Worldwide WDC CONTROL Series User manual

WDC CONTROL SERIES

LT84 (0220)

Phone (800) 808-2131

Fax (800) 711-1616

www.worldwideelectric.com

Instruction Manual

Variable Speed DC Control

A-5-3546F

WDCCONT WDCCONTREV

WARRANTY

WorldWideElectricCorporation(WWE)warrantsitsproductstobefreefromdefectsinmaterialandworkmanship.Theexclusive

remedy for this warranty is WWE factory replacement of any part or parts of such product which shall within 12 months after

delivery to the purchaser be returned to WWE factory with all transportation charges prepaid and which WWE determines to its

satisfaction to be defective.This warranty shall not extend to defects in assembly by other than WWE or to any article which has

been repaired or altered by other thanWWE or to any article whichWWE determines has been subjected to improper use.WWE

assumes no responsibility for the design characteristics of any unit or its operation in any circuit or assembly. This warranty is

in lieu of all other warranties, express or implied; all other liabilities or obligations on the part of WWE, including consequential

damages, are hereby expressly excluded.

NOTE:Carefully check the control for shipping damage.Report any damage to the carrier immediately.Do not attempt to operate

the drive if visible damage is evident to either the circuit or to the electronic components.

Allinformationcontainedinthismanualisintendedtobecorrect,howeverinformationanddatainthismanualaresubjecttochange

withoutnotice.WWEmakesno warrantyof anykind withregardto thisinformationordata.Further,WWEis not responsibleforany

omissions or errors or consequential damage caused by the user of the product.WWE reserves the right to make manufacturing

changes which may not be included in this manual. WARNING

Improper installation or operation of this control may cause injury to personnel or control failure.The control must be installed

inaccordancewith local,state,and national safetycodes.Make certain that the powersupplyis disconnected beforeattempting

to service or remove any components!!! If the power disconnect point is out of sight, lock it in disconnected position and tag

to prevent unexpected application of power. Only a qualiﬁed electrician or service personnel should perform any electrical

troubleshooting or maintenance. At no time should circuit continuity be checked by shorting terminals with a screwdriver or

other metal device.

WARRANTY ............................................................................................................................................................................... 1

INTRODUCTION ........................................................................................................................................................................ 2

CONTROL FEATURES .............................................................................................................................................................. 2

HEATSINK DIMENSIONS .......................................................................................................................................................... 2

WDCCONT HOOK-UP DIAGRAM ............................................................................................................................................. 3

WDCCONTREV HOOK-UP DIAGRAM ......................................................................................................................................4

WIRING PROCEDURE & FUSING ............................................................................................................................................ 5

TERMINAL STRIPWIRING ....................................................................................................................................................... 5

START-UP PROCEDURE & ADJUSTMENTS ........................................................................................................................... 6

TRIMPOT ADJUSTMENT PROCEDURE & SETTING CHART ................................................................................................. 7

CONTROL MODIFICATIONS .................................................................................................................................................... 8

IN CASE OF DIFFICULTY ......................................................................................................................................................... 8

SPECIFICATIONS &TYPICAL MOTOR CURRENTS ............................................................................................................... 9

WDC SERIES PARTS PLACEMENT & LIST ............................................................................................................................ 9

WDC SERIES SCHEMATIC ..................................................................................................................................................... 10

TABLE OF CONTENTS

INTRODUCTION

• TheWDC Series variable speed DC motor control is a versatile, general purpose control rated to 2 HP.

• The control has a dual voltage input (may accommodate either 120 or 240 VAC).It is available with an adjustable HP

range of 1/8 thru 1 HP for 120VAC, and 1/4 thru 2 HP for 240 VAC input.

• Designed for DC Permanent Magnet, Shunt Wound, and some Universal (AC/DC) motors in the above horsepower ranges.

• IncomingACvoltageisalsoconvertedtoadjustablefullwaverectiﬁedDCvoltage(viaapackagedbridge)tooperatetheDC

motor. Also, a full wave ﬁeld voltage is provided for shunt wound motors (see page 4 for voltages).

• The control incorporates transient voltage protection with adjustable current limit and an AC fuse for protection.It

features adjustable minimum and maximum speeds along with adjustable acceleration and IR Compensation.Tach feedback

is accomplished thru a connection to a pin (P2) on the printed circuit board.

• The WDC Series has a linear acceleration/deceleration ramp.

• The control also has a barrier type terminal strip for all power and control wiring.

• The enclosed model uses a gasketed cover assembly that is rated NEMA 4/12.

• cULus Listed.

HEATSINK DIMENSIONS

Allow 3.50" for height clearance, 7.40" for overall length.

MIN. SPEED (minimum speed) - Allows adjustment of the motor speed when the speedpot is set at minimum (CCW). This

permits the user to eliminate the “deadband” on the main speed control permitting zero calibration. Clockwise rotation of “MIN”

trimpot increases minimum motor speed.

MAX.SPEED (maximum speed) - provides for adjustment of the motor speed when the speedpot is set at maximum (CW).This

permits the user to eliminate the top end “deadband”, which will provide full speed at maximum rotation. Rotation of the “MAX”

trimpot in the clockwise direction increases the maximum motor speed.

ACCEL (acceleration) - allows adjustment of the motor acceleration from a minimum of 0.5 seconds to approximately 8.0 sec-

onds.The deceleration time depends on the ACCEL setting.For DECEL time equal to ACCEL time, see -17B option.

IR COMP (speed regulation) - adjusts the control output to compensate for speed changes caused by varying motor loads. As

the motor load is increased, IR COMP increases the voltage output of the control. Clockwise rotation of the “IR COMP” trimpot

will increase compensation.

CUR. LIM. (current limit) - provides protection from excessive armature current by limiting the maximum armature current the

control can provide.This enables adjustment of the maximum torque the motor can deliver.Current limit adjustment (CUR.LIM.)

is set at 125% of the rated motor current (torque) based on horsepower. Clockwise rotation of the “CUR. LIM.” trimpot increases

the current (torque) the control will provide.

TERMINAL STRIP - allows for connection of AC lines, motor leads, motor ﬁeld (if needed), and speed potentiometer.

CONTROL FEATURES

5.500

7.000

.750

5.125

7/32 SLOTS (4)

TYP. .350 DEEP

5.530

WARNING

1. Be sure the control housing is properly grounded.

2. Arm connections must not be switched or broken while the control is on. Serious damage may result.

3. For non-speedpot applications, the input connections to the Lo-Wiper-Hi leads must not be grounded. Serious

control damage may result from a grounded input.

INSIDE OF COVER

SPEEDPOT

DPST SWITCH

(black)

(black

or brown)

Endplate with holes for 1/2" NPT conduit

-11

-9-8-4 -5 -6 -7-1 -2 -3

Inhibit

Pot Lo

Wiper

Pot Hi

-Arm

+Arm

P1_6

P1_7

motor

armature ac input

field*

chassis

ground

Switched AC

Min Max Accel IR

Comp Cur.

Lim. LO (orange)

HI (white)

WIPER (red)

(white)

(white

or yellow)

-10

WDCCONT HOOK-UP DIAGRAM (SEE PAGE 4 FOR WDCCONTREV)

* Used for shunt wound motors only! No connection is made to these terminals when using permanent magnet motors.

P3-1 P3-2 P1-8 P1-9

P1-4 P1-5 P1-10 P1-11

AC INPUTARM INPUT

-7

-6

-3

-2

-1

4PDT SWITCH

-4

-11

-10

-5

-2

-1

-9

-8

ARM

black

white

brown

yellow

red

blue

purple

or brown

gray or

yellow

brown

yellow

purple

or brown

gray or

yellow

Permitsreversing of motor.Thisis accomplished usinga4PDTblockedcenterswitch.When switchedbetweenthe forward/reverse

positions, a delay is encountered due to the blocked center position, which protects the control from any voltage that may be at

the armature terminals.The center position is OFF/NEUTRAL.

THE MOTOR MUST COMETO A COMPLETE STOP BEFORE CHANGING DIRECTIONS. IFTHE MOTOR DOES NOT COME

TO A COMPLETE STOP, SERIOUS DAMAGETOTHE CONTROL MAY RESULT.BYPASS OFTHE CENTER BLOCK OFTHE

SWITCH MAY RESULT IN DAMAGETOTHE CONTROL.

A 4PDT blocked center-off switch is factory installed into the cover assembly. The two position terminal strip (P3) is factory in-

stalled on the main board (below).The output on P3 is the switched (FWD/REV) output and the output of terminals P1-4 and

P1-5 is not switched.

WDCCONTREV HOOK-UP DIAGRAM

INSIDE OF COVER

SPEEDPOT

DPST SWITCH

(black)

Endplate with holes for 1/2" NPT conduit

-11

-9-8-4 -5 -6 -7-1 -2 -3

Inhibit

Pot Lo

Wiper

Pot Hi

P1_6

P1_7

motor

armature ac input

field*

chassis

ground

Switched AC

Min Max Accel IR

Comp Cur.

Lim. LO (orange)

HI (white)

WIPER (red)

(white)

-10

-Arm

+Arm

(brown)

(yellow)

(purple)

(gray)

(blue)

(red)

-1 -2

* Used for shunt wound motors only! No connection is made to these terminals when using permanent magnet motors.

Wiring Diagram

Hook-Up Diagram

P1-7 (-FIELD) Connect minus (-) Field wire of SHUNT WOUND MOTOR.

P1-8 VERY IMPORTANT !!! Refer to“FUSING”, shown above.

P1-9 (AC) 120VAC - Connect incoming hot AC (black wire) to P1-9 and Neutral (white wire) to P1-8.

Connect ground (green wire) to Chassis Ground, as shown in diagram - page 3.

240VAC - Connect both hot sides, one to P1-8 and one to P1-9.Also connect ground wire to

Chassis Ground.

P1-10 VERY IMPORTANT !!! Refer to“FUSING”, shown above.

P1-11 (SWITCHED AC) No connections to P1-10 and P1-11.This is for switched AC output.

Note Wiring Hook-Up diagram (page 3).Pilot lights can be connected between these

terminals. The voltage present at these terminals is AC input voltage.

FIELDVOLTAGETABLE

VAC INPUT 120 240

VDC FIELD 100 200

}

P1-1 (SPEEDPOT LO) Connects to low side (orange wire) of the 5K speedpot (normally the CCW end).This input is raised

and lowered by the MIN.trimpot.

P1-2 (SPEEDPOTWIPER) Connects to wiper (red wire) of the 5K speedpot (center lead).

P1-3 (SPEEDPOT HI) Connects to high side (white wire) of the 5K speedpot (CW end).This is internal +12 volts.For start-

stop applications, the connection between this terminal and speedpot HI can be opened and closed by a SPST switch.

NOTE: INPUT MUST NOT BE GROUNDED!!

P1-4 (-ARM) Connects to minus (-) Armature wire (A2) on motor.

P1-5 (+ARM) Connects to plus (+) Armature wire (A1) on motor.0-90 VDC for 120 VAC input OR 0-180 VDC for 240 VAC

input. See “SPECIFICATIONS” for output rating.

P1-6 (+FIELD) DO NOT USE for permanent magnet motor.This supplies +Field voltage for a SHUNT WOUND MOTOR. Refer

to Field Voltage table.For motors with dual voltage ﬁeld (i.e.50/100V or 100/200V), make sure highest value is connected.

TheWDC Series has an 11 position terminal strip for ease of connection.

TERMINAL STRIPWIRING

FUSING

The control is provided with a fuse in AC line 1 (P1-11). This fuse is sized to open in the event of a shorted armature or if an

armature line is shorted to earth ground.As long as 120 VAC input is connected properly, there is no additional fusing needed.

For 240VAC applications, an external fuse may be used in AC line 2 (P1-10).This fuse should be a Bussman ABC10 or LittleFuse

314-010.This added fuse will provide protection on both AC legs to the 250G. If you desire not to fuse both legs, the fuse in the

control will open in the event of excessive armature currents.

Note: AC current is determined by motor characteristics.In some applications it may be necessary to increase fuse value.

WIRING PROCEDURE

1. Size all wires which carry armature or line current to handle currents as speciﬁed by national, state, and/or local codes. All

other wires may be #18 AWG or smaller as permitted by local code.

2. Separate control wires from all the Armature and AC line wires when routed in conduits or in wire trays.The enclosed

version has two threaded holes (1/2" NPT) in one endplate, located near the terminal strip, for this purpose.

The trimpot adjustments, MIN, MAX, IR COMP, and CUR LIM are checked at the factory using a typical motor at 240 VAC input.

Use the TRIMPOT SETTING CHART on page 6 to preset the trimpots for the proper setting for your application.The remaining

trimpot - ACCEL, is a variable acceleration and should be set for your particular application.

The trimpot chart is approximate.The chart is valid when using the speedpot or a 0-10/12 VDC input signal to set speed.

Theseadjustmentsarepermanent;periodicreadjustmentisnormallynot needed.Operationofthe controlbeyond±10%ofnormal

line voltage could result in readjustments.

ADJUSTMENTS

WARNING: ALL POWER MUST BETURNED OFF BEFORE PROCEEDING !!!

1. Recheck all wiring. Accidental grounds, loose or pinched wires on armature or speedpot wires may damage the control

when power is applied.

2. Check to see that incoming service is of correct voltage.

3. Turn speedpot to zero (fully CCW).

4. Turn power on and advance speedpot while observing motor.

WARNING: POWER MUST BE OFF BEFORE STEP 5 CAN BE ACCOMPLISHED!

5. If motor rotation is incorrect, turn power off at external disconnect and reverse +ARM and -ARM connections.

6. Check for satisfactory operation throughout the speed range.

7. If operation is satisfactory, no readjustments are needed.

8. If instability or surging is observed, or maximum speed is higher than desired, see section “TRIMPOT ADJUSTMENT”.

9. For other problems, consult section “IN CASE OF DIFFICULTY”.

START-UP PROCEDURE

Warning: Do not attempt to perform a Hi-Pot test across AC lines with control in circuit.

This will result in immediate or long term damage to the control.

1. CW rotation increases time of acceleration.

ALLOWS ADJUSTMENT OF ACCELERA-

TION by user.

1. TURN DRIVE POWER OFF !!

2. Connect a DC ammeter between A1 on the motor and

+ARM on the control.This is in series with the motor.

3. Turn power on.

4. Set speedpot at the 50% position.

5. Set CUR LIM trimpot fully CCW.

6. Apply friction braking to the motor shaft until motor is

stalled (zero RPM).

7. While motor is stalled, set current at 125% of rated

nameplate motor armature current by adjusting the

CUR LIM trimpot.

LIMITSDCMOTORARMATURECURRENT

(Torque) to prevent damage to the motor

or control.The current limit is set for the

rated motor current. CW rotation of this

trimpot increases the armature current

(or torque produced).

1. Set speedpot at 50%,

2. Observe motor speed at no load condition.

3. Apply a full load to the motor.

4. Adjust IR COMP trimpot CW to obtain the same motor

speed as with no load.

CALIBRATESSPEEDREGULATION-Pro-

vides a means of improving motor speed

regulationinthearmaturefeedbackmode.

If a slowdown due to load change is of no

concern, rotate this trimpot fully CCW.

1. Set speedpot to zero (fully CCW).

2. Rotate MIN trimpot CW until motor rotates.

3. Slowly rotate MIN trimpot CCW until motor stops.NOTE:

If motor rotation at zero is desired, rotate MIN trimpot

CW until desired minimum speed is reached.

SETS MINIMUM MOTOR SPEED when

speedpot is set at zero. CW rotation will

increase minimum motor speed.

1. TURN DRIVE POWER OFF!!

2. Connect DC Voltmeter: + to +ARM, - to -ARM.

3. Set meter voltage range: (90VDC or 180VDC).

4. Turn power on. Set speedpot at 100%.

5. Adjust MAX trimpot to rated motor armature voltage as

shown on meter.

NOTE:A tachometer or strobe may be used in lieu of a meter.

Follow above steps, except adjust MAX trimpot to rated

motor base speed indicated by tachometer or strobe.

SETS MAXIMUM MOTOR SPEED when

speedpotissetatmaximum(100%rotation

CW).CWrotationofMAXtrimpotincreases

maximum motor speed.

TRIMPOT FUNCTION ADJUSTMENT

MAX

MIN

COMP.

CUR.

LIM.

ACCEL

TRIMPOT ADJUSTMENT PROCEDURE

1/4

1/3

1/2

3/4

1.0

MIN MAX ACCEL IR CUR.

LIM. H.P.

1/8

INPUT

VOLTAGE OUTPUT

VOLTAGE

120VAC

MIN MAX ACCEL IR H.P. INPUT

VOLTAGE OUTPUT

VOLTAGE

CUR.

LIM.

0-90VDC

1/4

1/2

3/4

1.0

1.5

2.0

240VAC

0-180VDC

0-90VDC

TRIMPOT SETTING CHART

These settings apply when using a 5000WMaster Speedpot.

This trimpot chart is approximate. Use it in conjunction with the Adjustment Procedures.

IN CASE OF DIFFICULTY

If a newly installed control will not operate, it is possible that a terminal or connection is loose. Check to make sure that all con-

nections are secure and correct. If control still doesn't operate, refer to the following chart.

- replace fuse

- install proper service

- adjust speedpot CW to start

- replace motor brushes

- check that motor or load is connected

to armature terminals

- check that speedpot low wire is connected

- check - should be above 108V

- reduce load

- replace motor brushes

- see ADJUSTMENT PROCEDURE

- current must be greater than 150 mA D.C.

- see ADJUSTMENT PROCEDURE

- reduce speed

- check - should be above 108V

- reduce load

- replace

- callWorldWide Distributor or Representative

- checkTERMINAL STRIP WIRING for

correct wiring instructions (note AC line

connection in particular)

- check wiring

- callWorldWide Distributor or Representative

Motor doesn't operate

Armature output voltage

cannot be adjusted,output

is a constant DC level

Motor stalls, or runs very

slowly with speedpot

turned fully CW

Motor hunts

Repeated fuse blowing

Motor runs but will not

stop

- blown fuse

- incorrect or no power source

- speedpot set at zero

- worn motor brushes

- no motor or load connected

- speedpot low connection open

- low voltage

- overload condition

- worn motor brushes

- max speed set incorrectly

- too much IR Comp.

- motor is in current limit

- motor not pulling enough current

- max trimpot set too high

- motor speed is above rated speed

- low voltage

- overload condition

- worn motor brushes

- defective motor bearings

- defective electrical component

- incorrect wiring (enclosed version)

- defective wiring

- defective component

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION(S)

If control still will not operate, consult your WorldWide Electric Distributor or Representative.

Two pot operation is done using two 10K

Ohm speed potentiometers in parallel (both

HI's to P1-3, both LO's to P1-1). The

WIPER is switched using a SPDT switch.

TWO SPEED OPERATION A DPDT switch is used to inhibit the control and to connect the

DBR. Typical values for the DBR (dynamic brake resistor) are 5

Ohms for 120V, 10 Ohms for 240V (both 35W to 50W). Note that

motor horsepower, inertia, and cycle time effect sizing of the DBR.

NOTE: This modification cannot be used with the -17B option.

DYNAMIC BRAKING

-2

-1

MOTOR DYNAMIC

BRAKE

RESISTOR

-2

-1

-3

WHI

LO WHI

SPDT

TWO 10K SPEEDPOTS

-4

-3

INHIBIT

-5

CONTROL MODIFICATIONS

DPDT SWITCH (N.C.)

SPECIFICATIONS

AC input voltage .................................................................................................................................. ±10% of rated line voltage

Acceleration ........................................................................................................................ 0.5 to 8.0 seconds (note -17B option)

Amps - DC output ................................................................................................................................ 150 mA to 10.8 Amps D.C.

Controller overload capacity ......................................................................................................................... 150% for one minute

Current limit trimpot range ...........................................................................................................................1.0 to 15.0 Amps D.C.

Deceleration (dependent on acceleration time setting) .......................................................................... .06 to .80 second range

Dimensions and weight:

TYPICAL MOTOR CURRENTS

WDC SERIES PARTS PLACEMENT & LIST

RESISTORS

R10

R11

R12

R13

R14

R15

R16

R17

R18

R19

15K 8W

2.7K

1.2M

180K

82K

470K

15K

250K (ACCEL)

5K SPEEDPOT*

10K

5K (MIN)

470K

300K

5K (C.L.)

4.7K

390K

4.7K

150K

NOTE: ALL RESISTORS 1/2W UNLESS SPECIFIED

* CUSTOMER WIRED SPEEDPOT

DIODES

D10

1N4005

1N914B

1N5242B

L512FY131

1N914B

1N4005

1N5233B

ACTIVE DEVICES

2N6027

3052 MOC

L512FY131

LM324N IC

275V G-MOV

MISC. PARTS

JU1

JU2

10 AMP FUSE (Bussman ABC or Little Fuse 314

Series ceramic fuses)

S-8201-1X FUSE HOLDER

1.75" - 16GA. SOLID INS.WIRE

2.50" - 16GA. SOLID INS.WIRE

11 POS.TERMINAL STRIP

1/4" SPADE PIN TERMINAL

CAPACITORS

C10

C11

C12

10uf 35V

.01uf 100V

.001uf 1KV

.033uf 400V

.1uf 50V

22uf 16V

.1uf 50V

.001uf 1KV

.22uf 250V

.01uf 100V

.068uf 250V

(across-the-line)

P1-1

R28

R37

R12

P1-2 P1-3 P1-4 P1-5 P1-6 P1-7 P1-8 P1-9 P1-10

R22 R9 R23 R15

D10

R29

R30

R31

R21

C10

R32

R17

R20

R19 R27

R36

R35

R34

C11 R33 R18

R14

R13

R11

R16

R25

R26

P1-11

JU2

R24

JU1

GENTRON PKG.

D5, D6, D7, Q3, Q4

C12

R20

R21

R22

R23

R24

R25

R26

R27

R28

R29

R30

R31

R32

R33

R34

R35

R36

R37

50K (MAX)

100W(IR)

.01W5W

390W

20K 1/4W

10K

180K

390K

47K

470K

100K

470W

91K

Drive service factor ................................................................................................................................................................... 1.0

Efﬁciency ..................................................................................................................................................................... 85% typical

Input frequency ....................................................................................................................................................... 50 or 60 Hertz

Max. trimpot speed range ................................................................................................................. 66% to 110% of base speed

Min. trimpot speed range .............................................................................................................. 0% to 30% of maximum speed

Minimum external impedance (pot hi to pot low) .................................................................................................................... 5KW

Power devices ....................................................................................................................................... packaged full wave bridge

Shunt ﬁeld voltage .........................................................100VDC for 120VAC input; 200VDC for 240VAC input; 1 amp maximum

Speed control ......................................................................... via 5K ohms 2W linear potentiometer or 0-10VDC isolated signal

Speed range ........................................................................................................................................................................... 50:1

Speed regulation ............................................................................................................................................ ±1% of base speed

Temperature range ............................................................................................................. -10oto 45oC. ambient (15oto 115oF.)

Transient protection ............................................................................................................................................................ G-Mov

Type ramp of accel/decel ...................................................................................................................................................... linear

ENGLISH

METRIC

5.53"

140mm

7.25"

184mm

3.50"

89mm

25.50 oz.

723 grams

WEIGHT

HEIGHT