LEESON SPEEDMASTER DC MOTOR ADJUSTABLE SPEED CONTROL INSTALLATION AND OPERATING INSTRUCTIONS THIS BOOK COVERS LOW VOLTAGE CONTROL CATALOG NUMBERS 175135.00REV1 and 175136.00REV1 INSTALLATION and OPERATING INSTRUCTIONS FOR CATALOG NUMBERS 175135.00REV1 AND 175136.00REV1 SPEEDMASTER™ ADJUSTABLE SPEED CONTROLS for BATTERY POWERED EQUIPMENT UP TO 60 AMPS TABLE OF CONTENTS STANDARD FEATURES ....................................................................... 2 CONTROL DIMENSIONS ..................................................................... 2 MODEL SELECTION ............................................................................ 2 MOUNTING DIMENSIONS ................................................................... 3 INSTALLATION & HOOK-UP ............................................................... 3 STANDARD HOOK-UP DIAGRAM ....................................................... 4 REVERSING HOOK-UP DIAGRAM ..................................................... 4 INHIBIT CIRCUIT .................................................................................. 4 TRIMPOT ADJUSTMENTS ................................................................... 5 IN CASE OF DIFFICULTY .................................................................... 6 SPECIFICATIONS ................................................................................. 6 SCHEMATIC DIAGRAM ....................................................................... 7 DISCLAIMER ........................................................................................ 8 WARRANTY .......................................................................................... 9 1 STANDARD FEATURES • Provides smooth variable speed capability for mobile equipment. • Maintains variable speed control as batteries discharge. • Adjustable min speed, max speed, i.r. compensation, current limit, and accel. • Inhibit terminal permits optional start-stop without breaking battery lines. • Speed potentiometer, knob, and dialplate included. • Increases range OR running time of battery operated equipment through high efficiency. • Automatic current limit foldback decreases current limit to 50% of setpoint when heatsink temperatures reach 80° C. - provides protection from overheating. DIMENSIONS MODEL WIDTH LENGTH DEPTH INCHES (CENTIMETERS) WEIGHT OZ. (g.) 175135 6.7 (17.1) 9.0 (22.9) 2.27 (5.77) 34.0 (962) 175136 6.7 (17.1) 9.0 (22.9) 2.27 (5.77) 34.0 (963) MODEL SELECTION CONTINUOUS CURRENT MODEL NUMBER (12VDC INPUT ± 15%) 60 (24/36VDC INPUT ± 15%) 60 (0 - 12VDC OUTPUT) 175135 (0 - 24/36VDC OUTPUT) 175136 WARNING: MAKE CERTAIN THAT THE POWER SUPPLY IS DISCONNECTED BEFORE ATTEMPTING TO SERVICE OR REMOVE ANY COMPONENTS!!! IF THE POWER DISCONNECT POINT IS OUT OF SIGHT, LOCK IT IN DISCONNECTED POSITION AND TAG TO PREVENT UNEXPECTED APPLICATION OF POWER. ONLY A QUALIFIED ELECTRICIAN OR SERVICEMAN SHOULD PERFORM ANY ELECTRICAL TROUBLESHOOTING OR MAINTENANCE. AT NO TIME SHOULD CIRCUIT CONTINUITY BE CHECKED BY SHORTING TERMINALS WITH A SCREWDRIVER OR OTHER METAL DEVICE. 2 175135.00REV1 / 175136.00REV1 MOUNTING 9.00” 7.50” 2.27” .75” 2.00” 7/32” DIA. (4 SLOTS) 6.30” 6.70” NOTE: When mounting the control, allow clearance above components to prevent shorting CAUTION: DO NOT MOUNT CONTROLLER WHERE AMBIENT TEMPERATURE IS OUTSIDE THE RANGE OF -10° C (15° F) TO 45° C ( 115° F). INSTALLATION & HOOK-UP Before attempting to wire the control, make sure all power is disconnected. Recheck code designation to assure proper voltage is present for the control. Caution should be used in selecting proper size of hook-up wire for current and voltage drop. Note: The battery and armature wire size on 175135.00REV1 and 175136.00REV1 models must be a minimum of 12 gauge. Warning: Do not reverse positive or negative battery leads, this will damage the control. To change motor direction, interchange the positive and negative Armature leads. Refer to the following wiring diagrams for proper location when connecting DC Voltage, Armature, and Speedpot wires to the control. CAUTION !! TURN POWER OFF WHILE MAKING CONNECTIONS. To properly adjust the CURRENT LIMIT setting, a DC ammeter should be placed in series with the armature line. This meter can be removed after the control is adjusted. Warning: Improper installation or operation of this control may cause injury to personnel or control failure. The control must be installed and grounded in accordance with local, state, and national safety codes. 3 175135.00REV1 / 175136.00REV1 HOOKUP DIAGRAMS 175135.00REV1 / 175136.00REV1 HOOKUP ++ P2 -Arm (P1-2) - - Battery White Red Orange Pot High (P2-1) Pot Wiper (P2-2) Pot Low (P2-3) Common (P2-4) Inhibit (P2-5) -Battery (P1-1) Optional Inhibit (see hook-up I.R. Comp. below) No Connect (P1-3) + Motor Accel +Battery (P1-4) Customer supplied SPST switch Current Limit +Arm (P1-5) + + + Caution: Motor and battery wire must be a minimum of 12 ga. and a maximum of 6 ga. 5KΩ Speedpot Max Speed Min Speed P1 175135.00REV1 / 175136.00REV1 REVERSING HOOKUP Customer supplied 3PDT Center-off Center-blocked switch CAUTION: DO NOT OPERATE CONTROL Relays may be used in place of switch, but a neutral position must OUTSIDE be provided to prevent plug reversing. Do not engage opposite direction until motor has RECOMMENDED INPUT +/-10% come to a complete stop. Failure to do so may result in damage to the control. THE White Motor + + P2 Pot High (P2-1) Pot Wiper (P2-2) Pot Low (P2-3) Common (P2-4) Inhibit (P2-5) -Battery (P1-1) -Arm (P1-2) Battery No Connect (P1-3) + Customer supplied SPST switch Red Orange Optional Inhibit (see hook-up I.R. Comp. below) Accel +Battery (P1-4) Current Limit +Arm (P1-5) Max Speed Min Speed + P1 + Caution: Motor and battery wire must be a minimum of 12 ga. and a maximum of 6 ga. 5KΩ Speedpot Relays may be used in place of switch, but a neutral position must be provided to prevent plug reversing. DO NOT ENGAGE OPPOSITE DIRECTION UNTIL MOTOR HAS COME TO A COMPLETE STOP. Failure to do so may result in damage to the control. INHIBITING THE CONTROL - There are two methods that may be used to shut down the output without having to break the battery supply (ie. inhibit the control). Using inhibit input - provide fast startstop by bypassing accel/decel circuit Pot High (P2-1) Pot Wiper (P2-2) Pot Low (P2-3) Common (P2-4) Inhibit (P2-5) SPST Switch open = run close = stop Inhibit via speedpot - provides starting and stopping through accel/decel parameters White Red Orange Pot High (P2-1) Pot Wiper (P2-2) Pot Low (P2-3) Common (P2-4) Inhibit (P2-5) P2 P2 4 SPST Switch open = stop close = run 5KΩ Speedpot TRIMPOT ADJUSTMENTS Before power is applied, the speed potentiometer and trimpots should be preset as follows: TRIMPOT PRESET 1. Rotate Speedpot fully CCW. 2. Rotate Max trimpot CW 1/2 way. 3. Rotate Current Limit trimpot fully CW. 4. Rotate Min trimpot fully CCW. 5. Rotate Accel trimpot CW 1/2 way. 6. Rotate I.R. trimpot fully CW. DC power can now be applied to the system and the control adjusted as follows: TRIMPOT ADJUSTMENT 7. Increase the MIN trimpot in a CW direction until the desired minimum speed is reached. 8. Turn the Speedpot fully CW and adjust the MAX trimpot until the desired maximum speed is reached. 9. Adjust the ACCEL trimpot to achieve the desired soft start time. CW rotation will increase accel time. 10. Rotate the CURRENT LIMIT trimpot fully CCW until the motor begins to stall. Apply a full load to the motor and adjust the trimpot until a desired current setting is obtained. 11. Adjust I.R. trimpot CW 1/2 way. If motor RPM is inconsistent (jumpy), rotate I.R. trimpot CCW until rotation is stable. IMPORTANT: DO NOT EXCEED CURRENT LIMIT AMPERAGE RATING. (see below) LEESON SPEEDMASTER™ low voltage controls = 60 AMP MAX Adjustment is now complete for the 175135.00REV1 and 175136.00REV1 models and the ammeter may be removed. 5 IN CASE OF DIFFICULTY If a newly installed control will not operate, it is likely that a terminal or connection is loose. Check to make sure connections are secure and correct. If the control is still inoperative, refer to the following chart for reference: PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION MOTOR DOESN’T RUN * * * * INCORRECT OR NO POWER SPEEDPOT SET AT ZERO WORN MOTOR BRUSHES CURRENT LIMIT SET TOO LOW INSTALL PROPER SERVICE ROTATE SPEEDPOT FULLY CW REPLACE MOTOR BRUSHES ADJUST CURRENT LIMIT POT CW MOTOR “HUNTS” * MOTOR SPEED IS ABOVE RATED SPEED I.R. COMP. TRIMPOT SET TOO HIGH SEE TRIMPOT ADJUSTMENTS ON PAGE 5 SEE TRIMPOT ADJUSTMENTS ON PAGE 5 LOOSE SPEEDPOT CONNECTIONS MIN OR MAX TRIMPOTS NOT PROPERLY ADJUSTED POSSIBLE CONTROL FAILURE SECURE ALL CONNECTIONS SEE TRIMPOT ADJUSTMENTS ON PAGE 5 SEND TO LEESON ELECTRIC CORP. * MOTOR RUNS AT “FULL SPEED” UNCONTROLLABLE * * * MOTOR ROTATES IN WRONG DIRECTION * MOTOR ARMATURE HOOKED UP BACKWARDS REVERSE ARMATURE + AND LEADS MOTOR STALLS UNDER A LIGHT LOAD * CURRENT LIMIT TRIMPOT IMPROPERLY ADJUSTED SEE TRIMPOT ADJUSTMENTS ON PAGE 5 SPECIFICATIONS 175135.00REV1 and 175136.00REV1 Models Load current (continuous) Input Voltage Output Voltage Speed adjustment 60 amps continuous 12VDC ± 10% (model 175135) 24/36VDC ± 10% (model 175136) 0-12VDC (model 175135) 0-24/36VDC (model 175136) 5K9 potentiometer or 0 to +10VDC input signal Speed range Overload capacity 30 : 1 200% for 10 seconds; 150% for one minute Current limit adjustable 100% to 200% of full motor load, up to continuous current rating (page 5) Acceleration adjustable - 0 to 10 seconds Deceleration non-adjustable - 0.5 seconds Maximum speed adjustable - 50 to 100% of base speed Minimum speed adjustable - 30% of max speed Connections barrier terminal block Speed regulation Package configuration 1% of base speed black anodized aluminum extrusion Internal operating frequency Thermal protection approximately 1.6K Hertz Current foldback at 80o C. heatsink temperature 6 175135.00REV1 / 175136.00REV1 SCHEMATIC +12V R1 ........................ 10W 1W R6 ........................ 22K 1/8W R31 ...................... 2.2K 1/8W R35 ...................... 1K 1/8W R42 ...................... 22K 1/8W R48 ...................... 1K 1/8W U1 - 40106 U2 - LM324 U3 - LM324 U4 - LM358 C10 47µF 16V MAX R7 20K cw 14 R17 470K ACCEL R16 20K 1/2W 1% +12V HI P2-1 9 10 R19 47K P2-2 P1-4 P1-5 R3 470W 13 C11 1000uF 50V C12 1000uF 50V R12 100K 6 R8 33K P1-2 R20 MIN 5K R10 47K R9 220K - 2 R36 C8 .01µF 100V 1 U3-1 R13 10K C5 .1µF 63V CW 22W S Q2 IRFZ44 R38 +12V 10 9 C14 .1µF 63V - 22W 1 C9 .01µF 100V 8 11 R50 100K 4 1 I.R. R32 5K cw R46 22K D1 1N4005 D5 1N914B 7 C13 .1µF 63V + 14 12 R27 47K C15 .01µF 100V U2-4 - R28 10K C3 .22µF 100V R29 300K CW SW1 TEMP SWITCH C.L. R30 20K R31 4.7K 4 22W S 8 U1-3 R40 11 R51 15K U4-2 U1-5 S Q6 IRFZ44 10 D - ARM R41 5 13 D6 1N5233B 1 G 22W 6 D 6 D7 1N914B R48 2.7K +12V 13 U1-2 Q5 IRFZ44 5 3 G 22W 12 S R LINE 2 R33 100K R34 47K C1 .1µF 63V C2 .1µF 63V U1-6 7 U2-1 - 3 + - U4-1 U1-4 + 8 - 9 7 U2-2 C4 .1µF 63V D G + 6 + 2 5 R24 6.8K +12V U1-1 R39 3 R47 680K R42 47K S Q4 IRFZ44 2 R22 10K +12V R26 4.7K R21 82K D G 14 4 U2-3 R25 10K INHIBIT P2-5 + S Q3 IRFZ44 +12V D G 22W C7 .1µF 63V R43 1.2M R23 4.7K R49 100K R37 +12V +12V S -A G 11 R11 10K COM P2-4 S D 4 + LO P2-3 R18 300K D G G S Q10 IRFZ44 D Q1 IRFZ44 +12V 3 + 5 R14 180K Q9 IRFZ44 D G G MOTOR Q8 IRFZ44 D 7 U3-2 + Q7 IRFZ44 S R5 470W - +A R4 47K R15 250K 8 U3-3 WIPER R45 REMOTE SPEEDPOT 5K - +B R2 47K R6 10K C6 .22µF 100V CW R1 300W 5W U3-4 D4 1N963B +12V N.C. D3 1N5349B 12 - R44 150W P1-3 D2 1N4005 7 NOTES: + 12 VOLT VERSION CHANGES: R35 2.7K P1-1 -B ALL RESISTORS 1/8W UNLESS NOTED OTHERWISE DISCLAIMER The information and technical data in this manual are subject to change without notice. LEESON Electric Corporation and its Divisions make no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. LEESON Electric 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. LEESON SPEEDMASTER LEESON ELECTRIC CORPORATION GRAFTON, WI 53024-0241 U.S.A. (262) 377-8810 FAX (262) 377-9025 8 LIMITED WARRANTY A. WARRANTY: LEESON Electric Corporation warrants that their products will be free from defects in material and workmanship for a period of one (1) year from date of shipment thereof. Within the warranty period LEESON Electric will repair or replace such products which are returned to LEESON Electric or to the nearest Branch Office, with shipping charges prepaid. At our option, all return shipments are F.O.B. LEESON Electric or its Branch Office. This warranty will not apply to any product which has been subjected to misuse, negligence; or misapplied; or repaired by unauthorized persons; or improperly installed. LEESON is not responsible for removal, installation or any other incidental expenses incurred in shipping the products to or from the repair point. B. DISCLAIMER: The provisions of paragraph 'A' are LEESON'S sole obligation and exclude all other warranties of MERCHANTABILITY or use, express or implied. We further disclaim any responsibility whatsoever to the customer or to any other person for injury to person, or damage to or loss of property of value, caused by any product which has been subjected to misuse, negligence or accident; or misapplied; or modified or repaired by unauthorized persons; or improperly installed. C. LIMITATION of LIABILITY: In the event of any claim for breach of any of LEESON'S obligations, whether express or implied, and particularly in the event of any claim of the warranty contained in paragraph 'A', or any other warranties, express or implied, or claim of liability, which might, despite paragraph 'B', be decided against us by any lawful authority, LEESON Electric shall under no circumstances be liable for any consequential damages, losses or expenses arising in connection with the use of, or inability to use, our product for any purpose whatsoever. An adjustment made under the warranty does not void the warranty, nor does it imply an extension of the original one (1) year 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 Company'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 Company 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. LEESON SPEEDMASTER 9 NOTES: Bulletin #302 10/00 10