Minarik BOSS Series User Manual
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Minarik BOSS Series User Manual

Brushless drives
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BOSS Series
Models:
BOSS04-115AC-1Q
BOSS08-115AC-1Q
BOSS15-115AC-1Q
BOSS Series Brushless Drives

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Summary of Contents for Minarik BOSS Series

  • Page 1 BOSS Series Models: BOSS04-115AC-1Q BOSS08-115AC-1Q BOSS15-115AC-1Q 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 5: Table Of Contents

    Contents Specifications Dimensions Installation Drive mounting ..........4 Wiring .
  • Page 6 Contents Operation Before applying power ........25 Startup .
  • Page 7 Illustrations Figure 1. BOSS Series Dimensions ......2 Figure 2. BOSS DB Regen Dump Circuit Dimensions ....3 Figure 3.
  • Page 8 Notes...

  • Page 9: Specifications

    Specifications Maximum Maximum Phase Current Line Input Output Voltage Drive (AC Amps) Voltage Range Voltage Range (VAC) BOSS04-115AC-1Q 90 - 130 100 - 180 BOSS08-115AC-1Q 90 - 130 100 - 180 BOSS15-115AC-1Q 90 - 130 100 - 180 AC Input Voltage Tolerance ±...

  • Page 10: Dimensions

    Dimensions Figure 1. BOSS Series Dimensions...

  • Page 11: Figure 2. Boss Db Regen Dump Circuit Dimensions

    Dimensions Figure 2. BOSS DB Regen Dump Circuit Dimensions...

  • Page 12: 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 13: 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 VAC above ground. To prevent the risk of injury or fatality, avoid direct contact with the printed circuit board or with circuit elements.

  • Page 14: 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 15: 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 terminal AC1 or DC voltage input terminal +VDC, whichever is used. See motherboard connections (Figure 6) on page 14.

  • Page 16: 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 17: 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 18: 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 19: 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 160-0126, 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 20: 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 21: 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 22: Figure 6. Motherboard Connections For

    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 23: 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 24: 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 25: Figure 8. Regen Dump Circuit Connections

    Installation 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 26: Boss-1Q Terminal Descriptions

    Installation BOSS-1Q terminal descriptions NOTE: Make no connection to terminal 7 of the removable terminal plug. Refer to Figure 9 (page 21) for a connection diagram. Refer to Figure 10 (page 23) for information on connecting hall sensors. COM (terminals 1 and 12) Warning Do not connect these terminals to earth ground.
  • Page 27 Installation +V POT (terminal 5) Floating +10 VDC reference for 10K ohm speed adjust potentiometer. SPEED IN (terminal 6) Accepts floating (ungrounded) 0 to +10 VDC reference or 10K ohm speed adjust potentiometer wiper. –V POT (terminal 7) Floating –10 VDC reference; used on future drives. Make no connections to this terminal.

  • Page 28: Boss-1Q Terminal Connections

    Installation BOSS-1Q terminal connections 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. 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.

  • Page 29: Figure 9. Boss-1Q Terminal Connections

    Installation ENABLE/DISABLE SWITCH (SEE NOTE 1) RUN/BRAKE SWITCH (SEE NOTE 2) FWD/REV SWITCH (SEE NOTE 3) NOTES: 1. CLOSE THE ENABLE/DISABLE SWITCH TO COAST THE MOTOR TO A STOP; LEAVE OPEN TO RUN. 2. OPEN THE RUN/BRAKE SWITCH TO BRAKE THE MOTOR TO A STOP; CLOSE THE SWITCH TO RUN.

  • Page 30: Motor Hall Sensors

    Installation Motor hall sensors Warning BOSS series drives provide a +5 VDC supply to drive external sensors. This voltage has a maximum capacity of 20 mADC. To avoid damage to the drive, ensure that any sensor package powered by the BOSS drive does not draw more than 20 mADC.

  • Page 31: Figure 10. Boss-1Q Sensor Connections

    Installation Figure 10. BOSS-1Q Sensor Connections...

  • Page 32: Voltage Follower

    Installation Voltage follower Instead of using a speed adjust potentiometer, BOSS-1Q series drives may be wired to follow a floating voltage signal that is isolated from earth ground. Connect a 0 to +10 VDC signal to terminals 1 and 6 (see Figure 11 for connections). Figure 11.

  • Page 33: 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. Before applying power • Verify that no conductive material is present on the printed circuit board (PCB).

  • Page 34: Startup

    Operation Startup Verify that no conductive material is present on the PCB. Check that the ENABLE/DISABLE switch is in the enable position (open). If no switch is installed, remove the jumper between the ENABLE and COM terminals on TB501. Check that the RUN/BRAKE switch is in the run position (closed).

  • Page 35: Starting And Stopping Methods

    Removing line voltage (AC1 and AC2 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 of the power input leads (see Motherboard Connections on page 12).

  • Page 36: Line Starting And Line Stopping

    Operation Line starting and line stopping Line starting and line stopping (applying and removing AC or DC voltage input) is not recommended for frequent starting and stopping of the drive. It is the only recommended method for emergency stopping of the drive. When AC or DC voltage input is applied to the drive, the motor accelerates to the speed set by the speed adjust potentiometer or analog voltage signal.

  • Page 37: 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 38: Figure 12. Boss-1Q Calibration Trimpot Layout

    Calibration MINIMUM ACCELERATION TQ LIMIT SPEED MAXIMUM REGULATION DECELERATION SPEED Figure 12. BOSS-1Q Calibration Trimpot Layout...

  • Page 39: Calibration Procedure

    Calibration Calibration procedure Calibrate the BOSS-1Q using the following procedure: Ensure that no power is applied to the drive. Set the ENABLE/DISABLE switch to the ENABLE position (open), or remove the short between the ENABLE and COM terminals on TB501. Set the RUN/BRAKE switch to the RUN position (closed), or add a jumper between the RUN/BRAKE and COM terminals on TB501.

  • Page 40: Minimum Speed (Min Spd)

    Calibration MINIMUM SPEED (MIN SPD) The MIN SPD setting determines the motor speed when the speed adjust potentiometer is turned full CCW. It is factory set to zero speed. To calibrate, set the reference potentiometer or reference signal to zero. To set the minimum speed to zero, rotate the MIN SPD trimpot CCW until the motor has stopped.

  • Page 41: Acceleration (Accel)

    Calibration ACCELERATION (ACCEL) The ACCEL setting determines the time the motor takes to ramp to a higher speed. See Specifications (page 1) for approximate acceleration times. The ACCEL setting is factory set to its minimum value (full CCW). Set the speed adjust potentiometer or input signal to zero speed.

  • Page 42: Regulation

    Calibration REGULATION The REGULATION setting determines the degree to which motor speed is held constant as the motor load changes. It is factory set for optimum motor gain. Recalibrate the REGULATION setting when using a lower horsepower motor. Use the following procedure: If the motor does not maintain set speed as the load increases, gradually rotate the REGULATION trimpot CW.

  • Page 43: Torque Limit (Tq Limit)

    Although TQ LIMIT is set to 120% of the drive’s maximum current rating, continuous operation beyond that rating may damage the motor or drive. If you intend to operate beyond the rating, contact your Minarik representative for assistance. The TQ LIMIT setting determines the maximum motor current output of the drive.

  • Page 44: 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 45: Boss-1Q Diagnostic Leds

    Troubleshooting BOSS-1Q Diagnostic LEDs Diagnostic LEDs on the BOSS-1Q plug-in card: POWER ON The POWER ON LED lights when power is applied to the drive and the plug-in card is connected properly. FAULT The FAULT LED lights in any of the following conditions: The hall sensors are miswired, not operating properly, not properly nulled, or draw current in excess of 20 mA.

  • Page 46: Figure 13. Boss-1Q Diagnostic Led Location

    Troubleshooting TORQUE POWER LIMIT LIMIT FAULT Figure 13. BOSS-1Q Diagnostic LED Location...
  • Page 47 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 2. Check motor cable is shorted to ground. and motor for shorts.
  • Page 48 Troubleshooting Symptom Possible Suggested Causes Solutions External line fuse 4. Drive is in torque 4. Verify that motor is does not blow, but limit. not jammed. Increase the motor does not TQ LIMIT setting if run (cont.) it is set too low. 5.
  • Page 49 Troubleshooting Symptom Possible Suggested Causes Solutions Motor runs too 1. MIN SPD or MAX 1. Calibrate MIN SPD slow or too fast at SPEED not calibrated and MAX SPD. set speed properly. 2. Hall sensors 2. Check hall sensor miswired. connections.
  • Page 50 Troubleshooting Symptom Possible Suggested Causes Solutions Motor pulsates or 1. REGULATION is set 1. Adjust the surges under load too high. REGULATION setting until the motor speed stabilizes. 2. Motor “bouncing” in 2. Make sure motor is and out of torque limit. not undersized for load;...
  • Page 51 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 52 Notes...
  • Page 53 Notes...
  • Page 54 Notes...
  • Page 55 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 56 Also available from Minarik Corporation: MMRGD Series DLC600 NRGD Series Digital SCR Regen Digi-Lok© Controller Digital Brush Servo NRG–4Q Series Brush Servo 901 East Thompson Avenue Glendale, California 91201-2011 Tel.: 1-800-MINARIK (646-2745) Fax: 1-800-394-6334 www.minarikcorp.com Document number 250-0224, Revision 2 Printed in the U.S.A –...

This manual is also suitable for:

Boss08-115ac-1qBoss04-115ac-1qBoss15-115ac-1q

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