American Control Electronics PWL400-15 User manual

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14300 De La Tour Drive
South Beloit, IL 61080
Phone: [phone]
Fax: [phone]
www.americancontrolelectronics.com
1Q PWM Chassis Adjustable Speed Drive
for PMDC or Field Wound Brushed Motors
PWL400PWL400-15
......................................................115/230 VAC ± 10%, 50/60 Hz, single phase
..........................................................................................................................1.05
..............................................................50 or 100 VDC
............................................................100 or 200 VDC
...................................................................................................1 Amp
.....................................1 - 9 seconds
.................................1 - 15 seconds
................coast to stop - 10 seconds
...............coast to stop - 18 seconds
..................................................................0 - 2.5 VDC
.....................................................................0 - 5 VDC
.........................................................................................50K ohms
................................................................................0.5% base speed or beer
......................................................................................................................100:1
............................................................................................0.5G maximum
...............................................................................................0.1G maximum
...................................................................................10°C - 40°C
..............................................................................................................................4.5 lbs
UL/cUL Recognized Equipment, file # E132235
CSA Cerfied Component, file # LR41380
AC Line Voltage
Form Factor
Field Voltage with 115 VAC line voltage
with 230 VAC line voltage
Maximum Field Current
Acceleraon Time Range with 90 VDC armature voltage
with 180 VDC armature voltage
Deceleraon Time Range with 90 VDC armature voltage
with 180 VDC armature voltage
Analog Input Voltage 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)
(>50 Hz)
Ambient Temperature Range
Weight
Safety Cerficaons..........................................
Safety Cerficaons..................................................
1/4 - 1 1/2
1/2 - 3
Horsepower
Range
15.0
Connuous
Armature
Current (Amps)
0 - 130
0 - 240
Armature
Voltage Range
(VDC)
115
230
Line
Voltage
(VAC)
PWL400-15
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 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.
• 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.
ALL DIMENSIONS IN INCHES [MILLIMETERS]
3.92
[
99
]
6.90
[
175
]
6.30
[
160
]
0.19
[
5
]
9.78
[
248
]
7.00
[
178
]
1.39 [35]
0.13 [3]
8
0
5
C
AC1
RB +
-
RB
+BUS
R
503
-B
US
T501
P
S
2
PS1
S
S
P
S4
PS3
P
S
LIMIT
11
5
F+
A1
A
1
C507
C506
C505
G
F-
A2
A2
TH50
1
R50
1
S 2
0
5WS 10
5
W
0
32 03
2
AC2
POWER CURR +15 INHIBIT
L1 230
S1 S2 S3 SPD SPD
IN
JOG
MIN SPD DECEL ACCEL JOG
MAX SPD TORQ LIMIT IR COMP
C502 IC502 IC501 C504
Dimensions
Installation
Mounng
• Drive components are sensive to electrostac discharge. Avoid direct contact with the circuit
• board. Hold the drive by the heat sink only.
• Protect the drive from dirt, moisture, and accidental contact.
• Provide sufficient room for access to the terminal block 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. Four 0.19” (5 mm) wide slots
• in the heat sink accept #8 pan head screws.
• The heat sink should be earth grounded. Use a star washer beneath the head of at least one of the
• mounng screws to penetrate the anodized heat sink surface and to reach bare metal.
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
PWL400-15 series drives provide on board fusing for the AC line (L1, 230). Fuses are fast acng fuses
rated for 20A at 250 VAC.
Line Input
Connect the AC line power leads to terminals L1 and 115 if using 115 VAC line power or to L1 and 230
if using 230 VAC line power. ACE recommends the use of a double-pole, single-throw master power
switch. The switch should be rated at a minimum of 250 VAC and 200% of motor current.
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 F+ and L1 for a 50 VDC field or to F+ and F- for a 100 VDC field.
At 230 VAC, connect the field leads to terminals F+ and L1 for a 100 VDC field or to F+ and F- for a 200 VDC field.
Do not make any connecons to F+ and F- if using a permanent magnet motor.
Speed Potenometer
Use a 10K ohm, 1/4 W potenometer for speed control. Connect the counter-clockwise end of the potenometer
to S1, the wiper to S2, and the clockwise end to S3. If the potenometer works inversely of desired funconality,
(i.e. to increase motor speed, you must turn the potenometer counterclockwise), power off the drive and swap
the S1 and S3 connecons.
Inhibit
Short the INHIBIT terminals to coast the motor to zero 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].
Connections
POWER
LOGIC
MOTOR
ARMATURE
FIELD
OUTPUT
AC LINE
VOLTAGE
230
VAC
115 VAC
NOTE: DO NOT make
any connections to
F1 and F2 if using a
permanent magnet motor.
P
S
2
PS1
S
S
P S4
PS3
P
S
11
5
F+
A1
C505
G
F-
A2
A2
POWER CURR +15 INHIBIT
L1 230
S1 S2 S3 SPD SPD
IN
JOG
MIN SPD DECEL ACCEL JOG
MAX SPD TORQ LIMIT IR COMP
Inhibit
Terminals

Copyright 2012 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.
QSG-0021 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 (TORQ LIMIT): The TORQ LIMIT seng determines the maximum torque for accelerang and
driving the motor. To calibrate the TORQ LIMIT:
1. With the power disconnected from the drive, connect a DC ammeter in series with the
1. armature.
2. Set the TORQ 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 TORQ 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. 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.
Jog (JOG): The JOG seng determines the constant motor speed when the drive is set to Jog mode.
To calibrate the JOG:
1. Make sure the drive is in Jog mode. This is done by connecng the SPD IN and JOG terminals.
2. Calibrate the JOG trim pot unl the motor runs at the desired JOG speed.
Run Mode
Jumper terminals SPD and SPD IN if you want to control the motor speed using a speed adjust
potenometer. The drive comes factory set for run mode. Make sure JOG and SPD IN are not
connected while in Run Mode.
Jog Mode
Jumper terminals JOG and SPD IN if you want to run the motor at a constant speed. In jog mode, the
on-board JOG trim pot sets the constant speed of the motor. Make sure SPD and SPD IN are not
connected while in Jog Mode.
MODES
MOTOR
A1 A2
FWD
BRAKE
REV
DYNAMIC
BRAKE
RESISTOR
INHIBIT
Reversing with a Dynamic Brake
A dynamic brake may be used when reversing the motor direcon. 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 130 VDC motor and 30 ohms for 240 VDC motor. The motor must come to a complete stop
before changing direcons.
REVERSING
S3
S2
S1
RUN
DECEL TO
MIN SPEED
10K OHM
SPEED ADJUST
POTENTIOMETER
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 Zero Speed (Coast)
See INHBIT 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. 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 130 VDC motor and 30 ohms for 240 VDC motor.
DECELERATING & STOPPING
INHIBIT
MOTOR
A2
A1
RUN
BRAKE
DYNAMIC BRAKE
RESISTOR
Operation
805C
AC1
R
B
+
-RB
+BUS
R
503
-B
US
T501
PS2
PS1
S
S
PS4
PS3
P
S
LIMIT
115F+ A1
A1
C507
C506
C505
G
F- A2
A2
TH50
1
R501
S
2
05W
S
10
5
W
0
32 032
AC2
POWER CURR +15 INHIBIT
L1 230
S1 S2 S3 SPD SPD
IN
JOG
MIN SPD DECEL ACCEL JOG
MAX SPD TORQ LIMIT IR COMP
C502 IC502 IC501 C504
Current Limit
LED
Power
LED
Current Limit (CURR LIMIT): Red LED lights whenever the drive reaches current limit.
Power (POWER ON): Green LED lights whenever AC line voltage is applied to the drive.
LEDs
Startup
STARTUP
Input Voltage Select (SW501, SW502)
Set the voltage switch SW501
and SW502 to either 115V or
230V to match the AC line voltage.
- Verify that no foreign conducve material is present on the printed circuit board.
- Ensure that all switches are properly set.
1. Turn the speed adjust potenometer full counterclockwise (CCW).
2. Apply AC line voltage.
3. 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.
4. Remove AC line voltage from the drive to coast the motor to a stop.
SELECT SWITCHES
Input Voltage Select
(SW501, SW502)
8
0
5C
AC1
RB +-
RB
+BUS
R503
-B
US
T501
P
S
2
PS1
S
S
P
S4
PS3
P
S
LIMIT
11
5
F+
A1
A1
C507
C506
C505
G
F-
A2
A2
TH50
1
R50
1
S
2
05W
S
10
5
W
0
32 032
AC2
POWER CURR +15 INHIBIT
L1 230
S1 S2 S3 SPD SPD
IN
JOG
MIN SPD DECEL ACCEL JOG
MAX SPD TORQLIMIT IR COMP
C502 IC502 IC501 C504