User Manual
Contents
1. FORWARD REVERSE F TRIGGERING gt H STAGE cw DEAD BAND rn gt gt gt Figure 19 4 1 3025 Series Block Diagram 41 Y29019 vOOZETXPO 02 5 quaa 4 sor as wn 1Nadano aaads vo Sor Sie LNT sino NI 095 r ads is am oly Mawod SL adoJSNVHL 10H1NOO ote Es 5 aaads H NIW Moloalaa JNadanoyvad aolvaaNae E m 21901 1 oly Se Si sie aNnouo SISSVHO T esd I gt ate Fn 3ovis 1Hon me H raw indino T X nun isd isd z4 Adans 42 Replacement Parts Replacement parts are available from Minarik Corporation and its distributors for this drive series Model No Symbol Description Minarik P N C4XL3025 C506 470 MF 400 VDC Capacitor 011 0120 D501 8A 6002. Power Switch black black whit PS1 BE or Q e ps2 lan Power 5 7 white white black PS3 Go 54 violet CW 51 brown 10K ohm 2 Speed Adjust Potentiometer re 53 grey Figure 5 Prewired Connections for Models C4XL3025 and C4XL3200A 12 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 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 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 this drive In
3. 18 Startup Di da raeadr eee eat 19 Diagnostic LEDS rex ERE e ERE RUD E 19 Line starting and line stopping 21 Inhibit circuit dr drea eve peores qt Yl D d D Ut es ate 21 Decelerating to minimum speed 23 Dyriamic brakirng tees saad 24 Calibration aiaks rieren a c 26 MINIMUM SPEED MIN SPD 27 MAXIMUM SPEED MAX SPD 27 ACCELERATION ACCEL 28 DECELERATION DECEL 28 IR COMPENSATION IR COMP 29 CURRENT LIMIT CURR LIMIT C4XL3025 TORQUE LIMIT TORQ LIMIT CAXL3200A 30 Calibration with low voltage DC motors 32 Application Notes 34 Leader follower application 34 Single speed potentiometer control of multiple drives 35 Troubleshooting 222 bbe tiles Pee eas aed eR 36 Before troubleshooting 36 Block Diagrarri x cessere EE NEM 40 Replacement Parts 42 Certificate of Compliance
4. Excel XL Series USER S MANUAL MODELS C4XL3025 C4XL3200A Pulse Width Modulated Adjustable Speed Cased Drives for DC Brush Motors Copyright 2006 by Drives rights reserved part of this manual may be reproduced or transmitted in any form without written permission from Minarik Drives 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 0 Safety Warnings A 2 IAZARD HEAT DRY VIBRATION This symbol AN denotes an important safety tip or warning Please read these sections carefully prior to performing any of the instructions contained in that section Have a qualified electrical maintenance 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 groundi
5. 44 AC Line Filters secon cece RIP eee ta DAL eA Logs LPS 44 Unconditional Warranty inside back cover Tables Table 1 Field Output Connections 13 Table 2 Fuse IRR 15 Table 3 Recommended Dynamic Brake Resistor Sizes 25 Table 4 AC Line Filters 45 Illustrations Figure 1 C4XL3025 Dimensions 5 Figure 2 C4XL3200A Dimensions 6 Figure 3 C4XL3025 Connections 9 Figure 4 C4XL3200A Connections 10 Figure 5 Prewired Connections for Models C4XL3025 and C4XL3200A 11 Figure 6 Voltage Follower Connections 16 Figure 7 Cage Clamp Terminal 17 Figure 8 Voltage Switch Location asaan uee uenee 18 Figure 9 Diagnostic LED Location 20 Figure 10 Inhibit Plug with Run Coast to Zero Speed Switch 22 Figure 11 Run Decelerate to Minimum Speed Switch 23 Figure 12 Dynamic Brake Connection 24 Figure 13 C4XL3025 CURR LIMIT and IR COMP Settings 31 Figure 14 C4XL3200A TORQ LIMIT and IR COMP Settings 31 Figure 15 C4XL3025
6. MAX SPEED Settings for Low Voltage DC Motors 32 Figure 16 C4XL3200A MAX SPD Settings for Low Voltage DC Motors 33 Figure 17 Leader Follower 34 Figure 18 Single Speed Potentiometer Control of Multiple Drives 35 Figure 19 C4XL3025 Series Block Diagram 40 Figure 20 C4XL3200A Block Diagram 41 Specifications Model Number C4XL3025 Type Cased NEMA Rating NEMA 4X AC Line Voltage 115 VAC 230 VAC 10 50 60 Hz single phase Line Fuse Rating 8A Horsepower Range 130 VDC Output 1 20 1 3 HP Horsepower Range 240 VDC Output 1 8 1 2 HP Maximum Armature Voltage Range 115 VAC Input 50 130 VDC Maximum Armature Voltage Range 230 VAC Input 50 240 VDC Minimum Speed Adjustment Range 115 VAC Input 0 65 VDC Minimum Speed Adjustment Range 230 VAC Input 0 65 VDC Maximum Armature Current 3 ADC Field Voltage 115 VAC Input 50 VDC 100 VDC Field Voltage 230 VAC Input 100 VDC 200 VDC Maximum Field Current 1 ADC Form Factor 1 05 Acceleration Time Range no load for 0 130 VDC Armature Voltage Range 1 10 seconds for 0 240 VDC Armature Voltage Range 1 19 seconds Deceleration Time Range no load for 0 130 VDC Armature Voltage Range 3 9 seconds for 0 240 VDC Armature Voltage Range 4 19
7. is turned CW Continue until the desired speed is reached 5 Set the POWER switch to the OFF position to coast the motor to a stop the motor or drive does not perform as described disconnect the AC line voltage immediately Refer to the Troubleshooting section on page 36 for further assistance Diagnostic LEDs XL series drives are equipped with diagnostic LEDs The green POWER ON LED turns on when power is applied to the drive and turns off when power is removed The red CURR LIMIT LED turns on when the drive reaches current limit and turns off when the drive is not in current limit normal operation See Figure 9 on page 20 for Diagnostic LED locations 20 Operation eis 502 1C502 1 501 C504 L 7 POWER ON CURR LIMIT i PS2 psa 10501 1509027 i 5050 50504 9 9 p i POWER CURR 5 i C4XL3200 LEDs C4XL3025A LEDs PS1 PS3 841 52 53 IAXSPD CURRLIMT IRCOMP POWER CURR 50901 ON LIMIT 1 M olo c MINSPD ACCEL DECEL NHIBN 1501 1502 115 230 F1 F2 A2 A1 Figure 9 Diagnostic LED Location Operation 21 Line starting and line stopping Line starting and line stopping applying and removing AC line voltage is recommended for infrequent starting and stopping of a drive only When AC line voltage is applied to the drive the motor accele
8. power disconnected from the control connect a DC ammeter 0 15 A minimum scale in series with the armature 2 Set the CURR LIMIT or TORQ LIMIT trimpot to minimum full CCW 3 Set the speed adjust potentiometer to maximum full CW 4 Lock the motor armature Be sure that the motor is firmly mounted 5 Connect power to the drive The motor should remain stopped 6 Adjust the CURR LIMIT or TORQ LIMIT trimpot CW slowly until armature current is 120 of motor rated current 7 Set the speed adjust potentiometer to minimum 8 Remove power 9 Remove the stall from the motor Calibration 31 1 20 HP 1 8 HP 90 VDC O 180 VDC 1750 RPM 1750 0 5 Amps 0 67 Amps CURR LIMIT IR COMP CURR LIMIT IR COMP 1 8 HP 1 4 HP O Q 90 VDC O Q 180 VDC O 1750 RPM K xx f 1750 RPM 1 3 Amps 1 4 Amps CURR LIMIT IR COMP CURR LIMIT IR COMP 1 4 HP 1 3 HP 90 VDC 180 1750 1750 2 5 Amps 1 75 Amps CURR LIMIT IR COMP CURR LIMIT IR COMP Figure 13 C4XL3025 CURR LIMIT and IR COMP Settings 1 4 HP 1 2 90 VDC 180 VDC 5 1750RPM 1750 RPM 2 5 Amps IRcoMP 2 5 Amps 1 2 1 Q 2 30 VDE A 180 VDC Coy 1750 RPM 1750 RPM 5Amps TORQLIMIT 5 Amps 1 4 2HP 2 30006 O 180 VDC cf Wey 1750RPM ux M 1750 RPM 10 Amps 9 Amps TORQ LIMIT IR COMP TO
9. seconds Analog Input Voltage Range signal must be isolated 51 to 52 for 0 130 VDC Armature Voltage 0 2 7 VDC for 0 240 VDC Armature Voltage 0 5 0 VDC 2 Specifications Speed Adjustment Potentiometer 10K ohms Approximate Input Impedance from S1 to S2 100K ohms Speed Regulation at base speed 1 Weight 4 4 Ib Ambient Operating Temperature Range 10 C 40 C Vibration 0 5g max 0 50 Hz 0 1g max above 50 Hz Specifications 3 Model Number C4XL3200A Type Cased NEMA Rating NEMA 4X AC Line Voltage 115 VAC 230 VAC 10 50 60 Hz single phase Line Fuse Rating 15A Horsepower Range 130 VDC Output 1 4 1 Horsepower Range 240 VDC Output 1 2 2 HP Maximum Armature Voltage Range 115 VAC Input 50 130 VDC Maximum Armature Voltage Range 230 VAC Input 50 240 VDC Minimum Speed Adjustment Range 115 VAC Input 0 120 VDC Minimum Speed Adjustment Range 230 VAC Input 0 120 VDC Maximum Armature Current 10 ADC Field Voltage 115 VAC Input 50 VDC 100 VDC Field Voltage 230 VAC Input 100 VDC 200 VDC Maximum Field Current 1 ADC Form Factor 1 05 Acceleration Time Range no load for 0 130 VDC Armature Voltage Range 1 10 seconds for 0 240 VDC Armature Voltage Range 1 15 seconds Deceleration Time Range no load for 0 130 VDC Armature Voltage Range 1 10 seconds for 0 240 VDC Armature Voltage Range 1 19 seconds Analog Input Voltage Range signal must be isol
10. the front of the motor If the opposite is desired simply reverse the wiring of A1 and A2 with each other TB501 L1 115 230 1 2 1 115 2 Output AC Line Voltage 2 1 115 230 2 230 Field Output Shunt wound motors only See Field Output section for connections Figure 3 C4XL3025 Connections 10 Installation 1 234 POWERON CURR LIMIT Ps3 i d 1501 50503 50502 505 TNHIBIT 115 53 EH MINSPD DECEL Eu ee oo St s2 SPD SPD JOG IN Te 7 SPD and SPD IN are n prewired for speed adjust 4 poteniometer control i jjo m A2 b To control speed with JOG H N trimmer potentiometer if X N connect SPD IN to JOG i P N H N Motor will not turn if there is TB501 S no connection to SPD IN Si L1 230 115 F A1 A2 230 C Armature C Output AC Line Voltage 115 230 L Field Output Shunt wound motors only See Field Output section for connections Figure 4 C4XL3200A Connections Installation 11
11. 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 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 exten
12. 0W 10 17 ADC 40 ohm 50W For motors rated 1 7 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 with 12 gauge wire 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 Each drive is factory calibrated to its maximum current rating Readjust the calibration trimpot settings to accommodate lower current rated motors 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 MINIMUM SPEED MIN SPD The MIN SPD setting determines the motor speed when the speed adjust potentiometer is turned full CCW It is factory set to zero speed To calibrate turn the speed adjust potentiometer full CCW To set the minimum speed to zero rotate the MIN SPD trimpot CCW until the motor has stopped To set a minimum speed higher than zero rotate the MIN SPD trimpot CW until the motor is running at the desired minimum spe
13. RQ LIMIT IR COMP Figure 14 C4XL3200A TORQ LIMIT and IR COMP Settings 32 Calibration Calibration with low voltage DC motors Using an XL series drive with a low voltage DC motor requires using a lower resistance speed adjust potentiometer and recalibrating the MAX SPEED trimpot settings See Figure 15 below and Figure 16 on page 34 for MAX SPEED trimpot settings NOTE MAX SPEED trimpot settings are approximate Verify maximum armature voltage with a voltmeter MAX SPEED TRIMPOT SETTING MOTOR ARMATURE USING 2 5K OHM USING 1 5K OHM VOLTAGE VDC SPEED ADJUST SPEED ADJUST POTENTIOMETER POTENTIOMETER 202 0056 202 0001 s Figure 15 C4XL3025 MAX SPEED Settings for Low Voltage DC Motors E Calibration MAX SPEED TRIMPOT SETTING MOTOR ARMATURE USING 2 5K OHM USING 1 5K OHM VOLTAGE VDC SPEED ADJUST SPEED ADJUST POTENTIOMETER POTENTIOMETER 202 0056 202 0001 19 APPLICABLE APPLICABLE NOT NOT 24 APPLICABLE APPLICABLE Figure 16 C4XL3200A SPD Settings for Low Voltage DC Motors 33 34 Application Notes Leader follower application In this application use a PCM4 to monitor the speed of the leader motor Figure 17 The PCM4 isolates the leader motor from the follower drive and outputs a voltage proportional to the leader motor armature voltage The follower
14. V Diode 071 0055 Q501 IGBT Module 070 0051 R501 502 0 05 ohm 5 W Resistor 032 0146 T501 3FD 436 Transformer 230 0072 TH501 WS380 15A Imax Limiter 033 0006 Pot 10K ohm 5 W Potentiometer 120 0009 Knob 140 0013 DPDT Power Switch 080 0009 Power Switch Boot 155 0078 43 Model No Symbol Description Minarik P N C4XL3200A 505 507 680 MF 400 VDC Capacitor 011 0080 D501 FES16FT Diode 071 0044 Q501 502 Power Mosfet 070 0066 R501 0 01 ohm 5 W Resistor 032 0129 T501 3FD 436 Transformer 230 0072 TH501 30A 1 ohm Thermistor 033 0016 pot 10K ohm 5 W Potentiometer 120 0009 Knob 140 0013 DPDT Power Switch 080 0037 Power Switch Boot 155 0078 44 Certificate of Compliance Minarik Corporation hereby certifies that its XL series drives models C4XL3025 and C4XL3200A have been approved to bear the CE mark provided the conditions of approval have been met by the end user The XL series has been tested to the following test specifications EN55014 1993 emmisions and EN50082 1 1992 immunity Compliance allows Minarik s XL 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 AC Line Filters In addition to EMI RFI safeguards inhe
15. ated S1 to 52 for 0 130 VDC Armature Voltage 0 2 7 VDC for 0 240 VDC Armature Voltage 0 5 0 VDC Speed Adjustment Potentiometer 10K ohms 4 Specifications Approximate Input Impedance from S1 to S2 50K ohms Speed Regulation at base speed 1 Weight 7 4 Ib Ambient Operating Temperature Range 109 409 Vibration 0 59 max 0 50 Hz 0 1g max above 50 Hz Dimensions 6 90 175 gt 0 91 23 8 20 207 POWER SPEED 50 Q 40 60 20 80 10 90 0 100 OFF 1 4 SOUTH BELOTTL MADEINUSA 7 78 197 6 00 152 4 43 112 0 13 3 d i Ga FOUR MOUNTING SLOTS 0 19 5 WIDE QO 3 29 83 2 50 63 TWO 0 88 22 KNOCKOUTS ALL DIMENSIONS IN INCHES MILLIMETERS 1 92 49 Figure 1 4 1 3025 Dimensions Dimensions 690 751 6 30 159 1 37 35 i 5 40 50 60 ri 30 H 1d ON 20 80 X n 10 22 259 9 75 247 7 00 177 Jo FOUR MOUNTING SLOTS 0 19 5 WIDE 5 79 146 aH 4 69 119 1 45 37 4 2 31 58 B 0 12 3 1 50 38 1 50 38 THREE 0 88 22 KNOCKOUTS ALL DIMENSIONS IN INCHES MILLIMETERS Figure 2 C4XL3200A Di
16. 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 Follower 91 Drive PCM4 10K Ohm optional Figure 17 Leader Follower Application Application Notes 35 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 18 Optional ratio potentiometers can be used to scale the PCM4 output voltage allowing independent control of each drive ratio potA optional 10K Ohms 10K Ohms 5 7 1 TB501 TB502 A1 Drive 2 1 2 ratio pot optional 10K Ohms PCM4 7 1 501 TB502 A1 52 51 2 Figure 18 Single Speed Potentiometer Control of Multiple Drives 36 Troubleshooting 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 AC line voltage from the drive while troubleshooting Be alert High voltages can cause serious or fatal injury Before troubleshooting Perform the following steps before starting any procedure in this section 1 Disconnect AC line voltage from the drive 2 Check the drive closely for damaged components 3 Check that no conductive or ot
17. ed 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 Turn the speed adjust potentiometer full CW Adjust the MAX SPD trimpot until the desired maximum motor speed is reached Note Check the MIN SPD and MAX SPD adjustments after recalibrating to verify that the motor runs at the desired minimum and maximum speed 28 Calibration ACCELERATION ACCEL The ACCEL setting determines the time the motor takes to ramp to a higher speed See Specifications on page 1 for approximate acceleration times The ACCEL setting is factory set to its minimum value full CCW Turn the ACCEL trimpot CW to increase the acceleration time and CCW to decrease the acceleration time DECELERATION DECEL The DECEL setting determines the time the motor takes to ramp to a lower speed See Specifications on page 1 for approximate deceleration times The DECEL setting is factory set to its minimum value full CCW Turn the DECEL trimpot CW to increase the deceleration time and CCW to decrease the deceleration time Calibration 29 IR COMPENSATION IR COMP The IR COMP setting determines the degree to which motor speed is held constant as the motor load changes It is factory set for optimum motor regulation Recalibrate the IR COMP setting when using a lower horsepower motor Re
18. fer to the recommended IR COMP settings in Figure 13 or 14 on Page 31 or recalibrate using the following procedure To calibrate IR COMP exact calibration 1 Set the speed adjust potentiometer until the motor runs at midspeed for example 900 RPM for an 1800 RPM motor 2 Load the motor armature to its full load armature current rating The motor should slow down 3 While keeping the load on the motor rotate the IR COMP trimpot until the motor runs at the speed measured in step 1 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 30 Calibration CURRENT LIMIT CURR LIMIT C4XL3025 or TORQUE LIMIT TORQ LIMIT C4XL3200A A Warning Although TORQUE 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 CURR LIMIT or TORQ LIMIT setting determines the maximum armature current output of the drive It is factory set at 120 of rated motor current Recalibrate the CURR LIMIT or TORQ LIMIT setting when using a lower horsepower motor Refer to the recommended trimpot settings on page 31 or recalibrate using the following procedure 1 With the
19. her foreign material is lodged on the printed circuit board 4 Verify that every connection is correct and in good condition 5 Verify that there are no short circuits or grounded connections 6 Check that the voltage selection switch settings match the AC line and output voltages Problem Possible Causes Troubleshooting Suggested Solutions Line fuse blows Motor runs too fast at maximum speed setting Line fuses are the wrong size Motor cable or armature is shorted to ground Nuisance tripping caused by a combination of ambient conditions and high current spikes i e reversing MIN SPD and MAX SPD settings are too high 1 Check that line fuses are the correct size Check motor cable and armature for shorts 3 Add a blower to cool the drive components increase CURR LIMIT or TORQ LIMIT settings Recalibrate MIN SPD and MAX SPD 37 38 Troubleshooting Problem Possible Causes Suggested Solutions Line fuse is not blown but the motor does not run Speed adjust potentiometer or voltage input signal is set to zero speed Speed adjust pot or voltage input signal is not connected to drive input properly connections are open 82 is shorted to SO Drive is in current limit Drive is not receiving AC line voltage Motor is not connected Increase the speed adjust potentiomete
20. mensions Installation Mounting Nema 4X cased drives come with 0 88 inch 22 mm conduit knockout holes at the bottom of the case The units may be vertically wall mounted using the four 0 19 inch 5 mm slotted holes on the attached heat sink For motor loads less than 5 ADC the drive may be bench mounted horizontally or operated without mounting 1 Install the mounting screws through the drive s four mounting slots 2 For access to the terminal strip turn the slotted screw on the front cover counterclockwise until it is free from the case The right side of the cover is hinged to the case Pull the slotted screw to open the case 3 Carefully remove the 0 88 inch 22 mm conduit knockouts by tapping them into the case and twisting them off with pliers 4 Install conduit hardware through the knockout holes Connect external wiring to the terminal block 8 Installation 5 Grasp the slotted screw and tilt the front cover back into place Avoid pinching any wires between the front cover and the case 6 Turn the slotted screw clockwise until tight to secure the front cover 7 Set the POWER switch to the OFF position before applying the AC line voltage Installation 9 Connections Minarik drives supply motor voltage to terminals 1 2 1 is positive with respect to A2 It is assumed throughout this manual that the driven motor will rotate clockwise CW while looking at the output shaft protruding from
21. ng 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 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 i Specifications Pa eS 1 5 Installation 7 Mounting fet meee teckel ad yale 7 9 Shielding guidelines 12 Field Output lt LASS ee hed Vee eR Cd 13 FUSING A 14 Line Fusing for XL Series Drives 15 Voltage Follower 16 Terminal Block oe een ne kee eres ER E YEA EVE le a wade 17 Operation 4 se dels eruere 18 Before applying power
22. ot is set full CCW the motor decelerates to zero speed when the switch between 51 and 52 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 10K OHM SPEED ADJUST POTENTIOMETER DECEL TO MIN SPEED Figure 11 Run Decelerate to Minimum Speed Switch 24 Operation Dynamic braking Dynamic braking may be used to rapidly stop a motor Figure 12 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 DYNAMIC BRAKE RESISTOR INHIBIT Figure 12 Dynamic Brake Connection Operation 25 A Warning Wait for the motor to come to a complete STOP before switching back to the RUN position This will prevent high armature currents from damaging the motor or drive Size the dynamic brake resistor according to the motor current rating see Table 3 The dynamic brake resistance listed in the table is the smallest recommended resistance allowed to prevent possible demagnetization of the motor The motor stops less rapidly with higher brake resistor values Table 3 Recommended Dynamic Brake Resistor Sizes Minimum Minimum Motor 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 2
23. r or voltage setting Check connections to input Verify that connections are not open Remove short Verify that motor is not jammed Increase the TORQ or CURR LIMIT setting It may be set too low 5 Apply AC line voltage to L1 and 12 Connect motor to 1 and 2 Problem Possible Causes Troubleshooting 39 Suggested Solutions Motor runs too slow or too fast Motor will not reach the desired speed Motor pulsates or surges under load MIN SPD and MAX SPD not calibrated MAX SPD setting is too low IR COMP setting is too low Motor is overloaded IR COMP is set too high Motor bouncing in and out of torque limit 1 Calibrate MIN SPD and MAX SPD Increase MAX SPD setting Increase the IR COMP setting Check motor load Resize the motor and drive if necessary Adjust the IR COMP setting slightly CCW until the motor speed stabilizes Make sure motor is not undersized for load adjust the CURR or TORQ LIMIT trimpot 40 Block Diagram F1 FIELD SL NN SUPPLY L2 L1 CONTROL LOGIC POWER CONTROL 40 TRANSFORMER 10K s2 s1 OUTPUT STAGE E TAS R501 INHIBIT STAGE so m
24. rates to the speed set by the speed adjust potentiometer When AC line voltage is removed the motor coasts to a stop Inhibit circuit A Warning The inhibit circuit is used for frequent starts and stops It must never be used as an emergency stop The inhibit circuit may not stop a drive that is malfunctioning Removing AC line power both L1 and L2 is the only acceptable method for emergency stopping Maintaining a connection between the inhibit pins causes the motor to coast to zero speed Removing the connection between the inhibit pins allows the motor to accelerate the speed set by the speed adjust potentiometer See Figure 10 on Page 22 22 Operation Minarik Corporation offers two accessory plug harnesses for connecting to the inhibit pins part number 201 0024 inhibit plug with 18 in 46 cm leads and part number 201 0079 inhibit plug with 36 in 91 cm leads Twist these leads and separate them from other power carrying wires or sources of electrical noise Use shielded cable if the inhibit leads are longer than 18 in 46 cm RUN COAST TO ZERO SPEED INHIBIT Figure 10 Inhibit Plug with Run Coast to Zero Speed Switch Operation 23 Decelerating to minimum speed The circuit shown in Figure 11 may be used to decelerate a motor to a minimum speed Closing the switch between 51 and 52 decelerates the motor from set speed to a minimum speed determined by the MIN SPD trimpot setting If the MIN SPD trimp
25. rent in the XL series design external filtering is required Minarik requires the AC line filters listed in Table 4 Use model CE04XL with drives rated for AC or below model CE10XL with drives rated for 10A AC or below and model CE15XL for drives rated 15AAC or below Certificate of Compliance 45 Table 4 AC Line Filters Minarik Model Number CE04XL CE10XL CE15XL Rated Current 4A 10A 15A Inductance 17 5 mH 14 3 mH 10 0mH Capacitance Line to Line 0 82 mF 0 82 mF 0 82 mF Line to Ground 0 0056 mF 0 0056 0 0056 mF Discharge Resistor 330 KW 330 KW 330 KW Wire the AC line filter 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 If the end user is using a CE approved motor the correct filter from Table 4 is all that is necessary to meet the EMC directives listed herein 46 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
26. ses rated for 250 VAC or higher and approximately 150 of the maximum armature current Fuse both L1 and L2 when the line voltage is 230 VAC Fuse blocks are included on cased drives only The fuse chart below lists the recommended line fuse sizes Table 2 Fuse Chart 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 a 63 mA pico fuse for the C4XL3025 part number 050 0081 which protects the transformer and logic 16 Installation Voltage Follower Instead of using a speed adjust potentiometer the drive may be wired to follow a 0 10 VDC voltage signal that is isolated from earth ground Figure 6 Connect the signal input to 51 Connect the signal common to S2 Make no connection to S3 A potentiometer can be used to scale the analog input voltage To achieve greater linearity and control use an interface device such as Minarik model PCM4 to scale the analog input voltage Refer to the Specifications section on page 1 for the analog input voltage range of the XL drive you are using XL SERIES DRIVE SIGNAL INPUT 2 SIGNAL COMMON 1 Figure 6 Voltage Follower Connections Installation 17 Terminal Block All XL drives use a cage clamp spring terminal block To open the clamp spring
27. sion 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 MINARIK DRIVES www minarikdrives com 14300 De La Tour Drive South Beloit IL 61080 Phone 800 MINARIK 646 2745 Fax 815 624 6960 Document Number 250 0207 Revision 4 Printed in the U S A July 2006
28. stallation 13 Field Output The field output is for shunt wound motors only Do not make any connections to the field output when using a permanent magnet motor Table 1 shows where to connect the field leads of a shunt wound motor Table 1 Field Output Connections Line Voltage Approximate Field C4XL3025 C4XL3200A VAC Voltage VDC Connections Connections 115 50 F1 and L1 F and L1 115 100 F1 and F2 F and F 230 100 F1 and L1 F and L1 230 200 F1 and F2 F and F Use 16 AWG wire to connect the field output to a shunt wound motor 14 Installation Fusing C4XL3025 This drive comes with two 8A fuses installed FU501 amp FU502 FU501 connects with the L1 terminal the hot leg of the AC line voltage FU502 connects with the 230 terminal If the current rating of the motor is less than the maximum current rating of the drive replace the fuse with a lower rated one Rate fuses at 150 times the maximum armature current C4XL3200A This drive comes with two 15A fuses installed FU501 amp FU502 FU501 connects with the L1 terminal the hot leg of the AC line voltage FU502 connects with the 230 terminal the current rating of the motor is less than the maximum current rating of the drive replace the fuse with a lower rated one Rate fuses at 150 times the maximum armature current Installation 15 Line Fusing for XL Series Drives Minarik drives require an external fuse for protection Use fast acting fu
29. use a small screwdriver to press down on the lever above the terminal block To insert a wire into a terminal use the following procedure 1 Press down on the lever arm using a small screwdriver 2 Insert wire into the wire clamp 3 Release the lever arm to clamp the wire Figure 7 Cage Clamp Terminal 18 Operation Before applying power 1 Verify that no conductive material is present on the printed circuit board 2 Set both voltage selection switches SW501 and SW502 to either 115 or 230 VAC to match the AC line voltage being used see Figure 8 below Warning Change voltage selection switch settings only when the drive is disconnected from the AC line voltage Make sure that both switches are set to the correct position If the switches are improperly set to a lower voltage position the motor will not run at full voltage If the switches are improperly set to a higher voltage position the motor will over speed which may cause motor damage VOLTAGE SELECT SWITCHES SW501 and SW502 Figure 8 Voltage Switch Location Operation 19 Startup Set the speed adjust potentiometer to zero full CCW Apply AC line voltage Set the POWER switch to the ON position Slowly advance the speed adjust potentiometer clockwise CW The motor slowly accelerates as the potentiometer
Download Pdf Manuals
Related Search