Minarik LV Series User manual

USER’S MANUAL
LV Series
Low Voltage Input, Pulse-Width Modulated,
Adjustable Speed Drives
for DC Brush Motors
Models: LV01-24AC-E10U
LV02-24AC
LV02-24DC

All rights reserved. No part of this manual may be reproduced or transmitted in any
form without written permission from Minarik Drives. The information and technical
data in this manual are subject to change without notice. Minarik Drives makes no
warranty of any kind with respect tothis material, including, but not limited to, the
implied warranties of its merchantability and fitness for a given purpose. Minarik
Drives assumes no responsibility for any errors that may appear in this manual and
makes no commitment to update or tokeep current the information in this manual.
Copyright © 2013 by
Minarik Drives
Printed in the United States of America.

i
Safety Warnings
Throughout this manual, this symbol denotes an
important safety tip. Read these sections very carefully!
• 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.
•It is possible for a drive to run at full speed as a result of a
component failure. To stop the drive in an emergency, ensure
that a master switch has been installed in the AC line.
•This drive is not isolated from earth ground. Circuit
potentials of up to 115 VAC exist on the board.Direct contact
with the printed circuit board or with circuit elements poses the
risk of serious injury or fatality. Use a non-metallic screwdriver
for adjusting the calibration trimpots

ii
Contents
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1snoitacificepS
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4noitallatsnI
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
5gniriW
Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Speed adjust potentiometer installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Connections (LV series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Connections (LV-E10U series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Voltage follower (LV series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Voltage follower (LV-E10U series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
31noitarepO
31rewopgniylppaerofeB
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Line starting and stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Decelerating to a stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
61noitarbilaC
MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
TORQUE LIMIT (TQ LIMIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
IR COMPENSATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

iii
12setoNnoitacilppA
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . . .22
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
62gnitoohselbuorT
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
revockcabedisniytnarraWdetimiL

iv
Illustrations
Figure 1. LV Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Figure 2. LV-E10U Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Figure 3. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Figure 4. LV Series Line Input and Speed Potentiometer Connections . . . . . . . . .8
Figure 5. LV Series Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 6. LV-E10U Series Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Figure 7. LV Series Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . .11
Figure 8. LV-E10U Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 9. Run/Decelerate to Zero Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 10. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 11. LV SERIES Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 12. LV-E10U SERIES Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . .17
Figure 13. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Figure 14. Adjustable Fixed Speeds Using Potentiometers in Series . . . . . . . . . .22
Figure 15. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Figure 16. RUN/JOG Switch Connection to Speed Adjust Potentiometer . . . . . .24
Figure 17. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Specifications
Maximum
Armature Armature
Input Current Voltage HP
Model Voltage (Amps DC) Range** Range
LV01–24AC-E10U 8–24 VAC* 1.0 0–22 VDC 1/500–1/100
LV02–24AC 8–24 VAC* 2.0 0–22 VDC 1/250–1/50
LV02–24DC 10–36 VDC 2.0 0–22 VDC 1/250–1/50
**AC input voltage is ±10%, 50/60 Hz, single phase
** Maximum output voltage is 91% of input voltage. Rating shown is with 24V input.
Form Factor 1.05 at base speed
Acceleration Time 1 second
Deceleration Time 1 second
Load Regulation (at base speed) 2%
Ambient Temp. Range 10°C–40°C
Vibration 0.5g max (0 – 50 Hz)
0.1g max (above 50 Hz)
1
Analog Input Voltage Range (S1 to S2) 0-4.6 VDC

2
Dimensions
VFB INGN D
OUT
COMP
D 5 0 4
D 5 0 3
R 5 0 1
IC 5 0 1
C 5 0 1
D 5 0 1
D 5 0 2
M IN S P DM A X S P D
A C 1 A C 2 A 2 S 3 S2 S 1A 1
D 5 0 5
C 5 0 2
0.150" [4]
2.100" [53]
2.250" [57]
0.150" [4]
2.100" [53]
2.250" [57]
Figure 1. LV01 Series Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
2.250 [57]
2.100 [53]
0.150 [4]
2.100 [53]
2.250 [57]
0.150 [4]

3
Dimensions
A 1
IC 5 0 1
D 5 0 1
A 2
R 5 0 1
IR C O M P
TQ LIM I T
C 5 0 1
B R 5 0 1
L2
R 5 0 2
L1
S 1
S 2
S 3
C 5 0 3
M A X S P D
M IN S P D
C 5 0 2
D C + I N
D C - I N
C501 ( ALTERNA TE)
+ ~ ~ -
0.97 [25]
1.28 [33]
1.40 [36]
0.74 [19]
1.75 [44]
3.58 [91]
3.80 [97]
4.30 [109]
0.64 [16]
0.19 [5]
0.19 [5]
Figure 2. LV02 Series Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
3.58 [91]
1.75 [44]
0.74 [19]
3.80 [97]
4.30 [109]
0.19 [5]
0.97 [25]
1.28 [33]
1.40 [36]
0.19 [5]
0.64 [16]

4
*Does not apply to LV01-24AC/DC-E10U
Mounting
• 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.
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 on pg i before attempting installation.
Installation

5
Installation
Line Fusing
Protect all Minarik Drives’s drives with a line fuse. Use fast acting
fuses rated for 250 volts, 3 amps.
•
•
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 230 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.
Wiring
For LV01/02-24AC drives, fuse only the hot side of the AC line (L1).
For LV01/02-24DC drives, fuse the DC+ IN side of the DC voltage input.
This product does not have internal solid state motor overload
protection. It does not contain speed-sensitive overload
protection, thermal memory retention or provisions to receive
and act upon signals from remote devices for over temperature
protection. If motor overload protection is needed in the end-
use product, it needs to be provided by additional equipment
in accordance with NEC standards.

6Installation
As a general rule, Minarik Drives recommends shielding of all
conductors.
If it is not practical to shield power conductors, Minarik Drives
recommends shielding all logic-level leads. If shielding logic
level 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.
Logic wires from other input devices, such as motion controllers
and PLL velocity controllers, must be separated from power lines
in the same manner as the logic I/O on this drivedrive.
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.
Shielding guidelines

7
Installation
Warning
Be sure that the potentiometer tabs do not make contact with
the potentiometer enclosure. Grounding the input will cause
damage to the drive.
Install the circular insulating disk between the panel and the 10K
ohm speed adjust potentiometer. Mount the speed adjust
potentiometer through a 0.38 inch (10 mm) hole with the
hardware provided (Figure 3). Twist the speed adjust
potentiometer wire to avoid picking up unwanted electrical noise.
If potentiometer leads are longer than 18 inch (457 mm), use
shielded cable.
Speed adjust potentiometer installation
Figure 3. Speed Adjust Potentiometer
POT TAB ASSIGNMENTS
WIPER
CW
CCW
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
PANEL
STAR
WASHER
NUT
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
NUT
STAR
WASHER
PANEL
CW
CCW
WIPER
SPEED ADJUST
POTENTIOMETER
INSULATING DISK POT TAB ASSIGNMENTS
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE

8Installation
B R 5 0 1
L2
L1
S1
S2
S3
D C + IN
D C - IN
+
STOP
SWITCH FUSE
FUSE
STOP
SWITCH
+
-
+
-
24 VAC
INPUT
24 VDC
INPUT
OR
CW
10K OHM
SPEED ADJUST
POTENTIOMETER
Figure 4. LV Series Line Input and
Speed Potentiometer Connections
Connections (LV series)
WARNING!
DO NOT APPLY AC
AND DC POWER AT
THE SAME TIME!
STOP
SWITCH
24 VAC
INPUT
24 VDC
INPUT
10K OHM
SPEED ADJUST
POTENTIOMETER
OR STOP
SWITCH
+
+
-
CCW
-
FUSE
FUSE

9
A 1
IC 5 0 1
D 5 0 1
A 2
R 5 0 1
MOTOR
+
Figure 5. LV Series Motor Connections
ASSUMPTIONS: Minarik Drives’s drives supply motor voltage
to terminals A1 and A2 (A1 is positive with respect to A2). It is
assumed throughout this manual that the driven motor will rotate
clockwise (CW) while looking at the output shaft protruding from
the front of the motor. If the opposite is desired, simply reverse
the wiring of A1 and A2.
Installation
MOTOR
+

10
Figure 6. LV-E10U Series Drive Connections
Connections (LV-E10U series)
D 5 0 4
1S2S3S2A2CA1CA 1A
D 5 0 5
S TOP
S WITC H FUS E
24 V
INP UT
MOTOR
+
10K OHM
SP EE D ADJ US T
P OTE NTIOME TE R
C W
Installation
STOP
SWITCH FUSE
MOTOR
+
CCW
10K OHM
SPEED ADJUST
POTENTIOMETER
24V
INPUT

11
Installation
Voltage follower (LV series)
Figure 7. LV Series Voltage Follower Connections
S 1
S 2
S 3
C 5 0 3
- ( LO)
+ ( HIGH)
0 - 3 VDC
IS OLATED
S IGNA L INP UT
Warning
Do not connect a non-isolated input voltage signal to an LV
series drive. Connecting a non-isolated signal will damage
the drive.
Instead of using a speed adjust potentiometer, the drive may be
wired to follow a 0 – 4.6 VDC voltage signal that is isolated from
earth ground (Figure 7). Connect the signal input (-) to S1.
Connect the signal common (+) to S2. Make no connection to S3.
A potentiometer can be used to scale the analog input voltage.
To achieve greater linearity and control, use an interface device
such as Minarik Drives model PCM4 to scale the analog input
voltage. Follow the same wiring guidelines used for speed adjust
potentiometer wiring (see page 5).
0 - 4.6 VDC
ISOLATED
SIGNAL INPUT
+ (HIGH)
- (LO)

12
Voltage follower (LV-E10U series)
Instead of using a speed adjust potentiometer, the drive may be
wired to follow a 0 – 4.6 VDC voltage signal that is isolated from
earth ground (Figure 8). Connect the signal input (-) to S1.
Connect the signal common (+) to S2. Make no connection to S3.
A potentiometer can be used to scale the analog input voltage.
To achieve greater linearity and control, use an interface device
such as Minarik Drives model PCM4 to scale the analog input
voltage. Follow the same wiring guidelines used for speed adjust
potentiometer wiring (see page 5).
Figure 8. LV-E10U Voltage Follower Connections
1S2S3S1A
+ ( HIGH)
- ( LO)
0 - 3 VDC
IS OLATE D
S IGNA L INP UT
Installation
Warning
Do not connect a non-isolated input voltage signal to an
LV-E10U series drive. Connecting a non-isolated signal
will damage the drive.
0 - 4.6 VDC
ISOLATED
SIGNAL INPUT
+ (HIGH)
- (LO)

13
Startup
•Verify that no conductive material is present on the printed
circuit board.
•Verify that the AC supply is properly balanced.
•Turn the speed adjust potentiometer (if installed) to zero speed
(fully CCW).
Warning
DO NOT apply AC and DC power to the drive at the same
time. This may cause severe damage to the drive.
To start the drive:
1. Apply 24 VAC or 24 VDC to the drive.
2. Rotate the speed adjust potentiometer knob clockwise until the
desired motor speed is reached.
3. To shut down the drive, rotate the speed adjust potentiometer
fully CCW (zero or minimum speed). Remove power and let
the motor coast to a stop.
Before applying power
Operation

14 Operation
Line starting and stopping
When AC or DC line voltage is applied to the drive, the motor
accelerates to the set speed. When line voltage is removed, the
motor coasts to a stop. Line starting and line stopping (applying
and removing line voltage) is recommended for starting and
stopping in emergency situations only. It is not recommended for
frequent starting and stopping.
Decelerating to a stop
A switch may be used to decelerate the motor to a stop. Connect
the switch as shown in Figure 9. Close the switch between S1
and S2 to stop the motor from set speed. Open the switch to
accelerate the motor to set speed.
RUN
STOP
CCW
10K
Ω
SPEED ADJUST
POTENTIOMETER
S3
S2
S1
CW
Figure 9. Run/Decelerate to Zero Speed Switch
S3
S2
S1
RUN
STOP
CCW
CW
10K OHM
SPEED ADJUST
POTENTIOMETER