User’s Manual 250-0089r3_readers_spreads.qxd 7/3/01 10:47 AM Page a MM20000 Series Models: MM21000A MM21001A MM21010A MM21011A MM22000A MM22001A MM22011A SCR, Adjustable Speed Drives for DC Brush Motors 250-0089r3_readers_spreads.qxd 7/3/01 10:47 AM Page b Copyright © 2001 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. Printed in the United States of America. 250-0089r3_readers_spreads.qxd 7/3/01 10:47 AM Page i i Safety Warnings This symbol� denotes an important safety tip or warning. Please read these instructions carefully before performing any of the procedures contained in this manual. DO NOT INSTALL, REMOVE, OR REWIRE THIS EQUIPMENT WITH POWER APPLIED. Have a qualified electrical 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. 250-0089r3_readers_spreads.qxd 7/3/01 10:47 AM Page ii ii Contents Specifications 1 Dimensions 2 Installation 4 Mounting ..............................................4 Wiring .................................................5 Shielding guidelines ....................................6 Speed adjust potentiometer connections .......................7 Heat sinking ............................................8 Line fusing .............................................8 Connections ............................................9 Motor connections .....................................9 Power connections ...................................10 Line fuse connections .................................10 Field output connections ................................10 Voltage follower connection .............................13 Operation 14 Before applying power ...................................14 Drive startup and shutdown ...............................14 To shut downthe drive: ................................15 Reversing ..........................................15 Starting and Stopping Methods .............................15 Line starting and stopping ..............................16 Decelerating to minimum speed ..........................16 Coast to minimum speed using INHIBIT terminals ............17 Dynamic braking ......................................18 Calibration 20 Calibration procedure ....................................22 MINIMUM SPEED (MIN SPD) ...........................22 MAXIMUM SPEED (MAX SPD) ..........................23 250-0089r3_readers_spreads.qxd 7/3/01 10:47 AM Page iii Contents iii ACCELERATION (ACCEL) .............................23 DECELERATION (DECEL) .............................24 REGULATION (IR COMP) ..............................25 TORQUE LIMIT (TORQUE) .............................26 Application Notes 28 FWD-STOP-REV switch ..................................28 Reversing with dynamic braking ............................29 Reversing with a DLC600 .................................30 Independent adjustable speeds ............................31 Adjustable speeds using potentiometers in series ...............32 Multiple fixed speeds ....................................33 RUN/JOG switch .......................................34 Leader-follower application ................................35 Single speed potentiometer control of multiple drives ............36 Troubleshooting 37 Before troubleshooting ...................................37 Replacement Parts ......................................41 Certificate of Compliance 43 Exhibit“A” ............................................44 Unconditional Warranty inside back cover 250-0089r3_readers_spreads.qxd 7/3/01 10:47 AM Page iv iv Illustrations Figure 1. Dimensions ........................................2 Figure 2. 223-0159 Heat Sink Dimensions .........................3 Figure 3. Speed Adjust Potentiometer Installation ...................7 Figure 4. Power, Fuse and Motor Connections ....................12 Figure 5. Voltage Follower Connections ..........................13 Figure 6. Run / Decelerate to Minimum Speed Switch ...............16 Figure 7. RUN / Coast to Minimum Speed Switch ..................17 Figure 8. Dynamic Brake Connection ...........................19 Figure 9. Calibration Trimpot Layout ............................21 Figure 10. Typical IR COMP and TORQUE Settings .................27 Figure11. FWD-STOP-REV Switch..............................28 Figure 12. Reversing Circuit Connection ..........................29 Figure 13. Reversing with a DLC600 .............................30 Figure 14. Independent Adjustable Speeds .......................31 Figure 15. Adjustable Fixed Speeds Using Potentiometers in Series .....32 Figure 16. Multiple Fixed Speeds ...............................33 Figure 17. RUN/JOG Switch Connection to Speed Adjust Potentiometer . .34 Figure 18. Leader-Follower Application ...........................35 Figure 19. Single Speed Potentiometer Control of Multiple Drives .......36 250-0089r3_readers_spreads.qxd 7/3/01 10:47 AM Page v v Tables Table 1. Replacement Line Fuse Sizes ..........................8 Table 2. Field Output Connections ............................11 Table 3. Recommended Dynamic Brake Resistor Sizes ............18 Table4. Replacement Parts .................................41 Table 5. Corcom Filters .....................................44 Table6. Minarik Filters .....................................45 250-0089r3_readers_spreads.qxd 7/3/01 10:47 AM Page vi vi MM20000 Series Numbering System 250-0089r3_readers_spreads.qxd 7/3/01 10:47 AM Page 1 1 Specifications Max. Max. Input Input Armature Voltage Current Current HP Model (AC) (Amps AC) (Amps DC) Range Style MM21000A 115 3 5* 1/8 – 1/2* Chassis MM21001A 115 3 5* 1/8 – 1/2* Chassis MM21010A 115 3 1.5 1/20 – 1/8 Chassis MM21011A 115 3 1.5 1/20 – 1/8 Chassis MM22000A 230 3 5** 1/4 – 1** Chassis MM22001A 230 3 5** 1/4 – 1** Chassis *Max HP = 1 and max armature current = 10A if mounted on 223-0159 heat sink. **Max HP = 2 and max armature current = 10A if mounted on 223-0159 heat sink. AC Line Voltage Tolerance ±10%, 50/60 Hz, single phase Armature Voltage 115 VAC line voltage 0 – 90 VDC 230 VAC line voltage 0 – 180 VDC Field Voltage (1 ADC max) 50 – 100 VDC Maximum Output Field Current 1 ADC Form Factor 1.37 at base speed Accel. Time Range 0.5 – 11 seconds Decel. Time Range coast to a stop – 13 seconds Analog Input Voltage Range (signal must be isolated; S1 to S2) 0–90VDC Motors 0–1.4 VDC 0 – 180 VDC Motors 0 – 2.8 VDC Input Impedance (S1 to S2) 100K ohms Load Regulation 1% base speed or better Vibration 0.5G max (0 – 50 Hz) 0.1G max (>50 Hz) Ambient Temp. Range 10°C – 55°C 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 2 2 Dimensions Figure 1. Dimensions 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 3 Dimensions 3 ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 2. 223-0159 Heat Sink Dimensions 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 4 4 Installation Mounting Warning � Do not install, rewire, or remove this control with power applied. Doing so may cause fire or serious injury. Make sure you have read and understood the Safety Warnings on page i before attempting installation. The chassis must be earth grounded. Use a star washer beneath the head of at least one of the mounting screws to penetrate the anodized chassis surface and to reach bare metal. Drive components are sensitive to electrostatic fields. Avoid direct contact with the circuit board. Hold drive by the chassis only. Protect the drive from dirt, moisture, and accidental contact. Provide sufficient room for access to the terminal block and calibration trimpots. Mount the drive away from heat sources. Operate the drive within the specified ambient operating temperature range. Prevent loose connections by avoiding excessive vibration of the drive. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 5 Installation 5 Wiring Warning � Do not install, remove, or rewire this equipment with power applied. Failure to heed this warning may result in � fire, explosion, or serious injury. Circuit potentials are at 115 or 230 VAC above ground. To prevent the risk of injury or fatality, avoid direct contact with the printed circuit board or with circuit elements. Do not disconnect any of the motor leads from the drive unless power is removed or the drive is disabled. Opening any one motor lead may destroy the drive. Use 18–24 AWG wire for speed adjust potentiometer wiring. Use 14–16 AWG wire for AC line (L1, L2), field (F1, F2) and motor (A1, A2) wiring. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 6 6 Installation Shielding guidelines Warning � Under no circumstances should power and logic leads be bundled together. Induced voltage can cause unpredictable behavior in any electronic device, including motor controls. As a general rule, Minarik recommends shielding of all conductors. If it is not practical to shield power conductors, Minarik recommends shielding all logic-level leads. If shielding 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. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 7 Installation 7 Speed adjust potentiometer connections Warning � Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure. Grounding the input will cause damage to the drive. Install the circular insulating disk between the mounting panel and the 10K ohm speed adjust potentiometer (see Figure 3). Mount the speed adjust potentiometer through a 0.38-inch (10 mm) hole with the hardware provided. Twist the speed adjust potentiometer wires to avoid picking up unwanted electrical noise. Figure 3. Speed Adjust Potentiometer Installation 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 8 8 Installation Heat sinking MM20000-series drives require an additional heat sink, p/n 223-0159, when the continuous armature current is above 5 ADC. Apply a thermally conductive heat sink compound (such as Dow Corning® 340 Heat Sink Compound) between the drive chassis and heat sink surface for optimum heat transfer. Line fusing Minarik drives require an external fuse for protection. Use fast acting fuses rated for 250 VAC or higher. Table 1 lists the recommended line fuse sizes. Table 1. Replacement Line Fuse Sizes 90 VDC Motor 180 VDC Max. DC Armature AC Line Fuse Horsepower Horsepower Current (amps) Size (amps) 1/20 1/10 0.5 1 1/15 1/8 0.8 1.5 1/8 1/4 1.5 3 1/6 1/3 1.7 3 1/4 1/2 2.6 5 1/3 3/4 3.5 8 1/2 1 5.0 10 3/4 1 1/2 7.6 15 1 2 10 15 Minarik Corporation offers two fuse kits: part number 050–0066 (1–5A Fuse Kit) and 050–0071 (5–15A Fuse Kit). See Replacement Parts (page 41) for fuse kit contents. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 9 Installation 9 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. The switch contacts must be rated at a minimum of 200% of motor nameplate current and 250 volts. Connect the power input leads, field output, external line fuse(s) and DC motor to the drive’s printed circuit board (PCB) as shown in Figure 4 (page 12). Motor connections Minarik drives supply motor voltage from A1 and A2 terminals. It is assumed throughout this manual that, when A1 is positive with respect to A2 , the motor will rotate clockwise (CW) while looking at the output shaft protruding from the front of the motor. If this is opposite of the desired rotation, simply reverse the wiring of A1 and A2 with each other. Connect a DC motor to PCB terminals A1 and A2 as shown in Figure 4 (page 12). Ensure that the motor voltage rating is consistent with the drive’s output voltage. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 10 10 Installation Power connections Connect the AC line power leads to terminals L1 and L2, or to a double-throw, single-pole master power switch as shown in Figure 4 on page 12 (recommended). Line fuse connections Wire an external line fuse between the stop switch (if installed) and the L1 terminal as shown in Figure 4 on page 12. An additional line fuse should be installed on L2 if the input voltage is 230 VAC. The line fuse(s) should be rated at 250 volts and 150 - 200% of maximum motor nameplate current. Refer to the line fuse chart on page 9 for fuse ratings. Field output connections Warning � The field output is for shunt wound motors only. Do not make any connections to F1 and F2 when using a permanent magnet motor. Use 18 AWG wire to connect the field output to a shunt wound motor as shown in Figure 4 on page 12. See Table 2 for alternate field output connections. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 11 Installation 11 Table 2. Field Output Connections Line Voltage Approximate Connec Motor (VAC) Field Voltage (VDC) Field To 115 50 F1 and L1 115 100 F1 and F2 230 100 F1 and L1 230 200 F1 and F2 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 12 12 Installation NOTES: 1. DO NOT CONNECT FIELD OUTPUT IF USING A PERMANENT-MAGNET MOTOR. REFER TO TABLE 2 (PAGE 11) FOR ALTERNATE FIELD CONNECTIONS. 2. DO NOT ADD A LINE FUSE TO L2 UNLESS LINE VOLTAGE IS 230 VAC. Figure 4. Power, Fuse and Motor Connections 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 13 Installation 13 Voltage follower connection 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 reference (+) to S2. Connect the signal common (–) to S1. Make no connection to S3. A potentiometer can be used to scale the analog input voltage. An interface device, such as Minarik model PCM4, may be used to scale and isolate an analog input voltage. With either 115 VAC or 230 VAC line voltage, an analog input voltage range of approximately 0–1.4 VDC is required to produce an armature voltage range of 0–90 VDC. With 230 VAC line voltage, an analog input voltage range of approximately 0–2.8 VDC is required to produce an armature voltage range of 0–180 VDC. Figure 5. Voltage Follower Connections 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 14 14 Operation Warning � Dangerous voltages exist on the drive when it is powered. BE ALERT. High voltages can cause serious or fatal injury. Before applying power Verify that no conductive material is present on the printed circuit board. Verify that the AC supply is properly balanced. Drive startup and shutdown 1. Set the reference signal or speed adjust potentiometer to minimum speed. 2. Apply AC line voltage. 3. Slowly turn the speed adjust potentiometer or increase the reference voltage until the desired speed is reached. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 15 Operation 15 To shut down the drive: To decelerate the motor from set speed to a stop, set the speed adjust potentiometer to zero speed. To coast the motor from set speed to a stop, remove AC line voltage from the drive. Reversing Refer to Application Notes (page 28) for reversing options, or contact your Minarik sales representative. Starting and Stopping Methods Warning � For frequent starts and stops, use inhibit mode, or decelerating to a stop (shorting S2 to S1). Do not use any of these methods for emergency stopping. They may not stop a drive that is malfunctioning. Removing AC line power (both L1 and L2) is the only acceptable method for emergency stopping. Minarik strongly recommends the installation of an emergency stop switch for chassis drives. The switch contacts should be rated at a minimum of 250 volts and 200% of maximum motor current. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 16 16 Operation Line starting and stopping When AC line voltage is applied to the drive, the motor accelerates to the set speed. When AC line voltage is removed, the motor coasts to a stop. Line stopping (removing AC line voltage) is recommended for stopping in emergency situations only. It is not recommended for frequent starting and stopping. Decelerating to minimum speed The switch shown in Figure 6 may be used to decelerate a motor to a minimum speed. Closing the switch between S1 and S2 decelerates the motor from set speed to a minimum speed determined by the MIN SPD trimpot setting. If the MIN SPD trimpot is set full CCW, the motor decelerates to zero speed when the switch between S1 and S2 is closed. The DECEL trimpot setting determines the rate at which the drive decelerates. By opening the switch, the motor accelerates to set speed at a rate determined by the ACCEL trimpot setting. Figure 6. Run / Decelerate to Minimum Speed Switch 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 17 Operation 17 Coast to minimum speed using INHIBIT terminals Short the INHIBIT terminals to coast the motor to minimum speed (Figure 7). Reopen the INHIBIT terminals to accelerate the motor to set speed. Twist inhibit wires and separate them from other 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 Corporation offers two accessory plug harnesses for connecting to the INHIBIT terminals: part number 201-0024 [inhibit plug with 18-inch (46 cm) leads]; and part number 201-0079 [inhibit plug with 36-inch (91 cm) leads]. COAST Figure 7. RUN / Coast to Minimum Speed Switch 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 18 18 Operation Dynamic braking Warning � Wait for the motor to completely stop before switching it back to RUN. This will prevent high armature currents from damaging the motor or drive. NOTE: For motors rated 1/17 horsepower and lower, a 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. Dynamic braking may be used to rapidly stop a motor (Figure 8). For the RUN/BRAKE switch, use a double-pole, double-throw switch rated for at least the maximum DC armature voltage and maximum braking current. Table 3. Recommended Dynamic Brake Resistor Sizes Motor Minimum Minimum Armature Dynamic Brake Dynamic Brake Current Rating Resistor Value Resistor Wattage Less than 2 ADC 1 ohm 1W 2–3 ADC 5 ohm 5W 3–5 ADC 10 ohm 10W 5–10 ADC 20 ohm 20W 10–17 ADC 40 ohm 50W 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 19 Operation 19 Figure 8. Dynamic Brake Connection 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 20 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. MM21xx1A and MM22xx1A Series drives have six user- adjustable trimpots. Each drive is factory calibrated to its maximum current rating. Readjust the calibration trimpot settings to accommodate lower current rated motors. See Figure 9 for trimpot location. 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. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 21 Calibration 21 REGULATION DECELERATION MINIMUM SPEED (IR COMP) ACCELERATION MAXIMUM TORQUE LIMIT SPEED Figure 9. Calibration Trimpot Layout 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 22 22 Calibration Calibration procedure Calibrate the drive using the following procedure: 1. Set the MIN SPD, MAX SPD, ACCEL and DECEL trimpots to zero (full CCW). 2. Set the TORQUE trimpot to maximum (full CW). 3. Set the IR COMP trimpot to midrange (approximate 12 o’clock position). 4. Set the signal input (analog voltage signal or speed adjust potentiometer) to zero. 5. Apply power to the drive. 6. Calibrate the trimpots as follows: MINIMUM SPEED (MIN SPD) The MIN SPD setting determines the motor speed when the speed adjust potentiometer is turned full CCW. It is factory set for zero rated speed. To calibrate, set the MIN SPD trimpot full CCW. Set the speed adjust potentiometer or reference signal to minimum. Adjust the MIN SPD trimpot until the desired minimum motor speed is reached. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 23 Calibration 23 MAXIMUM SPEED (MAX SPD) The MAX SPD setting determines the motor speed when the speed adjust potentiometer is turned full CW. It is factory set for maximum rated speed. To calibrate, set the MAX SPD trimpot full CCW. Set the speed adjust potentiometer or reference voltage to maximum. 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 ramp to a higher speed. See Specifications on page 1 for approximate acceleration times. ACCEL is factory set for the fastest acceleration time (full CCW). To set the acceleration time: 1. Set the speed adjust potentiometer or reference signal to minimum. The motor should run at minimum speed. 2. Set the speed adjust potentiometer or reference signal to maximum and measure the time it takes the motor to go from minimum to maximum speed. 3. If the time measured in step 2 is not the desired acceleration time, turn the ACCEL trimpot CW for a slower acceleration time, or CCW for a faster acceleration time. Repeat steps 1 through 3 until the acceleration time is correct. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 24 24 Calibration DECELERATION (DECEL) The DECEL setting determines the time the motor takes to ramp to a lower speed. See Specifications on page 1 for approximate deceleration times. DECEL is factory set for the fastest deceleration time (full CCW). To set the deceleration time: 1. Set the speed adjust potentiometer or reference signal to maximum. The motor should run at maximum speed. 2. Set the speed adjust potentiometer or reference signal to minimum and measure the time it takes the motor to go from maximum to minimum speed. 3. If the time measured in step 2 is not the desired deceleration time, turn the DECEL trimpot CW for a slower deceleration time, or CCW for a faster deceleration time. Repeat steps 1 through 3 until the deceleration time is correct. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 25 Calibration 25 REGULATION (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. To calibrate IR COMP (exact calibration): 1. Turn the IR COMP trimpot full CCW. 2. Set 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. Approximate calibration: If the motor does not maintain set speed as the load changes, gradually rotate the IR COMP trimpot CW. 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 speed. See Figure 10 (page 27) for typical IR COMP and TORQUE trimpot settings. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 26 26 Calibration TORQUE LIMIT (TORQUE) Warning � Although TORQUE LIMIT is set to 120% of maximum drive current rating, continuous operation beyond that rating may damage the motor. If you intend to operate beyond the rating, contact your Minarik representative for assistance. The TORQUE setting determines the maximum torque for accelerating and driving the motor. TORQUE is factory set at 120% of maximum drive current. You must recalibrate the TORQUE setting if using a lower current rated motor. 1. With no power applied to the drive, connect a DC ammeter in series with the motor armature. 2. Set the TORQUE trimpot to full CCW. 3. Carefully lock the motor armature. Ensure that the motor is firmly mounted. 4. Apply line power. The motor should be stopped. 5. Set the speed potentiometer or reference signal to maximum speed. The motor should remain stopped. 6. Slowly rotate the TORQUE trimpot clockwise (CW) until the ammeter reads 120% of maximum motor armature current. 7. Set the speed adjust potentiometer or reference signal to zero speed. 8. Remove power from the drive. 9. Remove the lock from the motor shaft. 10. Remove the ammeter in series with the motor armature. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 27 Calibration 27 Figure 10. Typical IR COMP and TORQUE Settings (settings may vary by application) 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 28 28 Application Notes FWD-STOP-REV switch Use a three-pole, three-position switch with a single speed adjust potentiometer to coast to a stop between reversals (Figure 11). Set the switch to the center position to decelerate the motor to a stop. The switch contacts should be rated at a minimum of 250 volts and 150% to 200% of motor nameplate current. Wait for the motor to come to a stop before switching to either the forward or reverse direction. This will prevent high armature currents from damaging the motor or drive. Figure 11. FWD-STOP-REV Switch 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 29 Application Notes 29 Reversing with dynamic braking A dynamic brake may be used when reversing the motor direction (Figure 12). Use a three-pole, three-position switch rated for at least the maximum DC armature voltage and maximum braking current. Wait for the motor to stop completely before switching it to either the forward or reverse direction. Figure 12. Reversing Circuit Connection 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 30 30 Application Notes Reversing with a DLC600 DIGI-LOK controller DL600 can be used in a reversing application. The controller must be inhibited while braking. Without the inhibit feature, the controller will continue to regulate, causing overshoot when the DIGI-LOK is switched back to the drive. Figure 13 shows the connection of the reversing circuit to an MM20000 series drive and a DLC600. Only one feedback device (encoder or magnetic pickup) may be used at any time. Figure 13. Reversing with a DLC600 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 31 Application Notes 31 Independent adjustable speeds Connect two speed adjust potentiometers with a single pole two position switch to select between two independent speeds shown in the forward direction (Figure 14). The speed adjust potentiometers can be mounted at two separate operating stations. Figure 14. Independent Adjustable Speeds 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 32 32 Application Notes 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. Figure 15. Adjustable Fixed Speeds Using Potentiometers in Series 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 33 Application Notes 33 Multiple fixed speeds Replace the speed adjust potentiometer with series resistors with a total series resistance of 10K ohms (Figure 16). Add a single pole, multi-position switch with the correct number of positions for the desired number of fixed speeds. Figure 16. Multiple Fixed Speeds 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 34 34 Application Notes RUN/JOG switch Using a RUN/JOG switch is recommended in applications where quick stopping is not needed and frequent jogging is required. Use a single pole, two position switch for the RUN/JOG switch, and a single pole, normally closed, momentary operated pushbutton for the JOG pushbutton as shown in Figure 17. 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. Figure 17. RUN/JOG Switch Connection to Speed Adjust Potentiometer 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 35 Application Notes 35 Leader-follower application In this application, use a PCM4 to monitor the speed of the leader motor (Figure 18). 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. Figure 18. Leader-Follower Application 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 36 36 Application Notes Single speed potentiometer control of multiple drives Multiple drives can be controlled with a single speed adjust potentiometer using a PCM4 at the input of each drive to provide isolation (Figure 19). Optional ratio potentiometers can be used to scale the PCM4 output voltage, allowing independent control of each drive. Figure 19. Single Speed Potentiometer Control of Multiple Drives 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 37 37 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: Disconnect AC line voltage from the drive. Check the drive closely for damaged components. Check that no conductive or other foreign material has become lodged on the printed circuit board. Verify that every connection is correct and in good condition. Verify that there are no short circuits or grounded connections. Check that the drive’s rated armature outputs are consistent with the motor ratings. For additional assistance, contact your local Minarik distributor, or the factory direct: (800) MINARIK (phone) or (800) 394-6334 (fax). 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 38 38 Symptom Possible Suggested Causes Solutions Line fuse blows 1. Line fuses are the wrong 1. Check that line fuses size. are the proper size. 2. Motor cable or armature 2. Check motor cable and is shorted to ground. armature for shorts. 3. Nuisance tripping caused 3. Add a blower to cool by a combination of the drive components; ambient conditions and decrease TORQUE high-current spikes. settings, or resize motor and drive for actual load demand, or check for incorrectly aligned mechanical components or “jams”. See page 26 for information on adjusting the TORQUE trimpot. 4. Field circuit is shorted. 4. Send in drive to Minarik repair department. Line fuse does not 1. Reference signal or 1. Increase reference blow, but the motor speed adjust pot is set to signal or speed adjust does not run zero speed. potentiometer setting. 2. Reference signal or 2. Check that the speed adjust potentiometer reference signal or speed connections are open. adjust potentiometer connections are not open. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 39 39 Symptom Possible Suggested Causes Solutions Line fuse does not 3. Drive is overloaded. 3. Verify that the motor is blow, but the motor not jammed. Increase does not run (cont.) TORQUE setting (page 26). 4. Drive is not receiving 4. Apply AC line voltage AC line voltage. to L1 and L2. 5. Motor is not connected. 5. Connect motor to A1 and A2. Motor runs too fast at 1. MIN SPD and MAX 1. Recalibrate MIN SPD maximum speed SPD settings are too high. (page 22) and MAX SPD setting (page 23). 2. Field connections are 2. Check field loose (shunt-wound motors connections only) Motor runs too slow or MIN SPD and MAX SPD 1. Recalibrate MIN SPD too fast are not calibrated. (page 22) and MAX SPD (page 23). Motor will not reach 1. MAX SPD setting is too 1. Increase MAX SPD the desired speed. low. setting (page 23). 2. IR COMP setting is too 2. Increase IR COMP low. setting (page 25). 3. Motor is overloaded. 3. Check motor load. Resize the motor if necessary. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 40 40 Symptom Possible Suggested Causes Solutions Motor pulsates or 1. IR COMP is set too 1. Adjust the IR COMP surges under load high. setting slightly CCW until the motor speed stabilizes (page 25). 2. Control is in current 2. Check that motor is of limit mode. sufficient horsepower and amperage. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 41 Troubleshooting 41 Replacement Parts Replacement parts are available from Minarik Corporation and its distributors for this drive series. Table 4. Replacement Parts Model No. Symbol Description Minarik P/N MM21001A C501–502 220 uF, 35 VDC Capacitor 011-0027 D501–503 1N5406 Diode 071-0007 SCR501–502 S8020L High-power SCR 072-0043 R501 0.05 Ohm, 3W Resistor 032-0073 T501 ST-3-3109 Transformer 230-0083 Chassis 222-0079 10K Ohm Pot Kit 202-0031 MM22001A Same as MM21011A except: R501 0.01 Ohm, 5W Resistor 032-0129 202-0031 POTENTIOMETER KIT CONTENTS Description Minarik P/N 1 EA 10K OHM Potentiometer, 5W, 5% TOL 120-0009 1 EA 3/8-32 X 1/2 NUT 151-0007 1 EA 3/8IN INT TOOTH LOCK WSHR 152-0007 1 EA POT INSULATING WASHER 156-0022 9 EA NON-INSULATED FEMALE TAB 1/4IN 163-0028 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 42 42 Troubleshooting FUSE KIT CONTENTS 1 -5A FUSE KIT (050-0066) Description Minarik P/N 2 EA 1 AMP 3AG FAST-ACTING FUSE 050-0042 2 EA 1-1/2 AMP 3AG FAST-ACTING 050-0026 2 EA 3 AMP 3AG FAST-ACTING FUSE 050-0021 2 EA 5 AMP 3AG FAST-ACTING FUSE 050-0022 5 - 15A FUSE KIT (050-0071) Description Minarik P/N 2 EA 5 AMP 3AG FAST-ACTING FUSE 050-0022 2 EA 8 AMP 3AG FAST-ACTING FUSE 050-0059 2 EA 10 AMP 3AB NORMAL-BLO FUSE 050-0024 2 EA 15 AMP 3AB NORMAL-BLO FUSE 050-0018 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 43 43 Certificate of Compliance Minarik Corporation hereby certifies that its MM21000A series drives have been approved to bear the “CE” mark provided the conditions of approval (listed in Exhibit “A”) have been met by the end user. The MM20000 series has been tested to the following test specifications: EN55011:1991 (emissions), and EN50082-1:1992 (immunity) Compliance allows Minarik’s MM21000 series to bear the CE mark. The end user, as described herein, falls into one of two categories: 1. The Consumer will deploy a stand-alone unit as an integral, yet external, portion of the machine being operated. 2. The Original Equipment Manufacturer (OEM) will implement the product as a component of the machine being manufactured. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 44 44 CE Compliance Exhibit “A” In addition to EMI/RFI safeguards inherent in the MM20000 series’ design, external filtering is required. Minarik requires the Corcom® filters listed in Table 5. If the exact filter is not available, the specifications are as follows: L = (1.73 + 0.03) milliHenries. C = (0.27 + 0.54) microFarads (X); 0.0055 microFarads (Y). R = 330Kohms. Rated current: 1.4 times maximum DC motor current. Filter type: Balanced 2-section. Table 5. Corcom Filters Nameplate Current of Motor Wired to the Drive Corcom Filter Part Number 0 to 4 amps 6VV1 4.1 to 13 amps 20VV1 The filters in Table 5 should be wired to the AC line within 0.25 meters of the drive. The ground connection from the filter must be wired to solid earth ground (resistance less than 500 ohms); not machine ground. This is very important! 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 45 CE Compliance 45 If the end-user is using a CE-approved motor, the correct filter from Table 5 (page 45) is all that is necessary to meet the EMC directives listed herein. If the end-user is not using a CE-approved motor, a second filter, part number CEXXMM, must be deployed on the output. XX = rated current of the filter. The CE20MM is a Real-Pole Balanced-Pi 3-pole filter. If the exact filter is not available, the specifications are as follows: L&L1=2*(0.8) milliHenries. C&C1=2*(0.1) microFarads @ 400W VDC. R = 0.1 ohm; R = 1.2 ohm. in out Table 6. Minarik Filters Nameplate Current of Motor Wired to the Drive Minarik Filter Part Number 0 to 4 amps CE4MM 4.1 to 13 amps CE20MM The filters in Table 6 must be wired to the DC output of the drive, as close to the drive as possible. The ground connection from the filter must be wired to solid earth ground (resistance less than 500 ohms); not machine ground. This is very important! 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 46 46 CE Compliance The end user must use the filtration listed in Exhibit A to comply with CE. The OEM may choose to provide alternative filtering that encompasses the Minarik drive and other electronics within the same panel. The OEM has this liberty because CE is a machinery directive. Whether or not every component in the OEM’s machinery meets CE, the OEM must still submit his machine for CE approval. Thus, no component must necessarily meet CE within the machine, as long as the OEM takes the necessary steps to guarantee the machine does meet CE. By the same token, even if every component in the OEM’s machine does meet CE, the machine will not necessarily meet CE as a machine. Using CE-approved wiring practices (like proper shielding) and the filters listed in Exhibit A guarantee the drive will meet EN55011 (1991 emissions standard) and EN50082-1 (1992 immunity standard). 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 47 Unconditional Warranty A. Warranty Minarik Corporation (referred to as "the Corporation") warrants that its products will be free from defects in workmanship and material for twelve (12) months or 3,000 hours, whichever comes first, from date of manufacture thereof. Within this warranty period, the Corporation will repair or replace, at its sole discretion, such products that are returned to Minarik Corporation, 901 East Thompson Avenue, Glendale, CA 91201- 2011 USA. This warranty applies only to standard catalog products, and does not apply to specials. Any returns for special controls will be evaluated on a case-by-case basis. The Corporation is not responsible for removal, installation, or any other incidental expenses incurred in shipping the product to and from the repair point. B. Disclaimer The provisions of Paragraph A are the Corporation's sole obligation and exclude all other warranties of merchantability for use, express or implied. The Corporation further disclaims any responsibility whatsoever to the customer or to any other person for injury to the person or damage or loss of property of value caused by any product that has been subject to misuse, negligence, or accident, or misapplied or modified by unauthorized persons or improperly installed. C. Limitations of Liability In the event of any claim for breach of any of the Corporation's obligations, whether express or implied, and particularly of any other claim or breech of warranty contained in Paragraph A, or of any other warranties, express or implied, or claim of liability that might, despite Paragraph B, be decided against the Corporation by lawful authority, the Corporation shall under no circumstances be liable for any consequential damages, losses, or expense arising in connection with the use of, or inability to use, the Corporation's product for any purpose whatsoever. An adjustment made under warranty does not void the warranty, nor does it imply an extension of the original 12-month warranty period. Products serviced and/or parts replaced on a no-charge basis during the warranty period carry the unexpired portion of the original warranty only. If for any reason any of the foregoing provisions shall be ineffective, the Corporation's liability for damages arising out of its manufacture or sale of equipment, or use thereof, whether such liability is based on warranty, contract, negligence, strict liability in tort, or otherwise, shall not in any event exceed the full purchase price of such equipment. Any action against the Corporation based upon any liability or obligation arising hereunder or under any law applicable to the sale of equipment or the use thereof, must be commenced within one year after the cause of such action arises. 250-0089r3_readers_spreads.qxd 7/3/01 10:48 AM Page 48 Other drives from Minarik Corporation: DLC600 NRGD Series MMRGD Series BOSS Series 901 East Thompson Avenue Glendale, California 91201-2011 Tel: (800) MINARIK Fax: (800) 394-6334 www.minarikcorp.com Document Number 250-0089, Revision 3 Printedinthe U.S.A–6/01 $12.00 North America, $13.00 Outside North America