Minarik BOSS Series User manual

BOSS Series
Models:
BOSS04-115AC-1Q
BOSS08-115AC-1Q
BOSS15-115AC-1Q
BOSS Series Brushless Drives
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.
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 approved
personal protective equipment and insulated tools if
working on this drive with power applied.

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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.
Introduction
ii
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iii
Specifications 1
Dimensions 2
Installation 4
Drive mounting ............................................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
Motor connections ......................................15
Regen dump circuit ........................................16
UsingthedumpcircuitwithaDCpowersource ................16
BOSS-1Qterminaldescriptions ..............................18
BOSS-1Q terminal connections ...............................20
ENABLE/DISABLE switch ................................20
RUN/BRAKE switch .....................................20
FWD/REVswitch .......................................20
Motor hall sensors .......................................22
Voltagefollower ........................................24
Contents
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Operation 25
Before applying power .....................................25
Startup .................................................26
To reverse motor direction: ................................26
Starting and stopping methods ...............................27
Tobrakethemotor ......................................27
To coast the motor to a stop without disconnecting power .........27
Line starting and line stopping .............................28
Calibration 29
Calibration procedure ......................................31
MINIMUM SPEED (MIN SPD) .............................32
MAXIMUM SPEED (MAX SPD) ............................32
ACCELERATION (ACCEL) ................................33
DECELERATION (DECEL) ................................33
REGULATION .........................................34
TORQUE LIMIT (TQ LIMIT) ................................35
Troubleshooting 36
Before troubleshooting .....................................36
BOSS-1Q Diagnostic LEDs ..................................37
Diagnostic LEDs on the BOSS-1Q plug-in card: ................37
POWERON ........................................37
FAULT .............................................37
Diagnostic LEDs on the motherboard: .......................37
BUSLIMIT ..........................................37
TQLIMIT ...........................................37
Unconditional Warranty inside back cover
iv Contents
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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-1Q Terminal Connections ........................21
Figure 10. BOSS-1Q Sensor Connections .........................23
Figure 11. BOSS-1Q Voltage Signal Connections ...................24
Figure 12. BOSS-1Q Calibration Trimpot Layout ....................30
Figure 13. BOSS-1Q Diagnostic LED Location .....................38
Tables
Table 1. Recommended Line Fuse Sizes ...........................7
v
Illustrations
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Notes
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Maximum AC DC Maximum
Phase Current Line Input Output Voltage
Drive (AC Amps) Voltage Range Voltage Range (VAC)
BOSS04-115AC-1Q 4 90 - 130 100 - 180 130
BOSS08-115AC-1Q 8 90 - 130 100 - 180 130
BOSS15-115AC-1Q 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 (signal must be isolated) 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
*Speed range is based on 8000 RPM motor. Minimum recommended speed is 100
RPM.
Specifications
1
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2
Dimensions
Figure 1. BOSS Series Dimensions
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3Dimensions
Figure 2. BOSS DB Regen Dump Circuit Dimensions
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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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5Installation
Wiring
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 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
• Use 16 AWG wire for the AC or DC voltage input wiring
(AC1 and AC2 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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6 Installation
Shielding guidelines
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.
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.

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7Installation
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 terminal AC1 or DC voltage input terminal
+VDC, whichever is used. 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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8 Installation
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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9Installation
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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11Installation
Quick-connect terminal block
The quick-connect terminal block is composed of a header
block and terminal plug. The removable terminal plug, Minarik
part number 160-0126, connects to the header block as shown
in Figure 5. To use the quick-connect terminal block:
1. Carefully pull terminal plug from header block.
2. With a small flat-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.
6. Insert plug into header block until securely fastened.
Figure 5. Quick-Connect Terminal Plug
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12 Installation
Motherboard connections
Warning
Do not install, remove, or 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 switch in the voltage input line. The switch
contacts should be rated at a minimum of 200% of motor
nameplate current and 150% of input voltage.
Do not connect DC and AC power inputs at the same
time. Applying AC and DC power simultaneously will
destroy the drive and may result in fire or serious injury.

Power connections
See Figure 6 (page 14) for motherboard connections. Connect
the AC voltage source to AC1 and AC2 if using an AC voltage
source. If the drive is being powered by a DC voltage source,
connect the DC voltage source to +VDC and –VDC. Do not
connect AC and DC voltage sources at the same time!
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