Minarik XL1100A User manual

Pulse-Width Modulated,
Variable Speed DC Drives
User’s Manual
XLA Series
Models:
XL1100A
XL3025A
XL3050A
XL3200A

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. MVD040902
Printed in the United States of America.
The XLA Series of open chassis, PWM Drives ranges from 1/20
HP to 2 HP. An additional heatsink kit (PN 223-0271) may be
added if the armature current is greater than 5 amps. The XLA
Series of drives has a cage-clamp terminal block for user-
friendly wiring. There are six user-adjustable trimmer
potentiometers in addition to diagnostics.

i
Safety Warnings
•This symbol  denotes an important safety tip or warning.
Failure to observe these warnings may result in serious injury.
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.

S
H
OC
K
HAZARD
AV
O
I
D
HEAT
KEE
DR
O
I
D
A
TI
ON

ii
Contents
Safety Warnings i
Tables iii
Illustrations iv
Specifications 1
Dimensions 8
Installation 10
Drive mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Line Fusing for XL Series Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Speed adjust potentiometer mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Cage-clamp terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
External line fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Field output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Voltage follower connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Voltage switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Operation 23
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Inhibit terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Decelerate to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Calibration 31
Calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

iii
IR COMPENSATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
CURRENT LIMIT (CURR. LIMIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
ACCELERATION (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
DECELERATION (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Application Notes 41
Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . .42
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
RUN/JOG option #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
RUN/JOG option #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Single speed potentiometer control of multiple drives . . . . . . . . . . . . . . . .47
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Reversing with a DIGI-LOK® controller . . . . . . . . . . . . . . . . . . . . . . . . . .49
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Troubleshooting 50
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
POWER ON (IL501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
CURR LIM (IL502) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Certificate of Compliance 59
AC line filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
End User Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Unconditional Warranty inside back cover
Tables
Table 1. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Table 2. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Table 3. Inhibit Plug Harness Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Table 4. Minimum recommended
dynamic brake resistor sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Table 5. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Table 6. Minarik AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Figure 1. XLA Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 2. Heat Sink Dimensions (KIT 223-0271) . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 3. Speed Adjust Potentiometer Installation . . . . . . . . . . . . . . . . . . . . . . .15
Figure 4. Cage-Clamp Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 5. XLA Series Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Figure 6. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Figure 7. Voltage Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Figure 8. Inhibit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Figure 9. Run/Decelerate to Minimum Speed Switch . . . . . . . . . . . . . . . . . . . . .28
Figure 10. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Figure 11. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Figure 12. Low-Voltage DC Motor Calibration Settings . . . . . . . . . . . . . . . . . . .35
Figure 13. Typical CURR. LIMIT and IR COMP settings
(actual settings may vary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Figure 14. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Figure 15. Adjustable Speeds Using Potentiometers In Series . . . . . . . . . . . . . .42
Figure 16. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Figure 17. RUN/JOG Switch (first wiring option) . . . . . . . . . . . . . . . . . . . . . . . .44
Figure 18. RUN/JOG Switch (second wiring option) . . . . . . . . . . . . . . . . . . . . . .45
Figure 19. Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Figure 20. Single Speed Potentiometer Control of Multiple Drives . . . . . . . . . . .47
Figure 21. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Figure 22. Reversing with a DLC600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Figure 23. Diagnostic LED Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Figure 24. CEXL Filter Connection to XLA Series Drive . . . . . . . . . . . . . . . . . . .62
iv
Illustrations

Model Number XL1100A
Type open chassis
AC Line Voltage 115 VAC, ±10%, 50/60 Hz, single phase
Line Fuse Rating 15 A
Horsepower Range 1/4–1 HP
Form Factor 1.05
Maximum Armature Current 5 ADC
Maximum Armature Current with Heat Sink* 10 ADC
Field Voltage @ 115 VAC Input 50 VDC/100 VDC
Maximum Field Current 1 ADC
Maximum Armature Voltage Adjustment Range 50–150 VDC
Minimum Armature Voltage Adjustment Range 0–70 VDC
Acceleration Time Range (with no load) 1–12 seconds
Deceleration Time Range (with no load) coast to a stop–12 seconds
Speed Adjustment Potentiometer 10K ohms
Analog Signal Voltage Range (signal must be isolated; S1 to S2) 0–2.7 VDC
Approximate Input Impedance (from S1 to S2) 100K ohms
Speed Regulation (at base speed) 1%
Safety Certification UL Recognized Component, file E132235
CSA Certified Component, file LR41380
Power Device Switching Frequency 18 KHz
Weight 1.4 lb
Ambient Operating Temperature Range 10ºC–40ºC
*Use heat sink kit part number 223-0271 when continuous armature current is
above 5 ADC.
1
Specifications

Model Number XL3025A
Type open chassis
AC Line Voltage 115 VAC/230 VAC, ±10%, 50/60 Hz, single phase
Line Fuse Rating 8 A
Horsepower Range @ 130 VDC Output 1/20–1/4 HP
Horsepower Range @ 240 VDC Output 1/8–1/3 HP
Form Factor 1.05
Maximum Armature Current 3 ADC
Field Voltage @ 115 VAC Input 50 VDC/100 VDC
Field Voltage @ 230 VAC Input 100 VDC/200 VDC
Maximum Field Current 1 ADC
Maximum Armature Voltage Adjustment Range @ 115 VAC Input 60–150 VDC
Minimum Armature Voltage Adjustment Range @ 115 VAC Input 0–70 VDC
Maximum Armature Voltage Adjustment Range @ 230 VAC Input 60–240 VDC
Minimum Armature Voltage Adjustment Range @ 230 VAC Input 0–70 VDC
Acceleration Time Range (with no load) 1–12 seconds
Deceleration Time Range (with no load) coast to a stop–12 seconds
Speed Adjustment Potentiometer 10K ohms
Analog Signal Voltage Range (signal must be isolated; S1 to S2)
for 0–130 VDC Armature Voltage 0–2.7 VDC
for 0–240 VDC Armature Voltage 0–5.0 VDC
Approximate Input Impedance (from S1 to S2) 100 Kohms
Speed Regulation (at base speed) 1%
Vibration 0.5G max (20–50 Hz)
0.1G max (>50 Hz)
Safety Certification UL Recognized Component, file E132235
CSA Certified Component, file LR41380
2 Specifications

Power Device Switching Frequency 18 KHz
Weight 1.4 lb
Ambient Operating Temperature Range 10°C–40°C
3Specifications

Model Number XL3050A
Type open chassis
AC Line Voltage 115 VAC/230 VAC, ±10%, 50/60 Hz, single phase
Line Fuse Rating 10 A
Horsepower Range @ 130 VDC Output 1/8–1/2 HP
Horsepower Range @ 240 VDC Output 1/4–3/4 HP
Form Factor 1.05
Maximum Armature Current 5 ADC
Field Voltage @ 115 VAC Input 50 VDC/100 VDC
Field Voltage @ 230 VAC Input 100 VDC/200 VDC
Maximum Field Current 1 ADC
Maximum Armature Voltage Adjustment Range @ 115 VAC Input 55–150 VDC
Minimum Armature Voltage Adjustment Range @ 115 VAC Input 0–65 VDC
Maximum Armature Voltage Adjustment Range @ 230 VAC Input 55–240 VDC
Minimum Armature Voltage Adjustment Range @ 230 VAC Input 0–65 VDC
Acceleration Time Range (with no load) 1–12 seconds
Deceleration Time Range (with no load) coast to a stop–12 seconds
Speed Adjustment Potentiometer 10K ohms
Analog Signal Voltage Range (signal must be isolated; S1 to S2)
for 0–130 VDC Armature Voltage 0–2.7 VDC
for 0–240 VDC Armature Voltage 0–5.0 VDC
Approximate Input Impedance (from S1 to S2) 100K ohms
Speed Regulation (at base speed) 1%
Vibration 0.5G max (20–50 Hz)
0.1G max (>50 Hz)
Safety Certification UL Recognized Component, file E132235
CSA Certified Component, file LR41380
4 Specifications

Power Device Switching Frequency 18 KHz
Weight 1.5 lb
Ambient Operating Temperature Range 10°C–40°C
5Specifications

Model Number XL3200A
Type open chassis
AC Line Voltage 115 VAC/230 VAC, ±10%, 50/60 Hz, single phase
Line Fuse Rating 15 A
Horsepower Range @ 130 VDC Output 1/4–1/2 HP
Horsepower Range @ 130 VDC Output with Heat Sink* 1/4–1 HP
Horsepower Range @ 240 VDC Output 1/2–1 HP
Horsepower Range @ 240 VDC Output with Heat Sink* 1/2–2 HP
Form Factor 1.05
Maximum Armature Current 5 ADC
Maximum Armature Current with Heat Sink* 9 ADC
Field Voltage @ 115 VAC Input 50 VDC/100 VDC
Field Voltage @ 230 VAC Input 100 VDC/200 VDC
Maximum Field Current 1 ADC
Maximum Armature Voltage Adjustment Range @ 115 VAC Input 55–150 VDC
Minimum Armature Speed Adjustment Range @ 115 VAC Input 0–65 VDC
Maximum Armature Voltage Adjustment Range @ 230 VAC Input 55–240 VDC
Minimum Armature Speed Adjustment Range @ 230 VAC Input 0–65 VDC
Acceleration Time Range (with no load) 1–12 seconds
Deceleration Time Range (with no load) coast to a stop–12 seconds
Speed Adjustment Potentiometer 10K ohms
Analog Signal Voltage Range (signal must be isolated; S1 to S2)
for 0–130 VDC Armature Voltage 0–2.7 VDC
for 0–240 VDC Armature Voltage 0–5.0 VDC
Approximate Input Impedance (from S1 to S2) 100K ohms
Speed Regulation (at base speed) 1%
6 Specifications

Vibration 0.5G max (20–50 Hz)
0.1G max (>50 Hz)
Safety Certification UL Recognized Component, file E132235
CSA Certified Component, file LR4138
Power Device Switching Frequency 18 KHz
Weight 1.6 lb
Ambient Operating Temperature Range 10°C–40°C
*Use heat sink kit part number 223-0271 or equivalent when continuous armature
current is above 5 ADC.
7Specifications

8
S
W50
2
C504
TB
501
L1
C502
FA
S
T-A
C
TIN
G
FU501
I
C502
I
C501
L2
S1
S2
S3
F1
F2
A1
I
C503
C501
BR-
S
W50
1
T
501
A
C1
A
C2
BR+
C505
C503
R
503
TH
501
Q
50
1
IL
502
INHIBI
T
IL
501
CU
R
R
LIMIT
R502
R
501
B1
D
501
B2
Q
50
2
BR
501
4.97 [126
]
4.13
[
105
]
0
.25
[
6
]
5.38
[
137
]
0
.
50"
1.75
[
45
]
H
Dimensions
Figure 1. XLA Series Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
MODEL DIM “H”
XL1100A 3.00 [76]
XL3025A 2.25 [57]
XL3050A 3.00 [76]
XL3200A 3.75 [95]

Figure 2. Heat Sink Dimensions (KIT 223-0271)
9Dimensions
(
4 PLACES
)
0
.1
88
WIDE
S
L
OT
8
-
3
2 TH
D
(
4 PLACES
)
C
C
2.50
[
64
]
2.50
[
64
]
3.15
[
80
]
3.15
[
80
]
6.90 [175
]
1.41
[
35
]
3.08
[
78
]
6
.70
[
170
]
8.41
[
214
]
9
.78
[
248
]
1.00 [25]

10
• 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 the drive in either the horizontal or vertical plane.
Six 0.19-in. (5 mm) wide slots in the chassis accept #8
panhead screws. Fasten wither the large base or the narrow
flange of the chassis to the subplate.
Drive mounting
Installation
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.


11Installation
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 12 AWG wire for AC line voltage (L1 and L2) and motor
armature (A1 and A2) wiring. Use 18 AWG wire for logic ( S1, S2,
and S3) and motor field (F1 and F2) wiring.

12 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.
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.


Heat sinking
XLA series models XL1100A and XL3200A require an additional
heat sink (Minarik part number 223–0271) when the continuous
armature current is above 5 ADC. All other XLA Series drives have
sufficient heat sinking in their basic configuration. Use 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.
Fusing
NOTE: Model XL1100A drives do not require a line fuse on L2.
All XLA Series drives are fused for maximum rated current at 115
VAC line input. A factory installed fuse is connected to L1 (hot) of
the AC line input. See Replacement Parts (page 57) for exact fuse
size. For 230 VAC operation, add an additional line fuse for L2
(neutral). Use a 250 volt, fast-acting fuse rated at 150% of the
maximum armature current. See Table 1 on page 14 for
recommended sizes.
13Installation

Line Fusing for XL Series Drives
Minarik Corporation offers three fuse kits: part number 050–0068
(1–8A Fuse Kit), 050–0070 (3–10A Fuse Kit), and 050–0072
(5–15A Fuse Kit). All fuse kits include a 1/2A pico fuse (part
number 050–0074) which protects the transformer and logic. Refer
to Replacement Parts (page 57) for fuse kit contents.
Table 1. Recommended Line Fuse Sizes
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 2.6 5
1/3 3/4 3.5 8
1/2 1 5.0 10
3/4 1 1/2 7.6 15
1 2 10 15
14 Installation