Minarik BOSS Series User Manual

Minarik BOSS Series User Manual

Brushless drives
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BOSS Series
Models:
BOSS04-D240AC-4Q
BOSS04-D240AC-CM
BOSS08-D240AC-4Q
BOSS08-D240AC-CM
BOSS15-115AC-4Q
BOSS15-115AC-CM
BOSS Series Brushless Drives

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Summary of Contents for Minarik BOSS Series

  • Page 1 BOSS Series Models: BOSS04-D240AC-4Q BOSS04-D240AC-CM BOSS08-D240AC-4Q BOSS08-D240AC-CM BOSS15-115AC-4Q BOSS15-115AC-CM BOSS Series Brushless Drives...
  • Page 2 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 3 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. • 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.
  • Page 4 Introduction The BOSS series is a family of analog brushless servo controls. They are designed to be flexible and adaptable to a multitude of needs by using the “modular” concept. The modular concept has two parts: a motherboard and a daughter card.
  • Page 6: Table Of Contents

    Contents Specifications Dimensions Installation Drive mounting ..........4 Wiring .
  • Page 7 Contents BOSS-CM Installation ........31 BOSS-CM Terminal Descriptions .
  • Page 8 Contents DECELERATION (DECEL) .......53 GAIN ..........53 FORWARD AND REVERSE TORQUE LIMIT (FWD TQLIM AND REV TQLIM) .
  • Page 9 Illustrations Figure 1. BOSS Series Dimensions .......2 Figure 2. BOSS DB Regen Dump Circuit Dimensions ....3 Figure 3.
  • Page 10 viii Tables Table 1. Recommended Replacement Line Fuse Sizes ....7 Table 2. BOSS-4Q ENABLE/BRAKE Configuration Options ...22 Table 3.
  • Page 11: Specifications

    Specifications Maximum Maximum Phase Current Line Input Output Voltage Drive (AC Amps) Voltage Range Voltage Range (VAC) BOSS04-D240AC 90 - 240 100 - 360 BOSS08-D240AC 90 - 240 100 - 360 BOSS15-115AC 90 - 130 100 - 180 AC Input Voltage Tolerance ±...
  • Page 12: Dimensions

    Dimensions Drive Dimension “A” BOSSxx-115AC 2.62 [67] BOSSxx-D240AC 3.87 [98] All Dimensions in Inches [Millimeters] Figure 1. BOSS Series Dimensions...
  • Page 13: Figure 2. Boss Db Regen Dump Circuit Dimensions

    Dimensions All Dimensions in Inches [Millimeters] Figure 2. BOSS DB Regen Dump Circuit Dimensions...
  • Page 14: Installation Drive Mounting

    Installation Drive mounting 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. • Drive components are sensitive to electrostatic fields. Avoid contact with the circuit board directly.
  • Page 15: 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 240 VAC above ground. To prevent the risk of injury or fatality, avoid direct contact with the printed circuit board or with circuit elements.
  • Page 16: Shielding Guidelines

    Induced voltage can cause unpredictable behavior in any electronic device, including motor controls. Minarik recommends shielding all leads. If shielding 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.
  • Page 17: Fusing

    Installation Fusing An external line fuse must be installed on all BOSS series drives. Connect the external line fuse in series with the AC voltage input or DC voltage input, whichever is used. Do not install a fuse on L2 unless the input voltage is 240 VAC. See motherboard connections (Figure 6) on page 14.
  • Page 18: Plug-In Card Mounting

    Installation Plug-in card mounting Warning Make sure AC or DC line voltage input is disconnected for 30 seconds before installing or removing the plug-in card. To mount the plug-in card to the motherboard, line up the motherboard docking pins to the docking holes (Figure 3). Align the header pins on the plug-in card with the corresponding header sockets on the motherboard.
  • Page 19: Figure 3. Plug-In Card Installation

    Installation (Make sure AC or DC voltage input is removed for 30 seconds before installing or removing plug-in card) Figure 3. Plug-In Card Installation...
  • Page 20: Speed Adjust Potentiometer Mounting

    Installation Speed adjust potentiometer mounting 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-inch (1.0 cm) hole with the hardware provided (Figure 4). Install the circular insulating disk between the panel and the 10K ohm speed adjust potentiometer.
  • Page 21: Quick-Connect Terminal Block

    Quick-connect terminal block The quick-connect terminal block is composed of a header block and terminal plug. The removable terminal plug, Minarik part number 160-0136, connects to the header block as shown in Figure 5. To use the quick-connect terminal block: Carefully pull terminal plug from header block.
  • Page 22: Motherboard Connections

    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 150% of input voltage.
  • Page 23: Line Fusing

    Power switch Warning 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 24: Figure 6. Motherboard Connections For (A) Dc Input Voltage And

    Installation Warning Do not connect AC and DC voltage at the same time. This will destroy the BOSS drive and may result in fire or serious personal injury. Figure 6. Motherboard Connections for (a) DC input voltage and (b) AC input voltage...
  • Page 25: Motor Connections

    Installation Motor connections Connect a three-phase motor to the motherboard as shown in Figure 7. Ensure that the motor’s voltage and current ratings are compatible with the drive ratings before making any connections. Figure 7. Motherboard Connections for Three-Phase Motor...
  • Page 26: Regen Dump Circuit

    Installation Regen dump circuit The regen dump circuit is recommended for all BOSS Series drives. Regenerative loads may cause the bus voltage to increase. The regen dump circuit prevents the voltage across the bus capacitors from exceeding their voltage rating.
  • Page 27: Figure 8. Regen Dump Circuit Connections

    Installation BOSS SERIES DRIVE REGEN DUMP CIRCUIT NOTE: CONNECTIONS SHOWN ARE FOR DC POWER SOURCE. REFER TO FIGURE 6 (PAGE 14) FOR AC POWER SOURCE CONNECTIONS. Figure 8. Regen Dump Circuit Connections...
  • Page 28: Boss-4Q Installation

    Installation BOSS-4Q Installation BOSS-4Q Terminal Descriptions COM (terminals 1 and 13) Warning Do not connect these terminals to earth ground. Circuit common. ENABLE (terminal 2) Short to COM to run the motor; leave open to coast to a stop. BRAKE (terminal 3) Short to COM to brake the motor;...
  • Page 29 Installation –V POT (terminal 7) Floating –10 VDC reference for 10K ohm speed adjust potentiometer. + 15 (terminal 8) Floating +15 VDC supply (25 mA maximum). NOTE: This terminal is not identified on the printed circuit board (PCB) or terminal block. –...
  • Page 30: Boss-4Q Plug-In Card Connections (Tb501)

    Installation BOSS-4Q Plug-in card connections (TB501) ENABLE/DISABLE switch Connect a single-pole, single-throw switch between the COM and ENABLE terminals (terminals 1 and 2) of TB501 as shown in Figure 9. Open the switch to coast the motor to a stop. Close the switch to accelerate to set speed.
  • Page 31: Figure 9. Boss-4Q Terminal Connections

    Installation TB501 NOTES: 1. SEE PG 72 FOR COMMUTATION SEQUENCE 2. SEE PG 22 FOR USE WITH SENSOR FEEDBACK 3. FOR BIDIRECTIONAL OPERATION, CONNECT CCW LEAD OF SPEED ADJUST POTENTIOMETER TO TB501 TERMINAL 4. FOR ENABLE/BRAKE CONFIGURATION OPTIONS SEE TABLE 2 (PAGE 22). Figure 9.
  • Page 32: Motor Hall Sensors

    COAST TO STOP Motor hall sensors Warning BOSS series drives provide a +5 VDC supply to external sensors. This voltage has a maximum capacity of 20 mADC. To avoid damage to the drive, ensure that any sensor package connected to this terminal does not draw more than 20 mADC.
  • Page 33: Figure 10. Boss-4Q Sensor Connections

    Installation Figure 10. BOSS-4Q Sensor Connections...
  • Page 34: Voltage Follower

    Installation Voltage follower Instead of using a speed adjust potentiometer, BOSS-4Q series drives may be wired to follow a floating (differential) –10 VDC to +10 VDC signal that is isolated from earth ground. Connect a voltage signal to terminals 1 and 6 (see Figure 15 for connections).
  • Page 35: Motor Hall Sensor Header Sw502

    Installation Motor hall sensor header (SW502) Set the motor hall sensor header according to the hall effect feedback spacing (see Figure 16 for location). Jumper SW502 if the hall effect feedback spacing is 120°. Do not add a jumper if the hall effect feedback spacing is 60°. Hall sensors are not allowed to be advanced or retarded.
  • Page 36: Mode Select Switches (Sw501)

    Installation Mode select switches (SW501) Warning Be sure that drive power is removed before changing any mode select switch settings. Unpredictable behavior may occur if this warning is not followed. The mode select switches set the BOSS drive to one of the four operating modes: 1.
  • Page 37: Figure 17. Boss-4Q Mode Select Switches

    Installation Table 3. Mode select switch settings Operating Mode Select Switch Modes Voltage Mode (no internal velocity loop) Velocity Mode (Voltage Mode plus internal velocity loop) Tachometer Feedback Mode ON Current Mode X = Don’t care. SW501 Figure 17. BOSS-4Q Mode Select Switches...
  • Page 38: Tb504 Drive Diagnostics

    Installation TB504 Drive Diagnostics TB504 is a 10-pin male connector used for non-isolated drive diagnostics outputs. See Figure 18 for connector location and Table 4 for pin functions. PIN 1 PIN 2 PIN 10 PIN 9 Figure 18. BOSS-4Q TB504 Pin Assignments...
  • Page 39: Table 4. Drive Diagnostics (All Signals Referenced To Pin 4)

    Installation Table 4. Drive Diagnostics (All signals referenced to pin 4) Pins Description Waveform Pin 1- 12 pulses per Tachometer Out revolution, 5 VDC square wave output; proportional to motor speed. Pin 2- 0 VDC when Run/Stop Run/Stop switch is set for run; 5 VDC when Run/Stop switch is set for stop.
  • Page 40 Installation Table 4. Drive Diagnostics (All signals referenced to pin 4) (cont.) Pins Description Waveform Pin 6- AC current in phase A AC Current - is converted to voltage Phase A output (500 mV per amp AC). Pin 7- AC current in phase B AC Current - is converted to voltage Phase B...
  • Page 41: Boss-Cm Installation

    Installation BOSS-CM Installation BOSS-CM Terminal Descriptions COM (terminals 1 and 13) Warning Do not connect these terminals to earth ground. Circuit common. ENABLE (terminal 2) Short to COM to run the motor; leave open to coast to a stop. PWM IN (terminal 3) Accepts a square-wave +5 VDC PWM input from an external signal source.
  • Page 42 Installation +10 VDC (terminal 7) + 10 VDC reference voltage output for reference potentiometer. See Figure 22 (page 46) and Figure 23 (page 47). – 10 VDC (terminal 8) – 10 VDC reference voltage output for reference potentiometer. See Figure 22 (page 46) and Figure 23 (page 47). FAULT OUT (terminal 9) Drive status signal to controller.
  • Page 43: Boss-Cm Plug-In Card Connections To Tb501

    Installation BOSS-CM Plug-in card connections to TB501 ENABLE/DISABLE switch Connect a single-pole, single-throw switch between the COM and ENABLE terminals (terminals 1 and 2) of TB501 as shown in Figure 6. Close the switch to coast the motor to a stop. Open the switch to accelerate to set speed.
  • Page 44 Installation When the wiper is in the center position, the motor will not rotate. The motor will accelerate as the potentiometer is turned in either the forward or reverse direction. Unidirectional operation Connect the reference potentiometer as shown in Figure 16 (page 36) for unidirectional (one-way) operation.
  • Page 45: Figure 15. Boss-Cm Terminal Connections To Tb501

    Installation NOTES: 1. CONNECT ENABLE/DISABLE SWITCH TO TERMINALS 1 AND 2 AS SHOWN. CLOSE TO ENABLE; OPEN TO DISABLE. 2. CONNECT DIR SWITCH TO TERMINALS 1 AND 4 AS SHOWN. OPEN FOR FORWARD DIRECTION; CLOSE TO REVERSE. 3. REFER TO PAGE 36 FOR REFERENCE POTENTIOMETER CONNECTIONS.
  • Page 46: Figure 16. Reference Potentiometer Connection For (A) Bidirectional And (B) Unidirectional Operation

    Installation A) BIDIRECTIONAL OPERATION B) UNIDIRECTIONAL OPERATION NOTE: FORWARD DIRECTION SHOWN. CONNECT CW TERMINAL OF POTENTIOMETER TO -10 VDC (TB501 TERMINAL 8) FOR OPERATION IN THE REVERSE DIRECTION. Figure 16. BOSS-CM Reference Potentiometer Connection for (a) Bidirectional and (b) Unidirectional Operation...
  • Page 47: Motor Hall Sensors

    Installation Motor hall sensors Warning BOSS series drives provide a +5 VDC supply to external sensors. This voltage has a maximum capacity of 20 mADC. To avoid damage to the drive, ensure that any sensor package connected to this terminal does not draw more than 20 mADC.
  • Page 48: Figure 17. Boss-Cm External Sensor Connections

    Installation CONNECT SENSOR AS SHOWN IF SENSOR PACKAGE DRAWS LESS THAN 20 mA AT 5VDC CONNECT SENSOR AS SHOWN IF SENSOR PACKAGE DRAWS MORE THAN 20 mA AT 5VDC Figure 17. BOSS-CM External Sensor Connections...
  • Page 49: Boss-Cm Jumper Settings

    Installation BOSS-CM Jumper Settings BOSS-CM series drives contain two jumper switches, used to configure various outputs. Refer to Figure 18 for jumper locations. Hall Sensor Spacing (J501) Set the motor hall sensor header according to the hall effect feedback spacing (see Figure 18 for location). Jumper J501 if the hall effect feedback spacing is 120°.
  • Page 50: Pwm/Vdc (J502)

    Installation Figure 19. BOSS-CM Hall Sensor Spacer Settings (J501) PWM/VDC (J502) J502 sets the input signal as either an analog voltage signal, reference potentiometer, or PWM input (Figure 20). Jumper terminals 1 and 2 if the input is PWM. Jumper terminals 2 and 3 for analog voltage or reference potentiometer input.
  • Page 51: Operation

    Operation Warning Dangerous voltages exist on the drive when it is powered, and up to 30 seconds after power is removed and the motor stops. BE ALERT. High voltages can cause serious or fatal injury. For your safety, use personal protective equipment (PPE) when operating this drive.
  • Page 52: Startup

    Operation Startup Verify that no conductive material is present on the PCB. Check that the ENABLE switch is in the enable position (closed). If no switch is installed, ensure that a jumper is installed between the ENABLE and COM terminals of TB501.
  • Page 53: Boss-Cm Operation

    Operation BOSS-CM Operation Operating Mode The BOSS-CM provides a current output proportional to the input signal, up to the threshold set by the CURRENT LIMIT trimpot. For example, if the input voltage range is 0-10 VDC, the BOSS-CM current output will be zero with 0 VDC input and maximum current (as defined by the CURRENT LIMIT trimpot setting) with a 10 VDC input.
  • Page 54: Startup

    Operation Startup Verify that no conductive material is present on the PCB. Check that the ENABLE switch is in the enable position (closed), or that a jumper has been installed beween the COM and ENABLE terminals (terminals 1 and 2) of TB501.
  • Page 55: Starting And Stopping Methods

    Removing AC or DC power (both L1 and L2 or +VDC and -VDC) is the only acceptable method for emergency stopping. For this reason, Minarik strongly recommends installing an emergency stop switch on both power input leads (see Connections on page 14).
  • Page 56: To Coast The Motor To A Stop Without Disconnecting Power

    To coast the motor to a stop without disconnecting power: Open the ENABLE switch.
  • Page 57: Calibration

    Calibration Warning Dangerous voltages exist on the drive when it is powered, and up to 30 seconds after power is removed and the motor stops. 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 58: Figure 21. Boss-4Q Calibration Trimpot Dip Switch And Header Layout

    Calibration TACHOGENERATOR HEADER SO501 TEST POINT MODE SELECT (TACH IN) SWITCHES FORWARD DECELERATION REVERSE TACH MAXIMUM COMP TORQUE SPEED LIMIT REVERSE ACCELERATION MINIMUM FORWARD GAIN MAXIMUM SPEED TORQUE SPEED LIMIT Figure 21. BOSS-4Q Calibration Trimpot, DIP Switch and Header Layout...
  • Page 59: Boss-4Q Calibration Procedure

    Calibration BOSS-4Q calibration procedure Ensure that no power is applied to the drive. Set the ENABLE/DISABLE switch to the ENABLE position (closed), or install a jumper between the ENABLE and COM terminals on TB501. Set the RUN/BRAKE switch to the RUN position (open), or remove the jumper between the BRAKE and COM terminals on TB501.
  • Page 60: Minimum Speed (Min Speed)

    Calibration MINIMUM SPEED (MIN SPEED) The MIN setting determines the minimum speed when the speed adjust potentiometer or voltage input signal is set for minimum speed. It is factory set to zero speed. To calibrate MIN SPD: Set the MIN SPD trimpot to the center position (12 o’clock).
  • Page 61: Forward Maximum Speed (Fwd Maxspd)

    Calibration FORWARD MAXIMUM SPEED (FWD MAXSPD) The FWD MAXSPD setting determines the maximum motor speed when the speed adjust potentiometer or voltage input signal is set for maximum forward speed. It is factory set for maximum rated motor speed. To calibrate FWD MAXSPD: Set the FWD MAXSPD trimpot full CCW.
  • Page 62: Acceleration (Accel)

    Calibration ACCELERATION (ACCEL) The ACCEL setting determines the time the motor takes to ramp to a higher speed in the forward direction or a lower speed in the reverse direction. ACCEL is factory set for the fastest acceleration time (full CCW). To calibrate ACCEL: Set the speed adjust potentiometer or voltage input signal for minimum speed.
  • Page 63: Deceleration (Decel)

    Calibration DECELERATION (DECEL) The DECEL setting determines the time the motor takes to ramp to a higher speed in the reverse direction or a lower speed in the forward direction. DECEL is factory set for the fastest acceleration time (full CCW). To calibrate DECEL: Set the speed adjust potentiometer or voltage input signal for maximum forward speed.
  • Page 64: Forward And Reverse Torque Limit (Fwd Tqlim And Rev Tqlim)

    If you intend to operate beyond that rating, contact your Minarik representative for assistance. The TQLIM settings determine the maximum current limit for accelerating and driving the motor. They are factory set at 150% of rated drive current.
  • Page 65 Calibration Slow rotate the FWD TQLIM trimpot clockwise (CW) until the ammeter reads 150% of maximum motor current. Set the speed adjust potentiometer or input signal to zero speed. Remove power from the drive and motor. Set the REV TQLIM trimpot full CCW. 10.
  • Page 66: Tachogenerator (Tach)

    Calibration TACHOGENERATOR (TACH) Warning Be sure that drive power is removed before changing any mode select switch settings. Unpredictable behavior may occur if this warning is not followed. A DC tachometer can be used to augment the hall-effect feedback. Since a tachometer can generate an error voltage down to zero speed, the speed range can be widened considerably.
  • Page 67: Figure 22. Boss-4Q Mode Select Switch Settings

    Calibration 7. Set the MODE SELECT switch (SW501) for tach feedback as follows: Set switch 1 to ON. Set switches 2, 3 and 4 to OFF. Set the GAIN trimpot full CCW. Set the TACH trimpot full CW. 10. Run the motor at full speed. 11.
  • Page 68: Boss-Cm Calibration

    Calibration BOSS-CM Calibration BOSS-CM series drives have one user-adjustable trimpot (Figure 23). Each drive is factory calibrated to its maximum current rating. Readjust the calibration trimpot when using a motor with a lower current rating. All adjustments increase with CW rotation, and decrease with CCW rotation.
  • Page 69: Current Limit

    Although CURRENT LIMIT is set to 150% of drive current rating, continuous operation beyond that rating may damage the motor. If you intend to operate beyond the rating, contact your Minarik representative for assistance. BOSS-CM series drives have one user-adjustable trimpot.
  • Page 70 Calibration Apply line power. The motor should be stopped. Set the speed potentiometer or reference signal to maximum speed. The motor should remain stopped. Slowly rotate the CURRENT LIMIT trimpot clockwise (CW) until the ammeter reads 150% of maximum motor current.
  • Page 71: Troubleshooting

    • Verify that there are no short circuits or grounded connections. • Check that the drive’s rated phase current and RMS voltage are consistent with the motor ratings. For additional assistance, contact your local Minarik® distributor, or the factory direct: 1-800-MINARIK (646-2745) or Fax: 1-800-394-6334.
  • Page 72: Boss-4Q Diagnostic Leds

    Troubleshooting BOSS-4Q Diagnostic LEDs Diagnostic LEDs on the BOSS-4Q plug-in card: POWER ON The green POWER ON LED lights when power is applied to the drive and the plug-in card is connected properly. FAULT The red FAULT LED lights in any of the following conditions: 1.
  • Page 73: Figure 24. Boss-4Q Diagnostic Led Location

    Troubleshooting BUS LIMIT POWER FAULT Figure 24. BOSS-4Q Diagnostic LED Location...
  • Page 74: Boss-Cm Diagnostic Leds

    Troubleshooting BOSS-CM Diagnostic LEDs Diagnostic LEDs on the BOSS-CM plug-in card: POWER ON The green POWER ON LED lights when power is applied to the drive and the plug-in card is connected properly. FAULT The red FAULT LED lights in any of the following conditions: 1.
  • Page 75: Figure 25. Boss-Cm Diagnostic Led Location

    Troubleshooting BUS LIMIT FAULT POWER Figure 25. BOSS-CM Diagnostic LED Location...
  • Page 76 Troubleshooting Symptom Possible Suggested Causes Solutions External line fuse 1. Line fuses are the 1. Check that line blows wrong size. fuses are properly sized for the motor being used. 2. Motor cable or motor is shorted to 2. Check motor cable ground.
  • Page 77 Troubleshooting Symptom Possible Suggested Causes Solutions External line fuse 3. Drive is disabled; 3. Check connections. does not blow, but BRAKE terminal is the motor does not shorted to COM run (cont.) (BOSS-4Q only). 4. Drive is in current 4. Verify that motor is limit.
  • Page 78 Troubleshooting Symptom Possible Suggested Causes Solutions Motor runs too 1. Switches or jumpers 1. Verify all switch slow or too fast at are set incorrectly. and jumper settings. set speed 2. MIN SPD, FWD 2. Calibrate MIN SPD, MAXSPD, and REV FWD MAXSPD, and MAXSPD are not REV MAXSPD.
  • Page 79 Troubleshooting Symptom Possible Suggested Causes Solutions Motor pulsates or 1. GAIN or IR COMP 1. Adjust the GAIN or surges under load is set too high. IR COMP setting until the motor speed stabilizes. 2. Motor “bouncing” in 2. Make sure motor is and out of torque limit.
  • Page 80 Troubleshooting Symptom Possible Suggested Causes Solutions FAULT LED lit 1. The hall sensors are 1. Check hall sensor miswired, not operating wiring. properly, or not properly nulled. 2. The drive reaches its 2. Check that motor is peak phase current properly sized for limit.
  • Page 81 Troubleshooting Symptom Possible Suggested Causes Solutions FAULT LED lit 6. Sensor draws too 6. Check sensor (cont.) much current for BOSS wiring. If sensor drive to supply. needs more than 20 mADC provided by BOSS drive, connect sensor to external power supply.
  • Page 82: Boss Commutation Sequence Diagram

    Troubleshooting BOSS Commutation Sequence Diagram FOR CLOCKWISE ROTATION VIEWING MOTOR FROM MOUNTING FACE Figure 26. Commutation Sequence Diagram...
  • Page 83: Ce Compliance

    CE Compliance Minarik Corporation hereby certifies that its BOSS-4Q and BOSS-CM series drives have been approved to bear the “CE” mark provided the conditions of approval have been met by the end user. The BOSS-4Q/BOSS-CM series have been tested to the following test specifications: EN50081-2/08.93 (emissions), and...
  • Page 84: Ac Line Filters

    CE Compliance AC Line Filters In addition to EMI/RFI safeguards inherent in the BOSS design, external filtering is required. Minarik requires the 20VDK1 filter for all BOSS drives. Wire the AC line filter within 0.25 meters of the drive. The ground connection from the filter must be wired to solid earth ground (resistance less than 500 ohms);...
  • Page 85: Connections

    Figure 27 (page 76). Install an EMI filter on the input power leads as shown in Figure 27 (page 76). Refer to Minarik document 250- 0315, CE Filter Installation Guide, for detailed installation and connection information.
  • Page 86: Ce Filter Part Numbers

    CE Compliance CE Filter Part Numbers Table 5. CE Compliance Part Numbers Description Part # Minarik EMI Filter 20VDK1 Enclosure The BOSS motor control module must be enclosed in a solid metal enclosure (Figure 27). The enclosure lid, body and backplane must all be tied to a low-impedance earth ground (Figure 28).
  • Page 87: Figure 28. Boss Shielding Connections For Ce Compliance

    CE Compliance Figure 28. BOSS Shielding Connections for CE Compliance...
  • Page 88 Notes...
  • Page 89 Notes...
  • Page 90 Notes...
  • Page 91 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,...
  • Page 92 901 East Thompson Avenue Glendale, California 91201-2011 Tel.: 1-800-MINARIK (646-2745) Fax: 1-800-394-6334 www.minarikcorp.com Document number 250-0280, Revision 1 Printed in the U.S.A – 5/01 $11.00 North America – $12.00 Outside North America...

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