PWL SERIES - American Control Electronics
Contents
1. 1 1 39 35 6 30 160 E 6 90 175 3 92 99 0 13 3 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 2 PWL400 15 Dimensions PWL Series 8 20 208 MOTOR CONTROL 0 87 22 7 76 197 6 00 152 2 50 64 3 70 94 2 25 57 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 3 PWL440 3 Dimensions 6 90 175 6 30 160 AMERICAN f ConTROL 6X93 ELECTRONICS A A mM 0 88 22 3 SORO be 1 45 37 B 1 50 38 lt 1 50 38 ALL DIMENSIONS IN INCHES MILLIM LS rir ETERS Figure 4 PWL440 10 Dimensions PWL Series PWL Series 6 90 175 6 30 160 dom Conor PXS ELECTRONICS ALL DIMENSIONS IN INCHES MILLIMETERS Figure 5 PWL440 10 JOG Dimensions PWL Series j 0 188 WIDE SLOT 4 PLACES Xa sa2mo 4 PLACES 78 248 8 41 3 08 78 4 41 35 2 50 64 2 50 64 3 16 80 3 15 80 6 90 175 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 6 HSK 0003 Dimensions PWL Series Section 3 Installlation Do not install rewire or remove this control with input power applied Fa2. 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 PWL Series Table 3 Minimum Recommended Dynamic Brake Resistor Values 130 VDC 15 ohms 240 VDC 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 INHIBIT Figure 14 Dynamic Brake Wiring 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 tw
3. Before Applying Power 1 Verify that no foreign conductive material is present on the printed circuit board Ensure that all switches are properly set 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 Input Voltage Select SW501 SW502 SW501 SW502 PWL400 3 PWL400 5 PWL400 15 PWL440 10 and PWL400 10 and PWL440 3 PWL440 10 JOG Figure 13 Select Switches 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 PWL Series Startup PWL400 3 PWL400 5 PWL400 10 and PWL400 15 Turn the speed adjust potentiometer full counterclockwise CCW or set the input voltage signal to minimum Apply AC line voltage Slowly advance the
4. 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 Disconnect AC line voltage from the drive Check the drive closely for damaged components Check that no conductive or other foreign material has become lodged on the printed circuit board Verify that every connection is correct and in good condition Verify that there are no short circuits or grounded connections Check that the selection switch settings are correctly set 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 PWL Series PROBLEM Line fuse blows Line fuse does not blow but the motor does i not run Motor cable or armature is shorted to ground Nuisance tripping caused by a combination of ambient conditions and high current spikes i e reversing Speed adjust potentiometer or input voltage signal is set to zero speed INHIBIT mode is active Drive is not receiving AC line voltage Motor is not connected SUGGESTED SOLUTIONS Check that the line fuse is correct for the
5. Turn the speed adjust potentiometer CCW or decrease the input voltage signal Remove line power Remove the stall from the motor Remove the ammeter in series with the motor armature if it is no longer needed 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 Load the motor armature to its full load armature current rating The motor should slow down 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 MODELS PWL400 3 PWL440 3 IR COMP IR COMP IR COMP IR COMP IR COMP CURR LIMIT IR COMP 1 4 HP 90 VDC 2 50 AMPS CURR LIMIT 1 8 HP 90 VDC 1 25 AMPS CURR LIMIT 1 20 HP 90 VDC 0 50 AMPS CURR LIMIT 1 4 HP 130 VDC 1 75 AMPS 1 8 HP 130 VDC 0 9
6. VOLTAGE 120 240 VAC NOTE Do not add fuse to L2 unless input voltage is 230 VAC Figure 10 PWL400 3 PWL400 5 and PWL400 10 Connections PWL Series FIELD MOTOR OUTPUT ARMATURE NOTE DO NOT make any connections to F1 and F2 if using a permanent magnet motor Figure 11 PWL440 3 Connections PWL Series Ititi S1 S2 S3 SPD RS TB501 MOTOR ARMATURE POWER SWITCH NOTE DO NOT make any connections to F1 and F2 if using a AC LINE permanent magnet motor VOLTAGE Figure 12 PWL400 15 PWL440 10 and PWL440 10 JOG Connections PWL Series Section 4 Operation 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
7. a stop 19 seconds PWL440 10 and PWL440 10 JOG for 0 130 VDC Armature Voltage coast to a stop 10 seconds for 0 240 VDC Armature Voltage coast to a stop 19 seconds Analog Input Range signal must be isolated S1 to 2 for 0 130 VDC Armature Voltage for 0 240 VDC Armature Voltage Input Impedance S1 to 2 PWL400 15 All other models Form Factor Load Regulation PWL400 15 All other models Speed Range Vibration PWL400 3 PWL400 5 PWL400 10 PWL400 15 PWL440 3 PWL440 10 and PWL440 10 JOG Safety Certifications Suffix Definitions PWL Series 50K ohms 100K ohms 0 5 base speed or better 1 base speed or better 0 5G maximum 20 50 Hz 0 1G maximum gt 50 Hz 0 5G maximum 0 50 Hz 0 1G maximum gt 50 Hz UL Recognized Component File E132235 CSA Certified Component File LR41380 JOG Basic Drive with Run Jog Switch PWL Series Section 2 Dimensions 105 L 0 25 6 H 5 38 137 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 1 PWL400 3 PWL400 5 and PWL400 10 Dimensions PWL Series
8. 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 Insert wire into the wire clamp Release the lever arm to clamp the wire Figure 8 Cage Clamp Terminal Block 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
9. operated without mounting 1 2 Install the mounting screws 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 Carefully remove the conduit knockouts by tapping them into the case and twisting them off with pliers Set the POWER switch to the OFF position before applying the AC line voltage Install conduit hardware through the 0 88 inch 22 mm knockout holes Connect external wiring to the terminal block Grasp the slotted screw and tilt the front cover back into place Avoid pinching any wires between the front cover and the case Turn the slotted screw clockwise until tight to secure the front cover PWL Series 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 the
10. 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 Remove AC line voltage from the drive to coast the motor to a stop PWL440 3 and PWL440 10 Set the POWER switch to the OFF position Turn the speed adjust potentiometer to O full CCW or set the input voltage signal to minimum Apply AC line voltage Set the POWER switch to the ON position 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 Set the POWER switch to the OFF position to coast the motor to a stop PWL Series PWL440 10 JOG Make sure the RUN JOG switch is set to RUN Turn the speed adjust potentiometer to 0 full CCW or set the input voltage signal to minimum Set the POWER switch to the ON position 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 To jog the motor set the RUN JOG switch to JOG This is a momentary switch and must be physically held to stay acti
11. 0 AMPS 1 20 HP 130 VDC 0 35 AMPS CURR LIMIT IR COMP IR COMP IR COMP IR COMP IR COMP IR COMP PWL Series 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 PWL Series CURR LIMIT CURR LIMIT CURR LIMIT MODELS PWL400 5 1 2 HP 90 VDC 5 00 AMPS IR COMP IR COMP 1 4 HP 90 VDC 2 50 AMPS IR COMP IR COMP 1 8 HP 90 VDC 1 25 AMPS IR COMP IR COMP 1 2 HP 130 VDC 3 50 AMPS IR COMP IR COMP 1 4 HP 130 VDC 1 75 AMPS IR COMP IR COMP 1 8 HP 130 VDC 0 90 AMPS IR COMP CURR IR COMP LIMIT 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 PWL Series MODELS PWL400 10 IR COMP IR COMP IR COMP IR COMP 1 4 HP 1 2 HP 90 VDC 180 VDC 2 50 AMPS 2 50 AMPS IR COMP IR COMP 1HP 2HP 130 VDC 240 VDC 7 00 AMPS 7 50 AMPS CURR IR COMP IR COMP LIMIT CURR IR COMP IR COMP LIMIT CURR IR COMP CURR IR COMP LIMIT LIMIT Figure 19 Recommended CURR LIMIT and I
12. R COMP Settings for model PWL400 10 actual settings may vary with each application PWL Series MODELS PWL400 15 PWL440 10 and PWL440 10 JOG IR COMP IR COMP 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 1HP 130 VDC 7 00 AMPS 1 2 HP 130 VDC 3 50 AMPS 1 4 HP 130 VDC 1 75 AMPS CURR IR COMP LIMIT IR COMP IR COMP IR COMP IR COMP e e e IR COMP 3 HP 180 VDC 15 0 AMPS 2HP 180 VDC 10 0 AMPS 1HP 180 VDC 5 00 AMPS 1 2 HP 180 VDC 2 50 AMPS 3HP 240 VDC 11 3 AMPS 2HP 240 VDC 7 50 AMPS 1HP 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 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 Set the speed adjust potentiometer or input voltage signal for maximum speed Measure the time it takes the motor to go from minimum to m
13. 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 PWL440 10 JOG set the RUN JOG switch on the front cover to JOG Turn the JOG trim pot until the motor runs at the desired JOG speed PWL Series Torque CURR LIMIT or TORQ LIMIT 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 WARNING 5 CARING 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 With the power disconnected from the drive connect a DC ammeter in series with the armature Set the CURR LIMIT trim pot to minimum full CCW Set the speed adjust potentiometer full CW or input voltage signal to maximum speed Carefully lock the motor armature Be sure that the motor is firmly mounted Apply line power The motor should be stopped Slowly adjust the CURR LIMIT trim pot CW until the armature current is 150 of motor rated armature current
14. TM AMERICAN CONTROL Xa ELECTRONICS PWL SERIES USER MANUAL PWL400 3 PWL400 5 PWL400 10 PWL400 15 PWL440 3 PWL440 10 PWL440 10 JOG 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 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 qualifie
15. arranty 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 tm I A Te L EITT EaR ea Aas FES mre meses PWL400 3 PWL400 5 PWL400 10 PWL400 15 mT HEN mom ae feya rests ea Ra ee PWL440 3 PWL440 10 PWL440 10 JOG AMERICAN CONTROL Xa ELECTRONICS www americancontrolelectronics com 14300 DE LA TOUR DRIVE SOUTH BELOIT IL 61080 844 AMCNTRL MAN O0007 Rev 1
16. assis PWL400 10 Chassis PWL440 10 NEMA 4X PWL440 10 JOG NEMA 4X PWL400 15 1 4 11 2 Chassis Heat sink kit part number HSK 0003 must be used when the continuous current output is over 5 amps 115 230 VAC 10 50 60 Hz single phase DC Armature Voltage with 115 VAC Line Voltage 0 130 VDC with 230 VAC Line Voltage 0 240 VDC Field Voltage with 115 VAC Line Voltage 50 VDC F1 F to L1 100 VDC F1 F to F2 F with 230 VAC Line Voltage 100 VDC F1 F to L1 200 VDC F1 F to F2 F PWL Series Acceleration Time Range with no load PWL400 3 PWL400 5 and PWL400 10 for 0 130 VDC Armature Voltage 1 12 seconds for 0 240 VDC Armature Voltage 1 12 seconds PWL400 15 for 0 130 VDC Armature Voltage 1 9 seconds for 0 240 VDC Armature Voltage 1 15 seconds PWL440 3 for 0 130 VDC Armature Voltage 1 10 seconds for 0 240 VDC Armature Voltage 1 19 seconds PWL440 10 and PWL440 10 JOG for 0 130 VDC Armature Voltage 1 10 seconds for 0 240 VDC Armature Voltage 1 15 seconds Deceleration Time Range with no load PWL400 3 PWL400 5 and PWL400 10 for 0 130 VDC Armature Voltage coast to a stop 12 seconds for 0 240 VDC Armature Voltage coast to a stop 12 seconds PWL400 15 for 0 130 VDC Armature Voltage coast to a stop 10 seconds for 0 240 VDC Armature Voltage coast to a stop 18 seconds PWL440 3 for 0 130 VDC Armature Voltage coast to a stop 9 seconds for 0 240 VDC Armature Voltage coast to
17. aximum speed 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 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 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 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 multi position switch with the correct number of positions for the desired number of fixed speeds TOTAL SERIES RESISTANCE 10K OHMS Figure 21 Multiple Fixed Speeds PWL Series Adjustable Speeds Using Potentio
18. d 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 It is possible for a drive to run at full speed as a result of a AN 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 PWL Series Table of Contents Section 1 Specifications Suffix Definitions Section 2 Dimensions Section 3 Installlation Heat Sinking Chassis NEMA 4X Mounting Chassis Speed Adjust Potentiometer NEMA 4X Cage Clamp Terminal Block Power Input Field Output Connections Speed Adjust Potentiometer Analog Signal Input Section 4 Operation Before Appl
19. ersonal 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 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 Set the MIN SPD trim pot full CCW Set the speed adjust potentiometer or input voltage signal for minimum speed 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 Set the MAX SPD trim pot full CCW Set the speed adjust potentiometer or input voltage signal for maximum speed 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 PWL
20. f 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 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 i 1 SP 83 TB501 SIGNAL SIGNAL SIGNAL SIGNAL COMMON INPUT COMMON INPUT Figure 9 Analog Input Signal Connections PWL Series PPppppRpRI S1 S2 S3 F1 F2 A2 A1 Ala Lg 10K OHM FIELD MOTOR SPEED ADJUST OUTPUT ARMATURE POTENTIOMETER POWER SWITCH NOTE DO NOT make any connections to F1 and F2 if using a AG LINE permanent magnet motor
21. for load adjust CURR LIMIT trim pot CW See PWL Series Section 9 Accessories amp Replacement Parts Displays Closed Loop CLD100 1 Open Loop OLD100 1 Heat Sinks Chassis HSK 0001 Kits Potentiometer amp 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 CMC100 5 CMC100 20 Isolation Cards Unidirectional 8 outputs 1SO101 8 Bidirectional 1 output 1SO202 1 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 doe
22. 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 PWL Series Field Output Connections 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 PWL400 3 Approximate PWL400 5 Field Voltage PWL400 10 PWL440 3 Connections PWL400 15 PWL440 10 PWL440 10 JOG Connections F1 and L1 F and L1 F1 and F2 F and F F1 and L1 F and L1 F1 and F2 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 of
23. ilure 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 PWL Series Mounting Chassis e 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 eithe
24. itch Connection to Inhibit Plug 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 SPEED ADJUST POTENTIOMETER JOG PUSHBUTTON Figure 25 RUN JOG Switch Connection to Speed Adjust Potentiometer 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 cc S2 9 2 1 0202 1 1 Follower Drive TB502 S1 10K Ohm optional Figure 26 Leader Follower Application PWL Series Single Speed Potentiometer Control Of Multiple Drives Multiple drives can be controlled with a single speed adjust potentiometer using a 1SO101 8 at the input of each drive to provide isolation Figure 27 Optional ratio potentiometers can be used to scale the 1SO101 8 output voltage allowing independent cont
25. meters 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 multi position switch with the correct number of positions for the desired number of fixed speeds CW 5K OHM Figure 22 Adjustable Speeds Using Potentiometers In Series PWL Series Independent Adjustable Speeds Replace the speed adjust potentiometer with a single pole multi position 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 SPEED 2 SPEED 1 Figure 23 Independent Adjustable Speeds 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 JOG PUSHBUTTON RUN Se als INHIBIT JOG Figure 24 RUN JOG Sw
26. motor size Check motor cable and armature for shorts 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 Increase the speed adjust potentiometer setting or input voltage signal Remove the short from the INHIBIT terminals Verify that the motor is not jammed Increase CURR LIMIT setting if set too low See page Remove power Connect the motor to A1 and A2 Reapply PROBLEM Motor does not stop when the speed adjust potentiometer is full CCW Motor runs in the opposite direction Motor runs too Motor will i not reach the desired speed Motor pulsates i or surges under load MIN SPD is set too high Motor connections to A1 and A2 are reversed Motor field connections are loose shunt wound motors Motor bouncing in and out of current limit PWL Series SUGGESTED SOLUTIONS Calibrate MIN SPD See page 39 Remove power Reverse connections to A1 and A2 Reapply power Increase CURR LIMIT setting See page 39 Check motor load Resize the motor and drive if necessary Adjust the IR COMP setting slightly CCW until the motor speed stabilizes See page 40 Make sure motor is not undersized
27. o 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 e j jee Neh k DPEPPREI o R Figure 15 Inhibit Terminals 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 10K OHM SPEED ADJUST POTENTIOMETER DECEL TO MIN SPEED Figure 16 Run Decelerate to Minimum Speed Switch PWL Series Section 5 Calibration 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 p
28. r 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 PWL Series Speed Adjust Potentiometer 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 OOOOOO0OROOOOOOOOOMMOIMMMoOoOe OOCR Woo0ER OPEEODO0OOOI POOEQOUOEOER logoooolmoono POT TAB ASSIGNMENTS POOE Figure 7 Speed Adjust Potentiometer 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
29. rmal 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 PWL Series Shielding Guidelines 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 f
30. rol of each drive ratio pot A optional 10K Ohms 10K Ohms ratio pot B optional 10K Ohms 180101 8 ratio pot H optional 10K Ohms Figure 27 Single Speed Potentiometer Control of Multiple Drives 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 DYNAMIC RESISTOR INHIBIT Figure 28 Reversing Circuit Wiring PWL Series Section 7 Diagnostic LEDs PWL series drives are equipped with two diagnostic LEDs e Power POWER ON Green LED lights whenever AC line voltage is applied to the drive e Current Limit CURR LIMIT Red LED lights whenever the drive reaches current limit Current Limit Teletshe obbbhbb x 7711710 Power LED Figure 29 Diagnostic LED Locations PWL Series Section 8 Troubleshooting
31. rom power lines in the same manner as the logic I O on this drive 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 PWL440 10 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 PWL Series Table 1 Recommended Line Fuse Sizes 90 130 VDC 180 240 VDC Maximum DC AC Line Motor Motor Armature Current Fuse Size Horsepower Horsepower See Section 9 Accessories and Replacement Parts for fuse kit part numbers PWL Series Connections Do not connect this equipment with power applied Failure to heed this warning may result in fire explosion or serious
32. s 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 w
33. ure 24 Figure 25 PWL400 3 PWL400 5 and PWL400 10 Dimensions PWL400 15 Dimensions PWL440 3 Dimensions PWL440 10 Dimensions PWL400 10 JOG Dimensions HSK 0003 Dimensions Speed Adjust Potentiometer Cage Clamp Terminal Block PWL400 3 PWL400 5 and PWL400 10 Connections PWL400 15 Connections Analog Input Signal Connections PWL440 3 Connections PWL440 10 and PWL440 10 JOG Connections Select Switches Dynamic Brake Wiring Inhibit Terminals Run Decelerate to Minimum Speed Switch Recommended CURR LIMIT and IR COMP Settings for models PWL400 3 and PWL440 3 Recommended CURR LIMIT and IR COMP Settings for models PWL400 5 Recommended CURR LIMIT and IR COMP Settings for models PWL400 10 Recommended CURR LIMIT and IR COMP Settings for models PWL400 15 PWL440 10 and PWL440 10 JOG Multiple Fixed Speeds Adjustable Speeds Using Potentiometers In Series Independent Adjustable Speeds RUN JOG Switch Connection to Inhibit Plug PWL Series Figure 26 RUN JOG Switch Connection to Speed Adjust Potentiometer Figure 27 Leader Follower Application Figure 28 Single Speed Potentiometer Control of Multiple Drives Figure 29 Reversing Circuit Wiring Figure 30 Reversing with a CLD100 1 Figure 31 Diagnostic LED Locations PWL Series Section 1 Specifications Maximum HP Range HP Range Armature with 130 VDC with 240 VDC Current ADC Motor Enclosure PWL400 3 Chassis PWL440 3 NEMA 4X PWL400 5 Ch
34. vated Set the POWER switch to the OFF position to coast the motor to a stop PWL Series Starting and Stopping Methods 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 WARNING 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 PWL Series Dynamic Braking Wait for the motor to completely stop before switching back to RUN This will prevent high armature currents from damaging the motor or drive
35. ying Power Startup PWL400 3 PWL400 5 PWL400 10 and PWL400 15 PWL440 3 and PWL440 10 PWL Series PWL440 10 JOG Starting and Stopping Methods Line Starting and Stopping Dynamic Braking Inhibit Terminals Decelerating to Minimum Speed Section 5 Calibration Minimum Speed MIN SPD Maximum Speed MAX SPD og JOG PWL400 15 PWL440 10 and PWL440 10 JOG only Torque CURR LIMIT or TORQ LIMIT R Compensation IR COMP Acceleration ACCEL Deceleration DECEL Section 6 Application Notes Multiple Fixed Speeds Adjustable Speeds Using Potentiometers In Series ndependent Adjustable Speeds RUN JOG Switch Inhibit Connection RUN JOG Switch Potentiometer Connection Leader Follower Application a Single Speed Potentiometer Control Of Multiple Drives Reversing Section 7 Diagnostic LEDs Section 8 Troubleshooting Before Troubleshooting Section 9 Accessories amp Replacement Parts Unconditional Warranty PWL Series List of Tables Table 1 Recommended Line Fuse Sizes Table 2 Field Output Connections Table 3 Field Output Connections Table 4 Minimum Recommended Dynamic Brake Resistor Values 35 PWL Series List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure Figure Figure Figure Figure Figure Figure Figure Figure ON DU BWN FP OO Figure Figure 20 Figure 21 Figure 22 Figure 23 Fig
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