PAT SERIES - American Control Electronics

PAT SERIES - American Control Electronics
TM
PAT SERI ES
USER MANUAL
PAT440-10
PAT443-10
PAT450-10
www.americancontrolelectronics.com
Dear Valued Consumer:
Congratulations on your purchase of the PAT Series drive.
This User Manual was created for you to get the most out of
your new device and assist with the initial setup. Please visit
www.americancontrolelectronics.com to learn more about our
other drives.
Thank you for choosing American Control Electronics!
No part of this document may be reproduced or transmitted in any form without written permission
from American Control Electronics®. The information and technical data in this document are
subject to change without notice. American Control Electronics® makes no warranty of any kind with
respect to this material, including, but not limited to, the implied warranties of its merchantability
and fitness for a given purpose. American Control Electronics® assumes no responsibility for any
errors that may appear in this document and makes no commitment to update or to keep current
the information in this document.
PAT Series
Safety First!
SAFETY WARNINGS

!
WARNING!
Text in gray boxes denote important safety tips or warnings.
Please read these instructions carefully before performing any of
the procedures contained in this manual.
• DO NOT INSTALL, REMOVE, OR REWIRE THIS EQUIPMENT WITH
POWER APPLIED. Have a qualified electrical technician install, adjust
and service this equipment. Follow the National Electrical Code
and all other applicable electrical and safety codes, including the
provisions of the Occupational Safety and Health Act (OSHA), when
installing equipment.
• Reduce the chance of an electrical fire, shock, or explosion by using
proper grounding techniques, over-current protection, thermal
protection, and enclosure. Follow sound maintenance procedures.

!
WARNING!
It is possible for a drive to run at full speed as a result of a
component failure. American Control Electronics strongly
recommends the installation of a master switch in the main
power input to stop the drive in an emergency.
Circuit potentials are at 115 VAC or 230 VAC above earth ground.
Avoid direct contact with the printed circuit board or with circuit
elements to prevent the risk of serious injury or fatality. Use a
non-metallic screwdriver for adjusting the calibration trim pots.
Use approved personal protective equipment and insulated tools
if working on this drive with power applied.
i
PAT Series
Table of Contents
Section 1. Specifications...................................................... 1
Section 2. Dimensions.. ........................................................ 3
Section 3. Installation. . ........................................................ 6
Mounting...................................................................................... 6
Wiring........................................................................................... 7
Shielding Guidelines.............................................................. 8
Line Fusing............................................................................ 9
Connections.................................................................................11
Power Inputs........................................................................11
Motor.. .................................................................................11
Field Output Connections. . ....................................................12
Analog Input Signal (PAT440 and PAT450). . .............................13
Analog Input Signal (PAT443).................................................14
Section 4. Operation. . ........................................................ 16
Before Applying Power..................................................................16
Select Switches.............................................................................17
Input Voltage Select (SW501)................................................17
Armature Voltage Select (SW502)..........................................17
Operation Modes (PAT443)............................................................17
Manual Mode.......................................................................17
Signal Mode.........................................................................17
Startup.........................................................................................18
PAT440.................................................................................18
PAT450.................................................................................18
PAT443.................................................................................19
Starting and Stopping Methods.....................................................20
Line Starting and Stopping....................................................20
Dynamic Braking...................................................................21
Inhibit Terminals. . .................................................................23
Decelerating to Minimum Speed. . ..........................................24
ii
PAT Series
Section 5. Calibration........................................................ 25
Minimum Speed (MIN SPD)...........................................................26
Maximum Speed (MAX SPD)..........................................................26
Torque (TQ LIMIT).........................................................................27
IR Compensation (IR COMP)..........................................................28
Acceleration (ACCEL). . ...................................................................30
Deceleration (DECEL)....................................................................30
Section 6.Application Notes................................................ 31
Multiple Fixed Speeds...................................................................31
Adjustable Speeds Using Potentiometers In Series . . ........................32
Independent Adjustable Speeds.. ...................................................33
RUN/JOG Switch - Inhibit Connection. . ...........................................34
RUN/JOG Switch - Potentiometer Connection. . ...............................35
Leader-Follower Application..........................................................36
Single Speed Potentiometer Control Of Multiple Drives..................37
Reversing.. ....................................................................................38
Section 7. Diagnostic LEDs.. ................................................ 39
Section 8. Troubleshooting. . ............................................... 40
Before Troubleshooting.................................................................40
Section 9. Accessories & Replacement Parts........................ 43
Unconditional Warranty.. .................................................... 44
iii
PAT Series
List of Tables
Table
Table
Table
Table
iv
1
2
3
4
Recommended Line Fuse Sizes............................................ 9
Short Circuit Current Ratings.............................................10
Field Output Connections..................................................12
Minimum Recommended Dynamic Brake Resistor Values....22
PAT Series
List of Figures
Figure 1
PAT440 Dimensions........................................................... 3
Figure 2
PAT443 Dimensions............................................................ 4
Figure 3
PAT450 Dimensions............................................................ 5
Figure 4
Power Connections...........................................................13
Figure 5
Analog Input Signal Connections (PAT440 and PAT450) . . ......14
Figure 6
Analog Input Signal Connections (PAT443). . ........................15
Figure 7
Select Switches.................................................................17
Figure 8
Dynamic Braking...............................................................22
Figure 9
Inhibit Terminals...............................................................23
Figure 10 Run/Decelerate to Minimum Speed Switch. . .......................24
Figure 11 Recommended TORQUE and IR COMP Settings...................29
Figure 12 Multiple Fixed Speeds.......................................................31
Figure 13 Adjustable Speeds Using Potentiometers in Series..............32
Figure 14 Independent Adjustable Speeds. . .......................................33
Figure 15 RUN/JOG Switch - Connection to Inhibit Plug.....................34
Figure 16 RUN/JOG Switch - Connection to Speed Adjust
Potentiometer..................................................................35
Figure 17 Leader-Follower Application..............................................36
Figure 18 Single Speed Potentiometer Control of Multiple Drives. . .....37
Figure 19 Reversing Circuit Wiring....................................................38
Figure 20 Diagnostic LED Locations...................................................39
v
PAT Series
Section 1. Specifications
Model
Maximum
Armature
Current (ADC)
HP Range
with 90 VDC
Motor
HP Range
with 180 VDC
Motor
10
1/8 - 1
1/4 - 2
PAT440
PAT443
PAT450
AC Line Voltage
NEMA 4X
NEMA 4X
NEMA 4X
115/230 VAC ± 10%, 50/60 Hz, single phase
DC Armature Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
0 - 90 VDC
0 - 180 VDC
Field Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
50 VDC (F1 to L1); 100 VDC (F1 to F2)
100 VDC (F1 to L1); 200 VDC (F1 to F2)
Maximum Field Current
1 ADC
Acceleration Time Range
1 - 15 seconds
Deceleration Time Range
coast to a stop - 15 seconds
Analog Input Range
PAT440 and PAT450 (signal must be isolated; S1 to S2)
with 115 VAC Line Voltage
with 230 VAC Line Voltage
PAT443 (2 to 3)
Voltage Signal Range
Current Signal Range
Input Impedance (S1 to S2)
Form Factor
Load Regulation
Speed Range
1
Enclosure
0 - 1.4 VDC
0 - 2.8 VDC
0 - 10 VDC
1 - 5, 4 - 20, 10 - 50 mA
>100K ohms
1.37 at base speed
1% base speed or better
60:1
PAT Series
Vibration
Safety Certifications
Ambient Temperature Range
1G maximum (0 - 50 Hz)
0.1G maximum (> 50 Hz)
UL/cUL Listed Equipment, File # E132235
10°C - 40°C
2
PAT Series
Section 2. Dimensions
5.63 [143]
5.16 [ 131]
0.19 [5.00]
SLOTTED HOLES
4 PLACES
7.50 [191]
5.50 [140]
BOTTOM PLATE
0.73 [18.5]
CONDUIT HOLES
2 PLACES
4.56 [116]
2.12 [53.8]
2.20
[55.9]
3.40
[86.4]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
3
Figure 1. PAT440-10 Dimensions
PAT Series
5.63 [143]
5.16 [ 131]
0.19 [5.00]
SLOTTED HOLES
4 PLACES
MANUAL
SIGNAL
7.50 [191]
5.50 [140]
BOTTOM PLATE
0.73 [18.5]
CONDUIT HOLES
2 PLACES
4.56 [116]
2.12 [53.8]
2.20
[55.9]
3.40
[86.4]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 2. PAT443-10 Dimensions
4
PAT Series
5.63 [143]
5.16 [ 131]
0.19 [5.00]
SLOTTED HOLES
4 PLACES
7.50 [191]
5.50 [140]
BOTTOM PLATE
0.73 [18.5]
CONDUIT HOLES
2 PLACES
4.56 [116]
2.12 [53.8]
2.20
[55.9]
3.40
[86.4]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 3. PAT450-10 Dimensions
5
PAT Series
Section 3. Installation

!
WARNING!
Do not install, rewire, or remove this control with input power
applied. Failure to heed this warning may result in fire, explosion,
or serious injury. Make sure you read and understand the Safety
Precautions on page i before attempting to install this product.
Mounting
NEMA 4X cased drives come with two 0.73 inch (18.5 mm) conduit
knockout holes at the bottom of the case. The units may be vertically wall
mounted using the four 0.19 inch (5 mm) slotted holes on the attached
heat sink. For motor loads less than 5 ADC, the drive may be bench
mounted horizontally or operated without mounting.
1.
Install the mounting screws.
2.
For access to the terminal strip, remove the six phillips screws
on the front cover.
3.
Remove the five phillips screws on the bottom plate. Do not
remove the three screws securing the bottom plate to the
heat sink.
4.
Set the POWER switch to the off position before applying
applying AC line voltage.
5.
Install conduit hardware through the 0.73 inch (18.5 mm)
knockout holes. Connect external wiring to the terminal block.
6. Place the front cover back into place. Avoid pinching any wires
between the front cover and the heat sink.
7.
Reinstall the 6 screws on the front cover. The two shorter
screws are for the two lower holes of the front cover. Reinstall
the 5 screws on the bottom plate.
6
PAT Series
Wiring

!
WARNING!
Do not install, rewire, or remove this control with input power
applied. Failure to heed this warning may result in fire, explosion,
or serious injury.
Circuit potentials are at 115 or 230 VAC above ground. To prevent
the risk of injury or fatality, avoid direct contact with the printed
circuit board or with circuit elements.
Do not disconnect any of the motor leads from the drive unless
power is removed or the drive is disabled. Opening any one
motor lead while the drive is running may destroy the drive.
This product does not have internal solid state motor overload
protection. It does not contain speed-sensitive overload
protection, thermal memory retention or provisions to receive
and act upon signal from remote devices for over temperature
protection. If motor over protection is needed in the end-use
product, it needs to be provided by additional equipment in
accordance with NEC standards.
• Use 18 - 24 AWG wire for logic wiring. Use 14 - 16 AWG wire for
AC line and motor wiring.
7
PAT Series
Shielding Guidelines

!
WARNING!
Under no circumstances should power and logic level leads be
bundled together. Induced voltage can cause unpredictable
behavior in any electronic device, including motor controls.
As a general rule, it is recommended to shield all conductors. If it is
not practical to shield power conductors, it is recommended to shield all
logic-level leads. If shielding of all logic-level leads is not practical, the
user should twist all logic leads with themselves to minimize induced
noise.
It may be necessary to earth ground the shielded cable. If noise is
produced by devices other than the drive, ground the shield at the drive
end. If noise is generated by a device on the drive, ground the shield at
the end away from the drive. Do not ground both ends of the shield.
If the drive continues to pick up noise after grounding the shield, it may
be necessary to add AC line filtering devices, or to mount the drive in a
less noisy environment.
Logic wires from other input devices, such as motion controllers and PLL
velocity controllers, must be separated from power lines in the same
manner as the logic I/O on this drive.
8
PAT Series
Line Fusing
Drives are preinstalled with 15 amp fuses.
Preinstalled line fuses are rated for maximum horsepower. If the
horsepower rating of the motor being used is less than the maximum
horsepower rating of the drive, the line fuse may have to be replaced
with a lower rated one. Fuses should be rated for 250 VAC or higher and
approximately 150% of the maximum armature current. Refer to Table 1
to install a lower rated fuse.
Table 1. Recommended Line Fuse Sizes
90 VDC
Motor
Horsepower
180 VDC
Motor
Horsepower
Maximum DC
Armature Current
(amps)
AC Line
Fuse Size
(amps)
1/8
1/6
1/4
1/3
1/2
1/4
1/3
1/2
3/4
1
1.5
1.7
2.5
3.5
5.0
3
3
5
8
8
3/4
1
1 1/2
2
7.5
10
15
15
See Section 10: Accessories and Replacement Parts for fuse kit part
numbers.
9
PAT Series

!
WARNING!
Short-circuit current rating (SCCR) is the maximum short-circuit
current that the speed control can safely withstand when
protected by a specific over-current protective device(s).
Table 2. Short Circuit Current Ratings
Short Circuit Current Rating
Drive Model
Maximum
Current, A
Maximum
Voltage, V
PAT440-10
PAT443-10
PAT450-10
10,000
240 V
Types of Branch
Circuit Protection
Non-time
Delay
K5 Fuse
Inverse
Time
Circuit
Breaker
Maximum
Rating of
Overcurrent
Protection
30 A
10
PAT Series
Connections

!
WARNING!
Do not connect this equipment with power applied. Failure to
heed this warning may result in fire, explosion, or serious injury.
Power Input
Connect the AC line power leads to screw terminals L1 and L2 115 if using
a 115 VAC line or to terminals L1 and L2 230 if using a 230 VAC line. Refer
to Figure 4 on page 13.
Motor
Drives supply motor armature voltage from A1 and A2 terminals. It is
assumed throughout this manual that, when A1 is positive with respect
to A2, the motor will rotate clockwise (CW) while looking at the output
shaft protruding from the front of the motor. If the motor does not
spin in the desired direction, remove power and reverse the A1 and A2
connections.
Connect a DC motor to terminals A1 and A2 as shown in Figure 4 on page
13. Ensure that the motor voltage rating is consistent with the drive’s
output voltage.
11
PAT Series
Field Output Connections

!
WARNING!
The field output is for shunt wound motors only. Do not make
any connections to F1 and F2 when using a permanent magnet
motor.
See Table 3 for field output connections. Use 18 AWG wire to connect
the field output to a shunt wound motor.
Table 3. Field Output Connections
Line Voltage (VAC)
Approximate Field
Voltage (VDC)
Connect Motor
Field To
115
115
230
230
50
100
100
200
F1 and L1
F1 and F2
F1 and L1
F1 and F2
12
MOV502
R5 0 2
PAT Series
MOV501
F502
A2 TO SW A1
L2 TO SW L1
A2 FRM SW A1
F501
MOV503
A1
A2
L1
L2-230
L2-115
TB501
F2
F1
L2 FRM SW L1
+
230 VAC
115 VAC
EARTH GROUND
(GREEN SCREW)
FIELD
OUTPUT
LINE VOLTAGE INPUT
(115 or 230 VAC)
NOTE: DO NOT make
any connections to
F1 and F2 if using a
permanent magnet motor.
Figure 4. Power Connections
13
MOTOR
ARMATURE
PAT Series
Analog Input Signal (PAT440 and PAT450)
Instead of using a speed adjust potentiometer, the drive may be wired to
follow an analog input voltage signal that is isolated from earth ground
(Figure 5). Connect the signal common (–) to S1. Connect the signal
reference (+) to S2. Make no connection to S3. A potentiometer can
be used to scale the analog input voltage. An interface device, such as
American Control Electronics model ISO202-1, may be used to scale and
isolate an analog input voltage.
With 115 VAC line voltage, an analog input voltage range of 0–1.4 VDC is
required to produce an armature voltage range of 0–90 VDC. With 230
VAC line voltage, an analog input voltage range of 0–2.8 VDC is required
to produce an armature voltage range of 0–180 VDC.
TQ LIMIT
ACCEL
DECEL
IR COMP
MIN SPD
MAX SPD
T501
230 - 115
R501
SO502
SW501
S3 S2 S1
IC502
90 - 180 SW502 INHIBIT
C504
CURRENT
LIMIT
IL501
SO501
C501
IL502
IC501
POWER
C502
S1 (-)
SIGNAL COMMON
S2 (+) SIGNAL REFERENCE
Figure 5. Analog Input Signal Connections (PAT440 and PAT450)
14
PAT Series
IC1
Analog Input Signal 3(PAT443)
R9
R7
2
speed
Instead of using a
adjust potentiometer, the drive may be wired
R8
C4
to follow an analog input
voltage orSIG
current
signal that is either isolated
1
MIN. SIG MAX
or non-isolated from earthSO501
ground. Connect the signal common (-) to S1.
Connect the signal reference (+) to S2. Refer to Figure 6.
An analog input signal range of 0–10 VDC,
mA, 4–20 mA, or 10-50 mA
P502 1-5P501
is required to produce an PL501
armature voltage range of 0–90 VDC with 115
VAC line voltage or 0-180 VDC with 230 VAC line voltage.
If using an analog input current signal range of 4-20 mA or 10-50 mA, a
resistor (RSH) must be placed
DECEL 1 and 4. Refer to Figure
ACCEL terminals
TQ LIMIT between
D501
6 for resistor values.
D502
MIN. SPD
C3
IR COMP
R6
MAX SPD
R5
1
2
3
4
TB501
Q2
C2
TERMINAL 2
+ 0 - 10V
SPEED ADJUST
SIGNAL INPUT
15
T501
C1
R3
RSH
RSH = 1000 OHM* for 4 - 20 mA
RSH = 250 OHM* for 10 - 50 mA
RSH = NOT USED for 1 - 5 mA
RSH = NOT USED for 0 - 10V signal
* Use 1/4 Watt 5% Tolerance
R1
Q1
R4
R2
TERMINAL 3
(-) COMMON
Figure 6. Analog Input Signal Connections (PAT443)
PAT Series
Section 4. Operation

!
WARNING!
Change voltage switch settings only when the drive is
disconnected from AC line voltage. Make sure both switches are
set to their correct position. If the switches are improperly set
to a lower voltage position, the motor will not run at full voltage
and may cause damage to the transformer. If the switches are
improperly set to a higher voltage position, the motor will
overspeed, which may cause motor damage, or result in bodily
injury or loss of life.
Dangerous voltages exist on the drive when it is powered. BE
ALERT. High voltages can cause serious or fatal injury. For your
safety, use personal protective equipment (PPE) when operating
this drive.
If the motor or drive does not perform as described, disconnect
the AC line voltage immediately. Refer to the Troubleshooting
section, page 40, for further assistance.
Before Applying Power
1. Verify that no foreign conductive material is present on the
printed circuit board.
2. Ensure that all switches are properly set.
16
PAT Series
Select Switches
Input Voltage Select (SW501)
Set the input voltage select switch SW501 to either 115 or 230 to match
the AC line voltage. See Figure 7.
Armature Voltage Select (SW502)
IC501
C502
IL502
CURRENT
LIMIT
IL501
ACCEL
DECEL
IR COMP
MIN SPD
MAX SPD
MOV501
Armature Voltage
Select (SW502)
C503
R502
R501
230 - 115
SO502
SW501
90 - 180 SW502 INHIBIT
TQ LIMIT
T501
MOV502
Input Voltage
Select
(SW501)
S3 S2 S1
IC502
SO501
C501
C504
POWER
Set the armature voltage select switch SW502 to either 90 or 180 to
match the maximum armature voltage. See Figure 7.
Figure 7. Select Switches
F502
Operation Modes (PAT443)
Manual Mode
L2 FRM SW L1
A2 TO SW A1
L2 TO SW L1
A2 FRM SW A1
F501
MOV503
TB501
In Manual Mode, the potentiometer adjusts the speed (voltage) of the
motor.
F1
F2
L2-115
L2-230
L1
A2
A1
Signal Mode
In Signal Mode, the drive follows an analog input signal of either 0-10
VDC, 1-5 mA, 4-20 mA, or 10-50 mA for adjust the speed (voltage) of
the motor.
17
PAT Series
Startup
PAT440
1.
Turn the speed adjust potentiometer to “0” (full CCW) or set
the input voltage signal to minimum.
2. Set the POWER switch to the ON position.
3. Slowly advance the speed adjust potentiometer clockwise
(CW) or increase the input voltage signal. The motor slowly
accelerates as the potentiometer is turned CW or as the input
voltage signal is increased. Continue until the desired speed is
reached.
4. Set the POWER switch to the OFF position to coast the motor to
a stop.
PAT443
1.
Turn the speed adjust potentiometer to “0” (full CCW) or set
the input voltage signal to minimum.
2. If using a speed adjust potentiometer, set the MANUAL/SIGNAL
switch to MANUAL. If using a input voltage or current signal, set
it to SIGNAL.
3. Set the POWER switch to the ON position.
4.
If in manual mode, slowly advance the speed adjust
potentiometer clockwise (CW). If is signal mode, increase the
input voltage or current signal. The motor slowly accelerates
as the potentiometer is turned CW or as the input voltage or
current signal is increased. Continue until the desired speed is
reached.
4. Set the POWER switch to the OFF position to coast the motor to
a stop.
18
PAT Series
PAT450

!
WARNING!
Do not change direction while the motor is running. The motor
must come to a complete stop before reversing. Changing motor
direction before allowing the motor to completely stop will cause
excessively high current to flow in the armature circuit, and will
damage the drive and/or motor.
1. Set the FWD/OFF/REV switch to the OFF position.
2. Turn the speed adjust potentiometer to “0” (full CCW) or set
the input voltage signal to minimum.
3. Set the FWD/OFF/REV switch to the desired direction of
rotation.
4. Slowly advance the speed adjust potentiometer clockwise
(CW) or increase the input voltage signal. The motor slowly
accelerates as the potentiometer is turned CW or as the input
voltage signal is increased. Continue until the desired speed is
reached.
5. To reverse direction:
a.
Set the FWD/OFF/REV switch to the OFF position.
b. Wait for the motor to come to a complete stop.
c. Set the FWD/OFF/REV switch to the desired direction of
rotation.
19
PAT Series
Starting and Stopping Methods

!
WARNING!
Dynamic braking, coasting to a stop, or decelerating to minimum
speed is recommended for frequent starts and stops. Do not use
any of these methods for emergency stopping. They may not stop
a drive that is malfunctioning. Removing AC line power (both
lines) is the only acceptable method for emergency stopping.
Frequent starting and stopping can produce high torque. This
may cause damage to motors, especially gearmotors that are not
properly sized for the application.
Automatic Restart Upon Power Restoration
All drives automatically run to set speed when power is applied and the
inhibit is not active.
Line Starting and Stopping
Line starting and stopping (applying and removing AC line voltage) is
recommended for infrequent starting and stopping of a drive only. When
AC line voltage is applied to the drive, the motor accelerates to the speed
set by the speed adjust potentiometer or analog signal. When AC line
voltage is removed, the motor coasts to a stop.
20
PAT Series
Dynamic Braking

!
WARNING!
Wait for the motor to completely stop before switching back to
RUN. This will prevent high armature currents from damaging
the motor or drive.
Dynamic braking may be used to rapidly stop a motor (Figure 8 on page
22). For the RUN/BRAKE switch, use a two pole, two position switch
rated for at least the armature voltage rating and 150% of the armature
current rating. For the dynamic brake resistor, use a 40 watt minimum,
high power, wirewound resistor.
Sizing the dynamic brake resistor depends on load inertia, motor voltage,
and braking time. Use a lower-value, higher-wattage dynamic brake
resistor to stop a motor more rapidly. Refer to Table 4 on page 22 for
recommended dynamic brake resistor sizes.
21
PAT Series
Table 4. Minimum Recommended Dynamic Brake Resistor Values
Motor Armature Voltage
Dynamic Brake Resistor Value
90 VDC
180 VDC
15 ohms
30 ohms
For motors rated 1/17 horsepower and lower, a brake resistor is not
necessary since the armature resistance is high enough to stop the
motor without demagnetization. Replace the dynamic brake with
12-gauge wire.
A1
A2
RUN
MOTOR
DYNAMIC BRAKE
RESISTOR
BRAKE
INHIBIT
Figure 8. Dynamic Braking
22
PAT Series
Inhibit Terminals
Short the INHIBIT terminals to coast the motor to minimum speed (see
Figure 9 for INHIBIT terminal location). Open the INHIBIT terminals to
accelerate the motor to set speed.
Twist inhibit wires and separate them from power-carrying wires or
sources of electrical noise. Use shielded cable if the inhibit wires are
longer than 18 inches (46 cm). If shielded cable is used, ground only one
end of the shield to earth ground. Do not ground both ends of the shield.
American Control Electronics offers two accessory plug harnesses for
connecting to the INHIBIT terminals: part number 201-0024 [plug with
18 in. (46 cm) leads]; and part number 201-0079 [plug with 36 in. (91
cm) leads].
IL502
IC501
CURRENT
LIMIT
IL501
SO501
TQ LIMIT
ACCEL
DECEL
IR COMP
MIN SPD
MAX SPD
T501
MOV501
C503
MOV502
R502
R501
230 - 115
SO502
SW501
90 - 180 SW502 INHIBIT
IC502
S3 S2 S1
C501
C504
POWER
C502
F502
MOV503
F1
23
L2 FRM SW L1
A2 TO SW A1
L2 TO SW L1
A2 FRM SW A1
F501
TB501
F2
L2-115
L2-230
L1
A2
A1
Figure 9. Inhibit Terminals
Inhibit
Terminals
PAT Series
Decelerating to Minimum Speed
The switch shown in Figure 10 may be used to decelerate a motor to
a minimum speed. Closing the switch between S1 and S2 decelerates
the motor from set speed to a minimum speed determined by the
MIN SPD trim pot setting. If the MIN SPD trim pot is set full CCW, the
motor decelerates to zero speed when the switch between S1 and S2 is
closed. The DECEL trim pot setting determines the rate at which the drive
decelerates. By opening the switch, the motor accelerates to set speed at
a rate determined by the ACCEL trim pot setting.
CW
S3
10K OHM
SPEED ADJUST
POTENTIOMETER
S2
S1
RUN
DECEL TO
MIN SPEED
Figure 10. Run/Decelerate to Minimum Speed Switch
24
PAT Series
Section 5. Calibration

!
WARNING!
Dangerous voltages exist on the drive when it is powered. When
possible, disconnect the voltage input from the drive before
adjusting the trim pots. If the trim pots must be adjusted with
power applied, use insulated tools and the appropriate personal
protection equipment. BE ALERT. High voltages can cause serious
or fatal injury.
PAT series drives have user-adjustable trim pots. Each drive is factory
calibrated to its maximum current rating. Readjust the calibration trim
pot settings to accommodate lower current rated motors.
All adjustments increase with CW rotation, and decrease with CCW
rotation. Use a non-metallic screwdriver for calibration. Each trim pot is
identified on the printed circuit board.
25
PAT Series
Minimum Speed (MIN SPD)
The MIN SPD setting determines the minimum motor speed when the
speed adjust potentiometer or input voltage signal is set for minimum
speed. It is factory set for zero speed.
To calibrate the MIN SPD:
1.
Set the MIN SPD trim pot full CCW.
2. Set the speed adjust potentiometer or input voltage signal for
minimum speed.
3.
Adjust MIN SPD until the desired minimum speed is reached or
is just at the threshold of rotation.
Maximum Speed (MAX SPD)
The MAX SPD setting determines the maximum motor speed when the
speed adjust potentiometer or input voltage signal is set for maximum
speed.
To calibrate MAX SPD:
1.
Set the MAX SPD trim pot full CCW.
2.
Set the speed adjust potentiometer or input voltage signal for
maximum speed.
3. Adjust MAX SPD until the desired maximum speed is reached.
Note: Check the MIN SPD and MAX SPD adjustments after recalibrating
to verify that the motor runs at the desired minimum and maximum
speed.
26
PAT Series
Torque (TQ LIMIT)

!
WARNING!
TQ LIMIT should be set to 150% of motor nameplate current
rating. Continuous operation beyond this rating may damage the
motor. If you intend to operate beyond the rating, contact your
American Control Electronics representative for assistance.
The TQ LIMIT setting determines the maximum torque for accelerating
and driving the motor. To calibrate TORQUE, refer to the recommended
TQ LIMIT settings in Figure 11 on page 29 or use the following procedure:
1. With the power disconnected from the drive, connect a DC
ammeter in series with the armature.
2. Set the TQ LIMIT trim pot to minimum (full CCW).
3. Set the speed adjust potentiometer full CW or input voltage
signal to maximum speed.
4. Carefully lock the motor armature. Be sure that the motor is
firmly mounted.
5. Apply line power. The motor should be stopped.
6. Slowly adjust the TQ LIMIT trim pot CW until the armature
current is 150% of motor rated armature current.
7. Turn the speed adjust potentiometer CCW or decrease the
input voltage signal.
8. Remove line power.
9. Remove the stall from the motor.
10. Remove the ammeter in series with the motor armature if it is
no longer needed.
27
PAT Series
IR Compensation (IR COMP)
The IR COMP setting determines the degree to which motor speed is held
constant as the motor load changes.
Use the following procedure to recalibrate the IR COMP setting:
1.
Set the IR COMP trim pot to minimum (full CCW).
2. Increase the speed adjust potentiometer or input voltage signal
until the motor runs at midspeed without load (for example,
900 RPM for an 1800 RPM motor). A handheld tachometer may
be used to measure motor speed.
3. Load the motor armature to its full load armature current rating.
The motor should slow down.
4. While keeping the load on the motor, rotate the IR COMP trim
pot until the motor runs at the speed measured in step 2. If
the motor oscillates (overcompensation), the IR COMP trim pot
may be set too high (CW). Turn the IR COMP trim pot CCW to
stabilize the motor.
5. Unload the motor.
See Figure 11 on page 29 for recommended IR COMP settings.
28
PAT Series
MODELS PAT440-10, PAT443-10, PAT450-10
TQ LIMIT
TQ LIMIT
TQ LIMIT
IR COMP
IR COMP
IR COMP
1 HP
90 VDC
10.0 AMPS
1/2 HP
90 VDC
5.00 AMPS
1/4 HP
90 VDC
2.50 AMPS
TQ LIMIT
TQ LIMIT
TQ LIMIT
IR COMP
IR COMP
IR COMP
2 HP
180 VDC
10.0 AMPS
1 HP
180 VDC
5.00 AMPS
1/2 HP
180 VDC
2.50 AMPS
Figure 11. Recommended TQ LIMIT and IR COMP Settings
(actual settings may vary with each application)
29
PAT Series
Acceleration (ACCEL)
The ACCEL setting determines the time the motor takes to ramp to a
higher speed. See Specifications on page 1 for approximate acceleration
times. ACCEL is factory set for the shortest acceleration time (full CCW).
To set the acceleration time:
1.
Set the speed adjust potentiometer or input voltage signal for
minimum speed. The motor should run at minimum speed.
2.
Set the speed adjust potentiometer or input voltage signal for
maximum speed. Measure the time it takes the motor to go
from minimum to maximum speed.
3. If the time measured in step 2 is not the desired acceleration
time, turn the ACCEL trim pot CW for a longer acceleration time
or CCW for a shorter acceleration time. Repeat steps 1 through
2 until the acceleration time is correct.
Deceleration (DECEL)
The DECEL setting determines the time the motor takes to ramp to a
lower speed. See Specifications on page 1 for approximate deceleration
times. DECEL is factory set for the shortest deceleration time (full CCW).
To set the deceleration time:
1.
Set the speed adjust potentiometer or input voltage signal for
maximum speed. The motor should run at maximum speed.
2. Set the speed adjust potentiometer or input voltage signal for
minimum speed. Measure the time it takes the motor to go
from maximum to minimum speed.
3. If the time measured in step 2 is not the desired deceleration
time, turn the DECEL trim pot CW for a longer deceleration time
or CCW for a shorter deceleration time. Repeat steps 1 through
2 until the deceleration time is correct.
30
PAT Series
Section 6.Application Notes
Multiple Fixed Speeds
Replace the speed adjust potentiometer with a series of resistors with a
total series resistance of 10K ohms (Figure 12). Add a single pole, multiposition switch with the correct number of positions for the desired
number of fixed speeds.
R1
S3
R2
S2
R3
S1
TOTAL SERIES
RESISTANCE
10K OHMS
R4
Figure 12. Multiple Fixed Speeds
31
PAT Series
Adjustable Speeds Using Potentiometers In Series
Replace the speed adjust potentiometer with a series of resistors with a
total series resistance of 10K ohms (Figure 13). Add a single pole, multiposition switch with the correct number of positions for the desired
number of fixed speeds.
CW
S3
HIGH
SPEED
5K
OHM
LOW
SPEED
CW
S2
S1
5K
OHM
Figure 13. Adjustable Speeds Using Potentiometers In Series
32
PAT Series
Independent Adjustable Speeds
Replace the speed adjust potentiometer with a single pole, multiposition switch, and two or more potentiometers in parallel, with a total
parallel resistance of 10K ohms. Figure 14 shows the connection of two
independent speed adjust potentiometers that can be mounted at two
separate operating stations.
S3
SPEED 2
CW
CW
SPEED 1
20K
OHM
20K
OHM
S2
S1
Figure 14. Independent Adjustable Speeds
33
PAT Series
RUN/JOG Switch - Inhibit Connection
Using a RUN/JOG switch is recommended in applications where quick
stopping is not needed and frequent jogging is required. Use a single pole,
two position switch for the RUN/JOG switch, and a single pole, normally
closed, momentary operated pushbutton for the JOG pushbutton.
Connect the RUN/JOG switch and JOG pushbutton to the inhibit plug
as shown in Figure 15. The motor coasts to a stop when the RUN/JOG
switch is set to JOG. Press the JOG pushbutton to jog the motor. Return
the RUN/JOG switch to RUN for normal operation.
RUN
INHIBIT
JOG
PUSHBUTTON
JOG
Figure 15. RUN/JOG Switch - Connection to Inhibit Plug
34
PAT Series
RUN/JOG Switch - Potentiometer Connection
Connect the RUN/JOG switch and the JOG pushbutton as shown in Figure
16. When the RUN/JOG switch is set to JOG, the motor decelerates to
minimum speed (minimum speed is determined by the MIN SPD trim pot
setting). Press the JOG pushbutton to jog the motor. Return the RUN/JOG
switch to RUN for normal operation.
S3
CW
S2
10K OHM
SPEED ADJUST
POTENTIOMETER
S1
RUN
JOG
JOG
PUSHBUTTON
Figure 16. RUN/JOG Switch - Connection to Speed Adjust Potentiometer
35
PAT Series
Leader-Follower Application
In this application, use a PCM4 to monitor the speed of the leader motor
(Figure 17). The ISO202-1 isolates the leader motor from the follower
drive, and outputs a voltage proportional to the leader motor armature
voltage. The follower drive uses this voltage reference to set the speed of
the follower motor. An optional ratio potentiometer may be used to scale
the ISO202-1 output voltage.
MOTOR
A2
(+) 2
9 (+)
A1
Leader
Drive
ISO202-1
8
7 (-)
TB501
S2
(-) 1
TB502
S1
Follower
Drive
10K Ohm
(optional)
Figure 17. Leader-Follower Application
36
PAT Series
Single Speed Potentiometer Control Of Multiple Drives
Multiple drives can be controlled with a single speed adjust potentiometer
using a ISO101-8 at the input of each drive to provide isolation (Figure
18). Optional ratio potentiometers can be used to scale the ISO101-8
output voltage, allowing independent control of each drive.
10K Ohms
ratio pot A
(optional)
10K Ohms
S3
+
S2
1
S2
S1
-
S1
+
Drive
A
A1
ratio pot B
(optional)
10K Ohms
A1
2
S2
-
S1
Motor
A
A2
Drive
B
Motor
B
A2
ISO101-8
+
ratio pot H
(optional)
10K Ohms
A1
8
S2
-
S1
Drive
H
Motor
H
A2
Figure 18. Single Speed Potentiometer Control of Multiple Drives
37
PAT Series
Reversing
A dynamic brake may be used when reversing the motor direction
(Figure 19). Use a three pole, three position switch rated for at least the
maximum DC armature voltage and maximum braking current. Wait for
the motor to stop completely before switching it to either the forward
or reverse direction. See the Dynamic braking section on page 22 for
recommended dynamic brake resistor sizes.
NOTE: Model PAT450-10 is equipped with the reversing feature, but not
the dynamic brake feature.
A1
A2
DYNAMIC
BRAKE
RESISTOR
MOTOR
FWD
BRAKE
REV
INHIBIT
Figure 19. Reversing Circuit Wiring
38
PAT Series
Section 7. Diagnostic LEDs
PAT series drives are equipped with two diagnostic LEDs:
•
Power (POWER): Green LED lights whenever AC line voltage is
applied to the drive.
•
Current Limit (TQ LIMIT): Red LED lights whenever the drive reaches
current limit.
IL502
IC501
CURRENT
LIMIT
IL501
TQ LIMIT
ACCEL
DECEL
IR COMP
MIN SPD
MAX SPD
T501
MOV501
C503
MOV502
R502
R501
SO502
SW501
S3 S2 S1
Current Limit
LED
Power LED
230 - 115
90 - 180 SW502 INHIBIT
IC502
SO501
C501
C504
POWER
C502
F502
A2 TO SW A1
L2 TO SW L1
A2 FRM SW A1
F501
MOV503
F1
L2 FRM SW L1
TB501
F2
L2-115
L2-230
L1
A2
A1
Figure 20. Diagnostic LED Locations
39
PAT Series
Section 8. Troubleshooting

!
WARNING!
Dangerous voltages exist on the drive when it is powered. When
possible, disconnect the drive while troubleshooting. High
voltages can cause seroius or fatal injury.
Before Troubleshooting
Perform the following steps before starting any procedure in this
section:
1.
Disconnect AC line voltage from the drive.
2. Check the drive closely for damaged components.
3. Check that no conductive or other foreign material has become
lodged on the printed circuit board.
4. Verify that every connection is correct and in good condition.
5. Verify that there are no short circuits or grounded
connections.
6. Check that the selection switch settings are correctly set.
7. Check that the drive’s rated armature is consistent with the
motor ratings.
For additional assistance, contact your local American Control
Electronics distributor or the factory direct:
(844) AMCNTRL or FAX: (800) 394-6334
40
PAT Series
PROBLEM
Line fuse
blows.
Line fuse does
not blow, but
the motor does
not run.
41
POSSIBLE CAUSE
SUGGESTED SOLUTIONS
1. Line fuse is the wrong size.
1. Check that the line fuse is
correct for the motor size.
2. Motor cable or armature is
shorted to ground.
2. Check motor cable and
armature for shorts.
3. Nuisance tripping caused by
a combination of ambient
conditions and high-current
spikes (i.e. reversing).
3. Add a blower to cool the
drive components, decrease
TQ LIMIT settings, resize
motor and drive for actual
load demand, or check for
incorrectly aligned mechanical
components or “jams”. See
page 27 for information on
adjusting the TQ LIMIT trim
pot.
1. Speed adjust potentiometer
or input voltage or current
signal is set to zero speed.
1. Increase the speed adjust
potentiometer setting or input
voltage or current signal.
2. INHIBIT mode is active.
2. Remove the short from the
INHIBIT terminals.
3. S2 is shorted to S1.
3. Remove the short.
4. Drive is in current limit.
4. Verify that the motor is not
jammed. Increase TQ LIMIT
setting if set too low.
5. Drive is not receiving AC line
voltage.
5. Apply AC line voltage.
6. Motor is not connected.
6. Remove power. Connect the
motor to A1 and A2. Reapply
power.
PAT Series
PROBLEM
POSSIBLE CAUSE
SUGGESTED SOLUTIONS
Motor does not
stop when the
speed adjust
potentiometer
is full CCW.
1. MIN SPD is set too high.
1. Calibrate MIN SPD.
Motor runs in
the opposite
direction
1. Motor connections to A1
and A2 are reversed.
1. Remove power. Reverse
connections to A1 and A2.
Reapply power.
Motor runs too
fast.
1. MAX SPD is set too high.
1. Calibrate MAX SPD.
Motor will
not reach the
desired speed.
1. MAX SPD setting is too low.
1. Increase MAX SPD setting.
2. IR COMP setting is too low.
2. Increase IR COMP setting.
3. TQ LIMIT setting is too low.
3. Increase TQ LIMIT setting.
4. Motor is overloaded.
4. Check motor load. Resize the
motor and drive if necessary.
1. IR COMP is set too high.
1. Adjust the IR COMP setting
slightly CCW until the motor
speed stabilizes.
2. Motor bouncing in and out
of current limit.
2. Make sure motor is not
undersized for load; adjust TQ
LIMIT trim pot CW.
Motor pulsates
or surges under
load.
42
PAT Series
Section 9. Accessories & Replacement Parts
Displays
Closed Loop.............................................................................. CLD100-1
Open Loop.............................................................................. OLD100-1
Kits
Fuse
2 1.5 Amp 250V 3AG Fast-blow Glass Fuses........................ KTF-0001
2 3 Amp 250V 3AG Fast-blow Glass Fuses........................... KTF-0002
2 5 Amp 250V 3AG Fast-blow Glass Fuses........................... KTF-0003
2 8 Amp 250V 3AG Fast-blow Glass Fuses........................... KTF-0004
2 10 Amp 250V 3AB Normal-blow Ceramic Fuses............... KTF-0005
2 15 Amp 250V 3AB Normal-blow Ceramic Fuses............... KTF-0006
Wiring
Inhibit Plug (18 in. leads)....................................................KTW-0001
Inhibit Plug (36 in. leads)....................................................KTW-0002
Logic Cards
Current Sensing
5 Amps................................................................................CMC100-5
20 amps............................................................................CMC100-20
Isolation Cards
Unidirectional, 8 outputs......................................................ISO101-8
Bidirectional, 1 output..........................................................ISO202-1
43
PAT Series
Unconditional Warranty
A. Warranty
American Control Electronics warrants that its products will be free from defects in workmanship
and material for twelve (12) months or 3000 hours, whichever comes first, from date of
manufacture thereof. Within this warranty period, American Control Electronics will repair or
replace, at its sole discretion, such products that are returned to American Control Electronics,
14300 De La Tour Drive, South Beloit, Illinois 61080 USA.
This warranty applies only to standard catalog products, and does not apply to specials. Any
returns of special controls will be evaluated on a case-by-case basis. American Control Electronics
is not responsible for removal, installation, or any other incidental expenses incurred in shipping
the product to and from the repair point.
B. Disclaimer
The provisions of Paragraph A are American Control Electronics’s sole obligation and exclude all
other warranties of merchantability for use, expressed or implied. American Control Electronics
further disclaims any responsibility whatsoever to the customer or to any other person for
injury to the person or damage or loss of property of value caused by any product that has been
subject to misuse, negligence, or accident, or misapplied or modified by unauthorized persons
or improperly installed.
C. Limitations of Liability
In the event of any claim for breach of any of Americn Control Electronics’s obligations, whether
expressed or implied, and particularly of any other claim or breach of warranty contained in
Paragraph A, or of any other warranties, expressed or implied, or claim of liability that might,
despite Paragraph B, be decided against American Control Electronics by lawful authority,
American Control Electronics shall under no circumstances be liable for any consequential
damages, losses, or expenses arising in connection with the use of, or inability to use, American
Control Electronics’s product for any purpose whatsoever.
An adjustment made under warranty does not void the warranty, nor does it imply an extension
of the original 12-month warranty period. Products serviced and/or parts replaced on a
no-charge basis during the warranty period carry the unexpired portion of the original warranty
only.
If for any reason any of the foregoing provisions shall be ineffective, American Control Electronics’s
liability for damages arising out of its manufacture or sale of equipment, or use thereof, whether
such liability is based on warranty, contract, negligence, strict liability in tort, or otherwise, shall
not in any event exceed the full purchase price of such equipment.
Any action against American Control Electronics based upon any liability or obligation arising
hereunder or under any law applicable to the sale of equipment or the use thereof, must be
commenced within one year after the cause of such action arises.
44
PAT 440-10
PAT443-10
PAT450-10
TM
w w w.a m ericancont rolelect ronics.com
1430 0 DE LA TOUR DRIV E
SO U TH BELOIT, IL 61080
(844) A MCNTRL
MA N-0005 Rev 1
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