BOSS Series USER`S MANUAL
Contents
1. Quick Connect Terminal 0 Motherboard Connections for a DC input voltage and b AG od owed pk Xe En eR RR RA wees cane Motherboard Connections for Three Phase Motor Regen Dump Circuit Connections BOSS 4Q Terminal Connections BOSS 4Q Sensor Connections BOSS 4Q Voltage Follower Connections BOSS 4Q Motor Hall Sensor Header BOSS 4Q Mode Select Switches BOSS 4Q 504 Pin Assignments BOSS CM Terminal Connections to 501 Reference Potentiometer Connection for a Bidirectional and b Unidirectional Operation BOSS CM External Sensor Connections BOSS CM Jumper Locations BOSS CM Hall Sensor Spacer Settings J501 BOSS CM PWM VDC Jumper Settings 4502 BOSS 4Q Calibration Trimpot DIP Switch and Header Layout BOSS 4Q Mode Select Switch Settings BOSS CM Calibration Trimpot Layout BOSS 4Q Diagnostic LED Location BOSS CM Diagnostic LED Location Commutation Sequence Diagram BOSS Connections for CE Compliance BOSS Shielding Connections for CE Compliance2. vii viii Tables Table 1 Table 2 Table 3 Table 4 Table 5 Recommended Replacement Line Fuse Sizes 7 BOSS 4Q ENABLE BRAKE Configuration Options 22 Mode select switch settings 27 Drive Diagnostics All signals referenced to pin 4 29 CE Compliance Part Numbers 76 Specifications Maximum AC DC Maximum Phase Current Line Input Output Voltage Drive ACAmps Voltage Range Voltage Range BOSS04 D240AC 4 90 240 100 360 240 BOSS08 D240AC 8 90 240 100 360 240 BOSS15 115AC 15 90 130 100 180 130 AC Input Voltage Tolerance 10 50 60 Hz Maximum Phase Current Limit 1 5 times Maximum Phase Current continuous Peak Phase Current Limit 2 times Maximum Phase Current for 1 second Acceleration Time Ranget 0 5 6 seconds Deceleration Time Ranget 0 5 6 seconds Speed Range 80 1 Speed Regulation typical 0 06 of base speed Speed Adjust Potentiometer 10K ohms Analog Input Voltage Range 0 10 VDC Input Impedance 60K ohms Power Device Switching Frequency 6 step trapezoidal 22 kHz Vibration 0 5G max 20 50 Hz 0 1G max gt 50 Hz Weight 2 1b Ambient Operating Temperature Range 0 40 C Acceleration and deceleration times for BOSS 4Q only Speed range is based on 8000 RPM motor Minimum recommended speed is 100 RPM Voltage input mu
3. TACHOGENERATOR TACH BOSS CM Calibration CURRENT LIMIT Troubleshooting Before troubleshooting BOSS 4Q Diagnostic LEDS Diagnostic LEDs on the BOSS 4Q plug in card Diagnostic LEDs on the BOSS CM plug in card CE Compliance AC Une Fillets 1 ra tween dit CONNECHONS cues a ea o EHE ee eee ees CE Filter Part Numbers Enclosure eee NERA RID ALES Unconditional Warranty POWERON FAULT EVE Diagnostic LEDs on the motherboard BUS LIMIT BOSS CM Diagnostic LEDs POWER ON is sete ar eue IC Reg FAULT 2455275892 SS Diagnostic LEDs on the motherboard BUS LIMIT Siero miae one RR ER BOSS Commutation Sequence Diagram inside back cover Illustrations Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 15 Figure 16 Figure 17 Figure 18 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 BOSS Series Dimensions BOSS DB Regen Dump Circuit Dimensions Plug In Card Installation Speed Adjust Potentiometer Mounting
4. Automation In ari amp Control BOSS Series Models BOSS04 D240AC 4Q BOSS04 D240AC CM BOSS08 D240AC 4Q BOSS08 D240AC CM BOSS15 115AC 4Q BOSS15 115AC CM BOSS Series Brushless Drives Copyright 2001 by Minarik Corporation All rights reserved No part of this manual may be reproduced or transmitted in any form without written permission from Minarik Corporation The information and technical data in this manual are subject to change without notice Minarik Corporation and its Divisions make no warranty of any kind with respect to this material including but not limited to the implied warranties of its merchantability and fitness for a given purpose Minarik Corporation and its Divisions assume no responsibility for any errors that may appear in this manual and make no commitment to update or to keep current the information in this manual Printed in the United States of America Safety Warnings X X ak SHOCK AVOID KEEP AVOID 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 Have a qualified electrical maintenance technician install adjust and service this equipment Follow the National Electrical Code and all other applicable electrical and safety codes including the provisions of the Occupational Safety and Health Act OSHA when installing equipment Reduce the cha
5. C FOR CLOCKWISE ROTATION VIEWING MOTOR FROM MOUNTING FACE Figure 26 Commutation Sequence Diagram 73 CE Compliance Minarik Corporation hereby certifies that its BOSS 4Q and BOSS CM series drives have been approved to bear the CE mark provided the conditions of approval have been met by the end user The BOSS 4Q BOSS CM series have been tested to the following test specifications EN50081 2 08 93 emissions and 50082 2 1995 immunity Compliance allows the BOSS 4Q BOSS CM 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 74 CE Compliance AC Line Filters In addition to EMI RFI safeguards inherent in the BOSS design external filtering is required Minarik requires the 20VDKI filter for all BOSS drives Wire the AC line filter within 0 25 meters of the drive The ground connection from the filter must be wired to solid earth ground resistance less than 500 ohms not machine ground This is very important If the end user is using a CE approved motor the correct filter from Table 5 page 76 is all that is necessary to meet the EMC directives listed herein The end user must use the filtration listed in this a
6. A Warning Decelerating to minimum speed regenerative braking or coasting to a stop is recommended for frequent starts and stops Do not use any of these methods for emergency stopping They may not stop a drive that is malfunctioning Removing AC or DC power both L1 and L2 or VDC and VDC is the only acceptable method for emergency stopping For this reason Minarik strongly recommends installing an emergency stop switch on both power input leads see Connections on page 14 Line starting and line stopping Line starting and line stopping applying and removing AC or DC voltage input is not recommended for frequent starting and stopping of the drive It is the only recommended method for emergency stopping of the drive When line voltage input is applied to the drive the motor accelerates to the current level set by the external reference signal When line voltage input is removed the motor coasts to a stop To brake the motor BOSS 4Q series drives only Close the BRAKE switch 46 To coast the motor to a stop without disconnecting power Open the ENABLE switch 47 Calibration Warning Dangerous voltages exist on the drive when it is powered and up to 30 seconds after power is removed and the motor stops When possible disconnect the voltage input from the drive before adjusting the trimpots If the trimpots must be adjusted with power applied use insulated tools and the appropriate personal protection
7. Acts as signal common for reference voltage applied at terminal 5 Connect to COM when using voltage signal input at terminal 5 32 Installation 10 VDC terminal 7 10 VDC reference voltage output for reference potentiometer See Figure 22 page 46 and Figure 23 page 47 10 VDC terminal 8 10 VDC reference voltage output for reference potentiometer See Figure 22 page 46 and Figure 23 page 47 FAULT OUT terminal 9 Drive status signal to controller HALL C B A terminals 10 11 and 12 Inputs from motor hall sensors 5 VDC Vref terminal 14 A Warning The 5 VDC supply has a maximum capacity of 20 mADC Please ensure that any sensor package connected to this terminal does not draw more than 20 mADC If the sensor package draws more than 20 mADC it must be connected to an external regulated power supply as shown in Figure 14 page 28 Floating isolated 5 VDC 20 mA supply for external sensors Installation 33 BOSS CM Plug in card connections to TB501 ENABLE DISABLE switch Connect a single pole single throw switch between the COM and ENABLE terminals terminals 1 and 2 of TB501 as shown in Figure 6 Close the switch to coast the motor to a stop Open the switch to accelerate to set speed DIR switch Connect a single pole single throw switch between the COM and DIR terminals terminals 1 and 4 of TB501 as shown in Figure 6 Open the switch to run the motor in the forward dir
8. 2 Make sure motor is not undersized for load adjust FWD TQLIM REV TQLIM or CURRENT LIMIT setting 1 Check DIR switch connection 2 Check reversing circuit by shorting DIR terminal to COM terminal with jumper wire 3 Check hall sensor connections 70 Troubleshooting Symptom FAULT LED lit Possible Causes 1 The hall sensors are miswired not operating properly 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 The drive reaches maximum bus voltage limit Suggested Solutions 1 Check hall sensor wiring 2 Check that motor is properly sized for load check that FWD TQLIM REV TQLIM and CURRENT LIMIT trimpots are properly calibrated 3 Check input power 4 Check that ENABLE switch is in the proper operating position 5 Check motor load check that motor is properly sized for load and is not stuck or jammed FAULT LED lit cont Possible Causes 6 Sensor draws too much current for BOSS drive to supply Troubleshooting 71 Suggested Solutions 6 Check sensor wiring If sensor needs more than 20 mADC provided by BOSS drive connect sensor to external power supply 72 Troubleshooting BOSS Commutation Sequence Diagram PHASE TO PHASE VOLTAGE ELECTRICAL DEGREES 60 120 180 240 300 360 HALL A HALL B
9. differential 10 VDC to 10 VDC signal that is isolated from earth ground Connect a voltage signal to terminals 1 and 6 see Figure 15 for connections COM BRAKE ENABLE FWD REV SPD IN SNARES 112131415 6789 10 10 VOLTAGE SIGNAL INPUT COM REF Figure 15 BOSS 4Q Voltage Follower Connections Installation 25 Motor hall sensor header SW502 Set the motor hall sensor header according to the hall effect feedback spacing see Figure 16 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 Motor Hall Sensor Header SW502 SW502 60 120 LI 00000 FAULT 504 1 502 TACH IN PWR C501 C502 LI Tel MODE SELE LI ON Ey Figure 16 BOSS 4Q Motor Hall Sensor Header 26 Installation Mode select switches SW501 A Warning Be sure that drive power is removed before changing any mode select switch settings Unpredictable behavior may occur if this warning is not followed The mode select switches set the BOSS drive to one of the four operating modes 1 Voltage Mode no internal velocity loop 2 Velocity Mode voltage mode plus internal velocity loop 3 Tachomete
10. equipment BE ALERT High voltages can cause serious or fatal injury BOSS 4Q Calibration BOSS 4Q series drives have eleven user adjustable trimpots Each drive is factory calibrated to its maximum current rating Readjust the calibration trimpot settings to accommodate lower current 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 48 Calibration TACHOGENERATOR HEADER SO501 TEST POINT MODE SELECT TACH IN TP1 SWITCHES MALLS swso2 60 120 FAULT 1 502 N IR FWD REV MAXSPD ACCEL DECEL SPD COMP TQLIM OS GAIN TACH REV FWD MIN REVERSE OFF TACH TORQUE SET LIMIT DECELERATION FORWARD MAXIMUM SPEED REVERSE ACCELERATION MINIMUM FORWARD GAIN MAXIMUM SPEED TORQUE SPEED LIMIT Figure 21 BOSS 4Q Calibration Trimpot DIP Switch and Header Layout Calibration 49 BOSS 4Q calibration procedure Ensure that no power 15 applied to the drive Set the ENABLE DISABLE switch to the ENABLE position closed or install a jumper between the ENABLE and COM terminals on TB501 Set the RUN BRAKE switch to the RUN position open or remove the jumper between the BRAKE and COM terminals on TB501 Set the DIR switch to the desired direction or install or remove a jumper between the DIR and COM terminals as required Set all trimpots except TACH
11. for maximum gain 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 If the motor oscillates under load the GAIN setting is too high Reduce the GAIN setting until motor oscillation subsides 54 Calibration FORWARD AND REVERSE TORQUE LIMIT FWD TQLIM AND REV TQLIM A Warning Although FWD TQ LIM and REV TQLIM are set to 150 of maximum drive current continuous operation beyond that maximum drive current may damage the motor or drive If you intend to operate beyond that rating contact your Minarik representative for assistance The TQLIM settings determine the maximum current limit for accelerating and driving the motor They are factory set at 150 of rated drive current Recalibrate the TQLIM trimpots if you use a lower current motor s Calibrate the FWD TQLIM and REV TQLIM trimpots as follows 1 With no power applied to the drive or motor connect AC ammeter in series with one of the motor phases 2 Set the FWD TQLIM trimpot full counterclockwise CCW 3 Set the speed adjust potentiometer or input signal to maximum speed in the forward direction 4 Carefully lock the motor shaft 5 Apply line power to the drive and motor The motor should remain stopped 11 12 13 14 15 16 17 Calibration 55 Slow rotate the FWD TQLIM trimpot clockwise CW until the ammeter reads 150 of maxi
12. 10K ohm 5W speed adjust potentiometer as shown in Figure 9 for unidirectional one way operation in the forward direction For unidirectional operation in the reverse direction connect the CW terminal to VPOT terminal 7 of TB501 and connect the CCW terminal to COM terminal 1 of 501 For bidirectional two way operation connect the CCW terminal to VPOT terminal 7 of TB501 The motor will stop when the potentiometer is in the middle of its travel Installation 21 CONNECT TO 4Q HEADER BLOCK TB501 ENABLE DISABLE SWITCH OPEN TO STOP CLOSE TO RUN RUN BRAKE SWITCH OPEN TO RUN CLOSE TO BRAKE FWD REV SWITCH OPEN FOR FORWARD CLOSE FOR REVERSE 10K OHM SPEED ADJUST POTENTIOMETER TO MOTOR SENSORS NOTES SEE PG 72 FOR COMMUTATION SEQUENCE 2 SEE PG 22 FOR USE WITH SENSOR FEEDBACK 3 FOR BIDIRECTIONAL OPERATION CONNECT CCW LEAD OF SPEED ADJUST POTENTIOMETER TO TB501 TERMINAL T 4 FOR ENABLE BRAKE CONFIGURATION OPTIONS SEE TABLE 2 PAGE 22 Figure 9 BOSS 4Q Terminal Connections 22 Installation Table 2 BOSS 4Q ENABLE BRAKE Configuration Options 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 Motor hall sensors A Warning BOSS series drives provide a 5 VDC supply to external sensors This voltage
13. VDC input Before applying power Verify that no conductive material is present on the printed circuit board Verify that hall sensor spacing jumper J501 and PWM VDC input jumper J502 are set to the proper positions for your application 44 Operation Startup 1 Verify that no conductive material is present on the PCB 2 Check that the ENABLE switch is in the enable position closed or that a jumper has been installed beween the COM and ENABLE terminals terminals 1 and 2 of 501 3 Verify that hall sensor header 1501 is the desired position 4 Verify that PWM VDC SELECT header J502 is in the desired position 5 Setthe DIR switch to the direction you want the motor to rotate upon startup 6 Apply AC voltage input or DC voltage input to the drive 7 Slowly increase the reference signal The motor slowly accelerates as the signal is increased Continue until the desired speed is reached To reverse motor direction Switch the DIR switch to the opposite position To prevent possible demagnetization of the motor consider bringing the motor to a stop before reversing polarity Once stopped enable the drive or apply input power You may also apply a negative voltage signal at the REF IN inputs Again to prevent possible demagnetization of the motor consider bringing the motor to a stop before reversing polarity Once stopped enable the drive or apply input power Operation 45 Starting and Stopping Methods
14. VDC supply 25 mA maximum NOTE This terminal is not identified on the printed circuit board PCB or terminal block HALL C B A terminals 10 11 and 12 Inputs from motor hall sensors 5 VDC Vref terminal 14 A Warning The 5 VDC supply has a maximum capacity of 20 mADC Please ensure that any sensor package connected to this terminal does not draw more than 20 mADC If the sensor package draws more than 20 mADC it must be connected to an external regulated power supply as shown in Figure 10 page 23 Floating isolated 5 VDC 20 mA supply for external sensors 20 Installation BOSS 4Q Plug in card connections TB501 ENABLE DISABLE switch Connect a single pole single throw switch between the COM and ENABLE terminals terminals 1 and 2 of TB501 as shown in Figure 9 Open the switch to coast the motor to a stop Close the switch to accelerate to set speed RUN BRAKE switch Connect a single pole single throw switch between the COM and BRAKE terminals terminals 1 and 3 of TB501 as shown in Figure 9 Close the switch to brake the motor to a stop Open the switch to accelerate to set speed FWD REV switch Connect a single pole single throw switch between the COM and FWD REV terminals terminals 1 and 4 of TB501 as shown in Figure 9 Open the switch to run the motor in the forward direction Close the switch to run the motor in the reverse direction Speed adjust potentiometer connections Connect a
15. low 5 Apply AC line voltage to L1 and L2 or DC voltage input to VDC or 6 Check motor connections 7 Connect hall sensors 8 Check sensor wiring If sensor needs more than 20 mADC provided by BOSS drive connect sensor to external power supply 68 Troubleshooting Motor runs too slow or too fast at set speed Motor will not reach the desired 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 1 FWD MAXSPD REV MAXSPD settings are too low 2 GAIN or IR COMP setting is too low 3 Motor is overloaded 4 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 1 Increase FWD MAXSPD or REV MAXSPD settings 2 Recalibrate IR COMP setting 3 Check motor load Resize the motor and drive if necessary 4 Check hall sensor connections Motor pulsates or surges under load Motor does not reverse Possible Causes 1 GAIN or IR COMP is set too high 2 Motor bouncing in and out of torque limit 1 Bad DIR switch connection 2 Reversing circuit not working properly 3 Hall sensors miswired Troubleshooting 69 Suggested Solutions 1 Adjust the GAIN or IR COMP setting until the motor speed stabilizes
16. 2 PWM VDC INPUT SELECT CUR LIM C502 C503 TB502 in U J501 HALL SENSOR Figure 18 BOSS CM Jumper Locations 40 Installation Dm 97 BPACNG DEFALILT BETTING Figure 19 BOSS CM Hall Sensor Spacer Settings J501 PWM VDC J502 1502 sets the input signal as either an analog voltage signal reference potentiometer or PWM input Figure 20 Jumper terminals 1 and 2 if the input is PWM Jumper terminals 2 and 3 for analog voltage or reference potentiometer input The factory default is for voltage signal input terminals 2 and 3 jumpered 200 DE Os JUMPER BET JUMPER SET VOLTAGE SIGNAL PAM IKPLIT DEFALLT Figure 20 BOSS CM PWM VDC Jumper Settings J502 41 Operation 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 BE ALERT High voltages can cause serious or fatal injury For your safety use personal protective equipment PPE when operating this drive Be sure that drive power is removed before changing any mode select switch settings Unpredictable behavior may occur if this warning is not followed BOSS 4Q Operation Before applying power Verify that no conductive material is present on the printed circuit board Verify that hall sensor spacing jumper SW502 is set to the proper position for your application 42 Operation Startup 1 2 V
17. 9 PMWMIVDO 502 oi herd es wad 40 Operation 41 BOSS 4 Operation ale asks ETE luu 41 Before applying power 41 aaa masay dated 42 To reverse motor direction 42 BOSS CM eene censa nier nexa ruber Sek qae d 43 Operating Mods hokey venn ech ete et E ere acd ee 43 Before applying power 43 ER 44 reverse motor direction 44 Starting and Stopping Methods 45 Line starting and line stopping 45 To brake the motor BOSS 4Q series drives only 45 To coast the motor to a stop without disconnecting power 46 Calibration 47 BOSS 4Q Calibration 47 BOSS 4Q calibration procedure 49 MINIMUM SPEED MIN SPEED 50 ZERO OFFSET OS cha a Pact 50 FORWARD MAXIMUM SPEED FWD MAXSPD 51 REVERSE MAXIMUM SPEED REV MAXSPD 51 ACCELERATION ACCEL 52 vi Contents DECELERATION DECEL GAIN Re FORWARD AND REVERSE TORQUE LIMIT FWD TQLIM AND REV TQLIM
18. C when Run Stop switch is set for run 5 VDC when Run Stop switch is set for stop 5 VDC when the drive is in a fault condition Circuit common All other pins are referenced to circuit common 0 10 VDC output corresponding to the sum of all AC phase currents AC phase currents are rectified summed then scaled to 0 10 VDC output Waveform 0 volts 30 Installation Table 4 Drive Diagnostics All signals referenced to pin 4 cont Pins Description Waveform Pin 6 AC current in phase A AC Current is converted to voltage Phase A output 500 mV per amp AC Pin 7 AC current in phase B AC Current is converted to voltage Phase B output 500 mV per amp AC Pin 8 AC current in phase C AC Current is converted to voltage Phase C output 500 mV per amp AC Pin 9 and 10 not No function None used Installation 31 BOSS CM Installation BOSS CM Terminal Descriptions COM terminals 1 and 13 A Warning Do not connect these terminals to earth ground Circuit common ENABLE terminal 2 Short to COM to run the motor leave open to coast to a stop PWM IN terminal 3 Accepts a square wave 5 VDC PWM input from an external signal source DIR terminal 4 Short to COM to run the motor in the reverse direction leave open to run the motor in the forward direction REF IN terminal 5 Accepts floating ungrounded 10 VDC to 10 VDC voltage signal REF IN terminal 6
19. FOR FORWARD CLOSE TO REVERSE REFI 1 10 hy O TO PWM I 1 O 10VDC MOTOR 1 ANALOG SENSORS 1 1 CONNECT ENABLE DISABLE SWITCH TO TERMINALS 1 AND 2 AS SHOWN CLOSE TO ENABLE OPEN TO DISABLE 2 CONNECT DIR SWITCH TO TERMINALS 1 AND 4 AS SHOWN OPEN FOR FORWARD DIRECTION CLOSE TO REVERSE 3 REFER TO PAGE 36 FOR REFERENCE POTENTIOMETER CONNECTIONS 4 DO NOT CONNECT PWM AND ANALOG VOLTAGE INPUTS AT THE SAME TIME Figure 15 BOSS CM Terminal Connections to TB501 36 Installation PWM COM REF IN 10 VDC FAULT OUT HALL_B ENABLE 5 VDC DIR REF IN 10 HALL C HALL A FWD REV EXTERNAL REFERENCE POTENTIOMETER 10K OHMS PWM REF IN 10 VDC FAULT OUT HALL_B COM 5 VDC ENABLE DIR REF IN 10 VDC HALL C HALL A a 22220100 B UNIDIRECTIONAL OPERATION NOTE FORWARD DIRECTION SHOWN CONNECT CW TERMINAL OF POTENTIOMETER TO 10 VDC EXTERNAL REFERENCE 501 TERMINAL 8 FOR POTENTIOMETER OPERATION IN THE REVERSE 10K OHMS DIRECTION Figure 16 BOSS CM Reference Potentiometer Connection for a Bidirectional and b Unidirectional Operation Installation 37 Motor hall sensors A Warning BOSS series drives provide a 5 VDC supply to external sensors This voltage has a maximum capacity of 20 mADC To avoid damage to the drive ensure that any sensor package connected to this ter
20. FWD TQ LIM and REV TQ LIM to the center of travel Set the FWD TQ LIM and REV TQ LIM trimpots full clockwise CW Make no adjustment to TACH unless you use tachogenerator feedback Set the signal input analog voltage signal or speed adjust potentiometer to zero or minimum speed Apply power to the drive Calibrate the trimpots in the order shown starting on page 50 50 Calibration MINIMUM SPEED MIN SPEED The MIN setting determines the minimum speed when the speed adjust potentiometer or voltage input signal is set for minimum speed It is factory set to zero speed To calibrate MIN SPD 1 Setthe MIN SPD trimpot to the center position 12 o clock 2 Setthe speed adjust potentiometer or voltage input signal for minimum speed 3 Adjust the MIN SPD trimpot to the desired minimum speed ZERO OFFSET OS The OS setting adjusts the zero offset voltage in the internal velocity loop This affects the gain circuit which controls motor gain 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 TP1 4 Using a non metallic screwdriver calibrate the OS trimpot until the voltmeter reads approximately 0 VDC Calibration 51 FORWARD MAXIMUM SPEED FWD MAXSPD The FWD MAXSPD setting determines th
21. cessary 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 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 Do not install a fuse on L2 unless the input voltage is 240 VAC See motherboard connections Figure 6 on page 14 Table 1 lists the recommended line fuse sizes Use fast acting fuses rated for 250 VAC or higher Table 1 Recommended Line Fuse Sizes Model Line Fuse Size Series AC Amps BOSS04 10 5508 15 5515 25 8 Installation Plug in card mounting A Warning Make sure AC or DC line voltage input is disconnected for 30 seconds before installing or removing the plug in card To mount the plug in card to the motherboard line up the motherboard docking pins to the docking holes 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 pins will lock
22. ck connect terminal block 1 2 Carefully pull terminal plug from header block With a small flat head screwdriver turn terminal plug screw counterclockwise to open wire clamp Insert stripped wire into the large opening in front of the plug Turn the terminal plug screw clockwise to clamp the wire Repeat steps 2 4 for each terminal until all connections are made Insert plug into header block until securely fastened Terminal Plug Figure 5 Quick Connect Terminal Plug 12 Installation Motherboard connections A Warning Do not install remove or connect this equipment with power applied Failure to heed this directive may result in fire or serious injury Minarik strongly recommends the installation of a master power switch in the voltage input line The switch contacts should be rated at a minimum of 200 of motor nameplate current and 150 of input voltage Do not connect DC and AC power inputs at the same time Applying AC and DC power simultaneously will destroy the drive and may result in fire or serious injury Power connections See Figure 6 page 14 for motherboard connections Connect the AC voltage source to L1 and L2 if using an AC voltage source If the drive is being powered by a DC voltage source connect the DC voltage source to VDC and VDC Do not connect AC and DC voltage sources at the same time Installation 13 Line fusing Connect an external fuse between the drive and master st
23. ddendum 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 CE Compliance 75 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 Connections Connect the BOSS drive to the 20VDKI filter as follows 1 Add ferrite beads to the motor load wires a Install two ferrite beads on the wire combination of T1 T2 T3 Place the beads between the T1 T2 and T3 terminals on the BOSS motherboard and the terminal board on the shielded enclosure as shown in Figure 27 page 76 b Install one ferrite bead on leads T2 and T3 Place the bead between the shielded enclosure and the motor under load Refer to Figure 27 page 76 2 Install a ferrite bead on the input power leads Place the bead between the EMI filter and the terminal board on the shielded enclosure as s
24. e 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 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 war
25. e fuse does not blow but the motor does not run Possible Causes 1 Line fuses are the wrong size 2 Motor cable or motor is shorted to ground 3 Nuisance tripping caused by a combination of ambient conditions and high current spikes i e reversing 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 Suggested Solutions 1 Check that line fuses are properly sized for the motor being used 2 Check motor cable and motor for shorts 3 Add a blower to cool the drive components increase FWD TQLIM REV TQLIM or CURRENT LIMIT setting 1 Increase the speed adjust potentiometer setting or voltage input signal 2 Check connections to input Verify that connections are not open External line fuse does not blow but the motor does not run cont Possible Causes 3 Drive is disabled BRAKE terminal is shorted to COM BOSS 4Q only 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 Sensor draws too much current for BOSS drive to supply Troubleshooting 67 Suggested Solutions 3 Check connections 4 Verify that motor is not jammed Increase FWD TQLIM REV TQLIM or CURRENT LIMIT setting if they are set too
26. e 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 DIR switch if installed to FWD If no switch is installed install a jumper between terminals 1 COM and 4 DIR of TB501 3 Setthe speed adjust potentiometer or voltage input signal for maximum speed 4 Adjust the FWD MAXSPD trimpot to the desired maximum speed REVERSE MAXIMUM SPEED REV MAXSPD The REV MAXSPD 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 Setthe REV MAXSPD trimpot full CCW 2 Setthe DIR switch if installed to REV If no switch is installed remove the jumper between terminals 1 COM and 4 DIR 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 52 Calibration ACCELERATION 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 min
27. ection Close the switch to run the motor inthe reverse direction Speed adjust potentiometer connections You can use an external reference potentiometer to control motor speed instead of a PWM or analog voltage signal The potentiometer may be connected for bidirectional two way or unidirectional one way operation Bidirectional operation Connect a 10K ohm reference potentiometer as shown in Figure 16 page 36 for bidirectional operation Connect the CW terminal on the reference potentiometer to TB501 terminal 7 Connect the CCW terminal to TB501 terminal 8 Connect the wiper terminal to TB501 terminal 5 34 Installation When the wiper is in the center position the motor will not rotate The motor will accelerate as the potentiometer is turned in either the forward or reverse direction Unidirectional operation Connect the reference potentiometer as shown in Figure 16 page 36 for unidirectional one way operation To operate in the forward direction connect the CW terminal on the reference potentiometer to TB501 terminal 7 To operate in the reverse direction connect the CW terminal to TB501 terminal 8 Connect the wiper terminal to TB501 terminal 5 Installation COM FAULT OUT HALL B COM 10 VDC PWM IN REF IN ENABLE REF IN 10 _ 5 DIR HALL C ENABLE DISABLE SWITCH CLOSE TO ENABLE OPEN TO DISABLE DIRECTION SWITCH OPEN
28. erify that no conductive material is present on the PCB Check that the ENABLE switch is in the enable position closed If no switch is installed ensure that a jumper is installed between the ENABLE and COM terminals of 501 Check that the RUN BRAKE switch is in the run position open If no switch is installed ensure that there is no jumper between the BRAKE and COM terminals of 501 Set the FWD REV switch to the direction you want the motor to rotate upon startup Ensure that mode select switch SW501 is properly set for your application Apply AC voltage input or DC voltage input to the drive 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 Switch the FWD REV switch to the opposite position To prevent possible demagnetization of the motor consider bringing the motor to a stop before reversing polarity Once stopped enable the drive or apply input power Operation 43 BOSS CM Operation Operating Mode The BOSS CM provides a current output proportional to the input signal up to the threshold set by the CURRENT LIMIT trimpot For example if the input voltage range is 0 10 VDC the BOSS CM current output will be zero with 0 VDC input and maximum current as defined by the CURRENT LIMIT trimpot setting with a 10
29. has a maximum capacity of 20 mADC To avoid damage to the drive ensure that any sensor package connected to this terminal does not draw more than 20 mADC Connect an external sensor such as a hall motor sensor as shown in Figure 10 Connect the sensor to TB501 terminals 13 common and 14 5 VDC If the sensor draws more than 20 mADC an external power supply must be used to avoid damage to the BOSS drive Installation 23 USE THIS ARRANGEMENT an IF SENSOR PACKAGE DRAWS LESS THAN 20 mA 5 VDC TOMBE DIR SPD IN 15 HALL C 15 HALL B HALL A COM VREF SQ Ge eed 11213 415161718 9 10 11 S 12 w S MOTOR HALL SENSOR SENSOR COMMON SENSOR USE THIS ARRANGEMENT NES IF SENSOR PACKAGE DRAWS BRAKE VPOT 15 MORE THAN 20 mA 5 VDC ENABLE DIR SPD IN 15 HALL C B HALL A COM VREF 213 4156 7 8 9 10 11 e 12 S 14 MOTOR HALL FLOATING SENSOR ISOLATED EXTERNAL 45 VDC SENSOR COMMON POWER SUPPLY Figure 10 BOSS 4Q Sensor Connections 24 Installation Voltage follower Instead of using a speed adjust potentiometer BOSS 4Q series drives may be wired to follow a floating
30. he DC power source to the L1 terminal on the BOSS drive motherboard Connect the negative or lead from the DC power source to the L2 terminal on the BOSS drive motherboard Installation 17 EMERGENCY STOP SWITCH POS COM 0 REGEN DUMP CIRCUIT 100 320 VDC POWER SOURCE NOTE CONNECTIONS SHOWN ARE FOR DC POWER SOURCE REFER TO FIGURE 6 PAGE 14 FOR AC POWER SOURCE CONNECTIONS Figure 8 Regen Dump Circuit Connections 18 Installation BOSS 4Q Installation BOSS 4Q Terminal Descriptions COM terminals 1 and 13 A Warning Do not connect these terminals to earth ground Circuit common ENABLE terminal 2 Short to COM to run the motor leave open to coast to a stop BRAKE terminal 3 Short to 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 10K ohm speed adjust potentiometer SPD IN terminal 6 Accepts floating ungrounded 10VDC to 10 VDC reference or 10K ohm speed adjust potentiometer wiper Installation 19 POT terminal 7 Floating 10 VDC reference for 10K ohm speed adjust potentiometer 15 terminal 8 Floating 15 VDC supply 25 mA maximum NOTE This terminal is not identified on the printed circuit board PCB or terminal block 15 terminal 9 Floating 15
31. he country Each daughter card is packed separately as 40 or The BOSS 4Q does not have isolation and requires application specific calibration The BOSS CM is designed exclusively to follow a front end servo controller It is a current mode drive with optical isolation and requires no calibration except for a simple current limit adjustment BOSS SERIES PART NUMBERS BOSS04 D240AC 4Q CURRENT RATING SE DAUGHTER CARD 04 4 08 8 AMPS 1Q SINGLE QUADRANT 15 15 AMPS 4Q FOUR QUADRANT CM CURRENT MODE D DUAL VOLTAGE VOLTAGE RATING INPUT VOLTAGE TYPE 115 115 AC OR DC 240 240 V 15 AMP DRIVE REQUIRES 115 VAC INPUT iv Contents Specifications 1 Dimensions Installation Drive mounting EM 4 s se PA E Le du 5 Shielding g idelin s coss cruce uh m 6 FUSING zx date Rb TRECE d n a oe eS 7 Pl g in card 2225 dete Se ru 8 Speed adjust potentiometer mounting 10 Quick connect terminal 11 Motherboard connections 12 Power cotinectioris em c SIE ee a LyEGHIRE TE 12 COG Della de EQUI d MER echa CRAS do 13 Power switch ctia ose ara 13 Motor connections sg eds Pe
32. hown in Figure 27 page 76 3 Install an EMI filter on the input power leads as shown in Figure 27 page 76 Refer to Minarik document 250 0315 CE Filter Installation Guide for detailed installation and connection information 76 CE Compliance CE Filter Part Numbers Table 5 CE Compliance Part Numbers Description Part Minarik EMI Filter 20VDK1 Enclosure The BOSS motor control module must be enclosed in a solid metal enclosure Figure 27 The enclosure lid body and backplane must all be tied to a low impedance earth ground Figure 28 Proper wire routing inside the enclosure is critical power and logic leads must be routed in different avenues inside the enclosure Ta BEAD Figure 27 BOSS Connections for CE Compliance L1 L2 CE Compliance 77 CE BOSS BOSS FILTER DRIVE DRIVE ENCLOSURE L1 L2 GND SCREW SOLID EARTH GROUND Figure 28 BOSS Shielding Connections for CE Compliance Notes Notes 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 Avenu
33. igure 7 Ensure that the motor s voltage and current ratings are compatible with the drive ratings before making any connections i THREE PHASE MOTOR i MOTOR MOTOR MOTOR 1 PHASE A PHASE B PHASEC PHASE 1 PHASE 2 PHASE 3 1 1 0502 0503 0504 10503 m 8 0508 5514 10505 10502 10504 C516 C517 gt TAT 5503 505 TB503 Figure 7 Motherboard Connections for Three Phase Motor 16 Installation Regen dump circuit The regen dump circuit is recommended for all BOSS Series drives Regenerative loads may cause the bus voltage to increase The regen dump circuit prevents the voltage across the bus capacitors from exceeding their voltage rating Connect the BUS terminal on the regen dump circuit to the VDC terminal on the BOSS drive motherboard Connect the BUS terminal on the regen dump circuit to the VDC terminal on the BOSS drive motherboard See Figure 8 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 Using the dump circuit with a DC power source If you use a DC power source and you wish to use the regen dump circuit you must connect the power source to the BOSS drive L1 and L2 terminals as shown in Figure 8 Connect the positive lead from t
34. imum speed The motor should run at minimum speed 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 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 53 DECELERATION 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 Set the speed adjust potentiometer or voltage input signal for minimum speed and measure the time it takes the motor to go from maximum to minimum speed 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 GAIN The GAIN setting determines how much effect the OS setting will have on the gain Calibrate the GAIN trimpot only when the drive is operating in Velocity Mode Set the gain trimpot full CCW for minimum gain or full CW
35. minal does not draw more than 20 mADC Connect an external sensor such as hall motor sensor as shown in Figure 17 page 38 Connect the sensor to TB502 terminals 13 common and 14 5 VDC If the sensor draws more than 20 mADC an external power supply must be used to avoid damage to the BOSS drive 38 Installation FAULT OUT PWM IN REF IN 10VDC HALL ENABLE DIR REF IN 10VDC HALL C HALL A 5VDC L CC Ca i itii ER i FAULTOUT B CONNECT SENSOR AS SHOWN IF SENSOR PACKAGE DRAWS LESS THAN 20 mA AT 5VDC SENSOR COMMON COM PWMIN ENABLE DR REFIN 10 HALL C HALL 35VDC LJ 1 2 7 12 43 14 Cb OL L UT L TL OL P CL CONNECT SENSOR AS SHOWN IF SENSOR PACKAGE DRAWS MORE THAN 20 mA AT 5VDC REFIN 10 VDC Figure 17 BOSS CM External Sensor Connections Installation 39 BOSS CM Jumper Settings BOSS CM series drives contain two jumper switches used to configure various outputs Refer to Figure 18 for jumper locations Hall Sensor Spacing J501 Set the motor hall sensor header according to the hall effect feedback spacing see Figure 18 for location Jumper J501 if the hall effect feedback spacing is 1209 Do not add a jumper if the hall effect feedback spacing is 60 The factory default is 120 jumper installed See Figure 19 page 40 J50
36. mum motor current Set the speed adjust potentiometer or input signal to zero speed Remove power from the drive and motor Set the REV TQLIM trimpot full CCW Set the speed adjust potentiometer or input signal to maximum speed in the reverse direction Carefully lock the motor shaft Apply power to the drive and motor The motor should remain stopped Slowly rotate the REV TQLIM trimpot CW until the ammeter reads 150 of maximum motor current Set the speed adjust potentiometer or input signal to zero speed Remove power from the drive and motor Remove the lock from the motor shaft Remove the ammeter 56 Calibration TACHOGENERATOR TACH A Warning Be sure that drive power is removed before changing any mode select switch settings Unpredictable behavior may occur if this warning is not followed 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 Ensure that power is not applied to the drive and motor 2 Connect the tachometer to the TACH IN header 50501 The polarity is for and for T2 with the motor running in the forward direction 3 Setthe MODE SELECT switch SW501 fo
37. nce of an electrical fire shock or explosion by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures A Warning Although the drive includes protective circuitry to prevent damage in the event of an accidental short circuit of the armature it is 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 Inadvertent grounding of drive inputs could result in damage to the drive 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 insulated tools if working on this drive with power applied Introduction The BOSS series is a family of analog brushless servo controls They are designed to be flexible and adaptable to a multitude of needs by using the modular concept The modular concept has two parts a motherboard and a daughter card The motherboard contains power and motor connections Each daughter card is designed to fit into the same motherboard yet each daughter card is optimized for different applications This allows you to customize your BOSS drive to suit your needs unlike the standard one size fits all approach The BOSS motherboard is stocked throughout t
38. on 59 CURRENT LIMIT A Warning Although CURRENT LIMIT is set to 150 of 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 BOSS CM series drives have one user adjustable trimpot Each drive is factory calibrated to its maximum current rating Readjust the calibration trimpot when using a motor with a lower current rating All adjustments increase with CW rotation and decrease with CCW rotation Use a non metallic screwdriver for calibration The trimpot is identified on the printed circuit board The CURRENT LIMIT setting determines the maximum current allowed for accelerating and driving the motor It is factory set at 150 of rated drive current CURRENT LIMIT should be recalibrated when using a motor with a lower current rating To calibrate CURRENT LIMIT 1 With no power applied to the drive connect a DC ammeter in series with the motor armature 2 Setthe CURRENT LIMIT trimpot to full CCW 3 Carefully lock the motor armature Ensure that the motor is firmly mounted 60 Calibration 4 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 CURRENT LIMIT trimpot clockwise CW until the ammeter reads 150 of maximum motor current 7 Set the speed adjust potentiometer or
39. op switch as shown in Figure 6 page 14 Install the switch between the external fuse and AC or DC power input as shown Place a line fuse on VDC if using DC input voltage or L1 if the AC input voltage is 115 VAC Do not add a line fuse to L2 unless the input voltage is 240 VAC Refer to Table 1 page 7 for replacement line fuse sizes Power switch A Warning 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 Install a master power switch in the voltage input line as shown in Figure 6 page 14 The switch contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts 14 Installation EMERGENCY STOP C507 SWITCH FUSE O 1 0 GOL D A CONNECTION FOR DC INPUT VOLTAGE EMERGENCY STOP VDC SWITCH FUSE Q 0 I 1 FUSE 1 1 C j L2 B CONNECTION FOR AC INPUT VOLTAGE NOTE DO NOT ADD FUSE TO L2 BR501 UNLESS INPUT VOLTAGE x IS 230 VAC PR Do not connect AC and DC voltage at the same time This will destroy the BOSS drive and may result in fire or serious personal injury Figure 6 Motherboard Connections for a DC input voltage and b AC input voltage Installation 15 Motor connections Connect a three phase motor to the motherboard as shown in F
40. r Feedback Mode 4 Current Mode no voltage or velocity loops Set the mode select switches according to the appropriate operating mode Refer to Table 3 for mode select switch settings and Figure 17 for mode select switch location Installation 27 Table 3 Mode select switch settings Operating Mode Select Switch Modes 1 2 3 4 Voltage Mode ON OFF OFF ON no internal velocity loop Velocity Mode ON OFF ON ON Voltage Mode plus internal velocity loop Tachometer Feedback Mode Current Mode X Don t care ON OFF X OFF OFF ON X X SW501 li 1501 LI LI LI LI lI av VOLTAGE VELOCITY SW501 SW501 TACHOMETER CURRENT FEDBACK Figure 17 BOSS 4Q Mode Select Switches 28 Installation TB504 Drive Diagnostics TB504 is a 10 pin male connector used for non isolated drive diagnostics outputs See Figure 18 for connector location and Table 4 for pin functions PIN 1 PIN 2 PIN 10 PIN 9 HALLS SW502 Co 60 120 LI 1C501 PWR ON 7 C501 C502 C503 MODE SELECT Figure 18 BOSS 4Q TB504 Pin Assignments Installation 29 Table 4 Drive Diagnostics All signals referenced to pin 4 Pins Pin 1 Tachometer Out Pin 2 Run Stop Pin 3 Fault Out Pin 4 Circuit Common A Do not connect to earth ground Pin 5 I AVG Out Description 12 pulses per revolution 5 VDC square wave output proportional to motor speed 0 VD
41. r heck a i eee 15 Regen d mp circuit one oin mE rte PIER deba 16 Using the dump circuit with DC power source 16 BOSS 4Q Installation usuris rae RR Rte kem rmm u sisa 18 BOSS 4Q Terminal Descriptions 18 BOSS 4Q Plug in card connections TB501 20 ENABLE DISABLE switch 20 RUN BRAKE SWIiCh 255550 ns CS mu kas 20 FWD REV SWIIOID 20 Speed adjust potentiometer connections 20 Motorhallsensors vci het p si T eae una ag tudo 22 Voltage follower eror E uE 24 Motor hall sensor header SW502 25 Mode select switches 5 501 26 TB504 Drive Diagnostics 28 Contents v BOSS CM Installation sess zie Be kak bene Ds 31 BOSS CM Terminal Descriptions 31 BOSS CM Plug in card connections to TB501 33 ENABLE DISABLE swWiteli iiia cer kon e ea naw e ee ene m an E 33 DIRESWILON L ete etr mtn D erigi 33 Speed adjust potentiometer connections 33 Motor hall Sensors is jer ade Rives 37 BOSS CM Jumper Settings 39 Hall Sensor Spacing 4501 3
42. r voltage mode by setting switches 1 and 4 to ON Set switches 2 and 3 to OFF Refer to Figure 22 page 57 4 Run the motor at full speed Measure the AC phase voltage across any two of the three phases of the drive Run the motor at either minimum speed or zero speed 6 Remove power to the drive a Calibration 57 7 Set the MODE SELECT switch SW501 for tach feedback as follows Set switch 1 to ON Set switches 2 3 and 4 to OFF 8 Setthe GAIN trimpot full CCW 9 Setthe TACH trimpot full CW 10 Run the motor at full speed 11 Adjust the TACH trimpot until the armature voltage is the same value as the voltage measured in step 4 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 SW501 SW501 MODE SW501 SW501 TACHOMETER CURRENT Figure 22 BOSS 4Q Mode Select Switch Settings 58 Calibration BOSS CM Calibration BOSS CM series drives have one user adjustable trimpot Figure 23 Each drive is factory calibrated to its maximum current rating Readjust the calibration trimpot when using a motor with a lower current rating adjustments increase with CW rotation and decrease with CCW rotation Use a non metallic screwdriver for calibration The trimpot is identified on the printed circuit board CURRENT LIMIT PWMA DC CUR LIM Figure 23 BOSS CM Calibration Trimpot Layout Calibrati
43. ranty does not void the warranty nor does it imply an extension of the original 12 month warranty period Products serviced and or parts replaced on a no charge basis during the warranty period carry the unexpired portion of the original warranty only If for any reason any of the foregoing provisions shall be ineffective the Corporation s liability for damages arising out of its manufacture or sale of equipment or use thereof whether such liability is based on warranty contract negligence strict liability in tort or otherwise shall not in any event exceed the full purchase price of such equipment Any action against the Corporation based upon any liability or obligation arising hereunder or under any law applicable to the sale of equipment or the use thereof must be commenced within one year after the cause of such action arises Automation amp Control 901 East Thompson Avenue Glendale California 91201 2011 Tel 1 800 MINARIK 646 2745 Fax 1 800 394 6334 www minarikcorp com Document number 250 0280 Revision 1 Printed in the U S A 5 01 11 00 North America 12 00 Outside North America
44. reference signal to Zero speed 8 Remove power from the drive Remove the lock from the motor shaft 10 Remove the ammeter in series with the motor armature 61 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 BE ALERT High voltages can cause serious or fatal injury Before troubleshooting Disconnect 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 62 Troubleshooting BOSS 4Q Diagnostic LEDs Diagnostic LEDs on the BOSS 4Q plug in card POWER ON The green POWER ON LED lights when power is applied to the drive and the plug in card is connected properly FAULT The red FAULT LED lights in any of the following conditions 1 The hall sensors are miswired not operating properly or not properly nulled 2 The drive reaches its peak phase curren
45. st be isolated on BOSS 4Q series drives BOSS CM inputs are isolated and do not require additional isolation 2 Dimensions 494 444 3 00 125 113 76 6 90 175 Drive Dimension A BOSSxx 115AC 2 62 67 BOSSxx D240AC 3 87 98 All Dimensions in Inches Millimeters Figure 1 BOSS Series Dimensions Dimensions 3 00 7 oet 3 64 92 1 75 44 0 73 18 1 62 41 1 03 26 P 3 80 97 4 30 109 Dimensions in Inches Millimeters Figure 2 BOSS DB Regen Dump Circuit Dimensions Installation Drive 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 the Safety Warnings before attempting installation Drive components are sensitive to electrostatic fields Avoid contact with the circuit board directly Hold the 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 Mount the drive away from other 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 Six 0 19 in 5 mm
46. t limit 3 The drive has insufficient AC or DC power 4 The enable switch is closed drive is disabled 5 The drive reaches maximum bus voltage limit Diagnostic LEDs on the motherboard BUS LIMIT The red BUS LIMIT LED lights when the drive exceeds the maximum bus voltage Troubleshooting 63 BUS LIMIT FAULT POWER LL LLLI ER 2 000000 00000000 REV FWD MIN IR FWD REV MAXSPD ACCEL DECEL SPD COMP TQLIM Taa eeke aeae Figure 24 BOSS 4Q Diagnostic LED Location 64 Troubleshooting BOSS CM Diagnostic LEDs Diagnostic LEDs on the BOSS CM plug in card POWER ON The green POWER ON LED lights when power is applied to the drive and the plug in card is connected properly FAULT The red FAULT LED lights in any of the following conditions 1 The hall sensors are miswired not operating properly 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 The drive reaches maximum bus voltage limit Diagnostic LEDs on the motherboard BUS LIMIT The red BUS LIMIT LED lights when the drive exceeds the maximum bus voltage Troubleshooting 65 BUS LIMIT FAULT POWER a rr L L an E ____ ICT E C502 C503 m Figure 25 BOSS CM Diagnostic LED Location 66 Troubleshooting External line fuse blows External lin
47. the plug in card into place when the header pins are correctly mounted into the header sockets Installation 9 HEADER PINS DOCKING DOCKING HOLE SOCKETS DOCKING I HEADER DOCKING PIN HEADER T Jm Make sure AC or DC voltage input is removed for 30 seconds before installing or removing plug in card Figure 3 Plug In Card Installation 10 Installation Speed adjust potentiometer mounting A 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 the speed adjust potentiometer through a 0 38 inch 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 MOUNT THROUGH A 0 38 IN 10 MM HOLE SPEED ADJUST POTENTIOMETER INSULATING PANEL DISK POT TAB ASSIGNMENTS Figure 4 Speed Adjust Potentiometer Mounting Installation 11 Quick connect terminal block The quick connect terminal block is composed of a header block and terminal plug The removable terminal plug Minarik part number 160 0136 connects to the header block as shown in Figure 5 To use the qui
48. wide slots in 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 Installation Wiring A Warning 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 240 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 Opening any one motor lead may destroy the drive Use 16 AWG wire for the AC or DC voltage input wiring L1 and L2 or VDC and VDC regen dump circuit and motor wiring U V W Use 18 20 AWG wire for speed adjust potentiometer wiring 5 6 Installation Shielding guidelines A Warning Under no circumstances should power and logic leads be bundled together Induced voltage can cause unpredictable behavior in any electronic device including motor controls Minarik recommends shielding all leads If shielding is not practical the user should twist all logic leads with themselves to minimize induced noise It may be ne
Download Pdf Manuals
Related Search