User`s Manual - Minarik Drives
Contents
1. Contro 4 9 0 Pulse VVidth Modulated Adjustable Speed Chassis Drive for DC Brush Motors Copyright 2002 by Minarik Corporation rights reserved this manual may transmitted any form without written permission 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 MvD102302 Printed in the United States of America Safety Warnings k x amp HAZARD HEAT DRY VIBRATION 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 ins2. 2 s Signal Input i PE gt i EJ e NOTE The analog input voltage range is 0 2 5 VDC for 0 130 VDC armature voltage range and t 0 5 VDC for 0 240 VDC armature voltage range N Figure 7 Voltage Follower Connections 14 Operation Before applying power A Warning Change voltage selection switch settings only when the drive is disconnected from the AC line voltage Make sure both switches are set to their 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 overspeed which may cause motor damage Verify that no conductive material is present on the printed circuit board Set both voltage selection switches SW501 and SW502 to either 115 or 230 to match the AC line voltage being used See Figure 8 page 16 Operation 15 C U 81 502 8 i g Figure 8 Voltage Selector Switches 16 Operation Startup 1 Turn the speed adjust potentiometer full counterclockwise CCW 2 Apply AC line voltage 3 Slowly advance the speed adjust poten
3. Erde Po au datis b EVE Ska yau 16 Diagnostic LEDS bass asawa 16 Starting and Stopping Methods 17 Calibration 22 Minimum Speed MIN SPD 24 Maximum Speed MAX SPD 24 Torque Limit TORQ LIMIT 25 Acceleration ACCEL scie teen pe dn apa 26 Deceleration DECEL 27 IR Compensation COMP 28 rcr PEDE TEE 29 Calibration with low voltage DC motors 30 Application Notes 31 Multiple Fixed Speeds 31 Adjustable Speeds using Potentiometers in Series 32 Independent Adjustable Speeds 33 Leader Follower Application 34 Single Speed Potentiometer Control of Multiple DriVeS crack crt sasa mm ner meyer 35 525222585554 ea wed w ee ed 36 Reversing with DLC600 Controller 37 Troubleshooting 38 Before applying power 38 Block Diagrams 42 Replacement Parts 43 Certificate of Compliance 44 AG Line Filters 2 u gaa 45 Unconditional Warranty inside back cover Tables Table 1 Field Output Connections 10 Table 2 Recommended Dynamic Brake Resistor Sizes
4. allowing independent control of each drive ratio pot optional 10K Ohms 10K Ohms PCM4 7 1 TB501 TB502 ratio pot B optional 10K Ohms PCM4 7 1 501 TB502 Figure 19 Single Speed Potentiometer Control of Multiple Drives 36 Application Notes Reversing A dynamic brake may be used when reversing the motor direction Figure 20 Use a three pole three position switch rated for at least the maximum DC armature voltage and maximum braking current Wait for the motor to stop completely before switching it to either the forward or reverse direction See page 22 for recommended dynamic brake resistor sizes DYNAMIC BRAKE RESISTOR INHIBIT Figure 20 Independent Forward and Reverse Speeds Application Notes 37 Reversing with a DLC600 Controller A DLC600 controller can be used in a reversing application The DLC600 must be inhibited while braking Without the inhibit feature the DLC600 will continue to regulate This will cause overshoot when the DLC600 is switched back to the drive Figure 21 shows the connection of the reversing circuit to an XL3300A series drive and a DLC600 NOTE Only one DLC option Optical Encoder or Magnetic Pickup may be used at a time 83 52 DRIVE 51 Dynamic Brake 1 52 Resistor O fo DLC600 Inhibit Leads Common Optical Signal Encoder 5 VDC Magnetic Pickup Fig
5. 21 Table 3 Replacement Parts 43 Table 4 AC Line Filters 45 iv Illustrations Figure 1 XL3300A Dimensions 2 Figure 2 XL3300A PC Board Layout 3 Figure 3 Earth Ground Screw 5 Figure 4 Cage Clamp Terminal 8 Figure 5 XL3300A Connections 9 Figure 6 Speed Adjust Potentiometer 11 Figure 7 Voltage Follower Connections 13 Figure 8 Voltage Selector Switches 15 Figure 9 Inhibit Pins erm te em mm Rem 18 Figure 10 Run Decelerate to Minimum Speed Switch 19 Figure 11 Run Decelerate to Zero Speed Switch 20 Figure 12 Calibration Trimpot Layout 23 Figure 13 XL3300A LIMIT and IR COMP Settings 29 Figure 14 XL3300A MAX SPD Settings for Low Voltage DC Motors 30 Figure 15 Multiple Fixed Speeds 31 Figure 16 Adjustable Fixed Speeds Using Potentiometers in Series 32 Figure 17 Independent Adjustable Speeds 33 Figure 18 Independent Forward and Reverse Speeds 34 Figure 19 Single Speed Potentiometer Control of Multiple Drives 35 Figure 20 Independent Forward and Reverse Speeds 36 Figure 21 I
6. disabled Opening any one motor lead may destroy the drive Use 18 AWG wire for speed adjust potentiometer wiring Use 16 AWG wire for field F1 F2 wiring Use 14 AWG wire for AC line L1 L2 and motor A1 A2 wiring Installation 7 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 environment 8 Installation Connections Cage clamp terminal block XL3300A connections are made to a cage clamp terminal block Figure 4 To insert a wire into the terminal block press down on the lever arm using a small screwdrive Insert stripped wire in
7. leads are longer than 18 inches 457 mm use shielded cable Ground only one end ol the shield MOUNT THROUGH A 0 38 IN 10 MM HOLE NUT STAR WASHER SPEED ADJUST POTENTIOMETER INSULATING DISK POT TAB ASSIGNMENTS PANEL Figure 6 Speed Adjust Potentiometer 12 Installation Fusing The XL3300A has three 25A fast acting fuses installed FU501 FU503 FU501 connects with the L1 terminal the hot leg of the AC line voltage FU502 connects with the 230 terminal FU503 connects with the A2 terminal to protect the motor from related conditions not protected by the AC line fuses If the horsepower rating of the motor is less than the maximum horsepower rating of the drive replace the fuse with a lower rated one Rate fuses at 150 times the maximum armature current Installation 13 Voltage Follower Instead of using a speed adjust potentiometer the drive may be wired to follow an analog input voltage that is isolated from earth ground Connect the signal input to S2 and the signal common to S1 Figure 7 Make no connection to S3 A potentiometer can be used to scale the analog input voltage if needed To achieve greater linearity and control use an interface device such as a Minarik model PCM4 to scale the analog input voltage Signal Common ooo e
8. to zero speed when the inhibit pins are shorted together Removing the connection between the inhibit pins allows the motor to accelerate to the speed set by the speed adjust potentiometer see Figure 9 page 19 18 Operation uu S de c INHIBIT G PINS 2 Figure 9 Inhibit Corporation offers two accessory plug 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 If shielded cable is used ground only one end of the shield to earth ground Do not ground both ends of the shield Operation 19 Decelerating to minimum speed The circuit shown in Figure 10 may be used to decelerate a motor to a minimum speed Closing the switch between S1 and S2 decelerates the motor from set speed to a minimum speed determined the MIN SPD trimpot setting If the MIN SPD trimpot is set full CCW the motor decelerates to zero speed when the switc
9. 0 50 Hz 0 1G max above 50 Hz 2 Dimensions 1 um 9 78 248 7 00 178 0 19 5 L gt 7 1 39 35 1 39 35 6 30 160 6 90 175 3 92 99 0 13 3 ALL DIMENSIONS IN INCHES MILLIMETERS MOUNTING SLOTS 0 19 X 3 4 5 X 9 Figure 1 XL3300A Dimensions Dimensions 3 PC Board Layout 2 PIN CONNECTORS Aca us aus E ECL ei VOLTAGE SELECTION P SWITCHES nm E N POWER CURR and 15 used on future drives POWER ON and CURRENT LIMIT LEDs Ux CALIBRATION TRIMMER POTENTIOMETERS gt FUSE HOLDERS FUSE i i HOLDERS i meus bh ss POTENTIOMETER 1 TERMINALS SPD PDIN and JOG TERMINALS CAGE CLAMP TERMINAL BLOCK Figure 2 XL3300A PC Board Layout 4 Installation Mounting 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
10. K ohms Figure 16 shows a connection for fixed high and low speed adjust potentiometers OHM Figure 16 Adjustable Fixed Speeds Using Potentiometers in Series Application Notes 33 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 17 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations SPEED 1 Figure 17 Independent Adjustable Speeds 34 Application Notes Leader Follower Application In this application use a PCM4 to monitor the speed of the leader motor Figure 18 The PCMA 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 4 output voltage Follower Drive Leader Drive 4 Q1 10K Ohm optional Figure 18 Independent Forward and Reverse Speeds 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 19 Optional ratio potentiometers can be used to scale the PCM4 output voltage
11. O Suggested Solutions 1 Check that the line fuse is correct for the motor size Check motor cable and armature for shorts Increase the speed adjust potentiometer setting or reference voltage Check connections to input Verify that connections are not open Remove jumper from the INHIBIT terminals Remove short 40 Troubleshooting Problem Line fuse does not blow but the motor does not run cont Possible Causes 5 Drive is in current limit Drive is not receiving AC line voltage Motor is not connected Suggested Solutions 5 The red current limit LED must be off If the red current limit LED is on verify that the motor is not jammed It may be necessary to increase the TORQ LIMIT setting if it is set to a value lower than the current rating of the motor Apply AC line voltage to L1 and L2 Connect motor to 1 and A2 Motor runs too fast at maximum speed setting MIN SPD and MAX SPD not calibrated Field output connections are not Secure Calibrate MIN SPD and MAX SPD Make sure settings are not set too high Check that the field output connections are secure if you are using a shunt wound motor Problem Motor runs in opposite direction Troubleshooting 41 Possible Causes 1 Connections to motor armature are reversed Suggested Solutions Remove AC line voltage and reverse connections t
12. Settings 30 Calibration Calibration with low voltage DC motors Using XL3300A with a low voltage DC motor requires using a lower resistance speed adjust potentiometer and recalibrating the MAX SPD trimpot settings See Figure 14 for MAX SPD trimpot settings NOTE MAX SPD trimmer pot settings are approximate Verify maximum armature voltage with a voltmeter Care should be taken when using low voltage motors to ensure motor insulation rating is above bus voltage of the drive 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 m NOT NOT APPLICABLE APPLICABLE 20 NOT NOT APPLICABLE APPLICABLE Cod Lj a Cry Figure 14 XL3300A SPD Settings for Low Voltage DC Motors 31 Application Notes Multiple Fixed Speeds Replace the speed adjust potentiometer with series resistors with a total series resistance of 10K ohms Figure 15 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 15 Multiple Fixed Speeds 32 Application Notes Adjustable Speeds using Potentiometers in Series Replace the speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in series with a total series resistance of 10
13. butors for this drive series Table 3 Replacement Parts Model Symbol Descriptin P N _ XL3300A BR601 600V Bridge 073 0008 C505 507 680 400 VDC Capacitor 011 0080 D501 16A 600V Diode 071 0044 Q501 502 Power Mosfet 070 0066 R501 0 01 ohm 5W Resistor 032 0129 T501 3FD 436 Transformer 230 0072 TH501 30A 1 ohm Thermistor 033 0009 FU501 503 20A Slow Acting Fuse 050 0063 10K ohm Potentiometer Kit 202 0003 Line Fuse Kit 1 8A 050 0068 Line Fuse Kit 3 10A 050 0070 Line Fuse Kit 5 15A 050 0072 1 2A Pico Fuse 050 0064 44 Certificate of Compliance Minarik Corporation hereby certifies that its MMRG series drives has been approved to bear the CE mark provided the conditions of approval have been met by the end user The MMRG series has been tested to the following test specifications EN55011 1993 emissions and EN50082 1 1992 immunity Compliance allows Minarik s XL series drives 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 will implement the product as a component of the machine being manufactured AC Line Filters In addition to EMI RFI safeguards inherent in the XL series design external filtering is required Minarik requires the AC
14. h between 1 52 is closed 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 10 Run Decelerate to Minimum Speed Switch 20 Operation Dynamic braking Dynamic braking may be used to rapidly stop a motor Figure 11 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 11 Run Decelerate to Zero Speed Switch Operation 21 Size the dynamic brake resistor according to the motor current rating see Table 2 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 2 Recommended Dynamic Brake Resistor Sizes Motor Armature Minimum Dynamic Minimum Dynamic Current Rating Brake Resistor Brake Resistor ADC Value Ohms Power Watts 5 10 20 20 10 17 40 50 22 Calibration A Warning Dangerous voltages exist on the drive when it is powered When possible disconnect the voltage input from the drive before adjusting the trimpots If the trimpots must be adjusted with power applied use insulated tools and the appropria
15. line filters listed in Table 4 Use model CE15XL with drives rated for 15A AC or below Table 4 AC Line Filters Minarik Model Number CE04XL CE10XL CE15XL Rated Current 4A 10 15 Inductance 17 5 mH 14 3 mH 10 0 mH 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 Kohms 330 Kohms 330 Kohms Wire the 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 D 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 directirves listed herein 46 NOTES NOTES 47 48 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 re
16. moval installation or any other incidental expenses incurred in shipping the product to and from the repair point B Disclaimer The provisions of Paragraph A are the Corporation s sole obligation and exclude all other warranties of merchantability for use express or implied The Corporation further disclaims any responsibility whatsoever to the customer or to any other person for injury to the person or damage or loss of property of value caused by any product that has been subject to misuse negligence or accident or misapplied or modified by unauthorized persons or improperly installed C Limitations of Liability In the event of any claim for breach of any of the Corporation s obligations whether express or implied and particularly of any other claim or breech of warranty contained in Paragraph A or of any other warranties express or implied or claim of liability that might despite Paragraph B be decided against the Corporation by lawful authority the Corporation shall under no circumstances be liable for any consequential damages losses or expense arising in connection with the use of or inability to use the Corporation s product for any purpose whatsoever An adjustment made under warranty does not void the warranty nor does it imply an extension of the original 12 month warranty period Products serviced and or parts replaced on a no charge basis during the warranty period carry the unexpired portion of the original warrant
17. ndependent Forward and Reverse Speeds 37 Figure 22 XL3300A Block Diagram 42 Specifications Type open chassis AC Line Voltage 115 VAC 230 vac 10 50 60 Hz single phase Line Fuse Rating 25A fast acting Horsepower Range 130 VDC Output 1 4 1 1 2 HP Horsepower Range 240 VDC Output 1 4 3 HP Maximum Armature Voltage Range 115 VAC Input 45 130 VDC Maximum Armature Voltage Range 230 VAC Input 45 260 VDC Minimum Speed Adjustment Range 115 VAC Input 0 120 VDC Minimum Speed Adjustment Range G 230 VAC Input 0 120 VDC Maximum Armature Current 13 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 9 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 18 seconds Analog Input Voltage Range isolated signal S1 to S2 for 0 130 VDC Armature Voltage Range 0 2 5 VDC for 0 240 VDC Voltage Range 0 5 0 VDC Speed Adjust Potentiometer 10K ohms Approximate Input Impedance from 1 to 2 50K ohms Speed Regulation at base speed 0 5 Ambient Operating Temperature Range 10 40 C Vibration 0 5G max
18. o the motor armature Motor will not stop when the speed adjust potentiometer is full counterclockwise MIN SPD is not calibrated to zero Calibrate MIN SPD trimpot to zero speed Motor pulsates or surges under load IR is set too high Motor bouncing in and out of current limit Adjust the IR COMP setting slightly CCW until the motor speed stabilizes Make sure motor is not undersized for load adjust TORQ LIMIT trimpot CW n FIELD SUPPLY Ps1 Ps2 u INPUT OUTPUT RECTIFIER STAGE om 15 Ps3 Ps4 1 CHASSIS 1 15 GROUND 18 l 470 rower 9 E CURRENT 1 DETECTOR CONTROL TRANSFORMER 45 ones 470 E SPD ane IR COMP CURR LIMIT 15 Boa sox my SPD terminal speen CURRENT 50K is prewired to LIMIT LED SPD IN terminal 500K INHIBIT 1 Figure 22 XL3300A Block Diagram sweibeig 201 ev 43 Replacement Parts Replacement parts are available from Corporation and its distri
19. or 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 current rated motor Refer to Figure 13 page 30 for approximate IR COMP settings or use the following procedure to recalibrate the IR COMP 1 Setthe IR COMP trimpot to minimum full CCW 2 Rotate the speed adjust potentiometer until the motor runs at midspeed without load for example 900 RPM for an 1800 RPM motor A hand held tachometer may be used to measure motor speed 3 Load the motor armature to its full load armature current rating The motor should slow down 4 While keeping the load on the motor rotate the IR COMP trimpot until the motor runs at the speed measured in step 2 If the motor oscillates overcompensation the IR COMP trimpot may be set too high CW Turn the IR COMP trimpot CCW to stabilize the motor 5 Unload the motor Calibration 29 JOG The JOG setting determines the motor speed when the drive is set to the JOG mode To control the speed with the JOG trimpot 1 Connect the SPD IN and JOG terminals 2 Calibrate the JOG trimpot until the motor runs at the desired JOG speed 1 4 HP 1 2 HP 90 VDC 180 VDC 1750 RPM 1750 RPM 2 5 AMPS 2 5 AMPS 1 2 HP 1 90 VDC 180 VDC 1750 RPM 1750 RPM 5 AMPS 5 AMPS 1 2 90 VDC 180 VDC 1750 RPM 1750 RPM TORQ LIMIT 10 AMPS TORQ LIMIT 9 AMPS Figure 13 XL3300A LIMIT and IR COMP
20. talling equipment Reduce the chance of an electrical fire shock or explosion by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures It is possible for a drive to run at full speed as a result of a component failure Minarik strongly recommends the installation of a master switch in the main power input to stop the drive in an emergency Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Use a non metallic screwdriver for adjusting the calibration trimpots Use approved personal protective equipment and insulated tools if working on this drive with power applied Contents Safety Warnings i Specifications 1 Dimensions 2 PC Board Layout 3 Installation 4 Mounting sapis ex 4 WIND ci sama sus ata a br ste ile Mew qu Son 6 Shielding guidelines 7 Connections ber eae ke a sya 8 Cage clamp terminal block 8 Field output l ee Chae cee ee ee 10 Speed adjust potentiometer 11 RUSINO 12 Voltage Follower 13 Operation 14 Before applying power 14 Stait p
21. te personal protection equipment BE ALERT High voltages can cause serious or fatal injury Each drive is factory calibrated to its maximum horsepower 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 See Figure 12 page 24 for trimmpot locations Calibration 23 MAX SPD TORQ LIMIT IR COMP 8 E MIN SPD DECEL Figure 12 Calibration Trimpot Layout ACCEL JOG 24 Calibration Minimum Speed MIN SPD The MIN SPD setting determines the motor speed when the speed adjust potentiometer is turned full CCW It is factory set for minimum rated speed To calibrate set the MIN SPD trimpot full CCW Turn the speed adjust potentiometer full CCW Adjust the MIN SPD trimpot until the desired minimum motor speed is reached 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 Calibration 25 Torque Limit TORQ LIMIT A Warning TORQ LIMIT should be set
22. the Safety Warnings on page i before attempting installation Drive components are sensitive to electrostatic fields Avoid direct contact with the circuit board Hold drive by the chassis only Protect the drive from dirt moisture and accidental contact Provide sufficient room for access to the terminal block and calibration trimpots The minimum enclosure size for the XL3300A is six cubic feet Mount the drive away from heat sources Operate the drive within the specified ambient operating temperature range Prevent loose connections by avoiding excessive vibration of the drive Mount drive with its board in either a horizontal or vertical plane Four 0 19 inch 5 mm wide slots in the chassis accept 8 pan head screws Connect earth ground to the green earth ground screw attached to the heat sink See Figure 3 page 5 for the earth ground screw location Installation 5 EARTH GROUND SCREW Corp Figure 3 Earth Ground Screw 6 Installation Do not install remove or rewire this equipment with power applied Failure to heed this warning may result in fire explosion or serious injury Circuit potentials are at 115 or 230 VAC above ground To prevent the risk of injury or fatality avoid direct contact with the printed circuit board or with circuit elements Do not disconnect any of the motor leads from the drive unless power is removed and the drive is
23. tiometer clockwise CW The motor slowly accelerates as the potentiometer is turned CW Continue until the desired speed is reached 4 Remove AC line voltage from the drive to coast the motor to a stop If the motor or drive does not perform as described disconnect the AC line voltage immediately Refer to the Troubleshooting section on page 40 for further assistance Diagnostic LEDs XL3300A drives are equipped with the following 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 Operation 17 Starting and Stopping Methods Line starting and line stopping Line starting and line stopping applying and removing AC line voltage is recommended for infrequent starting and stopping of a drive only When AC line voltage is applied to the drive the motor accelerates to the speed set by the speed adjust potentiometer When AC line voltage is removed the motor coasts to a stop Inhibit circuit A Warning The inhibit circuit is used for frequent starts and stops It must never be used as an emergency stop It may not stop a drive that is malfunctioning Removing AC line power both L1 and L2 is the only acceptable method for emergency stopping The XL3300A has an inhibit circuit that causes the motor to coast
24. to the large opening in front of the terminal block Release the lever arm to clamp the wire LEVERARM Figure 4 Cage Clamp Terminal Block Installation 9 JOG TRIMMER SPD and SPD IN are prewired for speed adjust potentiometer control To control speed with JOG trimmer potentiometer connect SPD IN to JOG Motor will not turn if there is no connection to SPD IN SPD SPD JOG IN TB501 L1 230 115 F E v 230 N 6 1 115 FIELD OUTPUT Shunt wound motors only See Field Output section for connections Figure 5 XL3300A Connections 10 Installation 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 VAC Voltage VDC Connections 115 50 F and 11 115 100 F and F 230 100 F and L1 230 200 F and F Use 18 AWG wire to connect the field output to a shunt wound motor Installation 11 Speed adjust potentiometer Install the circular insulating disk between the panel and the 10K ohm speed adjust potentiometer Mount the speed adjust potentiometer through a 0 38 inches 10 mm hole with the hardware provided Figure 6 Twist the speed adjust potentiometer wire to avoid picking up unwanted electrical noise If potentiometer
25. to 120 of motor nameplate current rating Continuous operation beyond this rating may damage the motor If you intend to operate beyond the rating contact your Minarik representative for assistance The TORQ LIMIT setting determines the maximum armature current output of the drive It is factory set at 120 of rated motor current Recalibrate the TORQ LIMIT setting when using a lower horsepower motor Refer to Figure 13 page 30 for approximate TORQ LIMIT settings or recalibrate using the following procedure 1 With the power disconnected from the control connect a DC ammeter 0 15 minimum scale in series with the armature 2 Set the TORQ LIMIT trimpot to minimum full CCW 3 Set the speed adjust potentiometer to maximum speed full CW 4 Carefully lock the motor armature Be sure that the motor is firmly mounted 5 Apply line power The motor should be stopped 6 Slowly adjust the TORQ LIMIT trimpot CW until the armature current is 120 of motor rated armature current 7 Turn the speed adjust potentiometer CCW until the motor stops 8 Remove the line power 9 Remove the stall from the motor 10 Remove the ammeter in series with the motor armature if it is no longer needed 26 Calibration Acceleration ACCEL The ACCEL setting determines the time the motor takes to ramp to a higher speed See Specifications on page 1 for approximate acceleration times ACCEL is factory set to its minimum value f
26. ull CCW Use the following procedure to set the acceleration time 1 Setthe speed adjust potentiometer full CCW The motor should run at minimum speed as set by the MIN SPD trimpot page 25 2 Turn the speed adjust potentiometer full CW and measure the time it takes the motor to go from minimum to maximum speed 3 Ifthe time measured in step 2 is not the desired acceleration time turn the ACCEL trimpot CW for a slower acceleration time or CCW for a faster acceleration time Repeat steps 1 through 3 until the acceleration time is correct Calibration 27 Deceleration DECEL The DECEL setting determines the time the motor takes to ramp to a lower speed See Specifications on page 1 for approximate deceleration times DECEL is factory set for the fastest deceleration time full CCW Use the following procedure to set the deceleration time 1 Setthe speed adjust potentiometer full CW The motor should run at maximum speed as set by MAX SPD trimpot page 25 2 Turn the speed adjust potentiometer full CCW 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 28 Calibration IR Compensation IR The IR COMP trimpot setting determines the degree to which mot
27. ure 21 Independent Forward and Reverse Speeds 38 Troubleshooting A Warning Dangerous voltages exist on the drive when it is powered When possible disconnect the drive while troubleshooting High voltages can cause serious or fatal injury Before applying power Check the following steps before proceeding 1 2 3 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 voltage selection switch settings match the AC line and output voltages Check that the drive s rated armature and field outputs are consistent with the motor ratings For additional assistance contact your local Minarik distributor or the factory direct 1 800 MINARIK 646 2745 or Fax 1 800 394 6334 Problem Line fuse blows Line fuse does not blow but the motor does not run Troubleshooting 39 Possible Causes 1 Line fuse is the wrong size Motor cable or armature is shorted to ground Speed adjust potentiometer or reference voltage is Set to zero speed Speed adjust potentiometer or reference voltage is not connected to drive input properly connections are open INHIBIT terminals are jumpered S2 is shorted to S
28. y 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 Pro _ Automation TEA amp Control 901 E Thompson Avenue Glendale CA 91201 2011 Tel 1 800 MINARIK 646 2745 Fax 1 800 394 6334 www minarikcorp com Document Number 250 0217 Rev 2 Printed in the U S A October 2002
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