Minarik Drives XP-AC SERIES Users Manual

USER’S MANUAL

XP-AC SERIES

MODELS

XP02-115AC
XP05-115AC
XP10-115AC

Pulse-Width Modulated, Adjustable Speed Drives for DC Brush Motors

Copyright © 2006 by

Minarik Drives

All rights reserved. No part of this manual may be reproduced or transmitted in any form
without written permission from Minarik Drives. 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 tness 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.

m Safety Warnings

Have a qualied 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 Healthy Act
(OSHA) when installing equipment.

Reduce the chance of an electrical re, 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. Install a

•
master switch in the AC line for stopping the drive in an emergency.

This drive is not isolated from earth ground. 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.

i

ii

Table of Contents

Specications 1

Dimensions 2

Installation 3

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

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Voltage Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operation 8

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Decelerating to a stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Calibration 12

MAX SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

ACCEL/DECEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

IR COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CURRENT LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

ApplicationNotes 15

Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Connection to other Minarik devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Single speed potentiometer control of multiple drives . . . . . . . . . . . . . . . . . . . . . . . . . 18

Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Troubleshooting 20

Replacement Parts 23

Limited Warranty inside back cover

iii

iviv

Illustrations

Fig 1. XP-AC Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Fig 2. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fig 3. XP-AC Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Fig 4. Voltage Follower Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fig 5. Run/Decelerate to Zero Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Fig 6. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Fig 7. Typical CURRENT LIMIT and IR COMP Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fig 8. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Fig 9. Adjustable Fixed Speeds using Potentiometers in Series . . . . . . . . . . . . . . . . . . . . . . 15

Fig 10. Independent Adjustable Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Fig 11. RUN/JOG Switch Connection to Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . 16

Fig 12. Connecting an XP-AC Series Drive to a PCM4 or DLC600 . . . . . . . . . . . . . . . . . . . . 17

Fig 13. Leader-Follower Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fig 14. Single Speed Potentiometer Control of Multiple Drives . . . . . . . . . . . . . . . . . . . . . . 18

Fig 15. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Specications

Max. Continuous Armature HP Range with

Model  ArmatureCurrent(AmpsDC) 115VACApplied

XP02-115AC
XP05-115AC
XP10-115AC

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

2
5
10 †

1/20 - 1/8
1/4 - 1/2
1/2 - 1

1

ACLineVoltage

ArmatureVoltageRange

Form Factor (at base speed)

Acceleration/Deceleration Time Range (no load)

AnalogInputVoltageRange[isolated;S1(+)toS2(–)]

InputImpedence(S1toS2with5VDCinput)

Speed Regulation

SafetyCertication

Ambient Temperature Range (chassis drive)

Weight

XP02-115AC

XP05-115AC

XP10-115AC

115VAC,±10%,50/60Hz,singlephase

ULRecognizedComponent,le#E132235

CSACertiedComponent,le#LR41380

0–130VDC

1.05

0.5-6seconds

0–10VDC

approximately10Kohms

1%basespeedorbetter

10°C–40°C

0.66lb

0.72 lb

0.82 lb

2

0.73 [19]

1.75 [44]

3.64 [93]

4.30 [109]

3.80 [97]

0.19 [5]

6 PLACES

A-

A+

+ DC IN

- DC IN

R501

R504

R502

CURRENT

LIMIT

MAX SPEED

ACCEL /

DECEL

IR COMP

R503

+

C501

S3

S2

S1

H

W

L

A

1.03 [26]

1.35 [34]

0.19 [5]

Dimensions

SIX MOUNTING SLOTS

0.19 [5] WIDE x 0.34 [9] DEEP

MODEL

XP02-115AC
XP05-115AC
XP10-115AC

DIMENSION “A”

1.77 [45]

2.36 [60]

2.88 [73]

FIGURE1.XP-ACSeriesDimensions

Installation

Mounting

Drive components are sensitive to electrostatic elds. Avoid contact with the circuit

•
board directly. Hold drive by the chassis only.

Protect the drive from dirt, moisture, and accidental contact. Provide sufcient room for

•
access to the terminal block and calibration trimpots.

Mount the drive away from the other heat sources. Operate the drive within the speci-

•

ed 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 ange 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

Use 18 AWG wire for speed adjust potentiometer wiring. Use 16 AWG wire for motor

•
wiring.

Twist logic wires (for speed adjust potentiometer) to avoid picking up unwanted electri-

•
cal noise. Use shielded cable if wires are longer than 18 in. (46 cm).

Keep logic wires away from power carrying lines or sources of electrical noise that

•
can cause erratic operation. Never run speed adjust potentiometer wires in the same
conduit used for motor and AC line voltage wires.

3

4 Installation

•

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.

Keep logic wires away from the power carrying lines or sources of electrical noise that

•
can cause erratic operation.

Heat sinking

Model XP10-115AC 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

sufcient heat sinking in their basic congurations. 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 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. See the chart below for recom­mended line fuse sizes.

RecommendedLineFuseSizes

Maximum Armature

Current (DC Amps)

1.5 & below

2.6

3.5

5.0

7.6
10

AC Line Fuse

Rating (AC Amps)

3
5

8
10
15
15