User Manual - Galco Industrial Electronics

User Manual - Galco Industrial Electronics
User’s Manual
MM501U
SCR, Dual-Voltage, Adjustable Speed
Drive for DC Brush Motors
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. MVD091302
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
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
Specifications
1
Dimensions
2
Installation
3
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Cage-clamp Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Power, fuse and motor connections . . . . . . . . . . . . . . . . . . . . . . .8
Power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Field Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Start/Stop Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Tachogenerator Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Voltage Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Current Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Operation
14
Before applying power: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . .17
Start/Stop Pushbuttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Dynamic Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Calibration
20
Maximum Speed (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Minimum Speed (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
iii
Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
IR Compensation (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Acceleration (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Deceleration (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
TACH VOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Application Notes
30
Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Adjustable speeds using potentiometers in series . . . . . . . . . . . . .31
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Reversing with a DLC600 controller . . . . . . . . . . . . . . . . . . . . . . .34
Troubleshooting
35
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Unconditional Warranty
41inside back cover
Tables
Table 1. Field Ouptut Connections . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 2. Recommended Dynamic Brake Resistor Sizes . . . . . . . . . .18
Table 3. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
iv
Illustrations
Figure 1. MM501U Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Figure 2. Cage-Clamp Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . .5
Figure 3. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . .6
Figure 4. MM501U Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Figure 5. Voltage or Current Signal Connections . . . . . . . . . . . . . . . .13
Figure 6. Diagnostic LED Locations . . . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 7. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . .19
Figure 8. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . .21
Figure 9. CURRENT LIMIT and IR COMP Settings . . . . . . . . . . . . . .25
Figure 10. Feedback Switch (SW503) Location . . . . . . . . . . . . . . . . .28
Figure 11. Tachogenerator Connections . . . . . . . . . . . . . . . . . . . . . .29
Figure 12. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Figure 13. Adjustable Speeds Using Potentiometers in Series . . . . . .31
Figure 14. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . .32
Figure 15. Reversing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 16. Independent Forward and Reverse Speeds . . . . . . . . . . . .34
1
Specifications
Model Number
MM501U
Type
Open Chassis
Line Fuse Rating
40A (Buss Type SC-40 or equivalent)
Field Fuse Rating
3A, fast-acting
Horsepower Range @ 90 VDC Output
1 - 2.5 HP
Horsepower Range @ 180 VDC Output
2 - 5 HP
Maximum Armature Voltage Range @ 115 VAC Input
0 - 90 VDC
Maximum Armature Voltage Range @ 230 VAC Input
0 - 180 VDC
Minimum Speed Adjustment Range @ 115 VAC Input
0 - 60 VDC
Minimum Speed Adjustment Range @ 230 VAC Input
0 - 120 VDC
Maximum Armature Current
25 ADC
Field Voltage @ 115 VAC Input
50 VDC (F1 to L1) or 100 VDC (F1 to F2)
Field Voltage @ 230 VAC Input
100 VDC (F1 to L1) or 200 VDC (F1 to F2)
Form Factor
1.37
Acceleration Time Range (no load)
0 - 90 VDC Armature Voltage
0.5 - 12 seconds
0 - 180 VDC Armature Voltage
0.5 - 12 seconds
Deceleration Time Range (no load)
0 - 90 VDC Armature Voltage
0.5 - 12 seconds
0 - 180 VDC Armature Voltage
0.5 - 12 seconds
Analog Input Voltage Range
(grounded and isolated signal; S1 to S2)
0 - 10 VDC
Speed Adjustment Potentiometer
10Kohm
Approximate Input Impedance
(S1 to S2; voltage signal setting)
100K ohm
Speed Regulation (% of base speed)
Armature Feedback
1% or better
Tachogenerator Feedback
0.1%
Tachogenerator Feedback Voltage Range
7 - 50 VDC per 1000 RPM
Weight
3.8 lb
Ambient Operating Temperature Range *
see notes
Notes:
* 10º - 40ºC when mounted flat (horizontally), or in an enclosure whose volume is between 4 and 6 cubic feet;
10ºC - 50ºC when mounted upright (with heatsink fins vertical) in an enclosure greater than 6 cubic feet.
2
Dimensions
L1
SC
L2
AC1
AC2
SCR502
F1
FU504
T501
TB501
F2
9.80 [249]
D503
SCR
A1
A2
C504
IN
+
+
C
COM
IN
N
C503
OUT
SCR504
C507
IC504
C508
IL501
POWER
IL502
CL
IL503
RUN
C502
R504
R505
K501
C501
R501
7.00 [178]
MAX
D504
MIN
B1
TB502
SCR5
B2
B3
P
S1
ACCEL
S2
S3
DECEL
T1
T2
1.40 [36]
6.30 [160]
6.90 [175]
2.50 [66]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
FOUR (4) MOUNTING SLOTS 0.19 [5] X 0.30 [8] DEEP
Figure 1. MM501U Dimensions
3
Installation
Mounting
Warning
Do not install, rewire, or remove this control with input
power applied. Doing so may cause fire or serious injury.
Make sure you have read and understood the Safety
Warnings on page i before attempting installation.
• 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 drive with its board in either a horizontal or vertical plane
(vertical mounting is preferred; see Figure 1, page 2). Four 0.19
in. (5 mm) wide slots in the chassis accept #8 pan head screws.
Fasten either the large base or the narrow flange of the chassis
to the subplate.
• The chassis must be earth grounded. Use a star washer beneath
the head of at least one of the mounting screws to penetrate the
anodized chassis surface and to reach bare metal.
4
Installation
Fuses
MM501U drives have two 40A line fuses installed in Fuse Holder
501 (FH501). Line fuses are rated for maximum rated horsepower.
Resize line fuses if using a smaller horsepower motor. Size fuses
for approximately 150% of the maximum motor armature current.
One 3A field fuse (FU503) is also installed on the drive. This fuse
does not have to be resized if using a smaller horsepower motor.
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 and the drive is disabled. Opening
any one motor lead may destroy the drive.
• Use 18 AWG wire for speed adjust potentiometer wiring. Use 16
AWG wire for field (F1, F2) wiring. Use 14 AWG wire for AC line
(L1, L2) and motor (A1, A2) wiring.
Installation
Cage-clamp Terminal Block
MM501U drives use a cage-clamp terminal block for terminal
block 502 (TB502). To connect a wire to the cage-clamp terminal
block (see Figure 2), use a small screwdriver to press down on
the lever arm. Insert a wire stripped approximately 0.25 inches (6
mm) into the opening in front of the terminal block. Release the
lever arm to clamp the wire.
Press down on the
lever arm using
a small screwdriver.
1
2
Insert wire into the
wire clamp.
3
Release the lever arm
to clamp the wire.
Figure 2. Cage-Clamp Terminal Block
5
6
Installation
Speed adjust potentiometer
Warning
Be sure that the potentiometer tabs do not make contact with
the potentiometer enclosure. Grounding the input will cause
damage to the drive.
Mount the speed adjust potentiometer through a 0.38 in. (10 mm)
hole with the hardware provided (Figure 3). Install the circular
insulating disk between the panel and the 10K ohm speed adjust
potentiometer.
Twist the speed adjust potentiometer wire to avoid picking up
unwanted electrical noise. If speed adjust potentiometer wires are
longer than 18 in. (457 mm), use shielded cable. Keep speed
adjust potentiometer wires separate from power leads.
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
7
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.
8
Installation
Connections
Warning
Do not connect this equipment with power applied.
Failure to heed this directive may result in fire or serious
injury.
Minarik strongly recommends the installation of a master
power switch in the voltage input line, as shown in
Figure 4, page 10. The switch contacts should be rated at a
minimum of 200% of motor nameplate current and
250 volts.
Power, fuse and motor connections
Connect the power input leads, an external line fuse and a DC
motor to the drive’s printed circuit board (PCB) as shown in Figure
4, page 10.
Installation
9
Power input
Connect the AC line power leads to terminals L1 and L2, or to a
double-throw, single-pole master power switch (recommended).
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 with each other.
Connect a DC motor armature to PCB terminals A1 and A2 as
shown in Figure 4, page 10. Ensure that the motor voltage
rating is consistent with the drive’s output voltage.
10
Installation
TACHOGENERATOR
(OPTIONAL)
VOLTS
NEG (-)
POS (+)
T1
DECEL
T2
P506
10KOHM
SPEED ADJUST
POTENTIOMETER
S2
ACCEL
CW
SIGNAL
CONNECTIONS
B1 B2
MIN
SPD
IC502
IC501
K501
C502
IL501
C501
START
(N.O.)
C508
CL
IL502
POWER
MAX
SPD
RUN
IL503
B3
P505
STOP
(N.C.)
C507
A2
C503
F1
F2
A1
NEG (-)
MOTOR
POWER
CONNECTIONS
L2
FIELD OUTPUT
SHUNT WOUND
MOTORS ONLY
115/230 VAC
INPUT VOLTAGE
L1
TB501
POS (+)
FU504
+
+
C506
IN
+
EMERGENCY
STOP SWITCH
Figure 4. MM501U Connections
Installation
11
Field Output
The field output is for shunt wound motors only. DO NOT make
any connections to the field output when using a permanent
magnet motor. Table 1 lists the field output connections.
Table 1. Field Ouptut 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
Use 18 AWG wire to connect the field output to a shunt wound motor.
Start/Stop Pushbuttons
The drive can be operated with Start/Stop pushbuttons to start and
stop the motor (pushbuttons are not included with the drive). See
Figure 4 (page 10) for connections. Connect a momentary
operated, normally closed STOP pushbutton to B2 and B3.
Connect a momentary operated, normally open START pushbutton
to B2 and B3. If the Start/Stop pushbuttons are not used, jumper
terminal B1 and B3. As an added safety feature, the Start/Stop
pushbutton terminals (B1, B2, and B3) are isolated from earth
ground.
12
Installation
Tachogenerator Feedback
Using tachogenerator feedback will improve speed regulation from
approximately 1% of motor base speed to approximately 0.1% of
motor base speed. Use tachogenerators rated from 7 VDC per
1000 RPM to 50 VDC per 1000 RPM. Connect the tachogenerator
to terminals T1 (-) and T2 (+) of terminal block 502 (TB502). See
Figure 4 (page 10) for tachogenerator feedback connections.
Voltage Signal
Instead of using a speed adjust potentiometer, the drive may be
wired to follow a grounded or ungrounded 0 - 10 VDC signal.
Connect the signal input (+) to S2 and the signal common (-) to S1
(see Figure 5, page 13). Make no connections to S3. NOTE: Set
SW505 to VOLTAGE SIGNAL if the drive is following a voltage
signal.
Current Signal
The MM501U can follow a 4 - 20 mA current signal. Connections
are the same as the voltage follower. Connect the signal input to
S1 and S2 (see Figure 5, page 13). Make no connections to S3.
NOTE: Set SW503 to CURRENT SIGNAL when the drive is follow
a current signal.
T1
DECEL
P506
T2
VOLTAGE
SIGNAL
Installation
MIN
SPD
TB502
P502
S1
-
B3
P505
0 - 10 VDC VOLTAGE SIGNAL
or
4 - 20 mA CURRENT SIGNAL
B1 B2
CURRENT
SIGNAL
S2
ACCEL
S3
+
IC501
K501
IC502
P501
IC505
C506
C507
Figure 5. Voltage or Current Signal Connections
13
14
Operation
Warning
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.
To avoid drive or motor damage, change switch settings only
when the drive is disconnected from the AC line voltage. Make
sure all switches are set to their correct position.
Before applying power
• Verify that no conductive material is present on the printed circuit
board.
• Set SW501 and SW502 to either 115 or 230 to match the AC line
voltage.
• Set SW503 to either TACH for tachogenerator feedback or ARM
for armature feedback.
• Set SW504 to either 90 or 180 to match the motor armature
voltage.
• Set SW505 to either CURRENT SIGNAL or VOLTAGE SIGNAL to
match the input signal being used. If a speed adjust
potentiometer is being used, set the switch to VOLTAGE SIGNAL.
Operation
15
Startup
1. Turn the speed adjust potentiometer full counterclockwise
(CCW). If the drive is following a voltage signal, set the voltage
signal to 0 VDC. If the drive is following a current signal, set the
current signal to minimum.
2. Apply AC line voltage.
3. Slowly advance the speed adjust potentiometer clockwise (CW).
If a voltage or current signal is used, slowly increase the voltage
or current signal. The motor slowly accelerates as the
potentiometer is turned CW, or the voltage or current signal is
increased. Continue until the desired speed is reached.
4. Remove AC line voltage from the drive to coast the motor to a
stop.
16
Operation
Diagnostic LEDs
The MM501U is equipped with the following diagnostic LEDs:
• POWER: Lights whenever AC line voltage is applied to the drive.
• CURRENT LIMIT (CL): Lights whenever the drive reaches
current limit.
• RUN: Lights whenever the motor is rotating.
B3
S1
S2
C503
SCR504
R501
C501
R504
IC502
IL502
IL501
P501
C502
CL
POWER
R505
B1 B2
CURRENT
SIGNAL
TB502
IL503
RUN
P502
D504
Figure 6. Diagnostic LED Locations
K501
SCR505
P503
LIMIT
P504
ACCEL
S3
T1
DECEL
T2
P507
DIAGNOSTIC
LEDs
Operation
17
Line starting and line stopping
Line starting and line stopping (applying and removing AC line
voltage) is recommended for infrequent starting and stopping of a
drive only. When AC line voltage is applied to the drive, the motor
accelerates to the speed set by the speed adjust potentiometer.
When AC line voltage is removed, the motor coasts to a stop.
Start/Stop Pushbuttons.
Start/Stop pushbuttons allow you to accelerate the motor to set
speed, and to decelerate the motor to a stop. See Figure 4, page
10 for connection information.
Dynamic Braking
Dynamic braking may be used to rapidly stop a motor (Figure 7,
page 19). For the RUN/BRAKE switch, use a three-pole, doublethrow switch rated for at least the maximum DC armature voltage
and maximum braking current.
Size the dynamic braking resistor according to the motor current
rating (Table 2, page 18). The dynamic brake resistance listed in
the table is the smallest recommended resistance allowed to
prevent possible demagnetization of the motor. The motor stops
less rapidly with higher brake resistor values.
18
Operation
Table 2. Recommended Dynamic Brake Resistor Sizes
Motor Armature
Current Rating
(ADC)
Less than 2
2-3
3-5
5 - 10
10 - 17
17 - 30
Minimum Dynamic
Brake Resistor
Value (Ohms)
1
5
10
20
40
100
Minimum Dynamic
Brake Resistor
Power (Watts)
1
5
10
20
50
200
For motors rated 1/17 horsepower and less, a dynamic brake resistor
is not necessary since the armature resistance is high enough to stop
the motor without demagnetization. Replace the dynamic brake
resistor with 12 gauge wire.
Operation
MM501U
A1
A2
B1
DYNAMIC BRAKE
RESISTOR
RUN
BRAKE
MOTOR
Figure 7. Dynamic Brake Connection
B3
19
20
Calibration
Warning
Dangerous voltages exist on the drive when it is powered.
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.
The MM501U is factory calibrated with a 2 HP, 180 VDC motor.
Re-adjust the calibration trimpot settings to accommodate motors
with different ratings.
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. See Figure 8,
page 21 for trimmer pot locations on the PCB.
Calibration
4
SCR505
D504
R505
R504
R501
CURRENT LIMIT
IR COMP
TACH VOLTS
P504
P503
09
POWER
CL
RUN
IL501
IL502
IL503
P507
ACCELERATION
C501
DECELERATION
C502
ACCEL
MIN
P502
P501
TB502
B1 B2
P506
P505
MAX
DECEL
CURRENT
SIGNAL
B3
S1
VOLTAGE
SIGNAL
S2
S3
T1
T2
K501
Figure 8. Calibration Trimpot Layout
21
22
Calibration
Maximum Speed (MAX SPD)
The MAX SPD trimpot setting determines the maximum
speed. It is factory set for maximum rated motor speed.
To calibrate MAX SPD:
1. Set the MAX SPD trimpot full CCW.
2. Turn the speed adjust potentiometer full CW.
3. Adjust the MAX SPD trimpot CW until the desired maximum
motor speed is reached.
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 to zero
speed.
To calibrate MIN SPD:
1. Set the MIN SPD trimpot full CCW.
2. Turn the speed adjust potentiometer full CCW.
3. Adjust the MIN SPD trimpot CW until the desired maximum
motor speed is reached.
Calibration
23
Current Limit
Warning
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 representative for assistance.
The CURRENT LIMIT setting determines the maximum armature
output of the drive. It is factory set at 120% of rated motor current.
Re-calibrate the CURRENT LIMIT when using a lower current rated
motor. See Figure 9, page 25 for approximate trimpot settings or
re-calibrate using the following procedures:
1. With the power disconnected from the drive, connect a DC
ammeter in series with the armature.
2. Set the TORQUE trimpot to minimum (full CCW).
3. Set the speed adjust potentiometer to maximum speed (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 TORQUE trimpot CW until the armature
current is 120% of motor rated armature current.
7. Turn the speed adjust potentiometer CCW until the motor stops.
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.
24
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 9 on page 25 for recommended settings or 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 CW 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.
Calibration
5 HP
180 VDC
1750 RPM
24 AMPS
LIMIT
1 1/2 HP
180 VDC
1800 RPM
7 AMPS
LIMIT
3 HP
180 VDC
1750 RPM
13.7 APMS
1 HP
90 VDC
10 AMPS
2 HP
180 VDC
1750 RPM
9.2 AMPS
Figure 9. CURRENT LIMIT and IR COMP Settings
25
26
Calibration
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. The ACCEL setting is factory set to its
minimum value (full CCW).
Turn the ACCEL trimpot CW to increase the acceleration time, and
CCW to decrease the acceleration time.
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. The DECEL setting is factory set to its
minimum value (full CCW).
Turn the DECEL trimpot CW to increase the deceleration time, and
CCW to decrease the deceleration time.
Calibration
27
TACH VOLTS
Warning
Calibrate the TACH VOLTS setting only when a tachogenerator
is used.
The TACH VOLTS setting, like the IR COMP setting, determines
the degree to which motor speed is held constant as the motor
load changes. To calibrate the TACH VOLTS trimpot:
1. Connect the tachogenerator to T1 and T2. The polarity is
positive (+) for T1 and negative (-) for T2 when the motor is
running in the forward direction.
2. Set switch 503 (SW503) to ARM for armature feedback.
3. Set the speed adjust potentiometer full CW. Measure the
armature voltage across A1 and A2 using a voltmeter.
4. Set the speed adjust potentiometer to 0 (zero speed).
5. Set SW503 to TACH for tachogenerator feedback.
6. Set the IR COMP trimpot to full CCW.
7. Set the TACH VOLTS trimpot to full CW.
8. Set the speed adjust potentiometer to full CW.
9. Adjust the TACH VOLTS trimpot until the armature voltage is
the same value as the voltage measured in step 3.
Check that the TACH VOLTS is properly calibrated. The motor
should run at the same set speed when SW503 is set to either
armature or tachogenerator feedback.
2
+
C503
+
C509
K501
C502
IL502
IL501
C501
CL
R504
POWER
R501
IN
R505
COM
C504
SCR504
P502
C506
Figure 10. Feedback Switch (SW503) Location
B3
S1
S2
ACCEL
P504
CURRENT
SIGNAL
LIMIT
P503
S3
T1
DECEL
P507
T2
P5
B1 B2
RUN
SCR505
28
Calibration
SW503
FEEDBACK
SWITCH
D504
P501
C507
Calibration
TACH-GENERATOR
(optional)
NEG (-)
POS (+)
P502
S1
B3
B1 B2
LIMIT
CURRENT
SIGNAL
S2
ACCEL
S3
T1
DECEL
T2
P5
K501
C509
C501
IL501
C502
IL502
P501
C507
C503
COM
+
C506
Figure 11. Tachogenerator Connections
29
30
Application Notes
Multiple Fixed Speeds
Replace the speed adjust potentiometer with series resistors with a
total series resistance of 10K ohms (Figure 12). 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 12. Multiple Fixed Speeds
Application Notes
31
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 13 shows a connection
for fixed high and low speed adjust potentiometers.
CW
S3
HIGH
SPEED
5K
OHM
LOW
SPEED
CW
S2
S1
5K
OHM
Figure 13. Adjustable Speeds Using Potentiometers in Series
32
Application Notes
Independent adjustable speeds
Replace the speed adjust potentiometer with a single-pole, multiposition switch, and two or more potentiometers in parallel
resistance of 10K ohms. Figure 14 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 14. Independent Adjustable Speeds
Application Notes
33
Reversing
To reverse motor direction, use a dynamic brake and a three-pole,
three-position switch rated for at least the maximum DC armature
voltage and maximum braking current. See Figure 15 for
connections. Wait for the motor to stop completely before
switching it to either the forward or reverse direction. See the
Dynamic Braking section on page 17 for sizing the dynamic brake
resistor.
MM501U
A1
A2
B1
B3
DYNAMIC BRAKE
RESISTOR
BRAKE
FWD
MOTOR
Figure 15. Reversing Circuit
REV
34
Application Notes
Reversing with a DLC600 controller
A DLC600 controller, can be used in a reversing application. The
DLC600 must be inhibited while braking. Without the inhibit
feature, the DLC600 will continue to regulate. This will cause
overshoot when the DLC600 is switched back to the drive.
Figure 16 show the connection of the reversing circuit to an
MM501U drive and a DLC600. Note: Only one DLC option
(Optical Encoder or Magnetic Pickup) may be used simultaneously.
S3
MINARIK
DRIVE
A1
S2
S1
A2
Dynamic
Brake
Resistor
S1
S2
BRAKE
FWD
REV
DLC600
Inhibit
Leads
C
IN
+
Motor
Common
Optical
Encoder
Signal
+5 VDC
Magnetic
Pickup
Figure 16. Independent Forward and Reverse Speeds
35
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 wire chips 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 voltage selection switch settings match the AC
line voltage.
For additional assistance, contact your local Minarik distributor, or
the factory direct: 1-800-MINARIK (646-2745) or
Fax: 1-800-394-6334
36
Troubleshooting
Problem
Possible
Causes
Suggested
Solutions
Line fuse blows.
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 CURRENT
LIMIT setting, or
resize motor and
drive for actual load
demand. Check for
incorrectly aligned
mechanical
components or
“jams”.
Troubleshooting
37
Problem
Possible
Causes
Suggested
Solutions
Line fuse does not blow,
but the motor does not
run.
1. Speed adjust
potentiometer or
reference voltage is
set to zero speed.
1. Increase the speed
adjust potentiometer
setting or reference
voltage.
2. Speed adjust
potentiometer or
reference voltage is
not connected to
drive input properly;
connections are
open.
2. Check connections to
input. Verify that
connections are not
open.
3. The drive is not
receiving AC line
voltage.
3. Verify that the drive
is receiving AC line
voltage. The green
POWER LED should
be lit when AC line
voltage is applied.
4. Drive is in current
limit. The red
CURRENT LIMIT
LED must be off.
4. If the red CURRENT
LIMIT LED is on,
verify that the motor
is not jammed. It
may be necessary to
increase the
CURRENT LIMIT
trimpot setting.
38
Troubleshooting
Problem
Possible
Causes
Suggested
Solutions
Motor runs too fast.
1. MAX SPD not
calibrated.
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. Motor is overloaded.
3. 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
CURRENT LIMIT
trimpot CW.
Motor pulsates or
surges under load.
Troubleshooting
39
Replacement Parts
Replacement parts are available form Minarik Corporation and its
distributors for this drive series.
Table 3. Replacement Parts
Model No.
MM501U
Symbol
D501,502
D503,504
IC505
IC506
R501
SCR501-505
T501
FU501,502
FU503
Description
3A, 800V Diode
1.5A, 600V PIV Diode
IS0122P IC
4N35 Opto-Coupler
.002 OHM, 13W Resistor
800V, 65A SCR
3FD-436 Transformer
40A Fuse
3A, Fast-Acting Fuse
Heat Sink
10 Kohm Potentiometer Kit
Minarik P/N
071-0003
071-0012
060-0106
060-0101
032-0133
072-0059
230-0072
050-0060
050-0021
223-0294
202-0003
40
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 912012011 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.
901 E Thompson Avenue
Glendale, CA 91201-2011
Tel.: 1-800-MINARIK (646-2745)
Fax: 1-800-394-6334
www.minarikcorp.com
Document number 250-0215, Revision 2
Printed in the U.S.A – September 2002
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