User`s Manual - Minarik Drives

User`s Manual - Minarik Drives
DC-4Q SERIES
DC250-12/24-4Q
DC240-36/48-4Q
PWM REGENERATIVE DC TO DC DRIVES
II
Table of Contents
DC-4Q Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV
Regenerative Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shielding guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Speed adjust potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Logic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Heat Sinking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Contactor Connections (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Startup and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Starting and stopping methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Automatic restart upon power restoration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Enable/Brake/Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
MAXIMUM SPEED (MAX SPD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ACCELERATION (ACCEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DECELERATION (DECEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
IR COMPENSATION (IR COMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MOTOR CURRENT LIMIT (MOTOR CL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
III
REGENERATIVE CURRENT LIMIT (REGEN CL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustable speeds using potentiometers in series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RUN/JOG Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
22
22
23
24
25
25
26
Illustrations
Figure 1. Four Quadrant Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V
Figure 2. DC250-12/24-4Q and DC240-36/48-4Q Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 3. TB501 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 5. Speed Adjust Potentiometer Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 6. Motor and Battery Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 7. Optional Coil Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 8. Optional Contactor Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 9. Open Collector Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 10. Voltage Follower Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 11. Calibration Trimpot Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 12. Approximate MOTOR CL and REGEN CL Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 13. Approximate MOTOR CL and REGEN CL Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 14. Multiple Fixed Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 15. Adjustable Fixed Speeds Using Potentiometers in Series. . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 16. RUN/JOG Switch Connection to Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . 24
IV
DC-4Q Drives
Minarik’s DC-4Q Series drives are four-quadrant regenerative PWM drives for low voltage applications.
These open chassis drives come with the following features:
• PULSE WIDTH MODULATION
Lower form factor than SCR drives (1.01 versus 1.37) throughout the motor speed range.
Motor runs quieter, with greater efficiency and less maintenance.
• FOUR QUADRANT REGENERATIVE OPERATION
See the Regenerative Drives section.
• REGENERATIVE BRAKING
No contactors required. No electromechanical components to overheat or wear out.
• ENABLE / BRAKE / DIRECTION TERMINALS
Choose a function by simply opening or closing a dry contact or through an open collector
transistor.
• STATUS LEDs
Power and Fault LEDs provide a visual status of the drive.
• OVER TEMPERATURE PROTECTION
Drive will fold the output power back to prevent from overheating. Drive will fault if it still
remains too hot.
• MICROPROCESSOR BASED
Allows for factory programming of DC-4Q drives for custom drives designed for OEMs.
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 1, and also in Quadrant 3 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.
Regenerative drives operate in two additional quadrants: Quadrant 2 and Quadrant 4. In these
quadrants, motor torque is in the opposite direction of motor rotation. This allows regenerative drives
to reverse a motor without contactors or switches, to control an overhauling load, and to decelerate a
load faster than it would take to coast to a lower speed.
MOTOR
ROTATION
MOTOR
TORQUE
NOTE: ARROWS IN SAME DIRECTION = MOTOR ACTION
ARROWS IN OPPOSITE DIRECTION = REGENERATIVE ACTION
Figure 1. Four Quadrant Operation
Specifications
MAX ARMATURE
1 MIN. PEAK ARMATURE MAX ARMATURE DC INPUT VOLTAGE
CURRENT (AMPS DC)
CURRENT (AMPS DC)
VOLTAGE (VDC)
RANGE (VDC)
DC250-12/24-4Q
120*
250
12 or 241
10 - 32
DC240-36/48-4Q
100**
240
36 or 481
20 - 62
MODEL
Acceleration Time Range
Deceleration Time Range
Analog Input Voltage Range (Signal Common must be same as battery common)
Input Impedance (S1 to S2)
Speed Regulation
Speed Range
Form Factor
Ambient Operating Temperature Range
Weight
DC250-12/24-4Q
DC240-36/48-4Q
Vibration
* Derate by 15% when mounted horizontally.
** Derate by 20% when mounted horizontally.
1
0 - 100% of Input Voltage.
0.2 - 20 seconds
0.2 - 20 seconds
0 - 5 VDC
520 K
1%
100:1
1.01
0° C - 40° C
2.25 lbs
2.25 lbs
0.5G max (0 - 50 Hz)
0.1G max (>50 Hz)
Dimensions
;=
;=
;=
;=
;=
;=
;=
;=
-/5.4).'3,/43
;=8;=
;=
Figure 2. DC250-12/24-4Q and DC240-36/48-4Q Dimensions
; =
;=
3/,)$#,
56&,4
/6&,4
3(/24#+4
/6%2(%!4
; =
072 &,4#/$%
Installation
Mounting
m
WARNING
Do not install, rewire, or remove this control with input power applied. Doing so may
cause damage or serious injury. Make sure you have read and understood the
Safety Warnings section before attempting installation.
• Drive components are sensitive to electrostatic fields. Avoid contact with the circuit board directly.
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 other heat sources. Operate the drive within the specified ambient operating temperature range.
• Keep 2” of clearance on each side of the drive and 4” of clearance above and below the drive.
• Prevent loose connections by avoiding excessive vibration of the drive.
• Mount drive with its heat sink in a vertical plane. Four 0.19 in. (5 mm) wide slots in the chassis accept #8 pan head screws. If heat sink is mounted horizontally then derate the drive as specified in
Specifications section.
Shielding guidelines
m
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 of 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 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 then 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.
Speed adjust potentiometer
m
WARNING
Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure.
Mount the speed adjust potentiometer through a 0.38 in. (10 mm) hole with the hardware provided
(see Figure 4). 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 speed
adjust potentiometer wires are longer than 18 in. (457 mm), use shielded cable. Keep speed adjust
potentiometer wires separate from power leads (BAT +, BAT -, A1, A2).
Logic Connections
3
3
3
#/-
#/-
$)2%#4)/.
#/-
%.!",%
#/),
"2!+%
#/),
4"
#,/3%&/2&/2 7!2$
#,/3%4/%.!",%
#,/3%4/"2 !+%
#/.4!#4/2#/),OPTIONA L
Figure 3. TB501 Connections
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
CW
WIPER
CCW
NUT
STAR
WASHER
SPEED ADJUST
POTENTIOMETER
POT TAB ASSIGNMENTS
INSULATING DISK
PANEL
Figure 4. Speed Adjust Potentiometer
3
3
#7
3
4"
Figure 5. Speed Adjust Potentiometer Connections
Heat Sinking
DC250-12/24-4Q and DC240-36/48-4Q drives are pre-mounted on a heat sink. For optimum heat
transfer, mount the drive with heat sink fins standing vertically.
Connections
m
WARNING
Do not initially connect this equipment with power applied. Failure to heed this directive
may result in damage or serious injury.
Minarik strongly recommends the installation of a master power switch in the voltage input
line, as shown in Figure 6. The switch contacts should be rated at a minimum of 150-200% of
motor nameplate current and 150% of the input voltage.
Motor
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, or close the direction terminals on TB501.
Connect a DC motor to terminals A1 and A2 as shown in Figure 6. Ensure that the motor voltage rating is consistent with the drive’s output voltage.
Power Input
m
WARNING
This drive is not diode-protected from reverse battery voltage. You must assure that POS (+)
is wired to BAT+ and NEG (-) is wired to BAT-.
Connect the DC power leads to terminals BAT+ and BAT-, or to a single-throw, single-pole master
power switch as shown in Figure 6 (recommended).
Fuse
Wire a power input fuse between the stop switch (if installed) and the BAT+ terminal on the circuit
board. The fuse should be rated at 150% of input voltage and 150 - 200% of maximum motor nameplate current. An example of a fuse we recommend would be Cooper Bussmann AMG-125, AMG-150,
AMG-175, or AMG-200.
!
"!4
"!4
%MERGENCY
3TOP3WITCH
&USE
"!44%290!#+
-/4/2
!
!
Figure 6. Motor and Battery Connections
!
Wiring
m
WARNING
Do not install, remove, or rewire this equipment with power applied. Failure to heed this
warning may result in damage, explosion, or serious injury.
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. Opening
any one motor lead may destroy the drive.
This drive is not diode-protected from reverse battery voltage. You must assure that POS (+)
is wired to BAT+ and NEG(-) is wired to BAT-.
Use 18 AWG wire for speed adjust potentiometer wiring.
Size the DC voltage input and motor wire according to the following chart:
Table 1. Wire Gauge / Length Chart
Maximum Wire Length (feet)
Wire Gauge (AWG)
Armature Current (amps)
8
10
10
10
10
10
14
10
8
6
4
3
0 - 19
20 - 32
60
80
100
120
10
Contactor Connections (Optional)
A contactor may be connected between the battery and the drive as shown in Figure 8. The contactor and precharge circuit allow the drive to be soft charged which helps prevent sparking when the
battery is being connected to the drive. Another advantage of using the contactor is that it serves as
an additional safety device to protect against a run away condition, some cases of reverse polarity
battery connection, and excessive charging voltages.
Once the drive is enabled, the coil output will energize and the contactor will close. The contactor’s
coil voltage must be the same voltage rating as the battery supply to the drive. The COIL+ can source
up to 1 Amp. See Figures 7 and 8 for wiring information. An example of a contactor we recommend
would be White Rogers 586 or 124 type.
Leave COIL+ and COIL- open if a contactor is not used. DO NOT place a jumper across COIL+ and
COIL-, doing so will damage the drive.
#/),
#/),
4"
-AIN#ONTACTOR#OIL
OPTIONAL
Figure 7. Optional Coil Connections
11
0RE#HARGE
"!4
Main Contactor
(optional)
-ASTER3WITCH
&USE
"!44%290!#+
Figure 8. Optional Contactor Connections
12
Operation
m
WARNING
Dangerous voltages exist on the drive when it is powered, and up to 60 seconds after power
is removed and the motor stops. BE ALERT. High current can cause serious or fatal injury.
For your safety, use personal protective equipment (PPE) when operating this drive.
Before applying power
• Verify that no foreign conductive material is present on the printed circuit board.
• Verify battery pack connections to the drive. Check for proper polarity. Incorrect polarity will damage
the drive.
Startup and Shutdown
To start the drive:
1. Turn the speed adjust potentiometer full counter-clockwise (CCW) or set the voltage signal to zero.
2. Open the brake, enable and direction switches.
3. Apply DC power to (BAT +) and (BAT -) then close the enable switch.
4. Slowly advance the speed adjust potentiometer clockwise (CW), or increase the voltage signal.
The motor slowly accelerates as the potentiometer is turned CW or the signal is increased.
Continue until the desired motor voltage is reached.
5. Close the direction switch to change motor direction.
6. Open the ENABLE to coast the motor to a stop. To brake the motor to a stop, close the brake
switch while the drive is powered.
If the motor or drive do not perform as described, disconnect the DC voltage input immediately. Refer
to the Troubleshooting section for further assistance.
13
Starting and stopping methods
m
WARNING
Decelerating to minimum speed, braking or coasting to a stop 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 the DC power to the drive is the only acceptable method for emergency stopping.
Frequent decelerating to minimum speed produces high torque. This may cause damage to motors,
especially gear motors that are not properly sized for the application.
Automatic restart upon power restoration
If the enable switch is closed all drives will automatically run to set speed when power is applied.
Line starting and line stopping
Line starting and line stopping (applying and removing DC voltage input) is recommended for infrequent starting and stopping of a drive only. When DC voltage input is applied to the drive, the motor
accelerates to the speed set by the speed adjust potentiometer. When DC voltage input is removed,
the motor coasts to a stop.
14
Enable/Brake/Direction
Enable
Close the enable to allow the motor to run at the speed set by the speed pot or input signal.
Brake
Close the brake terminals to brake the motor to the speed set by the MIN SPD trimpot. The amount of
time the drive takes to brake the motor to MIN SPD is determined by the DECEL trimpot. The amount
of braking Torque used to stop the motor is set by the REGEN CL trimpot. MIN SPD is typically set to
zero speed.
Direction
Close the direction terminals to change the motor direction.
#/-
#/-
$)2%#4)/.
%.!",%
#/-
"2!+%
Note: In addition to dry contact inputs, the enable, brake and direction function also accept open collector inputs. Rated at 0.5 mA or greater. See Figure 9.
#,/3%4/"2!+%
#,/3%4/%.!",%
#,/3%&/2&/27!2$
Figure 9. Open Collector Input
15
Voltage follower
Instead of using a speed adjust potentiometer, the drive may be wired to follow a 0 - 5 VDC
signal (Figure 10). Connect the signal input (+) to S2. Connect the signal common (-) to S1. Make no
connection to S3. A potentiometer can be used as a voltage divider to scale the analog input voltage.
The analog signal common must be the same common as the battery common connected to BAT-. It
is acceptable to connect the negative side of the battery to Earth ground in some applications.
+
S1
S2
TB501
_
0 - 5 VDC
Figure 10. Voltage Follower Connections
16
Calibration
m
WARNING
Dangerous voltages exist on the drive when it is powered, and up to 60 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 current
can cause serious or fatal injury.
Each drive is factory calibrated to its maximum armature voltage. The DC240-36/48-4Q is factory calibrated
at 170A. The DC250-12/24-4Q is factory calibrated at 200A. Readjust the calibration trimpot settings to accommodate a motor with a lower armature voltage and current rating.
All adjustments increase with clockwise rotation (CW), and decrease with counter-clockwise rotation (CCW).
Use a nonmetallic screwdriver for calibration. Each trimpot is identified on the printed circuit board (see
Figure 11).
)2#/-0
-/4/2#,
2%'%.#,
&7$-!830$ 2%6-!830$
-).30
Figure 11. Calibration Trimpot Layout
$%#%,
!##%,
17
MINIMUM SPEED (MIN SPD)
The MIN SPD setting determines the motor speed when the speed adjust potentiometer is turned full
CCW or when the BRAKE is closed. It is factory set for zero speed.
To Calibrate MIN SPD:
1. Close the BRAKE terminals.
2. Turn the MIN SPD trimpot clock-wise until the desired motor speed is reached (usually zero).
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 MAX SPD:
1. Set the MAX SPD trimpot full CCW.
2. Apply power to the drive and turn the speed adjust potentiometer full CW. If an input voltage signal is used instead of a speed adjust pot, set the input signal to maximum.
3. Adjust the MAX SPD trimpot until the desired maximum motor speed is reached.
ACCELERATION (ACCEL)
The ACCEL setting determines the time the motor takes to accelerate to a higher speed. See
Specifications for approximate accelerating times. The ACCEL setting is factory set to its minimum
value (full CCW).
To Calibrate ACCEL:
1. Set the ACCEL trimpot full CCW.
2. Apply power to the drive and turn the main speed adjust potentiometer full CW. If an input voltage
signal is used instead of a speed adjust pot, set the input signal to maximum. Note the time that
the drive takes to accelerate to the desired speed.
3. Adjust the ACCEL trimpot until the desired acceleration time is reached. Turn the ACCEL trimpot
CW to increase the acceleration time, and CCW to decrease the acceleration time.
18
DECELERATION (DECEL)
The DECEL setting determines the time the motor takes to decelerate to a lower speed. See
Specifications for approximate deceleration times. The DECEL setting is factory set to its minimum
value (full CCW).
To calibrate DECEL:
1. Set the DECEL trimpot full CCW.
2. Apply power to the drive and turn the main speed adjust potentiometer from full CW to full CCW.
If an input voltage signal is used instead of a speed adjust pot, set the input signal from maximum
to minimum. Note the time that the drive takes to decelerate to the desired speed.
3. Adjust the DECEL trimpot until the desired deceleration time is reached. Turn the DECEL trimpot
CW to increase the deceleration time, and CCW to decrease the deceleration time.
IR COMPENSATION (IR COMP)
The IR COMP setting determines the degree to which motor speed is held constant as the motor load
changes. It is factory set for no compensation.
Use the following procedure to recalibrate the IR COMP setting:
1. Set the IR COMP trimpot to minimum (full CCW).
2. Rotate the speed adjust potentiometer 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. If the motor oscillates (overcompensation), the IR COMP trimpot may be
set too high (CW). Turn the IR COMP trimpot CCW to stabilize the motor.
5. Unload the motor.
19
MOTOR CURRENT LIMIT (MOTOR CL)
m
WARNING
MOTOR CURRENT LIMIT should be set to 120% of motor nameplate current rating.
Continuous operation beyond this setting may damage the motor. If you intend to operate
beyond the rating, contact your Minarik representative.
The MOTOR CURRENT LIMIT setting determines the maximum armature current output of the drive.
Recalibrate the MOTOR CL setting when a lower current limit is required. Refer to the MOTOR CL
settings in Figure 12 or 13, or recalibrate using the following procedure:
1. With the power disconnected from the control, connect a DC ammeter in series with the armature.
2. Set the MOTOR CL trimpot to minimum (full CCW).
3. Set the speed adjust potentiometer to maximum (full CW).
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 MOTOR CL trimpot CW slowly until the armature current is 120% of motor rated
armature current.
7. Set the speed adjust potentiometer, or input voltage to minimum.
8. Remove the power from the drive and unlock the motor shaft.
9. Remove the ammeter in series with the motor armature if it is no longer needed and re-apply
power to the drive.
REGENERATIVE CURRENT LIMIT (REGEN CL)
The REGENERATIVE CURRENT LIMIT setting determines the maximum armature current available
for braking. Set the REGEN CL based on the desired amount of braking.
20
DC250-12/24-4Q
1/2 HP
24 VDC
1/2 HP
12 VDC
MOTOR CL
REGEN CL
MOTOR CL
REGEN CL
3/4 HP
24 VDC
3/4 HP
12 VDC
MOTOR CL
REGEN CL
MOTOR CL
REGEN CL
1 HP
24 VDC
1 HP
12 VDC
MOTOR CL
REGEN CL
MOTOR CL
REGEN CL
1 1/2 HP
24 VDC
1 1/2 HP
12 VDC
MOTOR CL
REGEN CL
MOTOR CL
REGEN CL
2 1/2 HP
24 VDC
2 HP
24 VDC
MOTOR CL
REGEN CL
MOTOR CL
REGEN CL
3 HP
24 VDC
MOTOR CL
REGEN CL
Note: The above settings are approximate. Your settings may be
different due to tolerance in the drive and motor along with application
requirements.
Figure 12. Approximate MOTOR CL and REGEN CL Settings
21
DC240-36/48-4Q
1 HP
48 VDC
1 HP
36 VDC
MOTOR CL
REGEN CL
MOTOR CL
REGEN CL
1 1/2 HP
48 VDC
1 1/2 HP
36 VDC
MOTOR CL
REGEN CL
MOTOR CL
REGEN CL
2 HP
48 VDC
2 HP
36 VDC
MOTOR CL
REGEN CL
MOTOR CL
REGEN CL
3 HP
48 VDC
3 HP
36 VDC
MOTOR CL
REGEN CL
MOTOR CL
REGEN CL
4 HP
48 VDC
3 3/4 HP
36 VDC
MOTOR CL
REGEN CL
MOTOR CL
REGEN CL
5 HP
48 VDC
MOTOR CL
REGEN CL
Note: The above settings are approximate. Your settings may be
different due to tolerance in the drive and motor along with application
requirements.
Figure 13. Approximate MOTOR CL and REGEN CL Settings
22
Application Notes
Multiple fixed speeds
Replace the speed adjust potentiometer with series resistors with a total series resistance of
10K ohms (Figure 14). Add a single pole, multiposition switch with the correct number of postions for the desired number of fixed speeds.
S3
TOTAL SERIES
RESISTANCE
10K OHMS
S2
S1
Figure 14. Multiple Fixed Speeds
23
Adjustable speeds using potentiometers in series
Replace the speed adjust potentiometer with a single pole, multi-position switch, and two or more
potentiometers in series, with a total series resistance of 10K ohms. Figure 15 shows a connection for
fixed high and low speed adjust potentiometers.
CW
S3
HIGH
SPEED
5K
OHM
S2
LOW
SPEED
S1
CW
5K
OHM
Figure 15. Adjustable Fixed Speeds Using Potentiometers in Series
24
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
normally closed, momentary operated pushbutton for the JOG pushbutton (see Figure 16). When the
RUN/JOG switch is set to JOG, the motor decelerates to minimum speed. Press the JOG pushbutton
to jog the motor. Return the RUN/JOG switch to RUN for normal operation.
S3
CW
S2
10K OHM
SPEED POT
S1
RUN
JOG
JOG
PUSHBUTTON
Figure 16. RUN/JOG Switch Connection to Speed Adjust Potentiometer
25
Troubleshooting
m
WARNING
Dangerous voltages and currents exist on the drive when it is powered, and up to 60 seconds
after power is removed and the motor stops. When possible, disconnect the drive while
troubleshooting. High current can cause serious or fatal injury.
Before troubleshooting
Perform the following steps before starting any procedure in this section:
1. Disconnect DC voltage input from the drive.
2. Check the drive closely for damaged components.
3. Check that no foreign conductive material has become lodged on the printed circuit board.
4. Verify that all connections are correct and in good condition.
5. Verify that there are no short circuits or grounded connections.
6. Check that the drive’s rated armature voltage and current is consistent with the motor ratings.
7. Verify that input voltage (battery) is within specified range.
For additional assistance, contact your local Minarik distributor.
26
Status LEDs
Power LED
Green LED lights up when power is applied to the drive.
Fault Code LED
Provides a visual representation of the cause of a fault. Faults 2 - 5 require either the Enable or battery
voltage to be cycled in order to clear the fault.
• Solid ON
• 2 Blinks
• 3 Blinks
• 4 Blinks
• 5 Blinks
- Current Limit
- Under Voltage fault1
- Over Voltage fault2
- Short circuit on output
- Over Temperature Fault
Over Temperature current fold back/trip:
If the drive heats up because it is overloaded or it is in an undersized enclosure, the drive will
scale back the current limit in an attempt to lower the temperature. If the temperature isn’t
reduced after a period of time, the drive will trip.
1
Under Voltage fault set at 7.5 VDC for the DC250-12/24-4Q and at 16 VDC for the DC240-36/48-4Q
2
Over Voltage fault set at 30.5 VDC for the DC250-12/24-4Q and at 62 VDC for the DC240-36/48-4Q.
27
Symptom
Possible Causes
Suggested Solutions
Line fuse blows
Line fuses are the wrong size.
Check that line fuses are the correct
size.
Check motor cable and armature for
shorts.
Motor cable or armature is
shorted to ground.
Line fuse does not blow, but
the motor does not run.
Nuisance tripping caused by a
combination of ambient conditions and high-current spikes.
Add a blower to cool the drive components; decrease MOTOR CL settings,
or resize motor and drive for actual load
demand, or check for incorrectly aligned
mechanical components for “jams”. See
the Calibration section for information
on adjusting the MOTOR CL trimpot.
Damaged Drive
Contact Minarik Drives Distributor
Speed adjust pot or reference
voltage is set to zero speed.
Increase speed adjust pot or reference
voltage setting.
MAX SPD pot is set to zero.
Increase MAX SPD pot.
Speed adjust pot or reference
voltage connections are open.
Check that the speed adjust pot or reference voltage connections are not open.
Drive is overloaded.
Verify that the motor is not jammed.
Increase MOTOR CL setting.
Drive is not receiving DC line
voltage.
Apply DC line voltage to
BAT + and BAT -. Confirm power LED is
illuminated.
Motor is not connected.
Connect motor to A1 and A2.
Brake terminals are closed or
ENABLE is open.
Open the BRAKE or close the ENABLE.
28
Symptom
Possible Causes
Suggested Solutions
Motor runs too fast at
maximum speed setting or
minimum speed setting.
MIN SPD and MAX SPD settings are too high.
Recalibrate MIN SPD and MAX SPD.
Battery voltage too low.
Charge batteries.
MAX SPD setting is too low.
Increase MAX SPD setting.
IR COMP setting is too low.
Increase IR COMP setting.
Motor is overloaded.
Check motor load. Resize the motor
and drive if necessary. Check red fault
LED status.
Drive is reaching over temperature trip.
Check motor load. Resize the motor or
enclosure.
IR COMP is set too high.
Adjust the IR COMP setting slightly
CCW until the motor speed stabilizes.
Control is in current limit mode.
Check that motor and drive are of sufficient horsepower and current rating.
Motor will not reach the
desired speed.
Motor pulsates or surges
under load.
29
Minarik Drives
w w w. m i n a r i k d r i v e s . c o m
14300 De La Tour Drive, South Beloit, IL 61080
Phone: (800) MINARIK or (646-2745); Fax: (815) 624-6960
Document Number: 250-0404, Revision 0, Printed in the U.S.A. -- March 2006
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