Related Manuals for Minarik MAC Series
Summary of Contents for Minarik MAC Series
- Page 1 MAC Series Models: MAC05–D240AC MAC08–D240AC MAC05–D240AC-PCM MAC08–D240AC-PCM 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 main power input to stop the drive in an emergency.
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Page 4: Table Of Contents
Contents Specifications Dimensions Installation Mounting ...........3 Wiring . - Page 5 Table of Contents Thermal protection of the motor ......28 Calibration Calibration Procedure Setup for 60 Hz Motors (See Figure 12): ..34 MINIMUM SPEED (MIN SPD) .
- Page 6 Illustrations Figure 1. Dimensions ......... .2 Figure 2.
- Page 7 Tables Table 1. Motor Phase DIP Switch Settings ......15 Table 2. Voltage Doubler Configuration ......19 Table 3.
- Page 8 General Information Minarik MAC Series drives are voltage-vector-controlled, microprocessor-based, variable-frequency AC motor drives. With a 115 or 230 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 motor through a speed range of zero* through nameplate speed.
- Page 9 33 kHz. The MAC is one of the only drives on the market with truly silent operation. 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 Caution should be taken when operating fan-cooled motors at low speeds because their fans may not move sufficient air to properly cool the motor. Minarik recommends “inverter- duty” motors when the speed range is beyond 10:1. IMPORTANT INFORMATION...
- Page 11 General Information MAC Series Features • Microprocessor-based • Voltage-vector-control drive • True 16.5 kHz carrier frequency (in silent mode) • Solid-state circuitry • Adjustable minimum and maximum speed • Adjustable acceleration and deceleration • Solid-state reversing • Adjustable current limit •...
- Page 12 Notes...
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Page 13: Specifications
Specifications Peak Continuous HP Range HP Range Phase Current Phase Current with 120 VAC with 240 VAC Drive Model Number (ADC) (ADC) Applied* Applied MAC05-D240AC(-PCM) 1/15–1/4* 1/6 – 1/2 MAC08-D240AC(-PCM) 8† 1/4–1/2* 1/2 – 1 AC Voltage Input Range 120/240 VAC ± 10%, 50/60 Hz single phase Output Frequency Range 3 –... -
Page 14: Dimensions
Dimensions ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 1. Dimensions... -
Page 15: Installation Mounting
Installation Mounting Warning Do not install, remove, or rewire this equipemnt with power applied. Failure to heed this warning may result in fire, explosion, or serious injury. The chassis must be earth grounded. Use a star washer beneath the head of at least one of the mounting screws to penetrate the anodized chassis surface and to reach bare metal. -
Page 16: Wiring
Installation • Mount drive with its board in either a horizontal or vertical plane. Six 0.19 in. (5 mm) wide slots in the chassis accept #8 pan head screws. Fasten either the large base or the narrow flange of the chassis to the subplate. Wiring Warning Do not install, remove, or rewire this equipment with power... -
Page 17: Shielding Guidelines
As a general rule, Minarik recommends shielding of all conductors. If it is not practical to shield power conductors, Minarik recommends shielding all logic-level leads. If shielding logic leads is not practical, the user should twist all logic leads with themselves to minimize induced noise. -
Page 18: Isolation (-Pcm Drives Only)
MAC08-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: Speed Adjust Potentiometer
Installation Speed adjust potentiometer Warning Be sure that the potentiometer tabs do not make contact with the 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 2). Install the circular insulating disk between the panel and the 10K ohm 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: Connections
Do not install, remove, or rewire this equipemnt with power applied. Failure to heed this warning may result in fire, explosion, or serious injury. Minarik strongly recommends the installation of a master power switch in the voltage input line, as shown in Figure 4 (page 10). The switch contacts should be rated at a minimum of 200% of drive current and 250 volts. -
Page 22: Power And Fuse Connections
2. Install a line fuse on L1 as shown. Do not install a line fuse on L2 unless the input voltage is 240 VAC. Minarik strongly recommends the installation of a master power switch in the voltage input line, as shown in Figure 4. - Page 23 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 10, page 27) or remove power if the motor is to remain idle. Disable the drive or remove power after the motor has come to a stop.
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Page 24: Figure 5. Signal And Optional Switch Connections
Installation 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. The amber FWD or REV LED will blink as the drive decelerates the motor but before it has changed direction. TB501 Figure 5. -
Page 25: Motor Connections
It is very important that terminal U be left open (no connection) for single-phase operation. If the motor and capacitor are sold separately, Minarik highly recommends buying only the motor and operating in 2-phase mode. The resulting speed range will be considerably wider, while starting torque will approach that of a 3-phase motor. -
Page 26: Figure 6. Motor Connections For Single-Phase Operation
Installation NOTE: MAKE NO CONNECTION TO TERMINAL “U” DIP SWITCH 5 = ON Figure 6. Motor Connections for Single-Phase Operation (Motor With Pre-Wired Capacitor) -
Page 27: Three-Phase Motors
Installation Three-phase motors NOTE: Ensure that DIP switch 5 on SW501 is set to OFF for three-phase motor operation. Connect a three-phase motor to terminals U, V and W as shown in Figure 7 (page 16). Table 1. Motor Phase DIP Switch Settings MOTOR DIP SWITCH PHASE... -
Page 28: Figure 7. Motor Connections For Three-Phase Motors
Installation DIP SWITCH 5 = OFF Figure 7. Motor Connections for Three-Phase Motors... -
Page 29: 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. Do not use the voltage-doubling feature when line voltage is greater than 120 VAC. -
Page 30: Voltage Doubler
Do not apply line voltage greater than 120 VAC. Jumper wire, if used, must be 14 AWG (1.63 mm) or greater. Minarik highly recommends using the jumper included with the MAC drive. MAC-series drives are equipped with a unique voltage-doubling feature, for use when 240 VAC input voltage is not available. -
Page 31: To Enable Voltage Doubling
Operation To enable voltage doubling: 1. Verify that the line voltage source is 120 VAC. Do not apply power at this time. 2. Add a jumper to the voltage doubling terminals. Refer to Figure 8 for terminal location. Table 2. Voltage Doubler Configuration Jumper Setting Input Voltage Output Voltage... -
Page 32: Before Applying Power
Operation Before applying power 1. Verify that no conductive material is present on the PCB. 2. Verify that the voltage output is properly set by installing or removing a jumper on the voltage doubler terminals, as required. Refer to Figure 8 (page 19). 3. -
Page 33: Startup
Operation Startup NOTE: When power is applied, a one-second delay will occur before motor operation. 1. Apply 120 or 240 VAC, 50/60 Hz, single-phase power to the drive. The green POWER LED will come on. If it does not, check the external line fuses to ensure that they are properly installed and not blown. -
Page 34: To Reverse Motor Direction
Operation To reverse motor direction: When the motor is running in the forward direction, the amber FWD LED will light; when the motor is running in reverse, the amber REV LED will come on. To reverse the direction of motor shaft rotation while the motor is running, set the FWD/REV switch to the opposite position. -
Page 35: Starting And Stopping Methods
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 (page 12) for ENABLE/DISABLE switch installation. -
Page 36: I²T Trip Operation (Class 10 Characteristics)
ENABLE input to reset and restart the drive. Line starting and line stopping Warning Minarik strongly recommends the installation of a master power switch in the voltage input line (see Figure 4, page 10). The switch contacts should be rated at a minimum of 200% of drive current and 250 volts. -
Page 37: Decelerate To Minimum Speed
Operation Decelerate to minimum speed The circuit shown in Figure 9 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. If the MIN SPD trimpot is set full CCW, the motor decelerates to zero speed when the switch between S2 and S1 is closed. -
Page 38: Decelerate To Minimum With Dc Injection Braking
Disable the drive or remove power after the motor has come to a stop. The MAC series is equipped with DC injection braking, for use with high-inertia applications. As a rule, DC motors do not convert AC ripple in the DC voltage to mechanical energy;... -
Page 39: Figure 10. Run-Brake Switch With Optional Enable-Disable Switch
Operation When injection braking is selected and the drive is disabled, the normal AC phase output to the motor from the drive is set to its minimum frequency. The drive simultaneously introduces a DC voltage (not to exceed the threshold set by the CURRENT LIMIT trimpot) into the motor stator. -
Page 40: Drive Thermal Protection
Operation 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 condition. 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. -
Page 41: Figure 11. Thermal Overload Switch With Optional Enable/Disable Switch
Operation TB501 Figure 11. Thermal Overload Switch with Optional Enable/Disable Switch... -
Page 42: Calibration
BE ALERT. High voltages can cause serious or fatal injury. 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. -
Page 43: Figure 12. Calibration Trimpot Layout
Calibration TORQUE ACCELERATION/ MAXIMUM BOOST DECELERATION SPEED CURRENT MINIMUM SLIP LIMIT SPEED COMPENSATION Figure 12. Calibration Trimpot Layout... -
Page 44: Figure 13. Dip Switch Layout And Initial Settings
Calibration Max Frequency DIP Switch Settings NOTE: Whenever a DIP switch state is changed, it will be ignored by the microprocessor until the drive is disabled, then re-enabled. NOTE: DIP switches are shown in their initial settings prior to drive calibration. Figure 13. -
Page 45: Table 3. Max Frequency Dipswitch Settings
Calibration Table 3. Max Frequency DIP Switch Settings (SW501) 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 46: Calibration Procedure Setup For 60 Hz Motors (See Figure 12)
Calibration Calibration Procedure Setup for 60 Hz Motors (See Figure 12): 1. Set all trimpots except I LIMIT and TQ BOOST full counterclockwise (CCW). 2. Set the I LIMIT trimpot full CW. 3. Set the TQ BOOST trimpot to the 12 o’clock position. 4. -
Page 47: Figure 14. Carrier Frequency Mode Dip Switch Layout
Calibration Table 4. Carrier Frequency DIP Switch Settings DIP SWITCH MODE #7 SETTING † SILENT ON†† NORMAL SILENT MODE “ON” Figure 14. Carrier Frequency Mode DIP Switch Layout † Silent mode operates with a fundamental carrier frequency of 16/32 kHz. Normal mode operates with a fundamental carrier frequency of 11/22 kHz. -
Page 48: Minimum Speed (Min Spd)
Calibration MINIMUM SPEED (MIN SPD) Apply power to the drive. Slowly rotate the MIN SPD trimpot CW until the motor begins to turn, then slowly rotate the pot CCW until the motor just stops. This step calibrates the MIN SPD pot to zero speed without hysteresis. MAXIMUM SPEED (MAX SPD) Rotate the speed adjust pot full CCW. -
Page 49: Slip Compensation (Slip Comp)
Calibration SLIP COMPENSATION (SLIP COMP) Increase the motor speed to maximum. Slowly load the motor until the AC phase current is at its maximum (100%). If the motor slowed at all, rotate the SLIP COMP trimpot CW until the motor shaft rotates at the original set speed. ACCELERATION/DECELERATION (ACCEL/DECEL) Quickly set the speed adjust pot to zero speed (full CCW) and note the time the motor takes to stop. -
Page 50: Torque Boost Adjustment
Calibration Torque Boost Adjustment OPTIONAL: To increase system efficiency, the torque boost may be increased at this time. Torque boost should be set to zero if the motor has no load or a slight load. If the drive trips, or the TQ LIMIT LED flickers or illuminates during acceleration, you must increase the torque boost setting. -
Page 51: Figure 15. Accel Torque Boost Dip Switch Setting
Calibration Table 5. Torque Boost DIP Switch Settings TORQUE DIP SWITCH BOOST #4 SETTING 115% 100% TORQUE BOOST SET TO 115% Figure 15. Torque Boost DIP Switch Setting... -
Page 52: 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 16. An option is to install an ENABLE/DISABLE switch in series with the thermal protection switch (Figure 17). TB501 Figure 16. -
Page 53: 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 18 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations. -
Page 54: 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 55: 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 20 below. -
Page 56: 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 21. 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 57: Voltage Follower
NOTE: An isolated reference signal must be used with the non- PCM MACdrive. Do not use a grounded reference with any non- PCM MAC series drive. TB501 Figure 22. Voltage Follower Connections... -
Page 58: 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 59: Diagnostic Leds
Troubleshooting Diagnostic LEDs MAC-series drives contain six diagnostic LEDs (see Figure 23, pg. 49): POWER ON (green) The green POWER ON LED lights when power is applied to the drive. FAULT (red) The red FAULT LED lights in any of the following conditions: 1. -
Page 60: Rev (Amber)
Troubleshooting REV (amber) The amber 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 amber FWD LED lights to show the motor is moving in the forward direction. -
Page 61: Figure 23. Diagnostic Led Layout
Troubleshooting FAULT POWER TORQUE I²T TORQUE LIMIT TRIP REVERSE FORWARD Figure 23. Diagnostic LED Layout... - Page 62 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 63 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.
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Page 64: 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 Signal and... - Page 65 Troubleshooting Problem Possible 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 or motor 2. Check motor cable and cable is shorted to motor for shorts.
- Page 66 Troubleshooting Possible Problem Suggested Cause Solution External line fuse 4. Drive has been 4. Ensure that EN and does not blow, but disabled. COM terminals are the motor does not properly connected. run (cont.) 5. Drive is in brake 5. Ensure that BRAKE mode.
- Page 67 Troubleshooting Problem Possible Suggested Cause Solution Motor will not reach 3. BOOST and SLIP 3. Recalibrate BOOST the desired speed COMP settings are too and SLIP COMP settings (cont.) low. (pp 37-38). 4. Nominal input 4. Compare motor voltage may be too voltage to input voltage;...
- Page 68 Troubleshooting Possible Problem Suggested Cause Solution Motor does not 1. Bad FWD/REV 1. Check FWD/REV reverse switch connection. switch connection. 2. Reversing circuit 2. Check reversing circuit not working properly. by shorting FWD/REV terminal to COM terminal with jumper wire. TQ is unsatisfactory 1.
- Page 69 Troubleshooting Problem Suggested Solution Drive goes into 1. Motor is 1. Resize motor or use current limit or I 2 T undersized for load. proper drive for motor. trip on power-up 2. TQ BOOST set too 2. Reduce TQ BOOST high.
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Page 70: Replacement Parts
Troubleshooting Replacement Parts Replacement parts are available from Minarik Corporation and its distributors for this drive series. Table 6. Replacement Parts ® Model No. Symbol Description Minarik MAC05-D240AC C502-503 1000 uF, 200 VDC Capacitor 011-0096 Q502-Q507 IGBT 070-0085 TH501 20-amp Thermistor... - Page 71 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 91151-2011 USA.
- Page 72 901 E Thompson Avenue Glendale, CA 91201-2011 Tel: (800) MINARIK (646-2745) Fax: (800) 394-6334 www.minarikcorp.com Document number 250-0275, Revision 2 Printed in the U.S.A – 01/01 North America $12.00, Outside North America $15.00...
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