User`s Manual
Contents
1. Dimensions pe TT M De Le Minarik D L rf OO i Corporation 4 97 126 4 13 105 EE kk _ i 188 ii e BEBEEBEBEI e LA L2 S1 S2 S3 F1 F2 A2 A1 ml 0 25 6 5 38 137 I i PJ I 1 75 45 dade 0000010 ma ALL DIMENSIONS IN INCHES MILLIMETERS MODEL DIM H Figure 1 XLA Series Dimensions Dimensions 9 0 188 WIDE SLOT 4 PLACES 8 32 THD 4 PLACES 9 78 248 6 70 170 1 41 35 2 50 64 2 50 64 3 15 80 3 15 80 6 90 175 Figure 2 Heat Sink Dimensions KIT 223 0271 10 Installation Drive mounting AN VVarning Do not install revvire or remove this control with power applied Doing so may cause fire or serious injury Make sure you have read and understood the Safety VVarnings before attempting installation The chassis must be earth grounded Use a star washer beneath the head of at least one of the mounting screws to penetrate the anodized chassis surface and to reach bare metal Drive components are sensitive to electrostatic fields Avoid direct contact with the circuit board Hold drive by the chassis only e Protect the drive from dirt moisture and accidental contact e Provide sufficient room for access to the terminal2. Speed adjust potentiometer mounting Cage clamp terminals Motor connections Connections Power connections External line fuse Field output connections Voltage follower connections Voltage switches Before applying power Operation oll e AA E BE ES HE E DEAR Starting and Stopping Methods Line starting and line stopping MDI sr ie OR DER OE EA RE OR DEE Decelerate to minimum speed Dynamic braking Calibration Calibration procedure MINIMUM SPEED MIN SPD MAXIMUM SPEED MAX SPD IR COMPENSATION IR COMP CURRENT LIMIT CURR LIMIT ACCELERATION ACCEL DEGELERATION DECEL Multiple fixed speeds Application Notes Adjustable speeds using potentiometers in series Independent adjustable speeds RUN
3. Lej CURR LIMIT Lej CURR LIMIT 9 Le CURR LIMIT Lej CURR LIMIT Le CURR LIMIT Cc IR COMP IR COMP IR COMP Day IR COMP IR COMP IR COMP Cory IR COMP IR COMP IR COMP IR COMP XL1100 1 4 HP 90 VDC 1750 RPM CE 2 5 AMPS CURR LIMIT XL3025A 1 20 HP 90 VDC 1750 RPM Le 0 5 AMPS CURR LIMIT 1 8H P 90 VDC E 1750 RPM Da 1 3 AMPS CURR LIMIT 1 4H P 90 VDC OQ 1750 RPM CE 2 5 AMPS CURR LIMIT XL3050A 1 8H P mwe 1 3 AMPS CURR LIMIT 1 4H P 90 VDC 1750 RPM DY 2 5 AMPS CURR LIMIT 1 2H P 90 VDC 1750 RPM CET 5 AMPS CURR LIMIT XL3200A 1 4H P ava 2 5 AMPS CURR LIMIT 1 2H P 90 VDC 1750 RPM CET 5 AMPS CURR LIMIT 1HP 90 VDC E 1750 RPM CEY 10 AMPS CURR LIMIT IR COMP IR COMP CEY IR COMP CY IR COMP 9 Le IR COMP IR COMP IR COMP IR COMP actual settings may vary 1HP 90 VDC 1750 RPM 10 AMPS 1 8 HP 180 VDC 1750 RPM 0 67 AMPS 1 4H P 180 VDC 1750 RPM 1 4 AMPS 1 3H P 180 VDC 1750 RPM 1 75 AMPS 1 4H P 180 VDC 1750 RPM 1 4 AMPS 1 2H P 180 VDC 1750 RPM 2 5 AMPS 3 4H P 180 VDC 1750 RPM 3 8 AMPS 1 2H P 180 VDC 1750 RPM 2 5 AMPS 1HP 180 VDC 1750 RPM 5 AMPS 2HP 180 VDC 1750 RPM 10 AMPS Figure 13 Typical CURR LIMIT and IR COMP settings 41 Application Notes Multiple fixed speeds Replace t
4. 62 Specifications Model Number XL1100A Type open chassis AC Line Voltage 115 VAC 10 50 60 Hz single phase Line Fuse Rating 15A Horsepower Range 1 4 1 HP Form Factor 1 05 Maximum Armature Current 5 ADC Maximum Armature Current with Heat Sink 10 ADC Field Voltage 115 VAC Input 50 VDC 100 VDC Maximum Field Current 1 ADC Maximum Armature Voltage Adjustment Range 50 150 VDC Minimum Armature Voltage Adjustment Range 0 70 VDC Acceleration Time Range with no load 1 12 seconds Deceleration Time Range with no load coast to a stop 12 seconds Speed Adjustment Potentiometer 10K ohms Analog Signal Voltage Range signal must be isolated S1 to S2 0 2 7 VDC Approximate Input Impedance from S1 to S2 100K ohms Speed Regulation at base speed 1 Safety Certification UL Recognized Component file E132235 CSA Certified Component file LR41380 Power Device Switching Frequency 18 KHz Weight 1 4 Ib Ambient Operating Temperature Range 10 C 40 C Use heat sink kit part number 223 0271 when continuous armature current is above 5 ADC 2 Specifications Model Number XL3025A Type open chassis 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 4 HP Horsepower Range 240 VDC Output 1 8 1 3 HP Form Factor 1 05 Maximum Armature Current 3 ADC Field Voltage 115
5. Automation S Control XLA Series Models XL3200A Pulse Width Modulated Variable Speed DC Drives ENUEN sJasp The XLA Series of open chassis PWM Drives ranges from 1 20 HP to 2 HP An additional heatsink kit PN 223 0271 may be added if the armature current is greater than 5 amps The XLA Series of drives has a cage clamp terminal block for user friendly wiring There are six user adjustable trimmer potentiometers in addition to diagnostics Copyright O 2002 by Minarik Corporation All rights reserved No part of this manual may be reproduced or transmitted in any form without written permission from Minarik Corporation The information and technical data in this manual are subject to change without notice Minarik Corporation and its Divisions make no warranty of any kind with respect to this material including but not limited to the implied warranties of its merchantability and fitness for a given purpose Minarik Corporation and its Divisions assume no responsibility for any errors that may appear in this manual and make no commitment to update or to keep current the information in this manual mvoo40902 Printed in the United States of America safety Warnings A X X 2 VOID HAZARD HEAT DRY VIBRATION This symbol A denotes an important safety tip or warning Failure to observe these warnings may result in serious injury Please read these instructions carefully before performing any of the procedures contained
6. 91 cm wires Twist inhibit plug wires and separate them from other power carrying wires or sources of electrical noise Use shielded cable if the inhibit plug wires are longer than 12 inches 30 cm If shielded cable is used ground only one end ofthe shield to earth ground Do not ground both ends of the shield See Wiring page 11 for more wiring information 28 Operation Decelerate to minimum speed The circuit shown in Figure 9 may be used to decelerate a motor to a minimum speed Closing the switch between S2 and S1 decelerates the motor from set speed to a minimum speed determined by the MIN SPD trimpot setting If the MIN SPD trimpot is set full CCW the motor decelerates to zero speed when the switch between S2 and S1 is closed Calibrate the ACCEL and DECEL trimpots to control the acceleration and deceleration ramp Set the switch to the RUN position to accelerate the motor to set speed 10K OHM SPEED ADJUST POTENTIOMETER DECEL TO MIN SPEED Figure 9 Run Decelerate to Minimum Speed Switch Operation 29 Dynamic braking Dynamic braking may be used to rapidly stop a motor see Figure 10 For the RUN BRAKE switch use a two pole two position switch rated to handle the motor voltage and current For the dynamic brake resistor use a high power wirewound resistor minimum 40 watts Table 4 page 30 lists the minimum recommended dynamic brake resistor values DYNAMIC BRAKE RESISTOR INHIBIT Figure 10 Dy
7. 8 Heat Sink Dimensions KIT 223 0271 9 Speed Adjust Potentiometer Installation 15 Cage Clamp Terminal 16 XLA Series Connections 19 Voltage Follower Connections 21 Voltage Switches 22 Inhibit Terminals si EA DR AE e rss cate ad 26 Run Decelerate to Minimum Speed Switch 28 Dynamic Brake Connection 29 Calibration Trimpot Layout 32 Low Voltage DC Motor Calibration Settings 35 Typical CURR LIMIT and IR COMP settings actualsettingsmayvary 40 Multiple Fixed Speeds 41 Adjustable Speeds Using Potentiometers In Series 42 Independent Adjustable Speeds 4 43 RUN JOG Switch first wiring option 44 RUN JOG Switch second wiring option 45 Leader follower application 46 Single Speed Potentiometer Control of Multiple Drives 47 Reversing Circuit Connection 48 Reversing with a DLC600 49 Diagnostic LED Location 51 CEXL Filter Connection to XLA Series Drive
8. IC503 MAX SPD CURRLIMIT IR COMP oo POWER CURR ON LIMIT N 7 N 7 ADS ACCEL DECEL id IL501 11502 POVVER ON IL501 CURR LIMIT IL502 Figure 23 Diagnostic LED Location 52 Troubleshooting Line fuse blows Line fuse does not blow but the motor does not run Possible Causes Line fuses are not the correct size Motor cable or armature shorted to ground Field circuit is open Speed adjust potentiometer or input signal is set to zero speed Suggested Solutions Check that line fuses are the correct size See Replacement Parts section for the correct fuse size Check motor cable and armature for shorts Send drive to Minarik repair department Increase the speed adjust potentiometer or voltage setting Line fuse does not blow but motor does not run cont Possible Causes 2 Speed adjust potentiometer or voltage input signal not connected to drive input properly connections are open INHIBIT terminals are jumpered S2 is shorted to SO Drive is in current limit Drive is not receiving AC line voltage Troubleshooting 53 Suggested Solutions Check connections to input Verify that connections are not open Remove jumper from INHIBIT terminals Remove short Check that the motor is not jammed Increase the CURR LIMIT setting if it is set too
9. JOG switch RUN JOG option 1 RUN JOG option 2 Leader follower application Single speed potentiometer control of multiple drives Reversing Reversing with a DIGI LOK controller Before troubleshooting Troubleshooting Diagnostic LEDS POWER ON IL501 CURR LIM 11502 Replacement Parts Certificate of Compliance AG line filters ss eke sadas oe ee EERS ocd see End User Responsibility Unconditional Warranty Tables Table 1 Recommended Line Fuse Sizes Table 2 Field Output Connections Table 3 Inhibit Plug Harness Part Numbers Table 4 Minimum recommended dynamic brake resistor sizes Table 5 Replacement Parts Table 6 Minarik AC Line Filters inside back cover IV Illustrations Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 XLA Series Dimensions
10. Only one DLC option Optical Encoder or Magnetic Pickup may be used at a time S3 MINARIK S2 DRIVE S1 Dynamic Brake Resistor DLC600 Inhibit Leads C IN Common Signal 5 VDC Optical Encoder Magnetic Pickup Figure 22 Reversing with a DLC600 50 Troubleshooting AN VVarning 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 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 other foreign material has become lodged on the printed circuit board 4 Verify that every connection is correct and in good condition 5 Verify that there are no short circuits or grounded connections 6 Check that the drive s rated armature outputs are consistent with the motor ratings For additional assistance contact your local Minarik distributor or the factory direct 800 MINARIK phone or 800 394 6334 fax Troubleshooting 91 Diagnostic LEDs XLA Series drives are equipped with the following diagnostic LEDs POWER ON IL501 The green POWER LED lights whenever AC line voltage is applied to the drive CURR LIM IL502 The red CURR LIM LED lights whenever the drive reaches current limit
11. See Specifications on page 1 for approximate acceleration times ACCEL is factory set for the fastest acceleration time full CCW To set the acceleration time 1 Set the speed adjust potentiometer full CCW The motor should run at minimum speed 2 Turn the speed adjust potentiometer full CW 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 Calibration 39 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 To set the deceleration time 1 Set the speed adjust potentiometer full CW The motor should run at maximum speed 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 40 Calibration Le CURR LIMIT CURR LIMIT CURR LIMIT Ue CURR LIMIT Le CURR LIMIT
12. The XL series has been tested to the following test specifications EN55014 1993 emissions 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 60 Certificate of Compliance AC line filters In addition to EMI RFI safeguards inherent in the XLA series design external filtering is reguired Minarik reguires the AC line filters listed in Table 6 Use model CE04XL with drives rated for 3 ADC or below model CE10XL with drives rated for 10 ADC or below and model CE15XL for drives rated for 15 ADC or below If the end user is using a CE approved motor the correct filter from Table 6 is all that is necessary to meet the EMC directives listed herein Table 6 Minarik AC Line Filters Minarik Model Number CE04XL CE10XL CE15XL Rated Current 4A 10 A 15A Inductance 17 46 mH 14 26 mH 10 0 mH Capacitance Line to Line 0 811 mF 0 811 mF 0 082 mF Line to Ground 0 0056 mF 0 0056 mF 0 0056 mF Discharge Resistor 330 K ohms 330 K ohms 330 K ohms Wire the AC line filter within 10 inches 25 cm of the drive as shown in Figure 24 page 62 The ground connection from the filter must be wired to soli
13. the AC line power leads to TB501 terminals L1 and L2 or to a double throw single pole master power switch recommended External line fuse NOTE Model XL1100A drives do not reguire additional line fusing An additional line fuse should be installed on L2 if the input voltage is 230 VAC The line fuse should be rated at 250 volts and 150 200 of maximum motor nameplate current Refer to the line fuse chart on page 14 for fuse ratings Installation 19 STC C501 Ld MAX SPD CURR LIMIT IR COMP C502 AINO 3SN4 ONILOV LSVA LOSN4 ON INHIBIT IL 501 ol COIL MOTOR FUSE SWITCH see note 1 10K OHM see note 2 SPEED ADJUST POT NOTES 1 DO NOTADD LINE FUSE TO L2 IF USING MODEL XL1100A DRIVES ADD LINE FUSE TO L2 FOR ALL OTHER DRIVES IF LINE VOLTAGE IS 230 VAC 2 DO NOT CONNECT FIELD CIRCUIT IF USING A PERMANENT MAGNET MOTOR REFER TO TABLE 2 PAGE 20 FOR ALTERNATE FIELD CONNECTIONS Figure 5 XLA Series Connections 20 Installation Field output connections Warning The field output is for shunt wound motors only Do not make any connections to the field output when using a permanent magnet motor Use 18 AWG wire for field connections See Table 2 for field output connections Table 2 Field Output Connections Line Voltage Approximate Field Field VAC Voltage VDC Connections 115 50 F1 and L1 115 100 F1 and F2 230 100 F1 and L1 230 200 F1 and F2 Installation 21 Vol
14. 502 20 A 500 V MOSFET R501 R502 0 01 ohm 5 W Resistor T501 3FD 436 Transformer TH501 WS1090 20 A Limiter FU501 15 A 3 AB Normal Blo Fuse pot kit 10K ohm 5 W Potentiometer POTENTIOMETER KIT CONTENTS KIT P N 202 0003 1 ea 10K OHM 5W 5 TOL Potentiometer 120 0009 1 ea 3 8 32 X 1 2 NUT 151 0007 1 ea 3 8IN INT TOOTH LOCK WSHR 152 0007 1 ea POT INSULATING WASHER 156 0022 FUSE KIT CONTENTS 1 8A FUSE KIT 050 0068 2 EA 1 AMP 3AG FAST ACTING FUSE 050 0042 2 EA 1 5 AMP 3AG FAST ACTING 050 0026 2 EA3 AMP 3AG FAST ACTING FUSE 050 0021 2 EA 5 AMP 3AG FAST ACTING FUSE 050 0022 2 EA8 AMP 3AG FAST ACTING FUSE 050 0059 1 EA 0 5 AMP PICO FUSE 050 0074 3 10A FUSE KIT 050 0070 2 EA3 AMP 3AG FAST ACTING FUSE 050 0021 2 EA5 AMP 3AG FAST ACTING FUSE 050 0022 2 EA8 AMP 3AG FAST ACTING FUSE 050 0059 2 EA 10 AMP 3AB NORMAL BLO FUSE 050 0024 1 EA 0 5 AMP PICO FUSE 050 0074 5 15A FUSE KIT 050 0072 2 EA5 AMP 3AG FAST ACTING FUSE 050 0022 2 EA8 AMP 3AG FAST ACTING FUSE 050 0059 2 EA 10 AMP 3AB NORMAL BLO FUSE 050 0024 2 EA 15 AMP 3AB NORMAL BLO FUSE 050 0018 1 EA 0 5 AMP PICO FUSE 050 0074 073 0008 011 0099 071 0044 070 0066 032 0129 230 0072 033 0007 050 0018 202 0003 59 Certificate of Compliance Minarik Corporation hereby certifies that its XLA series drives models XL3025A XL3050A and XL3200A have been approved to bear the CE mark provided the conditions of approval have been met by the end user
15. B1 T501 C503 a 0 R501 A a Y bx o IR N 8 COMPENSATION A Y S 3 IC502 1C501 C501 CI CEY oz MAX SPD CURRLIMIT IR COMP C502 O O a ON LIMIT C504 CEY CEY 51 MIN SPD ACCEL DECEL INHIBIT IL501 11502 LOSNA AINO 3SN4 NIL V LSY4 TB501 L1 L2 1 S2 S3 1 F2 A2 A MINIMUM SPEED ACCELERATION DECELERATION Figure 11 Calibration Trimpot Layout Calibration 33 Calibration procedure Calibrate the drive using the following procedure 1 Set the MIN SPD MAX SPD ACCEL and DECEL trimpots to zero full CCW 2 Set the CURRENT LIMIT trimpot to maximum full CW 3 Set the IR COMP trimpot to midrange approximate 12 o clock position 4 Set the signal input analog voltage signal or speed adjust potentiometer to zero 5 Apply power to the drive 6 Calibrate the trimpots as follows 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 Set the speed adjust potentiometer or reference signal to zero speed Adjust the MIN SPD trimpot until the desired minimum motor speed is reached 34 Calibration 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 Set the speed ad
16. C Field Voltage 230 VAC Input 100 VDC 200 VDC Maximum Field Current 1 ADC Maximum Armature Voltage Adjustment Range 115 VAC Input 55 150 VDC Minimum Armature Voltage Adjustment Range 115 VAC Input 0 65 VDC Maximum Armature Voltage Adjustment Range 230 VAC Input 55 240 VDC Minimum Armature Voltage Adjustment Range 230 VAC Input 0 65 VDC Acceleration Time Range with no load 1 12 seconds Deceleration Time Range with no load coast to a stop 12 seconds Speed Adjustment Potentiometer 10K ohms Analog Signal Voltage Range signal must be isolated S1 to S2 for 0 130 VDC Armature Voltage 0 2 7 VDC for 0 240 VDC Armature Voltage 0 5 0 VDC Approximate Input Impedance from S1 to S2 100K ohms Speed Regulation at base speed 1 Vibration 0 5G max 20 50 Hz 0 1G max gt 50 Hz Safety Certification UL Recognized Component file E132235 CSA Certified Component file LR41380 Specifications 5 Power Device Switching Freguency 18 KHz Weight 1 5 Ib Ambient Operating Temperature Range 10 C 40 C 6 Specifications Model Number XL3200A Type open chassis 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 2 HP Horsepower Range 130 VDC Output with Heat Sink 1 4 1 HP Horsepower Range 240 VDC Output 1 2 1 HP Horsepower Range 240 VDC O
17. E AC VOLTAGE CEXL FILTER BIE VOLTAGE IN OUT TO DRIVE 115 VAC 115 VAC 230 VAC 230 VAC Figure 24 CEXL Filter Connection to XLA Series Drive C9 QOUBI IGWOY JO 23891411199 NOTES 64 NOTES Unconditional Warranty A Warranty Minarik Corporation referred to as the Corporation warrants that its products will be free from defects in workmanship and material for twelve 12 months or 3 000 hours whichever comes first from date of manufacture thereof Within this warranty period the Corporation will repair or replace at its sole discretion such products that are returned to Minarik Corporation 901 East Thompson Avenue Glendale CA 91201 2011 USA This warranty applies only to standard catalog products and does not apply to specials Any returns for special controls will be evaluated on a case by case basis The Corporation is not responsible for removal installation or any other incidental expenses incurred in shipping the product to and from the repair point B Disclaimer The provisions of Paragraph A are the Corporation s sole obligation and exclude all other warranties of merchantability for use express or implied The Corporation further disclaims any responsibility whatsoever to the customer or to any other person for injury to the person or damage or loss of property of value caused by any product that has been subject to misuse negligence or accident or misapplied or modified by unauthorized persons or impr
18. OLTAGE SWITCHES SW501 8 SW502 GLle 0872 062 gt SIL ZOSMS IC5O3 IC502 1C501 OS OS a Figure 7 Voltage Switches ISNA W LSVd n E a 23 Operation AN VVarning Dangerous voltages exist on the drive when itis powered and up to 30 seconds after povver is removed and the motor stops BE ALERT High voltages can cause serious or fatal injury Chane switch settings only when the drive is disconnected from AC line voltage Make sure both switches are set to their correct position If the switches are improperly set to a lovver voltage position the motor vvill not run at full voltage If the switches are improperly set to a higher voltage position the motor vvill overspeed vvhich may cause motor damage Before applying povver 1 Verify that no conductive material is present on the printed circuit board 2 Setall switches to their proper settings if required 3 Verify that the AC supply is properly balanced 24 Operation Startup 1 Turn the speed adjust potentiometer full counterclockwise CCW If the drive is following a voltage signal set the voltage signal to 0 VDC 2 Apply AC line voltage 3 Slowly advance the speed adjust potentiometer clockwise CW If a voltage signal is used slowly increase the voltage signal The motor slowly accelerates as the potentiometer is turned CW or the voltage signal is increased Continue until the desired speed is reached 4 To stop t
19. VAC Input 50 VDC 100 VDC Field Voltage 230 VAC Input 100 VDC 200 VDC Maximum Field Current 1 ADC Maximum Armature Voltage Adjustment Range 115 VAC Input 60 150 VDC Minimum Armature Voltage Adjustment Range 115 VAC Input 0 70 VDC Maximum Armature Voltage Adjustment Range 230 VAC Input 60 240 VDC Minimum Armature Voltage Adjustment Range 230 VAC Input 0 70 VDC Acceleration Time Range with no load 1 12 seconds Deceleration Time Range with no load coast to a stop 12 seconds Speed Adjustment Potentiometer 10K ohms Analog Signal Voltage Range signal must be isolated S1 to S2 for 0 130 VDC Armature Voltage 0 2 7 VDC for 0 240 VDC Armature Voltage 0 5 0 VDC Approximate Input Impedance from S1 to S2 100 Kohms Speed Regulation at base speed 1 Vibration 0 5G max 20 50 Hz 0 1G max gt 50 Hz Safety Certification UL Recognized Component file E132235 CSA Certified Component file LR41380 Specifications 3 Power Device Switching Freguency 18 KHz Weight 1 4 Ib Ambient Operating Temperature Range 10 C 40 C 4 Specifications Model Number XL3050A Type open chassis AC Line Voltage 115 VAC 230 VAC 10 50 60 Hz single phase Line Fuse Rating 10A Horsepower Range 130 VDC Output 1 8 1 2 HP Horsepower Range 240 VDC Output 1 4 3 4 HP Form Factor 1 05 Maximum Armature Current 5 ADC Field Voltage 115 VAC Input 50 VDC 100 VD
20. abilizes Make sure motor is not undersized for load calibrate CURR LIMIT trimpot Troubleshooting 57 Replacement Parts Replacement parts are available form Minarik Corporation and its distributors for this drive series Model No Symbol Description Minarik P N XL1100A BR601 KBPC3506 Bridge 073 0008 C503 1500 mF 250 VDC Capacitor 011 0089 D501 16 A 600 V Diode 071 0055 Q501 Q502 IRF640 POWER MOSFET 070 0043 R501 R502 0 01 ohm 5 W Resistor 032 0129 T501 ST 436 Transformer 230 0071 TH501 WS1090 20A Limiter 033 0007 FU501 15A 3 AB Normal Blo Fuse 050 0018 pot kit 10K ohm 5 W Potentiometer 202 0003 XL3025A BR501 GBU8J Bridge 073 0006 C503 470 mF 400 VDC Capacitor 011 0120 D501 8 A 600 V Diode 071 0055 Q501 8 A 500 V MOSFET 070 0075 R501 R502 0 05 ohm 5 W Resistor 032 0113 T501 3FD 436 Transformer 230 0072 TH501 10 ohm NTC Thermistor 033 0005 FU501 8 A 3 AB Normal Blo Fuse 050 0023 pot kit 10K ohm 5 W Potentiometer 202 0003 XL3050A BR601 KBPC3506 Bridge 073 0008 C503 680mF 400 VDC Capacitor 011 0080 D501 16 A 600 V Diode 071 0044 Q501 Q502 8 A 500 V MOSFET 070 0075 R501 R502 0 05 ohm 5 W Resistor 032 0113 T501 3FD 436 Transformer 230 0072 TH501 WS380 15 A Imax Limiter 033 0006 FU501 10 A 3 AB Normal Blo Fuse 050 0024 pot kit 10K ohm 5 W Potentiometer 202 0003 Table 5 Replacement Parts 58 Troubleshooting XL3200A BR601 KBPC3506 Bridge C503 1000 mF 400 VDC Capacitor D501 MUR1560 Diode Q501 Q
21. at 150 of the maximum armature current See Table 1 on page 14 for recommended sizes 14 Installation Line Fusing for XL Series Drives Minarik Corporation offers three fuse kits part number 050 0068 1 8A Fuse Kit 050 0070 3 10A Fuse Kit and 050 0072 5 15A Fuse Kit All fuse kits include a 1 2A pico fuse part number 050 0074 which protects the transformer and logic Refer to Replacement Parts page 57 for fuse kit contents Table 1 Recommended Line Fuse Sizes 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 Installation 15 Speed adjust potentiometer mounting AN VVarning Be sure that the potentiometer tabs do not make contact vvith the potentiometer enclosure Grounding the input vvill cause damage to the drive Install the circular insulating disk between the mounting panel and the 10K ohm speed adjust potentiometer see Figure 3 Mount the speed adjust potentiometer through a 0 38 inch 10 mm hole vvith the hardware provided Twist the speed adjust potentiometer wires to avoid picking up unvvanted electrical noise MOUNT THROUGH A 0 38 IN 10 MM HOLE za NUT STAR VVASHER SPEED ADJUST POTENTIOMETER POT TAB ASSIGNMENTS INSULATING DISK PANEL Figure 3 Speed Adjust Potentiometer Installat
22. block and calibration trimpots 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 the drive in either the horizontal or vertical plane Six 0 19 in 5 mm wide slots in the chassis accept 8 panhead screws Fasten wither the large base or the narrow flange of the chassis to the subplate Installation 11 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 or the drive is disabled Opening any one motor lead may destroy the drive Use 12 AWG wire for AC line voltage L1 and L2 and motor armature A1 and A2 wiring Use 18 AWG wire for logic S1 S2 and S3 and motor field F1 and F2 wiring 12 Installation Shielding guidelines AN VVarning 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 con
23. d 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 6 is all that is necessary to meet the CE directives listed herein Certificate of Compliance 61 End User Responsibility The end user must use the filtration listed in this addendum to comply with CE The OEM may choose to provide alternative filtering that encompasses the Minarik drive and other electronics within the same panel The OEM has this liberty because CE is a machinery directive Whether or not every component in the OEM s machinery meets CE the OEM must still submit his machine for CE approval Thus no component must necessarily meet CE within the machine as long as the OEM takes the necessary steps to guarantee the machine does meet CE By the same token even if every component in the OEM s machine does meet CE the machine will not necessarily meet CE as a machine Using CE approved wiring practices such as proper shielding and the filters should assure the drive will meet EN50081 1993 emissions standard and EN50082 2 1995 immunity standard MIN SPD ACCEL DECEL INHIBIT 11501 L502 C502 C 0 O O POWER CURR ON LIMIT kk O 4 O oO oO O O CEY Cc Gj e S TB501 XLA SERIES DRIVE EARTH GROUND AC VOLTAGE OUTPUT TO XLA SERIES DRIVE WIRE FILTER WITHIN 10 INCHES 25 CM OF DRIVE AC LINE AC LIN
24. ductors 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 Installation 13 Heat sinking XLA series models XL1100A and XL3200A require an additional heat sink Minarik part number 223 0271 when the continuous armature current is above 5 ADC All other XLA Series drives have sufficient heat sinking in their basic configuration Use a thermally conductive heat sink compound such as Dow Corning 340 Heat Sink Compound between the drive chassis and heat sink surface for optimum heat transfer Fusing NOTE Model XL1100A drives do not reguire a line fuse on L2 All XLA Series drives are fused for maximum rated current at 115 VAC line input A factory installed fuse is connected to L1 hot of the AC line input See Replacement Parts page 57 for exact fuse size For 230 VAC operation add an additional line fuse for L2 neutral Use a 250 volt fast acting fuse rated
25. he drive set the speed adjust potentiometer or voltage signal to zero Operation 25 Starting and Stopping Methods AN VVarning For frequent starts and stops use dynamic braking inhibit mode or decelerating to minimum speed shorting S2 to S1 DO NOT use any of these methods for emergency stopping They may not stop a drive that is malfunctioning Removing AC line power both L1 and L2 is the only acceptable method for EMERGENCY stopping For this reason Minarik strongly recommends the installation of an emergency stop switch The switch contacts should be rated at a minimum of 250 volts and 200 of maximum motor current Line starting and line stopping When AC line voltage is applied to the drive the motor accelerates to the set speed When AC line voltage is removed the motor coasts to a stop Line stopping removing AC line voltage is not necessary and therefore not recommended for stopping except for emergency situations 26 Operation Inhibit terminals Jumper the INHIBIT terminals to coast the motor to a stop see Figure 8 Remove the jumper to accelerate the motor to set speed nej 228 NE Figure 8 Inhibit Terminals Operation 27 Inhibit plug Minarik Corporation offers two accessory plug harnesses for use with the INHIBIT terminals Table 3 Inhibit Plug Harness Part Numbers Minarik Part Number Description 201 0024 Inhibit plug with 18 in 46 cm wires 201 0079 Inhibit plug with 36 in
26. he speed adjust potentiometer with series resistors with a total series resistance of 10K ohms see Figure 14 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 14 Multiple Fixed Speeds 42 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 10K ohms Figure 15 shows the connection for two speed control with high and low speed adjust potentiometers OHM Figure 15 Adjustable Speeds Using Potentiometers In Series Application Notes 43 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 16 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations SPEED 1 Figure 16 Independent Adjustable Speeds 44 Application Notes RUN JOG switch Using a RUN JOG switch is recommended in applications where guick stopping is not needed and freguent jogging is reguired Use a single pole two position switch for the RUN JOG switch and a single pole normally closed momentary operated pushbutton for the JOG pushbutton RUN JOG o
27. in this manual DO NOT INSTALL REMOVE OR REWIRE THIS EQUIPMENT WITH POWER APPLIED Have a qualified electrical technician install adjust and service this equipment Follow the National Electrical Code and all other applicable electrical and safety codes including the provisions of the Occupational Safety and Health Act OSHA when installing equipment Reduce the chance of an electrical fire shock or explosion by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures N 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 eguipment and insulated tools if working on this drive with power applied Contents Safety Warnings Tables Illustrations Specifications Dimensions Installation Drive MOUNINO sopresa rana AA WIIG AE DT Shielding guidelines Heat SINKIN t ea eee let Oe Re EE RED EE Bee sa FUSING e pa naasis usi WEE EE DEE Sk El Line Fusing for XL Series Drives
28. ion 16 Installation Cage clamp terminals XLA Series drive connections are of the cage clamp terminal type see Figure 4 To insert a wire into a terminal 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 wire Figure 4 Cage Clamp Terminal Installation 17 Connections AN VVarning Do not connect this equipment vvith povver applied Failure to observe this precaution may result in fire or serious injury Minarik strongly recommends the installation of a master power switch in the voltage input line The switch contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts Connect the power input leads an external line fuse if required and a DC motor to TB501 on the drive s printed circuit board PCB as shown in Figure 5 page 19 Motor connections Minarik drives supply motor voltage from A1 and A2 terminals It is assumed throughout this manual that when A1 is positive with respect to A2 the motor will rotate clockwise CW while looking at the output shaft protruding from the front of the motor If this is opposite of the desired rotation simply reverse the wiring of A1 and A2 with each other Connect a DC motor to TB501 terminals A1 and A2 as shown in Figure 5 Ensure that the motor voltage rating is consistent with the drive s output voltage 18 Installation Power connections Connect
29. just potentiometer or reference signal to maximum Adjust the MAX SPD trimpot until the desired maximum motor speed is reached MAX SPD calibration with low voltage DC motors Using an XLA series drive with a low voltage DC motor reguires that a lower resistance speed adjust potentiometer be used Recalibrate the MAX SPD trimpot setting to the positions shown in Figure 12 Note MAX SPD settings are approximate Verify maximum armature voltage with a voltmeter MOTOR ARMATURE VOLTAGE VDC Calibration 35 MAXIMUM SPEED TRIMPOT SETTING USING 2 5K OHM USING 1 5K OHM SPEED ADJUST SPEED ADJUST POTENTIOMETER POTENTIOMETER NOT APPLICABLE Figure 12 Low Voltage DC Motor Calibration Settings 36 Calibration IR COMPENSATION IR COMP The IR COMP trimpot setting determines the degree to which motor speed is held constant as the motor load changes It is factory set for optimum motor regulation Refer to Figure 13 page 40 for typical CURR LIMIT and IR COMP settings To calibrate IR COMP exact calibration 1 Turn the IR COMP trimpot full CCW 2 Setthe speed adjust potentiometer or reference signal 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 mot
30. low Apply AC line voltage to L1 and L2 54 Troubleshooting Line fuse does not blow but motor does not run cont Motor runs too fast at maximum speed setting Possible Causes Motor is not connected MIN SPD and MAX SPD settings are too high Motor field connections are loose shunt wound motors only Suggested Solutions Connect motor to A1 and A2 Recalibrate MIN SPD and MAX SPD Check motor field connections Motor runs too slow or too fast Motor will not reach the desired speed Possible Causes Voltage switches set incorrectly NOTE This does not apply to XL1100A drives MIN SPD and MAX SPD not calibrated Motor field not properly connected shunt wound motors only MAX SPD setting is too low IR COMP setting is too low Motor is overloaded Troubleshooting 55 Suggested Solutions Verify all switch settings Calibrate MIN SPD and MAX SPD Verify motor field connections Increase MAX SPD setting Increase the IR COMP setting Check motor load Resize the motor or drive if necessary 56 Motor pulsates or surges under load Troubleshooting Motor bouncing Possible Causes IR COMP is set too high in and out of current limit Suggested Solutions Adjust the IR COMP setting slightly CCW until the motor speed st
31. namic Brake Connection 30 Operation Sizing the dynamic brake resistor Sizing the dynamic brake resistor depends on load inertia motor voltage and braking time Use a lower ohm value higher wattage dynamic brake resistor to stop a motor more rapidly Refer to Table 4 below for minimum recommended dynamic brake resistor sizes Table 4 Minimum recommended dynamic brake resistor sizes Motor Minimum Recommended Dynamic Voltage VDC Brake Resistor Size ohms 90 15 130 22 180 30 240 40 31 Calibration AN VVarning Dangerous voltages exist on the drive when itis 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 eguipment BE ALERT High voltages can cause serious or fatal injury XLA Series drives have six user adjustable trimpots MAX SPD MIN SPD ACCEL DECEL IR COMP and CURR LIMIT All trimpots are factory calibrated see Figure 13 page 40 for factory CURR LIMIT and IR COMP settings 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 Refer to Figure 11 page 32 for trimpot location 32 Calibration BR501 Q502 Q501 D501 TH501 R503 B2 AC1 AC2 BR BR
32. of such action arises Other drives from Minarik Corporation DLC600 MMRGD Series BOSS Series Automation amp Control 901 East Thompson Avenue Glendale California 91201 2011 Tel 800 MINARIK or 800 646 2745 Fax 800 394 6334 www minarikcorp com Document Number 250 0233 Revision 6 Printed in the U S A 4 02
33. operly 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 conseguential damages losses or expense arising in connection with the use of or inability to use the Corporation s product for any purpose whatsoever An adjustment made under warranty does not void the warranty nor does it imply an extension of the original 12 month warranty period Products serviced and or parts replaced on a no charge basis during the warranty period carry the unexpired portion of the original warranty only If for any reason any of the foregoing provisions shall be ineffective the Corporation s liability for damages arising out of its manufacture or sale of eguipment 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 eguipment Any action against the Corporation based upon any liability or obligation arising hereunder or under any law applicable to the sale of eguipment or the use thereof must be commenced within one year after the cause
34. or runs at the speed measured in step 2 Calibration 37 CURRENT LIMIT CURR LIMIT AN VVarning Although CURRENT LIMIT is set to 120 of maximum drive 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 CURRENT LIMIT setting determines the maximum torque for accelerating and driving the motor CURRENT LIMIT is factory set at 120 of maximum drive current You must recalibrate the CURR LIMIT setting if using a lower current motor Refer to Figure 13 page 40 for typical CURR LIMIT and IR COMP settings 1 With no power applied to the drive connect a DC ammeter in series with the motor armature 2 Set the CURR LIMIT trimpot to full CCW 3 Carefully lock the motor armature Ensure that the motor is firmly mounted Apply line power The motor should be stopped 5 Set the speed potentiometer or reference signal to maximum speed The motor should remain stopped 6 Slowly rotate the CURR LIMIT trimpot clockwise CW until the ammeter reads 120 of maximum motor armature current 7 Set the speed adjust potentiometer or reference signal to zero speed 38 Calibration 8 Remove power from the drive 9 Remove the lock from the motor shaft 10 Remove the ammeter in series with the motor armature ACCELERATION ACCEL The ACCEL setting determines the time the motor takes to ramp to a higher speed
35. ption 1 In the first wiring option see Figure 17 connect the RUN JOG switch and JOG pushbutton to the inhibit plug as shown below The motor coasts to a stop when the RUN JOG switch is set to JOG Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation JOG PUSHBUTTON RUN JOG INHIBIT Figure 17 RUN JOG Switch first wiring option Application Notes 45 RUN JOG option 2 In the second wiring option connect the RUN JOG switch and the JOG pushbutton as shown in Figure 18 When the RUN JOG switch is set to JOG the motor decelerates to minimum speed minimum speed is determined by the MIN SPD trimpot setting Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation CW OS 10K OHM SPEED ADJUST POTENTIOMETER JOG PUSHBUTTON Figure 18 RUN JOG Switch second wiring option 46 Application Notes Leader follower application In this application use a PCM4 to monitor the speed of the leader motor see Figure 19 The PCM4 isolates the leader motor from the follower drive and outputs a voltage proportional to the leader motor s armature voltage The follower drive uses this voltage reference to set the speed of the follower motor An optional ratio potentiometer can be used to scale the PCM4 output voltage Follower Drive Drive 10K Ohm optional Figure 19 Leader follower application Application Note
36. s 47 Single speed potentiometer control of multiple drives You can control multiple drives with a single speed potentiometer using a PCM4 atthe input of each drive see Figure 20 A PCM4 is used atthe input of each drive for isolation Optional ratio potentiometers can be used to scale the PCM4 output voltage allowing independent control of each drive ratio pot A optional 10K Ohms 10K Ohms ratio pot B optional 10K Ohms 7 TB501 TB502 Figure 20 Single Speed Potentiometer Control of Multiple Drives 48 Application Notes Reversing Always use a dynamic brake when reversing the motor direction see Figure 21 Use a three pole three position switch rated for the DC armature voltage and high braking current Wait for the motor to stop completely before switching it to either the forward or reverse direction See the Dynamic Braking section on page 29 for information on sizing the dynamic brake resistor DYNAMIC BRAKE RESISTOR INHIBIT Figure 21 Reversing Circuit Connection Application Notes 49 Reversing with a DIGI LOK controller A DIGI LOK controller model DLC600 can be used in a reversing application The DIGI LOK must be inhibited while braking Without the inhibit feature the DIGI LOK will continue to regulate This will cause overshoot when the DIGI LOK is reengaged with the drive Figure 22 shows the reversing circuit connections with an XL Series drive and DIGI LOK controller Note
37. tage follower connections Instead of using a speed adjust potentiometer the drive may be wired to follow a voltage signal that is isolated from earth ground Figure 6 Use an analog voltage range of 0 2 7 VDC with 115 VAC line voltage Use an analog voltage range of 0 5 VDC with 230 VAC line voltage Connect the signal input to S2 Connect the signal common to S1 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 Follow the same wiring guidelines used for speed adjust potentiometer wiring dd L1 L2 S1 S2 S3 F1 F2 A2 A COM REF ANALOG VOLTAGE SIGNAL Figure 6 Voltage Follower Connections 22 Installation Voltage switches AN VVarning Change switch settings only when the drive is disconnected from AC line voltage Make sure both switches are set to their correct positions 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 NOTE Model XL1100A does not include these switches Two voltage switches SW501 and SW502 must be set to either 115 or 230 to match the AC line voltage being used See Figure 7 for the location of the voltage switches T501 C503 V
38. utput with Heat Sink 1 2 2 HP Form Factor 1 05 Maximum Armature Current 5 ADC Maximum Armature Current with Heat Sink 9 ADC Field Voltage 115 VAC Input 50 VDC 100 VDC Field Voltage 230 VAC Input 100 VDC 200 VDC Maximum Field Current 1 ADC Maximum Armature Voltage Adjustment Range 115 VAC Input 55 150 VDC Minimum Armature Speed Adjustment Range 115 VAC Input 0 65 VDC Maximum Armature Voltage Adjustment Range 230 VAC Input 55 240 VDC Minimum Armature Speed Adjustment Range 230 VAC Input 0 65 VDC Acceleration Time Range with no load 1 12 seconds Deceleration Time Range with no load coast to a stop 12 seconds Speed Adjustment Potentiometer 10K ohms Analog Signal Voltage Range signal must be isolated S1 to S2 for 0 130 VDC Armature Voltage 0 2 7 VDC for 0 240 VDC Armature Voltage 0 5 0 VDC Approximate Input Impedance from S1 to S2 100K ohms Speed Regulation at base speed 1 Specifications 7 Vibration 0 5G max 20 50 Hz 0 1G max gt 50 Hz Safety Certification UL Recognized Component file E132235 CSA Certified Component file LR4138 Power Device Switching Freguency 18 KHz Weight 1 6 Ib Ambient Operating Temperature Range 10 C 40 C Use heat sink kit part number 223 0271 or equivalent when continuous armature current is above 5 ADC 8
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