Ace PMB703-3 User manual

4Q PWM Chassis Adjustable Speed Drive
with Isolation for PMDC Brush Motors
14300 De La Tour Drive • South Beloit, IL 61080
Phone: [phone] • Fax: [phone]
www.americancontrolelectronics.com
PMB703-3
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Dimensions
205
B
T
L1 L2/230 L2/115 U V W
IL2
IL1
J502
31 5
.75
[19]
5.25 [133]
3.00 [76]
6.00 [152]
4.255 [108]
3.870 [98]
.193 [5]
2.250 [58]
.187 [5]
TB501
SW501
J503
TB502
4
7 9
8 10
2 6
FUSE
*FUSE
STOP
SWITCH
AC LINE
VOLTAGE
115 / 230 VAC
Line Input Speed Potenometer
If using a 115 VAC line with a 90/130 VDC motor or a 230 VAC line with a 90/130/180/240 VDC motor, Use a 10K ohm, 1/4 W potenometer for speed control. Connect the counter-clockwise end of the
connect to terminals L1 and L2. If using a 115 VAC line with a 180/240 VDC motor, connect to terminals potenometer to S1, wiper to S2, and the clockwise end to S3. If the potenometer works
L1 and L2-DBL. ACE recommends the use of a double-pole, single-throw master power switch. The inversely of desired funconality, (i.e. to increase motor speed, you must turn the potenometer
switch should rated at a minimum of 250 VAC and 200% of motor current. counterclockwire), power off the drive and swap the S1 and S3 connecons.
Motor Analog Input Signal Range
Connect the DC armature leads to terminals U/A2 and V/A1. If the motor does not spin in the desired Instead of using a speed adjust potenometer, PMB703 series drives may be wired to follow an
direcon, power down the drive and reverse these connecons. analog input signal. This input signal can be in the form of voltage (0-5, 0 to ±10 VDC) or current
(4-20 mA). Because these drives have built in isolaon, the input signal can be grounded or
ungrounded (floang). Connect the signal common (-) to S1 and the signal reference (+) to S2. See the
Operaons secon for jumper sengs.
Enable
Short terminals EN and COM to accelerate the motor to set speed. Open the ENABLE terminals to coast
the motor to zero speed. If no ENABLE switch is desired, wire a jumper between terminals COM and EN.
Do not use the enable for emergency stopping.
Direcon
Short terminals DIR and COM to change the direcon of the motor. If no direcon switch is desired,
leave this connecon open.
LOGIC (TOP BOARD)POWER (BOTTOM BOARD)
Connections
205
B
T
L1 L2 L2-DBL U/A2 V/A1 W
MOTOR
DIR
S3 S2 S1
COM
EN
10K OHM
SPEED ADJUST
POTENTIOMETER
CW
DIRECTION
SWITCH
ENABLE
SWITCH
NOTE: DO NOT make
any connections to
terminal L2-DBL if using
a 230 VAC line.
Installation
Mounng
• Drive components are sensive to electrostac discharge. Avoid direct contact with the circuit
• board. Hold the drive by the plate only.
• Protect the drive from dirt, moisture, and accidental contact.
• Provide sufficient room for access to the terminals and calibraon trim pots.
• Mount the drive away from heat sources. Operate the drive within the specified ambient operang
• temperature range.
• Prevent loose connecons by avoiding excessive vibraon of the drive.
• Mount the drive with its board in either a horizontal or vercal plane. Six 0.17” (4 mm) holes in the
• plate accept #8 pan head screws. If mounted horizontally, the drive must be de-rated to 3.0 amps.
• The plate should be earth grounded.
Wiring
Use 18 - 24 AWG wire for logic wiring. Use 14 - 16 AWG wire for AC line and motor wiring.
Shielding Guidelines
As a general rule, ACE recommends shielding of all conductors. If it is not praccal to shield power
conductors, ACE recommends shielding all logic-level leads. If shielding of logic-level leads is not
praccal, 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 the drive, ground the shield at the end
away from the drive. Do not ground both ends of the shield.
Fusing
ACE drives require an external line fuse for protecon. Use fast acng fuses rated for 250 VAC or
higher and 150% of the maximum armature current. Fuse the HOT leg of the AC line when using 115
VAC and both lines when using 230 VAC.
Safety Warnings
• DO NOT INSTALL, REMOVE, OR REWIRE THIS EQUIPMENT WITH POWER APPLIED. Have a
• qualified electrical technician install, adjust and service this equipment. Follow the Naonal
• Electrical Code and all other applicable electrical and safety codes, including the provisions of the
• Occupaonal Safety and Health Act (OSHA), when installing equipment.
• Circuit potenals are at 115 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 adjusng the calibraon trim pots. Use approved personal protecon
• equipment and insulated tools if working on this drive with power applied.
• Reduce the chance of an electrical fire, shock, or explosion by using proper grounding techniques,
•over-current protecon, thermal protecon, and enclosure. Follow sound maintenance procedures.
• ACE strongly recommends the installaon of a master power switch in the line voltage input. The
• switch contacts should be rated for 250 VAC and 200% of motor nameplate current.
• Removing AC line power is the only acceptable method for emergency stopping. Do not use
• regenerave braking, decelerang to minimum speed, or coasng to a stop for emergency stopping.
• They may not stop a drive that is malfunconing. Removing AC line power is the only acceptable
• method for emergency stopping.
• Line starng and stopping (applying and removing AC line voltage) is recommended for infrequent
• starng and stopping of a drive only. Regenerave braking, decelerang to minimum speed, or
•coasng to a stop is recommended for frequent starts and stops. Frequent starng and stopping can
• produce high torque. This may cause damage to motors.
• Do not disconnect any of the motor leads from the drive unless power is removed or the drive is
• disabled. Opening any one lead while the drive is running may destroy the drive.
• Under no circumstances should power and logic level wires be bundled together.
• Be sure potenometer tabs do no make contact with the potenometer’s body. Grounding the
• input will cause damage to the drive.
• Only connect to terminal L2-DBL if using a 115 VAC line with a motor rated higher than 130 VDC.
READ ALL SAFETY WARNINGS BEFORE INSTALLING THIS EQUIPMENT
1/20 - 1/3
1/20 - 1/2
1/10 - 2/3
1/10 - 3/4
Horsepower
Range
3.6*
Connuous
Armature
Current (Amps)
0 - 90
0 - 130
0 - 180
0 - 240
Armature
Voltage Range
(VDC)
115
or
230
Line
Voltage
(VAC)
PMB703-3
Model
Specifications
......................................................115/230 VAC ± 10%, 50/60 Hz, single phase
..........................................................................................................................1.05
..........................0.5 - 11 seconds
........................0.5 - 20 seconds
.........................0.5 - 11 seconds
.......................0.5 - 20 seconds
........................................................0 - 5; 0 to ± 10 VDC
........................................................................4 - 20 mA
.......................................................................................>50K ohms
...................................................................................1% base speed or beer
.......................................................................................................................100:1
...........................................................................................0.5G maximum
..............................................................................................0.1G maximum
.....................................................................................0°C - 40°C
..............................................................................................................................1.1 lbs
AC Line Voltage
Form Factor
Acceleraon Time Range for 90 / 130 VDC armature voltage
for 180 / 240 VDC armature voltage
Deceleraon Time Range for 90 / 130 VDC armature voltage
for 180 / 240 VDC armature voltage
Analog Input Voltage Range (S1 to S2)
Analog Input Current Range (S1 to S2)
Input Impedance (S1 to S2)
Load Regulaon
Speed Range
Vibraon (0 - 50 Hz)
(>50 Hz)
Ambient Temperature Range
Weight
* When mounted vercally. De-rate to 3.0 amps when mounted horizontally.

Select Switch (SW501)
Dip Switch 1: ON - Torque Mode - The drive will control the torque (current) of the motor. This is used
Dip Switch 1: ON - in tensioning applicaons.
Dip Switch 1: OFF - Speed Mode - The drive will control the speed (voltage) or the motor. This is used
Dip Switch 1: OFF - in variable speed applicaons.
Dip Switch 2: ON - WigWag Mode - The potenometer or analog signal determines both motor speed
Dip Switch 1: ON - WigWag Mode - and direcon. The direcon switch will sll come into effect.
Dip Switch 1: OFF - Pot/Switch Mode - The potenometer or analog signal (0 - 5 VDC, 0 - 10 VDC,
Dip Switch 1: OFF - Pot/Switch Mode - 4-20 mA) determines the motor speed while the direcon
Dip Switch 1: OFF - Pot/Switch Mode - switch determines the direcon. If using a bidireconal
Dip Switch 1: OFF - Pot/Switch Mode - analog signal (0 to ± 10 VDC), the polarity of the signal
Dip Switch 1: OFF - Pot/Switch Mode - determines the direcon (ie -10 VDC is full speed reverse,
Dip Switch 1: OFF - Pot/Switch Mode - 0 VDC is zero speed, 10 VDC is full speed forward). The direcon
Dip Switch 1: OFF - Pot/Switch Mode - switch will sll come into effect even with a bidireconal signal.
Dip Switch 3: ON - Brake Mode - Opening the ENABLE switch will regeneravely brake the motor to
zero speed without applying the decel ramp. At zero speed, the drive
will apply holding torque.
Dip Switch 1: OFF - Enable Mode - Opening the ENABLE switch will coast the motor to a stop. The drive
cannot provide holding torque at zero speed because it’s disabled.
SELECT SWITCHES
JUMPERS
Startup
1
2
3
4
7
8
5
6
9
10
1
2
3
4
7
8
5
6
9
10
1
2
3
4
7
8
5
6
9
10
STARTUP
- Verify that no foreign conducve material is present on the printed circuit board.
- Ensure that all switches and jumpers are properly set.
1. Turn the speed adjust potenometer full counterclockwise (CCW) or set the analog input voltage
1. or current signal to minimum.
2. Apply AC line voltage.
3. Close the enable switch and verify that the green Power LED (IL1) if flashing.
4. Slowly advance the speed adjust potenometer clockwise (CW) or increase the analog input voltage
3. or current signal. The motor slowly accelerates as the potenometer is turned CW or as the analog
3. input voltage or current signal is increased. Connue unl the desired speed is reached.
5. Remove AC line voltage from the drive to coast the motor to a stop.
0-5 VDC or Potenometer 0 to ± 10 VDC 4-20 mA
Jumper Pins 1&2 and 7&8 Jumper Pins 3&5 and 7&8 Jumper Pins 5&6 and 9&10
Potenometer
0 - 5 VDC
0 - 10 VDC
4 - 20 mA
Full Speed
Reverse
Full CCW
0 VDC
0 VDC
4 mA
Zero
Speed
12 o’clock
2.5 VDC
5 VDC
12 mA
Full Speed
Forward
Full CW
5 VDC
10 VDC
20 mA
Calibration
CALIBRATION INSTRUCTIONS ARE ASSUMING THAT THE DRIVE IS SET UP FOR SPEED MODE AND
POT/SWITCH MODE. IF USING TORQUE MODE OR WIGWAG MODE, PLEASE REFER TO THE USER’S
MANUAL.
Zero Adjust (P1 / ZERO ADJ): The ZERO ADJ seng adjusts out any non-linearies in the logic circuit that
might arise from component tolerances. This factory calibrated and should not need any adjustment.
Minimum Speed (P2 / MIN SPEED): The MIN SPEED seng determines the minimum motor speed
when the speed adjust potenometer is set for minimum speed. It is factory set for zero speed. To
calibrate the MIN SPEED:
1. Set the MIN SPEED trim pot full CCW.
2. Set the speed adjust potenometer or input voltage or current signal for minimum speed.
3. Adjust the MIN SPEED trim pot unl the desired minimum speed is reached or is just at the
3. threshold of rotaon.
Maximum Forward Speed (P3 / MAX FWD SPEED): The MAX FWD SPEED seng determines the
maximum motor speed in the forward direcon when the speed adjust potenometer or input voltage
or current signal is set for maximum speed. It is factory set for maximum motor rated speed. To
calibrate the MAX FWD SPEED:
1. Set the MAX FWD SPEED trim pot full CCW.
2. Set the speed adjust potenometer or input voltage or current signal for maximum forward
speed.
3. Adjust the MAX FWD SPEED trim pot unl the desired maximum forward speed is reached.
Maximum Reverse Speed (P4 / MAX REV SPEED): The MAX REV SPEED seng determines the
maximum motor speed in the reverse direcon when the speed adjust potenometer or input voltage
or current signal is set for maximum speed. It is factory set for maximum motor rated speed. To
calibrate the MAX REV SPEED:
1. Set the MAX REV SPEED trim pot full CCW.
2. Set the speed adjust potenometer or input voltage or current signal for maximum reverse
speed.
3. Adjust the MAX REV SPEED trim pot unl the desired maximum reverse speed is reached.
Check the ZERO ADJ, MIN SPEED, MAX FWD SPEED and MAX REV SPEED adjustments aer recalibrang
to verify that the motor runs at the desired minimum and maximum speeds.
Acceleraon (P5 / ACCEL TIME): The ACCEL TIME seng determines the me the motor takes to ramp
to a higher speed regardless of direcon. To calibrate the ACCEL TIME, turn the ACCEL TIME trim pot
CW to increase the forward acceleraon me and CCW to decrease the forward acceleraon me.
Deceleraon (P6 / DECEL TIME): The DECEL TIME seng determines the me the motor takes to ramp
to a lower speed regardless of direcon. To calibrate the DECEL TIME, turn the DECEL TIME trim pot
CW to increase the forward deceleraon me and CCW to decrease the forward deceleraon me.
Forward Torque (P7 / MOTOR CUR LIM): The MOTOR CUR LIM seng determines the maximum
torque for accelerang and driving the motor in the forward or reverse direcons. To calibrate the
MOTOR CUR LIM:
1. With the power disconnected from the drive, connect a DC ammeter in series with the
1. armature.
2. Set the MOTOR CUR LIM trim pot to minimum (full CCW).
3. Set the speed adjust potenometer (full CW) or input voltage or current signal to maximum
6. forward speed (full CW).
4. Carefully lock the motor armature. Be sure that the motor is firmly mounted.
5. Apply power source. The motor should be stopped.
6. Slowly adjust the MOTOR CUR LIM trim pot CW unl the armature current is 150% of motor
6. rated armature current.
7. Turn the speed adjust potenometer to minimum speed (full CCW).
8. Remove power source.
9. Remove the stall from the motor.
10. Remove the ammeter in series with the motor armature if it is no longer needed.
Reverse Torque (P8 / REGEN CUR LIM): The REGEN CUR LIM seng determines the maximum torque
for decelerang the motor and resisng an overhauling load in the forward and reverse direcons.
Turn the REGEN CUR LIM trim pot CW to increase the regen current limit and CCW to decrease the
regen current limit.
IR Compensaon (P9 / IR COMP): The IR COMP seng determines the degree to which motor speed is
held constant as the motor load changes. It is factory set for opmum motor regulaon. To calibrate
the IR COMP:
1. Set the IR COMP trim pot full CCW.
2. Increase the speed adjust potenometer or input voltage or current signal unl the motor runs
2. at midspeed without load. A handheld tachometer may be used to measure motor speed.
3. Load the motor armature to its full load armature current rang. The motor should slow down.
4. While keeping the load on the motor, rotate the IR COMP trim pot unl the motor runs at the
4. speed measured in step 2. If the motor oscillates (overcompensaon), the IR COMP trim pot
4. may be set too high (CW). Turn the IR COMP trim pot CCW to stabilize the motor.
5. Unload the motor.
LEDs
POWER
LED STATUS
LED
Power (IL1): Green LED is solid when AC line voltage is applied to the drive, but the drive is disabled. It
flashes whenever AC line voltage is applied to the drive and the drive is enabled.
Status (IL2): Red LED is solid when in current limit or flashes following fault code:
2 Flashes: Undervoltage - Internal DC BUS voltage dropped too low.
3 Flashes: Overvoltage - Internal DC BUS voltage rose too high.
4 Flashes: Current Limit or Short Circuit - The drive is in current limit or has detected a short across the
motor.
5 Flashes: Overtemperature Shut Down - Drive’s temperature has reached crical temperature.
6 Flashes: Overtemperature Warning - Drive’s temperature is approaching crical temperature.
Maximum motor current is being reduced gradually as the drive’s temperature rises.
205
BT
L1 L2 L2-DBL U/A2 V/A1 W
IL2
IL1
J502
SW501
J503
TB502
Operation
S3
S2
S1
RUN
DECEL TO
MIN SPEED
10K OHM
SPEED ADJUST
POTENTIOMETER
CW
Decelerate to Minimum or Zero Speed
The switch shown below may be used to decelerate a motor to a minimum speed. Opening the switch
between S3 and the potenometer decelerates the motor from set speed to a minimum speed
determined by the MIN SPEED trim pot seng. If the MIN SPEED trim pot is set full CCW, the motor
decelerates to zero speed when the switch is opened. The DECEL TIME trim pot seng determines the
rate at which the drive decelerates when travling in the forward direcon. By opening the switch, the
motor accelerates to set speed at a rate determined by the ACCEL TIME trim pot seng if accelerang
in the forward direcon.
DECELERATING & STOPPING
PWM drives are limited in their regnerave capability. The regenerave energy is returned into the
drive’s bus capacitor. When this capacitor is full, the drive can no longer regen unl the capacitor begins
to empty. During these periods, the motor actually coasts. While the regen/coast periods are frequent
enough that the user may not see the transions, it does result in a longer deceleraon me.
The soluon is a brake resistor. When the capacitor is full, the drive will divert the regen energy through
through the resistor. For the regenerave brake resistor, use a 40 wa minimum, high power, wire-
wound resistor. Sizing the regenerave brake resistor depends on load inera, motor voltage, and
braking me. Use a lower-value, higher-waage dynamic brake resistor to stop a motor more rapidly.
Brake resistor values must not be less than 40 ohms.
Please note that applicaons with light regenerave loads may not require the
use of a regenerave brake resistor.
If using a regenerave brake resistor, connect the resistor across terminals W and +BUS.
REGENERATIVE BRAKE RESISTOR
205B
T
L1 L2/230 L2/115 U V W
IL2
IL1
J502
TB501
SW501
J503
TB502
+BUS
REGENERATIVE
BRAKE
RESISTOR
31 5
4
7 9
8 10
2 6
QSG-0067 rev 0
Copyright 2013 by American Control Electronics® - All rights reserved. No part of this document may be
reproduced or retransmied in any form without wrien permission from American Control Electronics®.
The informaon and technical data in this document are subject to change without noce. American
Control Electronics® makes no warranty of any kind with respect to this material, including, but not
limited to, the implied warranes 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 informaon in this document.