Minarik Drives XP-DC Series Users Manual
USER’S MANUAL
Pulse-Width Modulated,
Adjustable Speed Drives
for Low Voltage DC Brush Motors
Models:
M ode l s :
XP10-36/48DC
M ode l s :
XP12-24DC
M ode l s :
XP16-36/48DC
M ode l s:
XP60-12/24DC
XP-DC Series
XP08-60DC
XP32-12/24DC
Copyright © 2013
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 data 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 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 instructions carefully before performing
any of the procedures contained in this manual.
• DO NOT INSTALL, REMOVE, OR REWIRE THIS
EQUIPMENT WITH POWER APPLIED. Minarik assumes
the qualified technician is intimate with the dangers involving
batteries, especially lead-acid type. This manual presupposes
that you have taken all the necessary precautions to prevent a
potentially fatal accident involving such batteries, and have
followed all standard electrical precautions.
• 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 r esult 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.
This drive is isolated from 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 nonmetallic screwdriver for adjusting the calibration trimpots.
Use approved personal protective equipment and insulated
tools if working on this drive with power applied.
Contents
Safety Warnings i
Specifications 1
Dimensions 2
Installation 4
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuse / Circuit breaker protection . . . . . . . . . . . . . . . . . . . . . . . . .7
Switch 501 (SW501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Operation 15
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Startup and shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . .17
Calibration 19
MAX SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
ACC/DEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
IR COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
TQ LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
ii
Application Notes 25
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Adjustable speeds using potentiometers in series . . . . . . . . . . .26
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . .27
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Troubleshooting 29
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Motor does not run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Fuse blows or circuit breaker trips . . . . . . . . . . . . . . . . . . . . . .30
Motor runs too fast at the maximum speed setting . . . . . . . . . .30
Motor runs in the opposite direction . . . . . . . . . . . . . . . . . . . . .31
Motor is unstable under load . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Motor slows under load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Unconditional Warranty inside back cover
iii
iv
Illustrations
Figure 1. XP–DC Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . .2
Figure 2. XP-DC Heat Sink Dimensions . . . . . . . . . . . . . . . . . . . . . . .3
Figure 3. Switch 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 4. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . .10
Figure 5. Speed Adjust Potentiometer Connections . . . . . . . . . . . . .10
FIgure 6. Power, Fuse and Motor Armature Connections . . . . . . . . .13
Figure 7. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . .14
Figure 8. Run/Decelerate to Zero Speed Switch . . . . . . . . . . . . . . . .18
Figure 9. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . .19
Figure 10. Approximate TQ LIMIT Settings . . . . . . . . . . . . . . . . . . . .23
Figure 11. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Figure 12. Adjustable Fixed Speeds Using Potentiometers
in Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Figure 13. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . .26
Figure 14. RUN/JOG Switch Connection to Speed Adjust
Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Figure 15. XP–DC Series Block Diagram . . . . . . . . . . . . . . . . . . . . .31
Tables
Table 1. Wire Gauge/Length Chart . . . . . . . . . . . . . . . . . . . . . . . . . .5
Table 2. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Max. Max.
Armature Armature DC Voltage
Current Voltage
3
Input Range
Model (Amps DC) (VDC) (VDC)
XP08–60DC 8
1
60 50–70
XP12–24DC 12
1
24 20–28
XP10–36/48DC 10
2
36 or 48
4
32–50
XP16–36/48DC 16
1
36 or 48
4
32–50
XP32–12/24DC 32
2
12 or 24
4
10–32
XP60-12/24DC 60
2
12 or 24
4
10–32
Acceleration Time Range 0.5 – 10 seconds
Deceleration Time Range 0.5 – 10 seconds
Analog Input Voltage Range (signal must be isolated; S1 to S2) 0 – 10 VDC
Input Impedance (S1 to S2) 80KΩ
Speed Regulation (% of base speed) 1%
Speed Range 80:1
Form Factor 1.01
Ambient Operating Temperature Range 10°C – 40°C
Weight 0.6 lb
1 At 40°C ambient. No additional heat sink is necessary .
2 Heat sink kit 223-0159 or equivalent is required for XP10-series drives with continuous
armature current above 5 ADC and for XP32 and XP60-series drives with continuous
current above 20 amps.
3 Or up to 95% of available battery voltage.
4 Maximum armature voltage is selectable by connecting jumper to pins 2 and 3 of
SW501 (see page 8).
1
Specifications
2
Dimensions
1.37 [35]
3.64 [93]
1.35 [34]
502
321
SW501
R501
C503
C504
TQ LIMIT
P503
P502
ACC/DEC
R502
C502
1.75 [44]
0.74 [19]
501
S1
S2
S3
IR COMP
P504
P501
MAX SPD
1.03 [26]
3.80 [97]
4.30 [109]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 1. XP–DC Series Dimensions
D501
A1
C501
- VDC IN
+ VDC IN
A2
L501
0.19 [5]
3
Figure 2. XP-DC Heat Sink Dimensions
Dimensions
MOUNTING SLOTS 0.19 X 0.34 [5 X 9]
A LL D IM EN S IO NS IN INC H E S [M IL LIM ET E RS ]
5.90 [150]
6.30 [160]
6.90 [175]
3.70 [94]
4.40 [112]
0.13 [3]
0.70 [18]
1.00 [25]
4
• 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.
Mounting
Warning
Do not install, rewire, or remove this control with input
power applied. Doing so may cause fire or serious injury.
Make sure you have read and understood the Safety
Warnings on pg i before attempting installation.
Installation
Installation
Wiring
Warning
Do not install, remove, or rewire this equipment with
power applied. Failure to heed this warning may result in
fire, explosion, or serious injury.
This drive is isolated from earth 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. Opening any one motor lead
may destroy the drive.
This drive is not diode-protected from reverse battery
voltage. You must assure that POS (+) is wired to +VDC
IN and NEG (–) is wired to –VDC IN.
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 wiring. Size the DC
voltage input and motor wire according to the following chart:
Table 1. Wire Gauge/Length Chart
Phase Current Wire Gauge Maximum Wire
(amps) (AWG) Length (feet)
0 – 19 14 8
20 – 32 10 10
60 8 10
5
6
Installation
Shielding guidelines
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.
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 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.
Installation
Heat sinking
XP10–DC series drives require an additional heat sink when the
continuous armature current is above 5 ADC. XP32–DC and
XP60–DC series drives require an additional heat sink when the
continuous armature current is above 20 ADC. All other chassis
drives have sufficient heat sinking in their basic configurations.
Use Minarik Drives part number 223–0159 for XP10, XP32 and
XP60 series drives when the above conditions are met. Apply a
thermally conductive heat sink compound (such as Dow Corning®
340 Heat Sink Compound) between the drive chassis and heat
sink surface for optimum heat transfer.
Fuse / Circuit breaker protection
All XP-DC drives should be protected by a fuse or circuit breaker.
Use a fast acting fuse or circuit breaker rated for approximately
200% of the maximum armature current and armature voltage.
Connect the fuse or circuit breaker to the VDC+ IN side of the
DC voltage input.
7
8
Installation
Switch 501 (SW501)
XP10-, XP16-, XP32- and XP60-series drives are shipped with
SW501 open (no jumper applied). This allows you to use 48
VDC motors with the XP10–36/48DC and XP16–36/48DC, or
24 VDC motors with the XP32–12/24DC and XP60–12/24DC.
To use lower voltage DC motors (36 VDC or 12 VDC,
respectively) jumper pins 2 and 3 with the jumper provided. See
Figure 3 for the location of SW501.
Switch 501
502501
321
SW501
Figure 3. Switch 501
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