USER`S MANUAL - Minarik Drives
Contents
1. 24 Input voltage calibration 24 Input current calibration 25 Troubleshooting 26 Before troubleshooting 26 Unconditional Warranty inside back cover iv Illustrations Figure 1 Process Control Module PCM4 Dimensions 2 Figure 2 Screw Terminal Block 7 Figure 3 115 VAC Power Connection 9 Figure 4 230 VAC Power Connection 9 Figure 5 Connection Following an External Signal 10 Figure 6 Unidirectional Manual Master Signal Source Connection 13 Figure 7 Bidirectional Manual Master Signal Source Connection 13 Figure 8 Connection Output Voltage 16 Figure 9 Connection Multiple Follower System 18 Figure 10 Signal Input Adjust 19 Figure 11 Connection Ratio Potentiometers Multiple Follower System 20 Figure 12 SIGNAL INPUT ADJ Calibration Positions 22 Figure 13 DIP Switch Settings 23 Specifications Power Requirements Line input 120 240 VAC 50 60 Hz single phase Input Signal Ranges input circuit is isolated Voltage signa Narrow_range 25 to 25 VDC Wide range 250 to 250 VDC Current signa 1 5 mADC 4 202. 18504 TE PT T zent 501 SAJ o C504 15 15 COM INPUT 1INPUT 2 T TB501 NTN O NS S S IS SI S S Ree Fe sau 5 6 7 8 9 1 AC POWER 230 VAC Figure 4 230 VAC Power Connection 10 Installation Input signal connections Connect the incoming voltage or current signal leads to INPUT 1 terminal 8 and to COM terminal 7 If the maximum input voltage will exceed 25V connect the signal leads to INPUT 2 terminal 9 and to COM terminal 7 See Figure 5 below Use insulated shielded wire or twisted pair for PCMA input and output signal leads longer than 18 inches Connect the shielding to earth ground at the end away from the PCM4 and trim the exposed shielding at the PCM4 to preclude accidental grounding of the PCM4 Bundle the signal carrying leads separately from the motor leads or AC power leads TO SU U 04 15 15 Con INPUT 1INPUT 2 TP 15 15 COM INPUT 1INPUT 2 TP SSSR GI SIS SO 5 6 7 8 9 10 5 6 7 8 9 10 C COM SIG COM SIG VOLTAGE SIGNAL RANGE VOLTAGE SIGNAL RANGE 0 25 VDC 0 250 VDC CURRENT SIGNAL RANGES 1 5mA 4 20 mA 10 50 mA Figure 5 Connection Following an External Signal Installation 11 Master signal generator A Warning Bidirectional output mode sh
3. Check voltage at TP vs COM to ensure that it is approximately 5VDC at the maximum input voltage Adjust SIGNAL INPUT ADJ if necessary Repeat steps 3 6 until no further recalibration is needed Input current calibration To calibrate when using a current input signal Verify that the correct DIP switch is ON and that the others are in the OFF position 2 Set the SIGNAL INPUT ADJ fully CW S Apply the lower current input 4 Set MIN OUT adjustment to obtain the desired lower voltage output Apply the higher current input Set MAX OUT adjustment to obtain the desired higher voltage output Repeat steps 3 6 until no further recalibration is necessary 26 Troubleshooting A Warning Dangerous voltages exist on the PCM4 when it is powered 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 PCM4 and variable speed drive 2 Check the PCMA and drive closely for damaged components 3 Check that no conductive or other foreign material has become lodged on the printed circuit board 4 Verify that every connection is correct and in good condition 5 Verify that there are no short circuits or grounded connections 6 Check that the input voltage jumpers are installed properly for the input voltage being used see page 6 7 Check that the drive s rated armature and
4. Figure 11 Connection Ratio Potentiometers Multiple Follower System 21 Calibration A Warning Dangerous voltages exist on the PCM4 when it is powered 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 22 Calibration Signal Input Adjust The SIGNAL INPUT ADJ potentiometer is used to set the maximum Test Point voltage to approximately 5 VDC as measured between terminals TP and COM The importance of this step is to scale the input signal voltage to keep it well within the range of the PCM4 s comparator chip This calibration is only approximate A tolerance of 0 2 Volts is acceptable The SIGNAL INPUT ADJ is calibrated only when the PCM4 is following a voltage signal When the PCM4 is following a current signal set the SIGNAL INPUT ADJ fully CW See Figure 12 for approximate calibration of SIGNAL INPUT ADJ To calibrate the SIGNAL INPUT ADJ 1 Apply the true maximum voltage input 2 Check voltage at TP vs COM to verify that it is approximately 5V Adjust SIGNAL INPUT ADJ if needed 0 25 VDC 0 250 VDC Figure 12 SIGNAL INPUT ADJ Calibration Positions Calibration 23 DIP switches A Warning Only one DIP switch should be ON at a time and only when the PCM4 is set up to follow a current signal All three DIP switches must be OFF when following a voltage signal
5. Screw terminal block Connections to Minarik s PCM4 are made to a screw terminal block Using a screwdriver turn the terminal block screw counter clockwise to open the wire clamp Insert stripped wire into the wire clamp Turn the terminal block screw clockwise to clamp the wire See Figure 2 Figure 2 Screw Terminal Block 8 Installation 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 2 amps AC and 250 volts AC line connections When operating on 120 VAC leave the jumper bars installed between terminals 1 and 2 and between 3 and 4 see Figure 3 This is how the unit is shipped from the factory When operating on 230V AC remove both jumper bars and place one jumper bar between terminals 2 and 3 see Figure 4 Connect the AC power leads to terminals 1 and 4 Installation 9 1C 504 EE P501 SW501 SAM C504 15 15 COM INPUT IINPUT 2 T 5 6 7 8 9 1 AC POWER 115 VAC Figure 3 115 VAC Power Connection
6. The center position of the wiper produces zero input voltage Potentiometer rotation CW from center produces increasing positive voltage CCW rotation from center produces increasing negative voltage Installation 13 S U C504 15 15 COM INPUT 1INPUT 2 TP MENU 5 6 7 8 9 10 CW 10K OHM SPEED ADJUST POTENTIOMETER NOT PROVIDED Manual Master Signal Source Connection Figure 6 Unidirectional 1 C504 15 15 COM INPUT TINPUT 2 50 SOSSSS UI A TE NE 10K OHM SPEED ADJUST POTENTIOMETER NOT PROVIDED n Figure 7 Bidirectional Manual Master Signal Source Connection 14 Installation Output voltage connections A Warning Always check the instruction manual supplied with the variable speed drive that will be interfaced with the PCM4 module The scheme shown for wiring to an external voltage source as well as the specifications on that input must be well understood before proceeding Output connections are made to the small terminal block on the board TB502 Connect the output leads to terminal 1 and 2 Figure 8 page 16 When the input signal at INPUTI is positive with respect to COM terminal 2 will be positive The exception to this polarity rule occurs when the PCMA has been calibrated to bias its ou
7. field outputs are consistent with the motor ratings Problem Motor attached to the drive does not run Possible Causes 1 No output voltage from PCM4 TB502 Loose connections between PCM4 and motor drive PCMd is not receiving AC line voltage Input signal is not connected SIGNAL INPUT ADJ potentiometer is not calibrated Motor drive not calibrated properly Troubleshooting 27 Suggested Solutions Recalibrate the PCMA If there is still no output send PCMA to Minarik for repair Check connections between TB502 and the input of motor drive Apply AC line voltage to terminals land 4 Check that the PCM4 is receiving voltage or current input signal Calibrate SIGNAL INPUT ADJ page 26 Re calibrate motor drive according to manufacturer s instructions 28 Troubleshooting Possible Causes Problem Suggested Solutions Motor is not running 1 Voltage out TB502 1 Check that the at full speed Motor runs too slow or too fast is not changing as input changes Loose connections between PCM4 and motor drive DIP switches are not set properly for current input Motor drive not calibrated properly voltage out TB502 is changing as input changes Recalibrate the PCMA If voltage is still not changing send the drive to Minarik repair Check connections between TB502 and the input of motor dri
8. Each DIP switch selects the range for input current following DIP switch 1 is for 1 5 mA input DIP switch 2 is for 4 20 mA input and DIP switch 3 is for 10 50 mA input VOLTACE 1 5 mA CLRRENT EN 1053 mA CURAENT SIGNAL SIGNAL SIGN SIGNAJ INPUT IN NPI INPUT z z z 3 S E 1E ER q t FEI seem sweet Bus swam Figure 13 DIP Switch Settings 24 Calibration Input signal calibration Calibration of the MIN OUT and MAX OUT 15 turn trimpots is required to establish the relationship between the input voltage signal range and the output range The true maximum and minimum input signal values are not required Because the PCM4 response is linear any two calibration points define the output vs input relationship Select points as close to the range extremes as possible to minimize extrapolation error The absolute maximum output from the PCM4 is 10 VDC The minimum input voltage to the PCM4 that can produce 10 VDC output is 5 VDC Input voltage calibration To calibrate when using a voltage input signal 1 Verify that all DIP switches are OFF 2 Set the SIGNAL INPUT ADJ to the input range position as indicated on Figure 12 page 22 3 Apply the lower voltage input 4 Set MIN OUT adjustment to obtain the desired lower voltage output 9 Calibration 25 Apply the higher voltage input Set MAX out adjustment to obtain the desired higher voltage output Apply the true maximum input voltage
9. USER S MANUAL PROCESS CONTROL MODULE PCM 4 M Autometion mar k Control Copyright O 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 A X X as ACID Er SO IS DRY VIDRATION This symbol A 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 c
10. ch variable speed drive Included are all Minarik models in the MM20000 series XL series and all regenerative drives RG series A multiple follower system using any of these drives must consist of a master PCMA driving follower PCM4 modules See pages 18 and 19 of this manual MM30000 series Minarik s MM30000A series drives can be operated with their boards sharing one common This series of drives is the only Minarik series that permits more that one drive to follow a single PCM4 module See Figure 9 The number of MM30000 type drives that can be driven by one PCM4 is limited by the output impedance of the PCMA Potentiometers may be wired in parallel with the PCM4 output for final speed adjustments and ratioing The net resistance of these paralleled ratioing pots must be at least 800 ohms 18 Installation When using ratioing potentiometers connect each MM30000 series drive to the master PCM4 as detailed in Figure 9 The input to the master PCMA can be any of the standard single quadrant inputs discussed in this manual MM31002A DRIVE INH2 S2 MM31002A DRIVE INH2 S2 cw PCM 4 OUTPUT 2 OUTPUT 1 15 COM INPUT TERM 5 TERM 7 TERM 8 cw av cw MM31002A DRIVE INH2 S2 Figure 9 Connection Multiple Follower System Installati
11. e mounting surface Installation Wiring A Warning Do not install remove or rewire this equipment with power Y applied Failure to heed this warning may result in fire explosion or serious injury Circuit potentials are at 120 or 240 VAC above ground To prevent the risk of injury or fatality avoid direct contact with the printed circuit board or with circuit elements Use 18 24 AWG wire for signal wiring Use 16 18 AWG wire for AC line L1 L2 wiring 5 6 Installation Shielding guidelines A Warning Under no circumstances should power and logic leads be bundled together Induced voltage can cause unpredictable behavior any electronic device As a general rule Minarik recommends shielding of all conductors Tf it is not practical to shield power conductors Minarik recommends shielding all logic level leads If shielding of logic level leads is not practical the user should twist all logic leads with themselves to minimize induced noise It may be necessary to earth ground the shielded cable Do not ground both ends of the shield If the drive continues to pick up noise after grounding the shield it may be necessary to add AC line filtering devices or to mount the drive in a less noisy environment Logic wires from other input devices such as motion controllers and PLL velocity controllers must be separated from power lines in the same manner as the logic I O on the PCMA Installation 7
12. erly installed C Limitations of Liability In the event of any claim for breech 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
13. mADC 10 50 mADC Input Impedance Voltage signa gt 25K ohms Current signal 1 5 mADC 1K ohm 4 20 mADC 235 ohms 10 50 mADC 100 ohms Output Impedance 800 ohms Voltage range max 10 to 10 VDC Linearity 0 01 Operating Temperature Range 0 50 EV Dimensions 4 83 123 1 MODEL PCM4 c50 CHE WWW MINARIKCORP COM w 120 240 VAC maris Corp Our A O A 2 1 WATTS E k O E E hue 1 93 49 au int Rte 123 3 bad Ls 2 70 69 S csee len ae Kei Fase ant NOS FOTEN NA ON SS SISI O dt AM ei KT 5 6 7 8 9 10 a a in A 1 30 33 i 31 0 35 9 4 22 107 4 x 0 25 6 STANDOFF USE 8 PANHEAD SCREWS ALL DIMENSIONS IN INCHES MILLIMETERS Figure 1 Process Control Module PCM4 Dimensions Introduction Model PCM4 accepts a grounded or floating bipolar DC signal input and generates a proportional floating output voltage The output of the PCM4 follows the variations of its input it increases as the signal increases and decreases as the signal decreases This output can be supplied to the speed setting circuit of a motor drive to rotate the motor at a speed proportional to the signal inp
14. of such action arises M Automation nari k amp Control 901 East Thompson Avenue Glendale CA USA 91201 2011 Tel 1 800 MINARIK 646 2745 Fax 1 800 394 6334 www minarikcorp com Document number 250 0152 Revision 5 Printed in the U S A 4 01 North America 10 00 Outside North America 11 00
15. on 19 Multiple drives following a single signal input When more that one Minarik drive must follow one voltage signal each must be wired individually to dedicated PCM4 modules Each PCM4 module then receives the master input signal The MM30000 series discussed in the preceding paragraphs is the only exception Each of the PCM4 units must first be modified 1 Check that all 3 DIP switches SW501 located near the center of the board are in their OFF position 2 Cut the left hand CCW pin of P501 the SIGNAL INPUT ADJ off each PCM4 The figure below shows this trimmer potentiometer SIGNAL INPUT ADJ CUT AND REMOVE LEFT PIN OF THE SIGNAL INPUT ADJ TRIMPOT ON EACH PCM4 BOARD Figure 10 Signal Input Adjust 20 Installation Connect one 50K ohm ratioing potentiometer across the master input voltage signal for each dedicated PCM4 module Wire each ratioing pot to the input signal source potentiometer as shown in Figure 11 below Master PCM4 with multiple drives following If a PCM4 is to provide the master input voltage signal as detailed on pages 14 15 dedicated PCM4s are again necessary Each of the PCM4s must be modified as detailed on page 19 Ratioing potentiometers may then be wired with their CW sides to terminal 2 of the master PCM4 and their CCW sides to terminal 1 of the master PCM4 MASTER INPUT SIGNAL POTENTIOMETER 50K 50K 50K 9 PCM4 1 10
16. ould never be used with standard SCR single quadrant variable speed drives These drives only respond to one polarity in their speed setting circuits The PCM4 can be used as a master controller to 1 provide a floating DC master voltage input to other PCM4 modules interfacing with standard variable speed drives or 2 to drive several variable speed drives directly provided that their circuit design permits wiring of their speed circuits in common Unidirectional applications require a positive PCMA output Connect a 10K ohm potentiometer not provided with the PCM4 as the master control pot using the 15 VDC supply on the PCM4 The normal wiring of an external master control potentiometer is the CW side of the potentiometer to 15 V supply terminal 6 and the CCW side to COM terminal 7 The potentiometer wiper is connected to INPUT 1 terminal 8 See Figure 6 pagel3 The potentiometer is rotated clockwise to increase the voltage at INPUT 1 and therefore increasing the PCM4 output voltage 12 Installation Bipolar input is necessary to control motor reversals when the motor is being driven by a four quadrant regenerative variable speed drive To wire the external master control potentiometer to provide a bipolar adjustable voltage input signal wire the potentiometer across the 15 and 15V supply terminals with the CW end at 15V Connect the pot wiper to the INPUT 1 terminal 8 See Figure 7 page 13
17. tput as a voltage follower An input of zero volts can be calibrated to produce a finite positive or negative output voltage The PCM4 output is a floating DC voltage It is brought into the speed setting circuit of a variable speed drive to replace the main speed adjust potentiometer Installation 15 Most Minarik SCR type non regenerative drives are designed with the speed setting voltage positive with respect to board common The positive external signal is brought to the speed pot wiper terminal usually designated S2 and the common signal lead to the speed pot CCW terminal usually S1 16 Installation PCM4 XL XLT ka SERIES DRIVE TB502 S 0 5 VDC OUTPUT 52 st PCM4 MM20000 SERIES DRIVE TB502 S 0 2 8 VDC OUTPUT s st PCM4 RG51UA TB502 eN amp 0 10 VDC OUTPUT 52 so RG300 RG310 POM RG400 TB502 S 0 10 VDC OUTPUT RB2 RB1 PCM4 RG300A RG310A RG400A TB502 et amp 0 10 VDC OUTPUT RB1 AY s2 E Figure 8 Connection Output Voltage Installation 17 Multiple follower requirements A Warning Most Minarik variable speed drives cannot be wired with their speed setting circuits in common with each other They require a dedicated PCMA for ea
18. urrent protection thermal protection and enclosure Follow sound maintenance procedures Circuit potentials are at 120 VAC or 240 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 Safety Warnings sasa EN di ER RYE i Specifications i s nba VA A xe RE dame 1 Dimensions T ER Se ener ee ees 2 Introduction cle E ees 3 Installation 7 88 up ge et yest R Tea 5 Epp a 4 MOUNTING Suicida ana oc ay V 4 WINING crm a a RE pu 5 Shielding guidelines 6 Screw terminal block 7 CONNECHIONS isak Yrs y us ie vu 8 AC line connections 8 Input signal connections 10 Master signal generator 11 Output voltage connections 14 Multiple follower requirements 17 MM30000 series 17 Multiple drives following a single signal input 19 Master PCM4 with multiple drives following 20 Calibration A id eee elas 21 Signal Input Adjust 22 DIP Switches toe o weed shake 23 Input signal calibration
19. ut Because the PCM4 can follow bipolar input voltage signals it can drive a regenerative variable speed drive through the complete range of motor speeds in both forward and reverse directions This manual contains specifications installation procedures connections and calibration procedures for the process control module model PCM4 Refer to your variable speed drive user s manual for additional installation operation and troubleshooting procedures 4 Installation A 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 before attempting installation Mounting PCM4 components are sensitive to electrostatic fields Avoid contact with the circuit board directly e Protect the PCM4 from dirt moisture and accidental contact Provide sufficient room for access to the terminal block Mount the PCM4 away from other heat sources Operate within the specified ambient operating temperature range The operating temperature range for the PCM4 is 0 C through 50 C Prevent loose connections by avoiding excessive vibration of the process control module board Mount the PCM4 in either a horizontal or vertical plane The PCM4 is mounted using 4 0 25 inch 6mm standoffs See Figure 1 page 2 for the physical locations of these standoffs Use 8 panhead screws to fasten the standoffs to th
20. ve Check DIP switch positions if using current input Re calibrate motor drive according to manufacturer s instructions Notes 29 30 Notes Notes 31 32 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 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 improp
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