Minarik BOSS Series User manual

BOSS Series
BOSS Series Brushless Drives
Models:
BOSS04-D240AC-4Q
BOSS04-D240AC-CM
BOSS08-D240AC-4Q
BOSS08-D240AC-CM
BOSS15-115AC-4Q
BOSS15-115AC-CM
USER’S MANUAL
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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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i
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.
• Have a qualified electrical maintenance 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.
Warning
Although the drive includes protective circuitry to prevent
damage in the event of an accidental short circuit of the
armature, it is not fail-safe. It is possible for a drive to
run at full speed as a result of a component failure.
Install a master switch in the drive’s AC or DC voltage
input line for stopping the drive in an emergency.
Inadvertent grounding of drive inputs could result in
damage to the drive. 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 insulated tools
if working on this drive with power applied.

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Introduction
The BOSS series is a family of analog brushless servo controls.
They are designed to be flexible and adaptable to a multitude
of needs by using the “modular” concept. The modular
concept has two parts: a motherboard and a daughter card.
The motherboard contains power and motor connections. Each
daughter card is designed to fit into the same motherboard, yet
each daughter card is optimized for different applications. This
allows you to customize your BOSS drive to suit your needs,
unlike the standard “one size fits all” approach.
The BOSS motherboard is stocked throughout the country.
Each daughter card is packed separately as 4Q or CM. The
BOSS-4Q does not have isolation, and requires application-
specific calibration.
The BOSS-CM is designed exclusively to follow a front-end
servo controller. It is a current-mode drive with optical
isolation and requires no calibration except for a simple
current-limit adjustment.
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iii
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iv
Contents
Specifications 1
Dimensions 2
Installation 4
Drivemounting .............................................4
Wiring.....................................................5
Shieldingguidelines ........................................6
Fusing ....................................................7
Plug-in card mounting .........................................8
Speed adjust potentiometer mounting ............................10
Quick-connect terminal block ..................................11
Motherboard connections .....................................12
Power connections .......................................12
Linefusing ..............................................13
Powerswitch ............................................13
Motor connections ........................................15
Regen dump circuit .........................................16
UsingthedumpcircuitwithaDCpowersource ..................16
BOSS-4QInstallation ........................................18
BOSS-4Q Terminal Descriptions .............................18
BOSS-4Q Plug-in card connections (TB501) ....................20
ENABLE/DISABLE switch ................................20
RUN/BRAKE switch ....................................20
FWD/REVswitch ......................................20
Speed adjust potentiometer connections .....................20
Motor hall sensors ........................................22
Voltagefollower ..........................................24
Motor hall sensor header (SW502) ...........................25
Mode select switches (SW501) ...............................26
TB504 Drive Diagnostics ...................................28
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BOSS-CMInstallation .......................................31
BOSS-CM Terminal Descriptions .............................31
BOSS-CM Plug-in card connections to TB501 ...................33
ENABLE/DISABLE switch ................................33
DIRswitch ...........................................33
Speed adjust potentiometer connections .....................33
Motor hall sensors ........................................37
BOSS-CM Jumper Settings .................................39
Hall Sensor Spacing (J501) ...............................39
PWM/VDC (J502) ......................................40
Operation 41
BOSS-4Q Operation ........................................41
Before applying power .....................................41
Startup ................................................42
To reverse motor direction: ...............................42
BOSS-CM Operation ........................................43
OperatingMode ..........................................43
Before applying power .....................................43
Startup ................................................44
To reverse motor direction ................................44
Starting and Stopping Methods .................................45
Line starting and line stopping ...............................45
Tobrakethemotor(BOSS-4Qseriesdrivesonly) ................45
To coast the motor to a stop without disconnecting power: ..........46
Calibration 47
BOSS-4QCalibration ........................................47
BOSS-4Q calibration procedure ..............................49
MINIMUM SPEED (MIN SPEED) ..........................50
ZERO OFFSET (OS) ...................................50
FORWARD MAXIMUM SPEED (FWD MAXSPD) ..............51
REVERSE MAXIMUM SPEED (REV MAXSPD) ...............51
ACCELERATION (ACCEL) ...............................52
v
Contents
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DECELERATION (DECEL) ...............................53
GAIN ...............................................53
FORWARD AND REVERSE TORQUE LIMIT
(FWDTQLIMANDREVTQLIM) ..........................54
TACHOGENERATOR (TACH) .............................56
BOSS-CMCalibration .......................................58
CURRENT LIMIT .........................................59
Troubleshooting 61
Before troubleshooting .......................................61
BOSS-4Q Diagnostic LEDs ...................................62
Diagnostic LEDs on the BOSS-4Q plug-in card: ..................62
POWERON ..........................................62
FAULT ..............................................62
Diagnostic LEDs on the motherboard: .........................62
BUSLIMIT ...........................................62
BOSS-CM Diagnostic LEDs ...................................64
Diagnostic LEDs on the BOSS-CM plug-in card: .................64
POWERON ..........................................64
FAULT ..............................................64
Diagnostic LEDs on the motherboard: .........................64
BUSLIMIT ...........................................64
BOSS Commutation Sequence Diagram .........................72
CE Compliance 73
AC Line Filters .............................................74
Connections ..............................................75
CE Filter Part Numbers ......................................76
Enclosure ................................................76
Unconditional Warranty inside back cover
vi Contents
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vii
Figure1. BOSSSeriesDimensions ...............................2
Figure 2. BOSS DB Regen Dump Circuit Dimensions ..................3
Figure3. Plug-InCardInstallation ................................9
Figure 4. Speed Adjust Potentiometer Mounting .....................10
Figure 5. Quick-Connect Terminal Plug ............................11
Figure 6. Motherboard Connections for (a) DC input voltage and
(b) AC input voltage ...................................14
Figure 7. Motherboard Connections for Three-Phase Motor ............15
Figure 8. Regen Dump Circuit Connections ........................17
Figure 9. BOSS-4Q Terminal Connections .........................21
Figure 10. BOSS-4Q Sensor Connections ..........................23
Figure 15. BOSS-4Q Voltage Follower Connections ...................24
Figure 16. BOSS-4Q Motor Hall Sensor Header ......................25
Figure 17. BOSS-4Q Mode Select Switches .........................27
Figure 18. BOSS-4Q TB504 Pin Assignments .......................28
Figure 15. BOSS-CM Terminal Connections to TB501 .................35
Figure 16. Reference Potentiometer Connection for
(a) Bidirectional and (b) Unidirectional Operation .............36
Figure 17. BOSS-CM External Sensor Connections ...................38
Figure 18. BOSS-CM Jumper Locations ............................39
Figure 19. BOSS-CM Hall Sensor Spacer Settings (J501) ..............40
Figure 20. BOSS-CM PWM/VDC Jumper Settings (J502) ...............40
Figure 21. BOSS-4Q Calibration Trimpot DIP Switch and Header Layout . . .48
Figure22. BOSS-4QModeSelectSwitchSettings ...................57
Figure23. BOSS-CMCalibrationTrimpotLayout .....................58
Figure 24. BOSS-4Q Diagnostic LED Location .......................63
Figure 25. BOSS-CM Diagnostic LED Location ......................65
Figure 26. Commutation Sequence Diagram ........................72
Figure 27. BOSS Connections for CE Compliance ....................76
Figure 28. BOSS Shielding Connections for CE Compliance ............77
Illustrations
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Table 1. Recommended Replacement Line Fuse Sizes ...............7
Table 2. BOSS-4Q ENABLE/BRAKE Configuration Options ...........22
Table3. Modeselectswitchsettings ............................27
Table 4. Drive Diagnostics (All signals referenced to pin 4) ............29
Table5. CECompliancePartNumbers ..........................76
viii
Tables
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1
Specifications
Maximum AC DC Maximum
Phase Current Line Input Output Voltage
Drive (AC Amps) Voltage Range Voltage Range (VAC)
BOSS04-D240AC 4 90 - 240 100 - 360 240
BOSS08-D240AC 8 90 - 240 100 - 360 240
BOSS15-115AC 15 90 - 130 100 - 180 130
AC Input Voltage Tolerance ±10%,50–60Hz
Maximum Phase Current Limit 1.5 times Maximum Phase Current (continuous)
Peak Phase Current Limit 2 times Maximum Phase Current (for 1 second)
Acceleration Time Range† 0.5 – 6 seconds
Deceleration Time Range† 0.5 – 6 seconds
Speed Range* 80:1
Speed Regulation (typical) 0.06% of base speed
Speed Adjust Potentiometer 10K ohms
Analog Input Voltage Range** 0–10VDC
Input Impedance 60K ohms
Power Device Switching Frequency (6–step, trapezoidal) 22 kHz
Vibration 0.5Gmax(20–50Hz)
0.1G max (>50 Hz)
Weight 2lb
Ambient Operating Temperature Range 0 – 40º C
†Acceleration and deceleration times for BOSS-4Q only.
*Speed range is based on 8000 RPM motor. Minimum recommended speed is 100
RPM.
**Voltage input must be isolated on BOSS-4Q series drives. BOSS-CM inputs are
isolated and do not require additional isolation.
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2
Dimensions
Figure 1. BOSS Series Dimensions
Drive Dimension “A”
BOSSxx-115AC 2.62 [67]
BOSSxx-D240AC 3.87 [98]
All Dimensions in Inches [Millimeters]
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3
Dimensions
Figure 2. BOSS DB Regen Dump Circuit Dimensions
All Dimensions in Inches [Millimeters]
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4
Installation
Drive mounting
• Drive components are sensitive to electrostatic fields. Avoid
contact with the circuit board directly. 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
calibration trimpots.
• Mount the drive away from other 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 does not have to be earth grounded. If you
choose to ground the chassis, 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.
Warning
Do not install, rewire, or remove this control with
input power applied. Doing so may cause fire or serious
injury. Make sure you have read and understood the
Safety Warnings before attempting installation.

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5
Installation
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 115 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. Opening any one motor lead
may destroy the drive.

쇵
Wiring
• Use 16 AWG wire for the AC or DC voltage input wiring
(L1 and L2 or +VDC and -VDC), regen dump circuit, and
motor wiring (U, V, W). Use 18-20 AWG wire for speed
adjust potentiometer wiring.
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6Installation
Shielding guidelines
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.

Minarik recommends shielding all leads. If shielding 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.
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7
Installation
Fusing
An external line fuse must be installed on all BOSS series
drives. Connect the external line fuse in series with the AC
voltage input or DC voltage input, whichever is used. Do not
install a fuse on L2 unless the input voltage is 240 VAC. See
motherboard connections (Figure 6) on page 14.
Table 1 lists the recommended line fuse sizes. Use fast acting
fuses rated for 250 VAC or higher.
Table 1. Recommended Line Fuse Sizes
Model Line Fuse Size
Series (AC Amps)
BOSS04 10
BOSS08 15
BOSS15 25
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8Installation
Warning
Make sure AC or DC line voltage input is disconnected
for 30 seconds before installing or removing the plug-in
card.

To mount the plug-in card to the motherboard, line up the
motherboard docking pins to the docking holes (Figure 3).
Align the header pins on the plug-in card with the
corresponding header sockets on the motherboard. Fasten the
header pins into the header sockets until secure. The docking
pins will lock the plug-in card into place when the header pins
are correctly mounted into the header sockets.
Plug-in card mounting
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9
Installation
Figure 3. Plug-In Card Installation
(Make sure AC or DC voltage input is removed for 30 seconds
before installing or removing plug-in card)
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10 Installation
Mount the speed adjust potentiometer through a 0.38-inch
(1.0 cm) hole with the hardware provided (Figure 4). 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 potentiometer leads are longer than 18 inches (46 cm),
use shielded cable.
Speed adjust potentiometer mounting
Warning
Be sure that the potentiometer tabs do not make contact
with the potentiometer enclosure. Grounding the input will
cause damage to the drive.

Figure 4. Speed Adjust Potentiometer Mounting
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