American Control Electronics PWL440-10 User manual

1Q PWM NEMA 4X Adjustable Speed Drive
for PMDC or Field Wound Brushed Motors
PWL4400-10
Full manual available online
14300 De La Tour Drive
South Beloit, IL 61080
Phone: (844) AMCNTRL
Fax: [phone]
www.americancontrolelectronics.com
TM
An ISO 9001:2008 Certified Company
......................................................115/230 VAC ± 10%, 50/60 Hz, single phase
..........................................................................................................................1.05
..............................................................50 or 100 VDC
............................................................100 or 200 VDC
...................................................................................................1 Amp
..................................1 - 10 seconds
.................................1 - 15 seconds
................coast to stop - 10 seconds
...............coast to stop - 19 seconds
..................................................................0 - 2.5 VDC
.....................................................................0 - 5 VDC
.........................................................................................50K ohms
...................................................................................1% base speed or beer
......................................................................................................................100:1
............................................................................................0.5G maximum
...............................................................................................0.1G maximum
...................................................................................10°C - 40°C
..............................................................................................................................8.1 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 130 VDC armature voltage
with 240 VDC armature voltage
Deceleraon Time Range with 130 VDC armature voltage
with 240 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 - 2
Horsepower
Range
10.0
Connuous
Armature
Current (Amps)
0 - 130
0 - 240
Armature
Voltage Range
(VDC)
115
230
Line
Voltage
(VAC)
PWL440-10
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.
• 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.
• Be sure potenometer tabs do no make contact with the potenometer’s body. Grounding the
• input will cause damage to 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
• signals from remote devices for over temperature protecon. If motor protecon is needed in the
• end-use product, it needs to be provided by addional equipment in accordance with NEC standards.
READ ALL SAFETY WARNINGS BEFORE INSTALLING THIS EQUIPMENT
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Dimensions
6.90 [175]
6.30 [160]
1.40
[36]
0.22
[6]
10.22
[260]
9.80
[249]
7.00
[178]
5.79
[146]
4.69
[119]
2.31
[58]
0.12
[3] 1.50 [38] 1.50 [38]
1.45 [37]
Ø0.88
[22] (3)
Installation
Mounng
NEMA 4X cased drives come with two 0.88 inch (22 mm) conduit knockout 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, turn the sloed screw on the front cover counterclockwise unl it is
2. free from the case. The right side of the cover is hinged to the case. Pull the sloed screw to open
2. the case.
3. Carefully remove the conduit knockouts by tapping them into the case and twisng them off with
3. pliers.
4. Set the POWER switch to the OFF posion before applying AC line voltage.
5. Install conduit hardware through the 0.88 inch (22 mm) knockout holes. Connect external wiring to
4. the terminal block.
6. Grasp the sloed screw and lt the front cover back into place. Avoid pinching any wires between
5. the front cover and the case.
7. Turn the sloed screw clockwise unl ght to secure the front cover.
Wiring
Use 14 - 16 AWG wire for AC line and motor wiring.
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 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
The drive provides on board fusing for the AC line (L1, 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 115 if using 115 VAC line power or to terminals
L1 and 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 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 (Pre-wired)
PWL440 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 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
P
S
2
PS1
S
S
P S4
PS3
P
S
C505
POWER CURR +15 INHIBIT
MIN SPD DECEL ACCEL JOG
MAX SPD TORQ LIMIT IR COMP
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.
11
5
F+
A1
G
F-
A2
A2
L1 230
S1 S2 S3 SPD SPD
IN
JOG
Inhibit
Terminals

QSG-0023 rev 1
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.
1. See the Modes secon for informaon about wiring in a Run / Jog switch.
2. Turn 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.
Run / Jog Mode
To wire in a RUN/JOG switch, connect a single pole, double throw switch to terminals SPD, SPD IN, and
JOG. When the switch connects terminals SPD and SPD IN, the drive will run at a speed set by the
external speed adjust potenometer. When the switch connects terminals JOG and SPD IN, the drive
will run at a speed set by the JOG trim pot.
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 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
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 to “0” (full CCW).
2. Set the POWER switch to the ON posion.
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. Set the POWER switch to the OFF posion 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 IRCOMP
C502 IC502 IC501 C504
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.