Minarik MAC Series User manual

USER’S MANUAL
Models:
MAC05–D240AC
MAC08–D240AC
MAC05–D240AC-PCM
MAC08–D240AC-PCM
Variable-frequency drives for 3-phase AC motors
MAC Series
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Copyright  2001 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  denotes an important safety tip or warning.
Please read these instructions carefully before performing
any of the procedures contained in this manual.
•DO NOT INSTALL, REMOVE, OR REWIRE THIS
EQUIPMENT WITH POWER APPLIED. 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.
•Reduce the chance of an electrical fire, shock, or explosion by
proper grounding, over-current protection, thermal protection,
and enclosure. Follow sound maintenance procedures.
i
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 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. Use approved personal protective
equipment and insulated tools if working on this drive with
power applied.

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Specifications 1
Dimensions 2
Installation 3
Mounting ...................................................3
Wiring .....................................................4
Shielding guidelines . . . ......................................5
Isolation (-PCM drives only) . ...................................6
Fusing ....................................................6
Heat sinking ................................................6
Speed adjust potentiometer .....................................7
Cage-clamp terminals . . . ......................................8
Connections . ................................................9
Power and fuse connections .................................10
Motor connections . . . . . . ..................................13
Three-phase motors . . . . . . .................................15
Operation 17
Voltage doubler .............................................18
To enable voltage doubling: .................................19
Before applying power . . . . . . .................................20
Startup ....................................................21
To reverse motor direction: ..................................22
Starting and stopping methods .................................23
Braking . . . ..............................................23
To coast the motor to a stop without disconnecting power: ..........23
I²T trip operation (class 10 characteristics) ......................24
Line starting and line stopping ...............................24
Decelerate to minimum speed ...............................25
Decelerate to minimum with DC injection braking .................26
Drive thermal protection ......................................28
ii
Contents
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Thermal protection of the motor ..............................28
Calibration 30
Calibration Procedure Setup for 60 Hz Motors (See Figure 12): .........34
MINIMUM SPEED (MIN SPD) ...............................36
MAXIMUM SPEED (MAX SPD) ...............................36
CURRENT LIMIT (I LIMIT) ..................................36
SLIP COMPENSATION (SLIP COMP) .........................37
ACCELERATION/DECELERATION (ACCEL/DECEL) ..............37
Torque Boost Adjustment ...................................38
Application Notes 40
Thermal Protection Switch Installation ............................40
Independent adjustable speeds with .............................41
FWD-REV switch ...........................................41
RUN/JOG switch ............................................42
Single speed potentiometer control of multiple motors ................43
Reversing . . . ..............................................44
Voltage follower ............................................45
Troubleshooting 46
Before troubleshooting . . . . . . .................................46
Diagnostic LEDs ............................................47
POWER ON (green) . . . . . . .................................47
FAULT (red) ...............................................
TRIP I²T (red) . . ............................................
REV (amber) ...............................................
FWD (amber) . . ............................................
TQ LIM (red) ............................................48
Clearing LED fault indications ..................................52
Replacement Parts ..........................................58
Unconditional Warranty inside back cover
iiiTable of Contents
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Figure 1. Dimensions . . . . . . ....................................2
Figure 2. Speed Adjust Potentiometer ..............................7
Figure 3. Cage-Clamp Terminal ...................................8
Figure 4. Power and Fuse Connections ............................10
Figure 5. Signal and Optional Switch Connections ....................12
Figure 6. Motor Connections for Single-Phase Operation ..............14
Figure 7. Motor Connections for Three-Phase Motors .................16
Figure 8. Voltage Doubler Terminals ..............................19
Figure 9. Run/Decelerate to Minimum Speed Switch ..................25
Figure 10. RUN-BRAKE switch with optional ENABLE-DISABLE Switch ....27
Figure 11. Thermal Overload Switch with Optional Enable/Disable Switch . . .29
Figure 12. Calibration Trimpot Layout ..............................31
Figure 13. DIP Switch Layout and Initial Settings ......................32
Figure 14. Carrier Frequency Mode DIP Switch Layout .................35
Figure 15. Accel Torque Boost DIP Switch Setting .....................39
Figure 16. Thermal Overload Protection Switch Installation ..............40
Figure 17. Thermal Overload Protection Switch Installation
With Optional Enable/Disable Switch .......................40
Figure 18. Independent Adjustable Speeds ..........................41
Figure 19. RUN/JOG Switch . . . ..................................42
Figure 20. Single Speed Potentiometer Control of Multiple Motors .........43
Figure 21. Reversing Circuit Connection ............................44
Figure 22. Voltage Follower Connections ............................45
Figure 23. Diagnostic LED Layout .................................49
iv
Illustrations
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Table 1. Motor Phase DIP Switch Settings .........................15
Table 2. Voltage Doubler Configuration ...........................19
Table 3. Max Frequency DIPSwitch Settings .......................33
Table 4. Carrier Frequency DIPSwitch Settings .....................35
Table 5. Accel Torque Boost DIP Switch Settings ....................39
Table 6. Replacement Parts ...................................58
v
Tables
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vi
*Actual minimum frequency will depend on motor type and the load to which it is
connected.
General Information
Minarik MAC Series drives are voltage-vector-controlled,
microprocessor-based, variable-frequency AC motor drives. With
a 115 or 230 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.
Using proprietary power-control circuitry, the MAC can also
double the input line voltage. This allows users to plug the MAC
into a 115 VAC line, but control a 208/230 VAC motor.
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.) 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.
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† In silent mode.
viiGeneral Information
The MAC carrier frequency is true 16.5 kHz.†Many AC drive
manufacturers count the leading and trailing edge of the
modulated signal, thereby doubling the published carrier
frequency; however, their fundamental frequency is only half
(8 kHz in this case). By this method, the MAC’s carrier
frequency would be 33 kHz. The MAC is one of the only drives
on the market with truly silent operation.
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.
Many 3-phase inverter manufacturers claim that they can run
single-phase motors effectively. This is normally accomplished
by wiring only 2 phases; however, this primitive method may
cause instabilities due to the lack of feedback from one of the
motor connections. Furthermore, motor torque will be reduced
considerably because the phases are still 120º apart. The MAC
can efficiently operate a single-phase motor because the ASIC
changes the phase shift to 90º in order to develop maximum
torque.
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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 10:1.
viii General Information

The following motor types MAY NOT be used:
• Split phase
• Capacitor start
• Repulsion induction
• Series Universal AC/DC
• Any motor with starting switch (centrifugal or relay) and/or
separate starting winding.

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.
IMPORTANT INFORMATION
In addition to standard 3-phase induction motors, the following
motor types may be used with the MAC:
• Permanent split capacitor (PSC)
• Shaded pole
• AC synchronous
• AC stepping: 28.8, 72 and 200-RPM type.
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MAC Series Features
• Microprocessor-based
• Voltage-vector-control drive
• True 16.5 kHz carrier frequency (in silent mode)
• Solid-state circuitry
• Adjustable minimum and maximum speed
• Adjustable acceleration and deceleration
• Solid-state reversing
• Adjustable current limit
•I
²T current trip (class 10)
• Adjustable torque power boost during acceleration
• Adjustable voltage boost at low speeds
• Adjustable slip compensation
• Multiple motor operation
• Doubled-voltage output option selected by jumper
• Optional optical isolation circuitry (MACxx-PCM only)
• Able to run single- and three-phase motors
ixGeneral Information
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Notes
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Specifications
Peak Continuous HP Range HP Range
Phase Current Phase Current with 120 VAC with 240 VAC
Drive Model Number (ADC) (ADC) Applied* Applied
MAC05-D240AC(-PCM) 5 2.5 1/15–1/4* 1/6 – 1/2
MAC08-D240AC(-PCM) 8†4 1/4–1/2* 1/2 – 1
AC Voltage Input Range 120/240 VAC ± 10%, 50/60 Hz single phase
Output Frequency Range 3 – 400 Hz
Selectable Carrier Frequency 11 kHz or 16.5 kHz
Minimum Output Frequency Range 0–11 Hz
Maximum Output Frequency Range 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 (S1 (-) to S2 (+) )** 0–10VDC
Input Impedance ~ 50k ohms
Isolation (-PCM drives only) 2500 VAC optical
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†
†MAC08-D240AC is rated at 5 amps continuous AC @ 25º C ambient (when run in silent
mode) or without heat sink. Derate to 4 amps continuous AC above 25º C (when run in
silent mode), or use heat sink kit p/n 223-0269.
*Horsepower is doubled when voltage doubler terminals are jumpered and using 120 VAC
input. Refer to the Operation section for more information.
**The voltage signal must be ungrounded when using a non-PCM MAC drive. MAC-
PCM drives may use grounded or isolated reference voltage signals.
1
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2
Figure 1. Dimensions
Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
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3
Installation
Warning
Do not install, remove, or rewire this equipemnt with power
applied. Failure to heed this warning may result in fire,
explosion, or serious injury.
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.

•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.
Mounting
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4Installation
Warning
Do not install, remove, or rewire this equipment with power
applied. Failure to heed this warning may result in fire,
explosion, or serious injury.
Circuit potentials are at 120 or 240 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 destroy 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.
•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.
Wiring
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5Installation
Warning
Under no circumstances should power and logic leads be
bundled together. Induced voltage can cause unpredictable
behavior in any electronic device, including motor controls.

As a general rule, Minarik recommends shielding of all
conductors.
If it is not practical to shield power conductors, Minarik
recommends shielding all logic-level leads. If shielding logic
leads is not practical, the user should twist all logic leads with
themselves to minimize induced noise.
It may be necessary to earth ground the shielded cable. If noise is
produced by devices other than the drive, ground the shield at the
drive end. If noise is 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.
Shielding guidelines
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6Installation
Isolation (-PCM drives only)
The reference circuit (S1, S2 and S3) is optically isolated from
the rest of the drive electronics via HCPL7840. It will accept
either a grounded or isolated signal reference.
All drive inputs (inhibit, enable, brake and direction) are also
optically isolated from the rest of the drive electronics via
HCPL0453. It will accept a grounded or isolated bit-type open
collector (or switch) input.
Fusing
MAC series drives require external AC power line fuses.
Connect the external line fuse(s) in series with the AC voltage
input (see Figure 4, page 10). Use fast-acting fuses rated for 250
VAC or higher.
Heat sinking
MAC08-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.
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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 (S1, S2, S3)separate from power leads
(L1, L2, U, V, W).
7
Installation
Warning
Be sure that the potentiometer tabs do not make contact with
the enclosure. Grounding the input will cause damage to the
drive.

Speed adjust potentiometer
Figure 2. Speed Adjust Potentiometer
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8 Installation
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
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