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Minarik MAC Series User Manual

Variable-frequency drives for 3-phase ac motors
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MAC Series
Models:
MAC03-115AC
MAC06–115AC
MAC03–D240AC
MAC06–D240AC
Variable-frequency drives for 3-phase AC motors

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Summary of Contents for Minarik MAC Series

  • Page 1 MAC Series Models: MAC03-115AC MAC06–115AC MAC03–D240AC MAC06–D240AC Variable-frequency drives for 3-phase AC motors...
  • Page 2 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.
  • Page 3 Follow sound maintenance procedures. • It is possible for a drive to run at full speed as a result of a component failure. Minarik strongly recommends the installation of a master switch in the AC power input to stop the drive in an emergency.

  • Page 4: Table Of Contents

    Contents Safety Warnings Illustrations Tables General Information Specifications Dimensions Installation Mounting ..........5 Wiring .
  • Page 5 Calibration Warning! ..........19 Max Frequency DIP Switch Settings .

  • Page 6: Illustrations

    Illustrations Figure 1. Dimensions ......... .3 Figure 2.

  • Page 7: Tables

    Tables Table 1. Max Frequency DIP Switch Settings ..... .22 Table 2. Torque Boost Calibration DIP Switch Settings ....28 Table 3.

  • Page 8: General Information

    General Information The Minarik AC (MAC) Series are solid-state, microprocessor- based, variable-frequency AC motor drives. With a 120 or 240 VAC, 50/60 Hz, single-phase input, MAC drives are factory calibrated for an output of 0 to 60 Hz*. They will operate any 1 HP or smaller, 115- or 208/230-volt†, three-phase AC induction...
  • Page 9 General Information MAC Series drives feature solid-state reversing with adjustable acceleration and deceleration. They also feature adjustable current limit and I²T class 10 current trip to protect the motor, the control and the driven machine from damage caused by motor overload or machine jamming.
  • Page 10 MAC Series Features • Microprocessor-based • Solid-state circuitry • Adjustable minimum and maximum speed • Adjustable acceleration and deceleration • Solid-state reversing • Adjustable current limit • I ² T current trip (class 10) • Adjustable torque power boost during acceleration •...

  • Page 11: Specifications

    1/6 – 1/2 MAC06-D240AC 6† 1/6–1/2 1/2 – 1 † Requires Minarik heat sink kit p/n 223-0269 when ambient temperature is greater than 25º C AC Voltage Input Range MACxx-115AC drives 120VAC ± 10%, 50/60 Hz single phase MACxx-D240AC drives 120/240VAC ±...

  • Page 13: Dimensions

    Dimensions DRIVE DIM. “H” MAC03-115AC 2.15 [55] MAC06-115AC 2.68 [68] MAC03-D240AC 2.40 [61] MAC06-D240AC 2.68 [68] ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 1. Dimensions...

  • Page 15: Installation

    Installation Mounting • Do not install, remove, or rewire this equipment with power applied. Failure to heed this directive may result in fire or serious injury. • Drive components are sensitive to electrostatic fields. Avoid direct contact with the circuit board. Hold drive by the chassis only.

  • Page 16: Wiring

    Opening any one motor lead may destroy the drive. Shielding guidelines As a general rule, Minarik recommends shielding of all conductors if: 1) wire lengths exceed 6 inches for PWM drives or 18 inches for SCR drives, with separation of power and logic leads;...
  • Page 17 *Minarik considers this an unfavorable condition and does not recommend bundling of power and logic leads for any length. If it is not practical to shield power conductors, Minarik recommends shielding all logic-level leads. If shielding is not practical, the user should twist all logic leads with themselves to minimize induced noise.

  • Page 18: Fusing

    MAC06-series drives require an additional heat sink (Minarik® part number 223-0269) when the continuous phase current is above 5 amps. All other MAC series drives have sufficient heat sinking in their basic configuration. Use a thermally conductive heat sink compound (such as Dow Corning® 340 Heat Sink Compound) between the drive chassis and heat sink surface for optimum heat transfer.

  • Page 19: Figure 2. Speed Adjust Potentiometer

    Installation Warning Be sure that the potentiometer tabs do not make contact with the enclosure. Grounding the input will cause damage to the drive. Figure 2. Speed Adjust Potentiometer...

  • Page 20: Cage-Clamp Terminals

    Installation Cage-clamp terminals MAC Series drive connections include cage-clamp terminals (see Figure 3). To insert a wire into a terminal: 1. Press down on the lever arm using a small screwdriver. 2. Insert wire into the wire clamp. 3. Release the lever arm to clamp wire.

  • Page 21: Power, Fuse And Motor Connections

    Installation Power, Fuse and Motor Connections Figure 4. Power and Motor Connections...

  • Page 22: Signal And Optional Switch Connections

    Installation Signal and Optional Switch Connections Figure 5. Signal and Optional Switch Connections...

  • Page 23: 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 24 Operation 5. Set the ENABLE/DISABLE switch (if installed) to ENABLE, or short the EN and COM terminals on TB501. Set the RUN/BRK switch (if installed) to RUN, or remove the jumper between the BRK and COM terminals on TB501. 6. Apply 120 or 240VAC, 50/60 Hz, single-phase power to the drive.

  • Page 25: To Reverse Motor Direction

    Warning! Allowing the RUN/BRAKE switch to remain in the BRAKE position for an extended period of time may cause motor overheating. Minarik recommends that you disable the drive or remove power if the motor is to remain idle. See Figure 5 for ENABLE/DISABLE switch installation.

  • Page 26: To Coast The Motor To A Stop Without Disconnecting Power

    ENABLE input to reset and restart the drive. Drive thermal protection MAC series drives have built-in thermal protection. If the power stage temperature reaches 100º C, the drive will turn off. The red TRIP LED will then light to indicate a temperature overload...

  • Page 27: Thermal Protection Of The Motor

    Operation Thermal protection of the motor The enable input can also act as a motor thermal protection circuit for motors having a built-in thermal protector. These thermal protectors are operated only by motor heat and open the enable circuit when the motor reaches a temperature which could cause damage to the motor winding.

  • Page 28: Line Starting And Line Stopping

    When AC voltage input is removed, the motor coasts to a stop. Minarik strongly recommends the installation of a master power switch in the voltage input line (see Figure 4, Power, Fuse and Motor Connections). The switch contacts should be rated at a minimum of 200% of motor nameplate current and 250 volts.

  • Page 29: Calibration

    Calibration MAC Series drives have six user-adjustable trimpots. Each drive is factory calibrated to its maximum horsepower rating. Readjust the calibration trimpot settings to accommodate lower horsepower motors. See Figure 7 for trimpot location. All adjustments increase with CW rotation and decrease with CCW rotation.

  • Page 30: Figure 7. Calibration Trimpot Layout

    Calibration TORQUE MAXIMUM ACCELERATION/ LIMIT SPEED DECELERATION SLIP MINIMUM TORQUE COMPENSATION SPEED BOOST Figure 7. Calibration Trimpot Layout...

  • Page 31: Max Frequency Dip Switch Settings

    Calibration Max Frequency DIP Switch Settings UNUSED SWITCHES ARE GREYED OUT Figure 8. DIP Switch Layout Note: Whenever a DIP switch state is changed, it will be ignored by the microprocessor until the drive is disabled, then re-enabled.
  • Page 32 Calibration Table 1. Max Frequency DIP Switch Settings DIP SWITCH BASE SPEED DIP SETTING SWITCH SETTING FREQUENCY (Hz) BASE BASE 60† ON OFF ON OFF OFF OFF OFF OFF NA OFF ON OFF OFF NA † = Default (factory) setting. Footnotes 1.

  • Page 33: Calibration Procedure Setup For 60 Hz Motors

    Calibration Calibration Procedure Setup for 60 Hz Motors: (See Figure 8, pg. 18) 1. Set all switches and trimpots to the OFF, CCW, or DOWN position. Set the TQ LIM trimpot full CW. 2. Set DIP switches 1, 2, and 6 to ON; set DIP switches 3, 4, 5, 7 and 8 to OFF.

  • Page 34: Tq Lim

    Calibration TQ LIM With the speed still set to to maximum and a clamp-on meter clipped around one of the motor leads, load the motor shaft to 120% of the motor nameplate rating. Rotate the TQ LIM trimpot CCW until the current limit LED (not the TRIP LED) lights.

  • Page 35: Tq Boost

    Calibration TQ BOOST Set the speed adjust pot to the slowest speed at which you intend to run the motor under load. Apply a load to the shaft of the motor. This load should be equivalent to the worst-case load the motor will see in your application.

  • Page 36: Accel/Decel

    Calibration ACCEL/DECEL Quickly set the speed adjust pot to zero speed (full CCW) and note the time the motor takes to stop. If the deceleration time differs from the desired time, adjust the ACCEL/DECEL trimpot until the desired time is reached. Rotating the ACCEL/DECEL pot CW slows acceleration, thereby increasing the ramp time.
  • Page 37 Calibration 3. Enable the drive and rotate the speed adjust pot full CW (maximum speed). If no change is noticed (for example, if the motor accelerates quickly enough and does not go into current limit), disable the drive and go to step 4. If an unacceptable difference was noted, restore the DIP switch settings to the previous step.
  • Page 38 Calibration Table 2. Torque Boost Calibration DIP Switch Settings 100†† UNUSED SWITCHES ARE GREYED OUT † Accel torque boost, as a percentage of the TQ boost pot setting, is applied by the drive during acceleration. Once the desired speed is reached, accel torque boost is turned off and only the TQ boost remains.

  • Page 39: Application Notes Thermal Protection Switch Installation

    Application Notes Thermal Protection Switch Installation To provide additional protection for the motor and drive, install a thermal overload protection switch as shown in Figure 9. An option is to install an ENABLE/DISABLE switch in series with the thermal protection switch (Figure 10). MOTOR THERMAL OVERLOAD...

  • Page 40: Decelerate To Minimum Speed

    Application Notes Decelerate to minimum speed The circuit shown in Figure 11 may be used to decelerate a motor to a minimum speed. Closing the switch between S2 and S1 decelerates the motor from set speed to a minimum speed determined by the MIN SPD trimpot setting.

  • Page 41: Decelerate To Minimum With Dc Injection Braking

    Warning! Allowing the RUN/BRAKE switch to remain in the BRAKE position for an extended period of time may cause motor overheating. Minarik recommends that you disable the drive (as shown in Figure 12) or remove power if the motor is to remain idle. Disable the drive or remove power after the motor has come to a stop.

  • Page 42: Independent Adjustable Speeds With

    Application Notes Independent adjustable speeds with FWD-REV switch Replace the speed adjust potentiometer with two single-pole multi-position switches, and two or more potentiometers in parallel, with a total parallel resistance of 10K ohms. Figure 14 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations.

  • Page 43: Run/Jog Switch

    Application Notes RUN/JOG switch 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 open, momentary operated pushbutton for the JOG pushbutton.

  • Page 44: Single Speed Potentiometer Control Of Multiple Motors

    Single speed potentiometer control of multiple motors The MAC series of controls is capable of operating up to eight 3- phase motors simultaneously. All motors must be of the same type and must control similar loads. Connect each motor as shown in Figure 15 below.

  • Page 45: Reversing

    Application Notes Reversing To reverse the direction of motor shaft rotation, remove or install a jumper between the DIR and COM terminals of TB501, as required. An option is to install a single-pole, two-position switch as shown in Figure 16. The drive will brake the motor before reversing, so there is no need to wait for the motor to coast to a stop before changing direction.

  • Page 47: Troubleshooting

    Troubleshooting 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 while troubleshooting. Be alert. High voltages can cause serious or fatal injury.

  • Page 48: Diagnostic Leds

    Troubleshooting Diagnostic LEDs MAC-series drives contain six diagnostic LEDs (see Figure 17, pg. 36): POWER ON (green) The POWER ON LED lights when power is applied to the drive. FAULT (red) The FAULT LED lights in any of the following conditions: 1.
  • Page 49 Troubleshooting REV (amber) The REV LED lights to show the motor is moving in the reverse direction. The LED blinks when the direction input has changed until the motor changes direction. FWD (amber) The FWD LED lights to show the motor is moving in the forward direction.

  • Page 50: Figure 17. Diagnostic Led Layout

    Troubleshooting FORWARD TORQUE LIMIT REVERSE I²T TORQUE TRIP FAULT COM +RUN RLY- POWER Figure 17. Diagnostic LED Layout...
  • Page 51 Troubleshooting LED fault indications Green POWER LED does not light when power is applied. 1. The input voltage may be too low. Check that the input voltage is above 90 VAC. 2. Check that the external fuse(s) is/are not blown. Replace if necessary.
  • Page 52 Troubleshooting Red TRIP LED is lit steadily (does not blink); red TQ LIM LED is not lit. 1. The drive has gone into thermal overload (drive temperature has exceeded 100º C). Red FAULT LED is lit. 1. The control has a power stage failure. 2.

  • Page 53: Clearing Led Fault Indications

    2. Re-install the jumper between the EN and COM terminals of TB501 to close the ENABLE input and restart the drive. To make this process easier, Minarik recommends installing a single-pole, single-throw DISABLE/ENABLE switch between the EN and COM terminals of terminal board TB501. See...
  • Page 54 Troubleshooting Possible Problem Suggested Cause Solution External line fuse 1. Line fuses are the 1. Check that line fuses blows wrong size. are properly sized for the motor being used. 2. Motor cable or 2. Check motor cable and armature is shorted to armature for shorts.
  • Page 55 Troubleshooting Possible Problem Suggested Cause Solution External line fuse 5. Drive is in brake 5. Ensure that BRAKE does not blow, but mode. terminal is not shorted to the motor does not COM terminal. run (cont.) 6. Drive is in current 6.
  • Page 56 Troubleshooting Problem Possible Suggested Cause Solution Motor will not reach 4. Nominal input voltage 4. Compare motor the desired speed may be too low for motor voltage to input voltage (cont.) replace motor if necessary (see page 11) 5. Motor is overloaded. 5.
  • Page 57 4. Compare motor voltage to input voltage. Replace motor if necessary (see page 11). For additional assistance, contact your local Minarik ® distributor, or the factory direct: Tel: (800) MINARIK Fax: (775) 823-9495...

  • Page 58: Replacement Parts

    Replacement Parts Replacement parts are available from Minarik Corporation and its distributors for this drive series. Table 3. Replacement Parts ® Model No. Symbol Description Minarik MAC03-115AC C502-503 470 uF, 200 VDC Capacitor 011-0114 Q502-Q507 IGBT 070-0085 TH501 20-amp Thermistor...
  • Page 59 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 from date of manufacture thereof. Within this warranty period, the Corporation will repair or replace such products that are returned to Minarik Corporation, 901 East Thompson Avenue, Glendale, CA 91201-2011 USA.
  • Page 60 901 E Thompson Avenue Glendale, CA 91201-2011 Tel: (800) MINARIK Fax: (775) 823-9495 www.minarikcorp.com Document number 250–0262, Revision 1 Printed in the U.S.A – 6/99 North America $12.00, Outside North America $15.00...

This manual is also suitable for:

Mac03-115acMac06–115acMac03–d240acMac06–d240ac

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