Minarik NRG-2Q Series User manual

User’s Manual
NRG–2Q
Series
Two Quadrant, Regenerative PWM Drives
for DC Brush Motors
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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.
Failure to heed these warnings may result in damage to the
drive or personal injury. Please read these instructions
carefully before performing any of the procedures contained in
this manual.
•DO NOT INSTALL, REMOVE, OR SERVICE 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.
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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ii
Contents
Specifications 1
NRG02–D240AC–2Q .........................................1
NRG05–D240AC–2Q .........................................2
NRG10–115AC–2Q ..........................................3
Dimensions 4
Regenerative Drives 5
Installation 7
Drivemounting .............................................7
Wiring.....................................................8
Shieldingguidelines ........................................9
Linefusing ................................................10
Connections ...............................................11
Motor connections ........................................11
Power lead connections ....................................12
Dynamic brake resistor connections ...........................12
Inhibit personality header .....................................14
+12VDCterminals ..........................................14
Voltage follower connection ...................................16
Operation 17
Before applying power .......................................17
Startupandshutdown .......................................18
Starting and stopping methods .................................19
Line starting and stopping ..................................20
Decelerating to minimum speed ..............................21
Inhibitterminals ..........................................22
Dynamic braking ..........................................23
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iii
Calibration 26
Calibration procedure ........................................28
MINIMUM SPEED (MIN) ...................................29
MAXIMUM SPEED (MAX) ..................................29
REGULATION (IR COMP) ..................................30
MOTOR CURR. LIMIT and REGEN CURR. LIMIT ................31
ACCEL ................................................32
DECEL ................................................33
Application Notes 35
Connection to other Minarik devices .............................35
Optional speed adjust potentiometer connections ...................36
Multiple fixed speeds ......................................36
Adjustable speeds using potentiometers in series ................37
Independent adjustable speeds ..............................38
RUN/JOG switch ...........................................39
RUN/JOG option #1 .......................................39
RUN/JOG option #2 .......................................40
Leader-follower application ....................................41
Single speed potentiometer control of multiple drives ................42
Troubleshooting 43
Before troubleshooting .......................................43
Diagnostic LEDs ...........................................44
Power .................................................44
MotorOutput ............................................44
Regen Output ...........................................44
ReplacementParts .........................................49
Unconditional Warranty inside back cover
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iv
Figure1. NRG–2QDimensions.....................................4
Figure 2. Two Quadrant Operation ..................................6
Figure 3. NRG–2Q Connections ...................................13
Figure 4. Inhibit Personality Header, Inhibit Terminals and +12 VDC Terminals 15
Figure 5. Voltage Follower Connections .............................16
Figure 6. Connections for Run/Decelerate to Minimum Speed Switch .......21
Figure 7. Dynamic Braking Circuit Connection .........................25
Figure8. CalibrationTrimpotLayout ................................27
Figure 9. Typical IR COMP and CURRENT LIMIT settings ...............34
Figure 10. NRG-2Q Connection to DLC600 DIGI-LOK Control
and PCM4 Signal Isolator .................................35
Figure 11. Multiple Fixed Speeds ...................................36
Figure 12. Adjustable Fixed Speeds Using Potentiometers in Series .........37
Figure 13. Independent Adjustable Speeds ............................38
Figure 14. RUN/JOG Switch Connection to Inhibit Plug ...................39
Figure 15. RUN/JOG Switch Connection to Speed Adjust Potentiometer ......40
Figure 16. Leader-Follower Application ...............................41
Figure 17. Single Speed Potentiometer Control of Multiple Drives ...........42
Figure 18. Diagnostic LED Location .................................44
Tables
Table 1. Recommended Line Fuse Sizes .............................10
Table 2. Inhibit Plug Harness Assembly Part Number ....................22
Illustrations
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Model Number NRG02–D240AC–2Q
Type Open Chassis
AC Line Voltage 115 VAC or 230 VAC, ±10%, 50Hz or 60 Hz, single phase
Maximum Continuous Armature Current 2 ADC
Horsepower Range @ 130 VDC Output 1/20 – 1/4
Horsepower Range @ 240 VDC Output 1/10 – 1/2
Maximum Armature Voltage Range @ 115 VAC Input 0–130 VDC
Maximum Armature Voltage Range @ 230 VAC Input 0–240 VDC
Form Factor 1.03
Acceleration Time Range 1–10 seconds
Deceleration Time Range 1–10 seconds
Input Signal Range (signal must be isolated) 0–5 VDC
Input Impedance 100K ohms minimum
Speed Regulation (% of base speed) 1% open loop
Speed Range 100:1
Vibration 0.5G max. (0–50 Hz); 0.1G max. (>50 Hz)
Weight 1.94 lb
Ambient Operating Temperature Range 10°C–40°C
1
Specifications
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Model Number NRG05–D240AC–2Q
Type Open Chassis
AC Line Voltage 115 VAC or 230 VAC, ±10%, 50Hz or 60 Hz, single phase
Maximum Continuous Armature Current 5 ADC
Horsepower Range @ 130 VDC Output 1/8 – 3/4
Horsepower Range @ 240 VDC Output 1/4–11/2
Maximum Armature Voltage Range @ 115 VAC Input 0–130 VDC
Maximum Armature Voltage Range @ 230 VAC Input 0–240 VDC
Form Factor 1.03
Acceleration Time Range 1–10 seconds
Deceleration Time Range 1–10 seconds
Input Signal Range (isolated) 0–5 VDC
Input Impedance 100K ohms minimum
Speed Regulation (% of base speed) 1% open loop
Speed Range 100:1
Vibration 0.5G max. (0–50 Hz); 0.1G max. (>50 Hz)
Weight 1.94 lb
Ambient Operating Temperature Range 10°C–40°C
2 Specifications
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Model Number NRG10–115AC–2Q
Type Open Chassis
AC Line Voltage 115 VAC, ±10%, 50Hz or 60 Hz, single phase
Maximum Continuous Armature Current 10 ADC
Horsepower Range @ 130 VDC Output 1/4–11/2
Maximum Armature Voltage Range 0–130 VDC
Form Factor 1.03
Acceleration Time Range 1–10 seconds
Deceleration Time Range 1–10 seconds
Input Signal Range (isolated) 0–5 VDC
Input Impedance 100KW minimum
Speed Regulation (% of base speed) 1% open loop
Speed Range 100:1
Vibration 0.5G max. (0–50 Hz); 0.1G max. (>50 Hz)
Weight 1.94 lb
Ambient Operating Temperature Range 10°C–40°C
3Specifications
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4
MAX
ACCEL
DECEL
MOTOR
REGEN
CURR.
LIMIT
CURR.
LIMIT
MIN
IR COMP
DB-
DB+
IN H IB IT
+12VDC
IN H IB IT
PERSONALITY
OUTPUT
L2-115V L2-230V
POWER
MOTOR
REGEN
1 2 3
1&2=Dynamic Brake
2&3=Disable Output
+ -
GND
R501
TH501
C503
C504
FU501
D501
L1
SO501
S1 S2 S3
BR1
SO502
SO503
L501
L502
L503
C501
C505
FU502
C506
C502
3.00 [76]
4.44 [113]
0.70 [18]
A2.20 [56]
0.97 [25]
6.30 [160]
6.90 [175]
A1
A2
4.44 [113] 3.00 [76]
0.70 [18]
0.97 [25]
2.20 [56]
A
6.30 [160]
6.90 [175]
Dimensions
Figure 1. NRG–2Q Dimensions
All dimensions in inches [millimeters]
Model Dimension A
NRG02–D240AC–2Q 2.62 [67]
NRG05–D240AC–2Q 2.62 [67]
NRG10–115AC–2Q 2.43 [62]
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5
Regenerative Drives
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 (see Figure 2, page 6). Unless dynamic
braking is used, non-regenerative drives decelerate a load faster
than coasting to a lower speed.
NRG–2Q drives operate in Quadrants 1 and 4. In Quadrant 4, the
direction of current flow is in the opposite direction of motor
rotation. This allows regenerative drives to control an
overhauling load and decelerate a load faster than it would take to
coast to a lower speed.
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6 Regenerative Drives
Figure 2. Two Quadrant Operation
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7
Installation
Drive mounting
• Drive components are sensitive to electrostatic fields. Avoid
contact with the circuit board directly. 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 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 inch (5 mm) wide slots in the chassis accept #8
pan head screws. Fasten either the large base or the flange of
the chassis to the subplate.
Warning
Do not install, rewire, or remove this control with power
applied. Doing so may cause fire or serious injury. Make
sure you have read and understood the Safety Warnings
before attempting installation.
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.

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8 Installation
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 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.


Use 16 AWG wire for AC line voltage (L1 and L2) and motor
armature (A1 and A2) wiring. Use 18 AWG wire for logic
(inhibit leads or S1, S2 and S3). For the dynamic brake resistor,
use 14 AWG wire for model NRG10–115AC–2Q, or 16 AWG
wire for models NRG05–D240AC–2Q and
NRG02–D240AC–2Q.
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9Installation
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.

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.
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Line fusing
NRG Series drives have preinstalled line fuses. See the
Replacement Parts section for preinstalled line fuse size. When
replacing the line fuses, use fast acting fuses rated for 250 VAC
or higher, and approximately 150% of the armature current. Two
line fuses are required for models NRG02–D240AC–2Q and
NRG05–D240AC–2Q, while only one is required for model
NRG10–115AC–2Q. See Table 1 for recommended line fuse
sizes.
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 2.6 8
1/3 3/4 3.5 8
1/2 1 5.0 10
3/4 1 1/2 7.6 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). See
Replacement Parts (page 49) for fuse kit contents.
10 Installation
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11Installation
Connections
Connect the power input leads and a DC motor to the drive’s
printed circuit board (PCB) as shown in Figure 3 (page 13).
Motor connections
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 to PCB terminals A1 and A2 as shown in
Figure 3. Ensure that the motor voltage rating is consistent
with the drive’s output voltage.
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. The switch contacts
should be rated at a minimum of 200% of motor nameplate
current and 250 volts.

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Power lead connections
Connect the AC line power leads to TB501 terminals L1 and L2,
or to a double-throw, single-pole master power switch
(recommended).
Dynamic brake resistor connections
If you plan to use dynamic braking to stop the motor, you must
connect a dynamic brake resistor across the DB+ and DB-
terminals on the PCB as shown in Figure 3.
The dynamic brake resistor reduces the voltage across the bus
capacitors (C503 and C504) when they reach their maximum
voltage rating. This occurs when the motor regenerates voltage
back to the drive. Bus capacitor maximum voltage ratings are 400
VDC for 240 VAC drives, and 200 VDC for 115 VAC drives.
For more information on dynamic braking, as well as selecting
dynamic brake resistor values, refer to the Dynamic Braking
section on page 23.
12 Installation
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13Installation
Also see Dynamic
brake resistor
sizing, page 23.
Figure 3. NRG–2Q Connections
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14 Installation
Inhibit personality header
The inhibit personality header (SO503) determines how the drive
responds when the INHIBIT terminals (SO501) are shorted
together. Set the inhibit personality before shorting the inhibit
terminal to each other. Jumper pins 1 and 2 for a dynamic brake
response, or pins 2 and 3 for a disable output response (coast to a
stop). (Also read Inhibit terminals section on page 22). See
Figure 4 for jumper and inhibit terminal locations.
+12 VDC terminals
To supply power to external devices, the +12VDC terminals can
supply an unregulated +12 VDC (30 mA) signal. – is the signal
common terminal, and + is the voltage signal terminal. See Figure
4 for terminal location.
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