Thermo AC-4000 Operating And Service Manual Download Page 45

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Summary of Contents for AC-4000

Page 1: ...REC 3838 REV G 10 05 PART NO 045848 OPERATING AND SERVICE MANUAL AC 4000 CONTROLLER WAREHOUSE APPLICATION ...

Page 2: ...RK AS CONFIDENTIAL INFORMATION THERMO ALSO MAY SEEK TO PROTECT THIS WORK AS AN UNPUBLISHED COPYRIGHT IN THE EVENT OF EITHER INADVERTENT OR DELIBERATE PUBLICATION THERMO INTENDS TO ENFORCE ITS RIGHTS TO THIS WORK UNDER THE COPYRIGHT LAWS AS A PUBLISHED WORK THOSE HAVING ACCESS TO THIS WORK MAY NOT COPY USE OR DISCLOSE THE INFORMATION IN THIS WORK UNLESS EXPRESSLY AUTHORIZED BY THERMO PLEASE READ AN...

Page 3: ... 2 Communications COM 1 3 1 3 WARRANTY 1 6 2 0 INSTALLATION 2 1 2 1 GENERAL 2 1 2 2 SAFETY PRECAUTIONS 2 1 2 2 1 Occupational Safety and Health Act OSHA 2 2 2 3 STORAGE 2 2 2 4 UNCRATING INSPECTION 2 2 2 5 EQUIPMENT LOCATION 2 3 2 6 INSTALLATION 2 4 2 6 1 Initial Power On 2 4 3 0 OPERATION 3 1 4 0 MAINTENANCE 4 1 4 1 GENERAL 4 1 4 2 SERVICE REPAIR 4 1 4 3 COMPONENT REPLACEMENT PROCEDURES ELECTRICA...

Page 4: ...dule Replacement 4 11 4 3 9 Cold Start Procedure 4 11 4 4 TROUBLESHOOTING 4 13 5 0 REPLACEMENT PARTS 5 1 5 1 GENERAL 5 1 5 2 ORDER INFORMATION 5 1 5 3 PARTS LIST INDEX 5 2 5 3 1 Return Material Authorization 5 3 6 0 AC 4000 OPTIONS 6 1 6 1 VARIABLE SPEED 6 1 6 1 1 Installation 6 1 6 2 COMMUNICATIONS 6 2 6 2 1 Installation 6 2 6 2 2 External Communication Cabling 6 4 6 2 3 Interconnect Information ...

Page 5: ...tion Board Replacement 4 8 4 4 Distribution Board with Options 4 8 4 5 Front Panel Replacement 4 10 6 1 Communications Board Dip Switches 6 3 6 2 RS 232 Connections 6 4 6 3 RS 485 Connections 6 5 LIST OF TABLES TABLE NO TITLE PAGE 1 1 Technical Specifications 1 4 4 1 Troubleshooting Procedures 4 13 4 2 Power Troubleshooting Procedure 4 18 5 1 AC 4000 Electronics Remote or Local 5 4 6 1 Variable Sp...

Page 6: ... D07226K E079 A 3 CPU Board Schematic D07226K E004 A 4 Analog Board Schematic D07226K E014 A 5 Display Board Schematic D07226K E024 A 6 Communications Board Schematic D07226K E034 A 7 Distribution Board Schematic C07226K E054 SUPPLEMENTAL MANUALS TITLE DOCUMENT NO Minarik Adjustable Speed Control Model MM 2300 MC 3 ...

Page 7: ...ion features options specifications and warranty Chapter 2 0 INSTALLATION outlines site preparation operating requirements and installation instructions Chapter 3 0 OPERATION explains the operating controls and procedures Chapter 4 0 MAINTENANCE includes troubleshooting electronic checkout and maintenance procedures Chapter 5 0 REPLACEMENT PARTS provides ordering information and replaceable parts ...

Page 8: ...REC 3838 1 0 AC 4000 ELECTRONICS FIGURE 1 1 ...

Page 9: ...amplification circuitry to interpret the signal from a loadcell The electronics enclosure houses the CPU A D and display boards A front panel keypad and vacuum fluorescent display The digital keypad is used to enter set up parameters The display presents weight 1 1 3 Operation Upon installation certain data must be entered into the AC 4000 electronics The AC 4000 s front panel is designed to simpl...

Page 10: ...REC 3838 1 2 SYSTEM BLOCK DIAGRAM FIGURE 1 2 ...

Page 11: ...ent Data Storage An EEPROM retains set up information and stores accumulated data 6 32 Bit Microprocessor This large memory capacity increases the flexibility of the AC 4000 and allows it to handle a broader range of applications 7 Corrosion Resistant Finish All exposed metal parts on the AC 4000 Electronics System are either stainless steel or painted mild steel 8 20 bit analog to digital convert...

Page 12: ... or 0 01 Units Zeroing Automatic self zeroing between packages REZERO light turns on if an autozero cannot occur within two minutes Environment Electrostatic Discharge Temperature Humidity 5000 V 14 to 122 F 10 to 50 C 0 to 95 Electrical Standard Neutral to Ground Maximum Voltage 100 130 200 250 VAC 50 60 Hz 300 VA 140 Volt AC ...

Page 13: ...REC 3838 1 5 TABLE 1 1 TECHNICAL SPECIFICATIONS Continued ...

Page 14: ...shed by the seller Said warranty shall not apply if the equipment shall not have been operated and maintained in accordance with seller s written instructions applicable to such equipment or if such equipment shall have been repaired or altered or modified without seller s approval provided however that the foregoing limitation of warranty insofar as it relates to repairs alterations or modificati...

Page 15: ...rts should always remain in place during operation They should be removed only for maintenance procedures with the machine s power OFF Be sure to replace all covers before resuming operation 4 WARNING All switches control motor power etc as applicable must be OFF when checking input AC electrical connections removing or inserting printed circuit boards or attaching voltmeters to the system 5 Incom...

Page 16: ...alth Act OSHA The Occupational Safety and Health Act clearly places the burden of compliance on the user of the equipment and the act is generalized to the extent that determination of compliance is a judgement decision on the part of the local inspection Hence Thermo Electron will not be responsible for meeting the full requirements of OSHA in respect to the equipment supplied or for any penalty ...

Page 17: ...nd so both the control panel and electronics enclosure rear doors are easily accessible This requires clear space behind and in front of the machine 2 There should be a minimum of vibration in the area Vibrations can be conducted to a loadcell and affect weighing accuracy 3 The electronics system is designed to operate in an environment where the temperature ranges no lower than 14 F 10 C nor high...

Page 18: ...ne 2 6 1 Initial Power On The initial power on procedures describe the checks to be performed before the initial system setup procedures are performed 1 Verify that the fuses on the Analog Board Figure 2 2 and Distribution Board Figure 2 3 inside the controller enclosure are correct for the AC input voltage The following lists define the correct fuses ...

Page 19: ...REC 3838 2 5 ANALOG BOARD FIGURE 2 2 ANALOG BOARD FUSE 115VAC 220VAC F1 for electronics 3 8A 3AG SB 3 16A 3AG SB F2 for line L2 10A 3AB SB 10A 3AB SB ...

Page 20: ...DISTRIBUTION BOARD FIGURE 2 3 DISTRIBUTION BOARD FUSE 115VAC 220VAC F1 for infeed motor 5A 3AG SB F2 for weightable motor 5A 3AG SB F3 for outfeed motor 5A 3AG SB F4 for line L1 15A 3AB SB F5 for line L2 15A 3AB SB ...

Page 21: ...IP SWITCHES SWITCH POSITION DESCRIPTION SW1 1 OFF OPEN ON CLOSED Reserved Switch must be in this position SW1 2 OFF OPEN ON CLOSED Standard weightable speed sensor No weightable speed sensor SW1 3 OFF OPEN ON CLOSED Optional infeed with speed sensor No infeed speed sensor SW1 8 ON CLOSED OFF OPEN Normal Run position Remove forgotten password Others OFF OPEN Not Used Default position 4 Turn the fro...

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Page 107: ...achine refer to your warranty or contact your Thermo Products Field Service Representative Thermo Products has a repair center located at our plant in Minneapolis Minnesota Please contact our Repair Parts Representative at 612 783 2783 for assistance Please have available your machine model and serial number as this will expedite your service request When returning parts for repair please use the ...

Page 108: ...14 Apply power to electronics and verify proper operation 4 3 2 Display Module Replacement To replace the Display Module proceed as indicated below 1 Turn off power at mains 2 Open the electronics controller enclosure door 3 Remove the Display Module cable See Figure 4 1 4 Remove mounting hardware securing Display Module to enclosure 5 Remove Module and place the new one on the four threaded studs...

Page 109: ...REC 3838 4 3 DISPLAY BOARD ASSEMBLY MODULE REPLACEMENT FIGURE 4 1 ...

Page 110: ...ta as possible before turning off power 1 Turn off power at mains 2 Open electronics controller enclosure door 3 Locate the CPU Board directly below the COMM Board near the upper back portion of the enclosure See Figure 4 2 4 Remove hardware securing CPU board Gently pull the CPU card handle extracting the board from the pin connectors 5 Place new CPU Board in enclosure Insure the board is in the ...

Page 111: ...ully seated 10 Place new Analog Board in enclosure 11 Secure new Analog Board to enclosure 12 Reconnect loadcell cables to Analog Board and reconnect wires to TB4 13 Connect Analog Board cables J3 and J4 to CPU Board connectors J3 J4 J5 J6 J9 J10 J11 J26 and J27 14 Perform a Cold Start Procedure 15 Apply power to electronics and recalibrate machine Refer to Chapter 3 for calibration procedures ...

Page 112: ...REC 3838 4 6 COMMUNICATION CPU AND ANALOG BOARD REPLACEMENT FIGURE 4 2 ...

Page 113: ...0 TB 8 9 Remove screw securing Distribution Board to enclosure 10 Remove Distribution Board from enclosure by sliding up and lifting out 11 Verify that fuses on new Distribution Board are the same as old board The following list defines the correct fuses FUSE F1 Infeed Motor F2 Weightable Motor F3 Outfeed Motor F4 Line L1 F5 Line L2 115 220 VAC 5A 5A 5A 15A 15A TYPE 3AG SB 3AG SB 3AG SB 3AB SB 3AB...

Page 114: ...REC 3838 4 8 21 Apply power to electronics and verify proper operation ...

Page 115: ...REC 3838 4 9 DISTRIBUTION BOARD REPLACEMENT FIGURE 4 3 DISTRIBUTION BOARD WITH OPTIONS FIGURE 4 4 ...

Page 116: ... 4 5 8 Discard the old front panel door 9 Fit the controller s new front panel door and insert the hinge pin 10 Re install all hardware in reverse order 11 Reattach cables 12 Close controller enclosure door 13 Reapply power to electronics and verify proper operation Stainless Steel Enclosure 1 Turn off power at mains 2 Open the controller enclosure door Figure 4 5 3 Disconnect display module cable...

Page 117: ...REC 3838 4 11 FRONT PANEL REPLACEMENT FIGURE 4 5 ...

Page 118: ...Guide Chassis Control Connections in the Appendix Set 115 230V switches to appropriate settings WIRE COLOR BOARD CONNECTION EXTRON OR MINARIK Brown Yellow Violet Red A1 L1 L2 A2 WIRE COLOR BOARD CONNECTION EXTRON MINARIK Orange Gray Blue 4 2 3 S1 S2 S3 7 Place new motor speed control module in enclosure 8 Secure new speed control module using screws removed in step 4 9 Connect cable harness as rem...

Page 119: ... Front panel display reads Memory Lost Enter All Values 4 Procedure complete Press RUN to re enter the required setup information which is machine prompted See Section 3 5 Initial Setup Procedure for required entries ...

Page 120: ...ay Perform power supply troubleshooting procedures refer to Table 4 2 Replace defective Display Module refer to Display Module Replacement Procedures in this chapter Front panel display blank or blinking randomly no display response to lamp test but LED s OK Incorrect DC voltage Bad Display Board or cable If problem persists Perform power supply troubleshooting procedures refer to Table 4 2 Replac...

Page 121: ...REC 3838 4 15 ...

Page 122: ...peed potentiometer to correct speed Check speed calibration constant and speed sensor Conveyor slows or stops Product build up on drive Timing belt broken or loose Seizure of drive shaft bearings Loose drive sprocket or timing gear Clean machine Adjust or replace timing belt Refer to Drive Belt Replacement and Adjustment Procedures in the weightable manual Lubricate bearings or if bearings are def...

Page 123: ...ule Check drive motor fuses on Distribution Board If fuse is blown free conveyor of jam or replace defective drive shaft bearing Refer to Chain Drive Sprocket Replacement Procedures in the weightable manual Install new fuses Using an ohmmeter measure motor wiring isolation with respect to chassis ground Locate short and correct wiring Replace fuses on Distribution Board Measure motor armature resi...

Page 124: ...TB4 17 and TB4 18 on Junction Box Board If voltage is incorrect per form Power Troubleshooting checklist per Table 4 2 Replace defective interlock Refer to Interlock system Replacement Procedures in the weightable manual Replace defective Analog Board Refer to Analog Board Replacement Procedures in this chapter Not weighing Bad Interlock No speed signal Bad Analog Board Check replace photo interlo...

Page 125: ...hing not done Interrogate delay is set too long Taking too many A D samples Weightable belt speed is too high Reset interrogate delay Decrease amount of A D samples taken Slow weightable belt speed No gap Packages spaced too close together Increase package spacing or check package size for possible skewing ...

Page 126: ...4 and F5 on Distribution Board and F1 and F2 on the Analog Board Refer to Distribution Board and Analog Board Replacement Procedures in this chapter for fuse location and value If fuse F4 and F5 are OK problem exists with main AC input power Check external power source If fuse F4 or F5 on Distribution Board or fuse F1 or F2 on Analog Board are blown replace fuse and restore power Isolate fault to ...

Page 127: ...k speed sensor and interlocks Remove AC power Disconnect speed sensor and interlock cables If DC voltage is OK replace repair speed sensor and interlock or wiring If not OK check Display Module Remove AC power and disconnect Display Module cable at J6 on CPU Board Reapply AC power If DC Voltage is OK replace defective Display Module or cable Refer to Display Module Replacement Procedures in this c...

Page 128: ... parts is as follows 1 Determine the broken or faulty part s 2 Locate the part s in the parts list given 3 Find the part number s for the item s needed and determine the quantity you require 4 Write or telephone Thermo Electron Customer Service Department 501 90th Ave NW Minneapolis Minnesota 55433 Fax 612 780 1537 Customers A through G 612 783 2781 Customers H through O 612 783 2693 Customers P t...

Page 129: ...LIST INDEX Parts lists are cross referenced to photographs or drawings to facilitate identification These parts lists are indexed as follows PARTS LIST DESCRIPTION TABLE NO PAGE NO AC 4000 Electronics Remote or Local 5 1 5 4 ...

Page 130: ...REC 3838 5 3 5 3 1 Return Material Authorization ...

Page 131: ...43259 1 5 Cable Assembly Analog Board Display Board 044725 1 6 Cable Assembly Analog Board Display Module 044726 1 7 Display Module 042758 1 8 Communication Board 043262 1 9 CPU Board 043253 1 10 Cable Assembly Signal and Loadcell for remote AC 4000 and 8000 series frames 045326 1 11 Cable Assembly Signal and Loadcell for remote AC 4000 and 20 25 40 and 44 series frames 045324 1 12 Cable Assembly ...

Page 132: ...ntroller Enclosure Distribution Enclosure 044729 1 17 Distribution Board 044687 1 18 Distribution Board with Motor Inhibit 045322 A R 19 Distribution Board Fuses F1 F2 F3 5 amp Slo Blo F4 F5 15 amp Slo Blo 001369 045320 1 ea 1 ea 20 Cable Assembly Motor Rejects for remote AC 4000 and 8000 series frames 045325 1 21 Cable Assembly Motor Rejects for remote AC 4000 and 20 25 40 and 44 series frames 04...

Page 133: ...REC 3838 5 6 TABLE 5 1 Continued Controller Front Panel ...

Page 134: ...REC 3838 5 7 TABLE 5 1 Continued Controller Enclosure Left Side ...

Page 135: ...REC 3838 5 8 TABLE 5 1 Continued Controller Enclosure Right Side ...

Page 136: ...REC 3838 5 9 TABLE 5 1 Continued Distribution Enclosure ...

Page 137: ...pen the controller enclosure door 3 Remove the switch pot bracket from the door 4 With a knife cut through the hole s in the front panel 5 Install the spacer onto the potentiometer s and tighten 6 Insert the potentiometer s spacer through the front panel 7 From the front of the panel insert the o ring on the spacer threads 8 Install the jack cover and jack cover nut on the protruding spacer thread...

Page 138: ...e cover plates on the bottom of the enclosure and discard Insert the circular connectors in the holes and tighten four hex nuts 9 Close electronics controller enclosure door 10 Apply power to electronics 11 Refer to Chapter 3 for all setup procedures Also see the Menu Tree drawing for menus that are available with the Communications option COMMUNICATION BOARD SWITCH SETTINGS PORT A SWITCH SW1 1 SW...

Page 139: ... ON CLOSED ON CLOSED ON CLOSED OFF OPEN EIA 422 485 with termination ON CLOSED ON CLOSED OFF OPEN OFF OPEN OFF OPEN EIA 422 485 no termination 4 wire multidrop ON CLOSED ON CLOSED OFF OPEN ON CLOSED OFF OPEN EIA 422 485 with termination 4 wire multidrop ON CLOSED ON CLOSED OFF OPEN OFF OPEN ON CLOSED EIA 422 485 no termination 2 wire multidrop ON CLOSED ON CLOSED OFF OPEN ON CLOSED ON CLOSED EIA 4...

Page 140: ...REC 3838 6 4 ...

Page 141: ...he selected serial channel If the AC 4000 receives the same data back as it sends out the menu indicates PASS Your device probably will not send back the data so the menu will indicate FAIL However if your device prints the alphabet the cabling is probably working RS 232 Typical connections are shown in Figure 6 2 In some cases wires may need to be swapped null modem connections This is done by sw...

Page 142: ...g shown includes a converter that changes the output back to RS 232 before entering your device If your device has RS 485 capability built in the converter can be removed and your device hooked directly to connector P2 To make the Comm Loop Back test pass hook a jumper between pins 2 and 3 If the converter box is not used connect pins 2 5 and 14 17 on connector P2 ...

Page 143: ...ied to the controller only The connections are defined in Table 6 3 Reference drawing C000 021790 01 TABLE 6 3 INTERCONNECT TERMINATIONS MS3106A CONNECTOR PIN FUNCTION SIGNAL A B Shield Signal Ground C D E F TxD A TxD B RxD A RxD B Î EIA 422 485 4 wire Ï E F TxD RxD A TxD RxD B EIA 422 485 2 wire G H I J K L N C DTR Data Terminal Ready TxD Transmit Data RxD Receive Data N C CTS Clear to Send Î EIA...

Page 144: ...ndle extracting the board from the pin connectors 5 Carefully remove the old software EPROM IC from socket U2 using an IC extractor 6 Insert new EPROM into socket U2 The orientation mark on the EPROM should be toward U1 the large square IC 7 If socket U3 is empty insert the new EPROM memory IC into the socket The orientation mark is again toward U1 8 Replace CPU Board in enclosure Insure the board...

Page 145: ...act across TB8 1 and 2 of the distribution board allows the motors to run Motor inhibit is not an E Stop See the section on the inhibit input in the motor control manual The motor controls minimum speed setting must be set properly or the motors may rotate at the minimum speed when the motor inhibit contact opens ...

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Page 147: ...REC 3838 A 1 Appendix Drawing A 1 Field Wiring Diagram INSERT FIELD WIRING DIAGRAM APPROPRIATE FOR YOUR APPLICATION See Engineering Manual Request Form or Consult Product Engineer ...

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Page 159: ...M MM M2 23 30 00 00 0 S Se er ri ie es s SCR Adjustable Speed Drives for DC Brush Motors User s Manual ...

Page 160: ... 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 161: ...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 162: ... 17 Power fuse and motor connections 17 Voltage follower 23 Cased drives 24 Mounting NEMA 1 enclosures 24 Mounting NEMA 12 enclosures 25 Heat sinking 26 Line fusing 26 Connections 27 Field output connections 28 Current limit LED C models only 30 Current limit header block C H models only 30 Meter header block cased C models only 30 MM23001C Q MM23071 and MM23072 diagnostic LEDs 31 Before applying ...

Page 163: ...D 43 IR COMPENSATION IR COMP 45 ACCELERATION ACCEL 47 DECELERATION DECEL 48 Application Notes 49 Multiple fixed speeds 49 Adjustable speeds using potentiometers in series 50 Independent adjustable speeds 51 RUN JOG switch 52 RUN JOG switch option 1 52 RUN JOG switch option 2 53 Leader follower application 54 Reversing 56 Reversing with a DIGI LOK controller 57 Before troubleshooting 58 Troubleshoo...

Page 164: ...nal Block 15 Figure 10 Speed Adjust Potentiometer 16 Figure 11 Chassis Drive Connections 21 Figure 12 MM23201C Q and MM23011C Q Connections 22 Figure 13 Voltage Follower Connections 23 Figure 14 Cased Drive Connections 29 Figure 15 Voltage Switches 33 Figure 16 INHIBIT Terminals 38 Figure 17 Run Decelerate to Minimum Speed Switch 39 Figure 18 Dynamic Brake Connection 41 Figure 19 Recommended Torqu...

Page 165: ...tion 54 Figure 26 Single Speed Potentiometer Control of Multiple Drives 55 Figure 27 Reversing Circuit Connection 56 Figure 28 Reversing with a DLC600 57 FIgure 29 MM23000 Series Block Diagram 62 FIgure 30 MM23101 MM23111 MM23401 and MM23411 Terminal Block Connections 63 FIgure 31 MM23201 and MM23211 Terminal Block Connections 64 Figure 32 MM23501 Terminal Block Connections 65 ...

Page 166: ...ine Fuse Sizes 19 Table 2 Field Output Connections 20 Table 3 Field Output Connections 28 Table 4 Minimum Recommended Dynamic Brake Resistor Values 41 Table 5 Replacement Parts 66 Table 6 Corcom Filters 69 Table 7 Minarik Filters 70 ...

Page 167: ... on heat sink part number 223 0174 AC Line Voltage 115 VAC or 230 VAC 10 50 60 Hz single phase Armature Voltage 115 VAC Input 0 90 VDC Armature Voltage 230 VAC Input 0 180 VDC Form Factor 1 37 at base speed Field Voltage 115 VAC Input 50 VDC F1 to L1 100 VDC F1 to F2 Field Voltage 230 VAC Input 100 VDC F1 to L1 200 VDC F1 to F2 Max Field Current 1 ADC Accel Time Range for 0 90 VDC Armature Voltage...

Page 168: ... Range cased drive 10 C 40 C Suffix Definitions A Basic drive C Basic drive with current limit LED C H Basic drive with current limit header block C Q Basic drive with current limit LED power LED and quick disconnect terminal block Note C suffix applies to all models except MM23071 and MM23072 C H and C Q suffixes apply only to models MM23001 and MM23011 MM23071A and MM23072A drives include a curr...

Page 169: ...3 Dimensions Figure 1 MM23001 and MM23011 Dimensions ALL DIMENSIONS IN INCHES MILLIMETERS ...

Page 170: ...4 Dimensions Figure 2 MM23001C Q and MM23011C Q Dimensions ALL DIMENSIONS IN INCHES MILLIMETERS ...

Page 171: ...5 Dimensions TWO 0 88 22 CONDUIT HOLES Figure 3 MM23101 and MM23111 Dimensions ALL DIMENSIONS IN INCHES MILLIMETERS ...

Page 172: ...6 ALL DIMENSIONS IN INCHES MILLIMETERS TWO 0 88 22 KNOCKOUTS FOUR MOUNTING SLOTS 0 19 INCHES 5 MILLIMETERS WIDE Dimensions Figure 4 MM23201 and MM23211 Dimensions ...

Page 173: ...7 Dimensions Figure 5 MM23401 and MM23411 Dimensions ALL DIMENSIONS IN INCHES MILLIMETERS TWO 0 88 22 KNOCKOUTS FOUR MOUNTING SLOTS 0 19 INCHES 5 MILLIMETERS WIDE ...

Page 174: ...8 Dimensions Figure 6 MM23501 Dimensions ALL DIMENSIONS IN INCHES MILLIMETERS TWO 0 88 22 KNOCKOUTS FOUR MOUNTING SLOTS 0 19 INCHES 5 MILLIMETERS WIDE ...

Page 175: ...9 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 7 MM23071 and MM23072 Dimensions Dimensions ...

Page 176: ...DIM D DIM E 223 0159 4 40 112 3 00 76 0 7 18 1 75 44 3 90 100 223 0174 7 78 198 6 00 152 0 89 23 6 00 152 5 35 136 Heat sinks sold separately Figure 8 Heat Sink Dimensions MOUNTING SLOTS 0 19 X 0 34 5 X 9 ALL DIMENSIONS IN INCHES MILLIMETERS ...

Page 177: ...sive 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 either the large base or the narrow flange of the chassis to the subplate The chassis must be earth grounded To ground the chassis use a star washer beneath the head of at least one of the mounting screws to penetrate the anodi...

Page 178: ... 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 destro...

Page 179: ...es 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 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 ...

Page 180: ...rmature current is above 5 ADC Use Minarik part number 223 0159 All other chassis drives have sufficient heat sinking in their basic configurations Use 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 ...

Page 181: ...at head screwdriver turn terminal plug screw counterclockwise to open wire clamp 3 Insert stripped wire into the large opening in front of the plug 4 Turn the terminal plug screw clockwise to clamp the wire 5 Repeat steps 2 4 for each terminal until all connections are made Make no connections to F1 and F2 if using a permanent magnet motor 6 Insert plug into header until securely fastened Figure 9...

Page 182: ...meter 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 driv...

Page 183: ...kwise 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 Chassis drive connections Warning Do not connect this equipment with power applied Failure to heed this directive may result in fire or serious injury Minarik strongly recommends the installation of a master power switc...

Page 184: ... Line fuse 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 only the HOT leg of the AC line that connects to L1 and leave L2 unfused when the AC line voltage is 115 VAC Table 1 page 19 lists the recommended line fuse sizes Wire an external line fuse between the stop switch if installe...

Page 185: ...AC Line Fuse Horsepower 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 ...

Page 186: ...le 2 Field Output Connections Line Voltage Approximate Connect Motor VAC Field Voltage VDC Field To 115 50 F1 and L1 115 100 F1 and F2 230 100 F1 and L1 230 200 F1 and F2 Warning The field output is for shunt wound motors only Do not make any connections to F1 and F2 when using a permanent magnet motor Field output connections ...

Page 187: ...21 Figure 11 Chassis Drive Connections Installation ...

Page 188: ...22 Figure 12 MM23201C Q and MM23011C Q Connections Installation ...

Page 189: ... scale the analog input voltage An interface device such as Minarik model PCM4 may be used to scale and isolate an analog input voltage With either 115 VAC or 230 VAC line voltage an analog input voltage range of approximately 0 1 4 VDC is required to produce an armature voltage range of 0 90 VDC With 230 VAC line voltage an analog input voltage range of approximately 0 2 8 VDC is required to prod...

Page 190: ... the mounting screws in the three keyholes 3 Install conduit hardware through the conduit holes at the bottom of the case Connect external wiring to the terminal block 4 Reinstall the front cover Avoid pinching any wires between the front cover and the case 5 Replace the two screws to the front cover Turn the screws clockwise to tighten 6 Set the POWER switch to the OFF position before applying th...

Page 191: ...r counterclockwise until it is free from the case The right side of the cover is hinged to the case Pull the slotted screw to open the case 3 Carefully remove the conduit knockouts by tapping them into the case and twisting them off with pliers 4 Install conduit hardware through the 0 88 inch 22 mm knockout holes Connect external wiring to the terminal block 5 Grasp the slotted screw and tilt the ...

Page 192: ...nk Compound between the back of the drive case and heat sink surface for optimum heat transfer Line fusing 15 amp line fuses are preinstalled on the cased models MM23101 MM23201 MM23401 and MM23501 3 amp line fuses are preinstalled on the cased models MM23111 MM23211 and MM23411 If the horsepower rating of the motor being used is less than the maximum horsepower rating of the drive the line fuse m...

Page 193: ...put leads and a DC motor to TB501 as shown in Figure 13 page 28 Motor Minarik drives supply motor voltage from A1 and A2 terminals It is assumed throughout this manual that when A1 is positive with respect to A2 the motor will 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 ...

Page 194: ... output is for shunt wound motors only Do not make any connections to F1 and F2 when using a permanent magnet motor See Table 3 for field output connections Use 18 AWG wire to connect the field output to a shunt wound motor Table 3 Field Output Connections Line Voltage Approximate Connect Motor VAC Field Voltage VDC Field To 115 50 F1 and L1 115 100 F1 and F2 230 100 F1 and L1 230 200 F1 and F2 ...

Page 195: ...29 Figure 14 Cased Drive Connections Installation ...

Page 196: ...rrent limit header block outputs approximately a floating 5 VDC 5 mADC signal whenever the drive reaches current limit The signal may be used as an input to an external device such as an alarm or shut down circuit that works when the drive reaches current limit Meter header block cased C models only To supply power to external devices the Meter header block can supply an unregulated 9 VDC 5 mA sig...

Page 197: ...c LEDs Models MM23001C Q MM23071 and MM23072 are equipped with two diagnostic LEDs Power PWR Lights whenever the AC line voltage is applied to the drive Current Limit CURR LIMIT or CL Lights whenever the drive reaches current limit Installation ...

Page 198: ...he motor will not run at full voltage and may cause damage to the transformer If the switches are improperly set to a higher voltage position the motor will overspeed which may cause motor damage or result in bodily injury or loss of life Dangerous voltages exist on the drive when it is powered BE ALERT High voltages can cause serious or fatal injury For your safety use personal protective equipme...

Page 199: ...501 Set the voltage switch SW501 to either 115V or 230V to match the AC line voltage See Figure 14 Armature voltage select SW502 Set the voltage switch SW502 to either 90V or 180V to match the maximum armature voltage See Figure 14 ARMATURE VOLTAGE SELECT SW502 INPUT VOLTAGE SELECT SW501 ...

Page 200: ...e desired speed is reached 4 Remove AC line voltage from the drive to coast the motor to a stop MM23101 MM23111 MM23401 and MM23411 1 Set the speed adjust potentiometer to 0 full CCW 2 Apply AC line voltage 3 Set the POWER switch to the ON position 4 Slowly advance the speed adjust potentiometer clockwise CW The motor slowly accelerates as the potentiometer is turned CW Continue until the desired ...

Page 201: ...reverse direction a Set the RUN BRAKE switch to the BRAKE position b Set the FORWARD REVERSE switch to the desired direction of rotation c Set the RUN BRAKE switch to the RUN position 9 To brake the motor set the RUN BRAKE switch to the BRAKE position To coast the motor to a stop set the POWER switch to the OFF position MM23201 and MM23211 Warning Do not change the FORWARD REVERSE switch while the...

Page 202: ...d speed is reached 8 To reverse direction a Set the FORWARD BRAKE REVERSE switch to the BRAKE position b After the motor comes to a complete stop set the FORWARD BRAKE REVERSE switch to the desired direction of rotation 9 To brake the motor set the FORWARD BRAKE REVERSE switch to the BRAKE position To coast the motor to a stop set the POWER switch to the OFF position MM23501 Warning The motor must...

Page 203: ...AC line voltage is removed the motor coasts to a stop 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 only acceptable method for emergency stopping For this reason Minarik strong...

Page 204: ...es of electrical noise Use shielded cable if the inhibit wires are longer than 18 inches 46 cm If shielded cable is used ground only one end of the shield to earth ground Do not ground both ends of the shield Minarik Corporation offers two accessory plug harnesses for connecting to the INHIBIT terminals part number 201 0024 inhibit plug with 18 inches 46 cm leads and part number 201 0079 inhibit p...

Page 205: ...eed determined by the MIN SPD trimpot setting If the MIN SPD trimpot is set full CCW the motor decelerates to zero speed when the switch between S1 and S2 is closed The DECEL trimpot setting determines the rate at which the drive decelerates By opening the switch the motor accelerates to set speed at a rate determined by the ACCEL trimpot setting Figure 17 Run Decelerate to Minimum Speed Switch Op...

Page 206: ... especially gearmotors that are not properly sized for the application Dynamic braking may be used to rapidly stop a motor Figure 17 page 40 For the RUN BRAKE switch use a two pole two position switch rated for at least 125 VDC 6 amps For the dynamic brake resistor use a 40 watt minimum high power wirewound resistor Sizing the dynamic brake resistor depends on load inertia motor voltage and brakin...

Page 207: ...Resistor Value 90 VDC 15 ohms 180 VDC 30 ohms For motors rated 1 17 horsepower and lower a brake resistor is not necessary since the armature resistance is high enough to stop the motor without demagnetization Replace the dynamic brake with 12 gauge wire Figure 18 Dynamic Brake Connection Operation ...

Page 208: ...h CCW rotation Use 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 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 equip...

Page 209: ... SPD The MAX SPD setting determines the maximum motor speed when the speed adjust potentiometer or voltage input signal is set for maximum forward speed It is factory set for maximum rated motor speed To calibrate MAX SPD 1 Set the MAX SPD trimpot full CCW 2 Set the speed adjust potentiometer or voltage input signal for maximum forward speed 3 Adjust MAX SPD until the desired maximum forward speed...

Page 210: ...ck the motor armature Be sure that the motor is firmly mounted 5 Apply line power The motor should be stopped 6 Slowly adjust the TORQUE trimpot CW until the armature current is 150 of motor rated armature current 7 Turn the speed adjust potentiometer CCW until the motor stops 8 Remove line power 9 Remove the stall from the motor 10 Remove the ammeter in series with the motor armature if it is no ...

Page 211: ...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 If the motor oscillates overcompensation the IR COMP trimp...

Page 212: ...46 Calibration Figure 19 Recommended Torque and IR COMP Settings actual settings may vary with each application ...

Page 213: ...n 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 measure the time it takes the motor to go from minimum to maximum speed 3 If the time measured in step 2 is not the desired acceleration time turn the ACCEL trimpot CW for a slower acceleration time or CCW for a faster acceleration time Repeat steps 1 through...

Page 214: ...ime 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 minimum speed 3 If the time measured in step 2 is not the desired deceleration time turn the DECEL trimpot CW for a slower deceleration time or CCW for a faster deceleration time Repeat steps 1 through 3 ...

Page 215: ...otentiometer with series resistors with a total series resistance of 10K ohms Figure 19 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds Application Notes Figure 20 Multiple Fixed Speeds ...

Page 216: ...adjust potentiometer with a single pole multi position switch and two or more potentiometers in series with a total series resistance of 10K ohms Figure 20 shows a connection for fixed high and low speed adjust potentiometers Figure 21 Adjustable Fixed Speeds Using Potentiometers in Series ...

Page 217: ...i position switch and two or more potentiometers in parallel with a total parallel resistance of 10K ohms Figure 21 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations Figure 22 Independent Adjustable Speeds Application Notes ...

Page 218: ...JOG switch and a single pole normally closed momentary operated pushbutton for the JOG pushbutton In the first wiring option connect the RUN JOG switch and JOG pushbutton to the inhibit plug as shown in Figure 22 The motor coasts to a stop when the RUN JOG switch is set to JOG Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation Figure 23 RUN JOG Switch C...

Page 219: ... 23 When 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 24 RUN JOG Switch Connection to Speed Adjust Potentiometer Option 2 Application Notes ...

Page 220: ... 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 voltage reference to set the speed of the follower motor An optional ratio potentiometer may be used to scale the PCM4 output voltage Figure 25 Leader Follower Application ...

Page 221: ...ngle speed adjust potentiometer using a PCM4 at the input of each drive to provide isolation Figure 25 Optional ratio potentiometers can be used to scale the PCM4 output voltage allowing independent control of each drive Figure 26 Single Speed Potentiometer Control of Multiple Drives Application Notes ...

Page 222: ...mum DC armature voltage and maximum braking current Wait for the motor to stop completely before switching it to either the forward or reverse direction See the Dynamic braking section page 39 for recommended dynamic brake resistor sizes Note Model MM23501 is equipped with this reversing feature Figure 27 Reversing Circuit Connection Application Notes ...

Page 223: ...t the inhibit feature the DIGI LOK will continue to regulate This will cause overshoot when the DIGI LOK is switched back to the drive Figure 27 shows the connection of the reversing circuit to a MM23000 series drive and to a DLC600 Note Only one DLC option Optical Encoder or Magnetic Pickup may be used at a time Figure 28 Reversing with a DLC600 Application Notes ...

Page 224: ...ndition 5 Verify that there are no short circuits or grounded connections 6 Check that the voltage selection switch settings match the AC line and output voltages 7 Check that the drive s rated armature and field outputs are consistent with the motor ratings For additional assistance contact your local Minarik Distributor or the factory direct at Tel 1 800 MINARIK 646 2745 or Fax 1 800 394 6334 Wa...

Page 225: ...s i e reversing 1 Check that the line fuse is correct for the motor size 2 Check motor cable and armature for shorts 3 Add a blower to cool the drive components decrease TORQUE settings or resize motor and drive for actual load demand or check for incorrectly aligned mechanical components or jams See page 43 for information on adjusting the TORQUE trimpot Problem Possible Causes Suggested Solution...

Page 226: ...ent limit 5 Drive is not receiving AC line voltage 6 Motor is not connected MIN SPD setting is too high Motor connections to A1 and A2 are reversed 1 Increase the speed adjust pot or speed reference voltage etting 2 Remove jumper from the INHIBIT terminals 3 Remove short 4 Verify that motor is not jammed Increase TORQUE setting if they are set too low See page 43 5 Apply AC line voltage to L1 and ...

Page 227: ...igh 2 Motor bouncing in and out of current limit 1 Calibrate MAX SPD and MIN SPD See page 42 2 Check motor field connections 1 Increase MAX SPD setting See page 42 2 Increase IR COMP setting See page 44 3 Increase TORQUE setting See page 43 4 Check motor load Resize the motor and drive if necessary 1 Adjust the IR COMP setting slightly CCW until the motor speed stabilizes See page 44 2 Make sure m...

Page 228: ...62 Troubleshooting FIgure 29 MM23000 Series Block Diagram ...

Page 229: ...63 FIgure 30 MM23101 MM23111 MM23401 and MM23411 Terminal Block Connections Troubleshooting ...

Page 230: ...64 Troubleshooting FIgure 31 MM23201 and MM23211 Terminal Block Connections ...

Page 231: ...65 Figure 32 MM23501 Terminal Block Connections Troubleshooting ...

Page 232: ...001 except SCR501 502 600 V 8 A SCR 072 0024 D501 503 600 V 3 A Diode 071 0007 R501 0 05 OHM 5W Resistor 032 0089 MM23101 Same as MM23001 except potentiometer kit and including Case Bottom 223 0170 Case Cover 223 0169 240V Pilot Light 040 0043 10K OHM 5W Potentiometer 120 0009 Knob 140 0013 DPST Power Switch 080 0037 15 A 3AB Fuse 050 0018 MM23111 Same as MM23011 except potentiometer kit Same as M...

Page 233: ...K OHM 1 2 W Potentiometer 120 0009 3A 3AG Fuse 050 0021 Heat Sink 223 0182 Case 223 0104 MM23401 Same as MM23001 except pot kit Same parts as MM23411 knob case except fuse and including 15 A 3AB Fuse 050 0018 MM23501 Same as MM23401 except heat sink and case and including Heat Sink 223 0183 Case 223 0106 20 OHM 40 W Resistor 032 0062 FWD BRAKE REV Switch 081 0037 Knob 140 0014 MM23072 Same as MM23...

Page 234: ...nd EN50082 1 1992 immunity Compliance allows Minarik s MM23000 series to bear the CE mark 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 being operated 2 The Original Equipment Manufacturer OEM will implement the product as a component of the machine being manufactured In addition to...

Page 235: ...s 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 The line filters should be wired to the AC line within 0 25 meters of the drive The ground connection from the line filter must be wired to solid earth ground resistance less than 500 ohms not machine ground This is very important If the end user is using a CE...

Page 236: ...rent of Minarik Filter Motor Wired to the Drive Part Number 0 to 4 amps CE4MM 4 1 to 13 amps CE20MM The filters listed above are Real Pole Balanced Pi 3 pole filters If the exact 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 The filters listed above must be wired to the DC output of the drive as close to t...

Page 237: ... 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 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 filte...

Page 238: ...NOTES 72 ...

Page 239: ...NOTES 73 ...

Page 240: ...NOTES 74 ...

Page 241: ... C Limitations of Liability In the event of any claim for breech of 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 ...

Page 242: ...IK 646 2745 Fax 1 800 394 6334 www minarikcorp com Document number 250 0091 Revision 5 Printed in the U S A 10 01 North America 12 00 Outside North America 15 00 DLC600 XP Series AC or DC Input MM PCM Series PCM20000 Series Other drives from Minarik Corporation ...

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