Dynamatic 4050 User manual

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Model 4000 and 4050 Controllers
Instruction Manual
Part Number IM-130006-9801
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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Table of Contents
Section 1........................................................................................................................................... 5
General Information .................................................................................................................... 5
Introduction ............................................................................................................................. 5
Safety ....................................................................................................................................... 5
Training .................................................................................................................................... 6
Receiving and Damage Claims ................................................................................................. 6
Warranty .................................................................................................................................. 6
Handling ................................................................................................................................... 6
Storage ..................................................................................................................................... 6
Long Term Storage ................................................................................................................... 7
Removal from Storage ............................................................................................................. 7
Numbering System................................................................................................................... 7
Symbols used in Illustrations .................................................................................................10
Section 2.........................................................................................................................................11
4000 and 4050 Controller Description....................................................................................... 11
Specifications .........................................................................................................................11
Basic Controller Assembly...................................................................................................... 12
Modification PCB’s................................................................................................................. 13
Packaging Options..................................................................................................................13
Table 2-1 Standard Enclosed Model 4000 Controller........................................................ 14
Table 2-2 Panel Mounted 4000 Controllers.......................................................................15
Table 2-3 Panel Mounted 4050 Controllers.......................................................................16
Table 2-4 NEMA 1 Enclosure 4050 Controllers.................................................................. 17
Section 3.........................................................................................................................................18
Assembly ....................................................................................................................................18
Identification..........................................................................................................................18
Main Printed Circuit Board Support.......................................................................................18
Modification PCB ...................................................................................................................19
Wiring..................................................................................................................................... 20
Section 4.........................................................................................................................................21
Installation ................................................................................................................................. 21
Location..................................................................................................................................21
Mounting Panel Mounted Model 4000 and 4050 Controllers .............................................. 21
Mounting an Input Transformer ............................................................................................ 22
Wiring..................................................................................................................................... 22

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Programming Dip Switch .......................................................................................................23
Section 5.........................................................................................................................................25
Operation...................................................................................................................................25
Basic Controller Theory.......................................................................................................... 25
Linear Acceleration Option .................................................................................................... 26
Fixed Brake Option................................................................................................................. 27
Figure 5-2: Model 4000/4050 Controller Block Diagram................................................. 27
Spring Set Brake Option......................................................................................................... 28
Adjustable Brake Modification, 15-444-4 ..............................................................................28
Alternate Speed Modification, 15-444-3 ............................................................................... 28
Tach Follower Modification, 15-444-1................................................................................... 29
Low signal Follower Modification 15-446-1/5/101 ...............................................................29
Torque/Speed Modification, 15-444-5 ..................................................................................29
Torque Limit Modification, 15-444-2..................................................................................... 30
Dancer Position Modification, 15-444-7................................................................................ 30
Figure 5-3: Model 4000 Controller Schematic with 15-530-5 Main Assembly ................ 31
Figure 5-4: Model 4050 Controller Schematic with 15-530-6 Main PCB Assembly........... 32
Mutuatrol® Modification, 15-446-2....................................................................................... 33
Variable Air Volume Modification (VAV), 15-446-3/102 ....................................................... 33
Linear Accel/Decel Modification, 15-446-4 ...........................................................................33
Section 6.........................................................................................................................................34
Start-Up and Adjustments .........................................................................................................34
Tools Required .......................................................................................................................35
Power Off Tests......................................................................................................................35
Power on Tests....................................................................................................................... 36
Set-Up of Main PCB Assembly ...............................................................................................37
Basic Speed Control ............................................................................................................... 37
LED Set-Up ............................................................................................................................. 38
Zero Adjust R19 with LED monitor- ................................................................................... 38
Zero Adjust R19, Alternate Method- .................................................................................38
Max Speed/Volts R21.........................................................................................................39
Max Speed/Volts R21 with LED Monitor ........................................................................... 39
Max Speed/Volts R21, Alternate Methods-.......................................................................39
Time Constant (TC) Adjust R26-.........................................................................................40
Accel Rate R18 ...................................................................................................................40

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Velocity Damping R22-....................................................................................................... 41
Current Feedback, R20- .....................................................................................................42
Basic Torque Control (Used when speed control is not used)............................................... 43
Section 7.........................................................................................................................................44
Maintenance and Trouble Shooting .......................................................................................... 44
Maintenance ..........................................................................................................................44
Trouble Shooting.................................................................................................................... 44
If the drive will not run: .....................................................................................................44
If the drive runs at full speed: ............................................................................................ 45
Renewal Parts and Service.....................................................................................................46

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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 4000 and 4050 Eddy Current Controllers. Please make it available to all
maintenance and operating personnel.
The Model 4000 and 4050 Eddy Current Controllers are high quality performance controllers capable of
operating Dynamatic Ajusto-Spede drives. The 4000 controller can be used with the Fractional Drives (.5
HP thru 1.5 HP), AS-14 thru AS-25 (.75 HP thru 20 HP) and the AT-140 thru AT-280 (1 HP thru 50 HP) The
4050 Controller can be used with the fractional Drives (.5 HP thru 1.5 HP), AS-14 thru AS-27 (.75 HP thru
40 HP), AT-140 thru AT-440 (1 HP thru 200 HP) and the AS-705 Air Cooled Brake
The Model 4000 and 4050 controllers are available in panel mount configurations designed for use in a
customer’s enclosure or they may be supplied in their own enclosure. Operator’s elements are provided
by Dynamatic at the customer’s request. Wiring of these elements is the customer’s responsibility.
The controllers’ flexible design allows them to be programmed by use of a Dip switch for wither speed
or torque control. They can be used with any combination of the basic controller and one of the
modifications, providing the interconnection is completed according to the schematic and connection
diagrams provided. Any combination of modifications or use of a modification not designed for the
controllers is not authorized.
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 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.

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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.
Receiving and Damage Claims
The Model 4000 and 4050 controllers 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 4000 or 4050 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 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 4000 and 4050 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.

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Ambient temperature should not exceed 25°C (77°F) on a continuous basis or 40°C (104°F) on an
intermittent basis. 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.
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.
Numbering System
The numbering system for electrical component and assembly part numbers contains some useful data
which could be of value to the technician working with or trouble shooting the controller. The number is
twelve digits, arranged in a two-six-four-digit sequence with the groups separated by dashes. As an
example, one printed circuit board part number is 15-000530-0006. This twelve-digit number is the
complete number as recognized by the computer. Frequently, the number is abbreviated by dropping
zeros, i.e.., 15-530-6. The number printed on the board and in the technical instruction material is the
abbreviated form. However, the actual bill of material and order paper work for the board would use
the complete number.

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The first two digits of the part number identifies the parts category. As in the precious example, the 15
designates an assembly. The following table lists the complete category listing and assigned numbers
used as the first two digits of the part number.
Category Number and Descriptions
14
Alarms
35
Generators
56
Shock Mountings
15
Assemblies
36
Hardware
57
Solenoids
16
Bearings
37
Instruments
58
Switches
17
Blocks
38
Insulators and Insulations
59
Servo mechanisms
18
Blowers
39
Lights & Fixtures
60
Terminals
19
Brackets
40
Motors
61
Thermal devices (excluding
motor starter heaters)
20
Cables
41
Motor starters & Controls
62
Timers
21
Cams & Gears, cam Switch
assemblies
42
Nameplates
63
Transducers
22
Cans
43
Operating mechanism
(breakers)
64
Transformers, chokes
23
Capacitors
44
Operator panels
65
Tube sockets
24
Chassis
45
Panels
66
Valves
25
Circuit Breakers
46
Phase Shifters
67
Wires
26
Coils & Coil Assemblies
47
Photoelectrical
68
Wiring Ducts
27
Connectors, plugs, sockets
48
Plates
69
Tubes
28
Control units & parts
49
Potentiometers
70
Insulated Mounting Boards
29
Counters
50
Power Converters
71
30
Dial plates & knobs
51
Reactors
72
Master bills of material
31
Enclosures
52
Regulators
73
Engineering Data Sheets
32
Fuses & Fuses Holders
53
Relays & Contactors
74
33
Filters (radio interference)
54
Resistors
75
Reworked Assemblies
34
Gaskets & Gasket
Materials
55
Semi-conductors
The middle six digits describe a basic type of part, such as physical or electrical characteristics of a group
or family of parts. As an example, a resistor family of ½ watt carbon resistors has the number 000045.
The part number of on specific resistor in this family is 54-000045-0102.
Category
Part Name
Parameter Described
23
Capacitor
Capacitance
32
Fuses
Ampere Rating
49
Potentiometer
Resistance
54
Resistors
Resistance
55
Power diodes & SCR’s
Peak Reverse Voltage

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The last four digits describe a specific part within the family and may be assigned in numerical sequence
or may describe the specific part value. The following table lists those part categories where the last
four digits have a significant meaning to the technician.
Last 4 Digits
Numeric Value
2593
.025
2592
.25
2591
2.5
0250
25
0251
250
0252
2500
0253
25000

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Symbols used in Illustrations