American Control Electronics PWL400 Series 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
PWL400
......................................................115/230 VAC ± 10%, 50/60 Hz, single phase
..........................................................................................................................1.05
..............................................................50 or 100 VDC
............................................................100 or 200 VDC
...................................................................................................1 Amp
.....................................................................................1 - 12 seconds
..................................................................coast to stop - 12 seconds
..................................................................0 - 2.5 VDC
.....................................................................0 - 5 VDC
.......................................................................................100K ohms
...................................................................................1% base speed or beer
......................................................................................................................100:1
............................................................................................0.5G maximum
...............................................................................................0.1G maximum
...................................................................................10°C - 40°C
..............................................................................................................................1.5 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
Deceleraon Time Range
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..................................................
* Heat sink kit HSK- 0003 must be used when the connuous output current is over 5 amps.
1/20 - 1/4
1/10 - 1/2
1/8 - 1/2
1/4 - 1
1/4 - 1
1/2 - 2
Horsepower
Range
3.0
5.0
10.0*
Connuous
Armature
Current (Amps)
0 - 130
0 - 240
0 - 130
0 - 240
0 - 130
0 - 240
Armature
Voltage Range
(VDC)
115
230
115
230
115
230
Line
Voltage
(VAC)
PWL400-3
PWL400-5
PWL400-10
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 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]
Dimensions
MODEL DIMENSION “A” HEIGHT
PWL400-3 2.25 [57]
PWL400-5 3.00 [76]
PWL400-10 3.75 [95]
05WS 2
4
05C
BT
1
0
5
1
L
20
5
C
AF
S
-T A
C
IT N
G
05UF
I 2
05C
I 1
05C
2L
1
S 2 S
3
S 1
F
2F
1
A
I
305C
105C
-RB
S 05
W
1
T 1
05
A
1
C
A
2C
+RB
505C
3
0
5
C
R
3
05
HT 1
05
Q 05 1
LI
205
IBIHNI
T
LI
105
U
C
R
R
TIMIL
2
05
R
R 1
05
B
1
D
1
05
B2
Q 05
2
R
B
1
0
5
621[79.4
]
31.4
[
501
]
0 52.
[
6
]
83.5 [ 731
]
0
.
"0
5
57.1 [ 54 ]
A
32 20 03
Installation
Mounng
• Drive components are sensive to electrostac discharge. Avoid direct contact with the circuit
• board. Hold the drive by the chassis or 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. Six 0.19” (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.
• The chassis should be earth grounded. Use a star washer beneath the head of at least one of the
• mounng screws to penetrate the anodized chassis surface and to reach bare metal.
Heat Sinking
The PWL400-10 requires an addional heat sink when the connuous armature current is above 5
amps. Use ACE heat sink kit part number HSK-0003. Use a thermally conducve heat sink compound
(such as Dow Corning 340® Heat Sink Compound) between the chassis and the heat sink surface for
opmal heat transfer.
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 series drives provide an on board fuse for the AC line (L1) HOT. Fuse is a fast acng fuse.
PWL400-3 models contain a fuse rated for 8A at 250 VAC. PWL400-5 models contain a fuse rated for
10A at 250 VAC, and PWL400-10 models contain a fuse rated for 20A at 250 VAC. If using 230 VAC line
power, fuse the L2 connecon. Use fast acng fuses rated for 250 VAC or higher and 150% of the
maximum armature current.
Line Input
Connect the AC line power leads to terminals L1 and L2. 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 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
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
BT
105
1L
2L
1S
2
S
3S
1F
2F
1A
MOTOR
ARMATURE
+
FIELD
OUTPUT
NOTE: DO NOT make
any connections to
F1 and F2 if using a
permanent magnet motor.
*FUSE
STOP
SWITCH
AC LINE
VOLTAGE
120/240 VAC
10K OHM
SPEED ADJUST
POTENTIOMETER
CW
* NOTE: Do not add fuse to L2
unless input voltage is 230 VAC.
LI
205
IBIHNI T LI
105
UC
R
R
TIMIL
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-0020 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 (CURR LIMIT): The CURR LIMIT seng determines the maximum torque for accelerang and
driving the motor. To calibrate the CURR LIMIT:
1. With the power disconnected from the drive, connect a DC ammeter in series with the
1. armature.
2. Set the CURR 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 CURR 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.
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
INHIBIT
MOTOR
A2
A1
RUN
BRAKE
DYNAMIC BRAKE
RESISTOR
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 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. 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
Operation
Current Limit
LED
05
W
S
2
4
05C
BT 1
0
5
1L
20
5
C
AF S-T ACIT NG
05UF
I 2
05C
I 1
05C
2L
1S
2
S
3S
1F
2F
1A
I
305C
105C
-RB
S
05
W
1
T 1
05
A
1
C
A
2C
+RB
505C
3
0
5
C
R
3
05
HT 1
05
Q05 1
LI
205
IBIHNI TLI
1
05
U
CRR
TIMIL
2
05
R
R1
05
B
1
D
1
05
B2
Q05 2
R
B
1
0
5
3
2 20 03
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
Power
LED
Operation
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)
05WS
2
4
05C
BT
1
0
5
1L
20
5
C
AF
S
-T A
C
IT N
G
05UF
I 2
05C
I 1
05C
2L
1
S2 S3
S
1F 2F 1A
I
305C
105C
-RB
S
05
W
1
T 1
05
A
1
C
A
2C
+RB
505C
3
0
5
C
R
3
05
HT 1
05
Q05 1
LI
205
IBIHNI
T
LI
105
U
CRR
TIMIL
2
05
R
R1
05
B
1
D
1
05
B2
Q05 2
R
B1
0
5
32 20 03