User`s Manual

User`s Manual
Models:
XL1100A
XL3025A
XL3050A
XL3200A
Pulse-Width Modulated,
Variable Speed DC Drives
User’s Manual
XLA Series
The XLA Series of open chassis, PWM Drives ranges from 1/20
HP to 2 HP. An additional heatsink kit (PN 223-0271) may be
added if the armature current is greater than 5 amps. The XLA
Series of drives has a cage-clamp terminal block for userfriendly wiring. There are six user-adjustable trimmer
potentiometers in addition to diagnostics.
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. MVD040902
Printed in the United States of America.
i
Safety Warnings
• This symbol denotes an important safety tip or warning.
SHOCK
HAZARD
•
•
AVOID
HEAT
KEE
DR
OID
ATION
Failure to observe these warnings may result in serious injury.
Please read these instructions carefully before performing
any of the procedures contained in this manual.
DO NOT INSTALL, REMOVE, OR REWIRE THIS EQUIPMENT
WITH POWER APPLIED. Have a qualified electrical technician
install, adjust and service this equipment. Follow the National
Electrical Code and all other applicable electrical and safety
codes, including the provisions of the Occupational Safety and
Health Act (OSHA), when installing equipment.
Reduce the chance of an electrical fire, shock, or explosion by
proper grounding, over-current protection, thermal protection,
and enclosure. Follow sound maintenance procedures.
It is possible for a drive to run at full speed as a result of
a component failure. Minarik strongly recommends the
installation of a master switch in the main power input to stop
the drive in an emergency.
Circuit potentials are at 115 VAC or 230 VAC above earth
ground. Avoid direct contact with the printed circuit board or
with circuit elements to prevent the risk of serious injury or
fatality. Use a non-metallic screwdriver for adjusting the
calibration trimpots. Use approved personal protective
equipment and insulated tools if working on this drive with
power applied.
ii
Contents
Safety Warnings
i
Tables
iii
Illustrations
iv
Specifications
1
Dimensions
8
Installation
10
Drive mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Line Fusing for XL Series Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Speed adjust potentiometer mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Cage-clamp terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
External line fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Field output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Voltage follower connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Voltage switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Operation
23
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Inhibit terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Decelerate to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Calibration
31
Calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
iii
IR COMPENSATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
CURRENT LIMIT (CURR. LIMIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
ACCELERATION (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
DECELERATION (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Application Notes
41
Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . .42
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
RUN/JOG option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
RUN/JOG option #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Single speed potentiometer control of multiple drives . . . . . . . . . . . . . . . .47
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Reversing with a DIGI-LOK® controller . . . . . . . . . . . . . . . . . . . . . . . . . .49
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Troubleshooting
50
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
POWER ON (IL501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
CURR LIM (IL502) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Certificate of Compliance
59
AC line filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
End User Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Unconditional Warranty
inside back cover
Tables
Table
Table
Table
Table
1.
2.
3.
4.
Recommended Line Fuse Sizes . .
Field Output Connections . . . . . . .
Inhibit Plug Harness Part Numbers
Minimum recommended
dynamic brake resistor sizes . . . . .
Table 5. Replacement Parts . . . . . . . . . . . .
Table 6. Minarik AC Line Filters . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .14
. . . . . . . . . . . . . . . . . . . . . . . . . . .20
. . . . . . . . . . . . . . . . . . . . . . . . . . .27
. . . . . . . . . . . . . . . . . . . . . . . . . . .30
. . . . . . . . . . . . . . . . . . . . . . . . . . .57
. . . . . . . . . . . . . . . . . . . . . . . . . . .60
iv
Illustrations
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1. XLA Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2. Heat Sink Dimensions (KIT 223-0271) . . . . . . . . . . . . . . . . . . . . . . . . .9
3. Speed Adjust Potentiometer Installation . . . . . . . . . . . . . . . . . . . . . . .15
4. Cage-Clamp Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5. XLA Series Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
7. Voltage Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
8. Inhibit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
9. Run/Decelerate to Minimum Speed Switch . . . . . . . . . . . . . . . . . . . . .28
10. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
11. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
12. Low-Voltage DC Motor Calibration Settings . . . . . . . . . . . . . . . . . . .35
13. Typical CURR. LIMIT and IR COMP settings
(actual settings may vary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
14. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
15. Adjustable Speeds Using Potentiometers In Series . . . . . . . . . . . . . .42
16. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
17. RUN/JOG Switch (first wiring option) . . . . . . . . . . . . . . . . . . . . . . . .44
18. RUN/JOG Switch (second wiring option) . . . . . . . . . . . . . . . . . . . . . .45
19. Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
20. Single Speed Potentiometer Control of Multiple Drives . . . . . . . . . . .47
21. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
22. Reversing with a DLC600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
23. Diagnostic LED Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
24. CEXL Filter Connection to XLA Series Drive . . . . . . . . . . . . . . . . . . .62
1
Specifications
Model Number
XL1100A
Type
open chassis
AC Line Voltage
115 VAC, ±10%, 50/60 Hz, single phase
Line Fuse Rating
15 A
Horsepower Range
1/4–1 HP
Form Factor
1.05
Maximum Armature Current
5 ADC
Maximum Armature Current with Heat Sink*
Field Voltage @ 115 VAC Input
10 ADC
50 VDC/100 VDC
Maximum Field Current
1 ADC
Maximum Armature Voltage Adjustment Range
50–150 VDC
Minimum Armature Voltage Adjustment Range
0–70 VDC
Acceleration Time Range (with no load)
1–12 seconds
Deceleration Time Range (with no load)
coast to a stop–12 seconds
Speed Adjustment Potentiometer
10K ohms
Analog Signal Voltage Range (signal must be isolated; S1 to S2)
0–2.7 VDC
Approximate Input Impedance (from S1 to S2)
100K ohms
Speed Regulation (at base speed)
Safety Certification
1%
UL Recognized Component, file E132235
CSA Certified Component, file LR41380
Power Device Switching Frequency
Weight
Ambient Operating Temperature Range
18 KHz
1.4 lb
10ºC–40ºC
*Use heat sink kit part number 223-0271 when continuous armature current is
above 5 ADC.
2
Specifications
Model Number
XL3025A
Type
AC Line Voltage
open chassis
115 VAC/230 VAC, ±10%, 50/60 Hz, single phase
Line Fuse Rating
8A
Horsepower Range @ 130 VDC Output
1/20–1/4 HP
Horsepower Range @ 240 VDC Output
1/8–1/3 HP
Form Factor
1.05
Maximum Armature Current
3 ADC
Field Voltage @ 115 VAC Input
50 VDC/100 VDC
Field Voltage @ 230 VAC Input
100 VDC/200 VDC
Maximum Field Current
1 ADC
Maximum Armature Voltage Adjustment Range @ 115 VAC Input
Minimum Armature Voltage Adjustment Range @ 115 VAC Input
Maximum Armature Voltage Adjustment Range @ 230 VAC Input
Minimum Armature Voltage Adjustment Range @ 230 VAC Input
60–150 VDC
0–70 VDC
60–240 VDC
0–70 VDC
Acceleration Time Range (with no load)
1–12 seconds
Deceleration Time Range (with no load)
coast to a stop–12 seconds
Speed Adjustment Potentiometer
10K ohms
Analog Signal Voltage Range (signal must be isolated; S1 to S2)
for 0–130 VDC Armature Voltage
0–2.7 VDC
for 0–240 VDC Armature Voltage
0–5.0 VDC
Approximate Input Impedance (from S1 to S2)
Speed Regulation (at base speed)
Vibration
100 Kohms
1%
0.5G max (20–50 Hz)
0.1G max (>50 Hz)
Safety Certification
UL Recognized Component, file E132235
CSA Certified Component, file LR41380
Specifications
Power Device Switching Frequency
Weight
Ambient Operating Temperature Range
3
18 KHz
1.4 lb
10°C–40°C
4
Specifications
Model Number
XL3050A
Type
AC Line Voltage
open chassis
115 VAC/230 VAC, ±10%, 50/60 Hz, single phase
Line Fuse Rating
10 A
Horsepower Range @ 130 VDC Output
1/8–1/2 HP
Horsepower Range @ 240 VDC Output
1/4–3/4 HP
Form Factor
1.05
Maximum Armature Current
5 ADC
Field Voltage @ 115 VAC Input
50 VDC/100 VDC
Field Voltage @ 230 VAC Input
100 VDC/200 VDC
Maximum Field Current
1 ADC
Maximum Armature Voltage Adjustment Range @ 115 VAC Input
Minimum Armature Voltage Adjustment Range @ 115 VAC Input
Maximum Armature Voltage Adjustment Range @ 230 VAC Input
Minimum Armature Voltage Adjustment Range @ 230 VAC Input
55–150 VDC
0–65 VDC
55–240 VDC
0–65 VDC
Acceleration Time Range (with no load)
1–12 seconds
Deceleration Time Range (with no load)
coast to a stop–12 seconds
Speed Adjustment Potentiometer
10K ohms
Analog Signal Voltage Range (signal must be isolated; S1 to S2)
for 0–130 VDC Armature Voltage
0–2.7 VDC
for 0–240 VDC Armature Voltage
0–5.0 VDC
Approximate Input Impedance (from S1 to S2)
Speed Regulation (at base speed)
Vibration
100K ohms
1%
0.5G max (20–50 Hz)
0.1G max (>50 Hz)
Safety Certification
UL Recognized Component, file E132235
CSA Certified Component, file LR41380
Specifications
Power Device Switching Frequency
Weight
Ambient Operating Temperature Range
5
18 KHz
1.5 lb
10°C–40°C
6
Specifications
Model Number
XL3200A
Type
AC Line Voltage
open chassis
115 VAC/230 VAC, ±10%, 50/60 Hz, single phase
Line Fuse Rating
15 A
Horsepower Range @ 130 VDC Output
1/4–1/2 HP
Horsepower Range @ 130 VDC Output with Heat Sink*
1/4–1 HP
Horsepower Range @ 240 VDC Output
1/2–1 HP
Horsepower Range @ 240 VDC Output with Heat Sink*
1/2–2 HP
Form Factor
1.05
Maximum Armature Current
5 ADC
Maximum Armature Current with Heat Sink*
9 ADC
Field Voltage @ 115 VAC Input
50 VDC/100 VDC
Field Voltage @ 230 VAC Input
100 VDC/200 VDC
Maximum Field Current
1 ADC
Maximum Armature Voltage Adjustment Range @ 115 VAC Input
Minimum Armature Speed Adjustment Range @ 115 VAC Input
Maximum Armature Voltage Adjustment Range @ 230 VAC Input
Minimum Armature Speed Adjustment Range @ 230 VAC Input
55–150 VDC
0–65 VDC
55–240 VDC
0–65 VDC
Acceleration Time Range (with no load)
1–12 seconds
Deceleration Time Range (with no load)
coast to a stop–12 seconds
Speed Adjustment Potentiometer
10K ohms
Analog Signal Voltage Range (signal must be isolated; S1 to S2)
for 0–130 VDC Armature Voltage
for 0–240 VDC Armature Voltage
Approximate Input Impedance (from S1 to S2)
Speed Regulation (at base speed)
0–2.7 VDC
0–5.0 VDC
100K ohms
1%
Specifications
Vibration
7
0.5G max (20–50 Hz)
0.1G max (>50 Hz)
Safety Certification
UL Recognized Component, file E132235
CSA Certified Component, file LR4138
Power Device Switching Frequency
Weight
Ambient Operating Temperature Range
18 KHz
1.6 lb
10°C–40°C
*Use heat sink kit part number 223-0271 or equivalent when continuous armature
current is above 5 ADC.
8
Dimensions
BR501
Q502
Q501
D501
TH501
B2
R503
AC1
AC2
BR+
BRB1
T501
C503
SW502
C505
SW501
R501
4.97 [126]
4.13 [105]
IC503
IC502
C501
IC501
R502
FU501
FAST-ACTING
C502
CURR
LIMIT
C504
INHIBIT
IL501
IL502
TB501
L1
L2
S1
S2
S3
F1
F2
A1
0.25 [6]
5.38 [137]
H
1.75 [45]
MODEL
XL1100A
XL3025A
XL3050A
XL3200A
DIM “H”
3.00 [76]
2.25 [57]
3.00 [76]
3.75 [95]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 1. XLA Series Dimensions
0.50"
Dimensions
C
0.188 WIDE SLOT
(4 PLACES)
8-32 THD
(4 PLACES)
9.78 [248]
8.41 [214]
6.70 [170]
3.08 [78]
1.41 [35]
2.50 [64]
2.50 [64]
3.15 [80]
3.15 [80]
6.90 [175]
1.00 [25]
Figure 2. Heat Sink Dimensions (KIT 223-0271)
9
10
Installation
Drive mounting
Warning
Do not install, rewire, or remove this control with power
applied. Doing so may cause fire or serious injury. Make sure
you have read and understood the Safety Warnings before
attempting installation.
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.
•
•
•
•
•
•
Drive components are sensitive to electrostatic fields. Avoid
direct contact with the circuit board. Hold drive by the
chassis only.
Protect the drive from dirt, moisture, and accidental contact.
Provide sufficient room for access to the terminal block and
calibration trimpots.
Mount the drive away from 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 in either the horizontal or vertical plane.
Six 0.19-in. (5 mm) wide slots in the chassis accept #8
panhead screws. Fasten wither the large base or the narrow
flange of the chassis to the subplate.
Installation
11
Wiring
Warning
Do not install, remove, or rewire this equipment with
power applied. Failure to heed this warning may result in
fire, explosion, or serious injury.
Circuit potentials are at 115 or 230 VAC above ground. To
prevent the risk of injury or fatality, avoid direct contact with
the printed circuit board or with circuit elements.
Do not disconnect any of the motor leads from the drive
unless power is removed or the drive is disabled. Opening
any one motor lead may destroy the drive.
Use 12 AWG wire for AC line voltage (L1 and L2) and motor
armature (A1 and A2) wiring. Use 18 AWG wire for logic ( S1, S2,
and S3) and motor field (F1 and F2) wiring.
12
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 logic leads
is not practical, the user should twist all logic leads with themselves
to minimize induced noise.
It may be necessary to earth ground the shielded cable. If noise is
produced by devices other than the drive, ground the shield at the
drive end. If noise is generated by a device on the drive, ground
the shield at the end away from the drive. Do not ground both ends
of the shield.
If the drive continues to pick up noise after grounding the shield, it
may be necessary to add AC line filtering devices, or to mount the
drive in a less noisy environment.
Installation
13
Heat sinking
XLA series models XL1100A and XL3200A require an additional
heat sink (Minarik part number 223–0271) when the continuous
armature current is above 5 ADC. All other XLA Series drives have
sufficient heat sinking in their basic configuration. Use a thermally
conductive heat sink compound (such as Dow Corning® 340 Heat
Sink Compound) between the drive chassis and heat sink surface
for optimum heat transfer.
Fusing
NOTE: Model XL1100A drives do not require a line fuse on L2.
All XLA Series drives are fused for maximum rated current at 115
VAC line input. A factory installed fuse is connected to L1 (hot) of
the AC line input. See Replacement Parts (page 57) for exact fuse
size. For 230 VAC operation, add an additional line fuse for L2
(neutral). Use a 250 volt, fast-acting fuse rated at 150% of the
maximum armature current. See Table 1 on page 14 for
recommended sizes.
14
Installation
Line Fusing for XL Series Drives
Minarik Corporation offers three fuse kits: part number 050–0068
(1–8A Fuse Kit), 050–0070 (3–10A Fuse Kit), and 050–0072
(5–15A Fuse Kit). All fuse kits include a 1/2A pico fuse (part
number 050–0074) which protects the transformer and logic. Refer
to Replacement Parts (page 57) for fuse kit contents.
Table 1. Recommended Line Fuse Sizes
90 VDC Motor
180 VDC
Horsepower Horsepower
1/20
1/15
1/8
1/6
1/4
1/3
1/2
3/4
1
1/10
1/8
1/4
1/3
1/2
3/4
1
1 1/2
2
Max. DC Armature AC Line Fuse
Current (amps)
Size (amps)
0.5
0.8
1.5
1.7
2.6
3.5
5.0
7.6
10
1
1.5
3
3
5
8
10
15
15
Installation
15
Speed adjust potentiometer mounting
Warning
Be sure that the potentiometer tabs do not make contact with
the potentiometer enclosure. Grounding the input will cause
damage to the drive.
Install the circular insulating disk between the mounting panel and
the 10K ohm speed adjust potentiometer (see Figure 3). Mount the
speed adjust potentiometer through a 0.38-inch (10 mm) hole with
the hardware provided. Twist the speed adjust potentiometer wires
to avoid picking up unwanted electrical noise.
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
CW
WIPER
W
NUT
STAR
WASHER
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
PANEL
Figure 3. Speed Adjust Potentiometer Installation
16
Installation
Cage-clamp terminals
XLA Series drive connections are of the cage-clamp terminal type
(see Figure 4). To insert a wire into a terminal:
1. Press down on the lever arm using
a small screwdriver.
2. Insert wire into the wire clamp.
3. Release the lever arm to clamp
wire.
Figure 4. Cage-Clamp Terminal
Installation
17
Connections
Warning
Do not connect this equipment with power applied.
Failure to observe this precaution may result in fire or serious
injury.
Minarik strongly recommends the installation of a master
power switch in the voltage input line. The switch contacts
should be rated at a minimum of 200% of motor nameplate
current and 250 volts.
Connect the power input leads, an external line fuse (if required)
and a DC motor to TB501 on the drive’s printed circuit board (PCB)
as shown in Figure 5 (page 19).
Motor connections
Minarik drives supply motor voltage from A1 and A2 terminals. It is
assumed throughout this manual that, when A1 is positive with
respect to A2 , the motor will rotate clockwise (CW) while looking at
the output shaft protruding from the front of the motor. If this is
opposite of the desired rotation, simply reverse the wiring of A1 and
A2 with each other.
Connect a DC motor to TB501 terminals A1 and A2 as shown in
Figure 5. Ensure that the motor voltage rating is consistent
with the drive’s output voltage.
18
Installation
Power connections
Connect the AC line power leads to TB501 terminals L1 and L2, or
to a double-throw, single-pole master power switch
(recommended).
External line fuse
NOTE: Model XL1100A drives do not require additional line fusing.
An additional line fuse should be installed on L2 if the input voltage
is 230 VAC. The line fuse should be rated at 250 volts and 150 200% of maximum motor nameplate current. Refer to the line fuse
chart on page 14 for fuse ratings.
Installation
19
IC503
IC502
C501
IC501
FAST-ACTING
FUSE ONLY
FU501
MAX SPD
CURR LIMIT
IR COMP
C502
POWER
ON
C504
MIN SPD
ACCEL
INHIBIT
DECEL
IL501
TB501
L1
L2
S1
S2
S3
F1
F2
A2
A1
+
STOP
SWITCH
CW
FUSE
(*see note 1)
10K OHM
SPEED
ADJUST POT
FIELD COIL
(*see note 2)
MOTOR
NOTES:
1. DO NOT ADD LINE FUSE TO L2 IF USING MODEL XL1100A DRIVES. ADD
LINE FUSE TO L2 FOR ALL OTHER DRIVES IF LINE VOLTAGE IS 230 VAC.
2. DO NOT CONNECT FIELD CIRCUIT IF USING A PERMANENT-MAGNET
MOTOR. REFER TO TABLE 2 (PAGE 20) FOR ALTERNATE FIELD
CONNECTIONS.
Figure 5. XLA Series Connections
20
Installation
Field output connections
Warning
The field output is for shunt wound motors only. Do not
make any connections to the field output when using a
permanent magnet motor.
Use 18 AWG wire for field connections. See Table 2 for field output
connections.
Table 2. Field Output Connections
Line Voltage
Approximate Field
Field
(VAC)
Voltage (VDC)
Connections
115
50
F1 and L1
115
100
F1 and F2
230
100
F1 and L1
230
200
F1 and F2
Installation
21
Voltage follower connections
Instead of using a speed adjust potentiometer, the drive may be
wired to follow a voltage signal that is isolated from earth ground
(Figure 6). Use an analog voltage range of 0 - 2.7 VDC with 115
VAC line voltage. Use an analog voltage range of 0 - 5 VDC with
230 VAC line voltage.
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. Follow the same wiring guidelines
used for speed adjust potentiometer wiring.
MIN SPD
ACCEL
50
DECEL
TB501
L1
L2
COM
(-)
S1
S2
S3
F1
F2
A2
A1
REF
(+)
ANALOG
VOLTAGE
SIGNAL
Figure 6. Voltage Follower Connections
IL502
22
Installation
Voltage switches
Warning
Change switch settings only when the drive is disconnected
from AC line voltage. Make sure both switches are set to
their correct positions. If the switches are improperly set to a
lower voltage position, the motor will not run at full voltage. If
the switches are improperly set to a higher voltage position,
the motor will overspeed, which may cause motor damage.
NOTE: Model XL1100A does not include these switches.
Two voltage switches (SW501 and SW502) must be set to either
115 or 230 to match the AC line voltage being used. See Figure 7
for the location of the voltage switches.
T501
C503
SW501
115
SW502
230
C505
230
VOLTAGE
SWITCHES
(SW501 & SW502)
115
IC503
IC502
IC501
FAST-AC
FUSE O
FU5
Figure 7. Voltage Switches
C501
MAX SPD
CUR
23
Operation
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.
Chane 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. If
the switches are improperly set to a higher voltage position,
the motor will overspeed, which may cause motor damage.
Before applying power
1. Verify that no conductive material is present on the printed
circuit board.
2. Set all switches to their proper settings, if required.
3. Verify that the AC supply is properly balanced.
24
Operation
Startup
1.
2.
3.
4.
Turn the speed adjust potentiometer full counterclockwise
(CCW). If the drive is following a voltage signal, set the
voltage signal to 0 VDC.
Apply AC line voltage.
Slowly advance the speed adjust potentiometer clockwise
(CW). If a voltage signal is used, 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.
To stop the drive, set the speed adjust potentiometer or
voltage signal to zero.
Operation
25
Starting and Stopping Methods
Warning
For frequent starts and stops, use dynamic braking, inhibit
mode, or decelerating to minimum speed (shorting S2 to S1).
DO NOT use any of these methods for emergency stopping.
They may not stop a drive that is malfunctioning. Removing
AC line power (both L1 and L2) is the only acceptable method
for EMERGENCY stopping.
For this reason, Minarik strongly recommends the installation
of an emergency stop switch. The switch contacts should be
rated at a minimum of 250 volts and 200% of maximum motor
current.
Line starting and line stopping
When AC line voltage is applied to the drive, the motor accelerates
to the set speed. When AC line voltage is removed, the motor
coasts to a stop. Line stopping (removing AC line voltage) is not
necessary, and therefore not recommended for stopping except for
emergency situations.
26
Operation
Inhibit terminals
Jumper the INHIBIT terminals to coast the motor to a stop (see
Figure 8). Remove the jumper to accelerate the motor to set speed.
501
Q502
Q501
D501
TH501
R503
AC1
AC2
BR+
BR-
T501
C503
SW502
C505
SW501
R501
IC503
C501
IC501
R502
POWER CURR
ON
LIMIT
C504
IL501
IL502
H
IB
INHIBIT
TB501
L1
IN
FAST-ACTING
S O
C502
IT
IC502
L2
S1
S2
S3
F1
F2
A2
A1
Figure 8. Inhibit Terminals
Operation
27
Inhibit plug
Minarik Corporation offers two accessory plug harnesses for use
with the INHIBIT terminals:
Table 3. Inhibit Plug Harness Part Numbers
Minarik
Part Number
Description
201-0024
Inhibit plug with 18 in. (46 cm) wires
201-0079
Inhibit plug with 36 in. (91 cm) wires
Twist inhibit plug wires and separate them from other powercarrying wires or sources of electrical noise. Use shielded cable if
the inhibit plug wires are longer than 12 inches (30 cm). If shielded
cable is used, ground only one end of the shield to earth ground.
Do not ground both ends of the shield. See Wiring, page 11, for
more wiring information.
28
Operation
Decelerate to minimum speed
The circuit shown in Figure 9 may be used to decelerate a motor to
a minimum speed. Closing the switch between S2 and S1
decelerates the motor from set speed to a minimum speed
determined by the MIN SPD trimpot setting. If the MIN SPD trimpot
is set full CCW, the motor decelerates to zero speed when the
switch between S2 and S1 is closed. Calibrate the ACCEL and
DECEL trimpots to control the acceleration and deceleration ramp.
Set the switch to the RUN position to accelerate the motor to set
speed.
CW
S3
10K OHM
SPEED ADJUST
POTENTIOMETER
S2
S1
RUN
DECEL TO
MIN SPEED
Figure 9. Run/Decelerate to Minimum Speed Switch
Operation
29
Dynamic braking
Dynamic braking may be used to rapidly stop a motor (see Figure
10). For the RUN/BRAKE switch, use a two pole, two position
switch rated to handle the motor voltage and current. For the
dynamic brake resistor, use a high power, wirewound resistor
(minimum 40 watts). Table 4 (page 30) lists the minimum
recommended dynamic brake resistor values.
A1
A2
RUN
MOTOR
DYNAMIC BRAKE
RESISTOR
BRAKE
INHIBIT
Figure 10. Dynamic Brake Connection
30
Operation
Sizing the dynamic brake resistor
Sizing the dynamic brake resistor depends on load inertia, motor
voltage, and braking time. Use a lower ohm value, higher wattage,
dynamic brake resistor to stop a motor more rapidly. Refer to Table
4 below for minimum recommended dynamic brake resistor sizes.
Table 4. Minimum recommended
dynamic brake resistor sizes
Motor
Minimum Recommended Dynamic
Voltage (VDC)
Brake Resistor Size (ohms)
90
15
130
22
180
30
240
40
31
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. When possible, disconnect the voltage input from the
drive before adjusting the trimpots. If the trimpots must be
adjusted with power applied, use insulated tools and the
appropriate personal protection equipment. BE ALERT. High
voltages can cause serious or fatal injury.
XLA Series drives have six user-adjustable trimpots: MAX SPD,
MIN SPD, ACCEL, DECEL, IR COMP, and CURR. LIMIT. All
trimpots are factory calibrated (see Figure 13, page 40, for factory
CURR. LIMIT and IR COMP settings).
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 11,
page 32, for trimpot location.
32
Calibration
BR501
Q501
Q502
D501
TH501
B2
R503
AC1
AC2
BR+
BRB1
T501
C503
SW501
115
R501
230
CURRENT LIMIT
C505
SW502
230
MAXIMUM
SPEED
IR
COMPENSATION
115
IC503
IC502
C501
IC501
R502
FAST-ACTING
FUSE ONLY
FU501
MAX SPD
CURR LIMIT
IR COMP
C502
POWER CURR
ON
LIMIT
C504
MIN SPD
ACCEL
INHIBIT
DECEL
IL501
IL502
TB501
L1
L2
S1
MINIMUM
SPEED
S2
S3
F1
F2
ACCELERATION
A2
A1
DECELERATION
Figure 11. Calibration Trimpot Layout
Calibration
33
Calibration procedure
Calibrate the drive using the following procedure:
1.
2.
3.
4.
5.
6.
Set the MIN SPD, MAX SPD, ACCEL and DECEL
trimpots to zero (full CCW).
Set the CURRENT LIMIT trimpot to maximum (full CW).
Set the IR COMP trimpot to midrange (approximate 12
o’clock position).
Set the signal input (analog voltage signal or speed adjust
potentiometer) to zero.
Apply power to the drive.
Calibrate the trimpots as follows:
MINIMUM SPEED (MIN SPD)
The MIN SPD setting determines the motor speed when the speed
adjust potentiometer is turned full CCW. It is factory set for
minimum rated speed.
To calibrate, set the MIN SPD trimpot full CCW. Set the speed
adjust potentiometer or reference signal to zero speed. Adjust the
MIN SPD trimpot until the desired minimum motor speed is
reached.
34
Calibration
MAXIMUM 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. Set the speed
adjust potentiometer or reference signal to maximum. Adjust the
MAX SPD trimpot until the desired maximum motor speed is
reached.
MAX SPD calibration with low voltage DC motors
Using an XLA series drive with a low voltage DC motor requires
that a lower resistance speed adjust potentiometer be used.
Recalibrate the MAX SPD trimpot setting to the positions shown in
Figure 12.
Note: MAX SPD settings are approximate. Verify maximum
armature voltage with a voltmeter.
Calibration
MAXIMUM SPEED TRIMPOT SETTING
MOTOR ARMATURE
VOLTAGE (VDC)
USING 2.5K OHM
SPEED ADJUST
POTENTIOMETER
12
NOT
APPLICABLE
USING 1.5K OHM
SPEED ADJUST
POTENTIOMETER
24
38
48
Figure 12. Low-Voltage DC Motor Calibration Settings
35
36
Calibration
IR COMPENSATION (IR COMP)
The IR COMP trimpot setting determines the degree to which
motor speed is held constant as the motor load changes. It is
factory set for optimum motor regulation. Refer to Figure 13 (page
40) for typical CURR. LIMIT and IR COMP settings.
To calibrate IR COMP (exact calibration):
1. Turn the IR COMP trimpot full CCW.
2. Set the speed adjust potentiometer or reference signal until the
motor runs at midspeed without load (for example, 900 RPM for
an 1800 RPM motor) A hand held tachometer may be used to
measure motor speed.
3. Load the motor armature to its full load armature current rating.
The motor should slow down.
4. While keeping the load on the motor, rotate the IR COMP
trimpot until the motor runs at the speed measured in step 2.
Calibration
37
CURRENT LIMIT (CURR. LIMIT)
Warning
Although CURRENT LIMIT is set to 120% of maximum drive
current rating, continuous operation beyond that rating may
damage the motor. If you intend to operate beyond the
rating, contact your Minarik representative for assistance.
The CURRENT LIMIT setting determines the maximum torque for
accelerating and driving the motor. CURRENT LIMIT is factory set
at 120% of maximum drive current. You must recalibrate the
CURR. LIMIT setting if using a lower current motor. Refer to
Figure 13 (page 40) for typical CURR. LIMIT and IR COMP
settings.
1. With no power applied to the drive, connect a DC
ammeter in series with the motor armature.
2. Set the CURR. LIMIT trimpot to full CCW.
3. Carefully lock the motor armature. Ensure that the motor
is firmly mounted.
4. Apply line power. The motor should be stopped.
5. Set the speed potentiometer or reference signal to
maximum speed. The motor should remain stopped.
6. Slowly rotate the CURR. LIMIT trimpot clockwise (CW)
until the ammeter reads 120% of maximum motor armature
current.
7. Set the speed adjust potentiometer or reference signal to
zero speed.
38
Calibration
8. Remove power from the drive.
9. Remove the lock from the motor shaft.
10. Remove the ammeter in series with the motor armature.
ACCELERATION (ACCEL)
The ACCEL setting determines the time the motor takes
to ramp to a higher speed. See Specifications on page 1 for
approximate acceleration times. ACCEL is factory set for the fastest
acceleration time (full CCW).
To set the acceleration time:
1. Set the speed adjust potentiometer full CCW. The motor
should run at minimum speed.
2. Turn the speed adjust potentiometer full CW and measure
the time it takes the motor to go from minimum to maximum
speed.
3. If the time measured in step 2 is not the desired acceleration
time, turn the ACCEL trimpot CW for a slower acceleration
time, or CCW for a faster acceleration time. Repeat steps 1
through 3 until the acceleration time is correct
Calibration
39
DECELERATION (DECEL)
The DECEL setting determines the time the motor takes to ramp to
a lower speed. See Specifications on page 1 for approximate
deceleration times. DECEL is factory set for the fastest
deceleration time (full CCW).
To set the deceleration time:
1. Set the speed adjust potentiometer full CW. The motor
should run at maximum speed.
2. Turn the speed adjust potentiometer full CCW and measure
the time it takes the motor to go from maximum to minimum
speed.
3. If the time measured in step 2 is not the desired deceleration
time, turn the DECEL trimpot CW for a slower deceleration
time, or CCW for a faster deceleration time. Repeat steps 1
through 3 until the deceleration time is correct.
40
Calibration
XL1100
1/4 HP
90 VDC
1750 RPM
CURR LIMIT IR COMP 2.5 AMPS
1H P
90 VDC
1750 RPM
CURR LIMIT IR COMP 10 AMPS
XL3025A
1/20 HP
90 VDC
1750 RPM
CURR LIMIT IR COMP 0.5 AMPS
CURR LIMIT IR COMP 0.67 AMPS
1/8 HP
180 VDC
1750 RPM
1/8H P
90 VDC
1750 RPM
CURR LIMIT IR COMP 1.3 AMPS
1/4H P
180 VDC
1750 RPM
CURR LIMIT IR COMP 1.4 AMPS
1/4H P
90 VDC
1750 RPM
CURR LIMIT IR COMP 2.5 AMPS
1/3H P
180 VDC
1750 RPM
CURR LIMIT IR COMP 1.75 AMPS
XL3050A
1/8H P
90 VDC
1750 RPM
CURR LIMIT IR COMP 1.3 AMPS
1/4H P
180 VDC
1750 RPM
CURR LIMIT IR COMP 1.4 AMPS
1/4H P
90 VDC
1750 RPM
CURR LIMIT IR COMP 2.5 AMPS
1/2H P
180 VDC
1750 RPM
CURR LIMIT IR COMP 2.5 AMPS
1/2H P
90 VDC
1750 RPM
CURR LIMIT IR COMP 5 AMPS
3/4H P
180 VDC
1750 RPM
CURR LIMIT IR COMP 3.8 AMPS
XL3200A
1/4H P
90 VDC
1750 RPM
CURR LIMIT IR COMP 2.5 AMPS
1/2H P
180 VDC
1750 RPM
CURR LIMIT IR COMP 2.5 AMPS
1/2H P
90 VDC
1750 RPM
CURR LIMIT IR COMP 5 AMPS
1H P
180 VDC
1750 RPM
CURR LIMIT IR COMP 5 AMPS
1H P
90 VDC
1750 RPM
CURR LIMIT IR COMP 10 AMPS
2H P
180 VDC
1750 RPM
CURR LIMIT IR COMP 10 AMPS
Figure 13. Typical CURR. LIMIT and IR COMP settings
(actual settings may vary)
41
Application Notes
Multiple fixed speeds
Replace the speed adjust potentiometer with series resistors with a
total series resistance of 10K ohms (see Figure 14). Add a single
pole, multi-position switch with the correct number of positions for
the desired number of fixed speeds.
R1
S3
R2
S2
R3
S1
TOTAL SERIES
RESISTANCE
10K OHMS
R4
Figure 14. Multiple Fixed Speeds
42
Application Notes
Adjustable speeds using potentiometers in
series
Replace the speed adjust potentiometer with a single pole, multiposition switch, and two or more potentiometers in series, with a
total series resistance of 10K ohms. Figure 15 shows the
connection for two speed control with high and low speed adjust
potentiometers.
CW
S3
HIGH
SPEED
5K
OHM
LOW
SPEED
CW
S2
S1
5K
OHM
Figure 15. Adjustable Speeds Using Potentiometers In Series
Application Notes
43
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 16 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 16. Independent Adjustable Speeds
44
Application Notes
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, two position switch for the RUN/JOG switch, and a
single pole, normally closed, momentary operated pushbutton for
the JOG pushbutton.
RUN/JOG option #1
In the first wiring option (see Figure 17), connect the RUN/JOG
switch and JOG pushbutton to the inhibit plug as shown below. The
motor coasts to a stop when the RUN/JOG switch is set to JOG.
Press the JOG pushbutton to jog the motor. Return the RUN/JOG
switch to RUN for normal operation.
RUN
INHIBIT
JOG
PUSHBUTTON
JOG
Figure 17. RUN/JOG Switch (first wiring option)
Application Notes
45
RUN/JOG option #2
In the second wiring option, connect the RUN/JOG switch and the
JOG pushbutton as shown in Figure 18. When the RUN/JOG
switch is set to JOG, the motor decelerates to minimum speed
(minimum speed is determined by the MIN SPD trimpot setting).
Press the JOG pushbutton to jog the motor. Return the RUN/JOG
switch to RUN for normal operation.
S3
CW
S2
10K OHM
SPEED ADJUST
POTENTIOMETER
S1
RUN
JOG
JOG
PUSHBUTTON
Figure 18. RUN/JOG Switch (second wiring option)
46
Application Notes
Leader-follower application
In this application, use a PCM4 to monitor the speed of the leader
motor(see Figure 19). The PCM4 isolates the leader motor from the
follower drive, and outputs a voltage proportional to the leader
motor’s armature voltage. The follower drive uses this voltage
reference to set the speed of the follower motor. An optional ratio
potentiometer can be used to scale the PCM4 output voltage.
MOTOR
A2
(+) 2
9 (+)
A1
Leader
Drive
8
PCM4
7 (-)
TB501
S2
(-) 1
TB502
S1
10K Ohm
(optional)
Figure 19. Leader-follower application
Follower
Drive
Application Notes
47
Single speed potentiometer control of
multiple drives
You can control multiple drives with a single speed potentiometer
using a PCM4 at the input of each drive (see Figure 20). A PCM4
is used at the input of each drive for isolation. Optional ratio
potentiometers can be used to scale the PCM4 output voltage,
allowing independent control of each drive.
6
10K Ohms
8
2
1
7
TB501
Drive
A
S1
A1
Motor
A
A2
TB502
6
8
S2
PCM4
7
TB501
ratio pot A
(optional)
10K Ohms
2
ratio pot B
(optional)
10K Ohms
A1
S2
PCM4
1
S1
Drive
B
Motor
B
A2
TB502
Figure 20. Single Speed Potentiometer Control of Multiple Drives
48
Application Notes
Reversing
Always use a dynamic brake when reversing the motor direction
(see Figure 21). Use a three pole, three position switch rated for
the DC armature voltage and high 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 29 for
information on sizing the dynamic brake resistor.
A1
A2
DYNAMIC
BRAKE
RESISTOR
MOTOR
FWD
BRAKE
REV
INHIBIT
Figure 21. Reversing Circuit Connection
Application Notes
49
Reversing with a DIGI-LOK controller
A DIGI-LOK® controller, model DLC600, can be used in a
reversing application. The DIGI-LOK must be inhibited while
braking. Without the inhibit feature, the DIGI-LOK will continue to
regulate. This will cause overshoot when the DIGI-LOK is
reengaged with the drive.
Figure 22 shows the reversing circuit connections with an XL
Series drive and DIGI-LOK controller. Note: Only one DLC option
(Optical Encoder or Magnetic Pickup) may be used at a time.
S3
MINARIK
DRIVE
A1
S2
S1
A2
Dynamic
Brake
Resistor
S1
S2
BRAKE
FWD
REV
DLC600
Inhibit
Leads
C
Motor
Common
Optical
Encoder
Signal
+5 VDC
Magnetic
Pickup
Figure 22. Reversing with a DLC600
IN
+
50
Troubleshooting
Warning
Dangerous voltages exist on the drive when it is powered.
When possible, disconnect the drive while troubleshooting.
High voltages can cause serious or fatal injury.
Before troubleshooting
Perform the following steps before starting any procedure in this
section:
1. Disconnect AC line voltage from the drive.
2. Check the drive closely for damaged components.
3. Check that no conductive or other foreign material has become
lodged on the printed circuit board.
4. Verify that every connection is correct and in good condition.
5. Verify that there are no short circuits or grounded connections.
6. Check that the drive’s rated armature outputs are consistent
with the motor ratings.
For additional assistance, contact your local Minarik distributor, or
the factory direct: (800) MINARIK (phone) or (800) 394-6334 (fax).
Troubleshooting
51
Diagnostic LEDs
XLA Series drives are equipped with the following diagnostic LEDs:
POWER ON (IL501)
The green POWER LED lights whenever AC line voltage is applied
to the drive.
CURR LIM (IL502)
The red CURR LIM LED lights whenever the drive reaches current
limit.
IC503
01
R502
POWER ON
(IL501)
MAX SPD
CURR LIMIT
IR COMP
POWER CURR
ON
LIMIT
PD
S3
ACCEL
F1
INHIBIT
DECEL
F2
A2
IL501
IL502
A1
Figure 23. Diagnostic LED Location
CURR LIMIT
(IL502)
52
Troubleshooting
Symptom
Line fuse blows
Line fuse does not
blow, but the motor
does not run
Possible
Causes
Suggested
Solutions
1. Line fuses are
not the correct
size.
1. Check that line
fuses are the
correct size. See
Replacement
Parts section for
the correct fuse
size.
2. Motor cable or
armature shorted
to ground.
2. Check motor
cable and
armature for
shorts.
3. Field circuit is
open.
3. Send drive to
Minarik repair
department.
1. Speed adjust
potentiometer or
input signal is set
to zero speed.
1. Increase the
speed adjust
potentiometer or
voltage setting.
Troubleshooting
53
Symptom
Possible
Causes
Suggested
Solutions
Line fuse does not
blow, but motor does
not run (cont.)
2. Speed adjust
potentiometer or
voltage input
signal not
connected to
drive input
properly;
connections are
open.
2. Check
connections
to input. Verify that
connections are
not open.
3. INHIBIT
terminals are
jumpered.
3. Remove jumper
from INHIBIT
terminals.
4. S2 is shorted to
S0.
4. Remove short.
5. Drive is in current
limit.
5. Check that the
motor is not
jammed. Increase
the CURR. LIMIT
setting if it is set
too low.
6. Drive is not
receiving AC line
voltage.
6. Apply AC line
voltage to L1 and
L2.
54
Troubleshooting
Symptom
Possible
Causes
Suggested
Solutions
Line fuse does not
blow, but motor does
not run (cont.)
7. Motor is not
connected.
7. Connect motor to
A1 and A2.
Motor runs too fast
at maximum speed
setting
1. MIN SPD and
MAX SPD
settings are too
high.
1. Recalibrate MIN
SPD and MAX
SPD.
2. Motor field
connections are
loose (shunt
wound motors
only).
2. Check motor field
connections.
Troubleshooting
55
Symptom
Possible
Causes
Motor runs too slow
or too fast
1. Voltage switches
set incorrectly.
(NOTE: This
does not apply to
XL1100A drives.)
1. Verify all switch
settings.
2. MIN SPD and
MAX SPD not
calibrated.
2. Calibrate MIN
SPD and MAX
SPD.
3. Motor field not
properly
connected (shunt
wound motors
only).
3. Verify motor field
connections.
1. MAX SPD setting
is too low.
1. Increase MAX
SPD setting.
3. IR COMP setting
is too low.
2. Increase the IR
COMP setting.
3. Motor is
overloaded.
3. Check motor load.
Resize the motor
or drive if
necessary.
Motor will not reach
the desired speed
Suggested
Solutions
56
Troubleshooting
Symptom
Motor pulsates or
surges under load
Possible
Causes
Suggested
Solutions
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; calibrate
CURR. LIMIT
trimpot.
Troubleshooting
57
Replacement Parts
Replacement parts are available form Minarik Corporation and its
distributors for this drive series.
Table 5. Replacement Parts
Model No.
XL1100A
Symbol
BR601
C503
D501
Q501, Q502
R501, R502
T501
TH501
FU501
pot kit
Description
KBPC3506 Bridge
1500 mF, 250 VDC Capacitor
16 A, 600 V Diode
IRF640 POWER MOSFET
0.01 ohm, 5 W Resistor
ST-436 Transformer
WS1090 20A Limiter
15A, 3 AB Normal-Blo Fuse
10K ohm, 5 W Potentiometer
Minarik P/N
073-0008
011-0089
071-0055
070-0043
032-0129
230-0071
033-0007
050-0018
202-0003
XL3025A
BR501
C503
D501
Q501
R501, R502
T501
TH501
FU501
pot kit
GBU8J Bridge
470 mF, 400 VDC Capacitor
8 A, 600 V Diode
8 A, 500 V MOSFET
0.05 ohm, 5 W Resistor
3FD-436 Transformer
10 ohm NTC Thermistor
8 A, 3 AB Normal-Blo Fuse
10K ohm, 5 W Potentiometer
073-0006
011-0120
071-0055
070-0075
032-0113
230-0072
033-0005
050-0023
202-0003
XL3050A
BR601
C503
D501
Q501, Q502
R501, R502
T501
TH501
FU501
pot kit
KBPC3506 Bridge
680mF, 400 VDC Capacitor
16 A, 600 V Diode
8 A, 500 V MOSFET
0.05 ohm, 5 W Resistor
3FD-436 Transformer
WS380 15 A Imax Limiter
10 A, 3 AB Normal-Blo Fuse
10K ohm, 5 W Potentiometer
073-0008
011-0080
071-0044
070-0075
032-0113
230-0072
033-0006
050-0024
202-0003
58
Troubleshooting
XL3200A
BR601
C503
D501
Q501, Q502
R501, R502
T501
TH501
FU501
pot kit
KBPC3506 Bridge
1000 mF, 400 VDC Capacitor
MUR1560 Diode
20 A, 500 V MOSFET
0.01 ohm, 5 W Resistor
3FD-436 Transformer
WS1090 20 A Limiter
15 A, 3 AB Normal-Blo Fuse
10K ohm, 5 W Potentiometer
POTENTIOMETER KIT CONTENTS (KIT P/N 202-0003)
1 ea 10K OHM, 5W, 5% TOL. Potentiometer
120-0009
1 ea 3/8-32 X 1/2 NUT
151-0007
1 ea 3/8IN INT TOOTH LOCK WSHR
152-0007
1 ea POT INSULATING WASHER
156-0022
FUSE KIT CONTENTS
1
2
2
2
2
2
1
- 8A FUSE KIT (050-0068)
EA 1 AMP 3AG FAST-ACTING FUSE
EA 1.5 AMP 3AG FAST-ACTING
EA 3 AMP 3AG FAST-ACTING FUSE
EA 5 AMP 3AG FAST-ACTING FUSE
EA 8 AMP 3AG FAST-ACTING FUSE
EA 0.5 AMP PICO FUSE
050-0042
050-0026
050-0021
050-0022
050-0059
050-0074
3
2
2
2
2
1
- 10A FUSE KIT (050-0070)
EA 3 AMP 3AG FAST-ACTING FUSE
EA 5 AMP 3AG FAST-ACTING FUSE
EA 8 AMP 3AG FAST-ACTING FUSE
EA 10 AMP 3AB NORMAL-BLO FUSE
EA 0.5 AMP PICO FUSE
050-0021
050-0022
050-0059
050-0024
050-0074
5
2
2
2
2
1
- 15A FUSE KIT (050-0072)
EA 5 AMP 3AG FAST-ACTING FUSE
EA 8 AMP 3AG FAST-ACTING FUSE
EA 10 AMP 3AB NORMAL-BLO FUSE
EA 15 AMP 3AB NORMAL-BLO FUSE
EA 0.5 AMP PICO FUSE
050-0022
050-0059
050-0024
050-0018
050-0074
073-0008
011-0099
071-0044
070-0066
032-0129
230-0072
033-0007
050-0018
202-0003
59
Certificate of Compliance
Minarik Corporation hereby certifies that its XLA series drives
(models XL3025A, XL3050A, and XL3200A) have been approved
to bear the “CE” mark provided the conditions of approval have
been met by the end user. The XL series has been tested to the
following test specifications:
EN55014:1993 (emissions), and
EN50082-1:1992 (immunity)
Compliance allows Minarik’s XL series to bear the CE mark.
The end user, as described herein, falls into one of two categories:
1. The Consumer will deploy a stand-alone unit as an
integral, yet external, portion of the machine being
operated.
2. The Original Equipment Manufacturer (OEM) will
implement the product as a component of the machine
being manufactured.
60
Certificate of Compliance
AC line filters
In addition to EMI/RFI safeguards inherent in the XLA series’
design, external filtering is required. Minarik requires the AC line
filters listed in Table 6. Use model CE04XL with drives rated for 3
ADC or below, model CE10XL with drives rated for 10 ADC or
below, and model CE15XL for drives rated for 15 ADC or below. If
the end-user is using a CE-approved motor, the correct filter from
Table 6 is all that is necessary to meet the EMC directives listed
herein.
Table 6. Minarik AC Line Filters
Minarik Model Number
CE04XL
CE10XL
CE15XL
Rated Current
Inductance
Capacitance
Line to Line
Line to Ground
Discharge Resistor
4A
17.46 mH
10 A
14.26 mH
15A
10.0 mH
0.811 mF
0.0056 mF
330 K ohms
0.811 mF
0.0056 mF
330 K ohms
0.082 mF
0.0056 mF
330 K ohms
Wire the AC line filter within 10 inches (25 cm) of
the drive as shown in Figure 24 (page 62). The
ground connection from the filter must be wired to
solid earth ground (resistance less than 500 ohms),
not machine ground. This is very important! If the
end-user is using a CE-approved motor, the correct
filter from Table 6 is all that is necessary to meet the CE directives
listed herein.
Certificate of Compliance
61
End User Responsibility
The end user must use the filtration listed in this addendum to
comply with CE. The OEM may choose to provide alternative
filtering that encompasses the Minarik drive and other electronics
within the same panel.The OEM has this liberty because CE is a
machinery directive.
Whether or not every component in the OEM’s machinery
meets CE, the OEM must still submit his machine for CE approval.
Thus, no component must necessarily meet CE within the machine,
as long as the OEM takes the necessary steps to guarantee the
machine does meet CE. By the same token, even if every
component in the OEM’s machine does meet CE, the machine will
not necessarily meet CE as a machine.
Using CE-approved wiring practices, such as proper shielding,
and the filters should assure the drive will meet EN50081 (1993
emissions standard) and EN50082-2 (1995 immunity standard).
62
POWER CURR
ON
LIMIT
C504
INHIBIT
DECEL
IL501
IL502
TB501
XLA SERIES DRIVE
GND
S1
S2
S3
F1
F2
A2
A1
FL501
L1
LOAD 1
EARTH
GROUND
AC1
C501
AC VOLTAGE
CHASSIS
GND
L501
L2
CHASSIS
GND
L1
C502
LINE 2
AC LINE
VOLTAGE
INPUT
AC LINE
VOLTAGE IN
AC VOLTAGE
OUT TO DRIVE
115 VAC
115 VAC
230 VAC
230 VAC
CEXL FILTER
L2
AC VOLTAGE
LOAD 2
AC2
AC VOLTAGE
OUTPUT TO
XLA SERIES DRIVE
(WIRE FILTER WITHIN 10
INCHES [25 CM] OF DRIVE)
Figure 24. CEXL Filter Connection to XLA Series Drive
Certificate of Compliance
C502
63
NOTES
64
NOTES
Unconditional Warranty
A. Warranty
Minarik Corporation (referred to as "the Corporation") warrants that its products will be
free from defects in workmanship and material for twelve (12) months or 3,000 hours,
whichever comes first, from date of manufacture thereof. Within this warranty period, the
Corporation will repair or replace, at its sole discretion, such products that are returned to
Minarik Corporation, 901 East Thompson Avenue, Glendale, CA 91201-2011 USA.
This warranty applies only to standard catalog products, and does not apply to specials.
Any returns for special controls will be evaluated on a case-by-case basis. The
Corporation is not responsible for removal, installation, or any other incidental expenses
incurred in shipping the product to and from the repair point.
B. Disclaimer
The provisions of Paragraph A are the Corporation's sole obligation and exclude all other
warranties of merchantability for use, express or implied. The Corporation further
disclaims any responsibility whatsoever to the customer or to any other person for injury
to the person or damage or loss of property of value caused by any product that has
been subject to misuse, negligence, or accident, or misapplied or modified by
unauthorized persons or improperly installed.
C. Limitations of Liability
In the event of any claim for breach of any of the Corporation's obligations, whether
express or implied, and particularly of any other claim or breech of warranty contained in
Paragraph A, or of any other warranties, express or implied, or claim of liability that
might, despite Paragraph B, be decided against the Corporation by lawful authority, the
Corporation shall under no circumstances be liable for any consequential damages,
losses, or expense arising in connection with the use of, or inability to use, the
Corporation's product for any purpose whatsoever.
An adjustment made under warranty does not void the warranty, nor does it imply an
extension of the original 12-month warranty period. Products serviced and/or parts
replaced on a no-charge basis during the warranty period carry the unexpired portion of
the original warranty only.
If for any reason any of the foregoing provisions shall be ineffective, the Corporation's
liability for damages arising out of its manufacture or sale of equipment, or use thereof,
whether such liability is based on warranty, contract, negligence, strict liability in tort, or
otherwise, shall not in any event exceed the full purchase price of such equipment.
Any action against the Corporation based upon any liability or obligation arising
hereunder or under any law applicable to the sale of equipment or the use thereof, must
be commenced within one year after the cause of such action arises.
Other drives from Minarik Corporation:
DLC600
NRGD Series
MMRGD Series
BOSS Series
901 East Thompson Avenue
Glendale, California 91201-2011
Tel: (800) MINARIK or (800) 646-2745
Fax: (800) 394-6334
www.minarikcorp.com
Document Number 250-0233, Revision 6
Printed in the U.S.A – 4/02
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