Model 200-0386A Switching Logic Board User s Manual For Use With Minarik Full-Wave Regenerative Drives
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 keep current the information in this manual. MVD062802 Printed in the United States of America.
Safety Warnings SHOCK HAZARD AVOID HEAT KEE DR OID ATION Have a qualified electrical maintenance 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. Install a master switch in the AC line for stopping the drive in an emergency. When the switching logic board is connected to a variable speed regenerative drive it is isolated from earth ground. 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 any necessary adjustments.
ii Contents Safety Warnings i Specifications 1 Dimensions 2 General Information 3 Installation 4 Mounting the Logic Board.....................................4 Wiring....................................................5 Screw terminal block.........................................5 Speed adjust potentiometer....................................6 Shielding Guidelines..........................................9 Modes of Operation 10 Pushbutton switches........................................11 Limit switches.............................................11 Foot pedals...............................................11 DIP switches..............................................11 Pushbutton operation: FORWARD/STOP/REVERSE................12 Pushbutton operation: RUN/STOP.............................13 Pushbutton operation: jog FORWARD/jog REVERSE...............14 Pushbutton operation: jog RUN................................15 Limit switch operation: no automatic reversing.....................16 Limit switch operation: FORWARD/STOP/REVERSE, 1 Cycle.........17 Limit switch operation: automatic cycling.........................18 Foot pedal operation: FORWARD/STOP/REVERSE................20 Foot pedal operation: RUN/STOP..............................21
iii Connection to Minarik Regenerative Drives 22 Unconditional Warranty inside back cover Illustrations Figure 1. Model 200-0386A Switching Logic Board Layout and Dimensions 2 Figure 2. Screw Terminal Block 5 Figure 3. Speed Adjust Potentiometer 6 Figure 4. Single Speed Potentiometer Connections 7 Figure 5. Two Speed Potentiometer Connection 8 Figure 6. Pushbutton Operation: FWD/STOP/REV 12 Figure 7. Pushbutton Operation: RUN/STOP 13 Figure 8. Pushbutton Operation: jog Forward/jog Reverse 14 Figure 9. Pushbutton Operation: jog RUN 15 Figure 10. Limit switch operation: no automatic reversing 16 Figure 11. Limit Switch Operation: FWD/STOP/REV, 1 cycle 17 Figure 12. Limit Switch Operation: automatic cycling 19 Figure 13. Foot pedal operation: FORWARD/STOP/REVERSE 20 Figure 14 Foot pedal operation: RUN/STOP 21 Figure 15. Connection diagram: Switching Logic Board (200-0386A) to RG100UC/RG200UC 22 Figure 16. Connection diagram: Switching Logic Board (200-0386A) to RG300UA/RG310UA/RG400UA 23 Figure 17. Connection diagram: Switching Logic Board (200-0386A) to RG500UA/RG510UA 24
iv Illustrations (cont.) Figure 18. Connection diagram: Switching Logic Board (200-0386A) to RG5500U 25 Figure 19. Connection diagram: Switching Logic Board (200-0386A) to MRG30U/MMRG31U/MMRG40U 26 Figure 20. Connection diagram: Switching Logic Board (200-0386A) to MMRGD03/MMRGD10 27 Figure 21. Connection diagram: Switching Logic Board (200-0386A) to RG60U 28 Figure 22. TTL Logic Input 29 Figure 23. NPN Open Collector Input 30 Figure 24. Contact Input 31
1 Specifications Input Power +15 VDC @ 20 ma -15 VDC @ 1.5 ma Acceptable Input Devices Dry Contacts Current-Sinking Open Collectors TTL Logic Devices Number of Switching Modes Four (4) Speed adjust potentiometer 10 K Ohms Maximum Reference Voltage to Drive ±15 VDC Ambient Operating Temperature Range 10 C - 40 C Weight 0.2 lbs Note: This switching logic board is specifically designed to operate with Minarik control models RG100UC, RG200UC, RG300U, RG400U, RG500U, RG5500U, and RG60U. Consult factory before attempting to use with other models.
2 Dimensions TB502 TB501 8 9 10 11 12 13 14 15 16 POWER IL501 6 IC501 7 K501 IC502 2 3 4 5 3.10 [79] 17 18 K 1 0.20 [5] 0.87 [22] 2.49 [63] 3.45 [88] MOUNTING HOLES 0.19 [5] - 4 PLACES 1.0525" Figure 1. Model 200-0386A Switching Logic Board Layout and Dimensions
3 General Information Caution Regenerative braking imposes very high stress on the rotating components of the drive train. It is very important that these deceleration forces be considered before selecting a drive system that applies regenerative braking to a gearmotor or other gearbox. Minarik Corporation s model 200-0386A provides the logic interface between the regenerative drive and pushbutton stations, foot switches, or programmable controls. It accepts dry contact mechanical closures, current-sinking open collectors, and TTL logic devices. The limit switch logic board has four operating modes, which can be configured nine different ways. Select the one that fits your application and follow the wiring and DIP switch instructions for that configuration. The speed adjust potentiometer (10K ohms, 2 watts) is wired through the logic board (200-0386A) module, rather than directly to the regenerative drive. Use either one potentiometer for both forward and reverse speeds (Figure 4, page 7) or if different speeds are required in each direction one potentiometer for forward and one potentiometer for reverse speed settings (Figure 5, page 8).
4 Installation Mounting the Logic Board Logic board components are sensitive to electrostatic fields. Avoid contact with the circuit board directly. Protect the logic board from dirt, moisture, and accidental contact. Provide sufficient room for access to the terminal block. Mount the logic board away from other heat sources. Operate within the specified ambient operating temperature range. The operating temperature range for the 200-0386A is 10 C through 40 C. Prevent loose connections by avoiding excessive vibration of the logic board. Mount the logic board in either a horizontal or vertical plane using the four 0.19 inch [5 mm] mounting holes located on the board.
Installation 5 Wiring Screw terminal block Connections to Minarik s 200-0386A logic board are made to a screw terminal block. There are two screw terminal blocks on the board. The large one is shown in Figure 2. The smaller screw terminal block has a similar connection style to the one shown. Using a screwdriver, turn the terminal block screw counterclockwise to open the wire clamp. Insert stripped wire into the wire clamp. Turn the terminal block screw clockwise to clamp the wire. TERMINAL BLOCK SCREW WIRE CLAMP Figure 2. Screw Terminal Block
6 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 regenerative drive. Install the circular insulating disk between the panel and the 10K ohm speed adjust pot. Mount the speed adjust pot through a 0.38 inch (10mm) hole with the hardware provided (Figure 3). Twist the speed adjust pot wire to avoid picking up unwanted electrical noise. If potentiometer leads are longer than 18 inch (457mm), use shielded cable. Logic lines of this length act as an antenna and can pick up noise from the drive components, noise from other devices or other ground wires, or voltage from power lines that can cause erratic operation. The 200-0386A does not include this pot. MOUNT THROUGH A 0.38 IN. (10 MM) HOLE CW WIPER W NUT STAR WASHER SPEED ADJUST POTENTIOMETER PANEL INSULATING DISK Figure 3. Speed Adjust Potentiometer
Installation 7 It may be necessary to earth ground the shielded cable. If noise is produced by devices other that 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. The following diagrams show the potentiometer connections to terminal block 2 (TB2). Use Figure 4 when a single speed is desired in both the forward and reverse directions. Use Figure 5 when one speed is desired in the forward direction, and a different speed is desired in the reverse direction. 15 14 13 12 11 10 9 8 CW 10K OHM SPEED ADJUST POTENTIOMETER Figure 4. Single Speed Potentiometer Connections
8 Installation 15 14 13 12 11 10 9 8 CW CW Figure 5. Two Speed Potentiometer Connection
Installation 9 Shielding Guidelines Warning Under no circumstances should power and logic leads be bundled together. Induced voltage can cause unpredicatble 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 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 shielf at the drive end. If noise is generated by a device on the drive, ground the sheild at the end away from the drive. Do not ground both ends of the shield. 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.
10 Modes of Operation The limit switch logic board has four (4) different modes of operation which can be configured into nine (9) difference connections. They are as follows: 1) FORWARD/STOP/REVERSE Pushbutton Operation Limit Switch Operation Foot Pedal Operation 2) RUN/STOP Pushbutton Operation Foot Pedal Operation Limit Switch Operation (no automatic reversing) 3) jog FORWARD/jog REVERSE Pushbutton Operation 4) jog RUN Pushbutton Operation Limit Switch Operation
Modes of Operation 11 Pushbutton switches Pushbutton switches are momentary operated type. RUN, FWD, and REV switches are normally open. STOP switches are normally closed. Limit switches Limit switches are single pole, single throw, normally closed. Foot pedals Foot pedals are single pole, single throw, normally open. DIP switches Use a small screwdriver to change DIP switch settings. The arrow on the dip switch box indicates the ON position.
12 Modes of Operation Pushbutton operation: FORWARD/STOP/REVERSE In this mode the appropriate pushbutton initiates travel. The motor is reversed by pressing the opposite direction pushbutton. The stop pushbutton will regeneratively brake the motor. OFF OFF O N 1 2 3 4 5 6 7 TB501 FWD REV STOP JUMPER Figure 6. Pushbutton Operation: FWD/STOP/REV
Modes of Operation 13 Pushbutton operation: RUN/STOP In this mode the RUN pushbutton is actuated to start the motor. The motor will continue to run until the STOP pushbutton is depressed. This mode does not allow reversing. If the motor runs in the wrong direction, shut down the system and reverse the armature connections to the regenerative drive. OFF OFF O N 1 2 3 4 5 6 7 TB501 RUN STOP JUMPER Figure 7. Pushbutton Operation: RUN/STOP
14 Modes of Operation Pushbutton operation: jog FORWARD/jog REVERSE In this mode the motor turns only when the forward or reverse pushbutton is being depressed. To reverse the motor, first release the activated pushbutton to regeneratively brake the motor. Then push the opposite direction pushbutton. ON ON O N 1 2 3 4 5 6 7 TB501 FWD REV JUMPER JUMPER Figure 8. Pushbutton Operation: jog Forward/jog Reverse
Modes of Operation 15 Pushbutton operation: jog RUN In this mode the motor turns only as long as the RUN pushbutton is depressed. When the pushbutton is released the drive will regeneratively brake the motor. If the motor runs in the wrong direction, shut down the system and reverse the armature connections to the regenerative drive. ON ON O N 1 2 3 4 5 6 7 TB501 RUN JUMPER JUMPER Figure 9. Pushbutton Operation: jog RUN
16 Modes of Operation Limit switch operation: no automatic reversing In this mode activating the appropriate pushbutton will initiate travel. The motor will regeneratively brake when the corresponding limit switch is actuated (opened) or when the STOP pushbutton is depressed. If travel is interrupted by STOP before the limit switch is reached, it can be resumed by pressing the appropriate direction pushbutton. OFF OFF O N 1 2 3 4 5 6 7 TB501 REV FWD REV STOP FWD Figure 10. Limit switch operation: no automatic reversing
Modes of Operation 17 Limit switch operation: FORWARD/STOP/REVERSE, 1 Cycle In this single-cycle mode the motor automatically returns to the REV limit switch location. It normally begins at that site with the actuation of the FWD pushbutton. If the starting position is not at the FWD limit switch, press FWD to complete the balance of the automatic FWD/STOP/REV cycle or press REV to complete the REV portion of the cycle. ON OFF O N 1 2 3 4 5 6 7 TB501 REV FWD REV STOP FWD Figure 11. Limit Switch Operation: FWD/STOP/REV, 1 cycle
18 Modes of Operation Limit switch operation: automatic cycling In this mode the motor will continuously cycle the load between the FWD and REV limit switches. To stop the cycling process, press the STOP pushbutton. Re-starting the cycle is dependent upon the position of the machine when stopped: If stopping occurs with the FWD limit switch activated, the REV pushbutton must be pressed to re-start. If stopping occurs with the REV limit switch activated, the FWD pushbutton must be pressed to re-start the cycle. If stopping occurs between the FWD and REV limit switches, either pushbutton may be pressed to re-start the cycle.
Modes of Operation 19 OFF ON O N 1 2 3 4 5 6 7 TB501 REV FWD REV STOP FWD Figure 12. Limit Switch Operation: automatic cycling
20 Modes of Operation Foot pedal operation: FORWARD/STOP/REVERSE In this mode the motor runs as long as a pedal is depressed. When the pedal is released the drive will regeneratively brake the motor. When reversing the direction of travel it is necessary to release one pedal before depressing the other. ON ON O N 1 2 3 4 5 6 7 TB501 FWD REV JUMPER JUMPER Figure 13. Foot pedal operation: FORWARD/STOP/REVERSE
Modes of Operation 21 Foot pedal operation: RUN/STOP In this mode the motor runs as long as the pedal is depressed. Release the pedal and the drive will regeneratively brake the motor. If the motor runs in the wrong direction, shut down the system and reverse the armature connections to the regenerative drive. ON ON O N 1 2 3 4 5 6 7 TB501 RUN JUMPER JUMPER Figure 14 Foot pedal operation: RUN/STOP
22 Connection to Minarik Regenerative Drives K501 K502 IC502 1 2 P501 K501 P502 P509 C501 P503 P510 IC501 C502 P504 IC502 TB502 2 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 200-0386A RG100UC/RG200UC Figure 15. Connection diagram: Switching Logic Board (200-0386A) to RG100UC/RG200UC
Connection to Minarik Regenerative Drives 23 02 GND 1 2 3 F1 T505 F2 A2 K502 IC502 C504 C502 C503 TB501 A1 2 1 C511 IC502 IC501 C505 + INHIBIT + TB502 14 15 16 17 18 S3 S2 S1 S0 RB1 RB2-15 +15 200-0386A RG300UA/RG310UA/ RG400UA Figure 16. Connection diagram: Switching Logic Board (200-0386A) to RG300UA/RG310UA/RG400UA
24 Connection to Minarik Regenerative Drives 200-0386A RG500UA/RG510UA TB502 C505 3 14 15 16 17 18 S3 S2 S1 S0 RB1 RB2-15 +15 T1 T2 Figure 17. Connection diagram: Switching Logic Board (200-0386A) to RG500UA/RG510UA
Connection to Minarik Regenerative Drives 25 200-0386A RG5500U A2 A1 DISABLE/ENABLE CFVS 1-5 4-20 10-50 SW505 TB502 C503 C516 IC502 4 15 16 17 18 TB501 L1 L2 CS S3 S2 S1 SO TP -15 S1 S2 S3 S0 Figure 18. Connection diagram: Switching Logic Board (200-0386A) to RG5500U
26 Connections to Minarik Regenerative Drives 200-0386A MMRG30U/MMRG31U/ MMRG40U S1 8 18 DS5 1 K502 17 60HZ PL2 2 15 16 K501 14 13 DC VOLTAGE DC VOLTAGE S2 9 11 SW501 MMRG PL1 12 DC VOLTAGE 10 TB502 DC VOLTAGE +15V -15V T501 SO501 COMMON S0 IC501 Figure 19. Connection diagram: Switching Logic Board (200-0386A) to MRG30U/MMRG31U/MMRG40U
Connections to Minarik Regenerative Drives 27 200-0386A MMRGD03/MMRGD10 POWER S0 IL503 IL504 IL505 IC501 K502 K501 8 9 10 11 12 13 14 15 16 17 18 C502 C501 SW502 IC502 SW501 115 230 230 115 P501 P502 P503 P504 SW503 T501 S1 REV FWD S2 S3 +15V -15V RB4 RB3 RB2 RB1/COM TACHO FEEDBACK TACH ARM SO501 IC501 PL2 ARMATUR 180 90 TB502 FWD ACC REV ACC FWD TQ REV TQ P508 P507 P506 P505 MAX MIN IR SPD SPD COMP TACH Figure 20. Connection diagram: Switching Logic Board (200-0386A) to MMRGD03/MMRGD10
K 28 Connections to Minarik Regenerative Drives REV C50 IC502 L2 L1 X INVERT INHIBIT MP INVERT ENABLE LIMIT FWD REV D IL501 IL502 TB502 Y501 JP502 C503 IC501 IC504 TB503 ENABLE C5 IL503 K501 POWER TACH T2 T1 RB1 RB2-15V +15V S3 S2 S1 S0 3 14 15 16 17 18 TB501 T501 S3 S2 S1 S0 200-0386A RG60U Figure 21. Connection diagram: Switching Logic Board (200-0386A) to RG60U
TB502 NOTE: TTL GATES MAY REQUIRE PULL-UP RESISTORS FWD PB N.O. REV PB N.O. TTL GATES STOP PB N.C. COMMON FWD LS N.C. REV LS N.C. TTL LOGIC +5 R 2.2K TB501 1 2 3 4 5 6 7 200-0386A SWITCHING LOGIC BOARD TB502 18 17 16 15 14 13 12 11 10 Figure 22. TTL Logic Input 9 8 (RB1/COM) (+15) (S2) (-15) JUMPER REV CW 14 13 12 11 10 9 8 FWD CW INDEPENDENT FWD & REV SPEED CONNECTIONS SHOWN CAUTION! TTL LOGIC MUST BE ISOLATED FROM THE AC LINE. CW JUMPERS SINGLE SPEED FOR FWD & REV CONNECTIONS SHOWN Connections to Minarik Regenerative Drives 29
TB502 30 BASE CURRENT LIMITING RESISTORS FWD PB R N.O. +BASE VOLTAGE REV PB R N.O. +BASE VOLTAGE STOP PB R N.C. +BASE VOLTAGE COMMON FWD LS N.C. REV LS N.C. TB501 1 2 3 4 5 6 7 200-0386A SWITCHING LOGIC BOARD TB502 18 17 16 15 14 13 12 11 10 9 8 (RB1/COM) (+15) (S2) (-15) JUMPER REV CW 14 13 12 11 10 9 8 FWD CW INDEPENDENT FWD & REV SPEED CONNECTIONS SHOWN CW JUMPERS SINGLE SPEED FOR FWD & REV CONNECTIONS SHOWN Connections to Minarik Regenerative Drives CAUTION! NPN TRANSISTOR SUPPLY VOLTAGE MUST BE ISOLATED FROM THE AC LINE. Figure 23. NPN Open Collector Input
TB502 FWD PB N.O. REV PB N.O. STOP PB N.C. FWD LS N.C. REV LS N.C. TB501 1 2 3 4 5 6 7 200-0386A SWITCHING LOGIC BOARD TB502 18 17 16 15 14 13 12 11 10 9 8 (RB1/COM) (+15) (S2) (-15) JUMPER REV CW 14 13 12 11 10 9 8 FWD CW INDEPENDENT FWD & REV SPEED CONNECTIONS SHOWN CW JUMPERS SINGLE SPEED FOR FWD & REV CONNECTIONS SHOWN Connections to Minarik Regenerative Drives Figure 24. Contact Input 31
32 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.
901 East Thompson Avenue Glendale, California 91201-2011 Phone: (818) 502-1528 Fax: (818) 502-0716 www.minarikcorp.com Document number 250 0222, Revision 2 Printed in the U.S.A June 2002