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
 Copyright © 2002 by
Minarik Corporation

All rights reserved. No part of this manual may be reproduced or transmitted in any
form without written permission from 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. 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. MVD082602

Printed in the United States of America.

 i

Safety Warnings SHOCK

HAZARD
AVOID
HEAT
KEE
DR
OID
ATION

• This symbol  denotes an important safety tip or

warning. Please read these instructions carefully
before performing any of the procedures contained in
this manual.
• DO NOT INSTALL, REMOVE, OR REWIRE THIS
EQUIPMENT WITH POWER APPLIED. Have a qualified
electrical technician install, adjust and service this
equipment. Follow the National Electrical Code and all
other applicable electrical and safety codes, including the
provisions of the Occupational Safety and Health Act
(OSHA), when installing equipment.
• Reduce the chance of an electrical fire, shock, or
explosion by using proper grounding, over-current
protection, thermal protection, and enclosure. 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.
Circuit potentials are at 115 VAC or 230 VAC above earth
ground. Avoid direct contact with the printed circuit board or
with circuit elements to prevent the risk of serious injury or
fatality. Use a non-metallic screwdiver for adjusting the
calibration trimpots. Use approved personal protective
equipment and insulated tools if working on this drive with
power applied.
ii

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
will operate any 1 HP or smaller, 115 or 208/230-volt, three-
phase-AC-induction, single-phase permanent split capacitor
motor (see page v) and can be user calibrated for 0 through
120 Hz output.

Although VFD inverters can operate over their full speed

range, most motors will operate with constant torque over a
10:1 speed range, 6 Hz to 60 Hz, and constant horsepower
above 60 Hz. (Inverter-duty motors may operate
satisfactorily over a 20:1 speed range.) Some motors can
be satisfactorily operated at speeds as low as 50 rpm
(speed range 50:1). Below 50 rpm, some motors may
show signs of “stepping” or “cogging”, and may run warmer.

*Although the VFD will allow a minimum of 0 Hz, the actual minimum
frequency is dependent on motor type and load. The motor may need to be
derated for low-frequency (30 Hz and lower) operation. Please consult the
motor manufacturer.
 General Information iii

Many 3-phase inverter manufacturers claim that they can

run single-phase motors effectively. This is normally
accomplished by wiring only 2 phases; however, this
method may cause instabilities due to the lack of feedback
from one of the motor connections. Furthermore, motor
torque will be reduced considerably because the phases
are 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
enable circuit.
iv General Information

VFD SERIES FEATURES & BENEFITS

• SOLID-STATE CIRCUITRY
• SOLID-STATE REVERSING
• ADJUSTABLE CARRIER FREQUENCY (4 kHz - 16 kHz)
LED INDICATORS
• MULTIPLE MOTOR OPERATION
• THREE-PHASE AND SINGLE-PHASE MOTOR CONTROL POWER
(green)

FAULT
(red)

TORQUE
U V W (yellow)

TB501
TH501

L2
DECEL BOO ADJUSTABLE
TQ CALIBRATION
ACCEL C501 TRIMPOTS
TQ

DECEL
JMP501:INPUT RANGE

C502
J501
ACCEL
JMP502:INPUT TYPE

115V
2-3:CURRENT
1-2:VOLTAGE
2:0-10VDC
ZERO
4 mA

1:0-5VDC
3:4-20MA
SET

MAX
JMP502

230V

BOOST
TB501
E2

E1

S1

S2

S3

D
3
2
1

L1

TQ LIMIT

optional
ACCEPTS A 0 - 5 VDC, DOUBLES THE OUTPUT ZERO SET
0 - 10 VDC, or 4 - 20 mA VOLTAGE TO THE AC
NON-ISOLATED SIGNAL MOTOR WHEN 115 IS APPLIED on isolation board

OPTIONAL ISOLATION BOARD DOUBLER VERSIONS

Figure 1. VFD Series Features & Benefits

 v

Important Information

 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:

• Permanent split capacitor (PSC)

• Shaded pole
• AC synchronous

 The following motor types MAY NOT be used:

• Split phase
• Capacitor start
• Repulsion induction
• Series Universal AC/DC
• Any motor with starting switch (centrifugal or relay)
and/or separate starting winding.
vi

Contents
Safety Warnings i
General Information ii
Important Information v
Specifications 1
Dimensions 2
Installation 10
- PCM Isolation Option Board Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Power and fuse connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Motor connections (all VFD-series controls) . . . . . . . . . . . . . . . . . . . . . . . .27
Speed Adjust Potentiometer Connections . . . . . . . . . . . . . . . . . . . . . . . . . .31
Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Signal and Optional Switch Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Voltage or Current Follower (-PCM models) . . . . . . . . . . . . . . . . . . . . . . . .35
Operation 37
Voltage Doubler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
To reverse motor direction: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Starting and stopping methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
To coast the motor to a stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Thermal protection of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
 Contents vii

Calibration 44
Calibration Procedure Setup for 60 Hz Motors: . . . . . . . . . . . . . . . . . . . . . . . .46
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
TORQUE LIMIT (TQ LIMIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
ACCELERATION (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
DECELERATION (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Calibration Procedure Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Application Notes 51
Independent adjustable speeds with DIR switch . . . . . . . . . . . . . . . . . . . . . . .51
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Single speed potentiometer control of multiple motors . . . . . . . . . . . . . . . . . . .53
Quick Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Troubleshooting 55
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
POWER LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
FAULT LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
TQ LIMIT LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Optional C510 Capacitor Kit (p/n: 202-0108) . . . . . . . . . . . . . . . . . . . . . . . . . .63
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Unconditional Warranty 67

Tables
Table 1. Line Fusing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Table 2. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
viii

Illustrations
Figure 1. VFD Series Features & Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Figure 2. VFD01-230AC, VFD02-115AC, VFD02-230AC Dimensions . . . . . . . . . . . . . . . . . . . . .2
Figure 3. VFD04-115AC and VFD04-230AC Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Figure 4. VFD01-230AC-PCM, VFD02-115AC-PCM
and VFD02-230AC-PCM Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Figure 5. VFD04-115AC-PCM and VFD04-230AC-PCM Dimensions . . . . . . . . . . . . . . . . . . . . .5
Figure 6. VFD01-D230AC & VFD02-D230AC Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Figure 7. VFD04-D230AC Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Figure 8. VFD01-D230AC-PCM and VFD02-D230AC-PCM Dimensions . . . . . . . . . . . . . . . . . . .8
Figure 9. VFD04-D230AC-PCM Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 10. VFD Series Drive with PCM adder board & -PCM adder kit . . . . . . . . . . . . . . . . . . .11
Figure 11. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Figure 12. AC Line and Fuse Connections for VFDxx-115AC and
VFDxx-230AC Series Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Figure 13. AC Line and Fuse Connections for VFDxx-D230AC Series Drives
(Voltage Doubler Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Figure 14. AC Line and Fuse Connections for VFDxx-D230AC Series Drives
(No Voltage Doubler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Figure 15. Motor Connections for Single-Phase Operation
(Motor With Pre-Wired Capacitor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Figure 16. Motor Connections for Single-Phase Operation
(Configured for use with DIRECTION switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Figure 17. Motor Connections for Three-Phase Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Figure 18. Speed Adjust Potentiometer Connections to TB501 . . . . . . . . . . . . . . . . . . . . . . . . .31
Figure 19. Voltage Follower connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Figure 20. Enable / Disable Switch connections to TB501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 21. Signal and Optional Switch Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Figure 22. -PCM jumper locations and terminal connections . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Figure 23. Thermal Overload Switch with Optional Enable / Disable Switch . . . . . . . . . . . . . . .42
Figure 24. VFD Series Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Figure 25. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Figure 26. RUN/JOG Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Figure 27. Single Speed Potentiometer Control of Multiple Motors . . . . . . . . . . . . . . . . . . . . . .53
Figure 28. VFD Quick Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Figure 29. VFD Series diagnostic LED locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Figure 30. Carrier frequency capacitor location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
 1

Specifications
1-Phase 1 or 3-Phase Max Continuous AC
Input Output Max Output Amps
Drive (VAC) (VAC) HP Current (AC) In
VFD01-230AC 230 230 ¼ 1.2 3
VFD01-D230AC *115 / 230 230 ¼ 1.2 7/3
VFD02-115AC 115 115 ¼ 2.4 7
VFD02-230AC 230 230 ½ 2.4 7
VFD02-D230AC *115 / 230 230 ½ 2.4 10 / 7
VFD04-115AC 115 115 ½ 4.0† 10
VFD04-230AC 230 230 1 4.0† 10
VFD04-D230AC *115 / 230 230 1 4.0† 15 / 10
* Connect only 115 VAC line input to the 115 VAC terminals. Application of 230 VAC line input when set for 115
VAC will result in severe damage to the motor and drive, and possible explosion and injury.
† Derate current by 2% per degree if the operating temperature is above 40°C. Under no circumstances may the
ambient temperature exceed 55° C.

AC Voltage Input Range

VFDxx-115AC drives 115 VAC ± 10%, 50/60 Hz single phase
VFDxx-230AC drives 230 VAC ± 10%, 50/60 Hz single phase
VFDxx-D230AC drives 115/230 VAC ± 10%, 50/60 Hz single phase
Standard Carrier Frequency 16 KHz
Output Frequency Range 0 – 120 Hz
Adjustable Maximum Output Frequency Range 30 – 120 Hz
Acceleration Time Range 1 – 12 seconds
Deceleration Time Range 1 – 12 seconds
Analog Input Voltage Range (signal must be isolated; S1 [-] to S2 [+]) 0 – 5VDC**
Input Impedance, S1 to S2 ~ 100K ohms
Vibration 0.5G max (20 – 50 Hz)
0.1G max (> 50 Hz)
Weight 1.2 lb
Ambient Operating Temperature Range 10° – 40° C
** An isolation board option that allows for a non-isolated 0 - 5 VDC, 0 - 10 VDC, or 4 - 20 mA input signal is
available (-PCM option). The option board is installed directly above the main board, maintaining the same
footprint and dimensions. Call the factory for more information regarding the -PCM option.
 2

2.12 [54] 4.30 [109]

0.96 [24] 3.80 [97]

U V W
Dimensions

TB501

DECEL BOOST
TQ
ACCEL
3.70 [94] TQ LIMIT

FAULT
MAX
J503

J501 JMP501
2.72 [69]

E2 E1 S1 S2 S3 D
POWER
AC AC -
IC502

C510 L2
0.97 [25]
J502

L1

TOTAL HEIGHT (H)

(TOP OF CAP TO BOTTOM OF CHASSIS)

VFD01-230AC 2.03 [51.6]

VFD02-115AC 2.68 [68.1]
ALL DIMENSIONS IN
INCHES [MILLIMETERS] VFD02-230AC 2.48 [ 63.0]

Figure 2. VFD01-230AC, VFD02-115AC, VFD02-230AC Dimensions

 1.00 [25]

U Y W

4.40 [112]
TB501

DECEL BOOST
TQ
ACCEL
TQ LIMIT
3.00 [72]
FAULT
MAX
J503

J501 JMP501

E2 E1 S1 S2 S3 D
POWER
AC AC -
IC502

C510 L2
J502

0.7 [18]
L1

0.13 [3] 6.30 [160]

3.68 [93.5] 6.90 [175]

ALL DIMENSIONS IN INCHES [MILLIMETERS]

Dimensions

Figure 3. VFD04-115AC and VFD04-230AC Dimensions

3
4 Dimensions

4.30 [109]

3.80 [97]

U V W

TB501

DECEL BOOST
TQ
ACCEL
TQ LIMIT 3.70 [94]
FAULT

J503
2.72 [69]
JMP501:INPUT RANGE

JMP502:INPUT TYPE
2-3:CURRENT
1-2:VOLTAGE

AC AC -
2:0-10VDC
1:0-5VDC
3:4-20MA
ZERO
4 mA
SET

L2
JMP502

0.97 [25]

J502
TB501
E2

E1

S1

S2

S3

D
3

2
1

L1

H
E2 E1 S1 S2 S3 D
2.12 [54]

0.96 [24]

TOTAL HEIGHT (H)

(TOP OF CAP TO
BOTTOM OF CHASSIS)
VFD01-230AC -PCM 2.03 [51.6]
VFD02-115AC-PCM 2.68 [68.1]
ALL DIMENSIONS IN
VFD02-230AC-PCM 2.48 [63.0] INCHES [MILLIMETERS]

Figure 4. VFD01-230AC-PCM, VFD02-115AC-PCM

and VFD02-230AC-PCM Dimensions
 Dimensions 5

U Y W

4.40 [112]
TB501

DECEL BOOST
TQ
ACCEL
TQ LIMIT
3.00 [72]
FAULT

J503
JMP501:INPUT RANGE

JMP502:INPUT TYPE

POWER
2-3:CURRENT
1-2:VOLTAGE

AC AC -
2:0-10VDC
ZERO
4 mA

1:0-5VDC
3:4-20MA
SET

L2
JMP502

J502
TB501
E2

E1

S1

S2

S3

0.70 [18]
3

2
1

L1

6.30 [160]
ALL DIMENSIONS IN
6.90 [175] INCHES [MILLIMETERS]

E2 E1 S1 S2 S3 D
3.68 [93.5]

1.00 [25]

0.12 [3]

Figure 5. VFD04-115AC-PCM and VFD04-230AC-PCM Dimensions

 6

2.12 [54] 4.30 [109]

0.96 [24] 3.80 [97]

Dimensions

U V W

TB501
TH501

DECEL BOO
L2

TQ
C501
ACCEL
3.70 [94] TQ

MAX
J501 JMP501
2.72 [69]

E2 E1 S1 S2 S3 D
C502
J501
115V

IC502

C510

0.97 [25]
230V
L1

TOTAL HEIGHT
(TOP OF CAP TO BOTTOM OF CHASSIS)

VFD01-D230AC 2.56 [65.0] MAX

ALL DIMENSIONS IN
INCHES [MILLIMETERS] VFD02-D230AC 3.02 [76.7] MAX

Figure 6. VFD01-D230AC & VFD02-D230AC Dimensions

 1.00 [25]

U Y W

4.40 [112]
TB501
TH501

DECEL BOO
L2

TQ
ACCEL C501
TQ
3.00 [72]
MAX
J501 JMP501

E2 E1 S1 S2 S3 D
C502
J501
115V

IC502

C510
230V

0.70 [18]
L1

0.13 [3] 6.30 [160]

4.45 [113] MAX 6.90 [175]

ALL DIMENSIONS IN INCHES [MILLIMETERS]

Dimensions

Figure 7. VFD04-D230AC Dimensions

7
8 Dimensions

4.30 [109]

3.80 [97]

U V W

TB501
TH501

L2
DECEL BOO
TQ
ACCEL C501
TQ 3.70 [94]

2.72 [69]
C502
JMP501:INPUT RANGE

J501
JMP502:INPUT TYPE

115V
2-3:CURRENT
1-2:VOLTAGE
2:0-10VDC
1:0-5VDC
ZERO
4 mA

3:4-20MA
SET

JMP502

0.97 [25]

230V
TB501
E2

E1

S1

S2

S3

D
3

2
1

L1

E2 E1 S1 S2 S3 D
H

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]

Figure 8. VFD01-D230AC-PCM and VFD02-D230AC-PCM Dimensions

 Dimensions 9

6.30 [160]

U Y W

4.40 [112]
TB501
TH501

L2
DECEL BOO
TQ
ACCEL C501
3.00 [76]
TQ
JMP501:INPUT RANGE

C502
J501
JMP502:INPUT TYPE
3:4-20MA
2:0-10VDC
1:0-5VDC

115V
2-3:CURRENT
1-2:VOLTAGE
ZERO
4 mA
SET

JMP502

230V
TB501
E2

E1

S1

S2

S3

0.70 [18]
3
2
1

L1
6.90 [175]

ALL DIMENSIONS IN
INCHES [MILLIMETERS]

E2 E1 S1 S2 S3 D

4.45 [113] MAX

1.00 [25]

Figure 9. VFD04-D230AC-PCM Dimensions

10

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. It
mounts directly over the main AC board (bottom board) thus
maintaining the same footprint. Step-by-step information for
mounting the -PCM Adder Board to a VFD Series drive is
shown on pages 12 - 14.

Figure 10 (page 11) shows a VFD Series drive with the -PCM
adder board installed on the unit and the parts supplied in the
-PCM adder kit.
 Installation 11

MAIN AC BOARD
U Y W
(BOTTOM BOARD)
TB501
TH501

L2
DECEL BOO
TQ
ACCEL C501
TQ

PCM ADDER
BOARD

JMP501:INPUT RANGE
C502
J501

JMP502:INPUT TYPE
3:4-20MA
2:0-10VDC
1:0-5VDC

115V
2-3:CURRENT
1-2:VOLTAGE
ZERO
4 mA
SET

JMP502

230V
TB501
E2

E1

S1

S2

S3

D
3
2
1

L1
PARTS SUPPLIED IN THIS KIT

J501

PCM ADDER PCB

BOARD (1) STANDOFF (2) JUMPER (1)
JMP501:INPUT RANGE

JMP502:INPUT TYPE
3:4-20MA
2:0-10VDC
1:0-5VDC

2-3:CURRENT
1-2:VOLTAGE
ZERO
4 mA
SET

JMP502

TB501
E2

E1

S1

S2

S3

D
3
2
1

6-PIN SHOULDER 0.578" NYLON 6-32 x 1 5/16"

HEADER (1) WASHER (1) SPACER (1) PHILLIPS SCREW (1)

Required Tools: Phillips Screwdriver

Figure 10. VFD Series Drive with PCM adder board & -PCM adder kit
12 Installation

U V W

TB501
TH501

L2
DECEL BOO
TQ
C501
ACCEL
TQ

MAX
J501 JMP501

C502
J501

115V
IC502

C510

230V
STEP #1

L1
USING A PHILLIPS
SCREWDRIVER REMOVE
SCREW AND PLASTIC CAP
FROM BOTTOM BOARD
AND DISCARD. NOTE:
DO NOT REMOVE THE
SHOULDER WASHER
FROM THE BOTTOM BOARD.

U V W

TB501
TH501
L2

DECEL BOO
TQ
C501
ACCEL
TQ

STEP #2 J501
MAX
JMP501

C502
PLACE THE JUMPER J501
115V

(NOTCH SIDE UP)

ON JMP501 OF THE IC502

BOTTOM BOARD.
C510
230V
L1
 Installation 13

U V W

TB501
TH501

L2
DECEL BOO
TQ
C501
ACCEL
TQ

MAX
J501 JMP501

C502

STEP #3 J501

115V
IC502
INSTALL TWO
(2) PLASTIC C510

230V
STANDOFFS
ONTO BOTTOM

L1
BOARD

U V W

TB501
TH501

L2
DECEL BOO
TQ
C501
ACCEL
TQ

STEP #4
MAX
SNAP THE J501 JMP501

C502
SHORT J501

115V
SIDE OF THE
6-PIN HEADER J501 IC502

INTO J501 C510

LOCATED ON

230V
THE BOTTOM

L1
BOARD

J501 J501

TOP VIEW TOP VIEW

JMP501:INPUT RANGE

JMP501:INPUT RANGE
JMP502:INPUT TYPE

JMP502:INPUT TYPE
3:4-20MA
2:0-10VDC
1:0-5VDC

3:4-20MA
2:0-10VDC
1:0-5VDC
2-3:CURRENT
1-2:VOLTAGE

2-3:CURRENT
1-2:VOLTAGE
ZERO
4 mA

ZERO
4 mA
SET

SET
JMP502

JMP502
TB501

TB501
E2

E1

S1

S2

S3

E2

E1

S1

S2

S3
D

D
3
2
1

3
2
1

STEP #5
INSERT THE SHOULDER SIDE VIEW
WASHER (included with SIDE VIEW
the kit) THROUGH THE
TOP SIDE OF THE PCM
ADDER BOARD.
STEP #6
ATTACH THE 0.578"
SPACER TO THE BOTTOM
SIDE OF THE SHOULDER
WASHER AS SHOWN.
14 Installation

J501

J501

JMP501:INPUT RANGE

JMP502:INPUT TYPE
3:4-20MA
2:0-10VDC
1:0-5VDC

2-3:CURRENT
1-2:VOLTAGE
U V W
ZERO
4 mA
SET

JMP502
TB501
TH501

TB501
E2

E1

S1

S2

S3

L2
3
2
1

DECEL BOO
TQ
C501
ACCEL
TQ

STEP #7
MAX
J501 JMP501

POSITION THE PCM C502

J501
ADDER BOARD OVER

115V
THE BOTTOM BOARD IC502

AS SHOWN.
C510

230V
NOTE: First align the
bottom holes of J501 (on

L1
the PCM adder board) with
the 6 pin header installed
on the bottom board. The
PCM adder board will
snap into place at J501
and the two standoffs.

U V W

TB501
TH501

L2
DECEL BOO
J501
TQ
C501
ACCEL
TQ
JMP501:INPUT RANGE

C502
J501
JMP502:INPUT TYPE
3:4-20MA
2:0-10VDC
1:0-5VDC

115V
2-3:CURRENT
1-2:VOLTAGE
ZERO
4 mA
SET

JMP502

230V
TB501
E2

E1

S1

S2

S3

D
3
2
1

STEP #8
L1

SECURE THE
PCM ADDER
BOARD WITH
THE 6-32 x 1 5/16"
PHILLIPS SCREW.

INSTALLATION COMPLETE.
 Installation 15

Mounting

 Warning
DO NOT install, rewire, or remove this control with
input power applied. Doing so may cause fire or
serious injury. Make sure that you read and
understand the 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.

• Six 0.19-inch (5 mm) wide slots accept #8 pan head

screws. Fasten either the large base or narrow flange of
the chassis to the subplate.

• Drive components are sensitive to electrostatic fields.

Avoid direct contact with the circuit board. Hold the drive
by the chassis only.
16 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.

• Prevent loose connections by avoiding excessive

vibration of the drive.

• 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.
 Installation 17

Wiring

 Warning
DO NOT install, rewire, or remove this control with

쇵 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.

Do not disconnect any of the motor leads from the

drive unless power is removed. Opening any one
motor lead may destroy the drive.

• Use 20 – 24 AWG wire for speed adjust potentiometer

wiring. Use 14 – 16 AWG wire for AC line (L1, L2) and
motor (U,V and W) wiring.
18 Installation

Shielding guidelines

 Warning
Under no circumstances should power and logic leads
be bundled together. Induced voltage can cause
unpredictable behavior in any electronic device,
including motor controls.

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.

It may be necessary to earth ground the shielded cable. If

noise is produced by devices other than the drive, ground
the shield at the drive end. If noise is generated by a device
on the drive, ground the shield at the end away from the
drive. Do not ground both ends of the shield.
 Installation 19

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.

Heat sinking
All VFD04-series drives are delivered with a factory-
installed heat sink. All other VFD-series drives have
sufficient heat sinking in their basic configurations. No
additional heat sinking is necessary.
20 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.

Table 1. Line Fusing Chart

1-Phase AC AC Line
Input Max Amps Fuse
Drive (VAC) HP In Size (Amps)
VFD01-230AC 230 ¼ 3 5
VFD01-D230AC 115 / 230 ¼ 7/3 10 / 5
VFD02-115AC 115 ¼ 7 10
VFD02-230AC 230 ½ 7 10
VFD02-D230AC 115 / 230 ½ 10 / 7 15 / 10
VFD04-115AC 115 ½ 10 15
VFD04-230AC 230 1 10 15
VFD04-D230AC 115 / 230 1 15 / 10 20 / 15
 Installation 21

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. Twist the speed adjust
potentiometer wire to avoid picking up unwanted electrical
noise. If speed adjust potentiometer wires are longer than
18 in. (457 mm), use shielded cable. Keep speed adjust
potentiometer wires separate from power leads (L1, L2, U,
V, W).

MOUNT THROUGH A 0.38 IN. (10 MM) HOLE

WIPER
CW
CCW

NUT
STAR
WASHER SPEED ADJUST
POTENTIOMETER

INSULATING DISK POT TAB ASSIGNMENTS

PANEL

Figure 11. Speed Adjust Potentiometer

22 Installation

Connections

 Warning
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.

Power and fuse connections

VFDxx-115AC and VFDxx-230AC Series

Connect the AC power input to L1 and L2 as shown in
Figure 12 (page 23). Connect an external fuse between the
drive and master stop switch. Install the switch between
the external fuse and AC power input as shown.
 Installation 23

V W

LIMIT

AULT
J503

OWER
AC AC -
START/STOP
* FUSE SWITCH

L2
115 / 230 VAC
J502

LINE INPUT
FUSE
L1

* 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
24 Installation

VFDxx-D230AC series

 Warning
Ꮨ
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.

Connect AC power input to L1 and L2 as shown in Figure 13

and 14 (pages 25 & 26), depending on your power needs.

NOTE: VFDxx-D230AC series drives are equipped with a

voltage-doubling feature, which converts a 115 VAC input to
a 230 VAC output, for use with 230V motors. The drive
output current rating remains the same. Use caution when
connecting this output.

• If the input voltage is 115 VAC and the desired output

voltage is 230 VAC (voltage doubler mode), set
115V/230V jumper as shown in Figure 13 (page 25). A
line fuse may be added to L2.

• If the input voltage is 230 VAC and the desired output

voltage is 230 VAC (no voltage doubler), set 115V/230V
jumper as shown in Figure 14 (page 26). Add a line fuse
to L1 and L2. Do not use the voltage doubler feature with
230 VAC line voltage.
 Installation 25

WARNING

V W
Ꮨ
Do not connect 230 VAC
line input when the drive is
TH501 set for 115 VAC input. This

L2
DECEL will result in severe
TQ damage to the motor and
ACCEL
TQ
C501
drive, and can lead to
explosion and/or injury.

C502
J501
START/STOP
SWITCH
115V

IC502

115 VAC
230V

LINE INPUT
FUSE
L1

J501 Voltage
Doubler Mode Setting
(115 VAC in - 230 VAC out)

Figure 13. AC Line and Fuse Connections for VFDxx-D230AC

Series Drives (Voltage Doubler Mode)
 26 Installation

V W

TH501

L2
ECEL
TQ
CCEL C501
TQ

C502
J501
START/STOP
SWITCH
115V

FUSE
IC502

230 VAC
230V

LINE INPUT
FUSE
L1

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)
 Installation 27

Motor connections (all VFD-series controls)

Single-phase operation
For single-phase operation, connect the motor as shown in
Figure 15 (page 28). Ensure that the prewired capacitor
and its associated motor coil are connected to terminals U
and V as shown. This connection may be internal if using a
2-wire motor. If the motor has three leads, you must make
this connection yourself.
To reverse a single phase split capacitor motor, connect the
motor as shown in 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
shown in Figure 17 (page 30).
28 Installation

PREWIRED
MOTOR RUN
WINDINGS
NOTE 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.

U V W

TB501

DECEL BOOST
TQ
ACCEL
TQ LIMIT

FAULT

J503
J501 JMP501

POWER
AC AC -
IC502

C510 L2
J502

L1

Figure 15. Motor Connections for Single-Phase Operation

(Motor With Pre-Wired Capacitor)
 Installation 29

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

U V W

TB501

DECEL BOOST
TQ
ACCEL
TQ LIMIT

FAULT

J503
MAX
J501 JMP501

POWER
AC AC -
IC502

C510 L2
J502

L1

Figure 16. Motor Connections for Single-Phase Operation

(Configured for use with DIRECTION switch)
30 Installation

MOTOR
WINDINGS

U V W

TB501

DECEL
TQ
ACCEL
TQ LIMIT

FAULT

J503
MAX
J501 JMP501

POWER
AC AC -
IC502

C510 L2
J502

L1

Figure 17. Motor Connections for Three-Phase Motors

 Installation 31

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

E2
10K OHM
SPEED ADJUST E1
U V W
POTENTIOMETER

S1 TB501

DECEL BOOST
TQ
S2 ACCEL
TQ LIMIT

S3 MAX
FAULT
J501 JMP501
CW
D POWER
AC
IC502

C510

Figure 18. Speed Adjust Potentiometer Connections to TB501

32 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).

TB501

E2

E1
SIGNAL COMMON (-)
S1
0 TO + 5 VDC VOLTAGE SIGNAL
S2
SIGNAL INPUT (+)
S3

Figure 19. Voltage Follower connections

 Installation 33

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)
terminals as shown. Open the switch to disable the drive
and coast to a stop. Close the switch to accelerate to set
speed at a rate controlled by the ACCEL trimpot.

ENABLE/DISABLE SWITCH TB501

OPEN TO DISABLE

E2

E1 (COMMON)

S1

S2

S3

Figure 20. Enable / Disable Switch connections to TB501

34 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.
The drive will decelerate the motor to a stop, (at the DECEL
trimpot setting), before reversing, so there is no need to
wait for the motor to coast to a stop before changing
direction.

TB501

E2

E1 (COMMON)

S1

S2

DIRECTION SWITCH S3
CLOSE TO REVERSE

Figure 21. Signal and Optional Switch Connections

 Installation 35

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.
Set jumper in position 2 for 0 - 10 VDC signal input.
Set jumper in position 3 for 4 - 20 mA signal input.

JMP502 Input Type

Jumper pins 1 & 2 for Voltage follower mode.
Jumper pins 2 & 3 for Current follower mode.

See Figure 22 on page 36 for jumper locations and terminal

connections.
 JMP501: INPUT RANGE
36

1: 0-5VDC
• Jumper position 1 for
0 - 5 VDC signal input

PCM ADDER BOARD

• Jumper position 2 for 2: 0-10VDC
0 - 10 VDC signal input
Installation

• Jumper position 3 for

4 - 20 mA signal input 3: 4-20MA

SET
4 mA
3:4-20MA
2:0-10VDC
1:0-5VDC
JMP501:INPUT RANGE
1-2:VOLTAGE
2-3:CURRENT
JMP502:INPUT TYPE

JMP502: INPUT TYPE

• Jumper pins 1 & 2 for E2 E1 S1 S2 S3 D

3
2
1
TB501

VOLTAGE follower mode

3
2
1
• Jumper pins 2 & 3 for

3
2
1
CURRENT follower mode

S1 S2 S3
S1 S2 S3
TO SPEED POT or
SIGNAL INPUT

SIGNAL NO
CW INPUT CONNECTION
0 - 5 VDC or
10K OHM 0 - 10 VDC or ENABLE DIRECTION
SPEED ADJUST 4 - 20 mA
POTENTIOMETER

Figure 22. -PCM jumper locations and terminal connections

 37

Operation

 Warning
Dangerous voltages exist on the drive when it is

쇵 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.

 Voltage Input Warning for VFDxx-D230AC Drives

DO NOT connect 230 VAC line input when the
쇵 drive is set for 115 VAC input. This will result in
severe damage to the motor and drive, and possible
explosion and/or injury.
38 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. This feature converts a 115 VAC
input to a 230 VAC output, for use with 230V motors. The
drive output current rating remains the same.

Refer to Figure 12 (page 23) for connection information.

Use extreme caution when connecting this feature.
Incorrect use of this feature may result in fire and serious
injury.
 Operation 39

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. Verify that the correct voltage is connected to the inputs
before applying power. DO NOT CONNECT 230 VAC
line voltage to a 115 VAC drive. Applying power in this
manner will damage the motor and drive.
3. Set the speed adjust potentiometer to zero (full CCW).
4. Set the DIRECTION switch (if installed) to the desired
direction. If no switch is installed, add or remove a
jumper across the (D) and (E1) terminals, as required.
5. Set the ENABLE/DISABLE switch (if installed) to
ENABLE, or short the ENABLE (E2) and (E1) terminals
on TB501.
6. Apply 115 or 230 VAC, 50/60 Hz, single-phase power to
the drive. The green POWER LED will come on after an
initial delay of 1 - 2 seconds. If the POWER LED does
not light, check the external line fuses to ensure that
they are properly installed and not blown.
40 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.

* Do not set the torque limit setting above 150% of the motor’s
nameplate current rating.

To reverse motor direction:

To reverse the direction of motor shaft rotation while the

motor is running, set the DIRECTION switch to the opposite
position. If no DIRECTION switch is installed, open or short
the (D) and (E1) terminals on TB501, as required.

When a new direction is selected, there is no need to open

the enable input. The control will automatically decelerate
the motor to zero speed, reverse direction, and then
accelerate the motor back to the set speed. Acceleration
and deceleration rates are controlled by the ACCEL/DECEL
trimpot settings. If quicker reversing is needed refer to
applications notes section (page 51) for further detail.
 Operation 41

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. These
thermal protectors are operated only by motor heat and
open the enable circuit when the motor reaches a
temperature capable of causing damage to the motor
winding.

Normally, these thermal protectors automatically close the

circuit when the motor has cooled to a safe temperature. In
operation, when the drive is disabled, or when the motor
overheats, the thermal protector opens the circuit. See
Figure 23 (page 42).
42 Operation

ENABLE / DISABLE
SWITCH THERMAL TB501
OVERLOAD
CLOSE TO ENABLE SWITCH

E2 (ENABLE)

E1 (COMMON)

S1

S2

S3

Figure 23. Thermal Overload Switch with Optional

Enable / Disable Switch
 Operation 43

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.

Line starting and line stopping (applying and removing

AC voltage input) is not recommended and should be
used for emergency stopping only. When AC voltage
input is applied to the drive, the motor accelerates to the
speed set by the speed adjust potentiometer. When AC
voltage input is removed, the motor coasts to a stop. To
“jog” a motor, install a normally-open pushbutton switch on
the ENABLE input.
44

Calibration

 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 before
adjusting the trimpots. If the trimpots must be
adjusted with power applied, use insulated tools and
the appropriate personal protection equipment. 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.

All adjustments increase with clockwise (CW) rotation and

decrease with counter-clockwise (CCW) rotation. Use a
non-metallic screwdriver for calibration. Each trimpot is
identified on the printed circuit board.
 U V W

TB501
BOOST
DECEL TH501

DECEL BOO
L2

TQ
ACCEL C501
ACCEL
TQ TQ LIMIT

MAX
C502
J501
115V

4 mA

SET
ZERO
JMP501:INPUT RANGE

3:4-20MA
2:0-10VDC
1:0-5VDC
1-2:VOLTAGE
2-3:CURRENT
JMP502:INPUT TYPE

ZERO SET

JMP502
230V

E2
E1
S1
S2
S3
TB501

on isolation board

3
2
1
L1
Calibration

Figure 24. VFD Series Calibration Trimpot Layout

45
46 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.
3. Set all trimpots except TQ LIMIT and MAX fully
counterclockwise (CCW).
4. Set the TQ LIMIT trimpot to maximum (full CW).
5. Set the speed adjust potentiometer to zero (full CCW).
6. Calibrate the trimmer pots as follows:

MAXIMUM SPEED (MAX SPD)

Rotate the speed adjust potentiometer full CW. Using a

hand-held tachometer or analog frequency meter as a
reference, adjust the MAX trimpot until the desired speed or
frequency is reached.
 Calibration 47

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.
2. Set the TQ LIMIT trimpot to full CCW.
3. Carefully lock the motor shaft. Ensure that the motor is
firmly mounted.
4. Apply line power. The motor should be stopped.
5. Set the speed adjust potentiometer or reference signal
to maximum speed. The motor should remain stopped.
6. Slowly rotate the TQ LIMIT trimpot clockwise (CW) until
the ammeter reads 120% of maximum motor current.
7. Set the speed adjust potentiometer or reference signal
to zero speed.
8. Remove power from the drive.
9. Remove the lock from the motor shaft.
10. Remove the ammeter in series with the motor lead.
48 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.
3. If the acceleration time differs from the desired time,
adjust the ACCEL trimpot until the desired time is
reached. Rotating the ACCEL trimpot CW increases the
acceleration time.

DECELERATION (DECEL)

1. Set the speed adjust potentiometer to maximum (full

CW) and wait for the motor to come to maximum speed.
2. Set the speed adjust potentiometer to minimum speed
(full CCW) and note the time the motor takes to
decelerate to minimum speed.
3. If the deceleration time differs from the desired time,
adjust the DECEL trimpot until the desired time is
reached. Rotating the DECEL pot CW increases the
deceleration time.
 Calibration 49

BOOST

The boost trimpot is used to increase motor torque at low

speeds. The minimum setting is sufficient for most
applications and does not need to be adjusted. If the motor
stalls or runs erratically at very low speeds (below 10 Hz),
the boost trimpot may need adjustment.

1. Run the motor at the lowest continuous frequency/speed

required.

2. Monitor the motor phase current (with a true RMS

meter) while very slowly turning the BOOST trimpot CW
until the motor operates properly, or 100% of the motor
nameplate current is reached.

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.
50 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.
 51

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.

TB501

E2
FORWARD
SPEED
20K OHM
E1

REVERSE
SPEED S1
20K OHM

S2

S3

FORWARD
D (DIRECTION)
REVERSE

Figure 25. Independent Adjustable Speeds

52 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 motor
coasts to a stop when the RUN/JOG switch is set to JOG.
Press the JOG pushbutton to jog the motor. Return the
RUN/JOG switch to RUN for normal operation.
NORMALLY OPEN
RUN/JOG
PUSHBUTTON RUN/JOG
SWITCH

JOG
TB501
(motor coasts to stop)

E2 (ENABLE)
RUN

E1 (COMMON)

S1

S2

S3

Figure 26. RUN/JOG Switch

 Application Notes 53

Single speed potentiometer control of

multiple motors

 Warning
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.

MOTOR MOTOR
A B

CW U V W
S3

S2

S1
VFD SERIES
10K OHM
SPEED ADJUST DRIVE
POTENTIOMETER

Figure 27. Single Speed Potentiometer Control of Multiple Motors

54 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.

TB501

E2 (ENABLE)
DPDT CENTER
OFF SWITCH
E1 (COMMON)
FWD

STOP
S1

REV
S2

S3

Figure 28. VFD Quick Reversing

 55

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.

Before troubleshooting
Perform the following steps before starting any procedure in
this section:

• Disconnect AC voltage input from the drive. Wait 60

seconds for power to discharge. The green POWER LED
will blink while power is discharging.

• Check the drive closely for damaged components.

• Check that no wire, chips, or other foreign material has

become lodged on the printed circuit board.

• Verify that every connection is correct and in good

condition.
56 Troubleshooting

• 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 57

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
operational.

FAULT LED

The red FAULT LED turns on when the drive output is

locked out or not ENABLED and any one of the following
fault conditions occur:

1. Overvoltage
• VFD 230AC controls: DC bus exceeds 400 VDC
• VFD 115AC controls: DC bus exceeds 200 VDC
2. Undervoltage
• VFD 230AC controls: DC bus drops below 200 VDC
• VFD 115AC controls: DC bus drops below 100 VDC
3. Instantaneous Overcurrent Trip - Inverter output current has
exceeded safe levels.

Note: The FAULT condition must be reset using the

ENABLE function of the VFD (opening and closing
the ENABLE input).
58 Troubleshooting

TQ LIMIT LED

The yellow TQ LIMIT LED is on when the drive output

current exceeds the threshold set by the TQ LIMIT trimpot.
When the TQ LIMIT LED turns on, shut down the motor and
drive by disabling or removing power. Check the motor to
make sure it is not jammed or overloaded. The TQ LIMIT
trimpot may need to be recalibrated. See the Calibration
section (page 47) for information on calibrating the TQ
LIMIT trimpot.

U V W

TB501

DECEL BOOST

TQ TQ
ACCEL
TQ LIMIT

FAULT
J503

MAX
FAULT J501 JMP501

POWER
AC AC -
POWER IC502

C510
L2
J502

L1

Figure 29. VFD Series diagnostic LED locations

 Troubleshooting 59

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.

3. Nuisance tripping 3. Add a blower to

caused by a cool the drive
combination of components;
ambient conditions increase TQ LIMIT
and high-current settings (page 41).
spikes
(i.e. reversing).

External line fuse does 1. Speed adjust 1. Increase the speed

not blow, but the motor potentiometer or adjust
does not run voltage input signal is potentiometer
set to zero speed. setting or voltage
input signal.

2. Speed adjust 2. Check connections

potentiometer or to input. Verify that
voltage input signal is connections are not
not properly open.
connected to drive
input; connections are
open.
60 Troubleshooting

Problem Possible Suggested

Cause Solution

External line fuse does 3. Drive is “tripped” off 3. Disable, then re-
not blow, but the motor or has gone into enable the drive.
does not run (cont.) thermal overload.

4. Drive has been 4. Ensure that

disabled. ENABLE (EN) and
COM terminals are
properly connected.

5. Drive is in current 5. Verify that motor is

limit. not jammed.
Increase TQLIM
setting if it is set
too low (page 41).

6. Drive is not receiving 6. Apply AC line

AC voltage input. voltage to L1 and
L2.

7. Motor is not 7. Connect motor to

connected. drive outputs U, V
and W.

Motor runs too slow or 1. MAX SPD trimpot is 1. Calibrate MAX SPD
too fast at set not calibrated trimpot (page 40).
speed correctly.
 Troubleshooting 61

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; replace
motor motor if necessary

3. Check motor load.

3. Motor is overloaded. Resize the motor or
drive if necessary.

Motor pulsates or surges 1. Motor “bouncing” in 1. Make sure motor is

under load and out of torque limit. not undersized for
load; adjust TQ LIM
setting CW (page
41).

Motor does not reverse 1. Defective DIRECTION 1. Check DIRECTION

switch connection. switch connection.

2. Reversing circuit not 2. Check reversing

working properly. circuit by shorting
TB501 (D) terminal
to (E1) terminal
with jumper wire.
62 Troubleshooting

Problem Possible Suggested

Cause Solution

TQ is unsatisfactory at 1. TQ LIMIT set too low. 1. Check TQ LIM

high speeds. setting (page 41).

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
higher horsepower.

3. Nominal input voltage 3. Compare motor

may be too low for voltage to input
motor. voltage. Replace
motor if necessary.
 Troubleshooting 63

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.

Using one of the capacitors supplied in the kit, the carrier
frequency can be lowered to a range of 12kHz to 4kHz.
Note: Audible noise will increase when the carrier
frequency is lowered.

To lower the carrier freqency on all VFD controls, install one

of the following 2-pin capacitors (C510) on the bottom
board:

LABEL ON CAPACITOR FREQUENCY VALUE

3n3J 12kHz 0.0033uF
6n8 10kHz 0.0068uF
10n 8kHz 0.01uF
33n 4kHz 0.033uF

See Figure 30 on page 64 for C510 location and installation

instructions.
64 Troubleshooting

U V

TB501

DECEL BOOST
TQ
ACCEL
TQ LIMIT
Cap Label

3n3 J100 FAULT

MAX
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 65

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
3 ea Insulated Female Connector
66

NOTES
 67

NOTES
68

NOTES
 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.
This warranty applies only to standard catalog products, and does not apply to
specials. Any returns for special controls will be evaluated on a case-by-case basis.
The Corporation is not responsible for removal, installation, or any other incidental
expenses incurred in shipping the product to and from the repair point.
B. Disclaimer
The provisions of Paragraph A are the Corporation's sole obligation and exclude all
other warranties of merchantability for use, express or implied. The Corporation
further disclaims any responsibility whatsoever to the customer or to any other
person for injury to the person or damage or loss of property of value caused by any
product that has been subject to misuse, negligence, or accident, or misapplied or
modified by unauthorized persons or improperly installed.
C. Limitations of Liability
In the event of any claim for breach of any of the Corporation's obligations, whether
express or implied, and particularly of any other claim or breech of warranty
contained in Paragraph A, or of any other warranties, express or implied, or claim of
liability that might, despite Paragraph B, be decided against the Corporation by
lawful authority, the Corporation shall under no circumstances be liable for any
consequential damages, losses, or expense arising in connection with the use of, or
inability to use, the Corporation's product for any purpose whatsoever.
An adjustment made under warranty does not void the warranty, nor does it imply an
extension of the original 12-month warranty period. Products serviced and/or parts
replaced on a no-charge basis during the warranty period carry the unexpired
portion of the original warranty only.
If for any reason any of the foregoing provisions shall be ineffective, the
Corporation's liability for damages arising out of its manufacture or sale of
equipment, or use thereof, whether such liability is based on warranty, contract,
negligence, strict liability in tort, or otherwise, shall not in any event exceed the full
purchase price of such equipment.
Any action against the Corporation based upon any liability or obligation arising
hereunder or under any law applicable to the sale of equipment or the use thereof,
must be commenced within one year after the cause of such action arises.
 MINARIK DRIVES
www.minarikdrives.com

14300 De La Tour Drive, South Beloit, IL 61080

Phone: (815) 646-2745; Fax: (815) 624-6960
Document number 250–0348, Revision 3
Printed in the U.S.A – March 2006