Minarik NRG–2Q Series User Manual
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Minarik NRG–2Q Series User Manual

Two quadrant, regenerative pwm drives for dc brush motors
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NRG–2Q
Series
Two Quadrant, Regenerative PWM Drives
for DC Brush Motors

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Summary of Contents for Minarik NRG–2Q Series

  • Page 1 NRG–2Q Series Two Quadrant, Regenerative PWM Drives for DC Brush Motors...
  • 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 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.

  • Page 4: Table Of Contents

    Contents Specifications NRG02–D240AC–2Q .........1 NRG05–D240AC–2Q .
  • Page 5 Application Notes Connection to other Minarik devices ......35 Optional speed adjust potentiometer connections ....36 Multiple fixed speeds .
  • Page 6 Illustrations Figure 1. NRG–2Q Dimensions ........4 Figure 2.

  • Page 7: Specifications

    Specifications Model Number NRG02–D240AC–2Q Type Open Chassis AC Line Voltage 115 VAC or 230 VAC, ±10%, 50Hz or 60 Hz, single phase Maximum Continuous Armature Current 2 ADC Horsepower Range @ 130 VDC Output 1/20 – 1/4 Horsepower Range @ 240 VDC Output 1/10 –...

  • Page 8: Nrg05-D240Ac-2Q

    Specifications Model Number NRG05–D240AC–2Q Type Open Chassis AC Line Voltage 115 VAC or 230 VAC, ±10%, 50Hz or 60 Hz, single phase Maximum Continuous Armature Current 5 ADC Horsepower Range @ 130 VDC Output 1/8 – 3/4 Horsepower Range @ 240 VDC Output 1/4 –...

  • Page 9: Nrg10-115Ac-2Q

    Specifications Model Number NRG10–115AC–2Q Type Open Chassis AC Line Voltage 115 VAC, ±10%, 50Hz or 60 Hz, single phase Maximum Continuous Armature Current 10 ADC Horsepower Range @ 130 VDC Output 1/4 – 1 1/2 Maximum Armature Voltage Range 0–130 VDC Form Factor 1.03 Acceleration Time Range...

  • Page 10: Dimensions

    Dimensions D 5 0 1 C506 C 503 C 5 0 1 L 5 0 1 L 5 0 3 AC C EL C 505 D E C E L C 502 4.44 [113] 4.44 [113] 3.00 [76] L 5 0 2 3.00 [76] C504 SO503...

  • Page 11: Regenerative Drives

    Regenerative Drives Most non-regenerative, variable speed, DC drives control current flow to a motor in one direction. The direction of current flow is the same direction as the motor rotation. Non-regenerative drives operate in Quadrant 1 (see Figure 2, page 6). Unless dynamic braking is used, non-regenerative drives decelerate a load faster than coasting to a lower speed.

  • Page 12: Figure 2. Two Quadrant Operation

    Regenerative Drives Figure 2. Two Quadrant Operation...

  • Page 13: Installation

    Installation Drive mounting Warning Do not install, rewire, or remove this control with power applied. Doing so may cause fire or serious injury. Make sure you have read and understood the Safety Warnings before attempting installation. 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 14: 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 15: 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 16: Line Fusing

    90 VDC Motor 180 VDC Motor 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 050–0069 (3–8A Fuse Kit) and 050–0073 (5–20A Fuse Kit). See Replacement Parts (page 49) for fuse kit contents.

  • Page 17: Connections

    (PCB) as shown in Figure 3 (page 13). Motor connections Minarik drives supply motor voltage from A1 and A2 terminals. It is assumed throughout this manual that, when A1 is positive with respect to A2 , the motor will rotate clockwise (CW) while looking at the output shaft protruding from the front of the motor.

  • Page 18: Power Lead Connections

    Installation Power lead connections Connect the AC line power leads to TB501 terminals L1 and L2, or to a double-throw, single-pole master power switch (recommended). Dynamic brake resistor connections If you plan to use dynamic braking to stop the motor, you must connect a dynamic brake resistor across the DB+ and DB- terminals on the PCB as shown in Figure 3.

  • Page 19: Figure 3. Nrg-2Q Connections

    Installation Also see Dynamic brake resistor sizing, page 23. Figure 3. NRG–2Q Connections...

  • Page 20: Inhibit Personality Header

    Installation Inhibit personality header The inhibit personality header (SO503) determines how the drive responds when the INHIBIT terminals (SO501) are shorted together. Set the inhibit personality before shorting the inhibit terminal to each other. Jumper pins 1 and 2 for a dynamic brake response, or pins 2 and 3 for a disable output response (coast to a stop).

  • Page 21: Figure 4. Inhibit Personality Header, Inhibit Terminals And +12 Vdc Terminals

    Installation Inhibit Personality Header Inhibit Terminals +12 VDC Terminals Figure 4. Inhibit Personality Header, Inhibit Terminals, and +12 VDC Terminals...

  • Page 22: Voltage Follower Connection

    Installation Voltage follower connection Instead of using a speed adjust potentiometer to set motor speed, the drive may follow a floating (isolated) 0 to +5 VDC signal. Connect the signal input to S2, and signal common to S1. Make no connection to S3. See Figure 5. Figure 5.

  • 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. Before applying power • Verify that no conductive material is present on the printed circuit board.

  • Page 24: Startup And Shutdown

    Operation Startup and shutdown 1. Set the speed adjust potentiometer for zero speed (full CCW). If the drive is following a voltage signal, set the voltage signal to 0 VDC. 2. Apply AC line voltage. 3. Rotate the speed adjust potentiometer or increase the voltage signal until the desired speed is reached.

  • Page 25: Starting And Stopping Methods

    Operation Starting and stopping methods Warning Decelerating to minimum speed, regenerative 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 26: Line Starting And Stopping

    It is not recommended for frequent starting and stopping. For this reason, Minarik strongly recommends that you install a stop switch on the line voltage inputs (both L1 and L2). Refer to Figure 3 (page 13).

  • Page 27: Decelerating To Minimum Speed

    Operation Decelerating to minimum speed Shorting terminal S2 to S1 decelerates the motor to minimum speed (Figure 6). The ACCEL and DECEL trimpots determine the rate of acceleration and deceleration, respectively. Set the minimum speed by calibrating the MIN trimpot. See Calibration on page 26 for specific calibration instructions Figure 6.

  • Page 28: Inhibit Terminals

    14). Next, short the inhibit pins to coast or brake to a stop. Remove the short to accelerate the motor to set speed. Minarik Corporation offers two accessory plug harnesses for use with the Inhibit terminals: Table 2. Inhibit Plug Harness Assembly Part Number...

  • Page 29: Dynamic Braking

    Operation Dynamic braking Warning Wait for the motor to completely stop before switching it back to RUN. This will prevent high armature currents from damaging the motor or drive. Inhibit personality header SO503 must be set to BRAKE for dynamic brake operation. See Figure 7, page 25. Dynamic braking may be used to rapidly stop a motor (Figure 7, page 25).
  • Page 30 Operation Dynamic brake resistor power rating Use the following equation to determine the dynamic brake resistor power rating: DBwatts = (Motor Power watts X duty cycle) X 1.2 = [(Horsepower X 746) X duty cycle] X 1.2 T REGEN duty cycle = T MOTOR + T REGEN where T REGEN is the amount of time the motor is generating voltage back into the drive, and T MOTOR is the amount of time...

  • Page 31: Figure 7. Dynamic Braking Circuit Connection

    Operation Figure 7. Dynamic Braking Circuit Connection...

  • Page 32: 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 33: Figure 8. Calibration Trimpot Layout

    Calibration ACCELERATION DECELERATION MAXIMUM SPEED MINIMUM SPEED MOTOR CURRENT LIMIT REGEN CURRENT LIMIT REGULATION (IR COMP) Figure 8. Calibration Trimpot Layout...

  • Page 34: Calibration Procedure

    Calibration Calibration procedure Calibrate the drive using the following procedure: 1. Set the MIN SPD, MAX SPD, ACCEL and DECEL trimpots to zero (full CCW). 2. Set the MOTOR CURRENT LIMIT and REGEN CURRENT LIMIT trimpots to maximum (full CW). 3.

  • Page 35: Minimum Speed (Min)

    Calibration MINIMUM SPEED (MIN) 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: 1. Set the MIN trimpot CCW. 2.

  • Page 36: Regulation (Ir Comp)

    Calibration REGULATION (IR COMP) The IR COMP setting determines the degree to which motor speed is held constant as the motor load changes. It is factory set for optimum motor regulation at maximum rated current. To calibrate IR COMP (exact calibration): 1.

  • Page 37: Motor Curr. Limit And Regen Curr. Limit

    Although CURRENT LIMIT is set to 120% of motor nameplate 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. The MOTOR CURR. LIMIT setting determines the maximum current limit for accelerating and driving the motor.

  • Page 38: Accel

    Calibration Set the speed adjust potentiometer or voltage input signal for maximum forward speed. Slowly adjust the MOTOR CURR. LIMIT trimpot CW until the armature current is 120% of motor rated current. Set the REGEN CURR. LIMIT trimpot to approximately the same setting as the MOTOR CURR.

  • Page 39: Decel

    Calibration DECEL The DECEL setting determines the time the motor takes to ramp to a lower speed. DECEL is factory set for the fastest deceleration time (full CCW). To calibrate DECEL: 1. Set the speed adjust potentiometer or voltage input signal to maximum forward speed.

  • Page 40: Figure 9. Typical Ir Comp And Current Limit Settings

    Calibration NRG10- 115AC - 2Q 1 HP 1/3 HP 90 VDC 90 VDC 10 ADC 3.5 ADC IR COMP REGEN MOTOR IR COMP REGEN MOTOR CURR. CURR. CURR. CURR. LIMIT LIMIT LIMIT LIMIT 1/2 HP 1/4 HP 90 VDC 90 VDC 5 ADC 2.5 ADC IR COMP...

  • Page 41: Application Notes

    Application Notes Connection to other Minarik devices NRG- 2Q DLC 600 DRIVE DIGI- LOK C ONTROL NRG- 2Q PC M 4 DRIVE SIGNAL ISOLATOR Figure 10. NRG-2Q Connection to DLC600 DIGI-LOK Control and PCM4 Signal Isolator...

  • Page 42: Optional Speed Adjust Potentiometer Connections

    Application Notes Optional speed adjust potentiometer connections Multiple fixed speeds Replace the speed adjust potentiometer with series resistors with a total series resistance of 10K ohms (Figure 11). Add a single pole, multi-position switch with the correct number of positions for the desired number of fixed speeds. Figure 11.

  • Page 43: 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 12 shows a connection for fixed high and low speed adjust potentiometers. Figure 12.

  • Page 44: 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 13 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations.

  • Page 45: Run/Jog Switch

    Application Notes RUN/JOG switch Using a RUN/JOG switch is recommended in applications where quick 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 46: Run/Jog Option #2

    Application Notes RUN/JOG option #2 In the second wiring option, connect the RUN/JOG switch and the JOG pushbutton as shown in the Figure 15. When the RUN/JOG switch is set to JOG, the motor decelerates to minimum speed (minimum speed is determined by the MIN trimpot setting).

  • Page 47: Leader-Follower Application

    Application Notes Leader-follower application In this application, use a PCM4 to monitor the speed of the leader motor (Figure 16). 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 48: Single Speed Potentiometer Control Of Multiple Drives

    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 17). Optional ratio potentiometers can be used to scale the PCM4 output voltage, allowing independent control of each drive.

  • Page 49: Troubleshooting

    • Verify that there are no short circuits or grounded connections. • Check that the drive’s rated armature outputs are consistent with the motor ratings. For additional assistance, contact your local Minarik® distributor, or the factory direct: (800) MINARIK (phone) or (800) 394-6334 (fax).

  • Page 50: Diagnostic Leds

    Troubleshooting Diagnostic LEDs All 2 quadrant NRG drives have three diagnostic LEDs: Power Lights whenever the AC line voltage is applied to the drive. Motor Output Lights whenever motor current flows in the direction of motor rotation. Regen Output Lights whenever motor current flows in the opposite direction of motor rotation.
  • Page 51 Troubleshooting Symptom Possible Suggested Causes Solutions Line fuses blow 1. Line fuses are the 1. Check that line wrong size. fuses are properly sized for the motor being used. 2. Motor cable or 2. Check motor cable armature is and armature for shorted to ground.
  • Page 52 Troubleshooting Symptom Possible Suggested Causes Solutions Line fuse does not 2. Speed adjust 2. Check connections blow, but the motor potentiometer or to input. Verify does not run (cont.) voltage input that connections signal not are not open. connected to drive input properly;...
  • Page 53 Troubleshooting Symptom Possible Suggested Causes Solutions Line fuse does not 7. Motor is not 7. Connect motor to blow, but the motor connected. A1 and A2. does not run (cont.) Motor runs too 1. Verify all switch 1. Switches or slow or too fast at and jumper jumpers are set...
  • Page 54 Troubleshooting Symptom Possible Suggested Causes Solutions Motor pulsates or 1. IR COMP is set 1. Adjust the IR surges under load too high. COMP setting slightly CCW until the motor speed stabilizes. 2. Motor “bouncing” 2. Make sure motor in and out of is not undersized torque limit.

  • Page 55: Replacement Parts

    Troubleshooting Replacement Parts Replacement parts are available from Minarik Corporation and its distributors for this drive series. Model No. Symbol Description Minarik P/N NRG02–D240AC–2Q Power Bridge 073–0010 C503 470mF, 400 VDC Capacitor 011–0120 FU501, 502 6A, 3AB Fuse 050–0016 Q501–504 IRFP440 MOSFET 070–0077...
  • Page 56 Troubleshooting Potentiometer Kit Contents (202-0039) 11 ea NON/INSU FEMALE TAB 1/4IN 163-0028 1 ea 10K OHM, 5W, 5% TOL. 120-0009 1 ea 3/8-32 X 1/2 NUT 151-0007 1 ea 3/8IN INT TOOTH LOCK WASHER 152-0007 1 ea POT INSULATING WASHER 156-0022 FUSE KIT CONTENTS 3–8A Fuse Kit (050–0069)
  • Page 57 Notes...
  • Page 58 Notes...
  • 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 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 60 Other drives from Minarik Corporation: DLC500 MMRGD Series NRGD Series XP Series (AC or DC Input) 901 East Thompson Avenue Glendale, California 91201-2011 Tel: (800) MINARIK Fax: (800) 394-6334 www.minarikcorp.com Document Number 250-0246, Revision 2 Printed in the U.S.A – 5/01...

This manual is also suitable for:

Nrg05–d240ac–2qNrg02–d240ac–2qNrg10–115ac–2q

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