Minarik MMRG Series User manual

MMRG30U
MMRG31U
MMRG40U
MMRG30U-PCM
MMRG31U-PCM
MMRG40U-PCM
MMRG SERIES
User’s Manual
Four-Quadrant, Regenerative Drives
for DC Motors

Copyright © 2002 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. MVD081202
Printed in the United States of America.

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.
S
H
OCK
HAZARD
AV
O
I
D
HEAT
KEE
DR
O
I
D
A
TI
ON
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.

i

ii
Contents
Safety Warnings i
Regenerative Drives v
Specifications 1
Dimensions 2
Installation 5
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Power, fuse and motor connections . . . . . . . . . . . . . . . . . . . . . .10
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Line fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Voltage follower (-PCM models) . . . . . . . . . . . . . . . . . . . . . . . . . .16
Polarity reversal switch (-PCM models) . . . . . . . . . . . . . . . . . . . . .16
+15 and –15 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Line frequency switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Operation 20
Before applying power: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Startup and shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
To start the drive: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . . .22
Automatic restart upon power restoration . . . . . . . . . . . . . . . . . .22
Decelerate to a stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Regenerative brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

iii
Table 1. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . . .12
Table 2. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Table 3. AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Table 4. Armature Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Tables
Calibration 25
MAX SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
FORWARD TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
REVERSE TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
IR COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
ACC–DEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
FWD SIG ADJ (-PCM models) . . . . . . . . . . . . . . . . . . . . . . . . . . .32
REV SIG ADJ (-PCM models) . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Application Notes 34
Connection to Minarik DLC600 . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
FWD-REV switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
FWD-STOP-REV switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . .37
Independent forward and reverse speeds . . . . . . . . . . . . . . . . . . .38
Independent foward and reverse speeds
with FWD-STOP-REV switch . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Troubleshooting 40
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Certificate of Compliance 45
AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Armature Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Unconditional Warranty inside back cover

Figure 1. Four Quadrant Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .vi
Figure 2. MMRG Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Figure 3. MMRG Dimensions
(Drive mounted on 223–0159 heat sink kit) . . . . . . . . . . . . . .3
Figure 4. MMRG-PCM Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Figure 5. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 6. Power and Motor Connections . . . . . . . . . . . . . . . . . . . . . .13
Figure 7. Speed Adjust Potentiometer Connections . . . . . . . . . . . . .14
Figure 8. Voltage Follower Connection . . . . . . . . . . . . . . . . . . . . . . .15
Figure 9. Voltage Follower Connection (-PCM Models) . . . . . . . . . . .17
Figure 10. +15 and -15 Terminal Locations . . . . . . . . . . . . . . . . . . . .18
Figure 11. Line Frequency Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Figure 12. RUN/STOP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Figure 13. INHIBIT Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Figure 14. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . .26
Figure 15. Recommended IR COMP, REVERSE TORQUE, and
FORWARD TORQUE Settings . . . . . . . . . . . . . . . . . . . . .33
Figure 16. MMRG Connection to DLC600 . . . . . . . . . . . . . . . . . . . . .34
Figure 17. Forward-Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . .35
Figure 18. Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . . . . .36
Figure 19. Independent Adjustable Speeds (Forward Direction) . . . . .37
Figure 20. Independent Forward and Reverse Speeds . . . . . . . . . . . .38
Figure 21. Independent Forward and Reverse Speeds with a
Forward-Stop-Reverse Switch . . . . . . . . . . . . . . . . . . . . . .39
iv
Illustrations

v
Most non-regenerative, variable speed, DC drives control current
flow to a motor in one direction. The direction of current flow is the
same direction as the motor rotation. Non-regenerative drives
operate in Quadrant 1, and also in Quadrant 3 if the drive is
reversible (see Figure 1). Motors must stop before reversing
direction. Unless dynamic braking is used, non-regenerative drives
cannot oppose an overhauling load, and cannot decelerate a load
faster than coasting to a lower speed.
Regenerative drives operate in two additional quadrants: Quadrant
2 and Quadrant 4. In these quadrants, motor torque is in the
opposite direction of motor rotation.
This allows regenerative drives to reverse a motor without
contactors or switches, to control an overhauling load, and to
decelerate a load faster than it would take to coast to a lower
speed.
Regenerative Drives

vi Regenerative Drives
ARR
O
W
S
IN
O
PP
OS
ITE DIRE
C
TI
O
N = RE
G
ENERATIVE A
C
TI
ON
NOTE: ARROWS IN SAME DIRECTION = MOTOR ACTION
MO
T
O
R
TO
R
Q
U
E
RO
TATI
ON
MO
T
O
R
Q
uadrant II
I
Q
uadrant I
I
Q
uadrant IV
Q
uadrant
I
Figure 1. Four Quadrant Operation

1
Specifications
Maximum Armature Armature Voltage
Model Current Horsepower Range
(Amps DC) Range (Volts DC)
MMRG30U, MMRG30U-PCM 5.0* 1/8–1/2* 0 –90
MMRG31U, MMRG31U-PCM 3.0 1/20–1/8 0 –90
MMRG40U, MMRG40U-PCM 5.0** 1/4 - 1** 0 –180
* Max. Armature Current = 10 ADC
Max. Horsepower = 1 hp when mounted to heat sink kit part number 223–0159.
** Max. Armature Current = 10 ADC
Max. Horsepower = 2 hp when mounted to heat sink kit part number 223–0159.
AC Line Voltage
MMRG30U, MMRG30U-PCM 115 VAC, ±10%, 50/60 Hz, single phase
MMRG31U, MMRG31U-PCM 115 VAC, ±10%, 50/60 Hz, single phase
MMRG40U, MMRG40U-PCM 230 VAC, ±10%, 50/60 Hz, single phase
Form Factor 1.37 at base speed
Acceleration Time Range 0.5 –6 seconds
Deceleration Time Range 0.5 –6 seconds
Analog Input Voltage Range (signal must be isolated; S1 to S2) 0 ± 10 VDC
Input Impedance (S0 to S2) 30 kohms
Load Regulation 1% base speed
Vibration 0.5G max. (20–50 Hz)
0.1G max. (>50 Hz)
Ambient Temperature Range 10°C–55°C
Weight 1.1 lb
* With the -PCM option, a drive can be configured to follow a grounded non-isolated voltage signal.

2
ALL DIMENSIONS IN INCHES [MILLIMETERS]
MOUNTING SLOTS 0.19 X 3.4 [5 X 9]
Dimensions
C503 MMRG
C506
PL1
C507
C508
60HZ
C501
PL2
S1
S2
C509
S0
C510
C505
50HZ
-15V T501+15V
C512
S3
C511
INHIBIT
P505P504P503
SO501
TORQUE
FORWARDIR COMP
TORQUE
REVERSE
P502P501
MAX
SPD
ACC-DEC
SW501
C513
C502
DC VOLTAGEDC VOLTAGE
COMMON
DC VOLTAGE
DC VOLTAGE
3.80 [97]
0.96 [24]
1.50 [38]
2.87 [73]
1.75 [44]
0.99 [25]
3.72 [94]
4.30 [109]
4.42 [112]
Figure 2. MMRG Dimensions

3Dimensions
5.90 [150]
6.30 [160]
6.90 [175]
3.87 [98]
3.70 [94]
4.40 [112]
0.70 [18]
1.00 [25] 0.13 [3]
C503 MMRG
C506
PL1
C507
C508
60HZ
C501
PL2
S1
S2
C509
S0
C510
C505
50HZ
-15V T501+15V
C512
S3
C511
INHIBIT
P505
P504P503
SO501
TORQUE
FORWARDIR COMP
TORQUE
REVERSE
P502
P501
MAX
SPD
ACC-DEC
SW501
C513
C502
DCVOLTAGEDC VOLTAGE
COMMON
DCVOLTAGE
DCVOLTAGE
Figure 3. MMRG Dimensions
(Drive mounted on 223–0159 heat sink kit)
ALL DIMENSIONS IN INCHES [MILLIMETERS]
MOUNTING SLOTS 0.19 X 3.4 [5 X 9]

4
P
501
T
OR
Q
U
E
INHIBIT
5
SO501
S3
S0
0.99
[
25
]
1.75
[
44
]
3
.72
[
94
]
0.96
[
24
]
3
.375
[
86
]
4.30
[
109
]
4.42
[
112
]
4.10
[
104
]
F
WD
S
I
G
AD
J
DIR
NE
G
COM
P
OS
R
EV
S
I
G
AD
J
DIR
NE
G
T
B
50
1
T50
2
T50
1
Figure 4. MMRG-PCM Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
MOUNTING SLOTS 0.19 X 3.4 [5 X 9]
Dimensions

5
•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.
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 on page i before attempting installation.

Mounting
Installation

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.
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 and the drive is disabled. Opening
any one motor lead may destroy the drive.


Wiring
•Use 18 AWG wire for speed adjust potentiometer wiring. Use 16
AWG wire for field (F1, F2) wiring. Use 14 AWG wire for AC line
(L1, L2) and motor (A1, A2) wiring.

7Installation
Shielding guidelines
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.
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.


8Installation
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.
Heat sinking
MMRG Series drives require an additional heat sink when the
continuous armature current is above 5 ADC. Use Minarik heat sink
kit part number 223-0159. Use a thermally conductive heat sink
compound (such as Dow Corning®340 Heat Sink compound)
between the drive chassis and the heat sink surface for optimum
heat transfer. Model MMRG31U does not require an additional heat
sink.

9
Mount the speed adjust potentiometer through a 0.38 in. (10 mm)
hole with the hardware provided (Figure 5). 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 separate from power leads (L1, L2, A1,
A2).
WIPER
C
W
W
S
PEED AD
JUST
P
O
TENTI
O
METER
I
N
SU
LATIN
G
DI
S
K
PANEL
S
TAR
WA
S
HER
NUT
MO
UNT THR
O
U
G
H A 0.38 IN.
(
10 MM
)
H
O
L
E
Figure 5. Speed Adjust Potentiometer
Speed adjust potentiometer
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.


10 Installation
Power, fuse and motor connections
Connect the power input leads, an external line fuse and a DC
motor to the drive’s printed circuit board (PCB) as shown in Figure
6, page 13.
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 6, page 13. The switch contacts should be rated at a
minimum of 200% of motor nameplate current and
250 volts.

Connections

Motor
Minarik drives supply motor voltage from A1 and A2 terminals. It is
assumed throughout this manual that, when A1 is positive with
respect to A2 , the motor will rotate clockwise (CW) while looking at
the output shaft protruding from the front of the motor. If this is
opposite of the desired rotation, simply reverse the wiring of A1
and A2 with each other.
Connect a DC motor armature to PCB terminals A1 and A2 as
shown in Figure 6, page 13. Ensure that the motor voltage
rating is consistent with the drive’s output voltage.
Power input
Connect the AC line power leads to terminals L1 and L2, or to a
double-throw, single-pole master power switch (recommended).
Line fuse
Minarik drives require fuses for protection. Use fast acting fuses
rated for 250 VAC or higher, and approximately 150% of the
maximum armature current. Fuse L1 only when the line voltage is
115 VAC. Fuse both L1 and L2 when the line voltage is 230 VAC.
11Installation

Table 1. Recommended Line Fuse Sizes
90 VDC Motor 180 VDC Motor Max. DC Armature AC Line Fuse
Horsepower Horsepower Current (amps) Size (amps)
1/20 1/10 0.5 3
1/15 1/8 0.8 3
1/8 1/4 1.5 5
1/6 1/3 1.7 5
1/4 1/2 2.5 8
1/3 3/4 3.5 8
1/2 1 5.0 10
3/4 1 1/2 7.5 15
1 2 10 20
Minarik Corporation offers two fuse kits: part number 050–0069
(3–8A Fuse Kit) and 050–0073 (5–20A Fuse Kit). Both fuse kits
include a 1/2A pico fuse (part number 050–0064) which protects
the transformer and logic.
12 Installation
Wire an external line fuse between the stop switch (if installed) and
the terminal board. An additional line fuse should be installed on
L2 if the input voltage is 230 VAC. Refer to the line fuse chart
below for fuse ratings.