PWL SERIES - American Control Electronics

PWL SERIES - American Control Electronics
TM
P W L SE RI ES
USER MANUAL
PWL400 -3
PWL400 -5
PWL400 -10
PWL400 -15
PWL440 -3
PWL440 -10
PWL440 -10-J O G
www.americancontrolelectronics.com
Dear Valued Consumer:
Congratulations on your purchase of the PWL 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.
PWL 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
PWL Series
Table of Contents
Section 1. Specifications...................................................... 1
Suffix Definitions........................................................................... 3
Section 2. Dimensions.. ........................................................ 4
Section 3. Installlation....................................................... 10
Heat Sinking.................................................................................10
Chassis.................................................................................10
NEMA 4X..............................................................................10
Mounting.....................................................................................11
Chassis.................................................................................11
Speed Adjust Potentiometer..............................................12
NEMA 4X..............................................................................13
Wiring..........................................................................................14
Shielding Guidelines.............................................................15
Line Fusing...........................................................................16
Connections.................................................................................17
Cage-Clamp Terminal Block...................................................18
Power Input. . ........................................................................19
Motor.. .................................................................................19
Field Output Connections. . ....................................................20
Speed Adjust Potentiometer. . ................................................21
Analog Signal Input...............................................................22
Section 4. Operation. . ........................................................ 26
Before Applying Power..................................................................26
Select Switches.............................................................................27
Input Voltage Select (SW501, SW502)....................................27
Operation Modes..........................................................................28
Run Mode . . ...........................................................................28
Jog Mode.. ............................................................................28
Startup.........................................................................................29
PWL400-3, PWL400-5, PWL400-10, and PWL400-15. . ..............29
PWL440-3 and PWL440-10.. ...................................................29
ii
PWL Series
PWL440-10-JOG....................................................................30
Starting and Stopping Methods.....................................................31
Line Starting and Stopping....................................................31
Dynamic Braking...................................................................32
Inhibit Terminals. . .................................................................34
Decelerating to Minimum Speed. . ..........................................35
Section 5. Calibration........................................................ 36
Minimum Speed (MIN SPD)...........................................................37
Maximum Speed (MAX SPD)..........................................................37
Jog (JOG) (PWL400-15, PWL440-10, and PWL440-10-JOG only).......38
Torque (CURR LIMIT or TORQ LIMIT)..............................................39
IR Compensation (IR COMP)..........................................................40
Acceleration (ACCEL). . ...................................................................45
Deceleration (DECEL)....................................................................45
Section 6. Application Notes.............................................. 46
Multiple Fixed Speeds...................................................................46
Adjustable Speeds Using Potentiometers In Series . . ........................47
Independent Adjustable Speeds.. ...................................................48
RUN/JOG Switch - Inhibit Connection. . ...........................................49
RUN/JOG Switch - Potentiometer Connection. . ...............................50
Leader-Follower Application..........................................................51
Single Speed Potentiometer Control Of Multiple Drives..................52
Reversing.. ....................................................................................53
Section 7. Diagnostic LEDs.. ................................................ 54
Section 8. Troubleshooting. . ............................................... 55
Before Troubleshooting.................................................................55
Section 9. Accessories & Replacement Parts........................ 58
Unconditional Warranty.. .................................................... 59
iii
PWL Series
List of Tables
Table
Table
Table
Table
iv
1
2
3
4
Recommended Line Fuse Sizes...........................................15
Field Output Connections..................................................18
Field Output Connections..................................................25
Minimum Recommended Dynamic Brake Resistor Values....35
PWL Series
List of Figures
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Figure 19
Figure 20
Figure 21
Figure
Figure
Figure
Figure
22
23
24
25
PWL400-3, PWL400-5, and PWL400-10 Dimensions.. ............ 4
PWL400-15 Dimensions...................................................... 5
PWL440-3 Dimensions........................................................ 6
PWL440-10 Dimensions...................................................... 7
PWL400-10-JOG Dimensions............................................... 8
HSK-0003 Dimensions . . ....................................................... 9
Speed Adjust Potentiometer..............................................12
Cage Clamp Terminal Block................................................16
PWL400-3, PWL400-5, and PWL400-10 Connections...........19
PWL400-15 Connections. . ..................................................20
Analog Input Signal Connections. . ......................................21
PWL440-3 Connections . . ....................................................26
PWL440-10 and PWL440-10-JOG Connections.. ...................27
Select Switches.................................................................29
Dynamic Brake Wiring.......................................................35
Inhibit Terminals...............................................................36
Run/Decelerate to Minimum Speed Switch. . .......................37
Recommended CURR LIMIT and IR COMP Settings for
models PWL400-3 and PWL440-3.......................................43
Recommended CURR LIMIT and IR COMP Settings for
models PWL400-5.............................................................44
Recommended CURR LIMIT and IR COMP Settings for
models PWL400-10...........................................................45
Recommended CURR LIMIT and IR COMP Settings for
models PWL400-15, PWL440-10, and PWL440-10-JOG........46
Multiple Fixed Speeds.......................................................48
Adjustable Speeds Using Potentiometers In Series. . ............49
Independent Adjustable Speeds. . .......................................50
RUN/JOG Switch - Connection to Inhibit Plug.....................51
v
PWL Series
Figure 26 RUN/JOG Switch - Connection to Speed Adjust
Potentiometer..................................................................52
Figure 27 Leader-Follower Application..............................................53
Figure 28 Single Speed Potentiometer Control of Multiple Drives. . .....54
Figure 29 Reversing Circuit Wiring....................................................55
Figure 30 Reversing with a CLD100-1................................................56
Figure 31 Diagnostic LED Locations...................................................57
vi
PWL Series
Section 1. Specifications
Maximum
Armature
Current (ADC)
HP Range
with 130 VDC
Motor
HP Range
with 240 VDC
Motor
PWL400-3
PWL440-3
3
1/20 - 1/4
1/10 - 1/2
Chassis
NEMA 4X
PWL400-5
5
1/8 - 1/2
1/4 - 1
Chassis
PWL400-10*
PWL440-10
PWL440-10-JOG
10
1/4 - 1
1/2 - 2
Chassis
NEMA 4X
NEMA 4X
PWL400-15
15
1/4 - 1 1/2
1/2 - 3
Chassis
Model
Enclosure
* Heat sink kit part number HSK-0003 must be used when the continuous
current output is over 5 amps.
AC Line Voltage
115/230 VAC ± 10%
50/60 Hz, single phase
DC Armature Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
0 - 130 VDC
0 - 240 VDC
Field Voltage
with 115 VAC Line Voltage
with 230 VAC Line Voltage
50 VDC (F1/F+ to L1); 100 VDC (F1/F+ to F2/F-)
100 VDC (F1/F+ to L1); 200 VDC (F1/F+ to F2/F-)
Maximum Field Current
1 ADC
1
PWL Series
Acceleration Time Range (with no load)
PWL400-3, PWL400-5, and PWL400-10
for 0 - 130 VDC Armature Voltage
for 0 - 240 VDC Armature Voltage
1 - 12 seconds
1 - 12 seconds
PWL400-15
for 0 - 130 VDC Armature Voltage
for 0 - 240 VDC Armature Voltage
1 - 9 seconds
1 - 15 seconds
PWL440-3
for 0 - 130 VDC Armature Voltage
for 0 - 240 VDC Armature Voltage
1 - 10 seconds
1 - 19 seconds
PWL440-10 and PWL440-10-J0G
for 0 - 130 VDC Armature Voltage
for 0 - 240 VDC Armature Voltage
1 - 10 seconds
1 - 15 seconds
Deceleration Time Range (with no load)
PWL400-3, PWL400-5, and PWL400-10
for 0 - 130 VDC Armature Voltage
for 0 - 240 VDC Armature Voltage
coast to a stop - 12 seconds
coast to a stop - 12 seconds
PWL400-15
for 0 - 130 VDC Armature Voltage
for 0 - 240 VDC Armature Voltage
coast to a stop - 10 seconds
coast to a stop - 18 seconds
PWL440-3
for 0 - 130 VDC Armature Voltage
for 0 - 240 VDC Armature Voltage
coast to a stop - 9 seconds
coast to a stop - 19 seconds
PWL440-10 and PWL440-10-J0G
for 0 - 130 VDC Armature Voltage
for 0 - 240 VDC Armature Voltage
coast to a stop - 10 seconds
coast to a stop - 19 seconds
Analog Input Range
(signal must be isolated; S1 to S2)
2
for 0 - 130 VDC Armature Voltage
for 0 - 240 VDC Armature Voltage
0 - 2.5 VDC
0 - 5.0 VDC
PWL Series
Input Impedance (S1 to S2)
PWL400-15
All other models
50K ohms
100K ohms
Form Factor
1.05
Load Regulation
PWL400-15
All other models
0.5% base speed or better
1% base speed or better
Speed Range
100:1
Vibration
PWL400-3, PWL400-5, PWL400-10
0.5G maximum (20 - 50 Hz)
0.1G maximum (> 50 Hz)
PWL400-15, PWL440-3, PWL440-10 and
PWL440-10-JOG
Safety Certifications
0.5G maximum (0 - 50 Hz)
0.1G maximum (> 50 Hz)
UL Recognized Component, File # E132235
CSA Certified Component, File # LR41380
Ambient Temperature Range
10°C - 40°C
Suffix Definitions
-JOG:
Basic Drive with Run/Jog Switch
3
PWL Series
Section 2. Dimensions
Q502
BR501
Q501
D501
0.19"
TH501
B2
R503
AC1
AC2
BR+
BRB1
T501
C503
SW502
230
C505
230
SW501
4.97 [126]
R501
4.13 [105]
IC503
IC502
C501
IC501
R502
FU501
FAST-ACTING
C502
CURR
LIMIT
C504
INHIBIT
IL501
0.50"
IL502
TB501
L1
L2
S1
S2
S3
F1
F2
A1
0.25 [6]
5.38 [137]
A
1.75 [45]
MODEL
DIMENSION “A” HEIGHT
PWL400-3
2.25 [57]
PWL400-5
3.00 [76]
PWL400-10
3.75 [95]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 1. PWL400-3, PWL400-5, and PWL400-10 Dimensions
4
PWL Series
BRR503
C508
BR+
AC1
AC2
-BUS
+BUS
TH501
R501
C507
T501
230
SW501
SW502
230
9.78 [248]
A1
C506
C502
IC502
C504
IC501
7.00 [178]
LIMIT
PS2
PS4
PS1
S
PS
PS3
C505
POWER
CURR
MAX SPD
TORQ LIMIT
MIN SPD
DECEL
+15
INHIBIT
IR COMP
ACCEL
JOG
0.19 [5]
S1
L1
230
115
F+
S2
S3
A1
G
SPD SPD JOG
IN
F-
A2
A2
1.39 [35]
1.39 [35]
6.30 [160]
6.90 [175]
3.92 [99]
0.13 [3]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 2. PWL400-15 Dimensions
5
PWL Series
6.90 [175]
6.30 [160]
POWER
0.87 [22]
SPEED
50
a
I
0
NEMA 4X
DC
MOTOR
CONTROL
8.20 [208]
7.76 [197]
6.00 [152]
MADE IN THE U.S.A.
WARNING: DISCONNECT FROM SUPPLY BEFORE OPENING THIS COVER.
SEPARATE MOTOR OVERCURRENT AND OVERLOAD PROTECTION IN ACCORDANCE WITH
THE CANADIAN ELECTRICAL CODE PART 1 IS PROVIDED BY OTHERS.
4.50 [114]
0.13 [3]
3.70 [94]
Ø 0.88
[22] (2)
2.25 [57]
2.50 [64]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 3. PWL440-3 Dimensions
6
PWL Series
6.90 [175]
6.30 [160]
1.40
[36]
10.22
[260]
9.80
[249]
7.00
[178]
0.22
[6]
Ø0.88
[22] (3)
1.45 [37]
5.51
[140]
4.78
[121]
2.31
[59]
0.12
[3]
1.50 [38]
1.50 [38]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 4. PWL440-10 Dimensions
7
PWL Series
6.90 [175]
6.30 [160]
1.40
[36]
10.22
[260]
9.80
[249]
7.00
[178]
0.22
[6]
Ø0.88
[22] (3)
1.45 [37]
5.51
[140]
4.78
[121]
2.31
[59]
0.12
[3]
1.50 [38]
1.50 [38]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 5. PWL440-10-JOG Dimensions
8
PWL Series
C
0.188 WIDE SLOT
(4 PLACES)
8-32 THD
(4 PLACES)
9.78 [248]
8.41 [214]
6.70 [170]
3.08 [78]
1.41 [35]
2.50 [64]
2.50 [64]
3.15 [80]
3.15 [80]
6.90 [175]
1.00 [25]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 6. HSK-0003 Dimensions
9
PWL Series
Section 3. Installlation

!
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.
Heat Sinking
Chassis
Model PWL400-10 requires an additional heat sink when the continuous
armature current is above 5 amps. Use heat sink kit part number
HSK-0003. All other chassis drives have sufficient heat sinking in their
basic configuration. Use a thermally conductive heat sink compound
(such as Dow Corning® 340 Heat Sink Compound) between the chassis
and the heat sink surface for optimum heat transfer.
NEMA 4X
All NEMA 4X models come with the heat sink already attached.
Therefore, all NEMA 4X drives have sufficient heat sinking in their basic
configuration.
10
PWL Series
Mounting
Chassis
• Drive components are sensitive to electrostatic discharge. Avoid
direct contact with the circuit board. Hold the drive by the chassis
or heat sink only.
• Protect the drive from dirt, moisture, and accidental contact.
• Provide sufficient room for access to the terminals and calibration
trim pots.
• Mount the drive away from heat sources. Operate the drive within
the specified ambient operating temperature range.
• Prevent loose connections by avoiding excessive vibration of the
drive.
• Mount the drive with its board in either a horizontal or vertical
plane. Six 0.19” (5 mm) wide slots in the chassis accept #8 pan head
screws. Fasten either the large base or the narrow flange of the
chassis to the subplate.
• The chassis should be earth grounded. Use a star washer beneath
the head of at least one of the mounting screws to penetrate the
anodized surface and to reach bare metal.
11
PWL Series
Speed Adjust Potentiometer

!
WARNING!
Be sure that the potentiometer tabs do not make contact with the
potentiometer’s body. Grounding the input will cause damage to
the drive.
Mount the speed adjust potentiometer through a 0.38 in. (10 mm) hole
with the hardware provided (Figure 7). Install the circular insulating disk
between the panel and the 10K ohm speed adjust potentiometer.
Twist the speed adjust potentiometer wire to avoid picking up unwanted
electrical noise. If the speed adjust potentiometer wires are longer than
18 in. (46 cm), use shielded cable. Keep the speed adjust potentiometer
wires separate from power leads (L1, L2, 115, 230, A1, A2, F1, F2, F+, F-).
R
I
CW
E
WIPER
W
W
R
ER
P
I
P
I
PEE
E
I
E ER
I
E
Figure 7. Speed Adjust Potentiometer
12
PWL Series
Mounting (NEMA 4X Enclosures)
NEMA 4X cased drives come with two 0.88 inch (22 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, turn the slotted screw on the
front cover counterclockwise until it is free from the case. The
right side of the cover is hinged to the case. Pull the slotted
screw to open the case.
3. Carefully remove the conduit knockouts by tapping them into
the case and twisting them off with pliers.
4.
Set the POWER switch to the OFF position before applying the
AC line voltage.
5. Install conduit hardware through the 0.88 inch (22 mm)
knockout holes. Connect external wiring to the terminal block.
6. Grasp the slotted screw and tilt the front cover back into place.
Avoid pinching any wires between the front cover and the case.
7. Turn the slotted screw clockwise until tight to secure the front
cover.
13
PWL 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.
14
PWL 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.
15
PWL Series
Line Fusing
Models PWL400-3, PWL400-5, and PWL400-10 are preinstalled with one
line fuse in fuse holder FU501. They require an additional line fuse on L2
if the input voltage is 230 VAC. Model PWL400-3 is preinstalled with an
8 amp fuse. Model PWL400-5 is preinstalled with a 10 amp fuse. Model
PWL400-10 is preinstalled with a 10 amp fuse.
Models PWL400-15, PWL440-3, PWL440-10, and PWL440-10-JOG
are preinstalled with two lines fuse holders FU501 and FU502. Model
PWL440-3 is preinstalled with 8 amp fuses. Models PWL400-15, PWL44010, and PWL440-10-JOG are preinstalled with 20 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
on page 17 to install a lower rated fuse.
16
PWL Series
Table 1. Recommended Line Fuse Sizes
90 / 130 VDC
Motor
Horsepower
180 / 240 VDC
Motor
Horsepower
Maximum DC
Armature Current
(amps)
AC Line
Fuse Size
(amps)
1/20
1/15
1/8
1/6
1/10
1/8
1/4
1/3
0.5
0.8
1.5
1.7
1
1.5
3
3
1/4
1/2
2.5
5
1/3
1/2
3/4
1
3/4
1
1 1/2
2
3.5
5.0
7.5
10
8
10
15
15
1 1/2
3
15
25
See Section 9: Accessories and Replacement Parts for fuse kit part
numbers.
17
PWL Series
Connections

!
WARNING!
Do not connect this equipment with power applied. Failure to
heed this warning may result in fire, explosion, or serious injury.
American Control Electronics strongly recommends the
installation of a master power switch in the voltage input line,
as shown in Figures 10 and 11 (pages 23 and 24). The switch
contacts should be rated at a minimum of 200% of motor
nameplate current and 250 volts. This power switch is provided
with NEMA 4X models.
Cage-Clamp Terminal Block
PWL series drives use a cage-clamp terminal block. To connect a wire to
the cage-clamp terminal block (see Figure 8), use a small screwdriver to
press down on the lever arm. Insert a wire stripped approximately 0.25
inches (6 mm) into the opening in front of the terminal block. Release the
lever arm to clamp the wire.
Press down on the
lever arm using
a small screwdriver.
1
2
Insert wire into the
wire clamp.
3
Release the lever arm
to clamp the wire.
Figure 8. Cage Clamp Terminal Block
18
PWL Series
Power Input
For models PWL400-3, PWL400-5, and PWL400-10, connect the AC line
power leads to terminals L1 and L2.
For models PWL400-15, PWL440-3, PWL440-10, and PWL440-10-JOG,
connect the AC line power leads to terminals L1 and L2 (115) if using a
115 VAC line or to terminals L1 and L2 (230) if using a 230 VAC line.
ACE recommends the use of a single-throw, double-pole master power
switch. The switch should be rated at a minimum of 250 volts and 200%
of motor current. Refer to Figure 10 on page 23 and Figure 11 on page 24.
Motor
The drives supply motor armature voltage from the 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 Figures 10
through 12 on pages 23 through 25. Ensure that the motor voltage rating
is consistent with the drive’s output voltage.
19
PWL Series
Field Output Connections

!
WARNING!
The field output is for shunt wound motors only. Do not make
any connections to F1 / F+ and F2 / F- when using a permanent
magnet motor.
See Table 2 for field output connections. Use 14 - 16 AWG wire to
connect the field output to a field / shunt wound motor.
Table 2. Field Output Connections
20
Line Voltage
(VAC)
Approximate
Field Voltage
(VDC)
PWL400-3,
PWL400-5,
PWL400-10,
PWL440-3
Connections
PWL400-15,
PWL440-10,
PWL440-10-JOG
Connections
115
115
230
230
50
100
100
200
F1 and L1
F1 and F2
F1 and L1
F1 and F2
F+ and L1
F+ and FF+ and L1
F+ and F-
PWL Series
Speed Adjust Potentiometer
For chassis models, use a 10K ohm, 1/4 W potentiometer for speed
control. Connect the counter-clockwise end of the potentiometer to S1,
the wiper to S2, and the clockwise end to S3. If the potentiometer works
inversely of the desired functionality (e.g. to increase motor speed you
must turn the potentiometer counterclockwise), power off the drive and
swap the S1 and S3 connections. Refer to Figures 10 and 11 on pages 23
and 24.
For enclosed models, the speed adjust potentiometer is factory installed
and prewired.
21
PWL Series
Analog Input Signal
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 9). 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
ACE 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 0–2.5 VDC is
required to produce an armature voltage range of 0–130 VDC. With 230
VAC line voltage, an analog input voltage range of 0–5.0 VDC is required
to produce an armature voltage range of 0–240 VDC.
PWL400-3, PWL400-5, PWL400-10, PWL440-3
PWL400-15, PWL440-10, PWL440-10-JOG
TB501
SIGNAL
COMMON
SIGNAL
INPUT
SIGNAL
COMMON
Figure 9. Analog Input Signal Connections
22
S3
S2 (+)
S2
S1 (-)
S2 (+)
S1 (-)
S1
SIGNAL
INPUT
PWL Series
TB501
L1
L2
S1
S2
S3
F1
F2
A1
+
CW
*FUSE
POWER
SWITCH
10K OHM
SPEED ADJUST
POTENTIOMETER
AC LINE
VOLTAGE
120/240 VAC
FIELD
OUTPUT
MOTOR
ARMATURE
NOTE: DO NOT make
any connections to
F1 and F2 if using a
permanent magnet motor.
* NOTE: Do not add fuse to L2
unless input voltage is 230 VAC.
Figure 10. PWL400-3, PWL400-5, and PWL400-10 Connections
23
PWL Series
TB501
L1
115
115
VAC
230
F1
F2
+
230
VAC
FIELD
OUTPUT
AC LINE
VOLTAGE
A1
MOTOR
ARMATURE
NOTE: DO NOT make
any connections to
F1 and F2 if using a
permanent magnet motor.
Figure 11. PWL440-3 Connections
24
PWL Series
S1 S2 S3
L1
230
115
F+
A1
G
SPD SPD JOG
IN
F-
230
VAC
115
VAC
FIELD
OUTPUT
POWER
SWITCH
AC LINE
VOLTAGE
MOTOR
ARMATURE
NOTE: DO NOT make
any connections to
F1 and F2 if using a
permanent magnet motor.
Figure 12. PWL400-15, PWL440-10, and PWL440-10-JOG Connections
25
PWL 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 55, 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.
26
PWL Series
Select Switches
Input Voltage Select (SW501, SW502)
Set the input voltage select switches SW501 and SW502 to either 115 or
230 to match the AC line voltage. See Figure 13.
Input Voltage Select
(SW501, SW502)
Input Voltage Select
(SW501, SW502)
T501
SW502
C505
230
SW502
230
230
SW501
230
SW501
IC503
IC502
C501
IC501
FU501
FAST-ACTING
C502
IC502
IC501
C504
C502
C504
LIMIT
PS2
PWL400-3, PWL400-5,
PWL400-10, and PWL440-3
PS4
PWL400-15, PWL440-10, and
PWL440-10-JOG
Figure 13. Select Switches
27
PWL Series
Operation Modes
(PWL400-15, PWL440-10, and PWL440-10-JOG)
Run Mode
In Run Mode, the external potentiometer adjusts the speed (voltage) of
the motor. The on-board MAX SPD trim pot sets the maximum speed to
the motor. The drive comes factory set for Run Mode.
To run the drive in Run Mode, jumper terminals SPD and SPD IN.
Jog Mode
In Jog Mode, the motor runs at a constant speed (voltage). The on-board
JOG trim pot sets the constant speed to the motor.
To run the drive in Jog Mode, jumper terminals SPD IN and JOG.
28
PWL Series
Startup
PWL400-3, PWL400-5, PWL400-10, and PWL400-15
1.
Turn the speed adjust potentiometer full counterclockwise
(CCW) or set the input voltage signal to minimum.
2. Apply AC line voltage.
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.
Remove AC line voltage from the drive to coast the motor to a
stop.
PWL440-3 and PWL440-10
1.
Set the POWER switch to the OFF position.
2.
Turn the speed adjust potentiometer to “0” (full CCW) or set
the input voltage signal to minimum.
3. Apply AC line voltage.
4. Set the POWER switch to the ON position.
5. 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.
6. Set the POWER switch to the OFF position to coast the motor to
a stop.
29
PWL Series
PWL440-10-JOG
1. Make sure the RUN/JOG switch is set to RUN.
2. Turn the speed adjust potentiometer to “0” (full CCW) or set
the input voltage signal to minimum.
3. Set the POWER switch to the ON position.
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 jog the motor, set the RUN/JOG switch to JOG. This is
a momentary switch and must be physically held to stay
activated.
6. Set the POWER switch to the OFF position to coast the motor to
a stop.
30
PWL 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.
For this reason, ACE strongly recommends installing an
emergency stop switch on both AC line inputs (see Figure 10 on
page 23 and Figure 11 on page 24).
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.
31
PWL 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 14 on page
33). 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 3 on page 33 for
recommended dynamic brake resistor sizes.
32
PWL Series
Table 3. Minimum Recommended Dynamic Brake Resistor Values
Motor Armature Voltage
Dynamic Brake Resistor Value
130 VDC
240 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 14. Dynamic Brake Wiring
33
PWL Series
Inhibit Terminals
Short the INHIBIT terminals to coast the motor to zero speed (see
Figure 15 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.
ACE offers two accessory plug harnesses for connecting to the INHIBIT
terminals: part number KTW-0001 [plug with 18 in. (46 cm) leads]; and
part number KTW-0002 [plug with 36 in. (91 cm) leads].
BRR503
C508
BR+
AC1
AC2
-BUS
+BUS
TH501
R501
C507
T501
A1
SW502
230
Q502
230
BR501
SW501
Inhibit
Terminals
C506
C502
IC502
C504
IC501
D501
Q501
LIMIT
TH501
AC2
BR+
PS2
PS4
PS1
S
PS
PS3
C505
B2
R503
AC1
BRB1
POWER
CURR
+15
INHIBIT
T501
C503
SW502
230
C505
230
SW501
R501
MAX SPD
TORQ LIMIT
MIN SPD
DECEL
IR COMP
ACCEL
JOG
IC503
IC502
C501
IC501
S1
R502
FU501
FAST-ACTING
C502
INHIBIT
IL501
IL502
L1
230
115
TB501
L2
S1
S2
S3
F1
F2
A1
Figure 15. Inhibit Terminals
34
S3
G
SPD SPD JOG
IN
CURR
LIMIT
C504
L1
S2
F+
A1
F-
A2
A2
PWL Series
Decelerating to Minimum Speed
The switch shown in Figure 16 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 16. Run/Decelerate to Minimum Speed Switch
35
PWL 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.
PWL 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.
36
PWL 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.
37
PWL Series
Jog (JOG) (PWL400-15, PWL440-10, and PWL440-10-JOG only)
The JOG setting determines the constant motor speed when the drive is
set to Jog Mode.
To calibrate the Jog trim pot:
1. Make sure the drive is set to Jog Mode. This is done by
connecting the SPD IN and JOG terminals. If using the PWL44010-JOG, set the RUN / JOG switch on the front cover to JOG.
2.
38
Turn the JOG trim pot until the motor runs at the desired JOG
speed.
PWL Series
Torque (CURR LIMIT or TORQ LIMIT)

!
WARNING!
CURR 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
ACE representative for assistance.
The CURR LIMIT setting determines the maximum torque for accelerating
and driving the motor. To calibrate CURR LIMIT, refer to the recommended
CURR LIMIT settings in Figures 17 through 20 (pages 41 through 44) 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 CURR 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 CURR 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.
39
PWL 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 Figures 17 through 20 (pages 41 through 44) for recommended IR
COMP settings.
40
PWL Series
MODELS PWL400-3, PWL440-3
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
1/4 HP
90 VDC
2.50 AMPS
1/8 HP
90 VDC
1.25 AMPS
1/20 HP
90 VDC
0.50 AMPS
1/4 HP
130 VDC
1.75 AMPS
1/8 HP
130 VDC
0.90 AMPS
1/20 HP
130 VDC
0.35 AMPS
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
1/2 HP
180 VDC
2.50 AMPS
1/4 HP
180 VDC
1.25 AMPS
1/10 HP
180 VDC
0.50 AMPS
1/2 HP
240 VDC
1.90 AMPS
1/4 HP
240 VDC
0.95 AMPS
1/10 HP
240 VDC
0.40 AMPS
Figure 17. Recommended CURR LIMIT and IR COMP Settings
for models PWL400-3 and PWL440-3
(actual settings may vary with each application)
41
PWL Series
MODELS PWL400-5
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
1/2 HP
90 VDC
5.00 AMPS
1/4 HP
90 VDC
2.50 AMPS
1/8 HP
90 VDC
1.25 AMPS
1/2 HP
130 VDC
3.50 AMPS
1/4 HP
130 VDC
1.75 AMPS
1/8 HP
130 VDC
0.90 AMPS
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
IR COMP
1 HP
180 VDC
5.00 AMPS
1/2 HP
180 VDC
2.50 AMPS
1/4 HP
180 VDC
1.25 AMPS
1 HP
240 VDC
3.75 AMPS
1/2 HP
240 VDC
1.90 AMPS
1/4 HP
240 VDC
0.95 AMPS
Figure 18. Recommended CURR LIMIT and IR COMP Settings
for model PWL400-5
(actual settings may vary with each application)
42
PWL Series
MODELS PWL400-10
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
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
1 HP
130 VDC
7.00 AMPS
1/2 HP
130 VDC
3.50 AMPS
1/4 HP
130 VDC
1.75 AMPS
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
CURR
LIMIT
IR COMP
IR COMP
IR COMP
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
2 HP
240 VDC
7.50 AMPS
1 HP
240 VDC
3.75 AMPS
1/2 HP
240 VDC
1.90 AMPS
Figure 19. Recommended CURR LIMIT and IR COMP Settings
for model PWL400-10
(actual settings may vary with each application)
43
PWL Series
MODELS PWL400-15, PWL440-10, and PWL440-10-JOG
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
1-1/2 HP
90 VDC
15.0 AMPS
1 HP
90 VDC
10.00 AMPS
1/2 HP
90 VDC
5.00 AMPS
1/4 HP
90 VDC
2.50 AMPS
1-1/2 HP
130 VDC
10.5 AMPS
1 HP
130 VDC
7.00 AMPS
1/2 HP
130 VDC
3.50 AMPS
1/4 HP
130 VDC
1.75 AMPS
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
CURR
LIMIT
IR COMP
3 HP
180 VDC
15.0 AMPS
2 HP
180 VDC
10.0 AMPS
1 HP
180 VDC
5.00 AMPS
1/2 HP
180 VDC
2.50 AMPS
3 HP
240 VDC
11.3 AMPS
2 HP
240 VDC
7.50 AMPS
1 HP
240 VDC
3.75 AMPS
1/2 HP
240 VDC
1.90 AMPS
Figure 20. Recommended CURR LIMIT and IR COMP Settings
for models PWL400-15, PWL440-10, and PWL440-10-JOG
(actual settings may vary with each application)
44
PWL Series
Acceleration (ACCEL)
The ACCEL setting determines the time the motor takes to ramp to a
higher speed. See Specifications on page 2 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 2 for approximate deceleration
times. DECEL is factory set for the fastest 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.
45
PWL 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 21). 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 21. Multiple Fixed Speeds
46
PWL 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 22). 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 22. Adjustable Speeds Using Potentiometers In Series
47
PWL 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 23 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 23. Independent Adjustable Speeds
48
PWL 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 24. 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 24. RUN/JOG Switch - Connection to Inhibit Plug
49
PWL Series
RUN/JOG Switch - Potentiometer Connection
Connect the RUN/JOG switch and the JOG pushbutton as shown in Figure
25. 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 25. RUN/JOG Switch - Connection to Speed Adjust Potentiometer
50
PWL Series
Leader-Follower Application
In this application, use a ISO202-1 to monitor the speed of the leader
motor (Figure 26). 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 26. Leader-Follower Application
51
PWL 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
27). 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 27. Single Speed Potentiometer Control of Multiple Drives
52
PWL Series
Reversing
A dynamic brake may be used when reversing the motor direction
(Figure 28). 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 33 for
recommended dynamic brake resistor sizes.
A1
A2
DYNAMIC
BRAKE
RESISTOR
MOTOR
FWD
BRAKE
REV
INHIBIT
Figure 28. Reversing Circuit Wiring
53
PWL Series
Section 7. Diagnostic LEDs
PWL series drives are equipped with two diagnostic LEDs:
•
Power (POWER ON): Green LED lights whenever AC line voltage is
applied to the drive.
•
Current Limit (CURR LIMIT): Red LED lights whenever the drive
reaches current limit.
BR +
C508
BR-
Current Limit
LED
AC1
AC2
R503
-BUS
+BUS
TH501
R501
C507
T501
230
D501
Q501
A1
SW502
230
Q502
SW501
BR501
C506
C502
IC502
TH501
B2
R503
AC1
AC2
BR+
C504
IC501
BR-
LIMIT
B1
PS2
PS4
PS1
S
PS
PS3
C505
T501
C503
SW502
230
C505
230
SW501
R501
POWER
CURR
MAX SPD
TORQ LIMIT
MIN SPD
DECEL
+15
INHIBIT
IR COMP
ACCEL
JOG
IC503
IC502
C501
IC501
R502
FU501
FAST-ACTING
S1
C502
INHIBIT
IL501
IL502
L1
230
TB501
L2
S1
S2
S3
F1
F2
A1
Power LED
Figure 29. Diagnostic LED Locations
54
S3
SPD SPD JOG
IN
CURR
LIMIT
C504
L1
S2
115
F+
A1
F-
A2
A2
PWL Series
Section 8. Troubleshooting

!
WARNING!
Dangerous voltages exist on the drive when it is powered. When
possible, disconnect the drive while troubleshooting. wHigh
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 and field outputs are
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
55
PWL Series
PROBLEM
Line fuse
blows.
Line fuse does
not blow, but
the motor does
not run.
56
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
CURR LIMIT settings, resize
motor and drive for actual
load demand, or check for
incorrectly aligned mechanical
components or “jams”. See
page 39 for information on
adjusting the CURR LIMIT trim
pot.
1. Speed adjust potentiometer
or input voltage signal is set
to zero speed.
1. Increase the speed adjust
potentiometer setting or input
voltage 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 CURR LIMIT
setting if set too low. See page
41.
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.
PWL 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. See page
39.
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. See page
37.
2. Motor field connections are
loose (shunt wound motors
only).
2. Check motor field connections.
1. MAX SPD setting is too low.
1. Increase MAX SPD setting. See
page 37.
2. IR COMP setting is too low.
2. Increase IR COMP setting. See
page 40.
3. CURR LIMIT setting is too
low.
3. Increase CURR LIMIT setting.
See page 39.
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. See page 40.
2. Motor bouncing in and out
of current limit.
2. Make sure motor is not
undersized for load; adjust
CURR LIMIT trim pot CW. See
page 39.
Motor will
not reach the
desired speed.
Motor pulsates
or surges under
load.
57
PWL Series
Section 9. Accessories & Replacement Parts
Displays
Closed Loop.............................................................................. CLD100-1
Open Loop.............................................................................. OLD100-1
Heat Sinks
Chassis..................................................................................... HSK-0001
Kits
Potentiometer & Connector
10K Pot, Insulating Washer................................................. KTP-0001
10K Pot, Insulating Washer, 3 Insulated Tabs..................... KTP-0009
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
2 20 Amp 250V 3AB Normal-blow Ceramic Fuses............... KTF-0007
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
58
PWL 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.
59
PWL 400- 3
PWL400-5
PWL400-10
PWL400-15
PWL 440- 3
PWL440-10
PWL440-10-J OG
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-0007 Rev 1
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