driver c4xl3200a_um
driver c4xl3200a_um
USER’S MANUAL
MODELS
C4XL3025
C4XL3200A
All rights reserved. No part of this manual may be reproduced or transmitted in any
form without written permission from Minarik Drives. 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.
Contents
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Field Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Line Fusing for XL Series Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Voltage Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Before applying power: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Inhibit circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Decelerating to minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
MINIMUM SPEED (MIN SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
MAXIMUM SPEED (MAX SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
ACCELERATION (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
DECELERATION (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
IR COMPENSATION (IR COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
iii
Tables
Table 1. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Table 2. Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Table 3. Recommended Dynamic Brake Resistor Sizes . . . . . . . . . . . . . . . . . . .25
Table 4. AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
iv
Illustrations
Figure 1. C4XL3025 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Figure 2. C4XL3200A Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Figure 3. C4XL3025 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 4. C4XL3200A Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Figure 5. Prewired Connections for Models C4XL3025 and C4XL3200A . . . . . .11
Figure 6. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 7. Cage-Clamp Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Figure 8. Voltage Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Figure 9. Diagnostic LED Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Figure 10. Inhibit Plug with Run/Coast to Zero Speed Switch . . . . . . . . . . . . . . .22
Figure 11. Run/Decelerate to Minimum Speed Switch . . . . . . . . . . . . . . . . . . . . .23
Figure 12. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Figure 13. C4XL3025 CURR LIMIT and IR COMP Settings . . . . . . . . . . . . . . . . .31
Figure 14. C4XL3200A TORQ. LIMIT and IR COMP Settings . . . . . . . . . . . . . . .31
Figure 15. C4XL3025 MAX SPEED Settings for
Low Voltage DC Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Figure 16. C4XL3200A MAX SPD Settings for
Low Voltage DC Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 17. Leader-Follower Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Figure 18. Single Speed Potentiometer Control of Multiple Drives . . . . . . . . . . . .35
Figure 19. C4XL3025 Series Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Figure 20. C4XL3200A Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
1
Specifications
Model Number C4XL3025
Type: Cased
NEMA Rating NEMA 4X
AC Line Voltage 115 VAC/230 VAC, ±10%, 50/60 Hz, single phase
Line Fuse Rating 8A
Horsepower Range @ 130 VDC Output 1/20–1/3 HP
Horsepower Range @ 240 VDC Output 1/8–1/2 HP
Maximum Armature Voltage Range @ 115 VAC Input 50–130 VDC
Maximum Armature Voltage Range @ 230 VAC Input 50–240 VDC
Minimum Speed Adjustment Range @ 115 VAC Input 0–65 VDC
Minimum Speed Adjustment Range @ 230 VAC Input 0–65 VDC
Maximum Armature Current 3 ADC
Field Voltage @ 115 VAC Input 50 VDC/100 VDC
Field Voltage @ 230 VAC Input 100 VDC/200 VDC
Maximum Field Current 1 ADC
Form Factor 1.05
Acceleration Time Range (no load)
for 0–130 VDC Armature Voltage Range 1–10 seconds
for 0–240 VDC Armature Voltage Range 1–19 seconds
Deceleration Time Range (no load)
for 0–130 VDC Armature Voltage Range 3–9 seconds
for 0–240 VDC Armature Voltage Range 4–19 seconds
Analog Input Voltage Range (signal must be isolated; S1 to S2)
for 0–130 VDC Armature Voltage 0–2.7 VDC
for 0–240 VDC Armature Voltage 0–5.0 VDC
2 Specifications
Dimensions
6.90 [175]
0.91 [23]
50
40 60
30 70
20 80
10 90
0 100
6.00 [152]
4.43 [112]
3.29 [83]
1.92 [49]
6.90 [175]
50
40 60
30 70
20 80
10 90
0 100
7.00 [177]
5.79 [146]
4.69 [119]
1.45 [37]
2.31 [58]
0.12 [3]
1.50 [38]
1.50 [38]
Installation
Mounting
Nema 4X cased drives come with 0.88 inch (22 mm) conduit
knockout holes at the bottom of the case. The units may be
vertically wall mounted using the four 0.19 inch (5 mm) slotted
holes on the attached heat sink. For motor loads less than 5 ADC,
the drive may be bench mounted horizontally, or operated without
mounting.
2. For access to the terminal strip, turn the slotted screw on the
front cover counterclockwise until it is free from the case. The
right side of the cover is hinged to the case. Pull the slotted
screw to open the case.
5. Grasp the slotted screw and tilt the front cover back into place.
Avoid pinching any wires between the front cover and the case.
6. Turn the slotted screw clockwise until tight to secure the front
cover.
7. Set the POWER switch to the OFF position before applying the
AC line voltage.
Installation 9
Connections
TB501
L1 115 230 F1 F2 A2 A1
115
Armature
Motor Output
AC Line Voltage
115 or 230 VAC
+
230
Field Output -
Shunt wound motors only.
See Field Output section for
connections.
FAST-ACTING
L1 230 115 F+ A1 F- A2
230
Armature
Motor
Output
AC Line Voltage
115 or 230 VAC
115
Field Output -
Shunt wound motors only.
See Field Output section for
connections.
Power
Switch
black black/white
PS1 PS2
Power
Light
white white/black
PS3 PS4
violet CW
S1
grey
S3
Shielding guidelines
Field Output
The field output is for shunt wound motors only. Do not make any
connections to the field output when using a permanent magnet
motor. Table 1 shows where to connect the field leads of a shunt
wound motor.
Fusing
C4XL3025: This drive comes with two 8A fuses installed
(FU501 & FU502). FU501 connects with the L1 terminal (the hot
leg of the AC line voltage). FU502 connects with the 230 terminal.
If the current rating of the motor is less than the maximum current
rating of the drive, replace the fuse with a lower rated one. Rate
fuses at 150% times the maximum armature current.
Voltage Follower
Instead of using a speed adjust potentiometer, the drive may be
wired to follow a 0 - 10 VDC voltage signal that is isolated from
earth ground (Figure 6). Connect the signal input (+) to S1.
Connect the signal common (-) to S2. Make no connection to S3.
A potentiometer can be used to scale the analog input voltage. To
achieve greater linearity and control, use an interface device such
as Minarik model PCM4 to scale the analog input voltage.
XL
SERIES
DRIVE
SIGNAL INPUT (+) S2
Terminal Block
All XL drives use a cage-clamp spring terminal block. To open the
clamp spring, use a small screwdriver to press down on the lever
above the terminal block. To insert a wire into a terminal, use the
following procedure:
Operation
Before applying power:
TH501
BR+
Q501 D501
AC2
C504
BR-
B2
T501
R503
AC1
VOLTAGE SELECT 1
C505
115
SWITCHES
SW501
SW502
115
IC503
Startup
Diagnostic LEDs
XL series drives are equipped with diagnostic LEDs. The green
POWER ON LED turns on when power is applied to the drive and
turns off when power is removed. The red CURR LIMIT LED turns
on when the drive reaches current limit and turns off when the drive
is not in current limit (normal operation). See Figure 9 on page 20
for Diagnostic LED locations.
20 Operation
15
C4XL3200 LEDs
C4XL3025A LEDs
PS1 PS3 S1 S2 S3
SO502
-15V+
MAX SPD CURR LIMIT IR COMP
POWER CURR
SO501 ON LIMIT
TB501
L1 115 230 F1 F2 A2 A1
Inhibit circuit
Warning
The inhibit circuit is used for frequent starts and stops. It
must never be used as an emergency stop. The inhibit
circuit may not stop a drive that is malfunctioning.
Removing AC line power (both L1 and L2) is the only
acceptable method for emergency stopping.
RUN
COAST TO
ZERO SPEED
INHIBIT
CW
S3
10K OHM
S2 SPEED ADJUST
POTENTIOMETER
S1
RUN
DECEL TO
MIN SPEED
Dynamic braking
Dynamic braking may be used to rapidly stop a motor (Figure 12).
For the RUN/BRAKE switch, use a double pole, double throw
switch rated for at least the maximum DC armature voltage and
maximum braking current.
A1 A2
RUN
MOTOR
DYNAMIC BRAKE
RESISTOR
BRAKE
INHIBIT
Warning
Wait for the motor to come to a complete STOP before
switching back to the RUN position. This will prevent high
armature currents from damaging the motor or drive.
Minimum Minimum
Motor Armature Dynamic Brake Dynamic Brake
Current Rating Resistor Value Resistor Wattage
Less than 2 ADC 1 ohm 1W
2–3 ADC 5 ohm 5W
3–5 ADC 10 ohm 10W
5–10 ADC 20 ohm 20W
10–17 ADC 40 ohm 50W
For motors rated 1/17 horsepower and lower, a brake resistor is not
necessary since the armature resistance is high enough to stop the
motor without demagnetization. Replace the dynamic brake with 12
gauge wire.
26
Calibration
To calibrate, set the MAX SPD trimpot full CCW. Turn the speed
adjust potentiometer full CW. Adjust the MAX SPD trimpot until the
desired maximum motor speed is reached.
Note: Check the MIN SPD and MAX SPD adjustments after
recalibrating to verify that the motor runs at the desired minimum
and maximum speed.
28 Calibration
ACCELERATION (ACCEL)
The ACCEL setting determines the time the motor takes to ramp to
a higher speed. See Specifications on page 1 for approximate
acceleration times. The ACCEL setting is factory set to its
minimum value (full CCW).
DECELERATION (DECEL)
The DECEL setting determines the time the motor takes to ramp to
a lower speed. See Specifications on page 1 for approximate
deceleration times. The DECEL setting is factory set to its
minimum value (full CCW).
1/20 HP 1/8 HP
90 VDC 180 VDC
1750 RPM 1750 RPM
0.5 Amps 0.67 Amps
CURR LIMIT IR COMP CURR LIMIT IR COMP
1/8 HP 1/4 HP
90 VDC 180 VDC
1750 RPM 1750 RPM
1.3 Amps 1.4 Amps
CURR LIMIT IR COMP CURR LIMIT IR COMP
1/4 HP 1/3 HP
90 VDC 180 VDC
1750 RPM 1750 RPM
2.5 Amps 1.75 Amps
CURR LIMIT IR COMP CURR LIMIT IR COMP
1/4 HP 1/2 HP
90 VDC 180 VDC
1750 RPM 1750 RPM
2.5 Amps 2.5 Amps
TORQ LIMIT IR COMP TORQ LIMIT IR COMP
1/2 HP 1 HP
90 VDC 180 VDC
1750 RPM 1750 RPM
5 Amps 5 Amps
TORQ LIMIT IR COMP TORQ LIMIT IR COMP
1/4 HP 2 HP
90 VDC 180 VDC
1750 RPM 1750 RPM
10 Amps 9 Amps
TORQ LIMIT IR COMP TORQ LIMIT IR COMP
12
24
36
48
NOT NOT
12 APPLICABLE APPLICABLE
NOT NOT
24 APPLICABLE APPLICABLE
36
48
Application Notes
Leader-follower application
In this application, use a PCM4 to monitor the speed of the leader
motor (Figure 17). The PCM4 isolates the leader motor from the
follower drive, and outputs a voltage proportional to the leader
motor armature voltage. The follower drive uses this voltage
reference to set the speed of the follower motor. An optional ratio
potentiometer may be used to scale the PCM4 output voltage.
A1 9 (+) (+) 2 S2
Leader MOTOR 8 (-) 1 Follower
PCM4
Drive Drive
A2 7 (-) TB502 S1
ratio pot A
6 2 (optional)
10K Ohms A1
Drive Motor
8 S2
10K Ohms PCM4 A A
7 1 S1 A2
TB501 TB502
ratio pot B
6 2 (optional)
10K Ohms A1
Motor
8 S2 Drive
PCM4 B
B
7 1 S1 A2
TB501 TB502
Troubleshooting
Before troubleshooting
Perform the following steps before starting any procedure in this
section:
Motor runs too fast 1. MIN SPD and MAX 1. Recalibrate MIN
at maximum speed SPD settings are SPD and MAX
setting too high. SPD.
38 Troubleshooting
Block Diagram
F1 FIELD
F2 SUPPLY
G
L2
L1 CONTROL
LOGIC
POWER
+10
CONTROL -10
TRANSFORMER
S3
10K
S2
S1
OUTPUT
A2 STAGE
R501
A1
.01/5W INHIBIT
INHIBIT
STAGE
+15 FWD ACC
INPUT CW 1M
22K AMPLIFIER
-
-
+
.022
SO +
CW 1M SOFT
-15 REV ACC START
RB1
CW
RB2 CW
MIN SPD
.022 22K 5K
50K
MAX SPD
CW
50K -
IR COMP
+
FORWARD/REVERSE
TRIGGERING
-
- STAGE
+
+
-15
CW DEAD BAND
50K
REV TQ
-
STAGE
+
50K
+15 DB
CW CW
-
50K
FWD TQ
+
F1
FIELD
SUPPLY
F2
PS1 PS1 +
L1 A1
+ OUTPUT
POWER INPUT
230 POWER
LIGHT RECTIFIER
STAGE
115 A2
PS3 PS4
CHASSIS
+15 +15
GROUND
+15
470
115-230
CONTROL
5K PWM
LOGIC
470 GENERATOR PEAK CURRENT
POWER
DETECTOR
230-115
S3 MIN
SPEED
56K
10K
SPD 51K IR COMP
20K
50K
SPD IN CURR LIMIT
+15 6.8 +
+ 500K
JOG -15
50K
12K MAX 0.1 10K
SPEED 47K CURRENT 50K
LIMIT LED
JOG 12K
2.2K
5K
500K
INHIBIT
Replacement Parts
Certificate of Compliance
Minarik Corporation hereby certifies that its XL series drives
(models C4XL3025 and C4XL3200A) have been approved to bear
the “CE” mark provided the conditions of approval have been met
by the end user.
The end user, as described herein, falls into one of two categories:
AC Line Filters
In addition to EMI/RFI safeguards inherent in the XL series’ design,
external filtering is required.
Wire the AC line filter within 0.25 meters of the drive. The ground
connection from the filter must be wired to solid earth ground (resistance
less than 500 ohms); not machine ground. This is very important!
NOTES
47
NOTES
48
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 breech 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
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