USER`S MANUAL - Minarik Drives
Contents
1. 24 1 5 mA DC current signal input range 24 4 20 mA DC current signal input range 25 10 50 mA DC current signal input range 26 Troubleshooting 28 Certificate of Compliance 31 Unconditional Warranty inside back cover iv Illustrations Figure 1 Process Control Module Dimensions 2 Figure 2 Screw Terminal 7 Figure 3 115VAC Power Connection 8 Figure 4 230VAC Power Connection 9 Figure 5 Connection Following an External Voltage Signal 10 Figure 6 Connection Following an External Current Signal 11 Figure 7 Connection Unidirectional Manual Leader Signal Source 13 Figure 8 Connection Output Voltage 15 Figure 9 Armature Voltage Follower Connections 17 Figure 10 Multiple Follower Motors Connection 19 Figure 11 Voltage Current Selectro Slide Switch 20 Figure 12 Calibration Trimpot Layout 21 Figure 13 Shunt Resistor Installation 27 Specifications Power Requirements Line input 115VAC 230 VAC 50 60 Hz single phase Input Signal Ranges input circuit is isolated Voltage signal narrow range 0 to 25 VDC Voltage signal mid range 0 to 120 VDC2. VOLTAGE 1 2 3 4 5 6 7 SHUNT RESISTOR Figure 13 Shunt Resistor Installation 27 28 Troubleshooting A Warning Dangerous voltages exist on the PCMS when it is powered When possible disconnect and drive while trouble shooting High voltages can cause serious or fatal injury Before troubleshooting Perform the following steps before starting any procedure in this section Disconnect AC line voltage from the PCMS and variable speed drive Check the PCMS and drive closely for damaged components Check that no conductive or other foreign material has become lodged on the printed circuit board Verify that every connection is correct and in good condition Verify that there are no short circuits or grounded connections Check that the input voltage jumpers are installed properly for the input voltage being used see page 8 Check that the drive s rated armature and field outputs are consistent with the motor ratings For additional assistance contact your local Minarik distributor or the factory direct 1 800 MINARIK 646 2745 or Fax 1 800 394 6334 Problem End user s drive does not respond to encoder signal Possible Causes No output voltage from TB1 Loose connections between and motor drive is not recei
3. lead to Terminal 6 If the voltage signal is less than 120VDC connect the positive lead to Terminal 7 If the voltage signal is greater than 120VDC connect the positive lead to Terminal 8 3 4 Q INPUT VOLTAGE 0 20 VDC VOLTAGE CURRENT SIGNAL VOLTAGE SWITCH 0 120 VDC VOLTAGE SIGNAL 0 550 VDC VOLTAGE 7 REF SIGNAL COM Figure 5 Connection Following an External Voltage Signal Installation 11 Current follower connection 1 Set the Current Voltage Switch to Current 2 Connect the incoming current signal leads as shown in Figure 6 below 3 Connect the negative lead to Terminal 5 4 Connect the positive lead to Terminal 6 Rt R2 MAXIMUM OUTPUT CURRENT VOLTAGE 99 6 CURRENT VOLTAGE COM REF SWITCH o CURRENT FOLLOWER INPUT Figure 6 Connection Following an External Current Signal 12 Installation Leader signal generator connections The PCMS can be used as a leader controller in one of two ways It can provide a floating DC leader voltage input to other modules interfacing with standard variable speed drives It can also drive several variable speed drives directly provided that their circuit design permits wiring of their speed circuits in common
4. M Automation Marik lt contri USER S MANUAL Pig b n PROCESS CONTROL MODULE Copyright 2002 by Minarik Corporation rights reserved No part of this manual may be reproduced or transmitted in any form without written permission from Minarik Corporation The information and technical data in this manual are subject to change without notice Minarik Corporation and its Divisions make no warranty of any kind with respect to this material including but not limited to the implied warranties of its merchantability and fitness for a given purpose Minarik Corporation and its Divisions assume no responsibility for any errors that may appear in this manual and make no commitment to update or to keep current the information in this manual Printed in the United States of America Safety Warnings X 24 SHOCK AVOID KEEP AVOID HAZARD HEAT DRY VIBRATION This symbol AN denotes an important safety tip or warning PLEASE READ THESE INSTRUCTIONS CAREFULLY before performing any of the procedures contained in this manual DO NOT INSTALL REMOVE OR REWIRE THIS EQUIPMENT WITH POWER APPLIED Have qualified electrical maintenance technician install adjust and service this equipment Follow the National Electrical Code NEC and all other applicable electrical and safety codes including the provisions of the Occupational Safety and Health Act OSHA when installing equipment
5. Minarik controls connect Terminal 9 of the PCMS to the terminal for the CCW end of the control speed pot and Terminal 10 of the to the wiper terminal The pot wiper should be left disconnected from the control so that only the PCM3 output will control the motor speed Remember that the connections of Terminals 9 and 10 must be reversed if the Minarik control has a negative reference voltage Installation 17 Q Pt Qe m MINARIK SIGNAL ELECTRIC ISOLATOR C Ri R2 R3 Ies T I2 current 56 _ REF OUT gt INPUT VOLTAGE MINIMUM OUTPUT TBI oO MOTOR JOH 10K OHM SPEED ADJUST POTENTIOMETER MOTOR MM20000 MM20000 SERIES DRIVE SERIES DRIVE LEADER FOLLOWER Figure 9 Armature Voltage Follower Connections 18 Installation Multiple Follower Motors If more than one follower motor speed controller is to follow the output from a single leader setting the ratio between two more of the motor speeds can be accomplished with ratioing pots Figure 10 page 19 Wire Terminal 10 of the PCMS to the CW of the pot Disconnect that side of the speed pot from its terminal on the follower control Wire the pot wiper to the speed adjust wiper terminal Wire the CCW side of the
6. OUTPUT 0210 Iss s ES ESSE 1 2 3 4 6 7 8 9 Figure 11 Voltage Current Selectro Slide Switch 21 Calibration A Warning Dangerous voltages exist on the drive when it is powered and up to 30 seconds after power is removed and the motor stops BE ALERT High voltages can cause serious or fatal injury For your safety use personal protective equipment PPE when operating this drive 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 12 for trimpot layout INPUT Qs m MINAHI SIGNAL ELECTRIC ISOLATOR 4 J am i MAXIMUM 59 OY PL P2 E INPUT VOLTAGE lt MINIMUM NA OUTPUT MINIMUM OUTPUT les 1 2 3 4 6 7 8 9 10 Figure 12 Calibration Trimpot Layout 22 Calibration Voltage Signal Follower Calibration Set the VOLTAGE CURRENT selector switch to VOLTAGE Confirm that the positive DC voltage input lead is connected to the ap 1 2 propriate terminal Apply the maximum DC voltage inp
7. Reduce the chance of an electrical fire shock or explosion by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures Although this process control module isolates a voltage or AN current signal its internal 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 Contents Safety Warnings i Specifications 1 Dimensions 2 Introduction 3 Installation 4 Mounting ss oett eru ae erede 4 cep PRECOR 5 Shielding guidelines 6 Screw terminal block 7 line connections 8 Voltage follower connection 10 Current follower connection 11 Leader signal generator connections 12 Output Voltage Connections 14 Armature Voltage Follower 16 Multiple Follower Motors 18 Voltage Current Selector Slide Switch 20 Calibration 21 Voltage Signal Follower Calibration 22 Manual Leader Control 23 Current Signal Follower
8. 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 two 2 year or 6 000 hour 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 M E 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 0082 Revision 4 Printed in the U S A 6 02
9. signal fed to a speed controller allows a motor to be driven automatically at a speed proportional to the signal i e to follow the signal The maximum output voltage is 10 VDC The PCMS DC voltage output must be trimmed to not exceed the reference voltage i e the normal voltage drop across the speed adjust potentiometer of the motor speed controller For Minarik MM20000 series controls the reference voltage is approximately 3 5 VDC Putting higher DC voltage into the control speed adjust circuit will not produce correspondingly higher motor speeds Such an error can seriously degrade the linearity between the process signal level and motor speed This manual contains specifications installation procedures connections and calibration procedures for the process control module model Refer to your variable speed drive user s manual for additional installation operation and troubleshooting procedures 4 Installation Mounting A Warning Do not install rewire or remove this control with input power applied Doing so may cause fire or serious injury Make sure you read and understand the Safety Warnings on page i before attempting installation components are sensitive to electrostatic fields Avoid contact with the circuit board directly Protect the PCM3 from dirt moisture and accidental contact Provide sufficient room for access to the terminal block Mount the PCM3 a
10. Minarik Corporation 901 East Thompson Avenue Glendale CA 91201 2011 USA and 2 determined by the Corporation to be defective This warranty shall not apply to any product that has been subject to misuse negligence or accident or misapplied or repaired by unauthorized persons or improperly installed The Corporation is not responsible for removal installation or any other incidental expenses incurred in shipping the product to and from the repair point B Disclaimer The provisions of Paragraph A are the Corporation s sole obligation and exclude all other warranties of merchantability for use express or implied The Corporation further disclaims any responsibility whatsoever to the customer or to any other person for injury to the person or damage or loss of property of value caused by any product that has been subject to misuse negligence or accident or misapplied or modified by unauthorized persons or improperly installed C Limitations of Liability In the event of any claim for breech of any of the Corporation s obligations whether express or implied and particularly of any other claim or breech of warranty contained in Paragraph A or of any other warranties express or implied or claim of liability that might despite Paragraph B be decided against the Corporation by lawful authority the Corporation shall under no circumstances be liable for any consequential damages losses or expense arising in connection with the use
11. Unidirectional applications require a positive PCMS output Connect a 10K ohm potentiometer not provided with the PCM3 as the leader control pot using the 10 VDC REF OUT supply on the Refer to Figure 7 page 13 To connect an external leader control potentiometer attach the CW side of the potentiometer to the REF OUT terminal The potentiometer wiper is connected to terminal 6 The CCW terminal is connected to terminal 5 Installation 18 o Q o B MINARIK SIGNAL ELECTRIC ISOLATOR 1 R1 R2 R3 MAMUN 0 2 current GR OL CE REF our INPUT VOLTAGE m OUTPUT 09 0909 C9 SPEED ADJUST POTENTIOMETER Figure 7 Connection Unidirectional Manual Leader Signal Source 14 Installation Output Voltage Connections A Warning Always check the instruction manual supplied with the variable speed drive that will be interfaced with the PCM3 module The scheme shown for wiring to an external voltage source as well as the specifications on that input must be well understood before proceeding Most Minarik controls have positive reference voltage across the speed adjust pot with respect to the CCW side The pot wiper position determines the fraction of this control reference voltage that will be appl
12. Voltage signal wide range 0 to 550 VDC Current signal 1 5 mADC 4 20 10 50 mADC Input Impedance Voltage signal gt 25K ohms Current signal 1 5 mADC 1K ohms Current signal 4 20 mADC 235 ohms Current signal 10 50 mADC 100 ohms Output Impedance 800 ohms Voltage range max 0 to 10 VDC Linearity 0 196 Operating Temperature Range 0 50 2 Dimensions 4 825 123 gt 22 4225 107 gt 4 vo l MINARIK d SIGNAL 5 ELECTRIC ISOLATOR a o Ri R2 R3 TP L 2 700 69 59 ANSA 2 150 55 NS VOLTAGE MINIMUM OUTPUT 6 7 8 9 10 Y 1 280 33 1 N MOUNTING HOLE 4 EA 0 146 4 DIAMETER 0 250 6 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 1 Process Control Module Dimensions Introduction Minarik model signal isolators produce a floating DC voltage signal proportional to a variable DC current or voltage signal input It also can generate the floating DC voltage signal output controlled by an external potentiometer The output
13. d between terminals 1 and 2 and between 3 and 4 see Figure 3 This is the PCMS s default factory setting When operating on 230VAC remove both jumper bars and place one jumper bar between terminals 2 and 3 see Figure 4 page 9 0 Oo MINARIK SIGNAL ELECTRIC ISOLATOR MINIMUM OUTPUT 6 7 8 9 10 AC POWER 115 VAC INPUT JUMPER BARS INSTALLED BETWEEN TERMINALS 1 amp 2 AND TERMINALS 3 amp 4 Figure 3 115VAC Power Connection Installation 9 E MINARIK SIGNAL T ELECTRIC ISOLATOR 5 eiu 59 2969 5 6 7 8 9 10 1 4 AC POWER 230 VAC INPUT JUMPER BAR INSTALLED BETWEEN TERMINALS 2 amp 3 Figure 4 230VAC Power Connection 10 Installation Voltage follower connection 1 2 Set the Current Voltage Switch to Voltage Connect the incoming voltage signal leads as shown in Figure 5 below Connect the negative lead to Terminal 5 If the voltage signal is less than 20VDC connect the positive
14. e the leader potentiometer wiper fully CCW b Adjust MINIMUM OUTPUT trimpot to achieve the desired minimum output voltage across Terminals 9 and 10 or alternatively to achieve the desired minimum speed of the motor 24 Calibration Current Signal Follower Set the VOLTAGE CURRENT selector slide switch to CURRENT 1 5 mA DC current signal input range 1 2 4 5 6 Apply a 5 maDC signal across Terminals 5 and 6 Adjust INPUT trimpot until voltage measured between the Test Point post on board marked TP and Terminal 5 is approximately one half of the Reference Voltage of the speed control Adjust MAXIMUM OUTPUT trimpot to achieve the desired maximum output voltage across Terminals 9 and 10 which normally is equal to or less than the control Reference Voltage depending upon whether the motor is to run at its rated speed or at a slower speed with maximum DC input current to the Apply 1 mADC signal across Terminals 5 and 6 Adjust MINIMUM OUTPUT trimpot to achieve the desired minimum output voltage across Terminals 9 and 10 or alternatively to achieve the desired minimum speed of the motor Repeat Steps 1 through 5 once Calibration 25 4 20 mA DC current signal input range 1 Apply a 20 mADC signal across Terminals 5 and 6 2 Adjust MAXIMUM OUTPUT trimpot to achieve the desired maximum output voltage across Terminals 9 and 10 which normally is equal to or less than the con
15. ied to the speed adjustment circuit In these controls the application of a positive voltage at the wiper with reference to the CCW connection will cause the motor to run Output connections are made to terminals 9 and 10 of terminal board TB501 Connect the negative lead to terminal 9 Connect the positive lead to terminal 10 Refer to Figure 8 page 15 Some controls have a negative reference voltage across the speed adjust pot Reverse the polarity of the connection to such controls Installation 15 Ri R2 R3 MAXIMUM OUTPUT TP a CURRENT Pj H INPUT VOLTAGE MINIMUM OUTPUT COM REF 0 10 VDC OUTPUT Figure 8 Connection Output Voltage 16 Installation Armature Voltage Follower The PCMS may be used as an interface to control one motor speed in proportion to that of an independent DC motor The input signal would be taken from the voltage across the armature of the motor since speed is proportional to this voltage To follow the armature voltage signal wire the positive side of the armature voltage to Terminal 7 if 0 120 range or to Terminal 8 if 0 550 VDC range Wire the negative side of the armature voltage to Terminal 5 as shown in Figure 9 page 17 Connect Terminals 9 and 10 to the speed control circuit in the follower controller according to the instructions provided with the speed controller With most
16. ng motor controls As a general rule Minarik recommends shielding of all conductors If it is not practical to shield power conductors Minarik recommends shielding all logic level leads If shielding is not practical the user should twist all logic leads with themselves to minimize induced noise It may be necessary to earth ground the shielded cable If noise is produced by devices other than the PCM module ground the shield at the module end If noise is generated by a device on the PCM module ground the shield at the end away from the PCM module Do not ground both ends of the shield If the module continues to pick up noise after grounding the shield it may be necessary to add AC line filtering devices or to mount the PCM module in a less noisy environment Logic wires from other input devices such as motion controllers and PLL velocity controllers must be separated from power lines in the same manner as the logic I O on this drive Installation Screw terminal block Connections to Minarik s PCM3 are made to a screw terminal block Using a screwdriver turn the terminal block screw counter clockwise to open the wire clamp Insert stripped wire into the wire clamp Turn the terminal block screw clockwise to clamp the wire See Figure 2 Figure 2 Screw Terminal Block 7 8 Installation AC line connections Connect AC power leads to terminals 1 and 4 When operating on 115VAC leave the jumper bars installe
17. pot and the output from PCMS Terminal 9 to the speed adjust CCW terminal on the control Installation MINARIK SIGNAL ELECTRIC ISOLATOR P RI R2 R3 MM TP 2 current 5Q CX OUT INPUT VOLTAGE MINIMUM TB OUTPUT 1 2 3 4 5 6 7 8 J 10 10K OHM MASTER SPEED ADJUST POTENTIOMETER INH2 3 52 20000 SERIES s FOLLOWER 1 A1 Cte MOTOR 1 INH2 53 20000 SERIES 51 FOLLOWER 2 A1 HOHE Figure 10 Multiple Follower Motors Connection MOTOR 2 19 10K OHM SPEED ADJUST POTENTIOMETER 10K OHM SPEED ADJUST POTENTIOMETER 20 Installation Voltage Current Selector Slide Switch See Figure 11 for the Voltage Current Selector Slide Switch Set the swtich to VOLTAGE for voltage input mode otherwise set it to CURRENT for current input mode VOLTAGE CURRENT SELECTOR SLIDE SWITCH n MINARIK ELECTRIC T RI R2 SIGNAL ISOLATOR O MAXIMUM OUTPUT I2 Q INPUT VOLTAGE MINIMUM
18. the following test specifications EN55011 1991 emissions and EN50082 1 1992 immunity Compliance allows the PCMG 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 he she is operating 2 The Original Equipment Manufacturer OEM will implement the product as a component of the machine being manufactured 32 Certificate of Compliance CE is a machinery directive Whether or not every component in the OEM s machinery meets CE the OEM must still submit its 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 and filtering practices guarantee the controller will meet EN55011 1991 emissions standard and EN50082 1 1992 immunity standard 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 two 2 years or 6 000 hours whichever comes first from date of shipment thereof Within this warranty period the Corporation will repair or replace such products that are 1 returned to
19. trol Reference Voltage depending upon whether the motor is to run at its rated speed or at a slower speed with maximum DC input current to the 3 Apply a 4 mADC signal across Terminals 5 and 6 4 Adjust MINIMUM OUTPUT trimpot to achieve the desired minimum output voltage across Terminals 9 and 10 or alternatively to achieve the desired minimum speed of the motor 5 Repeat Steps 1 through 4 once 26 Calibration 10 50 mA DC current signal input range Shunt a 1K ohm 3W resistor across Terminals 5 and 6 as shown in Figure 13 page 27 1 Apply a 50 mADC signal across Terminals 5 and 6 2 Adjust MAXIMUM OUTPUT trimpot to achieve the desired maximum output voltage across Terminals 9 and 10 which normally is equal to or less than the control Reference Voltage depending upon whether the motor is to run at its rated speed or at a slower speed with maximum DC input current to the 3 Apply a 10 mA DC signal across Terminals 5 and 6 4 Adjust MINIMUM OUTPUT trim pot to achieve the desired minimum output voltage across Terminals 9 and 10 or alternatively to achieve the desired minimum speed of the motor 5 Repeat Steps 1 through 4 once Ici Calibration eA LEGS c2 oct MINARIK TA ELECTRIC ISOLATOR R2 Bi MM 1 OUTPUT TP CURRENT d d PY A INPUT
20. ut signal Adjust the INPUT trimpot until the voltage measured between the Test Point post on board marked TP and Terminal 5 is approximately one half of the Reference Voltage of the speed control Adjust MAXIMUM OUTPUT trimpot to achieve the desired maximum output voltage across Terminals 9 and 10 which normally is equal to or less than the control Reference Voltage depending upon whether the motor is to run at its rated speed or at a slower speed with maximum DC input voltage to the Apply the minimum DC voltage input signal Adjust MINIMUM OUTPUT trimpot to achieve the desired minimum output voltage across Terminals 9 and 10 or alternatively to achieve the desired minimum speed of the motor Calibration 23 Manual Leader Control Set the VOLTAGE CURRENT selector switch to VOLTAGE Confirm that a 10K ohm leader speed adjust potentiometer has been properly wired between REF OUT CW and Terminal 5 CCW with its wiper wired to Terminal 6 1 Set the leader speed adjust potentiometer to maximum full CW 2 Adjust INPUT trimpot until voltage measured between the Test Point post on board marked TP and Terminal 5 is approximately one half of the reference voltage of the speed control 3 Adjust MAXIMUM OUTPUT trimpot to achieve the desired maximum output voltage across Terminals 9 and 10 This voltage is equal to or less than the control reference voltage depending upon the desired motor speed 4 Rotat
21. ving AC line voltage Input signal is not connected INPUT pot is not calibrated Motor drive not calibrated properly Troubleshooting 29 Suggested Solutions 1 Recalibrate the If there is still no output send PCMS to Minarik for repair Check connections between TB1 and the input of motor drive Apply AC line voltage to terminals 1and 4 Check that the is receiving voltage or current input signal Calibrate INPUT pot page 24 Re calibrate motor drive according to manufacturer s instructions 30 Troubleshooting Possible Causes Problem Suggested Solutions End user s motor 1 Voltage out TB1 is 1 Check that the drive does not reach full speed End user s motor does not respond properly runs too slow or too fast to not changing as input changes Loose connections between and motor drive Motor drive not calibrated properly voltage out TB1 is changing as input changes Recalibrate the IF voltage is still not changing send the drive to Minarik repair Check connections between TB1 and the input of motor drive Re calibrate motor drive according to manufacturer s instructions 31 Certificate of Compliance Minarik Corporation hereby certifies that Signal Isolator has been approved to bear the mark The PCMS has been tested to
22. way from other heat sources Operate within the specified ambient operating temperature range The operating temperature range for the is O C through 50 Prevent loose connections by avoiding excessive vibration of the process control module board e Mount the PCMG in either a horizontal or vertical plane The is mounted using 4 ea 0 25 inch 6mm standoffs See Figure 1 page 2 for the physical locations of these standoffs Use 8 panhead screws to fasten the standoffs to the mounting surface Installation 5 Wiring A Warning Do not install rewire or remove this control with input power 4 applied Failure to heed this warning may result in fire explosion or serious injury This drive is isolated from earth ground Circuit potentials are at 115 or 230 VAC above ground To prevent the risk of injury or fatalisty 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 18 24 AWG wire for speed adjust potentiometer wiring Use 14 16 AWG wire for AC line L1 L2 and motor A1 and A2 wiring 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 includi
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