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

Installation 5

POT TAB ASSIGNMENTS

WIPER

CW

CCW

SPEED ADJUST

POTENTIOMETER

INSULATING DISK

PANEL

STAR

WASHER

NUT

MOUNT THROUGH A 0.38 IN. (10 MM) HOLE

Speed adjust potentiometer

Mount the speed adjust potentiometer through a 0.38 in. (10 mm) hole with the hardware
provided (Figure 2). 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, A–, A+).

m 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 2. Speed Adjust Potentiometer

6 Installation

A-

A+

+ DC IN

- DC IN

R501

R504

R502

CURRENT

LIMIT

CW

10K

Speed Adjust

Potentiometer

MOTOR

ARMATURE

MAX SPEED

ACCEL /

DECEL

IR COMP

R503

PRE-WIRED

Fuse hot 115 VAC leg.

Fuse size typically

150% motor nameplate

continuous rating.

+

C501

S3

S2

S1

H

W

L

LINE VOLTAGE

Connections

ASSUMPTIONS: Minarik drives supply motor voltage from A+ and A– terminals. It is as-

sumed throughout this manual that, when A+ is positive with respect to A–, 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 A+ and A– with

each other.

Figure 3. XP-AC Connections

A-

A+

+ DC IN

- DC IN

R501

R504

R502

CURRENT

LIMIT

0 – 10 VDC

Isolated Voltage

Signal Input

–

+

MAX SPEED

ACCEL /

DECEL

IR COMP

R503

+

C501

S3

S2

S1

H

W

L

Installation 7

Voltagefollower

Instead of using a speed adjust potentiometer, the drive may be wired to follow a

0–10 VDC voltage signal that is isolated from earth ground (Figure 4). Connect signal
input (+) to S1. Connect the signal common (–) to S2. Make no connection to S3. A poten-

tiometer can be used to scale the analog input voltage. To achieve greater linearity and
control, use an interface device such as Minarik® model PCM4 to scale the analog input
voltage. Follow the same wiring guidelines used for speed adjust potentiometer wiring (see

page 3.)

m WARNING

Do not connect a non-isolated input voltage signal to any XP Series drive. Connecting a
non-isolated signal will damage the drive.

Figure4.VoltageFollowerConnections

8

Operation

Startup

Note: Before applying power, verify that no conductive material is present on the printed
circuit board.

To start the drive:

Turn the speed adjust potentiometer full counterclockwise (CCW). If the drive is follow-

1.
ing a voltage signal, set the voltage signal to 0 VDC.

Apply AC line voltage.

2.

Slowly advance the speed adjust potentiometer clockwise (CW). If the drive is following

3.
a voltage signal, slowly increase the voltage signal. The motor slowly accelerates as
the potentiometer is turned CW, or the voltage signal is increased. Continue until the
desired speed is reached.

Remove AC line voltage from the drive to coast the motor to a stop.

4.

If the motor or drive does not perform as described, disconnect the AC line voltage immedi­ately. Refer to the Troubleshooting section for further assistance.

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.

Operation 9

S3

S2

S1

RUN

STOP

CCW

10K Ohm
Speed Adjust
Potentiometer

CW

Decelerating to a stop

A switch may be used to decelerate the motor to a stop. Connect the switch as shown in
Figure 5. Close the switch between S1 and S2 to stop the motor from set speed. Open the
switch to accelerate the motor to set speed. The ACCEL/DECEL trimpot setting determines
the rate at which the motor accelerates and decelerates, respectively.

Figure5.Run/DeceleratetoZeroSpeedSwitch

10 Operation

S3

S2

S1

A2

CCW

10K Ohm
Speed Adjust
Potentiometer

CW

BRAKE

RUN

A1

DYNAMIC
BRAKE
RESISTOR

MOTOR

Dynamic braking

Dynamic braking may be used to rapidly stop a motor (Figure 6). For the simplest RUN/

BRAKE switch, use a double pole, double throw switch rated for at least the maximum DC
armature voltage and maximum braking current. For the most reliable control scheme, use

a relay with a delay on the make for the motor, and use a relay with a delay on the break
for S1/S2.

Figure6.DynamicBrakeConnection

Operation 11

Size the dynamic brake resistor according to the motor current rating (see the table below).
The dynamic brake resistance listed in the table is the smallest recommended resistance
allowed to prevent possible demagnetization of the motor. The motor stops less rapidly
with higher brake resistor values.

RecommendedDynamicBrakeResistorSizes

Motor Armature

Current Rating

less than 2 ADC

2–3 ADC
3–5 ADC

5–10 ADC

10–17 ADC

For motors rated 1/17 horsepower and lower, a brake resistor is not necessary since the
armature resistance is high enough to stop the motor without demagnetization. Replace
the dynamic brake with 12 gauge wire.

Minimum Dynamic

BrakeResistorValue

1 ohm

5 ohm
10 ohm
20 ohm
40 ohm

Minimum Dynamic

BrakeResistorWattage

1W

5W
10W
20W
50W

m WARNING

Wait for the motor to completely stop before switching it back to RUN. This will prevent
high armature currents from damaging the motor or drive.

12

Calibration

Each drive is factory calibrated to its maximum horsepower rating. Readjust the calibration

trimpot settings to accommodate lower horsepower motors.

All adjustments increase with CW rotation, and decrease with CCW rotation. Use a non-me-

tallic screwdriver for calibration. Each trimpot is identied on the printed circuit board.

MAX SPD

The MAX SPD setting determines the motor speed when the speed adjust potentiometer is

turned full CW. It is factory set for maximum rated speed.

To calibrate, set the MAX SPD trimpot full CCW. Turn the speed adjust potentiometer full

CW. Adjust the MAX SPD trimpot until the desired maximum motor speed is reached.

ACCEL/DECEL

The ACCEL/DECEL setting determines the time the motor takes to ramp to a higher (or
lower) speed. See Specications on page 1 for approximate acceleration times. The
ACCEL/DECEL setting is factory set to its minimum value (full CCW).

Turn the ACCEL/DECEL trimpot CW to increase the acceleration and deceleration time, and
CCW to decrease the acceleration and deceleration time.

IR COMP

The IR COMP setting determines the degree to which motor speed is held constant as the
motor load changes. It is factory set for optimum motor regulation.

Recalibrate the IR COMP setting when using a lower horsepower motor. Refer to the recom­mended IR COMP settings on page 14, or recalibrate using the following procedure:

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 drive.

Calibration 13

CURRENT LIMIT

The CURRENT LIMIT setting determines the maximum armature current output of the drive.
It is factory set at 120% of rated motor current.

Recalibrate the CURRENT LIMIT setting when using a lower horsepower motor. Refer to
the recommended CURRENT LIMIT settings on page 14, or recalibrate using the following
procedure:

With the power disconnected from the drive, connect a DC ammeter (0–15 A minimum

1.
scale) in series with the armature.

Set the CURRENT LIMIT trimpot to minimum (full CCW).

2.

Connect power to the drive. The motor should remain stopped.

3.

Lock the motor armature. Be sure that the motor is rmly mounted.

4.

Set the speed adjust potentiometer to maximum (full CW).

5.

Adjust the CURRENT LIMIT trimpot CW slowly until the armature current is 120% of

6.
motor rated armature current.

Set the speed adjust potentiometer to minimum and remove the stall from the motor.

7.

m WARNING

Although the CURRENT LIMIT can be set to exceed the motor’s maximum armature

current rating, we recommend you do not run the motor continuously beyond that

rating. Continuous operating beyond the maximum armature current rating may cause

thermal degradation to the motor and drive.

14 Calibration

CURRENT

LIMIT

IR COMP

CURRENT

LIMIT

IR COMP

1/8 HP
90 VDC

1.3 ADC

1/10 HP
90 VDC

1.1 ADC

1/20 HP
90 VDC

0.56 ADC

XP02-115AC

CURRENT

LIMIT

IR COMP

XP05-115AC

1/2 HP
90 VDC
5 ADC

1/3 HP
90 VDC

3.5 ADC

1/4 HP
90 VDC

2.7 ADC

CURRENT

LIMIT

IR COMP

CURRENT

LIMIT

IR COMP

CURRENT

LIMIT

IR COMP

XP10-115AC

CURRENT

LIMIT

IR COMP

CURRENT

LIMIT

IR COMP

CURRENT

LIMIT

IR COMP

1 HP
90 VDC
10 ADC

3/4 HP
90 VDC

7.6 ADC

1/2 HP
90 VDC
5 ADC

Figure 7. Typical CURRENT LIMIT and IR COMP Settings

(actual settings may vary with each application)

15

S3

S2

S1

R1

R2

R3

R4

Total Series

Resistance

10K Ohms

S3

S2

S1

S3

S2

S1

High
Speed

CW

5K Ohm

CW

5K Ohm

Low
Speed

Application Notes

Multiplexedspeeds

Replace the speed adjust potentiometer with series resistors with a total series resistance
of 10K ohms (Figure 8). Add a single pole, multi-position switch with the correct number of

positions for the desired number of xed speeds.

Figure 8. Multiple Fixed Speeds

Adjustable speeds using potentiometers in series

Replace the speed adjust potentiometer with a single pole, multi-position switch, and two
or more potentiometers in series, with a total series resistance of 10K ohms. Figure 9

shows a connection for xed high and low speed adjust potentiometers.

Figure 9. Adjustable Fixed Speeds Using Potentiometers in Series

16 Application Notes

S3

S2

S1

S3

S2

S1

SPEED 2

SPEED 1

CW

20K ohm

CW

20K ohm

S3

S2

S1

CCW

JOGRUN

10K Ohm

CW

JOG

PUSHBUTTON

Independent adjustable speeds

Replace the speed adjust potentiometer with a single pole, multi-position switch, and two
or more potentiometers in parallel, with a total parallel resistance of 10K ohms. Figure
10 shows the connection of two independent speed adjust potentiometers that can be
mounted at two seperate operating stations.

Figure10.IndependentAdjustableSpeeds

RUN/JOG switch

Using a RUN/JOG switch is recommended in applications where quick stopping is not
needed and frequent jogging is required. Use a single pole, normally closed, momentary
operated pushbutton for the JOB pushbutton as shown in Figure 11. When the RUN/JOG
switch is set to JOG, the motor decelerates to zero speed. Press the JOG pushbutton to jog
the motor. Return the RUN/JOG switch to RUN for normal operation.

Figure11.RUN/JOGSwitchConnectiontoSpeedAdjustPotentiometer

Connections to other Minarik devices

DLC600

XP-AC

SERIES

DRIVE

S1

S2

S3

S2

S1

PCM4

XP-AC

SERIES

DRIVE

1

2

S3

S2

S1

Application Notes 17

Figure12.ConnectinganXP-ACSeriesDrivetoaPCM4orDLC600

18 Application Notes

MOTOR

PCM4

TB501

TB502

10K Ohm
(optional)

Follower
Drive

Leader
Drive

A1 9 (+) (+)

(-)

(-)

8

2

1

S2

S1

7

A2

MOTOR

MOTOR

PCM4

TB501

7

8

6

1

2

7

8

6

1

2

TB502

TB501 TB502

PCM4

DRIVE A

ratio pot A
(optional)

10KΩ

ratio pot B
(optional)

10KΩ

S2

S1

DRIVE B

S2

S1

A2

A1

A2

A1

Leader-follower application

In this application, use a PCM4 to monitor the speed of the leader motor (Figure 13). The
PCM4 isolates the leader motor from the follower drive, and outputs a voltage proportional
to the leader motor armature voltage. The follower drive uses this voltage reference to set
the speed of the follower motor. An optional ratio potentiometer may be used to scale the
PCM4 output voltage.

Figure13.Leader-FollowerApplication

Single speed potentiometer control of multiple drives

Multiple drives can be controlled with a single speed adjust potentiometer using a PCM4
at the input of each drive to provide isolation (Figure 14). Optional ratio potentiometers can
be used to scale the PCM4 output voltage, allowing independent control of each drive.

Figure14.SingleSpeedPotentiometerControlofMultipleDrives

Application Notes 19

MOTOR

A2

Forward

Brake

Reverse

A1

Dynamic
Brake
Resistor

S3

S2

S1

CCW

10K Ohm
Speed Adjust
Potentiometer

CW

Reversing

A dynamic brake may be used when reversing the motor direction (Figure 15). Use a three
pole, three positions switch rated for at least the maximum DC armature voltage and maxi­mum braking current. Wait for the motor to stop completely before switching it to either the
forward or reverse direction. See the Dynamic braking section for sizing the dynamic brake
resistor.

Figure15.ReversingCircuitConnection

20

Troubleshooting

m WARNING

Dangerous voltages exist on the drive when it is powered. When possible, disconnect

the AC line voltage from the drive while troubleshooting. Be alert. High voltages can
cause serious or fatal injury.

Perform the following steps before starting any procedure in this section:

Disconnect AC line voltage from the drive.

•

Check the drive closely for damaged components.

•

Check that no conductive or other foreign material has become lodged on the printed

•
circuit board.

Verify that every connection is correct and in good condition.

•

Verify that there are no short circuits or grounded connections.

•

Check that the drive’s rated armature output is consistent with the motor rating.

•

Motor does not run

Check for blown fuses or tripped circuit breaker.

1.

Check that the speed adjust potentiometer is securely connected to S1, S2, and S3. If

2.
an input voltage signal is used, check that the connections to S1 and S2 are secure.

Check that S1 and S2 are not shorted together.

3.

Check that the drive recieves AC power at L1 and L2.

4.

Check that the motor is not jammed or restricted from movement.

5.

Check that the drive is not in current limit. Recalibrate the CURRENT LIMIT trimpot if it

6.
is set too low (see page 14 for recommended trimpot settings).

Fuse blows or circuit breaker trips

1.

Check all wiring for shorts, grounds, or misconnections.

Check that the drive is congured to match the motor rating.

2.

Check that the motor is not jammed or restricted from movement.

3.

Check that the fuse size is correct for the motor being driven.

4.

Motor runs too fast at the maximum speed setting

Check that the MAX SPD setting is not set too high.

1.

Motor runs in the opposite direction

Remove AC line voltage.

1.

Reverse connections to the motor armature.

2.

Motor slows under load

1.

Check that the drive has been correctly calibrated for the motor.

2.

Check that the motor is not overloaded.

3.

Readjust the IR COMP slightly CW until motor runs at proper speed.

Motor is unstable under load

Troubleshooting 21

Readjust the IR COMP setting slightly CCW until the motor speed stabalizes.

1.

22 Troubleshooting

Motor only runs at full speed

1.

Check that S2 and S3 are not shorted together.

For additional assistance, contact your local Minarik Drives distributor, or the factory direct:
(800) MINARIK or [phone].

Replacement Parts

Replacement parts are available from Minarik Drives and its distributors for this drive
series.

Model No. Symbol Description Minarik P/N

XP02-115AC C501 220 μF, 200 V Capacitor 011-0069

D501 16 A, 300 V Diode 071-0054
Q502 Power MOSFET 070-0043
R501, 502 0.2 Ohm, 5 W Resistor 032-0093
R503 8.2 K Ohms, 5 W Resistor 032-0126
R504 3.3 K Ohms, 10 W Resistor 032-0131
BR601 25 A, 800 V Diode Bridge 073-0007
10 K Ohm Potentiometer Kit 202-0066

XP05-115AC C501 1000 μF, 200 V Capacitor 011-0096

D501 16 A, 300 V Diode 071-0054
Q501, 502 Power MOSFET 070-0043
R501, 502 0.05 Ohm, 5 W Resistor 032-0113
R503 8.2 K Ohm, 5 W Resistor 032-0126
R504 3.3 K Ohm, 10 W Resistor 032-0131
BR601 25 A, 800 V Diode Bridge 073-0007
10 K Ohm, Potentiometer Kit 202-0066

XP10-115AC C501 1500 μF, 250 V Capacitor 011-0089

D501 16 A, 300 V Diode 071-0054
Q501, 502 Power MOSFET 070-0043
R501, 502 0.01 Ohm, 5 W Resistor 032-0129
R503 8.2 K Ohm, 5 W Resistor 032-0126
R504 3.3 K Ohm, 10 W Resistor 032-0131
BR601 25 A, 800 V Diode Bridge 073-0007
10 K Ohm Potentiometer Kit 202-0066

23

24

NOTES

25

Limited 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 or 3,000 hours, which-

ever comes rst, from date of manufacture thereof. Within this warranty period, the Corporation

will repair or replace, at its sole discrection, such products that are returned to Minarik Corpora­tion, 14300 De La Tour Dr., South Beloit, IL 61080 USA.

This warranty applies only to standard catalog products, and does not apply to specials. Any
returns for special controls will be evaluated on a case-by-case basis. 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 less of property of value caused by any product that has been subject to misuse, negli-

gence, or accident, or misapplied or modied by unauthorized person or improperly installed.

C. Limitations of Liability - In the event of any claim for breech 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 Corpora-

tion 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 no-charge

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.

MINARIKDRIVES

www.minarikdrives.com

14300 De La Tour Dr., South Beloit, IL 61080

Phone: (800) MINARIK (646-2745); Fax: [phone]

Document Number: 250-0219; Revision 1. Printed in the U.S.A. -- August 2006