Minarik PCM21000A User manual

USER’S MANUAL
PCM20000
SERIES
Models: PCM21000A
PCM21000C
PCM21010A
PCM22000A
PCM22000C
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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.
•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.
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
Specifications 1
Dimensions 2
Installation 4
Mounting ....................................................4
Wiring .......................................................5
Shielding guidelines ..........................................6
Heat sinking ..................................................7
Line fusing ...................................................7
Speed adjust potentiometer .......................................9
Connections . . . ..............................................10
Power, fuse and motor connections .............................10
Motor . . . ..............................................10
Power input .............................................11
Linefuse ...............................................11
Voltage signal follower (PCM2x000A) ..............................14
Voltage signal follower (PCM2x000C) ..............................15
Current signal follower (PCM2x000C only) ...........................16
Operation 17
Before applying power . . . . . . . . . . . . . . . . . . . ......................17
Startup . . . . . . . . . . . . . . . . .....................................20
Starting and stopping methods . . .................................21
Line starting and line stopping .................................21
Decelerate to a stop ........................................22
Calibration 23
Calibration procedure . . . . . . ....................................24
Before applying power .......................................24
SIGNAL ADJUST (SIG ADJ) . . .................................25
MINIMUM SPEED (MIN SPD) .................................26
MAXIMUM SPEED (MAX SPD) .................................26
Contents
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iiiTable of Contents
TORQUE (CURRENT LIMIT on PCM2000C series drives) ............27
REGULATION (IR COMP) ....................................28
Application Notes 30
Independent Adjustable Speeds .................................30
Multiple fixed speeds . . . . . . ....................................31
Adjustable speeds using potentiometers in series .....................32
RUN/JOG switch .............................................33
Troubleshooting 34
Before troubleshooting . . . . . . . . . . . . . . . . . . . ......................34
Diagnostic LEDs (PCM20000C series only) .........................35
POWER (GREEN) . . . . . . ....................................35
SIGNAL (YELLOW) . . . . . . . . . . . . . . . . . . . ......................35
CURRENT LIMIT (CURR LIM (RED)) ............................35
Replacement Parts . . . .........................................39
Certificate of Compliance 41
End User Responsibilities .......................................41
Exhibit “A” ..................................................42
Unconditional Warranty inside back cover
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Figure 1. PCM2x000A and PCM2x000C Dimensions ....................2
Figure 2. Heat Sink Kit Dimensions . .................................3
Figure 3. Speed Adjust Potentiometer Installation .......................9
Figure 4. PCM2x000A Drive Connections ............................12
Figure 5. PCM2x000C Drive Connections ............................13
Figure 6. PCM2x000A Voltage Follower Connections ...................14
Figure 7. PCM2x000C Voltage Follower Connections ...................15
Figure 8. Current Follower Connections (PCM2x000C only) ..............16
Figure 9. PCM2x000A Jumper Locations and Settings ..................18
Figure 10. PCM2x000C Jumper Locations and Settings ..................19
Figure 11. Run/Decelerate to Zero Speed Switch .......................22
Figure 12. Calibration Trimpot Layout ................................23
Figure 13. Typical TORQUE and IR COMP settings .....................29
Figure 14. Independent Adjustable Speeds (Forward Direction) .............30
Figure 15. Multiple Fixed Speeds . . .................................31
Figure 16. Adjustable Fixed Speeds Using Potentiometers in Series ........32
Figure 17. RUN/JOG Switch Connection to Speed Adjust Potentiometer ......33
Figure 18. Diagnostic LED Location (PCM 20000C Series Only) ............36
Tables
Table 1. Line Fusing Chart .......................................8
Table 2. Replacement Parts .....................................39
Table 3. Corcom® Filters .......................................42
Table 4. Minarik® Filters ........................................43
iv
Illustrations
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Specifications
Model PCM21000 PCM21010 PCM22000
Line voltage† 115 VAC 115 VAC 230 VAC
Line current, max 7A AC 3A AC 7A AC
Line current, max†† 14A AC n/a 14A AC
Armature voltage range 0 – 90 VDC 0 – 90 VDC 0 – 180 VDC
Horsepower range 1/4 – 1/2 hp 1/20 – 1/8 hp 1/2–1hp
Horsepower range†† 1/4–1hp n/a 1/2–2hp
Armature current, max 5 ADC 2 ADC 5 ADC
Armature current, max†† 10 ADC n/a 10 ADC
Input signal range (input circuit is isolated)
Voltage 0 – 10 VDC
Current (PCM2x000C series only) 4 – 20 mADC
Ambient temperature range 10ºC – 55ºC
† Line voltage is ±10%, 50/60 Hz, single phase
†† When mounted on 223-0159 heat sink kit
1
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2
Dimensions
Figure 1. PCM2x000A and PCM2x000C Dimensions
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3Dimensions
Figure 2. Heat Sink Kit Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
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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.
4
Installation
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
• Use 18-24 AWG wire for speed adjust potentiometer wiring.
Use 14–16 AWG wire for AC line (L1, L2) and motor (A1 and
A2) 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.


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6 Installation
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.
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.
Warning
Under no circumstances should power and logic leads be
bundled together. Induced voltage can cause unpredictable
behavior any electronic device, including motor controls.

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7Installation
Heat sinking
PCM2x000-series drives require an additional heat sink when the
continuous armature current is above 5 ADC. Use Minarik® part
number 223–0159. All other chassis drives have sufficient heat
sinking in their basic configurations.
Apply a thermally conductive heat sink compound (such as Dow
Corning® 340 Heat Sink Compound) between the drive chassis
and heat sink surface for optimum heat transfer.
Line fusing
Minarik drives require an external fuse for protection. Use fast
acting fuses rated for 250 VAC or higher, and approximately
150% of the maximum armature current. Fuse both L1 and L2
when the line voltage is 230 VAC. Fuse blocks are included on
cased drives only.
Table 1 (page 8) lists the recommended replacement line fuse
sizes.
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Table 1. Line Fusing Chart
90 VDC Motor 180 VDC Max. DC Armature AC Line Fuse
Horsepower Horsepower Current (amps) Size (amps)
1/20 1/10 0.5 1
1/15 1/8 0.8 1.5
1/8 1/4 1.5 3
1/6 1/3 1.7 3
1/4 1/2 2.5 5
1/3 3/4 3.5 8
1/2 1 5.0 10
3/4 1 1/2 7.5 15
1 2 10 15
Minarik Corporation offers two fuse kits: part number 050–0066
(1–5A Fuse Kit) and 050–0071 (5–15A Fuse Kit).
8 Installation
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Speed adjust potentiometer
9Installation
Mount the speed adjust potentiometer through a 0.38 in. (10 mm)
hole with the hardware provided (Figure 3). 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).
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 3. Speed Adjust Potentiometer Installation
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10 Installation
Connections
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) or Figure 5 (page 14). The switch
contacts should be rated at a minimum of 200% of motor
nameplate current and 250 volts.

Power, fuse and motor connections
If you use a PCM2x000A-series drive, 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 4, page 13.
If you use a PCM2x000C-series drive, refer to Figure 5 (page 14).
Motor
Connect a DC motor to PCB terminals A1 and A2 as shown in
Figure 4. Ensure that the motor voltage rating is consistent
with the drive’s output voltage.
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11Installation
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.
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
Wire an external line fuse between the stop switch (if installed)
and the L1 terminal on terminal board TB501. An additional line
fuse should be installed on L2 if the input voltage is 230 VAC.
The line fuse(s) should be rated at 250 volts and 150 - 200% of
maximum motor nameplate current. Refer to the line fuse chart
on page 8 for fuse ratings.
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 250 volts.

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12 Installation
Figure 4. PCM2x000A Drive Connections
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13Installation
Figure 5. PCM2x000C Drive Connections
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14 Installation
Voltage signal follower (PCM2x000A)
Figure 6. PCM2x000A Voltage Follower Connections
Warning
Before applying power, ensure that SO501 is set to SIGNAL
as shown in Figure 6.

Instead of using a speed adjust potentiometer, the drive may be
wired to follow a 0–10 VDC grounded or ungrounded voltage
signal. Connect the signal input (+) to POS. Connect the signal
common (–) to NEG. A potentiometer can be used to scale the
analog input voltage.
SO501
CONTROL
SELECT
JUMPER
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