Siemens 4000i Service Manual

REC 3829 REV M 10/05PART NO. 045716OPERATING AND SERVICE MANUALTHERMO ELECTRONAC-4000 CONTROLLER

REC 3829 1-1CHAPTER 1.0INTRODUCTION1.1 GENERAL DESCRIPTIONThe AC-4000 Electronics System is a high accuracy machine. When combined with aweighing fra

REC 3829 4-0

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REC 3829 4-1CHAPTER 4.0MAINTENANCE4.1 GENERALYour electronics system is capable of efficient and reliable operation when it is properlymaintained. Cl

REC 3829 1-2SYSTEM BLOCK DIAGRAMFIGURE 1-2

REC 3829 4-28. Place new Display Board in enclosure with Display Board ribbon cable towardthe enclosure hinge.9. Connect front panel cable to Display

REC 3829 4-3DISPLAY BOARD ASSEMBLY/MODULE REPLACEMENTFIGURE 4-1

REC 3829 4-44.3.4 CPU Board ReplacementTo replace the CPU Board, proceed as indicated below.NOTE: If your electronics system is operating erratically,

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

REC 3829 4-64.3.6 Distribution Board ReplacementTo replace the Distribution Board, proceed as indicated below.1. Turn off power at mains.2. Open the d

REC 3829 4-7DISTRIBUTION BOARD REPLACEMENTFIGURE 4-3DISTRIBUTION BOARD WITH OPTIONSFIGURE 4-4

REC 3829 4-822. Close the distribution enclosure box.23. Apply power to electronics and verify proper operation.4.3.7 Front Panel ReplacementTo replac

REC 3829 4-9FRONT PANEL REPLACEMENTFIGURE 4-5

REC 3829 4-104.3.8 Motor Speed Control Module ReplacementIf you find it necessary to replace the motor speed control module, proceed asfollows:1. Turn

REC 3829 4-11Memory LostEnter All Values4. Procedure complete. Press RUN to re-enter the required setup informationwhich is machine prompted. See Se

REC 3829 1-3During operation, the package is transported by a conveying medium (such aschains or belts) across a weightable. The loadcell supporting

REC 3829 4-12TABLE 4-1TROUBLESHOOTING PROCEDURES - ContinuedSYMPTOM PROBABLE CAUSE CORRECTIVE ACTIONMessage "A/D OverRanged"Input from loadc

REC 3829 4-13TABLE 4-1TROUBLESHOOTING PROCEDURES - ContinuedSYMPTOM PROBABLE CAUSE CORRECTIVE ACTIONConveyor slows orstops (continued)Seizure of motor

REC 3829 4-14TABLE 4-1TROUBLESHOOTING PROCEDURES - ContinuedSYMPTOM PROBABLE CAUSE CORRECTIVE ACTIONNo Interlocks(Use Interlock Testmenu)Dirty interlo

REC 3829 4-15TABLE 4-1TROUBLESHOOTING PROCEDURES - ContinuedSYMPTOM PROBABLE CAUSE CORRECTIVE ACTIONNot weighing Bad InterlockNo speed signalBad Analo

REC 3829 4-16TABLE 4-2 POWER TROUBLESHOOTING PROCEDUREACTION CORRECTIVE ACTIONMeasure DC Voltages at AnalogBoard Test Points TP2 and TP3,loadcell exci

REC 3829 4-17TABLE 4-2 POWER TROUBLESHOOTING PROCEDURE - ContinuedACTION CORRECTIVE ACTIONRemove AC power and disconnectloadcell cables at TB3. Reapp

REC 3829 5-1CHAPTER 5.0REPLACEMENT PARTS5.1 GENERALThis chapter gives information on how to order replacement parts for your AC-4000Electronics and in

REC 3829 5-25.3 PARTS LIST INDEXParts lists are cross referenced to photographs or drawings to facilitate identification. These parts lists are indexe

REC 3829 5-35.3.1 Return Material Authorization

REC 3829 5-4TABLE 5-1AC-4000 ELECTRONICS(Remote or Local)KEY DESCRIPTION PARTNO.QTY.1A1BDoor Assembly, FiberglassHinge Pin, Replacement045765045836112

REC 3829 1-41.2 OPTIONSElectronics can be remote or local, and numerous options are available to transform theAC-4000 from a low-cost, basic electroni

TABLE 5-1AC-4000 ELECTRONICS(Remote or Local)KEY DESCRIPTION PARTNO.QTY.REC 3829 5-513 Analog Board, 115VAnalog Board, 230V0432560454731A/R14 Analog B

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

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

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

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

REC 3829 6-1CHAPTER 6.0AC-4000 OPTIONS6.1 GENERALFive basic types of reject systems are described in the following pages. These are:Swing Gate Reject

REC 3829 6-2The Air Bopper Reject should be mounted perpendicular to the conveying mediumand as close as possible (without touching) to the product an

REC 3829 6-3TABLE 6-1SWING GATE REJECT SYSTEM - REPLACEABLE PARTSKey Description Part No. Qty.1 Paddle 032082 12 Gusset, Paddle 034407 23 Air Cylinder

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

REC 3829 6-5TABLE 6-2AIR BOPPER REJECT SYSTEM - REPLACEABLE PARTSKey Description Part No. Qty.1 Bopper Plate Molding 026505 12 3" Stroke Air Cyli

REC 3829 1-5TABLE 1-1TECHNICAL SPECIFICATIONS - AC-4000 ELECTRONICSLine Speed 20 to 350 Ft./Min. (6 to 107 m/min.)Package Rate To 350 PPMAccuracy: Di

REC 3829 6-6TABLE 6-3AIR JET REJECT SYSTEM - REPLACEABLE PARTSKey Description Part No. Qty.1 *Air Manifold 026936 12 Hex Nipple 021060 23 Nozzle 02765

REC 3829 6-7TABLE 6-4AIR PUSHER REJECT SYSTEM - REPLACEABLE PARTSKey Description Part No. Qty.1 Bopper, Plate 7.0" Lg. 021506 12 4" Stroke A

REC 3829 6-86.2 VARIABLE SPEED Variable speed option is provided for those applications requiring variable conveyor linespeeds. With the variable spe

REC 3829 6-96.3 COMMUNICATIONS The Communications Option provides two communication channels, Port A and Port B,which are electrically identical but h

REC 3829 6-10TABLE 6-6COMMUNICATION BOARD SWITCH SETTINGSPORT ASWITCHSW1-1SWITCHSW1-2SWITCHSW1-5SWITCHSW1-7SWITCHSW2-1 DESCRIPTIONOFF / OPEN OFF / OPE

REC 3829 6-11COMMUNICATION BOARD SWITCHESFIGURE 6-16.3.2 External Communication CablingThis section describes the cabling necessary to connect the AC-

REC 3829 6-12EIA-232 CONNECTIONSFIGURE 6-2EIA-232Typical connections are shown in Figure 6-2. In some cases, wires may need to beswapped (null modem

REC 3829 6-13EIA-485 CONNECTIONSFIGURE 6-3EIA-485Figure 6-3 shows the connections typically used to connect the AC4000 EIA-485 output toan external de

REC 3829 6-146.3.3 External Cabling ConnectionsA 14-pin connector, Amphenol MS3106A-20-27P, is used to connect an externalcommunications device to the

REC 3829 6-156.4 STATISTICS OPTIONThe Statistics Option is provided to gather information on the products being weighed. Ifthe Communications Option

REC 3829 1-6TABLE 1-1TECHNICAL SPECIFICATIONS - (Continued)

REC 3829 6-166.6 MULTIPLE DIVERTER OPTIONThe Multiple Diverter Option is a combination of hardware and software that increases thenumber of diverter (

REC 3829 6-176.8 MOTOR INHIBIT OPTIONThe Motor Inhibit Option permits using an external motor inhibit signal. A closed contactacross TB8-1 and 2 of t

REC 3829 A/1-1Appendix Drawing A/1Field Wiring DiagramINSERT FIELD WIRING DIAGRAMAPPROPRIATE FOR YOUR APPLICATION(See Engineering Manual Request Form

MMMM2233000000SSeerriieessSCR, Adjustable Speed Drives for DC Brush MotorsUser’s Manual

Copyright  2001 byMinarik CorporationAll rights reserved. No part of this manual may be reproduced or transmitted in anyform without written permissi

iSafety Warnings• This symbol  denotes an important safety tip or warning. Please read these instructions carefully before performing any of the pro

REC 3829 1-71.3 WARRANTYTHERMO ELECTRONWARRANTYThe seller agrees, represents, and warrants that the equipment delivered hereunder shall be freefrom de

iiContentsSafety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iSpecifications . . . . .

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34MM23001, MM23011, MM23071, and MM2307

ivIllustrationsFigure 1. MM23001 and MM23011 Dimensions . . . . . . . . . . . . . . . . .3Figure 2. MM23001C-Q and MM23011C-Q Dimensions . . . . .

vFigure 23. RUN/JOG Switch Connection to Inhibit Plug (Option #1) .52Figure 24. RUN/JOG Switch Connection toSpeed Adjust Potentiometer (Option #2) .

viTablesTable 1. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . .19Table 2. Field Output Connections . . . . . . . . . . . .

1Specifications Max. Armature HP Range HP RangeCurrent with 115 VAC with 230 VACModel (Amps DC) Applied Applied StyleMM23011 1.5 1/20–1/8 1/10–1/4 Cha

2SpecificationsInput Impedance (S1 to S2) 100K ohmsLoad Regulation 1% base speed or betterVibration 0.5G max (0–50 Hz)0.1G max (>50 Hz)Safety Certi

3DimensionsFigure 1. MM23001 and MM23011 DimensionsALL DIMENSIONS IN INCHES [MILLIMETERS]

4DimensionsFigure 2. MM23001C-Q and MM23011C-Q DimensionsALL DIMENSIONS IN INCHES [MILLIMETERS]

5DimensionsTWO 0.88 [22] CONDUIT HOLESFigure 3. MM23101 and MM23111 DimensionsALL DIMENSIONS IN INCHES [MILLIMETERS]

REC 3829 2-1CHAPTER 2.0INSTALLATION2.1 GENERALThe customer is responsible for initial inspection of the equipment and site preparation. Itis essentia

6ALL DIMENSIONS IN INCHES [MILLIMETERS]TWO 0.88 [22] KNOCKOUTSFOUR MOUNTING SLOTS 0.19 INCHES [5 MILLIMETERS] WIDEDimensionsFigure 4. MM23201 and MM2

7DimensionsFigure 5. MM23401 and MM23411 DimensionsALL DIMENSIONS IN INCHES [MILLIMETERS]TWO 0.88 [22] KNOCKOUTSFOUR MOUNTING SLOTS 0.19 INCHES [5 MI

8DimensionsFigure 6. MM23501 DimensionsALL DIMENSIONS IN INCHES [MILLIMETERS]TWO 0.88 [22] KNOCKOUTSFOUR MOUNTING SLOTS 0.19 INCHES [5 MILLIMETERS] W

9ALL DIMENSIONS IN INCHES [MILLIMETERS]Figure 7. MM23071 and MM23072 DimensionsDimensions

10DimensionsPART NO. DIM “A” DIM “B” DIM “C” DIM “D” DIM “E”223-0159 4.40 [112] 3.00 [76] 0.7 [18] 1.75 [44] 3.90 [100]223-0174 7.78 [198] 6.00 [152]

11Chassis drivesMounting• Drive components are sensitive to electrostatic fields. Avoidcontact with the circuit board directly. Hold drive by the cha

12Installation• Use 18-24 AWG wire for speed adjust potentiometer wiring. Use14–16 AWG wire for AC line (L1, L2) and motor (A1 and A2)wiring. WiringW

13Shielding guidelinesWarningUnder no circumstances should power and logic leads bebundled together. Induced voltage can cause unpredictablebehavior

14InstallationHeat sinkingModels MM23001 and MM23071 require an additional heat sink when the continuous armature current is above 5 ADC. UseMinarik p

15Quick-disconnect terminal block (C-Q drives only)The quick-disconnect terminal block, found only on C-Q drives, iscomposed of a 9-pin header block a

REC 3829 2-211. Objects of any kind should never be placed or stored on the machine.12. This equipment should not be operated at more than the specifi

16InstallationSpeed adjust potentiometerMount the speed adjust potentiometer through a 0.38 in. (10 mm)hole with the hardware provided (Figure 9). Ins

17Power, fuse and motor connectionsConnect the power input leads, an external line fuse and a DCmotor to TB501 on the drive’s printed circuit board (P

18InstallationConnect a DC motor to PCB terminals A1 and A2 as shown inFigure 11, page 21. Ensure that the motor voltage rating isconsistent with the

19InstallationTable 1. Recommended Line Fuse Sizes90 VDC Motor 180 VDC Max. DC Armature AC Line FuseHorsepower Horsepower Current (amps) Size (amps)1

20InstallationSee Table 2 for field output connections. Use 18 AWG wire toconnect the field output to a shunt wound motor.Table 2. Field Output Conn

21Figure 11. Chassis Drive ConnectionsInstallation

22Figure 12. MM23201C-Q and MM23011C-Q ConnectionsInstallation

23Voltage followerInstead of using a speed adjust potentiometer, the drive may bewired to follow an analog input voltage signal that is isolated frome

24InstallationMounting (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 ver

25Mounting (NEMA 12 enclosures)NEMA 12 cased drives come with two 0.88 inch (22 mm) conduit knockout holes at the bottom of the case. The units may be

REC 3829 2-32.5 EQUIPMENT LOCATIONCareful consideration should be given to the location of the electronics, as systemperformance is affected by its lo

26InstallationHeat sinkingModels MM23101 and MM23201 require additional heat sinkingwhen the continuous armature current is above 5 ADC. UseMinarik pa

27ConnectionsWarningDo not connect this equipment with power applied.Failure to heed this directive may result in fire or seriousinjury.Minarik strong

28InstallationPower inputConnect the AC line power leads to TB501 terminals L1 and L2, orto a double-throw, single-pole master power switch(recommende

29Figure 14. Cased Drive ConnectionsInstallation

30InstallationCurrent limit LED (C models only)MM23000C series drives are equipped with a red current limit LED.The red current limit LED turns on whe

31MM23001C-Q, MM23071, and MM23072diagnostic LEDsModels MM23001C-Q, MM23071, and MM23072 are equipped withtwo diagnostic LEDs:Power (PWR): Lights when

32OperationBefore applying power• Verify that no conductive material is present on the printed circuitboard.• Ensure that the voltage select switche

33OperationFigure 15. Voltage SwitchesVoltage select switchesInput voltage select (SW501)Set the voltage switch SW501 to either 115V or 230V to match

34OperationStartupMM23001, MM23011, MM23071, and MM230721. Turn the speed adjust potentiometer full counterclockwise(CCW).2. Apply AC line voltage.3.

351. Set the RUN/BRAKE switch to the BRAKE position. 2. Set the speed adjust potentiometer to “0” (full CCW).3. Apply AC line voltage.4. Set the POWER

REC 3829 IIREVISION HISTORYREVISION A OCTOBER 1993REVISION B JANUARY 1994REVISION C APRIL 1994REVISION D FEBRUARY 1995REVISION E AUGUST 1995REVISION F

REC 3829 2-4INPUT POWER CONNECTIONSFIGURE 2-12.6 INSTALLATIONThe procedures given below provide for installing the electronics in your production line

36Operation1. Set the FORWARD/BRAKE/REVERSE switch to the BRAKEposition.2. Set the speed adjust potentiometer to “0” (full CCW).3. Apply AC line volta

37Starting and stopping methodsLine starting and line stoppingLine starting and line stopping (applying and removing AC linevoltage) is recommended fo

38OperationInhibit terminalsShort the INHIBIT terminals to coast the motor to minimum speed(see Figure 15 for INHIBIT terminal location). Open the INH

39Decelerating to minimum speedThe switch shown in Figure 16 may be used to decelerate a motor to a minimum speed. Closing the switch between S1 and S

40OperationDynamic brakingWarningFor frequent starts and stops, short the inhibit terminals,decelerate to a minimum speed, or apply a dynamic brake to

41Table 4. Minimum Recommended Dynamic BrakeResistor ValuesMotor Armature Dynamic BrakeVoltage Resistor Value90 VDC 15 ohms180 VDC 30 ohmsFor motors

42MM23000-series drives have user-adjustable trimpots. Each driveis factory calibrated to its maximum current rating. Readjust thecalibration trimpot

43CalibrationMINIMUM SPEED (MIN SPD)The MIN SPD trimpot establishes the motor speed obtained inresponse to the minimum input signal. It is factory set

TORQUE44CalibrationThe TORQUE setting determines the maximum torque foraccelerating and driving the motor. To calibrate TORQUE, refer tothe recommende

45IR COMPENSATION (IR COMP)The IR COMP trimpot setting determines the degree to whichmotor speed is held constant as the motor load changes. It isfact

REC 3829 2-5ANALOG BOARDFIGURE 2-2ANALOG BOARDFUSE 115VAC 220VACF1 (for electronics) 3/8A, 3AG, SB 3/16A, 3AG, SBF2 (for line [L2]) 10A, 3AB, SB 10A,

46CalibrationFigure 19. Recommended Torque and IR COMP Settings(actual settings may vary with each application)

47ACCELERATION (ACCEL)The ACCEL setting determines the time the motor takes to ramp to a higher speed. See Specifications on page 1 forapproximate acc

DECELERATION (DECEL)The DECEL setting determines the time the motor takes to ramp toa lower speed. See Specifications on page 1 for approximatedeceler

49Multiple fixed speedsReplace the speed adjust potentiometer with series resistors with a total series resistance of 10K ohms (Figure 19). Add a sing

50Application NotesAdjustable speeds using potentiometers inseriesReplace the speed adjust potentiometer with a single pole, multi-position switch, an

51Independent adjustable speedsReplace the speed adjust potentiometer with a single pole, multi-position switch, and two or more potentiometers in par

52Application NotesRUN/JOG switchRUN/JOG switch option #1Using a RUN/JOG switch is recommended in applications wherequick stopping is not needed and f

53RUN/JOG switch option #2In the second wiring option, connect the RUN/JOG switch and theJOG pushbutton as shown in the Figure 23. When the RUN/JOGswi

54Application NotesLeader-follower applicationIn this application, use a PCM4 to monitor the speed of the leader motor (Figure 24). The PCM4 isolates

55Single speed potentiometer control ofmultiple drivesMultiple drives can be controlled with a single speed adjustpotentiometer using a PCM4 at the in

REC 3829 2-6DISTRIBUTION BOARDFIGURE 2-3DISTRIBUTION BOARDFUSE 115VAC/220VACF1 (for Indeed motor) 5A, 3AG, SBF2 (for weightable motor) 5A, 3AG, SBF3 (

56ReversingA dynamic brake may be used when reversing the motor direction(Figure 26). Use a three pole, three position switch rated for atleast the ma

57Reversing with a DIGI-LOK controllerA DIGI-LOK controller, model DLC600, can be used in a reversingapplication. The DIGI-LOK must be inhibited while

58TroubleshootingBefore troubleshootingPerform the following steps before starting any procedure in thissection:1. Disconnect AC line voltage from th

59TroubleshootingLine fuse blows. 1. Line fuse is the wrongsize.2. Motor cable orarmature is shorted toground.3. Nuisance trippingcaused by acombin

60TroubleshootingLine fuse does not blow,but the motor does notrun.Motor does not stop when the speed adjustpotentiometer is full CCW.Motor runs in th

61Motor runs too fast.Motor will not reach thedesired speed.Motor pulsates or surgesunder load.1. MAX SPD and MINSPD are set too high.2. Motor field

62TroubleshootingFIgure 29. MM23000 Series Block Diagram

63FIgure 30. MM23101, MM23111, MM23401 and MM23411 Terminal Block ConnectionsTroubleshooting

64TroubleshootingFIgure 31. MM23201 and MM23211 Terminal Block Connections

65Figure 32. MM23501 Terminal Block ConnectionsTroubleshooting

REC 3829 2-72. Verify that switch SW-2 on the Analog Board is set to the correct AC inputvoltage.3. Verify that the dip switches on the Analog Board a

66TroubleshootingReplacement PartsReplacement parts are available from Minarik Corporation and itsdistributors for this drive series.Table 5. Replace

67Table 5. Replacement Parts (continued)Model No. Symbol Description Minarik P/NMM23211 Same as MM23011 except potentiometer kit. Same as MM23201exce

68CE ComplianceMinarik Corporation hereby certifies that its MM23000 series driveshave been approved to bear the “CE” mark provided the conditionsof a

69CE ComplianceLine filtersMinarik requires the Corcom®line filters listed below.Table 6. Corcom® FiltersNameplate Current of Corcom®FilterMotor Wire

Armature filtersIf 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 curr

The end user must use the filters listed in this section to complywith CE. The OEM may choose to provide alternative filtering thatencompasses the Min

NOTES72

NOTES73

NOTES74

Unconditional WarrantyA. Warranty - Minarik Corporation (referred to as “the Corporation”) warrants that itsproducts will be free from defects in work

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901 E Thompson AvenueGlendale, CA 91201-2011Tel.: 1-800-MINARIK (646-2745) Fax: 1-800-394-6334www.minarikcorp.comDocument number 250–0091, Revision 5P

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REC 3829 IIITHERMO RAMSEY ICORE PRODUCTSAC-4000 CONTROLLERTABLE OF CONTENTSCHAPTER TITLE PAGE1.0 INTRODUCTION ...

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TABLE OF CONTENTS(continued)CHAPTER TITLE PAGEREC 3829 IV4.3 COMPONENT REPLACEMENT PROCEDURES (ELECTRICAL) . . . 4-14.3.1 Display Board Assembly Repla

TABLE OF CONTENTS(continued)CHAPTER TITLE PAGEREC 3829 V6.3.5 Free Run Data ...6-146.4 STATISTICS OPTION ...

REC 3829 VILIST OF ILLUSTRATIONSFIGURE NO. TITLE PAGE1-1 AC-4000 Electronics ... 1-01-2 System Block Diagram ...

REC 3829 VIIAPPENDIXLIST OF DRAWINGSTITLE DRAWING NO.A/1 Field Wiring Diagram Engineer SelectedA/3 Full Menu Tree D07226K-V002A/5 Comm I/Comm II Cabl

REC 3829 VIIIPREFACEThis manual contains information necessary to install, operate, and service the Thermo AC-4000 Electronics (see Figure 1-1). All

REC 3829 1-0AC-4000 ELECTRONICSFIGURE 1-1