USER’S MANUAL
M1740009.OO
Pulse-Width Modulated,
Adjustable Speed Drives
for DC Brush Motors
All rights reserved. No part of this manual may be reproduced or transmitted in any
form without written permission from Leeson Corporation. The information and
technical data in this manual are subject to change without notice. Leeson
Corporation 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. Leeson Corporation 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.
Printed in the United States of America.
Copyright 1997 by
Leeson Corporation
m Safety Warnings
• Throughout this manual, this symbol m denotes an important
safety message. Please read these sections very carefully
before performing any of the instructions contained in this
manual.
• Have a qualified electrical maintenance 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
proper grounding, 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
component failure. In order to stop the drive in an emergency,
please ensure that a master switch has been placed in the AC
power line.
• This drive is not isolated from earth ground. Circuit
potentials are at 115 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 nonmetallic screwdriver for adjusting the calibration trimpots.
ii
Contents
Specifications 1
Dimensions 2
Installation 3
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Line fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Speed adjust potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Quick-connect terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Voltage follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Operation 10
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Inhibit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Dynamic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Calibration 14
MIN SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
MAX SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
IR COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Contents
iii
Application Notes 17
Multiple fixed speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Adjustable speeds using potentiometers in series . . . . . . . . . . . . . . . . . . .18
Independent adjustable speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
RUN/JOG switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Troubleshooting 22
Block Diagrams 25
Limited Warranty inside back cover
Index of Illustrations
Fig. Description Page
1. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2. Fuseholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4. Quick-Connect Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5. Drive Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6. Voltage Follower Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
7. Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
8. Inhibit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
9. Dynamic Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
10. Typicqal TORQUE and IR COMP settings . . . . . . . . . . . . . . . . . . . . . . . . .16
11. Multiple Fixed Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
12. Adjustable Fixed Speeds Using Potentiometers In Series . . . . . . . . . . . . .18
13. Independent Adjustable Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
14. RUN/JOG Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
15. Reversing Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
16. Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
17. Input Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Specifications
Model M1740009.OO
AC Line Voltage 115 VAC, ±10%, 50/60 Hz, single phase
Horsepower Range (with 130 VDC motors) 1/20 – 1/3 HP
Armature Voltage 0 – 130 VDC
Maximum Continuous Armature Current 2 ADC
Form Factor (at base speed) 1.05
Acceleration Time (with load) 1 second
Deceleration Time (with load) 2 seconds
1
Analog Input Voltage Range (isolated; S1 to S2) 0 – 5 VDC
Input Impedance (S1 to S2) > 100K ohms
Speed Regulation 1% of base speed or better
Ambient Temperature Range 10°C–40°C
Weight 0.6 lb
2
Dimensions
Figure 1. M1740009.OO Dimensions
Installation
Mounting
Drive components are sensitive to electrostatic fields. Avoid
•
direct contact with the circuit board. Hold drive by the chassis
only.
Protect the drive from dirt, moisture, and accidental contact.
•
Provide sufficient room for access to the terminal block and
3
calibration trimpots.
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 drive with its board in either a horizontal or vertical
•
plane. Six 0.19 in. (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 must be earth grounded. Use a star washer beneath
•
the head of at least one of the mounting screws to penetrate the
anodized chassis surface and reach bare metal.
4
Installation
Wiring
• Use 18 AWG wire for speed adjust potentiometer wiring. Use
16 AWG wire for motor and AC line voltage wiring.
• Twist logic wires (for speed adjust potentiometer and inhibit) to
avoid picking up unwanted electrical noise. Use shielded cable
if wires are longer than 18 in. (46 cm).
• Keep logic wires away from power carrying lines or sources
of electrical noise that can cause erratic operation. Never run
speed adjust potentiometer or inhibit wires in the same conduit
as the motor and AC line voltage wires.
• 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.
Line fuse
The M1740009.OO drive is protected by a 5 A, 250 V
AC line fuses. The fuse does not have to be resized as long as the
motor used is within the drive’s specified horsepower range.
The fuse is mounted in the fuseholder (see Figure 2). To
replace a blown fuse, use a screwdriver to turn the fuseholder
knob counterclockwise. Remove the blown fuse and replace with
a new fuse.
Installation
5
Figure 2. Fuseholder
6
Installation
Speed adjust potentiometer
Mount the speed adjust potentiometer through a 0.38 in. (10 mm)
hole with the hardware provided (Figure 3). Install the circular
insulating disk between the panel and the 10K ohm speed adjust
potentiometer. Twist the speed adjust potentiometer wire to avoid
picking up unwanted electrical noise. If potentiometer leads are
longer than 18 in. (457 mm), use shielded cable (see Wiring
section).
m Warning
Be sure that the potentiometer tabs do not make contact with the
potentiometer enclosure. Grounding the input will cause damage
to the drive.
Figure 3. Speed Adjust Potentiometer
Quick-connect terminal block
The quick-connect terminal block has an 8-pin header block
and 8-screw terminal plug (Figure 4). To use the quick-connect
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.
3. Insert stripped wire into the large opening in front of the plug.
Installation
7
4. Turn the terminal plug screw clockwise to clamp the wire.
5. Repeat steps 2–4 for each terminal until all connections are
made.
6. Insert plug into header until securely fastened.
Figure 4. Quick-Connect Terminal Block
8
Installation
Connections
Figure 5. Drive Connections
ASSUMPTIONS: This drive series supplies motor voltage from
its 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 this is opposite of the desired rotation,
simply reverse the wiring to the motor from A1 and A2.
Voltage follower
Instead of using a speed adjust potentiometer, the drive may be
wired to follow a 0–5 VDC voltage signal that is isolated from
earth ground (Figure 6). Connect the signal input (+) to S2.
Connect the signal common (–) to S1. Make no connection to S3.
A potentiometer can be used to scale the analog input voltage.
Installation
9
Figure 6. Voltage Follower Connections
10
Operation
Startup
Note: Before applying power, verify that no conductive material
is placed on the printed circuit board.
To start the drive:
1. Turn the speed adjust potentiometer full counterclockwise
(CCW). If the drive is following a voltage signal, set the
voltage signal to 0 VDC.
2. Apply power.
3. Slowly advance the speed adjust potentiometer clockwise
(CW). If the drive is following a voltage signal, slowly increase
the voltage signal. The motor will slowly accelerate as the
speed adjust potentiometer is turned CW, or the voltage signal
is increased. Increase the signal until the desired speed is
reached.
4. Remove power from the drive. The motor will coast to a stop.
If the motor or drive does not perform as described, disconnect
the AC line voltage immediately. Refer to the Troubleshooting
section, page 27, for further assistance.
Diagnostic LEDs
This drive is equipped with two diagnostic LEDs: power status
(PWR) and current limit mode (CUR LIM). See Figure 7 for
LED location.
POWER (PWR): Green LED lights whenever AC line voltage
is applied to the drive.
CURRENT LIMIT (CUR LIM): Red LED lights whenever the
drive reaches current limit.
Operation
11
Figure 7. Diagnostic LEDs
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. When AC line voltage is removed, the motor
coasts to a stop.
12
Operation
Inhibit switch
An inhibit switch allows the motor to decelerate to zero speed
when the switch is closed. Connect a single pole, single throw
switch between H1 and H2 (see Figure 8). Close the switch to
decelerate the motor to zero speed. Open the switch to accelerate
the motor to set speed. An open-collector output rated for at least
10 mA (I
) may also be used as an inhibit switch. Wire the
CE
collector to H1, and the emitter to H2.
Figure 8. Inhibit Switch
Dynamic braking
Dynamic braking may be used to rapidly stop a motor
(Figure 9). For the RUN/BRAKE switch, use a double pole,
double throw switch rated for at least the maximum DC armature
voltage and maximum braking current.
Operation
13
Figure 9. Dynamic Brake Connection
A 1 Ω, 1 W resistor is used as the dynamic brake resistor. For
motors rated
1
/
horsepower and lower, a dynamic brake resistor
17
is not necessary since the armature resistance is high enough to
stop the motor without demagnetization. In this case, replace the
dynamic brake resistor with 12 gauge wire.
m Warning
Wait for the motor to completely stop before switching it back
to RUN. This will prevent high armature currents from
damaging the motor or drive.
14
Calibration
Each drive is factory calibrated to its maximum horsepower
rating. Readjust the calibration trimpot settings to accommodate
lower horsepower motors.
All adjustments increase with CW rotation, and decrease with
CCW rotation. Use a non-metallic screwdriver for calibration.
Each trimpot is identified on the printed circuit board.
MINIMUM SPEED (MIN SPD)
The MIN SPD setting determines the motor speed when the speed
adjust potentiometer is turned full CCW. It is factory set for zero
speed.
To calibrate turn the speed adjust potentiometer full CCW. Adjust
the MIN SPD trimpot until the motor has stopped, or is running at
the desired minimum speed.
MAXIMUM SPEED (MAX SPD)
The MAX SPD setting determines the motor speed when the
speed adjust potentiometer is turned full CW. It is factory set for
maximum rated speed.
To calibrate, set the MAX SPD trimpot full CCW. Turn the speed
adjust potentiometer full CW. Adjust the MAX SPD trimpot until
the desired maximum motor 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.
REGULATION (IR COMP)
The IR COMP setting determines the degree to which motor
speed is held constant as the motor load changes. It is factory
calibrated for a 1/8 HP, 90 VDC motor.
Recalibrate the IR COMP setting when using a lower
horsepower motor . Refer to the recommended IRCOMP settings in
Calibration
15
Figure 10, or recalibrate using the following procedure:
If the motor does not maintain set speed as the load changes,
gradually rotate the IR COMP trimpot CW. If the motor oscillates
(overcompensation), the IR COMP trimpot may be set too high
(CW). Turn the IR COMP trimpot CCW to stabilize the drive.
TORQUE
The TORQUE setting determines the maximum armature current
output of the drive. It is factory calibrated for a 1/8 HP, 90 VDC
motor.
Recalibrate the TORQUE setting when using a lower
horsepower motor . Refer to the recommended T ORQUE settings in
Figure 10, or recalibrate using the following procedure:
16
Calibration
1. With the power disconnected from the control, connect a DC
ammeter (0–15 A minimum scale) in series with the armature.
2. Set the TORQUE trimpot to minimum (full CCW).
3. Connect power to the drive. The motor should remain stopped.
4. Lock the motor armature. Be sure that the motor is firmly
mounted.
5. Set the speed adjust potentiometer to maximum (full CW).
6. Adjust the TORQUE trimpot CW slowly until the armature
current is 120% of motor rated armature current.
7. Set the speed adjust potentiometer to minimum and remove the
stall from the motor.
*
Factory Setting
*
Figure 10. Typical TORQUE and IR COMP Settings
(actual settings may vary with each application)
Application Notes
Multiple fixed speeds
Replace the speed adjust potentiometer with series resistors
with a total series resistance of 10K ohms (Figure 11). Add a
single pole, multi-position switch with the correct number of
positions for the desired number of fixed speeds.
17
Figure 11. Multiple Fixed Speeds
18
Application Notes
Adjustable speeds using potentiometers in
series
Replace the speed adjust potentiometer with a single pole,
multi-position switch, and two or more potentiometers in series,
with a total series resistance of 10K ohms. Figure 12 shows a
connection for fixed high and low speed adjust potentiometers.
Figure 12. Adjustable Fixed Speeds Using Potentiometers in
Series
Application Notes
Independent adjustable speeds
Replace the speed adjust potentiometer with a single pole, multiposition switch, and two or more potentiometers in parallel, with
a total parallel resistance of 10K ohms. Figure 13 shows the
connection of two independent speed adjust potentiometers that
can be mounted at two separate operating stations.
19
Figure 13. Independent Adjustable Speeds
20
Application Notes
RUN/JOG switch
Using a RUN/JOG switch is recommended in applications where
quick stopping is not needed and frequent jogging is required.
Use a single pole, single throw switch for the RUN/JOG switch,
and a single pole, normally closed, momentary operated
pushbutton for the JOG pushbutton (see Figure 14). When the
RUN/JOG switch is set to JOG, the motor decelerates to zero
speed. Press the JOG pushbutton to jog the motor. Return the
RUN/JOG switch to RUN for normal operation.
Figure 14. RUN/JOG Switch Connection
Application Notes
Reversing
A dynamic brake may be used when reversing the motor direction
(Figure 18). 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.
21
Figure 18. Reversing Circuit Connection
22
Troubleshooting
m Warning
Dangerous voltages exist on the drive when it is powered. When
possible, disconnect the AC line voltage from the drive while
troubleshooting. Be alert. 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 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 voltage selection switch settings match the AC
•
line and output voltages.
Check that the drive’s rated armature and field outputs are
•
consistent with the motor ratings.
Troubleshooting
Motor does not run
1. Check for blown fuses or tripped circuit breaker.
2. Verify that the speed adjust potentiometer is not set to zero
speed position.
3. Verify that the inhibit terminals (H1 and H2) are not shorted
together.
4. Verify that the drive is receiving AC line voltage.
5. Check that the drive is not in current limit. The red current
limit (CUR LIM) LED must be off. If the red current limit
LED is on, verify that the motor is not jammed. It may be
necessary to increase the TORQUE setting if it is set to a value
23
lower than the current rating of the motor.
Fuses or circuit breaker blows
1. Check all wiring for shorts, grounds, or misconnections.
2. Check that the drive is configured to match the motor rating.
3. Check that the motor is not jammed or restricted from
movement.
4. Check that the fuse size is correct for the motor being driven.
Motor runs too fast at the maximum speed setting
1. Check that the MIN SPD and MAX SPD setting are not set too
high.
2. Check that the field output connections are secure if you are
using a shunt wound motor.
24
Troubleshooting
Motor will not stop when the speed adjust potentiometer is
full counterclockwise
Turn the MIN SPD trimpot CCW until the motor stops.
Motor runs in the opposite direction
1. Remove AC line voltage.
2. Reverse connections to the motor armature.
Motor slows under load
1. Check that the drive has been correctly calibrated for the
motor.
2. Check that the motor is not overloaded.
3. Readjust the IR COMP slightly CW until motor runs at proper
speed.
Motor is unstable under load
Readjust the IR COMP setting slightly CCW until motor speed
is stabilized.
Motor only runs at full speed
Check that S2 and S3 are not shorted together.
For additional assistance, contact your local Leeson distributor, or
the factory direct: phone (414) 377-8810, fax (414) 377-3440.
Block Diagrams
25
Figure 16. Block Diagram
26
Block Diagrams
Figure 22. Input Circuit Diagram
Notes
27
28
Notes
Limited Warranty
A. Warranty - Leeson Corporation (referred to as “the Corporation”) warrants that its products will
be free from defects in workmanship and material for one (1) year or 3,000 hours, whichever
comes first, from date of shipment thereof. Within this warranty period, the Corporation will repair
or replace such products that are: (1) returned to Leeson Corporation, 2100 Washington Street,
Grafton, WI 53024-0241 USA; and, (2) determined by the Corporation to be defective.
This warranty shall not apply to any product that has been subject to misuse, negligence, or
accident; or misapplied; or repaired by unauthorized persons; or improperly installed. 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, express or implied. The Corporation further
disclaims any responsibility whatsoever to the customer or to any other person for injury to the
person or damage or loss of property of value caused by any product that has been subject to
misuse, negligence, or accident, or misapplied or modified by unauthorized persons or improperly
installed.
C. Limitations of Liability - In the event of any claim for breech of any of the Corporation’s
obligations, whether express or implied, and particularly of any other claim or breech of warranty
contained in Paragraph A, or of any other warranties, express 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
expense 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 one (1) year or 3,000 hour warranty period. Products serviced and/or parts replaced
on a no-charge basis during the warranty period carry the unexpired portion of the original
warranty only.
If for any reason any of the foregoing provisions shall be ineffective, the Corporation’s liability for
damages arising out of its manufacture or sale of equipment, or use thereof, whether such liability
is based on warranty, contract, negligence, strict liability in tort, or otherwise, shall not in any event
exceed the full purchase price of such equipment.
Any action against the Corporation based upon any liability or obligation arising hereunder or
under any law applicable to the sale of equipment or the use thereof, must be commenced within
one year after the cause of such action arises.
Grafton, WI 53024-0241U.S.A.
Document Number 250-0256, Revision 0
U.S.A. $12.00, Canada $13.00
2100 Washington Street
Phone: (414) 377-8810
Fax: (414) 377-3440
Printed in the U.S.A – 4/96
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