Minarik UPVFD04-D230AC User manual

Open Chassis Microprocessor-based
Variable Frequency AC Drive
UPVFD04-D230AC 14300 De La Tour Drive
South Beloit, IL 61080
Phone: [phone]
Fax: [phone]
www.minarikdrives.com
Specifications
......................................................115/230 VAC ± 10%, 50/60 Hz, single phase
......... approx. 2x motor current
......... approx. 4x motor current
..........approx. 2x motor current
...........................................................115/230 VAC, 50/60 Hz, single or three phase
...............................................................................200% (2x) for 1 minute
.............................................................................................16 kHz
............................................................................................0 - 120 Hz
.....................................................30 - 120 Hz
.......................................0 - 50% of maximum
................................................................................0 - 35 VDC
.....................................................................................1 - 12 seconds
.....................................................................................1 - 12 seconds
................................................0 - 5 VDC
....................................................................................>100K ohms
............................................................................................0.5G maximum
..............................................................................................0.1G maximum
.....................................................................................0°C - 40°C
..............................................................................................................................1.4 lbs
AC Line Voltage
AC Line Current with 115 VAC line voltage with a 115V motor
AC Line Current with 115 VAC line voltage with a 230V motor
AC Line Current with 230 VAC line voltage with a 230V motor
AC Motor Voltage
Overload Capability
Standard Carrier Frequency
Output Frequency Range
Adjustable Maximum Output Frequency Range
Adjustable Minimum Output Frequency Range
Adjustable DC Injecon Voltage
Acceleraon Time Range
Deceleraon Time Range
Analog Input Voltage Range (Signal must be isolated)
Input Impedance (S1 to S2)
Vibraon (0 - 50 Hz)
(>50 Hz)
Ambient Temperature Range
Weight
1/8 - 1/2
1/4 - 1
1/4 - 1
Motor
Horsepower
Range
4.0
Connuous
Motor Current
(Amps)
115
230
230
Motor
Voltage
(VAC)
Line
Voltage
(VAC)
UPVFD04-D230AC
Model
115
115
230
Safety Warnings
READ ALL SAFETY WARNINGS BEFORE INSTALLING THIS EQUIPMENT
• DO NOT INSTALL, REMOVE, OR REWIRE THIS EQUIPMENT WITH POWER APPLIED. Have a
• qualified electrical technician install, adjust and service this equipment. Follow the Naonal
•Electrical Code and all other applicable electrical and safety codes, including the provisions of the
• Occupaonal Safety and Health Act (OSHA), when installed equipment.
• Circuit potenals are at 115 or 230 VAC above earth ground. Avoid direct contact with the printed
• circuit board or with circuit elements to prevent the risk of serious injury or fatality. Use a
• non-metallic screwdriver for adjusng the calibraon trim pots. Use approved personal protecon
• equipment and insulated tools if working on this drive with power applied.
• Reduce the chance of an electrical fire, shock, or explosion by proper grounding, over-current
• protecon, thermal protecon, and enclosure. Follow sound maintenance procedures.
• Minarik Drives strongly recommends the installaon of a master power switch in the line voltage
•input. The switch contacts should be rated for 250 VAC and 200% of motor nameplate current.
• Removing AC line power is the only acceptable method for emergency stopping. Do not use
• DC injecon braking, decelerang to minimum speed, or coasng to a stop for emergency stopping.
• They may not stop a drive that is malfunconing. Removing AC line power is the only acceptable
•method for emergency stopping.
• Line starng and stopping (applying and removing AC line voltage) is recommended for infrequent
• starng and stopping of a drive only. DC injecon braking, decelerang to minimum speed, or
• coasng to a stop is recommended for frequent starts and stops. Frequent starng and stopping can
•produce high torque. This may cause damage to motors.
• Do not disconnect any of the motor leads from the drive unless power is removed or the drive is
• disabled. Opening any one lead while the drive is running may destroy the drive.
• Under no circumstances should power and logic level wires be bundled together.
• Be sure potenometer tabs do no make contact with the potenometer enclosure. Grounding the
• input will cause damage to the drive.
• Cauon should be taken when operang fan-cooled motors at low speeds because their fans may
• may not move sufficient air to properly cool the motor. Minarik Drives recommends “inverter-duty”
• motors when the speed range is beyond 10:1.
• Drive is designed to work with permanent split capacitor, shaded pole, and standard three phase
• inducon motors. In general, the drive can work with capacitor-start motors, but it is condional
• on the current pull when the capacitor is in effect and how long the applicaon calls for a speed that
•the capacitor will stay in the auxiliary winding. It is recommended to contact the motor manufacturer
• to see if the motor can be ran with a VFD.
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Dimensions
0
1.
88
5[
]
0.700 [17.80]
4.41 [112]
3.71 [94.2]
6.90 [17.5]
DIR
S3
S2
S1
COM
EN
MAX
ACCEL
BOOST
MIN
TQ/LIM
1 2 3 4
ON
SLIP
COMP
SW501
TB501
U
V
W
MOTOR OUT
STATUS LEDS
3.45
[87.63]
N
L1
L2
DEC/BK
Installation
Mounng
• Drive components are sensive to electrostac discharge. Avoid direct contact with the circuit
• board. Hold the drive by the chassis only.
• Protect the drive from dirt, moisture, and accidental contact.
• Provide sufficient room for access to the terminal block and calibraon trim pots.
• Mount the drive away from heat sources. Operate the drive within the specified ambient operang
• temperature range.
• Prevent loose connecons by avoiding excessive vibraon of the drive.
• Mount the drive with its board in either a horizontal or vercal plane. Four 0.20” (5 mm) wide slots
• in the chassis accept #8 pan head screws.
• The heat sink should be earth grounded. Use a star washer beneath the head of at least one of the
• mounng screws to penetrate the anodized heat sink surface and to reach bare metal.
Wiring
Use 18 - 24 AWG wire for logic wiring (COM, DIR, EN, S1, S2, S3).
Use 14 - 16 AWG wire for AC line (L1, L2, N) and motor (U, V, W) wiring.
Shielding Guidelines
As a general rule, Minarik Drives recommends shielding of all conductors. If it is not praccal to shield
power conductors, Minarik Drives recommends shielding all logic-level leads. If shielding of logic-level
leads is not praccal, the user should twist all logic leads with themselves to minimize induced noise.
Refer to the user’s manual for details on earth grounding shielded wires and filtering.
Fusing
Minarik Drives drives require an external line fuse for protecon. Use fast acng fuses rated for 250
VAC or higher and 150% of the maximum line current. Fuse the HOT leg of the AC line when using 115
VAC or both legs when using a 230 VAC line.
Connections
Line Input
Connect the AC line power leads to terminals L1 and N if using 115 VAC line power or to L1 and L2 if using 230 VAC
line power. Minarik Drives recommends the use of a single-throw, double-pole master power switch. The switch
should be rated at a minimum of 250 VAC and 200% of motor current.
Motor
If using a three phase motor, connect the AC motor leads to terminals U, V, and W. If the motor does not
spin in the desired direcon, power down the drive and swap any two of these connecons. If using a single
phase motor, connect the AC motor leads to terminals U and V. Refer to the Operaons secon for
possible wiring setups.
Speed Potenometer or Analog Input Signal
Use a 5K - 20K ohm, 1/4 W potenometer for speed control. Connect the counter-clockwise end of the potenometer
to S1, the wiper to S2, and the clockwise end to S3. If the potenometer works inveresly of desired funconality,
(i.e. to increase motor speed, you must turn the potenometer counterclockwise), power off the drive and swap
the S1 and S3 connecons. The drive may also follow a 0-5 VDC analog signal that is isolated from earth ground. Connect
the signal common to terminal S1 and the signal input to terminal S2. To use a PWM signal, use adder card 200-0441.
Direcon Switch
If a direcon switch is desired, wire a switch to terminals COM and DIR. When the connecon is open, the motor will
run in the forward direcon. When the connecon is closed, the motor will run in reverse. If no direcon switch is
desired, leave this connecon open.
Enable
Open the terminals COM and EN to coast the motor to minimum speed. Close terminals COM and EN to accelerate the
motor to set speed. If no enable switch is desired, jumper terminals COM and EN. Do not use the enable for
emergency stopping.
POWER
LOGIC
115 VAC LINE
DIR
S3
S2
S1
COM
EN
TB501
DIRECTION SWITCH
ENABLE/ DISABLE SWITCH
(open to disable)
10K OHM SPEED
ADJUST POTENTIOMETER
MOTOR
U
V
W
STOP
SWITCH
FUSE
FUSE
STOP
SWITCH
FUSE
230 VAC LINE
OR
N
L1
L2

Copyright 2014 by Minarik Drives - All right reserved. No part of this document may be reproduced
or retransmied in any form without wrien permission from Minarik Drives. The informaon and
technical data in this document are subject to change without noce. Minarik Drives makes
no warranty of any kind with respect to this material, including, but not limited to, the
implied warranes of its merchantability and fitness for a given purpose. Minarik Drives
assumes no responsibility for any errors that may appear in this document and makes no
commitment to update or to keep current the informaon in this document.
250-0498 rev 2
Minimum Speed (MIN): The MIN seng determines the motor speed when the speed adjust
potenometer is set for minimum speed. It is factory set for zero speed. To calibrate the MIN:
1. Set the MIN trim pot full CCW.
2. Set the speed adjust potenometer for minimum speed (full CCW).
3. Adjust MIN trim pot unl the desired minimum speed is reached.
Maximum Speed (MAX SPD): The MAX seng determines the motor speed when the speed adjust
potenometer is set for maximum speed. To calibrate the MAX SPD:
1. Set the MAX SPD trim pot full CCW.
2. Set the speed adjust potenometer for maximum speed (full CCW).
3. Adjust MAX SPD trim pot unl the desired maximum speed is reached.
Slip Compensaon (SLIP COMP): The SLIP COMP seng determines the degree to which motor speed
is held constant as the motor load changes. It is factory set for opmum motor regulaon. To calibrate
the SLIP COMP:
1. Set the SLIP COMP trim pot full CCW.
2. Increase the speed adjust potenometer unl the motor runs at midspeed without load. A
2. handheld tachometer may be used to measure motor speed.
3. Load the motor to its full load current rang. The motor should slow down.
4. While keeping the load on the motor, rotate the SLIP COMP trim pot unl the motor runs at
4. the speed measured in step 2. If the motor oscillates (overcompensaon), the SLIP COMP trim
4. pot may be set too high (CW). Turn the SLIP COMP trim pot CCW to stabilize the motor.
5. Unload the motor.
Boost (BOOST): The BOOST seng increases the motor torque at low speeds. The minimum seng
is sufficient for most applicaons and does not need to be adjusted. If the motor stalls or runs
erracally at very low speeds (below 10 Hz), the boost trim pot may need adjustment. To calibrate the
BOOST:
1. Run the motor at the lowest connuous speed/frequency required.
2. Increase the BOOST trim pot unl the motor runs smoothly. Connuous operaon beyond the
2. motor’s current rang may damage the motor.
Acceleraon (ACCEL): The ACCEL seng determines the me the motor takes to ramp to a higher
speed. ACCEL is factory set for the shortest acceleraon me (full CCW). To calibrate the ACCEL:
1. Set the speed adjust potenometer for minimum speed.
2. Set the speed adjust potenometer for maximum speed. Measure the me is takes the motor
2. to go from minimum speed to maximum speed.
3. If the me measured in step 2 is not the desired acceleraon me, turn the ACCEL trim pot
3. CW for a longer acceleraon me, or CCW for a shorter acceleraon me. Repeat steps 1
3. through 3 unl the acceleraon me is correct.
Deceleraon / DC Injecon Braking (DEC/BK):
In Coast to Stop Mode (Dip Switch 2 = OFF), the DEC/BK seng determines the me the motor takes to
ramp to a lower speed. DEC/BK is factory set for the shortest deceleraon me (full CCW). To calibrate
the DEC/BK:
1. Make sure Dip Switch 2 is OFF. See STARTUP secon for dip switch locaon.
2. Set the speed adjust potenometer for maximum speed.
3. Set the speed adjust potenometer for minimum speed. Measure the me is takes the motor
3. to go from maximum speed to minimum speed.
4. If the me measured in step 2 is not the desired deceleraon me, turn the DEC/BK trim pot
4. CW for a longer deceleraon me, or CCW for a shorter deceleraon me. Repeat steps 1
4. through 3 unl the deceleraon me is correct.
In DC Injecon Braking Mode (Dip Switch 2 = ON), the DC Injecon Braking seng determines the
amount of current injected into the motor to quickly brake the motor. To calibrate the DEC/BK:
1. Make sure Dip Switch 2 is ON. See STARTUP secon for dip switch locaon.
2. Set the DEC/BK trim pot full CCW.
3. Enable the drive.
4. Turn up the speed adjust potenomter to full speed.
5. Disable the drive.
6. If the motor decelerates to zero speed too slowly, increase the DEC/BK trim pot and repeat
6. steps 2 through 5 unl the motor stops within the desired me.
Torque (TQ/LIM): The TQ/LIM seng determines the maximum torque for accelerang and driving
the motor. If torque limit adjustment is desireable, but not crical, use the chart below for
approximate TQ/LIM trim pot sengs. Note that posions are relave to trim pot, not mounng
posion (ie 8:00 is full CCW on trim pot).
If torque limit adjustment is crical, determine the motor’s RMS current that correlates to desired
torque limit and then;
1. With power disconnected from the drive, connect a RMS ammeter in series with one of the
1. motor leads.
2. Turn the TQ/LIM trim pot to full CW. Apply power and adjust the motor speed to full rated
2. speed.
3. Load the motor so that it draws the RMS current previously determined.
4. Slowly turn the TQ/LIM trim pot CCW unl the red LED starts flickering. Then turn the trim pot
4. slightly more so that it just starts to reduce the motor amps on the RMS ammeter.
Calibration
115 V
1/2 HP
1/3 HP
1/4 HP
1/8 HP
100%
11:30
10:30
9:30
8:30
150%
2:00
11:30
10:30
9:00
200%
4:00
2:00
11:30
9:30
230 V
1 HP
2/3 HP
1/2 HP
1/4 HP
Single Phase Operaon - Non-reversing
For single phase operaon, connect the motor as show in the figure below. Ensure that the prewired
capacitor and its associated motor coil are connected to terminals U and V as shown. This connecon
may be internal if using a 2-wire motor. If the motor has three leads, you must make this connecon
yourself.
Single Phase Operaon - Reversing
Remove the capacitor and connect the motor as show in the figure below. While allowing for solid-state
reversing, this wiring scheme may result in sub-opmal motor operaon. Depending on the motor
construcon and applicaon requirements, the motor may need to be derated.
Three Phase Operaon
For three phase operaon, connect the motor as show in the figure below. Connect to terminals U, V,
and W as shown.
MOTOR CONNECTIONS
U V
AUXILIARY
WINDING
PREWIRED
RUN CAPACITOR
This connecon may be
internal to the motor
(2-wire). If not, you must
make this connecon
yourself.
U V
MAIN
WINDING
W
AUXILIARY WINDING
WITHOUT CAPACITOR
U V
MOTOR
WINDING
W
MOTOR
WINDING
MOTOR
WINDING
MAIN
WINDING
Operation
Power (IL2): Green LED lights whenever AC line voltage is applied to the drive.
Solid: Power is applied and the output is disabled.
Flashing: Power is applied and the output is enabled.
Status (IL1): Red LED lights whenever a fault condion occurs.
Solid: Current Limit - The motor is asking for more current than drive is set to allow out.
2: Undervoltage - Internal DC BUS voltage dropped too low.
3: Overvoltage - Internal DC BUS voltage rose too high.
4: Short Circuit - Short circuit between any two phases on output.
5: Overtemperature Warning - Drive’s temperature is approaching crical temperature.
6: Overtemperature Shut Down - Drive’s temperature has reached crical temperature.
7: Manual Start Trip - Power was applied while the enable was closed (only applicable
7: if switch 1 on SW501 is set to ON).
LEDs
DIR
S3
S2
S1
COM
EN
MAX
ACCEL
BOOST
MIN
TQ/LIM
1 2 3 4
ON
SLIP
COMP
SW501
TB501
U
V
W
MOTOR OUT
STATUS LEDS
Status
LED
Power
LED
N
L1
L2
DEC/BK
Select Switch (SW501)
Switch 1: ON - 115 VAC out - Sets a 115 VAC output at base frequency determined by switch 3.
Switch 1: OFF - 230 VAC out - Sets a 230 VAC output at base frequency determined by switch 3.
Switch 2: ON - DC Injecon Braking. The drive will use DC injecon braking to quickly decelerate the
Switch 2: ON - motor.
Switch 2: OFF - Coast to Stop. The fastest the motor will decelerate is a natural coast to a stop.
Switch 3: ON - 50 Hz motor seng
Switch 3: OFF - 60 Hz motor seng
Switch 4: ON - 1.6 kHz Carrier Frequency
Switch 4: OFF - 16 kHz Carrier Frequency
- Verify that no foreign conducve material is present on the printed circuit board.
- Ensure that all dip switches are properly set.
1. Turn the speed adjust potenometer full counterclockwise (CCW).
2. Apply AC line voltage.
3. Enable the drive.
4. Slowly advance the speed adjust potenometer clockwise (CW). The motor slowly accelerates as
the potenometer is turned CW. Connue unl the desired speed is reached.
5. Remove AC line voltage from the drive to coast the motor to a stop.
STARTUP
SELECT SWITCHES
Startup
DIR
S3
S2
S1
COM
EN
MAX
ACCEL
BOOST
MIN
TQ/LIM
1 2 3 4
ON
SLIP
COMP
SW501
TB501
U
V
W
MOTOR OUT
STATUS LEDS
Dip Switch
(SW501)
N
L1
L2
DEC/BK