Minarik XP-AC-SL Series User manual

XP–AC–SL
Series
Pulse-Width Modulated,
Adjustable Speed Drives
for DC Brush Motors
Models:
XP01–115AC–E10U
XP01–115AC–SL
XP03–115AC–SL

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.

mSafety Warnings
Note: This symbol m denotes an important safety message. Please read
these sections carefully before performing any instructions contained in this
manual.
• Have a qualified 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 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.
i

ii
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Linefusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
XP-AC-SL series connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Line fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
XP-AC-E10U series connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Line fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Voltage follower configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Automatic restart upon power restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

iiiTable of Contents
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Decelerating to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
MINIMUM SPEED (MIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
TORQUE (TQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
IR COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Connection to other Minarik devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Leader-follower application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Single speed potentiometer control of multiple drives . . . . . . . . . . . . . . . . . . . . . . . . .34
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Reversing with a DIGI-LOK® controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Unconditional Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inside back cover

iv
Illustrations
Figure 1. XP-AC-SL Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Figure 2. XP-AC-E10U Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Figure 3. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 4. XP-AC-SL Series Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Figure 5. XP-115AC-E10U Series Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 6. XP-AC-SL Voltage Follower Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 7. XP-115AC-E10U Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 8. Decelerate to Minimum Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Figure 9. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Figure 10. XP-AC-SL CalibrationTrimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Figure 11. XP-AC-E10U Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Figure 12 Recommended Torque and IR COMP Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Figure 13. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Figure 14. Adjustable Fixed Speeds Using Potentiometers in Series . . . . . . . . . . . . . . . . . . . . . .29
Figure 15. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Figure 16. RUN/JOG Switch Connection to Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . .31
Figure 17. Connecting an XP–AC Series Drive to a PCM4 or DLC600 . . . . . . . . . . . . . . . . . . . .32
Figure 18. Leader-Follower Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 19. Single Speed Potentiometer Control of Multiple Drives . . . . . . . . . . . . . . . . . . . . . . . .34
Figure 20. PCM4 Speed Ratio Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Figure 21. Reversing Circuit Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Figure 22. Reversing with a DLC500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Figure 23. XP–AC Series Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Figure 24. XP–AC Series Input Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

1
Specifications
Max. Continuous
Armature HP Range
Current with 115 VAC
Model (DC Amps) Applied
XP01-115AC-E10U 11/100 – 1/25
XP01–115AC-SL 11/100 – 1/25
XP03–115AC-SL 31/20 – 1/4
AC Line Voltage 115 VAC ±10%, 50/60 Hz, single phase
Armature Voltage Range 0–130 VDC
Form Factor (at base speed) 1.05
Acceleration/Deceleration Time Range (no load) 1 second
Analog Input Voltage Range (signal must be isolated) 0 – 5 VDC
Input Impedance (S1 to S2) approximately 150K ohms
Speed Regulation 1% base speed or better
Ambient Temp. Range (chassis drive) 10°C–55°C
Weight 0.3 lb

2
Dimensions
0.1875[5]
TH501
I LIMIT
R502
MAX SPD
.035
R501
FU501
PWR ON
IL501
R503
P501
C501
BR501
C503
C502
D501
IR COMP
P504
IL502
TQ
P503
MIN
P502
Q501
SO501
.052
4.125[105]
4.5[114]
3.00[76]
2.625[67]
0.1875[5]
1.35[34.29]
Figure 1. XP-AC-SL Series Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]

3Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
MAX SPD MIN SPDIR COMP TORQUE PWR ON
L1 L2 A1 A2 S3
S2
S1
TB501
Q501D501
C502
C503
C501
IL501
TH501
R501
BLACK WHITE BLUE YELLOW PURPLE BROWN GRAY
1.95 [50]
2.25 [57]
1.95 [50]
2.25 [57]
Figure 2. XP-AC-E10U Series Dimensions

4
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 on page i 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.
Warning
m
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 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.
Installation

5Installation
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 and the drive is disabled. Opening any one
motor lead may destroy the drive.
Warning
m (
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.

6Installation
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 of 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
mUnder no circumstances should power and logic leads be bundled
together. Induced voltage can cause unpredictable behavior in any
electronic device, including motor controls.

7Installation
Mount the speed adjust potentiometer through a 0.38 in. (10 mm) hole with the
hardare provided (see Figure 3, page 8). 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 the speed adjust potentiometer wires separate from power
leads (L1, L2, A1, A2).
Be sure that the potentiometer tabs do not make contact with the
potentiometer enclosure. Grounding the input will cause damage to
the drive.
Warning
m
Speed adjust potentiometer
Line fusing
Protect all Minarik drives with AC line fuses. For XP03-115AC-SL, use fast acting AC line
fuse rated for 8 amps at 250 volts. For all other XP series drives, use fast acting AC line
fuse rated for 3 amps at 250 volts. Fuse only the “hot” side of the AC line (L1).

8Installation
Figure 3. Speed Adjust Potentiometer
POT TAB ASSIGNMENTS
WIPER
CW CCW
SPEED ADJUST
POTENTIOMETER
INSULATING DISK
PANEL
STAR
WASHER
NUT
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE
NUT
STAR
WASHER
PANEL
CW
CCW
WIPER
SPEED ADJUST
POTENTIOMETER
INSULATING DISK POT TAB ASSIGNMENTS
MOUNT THROUGH A 0.38 IN. (10 MM) HOLE

9
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 5 (page 13). The
switch contacts should be rated at a minimum of 200% of motor
nameplate current and 250 volts.
Warning
m
XP-AC-SL series connections
Connect the power input leads, an external line fuse and a DC motor as shown in
Figure 4 (page 11).
Motor
Minarik drives supply 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.
Connections

10 Connections
Connect a DC motor to terminals A1 and A2 as shown in Figure 4 (page 11). Ensure
that the motor voltage and current ratings are consistent with the drive’s output
voltage and current.
Power input
Connect the AC line power leads to terminals L1 and L2, or to a single-throw, double-
pole master power switch (recommended).
Line fuse
Wire an external line fuse between the stop switch (if installed) and the L1 terminal as
shown in Figure 4. The XP03-115-SL line fuse should be rated at 250 volts and 8
amps.

11Connections
HEADER
BLOCK
TERMINAL
PLUG
L1 DC+
IN F1 A1 S1 S2 S3 A2 F2 DC-
IN L2
L2DC-
IN
F2A2S3S2S1A1F1DC+
IN
L1
SO501
CW
SPD
ADJ
POT
10K Ω
MOTOR
MOTOR
FIELD
LEADS
(SHUNT-
WOUND
MOTORS
ONLY)
115 VAC
INPUT
STOP
SWITCH
FUSE
Figure 4. XP-AC-SL Series Connections
HEADER
BLOCK TERMINAL PLUG FUSE STOP
SWITCH 115 VAC
INPUT
10K OHM
SPEED
ADJUST
POT
CW
S0501
MOTOR
FIELD LEADS
(SHUNT-
WOUND
MOTORS
ONLY)
MOTOR

12 Connections
XP-AC-E10U series connections
Connect the power input leads, an external line fuse and a DC motor to terminal
board TB501 as shown in Figure 5 (page 13).
Motor
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 terminals A1 and A2 as shown in Figure 5 (page 13). Ensure
that the motor voltage and current ratings are consistent with the drive’s output
voltage and current.
Power input
Connect the AC line power leads to terminals L1 and L2, or to a single-throw, double-
pole master power switch (recommended).

13Connections
Line fuse
Wire an external line fuse between the stop switch (if installed) and the L1 terminal.
The line fuse should be rated at 250 volts and 3 amps.
MOTOR
C501
MAX SPD MIN SPD
IR COMP
PWR ON
TB501 D501
IL501
TH501
R501
Q501
STOP
SWITCH FUSE
+
10K Ω
SPEED
ADJUST
POT
CW
115 VAC
INPUT
L1
L2
A1
A2
S3
S2
S1
Figure 5. XP-115AC-E10U Series Connections
115 VAC
INPUT
STOP
SWITCH FUSE
MOTOR
CW
+
10K OHM
SPEED
ADJUST
POT

14
Voltage follower configuration
Connections
Instead of using a speed adjust potentiometer, the drive may be wired to follow a 0–5
VDC voltage signal that is isolated from earth ground (Figure 6 & 7). Connect the
signal input (+) to S2. Connect the signal common (–) to S1. Make no connection to
S3. A potentiometer 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 7 & 8).
Do not connect a non-isolated input voltage signal to any XP Series
drive. Connecting a non-isolated signal will damage the drive.
Warning
m
Figure 6. XP-AC-SL Voltage Follower Connections
A1
S1 S2
S3
SIG (+)
0 - 5 VDC
SIGNAL INPUT
COM (-)
COM (-)
SIG (+)
0 - 5 VDC
SIGNAL INPUT