on the
PCM module, ground the shield at the end away from the PCM
module. Do not ground both ends of the shield.
If the module continues to pick up noise after grounding the shield,
it may be necessary to add AC line filtering devices, or to mount
the PCM module 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
Screw terminal block
Connections to Minarik’s PCM3 are made to a screw terminal
block. Using a screwdriver, turn the terminal block screw counterclockwise to open the wire clamp. Insert stripped wire into the wire
clamp. Turn the terminal block screw clockwise to clamp the wire.
See Figure 2.
Figure 2. Screw Terminal Block
8
Installation
AC line connections
Connect AC power leads to terminals 1 and 4. When operating on
115VAC, leave the jumper bars installed between terminals 1 and 2
and between 3 and 4 (see Figure 3). This is the PCM3’s default
(factory) setting. When operating on 230VAC, remove both
jumper bars and place one jumper bar between terminals 2 and 3
(see Figure 4, page 9).
IC1
C1
C2
OC1
MINARIK
ELECTRIC
T1
SIGNAL
ISOLATOR
R1
C3
R2
MAXIMUM
OUTPUT
R3
TP
C4
CURRENT
IC2
P1
C5
P2
P3
MINIMUM
OUTPUT
TB1
5
1
6
7
8
4
AC POWER
115 VAC INPUT
JUMPER BARS INSTALLED
BETWEEN TERMINALS 1 & 2
AND TERMINALS 3 & 4
Figure 3. 115VAC Power Connection
9
10
9
Installation
IC1
C1
C2
OC1
MINARIK
ELECTRIC
T1
SIGNAL
ISOLATOR
R1
C3
R2
MAXIMUM
OUTPUT
R3
TP
C4
CURRENT
IC2
P1
C5
P2
P3
MINIMUM
OUTPUT
TB1
5
1
6
7
8
4
AC POWER
230 VAC INPUT
JUMPER BAR INSTALLED
BETWEEN TERMINALS 2 & 3
Figure 4. 230VAC Power Connection
9
10
10
Installation
Voltage follower connection
(1) Set the Current/Voltage Switch to Voltage.
(2) Connect the incoming voltage signal leads as shown in Figure
5 below.
(3) Connect the negative lead to Terminal 5.
(4) If the voltage signal is less than 20VDC, connect the positive
lead to Terminal 6. If the voltage signal is less than 120VDC,
connect the positive lead to Terminal 7. If the voltage signal is
greater than 120VDC, connect the positive lead to Terminal 8.
R1
R2
MAXIMUM
OUTPUT
R3
TP
CURRENT
P1
INPUT
P2
P3
VOLTAGE
MINIMUM
OUTPUT
1
2
3
4
5
0 - 20 VDC
VOLTAGE
SIGNAL
6
7
8
9
CURRENT/
VOLTAGE
SWITCH
REF
(+)
0 - 120 VDC
VOLTAGE
SIGNAL
10
REF
(+)
0 - 550 VDC
VOLTAGE
SIGNAL
COM (-)
REF
(+)
Figure 5. Connection – Following an External Voltage Signal
Installation
11
Current follower connection
(1) Set the Current/Voltage Switch to Current.
(2) Connect the incoming current signal leads as shown in Figure
6 below.
(3) Connect the negative lead to Terminal 5.
(4) Connect the positive lead to Terminal 6.
R1
R2
MAXIMUM
OUTPUT
R3
TP
CURRENT
P1
INPUT
P2
P3
VOLTAGE
MINIMUM
OUTPUT
1
2
3
4
5
6
COM
(-)
REF
(+)
7
8
9
10
CURRENT/
VOLTAGE
SWITCH
CURRENT
FOLLOWER INPUT
Figure 6. Connection – Following an External Current Signal
12
Installation
Leader signal generator connections
The PCM3 can be used as a leader controller in one of two ways.
It can provide a floating DC leader voltage input to other PCM3
modules interfacing with standard variable speed drives.It can also
drive several variable speed drives directly, provided that their
circuit design permits wiring of their speed circuits in common.
Unidirectional applications require a positive PCM3 output. Connect
a 10K ohm potentiometer (not provided with the PCM3) as the
leader control pot using the +10 VDC REF OUT supply on the
PCM3. Refer to Figure 7 (page 13).
To connect an external leader control potentiometer, attach the CW
side of the potentiometer to the REF OUT terminal. The
potentiometer wiper is connected to terminal 6. The CCW terminal
is connected to terminal 5.
Installation
13
IC1
C1
C2
OC1
MINARIK
ELECTRIC
T1
SIGNAL
ISOLATOR
R1
C3
R2
MAXIMUM
OUTPUT
R3
TP
C4
CURRENT
IC2
P1
C5
REF OUT
P2
INPUT
P3
VOLTAGE
MINIMUM
OUTPUT
TB1
1
2
3
4
5
6
7
8
9
10
CW
10K OHM
SPEED ADJUST
POTENTIOMETER
Figure 7. Connection – Unidirectional Manual Leader Signal Source
14
Installation
Output Voltage Connections
 Warning
Always check the instruction manual supplied with the
variable speed drive that will be interfaced with the PCM3
module. The scheme shown for wiring to an external
voltage source, as well as the specifications on that input,
must be well understood before proceeding.
Most Minarik controls have positive reference voltage across the
speed adjust pot with respect to the CCW side. The pot wiper
position determines the fraction of this control reference voltage
that will be applied to the speed adjustment circuit.
In these controls, the application of a positive voltage at the wiper
with reference to the CCW connection will cause the motor to run.
Output connections are made to terminals 9 and 10 of terminal
board TB501. Connect the negative lead to terminal 9. Connect
the positive lead to terminal 10. Refer to Figure 8 (page 15).
Some controls have a negative reference voltage across the speed
adjust pot. Reverse the polarity of the connection to such controls.
Installation
R1
R2
MAXIMUM
OUTPUT
R3
TP
CURRENT
P1
P2
P3
MINIMUM
OUTPUT
2
3
4
5
6
7
8
9
10
COM
(-)
REF
(+)
0 - 10 VDC
OUTPUT
Figure 8. Connection – Output Voltage
15
16
Installation
Armature Voltage Follower
The PCM3 may be used as an interface to control one motor speed
in proportion to that of an independent DC motor. The input signal
would be taken from the voltage across the armature of the 'leader'
motor, since speed is proportional to this voltage. To follow the
armature voltage signal, wire the positive side of the armature
voltage to Terminal 7 (if 0-120 VDC range) or to Terminal 8 (if 0550 VDC range). Wire the negative side of the armature voltage to
Terminal 5 as shown in Figure 9 (page 17).
Connect Terminals 9 and 10 to the speed control circuit in the
follower controller, according to the instructions provided with the
speed controller.
With most Minarik controls, connect Terminal 9 of the PCM3 to the
terminal for the CCW end of the control speed pot and Terminal 10
of the PCM3 to the wiper terminal. The pot wiper should be left
disconnected from the control so that only the PCM3 output will
control the motor speed.
Remember that the connections of Terminals 9 and 10 must be
reversed if the Minarik control has a negative reference voltage.
Installation
IC1
C1
C2
OC1
MINARIK
ELECTRIC
T1
SIGNAL
ISOLATOR
R1
C3
R2
MAXIMUM
OUTPUT
R3
TP
C4
CURRENT
IC2
P1
C5
REF OUT
INPUT
P2
P3
VOLTAGE
MINIMUM
OUTPUT
TB1
1
2
3
4
5
6
7
8
9
10
MOTOR
A2
S3
A1
S2
S1
S1
10K OHM
SPEED ADJUST
POTENTIOMETER
S2
A1
S3
A2
CW
MOTOR
MM20000
SERIES DRIVE
(LEADER)
MM20000
SERIES DRIVE
(FOLLOWER)
Figure 9. Armature Voltage Follower Connections
17
18
Installation
Multiple Follower Motors
If more than one 'follower' motor speed controller is to follow the
output from a single 'leader' PCM3, setting the ratio between two or
more of the motor speeds can be accomplished with ratioing pots
(Figure 10, page 19). Wire Terminal 10 of the PCM3 to the CW end
of the pot. Disconnect that side of the speed pot from its terminal
on the follower control. Wire the pot wiper to the speed adjust wiper
terminal. Wire the CCW side of the pot and the output from PCM3
Terminal 9 to the speed adjust CCW terminal on the control.
Installation
19
IC1
C1
C2
OC1
MINARIK
ELECTRIC
T1
SIGNAL
ISOLATOR
R1
C3
R2
MAXIMUM
OUTPUT
R3
TP
C4
CURRENT
IC2
P1
C5
REF OUT
P2
INPUT
P3
VOLTAGE
MINIMUM
OUTPUT
TB1
1
2
3
4
5
6
7
8
9
10
10K OHM MASTER
SPEED ADJUST
POTENTIOMETER
INH2
CW
S3
S2
MM20000 SERIES
FOLLOWER #1
10K OHM
SPEED ADJUST
POTENTIOMETER
S1
CW
A1
A2
MOTOR #1
INH2
S3
S2
MM20000 SERIES
FOLLOWER #2
10K OHM
SPEED ADJUST
POTENTIOMETER
S1
CW
A1
A2
MOTOR #2
Figure 10. Multiple Follower Motors Connection
20
Installation
Voltage/Current Selector Slide Switch
See Figure 11 for the Voltage/Current Selector Slide Switch. Set
the swtich to VOLTAGE for voltage input mode, otherwise, set it to
CURRENT for current input mode.
VOLTAGE/CURRENT
SELECTOR SLIDE
SWITCH
IC1
C1
C2
OC1
MINARIK
ELECTRIC
T1
SIGNAL
ISOLATOR
R1
C3
R2
MAXIMUM
OUTPUT
R3
TP
C4
CURRENT
IC2
P1
C5
P2
P3
MINIMUM
OUTPUT
TB1
1
2
3
4
5
6
7
8
9
10
Figure 11. Voltage/Current Selectro Slide Switch
21
Calibration
 Warning
Dangerous voltages exist on the drive when it is powered
and up to 30 seconds after power is removed and the motor
stops. BE ALERT. High voltages can cause serious or fatal
injury. For your safety, use personal protective equipment
(PPE) when operating this drive.
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. Refer to Figure 12
for trimpot layout.
INPUT
IC1
C1
C2
OC1
MINARIK
K
ELECTRIC
RI
T1
SIGNAL
ISOLATOR
R1
C3
R2
MAXIMUM
OUTPUT
R3
MAXIMUM
OUTPUT
TP
C4
CURRENT
IC2
P1
C5
P2
MINIMUM
OUTPUT
P3
MINIMUM
OUTPUT
TB1
1
2
3
4
5
6
7
8
9
10
Figure 12. Calibration Trimpot Layout
22
Calibration
Voltage Signal Follower Calibration
Set the VOLTAGE/CURRENT selector switch to VOLTAGE.
Confirm that the positive DC voltage input lead is connected to the
appropriate terminal.
(1) Apply the maximum DC voltage input signal.
(2) Adjust the INPUT trimpot until the voltage measured between
the Test Point (post on board, marked TP) and Terminal 5 is
approximately one-half of the Reference Voltage of the speed
control.
(3) Adjust MAXIMUM OUTPUT trimpot to achieve the desired
maximum output voltage across Terminals 9 and 10, which
normally is equal to or less than the control Reference Voltage,
depending upon whether the motor is to run at its rated speed
or at a slower speed with maximum DC input voltage to the
PCM3.
(4) Apply the minimum DC voltage input signal.
(5) Adjust MINIMUM OUTPUT trimpot to achieve the desired
minimum output voltage across Terminals 9 and 10 or,
alternatively, to achieve the desired minimum speed of the
motor.
Calibration
23
Manual Leader Control
Set the VOLTAGE/CURRENT selector switch to VOLTAGE.
Confirm that a 10K ohm leader speed adjust potentiometer has
been properly wired between REF OUT (CW) and Terminal 5
(CCW), with its wiper wired to Terminal 6.
(1) Set the leader speed adjust potentiometer to maximum (full
CW).
(2) Adjust INPUT trimpot until voltage measured between the Test
Point (post on board, marked TP) and Terminal 5 is
approximately one-half of the reference voltage of the speed
control.
(3) Adjust MAXIMUM OUTPUT trimpot to achieve the desired
maximum output voltage across Terminals 9 and 10. This
voltage is equal to or less than the control reference voltage,
depending upon the desired motor speed.
(4) Rotate the leader potentiometer wiper fully CCW.
(5) Adjust MINIMUM OUTPUT trimpot to achieve the desired
minimum output voltage across Terminals 9 and 10 or,
alternatively, to achieve the desired minimum speed of the
motor.
24
Calibration
Current Signal Follower
Set the VOLTAGE/CURRENT selector slide switch to CURRENT.
1-5 mA DC current signal input range:
(1) Apply a 5 maDC signal across Terminals 5 and 6.
(2) Adjust INPUT trimpot until voltage measured between the Test
Point (post on board, marked TP) and Terminal 5 is
approximately one-half of the Reference Voltage of the speed
control.
(3) Adjust MAXIMUM OUTPUT trimpot to achieve the desired
maximum output voltage across Terminals 9 and 10, which
normally is equal to or less than the control Reference Voltage,
depending upon whether the motor is to run at its rated speed
or at a slower speed with maximum DC input current to the
PCM3.
(4) Apply a 1 mADC signal across Terminals 5 and 6.
(5) Adjust MINIMUM OUTPUT trimpot to achieve the desired
minimum output voltage across Terminals 9 and 10 or,
alternatively, to achieve the desired minimum speed of the
motor.
(6) Repeat Steps 1 through 5 once.
Calibration
25
4-20 mA DC current signal input range:
(1) Apply a 20 mADC signal across Terminals 5 and 6.
(2) Adjust MAXIMUM OUTPUT trimpot to achieve the desired
maximum output voltage across Terminals 9 and 10, which
normally is equal to or less than the control Reference Voltage,
depending upon whether the motor is to run at its rated speed
or at a slower speed with maximum DC input current to the
PCM3.
(3) Apply a 4 mADC signal across Terminals 5 and 6.
(4) Adjust MINIMUM OUTPUT trimpot to achieve the desired
minimum output voltage across Terminals 9 and 10 or,
alternatively, to achieve the desired minimum speed of the
motor.
(5) Repeat Steps 1 through 4 once.
26
Calibration
10-50 mA DC current signal input range:
Shunt a 1K ohm, 3W resistor across Terminals 5 and 6 as shown in
Figure 13 (page 27).
(1) Apply a 50 mADC signal across Terminals 5 and 6.
(2) Adjust MAXIMUM OUTPUT trimpot to achieve the desired
maximum output voltage across Terminals 9 and 10, which
normally is equal to or less than the control Reference Voltage,
depending upon whether the motor is to run at its rated speed
or at a slower speed with maximum DC input current to the
PCM3.
(3) Apply a 10 mA DC signal across Terminals 5 and 6.
(4) Adjust MINIMUM OUTPUT trim pot to achieve the desired
minimum output voltage across Terminals 9 and 10 or,
alternatively, to achieve the desired minimum speed of the
motor.
(5) Repeat Steps 1 through 4 once.
Calibration
IC1
C1
C2
OC1
MINARIK
ELECTRIC
T1
SIGNAL
ISOLATOR
R1
C3
R2
MAXIMUM
OUTPUT
R3
TP
C4
CURRENT
IC2
P1
C5
P2
P3
MINIMUM
OUTPUT
TB1
1
2
3
4
5
6
7
8
9
SHUNT
RESISTOR
Figure 13. Shunt Resistor Installation
10
27
28
Troubleshooting
 Warning
Dangerous voltages exist on the PCM3 when it is powered.
When possible, disconnect PCM3 and drive while troubleshooting. 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 PCM3 and variable speed
drive.
• Check the PCM3 and 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 input voltage jumpers are installed properly for
the input voltage being used (see page 8).
• Check that the drive’s rated armature and field outputs are
consistent with the motor ratings.
For additional assistance, contact your local Minarik distributor, or
the factory direct:
1-800-MINARIK (646-2745) or Fax: 1-800-394-6334
Troubleshooting
29
Problem
Possible
Causes
Suggested
Solutions
End user’s drive
does not respond
to encoder signal
1. No output voltage
from PCM3 (TB1).
1. Recalibrate the
PCM3. If there is
still no output send
PCM3 to Minarik
for repair.
2. Loose connections
between PCM3
and motor drive.
2. Check connections
between TB1 and
the input of motor
drive.
3. PCM3 is not
receiving AC line
voltage.
3. Apply AC line
voltage to
terminals 1and 4.
4. Input signal is not
connected.
4. Check that the
PCM3 is receiving
voltage (or current)
input signal.
5. INPUT pot is not
calibrated.
5. Calibrate INPUT
pot (page 24).
6. Motor drive not
calibrated
properly.
6. Re-calibrate motor
drive according to
manufacturer’s
instructions.
30
Troubleshooting
Problem
Possible
Causes
Suggested
Solutions
1. Voltage out (TB1) is
End user’s motor
not changing as
drive does not reach
input changes
full speed
1. Check that the
voltage out (TB1)
is changing as
input changes.
Recalibrate the
PCM3. IF voltage
is still not changing
send the drive to
Minarik repair.
2. Loose connections
between PCM3 and
motor drive.
2. Check connections
between TB1 and
the input of motor
drive.
1. Motor drive not
calibrated properly.
1. Re-calibrate motor
drive according to
manufacturer’s
instructions.
End user’s motor
does not respond
properly (runs too
slow, or too fast) to
PCM3
31
Certificate of Compliance
Minarik Corporation hereby certifies that PCM3 Signal Isolator has
been approved to bear the “CE” mark.
The PCM3 has been tested to the following test specifications:
EN55011:1991 (emissions), and
EN50082-1:1992 (immunity)
Compliance allows the PCM3 to bear the CE mark.
The end user, as described herein, falls into one of two categories:
1. The Consumer will deploy a stand-alone unit as an
integral, yet external, portion of the machine he/she is
operating.
2. The Original Equipment Manufacturer (OEM) will
implement the product as a component of the machine
being manufactured.
32
Certificate of Compliance
CE is a machinery directive. Whether or not every component in
the OEM’s machinery meets CE, the OEM must still submit its
machine for CE approval. Thus, no component must necessarily
meet CE within the machine, as long as the OEM takes the
necessary steps to guarantee the machine does meet CE. By the
same token, even if every component in the OEM’s machine does
meet CE, the machine will not necessarily meet CE as a machine.
Using CE-approved wiring and filtering practices guarantee
the controller will meet EN55011 (1991 emissions standard) and
EN50082-1 (1992 immunity standard).
Notes
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 two (2) years or
6,000 hours, whichever comes first, from date of shipment thereof. Within this
warranty period, the Corporation will repair or replace such products that are: (1)
returned to Minarik Corporation, 901 East Thompson Avenue, Glendale, CA 912012011 USA; and, (2) determined by the Corporation to be defective.
This warranty shall not apply to any product that has been subject to misuse,
negligence, or accident; or misapplied; or repaired by unauthorized persons; or
improperly installed. 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 two (2) year or 6,000 hour warranty period. Products
serviced and/or parts replaced on a no-charge basis during the warranty period carry
the unexpired portion of the original warranty only.
If for any reason any of the foregoing provisions shall be ineffective, the
Corporation’s liability for damages arising out of its manufacture or sale of
equipment, or use thereof, whether such liability is based on warranty, contract,
negligence, strict liability in tort, or otherwise, shall not in any event exceed the full
purchase price of such equipment.
Any action against the Corporation based upon any liability or obligation arising
hereunder or under any law applicable to the sale of equipment or the use thereof,
must be commenced within one year after the cause of such action arises.
901 East Thompson Avenue
Glendale, California 91201-2011
Tel.: 1-800-MINARIK (646-2745)
Fax: 1-800-394-6334
www.minarikcorp.com
Document Number 250-0082, Revision 4
Printed in the U.S.A – 6/02
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