Minarik Drives XP–AC–SL SERIES Users Manual

User’s Manual

XP–AC–SL

Series

Pulse-Width Modulated,

Adjustable Speed Drives

for DC Brush Motors

Models:

XP01–115AC–E10U

XP01–115AC–SL
XP03–115AC–SL

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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.

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 Safety Warnings

Note: This symbol  denotes an important safety message. Please read

these sections carefully before performing any instructions contained in this
manual.

• 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.

i

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ii

Table of Contents

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

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

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

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

XP-AC-SL series connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Line fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

XP-AC-E10U series connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Line fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Voltage follower configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Automatic restart upon power restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

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iiiTable of Contents

Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Decelerating to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

MINIMUM SPEED (MIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

TORQUE (TQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

IR COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Connection to other Minarik devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Single speed potentiometer control of multiple drives . . . . . . . . . . . . . . . . . . . . . . . . . .34

Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Reversing with a DIGI-LOK® controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

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

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iv

Illustrations

Figure 1. XP-AC-SL Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Figure 2. XP-AC-E10U Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Figure 3. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Figure 4. XP-AC-SL Series Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Figure 5. XP-115AC-E10U Series Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Figure 6. XP-AC-SL Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Figure 7. XP-115AC-E10U Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Figure 8. Decelerate to Minimum Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Figure 9. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Figure 10. XP-AC-SL Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Figure 11. XP-AC-E10U Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Figure 12 Recommended Torque and IR COMP Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Figure 13. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Figure 14. Adjustable Fixed Speeds Using Potentiometers in Series . . . . . . . . . . . . . . . . . . . . . . .29

Figure 15. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Figure 16. RUN/JOG Switch Connection to Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . .31

Figure 17. Connecting an XP–AC Series Drive to a PCM4 or DLC600 . . . . . . . . . . . . . . . . . . . . .32

Figure 18. Leader-Follower Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Figure 19. Single Speed Potentiometer Control of Multiple Drives . . . . . . . . . . . . . . . . . . . . . . . . .34

Figure 20. PCM4 Speed Ratio Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Figure 21. Reversing Circuit Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Figure 22. Reversing with a DLC600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Figure 23. XP–AC Series Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Figure 24. XP–AC Series Input Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

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1

Specifications

Max. Continuous

Armature HP Range

Current with 115 VAC

Model (DC Amps) Applied

XP01-115AC-E10U 1 1/100 – 1/25

XP01–115AC-SL 1 1/100 – 1/25

XP03–115AC-SL 3 1/20 – 1/4

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 Range (no load) 1 second
Analog Input Voltage Range (signal must be isolated) 0 – 5 VDC
Input Impedance (S1 to S2) approximately 150K ohms
Speed Regulation 1% base speed or better
Ambient Temp. Range (chassis drive) 10°C–55°C
Weight 0.3 lb

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2

Dimensions

0.1875 [5]

TH501

I LIMIT

R502

MAX SPD

.035

R501

FU501

PWR ON

IL501

R503

P501

C501

BR501

C503

C502

D501

IR CO MP

P504

IL502

TQ

P503

MIN

P502

Q501

SO501

.052

4.125 [105]

4.5 [114]

3.00 [76]

2.625 [67]

0.1875 [5]

1.35 [34.29]

Figure 1. XP-AC-SL Series Dimensions

ALL DIMENSIONS IN INCHES [MILLIMETERS]

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3Dimensions

ALL DIMENSIONS IN INCHES [MILLIMETERS]

MAX SPD MIN SPDIR COMP TORQUE

PWR ON

L1L2A1

A2

S3S2S1

TB501

Q501D501

C502

C503

C501

IL501

TH501

R501

BLACK

WHITE

BLUE

YELLOW

PURPLE

BROWN

GRAY

1.95 [50]

2.25 [57]

1.95 [50]

2.25 [57]

Figure 2. XP-AC-E10U Series Dimensions

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4

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.

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



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 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.

Installation

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5Installation

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.

Warning

 

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.

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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 of 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 in any
electronic device, including motor controls.

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7Installation

Mount the speed adjust potentiometer through a 0.38 in. (10 mm) hole with the
hardare provided (see Figure 3, page 8). 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 the speed adjust potentiometer wires separate from power
leads (L1, L2, A1, A2).

Be sure that the potentiometer tabs do not make contact with the
potentiometer enclosure. Grounding the input will cause damage to
the drive.

Warning



Speed adjust potentiometer

Line fusing

Protect all Minarik drives with AC line fuses. For XP03-115AC-SL, use fast acting AC line
fuse rated for 8 amps at 250 volts. For all other XP series drives, use fast acting AC line
fuse rated for 3 amps at 250 volts. Fuse only the “hot” side of the AC line (L1).

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8 Installation

Figure 3. Speed Adjust Potentiometer

POT TAB A SSIGNMENTS

WIPER

CW

CCW

SPEED ADJUST

POTENTIOMETER

INSULATING DI SK

PANEL

STAR

WASHER

NUT

MOUNT THROUGH A 0.38 IN. (10 MM) HOLE

NUT

STAR

WASHER

PANEL

CW

CCW

WIPER

SPEED ADJUST

POTENTIOMETER

INSULATING DISK

POT TAB ASSIGNMENTS

MOUNT THROUGH A 0.38 IN. (10 MM) HOLE

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9

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 5 (page 13). The
switch contacts should be rated at a minimum of 200% of motor
nameplate current and 250 volts.

Warning



XP-AC-SL series connections

Connect the power input leads, an external line fuse and a DC motor as shown in
Figure 4 (page 11).

Motor

Minarik drives supply 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.

Connections

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10 Connections

Connect a DC motor to terminals A1 and A2 as shown in Figure 4 (page 11). Ensure

that the motor voltage and current ratings are consistent with the drive’s output
voltage and current.

Power input

Connect the AC line power leads to terminals L1 and L2, or to a single-throw, double­pole master power switch (recommended).

Line fuse

Wire an external line fuse between the stop switch (if installed) and the L1 terminal as
shown in Figure 4. The XP03-115-SL line fuse should be rated at 250 volts and 8
amps.

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11Connections

HEADER

BLOCK

TERMINAL

PLUG

L1 DC+

IN

F1 A1 S1 S2 S3 A2 F2 DC-

IN

L2

L2DC -

IN

F2A2S3S2S1A1F1DC +

IN

L1

SO501

CW

SPD
ADJ
POT

10 KΩ

MOTOR

MOTOR

FIELD

LEADS

( SHUNT-

WOUND

MOTORS

ONL Y )

115 VAC

INPUT

STOP

SWITCH

FUSE

Figure 4. XP-AC-SL Series Connections

HEADER

BLOCK

TERMINAL

PLUG

FUSE

STOP

SWITCH

115 VAC

INPUT

10K OHM

SPEED

ADJUST

POT

CW

S0501

MOTOR

FIELD LEADS

(SHUNT­WOUND
MOTORS

ONLY)

MOTOR

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12 Connections

XP-AC-E10U series connections

Connect the power input leads, an external line fuse and a DC motor to terminal
board TB501 as shown in Figure 5 (page 13).

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 to terminals A1 and A2 as shown in Figure 5 (page 13). Ensure

that the motor voltage and current ratings are consistent with the drive’s output
voltage and current.

Power input

Connect the AC line power leads to terminals L1 and L2, or to a single-throw, double­pole master power switch (recommended).

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13Connections

Line fuse

Wire an external line fuse between the stop switch (if installed) and the L1 terminal.
The line fuse should be rated at 250 volts and 3 amps.

MOTOR

C501

MAX SPDMIN SPD

IR COMP

PWR ON

TB501

D501

IL5 0 1

TH501

R501

Q50

STOP

SWITCH

FUSE

+

10K Ω

SPEED

ADJUST

POT

CW

115 VAC

INPUT

L1

L2

A1

A2

S3

S2

S1

Figure 5. XP-115AC-E10U Series Connections

115 VAC

INPUT

STOP

SWITCH

FUSE

MOTOR

CW

+

10K OHM

SPEED

ADJUST

POT

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14

Voltage follower configuration

Connections

Instead of using a speed adjust potentiometer, the drive may be wired to follow a 0–5
VDC voltage signal that is isolated from earth ground (Figure 6 & 7). Connect the
signal input (+) to S2. Connect the signal common (–) to S1. Make no connection to
S3. A potentiometer 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 7 & 8).

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

Warning



Figure 6. XP-AC-SL Voltage Follower Connections

A1 S1 S2 S3

SI G (+)

0 - 5 VDC

SI GNAL I NPUT

COM (- )

COM (-)

SIG (+)

0 - 5 VDC

SIGNAL INPUT

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 14

15Connections

Figure 7. XP-115AC-E10U Voltage Follower Connections

C501

MAX SPDM

IR COMP

PWR ON

IL501

A1

S3

S2

S1

SIG (+)

COM (- )

ISOLATED

0 - 5 VDC

INPUT

ISOLATED

0 - 5 VDC INPUT

SIG (+)

COM (-)

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 15

Startup

To start the drive:

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

following a voltage signal, set the voltage signal to 0 VDC.

2. Apply AC line voltage.

Before applying power

Verify that no conductive material is present on the printed circuit board.

16

Dangerous voltages exist on the drive when it is powered, and up to
30 seconds after power is removed and the motor stops. BE ALERT.
High voltages can cause serious or fatal injury. For your safety, use
personal protective equipment (PPE) when operating this drive.

Warning



Operation

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 16

17Operation

Decelerating to minimum speed or coasting to a stop is
recommended for frequent 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, page 9).

Warning



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

following 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.

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

If the motor or drive does not perform as described, disconnect the AC line voltage
immediately. Refer to the Troubleshooting section, page 38, for further assistance.

Starting and Stopping Methods

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 17

18 Operation

Automatic restart upon power restoration

After a one-second time delay, all drives automatically run to set speed when power
is applied.

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.

Decelerating to minimum speed

Connect the switch as shown in Figure 8 (page 19). Close the switch between S1 and
S2 to decelerate the motor from set speed. Open the switch to accelerate the motor
to set speed.

Dynamic braking

Dynamic braking may be used to rapidly stop a motor (see Figure 9, page 20). For
the RUN/BRAKE switch, use a double pole, double throw switch rated for at least the
maximum DC armature voltage and maximum braking current.

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 18

19Operation

Figure 8. Decelerate to Minimum Speed

10K OHM

SPEED ADJUST

POTENTIOMETER

CCW

RUN

MINIMUM

SPEED

S1

S2

S3

CW

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 19

20

A1

S3

S2

S1

A2

MOTOR

DYNA MI C

BRAKE

RESISTOR

BRAKE

RUN

CW

CCW

10K

Ω

SPEED ADJUST

POTENTIOMETER

RUN

BRAKE

Figure 9. Dynamic Brake Connection

DYNAMIC

BRAKE

RESISTOR

RUN

MOTOR

BRAKE

RUN

BRAKE

CW

CCW

10K OHM

SPEED ADJUST

POTENTIOMETER

A2

A1

S3

S2

S1

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 20

XP-AC series drives have four user-adjustable trimpots: maximum speed (MAX
SPD), minimum speed (MIN), torque limit (TQ), and regulation under load (IR
COMP).

The XP01-115AC-SL is factory calibrated for a 1/100 HP, 90 VDC motor. The XP01­115AC-E10U is calibrated for a 1/15 HP, 90 VDC motor. The XP03-115AC-SL is
calibrated for a 1/4 HP, 130 VDC motor.

All adjustments increase with CW rotation, and decrease with CCW rotation. Use a
non-metallic screwdriver for calibration. Each trimpot is identified on the printed circuit
board.

21

Calibration

Dangerous voltages exist on the drive when it is powered and up to
30 seconds after power is removed and the motor stops. 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.

Warning



250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 21

22 Calibration

MAX SPD

R501

PWR ON

IL501

.035

R503

P501

C501

IR COMP

P504

IL502

TQ

P503

I LIMIT MIN

P502

SO501

.052

Figure 10. XP-AC-SL Calibration Trimpot Layout

MAXIMUM

SPEED

MINIMUM

SPEED

TORQUE IR COMP

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 22

23Calibration

Figure 11. XP-AC-E10U Calibration Trimpot Layout

C501

MAX SPDMIN SPD

IR COMP

TORQUE

PWR ON

A1

S3

S2

S1

C502

IL501

MAXIMUM

SPEED

MINIMUM

SPEED

TORQUEIR COMP

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 23

24 Calibration

MAXIMUM SPEED (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 MAX SPD:

1. Set the MAX SPD trimpot full CCW.

2. Turn the speed adjust potentiometer full CW.

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

MINIMUM SPEED (MIN)

The MIN setting determines the motor speed when the speed adjust potentiometer is
turned full CCW. It is factory set for zero speed (full CCW).

To calibrate MIN SPD:

1. Set the MIN trimpot full CCW.

2. Turn the speed adjust potentiometer full CCW.

3. Adjust the MIN trimpot until the desired minimum motor speed is reached.

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 24

25Calibration

The TQ setting determines the maximum armature current output of the drive.
Recalibrate the TQ setting when using a lower current rated motor. Refer to Figure 12
on page 27 for recommended TQ settings, or recalibrate using the following procedure:

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

minimum scale) in series with the armature.

2. Set the TQ trimpot to minimum (full CCW).

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

4. Lock the motor armature. Be sure that the motor is firmly mounted to withstand

maximum torque generated by the motor.

5. Apply line power. The motor should be stopped.

6. Slowly adjust the TQ trimpot CW until the armature current is 120% of motor rated

armature current.

7. Set the speed adjust potentiometer to minimum.

8. Disconnect power from the drive.

9. Remove the ammeter in series with the motor armature if it is no longer needed

and unlock the motor shaft.

10. Re-apply power to the drive.

TORQUE (TQ)

Although TORQUE can be set to 120% of motor nameplate current
rating, continuous operation beyond this rating may damage the
motor. If you intend to operate beyond the rating, contact your
Minarik representative for assistance.

Warning



250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 25

26 Calibration

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 current rated motor. Refer to the
recommended IR COMP settings in Figure 12 on page 27 or recalibrate using the
following procedure:

1. Set the IR COMP trimpot to minimum (full CCW).

2. Rotate the speed adjust potentionmeter 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. 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.

5. Unload the motor.

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 26

27Calibration

Figure 12 Recommended Torque and IR COMP Settings

(actual settings may vary with each application)

1/100 HP
90 VDC
1750 RPM
70 mADC

1/50 HP
90 VDC
1750 RPM

1.1 ADC

1/20 HP
90 VDC
1750 RPM

0.56 ADC

1/15 HP
90 VDC
1750 RPM

0.75 ADC

1/8 HP
90 VDC
1750 RPM

1.3 ADC

1/4 HP
90 VDC
1750 RPM

2.7 ADC

1/20 HP
90 VDC
1800 RPM

0.75 ADC

1/25 HP
90 VDC
1800 RPM

0.47 ADC

TORQUE IR COMP

TORQUE IR COMP

TORQUE IR COMP

TORQUE

IR COMP

TORQUE IR COMP

XP01-115AC-SL XP03-115AC-SL

XP01-115AC-E10U

TORQUE IR COMP

TORQUE IR COMP

TORQUE IR COMP

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 27

Multiple fixed speeds

Replace the speed adjust potentiometer with series resistors having a total series
resistance of 10K ohms (Figure 13). Add a single pole, multi-position switch with the
correct number of positions for the desired number of fixed speeds.

28

Application Notes

R4

Tot al Ser i es

Resist ance

10K Ohm

R1

R2

R3

S3

S2

S1

Figure 13. Multiple Fixed Speeds

S3

R1

R2

R3

R4

TOTAL SERIES

RESISTANCE

10K OHM

S2

S1

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 28

29Application Notes

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 14 shows a connection for fixed high and low speed adjust potentiometers.

CW

5K

Ω

5K Ω

CW

LOW

SPEED

HI GH

SPEED

S1

S2

S3

Figure 14. Adjustable Fixed Speeds Using Potentiometers in Series

S3

HIGH

SPEED

CW

CW

5K OHM

5K OHM

LOW

SPEED

S2

S1

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 29

30 Application Notes

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 15 shows the connection of two independent speed adjust potentiometers that
can be mounted at two separate operating stations.

S3

S2

S1

SPEED 2

20K Ω

CW

20K Ω

CW

SPEED 1

Figure 15. Independent Adjustable Speeds

S3

S2

S1

SPEED 1

SPEED 2

CW CW

20K

OHM

20K

OHM

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 30

31Application Notes

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, two position switch for
the RUN/JOG switch,
and a single pole,
normally closed,
momentary operated
pushbutton for the JOG
pushbutton as shown in
Figure 16. When the
RUN/JOG switch is set
to JOG, the motor
decelerates to minimum
speed. Press the JOG
pushbutton to jog the
motor. Return the
RUN/JOG switch to RUN
for normal operation.

JOGRUN

JOG

PUSH B UTTON

10K Ω

S1

S2

S3

Figure 16. RUN/JOG Switch Connection to Speed Adjust Potentiometer

S3

S2

S1

RUN

JOG PUSH

BUTTON

JOG

10K

OHM

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 31

32 Application Notes

Connection to other Minarik devices

1
2

S1

S2

S3

S3
S2
S1

S1

S2

S3

XP- AC
SERIES

DRI VE

DLC600

XP- AC

SERIES

DRI VE

PCM4

Figure 17. Connecting an XP–AC Series Drive to a PCM4 or DLC600

1

2

PCM4

DLC 600

XP-AC

SERIES

DRIVE

XP-AC

SERIES

DRIVE

S3

S2

S1

S3

S2

S1

S3

S2

S1

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 32

33Application Notes

Leader-follower application

In this application, use a PCM4 to monitor the speed of the leader motor (Figure 18).
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 18. Leader-Follower Application

LEADER

DRIVE

A1

9 (+)

8

7 (-)

TB501

TB502

10K OHM
(optional)

PCM4

FOLLOWER

DRIVE

(+) 2

(-) 1

A2

S1

S2

Motor

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 33

34 Application Notes

Single speed potentiometer control of multiple drives

Multiple drives can be controlled with a single speed adjust potentiometer (Figure 19).
Optional ratio potentiometers can be used to scale the PCM4 output voltage, allowing
independent control of each drive (Figure 20, page 35).

Mo t or

B

Mo t or

A

A2

A1

S2

S1

Dr i ve B

A2

A1

S2

S1

Dr i ve A

rat i o pot B

10K

Ω

rat i o pot A

10K

Ω

S3

Figure 19. Single Speed Potentiometer Control of Multiple Drives

RATIO POT A

10K OHM

S3

A1

A2

DRIVE A

MOTOR

A

MOTOR

B

S1

S2

A1

A2

DRIVE B

S1

S2

RATIO POT B

10K OHM

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 34

35Application Notes

PCM4

PCM4

Mo t o r

B

Mo t o r

A

A2

A1

S2

S1

Dr i v e B

A2

A1

S2

S1

Dr i v e A

RATI O
POT B
10K OHM

S3

S3

(no connecti on)

(no connecti on)

RATI O
POT A
10K OHM

2

1

7

8

6

8

7

1

2

+

-

+

-

+

-

SIGNAL

INPUT

C OMMON

A1

A2

Motor

A

Motor

B

RATIO
POT B
10K OHM

RATIO
POT A
10K OHM

S3 (no connection)

S2

1

2

+

-

+

+

-

-

6

8

7

SIGNAL

INPUT

COMMON

S1

Drive A

PCM4

1

2

8

7

PCM4

A1

A2

S3 (no connection)

S2

S1

Drive B

Figure 20. PCM4 Speed Ratio Application

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 35

36 Application Notes

Reversing with a DIGI-LOK® controller

DIGI-LOK® controller model DLC600 can be used in a reversing application. The
DLC600 must be inhibited while braking. Without the inhibit feature, the controller will
continue to regulate, causing overshoot when the DIGI-LOK® is switched back to the
drive.

Figure 22, page 37 shows the connection of the reversing circuit to an XP–AC Series
drive and a DLC600. Note: Only one DLC option (Optical Encoder or Magnetic
Pickup) may be used at a time.

Reversing

A dynamic brake may be used when reversing the motor direction (Figure 21, page

36). Use a three pole, three position 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.

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 36

37Application Notes

Figure 21. Reversing

Circuit Connections

S1

S2

S3

CW

SPEED ADJUST

POTENTIOMETER

CCW

10K

W

A1

A2

MOTOR

FORWARD

BRAKE

REVERSE

FORWARD

BRAKE

REVERSE

FORWARD

BRAKE

REVERSE

-

+

+

-

DYNAMIC

BRAKE

RESISTOR

FORWARD

BRAKE

A2

A1

S3

S2

S1

-

+

REVERSE

FORWARD

BRAKE

REVERSE

FORWARD

CW

CCW

10K OHM

SPEED ADJUST

POTENTIOMETER

BRAKE

REVERSE

Dynamic

Brake

Resistor

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 37

38 Application Notes

Figure 22. Reversing with a DLC600

S3

DLC 600

Inhibi t Leads

CIN+

Common
Signal
+5 VDC

Opt i cal

Encoder

BRAKE

REVFWDFWD

BRAKE

REVREV

BRAKE

FWD

Dynamic

Br ake Resist or

A1 A2

S1

MM23002

SERIES DRI VE

MOTOR

S2

S1 S2

Magnet ic
Pickup

MM23002

SERIES DRIVE

A1

Dynamic Brake

Resistor

BRAKE

BRAKE

BRAKE

FWD

REV

FWD

MOTOR

COMMON

OPTICAL

ENCODER

MAGNETIC

PICKUP

SIGNAL

+5 VDC

FWD

REV

REV

A2

S1

S2

S1 S2

C

C

INH

IN +

Inhibit Leads

DLC 600

S3

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 38

39

Before troubleshooting

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

1. Disconnect AC line voltage from the drive.

2. Check the drive closely for damaged components.

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

circuit board.

4. Verify that every connection is correct and in good condition.

5. Verify that there are no short circuits or grounded connections.

6. Check that the voltage selection switch settings match the AC line and output voltages.

7. Check that the drive’s rated armature and field output is consistent with the motor

rating.

For additional assistance, contact your local Minarik® distributor, or the factory direct:
1-800-MINARIK (646-2745) or Fax: [phone]

Dangerous voltages exist on the drive when it is powered, and up to
30 seconds after power is removed and the motor stops. BE ALERT.
High voltages can cause serious or fatal injury. When possible,
disconnect the drive while troubleshooting. For your safety, use
personal protective equipment (PPE) when operating this drive.

Warning



Troubleshooting

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 39

40 Troubleshooting

PROBLEM POSSIBLE CAUSE AND SOLUTION

Motor does not run 1. Check for blown fuses or tripped circuit breaker.

2. Check that the speed adjust potentiometer is securely
connected to S1, S2, and S2. If an input voltage signal is
used, check that the connections to S1 and S2 are
secure.

3. Check that S1 and S2 are not shorted together.

4. Check that the drive receives AC power at L1 and L2.

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

6. Check that the drive is not in current limit. Recalibrate the
CURRENT LIMIT (TORQUE) trimpot if it is set too low
(see page 27 for recommended trimpot settings).

Fuse blows or 1. Check all wiring for shorts, grounds, or misconnections.
circuit breaker 2. Check that the drive is configured to match the motor
trips rating.

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

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

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 40

41

PROBLEM POSSIBLE CAUSE AND SOLUTION

Motor runs too fast 1. Check that the MAX SPD setting is not set too high.
at the maximum
speed setting

Motor runs in the 1. Remove AC line voltage.
wrong direction 2. Reverse connection to the motor armature.

Motor slows or is 1. Check that the drive has been correctly calibrated for
unstable under load 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 runs at full 1. Check that S2 and S3 are not shorted together.
speed at all times

Troubleshooting

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 41

42

Block Diagrams

MAX

SP EED

CIRCUIT

ACCEL/

DECEL

CIRCUIT

PWM

CIRCUIT

POWER

SWITCHING

CIRCUIT

CU RRENT

LIMIT

CIRCUIT

IR COMP

CIRCUIT

POWER

BRIDGE

CIRCUIT

A1

A2

+ VBUS

L1

L2

S1
S2

S3

Figure 23. XP–AC Series Block Diagram

POWER

SWITCHING

CIRCUIT

PWM

CIRCUIT

IR COMP
CIRCUIT

CURRENT

LIMIT

CIRCUIT

ACCEL /

DECEL

CIRCUIT

MAX

SPEED

CIRCUIT

POWER
BRIDGE
CIRCUIT

S1

S2

S3

L1

L2

+ VBUS

A1

A2

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 42

43Block Diagrams

Figure 24. XP–AC Series Input Circuit Diagram

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 43

44

Replacement Parts

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

Table 4. Replacement Parts

Model No. Symbol Description Minarik® P/N
XP01-115AC-E10U C503 100 mF, 25VDC Radial 011–0079

D501 16 A, 300 V Diode 071–0054
Q501 Power MOSFET 070–0043
R501 6.8K W 10W Resistor 032-0103

10 KW Potentiometer Kit 202–0003

XP01–115AC-SL C503 220 MFD 200V High Ripple 011–0069

D501 Isolated, 16 AMP, 300 V 071-0050
Q501 Power MOSFET 070–0043
R501 1.5W, 5W Resistor 032–0161
R502 3.9KW, 5 W Resistor 032–0149

FU501 2A, 3AG Fast-Acting Fuse 050-0030

10 KW Potentiometer Kit 202–0003

XP03–115AC-SL C503 220 MFD 200 V High Ripple 011–0069

D501 16 A, 300 V Diode 071–0054
Q501 IRF640 Power MOSFET 070–0043

R502 3.9KW, 5 W Resistor 032–0149
BR501 25 A, 800 V Diode Bridge 073–0006
FU501 4A, 3AG Fast-Acting Fuse 050-0028

10 KW Potentiometer Kit 202–0003

250-0251r2.qxd:250-0251r2_readers.qxd 6/6/2007 2:54 PM Page 44

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 or 3,000 hours, whichever comes first, from date of manufacture
thereof. Within this warranty period, the Corporation will repair or replace, at its sole discretion, such products that
are returned to Minarik Corporation, 901 East Thompson Avenue, Glendale, CA 91201-2011 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 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 12­month 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.

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