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Minarik NRGD–4Q Series User Manual

Digitally-controlled, four-quadrant, regenerative pwm drives for dc brush motors
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NRGD–4Q Series
Models:
NRGD05-D240AC-4Q
NRGD10-D240AC-4Q
Digitally-Controlled, Four-Quadrant,
Regenerative PWM Drives
for DC Brush Motors

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Summary of Contents for Minarik NRGD–4Q Series

  • Page 1 NRGD–4Q Series Models: NRGD05-D240AC-4Q NRGD10-D240AC-4Q Digitally-Controlled, Four-Quadrant, Regenerative PWM Drives for DC Brush 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.

  • Page 4: Table Of Contents

    Contents Specifications Dimensions Installation Mounting ........... . .6 Wiring .
  • Page 5 Application Notes Connection to other Minarik devices .......45 DIRECTION switch ..........46 FWD-STOP-REV switch .
  • Page 6 Illustrations Figure 1. Four Quadrant Operation ....... .vii Figure 2. NRGD05 Series Dimensions .
  • Page 7 Tables Table 1. Recommended Line Fuse Sizes ......10 Table 2. Regen Dump Circuit Part Numbers .
  • Page 8 Regenerative Drives Non-regenerative, variable speed DC drives control current and speed to a motor in one direction only. The direction of current flow is in the same direction as the motor rotation. This is commonly described as Single Quadrant operation. (Quadrants 1 or 3 depending on your direction of rotation-see Figure 1).

  • Page 9: Figure 1. Four Quadrant Operation

    Regenerative Drives Figure 1. Four Quadrant Operation...
  • Page 10 NRGD–4Q Drives Minarik’s NRGD–4Q Series drives are four-quadrant, full-wave, regenerative PWM drives. These open-chassis drives come with the following features: Low power consumption. The NRGD series consume 30% less power than typical analog PWM drives, and 50% less power than typical SCR drives.
  • Page 11 NRGD-4Q Drives Fast brake/inhibit. Active braking as fast as user-adjusted current limit allows. Enable/Disable. Turns off the output stage, allowing the motor to coast to a stop. Cage-clamp terminals. Quicker and easier wiring than screw terminals. Plug reversing. Quickly switch from forward to reverse without contactors. Autoranging dual voltage input Power the drive with either 120 VAC or 240 VAC.
  • Page 12 Notes...

  • Page 13: Specifications

    Specifications NRGD05-D240AC-4Q Maximum Continuous Armature Current 5.0 amps DC Peak Armature Current* 7.5 amps DC HP Range (120 VAC Line Voltage) 1/8 – 1/2 HP Range (240 VAC Line Voltage) 1/4 – 1 NRGD10-D240AC-4Q Maximum Continuous Armature Current – No Heat Sink 5.0 amps DC Maximum Continuous Armature Current with Heat Sink Installed** 10.0 amps DC...
  • Page 14 Specifications Input Impedance 100K ohms minimum Speed Regulation (% of base speed) 1% open loop 0.1% in tachogenerator feedback mode Vibration 0.5G max. (0–50 Hz); 0.1G max. (>50 Hz) Weight 0.78 lb Ambient Operating Temperature Range† 10° C – 40° C †...

  • Page 15: Dimensions

    Dimensions ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 2. NRGD05 Series Dimensions...

  • Page 16: Figure 3. Nrgd10 Series Dimensions

    Dimensions ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 3. NRGD10 Series Dimensions...

  • Page 17: Figure 4. Heat Sink Dimensions For Nrgd10 Series Drives

    Dimensions Figure 4. Heat Sink Dimensions for NRGD10 Series Drives...

  • Page 18: Installation Mounting

    Installation Mounting Warning Do not install, rewire, or remove this control with line voltage 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 direct contact with the circuit board.

  • Page 19: 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 120 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 20: 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 is not practical, the user should twist all logic leads with themselves to minimize induced noise.

  • Page 21: Heat Sinking

    Installation Heat sinking NRGD05-series drives do not require an external heat sink. NRGD10-series drives require an external heat sink kit, part number 223-0363, when the continuous armature current is above 5 amps DC. Apply a thermally conductive heat sink compound (such as Dow Corning®...

  • Page 22: Line Fusing

    Installation Line fusing Protect all Minarik drives with AC line fuses. Use fast acting AC line fuses rated for 250 volts, and approximately 150% – 200% of the maximum armature current. Fuse only the “hot” side of the AC line (L1) if using 120 VAC line voltage. See Table 1 below for recommended line fuse sizes.

  • Page 23: Speed Adjust Potentiometer Installation

    Installation Speed adjust potentiometer installation 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 in. (10 mm) hole with the hardware provided (Figure 4).

  • Page 24: Connections

    Figure 5, page 14. Motor 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 25 Failure to follow 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 5, page 14. The switch contacts should be rated at a minimum of 200% of motor nameplate current and 250 volts.

  • Page 26: Figure 5. Power And Motor Connections

    Installation TO REGEN DUMP CIRCUIT BUS+ AND BUS- TERMINALS (OPTIONAL); SEE PAGE 20 NOTE: INSTALL FUSE ON L2 WHEN LINE VOLTAGE IS 240 VAC. DO NOT INSTALL IF LINE VOLTAGE IS 120 VAC. Figure 5. Power and Motor Connections...

  • Page 27: Optional Switch Connections

    Installation Optional switch connections Connect the following switches or jumpers to terminal board TB502 as shown in Figure 6, page 17. ENABLE/DISABLE switch Install a single-pole, single-throw switch between the ENABLE and COM terminals. Open the switch to disable the drive and coast the motor to a stop.
  • Page 28 Installation INHIBIT switch Shorting the INH and COM terminals on connector TB502 to each other causes the motor to regeneratively brake the motor to a stop at the maximum current allowed by the CURRENT LIMIT trimpot setting, bypassing the DECEL trimpot circuit. Remove the short to accelerate the motor to set speed.

  • Page 29: Figure 6. Signal And Optional Switch Connections

    Installation NOTE: REFER TO FIGURE 7 (PAGE 19) FOR ADDITIONAL SPEED ADJUST POTENTIOMETER CONNECTIONS Figure 6. Signal and Optional Switch Connections...

  • Page 30: Optional Speed Adjust Potentiometer Connections

    Installation Optional speed adjust potentiometer connections The motor can operate in one direction (unidirectionally) or two directions (bidirectionally) depending on how the speed adjust potentiometer is connected to the drive. Connect the speed adjust potentiometer as shown in Figure 7a for bidirectional operation.

  • Page 31: Figure 7. Speed Adjust Potentiometer Connections

    Installation Figure 7. Speed Adjust Potentiometer Connections for (a) Bidirectional Operation; (b) Unidirectional Operation (Forward); and (c) Unidirectional Operation (Reverse)

  • Page 32: Regen Dump Circuit Connections

    Installation Regen dump circuit connections Warning Minarik strongly recommends the installation of an extenal regen dump circuit if you plan to use regenerative braking. This will help avoid damage to the motor or drive. The external regen dump circuit reduces the voltage across the bus capacitor when it reaches a factory-set trip point.

  • Page 33: Figure 8. Regen Dump Circuit Connections To Nrgd Drives

    Installation Figure 8. Regen Dump Circuit Connections To NRGD Drives...

  • Page 34: Voltage Signal Follower Connections

    Installation Voltage signal follower connections Instead of using a speed adjust potentiometer to set motor speed, the drive may follow a floating (isolated) –10 to +10 VDC signal. Connect the signal input (+) to S2, and signal common (-) to S0. See Figure 9.

  • Page 35: Jumper Settings

    Installation Jumper settings Warning Do not change jumper settings with power applied. Remove line voltage or disable the drive before changing jumper settings. Failure to follow these instructions may result in damage to the drive or motor or serious injury. For NRGD05-series jumper locations, refer to Figure 10 (page 25).

  • Page 36: Motor Armature Voltage Select (J505/J506)

    Installation Motor armature voltage select (J505/J506) Jumper terminals 1 and 2 on J505 and J506 if the motor armature voltage is 90 volts. Jumper terminals 2 and 3 on J505 and J506 if the motor armature voltage is 180 volts. The factory (default) setting is 180 volts (terminals 2 and 3).

  • Page 37: Figure 10. Nrgd05 Jumper Terminal Location

    Installation ARMATURE VOLTAGE SELECT (J505 AND J506) ARM/TACH FEEDBACK SELECT (J502 AND J503) TACH VOLTAGE RANGE SELECT (J501) Figure 10. NRGD05 Jumper Terminal Location...

  • Page 38: Figure 11. Nrgd10 Jumper Terminal Location

    Installation ARMATURE VOLTAGE SELECT (J505 AND J506) TACH VOLTAGE RANGE SELECT (J501) ARM/TACH FEEDBACK SELECT (J502 AND J503) Figure 11. NRGD10 Jumper Terminal Location...

  • Page 39: Figure 12. Jumper Settings

    Installation J502/J503 ARM/TACH FEEDBACK SELECT J505/J506 MOTOR ARMATURE VOLTAGE J501 TACH FEEDBACK VOLTAGE RANGE Figure 12. Jumper Settings...

  • Page 40: 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 41: Startup And Shutdown

    Operation Startup and shutdown To start the drive: 1. Turn the speed adjust potentiometer full counterclockwise (CCW). If the speed adjust potentiometer is wired for bidirectional operation, set the pot to its center of travel. If the drive is following a voltage signal, set the voltage signal to 0 VDC.

  • Page 42: Starting And Stopping Methods

    This may cause damage to motors, especially gearmotors that are not properly sized for the application. Minarik strongly recommends the installation of an external regen dump circuit if you plan to use the NRGD’s regenerative braking capability. This will help avoid damage to the motor and/or drive.
  • Page 43 Operation INHIBIT switch Shorting the INH and COM terminals on connector TB502 to each other causes the motor to regeneratively brake the motor to a stop at a rate controlled by the CURRENT LIMIT trimpot, bypassing the DECEL trimpot circuit. Remove the short to accelerate the motor to set speed.

  • Page 44: 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 45: Nrgd05 Series Calibration Trimpots

    Calibration NRGD05 Series Calibration Trimpots TACHOGENERATOR BALANCE MAXIMUM LOOP SPEED CURRENT ACCELERATION LIMIT IR COMP OFFSET DECELERATION Figure 13. NRGD05 Calibration Trimpot Layout...

  • Page 46: Nrgd10 Series Calibration Trimpots

    Calibration NRGD10 Series Calibration Trimpots MAXIMUM TACHOGENERATOR SPEED BALANCE CURRENT LIMIT LOOP OFFSET ACCELERATION IR COMP DECELERATION Figure 14. NRGD10 Calibration Trimpot Layout...

  • Page 47: Calibration Procedure

    Calibration Calibration procedure: Before applying power 1. Verify that no conductive material is present on the printed circuit board. 2. Ensure that all jumpers are properly set. 3. Set the following trimpots full counterclockwise (CCW): • IR COMP • ACCEL •...
  • Page 48 Calibration 11. Set the RUN/BRAKE switch to RUN, or remove the jumper between the RB and COM terminals of terminal board TB502. 12. Apply line voltage to the drive. The green POWER LED shall light. 13. Set the ENABLE/DISABLE switch to ENABLE, or insert a jumper between the ENBL and COM terminals of terminal board TB502.
  • Page 49 The OFFSET trimpot is used to provide low-speed regulation for certain drives. It is calibrated at the factory and should not require adjustment. Please consult your Minarik representative for more information before adjusting this trimpot. The OFFSET setting adjusts the zero offset voltage in the internal velocity loop.
  • Page 50 Calibration MAXIMUM SPEED (MAX SPD) The MAX SPD 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 MAX SPD: 1.
  • Page 51 Calibration 2. Set ARM/TACH FEEDBACK jumpers J502 and J503 for armature feedback. Refer to Figures 10 (pg. 24) and 11 (pg. 25) for jumper locations. 3. Run the motor at full speed. Measure the armature voltage across A1 and A2 using a voltmeter. 4.
  • Page 52 Calibration REGULATION (IR COMP) The IR COMP trimpot (also known as regulation) 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 horsepower. To calibrate IR COMP (exact calibration): 1.
  • Page 53 Although CURRENT LIMIT is set to 120% of drive 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. 1. With no power applied to the drive, connect a DC ammeter in series with the motor armature.
  • Page 54 Calibration ACCELERATION (ACCEL) The ACCEL setting determines the time the motor takes to ramp to a higher speed in either direction. ACCEL is factory set for the fastest acceleration time (full CCW). To calibrate ACCEL: 1. Set the speed adjust potentiometer or voltage input signal for zero speed.
  • Page 55 Calibration DECELERATION (DECEL) The DECEL setting determines the time the motor takes to ramp to a lower speed in either direction. DECEL is factory set for the shortest deceleration time (full CCW). To calibrate DECEL: 1. Set the speed adjust potentiometer or voltage input signal for maximum forward speed.
  • Page 56 The LOOP trimpot is used to provide additional regulation for certain low-horsepower, high-inductance motors. It is unused in most applications and is factory set to zero (full CCW). Please consult your Minarik representative for more information before adjusting this trimpot. If calibration is necessary, perform the following procedure: 1.

  • Page 57: Application Notes Connection To Other Minarik Devices

    Application Notes Connection to other Minarik devices Figure 15. Connection to DLC600 and PCM4...

  • Page 58: Direction Switch

    Application Notes DIRECTION switch NOTE: You may need to adjust the OFFSET trimpot when using a DIRECTION switch in unidirectional mode. Use a single-pole, single-throw switch with a single speed adjust potentiometer to reverse a motor (Figure 16). Brake the drive before reversing by using a RUN/BRAKE switch as shown.

  • Page 59: Fwd-Stop-Rev Switch

    Application Notes FWD-STOP-REV switch Use a single-pole, three-position switch with a single speed adjust potentiometer to stop a motor between reversals (Figure 17). Set the switch to the center position to decelerate the motor to a stop. Figure 17. Forward-Stop-Reverse Switch...

  • Page 60: Independent Adjustable Speeds

    Application Notes Independent adjustable speeds NOTE: Minarik recommends disabling the drive before changing speeds. Connect two speed adjust potentiometers with a single-pole, two-position switch to select between two independent speeds in the same direction. Refer to Figure 18. Figure 18. Independent Adjustable Speeds...

  • Page 61: Independent Forward And Reverse Speeds

    Application Notes Independent forward and reverse speeds NOTE: Minarik recommends disabling the drive before changing directions. Connect two speed adjust potentiometers with a single-pole, two- position switch as shown in Figure 19 to select between independent forward and reverse speeds.

  • Page 62: Independent Forward And Reverse Speeds With Fwd-Stop-Rev Switch

    Application Notes Independent forward and reverse speeds with FWD-STOP-REV switch NOTE: Minarik recommends disabling the drive before changing direction. Use a switch to select forward, stop or reverse (Figure 20). Set the switch to the center position to decelerate the motor to a stop.

  • Page 63: Troubleshooting

    3. The motor must be rated for the drive’s rated armature voltage and current. 4. Check that all terminal block connections are correct. For additional assistance, contact your local Minarik® distributor, or the factory direct: 1-800-MINARIK (646-2745) or Fax: 1-800-394-6334...

  • Page 64: Diagnostic Leds

    Troubleshooting Diagnostic LEDs NRGD05 and NRGD10 series drives are equipped with the following diagnostic LEDs to aid in troubleshooting. Refer to Figure 21 (NRGD05) and Figure 22 (NRGD10) for diagnostic LED locations. POWER The green POWER LED lights when AC line voltage is applied to the drive (the drive’s power supply is active).

  • Page 65: Figure 21. Nrgd05 Diagnostic Led Location

    Troubleshooting CURRENT PEAK LIMIT POWER Figure 21. NRGD05 Diagnostic LED Location PEAK POWER CURRENT LIMIT Figure 22. NRGD10 Diagnostic LED Location...

  • Page 66: Terminal Assignments

    Troubleshooting Terminal assignments Circuit common for 10K ohm speed adjust potentiometer or isolated voltage input signal. Floating +10 VDC reference for 10K ohm speed adjust potentiometer. Accepts a 10K ohm speed adjust potentiometer wiper or isolated –10 VDC to +10 VDC reference. Floating –10 VDC reference for 10K ohm speed adjust potentiometer.
  • Page 67 Troubleshooting Short RB to COM to decelerate the motor to minimum speed using regenerative braking. The braking rate is controlled by the DECEL trimpot. ENBL Short the ENBL and COM terminals to enable the drive’s power section. Removing the short will disable the drive and coast the motor to a stop.
  • Page 68 Troubleshooting Problem Possible Suggested Cause Solution 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 2. Check motor armature is shorted cable and armature to ground.
  • Page 69 Troubleshooting Problem Possible Suggested Cause Solution Line fuse does not 3. INH terminal is 3. Remove short. blow, but the motor shorted to COM; S2 does not run (cont.) is shorted to S0, or RB is shorted to COM. 4. Drive is in current 4.
  • Page 70 Troubleshooting Problem Possible Suggested Cause Solution Motor runs too slow 2. MAX SPD is not 2. Calibrate MAX or too fast at set calibrated. SPD (see page 38). speed (cont.) Motor will not reach 1. MAX SPD setting 1. Increase MAX the desired speed is too low.
  • Page 71 Troubleshooting Problem Possible Suggested Cause Solution Motor pulsates or 2. Motor “bouncing” 2. Make sure motor surges under load in and out of torque is not undersized for (cont.) limit. load. Motor does not 1. Bad switch 1. Check switch reverse connection to DIR connection to DIR...

  • Page 72: Replacement Parts

    Troubleshooting 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® P/N NRGD05-D240AC-4Q C501, 509 10 uF, 25V Capacitor 011-0059 C502 220 uF, 25VDC Capacitor...
  • Page 73 Troubleshooting FUSE KIT CONTENTS 3 - 8A FUSE KIT 3 AMP 3AG Fast-Acting Fuse (2 ea) 5 AMP 3AG Fast-Acting Fuse (2 ea) 8 AMP 3AG Fast-Acting Fuse (2 ea) 1/2A Pico Fuse (1 ea) 5 - 20A FUSE KIT 5 AMP 3AG Fast-Acting Fuse (2 ea) 8 AMP 3AG Fast-Acting Fuse (2 ea) 10 AMP 3AB Normal-blo Fuse (2 ea)
  • Page 74 Index Application Notes 45 Connection to other Minarik devices 45 DIRECTION switch 46 FWD-STOP-REV switch 47 Independent adjustable speeds 48 Independent forward and reverse speeds 49 Independent forward and reverse speeds with FWD-STOP-REV switch 50 Calibration 32 Calibration procedure 35...
  • Page 75 Index Illustrations iv Figure 1. Four Quadrant Operation vii Figure 2. NRGD05 Series Dimensions 3 Figure 3. NRGD10 Series Dimensions 4, 5 Figure 4. Speed Adjust Potentiometer 11 Figure 5. Power and Motor Connections 14 Figure 6. Signal and Optional Switch Connections 17 Figure 7.
  • Page 76 Index RUN/BRAKE switch 15 Power, fuse and motor connections 12 Line fuse 13 Motor 12 Power input 13 Regen dump circuit connections 20 Voltage signal follower connections 22 Heat sinking 9 Jumper settings 23 Feedback select (J502/J503) 23 Motor armature voltage select (J505/J506) 24 Tach-generator feedback voltage select (J501) 23 Line fusing 10 Mounting 6...
  • Page 77 Index Tables v Table 1. Recommended Line Fuse Sizes 10 Table 2. Regen Dump Circuit Part Numbers 20 Table 3. Replacement Parts 60 Troubleshooting 51 Before applying power 51 Diagnostic LEDs 52 CURRENT LIMIT (CL/FTL) 52 PEAK 52 POWER 52 RUN 52 Replacement Parts 60 Terminal assignments 54...
  • Page 78 Notes...
  • Page 79 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 80 901 E Thompson Avenue Glendale, CA 91201-2011 Tel.: 1-800-MINARIK (646-2745) Fax: 1-800-394-6334 www.minarikcorp.com Document number 250–0281, Revision 1 Printed in the U.S.A – 01/01 North America $12.00, Outside North America $15.00...

This manual is also suitable for:

Nrgd05-d240ac-4qNrgd10-d240ac-4q

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