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

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2. Shorting of terminal B1 to B2
3. Shorting of terminals C1 or C2 to earth ground
4. Shorting of terminals B1 or B2 to earth ground
If any of these events occur, the controller shall be completely self-protecting without damage to any of
its internal components. Input power for the controller can be supplied from either a 115 Vac
transformer winding mounted in the controller or in the drive’s ac motor. A separately mounted 115 Vac
transformer is also available if required. Pushbutton operation by Run relay is standard; also, the Run
relay has an extra set of NO (normally open) contacts available for customer’s use.
Various features have been added to prevent possible damage and improve the reliability of the Model
4050 controller. Additional circuitry has also been added to improve performance and simplify set up.
These features include primarily the output circuit short circuit protection, transient overvoltage
protection and higher rated power devices. An addition of a buffer amplifier circuit will shut off the
controller output with a loss of reference input signal. LED circuitry allows for minimum and maximum
speed adjustment to be made easily without instrumentation feedback. Also, the current circuit
improves drive response under special low inverter, light load applications.
The Model 4050 stamping press controllers are designed for customer mounting within existing
enclosures. These are two basic configurations of the panel mounted controller. One version includes an
optional transformer and the other does not.
All versions of the Model 4050 stamping press controller include a Minimum Speed potentiometer
controls the range that the external Run Speed potentiometer will have to adjust the speed of the drive.
It can be adjusted to prevent the Run Speed potentiometer from setting the drive speed below a
minimum safe flywheel operating speed.
The Torque Limit feature is used to accelerate the flywheel at the fastest rate possible without
excessively overloading the motor. The Ajusto-Speede drive has an overload capability of approximately
200% of rated motor capacity. If the flywheel was accelerated using the full overload capacity of the
drive, it could shorten the life of the motor or permanently damage it. The torque Limit circuit overrides
the speed reference (100% to 150% of rated motor torque). The drive continues to deliver torque and
accelerate the flywheel, but at a controlled value that will not damage the motor or trip the motor
starter overloads.
The Trip Circuit functions at one fixed speed by utilizing on input signal and setting the desired trip point
with the Trip Speed potentiometer R1. The input signal is usually obtained from a generator
(tachometer) which indicated speed. The output of the trip circuit is a set of dpdt relay contacts which
switch when the trip point is reached for customer use.
Basic Controller Assembly
Basic Model 4050 stamping press controllers are available with or without a transformer. The panel
transformer model has an optional trip circuit available in addition to various input voltages.
See table 2-2.

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Mounting of the 15.12” x 11.38” transformer mount panel is by means of the four corner holes
provided. See Figures 2-1 and 2-2 for mounting dimensions and depth requirements. Requirements.
Components included on each panel are as follows: main PCB1, 15-530-6; modification PCB2, 15-444-2;
T1 transformer; and the TB1 terminal board. The trip circuit assembly is included only on those
assemblies covered by Figure 2-1.
Table 2-2 Panel Mount 4050 Controllers with a Transformer
Panel Number with Torque
Limit and Trip Circuit
Panel Number with Torque
Limit (less Trip Circuit)
Input Voltage, Frequency
15-541-0001
15-541-0021
115 V, 50/60 Hz.
15-541-0002
15-541-0022
208 V, 50/60 Hz.
15-541-0003
15-541-0023
390 V, 50/60 Hz.
15-541-0004
15-541-0024
230/460 V, 60 Hz.
15-541-0005
15-541-0025
575 V, 60 Hz.
15-541-0007*
--
208/230/460 V, 50/60 Hz
*Special reduced output controllers: 5.5 Adc output current.
The panel mount version without a transformer is available with or without the Torque Limit
modification. Both versions include Minimum Speed adjustments. The 10.25” x 6.00” panel is mounted
by the three holes provided. See Figures 2-3 and 2-4 for outline drawings and mounting dimensions.
Components included on each panel are as follows: main PCB, 15-530-6. TB1 terminal board; and the
Minimum Speed potentiometer. The 15-444-2 Torque Limit modification PCB is included on the 15-539-
19 assembly (Figure 2-3)
The main PCB (15-530-6) is mounted to the panel with four standoffs. A ground stud is provided for
grounding the panel. A13 position terminal block across on end of the main PCB assembly is provided to
make connections to it. Near the center, along on side of the board, is a 16 pin receptacle (RECP1) into
which is plugged a 4 pole, 8 pin Dip Switch (SW1). When modification PCB 15-444-2 is used, this Dip
switch is removed and replaced with a 16 pin plug and mod interconnect ribbon cable.
Modification printed circuit boards (15-444-2) is mounted to the main PCB with four nylon standoffs.
These standoffs serve as licking devices to hold the two PCBs together securely. See Figure 2-1, 2-2 and
2-3. This modification printed circuit board measures 3.50” x 3.90”. It is connected electrically to the
main PCB assembly with a 16 pin ribbon connector and a separate push-on jumper that connects
terminal C2 of the mod PCB to terminal FC2 of the main PCB assembly. A separate current transformer is
furnished for mounting in the junction box of the mechanical unit, or as a loose item for mounting by
the customer.
Drive Description and Application
The Ajusto-Spede drive is a combination of an air cooled, eddy current clutch and an integrally mounted,
design 88, ac induction motor. The Ajusto-Spede drive transmits constant torque at variable speeds.
With the eddy-current principle of torque transmission, these is no physical contact between input and

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output members. This results in smooth response, eliminating shock loading and extending the life of
the equipment.
The Ajusto-Spede drive restores the energy extracted by the flywheel going through the work portion of
the stroke. In this application, it is the flywheel that delivers the energy to the press for the work, not
the Ajusto-Spede drive. Because of this, it is the flywheel capacity that determines the minimum
operable press speed.
The 4050 stamping press controller is designed to meet the requirements of stamping press applications
by providing these two basic functions:
1. To accelerate the flywheel to an adjustable running speed within the speed range of the press.
2. To provide minimum and maximum limits of Run Speed adjustments to avoid improper
operation of the press.
When the Torque Limit modification is furnished, the drive torque is limited by the setting of the Torque
Limit potentiometer. This feature is used to avoid excessive overload of the motor when accelerating a
high inertia flywheel, or when the press load causes a significant change in the flywheel, or when the
press load causes a significant change in the flywheel speed.
When the Speed Trip circuit is furnished with the press drive controller, it is employed as a speed trip
that will energize above zero speed. The setting of the Trip speed potentiometer determines the Speed
Trip setting.
Model 4000-4050 Comparison
The assemblies 15/533-1019 (Model 4000) and 15-539-0019 (Model 4050) panel mount controllers are
very similar in appearance. The primary difference is the 4050 heatsink, HR1, with the power
semiconductors. On the Model 4000 these semiconductors (D1, D2, and Q1) are mounted on the main
PCB assembly so the off-board heatsink is not required.
Item Specifications
4000
4050
Drive Range
1 to 20 Hp
1 to 125 Hp
Main PCB Assy
15-530-5
15-530-6
Input Current
4 Aac rms
7 Aac rms
Output Current
4.3 Adc continuous
8 Adc continuous
Fuses FU1, FU2
4 A, 250 Vac
10 A, 250 Vac
Installation Follow the installation instructions in section 3 of this manual, except that the input
wiring is only required to carry at 4amps at 115 Vac. The dc output to the coils is 45 Vdc at 4.3 amps. All
other controller wiring is 5 amps or less
Operation of the model 4000 controller is similar to the Model 4050 controller as described in
the manual. However, the Model 4000 controller is not available with the Speed Trip option
Start-up and Adjustments for Model 4000 stamping press controllers, follow the applicable
Model 4050 Start-Up and Adjustment procedure in the manual

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Figure 2-1 Stamping Press Controller 15-541-000* with torque Limit, Speed Trip, and Minimum
Adjustment Panel Outline Mounting Dimensions

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Figure 2-2 Stamping Press Controller 15-541-002* with Torque Limit Minimum Speed Adjustment
(w/o Speed Trip) Panel Outline Mounting Dimensions

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Figure 2-3 Stamping Press Controller 15-539-0019 with Torque Limit and Minimum Speed
Adjustment Panel Outline Mounting Dimensions

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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)

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Section 3
Installation
Mounting Panel Mounted Controllers
The Model 4050 panel mount stamping press controllers should be mounted with the main PCB/panel
terminal block toward the bottom of your enclosure. The minimum depth required for the controller is
wither 4” or 8” (refer to the panel outline mounting dimension drawings in figures 2-1 through 2-4 for
your specific models) You may use the controller as a template or use the appropriate outline mounting
drawing to locate the required mounting holes. The panels with a transformer that are shown in Figures
2-1 and 2-2 should be mounted with 3/8” hardware in each of the four corner holes. Panels without a
transformer should be mounted with No. 10 hardware, such as 10-24 or 10-32, in the three positions
shown.
Mounting an Input Transformer
If a loose transformer is furnished, a suitable location should be selected for installing it. Figure 3-1
includes mounting dimensions. Orient the transformer for ready access to primary and secondary
terminals, which are clearly marked. Using adequate size hardware, secure the transformer in place.
Check transformer input and output requirements. Before wiring it to the input supply and to the
controller.
Figure 3-1 Input Transformer

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Main Printed Circuit Board Support
If it is necessary to install the main PCB 15-530-6 onto the panel, the following instructions are provided
to help you with this task. Position the board so that it is supported by each of the two support brackets.
Then mount the printed circuit board to the panel with the four mounting screws that are furnished.
Modification PCB
The Torque Limit modification PCB 15-444-2 schematic is included in Figure 3-11. If its is necessary to
install this modification PCB onto the main PCB, 15-530-6, the following instructions are provided to
help you with this task:
1. Place the main PCB in front of you with the long dimension in a horizontal position and the
terminal strip to the left
2. Locate the dual in-line, 4 position Dip switch plugged into receptacle RECP 1 on the main PCB
assembly. With the main PCB terminal block to the left, RECP1 is 2.5” from the right edge and
1.0” from the bottom, edge of the board.
3. Remove the Dip switch by pulling it straight out of the receptacle. Save the switch for some
future use. Then, peel the adhesive-backed label off the other half of RECP 1.
4. Four nylon standoffs are supplied with each modification PCB assembly. Locate the four 0.188”
diameter holes in the main PCB assembly. Insert the arrow type locking head of a standoff into
each of the holes in the main PCB assembly and press them in (see Figure 3-2) The Tabs will snap
out to lock the stand-offs permanently in position. Replacement standoffs are available by
ordering the standoff kit assembly 15-263-16, which contains four standoffs.
Figure 3-2 Modification PCB Standoff
5. Hold the modification PCB
assembly over the standoffs with the
ribbon connector toward you, which
should be over the RECP 1 Receptacle.
Insert the ribbon connector plug into
RECP 1. Be careful to see that all 16
pins are started properly into the
receptacle before pressing the plug in.
These pins are easily bent. To remove
this connector, pull straight up on the
body of the plug. Do not pull on the
ribbon itself.

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6. Align the holes in the modification PCB assembly over the standoffs and press ober the tapered
posts until the locking flanges snap out to lock the board in position. TO remove the board,
squeeze the locking flanges in with your fingers and lift off the board.
Wiring
The connection diagrams and schematics for all of the 4050 stamping press controllers are included in
Figures 3-4 through 3-8. The connection diagrams are in simplified block form. The large rectangular box
in the center of the diagram represents the controller panel, with the terminal strips shown, numbered
and lettered exactly as they appear on the actual controller panel. The rotating unit’s electrical devices
that must be wired are shown on the left side of the connection diagram. Connections between the
drive and controller are shown by the solid lines that are drawn between the appropriate terminal
points. The heavy solid lines represent a raceway or conduit run.
Starting at the top of the connection diagram, note the dotted box, labeled “Recommended disconnect
switch and motor starter circuit”. This dotted line indicates that these items are not included in the
Model 4050 stamping press controller packages. Since the drive uses a standard ac induction motor, it
must be connected with the proper branch circuit protection, motor starter and overload devices. The
minimum requirements are specified in the National Electrical Code; other local regulations may also
apply. If a question exists, consult Dynamatic 800-548-2169.
Wire size, number of conductors in a conduit or raceway and grounding are also specified by the
National Electrical Code and other applicable local regulations. Make sure that you meet minimum
requirements of theses codes. Consult the nameplate of the drive for full load current at the voltage you
are using. Controller input wiring should be sized to carry 115 Vac at 7 amps. The dc output to the coils
is 45 Vdc at 8 amps. All other controller wiring is 5 amps. All other controller wiring is 5 amps or less. In
most cases, the minimum conductor size allowed by code will be adequate. To avoid stray signal
interference, do not run the reference signal interconnection wires in the same conduit as the power
wiring.
Note that it is necessary to use shielded conductors for the generator leads, both for runs to the
controller and to any tachometer indicator that may be used. The shielded conductor should be a
twisted, insulated pair of conductors having a continuous metallic shield around the twisted pair with an
insulating jacket over the shield. At the generator and indicator ends, cut back the shield as required to
expose enough lead to make the connections. Then, tape the exposed shield so that it does not ground
at that point. On the controller panel, strip off enough of the outer jacket to expose several inches of
shield. Unwrap or unbraid the shield to obtain a bundle of separate strands. Twist the strands to form a
conductor and attach it to the ground. Make sure the shield ground connection cannot make contact
with the terminals at the terminal strip. Shielded cable should have the shield grounded at one end only.
When shielded cable is used, the generator leads may be run in the same conduit as the other
conductors. You may prefer to not use shielded cable; and if so, you must run the generator leads in
separate conduit with no other conductors. Keep wire length as short as possible.
After pulling the proper size conductors, connect each terminal at the drive to a controller terminal
having the same number or letters. As an example, C1 at the drive unit should be connected to terminal