USER`S MANUAL
Contents
1. USER S MANUAL XP AC SERIES Pulse Width Modulated Adjustable Speed Drives for DC Brush Motors MODEL XP02 115AC Q Copyright O 2006 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 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 chance of an electrical fire shock or explosion by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures It is possible for a drive to run at full speed as a result of a component failure Install a master switch in the AC line for stopping the drive2. recalibrating to verify that the motor runs at the desired minimum and maximum speed IR COMP The IR COMP setting determines the degree to which motor speed is held constant as the motor load changes It is factory calibrated for a 1 8 HP 90 VDC motor Recalibrate the IR COMP setting when using a lower horsepower motor Refer to the recommend ed IR COMP settings in Figure 10 or recalibrate using the following procedure If the motor does not maintain set speed as the load changes gradually rotate the IR COMP trimpot CW If the motor oscillates overcompensation the IR COMP trimpot may be set too high CW Turn the IR COMP trimpot CCW to stabilize the drive 13 TORQUE The TORQUE setting determines the maximum armature current output of the drive It is factory calibrated for a 1 8 HP 90 VDC motor Recalibrate the TORQUE setting when using a lower horsepower motor Refer to the recommend ed TORQUE settings in Figure 10 or recalibrate using the following procedure 1 With the power disconnected from the control connect a DC ammeter 0 15 A minimum scale in series wit h the armature 2 Set the TORQUE trimpot to minimum full CCW 3 Connect power to the drive The motor should remain stopped 4 Lock the motor armature Be sure that the motor is firmly mounted 5 Set the speed adjust potentiometer to maximum full CW 6 Adjust the TORQUE trimpot CW slowly until the armature current is 120 of
3. 3 are not shorted together For additional assistance contact your local Minarik distributor or the factory direct Phone 800 646 2745 Fax 815 624 6960 24 Replacement Parts Replacement parts are available from Minarik Corporation and its distributors for this drive series BR501 GBU8J Bridge 073 0006 C503 470 uF 400 VDC Capacitor 011 0120 D501 16 A 300V Diode 071 0054 FU501 Fuse Holder 050 0050 Q501 Power MOSFET 070 0043 R501 0 2 Q 5 W Resistor 032 0093 R502 6 8 KQ 10 W Resistor 032 0103 5A 3 AG Fast Acting Fuse 050 0022 10 KQ Potentiometer Kit with Terminal Plug 202 0074 25 Unconditional Warranty A Warranty Minarik Drives 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 Minarik Drives will repair or replace at its sole discretion such products that are returned to Minarik Drives 14300 De La Tour Drive South Beloit IL 61080 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 Minarik Drives 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 Minarik Drives sole obli
4. Hold the drive by the chassis only Protect the drive from dirt moisture and accidental contact Provide sufficient room for access to the termi nal block and calibration trimpots Mount the drive away from other heat sources Operate the drive within the specified ambient operation 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 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 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 Wiring Use 18 AWG wire for speed adjust potentiometer wiring Use 16 AWG wire for motor and AC line voltage wiring Twist logic wires for speed adjust potentiometer and inhibit to avoid picking up unwanted electrical noise Use shielded cable if wires are longer than 18 in 46 cm Keep logic wires away from power carrying lines or sources of electrical noise that can cause erratic opera tion Never run speed adjust potentiometer or inhibit wires in the same conduit used for the motor and AC line voltage wires lt 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 ge
5. ake resistor For motors rated 1 17 horsepower and lower a dy namic brake resistor is not necessary since the armature resistance is high enough to stop the motor without demagnetization In this case replace the dynamic brake resistor with 12 gauge wire A Warning Wait for the motor to completely stop before switching it back to RUN This will prevent high armature currents from damaging the motor or drive 12 Calibration Each drive is factory calibrated to its maximum horsepower rating Readjust the calibration trimpot settings to accommodate lower horsepower motors All adjustments increase with CW rotation and decrease with CCW rotation Use a non metallic screwdriver for calibration Each trimpot is identified on the printed circuit board MIN SPD The MIN SPD setting determines the motor speed when the speed adjust potentiometer is turned full CCW It is factory set for zero speed To calibrate turn the speed adjust potentiometer full CCW Adjust the MIN SPD trimpot until the motor has stopped or is running at the desired minimum speed MAX SPD The MAX SPD setting determines the motor speed when the speed adjust potentiometer is turned full CW It is factory set for maximum rated speed To calibrate set the MAX SPD trimpot full CCW Turn the speed adjust potentiometer full CW Adjust the MAX SPD trimpot until the desired maximum motor speed is reached Note Check the MIN SPD and MAX SPD adjustments after
6. ed of the leader motor Figure 16 The PCM4 isolates the leader motor from the follower drive and outputs a voltage proportional to the leader motor armature voltage The follower drive uses this voltage reference to set the speed of the fol lower motor An optional ratio potentiometer may be used to scale the PCM4 output voltage e Al 9 1 2 sa Leader A pend e Follower Drive Drive A2 710 18502 a TB501 10K Ohm hd optional Figure 16 Leader Follower Application 19 Single speed potentiometer control of multiple drives Multiple drives can be controlled with a single speed adjust potentiometer using a PCMA at the input of each drive to provide isolation Figure 17 Optional ratio potentiometers can be used to scale the PCM4 output voltage allowing independent control of each drive 8 PcM4 ratio pot A optional 10KQ 8 PCM4 s1 s2 DRIVE A Al A2 ratio pot B optional 10KQ TB501 TB502 s1 s2 DRIVEB Figure 17 Single Speed Potentiometer Control of Multiple Drives 20 Reversing A dynamic brake may be used when reversing the motor direction Figure 18 Use a three pole three position switch rated for at least the maximum DC armature voltage and maximum brakin
7. g current Wait for the motor to stop completely before switching it to either the forward or reverse direction Forward O 9 Brake SO 1 Reverse 1 ma i 19 1W H Dynamic i Brake 1 Resistor 1 m Al i 1 O O H2 HO O 5 H1 Figure 18 Reversing Circuit Connection 21 Troubleshooting A Warning Dangerous voltages exist on the drive when it is powered When possible disconnect the AC line voltage from the drive while troubleshooting Be Alert High voltages can cause serious or fatal injury Before troubleshooting Perform the following steps before starting any procedure in this section Disconnect AC line voltage from the drive Check the drive closely for damaged components Check that no conductive or other foreign material has become lodged on the printed circuit board Verify that every connection is correct and in good condition Verify that there are no short circuits or grounded connections Check that the voltage selection switch settings match the AC line and output voltages Check that the drive s rated armature and field outputs are consistent with the motor ratings 22 Motor does not run 1 Check for blown fuses or tripped circuit breaker 2 Verify that the speed adjust potentiometer is not set to zero speed position 3 Verify that the inhibit terminals H1 and H2 are not shorted together 4 Verify tha
8. gation and exclude all other warranties of merchantability for use express or implied Minarik Drives 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 Minarik Drives 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 Minarik Drives by lawful authority Minarik Drives shall under no circumstances be liable for any consequential damages losses or expense arising in connection with the use of or inability to use Minarik Drives 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 Minarik Drives liability for damages arising out of its manufacture or sale of equipment or use thereof whether such liabili
9. ick connect terminal block 1 Carefully pull terminal plug from header block 2 With a small flat head screwdriver turn terminal plug screw counterclockwise to open wire clamp 3 Insert stripped wire into the large opening in front of the plug 4 Turn the terminal plug screw clockwise to clamp the wire 5 Repeat steps 2 4 for each terminal until all connections are made 6 Insert plug into header until securely fastened Terminal Plug Header Block Figure 4 Quick Connect Terminal Block Connections MAX SPD P501 HHHHHHHH Li L2 Al A2 TORQUE P502 MINSPD IR ComP E Line Voltage 115 Vac Inhibit Switch Motor Armature optional Figure 5 XP02 115AC Q Connections ASSUMPTIONS Minarik drives supply motor voltage from A1 and A2 terminals It is assumed through 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 Voltage Follower Instead of using a speed adjust potentiometer the drive may be wired to follow a 0 5 VDC voltage signal that is isolated from Earth ground Figure 6 Connect the signal input to S2 Connect the signal com mon to S1 Make no connection to S3 A potentiometer can be used to scale the analog inpu
10. in an emergency This drive is not isolated from Earth ground Circuit potentials are at 115 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 Il Table of Contents Application Notes Safety WamingsS gt 0s iia iaa Saeed wah aera de aaa eee SPOCiIICATIONS LE A A wide E AE 1 DIMENSIONS cad dio dl A da cias 2 Installation cia AAA A a OE a A 3 Mounting 240 WINN oes strates A tend NEEE EE eae 3 LiN RUSCH tt IREE P IEE E E TTTS ETAT TTILE TETTETETT ead 4 Speed adjust potentiometer oocircicicorn aria tees par A ERa 5 Quick conne ct terminal block vii sonia A RAEE a dec 6 Connections Voltage Follower Operation A A AAA A SUN AS IE AA DEA SAA AAA ASA LERN OE 9 Diagnostic LEDS bi ii da a oe 9 Line Starting and line StOppING coins a a 10 IMhibit SWIHCH s202 2 2c cac ites rra ra rr ra naan ees 10 Dynamic Drakkar peck ued tears cee ee ace ate he Mk Re eS 10 Calibration ci iaaea daiwa AA aan A a a EEEE de eaves MINISPD RPTE EEE IAESTE o luca a oil baat wank MAXOSPD coria rada da IRCOMP pornos Ea ASAS A DAA TORQUE Multiple Tixed SpeedS osooocccosirsai tan nevera viaria rad a ra ia 14 Adjustable speeds using potentiometers in serieS 2 6 cece cece eee eee tenet eee eens 14 Independent adjuistable Speeds ocor
11. io aa side rie le ce ai RUN JOG switch Connection to other Minarik devices Leaderfollower applications 35 2000 ida ia SS date a Cares au ea Aa Single speed potentiometer control of multiple drives 00 00000 19 REVErSING asta id 20 Troubleshooting 21 Before troubleshooting si cia A A ai a 21 Replacement Parts ii A it o EE A fed asada E A ded asa ese e dE E tee a ole 24 Unconditional Warranty ooccocccccnnnnnn a a inside back cover HI 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 XP02 115AC Q DIMENSIONS ocio es adi 2 Fuseholder lt lt Speed Adjust Potentiometer Quick Connect Terminal Block XP02 115AC Q Connections Voltage Signal Connections DiagnosticiLEDS iconos rr need pa la NEE E 9 bib S Witkin ia A O AAA AA 10 Dynamic Brake Connection oir di iii 11 Typical TORQUE and IR COMP SettidgS oooocccccccccccccccccnc 13 Multiple Fixed Speeds cu ciociociraia rice 14 Adjustable Fixed Speeds Using Potentiometers in Series 0ooocccccooo oo 14 Independent Adjustable Speeds 0 cece eee eee eee 15 RUN JOG Switch Connection 0 00 00 ccc 16 XP02 115AC Q Connections to Minarik Devices 000002 e cece 47 Leader Fo
12. llower Applicationtss 2 c40 1 iaa dr ae SS 18 Single Speed Potentiometer Control of Multiple Drives 0cccccccccc o 19 Reversing Circuit Connection Specifications Model XP02 115AC Q AC Line Voltage 115 VAC 10 50 60 Hz single phase Horsepower Range with 130 VDC motors 1 20 1 3 HP Armature Voltage 0 130 VDC Maximum Continuous Armature Current 2 ADC Form Factor at base speed 1 05 Acceleration Time with load 1 second Deceleration Time with load 2 seconds Analog Input Voltage Range isolated S1 to S2 0 5 VDC Input Impedance S1 to S2 gt 100K ohms Speed Regulation 1 of base speed or better Ambient Temperature Range 10 C 40 C Weight 0 6 Ibs 2 Dimensions tf 3 58 91 1 75 44 e MAXSPD TORQUE P501 P502 69 ps pon E F 0 74 19 0 65 16 je 3 80 97 gt ja 4 30 109 gt 2 olelela olelslaleja ol E E 2 15 55 ij 1 28 33 t F Y l e QUO Figure 1 XP02 115AC Q Dimensions Installation Mounting Drive components are sensitive to electrostatic fields Avoid contact with the circuit board directly
13. motor rated armature current 7 Set the speed adjust potentiometer to minimum and remove the stall from the motor iD D iD iD TORQUE TORQUE IR COMP 1 4 HP 130 VDC 2500 RPM 1 40 ADC 1 8 HP 90 VDC 1800 RPM 1 30 ADC 1 8 HP 130 VDC 2500 RPM 1 00 ADC factory settings 0 19 19 9 IR COMP IR COMP Q IR COMP 1 10 HP 90 VDC 1725 RPM 1 10 ADC 1 15 HP 90 VDC 1800 RPM 0 75 ADC 1 20 HP 90 VDC 1750 RPM 0 56 ADC Figure 10 Typical TORQUE and IR COMP Settings Actual settings may vary with each application Application Notes Multiple fixed speeds Replace the speed adjust potentiometer with series resistors with a total series resistance of 10K ohms Figure 11 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds S3 S2 Y S1 Total Series Resistance 10K Ohms Figure 11 Multiple Fixed Speeds Adjustable speeds using potentiometers in series Replace the speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in series with a total series resistance of 10K ohms Figure 12 shows a connection for fixed high and low speed adjust potentiometers 53 S2 S1 CW 5K Ohm CW 5K Ohm Figure 12 Adjustable Fixed Speeds Using Potentiometers in Series 15 Independent adju
14. nerated by a device on the drive ground the shield at the end away from the drive Do not ground both ends of the drive Line Fuse All XP02 115AC Q drives are protected by a 5A 250V AC line fuse The fuse does not have to be resized as long as the motor used is within the drive s specified horsepower range The fuse is mounted in the fuseholder see Figure 2 To replace a blown fuse use a screwdriver to turn the fuseholder knob counterclockwise Remove the blown fuse and replace with a new fuse Fuseholder Knob Figure 2 Fuseholder Speed adjust potentiometer Mount the speed adjust potentiometer through a 0 38 in 10 mm hole with the hardware provide Figure 3 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 in 457 mm use shielded cable see Wiring section A Warning Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure Ground ing the input will cause damage to the drive MOUNT THROUGH A 0 38 IN 10 MM HOLE NUT STAR WASHER SPEED ADJUST POTENTIOMETER POT TAB ASSIGNMENTS INSULATING DISK PANEL Figure 3 Speed Adjust Potentiometer Quick connect terminal block The quick connect terminal block has an 8 pin header block and 8 screw terminal plug Figure 4 To use the qu
15. s 10 Line starting and line stopping Line starting and line stopping applying and removing AC line voltage is recommended for infre quent starting and stopping of a drive only When AC line voltage is applied to the drive the motor accelerates to the speed set by the speed adjust potentiometer When AC line voltage is removed the motor coasts to a stop Inhibit switch An inhibit switch allows the motor to decelerate to zero speed when the switch is closed Connect a single pole single throw switch between H1 and H2 see Figure 8 Close the switch to decelerate to the motor to zero speed Open the switch to accelerate the motor to set speed An open collector output rated for at least 10 mA 1 may also be used as an inhibit switch Wire the collector to H1 and the emitter to H2 LI OO H2 L 12 Al A2 53 S52 Si H RUN Lo STOP Inhibit Switch optional Figure 8 Inhibit Switch Dynamic braking Dynamic braking may be used to rapidly stop a motor Figure 9 For the RUN BRAKE switch use a double pole double throw switch rated for at least the maximum DC armature voltage and maximum braking current 11 10 1W Dynamic Brake Resistor RUN BRAKE O e IM Figure 9 Dynamic Brake Connection A 1 Q 1W resistor is used as the dynamic br
16. stable speeds Replace the speed adjust potentiometer with a single pole multi position switch and two or more poten tiometers in parallel with a total parallel resistance of 10K ohms Figure 13 shows the connection of two independant speed adjust potentiometers that can be mounted at two separate operating stations S3 5 or S1 SPEED 2 SPEED 1 20K ohm 20K ohm Figure 13 Independent Adjustable Speeds 16 RUN JOG switch Using a RUN JOG switch is recommended in applications where quick stopping is not needed and frequent jogging is required Use a single pole single throw switch for the RUN JOG switch and a single pole normally closed momentary operated pushbutton for the JOG pushbutton see Figure 14 When the RUN JOG switch is set to JOG the motor decelerates to zero speed Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation MAX SPD P501 TORQUE P502 MIN SPD IRCOMP HH i H2 11 12 Al A2 S3 52 S1 Hi OO 10K Ohm JOG JOG Pushbutton Figure 14 RUN JOG Switch Connection 17 Connection to other Minarik devices XP02 115AC Q DLC600 XP02 115AC Q Figure 15 XP02 115AC Q Connections to Minarik Devices PCM4 DLC100 and DLC300 18 Leader follower application In this application use a PCM4 to monitor the spe
17. t the drive is receiving AC line voltage 5 Check that the drive is not in current limit The red current limit CUR LIM LED must be off If the red current limit LED is on verify that the motor is not jammed It may be necessary to increase the TORQUE setting if it is set to a value lower than the current rating of the motor Fuses or circuit breaker blows 1 Check all wiring for shorts grounds or misconnections 2 Check that the drive is configured to match the motor rating 3 Check that the motor is not jammed or restricted from movement 4 Check that the fuse size is correct for the motor being driven Motor runs too fast at the maximum speed setting 1 Check that the MIN SPD and MAX SPD settings are not set too high 2 Check that the field output connections are secure if you are using a shunt wound motor Motor will not stop when the speed adjust potentiometer is full CCW 1 Turn the MIN SPD trimpot CCW until the motor stops Motor runs in the opposite direction 1 Remove AC line voltage 2 Reverse connections to the motor armature 23 Motor slows under load 1 Check that the drive has been correctly calibrated for the motor 2 Check that the motor is not overloaded 3 Readjust the IR COMP slightly CW until motor runs at proper speed Motor is unstable under load 1 Readjust the IR COMP setting slightly CCW until motor speed is stabilized Motor only runs at full speed 1 Check that S2 and S
18. t voltage To achieve greater linearity and control use an interface device such as Minarik model PCM4 to scale the analog input voltage HHHHHHHE L1 L2 Al A2 3 2 0 5VDC Isolated Voltage Signal Input Figure 6 Voltage Signal Connections Operation Startup Note Before applying power verify that no foreign conductive material is placed on the printed circuit board To start the drive 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 the drive is following a voltage sig nal slowly increase the voltage signal The motor slowly accelerates as the potentiometer is turned CM or the voltage signal is increased Continue until the desired speed is reached 4 Remove AC line voltage form the drive to coast the motor to a stop If the motor or drive does not perform as described disconnect the AC line voltage immediately Refer to the Troubleshooting section for further assistance Diagnostic LEDs All XP02 115AC Q drives are equipped with diagnostic LEDs See Figure 7 for LED locations POWER PWR Green LED lights whenever AC line voltage is applied to drive CURRENT LIMIT CUR LIM Red LED lights whenever the drive reaches current limit CURRENT LIMIT POWER LED LED red green Figure 7 Diagnostic LED
19. ty 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 Minarik Drives 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 MINARIK DRIVES www minarikdrives com 14300 De La Tour Drive South Beloit IL 61080 Phone 800 MINARIK 646 2745 Fax 800 394 6334 Document Number 250 0213 Revision 1 Printed in the U S A April 2006
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