PAT SERIES - American Control Electronics
Contents
1. PAT Series Analog Input Signal PAT443 Instead of using a speed adjust potentiometer the drive may be wired to follow an analog input voltage or current signal that is either isolated or non isolated from earth ground Connect the signal common to S1 Connect the signal reference to S2 Refer to Figure 6 An analog input signal range of 0 10 VDC 1 5 mA 4 20 mA or 10 50 mA is required to produce an armature voltage range of 0 90 VDC with 115 VAC line voltage or 0 180 VDC with 230 VAC line voltage If using an analog input current signal range of 4 20 mA or 10 50 mA a resistor RSH must be placed between terminals 1 and 4 Refer to Figure 6 for resistor values IR COMP MIN SPD MAX SPD T501 RSH 1000 OHM for 4 20 mA RSH 250 OHM for 10 50 mA RSH NOT USED for 1 5 mA RSH NOT USED for 0 10V signal Use 1 4 Watt 5 Tolerance TERMINAL 2 TERMINAL 3 0 10V COMMON SPEED ADJUST SIGNAL INPUT Figure 6 Analog Input Signal Connections PAT443 PAT 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 tr2. 18 5 CONDUIT HOLES 2 PLACES 0 19 5 00 SLOTTED HOLES 4 PLACES BOTTOM PLATE 2 12 53 8 e e 2 20 55 9 3 40 86 4 JL ALL DIMENSIONS IN INCHES MILLIMETERS Figure 1 PAT440 10 Dimensions PAT Series 5 63 143 5 16 131 0 19 5 00 SLOTTED HOLES 7 AMERICAN 1 4 PLACES CONTROL Exi ELECTRONICS MANUAL SIGNAL 5 50 BOTTOM PLATE 0 73 18 5 CONDUIT HOLES 2 PLACES 2 12 53 8 220 55 9 3 40 86 4 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 2 PAT443 10 Dimensions PAT Series 5 63 143 5 16 131 0 19 5 00 SLOTTED HOLES Ni AMERICAN 4 PLACES CONTROL ELECTRONICS 5 50 BOTTOM PLATE 0 73 18 5 CONDUIT HOLES 22 2 PLACES 7 rhim ER 55 a 3 40 86 4 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 3 PAT450 10 Dimensions PAT Series Section 3 Installation 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
3. 5 00 AMPS 5 00 AMPS TQ LIMIT IR COMP TQ LIMIT IR COMP 1 4 HP 1 2 HP 2 50 AMPS 2 50 AMPS TQ LIMIT IR COMP TQLIMIT IR COMP Figure 11 Recommended TQ LIMIT and IR COMP Settings actual settings may vary with each application PAT Series Acceleration ACCEL The ACCEL setting determines the time the motor takes to ramp to a higher speed See Specifications on page 1 for approximate acceleration times ACCEL is factory set for the shortest acceleration time full CCW To set the acceleration time 1 Set the speed adjust potentiometer or input voltage signal for minimum speed The motor should run at minimum speed 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 If the time measured in step 2 is not the desired acceleration time turn the ACCEL trim pot CW for a longer acceleration time or CCW for a shorter acceleration time Repeat steps 1 through 2 until the acceleration time is correct Deceleration DECEL The DECEL setting determines the time the motor takes to ramp to a lower speed See Specifications on page 1 for approximate deceleration times DECEL is factory set for the shortest deceleration time full CCW To set the deceleration time 1 Set the speed adjust potentiometer or input voltage signal for maximum speed The motor should run at maximum speed Set the speed adjust potentiometer or i
4. 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 PAT Series Table of Contents Section 1 Specifications Section 2 Dimensions Shielding Guidelines Line Fusing Connections Field Output Connections Analog Input Signal PAT440 and PAT450 Analog Input Signal PAT443 Section 4 Operation Before Applying Power Select Switches Input Voltage Select SW501 Armature Voltage Select SW502 Operation Modes PAT443 Manual Mode Signal Mode Startup PAT440 PAT450 PA
5. understand the Safety Precautions on page i before attempting to install this product Mounting NEMA 4X cased drives come with two 0 73 inch 18 5 mm conduit knockout holes at the bottom of the case The units may be vertically wall mounted using the four 0 19 inch 5 mm slotted holes on the attached heat sink For motor loads less than 5 ADC the drive may be bench mounted horizontally or operated without mounting Install the mounting screws For access to the terminal strip remove the six phillips screws on the front cover Remove the five phillips screws on the bottom plate Do not remove the three screws securing the bottom plate to the heat sink Set the POWER switch to the off position before applying applying AC line voltage Install conduit hardware through the 0 73 inch 18 5 mm knockout holes Connect external wiring to the terminal block Place the front cover back into place Avoid pinching any wires between the front cover and the heat sink Reinstall the 6 screws on the front cover The two shorter screws are for the two lower holes of the front cover Reinstall the 5 screws on the bottom plate PAT 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 printe
6. voltage of the motor Signal Mode In Signal Mode the drive follows an analog input signal of either 0 10 VDC 1 5 mA 4 20 mA or 10 50 mA for adjust the speed voltage of the motor PAT Series Startup PAT440 Turn the speed adjust potentiometer to O 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 Set the POWER switch to the OFF position to coast the motor to a stop PAT443 1 Turn the speed adjust potentiometer to 0 full CCW or set the input voltage signal to minimum If using a speed adjust potentiometer set the MANUAL SIGNAL switch to MANUAL If using a input voltage or current signal set it to SIGNAL Set the POWER switch to the ON position If in manual mode slowly advance the speed adjust potentiometer clockwise CW If is signal mode increase the input voltage or current signal The motor slowly accelerates as the potentiometer is turned CW or as the input voltage or current signal is increased Continue until the desired speed is reached Set the POWER switch to the OFF position to coast the motor to a stop PAT Series PAT450 Do not change direction while the motor is runni
7. 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 150202 1 output voltage cc 9 2 52 1S0202 1 Q1 Follower Drive TB502 51 10K Ohm optional Figure 17 Leader Follower Application PAT Series Single Speed Potentiometer Control Of Multiple Drives Multiple drives can be controlled with a single speed adjust potentiometer using a 150101 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 ratio pot A optional 10K Ohms 10K Ohms ratio pot B optional 10K Ohms 180101 8 ratio pot H optional 10K Ohms Figure 18 Single Speed Potentiometer Control of Multiple Drives PAT Series Reversing A dynamic brake may be used when reversing the motor direction Figure 19 Use a three pole three position switch rated for at least the maximum DC armature voltage and maximum braking current Wait for the motor to stop completely before switching it to either the forward or reverse direction See the Dynamic braking section on page 22 for recommended dynamic brake resistor sizes NOTE Model PAT450 10 is equipped w
8. AMERICAN CONTROL ELECTRONICS PAT SERIES USER MANUAL PAT440 10 PAT443 10 PAT450 10 www americancontrolelectronics com Dear Valued Consumer Congratulations on your purchase of the PAT Series drive This User Manual was created for you to get the most out of your new device and assist with the initial setup Please visit www americancontrolelectronics com to learn more about our other drives Thank you for choosing American Control Electronics No part of this document may be reproduced or transmitted in any form without written permission from American Control Electronics The information and technical data in this document are subject to change without notice American Control Electronics makes no warranty of any kind with respect to this material including but not limited to the implied warranties of its merchantability and fitness for a given purpose American Control Electronics assumes no responsibility for any errors that may appear in this document and makes no commitment to update or to keep current the information in this document PAT Series Safety First SAFETY WARNINGS 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
9. MIT setting if set too low Remove power Connect the motor to A1 and A2 Reapply power PROBLEM Motor does not i 1 MIN SPD is set too high i stop when the speed adjust i potentiometer 1 is full CCW Motor connections to A1 and A2 are reversed Motor runs in i the opposite direction Motor runs too fast Motor will i not reach the desired speed Motor pulsates or surges under Motor bouncing in and out of current limit PAT Series SUGGESTED SOLUTIONS Calibrate MIN SPD Remove power Reverse connections to A1 and A2 Reapply power Check motor load Resize the motor and drive if necessary Adjust the IR COMP setting slightly CCW until the motor speed stabilizes Make sure motor is not undersized for load adjust TQ LIMIT trim pot CW PAT Series Section 9 Accessories amp Replacement Parts Displays Closed Loop CLD100 1 Open Loop OLD100 1 Kits Fuse 2 1 5 Amp 250V 3AG Fast blow Glass Fuses KTF 0001 2 3 Amp 250V 3AG Fast blow Glass Fuses KTF 0002 2 5 Amp 250V Fast blow Glass Fuses KTF 0003 2 8 Amp 250V 3AG Fast blow Glass Fuses KTF 0004 2 10 Amp 250V 3AB Normal blow Ceramic Fuses KTF 0005 2 15 Amp 250V 3AB Normal blow Ceramic Fuses KTF 0006 Wiring Inhibit Plug 18 in leads KTW 0001 Inhibit Plug 36 in leads KTW 0002 Logic Cards Current Sensing CMC100 5 CMC100 20 Isolation Cards Unid
10. 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 PAT 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 Dynamic braking may be used to rapidly stop a motor Figure 8 on page 22 For the RUN BRAKE switch use a two pole two position switch rated for at least the armature voltage rating and 15096 of the armature current rating For the dynamic brake resistor use a 40 watt minimum high power wirewound resistor Sizing the dynamic brake resistor depends on load inertia motor voltage and braking time Use a lower value higher wattage dynamic brake resistor to stop a motor more rapidly Refer to Table 4 on page 22 for recommended dynamic brake resistor sizes PAT Series Table 4 Minimum Recommended Dynamic Brake Resistor Values 15 ohms 180 VDC 30 ohms For motors rated 1 17 horsepower and lower a brake resistor is not necessary since the armature resistance
11. T443 ET Starting and Stopping Methods Line Starting and Stopping Dynamic Braking Inhibit Terminals Decelerating to Minimum Speed PAT Series Section 5 Calibration Minimum Speed MIN SPD Maximum Speed MAX SPD Torque TQ 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 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 PAT Series List of Tables Table 1 Recommended Line Fuse Sizes Table 2 Short Circuit Current Ratings Table 3 Field Output Connections Table 4 Minimum Recommended Dynamic Brake Resistor Values 22 PAT 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 Figure Figure 2 7 8 9 0 440 Dimensions PAT443 Dimensions PAT450 Dimensions Power Connections Analog Input Signal Connections PAT440 and PAT450 Analog Input Signal Connections PAT443 Select Switches Dynamic Braking Inhibit Term
12. ansformer If the switches are improperly set to a higher voltage position the motor will overspeed which may cause motor damage or result in bodily injury or loss of life Dangerous voltages exist on the drive when it is powered BE ALERT High voltages can cause serious or fatal injury For your safety use personal protective equipment PPE when operating this drive If the motor or drive does not perform as described disconnect the AC line voltage immediately Refer to the Troubleshooting section page 40 for further assistance Before Applying Power 1 Verify that no foreign conductive material is present on the printed circuit board Ensure that all switches are properly set PAT Series Select Switches Input Voltage Select SW501 Set the input voltage select switch SW501 to either 115 or 230 to match the AC line voltage See Figure 7 Armature Voltage Select SW502 Set the armature voltage select switch SW502 to either 90 or 180 to match the maximum armature voltage See Figure 7 CST icso2 amp TouMT Armature Voltage Select SW502 Input Voltage Select S3 5251 95 180 SWS02 INHIBIT 90 501 ET erede Movsos Figure 7 Select Switches Operation Modes PAT443 Manual Mode In Manual Mode the potentiometer adjusts the speed
13. d 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 PAT 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 sh
14. elerates 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 10 Run Decelerate to Minimum Speed Switch PAT 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 personal protection equipment BE ALERT High voltages can cause serious or fatal injury WARNING PAT series drives have user adjustable trim pots Each drive is factory calibrated to its maximum current rating Readjust the calibration trim pot settings to accommodate lower current rated motors All adjustments increase with CW rotation and decrease with CCW rotation Use a non metallic screwdriver for calibration Each trim pot is identified on the printed circuit board PAT Series Minimum Speed MIN SPD The MIN SPD setting determines the minimum motor speed when the speed adjust potentiometer or input voltage signal is set for minimum speed It is factory set for zero speed To calibrate the MIN SPD Set the MIN SPD trim pot full CCW Set the speed adjust pot
15. entiometer 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 PAT Series Torque TQ LIMIT TQ LIMIT should be set to 150 of motor nameplate current rating Continuous operation beyond this rating may damage the motor If you intend to operate beyond the rating contact your American Control Electronics representative for assistance The TQ LIMIT setting determines the maximum torque for accelerating and driving the motor To calibrate TORQUE refer to the recommended TQ LIMIT settings in Figure 11 on page 29 or use the following procedure With the power disconnected from the drive connect a DC ammeter in series with the armature Set the TQ 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
16. ield 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 PAT Series Line Fusing Drives are preinstalled with 15 amp fuses Preinstalled line fuses are rated for maximum horsepower If the horsepower rating of the motor being used is less than the maximum horsepower rating of the drive the line fuse may have to be replaced with a lower rated one Fuses should be rated for 250 VAC or higher and approximately 15096 of the maximum armature current Refer to Table 1 to install a lower rated fuse Table 1 Recommended Line Fuse Sizes 180 VDC Maximum DC AC Line Motor Armature Current Fuse Size Horsepower See Section 10 Accessories and Replacement Parts for fuse kit part numbers PAT Series Short circuit current rating SCCR is the maximum short circuit current that the speed control can safely withstand when protected by a specific over current protective device s WARNING Table 2 Short Circuit Current Ratings Short Circuit Current Rating Maximum Dive Model Types of Branch Rating of rive Mode i i Maximum Maximum Circuit Protec
17. inals Run Decelerate to Minimum Speed Switch Recommended TORQUE and IR COMP Settings Multiple Fixed Speeds Adjustable Speeds Using Potentiometers in Series Independent Adjustable Speeds RUN JOG Switch Connection to Inhibit Plug RUN JOG Switch Connection to Speed Adjust Potentiometer Leader Follower Application vu Single Speed Potentiometer Control of Multiple Drives Reversing Circuit Wiring Diagnostic LED Locations PAT Series Section 1 Specifications Maximum HP Range HP Range Armature with 90 VDC with 180 VDC Current ADC Motor Enclosure PAT440 NEMA 4X PAT443 NEMA 4X PAT450 NEMA 4X DC Armature Voltage with 115 VAC Line Voltage with 230 VAC Line Voltage 0 180 VDC Field Voltage with 115 VAC Line Voltage 50 VDC F1 to L1 100 VDC F1 to F2 with 230 VAC Line Voltage 100 VDC F1 to L1 200 VDC F1 to F2 Acceleration Time Range 1 15 seconds Deceleration Time Range coast to a stop 15 seconds Analog Input Range PAT440 and PAT450 signal must be isolated S1 to S2 with 115 VAC Line Voltage with 230 VAC Line Voltage 0 2 8 VDC PAT443 2 to 3 Voltage Signal Range 0 10 VDC Current Signal Range 1 5 4 20 10 50mA Input Impedance S1 to S2 gt 100K ohms Load Regulation Speed Range PAT Series 1G maximum 0 50 Hz 0 16 maximum gt 50 Hz PAT Series Section 2 Dimensions 5 63 143 5 16 131 5 50 AMERICAN d CONTROL EXA ELECTRONICS 0 73
18. irectional 8 outputs 150101 8 Bidirectional 1 output 150202 1 PAT Series Unconditional Warranty A Warranty American Control Electronics warrants that its products will be free from defects in workmanship and material for twelve 12 months or 3000 hours whichever comes first from date of manufacture thereof Within this warranty period American Control Electronics will repair or replace at its sole discretion such products that are returned to American Control Electronics 14300 De La Tour Drive South Beloit Illinois 61080 USA This warranty applies only to standard catalog products and does not apply to specials Any returns of special controls will be evaluated on a case by case basis American Control Electronics is not responsible for removal installation or any other incidental expenses incurred in shipping the product to and from the repair point B Disclaimer The provisions of Paragraph A are American Control Electronics s sole obligation and exclude all other warranties of merchantability for use expressed or implied American Control Electronics further disclaims any responsibility whatsoever to the customer or to any other person for injury to the person or damage or loss of property of value caused by any product that has been subject to misuse negligence or accident or misapplied or modified by unauthorized persons or improperly installed C Limitations of Liability In the event of any claim for b
19. is firmly mounted Apply line power The motor should be stopped Slowly adjust the TQ LIMIT trim pot CW until the armature current is 15096 of motor rated armature current 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 PAT Series IR Compensation IR COMP The IR COMP setting determines the degree to which motor speed is held constant as the motor load changes Use the following procedure to recalibrate the IR COMP setting 1 Set the IR COMP trim pot to minimum full CCW 2 Increase the speed adjust potentiometer or input voltage signal until the motor runs at midspeed without load for example 900 RPM for an 1800 RPM motor A handheld tachometer may be used to measure motor speed 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 Figure 11 on page 29 for recommended IR COMP settings PAT Series MODELS PAT440 10 PAT443 10 PAT450 10 1HP 2HP 10 0 AMPS 10 0 AMPS TQ LIMIT IR COMP TQ LIMIT IR COMP 1 2 HP 1HP
20. is high enough to stop the motor without demagnetization Replace the dynamic brake with 12 gauge wire INHIBIT Figure 8 Dynamic Braking PAT Series Inhibit Terminals Short the INHIBIT terminals to coast the motor to minimum speed see Figure 9 for INHIBIT terminal location Open the INHIBIT terminals to accelerate the motor to set speed Twist inhibit wires and separate them from power carrying wires or sources of electrical noise Use shielded cable if the inhibit wires are longer than 18 inches 46 cm If shielded cable is used ground only one end of the shield to earth ground Do not ground both ends of the shield American Control Electronics offers two accessory plug harnesses for connecting to the INHIBIT terminals part number 201 0024 plug with 18 in 46 cm leads and part number 201 0079 plug with 36 in 91 cm leads i Inhibit d Terminals a M Figure 9 Inhibit Terminals PAT Series Decelerating to Minimum Speed The switch shown in Figure 10 may be used to decelerate a motor to a minimum speed Closing the switch between S1 and S2 decelerates the motor from set speed to a minimum speed determined by the MIN SPD trim pot setting If the MIN SPD trim pot is set full CCW the motor dec
21. ith the reversing feature but not the dynamic brake feature DYNAMIC BRAKE RESISTOR INHIBIT Figure 19 Reversing Circuit Wiring PAT Series Section 7 Diagnostic LEDs PAT series drives are equipped with two diagnostic LEDs Green LED lights whenever AC line voltage is e Power POWER applied to the drive Current Limit TQ LIMIT Red LED lights whenever the drive reaches current limit Ve CURRENT e T gu xm Power LED eje E mcow wwseo waxspo 8 MOVSO1 0 2 FRMSW 11 A2 TOSW A1 Li 2 FRMSW Ai A1 A 1 F2 L215 L2230 11 A2 Figure 20 Diagnostic LED Locations PAT Series Section 8 Troubleshooting Dangerous voltages exist on the drive when it is powered When possible disconnect the drive while troubleshooting High voltages can cause seroius or fatal injury Before Troubleshooting Perform the following steps before starting any procedure in this section 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 con
22. nection 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 is consistent with the motor ratings For additional assistance contact your local American Control Electronics distributor or the factory direct 844 AMCNTRL or FAX 800 394 6334 PAT Series PROBLEM Line fuse blows Line fuse does i 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 or current 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 motor size Check motor cable and armature for shorts Add a blower to cool the drive components decrease TQ LIMIT settings resize motor and drive for actual load demand or check for incorrectly aligned mechanical components or jams See page 27 for information on adjusting the TQ LIMIT trim Increase the speed adjust potentiometer setting or input voltage or current signal Remove the short from the INHIBIT terminals Verify that the motor is not jammed Increase TQ LI
23. ng The motor must come to a complete stop before reversing Changing motor direction before allowing the motor to completely stop will cause excessively high current to flow in the armature circuit and will damage the drive and or motor Set the FWD OFF REV switch to the OFF position Turn the speed adjust potentiometer to O full CCW or set the input voltage signal to minimum Set the FWD OFF REV switch to the desired direction of rotation 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 reverse direction a Set the FWD OFF REV switch to the OFF position b Wait for the motor to come to a complete stop c Set the FWD OFF REV switch to the desired direction of rotation PAT 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 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
24. nput 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 PAT Series Section 6 Application Notes Multiple Fixed Speeds Replace the speed adjust potentiometer with a series of resistors with a total series resistance of 10K ohms Figure 12 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds R1 R2 TOTAL SERIES RESISTANCE R3 10K OHMS R4 Figure 12 Multiple Fixed Speeds PAT Series Adjustable Speeds Using Potentiometers In Series Replace the speed adjust potentiometer with a series of resistors with a total series resistance of 10K ohms Figure 13 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds CW 5K OHM Figure 13 Adjustable Speeds Using Potentiometers In Series PAT 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 14 shows the connection of two independent speed adjust potentiometers that can be mou
25. nted at two separate operating stations Figure 14 Independent Adjustable Speeds PAT Series RUN JOG Switch Inhibit Connection Using a RUN JOG switch is recommended in applications where quick stopping is not needed and frequent jogging is required Use a single pole two position switch for the RUN JOG switch and a single pole normally closed momentary operated pushbutton for the JOG pushbutton Connect the RUN JOG switch and JOG pushbutton to the inhibit plug as shown in Figure 15 The motor coasts to a stop when the RUN JOG switch is set to JOG Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation JOG PUSHBUTTON RUN 6 INHIBIT JOG Figure 15 RUN JOG Switch Connection to Inhibit Plug PAT Series RUN JOG Switch Potentiometer Connection Connect the RUN JOG switch and the JOG pushbutton as shown in Figure 16 When the RUN JOG switch is set to JOG the motor decelerates to minimum speed minimum speed is determined by the MIN SPD trim pot setting Press the JOG pushbutton to jog the motor Return the RUN JOG switch to RUN for normal operation 10K OHM SPEED ADJUST POTENTIOMETER RUN I JOG JOG PUSHBUTTON Figure 16 RUN JOG Switch Connection to Speed Adjust Potentiometer PAT Series Leader Follower Application In this application use a PCM4 to monitor the speed of the leader motor Figure 17 The ISO202
26. reach 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 ca
27. tage VDC Field To F1 and L1 F1 and F2 F1 and L1 F1 and F2 PAT Series MOV501 L2 FRMSW L1 A2 TOSW A1 L2 TOSW L1 2 FRMSW A1 00 DOO 115 EARTH GROUND FIELD LINE VOLTAGE INPUT MOTOR GREEN SCREW OUTPUT 115 or 230 VAC ARMATURE NOTE DO NOT make any connections to F1 and F2 if using a permanent magnet motor Figure 4 Power Connections PAT Series Analog Input Signal PAT440 and PAT450 Instead of using a speed adjust potentiometer the drive may be wired to follow an analog input voltage signal that is isolated from earth ground Figure 5 Connect the signal common to S1 Connect the signal reference to S2 Make no connection to S3 A potentiometer can be used to scale the analog input voltage An interface device such as American Control Electronics model 150202 1 may be used to scale and isolate an analog input voltage With 115 VAC line voltage an analog input voltage range of 0 1 4 VDC is required to produce an armature voltage range of 0 90 VDC With 230 VAC line voltage an analog input voltage range of 0 2 8 VDC is required to produce an armature voltage range of 0 180 VDC 1c507 Oq csi VY CURRENT i FS 51 siGNAL COMMON 52 05 SIGNAL REFERENCE mcow B amp lo o Figure 5 Analog Input Signal Connections PAT440 and PAT450
28. tion Overcurrent Current A Voltage V Protection 10 10 Inverse Time 10 10 10 000 240V Circuit PAT450 10 Breaker PAT Series Connections AN Do not connect this equipment with power applied Failure to heed this warning may result in fire explosion or serious injury Power Input Connect the AC line power leads to screw terminals L1 and L2 115 if using a 115 VAC line or to terminals L1 and L2 230 if using a 230 VAC line Refer to Figure 4 on page 13 Motor Drives supply motor armature voltage from A1 and A2 terminals It is assumed throughout this manual that when A1 is positive with respect to A2 the motor will rotate clockwise CW while looking at the output shaft protruding from the front of the motor If the motor does not spin in the desired direction remove power and reverse the A1 and A2 connections Connect a DC motor to terminals A1 and A2 as shown in Figure 4 on page 13 Ensure that the motor voltage rating is consistent with the drive s output voltage PAT Series Field Output Connections The field output is for shunt wound motors only Do not make any connections to F1 and F2 when using a permanent magnet motor WARNING See Table 3 for field output connections Use 18 AWG wire to connect the field output to a shunt wound motor Table 3 Field Output Connections Approximate Field Connect Motor Line Voltage VAC Vol
29. use of such action arises Rem mem Eo IM PAT440 10 PAT443 10 PAT450 10 TM AMERICAN CONTROL ELECTRONICS www americancontrolelectronics com 14300 DE LA TOUR DRIVE SOUTH BELOIT IL 61080 844 AMCNTRL MAN 0005 Rev 1
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