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250-0252r6_readers_spreads2.qxd 2:02 PM Page a User’s Manual MMX L S e r i e s 5/30/02 Mo d e l s : MMX L 0 2 – D 2 4 0 A C MMX L 0 5 – D 2 4 0 A C MMX L 1 0 – D 2 4 0 A C MMX L 0 2 – D 2 4 0 A C -P C M MMX L 0 5 – D 2 4 0 A C -P C M MMX L 1 0 – D 2 4 0 A C -P C M P uls e -W idt h M odula t e d, A djus t a ble S pe e d D r ive s f or D C B r us h M ot or s 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page b i Safety Warnings Copyright 2002 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. SHOCK HAZARD AVOID HEAT KEE DR OID ATION • This symbol 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, 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. 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. 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page b i Safety Warnings Copyright 2002 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. SHOCK HAZARD AVOID HEAT KEE DR OID ATION • This symbol 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, 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. 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. 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page ii Contents ii iii Contents Safety Warnings i Inhibit plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Specifications 1 Decelerating to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Dimensions 2 Installation 4 Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 RUN/BRAKE switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Dynamic brake resistor sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Calibration 23 Calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 ACCELERATION (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 DECELERATION (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 REGULATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Power, fuse and motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Master power switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Line fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Operation 15 Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 CURRENT LIMIT (CURR LIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Application Notes 34 Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . . . .35 Independent adjustable speeds RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 RUN/JOG option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 RUN/JOG option #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Single speed potentiometer control of multiple drives (-PCM models only) Automatic restart upon power restoration . . . . . . . . . . . . . . . . . . . . . . . . .18 Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 . .40 Inhibit terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Reversing with a DIGI-LOK controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page ii Contents ii iii Contents Safety Warnings i Inhibit plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Specifications 1 Decelerating to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Dimensions 2 Installation 4 Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 RUN/BRAKE switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Dynamic brake resistor sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Calibration 23 Calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 ACCELERATION (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 DECELERATION (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 REGULATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Power, fuse and motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Master power switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Line fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Operation 15 Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 CURRENT LIMIT (CURR LIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Application Notes 34 Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . . . .35 Independent adjustable speeds RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 RUN/JOG option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 RUN/JOG option #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Single speed potentiometer control of multiple drives (-PCM models only) Automatic restart upon power restoration . . . . . . . . . . . . . . . . . . . . . . . . .18 Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 . .40 Inhibit terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Reversing with a DIGI-LOK controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 250-0252r6_readers_spreads2.qxd iv 5/30/02 2:02 PM Page iv Contents v Troubleshooting 43 Illustrations Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 CURRENT LIMIT (CL/FLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Certificate of Compliance CE Certification 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Unconditional Warranty inside back cover Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 1. MMXL Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 2. MMXL10 Drive Dimensions With Heat Sink Installed . . . . . . . . . . . . . .3 3. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 4. MMXL Series Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 5. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 6. Inhibit Terminal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 7. Run/Decelerate to Minimum Speed Switch . . . . . . . . . . . . . . . . . . . . .20 8. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 9. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 10. Approximate CURRENT LIMIT and IR COMP Settings for 120 VAC in, 90 VDC out (actual settings may vary) . . . . . . . . . . .30 11. Approximate CURRENT LIMIT and IR COMP Settings for 120 VAC in, 130 VDC out (actual settings may vary) . . . . . . . . . .31 12. Approximate CURRENT LIMIT and IR COMP Settings for 240 VAC in, 180 VDC out (actual settings may vary) . . . . . . . . . .32 13. Approximate CURRENT LIMIT and IR COMP Settings for 240 VAC in, 240 VDC out (actual settings may vary) . . . . . . . . . .33 14. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 15. Adjustable Speeds Using Potentiometers In Series . . . . . . . . . . . . . .35 16. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 17. RUN/JOG Option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 18. RUN/JOG Option #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 19. Leader-Follower Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 20. Single Speed Potentiometer Control of Multiple MMXL-PCM Series Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 21. Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 22. Reversing with a DLC600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 23. Diagnostic LED locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 24. MMXL CE Filter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 250-0252r6_readers_spreads2.qxd iv 5/30/02 2:02 PM Page iv Contents v Troubleshooting 43 Illustrations Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 CURRENT LIMIT (CL/FLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Certificate of Compliance CE Certification 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Unconditional Warranty inside back cover Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 1. MMXL Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 2. MMXL10 Drive Dimensions With Heat Sink Installed . . . . . . . . . . . . . .3 3. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 4. MMXL Series Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 5. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 6. Inhibit Terminal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 7. Run/Decelerate to Minimum Speed Switch . . . . . . . . . . . . . . . . . . . . .20 8. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 9. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 10. Approximate CURRENT LIMIT and IR COMP Settings for 120 VAC in, 90 VDC out (actual settings may vary) . . . . . . . . . . .30 11. Approximate CURRENT LIMIT and IR COMP Settings for 120 VAC in, 130 VDC out (actual settings may vary) . . . . . . . . . .31 12. Approximate CURRENT LIMIT and IR COMP Settings for 240 VAC in, 180 VDC out (actual settings may vary) . . . . . . . . . .32 13. Approximate CURRENT LIMIT and IR COMP Settings for 240 VAC in, 240 VDC out (actual settings may vary) . . . . . . . . . .33 14. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 15. Adjustable Speeds Using Potentiometers In Series . . . . . . . . . . . . . .35 16. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 17. RUN/JOG Option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 18. RUN/JOG Option #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 19. Leader-Follower Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 20. Single Speed Potentiometer Control of Multiple MMXL-PCM Series Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 21. Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 22. Reversing with a DLC600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 23. Diagnostic LED locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 24. MMXL CE Filter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page vi vi 1 Tables Table Table Table Table Table 1. 2. 3. 4. 5. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Inhibit Plug Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Dynamic Brake Resistor Part Numbers . . . . . . . . . . . . . . . . . . . . . . . .22 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Specifications Model MMXL02–D240AC MMXL05–D240AC MMXL10–D240AC† AC Line Voltage 120 OR 240 120 OR 240 120 OR 240 Max. Continuous HP Range Armature with 120 Current VAC (Amps DC) Applied 2 1/20 – 1/4 5 1/4 – 1/2 10† 1/2 – 1 HP Range with 240 VAC Applied 1/10 – 1/2 1/2 – 1 1–2 † Requires Minarik heat sink kit p/n 223–0159 above 5 amps AC Line Voltage 120/240 VAC ± 10%, 50/60 Hz, single phase Armature Voltage Range 120 VAC input 0-130 VDC 240 VAC input 0 – 240 VDC Form Factor (at base speed) 1.05 Acceleration/Deceleration Time Range (no load) 0.5 – 6 seconds Analog Input Voltage Range* [S1(–) to S2(+)] 0 – 5 VDC Input Impedance (S1 to S2 with 5 VDC input) approximately 70K ohms Potentiometer Circuit Isolation (-PCM models only) HCPL 7840:2500 VAC Inhibit Circuit Isolation (-PCM models only) HCPL 0453:2500 VAC Speed Regulation 1% base speed or better Ambient Temp. Range (chassis drive) 10°C – 40°C†† †† MMXL 10-D240A C is rated for 10 amps DC max @ 25ºC ambient. Derate to 7 amps DC above 25ºC. * Signal must be isolated on non-PCM drives; -PCM drives can use grounded or isolated voltage signal. Vibration 0.5g max (20 – 50 Hz) 0.1 g max (>50 Hz) Weight MMXL02–D240AC MMXL05–D240AC MMXL10–D240AC 0.66 lb [0.30 kg] 0.72 lb [0.32 kg] 0.82 lb [0.37 kg] 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page vi vi 1 Tables Table Table Table Table Table 1. 2. 3. 4. 5. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Inhibit Plug Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Dynamic Brake Resistor Part Numbers . . . . . . . . . . . . . . . . . . . . . . . .22 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Specifications Model MMXL02–D240AC MMXL05–D240AC MMXL10–D240AC† AC Line Voltage 120 OR 240 120 OR 240 120 OR 240 Max. Continuous HP Range Armature with 120 Current VAC (Amps DC) Applied 2 1/20 – 1/4 5 1/4 – 1/2 10† 1/2 – 1 HP Range with 240 VAC Applied 1/10 – 1/2 1/2 – 1 1–2 † Requires Minarik heat sink kit p/n 223–0159 above 5 amps AC Line Voltage 120/240 VAC ± 10%, 50/60 Hz, single phase Armature Voltage Range 120 VAC input 0-130 VDC 240 VAC input 0 – 240 VDC Form Factor (at base speed) 1.05 Acceleration/Deceleration Time Range (no load) 0.5 – 6 seconds Analog Input Voltage Range* [S1(–) to S2(+)] 0 – 5 VDC Input Impedance (S1 to S2 with 5 VDC input) approximately 70K ohms Potentiometer Circuit Isolation (-PCM models only) HCPL 7840:2500 VAC Inhibit Circuit Isolation (-PCM models only) HCPL 0453:2500 VAC Speed Regulation 1% base speed or better Ambient Temp. Range (chassis drive) 10°C – 40°C†† †† MMXL 10-D240A C is rated for 10 amps DC max @ 25ºC ambient. Derate to 7 amps DC above 25ºC. * Signal must be isolated on non-PCM drives; -PCM drives can use grounded or isolated voltage signal. Vibration 0.5g max (20 – 50 Hz) 0.1 g max (>50 Hz) Weight MMXL02–D240AC MMXL05–D240AC MMXL10–D240AC 0.66 lb [0.30 kg] 0.72 lb [0.32 kg] 0.82 lb [0.37 kg] 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page 2 Dimensions 2 Dimensions 3 6.90 [175] 6.30 [160] 5.90 [150] C505 C503 S3 C504 C502 R501 C502 R501 C504 A1 0.19 [5] T501 S2 S1 C501 4.40 [112] L2 2 Q503 L1 D C501 3.64 [92] 1.75 [44] IL502 IL502 3.70 [94] CURRENT LIMIT TH501 IL501 POWER LIMIT POWER MIN SPD IR COMP DECEL TH501 IL501 0.70 [18] ACCEL CURRENT LIMIT L 0.70 [18] 3.80 [97] 4.30 [109] 4.00 [102] A 0.82 [21] 1.00 [25] 2.10 [53] 0.19 [5] 0.96 [24] 0.13 [3] MODEL DIMENSION “A” HEIGHT MMXL02 MMXL05 MMXL10 2.50 [62] 3.20 [81] 3.90 [99] ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 1. MMXL Dimensions ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 2. MMXL10 Drive Dimensions With Heat Sink Installed 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page 2 Dimensions 2 Dimensions 3 6.90 [175] 6.30 [160] 5.90 [150] C505 C503 S3 C504 C502 R501 C502 R501 C504 A1 0.19 [5] T501 S2 S1 C501 4.40 [112] L2 2 Q503 L1 D C501 3.64 [92] 1.75 [44] IL502 IL502 3.70 [94] CURRENT LIMIT TH501 IL501 POWER LIMIT POWER MIN SPD IR COMP DECEL TH501 IL501 0.70 [18] ACCEL CURRENT LIMIT L 0.70 [18] 3.80 [97] 4.30 [109] 4.00 [102] A 0.82 [21] 1.00 [25] 2.10 [53] 0.19 [5] 0.96 [24] 0.13 [3] MODEL DIMENSION “A” HEIGHT MMXL02 MMXL05 MMXL10 2.50 [62] 3.20 [81] 3.90 [99] ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 1. MMXL Dimensions ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 2. MMXL10 Drive Dimensions With Heat Sink Installed 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page 4 Installation 4 Installation • Mounting 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 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. Wiring Warning Ꮨ 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. 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 or the drive is disabled. Opening any one motor lead may destroy the drive. • Use 16–20 AWG wire for speed adjust potentiometer wiring. Use 14–16 AWG wire for AC line (L1, L2) and motor (A1 and A2) wiring. 5 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page 4 Installation 4 Installation • Mounting 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 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. Wiring Warning Ꮨ 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. 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 or the drive is disabled. Opening any one motor lead may destroy the drive. • Use 16–20 AWG wire for speed adjust potentiometer wiring. Use 14–16 AWG wire for AC line (L1, L2) and motor (A1 and A2) wiring. 5 250-0252r6_readers_spreads2.qxd 6 5/30/02 2:02 PM Page 6 Installation Shielding guidelines 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. 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 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 Model MMXL10-D240AC requires an additional heat sink (Minarik part number 223–0159) when the continuous armature current is above 5 ADC. All 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 Protect all Minarik drives with AC line fuses. Use fast acting AC line fuses rated for 250 volts, and approximately 150% – 200% of the maximum armature current. Fuse only the “hot” side of the AC line (L1) if using 115 VAC line voltage. Do not add line fuses to L1 and L2 unless you use 240 VAC line voltage. See Table 1 on page 8 for recommended line fuse sizes: 250-0252r6_readers_spreads2.qxd 6 5/30/02 2:02 PM Page 6 Installation Shielding guidelines 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. 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 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 Model MMXL10-D240AC requires an additional heat sink (Minarik part number 223–0159) when the continuous armature current is above 5 ADC. All 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 Protect all Minarik drives with AC line fuses. Use fast acting AC line fuses rated for 250 volts, and approximately 150% – 200% of the maximum armature current. Fuse only the “hot” side of the AC line (L1) if using 115 VAC line voltage. Do not add line fuses to L1 and L2 unless you use 240 VAC line voltage. See Table 1 on page 8 for recommended line fuse sizes: 250-0252r6_readers_spreads2.qxd 8 5/30/02 2:02 PM Page 8 Installation Table 1. Recommended Line Fuse Sizes Maximum Armature AC Line Fuse Current (DC Amps) Rating (AC Amps) 1.5 and below 3 2.6 5 3.5 8 5.0 10 7.6 15 10 15 Minarik Corporation offers two fuse kits: part number 050–0069 (3–8A Fuse Kit) and 050–0073 (5–20A Fuse Kit). Refer to Replacement Parts (page 47) for fuse kit contents. Installation 9 Speed adjust potentiometer 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 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, A1, A2). MOUNT THROUGH A 0.38 IN. (10 MM) HOLE CW WIPER W NUT STAR WASHER SPEED ADJUST POTENTIOMETER INSULATING DISK PANEL Figure 3. Speed Adjust Potentiometer 250-0252r6_readers_spreads2.qxd 8 5/30/02 2:02 PM Page 8 Installation Table 1. Recommended Line Fuse Sizes Maximum Armature AC Line Fuse Current (DC Amps) Rating (AC Amps) 1.5 and below 3 2.6 5 3.5 8 5.0 10 7.6 15 10 15 Minarik Corporation offers two fuse kits: part number 050–0069 (3–8A Fuse Kit) and 050–0073 (5–20A Fuse Kit). Refer to Replacement Parts (page 47) for fuse kit contents. Installation 9 Speed adjust potentiometer 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 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, A1, A2). MOUNT THROUGH A 0.38 IN. (10 MM) HOLE CW WIPER W NUT STAR WASHER SPEED ADJUST POTENTIOMETER INSULATING DISK PANEL Figure 3. Speed Adjust Potentiometer 250-0252r6_readers_spreads2.qxd 10 5/30/02 2:02 PM Page 10 Installation Isolation NOTE: Isolation is incorporated in MMXL-PCM drives only. The reference circuit (S1, S2 and S3) is optically isolated from the rest of the drive electronics via HCPL7840. It will accept either a grounded or isolated signal reference. The inhibit input is also optically isolated from the rest of the drive electronics via HCPL0453. It will accept a grounded or isolated bittype open collector (or switch) input. Installation 11 Connections 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). The switch contacts should be rated at a minimum of 200% of motor nameplate current and 250 volts. Power, fuse and motor connections 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. Master power switch Decelerating to minimum speed, regenerative braking, or coasting to a stop 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. The switch contacts must be rated at a minimum of 250 volts and 200% of maximum drive current. 250-0252r6_readers_spreads2.qxd 10 5/30/02 2:02 PM Page 10 Installation Isolation NOTE: Isolation is incorporated in MMXL-PCM drives only. The reference circuit (S1, S2 and S3) is optically isolated from the rest of the drive electronics via HCPL7840. It will accept either a grounded or isolated signal reference. The inhibit input is also optically isolated from the rest of the drive electronics via HCPL0453. It will accept a grounded or isolated bittype open collector (or switch) input. Installation 11 Connections 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). The switch contacts should be rated at a minimum of 200% of motor nameplate current and 250 volts. Power, fuse and motor connections 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. Master power switch Decelerating to minimum speed, regenerative braking, or coasting to a stop 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. The switch contacts must be rated at a minimum of 250 volts and 200% of maximum drive current. Page 12 Installation L2 FUSE * D TH501 IL501 C503 ACCEL DECEL POWER C505 C502 R501 Power input C501 S2 S1 S3 10K OHM SPEED ADJUST POTENTIOMETER INHIBIT CW MIN SPD IR COMP CURRENT LIMIT Line fuse CURRENT LIMIT IL502 C504 Connect the AC line power leads to PCB terminals L1 and L2, or to a double-throw, single-pole master power switch (recommended). Wire an external line fuse between the stop switch (if installed) and the L1 terminal the circuit board. An additional line fuse should be installed on L2 if the input voltage is 230VAC. 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. 13 L1 MOTOR A2 A1 + 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. Connect a DC motor to PCB terminals A1 and A2 as shown in Figure 4. Ensure that the motor voltage rating is consistent with the drive’s output voltage. * NOTE: FUSE L2 ONLY IF LINE VOLTAGE IS 240 VAC. Motor STOP SWITCH Installation Figure 4. MMXL Series Connections 2:02 PM T501 12 5/30/02 120/240 VAC LINE VOLTAGE 250-0252r6_readers_spreads2.qxd Page 12 Installation L2 FUSE * D TH501 IL501 C503 ACCEL DECEL POWER C505 C502 R501 Power input C501 S2 S1 S3 10K OHM SPEED ADJUST POTENTIOMETER INHIBIT CW MIN SPD IR COMP CURRENT LIMIT Line fuse CURRENT LIMIT IL502 C504 Connect the AC line power leads to PCB terminals L1 and L2, or to a double-throw, single-pole master power switch (recommended). Wire an external line fuse between the stop switch (if installed) and the L1 terminal the circuit board. An additional line fuse should be installed on L2 if the input voltage is 230VAC. 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. 13 L1 MOTOR A2 A1 + 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. Connect a DC motor to PCB terminals A1 and A2 as shown in Figure 4. Ensure that the motor voltage rating is consistent with the drive’s output voltage. * NOTE: FUSE L2 ONLY IF LINE VOLTAGE IS 240 VAC. Motor STOP SWITCH Installation Figure 4. MMXL Series Connections 2:02 PM T501 12 5/30/02 120/240 VAC LINE VOLTAGE 250-0252r6_readers_spreads2.qxd 250-0252r6_readers_spreads2.qxd 14 5/30/02 Page 14 2:02 PM 15 I ns ta lla tion V o l ta g e f o l l o w e r O p e r a ti o n I ns te a d of us ing a s pe e d a djus t pote ntiome te r, the drive ma y be wire d to follow a 0 – 5 V D C grounde d* or is ola te d volta ge s igna l ( F igure 5 ) . C onne c t the s igna l re turn ( – ) to S 1 . C onne c t the s igna l high or ( +) to S 2 . Ma k e no c onne c tion to S 3 . A pote ntiome te r c a n be us e d to s c a le the a na log input volta ge . W a r ning D a nge rous volta ge s e x is t on the drive whe n it is powe re d, a nd up to 3 0 s e c onds a fte r powe r is re move d a nd the motor s tops . B E A L E R T. H igh volta ge s c a n c a us e s e rious or fa ta l injury. F or your s a fe ty, us e pe rs ona l prote c tive e quipme nt ( P P E ) whe n ope ra ting this drive . * R e fe rs to MMX L -P C M mode ls only. I f the motor or drive doe s not pe rform a s de s c ribe d, dis c onne c t the A C line volta ge imme dia te ly. R e fe r to the T rouble s hooting s e c tion on pa ge 3 9 for furthe r a s s is ta nc e . 0 - 5 V DC V O L T A G E S IG N A L C 505 C C 502 R E F (+) R 501 C 504 S2 S1 B e fo r e a pply in g po we r C O M (-) C50 1 INHIBIT • IL 5 0 2 C UR R E NT L I MI T P OWE R C U R R E N T L I MI T MA X S P D MI N S P D IR C O MP F i g u r e 5 . V o l ta g e F o l l o w e r C o n n e c ti o n s DE C E L AC C E L T H 50 IL 5 0 V e rify tha t no c onduc tive ma te ria l is pre s e nt on the printe d c irc uit boa rd. 250-0252r6_readers_spreads2.qxd 14 5/30/02 Page 14 2:02 PM 15 I ns ta lla tion V o l ta g e f o l l o w e r O p e r a ti o n I ns te a d of us ing a s pe e d a djus t pote ntiome te r, the drive ma y be wire d to follow a 0 – 5 V D C grounde d* or is ola te d volta ge s igna l ( F igure 5 ) . C onne c t the s igna l re turn ( – ) to S 1 . C onne c t the s igna l high or ( +) to S 2 . Ma k e no c onne c tion to S 3 . A pote ntiome te r c a n be us e d to s c a le the a na log input volta ge . W a r ning D a nge rous volta ge s e x is t on the drive whe n it is powe re d, a nd up to 3 0 s e c onds a fte r powe r is re move d a nd the motor s tops . B E A L E R T. H igh volta ge s c a n c a us e s e rious or fa ta l injury. F or your s a fe ty, us e pe rs ona l prote c tive e quipme nt ( P P E ) whe n ope ra ting this drive . * R e fe rs to MMX L -P C M mode ls only. I f the motor or drive doe s not pe rform a s de s c ribe d, dis c onne c t the A C line volta ge imme dia te ly. R e fe r to the T rouble s hooting s e c tion on pa ge 3 9 for furthe r a s s is ta nc e . 0 - 5 V DC V O L T A G E S IG N A L C 505 C C 502 R E F (+) R 501 C 504 S2 S1 B e fo r e a pply in g po we r C O M (-) C50 1 INHIBIT • IL 5 0 2 C UR R E NT L I MI T P OWE R C U R R E N T L I MI T MA X S P D MI N S P D IR C O MP F i g u r e 5 . V o l ta g e F o l l o w e r C o n n e c ti o n s DE C E L AC C E L T H 50 IL 5 0 V e rify tha t no c onduc tive ma te ria l is pre s e nt on the printe d c irc uit boa rd. 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page 16 Operation 16 Startup 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 signal, 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. 4. Remove AC line voltage from the drive to coast the motor to a stop. Operation 17 Starting and Stopping Methods Warning Decelerating to minimum speed, regenerative braking, or coasting to a stop is recommended for frequent starts and stops. Do not use any of these methods for emergency stopping. They may not stop a drive that is malfunctioning. Removing AC 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 page 13). Frequent decelerating to minimum speed or regenerative braking produces high torque. This may cause damage to motors, especially gearmotors that are not properly sized for the application. 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. 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page 16 Operation 16 Startup 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 signal, 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. 4. Remove AC line voltage from the drive to coast the motor to a stop. Operation 17 Starting and Stopping Methods Warning Decelerating to minimum speed, regenerative braking, or coasting to a stop is recommended for frequent starts and stops. Do not use any of these methods for emergency stopping. They may not stop a drive that is malfunctioning. Removing AC 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 page 13). Frequent decelerating to minimum speed or regenerative braking produces high torque. This may cause damage to motors, especially gearmotors that are not properly sized for the application. 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. 2:02 PM Page 18 Operation Automatic restart upon power restoration All drives automatically run to set speed when power is applied and the drive is enabled. The drive will accelerate at a rate controlled by the ACCEL trimpot. Refer to the Calibration section for information on adjusting this setting. Inhibit terminals Warning Inhibit is used for frequent starts and stops. It must never be used as an emergency stop because it may not stop a drive that is malfunctioning. Removing AC power (L1 and L2) is the only acceptable method for emergency stopping. Jumper the inhibit terminals to coast the motor to a stop (Figure 6). Remove the jumper to accelerate the motor to set speed. Operation 19 Inhibit plug Minarik Corporation offers two accessory plug harnesses for use with the inhibit terminals: Table 2. Inhibit Plug Part Numbers Minarik® Part Number 201-0024 201-0079 Description Inhibit plug with 18-in. (46 cm) wires Inhibit plug with 36-in. (91 cm) wires Twist inhibit plug wires and separate them from other powercarrying wires or sources of electrical noise. Use shielded cable if the inhibit plug wires are longer than 18 inches (46 cm). If shielded cable is used, ground only one end of the shield to earth ground. Do not ground both ends of the shield. INHIBIT TERMINAL C505 C504 C503 C502 T501 S2 S1 IL502 CURRENT Figure 6. Inhibit Terminal Location D Q503 C501 The inhibit terminals on MMXL-PCM model drives are optically isolated from the drive electronics. The user may apply a simple switch closure or an open-collector input, which may be isolated or non-isolated. INHIBIT 18 5/30/02 R501 250-0252r6_readers_spreads2.qxd 2:02 PM Page 18 Operation Automatic restart upon power restoration All drives automatically run to set speed when power is applied and the drive is enabled. The drive will accelerate at a rate controlled by the ACCEL trimpot. Refer to the Calibration section for information on adjusting this setting. Inhibit terminals Warning Inhibit is used for frequent starts and stops. It must never be used as an emergency stop because it may not stop a drive that is malfunctioning. Removing AC power (L1 and L2) is the only acceptable method for emergency stopping. Jumper the inhibit terminals to coast the motor to a stop (Figure 6). Remove the jumper to accelerate the motor to set speed. Operation 19 Inhibit plug Minarik Corporation offers two accessory plug harnesses for use with the inhibit terminals: Table 2. Inhibit Plug Part Numbers Minarik® Part Number 201-0024 201-0079 Description Inhibit plug with 18-in. (46 cm) wires Inhibit plug with 36-in. (91 cm) wires Twist inhibit plug wires and separate them from other powercarrying wires or sources of electrical noise. Use shielded cable if the inhibit plug wires are longer than 18 inches (46 cm). If shielded cable is used, ground only one end of the shield to earth ground. Do not ground both ends of the shield. INHIBIT TERMINAL C505 C504 C503 C502 T501 S2 S1 IL502 CURRENT Figure 6. Inhibit Terminal Location D Q503 C501 The inhibit terminals on MMXL-PCM model drives are optically isolated from the drive electronics. The user may apply a simple switch closure or an open-collector input, which may be isolated or non-isolated. INHIBIT 18 5/30/02 R501 250-0252r6_readers_spreads2.qxd 250-0252r6_readers_spreads2.qxd 20 5/30/02 2:02 PM Page 20 Operation Operation Decelerating to minimum speed Dynamic braking A switch may be used to decelerate the motor to minimum speed. Connect the switch as shown in Figure 7. Close the switch between S1 and S2 to decelerate the motor from set speed. Open the switch to accelerate the motor to set speed. The ACCEL and DECEL trimpot settings determine the rate at which the motor accelerates and decelerates, respectively. CW S3 10K OHM SPEED ADJUST POTENTIOMETER S2 21 S1 RUN DECEL TO MIN SPEED Warning Wait for the motor to come to a complete stop before setting the RUN/BRAKE switch to RUN. This will prevent high armature currents from damaging the motor or drive. Dynamic braking may be used to rapidly stop a motor (see Figure 8 on page 22). For the RUN/BRAKE switch, use a doublepole, double throw switch rated for at least the maximum DC armature voltage and maximum braking current. RUN/BRAKE switch Install a double-pole, double-throw switch between the INHIBIT terminals and a dynamic brake resistor as shown in Figure 8 on page 22. Set the switch to the BRAKE position to dynamically brake the motor to a stop. Set the switch to the RUN position to accelerate the motor to set speed at a rate controlled by the ACCEL trimpot. Dynamic brake resistor sizes Figure 7. Run/Decelerate to Minimum Speed Switch Size the dynamic brake resistor according to the motor current rating (refer to Table 3 on page 22). The dynamic brake resistance listed in the table is the smallest recommended resistance allowed to prevent possible demagnetization of the motor. The motor stops less rapidly with higher brake resistor values. 250-0252r6_readers_spreads2.qxd 20 5/30/02 2:02 PM Page 20 Operation Operation Decelerating to minimum speed Dynamic braking A switch may be used to decelerate the motor to minimum speed. Connect the switch as shown in Figure 7. Close the switch between S1 and S2 to decelerate the motor from set speed. Open the switch to accelerate the motor to set speed. The ACCEL and DECEL trimpot settings determine the rate at which the motor accelerates and decelerates, respectively. CW S3 10K OHM SPEED ADJUST POTENTIOMETER S2 21 S1 RUN DECEL TO MIN SPEED Warning Wait for the motor to come to a complete stop before setting the RUN/BRAKE switch to RUN. This will prevent high armature currents from damaging the motor or drive. Dynamic braking may be used to rapidly stop a motor (see Figure 8 on page 22). For the RUN/BRAKE switch, use a doublepole, double throw switch rated for at least the maximum DC armature voltage and maximum braking current. RUN/BRAKE switch Install a double-pole, double-throw switch between the INHIBIT terminals and a dynamic brake resistor as shown in Figure 8 on page 22. Set the switch to the BRAKE position to dynamically brake the motor to a stop. Set the switch to the RUN position to accelerate the motor to set speed at a rate controlled by the ACCEL trimpot. Dynamic brake resistor sizes Figure 7. Run/Decelerate to Minimum Speed Switch Size the dynamic brake resistor according to the motor current rating (refer to Table 3 on page 22). The dynamic brake resistance listed in the table is the smallest recommended resistance allowed to prevent possible demagnetization of the motor. The motor stops less rapidly with higher brake resistor values. 250-0252r6_readers_spreads2.qxd 2:02 PM Page 22 Operation 23 Minimum Dynamic Brake Resistor Value 1 ohm 5 ohm 10 ohm 20 ohm 40 ohm Dynamic Brake Resistor Wattage 1W 5W 10W 20W 50W 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. For motors rated 1/17 horsepower and lower, a brake resistor is not necessary since the armature resistance is high enough to stop the motor without demagnetization. Replace the dynamic brake with 12 gauge wire. A1 S2 S1 A2 A2 L2 D Q503 C501 A1 C502 T501 Minimum Motor Armature Current Rating Less than 2 ADC 2–3 ADC 3–5 ADC 5–10 ADC 10–17 ADC Calibration R501 Table 3. Dynamic Brake Resistor Part Numbers INHIBIT 22 5/30/02 L1 IL502 CURRENT LIMIT RUN POWER MOTOR DYNAMIC BRAKE RESISTOR BRAKE INHIBIT Figure 8. Dynamic Brake Connection TH501 IL501 CURRENT LIMIT CURRENT LIMIT MAX SPD MIN SPD IR COMP MAX SPEED MIN SPEED IR COMP DECEL ACCEL DECELERATION Figure 9. Calibration Trimpot Layout ACCELERATION 250-0252r6_readers_spreads2.qxd 2:02 PM Page 22 Operation 23 Minimum Dynamic Brake Resistor Value 1 ohm 5 ohm 10 ohm 20 ohm 40 ohm Dynamic Brake Resistor Wattage 1W 5W 10W 20W 50W 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. For motors rated 1/17 horsepower and lower, a brake resistor is not necessary since the armature resistance is high enough to stop the motor without demagnetization. Replace the dynamic brake with 12 gauge wire. A1 S2 S1 A2 A2 L2 D Q503 C501 A1 C502 T501 Minimum Motor Armature Current Rating Less than 2 ADC 2–3 ADC 3–5 ADC 5–10 ADC 10–17 ADC Calibration R501 Table 3. Dynamic Brake Resistor Part Numbers INHIBIT 22 5/30/02 L1 IL502 CURRENT LIMIT RUN POWER MOTOR DYNAMIC BRAKE RESISTOR BRAKE INHIBIT Figure 8. Dynamic Brake Connection TH501 IL501 CURRENT LIMIT CURRENT LIMIT MAX SPD MIN SPD IR COMP MAX SPEED MIN SPEED IR COMP DECEL ACCEL DECELERATION Figure 9. Calibration Trimpot Layout ACCELERATION 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page 24 Calibration 24 Calibration procedure Before applying power 1. Verify that no conductive material is present on the printed circuit board. 2. Set all trimpots full except CURRENT LIMIT full counterclockwise (CCW). 3. Set the CURRENT LIMIT trimpot full clockwise (CW). 4. Set the speed adjust potentiometer or input signal to zero speed. 5. Set the INHIBIT switch to INHIBIT, or install the jumper between the INHIBIT terminals of SO501. 6. Apply line voltage to the drive. The green POWER LED shall light, but the motor should remain stopped. 7. Set the INHIBIT switch to ENABLE, or remove the jumper between the INHIBIT terminals of SO501. 25 MINIMUM SPEED (MIN SPD) MIN SPD determines the minimum speed when the speed adjust potentiometer is turned full CCW. It is factory set to zero speed. To calibrate MIN SPD: 1. Set the speed adjust potentiometer full CCW. 2. Adjust the MIN SPD trimpot until the motor turns at the desired minimum speed. MAXIMUM SPEED (MAX SPD) The MAX SPD setting determines the maximum motor speed when the speed adjust potentiometer is turned full CW. It is factory set for maximum rated motor speed. To calibrate MAX SPD: 1. Set the MAX trimpot full CCW. 2. Turn the speed adjust potentiometer full CW. 3. Adjust the MAX SPD trimpot until the desired maximum motor speed is reached. 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page 24 Calibration 24 Calibration procedure Before applying power 1. Verify that no conductive material is present on the printed circuit board. 2. Set all trimpots full except CURRENT LIMIT full counterclockwise (CCW). 3. Set the CURRENT LIMIT trimpot full clockwise (CW). 4. Set the speed adjust potentiometer or input signal to zero speed. 5. Set the INHIBIT switch to INHIBIT, or install the jumper between the INHIBIT terminals of SO501. 6. Apply line voltage to the drive. The green POWER LED shall light, but the motor should remain stopped. 7. Set the INHIBIT switch to ENABLE, or remove the jumper between the INHIBIT terminals of SO501. 25 MINIMUM SPEED (MIN SPD) MIN SPD determines the minimum speed when the speed adjust potentiometer is turned full CCW. It is factory set to zero speed. To calibrate MIN SPD: 1. Set the speed adjust potentiometer full CCW. 2. Adjust the MIN SPD trimpot until the motor turns at the desired minimum speed. MAXIMUM SPEED (MAX SPD) The MAX SPD setting determines the maximum motor speed when the speed adjust potentiometer is turned full CW. It is factory set for maximum rated motor speed. To calibrate MAX SPD: 1. Set the MAX trimpot full CCW. 2. Turn the speed adjust potentiometer full CW. 3. Adjust the MAX SPD trimpot until the desired maximum motor speed is reached. 250-0252r6_readers_spreads2.qxd 26 5/30/02 2:02 PM Page 26 Calibration ACCELERATION (ACCEL) The ACCELERATE setting determines the time the motor takes to ramp to a higher speed. See Specifications on page 1 for approximate acceleration times. The ACCELERATE setting is factory set to its minimum value (full CCW). Turn the ACCEL trimpot CW to increase the acceleration time and CCW to decrease the acceleration time. DECELERATION (DECEL) The DECELERATE setting determines the time the motor takes to ramp to a lower speed. See Specifications on page 1 for approximate deceleration times. The DECELERATE setting is factory set to its minimum value (full CCW). Turn the DECEL trimpot CW to increase the deceleration time and CCW to decrease the deceleration time. Calibration 27 REGULATION (IR COMP) The IR COMP setting determines the degree to which motor speed is held constant as the motor load changes. It is factory set for optimum motor regulation. Recalibrate the IR COMP setting when using a lower current rated motor. Refer to Figures 10 - 13 (pp 29 32) for typical IR COMP settings, 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. 250-0252r6_readers_spreads2.qxd 26 5/30/02 2:02 PM Page 26 Calibration ACCELERATION (ACCEL) The ACCELERATE setting determines the time the motor takes to ramp to a higher speed. See Specifications on page 1 for approximate acceleration times. The ACCELERATE setting is factory set to its minimum value (full CCW). Turn the ACCEL trimpot CW to increase the acceleration time and CCW to decrease the acceleration time. DECELERATION (DECEL) The DECELERATE setting determines the time the motor takes to ramp to a lower speed. See Specifications on page 1 for approximate deceleration times. The DECELERATE setting is factory set to its minimum value (full CCW). Turn the DECEL trimpot CW to increase the deceleration time and CCW to decrease the deceleration time. Calibration 27 REGULATION (IR COMP) The IR COMP setting determines the degree to which motor speed is held constant as the motor load changes. It is factory set for optimum motor regulation. Recalibrate the IR COMP setting when using a lower current rated motor. Refer to Figures 10 - 13 (pp 29 32) for typical IR COMP settings, 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. 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page 28 Calibration 28 CURRENT LIMIT (CURR LIM) Warning Although the current limit trimpot can be set to exceed the motor's maximum armature current rating, Minarik recommends you do not run the motor continuously beyond that rating. Continuous operation beyond the maximum armature current rating may cause thermal degradation of the motor and drive. The CURRENT LIMIT setting determines the maximum torque for accelerating and driving the motor. CURRENT LIMIT is factory set at 120% of maximum drive current. You must recalibrate the CURRENT LIMIT setting if using a lower current rated motor. Refer to Figures 10 - 13 (pp 29 - 32) for typical CURRENT LIMIT settings. 1. With no power applied to the drive, connect a DC ammeter in series with the motor armature. 2. Set the CURRENT 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. Calibration 29 CURRENT LIMIT (cont.) 6. Slowly rotate the CURRENT LIMIT trimpot clockwise (CW) until the ammeter reads 120% of maximum motor armature current. 7. Set the speed adjust potentiometer or reference signal to zero speed. 8. Remove power from the drive. 9. Remove the lock from the motor shaft. 10. Remove the ammeter in series with the motor armature. 250-0252r6_readers_spreads2.qxd 5/30/02 2:02 PM Page 28 Calibration 28 CURRENT LIMIT (CURR LIM) Warning Although the current limit trimpot can be set to exceed the motor's maximum armature current rating, Minarik recommends you do not run the motor continuously beyond that rating. Continuous operation beyond the maximum armature current rating may cause thermal degradation of the motor and drive. The CURRENT LIMIT setting determines the maximum torque for accelerating and driving the motor. CURRENT LIMIT is factory set at 120% of maximum drive current. You must recalibrate the CURRENT LIMIT setting if using a lower current rated motor. Refer to Figures 10 - 13 (pp 29 - 32) for typical CURRENT LIMIT settings. 1. With no power applied to the drive, connect a DC ammeter in series with the motor armature. 2. Set the CURRENT 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. Calibration 29 CURRENT LIMIT (cont.) 6. Slowly rotate the CURRENT LIMIT trimpot clockwise (CW) until the ammeter reads 120% of maximum motor armature current. 7. Set the speed adjust potentiometer or reference signal to zero speed. 8. Remove power from the drive. 9. Remove the lock from the motor shaft. 10. Remove the ammeter in series with the motor armature. 250-0252r6_readers_spreads2.qxd 30 5/30/02 2:02 PM Page 30 Calibration Calibration MMXL02-D240AC MOTOR HP: VOLTS RPM: AMPS: MOTOR HP: VOLTS RPM: AMPS: CURR LIM I/R COMP HP: VOLTS RPM: AMPS: I/R COMP CURR LIM HP: VOLTS RPM: AMPS: I/R COMP CURR LIM I/R COMP CURR LIM I/R COMP 1/3 90 VDC 1750 3.5 ADC MOTOR 1/4 90 VDC 1750 2.5 ADC CURR LIM 1/2 90 VDC 1750 5.0 ADC MOTOR 1/8 90 VDC 1750 1.3 ADC MOTOR HP: VOLTS RPM: AMPS: I/R COMP 1/20 90 VDC 1750 0.5 ADC MOTOR HP: VOLTS RPM: AMPS: CURR LIM MMXL02-D240AC MMXL05-D240AC 1/4 90 VDC 1750 2.7 ADC HP: VOLTS RPM: AMPS: HP: VOLTS RPM: AMPS: I/R COMP CURR LIM I/R COMP CURR LIM I/R COMP 3/4 90 VDC 1750 7.6 ADC MOTOR HP: VOLTS RPM: AMPS: CURR LIM 1/20 90 VDC 1750 5.0 ADC MOTOR MMXL05-D240AC I/R COMP MOTOR HP: 1/20 VOLTS: 130 VDC RPM: 2500 AMPS: 0.4 ADC MOTOR I/R COMP CURR LIM I/R COMP CURR LIM I/R COMP HP: 1/2 VOLTS: 130 VDC RPM: 2500 AMPS: 3.8 ADC CURR LIM I/R COMP MOTOR HP: 1/8 VOLTS: 130 VDC RPM: 2500 AMPS: 1.0 ADC MOTOR CURR LIM HP: 1/3 VOLTS: 130 VDC RPM: 2500 AMPS: 2.6 ADC CURR LIM I/R COMP MOTOR HP: 1/4 VOLTS: 130 VDC RPM: 2500 AMPS: 1.8 ADC HP: 1/4 VOLTS: 130 VDC RPM: 2500 AMPS: 2.0 ADC MMXL10-D240AC MMXL10-D240AC MOTOR MOTOR CURR LIM 31 1 90 VDC 1750 10.0 ADC Figure 10. Approximate CURRENT LIMIT and IR COMP Settings for 120 VAC in, 90 VDC out (actual settings may vary) MOTOR CURR LIM I/R COMP CURR LIM I/R COMP CURR LIM I/R COMP HP: 1/2 VOLTS: 130 VDC RPM: 2500 AMPS: 3.8 ADC MOTOR HP: 3/4 VOLTS: 130 VDC RPM: 1750 AMPS: 5.7 ADC MOTOR HP: 1 VOLTS: 130 VDC RPM: 1750 AMPS: 7.5 ADC Figure 11. Approximate CURRENT LIMIT and IR COMP Settings for 120 VAC in, 130 VDC out (actual settings may vary) 250-0252r6_readers_spreads2.qxd 30 5/30/02 2:02 PM Page 30 Calibration Calibration MMXL02-D240AC MOTOR HP: VOLTS RPM: AMPS: MOTOR HP: VOLTS RPM: AMPS: CURR LIM I/R COMP HP: VOLTS RPM: AMPS: I/R COMP CURR LIM HP: VOLTS RPM: AMPS: I/R COMP CURR LIM I/R COMP CURR LIM I/R COMP 1/3 90 VDC 1750 3.5 ADC MOTOR 1/4 90 VDC 1750 2.5 ADC CURR LIM 1/2 90 VDC 1750 5.0 ADC MOTOR 1/8 90 VDC 1750 1.3 ADC MOTOR HP: VOLTS RPM: AMPS: I/R COMP 1/20 90 VDC 1750 0.5 ADC MOTOR HP: VOLTS RPM: AMPS: CURR LIM MMXL02-D240AC MMXL05-D240AC 1/4 90 VDC 1750 2.7 ADC HP: VOLTS RPM: AMPS: HP: VOLTS RPM: AMPS: I/R COMP CURR LIM I/R COMP CURR LIM I/R COMP 3/4 90 VDC 1750 7.6 ADC MOTOR HP: VOLTS RPM: AMPS: CURR LIM 1/20 90 VDC 1750 5.0 ADC MOTOR MMXL05-D240AC I/R COMP MOTOR HP: 1/20 VOLTS: 130 VDC RPM: 2500 AMPS: 0.4 ADC MOTOR I/R COMP CURR LIM I/R COMP CURR LIM I/R COMP HP: 1/2 VOLTS: 130 VDC RPM: 2500 AMPS: 3.8 ADC CURR LIM I/R COMP MOTOR HP: 1/8 VOLTS: 130 VDC RPM: 2500 AMPS: 1.0 ADC MOTOR CURR LIM HP: 1/3 VOLTS: 130 VDC RPM: 2500 AMPS: 2.6 ADC CURR LIM I/R COMP MOTOR HP: 1/4 VOLTS: 130 VDC RPM: 2500 AMPS: 1.8 ADC HP: 1/4 VOLTS: 130 VDC RPM: 2500 AMPS: 2.0 ADC MMXL10-D240AC MMXL10-D240AC MOTOR MOTOR CURR LIM 31 1 90 VDC 1750 10.0 ADC Figure 10. Approximate CURRENT LIMIT and IR COMP Settings for 120 VAC in, 90 VDC out (actual settings may vary) MOTOR CURR LIM I/R COMP CURR LIM I/R COMP CURR LIM I/R COMP HP: 1/2 VOLTS: 130 VDC RPM: 2500 AMPS: 3.8 ADC MOTOR HP: 3/4 VOLTS: 130 VDC RPM: 1750 AMPS: 5.7 ADC MOTOR HP: 1 VOLTS: 130 VDC RPM: 1750 AMPS: 7.5 ADC Figure 11. Approximate CURRENT LIMIT and IR COMP Settings for 120 VAC in, 130 VDC out (actual settings may vary) 250-0252r6_readers_spreads2.qxd 32 5/30/02 2:02 PM Page 32 Calibration Calibration MMXL02-D240AC MOTOR CURR LIM MMXL05-D240AC I/R COMP MOTOR CURR LIM I/R COMP MOTOR I/R COMP CURR LIM I/R COMP 3/4 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 3.5 ADC 1/4 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 1.0 ADC MOTOR CURR LIM 1 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 5.0 ADC 1/2 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 1.4 ADC MOTOR CURR LIM 33 I/R COMP MOTOR CURR LIM I/R COMP 1/2 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 2.7 ADC 1/8 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 0.6 ADC MMXL02-D240AC MOTOR CURR LIM MMXL05-D240AC I/R COMP MOTOR HP: 1/2 VOLTS: 240 VDC RPM: 2500 AMPS: 1.9 ADC MOTOR CURR LIM I/R COMP MOTOR HP: 1/3 VOLTS: 240 VDC RPM: 2500 AMPS: 1.0 ADC MOTOR CURR LIM I/R COMP CURR LIM I/R COMP CURR LIM I/R COMP HP: 1 VOLTS: 180 VDC RPM: 1750 AMPS: 5.0 ADC HP: 3/4 VOLTS: 240 VDC RPM: 2500 AMPS: 2.7 ADC CURR LIM I/R COMP MOTOR HP: 1/4 VOLTS: 240 VDC RPM: 2500 AMPS: 0.75 ADC HP: 1/2 VOLTS: 240 VDC RPM: 2500 AMPS: 2.0 ADC MMXL10-D240AC MOTOR CURR LIM I/R COMP HP: 1 VOLTS: 180 VDC RPM: 1750 AMPS: 5.0 ADC MOTOR CURR LIM I/R COMP HP: 1 1/2 VOLTS: 180 VDC RPM: 1750 AMPS: 7.6 ADC MOTOR CURR LIM I/R COMP 2 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 10.0 ADC Figure 12. Approximate CURRENT LIMIT and IR COMP Settings for 240 VAC in, 180 VDC out (actual settings may vary) MMXL10-D240AC MOTOR CURR LIM I/R COMP CURR LIM I/R COMP CURR LIM I/R COMP HP: 1 VOLTS: 240 VDC RPM: 2500 AMPS: 3.8 ADC MOTOR HP: 1 1/2 VOLTS: 240 VDC RPM: 2500 AMPS: 5.7 ADC MOTOR HP: 2 VOLTS: 240 VDC RPM: 2500 AMPS: 7.5 ADC Figure 13. Approximate CURRENT LIMIT and IR COMP Settings for 240 VAC in, 240 VDC out (actual settings may vary) 250-0252r6_readers_spreads2.qxd 32 5/30/02 2:02 PM Page 32 Calibration Calibration MMXL02-D240AC MOTOR CURR LIM MMXL05-D240AC I/R COMP MOTOR CURR LIM I/R COMP MOTOR I/R COMP CURR LIM I/R COMP 3/4 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 3.5 ADC 1/4 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 1.0 ADC MOTOR CURR LIM 1 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 5.0 ADC 1/2 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 1.4 ADC MOTOR CURR LIM 33 I/R COMP MOTOR CURR LIM I/R COMP 1/2 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 2.7 ADC 1/8 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 0.6 ADC MMXL02-D240AC MOTOR CURR LIM MMXL05-D240AC I/R COMP MOTOR HP: 1/2 VOLTS: 240 VDC RPM: 2500 AMPS: 1.9 ADC MOTOR CURR LIM I/R COMP MOTOR HP: 1/3 VOLTS: 240 VDC RPM: 2500 AMPS: 1.0 ADC MOTOR CURR LIM I/R COMP CURR LIM I/R COMP CURR LIM I/R COMP HP: 1 VOLTS: 180 VDC RPM: 1750 AMPS: 5.0 ADC HP: 3/4 VOLTS: 240 VDC RPM: 2500 AMPS: 2.7 ADC CURR LIM I/R COMP MOTOR HP: 1/4 VOLTS: 240 VDC RPM: 2500 AMPS: 0.75 ADC HP: 1/2 VOLTS: 240 VDC RPM: 2500 AMPS: 2.0 ADC MMXL10-D240AC MOTOR CURR LIM I/R COMP HP: 1 VOLTS: 180 VDC RPM: 1750 AMPS: 5.0 ADC MOTOR CURR LIM I/R COMP HP: 1 1/2 VOLTS: 180 VDC RPM: 1750 AMPS: 7.6 ADC MOTOR CURR LIM I/R COMP 2 HP: VOLTS: 180 VDC RPM: 1750 AMPS: 10.0 ADC Figure 12. Approximate CURRENT LIMIT and IR COMP Settings for 240 VAC in, 180 VDC out (actual settings may vary) MMXL10-D240AC MOTOR CURR LIM I/R COMP CURR LIM I/R COMP CURR LIM I/R COMP HP: 1 VOLTS: 240 VDC RPM: 2500 AMPS: 3.8 ADC MOTOR HP: 1 1/2 VOLTS: 240 VDC RPM: 2500 AMPS: 5.7 ADC MOTOR HP: 2 VOLTS: 240 VDC RPM: 2500 AMPS: 7.5 ADC Figure 13. Approximate CURRENT LIMIT and IR COMP Settings for 240 VAC in, 240 VDC out (actual settings may vary) 250-0252r6_readers_spreads2.qxd 5/30/02 2:03 PM Page 34 34 A pplic a tion N ote s A p p l i c a ti o n N o te s A d j u s ta b l e s p e e d s u s i n g p o te n ti o m e te r s i n s er ies M u l ti p l e f i x e d s p e e d s C onne c t two s pe e d a djus t pote ntiome te rs a s s hown in F igure 1 5 to s e le c t be twe e n multiple forward speeds. R e pla c e the s pe e d a djus t pote ntiome te r with s e rie s re s is tors ha ving a tota l s e rie s re s is ta nc e of 1 0 K ohms ( F igure 1 4 ) . A dd a s ingle pole , multi-pos ition s witc h with the c orre c t numbe r of pos itions for the de s ire d numbe r of fix e d s pe e ds . S3 R1 S3 R2 S2 R3 S1 CW T O T A L S E R IE S R E S IS T A N C E 1 0 K O H MS HI G H SPEED 5K OHM LOW SPEED CW S2 S1 R4 5K OHM F i g u r e 1 4 . M u l ti p l e F i x e d S p e e d s F i g u r e 1 5 . Selectable Speeds Using Potentiometers In Series 35 250-0252r6_readers_spreads2.qxd 5/30/02 2:03 PM Page 34 34 A pplic a tion N ote s A p p l i c a ti o n N o te s A d j u s ta b l e s p e e d s u s i n g p o te n ti o m e te r s i n s er ies M u l ti p l e f i x e d s p e e d s C onne c t two s pe e d a djus t pote ntiome te rs a s s hown in F igure 1 5 to s e le c t be twe e n multiple forward speeds. R e pla c e the s pe e d a djus t pote ntiome te r with s e rie s re s is tors ha ving a tota l s e rie s re s is ta nc e of 1 0 K ohms ( F igure 1 4 ) . A dd a s ingle pole , multi-pos ition s witc h with the c orre c t numbe r of pos itions for the de s ire d numbe r of fix e d s pe e ds . S3 R1 S3 R2 S2 R3 S1 CW T O T A L S E R IE S R E S IS T A N C E 1 0 K O H MS HI G H SPEED 5K OHM LOW SPEED CW S2 S1 R4 5K OHM F i g u r e 1 4 . M u l ti p l e F i x e d S p e e d s F i g u r e 1 5 . Selectable Speeds Using Potentiometers In Series 35 250-0252r6_readers_spreads2.qxd 36 5/30/02 2:03 PM Page 36 Application Notes Application Notes Independent adjustable speeds 37 RUN/JOG switch Connect two speed adjust potentiometers with a single-pole, multiposition switch and two or more potentiometers in parallel, with a total resistance of 10K ohms. Figure 16 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations. Using a RUN/JOG switch is recommended in applications where quick stopping is not needed and frequent jogging is required. Use a single pole, two position switch for the RUN/JOG switch, and a single-pole, normally-closed, momentary operated pushbutton for the JOG pushbutton. RUN/JOG option #1 S3 SPEED 2 CW CW SPEED 1 20K OHM 20K OHM S2 S1 In option #1 (Figure 17), connect the RUN/JOG switch and the JOG pushbutton to the INHIBIT terminals. When the RUN/JOG switch is set to JOG, the motor coasts to minimum speed. Press the JOG pushbutton to jog the motor. Return the RUN/JOG switch to RUN for normal operation. RUN Figure 16. Independent Adjustable Speeds INHIBIT JOG PUSHBUTTON JOG Figure 17. RUN/JOG Option #1 250-0252r6_readers_spreads2.qxd 36 5/30/02 2:03 PM Page 36 Application Notes Application Notes Independent adjustable speeds 37 RUN/JOG switch Connect two speed adjust potentiometers with a single-pole, multiposition switch and two or more potentiometers in parallel, with a total resistance of 10K ohms. Figure 16 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations. Using a RUN/JOG switch is recommended in applications where quick stopping is not needed and frequent jogging is required. Use a single pole, two position switch for the RUN/JOG switch, and a single-pole, normally-closed, momentary operated pushbutton for the JOG pushbutton. RUN/JOG option #1 S3 SPEED 2 CW CW SPEED 1 20K OHM 20K OHM S2 S1 In option #1 (Figure 17), connect the RUN/JOG switch and the JOG pushbutton to the INHIBIT terminals. When the RUN/JOG switch is set to JOG, the motor coasts to minimum speed. Press the JOG pushbutton to jog the motor. Return the RUN/JOG switch to RUN for normal operation. RUN Figure 16. Independent Adjustable Speeds INHIBIT JOG PUSHBUTTON JOG Figure 17. RUN/JOG Option #1 250-0252r6_readers_spreads2.qxd 38 5/30/02 2:03 PM Page 38 Application Notes Application Notes RUN/JOG option #2 Leader-follower application In option #2, connect the RUN/JOG switch to the speed adjust potentiometer using a single-pole, two-position switch for the RUN/JOG switch, and a single-pole, normally-closed, momentary operated pushbutton for the JOG pushbutton as shown in Figure 18. When the RUN/JOG switch is set to JOG, the motor decelerates to minimum speed. Press the JOG pushbutton to jog the motor. Return the RUN/JOG switch to RUN for normal operation. In this application, use a PCM4 to monitor the speed of the leader motor (Figure 19). The PCM4 outputs a voltage proportional to the leader motor armature voltage. The follower drive uses this voltage reference to set the speed of the follower motor. An optional ratio potentiometer may be used to scale the PCM4 output voltage. MOTOR A2 S3 S2 10K OHM SPEED ADJUST POTENTIOMETER S1 JOG JOG PUSHBUTTON Figure 18. RUN/JOG Option #2 8 PCM4 7 (-) TB501 CW (+) 2 9 (+) A1 Leader Drive RUN 39 S2 (-) 1 TB502 S1 10K Ohm (optional) Figure 19. Leader-Follower Application Follower Drive 250-0252r6_readers_spreads2.qxd 38 5/30/02 2:03 PM Page 38 Application Notes Application Notes RUN/JOG option #2 Leader-follower application In option #2, connect the RUN/JOG switch to the speed adjust potentiometer using a single-pole, two-position switch for the RUN/JOG switch, and a single-pole, normally-closed, momentary operated pushbutton for the JOG pushbutton as shown in Figure 18. When the RUN/JOG switch is set to JOG, the motor decelerates to minimum speed. Press the JOG pushbutton to jog the motor. Return the RUN/JOG switch to RUN for normal operation. In this application, use a PCM4 to monitor the speed of the leader motor (Figure 19). The PCM4 outputs a voltage proportional to the leader motor armature voltage. The follower drive uses this voltage reference to set the speed of the follower motor. An optional ratio potentiometer may be used to scale the PCM4 output voltage. MOTOR A2 S3 S2 10K OHM SPEED ADJUST POTENTIOMETER S1 JOG JOG PUSHBUTTON Figure 18. RUN/JOG Option #2 8 PCM4 7 (-) TB501 CW (+) 2 9 (+) A1 Leader Drive RUN 39 S2 (-) 1 TB502 S1 10K Ohm (optional) Figure 19. Leader-Follower Application Follower Drive 250-0252r6_readers_spreads2.qxd 40 5/30/02 2:03 PM Page 40 Application Notes Application Notes Single speed potentiometer control of multiple drives (-PCM models only) Reversing Because the potentiometer circuit is optically isolated from the drive circuitry, the inputs may be tied together. Up to eight (8) drives can be controlled with a single speed adjust potentiometer (see Figure 20 below). S1 S2 A dynamic brake may be used when reversing the motor direction (Figure 21). Use a three-pole, three-position switch rated for at least the maximum DC armature voltage and maximum braking current. Wait for the motor to stop completely before switching it to either the forward or reverse direction. See the Dynamic braking section on page 21 for sizing the dynamic brake resistor. A1 S3 A1 A2 DYNAMIC BRAKE RESISTOR MOTOR FWD BRAKE S1 S2 S3 A2 MOTOR A DRIVE A A1 REV MOTOR B DRIVE B 41 A2 INHIBIT Figure 20. Single Speed Potentiometer Control of Multiple MMXL-PCM Series Drives Figure 21. Reversing 250-0252r6_readers_spreads2.qxd 40 5/30/02 2:03 PM Page 40 Application Notes Application Notes Single speed potentiometer control of multiple drives (-PCM models only) Reversing Because the potentiometer circuit is optically isolated from the drive circuitry, the inputs may be tied together. Up to eight (8) drives can be controlled with a single speed adjust potentiometer (see Figure 20 below). S1 S2 A dynamic brake may be used when reversing the motor direction (Figure 21). Use a three-pole, three-position switch rated for at least the maximum DC armature voltage and maximum braking current. Wait for the motor to stop completely before switching it to either the forward or reverse direction. See the Dynamic braking section on page 21 for sizing the dynamic brake resistor. A1 S3 A1 A2 DYNAMIC BRAKE RESISTOR MOTOR FWD BRAKE S1 S2 S3 A2 MOTOR A DRIVE A A1 REV MOTOR B DRIVE B 41 A2 INHIBIT Figure 20. Single Speed Potentiometer Control of Multiple MMXL-PCM Series Drives Figure 21. Reversing 250-0252r6_readers_spreads2.qxd 42 5/30/02 2:03 PM Page 42 Application Notes 43 Reversing with a DIGI-LOK controller Troubleshooting A DIGI-LOK controller, model DLC600, can be used in a reversing application (Figure 22). The controller must be inhibited while braking. Without the inhibit feature, the controller will continue to regulate, causing overshoot when the DIGI-LOK is switched back to the drive. S3 MINARIK DRIVE A1 Dangerous voltages exist on the drive when it is powered, and up to 30 seconds after power is removed. When possible, disconnect the drive while troubleshooting. High voltages can cause serious or fatal injury. Before troubleshooting S2 S1 A2 Perform the following steps before starting any procedure in this section: Dynamic Brake Resistor S1 S2 BRAKE FWD Warning REV DLC600 Inhibit Leads C Motor IN + • 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. Common Optical Encoder Signal +5 VDC Magnetic Pickup Figure 22. Reversing with a DLC600 For additional assistance, contact your local Minarik distributor, or the factory direct: Phone: 1-800-MINARIK (646-2745) or Fax: 1-800-394-6334 250-0252r6_readers_spreads2.qxd 42 5/30/02 2:03 PM Page 42 Application Notes 43 Reversing with a DIGI-LOK controller Troubleshooting A DIGI-LOK controller, model DLC600, can be used in a reversing application (Figure 22). The controller must be inhibited while braking. Without the inhibit feature, the controller will continue to regulate, causing overshoot when the DIGI-LOK is switched back to the drive. S3 MINARIK DRIVE A1 Dangerous voltages exist on the drive when it is powered, and up to 30 seconds after power is removed. When possible, disconnect the drive while troubleshooting. High voltages can cause serious or fatal injury. Before troubleshooting S2 S1 A2 Perform the following steps before starting any procedure in this section: Dynamic Brake Resistor S1 S2 BRAKE FWD Warning REV DLC600 Inhibit Leads C Motor IN + • 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. Common Optical Encoder Signal +5 VDC Magnetic Pickup Figure 22. Reversing with a DLC600 For additional assistance, contact your local Minarik distributor, or the factory direct: Phone: 1-800-MINARIK (646-2745) or Fax: 1-800-394-6334 250-0252r6_readers_spreads2.qxd 5/30/02 2:03 PM Page 44 Troubleshooting 44 Symptom Diagnostic LEDs MMXL series drives are equipped with the following diagnostic LEDs to aid in troubleshooting or monitoring equipment status. Refer to Figure 23 below. Line fuse blows POWER Green LED lights when AC line voltage is applied to the drive. CURRENT LIMIT (CL/FLT) Possible Causes 1. Check that line fuses are the proper size. 2. Motor cable or armature is shorted to ground. 2. Check motor cable and armature for shorts. 3. Nuisance tripping caused by a combination of ambient conditions and highcurrent spikes. 3. Add a blower to cool the drive components; decrease CURRENT LIMIT settings, or resize motor and drive for actual load demand, or check for incorrectly aligned mechanical components or “jams”. See page 27 for information on adjusting the CURRENT LIMIT trimpot. 1. Reference signal or speed adjust pot is set to zero speed. 1. Increase reference signal or speed adjust potentiometer setting. 2. Reference signal or speed adjust potentiometer connections are open. 2. Check that the reference signal or speed adjust potentiometer connections are not open. A2 2 T501 L2 2 INHIBIT Suggested Solutions 1. Line fuses are the wrong size. Red LED lights when drive output current exceeds the threshold set by the CURRENT LIMIT trimpot. S2 S1 45 L1 Q503 C501 D IL502 CURRENT LIMIT POWER TH501 IL501 CURRENT LIMIT MAX SPD MIN I SPD IR COMP DECEL ACCEL CURRENT LIMIT LED Figure 23. Diagnostic LED locations POWER LED Line fuse does not blow, but the motor does not run 250-0252r6_readers_spreads2.qxd 5/30/02 2:03 PM Page 44 Troubleshooting 44 Symptom Diagnostic LEDs MMXL series drives are equipped with the following diagnostic LEDs to aid in troubleshooting or monitoring equipment status. Refer to Figure 23 below. Line fuse blows POWER Green LED lights when AC line voltage is applied to the drive. CURRENT LIMIT (CL/FLT) Possible Causes 1. Check that line fuses are the proper size. 2. Motor cable or armature is shorted to ground. 2. Check motor cable and armature for shorts. 3. Nuisance tripping caused by a combination of ambient conditions and highcurrent spikes. 3. Add a blower to cool the drive components; decrease CURRENT LIMIT settings, or resize motor and drive for actual load demand, or check for incorrectly aligned mechanical components or “jams”. See page 27 for information on adjusting the CURRENT LIMIT trimpot. 1. Reference signal or speed adjust pot is set to zero speed. 1. Increase reference signal or speed adjust potentiometer setting. 2. Reference signal or speed adjust potentiometer connections are open. 2. Check that the reference signal or speed adjust potentiometer connections are not open. A2 2 T501 L2 2 INHIBIT Suggested Solutions 1. Line fuses are the wrong size. Red LED lights when drive output current exceeds the threshold set by the CURRENT LIMIT trimpot. S2 S1 45 L1 Q503 C501 D IL502 CURRENT LIMIT POWER TH501 IL501 CURRENT LIMIT MAX SPD MIN I SPD IR COMP DECEL ACCEL CURRENT LIMIT LED Figure 23. Diagnostic LED locations POWER LED Line fuse does not blow, but the motor does not run 250-0252r6_readers_spreads2.qxd 46 5/30/02 2:03 PM Page 46 Troubleshooting Symptom Line fuse does not blow, but the motor does not run (cont.) Troubleshooting Possible Causes Suggested Solutions 3. Drive is overloaded. 3. Verify that the motor is not jammed. Increase CURRENT LIMIT setting (page 27). 4. Drive is not receiving AC line voltage. 4. Apply AC line voltage to L1 and L2. 5. Motor is not connected. 5. Connect motor to A1 and A2. Motor runs too fast at maximum speed setting 1. MIN SPD and MAX SPD settings are too high. 1. Recalibrate MIN SPD (page 24) and MAX SPD (page 25). Motor runs too slow or too fast 1. MIN SPD and MAX SPD are not calibrated. 1. Recalibrate MIN SPD (page 24) and MAX SPD (page 25). Motor will not reach the desired speed. 1. MAX SPD setting is too low. 1. Increase MAX SPD setting (page 25). 2. IR COMP setting is too low. 2. Increase IR COMP setting (page 26). 3. Motor is overloaded. 3. Check motor load. Resize the motor if necessary. Symptom Motor pulsates or surges under load Possible Causes 47 Suggested Solutions 1. IR COMP is set too high. 1. Adjust the IR COMP setting slightly CCW until the motor speed stabilizes (page 26). 2. Control is in current limit mode. 2. Check that motor and drive are of sufficient horsepower and amperage. You may need to replace the motor and/or the drive. 250-0252r6_readers_spreads2.qxd 46 5/30/02 2:03 PM Page 46 Troubleshooting Symptom Line fuse does not blow, but the motor does not run (cont.) Troubleshooting Possible Causes Suggested Solutions 3. Drive is overloaded. 3. Verify that the motor is not jammed. Increase CURRENT LIMIT setting (page 27). 4. Drive is not receiving AC line voltage. 4. Apply AC line voltage to L1 and L2. 5. Motor is not connected. 5. Connect motor to A1 and A2. Motor runs too fast at maximum speed setting 1. MIN SPD and MAX SPD settings are too high. 1. Recalibrate MIN SPD (page 24) and MAX SPD (page 25). Motor runs too slow or too fast 1. MIN SPD and MAX SPD are not calibrated. 1. Recalibrate MIN SPD (page 24) and MAX SPD (page 25). Motor will not reach the desired speed. 1. MAX SPD setting is too low. 1. Increase MAX SPD setting (page 25). 2. IR COMP setting is too low. 2. Increase IR COMP setting (page 26). 3. Motor is overloaded. 3. Check motor load. Resize the motor if necessary. Symptom Motor pulsates or surges under load Possible Causes 47 Suggested Solutions 1. IR COMP is set too high. 1. Adjust the IR COMP setting slightly CCW until the motor speed stabilizes (page 26). 2. Control is in current limit mode. 2. Check that motor and drive are of sufficient horsepower and amperage. You may need to replace the motor and/or the drive. 250-0252r6_readers_spreads2.qxd 5/30/02 2:03 PM Page 48 Troubleshooting 48 FUSE KIT CONTENTS Replacement Parts Replacement parts are available from Minarik Corporation and its distributors for this drive series. Table 4. Replacement Parts Model No. MMXL02-D240AC Symbol Troubleshooting Description 3 - 8A FUSE KIT (050-0069) 3 AMP 3AG Fast-Acting Fuse (2 ea) 5 AMP 3AG Fast-Acting Fuse (2 ea) 8 AMP 3AG Fast-Acting Fuse (2 ea) 1/2A Pico Fuse (1 ea) Minarik P/N C504 D501 Q502 Q503 R501 T501 470 mF, 400 V Capacitor 16 A, 600V Diode Power MOSFET Power MOSFET 0.1 ohm, 5 W Resistor Transformer TSD1017 10 Kohm Potentiometer Kit 011-0120 071-0044 070^)085 070-0083 032-0100 230-0108 202-0066 C504 D501 Q502 Q503 R501 T501 680 mF, 400 V Capacitor 16 A, 600V Diode Power MOSFET Power MOSFET 0.1 ohm, 5 W Resistor Transformer TSD1017 10 Kohm Potentiometer Kit 011-0080 071-0044 070-0085 070-0083 032-0100 230-0108 202-0066 C504 D501 Q502 Q503 R501 T501 1000 mF, 400 V Capacitor 16 A, 600V Diode Power MOSFET Power MOSFET 0.01 ohm, 5 W Resistor Transformer TSD1017 10 Kohm Potentiometer Kit 011-0089 071-0044 070-0086 070-0083 032-0129 230-0108 202-0066 5 - 20A FUSE KIT (050-0073) 5 AMP 3AG Fast-Acting Fuse (2 ea) 8 AMP 3AG Fast-Acting Fuse (2 ea) 10 AMP 3AB Normal-blo Fuse (2 ea) 5 AMP 3AB Normal-blo Fuse (2 ea) 20 AMP 3AB Normal-blo Fuse (2 ea) 1/2A Pico Fuse (1 ea) MMXL05-D240AC MMXL10-D240AC POTENTIOMETER KIT CONTENTS (202-0066) 10k ohm ± 5%, 5W Potentiometer (1 ea) 3/8-32 X 1/2 Nut (1 ea) Potentiometer Insulating Washer (1 ea) Non-insulated 1/4-inch Female Tab (7 ea) 49 250-0252r6_readers_spreads2.qxd 5/30/02 2:03 PM Page 48 Troubleshooting 48 FUSE KIT CONTENTS Replacement Parts Replacement parts are available from Minarik Corporation and its distributors for this drive series. Table 4. Replacement Parts Model No. MMXL02-D240AC Symbol Troubleshooting Description 3 - 8A FUSE KIT (050-0069) 3 AMP 3AG Fast-Acting Fuse (2 ea) 5 AMP 3AG Fast-Acting Fuse (2 ea) 8 AMP 3AG Fast-Acting Fuse (2 ea) 1/2A Pico Fuse (1 ea) Minarik P/N C504 D501 Q502 Q503 R501 T501 470 mF, 400 V Capacitor 16 A, 600V Diode Power MOSFET Power MOSFET 0.1 ohm, 5 W Resistor Transformer TSD1017 10 Kohm Potentiometer Kit 011-0120 071-0044 070^)085 070-0083 032-0100 230-0108 202-0066 C504 D501 Q502 Q503 R501 T501 680 mF, 400 V Capacitor 16 A, 600V Diode Power MOSFET Power MOSFET 0.1 ohm, 5 W Resistor Transformer TSD1017 10 Kohm Potentiometer Kit 011-0080 071-0044 070-0085 070-0083 032-0100 230-0108 202-0066 C504 D501 Q502 Q503 R501 T501 1000 mF, 400 V Capacitor 16 A, 600V Diode Power MOSFET Power MOSFET 0.01 ohm, 5 W Resistor Transformer TSD1017 10 Kohm Potentiometer Kit 011-0089 071-0044 070-0086 070-0083 032-0129 230-0108 202-0066 5 - 20A FUSE KIT (050-0073) 5 AMP 3AG Fast-Acting Fuse (2 ea) 8 AMP 3AG Fast-Acting Fuse (2 ea) 10 AMP 3AB Normal-blo Fuse (2 ea) 5 AMP 3AB Normal-blo Fuse (2 ea) 20 AMP 3AB Normal-blo Fuse (2 ea) 1/2A Pico Fuse (1 ea) MMXL05-D240AC MMXL10-D240AC POTENTIOMETER KIT CONTENTS (202-0066) 10k ohm ± 5%, 5W Potentiometer (1 ea) 3/8-32 X 1/2 Nut (1 ea) Potentiometer Insulating Washer (1 ea) Non-insulated 1/4-inch Female Tab (7 ea) 49 250-0252r6_readers_spreads2.qxd 5/30/02 2:03 PM Page 50 CE Compliance 50 Certificate of Compliance 51 Compliance allows Minarik's MMXL series to bear the CE mark. The end user, as described herein, falls into one of two categories: CE Certification Minarik Corporation hereby certifies that its MMXL series drives, including the MMXL-PCM series, have been approved to bear the CE" mark provided the conditions of approval have been met by the end user. 1. The Consumer will deploy a stand-alone unit as an integral, yet external, portion of the machine being operated. 2. The Original Equipment Manufacturer (OEM) will implement the product as a component of the machine being manufactured. The OEM must meet the following conditions: AC Line Filters • All wires, including logic, AC power and motor leads, must be shielded. Do not ground both ends of the shield. • The MMXL motor control module must be enclosed in a solid metal enclosure. The enclosure lid, body and backplane must all be tied to a low-impedance earth ground. • A VV-series Corcom© filter (or equivalent) must be wired into the AC main. (See Table 5 on page 50.) • The ground connection between the shielded cable, installed line filter and metal enclosure must be wired to solid earth ground (resistance less than 500 ohms), not machine ground. This is very important! In addition to EMI/RFI safeguards inherent in the MMXL series' design, external filtering is required. To meet CE approval conditions, use the line filters (or equivalent) listed in Table 5. Connect the filter as shown in Figure 24. Table 5. AC Line Filters Drive MMXL02 MMXL05 MMXL10 AC Current 3A 7A 12A Corcom Filter 6VV1 10VV1 20VV1 250-0252r6_readers_spreads2.qxd 5/30/02 2:03 PM Page 50 CE Compliance 50 Certificate of Compliance 51 Compliance allows Minarik's MMXL series to bear the CE mark. The end user, as described herein, falls into one of two categories: CE Certification Minarik Corporation hereby certifies that its MMXL series drives, including the MMXL-PCM series, have been approved to bear the CE" mark provided the conditions of approval have been met by the end user. 1. The Consumer will deploy a stand-alone unit as an integral, yet external, portion of the machine being operated. 2. The Original Equipment Manufacturer (OEM) will implement the product as a component of the machine being manufactured. The OEM must meet the following conditions: AC Line Filters • All wires, including logic, AC power and motor leads, must be shielded. Do not ground both ends of the shield. • The MMXL motor control module must be enclosed in a solid metal enclosure. The enclosure lid, body and backplane must all be tied to a low-impedance earth ground. • A VV-series Corcom© filter (or equivalent) must be wired into the AC main. (See Table 5 on page 50.) • The ground connection between the shielded cable, installed line filter and metal enclosure must be wired to solid earth ground (resistance less than 500 ohms), not machine ground. This is very important! In addition to EMI/RFI safeguards inherent in the MMXL series' design, external filtering is required. To meet CE approval conditions, use the line filters (or equivalent) listed in Table 5. Connect the filter as shown in Figure 24. Table 5. AC Line Filters Drive MMXL02 MMXL05 MMXL10 AC Current 3A 7A 12A Corcom Filter 6VV1 10VV1 20VV1 250-0252r6_readers_spreads2.qxd 52 5/30/02 2:03 PM Page 52 CE Compliance Unconditional Warranty VV1 FILTER MMXL DRIVE L1 L1 L2 L2 MMXL DRIVE ENCLOSURE GND SCREW SOLID EARTH GROUND Figure 24. MMXL CE Filter Connections 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 does not apply to specials. Any returns for special controls will be evaluated on a case-by-case basis. The Corporation is not responsible for removal, installation, or any other incidental expenses incurred in shipping the product to and from the repair point. B. Disclaimer - The provisions of Paragraph A are the Corporation’s sole obligation and exclude all other warranties of merchantability for use, express or implied. The Corporation further disclaims any responsibility whatsoever to the customer or to any other person for injury to the person or damage or loss of property of value caused by any product that has been subject to misuse, negligence, or accident, or misapplied or modified by unauthorized persons or improperly installed. C. Limitations of Liability - In the event of any claim for breech of any of the Corporation’s obligations, whether express or implied, and particularly of any other claim or breech of warranty contained in Paragraph A, or of any other warranties, express or implied, or claim of liability that might, despite Paragraph B, be decided against the Corporation by lawful authority, the Corporation shall under no circumstances be liable for any consequential damages, losses, or expense arising in connection with the use 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 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. 250-0252r6_readers_spreads2.qxd 52 5/30/02 2:03 PM Page 52 CE Compliance Unconditional Warranty VV1 FILTER MMXL DRIVE L1 L1 L2 L2 MMXL DRIVE ENCLOSURE GND SCREW SOLID EARTH GROUND Figure 24. MMXL CE Filter Connections 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 does not apply to specials. Any returns for special controls will be evaluated on a case-by-case basis. The Corporation is not responsible for removal, installation, or any other incidental expenses incurred in shipping the product to and from the repair point. B. Disclaimer - The provisions of Paragraph A are the Corporation’s sole obligation and exclude all other warranties of merchantability for use, express or implied. The Corporation further disclaims any responsibility whatsoever to the customer or to any other person for injury to the person or damage or loss of property of value caused by any product that has been subject to misuse, negligence, or accident, or misapplied or modified by unauthorized persons or improperly installed. C. Limitations of Liability - In the event of any claim for breech of any of the Corporation’s obligations, whether express or implied, and particularly of any other claim or breech of warranty contained in Paragraph A, or of any other warranties, express or implied, or claim of liability that might, despite Paragraph B, be decided against the Corporation by lawful authority, the Corporation shall under no circumstances be liable for any consequential damages, losses, or expense arising in connection with the use 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 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. 250-0252r6_readers_spreads2.qxd 5/30/02 2:03 PM 14300De La Tour Drive South Beloit, IL 61080 Te l: ( 8 0 0 ) MI N A R I K ( 6 4 6 -2 7 4 5 ) F a x : ( 8 0 0 ) 3 9 4 -6 3 3 4 www. mina rik c orp. c om D oc ume nt numbe r 2 5 0 – 0 2 5 2 , R e vis ion 7 P rinte d in the U . S . A – 0 8 /0 7 Page 54