USER’S MANUAL
PCM20000
SERIES
Models:
PCM21000A
PCM21000C
PCM21010A
PCM22000A
PCM22000C
Copyright 2001 by
Minarik Corporation
All rights reserved. No part of this manual may be reproduced or transmitted in any
form without written permission from Minarik Corporation. The information and
technical data in this manual are subject to change without notice. Minarik
Corporation and its Divisions make no warranty of any kind with respect to this
material, including, but not limited to, the implied warranties of its merchantability
and fitness for a given purpose. Minarik Corporation and its Divisions assume no
responsibility for any errors that may appear in this manual and make no
commitment to update or to keep current the information in this manual.
Printed in the United States of America.
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.
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 V AC 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.
ii
Specifications 1
Dimensions 2
Installation 4
Mounting ....................................................4
Wiring .......................................................5
Shielding guidelines ..........................................6
Heat sinking ..................................................7
Line fusing ...................................................7
Speed adjust potentiometer .......................................9
Connections . . . ..............................................10
Power, fuse and motor connections .............................10
Motor . . . ..............................................10
Power input .............................................11
Linefuse ...............................................11
Voltage signal follower (PCM2x000A) ..............................14
Voltage signal follower (PCM2x000C) ..............................15
Current signal follower (PCM2x000C only) ...........................16
Operation 17
Before applying power . . . . . . . . . . . . . . . . . . . ......................17
Startup . . . . . . . . . . . . . . . . .....................................20
Starting and stopping methods . . .................................21
Line starting and line stopping .................................21
Decelerate to a stop ........................................22
Calibration 23
Calibration procedure . . . . . . ....................................24
Before applying power .......................................24
SIGNAL ADJUST (SIG ADJ) . . .................................25
MINIMUM SPEED (MIN SPD) .................................26
MAXIMUM SPEED (MAX SPD) .................................26
Contents
iiiTable of Contents
TORQUE (CURRENT LIMIT on PCM2000C series drives) ............27
REGULATION (IR COMP) ....................................28
Application Notes 30
Independent Adjustable Speeds .................................30
Multiple fixed speeds . . . . . . ....................................31
Adjustable speeds using potentiometers in series .....................32
RUN/JOG switch .............................................33
Troubleshooting 34
Before troubleshooting . . . . . . . . . . . . . . . . . . . ......................34
Diagnostic LEDs (PCM20000C series only) .........................35
POWER (GREEN) . . . . . . ....................................35
SIGNAL (YELLOW) . . . . . . . . . . . . . . . . . . . ......................35
CURRENT LIMIT (CURR LIM (RED)) ............................35
Replacement Parts . . . .........................................39
Certificate of Compliance 41
End User Responsibilities .......................................41
Exhibit “A” ..................................................42
Unconditional Warranty inside back cover
Figure 1. PCM2x000A and PCM2x000C Dimensions ....................2
Figure 2. Heat Sink Kit Dimensions . .................................3
Figure 3. Speed Adjust Potentiometer Installation .......................9
Figure 4. PCM2x000A Drive Connections ............................12
Figure 5. PCM2x000C Drive Connections ............................13
Figure 6. PCM2x000A Voltage Follower Connections ...................14
Figure 7. PCM2x000C Voltage Follower Connections ...................15
Figure 8. Current Follower Connections (PCM2x000C only) ..............16
Figure 9. PCM2x000A Jumper Locations and Settings ..................18
Figure 10. PCM2x000C Jumper Locations and Settings ..................19
Figure 11. Run/Decelerate to Zero Speed Switch .......................22
Figure 12. Calibration Trimpot Layout ................................23
Figure 13. Typical TORQUE and IR COMP settings .....................29
Figure 14. Independent Adjustable Speeds (Forward Direction) .............30
Figure 15. Multiple Fixed Speeds . . .................................31
Figure 16. Adjustable Fixed Speeds Using Potentiometers in Series ........32
Figure 17. RUN/JOG Switch Connection to Speed Adjust Potentiometer ......33
Figure 18. Diagnostic LED Location (PCM 20000C Series Only) ............36
Tables
Table 1. Line Fusing Chart .......................................8
Table 2. Replacement Parts .....................................39
Table 3. Corcom® Filters .......................................42
Table 4. Minarik® Filters ........................................43
iv
Illustrations
Specifications
Model PCM21000 PCM21010 PCM22000
Line voltage† 115 VAC 115 VAC 230 VAC
Line current, max 7A AC 3A AC 7A AC
Line current, max†† 14A AC n/a 14A AC
Armature voltage range 0 – 90 VDC 0 – 90 VDC 0 – 180 VDC
Horsepower range 1/4 – 1/2 hp 1/20 – 1/8 hp 1/2–1hp
Horsepower range†† 1/4–1hp n/a 1/2–2hp
Armature current, max 5 ADC 2 ADC 5 ADC
Armature current, max†† 10 ADC n/a 10 ADC
Input signal range (input circuit is isolated)
Voltage 0 – 10 VDC
Current (PCM2x000C series only) 4 – 20 mADC
Ambient temperature range 10ºC – 55ºC
† Line voltage is ±10%, 50/60 Hz, single phase
†† When mounted on 223-0159 heat sink kit
1
2
Dimensions
Figure 1. PCM2x000A and PCM2x000C Dimensions
3Dimensions
Figure 2. Heat Sink Kit Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Mounting
•
Drive components are sensitive to electrostatic fields. Avoid
direct contact with the circuit board. Hold drive by the chassis
only.
• Protect the drive from dirt, moisture, and accidental contact.
Provide sufficient room for access to the terminal block and
calibration trimpots.
• Mount the drive away from heat sources. Operate the drive
within the specified ambient operating temperature range.
•
Prevent loose connections by avoiding excessive vibration of
the drive.
• Mount drive with its board in either a horizontal or vertical
plane. Six 0.19 in. (5 mm) wide slots in the chassis accept #8
pan head screws. Fasten either the large base or the narrow
flange of the chassis to the subplate.
• The chassis must be earth grounded. Use a star washer beneath
the head of at least one of the mounting screws to penetrate the
anodized chassis surface and to reach bare metal.
4
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.
5Installation
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.
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.
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 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 unpredictable
behavior any electronic device, including motor controls.
7Installation
Heat sinking
PCM2x000-series drives require an additional heat sink when the
continuous armature current is above 5 ADC. Use Minarik® part
number 223–0159. 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
Minarik drives require an external fuse for protection. Use fast
acting fuses rated for 250 VAC or higher, and approximately
150% of the maximum armature current. Fuse both L1 and L2
when the line voltage is 230 VAC. Fuse blocks are included on
cased drives only.
Table 1 (page 8) lists the recommended replacement line fuse
sizes.
Table 1. Line Fusing Chart
90 VDC Motor 180 VDC Max. DC Armature AC Line Fuse
Horsepower Horsepower Current (amps) Size (amps)
1/20 1/10 0.5 1
1/15 1/8 0.8 1.5
1/8 1/4 1.5 3
1/6 1/3 1.7 3
1/4 1/2 2.5 5
1/3 3/4 3.5 8
1/2 1 5.0 10
3/4 1 1/2 7.5 15
1 2 10 15
Minarik Corporation offers two fuse kits: part number 050–0066
(1–5A Fuse Kit) and 050–0071 (5–15A Fuse Kit).
8 Installation
Speed adjust potentiometer
9Installation
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).
Warning
Be sure that the potentiometer tabs do not make contact with
the potentiometer enclosure. Grounding the input will cause
damage to the drive.
Figure 3. Speed Adjust Potentiometer Installation
10 Installation
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) or Figure 5 (page 14). The switch
contacts should be rated at a minimum of 200% of motor
nameplate current and 250 volts.
Power, fuse and motor connections
If you use a PCM2x000A-series drive, connect the power input
leads, an external line fuse and a DC motor to the drive’s printed
circuit board (PCB) as shown in Figure 4, page 13.
If you use a PCM2x000C-series drive, refer to Figure 5 (page 14).
Motor
Connect a DC motor to PCB terminals A1 and A2 as shown in
Figure 4. Ensure that the motor voltage rating is consistent
with the drive’s output voltage.
11Installation
Minarik drives supply motor voltage from A1 and A2 terminals.
It is assumed throughout this manual that, when A1 is positive
with respect to A2 , the motor will rotate clockwise (CW) while
looking at the output shaft protruding from the front of the motor.
If this is opposite of the desired rotation, simply reverse the
wiring of A1 and A2 with each other.
Power input
Connect the AC line power leads to terminals L1 and L2, or to a
double-throw, single-pole master power switch (recommended).
Line fuse
Wire an external line fuse between the stop switch (if installed)
and the L1 terminal on terminal board TB501. An additional line
fuse should be installed on L2 if the input voltage is 230 VAC.
The line fuse(s) should be rated at 250 volts and 150 - 200% of
maximum motor nameplate current. Refer to the line fuse chart
on page 8 for fuse ratings.
Warning
Minarik strongly recommends the installation of a master
power switch in the voltage input line, as shown in
Figure 4. The switch contacts should be rated at a minimum
of 200% of motor nameplate current and 250 volts.
12 Installation
Figure 4. PCM2x000A Drive Connections
13Installation
Figure 5. PCM2x000C Drive Connections
14 Installation
Voltage signal follower (PCM2x000A)
Figure 6. PCM2x000A V oltage Follower Connections
Warning
Before applying power, ensure that SO501 is set to SIGNAL
as shown in Figure 6.
Instead of using a speed adjust potentiometer, the drive may be
wired to follow a 0–10 VDC grounded or ungrounded voltage
signal. Connect the signal input (+) to POS. Connect the signal
common (–) to NEG. A potentiometer can be used to scale the
analog input voltage.
SO501
CONTROL
SELECT
JUMPER
15Installation
Voltage signal follower (PCM2x000C)
Figure 7. PCM2x000C V oltage Follower Connections
Warning
Before applying power, ensure that SO501 is set to SIGNAL
and SO502 is set to 0-10 V as shown in Figure 7.
Instead of using a speed adjust potentiometer, the drive may be
wired to follow a 0–10 VDC voltage signal. Connect the signal
input (+) to POS. Connect the signal common (–) to NEG. A
potentiometer can be used to scale the analog input voltage.
16 Installation
Figure 8. Current Follower Connections (PCM2x000C only)
Current signal follower (PCM2x000C only)
Warning
Before applying power, ensure that SO501 is set to SIGNAL
and SO502 is set to 4-20 mA as shown in Figure 8.
Instead of using a speed adjust potentiometer, the drive may be
wired to follow a 4-20 mADC signal (Figure 8). Connect the
signal input (+) to POS. Connect the signal common (–) to NEG.
17
Operation
Warning
Floating voltages exist on the drive when it is powered. BE
ALERT. High voltages can cause serious or fatal injury. For
your safety, use personal protective equipment (PPE) when
operating this drive.
Do not change jumper settings with power applied. Failure
to follow these instructions may result in damage to the
motor or drive, or serious injury to personnel.
Before applying power
•
Ensure that all jumpers are properly set prior to applying
power. See Figure 9 (page 18) for PCM2x000A jumper
location and settings. See Figure 10 (page 19) for
PCM2x000C jumper locations and settings.
•
Verify that no conductive material is present on the printed
circuit board.
18
Operation
Figure 9. PCM2x000A Jumper Locations and Settings
SO501
CONTROL
SELECT
JUMPER
SPEED ADJ. POTCONFIGURATION
(MANUAL MODE)
VOLTAGE FOLLOWER CONFIGURATION
(SIGNAL MODE)
SO501 SO501
19Operation
Figure 10. PCM2x000C Jumper Locations and Settings
SO501
CONTROL
SELECT
JUMPER
SO502
INPUT
SELECT
JUMPER
(MANUAL MODE) (SIGNAL MODE)
(SIGNAL MODE)
Startup
To start the drive:
1. Turn the speed adjust potentiometer full counterclockwise
(CCW). If the drive is following a voltage or current signal,
set the signal to zero.
2. Apply AC line voltage.
3. Slowly advance the speed adjust potentiometer clockwise
(CW), or slowly increase the reference signal. The motor
slowly accelerates as the potentiometer is turned CW, or the
signal is increased. Continue until the desired speed is
reached.
4. Set the speed adjust potentiometer to zero, remove AC line
voltage, or set the input signal to zero. The drive will coast
to a stop.
If the motor or drive does not perform as described, disconnect
the AC line voltage immediately. Refer to the Troubleshooting
section for further assistance.
20
Operation
21
Line starting and line stopping
Line starting and line stopping (applying and removing AC
line voltage) is recommended for infrequent starting and stopping
of a drive only. When AC line voltage is applied to the drive,
the motor accelerates to the speed set by the speed adjust
potentiometer. When AC line voltage is removed, the motor
coasts to a stop.
Minarik strongly recommends installing an emergency stop
switch on both the L1 and L2 inputs (see Connections on pages
12 and 13).
Operation
Starting and stopping methods
Warning
Decelerating to minimum speed, dynamic braking, or
coasting to a stop is recommended for frequent starts and
stops. Do not use any of these methods for emergency
stopping. They may not stop a drive that is malfunctioning.
Removing AC line power (both L1 and L2) is the only
acceptable method for emergency stopping.
For this reason, Minarik strongly recommends installing
an emergency stop switch on both the L1 and L2 inputs
(see Connections on pages 13 and 14).
22 Operation
Decelerate to a stop
The RUN/STOP switch shown in Figure 11 may be used to
decelerate a motor to a stop. Closing the switch between S2 and
S1 decelerates the motor from set speed to a stop. Opening the
switch will cause the motor to accelerate to set speed.
Figure 11. Run/Decelerate to Zero Speed Switch
23
Each drive is factory calibrated to its maximum current rating.
Readjust the calibration trimpot settings to accommodate lower
horsepower motors. All adjustments increase with CW rotation,
and decrease with CCW rotation.
Figure 12. Calibration Trimpot Layout
Warning
Floating voltages exist on the drive when it is powered.
When possible, disconnect the voltage input from the drive
before adjusting the trimpots. If the trimpots must be
adjusted with power applied, use insulated tools and the
appropriate personal protection equipment. BE ALERT.
High voltages can cause serious or fatal injury.
Calibration
SO501
Calibration procedure
Before applying power
1. Verify that no conductive material is present on the printed
circuit board.
2. Ensure that all jumpers are properly set.
3. Set all trimpots except TORQUE (CURR LIMIT on
PCM20000C series drives) to full counterclockwise (CCW).
4. Set the TORQUE (CURR LIMIT on PCM20000C series
drives) trimpot full clockwise (CW).
5. Set the speed adjust potentiometer or reference input signal
to zero.
6. Apply line power to the drive.
7. Calibrate the trimpots in the following order:
• SIGNAL ADJUST (SIG ADJ)
• MINIMUM SPEED (MIN SPD)
• MAXIMUM SPEED (MAX SPD)
• TORQUE (CURR LIMIT on PCM20000C series drives)
• REGULATION (IR COMP)
24
Calibration
25
NOTE: This adjustment is not functional when operating in
MANUAL mode.
SIGNAL ADJUST (SIG ADJ)
Calibration for PCM21000x drives:
The SIG ADJ setting determines the speed that the motor will
achieve when the input voltage or current signal is at its
maximum level. It is factory-set to deliver a 90 VDC armature
output with a 10 VDC input signal. PCM22000x-series drives are
calibrated to deliver a 180 VDC armature output with a 10 VDC
input signal.
To calibrate SIG ADJ:
1. Ensure that no power is applied to the drive.
2. Set jumper SO501 to SIGNAL mode.
3. If using a PCM2x000C-series drive, set SO502 to 0-10V.
4. Apply line voltage.
5. Apply the maximum voltage or current signal
6. Rotate SIG ADJ until the desired motor speed is reached. If
the drive is operated as a voltage follower, the signal required
for rated output voltage must be at least 5 VDC, but no
greater than 20 VDC.
7. Set the voltage signal to zero.
Calibration
26
Calibration
MINIMUM SPEED (MIN SPD)
The MIN SPD setting determines the minimum speed when the
speed adjust potentiometer is turned full CCW, or when the signal
input is set to its minimum value. It is factory set to zero speed.
To calibrate MIN SPD:
1. Set the speed adjust potentiometer full CCW, or set the
signal input to its minimum value.
2. Adjust the MIN SPD trimpot until the motor turns at the
desired minimum speed.
MAXIMUM 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 to its maximum setting.
To calibrate MAX SPD:
1. Ensure that no power is applied to the drive.
2. Set jumper SO501 to MANUAL mode.
3. Apply line voltage.
4. Set the MAX trimpot full CCW.
5. Turn the speed adjust potentiometer full CW.
6. Adjust the MAX SPD trimpot until the desired maximum
motor speed is reached.
NOTE: This adjustment is not functional when operating in
SIGNAL mode.
27Calibration
TORQUE (CURR LIMIT on PCM2000C series drives)
The TORQUE (CURR LIMIT on PCM2000C series) setting
determines the maximum armature current output of the drive. It
is factory set at 120% of maximum drive current.
TORQUE/CURR LIMIT must be recalibrated if you use a lower
horsepower motor.
To calibrate TORQUE/CURR LIMIT, use the following
procedure:
1. With no power applied to the drive, connect a DC ammeter in
series with the motor armature.
2. Set the TORQUE/CURR LIMIT trimpot to full CCW.
3. Carefully lock the motor armature. Ensure that the motor is
firmly mounted.
4. Apply line power. The motor should be stopped.
5. Set the speed potentiometer or reference signal to maximum
speed. The motor should remain stopped.
6. Slowly rotate the TORQUE/CURR LIMIT trimpot clockwise
(CW) until the ammeter reads 120% of maximum motor
armature current.
Warning
Although TORQUE/CURR LIMIT is set to 120% of motor
nameplate current rating, continuous operation beyond that
rating may damage the motor. If you intend to operate
beyond the rating, contact your Minarik representative for
assistance.
28
Calibration
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.
REGULATION (IR COMP)
The IR COMP trimpot setting determines the degree to which
motor speed is held constant as the motor load changes. It is
factory set for optimum motor regulation. To calibrate IR COMP
(exact calibration):
1. Turn the IR COMP trimpot full CCW.
2. Set the speed adjust potentiometer until the motor runs at
midspeed without load (for example, 900 RPM for an 1800
RPM motor). A hand held tachometer may be used to
measure motor speed.
3. Load the motor armature to its full load armature current
rating. The motor should slow down.
4. While keeping the load on the motor, rotate the IR COMP
trimpot until the motor runs at the speed measured in step 2.
Approximate calibration:
If the motor does not maintain set speed as the load changes,
gradually rotate the IR COMP trimpot CW. If the motor oscillates
(overcompensation), the IR COMP trimpot may be set too high
(CW). Turn the IR COMP trimpot CCW to stabilize the motor
speed.
29
NOTE: TORQUE settings may be substituted for CURRENT LIMIT on
PCM2x000C series controls
PCM20010 SERIES
ALL OTHER PCM20000 SERIES DRIVES
Figure 13. Typical TORQUE and IR COMP settings
(actual settings may vary with each application)
Calibration
30
Application Notes
Independent Adjustable Speeds
Connect two speed adjust potentiometers with a single-pole twoposition switch to select between two independent speeds shown
in the forward direction (Figure 14). The speed adjust
potentiometers can be mounted at two separate operating stations.
Figure 14. Independent Adjustable Speeds
(Forward Direction)
31
Multiple fixed speeds
Replace the speed adjust potentiometer with series resistors with a
total series resistance of 10K ohms (Figure 15). Add a single
pole, multi-position switch with the correct number of positions
for the desired number of fixed speeds.
Figure 15. Multiple Fixed Speeds
32
Adjustable speeds using potentiometers in series
Replace the speed adjust potentiometer with a single pole, multiposition switch, and two or more potentiometers in series, with a
total series resistance of 10K ohms. Figure 16 shows a connection
for fixed high and low speed adjust potentiometers
Figure 16. Adjustable Fixed Speeds Using
Potentiometers in Series
33
RUN/JOG switch
Connect a RUN/JOG switch and the JOG pushbutton as shown is
Figure 17. When the RUN/JOG switch is set to JOG, the motor
decelerates to minimum speed (minimum speed is determined by
the MIN SPD trimpot setting). Press the JOG pushbutton to jog
the motor. Return the RUN/JOG switch to RUN for normal
operation.
Figure 17. RUN/JOG Switch Connection to Speed Adjust
Potentiometer
34
Troubleshooting
Before troubleshooting
Check the following steps before proceeding:
• The AC line voltage must be balanced, and match the voltage
on the drive nameplate.
• The motor must be rated for the drive’s rated armature outputs.
• Terminal block connections should be consistent with the
connections shown in this manual.
For additional assistance, contact your local Minarik® distributor,
or the factory direct at:
(800) MINARIK (646-2745) (phone) or (800) 394-6334 (fax).
Warning
Floating voltages exist on the drive when it is powered.
When possible, disconnect the drive while troubleshooting.
High voltages can cause serious or fatal injury.
35Troubleshooting
Diagnostic LEDs (PCM20000C series only)
PCM2x000C series drives are equipped with three diagnostic
LEDs to aid in system evaluation and troubleshooting. See
Figure 18 (page 40) for LED location.
POWER (GREEN)
The green POWER LED lights when AC line voltage is applied
to the drive. The POWER LED is extinguished when power is
disconnected.
SIGNAL (YELLOW)
The yellow SIGNAL LED lights when power is applied, and a
voltage, current, or manual signal is sent to the drive. The
SIGNAL LED is extinguished when no signal is applied.
CURR LIM (RED)
The red CURR LIM LED lights when the current required to
drive the motor is greater than is allowed by the CURR LIMIT
trimpot. If the CURR LIM LED lights, shut down the drive and
remove or reduce the load on the motor. Restart the drive and
check the TORQUE trimpot setting.
36
Troubleshooting
Figure 18. Diagnostic LED Location (PCM 20000C Series Only)
CURRENT
LIMIT
POWER SIGNAL
37Troubleshooting
Motor does not run
1. Check that the motor is receiving AC power. Check fuses
and circuit breakers. Verify that the main power switch is on.
Check whether the speed adjust pot is turned fully CCW
(MANUAL mode) or the input signal is at zero.
2. The speed adjust pot may be open or the signal input leads
may be open.
3. Check whether the motor or its load is mechanically
jammed. Remove the cause of the jam. NOTE: If an
application requires more torque than is allowed by the
TORQUE trimpot setting, the control will go to current limit
under maximum loading conditions. Assuming that the
motor is properly sized, it then will be necessary to reset
TORQUE slightly CW until the stalled condition is
removed.
Fuses or circuit breakers blow
1. Check all wiring for shorts, grounds, and misconnections to
the control and motor.
2. Check that the motor ratings are within the ratings of the
control.
38
Troubleshooting
Motor will not stop at zero speed setting
The MIN SPEED adjustment is set too high.
Motor runs in reverse
Disconnect AC power. Reverse the armature connections. Restore
power to the control.
Motor slows under increased load
The IR COMP adjustment may be set too low. Increase the setting
until the speed remains acceptably constant over the load
range.
Motor speed is unstable under load
The IR COMP adjustment may be set too high. Decrease it until
the symptom disappears.
The motor may be “bouncing” in and out of current limit. Verify
that the TORQUE setting (CURR LIMIT on PCM2x000C series
drives) is sufficient for your application. Increase the setting if it
is too low.
Motor runs at full speed at all times
If in the MANUAL mode, the speed adjust pot, or leads from the
pot to the control, may be open.
39
Replacement Parts
Replacement parts are available from Minarik Corporation and its
distributors for this drive series.
Table 2. Replacement Parts
Model No. Symbol Description Minarik®
P/N
PCM21000A C501-502 220 uF, 35 VDC Capacitor 011-0027
D501–502 Schottky Diode 071-0017
SCR501–502 S8020L High-power SCR 072-0043
T501 ST-3-3109 115VAC Transformer 230-0083
T502 Transformer 230-0077
Chassis 222-0079
10K Ohm Pot Kit 202-0031
1-5A Fuse Kit 050–0066
5-15A Fuse Kit 050–0071
PCM21000C Same as PCM21000A, except:
C501-502 100 uF, 25 VDC Capacitor 011-0079
D504–505 Schottky Diode 071-0017
MOV501-502 2725V RMS, 4500A MOV 075-0011
R501 0.01 Ohm 5W Standup Resistor 032-0129
PCM21010A Same as PCM21000A
PCM22000A Same as PCM21000A
PCM22000C Same as PCM21000C
Troubleshooting
1-5A Fuse Kit Contains
1 Amp 3AG Fast-blo Fuse 050-0042
1.5 Amp 3AG Fast-blo Fuse 050-0026
3 Amp 3AG Fast-blo Fuse 050-0021
5 Amp 3AG Fast-blo Fuse 050-0022
5-15A Fuse Kit Contains
5 Amp 3AG Fast-blo Fuse 050-0022
8 Amp 3AG Fast-blo Fuse 050-0059
10 Amp 3AG Normal-blo Fuse 050-0024
15 Amp 3AG Normal-blo Fuse 050-0018
Potentiometer Kit Contains
10K Ohm ± 5%, 1/4W Potentiometer 120-0009
3/8-32 X 1/2 Nut 151-0007
3/8 Int Tooth Lockwasher 152-0007
9 ea Non-insulated Female Tabs 163-0028
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Troubleshooting
41
Certificate of Compliance
Minarik Corporation hereby certifies that its PCM20000 series
drives have been approved to bear the “CE” mark provided the
conditions of approval (listed in Exhibit “A”) have been met by
the end user.
The PCM20000 series has been tested to the following test
specifications:
EN55011:1991 (emissions), and
EN50082-1:1992 (immunity)
Compliance allows Minarik’s PCM20000 series to bear the CE
mark.
End User Responsibilities
The end user, as described herein, falls into one of two categories:
1. The Consumer will deploy a stand-alone unit as an
integral, yet external, portion of the machine he/she is
operating.
2. The Original Equipment Manufacturer (OEM) will
implement the product as a component of the machine
being manufactured.
42
Certificate of Compliance
Exhibit “A”
In addition to EMI/RFI safeguards inherent in the PCM20000
series’ design, external filtering is required.
Minarik requires the Corcom® filters listed in Table 3. If the
exact filter is not available, use a filter matching the following
specifications:
L = (1.73 + 0.03) milliHenries.
C = (0.27 + 0.54) microFarads (X); 0.0055 microFarads (Y).
R = 330Kohms.
Rated current: 1.4 times maximum DC motor current.
Filter type: Balanced 2-section.
Table 3. Corcom® Filters
Nameplate Current of Corcom® Filter
Motor Wired to the Drive Part Number
0 to 4 amps 6VV1
4.1 to 13 amps 20VV1
The filters in Table 3 should be wired to the AC line
within 0.25 meters of the drive. The ground
connection from the filter must be wired to solid
earth ground (resistance less than 500 ohms); not
machine ground. This is very important!
43
If the end-user is using a CE-approved motor, the correct filter
from Table 3 is all that is necessary to meet the EMC directives
listed herein.
If the end-user is not using a CE-approved motor, a second
filter, Minarik p/n CEXXMM, on the output must be deployed.
XX = rated current of the filter.
The CE20MM is a Real-Pole Balanced-Pi 3-pole filter. If the
exact filter is not available, the specifications are as follows:
L&L1=2*(0.8) milliHenries.
C&C1=2*(0.1) microFarads @ 400W VDC.
Rin = 0.1 ohm; Rout = 1.2 ohm.
Table 4. Minarik® Filters
Nameplate Current of Minarik® Filter
Motor Wired to the Drive Part Number
0 to 4 amps CE4MM
4.1 to 13 amps CE20MM
The filters in Table 4 must be wired to the DC
output of the drive, as close to the drive as possible.
The ground connection from the filter must be wired
to solid earth ground (resistance less than 500
ohms); not machine ground. This is very important!
Certificate of Compliance
The end user must use the filtration listed in Exhibit A to comply
with CE. The OEM may choose to provide alternative filtering
that encompasses the Minarik drive and other electronics within
the same panel.
The OEM has this liberty because CE is a machinery directive.
Whether or not every component in the OEM’s machinery meets
CE, the OEM must still submit his machine for CE approval.
Thus, no component must necessarily meet CE within the
machine, as long as the OEM takes the necessary steps to
guarantee the machine does meet CE. By the same token, even if
every component in the OEM’s machine does meet CE, the
machine will not necessarily meet CE as a machine.
Using CE-approved wiring practices (like proper shielding) and
the filters listed in Exhibit A guarantee the drive will meet
EN55011 (1991 emissions standard) and EN50082-1 (1992
immunity standard).
44
Certificate of Compliance
Unconditional Warranty
A. Warranty
Minarik Corporation (referred to as “the Corporation”) warrants that its products will be free from
defects in workmanship and material for twelve (12) months from date of shipment thereof.
Within this warranty period, the Corporation will repair or replace such products that are returned
to Minarik Corporation, 901 East Thompson Avenue, Glendale, CA 91201-2011 USA.
This warranty shall not apply to any product that has been repaired by unauthorized persons.
The Corporation is not responsible for removal, installation, or any other incidental expenses
incurred in shipping the product to and from the repair point.
B. Disclaimer
The provisions of Paragraph A are the Corporation’s sole obligation and exclude all other
warranties of merchantability for use, express or implied. The Corporation further disclaims any
responsibility whatsoever to the customer or to any other person for injury to the person or
damage or loss of property of value caused by any product that has been subject to misuse,
negligence, or accident, or misapplied or modified by unauthorized persons or improperly
installed.
C. Limitations of Liability
In the event of any claim for breach of any of the Corporation’s obligations, whether express or
implied, and particularly of any other claim or breech of warranty contained in Paragraph A, or of
any other warranties, express or implied, or claim of liability that might, despite Paragraph B, be
decided against the Corporation by lawful authority, the Corporation shall under no
circumstances be liable for any consequential damages, losses, or expense arising in
connection with the use of, or inability to use, the Corporation’s product for any purpose
whatsoever.
An adjustment made under warranty does not void the warranty, nor does it imply an extension
of the original 12-month warranty period. Products serviced and/or parts replaced on a nocharge 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.
901 E Thompson Avenue
Glendale, CA 91201-2011
Tel.: 1-800-MINARIK (646-2745)
Fax: 1-800-394-6334
www.minarikcorp.com
Document number 250-0090, Revision 5
Printed in the U.S.A – 1/01
North America $12.00, Outside North America $15.00
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