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Thermo AC-4000 Operating And Service Manual

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OPERATING AND SERVICE MANUAL
AC-4000 CONTROLLER
WAREHOUSE APPLICATION
REC 3838 REV G 10/05
PART NO. 045848

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  • Page 1 OPERATING AND SERVICE MANUAL AC-4000 CONTROLLER WAREHOUSE APPLICATION REC 3838 REV G 10/05 PART NO. 045848...
  • Page 2 OCTOBER 2005 COPYRIGHT 1993, 1994, 1995, 1999 BY THERMO ELECTRON, INC THIS DOCUMENT IS CONFIDENTIAL AND IS THE PROPERTY OF THERMO ELECTRON IT MAY NOT BE COPIED OR REPRODUCED IN ANY WAY WITHOUT THE EXPRESS WRITTEN CONSENT OF THERMO. THIS DOCUMENT ALSO IS AN UNPUBLISHED WORK OF THERMO.

  • Page 3: Table Of Contents

    ICORE PRODUCTS AC-4000 ELECTRONICS TABLE OF CONTENTS CHAPTER TITLE PAGE INTRODUCTION ..........1-1 GENERAL DESCRIPTION .

  • Page 4: Title Page

    AC-4000 OPTIONS ........
  • Page 5 Power Troubleshooting Procedure ........4-18 AC-4000 Electronics (Remote or Local) ....... 5-4 Variable Speed Option .
  • Page 6 APPENDIX TITLE DRAWING NO. Field Wiring Diagram ........Engineer Selected Interconnect Wiring Diagram .
  • Page 7 PREFACE This manual contains information necessary to install, operate, and service the Thermo AC- 4000 Electronics (see Figure 1-1). All persons concerned with the operation and servicing of the electronics should read the contents of this manual carefully and thoroughly. Keep this manual in a convenient place and refer to it often, as it is an important tool in performing proper service.
  • Page 8 AC-4000 ELECTRONICS FIGURE 1-1 REC 3838...

  • Page 9: Introduction

    INTRODUCTION GENERAL DESCRIPTION The AC-4000 Electronics System is a high accuracy machine. When combined with a weighing frame, it performs weight inspection of individual product packages in a production process or package line. The AC-4000 and a weighing frame perform these functions without interrupting product flow.

  • Page 10: System Block Diagram

    SYSTEM BLOCK DIAGRAM FIGURE 1-2 REC 3838...

  • Page 11: 1.1.4 Features

    These options include the following: 1.2.1 15 Programmable Product Set-Ups The set-up parameters for 15 products can be preset into the electronics. The AC-4000 can then be switched from one product to another in a matter of seconds. 1.2.2 Communications (COM) Provides for communication of weight or statistical information from the AC-4000 to a printer, CRT, or host computer.
  • Page 12 TABLE 1-1 TECHNICAL SPECIFICATIONS - AC-4000 ELECTRONICS Package Rate To 350 PPM Accuracy: Displayed Resolution ±1, ±0.1, or ±0.01 Units Zeroing Automatic self zeroing between packages. REZERO light turns on if an autozero cannot occur within two minutes. Environment: Electrostatic Discharge...
  • Page 13 TABLE 1-1 TECHNICAL SPECIFICATIONS - (Continued) REC 3838...

  • Page 14: Warranty

    BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES." FIELD SERVICE Purchaser agrees to underwrite the cost of any labor required for replacement; including time, travel, and living expenses of Thermo Field Service Engineer at closest factory base. Thermo Electron 501 90th Avenue N.W.

  • Page 15: Installation

    Maintenance procedures should be performed only by qualified personnel and in accordance with procedures/instructions given in this manual. During maintenance, a safety tag (not supplied by Thermo) should be displayed in the ON/OFF switch areas as a precaution instructing others not to operate the unit (ANSI:B157.1).

  • Page 16: Occupational Safety And Health Act (Osha)

    Hence Thermo Electron will not be responsible for meeting the full requirements of OSHA in respect to the equipment supplied or for any penalty...

  • Page 17: Equipment Location

    EQUIPMENT LOCATION Careful consideration should be given to the location of the electronics, as system performance is affected by its location. The following requirements must be followed. The electronics should be located so maintenance personnel can easily perform cleaning and adjustment procedures, and so both the control panel and electronics enclosure rear doors are easily accessible.

  • Page 18: Input Power Connections

    INSTALLATION The procedures given below provide for installing the electronics in your production line. INPUT POWER CONNECTIONS FIGURE 2-1 2.6.1 Initial Power On The initial power on procedures describe the checks to be performed before the initial system setup procedures are performed. Verify that the fuses on the Analog Board (Figure 2-2) and Distribution Board (Figure 2-3) inside the controller enclosure are correct for the AC input voltage.

  • Page 19: Analog Board

    ANALOG BOARD FUSE 115VAC 220VAC F1 (for electronics) 3/8A, 3AG, SB 3/16A, 3AG, SB F2 (for line [L2]) 10A, 3AB, SB 10A, 3AB, SB ANALOG BOARD FIGURE 2-2 REC 3838...

  • Page 20: Distribution Board

    DISTRIBUTION BOARD FUSE 115VAC/220VAC F1 (for infeed motor) 5A, 3AG, SB F2 (for weightable motor) 5A, 3AG, SB F3 (for outfeed motor) 5A, 3AG, SB F4 (for line [L1]) 15A, 3AB, SB F5 (for line [L2]) 15A, 3AB, SB DISTRIBUTION BOARD FIGURE 2-3 REC 3838...
  • Page 21 Verify that switch SW-2 on the Analog Board is set to the correct AC input voltage. Verify that the dip switches on the Analog Board are correct for your configuration. The following list defines the standard switch settings for the Analog Board, if the specific options noted are installed.
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  • Page 105 REC 3838...
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  • Page 107: Maintenance

    Before performing any drastic modifications to this machine, refer to your warranty or contact your Thermo Products Field Service Representative. Thermo Products has a repair center located at our plant in Minneapolis, Minnesota. Please contact our Repair Parts Representative at (612)783-2783 for assistance.

  • Page 108: Display Module Replacement

    Place new Display Board in enclosure with Display Board ribbon cable toward the enclosure hinge. Connect front panel cable to Display Board connector J7. 10. Install new Display Board on mounting bolts. 11. Replace mounting hardware securing board to enclosure. 12.

  • Page 109: Display Board Assembly/Module Replacement

    DISPLAY BOARD ASSEMBLY/MODULE REPLACEMENT FIGURE 4-1 REC 3838...

  • Page 110: Communications Board Replacement

    4.3.3 Communications Board Replacement To replace the Communications Board, proceed as indicated below. Turn off power at mains. Open electronics controller enclosure door. Locate the Communications Board (directly above the CPU Board) near the upper, back portion of the enclosure. See Figure 4-2. Gently pull the Communications card handle, extracting the board from the pin connectors.
  • Page 111 Verify fuses. Remove CPU Board and optional Communication Board from old Analog Board and place in the new Analog Board. Verify that the boards are in their proper slots and are fully seated. 10. Place new Analog Board in enclosure. 11.

  • Page 112: Communications, Cpu And Analog Board Replacement

    COMMUNICATION, CPU, AND ANALOG BOARD REPLACEMENT FIGURE 4-2 REC 3838...

  • Page 113: Distribution Board Replacement

    4.3.6 Distribution Board Replacement To replace the Distribution Board, proceed as indicated below. Turn off power at mains. Open the distribution enclosure box (Figure 4-3). Disconnect main AC power cable at Distribution Board terminal block TB-7. Disconnect drive motor cables at Distribution Board terminal block TB-5. Disconnect speed sensor cables at Distribution Board terminal block TB-9.
  • Page 114 21. Apply power to electronics and verify proper operation. REC 3838...

  • Page 115: Distribution Board Replacement

    DISTRIBUTION BOARD REPLACEMENT FIGURE 4-3 DISTRIBUTION BOARD WITH OPTIONS FIGURE 4-4 REC 3838...

  • Page 116: Front Panel Replacement

    4.3.7 Front Panel Replacement To replace the controller front panel door, proceed as indicated below. Fiberglass Enclosure Turn off power at mains. Disconnect the cables (display board, display module ribbon, and pot/switch) attached to the front door. See Figure 4-5. Using a drive pin, force the hinge pin up from the bottom until it can be grasped with a pliers and removed from the controller enclosure door.

  • Page 117: Front Panel Replacement

    FRONT PANEL REPLACEMENT FIGURE 4-5 REC 3838 4-11...

  • Page 118: Motor Speed Control Module Replacement

    11. Apply power to electronics and verify proper operation. 4.3.9 Cold Start Procedure This procedure clears the AC-4000 memory. It is recommended that this procedure be done each time a printed circuit board is changed or memory is scrambled. Thermo also recommends all product and setup information be recorded prior to cold start.
  • Page 119 Front panel display reads: Memory Lost Enter All Values Procedure complete. Press RUN to re-enter the required setup information which is machine prompted. See Section 3.5, Initial Setup Procedure, for required entries. REC 3838 4-13...

  • Page 120: Troubleshooting

    Replaceable Parts in Chapter 5.0. Other section references are provided where necessary. If the procedures recommended do not provide a solution to your particular problem, contact Thermo Products Technical Service for assistance. TABLE 4-1 TROUBLESHOOTING PROCEDURES...
  • Page 121 REC 3838 4-15...
  • Page 122 TABLE 4-1 TROUBLESHOOTING PROCEDURES - Continued SYMPTOM PROBABLE CORRECTIVE ACTION CAUSE Message "A/D Over Input from Check for objects on weightable Ranged" loadcell has that exceed loadcell capacity. exceeded A/D input range Incorrect Conveyor Speed Speed Display speed on front panel and incorrectly set re-adjust speed potentiometer to correct speed.
  • Page 123 TABLE 4-1 TROUBLESHOOTING PROCEDURES - Continued SYMPTOM PROBABLE CORRECTIVE ACTION CAUSE Conveyor slows or stops Seizure of motor Remove drive motor and (continued) shaft bearings rotate shaft. If motor bearings are defective, replace drive motor. Refer to Motor Replacement Procedures in the weightable manual.
  • Page 124 TABLE 4-1 TROUBLESHOOTING PROCEDURES - Continued SYMPTOM PROBABLE CORRECTIVE ACTION CAUSE No Interlocks Dirty interlock Clean interlock. (Use Interlock Test menu) Misaligned Realign interlocks or remove interlock or blockage using visible red blocked path indicator light on receiver as an aid.
  • Page 125 TABLE 4-1 TROUBLESHOOTING PROCEDURES - Continued SYMPTOM PROBABLE CORRECTIVE ACTION CAUSE Weighing not done Interrogate delay Reset interrogate delay. is set too long. Taking too many Decrease amount of A/D samples A/D samples. taken. Weightable belt Slow weightable belt speed. speed is too high.
  • Page 126 TABLE 4-2 POWER TROUBLESHOOTING PROCEDURE ACTION CORRECTIVE ACTION Measure DC Voltages at Analog If all DC Voltages are OK, perform board Board Test Points TP2 and TP3, troubleshooting procedures, refer to Table 4- loadcell excitation voltage at TB3- 1,2 and +12V at TB4-2. Use test connector J13-6 as common.
  • Page 127 TABLE 4-2 POWER TROUBLESHOOTING PROCEDURE ACTION CORRECTIVE ACTION Remove AC power and disconnect If DC Voltage is OK, replace either defective loadcell cables at TB3. Reapply AC loadcell or loadcell cable. Refer to power. Weightable Replacement Procedures in the weightable manual. If DC Voltage is not OK, check speed sensor and interlocks.

  • Page 128: Replacement Parts

    CHAPTER 5.0 REPLACEMENT PARTS GENERAL This chapter gives information on how to order replacement parts for your AC-4000 Electronics and includes photographs and drawings with corresponding parts lists to enable you to identify parts quickly and accurately. ORDER INFORMATION For faster service when ordering parts, fax or telephone Thermo Products Parts Department.

  • Page 129: Parts List Index

    PARTS LIST INDEX Parts lists are cross referenced to photographs or drawings to facilitate identification. These parts lists are indexed as follows: PARTS LIST DESCRIPTION TABLE NO. PAGE NO. AC-4000 Electronics (Remote or Local) REC 3838...

  • Page 130: Return Material Authorization

    5.3.1 Return Material Authorization REC 3838...

  • Page 131: Ac-4000 Electronics

    Display Module 042758 Communication Board 043262 CPU Board 043253 Cable Assembly, Signal and Loadcell (for remote AC-4000 045326 and 8000 series frames) Cable Assembly, Signal and Loadcell (for remote AC-4000 045324 and 20, 25, 40 and 44 series frames) Cable Assembly, COM I/COM II (Optional)
  • Page 132 F1, F2, F3 - 5 amp, Slo-Blo 001369 1 ea F4, F5 - 15 amp, Slo-Blo 045320 1 ea Cable Assembly, Motor/Rejects (for remote AC-4000 and 045325 8000 series frames) Cable Assembly, Motor/Rejects (for remote AC-4000 and 045323 20, 25, 40 and 44 series frames)
  • Page 133 TABLE 5-1 (Continued) Controller Front Panel REC 3838...
  • Page 134 TABLE 5-1 (Continued) Controller Enclosure - Left Side REC 3838...
  • Page 135 TABLE 5-1 (Continued) Controller Enclosure - Right Side REC 3838...
  • Page 136 TABLE 5-1 (Continued) Distribution Enclosure REC 3838...

  • Page 137: Ac-4000 Options

    CHAPTER 6.0 AC-4000 OPTIONS VARIABLE SPEED Variable speed option is provided for those applications requiring variable conveyor line speeds. With the variable speed option, you can adjust the speed of your weightable and infeed or outfeed conveyors right at the front panel. The controls are screw driver adjustable and remain washdown sealed when not in use.

  • Page 138: Installation

    COMMUNICATIONS A communications option is provided for digital communication with external devices such as a printer, terminal, or computer. Both RS-232 and RS-422/485 communications standards are supported and two channels are provided. Baud rates, character size, and parity are front panel selectable. 6.2.1 Installation To install the Communications Board and cable, proceed as follows: Turn off power at mains.

  • Page 139: Communications

    PORT B SWITCH SWITCH SWITCH SWITCH SWITCH SW1-3 SW1-4 SW1-6 SW1-8 SW2-2 DESCRIPTION OFF / OPEN OFF / OPEN ON / CLOSED OFF / OPEN OFF / OPEN EIA-232 with hardware OFF / OPEN ON / CLOSED ON / CLOSED OFF / OPEN OFF / OPEN EIA-232 data leads only...
  • Page 140 REC 3838...

  • Page 141: External Communication Cabling

    AC-4000. This menu outputs the alphabet on the selected serial channel. If the AC-4000 receives the same data back as it sends out, the menu indicates "PASS". Your device probably will not send back the data, so the menu will indicate "FAIL".

  • Page 142: Connections

    RS-485 The connections in Figure 6-3 show the typical connections to hook up the RS485 to your external device. The cabling shown includes a converter that changes the output back to RS-232 before entering your device. If your device has RS-485 capability built in, the converter can be removed and your device hooked directly to connector P2.

  • Page 143: Interconnect Information

    6.2.3 Interconnect Information A 14-pin connector, Amphenol MS3106A-20-27P, is used to hook up an external communications device to the controller. A shielded cable should be used and the shield should be tied to the controller only. The connections are defined in Table 6-3.

  • Page 144: Installation

    This optional software package allows storing of setup parameters and information for up to 15 different products. This information is stored in memory and using the Product menu, the AC-4000 can be switched over from one product to another in a matter of seconds.

  • Page 145: Motor Inhibit

    MOTOR INHIBIT This option is used when an external motor inhibit signal is desired. A closed contact across TB8-1 and 2 of the distribution board allows the motors to run. Motor inhibit is not an E-Stop. See the section on the inhibit input in the motor control manual. The motor controls minimum speed setting must be set properly or the motors may rotate at the minimum speed when the motor inhibit contact opens.
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  • Page 147 Appendix Drawing A/1 Field Wiring Diagram INSERT FIELD WIRING DIAGRAM APPROPRIATE FOR YOUR APPLICATION (See Engineering Manual Request Form or Consult Product Engineer) REC 3838...
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  • Page 159 M M M M 2 2 3 3 0 0 0 0 0 0 S S e e r r i i e e s s SCR, Adjustable Speed Drives for DC Brush Motors...
  • Page 160 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.
  • Page 161 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.
  • Page 162 Contents Safety Warnings ..........i Specifications .
  • Page 163 Startup ...........34 MM23001, MM23011, MM23071, and MM23072 .
  • Page 164 Illustrations Figure 1. MM23001 and MM23011 Dimensions ....3 Figure 2. MM23001C-Q and MM23011C-Q Dimensions ..4 Figure 3.
  • Page 165 Figure 23. RUN/JOG Switch Connection to Inhibit Plug (Option #1) .52 Figure 24. RUN/JOG Switch Connection to Speed Adjust Potentiometer (Option #2) ... . .53 Figure 25. Leader-Follower Application ..... .54 Figure 26.
  • Page 166 Tables Table 1. Recommended Line Fuse Sizes ....19 Table 2. Field Output Connections ......20 Table 3.

  • Page 167: Specifications

    Specifications Max. Armature HP Range HP Range Current with 115 VAC with 230 VAC Model (Amps DC) Applied Applied Style MM23011 1/20–1/8 1/10–1/4 Chassis MM23111 NEMA 1 MM23211 NEMA 1 MM23411 NEMA 4/4X/ 12 MM23072 Chassis MM23001 † 1/8–1/2 1/4–1 Chassis MM23101 ‡...

  • Page 168: Specifications (Continued)

    Specifications Specifications (Continued) Input Impedance (S1 to S2) 100K ohms Load Regulation 1% base speed or better Vibration 0.5G max (0–50 Hz) 0.1G max (>50 Hz) Safety Certification UL Recognized Component, file # E132235 CSA Certified Component, file # LR41380 CE Certificate of Compliance Ambient Temp.

  • Page 169: Dimensions

    Dimensions ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 1. MM23001 and MM23011 Dimensions...
  • Page 170 Dimensions ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 2. MM23001C-Q and MM23011C-Q Dimensions...
  • Page 171 Dimensions TWO 0.88 [22] CONDUIT HOLES ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 3. MM23101 and MM23111 Dimensions...
  • Page 172 Dimensions FOUR MOUNTING SLOTS 0.19 INCHES [5 MILLIMETERS] WIDE TWO 0.88 [22] KNOCKOUTS ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 4. MM23201 and MM23211 Dimensions...
  • Page 173 Dimensions FOUR MOUNTING SLOTS 0.19 INCHES [5 MILLIMETERS] WIDE TWO 0.88 [22] KNOCKOUTS ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 5. MM23401 and MM23411 Dimensions...
  • Page 174 Dimensions FOUR MOUNTING SLOTS 0.19 INCHES [5 MILLIMETERS] WIDE TWO 0.88 [22] KNOCKOUTS ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 6. MM23501 Dimensions...
  • Page 175 Dimensions ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 7. MM23071 and MM23072 Dimensions...
  • Page 176 Dimensions MOUNTING SLOTS 0.19 X 0.34 [5 X 9] ALL DIMENSIONS IN INCHES [MILLIMETERS] PART NO. DIM “A” DIM “B” DIM “C” DIM “D” DIM “E” 223-0159 4.40 [112] 3.00 [76] 0.7 [18] 1.75 [44] 3.90 [100] 223-0174 7.78 [198] 6.00 [152] 0.89 [23] 6.00 [152]...

  • Page 177: Installation

    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. Chassis drives Mounting • Drive components are sensitive to electrostatic fields. Avoid contact with the circuit board directly.

  • Page 178: Wiring

    Installation 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.

  • Page 179: Shielding Guidelines

    Installation Shielding guidelines 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. 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.

  • Page 180: Heat Sinking

    Installation Heat sinking Models MM23001 and MM23071 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. Use a thermally conductive heat sink compound (such as Dow Corning®...

  • Page 181: Quick-Disconnect Terminal Block (C-Q Drives Only)

    Installation Quick-disconnect terminal block (C-Q drives only) The quick-disconnect terminal block, found only on C-Q drives, is composed of a 9-pin header block and 9-screw terminal plug (Figure 8). To use the quick-disconnect terminal block: 1. Carefully pull terminal plug from header block. 2.

  • Page 182: Speed Adjust Potentiometer

    Installation Speed adjust potentiometer Warning Be sure that the potentiometer tabs do not make contact with the potentiometer enclosure. Grounding the input will cause damage to the drive. Mount the speed adjust potentiometer through a 0.38 in. (10 mm) hole with the hardware provided (Figure 9). Install the circular insulating disk between the panel and the 10K ohm speed adjust potentiometer.

  • Page 183: Chassis Drive Connections

    Installation Chassis drive 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 10 (page 20).
  • Page 184 Installation Connect a DC motor to PCB terminals A1 and A2 as shown in Figure 11, page 21. Ensure that the motor voltage rating is consistent with the drive’s output voltage. Power input Connect the AC line power leads to TB501 terminals L1 and L2, or to a double-throw, single-pole master power switch (recommended).
  • Page 185 Installation 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 1/15 1 1/2 Minarik Corporation offers two fuse kits: part number 050–0066 (1–5A Fuse Kit) and 050–0071 (5–15A Fuse Kit).
  • Page 186 Installation Field output connections Warning The field output is for shunt wound motors only. Do not make any connections to F1 and F2 when using a permanent magnet motor. See Table 2 for field output connections. Use 18 AWG wire to connect the field output to a shunt wound motor.
  • Page 187 Installation Figure 11. Chassis Drive Connections...
  • Page 188 Installation Figure 12. MM23201C-Q and MM23011C-Q Connections...

  • Page 189: Voltage Follower

    Installation Voltage follower Instead of using a speed adjust potentiometer, the drive may be wired to follow an analog input voltage signal that is isolated from earth ground (Figure 12). 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.

  • Page 190: Cased Drives

    Installation Cased drives 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. Mounting (NEMA 1 enclosures) NEMA 1 cased drives come with 0.88 inch (22 mm) conduit holes at the bottom of the case.

  • Page 191: Mounting (Nema 12 Enclosures)

    Installation Mounting (NEMA 12 enclosures) NEMA 12 cased drives come with two 0.88 inch (22 mm) conduit knockout holes at the bottom of the case. The units may be vertically wall mounted using the four 0.19 inch (5 mm) slotted holes on the attached heat sink. For motor loads less than 5 ADC, the drive may be bench mounted horizontally, or operated without mounting.

  • Page 192: Heat Sinking

    Installation Heat sinking Models MM23101 and MM23201 require additional heat sinking when the continuous armature current is above 5 ADC. Use Minarik part number 223-0174. All other cased drives have sufficient heat sinking in their basic configurations. Use a thermally ®...

  • Page 193: Connections

    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. The switch contacts should be rated at a minimum of 200% of motor nameplate current and 250 volts.

  • Page 194: Field Output Connections

    Installation Power input Connect the AC line power leads to TB501 terminals L1 and L2, or to a double-throw, single-pole master power switch (recommended). Field output connections Warning The field output is for shunt wound motors only. Do not make any connections to F1 and F2 when using a permanent magnet motor.
  • Page 195 Installation Figure 14. Cased Drive Connections...

  • Page 196: Current Limit Led (C Models Only)

    Installation Current limit LED (C models only) MM23000C series drives are equipped with a red current limit LED. The red current limit LED turns on whenever the drive reaches current limit and turns off whenever the drive is not in current limit (normal operation).

  • Page 197: Mm23001C-Q, Mm23071, And Mm23072 Diagnostic Leds

    Installation MM23001C-Q, MM23071, and MM23072 diagnostic LEDs Models MM23001C-Q, MM23071, and MM23072 are equipped with two diagnostic LEDs: Power (PWR): Lights whenever the AC line voltage is applied to the drive. Current Limit (CURR LIMIT or CL): Lights whenever the drive reaches current limit.

  • Page 198: Before Applying Power

    Operation Warning Change voltage switch settings only when the drive is disconnected from AC line voltage. Make sure both switches are set to their correct position. If the switches are improperly set to a lower voltage position, the motor will not run at full voltage and may cause damage to the transformer.

  • Page 199: Voltage Select Switches

    Operation Voltage select switches Input voltage select (SW501) Set the voltage switch SW501 to either 115V or 230V to match the AC line voltage. See Figure 14. Armature voltage select (SW502) Set the voltage switch SW502 to either 90V or 180V to match the maximum armature voltage.

  • Page 200: Startup

    Operation Startup MM23001, MM23011, MM23071, and MM23072 1. Turn the speed adjust potentiometer full counterclockwise (CCW). 2. Apply AC line voltage. 3. Slowly advance the speed adjust potentiometer clockwise (CW). The motor slowly accelerates as the potentiometer is turned CW. Continue until the desired speed is reached.

  • Page 201: Mm23201 And Mm23211

    Operation MM23201 and MM23211 Warning Do not change the FORWARD / REVERSE switch while the motor is running. The motor must come to a complete stop before reversing. Changing motor direction before allowing the motor to completely stop will cause excessively high current to flow in the armature circuit, and will damage the drive and/or motor.

  • Page 202: Mm23501

    Operation MM23501 Warning The motor must come to a complete stop before reversing. Changing motor direction before allowing the motor to completely stop will cause excessively high current to flow in the armature circuit, and will damage the drive and/or motor. 1.

  • Page 203: Line Starting And Line Stopping

    Operation Starting and stopping methods Warning Decelerating to minimum speed, dynamic braking, or coasting to a stop is recommended for frequent starts and stops. Do not use any of these methods for emergency stopping. They may not stop a drive that is malfunctioning. Removing AC line power (both L1 and L2) is the only acceptable method for emergency stopping.

  • Page 204: Inhibit Terminals

    Operation Inhibit terminals Short the INHIBIT terminals to coast the motor to minimum speed (see Figure 15 for INHIBIT terminal location). Open the INHIBIT terminals to accelerate the motor to set speed. Twist inhibit wires and separate them from power-carrying wires or sources of electrical noise.

  • Page 205: Decelerating To Minimum Speed

    Operation Decelerating to minimum speed The switch shown in Figure 16 may be used to decelerate a motor to a minimum speed. Closing the switch between S1 and S2 decelerates the motor from set speed to a minimum speed determined by the MIN SPD trimpot setting. If the MIN SPD trimpot is set full CCW, the motor decelerates to zero speed when the switch between S1 and S2 is closed.

  • Page 206: Dynamic Braking

    Operation Dynamic braking Warning For frequent starts and stops, short the inhibit terminals, decelerate to a minimum speed, or apply a dynamic brake to the motor. Do not use any of these methods for emergency stopping. They may not stop a drive that is malfunctioning. Removing AC line power (both L1 and L2) is the only acceptable method for emergency stopping.
  • Page 207 Operation Table 4. Minimum Recommended Dynamic Brake Resistor Values Motor Armature Dynamic Brake Voltage Resistor Value 90 VDC 15 ohms 180 VDC 30 ohms For motors rated horsepower and lower, a brake resistor is not necessary since the armature resistance is high enough to stop the motor without demagnetization.

  • Page 208: Calibration

    Calibration Warning Dangerous voltages exist on the drive when it is powered. When possible, disconnect the voltage input from the drive before adjusting the trimpots. If the trimpots must be adjusted with power applied, use insulated tools and the appropriate personal protection equipment.

  • Page 209: Minimum Speed (Min Spd)

    Calibration MINIMUM SPEED (MIN SPD) The MIN SPD trimpot establishes the motor speed obtained in response to the minimum input signal. It is factory set for zero speed. To calibrate the MIN SPD pot, apply the minimum signal. Adjust the MIN SPD trimpot until the motor runs at the desired speed or is just at the threshold of rotation.
  • Page 210 Calibration TORQUE Warning TORQUE should be set to 150% of motor nameplate current rating. Continuous operation beyond this rating may damage the motor. If you intend to operate beyond the rating, contact your Minarik representative for assistance. The TORQUE setting determines the maximum torque for accelerating and driving the motor.

  • Page 211: Ir Compensation (Ir Comp)

    Calibration IR COMPENSATION (IR COMP) The IR COMP trimpot setting determines the degree to which motor speed is held constant as the motor load changes. It is factory set for optimum motor regulation. Use the following procedure to recalibrate the IR COMP setting: 1.
  • Page 212 Calibration Figure 19. Recommended Torque and IR COMP Settings (actual settings may vary with each application)

  • Page 213: Acceleration (Accel)

    Calibration ACCELERATION (ACCEL) The ACCEL setting determines the time the motor takes to ramp to a higher speed. See Specifications on page 1 for approximate acceleration times. ACCEL is factory set for the fastest acceleration time (full CCW). To set the acceleration time: 1.

  • Page 214: Deceleration (Decel)

    Calibration DECELERATION (DECEL) The DECEL setting determines the time the motor takes to ramp to a lower speed. See Specifications on page 1 for approximate deceleration times. DECEL is factory set for the fastest deceleration time (full CCW). To set the deceleration time: 1.

  • Page 215: Application Notes

    Application Notes Multiple fixed speeds Replace the speed adjust potentiometer with series resistors with a total series resistance of 10K ohms (Figure 19). Add a single pole, multi-position switch with the correct number of positions for the desired number of fixed speeds. Figure 20.

  • Page 216: Adjustable Speeds Using Potentiometers In Series

    Application Notes Adjustable speeds using potentiometers in series Replace the speed adjust potentiometer with a single pole, multi-position switch, and two or more potentiometers in series, with a total series resistance of 10K ohms. Figure 20 shows a connection for fixed high and low speed adjust potentiometers. Figure 21.

  • Page 217: Independent Adjustable Speeds

    Application Notes Independent adjustable speeds Replace the speed adjust potentiometer with a single pole, multi- position switch, and two or more potentiometers in parallel, with a total parallel resistance of 10K ohms. Figure 21 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations.

  • Page 218: Run/Jog Switch

    Application Notes RUN/JOG switch RUN/JOG switch option #1 Using a RUN/JOG switch is recommended in applications where quick stopping is not needed and frequent jogging is required. Use a single pole, two position switch for the RUN/JOG switch, and a single pole, normally closed, momentary operated pushbutton for the JOG pushbutton.

  • Page 219: Run/Jog Switch Option #2

    Application Notes RUN/JOG switch option #2 In the second wiring option, connect the RUN/JOG switch and the JOG pushbutton as shown in the Figure 23. When the RUN/JOG switch is set to JOG, the motor decelerates to minimum speed (minimum speed is determined by the MIN SPD trimpot setting). Press the JOG pushbutton to jog the motor.

  • Page 220: Leader-Follower Application

    Application Notes Leader-follower application In this application, use a PCM4 to monitor the speed of the leader motor (Figure 24). The PCM4 isolates the leader motor from the follower drive, and outputs a voltage proportional to the leader motor armature voltage. The follower drive uses this voltage reference to set the speed of the follower motor.
  • Page 221 Application Notes Single speed potentiometer control of multiple drives Multiple drives can be controlled with a single speed adjust potentiometer using a PCM4 at the input of each drive to provide isolation (Figure 25). Optional ratio potentiometers can be used to scale the PCM4 output voltage, allowing independent control of each drive.

  • Page 222: Reversing

    Application Notes Reversing A dynamic brake may be used when reversing the motor direction (Figure 26). Use a three pole, three position switch rated for at least the maximum DC armature voltage and maximum braking current. Wait for the motor to stop completely before switching it to either the forward or reverse direction.

  • Page 223: Reversing With A Digi-Lok Controller

    Application Notes Reversing with a DIGI-LOK controller A DIGI-LOK controller, model DLC600, can be used in a reversing application. The DIGI-LOK must be inhibited while braking. Without the inhibit feature, the DIGI-LOK will continue to regulate. This will cause overshoot when the DIGI-LOK is switched back to the drive. Figure 27 shows the connection of the reversing circuit to a MM23000 series drive and to a DLC600.

  • Page 224: Before Troubleshooting

    Troubleshooting Warning Dangerous voltages exist on the drive when it is powered. When possible, disconnect the drive while troubleshooting. High voltages can cause serious or fatal injury. Before troubleshooting Perform the following steps before starting any procedure in this section: 1.
  • Page 225 Troubleshooting Problem Possible Suggested Causes Solutions Line fuse blows. 1. Line fuse is the wrong 1. Check that the line size. fuse is correct for the motor size. 2. Motor cable or 2. Check motor cable and armature is shorted to armature for shorts.
  • Page 226 Troubleshooting Problem Possible Suggested Causes Solutions Line fuse does not blow, 1. Speed adjust pot or 1. Increase the speed but the motor does not speed reference adjust pot or speed run. voltage is set to zero reference voltage speed. etting.
  • Page 227 Troubleshooting Problem Possible Suggested Causes Solutions Motor runs too fast. 1. MAX SPD and MIN 1. Calibrate MAX SPD SPD are set too high. and MIN SPD. See page 42. 2. Motor field connections 2. Check motor field are loose (shunt wound connections.
  • Page 228 FIgure 29. MM23000 Series Block Diagram...
  • Page 229 Troubleshooting FIgure 30. MM23101, MM23111, MM23401 and MM23411 Terminal Block Connections...
  • Page 230 Troubleshooting FIgure 31. MM23201 and MM23211 Terminal Block Connections...
  • Page 231 Troubleshooting Figure 32. MM23501 Terminal Block Connections...
  • Page 232 Troubleshooting Replacement Parts Replacement parts are available from Minarik Corporation and its distributors for this drive series. Table 5. Replacement Parts Model No. Symbol Description Minarik P/N MM23001 and SCR501, 502 800 V, 20 A SCR 072-0043 MM23071 D501-503 800 V, 20 A Diode 071-0039 R501 0.01 OHM, 5 W Resistor...
  • Page 233 Troubleshooting Table 5. Replacement Parts (continued) Model No. Symbol Description Minarik P/N MM23211 Same as MM23011 except potentiometer kit. Same as MM23201 except fuse. Include: 20KΩ, 10W Resistor 032-0043 3 A, 3AG Fuse 050-0021 MM23411 Same as MM23011 except potentiometer kit, and including: Knob 140-0013 240V Pilot Light...
  • Page 234 CE Compliance Minarik Corporation hereby certifies that its MM23000 series drives have been approved to bear the “CE” mark provided the conditions of approval have been met by the end user. The MM23000 series has been tested to the following test specifications: EN55011:1991 (emissions), and EN50082-1:1992 (immunity)
  • Page 235 CE Compliance Line filters Minarik requires the Corcom ® line filters listed below. Table 6. Corcom® Filters Corcom ® Filter Nameplate Current of Motor Wired to the Drive Part Number 0 to 4 amps 6VV1 4.1 to 13 amps 20VV1 If the exact line filter is not available, the specifications are as follows: L = (1.73 + 0.03) milliHenries.
  • Page 236 CE Compliance Armature filters If the end-user is not using a CE-approved motor, a second filter on the armature must be used. It is Minarik’s CEXXMM. XX = rated current of the filter. Minarik Filters are listed below. Table 7. Minarik Filters Nameplate Current of Minarik Filter Motor Wired to the Drive...
  • Page 237 CE Compliance The end user must use the filters listed in this section to comply with CE. The OEM may choose to provide alternative filtering that encompasses the Minarik drive and other electronics within the same panel. The OEM has this liberty because CE is a machinery directive. Whether or not every component in the OEM’s machinery meets CE, the OEM must still submit his machine for CE approval.
  • Page 238 NOTES...
  • Page 239 NOTES...
  • Page 240 NOTES...
  • Page 241 Unconditional Warranty A. Warranty - Minarik Corporation (referred to as “the Corporation”) warrants that its products will be free from defects in workmanship and material for twelve (12) months or 3,000 hours, whichever comes first, from date of manufacture thereof. Within this warranty period, the Corporation will repair or replace, at its sole discretion, such products that are returned to Minarik Corporation, 901 East Thompson Avenue, Glendale, CA 91201-2011 USA.
  • Page 242 Other drives from Minarik Corporation: DLC600 PCM20000 Series MM-PCM Series XP Series (AC or DC Input) 901 E Thompson Avenue Glendale, CA 91201-2011 Tel.: 1-800-MINARIK (646-2745) Fax: 1-800-394-6334 www.minarikcorp.com Document number 250–0091, Revision 5 Printed in the U.S.A – 10/01 North America $12.00, Outside North America $15.00...

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