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7

Installation

Heat sinking

PCM2x000-series drives require an additional heat sink when the
continuous armature current is above 5 ADC. Use Minarik® part
number 223–0159. All other chassis drives have sufficient heat
sinking in their basic configurations.

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.

Line fusing

Minarik drives require an external fuse for protection. Use fast
acting fuses rated for 250 VAC or higher, and approximately
150% of the maximum armature current. Fuse both L1 and L2
when the line voltage is 230 VAC. Fuse blocks are included on
cased drives only.

Table 1 (page 8) lists the recommended replacement line fuse
sizes.

250-0090-rev5.qxd 3/9/01 10:25 AM Page 7

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Summary of Contents for PCM21000A

Page 1: ...USER S MANUAL PCM20000 SERIES Models PCM21000A PCM21000C PCM21010A PCM22000A PCM22000C ...

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: ...ce 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 result 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 Circuit potentials are at 115 VAC or 2...

Page 4: ... 11 Line fuse 11 Voltage signal follower PCM2x000A 14 Voltage signal follower PCM2x000C 15 Current signal follower PCM2x000C only 16 Operation 17 Before applying power 17 Startup 20 Starting and stopping methods 21 Line starting and line stopping 21 Decelerate to a stop 22 Calibration 23 Calibration procedure 24 Before applying power 24 SIGNAL ADJUST SIG ADJ 25 MINIMUM SPEED MIN SPD 26 MAXIMUM SPE...

Page 5: ...d speeds 31 Adjustable speeds using potentiometers in series 32 RUN JOG switch 33 Troubleshooting 34 Before troubleshooting 34 Diagnostic LEDs PCM20000C series only 35 POWER GREEN 35 SIGNAL YELLOW 35 CURRENT LIMIT CURR LIM RED 35 Replacement Parts 39 Certificate of Compliance 41 End User Responsibilities 41 Exhibit A 42 Unconditional Warranty inside back cover ...

Page 6: ... 18 Figure 10 PCM2x000C Jumper Locations and Settings 19 Figure 11 Run Decelerate to Zero Speed Switch 22 Figure 12 Calibration Trimpot Layout 23 Figure 13 Typical TORQUE and IR COMP settings 29 Figure 14 Independent Adjustable Speeds Forward Direction 30 Figure 15 Multiple Fixed Speeds 31 Figure 16 Adjustable Fixed Speeds Using Potentiometers in Series 32 Figure 17 RUN JOG Switch Connection to Sp...

Page 7: ... 0 180 VDC Horsepower range 1 4 1 2 hp 1 20 1 8 hp 1 2 1 hp Horsepower range 1 4 1 hp n a 1 2 2 hp Armature current max 5 ADC 2 ADC 5 ADC Armature current max 10 ADC n a 10 ADC Input signal range input circuit is isolated Voltage 0 10 VDC Current PCM2x000C series only 4 20 mADC Ambient temperature range 10ºC 55ºC Line voltage is 10 50 60 Hz single phase When mounted on 223 0159 heat sink kit 1 ...

Page 8: ...2 Dimensions Figure 1 PCM2x000A and PCM2x000C Dimensions ...

Page 9: ...3 Dimensions Figure 2 Heat Sink Kit Dimensions ALL DIMENSIONS IN INCHES MILLIMETERS ...

Page 10: ...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 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...

Page 11: ...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 or the drive is disabled Opening any one motor lead may destroy...

Page 12: ...e 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 controlle...

Page 13: ...ctive heat sink compound such as Dow Corning 340 Heat Sink Compound between the drive chassis and heat sink surface for optimum heat transfer Line fusing Minarik drives require an external fuse for protection Use fast acting fuses rated for 250 VAC or higher and approximately 150 of the maximum armature current Fuse both L1 and L2 when the line voltage is 230 VAC Fuse blocks are included on cased ...

Page 14: ...wer Horsepower Current amps Size amps 1 20 1 10 0 5 1 1 15 1 8 0 8 1 5 1 8 1 4 1 5 3 1 6 1 3 1 7 3 1 4 1 2 2 5 5 1 3 3 4 3 5 8 1 2 1 5 0 10 3 4 1 1 2 7 5 15 1 2 10 15 Minarik Corporation offers two fuse kits part number 050 0066 1 5A Fuse Kit and 050 0071 5 15A Fuse Kit 8 Installation ...

Page 15: ...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 speed adjust potentiometer wires separate from power leads L1 L2 A1 A2 Warning Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure Grounding the input will cause damage to the drive Figu...

Page 16: ... contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts Power fuse and motor connections If you use a PCM2x000A series drive connect the power input leads an external line fuse and a DC motor to the drive s printed circuit board PCB as shown in Figure 4 page 13 If you use a PCM2x000C series drive refer to Figure 5 page 14 Motor Connect a DC motor to PCB terminals A1 ...

Page 17: ...or to a double throw single pole master power switch recommended Line fuse Wire an external line fuse between the stop switch if installed and the L1 terminal on terminal board TB501 An additional line fuse should be installed on L2 if the input voltage is 230 VAC The line fuse s should be rated at 250 volts and 150 200 of maximum motor nameplate current Refer to the line fuse chart on page 8 for ...

Page 18: ...12 Installation Figure 4 PCM2x000A Drive Connections ...

Page 19: ...13 Installation Figure 5 PCM2x000C Drive Connections ...

Page 20: ...re that SO501 is set to SIGNAL as shown in Figure 6 Instead of using a speed adjust potentiometer the drive may be wired to follow a 0 10 VDC grounded or ungrounded voltage signal Connect the signal input to POS Connect the signal common to NEG A potentiometer can be used to scale the analog input voltage SO501 CONTROL SELECT JUMPER ...

Page 21: ...g power ensure that SO501 is set to SIGNAL and SO502 is set to 0 10 V as shown in Figure 7 Instead of using a speed adjust potentiometer the drive may be wired to follow a 0 10 VDC voltage signal Connect the signal input to POS Connect the signal common to NEG A potentiometer can be used to scale the analog input voltage ...

Page 22: ...2x000C only Warning Before applying power ensure that SO501 is set to SIGNAL and SO502 is set to 4 20 mA as shown in Figure 8 Instead of using a speed adjust potentiometer the drive may be wired to follow a 4 20 mADC signal Figure 8 Connect the signal input to POS Connect the signal common to NEG ...

Page 23: ...er settings with power applied Failure to follow these instructions may result in damage to the motor or drive or serious injury to personnel Before applying power Ensure that all jumpers are properly set prior to applying power See Figure 9 page 18 for PCM2x000A jumper location and settings See Figure 10 page 19 for PCM2x000C jumper locations and settings Verify that no conductive material is pre...

Page 24: ...18 Operation Figure 9 PCM2x000A Jumper Locations and Settings SO501 CONTROL SELECT JUMPER SPEED ADJ POT CONFIGURATION MANUAL MODE VOLTAGE FOLLOWER CONFIGURATION SIGNAL MODE SO501 SO501 ...

Page 25: ...19 Operation Figure 10 PCM2x000C Jumper Locations and Settings SO501 CONTROL SELECT JUMPER SO502 INPUT SELECT JUMPER MANUAL MODE SIGNAL MODE SIGNAL MODE ...

Page 26: ... increase the reference signal The motor slowly accelerates as the potentiometer is turned CW or the signal is increased Continue until the desired speed is reached 4 Set the speed adjust potentiometer to zero remove AC line voltage or set the input signal to zero The drive will coast to a stop If the motor or drive does not perform as described disconnect the AC line voltage immediately Refer to ...

Page 27: ... an emergency stop switch on both the L1 and L2 inputs see Connections on pages 12 and 13 Operation Starting and stopping methods Warning Decelerating to minimum speed dynamic braking or coasting to a stop is recommended for frequent starts and 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 ...

Page 28: ...own in Figure 11 may be used to decelerate a motor to a stop Closing the switch between S2 and S1 decelerates the motor from set speed to a stop Opening the switch will cause the motor to accelerate to set speed Figure 11 Run Decelerate to Zero Speed Switch ...

Page 29: ...with CCW rotation Figure 12 Calibration Trimpot Layout Warning Floating voltages exist on the drive when it is powered 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 Calibration SO...

Page 30: ...C series drives to full counterclockwise CCW 4 Set the TORQUE CURR LIMIT on PCM20000C series drives trimpot full clockwise CW 5 Set the speed adjust potentiometer or reference input signal to zero 6 Apply line power to the drive 7 Calibrate the trimpots in the following order SIGNAL ADJUST SIG ADJ MINIMUM SPEED MIN SPD MAXIMUM SPEED MAX SPD TORQUE CURR LIMIT on PCM20000C series drives REGULATION I...

Page 31: ...es drives are calibrated to deliver a 180 VDC armature output with a 10 VDC input signal To calibrate SIG ADJ 1 Ensure that no power is applied to the drive 2 Set jumper SO501 to SIGNAL mode 3 If using a PCM2x000C series drive set SO502 to 0 10V 4 Apply line voltage 5 Apply the maximum voltage or current signal 6 Rotate SIG ADJ until the desired motor speed is reached If the drive is operated as a...

Page 32: ...until the motor turns at the desired minimum speed MAXIMUM SPEED MAX SPD The MAX SPD setting determines the maximum motor speed when the speed adjust potentiometer is turned full CW It is factory set to its maximum setting To calibrate MAX SPD 1 Ensure that no power is applied to the drive 2 Set jumper SO501 to MANUAL mode 3 Apply line voltage 4 Set the MAX trimpot full CCW 5 Turn the speed adjust...

Page 33: ...armature 2 Set the TORQUE CURR 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 signal to maximum speed The motor should remain stopped 6 Slowly rotate the TORQUE CURR LIMIT trimpot clockwise CW until the ammeter reads 120 of maximum motor armature current ...

Page 34: ...CW 2 Set the speed adjust potentiometer 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 Ap...

Page 35: ...gs may be substituted for CURRENT LIMIT on PCM2x000C series controls PCM20010 SERIES ALL OTHER PCM20000 SERIES DRIVES Figure 13 Typical TORQUE and IR COMP settings actual settings may vary with each application Calibration ...

Page 36: ... potentiometers with a single pole two position switch to select between two independent speeds shown in the forward direction Figure 14 The speed adjust potentiometers can be mounted at two separate operating stations Figure 14 Independent Adjustable Speeds Forward Direction ...

Page 37: ... adjust potentiometer with series resistors with a total series resistance of 10K ohms Figure 15 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds Figure 15 Multiple Fixed Speeds ...

Page 38: ...tentiometer with a single pole multi position switch and two or more potentiometers in series with a total series resistance of 10K ohms Figure 16 shows a connection for fixed high and low speed adjust potentiometers Figure 16 Adjustable Fixed Speeds Using Potentiometers in Series ...

Page 39: ... the RUN JOG switch is set to JOG the motor decelerates to minimum speed minimum speed is determined by the MIN SPD trimpot setting Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation Figure 17 RUN JOG Switch Connection to Speed Adjust Potentiometer ...

Page 40: ...d armature outputs Terminal block connections should be consistent with the connections shown in this manual For additional assistance contact your local Minarik distributor or the factory direct at 800 MINARIK 646 2745 phone or 800 394 6334 fax Warning Floating voltages exist on the drive when it is powered When possible disconnect the drive while troubleshooting High voltages can cause serious o...

Page 41: ...is extinguished when power is disconnected SIGNAL YELLOW The yellow SIGNAL LED lights when power is applied and a voltage current or manual signal is sent to the drive The SIGNAL LED is extinguished when no signal is applied CURR LIM RED The red CURR LIM LED lights when the current required to drive the motor is greater than is allowed by the CURR LIMIT trimpot If the CURR LIM LED lights shut down...

Page 42: ...36 Troubleshooting Figure 18 Diagnostic LED Location PCM 20000C Series Only CURRENT LIMIT POWER SIGNAL ...

Page 43: ...e motor or its load is mechanically jammed Remove the cause of the jam NOTE If an application requires more torque than is allowed by the TORQUE trimpot setting the control will go to current limit under maximum loading conditions Assuming that the motor is properly sized it then will be necessary to reset TORQUE slightly CW until the stalled condition is removed Fuses or circuit breakers blow 1 C...

Page 44: ...til the speed remains acceptably constant over the load range Motor speed is unstable under load The IR COMP adjustment may be set too high Decrease it until the symptom disappears The motor may be bouncing in and out of current limit Verify that the TORQUE setting CURR LIMIT on PCM2x000C series drives is sufficient for your application Increase the setting if it is too low Motor runs at full spee...

Page 45: ...2 S8020L High power SCR 072 0043 T501 ST 3 3109 115VAC Transformer 230 0083 T502 Transformer 230 0077 Chassis 222 0079 10K Ohm Pot Kit 202 0031 1 5A Fuse Kit 050 0066 5 15A Fuse Kit 050 0071 PCM21000C Same as PCM21000A except C501 502 100 uF 25 VDC Capacitor 011 0079 D504 505 Schottky Diode 071 0017 MOV501 502 2725V RMS 4500A MOV 075 0011 R501 0 01 Ohm 5W Standup Resistor 032 0129 PCM21010A Same a...

Page 46: ...0 0022 5 15A Fuse Kit Contains 5 Amp 3AG Fast blo Fuse 050 0022 8 Amp 3AG Fast blo Fuse 050 0059 10 Amp 3AG Normal blo Fuse 050 0024 15 Amp 3AG Normal blo Fuse 050 0018 Potentiometer Kit Contains 10K Ohm 5 1 4W Potentiometer 120 0009 3 8 32 X 1 2 Nut 151 0007 3 8 Int Tooth Lockwasher 152 0007 9 ea Non insulated Female Tabs 163 0028 40 Troubleshooting ...

Page 47: ...llowing test specifications EN55011 1991 emissions and EN50082 1 1992 immunity Compliance allows Minarik s PCM20000 series to bear the CE mark End User Responsibilities The end user as described herein falls into one of two categories 1 The Consumer will deploy a stand alone unit as an integral yet external portion of the machine he she is operating 2 The Original Equipment Manufacturer OEM will i...

Page 48: ...ries C 0 27 0 54 microFarads X 0 0055 microFarads Y R 330Kohms Rated current 1 4 times maximum DC motor current Filter type Balanced 2 section Table 3 Corcom Filters Nameplate Current of Corcom Filter Motor Wired to the Drive Part Number 0 to 4 amps 6VV1 4 1 to 13 amps 20VV1 The filters in Table 3 should be wired to the AC line within 0 25 meters of the drive The ground connection from the filter ...

Page 49: ...xact filter is not available the specifications are as follows L L1 2 0 8 milliHenries C C1 2 0 1 microFarads 400W VDC Rin 0 1 ohm Rout 1 2 ohm Table 4 Minarik Filters Nameplate Current of Minarik Filter Motor Wired to the Drive Part Number 0 to 4 amps CE4MM 4 1 to 13 amps CE20MM The filters in Table 4 must be wired to the DC output of the drive as close to the drive as possible The ground connect...

Page 50: ...ust still submit his machine for CE approval Thus no component must necessarily meet CE within the machine as long as the OEM takes the necessary steps to guarantee the machine does meet CE By the same token even if every component in the OEM s machine does meet CE the machine will not necessarily meet CE as a machine Using CE approved wiring practices like proper shielding and the filters listed ...

Page 51: ...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 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 ex...

Page 52: ...mpson Avenue Glendale CA 91201 2011 Tel 1 800 MINARIK 646 2745 Fax 1 800 394 6334 www minarikcorp com Document number 250 0090 Revision 5 Printed in the U S A 1 01 North America 12 00 Outside North America 15 00 ...

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