User Manual - American Control Electronics

User Manual - American Control Electronics
P WM S eries
USER MANUAL
PW M400-2
PW M400-5
PW M400-10
PW M401-2
PW M401-5
PW M401-10
www.americancontrolelectronics.com
Dear Valued Consumer:
Congratulations on your purchase of the PWM 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®!
© 2012 American Control Electronics®. All rights reserved.
No part of this manual 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® and its divisions make 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® and its divisions
assume no responsibility for any errors that may appear in this manual and make no commitment to
update or to keep current the information in this manual.
PWM 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® (ACE)
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 protection equipment and insulated tools
if working on this drive with power applied.
i
PWM Series
Table of Contents
Section 1. Specifications...................................................... 1
Section 2. Dimensions.. ........................................................ 3
Section 3. Installation. . ........................................................ 5
Mounting.............................................................................. 5
Heat Sinking. . ..................................................................... 6
Speed Adjust Potentiometer............................................... 7
Wiring................................................................................... 8
Shielding Guidelines........................................................... 8
Line Fusing. . ....................................................................... 9
Connections.........................................................................11
Section 4. Operation. . ........................................................ 14
Before Applying Power..................................................................14
Startup.........................................................................................14
Starting and Stopping Methods.....................................................15
Line Starting and Stopping....................................................15
Dynamic Braking...................................................................16
Inhibit Terminals. . .................................................................18
Decelerating to Minimum Speed. . ..........................................19
Section 5. Calibration........................................................ 20
Minimum Speed (MIN SPD)...........................................................21
Maximum Speed (MAX SPD)..........................................................21
Torque (CURRENT LIMIT)...............................................................22
IR Compensation (IR COMP)..........................................................23
Acceleration (ACCEL). . ...................................................................27
Deceleration (DECEL)....................................................................27
Section 6. Application Notes.............................................. 28
Multiple Fixed Speeds...................................................................28
Adjustable Speeds Using Potentiometers In Series . . ........................29
Independent Adjustable Speeds.. ...................................................30
RUN/JOG Switch - Inhibit Connection. . ...........................................31
RUN/JOG Switch - Potentiometer Connection. . ...............................32
ii
PWM Series
Leader-Follower Application..........................................................33
Single Speed Potentiometer Control Of Multiple Drives..................34
Reversing.. ....................................................................................35
Reversing with a CLD100-1 Controller............................................36
Section 7. Diagnostic LEDs.. ................................................ 37
Section 8. Troubleshooting. . ............................................... 38
Before Troubleshooting.................................................................38
Section 9. Accessories & Replacement Parts........................ 41
Notes................................................................................ 43
Unconditional Warranty.. .................................................... 45
iii
PWM Series
List of Tables
Table 1
Table 2
Recommended Line Fuse Sizes...........................................10
Minimum Recommended Dynamic Brake Resistor Values....17
List of Figures
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
PWM Series Dimensions..................................................... 3
HSK-0001 Dimensions . . ....................................................... 4
Speed Adjust Potentiometer............................................... 7
Chassis Drive Connections.................................................12
Analog Input Signal Connections. . ......................................13
Dynamic Brake Wiring.......................................................17
Inhibit Terminals...............................................................18
Run/Decelerate to Minimum Speed Switch. . .......................19
Recommended CURRENT LIMIT and IR COMP Settings for
models PWM400-2 and PWM401-2....................................24
Figure 10 Recommended CURRENT LIMIT and IR COMP Settings for
models PWM400-10 and PWM401-10................................25
Figure 11 Recommended CURRENT LIMIT and IR COMP Settings for
models PWM400-10 and PWM401-10................................26
Figure 12 Multiple Fixed Speeds.......................................................28
Figure 13 Adjustable Speeds Using Potentiometers In Series. . ............29
Figure 14 Independent Adjustable Speeds. . .......................................30
Figure 15 RUN/JOG Switch - Connection to Inhibit Plug.....................31
Figure 16 RUN/JOG Switch - Connection to Speed Adjust
Potentiometer..................................................................32
Figure 17 Leader-Follower Application..............................................33
Figure 18 Single Speed Potentiometer Control of Multiple Drives. . .....34
Figure 19 Reversing Circuit Wiring....................................................35
Figure 20 Reversing with a CLD100-1................................................36
Figure 21 Diagnostic LED Location....................................................37
iv
1
2
3
4
5
6
7
8
9
PWM Series
Section 1. Specifications
Maximum
Armature
Current (ADC)
HP Range
with 130 VDC
Motor
HP Range
with 240 VDC
Motor
PWM400-2
PWM401-2
2.0
1/20 - 1/6
1/10 - 1/3
Chassis
Chassis
PWM400-5
PWM401-5
5.0
1/6 - 1/2
1/3 - 1
Chassis
Chassis
PWM400-10*
PWM401-10*
10.0
1/2 - 1
1-2
Chassis
Chassis
Model
Enclosure
* Heat sink kit part number HSK-0001 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
Acceleration Time Range
0.5 - 6 seconds
Deceleration Time Range
coast to a stop - 6 seconds
Analog Input Range
P
PWM400 models (Signal must be isolated; S1 to S2)
PWM401 models (Signal may be isolated or non-isolated; S1 to S2)
P
Input Impedance (S1 to S2)
Form Factor
0 - 5 VDC
0 - 5 VDC
~70K ohms
1.05
1
PWM Series
Load Regulation
Speed Range
Vibration
Safety Certifications
Ambient Temperature Range
2
1% base speed or better
100:1
0.5G maximum (0 - 50 Hz)
0.1G maximum (> 50 Hz)
UL Recognized Component, File #E132235
CSA Certified Component, File # LR41380
10°C - 40°C
PWM Series
Section 2. Dimensions
C505
C504
C503
C502
A1
S3
R501
D
Q503
C501
3.64 [92]
L2
INHIBIT
T501
A2
S2
S1
IL502
CURRENT
LIMIT
POWER
L1
0.19 [5]
1.75 [44]
TH501
IL501
CURRENT LIMIT
MAX SPD MIN SPD IR COMP
DECEL
ACCEL
0.70 [18]
3.80 [97]
4.30 [109]
A
0.82 [21]
2.10 [53]
0.19 [5]
0.96 [24]
MODEL
DIMENSION “A” HEIGHT
PWM40x-2
2.50 [62]
PWM40x-5
3.20 [81]
PWM40x-10
3.90 [99]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 1. PWM Series Dimensions
3
PWM Series
6.90 [175]
6.30 [160]
5.90 [150]
0.7 [18]
4.40 [112]
3.00 [76]
1.75 [44]
3.90 [100]
0.125 [3]
1.00 [26]
ALL DIMENSIONS IN INCHES [MILLIMETERS]
Figure 2. HSK-0001 Dimensions
4
PWM 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.
Mounting
• 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.
5
PWM Series
Heat Sinking
The PWM series drives PWM400-10 and PWM401-10 require an
additional heat sink when the continuous armature current is above 5
amps. Use ACE heat sink kit part number HSK-0001. 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.
6
PWM 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 3). Install the circular insulating disk
between the panel and the 10K ohm speed adjust potentiometer.
Twist the speed adjust potentiometer wires 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, A1, A2).
R
I
CW
E
WIPER
W
W
R
ER
P
I
P
I
PEE
E
I
E ER
I
E
Figure 3. Speed Adjust Potentiometer
7
PWM 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.
• Use 18 - 24 AWG wire for logic wiring. Use 14 - 16 AWG wire for
AC line and motor wiring.
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, AMERICAN CONTROL ELECTRONICS® (ACE)
recommends shielding of all conductors. If it is not practical to shield
power conductors, ACE recommends shielding 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.
8
PWM Series
Shielding Guidelines (continued)
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.
Line Fusing
ACE drives should be fused for protection. Use fast acting fuses rated for
250 VAC or higher and 150% of maximum armature current. Fuse HOT
L1 only when the line voltage is 115 VAC. Fuse both L1 and L2 when the
line voltage is 230 VAC. Table 1 on page 10 lists the recommended line
fuse sizes.
9
PWM 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
ACE offers fuse kits. See Section 10: Accessories and Replacement Parts
on page 41 for fuse kit part numbers.
10
PWM Series
Connections

!
WARNING!
Do not connect this equipment with power applied. Failure to
heed this warning may result in fire, explosion, or serious injury.
ACE strongly recommends the installation of a master power
switch in the voltage input line, as shown in Figure 4 (page 12).
The switch contacts should be rated at a minimum of 200% of
motor nameplate current and 250 volts.
Power Input
Connect the AC line power leads to terminals L1 and L2. 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 4 on page 12.
Motor
ACE drives supply motor armature voltage from A1 and A2 terminals,
where A1 is positive with respect to A2. 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
12. Ensure that the motor voltage rating is consistent with the drive’s
output voltage.
Speed Adjust Potentiometer
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 Figure 4 on page 12.
11
PWM Series
CW
C505
MOTOR
C503
C502
A1
C504
R501
S3
T501
L2
INHIBIT
Q503
IL502
CURRENT
LIMIT
POWER
L1
D
C501
10K OHM
SPEED ADJUST
POTENTIOMETER
A2
S2
S1
*FUSE
TH501
IL501
CURRENT LIMIT
FUSE
MAX SPD MIN SPD IR COMP
DECEL
ACCEL
* NOTE: Do not add fuse to L2
unless input voltage is 230 VAC.
STOP
SWITCH
AC LINE
VOLTAGE
120/240 VAC
Figure 4. Chassis Drive Connections
12
PWM Series
Analog Input Signal
Instead of using a speed adjust potentiometer, PWM400 drives may be
wired to follow an analog input voltage signal that is isolated from earth
ground. PWP401 drives may be wired to follow an analog input voltage
signal that is either isolated or non-isolated from earth ground (Figure
12). Connect the signal common (–) to S1. Connect the signal input (+) 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.
An analog input voltage range of 0–5 VDC is required to produce an
armature voltage range of 0–130 VDC with 115 VAC line voltage, or 0-240
VDC with 230 VAC line voltage.
A1
C503
C502
R501
C504
T501
A2
S2
S1
L2
D
Q503
IL502
CURRENT
LIMIT
POWER
L1
S1 (-)
C501
SIGNAL COMMON
C505
S3
S2 (+)
INHIBIT
SIGNAL REFERENCE
TH501
IL501
CURRENT LIMIT
MAX SPD MIN SPD IR COMP
DECEL
ACCEL
Figure 5. Analog Input Signal Connections
13
PWM Series
Section 4. Operation

!
WARNING!
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 38, for further assistance.
Before Applying Power
1. Verify that no foreign conductive material is present on the
printed circuit board.
Startup
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.
14
Remove AC line voltage from the drive to coast the motor to a
stop.
PWM 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 4 on page 12).
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.
15
PWM 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 6 on page
17). 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 2 on page 17 for
recommended dynamic brake resistor sizes.
16
PWM Series
Table 2. 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 6. Dynamic Brake Wiring
17
PWM Series
Inhibit Terminals
Short the INHIBIT terminals to coast the motor to minimum speed (see
Figure 7 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].
C505
C503
C502
A1
C504
R501
S3
T501
L2
INHIBIT
Q503
IL502
CURRENT
LIMIT
POWER
CURRENT LIMIT
MAX SPD MIN SPD IR COMP
DECEL
Figure 7. Inhibit Terminals
18
ACCEL
TH501
IL501
L1
D
C501
Inhibit
Terminals
A2
S2
S1
PWM Series
Decelerating to Minimum Speed
The switch shown in Figure 8 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 8. Run/Decelerate to Minimum Speed Switch
19
PWM 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.
PWM 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.
20
PWM 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.
21
PWM Series
Torque (CURRENT LIMIT)

!
WARNING!
CURRENT 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 CURRENT LIMIT setting determines the maximum torque for
accelerating and driving the motor. To calibrate CURRENT LIMIT, refer
to the recommended CURRENT LIMIT settings in Figures 9 through 11
(pages 24 through 26) 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 CURRENT LIMIT trim pot to minimum (full CCW).
3. Set the speed adjust potentiometer 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 CURRENT 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.
22
PWM 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 9 through 11 (pages 24 through 26) for recommended IR
COMP settings.
23
PWM Series
MODELS PWM400-2, PWM401-2
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
1/6 HP
90 VDC
1.67 AMPS
1/10 HP
90 VDC
1.00 AMP
1/20 HP
90 VDC
0.50 AMPS
1/6 HP
130 VDC
1.15 AMPS
1/10 HP
130 VDC
0.70 AMPS
1/20 HP
130 VDC
0.35 AMPS
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
1/3 HP
180 VDC
1.67 AMPS
1/4 HP
180 VDC
1.25 AMPS
1/10 HP
180 VDC
0.50 AMPS
1/3 HP
240 VDC
1.25 AMPS
1/4 HP
240 VDC
0.95 AMPS
1/10 HP
240 VDC
0.40 AMPS
Figure 9. Recommended CURRENT LIMIT and IR COMP Settings
for models PWM400-2 and PWM401-2
(actual settings may vary with each application)
24
PWM Series
MODELS PWM400-5, PWM401-5
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
1/2 HP
90 VDC
5.00 AMPS
1/4 HP
90 VDC
2.50 AMPS
1/6 HP
90 VDC
1.67 AMPS
1/2 HP
130 VDC
3.50 AMPS
1/4 HP
130 VDC
1.75 AMPS
1/6 HP
130 VDC
1.15 AMPS
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
1 HP
180 VDC
5.00 AMPS
1/2 HP
180 VDC
2.50 AMPS
1/3 HP
180 VDC
1.67 AMPS
1 HP
240 VDC
3.75 AMPS
1/2 HP
240 VDC
1.90 AMPS
1/3 HP
240 VDC
1.25 AMPS
Figure 10. Recommended CURRENT LIMIT and IR COMP Settings
for models PWM400-5 and PWM401-5
(actual settings may vary with each application)
25
PWM Series
MODELS PWM400-10, PWM401-10
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
1 HP
90 VDC
10.0 AMPS
3/4 HP
90 VDC
7.50 AMPS
1/2 HP
90 VDC
5.00 AMPS
1 HP
130 VDC
7.00 AMPS
3/4 HP
130 VDC
5.20 AMPS
1/2 HP
130 VDC
3.50 AMPS
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
CURRENT IR COMP
LIMIT
2 HP
180 VDC
10.0 AMPS
1 1/2 HP
180 VDC
7.50 AMPS
1 HP
180 VDC
5.00 AMPS
2 HP
240 VDC
7.50 AMPS
1 1/2 HP
240 VDC
5.63 AMPS
1 HP
240 VDC
3.75 AMPS
Figure 11. Recommended CURRENT LIMIT and IR COMP Settings
for models PWM400-10 and PWM401-10
(actual settings may vary with each application)
26
PWM 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 2 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.
27
PWM 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
28
PWM Series
Adjustable Speeds Using Potentiometers In Series
Replace the speed adjust potentiometer with a series of potentiometers
with a total series resistance of 10K ohms (Figure 13). Add a single
pole, multi-position 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
29
PWM 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
30
PWM 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 normally closed
momentary 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
31
PWM 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
32
PWM Series
Leader-Follower Application
In this application, use a ISO202-1 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.
(+)
(+)
O
MOTOR
( )
T
( )
T
(
O
)
Figure 17. Leader-Follower Application
33
PWM 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
S3
+
S2
1
ratio pot A
(optional)
10K Ohms
S2
-
S1
+
Drive
A
S1
A1
A2
ratio pot B
(optional)
10K Ohms
A1
2
S2
-
S1
Motor
A
Drive
B
Motor
B
A2
ISO101-8
+
ratio pot H
(optional)
10K Ohms
A1
8
S2
-
S1
Drive
H
A2
Figure 18. Single Speed Potentiometer Control of Multiple Drives
34
Motor
H
PWM 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 17 for
recommended dynamic brake resistor sizes.
A1
A2
DYNAMIC
BRAKE
RESISTOR
MOTOR
FWD
BRAKE
REV
INHIBIT
Figure 19. Reversing Circuit Wiring
35
PWM Series
Reversing with a CLD100-1 Controller
A CLD100-1 controller can be used in a reversing application. The
CLD100-1 must be inhibited while braking. If the inhibit feature is not
used, the CLD100-1 will continue to regulate. This will cause overshoot
when the motor is reconnected to the drive. Figure 20 shows a wiring
diagram of the reversing circuit using a PWM series drive and a CLD100‑1.
Note: Only one feedback device (Optical Encoder or Magnetic Pickup)
may be connected to a CLD100-1 at a time.
S3
S2
ACE DRIVE
A1
S1
A2
Dynamic
Brake
Resistor
S1
S2
BRAKE
FWD
REV
CLD100-1
Inhibit
Leads
C
Motor
Common
Optical
Encoder
Signal
+5 VDC
Magnetic
Pickup
Figure 20. Reversing with a CLD100-1
36
IN
+
PWM Series
Section 7. Diagnostic LEDs
PWM series drives are equipped with one or two diagnostic LEDs:
•
Current Limit (CURRENT LIMIT): Red LED lights whenever the drive
reaches current limit.
•
Power (POWER): Green LED lights whenever AC line voltage is
applied to the drive.
C505
C503
C502
A1
C504
R501
S3
T501
L2
INHIBIT
Q503
IL502
CURRENT
LIMIT
POWER
L1
D
C501
Current Limit
LED
A2
S2
S1
Power LED
TH501
IL501
CURRENT LIMIT
MAX SPD MIN SPD IR COMP
DECEL
ACCEL
Figure 21. Diagnostic LED Locations
37
PWM 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 serious 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 drive’s rated armature is consistent with the
motor ratings.
For additional assistance, contact your local AMERICAN CONTROL
ELECTRONICS® distributor, or the factory direct:
1-815-624-6915 or FAX: 1-815-624-6965
38
PWM Series
PROBLEM
Line fuse
blows.
Line fuse does
not blow, but
the motor does
not run.
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
CURRENT LIMIT settings, resize
motor and drive for actual
load demand, or check for
incorrectly aligned mechanical
components or “jams”. See
page 22 for information on
adjusting the CURRENT 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 CURRENT
LIMIT setting if set too low. See
page 22.
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.
39
PWM Series
PROBLEM
SUGGESTED SOLUTIONS
1. MIN SPD is set too high.
1. Calibrate MIN SPD. See page
21.
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
21.
2. S1 is disconnected.
2. Connect S1.
1. MAX SPD setting is too low.
1. Increase MAX SPD setting. See
page 21.
2. IR COMP setting is too low.
2. Increase IR COMP setting. See
page 23.
3. CURRENT LIMIT setting is
too low.
3. Increase CURRENT LIMIT
setting. See page 22.
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 23.
2. Motor bouncing in and out
of current limit.
2. Make sure motor is not
undersized for load; adjust
CURRENT LIMIT trim pot CW.
See page 22.
Motor will
not reach the
desired speed.
Motor pulsates
or surges under
load.
40
POSSIBLE CAUSE
Motor does not
stop when the
speed adjust
potentiometer
is full CCW.
PWM Series
Section 9. Accessories & Replacement Parts
Displays
D
Closed Loop............................................................................ CLD100-1
Open Loop..............................................................................OLD100-1
Heat sinks
H
Chassis.................................................................................... HSK-0001
Kits
K
Potentiometer & Connector
10K Pot, Insulating Washer................................................. KTP-0001
10K Pot, Insulating Washer, 9 Insulated Tabs......................KTP-0005
9 Insulated Tabs.................................................................. KTP-0011
F
Fuse
2 1.5 Amp 250 V 3AG Fast-blow Glass Fuses...................... KTF-0001
2 3 Amp 250 V 3AG Fast-blow Glass Fuses......................... KTF-0002
2 5 Amp 250 V 3AG Fast-blow Glass Fuses......................... KTF-0003
2 8 Amp 250 V 3AG Fast-blow Glass Fuses......................... KTF-0004
2 10 Amp 250 V 3AB Normal-blow Ceramic Fuses............. KTF-0005
2 15 Amp 250 V 3AB Normal-blow Ceramic Fuses............. KTF-0006
Wiring
Inhibit Plug (18 in. leads).................................................. KTW-0001
Inhibit Plug (36 in. leads).................................................. KTW-0002
41
PWM Series
Logic Cards
Current Monitoring
5 Amps..............................................................................CMC100-5
20 Amps..........................................................................CMC100-20
Isolation
Uni-directional, 8 outputs...................................................ISO101-8
Bi-directional, 1 output.......................................................ISO202-1
42
PWM Series
Notes
43
PWM Series
Notes
44
PWM Series
Unconditional Warranty
A. Warranty
American Control Electronics®, referred to as “the Corporation” 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, the Corporation
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. The Corporation 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 the Corporation’s sole obligation and exclude all other
warranties of merchantability for use, expressed or implied. The Corporation 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 the Corporation’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 the Corporation by lawful authority, the Corporation shall under no
circumstances be liable for any consequential damages, losses, or expenses arising in connection
with the use of, or inability to use, the Corporation’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, the Corporation’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 the Corporation 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.
45
w w w.a m ericancont rolelect ronics.com
• 14300 D E L A TO UR DRIV E • S OUTH BELOIT, IL 61080 •
• ( 815) 624-6915 • (815) 624-6965 fax •
D oc um ent Num ber - MA N-0001, Rev 0 - March 2012
© 2011 AM E RICA N CONTROL ELEC TRONICS ®
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