Total solder points: 95

Difficulty level: beginner 1 2 3 4 5 advanced

UNIVERSAL AC MOTOR CONTROL

K2636

rs.
collector moto
l of AC
y speed contro
Eas

ILLUSTRATED ASSEMBLY MANUAL H2636IP-1

Total solder points: 95

Difficulty level: beginner 1 2 3 4 5 advanced

UNIVERSAL AC MOTOR CONTROL

K2636

rs.
collector moto
ol of AC
sy speed contr
Ea

ILLUSTRATED ASSEMBLY MANUAL H2636IP-1

Features & Specifications

This kit is especially designed to control the speed of drills or any other AC-motors with carbon brushes. Contrary to the usual
dimmers, there isn't a phase cut every 1/2 period but only once per period. The moment of cutting determines the speed which can
be adjusted from 5 to about 95 %. Owing to this kind of controling, we keep a higher torque at low speed.This does not mean on
the other hand, that this circuit cannot be used for a resistive load (e.g. lamps, heating devices.).

A few advantages are :

The control range is from 5 % to 95 %.

There is an anti-RF interference circuit included.
The triac is protected against inductive voltage peaks from the motor.
The control circuit is powered by the mains, but the load supply may be derived from a different AC source. Both
voltages should have the same frequence though, and they should have completely the same phase or the opposite
phase (derived from one and the same phase out of the 3-Phase power source).
By keeping the MAINS- and LOAD SUPPLY separated this circuit is extremely appropriate for the use in low voltage
applications: e.g. in swimming pools, outdoors ...

Specifications
Power voltage :
MAINS 220-240 VAC or 115 VAC
LOAD SUPPLY 24VAC to 240VAC
MAINS AND LOAD SUPPLY are galvanically separated
Max. power to be regulated : 1200W at 240V (max. 5A).
Control range : 5 to 95 %.
Separate adjustment for the lowest speed.
Anti-RF interference circuit included.
Dimensions : 120 x 75 x 41mm.

Features & Specifications

This kit is especially designed to control the speed of drills or any other AC-motors with carbon brushes. Contrary to the usual
dimmers, there isn't a phase cut every 1/2 period but only once per period. The moment of cutting determines the speed which can
be adjusted from 5 to about 95 %. Owing to this kind of controling, we keep a higher torque at low speed.This does not mean on
the other hand, that this circuit cannot be used for a resistive load (e.g. lamps, heating devices.).

A few advantages are :

The control range is from 5 % to 95 %.

There is an anti-RF interference circuit included.
The triac is protected against inductive voltage peaks from the motor.
The control circuit is powered by the mains, but the load supply may be derived from a different AC source. Both
voltages should have the same frequence though, and they should have completely the same phase or the opposite
phase (derived from one and the same phase out of the 3-Phase power source).
By keeping the MAINS- and LOAD SUPPLY separated this circuit is extremely appropriate for the use in low voltage
applications: e.g. in swimming pools, outdoors ...

Specifications
Power voltage :
MAINS 220-240 VAC or 115 VAC
LOAD SUPPLY 24VAC to 240VAC
MAINS AND LOAD SUPPLY are galvanically separated
Max. power to be regulated : 1200W at 240V (max. 5A).
Control range : 5 to 95 %.
Separate adjustment for the lowest speed.
Anti-RF interference circuit included.
Dimensions : 120 x 75 x 41mm.

2
 Assembly hints

1. Assembly (Skipping this can lead to troubles ! )

Ok, so we have your attention. These hints will help you to make this project successful. Read them carefully.

1.1 Make sure you have the right tools:

• A good quality soldering iron (25-40W) with a small tip.

• Wipe it often on a wet sponge or cloth, to keep it clean; then apply solder to the tip, to give it a wet look. This is called ‘thinning’ and will
protect the tip, and enables you to make good connections. When solder rolls off the tip, it needs cleaning.
• Thin raisin-core solder. Do not use any flux or grease.
• A diagonal cutter to trim excess wires. To avoid injury when cutting excess leads, hold the lead so they
cannot fly towards the eyes.
• Needle nose pliers, for bending leads, or to hold components in place.
• Small blade and Phillips screwdrivers. A basic range is fine. 0.0
00

For some projects, a basic multi-meter is required, or might be handy

1.2 Assembly Hints :

⇒ Make sure the skill level matches your experience, to avoid disappointments.
⇒ Follow the instructions carefully. Read and understand the entire step before you perform each operation.
⇒ Perform the assembly in the correct order as stated in this manual
⇒ Position all parts on the PCB (Printed Circuit Board) as shown on the drawings.
⇒ Values on the circuit diagram are subject to changes.
⇒ Values in this assembly guide are correct*
⇒ Use the check-boxes to mark your progress.
⇒ Please read the included information on safety and customer service
* Typographical inaccuracies excluded. Always look for possible last minute manual updates, indicated as ‘NOTE’ on a separate leaflet.

Assembly hints

1. Assembly (Skipping this can lead to troubles ! )

Ok, so we have your attention. These hints will help you to make this project successful. Read them carefully.

1.1 Make sure you have the right tools:

• A good quality soldering iron (25-40W) with a small tip.

• Wipe it often on a wet sponge or cloth, to keep it clean; then apply solder to the tip, to give it a wet look. This is called ‘thinning’ and will
protect the tip, and enables you to make good connections. When solder rolls off the tip, it needs cleaning.
• Thin raisin-core solder. Do not use any flux or grease.
• A diagonal cutter to trim excess wires. To avoid injury when cutting excess leads, hold the lead so they
cannot fly towards the eyes.
• Needle nose pliers, for bending leads, or to hold components in place.
• Small blade and Phillips screwdrivers. A basic range is fine. 0.0
00

For some projects, a basic multi-meter is required, or might be handy

1.2 Assembly Hints :

⇒ Make sure the skill level matches your experience, to avoid disappointments.
⇒ Follow the instructions carefully. Read and understand the entire step before you perform each operation.
⇒ Perform the assembly in the correct order as stated in this manual
⇒ Position all parts on the PCB (Printed Circuit Board) as shown on the drawings.
⇒ Values on the circuit diagram are subject to changes.
⇒ Values in this assembly guide are correct*
⇒ Use the check-boxes to mark your progress.
⇒ Please read the included information on safety and customer service
* Typographical inaccuracies excluded. Always look for possible last minute manual updates, indicated as ‘NOTE’ on a separate leaflet.

3
Assembly hints

1.3 Soldering Hints :

1- Mount the component against the PCB surface and carefully solder the leads

2- Make sure the solder joints are cone-shaped and shiny

3- Trim excess leads as close as possible to the solder joint

REMOVE THEM FROM THE TAPE ONE AT A TIME !

AXIAL COMPONENTS ARE TAPED IN THE

CORRECT MOUNTING SEQUENCE !

You will find the colour code for the resistances and the LEDs on our website:
http://www.velleman.be/common/service.aspx

Assembly hints

1.3 Soldering Hints :

1- Mount the component against the PCB surface and carefully solder the leads

2- Make sure the solder joints are cone-shaped and shiny

3- Trim excess leads as close as possible to the solder joint

REMOVE THEM FROM THE TAPE ONE AT A TIME !

AXIAL COMPONENTS ARE TAPED IN THE

CORRECT MOUNTING SEQUENCE !

You will find the colour code for the resistances and the LEDs on our website:
http://www.velleman.be/common/service.aspx

4
 Construction

1. Jumper SK4 3. Resistors 4. Metal film resistors

Mount jumper according to the
main voltage : R...
R...

R9 : 100 (1 - 0 - 1 - B - 9)
R1 : 4K7 (4 - 7 - 2 - B) R10 : 120 (1 - 2 - 1 - B - 9)
R2 : 3K3 (3 - 3 - 2 - B) R11 : 68 (6 - 8 - 0 - B - 9)
R3 : 680 (6 - 8 - 1 - B) R13 : 27 (2 - 7 - 0 - B - 9)
R4 : 22K (2 - 2 - 3 - B) R14 : 390K (3 - 9 - 4 - B - 9)
R5 : 22K (2 - 2 - 3 - B)
J1 : 115V R6 : 1K5 (1 - 5 - 2 - B) 5. Capacitor
J2 : 230V
Choose operating frequency :
C3 : 100nF (104)
2. Diodes. Watch the polar- Europe (50Hz)
ity ! R7 : 47K (4 - 7 - 3 - B)

D1 : 1N4007 US (60Hz)
D2 : 1N4007 R7 : 10K (1 - 0 - 3 - B) 6. Trim potentiometer
D3 : 1N4148 R...
D...
D4 : 1N4148 CATHODE

D5 : 1N4148 RV2 : 100K

R8 : 100K (1 - 0 - 4 - B)
D6 : 1N4148 R12 : 1K (1 - 0 - 2 - B)
D7 : 1N4007 R15 : 2K2 (2 - 2 - 2 - B)

Construction

1. Jumper SK4 3. Resistors 4. Metal film resistors

Mount jumper according to the
main voltage : R...
R...

R9 : 100 (1 - 0 - 1 - B - 9)
R1 : 4K7 (4 - 7 - 2 - B) R10 : 120 (1 - 2 - 1 - B - 9)
R2 : 3K3 (3 - 3 - 2 - B) R11 : 68 (6 - 8 - 0 - B - 9)
R3 : 680 (6 - 8 - 1 - B) R13 : 27 (2 - 7 - 0 - B - 9)
R4 : 22K (2 - 2 - 3 - B) R14 : 390K (3 - 9 - 4 - B - 9)
R5 : 22K (2 - 2 - 3 - B)
J1 : 115V R6 : 1K5 (1 - 5 - 2 - B) 5. Capacitor
J2 : 230V
Choose operating frequency :
C3 : 100nF (104)
2. Diodes. Watch the polar- Europe (50Hz)
ity ! R7 : 47K (4 - 7 - 3 - B)

D1 : 1N4007 US (60Hz)
D2 : 1N4007 R7 : 10K (1 - 0 - 3 - B) 6. Trim potentiometer
D3 : 1N4148 R...
D...
D4 : 1N4148 CATHODE

D5 : 1N4148 RV2 : 100K

R8 : 100K (1 - 0 - 4 - B)
D6 : 1N4148 R12 : 1K (1 - 0 - 2 - B)
D7 : 1N4007 R15 : 2K2 (2 - 2 - 2 - B)

5
Construction

7. Transistors. 10. Terminal blocks. 13. LED

T1 : BC547B VAC : 2p
T2 : BC547B LOAD : 2p LD1 : 3mm RED
T3 : BC547B MAINS : 2p LD...

T4 : BC517 CATHODE

8. Capacitors 14. Coil.

11. Fuse holders + fuses
L1 : 1mH/5A/1Khz.
F...

C5 : 47nF
C6 : 100nF/275VAC X2 15. Transformer
C7 : 47nF/400V
F1 : 250mA (slow)
F2 : 5A (slow)
9. Electrolytic Capacitors.
Watch the polarity ! 12. Trim potentiometer
...

C1 : 470µF
FO
TR A

RV...
C2 : 1µF RV1 : 100K
C... TRAFO1 : 2 x 6V / 2 x 0,3A
Mount the 6V connections to
the OUTSIDE of the print !
6

Construction

7. Transistors. 10. Terminal blocks. 13. LED

T1 : BC547B VAC : 2p
T2 : BC547B LOAD : 2p LD1 : 3mm RED
T3 : BC547B MAINS : 2p LD...

T4 : BC517 CATHODE

8. Capacitors 14. Coil.

11. Fuse holders + fuses
L1 : 1mH/5A/1Khz.
F...

C5 : 47nF
C6 : 100nF/275VAC X2 15. Transformer
C7 : 47nF/400V
F1 : 250mA (slow)
F2 : 5A (slow)
9. Electrolytic Capacitors.
Watch the polarity ! 12. Trim potentiometer
...

C1 : 470µF
FO
TR A

RV...
C2 : 1µF RV1 : 100K
C... TRAFO1 : 2 x 6V / 2 x 0,3A
Mount the 6V connections to
the OUTSIDE of the print !
6
 Construction

16. Triac.

TR1 : BT137F-600

mm
10mm
M3 BOLT
3 BOLT

LOCK
WASHER

M3
NUT

Place the heatsink and the triac on the PCB.

Fix the two components with a M3 bolt and nut.
Now, the triac may be soldered.

Construction

16. Triac.

TR1 : BT137F-600

mm
10mm
M3 BOLT
3 BOLT

LOCK
WASHER

M3
NUT

Place the heatsink and the triac on the PCB.

Fix the two components with a M3 bolt and nut.
Now, the triac may be soldered.

7
Test & connection

17. Test & connection

ATTENTION:
N
N L
N A PART OF THE CIRCUIT IS ALWAYS UNDER MAIN

MAINS
110 - 240VAC VOLTAGE. TAKE ALL POSSIBLE PRECAUTIONS, SO
LL N
L
THAT NO-ONE CAN TOUCH ANY PART. FOR YOUR
L OWN SECURITY AS FOR THE USERS' SECURITY.

LOAD
M N MOUNT THIS KIT PREFERABLY IN AN ISOLATING
HOUSING. THE FUSE WILL MELT IN CASE OF AN OVER-
N
VAC LOAD, REPLACE IT BY EXACTLY THE SAME TYPE.
L
Fig 1.0

Connect the load to the screw connector marked by "LOAD" see fig. 1. Consider the max. load (5,5A)
Connect the mains voltage on the screw connector "MAINS".
See whether you have mounted the right jumper (J1 or J2).
The power voltage for the load is put on the connector. "VAC" (24 … 240VAC).
See that this voltage and the "MAINS" voltage have the same frequency and that they are either in phase
or in the opposite phase. Owing to the fact that the supply voltages of the load and the control circuit are
completely separated, one can also connect low voltage loads. This makes this circuits fits for regulations
in swimming pools, outdoors ect...

Test & connection

17. Test & connection

ATTENTION:
N
N L
N A PART OF THE CIRCUIT IS ALWAYS UNDER MAIN
MAINS

110 - 240VAC VOLTAGE. TAKE ALL POSSIBLE PRECAUTIONS, SO

LL N
L
THAT NO-ONE CAN TOUCH ANY PART. FOR YOUR
L OWN SECURITY AS FOR THE USERS' SECURITY.
LOAD

M N MOUNT THIS KIT PREFERABLY IN AN ISOLATING

HOUSING. THE FUSE WILL MELT IN CASE OF AN OVER-
N
LOAD, REPLACE IT BY EXACTLY THE SAME TYPE.
VAC

L
Fig 1.0

Connect the load to the screw connector marked by "LOAD" see fig. 1. Consider the max. load (5,5A)
Connect the mains voltage on the screw connector "MAINS".
See whether you have mounted the right jumper (J1 or J2).
The power voltage for the load is put on the connector. "VAC" (24 … 240VAC).
See that this voltage and the "MAINS" voltage have the same frequency and that they are either in phase
or in the opposite phase. Owing to the fact that the supply voltages of the load and the control circuit are
completely separated, one can also connect low voltage loads. This makes this circuits fits for regulations
in swimming pools, outdoors ect...

8
 Test & connection

Turn RV1 completely to the left (minimal position) and RV2 completely to the right.
Switch the power on.

BE CAREFUL: a large part of the circuit is under mains power, do not touch it!

Adjust RV2 so that the motor will have the lowest speed. It is important for the motor to start at any time,
even where RV1 is put in its minimal position, otherwise there might be large currents causing sparks
that burn the carbon brushes.

NOTE: If the torque is poor, swap the two wires, connected to "VAC", mutually. The connections to
"MAINS" must remain un-changed!

Test & connection

Turn RV1 completely to the left (minimal position) and RV2 completely to the right.
Switch the power on.

BE CAREFUL: a large part of the circuit is under mains power, do not touch it!

Adjust RV2 so that the motor will have the lowest speed. It is important for the motor to start at any time,
even where RV1 is put in its minimal position, otherwise there might be large currents causing sparks
that burn the carbon brushes.

NOTE: If the torque is poor, swap the two wires, connected to "VAC", mutually. The connections to
"MAINS" must remain un-changed!

9
PCB

PCB

10

PCB

PCB

10
 Diagram

Schematic diagram

470µF

1µF

11

Diagram

Schematic diagram

470µF

1µF

11
 VELLEMAN Components NV
Legen Heirweg 33
9890 Gavere
Belgium Europe
www.velleman.be
www.velleman-kit.com

Modifications and typographical errors reserved

© Velleman Components nv.
H2636IP - 2004 - ED1 (rev.2)
5 410329 311414

VELLEMAN Components NV
Legen Heirweg 33
9890 Gavere
Belgium Europe
www.velleman.be
www.velleman-kit.com

Modifications and typographical errors reserved

© Velleman Components nv.
H2636IP - 2004 - ED1 (rev.2)
5 410329 311414