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Printed in the United States of America.

250-0246r2_readers.qxd 6/7/01 10:51 AM Page b

Summary of Contents for NRG-2Q Series

Page 1: ...User s Manual NRG 2Q Series Two Quadrant Regenerative PWM Drives for DC Brush Motors...

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 f...

Page 3: ...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...

Page 4: ...using 10 Connections 11 Motor connections 11 Power lead connections 12 Dynamic brake resistor connections 12 Inhibit personality header 14 12 VDC terminals 14 Voltage follower connection 16 Operation...

Page 5: ...otentiometer connections 36 Multiple fixed speeds 36 Adjustable speeds using potentiometers in series 37 Independent adjustable speeds 38 RUN JOG switch 39 RUN JOG option 1 39 RUN JOG option 2 40 Lead...

Page 6: ...ngs 34 Figure 10 NRG 2Q Connection to DLC600 DIGI LOK Control and PCM4 Signal Isolator 35 Figure 11 Multiple Fixed Speeds 36 Figure 12 Adjustable Fixed Speeds Using Potentiometers in Series 37 Figure...

Page 7: ...e Voltage Range 115 VAC Input 0 130 VDC Maximum Armature Voltage Range 230 VAC Input 0 240 VDC Form Factor 1 03 Acceleration Time Range 1 10 seconds Deceleration Time Range 1 10 seconds Input Signal R...

Page 8: ...Armature Voltage Range 115 VAC Input 0 130 VDC Maximum Armature Voltage Range 230 VAC Input 0 240 VDC Form Factor 1 03 Acceleration Time Range 1 10 seconds Deceleration Time Range 1 10 seconds Input S...

Page 9: ...2 Maximum Armature Voltage Range 0 130 VDC Form Factor 1 03 Acceleration Time Range 1 10 seconds Deceleration Time Range 1 10 seconds Input Signal Range isolated 0 5 VDC Input Impedance 100KW minimum...

Page 10: ...0 1 TH 501 C503 C504 FU 5 01 D 5 0 1 L 1 SO 501 S 1 S2 S3 B R 1 SO502 SO503 L 5 0 1 L502 L503 C 5 0 1 C505 FU502 C506 C502 3 00 76 4 44 113 0 70 18 A 2 20 56 0 97 25 6 30 160 6 90 175 A 1 A2 4 44 113...

Page 11: ...ate in Quadrant 1 see Figure 2 page 6 Unless dynamic braking is used non regenerative drives decelerate a load faster than coasting to a lower speed NRG 2Q drives operate in Quadrants 1 and 4 In Quadr...

Page 12: ...6 Regenerative Drives Figure 2 Two Quadrant Operation...

Page 13: ...ctions by avoiding excessive vibration of the drive Mount drive with its board in either a horizontal or vertical plane Six 0 19 inch 5 mm wide slots in the chassis accept 8 pan head screws Fasten eit...

Page 14: ...act with the printed circuit board or with circuit elements Do not disconnect any of the motor leads from the drive unless power is removed or the drive is disabled Opening any one motor lead may dest...

Page 15: ...leads If shielding 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 produ...

Page 16: ...le only one is required for model NRG10 115AC 2Q See Table 1 for recommended line fuse sizes Table 1 Recommended Line Fuse Sizes 90 VDC Motor 180 VDC Motor Max DC Armature AC Line Fuse Horsepower Hors...

Page 17: ...he 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 PCB terminals A1 and A2 as shown in Figure 3 Ensure that...

Page 18: ...DB terminals on the PCB as shown in Figure 3 The dynamic brake resistor reduces the voltage across the bus capacitors C503 and C504 when they reach their maximum voltage rating This occurs when the mo...

Page 19: ...13 Installation Also see Dynamic brake resistor sizing page 23 Figure 3 NRG 2Q Connections...

Page 20: ...h other Jumper pins 1 and 2 for a dynamic brake response or pins 2 and 3 for a disable output response coast to a stop Also read Inhibit terminals section on page 22 See Figure 4 for jumper and inhibi...

Page 21: ...15 Installation Figure 4 Inhibit Personality Header Inhibit Terminals and 12 VDC Terminals Inhibit Personality Header Inhibit Terminals 12 VDC Terminals...

Page 22: ...speed adjust potentiometer to set motor speed the drive may follow a floating isolated 0 to 5 VDC signal Connect the signal input to S2 and signal common to S1 Make no connection to S3 See Figure 5 I...

Page 23: ...rcuit board Set all switches and jumpers to their proper settings Verify that the AC supply is properly balanced Warning Dangerous voltages exist on the drive when it is powered and up to 30 seconds a...

Page 24: ...d full CCW If the drive is following a voltage signal set the voltage signal to 0 VDC 2 Apply AC line voltage 3 Rotate the speed adjust potentiometer or increase the voltage signal until the desired s...

Page 25: ...stopping Frequent decelerating to minimum speed regenerative braking or coasting to a stop produces high torque This may cause damage to motors especially gearmotors that are not properly sized for t...

Page 26: ...s not recommended for frequent starting and stopping For this reason Minarik strongly recommends that you install a stop switch on the line voltage inputs both L1 and L2 Refer to Figure 3 page 13 Auto...

Page 27: ...nimum speed Figure 6 The ACCEL and DECEL trimpots determine the rate of acceleration and deceleration respectively Set the minimum speed by calibrating the MIN trimpot See Calibration on page 26 for s...

Page 28: ...narik Corporation offers two accessory plug harnesses for use with the Inhibit terminals Table 2 Inhibit Plug Harness Assembly Part Number Minarik Part Number Description 201 0024 Inhibit plug with 18...

Page 29: ...age rating This occurs when the motor regenerates voltage back to the drive Bus capacitor maximum voltage ratings are 400 VDC for 240 VAC drives and 200 VDC for 115 VAC drives Dynamic brake resistor v...

Page 30: ...time the drive is generating voltage into the motor The absolute minimum dynamic brake resistor power rating is typically 100 watts Example Size a DB resistor for a 1 HP motor that has a 50 duty cycle...

Page 31: ...25 Operation Figure 7 Dynamic Braking Circuit Connection...

Page 32: ...se a non metallic screwdriver for calibration 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...

Page 33: ...27 Calibration Figure 8 Calibration Trimpot Layout ACCELERATION MAXIMUM SPEED MINIMUM SPEED MOTOR CURRENT LIMIT REGEN CURRENT LIMIT REGULATION IR COMP DECELERATION...

Page 34: ...zero full CCW 2 Set the MOTOR CURRENT LIMIT and REGEN CURRENT LIMIT trimpots to maximum full CW 3 Set the IR COMP trimpot to midrange approximate 12 o clock position 4 Set the signal input analog volt...

Page 35: ...signal for minimum speed 3 Adjust the MIN trimpot to the desired minimum speed MAXIMUM SPEED MAX The MAX setting determines the maximum motor speed when the speed adjust potentiometer or voltage input...

Page 36: ...RPM for an 1800 RPM motor Use a hand held tachometer 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 th...

Page 37: ...Figure 9 page 34 for recommended CURRENT LIMIT trimpot settings To calibrate the CURRENT LIMIT trimpots 1 With the power disconnected from the drive connect a DC ammeter in series with the armature 2...

Page 38: ...g determines the time the motor takes to ramp to a higher speed ACCEL is factory set for the fastest acceleration time full CCW To calibrate ACCEL 1 Set the speed adjust potentiometer or voltage input...

Page 39: ...rd speed The motor should run at maximum speed 2 Set the speed adjust potentiometer or voltage input signal to minimum speed and measure the time it takes the motor to go from maximum to minimum speed...

Page 40: ...CURR LIMIT REGEN CURR LIMIT IR COMP 5 ADC 1 8 HP 90 VDC MOTOR CURR LIMIT REGEN CURR LIMIT IR COMP 1 3 ADC 1 4 HP 90 VDC MOTOR CURR LIMIT REGEN CURR LIMIT IR COMP 2 5 ADC 1 3 HP 90 VDC MOTOR CURR LIMIT...

Page 41: ...tes S2 S1 S1 S2 NRG 2Q DRIVE DLC 600 DIGI LOK C ONTROL S2 2 1 S1 NRG 2Q DRIVE PC M 4 SIGNAL ISOLATOR Figure 10 NRG 2Q Connection to DLC600 DIGI LOK Control and PCM4 Signal Isolator Connection to other...

Page 42: ...otentiometer connections Multiple fixed speeds Replace the speed adjust potentiometer with series resistors with a total series resistance of 10K ohms Figure 11 Add a single pole multi position switch...

Page 43: ...djust potentiometer with a single pole multi position switch and two or more potentiometers in series with a total series resistance of 10K ohms Figure 12 shows a connection for fixed high and low spe...

Page 44: ...single pole multi position switch and two or more potentiometers in parallel with a total parallel resistance of 10K ohms Figure 13 shows the connection of two independent speed adjust potentiometers...

Page 45: ...ed momentary operated pushbutton for the JOG pushbutton RUN JOG option 1 In the first wiring option connect the RUN JOG switch and JOG pushbutton to the inhibit plug as shown in Figure 14 The motor co...

Page 46: ...en the RUN JOG switch is set to JOG the motor decelerates to minimum speed minimum speed is determined by the MIN trimpot setting Press the JOG pushbutton to jog the motor Return the RUN JOG switch to...

Page 47: ...e speed of the leader motor Figure 16 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 vo...

Page 48: ...trolled with a single speed adjust potentiometer using a PCM4 at the input of each drive to provide isolation Figure 17 Optional ratio potentiometers can be used to scale the PCM4 output voltage allow...

Page 49: ...erify 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 outputs are consistent with the motor...

Page 50: ...AC line voltage is applied to the drive Motor Output Lights whenever motor current flows in the direction of motor rotation Regen Output Lights whenever motor current flows in the opposite direction o...

Page 51: ...by a combination of ambient conditions and high current spikes i e reversing 1 Speed adjust potentiometer or voltage input signal set to zero speed 1 Check that line fuses are properly sized for the...

Page 52: ...onnections are open 3 Inhibit terminals are jumpered 4 S2 is shorted to S1 5 Drive is in current limit 6 Drive is not receiving AC line voltage 2 Check connections to input Verify that connections are...

Page 53: ...ired speed 7 Motor is not connected 1 Switches or jumpers are set incorrectly 2 MIN and MAX are not calibrated 1 MAX setting is too low 2 IR COMP setting is too low 3 Motor is overloaded 7 Connect mot...

Page 54: ...lsates or surges under load 1 IR COMP is set too high 2 Motor bouncing in and out of torque limit 1 Adjust the IR COMP setting slightly CCW until the motor speed stabilizes 2 Make sure motor is not un...

Page 55: ...3 10KW Potentiometer Kit 202 0039 NRG05 D240AC 2Q BR1 Power Bridge 073 0010 C503 504 470mF 400 VDC Capacitor 011 0120 FU501 502 10A 3AB Fuse 050 0024 Q501 502 INXFH26N50 MOSFET 070 0079 Q503 IRFP460 M...

Page 56: ...2 ea 5 AMP 3AG FAST ACTING FUSE 050 0022 2 ea 8 AMP 3AG FAST ACTING FUSE 050 0059 1 ea 1 2A 500 PICO FUSE 050 0074 5 20A Fuse Kit 050 0073 2 ea 5 AMP 3AG FAST ACTING FUSE 050 0022 2 ea 8 AMP 3AG FAST...

Page 57: ...Notes...

Page 58: ...Notes...

Page 59: ...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 i...

Page 60: ...el 800 MINARIK Fax 800 394 6334 www minarikcorp com Document Number 250 0246 Revision 2 Printed in the U S A 5 01 12 00 North America 13 00 Outside North America DLC500 XP Series AC or DC Input NRGD S...

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