null  null
INSTALLATION
OPERATION
MAINTENANCE
MELLTRONICS DRIVES
SINGLE PHASE NON-REGENERATIVE
DC DRIVE CONTROLLER
¼ HP TO 5 HP
MAIL: PO BOX 2368
INDIAN TRAIL, NC 28079-2368
SHIPPING: 3479 GRIBBLE ROAD
MATTHEWS, NC 28104-8114
PHONE: 704-821-6651
www.melltronics.com
SAFETY WARNINGS:
Improper installation or operation of this drive control may cause serious injury to personnel or equipment. Before
you begin installation or operation of this equipment you should thoroughly read this instruction manual and any
supplementary operating instructions provided. The drive must be installed and grounded in accordance with
local and national electrical codes. To reduce potential of electric shock, disconnect all power sources before
initiating any maintenance or repairs. Keep fingers and foreign objects away from ventilation and other openings.
Keep air passages clear. Potentially lethal voltages exist within the control unit and connections. Use extreme
caution during installation and start-up.
BRANCH CIRCUIT PROTECTION:
Branch circuit protection is to be provided by end user, if not included.
INITIAL CHECKS:
Before installing the drive control, check the unit for physical damage sustained during shipment. Remove all
shipping restraints and padding.
INSTALLATION LOCATION OF CONTROL:
Controls are suitable for most factory areas where industrial equipment is installed. The control and operator’s
control station should be installed in a well-ventilated area. Locations subject to steam vapors or excessive
moisture, oil vapors, flammable or combustible vapors, chemical fumes, corrosive gases or liquids, excessive dirt,
dust or lint should be avoided unless an appropriate enclosure has been supplied or a clean air supply is provided
o
to the enclosure. The location should be dry and the ambient temperature should not exceed 104 F for an
o
enclosed unit or 131 F for a chassis mount unit. If the mounting location is subject to vibration, the enclosure
should be shock-mounted.
If the enclosure has a ventilating fan, avoid, wherever possible, and environment having a high foreign-matter
content; otherwise the filters will have to be changed more frequently or micron-filters installed. Should a control
enclosure require cleaning on the inside, a low pressure vacuum cleaner is recommended, not an air hose,
because of the possible oil vapor in the compressed air and its high pressure.
ES2700 – RECEIVING INFORMATION
Please record the following before installing the unit and use these numbers when communication with
the factory.
MODEL NAME
PART NUMBER
SERIAL NO.
REVISION
MODIFICATIONS
ACCEPTANCE:
Carefully inspect shipment upon arrival and check items with packing list. Shortage or damage should be
reported promptly to the carrier and your distributor.
ES-2700 MANUAL
TABLE OF CONTENTS
SECTION 1
1.1
1.2
1.3
1.4
INTRODUCTION..........................................................................................................................................................5
GENERAL DESCRIPTION...........................................................................................................................................5
TYPICAL PACKAGING ................................................................................................................................................5
EQUIPMENT IDENTIFICATION ..................................................................................................................................6
SECTION 2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
OPERATION AND START-UP PROCEDURE .............................................................................. 18
INTRODUCTION........................................................................................................................................................18
OPERATOR CONTROLS ..........................................................................................................................................18
ADJUSTMENTS.........................................................................................................................................................21
JUMPER PROGRAMMING........................................................................................................................................22
START-UP PROCEDURE .........................................................................................................................................24
SECTION 6
6.1
6.2
6.3
6.4
6.5
INSTALLATION ............................................................................................................................. 13
SAFETY WARNINGS.................................................................................................................................................13
INITIAL CHECKS .......................................................................................................................................................13
DETERMINING THE CONTROL LOCATION ............................................................................................................13
INSTALLING CHASSIS MOUNT CONTROLS...........................................................................................................13
INSTALLING ENCLOSED CONTORLS.....................................................................................................................13
POWER WIRING .......................................................................................................................................................13
CONTROL LOGIC WIRING .......................................................................................................................................14
SIGNAL WIRING........................................................................................................................................................14
CIRCUIT BOARD INTERCONNECTIONS.................................................................................................................14
INSTALLING MODIFICATIONS .................................................................................................................................15
SECTION 5
5.1
5.2
5.3
5.4
5.5
FUNCTIONAL DESCRIPTION....................................................................................................... 10
GENERAL DESCRIPTION.........................................................................................................................................10
POWER CONVERSION ASSEMBLY ........................................................................................................................10
REGULATOR ASSEMBLY.........................................................................................................................................10
SECTION 4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
CONTROL SPECIFICATIONS AND FEATURES ........................................................................... 7
EQUIPMENT RATINGS ...............................................................................................................................................7
PERFORMANCE FEATURES .....................................................................................................................................7
PROTECTIVE FEATURES ..........................................................................................................................................8
PERFORMANCE SPECIFICATIONS...........................................................................................................................8
OPERATING CONDITIONS.........................................................................................................................................8
ENVIRONMENTAL CONDITIONS ...............................................................................................................................8
ADJUSTMENTS...........................................................................................................................................................9
CONTROL DIMENSIONS AND WEIGHTS..................................................................................................................9
SECTION 3
3.1
3.2
3.3
SAFETY............................................................................................................................................ 5
MAINTENANCE AND TROUBLESHOOTING............................................................................... 27
IMPORTANT SAFEGUARDS ....................................................................................................................................27
ROUTINE MAINTENANCE ........................................................................................................................................27
TROUBLESHOOTING ...............................................................................................................................................27
CORRECTIVE ACTION FOR DRIVE MALFUNCTIONS............................................................................................28
SCR REPLACEMENT................................................................................................................................................30
SECTION 7
ORDERING SPARE PARTS.......................................................................................................... 31
SECTION 8
SUPPLEMENTARY TECHNICAL INFORMATION ....................................................................... 32
SECTION 9
WARRANTY ................................................................................................................................... 39
MELLTRONICS
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ES-2700 MANUAL
LIST OF TABLES
Table 1: Armature Circuit Rating Table..................................................................................................................... 7
Table 2: MELLTRONICS ES-2700 Field Data .......................................................................................................... 7
Table 3: MELLTRONICS ES-2700 Weights and Dimensions .................................................................................. 9
Table 4: Armature Current Overload Scaling.......................................................................................................... 23
Table 5: Recommended Spare Parts for the ES-2700 ........................................................................................... 31
Table 6: Terminal Strip Connections....................................................................................................................... 33
Table 7: Jumper Programming Quick Guide........................................................................................................... 33
LIST OF FIGURES
Figure 1: Typical Chassis Mount Control ................................................................................................................... 5
Figure 2: Typical MELLTRONICS ES-2700 Nameplate ........................................................................................... 6
Figure 3: Product Nameplate Location ..................................................................................................................... 6
Figure 4: ES-2700 Block Diagram .......................................................................................................................... 12
Figure 5: Connector J1 Pin Assignments................................................................................................................ 15
Figure 6: User Connection Diagram ....................................................................................................................... 16
Figure 7: Upper PC Board....................................................................................................................................... 17
Figure 8: Lower PC Board....................................................................................................................................... 17
Figure 9: Inverse Time Trip Overload Characteristics ............................................................................................ 18
Figure 10: Upper Control Board Operating Features.............................................................................................. 20
Figure 11: Stability Effects on the Velocity Profile .................................................................................................. 21
Figure 12: Lower PC Board Details ........................................................................................................................ 26
Figure 13: SCR Location......................................................................................................................................... 30
Figure 14: Chassis Mount Control .......................................................................................................................... 32
Figure 15: Enclosed Control.................................................................................................................................... 32
Figure 16: Control Logic and Test Meter Connections ........................................................................................... 34
Figure 17: Interconnect Diagram 272-1000-I, Sheet 1 ........................................................................................... 35
Figure 18: Interconnect Diagram 272-1000-I, Sheet 2 ........................................................................................... 36
Figure 19: Top PC Board Schematic - Diagram 272-1000 ..................................................................................... 37
Figure 20: Bottom PC Board Schematic - Diagram 272-1005................................................................................ 38
MELLTRONICS
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ES-2700 MANUAL
SECTION 1
SAFETY
1.1
INTRODUCTION
MELLTRONICS ES-2700 to operate from either 120
or 240 volt AC input power at 50 or 60 Hz. Additional
This instruction manual contains installation
jumpers program the control to operate as either a
information, operating instructions and troubleshooting
speed regulator with armature voltage or as a torque
procedures for the MELLTRONICS ES-2700
regulator with armature current feedback.
Adjustable Speed Non- Regenerative DC Motor
The entire 1/4 to 5HP range of applications is covered
Control.
A comprehensive description of the
by two control models (See Table 1). Drive current
MELLTRONICS ES-2700 control with detailed product
limit and inverse time overload protective circuits for
specifications and a complete description of all
ratings within this range are calibrated by means of a
customer selectable functions and customer
jumper change on the main printed circuit board.
installable option kits is included.
Included in the MELLTRONICS ES-2700 control are
The information in this instruction manual will
many built-in features. Motor field economy and
describe all drive system set-up and operating
separately adjustable rates of acceleration and
procedure for most drive applications. Also provided
deceleration are included on all units. If desired, the
is all the information required by the customer to
built-in Accel-Decel control ramps can be by-passed
install and maintain a MELLTRONICS ES-2700
completely by a jumper change on the control.
control. Additional drive system set-up and operating
Current compounding can be added to the speed
information may be required in some applications.
regulator by changing another jumper position.
This information will normally be supplied in the form
Current limit is normally set by a potentiometer
of a system schematic and system interconnection
located on the main printed circuit board, but if
diagrams.
desired, it can be adjusted using a remote mounted
Before beginning installing and before performing any
potentiometer or a customer supplied voltage signal.
start-up or maintenance on the drive system read this
An output signal is available for use with one of the
instruction manual in its entirety .
MELLTRONICS ES-2700 ammeter kits to provide an
1.2
GENERAL DESCRIPTION
indication of drive output current without the addition
of an ammeter shunt.
The MELLTRONICS ES-2700 is a high performance,
1.3
TYPICAL PACKAGING
non-regenerative DC motor control. Included are
many standard features that are available only as
The normal MELLTRONICS ES-2700 control is
options on many other regenerative drives.
chassis mounted non-enclosed control suitable for
Accessibility to all important internal regulator points is
subpanel mounting inside a customer furnished
provided by terminals on the control. This permits the
control enclosure. (see Figure 1)
MELLTRONICS ES-2700 to be used in custom
engineered applications, as well as in standard speed
regulated applications.
The MELLTRONICS ES-2700 controls a DC motor’s
speed or torque by varying the DC voltage applied to
the motor’s armature.
Rectilinear phase control
assures stable operation at low speeds and low
torque where other controls may exhibit instability.
The MELLTRONICS ES-2700 control converts single
phase AC input power to variable voltage DC output
power. In speed regulated applications, the DC
output voltage varies as a function of an input
reference voltage. (Typically, this input reference
voltage is provided by an operator adjustable
potentiometer).
Changing the speed reference
(potentiometer setting) results in a motor speed
change. In torque regulated applications, the DC
output current varies as a function of an input
reference voltage. Changing the torque reference
(potentiometer setting) changes the current supplied
to the motor and results in a change in motor torque
output.
The MELLTRONICS ES-2700 is a versatile control.
Figure 1: Typical Chassis Mount Control
Simple
jumpered
programming
allows
the
MELLTRONICS
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REV. 04/03/2006
ES-2700 MANUAL
Typically MELLTRONICS ES-2700
controls are
furnished without operator’s devices. Terminals are
provided on the basic MELLTRONICS ES-2700
control for connection of one or more of the following
operator’s devices:
 Jog Push-button
 Remote Current Limit Potentiometer
 Speed Adjust Potentiometer
 Start Push-button
 Stop Push-button
Customer requirements may dictate that the
operator’s devices be mounted on the door of the
enclosure. For these applications, see schematic and
interconnection diagrams furnished with your control
for specific variations in packaging.
1.4
EQUIPMENT IDENTIFICATION
Identification of your drive control completely and
accurately is necessary when you contact Melltronics
Industrial to order spare parts or request assistance in
service. Every MELLTRONICS ES-2700 includes a
product nameplate located on the right side of the
chassis. Record both the part number and serial
number for your future reference.
MODEL
ES2700
———–———ACINPUT —–———–—
V
AC
120/240
HZ
50/60
A
PH
17
1
—––——–—MAX DC OUT—–————
V
DC
90/180
HP
1-2
A
10
KW
—————-––FIELD OUT—————–
V
FL
100/200
A
3
PN
SC
2710-1000-I
SN
Figure 2: Typical MELLTRONICS ES-2700
Nameplate
NAMEPLATE
Figure 3: Product Nameplate Location
MELLTRONICS
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REV. 04/03/2006
ES-2700 MANUAL
SECTION 2
CONTROL SPECIFICATIONS AND FEATURES
 Common Control Circuit Boards – All ES-2700
2.1
EQUIPMENT RATINGS
controls utilize the same PC board regardless of
The MELLTRONICS ES-2700 was designed so that a
HP, voltage, frequency or control mode.
minimum number of different models could be used in
 Field Economy - Promotes longer life for wound
a wide variety of different drive applications.
field DC motors. Easily by-passed or time delayed
to meet specific application requirements.
Two ES-2700 control models cover the entire ¼ to 5
 Inner Current Loop Regulator - Inherent high
HP range of DC drive applications. ES-2700 controls
band width capability for fast response.
are reconnectable for 120VAC or 240VAC single
 Circuit Board Indicators - Light emitting diodes
phase input at either 50 or 60Hz. One control model
(LEDs) on the main printed circuit board indicate:
covers ¼ through 1 HP applications at 120VAC input
 DC Overload DC Power ON
and ½ through 2 HP applications at 240VAC input. A
 Field Loss
Jog Mode
second control model covers 3 to 5HP applications at
 Instantaneous Overcurrent Trip
240VAC input. Drive current limit and inverse time
 Run Mode
SCRs Being Gated
overload protective circuits are calibrated for the
 Ammeter Output - Motor current can be indicated
application by jumper on the main PC board.
with the simple addition of a remote meter.
Table 1 lists the AC input and DC output current

Isolated Control Circuitry - Provides complete
ratings by control part number and motor horsepower
isolation of the control and regulator circuitry from
for all possible combinations.
the AC power bus for protection in the event of a
ground fault. The speed potentiometer, ammeter
Table 1: Armature Circuit Rating Table
and tachometer are not at line potential. Complete
DC
system compatibilities is also possible without
AC
Armature
additional isolation accessories.
Input
 Dual Frequency Operation - Controls may be
Control
Horsepower
Amps @
Amps
operated from 50 or 60Hz power supplies by simple
240
@Full
jumper change.
Part No. 120 VAC
Full Load
VAC
Load
 Exclusive Static Adjustable Current Limit Permits static setting of the desired current limit
1/4
1/2
4.2
3
value without applying DC power and without a
1/3
—
5.6
4
connected output load when the optional test meter
—
3/4
5.6
4
272-8000
is connected.
1/2
1
8.5
6
 Jog Set at Preset Speed - Separately adjustable
3/4
1 1/2
11
8
from zero to 50% of base speed.
1
2
14
10
 Negative IR Compensation - enables this drive to
operate in load sharing applications. This feature
—
3
21
14
becomes available by jumper connection.
—
—
28
20
272-8001
 Speed Regulator – Two percent accuracy using
—
5
38
25
armature voltage feedback with IR compensation of
A fixed voltage unregulated DC motor field supply is
1% accuracy with tachometer feedback. Regulation
provided on all MELLTRONICS ES-2700 controls.
may be improved by selecting the proper motor
The DC voltage output level is a function of the AC
mounted tachometer.
voltage input level. Field data for the MELLTRONICS
 Separately
Adjustable Linear Accel/Decel
ES-2700 control is tabulated in Table 2.
Control - Two ranges; 0.2-4 seconds and 2-30
Table 2: MELLTRONICS ES-2700 Field Data
Voltage:
100 VDC with 120 VAC input
200 VDC with 240 VAC input
Current:
3 amperes maximum
2.2


PERFORMANCE FEATURES
Every ES-2700 control includes the following standard
features and functions:
 Current (Torque) Regulator - One percent
accuracy armature current regulator allows the
operator to control motor torque instead of speed.
MELLTRONICS
-7-

seconds.
Solid State Full Wave Power Bridge - Provides
generously rated power semiconductors for
maximum reliability and long life.
Standard Adjustments – Maximum speed,
minimum speed, IR compensation, acceleration
time, deceleration time, current limit, jog speed,
velocity stability, speed rate and current stability.
Remote Current Limit - Available by the simple
addition of a potentiometer of DC voltage input.
REV. 04/03/2006
ES-2700 MANUAL



SCR Trigger Circuits - Pulse transformer isolated,
hard firing, high frequency “burst” type pulse train
output from individually gated oscillators insures
SCR conduction regardless of the effects of line
notching on the incoming AC power line.
AC Line Filter and Transient Voltage
Suppressor Network - Eliminates interaction
between other drives or AC equipment.
Power Supplies – Each ES-2700 contains an
internal 115 VAC power supply to power the DC
loop contactor and drive logic relays. Internal
±24VDC, ±15VDC and a regulated –10VDC power
supply are also included.
2.3
PROTECTIVE FEATURES
The following list identifies the protective features of
the ES-2700.
 DC Overload (Armature) - Senses over-current
conditions with inverse time shutdown.
 Fault Trip Circuit - Visual indication of the fault
condition is provided when a DC overload, field
loss, or instantaneous over-current conditions
occurs. Protective circuits are designed to quickly
shut the drive down whenever a drive fault condition
occurs. A fault trip circuit prevents unintended drive
restart after a fault has occurred and must be reset
before the drive can run again.
 Field Loss Protection - Protects against runaway
due to loss of motor field by shutting down the
drive.
 Double Break DC Armature Loop Contactor Full rated and fully sequenced contactor assures
positive disconnect of DC motor when the stop
push-button is pushed or whenever an undervoltage condition occurs.
 High
Speed
Current
Limiting
SCR
Semiconductor Fuses - Gives the ultimate in fuse
coordination and protection of the SCRs and motor
with positive circuit clearing on both AC and DC
faults.
 Reactors,
Snubber Networks - Prevents
interaction and SCR DV/DT failures, due to line
spikes and transients. Provides DI/DT protection
during SCR turn-on and aids in SCR turn-off during
SCR commutation, therefore minimizing the effects
of AC power-line notching.
 Instantaneous Overcurrent Protection – Senses
armature fault currents quickly to protect both semiconductors and motors against damaging current
levels.
NOTE
Additional electrical equipment to insure proper
control operation may be required for severe
system applications.
For further information,
contact Melltronics Industrial.
MELLTRONICS
-8-
2.4
PERFORMANCE SPECIFICATIONS
20:1 basic control. May be
extended to 200:1 by
modification
Controlled Speed
Range:
Speed Regulation:
For a 95% Load
Change:
Voltage Regulated:
2-5% of maximum speed
Speed Regulated:
1% of maximum speed with
any DC tachometer.
For All Other Variables:
Voltage Regulated:
Changes up to 15% of top
speed can result from
temperature
variations,
voltage
and
frequency
variations, and drift.
Speed Regulated:
1% of maximum speed with
any DC tachometer
2% of maximum speed with
any AC tachometer
NOTE
Speed regulation may be modified to achieve 0.1%
due to a 95% load change and 0.15% due to all
other variables.
Overload Capacity: 150% of related current for 1
minute
Service Factor:
1.0
2.5
OPERATING CONDITIONS
 Rated Line Voltage:
 Line voltage Variations:
120 or 240VAC , SinglePhase
±10%
 Rated Line Frequency:
50 or 60Hz
±2Hz
ENVIRONMENTAL CONDITIONS
 Line Frequency Variations:
2.6
0
0
0
0
 Storage Temperature: -30 C to 65 C (-20 F to 150 F)
 Ambient Temperature
(Enclosed Control):
Ambient Temperature
(Chassis Mount
Control):
 Altitude:
00 C to 400 C (320 F to 1040 F)*
00 C to 550 C (320 F to 1310 F)*
Sea level to 3300 feet *(1000
meters)
 Relative Humidity:
0 to 95%
*Operation at elevated temperature and higher altitudes
requires derating of the control.
REV. 04/03/2006
ES-2700 MANUAL
2.7
ADJUSTMENTS
The MELLTRONICS ES-2700 control includes a
number of potentiometers that may require adjustment
during drive installation and start-up.
These
adjustment potentiometers are located on the main
(regulator) PC board.
2.8
 Vel. Stability
User adjusted for best results
 Deceleration
User adjustable from 0.2-4 sec. or 2-30
sec. (selectable)
Time
 Acceleration
Time
CAUTION
ANY ALTERNATION TO FACTORY-ADJUSTED
POTENTIOMETERS MAY CAUSE EQUIPMENT DAMAGE
AND/OR MACHINERY PROCESS PROBLEMS. FOR
FURTHER ADJUSTMENTS, CONTACT:
MELLTRONICS INDUSTRIAL, INC.
User adjustable from 0.2-4 sec. or 2-30
sec. (selectable)
CONTROL DIMENSIONS AND WEIGHTS
Table 3 gives the approximate weight and dimensions
for various MELLTRONICS ES-2700 controls. Figure
14 shows the outline and mounting dimensions for
these MELLTRONICS ES-2700 controls.
 Maximum Speed User adjustable from 70-130% of rated
speed.
User adjustable from 0-50% of rated
speed
 Current Stability User adjustable for best results
 Speed Rate
User adjustable for best results.
Table 3: MELLTRONICS ES-2700 Weights and
Dimensions
 Jog Speed
 IR
Compensation
 Min Speed
 I Limit
Control
Type
User adjustable from 0-15% of rated
voltage.
User adjustable from 0 to 30% of rated
speed.
User adustable from 0-150% of selected
current range
Approximate
Weight (lbs)
Approximate
Dimensions
Chassis Mount
10
13.0 x 9.5 x 4.75
Chassis Mount with
Test Meter
10
13.0 x 9.5 x 7.0
Included on the MELLTRONICS ES-2700 are several
additional adjustment potentiometers.
These
potentiometers are all factory set and normally do not
require further adjustment.
MELLTRONICS
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REV. 04/03/2006
ES-2700 MANUAL
SECTION 3
FUNCTIONAL DESCRIPTION
The ES-2700 is a non-regenerative DC motor control
supply anytime the DC loop contactor is opened. This
which consists of two basic functional blocks: a power
reduces the field voltage applied to the DC motor
conversion assembly and a regulator assembly.
(field economy) and helps to increase motor life in the
applications where the motor field remains energized
3.1
GENERAL DESCRIPTION
while the motor is stopped.
The power conversion assembly consists of two
The control power supply assembly steps down the
silicon controlled rectifiers (SCRs) and two diodes
incoming AC line voltage, and then rectifies filters and
connected in a full wave bridge configuration, with a
regulates it to provide two DC power sources
third “freewheeling” diode connected across the
(±24VDC and ±15VDC) that are used internally by the
armature output terminals of the bridge. Normally
ES-2700 regulator assembly.
reverse biased, this “freewheeling” diode conducts
A –10VDC output is also produced which may be
only when both SCRs have been commutated off,
used in conjunction with an external potentiometer to
allowing the current in the armature circuit a path to
create a drive reference signal. The control power
circulate.
supply assembly includes a fused and isolated
The Regulator Assembly includes all of the electronic
115VAC power source that is used to operate the
circuitry used to control (provide gating signals to) the
control logic relays and DC loop contactor.
Power Conversion Assembly. The regulator used in
All of the remaining functional blocks shown in Figure
the ES-2700 employs two control loops – an outer
4 are functional blocks associated with the ES-2700
velocity loop and an inner current loop. There are
regulator assembly. An overview of the ES-2700
several advantages inherent in a DC motor control
regulator assembly follows.
that employs this dual control loop concept. First of
3.3
REGULATOR ASSEMBLY
all, the inner current loop can easily and effectively be
The ES-2700 control works off of a zero to –10VDC
used to limit DC motor armature current. This protects
reference signal. This input reference signal can
the motor, the power bridge, and the fuses during
represent either a DC motor speed reference or a DC
stable drive operation under varying load conditions.
motor torque reference depending on the placement
Another advantage of a DC motor control that
of a terminal board jumper (this will be explained
employs an inner current loop is the ease with which it
later). The input reference signal is usually introduced
can be converted from speed regulated drive to a
to the control at terminal #12 (TB-1) on the regulator
torque regulated drive. This provides application
(top) printed circuit board.
flexibility that would not otherwise be available.
In the following section, the ES-2700 will be analyzed
3.3.1
ACCEL/DECEL CIRCUIT
and described using the functional block diagram
Terminal #12 is connected to the input of the ES-2700
shown in Figure 4.
accel/decel (reference ramp) circuit.
This circuit
3.2
POWER CONVERSION ASSEMBLY
controls the rate at which the drive reference can
change. When a reference signal is applied to the
Incoming AC power is applied to the ES-2700 control
input of the accel/decel circuit, the output of the
at terminals L1 and L2. A pair of current limiting type
accel/decel circuit changes at a linear rate with
fuses (1FU and 2FU) provides AC line short circuit
respect to time until the output of the accel/decel
protection and serves to protect the SCRs from DC
circuit TB-1, Terminal #3 is equal to its input (Terminal
fault currents. AC line power is distributed within the
#12). The rate of change is adjustable and separate
ES-2700 control to three major functional blocks: the
adjustments are provided for positive going and
power conversion assembly, the DC motor field
negative going reference changes. The accel/decel
supply and the control power supply.
(ramp reference) circuit is most commonly used in
The power conversion assembly consists of a single
speed regulated drive applications. If the operator
phase controlled, full wave rectified, SCR power
rapidly changes the speed reference to the drive, the
conversion assembly.
The output of the power
accel/decel circuit will limit the acceleration of
conversion assembly is connected to the DC motor
deceleration rate to a rate that will not cause machine
armature through a DC loop contactor (M). The DC
or process problems. The accel/decel (reference
loop contactor provides a positive means of
ramp) circuit can also be used in torque-regulated
disconnecting the DC motor armature from the power
applications to limit the rate at which the torque
conversion assembly in the event of a drive fault.
reference to the drive can change.
The DC motor field supply rectifies AC line voltage to
The output of the accel/decel circuit (TB-1 Terminal
produce a fixed DC voltage that may be connected to
#3) is usually connected to the velocity error amplifier
the field windings of a wound field DC motor. The
input (Terminal #4) via a jumper connection at the
field power supply produces an output of 200VDC with
customer terminal strip (TB-1). It is possible to by240VAC input or 100VDC with a 120VAC input. An
pass the accel/decel circuit completely by connecting
auxiliary contact (MAUX) “half waves” the field power
MELLTRONICS
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REV. 04/03/2006
ES-2700 MANUAL
the drive input reference signal to Terminal #4 instead
of terminal #12 and removing the jumper between
Terminals #3 and #4. The accel/decel circuit is often
by-passed in custom engineered drive applications..
3.3.2
VELOCITY ERROR AMPLIFIER
The velocity error amplifier circuit is used in speed
regulated drive applications. It compares a velocity
reference signal with a velocity feedback signal to
determine whether the DC motor is operating faster or
slower than its commanded velocity. The output of
the velocity error amplifier circuit is used as a
reference signal to the ES-2700’s “inner current loop”.
The “inner current loop” directly controls DC motor
armature current.
The feedback signal to the velocity error amplifier can
be a signal proportional to DC motor armature voltage
or it can be a signal from a DC tachometer generator.
Armature voltage feedback is used in those
applications where the speed regulation and drift
characteristics (See section 2.4).
The velocity
feedback selection and scaling circuitry allows the
control to be programmed for armature voltage
feedback or tachometer feedback. It allows the
control to be used with 90VDC or 180VDC motors
(voltage regulated applications) or with a variety of
tachometer voltage output levels (speed regulated
applications). The velocity error amplifier circuit has
one additional input, IR compensation.
3.3.3
IR COMPENSATION
The IR compensation network introduces an increase
or decrease) in the velocity reference proportional to
motor armature current.
The magnitude of the
increase (or decrease) can be adjusted using the IR
compensation potentiometer. On the ES-2700 the IR
compensation signal can be either positive or
negative.
Positive IR compensation increases the motor velocity
reference as the motor armature current increases.
Positive IR compensation is used in armature voltage
regulated control applications to offset the natural
tendency for the speed of a motor to decease as the
load on the motor increases.
Positive IR
compensation is generally not used in applications
that employ tachometer feedback.
Negative IR compensation is just the opposite of
positive IR compensation.
It causes the motor
velocity reference to decrease as motor armature
current increases. When negative IR compensation is
employed, the DC drive motor will function much like a
compound wound DC motor would function in the
same application. Negative IR compensation is used
in “helper drive” applications where the speed of the
drive must conform to the speed of the process it
drives. Negative IR compensation may be used with
both armature voltage and tachometer feedback
regulated controls.
MELLTRONICS
- 11 -
3.3.4
ARMATURE CURRENT ERROR AMPLIFIER
The armature current error amplifier compares an
armature current reference signal (the output of the
velocity error amplifier) with an armature current
feedback signal (the output of the armature current
scaling amplifier). The output of the armature current
error amplifier is one of two reference signals applied
to the phase angle reference circuitry.
3.3.5
PHASE ANGLE REFERENCE
The phase angle reference circuitry determines the
correct SCR firing angle for the SCR power
conversion assembly. Actual SCR firing is controlled
by the SCR gating circuit.
3.3.6
CURRENT SENSING TRANSFORMER (CT1)
A current sensing transformer (CT1) measures the AC
line current flowing in the power conversion assembly.
The CT output waveform is rectified and normalized
by the armature current scaling amplifier to provide a
signal that is directly proportional to the current
flowing in the DC motor. This signal is utilized as the
feedback signal to the armature current error amplifier
and it is also used as an input to the IR compensation
circuitry.
3.3.7
ARMATURE VOLTAGE BUFFER/SCALING
AMPLIFIER
The armature voltage buffer/scaling amplifier is used
to isolate and scale the DC motor armature voltage for
use by the phase angle reference circuit. The output
of the armature voltage buffer/scaling amplifier is also
used as “velocity” feedback in some applications.
The velocity error amplifier circuit is designed to
function normally as a very high gain error amplifying
circuit. It can also be configured to function as a low
gain, input reference buffer amplifier.
This
configuration is normally used in current regulated
drive applications. By jumpering Terminals #1 and #2
at the user terminal board (TB-1) and eliminating both
the armature voltage and tachometer feedback
signals, it is possible to reconfigure the ES-2700 to
function as a current (torque) regulated DC drive
control. When configured in this manner, the input
reference signal applied to TB-1 Terminals #12 (or
Terminal #4) will control DC motor current (torque)
instead of DC motor speed.
Drive current limit is typically set using a
potentiometer located on the ES-2700 control. In
many applications, it is desirable to adjustable drive
current limit using either a remote mounted
potentiometer or a customer supplied voltage signal.
A 0 to –12VDC signal applied to Terminal #15 (TB-1)
adjusts drive current limit between 0 and 150% of the
selected current range.
REV. 04/03/2006
MELLTRONICS
2FU
L2
- 12 -
REMOTE CURRENT
LIMIT INPUT
OVDC TO -12VDC
CURRENT
REGULATION
TACH FEEDBACK (LOW)
TACH FEEDBACK (MED)
TACH FEEDBACK (HIGH)
ARMATURE FEEDBACK
JUMPER FOR:
ACCEL/DECEL
REFERENCE INPUT
-10 VDC TO 0 VDC
1FU
L1
15
2
1
17
18
19
20
21
4
3
14
12
CONTROL
POWER
SUPPLY
DECEL
VELOCITY
FEEDBACK
SELECTION
& SACLING
CIRCUITRY
MAX SPEED
ACCEL
ACCEL/DECEL
(REF. RAMP)
CIRCUITRY
IR
COMP
+
-
IR
COMPENSATION
NETWORK
CONTROL
(RELAY)
LOGIC
VELOCITY
ERROR
AMPLIFIER
CIRCUIT
DC MOTOR
FIELD
SUPPLY
M
AUX
A-
M
CT1
PHASE
ANGLE
REFERENCE
CIRCUITRY
SCR
GATING
CIRCUITS
POWER CONVERSION
ASSEMBLY
interconnect2.vsd:p1
A-5 REV. 03/02/2006
NOTICE: This drawing is furnished for reference only.
The furnishing or possession of this drawing or any
reproduction
thereof,
does
not
convey
any
manufacturing rights.
ARMATURE
CURRENT
BUFFER/
SCALING
AMPLIFIER
90VDC
180VDC
ARMATURE
CURRENT
ERROR
AMPLIFIER
CURRENT
LIMIT
MOTOR
ARMATURE
ARMATURE
CURRENT
SCALING
AMPLIFIER
LOW
MED
HIGH
F-
F+
A+
ES-2700 MANUAL
Figure 4: ES-2700 Block Diagram
REV. 04/03/2006
ES-2700 MANUAL
SECTION 4
INSTALLATION
4.1
SAFETY WARNINGS
Improper installation or operation of this control may
cause injury to personnel or equipment. Read the
operating instructions. The control and its associated
motors and operator control devices must be installed
and grounded in accordance with all local codes and
the national electrical code. To reduce the potential
for electric shock, disconnect all power sources before
initiating any maintenance or repairs. Potentially
lethal voltages exist within the control unit and
connections. Use extreme caution during installation
and start-up.
4.2
INITIAL CHECKS
Before installing the drive control, check the unit for
physical damage sustained during shipment. Remove
all shipping restraints and padding Check nameplate
data for conformance with the AC power source and
motor.
4.3
DETERMINING THE CONTROL LOCATION
The ES-2700 is suitable for most well ventilated
factory areas where industrial equipment is installed.
Locations subject to steam vapors or excessive
moisture, oil vapors, flammable vapors, chemical
fumes, corrosive gases or liquids, excessive dirt, dust
or lint should be avoided unless an appropriate
enclosure has been supplied or a clean air supply is
provided to the enclosure. The location should be dry
and the ambient temperature should not exceed 40oC
If the mounting location is subject to
(104oF).
vibration, the unit should be shock mounted.
If the enclosure is force ventilated, avoid, wherever
possible, an environment having high foreign-matter
content, as this requires frequent filter changes or the
installation of micron filters.
Should a control
enclosure require cleaning on the inside a lowpressure vacuum cleaner is recommended. Do not
use an air hose because of the possibility of oil vapor
in the compressed air and the high air pressure.
4.4
INSTALLING
CHASSIS
MOUNT
CONTROLS
The chassis mount ES-2700 is suitable for mounting
in a user’s enclosure where internal temperature will
not exceed 55oC (131o F). The following instructions
are recommended:
Mount the chassis vertically
against the mounting surface. Dimensions are shown
in Figure 14. A minimum clearance of 3 inches
around the ES-2700 is recommended for proper
cooling when installing a chassis mount control.
MELLTRONICS
- 13 -
CAUTION
NEVER OPERATE THE CONTROL FOR AN EXTENDED
PERIOD OF TIME ON ITS BACK. DOING THIS WILL
CAUSE THE HEAT FROM THE HEAT SINKS TO
PENETRATE THE CONTROL LOGIC WIRING.
4.5
INSTALLING ENCLOSED CONTORLS
Enclosed ES-2700 controls are suitable for wall
mounting in an ambient atmosphere between 0oC
(32oF) and 40oC (104oF). Mount the control so that
there is access to the front panel. See Figure 15 for
Never operate the control for an
dimensions.
extended time on its back for the reason explained in
section 4.4.
4.6
POWER WIRING
The ES-2700 control will operate from typical AC
power lines. The line should be monitored with an
oscilloscope to insure that transients do not exceed
limitations as listed below:
 Repetitive line spikes of less than 10
microseconds must not exceed the following
magnitude:
 120 Volt Drives 200 V. Peak
 240 Volt Drives 400 V. Peak
 Non-repetitive transients must not exceed 25watt seconds of energy. Transients of excessive
magnitude or time duration can damage dv/dt
networks or surge suppressors.
 Line notches must not exceed 300 microseconds
in duration.
An abnormal line condition can reflect itself as an
intermittent power unit fault. High amplitude spikes or
excessive notch conditions in the applied power could
result in a power unit failure.
Refer to Figure 5 for power wiring connections. The
ES-2700 is insensitive to the AC line phase
sequencing. Designation of inputs L1 and L2 is
arbitrary.
CAUTION
A SEPARATE FUSED DISCONNECT OR CIRCUIT
BREAKER SHALL BE INSTALLED IN THE INCOMING AC
POWER LINE TO THE CONTROL, AS PER THE
NATIONAL ELECTRICAL CODE.
Use the AC line current specified on the nameplate of
the control being installed to size the AC input wiring.
Size the motor leads according to the motor
nameplate
current
ratings
following
NEC
requirements.
Connect the armature leads to the terminal lugs
marked A+ and A- on contactor MC located above the
upper right hand corner of the lower PC board.
Consult the motor connection diagram supplied with
the motor for proper polarity.
REV. 04/03/2006
ES-2700 MANUAL
Check that the proper number of turns of the armature
lead (from the SCR to the contactor) have been made
around transductor CT1. The low (1/4-2) HP control
should have 5 turns. The high (3-5) HP control should
have 2 turns.
Connections to the motor field should be made with
due consideration to the proper polarity. Consult the
motor connection diagram. The ES-2700 field supply
provides 100VDC when the control is wired to a
120VAC line and 200VDC when wired to a 240VAC
line. The field supply provides 50VDC or 100VDC
respectively when the field economy feature is wired
in, AC power is applied to the control, and the loop
contactor is open.
NOTE
The ES-2700 is shipped for the factory with the
field economy feature wired for operation. It is
recommended that this feature not be by-passed.
It reduces the voltage to the motor field when the
control is stopped but not removed from the AC
input line. If the field economy feature is not used,
then these terminals must be jumpered together.
All power connections (i.e., armature, line voltage) are
made to the lower PC board through faston
connections. In cases where polarity or phasing is
critical, two different size fastons are used to insure
proper polarity.
Verify that the input voltage and frequency select
program jumpers A, B and L-M are correct for your
application. The ES-2700 is shipped programmed for:
 60Hz
 240VAC
 High voltage armature feedback.
NOTE
A functional description of all jumpers is
contained in Section 5, Operation and Startup
Procedure. Check that all program jumpers are
correct for you application.
CAUTION
NO POINTS IN THE CONTROL CIRCUITRY, INCLUDING
COMMON, SHOULD BE CONNECTED TO EARTH
GROUND UNLESS SPECIFICALLY SHOWN ON SYSTEM
DIAGRAMS.
CONNECT EARTH GROUND TO THE
GROUND LUG BESIDE 3FU AND 4FU ON THE HEAT
SINK CHASSIS ASSEMBLY.
WHEN READY TO APPLY POWER TO THE ES-2700,
CONNECT THE 120VAC OR 240VAC SUPPLY LINES TO
TERMINALS L1 AND L2 ON FUSE BLOCKS 3FU AND
4FU ON THE HEAT SINK/CHASSIS ASSEMBLY.
4.7
CONTROL LOGIC WIRING
Terminal strip TB-2 consists of two sections of
terminal block. Terminals #1 through #15 are located
along the left edge of the lower control board.
Terminals #16 through #25 are along the bottom.
Terminals #1 through #21 are used for control logic.
See Table 6, Figure 6 and Figure 16 for terminal strip
connections. A detailed description of control logic
MELLTRONICS
- 14 -
functions is contained in SECTION 5. The wiring of
the lower PC board is shown in Figure 20.
4.8
SIGNAL WIRING
Terminals #1 through #21 on terminal strip TB-1 are
used for connection drive reference and feedback
signals to the ES-2700. Terminals #1 through #15 are
along the left edge. Terminals #16 through #21 are
located along the bottom edge of the upper control
board. See Table 6, Figure 6 and Figure 16 for
terminal strip connections. The wiring of the upper PC
board is shown in Figure 19.
NOTE
It is recommended that shielded wire be used for
reference, tachometer, optional ammeter and other
signal wire connections.
Belden #83394 (2
conductor) and Belden #83395 (3 conductor)
shielded wire (or equivalent) is recommended.
The shields should be taped off at the remote end.
At the drive control, the shields should be
connected to common, TB-1 terminal 14.
Additional consideration is recommended to route
this wiring away from high current lines (i.e., AC
line and armature wiring).
4.9
CIRCUIT BOARD INTERCONNECTIONS
There are six (6) multi-pin connectors used in the ES2700 to supply power and transmit control signals for
the upper and lower PC boards.
J1 is a 15 pin AMP connector that attaches to the
upper right hand side of the lower PC board. It
supplies power to the board from the AC inputs L1
and L2 and, in turn, feeds the primary of the control
transformer. It also supplies AC power from the
control transformer secondary to the DC power
supplies and the 120VAC control logic. See Figure 5
for pin assignments.
CAUTION
CARE MUST BE TAKEN TO ALIGN THE PINS AND
JACKS ON THE FOLLOWING MOLEX CONNECTORS TO
AVOID WRONG CONNECTIONS AND DAMAGE TO THE
CONTROL.
J2 is a 2 pin AMP connector located on the top edge
of the lower PC board.
The armature current
feedback signal from transductor CT1 flows through
J2.
J3 is a 15 pin Molex connector located in the center of
the top edge of the lower PC board. It provides a
quick means of connecting the optional test meter kit
to the ES-2700. (The optional test meter kit will be
discussed later in this section.) See Figure 16 for pin
assignments.
REV. 04/03/2006
ES-2700 MANUAL
J4 is a 16-pin ribbon connector that supplies
± 15VDC power, circuit common and the raw sync
signal to the upper PC board. It is located on the
back of the upper PC board in the top right hand
corner. See Figure 16 for pin assignments.
J5 is a 16-pin ribbon connector located on the back
of the upper PC board in the bottom right hand
corner. It provides feedback and control signals
from the lower PC board. See Figure 16 for pin
assignment.
J6, located on the bottom right hand corner of the
lower PC board, is a 2-pin AMP connector. It
supplies the gate pulse signals from the firing
circuitry to the SCR gates. See Figure 12.
J1
13
10
7
X
X
X
15
INSTALLING MODIFICATIONS
4.10
4.10.1
TEST METER
The test meter kit, available for use in starting up
and troubleshooting the ES-2700, screws down onto
the upper PC board of the control. It is easily
connected by installing the Molex connector, wired
to the test meter PC board, into connector J3 on the
lower PC board of the ES-2700.
This modification consists of a digital panel meter
and multi-position selector switch. It provides the
capacity to monitor nine critical drive parameters,
including:
 Field Voltage
 Line Voltage
 Control Voltage
 Armature Voltage Armature Current (%)
 Current Limit (%) Trigger Signal
 Negative 15 VDC Reference
 Positive 15 VDC Reference
Pin #
3
Input to Control
Transformer from:
AC Line L2 Input Voltage
6 B
12 A
Program Jumpers
(to center tap)
15
Fused AC Line L1
12
X
4
X
6
1
X
3
X = NOT USED
Pin #
1
4
7
13
10
From Output of Control
Transformer to:
120VAC Control Power
Fused 120 VAC Control Power
Rectifier for DC Power
Supplies Common
Figure 5: Connector J1 Pin Assignments
MELLTRONICS
- 15 -
REV. 04/03/2006
MELLTRONICS
- 16 -
STOP
9
START
10
CRR
11
CRR
12
JPG
13
CRJ
24
user connection diagram rotate.vsd
REV. 03/02/2006
OPTIONAL
AMMETER
A
25
LOWER PC BOARD
NOTICE: This drawing is furnished for reference only.
The furnishing or possession of this drawing or any
reproduction
thereof,
does
not
convey
any
manufacturing rights.
MOTOR
THERMAL
E-STOP
8
120
VAC
TB2
CRR
SOLID LINE- USER CONNECTION
DOTTED LINES - FACTORY CONNECTION
3
FU
4FU
USER SUPPLIED
CICUIT BREAKER
OR FUSED
DISCONNECT
2
FU
1
FU
TB1
F
+
FIELD
F-
12
13
14
-
16
COM
MC
A-
+
18
LOOP
CONTACTOR
A+
DRIVE CONTROL IS SUPPLIED CONNECTED FOR
ARMATURE VOLTAGE FEEDBACK, IF TACHOMETER
FEEDBACK IS REQUIRED CONNECT THE TACHOMETER
AS SHOWN AND SEE PARAGRAPH 5.4 FOR JUMPER
REQUIREMENTS
SPEED POT
-10
VDC
11
T
FE2
MC
FE1
LOWER CHASSIS/HEAT SINK ASS'Y
GN
D
UPPER PC BOARD
L2
L1
A.C. SUPPLY EARTH
GROUND
ARMATURE
ES-2700 MANUAL
Figure 6: User Connection Diagram
REV. 04/03/2006
ES-2700 MANUAL
4.10.2
AMMETER KIT
4.10.3
REMOTE CURRENT LIMIT
The ES-2700 includes circuitry to drive an external
ammeter without the addition of an ammeter shunt.
This external meter can be calibrated in either percent
load or in amperes. As shipped, the control has a
minimum 100% current output rating of 6 amps. For
applications below 1HP at 240VAC (1/2HP at 120VAC
input), the built-in DC overload protection will be
scaled for too much output current and will not
function. To provide overload protection and properly
calibrate the ammeter kit, removal of jumper N-O is
required.
The appropriate current range jumper
settings are given in SECTION 5.
TB-2, terminals #24, located at the bottom of the lower
PC board (see Figure 6), are for connecting the
optional external ammeter. This meter should have a
0-100 μA movement, 3700Ω coil resistance and read
150% current full scale. A 200% full scale ammeter
can be used when jumper JP-1 is removed from the
lower PC board. A complete line of ammeters for the
ES-2700 is available from Melltronics. Consult the
web site, www.melltronics.com, and SECTION 5 of
this manual for assistance in ordering a meter.
A potentiometer to modify the current limit setting of
the ES-2700 from a remote location may be installed.
The voltage signal from the wiper of the potentiometer
is wired to TB-1 terminal 15. A –12V signal at that
terminal yields 150% current limit. The –10VDC
power supply, TB-1 terminal 11 and TB-1 terminal 14
(common) may be used to supply voltage for the
remote current limit potentiometer. The equivalent
resistance of the remote current limit potentiometer is
parallel with the speed reference potentiometer,
should not go below 5KΩ as this would excessively
load the –10VDC power supply.
If remote current limit is used, remove jumper H-1
from the upper PC board and install jumper G-H. This
is necessary to eliminate the local current limit
potentiometer (on the upper PC board) from the circuit
and provide a path for the remote current limit signal
to enter the control.
Figure 7: Upper PC Board
Figure 8: Lower PC Board
MELLTRONICS
- 17 -
REV. 04/03/2006
ES-2700 MANUAL
SECTION 5
OPERATION AND START-UP PROCEDURE
INTRODUCTION
150%
This section describes the operator controls and their
functions, initial start-up procedure, and applications
adjustments of potentiometers and jumpers for the
ES-2700.
Read this section thoroughly to develop an
understanding of the operation and logic incorporated
in the ES-2700.
5.2
120%
110%
TIME (MIN)
CONTROL VOLTAGE
FAULT TRIP RELAY (CRFT)
Under normal conditions, this relay is energized when
AC power is applied to the ES-2700 control. When
energized, CRFT enables the operator control devices
by closing the contact that provides control voltage to
these devices at terminal TB-2 #8.
There are three causes for a fault trip that drops out
CRFT.
5.2.2.1
130%
15
Terminals TB-2#1 and #2 provide 120VAC control
power for your use. A total of 5VA of power is
available for user supplied devices.
5.2.2
140%
OPERATOR CONTROLS
Refer to Figure 16, Figure 17, Figure 18 and Table 6
for operator control locations.
5.2.1
% RATED CURRENT
5.1
FIELD LOSS
The field loss circuit monitors the presence of field
current. If field current is absent after the start
pushbutton is depressed, the FL LED lights and CRFT
drops out. The field loss LED may flash when AC
power is first applied and the DC power supplies are
coming up to their proper voltages. No fault trip will
occur until the start pushbutton is depressed.
Figure 9: Inverse Time Trip Overload Characteristics
When a fault trip occurs and CRFT drops out, the
control voltage to the operator devices is removed and
the drive sequences down the same as if the STOP
pushbutton were depressed. This sequence is given
in the description of the STOP circuit.
The three causes of fault trips are sensed by latching
type circuits and must be reset using the RESET
pushbutton on the upper PC board.
A set of form C contacts off of CRFT is available to
the user at TB-2 terminals #3, #4, and #5.
See Figure 16.
5.2.3
INSTANTANEOUS OVERCURRENT (IFT)
A fault trip occurs dropping out CRFT and lighting the
IFT LED when an armature current, 300% of the rated
current, is detected.
5.2.2.3
INVERSE TIME DC OVERLOAD (DCOL)
The DC overload circuit drops out CRFT and lights the
yellow DCOL LED when the drive has run at 150%
current limit for approximately one minute. Less
severe overloading will take longer to trip out. See the
inverse time trip characteristic in Figure 9.
MELLTRONICS
- 18 -
MOTOR THERMAL SWITCH/E-STOP
Motors with built-in fans may overheat when run for
extended periods at low speed. A thermal sensing
switch inside the motor will open before overheating
occurs. When wired to terminals TB-2 #8 and #9, the
open switch will stop the drive to protect the motor. A
user supplied, normally closed switch may be wired in
series with the thermal switch or in place of it to
provide and E-stop function. If neither the thermal
switch nor the E-stop is used, TB-2#8 and #9 must be
jumpered. The shut-down sequence is the same as
the stop function sequence.
5.2.4
5.2.2.2
30
STOP
When pressed, the STOP switch interrupts the path
that supplies the current to keep the run relay (CRR)
energized. This interruption results in the following
reaction.
 The contact that locks in the relay (CRR) is
opened,
 The contacts that permit the jog button to function
are closed;
 The supply voltage that keeps the motor
contactor energized is removed;
 The circuit from the speed potentiometer is open;
 The accel/decel, and velocity error and current
error amplifiers are clamped.
REV. 04/03/2006
ES-2700 MANUAL
5.2.5
5.2.9
START
When permitted by the fault trip relay (CRFT), the
START switch momentarily closes the circuit that
energizes relay CRR. When CRR is energized,
contacts close that cause the following:
 CRR is locked on;
 A path is provided to energize the motor
contactor;
 The reference voltage is connected from the
speed pot to the accel/decel circuit;
 Controls that clamped the accel/decel, and
velocity and current error amplifiers are opened;
 The jog switch that energizes the jog relay (CRJ)
is disabled.
A set of normally open contacts off of CRR is
available between terminals TB-2 #6 and #7. The
RUN LED lights when CRR is energized.
5.2.6
JOG
When permitted by the run relay (CRR) and fault trip
relay (CRFT), the JOG switch completes the circuit to
energize the jog relay (CRJ). The jog relay then
provides a path to energize the motor contactor and
connect the jog reference signal to the jog circuitry.
CRJ does not lock in so that when the jog pushbutton
is released, the motor contactor drops out and the
controller is in a stop condition. A set of N.O. contacts
off of CRJ in parallel with N.O. contacts off of CRR is
available to the user at terminals TB-2#14 and #15.
The jog LED lights when CRJ is energized.
5.2.7
MISCELLANEOUS USER CONNECTIONS
 Terminal TB-1 #14 is control common
 Terminals TB-1 #5 through #8 are not for
customer use.
 Terminal TB-1 #15 is the connection for the
remote current limit signal covered in section 4.10.3.
 The field loss detection circuit is disabled when
terminals TB 2 #20 and #21 are jumpered together.
This is generally not recommended as severe motor
and machine damage may result if overspeed
occurs due to field loss.
 Operation as a current regulated drive using
terminals TB-1 #1, #2 and #4 is covered in section
5.4.2.8 of this instruction manual. Tachometer
feedback and the usage of terminals TB-1#16
through #21 is detailed in section 5.4.2.11 of this
manual.
 Turret terminal ‘S’ on the upper PC board is an
armature current signal for factory assembled
customer applications and is not calibrated for
customer use. A calibrated armature current signal
is available at terminal strip TB-2 as explained in
section 4.10.2.
MOTOR CONTACTOR
The motor contactor is factory wired to terminals TB-2
#16 and #17. When energized, the contactor closes
the DC loop that energizes the motor armature and
the N.O. “A” auxiliary contacts disable the field
economy circuit so that the motor receives full field
voltage.
5.2.8
SPEED REFERENCE POTENTIOMETER
The signal from the speed reference potentiometer
wiper is wired to Terminal TB-1 #12. A negative
voltage reference signal corresponds to positive
armature voltage. Negative 10VDC is available for
the speed reference potentiometer at terminal TB-1
#11.
The third lead of the speed reference
potentiometer is connected to TB-1 terminal #13. This
connection provides a voltage bias to the base of the
speed reference potentiometer corresponding to
minimum speed. This bias is adjusted using the MIN
SPEED potentiometer on the upper PC board.
MELLTRONICS
- 19 -
REV. 04/03/2006
TB1
DC POWER
MELLTRONICS
- 20 -
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
U
TB1
MIN
SPEED
V
16
17
DECEL
TIME
18
19
20
21
MAX SPEED
P2
ACCEL
TIME
BIAS
P1
RESET
JOG
G
H
D9
I LIMIT
I
CURR STAB
P3
L
IFT
IR
-IR
P
R
CUT FOR
90V ARM
W
VEL STAB
N
O
T
IR COMP
HI MED LO
upper control bd oper feat rotate.vsd
REV. 03/02/2006
NOTICE: This drawing is furnished for reference only.
The furnishing or possession of this drawing or any
reproduction
thereof,
does
not
convey
any
manufacturing rights.
SPEED
RATE
M
ZERO
P4
ES-2700 MANUAL
Figure 10: Upper Control Board Operating Features
REV. 04/03/2006
ES-2700 MANUAL
5.3
ADJUSTMENTS
There are ten (10) adjustment potentiometers
located on the upper control board (P/N 272-4000)
Figure 10.
Exercise caution when making
adjustments. With the control driving a motor, do not
exceed ten (10) degrees of pot rotation per second.
5.3.1
MIN SPEED
The MIN SPEED potentiometer adjusts the minimum
speed of the drive according to the reference signal
from the speed potentiometer. Minimum reference
is from 0-30% of full rated speed.
5.3.2
DECEL TIME
The decel time potentiometer adjusts the amount of
time the drive takes to decelerate. This rate of
change of speed (ramp) is linear (constant)
throughout the speed range but may be limited by
the current limit setting. Set to mid-position by the
factory, clockwise adjustment of this potentiometer
causes the drive to ramp down in speed more
slowly.
5.3.3
OVER-RESPONSIVE
VELOCITY
OVER-DAMPED
TIME
JOG
I LIMIT (ARMATURE CURRENT LIMIT)
The I LIMIT potentiometer adjusts the maximum
armature current that the control will supply to the
motor. The range of adjustment is 0 to 150% of the
rated current selected with jumpers T (LO, MED, HI)
and N-O (Jumper T will be described later in this
section). Clockwise rotation of this potentiometer
increases the armature current.
5.3.6
VEL STAB (VELOCITY STABILITY)
IDEAL
If a jog pushbutton is wired in, the jog potentiometer
will adjust the speed at which the motor will run in
jog. Jog speed may be set from 0 to 50% of
maximum speed. Set fully counterclockwise by the
factory, clockwise rotation of the jog potentiometer
increases the jog speed.
5.3.5
5.3.7
This potentiometer adjusts the electrical “lead” of the
compensating network in the velocity error circuit to
correct for mechanical lags in the motor and driven
system. Clockwise rotation causes the drive to
respond more quickly to speed reference or speed
feedback changes, but increases the ‘overshoot’
experienced by the drive.
Counterclockwise
adjustment of this potentiometer dampens the drive
response. The factory shipped setting is at the 11
o’clock position.
ACCEL TIME
The ACCEL TIME potentiometer adjusts the amount
of time the drive takes to accelerate to the speed set
by the speed reference potentiometer. This rate of
change of speed (ramp) is linear (constant)
throughout the speed range but may be limited by
the current limit setting. Set to the mid-position by
the factory, clockwise rotation of the ACCEL TIME
potentiometer increases the time required to
accelerate to set speed.
5.3.4
change of the feedback signal and is adjusted using
the speed rate potentiometer. Clockwise rotation of
this potentiometer causes a reduction in the rate of
change of drive velocity and less overshoot.
Normally used in tachometer feedback applications,
the speed rate potentiometer is factory adjusted to
its counterclockwise position.
5.3.8
When the drive experiences a step change in
velocity, the velocity feedback signal lags behind this
change. A “lead” compensation network is used to
supply some additional feedback to compensate for
the lag and reduce the rate of change in drive
velocity. This also reduces the overshoot in the
speed response of the drive. The amount of
feedback compensation is proportional to the rate of
- 21 -
IR COMP (IR COMPENSATION)
The IR compensation circuit increases the drive
speed reference signal as armature current
increases. The effect of the increase in current is an
increased voltage drop due to the impedance of the
motor and also distortion of the field flux. The result
is a reduction in counter emf produced by the motor
and a reduction in speed, commonly called droop.
Clockwise rotation of the IR comp potentiometer
increases the amount of droop correction added to
the speed reference signal. See section 5.4.2.7 for
use of IR compensation.
5.3.9
SPEED RATE
MELLTRONICS
Figure 11: Stability Effects on the Velocity Profile
MAX SPEED
When using armature voltage feedback, the max
speed potentiometer scales the armature voltage
feedback signal so that it exactly offsets a –10VDC
reference signal when the motor reaches the desired
maximum RPM. The speed reference potentiometer
must be set for maximum (-10VDC) reference
voltage, and the motor must be running at constant
speed
before
adjusting
the
max
speed
potentiometer.
REV. 04/03/2006
ES-2700 MANUAL
Determine the maximum motor speed required for
your machine or process; do not exceed the rated
speed of the motor. Using a tachometer or strobe
light to measure the motor or the desired maximum
speed is obtained.
Clockwise rotation of this
potentiometer increases the armature voltage and
motor speed.
The range of adjustment is 70 to 130% of rated
armature voltage.
For applications using tachometer feedback, the
Max Speed potentiometer scales the tachometer
feedback signal to offset the –10VDC reference
signal at the chosen maximum motor speed.
Calculate
the
tachometer
output
voltage
corresponding to the desired maximum motor
speed, and adjust the max Speed potentiometer
until this voltage is read at the output of the
tachometer.
5.3.10
CURR STAB (CURRENT STABILITY)
This potentiometer performs the same function in
the current error circuit as the Vel Stab
potentiometer performs in the velocity error circuit.
However, since the current loop responds to current
changes much faster than the velocity loop does to
speed changes, the Cur Stab adjustment is much
more sensitive and harder to adjust properly.
Clockwise rotation increases response. The factory
shipped
setting
of
4.5
turns
from
full
counterclockwise is adequate for most applications.
5.4
JUMPER PROGRAMMING
The drive can be programmed for
applications
by
programming
the
configurations.
specific
jumper
WARNING
EQUIPMENT DAMAGE AND/OR PERSONAL INJURY
MAY RESULT IF ANY JUMPER PROGRAMMING IS
ATTEMPTED WHILE THE ES-2700 IS OPERATIONAL.
LOCK OUT POWER AT THE DISCONNECT BEFORE
CHANGING ANY JUMPER POSITIONS.
5.4.1
A/B LINE VOLTAGE SELECTORS
This pair of jumpers connects the incoming AC line
to the control transformer and must be set to match
the user supplied AC voltage.
For 120VAC input
A to E
B to D
For 240VAC Input:
A to C
B to CX
5.4.1.2
JP1 AMMETER SCALE SELECTOR
The optional ammeter, which is wired to TB-2, can
be scaled to read 150% rated current full scale or
200% rated current full scale.
MELLTRONICS
5.4.2
- 22 -
UPPER PC BOARD
The locations of the upper PC board jumpers are
shown in Figure 10.
5.4.2.1
CURRENT LIMIT JUMPERS G-I, H-I
If the current limit is being set by the internal current
limit potentiometer, Jumper terminals H and I on the
upper PC board should be left connected.
A potentiometer to modify the current limit setting of
the ES-2700 from a remote location may be
installed. In this case, jumper H-I should be removed
and jumper should be connected across G-I.
The voltage signal from the wiper of the
potentiometer is wired to TB-1 terminal #15. A –12V
signal at the terminal yields 150% current limit.
The –10VDC power supply, TB-1 terminal #11 and
TB-1 terminal #14 (common), may be used to supply
voltage for the remote current limit potentiometer.
The equivalent resistance of the remote current limit
potentiometer in parallel with the speed reference
potentiometer should not go below 5K ohms as this
would excessively load the –10VDC power supply.
5.4.2.2
JUMPER J-K VOLTAGE ERROR AMPLIFIER
This jumper must be left in; it is for factory use in
customized system applications.
5.4.2.3
JUMPER L-M FREQUENCY SELECTOR
The ES-2700 will operate on either 50Hz or 60Hz
AC power.
5.4.2.4
JUMPER N-O LOW HP SELECTOR
This jumper is to be removed for very low HP (up to
1/3HP 120VAC; up to 3/4HP for 240VAC). Leave
connected for higher HP.
5.4.2.5
JUMPER P-R ARMATURE VOLTAGE
Jumper P-R selects the armature voltage output for
the ES-2700 control.
For 180VDC armature voltage, install jumper P-R.
For 90VDC armature voltage, remove P-R.
5.4.2.6
LOWER PC BOARD
The locations of the lower printed circuit board
jumpers are shown in Figure 12.
5.4.1.1
For 150% rated current full scale, install JP1.
For 200% rated current full scale, remove JP1.
JUMPER T- (LO-MED-HI) CURRENT
SELECTOR
This jumper selects the value of armature current
that the drive will see as 100% rated current. The
jumper selection sets the horsepower rating of the
control by scaling the value of the armature current
at which current limit will occur. Table 4 gives the
jumper settings along with the 100% current values
and subsequent horsepower ratings.
This ES-2700 control as shipped has a 100%
current rating of 6 amps. For applications below
1HP at 240VAC input (1/2 HP at 120VAC input), the
built-in DC overload protection will not be functional.
For applications where overload protection is
required or where the ammeter kit is used, remove
jumper N-O.
REV. 04/03/2006
ES-2700 MANUAL
To use the 150% ammeter scale, jumper JP1 on the
lower PC board should be in. For a 200% full scale
ammeter scale, remove JP1.
5.4.2.7
JUMPER W-(+IR, -IR) COMPENSATION
SELECTOR
Jumper W- (+IR or –IR) selects either positive or
negative IR compensation to be adjusted by the IR
Comp potentiometer. Positive IR compensation was
explained in section 5.3.8 as an increase in the
speed reference when increasing armature current
and speed droop occur. Negative IR compensation
is useful when the ES-2700 is used in a follower or
helper type application to keep the follower drive
from taking too much load on itself or overrunning
the lead drive. The IR Comp potentiometer reduces
speed when it is turned clockwise and Jumper W is
set for negative IR compensation.
5.4.2.8
JUMPER TB-1 #1 AND #2 CURRENT
REGULATION
5.4.2.9
JUMPER U-V ACCEL/DECEL TIME
REGULATOR
Accel/Decel time is adjustable from approximately
0.2 to 4 seconds when jumper U-V is connected,
and
accel/decel
time
is
adjustable
from
approximately 2 to 30 seconds when this jumper is
removed.
5.4.2.10
JUMPER TB-1 #3 AND #4
The output of the accel/decel circuit (TB-1, Terminal
#3) is usually jumpered to the input of the velocity
error amplifier (TB-1, Terminal #4).
5.4.2.11
JUMPERS FOR VELOCITY FEEDBACK TB-1,
#17-18, #18-19, #19-20, #20-21
The velocity feedback signal may be an armature
voltage feedback signal or it may be a signal from a
motor mounted AC or DC tachometer. Terminals
#16 through #21 (TB-1) are used to select the
desired feedback signal and properly scale it for the
application.
If armature voltage feedback is used, a jumper
should be connected between Terminals #20 and
#21 (TB-1). No other connections should be made to
Terminals #16 through #21. When connected for
armature voltage feedback, the ‘Max Speed’
potentiometer provides an adjustment range of
gated armature voltage (90VDC or 180VDC plus or
minus 30% assuming a –10VDC reference voltage).
Standard ES-2700 controls are shipped from the
factory programmed for armature voltage feedback.
By jumpering terminals #1 and #2 at the user
terminal board TB-1 and eliminating both the
armature voltage and tachometer feedback signals,
it is possible to reconfigure the ES-2700 to function
as a current (torque) regulated DC drive control.
When configured in this manner, the input reference
signal applied to Terminals #12 will control DC motor
current (torque) instead of DC motor speed. The
accel/decel potentiometers will now control the rate
of change of the torque reference. To eliminate the
accel/decel potentiometer from this current regulator
configuration, remove the jumper from TB-1
terminals #2 and #4 and connect the input reference
signal to terminal TB-1 #4.
Table 4: Armature Current Overload Scaling
Horsepower
DC Armature T- (LO, MED,HI)
Input Amps
Amps
Current Range 100%
Control 120VAC 240VAC @ Full Load @ Full Load
1/4
1/3
272-8000
-1/2
3/4
1
1 1/2
272-8001
2
--
1/2
-3/4
1
1 1/2
2
3
-5
4.2
5.6
5.6
8.5
11
14
21
28
35
3.00
3.00
4.00
6.00
8.00
10.00
15.00
20.00
25.00
*This ES-2700 control as shipped has 100% current
rating of 6 amps. For applications below 1HP at
240VAC input (1/2 HP at 120VAC input), the built-in
DC overload protection will not be functional. For
applications where overload protection is required or
where the ammeter kit is used, remove jumper N-O.
MELLTRONICS
- 23 -
Jumper
LOW
LOW
LOW
LOW
MED
HI
LOW
MED
HI
Ammeter** Jumper
Scale
N-O
Current 150% 200% Status
3A*
4A*
4A*
6A
8A
10A
15A
20A
25A
-6A
6A
-12A
--30A
--
6A
--12A
-20A
30A
40A
50A
Out
Out
Out
In
In
In
In
In
In
**To use the 150% ammeter scale, jumper JP1 on the
lower PC board should be in. For a 200% full scale
ammeter scale, remove JP1.
REV. 04/03/2006
ES-2700 MANUAL
If DC tachometer feedback is used, the motor
mounted DC tachometer should be connected
between Terminals #16 and #18 on TB-1.
NOTE
Check that the polarity of the DC tachometer
output voltage is correct for the chosen direction
of motor rotation.
The armature voltage feedback jumper connected
between terminals #20 and #21 must be removed and
reinstalled as a tachometer feedback scaling jumper
to two of the four feedback scaling terminals located
on TB-1.
The placement of the tachometer feedback scaling
jumper depends on the output voltage of the DC
tachometer at maximum output voltages (at Max
motor speed) that can be accommodated in each
feedback range.
Feedback Tachometer Voltage Output Jumper
Range
at Maximum Speed
Terminals
LOW
MED
HIGH
65VDC-130VDC
94VDC-188VDC
131VDC-262VDC
17 to 18
18 to 19
19 to 20
When connected for tachometer feedback the Max
Speed potentiometer scales the tachometer feedback
signal so that the tachometer feedback signal exactly
offsets a –10VDC reference signal when the motor
reaches the desired maximum RPM.
Provision has been made for the use of an AC
tachometer connected to TB-1 Terminals #9 and #10.
When using an AC tachometer, remove all jumpers or
wire connections from TB-1 Terminals #17 through
#21.
5.5
START-UP PROCEDURE
To insure maximum efficiency with a minimum amount
of delay in production, factory start-up assistance by a
factory engineer is available. Requests for factory
start-up assistance should be made by contacting a
Field Service Engineer prior to the required date.
NOTE
The following start-up instructions are intended
only as a guide and should be clearly understood
by the responsible installation personnel before
proceeding.
MELLTRONICS
- 24 -
5.5.1
POWER OFF CHECKS
1) Check that the motor armature, motor field, AC
input power and operator devices are connected
in accordance with these instructions and existing
system diagrams. Check that the correct line
fuses and power block are installed.
2) On the upper PC board, make the following
jumper connections: (Jumpers were explained
earlier in this section.)
a) W to IR
b) N-O according to Table 4.
c) Configuration of jumper L-M installed for
60Hz, removed for 50Hz operation.
d) Jumper H-I selected for internal current limit.
e) Configuration of jumper P-R set for proper
armature voltage.
f) Proper selection of feedback range jumpers.
3) On the lower PC board, make the following
checks and adjustments:
a) For 120VAC operation, A to E and B to D
b) For 240VAC operation, A to C and B to CX
4) Set the potentiometers on the upper PC board as
follows:
a) Minimum Speed—Fully Counterclockwise
b) Decel Time—Fully Counterclockwise
c) Accel Time—Fully Counterclockwise
d) Jog Speed—Fully Counterclockwise
e) Current Limit—25% Clockwise
f) Speed Rate—Fully Clockwise
g) Velocity Stability—25% Clockwise
h) IR Comp—Fully Clockwise
i) Maximum Speed—Fully Counterclockwise
j) Current Stability—4.5 Turns from Full
Counterclockwise Position (approximately
12K ohms factory supplied setting.
5) Make a detailed visual inspection of the system
checking for:
a) Loose electrical connections.
b) Pinched wires at the control, motor or
operator’s station.
c) Loose mechanical connections, especially the
tachometer coupling.
d) Mechanical binding.
e) Incorrect power transformer connections.
f) Metallic chips within the drive caused by
drilling into the enclosure.
g) Incorrect jumper programming.
REV. 04/03/2006
ES-2700 MANUAL
6) Using a VOM, measure the resistance between
the following points. Disconnect test meter plug
P3 from connector J3 if the optional test meter is
installed.
(+) Test
(-) Test
Reading
Lead
Lead
L1
S2
Greater than 10 Ohm
L1
Chassis
infinite
L2
Chassis
infinite
L1
A+
Greater than 1 Meg
L1
AGreater than 1 Meg
L2
A+
Greater than 1 Meg
L2
AGreater than 1 Meg
L1
Signal Comm Greater than 1 Meg
L2
Signal Comm Greater than 1 Meg
A+
Signal Comm Greater than 1 Meg
ASignal Comm Greater than 1 Meg
A+*
Chassis
Greater than 1 Meg
A-*
Chassis
Greater than 1 Meg
F+
Chassis
Greater than 1 Meg
FChassis
Greater than 1 Meg
A+
Chassis
Greater than 1 Meg
AChassis
Greater than 1 Meg
*Refer to motor side of contactor.
NOTE: Signal Common is TB-1, terminal 14. A+
and A- connections, listed above, are on the drive
side of the armature contactor.
5.5.2
POWER ON CHECKS
1) Remove the 2-pin AMP connector P6 from the
bottom edge of the lower PC board. These are
the gate lead connections to the SCRs.
2) Apply AC power.
3) With a voltmeter, check the power supply voltages
using the following table:
(+)
(-)
Lead
Lead
Reading
TB-2, #1
TB-2, #2
115VAC
TB-1, #11 TB-1, #14
-10VDC
J3-8
TB-1, #14
+15VDC
J3-7
TB-1, #14
-15VDC
TB-2, #22 TB-1, #14
+24VDC
TB-2, #23 TB-1, #14
-24VDC
4) If test meter is not connected, use a voltmeter to
check the following voltages on test meter jack J3.
(+)
(-)
Lead Lead Reading Parameter
Pin 12
Pin 13
Pin 15
Pin 9
0 VDC Armature Volts
Pin 9
0 VDC Armature Amps
Pin 9 ± 0.1 VDC Trigger Signal
MELLTRONICS
- 25 -
5) Check the field voltage at terminals F+ and F-.
With the field economy feature operational, you
should read:
Approximately 100VDC for a 240VAC input
Approximately 50VDC for a 120VAC input
6) Set the speed reference potentiometer to
–10VDC. Note that the gate-firing indicator LED
GP is now illuminated.
7) Depress the stop pushbutton. The gate-firing
indicator is now dark.
5.5.3
DYNAMIC CHECKS
1) Remove AC power. Connect the gate lead
connector P6 to the lower PC board. Apply AC
power.
2) Set
the
current
limit
potentiometer
to
approximately 10% current (9 o’clock position).
3) Set the speed reference potentiometer to
–10VDC.
4) Start the drive and slowly adjust the current limit
potentiometer to the mid-position. When the
motor no longer accelerates, adjust the maximum
speed pot so that the voltage at the armature
terminals is 180VDC for 240VAC input or 90VDC
for a 120VAC input.
See section 5.3.9 for
adjusting Max Speed to suit your application.
5) Adjust the velocity stability (Vel Stab) and speed
rate potentiometers to achieve the desired motor
response to speed changes. These adjustments
were discussed previously in this section.
WARNING
THESE
STABILITY
ADJUSTMENTS
MUST
BE
PERFORMED WITH CARE. MOTOR INSTABILITY WILL
RESULT IF THESE POTENTIOMETERS ARE ADJUSTED
TOO QUICKLY OR SET TOO HIGH.
THESE
POTENTIOMETERS SHOULD BE TURNED CLOCKWISE
JUST ENOUGH TO PREVENT VELOCITY OVERSHOOT.
Adjust the current limit potentiometer for 100% current
by turning it clockwise until 8VDC is measured at the
anode of D9 located on the upper board.
See Figure 10.
6) Check the accel/decel circuit for the 0.2-4 second
range.
a) Stop the drive and remove AC power.
b) Jumper pins U and V on the upper PC board.
c) Set the accel and decel potentiometers fully
clockwise.
d) Apply AC power and start the drive. Note that
the motor ramps to full speed in about 4
seconds.
e) Set each of the accel and decel
potentiometers for the required ramping rate
in the desired time range using the above
procedure.
Clockwise rotation of these
potentiometers increases the ramp time.
REV. 04/03/2006
ES-2700 MANUAL
7) Check the jog circuit.
a) Set the jog potentiometer fully clockwise.
b) While depressing the jog pushbutton, the
armature voltage should read approximately
60VDC for a 180 VDC armature (30VDC for
a
90VDC
armature).Set
the
jog
potentiometer for the desired jog speed.
8) Set the IR compensation. This adjustment is
used only if armature feedback is used. (Set
fully counterclockwise for tachometer feedback.)
a) Run the motor at maximum speed with no
load.
b) Record the motor RPM (hand tachometer
required).
c) Load the motor.
d) Again measure the motor RPM. Match this
‘loaded’ speed to the unloaded speed of
step ‘1’ using the IR Comp potentiometer
e) Repeat steps ‘1’ through ‘4’.
WARNING
EXCESSIVE IR COMPENSATION CAN CAUSE THE
DRIVE CONTROL TO BECOME UNSTABLE.
E
A
C
CX
B
D
J1
J2
J3
J4A
TB2
4FU
1
DC
OL
2
3FU
3
4
5
6
FIELD
LOSS
7
8
9
10
CRR
11
12
J5A
GP
13
14
CRJ
15
JP1
16
17
18
19
20
21
22
23
24
25
J6
TB2
Figure 12: Lower PC Board Details
MELLTRONICS
- 26 -
REV. 04/03/2006
ES-2700 MANUAL
SECTION 6
MAINTENANCE AND TROUBLESHOOTING
disposable. Any reduction in cooling air will
6.1
IMPORTANT SAFEGUARDS
increase motor heating.
All maintenance work on the drive should be
3) Inspect the commutator and brushes. Replace
preformed by personnel familiar with it and its
the brushes if needed. Make sure that the proper
application. Before performing any maintenance or
brush grade is used and that you sand in the
troubleshooting, read the instructions and consult the
brushes to fit the commutator.
system diagrams.
4) The motor bearing should be greased per the
manufacturer’s instructions as to type of grease
WARNING
and frequency.
Over-greasing can cause
MAKE SURE THAT ALL POWER SOURCES HAVE BEEN
excessive bearing heating and failure. Consult
DISCONNECTED
PRIOR
TO
MAKING
ANY
CONNECTION OR TOUCHING INTERNAL PARTS.
the instructions supplied with the motor for more
LETHAL VOLTAGES EXIST INSIDE THE CONTROL
details.
ANYTIME INPUT POWER IS APPLIED, EVEN IF THE
6.3
TROUBLESHOOTING
DRIVE IS IN A STOP MODE. EXERCISE CAUTION
WHEN MAKING ADJUSTMENTS. WITH THE CONTROL
DRIVING A MOTOR, DO NOT EXCEED TEN (10)
DEGREES OF POT ROTATION PER SECOND. NEVER
INSTALL OR REMOVE THE CONTROL BOARD WITH
POWER APPLIED TO THE CONTROL.
6.2
ROUTINE MAINTENANCE
Only minor adjustments should be necessary on initial
startup, depending on the application. In addition,
some common sense maintenance needs to be
followed.
KEEP IT CLEAN:
The control should be kept
free of dust, dirt, oil, caustic atmosphere and
excessive moisture.
KEEP IT COOL:
The control should be located
away from machines having a high ambient
temperature.
On chassis models, air flow
across heatsinks must not be restricted by other
equipment within the enclosure.
KEEP IT TIGHT:
The equipment should be kept away from high
vibration areas that could loosen connections or
cause chafing of wires. All interconnections
should be re-tightened at time of initial start-up
and at least EVERY six months, thereafter.
WARNING
THE MOTOR MAY BE AT LINE VOLTAGE EVEN WHEN
IT IS NOT IN OPERATION.
THEREFORE, NEVER
ATTEMPT TO INSPECT, TOUCH OR REMOVE ANY
INTERNAL PART OF THE DC MOTOR (E.G. BRUSHES,
ETC.) WITHOUT FIRST MAKING SURE THAT ALL AC
POWER TO THE CONTROL AS WELL AS THE MOTOR
HAS BEEN DISCONNECTED.
The motor should be inspected at regular intervals
and the following checks must be made:
1) See that both the inside and outside of the motor
is not excessively dirty. This can cause added
motor heating and therefore can shorten motor
life.
2) If a motor blower is used, make sure that the air
passages are clean and the impeller is free to
rotate. If air filters are used, they should be
cleaned at regular intervals or replaced if they are
MELLTRONICS
- 27 -
Fast and effective troubleshooting requires welltrained personnel supplied with the necessary test
instruments as well as a sufficient stock of
recommended spare parts.
Capable electronic
technicians who have received training in the controls
operation and who are familiar with the application are
well qualified to service this equipment.
6.3.1
SUGGESTED TRAINING
1) Study the system instruction manual and control
drawings.
2) Obtain practical experience during the system
installation and in future servicing.
3) Train in the use of test instruments.
4) Know assistance is available through the
Technical Assistance Department at Melltronics
Industrial.
6.3.2
MAINTENANCE RECORDS
It is strongly recommended that the user keep records
of ‘down-time’, symptoms, results of various checks,
meter readings, etc. Such records will often help
service engineers locate the problem in the minimum
time, should services be required.
6.3.3
GENERAL TROUBLESHOOTING
The most frequent causes of drive failure are:
 Interconnect wire discontinuity, caused by a
broken wire of loose connection.
 Circuit grounding within the interconnections of
the power wiring.
 Mechanical failure at the motor or tachometer.
DO NOT make adjustments or replace components
before checking all wiring. Also, monitor all indicator
lights before proceeding with troubleshooting checks,
and check for blown fuses.
REV. 04/03/2006
ES-2700 MANUAL
It should be noted that modern solid state electronic
circuitry is highly reliable.
Often problems which
appear to be electrical are actually mechanical. It is
advised that the motor be checked in the event of any
drive problems. Refer to the motor owner’s manual
for maintenance and repair procedures.
6.3.4
NOTES
FOR
TECHNICIAN
TROUBLESHOOTING
1) A minimum knowledge of system operation is
required, but it is necessary to be able to read the
system schematics and connection diagrams.
2) An oscilloscope (Tektronix 214 or equivalent) may
be needed to locate problem areas and to make
adjustments. However, the majority of problems
can be solved by using a multi-meter and by parts
substitution.
CAUTION
WHEN A TEST INSTRUMENT IS BEING USED, CARE
MUST BE TAKEN TO INSURE THAT ITS CHASSIS IS
NOT GROUNDED EITHER BY A GROUNDING PLUG
CONNECTION OR BY ITS CASE BEING IN CONTACT
WITH A GROUNDED SURFACE. EXTREME CARE MUST
BE TAKEN WHEN USING THE OSCILLOSCOPE SINCE
ITS CHASSIS WILL BE ELECTRICALLY ‘HOT’ TO
GROUND WHEN CONNECTED TO THE CONTROL
SYSTEM.
Multimeters having a sensitivity to 1,000 ohms per volt
on DC (or more) are recommended.
NOTE
Do NOT use the ohm portion of a multimeter to
check transistors, except where advised to do so
in this manual. Also, never use a megger to check
any portion of the control circuitry.
Before
troubleshooting the drive system, read the
warning section and the notes on the use of test
instruments.
6.3.5
USING THE TROUBLESHOOTING GUIDE
1) Refer to section 6.3.6 below and select the
malfunction that most closely fits the observed
condition of the drive
2) The number in parentheses indicates which
section in 6.4 pertains to that specific problem.
Proceed to the appropriate section.
3) Go through each section in 6.4 sequentially.
Check to see if your drive is experiencing the
symptom that is listed. If it is, perform the action
given in the section, either correcting the symptom
or referring to another subsection of 6.4.
Otherwise proceed to the next symptom on the
list.
4) If this troubleshooting guide does not indicate the
source and solution of the specific problem, call
Melltronics Industrial and request the Technical
Service Department.
MELLTRONICS
- 28 -
6.3.6
MALFUNCTION
OPERATOR
AS
OBSERVED
BY
1) Drive will not run at all. (6.4.1)
2) Drive runs to top speed. (6.4.2)
3) Drive is unstable. (6.4.3)
4) Drive is intermittent. (6.4.4)
5) Drive performance is unsatisfactory. (6.4.5)
6) Drive trips out. (6.4.6)
7) Motor will not reach top speed. (6.4.13)
8) Motor jumps upon starting. (6.4.14)
9) Various motor problems. (6.4.15 to 6.4.17)
6.4
CORRECTIVE
ACTION
FOR
DRIVE
MALFUNCTIONS
Refer to the appropriate section below (based on
directions from section 6.3.6) to correct a drive
malfunction.
6.4.1
DRIVE WILL NOT RUN AT ALL
1) No SCR module output
2) Motor Armature open-circuited. With all the power
off, check for continuity in the armature circuit and
for proper seating of the motor brushes.
3) Motor armature contactor does not pick up
4) Check that control is not in current limit. If it is,
verify that there is motor field and motor armature
is free to rotate and not binding excessively.
6.4.2
DRIVE RUNS TO TOP SPEED AT ALL
SPEED POT SETTINGS.
1) If drive is armature voltage regulated, ensure that
there is a jumper between terminals #20 and #21
on TB-1.
2) If drive is tach regulated, check for the presence
of the tach signal and the proper polarity.
3) Check for a false reference signal to operational
amplifier.
4) Check for loss of the –10VDC power supply.
5) Check to see if the reference pot is open.
6) IR Comp (if used) is set too high.
7) Shorted SCR(s).
8) ‘Max Speed’ pot is turned too far in the clockwise
direction.
Turn the ‘Max Speed’ pot fully
counterclockwise and readjust the maximum drive
speed per the startup instructions.
6.4.3
DRIVE IS UNSTABLE
1) If drive utilizes armature voltage feedback, insure
that IR compensation has not been set too high.
2) If drive utilizes tachometer feedback, insure that
the IR compensation pot is fully counterclockwise.
3) If the frequency of oscillation is a function of
speed, this could indicate that there is a
mechanical problem with the load.
REV. 04/03/2006
ES-2700 MANUAL
4) If the frequency of oscillation is the same
regardless of speed, Contact the Technical
Service Department at Melltronics Industrial. For
relatively small amplitude, fast oscillations, check
tachometer coupling to the variable speed drive,
gearbox backlash, timing belt oscillations, etc.
5) Check that the AC supply voltage is constant with
load.
6) Check that the brushes are not worn, seated
improperly, or sticking to the brush holders.
6.4.4
DRIVE IS INTERMITTENT
6.4.10
1) Keep an accurate log of the type of intermittent
malfunction and the operating conditions at that
time.
2) Monitor with the test instruments the circuits that
are believed to be causing the problem, i.e. the
reference circuit – if the drive intermittently slows
down; the feedback circuit – if the drive
intermittently speeds up, etc.
3) Check for loose connections, worn relay contacts,
excessive environmental vibration of control
panel, motor brushes, etc.
6.4.5
DRIVE PERFORMANCE UNSATISFACTORY
From knowledge of drive specifications and actual
drive performance, refer deviations to Melltronics
Industrial.
6.4.6
DRIVE TRIPS OUT
1) If ‘IFT’ light is on, refer to 6.4.9
2) If the IFT light is not on, refer to 6.4.8, and from a
knowledge of the permissive circuitry involved,
track down the cause of the trip-out.
6.4.7
NO SCR MODULE OUTPUT
1) No AC voltage input 6.4.12
2) Incomplete magnetic relay sequencing 6.4.8
3) Loss of reference 6.4.11
6.4.8
MAGNETIC SEQUENCING
Consult the description for operation for control relay
sequencing and function.
6.4.9
‘IFT’ LIGHT IS ON
1) This is an indication of an excessive armature
current which has shut the drive off. Depress the
reset pushbutton momentarily and the ‘IFT’ light
should extinguish.
2) By opening (and keeping open) the armature loop
and actuating the magnetic sequencing,
determine if the ‘IFT’ trip is due to electrical
‘noise’, refer to Melltronics Industrial.
3) If ‘IFT’ trips due to an actual over-current, check:
a) Balance wave-form.
b) Loss of the –10VDC power supply
c) DC short – shorted armature.
d) Rapid load change such as the application of
a brake.
MELLTRONICS
e) Presence of SCR module voltage output
before application to motor armature (if
armature contactor is supplied).
f) Current limit set too high, IFT too low.
g) Check for proper number of turns to
transductor CT1. (See section 4.6.)
h) Check for transients on the AC line at the time
of the IFT.
i) Unbalanced Armature Wave-Form
j) Contact the factory.
- 29 -
UNBALANCED ARMATURE WAVE-FORM
Contact the factory.
6.4.11
NO REFERENCE
1) Check for the loss of the –10 VDC power supply.
2) Check for reference volts at wiper of the speed
pot.
3) Check that ‘CRR’ and ‘CRJ’ relays do pick up
when run or jog is pressed respectively.
6.4.12
THE ‘POWER’ LIGHT IS EXTINGUISHED
Check the AC line fuses. If they are found to be bad,
replace them with good fuses, but do not turn AC
power on until the following checks have been made:
1) Check the condition of each of the power
semiconductors using an ohmmeter. Make sure
the polarity is correct. The ‘plus’ (+) lead will have
the positive polarity from the battery in the
multimeter. The SCR modules are tested as
shown below. See section 6.5 for instructions on
accessing the SCRs.
2) SCR TEST – Connect the positive lead from the
ohmmeter to the anode of the SCR and the
negative lead from the ohmmeter to the cathode
of the SCR. The ohmmeter should read a value
of resistance greater than 200,000 ohms.
a) Reverse the two ohmmeter leads and the
resistance should read approximately the
same (i.e., greater than 200,000 ohms.).
b) Connect the positive lead from the ohmmeter
to the gate lead of the SCR and the negative
lead to the cathode. The resistance should
read less than 100 ohms but greater than 2
ohms.
c) Reverse the leads and the resistance should
remain approximately the same.
d) Replace any defective SCRs, per section 6.5.
e) Turn on AC power after replacing fuses.
f) The ‘AC power on’ indicator should light.
g) Check line voltage.
h) Check control voltage. It should be 120 VAC
+10% to –5%.
i) Make all other adjustments as described in
the adjustment procedures.
REV. 04/03/2006
ES-2700 MANUAL
6.4.13
MOTOR WILL NOT REACH TOP SPEED
6.4.17
1) Incorrect adjustment. (See section 5.3)
2) Low line voltage.
3) Motor is overloaded (i.e., control is in current
limit).
4) Check that the motor brushes are not worn,
seated improperly, or sticking to the brush
holders.
5) Check for defective SCR(S).
6.4.14
MOTOR JUMPS UPON STARTING
Machine has high breakaway torque.
possible.
6.4.15
Reduce if
MOTOR OVERHEATS
1) Check that the motor is properly rated to run at
that speed with load applied.
2) Is ambient temperature below 40oC. (104oF)
3) Motor ventilation restricted.
4) If supplied, check the blower motor rotation for
proper direction.
5) Defective motor.
6.4.16
MOTOR NOISE EXCESSIVE
1) Loose motor mounting or load
coupling.
2) Damaged bearing.
3) Defective or maladjusted control.
connecting
MOTOR SPARKS EXCESSIVELY
1) Motor is overloaded.
2) Brushes are worn, or the wrong grade of brush is
being used.
3) Rough commutator.
4) Defective or maladjusted control.
5) Brush rigging is improperly adjusted.
6) Commutating poles are not properly shimmed.
6.5
SCR REPLACEMENT.
(See Figure 13)
1) Remove and lockout AC power to the control.
2) Label and remove all leads connected to AC1 and
AC2 of the SCR
NOTE
Power block uses metric (10mm) screw terminals.
When testing, remove the gate leads (G1 or G2) one
at a time, perform the test and replace the gate leads
to avoid connection errors.
3) To replace the SCR power block:
a) Remove the 2 hold down bolts and remove
the power block.
b) Sparingly apply silicon thermal compound to
the bottom of the new power block.
c) Bolt the new power block in place. Torque the
hold down bolts to 19 inch-pounds.
d) Transfer electrical connections from the used
power block to the new power block one at a
time to avoid connection errors.
SCR Power Block
Figure 13: SCR Location
MELLTRONICS
- 30 -
REV. 04/03/2006
ES-2700 MANUAL
SECTION 7
ORDERING SPARE PARTS
Table 5:
Recommended Spare Parts for the ES-2700
LINE FUSES (QTY 2)
Control
272-8000
272-8001
Rating
25A.600V
50A, 500V
Part Number
3707-602500
3401-505000
CONTROL POWER FUSES (ALL MODELS)*
Designation
3FU
4FU
Rating
3/8A, 250V
1/4A, 250V
Type
3AG
3AG
Part Number
3704-124
3704-120
POWER BLOCK (QTY1)
Control
272-8000
272-8001
Rating
25A.600V
50A, 500V
Part Number
3720-004
3720-010A
MAIN (REGULATOR) PC BOARD (ALL MODELS)
Part Number 272-4000
FIRING PC BOARD (ALL MODELS)
Part Number 272-4005
*Included on Main PC Board
MELLTRONICS
- 31 -
REV. 04/03/2006
ES-2700 MANUAL
SECTION 8
SUPPLEMENTARY TECHNICAL INFORMATION
Outline and Mounting Dimensions for Chassis Mount and Enclosed ES-2700 Controls
7"
5"
9 3/4"
1/2 "
13"
12"
OPTIONAL
TEST
METER
7/16"
8 7/8"
.272" DIA
4 MOUNTING HOLES
FOR 1/4" STUD
Figure 14: Chassis Mount Control
20"
10"
1 7/16"
24"
21 7/8"
2 1/2"

MELLTRONICS
15"
5/16" DIA
4 MOUNTING
HOLES
Figure 15: Enclosed Control
- 32 -
REV. 04/03/2006
ES-2700 MANUAL
Table 6: Terminal Strip Connections
TB-1 Signal Terminals
TB-2 Control Logic Terminals
1. Jumper for Current Regulator
1. 120 VAC Control Power (5VA Max)
2. Jumper for Current Regulator (8V - 100% Current)
2. 120VAC Control Power (5VA Max) Fuse Side
3. Output Accel/Decel Circuit
3. N.O.
4. Input to Velocity Error Amp
4. Form C Fault Trip Relay Contact (Arm)
5. Turret Terminal for Drive Modification
5. N.C.
6. Turret Terminal for Drive Modification
6. Run Contact N.O.
7. Turret Terminal for Drive Modification
7. Run Contact N.O.
8. Turret Terminal for Drive Modification
8. 120VAC Switched through IFT Contact for Operator Devices
9. AC/DC Tach Connection
9. Motor Thermal Connection/EStop
10. AC/DC Tach Connection
10. N.C. Stop Pushbutton
11. -10 VDC for Reference Input Only
11. N.O. Run Pushbutton
12. Reference Input (through Accel/Decel)
12. N.O. Jog Pushbutton
13. MIN SPEED potentiometer setting
13. N.O. Jog Pushbutton
14. Common
14. 120VAC Switched through IFT Run/Jog Contact
15. Remote Current Limit Phase to -12VDC (0-150%) 22K Input
15. 120VAC Switched through IFT Run/Jog Contact
16. Tach Input (-)
16. M Contactor (100VDC)
17. Low Tach Voltage Selection
17. M Contactor (100VDC)
18. Tach Input (+)
18. M Contactor Aux
19. MED Tach Voltage Selection
19. M Contactor Aux
20. HIGH Tach Voltage Selection
20. Field Loss Defeat
21. Output armature voltage isolator Amplifier
21. Field Loss Defeat
6Volts = Rated Voltage (Pos for Pos Arm)
22. +24VDC
23. -24VDC
24. Optional Ammeter Connection
25. Optional Ammeter Connection
Table 7: Jumper Programming Quick Guide
The following chart summarizes the various jumper functions on the printed circuit boards as well as at the
terminal strips. Amp pins 5, 6, 7, and 8 are connected to pins 5, 6, 7 and 8 respectively, at TB-1 for system
design applications. Except for the power supply input jumpers and the field loss defeat jumper, all jumpers are
located on the top board (272-4000). Test pin S is provided for looking at the current feedback.
Jumper (s)
Functional Description
A-C, B-C
Program power supply transformer for 230VAC input
A-E, B-D
Program power supply transformer for 115VAC input.
TB2, 20-21
Defeat field loss circuit
G-I
External current limit at TB1, pin 15.
H-I
Internal current limit.
J-K
Connect velocity error amplifier to current error amplifier.
L-M
Jumper for 60Hz operation. Remove for 50Hz operation.
N-O
Remove for very low horsepower.
P-R
Jumper for 180V armature. Remove for 90V armature.
T-LO
Low current feedback range, 6/15 amps (1/4-2HP/3-5HP)
T-MED
Medium current feedback range, 8/20amps (1/4-2HP/3-5HP)
T-HI
High current feedback range, 10/25 amps (1/4-2HP/3-5HP)
W-IR
Increase motor speed under load.
W to -IR
Reduce motor speed under load.
TB-1, 1-2
Jumper for current regulation.
TB-1, 3-4
Connect accel/decel circuit to velocity error amplifier.
TB-1, 2-3, 3-4
Reduce input resistance to velocity error amplifier to 5K ohm.
TB-1, 17-18
Low tachometer feedback range, 65 to 130V.
TB-1, 18-19
Medium tachometer feedback range, 94 to 188V.
TB-2, 19-20
High tachometer feedback range, 131 to 262V.
U-V
Add jumper for 1/4 to 4 second accel/decel time, 2 to 30 second accel/decel time without jumper.
MELLTRONICS
- 33 -
REV. 04/03/2006
J1-4
J1-1
2
1/4A
4FU
L11
+15V
R147
CONTROL VOLTAGE
115VAC
I FDBK
J4-10
TO T METER
J3-13
TB2-25
FROM
FIELD
1
1
QVR1
4
5
R
168
2
3
(6)
RC1
R146
R145
L10
4
TB2
(7) (7)
CRFT
3
2
+
5
(8)
1
R155
D56
C55
FIELD
LOSS
DZ5
TB2-20
(5)
6
5
-15V
6
4
L10
+15
V
7
CRR
(11) (10)
(4)
R
153
C56
D55
+15V
-15V
CRFT
R154
C63A
R169
8
C54
7
C53
R152
R
156
IMOT
F54
9
STOP
START
11
CRR
(13) (14)
10
R
167
R
148
R
130
CRR
(13) (12)
(2)
CRR
(1)
+
R
157
D57
DC
O.L.
R170
D57A
R151
Q3
R
135
D59
J4-7
-
12
BR2
-
13
R
144
R136
(8)
CRJ
15
(7)
CRR
(8)
(7)
14
(2)
R141
J5-16
+15V
R
140
CRJ
+
(1)
BR4
SCR1
C
R
131
A
G
JOG
C63
D58
+15V
2
3
16
4
C52
L9
M
BR3
-15V
8
17
C50
M
19
21
FIELD LOSS
20
J4-16
J4-14
L9-7
J5-6
(1)
22
I LIMIT
TB-2
23
-24V
R150
JP1
24
25
COM
I O.I.
6
7
COM
16
control logic and test mtr conn manual rotate.vsd
REV. 03/02/2006
RESET
15
14
IFT
13
NC
12
11
NC
CRJ
10
9
8
5
ARM V
CRR
4
COM
3
1A+
1A-
2
I FDBK
1
J5A
16
DC PWR
T2
15
I LIM
14
13
12
11
10
9
8
SYNC
7
NC
6
5
4
3
2
1
J4A
F.LOSS
-15V
+15V
TRIG SIG
R 147
15
14
13
ARM I
11
F-
12
10
F+
ARM V
9
COM
8
+15V
6
5
4
3
7
TRIG SIG
+24V
NC
NC
2
1
-15V
L1
L2
1L2
1L1
TEST
METER
JACK
J3
NOTICE: This drawing is furnished for reference only.
The furnishing or possession of this drawing or any
reproduction
thereof,
does
not
convey
any
manufacturing rights.
AUX 'B'
18
CRFT
Q2
L11-5
MA
J5-15
D52
D50
(2)
+24V
NOTE: USER IS TO FUSE (1 AMP MAX.) WIRING
PROVIDING POWER THROUGH CONTACTS CRFT AND CRR.
R139
R132
+24V
IFT
MA
R
136
D51
C51
+15V
RESET
R
142
R143
-
+24V
+
Figure 16: Control Logic and Test Meter Connections
Figure 17: Interconnect Diagram 272-1000-I, Sheet 1
OPTIONAL
AMMETER
6
OPTIONAL
FIELD
2
LOSS
DEFEAT
MC AUX
'A'
MC
JOG
START
STOP
MOTOR
THERMAL
-
+
CUSTOMER
CONNECTIONS
L2
2FU
25
24
21
20
19
18
17
16
13
12
11
10
9
8
1L2
1
3
3
J1
B
A
P1
-
+
1
1
2
BLK
6
6
BRN
12
12
RED
15
ORN
T1
272-6000
BLK/YEL
YEL
WHT/VIO
GRY
VIO
272-4005
P.C ASSY
FOR 120V OPERATION:
A TO E, B TO D
FOR 240V OPERATION:
A TO C, B TO CX
FU 3/8
3 AMP
3AG
C
15
D
E
(+)
J2
A1
J6
(-) A2
1
B
P2
PB1
(+)
(-)
P6
(Q1)
2
(Q2)
TRANSFORMER JUMPERING:
1L1
AC2
AC1
KL B
1FU
TH W
L1
1
DC CTI
10
10
7
1
1
NR G
7
2
2
NR G
13
13
A
1
4
4
1
1
1/4
FU AMP
4 3AG
TEST
METER
JACK
J3
P3
F-
F+
FE1
FE2
A+
A-
DB
OPTION
AC/DC
TACH
ACCEL
DECEL
JUMPER FOR
CURRENT
REG
272-7003
16 PIN RIBBON
CABLE ASSY
272-7002
16 PIN RIBBON
CABLE ASSY
TEST
METER
P.C. BOARD
262-4010
OPTIONAL
MC
MC
MC
MOTOR CONTACTOR
11
10
9
8
7
6
5
4
3
2
1
4
13
8
7
6
5
IR-
AUX
"A"
14
G
R
I
V
AUX
"B"
REMOVE FOR
90VDC ARM
REMOTE
I LIMIT
LOCAL
I LIMIT
ADD FOR
.2-4 SEC
I LIMIT
MAX
SPEED
15
9
16
-
DC
TACH
LOW
+
17
7
MED
19
SPEED
RATE
18
CURR (P3)
STAB
B3 B2
A3 A2
MC
JOG
B1
A1
272-4000
P.C. ASSY
P
H
U
ACCEL
TIME
IR COMP
DECEL
TIME
IR
A1
SPEED
POT
12
MIN
SPEED
M
A2
HI
21
O
M
J
REMOVE FOR
LOW H.P.
REMOVE
FOR 50Hz
IR
COMP
RESET
T
LO
CURRENT
SELECT
8
MED
ARM
FDBK
20
N
L
K
VEL
STAB
HI
MC AUX
'B'
5
F1
DUAL
WINDING
FIELD
MOTOR
FIELD
F2
3
1
2
3
4
5
6
7
ADD JUMPER TO DEFEAT FIELD LOSS
PROTECTION.
TO DEFEAT FIELD ECONOMY:
JUMPER FE1 TO FE2.
ARMATURE AND FIELD CONNECTIONS
SHOWN WILL PRODUCE CCW MOTOR
ROTATION FACING THE COMMUTATOR
END. TO REVERSE MOTOR ROTATION
REVERSE A1 AND A2 CONNECTONS.
REFER TO MOTOR NAMEPLATE FOR
PROPER CONNECTIONS.
OPTIONAL AMMETER CONNECTION
0-100µA, 3700
150% CURRENT FULL SCALE.
TACH VOLTAGE RANGE AT MAX SPEED
CURRENT RANGES
inter.dia272-1000i rotate.vsd
REV. 03/31/2006
NOTICE: This drawing is furnished for reference only.
The furnishing or possession of this drawing or any
reproduction
thereof,
does
not
convey
any
manufacturing rights.
F1
F2
F3
F4
F-
F+
FE1
FE2
TB3
8
Figure 18: Interconnect Diagram 272-1000-I, Sheet 2
MIN
SPEED
SPEED
A-
A+
ARM. FDBK
SCALING
CIRCUIT
T
TACH FDBK
SCALING
CIRCUIT
MAX
SPEED
JOG
SPEED
CURRRENT
LIMIT
IR COMP
IR COMP
CIRCUIT
CURRENT
LIMIT CLAMP
CIRCUIT
interconn dia sheet 2 rotate.vsd
REV. 03/02/2006
NOTICE: This drawing is furnished for reference only.
The furnishing or possession of this drawing or any
reproduction
thereof,
does
not
convey
any
manufacturing rights.
VOLTAGE
FEEDBACK
CIRCUIT
ACCEL/
DECEL
CIRCUIT
VELOCITY
ERROR AMP
CLAMP
CIRCUIT
TO FIELD
LOSS
CIRCUIT
FAULT TRIP
CIRCUIT
CURRENT
OVERLOAD
CIRCUIT
CURRENT
FEEDBACK
CIRCUIT
CURRENT
ERROR AMP
FIELD LOSS
CIRCUIT
F-
F+
FROM
CLAMP
CIRCUIT
FIELD
SUPPLY
FIRING
CIRCUIT
SYNC
CIRCUIT
FROM
POWER
SUPPLY
A1
RUN/STOP
LOGIC
POWER
SUPPLY
115
VAC
POWER BLOCK
A2
+15VDC
-15VDC
+24VDC
-24VDC
L2
L1
115/230 VAC
Figure 19: Top PC Board Schematic - Diagram 272-1000
DC
TAC
H
-
+
AC/DC
TACH
ARM
HI
MED
LO
SPEED
CURRENT
REGULATOR
7
8
7
8
16
21
20
19
18
17
9
10
R16
H
J5-6
ARM V, TO T. METER
C24B
R
23
R
28B
R14
R70A
C26
7
3
2
D4
C1
R4
4
5
6
R
68
C24A
R57
SPEED
RATE
JOG
D9
R8
C5
1
C6
-15V
4
L2
8
+15
V
+15V
1
D9B
1
+15V
-15V
L8
8
R45
L5
C7A
R32
L3
C27
2
3
-15V
D5
D9A
R70
R24
2
3
J4-15
R19
R
15
R31
J5-10
J5-9
P2
MAX
SPEED
C11A
-
G
I
+6V = RATED
VOLTAGE
R37A
BR1
R
13
(3)
(4)
CRR
(5)
-15V
I
LIMIT
R18
DC
PWR
ON BOTTOM BOARD
MIN
SPEED
R17
+
6
6
C2
J5-8
5
15
R10
DZ2
5
14
13
12
11
3
R3
4
J4-16
R2
R1
2
1
R12
R67
5
6
15
D1
R9
L2
R5
-15V
7
C1A
+ -
14
L1
R
P
3
4
L5-7
L5-3
L5-4
CUT FOR
90V ARM
5
CRJ
COM
(1A+)
(1A-)
+
J5-10
C11
R36
R35
R34
D
7
R
20
BIAS
D
8
(L1-4) -15V
C3
C4
R
22
5
6
1
L1
L1
9
3
10
R43
C7
7
C8
J5-16
-15V
4
L3
8
D6
VEL STAB
2
11
+15V
+15V
R33
R21
(L1-13) +15V
P1
C10A
J5-12
ON BOTTOM BOARD
DECEL
TIME
D3
R7
J5-11
V
R
58
R37
+
C20
R25
R69
-15V
ACCEL
TIME
D2
R11
U
R6
16
-15V
+
8
J
R
54
R55
IR
-IR
J5-15
R
40
Indicates connections made to TB1.
1 Connect +15V to J4, pins 1,2,&3.
2 Connect -15V to J4, pins 4,5,&6.
3 Connect common to J4, pins 11, 12, & 13.
7
+
-
5
6
R41
R
60
R
26
C22
IR
COMP
W
R28
C21
R59
Indicates connections made to amp pins.
5
6
+15V
IFT
R56
R30
+8V=100%
-15V
4
K
L5
4 19
5
C15
7
C16
R44
RESET
S
VELOCITY
ERROR
AMP
R29
C14
J4-7
24VAC
J4-9
6
L1
7
C20A
N
R66
O
R53A
R38
Q2
1
R65
2
3
J4-10
L7
7
R
39
C23
I FDBK SIG
-1V = 100%
C8A
8
L7
-15V
4
R27
D13
5
6
+15V
3
-15V
4
8
L4
R71
R72
R64
2
Q1
D10
-15V
+15
V
R
76
C9
1
R42
D12
+15
V C10
C13
C13A
R53
272-1000 manual rotate.vsd
REV. 03/02/2006
P4
ZERO
L8
R78
C17
R46
D17
1
NOTICE: This drawing is furnished for reference only.
The furnishing or possession of this drawing or any
reproduction
thereof,
does
not
convey
any
manufacturing rights.
C25
R75
C12
+
R
63
R61
R28A
CURRENT
ERROR
AMP
L4
D11
P3
I STAB
8
D16
D15
R62
C24
R51
M
3
2
R
47
C
18
R
49
3
2
6
7
S
R
77
J5-1
C19
R
73
T
MED
R
74
LOW
FROM
TRANSDUCTOR
J5-2
TO PULSE
TRANSFORMER
D14
+15V
CURRENT
FEEDBACK
HI
D
R
48
C16A R
50
Q1A G
1
L6
8
R79
5
4
CUT FOR
50HZ
L
R
52
2FU
L1
R165
R164
A-
1L1
QVR2
1L2
FE2
A+
T2-1
1FU
115/230
VAC
L2
ON HEAT SINK
M
AUX
FE1
C65
RC2
J3-11
D63
D69
R
137
J3-4
B
A
E
R162
R
175
C
C
D
D62
D68
D67
R
161
15
6
12
3
J1-P1
J4-9
4
1
7
C58
36V
J5-7
J5-5
J5-4
+
-
C59
115VAC
I
1/4A
4FU
R
133
BR5
+
+
C60
I
G VR2
+
+15V
J5-2
1
R
134
J3-1
J3-2
1
QVR1
2
CRR
(3)
(4)
-15V
4
Indicates connections made to TB2.
Indicates connections made to amp pins.
Indicates connections made to fastons.
3.
2.
1.
7
F54
9
STOP
+
START
11
CRR
(13) (14)
10
R
167
R
148
R
130
CRR
(13) (12)
(2)
CRR
(1)
R
157
D57
DC
O.L.
R170
D57A
R151
Q3
R
135
D59
J4-7
IMOT
8
C54
7
C53
R152
Indicates connections made to TB3.
6
8
L10
CRR
(11) (10)
CRFT
6
5
+15
V
D55
C56
R
156
4.
TB2
5
(8)
(5)
J5-12
J5-11
R
153
-15V
+15V
Indicates connections between P1 & J1.
4
(7) (7)
CRFT
J5-10
CRJ
(4)
(5)
R154
C63A
R169
5.
3
L10
1
R155
D56
CRJ
3
2
FIELD
LOSS
C55
+
TB2-20
DZ5
(6)
RC1
(3)
R146
R145
CONT V. TO
T. METER
TO I
SCALE RES
J2
2
TO
TRANSDUCTOR
+24V
J5-9
4
5
R
168
CRR
(5)
(4)
L11
4N36
R147
J5-8
+15V
I FDBK
J4-10
VR1 G
+
C61
C66
2
1
+24V
TO T METER
J3-13
TB2-25
O
C67
C62
COM
R172
R173
O
J5-3
10
13
P1-J1
-25V
-15V
ARM V.
FEEDBACK
R
166
TO SYNC
CIRC
D64
QVR4
F-
F+
R
176
C57
L.V. TO
METER
J3-5
3/8A
3FU
RC3
D65
R174
R171
QVR3
R163
FIELD V.
TO T. METER
J3-10
F-
-
12
BR2
-
13
1K
R
144
R136
J5-16
(8)
CRJ
15
(7)
2
3
5
6
16
T2
L9
7
IFT
M
D50
19
L9-7
21
J4-16
J4-14
2
1
J6
22
I LIMIT
TB-2
23
-24V
R150
JP1
24
25
8
COM
I O.I.
3
15
272-1005 manual rotate.vsd
REV. 03/02/2006
16
14
RESET
IFT
13
12
11
NC
NC
CRJ
10
9
8
7
CRR
6
COM
5
ARM V
COM
4
2
1A+
1A-
I FDBK
1
J5A
16
T2
15
I LIM
DC PWR
14
13
12
11
10
9
7
SYNC
NC
6
5
4
3
2
1
J4A
F.LOSS
-15V
+15V
TRIG SIG
R 147
15
14
13
11
F-
ARM I
10
F+
12
9
CO
M
8
+15
V
6
5
4
3
2
7
TRIG SIG
+24V
NC
NC
1
-15V
L1
L2
1L2
1L1
TEST
METER
JACK
J3
ARM V
TO
SCR
GATES
A+
NOTICE: This drawing is furnished for reference only.
The furnishing or possession of this drawing or any
reproduction
thereof,
does
not
convey
any
manufacturing rights.
FIELD LOSS
20
(1)
(2)
J5-6
CR
FT
+24V
Q2
R79
R178
L11-5
MA
J5-15
D52
R139
J3-14
AUX 'B'
18
+24V
C50
C68
R
177
I LIMIT
TO T.
METER
R132
MA
R
138
D51
17
BR3
-15V
4
C52
L9
C51
+15V
M
2
D68
1
R137A
8
6
5
RESET
R
142
R143
R136A
R160
D60
R159
R141
CRR
(8)
(7)
14
(2)
+
+15V
R
140
+15V
CRJ
(1)
+
BR4
R
158
I LIMIT
SET V.
J4-15
C64
SCR1
C
R
131
A
G
JOG
C63
D58
+24V
GP
-
F+
GATE PULSES
J5-1
+
Figure 20: Bottom PC Board Schematic - Diagram 272-1005
REVISION TABLE
REV
DATE
DESCRIPTION
REVISIONS
NONE
04/03/2006
1ST RELEASE BY MELLTRONICS
NONE
SECTION 9
WARRANTY
MELLTRONICS warrants to the Buyer whom purchases for use and not for resale that the equipment described
in this instruction manual is sold in accordance with published specifications or the specifications agreed to in
writing at the time of sale. Melltronics further warrants that such goods are free of defects in material and
workmanship.
The warranty shall apply for a period of twelve months (12) from date of purchase, not to exceed eighteen months
(18) from the date of manufacture.
If the goods fail to perform to Melltronics specifications as outlined in the warranty, then Buyer should contact
Melltronics to obtain a “Material Return Authorization” (MRA), prepare the goods for shipment and return the
goods to Melltronics for repair or replacement at Melltronics option. Buyer will bear all costs of transportation to
and from Melltronics factory, risk of loss for goods not at Melltronics factory and any cost required to remove or
prepare the goods for shipment to the repair facility, and to reinstall equipment subsequent to repair.
This warranty is effective only if written notification of any claim under this warranty is received by Melltronics at
the address indicated below within thirty-days (30) from recognition of defect by Buyer.
The above indicates the full extent of Melltronics liability under this warranty. Melltronics specifically disclaims
any liability for: (a) damage or failure due to improper use or installation; (b) damages in shipment; (c) damage or
failure due to abnormal operation conditions of load, temperature, altitude or atmosphere whether intentional or
unintentional; (d) non-authorized service, repair, modification, inspection, removal, transportation or installation;
(e) misapplication or misuse, or; (f) consequential damages arising out of the use, operation or maintenance of
the goods.
THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, WHICH EXTEND BEYOND THAT
DESCRIBED HEREIN.
MELLTRONICS SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY OF
MERCHANTABILITY OF GOODS OR OF THE FITNESS OF THE GOODS FOR ANY PURPOSE.
Melltronics neither assumes nor authorizes any representative or any other person to assume for Melltronics any
other liability in connection with the sale or any shipment of Melltronics goods. Melltronics reserves the right to
make changes and improvements in Melltronics goods without incurring any obligation to similarly alter goods
previously purchased.
MAIL: PO BOX 2368
INDIAN TRAIL, NC 28079-2368
SHIPPING: 3479 GRIBBLE ROAD
MATTHEWS, NC 28104-8114
PHONE: 704-821-6651
www.melltronics.com
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