USER’S MANUAL

XP–DC Series
Pulse-Width Modulated,
Adjustable Speed Drives
for DC Brush Motors

Models: XP08–60DC
XP12–24DC
XP10–36/48DC
XP16–36/48DC
XP32–12/24DC
XP60–12/24DC
 Copyright  1999 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 to keep current the information in this manual.

Printed in the United States of America.

 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

EQUIPMENT WITH POWER APPLIED. Minarik assumes
the qualified technician is intimate with the dangers involving
batteries, especially lead-acid type. This manual presupposes
that you have taken all the necessary precautions to prevent a
potentially fatal accident involving such batteries, and have
followed all standard electrical precautions.

• 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.

This drive is isolated from 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.
ii

Contents
Safety Warnings i

Specifications 1

Dimensions 2

Installation 4
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Heat sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuse / Circuit breaker protection . . . . . . . . . . . . . . . . . . . . . . . . .7
Switch 501 (SW501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Operation 15
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Startup and shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Starting and Stopping Methods . . . . . . . . . . . . . . . . . . . . . . . . .17

Calibration 19
MAX SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
ACC/DEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
IR COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
TQ LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
 iii

Application Notes 25
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Adjustable speeds using potentiometers in series . . . . . . . . . . .26
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . .27
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Troubleshooting 29
Before troubleshooting . . . . . . . . . . . . . . . . . . . . .... . . . . . . .29
Motor does not run . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . .30
Fuse blows or circuit breaker trips . . . . . . . . . . . .... . . . . . . .30
Motor runs too fast at the maximum speed setting ... . . . . . . .30
Motor runs in the opposite direction . . . . . . . . . . .... . . . . . . .31
Motor is unstable under load . . . . . . . . . . . . . . . . .... . . . . . . .31
Motor slows under load . . . . . . . . . . . . . . . . . . . .... . . . . . . .31
Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . .32
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . .34

Unconditional Warranty inside back cover

iv

Illustrations
Figure 1. XP–DC Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . .2
Figure 2. XP-DC Heat Sink Dimensions . . . . . . . . . . . . . . . . . . . . . . .3
Figure 3. Switch 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 4. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . .10
Figure 5. Speed Adjust Potentiometer Connections . . . . . . . . . . . . .10
FIgure 6. Power, Fuse and Motor Armature Connections . . . . . . . . .13
Figure 7. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . .14
Figure 8. Run/Decelerate to Zero Speed Switch . . . . . . . . . . . . . . . .18
Figure 9. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . . .19
Figure 10. Approximate TQ LIMIT Settings . . . . . . . . . . . . . . . . . . . .23
Figure 11. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Figure 12. Adjustable Fixed Speeds Using Potentiometers
in Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Figure 13. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . .26
Figure 14. RUN/JOG Switch Connection to Speed Adjust
Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Figure 15. XP–DC Series Block Diagram . . . . . . . . . . . . . . . . . . . . .31

Tables
Table 1. Wire Gauge/Length Chart . . . . . . . . . . . . . . . . . . . . . . . . . .5
Table 2. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
 1

Specifications
Max. Max.
Armature Armature DC Voltage
Current Voltage3 Input Range
Model (Amps DC) (VDC) (VDC)
XP08–60DC 81 60 50–70
XP12–24DC 12 1 24 20–28
XP10–36/48DC 10 2 36 or 48 4 32–50
XP16–36/48DC 16 1 36 or 48 4 32–50
XP32–12/24DC 32 2 12 or 24 4 10–32
XP60-12/24DC 60 2 12 or 24 4 10–32

Acceleration Time Range 0.5 – 10 seconds

Deceleration Time Range 0.5 – 10 seconds
Analog Input Voltage Range (signal must be isolated; S1 to S2) 0 – 10 VDC
Input Impedance (S1 to S2) 80KΩ
Speed Regulation (% of base speed) 1%
Speed Range 80:1
Form Factor 1.01
Ambient Operating Temperature Range 10°C – 40°C
Weight 0.6 lb

1 At 40°C ambient. No additional heat sink is necessary.

2 Heat sink kit 223-0159 or equivalent is required for XP10-series drives with continuous
armature current above 5 ADC and for XP32 and XP60-series drives with continuous
current above 20 amps.
3 Or up to 95% of available battery voltage.
4 Maximum armature voltage is selectable by connecting jumper to pins 2 and 3 of
SW501 (see page 8).
2

Dimensions

501 502 D501

A1
1 2 3
SW501

C501

- VDC IN

3.64 [93]

R501
S1
+ VDC IN

1.75 [44] S2

S3
C504 C503
IR COMP TQ LIMIT A2

0.19 [5]
P504

P503

R502
L501
P502
P501

C502
0.74 [19]
MAX SPD ACC/DEC

1.37 [35]
1.35 [34]
1.03 [26]

3.80 [97]

4.30 [109]

ALL DIMENSIONS IN INCHES [MILLIMETERS]

Figure 1. XP–DC Series Dimensions

 Dimensions 3

6.90 [175]
6.30 [160]
5.90 [150]

4.40 [112]

3.70 [94]
0.70 [18]

MOUNTING SLOTS 0.19 X 0.34 [5 X 9]

0.13 [3]
1.00 [25]

ALL DIMENSIONS IN INCHES [MILLIMETERS]

Figure 2. XP-DC Heat Sink Dimensions

4

Installation

Mounting

Warning
Do not install, rewire, or remove this control with input
power applied. Doing so may cause fire or serious injury.
Make sure you have read and understood the Safety
Warnings on pg i before attempting installation.

• Drive components are sensitive to electrostatic fields. Avoid

contact with the circuit board directly. Hold drive by the chassis
only.
• Protect the drive from dirt, moisture, and accidental contact.
Provide sufficient room for access to the terminal block and
calibration trimpots.
• Mount the drive away from other heat sources. Operate the
drive within the specified ambient operating temperature range.
• Prevent loose connections by avoiding excessive vibration of
the drive.
• Mount drive with its board in either a horizontal or vertical
plane. Six 0.19 in. (5 mm) wide slots in the chassis accept #8
pan head screws. Fasten either the large base or the narrow
flange of the chassis to the subplate.
 Installation 5

Wiring

Warning
Do not install, remove, or rewire this equipment with

 power applied. Failure to heed this warning may result in

fire, explosion, or serious injury.

This drive is isolated from earth 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. Opening any one motor lead
may destroy the drive.

This drive is not diode-protected from reverse battery

voltage. You must assure that POS (+) is wired to +VDC
IN and NEG (–) is wired to –VDC IN.

Use 18 AWG wire for speed adjust potentiometer wiring.

• Size the DC voltage input and motor wire according to the

following chart:

Table 1. Wire Gauge/Length Chart

Phase Current Wire Gauge Maximum Wire
(amps) (AWG) Length (feet)
0 – 19 14 8
20 – 32 10 10
60 8 10
6 Installation

Shielding guidelines

Warning
Under no circumstances should power and logic leads be
bundled together. Induced voltage can cause unpredictable
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 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.
 Installation 7

Heat sinking

XP10–DC series drives require an additional heat sink when the

continuous armature current is above 5 ADC. XP32–DC and
XP60–DC series drives require an additional heat sink when the
continuous armature current is above 20 ADC. All other chassis
drives have sufficient heat sinking in their basic configurations.

Use Minarik® part number 223–0159 for XP10, XP32 and XP60
series drives when the above conditions are met. Apply a
thermally conductive heat sink compound (such as Dow Corning®
340 Heat Sink Compound) between the drive chassis and heat
sink surface for optimum heat transfer.

Fuse / Circuit breaker protection

All Minarik drives should be protected by a fuse or circuit breaker.

Use a fast acting fuse or circuit breaker rated for approximately
200% of the maximum armature current and armature voltage.
Connect the fuse or circuit breaker to the VDC+ IN side of the
DC voltage input.
8 Installation

Switch 501 (SW501)

XP10-, XP16-, XP32- and XP60-series drives are shipped with

SW501 open (no jumper applied). This allows you to use 48
VDC motors with the XP10–36/48DC and XP16–36/48DC, or
24 VDC motors with the XP32–12/24DC and XP60–12/24DC.
To use lower voltage DC motors (36 VDC or 12 VDC,
respectively) jumper pins 2 and 3 with the jumper provided. See
Figure 3 for the location of SW501.

Switch 501 501 502

1 2 3
SW501

Figure 3. Switch 501

 Installation 9

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 drive.

Mount the speed adjust potentiometer through a 0.38 in. (10 mm)
hole with the hardware provided (see Figure 4 on Page 10). Install
the circular insulating disk between the panel and the 10K ohm
speed adjust potentiometer.

Twist the speed adjust potentiometer wire to avoid picking up

unwanted electrical noise. If speed adjust potentiometer wires are
longer than 18 in. (457 mm), use shielded cable. Keep speed
adjust potentiometer wires separate from power leads (L1, L2,
A1, A2).
10 Installation

Figure 4. Speed Adjust Potentiometer

S1

10K Ω S2
SPEED ADJUST
POTENTIOMETER
S3
CW
IR COMP TQ
P504

P503

Figure 5. Speed Adjust Potentiometer Connections

 Installation 11

Connections

Warning
Do not connect this equipment with power applied.
Failure to heed this directive may result in fire or serious
injury.

Minarik strongly recommends the installation of a

master power switch in the voltage input line, as shown
in Figure 6, page 13. The switch contacts should be rated
at a minimum of 200% of motor nameplate current and
150% of the input voltage.

Power, fuse and motor connections

Connect the power input leads, an external line fuse and a motor
to the drive’s printed circuit board (PCB) as shown in Figure 6,
page 13.

Motor

Minarik drives supply motor voltage from A1 and A2 terminals.

It is assumed throughout this manual that, when A1 is positive
with respect to A2, the motor will rotate clockwise (CW) while
looking at the output shaft protruding from the front of the motor.
If this is opposite of the desired rotation, simply reverse the
wiring of A1 and A2.
12 Installation

Connect a DC motor to PCB terminals A1 and A2 as shown in

Figure 6, page 13. Ensure that the motor voltage rating is
consistent with the drive’s output voltage.

Power input

WarningThis drive is not diode-protected from reverse battery

voltage. You must assure that POS (+) is wired to +VDC
IN and NEG (–) is wired to –VDC IN.

Connect the DC power leads to terminals + VDC IN and - VDC

IN, or to a single-throw, single-pole master power switch as
shown in Figure 6, page 13 (recommended).

Line fuse

Wire an external line fuse between the stop switch (if installed)
and the + VDC IN terminal on the circuit board. The line fuse(s)
should be rated at 150% of input voltage and 150 - 200% of
maximum motor nameplate current.
 Installation 13

A1

- VDC IN

MOTOR
+ VDC IN ARMATURE

A2

FUSE

WARNING:
BATTERY POLARITY
MUST MATCH INPUT
TERMINAL POLARITY!
EMERGENCY
STOP SWITCH

POS NEG
(+) (-)

DC VOLTAGE
INPUT

You must use OSHA® approved ring terminals (provided) or equivalent.

DO NOT USE BARE COPPER WIRE!

FIgure 6. Power, Fuse and Motor Armature Connections

14

Voltage follower

Instead of using a speed adjust potentiometer, the drive may be

wired to follow an isolated (floating, or differential) 0–10 VDC
signal that is isolated from earth ground (Figure 7). Connect the
signal input (+) to S2. Connect the signal common (–) to S1.
Make no connection to S3. A potentiometer can be used to scale
the analog input voltage. Use a battery to achieve greater linearity
and control.

S1

S2

S3

IR COMP TQ LIMIT
P504

P503

Figure 7. Voltage Follower Connections

 15

Operation

Warning
Dangerous voltages exist on the drive when it is powered,
and up to 30 seconds after power is removed and the motor
stops. BE ALERT. High voltages can cause serious or fatal
injury. For your safety, use personal protective equipment
(PPE) when operating this drive.

Before applying power

• Verify that no conductive material is present on the printed

circuit board.

• Ensure that all jumpers are properly set.

16 Operation

Startup and shutdown

To start the drive:

1. Turn the speed adjust potentiometer full counterclockwise
(CCW).
2. Apply DC voltage input.
3. Slowly advance the speed adjust potentiometer clockwise
(CW). The motor slowly accelerates as the potentiometer is
turned CW. Continue until the desired speed is reached.
4. Remove DC voltage input from the drive to coast the motor to
a stop.

If the motor or drive does not perform as described, disconnect

the DC voltage input immediately. Refer to the Troubleshooting
section (page 29) for further assistance.
 Operation 17

Starting and stopping methods

Warning!
Decelerating to minimum speed, regenerative braking, or
coasting to a stop is recommended for frequent starts and
stops. Do not use any of these methods for emergency
stopping. They may not stop a drive that is malfunctioning.
Removing DC line power is the only acceptable method for
emergency stopping.

For this reason, Minarik strongly recommends installing

an emergency stop switch (see Connections on page 11).

Frequent decelerating to minimum speed produces high torque.

This may cause damage to motors, especially gearmotors that are
not properly sized for the application.

Automatic restart upon power restoration

All drives automatically run to set speed when power is applied.

Line starting and line stopping

Line starting and line stopping (applying and removing DC
voltage input) is recommended for infrequent starting and
stopping of a drive only. When DC voltage input is applied to the
drive, the motor accelerates to the speed set by the speed adjust
potentiometer. When DC voltage input is removed, the motor
coasts to a stop.
18

Decelerating to zero speed

A single pole, single throw switch may be used to decelerate a

motor to zero speed (see Figure 8). Close the switch between S1
and S2 to decelerate the motor from set speed to zero speed. Open
the switch to accelerate the motor from zero speed to set speed.
The ACCEL/DECEL trimpot setting determines the rate at which
the motor accelerates and decelerates.

RUN

Figure 8. Run/Decelerate to Zero Speed Switch

 19

Calibration

Warning
Dangerous voltages exist on the drive when it is powered,
and up to 30 seconds after power is removed and the motor
stops. When possible, disconnect the voltage input from the
drive before adjusting the trimpots. If the trimpots 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.

Each drive is factory calibrated to its maximum armature voltage

and current rating. Readjust the calibration trimpot settings to
accommodate a motor with a lower armature and current rating.

All adjustments increase with clockwise rotation (CW), and

decrease with counter-clockwise rotation (CCW). Use a non-
metallic screwdriver for calibration. Each trimpot is identified on
the printed circuit board. (see Figure 9)

IR COMP TQ LIMIT

MAXIMUM ACCELERATION/
SPEED DECELERATION

Figure 9. Calibration Trimpot Layout

20 Calibration

MAX SPD

The MAX SPD setting determines the motor speed when the
speed adjust potentiometer is turned full CW. It is factory set for
maximum rated speed.

To calibrate MAX SPD:

1. Set the MAX SPD trimpot full CCW.
2. Apply power to the drive and turn the speed adjust
potentiometer full CW. If an input voltage signal is used
instead of a speed adjust pot, set the input signal to maximum.
3. Adjust the MAX SPD trimpot until the desired maximum
motor speed is reached.
 Calibration 21

ACC/DEC

The ACC/DEC setting determines the time the motor takes to

accelerate to a higher speed, or decelerate to a lower speed. See
Specifications on page 1 for approximate acceleration and
deceleration times. The ACC/DEC setting is factory set to its
minimum value (full CCW).

To calibrate ACC/DEC:
1. Set the ACC/DEC trimpot full CCW.
2. Apply power to the drive and turn the speed adjust
potentiometer full CW. If an input voltage signal is used
instead of a speed adjust pot, set the input signal to maximum.
Note the time that the drive takes to accelerate to the desired
speed.
3. Adjust the ACC/DEC trimpot until the desired acceleration
time is reached. Turn the ACC/DEC trimpot CW to increase
the acceleration and deceleration time, and CCW to decrease
the acceleration and deceleration time.
22 Calibration

IR COMP

The IR COMP setting determines the degree to which motor

speed is held constant as the motor load changes. It is factory set
for optimum motor regulation.

Use the following procedure to recalibrate the IR COMP setting :

1. Set the IR COMP trimpot to minimum (full CCW).

2. Rotate the speed adjust potentiometer until the motor runs at
midspeed without load (for example, 900 RPM for an 1800
RPM motor). A hand held tachometer may be used to
measure motor speed.
3. Load the motor armature to its full load armature current
rating. The motor should slow down.
4. While keeping the load on the motor, rotate the IR COMP
trimpot until the motor runs at the speed measured in step 2.
If the motor oscillates (overcompensation), the IR COMP
trimpot may be set too high (CW). Turn the IR COMP trimpot
CCW to stabilize the motor.
5. Unload the motor.
 Calibration 23

TQ LIMIT

Warning
TORQUE LIMIT should be set to 120% of motor nameplate
current rating. Continuous operation beyond this setting
may damage the motor. If you intend to operate beyond the
rating, contact your Minarik representative.

The TQ LIMIT setting determines the maximum armature current

output of the drive.

Recalibrate the TQ LIMIT setting when a lower current limit

is required. Refer to the TQ LIMIT settings in Figure 10, or
recalibrate using the following procedure:
1. With the power disconnected from the control, connect a DC
ammeter in series with the armature.
2. Set the TQ LIMIT trimpot to minimum (full CCW).
3. Set the speed adjust potentiometer to maximum (full CW).
4. Carefully lock the motor armature. Be sure that the motor is
firmly mounted.
5. Apply line power. The motor should be stopped.
6. Slowly adjust the TQ LIMIT trimpot CW slowly until the
armature current is 120% of motor rated armature current.
7. Set the speed adjust potentiometer to minimum
8. Remove the power from the drive and unlock the motor shaft.
9. Remove the ammeter in series with the motor armature if it is
no longer needed and re-apply power to the drive.
24 Calibration

XP08-60DC XP16-36/48DC
5.9A 9.8A
4.2A 8A (Factory Setting) 6.8A
16A (Factory Setting)
0A 11.9A 0A 19.9A
TQ LIMIT TQ LIMIT

XP12-24DC XP32-12/24DC
7A 15A
4.5A 10A 8A 23A
12A (Factory Setting)
0A 15A 0A 32A (Factory Setting)
TQ LIMIT TQ LIMIT

XP10-36/48DC
8A
10A (Factory Setting)
4.5A

0A 16A
TQ LIMIT

Figure 10. Approximate TQ LIMIT Settings

 25

Application Notes

Multiple fixed speeds

Replace the speed adjust potentiometer with series resistors
with a total series resistance of 10K ohms (Figure 11). Add a
single pole, multi-position switch with the correct number of
positions for the desired number of fixed speeds.

R1

S3
R2
Total Series
S2 Resistance
10K Ohm
R3
S1

R4

Figure 11. Multiple Fixed Speeds

26 Application Notes

Adjustable speeds using potentiometers in

series
Replace the speed adjust potentiometer with a single pole,
multi-position switch, and two or more potentiometers in series,
with a total series resistance of 10K ohms. Figure 12 shows a
connection for fixed high and low speed adjust potentiometers.

CW

S3 HIGH
SPEED 5K Ω

S2
LOW CW
S1 SPEED

5K Ω

Figure 12. Adjustable Fixed Speeds Using Potentiometers in

Series
 Application Notes 27

Independent adjustable speeds

Replace the speed adjust potentiometer with a single pole, multi-
position switch, and two or more potentiometers in parallel, with
a total parallel resistance of 10K ohms. Figure 13 shows the
connection of two independent speed adjust potentiometers that
can be mounted at two separate operating stations.

S3
SPEED 2 CW CW

S2
SPEED 1 20K Ω 20K Ω
S1

Figure 13. Independent Adjustable Speeds

28 Application Notes

RUN/JOG switch
Using a RUN/JOG switch is recommended in applications where
quick stopping is not needed and frequent jogging is required.
Use a single pole, two position switch for the RUN/JOG switch,
and a single pole, normally closed, momentary operated
pushbutton for the JOG pushbutton (see Figure 14). When the
RUN/JOG switch is set to JOG, the motor decelerates to zero
speed. Press the JOG pushbutton to jog the motor. Return the
RUN/JOG switch to RUN for normal operation.

S3

S2 10K Ω

S1

RUN JOG

JOG
PUSH BUTTON

Figure 14. RUN/JOG Switch Connection to Speed Adjust

Potentiometer
 29

Troubleshooting

Warning

Dangerous voltages exist on the drive 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 DC voltage input 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 circuit board.
4. Verify that all connections are correct and in good condition.
5. Verify that there are no short circuits or grounded connections.
6. Check that the drive’s rated armature voltage and current is
consistent with the motor ratings.

For additional assistance, contact your local Minarik® distributor,

or the factory direct:
1-800-MINARIK (646-2745) or Fax: 1-800-394-6334
30 Troubleshooting

Motor does not run

1. Check for blown fuses or tripped circuit breaker.
2. Verify that the speed adjust potentiometer is not set to zero
position.
3. Verify that the drive is receiving DC voltage input.
4. Check that the drive is not in current limit. It may be necessary
to increase the TQ LIMIT setting if it is set to a value lower
than the current rating of the motor. (see page 23)
5. Check that the motor is not jammed or restricted from
movement.

Fuse blows or circuit breaker trips

1. Check all wiring for shorts, grounds, or misconnections.
2. Check that the drive is configured to match the motor rating.
3. Check that the motor is not jammed or restricted from
movement.
4. Check that the fuse or circuit breaker size is correct for the
motor being driven.

Motor runs too fast at the maximum speed

setting
1. Check that the MAX SPD setting is not set too high. (see
page 20)
 Troubleshooting 31

Motor runs in the opposite direction

1. Remove DC voltage input.
2. Reverse connections to the motor armature. (see page 11)

Motor is unstable under load

1. Readjust the IR COMP setting slightly CCW until motor speed
is stabilized. (see page 22)

Motor slows under load

1. Check that the drive has been correctly calibrated for the
motor.
2. Check that the motor is not overloaded.
3. Readjust the IR COMP slightly CW until motor runs at proper
speed. (see page 22)
32

Block Diagram

Figure 15. XP–DC Series Block Diagram

33
34

Replacement Parts
Replacement parts are available from Minarik Corporation and its
distributors for this drive series.

Table 2. Replacement Parts

Model No. Symbol Description Minarik® P/N
All Drives 10KW Pot Kit w/ Ring Term. 202–0073
2 Pin Shunt 164–0181

XP08–60DC C501 15 MF, 100 V Capacitor 011–0119

D501 100 V, 15 A Diode 071–0059
R501 0.01 W, 5 W Resistor 032–0129
Q502 N-Channel MOSFET 070–0076
R502 1 KW, 5W Resistor 032–0098

XP12–24DC C501 2200 MF, 35 V Capacitor 011–0121

D501 20 A, 45 V Diode 071–0058
R501 0.01 W, 5 W Resistor 032–0129
Q502 N-Channel MOSFET 070–0060
R502 150 W, 5W Resistor 032–0138

XP10–36/48DC C501 15 MF, 100 V Capacitor 011–0119

D501 100 V, 15 A Diode 071–0059
R501 0.01 W, 5 W Resistor 032–0129
Q502 N-Channel MOSFET 070–0076
R502 500 W, 5W Resistor 032–0139

XP16–36/48DC C501 15 MF, 100 V Capacitor 011–0119

D501 100 V, 15 A Diode 071–0059
R501 0.01 W, 5 W Resistor 032–0129
Q501,502 N-Channel MOSFET 070–0076
R502 500 W, 5W Resistor 032–0139
 35

Model No. Symbol Description Minarik® P/N

XP32–12/24DC C501 2200 MF, 35 V Capacitor 011–0121
D501 20 A, 45 V Diode 071–0058
L501 1000mH Choke 240–0026
R501 0.002 W, 13 W Resistor 032–0133
Q501,502 N-Channel MOSFET 070–0060
R502 0.2 W, 5W Resistor 032–0093

XP32–12/24DC C501 2200 MF, 35 V Capacitor 011–0121

D501 20 A, 45 V Diode 071–0058
L501 1000mH Choke 240–0026
R501 0.002 W, 13 W Resistor 032–0133
Q501,502 N-Channel MOSFET 070–0060
R502 0.2 W, 5W Resistor 032–0093

XP60–12/24DC C501 5600 MF, 35 V Capacitor 011-0117

D501 20 A, 45 V Diode 071–0058
L501 1000mH Choke 240–0026
R501 0.002 W, 13 W Resistor 032–0133
Q501,502 N-Channel MOSFET 070–0060
R502 0.2 W, 5W Resistor 032–0093
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
Tel: 1-800-MINARIK (646-2745)
Fax: 1-800-394-6334
[Link]
Document Number 250–0223, Revision 2
Printed in the U.S.A – 12/00
U.S.A. $10.00, Canada $11.00