DIGITAL CLOSED LOOP POWER PRESS VARIABLE SPEED CONTROL SYSTEM

INSTRUCTION MANUAL (PDC2000-V2.5 – 2019)

7900 Durand Ave, Bldg 3 Sturtevant, WI USA 53177 Toll Free: 800-548-2169

Phone: 262-554-7977 – Fax 262-554-7041 Email: sales@dynamatic.com 24-hour Service: 262-554-7977

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Introduction 3 About this Manual 4 Content of Package 4 Warranty 4 Safety Considerations 5 Equipment Handling 5 Training 5 Damage Claims 5 Storage 6

Long-Term Storage 6 Removal From Storage 6 Fig 1 – PDC2000 Controller & Fluorescent Display 7

Mounting Instructions 8 Fig 2 – PDC2000 Fluorescent Display Mounting Dimensions 8 Fig 3 – PDC2000 Controller Mounting Dimensions 8

Operating the PDC2000 9 Controller Description 9 Theory of Operation 9 Fig 4 – Application Concept 9

Wiring the PDC2000 10 Fig 5 – Overview of Terminal Connections 11

Fig 6 – Connecting Main Power 12 Fig 7 – Connecting Drive Tach 13 Fig 8 – Connecting Drive Clutch Coil & Brake Coil 14 Fig 9 – Connecting Main Motor Current Sensor (Current Transformer) 15 RS232 Connections/Protocol 16 Fig 10 – Connecting Main Motor “ON” Signal 17 Fig 11 – Connecting Jog or Inch Signal 18 Fig 12 – Back view of the Fluorescent Display Board 19 Fig 13 – Drive Start/Stop Switch Wiring 20 Fig 14 – Main Speed Pot Wiring 20 Fig 15 – Local Start 2-wire Contact Wiring 20 Programming the PDC2000 21

Fig 16 – Faceplate of the Programmer 21 Basic Setup 22

Factory Settings 23 Table 1 – Factory Settings 24

Modifying Parameters for Optimizing the Controller 27 Controller PID Tuning 27

Trouble Shooting the PDC2000 28 PDC2000 Fault Listing 30 Renewal Parts and Service 31 PDC2000 Specifications 32 Chart 1 – Tachometer Feedback Generators – General Information 33 Index 34 Company Contact Page 35

TOPIC PAGE

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INTRODUCTION Thank you for purchasing the PDC-2000 Digital press drive controller. This controller was specifically designed to operate eddy current drives on metal forming and powdered metal presses. It is a new concept in eddy current control. Its user-friendly design emerges from years of press control experience by its designers and a desire to continuously improve performance, simplify operation and setup of press drive power controllers.

The PDC-2000 is designed with the future in mind. The controller will offer an optional and unique counter- balance pressure adjustment feature (Catalog Number: 15-2500-0002). Contact Drive Source’s Applications Group to learn more about passive or active counter balance control.

Unlike other press controller designs, the PDC-2000 was not designed to power interlock with the AC motor starter. It is designed to be powered at all times and merely accept a signal from the AC motor, which indicates that the motor contactor has been closed. The PDC2000 has a programmable time delay set by the user to determine when the AC motor is up to speed. The PDC2000 can enunciate a problem during AC motor start such as a stalled AC motor or a locked eddy-current clutch. This intelligent function helps protect the AC motor and limit the damage to the eddy current drive should there be a problem with the motor or the eddy current clutch assembly. This is one of many built-in diagnostics that offer two main advantages: greater up-time and reduced maintenance expense.

◆ The PDC-2000 reads tachometer frequency pulses and voltage. The controller is capable of helping to insure wiring integrity by monitoring clutch speed and tachometer feedback and enunciating any lack of signal that may occur. This helps in troubleshooting and can limit downtime by identifying quickly where the failure may have occurred.

◆ The PDC-2000 constantly monitors the eddy current coupling and evaluates the performance in an attempt to ensure the quality of the drive and apprising the machine operator of the condition that would lead to improper operation and subsequence failures.

◆ The PDC-2000 monitors tachometer feedback, clutch output current, motor current, motor status.

PDC2000 KEY FEATURES & ADVANTAGES include:

Feature Advantage All digital Microprocessor based One press controller for all eddy-current drives – up to

200 HP. No special protection, line reactors, cooling fans or large enclosures needed.

Universal Power Input with Programmable Tach input and coil voltage output

Quick & Easy step-by-step simple set-up. Failsafe design features shuts down press upon power loss. No runaway condition due to tach loss signal.

Modulated coil voltage output with motor current feedback cut-off control

No potentiometers to adjust or test equipment needed.

Automatic counter balance pressure (CBP) adjustment feature based on motor current

World’s first and only EC press controller with optional CBP feature.

Local or remote input command control of speed drive.

Easy PLC system integration Easy Computer upload and download of speed parameters

All parameter programmable from removable keypad

Programmable motor HP and SPM. Calibration for optimum performance

Main Motor monitor, optional clutch brake engagement for maintenance scheduling

Built-in diagnostics that simplify troubleshooting. Minimize press downtime, Maximize production.

Programmable motor current monitor and motor limits for start-up and continuous operations

Easy and Quick changes for production changeovers.

Drive start-up interlock and press controller trip Safe shut down upon power loss or press malfunction.

This manual is designed to explain in detail the operation, wiring, setup, control and troubleshooting of the PDC-2000 controller.

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DRIVE SOURCE INTERNATIONAL INC. 7900 Durand Avenue Bldg 3 Sturtevant, WI 53177 USA

Telephone: (262) 554-7977 or (800) 548-2169 Fax: (262) 554-7041

ABOUT THIS MANUAL

This Instruction Manual contains the necessary information for the normal operation and maintenance of the Model PDC2000. Please make it available to all design, engineering and maintenance personnel who install this controller.

Instructions provided in this manual are arranged in normal order of use. Beginning with general information on warranty safety training, equipment handling, receiving and damage claims, and storage, through system description, specifications and installation, startup and adjustments to maintenance and troubleshooting. These instructions do not cover or describe any modification that may be used with this control, but they do address each and every adjustment and/or user-accessible function of the controller. Certified drawings may be purchased, available upon request from Drive Source International Customer Service, take precedence over printed instruction manual material if a difference in content occurs.

While every effort is made to provide a complete and accurate manual, there is no substitute for trained and qualified personnel to handle unusual situations. If any questions arise regarding operation or maintenance of this controller please refer them immediately to Drive Source’s Application Group.

CONTENTS OF PACKAGE

The PDC2000 Controller is shipped in packaging designed to withstand normal shipping and handling conditions for electronic circuit boards. The following are the contents of the shipping box:

• PDC2000 Controller Assembly (cat # 15-2500-0100). Verify that the package includes:

o Hand-Held Programmer with wired DIN Connector Cable (cat # 15-2500-0101) o Fluorescent Display Unit (cat # 15-2500-0102) o Display Ribbon Cable (cat # 15-2500-0103) o Instruction Manual (cat # IM-PDC2000-V2.5.0303)

Contact Drive Source International immediately if one of the items above is missing.

• In addition to the above, the PDC2000 requires a Current Transformer, sold separately, if torque

limit is required. There are two models of the current transformer, as noted: o MI-100 – 100amp rating (cat # 15-394-2000) – for 5HP to 40 HP Motors o MI-500 – 500amp rating (cat # 15-394-2001) – for 50HP to 200 HP Motors

Contact Drive Source International, Order Services to purchase the current transformer.

WARRANTY The PDC2000 controller is covered by a ONE-year warranty against manufacturing defects in either material or workmanship from the date of original invoice, which is required to avail warranty service. Should the control unit fail within the specified warranty period, please return the controller to Drive Source’s Electronics Repair Service facility in Sturtevant, Wisconsin (USA) for warranty repair or exchange to the address listed below. Your controller will either be repaired or replaced with a fully reconditioned or new controller at Drive Source’s discretion. Shipping charges to and from Drive Source’s Repair facility are the responsibility of the customer. For further assistance, please contact the Customer Service Department at:

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SAFETY CONSIDERATIONS With any electronic or electrical rotating equipment, potential safety hazards are present and require safeguards for proper use. This equipment must be installed properly, using safe procedures that meet the requirements of all applicable safety codes. The electrical wiring must be in accordance with the National Electric Code and all other local codes and regulations. Shaft guards, as well as protection for operating and maintenance personnel against high voltage and moving machine parts are essential. Refer to OSHA rules and regulation, paragraph 1910.219 for guards on mechanical power transmission apparatus. Please heed these safety instructions.

Special instructions’ labels are applied, when required, to the equipment to remind the operator of the hazards that exist. Please pay special attention to these instructions.

Definitions:

DANGER is used where an immediate hazard exists. Failure to follow Instructions could be fatal.

WARNING means a possibility of injury to personnel, but not as severe as a danger designation.

CAUTION is used to warn of potential hazards and unsafe practices.

INSTRUCTION labels and NOTES are used when a need exists for special instructions related to safety, proper operation or maintenance.

EQUIPMENT HANDLING The PDC2000 controller weighs just over ten (10) lbs (4.54 kg) and can be hand carried safely. Do not drop or subject the controller to shock or vibration. Do not stack heavy material on the controller. The printed circuit boards and its various other components should be considered delicate, making the controller susceptible to damage. Mounting in suitable enclosure to protect the electronics will enhance the life of the controller, as well as protect it from damage.

TRAINING Training programs are an essential part of safe and correct operation and provide the know-how necessary to obtain top performance from your equipment. The technical staff at Drive Source International, Inc. recognizes this fact and is capable of conducting training schools to educate your plant personnel in safe maintenance and operating procedures. Special training schools structured around your specific equipment can be arranged in our plant or at your facility. Call our Customer Service Department and obtain a written quotation to schedule required training.

DAMAGE CLAIMS The PDC2000 controller has been operated and tested at the factory prior to shipment. Specific test procedures are followed to assure the quality of your controller. Carrier approved packing methods assure safe shipment to your plant. Shipment is made F.O.B. from our factory, with the carrier assuming responsibility for your unit. Therefore, it is essential that the shipment be carefully inspected upon delivery to ensure that no items were lost or that no damage occurred in transit. Loss or damage is covered by the carrier, not by the product warranty. File a claim immediately with the carrier if any damage or loss is found. If you require assistance in settling your claim with the carrier, contact the carrier or contact Drive Source International Customer Service. You will need the unit model number, serial number, and the purchase order number for identification purposes. It is suggested that you save the packing slip as proof of delivery.

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STORAGE

Store the controller in a clean location with a non-corrosive atmosphere, and protected from sudden temperature changes, high levels of moisture, shock or vibration. Electrical components are delicate and easily damaged; provide adequate protection for them.

Ambient temperature should not exceed 40°C (104°F) on a continuous basis, or 40°C (160°-F) on an intermittent basis. The minimum temperature must remain above freezing and above the dew point of the ambient air (non-condensing). High temperature, corrosive atmospheres, and moisture are detrimental to controller’s components.

Long-Term Storage

The manufacturer's warranty covers repair or replacement of the controller for defects in materials and/or workmanship. It does not cover degradation or damage, which occurs during the storage period.

Some examples of deterioration due to storage are:

1. Corrosion of terminals and contacts. 2. Breakdown of electrolytic capacitors. 3. Moisture absorption within insulation and composition components.

These are not manufacturer's defects and will not be covered by the warranty policy. Refer questions to Drive Source Customer Service Department.

Removal From Storage

Before returning the controller to service after long-term storage, it will be necessary to carefully inspect for any signs of damage or deterioration. Correct any deficiency. Carefully inspect the controller for signs of moisture, especially with respect to transformers and composition resistors. If moist, the transformers will require thorough drying. Dampness alters the impedance characteristics of film and composition type resistors, degrading the performance of the controller; and they should be replaced. Contact Drive Source Customer Service for repair and replacement.

Corrosion is an important factor. Inspect terminals, plugs, sockets, and contacts for signs of corrosion. If detected, cleaning will be necessary. Before applying power, make sure all connections are tight.

These procedures are given only as recommendations to aid our customers in preserving stored equipment. Drive Source International, Inc. cannot guarantee stored equipment, even if all suggestions are followed; damage or deterioration may still occur. Equipment in storage is only covered by warranty if the invoice matches the serial number of the controller board, the invoice is provided upon request and Drive Source engineering determines that storage is not the cause of any failure.

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BEFORE THE INSTALLATION BEGINS:

1. Assure that you have a complete Controller package (15-2500-0100)

and a current transformer if needed (15-394-2000 or 15-394-2001), purchased separately.

2. Mounting instructions are given on the next page for the controller and

the display. Take special care of the ribbon cable so as not to crimp it.

3. Decide on the mounting location for the controller as well as the display and check to make sure that the ribbon cable will be adequate for the installation. Longer ribbon cable may be used, however, RFI/EMI noise may cause erroneous readings on the display.

FIG. 1 CONTROLLER & FLOURESENT DISPLAY

Introducing the World’s First Digital Complete Closed Loop Power Press Variable Speed Control System with Optional Automation counter balance pressure adjustment feature based on motor current. A Drive Source exclusive offering for Metal Forming and Power Press control of eddy-current clutches.

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MOUNTING INSTRUCTIONS The Controller and Fluorescent Display are supplied in “native” formats. These items may also be purchased from Drive Source mounted in NEMA 1 or NEMA12 enclosure. Drive Source can quote special price and delivery, if desired.

The mounting dimensions for the controller and the display are shown in Figures 2 and 3, respectively. The mounting configuration must allow for heat dissipation. The controller must be mounted in the right-side-up direction to prevent overheating of the PCBs. Care should also be taken to avoid mounting the Controller above another component in the control panel/cabinet that could generate excessive heat. See specifications for PDC2000 temperature limits.

Control panel designers and installers are reminded that adequate ventilation inside the control panel will increase the life of the PCB and minimize chances of failure due to heat build-up.

NOTE: If you are replacing a Dynamatic Model 4050 Press Drive controller with the PDC2000, you may be pleased to note that the dimensions for the PDC2000 controller are identical to those of Model 4050. Installation of the PDC2000 takes the same space as well as the same mounting hole and screws.

3.450"

FIG 2 – PDC2000 FLUORESCENT DISPLAY MOUNTING DIMENSIONS

FIG 3 – PDC2000 CONTROLLER MOUNTING DIMENSIONS

5.750"

0.575"

6.900"

0.3

10"

0.3

10"

10.2

50"

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OPERATING THE PDC2000

CONTROLLER DESCRIPTION

The PDC2000 is a solid-state controller for use with mechanical power punch presses. This versatile controller features the simple set-up of analog circuitry, yet it’s a digital controller that offers a higher level of accuracy. Each unit is fully tested and adjusted at the factory for optimal performance. This allows the user to install and have the press running with a minimal amount of set up time. Some programming may be necessary for optimum response or for special load conditions. Consult Drive Source’s Application Group for details.

THEORY OF OPERATION – The Eddy-Current Drive

In the basic form, the Eddy Current Drive consists of an AC motor and an electrically controlled magnetic clutch. The Eddy Current Clutch is composed of an input drum that is driven by the motor at constant speed, and an output rotor, usually positioned concentrically within the drum. Both members are constructed of magnetically soft iron (low carbon steel) supported by ball and/or roller bearings and free to rotate independently of each other separated by a small air gap. Controls imparted by means of an electrical field coil strategically positioned to allow magnetic coupling; between the input and output members of the clutch The Eddy-Current brake operates in a similar manner except that the "drum" member remains stationary.

In a motor, a time-variant magnetic field is generated in the air gap at the poles by means of the current flowing in windings, the field reversals being accomplished by an alternating current in the AC motor. Or by mean of brushes and the electro-mechanical commutation in the DC motor.

In a motor, the Eddy-Current clutch is a rotating transformer. In the clutch, a static DC current produces a magnetic field in the air gap, coupling the rotating input drum and output rotor. The pole geometry of the coupled output member imprints a pattern of alternating magnetic polarities into the drum. Flux reversals are established in the field by virtue of the differential velocity between input and output members. A current of great magnitude is generated circumferentially at the rotating drum’s inner surface, which appears as a single turn secondary winding. This current regenerate the magnetic field, producing a radial coupling force, normal to the drum’s inner surface and the output member’s outer surface, dragging the output member along, in respect to the magnetic right hand law. The torque developed herein is essentially proportional to the coil current.

FIG 4 – APPLICATION CONCEPT

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WIRING THE PDC2000

This section describes the steps to wire and connect the PDC2000. Since the controller has been designed to be a simple and quick installation device, the wiring sequence listed is all that it takes to get the controller up and running.

WIRING STEPS:

1. Take a few minutes to review Fig 5 – TERMINALS AND CONNECTORS LAYOUT. 2. Note that there are two PCB boards, one above the other. The Bottom Board is the main

Power Supply board and the Top Board is the main CPU or Controller board. 3. There are Six (6) wiring terminals, Two terminals are on the Power Supply board (TB-3 &

TB-4) and Four (4) terminals (TB-1, TB-2, TB-5 & TB-6) on the CPU board. 4. Terminal functions are as follows:

TB1 – Logical Inputs (24 – 120V AC or DC) TB2 – Sensor Inputs TB3 – Power Connections TB4 – Tach Generator Input, Brake and Coil Outputs TB5 – Logical Outputs (Relays) TB6 – Tach Output & RS-232 Communication Port

5. Connect the Main Power to TB-3, as shown in Fig 6. 6. Connect the Drive Tach Generator Input to TB-4, as shown in Fig 7. 7. Connect the Drive Clutch Coil and Drive Brake Coil to TB-4 as shown in Fig 8. Note that

Clutch Coil is connected to Pins 1 & 7; Brake Coil is connected to Pins 3 & 8. Coil connections have no polarity.

8. Connect the Main Motor Current Sensor to TB-2, Pins 4 & 7, as shown in Fig 9. Note that the WHITE sensor wire is connected to Pin 4 and the BLACK sensor wire is connected to Pin 7. Also NOTE that only pass one phase of Motor Lead through Current Sensor (MI-100 or MI-500). Sensor is marked for wire “IN”, coming from the motor starter. DO NOT LOOP THE WIRE.

9. Connect the Motor “ON” signal to TB-1, Pins 1 & 2, as shown in Fig 10. Input connections have no polarity. If remote mode is to be used, wire the start circuit to TB-1, Pins 13 & 14 and the stop circuit to TB-1 15 & 16.

10. To wire other Logical Inputs, supply Hot and Neutral (AC or + & - DC) for each input (TB-1) to the controller. Inputs are 24 to 120 Volts AC or DC, and can be mixed. Inputs are also Isolated from each other.

11. Connect the Jog or Inch signal to TB-1, Pins 11 & 12, as shown in Fig 11. Connect Start and Stop to TB1 pins (13,14,15,16) and Analog Signal to TB-2 Pins 7,8 as shown in Fig 11 if Remote Input mode is to be used. Press interlock connections are placed on TB-1 (3,4,5,6). Input connections have no polarity

12. Fig 12 shows the back side of the Fluorescent Display unit. Notice the ribbon connector at the top and the 8-pin controls terminal located at the bottom right side.

13. Connect the Fluorescent Display Ribbon cable to the Display ribbon connector and the other end to connector labeled J2, bottom left of CPU board.

14. Refer to Figs 13, 14 & 15 on how to connect the Local Drive Start/Stop Switch, Main Speed Potentiometer and Remote Start Contact, respectively for local mode.

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15. Remote analog input (4-20MA, 0-5V scalable) is connected on TB-1 (Pins 7,8) 16. Remote Reset is connected on TB-1 (Pins 9,10) See Fig. 5. 17. Connect the output relays (for customer use) as desired on TB-5. The PDC-2000 has a

Drive Run relay (TB-5 Pins 1,2,3), a Fault Trip Relay (TB-5 Pins 4,5,6) , a Fault Condition Exists Relay (TB-5 Pins 7,8) an At Speed Relay (TB-5 Pins 12,13) and a Zero Speed Relay (TB-5 Pins 14,15,16). See Fig. 5.

18. A Tachometer Output Pulse Signal (For Customer use) can be connected on TB-6 (Pins 4 pos ,6 common) See Fig. 5

19. A Tachometer Output 0-5V Signal (For Customer use) can be connected on TB-6 (Pins 4 pos ,5 common) See Fig. 5

20. Verify that wiring is according to the instructions and figures given, above.

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FIG 5 – TERMINALS, CONNECTORS AND LOCATIONS

OVERVIEW OF ALL CONNECTIONS ON THE PDC-2000

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FIG 6 – MAIN POWER CONNECTIONS

CONNECTING THE MAIN POWER – Terminal TB-3

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FIG 7 – TACH GENERATOR INPUT CONNECTIONS

CONNECTING THE DRIVE TACH GENERATOR – Terminal TB-4

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FIG 8 – CLUTCH & BRAKE COIL CONNECTION

CONNECTING THE DRIVE CLUTCH AND DRIVE BRAKE COILS

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CONNECTING THE MAIN MOTOR CURRENT SENSOR – Terminal TB-2 CONNECTING THE MAIN MOTOR CURRENT SENSOR (CURRENT TRANSFORMER) – Terminal TB-2

FIG 9 – MAIN MOTOR CURRENT SENSOR CONNECTIONS

PASS ANY ONE OF THE THREE (3) MOTOR LEADS THROUGH THE HOLE OF THE CURRENT SENSOR (TRANSFORMER).

NOTE: SENSOR MARKED FOR WIRE “IN” COMING FROM STARTER DO NOT LOOP WIRE. THE WIRE SHOULD PASS THROUGH THE HOLE ONLY ONCE.

MI100 IS FOR 5-40 HP MI500 IS FOR 50-150 HP

CONNECT BLACK & WHITE WIRES FROM CURRENT TRANSFORMER AS SHOWN ON DIAGRAM BELOW.

Pay special attention to the note shown above the PCB drawing.

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FIG 10 – CONNECTING THE MAIN MOTOR “ON” SIGNAL The Main Motor “ON” Signal connections are on Connector TB-1 and is located on the Top Board as shown, above. Pay special attention to the note shown above the PCB drawing.

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1 2 3 4 5 6 7 8

CONNECTIONS FOR LOCAL MODE

FIG 12 – BACK VIEW OF THE FLUORESCENT DISPLAY BOARD The Ribbon Cable connector is shown at the top. The 8-pin connector, shown above serves the purpose of connecting various speed controls that may be required.

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Figs 13, 14 & 15 (next page) show how to wire Drive Start Stop Switch, Main Speed Potentiometer and the Remote Start Contact wiring These controls are wired to the 8-pin connector located on the back side of the Fluorescent Display.

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1 2 3 4 5 6 7 8

FIG 13 – Drive Start/Stop Switch is wired to Terminals 1,2 & 3 on the back side of the Fluorescent Display unit. The Drive Stop contact is N.C. and the Drive Start contact is N.O. The Logic for the start-stop circuit is built into the controller.

DRIVE START / STOP SWITCH WIRING

1 2 3 4 5 6 7 8

FIG 14 – Main Speed Potentiometer is wired to Terminals 5, 6 & 7, as shown, on the back side of the Fluorescent Display unit. The Potentiometer view is from the shaft side, looking down. Speed will increase when the shaft is turned in the clockwise direction.

MAIN SPEED

WIRING

FIG 15 – Local 2 Wire Start Contact, customer supplied, is wired to Terminals 1 & 3. This contact may be wired in parallel with the Start/Stop switch (in Fig 14, above). Note: The contact must be maintained, “closed”.

DRIVE START

DRIVE STOP

POT

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RS-232 Connections/Protocol

Cable Connections Hyper Terminal Protocol PDC2000 Terminal RS232-DB9 Connector Baud Rate (fixed) 19200

TB2-1 Pin 3 Data Bits 8 TB2-2 Pin 2 Parity None TB2-3 Pin 5 Stop Bits 1

Max Cable Length = 50 ft (15 m) Flow Control None

PROGRAMMING THE PDC2000

The PDC2000 controller is supplied with a hand-held programmer, which is specially designed as a data entry device and is equipped with a 5-pin DIN plug, which is connected to the port on the front side of fluorescent display. The programmer and the fluorescent display, together, allow the user to modify factory-programmed settings and enter vital data so the press parameters are easily and quickly modified in the memory of the PDC2000 controller.

The Programmer has a simple faceplate as shown below in Fig. 15. The “P” key is used to enter Program Mode. The “E” key is used to enter data and move to the next parameter. Once in Program Mode the “P” key can be used to back up in parameters. The numerals 1 thru 0 are used to enter data. See Tables 1, 2 and 3, for modifying and programming the PDC2000.

It is important to note that programming of the PDC2000 be conducted by authorized and knowledgeable engineers and press machine operators. This instruction manual does not cover control system knowledge outside the immediate PDC2000 press controller requirements (PLC, communications, etc.) and no claims are made as to the systems integration ability, which only professionals intimate with the specific press operation are capable of handling.

FIG 16 – FACEPLATE OF THE PROGRAMMER FOR DATA AND PARAMETER ENTRY

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BASIC SETUP The PDC-2000 is designed to be used for the control of stamping presses. It contains parameters that need to be set for the application. Most applications will not require all the parameters to be adjusted. Below is a listing of programmable features. This is followed by a parameter listing with explanation and purpose of each.

VELOCITY CONTROL

The PDC-2000 measures tachometer feedback pulses to calculate velocity. The revolutions per minute determined from this are then scaled according to the user’s entries in the Clutch Pulse Per Revolution Parameter, the Clutch Maximum Speed Parameter and The Max System Strokes Per Minute Parameter. The relationship between these three parameters will establish the strokes per minute on the PDC-2000 display. The control has a P.I.D. adjustable speed control loop to tune the control to the application.

BRAKING CONTROL

The PDC-2000 has built in Braking Control. This option can be turned off completely, used in run mode or in stopping mode or in both running and stopping modes. The brake control has an adjustable P.I.D. loop and adjustable dead band to allow it to be tuned to operate smoothly with the application.

TORQUE CONTROL

The PDC-2000 has built in torque control. A current transformer is required for this and when provided the motor current is monitored. When the amps value in the Max Torque Limit Capacity is reached the control goes into torque control mode. In this mode the clutch current is folded back to reduce the motor load. This is useful for starting high inertia loads, where the motor may overload. Torque mode has a P.I.D. control loop that allows this response to be adjusted

ADJUSTABLE ACCELERATION – DECELERATION

The PDC-2000 has separate adjustable acceleration parameters for both the jog mode and the run mode.

REMOTE OR LOCAL OPERATION

The PDC-2000 can be changed from local operation (display potentiometer and push buttons) or remote operation using terminal inputs (start, stop and analog signal, 0-5VDC or 4-20MA scalable). In remote mode the display can be removed if not required for displaying data. DO NOT REMOVE OR INSTLALL THE DISPLAY CABLE WHILE THE DRIVE IS POWERED UP.

JOG MODE

The PDC-2000 has a jog terminal which when closed will cause the control to jog the clutch at a user entered speed when the start button (local mode) or the start input is closed (remote mode)

FAULTS

The PDC-2000 monitors motor current (CT Required) clutch current and press speed. The control has 10 internal faults and 2 external faults that report malfunctions of the press, the motor or the control. See the listing that follows the parameter listing.

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MAX / MIN STROKE PER MINUTE SETTING

The PDC-2000 sets limits on the maximum and minimum strokes per minute based on parameter entries made by the user. Maximum and Minimum trip limits can also be set.

FACTORY DEFAULTS

The controls factory settings can be recalled by setting the factory default parameter to (1) yes and rebooting the control.

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PARAMETER LISTING

PARAMETER DESCRIPTION VALUES DEFAULT Motor Capacity Maximum Current

Set value in Amps. When current is greater or equal to value and fault delay time is exceeded drive will fault.

0 to 300 Amp 200 Amp

Motor Capacity Torque Limit

Set value in amps. When current is greater than set value torque limit control will take effect using the torque control parameters below

0 to 300 Amp 100 Amps

Motor Start Time in Seconds

Set value in seconds. Drive will not start until input #1 is closed and start time has elapsed.

0 to 60 Sec. 3 Sec.

Clutch Maximum Speed in RPM

Set Value in revolutions per minute as listed on the clutch name plate.

0 to 3600 RPM 1660 RPM

Clutch Coil Capacity Rated Voltage

Set Value as Listed on clutch nameplate. This setting limits the control output and calibrates the clutch voltage display.

0 to 300 VDC 45 VDC

Tach Feedback Pulses Per Rev

Set value as listed on clutch nameplate. If none is listed see chart on page 34, consult factory if use a measuring device to calculate.

0 to 120 PPR 12 PPR

Max System Speed Strokes Per Minute

Set Strokes Per Minute of press when clutch is at max speed as listed above.

0 to 600 SPM 100 SPM

Max Trip Speed Strokes Per Minute

Set Press Strokes Per Minute. If the press strokes are equal to or greater than the set value and the fault delay time is exceeded the drive will trip.

0 to 34463 SPM

110 SPM

Max Set Speed Strokes Per Minute

Set Press Strokes Per Minute. This is the maximum speed setting adjustment for the local potentiometer or the remote input

0 to 600 SPM 100 SPM

Min Trip Limit Strokes Per Minute

Set Press Strokes Per Minute. If the press strokes are equal to or less than the set value and the fault delay time is exceeded the drive will trip.

0 to 600 SPM

10 SPM

Min Set Speed Strokes Per Minute

Set Press Strokes Per Minute. This is the minimum speed setting adjustment for the local potentiometer or the remote input

0 to 600 SPM 20 SPM

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PARAMETER DESCRIPTION VALUES DEFAULT Set Accel / Decel Time In Seconds

Acceleration time for drive to change from 0 Strokes Per Minute to Max Set Strokes Per Minute

0 to 360 Seconds

20 Seconds

Jog or Inch Speed Strokes Per Minute

Set in Strokes per Minute When drive is in jog mode this setpoint is used

0 to 600 SPM 20 SPM

Jog or Inch Accel Rate in Seconds

Acceleration time for drive to change from 0 Strokes Per Minute to Max Set Strokes Per Minute when drive is in jog mode

0 to 360 Seconds 3 Seconds

Set Speed Proportional Gain

Proportional Gain Parameter. The drive speed error is multiplied by this value to create the proportional term of the PID speed control loop

0 to 10000 200

Set Speed Integral Gain

Integral Gain Parameter (repeats per sec) The speed error is multiplied by this value to create the integral term of the PID speed control loop.

0 to 10000 40

Set Speed Differential Gain

Differential Gain Parameter. The change in Speed (per sec) is multiplied by this value to create the differential term of the PID speed control loop.

0 to 10000 0

Brake Coil Capacity Rated Voltage

Set Value as Listed on brake nameplate. This setting limits the control output and calibrates the brake voltage display.

0 to 300VDC 45VDC

Set Run Braking On (1) Off (0)

Turn Braking on or off while drive is in the Run Mode

0, 1 0

Set Stop Mode Brake On in sec Off (0)

Drive stop mode. Set to time in seconds for braking or (0) to coast to stop.

0, time in sec. 0

Set Brake Proportional Gain

Proportional Gain Parameter. The drive over speed error is multiplied by this value to create the proportional term of the PID brake control loop

0, 10000 200

Set Brake Integral Gain

Integral Gain Parameter (repeats per sec) The overspeed speed error is multiplied by this value to create the integral term of the PID brake control loop.

0 to 10000 40

26 IM-PDC2000-V2..5.0303

PARAMETER DESCRIPTION VALUES DEFAULT Set Brake Differential Gain

Differential Gain Parameter. The change in Over Speed (per sec) is multiplied by this value to create the differential term of the PID brake speed control loop.

0 to 10000 0

Set Brake Deadband SPM

The Dead Band above set speed where braking action is inhibited.

0 to 600 SPM 5 SPM

Set Torque Limit Proportional Gain

Proportional Gain Parameter. The drive Current error is multiplied by this value to create the proportional term of the PID current limit control loop

0 to 10000 200

Set Torque Limit Integral Gain

Integral Gain Parameter (repeats per sec) The current error is multiplied by this value to create the integral term of the PID current limit control loop.

0 to 10000 40

Set Torque Limit Differential Gain

Differential Gain Parameter. The change in Speed (per sec) is multiplied by this value to create the differential term of the PID current limit control loop.

0 to 10000 0

Calibrate Motor Current Display

Set value to scale 0 - 5V Current Input To PDC Display. Also calibrates Torque limit control parameters

0 to 1000 % 100 %

Set Fault Delay Time in Seconds

Set Seconds for time delay before control trips out due to a fault condition.

0 to 10000 Sec. 2

Set Inputs Local (0) Set to (0) to use display pushbuttons and potentiometer to control drive. Set to (1) to control drive from terminal strip. Note: Settings are reversed it terminal input for remote / local is closed (high)

0, 1 0

Set Analog Zero Offset Percent % X 10

Set Input offset X 10 eg. 200 = 20.0% For the remote analog input

0 - 500 200

Set Analog Input Span Percent % X 10

Set Input Span X 10 eg. 1000 = 100.0% For the remote analog input

500 - 2000 1000

27 IM-PDC2000-V2..5.0303

PARAMETER DESCRIPTION VALUES DEFAULT External Faults Enable (1) Disable (0)

Set to (0) or (1) to allow or ignore external fault inputs

0, 1 0

Load Factory Defaults Yes (1) No (0)

Set to (1) to reload factory settings on next reboot of the control

0, 1 0

Special Options Yes (1) No (0)

Set to (1) to reload special option settings On next reboot of the control

0, 1 0

PID Tuning

The factory set PID parameters are adequate for many applications. However, some applications may require adjustment in the field to obtain desired operation. If the press speed tends to oscillate the following procedure should bring satisfactory results. Tuning is best attempted without a load on the press. Once the control is stabilized without a load, minor adjustments can be made while stamping parts.

1. Check the counterbalance pressure. If the load on the drive varies wildly through the

press cycle it will be difficult to stabilize the control. 2. Turn off drive run braking in the control parameters. 3. Set the Speed Differential Gain to Zero. Set the speed integral gain to Zero. Set the

Speed Proportional Gain to 50. 4. Start the Control. If the speed overshoots and continues to oscillate going over and under

the set point speed reduce the Speed Proportional Gain until the speed fails to reach the set point. If the control does not reach about 90% of set point increase the Speed proportional Gain until it does reach 90% of set point.

5. Gradually increase the Speed Integral gain until the control holds the speed close to the set point. With an even load + or – 2 RPM is achievable. Obviously, there will be a deviation when press strikes the load, but the idea is to obtain stability through the cycle.

6. Once satisfactory results are achieved stop and restart the press. If the control significantly overshoots the set point either lengthen the acceleration time or gradually increase the differential gain until the overshoot is reduced to a satisfactory level.

7. If run braking is used the values for the gains will normally be the same as those used for the speed PID loop. The Brake Dead band should be increased until the brake and clutch operate smoothly together. Using too low of a dead band will cause the control to oscillate between the brake and the clutch.

8. If torque limit is used, use the same techniques as listed above for speed tuning. Start with no torque limit integral and differential gain. On startup of the press adjust the proportional gain up until the current is almost held to the desired value. Then adjust the torque limit integral gain to get the value closer.

28 IM-PDC2000-V2..5.0303

TROUBLE SHOOTING THE PDC2000

The possibility of component failures or other electro-mechanical system problems always exists. This section of the manual is provided to assist you in troubleshooting the system to reduce press downtime and increase productivity.

Our design philosophy is based on assembly replacement. Trying to find a failed part on a printed circuit board is not economical when you compare the cost of labor and down time with the cost of a replacement PCB assembly. Therefore, this manual limit trouble shooting to the sub- assembly level.

◆ Check the obvious first. Are the plugs and switches in the right position and is the power

ON?

The PDC2000 controllers are extremely durable. If any of these conditions occur, the controller is self-protecting and damage or degradation to any controller internal components will usually not take place. Blowing of fuses may occur with some short circuit conditions. Mechanical drive & control panel are assumed to be at earth ground.

CAUTION: Turn OFF high voltage AC power to the motor and controller before making tests, except when voltage measurements are necessary. Most voltage measurements during troubleshooting procedure are at low levels. However, it is suggested that only qualified personnel acquainted with safety procedures should service this equipment.

The best option is to return the controller to Drive Source International for complete testing and board review to ensure that the controller has not been the subject of line voltage spike or shorting of any components. Drive Source is well equipped to test, repair and re-warranty the PDC2000 to its factory fresh state.

If the controller or drive will not run, we suggest you make these tests:

1. With ac power removed, set your multimeter on the 250 VAC range. Measure controller

terminals TB3-5 and TB3-1 it should read 120V nominal.

2. With power, OFF you should read zero volts. Do not proceed until a zero reading is obtained. Then pull both fuses marked 15A (main PCB assembly) and check for blown fuses. Replace, if required and re-install both 15A fuses in the controller.

3. Turn ON the AC power and start the motor. Use the meter, set on the 250 VAC range, to

check for 115 VAC at TB3-5 and TB3-1. If voltage is not found at these terminals, trace the problem back to the voltage source and correct it.

4. With ac power to the controller ON, remove the meter and switch to the 10 VDC range.

Connect the positive lead to the 100% end of the Run Speed potentiometer. If the correct voltages are found in to the zero end. You should read approximately 5 VDC. If 5 VDC is not obtained, replace the control.

5. With ac power ON, connect the meter (10 VDC) leads to back of fluorescent display

terminals 6 and 7 (6 is positive). You are now measuring the output of the Run Speed potentiometer. Turn the Run Speed potentiometer from zero to 100% (Full CW). The meter should indicate a voltage swing from 0 to 5 VDC. If you do not observe this voltage at terminals 5 and 6 , check or replace the potentiometer, or the main PCB assembly, one at a time.

29 IM-PDC2000-V2..5.0303

If the drive runs only at full speed, perform the following test:

With the drive running, set the multi-meter on the 250 VAC range, and connect test leads to terminals TB4-5 and TB4-6. At full speed, the generator voltage should be in the 40 to 65 VAC range. If no voltage is found, the problem is in the tachometer generator or the tachometer leads to the controller. If the voltage is present, check the Max Speed adjustment; and if that has no effect, replace the main PCB assembly.

If the drive will not run, perform the following test:

If a fuse blows on a cold start, there may be a short or ground in the coil lead wires. Disconnect both leads at the controller terminal strip (TB4-1 & TB4-8) and check the resistance of the coil and resistance to ground. Check the drive's nameplate or the drive’s instruction manual for the coil resistance. Resistance to ground should be about 20 megohms. When using a megger, make sure both coil leads are disconnected from the controller. Do not megger any portion of the PDC2000 controller. Minimum coil resistance as follows:

VOLT MINIMUM RESISTANCE HOT 40v 4.0ohms

45v 4.5ohms

60v 6.0ohms

90v 9.0ohms

125v 12.5ohms

* NOTE: Controls must be compatible

If the drive is operation is erratic or hunts, try the following:

Check for loose connections, proper brush seating, good slip ring surface (if used), and check for load pulsations that can reflect erratic load to the controller. If no external cause is found, try to tune the control (see the PID tuning discussion listed earlier). If tuning fails to stabilize the control, consult the factory or replace the main PCB assembly.

If drive senses a problem, it will display a fault code:

Feed bac k Fault No Tac h o meter Pulses

This is an indication that either the tachometer signal connection has been broken or the tachometer output is so poor that the drive cannot function properly. The PDC-2000 doesn’t require any particular voltage. But if the signal is weak or disappears at a particular speed the control will cease operation and display this fault.

Solution if this fault occurs-

Measure the tachometer feedback voltage at minimum SPM and maximum SPM. Check for linearity and max value. If the value is less than half of the rated 45-60VAC usually at full speed or non-linear it will require that the feedback device or parts of the motor be repaired or replaced.

Check the wiring between the motor and control with an ohmmeter for continuity. Check the tachometer coil resistance typically 100 to 300 ohms.

30 IM-PDC2000-V2..5.0303

DC Buss Fault High o r L o w Volt age

Indicate blown fuses or bad power supply components on the board.

If this fault occurs-

Check DC bus fuses.

Solution if fault occurs-

If fuses are blown replace fuses. If fuses are good replace control.

Clutch Over load Faul l

If the drives don’t reach full SPM upon start the controller will fault. The control expects the output to accelerate at a predetermined rate. If this doesn’t occur the control will fault. This can be caused by low field voltage setting or mechanical binding in the press.

Solution if this fault occurs- Try increasing the clutch field voltage rating and restart the control. Monitor acceleration and determine if the press is accelerating normally. If not check for bad bearings in the press or drive mechanical unit.

Faults are reset by pressing the start button or applying power to the reset input. Programming mode can be entered from a fault condition. Press the “P” button on the keypad while in the fault display. This allows the user to adjust the fault delay or other parameters that may be causing the fault.

PDC-2000 FAULTS

Note: most faults will wait for the fault delay to time out.

LOW BUS VOLTAGE - POWER SUPPLY FAULT

The DC Bus Voltage has dropped below 80VDC. This is caused by a severe overload, a bad output component on the control, blown fuses or shorted clutch.

HIGH BUS VOLTAGE – POWER SUPPLY FAULT

The DC Bus Voltage has risen above 200VDC. This is caused by the wrong applied voltage, line surge or bad controller.

SPEED FAULT – LOW SPEED TRIP

The press speed is at or below the low speed trip level parameter and the fault delay time has expired.

SPEED FAULT – HIGH SPEED TRIP

The press speed is at or above the high-speed trip level parameter and the fault delay time has expired.

FEEDBACK FAULT – NO TACH PULSES

The control was started, and the output reached 30% of maximum and no tachometer pulses were detected, and fault delay time has expired.

31 IM-PDC2000-V2..5.0303

OUTPUT FAULT – CLUTCH OVERLOAD

The control clutch output has reached the maximum limit value, but the press speed is not rising, and the fault delay time has expired.

HIGH AMPS TRIP – MOTOR FAULT

The maximum motor current limit has been reached or exceeded and the fault delay time has expired

MOTOR FAULT – MOTOR OFF DRIVE ON

The motor contactor dropped out while the control output was on.

INPUT FAULT - LOC-REM CHG DRIVE ON

The local - remote status was changed while the drive was running.

EXTERNAL FAULT - MOTOR FAULT ***

The input contact for motor overload was dropped and the fault relay expired.

EXTERNAL FAULT – PRESS INTERLOCK ***

The input contact from the press interlock was dropped and the fault relay expired.

*** These faults can be disabled

RENEWAL PARTS AND SERVICE

The Model PDC2000 has no real user serviceable parts. It is suggested that customers stock an extra PDC2000 controllers and replaceable fuses to minimize down time. Only the user can evaluate the cost of down time compared to the cost of stocking spares. If you need help in establishing stock level, consult your local Authorized Distributor or Drive Source International Customer Service.

Drive Source International maintains a Repair Service Department that works on a time and material basis. Controllers returned for repair will be repaired or replaced through Drive Source’s repair and exchange program. However, the Company will not accept replacement boards that are cracked, foil damaged, field modified or burned. All replacement boards or assemblies will carry a full one-year factory warranty. Additional warranty coverage is available for additional charge.

Contact Drive Source International’s Customer Service at (800) 548-2169 or (262) 554-7977.

32 IM-PDC2000-V2..5.0303

TABLE 2

PDC2000 SPECIFICATIONS

INPUT CHARACTERISTICS

Supply Voltage 120 VAC, Single Phase

Line Frequency 50 Hz or 60 Hz

Tachometer Generator Frequency 10 – 1000 Hz

Tachometer Generator Voltage 3 – 100 Volts

Input Current 10 Amps (15A peak)

Speed Control ± 1 Frequency Count

Inputs for Interfacing 8 (24-120VAC/DC) Isolated

Min Speed Adjustment Program Step

RS-232 Interface Optional – Consult Factory

OUTPUT CHARACTERISTICS

Outputs for Interlocks

5 – Dry Contact @ 5A 2 – Spare

Output Current 10 Amps Speed Variation To Line Voltage Fluctuation ± 1 Frequency Count

Speed Range 0 – 100%

CONNECTORS

Self-Locking Wire Connectors 5.08 mm pitch, 0.2”

Wire Gauge Size #16

TEMPERATURE

Ambient Air (Operating) 104°F 40°C

Ambient Air 140°F 60°C

DIMENSIONS & PHYSICAL

CHARACTERISTICS

Height 10.25 In (260 mm)

Width 6.88 In (175 mm)

Depth 4.38 In (111 mm)

Weight (Approximate) 10 Lb. (4.54 kg)

*Consult Factory for tacho-generator output specifications particular to your type of Eddy-Current Drive.

Specifications subject to change without notice

33 IM-PDC2000-V2..5.0303

CHART 1 GENERAL INFORMATION FOR ALL TYPES OF

TACHOMETER FEEDBACK GENERATORS USED IN EDDY CURRENT DRIVE APPLICATIONS

FRAME DESIGNATION

Pulse Per

Rev.

FREQ (Hz)

FREQ (Hz)

FREQ (Hz)

@ RPM (typical) 1200 1800 3600

AC 181 to 186 12 480 720 1440 AC 214 to 254 12 480 720 1440

AS 14 to AS 25 12 480 720 1440 AS 27 16 640 960 1920

AS-280 to AS 320 16 640 960 1920 AS 360 to AS 440 30 1200 1800 3600

AT 14 To AT 25 12 480 720 1440 AT 280 16 640 960 1920 AT 320 16 640 960 1920 AT 360 30 1200 1800 3600 AT 440 30 1200 1800 3600

ACM 902 to ACM 906 12 480 720 1440 ACM 907 (1, 2) 12 480 720 1440 ACM 908 (3,4) 12 480 720 1440 ACM 909 (1,2) 12 480 720 1440 ACM 910 (3) 12 480 720 1440

ACM 911 (3) 14 560 840 1680 ACM 912 (3) 14 560 840 1680

ACM 913 (3, 4) 14 560 840 1680 ACM 914 (3) 14 560 840 1680

G 2 12 480 720 1440

TASC 12 480 720 1440

TORSPEC 12 480 720 1440

Actual setting will be based on proper max speed, maximum adjustment or press operating speed less than full motor speed.

34 IM-PDC2000-V2..5.0303

INDEX

TOPIC PAGE

About this Manual 4 Address - Drive Source International, Inc. 4, 35 Application Concept – Fig 4 9 Board Mounting Dimensions - Fig 2 & Fig 3 8 Chart 1 – Tachometer Feedback Generators – General Information 33 Content of Package 4 Controller Description 9 Damage Claims 5 Dimensions 8 PDC2000 Board Settings 22 PDC2000 Set-Up 7 PDC2000 Specifications - Table 2 32 Equipment Handling 5 Fig 1 – Controller & Fluorescent Display 7 Fig 2 – Fluorescent Display Mounting Dimensions 8 Fig 3 – Controller Mounting Dimensions 8 Fig 4 – Application Concept 9 Fig 5 – Key Components 12 Fig 6 – Main Power Connections 13 Final Set-Up and Adjustments 22-24 Introduction 3 Key Components - Fig 5 12 Long-Term Storage 6 Mounting Instructions 8 Operating the PDC2000 9 Other Options and Adjustments 9 Programming the PDC2000 21 Removal From Storage 6 Renewal Parts and Service 31 Safety Considerations 5 Set Up 10-24 Specifications 32 Storage 6 Table 1 – Factory Settings 24 Table 2 – PDC2000 Specifications 32 Terminal Layout - Fig 5 12 Theory of Operation 9 Training 5 Trouble Shooting 28 Warranty 4 Wiring - Terminal Layout 10, 11, 21

35 IM-PDC2000-V2..5.0303

DRIVE SOURCE INTERNATIONAL, INC.

7900 Durand Avenue, Bldg 3 Sturtevant, WI 53177 USA

Toll Free: (800) 548-2169 Phone: (262) 554-7977 – Fax: (262) 554-7041

Email: sales@dynamatic.com 24 Hours Service: (262) 554-7977

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