An American Control Electronics Brand PCM4 SERIES USER MANUAL PCM4.

An American Control Electronics Brand PCM4 SERIES PCM4 USER MANUAL www.minarikdrives.com

Dear Valued Consumer: Congratulations on your purchase of the PCM4 Series isolation card. This User Manual was created for you to get the most out of your new device and assist with the initial setup. Please visit www.minarikdrives.com to learn more about our other drives. Thank you for choosing Minarik Drives! No part of this document may be reproduced or transmitted in any form without written permission from American Control Electronics. The information and technical data in this document are subject to change without notice. American Control Electronics makes 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. American Control Electronics assumes no responsibility for any errors that may appear in this document and makes no commitment to update or to keep current the information in this document.

Safety First!! WARNING! SAFETY WARNINGS Text in gray boxes denote important safety tips or warnings. 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 techniques, over-current protection, thermal protection, and enclosure. Follow sound maintenance procedures.! WARNING! It is possible for a drive to run at full speed as a result of a component failure. Minarik Drives 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 trim pots. Use approved personal protective equipment and insulated tools if working on this drive with power applied. i

Table of Contents Section 1. Specifications... 1 Section 2. Dimensions... 2 Section 3. Installation... 3 Mounting... 3 Wiring... 4 Shielding Guidelines... 5 Connections... 6 Screw Terminal Block... 6 Power Input... 7 Input Signal Connections... 8 Output Signal Connections... 9 Multiple Follower Applications...10 Section 5. Calibration... 11 Signal Input Adjust (SIGNAL INPUT ADJ)...12 DIP Switches...13 Input Signal Calibration...14 Input Voltage / PWM Calibration...14 Input Current Calibration...15 Section 8. Troubleshooting... 16 Before Troubleshooting...16 Unconditional Warranty... 18 ii

List of Figures Figure 1 Dimensions... 3 Figure 2 Screw Terminal Block... 4 Figure 3 115 VAC Power Connection... 5 Figure 4 230 VAC Power Connection... 6 Figure 5 Analog Input Signal Connections... 7 Figure 6 Analog Output Signal Connections... 8 Figure 7 Multiple Follower Applications... 9 Figure 8 SIGNAL INPUT ADJ Positions...12 Figure 9 DIP Switch Settings...13 iii

Section 1. Specifications AC Line Voltage Input Signal Ranges PWM Signal Voltage Signal (Narrow Range) Voltage Signal (Wide Range) Current Signal Input Impedance Voltage / PWM Signal 1-5 ma Current Signal 4-20 ma Current Signal 10-50 ma Current Signal Output Impedance Voltage Range (max) Linearity Vibration Safety Certifications 115/230 VAC ± 10% 50/60 Hz, single phase 0 to 25 VDC, >10 khz -25 to +25 VDC -250 to +250 VDC 1-5, 4-20, 10-50 ma >25K ohms 1K ohm 235 ohms 100 ohms 800 ohms -10 to + 10 VDC 0.01% 0.5G maximum (0-50 Hz) 0.1G maximum (> 50 Hz) UL Recognized Equipment, File # E132235 CSA Certified Component, File # LR41380 Ambient Temperature Range 0 C - 50 C 1

R PCM4 Series Section 2. Dimensions 4.83 [123] T501 120/240 VAC 2.1 WATTS C501 C502 C505 IC501 C506 IC501 MAX MIN OUT OUT 2.70 [69] 1.93 [49] 1 C503 IC502 IC503 C504 C508 C507 SIGNAL INPUT ADJ 1-5MA 4-20MA 10-50MA 1 2 3 SW501 R501 P502 P503 TB502 1 2 0-± 10VDC OUTPUT TB501 C504-15 +15 COM INPUT 1 INPUT 2 TP 5 6 7 8 9 10 1.30 [33] 0.35 [9] 4.22 [107] 4 x 0.25 [6] STANDOFF USE #8 PANHEAD SCREWS ALL DIMENSIONS IN INCHES [MILLIMETERS] Figure 1. Dimensions 2

Section 3. Installation! WARNING! Mounting Do not install, rewire, or remove this control with input power applied. Failure to heed this warning may result in fire, explosion, or serious injury. Make sure you read and understand the Safety Precautions on page i before attempting to install this product. Components are sensitive to electrostatic discharge. Avoid direct contact with the circuit board. Hold the drive by the chassis or heat sink only. Protect the circuit board from dirt, moisture, and accidental contact. Provide sufficient room for access to the terminals and calibration trim pots. Mount the circuit board away from heat sources. Operate the isolation card within the specified ambient operating temperature range. Prevent loose connections by avoiding excessive vibration of the drive. Mount the board in either a horizontal or vertical plane. Four 0.25 (6 mm) standoffs accept #8 pan head screws. 3

Wiring! WARNING! Do not install, rewire, or remove this control with input power applied. Failure to heed this warning may result in fire, explosion, or serious injury. Circuit potentials are at 115 or 230 VAC above ground. To prevent the risk of injury or fatality, avoid direct contact with the printed circuit board or with circuit elements. Do not disconnect any of the motor leads from the drive unless power is removed or the drive is disabled. Opening any one motor lead while the drive is running may destroy the drive. This product does not have internal solid state motor overload protection. It does not contain speed-sensitive overload protection, thermal memory retention or provisions to receive and act upon signal from remote devices for over temperature protection. If motor over protection is needed in the end-use product, it needs to be provided by additional equipment in accordance with NEC standards. Use 18-24 AWG wire for logic wiring. Use 14-16 AWG wire for AC line wiring. 4

Shielding Guidelines! WARNING! Under no circumstances should power and logic level leads be bundled together. Induced voltage can cause unpredictable behavior in any electronic device, including motor controls. As a general rule, it is recommended to shield all conductors. If it is not practical to shield power conductors, it is recommended to shield all logic-level leads. If shielding of all logic-level 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. 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. 5

Connections! WARNING! Do not connect this equipment with power applied. Failure to heed this warning may result in fire, explosion, or serious injury. Minarik Drives strongly recommends the installation of a master power switch in the voltage input line, as shown in Figures 3 and 4 (page 7). The switch contacts should be rated at 2 amps AC and 250 VAC. Screw Terminal Block Connections are made to a screw terminal block. Using a screwdriver, turn the terminal block screw counter-clockwise to open the wire clamp. Insert stripped wire into the wire clamp. Turn the terminal block screw clockwise to clamp the wire. See Figure 2. Figure 2. Screw Terminal Block 6

Power Input When operating on 115 VAC, leave the jumper bars installed between terminals 1 and 2 and between 3 and 4 (see Figure 3). This is how the unit is shipped from the factory. When operating on 230 VAC, remove both jumper bars and place one jumper bar between terminals 2 and 3 (see Figure 4). Connect the AC power leads to terminals 1 and 4. TB501 C504-15 +15 COM INPUT 1 INPUT 2 TP 5 6 7 8 9 10 1 4 AC POWER 115 VAC Figure 3. 115 VAC Power Connection TB501 C504-15 +15 COM INPUT 1 INPUT 2 TP 5 6 7 8 9 10 1 4 AC POWER 230 VAC Figure 4. 230 VAC Power Connection 7

Input Signal Connections Connect the incoming signal leads to INPUT 1 (terminal 8) and to COM (terminal 7). If the maximum input voltage will exceed 25V, connect the signal leads to INPUT 2 (terminal 9) and to COM (terminal 7). See Figure 5 below. Use insulated shielded wire or twist pair for input and output signal leads longer than 18 inches. Connect the shielding to earth ground at the end away from the PCM4 and trim the exposed shielding at the PCM4 to preclude accidental grounding of the PCM4. Bundle the signal-carrying leads separately from the motor leads or AC power leads. -15 +15 COM INPUT 1 INPUT 2 TP -15 +15 COM INPUT 1 INPUT 2 TP 5 6 7 8 9 10 5 6 7 8 9 10 COM (-) SIG (+) COM (-) SIG (+) VOLTAGE / PWM SIGNAL RANGE 0 - ±25 VDC VOLTAGE SIGNAL RANGE 0 - ±250 VDC CURRENT SIGNAL RANGES 1-5 ma 4-20 ma 10-50 ma Figure 5. Analog Input Signal Connections 8

Output Signal Connections! WARNING! Always check the instruction manual supplied with the variable speed drive that will be interfaced with the PCM4 module. The scheme shown for wiring to an external voltage source, as well as the specifications on that input, must be well understood for proceeding. Output connections are made to the small terminal block on the board (TB502). Connect the output leads to terminal 1 and 2 (Figure 6). When the input signal at INPUT 1 is positive with respect to COM, then terminal 2 on TB502 will be positive. The exception to this polarity rule occurs when the PCM4 has been calibrated to bias its output as a voltage follower. An input of zero volts can be calibrated to produce a finite positive or negative output voltage. The PCM4 output is an isolated DC voltage. It is brought into the speed setting circuit of a variable speed drive to replace the main speed adjust potentiometer. Most Minarik Drives SCR-type, non-regenerative drives are designed with the speed setting voltage positive with respect to board common. The positive external signal is brought to the speed pot wiper terminal, usually designated S2, and the common signal lead to the speed pot CCW terminal, usually designated S1. TB502 PCM 4 1 2 1Q SERIES DRIVE S2 S1 SIGNAL REF / WIPER (+) SIGNAL COM / CCW (-) TB502 PCM 4 1 2 4Q SERIES DRIVE S2 SIGNAL REF / WIPER (+) RB1 SIGNAL COM / CCW (-) Figure 6. Output Signal Connections 9

Multiple Follower Applications! WARNING! Most Minarik Drives variable speed drives cannot be wired with the speed-setting circuits in common with each other. They require a dedicated PCM4 for each variable speed drive. When more than one Minarik Drives non-isolated drive must follow one voltage signal, each must be wired individually to dedicated PCM4 modules. Each PCM4 module then receives the master input signal. MASTER SIGNAL - + PCM4 A OUTPUT 2 DRIVE A RATIO POT (OPTIONAL) CW DRIVE A S2 CW OUTPUT 1 COM MASTER RATIO POT (OPTIONAL) COM (TERM 7) INPUT (TERM 8 OR 9) PCM4 B OUTPUT 2 DRIVE B RATIO POT (OPTIONAL) CW DRIVE B S2 OUTPUT 1 COM COM (TERM 7) INPUT (TERM 8 OR 9) Figure 7. Multiple Follower Applications 10

Section 4. Calibration! WARNING! Dangerous voltages exist on the PCM4 when it is powered. When possible, disconnect the voltage input from the drive before adjusting the trim pots. If the trim pots 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. 11

Signal Input Adjust The SIGNAL INPUT ADJ trim pot is used to set the maximum Test Point voltage to approximately 5 VDC, as measured between terminals TP and COM. The importance of this step is to scale the input voltage to keep it well within the range of the PCM4 s comparator chip. This calibration is only approximate. A tolerance of 0.2 volts is acceptable. The SIGNAL INPUT ADJ is calibrated only when the PCM4 is following a PWM or voltage signal. When the PCM4 is following a current signal, set the SIGNAL INPUT ADJ fully clockwise. See Figure 8 for approximate calibration of SIGNAL INPUT ADJ. To calibrate the SIGNAL INPUT ADJ: 1. Apply the true maximum voltage input. 2. Check voltage at TP vs. COM to verify that it is approximately 5 VDC. Adjust SIGNAL INPUT ADJ if needed. 0-5 VDC 0-10 VDC 0-25 VDC 0-250 VDC Figure 8. SIGNAL INPUT ADJ Positions 12

DIP Switches! WARNING! Only one DIP switch should be ON at a time and only when the PCM4 is set up to follow a current signal. All three DIP switches must be OFF when following a voltage signal. Each DIP switch selects the range for input current following. DIP switch 1 is for 1-5 ma, DIP switch 2 is for 4-20 ma, and DIP switch 3 is for 10-50 ma. VOLTAGE 1-5 ma CURRENT 4-20 ma CURRENT 10-50 ma CURRENT SIGNAL INPUT SIGNAL INPUT SIGNAL INPUT SIGNAL INPUT 1-5 MA 4-20 MA 10-50 MA 1-5 MA 4-20 MA 10-50 MA 1-5 MA 4-20 MA 10-50 MA 1-5 MA 4-20 MA 10-50 MA ON ON ON ON SW501 SW501 SW501 SW501 Figure 9. DIP Switch Setings 13

Input Signal Calibration Calibration of the MIN OUT and MAX OUT 15-turn trim pots is required to establish the relationship between the input voltage signal range and the output range. The true maximum and minimum input signal values are not required. Because the PCM4 response is linear, any two calibration points define the output vs. input relationship. Select points as close to the range extremes as possible to minimize extrapolation error. The absolute maximum output from the PCM4 is 10 VDC. The minimum input voltage to the PCM4 that can produce 10 VDC output is 5 VDC. Input Voltage / PWM Calibration To calibrate when using a voltage or PWM input signal: 1. Verify that all DIP switches are OFF. 2. Set the SIGNAL INPUT ADJ to the input range position, as indicated in Figure 8, page 12. 3. Apply the lower voltage input. 4. Set the MIN OUT adjustment to obtain the desired lower voltage output.. 5. Apply the higher voltage input. 6. Set MAX OUT adjustment to obtain the desired higher voltage output. 7. Apply the true maximum input voltage. 8. Check voltage at TP vs. COM to ensure that it is approximately 5 VDC at the maximum input voltage. Adjust SIGNAL INPUT ADJ if necessary. 9. Repeat steps 3-6 until no further recalibration is needed. 14

Input Current Calibration To calibrate when using a voltage input signal: 1. Verify that the correct DIP switch is ON and that the others are in the OFF position. 2. Set the SIGNAL INPUT ADJ fully CCW. 3. Apply the lower current input. 4. Set the MIN OUT adjustment to obtain the desired lower voltage output.. 5. Apply the higher current input. 6. Set MAX OUT adjustment to obtain the desired higher voltage output. 7. Repeat steps 3-6 until no further recalibration is needed. 15

Section 5. Troubleshooting! WARNING! Dangerous voltages exist on the PCM4 when it is powered. When possible, disconnect the drive while troubleshooting. High voltages can cause serious or fatal injury. Before Troubleshooting Perform the following steps before starting any procedure in this section: 1. Disconnect AC line voltage from the PCM4. 2. Check the PCM4 closely for damaged components. 3. Check that no conductive or other foreign material has become lodged on the printed circuit board. 4. Verify that every connection is correct and in good condition. 5. Verify that there are no short circuits or grounded connections. 6. Check that the input voltage jumpers are installed properly for the input voltage being used (see page 7). 7. Check that the drive s rated armature is consistent with the motor ratings. For additional assistance, contact your local Minarik Drives distributor or the factory direct: (800) MINARIK or FAX: (800) 394-6334 16

PROBLEM POSSIBLE CAUSE SUGGESTED SOLUTIONS Motor does not run. 1. No output from PCM4 (TB502). 2. Loose connections between PCM4 and drive. 3. PCM4 is not receiving AC line voltage. 1. Recalibrate the PCM4. If there is still no output, contact the factory for technical assistance. 2. Check connections between TB502 and the input of drive. 3. Apply AC line voltage to terminals 1 and 4. 4. Input signal is not connected. 4. Check that the PCM4 is receiving a voltage or current input signal. Motor is not running at full speed. Motor runs too slow, or too fast 5. SIGNAL INPUT ADJ trim pot is no calibrated. 6. Drive is not calibrated properly. 1. Voltage out (TB502) is not changing as input changes. 2. Loose connections between PCM4 and drive. 1. DIP switches are not set properly for current input. 2. Motor drive not calibrated properly. 5. Calibrate SIGNAL INPUT ADJ (page 12). 6. Recalibrate drive according to manufacturer s user manual. 1. Check that the voltage out (TB502) is changing as input changes. Recalibrate the PCM4. If voltage is still not changing, contact the factory for technical assistance 2. Check connections between TB502 and the input of drive. 1. Check DIP switch positions. 2. Recalibrate drive according to manufacturer s user manual. 17

Unconditional Warranty A. Warranty American Control Electronics warrants that its products will be free from defects in workmanship and material for twelve (12) months or 3000 hours, whichever comes first, from date of manufacture thereof. Within this warranty period, American Control Electronics will repair or replace, at its sole discretion, such products that are returned to American Control Electronics, 14300 De La Tour Drive, South Beloit, Illinois 61080 USA. This warranty applies only to standard catalog products, and does not apply to specials. Any returns of special controls will be evaluated on a case-by-case basis. American Control Electronics 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 American Control Electronics s sole obligation and exclude all other warranties of merchantability for use, expressed or implied. American Control Electronics 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 Americn Control Electronics s obligations, whether expressed or implied, and particularly of any other claim or breach of warranty contained in Paragraph A, or of any other warranties, expressed or implied, or claim of liability that might, despite Paragraph B, be decided against American Control Electronics by lawful authority, American Control Electronics shall under no circumstances be liable for any consequential damages, losses, or expenses arising in connection with the use of, or inability to use, American Control Electronics 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, American Control Electronics 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 American Control Electronics 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. 18

PCM4 An American Control Electronics Brand www.minarikdrives.com 14300 DE LA TOUR DRIVE SOUTH BELOIT, IL 61080 (800) MINARIK 250-0152 Rev 9