Dynamatic 4000 User manual

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Model 4000 and 4050
Stamping Press Controllers
Instruction Manual
Part Number IM-110005-8404
7900 Durand Avenue, Bldg 3 Sturtevant, WI USA 53177
Toll Free: 800-548-2169 Phone: [phone]
Email: [e-mail] Website: dynamatic.com

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Please Observe the Following Safety Guidelines
Allow Installation and Service by Qualified Personnel Only: Electrical rotating equipment and
associated controls can be dangerous. Therefore, it is essential that only trained personnel be allowed
to work with this equipment, under competent supervision. The danger is when the equipment is not
handled, installed, maintained or used properly. This equipment must be installed, adjusted and
serviced only by qualified personnel familiar with the construction and operation of the equipment and
the hazards involved. Failure to observe this precaution could result in personal injury and/or equipment
damage.
Read Instruction and Warnings: These instructions should be read and clearly understood before
working on the equipment. Become especially familiar with all safety instructions and procedures. Read
and heed all danger, warning and caution notices contained in this manual and attached to the
equipment and be sure to instruct other is their meaning and importance.
Danger, High Voltage Disconnect Power Before Servicing Equipment: Various component parts and
terminals of the drive equipment are at or above line voltage when AC power is connected to the input
terminals. All ungrounded conductors of the AC power line must be disconnected before it is safe to
touch any internal parts of this equipment. Some control equipment may contain capacitors that retain
a hazardous electrical charge for a period after power is removed. After power is removed, wait at least
two minutes to allow capacitors to discharge before touching any internal parts of the equipment.
Failure to observe these precautions could result in fatal injury.
Precautions When Working on Live Circuits: Stand on an insulating mat. Make a habit of using only one
hand. Make sure that there is another person nearby in case emergency assistance is required.
Application of Equipment and Safety Devices: The adjustable speed drive and all components of the
drive system, such as operator control devices, electrical power distribution equipment, the motor and
mechanical power transmission equipment, must be properly selected and applies to assure a safe and
reliable installation. Each individual installation has unique requirements for safety equipment such as
emergency stop pushbuttons, pre-start alarms, motor and power disconnect devices and guards on
mechanical power transmission apparatus. The party responsible for the overall design and operation of
the facility must make sure that qualified personnel are employed to select and apply all components of
the drive system including appropriate safety devices.
Hazard of personal injury or equipment damage exists if the drive and/or the driven machine are
operated above their rated speed due to miss adjustment or electronic failure. Be sure to consider this
factor in selecting gear ratios and safety devices.

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Always Wear Safety Glasses: Safety glasses should be worn by all personnel involved in installing or
maintaining the equipment. This applies equally to all electrical and mechanical workers. Other safety
clothing should be selected as appropriate to the task and work environment.
Handle with Care: Handle the equipment carefully to avoid personal injury or damage to the unit.
Provide Appropriate Guards Around Moving Parts: Before operating the equipment, make sure that
appropriate guards and other safety devices are in place. Refer to OSHA rules and regulations,
paragraph 1910.219 for guards on mechanical power transmission apparatus.
Observe Requirements of the National Electric Code: All wiring must be in accordance with the National
Electrical Code (NEC) and/or other codes as required by the authority having jurisdiction. The electrical
connections completed by the installed must conform to the Instructions and diagrams supplied.
National Electric Code Article 430-102 requires a disconnecting means for each motor and controller
located in sight from the motor, controller and driven machinery locations or capable of being locked in
the open position if not located in sight. This disconnecting means is not included with the drive
equipment unless specifically ordered.
Not for Use in Hazardous Locations: Unless specifically labelled as approved for such use, this
equipment is not suitable for use in an explosive atmosphere or in a “Hazardous (Classified) Location” as
defined in article 500 of the National Electrical Code.
Provide Adequate Ground Connections: For personnel safety and reliable equipment operation, firmly
earth ground each piece of equipment as directed in this manual and shown on the connection diagrams
provided. The ground conductor should be the same size as the incoming power wires or sized according
to NEC table 250-95. A copper or aluminum conductor must be used. Grounded conduit connections are
not adequate for use as equipment ground connections.
Instruction Material and Drawings: In addition to this manual, data sheets, drawings, supplementary
instruction sheets may be included in the package of instruction material that is furnished for each drive.
Be sure to save each of these items for future reference. The drawings and data included in this manual
are generally representative of the product line, but do not accurately include every detail pertaining to
specific equipment provided for an individual customer order. Drawings and data sheets which are
identified by PRO/Serial number as pertaining to specific piece of equipment take precedence over this
manual. Note: The information furnished may not cover changes made to the equipment after
shipment. All data is subject to change without notice.
Technical Assistance: Please contact Dynamatic at 1-800-548-2169 or 262-554-7977

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Table of Contents
Section 1 ........................................................................................7
General Information .................................................................................................................... 7
Introduction ............................................................................................................................. 7
Safety ....................................................................................................................................... 7
Training .................................................................................................................................... 7
Receiving and Damage Claims ................................................................................................. 8
Warranty .................................................................................................................................. 8
Handling ................................................................................................................................... 8
Storage ..................................................................................................................................... 8
Long Term Storage ................................................................................................................... 8
Removal from Storage ............................................................................................................. 9
Section 2 ......................................................................................10
General Description ...................................................................................................................10
Table 2-1 Specifications ..................................................................................................... 10
Basic Controller Assembly...................................................................................................... 11
Table 2-2 Panel Mount 4050 Controllers with a Transformer...........................................12
Drive Description and Application .........................................................................................12
Model 4000-4050 Comparison ..............................................................................................13
Installation ............................................................................................................................. 13
Operation...............................................................................................................................13
Start-up and Adjustments......................................................................................................13
Figure 2-1 Stamping Press Controller 15-541-000* with torque Limit, Speed Trip, and
Minimum Adjustment Panel Outline Mounting Dimensions..........................................................14
Figure 2-2 Stamping Press Controller 15-541-002* with Torque Limit Minimum Speed
Adjustment (w/o Speed Trip) Panel Outline Mounting Dimensions ..............................................15
Figure 2-3 Stamping Press Controller 15-539-0019 with Torque Limit and Minimum
Speed Adjustment Panel Outline Mounting Dimensions ............................................................... 16
Figure 2-4 Stamping Press Controller 15-539-0020 with Torque Limit and Minimum
Speed Adjustment Panel Outline Mounting Dimensions (Typical Layout/Subject to Change) ......17
Section 3 ......................................................................................18
Installation ................................................................................................................................. 18
Mounting Panel Mounted Controllers................................................................................... 18
Mounting an Input Transformer ............................................................................................18
Figure 3-1 Input Transformer............................................................................................. 18
Main Printed Circuit Board Support....................................................................................... 19

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Modification PCB ...................................................................................................................19
Figure 3-2 Modification PCB Standoff................................................................................ 19
Wiring..................................................................................................................................... 20
Programming Dip Switch .......................................................................................................21
Figure 3-3 Dip Switch Installation & Programming............................................................ 21
Figure 3-4a Connection Diagram Model 4050 Stamping Press Controller with Torque
Limit, Speed Trip and Minimum Speed Adjustment 115V, 208V, 390V, 230/460V or 575V Input
and 8.0 Adc Output (15-541-*) ....................................................................................................... 22
Figure 3-4b Schematic Diagram for Model 4050 Stamping Press Controller (15-541-*)
continued… .....................................................................................................................................23
Figure 3-5a Connection Diagram for 4050 Stamping Press Controller with Torque Limit.
Speed Trip and Minimum Speed Adjustment 208/230/460V Input and 5.5 Adc Output (15-541-
0007) ...............................................................................................................................................24
Figure 3-5b Schematic Diagram for 4050 Stamping Press Controller with Torque Limit
continue ..........................................................................................................................................25
Figure 3-6a Connection Diagram for 4050 Stamping Press Controller with Torque Limit
and Minimum Speed Adjustment (without Speed Trip) 115V, 208V, 390V, 230/460V or 575V
Input and 8.0 Adc Output (15-451-002*)........................................................................................ 26
Figure 3-6b Schematic Diagram for 4050 Stamping Press Controller (15-451-002*)
continued… .....................................................................................................................................27
Figure 3-7a Connection Diagram for Model 4050 Stamping Press Controller with Torque
and Minimum Speed Adjustment 115V input and 8 Adc. Output (15-539-0019).......................... 28
Figure 3-7b Schematic Diagram for Model 4050 Stamping Press Controller (15-539-0019)
continued… .....................................................................................................................................29
Figure 3-8a Connection Diagram for Model 4050 Stamping Press Controller with
minimum Speed Adjustment (without Torque Limit) 115 V input and 8 Adv output (15-539-0020)
........................................................................................................................................................30
Figure 3-8b Schematic Diagram for Model 4050 Stamping Press Controller (15-539-0020)
continued ........................................................................................................................................ 31
Section 4 ......................................................................................32
Operation................................................................................................................................... 32
Basic Controller Theory.......................................................................................................... 32
Figure 4-1 Simple Closed Loop System ..............................................................................32
Torque Limit Modification 15-44-2........................................................................................ 33
Linear Acceleration Option .................................................................................................... 33
Fixed Brake Option................................................................................................................. 34
Spring Set Brake Option .........................................................................................................34
Speed Trip Option ..................................................................................................................34
Figure 4-2 Model 4050 Controller Block Diagram .............................................................35

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Section 5 ......................................................................................36
Start-Up and Adjustments .........................................................................................................36
Tools Required .......................................................................................................................36
Power Off Test .......................................................................................................................36
Power On Test........................................................................................................................37
Set-Up Main PCB Assembly.................................................................................................... 38
Preliminary Adjustments .......................................................................................................38
Figure 5-1 Trimpot Illustration...........................................................................................39
Basic Speed Control (without Torque Limit).......................................................................... 40
LED Set-Up ............................................................................................................................. 40
Max Speed/Volts R21, Alternate Methods ....................................................................41
Control with Torque Limit Modification ................................................................................ 43
Section 6 ......................................................................................45
Maintenance and Troubleshooting ...........................................................................................45
Maintenance ..........................................................................................................................45
Troubleshooting..................................................................................................................... 46
Renewal Parts and Service.....................................................................................................47
Renewal Parts List ..............................................................................................................48
Loose Parts for 4050 Stamping Press Controller ...............................................................51

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Section 1
General Information
Introduction
This instruction manual contains the necessary information required for normal installation, operation
and maintenance of the Model 4050 Stamping Press Controllers. Please make it available to all
maintenance and operating personnel.
Instructions provided in this manual are arranged in their normal order of use. Beginning with general
information, the instructions proceed from receiving, handling and storage, through installation, start-
up and adjustments to maintenance and trouble shooting. Written as a guide, these instructions do not
cover or describe each detail or modification in the controller. Use this instruction manual in conjunction
with any specific schematic, prints or instructions supplied with your controller. Certified drawings shall
take precedence over printed instruction material if a difference in content occurs.
While every effort has been made to provide a complete and accurate manual, there is no substitute for
trained, qualified personnel to handle unusual situations. If any questions arise regarding the operation
or maintenance of this controller, please refer them immediately to Dynamatic Customer Service at
1-800-548-2169 or 262-554-7977.
Safety
With any electronic or electrical rotating equipment, potential safety hazards are present and require
safeguards for proper use. This equipment must be installed properly, using safe procedures that meet
the requirements of all applicable safety codes. The wiring must be in accordance with the National
Electrical Code and all other local codes and regulations. Shaft guards, as well as protection for
operating and maintenance personnel against high voltage and moving machine parts, is essential. Refer
to OSHA rules and regulations, paragraph 1910.219, for guards on mechanical power transmission
apparatus. Pleases heed these safety instructions.
DANGER, WARNING, CAUTION and special INSTRUCTION labels are applied to the equipment to remind
you of the hazards the exist. Know your equipment before handling or working on it.
DANGER… is used where an immediate hazard exists. Failure to follow instructions could be fatal
WARING… means a possibility of injury to personnel, but not as severe as a Danger Warning.
CAUTION… is used to warn of potential hazards and unsafe practices.
INSTRUCTION… labels and notes are used when there is a need for special instructions related to safety,
proper operation or maintenance.
Training
Training programs are an essential part of safe and correct operation. Training provides the know-how
necessary to obtain top performance from your equipment. Dynamatic recognizes this fact and conducts
training schools to educate your plant personnel in safe maintenance and operating procedures. There is
a nominal charge for this service. Contact customer service at 262-554-7977 to set up a date.

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Receiving and Damage Claims
The Model 4050 Stamping Press controller have been operated and tested at the factory prior to
shipment. Specific test procedures are followed to assure the quality of your controller. Carrier
approved packing methods assure safe shipment to your plant. Shipment is made F.O.B. from our
factory, with the carrier assuming responsibility for your unit. Therefore, it is essential that you carefully
inspect the shipment upon delivery to ensure that no damage or lost items have occurred in transit, Loss
or damage is covered by the carrier, not by the product warranty. File a claim immediately with the
carrier if any damage or loss is found. Should you require assistance in settling your claim with the
carrier, contact Dynamatic. You will need the unit model number, serial number and your purchase
order number for identification.
Warranty
Your new Model 4050 Stamping Press controller is covered by a one-year warranty against any
manufacturing defect in either material or workmanship. Should the controller fail with in the one-year
warranty period, contact Dynamatic for a repair Return Material Authorization (RMA) form. Fill in all
required information on the form and return the form with the controller to our Repair Service
Department in Sturtevant, Wisconsin for warranty repair or exchange. Your controller will either be
repaired or replaced with a preciously repaired exchange controller. Freight charges both ways are your
responsibility.
Handling
Then Model 4050 Stamping Press controllers weigh only a few pounds and can be hand carried safely.
Do not drop or subject the controller to shock or vibration. Do not stack heavy material on the
controller. The printed circuit boards and other components may be mounted on an open panel making
the controller very accessible to damage
Storage
Store the controller in a clean dry location with a non-corrosive atmosphere protected from sudden
temperature changes, high levels of moisture, shock and vibration. Electrical components are delicate
and easily damaged; provide adequate protection for them.
Ambient temperature should not exceed 40°C (104°F). The minimum temperature must remain above
freezing and the dew point of ambient air. High temperature, corrosive atmosphere and moisture are
detrimental to controller equipment.
Long Term Storage
The manufacturer’s warranty covers repair or replacement of defective materials and rectification of
faulty workmanship. It does not cover damage and deterioration that transpire during the storage
period.
Some examples of deterioration due to storage are:
1. Corrosion of terminals and contacts
2. Breakdown of electrolytic capacitors
3. Moisture absorption within insulation and composition resistors.

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These are not manufacturer’s defects and will not be covered by the warranty policy. Refer questions to
the Field Service Department in Sturtevant Wisconsin.
Removal from Storage
Before returning the controller to service after long time storage, it will be necessary to carefully inspect
it for any signs of damage or deterioration. Correct any deficiency. Carefully inspect the controller for
signs of moisture, especially with respect to transformers and composition resistors. If moist, the
transformer will require thorough drying. Damp resistors will change impedance and affect performance
of the controller; they should be replaced.
Corrosion is an important factor. Inspect terminals, plugs, sockets and contacts for signs of corrosion. If
detected, cleaning will be necessary.
Before applying power, make sure all connections are tight.
These procedures are given only as recommendations offered to aid our customers in preserving stored
equipment. We cannot guarantee stored equipment, even if all suggestions are followed; damage or
deterioration may still occur. Equipment storage is not covered by warranty.

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Section 2
General Description
The Model 4050 stamping press controllers are solid state eddy current controllers employing an
integrated circuit design with a transistorized output. The controller is designed to provide a current
output of 8 amps at 45 volts, so it can be used on Ajusto-Spede drives from 1 through 125 hp. See table
2-1 for a full list of specifications. Descriptions of other features available on these controllers follow.
Table 2-1 Specifications
The adjustable time constant circuit matches the controller to the time constant of the mechanical unit.
An LED Set-Up Indicator Circuit enables the maximum speed and minimum bias to be set visually be
means of an “onboard” light emitting diode, in most cases eliminating the need for a meter. Because the
requirements for damping increase with higher horsepower drives and higher inertia, the velocity
damping ranges on the Model 4050 stamping press controllers have been extended to approximately
twice that of the original Model 4000 controller. Current feedback damping is available for customers
who require this type of response. The output of each controller is short circuit proof, which includes
the following conditions:
1. Shorting of terminal C1 to C2
Input Voltage
115 Vac, CT. +20%, -10%, 50/60 Hz
Input Current
7Aac rms
Output Voltage
45 Vdc nominal at either terminals C1 or C2
(clutch) or B1 and B2 (brake)
Output Current
8 Adc continuous
Extra Run Relay Contact (NO)
115 Vac, or 24 Vdc, 5A resistive, 150 V. pilot duty
Load Regulation
-0.5% of maximum rated speed for no load to
100% load change
Line Regulation
±0.1% of rated speed for ±10% input line voltage
change
Thermal Drift
±0.05% of rated speed per degree C. (or ±0.03%
per degree F.)
Linearity
±2% of maximum rate speed, reference voltage
to speed
Min Regulated Speed
50 rpm
Zero Adjust Range
0 to 15% of rated speed
Linear Accel Range
3 to 80 seconds
Fuses FU1, FU2
10 A, 250 Vac
Ambient
0°- 40°C. (32°- 104°F.) Cast enclosure Model 4000
only
0°- 65° (32° - 148° F.) Panel mount Model 4050
Mounting
NEMA 13 or open panel