Minarik Drives MM501U Users Manual
MM501U
User’s Manual
SCR, Dual-Voltage, Adjustable Speed
Drive for DC Brush Motors
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.
MVD091302
Printed in the United States of America.
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.
i
TI
ii
Contents
Specifications 1
Dimensions 2
Installation 3
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Cage-clamp Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Power, fuse and motor connections . . . . . . . . . . . . . . . . . . . . . . .8
Power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Field Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Start/Stop Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Tachogenerator Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Voltage Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Current Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Operation 14
Before applying power: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . .17
Start/Stop Pushbuttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Dynamic Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Calibration 20
Maximum Speed (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Minimum Speed (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
iii
Table 1. Field Ouptut Connections . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 2. Recommended Dynamic Brake Resistor Sizes . . . . . . . . . .18
Table 3. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Tables
Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
IR Compensation (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Acceleration (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Deceleration (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
TACH VOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Application Notes 30
Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Adjustable speeds using potentiometers in series . . . . . . . . . . . . .31
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Reversing with a DLC600 controller . . . . . . . . . . . . . . . . . . . . . . .34
Troubleshooting 35
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Unconditional Warranty 41inside back cover
Figure 1. MM501U Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Figure 2. Cage-Clamp Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . .5
Figure 3. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . .6
Figure 4. MM501U Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Figure 5. Voltage or Current Signal Connections . . . . . . . . . . . . . . . .13
Figure 6. Diagnostic LED Locations . . . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 7. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . .19
Figure 8. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . .21
Figure 9. CURRENT LIMIT and IR COMP Settings . . . . . . . . . . . . . .25
Figure 10. Feedback Switch (SW503) Location . . . . . . . . . . . . . . . . .28
Figure 11. Tachogenerator Connections . . . . . . . . . . . . . . . . . . . . . .29
Figure 12. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Figure 13. Adjustable Speeds Using Potentiometers in Series . . . . . .31
Figure 14. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . .32
Figure 15. Reversing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 16. Independent Forward and Reverse Speeds . . . . . . . . . . . .34
iv
Illustrations
1
Specifications
Model Number MM501U
Type Open Chassis
Line Fuse Rating 40A (Buss Type SC-40 or equivalent)
Field Fuse Rating 3A, fast-acting
Horsepower Range @ 90 VDC Output 1 - 2.5 HP
Horsepower Range @ 180 VDC Output 2 - 5 HP
Maximum Armature Voltage Range @ 115 VAC Input 0 - 90 VDC
Maximum Armature Voltage Range @ 230 VAC Input 0 - 180 VDC
Minimum Speed Adjustment Range @ 115 VAC Input 0 - 60 VDC
Minimum Speed Adjustment Range @ 230 VAC Input 0 - 120 VDC
Maximum Armature Current 25 ADC
Field Voltage @ 115 VAC Input 50 VDC (F1 to L1) or 100 VDC (F1 to F2)
Field Voltage @ 230 VAC Input 100 VDC (F1 to L1) or 200 VDC (F1 to F2)
Form Factor 1.37
Acceleration Time Range (no load)
0 - 90 VDC Armature Voltage 0.5 - 12 seconds
0 - 180 VDC Armature Voltage 0.5 - 12 seconds
Deceleration Time Range (no load)
0 - 90 VDC Armature Voltage 0.5 - 12 seconds
0 - 180 VDC Armature Voltage 0.5 - 12 seconds
Analog Input Voltage Range
(grounded and isolated signal; S1 to S2) 0 - 10 VDC
Speed Adjustment Potentiometer 10Kohm
Approximate Input Impedance
(S1 to S2; voltage signal setting) 100K ohm
Speed Regulation (% of base speed)
Armature Feedback 1% or better
Tachogenerator Feedback 0.1%
Tachogenerator Feedback Voltage Range 7 - 50 VDC per 1000 RPM
Weight 3.8 lb
Ambient Operating Temperature Range * see notes
Notes:
* 10º - 40ºC when mounted flat (horizontally), or in an enclosure whose volume is between 4 and 6 cubic feet;
10ºC - 50ºC when mounted upright (with heatsink fins vertical) in an enclosure greater than 6 cubic feet.
2
ALL DIMENSIONS IN INCHES [MILLIMETERS]
FOUR (4) MOUNTING SLOTS 0.19 [5] X 0.30 [8] DEEP
Dimensions
]
]
]
7
]
]
C
4
C
8
SC
4
1
1
2
2
1
2
C
FU
04
01
+
C
3
AC1
AC2
SC
SC
2
T501
D503
C
4
SCR
B2
01
1
3
S2
S1
1
S3
2
TB
02
MAX
MIN
02
C
1
C
2
01
03
P
CC
L
D
C
L
O
R
CL
RUN
R501
R504
R50
D504
SC
5
O
T
COM
C
IN
Figure 1. MM501U Dimensions
L
L
R50
R50
5
R
9.80 [249
.00 [178
F
5
F
TB5
A
A
50
50
507
K5
B
5
B
T
T
U
I
50
50
P
IL5
50
WE
50
IL5
IL5
A
E
E
E
6.30 [160
6.90 [175
2.50 [66
3
• 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
(vertical mounting is preferred; see Figure 1, page 2). Four 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.
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 on page i before attempting installation.
Mounting
Installation
4 Installation
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 and the drive is disabled. Opening
any one motor lead may destroy the drive.
Wiring
• Use 18 AWG wire for speed adjust potentiometer wiring. Use 16
AWG wire for field (F1, F2) wiring. Use 14 AWG wire for AC line
(L1, L2) and motor (A1, A2) wiring.
Fuses
MM501U drives have two 40A line fuses installed in Fuse Holder
501 (FH501). Line fuses are rated for maximum rated horsepower.
Resize line fuses if using a smaller horsepower motor. Size fuses
for approximately 150% of the maximum motor armature current.
One 3A field fuse (FU503) is also installed on the drive. This fuse
does not have to be resized if using a smaller horsepower motor.
5Installation
Figure 2. Cage-Clamp Terminal Block
Cage-clamp Terminal Block
MM501U drives use a cage-clamp terminal block for terminal
block 502 (TB502). To connect a wire to the cage-clamp terminal
block (see Figure 2), use a small screwdriver to press down on
the lever arm. Insert a wire stripped approximately 0.25 inches (6
mm) into the opening in front of the terminal block. Release the
lever arm to clamp the wire.
Press down on the
lever arm using
a small screwdriver.
1
Insert wire into the
2
wire clamp.
Release the lever arm
3
to clamp the wire.
6 Installation
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.
JUST
S
E
Figure 3. Speed Adjust Potentiometer
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.
UNT THROUGH A 0.38 IN. (10 MM) HOL
W
TAR
WA
HER
NSULATING DISK
PEED AD
POTENTIOMETER
7Installation
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 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.
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.
8
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 10.
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 10. The switch contacts should be rated at a
minimum of 200% of motor nameplate current and
250 volts.
Installation
Connections
9Installation
Power input
Connect the AC line power leads to terminals L1 and L2, or to a
double-throw, single-pole master power switch (recommended).
Motor
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 armature to PCB terminals A1 and A2 as
shown in Figure 4, page 10. Ensure that the motor voltage
rating is consistent with the drive’s output voltage.
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