Minarik Drives PCMXP Series Users Manual

USER’S MANUAL

PCMXP Series

Isolated Input, Pulse-Width Modulated,

Adjustable Speed Drives

for DC Brush Motors

Models: PCMXP02–115AC

PCMXP05–115AC
PCMXP10–115AC

Copyright © 2013 by

Minarik Drives

All rights reserved. No part of this document may be reproduced or transmitted in
any form without written permission from Minarik Drives. The information and
technical dat a in this document are subject to change without notice. Minarik
Drives makes 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 Drives assumes no responsibility for any errors that may appear in
this document and makes no commitment to update or to keep current the information
information in this document.

Printed in the United States of America.

i

Safety Warnings

• This symbol  denotes an important safety tip or warning.

Please read these sections carefully prior to performing any of
the instructions contained in that section.

• Have a qualified electrical maintenance 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 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

Contents

Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Manual/signal header (SW501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Before applying power: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Automatic restart upon power restoration . . . . . . . . . . . . . . . . . . . . . . . . .11

Decelerating to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

CURRENT LIMIT (CURR LIMIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

IR COMPENSATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

SIGNAL ADJUST (SIG ADJ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

iii

Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . .21

Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Reversing with a DIGI-LOK Controller . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Unconditional Warranty . . . . . . . . . . . . . . . . . . . . .inside back cover

Tables

Table 1. Recommended Dynamic Brake Resistor Sizes . . . . . . . . . . . . . . . . . .14

Table 2. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Illustrations

Figure 1. PCMXP Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Figure 2. Earth Ground Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Figure 3. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Figure 4. Manual/Signal Switch Set for

(a) Manual Input and (b) Signal Input . . . . . . . . . . . . . . . . . . . . . . . . . .8

Figure 5. PCMXP Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Figure 6. Decelerating to Minimum Speed Connections for

(a) Manual Input and (b) Signal Input . . . . . . . . . . . . . . . . . . . . . . . . .12

Figure 7. Dynamic Braking Connections for

(a) Manual Input and (b) Signal Input . . . . . . . . . . . . . . . . . . . . . . . . .13

Figure 8. Typical CURRENT LIMIT and IR COMP Settings

(actual settings may vary with each application) . . . . . . . . . . . . . . . . .19

Figure 9. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Figure 10. Adjustable Speeds Using Potentiometers in Series . . . . . . . . . . . . . .21

Figure 11. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Figure 12. RUN/JOG Switch for (a) Manual Input and (b) Signal Input . . . . . . . .23

Figure 13. Reversing with Manual Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Figure 14. Reversing with Signal Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Figure 15. Reversing with a DLC600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Figure 16. PCMXP Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

iv

1

Specifications

Max. Continuous

Armature HP Range

Current with 130 VDC

Model (Amps DC) Motors

PCMXP02–115AC 2 1/20 – 1/8

PCMXP05–115AC 5 1/4 – 1/2

PCMXP10–115AC 10 † 1/2 – 1

† Use heat sink part number 223–0159 when operating the drive above 5 ADC.

AC Line Voltage 115 VAC, ±10%, 50/60 Hz, single phase
Armature Voltage Range 0–130 VDC
Form Factor (at base speed) 1.05
Acceleration/Deceleration Time (with load) 1 second
Analog Input Voltage Range (input circuit isolated; POS to NEG) 0–10 VDC
Input Impedance (POS to NEG) > 2 KΩ
Speed Regulation 1% base speed or better
Ambient Temp. Range (chassis drive) 10°C – 40°C

Weight

PCMXP02–115AC 0.68 lb
PCMXP05–115AC 0.75 lb
PCMXP10–115AC 0.82 lb

2

Dimensions

PCMXP02–115AC 1.77 [45]
PCMXP05–115AC 2.36 [60]
PCMXP10–115AC 2.88 [73]

SIX MOUNTING SLOTS 0.19 [5] WIDE x 0.34 [9] DEEP

ALL DIMENSIONS IN INCHES [MILLIMETERS]

Figure 1. PCMXP Series Dimensions

Model Dimension “A”

Installation

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 terminal block and
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 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.

3

4 Installation

Wiring

Warning

Do not install, remove, or rewire this equipment with power
applied. Failure to heed this warning may result in re,
explosion, or serious injury.

This drive is isolated from earth ground. Circuit potentials are at
at 115 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 mya destroy the drive.

This product does not have internal solid state motor overload
protection. It does not contain speed-sensitive overload protection,
thermal memory retention or provisions to receive and act upon
signals from remote devices for over temperature protection. If
motor overload protection is needed in the end-use product, it
needs to be provided by additional equipment in accordance with
NEC standards.

• Use 18 AWG wire for speed adjust potentiometer or voltage signal

input wiring. Use 16 AWG wire for motor and AC line voltage wiring.

•

Connect earth ground to the earth ground screw attached to the PC
board. See Figure 2 for the earth ground screw location.

Earth

Ground

Screw

Figure

2.

Ground

Screw

5Installation

Shielding Guidelines

Warning

Under no circumstances should power and logic leads be
bundled together. Induced voltage can cause unpredictable
behavior any electronic device, including motor controls.

As a general rule, Minarik Drives recommends shielding of all conductors.

If it is not practical to shield power conductors, Minarik Drives

recommends shielding all logic-level leads. If shielding 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 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.

6 Installation

Heat sinking

Model PCMXP10-115AC requires 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.

Line fusing

Protect all PCMXP Series drives with AC line fuses. Use fast acting
AC line fuses rated for 250 volts, and approximately
150% to 200% of the maximum armature current. Fuse only the
“hot” side of the AC line (L1) if using 115 VAC line voltage.
See the chart below for recommended line fuse sizes:

Line Fuse Chart

Maximum Armature AC Line Fuse

Current (DC Amps) Rating (AC Amps)

0.5 1

0.8 1.5

1.5 3

2.6 5

3.5 8

5.0 10

7.6 15
10 15

7

Speed adjust potentiometer

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 potentiometer leads are
longer than 18 in. (457 mm), use shielded cable (see Wiring
section).

Figure 3. 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.



Installation

8 Installation

Manual/signal header (SW501)

Place a jumper on the manual/signal header (SW501) to set the
drive for manual (speed adjust potentiometer) input or 0–10 VDC
signal input. See Figure 4a and 4b for manual and signal settings.

Figure 4. Manual/Signal Switch Set for

(a) Manual Input and (b) Signal Input

(a) (b)