Minarik MMBOSS Series User manual

Model:
MMBOSS05-24DC-1Q
MMBOSS
Series
User’s Manual
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Copyright © 2000 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.
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.
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.
Use approved personal protective equipment and insulated
tools if working on this drive with power applied.

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Contents
Specifications 1
Dimensions 3
Installation 5
Mounting ...........................................5
Wiring ..............................................6
Shielding guidelines .................................7
Heat sinking .........................................8
Fusing .............................................8
Speed adjust potentiometer mounting ......................9
Quick-connect terminal block ...........................10
Connections ........................................11
Motor, power and fuse connections .....................11
Optional switch connections ..........................14
Voltage follower signal connections ......................16
Motor hall sensor connections ...........................17
Jumper Settings .....................................19
Input Voltage Range Select (SW501) ...................19
Hall Sensor Spacing (SW502) ........................19
Operation 21
Before applying power ................................21
Startup ............................................22
Reversing ..........................................23
Starting and Stopping Methods ..........................24
Automatic restart upon power restoration ................25
ENABLE/DISABLE switch ...........................25
RUN/BRAKE switch ................................25
Coast to a stop ....................................25
ii
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Decelerate to minimum speed ........................25
Calibration 27
MINSPD .........................................28
MAXSPD ........................................28
CURRENT LIMIT ...................................29
GAIN .............................................30
Application Notes 31
Multiple fixed speeds .................................31
Adjustable speeds using potentiometers in series ............32
Independent adjustable speeds .........................33
DIRECTION switch ..................................34
Troubleshooting 35
Before troubleshooting ................................35
Diagnostic LEDs ....................................36
Power On ........................................36
Fault ............................................36
Terminal Description ..................................37
Replacement Parts ...................................41
Index 42
Unconditional Warranty 47
iii
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Illustrations
Figure 1. MMBOSS Series Dimensions ......................3
Figure 2. Speed Adjust Potentiometer Mounting ................9
Figure 3. Quick-Connect Terminal Plug .....................10
Figure 4. PCB Power, Fuse and Motor Connections ............13
Figure 5. Optional Switch Connections ......................15
Figure 6. Voltage Signal Follower Connections ................16
Figure 7. Sensor Feedback Connections ....................18
Figure 8. Jumper Locations ..............................19
Figure 9. Decelerate to Minimum Speed Switch ...............26
Figure 10. Calibration Trimpot Layout .......................27
Figure 11. Multiple Fixed Speeds ..........................31
Figure 12. Adjustable Speeds Using Potentiometers in Series ....32
Figure 13. Independent Adjustable Speeds ..................33
Figure 14. DIRECTION Switch ............................34
Figure 15. Diagnostic LED Location ........................36
Figure 16. Terminal Assignments ..........................37
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Tables
Table 1. Line Fuse Chart .................................8
Table 2. Replacement Parts ..............................41
v
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Maximum Phase Current (continuous) 5 ADC
DC Bus Voltage Input Range† 12 – 40 VDC
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 6 seconds
Deceleration Time Range 6 seconds
Speed Regulation (typical) 0.06% of base speed
Speed Adjust Potentiometer 10K ohms
Analog Input Voltage Range (signal must be isolated) 0–10 VDC
Input Impedance 60K ohms
Power Device Switching Frequency (6–step, trapezoidal) 22 Khz
Hall sensor output , maximum +5 VDC @ 20mA
Vibration 0.5G max. (0–50 Hz); 0.1G max. (>50 Hz)
Weight 2 lb
Ambient Operating Temperature Range 0–40ºC
†Input voltage range is selected via SW501. Jumper terminals 1 and 2
for a voltage range of 15 - 40 VDC (this is the factory setting). Jumper
terminals 2 and 3 for 12 - 15 VDC input.
1
Specifications
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3
Dimensions
Figure 1. MMBOSS Series Dimensions
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Installation
5
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.

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.
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6Installation
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.
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.
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
• Use 18–24 AWG wire for speed adjust potentiometer wiring.
Use 16–18 AWG wire for DC line (L1, L2) and motor (phase1,
phase 2 and phase 3) wiring.
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7Installation
As a general rule, Minarik recommends shielding all conductors.
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.
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 drive.
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
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8Installation
Heat sinking
The MMBOSS series drive contains sufficient heat sinking in its
basic configuration. There is no need for additional heat sinking.
Fusing
All Minarik drives should be protected by fuses. Use fast acting
fuses, such as Bussman® 3AG or equivalent, rated for
approximately 150% – 200% of the maximum phase current.
Fuse only the BUS+ DC input voltage line. See the fuse chart
below for recommended line fuse sizes:
Table 1. Line Fuse Chart
Maximum Phase Fuse Rating
Current (DC Amps) ( Amps)1
0.5 1
0.8 1.5
1.5 3
2.6 5
3.5 8
5.0 10
Notes:
1. Use 250 volt fuses regardless of the input voltage.
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9Installation
Figure 2. 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.

Speed adjust potentiometer mounting
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 potentiometer leads are
longer than 18 in. (457 mm), use shielded cable.
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Quick-connect terminal block
The quick-connect terminal block, found on the 1Q plug in card,
is composed of a header block and terminal plug (Figure 3). 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 until securely fastened.
10 Installation
Figure 3. Quick-Connect Terminal Plug
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11Installation
Warning
Do not 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, as shown in
Figure 4 (page 13). The switch contacts should be rated at a
minimum of 200% of motor nameplate current and 125 volts.

Motor, power and fuse connections
Connect the power input leads, an external line fuse and a three-
phase motor to the drive’s printed circuit board (PCB) as shown
in Figure 4, page 13.
Warning
Do not reverse power input leads or apply reverse voltage at
the drive terminals. The drive will be damaged.
Connect switches to COM terminal 1 only. Do not connect
switches to COM terminal 12. Terminal 12 is to be used for
external hall sensors and encoders only.

Connections
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12 Installation
Motor
Connect a three-phase motor to PCB terminals U, V and W, as
shown in Figure 4. Connect motor phase A (or phase 1) to drive
terminal U. Connect motor phase B (or phase 2) to drive terminal
V. Connect motor phase C (or phase 3) to drive terminal W.
Power input
Warning
Minarik strongly recommends the installation of a master
power switch in the voltage input line, as shown in
Figure 4. The switch contacts should be rated at a minimum
of 200% of motor nameplate current and 125 volts.

Connect the DC input power leads to PCB terminals BUS+ and
BUS-. Connect the positive (+ or high) to BUS+. Connect the
negative (- or common) to BUS-.
Line fuse
Wire an external line fuse between the stop switch (if installed)
and the BUS+ terminal. The line fuse should be rated at
125 volts and 150 - 200% of maximum motor nameplate current.
Refer to the line fuse chart on page 8 for fuse ratings.
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