designing a control/power box

Discussion in 'Power Electronics' started by Caus-i-can, Sep 2, 2018.

  1. Caus-i-can

    Thread Starter New Member

    Jul 19, 2017
    11
    0
    Hi All,
    I am trying to make a power box i have a design in mind and was hoping to get some imput from everyone wether
    1) it is safe 2)its not just guna toast all my equipment
    i will post picture of my design.. thanks in advance for all advice and or help
    mark

    power box_Caus-i-can.jpg
     
  2. MisterBill2

    Distinguished Member

    Jan 23, 2018
    3,182
    624
    I suggest a fuse someplace in the line towards the 9 volt wall wart. Presently that section is fused at 10 amps. On the other side there is no clue as to how much power that motor and drive require. And the location of the E-Stop for a motor controller and motor combination depends on a number of things. But seldom is an emergency stop placed between the controller and the motor, because at that point it is breaking the actual motor load current, often not a wise choice.
     
  3. Caus-i-can

    Thread Starter New Member

    Jul 19, 2017
    11
    0
    Thanks for your reply.

    So would a 1amp fuse suffice before wall wart its only rated at 30ma

    the Controller is rated at 180-260 volts ac in

    the 180 volt dc motor uses under full load approx max 8 amps the most ive seen it up to is 6
    (the controller has led display for volts and amps)
     
  4. MisterBill2

    Distinguished Member

    Jan 23, 2018
    3,182
    624
    OK, then the only thing different that I suggest is adding a 1 amp key for the wall wart power connection
     
  5. Caus-i-can

    Thread Starter New Member

    Jul 19, 2017
    11
    0
    sorry when you say a 1amp key , do you mean a key switch
    upload_2018-9-5_1-12-36.jpeg
    like this?
     
  6. MaxHeadRoom

    Expert

    Jul 18, 2013
    17,903
    5,476
    What is the reason for the 30amp (7Kw)switch devices?
    What is the nature of the 240vdc motor controller? Ex Treadmill?
    10a fuse maybe a little light if it is in fact an average T.M. track motor.
    Max.
     
  7. -live wire-

    Active Member

    Dec 22, 2017
    858
    73
    Plus the inrush may be enough to blow it or even trip the breaker.
     
  8. MisterBill2

    Distinguished Member

    Jan 23, 2018
    3,182
    624
    Sorry, it was not during my best time. It should have said "one amp FUSE" in the wall wart power feed..
     
    Last edited: Sep 8, 2018
  9. Caus-i-can

    Thread Starter New Member

    Jul 19, 2017
    11
    0
    control board design.png
    so it will be used for my lathe and a mill

    here are details for motor controller

    PWM DC Motor Speed Controller AC180V-260V Input DC180V Output 8A Digital Display

    Features
    suit for the power of DC motor less than 1000w.

    Suit for the current of your dc motor less than 6A

    1, the input power supply (VAC): AC180-260V 50 / 60Hz (for global voltage)
    2, the output armature voltage range (VDC): DC180
    3, the output armature current range (A): 8A (If the working current over 8A, the motor will stop work)
    If the current is too big need to increase the heat
    4, the output excitation voltage range (VDC): 100/200 (default full-bridge rectifier, which is 0.9 times the input voltage)

    5, the output excitation current range (A): 1A
    6, the working frequency: 16 KHz
    7, given signal mode (V / mA): default potentiometer, 0-5V, 0-10V, 4-20mA, PWM, touchtone
    8, enable control mode (EN): switch
    9, soft start (acceleration time adjustment range) (S): 0-10S (default 2 seconds)
    10, soft stop (deceleration time adjustment range) (S): 0-10S (default 2 seconds)
    11, double loop PI regulation (voltage and current) control is more reliable
    12, IR torque compensation range: 0-100% (default 0)

    also have installed a on/off/on switch in between controller power out and motor.
     
    Last edited: Sep 8, 2018
  10. MaxHeadRoom

    Expert

    Jul 18, 2013
    17,903
    5,476
    Are you integrating the Tach or using the existing T.M. one.
    In many cases the T.M. motor controller does not use it it goes to the panel for processing.
    What make/model of control & motor?
    Max.
     
  11. Caus-i-can

    Thread Starter New Member

    Jul 19, 2017
    11
    0




    PWM DC Motor Speed Controller AC180V-260V Input DC180V Output 8A Digital Display



    Features
    suit for the power of DC motor less than 1000w.

    Suit for the current of your dc motor less than 6A

    1, the input power supply (VAC): AC180-260V 50 / 60Hz (for global voltage)
    2, the output armature voltage range (VDC): DC180
    3, the output armature current range (A): 8A (If the working current over 8A, the motor will stop work)
    If the current is too big need to increase the heat
    4, the output excitation voltage range (VDC): 100/200 (default full-bridge rectifier, which is 0.9 times the input voltage)

    5, the output excitation current range (A): 1A
    6, the working frequency: 16 KHz
    7, given signal mode (V / mA): default potentiometer, 0-5V, 0-10V, 4-20mA, PWM, touchtone
    8, enable control mode (EN): switch
    9, soft start (acceleration time adjustment range) (S): 0-10S (default 2 seconds)
    10, soft stop (deceleration time adjustment range) (S): 0-10S (default 2 seconds)
    11, double loop PI regulation (voltage and current) control is more reliable
    12, IR torque compensation range: 0-100% (default 0)

    also have installed a on/off/on switch in between controller power out and notor

    Last edited: Today at 1:46 AM
     
  12. Caus-i-can

    Thread Starter New Member

    Jul 19, 2017
    11
    0
    here is link for controller


    http://www.ebay.com/itm/PWM-DC-Moto...d=322290200231&_trksid=p2047675.c100752.m1982
     
  13. MisterBill2

    Distinguished Member

    Jan 23, 2018
    3,182
    624
    It appears to me that the tach is quite separate from the DC motor controller, since the controller lists a digital display of it's own. There would not be much inrush from switching on the motor controller since it includes adjustable acceleration time. It probably does not use the tach signal at all, but rather monitors the back EMF. And my guess is that the switch 30 amps is simply the rating of the switches available that are suitable for 220 volt service. So the block diagram is fine, it is the actual connections, which we have never seen, that will make the difference.

    So what we can help with next is an actual circuit drawing, one that includes all of the wiring, not a general block diagram, which is all we have seen so far. Other postings on motor controls may show details as to what I am talking about.
     
  14. MaxHeadRoom

    Expert

    Jul 18, 2013
    17,903
    5,476
    Not a good idea to place a switch between motor and controller, if for a E-stop, I would switch the EN_able input at the same time as removing supply power to the drive, if for reversal purposes, I would ensure the EN is activated at the same time if using the drive output to reverse..Remember if reversing motor leads, the automatic ramp up-soft start is not active.
    If you are retaining the flywheel and using the motor for lath/mill applications, if the flywheel is threaded on, it can spin off in the reverse direction.
    I always recommend removing it if fitted.
    Don't forget the earth ground, including the motor frame.
    Max.
     
    Last edited: Sep 9, 2018
  15. MisterBill2

    Distinguished Member

    Jan 23, 2018
    3,182
    624
    From the description it does not seem like the drive and motor came from a treadmill. That was another string a few months ago. This discussion seems to be about a purchased drive and motor. And a mill would not have a flywheel, neither would a lathe, if it is a motorized one. A hand-crank driven lathe would certainly need to have a flywheel, though.
     
  16. MaxHeadRoom

    Expert

    Jul 18, 2013
    17,903
    5,476
    Obviously the drive does not.

    Post #9 States 180v TREADMILL MOTOR.
    Max.
     
  17. MisterBill2

    Distinguished Member

    Jan 23, 2018
    3,182
    624
    Max, The only reference to a treadmill motor is made by you. And I can't imagine that a treadmill motor would have all those different control inputs available, or that it would have a current display. So we will need to wait for the thread starter to tell us about the motor and controller's previous life.
     
  18. MaxHeadRoom

    Expert

    Jul 18, 2013
    17,903
    5,476
    The Drawing in post #9 states 180V 7.5A BRUSHED PERMANENT MAGNET TREADMILL MOTOR!!.
    The controller is a Chinese Ebay listing.
    Max.
     
    Last edited: Sep 9, 2018
  19. MisterBill2

    Distinguished Member

    Jan 23, 2018
    3,182
    624
    OK, max, you are right. I did not examine the whole description closely enough. Sorry about that!
     
  20. Caus-i-can

    Thread Starter New Member

    Jul 19, 2017
    11
    0
    Hi All,

    Firstly the motor is indeed a treadmill motor, have about 4-5 to choose from IMG20180910191335[1].jpg

    so they range from 1.5 hp to 1.75hp the
    the one in the middle i have 3 of ..
    i have run it on my lathe with motor controller by its self and faces no problems
    just didnt llike the idea of swithching it on/off directly from wall socket.

    so wanting to make the the control box to incorporate a switch that is on or closer to lathe,
    which can also house the Tachometer display, and to also house a switch that lets me change the rotation cw/ccw.

    Max im not sure what you mean by not puting the cw/ccw switch in between the controller and motor.


    IMG20180910194004[1].jpg

    on the controler ther is a EN terminal (orange wire) that is attached to a spst swith this switch when used turns off controll off potenetiometer at the speed you have it adjusted to so that ou can stop start the motor to exacting speeds (i think)
     
Loading...