User`s Manual - Minarik Drives
Contents
1. 15 Figure 11 Motor Hall Sensor Header 16 Figure 12 Mode Select Switches 17 Figure 13 TB504 Pin Assignments 18 Figure 14 Calibration Trimpot Layout 23 Figure 15 Mode Select Switches 28 Figure 17 Adjustable Speeds Using Potentiometers in Series 29 Figure 16 Multiple Fixed Speeds 29 Figure 18 Independent Adjustable Speeds 30 Figure 19 Commutation Sequence 35 Tables Specifications Maximum AC Input Voltage Maximum Phase Current 10 50 60 Hz Output Voltage A NAE _ BOSS15 115AC 4Q 15 90 130 130 BOSS08 115AC 4Q 8 90 130 130 BOSS04 115AC 4Q 4 90 130 130 BOSS08 D240AC 4Q 8 90 240 240 BOSS04 D240AC 4Q 4 90 240 240 DC Voltage Input Range BOSSxx 115AC 4Q drives 100 180 VDC BOSSxx D240AC 4Q drives 100 360 VDC Maximum Phase Current Limit 1 5 times Maximum Phase Current continuous Peak Phase Current Limit 2 times Maximum Phase Current for 1 second Minimum Output Voltage Range 0 50 VAC Acceleration Time Range Zero to Max Speed 0 5 6 seconds Deceleration Time Range Max Speed to Zero 0 5 6 seconds Speed Regulation typical 0 06 of base speed Speed Adjust Potentiomet2. Pin 2 0 VDC when Run Stop Run Stop switch is set for run 5 VDC when Run Stop switch is set for stop Pin 3 5 VDC when the drive is Fault Out in a fault condition Pin 4 Circuit common 0 volts Circuit Common other pins are V Do not connect to referenced to earth ground circuit common Pin 5 0 10 VDC output Out corresponding to the sum Me of all AC phase currents AC phase currents are rectified summed then scaled to 0 10 VDC output Pin 6 AC A is AC Current Phase A EDDIE VOU output 500 mV per amp AC Pin 7 AC current in phase B is AC Current Phase B converted to voltage output 500 mV per amp AC Pin 8 AC current in phase C is AC Current Phase converted to voltage output 500 mV per amp AC No function None 20 21 Operation Startup 1 Verify that no conductive material is present on the 2 Check that the ENABLE switch is in the enable position closed 3 Check that the BRAKE switch is in the run position open 4 Set the FWD REV switch to the direction you want the motor to rotate upon startup 5 Apply AC voltage input or DC voltage input to the drive 6 Slowly advance the speed adjust potentiometer clockwise CW or increase the voltage signal The motor slowly accelerates as the potentiometer is turned CW or the voltage is increased Continue until the desired speed is reached To reverse motor direction Sw
3. 0 1234 5 REV Fwo MIN IR FWD REV MAXSPD ACCEL DECEL SPD COMP TQLIM OS GAIN TACH 2 A 2 1 501 1 2 3 4 5 6 7 8 9 10 11 12 43 T COM BRAKE VPOT 15 HALL B COM Figure 14 Calibration Trimpot Layout 24 Calibration FWD MAXSPD The FWD MAX setting determines the maximum motor speed when the speed adjust potentiometer or voltage input signal is set for maximum forward speed It is factory set for maximum rated motor speed To calibrate FWD MAXSPD 1 Set the FWD MAXSPD trimpot full CCW 2 Set the FWD REV switch if installed to FWD If no switch is installed install a jumper between terminals 1 COM and 4 FWD REV of TB501 3 Set the speed adjust potentiometer or voltage input signal for maximum speed 4 Adjust the FWD MAXSPD trimpot to the desired maximum speed REV MAXSPD The REV MAX setting determines the maximum motor speed when the speed adjust potentiometer or voltage input signal is set for maximum reverse speed It is factory set for maximum rated motor speed To calibrate REV MAXSPD 1 Set the REV MAXSPD trimpot full CCW 2 Set the FWD REV switch if installed to REV If no switch is installed remove the jumper between terminals 1 COM and 4 FWD REV of TB501 3 Set the speed adjust potentiometer or voltage input signal for maximum speed 4 Adjust the REV MAXSPD trimpot to the desired maximum speed MIN The MIN setting determines the minimum speed when th
4. BOSS Series BOSS Series Four Quadrant Brushless Drives Automation Imari amp Control Copyright 1999 by Minarik Corporation 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 e Have 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 grounding over current protection thermal protection and enclosure Follow sound maintenance procedures Although the drive includes protective circuitry to prevent damage in the event of an accidental short circuit of the armature it is
5. adjust potentiometer or voltage input signal for minimum speed and measure the time it takes the motor to go from maximum to minimum speed 3 If the time measured in step 2 is not the desired deceleration time turn the DECEL trimpot CW for a slower deceleration time or CCW for a faster deceleration time Repeat steps 1 through 3 until the deceleration time is correct 28 Calibration TACH for use with tachometer feedback only A DC tachometer can be used to augment the hall effect feedback Since a tachometer can generate an error voltage down to zero speed the speed range can be widened considerably Calibrate the TACH setting only when a tachometer is used The TACH setting determines the degree to which motor speed is held constant as the motor load changes To calibrate the TACH trimpot 1 Connect the tachometer to the TACH IN header 50501 2 Set the MODE SELECT switch SW501 for armature feedback as follows Set switches 1 and 4 to ON Set switches 2 and 3 to OFF 3 Run the motor at full speed Measure the armature voltage across Al and A2 using a voltmeter 4 Run the motor at either minimum speed or zero speed 5 Set the MODE SELECT switch SW501 for tach feedback as follows Set switch 1 to ON Set switches 2 3 and 4 to OFF 6 Set the IR COMP trimpot full CCW 7 Set the TACH trimpot full CW 8 Run the motor at full speed 9 Adjust the TACH trimpot until the armature voltage is the same value as the
6. all logic leads with themselves to minimize induced noise 7 Under no circumstances should power and logic leads be bundled together Induced voltage can cause unpredictable behavior any electronic device including motor controls 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 Do not disconnect any of the motor leads from the drive unless power is removed or the drive is disabled Opening any one motor lead may destroy the drive Installation 7 Fusing An external line fuse must be installed on all BOSS series drives Connect the external line fuse in series with the AC voltage input or DC voltage input whichever is used See motherboard connections on page 8 Table 1 lists the recommended line fuse sizes Use fast acting fuses rated for 250 or higher and approximately 200 of the maximum phase current Table 1 Recommended Line Fuse Sizes Model AC Line Fuse Size AC Amps BOSS04 xxx 4Q 10 BOSS08 xxx 4Q 15 BOSS15 xxx 4Q 25 8 Installation 4Q plug in card mounting Warning Make su
7. not fail safe It is possible for a drive to run at full speed as a result of a component failure Install a master switch in the drive s AC or DC voltage input line for stopping the drive in an emergency This drive is isolated from 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 A X X SHOCK AVOID KEEP AVOID HAZARD HEAT DRY VIBRATION Contents Safety Warnings Contents Specifications Dimensions Installation 4Q plug in card mounting Speed adjust potentiometer mounting Quick connect terminal block Motherboard connections Regen dump circuit 4Q plug in card connections 4Q Terminal Descriptions Voltage tolloWer eee ea iens Motor hall sensor header SW502 Encoder follower Satan eE em Ee beat Mode select switches SW501 IB504 ERROR GU ee E edi ded dep epe aiu E ERU Line starting and line stopping Operat
8. or voltage input signal 2 Check connections to input Verify that connections are not open 3 Check connections 4 Verify that motor is not jammed Increase FWD TQLIM or REV TQLIM setting if they are set too low 5 Apply AC line voltage to L1 and L2 or DC voltage input to VDC or VDC 6 Check motor connections 7 Connect hall sensors 8 Connect separate power supply which can provide sufficient voltage and current tosensors NOTE Voltage must be floating isolated 34 Troubleshooting Problem Motor runs too slow or too fast at set speed Possible Causes 1 Switches or jumpers are set incorrectly 2 MIN SPD FWD MAXSPD and REV MAXSPD are not calibrated 3 Hall sensors miswired Suggested Solutions 1 Verify all switch and jumper settings 2 Calibrate MIN SPD FWD MAXSPD and REV MAXSPD 3 Check hall sensor connections Motor will not reach the desired speed 1 MAXSPD and REV MAXSPD settings are too low 2 GAIN and IR COMP setting is too low 3 Motor is overloaded 4 Hall sensors miswired 1 Increase MAXSPD and REV MAXSPD settings 2 Recalibrate GAIN and IR COMP settings 3 Check motor load Resize the motor if necessary 4 Check hall sonsor connections Motor pulsates or surges under load 1 GAIN is set too high 2 Motor bouncing and out of torque limit 1 Adjust the GAIN setting slightly CCW unti
9. or not properly nulled 2 The drive reaches its peak phase current limit 3 The drive has insufficient AC or DC power 4 The enable switch is open drive is disabled 5 drive reaches maximum bus voltage limit Diagnostic LEDs on the motherboard BUS LIMIT The red BUS LIMIT LED lights when the drive exceeds maximum bus voltage Troubleshooting 33 Problem Line fuse blows Possible Causes 1 Line fuses the wrong size 2 Motor cable or armature is shorted to ground 3 Nuisance tripping caused by a combination of ambient conditions and high current spikes i e reversing Suggested Solutions 1 Check that line fuses are properly sized for the motor being used 2 Check motor cable and armature for shorts 3 Add a blower to cool the drive components increase FWD TQLIM or REV TQLIM settings Line fuse does not blow but the motor does not run 1 Speed adjust potentiometer or voltage input signal is set to zero speed 2 Speed adjust potentiometer or voltage input signal is not connected to drive input properly connections are open 3 ENABLE terminal is open BRAKE terminal is shorted to COM 4 Drive is in current limit 5 Drive is not receiving AC voltage input or DC voltage input 6 Motor is not connected 7 Hall sensors not connected 8 Encoder requires more than 20 mADC to run 1 Increase the speed adjust potentiometer setting
10. the original 12 month warranty period Products serviced and or parts replaced on a no charge basis during the warranty period carry the unexpired portion of the original warranty only If for any reason any of the foregoing provisions shall be ineffective the Corporation s liability for damages arising out of its manufacture or sale of equipment or use thereof whether such liability is based on warranty contract negligence strict liability in tort or otherwise shall not in any event exceed the full purchase price of such equipment Any action against the Corporation based upon any liability or obligation arising hereunder or under any law applicable to the sale of equipment or the use thereof must be commenced within one year after the cause of such action arises Other drives from Minarik Corporation RG5500U NRG 2Q Series MMRG Series NRG 4Q Series Automation nari 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 0253 Revision 4 Printed in the U S A 2 99 11 00 North America 12 00 Outside North America
11. 501 The mode select switches set the BOSS drive to one of the four operating modes Voltage Mode no internal velocity loop Velocity Mode voltage mode plus internal velocity loop Tachometer Feedback Mode Current Mode no voltage or velocity loops qu pc Set the mode select switches according to the appropriate operating mode Refer to Table 3 for mode select switch settings and Figure 12 for mode select switch location Table 3 Mode select switch settings Operating Mode Select Switch Modes 1 2 3 4 Voltage Mode ON OFF OFF no internal velocity loop Velocity Mode Voltage Mode plus internal velocity loop Tachometer Feedback Mode Current Mode X Don t care ON OFF ON ON OFF X OFF OFF ON X X Mode Select Switches B eB aa a e fe Figure 12 Mode Select Switches 18 Installation TB504 TB504 is a 10 pin male connector used for non isolated drive diagnostics outputs See Figure 13 for connector location and Table 4 for pin functions PIN 2 PIN 10 PIN 1 PIN 9 SW502 A P A FAULT 18504 1502 0501 Figure 13 504 Pin Assignments Installation 19 Table 4 TB504 Pin Functions Pins Description Waveform Pin 1 12 pulses per revolution Tachometer Out 5 VDC square wave output proportional to motor speed Pin 9 and 10 not used
12. IRFP440 MOSFET 1500 250VAC Capacitor 10 5W Potentiometer 14 Pin Terminal Plug Four Quadrant Plug In Card Power Bridge 300V 35A MOSFET IRFP440 MOSFET 1000uF 200VAC Capacitor 10KQ 5W Potentiometer 14 Pin Terminal Plug Four Quadrant Plug In Card Power Bridge 300V 35A MOSFET IRFP440 MOSFET 1000uF 200VAC Capacitor 10 5W Potentiometer 14 Pin Terminal Plug Four Quadrant Plug In Card Power Bridge INXFH26N50 MOSFET IRFP440 MOSFET 100005 400VAC Capacitor 10 5W Potentiometer 14 Pin Terminal Plug Four Quadrant Plug In Card Power Bridge INXFH26N50 MOSFET IRFP440 MOSFET 100005 400VAC Capacitor 10KQ 5W Potentiometer 14 Pin Terminal Plug 3 8A Fuse Kit 5 20A Fuse Kit Minarik P N 4Q 073 0010 070 0054 070 0077 011 0089 120 0009 160 0136 40 073 0010 070 0054 070 0077 011 0096 120 0009 160 0136 40 073 0010 070 0054 070 0077 011 0096 120 0009 160 0136 40 073 0010 070 0079 070 0077 011 0099 120 0009 160 0136 40 073 0010 070 0079 070 0077 011 0099 120 0009 160 0136 050 0069 050 0073 134 0038 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 from date of manufacture thereof Within this warranty period the Corporation will repair or replace such products that are returned to Minarik Corporation 901 East T
13. OLE STAR WASHER SPEED ADJUST POTENTIOMETER INSULATING DISK POT TAB ASSIGNMENTS PANEL Figure 4 Speed Adjust Potentiometer Mounting 10 Installation Quick connect terminal block The quick connect terminal block found on the 4Q plug in card is composed of a header block and terminal plug Figure 5 To use the quick connect terminal block 1 Carefully pull terminal plug from header block 2 With a small flat head screwdriver turn terminal plug screw counterclockwise to open wire clamp 3 Insert stripped wire into the large opening in front of the plug 4 Turn the terminal plug screw clockwise to clamp the wire 5 Repeat steps 2 4 for each terminal until all connections are made 6 Insert plug into header block until securely fastened Figure 5 Quick Connect Terminal Plug Installation 11 Motherboard connections See Figure 6 for motherboard connections If the drive is powered by a DC voltage source do not connect the AC voltage source to or AC2 Likewise if the drive is being powered by ac AC voltage source do not connect the DC voltage source to VDC and VDC 115 230 VAC INPUT DO NOT CONNECT IF USING DC VOLTAGE INPUT Figure 6 Motherboard Connections Regen dump circuit The regen dump circuit is required by all BOSS Series drives Regenerative loads cause the bus voltage to increase The regen dump circuit prevents the voltage across the bus capacitors from ex
14. R X X N 2 BRAKE VPOT 15 HALL ENABLE FWD REV SPD IN 15 HALL HALLA VREF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 FLOATING SENSOR Vcc ee os ISOLATED KAA EXTERNAL d 5 VDC SENSOR COMMON VN 2 SUPPLY xe s 5 ENCODER Figure 10 Sensor Connections 16 Installation Motor hall sensor header SW502 Set the motor hall sensor header according to the hall effect feedback spacing see Figure 11 for location Jumper SW502 if the hall effect feedback spacing is 120 Do not add a jumper if the hall effect feedback spacing is 60 Hall sensors are not allowed to be advanced or retarded To reverse motor rotation the BOSS drive switches hall sensor sequence eliminating the need to switch motor leads BOSS series drives provide a 5 VDC 20mA maximum output to drive the Hall sensors This voltage is provided at TB501 terminal 14 positive or high and terminal 13 common or low on the 4Q plug in card Encoder follower Instead of using a speed adjust potentiometer BOSS series drives may be wired to follow an optical encoder input as shown in Figure 10 Warning Use only 5 VDC encoders Do not connect any other type of encoder to the BOSS reference voltage terminals Motor Hall Sensor Header a a a a e a e a zi a e Figure 11 Motor Hall Sensor Header Installation 17 Mode select switches SW
15. ceed their voltage rating See Figure 7 for regen dump circuit connections Frequent regenerative reversing requires additional power resistors to be added to the regen dump circuit Contact the Minarik factory for more assistance OPTIONAL EXTERNAL Miinarik E POWER 77 Corporation RESISTOR Figure 7 Regen Dump Circuit Connections Table 2 ENABLE BRAKE Configuration Options See Figure 8 for terminal and switch locations Enable Brake Switch Switch Position Position Terminals 1 2 Terminals 1 3 Result CLOSED OPEN RUN CLOSED CLOSED REGEN BRAKE OPEN OPEN COAST TO STOP OPEN CLOSED COAST TO STOP 40 plug in card connections TACHOMETER OPTIONAL Q Te See Table 2 for ENABLE BRAKE Configuration Options ENABLE SWITCH CLOSE TO RUN OPEN TO STOP BRAKE SWITCH CLOSE TO BRAKE OPEN TO RUN FWD REV SWITCH CLOSE FOR REV OPEN FOR FWD s MOTOR SENSORS 9 10K OHM SPEED ADJUST POTENTIOMETER UNIDIRECTIONAL CONNECTION SEE PG 35 FOR COMMUTATION SEQUENCE SEE PG 15 FOR USE WITH ENCODER FEEDBACK A Figure 8 4Q Terminal Connections 14 Installation 4Q Terminal Descriptions COM terminals 1 and 13 Circuit common Do not connect to earth ground Enable terminal 2 Short to COM to run the motor leave open to coast to a stop Brake terminal 3 Short t
16. e speed adjust potentiometer or voltage input signal is set for minimum speed It is factory set to zero speed To calibrate MIN SPD 1 Set the MIN SPD trimpot to the center position 12 o clock 2 Set the speed adjust potentiometer or voltage input signal for minimum speed 3 Adjust the MIN SPD trimpot to the desired minimum speed Calibration 25 OS zero offset The OS setting adjusts the zero offset voltage in the internal velocity loop This affects the gain circuit which controls motor regulation Calibrating OS requires a voltmeter to measure the zero offset voltage To calibrate OS 1 Verify that there is no load on the motor 2 Run the motor at any arbitrary speed for example 1000 RPM 3 Using a voltmeter measure the voltage from circuit common to test point 4 Using non metallic screwdriver calibrate the OS trimpot until the voltmeter reads approximately 0 VDC GAIN The gain setting determines how much effect the OS setting will have on the regulation Calibrate the gain trimpot only when the drive is operating in Velocity Mode Set the gain trimpot full CCW for minimum regulation or full CW for maximum regulation Test the motor gain by applying a load to the motor and checking the change in motor speed The drive will maintain motor speed better with higher gain settings IR COMP The IR COMP setting determines the maximum limit the drive can regulate Calibrate the IR COMP setting
17. er 10KQ Analog Input Voltage Range isolated 0 10 VDC Input Impedance S2 to Common 60KQ Power Device Switching Frequency 6 step trapezoidal 22 KHz Hall sensor output max 5 VDC 20mA Weight 2 lb Ambient Operating Temperature Range 0 409 Dimensions Dimension Drive BOSSxx115AC 4Q 2 62 67 3 87 98 BOSSxx D240AC 4Q All Dimensions in Inches Millimeters Figure 1 BOSS Series Dimensions 3 Dimensions EIS so CES Minarik aN he NP b o Corporation C ERN 5 64 92 1 75 44 9 A M 0 73 18 M 1 E E 26 IN All Dimensions in Inches Millimeters Figure 2 Regen Dump Circuit Dimensions Installation A X X a amp SHOCK AVOID KEEP AVOID HAZARD HEAT DRY VIBRATION Mounting Printed circuit board components are sensitive to electrostatic fields Avoid contact with the printed circuit board directly Hold drive or regen dump circuit by the chassis only Protect the drive and regen dump circuit from dirt moisture and accidental contact Provide sufficient room for access to the terminal block and calibration trimpots Mount the drive and regen dump circui
18. hompson Avenue Glendale CA 91201 2011 USA This warranty shall not apply to any product that has been repaired by unauthorized persons The Corporation is not responsible for removal installation or any other incidental expenses incurred in shipping the product to and from the repair point B Disclaimer The provisions of Paragraph A are the Corporation s sole obligation and exclude all other warranties of merchantability for use express or implied The Corporation further disclaims any responsibility whatsoever to the customer or to any other person for injury to the person or damage or loss of property of value caused by any product that has been subject to misuse negligence or accident or misapplied or modified by unauthorized persons or improperly installed C Limitations of Liability In the event of any claim for breach of any of the Corporation s obligations whether express or implied and particularly of any other claim or breech of warranty contained in Paragraph A or of any other warranties express or implied or claim of liability that might despite Paragraph B be decided against the Corporation by lawful authority the Corporation shall under no circumstances be liable for any consequential damages losses or expense arising in connection with the use of or inability to use the Corporation s product for any purpose whatsoever An adjustment made under warranty does not void the warranty nor does it imply an extension of
19. ion Calibration FWD MAXSPD REV MAXSPD iz ke Se ame Rex ace Re c MMC OS zero offset GAIN peek peed etd bee inate ein did ecd suu usitas E FWD TQEIM recatat d eR as REV TQLEIM Luke a S ACCEL ESAE PE ple EP TACH for use with tachometer feedback only Application Notes Independent adjustable speeds Troubleshooting Diagnostic LEDS ee bbe the DADOS ERE apo eere ques Commutation Sequence Diagram Replacement Parts 36 Unconditional Warranty inside back cover Illustrations Figure 1 BOSS Series Dimensions 2 Figure 2 Regen Dump Circuit Dimensions 3 Figure 3 4Q Mounting to the Motherboard 8 Figure 4 Speed Adjust Potentiometer Mounting 9 Figure 5 Quick Connect Terminal 0 10 Figure 6 Motherboard Connections 11 Figure 7 Regen Dump Circuit Connections 12 Figure 8 4Q Terminal Connections 13 Figure 9 Voltage Signal Connections 15 Figure 10 Sensor Connections
20. itch the FWD REV switch to the opposite position To prevent possible demagnetization of the motor consider braking the motor to a stop before reversing polarity Once reversed release the brake input To brake the motor Close the BRAKE switch To coast the motor to a stop without disconnecting power Open the ENABLE switch Line starting and line stopping Line starting and line stopping applying and removing AC or DC voltage input is recommended for infrequent starting and stopping of the drive only It is also the recommended for emergency starting and stopping of the drive When AC or DC voltage input is applied to the drive the motor accelerates to the speed set by the speed adjust potentiometer or voltage signal input When AC or DC voltage input is removed the motor coasts to a stop 22 23 Calibration Boss Series drives have eleven user adjustable trimpots Each drive is factory calibrated to its maximum horsepower rating Readjust the calibration trimpot settings to accommodate lower horsepower motors 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 L VR ON 1 L501 N 7 C501 C502 C503 i MODE SELECT 5 5
21. l the motor speed stabilizes 2 Make sure motor is not undersized for load adjust FWD TQLIM and REVTQLIM settings Motor does not reverse 1 Bad FWD REV switch connection 2 Reversing circuit not working properly 3 Hall sensors miswired 1 Check FWD REV switch connection 2 Check reversing circuit by shorting FWD REV terminal to COM terminal with jumper wire 3 Check hall sensor connections For additional assistance contact your local Minarik Distributor or the factory direct phone 702 823 9475 or fax 702 823 9495 35 Commutation Sequence Diagram PHASE TO PHASE VOLTAGE V T1 T2 V T2 T3 V T3 T1 m 120 HALL EFFECT SWITCHING SEQUENCE ELECTRICAL DEGREES 0 60 120 180 240 300 360 HALL C FOR CLOCKWISE ROTATION VIEWING MOTOR FROM MOUNTING FACE Figure 19 Commutation Sequence Diagram 36 Replacement Parts Replacement parts are available form Minarik Corporation and its distributors for this drive series Model No Symbol BOSS15 115AC 4Q 501 0501 506 0507 C507 508 BOSS08 115A C 4Q BR501 Q501 506 Q507 C507 508 BOSS04 115AC 4Q BR501 Q501 506 Q507 C508 C507 not used BOSS08 D240A C 4Q BR501 Q501 506 Q507 C507 508 BOSS04 115AC 4Q BR501 Q501 506 Q507 C508 C507 not used Fuse Kits 12 Ribbon Cable Description Four Quadrant Plug In Card Power Bridge 300V 35A MOSFET
22. ng stations Figure 18 Independent Adjustable Speeds 31 Troubleshooting 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 AC or DC voltage input 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 Disconnect AC or DC voltage input from the drive Wait 30 seconds for power to discharge Check the drive closely for damaged components Check that no wire chips or other foreign material has become lodged on the printed circuit board Verify that every connection is correct and in good condition Verify that there are no short circuits or grounded connections Check that the drive s rated phase current and rms voltage 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 32 Operation Diagnostic LEDs Diagnostic LEDs on the 4Q plug in card POWER ON FAULT The green POWER ON LED lights when power is applied to the drive and the plug in card is connected properly The red FAULT LED lights in any of the following conditions 1 The hall sensors are miswired not operating properly demand more than 20 mADCcurrent 5V
23. o COM to brake the motor leave open to run the motor FWD REV terminal 4 Short to COM to run the motor in the reverse direction leave open to run the motor in the forward direction V POT terminal 5 Floating 10 VDC reference for 10 speed adjust potentiometer SPD IN terminal 6 Accepts floating ungrounded 10VDC to 10 VDC reference or 10 speed adjust potentiometer wiper V POT terminal 7 Floating 10 VDC reference for 10 speed adjust potentiometer 15 terminal 8 Floating 15 VDC supply 25 mA maximum 15 terminal 9 Floating 15 VDC supply 25 mA maximum HALL C B A terminals 10 12 Inputs from motor hall sensors V Ref terminal 14 Floating 5 VDC supply for hall sensors NOTE The maximum supply current at 5 VDC is 20mA Voltage follower Instead of using a speed adjust potentiometer BOSS series drives may be wired to follow a floating differential 10 VDC to 10 VDC signal that is isolated from earth ground Connect a voltage signal to terminals and 6 see Figure 9 for connections Installation 15 USE THIS ARRANGEMENT IF SENSOR DRAWS LESS THAN 20 mADC USE THIS ARRANGEMENT IF SENSOR DRAWS MORE THAN 20 mADC Figure 9 Voltage Signal Connections COM BRAKE VPOT 45 HALLB COM ENABLE FWDIREV SPD IN 15 HALLC HALL A VREF 12 34 5 6 7 8 9 10 11 12 13 14 2 8 51 O a Ol o 2 J z B 9 MOTOR AN N HALLSENSO
24. only when the drive is operating in the Velocity Mode If the GAIN trimpot is set for full gain full CW and the drive still needs more regulation increase the IR COMP setting CW If the GAIN trimpot is set for full gain and the drive has too much regulation decrease the IR COMP setting 26 Calibration FWD TQLIM The FWD TQLIM setting determines the maximum current limit for accelerating and driving the motor in the forward direction It is factory set at 120 of rated motor current To calibrate FWD TQLIM 1 With the power disconnected from the control connect ammeter in series with one of the motor phases Reapply power to the drive and run the motor at 200 RPM in the forward direction Carefully stall the motor The current limit value should register on the ammeter If it does not stall the motor again until the ammeter shows the current limit value Adjust the FWD TQLIM trimpot until the phase current is 120 of motor rated current Remove the stall from the motor REV TQLIM The REV TQLIM setting determines the maximum current limit for accelerating and driving the motor in the reverse direction It is factory set at 120 of rated motor current To calibrate REV TQLIM 1 With the power disconnected from the control connect ammeter in series with one of the motor phases Reapply power to the drive and run the motor at 200 RPM in the reverse direction Carefully
25. re or DC voltage input is disconnected for 30 seconds before installing or removing the 4Q plug in card To mount the 4Q plug in card to the motherboard line up the motherboard docking pins to the docking holes see Figure 3 Align the header pins on the plug in card with the corresponding header sockets on the motherboard Fasten the header pins into the header sockets until secure The docking pin will lock the plug in card into place when the header pins are correctly mounted into the header sockets Header Docking Pins Hole Docking imc e 1 1 1 1 1 1 1 1 1 1 1 1 1 1 i Docking Docking Pin Pin Y X Header Sockets Make sure AC or DC voltage input is removed for 30 seconds before removing and installing 4Q plug in card Figure 3 4Q Mounting to the Motherboard Installation 9 Speed adjust potentiometer mounting Mount the speed adjust potentiometer through a 0 38 inches 1 0 cm hole with the hardware provided Figure 4 Install the circular insulating disk between the panel and the 10K ohm speed adjust potentiometer Twist the speed adjust potentiometer wire to avoid picking up unwanted electrical noise If potentiometer leads are longer than 18 inches 46 cm use shielded cable Warning Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure Grounding the input will cause damage to the drive MOUNT THROUGH A 0 38 IN 10 MM H
26. stall the motor The current limit value should register on the ammeter If it does not stall the motor again until the ammeter shows the current limit value Adjust the REV TQLIM trimpot CW until the phase current is 120 of motor rated current Remove the stall from the motor Calibration 27 ACCEL The ACCEL setting determines the time the motor takes to ramp to a higher speed in the forward direction or a lower speed in the reverse direction ACCEL is factory set for the fastest acceleration time full CCW To calibrate ACCEL 1 Set the speed adjust potentiometer or voltage input signal for minimum speed The motor should run at minimum speed 2 Set the speed adjust potentiometer or voltage input signal to maximum forward speed and measure the time it takes the motor to go from minimum to maximum speed 3 If the time measured in step 2 is not the desired acceleration time turn the ACCEL trimpot CW for a slower acceleration time or CCW for a faster acceleration time Repeat steps 1 through 3 until the acceleration time is correct DECEL The DECEL setting determines the time the motor takes to ramp to a higher speed in the reverse direction or a lower speed in the forward direction DECEL is factory set for the fastest acceleration time full CCW To calibrate DECEL 1 Set the speed adjust potentiometer or voltage input signal for maximum forward speed The motor should run at maximum speed 2 Set the speed
27. t away from other heat sources Operate within the specified ambient operating temperature range Avoiding excessive vibration to prevent loose connections Mount drive and regen dump circuit with its printed circuit board in either a horizontal or vertical plane Six 0 19 inch 5 mm wide slots on the chassis accept 8 pan head screws Fasten either the large base or the narrow flange of the chassis to the subplate The chassis does not have to be earth grounded If you choose to ground the chassis use a star washer beneath the head of at least one of the mounting screws to penetrate the anodized chassis surface and to reach bare metal 6 Installation Wiring Use 16 20 AWG wire for speed adjust potentiometer wiring Use 14 16 AWG wire for AC line L1 L2 and motor A1 and A2 wiring Shielding guidelines As a general rule Minarik recommends shielding of all conductors if 1 wire lengths exceed 18 inches with separation of power and logic leads 2 wire lengths exceed 4 inches and power and logic leads must be bundled together 3 radiated and or conducted noise must be minimized due to concerns about immunity or general compliance CE FCC etc Minarik considers this an unfavorable condition and does not recommend bundling of power and logic leads for any length A 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
28. voltage measured in step 3 Check that the tachometer is properly calibrated The motor should run at the same set speed when SW501 is set to either armature or tachometer feedback E C501 C501 C502 C503 Mode Select Switches MIN IR FWD REV ECEL SPD COMP TQLIM J J J TB501 Figure 15 Mode Select Switches 29 Application Notes Multiple fixed speeds Replace the speed adjust potentiometer with series resistors with a total series resistance of 10K ohms Figure 16 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds Figure 16 Multiple Fixed Speeds Adjustable speeds using potentiometers in series Replace the speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in series with a total series resistance of 10K ohms Figure 17 shows a connection for fixed high and low speed adjust potentiometers Figure 17 Adjustable Speeds Using Potentiometers in Series 30 Application Notes Independent adjustable speeds Replace the speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in parallel with a total parallel resistance of 10K ohms Figure 18 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operati
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