Minarik NRGD-4Q Series User Manual Download Page 1

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USER’S

MANUAL

NRGD–4Q Series

Models:

NRGD05-D240AC-4Q
NRGD10-D240AC-4Q

Digitally-Controlled, Four-Quadrant,

Regenerative PWM Drives

for DC Brush Motors

250-0281.qxd 4/4/01 11:16 AM Page a

Summary of Contents for NRGD-4Q Series

Page 1: ...USER S MANUAL NRGD 4Q Series Models NRGD05 D240AC 4Q NRGD10 D240AC 4Q Digitally Controlled Four 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: ...of an electrical fire shock or explosion by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures i It is possible for a drive to run at full sp...

Page 4: ...speed adjust potentiometer connections 18 Regen dump circuit connections 20 Voltage signal follower connections 22 Jumper settings 23 Tach generator feedback voltage select J501 23 Feedback select J5...

Page 5: ...ch 46 FWD STOP REV switch 47 Independent adjustable speeds 48 Independent forward and reverse speeds 49 Independent forward and reverse speeds with FWD STOP REV switch 50 Troubleshooting 51 Before app...

Page 6: ...wer Connections 22 Figure 10 NRGD05 Jumper Terminal Location 25 Figure 11 NRGD10 Jumper Terminal Location 26 Figure 12 Jumper Settings 27 Figure 13 NRGD05 Calibration Trimpot Layout 33 Figure 14 NRGD1...

Page 7: ...v Table 1 Recommended Line Fuse Sizes 10 Table 2 Regen Dump Circuit Part Numbers 20 Table 3 Replacement Parts 60 Tables...

Page 8: ...load with reverse torque nor decelerate a load faster than coasting to a lower speed Dynamic braking with an external brake resistor can be added to accomplish these things however it would require th...

Page 9: ...vii Regenerative Drives Figure 1 Four Quadrant Operation...

Page 10: ...speed independent of direction The DECEL trimpot determines the time the motor takes to ramp down from higher to lower speed independent of direction Pulse width modulation Lower form factor than SCR...

Page 11: ...rse without contactors Autoranging dual voltage input Power the drive with either 120 VAC or 240 VAC Tachogenerator feedback option Improve the speed regulation from approximately 1 armature feedback...

Page 12: ...x Notes...

Page 13: ...k Armature Current 15 amps DC HP Range 120 VAC Line Voltage 1 4 1 HP Range 240 VAC Line Voltage 1 2 2 Applied for less than one minute NRGD10 series drives require heat sink kit 223 0363 when continuo...

Page 14: ...on of base speed 1 open loop 0 1 in tachogenerator feedback mode Vibration 0 5G max 0 50 Hz 0 1G max 50 Hz Weight 0 78 lb Ambient Operating Temperature Range 10 C 40 C Forced external air flow is requ...

Page 15: ...3 Dimensions Figure 2 NRGD05 Series Dimensions ALL DIMENSIONS IN INCHES MILLIMETERS...

Page 16: ...4 Dimensions Figure 3 NRGD10 Series Dimensions ALL DIMENSIONS IN INCHES MILLIMETERS...

Page 17: ...5 Dimensions Figure 4 Heat Sink Dimensions for NRGD10 Series Drives...

Page 18: ...t 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 connect...

Page 19: ...ove 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 i...

Page 20: ...nduced 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 dri...

Page 21: ...drives require an external heat sink kit part number 223 0363 when the continuous armature current is above 5 amps DC Apply a thermally conductive heat sink compound such as Dow Corning 340 Heat Sink...

Page 22: ...20 VAC line voltage See Table 1 below for recommended line fuse sizes Table 1 Recommended Line Fuse Sizes 90 VDC Motor 180 VDC Motor Max DC Armature AC Line Horsepower Horsepower Current amps Size amp...

Page 23: ...are provided Figure 4 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 electrica...

Page 24: ...l 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 Warnin...

Page 25: ...and the L1 terminal on terminal board TB501 An additional line fuse should be installed on L2 if the input voltage is 240 VAC The line fuse s should be rated at 250 volts and 150 200 of maximum motor...

Page 26: ...tallation Figure 5 Power and Motor Connections NOTE INSTALL FUSE ON L2 WHEN LINE VOLTAGE IS 240 VAC DO NOT INSTALL IF LINE VOLTAGE IS 120 VAC TO REGEN DUMP CIRCUIT BUS AND BUS TERMINALS OPTIONAL SEE P...

Page 27: ...witch is installed a jumper must be installed for the drive to run RUN BRAKE switch Install a single pole single throw switch between the RB and COM terminals Close the switch to regeneratively brake...

Page 28: ...stop at the maximum current allowed by the CURRENT LIMIT trimpot setting bypassing the DECEL trimpot circuit Remove the short to accelerate the motor to set speed An alternative is to install a singl...

Page 29: ...NOTE REFER TO FIGURE 7 PAGE 19 FOR ADDITIONAL SPEED ADJUST POTENTIOMETER CONNECTIONS 17 Installation Figure 6 Signal and Optional Switch Connections...

Page 30: ...hen the wiper is in the center position Turning the wiper CW from the center causes the motor to rotate in one direction while turning the wiper CCW from center causes rotation in the opposite directi...

Page 31: ...19 Installation b a c Figure 7 Speed Adjust Potentiometer Connections for a Bidirectional Operation b Unidirectional Operation Forward and c Unidirectional Operation Reverse...

Page 32: ...120 VAC drives and 400 VDC for 240 VAC drives Please contact your Minarik representative for more information on changing the dump circuit s regen dump trip setting Refer to Figure 8 page 21 for rege...

Page 33: ...21 Installation Figure 8 Regen Dump Circuit Connections To NRGD Drives...

Page 34: ...Connections Voltage signal follower connections Instead of using a speed adjust potentiometer to set motor speed the drive may follow a floating isolated 10 to 10 VDC signal Connect the signal input t...

Page 35: ...502 and J503 are set for tach generator feedback It is otherwise inoperative Jumper terminals 1 and 2 on J501 as shown if the tach generator voltage range is 7 5 20 volts 1000 RPM Jumper terminals 2 a...

Page 36: ...and 2 on J505 and J506 if the motor armature voltage is 90 volts Jumper terminals 2 and 3 on J505 and J506 if the motor armature voltage is 180 volts The factory default setting is 180 volts terminals...

Page 37: ...25 Installation Figure 10 NRGD05 Jumper Terminal Location TACH VOLTAGE RANGE SELECT J501 ARM TACH FEEDBACK SELECT J502 AND J503 ARMATURE VOLTAGE SELECT J505 AND J506...

Page 38: ...26 Installation Figure 11 NRGD10 Jumper Terminal Location TACH VOLTAGE RANGE SELECT J501 ARMATURE VOLTAGE SELECT J505 AND J506 ARM TACH FEEDBACK SELECT J502 AND J503...

Page 39: ...27 Installation Figure 12 Jumper Settings J502 J503 ARM TACH FEEDBACK SELECT J505 J506 MOTOR ARMATURE VOLTAGE J501 TACH FEEDBACK VOLTAGE RANGE...

Page 40: ...d 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 D...

Page 41: ...voltage 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...

Page 42: ...nd L2 inputs see Figure 5 page 14 Frequent decelerating to minimum speed or regenerative braking produces high torque This may cause damage to motors especially gearmotors that are not properly sized...

Page 43: ...MIT trimpot Open the switch to accelerate the motor to set speed ENABLE DISABLE switch Install a single pole single throw switch between the ENABLE and COM terminals Open the switch to disable the dri...

Page 44: ...otation and decreases with CW rotation Use a non metallic screwdriver for calibration Each trimpot is identified on the printed circuit board Warning Dangerous voltages exist on the drive when it is p...

Page 45: ...33 Calibration Figure 13 NRGD05 Calibration Trimpot Layout CURRENT LIMIT IR COMP LOOP TACHOGENERATOR ACCELERATION MAXIMUM SPEED BALANCE DECELERATION OFFSET NRGD05 Series Calibration Trimpots...

Page 46: ...34 Calibration Figure 14 NRGD10 Calibration Trimpot Layout NRGD10 Series Calibration Trimpots BALANCE CURRENT LIMIT IR COMP OFFSET LOOP TACHOGENERATOR DECELERATION ACCELERATION MAXIMUM SPEED...

Page 47: ...full clockwise CW 6 Make no adjustment to the OFFSET and LOOP trimpots 7 Set the speed adjust potentiometer or input signal to zero speed 8 Set the ENABLE DISABLE switch to DISABLE or remove the jump...

Page 48: ...l offset voltage which could be applied to the motor while the drive is in BRAKE mode This voltage may cause the motor shaft to continue to rotate even after the drive and motor have been braked To ca...

Page 49: ...ormation before adjusting this trimpot The OFFSET setting adjusts the zero offset voltage in the internal velocity loop This affects the gain circuit which controls motor regulation To calibrate OFFSE...

Page 50: ...the MAX SPD trimpot until the desired maximum forward speed is reached TACHOGENERATOR for use with tachogenerator feedback only Calibrate the TACH setting only when a tachogenerator is used The TACH...

Page 51: ...and J503 for tachogenerator feedback 7 Set the TACH VOLTAGE jumper to the correct tachogenerator voltage range 8 Apply AC line voltage 9 Set the IR COMP trimpot full CCW 10 Set the TACH trimpot full C...

Page 52: ...00 RPM motor Measure the motor speed with a hand held tachometer 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 rot...

Page 53: ...ENT LIMIT trimpot to full CCW 3 Carefully lock the motor armature Ensure that the motor is firmly mounted 4 Apply line power The motor should be stopped 5 Set the speed potentiometer or reference sign...

Page 54: ...input signal for zero speed The motor should run at zero or minimum speed 2 Set the speed adjust potentiometer or voltage input signal to maximum forward speed and measure the time it takes the motor...

Page 55: ...e input signal for maximum forward speed The motor should run at maximum speed 2 Set the speed adjust potentiometer or voltage input signal for minimum speed and measure the time it takes the motor to...

Page 56: ...50 of maximum motor speed If an input signal is used set the signal to approximately 50 of maximum 2 Adjust the LOOP trimpot slowly CW until the motor becomes unsteady under load A hum from the motor...

Page 57: ...45 Figure 15 Connection to DLC600 and PCM4 Application Notes Connection to other Minarik devices...

Page 58: ...throw switch with a single speed adjust potentiometer to reverse a motor Figure 16 Brake the drive before reversing by using a RUN BRAKE switch as shown Close the switch to regeneratively brake the mo...

Page 59: ...Stop Reverse Switch FWD STOP REV switch Use a single pole three position switch with a single speed adjust potentiometer to stop a motor between reversals Figure 17 Set the switch to the center posit...

Page 60: ...mmends disabling the drive before changing speeds Connect two speed adjust potentiometers with a single pole two position switch to select between two independent speeds in the same direction Refer to...

Page 61: ...rik recommends disabling the drive before changing directions Connect two speed adjust potentiometers with a single pole two position switch as shown in Figure 19 to select between independent forward...

Page 62: ...NOTE Minarik recommends disabling the drive before changing direction Use a switch to select forward stop or reverse Figure 20 Set the switch to the center position to decelerate the motor to a stop...

Page 63: ...or the drive s rated armature voltage and current 4 Check that all terminal block connections are correct For additional assistance contact your local Minarik distributor or the factory direct 1 800 M...

Page 64: ...shold set by the CURRENT LIMIT trimpot PEAK The red PEAK LED lights when the drive s output to the regen dump circuit exceeds the dump circuit s maximum input voltage When this condition exists the NR...

Page 65: ...53 Troubleshooting Figure 21 NRGD05 Diagnostic LED Location CURRENT LIMIT POWER PEAK RUN Figure 22 NRGD10 Diagnostic LED Location CURRENT LIMIT POWER PEAK RUN...

Page 66: ...Accepts a 10K ohm speed adjust potentiometer wiper or isolated 10 VDC to 10 VDC reference S3 Floating 10 VDC reference for 10K ohm speed adjust potentiometer DIR Short the DIR and COM terminals to rev...

Page 67: ...ng regenerative braking The braking rate is controlled by the DECEL trimpot ENBL Short the ENBL and COM terminals to enable the drive s power section Removing the short will disable the drive and coas...

Page 68: ...l set to zero speed 2 Speed adjust potentiometer or voltage input signal not connected to drive input properly connections are open 1 Check that line fuses are properly sized for the motor being used...

Page 69: ...to S0 or RB is shorted to COM 4 Drive is in current limit CURRENT LIMIT LED lit 5 Drive is not receiving AC line voltage 6 Motor is not connected 1 Switches or jumpers are set incorrectly 3 Remove sh...

Page 70: ...1 Increase MAX SPD setting see page 38 2 Increase the IR COMP setting see page 40 3 Check motor load Resize the motor if necessary 1 Adjust the IR COMP setting slightly CCW until the motor speed stabi...

Page 71: ...RB and COM terminals are shorted 2 Motor bouncing in and out of torque limit 1 Bad switch connection to DIR and COM 2 Reversing circuit not working properly BAL trimpot not set for zero speed 2 Make...

Page 72: ...011 0122 IC505 Isolation Unit HCPL7840 060 0121 Q501 IRG4BC30UD IGBT 070 0083 T501 POL 15204 Transformer 230 0111 TB501 6 Terminal Block 160 0108 TB502 10 Terminal Block 160 0153 Speed Adj Pot Kit 20...

Page 73: ...ea 5 AMP 3AG Fast Acting Fuse 2 ea 8 AMP 3AG Fast Acting Fuse 2 ea 1 2A Pico Fuse 1 ea 5 20A FUSE KIT 5 AMP 3AG Fast Acting Fuse 2 ea 8 AMP 3AG Fast Acting Fuse 2 ea 10 AMP 3AB Normal blo Fuse 2 ea 5...

Page 74: ...eeds with FWD STOP REV switch 50 Calibration 32 Calibration procedure 35 ACCEL trimpot 42 BALANCE BAL trimpot 37 Before applying power 35 CURRENT LIMIT trimpot 41 DECEL trimpot 43 IR COMP trimpot 40 L...

Page 75: ...igure 13 NRGD05 Calibration Trimpot Layout 33 Figure 14 NRGD10 Calibration Trimpot Layout 34 Figure 15 Connection to DLC600 and PCM4 45 Figure 16 Direction Switch 46 Figure 17 Forward Stop Reverse Swi...

Page 76: ...nerator feedback voltage select J501 23 Line fusing 10 Mounting 6 Speed adjust potentiometer installation 11 Wiring 7 Shielding guidelines 8 NRGD 4Q Drive Features viii Operation 28 Before applying po...

Page 77: ...Part Numbers 20 Table 3 Replacement Parts 60 Troubleshooting 51 Before applying power 51 Diagnostic LEDs 52 CURRENT LIMIT CL FTL 52 PEAK 52 POWER 52 RUN 52 Replacement Parts 60 Terminal assignments 54...

Page 78: ...Notes...

Page 79: ...f 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 cl...

Page 80: ...son Avenue Glendale CA 91201 2011 Tel 1 800 MINARIK 646 2745 Fax 1 800 394 6334 www minarikcorp com Document number 250 0281 Revision 1 Printed in the U S A 01 01 North America 12 00 Outside North Ame...

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