American Control Electronics PAT Series User manual

PAT440-10
PAT443-10
PAT450-10
USER MANUAL
TM
www.americancontrolelectronics.com
PAT SERIES

Dear Valued Consumer:
Congratulaons on your purchase of the PAT Series drive.
This User Manual was created for you to get the most out of
your new device and assist with the inial setup. Please visit
www.americancontrolelectronics.com to learn more about our
other drives.
Thank you for choosing American Control Electronics!
No part of this document may be reproduced or transmi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 tness 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.

i
PAT Series
Safety First!
• DO NOT INSTALL, REMOVE, OR REWIRE THIS EQUIPMENT WITH
POWER APPLIED. Have a qualified electrical technician install, adjust
and service this equipment. Follow the National Electrical Code
and all other applicable electrical and safety codes, including the
provisions of the Occupational Safety and Health Act (OSHA), when
installing equipment.
• Reduce the chance of an electrical fire, shock, or explosion by using
proper grounding techniques, over-current protection, thermal
protection, and enclosure. Follow sound maintenance procedures.
SAFETY WARNINGS
Text in gray boxes denote important safety ps or warnings.
Please read these instrucons carefully before performing any of
the procedures contained in this manual.
It is possible for a drive to run at full speed as a result of a
component failure. American Control Electronics strongly
recommends the installaon of a master switch in the main
power input to stop the drive in an emergency.
Circuit potenals are at 115 VAC or 230 VAC above earth ground.
Avoid direct contact with the printed circuit board or with circuit
elements to prevent the risk of serious injury or fatality. Use a
non-metallic screwdriver for adjusng the calibraon trim pots.
Use approved personal protecve equipment and insulated tools
if working on this drive with power applied.

!
WARNING!

!
WARNING!

ii
PAT Series
Table of Contents
Section 1. Specifications ..................................................... 1
Section 2. Dimensions......................................................... 3
Section 3. Installation......................................................... 6
Mounting ..................................................................................... 6
Wiring .......................................................................................... 7
Shielding Guidelines.............................................................. 8
Line Fusing ........................................................................... 9
Connections.................................................................................11
Power Inputs .......................................................................11
Motor..................................................................................11
Field Output Connections.....................................................12
Analog Input Signal (PAT440 and PAT450) ..............................13
Analog Input Signal (PAT443) ................................................14
Section 4. Operation......................................................... 16
Before Applying Power.................................................................16
Select Switches............................................................................17
Input Voltage Select (SW501) ...............................................17
Armature Voltage Select (SW502) .........................................17
Operation Modes (PAT443) ...........................................................17
Manual Mode ......................................................................17
Signal Mode.........................................................................17
Startup ........................................................................................18
PAT440 ................................................................................18
PAT450 ................................................................................18
PAT443 ................................................................................19
Starting and Stopping Methods ....................................................20
Line Starting and Stopping ...................................................20
Dynamic Braking ..................................................................21
Inhibit Terminals..................................................................23
Decelerating to Minimum Speed...........................................24

iii
PAT Series
Section 5. Calibration ....................................................... 25
Minimum Speed (MIN SPD) ..........................................................26
Maximum Speed (MAX SPD) .........................................................26
Torque (TQ LIMIT) ........................................................................27
IR Compensation (IR COMP) .........................................................28
Acceleration (ACCEL)....................................................................30
Deceleration (DECEL) ...................................................................30
Section 6.Application Notes ............................................... 31
Multiple Fixed Speeds ..................................................................31
Adjustable Speeds Using Potentiometers In Series.........................32
Independent Adjustable Speeds....................................................33
RUN/JOG Switch - Inhibit Connection............................................34
RUN/JOG Switch - Potentiometer Connection................................35
Leader-Follower Application.........................................................36
Single Speed Potentiometer Control Of Multiple Drives .................37
Reversing.....................................................................................38
Section 7. Diagnostic LEDs................................................. 39
Section 8. Troubleshooting................................................ 40
Before Troubleshooting ................................................................40
Section 9. Accessories & Replacement Parts ....................... 43
Unconditional Warranty..................................................... 44

iv
PAT Series
List of Tables
Table 1 Recommended Line Fuse Sizes ........................................... 9
Table 2 Short Circuit Current Ratings ............................................10
Table 3 Field Output Connections .................................................12
Table 4 Minimum Recommended Dynamic Brake Resistor Values ...22

v
PAT Series
List of Figures
Figure 1 PAT440 Dimensions .......................................................... 3
Figure 2 PAT443 Dimensions ........................................................... 4
Figure 3 PAT450 Dimensions ........................................................... 5
Figure 4 Power Connections ..........................................................13
Figure 5 Analog Input Signal Connections (PAT440 and PAT450).......14
Figure 6 Analog Input Signal Connections (PAT443).........................15
Figure 7 Select Switches ................................................................17
Figure 8 Dynamic Braking ..............................................................22
Figure 9 Inhibit Terminals ..............................................................23
Figure 10 Run/Decelerate to Minimum Speed Switch........................24
Figure 11 Recommended TORQUE and IR COMP Settings ..................29
Figure 12 Multiple Fixed Speeds ......................................................31
Figure 13 Adjustable Speeds Using Potentiometers in Series .............32
Figure 14 Independent Adjustable Speeds........................................33
Figure 15 RUN/JOG Switch - Connection to Inhibit Plug.....................34
Figure 16 RUN/JOG Switch - Connection to Speed Adjust
Potentiometer .................................................................35
Figure 17 Leader-Follower Application .............................................36
Figure 18 Single Speed Potentiometer Control of Multiple Drives......37
Figure 19 Reversing Circuit Wiring ...................................................38
Figure 20 Diagnostic LED Locations ..................................................39

1
PAT Series
Section 1. Specifications
AC Line Voltage 115/230 VAC ± 10%, 50/60 Hz, single phase
DC Armature Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
0 - 90 VDC
0 - 180 VDC
Field Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
50 VDC (F1 to L1); 100 VDC (F1 to F2)
100 VDC (F1 to L1); 200 VDC (F1 to F2)
Maximum Field Current 1 ADC
Acceleraon Time Range 1 - 15 seconds
Deceleraon Time Range coast to a stop - 15 seconds
0 - 1.4 VDC
0 - 2.8 VDC
0 - 10 VDC
1 - 5, 4 - 20, 10 - 50 mA
Input Impedance (S1 to S2) >100K ohms
Form Factor 1.37 at base speed
Load Regulaon 1% base speed or beer
Speed Range 60:1
Model
Maximum
Armature
Current (ADC)
HP Range
with 90 VDC
Motor
HP Range
with 180 VDC
Motor Enclosure
PAT440
PAT443
PAT450
10 1/8 - 1 1/4 - 2 NEMA 4X
NEMA 4X
NEMA 4X
Analog Input Range
PAT440 and PAT450 (signal must be isolated; S1 to S2)
with 115 VAC Line Voltage
with 230 VAC Line Voltage
PAT443 (2 to 3)
Voltage Signal Range
Current Signal Range

2
PAT Series
Vibraon 1G maximum (0 - 50 Hz)
0.1G maximum (> 50 Hz)
Safety Cercaons UL/cUL Listed Equipment, File # E132235
Ambient Temperature Range 10°C - 40°C

3
PAT Series
Section 2. Dimensions
Figure 1. PAT440-10 Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
7.50 [191]
5.63 [143]
0.19 [5.00]
SLOTTED HOLES
4 PLACES
BOTTOM PLATE
2.20
[55.9]
3.40
[86.4]
0.73 [18.5]
CONDUIT HOLES
2 PLACES
5.16 [ 131]
5.50 [140]
4.56 [116]
2.12 [53.8]

4
PAT Series
Figure 2. PAT443-10 Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
7.50 [191]
5.63 [143]
0.19 [5.00]
SLOTTED HOLES
4 PLACES
BOTTOM PLATE
2.20
[55.9]
3.40
[86.4]
0.73 [18.5]
CONDUIT HOLES
2 PLACES
5.16 [ 131]
5.50 [140]
4.56 [116]
2.12 [53.8]
MANUAL
SIGNAL

5
PAT Series
Figure 3. PAT450-10 Dimensions
ALL DIMENSIONS IN INCHES [MILLIMETERS]
7.50 [191]
5.63 [143]
0.19 [5.00]
SLOTTED HOLES
4 PLACES
BOTTOM PLATE
2.20
[55.9]
3.40
[86.4]
0.73 [18.5]
CONDUIT HOLES
2 PLACES
5.16 [ 131]
5.50 [140]
4.56 [116]
2.12 [53.8]

6
PAT Series
Section 3. Installation
Do not install, rewire, or remove this control with input power
applied. Failure to heed this warning may result in re, explosion,
or serious injury. Make sure you read and understand the Safety
Precauons on page i before aempng to install this product.

!
WARNING!
Mounng
NEMA 4X cased drives come with two 0.73 inch (18.5 mm) conduit
knockout holes at the boom of the case. The units may be vercally wall
mounted using the four 0.19 inch (5 mm) sloed holes on the aached
heat sink. For motor loads less than 5 ADC, the drive may be bench
mounted horizontally or operated without mounng.
1. Install the mounting screws.
2. For access to the terminal strip, remove the six phillips screws
on the front cover.
3. Remove the five phillips screws on the bottom plate. Do not
remove the three screws securing the bottom plate to the
heat sink.
4. Set the POWER switch to the off position before applying
applying AC line voltage.
5. Install conduit hardware through the 0.73 inch (18.5 mm)
knockout holes. Connect external wiring to the terminal block.
6. Place the front cover back into place. Avoid pinching any wires
between the front cover and the heat sink.
7. Reinstall the 6 screws on the front cover. The two shorter
screws are for the two lower holes of the front cover. Reinstall
the 5 screws on the bottom plate.

7
PAT Series
• Use 18 - 24 AWG wire for logic wiring. Use 14 - 16 AWG wire for
AC line and motor wiring.
Wiring
Do not install, rewire, or remove this control with input power
applied. Failure to heed this warning may result in re, explosion,
or serious injury.
Circuit potenals are at 115 or 230 VAC above ground. To prevent
the risk of injury or fatality, avoid direct contact with the printed
circuit board or with circuit elements.
Do not disconnect any of the motor leads from the drive unless
power is removed or the drive is disabled. Opening any one
motor lead while the drive is running may destroy the drive.
This product does not have internal solid state motor overload
protecon. It does not contain speed-sensive overload
protecon, thermal memory retenon or provisions to receive
and act upon signal from remote devices for over temperature
protecon. If motor over protecon is needed in the end-use
product, it needs to be provided by addional equipment in
accordance with NEC standards.

!
WARNING!

8
PAT Series
Shielding Guidelines
As a general rule, it is recommended to shield all conductors. If it is
not praccal to shield power conductors, it is recommended to shield all
logic-level leads. If shielding of all 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 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 connues to pick up noise aer grounding the shield, it may
be necessary to add AC line ltering devices, or to mount the drive in a
less noisy environment.
Logic wires from other input devices, such as moon controllers and PLL
velocity controllers, must be separated from power lines in the same
manner as the logic I/O on this drive.
Under no circumstances should power and logic level leads be
bundled together. Induced voltage can cause unpredictable
behavior in any electronic device, including motor controls.

!
WARNING!

9
PAT Series
Drives are preinstalled with 15 amp fuses.
Preinstalled line fuses are rated for maximum horsepower. If the
horsepower rang of the motor being used is less than the maximum
horsepower rang of the drive, the line fuse may have to be replaced
with a lower rated one. Fuses should be rated for 250 VAC or higher and
approximately 150% of the maximum armature current. Refer to Table 1
to install a lower rated fuse.
Line Fusing
90 VDC
Motor
Horsepower
180 VDC
Motor
Horsepower
Maximum DC
Armature Current
(amps)
AC Line
Fuse Size
(amps)
1/8
1/6
1/4
1/3
1/2
1/4
1/3
1/2
3/4
1
1.5
1.7
2.5
3.5
5.0
3
3
5
8
8
3/4
1

2
7.5
10
15
15
See Secon 10: Accessories and Replacement Parts for fuse kit part
numbers.
Table 1. Recommended Line Fuse Sizes

10
PAT Series
Table 2. Short Circuit Current Rangs
Drive Model
Short Circuit Current Rang
Types of Branch
Circuit Protection
Maximum
Rating of
Overcurrent
Protection
Maximum
Current, A
Maximum
Voltage, V
PAT440-10
10,000 240 V
Non-time
Delay
K5 Fuse
Inverse
Time
Circuit
Breaker
30 A
PAT443-10
PAT450-10
Short-circuit current rang (SCCR) is the maximum short-circuit
current that the speed control can safely withstand when
protected by a specic over-current protecve device(s).

!
WARNING!

11
PAT Series
Connecons
Do not connect this equipment with power applied. Failure to
heed this warning may result in re, explosion, or serious injury.

!
WARNING!
Power Input
Connect the AC line power leads to screw terminals L1 and L2 115 if using
a 115 VAC line or to terminals L1 and L2 230 if using a 230 VAC line. Refer
to Figure 4 on page 13.
Motor
Drives supply motor armature voltage from A1 and A2 terminals. It is
assumed throughout this manual that, when A1 is posive with respect
to A2, the motor will rotate clockwise (CW) while looking at the output
sha protruding from the front of the motor. If the motor does not
spin in the desired direcon, remove power and reverse the A1 and A2
connecons.
Connect a DC motor to terminals A1 and A2 as shown in Figure 4 on page
13. Ensure that the motor voltage rang is consistent with the drive’s
output voltage.

12
PAT Series
Line Voltage (VAC) Approximate Field
Voltage (VDC)
Connect Motor
Field To
115
115
230
230
50
100
100
200
F1 and L1
F1 and F2
F1 and L1
F1 and F2
Table 3. Field Output Connecons
Field Output Connecons
The eld output is for shunt wound motors only. Do not make
any connecons to F1 and F2 when using a permanent magnet
motor.

!
WARNING!
See Table 3 for eld output connecons. Use 18 AWG wire to connect
the eld output to a shunt wound motor.

13
PAT Series
L2 FRM SW L1
L2 TO SW L1
511-2L
032-2L
1L
2A
1F 2F
1A
F501
TB501
MOV503
F502
205VOM
MOV501
205R
A2 TO SW A1
A2 FRM SW A1
115 VAC
LINE VOLTAGE INPUT
(115 or 230 VAC)
EARTH GROUND
(GREEN SCREW)
MOTOR
ARMATURE
+
230 VAC
FIELD
OUTPUT
NOTE: DO NOT make
any connections to
F1 and F2 if using a
permanent magnet motor.
Figure 4. Power Connecons