Minarik Drives M1 Series Users Manual
M1 Series
SCR, Adjustable Speed Drives
for DC Brush Motors
User’s Manual
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.
i
Safety Warnings
• 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.
SHOCKAVOID
OID
ON
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.
TI
ii
Contents
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Power, fuse and motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Horsepower Jumper Terminal (J502) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Starting and stopping methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Inhibit terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
iii
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
IR COMPENSATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
ACCELERATION (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
DECELERATION (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
RUN/JOG switch option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
RUN/JOG switch option #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Reversing with a DIGI-LOK controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Unconditional Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inside back cover
Table 1. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 2. Minimum Recommended Dynamic Brake Resistor Values . . . . . . .20
Table 3. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Tables
iv
Illustrations
Figure 1. M1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Figure 2. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 3. M1 Series Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 4. J502 Jumper Location and Settings . . . . . . . . . . . . . . . . . . . . . . .14
Figure 5. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 6. INHIBIT Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Figure 7. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Figure 8. Recommended Torque and IR COMP Settings . . . . . . . . . . . . . . .26
Figure 9. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Figure 10. Adjustable Fixed Speeds Using Potentiometers in Series . . . . . .30
Figure 11. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . .31
Figure 12. RUN/JOG Switch Connection to Inhibit Plug (Option #1) . . . . . . .32
Figure 13. RUN/JOG Switch Connection to Speed Adjust Potentiometer
(Option #2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 14. Leader-Follower Application . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Figure 15. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Figure 16. Reversing with a DLC600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
1
Specifications
Max Armature HP Range
Current with 115 VAC
Model (Amps DC) Applied Style
M1 5.0 1/15 - 1/2 Chassis
M1 (w/ heatsink)* 10.0 1/2 - 1 Chassis
AC Line Voltage 115 VAC ±10%, 50/60 Hz, Single Phase
Armature Voltage (115 VAC Input) 0–90 VDC
Form Factor 1.37 at base speed
Accel. Time Range (for 0 - 90 Armature Voltage) 0.5 - 25 Seconds
Decel. Time Range (for 0 - 90 Armature Voltage) 0.5 - 25 Seconds
Analog Input Voltage Range (isolated; S1 to S2)
for 0 - 90 Armature Voltage 0 - 4.5 VDC
Input Impedence (S1 to S2) 100K Ohms
Load Regulation 1% base speed or better
Vibration 1G max (0 - 50 Hz)
Ambient Temp. Range 10°C - 55°C
* M1 Series drives require an additional heat sink (p/n 223-0159) when continuous armature
current is above 5ADC (see page 7).
2
502
C502
503
502D50
J501
502
C1
J2
501
502
/8
Features and Benefits
• Speed Range and Regulation: 1% over 60:1 Speed Range.
• Six (6) User Adjustable Calibration Pots:
ACCEL, DECEL, TORQUE, IR COMP, MIN SPEED, and MAX SPEED
• Stopping Modes: Coast to stop with inhibit terminals (N.O.). Choice of header plug or spade
lug connections.
• Spade Terminals: Easy to use, low cost, and able to fit in a smaller package.
SPADE LUG CONNECTIONS J502
L1 & L2 TO AC LINE VOLTAGE (115 VAC)
(see page 10)
JUMPER ON FOR MOTORS 1/8 HP OR LOWER
(see page 14)
T501
Coast to stop using either Header
Plug or Spade Lug Connections
(see page 18)
R501
1
Y
1
D
D
MOV
R
I
R
1
1
A
SPADE LUG
CONNECTIONS
TO MOTOR
(see page 9)
TO SPEED ADJUST
POTENTIOMETER
(see page 7)
IR COMP TORQUEACCEL DECEL MAX SPDMIN SPD
(see page 22)
USER ADJUSTABLE CALIBRATION TRIMPOTSINHIBIT
Dimensions 3
Figure 1. M1 Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
]
]
]
]
]
]
]
SCR50
SCR502
QC503
QC504
QC505
QC506
T50
503
502
QC
QC502
J50
QC507
502
J2
QC509
QC508
50
502
.64 [67
.75 [44
1
1
501
1
-
D
D
MOV
Y501
IC1
1
D501
1
R
R
1
.45 [37
.28 [33
.96 [24
.80 [97
4.30 [109
4
Mounting
• Drive components are sensitive to electrostatic fields. Avoid contact with the circuit
board directly. Hold drive by the chassis only.
• Protect the drive from dirt, moisture, and accidental contact.
• Provide sufficient room for access to the calibration trimpots.
• Mount the drive away from other 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 inch (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. To ground the chassis, use a star washer
beneath the head of at least one of the mounting screws to penetrate the anodized
chassis surface and to reach bare metal.
Installation
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.
Installation 5
Warning
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.
Wiring
• Use 18-24 AWG wire for speed adjust potentiometer wiring.
• Use 14–16 AWG wire for AC line (L1, L2) and motor (A1 and A2) wiring.
6 Installation
Shielding guidelines
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 of 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.
Warning
Under no circumstances should power and logic leads be bundled together.
Induced voltage can cause unpredicatble behavior in any electronic device,
including motor controls.
Installation 7
Warning
Be sure that the potentiometer tabs do not make contact with the potentiometer
enclosure. Grounding the input will cause damage to the drive.
Speed adjust potentiometer
Mount the speed adjust potentiometer through a 0.38 in. (10 mm) hole with the
hardware provided (Figure 2, page 8). 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).
Heat sinking
M1 Series drives require an additional heat sink when the continuous armature
current is above 5 ADC. Use Minarik part number 223-0159. All other chassis drives
have sufficient heat sinking in their basic configurations. Use 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.
8 Installation
Figure 2. Speed Adjust Potentiometer
JUST
S
E
UNT THROUGH A 0.38 IN. (10 MM) HOL
W
WA
TAR
HER
NSULATING DISK
PEED AD
POTENTIOMETER
9Installation
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 3 (page 12). 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 3, page 12.
Motor
Minarik drives supply motor armature 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.
Connections
Connect a DC motor to PCB terminals A1 and A2 as shown in Figure 3, page 12.
Ensure that the motor voltage rating is consistent with the drive’s output voltage.
Power input
Connect the AC line power leads to terminals L1 and L2, or to a double-throw, singlepole master power switch (recommended). The switch should be rated at a minimum
of 250 volts and 200% of motor current. Refer to Figure 3, page 12.
Line fuse
Minarik drives require an external fuse for protection. Use fast acting fuses rated for
250 VAC or higher, and approximately 150% of the maximum armature current. Fuse
only the HOT leg of the AC line that connects to L1 and leave L2 unfused. Table 1
(page 11) lists the recommended line fuse sizes.
Wire an external line fuse between the stop switch (if installed) and L1 terminal. The
line fuse(s) should be rated at 250 volts and 150 - 200% of maximum motor
nameplate current.
10 Installation
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