High to low voltage four quadrant dc drive (2 pages)
Summary of Contents for Minarik VFD Series
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USER’S MANUAL VFD SERIES Variable-frequency drives for 3-phase and single-phase AC motors VFD01-230AC VFD01-230AC-PCM VFD01-D230AC VFD01-D230AC-PCM VFD02-115AC VFD02-115AC-PCM VFD02-230AC VFD02-230AC-PCM VFD02-D230AC VFD02-D230AC-PCM VFD04-115AC VFD04-115AC-PCM VFD04-230AC VFD04-230AC-PCM VFD04-D230AC VFD04-D230AC-PCM...
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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.
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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.
General Information The Minarik Variable Frequency Drive (VFD) Series are solid-state, variable-frequency AC motor drives. The VFD utilizes a 115 or 230 VAC, 50/60 Hz, single-phase input, and is factory calibrated for an output of 0 to 60 Hz. They...
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120° apart. Although the VFD uses this method of connection, its fundamental design enables it to operate efficiently under these conditions. The VFD series features solid-state reversing with adjustable acceleration and deceleration. The VFD may also interface with motor thermal protection through the...
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DOUBLES THE OUTPUT ZERO SET 0 - 10 VDC, or 4 - 20 mA VOLTAGE TO THE AC on isolation board NON-ISOLATED SIGNAL MOTOR WHEN 115 IS APPLIED OPTIONAL ISOLATION BOARD DOUBLER VERSIONS Figure 1. VFD Series Features & Benefits...
Warning 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. In addition to standard 3-phase induction motors, the following motor types may be used with the VFD: •...
Contents Safety Warnings General Information Important Information Specifications Dimensions Installation - PCM Isolation Option Board Mounting ......10 Mounting .
Dimensions 4.30 [109] 3.80 [97] TB501 TH501 DECEL ACCEL C501 3.70 [94] 2.72 [69] C502 J501 0.97 [25] E2 E1 S1 S2 S3 D 2.00 [51] 0.96 [24] TOTAL HEIGHT (TOP OF CAP TO BOTTOM OF CHASSIS) VFD01-D230AC-PCM 2.56 [65.0] MAX VFD02-D230AC-PCM 3.02 [76.7] MAX ALL DIMENSIONS IN INCHES [MILLIMETERS]...
Installation - PCM Isolation Option Board Mounting The VFD Series - PCM Adder Board accepts a 0 - 5 VDC, 0 - 10 VDC, or 4-20 mA signal and outputs an isolated 0-5 VDC signal without requiring additional panel space.
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Installation TB501 TH501 DECEL C501 ACCEL J501 JMP501 C502 J501 IC502 C510 S T E P # 1 USING A PHILLIPS SCREWDRIVER REMOVE SCREW AND PLASTIC CAP FROM BOTTOM BOARD NOTE: AND DISCARD. DO NOT REMOVE THE SHOULDER WASHER FROM THE BOTTOM BOARD. TB501 TH501 DECEL...
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Installation TB501 TH501 DECEL C501 ACCEL J501 JMP501 C502 S T E P # 3 J501 IC502 INSTALL TWO (2) PLASTIC C510 STANDOFFS ONTO BOTTOM BOARD TB501 TH501 DECEL C501 ACCEL S T E P # 4 SNAP THE J501 JMP501 C502 SHORT...
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Installation J501 J501 TB501 TH501 DECEL C501 ACCEL S T E P # 7 J501 J501 JMP501 JMP501 POSITION THE PCM C502 J501 ADDER BOARD OVER THE BOTTOM BOARD IC502 IC502 AS SHOWN. C510 C510 NOTE: First align the bottom holes of J501 (on the PCM adder board) with the 6 pin header installed on the bottom board.
Safety Warnings before attempting installation. NOTE: Horizontal mouting may require derating the drive. See your Minarik representative for more information • It is recommended that the drive be oriented with the chassis vertical for best heat dissipation. Horizontal mounting, while acceptable, may require some thermal derating.
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Installation • Protect the drive from dirt, moisture, and accidental contact. Provide sufficient room for access to the terminal block and calibration trimpots. • Mount the drive away from heat sources. Operate the drive within the specified ambient operating temperature range.
Installation Wiring Warning DO NOT install, rewire, or remove this control with input 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.
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 the logic leads is not practical, the user should twist all logic leads with themselves to minimize induced noise.
Installation If the drive continues to pick up noise after grounding the shield, it may be necessary to add AC line filtering devices, or to mount the drive in a less noisy environment. Logic wires from other input devices, such as motion controllers and PLL velocity controllers, must be separated from power lines in the same manner as the logic I/O on this drive.
Installation Fusing VFD series drives require external AC power line fuses. Connect the external line fuse(s) in series with the AC voltage input. See Connections on page 22. Use fast- acting fuses rated for 250 VAC or higher. See Table 1 for recommended line fuse sizes.
Installation Speed adjust potentiometer 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 11). Install the circular insulating disk between the panel and the 10K ohm speed adjust potentiometer.
DO NOT connect this equipment with power applied. 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 250 volts.
Installation LIMIT AULT OWER START/STOP SWITCH * FUSE 115 / 230 VAC LINE INPUT FUSE * Do not add fuse to L2 unless line voltage is 230 VAC. Figure 12. AC Line and Fuse Connections for VFDxx-115AC and VFDxx-230AC Series Drives...
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Installation VFDxx-D230AC series Warning Do not connect 230 VAC line input when the drive is set for 115 VAC input. This will result in severe damage to the motor and drive, and can lead to explosion and/or injury. Check jumper settings before connecting AC power input.
Installation W A R N I N G Do not connect 230 VAC line input when the drive is set for 115 VAC input. This TH501 will result in severe DECEL damage to the motor and ACCEL drive, and can lead to C501 explosion and/or injury.
Installation TH501 ECEL CCEL C501 C502 START/STOP J501 SWITCH FUSE IC502 230 VAC LINE INPUT FUSE J501 No Voltage Doubler (230 VAC in - 230 VAC out) Figure 14. AC Line and Fuse Connections for VFDxx-D230AC Series Drives (No Voltage Doubler)
Figure 16 (page 29). The motor run cap must be removed from the circuit. Do not use a capacitor start motor on the VFD series. Three-phase operation Connect a three-phase motor to terminals U, V and W as...
Installation PREWIRED MOTOR NOTE WINDINGS CAPACITOR This connection may be DO NOT use a internal to the motor (2 wire DIRECTION switch with leads). If not, you must make this set-up. See Figure 16 this connection yourself. on Page 29 for setup using a DIRECTION switch.
Installation MOTOR WINDINGS NOTE Motor run cap must be removed from the circuit. This method works with most (but not all) motors. AUXILLIARY WINDING WITHOUT CAPACITOR TB501 BOOST DECEL ACCEL TQ LIMIT FAULT J501 JMP501 POWER IC502 C510 Figure 16. Motor Connections for Single-Phase Operation (Configured for use with DIRECTION switch)
Installation Speed Adjust Potentiometer Connections Connect a speed adjust potentiometer to terminals S1, S2 and S3. Make sure the potentiometer is connected so that the motor speed will increase as the wiper (S2) is turned clockwise (CW). See Figure 18 below. TB501 10K OHM SPEED ADJUST...
Installation Voltage Follower Connections Instead of using a speed adjust potentiometer, the drive may be wired to follow a 0 - 5 VDC isolated voltage signal (Figure 19). Connect the signal input (+) to S2 and signal common (-) to S1. Make no connection to S3. The VFD- PCM adder board may be used to scale and isolate an analog input voltage (see Page 34).
Installation Signal and Optional Switch Connections All signal and switch connections are made at TB501. Terminal block orientation and terminal names are identical for all VFD01, -02 and -04 series drives. Use 20 - 24 AWG wire for speed adjust potentiometer and switch connections. ENABLE/DISABLE switch Connect a single-pole, single-throw ENABLE/DISABLE switch between the ENABLE (E2) and COMMON (E1)
Installation DIRECTION (D) switch Connect a single-pole, single-throw DIRECTION switch between the (D) and COMMON (E1) terminals as shown in Figure 21 below. Opening the switch will cause the motor to rotate in the forward direction; closing the switch will reverse motor rotation.
Installation Voltage or Current Follower (-PCM models) -PCM series drives can be configured to follow a grounded (non-isolated) voltage or current signal. To configure the drive to follow a voltage or current signal, connect the signal leads to the S1 and S2 terminals on TB501. Ensure that the following jumper terminals are properly set: JMP501 Input Range Settings Set jumper in position 1 for 0 - 5 VDC signal input.
Operation Warning Dangerous voltages exist on the drive when it is powered, and up to 60 seconds after power is removed and the motor stops. BE ALERT. High voltages can cause serious or fatal injury. Do not change jumper settings with power applied. Ensure that jumper settings are compatible with the motor being controlled.
Operation Voltage Doubler Warning DO NOT connect 230 VAC line input when drive is set for 115 VAC input. This will result in severe damage to the motor and drive, and possible explosion or severe injury. VFDxx-D230AC series drives are equipped with a unique voltage-doubling feature, for use when 230 VAC input voltage is not available.
Operation Startup Warning DO NOT change jumper settings with power applied. Ensure that jumper settings are compatible with the motor being controlled. Before applying power, verify that no conductive material is present on the printed circuit board. 1. Verify that no conductive material is present on the PCB. 2.
Operation 7. If you attempt to startup and the yellow TQ LED comes on, the control has entered torque limit mode. To avoid this occurrence, you may: a. increase the torque limit setting*, or b. lengthen the acceleration time enough to accomodate the needed starting torque by adjusting the ACCEL trimpot.
Operation Starting and stopping methods To coast the motor to a stop Open the ENABLE/DISABLE switch, or remove the jumper between the ENABLE (E2) and COMMON (E1) terminals of TB501. Refer to the Application Notes section (page 50) for instructions on switch installation. 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.
Operation Line starting and line stopping Warning Minarik strongly recommends the installation of a master power switch in the voltage input line (see Power and Fuse connections, page 22). The switch contacts should be rated at a minimum of 200% of motor nameplate current and 250 volts.
BE ALERT. High voltages can cause serious or fatal injury. The VFD series has five user-adjustable trimpots. Each drive is factory calibrated to its maximum horsepower rating. Re-adjust the calibration trimpot settings to accommodate lower horsepower motors. See Figure 24 (page 45) for VFD series trimpot location.
Calibration Calibration Procedure Setup for 60 Hz Motors: 1. Set the ENABLE switch to the DISABLE (open) position. If no switch is installed, remove the jumper between the (E2) and (E1) terminals of TB501. 2. Set the DIRECTION switch to the FWD (open) position. If no switch is installed, remove the jumper between the (D) and (E1) terminals of TB501.
Calibration TORQUE LIMIT (TQ LIMIT) Warning Although the TQ LIMIT trimpot can be set up to 150% of the drive nameplate rating, continuous operation beyond the drive nameplate rating may cause damage to the motor and/or drive. 1. With no power applied to the drive, connect a (true RMS) ammeter in series with one of the motor leads.
Calibration ACCELERATION (ACCEL) 1. Set the speed adjust potentiometer to zero (full CCW) and wait for the motor to come to a stop (or minimum speed). 2. Set the speed adjust potentiometer or reference signal to maximum speed (full CW) and note the time the motor takes to accelerate to maximum speed.
NOTE: Use the absolute minimum amount of BOOST necessary to achieve proper motor operation. Improper use of the BOOST feature may cause motor and/or drive overheating and failure. If proper motion operation cannot be achieved with the above procedure, please contact your Minarik representative for assistance.
Calibration Calibration Procedure Conclusion 1. Set the speed adjust potentiometer to zero (full CCW). 2. Disable the drive by opening the ENABLE/DISABLE switch or removing the jumper from TB501 (E2) and (E1) terminals. 3. Remove power to the motor and drive. Calibration is now complete.
Application Notes Independent adjustable speeds with DIR 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 25 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations.
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. Connect the RUN/JOG switch and JOG pushbutton to terminal board TB501 as shown in Figure 26.
The combined current draw of all motors must not exceed the current rating of the drive. The VFD 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 27 below.
Application Notes Quick Reversing To reverse the direction of motor shaft rotation, install a DPDT center off switch as shown below (Figure 28). 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.
Troubleshooting Warning Dangerous voltages exist on the drive when it is powered, and up to 60 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.
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• 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 by telephone at: 1-800-MINARIK (646-2745) or Fax: 1-800-394-6334...
Troubleshooting Diagnostic LEDs Minarik VFD Series drives are equipped with diagnostic LED’s to assist the user in troubleshooting and monitoring equipment status while in use. Refer to Figure 29 (page 58) for diagnostic LED locations. POWER LED The green POWER LED is on when AC line voltage is applied and the control’s low-voltage power supply is...
See the Calibration section (page 47) for information on calibrating the TQ LIMIT trimpot. TB501 BOOST DECEL ACCEL TQ LIMIT FAULT FAULT J501 JMP501 POWER POWER IC502 C510 Figure 29. VFD Series diagnostic LED locations...
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Troubleshooting Problem Possible Suggested Cause Solution External line fuse blows 1. Line fuses are the 1. Check that line wrong size. fuses are properly sized for the motor being used. 2. Motor or motor cable 2. Check motor cable is shorted to ground. and motor for shorts.
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Troubleshooting Problem Possible Suggested Cause Solution 3. Drive is “tripped” off 3. Disable, then re- External line fuse does or has gone into enable the drive. not blow, but the motor thermal overload. does not run (cont.) 4. Drive has been 4.
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Troubleshooting Problem Possible Suggested Cause Solution Motor will not reach the 1. MAX SPD setting is 1. Increase MAX SPD desired speed too low. setting (page 40). 2. Compare motor 2. Nominal input voltage voltage to input may be too low for voltage;...
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Troubleshooting Problem Possible Suggested Cause Solution 1. TQ LIMIT set too low. 1. Check TQ LIM TQ is unsatisfactory at setting (page 41). high speeds. 2. Load may exceed 2. “Fix” load (i.e., rating of motor/drive. straighten mounting, coupling, etc.); or replace motor and drive with motor and drive rated for...
Optional C510 Capacitor Kit (p/n: 202-0108) In some applications, lowering carrier frequency reduces switching losses and increases bearing life in some motors. Minarik provides an optional capacitor kit for lowering the carrier frequency. The default carrier frequency on VFD controls is 16kHz.
Troubleshooting TB501 BOOST DECEL ACCEL TQ LIMIT Cap Label 3n3 J100 FAULT J501 JMP501 POWER IC502 C510 CARRIER FREQUENCY CAPACITOR (C510) Insert the 2-pins of the carrier frequency capacitor into the 2 socket-holes (C510) located on bottom board. Figure 30. Carrier frequency capacitor location...
Troubleshooting Replacement Parts Replacement parts are available from Minarik Corporation and its distributors for this drive series. Table 2. Replacement Parts Potentiometer Kit 202-0101 10K ohm, 5W Potentiometer 3/8-32 X 1/2 Nut 3/8IN Int. Tooth Lockwasher Pot Insulating Washer Non-insulated Female Connector...
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...
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M I N A R I K D R I V E S w w w . m i n a r i k d r i v e s . c o m 14300 De La Tour Drive, South Beloit, IL 61080 (815) 624-6960 Phone: (815) 646-2745;...
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