Speedmaster DC Motor Adjustable Speed Control

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