Siemens 4000i - User Manual

REC 3829 1-3 During operation, the package is transported by a conveying medium (such aschains or belts) across a weightable. The loadcell supporting a weightableproduces an electronic signal proportional to the package weight. As the packageinterrupts a beam from a photocell sensor (interlock), the...

REC 3829 1-4 1.2 OPTIONS Electronics can be remote or local, and numerous options are available to transform theAC-4000 from a low-cost, basic electronics into a sophisticated tool for monitoringproductivity and packaging line performance. These options include the following: 1.2.1 15 Programmable P...

REC 3829 1-5 TABLE 1-1 TECHNICAL SPECIFICATIONS - AC-4000 ELECTRONICS Line Speed 20 to 350 Ft./Min. (6 to 107 m/min.) Package Rate To 350 PPM Accuracy: Displayed Resolution Electrical Accuracy ±1, ±0.1, or ±0.01 Units±32 mg for 6000 gram loadcell Zeroing Automatic self zeroing between packages. REZE...

REC 3829 1-7 1.3 WARRANTY THERMO ELECTRON WARRANTY The seller agrees, represents, and warrants that the equipment delivered hereunder shall be freefrom defects in material and workmanship. Such warranty shall not apply to accessories, parts,or material purchased by the seller unless they are manufac...

REC 3829 2-2 11. Objects of any kind should never be placed or stored on the machine. 12. This equipment should not be operated at more than the specified production ratenor utilized in applications other than those stated in the original order. (To adaptproduction rates or applications, consult The...

REC 3829 2-3 2.5 EQUIPMENT LOCATION Careful consideration should be given to the location of the electronics, as systemperformance is affected by its location. The following requirements must be followed. 1. The electronics should be located so maintenance personnel can easily performcleaning and ad...

REC 3829 2-4 INPUT POW ER CONNECTIONS FIGURE 2-1 2.6 INSTALLATION The procedures given below provide for installing the electronics in your production line. 2.6.1 Initial Power On The initial power on procedures describe the checks to be performed before theinitial system setup procedures are perfor...

REC 3829 2-5 ANALOG BOARD FIGURE 2-2 ANALOG BOARD FUSE 115VAC 220VAC F1 (for electronics) 3/8A, 3AG, SB 3/16A, 3AG, SB F2 (for line [L2]) 10A, 3AB, SB 10A, 3AB, SB

REC 3829 2-6 DISTRIBUTION BOARD FIGURE 2-3 DISTRIBUTION BOARD FUSE 115VAC/220VAC F1 (for Indeed motor) 5A, 3AG, SB F2 (for weightable motor) 5A, 3AG, SB F3 (for outfield motor) 5A, 3AG, SB F4 (for line [L1]) 15A, 3AB, SB F5 (for line [L2]) 15A, 3AB, SB

REC 3829 4-3 DISPLAY BOARD ASSEMBLY/MODULE REPLACEMENT FIGURE 4-1

REC 3829 4-5 COMMUNICATION, CPU, AND ANALOG BOARD REPLACEMENT FIGURE 4-2

REC 3829 4-8 22. Close the distribution enclosure box. 23. Apply power to electronics and verify proper operation. 4.3.7 Front Panel Replacement To replace the controller front panel door, proceed as indicated below. Fiberglass Enclosure 1. Turn off power at mains. 2. Disconnect the cables (display ...

REC 3829 4-12 TABLE 4-1 TROUBLESHOOTING PROCEDURES - Continued SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Message "A/D OverRanged" Input from loadcellhas exceeded A/Dinput range Check for objects on weightablethat exceed loadcell capacity. Message "OutfeedQueue Full" Too many packageso...

REC 3829 4-13 TABLE 4-1 TROUBLESHOOTING PROCEDURES - Continued SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Conveyor slows orstops (continued) Seizure of motor shaftbearings Remove drive motor androtate shaft. If motor bearings aredefective, replace drive motor. Refer to Motor ReplacementProcedures in t...

REC 3829 4-16 TABLE 4-2 POWER TROUBLESHOOTING PROCEDURE ACTION CORRECTIVE ACTION Measure DC Voltages at AnalogBoard Test Points TP2 and TP3,loadcell excitation voltage at TB3-1,2 and +12V at TB4-2. Use testconnector J13-6 as common. If all DC Voltages are OK, perform boardtroubleshooting procedures,...

REC 3829 4-17 TABLE 4-2 POWER TROUBLESHOOTING PROCEDURE - Continued ACTION CORRECTIVE ACTION Remove AC power and disconnectloadcell cables at TB3. Reapply ACpower. If DC Voltage is OK, replace either defectiveloadcell or loadcell cable. Refer toW eightable Replacement Procedures in theweightable man...

REC 3829 5-1 CHAPTER 5.0 REPLACEMENT PARTS 5.1 GENERAL This chapter gives information on how to order replacement parts for your AC-4000Electronics and includes photographs and drawings with corresponding parts lists toenable you to identify parts quickly and accurately. 5.2 ORDER INFORMATION For fa...

REC 3829 5-2 5.3 PARTS LIST INDEX Parts lists are cross referenced to photographs or drawings to facilitate identification. These parts lists are indexed as follows: PARTS LIST DESCRIPTION TABLE NO. PAGE NO. AC-4000 Electronics (Remote or Local) 5-1 5-4

REC 3829 5-4 TABLE 5-1 AC-4000 ELECTRONICS (Remote or Local) KEY DESCRIPTION PART NO. QTY. 1A1B Door Assembly, FiberglassHinge Pin, Replacement 045765045836 11 2 Potentiometer (Indeed, W eightable, Outfield) 044727 A/R 3 Cable Assembly, Power Switch, Electronics/Conveyor 045328 A/R 4 Display Board 0...

TABLE 5-1 AC-4000 ELECTRONICS (Remote or Local) KEY DESCRIPTION PART NO. QTY. REC 3829 5-5 13 Analog Board, 115VAnalog Board, 230V 043256045473 1 A/R 14 Analog Board Fuses:F1, .37 amp, Slo-Blo (for 115V)F1, .19 amp, Slo-Blo (for 230V)F2, 10.00 amp, Slo-Blo 027784022898022612 1 A/R 1 15 Motor Control...

REC 3829 5-6 TABLE 5-1 (Continued) Controller Front Panel

REC 3829 5-7 TABLE 5-1 (Continued) Controller Enclosure - Left Side

REC 3829 5-8 TABLE 5-1 (Continued) Controller Enclosure - Right Side

REC 3829 5-9 TABLE 5-1 (Continued) Distribution Enclosure

REC 3829 6-1 CHAPTER 6.0 AC-4000 OPTIONS 6.1 GENERAL Five basic types of reject systems are described in the following pages. These are: Swing Gate Reject SystemAir Bopper Reject SystemAir Jet Reject SystemAir Pusher Reject SystemCarrier Reject System A brief description of each system and replaceab...

REC 3829 6-2 The Air Bopper Reject should be mounted perpendicular to the conveying mediumand as close as possible (without touching) to the product and the conveyingmedium. The air pressure required depends on product specifications and shouldbe balanced to obtain the desired reject action. The wea...

REC 3829 6-3 TABLE 6-1 SWING GATE REJECT SYSTEM - REPLACEABLE PARTS Key Description Part No. Qty. 1 Paddle 032082 1 2 Gusset, Paddle 034407 2 3 Air Cylinder 025231 1 4 Bushing, Flange 027907 4 5 Pivot, Swing Gate 032549 1 6 Pivot, Cylinder 033123 1 7 Shaft, Cylinder Mount 031874 1 8 4-Way Solenoid V...

REC 3829 6-4 TABLE 6-1 (Continued) SWING GATE REJECT SYSTEM - REPLACEABLE PARTS Key Description Part No. Qty. 10 Air Filter Regulator, 1/4 NPT w/Gauge 026178 1

REC 3829 6-5 TABLE 6-2 AIR BOPPER REJECT SYSTEM - REPLACEABLE PARTS Key Description Part No. Qty. 1 Bopper Plate Molding 026505 1 2 3" Stroke Air Cylinder4" Stroke Air Cylinder6" Stroke Air Cylinder8" Stroke Air Cylinder 034407014325014326014327 Select One 3 4-Way Valve 014877 1 4 Ai...

REC 3829 6-6 TABLE 6-3 AIR JET REJECT SYSTEM - REPLACEABLE PARTS Key Description Part No. Qty. 1 *Air Manifold 026936 1 2 Hex Nipple 021060 2 3 Nozzle 027659 2 4 Hex Bushing 027991 1 5 Solenoid Valve 051294 1 6 Air Regulator w/Gauge and Filter 041137 1

REC 3829 6-7 TABLE 6-4 AIR PUSHER REJECT SYSTEM - REPLACEABLE PARTS Key Description Part No. Qty. 1 Bopper, Plate 7.0" Lg. 021506 1 2 4" Stroke Air Cylinder6" Stroke Air Cylinder8" Stroke Air Cylinder 014325014326014327 Select One 3 4-Way Valve 014877 1 4 Air Regulator/Filter Assembl...

REC 3829 6-9 6.3 COMMUNICATIONS The Communications Option provides two communication channels, Port A and Port B,which are electrically identical but have different functional capabilities. This providesdigital communication with external devices such as printers, terminals, or computers. Both EIA-2...

REC 3829 6-10 TABLE 6-6 COMMUNICATION BOARD SWITCH SETTINGS PORT A SWITCHSW1-1 SWITCHSW1-2 SWITCHSW1-5 SWITCHSW1-7 SWITCHSW2-1 DESCRIPTION OFF / OPEN OFF / OPEN ON / CLOSED OFF / OPEN OFF / OPEN EIA-232 with hardware OFF / OPEN ON / CLOSED ON / CLOSED OFF / OPEN OFF / OPEN EIA-232 with data leads on...

REC 3829 6-11 COMMUNICATION BOARD SWITCHES FIGURE 6-1 6.3.2 External Communication Cabling This section describes the cabling necessary to connect the AC-4000 EIA-232(Figure 6-2) and the EIA-485 (Figure 6-3) serial interface to an external device. Appendix A contains drawings showing the required ca...

REC 3829 6-14 6.3.3 External Cabling Connections A 14-pin connector, Amphenol MS3106A-20-27P, is used to connect an externalcommunications device to the controller. A shielded cable should be used and theshield should be tied to the controller only. The connections are defined in Table6-8 below. TAB...

REC 3829 6-17 6.8 MOTOR INHIBIT OPTION The Motor Inhibit Option permits using an external motor inhibit signal. A closed contactacross TB8-1 and 2 of the distribution board allows the motors to run. Motor inhibit is notan E-Stop. See the section on the inhibit input in the motor control manual. Them...

REC 3829 A/1-1 Appendix Drawing A/1 Field Wiring Diagram INSERT FIELD WIRING DIAGRAM APPROPRIATE FOR YOUR APPLICATION (See Engineering Manual Request Form or Consult Product Engineer)

M MM M2233000000 S Seerriieess S C R , Ad j u s t a b l e S p e e d D r i v e s f o r D C B r u s h M o t o r s User ’s Manual

i 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 EQUIPMENTWITH POWER APPLIED. Have a qualified electrical technician install,...

ii Contents Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Specifications (Continued) . . . . . . . . . . . . . . . . . . . ...

iv Illustrations Figure 1. MM23001 and MM23011 Dimensions . . . . . . . . . . . . . . . . .3 Figure 2. MM23001C-Q and MM23011C-Q Dimensions . . . . . . . . . .4 Figure 3. MM23101 and MM23111 Dimensions . . . . . . . . . . . . . . . . .5 Figure 4. MM23201 and MM23211 Dimensions . . . . . . . . . . . ...

vi Tables Table 1. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . .19 Table 2. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . .20 Table 3. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . .28 Table 4. Minimum Recommended Dynamic Br...

1 Specifications Max. Armature HP Range HP Range Current with 115 VAC with 230 VAC Model (Amps DC) Applied Applied Style MM23011 1.5 1/20–1/8 1/10–1/4 Chassis MM23111 NEMA 1 MM23211 NEMA 1 MM23411 NEMA 4/4X/ 12 MM23072 Chassis MM23001 † 5.0 1/8–1/2 1/4–1 Chassis MM23101 ‡ NEMA 1 MM23201 ‡ NEMA 1 MM2...

2 Specifications Input Impedance (S1 to S2) 100K ohms Load Regulation 1% base speed or better Vibration 0.5G max (0–50 Hz) 0.1G max (>50 Hz) Safety Certification UL Recognized Component, file # E132235 CSA Certified Component, file # LR41380 CE Certificate of Compliance Ambient Temp. Range (chass...

3 Dimensions Figure 1. MM23001 and MM23011 Dimensions ALL DIMENSIONS IN INCHES [MILLIMETERS]

11 Chassis drives Mounting • Drive components are sensitive to electrostatic fields. Avoid contact with the circuit board directly. Hold drive by the chassisonly. • Protect the drive from dirt, moisture, and accidental contact. • Provide sufficient room for access to the terminal block and calibrati...

12 Installation • Use 18-24 AWG wire for speed adjust potentiometer wiring. Use 14–16 AWG wire for AC line (L1, L2) and motor (A1 and A2)wiring. Wiring Warning Do not install, remove, or rewire this equipment with powerapplied. Failure to heed this warning may result in fire,explosion, or serious in...

14 Installation Heat sinking Models MM23001 and MM23071 require an additional heat sink when the continuous armature current is above 5 ADC. UseMinarik part number 223-0159. All other chassis drives havesufficient heat sinking in their basic configurations. Use a thermallyconductive heat sink compou...

16 Installation Speed adjust potentiometer Mount the speed adjust potentiometer through a 0.38 in. (10 mm)hole with the hardware provided (Figure 9). Install the circularinsulating disk between the panel and the 10K ohm speed adjustpotentiometer. Twist the speed adjust potentiometer wire to avoid pi...

18 Installation Connect a DC motor to PCB terminals A1 and A2 as shown inFigure 11, page 21. Ensure that the motor voltage rating isconsistent with the drive’s output voltage. Power input Connect the AC line power leads to TB501 terminals L1 and L2, orto a double-throw, single-pole master power swit...

19 Installation Table 1. Recommended Line Fuse Sizes 90 VDC Motor 180 VDC Max. DC Armature AC Line Fuse Horsepower Horsepower Current (amps) Size (amps) 1/20 1/10 0.5 1 1/15 1/8 0.8 1.5 1/8 1/4 1.5 3 1/6 1/3 1.7 3 1/4 1/2 2.5 5 1/3 3/4 3.5 8 1/2 1 5.0 10 3/4 1 1/2 7.5 15 1 2 10 15 Minarik Corporatio...

20 Installation See Table 2 for field output connections. Use 18 AWG wire toconnect the field output to a shunt wound motor. Table 2. Field Output Connections Line Voltage Approximate Connect Motor (VAC) Field Voltage (VDC) Field To 115 50 F1 and L1 115 100 F1 and F2 230 100 F1 and L1 230 200 F1 and...

23 Voltage follower Instead of using a speed adjust potentiometer, the drive may bewired to follow an analog input voltage signal that is isolated fromearth ground (Figure 12). Connect the signal input (+) to S2.Connect the signal common (–) to S1. Make no connection to S3.A potentiometer can be use...

24 Installation Mounting (NEMA 1 enclosures) NEMA 1 cased drives come with 0.88 inch (22 mm) conduit holesat the bottom of the case. The units may be vertically wall mountedor horizontally bench mounted using the three keyholes on theback of the case. 1. For access to the keyholes and the terminal s...

27 Connections Warning Do not connect this equipment with power applied. Failure to heed this directive may result in fire or seriousinjury. Minarik strongly recommends the installation of a masterpower switch in the voltage input line. The switch contacts should be rated at a minimum of 200% of mot...

30 Installation Current limit LED (C models only) MM23000C series drives are equipped with a red current limit LED.The red current limit LED turns on whenever the drive reachescurrent limit and turns off whenever the drive is not in current limit(normal operation). Current limit header block (C-H mo...

32 Operation Before applying power • Verify that no conductive material is present on the printed circuit board. • Ensure that the voltage select switches switches are properly set. Warning Change voltage switch settings only when the drive isdisconnected from AC line voltage. Make sure both switche...

33 Operation Figure 15. Voltage Switches Voltage select switches Input voltage select (SW501) Set the voltage switch SW501 to either 115V or 230V to match the AC line voltage. See Figure 14. Armature voltage select (SW502) Set the voltage switch SW502 to either 90V or 180V to match themaximum armatu...

34 Operation Startup MM23001, MM23011, MM23071, and MM23072 1. Turn the speed adjust potentiometer full counterclockwise (CCW). 2. Apply AC line voltage.3. Slowly advance the speed adjust potentiometer clockwise (CW). The motor slowly accelerates as the potentiometer is turned CW.Continue until the ...

37 Starting and stopping methods Line starting and line stopping Line starting and line stopping (applying and removing AC linevoltage) is recommended for infrequent starting and stopping of adrive only. When AC line voltage is applied to the drive, the motoraccelerates to the speed set by the speed...

38 Operation Inhibit terminals Short the INHIBIT terminals to coast the motor to minimum speed(see Figure 15 for INHIBIT terminal location). Open the INHIBITterminals to accelerate the motor to set speed. Twist inhibit wires and separate them from power-carrying wires orsources of electrical noise. ...

39 Decelerating to minimum speed The switch shown in Figure 16 may be used to decelerate a motor to a minimum speed. Closing the switch between S1 and S2decelerates the motor from set speed to a minimum speeddetermined by the MIN SPD trimpot setting. If the MIN SPD trimpotis set full CCW, the motor ...

40 Operation Dynamic braking Warning For frequent starts and stops, short the inhibit terminals,decelerate to a minimum speed, or apply a dynamic brake tothe motor. Do not use any of these methods for emergencystopping. They may not stop a drive that is malfunctioning.Removing AC line power (both L1...

41 Table 4. Minimum Recommended Dynamic Brake Resistor Values Motor Armature Dynamic Brake Voltage Resistor Value 90 VDC 15 ohms 180 VDC 30 ohms For motors rated 1/ 17 horsepower and lower, a brake resistor is not necessary since the armature resistance is high enough to stop themotor without demagn...

42 MM23000-series drives have user-adjustable trimpots. Each driveis factory calibrated to its maximum current rating. Readjust thecalibration trimpot settings to accommodate lower current ratedmotors. All adjustments increase with CW rotation, and decrease with CCWrotation. Use a non-metallic screw...

TORQUE 44 Calibration The TORQUE setting determines the maximum torque foraccelerating and driving the motor. To calibrate TORQUE, refer tothe recommended TORQUE settings in Figure 18 (page 45) or usthe following procedure: 1. With the power disconnected from the drive, connect a DC ammeter in serie...

49 Multiple fixed speeds Replace the speed adjust potentiometer with series resistors with a total series resistance of 10K ohms (Figure 19). Add a singlepole, multi-position switch with the correct number of positions forthe desired number of fixed speeds. Application Notes Figure 20. Multiple Fixe...

51 Independent adjustable speeds Replace the speed adjust potentiometer with a single pole, multi-position switch, and two or more potentiometers in parallel, with atotal parallel resistance of 10K ohms. Figure 21 shows theconnection of two independent speed adjust potentiometers thatcan be mounted ...

54 Application Notes Leader-follower application In this application, use a PCM4 to monitor the speed of the leader motor (Figure 24). The PCM4 isolates the leader motor fromthe follower drive, and outputs a voltage proportional to the leadermotor armature voltage. The follower drive uses this volta...

56 Reversing A dynamic brake may be used when reversing the motor direction(Figure 26). Use a three pole, three position switch rated for atleast the maximum DC armature voltage and maximum brakingcurrent. Wait for the motor to stop completely before switching it toeither the forward or reverse dire...

57 Reversing with a DIGI-LOK controller A DIGI-LOK controller, model DLC600, can be used in a reversingapplication. The DIGI-LOK must be inhibited while braking. Withoutthe inhibit feature, the DIGI-LOK will continue to regulate. This willcause overshoot when the DIGI-LOK is switched back to the dri...

58 Troubleshooting Before troubleshooting Perform the following steps before starting any procedure in thissection: 1. Disconnect AC line voltage from the drive.2. Check the drive closely for damaged components.3. Check that no conductive or other foreign material has become lodged on the printed ci...

59 Troubleshooting Line fuse blows. 1. Line fuse is the wrong size. 2. Motor cable or armature is shorted toground. 3. Nuisance tripping caused by acombination of ambientconditions and high-current spikes (i.e.reversing). 1. Check that the line fuse is correct for themotor size. 2. Check motor cable...

66 Troubleshooting Replacement Parts Replacement parts are available from Minarik Corporation and itsdistributors for this drive series. Table 5. Replacement Parts Model No. Symbol Description Minarik P/N MM23001 and SCR501, 502 800 V, 20 A SCR 072-0043 MM23071 D501-503 800 V, 20 A Diode 071-0039 R5...

68 CE Compliance Minarik Corporation hereby certifies that its MM23000 series driveshave been approved to bear the “CE” mark provided the conditionsof approval have been met by the end user. The MM23000 series has been tested to the following testspecifications: EN55011:1991 (emissions), andEN50082-...

69 CE Compliance Line filters Minarik requires the Corcom® line filters listed below. Table 6. Corcom® Filters Nameplate Current of Corcom® Filter Motor Wired to the Drive Part Number 0 to 4 amps 6VV1 4.1 to 13 amps 20VV1 If the exact line filter is not available, the specifications are asfollows: L...

Armature filters If the end-user is not using a CE-approved motor, a second filter on the armature must be used. It is Minarik’s CEXXMM. XX =rated current of the filter. Minarik Filters are listed below. Table 7. Minarik Filters Nameplate Current of Minarik Filter Motor Wired to the Drive Part Numbe...

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 or3,000 hours, whichever comes first, from date of manufacture thereof. Within this warrantyperiod, the ...

901 E Thompson Avenue Glendale, CA 91201-2011 Tel.: 1-800-MINARIK (646-2745) Fax: 1-800-394-6334 www.minarikcorp.com Document number 250–0091, Revision 5 Printed in the U.S.A – 10/01 North America $12.00, Outside North America $15.00 DLC600 XP Series (AC or DC Input) MM-PCM Series PCM20000 Series O ...