User Manual - Galco Industrial Electronics
Contents
1. 1750 RPM 10050 1750 TORQUE IRCoMP 10 AMPS TORQUE IRCOMP 10 AMPS 3 4 HP 11 2 HP Q 90 VDC 180 VDC Cay 1750 RPM x f x f 1750 RPM TORQUE IRCOMP 7 5 AMPS TORQUE IRCOMP 7 5 ALL OTHER PCM20000 SERIES DRIVES 1HP 2HP 90 VDC 180 VDC 1750 RPM 1750 RPM TORQUE IRCoMP 10 AMPS TORQUE IRCoMP 10 AMPS 3 4 HP 1 1 2 HP 90 VDC 180 VDC lxx 1750 RPM lxx 1750 RPM TORQUE IRCOMP 7 5 AMPS TORQUE IRCOMP 7 5 AMPS 1 2 HP 1HP 99 1750 RPM IE 1750 RPM TORQUE IRcomp AMPS TORQUE IRcomp 1 3 HP 3 4 HP 90 VDC 180 VDC xx 1750 RPM Coy 1750 RPM TORQUE IRCOMP 3 5 AMPS TORQUE IRCOMP 3 5 AMPS 1 4 HP 1 2 HP 90 VDC 180 VDC Cory ory 1750 RPM x f xx 0 1750 RPM TORQUE IRCOMP 2 5 AMPS TORQUE IRCOMP 2 5 AMPS NOTE TORQUE settings may be substituted for CURRENT LIMIT on PCM2x000C series controls Figure 13 Typical TORQUE and IR COMP settings actual settings may vary with each application 30 Application Notes Independent Adjustable Speeds Connect two speed adjust potentiometers with a single pole two position switch to select between two independent speeds shown in the forward direction Figure 14 The speed adjust potentiometers can be mounted at two separate operating stations 20K OHMS SPEED2 Figure 14 Independent Adjustable Speeds Forward Direction 31 Multiple fixed speeds Replace the speed adjust poten2. 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 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
3. The OEM may choose to provide alternative filtering that encompasses the Minarik drive and other electronics within the same panel The OEM has this liberty because CE is a machinery directive Whether or not every component in the OEM s machinery meets CE the OEM must still submit his machine for CE approval Thus no component must necessarily meet CE within the machine as long as the OEM takes the necessary steps to guarantee the machine does meet CE By the same token even if every component in the OEM s machine does meet CE the machine will not necessarily meet CE as a machine Using CE approved wiring practices like proper shielding and the filters listed in Exhibit A guarantee the drive will meet EN55011 1991 emissions standard and EN50082 1 1992 immunity standard 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 from date of shipment thereof Within this warranty period the Corporation will repair or replace such products that are returned to Minarik Corporation 901 East Thompson Avenue Glendale CA 91201 2011 USA This warranty shall not apply to any product that has been repaired by unauthorized persons The Corporation is not responsible for removal installation or any other incidental expenses incurred in shipping the product to and from the repair point
4. SPEED MAX SPD NOTE This adjustment is not functional when operating in SIGNAL mode The MAX SPD setting determines the maximum motor speed when the speed adjust potentiometer is turned full CW It is factory set to its maximum setting To calibrate MAX SPD Ensure that no power is applied to the drive Set jumper SO501 to MANUAL mode Apply line voltage Set the MAX trimpot full CCW Turn the speed adjust potentiometer full CW Adjust the MAX SPD trimpot until the desired maximum motor speed is reached Qu plc Calibration 27 TORQUE CURR LIMIT on PCM2000C series drives Warning Although TORQUE CURR LIMIT is set to 12096 of motor nameplate current rating continuous operation beyond that rating may damage the motor If you intend to operate beyond the rating contact your Minarik representative for assistance The TORQUE CURR LIMIT on PCM2000C series setting determines the maximum armature current output of the drive It 15 factory set at 12096 of maximum drive current TORQUE CURR LIMIT must be recalibrated if you use a lower horsepower motor To calibrate TORQUE CURR LIMIT use the following procedure 1 With no power applied to the drive connect a DC ammeter in series with the motor armature 2 Setthe TORQUE CURR 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 potenti
5. TORQUE setting CURR LIMIT on PCM2x000C series drives is sufficient for your application Increase the setting if it is too low Motor runs at full speed at all times If in the MANUAL mode the speed adjust pot or leads from the pot to the control may be open Troubleshooting 39 Replacement Parts Replacement parts are available from Minarik Corporation and its distributors for this drive series Table 2 Replacement Parts Model No Symbol Description Minarik P N PCM21000A C501 502 220 uF 35 VDC Capacitor 011 0027 D501 502 Schottky Diode 071 0017 5 501 502 S8020L High power SCR 072 0043 T501 ST 3 3109 115VAC Transformer 230 0083 T502 Transformer 230 0077 Chassis 222 0079 10K Ohm Pot Kit 202 0031 1 5A Fuse Kit 050 0066 5 15A Fuse Kit 050 0071 PCM21000C Same as PCM21000A except C501 502 100 uF 25 VDC Capacitor 011 0079 D504 505 Schottky Diode 071 0017 MOV501 502 2725V RMS 4500A MOV 075 0011 R501 0 01 Ohm 5W Standup Resistor 032 0129 PCM21010A Same as PCM21000A PCM22000A Same as PCM21000A PCM22000C Same as PCM21000C 40 Troubleshooting 1 5A Fuse Kit Contains 1 Amp 3AG Fast blo Fuse 1 5 Amp 3AG Fast blo Fuse 3 Amp 3AG Fast blo Fuse 5 Amp Fast blo Fuse 5 15A Fuse Kit Contains 5 Amp Fast blo Fuse 8 Amp 3AG Fast blo Fuse 10 Amp 3AG Normal blo Fuse 15 Amp 3AG Normal blo Fuse Potentiometer Kit Contains 10K Ohm 596 1 4W Potentiometer 3 8 32 X 1 2 Nut 3 8 Int Tooth Lockwasher 9 ea
6. 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 speed as a result of a component failure Minarik strongly recommends the installation of a master switch in the main power input to stop the drive in an emergency Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Use a non metallic screwdriver for adjusting the calibration trimpots Use approved personal protective equipment and insulated tools if working on this drive with power applied Contents Specifications Dimensions 2 Installation MOUNTING 5o ED RESI heer ee hte RITE 4 a Tn rhe nb petenti nim ete Ne Ee ipee ia pene gue 5 Shielding guidelities s x MER E RUE 6 Heat SINKING 3 15 eis s Gilad eee cien Qi e mere ns ob iy dia du 7 rer et t dise Reb pcr Bu iie Sey Bee aed 7 Speed adjust 9 Connections zo ax nat ERES 10 Power fuse and motor connections 10 ee 10 Power ote esr ru mpra EU 11 LING fus euet E ERAS ER UE ru Eire ees oe ents 11 Voltage signal follower PCM
7. that the motor is receiving AC power Check fuses and circuit breakers Verify that the main power switch is on Check whether the speed adjust pot is turned fully CCW MANUAL mode or the input signal is at zero 2 The speed adjust pot may be open or the signal input leads may be open 3 Check whether the motor or its load is mechanically jammed Remove the cause of the jam NOTE If an application requires more torque than is allowed by the TORQUE trimpot setting the control will go to current limit under maximum loading conditions Assuming that the motor is properly sized it then will be necessary to reset TORQUE slightly CW until the stalled condition is removed Fuses or circuit breakers blow 1 Check all wiring for shorts grounds and misconnections to the control and motor 2 Check that the motor ratings are within the ratings of the control 38 Troubleshooting Motor will not stop at zero speed setting The MIN SPEED adjustment is set too high Motor runs in reverse Disconnect AC power Reverse the armature connections Restore power to the control Motor slows under increased load The IR COMP adjustment may be set too low Increase the setting until the speed remains acceptably constant over the load range Motor speed is unstable under load The IR COMP adjustment may be set too high Decrease it until the symptom disappears The motor may be bouncing in and out of current limit Verify that the
8. 2x000A 14 Voltage signal follower PCM2x000C 15 Current signal follower PCM2x000C 16 Operation 17 B lore applying POWe 2 add Mee XR RACER UR ea RA i 17 Sat 20 Starting and stopping methods 21 Line starting and line stopping 21 Becelerete SOD eee her Xue dec dace qna 22 Calibration 23 Calibration procedure 24 Before applying Power cuc EY CF EEG 24 SIGNAL ADJUST SIG ADJ 25 MINIMUM SPEED MIN SPD 26 MAXIMUM SPEED 5 26 Table of Contents iii TORQUE CURRENT LIMIT on PCM2000C series drives 27 REGULATION IR GOMP mre Ea ERI Exe y Re Exe EXE 28 Application Notes 30 Independent Adjustable Speeds 30 Multipletixed speeds P e ex eta RR a cp hee 31 Adjustable speeds using potentiometers in series 32 tae ek RE EIQUE 33 Troubleshooting 34 Before troubleshooting dee 34 Diagnostic LEDs PCM20000C series only 35 POWER GREEN uL E Pant 22 35 SI
9. 30 8 25 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 2 Heat Sink Kit Dimensions 4 Installation 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 Mounting Drive components are sensitive to electrostatic fields Avoid direct contact with the circuit board Hold 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 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 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 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 or 230 VAC above ground T
10. Automation PCM20000 Models PCM21000A PCM21000C PCM21010A PCM22000A PCM22000C J 0 lt 2 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 AZARD 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 a qualified electrical technician install adjust and service this equipment Follow the National Electrical Code and all other applicable electrical and safety codes including the provisions of the Occupational Safety and Health Act OSHA when installing equipment Reduce the chance of an electrical fire shock
11. D MIN SPD TORQUE IR COP _ o 2 2 Q Z 2 Q C U Z 2 gt gt gt C gt SPEED ADJ POT CONFIGURATION VOLTAGE FOLLOWER CONFIGURATION MANUAL MODE SIGNAL MODE Figure 9 PCM2x000A Jumper Locations and Settings 19 19 16502 150 50502 INPUT 50501 SELECT CONTROL JUMPER SELECT JUMPER C505 D504 SO501 Jes T502 MAN dc i um SIGNAL N N e e ui 9 8 lt 2 MANUAL INPUT SIGNAL MANUAL INPUT SIGNAL 5 ooo 5 0501 0501 SPEED ADJUST POTENTIOMETER VOLTAGE FOLLOWER CONFIGURATION CONFIGURATION MANUAL MODE SIGNAL MODE 8 lt 3 MANUAL INPUT SIGNAL B 0501 CURRENT FOLLOWER CONFIGURATION SIGNAL MODE Figure 10 PCM2x000C Jumper Locations and Settings 20 Operation Startup To start the drive Turn the speed adjust potentiometer full counterclockwise CCW If the drive is following a voltage or current signal set the signal to zero Apply AC line voltage 3 Slowly advance the speed adjust potentiometer clockwise CW or slowly increase the reference signal The motor slowly accelerates as the potentiometer is turned CW or the signal is increased Continue until the desired speed is reached 4 Setthe speed adjust potentiometer to zero remove AC line voltage or set the input signal to zero The drive will coast to a stop If the motor or drive does not perform as described disconnect t
12. GNAL YELLOW ee cde ete gen a eu dae d 35 CURRENT LIMIT CURR RED 35 Replacement PANS 2 aera ice eer Ae One be OER 39 Certificate of Compliance 41 End User BesporisiBlliligS ounces des E Race ERG EE OE RE ee od 41 AS i 42 Unconditional Warranty inside back cover iv Illustrations Figure 1 PCM2x000A and PCM2x000C Dimensions 2 Figure 2 Heat Sink Kit 3 Figure Speed Adjust Potentiometer Installation 9 Figure 4 PCM2x000A Drive Connections 12 Figure 5 PCM2x000C Drive Connections 13 Figure 6 PCM2x000A Voltage Follower Connections 14 Figure 7 PCM2x000C Voltage Follower Connections 15 Figure 8 Current Follower Connections PCM2x000C only 16 Figure 9 PCM2x000A Jumper Locations and Settings 18 Figure 10 PCM2x000C Jumper Locations and Settings 19 Figure 11 Run Decelerate to Zero Speed Switch 22 Figure 12 Calibration Trimpot Layout 23 Figure 13 Typical TORQUE and IR COMP settings 29 Figure 14 Independent Adjustable Speeds Forward Direction 30 Figure 15 Multiple Fixed Speeds 31 Figure 16 Adjustable Fi
13. Non insulated Female Tabs 050 0042 050 0026 050 0021 050 0022 050 0022 050 0059 050 0024 050 0018 120 0009 151 0007 152 0007 163 0028 41 Certificate of Compliance Minarik Corporation hereby certifies that its PCM20000 series drives have been approved to bear the mark provided the conditions of approval listed in Exhibit have been met by the end user The PCM20000 series has been tested to the following test specifications EN55011 1991 emissions and EN50082 1 1992 immunity Compliance allows Minarik s PCM20000 series to bear the CE mark End User Responsibilities 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 42 Certificate of Compliance Exhibit In addition to EMI RFI safeguards inherent in the PCM20000 series design external filtering is required Minarik requires the Corcom filters listed in Table 3 If the exact filter is not available use a filter matching the following specifications L 1 73 0 03 milliHenries C 0 27 0 54 microFarads X 0 0055 microFarads Y R 330Kohms Rated current 1 4 times maximum DC motor current Filter type Balanced 2 section Table 3 Corcom Fi
14. PCM20000C series drives REGULATION IR COMP Calibration 25 SIGNAL ADJUST SIG ADJ NOTE This adjustment is not functional when operating in MANUAL mode Calibration for PCM21000x drives The SIG ADJ setting determines the speed that the motor will achieve when the input voltage or current signal is at its maximum level It is factory set to deliver a 90 VDC armature output with a 10 VDC input signal PCM22000x series drives calibrated to deliver a 180 VDC armature output with a 10 VDC input signal To calibrate SIG ADJ Ensure that no power is applied to the drive Set jumper 0501 to SIGNAL mode If using a PCM2x000C series drive set 50502 to 0 10V Apply line voltage hi ix SUA iS des Apply the maximum voltage or current signal 6 Rotate SIG ADJ until the desired motor speed is reached If the drive is operated as a voltage follower the signal required for rated output voltage must be at least 5 VDC but no greater than 20 VDC 7 Setthe voltage signal to zero 26 Calibration MINIMUM SPEED MIN SPD The MIN SPD setting determines the minimum speed when the speed adjust potentiometer is turned full CCW or when the signal input is set to its minimum value It is factory set to zero speed To calibrate MIN SPD 1 Set the speed adjust potentiometer full CCW or set the signal input to its minimum value 2 Adjust the MIN SPD trimpot until the motor turns at the desired minimum speed MAXIMUM
15. PLL velocity controllers must be separated from power lines in the same manner as the logic I O on this drive Installation 7 Heat sinking PCM2x000 series drives require an additional heat sink when the continuous armature current is above 5 ADC Use Minarik part number 223 0159 other chassis drives have sufficient heat sinking in their basic configurations Apply a thermally conductive heat sink compound such as Dow Corning 340 Heat Sink Compound between the drive chassis and heat sink surface for optimum heat transfer Line fusing Minarik drives require an external fuse for protection Use fast acting fuses rated for 250 VAC or higher and approximately 150 of the maximum armature current Fuse both L1 and L2 when the line voltage is 230 VAC Fuse blocks are included on cased drives only Table 1 page 8 lists the recommended replacement line fuse sizes 8 Installation Table 1 Line Fusing Chart 90 VDC Motor 180 VDC Armature AC Line Fuse Horsepower Horsepower Current amps Size amps 1 20 1 10 0 5 1 1 15 1 8 0 8 1 5 1 8 1 4 1 5 3 1 6 1 3 1 7 3 1 4 1 2 2 5 5 1 3 3 4 3 5 8 1 2 1 5 0 10 3 4 1 1 2 7 5 15 1 2 10 15 Minarik Corporation offers two fuse kits part number 050 0066 1 5 Fuse Kit and 050 0071 5 15 Fuse Kit Installation 9 Speed adjust potentiometer A Warning Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure Grounding
16. TE TO MINIMUM SPEED Figure 11 Run Decelerate to Zero Speed Switch 23 Calibration A Warning Floating voltages exist on the drive when it is powered 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 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 horsepower motors All adjustments increase with CW rotation and decrease with CCW rotation 501 A1 T502 i SIG ADJ MAX SPD MIN SPD TORQUE IR Figure 12 Calibration Trimpot Layout 24 Calibration Calibration procedure Before applying power 1 Verify that no conductive material is present on the printed circuit board Ensure that all jumpers are properly set 3 Setall trimpots except TORQUE CURR LIMIT on 20000 series drives to full counterclockwise CCW 4 Setthe TORQUE CURR LIMIT on PCM20000C series drives trimpot full clockwise CW 5 Setthe speed adjust potentiometer or reference input signal to zero 6 Apply line power to the drive 7 Calibrate the trimpots in the following order SIGNAL ADJUST SIG ADJ MINIMUM SPEED MIN SPD MAXIMUM SPEED MAX SPD TORQUE CURR LIMIT on
17. al follower PCM2x000C only A Warning Before applying power ensure that 50501 is set to SIGNAL and 0502 is set to 4 20 mA as shown in Figure 8 Instead of using a speed adjust potentiometer the drive may be wired to follow a 4 20 mADC signal Figure 8 Connect the signal input to POS Connect the signal common to NEG 0 10 V 4 20mA 0502 INPUT SELECT JUMPER 0501 ale CONTROL 55 SELECT 394 JUMPER SIGNAL INPUT 4 20mADC Figure 8 Current Follower Connections PCM2x000C only 17 Operation A Warning Floating voltages exist on the drive when it is powered BE ALERT High voltages can cause serious or fatal injury For your safety use personal protective equipment PPE when operating this drive Do not change jumper settings with power applied Failure to follow these instructions may result in damage to the motor or drive or serious injury to personnel Before applying power Ensure that all jumpers are properly set prior to applying power See Figure 9 page 18 for PCM2x000A jumper location and settings See Figure 10 page 19 for PCM2x000C jumper locations and settings Verify that no conductive material is present on the printed circuit board 18 Operation L L L L L J ISU I amp T502 E O ay SO501 CONTROL SELECT JUMPER YNOS SOd SIG ADJ MAX SP
18. 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 E Automation 901 E Thompson Avenue Glendale CA 91201 2011 Tel 1 800 MINARIK 646 2745 Fax 1 800 394 6334 www minarikcorp com Document number 250 0090 Revision 5 Printed in the U S A 1 01 North America 12 00 Outside North America 15 00
19. eck the following steps before proceeding The AC line voltage must be balanced and match the voltage on the drive nameplate The motor must be rated for the drive s rated armature outputs Terminal block connections should be consistent with the connections shown in this manual For additional assistance contact your local Minarik distributor or the factory direct at 800 MINARIK 646 2745 phone or 800 394 6334 fax Troubleshooting 35 Diagnostic LEDs PCM20000C series only PCM2x000C series drives are equipped with three diagnostic LEDs to aid in system evaluation and troubleshooting See Figure 18 page 40 for LED location POWER GREEN The green POWER LED lights when AC line voltage is applied to the drive The POWER LED is extinguished when power is disconnected SIGNAL YELLOW The yellow SIGNAL LED lights when power is applied and a voltage current or manual signal is sent to the drive The SIGNAL LED is extinguished when no signal is applied CURR LIM RED The red CURR LIM LED lights when the current required to drive the motor is greater than is allowed by the CURR LIMIT trimpot If the CURR LIM LED lights shut down the drive and remove or reduce the load on the motor Restart the drive and check the TORQUE trimpot setting 36 Troubleshooting CURRENT LIMIT Figure 18 Diagnostic LED Location PCM 20000C Series Only Troubleshooting 37 Motor does not run 1 Check
20. erminals A1 and A2 as shown in Figure 4 Ensure that the motor voltage rating is consistent with the drive s output voltage Installation 11 Minarik drives supply motor voltage from A1 and A2 terminals It is assumed throughout this manual that when A1 is positive with respect to A2 the motor will rotate clockwise CW while looking at the output shaft protruding from the front of the motor If this is opposite of the desired rotation simply reverse the wiring of A1 and A2 with each other Power input A Warning Minarik strongly recommends the installation of a master power switch in the voltage input line as shown in Figure 4 The switch contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts Connect the AC line power leads to terminals L1 and L2 or to a double throw single pole master power switch recommended Line fuse Wire an external line fuse between the stop switch if installed and the L1 terminal on terminal board TB501 An additional line fuse should be installed on L2 if the input voltage is 230 VAC The line fuse s should be rated at 250 volts and 150 200 of maximum motor nameplate current Refer to the line fuse chart on page 8 for fuse ratings 12 Installation 115 230 LINE VOLTAGE m ws MAX SPD MINSPD TORQUE IR COMP CW SPEED ADJUST POTENTIOMETER 10K OHMS Figure 4 PCM2x000A Drive Connections Instal
21. he AC line voltage immediately Refer to the Troubleshooting section for further assistance Operation 21 Starting and stopping methods A Warning Decelerating to minimum speed dynamic 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 line power both L1 and L2 is the only acceptable method for emergency stopping For this reason Minarik strongly recommends installing an emergency stop switch on both the L1 and L2 inputs see Connections on pages 13 and 14 Line starting and line stopping Line starting and line stopping applying and removing AC line voltage is recommended for infrequent 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 Minarik strongly recommends installing an emergency stop switch on both the L1 and L2 inputs see Connections on pages 12 and 13 22 Operation Decelerate to a stop The RUN STOP switch shown in Figure 11 may be used to decelerate a motor to a stop Closing the switch between S2 and S1 decelerates the motor from set speed to a stop Opening the switch will cause the motor to accelerate to set speed SPEED ADJUST POT 10K OHMS RUN DECEL SWITCH CLOSE TO DECELERA
22. lation 13 SCR502 ma I COQOG C502 x O C FUSE D504 Qu MAN RS SPEED ADJUST POTENTIOMETER 10K OHMS 115 230 VAC LINE VOLTAGE Figure 5 PCM2x000C Drive Connections 14 Installation Voltage signal follower PCM2x000A A Warning Before applying power ensure that SO501 is set to SIGNAL as shown in Figure 6 Instead of using a speed adjust potentiometer the drive may be wired to follow a 0 10 VDC grounded or ungrounded voltage signal Connect the signal input to POS Connect the signal common to NEG A potentiometer can be used to scale the analog input voltage INNOJS R COMP SIGNAL INPUT 0 10 VDC CONTROL SELECT JUMPER Figure 6 PCM2x000A Voltage Follower Connections Installation 15 Voltage signal follower PCM2x000C A Warning Before applying power ensure that 50501 is set to SIGNAL and 50502 is set to 0 10 V as shown in Figure 7 Instead of using a speed adjust potentiometer the drive may be wired to follow a 0 10 VDC voltage signal Connect the signal input to POS Connect the signal common to NEG A potentiometer can be used to scale the analog input voltage 0502 0 10 V 4 20mA 0502 INPUT SELECT JUMPER CONTROL SELECT JUMPER SIGNAL INPUT 0 10 VDC Figure 7 PCM2x000C Voltage Follower Connections 16 Installation Current sign
23. lters Nameplate Current of Corcom6 Filter Motor Wired to the Drive Part Number 0 to 4 amps 6VV1 4 1 to 13 amps 20VV1 The filters in Table 3 should be wired to the AC line 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 Certificate of Compliance 43 If the end user is using a CE approved motor the correct filter from Table 3 is all that is necessary to meet the EMC directives listed herein If the end user is not using a CE approved motor a second filter Minarik p n CEXXMM on the output must be deployed XX rated current of the filter The CE20MM is a Real Pole Balanced Pi 3 pole filter If the exact filter is not available the specifications are as follows L amp L1 2 0 8 milliHenries C amp Cl 2 0 1 microFarads 400W VDC Rin 0 1 ohm Rout 1 2 ohm Table 4 Minarik Filters Nameplate Current of Minarik Filter Motor Wired to the Drive Part Number 0 to 4 amps CE4MM 4 1 to 13 amps CE20MM The filters in Table 4 must be wired to the DC output of the drive as close to the drive as possible 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 44 Certificate of Compliance The end user must use the filtration listed in Exhibit A to comply with CE
24. o prevent the risk of injury or fatality avoid direct contact with the printed circuit board or with circuit elements Do not disconnect any of the motor leads from the drive unless power is removed or the drive is disabled Opening any one motor lead may destroy the drive Use 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 any electronic device including 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 logic leads is not practical the user should twist all logic leads with themselves to minimize induced noise It may be necessary to earth ground the shielded cable If noise is produced by devices other than the drive ground the shield at the drive end If noise is generated by a device on the drive ground the shield at the end away from the drive Do not ground both ends of the shield If the drive continues to pick up noise after grounding the shield it may be necessary to add AC line filtering devices or to mount the drive in a less noisy environment Logic wires from other input devices such as motion controllers and
25. ometer or reference signal to maximum speed The motor should remain stopped 6 Slowly rotate the TORQUE CURR LIMIT trimpot clockwise CW until the ammeter reads 12096 of maximum motor armature current 28 8 9 Calibration Set the speed adjust potentiometer or reference signal to zero speed Remove power from the drive Remove the lock from the motor shaft 10 Remove the ammeter in series with the motor armature REGULATION IR COMP The IR COMP trimpot setting determines the degree to which motor speed is held constant as the motor load changes It is factory set for optimum motor regulation To calibrate IR COMP exact calibration Turn the IR COMP trimpot full CCW Set the speed adjust potentiometer until the motor runs at midspeed without load for example 900 RPM for an 1800 RPM motor hand held tachometer may be used to measure motor speed Load the motor armature to its full load armature current rating The motor should slow down While keeping the load on the motor rotate the IR COMP trimpot until the motor runs at the speed measured in step 2 Approximate calibration 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 motor speed Calibration 29 PCM20010 SERIES 1HP 2HP 90 VDC 180 VDC
26. the input will cause damage to the drive Mount the speed adjust potentiometer through a 0 38 in 10 mm hole with the hardware provided 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 speed adjust potentiometer wires are longer than 18 in 457 mm use shielded cable Keep speed adjust potentiometer wires separate from power leads L1 L2 Al A2 MOUNT THROUGH A 0 38 IN 10 MM HOLE WASHER SPEED ADJUST POTENTIOMETER INSULATING PANEL DISK POT TAB ASSIGNMENTS Figure 3 Speed Adjust Potentiometer Installation 10 Installation Connections A Warning Do not 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 as shown in Figure 4 page 13 or Figure 5 page 14 The switch contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts Power fuse and motor connections If you use a PCM2x000A series drive connect the power input leads an external line fuse and a DC motor to the drive s printed circuit board PCB as shown in Figure 4 page 13 If you use a PCM2x000C series drive refer to Figure 5 page 14 Motor Connect a DC motor to PCB t
27. tiometer with series resistors with a total series resistance of 10K ohms Figure 15 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds R2 Total Series Resistance ohms Figure 15 Multiple Fixed Speeds 32 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 16 shows a connection for fixed high and low speed adjust potentiometers CW High 3 Speed 5K ohm 92 S1 5K ohm Figure 16 Adjustable Fixed Speeds Using Potentiometers in Series 33 RUN JOG switch Connect a RUN JOG switch and the JOG pushbutton as shown is Figure 17 When the RUN JOG switch is set to JOG the motor decelerates to minimum speed minimum speed is determined by the MIN SPD trimpot setting Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation SPEED ADJUST POTENTIOMETER 10K ohm JOG PUSHBUTTON Figure 17 RUN JOG Switch Connection to Speed Adjust Potentiometer 34 Troubleshooting Warning Floating voltages exist on the drive when it is powered When possible disconnect the drive while troubleshooting High voltages can cause serious or fatal injury Before troubleshooting Ch
28. xed Speeds Using Potentiometers in Series 32 Figure 17 RUN JOG Switch Connection to Speed Adjust Potentiometer 33 Figure 18 Diagnostic LED Location PCM 20000C Series Only 36 Tables Table 1 Table 2 Table 3 Table 4 Ling Fusing dr 8 Replacement Paris ccs doa ei e poatea Rr aor 39 Corcom Filters Lt ali oboe eod 42 Minarik Fillets fo s s T ER Ghee fad 43 Specifications Model PCM21000 21010 PCM22000 Line voltaget 115 VAC 115 VAC 230 VAC Line current max 7A AC 3A AC 7A AC Line current maxtt 14A AC n a 14A AC Armature voltage range 0 90 VDC 0 90 VDC 0 180 VDC Horsepower range 1 4 1 2 hp 1 20 1 8 hp 1 2 1 hp Horsepower rangett 1 4 1 hp n a 1 2 2 hp Armature current max 5 ADC 2 ADC 5 ADC Armature current maxtt 10 ADC n a 10 ADC Input signal range input circuit is isolated Voltage 0 10 VDC Current PCM2x000C series only 4 20 mADC Ambient temperature range 10 C 55 C t Line voltage is 10 50 60 Hz single phase tt When mounted on 223 0159 heat sink kit 2 Dimensions 0 19 5 3 80 1971 T 50 COMP 4 30 109 1 60 41 1 28 33 0 96 24 3 80 97 4 30 109 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 1 PCM2x000A and PCM2x000C Dimensions Dimensions 4 40 112 Ps 33 6 90 175 0
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