American Control Electronics PAT440-10 User manual

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14300 De La Tour Drive
South Beloit, IL 61080
Phone: [phone]
Fax: [phone]
www.americancontrolelectronics.com
1Q SCR NEMA 4X Adjustable Speed Drive
for PMDC or Field Wound Brush Motors
PAT440
An ISO 9001:2008 Certified Company
......................................................115/230 VAC ± 10%, 50/60 Hz, single phase
...................................................................................................1.37 at base speed
..............................................................50 or 100 VDC
............................................................100 or 200 VDC
...................................................................................................1 Amp
.....................................................................................1 - 15 seconds
..................................................................coast to stop - 15 seconds
..................................................................0 - 1.4 VDC
..................................................................0 - 2.8 VDC
.........................................................................................3M ohms
...................................................................................1% base speed or beer
........................................................................................................................60:1
...............................................................................................1G maximum
...................................................................................10°C - 40°C
..............................................................................................................................3.1 lbs
UL/cUL Listed Equipment, file # E132235
AC Line Voltage
Form Factor
Field Voltage with 115 VAC line voltage
with 230 VAC line voltage
Maximum Field Current
Acceleraon Time Range
Deceleraon Time Range
Analog Input Range (Signal must be isolated; S1 to S2)
with 115 VAC line voltage
with 230 VAC line voltage
Input Impedance (S1 to S2)
Load Regulaon
Speed Range
Vibraon (0 - 50 Hz)
Ambient Temperature Range
Weight
Safety Cerficaons..................................................
1/8 - 1
1/4 - 2
Armature
Horsepower
Range
10.0
Connuous
Armature
Current (Amps)
0 - 90
0 - 180
Armature
Voltage Range
(VDC)
115
230
Line
Voltage
(VAC)
PAT440-10
Model
Specifications 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 installed 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 proper grounding, 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
• dynamic 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. Dynamic 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.
• The field output is for shunt wound motors only. Do not make any connecons to F1 and F2 when
•using a permanent magnet motor.
• Change voltage switch sengs only when the drive is disconnected from AC line voltage. Make sure
• both switches are set to their correct posion. If the switches are improperly set to a lower voltage
• posion, the motor will not run at full voltage and may cause damage to the transformer. If the
• switches are improperly set to a higher voltage, the motor will overspeed, which may cause motor
• damage, or result in bodily injury or loss of life.
• Under no circumstances should power and logic level wires be bundled together.
READ ALL SAFETY WARNINGS BEFORE INSTALLING THIS EQUIPMENT
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]
Installation
Mounng
NEMA 4X cased drives come with two 0.73 inch (18.5 mm) conduit holes at the boom of the case.
The drives may be vercally wall mounted using the four 0.19 inch (5 mm) sloed holes on the
aached heat sink. For loads less than 5 amps, the drive may be bench mounted horizontally or
operated without mounng.
1. Install the mounng 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 boom plate. Do not remove the three screws securing the
3. boom plate to the heat sink.
4. Set the POWER switch to the off posion before applying applying AC line voltage.
5. Install conduit hardware through the 0.73 inch (18.5 mm) knockout holes. Connect external wiring
3. to the terminal block.
6. Place the front cover back into place. Avoid pinching any wires between the front cover and the
3. heat sink.
7. Reinstall the 6 screws on the front cover. The two shorter screws are for the two lower holes of the
3. front cover. Reinstall the 5 screws on the boom plate.
Wiring
Use 14 - 16 AWG wire for AC line and motor.
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
PAT440 series drives provide on board fusing for the AC line (L1, L2 (230)). Fuses are fast acng fuses
rated for 15A at 250 VAC.
Line Input
Connect the AC line power leads to terminals L1 and L2-115 if using 115 VAC line power or to terminals
L1 and L2-230 if using 230 VAC line power.
Motor
Connect the DC armature leads to terminals A1 and A2. If the motor does not spin in the desired direcon,
power down the drive and reverse these connecons.
Field
At 115 VAC, connect the field leads to terminals F1 and L1 for a 50 VDC field or to F1 and F2 for a 100 VDC field.
At 230 VAC, connect the field leads to terminals F1 and L1 for a 100 VDC field or to F1 and F2 for a 200 VDC field.
Do not make any connecons to F1 and F2 if using a permanent magnet motor.
Speed Potenometer (Pre-wired)
PAT440 series drives are pre-installed with a 10K ohm, 1/4 W potenometer for speed control.
Inhibit
Short the INHIBIT terminals to coast the motor to minimum speed. Open the INHIBIT terminals to
accelerate the motor to set speed. Twist inhibit wires and seperate them from power-carrying wires or
sources of electrical noise. Use shielded cable if the inhibit wires are longer than 18 inches (46 cm). If
shielded cable is used, ground only one end of the shield to earth ground. Do not ground both ends of
the shield. Do not use the inhibit for emergency stopping.
ACE offers two accessory plug harnesses for connecng to the inhibit terminals; part number KTW-0001
[18 in (46 cm) leads] and part number KTW-0002 [36 in (91 cm) leads].
Inhibit
Terminals
Connections
511-2L
032-2L
1L
2A
1F
2F
1A
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.
105OS
TIBIHNI
MIN SPD
ACCEL
T501
SW501
230 - 115
TQ LIMIT
IR COMP
DECEL
MAX SPD
205OS
1S2S3S 205WS081-09
R501
POWER
LOGIC

Copyright 2011 by American Control Electronics®- All right 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 manual 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.
QSG-0015 rev 0
Calibration
Minimum Speed (MIN SPD): The MIN SPD 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 SPD:
1. Set the MIN SPD trim pot full CCW.
2. Set the speed adjust potenometer for minimum speed.
3. Adjust the MIN SPD trim pot unl the desired minimum speed is reached or is just at the
3. threshold of rotaon.
Maximum Speed (MAX SPD): The MAX SPD seng determines the maximum motor speed when the
speed adjust potenometer is set for maximum speed. To calibrate the MAX SPD:
1. Set the MAX SPD trim pot full CCW.
2. Set the speed adjust potenometer for maximum speed.
3. Adjust the MAX SPD trim pot unl the desired maximum speed is reached.
Check the MIN SPD and MAX SPD adjustments aer recalibrang to verify that the motor runs at the
desired minimum and maximum speed.
Torque (TQ LIMIT): The TQ LIMIT seng determines the maximum torque for accelerang and driving
the motor. To calibrate the TQ LIMIT:
1. With the power disconnected from the drive, connect a DC ammeter in series with the
1. armature.
2. Set the TQ LIMIT trim pot to minimum (full CCW).
3. Set the speed adjust potenometer to maximum speed (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 trim pot CW unl the armature current is 150% of motor rated
6. armature current. Connuous operaon beyond this rang may damage the motor.
7. Turn the speed adjust potenometer CCW.
8. Remove line power.
9. Remove the stall from the motor.
10. Remove the ammeter in series with the motor armature if it is no longer needed.
IR Compensaon (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 unl the motor runs at midspeed without load. A
2. 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.
Acceleraon (ACCEL): The ACCEL seng determines the me the motor takes to ramp to a higher
speed. ACCEL is factory set for the shortest acceleraon me (full CCW). To calibrate the ACCEL:
1. Set the speed adjust potenometer for minimum speed.
2. Set the speed adjust potenometer for maximum speed. Measure the me is takes the motor
2. to go from minimum speed to maximum speed.
3. If the me measured in step 2 is not the desired acceleraon me, turn the ACCEL trim pot
3. CW for a longer acceleraon me, or CCW for a shorter acceleraon me. Repeat steps 1
3. through 3 unl the acceleraon me is correct.
Deceleraon (DECEL): The DECEL seng determines the me the motor takes to ramp to a lower
speed. DECEL is factory set for the shortest deceleraon me (full CCW). To calibrate the DECEL:
1. Set the speed adjust potenometer for maximum speed.
2. Set the speed adjust potenometer for minimum speed. Measure the me is takes the motor
2. to go from maximum speed to minimum speed.
3. If the me measured in step 2 is not the desired deceleraon me, turn the DECEL trim pot
3. CW for a longer deceleraon me, or CCW for a shorter deceleraon me. Repeat steps 1
3. through 3 unl the deceleraon me is correct.
MOTOR
A1 A2
FWD
BRAKE
REV
DYNAMIC
BRAKE
RESISTOR
INHIBIT
Reversing with Dynamic Brake
A dynamic brake may be used when reversing the motor direcon. The MIN SPD trim pot must be set
for zero speed.Use a three pole, three posion switch rated for at least the armature voltage rang and
150% of the armature current rang. For the dynamic brake resistor, use a 40 wa minimum, high
power, wirewound resistor. Sizing the dynamic 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. Recommended values are 15 ohms for a 90 VDC motor and 30 ohms for 180 VDC motor.
The motor must come to a complete stop before changing direcons.
REVERSING
INHIBIT
MOTOR
A2
A1
RUN
BRAKE
DYNAMIC BRAKE
RESISTOR
S3
S2
S1
RUN
DECEL TO
MIN SPEED
10K OHM
SPEED ADJUST
POTENTIOMETE
R
CW
Decelerate to Minimum Speed
The switch shown below may be used to decelerate a motor to a minimum speed. Closing the switch
between S1 and S2 decelerates the motor from set speed to a minimum speed determined by the MIN
SPD trim pot seng. If the MIN SPD trim pot is set full CCW, the motor decelerates to zero speed when
the switch between S1 and S2 is closed. The DECEL trim pot seng determines the rate at which the
drive decelerates. By opening the switch, the motor accelerates to set speed at a rate determined by
the ACCEL trim pot seng.
Decelerate to Minimum Speed (Coast)
See INHIBIT in the CONNECTIONS secon on page 1 for a descripon of wiring and connecon
locaons.
Decelerate to Zero Speed (Dynamic Brake)
Dynamic braking may be used to rapidly stop a motor. The MIN SPD trim pot must be set for zero speed.
For the RUN/BRAKE switch, use a two pole, two posion switch rated for at least the armature voltage
rang and 150% of the armature current rang. For the dynamic brake resistor, use a 40 wa minimum,
high power, wirewound resistor. Sizing the dynamic 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. Recommended values are 15 ohms for a 90 VDC motor and 30 ohms for 180 VDC motor.
DECELERATING & STOPPING
Operation
105OS
TIBIHNI
ACCELTQ LIMIT DECEL
205WS081-09
IC501
IC502C501
C502
REWOP
IL502
IL501
CURRENT
LIMIT
405C
Current Limit
LED
Power LED
Current Limit (CURRENT LIMIT): Red LED lights whenever the drive reaches current limit.
Power (POWER): Green LED lights whenever the AC line voltage is applied to the drive.
LEDs
Input Voltage
Select (SW501)
Armature Voltage
Select (SW502)
105OS
TIBIHNI
MIN SPD
ACCEL
T501
SW501
230 - 115
TQ LIMIT
IR COMP
DECEL
MAX SPD
205OS
1S2S3S 205WS081-09
IC501
IC502C501
C502
REWOP
IL502
IL501
CURRENT
LIMIT
405C
R501
STARTUP
Input Voltage Select (SW501)
Set the voltage switch SW501 to either
115 or 230 to match the AC line voltage.
Armature Voltage Select (SW502)
Set the voltage switch SW502 to either
90 or 180 to match the maximum
armature voltage.
- Verify that no foreign conducve material is present on the printed circuit board.
- Ensure that all switches are properly set.
1. Set the speed adjust potenometer to “0” (full CCW).
2. Apply AC line voltage.
3. Set the POWER switch to the ON posion.
4. Slowly advance the speed adjust potenometer clockwise (CW). The motor slowly accelerates as the
potenometer is turned CW. Connue unl the desired speed is reached.
5. Set the POWER switch to the OFF posion to coast the motor to a stop.
SELECT SWITCHES
Startup