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15

Installation

Install the circular insulating disk between the mounting panel and
the 10K ohm speed adjust potentiometer (see Figure 3). Mount the
speed adjust potentiometer through a 0.38-inch (10 mm) hole with
the hardware provided. Twist the speed adjust potentiometer wires
to avoid picking up unwanted electrical noise.

WIPER

CW

W

SPEED ADJUST

POTENTIOMETER

INSULATING DISK

PANEL

STAR

WASHER

NUT

MOUNT THROUGH A 0.38 IN. (10 MM) HOLE

Figure 3. Speed Adjust Potentiometer Installation

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.

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Summary of Contents for XL1100A

Page 1: ...Pulse Width Modulated Variable Speed DC Drives User s Manual XLA Series Models XL1100A XL3025A XL3050A XL3200A...

Page 2: ...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...

Page 3: ...e the chance 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...

Page 4: ...ge clamp terminals 16 Motor connections 17 Connections 17 Power connections 18 External line fuse 18 Field output connections 20 Voltage follower connections 21 Voltage switches 22 Before applying pow...

Page 5: ...multiple drives 47 Reversing 48 Reversing with a DIGI LOK controller 49 Before troubleshooting 50 Troubleshooting 50 Diagnostic LEDs 51 POWER ON IL501 51 CURR LIM IL502 51 Replacement Parts 57 Certif...

Page 6: ...e DC Motor Calibration Settings 35 Figure 13 Typical CURR LIMIT and IR COMP settings actual settings may vary 40 Figure 14 Multiple Fixed Speeds 41 Figure 15 Adjustable Speeds Using Potentiometers In...

Page 7: ...cceleration Time Range with no load 1 12 seconds Deceleration Time Range with no load coast to a stop 12 seconds Speed Adjustment Potentiometer 10K ohms Analog Signal Voltage Range signal must be isol...

Page 8: ...Input 0 70 VDC Maximum Armature Voltage Adjustment Range 230 VAC Input 60 240 VDC Minimum Armature Voltage Adjustment Range 230 VAC Input 0 70 VDC Acceleration Time Range with no load 1 12 seconds Dec...

Page 9: ...Power Device Switching Frequency 18 KHz Weight 1 4 lb Ambient Operating Temperature Range 10 C 40 C 3 Specifications...

Page 10: ...Input 0 65 VDC Maximum Armature Voltage Adjustment Range 230 VAC Input 55 240 VDC Minimum Armature Voltage Adjustment Range 230 VAC Input 0 65 VDC Acceleration Time Range with no load 1 12 seconds Dec...

Page 11: ...Power Device Switching Frequency 18 KHz Weight 1 5 lb Ambient Operating Temperature Range 10 C 40 C 5 Specifications...

Page 12: ...VDC Maximum Field Current 1 ADC Maximum Armature Voltage Adjustment Range 115 VAC Input 55 150 VDC Minimum Armature Speed Adjustment Range 115 VAC Input 0 65 VDC Maximum Armature Voltage Adjustment Ra...

Page 13: ...Component file E132235 CSA Certified Component file LR4138 Power Device Switching Frequency 18 KHz Weight 1 6 lb Ambient Operating Temperature Range 10 C 40 C Use heat sink kit part number 223 0271 o...

Page 14: ...AC1 AC2 BR C505 C503 R503 TH501 Q501 IL502 INHIBIT IL501 CURR LIMIT R502 R501 B1 D501 B2 Q502 BR501 4 97 126 4 13 105 0 25 6 5 38 137 0 50 1 75 45 H Dimensions Figure 1 XLA Series Dimensions ALL DIMEN...

Page 15: ...Figure 2 Heat Sink Dimensions KIT 223 0271 9 Dimensions 4 PLACES 0 188 WIDE SLOT 8 32 THD 4 PLACES C C 2 50 64 2 50 64 3 15 80 3 15 80 6 90 175 1 41 35 3 08 78 6 70 170 8 41 214 9 78 248 1 00 25...

Page 16: ...vibration of the drive Mount the drive in either the horizontal or vertical plane Six 0 19 in 5 mm wide slots in the chassis accept 8 panhead screws Fasten wither the large base or the narrow flange o...

Page 17: ...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 o...

Page 18: ...able 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 drive ground the shield at the end away from the drive Do not grou...

Page 19: ...etween the drive chassis and heat sink surface for optimum heat transfer Fusing NOTE Model XL1100A drives do not require a line fuse on L2 All XLA Series drives are fused for maximum rated current at...

Page 20: ...use part number 050 0074 which protects the transformer and logic Refer to Replacement Parts page 57 for fuse kit contents Table 1 Recommended Line Fuse Sizes 90 VDC Motor 180 VDC Max DC Armature AC L...

Page 21: ...wist the speed adjust potentiometer wires to avoid picking up unwanted electrical noise WIPER CW W SPEED ADJUST POTENTIOMETER INSULATING DISK PANEL STAR WASHER NUT MOUNT THROUGH A 0 38 IN 10 MM HOLE F...

Page 22: ...a small screwdriver 2 Insert wire into the wire clamp 3 Release the lever arm to clamp wire Figure 4 Cage Clamp Terminal Cage clamp terminals XLA Series drive connections are of the cage clamp termina...

Page 23: ...t 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 Connect a DC motor to TB501 terminals A1 and A2 as shown in...

Page 24: ...mmended External line fuse NOTE Model XL1100A drives do not require additional line fusing An additional line fuse should be installed on L2 if the input voltage is 230 VAC The line fuse should be rat...

Page 25: ...CUIT IF USING A PERMANENT MAGNET MOTOR REFER TO TABLE 2 PAGE 20 FOR ALTERNATE FIELD CONNECTIONS POWER ON IR COMP IL501 INHIBIT CURR LIMIT C501 MAX SPD IC503 DECEL A1 A2 F2 F1 S3 S2 S1 L2 L1 MIN SPD AC...

Page 26: ...t Connections Line Voltage Approximate Field Field VAC Voltage VDC Connections 115 50 F1 and L1 115 100 F1 and F2 230 100 F1 and L1 230 200 F1 and F2 Field output connections Warning The field output...

Page 27: ...round Figure 6 Use an analog voltage range of 0 2 7 VDC with 115 VAC line voltage Use an analog voltage range of 0 5 VDC with 230 VAC line voltage Connect the signal input to S2 Connect the signal com...

Page 28: ...E SWITCHES SW501 SW502 Figure 7 Voltage Switches Voltage switches Warning Change switch settings only when the drive is disconnected from AC line voltage Make sure both switches are set to their corre...

Page 29: ...d and up to 30 seconds after power is removed and the motor stops BE ALERT High voltages can cause serious or fatal injury Chane switch settings only when the drive is disconnected from AC line voltag...

Page 30: ...ly AC line voltage 3 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 turn...

Page 31: ...ng and Stopping Methods Warning For frequent starts and stops use dynamic braking inhibit mode or decelerating to minimum speed shorting S2 to S1 DO NOT use any of these methods for emergency stopping...

Page 32: ...motor to a stop see Figure 8 Remove the jumper to accelerate the motor to set speed 501 Q502 D501 R501 R502 POWER ON LIMIT CURR IL501 INHIBIT IL502 Q501 TH501 R503 C503 C505 BR AC2 AC1 T501 SW501 BR C...

Page 33: ...with 18 in 46 cm wires 201 0079 Inhibit plug with 36 in 91 cm wires Twist inhibit plug wires and separate them from other power carrying wires or sources of electrical noise Use shielded cable if the...

Page 34: ...SPD trimpot setting If the MIN SPD trimpot is set full CCW the motor decelerates to zero speed when the switch between S2 and S1 is closed Calibrate the ACCEL and DECEL trimpots to control the accele...

Page 35: ...a two pole two position switch rated to handle the motor voltage and current For the dynamic brake resistor use a high power wirewound resistor minimum 40 watts Table 4 page 30 lists the minimum recom...

Page 36: ...ng time Use a lower ohm value higher wattage dynamic brake resistor to stop a motor more rapidly Refer to Table 4 below for minimum recommended dynamic brake resistor sizes Table 4 Minimum recommended...

Page 37: ...bration Each trimpot is identified on the printed circuit board Refer to Figure 11 page 32 for trimpot location Calibration Warning Dangerous voltages exist on the drive when it is powered and up to 3...

Page 38: ...MIT CURR IL501 INHIBIT IL502 Q501 TH501 R503 C503 C505 BR AC2 AC1 T501 SW501 BR CURR LIMIT C501 MAX SPD IC503 DECEL A1 A2 F2 F1 S3 S2 S1 L2 L1 MIN SPD ACCEL IC501 IC502 FU501 FAST ACTING FUSE ONLY C50...

Page 39: ...g voltage signal or speed adjust potentiometer to zero 5 Apply power to the drive 6 Calibrate the trimpots as follows MINIMUM SPEED MIN SPD The MIN SPD setting determines the motor speed when the spee...

Page 40: ...eference signal to maximum Adjust the MAX SPD trimpot until the desired maximum motor speed is reached MAX SPD calibration with low voltage DC motors Using an XLA series drive with a low voltage DC mo...

Page 41: ...gure 12 Low Voltage DC Motor Calibration Settings MOTOR ARMATURE VOLTAGE VDC 12 NOT APPLICABLE USING 2 5K OHM SPEED ADJUST POTENTIOMETER MAXIMUM SPEED TRIMPOT SETTING USING 1 5K OHM SPEED ADJUST POTEN...

Page 42: ...ct calibration 1 Turn the IR COMP trimpot full CCW 2 Set the speed adjust potentiometer or reference signal until the motor runs at midspeed without load for example 900 RPM for an 1800 RPM motor A ha...

Page 43: ...impot 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 maximu...

Page 44: ...e fastest acceleration time full CCW To set the acceleration time 1 Set the speed adjust potentiometer full CCW The motor should run at minimum speed 2 Turn the speed adjust potentiometer full CW and...

Page 45: ...me 1 Set the speed adjust potentiometer full CW The motor should run at maximum speed 2 Turn the speed adjust potentiometer full CCW and measure the time it takes the motor to go from maximum to minim...

Page 46: ...P 1 20 HP 90 VDC 1750 RPM 0 5 AMPS 1 8H P 90 VDC 1750 RPM 1 3 AMPS 1 4H P 90 VDC 1750 RPM 2 5 AMPS 1 8 HP 180 VDC 1750 RPM 0 67 AMPS 1 4H P 180 VDC 1750 RPM 1 4 AMPS 1 3H P 180 VDC 1750 RPM 1 75 AMPS...

Page 47: ...with series resistors with a total series resistance of 10K ohms see Figure 14 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds S3 S...

Page 48: ...e pole multi position switch and two or more potentiometers in series with a total series resistance of 10K ohms Figure 15 shows the connection for two speed control with high and low speed adjust pot...

Page 49: ...adjustable speeds Replace the speed adjust potentiometer with a single pole multi position switch and two or more potentiometers in parallel with a total parallel resistance of 10K ohms Figure 16 sho...

Page 50: ...ally closed momentary operated pushbutton for the JOG pushbutton RUN JOG option 1 In the first wiring option see Figure 17 connect the RUN JOG switch and JOG pushbutton to the inhibit plug as shown be...

Page 51: ...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 t...

Page 52: ...follower drive and outputs a voltage proportional to the leader motor s armature voltage The follower drive uses this voltage reference to set the speed of the follower motor An optional ratio potenti...

Page 53: ...sed at the input of each drive for isolation Optional ratio potentiometers can be used to scale the PCM4 output voltage allowing independent control of each drive Figure 20 Single Speed Potentiometer...

Page 54: ...ed for the DC armature voltage and high braking current Wait for the motor to stop completely before switching it to either the forward or reverse direction See the Dynamic Braking section on page 29...

Page 55: ...This will cause overshoot when the DIGI LOK is reengaged with the drive Figure 22 shows the reversing circuit connections with an XL Series drive and DIGI LOK controller Note Only one DLC option Opti...

Page 56: ...Verify that every connection is correct and in good condition 5 Verify that there are no short circuits or grounded connections 6 Check that the drive s rated armature outputs are consistent with the...

Page 57: ...POWER LED lights whenever AC line voltage is applied to the drive CURR LIM IL502 The red CURR LIM LED lights whenever the drive reaches current limit Figure 23 Diagnostic LED Location R502 POWER ON IR...

Page 58: ...cable or armature shorted to ground 3 Field circuit is open 1 Speed adjust potentiometer or input signal is set to zero speed 1 Check that line fuses are the correct size See Replacement Parts sectio...

Page 59: ...operly connections are open 3 INHIBIT terminals are jumpered 4 S2 is shorted to S0 5 Drive is in current limit 6 Drive is not receiving AC line voltage 2 Check connections to input Verify that connect...

Page 60: ...otor does not run cont Motor runs too fast at maximum speed setting 7 Motor is not connected 1 MIN SPD and MAX SPD settings are too high 2 Motor field connections are loose shunt wound motors only 7 C...

Page 61: ...100A drives 2 MIN SPD and MAX SPD not calibrated 3 Motor field not properly connected shunt wound motors only 1 MAX SPD setting is too low 3 IR COMP setting is too low 3 Motor is overloaded 1 Verify a...

Page 62: ...ons Motor pulsates or surges under load 1 IR COMP is set too high 2 Motor bouncing in and out of current limit 1 Adjust the IR COMP setting slightly CCW until the motor speed stabilizes 2 Make sure mo...

Page 63: ...10K ohm 5 W Potentiometer 202 0003 XL3025A BR501 GBU8J Bridge 073 0006 C503 470 mF 400 VDC Capacitor 011 0120 D501 8 A 600 V Diode 071 0055 Q501 8 A 500 V MOSFET 070 0075 R501 R502 0 05 ohm 5 W Resist...

Page 64: ...FUSE KIT CONTENTS 1 8A FUSE KIT 050 0068 2 EA 1 AMP 3AG FAST ACTING FUSE 050 0042 2 EA 1 5 AMP 3AG FAST ACTING 050 0026 2 EA 3 AMP 3AG FAST ACTING FUSE 050 0021 2 EA 5 AMP 3AG FAST ACTING FUSE 050 002...

Page 65: ...een tested to the following test specifications EN55014 1993 emissions and EN50082 1 1992 immunity Compliance allows Minarik s XL series to bear the CE mark The end user as described herein falls into...

Page 66: ...ves listed herein Table 6 Minarik AC Line Filters Minarik Model Number CE04XL CE10XL CE15XL Rated Current 4 A 10 A 15A Inductance 17 46 mH 14 26 mH 10 0 mH Capacitance Line to Line 0 811 mF 0 811 mF 0...

Page 67: ...y meets CE the OEM must 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 doe...

Page 68: ...C LINE VOLTAGE INPUT AC LINE VOLTAGE IN AC VOLTAGE OUT TO DRIVE 115 VAC 115 VAC 230 VAC 230 VAC AC VOLTAGE OUTPUT TO XLA SERIES DRIVE WIRE FILTER WITHIN 10 INCHES 25 CM OF DRIVE POWER ON LIMIT CURR IL...

Page 69: ...63 NOTES...

Page 70: ...64 NOTES...

Page 71: ...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 72: ...California 91201 2011 Tel 800 MINARIK or 800 646 2745 Fax 800 394 6334 www minarikcorp com Document Number 250 0233 Revision 6 Printed in the U S A 4 02 DLC600 BOSS Series MMRGD Series NRGD Series Oth...

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