User`s Manual - Minarik Drives
Contents
1. Ibat hn 12 Dynamic brake resistor connections 12 Inhibit personality header 14 112 VDC terminals bp TRECE Pene 14 Voltage follower connection 16 Operation 17 Before applying power 17 Startup Shutdown euh ix rer E 18 Starting and stopping methods 19 Line starting and stopping 20 Decelerating to minimum speed 21 Mhibitterminals oa od eds e ESOS eet es 22 Dynamic DAKINE arto a er d Ne CP eevee 23 Calibration 26 Calibration procedure 28 MINIMUM SPEED MIN 29 MAXIMUM SPEED MAX 29 REGULATION IR COMP 30 MOTOR CURR LIMIT and REGEN CURR LIMIT 31 PASE LL eua SU Rb ERTS Re ES Ref Un mute ek ore fa bre d go 32 poser ai ean ud Alain DUE P PC 33 Application Notes 35 Connection to other Minarik devices 35 Optional speed adjust potentiometer connections 36 Multiple fixed speeds 36 Adjustable speeds using potentiometers in series 372. 27 Figure 9 Typical IR COMP and CURRENT LIMIT settings 34 Figure 10 NRG 2Q Connection to DLC600 DIGI LOK Control and Signal Isolator 35 Figure 11 Multiple Fixed Speeds 36 Figure 12 Adjustable Fixed Speeds Using Potentiometers in Series 37 Figure 13 Independent Adjustable Speeds 38 Figure 14 RUN JOG Switch Connection to Inhibit Plug 39 Figure 15 RUN JOG Switch Connection to Speed Adjust Potentiometer 40 Figure 16 Leader Follower Application 41 Figure 17 Single Speed Potentiometer Control of Multiple Drives 42 Figure 18 Diagnostic LED Location 44 Tables Table 1 Recommended Line Fuse Sizes 10 Table 2 Inhibit Plug Harness Assembly Part Number 22 Specifications Model Number NRG02 D240AC 2Q Type Open Chassis AC Line Voltage 115 VAC or 230 VAC 10 50Hz or 60 Hz single phase Maximum Continuous Armature Current 2 ADC Horsepower Range 9 130 VDC Output 1 20 1 4 Horsepower Range 9 240 VDC Output 1 10 1 2 Maximum Armature Voltage Range 115 VAC Input 0 130 VDC Maximum Armature Voltage Range 230 VAC Input 0 240 VDC Form Factor 1 03 Acceleration Time Range 1 10 seconds Deceleration Ti
3. LINE VOLTAGE SWITCH SPEED ADJUST POTENTIOMETER 10K OHMS Figure 3 NRG 2Q Connections 14 Installation Inhibit personality header The inhibit personality header SO503 determines how the drive responds when the INHIBIT terminals 50501 are shorted together Set the inhibit personality before shorting the inhibit terminal to each other Jumper pins 1 and 2 for a dynamic brake response or pins 2 and 3 for a disable output response coast to a stop Also read Inhibit terminals section on page 22 See Figure 4 for jumper and inhibit terminal locations 12 VDC terminals To supply power to external devices the 12VDC terminals can supply an unregulated 12 VDC 30 mA signal is the signal common terminal and is the voltage signal terminal See Figure 4 for terminal location Installation 15 e LJ o C502 A2 INHIBIT PERSONALITY Res 123 1 amp 2 Dynamic Brake 2 amp 3 Disable Output INHIBIT 3 IR COMP 50501 12 VDC mm Terminals SO502 S1 2 83 80503 80503 1 2 3 1 2 3 DYNAMIC BRAKE COAST TO STOP Figure 4 Inhibit Personality Header Inhibit Terminals and 12 VDC Terminals 16 Installation Voltage follower connection Instead of using a speed adjust potentiometer to set motor speed the drive may follow a floating isolated 0 to 5 VDC signal Connect the signal input to S2 and signal common to S1 Make no connection to S3 See Figure 5 POWE
4. Automation Inari amp Control Two Quadrant Regenerative PWM Drives for DC Brush Motors 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 Safety Warnings 4 This symbol denotes an important safety tip or warning Failure to heed these warnings may result in damage to the drive or personal injury Please read these instructions carefully before performing any of the procedures contained in this manual DO NOT INSTALL REMOVE OR SERVICE 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
5. MIN and MAX are not calibrated MAX setting is too low IR COMP setting is too low 3 Motor is overloaded Troubleshooting 47 Suggested Solutions Connect motor to Al and A2 Verify all switch and jumper settings Calibrate MIN and MAX trimpots Increase MAX setting Increase the IR COMP setting Check motor load Resize the motor if necessary 48 Troubleshooting Motor pulsates or surges under load Possible Causes IR COMP is set too high Motor bouncing in and out of torque limit Suggested Solutions Adjust the IR COMP setting slightly CCW until the motor speed stabilizes Make sure motor is not undersized for load adjust MOTOR CURR LIMIT and REGEN CURR LIMIT trimpots Troubleshooting 49 Replacement Parts Replacement parts are available from Minarik Corporation and its distributors for this drive series Model No Symbol Description Minarik P N NRG02 D240AC 2Q BRI Power Bridge 073 0010 C503 470mF 400 VDC Capacitor 011 0120 501 502 Fuse 050 0016 0501 504 440 MOSFET 070 0077 R501 0 1W 5 W Resistor 032 0153 10KW Potentiometer Kit 202 0039 NRG05 D240AC 2Q BRI Power Bridge 073 0010 C503 504 470mF 400 VDC Capacitor 011 0120 501 502 10 Fuse 050 0024 Q501 502 INXFH26N50 MOSFET 070 0079 Q503 IRFP460 MOSFET 070 0066 Q504 IRFP440 MOSFET 070 0077 R501 0 01W 5 W Resist
6. Independent adjustable speeds 38 RUN JOG SWIICH RE Reese hE eee oe eee 39 RUN JOG ODptOR3ET iex iy etc eg pnto n 39 RUN JOG option 2 40 Leader follower application 41 Single speed potentiometer control of multiple drives 42 Troubleshooting 43 Betore troubles DOE vas aes obere ER pe meque eR EP RA or ae xg 43 Hiagnostic LEDS ke ees Habe ER USER E RI EIE E RACE edo Ra E 44 rang oad eae Oates ee ay S estu e tame ata 44 ODIDUC ll eal 44 Regen Outputs 44 Replacement Rs ea ade muy 49 Unconditional Warranty inside back cover iv Illustrations Figure 1 NRG 2Q Dimensions 4 Figure 2 Two Quadrant Operation 6 Figure NRG 2Q Connections 13 Figure 4 Inhibit Personality Header Inhibit Terminals and 12 VDC Terminals 15 Figure 5 Voltage Follower Connections 16 Figure 6 Connections for Run Decelerate to Minimum Speed Switch 21 Figure 7 Dynamic Braking Circuit Connection 25 Figure 8 Calibration Trimpot Layout
7. This may cause damage to motors especially gearmotors that are not properly sized for the application The 230 VAC line if used must be balanced Contact your local distributor for line balancing circuitry 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 20 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 For this reason Minarik strongly recommends that you install a stop switch on the line voltage inputs both L1 and L2 Refer to Figure 3 page 13 Automatic restart of the drive When line voltage is applied to the drive the motor will automatically accelerate to the speed commanded by the speed adjust potentiometer or reference signal Wiring a latching relay into the motor control circuit is one way to prevent undesirable restarts Operation 21 Decelerating to minimum speed Shorting terminal S2 to S1 decelerates the motor to minimum speed Figure 6 The ACCEL and DECEL trimpots determine the rate of acceleration and deceleration respectively Set the minimum speed by calibrating the MIN trimpot Se
8. environment 10 Installation Line fusing NRG Series drives have preinstalled line fuses See the Replacement Parts section for preinstalled line fuse size When replacing the line fuses use fast acting fuses rated for 250 VAC or higher and approximately 150 of the armature current Two line fuses are required for models 02 240 20 and NRG05 D240AC 2Q while only one is required for model NRGI10 115AC 2Q See Table 1 for recommended line fuse sizes Table 1 Recommended Line Fuse Sizes 90 VDC Motor 180 VDC Motor Max DC Armature AC Line Fuse Horsepower Horsepower Current amps Size amps 1 20 1 10 0 5 3 1 15 1 8 0 8 3 1 8 1 4 1 5 5 1 6 1 3 1 7 5 1 4 1 2 2 6 8 1 3 3 4 3 5 8 1 2 1 5 0 10 3 4 1 1 2 7 6 15 1 2 10 20 Minarik Corporation offers two fuse kits part number 050 0069 3 8A Fuse Kit and 050 0073 5 20A Fuse Kit See Replacement Parts page 49 for fuse kit contents Installation 11 Connections A 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 should be rated at a minimum of 200 of motor nameplate current and 250 volts Connect the power input leads and a DC motor to the drive s printed circuit board PCB as shown in Figure 3 page 13 Motor connections Minarik drives supply motor
9. or expense arising in connection with the use of or inability to use the Corporation s product for any purpose whatsoever An adjustment made under warranty does not void the warranty nor does it imply an extension of the original 12 month warranty period Products serviced and or parts replaced on a no charge basis during the warranty period carry the unexpired portion of the original warranty only If for any reason any of the foregoing provisions shall be ineffective the Corporation s liability for damages arising out of its manufacture or sale of equipment or use thereof whether such liability is based on warranty contract negligence strict liability in tort or otherwise shall not in any event exceed the full purchase price of such equipment Any action against the Corporation based upon any liability or obligation arising hereunder or under any law applicable to the sale of equipment or the use thereof must be commenced within one year after the cause of such action arises Other drives from Minarik Corporation AC or DC Input Automation amp Control 901 East Thompson Avenue Glendale California 91201 2011 Tel 800 MINARIK Fax 800 394 6334 www minarikcorp com Document Number 250 0246 Revision 2 Printed in the U S A 5 01 12 00 North America 13 00 Outside North America
10. 2Q DLC600 DRIVE DIG LOK CONTROL 52 52 X ___ m S2 2 NRG 2Q DRIVE SIGNAL ISOLATOR 51 1 ML EE Figure 10 NRG 2Q Connection to DLC600 DIGI LOK Control and PCM4 Signal Isolator 36 Application Notes Optional speed adjust potentiometer connections Multiple fixed speeds Replace the speed adjust potentiometer with series resistors with a total series resistance of 10K ohms Figure 11 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds Total Series Resistance 10K ohms Figure 11 Multiple Fixed Speeds Application Notes 37 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 12 shows a connection for fixed high and low speed adjust potentiometers Figure 12 Adjustable Fixed Speeds Using Potentiometers in Series 38 Application Notes Independent adjustable speeds Replace the speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in parallel with a total parallel resistance of 10K ohms Figure 13 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating s
11. D240AC 2Q Solution Use a 40 ohm resistor with a minimum power rating of at least 448 watts Operation 25 50503 1 2 3 INHIBIT PERSONALITY SET TO BRAKE T1 RUN DB DYNAMIC BRAKE RESISTOR Figure 7 Dynamic Braking Circuit Connection 26 Calibration A Warning Dangerous voltages exist on the drive when it is powered and up to 30 seconds after power is removed and the motor stops When possible disconnect the voltage input from the drive before adjusting the trimpots If the trimpots must be adjusted with power applied use insulated tools and the appropriate personal protection equipment BE ALERT High voltages can cause serious or fatal injury NRG 2Q Series drives have seven user adjustable trimpots Each drive is factory calibrated to its maximum current rating Readjust the calibration trimpot settings to accommodate lower current motors See Figure 8 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 Calibration 27 ACCELERATION DECELERATION MAXIMUM SPEED MINIMUM SPEED MOTOR CURRENT LIMIT REGEN CURRENT LIMIT REGULATION IR COMP Figure 8 Calibration Trimpot Layout 28 Calibration Calibration procedure Calibrate the drive using the following procedure 1 Set the MIN SPD MAX SPD ACCEL and DECEL trimpots to z
12. Dynamic braking may be used to rapidly stop a motor Figure 7 page 25 Connect a RUN BRAKE switch to the INHIBIT terminals Connect a dynamic brake resistor to the DB and DB terminals on the printed circuit board See Figure 3 on page 13 for dynamic brake resistor connections Dynamic brake resistor The dynamic brake resistor reduces the voltage across the bus capacitors C503 and C504 when they reach their maximum voltage rating This occurs when the motor regenerates voltage back to the drive Bus capacitor maximum voltage ratings are 400 VDC for 240 VAC drives and 200 VDC for 115 VAC drives Dynamic brake resistor value Use a 40 ohm dynamic brake resistor for models NRGO02 D240AC 2Q and NRG05 D240AC 2Q Use a 20 ohm dynamic brake resistor for model NRG10 115AC 2Q The dynamic brake resistor tolerance is 10 24 Operation Dynamic brake resistor power rating Use the following equation to determine the dynamic brake resistor power rating DBwatts Motor Power watts X duty cycle X 1 2 Horsepower X 746 X duty cycle X 1 2 TREGEN duty cycle TMOTOR TREGEN where TREGEN 15 the amount of time the motor is generating voltage back into the drive and TMOTOR is the amount of time the drive is generating voltage into the motor The absolute minimum dynamic brake resistor power rating is typically 100 watts Example Size a DB resistor for a 1 HP motor that has a 5046 duty cycle It will be used with model NRG05
13. PCM4 to monitor the speed of the leader motor Figure 16 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 Ead AL i a 92 52 eader 1 ollower drive ee 5 drive TB502 70 TB501 dO onm optional Figure 16 Leader Follower Application 42 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 17 Optional ratio potentiometers can be used to scale the PCM4 output voltage allowing independent control of each drive 6 2 ratio pot A optional 10K OHMS 8 a S2 DriveA Mi PCM4 Fa 7 1 51 2 501 TB502 6 2 ratio pot B optional 1 10K OHMS 8 52 7 1 51 2 501 TB502 Figure 17 Single Speed Potentiometer Control of Multiple Drives 43 Troubleshooting A Warning Dangerous voltages exist on the drive when it is powered When possible disconnect the drive while troubleshooting High voltag
14. R SO501 MOTOR OUTPUT i REGEN 50502 51 52 ss SIG 0 5 VOLTAGE SIGNAL Figure 5 Voltage Follower Connections 17 Operation A Warning Dangerous voltages exist on the drive when it is powered and up to 30 seconds after power is removed and the motor stops BE ALERT High voltages can cause serious or fatal injury Before applying power Verify that no conductive material is present on the printed circuit board Set all switches and jumpers to their proper settings Verify that the AC supply is properly balanced 18 Operation Startup and shutdown 1 Set the speed adjust potentiometer for zero speed full CCW If the drive is following a voltage signal set the voltage signal to 0 VDC 2 Apply AC line voltage 3 Rotate the speed adjust potentiometer or increase the voltage signal until the desired speed is reached 4 Remove AC line voltage from the drive to coast the motor to a stop Operation 19 Starting and stopping methods A Warning Decelerating to minimum speed regenerative 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 AC line power both L1 and L2 is the only acceptable method for emergency stopping Frequent decelerating to minimum speed regenerative braking or coasting to a stop produces high torque
15. d 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 16 AWG wire for AC line voltage L1 and L2 and motor armature A1 and A2 wiring Use 18 AWG wire for logic inhibit leads or S1 S2 and S3 For the dynamic brake resistor use 14 AWG wire for model 10 115 20 16 AWG wire for models NRG05 D240AC 2Q and NRG02 D240AC 2Q Installation 9 Shielding guidelines A 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
16. e Calibration on page 26 for specific calibration instructions INHIBIT POWER SO501 OC O MOTOR OUTPUT Q REGEN MIN SPD CW Figure 6 Connections for Run Decelerate to Minimum Speed Switch 22 Operation Inhibit terminals Shorting the inhibit terminals SO501 to each other causes the motor to either coast to a stop or brake to a stop First set the inhibit personality to coasting or braking to a stop see Inhibit personality on page 14 Next short the inhibit pins to coast or brake to a stop Remove the short to accelerate the motor to set speed Minarik Corporation offers two accessory plug harnesses for use with the Inhibit terminals Table 2 Inhibit Plug Harness Assembly Part Number Minarik Part Number Description 201 0024 Inhibit plug with 18 in 46 cm wires 201 0079 Inhibit plug with 36 in 91 cm wires Twist inhibit plug wires and separate them from other power carrying wires or sources of electrical noise Use shielded cable if the inhibit plug wires are longer than 12 inches 30 cm If shielded cable is used ground only one end of the shield to earth ground Do not ground both ends of the shield Operation 23 Dynamic braking A 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 Inhibit personality header SO503 must be set to BRAKE for dynamic brake operation See Figure 7 page 25
17. eleration time is correct Calibration 33 DECEL The DECEL setting determines the time the motor takes to ramp to a lower speed DECEL is factory set for the fastest deceleration time full CCW To calibrate DECEL 1 Set the speed adjust potentiometer or voltage input signal to maximum forward speed The motor should run at maximum speed 2 Set the speed adjust potentiometer or voltage input signal to minimum speed 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 34 Calibration NRGIO 115 20 1 HP 1 3 HP 90 VDC 90 VDC 10 ADC Cod 35 Apc 5 ADC 2 5 ADC 12 HP 1 4 HP 90 VDC Q Q 90 VDC CE 20 NRGO2 D240AC 20 1 2 HP 90 VDC 5 ADC 1 4 HP 90 VDC 2 5 ADC 13 HP 90 VDC 3 5 ADC 1 8 HP 90 VDC 13 ADC 1 4 HP 90 VDC 2 5 ADC 1 50 HP 90 VDC 28 ADC 1 8 HP 90 VDC 1 3 ADC 12 HP 180 VDC 2 5 ADC 1 4 HP 180 VDC 14 ADC 1 HP 180 VDC 5 ADC 3 4 HP 180 VDC 3 8 ADC 1 2 HP 180 2 5 ADC 1 4 HP 180 VDC Uy a 1 4 ADC Figure 9 Typical IR COMP and CURRENT LIMIT settings actual settings may vary 35 Application Notes Connection to other Minarik devices m S1 S1 NRG
18. ero full CCW 2 Set the MOTOR CURRENT LIMIT and REGEN CURRENT LIMIT trimpots 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 Calibration 29 MINIMUM SPEED MIN The MIN setting determines the minimum speed when the speed adjust potentiometer or voltage input signal is set for minimum speed It is factory set to zero speed To calibrate MIN 1 Set the MIN trimpot CCW 2 Set the speed adjust potentiometer or voltage input signal for minimum speed 3 Adjust the MIN trimpot to the desired minimum speed MAXIMUM SPEED MAX The MAX setting determines the maximum motor speed when the speed adjust potentiometer or voltage input signal is set for maximum speed It is factory set for maximum rated motor speed To calibrate MAX 1 Set the MAX trimpot full CCW 2 Set the speed adjust potentiometer or voltage input signal for maximum speed 3 Adjust the MAX trimpot to the desired maximum speed 30 Calibration REGULATION 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 optimum motor regulation at maximum rated current To calibrate IR COMP exact calibration 1 Turn the IR COMP trimpot full CCW 2 Set the speed adjust pote
19. es 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 44 Troubleshooting Diagnostic LEDs 2 quadrant NRG drives have three diagnostic LEDs Power Lights whenever the AC line voltage is applied to the drive Motor Output Lights whenever motor current flows in the direction of motor rotation Regen Output Lights whenever motor current flows in the opposite direction of motor rotation INHIBIT FUSC POWER FUSO2 12VDC MOTOR OUTPUT 12 230 11 POWER MOTOR REGEN OUTPUT OUTPUT Figure 18 Diagnostic LED Location Line fuses blow Line fuse does not blow but the motor does not run Possible Causes 1 Line fuses are the wrong size Motor cable or armature is shorted to ground Nuisance tripping caused by a combination of ambient co
20. me Range 1 10 seconds Input Signal Range signal must be isolated 0 5 VDC Input Impedance 100K ohms minimum Speed Regulation of base speed 1 open loop Speed Range 100 1 Vibration 0 5G max 0 50 Hz 0 1G max gt 50 Hz Weight 1 94 Ib Ambient Operating Temperature Range 10 C 40 C 2 Specifications Model Number NRG05 D240AC 2Q Type Open Chassis AC Line Voltage 115 or 230 VAC 10 50Hz or 60 Hz single phase Maximum Continuous Armature Current 5 ADC Horsepower Range 9 130 VDC Output 1 8 3 4 Horsepower Range 9 240 VDC Output 1 4 1 1 2 Maximum Armature Voltage Range 115 VAC Input 0 130 VDC Maximum Armature Voltage Range 230 VAC Input 0 240 VDC Form Factor 1 03 Acceleration Time Range 1 10 seconds Deceleration Time Range 1 10 seconds Input Signal Range isolated 0 5 VDC Input Impedance 100K ohms minimum Speed Regulation of base speed 1 open loop Speed Range 100 1 Vibration 0 5G max 0 50 Hz 0 1G max gt 50 Hz Weight 1 94 Ib Ambient Operating Temperature Range 10 C 40 C Specifications 3 Model Number NRG10 115AC 2Q Type Open Chassis AC Line Voltage 115 VAC 10 50Hz or 60 Hz single phase Maximum Continuous Armature Current 10 ADC Horsepower Range 9 130 VDC Output 1 4 1 1 2 Maximum Armature Voltage Range 0 130 VDC Form Factor 1 03 Acceleration Time Range 1 10 seconds Deceleration Time Ra
21. nditions and high current spikes i e reversing Speed adjust potentiometer or voltage input signal set to zero speed Troubleshooting 45 Suggested Solutions 1 Check that line fuses are properly sized for the motor being used Check motor cable and armature for shorts Add a blower to cool the drive components increase MOTOR CURR LIMIT and REGEN CURR LIMIT settings Increase the speed adjust potentiometer setting or voltage input signal 46 Line fuse does not blow but the motor does not run cont Troubleshooting Possible Causes 2 Speed adjust potentiometer or voltage input signal not connected to drive input properly connections are open Inhibit terminals are jumpered 4 S2 is shorted to S1 5 Drive is in current limit Drive is not receiving AC line voltage Suggested Solutions Check connections to input Verify that connections are not open Remove jumper from inhibit terminal Remove short Verify that motor is not jammed Increase MOTOR CURR LIMIT or REGEN CURR LIMIT setting if they are set too low Apply AC line voltage to L1 and L2 Line fuse does not blow but the motor does not run cont Motor runs too slow or too fast at set speed Motor will not reach the desired speed Possible Causes 7 Motor is not connected 1 Switches or jumpers are set incorrectly
22. nge 1 10 seconds Input Signal Range isolated 0 5 VDC Input Impedance 100KW minimum Speed Regulation 96 of base speed 196 open loop Speed Range 100 1 Vibration 0 5G max 0 50 Hz 0 1G max gt 50 Hz Weight 1 94 Ib Ambient Operating Temperature Range 10 40 4 Dimensions i 4 44 113 3 00 76 al 0 70 18 A 2 20 56 1 0 97 25 1 6 30 160 6 90 175 Dimension A NRG02 D240AC 2Q 2 62 67 NRG05 D240AC 2Q 2 62 67 NRG10 115AC 2Q 2 43 62 All dimensions in inches millimeters Figure 1 NRG 2Q Dimensions 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 see Figure 2 page 6 Unless dynamic braking is used non regenerative drives decelerate a load faster than coasting to a lower speed NRG 2Q drives operate in Quadrants 1 and 4 In Quadrant 4 the direction of current flow is in the opposite direction of motor rotation This allows regenerative drives to control an overhauling load and decelerate a load faster than it would take to coast to a lower speed 6 Regenerative Drives Figure 2 Two Quadrant O
23. ntiometer or voltage input signal until the motor runs at midspeed without load for example 900 RPM for an 1800 RPM motor Use a hand held tachometer 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 See Figure 9 page 34 for recommended IR COMP trimpot settings Calibration 31 MOTOR CURR LIMIT and REGEN CURR LIMIT A Warning Although CURRENT LIMIT is set to 120 of motor nameplate 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 MOTOR CURR LIMIT setting determines the maximum current limit for accelerating and driving the motor The REGEN CURR LIMIT setting determines the maximum current limit for decelerating and stopping the motor Both CURRENT LIMIT trimpots are factory set at approximately 120 of maximum drive current and must be recalibrated when using a lower current motor See Figure 9 page 34 for recommended CURRENT LIMIT trimp
24. 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 Contents Specifications 1 NRG02 D240AC 2Q edax EEE DEERE RU EE WY TS 1 NRGO5 D240AC 2Q wi gee yaw head cal Segue x a pu baie dia 2 10 115 26 ge dk 3 Dimensions Regenerative Drives Installation Drive mounting eke bln E nde det 7 oeste md PER UR NER elt iene Gal wet pU RAMOS a 8 Shielding guidelines 2 540 5805600 RR x Rr 9 Lite TOS anuos Sa ERREUR ARE ERO UR E TO Y TO EE GER 10 Connections ere eruta sy ce rernm m reduc p e daos og e 11 Motor Gonnectiona SOR E pen d 11 Power lead connections coco ca a seen
25. or 032 0129 10KW Potentiometer Kit 202 0039 NRG10 115AC 2Q BRI Power Bridge 073 0010 C503 504 1000 200 VDC Capacitor 011 0096 FU501 20A 3AB Fuse 050 0019 0501 503 300 35 A MOSFET 070 0105 Q504 IRFP440 MOSFET 070 0077 R501 0 01W 5 W Resistor 032 0129 10KW Potentiometer Kit 202 0039 50 Troubleshooting Potentiometer Kit Contents 202 0039 11 ea NON INSU FEMALE TAB 1 4IN 1 ea 10K OHM 5W 5 TOL 1 ea 3 8 32 X 1 2 NUT 1 ea 3 8IN INT TOOTH LOCK WASHER 1 ea POT INSULATING WASHER FUSE KIT CONTENTS 3 8A Fuse Kit 050 0069 2 ea 3 AMP 3AG FAST ACTING FUSE 2 ea 5 AMP 3AG FAST ACTING FUSE 2 ea 8 AMP 3AG FAST ACTING FUSE 1 ea 1 2A 500 PICO FUSE 5 20A Fuse Kit 050 0073 2 ea 5 AMP 3AG FAST ACTING FUSE 2 ea 8 AMP 3AG FAST ACTING FUSE 2 ea 10 AMP 3AB NORMAL BLO FUSE 2 ea 15 AMP 3AB NORMAL BLO FUSE 2 ea 20 AMP 3AB NORMAL BLO FUSE 1 ea 1 2A 500 PICO FUSE Inhibit Plugs Inhibit Plug with 18 in 46 cm wires Inhibit Plug with 36 in 91 cm wires 163 0028 120 0009 151 0007 152 0007 156 0022 050 0021 050 0022 050 0059 050 0074 050 0022 050 0059 050 0024 050 0018 050 0019 050 0074 201 0024 201 0079 Notes 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
26. ot settings To calibrate the CURRENT LIMIT trimpots 1 With the power disconnected from the drive connect a DC ammeter in series with the armature 2 Set the MOTOR CURR LIMIT trimpot to minimum full CCW 3 Lock the motor armature Be sure that the motor is firmly mounted 4 Connect power to the drive The motor should remain stopped 32 Calibration 5 Set the speed adjust potentiometer or voltage input signal for maximum forward speed 6 Slowly adjust the MOTOR CURR LIMIT trimpot CW until the armature current is 120 of motor rated current 7 Set the REGEN CURR LIMIT trimpot to approximately the same setting as the MOTOR CURR LIMIT 8 Setthe speed adjust potentiometer or voltage input signal for Zero speed 9 Remove AC power 10 Remove the stall from the motor ACCEL The ACCEL setting determines the time the motor takes to ramp to a higher speed ACCEL is factory set for the fastest acceleration time full CCW To 1 calibrate ACCEL Set the speed adjust potentiometer or voltage input signal to zero speed The motor should run at minimum speed Set the speed adjust potentiometer or voltage input signal to maximum forward speed and measure the time it takes the motor to go from minimum to maximum speed 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 acc
27. peration Installation Drive mounting A Warning Do not install rewire or remove this control with power applied Doing so may cause fire or serious injury Make sure you have read and understood the Safety Warnings before attempting installation The chassis must be earth grounded Use a star washer beneath the head of at least one of the mounting screws to penetrate the anodized chassis surface and to reach bare metal Drive components are sensitive to electrostatic fields Avoid 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 Prevent loose connections by avoiding excessive vibration of the drive Mount drive with its board in either a horizontal or vertical plane Six 0 19 inch 5 mm wide slots in the chassis accept 8 pan head screws Fasten either the large base or the flange of the chassis to the subplate 8 Installation Wiring A Warning Do not install remove or rewire this equipment with power A 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 printe
28. tations SPEED 1 Figure 13 Independent Adjustable Speeds Application Notes 39 RUN JOG switch Using a RUN JOG switch is recommended in applications where quick and frequent jogging is required Use a single pole two position switch for the RUN JOG switch and a single pole normally closed momentary operated pushbutton for the JOG pushbutton RUN JOG option 1 In the first wiring option connect the RUN JOG switch and JOG pushbutton to the inhibit plug as shown in Figure 14 The motor coasts or brakes to a stop when the RUN JOG switch is set to JOG Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation JOG PUSHBUTTON RUN O INHIBIT Figure 14 RUN JOG Option 1 RUN JOG Switch Connection to Inhibit Plug 40 Application Notes RUN JOG option 2 In the second wiring option connect the RUN JOG switch and the JOG pushbutton as shown in the Figure 15 When the RUN JOG switch is set to JOG the motor decelerates to minimum speed minimum speed is determined by the MIN trimpot setting Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation 3 SPEED ADJUST POTENTIOMETER 52 10K ohm 1 RUN JOG JOG PUSHBUTTON Figure 15 RUN JOG Option 2 RUN JOG Switch Connection to Speed Adjust Potentiometer Application Notes 41 Leader follower application In this application use a
29. 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 Al and A2 with each other Connect a DC motor to PCB terminals A1 and A2 as shown in Figure 3 Ensure that the motor voltage rating is consistent with the drive s output voltage 12 Installation Power lead connections Connect the AC line power leads to TB501 terminals L1 and L2 or to a double throw single pole master power switch recommended Dynamic brake resistor connections If you plan to use dynamic braking to stop the motor you must connect a dynamic brake resistor across the DB and DB terminals on the PCB as shown in Figure 3 The dynamic brake resistor reduces the voltage across the bus capacitors C503 and C504 when they reach their maximum voltage rating This occurs when the motor regenerates voltage back to the drive Bus capacitor maximum voltage ratings are 400 VDC for 240 VAC drives and 200 VDC for 115 VAC drives For more information on dynamic braking as well as selecting dynamic brake resistor values refer to the Dynamic Braking section on page 23 Installation 13 Also see Dynamic brake resistor DYNAMIC BRAKE sizing page 23 RESISTOR 115 GND LINE VOLTAGE 15 230
30. 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
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