PWP Series - American Control Electronics
Contents
1. O O F 0 65 16 Y 3 80 97 4 30 109 2 15 55 gt 1 28 33 i eL I QO 0 97 25 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 2 PWP100 2 QDT Dimensions PWP Series 4 30 109 3 80 97 i 01915 0 73 19 1 35 34 1 03 26 DIMENSION A HEIGHT ALL DIMENSIONS IN INCHES MILLIMETERS Figure 3 PWP101 2 PWP101 5 and PWP101 10 Dimensions PWP Series 6 90 175 6 30 160 ____ lt _______ 5 90 150 _________ gt 112 3 00 76 Hi 4 e 3 00 100 oaen LAANE ALL DIMENSIONS IN INCHES MILLIMETERS Figure 4 HSK 0001 Dimensions PWP Series Section 3 Installlation 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 f Do not install rewire or remove this control with input2. 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 It is possible for a drive to run at full speed as a result of a AN 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 PWP Series Table of Contents Section 1 Specifications Suffix Definitions Section 2 Dimensions Section 3 Installation Mounting Heat Sinking Speed Adjust Potentiometer Wiring Shielding Guidelines Line Fusing Connections Section 4 Operation Before Applying Powe
3. 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 PWP Series SIGNAL ADJUST SIGNAL ADJUST pwe101 models only The SIGNAL ADJUST setting determines the maximum motor speed when the input voltage signal is set for maximum speed To calibrate SIGNAL ADJUST 1 Set the SIGNAL ADJUST trim pot full CCW 2 Set the input voltage signal for maximum speed 3 Adjust SIGNAL ADJUST until the desired maximum speed is reached PWP Series Torque CURRENT LIMIT CUR LIMIT or TORQUE 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 WARNING Fs CARING 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 Figure 15 on page 34 or use the following procedure With the power disconnected from the drive
4. Verify that the motor is not jammed Increase CURRENT LIMIT setting if set too low See Remove power Connect the motor to A1 and A2 Reapply PROBLEM Motor does not i 1 MIN SPD is set too high stop when the speed adjust potentiometer is full CCW Motor connections to A1 and A2 are reversed Motor runs in the opposite direction Motor runs too fast Motor will not reach the desired speed Motor pulsates or surges under load Motor bouncing in and out of current limit PWP Series SUGGESTED SOLUTIONS Calibrate MIN SPD See page 30 Remove power Reverse connections to A1 and A2 Reapply power Increase CURRENT LIMIT setting See page 32 Check motor load Resize the motor and drive if necessary Adjust the IR COMP setting slightly CCW until the motor speed stabilizes See page 33 Make sure motor is not undersized for load adjust CURRENT LIMIT trim pot CW See page 32 PWP 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 WaShel cccecccecsecseeeseeteeeteeeeeeeeeeaes KTP 0001 10K Pot Insulating Washer 7 Insulated Tab KTP 0005 8 Pin Terminal Block included with QDT drives KTP 0006 9 Insulated Tabs KTP 0011 Fuse 2 1 5 Amp 250 V 3AG Fast bl
5. 8 and 9 on pages 16 through 18 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 This assumes the inhibit is not active on the QDT option 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 PWP 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 13 on page 26 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 26 for recommended
6. PWP Series f CONNECT TO HEADER BLOCK j 10K OHM SPEED ADJUST MOTOR POTENTIOMETER ARMATURE Figure 8 PWP100 2 QDT Connections PWP Series Signal Reference Signal Common A 10K OHM SPEED ADJUST POTENTIOMETER SWITCH AC LINE VOLTAGE 120 VAC Figure 9 PWP101 2 PWP101 5 and PWP101 10 Connections PWP Series Analog Input Follower PWP100 models 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 10 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 1SO101 1 may be used to scale and isolate an analog input voltage An analog input voltage range of 0 10 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 SIGNAL COMMON S1 SIGNAL REFERENCE 52 ojll e Figure 10 PWP100 Analog Input Signal Connections PWP Series Analog Input Signal PWP101
7. 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 5 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 OOOOOO0OROOOOOOOOOmMoOIMMMoOoOe OOCR Woo0o0ER OPEEODOOOOI POOEQOUOEOER logoooolmoono POT TAB ASSIGNMENTS POOE Figure 5 Speed Adjust Potentiometer PWP 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 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 e Use 18 24 AWG wire for logic wiring Use 14 16 AWG wire for AC line and motor wiring Shielding Guidelines Under no circumstances should power an
8. 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 AMERICAN CONTROL Xa ELECTRONICS www americancontrolelectronics com e 14300 DE LA TOUR DRIVE SOUTH BELOIT IL 61080 e 815 624 6915 815 624 6965 fax e Document Number MAN 0008 Rev 0 March 2012 2011 AMERICAN CONTROL ELECTRONICS
9. AMERICAN CONTROL Xa ELECTRONICS PWP Series USER MANUAL PWP100 2 PWP100 2 QDT PWP100 5 PWP100 10 PWP101 2 PWP101 5 PWP101 10 www americancontrolelectronics com Dear Valued Consumer Congratulations on your purchase of the PWP 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 PWP 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
10. CW to stabilize the motor 5 Unload the motor See Figure 15 on page 34 for recommended IR COMP settings PWP Series MODELS PWP100 2 PWP100 2 QDT and PWP101 2 e CURR IRCOMI LIMIT e e IR COMP 1 6 HP 90 VDC 1 67 AMPS 1 10 HP 90 VDC 1 00 AMP 1 20 HP a e CURR LIMIT IR COMI e CURR LIMIT IR COMP le e CURR LIMIT IR COMP MODELS PWP100 5 and PWP101 5 e e e e CURR IR COMP LIMIT MODELS PWP100 10 and PWP101 10 IR COMP 1 2 HP 90 VDC 5 00 AMPS 1 4 HP 90 VDC 2 50 AMPS 1HP 90 VDC 10 0 AMPS 3 4 HP 90 VDC 7 50 AMPS CURR LIMIT e e IR COMI CURR LIMIT e e IR COMP 8 e CURR LIMIT e IRCOMP re CURR LIMIT e 8 CURR LIMIT IR COMP e CURR LIMIT IRCOMP 1 6 HP 130 VDC 1 15 AMPS 1 10 HP 130 VDC 0 70 AMPS 1 20 HP 130 VDC 0 35 AMPS 1 2 HP 130 VDC 3 50 AMPS 1 6 HP 130 VDC 1 15 AMPS Figure 15 Recommended CURRENT LIMIT and IR COMP Settings actual settings may vary with each application PWP Series Acceleration Deceleration ACCEL DECEL PWP100 xx models only The ACCEL DECEL setting determines the time the motor takes to ramp to a lower or higher speed See Specifications on page 1 for approximate acceleration and de
11. P Series PWP Series 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 7 on page 16 Motor ACE drives supply motor armature voltage from A A1 and A A2 terminals where A A1 is positive with respect to A A2 If the motor does not spin in the desired direction remove power and reverse the A A1 and A A2 connections Connect a DC motor to terminals A1 and A2 as shown in Figure 7 on page 16 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 3 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 7 on page 16 PWP Series 8 10K OHM camer SPEED ADJUST Lan POTENTIOMETER ACCEL MAX SPEED IRCOMP SWITCH AC LINE VOLTAGE 120 VAC Figure 7 PWP100 2 PWP100 5 and PWP100 10 Connections
12. P100 2 QDT Dimensions PWP101 2 PWP101 5 and PWP101 10 Dimensions HSK 0001 Dimensions Speed Adjust Potentiometer Quick Disconnect Terminal Block PWP100 2 PWP100 5 and PWP100 10 Connections PWP100 2 QDT Connections PWP101 2 PWP101 5 and PWP101 10 Connections PWP100 Analog Input Signal Connections PWP101 Analog Input Signal Connections Manual Signal Jumper Dynamic Brake Wiring Run Decelerate to Minimum Speed Switch Recommended CURRENT LIMIT and IR COMP Settings Multiple Fixed Speeds Adjustable Fixed Speeds Using Potentiometers In Series Independent Adjustable Speeds RUN JOG Switch Option 1 Connection to Inhibit RUN JOG Switch Option 2 Connection to Speed Adjust Potentiometer Leader Follower Application Single Speed Potentiometer Control Of Multiple Drives Reversing Circuit Wiring Reversing with a CLD100 1 PWP Series Section 1 Specifications Maximum HP Range Armature with 130 VDC Current ADC PWP100 2 Chassis PWP100 2 QDT Chassis PWP101 2 Chassis PWP100 5 Chassis PWP101 5 Chassis PWP100 10 Chassis PWP101 10 Chassis Heat sink kit part number HSK 0001 must be used when the continuous current output is over 5 amps AC Line Voltage 115 VAC 10 50 60 Hz single phase DC Armature Voltage 0 130 VDC Acceleration Time Range PWP100 models 0 5 6 seconds PWP101 models and PWP100 2 QDT 1 second Deceleration Time Range PWP100 models coast to a stop 6 seconds PWP101
13. POTENTIOMETER JOG PUSHBUTTON Figure 20 RUN JOG Switch Connection to Speed Adjust Potentiometer PWP Series Leader Follower Application In this application use a IS0101 1 to monitor the speed of the leader motor Figure 21 The 1SO101 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 1SO101 1 output voltage 00000 9 I on00go r Figure 21 Leader Follower Application PWP 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 22 Optional ratio potentiometers can be used to scale the 1SO101 8 output voltage allowing independent control of each drive ratio pot A optional 10K Ohms 10K Ohms ratio pot B optional 10K Ohms 1S0101 8 ratio pot H optional 10K Ohms Figure 22 Single Speed Potentiometer Control Of Multiple Drives PWP Series Reversing A dynamic brake may be used when reversing the motor direction Figure 23 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 s
14. 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 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 1 815 624 6915 or FAX 1 815 624 6965 PWP 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 motor size Check motor cable and armature for shorts 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 32 for information on adjusting the CURRENT LIMIT trim pot Increase the speed adjust potentiometer setting or input voltage signal Remove the short from the H1 and H2 terminals
15. celeration times ACCEL DECEL is factory set for the shortest acceleration deceleration time full CCW To set the acceleration deceleration 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 DECEL trim pot CW for a longer acceleration time or CCW for a faster acceleration time Repeat steps 1 through 2 until the acceleration time is correct PWP 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 16 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 16 Multiple Fixed Speeds PWP 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 17 Add a single pole multi position switch with the correct number of positions for the desired number of fixed speeds CW 5K OHM Figure 17 Adjustable Speeds Using Potentiometers In Series PWP Serie
16. connect a DC ammeter in series with the armature Set the CURRENT LIMIT trim pot to minimum full CCW Set the speed adjust potentiometer 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 CURRENT LIMIT trim pot CW until the armature current is 150 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 PWP 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 C
17. d 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 PWP 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 120 VAC or higher and 150 of maximum armature current Fuse HOT L1 only Table 1 on page 12 lists the recommended line fuse sizes Model PWP100 2 QDT is preinstalled with a 5 amp line fuse in fuse holde
18. dynamic brake resistor sizes PWP Series Table 2 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 13 Dynamic Brake Wiring PWP Series Inhibit Terminals QDT model only Short the inhibit terminals H1 and H2 S1 to coast the motor to minimum speed see Figure 8 on page 17 for inhibit wiring connection 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 PWP Series Decelerating to Minimum Speed The switch shown in Figure 14 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
19. e properly set PWP101 only PWP Series Select Jumpers Manual Signal Select SW501 PWP401 models only Place a jumper on the Manual Signal select SW501 to set the drive for manual input MAN or signal input SIG See Figure 12 for settings and location MEEA AAEN Jumper SW501 8 SPO MNSD TOUT Figure 12 Manual Signal Jumper PWP Series Startup Turn the speed adjust potentiometer full counterclockwise CCW or set the input voltage signal to minimum Apply AC line voltage 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 Remove AC line voltage from the drive to coast the motor to a stop PWP 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 Figures 7
20. hatsoever 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
21. models Instead of using a speed adjust potentiometer the drive may be wired to follow an analog input voltage signal that is either isolated or non isolated from earth ground Connect the signal common to NEG Connect the signal input to POS Refer to Figure 11 Make sure SW501 is jumpered for SIG mode Refer to Figure 12 on page 22 for switch jumper SW501 settings and location An analog input voltage range of 0 10 VDC is required to produce an armature voltage range of 0 130 VDC with 115 VAC line voltage 3 Hro Signal Reference 7 Signal Common tS st 6 2 i TE le lel fea elele MAKSD MSD TOLMAT Figure 11 PWP101 Analog Input Signal Connections PWP Series Section 4 Operation 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 WARNING 5 3 this drive If the motor or drive does not perform as described disconnect the AC line voltage immediately Refer to the Troubleshooting section page 45 for further assistance Before Applying Power 1 Verify that no foreign conductive material is present on the printed circuit board Ensure that all jumpers ar
22. models and PWP100 2 QDT coast to a stop Analog Input Range PWP100 models Signal must be isolated 1 to 2 PWP100 2 QDT Signal must be isolated S1 to 2 0 5 VDC PWP101 models Signal may be isolated or non isolated S1 to 2 0 10 VDC PWP Series Input Impedance S1 to 2 PWP100 models PWP100 2 QDT PWP101 models Suffix Definitions 10K ohms gt 100K ohms gt 2K ohms 0 5G maximum 0 50 Hz 0 1G maximum gt 50 Hz UL Recognized Component File 132235 CSA Certified Component File LR41380 QDT Basic Drive with Current Limit and Power LEDs Line Fuse Inhibit MIN SPD trim pot and Quick Disconnect Terminal less the Accel Decel trim pot PWP Series Section 2 Dimensions 4 30 109 3 80 97 R504 S amp t A ie CURRENT UMT 0 1915 acceu oa O Wz s IRCOMP e 6 0 73 19 MAX SPEED i 1 35 34 1 03 26 ALL DIMENSIONS IN INCHES MILLIMETERS Figure 1 PWP100 2 PWP100 5 and PWP100 10 Dimensions PWP Series 58 91 LEI H 1 75 44 0 74 19 Y 6d dd O O MAXSPD TORQUE P501 P502 MINSPD IR COMP 503 504
23. ow 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 Logic Cards Current Monitoring 20 Amps Isolation Uni directional 8 outputs 1SO101 8 Bi directional 1 output 1SO202 1 PWP 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 w
24. power Mounting 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 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 PWP Series Heat Sinking The PWP series drives PWP100 10 and PWP101 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 PWP Series Speed Adjust Potentiometer Be sure that the potentiometer tabs do
25. r Select Jumpers Manual Signal Header SW501 PWP401 models only Startup Starting and Stopping Methods Line Starting and Stopping Dynamic Braking Inhibit Terminals QDT model only Decelerating to Minimum Speed Section 5 Calibration Minimum Speed MIN SPD PWP101 QDT models only Maximum Speed MAX SPD Signal Adjust SIGNAL ADJUST PWP101 models only Torque CURRENT LIMIT CUR LIMIT or TORQUE IR Compensation IR COMP Acceleration Deceleration ACCEL DECEL PWP100 xx models Section 6 Application Notes Multiple Fixed Speeds Adjustable Speeds Using Potentiometers In Series Independent Adjustable Speeds PWP Series RUN JOG Switch Inhibit Connection QDT Models Run JOG Switch Potentiometer Connection Leader Follower Application Single Speed Potentiometer Control Of Multiple Drives Reversing Reversing with a CLD100 1 Controller Section 8 Troubleshooting Before Troubleshooting Section 9 Accessories amp Replacement Parts Unconditional Warranty List of Tables Table 1 Recommended Line Fuse Sizes Table 2 Minimum Recommended Dynamic Brake Resistor Values 26 PWP 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 20 Oo WAN DUN BPWN RP OO Figure 21 Figure 22 Figure 23 Figure 24 PWP100 2 PWP100 5 and PWP100 10 Dimensions PW
26. r FU501 PWP Series Table 1 Recommended Line Fuse Sizes 90 130 VDC Maximum DC AC Line Motor Armature Current Fuse Size Horsepower ACE offers fuse kits See Section 9 Accessories and Replacement parts on page 48 for fuse kit part numbers PWP Series Connections Do not connect this equipment with power applied Failure to AN 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 7 page 16 and Figure 8 page 17 The switch contacts should be rated at a minimum of 200 of motor nameplate current and 250 volts WARNING Quick Disconnect Terminal Block QDT Drives Only The quick disconnect terminal block found only on QDT drives is composed of a 8 pin header block and 8 screw terminal plug Figure 6 on page 14 To use the quick disconnect terminal block 1 Carefully pull terminal plug from header block 2 With a small flat head screwdriver turn terminal plug screw counterclockwise to open wire clamp Insert stripped wire into the large opening in front of the plug Turn the terminal plug screw clockwise to clamp the wire Repeat steps 2 4 for each terminal until all connections are made Insert plug into header until securely fastened ao a T o 2 Figure 6 Quick Disconnect Terminal Block Header Block mounted on the drive PW
27. s 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 18 shows the connection of two independent speed adjust potentiometers that can be mounted at two separate operating stations O SPEED 1 Figure 18 Independent Adjustable Speeds PWP Series RUN JOG Switch Inhibit Connection QDT models 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 19 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 a INHIBIT JOG Figure 19 RUN JOG Switch Connection to Inhibit PWP Series RUN JOG Switch Potentiometer Connection Connect the RUN JOG switch and the JOG pushbutton as shown in Figure 20 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
28. set speed at a rate determined by the ACCEL trim pot setting 10K OHM SPEED ADJUST POTENTIOMETER DECEL TO MIN SPEED Figure 14 Run Decelerate to Minimum Speed Switch PWP 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 PWP 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 PWP Series Minimum Speed MIN SPD PwP101 QDT models only 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
29. witching it to either the forward or reverse direction See the Dynamic Braking section on page 26 for recommended dynamic brake resistor sizes DYNAMIC BRAKE RESISTOR INHIBIT Figure 23 Reversing Circuit Wiring PWP 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 24 shows a wiring diagram of the reversing circuit using a PWP 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 ACE DRIVE Dynamic Brake Resistor J BRAKE REV CLD100 1 Inhibit Leads 1 Common Optical Signal Encoder 5 VDC Figure 24 Reversing with a CLD100 1 Magnetic Pickup PWP 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 serious 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
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