Minarik XP-AC Series User manual

Pulse-Width Modulated, Adjustable Speed Drives for DC Brush Motors
USER’S MANUAL
XP-AC SERIES
MODELS
XP02-115AC
XP05-115AC
XP10-115AC

Copyright © 2006 by
Minarik Drives
All rights reserved. No part of this manual may be reproduced or transmitted in any form
without written permission from Minarik Drives. 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 tness 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.

i
m Safety Warnings
Have a qualied electrical maintenance 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 Healthy Act
(OSHA) when installing equipment.
Reduce the chance of an electrical re, 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. Install a
master switch in the AC line for stopping the drive in an emergency.
This drive is not isolated from earth ground. Circuit potentials are at 115 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 adjust-
ing the calibration trimpots.
•
•
•
•

ii
Table of Contents
Specications 1
Dimensions 2
Installation 3
Mounting...............................................................3
Wiring..................................................................3
Heatsinking ............................................................4
LineFusing .............................................................4
Speedadjustpotentiometer ...............................................5
Connections ............................................................6
VoltageFollower .........................................................7
Operation 8
Startup.................................................................8
Linestartingandlinestopping .............................................8
Deceleratingtoastop ....................................................9
Dynamicbraking........................................................10
Calibration 12
MAXSPD..............................................................12
ACCEL/DECEL..........................................................12
IRCOMP...............................................................12
CURRENTLIMIT.........................................................13
ApplicationNotes 15
Multiple Fixed Speeds ...................................................15
Adjustable speeds using potentiometers in series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Independentadjustablespeeds...........................................16

iii
RUN/JOGswitch........................................................16
ConnectiontootherMinarikdevices........................................17
Leader-followerapplication ...............................................18
Single speed potentiometer control of multiple drives . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reversing..............................................................19
Troubleshooting 20
Replacement Parts 23
Limited Warranty inside back cover

iviv
Illustrations
Fig1.XP-ACSeriesDimensions ................................................2
Fig2.SpeedAdjustPotentiometer..............................................5
Fig3.XP-ACConnections......................................................6
Fig4.VoltageFollowerConnection..............................................7
Fig5.Run/DeceleratetoZeroSpeedSwitch......................................9
Fig6.DynamicBrakeConnection..............................................10
Fig 7. Typical CURRENT LIMIT and IR COMP Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fig 8. Multiple Fixed Speeds ..................................................15
Fig 9. Adjustable Fixed Speeds using Potentiometers in Series ......................15
Fig 10. Independent Adjustable Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fig 11. RUN/JOG Switch Connection to Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . 16
Fig 12. Connecting an XP-AC Series Drive to a PCM4 or DLC600 . . . . . . . . . . . . . . . . . . . . 17
Fig13.Leader-FollowerApplication ............................................18
Fig 14. Single Speed Potentiometer Control of Multiple Drives . . . . . . . . . . . . . . . . . . . . . . 18
Fig15.ReversingCircuitConnection ...........................................19

1
Specications
Max. Continuous Armature HP Range with
Model  ArmatureCurrent(AmpsDC) 115VACApplied
XP02-115AC
XP05-115AC
XP10-115AC
2
5
10 †
1/20 - 1/8
1/4 - 1/2
1/2 - 1
ACLineVoltage
ArmatureVoltageRange
Form Factor (at base speed)
Acceleration/Deceleration Time Range (no load)
AnalogInputVoltageRange[isolated;S1(+)toS2(–)]
InputImpedence(S1toS2with5VDCinput)
Speed Regulation
SafetyCertication
Ambient Temperature Range (chassis drive)
Weight
XP02-115AC
XP05-115AC
XP10-115AC
115VAC,±10%,50/60Hz,singlephase
0–130VDC
1.05
0.5-6seconds
0–10VDC
approximately10Kohms
1%basespeedorbetter
ULRecognizedComponent,le#E132235
CSACertiedComponent,le#LR41380
10°C–40°C
0.66lb
0.72 lb
0.82 lb
† Use heat sink part number 223-0159 when operating the drive above 5 ADC.

2
Dimensions
0.73 [19]
1.75 [44]
3.64 [93]
4.30 [109]
3.80 [97]
0.19 [5]
6 PLACES
A-
A+
+ DC IN
- DC IN
R501
R504 R502
CURRENT
LIMIT
MAX SPEED
ACCEL /
DECEL
IR COMP
R503
+
C501
S3
S2
S1
H
W
L
A
1.03 [26]
1.35 [34]
0.19 [5]
SIX MOUNTING SLOTS
0.19 [5] WIDE x 0.34 [9] DEEP
MODEL
XP02-115AC
XP05-115AC
XP10-115AC
DIMENSION “A”
1.77 [45]
2.36 [60]
2.88 [73]
FIGURE1.XP-ACSeriesDimensions

3
Installation
Mounting
Drive components are sensitive to electrostatic elds. Avoid contact with the circuit
board directly. Hold drive by the chassis only.
Protect the drive from dirt, moisture, and accidental contact. Provide sufcient room for
access to the terminal block and calibration trimpots.
Mount the drive away from the other heat sources. Operate the drive within the speci-
ed 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 ange 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.
Wiring
Use 18 AWG wire for speed adjust potentiometer wiring. Use 16 AWG wire for motor
wiring.
Twist logic wires (for speed adjust potentiometer) to avoid picking up unwanted electri-
cal noise. Use shielded cable if wires are longer than 18 in. (46 cm).
Keep logic wires away from power carrying lines or sources of electrical noise that
can cause erratic operation. Never run speed adjust potentiometer wires in the same
conduit used for motor and AC line voltage wires.
•
•
•
•
•
•
•
•
•

4 Installation
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.
Keep logic wires away from the power carrying lines or sources of electrical noise that
can cause erratic operation.
Heat sinking
Model XP10-115AC requires an additional heat sink when the continuous armature cur-
rent is above 5 ADC. Use Minarik®part number 223-0159. All other chassis drives have
sufcient heat sinking in their basic congurations. 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.
Line fusing
Protect all Minarik drives with AC line fuses. Use fast acting AC line fuses rated for 250
volts, and approximately 150% – 200% of the maximum armature current. Fuse only the
“hot” side of the AC line (L1) if using 115 VAC line voltage. See the chart below for recom-
mended line fuse sizes.
•
•
Maximum Armature
Current (DC Amps)
1.5 & below
2.6
3.5
5.0
7.6
10
AC Line Fuse
Rating (AC Amps)
3
5
8
10
15
15
RecommendedLineFuseSizes

Installation 5
Speed adjust potentiometer
Mount the speed adjust potentiometer through a 0.38 in. (10 mm) hole with the hardware
provided (Figure 2). 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, A–, A+).
m WARNING
Be sure that the potentiometer tabs do not make contact with the potentiometer
enclosure. Grounding the input will cause damage to the drive.
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 2. Speed Adjust Potentiometer

6 Installation
ASSUMPTIONS: Minarik drives supply motor voltage from A+ and A– terminals. It is as-
sumed throughout this manual that, when A+ is positive with respect to A–, 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 A+ and A– with
each other.
A-
A+
+ DC IN
- DC IN
R501
R504 R502
CURRENT
LIMIT
CW
10K
Speed Adjust
Potentiometer
MOTOR
ARMATURE
MAX SPEED
ACCEL /
DECEL
IR COMP
R503
PRE-WIRED
Fuse hot 115 VAC leg.
Fuse size typically
150% motor nameplate
continuous rating.
+
C501
S3
S2
S1
H
W
L
LINE VOLTAGE
Figure 3. XP-AC Connections
Connections

Installation 7
Voltagefollower
Instead of using a speed adjust potentiometer, the drive may be wired to follow a
0–10 VDC voltage signal that is isolated from earth ground (Figure 4). Connect signal
input (+) to S1. Connect the signal common (–) to S2. Make no connection to S3. A poten-
tiometer can be used to scale the analog input voltage. To achieve greater linearity and
control, use an interface device such as Minarik® model PCM4 to scale the analog input
voltage. Follow the same wiring guidelines used for speed adjust potentiometer wiring (see
page 3.)
m WARNING
Do not connect a non-isolated input voltage signal to any XP Series drive. Connecting a
non-isolated signal will damage the drive.
A-
A+
+ DC IN
- DC IN
R501
R504 R502
CURRENT
LIMIT
0 – 10 VDC
Isolated Voltage
Signal Input –
+
MAX SPEED
ACCEL /
DECEL
IR COMP
R503
+
C501
S3
S2
S1
H
W
L
Figure4.VoltageFollowerConnections

8
Operation
Startup
Note: Before applying power, verify that no conductive material is present on the printed
circuit board.
To start the drive:
Turn the speed adjust potentiometer full counterclockwise (CCW). If the drive is follow-
ing a voltage signal, set the voltage signal to 0 VDC.
Apply AC line voltage.
Slowly advance the speed adjust potentiometer clockwise (CW). If the drive is following
a voltage signal, slowly increase the voltage signal. The motor slowly accelerates as
the potentiometer is turned CW, or the voltage signal is increased. Continue until the
desired speed is reached.
Remove AC line voltage from the drive to coast the motor to a stop.
If the motor or drive does not perform as described, disconnect the AC line voltage immedi-
ately. Refer to the Troubleshooting section for further assistance.
Line starting and line stopping
Line starting and line stopping (applying and removing AC line voltage) is recommended
for infrequent starting and stopping of a drive only. When AC line voltage is applied to the
drive, the motor accelerates to the speed set by the speed adjust potentiometer. When AC
line voltage is removed, the motor coasts to a stop.
1.
2.
3.
4.

Operation 9
Decelerating to a stop
A switch may be used to decelerate the motor to a stop. Connect the switch as shown in
Figure 5. Close the switch between S1 and S2 to stop the motor from set speed. Open the
switch to accelerate the motor to set speed. The ACCEL/DECEL trimpot setting determines
the rate at which the motor accelerates and decelerates, respectively.
S3
S2
S1
RUN
STOP
CCW
10K Ohm
Speed Adjust
Potentiometer
CW
Figure5.Run/DeceleratetoZeroSpeedSwitch

10 Operation
Dynamic braking
Dynamic braking may be used to rapidly stop a motor (Figure 6). For the simplest RUN/
BRAKE switch, use a double pole, double throw switch rated for at least the maximum DC
armature voltage and maximum braking current. For the most reliable control scheme, use
a relay with a delay on the make for the motor, and use a relay with a delay on the brake
for S1/S2.
S3
S2
S1
A2
CCW
10K Ohm
Speed Adjust
Potentiometer
CW
BRAKE
RUN
A1
DYNAMIC
BRAKE
RESISTOR
MOTOR
Figure6.DynamicBrakeConnection

Operation 11
Size the dynamic brake resistor according to the motor current rating (see the table below).
The dynamic brake resistance listed in the table is the smallest recommended resistance
allowed to prevent possible demagnetization of the motor. The motor stops less rapidly
with higher brake resistor values.
Motor Armature
Current Rating
less than 2 ADC
2–3 ADC
3–5 ADC
5–10 ADC
10–17 ADC
Minimum Dynamic
BrakeResistorValue
1 ohm
5 ohm
10 ohm
20 ohm
40 ohm
RecommendedDynamicBrakeResistorSizes
Minimum Dynamic
BrakeResistorWattage
1W
5W
10W
20W
50W
For motors rated 1/17 horsepower and lower, a brake resistor is not necessary since the
armature resistance is high enough to stop the motor without demagnetization. Replace
the dynamic brake with 12 gauge wire.
m WARNING
Wait for the motor to completely stop before switching it back to RUN. This will prevent
high armature currents from damaging the motor or drive.

12
Calibration
Each drive is factory calibrated to its maximum horsepower rating. Readjust the calibration
trimpot settings to accommodate lower horsepower motors.
All adjustments increase with CW rotation, and decrease with CCW rotation. Use a non-me-
tallic screwdriver for calibration. Each trimpot is identied on the printed circuit board.
MAX SPD
The MAX SPD setting determines the motor speed when the speed adjust potentiometer is
turned full CW. It is factory set for maximum rated speed.
To calibrate, set the MAX SPD trimpot full CCW. Turn the speed adjust potentiometer full
CW. Adjust the MAX SPD trimpot until the desired maximum motor speed is reached.
ACCEL/DECEL
The ACCEL/DECEL setting determines the time the motor takes to ramp to a higher (or
lower) speed. See Specications on page 1 for approximate acceleration times. The
ACCEL/DECEL setting is factory set to its minimum value (full CCW).
Turn the ACCEL/DECEL trimpot CW to increase the acceleration and deceleration time, and
CCW to decrease the acceleration and deceleration time.
IR COMP
The IR COMP setting determines the degree to which motor speed is held constant as the
motor load changes. It is factory set for optimum motor regulation.
Recalibrate the IR COMP setting when using a lower horsepower motor. Refer to the recom-
mended IR COMP settings on page 14, or recalibrate using the following procedure:
If the motor does not maintain set speed as the load changes, gradually rotate the IR
COMP trimpot CW. If the motor oscillates (overcompensation), the IR COMP trimpot may be
set too high (CW). Turn the IR COMP trimpot CCW to stabilize the drive.

Calibration 13
CURRENT LIMIT
The CURRENT LIMIT setting determines the maximum armature current output of the drive.
It is factory set at 120% of rated motor current.
Recalibrate the CURRENT LIMIT setting when using a lower horsepower motor. Refer to
the recommended CURRENT LIMIT settings on page 14, or recalibrate using the following
procedure:
With the power disconnected from the drive, connect a DC ammeter (0–15 A minimum
scale) in series with the armature.
Set the CURRENT LIMIT trimpot to minimum (full CCW).
Connect power to the drive. The motor should remain stopped.
Lock the motor armature. Be sure that the motor is rmly mounted.
Set the speed adjust potentiometer to maximum (full CW).
Adjust the CURRENT LIMIT trimpot CW slowly until the armature current is 120% of
motor rated armature current.
Set the speed adjust potentiometer to minimum and remove the stall from the motor.
1.
2.
3.
4.
5.
6.
7.
m WARNING
Although the CURRENT LIMIT can be set to exceed the motor’s maximum armature
current rating, we recommend you do not run the motor continuously beyond that
rating. Continuous operating beyond the maximum armature current rating may cause
thermal degradation to the motor and drive.

14 Calibration
CURRENT
LIMIT
IR COMP
CURRENT
LIMIT
IR COMP
1/8 HP
90 VDC
1.3 ADC
1/10 HP
90 VDC
1.1 ADC
1/20 HP
90 VDC
0.56 ADC
XP02-115AC
CURRENT
LIMIT
IR COMP
XP05-115AC
1/2 HP
90 VDC
5 ADC
1/3 HP
90 VDC
3.5 ADC
1/4 HP
90 VDC
2.7 ADC
CURRENT
LIMIT
IR COMP
CURRENT
LIMIT
IR COMP
CURRENT
LIMIT
IR COMP
XP10-115AC
CURRENT
LIMIT
IR COMP
CURRENT
LIMIT
IR COMP
CURRENT
LIMIT
IR COMP
1 HP
90 VDC
10 ADC
3/4 HP
90 VDC
7.6 ADC
1/2 HP
90 VDC
5 ADC
Figure 7. Typical CURRENT LIMIT and IR COMP Settings
(actual settings may vary with each application)