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MGC403-1.5MGC403-11

USER MANUAL

w w w . a m e r i c a n c o n t r o l e l e c t r o n i c s . c o m

MGC SERIES

Dear Valued Consumer:

Congratulations on your purchase of the MGC 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.

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MGC Series

Safety First!

• 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.

S A F E T Y W A R N I N G S

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.

It is possible for a drive to run at full speed as a result of a 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 protective equipment and insulated tools if working on this drive with power applied.

!WARNING!

!WARNING!

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MGC Series

Table of ContentsSection 1. Regenerative Drives ............................................ 1Section 2. Specifications ..................................................... 2Section 3. Dimensions ......................................................... 4Section 4. Installation ......................................................... 6

Heat Sinking ................................................................................. 6Mounting ..................................................................................... 7

Remote Adjust Potentiometers .............................................. 8Wiring .......................................................................................... 9

Short-Circuit Current Rating .................................................10Branch Circuit Protection .....................................................10Shielding Guidelines.............................................................11

Power Connections ......................................................................12AC Line ................................................................................12Earth Ground .......................................................................12Motor Armature ..................................................................12Motor Field (Shunt) ..............................................................13Tachogenerator Feedback .....................................................14

Jumper Settings ...........................................................................15Jumper Locations .........................................................................16Before Applying Power .................................................................17

Section 5. Speed & Torque Mode Operation ........................ 18Mode Selection ............................................................................18Logic Connections ........................................................................20

Input Signal 1 - Potentiometer ..............................................20Input Signal 1 - Analog Signal ...............................................20Direction Switch ..................................................................21Bidirectional Control with a Unidirectional Signal ..................21Auxilliary Output .................................................................22Auxilliary Input ....................................................................23Input Signal 2 - Potentiometer and Analog Signal ..................23

Application Examples with AUX as an Input ...................................24Independent Speed 1 / Speed 2 (Torque 1 / Torque 2) ...........24Independent Forward & Reverse ...........................................25Run / Jog Switch ..................................................................26

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MGC Series

Auto / Manual Switch (Remote / Local Switch) ......................27Linear Mode ................................................................................28Independent Mode ......................................................................29Starting and Stopping Methods ....................................................30

Automatic Restart Upon Power Restoration ...........................30Line Starting and Stopping ...................................................30Coast to Zero Speed (Enable) ................................................31Decelerate to Minimum Speed (Regen Brake) ........................32Regenerative Brake to Zero Speed (Inhibit) ...........................333-Wire Start/Stop ................................................................34

Calibration for Speed & Torque Modes ..........................................35Signal 1 Offset (OFS1) ..........................................................36Signal 2 Offset (OFS2) ..........................................................37Maximum Speed (MAX) ........................................................38Motor Overload Protection (MOP) ........................................39Forward Current Limit (FWCL) ..............................................40Reverse Current Limit (RVCL) ................................................41IR Compensation (IR/T) ........................................................42Foward Acceleration / Reverse Deceleration (FACC) ...............45Reverse Acceleration / Forward Deceleration (RACC) .............45

Section 6. Torque Limit Cycling Mode Operation ................. 46Mode Selection ............................................................................46Torque Limit Cycling Mode ...........................................................48

Section 7. Limit Switch Cycling Mode Operation .................. 50Mode Selection ............................................................................50Unidirectional Cycle with One Limit Switch ...................................52Indexing ......................................................................................54Auto Cycling with One Limit Switch ...............................................56Half Cycle with Two Limit Switches ...............................................58Single Cycle with Two Limit Switches ............................................60Continuous Cycling with Two Limit Switches ..................................62Calibration for Limit Switch Cycling Mode .....................................64

Offset (OFS1) .......................................................................65Maximum Speed (MAX) ........................................................65Forward Dwell Time (IR/T) ....................................................66Reverse Dwell Time (OFS2) ...................................................66Motor Overload Protection (MOP) ........................................67

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MGC Series

Forward Current Limit (FWCL) ..............................................68Reverse Current Limit (RVCL) ................................................69Acceleration (FACC) ..............................................................71Deceleration (RACC) .............................................................71

Section 8. Feedback Cycling Mode Operation ...................... 72Mode Selection ............................................................................72Feedback Cycling - Half Cycle ........................................................74Feedback Cycling - Single Cycle .....................................................76Feedback Cycling - Continuous Cycling ..........................................78Calibration for Feedback Cycling Mode .........................................80

Minimum Retract / Home / Reverse Limit Position (OSF1) ......81Maximum Extend / End-of-Travel / Forward Limit Position (OSF2) ..81Maximum Speed (MAX) ........................................................82Acceleration (FACC) ..............................................................82Forward Dwell Time (IR/T) ....................................................83Reverse Dwell Time (RACC) ...................................................83Motor Overload Protection (MOP) ........................................84Forward Current Limit (FWCL) ..............................................85Reverse Current Limit (RVCL) ................................................86

Section 9. Positioning Mode Operation .............................. 88Mode Selection ............................................................................88Logic Connections ........................................................................90

Potentiometer Command .....................................................90Analog Signal Command .......................................................90Direction Switch ..................................................................91Feedback Signal ...................................................................91Coast to Zero Speed (Enable) ................................................92Regenerative Brake to Zero Speed (Inhibit) ...........................93Auxillary Output ..................................................................94

Calibration for Feedback Cycling Mode .........................................95Minimum Retract / Home / Reverse Limit Position (OSF1) ......96Maximum Extend / End-of-Travel / Forward Limit Position (OSF2) ..96Speed (MAX) ........................................................................97Error (RACC) ........................................................................97Acceleration ........................................................................98Motor Overload Protection (MOP) ........................................99Forward Current Limit (FWCL) ............................................ 100Reverse Current Limit (RVCL) .............................................. 101

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MGC Series

List of FiguresFigure 1 Four Quadrant Operation .................................................. 1Figure 2 MGC403 Dimensions ......................................................... 4Figure 3 223-0159 Dimensions ........................................................ 5Figure 4 Remote Adjust Potentiometer ............................................ 8Figure 5 AC Line, Motor, and Tachogenerator Connections ..............14Figure 6 Jumper Locations .............................................................16Figure 7 SO501 Settings for Speed and Torque Mode Operations .....18Figure 8 DIP Switch SO501 .............................................................19Figure 9 Signal 1 Potentiometer and Analog Signal Connections ......20Figure 10 Direction Switch ...............................................................21Figure 11 Auxillary Output ...............................................................22Figure 12 Signal 2 Potentiometer and Analog Signal Connections ......23Figure 13 Independent Speed 1 / Speed 2 (Torque 1 / Torque 2) ........24Figure 14 Independent Forward & Reverse .......................................25Figure 15 Run/Jog Switch ................................................................26Figure 16 Auto / Manual Switch (Remote / Local Switch) ..................27Figure 17 Linear Mode ....................................................................28Figure 18 Independent Mode ...........................................................29Figure 19 Enable Switch ..................................................................31Figure 20 Regen Brake Switches .......................................................32Figure 21 Inhibit Switch ...................................................................33Figure 22 3-Wire Start/Stop .............................................................34Figure 23 Recommended Torque and IR Compensation Settings ........44

IR Compensation (IR/T) ...................................................... 102Reverse Current Limit (RVCL) .............................................. 101

Section 10. Diagnostic LEDs ..............................................104Section 11. Troubleshooting .............................................106Section 12. Accessories & Replacement Parts.....................110Unconditional Warranty ....................................................111

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MGC Series

List of TablesTable 1 Field Output Connections .................................................13

Figure 24 SO501 Settings for Torque Limit Cycling Mode Operation ...46Figure 25 DIP Switch SO501 .............................................................47Figure 26 Torque Limit Cycling with Limit Switch Wiring....................49Figure 27 SO501 Settings for Limit Switch Cycling .............................50Figure 28 DIP Switch SO501 .............................................................51Figure 29 Unidirectional Cycle Wiring ..............................................53Figure 30 Indexing Wiring with N.O. Limit Switches ..........................54Figure 31 Indexing Wiring with N.C. Limit Switches ...........................55Figure 32 Auto Cycling Wiring ..........................................................57Figure 33 Half Cycle Wiring..............................................................59Figure 34 Single Cycle Wiring ...........................................................61Figure 35 Continuous Cycling Wiring ................................................63Figure 36 Recommended Torque Settings .........................................70Figure 37 SO501 Settings for Feedback Cycling .................................72Figure 38 DIP Switch SO501 .............................................................73Figure 39 Half Cycling with Feedback ...............................................75Figure 40 Single Cycling with Feedback ............................................77Figure 41 Auto Cycling with Feedback ..............................................79Figure 42 Recommended Torque Settings .........................................87Figure 43 SO501 Settings for Feedback Positioning ...........................88Figure 44 DIP Switch SO501 .............................................................89Figure 45 Signal 1 Potentiometer and Analog Signal Connections ......90Figure 46 Siognal 2 Feedback Signal Connections .............................91Figure 47 Enable Switch ..................................................................92Figure 48 Inhibit Switch ...................................................................93Figure 49 Auxillary Output ...............................................................94Figure 50 Recommended Torque Settings ....................................... 103Figure 51 Diagnostic LED Locations ................................................ 105

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MGC Series

Figure 1. Four Quadrant Operation

ARROWS IN OPPOSITE DIRECTION = REGENERATIVE ACTIONNOTE: ARROWS IN SAME DIRECTION = MOTOR ACTION

MOTORTORQUEROTATION

MOTOR

Quadrant III

Quadrant II

Quadrant IV

Quadrant I

Most non-regenerative, variable speed, DC drives control current flow to a motor in one direction. The direction of current flow is the same direction as the motor rotation. Non-regenerative drives operate in Quadrant I, and also in Quadrant III if the drive is reversible (see Figure 1). Motors must stop before reversing direction. Unless dynamic braking is used, non regenerative drives cannot decelerate a load faster than coasting to a lower speed.

Regenerative drives operate in two additional quadrants: Quadrant II and Quadrant IV. In these quadrants, motor torque is in the opposite direction of motor rotation.

This allows regenerative drives to reverse a motor without contactors or switches, to control an overhauling load, and to decelerate a load faster than it would to coast to a lower speed.

Section 1. Regenerative Drives

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MGC Series

AC Line Voltage

AC Line Current

DC Armature Voltage with 115 VAC Line Voltage DC Armature Voltage with 230 VAC Line Voltage

DC Field (Shunt) Voltage with 115 VAC Line VoltageDC Field (Shunt) Voltage with 230 VAC Line Voltage

DC Field Current

Form Factor

Tachogenerator Feedback Range

Load Regulation with Armature FeedbackLoad Regulation with Tachogenerator Feedback

Speed Range with Armature FeedbackSpeed Range with Tachogenerator Feedback

Acceleration Time Range

Deceleration Time Range

I/O Isolation

Analog Input Range (COM to SIG1, SIG2)

Input Impedance (COM to SIG1, SIG2)

* Heat sink kit part number 223-0159 must be used when the continuous current output is over 5 amps.

Model

MaximumArmature

Current (ADC)

HP Rangewith 90 VDC

Motor

HP Rangewith 180 VDC

Motor Enclosure

MGC403-1.5 1.5 1/50 - 1/8 1/25 - 1/4 Chassis

MGC403-11 11.0* 1/8 - 1 1/4 - 2 Chassis

Section 2. Specifications

115 / 230 VAC ± 10%, 50/60 Hz, single phase

0 - 15 Amps

0 - 90 VDC0 - 180 VDC

50 VDC (F+ to L1); 100 VDC (F+ to F-)100 VDC (F+ to L1); 200 VDC (F+ to F-)

0.74 Amps

1.37 at base speed

0 to 7 through 50 VDC per 1000 RPM (Max 180 VDC)

1.0% of base speed or better0.1% of base speed or better

50:160:1

0.1 - 15 seconds

0.1 - 15 seconds

3 kV

0 to ± 10 VDC, 4-20 mA

>100K ohms

3

Section 2. Specifications

Vibration (0 - 50 Hz)Vibration (> 50 Hz)

Surrounding Air Temperature Range

Weight

Safety Certifications

0.5G maximum0.1G maximum

10°C - 50°C

0.70 lbs (0.32 kg)

cULus Listed, UL 61800-5-1, File # E132235

-FLL: Fuse Clips for L1 and L2 connections

Suffix Definitions

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MGC Series

Figure 2. MGC403 Dimensions

ALL DIMENSIONS IN INCHES [MILLIMETERS]

US

10A

5A

2.5A

1.7A

A2A1

F-F+

L2L1

COM SIG1 10V SIG2 DIR EN COM INH COM AUX

OU

TIN

SIG2SIG1

VDC

mA

T1 T2TAC

H

A90

A180

J504

STAT

LIM

IT

OFS1 OFS2 MAX

FWCL RVCL MOP

1 2 3 4 5 6 7 8

ON

3.64 [93]

3.00 [76]

1.25 [32]

0.50 [13]

3.80 [97]4.30 [110]

1.34 [34]0.95 [24]

1.94 [50]

FACC RACC IR/T

Section 3. Dimensions

5

Section 3. Dimensions

Figure 3. 223-0159 Dimensions

ALL DIMENSIONS IN INCHES [MILLIMETERS]

6.90 [175]6.30 [160]5.90 [150]

0.30 [8]0.50 [13]

0.70[18]

3.00[76]

0.19[5]

5.90[150]

0.125 [3] 1.00 [26]

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MGC Series

Model MGC403-11 requires an additional heat sink when the continuous armature current is above 8 amps. Use heat sink kit part number 223-0159. 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.

Heat Sinking

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 understand the Safety Precautions on page i before attempting to install this product.WARNING!

!

Section 4. Installation

7


• Install the drive in a Pollution Degree 2 environment only.

• 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 surrounding air 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. Eight 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. Connect the ground to the green screw located on the chassis.

Mounting

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MGC Series

Figure 4. Remote Adjust Potentiometer

POT TAB ASSIGNMENTS

WIPERCW

CCW

REMOTE ADJUSTPOTENTIOMETER

INSULATING DISKPANEL

STARWASHER

NUT

MOUNT THROUGH A 0.38 IN. (10 MM) HOLE

If using remote adjust potentiometers, mount the potentiometers through a 0.38 in. (10 mm) hole with the hardware provided (Figure 4). Install the circular insulating disk between the panel and the 10K ohm remote adjust potentiometers.

Twist the remote 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 remote adjust potentiometer wires separate from power leads (L1, L2, A1, A2, F1, F2, T1, T2).

Be sure that the potentiometer tabs do not make contact with the potentiometer’s body. Grounding the input will cause damage to the drive.WARNING!

!

Remote Adjust Potentiometers

9


• Use 18 - 24 AWG wire for logic wiring. Use 14 AWG wire for AC line and motor wiring.

• TB501 (quick disonnect plug) screw terminals should be tightened to 2.0 lb-in (0.23 N-m).

• J501 (tachogenerator connections T1 & T2) screw terminals should be tightened to 1.7 lb-in (0.19 N-m).

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 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 damage the drive.

WARNING!!

Wiring

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MGC Series

Class J, Class CC, or Class T fuses are to be rated with a minimum of 230 VAC and maximum current rating of 40 amps. Circuit breakers are to be rated at a minimum of 230 VAC and maximum current rating of 30 amps.

Branch Circuit Protection

Short-Circuit Current Rating

Drives are suitable for use on a circuit capable of delivering not more than 5,000 RMS symmetrical amperes, 115/230 volts maximum.

11


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 shield 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.

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.WARNING!

!

Shielding Guidelines

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MGC Series

Drives supply motor armature voltage from the 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. If using an actuator, it is assumed that a postive output will result in the actuator extending.

Connect a DC motor to terminals A1 and A2. Refer to Figure 5 on page 14. Ensure that the motor voltage rating is consistent with the drive’s output voltage.

Motor Armature

Connect the AC line power leads to terminals L1 and L2. American Control Electronics 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 5 on page 14.

AC Line

Do not connect this equipment with power applied. Failure to heed this warning may result in fire, explosion, or serious injury.

American Control Electronics strongly recommends the installation of a master power switch in the voltage input line, as shown in Figure 5 (page 14). The switch contacts should be rated at a minimum of 200% of motor nameplate current and 250 volts.

WARNING!!

Power Connections

Connect earth ground to the green screw located on the chassis. Refer to Figure 5 on page 14.

Earth Ground

13


Line Voltage (VAC)

Approximate Field Voltage (VDC)

Connect MotorField To..

115115230230

50100100200

F+ and L1F+ and F- F+ and L1F+ and F-

Table 1. Field Output Connections

See Table 1 for field output connections. Use 14 - 16 AWG wire to connect the field output to a field / shunt wound motor.

The field output is for shunt wound motors only. Do not make any connections to F+ and F- when using a permanent magnet motor.WARNING!

!

Motor Field (Shunt)

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MGC Series

Figure 5. AC Line, Motor, and Tachogenerator Connections

10A

5A

2.5A

1.7A

A2A1

F-F+

L2L1

USCOM SIG1 10V SIG2 DIR EN COM INH COM AUX

OU

TIN

SIG2SIG1

VDC

mA

T1 T2TAC

H

A90

A180

J504

STAT

LIM

IT

IR/TRACCFACC

MOPRVCLFWCL

MAXOFS2OFS1

1 2 3 4 5 6 7 8

ON

EARTHGROUND

AC LINE INPUT

115 or 230 VAC

MOTORARMATURE

POWERSWITCH FUSE

FUSE*

MOTOR FIELD**

**DO NOT MAKE ANYCONNECTIONS TO F- OR F+

IF USING A PERMANENTMAGNET DC MOTOR

*DO NOT ADD A FUSE TOL2 IF USING A 115 VAC INPUT

Using tachogenerator feedback improves speed regulation from approximately 1% to 0.1% of motor base speed. Use tachogenerators rated for 7 to 50 VDC per 1000 RPM. Connect the tachogenerator to terminals T1 and T2 of terminal block TB501. The polarity is positive (+) for T1 and negative (-) for T2 when the motor is running in the forward direction. Refer to Figure 5 for location and connections and to Figure 6 on page 16 for jumper settings.

Jumper J504 must be set to TACH if using tach feedback. See page 17 for jumper location.

Tachogenerator feedback is only used in Speed Mode, Torque Mode, Linear Torque Mode, and Independent Speed & Torque Mode, and is adjusted using the IR/T trim pot. It is not available in Positioning or either of the Cycling Modes.

Tachogenerator Feedback

15


Jumper Settings

J504 must be set to TACH if using tach feedback. If no tachogenerator is used, J504 must be set to either A90 for a 90 VDC motor or A180 for a 180 VDC motor.

Feedback Jumper (J504 on Top Board)

The Base Current Limit jumper on the bottom board sets the base scaling for the current limit trim pots. Select the rating nearest the amperage rating of the motor. The FWCL and RVCL trim pots will range from 0 to 150% of the selected base current.

For 1.5 amp models; 10A = 1A, 5A = 0.5A, 2.5A = 0.25A, and 1.7A = 0.12A.

Base Current Limit (Bottom Board)

Jumper SIG1 determines the type of signal being used on the SIG1 terminal. If using a potentiometer or analog voltage signal, set jumper SIG1 to VDC. If using a 4-20 mA signal, set jumper SIG1 for mA. See page 19 for more information.

SIG1 (Top Board)

Jumper SIG2 determines the type of signal being used on the SIG2 terminal. If using a potentiometer or analog voltage signal, set jumper SIG2 to VDC. If using a 4-20 mA signal, set jumper SIG2 for mA. See page 22 for more information.

SIG2 (Top Board)

Jumper AUX determines whether the AUX terminal will be used for an alarm output or a digital input. For an alarm output, refer to page 21. For a digital input, refer to page 22. Some modes, such as Cycling Modes with two limit switches, require the AUX terminal to set as an input.

AUX (Top Board)

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MGC Series

Jumper Locations

Figure 6. Jumper Locations

10A

5A

2.5A

1.7A

A2A1

F-F+

L2L1

USCOM SIG1 10V SIG2 DIR EN COM INH COM AUX

OU

TIN

SIG2SIG1

VDC

mA

T1 T2TAC

H

A90

A180

J504

STAT

LIM

IT

IR/TRACCFACC

MOPRVCLFWCL

MAXOFS2OFS1

1 2 3 4 5 6 7 8

ON

SIG1

SIG2 BaseCurrent Limit

AUX

Feedback (J504)

17


1. Verify that no foreign conductive material is present on the printed circuit board.

2. Ensure that all jumpers and DIP switches are properly set.

Change jumper and DIP switch settings only when the drive is disconnected from AC line voltage. Make sure all jumpers and DIP switches are set to their correct position. If improperly set, 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 102, for further assistance.

WARNING!!

Before Applying Power

18

MGC Series

Section 5. Speed & Torque Mode OperationsMode SelectionDIP Switches 1 through 3 on SO501 are used to determine the mode of operation.

1 2 3

ONSpeed Mode: The remote adjust potentiometers and / or analog reference signals are used to command speed. The drive will output whatever current (torque) is necessary to achieve the commanded voltage (speed).

1 2 3

ONTorque Mode: The remote adjust potentiometers and / or analog reference signals are used to command torque. The drive will output whatever voltage (speed) is necessary to achieve the commanded current (torque). Most commonly used in tensioning applications.

1 2 3

ONLinear Mode: The remote adjust potentiometers and / or analog reference signals are used to command both speed and torque. With a 50% command signal, the drive will try to achieve a 50% current draw from the motor up to 50% of maximum speed.

1 2 3

ONIndependent Mode: The input on SIG 1 is used to command speed and the input on SIG 2 is used to command torque.

Figure 7. SO501 Settings for Speed and Torque Mode Operations

19

Section 5. Speed & Torque Mode Operation

1 2 3 4 5 6 7 8

ON

DIP Switch 4: Automatic Restart

OFF: The drive will immediately try to run if commanded to do so upon power up.

ON: Upon power up, the drive will not run until it sees a no run condition. This prevents unexpected takeoff when AC power is applied. The drive will not run until either the Enable or Inhibit is toggled, or the remote potentiometer or analog input signal is set to a zero speed reference (ie. full CCW, 0 VDC, 4 mA).

DIP Switch 5: Alarm Output Type (see page 22)

OFF: AUX alarm output will signify a current limit condition.

ON: AUX alarm output will signify a run condition.

DIP Switch 6: 3-Wire Start/Stop (see pages 30-34)

OFF: The EN and INH terminals act as Enable and Inhibit.

ON: The EN and INH terminals act as a 3-Wire Start/Stop.

DIP Switch 7: Invert Enable (see page 31)

OFF: Enable is open to run, close to coast to a stop.

ON: Enable is close to run, open to coast to a stop.

DIP Switch 8: Invert Inhibit (see page 33)

OFF: Inhibit is open to run, close to regeneratively brake to a stop.

ON: Inhibit is close to run, open to regeneratively brake to a stop.

Figure 8. DIP Switch SO501

20

MGC Series

Input Signal 1 - Potentiometer

Instead of using a 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 negative (common) to terminal COM. Connect the signal positive (reference) to SIG1. If using an analog voltage signal, jumper SIG1 must be set to VDC. If using an analog current signal, jumper SIG1 must be set to mA.

Use a 10K ohm, 1/4 W potentiometer for speed or torque control. Connect the counter-clockwise end of the potentiometer to terminal COM, the wiper to terminal SIG1, and the clockwise end to terminal 10V. 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 COM and 10V connections. If using a potentiometer, jumper SIG1 must be set to VDC.Refer to Figure 9.

10K OhmSpeed / TorqueAdjust Potentiometer

SIG1 10VCOM

0 - 10 VDC-10 to 10 VDC

SIG1 10VCOM

CW

Common(-)

Reference(+)

VDC

mA

SIG1VDC

mA

SIG1

4 - 20 mA

SIG1 10VCOM

Common(-)

Reference(+)

VDC

mA

SIG1

Figure 9. Signal 1 Potentiometer and Analog Signal Connections

Input Signal 1 - Analog Signal

Logic Connections

21


Direction Switch

Bidirectional Control with a Unidirectional Signal

Figure 10. Direction Switch

A single-pole, single-throw switch can be used as a direction switch. Connect the switch to terminals COM and DIR. Close the switch to reverse the motor. Open the switch to return the motor back to it’s original direction. Refer to Figure 10.

SIG2 COMSIG1 INH10V AUXCOM COMDIR EN

DirectionSwitch

For bidirectional operation with a unidirectional signal, the motor does not operate when the potentiometer is in the center position. Turning the potentiometer clockwise (CW) from the center position causes the motor to rotate in the forward direction, while turning the potentiometer counterclockwise (CCW) causes rotation in the reverse direction.

For this type of operation, connect the speed adjust potentiometer as shown in Figure 9.

If using an analog signal, full speed reverse is at 0 VDC or 4 mA. Full speed forward is at 10 VDC or 20 mA.

To set the drive up for bidirectional control with a unidirectional signal (sometimes refered to as WigWag), refer to the OFS1 and OFS2 trim pot calibrations on pages 36 and 37.

22

MGC Series

Auxillary Output

Figure 11. Auxillary Output

The drive has the ability to output an alarm. If DIP Switch 5 on SO501 is set to the OFF position, the auxillary output is a current limit alarm. The alarm will activate whenever the motor is asking for more current than the FWCL or RVCL trim pots are set to allow. In Torque and Linear Modes, this is maximum speed alarm. If DIP switch 5 is set to the ON position, the alarm is a run alarm in all modes. The alarm will activate whenever the drive’s output is active (trying to accelerate the motor to speed or holding the motor at zero speed).

To use the AUX terminal as an alarm, the auxillary jumper must be set for OUT (refer to pages 15 and 16). When used as an alarm, the AUX terminal cannot be used for a digital input to alternate between SIG1 and SIG2.

When inactive, the AUX terminal is pulled up to 5 VDC. When active, the AUX terminal is pulled to drive common by an open collector transistor. The open collector transistor effectivately operates as a power switch for an external relay coil separately powered by a 5 to 24 VDC source.

Be aware that the analog signal inputs and the open collector transistor on the AUX terminal share the same common. When using both an external analog signal and the AUX terminal as an output, the common of the analog signals and the relay coil supply power must already be at the same potential, or one of the devices must be on an isolated common. Do not tie the commons of two non-isolated devices to the common of the drive. Doing so may damage the drive and the devices.

+5V

AUX

COM

5 - 24VRelayCoil

23


Auxillary Input

Figure 12. Signal 2 Potentiometer and Analog Signal Connections


SIG1 10VCOM

0 - 10 VDC-10 to 10 VDC

CW

Common(-)

Reference(+)

VDC

mA

SIG2

4 - 20 mA

Common(-)

Reference(+)

SIG2 SIG1 10VCOM

VDC

mA

SIG2

SIG2 SIG1 10VCOM

VDC

mA

SIG2

SIG2

If no alarm output is needed, the AUX terminal can be set as a digital input. The AUX switch toggles between the SIG1 and SIG2 inputs. Pages 24 through 27 show various application examples that could utilize this switch.

The second control signal can be a potentiometer, analog voltage, or analog current signal. Refer to page 20 for descriptions on how these setups are wired and used, with the only difference being this connection is made to terminal SIG2 instead of SIG1. The only way to use the SIG2 signal is to set the AUX terminal as an input (see pages 15 and 16) and to close the AUX terminal to COM through a switch. If the AUX terminal is set as an alarm output, the SIG2 terminal is not used in Speed Mode, Torque Mode, or Linear Mode.

Input Signal 2 - Potentiometer and Analog Signal

24

MGC Series

Independent Speed 1 / Speed 2 (Torque 1 / Torque 2)

Figure 13. Independent Speed 1 / Speed 2 (Torque 1 / Torque 2)

Set the auxillary connection for an input by setting the AUX jumper for IN. Use a single-pole, single-throw switch to connect the COM and AUX terminals. When this switch is open, the drive will follow the signal on terminal SIG1. When this switch is closed, the drive will follow the signal on terminal SIG2. The figure below demonstrates this with two potentiometers connected, but analog signals may be used as well. Refer to pages 20 and 23 for Signal 1 and Signal 2 wiring and jumper options.

The Direction switch on page 21 and any of the stopping options on pages 30 through 34 may be used with this setup.


Open to follow Speed 1Close to follow Speed 2

Speed 2Potentiometer

Speed1Potentiometer

Application Examples with AUX as an Input

25


Independent Forward & Reverse

Figure 14. Independent Forward & Reverse

Set the auxillary connection for an input by setting the AUX jumper for IN. Use a double-pole, single-throw switch to connect the COM and AUX terminals, as well as the COM and DIR terminals. When this switch is open, the drive will follow the signal on terminal SIG1 in the forward direction. When this switch is closed, the drive will follow the signal on terminal SIG2 in the reverse direction. The figure below demonstrates this with two potentiometers connected, but analog signals may be used as well. Refer to pages 20 and 23 for Signal 1 and Signal 2 wiring and jumper options.

Any of the stopping options on pages 30 through 34 may be used with this setup.


Open to run ForwardClose to run Reverse

Reverse SpeedPotentiometer

Forward SpeedPotentiometer

26

MGC Series

Run / Jog Switch

Figure 15. Run/Jog Switch


Open for Run ModeClose for Jog Mode

Run/Jog SpeedPotentiometer

In Jog ModeOpen to StopClose to Run


Open for Run Mode (Pot 1)Close for Jog Mode (Pot 2)Jog Speed

Potentiometer

Run SpeedPotentiometer

In Jog ModeOpen to StopClose to Run

Set the auxillary connection for an input by setting the AUX jumper for IN. Use a single-pole, single-throw switch to connect the COM and AUX terminals. When this switch is open, the drive will run continuously. When this switch is closed, the drive will only run when the Jog pushbutton is closed. For separate Run and Jog speeds, a second potentiometer can be used as shown in the bottom wiring diagram. Refer to pages 20 and 23 for Signal 1 and Signal 2 wiring and jumper options.


27


Auto / Manual Switch (Remote / Local Switch)

Figure 16. Auto/Manual Switch (Remote / Local Switch)


Open for Manual / Local ModeClose for Auto / Remote Mode

Manual / LocalPotentiometer

Auto / RemoteAnalog Signal

Signal Common (-) SignalReference (+)

Set the auxillary connection for an input by setting the AUX jumper for IN. Use a single-pole, single-throw switch to connect the COM and AUX terminals. When this switch is open, the drive will follow the signal on terminal SIG1. When this switch is closed, the drive will follow the signal on terminal SIG2. The figure below demonstrates this with one potentiometer and one analog signal connected, but two analog signals may be used as well.


Refer to pages 20 and 23 for Signal 1 and Signal 2 wiring and jumper options.

28

MGC Series

Linear Mode

Figure 17. Linear Mode

In Linear Mode, the command signal is used to vary both speed and torque proportionally. If the potentiometer is set to 50%, the drive will try to achieve 50% of the maximum torque set by the FWCL and RVCL trim pots, up to a speed of 50% determined by the OFS1 and MAX trim pots. The figure below demonstrates this with a potentiometer connected, but an analog signal may be used as well. Refer to page 20 for Signal 1 wiring and jumper options.

The AUX terminal can be used as either an alarm output or digital input so that two signals can be used. To use it as an alarm output, refer to page 22. To use the AUX terminal to toggle between two command signals, refer to page 23.


Refer to Figure 7 on page 18 for DIP switch SO501 settings to enter into Linear Mode.


Speed/TorquePotentiometer

29


Independent Mode

Figure 18. Independent Mode


TorquePotentiometer

SpeedPotentiometer

In Independent Mode, terminal SIG1 is used to determine the maximum speed within a range determined by the OFS1 and MAX trim pots. The signal on terminal SIG2 is used to set the desired current limit within a range determined by the OFS2 and FWCL & RVCL trim pots. The figure below demonstrates this with two potentiometers connected, but analog signals may be used as well. Refer to pages 20 and 23 for Signal 1 and Signal 2 wiring and jumper options.

Since both SIG1 and SIG2 have designated purposes in this mode, setting the AUX terminal as an input will have no functionality. The AUX terminal can still be used as an alarm output however. Refer to page 22.


Refer to Figure 7 on page 18 for DIP switch SO501 settings to enter into Independent Mode.

30

MGC Series

Starting and Stopping Methods

Regenerative braking, decelerating, or coasting to a stop are 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.

For this reason, American Control Electronics strongly recommends installing an emergency stop switch on both AC line inputs (see Figure 5 on page 14).

Frequent starting and stopping can produce high torque. This may cause damage to motors, especially gearmotors that are not properly sized for the application.

!WARNING!

By default, the drive will automatically run to set speed when power is applied and the Enable, Regen Brake, and Inhibit are set to run. To set the drive up so that it must see an input changed before running, set DIP Switch 4 to ON. In this setup, the drive must see a “no run” condition before it will acknowledge any run commands. Do one of the following;

- Set the Enable to “Coast”, then to “Run”.

- Set the Inhibit to “Brake”, then to “Run”.

- Set the potentiometer fully CCW, then turn it CW.

- Set the analog signal to zero speed, then to a run command.

Automatic Restart Upon Power Restoration

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 remote adjust potentiometer or analog signal. When AC line voltage is removed, the motor coasts to a stop.

Line Starting and Stopping

31


Figure 19. Enable Switch

Coast to Zero Speed (Enable)

When DIP switch 6 is set to OFF, the EN terminal acts as an enable switch. Connect the switch to terminals COM and EN.

Disabling the drive causes the motor to coast to zero speed. The enable bypasses both the minimum speed set by the OFS1 & OFS2 trim pots, as well as and the deceleration rate set by the FACC or RACC trim pots. Re-enable the drive to accelerate the motor to set speed. See Figure 19.

For an open to run / close to stop setup, set SO501 DIP switch 7 to OFF.

For a close to run /open to stop setup, set SO501 DIP switch 7 to ON.

If no Enable switch is desired, set SO501 DIP switch 7 to OFF and make no connection to terminal EN.


If DIP Switch 7 is OFFOpen to Run

Close to Stop

If DIP Switch 7 is ONOpen to StopClose to Run

32

MGC Series

Decelerate to Minimum Speed (Regen Brake)

To stop the motor at a rate determined by the FACC and RACC trim pots, use a stop switch in conjuncture with a remote adjust potentiometer. For a normally open switch (open to run, close to stop), connect the switch between terminals COM and SIG1. For a normally closed switch (close to run, open to stop), wire the switch in series with the potentiometer on terminal 10V.

Figure 20. Regen Brakes Switches

SIG1 10VCOM

SpeedPotentiometer

Close to RunOpen to Stop

Open to RunClose to Stop

33


Regenerative Brake to Zero Speed (Inhibit)

When DIP switch 8 is set to OFF, the INH terminal acts as an inhibit switch. Connect the switch to terminals COM and INH.

Activate the inhibit to regeneratively brake the motor to zero speed. The inhibit bypasses both the minimum speed set by the OFS1 and OFS2 trim pots, as well as the deceleration rate set by the FACC or RACC trim pots. Deactivate the inhibit to accelerate the motor to set speed. See Figure 21.

For an open to run, close to stop setup, set SO501 DIP switch 8 to OFF.

For a close to run, open to stop setup, set SO501 DIP switch 8 to ON.

If not Inhibit switch is desired, set SO501 DIP switch 8 to OFF and make no connection to terminal INH.

Figure 21. Inhibit Switch


If DIP Switch 8 is OFFOpen to Run

Close to Stop

If DIP Switch 8 is ONOpen to StopClose to Run

34

MGC Series

3-Wire Start/Stop

When DIP switch 6 on SO501 is set to ON, the EN and INH terminals act as a 3-Wire Start/Stop. Connect the START switch to terminals COM and EN. Connect the STOP switch to terminals COM and INH.

Terminal 7 determines if the Start (Enable) switch is open to start or close to start. Traditional 3-Wire Start/Stop setups use a normally open pushbutton, so DIP switch 7 should be OFF.

Terminal 8 determines if the Stop (Inhibit) switch is open to stop or close to stop. Traditional 3-Wire Start/Stop setups use a normally closed pushbutton, so DIP switch 7 should be ON.

When the drive sees a short between the COM and EN terminals (closing the START switch), the drive will enable and the motor will run. This connecton is momentary, meaning the motor will continue to run even after the START switch is let go and the connection opens.

To stop the motor, open the connection between terminals COM and INH (opening the STOP switch). The drive will regeneratively brake the motor to zero speed at a rate determined by the FACC and RACC trim pots.


In a traditional 3-Wire Start/Stop setup,the Start switch is N.O. and the Stop

switch is N.C. For this setup, DIP switch7 should be OFF and DIP switch 8

should be ON.

StopStart

Figure 22. 3-Wire Start/Stop

35


Calibration for Speed & Torque Modes

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!

MGC 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.

36

MGC Series

Signal 1 Offset (OFS1)

The OFS1 trim pot is used for 2 functions; setting the minimum speed in a unidirectional application or configuring the drive into bidirectional mode with a unidirectional signal (WigWag Mode). OFS1 only sets these adjustments for the signal coming into terminal SIG1.

To calibrate OFS1 as a minimum speed or offset in unidirectional mode:

1. Set the OFS1 trim pot full CCW.

2. Set the remote adjust potentiometer or analog signal on terminal SIG1 for minimum speed (ie full CCW, 0 VDC, or 4 mA).

3. Adjust OFS1 until the desired minimum speed is reached.

To calibrate OFS1 for bidirectional operation with a unidirectional signal:

1. Set the OFS1 trim pot at 50%.

2. Set the remote adjust potentiometer or analog signal on terminal SIG1 for zero speed (ie 12 o’clock on a remote potentiometer, 5 VDC, or 12 mA).

3. Adjust OFS1 until the motor does not move.

37


Signal 2 Offset (OFS2)

The OFS2 trim pot is used for 2 functions; setting the minimum speed in a unidirectional application or configuring the drive into bidirectional mode with a unidirectional signal (WigWag Mode). OFS2 only sets these adjustments for the signal coming into terminal SIG2.

To calibrate OFS2 as a minimum speed or offset:




To calibrate OFS2 for bidirectional operation with a unidirectional signal:

1. Set the OFS2 trim pot at 50%.

2. Set the remote adjust potentiometer or analog signal on terminal SIG2 for zero speed (ie 12 o’clock on a potentiometer, 5 VDC, or 12 mA).

3. Adjust OFS2 until the motor does not move.

38

MGC Series

Maximum Speed (MAX)

The MAX setting determines the maximum motor speed in both the forward and reverse directions for the SIG1 and SIG2 commands.

To calibrate MAX:

1. Set the MAX trim pot full CCW.

2. Set the speed adjust potentiometer or analog signal for maximum speed.

3. Adjust MAX until the desired maximum speed is reached.

39


Motor Overload Protection (MOP)

The MOP trim pot is used to set the amperage trip point that will cause the drive to fault out. This is used to satisfy UL standard 61800-5-1 for motor overload protection. To calibrate the MOP trim pot:

1. With the power disconnected from the drive, connect a DC ammeter in series with the motor armature.

2. Set the MOP trim pot to maximum (full CW) and the FWCL trim pot to minimum (full CCW).

3. Set the remote adjust potentiometer or analog signal to maximum speed.

4. Lock the motor armature. Be sure that the motor is firmly mounted.

5. Apply AC line power. The motor should be stalled in order to pull the maximum amount of current possible.

6. Slowly adjust the FWCL trim pot CW until the ammeter reads the amount of current you want to set as the motor overload trip point.

7. Slowly adjust the MOP trim pot CCW. The red LIMIT LED should being to flash slowly. Continue to adjust the MOP trim pot CCW until the red LIMIT LED becomes solid. If it begins to flash quickly, the trim pot has been turned too far CCW.

8. Remove AC line power. Wait 30 seconds before reapplying power.

Since calibrating the MOP trim pot requires changing the FWCL trim pot, it is recommended to calibrate the MOP before calibrating the FWCL. If not Motor Overloaded Protection is needed, turn the MOP trim pot fully clockwise.

40

MGC Series

Forward Current Limit (FWCL)

The FWCL setting determines the maximum torque for accelerating and driving the motor in the forward direction. It also determines the maximum torque for braking to zero speed if running in the reverse direction. To calibrate FWCL, refer to the recommended FWCL settings in Figure 23 on page 44 or use the following procedure:

1. With the power disconnected from the drive, connect a DC ammeter in series with the armature.

2. Set the FWCL trim pot to minimum (full CCW).

3. Carefully lock the motor armature. Be sure that the motor is firmly mounted.

4. Set the remote adjust potentiometer full CW or analog input signal to maximum speed.

5. Apply line power. The motor should be stopped.

6. Slowly adjust the FWCL trim pot CW until the armature current is 150% of motor rated armature current.

7. Turn the remote adjust potentiometer CCW or decrease the analog input signal.

8. Remove line power and then remove the stall from the motor.

9. Remove the ammeter in series with the motor armature if it is no longer needed.

If needing Motor Overloaded Protection, calibrate the MOP trim pot before the FWCL trim pot.

FWCL 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.

!WARNING!

41


Reverse Current Limit (RVCL)

The RVCL setting determines the maximum torque for braking to zero speed if running in the forward direction. It also determines the maximum torque for accelerating and driving the motor in the reverse direction. To calibrate RVCL, refer to the recommended RVCL settings in Figure 23 on page 44 or use the following procedure:


2. Set the RVCL trim pot to minimum (full CCW).


4. Set the remote adjust potentiometer full CW or analog input signal to maximum speed. Set the Direction Switch for reverse.


6. Slowly adjust the RVCL trim pot CW until the armature current is 150% of motor rated armature current.




RVCL 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.

!WARNING!

42

MGC Series

IR Compensation (IR/T)

No Tach Feedback

The IR/T setting determines the degree to which motor speed is held constant as the motor load changes.

Use the following procedure to recalibrate the IR/T setting when no tach feedback is used:

1. Set the IR/T trim pot to minimum (full CCW).

2. Increase the remote 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.

3. Load the motor armature to its full load armature current rating.The motor should slow down.

4. While keeping the load on the motor, rotate the IR/T trim pot until the motor runs at the speed measured in step 2. If the motor oscillates (overcompensation), the IR/T trim pot may be set too high (CW). Turn the IR/T trim pot CCW to stabilize the motor.

5. Unload the motor.

If the motor oscillates, the IR/T setting is too high. See Figure 23 on page 44 for recommended IR/T settings.

43


Tach Feedback

Use the following procedure to recalibrate the IR/T setting when tach feedback is used:

1. Connect the tachogenerator to T1 and T2. The polarity is positive (+) for T1 and negative (-) for T2 when the motor is running in the forward direction.

2. Set the feedback jumper J504 to A90 if using a 90 VDC motor or to A180 if using a 180 VDC motor.

3. Set the remote adjust potentiometer or analog input signal to maximum forward speed. Measure the armature voltage across A1 and A2 using a voltmeter.

4. Set the speed adjust potentiometer or analog input signal to zero speed.

5. Set J504 to TACH for tachogenerator feedback.

6. Set the IR/T trim pot to full CW.

7. Set the remote adjust potentiometer or analog input signal to maximum forward speed.

8. Adjust the IR/T trim pot until the armature voltage is the same value as the voltage measured in step 3.

Check that the TACH is properly calibrated. The motor should run at the same set speed when J504 is set to either A90/A180 or TACH.

44

MGC Series

Figure 23. Recommended Torque and IR Compensation Settings

MODEL MGC403-111 HP90 VDC10.0 AMPS

3/4 HP90 VDC7.50 AMPS



FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T

2 HP180 VDC10.0 AMPS

1 1/2 HP180 VDC7.50 AMPS



FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T

MODEL MGC403-1.51/8 HP90 VDC1.5 AMPS

1/10 HP90 VDC1.0 AMP



FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T



1/10 HP180 VDC0.50 AMPS

1/25 HP180 VDC0.20 AMPS

FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T

45


Forward Acceleration / Reverse Deceleration (FACC)

Reverse Acceleration / Forward Deceleration (RACC)

The FACC setting determines the time the motor takes to ramp to a different speed in the forward direction. If running from a slow forward speed to a faster forward speed, this would be an acceleration rate. If running from a fast reverse speed to a slower reverse speed, this would be a decleration rate. FACC is factory set for the shortest acceleration/deceleration time (full CCW).

To set the acceleration time:

1. Set the remote adjust potentiometer or analog signal for minimum speed. The motor should run at minimum speed.

2. Set the remote adjust potentiometer or analog signal for maximum speed. Measure the time it takes the motor to go from minimum to maximum speed.

3. If the time measured in step 2 is not the desired acceleration time, turn the FACC 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.

The RACC setting determines the time the motor takes to ramp to a different speed in the reverse direction. If running from a slow reverse speed to a faster reverse speed, this would be an acceleration rate. If running from a fast forward speed to a slower forward speed, this would be a decleration rate. RACC is factory set for the shortest acceleration/deceleration time (full CCW).

To set the reverse acceleration time, follow steps 1-3 above, but with the drive set to run in the reverse direction.

46

MGC Series

Section 6. Torque Limit Cycling Mode OperationsMode SelectionDIP Switches 1 through 3 on SO501 are used to determine the mode of operation.

1 2 3

ON Torque Limit Cycling Mode: The remote adjust potentiometers and / or analog reference signals are used to command speed. The drive will output whatever current (torque) is necessary to achieve the commanded voltage (speed). If the drive enters into a current limit condition, it will automatically change direction if the current limit condition lasts for a setable period of time.

To set the drive to cycle using a current limit, set DIP Switches 1 and 2 to the ON (up) position, and DIP Switch 3 to the OFF (down) position.

Figure 24. SO501 Settings for Torque Limit Cycling Mode Operation

47

Section 6. Torque Limit Mode Operation

1 2 3 4 5 6 7 8

ON




DIP Switch 5: Alarm Output Type (see page 22)



DIP Switch 6: 3-Wire Start/Stop (see pages 30-34)

OFF: The EN and INH terminals act as Enable and Inhibit.

ON: The EN and INH terminals act as a 3-Wire Start/Stop.

DIP Switch 7: Invert Enable (see page 31)

OFF: Enable is open to run, close to coast to a stop.

ON: Enable is close to run, open to coast to a stop.

DIP Switch 8: Invert Inhibit (see page 33)

OFF: Inhibit is open to run, close to regeneratively brake to a stop.

ON: Inhibit is close to run, open to regeneratively brake to a stop.


48

MGC Series

Torque Limit Cycling ModeIn Torque Limit Cycling Mode, the drive will automatically change direction if the motor asks for more current than the limit set by trim pot FWCL, for an amount of time longer than the time period set by trim pot RVCL.

Command signals on terminals COM, SIG1, SIG2, and 10V are the same as they are in Speed Mode. Refer to pages 20 and 23.

The AUX terminal can be used as either an alarm output or digital input so that two signals can be used. To use it as an alarm output, refer to page 22. To use the AUX terminal to toggle between two command signals, refer to page 23.

Any of the stopping options on pages 30 through 34 may be used with this setup.

The Direction Switch operates differently in Torque Limit Cycling Mode. Whenever movement is first commanded, an open Direction Switch between terminals DIR and COM will result in forward motor movement, while a closed switch will result in reverse. However, after the intial movement any state change in the direction switch will result in a direction change.

For example, if an application starts with an open switch, the motor will move in the forward direction. After an automatic reversal from a current limit hit however, an open switch is now used in reversed. Closing the switch would change the direction back to forward. Therefore, the direction of the motor is not tied to an open or closed state on the Direction Switch (other than at initial movement), but rather the direction will change from whichever direction the motor is currently moving if the Diretion Switch changes state.

Trim pots OFS1, OFS2, MAX, FACC, RACC, IR/T, and MOP all serve the same function as they do in Speed Mode. Refer to pages 35 through 45 for calibration procedures.

49

Section 6. Torque Limit Mode Operation

Figure 26. Torque Limit Cycling with Limit Switch Wiring

The FWCL trim pot is calibrated the same as on page 40. However, in Torque Limit Cycling Mode, the FWCL sets the current limit in both directions.

The RVCL trim pot is used to set a time period that determines if the drive should change direction. The time ranges from 0.2 (full CCW) to 10 (full CW) seconds and starts counting immediately after the current limit is reached.

Some applications may want a limit switch at the starting position to prevent over-travel in the reverse direction. Figure 26 below shows one possible wiring setup using 3-Wire Start/Stop (refer to page 34).

N.C.HOMELIMIT

START

STOP

AUXCOMINHCOMENDIRSIG210VSIG1COM

REV SPEEDPOT

FWD SPEEDPOT

1 2 3 4 5 6 7 8

ON

50

MGC Series

Section 7. Limit Switch Cycling Mode OperationsMode Selection

1 2 3

ONTo set the drive to cycle using limit switches, set DIP Switches 1 and 3 to the ON (up) position, and DIP Switch 2 to the OFF (down) position.

Figure 27. SO501 Settings for Limit Switch Cycling



ON: Upon power up, the drive will not run until it sees a “no run” condition first. This prevents unexpected takeoff when AC power is applied. The drive will not run until either the Enable or Inhibit is toggled, or the remote potentiometer or analog input signal is set to a zero speed reference (ie. full CCW, 0 VDC, 4 mA). See page 30 for more information.

DIP Switch 5: Alarm Output Type



NOTE: Refer to page 22 for wiring and more detailed description. The AUX alarm output may not be available in all cycling modes.

DIP Switches 1, 2, & 3: Limit Switch Cycling

51

Section 7. Limit Switch Cycling Mode Operation

1 2 3 4 5 6 7 8

ON

DIP Switches 6: Cycling Type

1 Limit Switch

OFF: Unidirectional Cycle / Indexing

ON: Auto Cycling

2 Limit Switches

OFF: Half Cycle

ON: Single Cycle / Continuous Cycling

DIP Switch 7: # of Limit Switches

OFF: 1 Limit Switch

ON: 2 Limit Switches

DIP Switch 8: Invert Limits

OFF: Normally open limit switches (i.e. limits close when activated).

ON: Normally closed limit swithes (i.e. limits open when activated).


52

MGC Series

Unidirectional Cycle with One Limit Switch

In Unidirectional Cycle Mode, the motor will travel in the commanded direction until the limit switch on terminal INH is activated or the drive is commanded to stop. Once stopped, the drive must see another RUN FWD or RUN REV command to start another cycle.

Close the RUN FWD switch to start travel in the forward direction. The motor will accelerate to the speed commanded by the FWD SPEED POT. When the limit switch is activated, the drive will decelerate the motor to a stop. Once the limit switch is activated, the drive will enter into a dwell period set by the IR/T trim pot. During the dwell period, the drive will ignore any RUN FWD or RUN REV commands.

After the dwell period, the drive will not run until it receives another RUN FWD or RUN REV command.

To initially start a cycle in the reverse direction, close the RUN REV switch. The reverse speed is determined by the REV SPEED POT and the reverse dwell time set by the OFS2 trim pot.

The RUN FWD and RUN REV switches are momentary. The drive will not stop if the RUN FWD or RUN REV switch is opened while the motor is running. To stop the motor in mid travel before it has reached the limit switch, close both the RUN FWD and RUN REV switches simultaneously or use a STOP switch to mimic the limit switch.

To use one potentiometer / analog signal to command the speed in both directions, only use the FWD SPEED POT or analog signal on SIG1, and jumper terminals SIG1 and SIG2. See pages 20 and 23 for a more details on potentiometer and analog signal wiring.

When running in the forward direction, the RUN REV switch may be used to change direction instantaneously. Likewise, when running in the reverse direction, the RUN FWD switch may be used to change direction.

53


STOP

N.O.LIMIT

SWITCH

REV SPEEDPOT

FWD SPEEDPOT


STOP

RUNFWD

AUXCOMINH

STOPN.C.LIMIT

SWITCH

RUNREV

1 2 3 4 5 6 7 8

ON

Figure 29. Unidirectional Cycle Wiring

Since the SIG2 input is a dedicated reverse speed, the AUX terminal serves no function if set to IN. It can still be set to OUT to be used as a current limit or run alarm. See page 22 for AUX wiring as an output.

54

MGC Series

Indexing

Indexing Mode is the same as Unidirectional Cycle Mode, except that the FWD RUN and REV RUN are maintained switches. Now when the drive finishes a Unidirectional Cycle, the run command is immediately present after the dwell time, so the motor will start another cycle automatically. Multiple limit switches can be wired in parallel or series to create indexing stations. However, the drive is not aware that there are multiple limit switches and treats them all as one. Therefore, activating any of the limit switches at any time will stop the motor and initiate a dwell period.

N.O.INDEXLIMIT 1


REV SPEEDPOT

FWD SPEEDPOT

STOP

RUNFWD

RUNREV

STOP

N.O.INDEXLIMIT 2

N.O.INDEXLIMIT 3

1 2 3 4 5 6 7 8

ON

Figure 30. Indexing Wiring with N.O. Limit Switches

55



N.C.INDEXLIMIT 1

REV SPEEDPOT

FWD SPEEDPOT

STOP

RUNFWD

RUNREV

STOP

N.C.INDEXLIMIT 2N.C.INDEXLIMIT 3

1 2 3 4 5 6 7 8

ON

Figure 31. Indexing Wiring with N.C. Limit Switches

Opening the RUN FWD or RUN REV switches will not stop the motor, but only prevent it from continuing past the next limit switch. To stop the motor, close both the RUN FWD and RUN REV switches simultaneously (close both DIR and EN terminals to COM) or mimic one of the index limit switches being activated.

56

MGC Series

Auto Cycling with One Limit Switch

In Auto Cycling Mode, the motor will travel in the commanded direction until the limit switch on terminal INH is activated. The motor will then stop, dwell, and travel in the opposite direction. It will continue to cycle until commanded to stop.

Close the maintained RUN FWD switch to start travel in the forward direction. The motor will accelerate to the speed commanded by the FWD SPEED POT. When the limit switch is activated, the drive will decelerate the motor to a stop. Once the limit switch is activated, the drive will enter into a dwell period set by the IR/T trim pot. During the dwell period, the drive will ignore any RUN FWD or RUN REV commands.

After the dwell period, the drive will automatically run the motor in reverse at the speed commanded by the REV SPEED POT until the limit switch is activated again. When the limit switch is activated while the motor is running in the reverse direction, the dwell time is set by the OFS2 trim pot. The drive will continue to cycle back and forth until commanded to stop.

To initially start a cycle in the reverse direction, close the maintained RUN REV switch.

The RUN FWD and RUN REV switches are maintained. The drive will not stop immediately if the RUN FWD or RUN REV switch is opened while the motor is running. This will only stop the motor once the limit has been activated. To stop the motor in mid travel before it has reached the limit switch, close both the RUN FWD and RUN REV switches simultaneously. If the motor is at a stopped position other than the limit switch, use a momentary pushbutton to move the motor to the limit switch position. Use the HOME FWD pushbutton to get to the limit switch with forward rotation and the HOME REV with reverse rotation.

To use one potentiometer / analog signal to command the speed in both directions, only use the FWD SPEED POT or analog signal on SIG1, and

57


N.O.LIMIT

SWITCH

REV SPEEDPOT

FWD SPEEDPOT


STOP

HOMEFWD

AUXCOMINH

STOPN.C.LIMIT

SWITCH

RUN REV

1 2 3 4 5 6 7 8

ON

RUNFWD

HOME REV

Figure 32. Auto Cycling Wiring

jumper terminals SIG1 and SIG2. See pages 20 and 23 for a more details on potentiometer and analog signal wiring.


Since the SIG2 input is a dedicated reverse speed, the AUX terminal serves no function if set to IN. It can still be set to OUT to be used as a current limit or run alarm. See page 22 for AUX wiring as an output.

58

MGC Series

Half Cycle with Two Limit Switches

In Half Cycle Mode, the motor will travel in the commanded direction until the limit switch in the corresponding direction is activated or the drive is commanded to stop. Once stopped, the drive must see another RUN FWD or RUN REV command to start another cycle.


Close the RUN REV switch to start travel in the reverse direction. The motor will accelerate to the speed commanded by the REV SPEED POT. When the REV LIMIT is activated, the drive will decelerate the motor to a stop. Once the limit switch is activated, the drive will enter into a dwell period set by the OFS2 trim pot. During the dwell period, the drive will ignore any RUN FWD or RUN REV commands.

After either dwell period, the drive will not run until it receives another RUN FWD or RUN REV command.

The RUN FWD and RUN REV switches are momentary. The drive will not stop if the RUN FWD or RUN REV switch is opened while the motor is running. To stop the motor in mid travel before it has reached the limit switch, close both the RUN FWD and RUN REV switches simultaneously or use a STOP switch to mimic the limit switches being activated simultaneously.


59


REV SPEEDPOT

FWD SPEEDPOT


RUNFWD

RUNREV

STOP

STOP

N.O.REVLIMIT

N.O.FWDLIMIT

AUXCOMINH

N.C. REVLIMIT

SWITCH

N.C. FWDLIMIT

SWITCH

STOP

1 2 3 4 5 6 7 8

ON

Figure 33. Half Cycle Wiring


Since the AUX terminal is designated as a limit switch input, jumper AUX must be set to IN. See pages 15 and 16.

60

MGC Series

Single Cycle with Two Limit Switches

In Single Cycle Mode, the motor will travel in the commanded direction until the limit switch in the corresponding direction is activated. The motor will then stop, dwell, and travel in the opposite direction until the other limit switch is activated. It will then stop and must see another RUN FWD or RUN REV command to start another cycle.


After the dwell period, the drive will automatically run the motor in reverse at the speed commanded by the REV SPEED POT until the REV LIMIT is activated. When the REV LIMIT is activated, the dwell time is set by the OFS2 trim pot. After the dwell period, the drive will not run until it receives another RUN FWD or RUN REV command.

To initially start a cycle in the reverse direction, close the RUN REV switch. The motor will then run to the REV LIMIT, stop, dwell, and then run to the FWD LIMIT.

The RUN FWD and RUN REV switches are momentary. The drive will not stop if the RUN FWD or RUN REV switch is opened while the motor is running. To stop the motor in mid travel before it has reached the limit switch, use a STOP switch to mimic the limit switches being activated simultaneously.


When running in the forward direction, the RUN REV switch may be used to change direction instantaneously. Likewise, when running in the

61


STOP

N.O.REVLIMIT

N.O.FWDLIMIT


REV SPEEDPOT

FWD SPEEDPOT

RUNFWD

AUXCOMINH

N.C. REVLIMIT

SWITCH

N.C. FWDLIMIT

SWITCH

STOP

RUNREV

1 2 3 4 5 6 7 8

ON

Figure 34. Single Cycle Wiring

reverse direction, the RUN FWD switch may be used to change direction.

Since the AUX terminal is designated as a limit switch input, jumper AUX must be set to IN. See pages 15 and 16.

If the motor happens to be at an undesired location at start-up and it is not acceptable in the application to run a single cycle back to a starting position at a limit switch, the drive can be put into Jog Mode. For more details on Jog Mode, see page 58.

62

MGC Series

Continuous Cycle with Two Limit Switches

Continuous Cycle Mode is the same as Single Cycle Mode, except that the FWD RUN and REV RUN are maintained switches. Now when the drive finishes a Single Cycle, the run command is immediately present after the dwell time. The end result is what appears to be a continuous cycling between the two limit switches.

If the motor is starting from an undesired position (e.g. it was previously stopped in mid-cycle), there are two methods for moving the motor to a desired start position.

One option is to use a momentary switch and run a single cycle (see pages 56 and 57). By momentarily closing terminals EN and COM, the motor will run foward, hit the forward limit, and then run to the reverse limit. Since the switch was momentary, the motor will stay here and not start another cycle. Use a momentary switch on terminals DIR and COM to run to the REV LIMIT first, and to end on the FWD LIMIT.

An alternative option is Jog Mode. Jog Mode can be entered into by closing both the FWD RUN and REV RUN switches simultaneously (closing both EN and DIR terminals to COM). Now the drive will use the input on SIG1 for bidirectional operation, meaning full CCW will run the motor full speed reverse and full CW will run the motor at full speed forward. This allows for both speed and directional control of the motor to either run it to a limit switch or to stop it at some desired position between the limits. If the motor will always start from a limit switch in the application, switches may be used instead of a potentiometer. Closing terminal SIG1 to COM will run the motor to the REV LIMIT without pause or cycling, and closing terminal SIG1 to 10V will run the motor to the FWD LIMT without pause or cycling.

It is recommended that the switch used to enter Jog Mode also disconnect the FWD SPEED POT from SIG1 and connect a seperate JOG SPEED POT that is kept at the 12 o’clock position. This is to prevent an unintended runway condition if Jog Mode is entered while the FWD SPEED POT is set full CCW.

63


Figure 35. Continuous Cycling Wiring

3P2T JOG SWITCH

FWDSPEED

POT COM

EN

DIR

COM

SIG1

10V

COM

JOGSPEED

POT

10V

COM

STOP

N.O.REVLIMIT

N.O.FWDLIMIT


REV SPEEDPOT

FWD SPEEDPOT

RUNREV

RUNFWD

64

MGC Series

Calibration for Limit Switch Cycling Mode


!WARNING!


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.

65


Offset (OFS1)

The OFS1 trim pot is used to set the minimum speed and/or adjusting the zero point if using a 4 - 20 mA analog signal. The OFS1 will adjust the minimum speed for both the SIG1 and SIG2 commands.

To calibrate OFS1:




Maximum Speed (MAX)

The MAX setting determines the maximum motor speed in both the forward and reverse directions for the SIG1 and SIG2 commands.

To calibrate MAX:




66

MGC Series

Forward Dwell Time (IR/T)

The IR/T trim pot is used to set a dwell time after the forward limit switch has been activated. If in a single limit switch mode, the forward dwell is active if the motor was traveling in a forward direction when the limit switch was activated. The drive will ignore any run commands that are sent during the dwell period. The dwell time ranges from 0.2 to 10 seconds and starts counting immediately after the limit switch is activated. If no forward dwell time is desired, set the trim pot fully CCW.

Reverse Dwell time (OFS2)

The OSF2 trim pot is used to set a dwell time after the reverse limit switch has been activated. If in a single limit switch mode, the reverse dwell is active if the motor was traveling in a reverse direction when the limit switch was activated. The drive will ignore any run commands that are sent during the dwell period. The dwell time ranges from 0.2 to 10 seconds and starts counting immediately after the limit switch is activated. If no reverse dwell time is desired, set the trim pot fully CCW.

67





2. Set the MOP trim pot to maximum (full CW) and the FWDCL trim pot to minimum (full CCW).





7. Slowly adjust the MOP trim pot CCW. The red LIMIT LED should being to flash slowly. Continue to adjust the MOP trim pot CCW until the red LIMIT LED becomes solid. If it beings to flash quickly, the trim pot has been turned too far CCW.



68

MGC Series














!WARNING!

69














!WARNING!

70

MGC Series

Figure 36. Recommended Torque Settings





FWCLRVCL

FWCLRVCL

FWCLRVCL

FWCLRVCL


1 1/2 HP180 VDC7.50 AMPS



FWCLRVCL

FWCLRVCL

FWCLRVCL

FWCLRVCL





FWCLRVCL

FWCLRVCL

FWCLRVCL

FWCLRVCL



1/10 HP180 VDC0.50 AMPS

1/25 HP180 VDC0.20 AMPS

FWCLRVCL

FWCLRVCL

FWCLRVCL

FWCLRVCL

71


Acceleration (FACC)

Deceleration (RACC)

The FACC setting determines the time the motor takes to ramp to a higher speed. FACC is factory set for the shortest acceleration time (full CCW).





The RACC setting determines the time the motor takes to ramp to a lower speed. RACC is factory set for the shortest deceleration time (full CCW).

To set the deceleration time:

1. Set the remote adjust potentiometer or analog signal for maximum speed. The motor should run at maximum speed.

2. Set the remote adjust potentiometer or analog signal for minimum speed. Measure the time it takes the motor to go from maximum to minimum speed.

3. If the time measured in step 2 is not the desired deceleration time, turn the RACC 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.

72

MGC Series

Section 8. Feedback Cycling Mode Operations

Mode Selection




1 2 3

ONTo set the drive to cycle using resistive feedback, set DIP Switches 2 and 3 to the ON (up) position, and DIP Switch 1 to the OFF (down) position.

Figure 37. SO501 Settings for Feedback Cycling

DIP Switches 1, 2, & 3: Feedback Cycling

DIP Switch 5: Alarm Output Type



NOTE: Feedback Cycling uses terminal SIG2 for the feedback signal. Therefore, setting the AUX to IN will have no effect. Set jumper AUX to OUT to use the AUX terminal for an alarm output. Refer to page 22 for wiring and more detailed description.

73

Section 8. Feedback Cycling Mode Operation

1 2 3 4 5 6 7 8

ON

OFF: Half Cycle

ON: Single Cycle / Continuous Cycle

DIP Switch 7 & 8: Not used


DIP Switch 6: Cycling Type

74

MGC Series

Feedback Cycling - Half Cycle

In Half Cycle Mode, the motor will travel in the commanded direction until the feedback limit in the corresponding direction is reached or the drive is commanded to stop. Once stopped, the drive must see another RUN FWD or RUN REV command to start another cycle.

Close the RUN FWD switch to start travel in the forward direction. The motor will accelerate to the speed commanded by the SPEED POT. When the forward limit position is reached, the drive will brake the motor to a stop and enter into a dwell period set by the IR/T trim pot. During the dwell period, the drive will ignore any RUN FWD or RUN REV commands.

Close the RUN REV switch to start travel in the reverse direction. The motor will accelerate to the speed commanded by the REV SPEED POT. When the reverse limit position is reached, the drive will brake the motor to a stop and enter into a dwell period set by the RACC trim pot. During the dwell period, the drive will ignore any RUN FWD or RUN REV commands.

After either dwell period, the drive will not run until it receives another RUN FWD or RUN REV command.

The RUN FWD and RUN REV switches are momentary. The drive will not stop if the RUN FWD or RUN REV switch is opened while the motor is running. To stop the motor in mid travel before it has reached the limit switch, use a STOP switch to close terminals INH and COM.


Since the SIG2 input is a dedicated feedback signal, the AUX terminal serves no function if set to IN. It can still be set to OUT to be used as a current limit or run alarm. See page 22 for AUX wiring as an output.

Setting the AUX to IN will have no effect since SIG2 is dedicated to the feedback signal. Set jumper AUX to OUT to use the AUX terminal for an alarm output. Refer to page 22 for wiring and more detailed description.

75


Figure 39. Half Cycling with Feedback

FEEDBACKPOT

SPEEDPOT


RUNFWD

RUNREV

STOP

1 2 3 4 5 6 7 8

ON

76

MGC Series

Feedback Cycling - Single Cycle

In Single Cycle Mode, the motor will travel in the commanded direction until the limit switch in the corresponding direction is activated. The motor will then stop, dwell, and travel in the opposite direction until the other limit switch is activated. It will then stop and must see another RUN FWD or RUN REV command to start another cycle.

Close the RUN FWD switch to start travel in the forward direction. The motor will accelerate to the speed commanded by the SPEED POT. When the forward limit position is reached, the drive will brake the motor to a stop and enter into a dwell period set by the IR/T trim pot. During the dwell period, the drive will ignore any RUN FWD or RUN REV commands.

After the dwell period, the drive will automatically run the motor in reverse at the speed commanded by the SPEED POT. When the reverse limit position is reached, the drive will brake the motor to a stop and enter into a dwell period set by the RACC trim pot. After the dwell period, the drive will not run until it receives another RUN FWD or RUN REV command.

To initially start a cycle in the reverse direction, close the RUN REV switch. The motor will then run to the reverse limit position, stop, dwell, and then run to the forward limit position.

The RUN FWD and RUN REV switches are momentary. The drive will not stop if the RUN FWD or RUN REV switch is opened while the motor is running. To stop the motor in mid travel before it has reached the limit switch, use a STOP switch to close terminals INH and COM.


Setting the AUX to IN will have no effect since SIG2 is dedicated to the feedback signal. Set jumper AUX to OUT to use the AUX terminal for an alarm output. Refer to page 22 for wiring and more detailed description.

77


Figure 40. Single Cycling with Feedback

If the motor happens to be at an undesired location at start-up and it is not acceptable in the application to run a single cycle back to a starting position at a limit switch, the drive can be put into Jog Mode. For more details on Jog Mode, see page 58.

FEEDBACKPOT

SPEEDPOT


RUNFWD

RUNREV

STOP

1 2 3 4 5 6 7 8

ON

78

MGC Series

Feedback Cycling - Continuous Cycle

Continuous Cycle Mode is the same as Single Cycle Mode, except that the FWD RUN and REV RUN are maintained switches. Now when the drive finishes a Single Cycle, the run command is immediately present after the dwell time. The end result is what appears to be a continuous cycling between the two limit positions.

If the motor is starting from an undesired position (e.g. it was previously stopped in mid-cycle), there are two methods for moving the motor to a desired start position.

One option is to use a momentary switch and run a single cycle (see pages 77 and 78). By momentarily closing terminals EN and COM, the motor will run foward, hit the forward limit position, and then run to the reverse limit position. Since the switch was momentary, the motor will stay here and not start another cycle. Use a momentary switch on terminals DIR and COM to run to the reverse limit position first, and to end at the forward limit position.

An alternative option is Jog Mode. Jog Mode can be entered into by closing both the FWD RUN and REV RUN switches simultaneously (closing both EN and DIR terminals to COM). Now the drive will use the input on SIG1 for bidirectional operation, meaning full CCW will run the motor full speed reverse and full CW will run the motor at full speed forward. This allows for both speed and directional control of the motor to either run it to a limit position or to stop it at some desired position between the limits. If the motor will always start from a limit position in the application, switches may be used instead of a potentiometer. Closing terminal SIG1 to COM will run the motor to the reverse limit position without pause or cycling, and closing terminal SIG1 to 10V will run the motor to the forward limit position without pause or cycling.

It is recommended that the switch used to enter Jog Mode also disconnect the SPEED POT from SIG1 and connect a seperate JOG POT that is kept at the 12 o’clock position. This is to prevent an unintended runway condition if Jog Mode is entered while the SPEED POT is set full CCW.

79


Figure 41. Auto Cycling with Feedback

3P2T JOG SWITCH

SPEEDPOT COM

EN

DIR

COM

SIG1

10V

COM

JOGPOT

10V

COM

FEEDBACKPOT

SPEEDPOT


RUNFWD

RUNREV

STOP

1 2 3 4 5 6 7 8

ON

80

MGC Series

Calibration for Feedback Cycling Mode


!WARNING!


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.

81


Minimum Retract / Home / Reverse Limit Position (OFS1)Depending on the application, the OSF1 trim pot is used to set the minimum retract, home, starting, or reverse limit position. Turning the trim pot clockwise will extend the actuator / move the motor in a forward direction. The range of the retract position is from 0 to 100% of the feedback range. To calibrate OFS1:


2. Set the remote adjust potentiometer or analog signal on terminal SIG1 for full retraction / home / reverse limit position (ie full CCW, 0 VDC, or 4 mA).

3. Adjust OFS1 until the desired retract / home / reverse limit position is reached.

OSF1 also sets the minimum range of the OFS2 extend position trim pot. Therefore, the OFS1 trim pot should be calibrated first. Adjusting the OSF1 trim pot AFTER calibrating the OFS2 trim pot will effect the OFS2 trim pot and require it to be recalibrated.

Maximum Extend / End-of-Travel / Forward Limit Position (OFS2)

Depending on the application, the OFS2 trim pot is used to set the maximum extend, end-of-travel, forward limit position. Turning the trim pot clockwise will extend the actuator / move the motor in a forward direction. The range of the extend position is from the retract positon to 100% of the feedback range. To calibrate OFS2:

1. Set the OFS2 trim pot half way.



82

MGC Series

Maximum Speed (MAX)

The MAX setting determines the maximum motor speed in both the forward and reverse directions.

To calibrate MAX:









Acceleration (FACC)

83


Forward Dwell Time (IR/T)

The IR/T trim pot is used to set a dwell time after the forward limit position has been activated. The drive will ignore any run commands that are sent during the dwell period. The dwell time ranges from 0.2 to 10 seconds and starts counting immediately after the forward limit position is reached. If no forward dwell time is desired, set the trim pot fully CCW.

Reverse Dwell Time (RACC)

The RACC trim pot is used to set a dwell time after the reverse limit position has been reached. The drive will ignore any run commands that are sent during the dwell period. The dwell time ranges from 0.2 to 10 seconds and starts counting immediately after the reverse limit position is reached. If no reverse dwell time is desired, set the trim pot fully CCW.

84

MGC Series












85















!WARNING!

86

MGC Series













!WARNING!

87







FWCLRVCL

FWCLRVCL

FWCLRVCL

FWCLRVCL


1 1/2 HP180 VDC7.50 AMPS



FWCLRVCL

FWCLRVCL

FWCLRVCL

FWCLRVCL





FWCLRVCL

FWCLRVCL

FWCLRVCL

FWCLRVCL



1/10 HP180 VDC0.50 AMPS

1/25 HP180 VDC0.20 AMPS

FWCLRVCL

FWCLRVCL

FWCLRVCL

FWCLRVCL

88

MGC Series

Section 9. Positioning Mode Operation

Mode Selection




DIP Switch 5: Alarm



1 2 3

ONTo set the drive to position using resistive feedback, set DIP Switches 2 and 3 to the ON (up) position, and DIP Switch 1 to the OFF (down) position. In this mode, the drive will compare a commanded position via the command signal on terminal SIG1, with the actual position via the feedback signal on terminal SIG2. If the commanded position is lower than the feedback position, the drive will output a positive DC armature voltage to run the motor forward. If the commanded position is higher than the feedback position, the drive will output a negative DC armature voltage to run the motor reverse.

Figure 43. SO501 Settings for Feedback Positioning

DIP Switches 1, 2, & 3: Positioning

89


1 2 3 4 5 6 7 8

ON


DIP Switches 6, 7, & 8: Not used

90

MGC Series

Potentiometer Command

Instead of using a 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 negative (common) to terminal COM. Connect the signal positive (reference) to SIG1. If using an analog voltage signal, jumper SIG1 must be set to VDC. If using an analog current signal, jumper SIG1 must be set to mA.

Use a 10K ohm, 1/4 W potentiometer for position control. Connect the counter-clockwise end of the potentiometer to terminal COM, the wiper to terminal SIG1, and the clockwise end to terminal 10V. If the potentiometer works inversely of the desired functionality (e.g. to extend the actuator / move the motor forward you must turn the potentiometer counterclockwise), power off the drive and swap the COM and 10V connections. If using a potentiometer, jumper SIG1 must be set to VDC.Refer to Figure 41.


SIG1 10VCOM

0 - 10 VDC-10 to 10 VDC

SIG1 10VCOM

CW

Common(-)

Reference(+)

VDC

mA

SIG1VDC

mA

SIG1

4 - 20 mA

SIG1 10VCOM

Common(-)

Reference(+)

VDC

mA

SIG1

Figure 45. Signal 1 Potentiometer & Analog Command Signal Connections

Analog Signal Command

Logic Connections

91


Direction Switch

Feedback Signal

The DIR terminal serves no purpose in positioning mode and is disabled.

If using a resistor-based feedback device, connect the common to terminal COM. Connect the feedback reference to SIG2 and the remaining connection to terminal 10V. If using a resistor-based feedback device, jumper SIG1 must be set to VDC. Refer to Figure 42.

If instead of using a 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 negative (common) to terminal COM. Connect the signal positive (reference) to SIG2. If using an analog voltage signal, jumper SIG2 must be set to VDC. If using an analog current signal, jumper SIG2 must be set to mA.


SIG1 10VCOM

CW

VDC

mA

SIG2

SIG2

Figure 46. Signal 2 Feedback Signal Connections

92

MGC Series

Figure 47. Enable Switch

Coast to Zero Speed (Enable)

An Enable switch can be used as a Start/Stop switch, causing the motor to coast to a stop. To run the motor, leave the switch open. To coast the motor to a stop, close the switch.

If no Enable switch is desired, make no connection to terminal EN.



93


Regenerative Brake to Zero Speed (Inhibit)

An Inhibit switch can be used as a Start/Stop switch, causing the motor to regeneratively brake to a stop. To run the motor, leave the switch open. To brake the motor to a stop, close the switch.

If no Inhibit switch is desired, make no connection to terminal INH.

Figure 48. Inhibit Switch



94

MGC Series

Auxillary Output

Figure 49. Auxillary Output

The drive has the ability to output an alarm. If DIP Switch 5 on SO501 is set to the OFF position, the auxillary output is a current limit alarm. The alarm will activate whenever the motor is asking for more current than the FWCL or RVCL trim pots are set to allow. If DIP switch 5 is set to the ON position, the alarm is a run alarm. The alarm will activate whenever the drive’s output is active (trying to accelerate the motor to speed or holding the motor at zero speed).

To use the AUX terminal as an alarm, the auxillary jumper must be set for OUT (refer to pages 15 and 16).

When inactive, the AUX terminal is pulled up to 5 VDC. When active, the AUX terminal is pulled to drive common by an open collector transistor. The open collector transistor effectivately operates as a power switch for an external relay coil separately powered by a 5 to 24 VDC source.

Be aware that the analog signal inputs and the open collector transistor on the AUX terminal share the same common. When using both an external analog signal and the AUX terminal as an output, the common of the analog signals and the relay coil supply power must already be at the same potential, or one of the devices must be on an isolated common. Do not tie the commons of two non-isolated devices to the common of the drive. Doing so may damage the drive and the devices.

+5V

AUX

COM

5 - 24VRelayCoil

95


Calibration for Positioning Mode


!WARNING!


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.

96

MGC Series

Minimum Retract / Home / Reverse Limit Position (OFS1)Depending on the application, the OSF1 trim pot is used to set the minimum retract, home, starting, or reverse limit position. Turning the trim pot clockwise will extend the actuator / move the motor in a forward direction. The range of the retract position is from 0 to 100% of the feedback range. To calibrate OFS1:




OSF1 also sets the minimum range of the OFS2 extend position trim pot. Therefore, the OFS1 trim pot should be calibrated first. Adjusting the OSF1 trim pot AFTER calibrating the OFS2 trim pot will effect the OFS2 trim pot and require it to be recalibrated.

Maximum Extend / End-of-Travel / Forward Limit Position (OFS2)

Depending on the application, the OFS2 trim pot is used to set the maximum extend, end-of-travel, forward limit position. Turning the trim pot clockwise will extend the actuator / move the motor in a forward direction. The range of the extend position is from the retract positon to 100% of the feedback range. To calibrate OFS2:

1. Set the OFS2 trim pot half way.



97


Error (RACC)

The RACC setting determines the amount of acceptable error on the final position. This can also be referred to as the deadband. Turning the trim pot fully CCW allows for the least amount of error / smallest deadband at the final position. However, because of brush commutation and potential slack in any gearing, it may be impossible for the drive to be within the error range for a commanded position. In these situations, the actuator / motor will oscillate as the drive hovers around the commanded position, but never able to achieve it within the limits set be the error RACC trim pot. To calibrate the RACC error trim pot:

1. Set the RACC trim pot full clockwise.

2. Set the remote adjust potentiometer or analog signal on terminal SIG1 for any random position.

3. After the actuator / motor has come to a stop, adjust the RACC trim pot CCW until the actuator / motor begins to oscillate, then turn it slightly back CW. If turning the trim pot fully CCW does not create oscillation, leave it there.

Speed (MAX)

The MAX setting determines the motor speed in both the forward and reverse directions.

To calibrate MAX:


2. Run the motor / actuator.


98

MGC Series

Acceleration (FACC)






99













100

MGC Series














!WARNING!

101














!WARNING!

102

MGC Series

IR Compensation (IR/T)

The IR/T setting determines the degree to which motor speed is held constant as the motor load changes.

Use the following procedure to recalibrate the IR/T setting when no tach feedback is used:

1. Set the IR/T 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.

3. Load the motor armature to its full load armature current rating.The motor should slow down.

4. While keeping the load on the motor, rotate the IR/T trim pot until the motor runs at the speed measured in step 2. If the motor oscillates (overcompensation), the IR/T trim pot may be set too high (CW). Turn the IR/T trim pot CCW to stabilize the motor.

5. Unload the motor.

See Figure 50 on page 103 for recommended IR/T settings.

103







FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T


1 1/2 HP180 VDC7.50 AMPS



FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T





FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T



1/10 HP180 VDC0.50 AMPS

1/25 HP180 VDC0.20 AMPS

FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T

FWCLRVCL

IR/T

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MGC Series

Section 10. Diagnostic LEDsMGC series drives are equipped with three diagnostic LEDs:

LIMIT (Red LED on Top Board)

Solid: Drive is in current limit. This means the motor is asking for more current (torque) than what the drive is set to allow out. This limit can be adjust using the FWCL and RVCL trim pots.

Flashing: Drive is in Motor Overload Protection Calibration Mode. This means the drive detected the MOP trim pot was adjusted and has automatically entered into calibration mode. The MOP is used to set a current level that if exceeded, will cause the drive to trip in accordance with UL 61800-5-1 standards.

STAT (Green LED on Top Board)

Solid: Normal operation.

1 Flash: The drive is being commanded to not run. Check the Enable and Inhibit connections, as well as DIP Switches 6, 7, and 8 settings.

2 Flashes: The drive is set for Auto Restart Prevention Mode (refer to DIP Switch 4) and has experienced a fault or temporary loss in AC power. To enable the drive, cycle either the enable or inhibit connections, or set the potentiometer or analog input signal to a zero speed command.

3 Flashes: The drive’s Operating Mode was changed (refer to DIP Switches 1, 2, and 3) while the drive was powered on. Cycle the AC line power to reset.

4 Flashes: The drive has tripped because of a Motor Overload Protection condition.

5 or More Flashes: Contact the factory.

105

Section 10. Diagnostic LEDs

STATUS (Green LED on Bottom Board)

Solid: Normal operation.

1 Flash: The bottom power board is not receiving a run command from the top logic board.

2 or More Flashes: Contact the factory.

Figure 51. Diagnostic LED Locations

US

10A

5A

2.5A

1.7A

A2A1

F-F+

L2L1

COM SIG1 10V SIG2 DIR EN COM INH COM AUX

OU

TIN

SIG2SIG1

VDC

mA

T1 T2TAC

H

A90

A180

J504

STAT

LIM

IT

OFS1 OFS2 MAX

FWCL REVCL MOP

1 2 3 4 5 6 7 8

ON

FACC RACC IR/T

LIMITLED

STATLED

STATUSLED

106

MGC Series

Section 11. 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.!

WARNING!

Before TroubleshootingPerform the following steps before starting any procedure in this section:

1. Disconnect AC line voltage from the drive.

2. Check the drive closely for damaged components.

3. Check that no conductive or other foreign material has become lodged on the printed circuit board.

4. Verify that every connection is correct and in good condition.

5. Verify that there are no short circuits or grounded connections.

6. Check that the jumpers and DIP switch settings are set correctly.

7. 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

107


PROBLEM POSSIBLE CAUSE SUGGESTED SOLUTIONS

Line fuse blows.

1. Line fuse is the wrong size. 1. Check that the line fuse is correct for the motor size.

2. Motor cable or armature is shorted to ground.

2. Check motor cable and armature for shorts.

3. Nuisance tripping caused by a combination of ambient conditions and high-current spikes (i.e. reversing).

3. Add a blower to cool the drive components, decrease FWCL and RVCL settings, resize motor and drive for actual load demand, or check for incorrectly aligned mechanical components or “jams”. See pages 40 and 41 for information on adjusting the torque trim pots.

Line fuse does not blow, but the motor does not run.

1. Speed adjust potentiometer or input analog signal is set to zero speed.

1. Increase the speed adjust potentiometer setting or input analog signal.

2. Drive is disabled. 2. Remove the short from the EN terminal or add a short if DIP Switch 7 is ON.

2. INHIBIT mode is active. 2. Remove the short from the INHIBIT terminals or add a short to INHIBIT terminals if INHIBIT is set to INVERTED.

3. S2 is shorted to S1. 3. Remove the short.

4. Drive is in current limit. 4. Verify that the motor is not jammed. Increase TORQUE setting if set too low.

5. Drive is not receiving AC line voltage.

5. Apply AC line voltage.

6. Motor is not connected. 6. Remove power. Connect the motor to A1 and A2. Reapply power.

108

MGC Series

PROBLEM POSSIBLE CAUSE SUGGESTED SOLUTIONS

Motor does not stop when the speed adjust potentiometer is full CCW.

1. MIN SPD is set too high. 1. Calibrate MIN SPD.

Motor runs in the opposite direction

1. Motor connections to A1 and A2 are reversed.

1. Remove power. Reverse connections to A1 and A2. Reapply power.

Motor runs too fast.

1. MAX SPD is set too high. 1. Calibrate MAX SPD.

Motor will not reach the desired speed.

1. MAX SPD setting is too low. 1. Increase MAX SPD setting.

2. IR COMP setting is too low. 2. Increase IR COMP setting.

3. TORQUE setting is too low. 3. Increase TORQUE setting.

4. Motor is overloaded. 4. Check motor load. Resize the motor and drive if necessary.

Motor pulsates or surges under load.

1. IR COMP is set too high. 1. Adjust the IR COMP setting slightly CCW until the motor speed stabilizes.

2. Motor bouncing in and out of current limit.

2. Make sure motor is not undersized for load; adjust TORQUE trim pot CW.

109


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MGC Series

Section 12. Accessories & Replacement PartsDisplays Closed Loop ............................................................................ OLD100-1 Open Loop............................................................................... CLD100-1Heat Sinks MGC Heat Sink ........................................................................ 223-0159Kits Potentiometer Kit ................................................................... KTP-0001 Potentiometer Knob................................................................ 140-0009

111

MGC Series

Unconditional WarrantyA. WarrantyAmerican 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. DisclaimerThe 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 LiabilityIn the event of any claim for breach of any of American 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 cause of such action arises.

www.americancontrole lectronics .com14300 DE LA TOUR DRIVESOUTH BELOIT, IL 61080

(844) AMCNTRL

MAN-0025 Rev 0

MGC403-1.5 MGC403-11

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