Minarik PCM23000A Series User manual

PCM23001A
PCM23411A
PCM23401A
USER MANUAL
www.minarikdrives.com
PCM23000A Series
An American Control Electronics Brand

Dear Valued Consumer:
Congratulaons on your purchase of the PCM23000A Series
drive. This User Manual was created for you to get the most out
of your new device and assist with the inial setup. Please visit
www.minarikdrives.com to learn more about our other drives.
Thank you for choosing Minarik Drives!
No part of this document may be reproduced or transmied in any form without wrien permission
from American Control Electronics®. The informaon and technical data in this document are
subject to change without noce. American Control Electronics® makes no warranty of any kind with
respect to this material, including, but not limited to, the implied warranes of its merchantability
and tness for a given purpose. American Control Electronics® assumes no responsibility for any
errors that may appear in this document and makes no commitment to update or to keep current
the informaon in this document.

i
PCM23000A Series
Safety First!
• 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 using
proper grounding techniques, over-current protection, thermal
protection, and enclosure. Follow sound maintenance procedures.
SAFETY WARNINGS
Text in gray boxes denote important safety ps or warnings.
Please read these instrucons carefully before performing any of
the procedures contained in this manual.
It is possible for a drive to run at full speed as a result of a
component failure. Minarik Drives strongly recommends the
installaon of a master switch in the main power input to stop
the drive in an emergency.
Circuit potenals 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 adjusng the calibraon trim pots.
Use approved personal protecve equipment and insulated tools
if working on this drive with power applied.

!
WARNING!

!
WARNING!

ii
PCM23000A Series
Table of Contents
Section 1. Specifications ..................................................... 1
Section 2. Dimensions......................................................... 2
Section 3. Installation......................................................... 4
Mounting ..................................................................................... 4
Chassis ................................................................................. 4
Speed Adjust Potentiometer .............................................. 5
NEMA 4X .............................................................................. 6
Wiring .......................................................................................... 7
Shielding Guidelines.............................................................. 8
Line Fusing ........................................................................... 9
Connections.................................................................................11
Power Inputs .......................................................................11
Motor..................................................................................11
Field Output Connections.....................................................12
Speed Adjust Potentiometer.................................................13
Analog Input Signal..............................................................13
Section 4. Operation......................................................... 16
Before Applying Power .................................................................16
Select Switches............................................................................17
Input Voltage Select (SW501) ...............................................17
Armature Voltage Select (SW502) .........................................17
Operation Modes .........................................................................18
Manual Mode ......................................................................18
Signal Mode.........................................................................18
Ratio Mode..........................................................................18
Startup ........................................................................................19
PCM23001A.........................................................................19
PCM23401A and PCM23411A ...............................................19
Starting and Stopping Methods ....................................................20
Line Starting and Stopping ...................................................20

iii
PCM23000A Series
Dynamic Braking ..................................................................21
Decelerating to Minimum Speed...........................................23
Section 5. Calibration ....................................................... 24
Minimum Speed (MIN SPD) ..........................................................25
Maximum Speed (MAX SPD) .........................................................25
Signal Minimum Speed (SIG MIN)..................................................26
Signal Maximum Speed (SIG MAX) ................................................26
Torque (TORQUE) .........................................................................27
IR Compensation (IR COMP) .........................................................28
Section 6.Application Notes ............................................... 30
Multiple Fixed Speeds ..................................................................30
Adjustable Speeds Using Potentiometers In Series.........................31
Independent Adjustable Speeds....................................................32
RUN/JOG Switch...........................................................................33
Leader-Follower Application .........................................................34
Single Speed Potentiometer Control Of Multiple Drives .................35
Reversing.....................................................................................36
Section 7. Troubleshooting................................................ 37
Before Troubleshooting ................................................................37
Section 8. Accessories & Replacement Parts ....................... 40
Unconditional Warranty..................................................... 41

iv
PCM23000A Series
List of Figures
Figure 1 PCM23001A Dimensions.................................................... 2
Figure 2 PCM23401A and PCM23411A Dimensions .......................... 3
Figure 3 Speed Adjust Potentiometer .............................................11
Figure 4 Chassis Drive Connections ................................................14
Figure 5 Cased Drive Connections ..................................................15
Figure 6 Select Switches ................................................................17
Figure 7 Operation Modes .............................................................18
Figure 8 Dynamic Brake Wiring ......................................................22
Figure 9 Run/Decelerate to Minimum Speed Switch........................23
Figure 10 Recommended TORQUE and IR COMP Settings ..................29
Figure 11 Multiple Fixed Speeds ......................................................30
Figure 12 Adjustable Speeds Using Potentiometers in Series .............31
Figure 13 Independent Adjustable Speeds........................................32
Figure 14 RUN/JOG Switch...............................................................33
Figure 15 Leader-Follower Application .............................................34
Figure 16 Single Speed Potentiometer Control of Multiple Drives......35
Figure 17 Reversing Circuit Wiring ...................................................36
List of Tables
Table 1 Recommended Line Fuse Sizes ..........................................10
Table 2 Field Output Connections .................................................12
Table 3 Minimum Recommended Dynamic Brake Resistor Values ...22

1
PCM23000A Series
Section 1. Specifications
AC Line Voltage 115/230 VAC ± 10%, 50/60 Hz, single phase
DC Armature Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
0 - 90 VDC
0 - 180 VDC
Field Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
50 VDC (F1 to L1); 100 VDC (F1 to F2)
100 VDC (F1 to L1); 200 VDC (F1 to F2)
Maximum Field Current 1 ADC
Acceleraon & Deceleraon Time 1 second
Analog Input Range 0 - 10 VDC, 4 - 20 mA
Input Impedance (S1 to S2) 1K ohms
Form Factor 1.37 at base speed
Load Regulaon 1% base speed or beer
Speed Range 60:1
Vibraon 0.5G maximum (0 - 50 Hz)
0.1G maximum (> 50 Hz)
Safety Cercaons
CSA Cered Component, File # LR41380
Ambient Temperature Range
Chassis Drive
Cased Drive
10°C - 55°C
10°C - 40°C
Model
Maximum
Armature
Current (ADC)
HP Range
with 90 VDC
Motor
HP Range
with 180 VDC
Motor Enclosure
PCM23411A 1.5 1/20 - 1/8 1/10 - 1/4 NEMA 4X
PCM23001A
PCM23401D
10.0 1/8 - 1 1/4 - 2 Chassis
NEMA 4X
UL/cUL Recognized Equipment, File # E132235 (not PCM23411A)

2
PCM23000A Series
Section 2. Dimensions
Figure 1. PCM23001A Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
2.30
[
58
]
6.90
[
175
]
6.30
[
160
]
4.40
[
112
]
0.70
[
18
]
3
.00
[
76
]
C516
SC
R502
R531
D508
C501
R525
M
O
V502
T501
I
C502
A1
I
C501
C502
A2
SCR501
SW501
F2
S3
S2
S1
M
O
V
503
F1
T502
D501
D
5
02
NE
G
RSH
S
I
G
NAL INPU
T
P
OS
C5
1
8
L1 L2
MOV501
D506
115 230
SIG MAX SIG MIN MAX SPD MIN SPD TORQUE IR COMP
1 2 3 4 5
SO501

3
PCM23000A Series
Figure 2. PCM23401A and PCM23411A Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
0
.22
[
6
]
6.90
[
175
]
6.30
[
160
]
9
.
80
[
249
]
1
0
.22
[
260
]
1.45
[
37
]
1.50
[
38
]
1.50
[
38
]
1.4
0
[36
]
7
.
00
[
178
]
0
.1
2
[
3
]
2.
31
[
59
]
4.7
8
[
121
]
5
.
5
1
[
140
]
THREE 0.88 [22] KNOCKOUTS

4
PCM23000A Series
Section 3. Installation
Do not install, rewire, or remove this control with input power
applied. Failure to heed this warning may result in re, explosion,
or serious injury. Make sure you read and understand the Safety
Precauons on page i before aempng to install this product.

!
WARNING!
• Drive components are sensitive to electrostatic discharge. Avoid
direct contact with the circuit board. Hold the drive by the heat sink
only.
• Protect the drive from dirt, moisture, and accidental contact.
• Provide sufficient room for access to the terminals and calibration
trim pots.
• 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 the drive with its board in either a horizontal or vertical
plane. Four 0.19” (5 mm) wide slots in the heat sink accept #8 pan
head screws.
• The heat sink should be earth grounded. Use a star washer beneath
the head of at least one of the mounting screws to penetrate the
anodized surface and to reach bare metal.
Mounng
Chassis

5
PCM23000A Series
POT TAB ASSIGNMENTS
WIPER
CW
CCW
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
PANEL
STAR
WASHER
NUT
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
Figure 3. Speed Adjust Potenometer
If using a remote potenometer with a chassis drive, mount the speed
adjust potenometer through a 0.38 in. (10 mm) hole with the hardware
provided (Figure 3). Install the circular insulang disk between the panel
and the 10K ohm speed adjust potenometer.
Twist the speed adjust potenometer wire to avoid picking up unwanted
electrical noise. If the speed adjust potenometer wires are longer than
18 in. (46 cm), use shielded cable. Keep the speed adjust potenometer
wires separate from power leads (L1, L2, A1, A2, F1, F2).
Speed Adjust Potenometer
Be sure that the potenometer tabs do not make contact with the
potenometer’s body. Grounding the input will cause damage to
the drive.

!
WARNING!

6
PCM23000A Series
NEMA 4X cased drives come with two 0.88 inch (22 mm) conduit
knockout holes at the boom of the case. The units may be vercally wall
mounted using the four 0.19 inch (5 mm) sloed holes on the aached
heat sink. For motor loads less than 5 ADC, the drive may be bench
mounted horizontally or operated without mounng.
1. Install the mounting screws.
2. For access to the terminal strip, turn the slotted screw on the
front cover counterclockwise until it is free from the case. The
right side of the cover is hinged to the case. Pull the slotted
screw to open the case.
3. Carefully remove the conduit knockouts by tapping them into
the case and twisting them off with pliers.
4. Set the POWER switch to the OFF position before applying the
AC line voltage.
5. Install conduit hardware through the 0.88 inch (22 mm)
knockout holes. Connect external wiring to the terminal block.
6. Grasp the slotted screw and tilt the front cover back into place.
Avoid pinching any wires between the front cover and the case.
7. Turn the slotted screw clockwise until tight to secure the front
cove r.
Mounng (NEMA 4X Enclosures)

7
PCM23000A Series
• Use 18 - 24 AWG wire for logic wiring. Use 14 - 16 AWG wire for
AC line and motor wiring.
Wiring
Do not install, rewire, or remove this control with input power
applied. Failure to heed this warning may result in re, explosion,
or serious injury.
Circuit potenals 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 while the drive is running may destroy the drive.
This product does not have internal solid state motor overload
protecon. It does not contain speed-sensive overload
protecon, thermal memory retenon or provisions to receive
and act upon signal from remote devices for over temperature
protecon. If motor over protecon is needed in the end-use
product, it needs to be provided by addional equipment in
accordance with NEC standards.

!
WARNING!

8
PCM23000A Series
Shielding Guidelines
As a general rule, Minarik Drives recommends shielding of all conductors.
If it is not praccal to shield power conductors, it is recommended
to shield all logic-level leads. If shielding of all logic-level leads is not
praccal, 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 connues to pick up noise aer grounding the shield, it may
be necessary to add AC line ltering devices, or to mount the drive in a
less noisy environment.
Logic wires from other input devices, such as moon 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 level leads be
bundled together. Induced voltage can cause unpredictable
behavior in any electronic device, including motor controls.

!
WARNING!

9
PCM23000A Series
Chassis drives should be fused for protecon. Use fast acng fuses rated
for 250 VAC or higher and 150% of maximum armature current. Fuse
HOT L1 only when the line voltage is 115 VAC. Fuse both L1 and L2 when
the line voltage is 230 VAC. Table 1 on page 10 lists the recommended
line fuse sizes.
Cased models come with preinstalled fuses. Model PCM23411A is
preinstalled with 5 amp fuses. Model PCM23401A is preinstalled with
15 amp fuses.
Preinstalled line fuses are rated for maximum horsepower. If the
horsepower rang of the motor being used is less than the maximum
horsepower rang of the drive, the line fuse may have to be replaced
with a lower rated one. Fuses should be rated for 250 VAC or higher and
approximately 150% of the maximum armature current. Refer to Table 1
on page 10 to install a lower rated fuse.
Line Fusing

10
PCM23000A Series
90 VDC
Motor
Horsepower
180 VDC
Motor
Horsepower
Maximum DC
Armature Current
(amps)
AC Line
Fuse Size
(amps)
1/20
1/15
1/8
1/6
1/10
1/8
1/4
1/3
0.5
0.8
1.5
1.7
1
1.5
3
3
1/4 1/2 2.5 5
1/3
1/2
3/4
1
3/4
1

2
3.5
5.0
7.5
10
8
10
15
15
Minarik Drives oers fuse kits. See Secon 10: Accessories and
Replacement Parts for fuse kit part numbers.
Table 1. Recommended Line Fuse Sizes

11
PCM23000A Series
Connecons
Do not connect this equipment with power applied. Failure to
heed this warning may result in re, explosion, or serious injury.
Minarik Drives strongly recommends the installaon of a
master power switch in the voltage input line, as shown in
Figure 4 (page 15). The switch contacts should be rated at a
minimum of 200% of motor nameplate current and 250 volts.
This power switch is provided with NEMA 1 and NEMA 4X models.

!
WARNING!
Power Input
For chassis models, connect the AC line power leads to terminals L1 and
L2. Minarik Drives recommends the use of a single-throw, double-pole
master power switch. The switch should be rated at a minimum of 250
volts and 200% of motor current. Refer to Figure 4 on page 14.
For enclosed models, connect the AC line power leads to screw terminals
1 (L1) and 2 (L2 115) if using a 115 VAC line or to terminals 1 (L1) and 3 (L2
230) if using a 230 VAC line. Refer to Figure 5 on page 15.
Motor
Drives supply motor armature voltage from A1 and A2 terminals. It is
assumed throughout this manual that, when A1 is posive with respect
to A2, the motor will rotate clockwise (CW) while looking at the output
sha protruding from the front of the motor. If the motor does not
spin in the desired direcon, remove power and reverse the A1 and A2
connecons.
For chassis models, connect a DC motor to terminals A1 and A2 as shown
in Figure 4 on page 14. For enclosed models, connect a DC motor to
terminals 4 (A1) and 5 (A2) as shown in Figure 5 on page 15. Ensure that
the motor voltage rang is consistent with the drive’s output voltage.

12
PCM23000A Series
Line Voltage (VAC) Approximate Field
Voltage (VDC)
Connect Motor
Field To
115
115
230
230
50
100
100
200
F1 (6) and L1 (1)
F1 (6) and F2 (7)
F1 (6) and L1 (1)
F1 (6) and F2 (7)
Table 2. Field Output Connecons
Field Output Connecons
The eld output is for shunt wound motors only. Do not make
any connecons to F1 and F2 when using a permanent magnet
motor.

!
WARNING!
See Table 2 for eld output connecons. Use 18 AWG wire to connect
the eld output to a shunt wound motor.

13
PCM23000A Series
Speed Adjust Potenometer
For chassis models, use a 10K ohm, 1/4 W potenometer for speed
control. Connect the counter-clockwise end of the potenometer to S1,
the wiper to S2, and the clockwise end to S3. If the potenometer works
inversely of the desired funconality (e.g. to increase motor speed you
must turn the potenometer counterclockwise), power o the drive and
swap the S1 and S3 connecons. Refer to Figure 4 on page 14.
For enclosed models, the speed adjust potenometer is factory installed
and prewired.
Analog Input Signal
Instead of using a speed adjust potenometer, the drive may be wired to
follow an analog input voltage or current signal that is either isolated or
non-isolated from earth ground. For chassis models, connect the signal
common (-) to NEG. Connect the signal reference (+) to POS. Refer to
Figure 4 on page 14. For enclosed models, connect the signal common
(-) to terminal 9. Connect the signal reference (+) to terminal 8. Refer to
Figure 5 on page 15.
An analog input signal range of 0–10 VDC or 4–20 mA is required to
produce an armature voltage range of 0–90 VDC with 115 VAC line
voltage or 0-180 VDC with 230 VAC line voltage.
If using an analog input current signal range of 4-20 mA, a 1000 ohm
resistor must be placed across RSH. Refer to Figure 4 on page 14.

14
PCM23000A Series
MOTOR
FUSE
STOP
SWITCH
AC LINE
VOLTAGE
115/230 VAC
10K OHM
SPEED ADJUST
POTENTIOMETER
CW
* NOTE: Do not add fuse to L2
unless input voltage is 230 VAC.
NOTE: DO NOT make
any connections to
F1 and F2 if using a
permanent magnet motor.
C5
1
6
SCR502
R53
1
D508
C501
R525
M
O
V502
T501
IC502
A1
IC501
C502
A2
SCR501
S
W
501
F2
S3
S2
S1
MOV503
F1
T502
D5
01
D
5
02
NE
G
R
SH
SIGNAL INPUT
P
OS
C518
L1 L2
MOV501
D506
115 230
SIG MAX SIG MIN MAX SPD MIN SPD TORQUE IR COMP
1 2 3 4 5
SO501
SIGNAL REFERENCE (+)
SIGNAL COMMON (-)
*FUSE RSH
Terminals
FIELD
Figure 4. Chassis Drive Connecons