Thermo AC-4000 User Manual

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REC 3838 REV G 10/05

PART NO. 045848

OPERATING AND SERVICE MANUAL

AC-4000 CONTROLLER

WAREHOUSE APPLICATION

Table of Contents

Questions and Answers:

E
Edward RobinsonAug 3, 2025
What to do if the Thermo Controller displays "A/D Over Ranged" message?
- W
  William CraigAug 3, 2025
  If the Thermo Controller displays the message "A/D Over Ranged", it means the input from the loadcell has exceeded the A/D input range. Check for objects on the weightable that exceed the loadcell capacity. Also, the conveyor may be slowing or stopping, so display the speed on the front panel and readjust the speed potentiometer to correct the speed. Check the speed calibration constant and speed sensor. Other solutions include cleaning the machine, adjusting or replacing the timing belt (refer to Drive Belt Replacement and Adjustment Procedures in the weightable manual), lubricating bearings, or replacing them if defective (refer to Chain Drive Sprocket Replacement Procedures in the weightable manual), and retightening any loose set screws on the drive sprocket or motor timing gear.
M
Morgan WatsonAug 18, 2025
How to fix a blank front panel on Thermo Controller?
- A
  Alyssa PetersenAug 18, 2025
  A blank front panel on the Thermo Controller with no lamps lit and no keyboard response can be caused by several issues. It may be due to incorrect DC voltage, requiring you to perform power supply troubleshooting procedures (refer to Table 4-2). It could also be a bad display, in which case you should replace the defective Display Module (refer to Display Module Replacement Procedures in this chapter). Other potential causes include a defective Analog Board (replace it following Analog Board Replacement Procedures in this chapter) or a defective front panel (replace it following Front Panel Replacement Procedures in this chapter). Also, check for objects between the loadcell and weightable.

Thermo AC-4000 Specifications

General

Brand	Thermo
Model	AC-4000
Category	Controller
Language	English

Summary

OPERATING AND SERVICE MANUAL

AC-4000 Controller: Warehouse Application

Manual for the AC-4000 controller system used in warehouse applications.

Chapter 1.0 Introduction

1.1 General Description

Overview of the AC-4000 Electronics System, its applications, and features.

Chapter 2.0 Installation

2.1 General

2.2 Safety Precautions

Crucial safety guidelines and warnings to ensure safe installation and operation.

2.6 Installation Steps

Detailed procedures for physically installing the AC-4000 electronics into the production line.

Chapter 3.0 Operation

3.1 General

Explains the AC-4000 controls and functions, operated from the front panel.

3.2 Belt Speed Adjustments and Power Switches

Chapter 4.0 Maintenance

4.2 Service & Repair

4.3 Component Replacement Procedures (Electrical)

Detailed instructions for replacing various electrical components within the system.

Chapter 6.0 AC-4000 Options

6.1 Variable Speed

Details on installing and using the variable speed option for conveyor line control.

6.2 Communications

Information on installing and configuring the communications option for data transfer.

6.3 Multiple Product

Safety Warnings (Minarik Manual)

General Safety Precautions

Important safety tips and warnings for handling electrical equipment.

Installation (Minarik Manual)

Chassis drives Mounting

Guidelines for mounting the chassis-type MM23000 drives safely and securely.

Wiring

Instructions and warnings related to the proper wiring of the drive components.

Speed adjust potentiometer

Chassis drive connections

Wiring instructions for connecting DC motors to chassis drives.

Power, fuse and motor connections

How to connect power input, fuses, and DC motors to the drive.

Cased drives Mounting (NEMA 1 enclosures)

Mounting (NEMA 12 enclosures)

Line fusing

Power and motor connections

How to connect power input and DC motors to the drive.

Operation (Minarik Manual)

Before applying power

Pre-operational checks and verifications before applying power to the drive.

Voltage select switches

Instructions for setting the input and armature voltage select switches.

Startup MM23001, MM23011, MM23071, and MM23072

Step-by-step guide for starting up specific MM23000 series drive models.

Startup MM23101, MM23111, MM23401, and MM23411

MM23201 and MM23211

MM23501

Starting and stopping methods

Recommended methods for starting and stopping the drive, including emergency procedures.

Dynamic braking

Calibration (Minarik Manual)

Warning

Critical warnings regarding voltage and safe adjustment of trimpots.

Minimum Speed (MIN SPD)

How to calibrate the MIN SPD trimpot for setting minimum motor speed.

Maximum Speed (MAX SPD)

Procedure for calibrating the MAX SPD trimpot to set maximum motor speed.

Torque

Setting and calibrating the TORQUE trimpot for motor acceleration and driving.

IR Compensation (IR COMP)

Adjusting IR COMP for maintaining motor speed under varying loads.

Acceleration (ACCEL)

Deceleration (DECEL)

Troubleshooting (Minarik Manual)

Before troubleshooting

Essential preliminary checks before starting troubleshooting procedures.

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