Minarik DC Drives - MMRG Series

Minarik DC Drives - MMRG Series
M M RG S E RI ES
USER MANUAL
M MRG30U
M MRG30U-PC M
M MRG31U
M MRG31U-PC M
M MRG40U
M MRG40U-PC M
www.minarikdrives.com
Dear Valued Consumer:
Congratulations on your purchase of the MMRG Series drive.
This User Manual was created for you to get the most out of
your new device and assist with the initial setup. Please visit
www.minarikdrives.com to learn more about our other drives.
Thank you for choosing Minarik Drives!
© 2014 Minarik Drives. All rights reserved.
No part of this document may be reproduced or transmitted in any form without written permission
from Minarik Drives. The information and technical data in this document are subject to change
without notice. Minarik Drives makes no warranty of any kind with respect to this material,
including, but not limited to, the implied warranties of its merchantability and fitness for a given
purpose. Minarik Drives assumes no responsibility for any errors that may appear in this document
and makes no commitment to update or to keep current the information in this document.
MMRG Series
Safety First!
SAFETY WARNINGS

!
WARNING!
Text in gray boxes denote important safety tips or warnings.
Please read these instructions carefully before performing any of
the procedures contained in this manual.
• DO NOT INSTALL, REMOVE, OR REWIRE THIS EQUIPMENT WITH
POWER APPLIED. Have a qualified electrical technician install, adjust
and service this equipment. Follow the National Electrical Code
and all other applicable electrical and safety codes, including the
provisions of the Occupational Safety and Health Act (OSHA), when
installing equipment.
• Reduce the chance of an electrical fire, shock, or explosion by using
proper grounding techniques, over-current protection, thermal
protection, and enclosure. Follow sound maintenance procedures.

!
WARNING!
It is possible for a drive to run at full speed as a result of a
component failure. Minarik Drives strongly recommends the
installation of a master switch in the main power input to stop
the drive in an emergency.
Circuit potentials are at 115 VAC or 230 VAC above earth ground.
Avoid direct contact with the printed circuit board or with circuit
elements to prevent the risk of serious injury or fatality. Use a
non-metallic screwdriver for adjusting the calibration trim pots.
Use approved personal protective equipment and insulated tools
if working on this drive with power applied.
i
MMRG Series
Table of Contents
Section 1. Regenerative Drives............................................. 1
Section 2. Specifications...................................................... 2
Section 3. Dimensions.. ........................................................ 3
Section 4. Installation. . ........................................................ 6
Heat Sinking.................................................................................. 6
Mounting...................................................................................... 7
Speed Adjust Potentiometer. . ................................................. 8
Wiring........................................................................................... 9
Shielding Guidelines.............................................................10
Line Fusing...........................................................................11
Connections.................................................................................12
Power Inputs........................................................................12
Motor.. .................................................................................12
Speed Adjust Potentiometer. . ................................................14
Analog Input Signal (MMRG models). . ....................................15
Analog Input Signal (MMRG-PCM models). . ............................16
+15 and -15..........................................................................17
Direction Switch (MMRG-PCM models)..................................17
Section 5. Operation. . ........................................................ 18
Before Applying Power..................................................................18
Select Switches.............................................................................19
Line Frequency Select (SW501). . ............................................19
Startup.........................................................................................20
Starting and Stopping Methods.....................................................21
Line Starting and Stopping....................................................21
Regenerative Brake to Zero Speed.........................................22
Regenerative Decel to Zero Speed.. ........................................23
Section 6. Calibration........................................................ 24
Maximum Speed (MAX SPD)..........................................................25
Acceleration and Deceleration (ACC-DEC).. .....................................25
ii
MMRG Series
Forward Torque (FORWARD TORQUE). . ...........................................26
Reverse Torque (REVERSE TORQUE).. ..............................................27
Deadband. . ...................................................................................27
IR Compensation (IR COMP)..........................................................28
Section 7.Application Notes................................................ 30
Direction Switch...........................................................................30
Multiple Fixed Speeds...................................................................31
Adjustable Speeds Using Potentiometers In Series . . ........................32
Independent Adjustable Speeds.. ...................................................33
Independent Adjustable Forward and Reverse Speeds....................34
RUN/JOG Switch - Inhibit Connection. . ...........................................35
RUN/JOG Switch - Potentiometer Connection. . ...............................36
Leader-Follower Application..........................................................37
Single Speed Potentiometer Control Of Multiple Drives..................38
Section 8. Troubleshooting. . ............................................... 39
Before Troubleshooting.................................................................39
Section 9. Accessories & Replacement Parts........................ 42
Notes................................................................................ 43
Unconditional Warranty.. .................................................... 44
iii
MMRG Series
List of Tables
Table 1
iv
Recommended Line Fuse Sizes...........................................11
MMRG Series
List of Figures
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Figure
Figure
Figure
Figure
22
23
24
25
15
16
17
18
19
20
21
Four Quadrant Operation................................................... 1
MMRG Dimensions. . ........................................................... 3
MMRG-PCM Dimensions. . ................................................... 4
223-0159 Dimensions......................................................... 5
Speed Adjust Potentiometer............................................... 8
Power and Motor Connections . . .........................................13
Speed Adjust Potentiometer Connections.. .........................14
MMRG Analog Input Signal Connections . . ...........................15
MMRG-PCM Analog Input Signal Connections. . ...................16
+15 and -15 Terminal Locations.........................................17
Line Frequency Switch Location.........................................19
Inhibit Terminal Location...................................................22
Run/Stop Switch...............................................................23
Recommended FORWARD TORQUE, REVERSE TORQUE, and
IR COMP Setting. . ..............................................................29
Forward-Reverse Switch....................................................30
Forward-Stop-Reverse Switch............................................30
Multiple Fixed Speeds.......................................................31
Adjustable Speeds Using Potentiometers in Series..............32
Independent Adjustable Speeds. . .......................................33
Independent Adjustable Forward and Reverse Speeds.. .......34
Independent Adjustable Forward and Reverse Speeds with
Stop.................................................................................34
RUN/JOG Switch - Inhibit Connection ................................35
RUN/JOG Switch - Speed Adjust Potentiometer Connection.. 36
Leader-Follower Application..............................................37
Single Speed Potentiometer Control of Multiple Drives. . .....38
v
MMRG Series
Section 1. Regenerative Drives
Most
non-regenerative,
variable speed, DC drives
control current flow to a
motor in one direction.
The direction of current
flow is the same direction
as the motor rotation.
Non-regenerative drives
operate in Quadrant I,
and also in Quadrant III if
the drive is reversible (see
Figure 1). Motors must stop
before reversing direction.
Unless dynamic braking
is used, non regenerative
drives cannot decelerate a
load faster than coasting to a
lower speed.
Quadrant II
Quadrant I
Quadrant III
Quadrant IV
MOTOR
ROTATION
MOTOR
TORQUE
NOTE: ARROWS IN SAME DIRECTION = MOTOR ACTION
ARROWS IN OPPOSITE DIRECTION = REGENERATIVE ACTION
Regenerative drives operate
in two additional quadrants:
Quadrant II and Quadrant
Figure 1. Four Quadrant Operation
IV. In these quadrants,
motor torque is in the
opposite direction of motor rotation.
This allows regenerative drives to reverse a motor without contractors
or switches, to control an overhauling load, and to decelerate a load
faster than it would to coast to a lower speed.
1
MMRG Series
Section 2. Specifications
Maximum
Armature
Current (ADC)
Armature
Voltage
Range (VDC)
Maximum
Armature
Current (ADC)
HP Range
MMRG31U
MMRG31U-PCM
115
0 - 90
3.0
1/20 - 1/4
MMRG30U
MMRG30U-PCM
115
0 - 90
10.0
1/8 - 1
MMRG40U
MMRG40U-PCM
230
0 -180
10.0
1/4 - 2
Model
* Heat sink kit part number 223-0159 must be used when the continuous
current output is over 5 amps.
AC Line Voltage
115 or 230 VAC ± 10%, 50/60 Hz, single phase
Acceleration & Deceleration Time Range
Analog Input Range
MMRG models (signal must be isolated; S0 to S2)
MMRG-PCM models (NEG to POS)
Input Impedance (S0 to S2)
Form Factor
Load Regulation
Speed Range
Vibration
Ambient Temperature Range
2
0.5 - 6 seconds
0 to ± 10 VDC
0 to ± 10 VDC
30K ohms
1.37 at base speed
1% base speed or better
60:1
0.5G maximum (0 - 50 Hz)
0.1G maximum (> 50 Hz)
10° - 55° C
MMRG Series
Section 3. Dimensions
S3
S0
S1
COMMON
0.99 [25]
C511
C512
DC VOLTAGE
S2
C510
DC VOLTAGE
C503
C509
MMRG
+15V
DC VOLTAGE
-15V
50HZ
T501
1.75 [44]
C507
DC VOLTAGE
3.72 [94]
C505
C508
60HZ
C506
PL1
SW501
C513
PL2
SO501
INHIBIT
C501
P501
P502
P503
P504
P505
C502
ACC-DEC
MAX
SPD
IR COMP REVERSE FORWARD
TORQUE TORQUE
2.87 [73]
1.50 [38]
0.96 [24]
3.80 [97]
4.30 [109]
4.42 [112]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 2. MMRG Dimensions
3
MMRG Series
3.72 [94] 1.75 [44]
T502
FWD SIG ADJ
T501
REV SIG ADJ
S0
COMMON
S3
0.99 [25]
SO501
TB501
DIR
INHIBIT
P501
ACC-DEC
P502
P503
MAX
SPD
IR COMP
P504
REVERSE
TORQUE
FORWARD
TORQUE
POS
DIR
COM
NEG
3.375 [86]
0.96 [24]
3.80 [97]
4.30 [109]
4.42 [112]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 3. MMRG-PCM Dimensions
4
COM
NEG
P505
POS
MMRG Series
6.90 [175]
6.30 [160]
5.90 [150]
0.7 [18]
4.40 [112]
3.00 [76]
1.75 [44]
3.90 [100]
0.125 [3]
1.00 [26]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 4. 223-0159 Dimensions
5
MMRG Series
Section 4. Installation

!
WARNING!
Do not install, rewire, or remove this control with input power
applied. Failure to heed this warning may result in fire, explosion,
or serious injury. Make sure you read and understand the Safety
Precautions on page i before attempting to install this product.
Heat Sinking
Models MMRG30U, MMRG30U-PCM, MMRG40U, and MMRG40U-PCM
require an additional heat sink when the continuous armature current
is above 5 amps. Use Minarik Drives heat sink kit part number 2230159. All other chassis 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 chassis and the
heat sink surface for optimum heat transfer.
6
MMRG Series
Mounting
• Drive components are sensitive to electrostatic discharge. Avoid
direct contact with the circuit board. Hold the drive by the heat sink
only.
• Protect the drive from dirt, moisture, and accidental contact.
• Provide sufficient room for access to the terminals and calibration
trim pots.
• Mount the drive away from heat sources. Operate the drive within
the specified ambient operating temperature range.
• Prevent loose connections by avoiding excessive vibration of the
drive.
• Mount the drive with its board in either a horizontal or vertical
plane. Eight 0.19” (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 should be earth grounded. Use a star washer beneath
the head of at least one of the mounting screws to penetrate the
anodized surface and to reach bare metal.
7
MMRG Series
Speed Adjust Potentiometer

!
WARNING!
Be sure that the potentiometer tabs do not make contact with the
potentiometer’s body. Grounding the input will cause damage to
the drive.
If using a remote potentiometer with a chassis drive, mount the speed
adjust potentiometer through a 0.38 in. (10 mm) hole with the hardware
provided (Figure 5). Install the circular insulating disk between the panel
and the 10K ohm speed adjust potentiometer.
Twist the speed adjust potentiometer wire to avoid picking up unwanted
electrical noise. If the speed adjust potentiometer wires are longer than
18 in. (46 cm), use shielded cable. Keep the speed adjust potentiometer
wires separate from power leads (L1, L2, A1, A2).
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
CW
WIPER
CCW
NUT
STAR
WASHER
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
POT TAB ASSIGNMENTS
PANEL
Figure 5. Speed Adjust Potentiometer
8
MMRG Series
Wiring

!
WARNING!
Do not install, rewire, or remove this control with input power
applied. Failure to heed this warning may result in fire, explosion,
or serious injury.
Circuit potentials are at 115 or 230 VAC above ground. To prevent
the risk of injury or fatality, avoid direct contact with the printed
circuit board or with circuit elements.
Do not disconnect any of the motor leads from the drive unless
power is removed or the drive is disabled. Opening any one
motor lead while the drive is running may destroy the drive.
This product does not have internal solid state motor overload
protection. It does not contain speed-sensitive overload
protection, thermal memory retention or provisions to receive
and act upon signal from remote devices for over temperature
protection. If motor over protection is needed in the end-use
product, it needs to be provided by additional equipment in
accordance with NEC standards.
• Use 18 - 24 AWG wire for logic wiring. Use 14 - 16 AWG wire for
AC line and motor wiring.
9
MMRG Series
Shielding Guidelines

!
WARNING!
Under no circumstances should power and logic level leads be
bundled together. Induced voltage can cause unpredictable
behavior in any electronic device, including motor controls.
As a general rule, Minarik Drives recommends shielding of all conductors.
If it is not practical to shield power conductors, it is recommended
to shield all logic-level leads. If shielding of all logic-level leads is not
practical, the user should twist all logic leads with themselves to
minimize induced noise.
It may be necessary to earth ground the shielded cable. If noise is
produced by devices other than the drive, ground the shield at the drive
end. If noise is generated by a device on the drive, ground the shield at
the end away from the drive. Do not ground both ends of the shield.
If the drive continues to pick up noise after grounding the shield, it may
be necessary to add AC line filtering devices, or to mount the drive in a
less noisy environment.
Logic wires from other input devices, such as motion controllers and PLL
velocity controllers, must be separated from power lines in the same
manner as the logic I/O on this drive.
10
MMRG Series
Line Fusing
Chassis drives should be fused for protection. Use fast acting fuses rated
for 250 VAC or higher and 150% of maximum armature current. Fuse HOT
L1 only when the line voltage is 115 VAC. Fuse both L1 and L2 when the
line fuse is 230 VAC. Table 1 lists the recommended fuse sizes.
Table 1. Recommended Line Fuse Sizes
90 VDC
Motor
Horsepower
180 VDC
Motor
Horsepower
Maximum DC
Armature Current
(amps)
AC Line
Fuse Size
(amps)
1/20
1/15
1/8
1/6
1/10
1/8
1/4
1/3
0.5
0.8
1.5
1.7
1
1.5
3
3
1/4
1/2
2.5
5
1/3
1/2
3/4
1
3/4
1
1 1/2
2
3.5
5.0
7.5
10
8
10
15
15
Minarik Drives offers fuse kits. See Section 9: Accessories and
Replacement Parts for fuse kit part numbers.
11
MMRG Series
Connections

!
Do not connect this equipment with power applied. Failure to
heed this warning may result in fire, explosion, or serious injury.
WARNING!
Minarik Drives strongly recommends the installation of a
master power switch in the voltage input line, as shown in
Figure 6 (page 13). The switch contacts should be rated at a
minimum of 200% of motor nameplate current and 250 volts.
Power Input
Connect the AC line power leads to terminals L1 and L2. Minarik Drives
recommends the use of a single-throw, double-pole master power
switch. The switch should be rated at a minimum of 250 volts and 200%
of motor current. Refer to Figure 6 on page 13.
Motor
Drives supply motor armature voltage from A1 and A2 terminals. It is
assumed throughout this manual that, when A1 is positive with respect
to A2, the motor will rotate clockwise (CW) while looking at the output
shaft protruding from the front of the motor. If the motor does not
spin in the desired direction, remove power and reverse the A1 and A2
connections.
Connect a DC motor to terminals A1 and A2 as shown in Figure 6 on page
13. Ensure that the motor voltage rating is consistent with the drive’s
output voltage.
12
MMRG Series
SCR504
SCR503
SCR502
SCR501
EARTH GND
FU501
T504
T503
SO501
SO502
C504
MOV501
R501
AC VOLTAGE
L1
C508
T501
R502
A1DC VOLTAGE
C502
SO504
AC VOLTAGE
L2
T502
MOTOR
C505
MMRG
*FUSE
C501
SO503
FUSE
C506
C507
GND
C503
EARTH
GROUND
R503
DC VOLTAGE
SCR505
SCR506
SCR507
SCR508
A2
* Add fuse to L2 with 230 VAC input only.
115 VAC
MMRG30U, MMRG30U-PCM
MMRG31U, MMRG31U-PCM
OR
230 VAC
90 VDC MOTOR
MMRG30U, MMRG30U-PCM
MMRG31U, MMRG31U-PCM
OR
180 VDC MOTOR
MMRG40U, MMRG40U-PCM
MMRG40U
Master
Power Switch
Figure 6. Power and Motor Connections
13
MMRG Series
Speed Adjust Potentiometer
Use a 10K ohm, 1/4 W potentiometer for speed control. The motor can
operate in one direction (unidirectional) or two directions (bidirectional)
depending on how the speed adjust potentiometer is connected to the
drive.
For unidirectional operation in the foward direction, connect the speed
adjust potentiometer as shown in Figure 7(a).
For unidirectional operation in the reverse direction, connect the speed
adjust potentiometer as shown in Figure 7(b).
For bidirectional operation, connect the speed adjust potentiometer
as shown in Figure 7(c). The motor does not operate when the
potentiometer is in the center position. Turning the potentiometer
clockwise (CW) from the center position causes the motor to rotate in
the forward direction, while turning the potentiometer counterclockwise
(CCW) causes rotation in the reverse direction.
REVERSE
FORWARD
FORWARD
CW
C512
C510
CW
C509
C509
IC502 IC501
IC502 IC501
S2
C512
S1
S0
C511
COMMON
S3
(a) Unidirectional Forward
C510
(c) Bidirectional
C509
IC502 IC501
(b) Unidirectional Reverse
Figure 7. Speed Adjust Potentiometer Connections
14
S2
C511
S1
REVERSE
S0
C510
COMMON
S3
S2
C512
S1
S0
COMMON
S3
C511
CW
MMRG Series
Analog Input Signal (MMRG models)
Instead of using a speed adjust potentiometer, the drive may be wired to
follow an analog input voltage signal that is isolated from earth ground
(Figure 5). Connect the signal common (–) S0. Connect the signal input
(+) to S2. A potentiometer can be used to scale the analog input voltage.
An interface device, such as Minarik Drives model PCM4, may be used to
scale and isolate an analog input voltage.
An analog input voltage range of -10 to 10 VDC is required to produce
an armature voltage range of -90 to 90 VDC with 115 VAC line voltage or
-180 to 180 VDC with 230 VAC line voltage.
SIGNAL
COMMON (-)
S1
S0
S2
C512
COMMON
S3
C511
SIGNAL
INPUT (+)
C510
C509
IC502 IC501
Figure 8. MMRG Analog Input Signal Connections
15
MMRG Series
Analog Input Signal (MMRG-PCM models)
Instead of using a speed adjust potentiometer, the drive may be wired
to follow an analog input voltage signal that is isolated or non-isolated
(Figure 5). Connect the signal common (–) to terminal COM. Connect the
signal input (+) to terminal POS. A potentiometer can be used to scale the
analog input voltage. Connections can be made to either the spade plug
terminals or to cage clamp terminal TB501.
T501
An analog input voltage range of -10 to 10 VDC is required to produce
an armature voltage range of -90 to 90 VDC with 115 VAC line voltage or
-180 to 180 VDC with 230 VAC line voltage.
DIR SWITCH
T502
OPEN OR CLOSE
TO CHANGE DIRECTION
TB501
DIR
DIR COM NEG POS
FAST-ON TERMINALS
PARALLEL TB501
COM
NEG
POS
POS (+)
NEG (-)
0 to ±10 VDC
VOLTAGE SIGNAL
INPUT
Figure 9. MMRG-PCM Analog Input Signal Connections
16
MMRG Series
+15 and -15

!
WARNING!
Do not short the +15 and -15 terminals for any reason. Shorting
these terminals will damage the drive.
MMRG series drives can supply a regulated +15 and -15 VDC signal
(each sourcing 15 mA maximum) with respect to S0, to isolated, external
devices. See Figure 10 for voltage supply terminal locations.
+15V TERMINAL
S3
S0
S1
COMMON
C511
C512
C510
DC VOLTAGE
S2
DC VOLTAGE
C509
C503
MMRG
+15V
DC VOLTAGE
C505
-15V
DC VOLTAGE
C507
C508
C506
PL1
-15V TERMINAL
Figure 10. +15 and -15 Terminal Locations
Direction Switch (MMRG-PCM models)
A single-pole, single-throw switch can be used as a reversal switch.
Connect the switch to terminals COM and DIR. Close the switch to
reverse the motor. Open the switch to return the motor back to it’s
original direction. Connections can be made to the spade terminals or to
cage clamp terminal TB501. Refer to Figure 9 on page 16.
17
MMRG Series
Section 5. Operation

!
WARNING!
Change voltage switch settings only when the drive is
disconnected from AC line voltage. Make sure both switches are
set to their correct position. If the switches are improperly set
to a lower voltage position, the motor will not run at full voltage
and may cause damage to the transformer. If the switches are
improperly set to a higher voltage position, the motor will
overspeed, which may cause motor damage, or result in bodily
injury or loss of life.
Dangerous voltages exist on the drive when it is powered. BE
ALERT. High voltages can cause serious or fatal injury. For your
safety, use personal protective equipment (PPE) when operating
this drive.
If the motor or drive does not perform as described, disconnect
the AC line voltage immediately. Refer to the Troubleshooting
section, page 39, for further assistance.
Before Applying Power
1. Verify that no foreign conductive material is present on the
printed circuit board.
2.
18
Ensure that all switches are properly set.
MMRG Series
Select Switches
Line Frequency Select (SW501)
Set the line frequency select switch to 60 HZ if the line frequency is 60 Hz
or to 50 HZ if the line frequency is 50 Hz. See Figure
S3
S0
S1
COMMON
C511
C512
DC VOLTAGE
S2
C510
DC VOLTAGE
C503
C509
MMRG
+15V
DC VOLTAGE
C505
-15V
DC VOLTAGE
C507
50HZ
C508
60HZ
T501
SW501
C513
LINE FREQUENCY
SWITCH
PL2
SO501
INHIBIT
C506
PL1
C501
P501
P502
P503
P504
P505
C502
ACC-DEC
MAX
SPD
IR COMP REVERSE FORWARD
TORQUE TORQUE
Figure 11. Line Frequency Switch Location
19
MMRG Series
Startup
1.
Turn the speed adjust potentiometer or input voltage signal to
minimum speed.
2. Apply AC line voltage.
3. Slowly advance the speed adjust potentiometer clockwise
(CW) or increase the input voltage signal. The motor slowly
accelerates as the potentiometer is turned CW or as the input
voltage signal is increased. Continue until the desired speed is
reached.
4.
20
Remove AC line voltage from the drive to coast the motor to a
stop.
MMRG Series
Starting and Stopping Methods

!
WARNING!
Regenerative braking, coasting to a stop, or decelerating to
minimum speed is recommended for frequent starts and stops.
Do not use any of these methods for emergency stopping. They
may not stop a drive that is malfunctioning. Removing AC line
power (both lines) is the only acceptable method for emergency
stopping.
For this reason, Minarik Drives strongly recommends installing
an emergency stop switch on both AC line inputs (see Figure 6
on page 13).
Frequent starting and stopping can produce high torque. This
may cause damage to motors, especially gearmotors that are not
properly sized for the application.
Automatic Restart Upon Power Restoration
All drives automatically run to set speed when power is applied, the
Start/Stop circuitry is closed, and the Run/Brake switch is opened.
Line Starting and Stopping
Line starting and stopping (applying and removing AC line voltage) is
recommended for infrequent starting and stopping of a drive only. When
AC line voltage is applied to the drive, the motor accelerates to the speed
set by the speed adjust potentiometer or analog signal. When AC line
voltage is removed, the motor coasts to a stop.
21
MMRG Series
Regenerative Brake to Zero Speed
Short the INHIBIT terminals to regeneratively brake the motor to zero
speed (see Figure 12). The inhibit bypasses both the MIN SPD trim pot
and the deceleration rate set by the FWD ACC or REV ACC trim pots.
Open the INHIBIT terminals to accelerate the motor to set speed.
Twist inhibit wires and separate them from power-carrying wires or
sources of electrical noise. Use shielded cable if the inhibit wires are
longer than 18 inches (46 cm). If shielded cable is used, ground only one
end of the shield to earth ground. Do not ground both ends of the shield.
Minarik Drives offers two accessory plug harnesses for connecting to
the INHIBIT terminals: part number 201-0024 [plug with 18 in. (46 cm)
leads]; and part number 201-0079 [plug with 36 in. (91 cm) leads].
S3
S0
S1
COMMON
C511
C512
DC VOLTAGE
S2
C510
DC VOLTAGE
C503
C509
MMRG
+15V
DC VOLTAGE
C505
-15V
DC VOLTAGE
C507
50HZ
C508
60HZ
T501
PL2
C513
C501
P502
P503
P504
PL1
SW501
SO501
INHIBIT
P501
C506
P505
INHIBIT
TERMINALS
C502
ACC-DEC
MAX
SPD
IR COMP REVERSE FORWARD
TORQUE TORQUE
Figure 12. Inhibit Terminal Location
22
MMRG Series
Regenerative Decel to Zero Speed
The Run/Stop switch shown in Figure 13 may be used to decelerate a
motor to a stop. Closing the switch between S0 and S2 decelerates the
motor from a set speed to a stop at a deceleration rate determined by
the ACC-DEC trim pot. Set the switch to the Run position to accelerate
the motor to set speed. Figure 13 shows the Run/Stop switch with a
potentiometer wired for bidirectional mode. For other possible wiring
setups, see pages 14 and 30.
CW
RUN
STOP
S1
S0
S2
C512
COMMON
S3
C511
C510
C509
IC502 IC501
Figure 13. Run/Stop Switch
23
MMRG Series
Section 6. Calibration

!
WARNING!
Dangerous voltages exist on the drive when it is powered. When
possible, disconnect the voltage input from the drive before
adjusting the trim pots. If the trim pots must be adjusted with
power applied, use insulated tools and the appropriate personal
protection equipment. BE ALERT. High voltages can cause serious
or fatal injury.
MMRG series drives have user-adjustable trim pots. Each drive is factory
calibrated to its maximum current rating. Readjust the calibration trim
pot settings to accommodate lower current rated motors.
All adjustments increase with CW rotation, and decrease with CCW
rotation. Use a non-metallic screwdriver for calibration. Each trim pot is
identified on the printed circuit board.
24
MMRG Series
Maximum Speed (MAX SPEED)
The MAX SPD setting determines the maximum motor speed when the
speed adjust potentiometer or input voltage signal is set for maximum
speed.
To calibrate MAX SPD:
1.
Set the MAX SPD trim pot full CCW.
2.
Set the speed adjust potentiometer or input voltage signal for
maximum speed.
3. Adjust MAX SPD until the desired maximum speed is reached.
Acceleration and Deceleration (ACC-DEC)
The ACC-DEC trim pot setting determines the time the motor takes
to accelerate to a higher speed or decelerate to a lower speed in the
forward or reverse directions, within the limits of available torque. Turn
the ACC-DEC trim pot CW to increase the acceleration and deceleration
time or CCW to decrease the acceleration and deceleration time. The
ACC-DEC setting is factory set for its fastest forward acceleration and
deceleration rate (full CCW).
25
MMRG Series
Forward Torque (FORWARD TORQUE)

!
WARNING!
FORWARD TORQUE should be set to 120% of motor nameplate
current rating. Continuous operation beyond this rating may
damage the motor. If you intend to operate beyond the rating,
contact your Minarik Drives representative for assistance.
The F0RWARD TORQUE setting determines the maximum torque for
accelerating and driving the motor in the forward direction. To calibrate
FORWARD TORQUE, refer to the recommended FORWARD TORQUE
settings in Figure 14 on page 29 or use the following procedure:
1. With the power disconnected from the drive, connect a DC
ammeter in series with the armature.
2. Set the FORWARD TORQUE trim pot to minimum (full CCW).
3. Set the speed adjust potentiometer full CW or input voltage
signal to maximum speed.
4. Carefully lock the motor armature. Be sure that the motor is
firmly mounted.
5. Apply line power. The motor should be stopped.
6. Slowly adjust the FORWARD TORQUE trim pot CW until the
armature current is 120% of motor rated armature current.
7. Turn the speed adjust potentiometer CCW or decrease the
input voltage signal.
8. Remove line power.
9. Remove the stall from the motor.
10. Remove the ammeter in series with the motor armature if it is
no longer needed.
26
MMRG Series
Reverse Torque (REVERSE TORQUE)

!
WARNING!
REVERSE TORQUE should be set to 120% of motor nameplate
current rating. Continuous operation beyond this rating may
damage the motor. If you intend to operate beyond the rating,
contact your Minarik Drives representative for assistance.
The REVERSE TORQUE setting determines the maximum torque for
accelerating and driving the motor in the reverse direction. To calibrate
REVERSE TORQUE, refer to the recommended REVERSE TORQUE settings
in Figure 14 on page 29 or use the following procedure:
1. With the power disconnected from the drive, connect a DC
ammeter in series with the armature.
2. Set the REVERSE TORQUE trim pot to minimum (full CCW).
3. Set the speed adjust potentiometer full CW or input voltage
signal to maximum speed.
4. Carefully lock the motor armature. Be sure that the motor is
firmly mounted.
5. Apply line power. The motor should be stopped.
6. Slowly adjust the REVERSE TORQUE trim pot CW until the
armature current is 120% of motor rated armature current.
7. Turn the speed adjust potentiometer CCW or decrease the
input voltage signal.
8. Remove line power.
9. Remove the stall from the motor.
10. Remove the ammeter in series with the motor armature if it is
no longer needed.
27
MMRG Series
IR Compensation (IR COMP)
The IR COMP setting determines the degree to which motor speed is held
constant as the motor load changes.
Use the following procedure to recalibrate the IR COMP setting:
1.
Set the IR COMP trim pot to minimum (full CCW).
2. Increase the speed adjust potentiometer or input voltage signal
until the motor runs at midspeed without load (for example,
900 RPM for an 1800 RPM motor). A handheld tachometer may
be used to measure motor speed.
3. Load the motor armature to its full load armature current rating.
The motor should slow down.
4. While keeping the load on the motor, rotate the IR COMP trim
pot until the motor runs at the speed measured in step 2. If
the motor oscillates (overcompensation), the IR COMP trim pot
may be set too high (CW). Turn the IR COMP trim pot CCW to
stabilize the motor.
5. Unload the motor.
See Figure 14 on page 29 for recommended IR COMP settings.
28
MMRG Series
MMRG31U
1 HP
90 VDC
1750 RPM
10 ADC
3/4 HP
90 VDC
1750 RPM
7.6 ADC
1/2 HP
90 VDC
1750 RPM
5 ADC
IR COMP
IR COMP
IR COMP
REVERSE
TORQUE
REVERSE
TORQUE
REVERSE
TORQUE
MMRG30U
FORWARD
TORQUE
FORWARD
TORQUE
1/8 HP
90 VDC
1750 RPM
1.3 ADC
IR COMP
REVERSE
TORQUE
FORWARD
TORQUE
1/15 HP
90 VDC
1750 RPM
0.85 ADC
IR COMP
REVERSE
TORQUE
FORWARD
TORQUE
IR COMP
REVERSE
TORQUE
FORWARD
TORQUE
1/20 HP
90 VDC
1750 RPM
0.56 ADC
FORWARD
TORQUE
MMRG40U
2 HP
180 VDC
1750 RPM
10 ADC
IR COMP
REVERSE
TORQUE
FORWARD
TORQUE
1 HP
180 VDC
1750 RPM
5 ADC
IR COMP
REVERSE
TORQUE
FORWARD
TORQUE
3/4 HP
180 VDC
150 RPM
3.8 ADC
IR COMP
REVERSE
TORQUE
FORWARD
TORQUE
Figure 14. Recommended FORWARD TORQUE, REVERSE TORQUE,
and IR COMP Settings
(actual settings may vary with each application)
29
MMRG Series
Section 7.Application Notes
Direction Switch
For a Forward/Reverse switch, use a single-pole, two-position switch
with a single speed adjust potentiometer to regeneratively reverse the
motor (Figure 15). If a Forward/Stop/Reverse switch is desired, use a
single-pole, three-position switch (Figure 16). The MIN SPD setting is in
effect for either direction.
10K OHM SPEED
POTENTIOMETER
10K OHM SPEED
POTENTIOMETER
CW
REV
CW
FWD
REV
FWD
STOP
S3
S0
S1
COMMON
Figure 15.
Forward-Reverse Switch
30
S3
S0
S1
COMMON
S2
S2
Figure 16.
Forward-Stop-Reverse Switch
MMRG Series
Multiple Fixed Speeds
Replace the speed adjust potentiometer with a series of resistors with a
total series resistance of 10K ohms (Figure 17). Add a single pole, multiposition switch with the correct number of positions for the desired
number of fixed speeds.
R1
S1 or S3
R2
S2
R3
S0
TOTAL SERIES
RESISTANCE
10K OHMS
R4
Figure 17. Multiple Fixed Speeds
31
MMRG Series
Adjustable Speeds Using Potentiometers In Series
Replace the speed adjust potentiometer with a series of resistors with a
total series resistance of 10K ohms (Figure 18). Add a single pole, multiposition switch with the correct number of positions for the desired
number of fixed speeds.
CW
S1
HIGH
SPEED
5K
OHM
LOW
SPEED
CW
S2
S0
5K
OHM
Figure 18. Adjustable Speeds Using Potentiometers In Series
32
MMRG Series
Independent Adjustable Speeds
Replace the speed adjust potentiometer with a single pole, multiposition switch, and two or more potentiometers in parallel, with a total
parallel resistance of 10K ohms. Figure 19 shows the connection of two
independent speed adjust potentiometers that can be mounted at two
separate operating stations.
CW
SPEED 2
20K OHMS
P2
CW
SPEED 1
20K OHMS
P1
SPEED 1
SPEED 2
S3
S0
S1
COMMON
S2
Figure 19. Independent Adjustable Speeds
33
MMRG Series
Independent Adjustable Forward and Reverse 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. Figures 20 and 21 show the connection of two
independent forward and reverse speed adjust potentiometers that can
be mounted at two separate operating stations.
CW
REV
10K OHMS
CW
REV
10K OHMS
CW
FWD
10K OHMS
CW
FWD
10K OHMS
FWD
FWD
STOP
REV
REV
S3
S0
S1
COMMON
S3
S0
S1
COMMON
S2
S2
Figure 20. Independent Adjustable Figure 21. Independent Adjustable
Forward and Reverse Speeds
Forward and Reverse Speeds
with Stop
34
MMRG Series
RUN/JOG Switch - Inhibit Connection
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.
Connect the RUN/JOG switch and JOG pushbutton to the inhibit terminals
as shown in Figure 22. 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
JOG
PUSHBUTTON
JOG
INHIBIT
TERMINALS
Figure 22. RUN/JOG Switch - Inhibit Connection
35
MMRG Series
RUN/JOG Switch - Potentiometer Connection
Connect the RUN/JOG switch and the JOG pushbutton as shown in Figure
23. 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.
S1 or S3
CW
S2
10K OHM
SPEED ADJUST
POTENTIOMETER
SO
RUN
JOG
JOG
PUSHBUTTON
Figure 23. RUN/JOG Switch - Speed Adjust Potentiometer Connection
36
MMRG Series
Leader-Follower Application
In this application, use a PCM4 to monitor the speed of the leader motor
(Figure 24). The PCM4 isolates the leader motor from the follower
drive, and outputs a voltage proportional to the leader motor armature
voltage. The follower drive uses this voltage reference to set the speed of
the follower motor. An optional ratio potentiometer may be used to scale
the PCM4 output voltage.
MOTOR
A2
(+) 2
9 (+)
A1
Leader
Drive
PCM4
8
7 (-)
TB501
S2
(-) 1
TB502
S1
Follower
Drive
10K Ohm
(optional)
Figure 24. Leader-Follower Application
37
MMRG Series
Single Speed Potentiometer Control Of Multiple Drives
Multiple drives can be controlled with a single speed adjust potentiometer
using a USIM-8 at the input of each drive to provide isolation (Figure 25).
Optional ratio potentiometers can be used to scale the USIM-8 output
voltage, allowing independent control of each drive.
10K Ohms
ratio pot A
(optional)
10K Ohms
S3
+
S2
1
5
S1
-
3
+
Drive
A
A1
ratio pot B
(optional)
10K Ohms
A1
2
5
-
3
Motor
A
A2
Drive
B
Motor
B
A2
USIM-8
+
ratio pot H
(optional)
10K Ohms
A1
8
5
-
3
Drive
H
Motor
H
A2
Figure 25. Single Speed Potentiometer Control of Multiple Drives
38
MMRG Series
Section 8. Troubleshooting

!
WARNING!
Dangerous voltages exist on the drive when it is powered. When
possible, disconnect the drive while troubleshooting. High
voltages can cause seroius or fatal injury.
Before Troubleshooting
Perform the following steps before starting any procedure in this
section:
1.
Disconnect AC line voltage from the drive.
2. Check the drive closely for damaged components.
3. Check that no conductive or other foreign material has become
lodged on the printed circuit board.
4. Verify that every connection is correct and in good condition.
5. Verify that there are no short circuits or grounded
connections.
6. Check that the drive’s rated armature is consistent with the
motor ratings.
For additional assistance, contact your local Minarik Drives distributor
or the factory direct:
(800) MINARIK or FAX: (800) 394-6334
39
MMRG Series
PROBLEM
Line fuse
blows.
Line fuse does
not blow, but
the motor does
not run.
40
POSSIBLE CAUSE
SUGGESTED SOLUTIONS
1. Line fuse is the wrong size.
1. Check that the line fuse is
correct for the motor size.
2. Motor cable or armature is
shorted to ground.
2. Check motor cable and
armature for shorts.
3. Nuisance tripping caused by
a combination of ambient
conditions and high-current
spikes (i.e. reversing).
3. Add a blower to cool the
drive components, decrease
FORWARD TORQUE / REVERSE
TORQUE settings, resize
motor and drive for actual
load demand, or check for
incorrectly aligned mechanical
components or “jams”. See
pages 26 or 27 for information
on adjusting the FORWARD
TORQUE / REVERSE TORQUE
trim pot.
1. Speed adjust potentiometer
or input voltage signal is set
to zero speed.
1. Increase the speed adjust
potentiometer setting or input
voltage signal.
2. Inhibit is active.
2. Remove the short from the
inhibit terminals
4. Drive is in current limit.
4. Verify that the motor is not
jammed. Increase FORWARD
TORQUE / REVERSE TORQUE
setting if set too low.
5. Drive is not receiving AC line
voltage.
5. Apply AC line voltage.
6. Motor is not connected.
6. Remove power. Connect the
motor to A1 and A2. Reapply
power.
MMRG Series
PROBLEM
POSSIBLE CAUSE
SUGGESTED SOLUTIONS
Motor does not
stop when the
speed adjust
potentiometer
is full CCW.
1. Noise on logic wires.
1. Place a .01 μF capacitor across
terminals S0 and S2.
Motor runs in
the opposite
direction
1. Motor connections to A1
and A2 are reversed.
1. Remove power. Reverse
connections to A1 and A2.
Reapply power.
Motor runs too
fast.
1. MAX SPD is set too high.
1. Calibrate MAX SPD.
Motor will
not reach the
desired speed.
1. MAX SPD setting is too low.
1. Increase MAX SPD setting.
2. IR COMP setting is too low.
2. Increase IR COMP setting.
3. FORWARD TORQUE /
REVERSE TORQUE setting is
too low.
3. Increase FORWARD TORQUE /
REVERSE TORQUE setting.
4. Motor is overloaded.
4. Check motor load. Resize the
motor and drive if necessary.
1. IR COMP is set too high.
1. Adjust the IR COMP setting
slightly CCW until the motor
speed stabilizes.
2. Motor bouncing in and out
of current limit.
2. Make sure motor is not
undersized for load; adjust
FORWARD TORQUE / REVERSE
TORQUE trim pot CW.
Motor pulsates
or surges under
load.
41
MMRG Series
Section 9. Accessories & Replacement Parts
Displays
Closed Loop................................................................................. DLC600
Open Loop....................................................................................... VT-8
Kits
Potentiometer & Connector
Pot Kit (MMRG models)....................................................... 202-0082
Fuse
1.5 - 5 Amp Fuse Kit............................................................. 050-0066
1 - 8 Amp Fuse Kit with Pico Fuse........................................ 050-0068
3 - 8 Amp Fuse Kit with Pico Fuse........................................ 050-0069
5 - 15 Amp Fuse Kit.............................................................. 050-0071
Logic Cards
Current Sensing
5 Amps..................................................................................... CSC1-5
20 amps................................................................................. CSC1-20
Isolation Cards
Unidirectional, 8 outputs........................................................ USIM-8
42
MMRG Series
Notes
43
MMRG Series
Unconditional Warranty
A. Warranty
Minarik Drives warrants that its products will be free from defects in workmanship and material
for twelve (12) months or 3000 hours, whichever comes first, from date of manufacture thereof.
Within this warranty period, 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, Illinois 61080
USA.
This warranty applies only to standard catalog products, and does not apply to specials. Any
returns of special controls will be evaluated on a case-by-case basis. 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’s sole obligation and exclude all other
warranties of merchantability for use, expressed 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’s obligations, whether expressed
or implied, and particularly of any other claim or breach of warranty contained in Paragraph
A, or of any other warranties, expressed or implied, or claim of liability that might, despite
Paragraph B, be decided against Minarik Drives by lawful authority, Minarik Drives shall under no
circumstances be liable for any consequential damages, losses, or expenses arising in connection
with the use of, or inability to use, Minarik Drives’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, Minarik Drives’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 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.
44
w w w.minarikdrives.com
1430 0 DE LA TOUR DRIV E
SO U TH BELOIT, IL 61080
(800) MINA RIK
250-0240 Rev 7
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