Minarik MAC Series User manual

USER’S MANUAL
Models:
MAC03-115AC
MAC06–115AC
MAC03–D240AC
MAC06–D240AC
Variable-frequency drives for 3-phase AC motors
MAC Series
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II
Copyright  1999 by
Minarik Corporation
All rights reserved. No part of this manual may be reproduced or transmitted in any
form without written permission from Minarik Corporation. The information and
technical data in this manual are subject to change 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 this manual.
Printed in the United States of America.
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Safety Warnings
• This symbol mdenotes an important safety tip or warning.
Please read these instructions carefully before performing
any of the procedures contained in this manual.
• Have a qualified electrical technician install, adjust and service
this equipment. Follow the National Electrical Code and all
other applicable electrical and safety codes, including the
provisions of the Occupational Safety and Health Act (OSHA),
when installing equipment. DO NOT INSTALL, REMOVE,
OR REWIRE THIS EQUIPMENT WITH POWER
APPLIED.
• Reduce 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 at full speed as a result of a
component failure. Minarik strongly recommends the
installation of a master switch in the AC power input to stop
the drive in an emergency.
• This drive is isolated from earth ground. Circuit potentials are
at 115 VAC 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 adjusting the calibration trimpots.
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Contents
Safety Warnings i
Illustrations iv
Tables v
General Information vi
Specifications 1
Dimensions 3
Installation 5
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Cage-clamp terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Power, Fuse and Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Signal and Optional Switch Connections . . . . . . . . . . . . . . . . . . . . . . . . . .12
Operation 13
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
To reverse motor direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
To brake the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
To coast the motor to a stop without disconnecting power . . . . . . . . . . . . .16
I²T trip operation (class 10 characteristics) . . . . . . . . . . . . . . . . . . . . . . . .16
Drive thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Thermal protection of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
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Calibration 19
Warning! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Max Frequency DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Calibration Procedure Setup for 60 Hz Motors: . . . . . . . . . . . . . . . . . . . . .23
MIN SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
MAX SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
TQ LIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
SLIP COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
TQ BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
ACCEL/DECEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Accel Torque Boost Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Application Notes 29
Thermal Protection Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Decelerate to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Decelerate to minimum with DC injection braking . . . . . . . . . . . . . . . . . . .31
Independent adjustable speeds with . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
FWD-REV switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Single speed potentiometer control of multiple motors . . . . . . . . . . . . . . .34
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Troubleshooting 37
Warning! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Clearing LED fault indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Unconditional Warranty inside back cover
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Illustrations
Figure 1. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Figure 2. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 3. Cage-Clamp Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Figure 4. Power and Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Figure 5. Signal and Optional Switch Connections . . . . . . . . . . . . . . . . . . .12
Figure 6. Thermal Overload Switch with Optional Enable/Disable Switch . .17
Figure 7. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Figure 8. DIP Switch Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Figure 9. Thermal Overload Protection Switch Installation . . . . . . . . . . . . . .29
Figure 10. Thermal Overload Protection Switch Installation With
Optional Enable/Disable Switch . . . . . . . . . . . . . . . . . . . . . . . .29
Figure 11. Run/Decelerate to Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Figure 12. RUN/BRAKE Switch with Optional Enable/Disable Switch . . . . . .31
Figure 13. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . .32
Figure 14. RUN/JOG Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 15. Single Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Figure 16. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Figure 17. Diagnostic LED Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
iv
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v
Tables
Table 1. Max Frequency DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . .22
Table 2. Torque Boost Calibration DIP Switch Settings . . . . . . . . . . . . . . .28
Table 3. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
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vi
General Information
The Minarik AC (MAC) Series are solid-state, microprocessor-
based, variable-frequency AC motor drives. With a 120 or 240
VAC, 50/60 Hz, single-phase input, MAC drives are factory
calibrated for an output of 0 to 60 Hz*. They will operate any
1 HP or smaller, 115- or 208/230-volt†, three-phase AC induction
motor through a speed range of zero* through nameplate speed.
They can be user calibrated for 0 through 400 Hz output.
Although MAC inverters can operate over a 100:1 speed range,
most motors will operate over a 10:1 speed range with constant
torque at 0* to 60 Hz and constant horsepower above 60 Hz.
(Inverter-duty motors may operate satisfactorily over a 20:1 speed
range, while vector-duty motors may operate satisfactorily over a
30:1 speed range.) Some motors can be satisfactorily operated at
speeds as low as 100 rpm (speed range 25:1). Below 100 rpm,
some motors may show signs of “stepping” or “cogging”, or they
may run warmer.
*Actual minimum frequency will depend on motor type and the load to which it is
connected.
† Motor voltage should be matched to the nominal AC line voltage (e.g., 208VAC
motor for 208VAC nominal input; 115VAC motor for 115VAC nominal input).
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viiGeneral Information
MAC Series drives feature solid-state reversing with adjustable
acceleration and deceleration. They also feature adjustable
current limit and I²T class 10 current trip to protect the motor, the
control and the driven machine from damage caused by motor
overload or machine jamming. The MAC may also interface with
motor thermal protection through the enable circuit.
The MAC is very efficient when the two (2) torque boost settings
are properly adjusted; the accel torque boost is applied only
during acceleration. Other drives, with only one torque boost
setting, can cause motor overheating by applying too much during
steady-state operating conditions.
Caution should be taken when operating 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 6:1.
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MAC Series Features
• Microprocessor-based
• Solid-state circuitry
• Adjustable minimum and maximum speed
• Adjustable acceleration and deceleration
• Solid-state reversing
• Adjustable current limit
• I²T current trip (class 10)
• Adjustable torque power boost during acceleration
• Adjustable voltage boost at low speeds
• Adjustable slip compensation
• Multiple motor operation
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Specifications
Peak HP Range HP Range
Phase Current with 115 VAC with 240 VAC
Drive (ADC) Applied Applied
MAC03-115AC 3 1/15–1/4 NA
MAC06-115AC 6† 1/6–1/2 NA
MAC03-D240AC 3 1/15–1/4 1/6 – 1/2
MAC06-D240AC 6† 1/6–1/2 1/2 – 1
† Requires Minarik heat sink kit p/n 223-0269 when ambient temperature is
greater than 25º C
AC Voltage Input Range
MACxx-115AC drives 120VAC ± 10%, 50/60 Hz single phase
MACxx-D240AC drives 120/240VAC ± 10%, 50/60 Hz single phase
Output Frequency Range 3 – 400 Hz
Minimum Output Frequency Range 0–11 Hz
Maximum Output Frequency Range (60 Hz output) 40–400 Hz
Acceleration Time Range (no load) 0.5 – 10 seconds
Deceleration Time Range (no load) 0.5 – 10 seconds
Analog Input Voltage Range (isolated; S1 (-) to S2 (+) 0 – 10 VDC
Input Impedance ~ 50KΩ
Slip Compensation better than 1%
Vibration 0.5G max (20–50 Hz)
0.1G max (>50 Hz)
Weight 1.2 lb
Ambient Operating Temperature Range 10 – 40ºC††
††MAC06-D240AC is rated at 3 amps continuous AC @ 25º C
ambient without heat sink. Derate to 2 amps above 25º C, or use heat
sink kit p/n 223-0269.
1
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2
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3
Figure 1. Dimensions
Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
DRIVE DIM. “H”
MAC03-115AC 2.15 [55]
MAC06-115AC 2.68 [68]
MAC03-D240AC 2.40 [61]
MAC06-D240AC 2.68 [68]
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4
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5
Installation
Mounting
• Do not install, remove, or rewire this equipment with
power applied. Failure to heed this directive may result in fire
or serious injury.
• Drive components are sensitive to electrostatic fields. Avoid
direct contact with the circuit board. Hold drive by the chassis
only.
• Protect the drive from dirt, moisture, and accidental contact.
Provide sufficient room for access to the terminal block and
calibration trimpots.
• Mount 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.
• Mount drive with its board in either a horizontal or vertical
plane. Six 0.19 in. (5 mm) wide slots in the chassis accept #8
pan head screws. Fasten either the large base or the narrow
flange of the chassis to the subplate.
• The chassis must be earth grounded. Use a star washer beneath
the head of at least one of the mounting screws to penetrate the
anodized chassis surface and to reach bare metal.
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6Installation
Wiring
•Use 18-24 AWG wire for speed adjust potentiometer wiring.
Use 14–16 AWG wire for AC line (L1, L2) and motor (A1 and
A2) wiring.
Warning
This drive is isolated from earth ground. 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. Use a non-metallic screwdriver for the
calibration trimpots.
Do not disconnect any of the motor leads from the drive
unless power is removed or the drive is disabled. Opening any
one motor lead may destroy the drive.
Shielding guidelines
As a general rule, Minarik recommends shielding of all
conductors if:
1) wire lengths exceed 6 inches for PWM drives or 18 inches for
SCR drives, with separation of power and logic leads;
2) wire lengths exceed 4 inches and power and logic leads must
be bundled together*;
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7Installation
3) radiated and/or conducted noise must be minimized due to
concerns about immunity or general compliance (CE, FCC, etc.)
*Minarik considers this an unfavorable condition and does not
recommend bundling of power and logic leads for any length.
m If it is not practical to shield power conductors, Minarik
recommends shielding all logic-level leads. If shielding is not
practical, the user should twist all logic leads with themselves to
minimize induced noise.
m ( Under no circumstances should power and logic leads be
bundled together. Induced voltage can cause unpredictable
behavior any electronic device, including motor controls.
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 AC line filtering devices, or to mount
the drive in a less noisy environment.
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8 Installation
Fusing
MAC series drives require external AC power line fuses.
Connect the external line fuse(s) in series with the AC voltage
input. See Connections on page 9. Use fast-acting fuses rated for
250 VAC or higher, and approximately 150% of the maximum
armature current.
Heat sinking
MAC06-series drives require an additional heat sink (Minarik®
part number 223-0269) when the continuous phase current is
above 5 amps. All other MAC series drives have sufficient heat
sinking in their basic configuration. 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.
Speed adjust potentiometer
Mount the speed adjust potentiometer through a 0.38 in. (10 mm)
hole with the hardware provided (Figure 2). Install the circular
insulating disk between the panel and the 10K ohm speed adjust
potentiometer. 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, U, V, W).
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9Installation
mWarning
Be sure that the potentiometer tabs do not make contact
with the enclosure. Grounding the input will cause
damage to the drive.
Figure 2. Speed Adjust Potentiometer
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10
Cage-clamp terminals
MAC Series drive connections include cage-clamp terminals (see
Figure 3). To insert a wire into a terminal:
1. Press down on the lever
arm using a small
screwdriver.
2. Insert wire into the wire
clamp.
3. Release the lever arm to
clamp wire.
Figure 3. Cage-Clamp Terminal
1
2
Installation
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