Minarik MAC Series Manuel utilisateur

USER’S MANUAL

Models:

MAC05–D240AC

MAC08–D240AC

MAC05–D240AC-PCM

MAC08–D240AC-PCM

Variable-frequency drives for 3-phase AC motors

MAC Series

250-0275 rev2.qxd 3/9/01 10:36 AM Page a

Minarik Corporation

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.

Printed in the United States of America.

250-0275 rev2.qxd 3/9/01 10:36 AM Page b

Safety Warnings

•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

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 screwdriver for adjusting the

calibration trimpots. Use approved personal protective

equipment and insulated tools if working on this drive with

power applied.



250-0275 rev2.qxd 3/9/01 10:36 AM Page i

Specifications 1

Dimensions 2

Installation 3

Mounting ...................................................3

Wiring .....................................................4

Shielding guidelines . . . ......................................5

Isolation (-PCM drives only) . ...................................6

Fusing ....................................................6

Heat sinking ................................................6

Speed adjust potentiometer .....................................7

Cage-clamp terminals . . . ......................................8

Connections . ................................................9

Power and fuse connections .................................10

Motor connections . . . . . . ..................................13

Three-phase motors . . . . . . .................................15

Operation 17

Voltage doubler .............................................18

To enable voltage doubling: .................................19

Before applying power . . . . . . .................................20

Startup ....................................................21

To reverse motor direction: ..................................22

Starting and stopping methods .................................23

Braking . . . ..............................................23

To coast the motor to a stop without disconnecting power: ..........23

I²T trip operation (class 10 characteristics) ......................24

Line starting and line stopping ...............................24

Decelerate to minimum speed ...............................25

Decelerate to minimum with DC injection braking .................26

Drive thermal protection ......................................28

Contents

250-0275 rev2.qxd 3/9/01 10:36 AM Page ii

Thermal protection of the motor ..............................28

Calibration 30

Calibration Procedure Setup for 60 Hz Motors (See Figure 12): .........34

MINIMUM SPEED (MIN SPD) ...............................36

MAXIMUM SPEED (MAX SPD) ...............................36

CURRENT LIMIT (I LIMIT) ..................................36

SLIP COMPENSATION (SLIP COMP) .........................37

ACCELERATION/DECELERATION (ACCEL/DECEL) ..............37

Torque Boost Adjustment ...................................38

Application Notes 40

Thermal Protection Switch Installation ............................40

Independent adjustable speeds with .............................41

FWD-REV switch ...........................................41

RUN/JOG switch ............................................42

Single speed potentiometer control of multiple motors ................43

Reversing . . . ..............................................44

Voltage follower ............................................45

Troubleshooting 46

Before troubleshooting . . . . . . .................................46

Diagnostic LEDs ............................................47

POWER ON (green) . . . . . . .................................47

FAULT (red) ...............................................

TRIP I²T (red) . . ............................................

REV (amber) ...............................................

FWD (amber) . . ............................................

TQ LIM (red) ............................................48

Clearing LED fault indications ..................................52

Replacement Parts ..........................................58

Unconditional Warranty inside back cover

iiiTable of Contents

250-0275 rev2.qxd 3/9/01 10:36 AM Page iii

Figure 1. Dimensions . . . . . . ....................................2

Figure 2. Speed Adjust Potentiometer ..............................7

Figure 3. Cage-Clamp Terminal ...................................8

Figure 4. Power and Fuse Connections ............................10

Figure 5. Signal and Optional Switch Connections ....................12

Figure 6. Motor Connections for Single-Phase Operation ..............14

Figure 7. Motor Connections for Three-Phase Motors .................16

Figure 8. Voltage Doubler Terminals ..............................19

Figure 9. Run/Decelerate to Minimum Speed Switch ..................25

Figure 10. RUN-BRAKE switch with optional ENABLE-DISABLE Switch ....27

Figure 11. Thermal Overload Switch with Optional Enable/Disable Switch . . .29

Figure 12. Calibration Trimpot Layout ..............................31

Figure 13. DIP Switch Layout and Initial Settings ......................32

Figure 14. Carrier Frequency Mode DIP Switch Layout .................35

Figure 15. Accel Torque Boost DIP Switch Setting .....................39

Figure 16. Thermal Overload Protection Switch Installation ..............40

Figure 17. Thermal Overload Protection Switch Installation

With Optional Enable/Disable Switch .......................40

Figure 18. Independent Adjustable Speeds ..........................41

Figure 19. RUN/JOG Switch . . . ..................................42

Figure 20. Single Speed Potentiometer Control of Multiple Motors .........43

Figure 21. Reversing Circuit Connection ............................44

Figure 22. Voltage Follower Connections ............................45

Figure 23. Diagnostic LED Layout .................................49

Illustrations

250-0275 rev2.qxd 3/9/01 10:36 AM Page iv

Table 1. Motor Phase DIP Switch Settings .........................15

Table 2. Voltage Doubler Configuration ...........................19

Table 3. Max Frequency DIPSwitch Settings .......................33

Table 4. Carrier Frequency DIPSwitch Settings .....................35

Table 5. Accel Torque Boost DIP Switch Settings ....................39

Table 6. Replacement Parts ...................................58

Tables

250-0275 rev2.qxd 3/9/01 10:36 AM Page v

*Actual minimum frequency will depend on motor type and the load to which it is

connected.

General Information

Minarik MAC Series drives are voltage-vector-controlled,

microprocessor-based, variable-frequency AC motor drives. With

a 115 or 230 VAC, 50/60 Hz, single-phase input, MAC drives are

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 motor through a speed range of zero* through

nameplate speed. They can be user calibrated for 0* through 400

Hz output.

Using proprietary power-control circuitry, the MAC can also

double the input line voltage. This allows users to plug the MAC

into a 115 VAC line, but control a 208/230 VAC motor.

Although MAC inverters can operate over a 100:1 speed range,

most motors will operate over a 10:1 speed range with constant

torque at 0* 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 100 rpm (speed range 25:1). Below 100 rpm, some

motors may show signs of “stepping” or “cogging”, or they may

run warmer.

250-0275 rev2.qxd 3/9/01 10:36 AM Page vi

†

In silent mode.

viiGeneral Information

The MAC carrier frequency is true 16.5 kHz.†Many AC drive

manufacturers count the leading and trailing edge of the

modulated signal, thereby doubling the published carrier

frequency; however, their fundamental frequency is only half

(8 kHz in this case). By this method, the MAC’s carrier

frequency would be 33 kHz. The MAC is one of the only drives

on the market with truly silent operation.

MAC Series drives feature solid-state reversing with adjustable

acceleration and deceleration. They also feature adjustable

current limit and I²T class 10 current trip to protect the motor, the

control and the driven machine from damage caused by motor

overload or machine jamming. The MAC may also interface with

motor thermal protection through the enable circuit.

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 primitive 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 still 120º apart. The MAC

can efficiently operate a single-phase motor because the ASIC

changes the phase shift to 90º in order to develop maximum

torque.

250-0275 rev2.qxd 3/9/01 10:36 AM Page vii

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.

viii General Information



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.



The MAC is very efficient when the two (2) torque boost settings

are properly adjusted; the accel torque boost is applied only

during acceleration. Other drives, with only one torque boost

setting, can cause motor overheating by applying too much during

steady-state operating conditions.

IMPORTANT INFORMATION

In addition to standard 3-phase induction motors, the following

motor types may be used with the MAC:

• Permanent split capacitor (PSC)

• Shaded pole

• AC synchronous

• AC stepping: 28.8, 72 and 200-RPM type.

250-0275 rev2.qxd 3/9/01 10:36 AM Page viii

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