User`s Manual - Minarik Drives
Contents
1. amp Control BOSS Series Models BOSS04 115AC 1Q BOSS08 115AC 1Q BOSS15 115AC 1Q 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 2 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 chance of an electrical fire shock or explosion by proper grounding over cu2. use insulated tools and the appropriate personal protection equipment BE ALERT High voltages can cause serious or fatal injury Each drive is factory calibrated to its maximum current rating Readjust the calibration trimpot settings to accommodate lower current 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 30 Calibration MINIMUM ACCELERATION TQ LIMIT MAX SPD REGULATION 2 FAULT MAXIMUM REGULATION DECELERATION SPEED Figure 12 BOSS 1Q Calibration Trimpot Layout Calibration 31 Calibration procedure Calibrate the BOSS 1Q using the following procedure 1 2 9 Ensure that power is applied to the drive Set the ENABLE DISABLE switch to the ENABLE position open or remove the short between the ENABLE and COM terminals on TB501 Set the RUN BRAKE switch to the RUN position closed or add a jumper between the RUN BRAKE and COM terminals on 501 Set the FWD REV switch to the desired direction Set the MAX SPD and REGULATION trimpots to the center of travel 12 o clock position Set the MIN SPD ACCEL and DECEL trimpots full counterclockwise CCW Set the TQ LIMIT trimpot full clockwise CW Set the signal input analog voltage signal or speed adjust potentiometer to zero Apply power to the drive 10 Calibrate the trimpots as
3. AC2 terminal on the BOSS drive motherboard Installation 17 QIL cant TH501 BOSS SERIES DRIVE EMERGENCY STOP SWITCH HI REGEN DUMP CIRCUIT 100 180 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 55 10 terminal descriptions NOTE Make no connection to terminal 7 of the removable terminal plug Refer to Figure 9 page 21 for a connection diagram Refer to Figure 10 page 23 for information on connecting hall sensors COM terminals 1 and 12 A Warning Do not connect these terminals to earth ground Circuit common ENABLE DISABLE terminal 2 Short to COM to coast the motor to a stop leave open to run the motor RUN BRAKE terminal 3 Short to COM to run the motor Open the connection to brake When braking high side power devices turn off low side power devices turn on and the motor brakes to a stop An external braking resistor is not required because current is dissipated through the motor windings FWD REV terminal 4 Short to COM for reverse direction leave open for forward direction Hall sensors A and C or 1 and 3 are exchanged reversing commutation sequence Installation 19 V POT terminal 5 Floating 10 VDC reference for 10K ohm speed adjust potentiometer SPEED IN terminal 6 Accepts float
4. ACCEL trimpot CW to increase the acceleration time and CCW to decrease the acceleration time until the desired acceleration time is reached DECELERATION DECEL The DECEL setting determines the time the motor takes to ramp to a lower speed See Specifications page 1 for approximate deceleration times The DECEL setting is factory set to its minimum value full CCW 1 Set the speed adjust potentiometer or input signal to maximum speed Set the speed adjust potentiometer or input signal to zero speed Measure the time the motor takes to reach zero speed Turn the DECEL trimpot CW to increase the deceleration time and CCW to decrease the deceleration time until the desired deceleration time is reached 34 Calibration REGULATION The REGULATION setting determines the degree to which motor speed is held constant as the motor load changes It is factory set for optimum motor gain Recalibrate the REGULATION setting when using a lower horsepower motor Use the following procedure If the motor does not maintain set speed as the load increases gradually rotate the REGULATION trimpot CW If the motor oscillates overcompensation the REGULATION trimpot may be set too high CW Turn the REGULATION trimpot CCW to stabilize the motor Calibration 35 TORQUE LIMIT TQ LIMIT A Warning Although TQ LIMIT is set to 120 of the drive s maximum current rating continuous operation beyond that rating may damage
5. DC voltage input to VDC or VDC 6 Check motor connections 7 Connect hall sensors 8 Check sensor wiring If sensor needs more than 20 mADC connect sensor to external power supply Motor runs too slow or too fast at set speed Motor will not reach the desired speed Possible Causes 1 MIN SPD or MAX SPEED not calibrated properly 2 Hall sensors miswired 1 MAX SPD setting is too low 2 REGULATION setting is too low 3 Motor is overloaded 4 Hall sensors miswired Troubleshooting 41 Suggested Solutions 1 Calibrate MIN SPD and MAX SPD 2 Check hall sensor connections 1 Increase MAX SPD setting 2 Recalibrate REGULATION setting 3 Check motor load Resize the motor and drive if necessary 4 Check hall sensor connections 42 Troubleshooting Motor pulsates or surges under load Motor does not reverse Possible Causes 1 REGULATION is set too high 2 Motor bouncing in and out of torque limit 1 Bad FWD REV switch connection 2 Reversing circuit not working properly 3 Hall sensors miswired Suggested Solutions 1 Adjust the REGULATION setting until the motor speed stabilizes 2 Make sure motor is not undersized for load adjust TQ LIMIT setting 1 Check FWD REV switch connection 2 Check reversing circuit by shorting FWD REV terminal to COM terminal with jumper wire 3 Check hall sensor c
6. Figure 11 BOSS 1Q Voltage Signal Connections 25 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 Before applying power Verify that no conductive material is present on the printed circuit board PCB 26 Operation Startup 1 Verify that no conductive material is present on the PCB 2 Check that the ENABLE DISABLE switch is in the enable position open If no switch is installed remove the jumper between the ENABLE and COM terminals on 501 3 Check that the RUN BRAKE switch is in the run position closed If no switch is installed install a jumper between the RUN BRK and COM terminals on TB501 4 Setthe FWD REV switch to the direction you want the motor to rotate upon startup 5 Apply AC or DC voltage input to the drive 6 Slowly advance the speed adjust potentiometer clockwise CW If a voltage signal is used slowly increase the voltage signal The motor slowly accelerates as the potentiometer is turned CW or the voltage signal is increased Continue until the desired speed is reached To reverse motor direction Switch the FWD REV switch to the opposite position To prevent possible demagnetization of the motor consider braking the motor to a stop before reversing polarity Once stopped release the brake input Operation 27 Starting
7. and stopping methods 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 line voltage AC1 and AC2 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 of the power input leads see Motherboard Connections on page 12 To brake the motor Open the RUN BRAKE switch To coast the motor to a stop without disconnecting power Close the ENABLE DISABLE switch 28 Operation 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 AC or DC voltage input is applied to the drive the motor accelerates to the speed set by the speed adjust potentiometer or analog voltage signal When AC or DC voltage input is removed the motor coasts to a stop 29 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 When possible disconnect the voltage input from the drive before adjusting the trimpots If the trimpots must be adjusted with power applied
8. the motor or drive If you intend to operate beyond the rating contact your Minarik representative for assistance The TQ LIMIT setting determines the maximum motor current output of the drive It is factory set at 120 of the drive s maximum current rating TQ LIMIT should be recalibrated when using a motor with a lower current rating 1 With no power applied to the drive connect DC ammeter in series with the motor armature 2 Setthe TQ LIMIT trimpot to full CCW 3 Carefully lock the motor armature Ensure that the motor is firmly mounted 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 TQ LIMIT trimpot clockwise CW until the ammeter reads 120 of maximum motor current 7 Set the speed adjust potentiometer or 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 36 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 AC or DC voltage input from the drive Wait 30 seconds for power to discharge Check the drive closely for damaged components Check that no wire chips or other f
9. 4 Wiring Rad ate See BT etas nem els cte ees sen SM 5 Shielding guidelines eyed eevee ee XY X48 x YD 6 FUSING 2 25 m dient iyu Lor UE ud ta Rs 7 Plug in card Mounting eed Rien piden pit 8 Speed adjust potentiometer mounting 10 Quick connect terminal 11 Motherboard connections ossa xe ex XE Xy tane 12 Power cotinections pede rfe Ee Pre 12 Lime TUSIBQ 13 Motor Connections cisco wd cane aan eo siete rm qur 15 Reden ee i 16 Using the dump circuit with a DC power source 16 BOSS 1Q terminal descriptions 18 BOSS 1Q terminal connections 20 ENABLE DISABLE switch 20 RUN BRAKE switch 20 FWD REV 52 ORI Ie EUR REIR REV ES 20 Motor all Sensors es sash ees See ML IE LESS 22 Voltage oops oA ae ean Dn de 24 iv Contents Operation 25 Before applying power 25 Slart p esae eadein ens etel Datis Mida 26 To reverse motor direction 26 Starting and stoppin
10. DC voltage sources at the same time Installation 13 Line fusing Connect an external fuse between the drive and master stop 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 AC1 if using AC line voltage 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 STOP SWITCH FUSE A CONNECTIONS FOR DC VOLTAGE INPUT STOP SWITCH FUSE 115 LINE VOLTAGE B CONNECTIONS FOR AC VOLTAGE INPUT 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 Figure 7 Ensure that the motor s voltage and current ratings are compatible with the drive rati
11. To reverse motor rotation the BOSS drive switches hall sensor sequence eliminating the need to switch motor leads BOSS 1Q drives are factory set for 120 spacing Contact the factory if you require 60 spacing To run with sensor hall track feedback refer to Figure 10 This voltage is provided at TB501 terminal 11 positive and terminal 12 common or ground If the sensor draws more than 20 mADC it must be connected to an external regulated power supply which provides a floating output Installation 23 HALL B ENABLE OR OR COM DISABLE BRAKE VPOT HALLI e 2 Vef SENSOR COMMON HALLE DAE B HALLA ENABLE RUN SPEED OR OR 5 COM DISABLE BRAKE IN VPOT HALLS HAL 2 HALLI SENSOR Vcc SENSOR COMMON FLOATING ISOLATED 5 VDC EXTERNAL SUPPLY Figure 10 BOSS 1Q Sensor Connections 24 Installation Voltage follower Instead of using a speed adjust potentiometer BOSS 1Q series drives may be wired to follow a floating voltage signal that is isolated from earth ground Connect a 0 to 10 VDC signal to terminals 1 and 6 see Figure 11 for connections CONNECT TO 1Q HEADER BLOCK HALLB HALL ENABLE FWD SPEED OR OR COM DISABLE RUN BRK TVPOT IN VPOT fine 3 HAL2 HALL 718 S VOLTAGE SIGNAL INPUT COM 7 POS
12. al must be isolated 0 10 VDC Input Impedance 60K ohms Power Device Switching Frequency 6 step trapezoidal 22 kHz Vibration 0 56 max 20 50 Hz 0 1G max gt 50 Hz Weight 21 Ambient Operating Temperature Range 0 40 Speed range is based 8000 RPM motor Minimum recommended speed is 100 RPM Dimensions 4 44 113 3 00 76 0 70 18 6 30 160 6 90 175 3 15 80 1 23 31 HE HU 0 97 25 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 1 BOSS Series Dimensions Dimensions 3 0 Corporation 3 64 92 1 75 44 0 73 18 1 62 41 1 03 26 P 3 80 97 4 30 109 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 temper
13. ature 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 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 5 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 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 and AC2 or VDC and VDC regen dump circuit and motor wiring U V W Use 18 20 AWG wire for speed adjust potentiometer 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 including motor controls Minarik reco
14. ct 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 Installation 21 CONNECT TO 1Q HEADER BLOCK HALL HALLB HALL A ENABLE 5VDC COM DISABLE BRAKE Re VPOI TURO 2 ENABLE DISABLE SWITCH SEE NOTE 1 RUN BRAKE SWITCH 10K OHM SEE NOTE 2 SPEED FWD REV ADJUST SWITCH POT SEE NOTE 3 TO MOTOR SENSORS NOTES 1 CLOSE THE ENABLE DISABLE SWITCH TO COAST THE MOTOR TO A STOP LEAVE OPEN TO RUN 2 OPEN THE RUN BRAKE SWITCH TO BRAKE THE MOTOR TO A STOP CLOSE THE SWITCH TO RUN 3 OPEN THE FWD REV SWITCH TO RUN THE MOTOR IN THE FORWARD DIRECTION CLOSE THE SWITCH TO REVERSE 4 MAKE NO CONNECTION TO TERMINAL 7 Figure 9 BOSS 1Q Terminal Connections 22 Installation Motor hall sensors A Warning BOSS series drives provide a 5 VDC supply to drive external sensors This voltage has a maximum capacity of 20 mADC To avoid damage to the drive ensure that any sensor package powered by the BOSS drive does not draw more than 20 mADC BOSS series drives work with three phase 130 VAC brushless motors with nulled hall sensors 60 or 120 electrical spacing Hall sensors are not allowed to be advanced or retarded
15. eriod 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 Also available from M inarik Corporation DLC600 Digi Lok Controller Digital Brush Servo NRG 4Q Series Brush Servo Inari 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 0224 Revision 2 Printed in the U S A 5 01 11 00 North America 12 00 Outside North America
16. ernal line fuse does not blow but the motor does not run Possible Causes 1 Line fuses 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 3 Drive is disabled BRAKE terminal is open to COM Troubleshooting 39 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 TQ LIMIT setting 1 Increase the speed adjust potentiometer setting or voltage input signal 2 Check connections to input Verify that connections are not open 3 Check connections 40 Troubleshooting External line fuse does not blow but the motor does not run cont Possible Causes 4 Drive is in torque 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 Suggested Solutions 4 Verify that motor is not jammed Increase TQ LIMIT setting if it is set too low 5 Apply AC line voltage to ACI and AC2 or
17. follows 32 Calibration MINIMUM SPEED MIN SPD The MIN SPD setting determines the motor speed when the speed adjust potentiometer is turned full CCW It is factory set to zero speed To calibrate set the reference potentiometer or reference signal to zero To set the minimum speed to zero rotate the MIN SPD trimpot CCW until the motor has stopped To set a minimum speed higher than zero rotate the MIN SPD trimpot CW until the motor is running at the desired minimum speed MAXIMUM SPEED MAX SPD The MAX SPD setting determines the motor speed when the speed adjust potentiometer is turned full CW It is factory set for maximum rated speed To calibrate set the MAX SPD trimpot full CCW Set the reference potentiometer or reference signal to maximum Adjust the MAX SPD trimpot until the desired maximum motor speed is reached NOTE Check the MIN SPD and MAX SPD adjustments after recalibrating to verify that the motor runs at the desired minimum and maximum speed Calibration 33 ACCELERATION ACCEL The ACCEL setting determines the time the motor takes to ramp to a higher speed See Specifications page 1 for approximate acceleration times The ACCEL setting is factory set to its minimum value full CCW 1 Set the speed adjust potentiometer or input signal to zero speed Set the speed adjust potentiometer or input signal to maximum speed Measure the time the motor takes to reach the set speed Turn the
18. g header sockets on the motherboard Fasten the header pins into the header sockets until secure The docking pins will lock the plug in card into place when the header pins are correctly mounted into the header sockets Installation 9 HEADER PINS EN DOCKING DOCKING HEADER SOCKETS DOCKING Y PIN xd 0 DOCKING HEADER pod T Im 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 Minar
19. g methods 27 To Brake the seo x doe d ERG CREE YU EK Eee s 27 To coast the motor to a stop without disconnecting power 27 Line starting and line stopping 28 Calibration 29 Calibration procedure 31 MINIMUM SPEED MIN SPD 32 MAXIMUM SPEED MAX SPD 32 ACCELERATION ACCEL o ex 33 DECELERATION DECEL 33 REGULATION SERIE vete 34 TORQUE LIMIT TQ LIMIT sis ERI RR ERR ie 35 Troubleshooting 36 Before troubleshooting 36 BOSS 1Q Diagnostic LEDs 37 Diagnostic LEDs on the BOSS 1Q plug in 37 Ra HEAR eek 37 FAULT 2 2 pod ta Em Rat 37 Diagnostic LEDs on the motherboard 37 BUS LIMIT 37 oreet pter or RUP RETE E dise d eerte 37 Unconditional Warranty 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 11 Figure 12 Figure 13 BOSS Series Dimensions 2 BOSS DB Regen Dump Circuit Dimensions 3 Plug I
20. ik part number 160 0126 connects to the header block as shown in Figure 5 To use the quick connect terminal block 1 Carefully pull terminal plug from header block 2 With a small flat head screwdriver turn terminal plug screw counterclockwise to open wire clamp 3 Insert stripped wire into the large opening in front of the plug 4 the terminal plug screw clockwise to clamp the wire 5 Repeat steps 2 4 for each terminal until all connections are made 6 Insert plug into header block until securely fastened Header Block 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 and AC2 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
21. ing ungrounded 0 to 10 VDC reference or 10K ohm speed adjust potentiometer wiper POT terminal 7 Floating 10 VDC reference used on future drives Make no connections to this terminal HALL C B A terminals 8 9 and 10 Inputs for motor hall sensors 5 VDC Vref terminal 11 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 1Q terminal connections 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 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 Close the switch to coast the motor to a stop Open the switch to accelerate to set speed RUN BRAKE switch Connect a single pole single throw switch between the COM and RUN BRAKE terminals terminals 1 and 3 of TB501 as shown in Figure 9 Open the switch to brake the motor to a stop Close the switch to accelerate to set speed FWD REV switch Conne
22. mmends shielding all 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 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 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 terminal or DC voltage input terminal VDC whichever is used 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 7 Model Line Fuse Size Series AC Amps 5504 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 correspondin
23. n Card Installation 9 Speed Adjust Potentiometer Mounting 10 Quick Connect Terminal Plug 11 Motherboard Connections for DC input voltage and b AC input voltage 14 Motherboard Connections for Three Phase 15 Regen Dump Circuit Connections 17 BOSS 1Q Terminal Connections 21 BOSS 1Q Sensor Connections 23 BOSS 1Q Voltage Signal Connections 24 BOSS 1Q Calibration Trimpot Layout 30 BOSS 1Q Diagnostic LED Location 38 Tables Table 1 Recommended Line Fuse Sizes 7 Notes Specifications Maximum AC DC Maximum Phase Current Line Input Output Voltage Drive AC Amps Voltage Range Voltage Range VAC BOSS04 115AC 1Q 4 90 130 100 180 130 BOSS08 115AC 1Q 8 90 130 100 180 130 BOSS15 115AC 1Q 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 Range 0 5 6 seconds Deceleration Time Range 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 sign
24. ngs before making any connections Ecc pe ROM eet A RP WEE BP Qr T QT E IU A 1 1 1 i i MOTOR MOTOR MOTOR 1 PHASE PHASE B PHASE C i PHASE 1 PHASE 2 PHASE 3 1 1 511 512 513 C505 C507 C506 C501 C502 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 and AC2 terminals as shown in Figure 8 Connect the positive lead from the DC power source to the ACI terminal on the BOSS drive motherboard Connect the negative or COM lead from the DC power source to the
25. onnections 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 closed drive is disabled 5 The drive reaches maximum bus voltage limit 6 Sensor draws too much current for BOSS drive to supply Troubleshooting 43 Suggested Solutions 1 Check hall sensor wiring 2 Check that motor is properly sized for load check that TQ LIMIT trimpot is 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 6 Check sensor wiring If sensor needs more than 20 mADC connect sensor to external power supply 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 Avenue Glendale CA 91201 2011 USA This warranty applies only to standard catalog products and doe
26. oreign 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 Troubleshooting 37 BOSS 1Q Diagnostic LEDs Diagnostic LEDs on the BOSS 1Q plug in card POWER ON The POWER ON LED lights when power is applied to the drive and the plug in card is connected properly FAULT The FAULT LED lights in any of the following conditions 1 hall sensors miswired not operating properly not properly nulled or draw current in excess of 20 mA 2 drive reaches its peak phase current limit 3 drive has insufficient or DC power 4 The enable switch is closed drive is disabled Diagnostic LEDs on the motherboard BUS LIMIT The red BUS LIMIT LED lights when the drive exceeds maximum bus voltage This applies when the drive is in the regenerative mode future drives TQ LIMIT The red TQ LIMIT LED lights when the drive output current reaches the maximum phase current limit 38 Troubleshooting TORQUE BUS POWER LIMIT FAULT LIMIT ON FAULT POWEI ON Figure 13 BOSS 1Q Diagnostic LED Location External line fuse blows Ext
27. rrent protection thermal protection and enclosure Follow sound maintenance procedures Although the drive includes protective circuitry to prevent damage in the event of an accidental short circuit of the armature it is 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 approved personal protective equipment and 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 Contents Specifications 1 Dimensions 2 Installation 4 Drive MOUNTING
28. s 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 warranty does not void the warranty nor does it imply an extension of the original 12 month warranty p
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