Minarik BOSS Series User Manual Download Page 1

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BOSS Series

Models:

BOSS04-115AC-1Q
BOSS08-115AC-1Q
BOSS15-115AC-1Q

BOSS Series Brushless Drives

User

’s

Manual

250-0224rev2.qxd 5/21/01 1:41 PM Page a

Summary of Contents for BOSS Series

Page 1: ...BOSS Series Models BOSS04 115AC 1Q BOSS08 115AC 1Q BOSS15 115AC 1Q BOSS Series Brushless Drives User s Manual ...

Page 2: ... 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 ...

Page 3: ...rotection and enclosure Follow sound maintenance procedures Although the drive includes protective circuitry to prevent damage in the event of an accidental short circuit of the armature it is not fail safe It is possible for a drive to run at full speed as a result of a component failure Install a master switch in the drive s AC or DC voltage input line for stopping the drive in an emergency Inad...

Page 4: ...odular concept has two parts a motherboard and a daughter card The motherboard contains power and motor connections Each daughter card is designed to fit into the same motherboard yet each daughter card is optimized for different applications This allows you to customize your BOSS drive to suit your needs unlike the standard one size fits all approach Introduction ii ...

Page 5: ...10 Quick connect terminal block 11 Motherboard connections 12 Power connections 12 Line fusing 13 Motor connections 15 Regen dump circuit 16 Using the dump circuit with a DC power source 16 BOSS 1Q terminal descriptions 18 BOSS 1Q terminal connections 20 ENABLE DISABLE switch 20 RUN BRAKE switch 20 FWD REV switch 20 Motor hall sensors 22 Voltage follower 24 Contents ...

Page 6: ... Calibration 29 Calibration procedure 31 MINIMUM SPEED MIN SPD 32 MAXIMUM SPEED MAX SPD 32 ACCELERATION ACCEL 33 DECELERATION DECEL 33 REGULATION 34 TORQUE LIMIT TQ LIMIT 35 Troubleshooting 36 Before troubleshooting 36 BOSS 1Q Diagnostic LEDs 37 Diagnostic LEDs on the BOSS 1Q plug in card 37 POWER ON 37 FAULT 37 Diagnostic LEDs on the motherboard 37 BUS LIMIT 37 TQ LIMIT 37 Unconditional Warranty ...

Page 7: ...ions for a DC input voltage and b AC input voltage 14 Figure 7 Motherboard Connections for Three Phase Motor 15 Figure 8 Regen Dump Circuit Connections 17 Figure 9 BOSS 1Q Terminal Connections 21 Figure 10 BOSS 1Q Sensor Connections 23 Figure 11 BOSS 1Q Voltage Signal Connections 24 Figure 12 BOSS 1Q Calibration Trimpot Layout 30 Figure 13 BOSS 1Q Diagnostic LED Location 38 Tables Table 1 Recommen...

Page 8: ...Notes ...

Page 9: ...it 2 times Maximum Phase Current for 1 second Acceleration Time Range 0 5 6 seconds Deceleration Time Range 0 5 6 seconds Speed Range 80 1 Speed Regulation typical 0 06 of base speed Speed Adjust Potentiometer 10K ohms Analog Input Voltage Range signal must be isolated 0 10 VDC Input Impedance 60K ohms Power Device Switching Frequency 6 step trapezoidal 22 kHz Vibration 0 5G max 20 50 Hz 0 1G max ...

Page 10: ...2 Dimensions Figure 1 BOSS Series Dimensions ...

Page 11: ...3 Dimensions Figure 2 BOSS DB Regen Dump Circuit Dimensions ...

Page 12: ...ve 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 The chassis does not have to be earth grounded If you choose to ground the chassis use a star washer beneath the head of at least one of the mounting screws ...

Page 13: ...revent 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 쇵 Use 16 AWG wire for the AC or DC voltage input wiring AC1 and AC2 or VDC and VDC regen dump circuit and motor wiring U V W Use 18 20 AWG wire for speed ad...

Page 14: ...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 Warning Under no circumstances should power and logic leads be bundled t...

Page 15: ...th the AC voltage input terminal AC1 or DC voltage input terminal VDC whichever is used See motherboard connections Figure 6 on page 14 Table 1 lists the recommended line fuse sizes Use fast acting fuses rated for 250 VAC or higher Table 1 Recommended Line Fuse Sizes Model Line Fuse Size Series AC Amps BOSS04 10 BOSS08 15 BOSS15 25 ...

Page 16: ...erboard line up the motherboard docking pins to the docking holes Figure 3 Align the header pins on the plug in card with the corresponding header sockets on the motherboard Fasten the header pins into the header sockets until secure The docking pins will lock the plug in card into place when the header pins are correctly mounted into the header sockets Plug in card mounting ...

Page 17: ...9 Installation Figure 3 Plug In Card Installation Make sure AC or DC voltage input is removed for 30 seconds before installing or removing plug in card ...

Page 18: ... potentiometer Twist the speed adjust potentiometer wire to avoid picking up unwanted electrical noise If potentiometer leads are longer than 18 inches 46 cm use shielded cable Speed adjust potentiometer mounting 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 4 Speed Adjust Potentiometer Mou...

Page 19: ...nnect terminal block 1 Carefully pull terminal plug from header block 2 With a small flat head screwdriver turn terminal plug screw counterclockwise to open wire clamp 3 Insert stripped wire into the large opening in front of the plug 4 Turn the terminal plug screw clockwise to clamp the wire 5 Repeat steps 2 4 for each terminal until all connections are made 6 Insert plug into header block until ...

Page 20: ...inimum of 200 of motor nameplate current and 150 of input voltage Do not connect DC and AC power inputs at the same time Applying AC and DC power simultaneously will destroy the drive and may result in fire or serious injury Power connections See Figure 6 page 14 for motherboard connections Connect the AC voltage source to AC1 and AC2 if using an AC voltage source If the drive is being powered by ...

Page 21: ...g AC line voltage Refer to Table 1 page 7 for replacement line fuse sizes Power switch Warning Minarik strongly recommends the installation of a master power switch in the voltage input line The switch contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts Install a master power switch in the voltage input line as shown in Figure 6 page 14 The switch contacts should ...

Page 22: ...gure 6 Motherboard Connections for a DC input voltage and b AC input voltage Warning Do not connect AC and DC voltage at the same time This will destroy the BOSS drive and may result in fire or serious personal injury OR ...

Page 23: ...Connections for Three Phase Motor Motor connections Connect a three phase motor to the motherboard as shown in Figure 7 Ensure that the motor s voltage and current ratings are compatible with the drive ratings before making any connections ...

Page 24: ...board See Figure 8 for regen dump circuit connections Frequent regenerative reversing requires additional power resistors to be added to the regen dump circuit Contact the Minarik factory for more assistance Using the dump circuit with a DC power source If you use a DC power source and you wish to use the regen dump circuit you must connect the power source to the BOSS drive AC1 and AC2 terminals ...

Page 25: ...17 Installation NOTE CONNECTIONS SHOWN ARE FOR DC POWER SOURCE REFER TO FIGURE 6 PAGE 14 FOR AC POWER SOURCE CONNECTIONS Figure 8 Regen Dump Circuit Connections ...

Page 26: ...SABLE terminal 2 Short to COM to coast the motor to a stop leave open to run the motor RUN BRAKE terminal 3 Short to COM to run the motor Open the connection to brake When braking high side power devices turn off low side power devices turn on and the motor brakes to a stop An external braking resistor is not required because current is dissipated through the motor windings FWD REV terminal 4 Shor...

Page 27: ...ves Make no connections to this terminal HALL C B A terminals 8 9 and 10 Inputs for motor hall sensors 5 VDC Vref terminal 11 Warning The 5 VDC supply has a maximum capacity of 20 mADC Please ensure that any sensor package connected to this terminal does not draw more than 20 mADC If the sensor package draws more than 20 mADC it must be connected to an external regulated power supply as shown in F...

Page 28: ...n Figure 9 Close the switch to coast the motor to a stop Open the switch to accelerate to set speed RUN BRAKE switch Connect a single pole single throw switch between the COM and RUN BRAKE terminals terminals 1 and 3 of TB501 as shown in Figure 9 Open the switch to brake the motor to a stop Close the switch to accelerate to set speed FWD REV switch Connect a single pole single throw switch between...

Page 29: ...TOP LEAVE OPEN TO RUN 2 OPEN THE RUN BRAKE SWITCH TO BRAKE THE MOTOR TO A STOP CLOSE THE SWITCH TO RUN 3 OPEN THE FWD REV SWITCH TO RUN THE MOTOR IN THE FORWARD DIRECTION CLOSE THE SWITCH TO REVERSE 4 MAKE NO CONNECTION TO TERMINAL 7 ENABLE DISABLE SWITCH SEE NOTE 1 RUN BRAKE SWITCH SEE NOTE 2 FWD REV SWITCH SEE NOTE 3 ...

Page 30: ...actory if you require 60º spacing To run with sensor hall track feedback refer to Figure 10 This voltage is provided at TB501 terminal 11 positive and terminal 12 common or ground If the sensor draws more than 20 mADC it must be connected to an external regulated power supply which provides a floating output Warning BOSS series drives provide a 5 VDC supply to drive external sensors This voltage h...

Page 31: ...23 Installation Figure 10 BOSS 1Q Sensor Connections ...

Page 32: ...eed adjust potentiometer BOSS 1Q series drives may be wired to follow a floating voltage signal that is isolated from earth ground Connect a 0 to 10 VDC signal to terminals 1 and 6 see Figure 11 for connections Figure 11 BOSS 1Q Voltage Signal Connections ...

Page 33: ...e material is present on the printed circuit board PCB Operation Warning 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 ...

Page 34: ...to the direction you want the motor to rotate upon startup 5 Apply AC or DC voltage input to the drive 6 Slowly advance the speed adjust potentiometer clockwise CW If a voltage signal is used 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 To reverse motor direction Swit...

Page 35: ...may not stop a drive that is malfunctioning Removing line voltage AC1 and AC2 or VDC and VDC is the only acceptable method for emergency stopping For this reason Minarik strongly recommends installing an emergency stop switch on both of the power input leads see Motherboard Connections on page 12 To brake the motor Open the RUN BRAKE switch To coast the motor to a stop without disconnecting power ...

Page 36: ...uent starting and stopping of the drive It is the only recommended method for emergency stopping of the drive When AC or DC voltage input is applied to the drive the motor accelerates to the speed set by the speed adjust potentiometer or analog voltage signal When AC or DC voltage input is removed the motor coasts to a stop 28 Operation ...

Page 37: ... Each trimpot is identified on the printed circuit board Calibration Warning 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 eq...

Page 38: ...30 Calibration TQ LIMIT MINIMUM SPEED ACCELERATION DECELERATION REGULATION MAXIMUM SPEED Figure 12 BOSS 1Q Calibration Trimpot Layout ...

Page 39: ... to the RUN position closed or add a jumper between the RUN BRAKE and COM terminals on TB501 4 Set the FWD REV switch to the desired direction 5 Set the MAX SPD and REGULATION trimpots to the center of travel 12 o clock position 6 Set the MIN SPD ACCEL and DECEL trimpots full counterclockwise CCW 7 Set the TQ LIMIT trimpot full clockwise CW 8 Set the signal input analog voltage signal or speed adj...

Page 40: ...N SPD trimpot CW until the motor is running at the desired minimum speed 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 set the MAX SPD trimpot full CCW Set the reference potentiometer or reference signal to maximum Adjust the MAX SPD trimpot until the desired maximum ...

Page 41: ...the acceleration time and CCW to decrease the acceleration time until the desired acceleration time is reached DECELERATION DECEL The DECEL setting determines the time the motor takes to ramp to a lower speed See Specifications page 1 for approximate deceleration times The DECEL setting is factory set to its minimum value full CCW 1 Set the speed adjust potentiometer or input signal to maximum spe...

Page 42: ... Recalibrate the REGULATION setting when using a lower horsepower motor Use the following procedure If the motor does not maintain set speed as the load increases gradually rotate the REGULATION trimpot CW If the motor oscillates overcompensation the REGULATION trimpot may be set too high CW Turn the REGULATION trimpot CCW to stabilize the motor 34 Calibration ...

Page 43: ...uld be stopped 5 Set the speed potentiometer or reference signal to maximum speed The motor should remain stopped 6 Slowly rotate the TQ LIMIT trimpot clockwise CW until the ammeter reads 120 of maximum motor current 7 Set the speed adjust potentiometer or reference signal to zero speed 8 Remove power from the drive 9 Remove the lock from the motor shaft 10 Remove the ammeter in series with the mo...

Page 44: ...ood condition Verify that there are no short circuits or grounded connections Check that the drive s rated phase current and RMS voltage are consistent with the motor ratings For additional assistance contact your local Minarik distributor or the factory direct 1 800 MINARIK 646 2745 or Fax 1 800 394 6334 Troubleshooting Warning Dangerous voltages exist on the drive when it is powered and up to 30...

Page 45: ...roperly nulled or draw current in excess of 20 mA 2 The drive reaches its peak phase current limit 3 The drive has insufficient AC or DC power 4 The enable switch is closed drive is disabled Diagnostic LEDs on the motherboard BUS LIMIT The red BUS LIMIT LED lights when the drive exceeds maximum bus voltage This applies when the drive is in the regenerative mode future drives TQ LIMIT The red TQ LI...

Page 46: ...38 Troubleshooting Figure 13 BOSS 1Q Diagnostic LED Location TORQUE LIMIT BUS LIMIT POWER ON FAULT ...

Page 47: ...eter or voltage input signal is set to zero speed 2 Speed adjust potentiometer or voltage input signal is not connected to drive input properly connections are open 3 Drive is disabled BRAKE terminal is open to COM 1 Check that line fuses are properly sized for the motor being used 2 Check motor cable and motor for shorts 3 Add a blower to cool the drive components increase TQ LIMIT setting 1 Incr...

Page 48: ...nput 6 Motor is not connected 7 Hall sensors not connected 8 Sensor draws too much current for BOSS drive to supply 4 Verify that motor is not jammed Increase TQ LIMIT setting if it is set too low 5 Apply AC line voltage to AC1 and AC2 or DC voltage input to VDC or VDC 6 Check motor connections 7 Connect hall sensors 8 Check sensor wiring If sensor needs more than 20 mADC connect sensor to externa...

Page 49: ... not calibrated properly 2 Hall sensors miswired 1 MAX SPD setting is too low 2 REGULATION setting is too low 3 Motor is overloaded 4 Hall sensors miswired 1 Calibrate MIN SPD and MAX SPD 2 Check hall sensor connections 1 Increase MAX SPD setting 2 Recalibrate REGULATION setting 3 Check motor load Resize the motor and drive if necessary 4 Check hall sensor connections ...

Page 50: ...limit 1 Bad FWD REV switch connection 2 Reversing circuit not working properly 3 Hall sensors miswired 1 Adjust the REGULATION setting until the motor speed stabilizes 2 Make sure motor is not undersized for load adjust TQ LIMIT setting 1 Check FWD REV switch connection 2 Check reversing circuit by shorting FWD REV terminal to COM terminal with jumper wire 3 Check hall sensor connections ...

Page 51: ... 5 The drive reaches maximum bus voltage limit 6 Sensor draws too much current for BOSS drive to supply 1 Check hall sensor wiring 2 Check that motor is properly sized for load check that TQ LIMIT trimpot is properly calibrated 3 Check input power 4 Check that enable switch is in the proper operating position 5 Check motor load check that motor is properly sized for load and is not stuck or jammed...

Page 52: ...Notes ...

Page 53: ...Notes ...

Page 54: ...Notes ...

Page 55: ... 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 ...

Page 56: ...394 6334 www minarikcorp com Document number 250 0224 Revision 2 Printed in the U S A 5 01 11 00 North America 12 00 Outside North America Also available from Minarik Corporation DLC600 Digi Lok Controller NRG 4Q Series Brush Servo MMRGD Series Digital SCR Regen NRGD Series Digital Brush Servo ...

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