Minarik VFD Series User Manual Download Page 9

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Contents

Calibration

Calibration Procedure Setup for 60 Hz Motors: . . . . . . . . . . . . . . . . . . . . . . . .46

MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

TORQUE LIMIT (TQ LIMIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

ACCELERATION (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

DECELERATION (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Calibration Procedure Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Application Notes

Independent adjustable speeds with DIR switch . . . . . . . . . . . . . . . . . . . . . . .51

RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Single speed potentiometer control of multiple motors . . . . . . . . . . . . . . . . . . .53

Quick Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Troubleshooting

Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

POWER LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

FAULT LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

TQ LIMIT LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Optional C510 Capacitor Kit (p/n: 202-0108) . . . . . . . . . . . . . . . . . . . . . . . . . .63

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Unconditional Warranty

Tables

Table 1. Line Fusing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Table 2. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Summary of Contents for VFD Series

Page 1: ...D02 115AC VFD02 115AC PCM VFD02 230AC VFD02 230AC PCM VFD02 D230AC VFD02 D230AC PCM VFD04 115AC VFD04 115AC PCM VFD04 230AC VFD04 230AC PCM VFD04 D230AC VFD04 D230AC PCM USER S MANUAL VFD SERIES Varia...

Page 2: ...ut 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...

Page 3: ...shock or explosion by using 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 o...

Page 4: ...erate over their full speed range most motors will operate with constant torque over a 10 1 speed range 6 Hz to 60 Hz and constant horsepower above 60 Hz Inverter duty motors may operate satisfactoril...

Page 5: ...feedback from one of the motor connections Furthermore motor torque will be reduced considerably because the phases are 120 apart Although the VFD uses this method of connection its fundamental design...

Page 6: ...d LED INDICATORS POWER green FAULT red TORQUE yellow SOLID STATE CIRCUITRY SOLID STATE REVERSING ADJUSTABLE CARRIER FREQUENCY 4 kHz 16 kHz MULTIPLE MOTOR OPERATION THREE PHASE AND SINGLE PHASE MOTOR C...

Page 7: ...g fan cooled motors at low speeds because their fans may not move sufficient air to properly cool the motor Minarik recommends inverter duty motors when the speed range is beyond 10 1 The following mo...

Page 8: ...21 Connections 22 Power and fuse connections 22 Motor connections all VFD series controls 27 Speed Adjust Potentiometer Connections 31 Voltage Follower Connections 32 Signal and Optional Switch Conne...

Page 9: ...cation Notes 51 Independent adjustable speeds with DIR switch 51 RUN JOG switch 52 Single speed potentiometer control of multiple motors 53 Quick Reversing 54 Troubleshooting 55 Before troubleshooting...

Page 10: ...ine and Fuse Connections for VFDxx D230AC Series Drives No Voltage Doubler 26 Figure 15 Motor Connections for Single Phase Operation Motor With Pre Wired Capacitor 28 Figure 16 Motor Connections for S...

Page 11: ...ceed 55 C AC Voltage Input Range VFDxx 115AC drives 115 VAC 10 50 60 Hz single phase VFDxx 230AC drives 230 VAC 10 50 60 Hz single phase VFDxx D230AC drives 115 230 VAC 10 50 60 Hz single phase Standa...

Page 12: ...L2 POWER FAULT MAX TQ LIMIT BOOST TQ ACCEL DECEL TB501 AC AC V U W 0 97 25 2 72 69 3 70 94 2 12 54 0 96 24 H 3 80 97 4 30 109 TOTAL HEIGHT H TOP OF CAP TO BOTTOM OF CHASSIS VFD01 230AC 2 03 51 6 VFD0...

Page 13: ...4 230AC Dimensions IC502 J501 JMP501 C510 J502 J503 L1 L2 POWER FAULT MAX TQ LIMIT BOOST TQ ACCEL DECEL TB501 AC AC Y U W 4 40 112 0 13 3 1 00 25 3 68 93 5 6 30 160 6 90 175 3 00 72 0 7 18 E2 E1 S1 S2...

Page 14: ...0 109 JMP502 S1 S2 S3 E2 E1 D 3 2 1 JMP501 INPUT RANGE 1 0 5VDC 2 0 10VDC 3 4 20MA JMP502 INPUT TYPE TB501 2 3 CURRENT 1 2 VOLTAGE ZERO 4 mA SET 0 97 25 2 72 69 3 70 94 ALL DIMENSIONS IN INCHES MILLIM...

Page 15: ...IT BOOST TQ ACCEL DECEL TB501 AC AC Y U W JMP502 S1 S2 S3 E2 E1 D 3 2 1 JMP501 INPUT RANGE 1 0 5VDC 2 0 10VDC 3 4 20MA JMP502 INPUT TYPE TB501 2 3 CURRENT 1 2 VOLTAGE ZERO 4 mA SET 4 40 112 6 30 160 6...

Page 16: ...U W 0 97 25 2 72 69 3 70 94 2 12 54 0 96 24 H 3 80 97 4 30 109 J501 C501 C502 TH501 L1 L2 115V 230V ALL DIMENSIONS IN INCHES MILLIMETERS TOTAL HEIGHT TOP OF CAP TO BOTTOM OF CHASSIS 2 56 65 0 MAX 3 0...

Page 17: ...Dimensions IC502 J501 JMP501 MAX TQ BOO TQ ACCEL DECEL TB501 Y U W J501 C501 C502 TH501 L1 L2 115V 230V 1 00 25 4 40 112 6 30 160 6 90 175 3 00 72 0 70 18 0 13 3 4 45 113 MAX E2 E1 S1 S2 S3 D ALL DIM...

Page 18: ...15V 230V JMP502 S1 S2 S3 E2 E1 D 3 2 1 JMP501 INPUT RANGE 1 0 5VDC 2 0 10VDC 3 4 20MA JMP502 INPUT TYPE TB501 2 3 CURRENT 1 2 VOLTAGE ZERO 4 mA SET 0 97 25 2 72 69 3 70 94 0 96 24 2 00 51 H ALL DIMENS...

Page 19: ...C501 C502 TH501 L1 L2 115V 230V JMP502 S1 S2 S3 E2 E1 D 3 2 1 JMP501 INPUT RANGE 1 0 5VDC 2 0 10VDC 3 4 20MA JMP502 INPUT TYPE TB501 2 3 CURRENT 1 2 VOLTAGE ZERO 4 mA SET 4 40 112 4 45 113 MAX 0 70 18...

Page 20: ...directly over the main AC board bottom board thus maintaining the same footprint Step by step information for mounting the PCM Adder Board to a VFD Series drive is shown on pages 12 14 Figure 10 page...

Page 21: ...501 2 3 CURRENT 1 2 VOLTAGE ZERO 4 mA SET PARTS SUPPLIED IN THIS KIT Required Tools Phillips Screwdriver MAIN AC BOARD BOTTOM BOARD TQ BOO TQ ACCEL DECEL TB501 Y U W J501 C501 C502 TH501 L1 L2 115V 23...

Page 22: ...PHILLIPS SCREWDRIVER REMOVE SCREW AND PLASTIC CAP FROM BOTTOM BOARD AND DISCARD S T E P 1 NOTE DO NOT REMOVE THE SHOULDER WASHER FROM THE BOTTOM BOARD IC502 J501 JMP501 TB501 V U W J501 C501 C502 TH5...

Page 23: ...S T E P 4 J501 INSERT THE SHOULDER WASHER included with the kit THROUGH THE TOP SIDE OF THE PCM ADDER BOARD S T E P 5 JMP502 S1 S2 S3 E2 E1 D 3 2 1 JMP501 INPUT RANGE 1 0 5VDC 2 0 10VDC 3 4 20MA JMP5...

Page 24: ...POSITION THE PCM ADDER BOARD OVER THE BOTTOM BOARD AS SHOWN NOTE First align the bottom holes of J501 on the PCM adder board with the 6 pin header installed on the bottom board The PCM adder board wi...

Page 25: ...he subplate Drive components are sensitive to electrostatic fields Avoid direct contact with the circuit board Hold the drive by the chassis only Mounting Warning DO NOT install rewire or remove this...

Page 26: ...ount the drive away from heat sources Operate the drive within the specified ambient operating temperature range Prevent loose connections by avoiding excessive vibration of the drive The chassis must...

Page 27: ...h input power 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...

Page 28: ...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 generate...

Page 29: ...gic 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 Heat sinking All VFD04 s...

Page 30: ...acting fuses rated for 250 VAC or higher See Table 1 for recommended line fuse sizes Table 1 Line Fusing Chart 1 Phase AC AC Line Input Max Amps Fuse Drive VAC HP In Size Amps VFD01 230AC 230 3 5 VFD...

Page 31: ...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 U V W Speed adjust potentiometer Warning Be su...

Page 32: ...ch in the voltage input line The switch contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts Power and fuse connections VFDxx 115AC and VFDxx 230AC Series Connect the...

Page 33: ...ART STOP SWITCH 115 230 VAC LINE INPUT J502 J503 L1 L2 OWER AULT LIMIT AC AC V W FUSE Do not add fuse to L2 unless line voltage is 230 VAC Figure 12 AC Line and Fuse Connections for VFDxx 115AC and VF...

Page 34: ...ut voltage is 230 VAC voltage doubler mode set 115V 230V jumper as shown in Figure 13 page 25 A line fuse may be added to L2 If the input voltage is 230 VAC and the desired output voltage is 230 VAC n...

Page 35: ...CCEL DECEL V W J501 C501 C502 TH501 L1 L2 115V 230V Figure 13 AC Line and Fuse Connections for VFDxx D230AC Series Drives Voltage Doubler Mode W A R N I N G Do not connect 230 VAC line input when the...

Page 36: ...SWITCH 230 VAC LINE INPUT FUSE J501 No Voltage Doubler 230 VAC in 230 VAC out IC502 TQ TQ CCEL ECEL V W J501 C501 C502 TH501 L1 L2 115V 230V Figure 14 AC Line and Fuse Connections for VFDxx D230AC Se...

Page 37: ...s U and V as shown This connection may be internal if using a 2 wire motor If the motor has three leads you must make this connection yourself To reverse a single phase split capacitor motor connect t...

Page 38: ...make this connection yourself NOTE DO NOT use a DIRECTION switch with this set up See Figure 16 on Page 29 for setup using a DIRECTION switch IC502 J501 JMP501 J502 J503 L1 L2 POWER FAULT TQ LIMIT BO...

Page 39: ...ust be removed from the circuit This method works with most but not all motors NOTE IC502 J501 JMP501 J502 J503 L1 L2 POWER FAULT MAX TQ LIMIT BOOST TQ ACCEL DECEL TB501 AC AC V U W C510 Figure 16 Mot...

Page 40: ...30 Installation MOTOR WINDINGS IC502 J501 JMP501 J502 J503 L1 L2 POWER FAULT MAX TQ LIMIT TQ ACCEL DECEL TB501 AC AC V U W C510 Figure 17 Motor Connections for Three Phase Motors...

Page 41: ...he potentiometer is connected so that the motor speed will increase as the wiper S2 is turned clockwise CW See Figure 18 below 10K OHM SPEED ADJUST POTENTIOMETER TB501 IC502 J501 JMP501 POWER FAULT MA...

Page 42: ...5 VDC isolated voltage signal Figure 19 Connect the signal input to S2 and signal common to S1 Make no connection to S3 The VFD PCM adder board may be used to scale and isolate an analog input voltage...

Page 43: ...st potentiometer and switch connections ENABLE DISABLE switch Connect a single pole single throw ENABLE DISABLE switch between the ENABLE E2 and COMMON E1 terminals as shown Open the switch to disable...

Page 44: ...DIRECTION switch between the D and COMMON E1 terminals as shown in Figure 21 below Opening the switch will cause the motor to rotate in the forward direction closing the switch will reverse motor rota...

Page 45: ...e S1 and S2 terminals on TB501 Ensure that the following jumper terminals are properly set JMP501 Input Range Settings Set jumper in position 1 for 0 5 VDC signal input Set jumper in position 2 for 0...

Page 46: ...2 0 10VDC 3 4 20MA Jumper position 1 for 0 5 VDC signal input Jumper position 2 for 0 10 VDC signal input Jumper position 3 for 4 20 mA signal input JMP502 INPUT TYPE Jumper pins 1 2 for VOLTAGE follo...

Page 47: ...cause serious or fatal injury Do not change jumper settings with power applied Ensure that jumper settings are compatible with the motor being controlled Voltage Input Warning for VFDxx D230AC Drives...

Page 48: ...or use with 230V motors The drive output current rating remains the same Refer to Figure 12 page 23 for connection information Use extreme caution when connecting this feature Incorrect use of this fe...

Page 49: ...a jumper across the D and E1 terminals as required 5 Set the ENABLE DISABLE switch if installed to ENABLE or short the ENABLE E2 and E1 terminals on TB501 6 Apply 115 or 230 VAC 50 60 Hz single phase...

Page 50: ...rection and then accelerate the motor back to the set speed Acceleration and deceleration rates are controlled by the ACCEL DECEL trimpot settings If quicker reversing is needed refer to applications...

Page 51: ...t can also act as a motor thermal protection circuit for motors having a built in thermal protector These thermal protectors are operated only by motor heat and open the enable circuit when the motor...

Page 52: ...42 Operation E2 ENABLE E1 COMMON S1 S2 D S3 ENABLE DISABLE SWITCH CLOSE TO ENABLE THERMAL OVERLOAD SWITCH TB501 Figure 23 Thermal Overload Switch with Optional Enable Disable Switch...

Page 53: ...200 of motor nameplate current and 250 volts Line starting and line stopping applying and removing AC voltage input is not recommended and should be used for emergency stopping only When AC voltage i...

Page 54: ...th counter clockwise CCW 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 powere...

Page 55: ...EL TQ LIMIT ACCEL MAX BOOST ZERO SET on isolation board TQ BOO TQ ACCEL DECEL TB501 V U W J501 C501 C502 TH501 L1 L2 115V 230V JMP502 S1 S2 S3 E2 E1 D 3 2 1 JMP501 INPUT RANGE 1 0 5VDC 2 0 10VDC 3 4 2...

Page 56: ...remove the jumper between the D and E1 terminals of TB501 3 Set all trimpots except TQ LIMIT and MAX fully counterclockwise CCW 4 Set the TQ LIMIT trimpot to maximum full CW 5 Set the speed adjust pot...

Page 57: ...ence 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...

Page 58: ...e adjust the ACCEL trimpot until the desired time is reached Rotating the ACCEL trimpot CW increases the acceleration time DECELERATION DECEL 1 Set the speed adjust potentiometer to maximum full CW an...

Page 59: ...ous frequency speed required 2 Monitor the motor phase current with a true RMS meter while very slowly turning the BOOST trimpot CW until the motor operates properly or 100 of the motor nameplate curr...

Page 60: ...nclusion 1 Set the speed adjust potentiometer to zero full CCW 2 Disable the drive by opening the ENABLE DISABLE switch or removing the jumper from TB501 E2 and E1 terminals 3 Remove power to the moto...

Page 61: ...nd two or more potentiometers in parallel with a total parallel resistance of 10K ohms Figure 25 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate...

Page 62: ...ent jogging is required Use a single pole two position switch for the RUN JOG switch and a single pole normally open momentary operated pushbutton for the JOG pushbutton Connect the RUN JOG switch and...

Page 63: ...ure 27 Single Speed Potentiometer Control of Multiple Motors The VFD series of controls is capable of operating up to eight 3 phase motors simultaneously All motors must be of the same type and must c...

Page 64: ...V S1 S2 D S3 TB501 To reverse the direction of motor shaft rotation install a DPDT center off switch as shown below Figure 28 The drive will brake the motor before reversing so there is no need to wai...

Page 65: ...for damaged components Check that no wire chips or other foreign material has become lodged on the printed circuit board Verify that every connection is correct and in good condition Warning Dangerous...

Page 66: ...ounded 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 dire...

Page 67: ...controls DC bus exceeds 200 VDC 2 Undervoltage VFD 230AC controls DC bus drops below 200 VDC VFD 115AC controls DC bus drops below 100 VDC 3 Instantaneous Overcurrent Trip Inverter output current has...

Page 68: ...drive by disabling or removing power Check the motor to make sure it is not jammed or overloaded The TQ LIMIT trimpot may need to be recalibrated See the Calibration section page 47 for information on...

Page 69: ...connections are not open External line fuse blows External line fuse does not blow but the motor does not run 1 Line fuses are the wrong size 2 Motor or motor cable is shorted to ground 3 Nuisance tr...

Page 70: ...ect motor to drive outputs U V and W 1 Calibrate MAX SPD trimpot page 40 External line fuse does not blow but the motor does not run cont Motor runs too slow or too fast at set speed 3 Drive is trippe...

Page 71: ...ON switch connection 2 Check reversing circuit by shorting TB501 D terminal to E1 terminal with jumper wire Motor will not reach the desired speed Motor pulsates or surges under load Motor does not re...

Page 72: ...nd drive with motor and drive rated for higher horsepower 3 Compare motor voltage to input voltage Replace motor if necessary TQ is unsatisfactory at high speeds 1 TQ LIMIT set too low 2 Load may exce...

Page 73: ...switching losses and increases bearing life in some motors Minarik provides an optional capacitor kit for lowering the carrier frequency The default carrier frequency on VFD controls is 16kHz Using on...

Page 74: ...citor location IC502 J501 JMP501 POWER FAULT MAX CARRIER FREQUENCY CAPACITOR C510 Cap Label Insert the 2 pins of the carrier frequency capacitor into the 2 socket holes C510 located on bottom board TQ...

Page 75: ...m Minarik Corporation and its distributors for this drive series Table 2 Replacement Parts Potentiometer Kit 202 0101 10K ohm 5W Potentiometer 3 8 32 X 1 2 Nut 3 8IN Int Tooth Lockwasher Pot Insulatin...

Page 76: ...66 NOTES...

Page 77: ...67 NOTES...

Page 78: ...68 NOTES...

Page 79: ...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 80: ...A R I K D R I V E S w w w m i n a r i k d r i v e s c o m 14300 De La Tour Drive South Beloit IL 61080 Phone 815 646 2745 Fax 815 624 6960 Document number 250 0348 Revision 3 Printed in the U S A Marc...

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Minarik VFD Series, User Manual

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