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MELLTRONICS F2 USER MANUAL

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1. SONON TIAN gt s ssyHo 15 NO G31v2013 InGOW YamOd 5 X0019 XVII OL zar 08 par RI SNOLLDSNNOSSALVOICHI z A OUO VI53936 SIIN O 4 one 5 esy H am 5 Ke NU NO 90V 017 gt Le SNOLLOINNOO S31VOIONIN NI v 181 32018 IVNIWH31 OL way 164 nme ED M099 0 SNOLIOSNNOO SILVINI 1 var gt anono 288 LI 5 4 9 4 LI A 21 9 or 5 eo n X 2 24 A od wer re Laver AS 1 rm Soit fue eT 7 1 3 I C i O 1 2C o 9 C pa E gt i 0 8 0 9 aus 5 z TO E dois er DIC m wma Em 91901 5011890 dpa Figure 24 Schematic Diagram Main PC Board 2450 1000 Re
2. OL SOLVINNWOO SHL ONIOVS NOLLV LOH NMOHS SNOILOANNOO 07915 ANY 38 1LVVIXV VNOLLdO 901 Y V LSNW 2 ON 9 STVNIIWH3L 319V IIV MV LON 0 M08L 2206 09V2 Nd way OL WW HEL OL SI NOLIO3NNOO QVOTH3AO TWWYSHL YOLOW 4 8106 0575 51 1 XNV Z ONISH3A3M OVA 4106 0892 SLOVLNOO XNV Z ONISH3A3MH OVA 021 ISN YSWOLSND SLOVLNOD NOILdO ONISH3A3H SIN3NOdWOO SNOILL O3NNOO SNI 091100 7281 OL 8 lVNIIAMH3L SAOWSY SI HOLIMS SOF NNY 31 NI NMOHS 6 HOLIMS M38 0M3 8L 29L0L 228101 6006 0692 Nd MM kar Edr SE Sod iGO 35VI10 09 1 aan HOWL BOVLIOA IH 9 onov o auno 2d 1206 0592 Nd 9313W 0334S 99395 ul NIN 0019 30LV OVAL 9 018 0 OLV OVAOZ NOILO3 3S 39VL OA 30 o 4 es OOS gt 91901 JOLSINNY 5 0007 0972 Nd
3. 31s VW MZ 104 1 eO 1106 2206 0Svz Nd my Sor ats S 9 1005 0652 2109 0996 313A 9939 Td v M NVI 6I 291 OL 21 281 OL uno Inanon Q 2747 tar 0 WRLC 04 4 6 Sov o 9 od 1206 0922 Nd O O 313A 0334S ad rnc 1M 3 NIW 13930399V 18 301v OvAOZI 901 8 901 v 3136 3VI10 91901 dOLSINNY C9MVCMVI 09V2 Nd 109IM0 0204 NO 440 OV Enclosed High HP Control with M Contactor 2450 1003 Rev Figure 21 6002 9 6 05M31V1C9 I F001 0972 SI 43385 90r LY N3HM 1172 SNOLLO3NNOO LV 3993 39 NOLLVLOM 3010 3SH3A3M OL HOLVIQWWOO SHL ONIOVS NOLLV LON TIM NMOHS SNOILO3NNOO 01414 39 1VVI9V OL Q3193NNOO 38 SHIM SNOILdO H3MOTIOJ IM3 JO LON 6300 LINN JI
4. Setting this jumper incorrectly results in the wrong voltage feedback level to the control thus causing the motor top speed to be too high or too low If the unit is used as torque current control the voltage feedback circuit is disabled and JP2 is simply set to the LO position 4 3 5 CURRENT FEEDBACK LEVEL SELECTION The control is designed to control motors rated from 74 to 5 that have a wide range of current ratings Because of this the current feedback must be scaled so that the proper level of IR compensation and correct current limit setting are attainable with each motor The control can be matched for low medium or high current feedback levels by setting jumper JP1 as follows A Refer to the motor nameplate for the horsepower rating and the DC armature voltage and current amperes B Use this data to determine the proper position of JP 1 LO MED or HI from Table 2 or Table 3 Table 2 Jumper Programming for Speed Regulated Operation INPUT DC DC FIELD TORQUE CONTROL ARMATURE OUT JUMPER PROGRAMMING OUTPUT PROGRAMMING L g g JUMPERS t gt gt lt gt lt 3 6 90 26 100 1 AE B D LO LO SPD ARM 52 90 37 100 1 A E B D LO LO SPD ARM M 77 90 5 5 100 1 A E B D LO LO SPD ARM 405 94 90 75 100 1 A E B D MED LO SPD ARM 14 1 90 10 100 1 A E B D HI LO SPD ARM 3 6 180 26 200 1 A C B C LO HI SPD ARM 5
5. Waldridwv 90993 SWIL T3oaq i399v 7104 WNOIS st X0V9033 1M3 0L Alddns 9 AN oNnvos 016 OH df II Woo LONI jar OVAOEZ SLL ovadaa4qaads EI 9 3 HOVL 2 0 L 1 0 V WHY HOWL ex IX 44 14 24 LaL Figure 9 Control Circuit Block Diagram SECTION 7 MAINTENANCE AND TROUBLESHOOTING 7 1 IMPORTANT SAFEGUARDS Personnel familiar with it and its application should perform all work on the drive Before performing any maintenance or troubleshooting read the instructions and consult the system diagrams WARNING MAKE SURE THAT ALL POWER SOURCES HAVE BEEN DISCONNECTED BEFORE MAKING CONNECTIONS OR TOUCHING INTERNAL PARTS LETHAL VOLTAGES EXIST INSIDE THE CONTROL ANYTIME INPUT POWER IS APPLIED EVEN IF THE DRIVE IS IN A STOP MODE TURNING MOTOR GENERATES VOLTAGE IN THE DRIVE EVEN IF THE AC LINE IS DISCONNECTED EXERCISE CAUTION WHEN MAKING ADJUSTMENTS WITH THE CONTROL DRIVING A MOTOR DO NOT EXCEED TEN 10 DEGREES OF POTENTIOMETER ROTATION PER SECOND NEVER INSTALL OR REMOVE ANY PC BOARD WITH POWER APPLIED TO THE CONTROL 7 2 ROUTINE MAINTENANCE Only minor adjustments should be necessary on initial start up depending on the application In addition some common sense maintenance needs to be followed KEEP IT CLEAN The control shou
6. 43385 03385 1M9 9 NIW XV sam 9018 901 V 2 0 2 NOILO3 13S LAdNI 30 o 4 es ao 4 91313 91901 dOLS NNY 15 000r 0972 Nd 1091M0 II S203 1VVI830L 3010 ov nab Figure 13 Connection Diagram for High HP Panel Mount amp Less Operators Controls 2450 1101 I Rev A 6005 7 6 I 000L 09V7C si 93395 LY N3HM Yad 5 1 3AOWSH SNOLLO3NNOO ZY CMV LV 3SH3A3H NOILV LOY YOLOW 3593 39 OL HOLVIQWAOO FHL NOILVLOY YOLOW 9 009 NMOHS SNOILOANNOO 07314 CMV 380 6 ON TVNIWH3L OL Q3103NNOO 3HIM SNOLLdO YSMOTIOS LNIYYNI 3AVH LON S3OQ LINN JHL 4 38 GINOHS 1031405 NO 104 IIVIII 1M3 5 SI NOILdO SIHL 3INLLANV LVHL ILON NOILISOd NI Lf LAd GASN SI SIHL NO 104 IM9 31 NOLLISOd NI Q39V ld 38 QINOHS 09V098 1M3 310W3H IHL NO If 935 SI LOd LNIYYNO 3LOW3Y V LINN GALNNOW SISSVHO NO IWNOILdO YSHLASOL 38 ASN 281 NO STIVNIIH3L 3 18V IIVAV LON SI NOLLO3NNOO QVOTH3AO WWYSHL YOLOW NO NO
7. ATIN 38 09V09 1 NO 104 IM3 IHL dasn SI SIHL LVHL 31ON NOLLISOd 8 NI 104 5 SI 1140 SIH L NO 104 IM38 dll V NOLLISOd NI 38 9308 IIVIII IM3 3103 IHL NO IP SI 104 IM3 SLOWEY V dl GALNNOW SISSVHO NO WNOILdO H3H13901 LSNW ZAL 40 S IVNIIWH3 LL 319VIIM IMV LON SI NOLO3NNOO QVO TH3AO TVWYEHL HOLON 21 444 4 NI NMOHS HOLIMS A3H QM d 5006 0852 D Ds 1314 E 1006 OSZ Nd 2106 0Svz Nd 1106 0892 Nd I888 LNT IM SLOWEY SOR AY OOK 11091 Mz Lod LIA 175115 xvn DL wav 90081 2206 0972 Nd Waly 20 06 2206 0892 Nd V 181 OL Y3L3W 9334 9 svig S 2109 0892 _939VL UNO 3 0 0L 9 S 1009 0892 01 23 omno oe 1 O INNO unn
8. Sd 1206 0892 Nd 9334 anoo G33ds 03385 an XVII 13030 1309 GOL 8 3 OL V OVAOZI 901 89 OL Nol19313S 39VLT0A 1ndNI e BOLON 3 91901 04 09 2 Nd 109IM0 0204 VW NO 440 OV Figure 23 Enclosed High HP Control with Reversing Kit 2450 1005 Rev A 1928 NIV Ol vWaHOS 0001 52
9. 1041NOO TVWYEHL 3010 V ov Figure 18 Panel Mount amp Less Operators Low HP Controls with Reversing Kit 2450 1104 Il Rev A 600460217 geugsnpur I 901 09V2 DET SNOILO3NNOO LV 3 93 39 NOLLV LON SOLON OL ONS SHL ONIOYS NOLLVLON HOLOW 30 009 TIM NMOHS SNOLLO3NNOO 01319 Way 6206 0572 Nd Q3VO8 O d NO NOLLO3NNOO NOLSV4 S310N3G 2 2206 0592 Nd USHLIOOL 38 OL 180112 ON 9 STVNINYAL 318V TIVAV LON SI NOLIO3NNOO QVOTTH3AO TIVINH3H L HOLOW 4 V V OL O d WO 1 38 QuvO8 NOILdO NO S3UIM CX LX 281 01 2281 TVNINY3L VI0C94 SAOWSY SI HOLIMS HOF NNA NOLLISOd NI NMOHS HOLIMS por 0 9334 51 281 01 2281 OL IN3YYN9 O10 8906 0892 var BOVIIOAQT SI 5 gt I aad way 2 AROA ae aan HENS IM IH oaov ema UNV 9M593 39 uno 1206 0592 Nd 03345 I 99995 4446 ul XVN 13030 13 V o 0019 301 018 204
10. Table 4 Voltage Check Ghart et e e e ede e e 32 Table 5 Control Standard Connection Scheme Terminal Blocks 1 and 2 37 Table 6 Customer Jumper Programming Chart filled out by customer Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 LIST OF FIGURES Oscilloscope Connectlons ete dete d d ecd ee On ae t e e e c ates 6 Typical Panel Mount Control Product Nameplate 8 Panel Mount I 8 ControlModification Kits nase rr tea rx er ren 12 Main PC Board Jumper Locations 14 Connection of Motor Leads to 20 Power Bridge Assembly RET nie nete tetra titt heh 25 Power Bridge Assembly niei ETENIM UMEN 26 Control Circuit Block Diagtam rrt t Dee 28 Outline and Mounting Dimensions for Enclosed 38 Outline and Mounting Dimensions for P
11. 0 d NO NOLLOSNNOO NOLSV4 S310N3G MO 38 IOH1NOO NIVW NO 104 IM3 SI 3WIL 1 31ON NOILISOd 9 LC 1 5 SI 130 NO 104 IM3 17 NOLLISOd NI 38 GINOHS 09V09 IM3 SLOWSY IHL NO If 5 SI 104 LNIYYNO 310W3H V dl V L91 0L GALNNON SISSVHO NO 1MM0I19 0 Hro WNOILdO 3H13901 15 VI ZAL VON STVNIWH3 L g 18V IIVAV LON SI NOLO3NNOO 0V0193 TIVIWHSHL 010 41 8106 0992 N d SLOV LNOO XNV M CMI 93 39 OVAOEZ 4106 0872 Nid SLOV LNOO XNVIM ONISHSAZY OVASLL HSN 93VI0195 612 1 WHY NOLdO 9NISH3A3H NO SIN3NOdWWOO SNOLL3ONNOO SLONAG SANIT 091100 Wav 6206 0972 Nd NYY 2006 2206 0972 Nd 1 1pis313W 93348 8006 0692 939VL 1N38309 SLOWSY MZ 10d o NI NMOHS 6 HOLIMS AYOM 6006 0692 Nd L L L 0996 2106 0882 N3MO SOVLION 1106 0892 S30 103 1 2unos diano 1006 0992 Nd SOHO HIA 039 5 90r 1v oor 002 01 9 G 2109 0892 93348
12. 41095 50 60HZ 2HZ OR 120 31096 50 60HZ 2HZ DEPENDING ON THE JUMPER PROGRAMMING DESCRIBED IN PARAGRAPH 4 3 IF THE INCOMING LINE VOLTAGE AND OR OUT OF THIS TOLERANCE THE CONTROL WILL FAIL TO OPERATE 4 7 2 OUTPUT POWER RANGES Table 2 and Table 3 list the AC line voltages line currents amps and DC field output currents amps for various motor horsepower ratings The AC line amps RMS should be used to size the wire for both the armature output and the AC line input connections The field current is less than one 1 ampere for each of the motors listed The wire for field connections can be sized accordingly 473 OUTPUT TERMINAL INSTALLATION CHECKS It is imperative that the control be connected to earth ground for the safety of the operating personnel This ground is provided by an enclosure or chassis installed screw On enclosed and less operators controls this ground screw is mounted to the bottom base half of the enclosure above the upper right hand corner of the main PC board Panel mount controls have the Screw mounted on the chassis near the lower right hand corner of the main PC board CAUTION NO POINTS IN THE CONTROL CIRCUITRY INCLUDING COMMON SHOULD BE CONNECTED TO EARTH GROUND UNLESS SPECIFICALLY SHOWN ON THE SUPPLIED WIRING DIAGRAMS NO GROUNDING CONNECTIONS SHOULD BE MADE ON THE TERMINAL BLOCK IMPROPER CONNECTIONS TO GROUND INCLUDING SPEED POTENTIOMETER CONNECTIONS WILL RESULT IN CO
13. In speed regulated applications the DC output voltage varies as a function of an input reference voltage Typically the input reference voltage is provided by an operator adjustable potentiometer NOTE THE ENCLOSED CONTROL ALONG WITH THE LESS OPERATORS CONTROL ARE NO LONGER MANUFACTURED THE INFORMATION REGARDING THESE CONTROLS IS FOR LEGACY REFERENCE ONLY The enclosed controls are furnished in a standard enclosure rated to meet or exceed NEMA type 1 4 12 and 13 requirements The enclosure package consists of two halves of a hinged shell which are opened by releasing a spring loaded screw on the right side of the cover The inside of the cover contains the switches and heat sink The inside of the base contains the main PC board The function of which are described in detail in Sections 4 and 5 The inside of the base on the 3 5HP enclosed and less operators models also contains the shunt resistor PC board The enclosed controls are equipped with pre installed on off run jog and start stop switches and a 1 turn speed potentiometer The less operators controls are furnished in the same enclosure design as the enclosed controls except for ventilation holes provided in each end of the cover End cover plate can be installed as an option to cover these ventilation holes and convert this control to a NEMA 4 12 enclosure without operators A remote operator station must then be used for operator controls A loose speed pot is f
14. Mode of Operation Jumper Programs control as a speed or torque regulated control JP4 Voltage Feedback Selection Jumper Selects either armature feedback or tachometer feedback as the voltage feedback source Refer to the following paragraphs and Table 1 and Table 2 for determining the correct jumper connections After the jumper programming is completed the jumper positions can be recorded for future reference on the Customer jumper Programming Chart Table 5 WARNING EQUIPMENT DAMAGE AND OR PERSONAL INJURY MAY RESULT IF ANY JUMPER PROGRAMMING IS ATTEMPTED WHILE THE CONTROL IS OPERATIONAL ALWAYS LOCK OUT POWER AT THE REMOTE DISCONNECT BEFORE CHANGING ANY JUMPER POSITIONS 4 3 1 OPERATING VOLTAGE SELECTION The first step is programming the control is determining what AC input voltage is required This is determined by the motor to be used If the motor is rated to 1HP and has 90VDC armature with either a 100VDC or permanent magnet field then 120VAC input power is required If the motor rating is to SHP and has 180VDC armature with either a 200VDC or permanent magnet field then a 240VAC input source is required Motors other than these cannot be used with these controls Refer to the motor nameplate for this information If the control is operating on 120VAC input and 0 90VDC output Connect jumper A to the E position and jumper B to the D position If the control is operating on 240VAC input and 0 180VDC outp
15. NOILO3 13S LfidNI o 4 es 21901 dOLSINNY QUYONVLS 3univiwuv YOLOW 000 097 Nd TOULNOI 160004 32018 u3MOd Figure 19 Panel Mount amp Less Operators High HP Controls with Reversing Kit 2450 1105 Il Rev A 6002 9 6 PS 31V LOM I 200L 09VC SI 0334S Lv SOF N3HM SIHL SAOWSY V SNOLLO3NNOO LV 3SH3A3H NOLLVLON 3593 39 OL NOLVIQWWOO 3HL SNIOY4 NOLLV LOH NOLO 009 TIM NMOHS SNOLLOSNNOO 01414 IYNLYWYY SON IVMIII93L Q3193NNOO 38 SHIM V LON 8300 LINN dl O d NO NOLLOSNNOO 0154 S310N3G 0 GNOHS IOH1NOO 3HL NO 104 LM39 435 SI SIHL 3INLL ANY 31ON NOLIISOd NI 1 5 SI 140 SIHL NO 104 IM3 3HL dl NOLLISOd NI 38 5 IM3 310 3H NO If SI 104 IM3 31038 V 3 2QAO8L 6206 0892 Nd 20 06 2206 0Svz Nd 18101 LINN GALNNOW SISSVHO NO NV 8101 V TVNOILdO IM 06 092 SLOVINOO XNVIM HOLOV INOO IW 6106 0892 SLOVINOO XNW M HO LOV INOO IN OVAOZL ISN 93VI015 S19V1NOO
16. NOLLdO YOLOVLNOO NO SLN3NOdWOO NOLLO3NNOO 31ON3d 5 091100 H3H13901 LSNW 281 40 S VNIWH3LL LON SI NOLOSNNOO QvOTH3 AO TIVINHSHI dl N 4313W 0334S 1006 08 2 Nid IM 8006 0572 Nd Y3dVL 3 0901 LNT IM38 SLOWSY 104 DOOM Mad 1006 09V2 Nd 9334 90r 1v 90r Sor 9 1007 0902 1108 0892 Nd sounos Ingen 2106 0882 Nd H3MOTIO4 39V L0 XVII 00 007 0L 2L0V 09V2 HOLOWLNOO N Z HL eq4 Qi PELLEM Og Le O imanoo M 93493345 2 0L er LI Y Y 21 OL 1 Qe 597 9 o 2 1206 0975 Nd 25 YaLaN 03348 9 wo 299 NIN QOL8 301V OvAOZI 9018 001 V 5VM0V2 NOLLO3 3S INdNI 39 21901 o 4 ev 09V2 Nd TOXLNOD IISNOO4 ow H3MOd R 7 NO 7440 Enclo
17. loop and an outer voltage or speed loop The current error amplifier is a proportional plus integral controller The input to this amplifier is and error current It is derived from the addition of a negative current reference from the velocity error amplifier and a positive feedback current from the current scaling amplifier This error current ramps the current error amplifier to a positive voltage When feed to the firing circuits this will enable the gated firing pulse generator at a phase angle that will provide the amount of current demanded by the velocity error amplifier The remaining input to this amplifier is a positive signal that is only present in a stop condition Its purpose is to clamp or reset the current amplifier whenever a stop command is given Then velocity error amplifier is also a proportional plus integral controller It functions in the same manner as the current error amplifier with this exception Its error current is derived from the sum of a positive reference current from the accel decel circuit and a negative feedback current from either the armature or tach generator The output of this amplifier is the negative current reference voltage There are also two additional inputs to this amplifier first one is the compensation signal This is a positive feedback signal and is derived from the current scaling amplifier Its purpose is to compensate for the IR drop in the motor This allows the
18. marked Comp and fully counterclockwise These pots serve no purpose in this mode 2 Start motor and turn the main torque potentiometer on operator control panel fully counterclockwise 3 Adjust the potentiometer on the main PC board marked MIN to a minimum torque level if desired 9 4 The CURRENT LIM adjustment on the main PC board should be set at full clockwise position It could be used to set the maximum torque current lever with the main torque potentiometer on the operator control panel turned fully clockwise This will over ride the main torque current reference potentiometer 5 The ACCEL DECEL potentiometer adjusts how quickly the motor torque level changes as the main torque potentiometer is varied After Steps A or B above are completed the potentiometer in the operator control panel may be used to adjust either 10 A Motor speed from the minimum to maximum speed setting if control is in the speed regulation mode or B Motor torque level from the minimum torque setting to the maximum torque level for the current range selected if the control has been set up as a torque control If the control has been equipped with the optional Magnetic Reversing Kit a forward reverse selector switch is supplied which changes the direction of motor rotation NOTE MOTOR MUST BE RESTARTED AFTER THE POSITION OF THE FORWARD REVERSE SWITCH IS CHANGED Flip thi
19. 0XV09 24 NO NOLLO3NNOO 16 5 1 z Men En 3H13901 38 15 ON 9 STVNIWYSL 318VTIVAV LON SI NOLIO3NNOO QVO TH3AO I WNOILdO NV 1 9 3a GINOHS NO S3HIM ZX ONY LX Lo 79 01 ZAL TVNINSEL SI HOLIMS N Freenet 3univWsv HOLOW C CV 8706 92 Nd 006 972 SISSVHO HOLOV INO 8L 291 OL OL I M 01 0 HOWL Grat m 4 0 ovora 04 999 9970 0 45 58 2550 0 9V LINT ur 5 3d 1206 0892 Nd 8313VI Sn 93395 ul 0019 3 OL V OVAOZL 9018 001v 136 SOVLIOA JOOK 3 1VVI930L YOLOW 0007 052 Nd 1OH1NOO 5 004 X 019 Figure 17 Panel Mount amp Less Operators High HP Controls 11034 with M Contactor 2450 6007 6L 31103 1900 0592 jeujsnpur 09V09 NO NOILOANNOO 15 4 SSLON30 L SNOLLO3NNOO V 3SY3N34 NOLLVLOH
20. 100 09 2 S 27 IYNLYWYY 3010 91313 YOLOW Way 23 ano Oe OL ziz8LOL o zar ommno 93345 una 1206 06 2 O 9313VI 83385 an 1M3 NIW 13 30 13 V GOL8 301 9 OL8 2 OL OvAOr NOILO3 S SOVLIOA 30 ao ow NV NO aao OV n o 4 ev 8 d 21901 dOLSINNY 09V0MVI 0972 Nd 1081M0 11 81204 Kit 2450 1004 I Rev A ing Enclosed Low HP Control with Reversi Figure 22 6002 9 LL 0 5M31VLC9 I 900L 09VC si 0334S LY N3HM Yad SIHL SAOWSY VY SNOILO3NNOO LV 3993 39 NOILY LOY 3010 3SY3N3 OL YOLYLNWWOO JHL SNIOV4 HOLOW 009 TIM NMOHS SNOILOSNNOO 07314 FUNLVWAV 6 ON OL Q3103NNOO 38 SHIM 3MOTIOJ IM3 JO 3AVH LON 9300 LINN dl 95909 0 d NO NOLLO3NNOO NOLSW4 S310N3G 8 4
21. 12 requirements but not submitted for listing LINE FREQUENCY VARIATION FIELD SUPPLY MAXIMUM ALTITUDE Without derating AMBIENT TEMPERATURE Panel Mount and Less Operators Enclosed Control SPACE REQUIREMENT FOR PANEL MOUNT CONTROL IN TOTALLY ENCLOSED NON 48 62Hz 1 Amp 3 300 ft above sea level 0 C to 55 C 32 F to 13196 0 C to 40 32 F to 1049F VENTILATED ENCLOSURE 20 x20 x8 or 24 x20 x6 AC LINE FUSES 14 2HP 15A 250V 3 5HP 40A 500V 3 8 PERFORMANCE SPECIFICATIONS SERVICE FACTOR SPEED REGULATION 1 0 maximum rating For a 95 Load Change using Armature Voltage Feedback with IR Compensation 1 of maximum speed For All Other Variables Voltage Regulated Changes up to 15 of top speed can result from temperature voltage frequency variations plus drift With AC Tachometer Feedback 1 2 of base speed due to load variations 1 of base speed due to variations in ambient conditions or line voltage With DC Tachometer Feedback 1 2 of base speed due to variations in load line voltage or ambient conditions OVERLOAD CAPACITY As a percent of maximum rating 150 for one minute EFFICIENCY Control Only Minimum Motor and Control Typical CURRENT LIMIT ACCELERATION DECELERATION TIME 98 86 0 150 2 to 30 seconds linear Actual percentages may vary depending on the type of tachometer used 3 4 OPERATOR FUNCTIONS SPEED ADJUSTME
22. 5000 PC BOARD ASSEMBLY 1 2450 4000A Shunt Resistor PC Assembly 1 2450 4010 Resistor only 005 ohm 5W R1 R2 2 0916 005 005 PANEL MOUNT CONTROL P N 2450 8010W 2HP ASSEMBLY COMPONENTS Fuse 15A 600V 1FU 2FU 2 3707 601500 Power cube 230V 1 3720 004 Potentiometer 5K 2W SPEED 1 3533 0502 Speed pot push on knob 1 3549 002 PC BOARD ASSEMBLY 2450 4000A PANEL MOUNT CONTROL P N 2450 8015W 3 5HP ASSEMBLY COMPONENTS Fuse 40A 500V 2FU 2 3701 504000 Power cube 230V 1 3720 010A Potentiometer 5K 2W SPEED 1 3533 0502 Speed pot push on knob 1 3549 002 PC BOARD ASSEMBLY 2450 4000A Shunt Resistor PC Assembly 1 2450 6010 Resistor only 005 ohm 5W 2 0916 R005 005 This board is used on all control models The part numbers on the components may differ from this parts list because ICD numbers in many cases has replaced vendor numbers MAIN PC BOARD P N 2450 4000 COMPONENTS CAPACITORS Consult factory with the value and board designation LED green DC POWER 4030 310 LED yellow CURRENT LIM 4030 410 DIODES ZENER I C S 11 2 4 4041 0358 POTENTIOMETERS HINT CURRENT UM 3545 053 MAX ACCEL DECEL 3545 254 RELAY CRR 3515 026 RESISTORS Consult factory with value and board designation TERMINAL BLOCKS 6 PIN TB1 3792 1606 13 PIN TB2 3792 1513 TRANSFORMER T1 3082 436 TRANSISTORS Q
23. DRIVEN MACHINE THEN DIRECTION OF MOTOR ROTATION SHOULD BE DETERMINED BEFORE 5 21 PRE START EQUIPMENT CHECKS Before starting the control all of the following pre start conditions must be met 1 Insure that the 74 2HP controls have been properly programmed for 120VAC or 240VAC operation as described in paragraph 4 3 1 2 Check that all the jumpers have been set correctly as in paragraph 4 3 3 Complete all the wiring procedures as described in paragraphs 4 7 4 8 and 4 9 After all of the above pre start conditions have been satisfied proceed to the start up procedure described as follows This start up procedure is equally applicable for the panel mount less operators and enclosed controls 5 2 2 OPERATION AND ADJUSTMENT 1 Turn the speed potentiometer fully counterclockwise Insure that the remote disconnect is admitting AC power to the control 2 Set the On Off switch if used to the ON position This will apply power to the control but it will not start the motor The DC POWER LED indicator light on the main control board will be off 3 For initial start up set the Run Jog switch if used to the RUN position I the process requires jog operation disconnect the motor shaft from the load 4 Set the Start Stop switch to the START position to start the motor The green DC POWER LED indicator light will illuminate CONNECTING THE MOTOR SHAFT TO THE LOAD If the drive trips off the motor will co
24. THE TORQUE SETTING MOTOR RPM COULD INCREASE TO DANGEROUS LEVELS FOR THIS REASON OVER SPEEDING IS PROTECTION AGAINST RECOMMENDED 2 IF LOAD TORQUE EXCEEDS CONTROL TORQUE SETTING MOTOR WILL STALL LEAVING MOTOR STALLED CONDITION FOR EXTENDED PERIODS CAN CAUSE MOTOR OVERHEATING AND WINDING INSULATION DAMAGE 4 3 3 ARMATURE OR TACHOMETER FEEDBACK SELECTION When the control is to be used as a speed control armature or tachometer voltage feedback is required Armature feedback is standard but if an application requires closer regulation of the motor RPM then tachometer feedback may be added to the drive This requires that an AC or DC tachometer generator be coupled to the motor shaft and the voltage produced by this generator is then used to provide voltage feedback to the control If the unit is to have armature voltage feedback when the speed control mode 1 Place JP4 in the ARM position If the unit is to have tachometer voltage feedback when in the speed control mode 1 Place JP4 in the position 2 Mount an AC or DC tachometer generator on the drive motor 3 Connect generator leads to terminals 12 and 13 of terminal strip TB2 on the main control PC board Polarity is not important this connection using two conductor No 18AWG insulated shielded cable 4 Connect shielding material to terminal 11 of terminal strip TB2 on the main control PC board Carefully tape off the shi
25. finer adjustment of the speed or torque when the unit is used as a torque control The potentiometer may also be used in conjunction with the Torque Taper Remote Current Limit Kit to provide and external current limit adjustment for the control Included are the ten turn potentiometer and a digital turns indicating knob suitable for mounting in the operator panel on the control enclosure or in a remote operator station When using this Ten Turn Potentiometer in an enclosed control the enclosure rating is NEMA 1 3 8 13 SPEED METER KITS The Speed Meter Kits provide a visual indication of DC motor speed They may be used to indicate DC Motor Speed by monitoring the output voltage of a motor mounted AC or DC tachometer generator They may also be used to indicate DC motor speed by monitoring DC motor armature voltage which is directly proportional to motor speed The Speed Meter Kits may be used with either a 90VDC 180VDC armature voltage which is directly proportional to motor speed They may also be used with any of the AC or DC tachometers listed in the price book A printed circuit board is included and mounted on the back of the meter to allow calibration of the Speed Meter for use with a wide range of inputs When used in conjunction with a motor mounted tachometer the Speed Meter Kit will provide an indication of motor speed with 2 accuracy When used with an armature voltage input the Speed Meter Kit provides motor speed i
26. is turned down but not when the start stop switch is placed it in the STOP position Current Limit Adjustment Current Limit is factory set at 10096 of the range selected by jumper JP1 Low Medium High b CURRENT LIM potentiometer should be set to limit the motor armature current to 15096 or less of the motor nameplate rating This setting should represent the lowest level consistent with satisfactory operation c Ifthe motor stalls or slows down under load check the motor armature current using a DC ammeter Stalling at less than the motor nameplate armature current rating indicates that the current limit is set too low Slowly rotate the potentiometer clockwise until the motor returns to the set speed but do not exceed the motor rated armature current m Stalling with more than the nameplate armature current flowing indicates that the motor is overloaded CAUTION THE CURRENT LIMIT MAY BE SET AS HIGH AS 150 OF THE MOTOR ARMATURE CURRENT RATING FOR A MAXIMUM OF ONE 1 MINUTE THE CURRENT SHOULD EXCEED THE MOTOR RATING ONLY DURING STARTING OR BRIEF OVERLOADS REPEATED OR EXTENDED OVERLOADS WILL DAMAGE THE CONTROL AND OR MOTOR d yellow CURRENT LIMIT LED indicator light on the main PC Board will illuminate when the armature current reaches 95 10096 of the current limit setting B ADJUSTMENT PROCEDURE FOR OPERATION IN THE TORQUE CURRENT MODE 1 Turn the potentiometers on the main PC Board
27. motor to maintain a constant speed within 1 of base speed from no load to full load The second of these inputs is the jog input This allows the drive to be stepped to jog speed 0 30 of maximum speed 6 5 FEEDBACK SCALING There are two scaling circuits one for the voltage or speed feedback and one for the current feedback The voltage scaling circuit is a passive network with three ranges high medium and low This network also filters the voltage feedback The current feedback scaling network consists of an adjustable gain inverting amplifier This circuit has three ranges The ranges mentioned above can be found in Table 2 and Table 3 of this manual 6 6 CURRENT LIMIT CIRCUIT Current limiting is achieved by limiting the current reference voltage As shown in Figure 15 the output of the velocity error amplifier is divided by the current limit potentiometer whose wiper then feeds the current error amplifier The divider ratio can be adjusted from 0 to 1 which will allow 0 to 5 6 volt maximum current reference signal A 5 6 volt value corresponds to 15096 of control normal rating 6 7 FIRING CIRCUITS The firing circuits consist of three parts 1 a timing ramp circuit 2 a comparator circuit and 3 a gated oscillator The timing ramp is produced by allowing a capacitor to charge to 10 volts in 10mSec This is reset to zero volts at every line zero crossing This ramp voltage is then compared to the output voltage o
28. operating instructions and troubleshooting procedures for this adjustable voltage DC drive It also includes a complete description of the control with detailed product specifications and a complete description of all customer selectable functions and customer installable option kits For most drive applications the information contained in this instruction manual will completely describe all drive system set up and operating procedures It should also provide all the information required by the customer to install and maintain the control In a few applications additional drive system set up and operating information may be required This information will generally be furnished in the form of system schematic and system interconnection diagrams An overall Systems Installation Manual may also be furnished This instruction manual should be read in its entirety before beginning installation and before performing any start up or maintenance on the drive system NOTE THE INFORMATION IN THIS MANUAL APPLIES TO THE ENCLOSED LESS OPERATORS AND PANEL MOUNT CONTROLS EXCEPT WHERE SPECIFICALLY STATED OTHERWISE Changing the potentiometer setting reference results in a motor speed change torque regulated applications the DC output current varies as a function of an input reference voltage Changing the torque reference changes the current supplied to the motor and results in a change in motor torque output The control is designed t
29. tachometer input and with JP3 in the current mode the outer speed loop is made inactive The output is controlled by the inner current loop using what was the speed pot as an adjustable current reference pot 4 4 DETERMINING THE CONTROL LOCATION The control is suitable for most well ventilated factory areas where industrial equipment is installed Locations subject to Steam vapors 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 to the enclosure The location should be dry and the ambient temperature should not exceed 55 C for panel mount and less operators controls or 40 C for enclosed controls If the mounting location is subject to vibration the unit should be shock mounted If the enclosure is force ventilated avoid wherever possible and environment having a high foreign matter content as this requires frequent filter changes or the installation of micron filters Should the control enclosure require cleaning on the inside a low pressure 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 5 INSTALLING PANEL MOUNT AND LESS OPERATORS CONTROLS The panel mount control is suitable for mounting in a user s enclosure where internal temperature wi
30. 2 180 37 200 1 A C B C LO HI SPD ARM 77 1 180 55 200 1 A C B C LO HI SPD ARM bos 105 15 180 75 200 1 A C B C MED HI SPD ARM n 44 2 180 10 200 1 A C B C HI HI SPD ARM 21 3 180 15 200 1 A C BC LO HI SPD ARM 35 5 180 25 200 1 A C B C HI HI SPD ARM These are typical motor current ratings See motor nameplate for exact current ratings The input voltage and current amps values are approximate Actual values may vary depending on input voltage input line impedance and actual motor efficiency JP1 sets the following current limit levels that are adjustable from 0 to 10096 in the torque mode 74 2 HP 3 5 LO 6 0 Amps 15 Amps MED 8 2 Amps 18 6 Amps HI 10 8 Amps 25 Amps If using a tachometer generator for voltage feedback A Place JP4 in the TACH position Select proper position for JP2 by determining maximum tach generator voltage at maximum speed Select appropriate range allowing sufficient range above and below for calibration by adjustment of the B maximum speed pot LO 54V to 126V MED 100V to 172V HI 162V to 234V For example Using a 50V 100RPM tach Base Base 1000 X Tach V Max Tach Volt Use 1750 1 75 50 87 5V LO 2500 2 5 50 125 MED 3000 3 0 50 150V MED Table 3 Jumper Programming for Torque Regulated Operation AC INPUT DCARMATURE DCFIELD T
31. 3H 7 SNOLLO3NNOO LV 3SU3A3U NOLLV LOS HOLOIN 3SH3A3H OL WO9 NOLLV LOS YOLOW NMOHS SNOLLO3NNOO 07314 ANY 3301 VIAHV TVNINY3L OLO3193NNOO 38 38IM SNOLLdO H3MOTIOd UNI HO 39V1 OA SHL 3AVH LON 5308 LINN 3l MO ATINA Q1n0HS 10H 1NOO 3HL NO 104 SI NOILdO 3WILANV LVHL ILON NOILISOd NI LL 1 SI 09V09 M0I1 0 SIHL 104 UWIT IM39 4 NOILISOd NI Gaovid 09V09 IM3 SLOINSH 3H NO If GASN SI LOd IM3 34033 V 31 LINN GALNNOW SISSVHO 1VNOlLdO M3H13901 LSNW 291 40 STYVNINY3L LON SI NOILO3NNOO TWWYSHL HO LOW V NO NOLLO3NNOO NO4S V4 1 39 1VVIMV 910018 8006 0992 Nd 1006 0972 Nd 30001 Q33ds 1v N SLOWSY WHY 2QAO81 6206 0892 Nd 6 2206 0572 Nd LV L91 OL IW _ 939VL ane 9 100 200 0802 8913VI 9334 0 010 var 3OVLIOA 0 93395 93345 ul NIA XVII 0019 30LV 3 OL 8 9 O
32. 5 3970 001 QVR1 4071 2515 SECTION 9 SUPPLEMENTARY TECHNICAL INFORMATION Table 5 Control Standard Connection Scheme Terminal Blocks TB1 and TB2 Terminal blocks TB1 and TB2 are installed on the main PC board 2450 4000 This board is used on all six control models TB1 F1 F2 Shunt field connections 1 2 DC Motor connections for 1 4 2HP controls only Do not wire directly to 1 1 and A2 with 3 5HP controls X1 X2 For M Contactor and Reversing Kit installations on 3 5 HP controls TB2 1 2 N C Motor thermal contact if required If contact is not used terminals 1 and 2 must be jumpered together 2 5 N C Stop contact 3 4 7 Run Jog switch contacts on Enclosed controls On Less Operators and Panel Mount models terminals 3 and 4 become the Run Jog contact if used or they are jumpered and become with terminal 5 the N O Start contact if a Run Jog switch is not used and terminal 7 is not used 6 Tied to N C contact of CRR relay 8 CW side of speed potentiometer 9 Wiper contact of speed potentiometer 10 CCW side of speed potentiometer MIN Speed 11 Shield connection for speed pot wiring 12 13 AC DC Tachometer connections Table 6 Customer Jumper Programming Chart filled out by customer JUMPER GROUP POSITION AT START UP JA JB JP1 JP2 JP3 ALL DIMENSIONS ARE IN INCHES 9 OUTLINE AND MOUNTI
33. 885 1N34H00 boo C 48 FOESEG NIW 13030 1300V 1206 0572 Nd 9334 GOL8 30LV OVAOZL 9018 001 OvAOrz NOWOaTaS ICH BEZ QOO 9 2 od ea 2501 dOLS NNY Quvauvis o e Q V000V 0552 Nd QMVOS 1081409 II 50204 Figure 12 Connection Diagram for Low HP Panel Mount amp Less Operators Controls 2450 1100 I Rev A 201 6007 6 9 1 14011 0892 SNOLLO3NNOO 39593 39 M0IIVI09 YOLON viv 3SH3A3MH OL BOLVLNWWOO 3H L ONIOV3 uy 2206 09X2 Na NOILVLOY HOLOW TIIM NMOHS SNOLLO3NNOO 01314 3UNLVWAV 4 24 NO SNOLLO3NNOO NOLSV4 S310N3G E 939413901 39 LSNW ONY VON MMIVI931 318V TIVAV LON SI NOILO3 LOHd QVOTH3AO TVWUFHL YOLOW 41 281 CMV 2 281 H3dlWnr SI 5 3l 4 4 elzal OL 01 BOVIIONCT INAWINDOTO TEN m Oe soviton caw 6 NaN aan 939 HOWL yaa wav o o 03345 39V L10 IH IH 3 1206 6972 Nd LIM 9319VI 03395 104
34. Blue cover only 2450 5001 Label for cover 2450 5007 Cover gasket 2450 5019 Fuse 40A 500V 1FU 2FU 3701 504000 Power cube 230V 3720 010A FACEPLATE ASSEMBLY Switch toggle ON OFF 3550 006 Switch toggle RUN JOG 3550 003 Switch toggle START STOP 3550 005 Potentiometer 5K 2W SPEED 3533 0502 Speed pot push on knob 3549 002 Switch boot 3555 001 Seal pot shaft 3555 002 MOLDED LOWER BACK CHASSIS Blue molded chassis 2450 5000 PC BOARD ASSEMBLY 2450 4000 Shunt Resistor Board 2450 4010 Resistor only 005 ohm 5W R1 R2 0916 R005 005 LESS OPERATORS CONTROL P N 2450 8002W 2HP ASSEMBLY COMPONENTS MOLDED UPPER FRONT CHASSIS Blue cover only 2450 5005 Label for cover 2450 5017 Cover gasket 2450 5019 Fuse 15a 250V 1FU 2FU 3705 032 Power cube 230V 3720 004 Potentiometer 5K 2W SPEED 3533 0502 Speed pot push on knob 3549 002 MOLDED LOWER BACK CHASSIS Blue molded chassis 2450 5000 PC BOARD ASSEMBLY 2450 4000A LESS OPERATORS CONTROL P N 2450 8003W 3 5HP ASSEMBLY COMPONENTS MOLDED UPPER FRONT CHASSIS Blue cover only 1 2450 5005 Label for cover 1 2450 5018 Cover gasket 1 2450 5019 Fuse 40a 500v 1FU 2FU 2 3701 504000 Power cube 230V 1 3720 010a Potentiometer 5K 2W SPEED 1 3533 0502 Speed pot push on knob 1 3549 002 MOLDED LOWER BACK CHASSIS Blue molded chassis 1 2450
35. ECEIVING AND STORAGE Please record information below before installing the unit and use these numbers when communicating with the factory CUSTOMER JOB NO HORSEPOWER RATING VOLTAGE MODIFICATIONS TABLE OF CONTENTS SECTION ua CC 9 X C 5 1 1 GENERAL SAFETY PRECAUTIONS 1 2 INSTALLATION SAFETY 1 3 Start up Safety SECTION 2 GENERAL INFORMATION 2 1 INTRODUCTION 22 GENERAL DESCRIPTION 2 3 TYPICAL PACKAGING 24 EQUIPMENT IDENTIFICATION SECTION 3 CONTROL SPECIFICATIONS AND FEATURES 3 1 EQUIPMENT RATINGS 32 SERVICE CONDITIONS 3 3 PERFORMANCE SPECIFICATIONS 34 OPERATOR FUNCTIONS 3 5 POTENTIOMETER ADJUSTMENTS 3 6 CUSTOMER PROGRAMMABLE SELECTIONS JUMPERS 3 7 STANDARD FEATURES sse een 3 8 PRE ENGINEERED MODIFICATION KITS SECTION INSTALLATION 4 1 SAFETY WARNINGS 4 2 INITIAL CHECKS 4 3 CONTROL JUMPER PROGRAMMING 44 4 5 4 6 INSTALLING ENCLOSED CONTROLS 4 7 POWER
36. INSTALLATION OPERATION MAINTENANCE MELLTRONICS DRIVES FOCUS 2 SINGLE PHASE CONTROL FOR DC MOTORS 5 Melltronics i Industrial Inc 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 OVERLOAD PROTECTION Overload protection must be provided per national electric code article 430 Section C INITIAL CHECKS Before installing the drive control check the unit for physical damage sustained during shipment Remove all shipping restraints and padding Shortage or damage should be reported promptly to CARRIER and your
37. LLO3NNOO NOLSV4 S3LON3Q 4 8006 0572 Nd 1006 0972 Nd 2106 0892 Nd 1106 0692 93 9V1I 3nOHOL 9334 90 1v 90r IM 83401103 39V L10 93M01104 IM3 ILONGA 3ounos 434 0L 4 104 9 6206 0572 Nd 0006 2206 0572 Nd OL Wiel OL 4 3ONVH 6 2109 06 2 300401 100 0972 4 9 o e Way Add 4 ommno 93393548 od 1206 06 2 Nd O 4313W 0334S do 9334 aaaas cioa NIA XVW o ao a 301 v ovaoz 9 OL8 0 OL V OvAOvZ NOILO3 3S 39VL10A LNANI 30 046 o 4 ev 91901 JOLSINNY 09V0MVI 000 0572 Nd 9508 1O31NOO I 60204 z 440 W3MOd OV Figure 14 Connection Diagram for Low HP Enclosed Controls 2450 1000 Rev 60021119 1001 0892 jeujsnpuy SI M0I1 0 oor LY N3HM SIHL 3AOW
38. LY 9VM0V2 NOILO3 13S BOVLIOA 10 30 o es o ev ao 0009 0892 Nd OH1NOO I 04 NO 440 83M0 OY 334 sor 9 zar inaano aan o Le 938800 04 934 03385 3 WIL 1aosaniaoov 0L 21060882 Nd 1106 0992 Nd LIM H3MOTIOJ 39v L10 H3MOTIOJ IM3 6966 104 SOLON V oL 101 1IX9313VI 9934 L206 09V7 Nd 91907 dOLSINNY 09V0MVI 8 Figure 15 Connection Diagram for High HP Enclosed Controls 2450 1001 Rev 6007 LL 9 05 3IV1CV 2011 0892 SNOLLO3NNOO LV 3SH3A3H NOLLVLOH YOLOW 3S43A3MH OL YOLVLNWWOO SNIOV4 NOLLVLOY HOLOIN TIM NMOHS SNOLLO3NNOO 971313 ONY 3S0 VIV 2 NO NOLLO3NNOO 15 D 2 4 WHY 6206 0572 Nd TWNOILdO LIM v106 09Hz WHY 2206 0892 Nd 810 1 XNV M HOLOV INOO W OVA 092 2 181 OL 6106 0672 IV 91 0L SLOVLNOO XNVIM HOLOVINOO N OVA 021 ISN YAWOLSND 904 S19V1NOO 9 HOIOVINOO N NO SLN3NOdIIOO NOLL 3H13901 38 15 281 VW 2 4 O3NNOO
39. NG DIMENSION DATA ENCLOSED CONTROL 13 812 FWD START REV STOP 272 DIA 2 PLACE 8 630 Me 2 gt 4 1 25 3 PLACES OUTLINE AND MOUNTING DIMENSION DATA LESS OPERATORS CONTROL 14250 2 PLACE 1 25 TYP 3 PLACES Figure 10 Outline and Mounting Dimensions for Enclosed Controls ALL DIMENSIONS ARE IN INCHES UNIT H WITH OPTION COVER 4 OUTLINE AND MOUNTING DIMENSIONS DATA PANEL MOUNT CONTROL Figure 11 Outline and Mounting Dimensions for Panel Mount Control 6206 05 2 Nd 6002 6 9 Wav 2206 09V2 Nd 93LVL0V OL OL SNOLLO3NNOO LV 3999 59 NOILYLOY 3010 OL YOLVLAWWOD JHL ONIOWS 96 HOLOW NMOHS SNOILO3NNOO 11314 CMV SYN LV O d NO SNOLLO3NNOO 15 S310N3d ta H313N 0334S YSHLS9O1 38 LSNW ANY VON SIVNINY3L 319V IIV MV ALON SI NOLLO31OSd QVOTH3AO TVIAHSH E HO LOW oL 7 91 6 281 H3dWnr z zaL OL SAOWSY SI HOLIMS 31 39VI10 01 1M8 07 HOWL 247 Ozar 939 647 4 4 iN3su00 034 o4 e 4 e 03
40. NT POWER ON OFF Enclosed Less Operators Panel Mount START STOP RUN JOG Enclosed Less Operators Panel Mount FORWARD REVERSE AUTO MANUAL Standard Standard Optional Customer supplied Standard Customer supplied Customer supplied Optional 3 5 ADJUSTMENTS The standard control includes five 5 customer adjustable potentiometers which are located on the main PC board These potentiometers have been preset However for proper operation in some applications minor readjustments may be necessary during drive installation and startup MAXIMUM SPEED 70 to 120 of rated speed MINIMUM SPEED 0 to 3096 of maximum speed IR COMPENSATION 0 to 2096 of rated voltage at rated current CURRENT LIMIT 0 to 150 of selected rating ACCELERATION DECELERATION 2 to 30 seconds linear 3 6 CUSTOMER PROGRAMMABLE SELECTIONS JUMPERS MODE OF CONTROL Speed or torque Regulation 120 or 240 1 4 2HP controls only FEEDBACK METHOD Armature or tachometer feedback VOLTAGE FEEDBACK LEVEL High Med Low CURRENT FEEDBACK LEVEL High Med Low 3 7 STANDARD FEATURES Control relay providing momentary Start Stop operation Control cannot restart without pushing Start button if AC power is momentarily disconnected and restored Both lines fused for maximum semiconductor protection in case of short circuit Designed for use with 50 or 60 Hz AC power LED light emitting diode i
41. NTROL FAILURE After connecting the motor to the control and grounding the following readings across terminals A1 and A2 or and for 30 HP panel mount controls F1 F2 and GND should be verified The reading connections for terminals A1 and A2 or A and A must be made where the actual DC motor connection is made as described in Output Power Connections Terminals F1 and F2 are located on TB1 on the main PC board The GND terminal is located as described earlier in this paragraph Perform these checks before connecting the AC power input In making the readings listed in the following table use volt ohm millimeter WARNING DO NOT USE A VACUUM TUBE VOLTMETER OR OTHER SIMILAR TYPE OF METER THAT REQUIRES AC POWER FOR OPERATION Using red as the positive lead make the following checks Checks Range of Acceptable Red Black Readings A2 or A A1 or A 1 4 ohms F2 F1 100 400 ohms ___ 2 Infinite Provided motor has wound field If any of the above checks are not within the indicated range verify all connections and recheck As a recommended safety practice use and isolated transformer to reduce the possibilities of ground paths 4 7 4 OUTPUT POWER CONNECTION The DC motor connects to terminals A1 and A2 of TB1 for all 74 2 HP controls The motor connects to terminals A1 and A2 of the shunt resistor PC board P N 2450 4010 for 3 5 HP enclosed and less op
42. NTROL SPECIFICATIONS AND FEATURES 3 1 EQUIPMENT RATINGS The 2 enclosed less operators and panel mount controls can be programmed for 120 VAC input 1 2 1HP or 240VAC input 1 2 2HP The 3 5HP enclosed less operators and panel mount controls can be programmed only for a 240VAC input Table 1 summarizes the horsepower outputs available in each programming mode Table 1 Control Rating Table AC Input HP DC Armature DC Field Output Output Volts Amps Volts Amps Volts Amps 120 3 6 90 2 6 100 1 VAC 52 90 3 7 100 1 18 77 90 5 5 100 1 50 60 10 5 90 7 5 100 1 HZ 14 1 90 10 100 1 240 3 6 180 2 6 200 1 VAC 52 Ya 180 3 7 200 1 19 77 1 180 5 5 200 1 50 60 10 5 1 1 2 180 7 5 200 1 HZ 14 2 180 10 200 1 21 3 180 15 200 1 35 5 180 25 200 1 These are typical motor current ratings See motor nameplate for exact current ratings The input voltage and current amp values are approximate Actual values may vary depending on input voltage input line impedance and actual motor efficiency 3 2 SERVICE CONDITIONS ENCLOSURE Chassis panel mount Open enclosure less operators with NEMA 4 12 Option NEMA 4 12 enclosed HORSEPOWER RATINGS Input power 120VAC 1 phase 50 60Hz 240VAC 1 phase 50 60Hz 2 Re connectable dual voltage 240VAC 1 phase 50 60Hz LINE VOLTAGE VARIATION 10 3 5HP single voltage Designed to meet NEMA 4 and
43. ORQUE CONTROL OUTPUT OUT JUMPER PROGRAMMING E TRANSFORMER du EN a a a a a zc 6 PROGRAMMING 6 a amp a gt s lt JUMPERS 36 7 90 26 10 1 AE B D LO LO CURR TACH 52 90 37 100 1 A E B D LO LO CURR TACH 52 77 90 55 100 1 A E B D LO LO CURR TACH 50 60 1 uz 105 90 75 100 1 A E B D MED LO CURR TACH 44 4 90 10 100 1 A E B D HI LO CURR TACH 36 7 180 26 2001 1 AC B C LO LO CURR TACH 52 180 37 200 1 A C B C LO LO CURR TACH 77 1 180 55 200 1 A C B C LO LO CURR TACH 105 15 180 75 2001 1 A C B C MED LO CURR TACH 50 60 d 44 2 180 10 200 1 B C HI LO CURR TACH 21 3 180 15 200 1 LO LO CURR TACH 35 5 180 25 200 1 B C HI LO CURR TACH js 2 3 These are typical motor current ratings See motor nameplate for exact current ratings The input voltage and current amps values are approximate Actual values may vary depending on input voltage input line impedance and actual motor efficiency JP1 sets the following current limit levels that are adjustable from 0 to 100 in the torque mode LO MED HI 6 0 Amps 8 0 Amps 10 7 Amps Do not use a tachometer generator when in the torque regulation mode By putting the control in the TACH feedback setting without a
44. SANI 091100 30 STVNIWYAL 319V TIVAV LON SI NOLLO3NNOO QVOTH3AO IVVI95LILL HOLOM 281 016 281 IVMIVI931 SAOWSY SI HOLIMS 41 N 8706 09V2 Nd 1006 09V2 Nd SISSVHO 9 HOLOVINOO 2 v L OL 2L 291 OL Figure 16 Panel Mount and Less Operators Low HP Controls with M Contactor 2450 1102 Rev A O10 Od lt 044 aan 04 e 935 5800 045948 Yaad way 9334 Ta BOVLIOAIH 9 e Sand do 6 1206 0892 Nd 1IX93L9VI hisis e Yl 104 09395 03385 03995 MI IM9 NIW as OK mais GO ODO 0019 30LV 0018 001 V OVAOvZ o 04 o 4 ev o 000 097 Nd 8 1OHLNOO 15003 ov 32018 U3MOd PS amp 31VLOH 16011 0892 6007 7 6 SNOLLO3NNOO LV 3SY3N3Y NOLLVLOS YOLOW 3593 39 OL HOLVLOWAOO JHL ONIOV4 NOLLVLON MOO TIM NMOHS SNOLLO3NNOO SARGON 6206
45. WIRING 4 8 PANEL MOUNT AND LESS OPERATORS CONTROL LOGIC AND SIGNAL WIRING 4 9 ENCLOSED CONTROL LOGIC AND SIGNAL WIRING 4 10 INSTALLING MODIFICATIONS SECTION 5 OPERATION AND START UP PROCEDURE 5 1 INTRODUCTION vic ecco eerte eee 22 5 2 START UP PROCEDURE 22 SECTION 6 FUNCTIONAL DESCRIPTION 25 6 1 POWER BRIDGE AND FIELD SUPPLY 25 6 2 RUN JOG AND START STOP LOGIC 6 3 ACCEL DECEL CIRCUIT 26 6 4 REGULATING CIRCUITRY 26 6 5 FEEDBACK SCALING 26 6 6 CURRENT LIMIT CIRCUIT 26 6 7 FIRING CIRCUITS 27 6 8 POWER SUPPLIES 6 9 INDICATORS SECTION 7 MAINTENANCE AND TROUBLESHOOTING nuunseusannnnunuunsunsunzunnannnnunnunzunnnnunnunnunzunnunnnnnnnunnunnunnnnunnunnannannne 29 7 1 IMPORTANT SAFEGUARDS 7 2 ROUTINE MAINTENANCE 7 3 TROUBLESHOOTING OVERVIEW 7 4 BASIC TROUBLESHOOTING SECTION 8 ORDERING SPARE PARTS SECTION 9 SUPPLEMENTARY TECHNICAL INFORMATION usuesuenssnsonsansanunnunsansnnunnunnunsunzunnannnnunnunzunsnnunnunnunnunsunnnnun 37 SECTION 10 Lruurgag aE aies 55 LIST OF TABLES Table 1 Control Rating Table na thier i ipa Ht hee doa te tob deb dd 9 Table 2 Jumper Programming for Speed Regulated 16 Table 3 Jumper Programming for Torque Regulated Operation 17
46. YELLOW CURRENT LIMIT LED LIGHTS ON THE MAIN PC BOARD OF A 3 5 HP CONTROL The A1 and A2 motor leads have been wired directly to TB1 A1 and A2 on the main PC board remove these connections and re wire as described in Paragraph 4 7 4 7411 SPEED CONTROL Defective rectifier cube replace as required Defective component on main PC board replace as required Incorrectly wired or defective speed potentiometer check the wiring procedure as described in SECTION 4 and SECTION 9 of this manual or replace as required Incorrect jumper programming check procedure described in Paragraph 4 3 If the control after rechecking all the wiring for proper and secure connections is still inoperative make the following voltage checks Double check to make sure that armature leads A1 and A2 are not grounded UNSTABLE OR Table 4 Voltage Check Chart STEP FUNCTION NORMAL VOLTAGE TERMINAL OR PROBABLE CAUSE READING POINT 1 Voltage to 120VAC 240VAC AC1 AC2 Defective switch or loose or broken with on off Rectifiers 10 10 On power cube wire to or from switch Switch 2 Speed 0 to 10 Oto 10 9 11 Defective speed adjustment Reference VDC VDC potentiometer or circuit board assembly 3 Field Supply 100 200 F1 Defective field diodes defective VDC VDC F2 encapsulated bridge rectifier assembly 4 Armature 0 90 0 180 A1 Defective encapsulated bridge Voltage VDC VDC A2 rectifier assembly or circuit board assem
47. a guide in connecting these kits to the control Refer to paragraph 3 8 for a listing of the modification kits SECTION 5 OPERATION AND START UP PROCEDURE 5 1 INTRODUCTION This section describes the start up procedure for the control and the adjustment of potentiometers that may be necessary for the application Read this section thoroughly to develop an understanding of the operation and logic incorporated into the control 52 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 Contact the factory to make arrangements CAUTION THE FOLLOWING START UP INSTRUCTIONS ARE INTENDED ONLY AS A GUIDE AND SHOULD BE CLEARLY UNDERSTOOD BY THE RESPONSIBLE INSTALLATION PERSONNEL BEFORE PROCEEDING NOTE ON THE ENCLOSURE MOUNT CONTROLS THE PROVIDED START STOP SWITCH WILL SPRING BACK TO A MIDDLE POSITION AFTER IT HAS BEEN PLACED IN THE START POSITION AND RELEASED THIS SWITCH MUST BE MOMENTARILY HELD IN THE START POSITION TO START THE MOTOR Adjust the speed potentiometer slowly clockwise until rotation begins If the motor rotates in the wrong direction simply place the Start Stop switch in the OFF position lock out power at the remote disconnect and exchange the A1 and A2 output leads to the motor On shunt wound motors exchange the shunt field F1 and F2 leads CAUTION IF BACKWARD ROTATION OF THE MOTOR COULD DAMAGE THE
48. actor mounted on a printed circuit board See Figure 4 It provides a positive disconnect of the motor armature when the control is stopped preventing motor turnover in case the SCRs should false fire addition and auxiliary form C contact rated for 1 amp at 120VAC is included for customer use when needed Note that this kit may be required by local and or national electrical codes The option mounting panel is needed with panel mount controls 3 8 2 JOG AT JOG SPEED KIT This kit provides a separate internal potentiometer for controlling the motor speed when operating in the jog mode See Figure 4 The kit automatically switches speed control from the normal run speed potentiometer to the jog speed potentiometer when the control switches to the jog mode The jog speed is adjustable from 0 to 30 of the control maximum speed setting 3 8 3 MAGNETIC REVERSING KIT This kit provides full armature reversing using a forward and a reverse contactor mounted on a printed circuit board with an anti plugging circuit See Figure 4 A forward reverse toggle switch is included to select the direction of motor rotation The electrical code requirements for an M contactor are also satisfied since the forward and reverse contactors disconnect the motor armature from the control when the motor is stopped An auxiliary form C contact rated for 1 amp at 120VAC is included on the printed circuit board for customer use when needed The option mountin
49. anel Mount 39 Connection Diagram for Low HP Panel Mount amp Less Operators Controls 2450 1100 1 Rev A 40 Connection Diagram for High HP Panel Mount amp Less Operators Controls 2450 1101 I Rev A 41 Connection Diagram for Low HP Enclosed Controls 2450 1000 Rev 42 Connection Diagram for High HP Enclosed Controls 2450 1001 Rev 43 Panel Mount and Less Operators Low HP Controls with M Contactor 2450 1102 Rev A 44 Panel Mount amp Less Operators High HP Controls with M Contactor 2450 1103 I Rev A Panel Mount amp Less Operators Low HP Controls with Reversing 2450 1104 1 46 Panel Mount amp Less Operators High HP Controls with Reversing Kit 2450 1105 I Rev A 47 Enclosed Low HP Control with M Contactor 2450 1002 Rev 08 48 Enclosed High HP Control with Contactor 2450 1003 Rev A nene 49 Enclosed Low HP Control with Reversing Kit 2450 1004 Rev nennen 50 Enclosed High HP Control with Reversing Kit 2450 1005 l Rev 51 Schematic Diagram Main PC Board 2450 1000 52 Shunt Resistor Board for High HP Enclosed 4 Less Operators Con
50. ast to a stop or fail to start A drive trip off is usually caused by incorrect wiring It also can be caused by either 1 a faulty motor or 2 a malfunctioning drive Proceed to Basic Troubleshooting paragraph 7 4 5 With the motor rotating adjust the operator speed potentiometer up and down Changing the potentiometer setting reference results in a motor RPM change when operating the RUN or JOG mode Check that the motor follows this speed reference When the unit is used as a torque control the potentiometer sets the motor torque level and the motor accelerates or decelerates until the load torque equals the torque setting 6 At this point place the Run Jog switch in the JOG position if jog operation is desired Connect the motor shaft to the load In this position the motor operates only when the Start Stop Switch is held in the START position T The control can be stopped in one of two 2 ways as follows a A coast stop is initiated by either placing the Start Stop switch in the STOP position or by removing the AC power at the local On Off switch or at the remote disconnect Once AC power is removed and then restored the Start Stop switch must be momentarily set to the START position to restart the motor b Afaster coast stop can be accomplished by installing the Dynamic Braking Kit The M Contactor Kit or Magnetic Reversing Kit is required in this application Refer to Figure 16 and Figure 23 and the i
51. ate from typical AC power lines The line should be monitored with an oscilloscope to insure that transients do not exceed limitations as listed below 1 Repetitive line spikes of less than 10 microseconds must not exceed the following magnitude 120 Volt Programming 200V Peak 240 Volt Programming 400V Peak 2 transients must not exceed 25 seconds of energy Transients of excessive magnitude or time duration damage dv dt networks or surge suppressors 3 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 The control is designed to accept signal phase AC line voltage See Table 1 for drive input and output ratings When using single phase power connect the incoming lines to terminals L1 andL2 On enclosed and less operators controls L1 and L2 are located in the bottom base half of the enclosure in the upper right hand corner On panel mount controls L1 and L2 are in the lower right hand corner of the chassis Either incoming line can be connected to either of the L1 and L2 terminals WARNING CONNECTING THE INPUT AC POWER LEADS TO ANY TERMINALS OTHER THAN L1 AND L2 WILL CAUSE AN IMMEDIATE FAILURE OF THE CONTROL CAUTION THE VOLTAGE OF THE INCOMING LINE TO THE CONTROL MUST BE 240
52. bly Depends on the setting of the speed adjustment knob SECTION 8 ORDERING SPARE PARTS Spare parts kit numbers 2400 9901 2450 9901 and 2450 9902 provide for most customers all the spare parts ever required These kits contain the following components COMPONENT DESIGNATION QUANTITY PART NUMBER Kit 2450 9901 for 2HP Panel Mount Controls Power Cube 230V 1 3720 004 Fuse 15A 1FU 2FU 6 3707 601500 Kit 2450 9902 for all 3 5HP Controls Power Cube 230V 1 3720 010A Fuse 40A 500V 1FU 2FU 6 3707 504000 If a more sophisticated level of troubleshooting is required see the following listed part numbers for reference ENCLOSED CONTROL P N 2450 8000W 1 4 2HP ASSEMBLY COMPONENTS MOLDED UPPER FRONT CHASSIS Blue cover only 1 2450 5001 Label for cover 1 2450 5004 Cover gasket 1 2450 5019 Fuse 15A 250V 1FR 2FU 2 37050 032 Power cube 230V 1 3720 004 FACEPLATE ASSEMBLY Switch toggle ON OFF 1 3550 004 Switch toggle RUN JOG 1 3550 003 Switch toggle START STOP 1 3550 005 Potentiometer 5K 2W SPEED 1 3533 0502 Speed pot push on knob 1 3549 002 Switch boot 3 3555 001 Seal pot shaft 1 3555 002 MOLDED LOWER BACK CHASSIS Blue molded chassis 1 2450 5000 PC BOARD ASSEMBLY 1 2450 4000A ENCLOSED CONTROL P N 2450 3001W 3 5HP ASSEMBLY COMPONENTS MOLDED UPPER FRONT CHASSIS
53. brushes in motor determine cause and correct 7 4 3 FUSES BLOW WHEN SPEED POTENTIOMETER IS ADVANCED FROM ZERO A Motor is overloaded reduce load as required B Motor is defective consult motor instruction manual and repair or replace motor as required C Current limit adjustment is set too high readjust as described in Paragraph 5 2 2 744 ACCEL DECEL RAMP IS MUCH LONGER THAN EXPECTED A Motor overloaded overhauling reduce load or apply optional braking kit 7 4 55 MOTOR DOES NOT REACH FULL SPEED Motor is overloaded correct overload condition Maximum Speed potentiometer MAX is set too low adjust MAX potentiometer clockwise Low AC line voltage more than 1096 below nominal check AC line voltage and correct Current limit set too low readjust as described in Paragraph 5 22 Incorrect jumper programming follow programming procedure described in Paragraph 13 Defective rectifier cube replace as required Motor brushes worn replace as specified in motor instruction manual 746 MOTOR RUNS IN WRONG DIRECTION The A1 and A2 output leads to the motor are incorrectly wired exchange these leads On shunt wound motors only the shunt field F1 and F2 leads are incorrectly wired exchange these leads The Forward Reverse switch if used is in the wrong position change this position 747 MOTOR DOES NOT MAINTAIN SPEED UNDER LOAD IR COMP potentiometer is set to
54. distributor 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 to the enclosure The location should be dry and the ambient temperature should not exceed 104 F 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 USING THIS INSTRUCTION BOOKLET Whenever equipment modifications are not involved the information contained in this instruction booklet describes drive System setup and operating procedures of most drive applications This manual should be provide to end user as it also provides the information required by the customer to install and maintain the equipment FOCUS 2 DRIVE R
55. e and other local codes for specific equipment grounding requirements Protective guards must be installed around all exposed rotating parts THIS CAN CAUTION DRILLING PUNCHING CAN CREATE LOOSE METAL CHIPS THIS CAN RESULT IN SHORTS OR GROUNDS THAT CAN DAMAGE THE EQUIPMENT If it is necessary to drill or punch holes in the equipment enclosures of conduit entry be sure that the metal chips do not enter the circuits Circuits shown on the drawings that require shielded cable are sensitive to pick up from other electrical circuits Examples include wiring from the tachometer and from the speed setting device Erratic or improper operation of the equipment is likely if the following precautions are not observed Where shielded cable is required use 2 or 3 conductor twisted and shielded cable with the shield either connected as shown in the drawings or floating if so specified If the shield is to be connected do so only at the specified terminal in the drive unit Do not connect at a remote location Shielded cables outside the drive enclosure should be run in separate steel conduit and should not be mixed in with other circuits that are not wired with shielded cable Inside the drive equipment whenever possible avoid running the shielded cable close to other circuits Avoid long parallel runs to other non shielded circuits and cross other cable bundles at right angles Do not connect any external circuits to the dri
56. ed such as in enclosed controls Figure 8 shows the logic required to provide these functions The run sequence is as follows A Switch Start Stop switch to START momentarily B CCR picks up and is sealed in through its normally open contacts C The accel decel circuit the regulator circuitry and the speed pot reference supply are released When the stop PB is depressed CRR is dropped out and all items mentioned in C above are clamped When jog at run speed is selected the Start Stop switch initiates the same sequence as detailed above A B amp C with the exception that CRR does not seal in and thus drops out when the Start Stop switch is released 6 3 ACCEL DECEL CIRCUIT The accel decel circuit accepts 0 to 10 volt 1mA maximum signal from either an isolated external voltage source or an internal 10 volt zener regulated supply with operator s speed potentiometer connected as shown in Figure 15 This circuit is non inverting and has a single linear accel decel time adjustment from 2 to 30 seconds The output is then used as a reference to the control s velocity error amplifier clamp circuit is provided to clamp the output to zero whenever the drive is not in the run mode Also note that the 10 volt speed potentiometer supply is only present in the run mode 6 4 REGULATING CIRCUITRY Throughout this paragraph refer to Figure 9 The multi loop regulator circuitry consists of an inner current
57. eld at tachometer generator with electrical tape so that it is well insulated CAUTION MAKE NO OTHER CONNECTIONS TO THE SHIELDING If the unit is used as torque current control voltage feedback is not required and the voltage feedback circuit must be disabled This is done by setting jumper JP4 to the TACH position with no tachometer generator connected to the control This causes the outer speed loop to be made inactive and the output is controlled by the inner current loop using what was the speed pot as an adjustable current reference pot 4 3 4 VOLTAGE FEEDBACK LEVEL SELECTION The voltage feedback circuit in the control must be capable of accepting different levels of voltage feedback since the voltage feedback may come from a 90VDC armature a 180VDC armature or a tachometer generator This circuit is switched to accept different voltage levels by jumper JP2 armature voltage feedback is used If armature voltage feedback is used Set JP2 to the LO position for use with a 90VDC armature Set JP2 to the position for use with a 180VDC armature See the motor nameplate for armature voltage rating If using a tachometer generator for the voltage feedback the setting of jumper JP2 depends on the voltage output from the tachometer generator with the motor rotating at its base speed TACHOMETER GENERATOR VOLTAGE AT BASE SPEED JP2 54 to 126 Volts LO 100 to 172 Volts MED 162 to 234 Volts HI
58. equipment or tampering by unqualified personnel will result in dangerous conditions which can cause equipment damage or personal injury Follow all safety precautions contained in this manual and all safety warning labels on the product 2 Loose rotating parts can cause personal injury or equipment damage Before starting the motor remove all unused shaft keys and other loose parts on the motor or the rotating mechanical load Be sure all covers and protective devices are in place Refer to the instruction manual supplied with the motor for further information and precautions 3 When using an oscilloscope to make measurements in the power circuits use the connections shown in Figure 1 and the procedures described in step 4 Failure to follow this procedure could result in the case of the oscilloscope being at line potential Only qualified personnel should be allowed to use the oscilloscope and other test equipment 4 Referring to Figure 1 set the oscilloscope to add channels A amp B and invert channel B Before making measurements connect both probes together and set the zero line This connection allows the oscilloscope case to be connected to ground for safe operation OSCILLOSCOPE CONNECT TO CIRCUIT UNDER TEST GROUND SCOPE CASE X100 PROBES REMOVE GROUND CLIPS Figure 1 Oscilloscope Connections SECTION 2 GENERAL INFORMATION 2 1 INTRODUCTION This instruction manual contains installation information
59. erators controls This board is located in the bottom base half of the enclosure near the upper left hand corner of the main PC board With 3 5HP panel mount controls the DC motor connects to the A and A lugs located in the upper right hand corner of the chassis These connections are shown in Figure 6 CAUTION NEVER ATTEMPT TO WIRE THE DC MOTOR DIRECTLY TO TERMINALS A1 AND A2 OF TB1 ON ANY 3 5HP CONTROL DOING THIS CAN CAUSE THE CONTROL TO GO INTO A CURRENT LIMIT CONDITION Terminals F1 and F2 on TB1 are for the customer supplied shunt field connections as shown in Figure 12 through Figure 15 The shunt field will be at 100VDC field voltage when the control is operated at 240VAC The motor shunt field supply is rated at 1amp NOTE TERMINALS F1 AND F2 ARE NOT USED WITH PERMANENT MAGNET MOTORS Motor Armature B1 2 Main Control Board P N 245 4000 For all 1 4 2HP Controls Motor Armature For 3 5 HP Enclosed and Less Operators Controls For 3 5HP Panel Mount Controls Figure 6 Connection of Motor Leads to Controls If the motor has a built in thermal overload protection device connect the thermal overload leads to TB2 1 and 2 on the main PC board CAUTION IF MOTOR THERMAL OVERLOAD PROTECTION IS NOT DESIRED TERMINALS 1 AND 2 OF TB2 MUST BE JUMPERED TOGETHER OR THE CONTROL WILL NOT OPERATE If with the motor connected the wrong rotational direction i
60. f the current error amplifier When the ramp voltage exceeds the current error voltage the comparator toggles to 15 volts DC and enables the gated oscillator This oscillator will produce firing pulses 40uSec wide and 800uSec apart 6 8 SUPPLIES For 4 power supplies are available These supplies are 24VDC and 15VDC The unit power supply transformer is jumper programmable on the main PC board for 240VAC or 120VAC and is rated at 6VA These power supplies are not for customer use except for pre engineered option kits 69 INDICATORS There are two indicators provided on the main control board The first of these is the CURRENT LIMIT indicator When this LED lights it indicates that the drive has reached the current level as set by the current limit potentiometer The second indicator provided is the DC POWER LED will be on any time gate pulses are present at the SCR gate terminals 21901 901V93 0 6002 V 2L jeujsnpu yooq jonuoo snooj sr L 2 6 5 9 89 6 SISSVHO NOLLdO 03346 90r LY DOP 21901 NNOO HOLOVINOO 9009015 M 9 TVOIdAL SNOILdO MM 0 68 419 G v 104 LNSYYNO L noy 9035VI10 30 HOLO3NNOO YANO SLOWSY HOLO3NNOO 90f er amp Lr c S v 2 v c S 9 8 v Ave 9 WOO WOO 9 885104 319355 NHO
61. fore installing the control check the unit for physical damage sustained during shipment If damaged file claim with shipper and return for repair following procedures outlined on the back cover Remove all shipping restraints and padding Check nameplate data for conformance with the AC power source and motor 4 3 CONTROL JUMPER PROGRAMMING Prior to installing the control the jumpers must be programmed for all of the following Using the correct AC line voltage Using either the speed or torque regulated mode of operation Choosing either armature voltage or tachometer feedback Choosing the correct voltage feedback level Matching the control to the motor being used These programming jumpers labeled JA JB and JP1 through JP4 on the main PC board which is common to all six control models are jumper wires that are connected to terminal pins as described as follows All of these jumpers are illustrated in Figure 5 These jumpers perform the following functions JA amp JB Transformer Programming Jumper programs unit for correct AC input voltage JP1 Current Feedback Level Jumper Sets current limit and IR Compensation adjustment ranges to properly match the control to the motor being used JP2 Voltage Feedback Level Jumper Sets voltage feedback level for 90 VDC or 180 VDC armature output with armature feedback or programs the unit to accept tachometer feedback voltages of different levels
62. g panel is needed with panel mount controls 3 8 4 CURRENT SIGNAL FOLLOWER This kit permits the speed of the DC motor to be controlled by a milliampere signal from a commercially available transducer The signal may be any one of the following 1 5mA 4 20 10 50mA Transducers which produce these current ranges are available for sensing temperature weight flow rate pressure pH and many other variables and must be supplied by the customer The applied current signal must be ungrounded and isolated from the control AC power sources or an isolation transformer must be used This kit also provides and auto manual switch so that control can be switched from the external signal to manual speed adjustment using the speed potentiometer 3 8 5 VOLTAGE SIGNAL FOLLOWER This kit allows the motor speed to be controlled by a voltage signal form an AC or DC tachometer generator or a process voltage signal See Figure 4 The kit consists of a printed circuit board and an auto manual toggle switch for switching form automatic control by the voltage signal to manual control by the speed potentiometer The printed circuit board is designed to accept voltage signal inputs with a range of 0 to 200 volts AC or DC with a calibration potentiometer provided to adjust the unit for the signal that is available The voltage signal input must be ungrounded and isolated form the AC power source and from any other controls which use the signal If the signal is n
63. he incoming AC power is turned off and locked out The drive and motor will have hazardous voltages present until the AC power is turned off The drive contactor does not remove hazardous voltages when it is opened When it is necessary to make measurements with the power turned on do not touch any electrical connection points Remove all jewelry form wrists and fingers Make sure test equipment is in good safe operating condition While servicing with the power on stand on some type of insulation being sure you are not grounded Follow the instruction given in this manual carefully and observe all warning and caution notices 1 2 INSTALLATION SAFETY When moving this control and associated motor into the installation position do any required lifting only with adequate equipment and trained personnel Eyebolts or lifting hooks when supplied are intended for lifting the product only and must not be used to lift additional weight mproper_ lifting can cause equipment damage or personal injury WARNING HAZARDOUS VOLTAGES MAY BE PRESENT ON EXTERNAL SURFACES OF UNGROUNDED CONTROLS RESULT IN PERSONAL INJURY OR EQUIPMENT If the drive cabinet or open chassis unit is mounted such that it is not grounded a ground wire must be connected to the panel or enclosure frame for personnel safety Also any motor frame transformer enclosure and operator station must be connected to earth ground Consult the National Electrical Cod
64. he proper brush grade is used D The motor bearing should be greased per the manufacture s instructions as to type of grease and maintenance frequency Over greasing can cause excessive bearing heating and failure Consult the instructions supplied with the motor for more details 7 3 TROUBLESHOOTING OVERVIEW Fast and effective troubleshooting requires well trained 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 control operation and who are familiar with the application are well qualified to service this equipment 7 3 1 SUGGESTED TRAINING A Study the system instruction manual and control drawings B Obtain practical experience during the system installation future servicing C Train in the use of test instruments 7 89 2 MAINTENANCE RECORDS It is strongly recommended that the user keeps records of downtime symptoms results of various checks meter readings etc Such records will often help a service engineer locate the problem in the minimum time should such services be required 7 33 GENERAL TROUBLESHOOTING The most frequent causes of drive failure are A Interconnect wires discontinuity caused by a broken wire or loose connection B Circuit grounding within the interconnections or the power wiring C Mechanical failure at the motor DO NOT make adjustments
65. ion 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 D 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 scr 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 Melltr
66. ld be kept free of dust dirt oil caustic atmosphere and excessive moisture KEEP IT COOL The control should be located away form machines having a high ambient temperature On panel mount controls air flow across heatsinks must not be restricted by other equipment within the enclosure KEEP CONNECTIONS 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 WARNING THE DC 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 SUCH AS THE BRUSHES WITHOUT FIRST MAKING SURE THAT ALL AC POWER TO THE CONTROL AS WELL AS THE DC POWER TO THE MOTOR HAS BEEN DISCONNECTED The motor should be inspected at regular intervals and the following checks must be made A See that both the inside and outside of the motor are not excessively dirty This can cause added motor heating and therefore can shorten motor life B 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 disposable Any reduction in cooling air will increase motor heating C Inspect the commutator and brushes Replace the brushes if needed Make sure that t
67. ll not exceed 55 When mounting the less operators control insure that the ventilation hole in each end of the box provided is clear The following procedure is recommended Mount the control vertically against the mounting surface Dimensions are shown in Figure 10 and Figure 11 CAUTION NEVER OPERATE THE CHASSIS CONTROL FOR AN EXTENDED TIME ON ITS BACK DOING THIS MAY CAUSE THE HEAT FROM THE HEAT SINK TO PENETRATE THE CONTROL LOGIC WIRING 4 6 INSTALLING ENCLOSED CONTROLS Enclosed controls are suitable for wall mounting in an ambient atmosphere between 0 C and 40 C Mount the control to provide access to the front panel See Figure 10 and Figure 11 for dimensions CAUTION THE NON METALLIC ENCLOSURE ON ENCLOSED AN LESS OPERATORS CONTROLS DOES NOT PROVIDE GROUNDING BETWEEN CONDUIT CONNECTIONS USE GROUNDING TYPE BUSHINGS AND JUMPER WIRES MAKING CONDUIT CONNECTIONS THE HUB MUST BE ASSEMBLED TO THE CONDUIT BEFORE IT IS CONNECTED TO THE ENCLOSURE 47 WIRING Throughout the following discussion reference to Figure 6 and to the connection and schematic diagrams shown in Figure 12 through Figure 15 and Figure 24 and Figure 25 4 7 1 INCOMING POWER REQUIREMENTS A remote fused AC line disconnect or circuit breaker is required by the National Electrical Code This AC line disconnect or circuit breaker must be installed in the incoming AC power line ahead of the control The control will oper
68. ly functioning control Included in the list are possible causes and corrective measures for each symptom described WARNING BEFORE PROCEEDING WITH ANY MAINTENANCE OR TROUBLESHOOTING ACTIVITY ALL POWER SOURCES MUST BE DISCONNECTED AS DESCRIBED IN PARAGRAPH 7 1 7 4 1 CONTROL APPEARS TO BE DEAD Terminals TB 1 and 2 on the main PC board not jumpered together install either a jumper or a motor thermal between these terminals No AC power apply AC power Blown line fuses replace line fuses Loose connections turn off AC power and tighten connections Control incorrectly wired recheck all wiring Defective Start Stop switch component on main PC board or rectifier cube replace bad components as required Speed potentiometer set to zero slowly advance from zero to begin motor rotation 7 4 2 FUSES BLOW OR MAIN CIRCUIT BREAKER TRIPS WHEN APPLYING AC POWER A Control is wired to AC voltage exceeding control rating require control to proper AC voltage or use step down transformer B Rectifier cube field diodes on main PC board motor winding or suppressor network shorted or a short to ground is present locate and remove short C wiring or jumper programming during installation referto SECTION 4 of this manual D Defective main PC board component replace as required E Motor shaft jammed determine cause and correct F Excessive carbon dust from
69. ndication with an accuracy of 5 The Speed Meter Kits are supplied in a NEMA 1 enclosure suitable for wall mounting They may be easily removed from their enclosures for panel mounting 3 8 4 OPTION MOUNTING PANEL This option provides mounting space for the reversing armature contactor and dynamic braking options when used with the panel mount control It comes pre drilled ready for immediate assembly 3 8 15 DEAD FRONT This kit is intended primarily for field installation on an existing panel mount control For most new applications it would be advisable to use the less operators control Jog at Jog Speed Voltage Signal Follower Reversing M Contactor Figure 4 Control Modification Kits SECTION 4 INSTALLATION 4 1 SAFETY WARNINGS Improper installation or operation of this control may cause injury to personnel or damage to 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 NEC To reduce the potential for electric shock disconnect all power Sources before initiating any maintenance or repairs 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 4 2 INITIAL CHECKS Be
70. ndicator lights to indicate if control is in current limit and to indicate SCR gate triggering Continuous full rated torque available over a 30 1 speed range Tachometer feedback circuitry is standard Addition of AC or DC tachometer generator to the motor converts the drive from armature to tachometer feedback for improved speed regulation Selectable current limit ranges to match control to the motor being used Provides overload protection and smooth acceleration of high inertia loads Varister transient voltage protection providing trouble free operation Jog at run speed standard Zener regulated control power supply compensation for line voltage fluctuation UL listed and CSA approved OPERATING VOLTAGE provides 3 8 PRE ENGINEERED MODIFICATION KITS The control can be purchased alone or with a selected group of pre engineered modification kit These kits allow the customer to create a custom engineered control to meet individual specific requirements Each modification kit is individually packaged identified and includes all mounting hardware wire terminals cable ties labels and instructions Following is a brief description of the modification kits currently available CAUTION THESE MODIFICATIONS KITS ARE THE ONLY KITS DESIGNED FOR USE WITH THIS CONTROL ANY MODIFICATIONS OTHER THAN THOSE SPECIFIED VOIDS ALL WARRANTIES STATED OR IMPLIED 3 8 1 M CONTACTOR KIT This kit is a magnetic cont
71. nstruction sheets provided with the individual kits for installation information 8 Five 5 customer adjustable potentiometers are located on the main PC board as shown in Figure 11 These potentiometers have been preset However for proper operation in some applications minor readjustments may be necessary Before making final adjustments allow the motor to warm up for at least 15 minutes With the control driving a motor so not exceed ten 10 degrees of potentiometer rotation per second Clockwise adjustment will cause an increase in the adjustment parameter WARNING DO NOT ALLOW THE ADJUSTING SCREW DRIVER TO TOUCH ANYTHING OTHER THAN THE POTENTIOMETER WHILE THE CONTROL IS OPERATIVE USE ONLY AN INSULATED SCREWDRIVER TO MINIMIZE THE HAZARDS OF ELECTRIC SHOCK Steps A and B describe respectively the potentiometer adjustment procedure for operation in the speed or torque current mode of control A ADJUSTMENT PROCEDURE FOR OPERATION IN THE SPEED MODE NOTE IF THE VOLTAGE OR CURRENT SIGNAL FOLLOWER KIT IS BEING USED PERFORM THESE ADJUSTMENTS WITH THE AUTO MANUAL SWITCH IN THE MANUAL POSITION 1 IR compensation Adjustment Compensation is provided to overcome the motors natural tendency to slow down as the load increases If the motor slows down excessively as it is loaded the potentiometer marked COMP should be adjusted clockwise b If the IR compensation is adjusted too far cl
72. o handle most single phase drive applications without the need for costly time consuming engineering Simple jumper programming allows for maximum versatility in the drive Functions such as input voltage selection 1 4 to 2HP only armature tachometer feedback voltage feedback level motor current range and speed torque regulation are achieved by customer selection of the jumper positions Each control also has standard adjustments for minimum maximum speed compensation acceleration deceleration time and current limit An enclosed less operators and panel mount control design is available Two models are provided for each design a low horsepower 1 4 2HP model and a high horsepower 3 5HP model 2 3 TYPICAL PACKAGING 22 GENERAL DESCRIPTION The control is a high performance DC drive It contains all the required circuitry to control the speed of or to control the current supplied to small horsepower shut wound or permanent magnet DC motors It includes many standard features that are available only as options on other single phase DC drives This allows the control to be used in custom engineered applications as well as standard speed regulated applications Varying the DC voltage applied to the motor armature controls the DC motor speed or varying the current applied to the motor armature controls the motor torque Single phase AC input power is converted to variable voltage DC output power by the control
73. o low adjust clockwise as described in Paragraph 5 2 2 Motor is overloaded correct overload condition Incorrect jumper programming follow procedure described in Paragraph 4 3 Defective component on main PC board replace as required Current limit set too low readjust as described in Paragraph 5 22 Motor brushes worn replace as specified in motor instruction manual 7 4 8 MOTOR IS OSCILLATES IR COMP potentiometer is set too high adjust IR COMP potentiometer counterclockwise until the motor speed stabilizes without oscillating Defective motor consult motor instruction manual and repair or replace as required Load is loosely coupled to motor or misaligned check and correct load coupling Loose wire connections tighten connections to motor Defective component on regulator PC board replace as required Motor overloaded overhauling decrease or increase load as required Low AC line voltage more than 1096 below nominal check AC line voltage and correct Incorrect jumper programming follow procedure described in Paragraph 4 3 Current limit set too low adjust as described in Paragraph 5 2 2 7 49 MOTOR DOES NOT COME TO FULL STOP Minimum Speed potentiometer MIN is set too high readjust as described in Paragraph 5 2 2 Defective speed or torque potentiometer component on regulator PC board Start Stop switch or rectifier cube replace as required 7 4 10
74. ockwise the motor will begin to oscillate in speed or hunt If this pulsing of speed occurs adjust the Compensation counterclockwise until the motor speed stabilizes c f the control has AC or DC tachometer feedback adjust the COMP potentiometer fully counterclockwise N Maximum Speed Adjustment a Run the motor with the load applied b Turn the speed potentiometer on the operator control panel fully clockwise C Adjust the potentiometer on the main PC Board marked MAX to set the maximum motor speed This may be adjusted form approximately 70 120 of motor base speed DO NOT EXCEED THE MOTOR NAMEPLATE MAXIMUM SPEED RATING d Using a hand held tachometer or by visually observing machine operation adjust MAX to the desired maximum setting 3 Minimum Speed Adjustment a With motor still running and full load applied turn the speed potentiometer on the operator control panel fully counterclockwise b Adjust the potentiometer on main PC board marked MIN to desired lowest motor speed setting This adjustment be set at 0 30 of the maximum speed setting 4 Acceleration Deceleration Time Adjustment a The ACCEL DECEL adjustment on the main board may be used to vary the motor acceleration and deceleration times linearly from 2 30 seconds Turn the adjustment clockwise to increase the time b Note that the controlled deceleration time occurs when the speed potentiometer
75. onics goods Melltronics reserves the right to make changes and improvements in Melltronics goods without incurring any obligation to similarly alter goods previously purchased Melltronics Industrial Inc MAIL PO BOX 2368 INDIAN TRAIL NC 28079 2368 SHIPPING 3479 GRIBBLE ROAD MATTHEWS NC 28104 8114 PHONE 704 821 6651 www melltronics com
76. or Diode D3 is called a free wheeling diode that insures continuity of the load current when the previously fired SCR becomes reverse biased This diode also helps the SCR return to its blocking state Three functional details are shown in Figure 7 Armature Voltage Feedback Signal This signal is used in determining when the correct drive operating speed voltage is reached as required by the operator speed potentiometer 2 Current Feedback Signal This signal provides current information to the drive inner current loop 3 Control Circuit Common This is tied to the positive terminal of the power bridge NOTE COMPONENT DESIGNATIONS IN Figure 7 SUCH AS D1 AND D2 ARE FOR REFERENCE PURPOSES ONLY THEY DO NOT CORRESPOND TO ACTUAL COMPONENT DESIGNATIONS ON THE CONTROL CAUTION THE CONTROL CIRCUIT COMMON IS FLOATING AND MUST NEVER BE TIED TO EARTH GROUND ATTEMPTING THIS WILL CAUSE EQUIPMENT DAMAGE OR FAILURE Figure 7 also shows the motor shunt field supply Diodes D1 D2 D4 and 05 form a single phase full wave uncontrolled rectifier bridge This bridge produces a 200VDC field voltage when operated at 240VAC and 100VDC field voltage when operated at 120VAC The motor shunt field supply rating is 1 amp 24VDC JOG INPUT MOTOR THERMAL OPTIONAL Figure 8 Power Bridge Assembly 6 2 RUN JOG AND START STOP LOGIC When the Run Jog and Start Stop switches are pre install
77. or replace components before checking all wiring Also monitor all LED indicator lights before proceeding with troubleshooting checks and check for blown fuses It should be noted that modern solid state electronic circuitry is highly reliable Often problems which appear to be electrical are actually mechanical 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 7 3 4 NOTES FOR A TROUBLESHOOTING TECHNICIAN A minimum knowledge of system operation is required but it is necessary to be able to read the system schematics and connections diagrams 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 multimeter and by parts substitution Multimeters having a sensitivity of 100 ohms per volt on DC or more are recommended such as a Triplett Model 630 a Simpson Model 260 or equivalent WARNING 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 74 BASIC TROUBLESHOOTING This paragraph contains a basic list of symptoms of an improper
78. ot isolated an isolation transformer must be used 3 8 6 TORQUE TAPER REMOTE CURRENT LIMIT KIT This kit consists of a printed circuit board with two related functions 1 Remote Current Limit Adjustment permits adjustment of the control current limit setting with an external 5000 ohm 2 watt potentiometer not provided in kit 2 Torque Taper Adjustment provides internal means of adjusting the speed vs torque limit relationship of the drive so that the motor torque limit will gradually drop off as motor speed increases This kit is shown in Figure 4 3 8 7 DYNAMIC BRAKING KIT This is for use with either the M Contactor Kit or the Magnetic Reversing Kit Dynamic braking causes the motor to decelerate rapidly to a stop with braking torque of approximately 15096 of the motor full load torque rating at full speed This is accomplished by a resistor s connected across the armature to absorb the energy of the coasting motor now acting as a generator Dynamic braking is not a holding fail safe brake and cannot be used as such The dynamic braking resistors have been sized to provide the proper amount of braking torque when used with company supplied DC motors with no appreciable inertia connected to the motor shaft The resistors are designed to withstand stopping frequencies less than or equal to the following Fractional HP 1 stop per 70 seconds Integral HP 3 quick stops within 7 minutes before the next stop For ine
79. other signal switch wiring is desired refer to Figure 18 and Figure 19 NOTE IT IS RECOMMENDED THAT SHIELDED WIRE BE USED FOR REFERENCE 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 CIRCUIT COMMON TB 2 TERMINAL 11 ADDITIONAL CONSIDERATION IS RECOMMENDED TO ROUTE THIS WIRING AWAY FORM HIGH CURRENT LINES AC LINES AND ARMATURE WIRING 4 9 ENCLOSED CONTROL LOGIC AND SIGNAL WIRING The local On Off Run Jog Start Stop and speed potentiometer controls associated with enclosed drives are pre installed on the enclosure cover A Forward Reverse switch installable on the enclosure cover is available as an option kit The On Off switch is wired into the 1FU and 2FU fuses located in the top cover half of the enclosure The Start Stop and Run Jog logic is pre wired as shown in Figure 8 Terminal block TB2 shown in this figure is located as shown in Figure 5 If a Forward Reverse switch is desired wire it as shown in Figure 22 and Figure 23 4 40 INSTALLING MODIFICATIONS When modifications are shipped loose as kits for field installation each kit is individually packaged identified and includes all mounting hardware wire terminals cable ties labels and instructions Figure 16 through Figure 23 can be used as
80. rtial loads more frequent stopping than specified above or motors that are not company supplied consult your company distributor for analysis and proper dynamic braking resistor selection The option mounting panel is needed with panel mount controls 3 8 8 POWER DISCONNECT SWITCH This double pole AC disconnect switch is the same AC power disconnect switch provided as a standard feature on the enclosed control operator panel may be added to the less operators control when a local AC power disconnect switch is desired 3 8 9 END COVER PLATES The standard less operators control is provided with ventilation holes in each end The end cover plates may be used to cover these ventilation holes and convert the less operators control to an enclosed control without operators A gasket is provided so that the enclosure is rated NEMA 4 12 A remote operator station must then be used for operator controls 3 8 10 SPARE PARTS KIT For most customers this kit provides all the spare parts ever required The kit contains three complete sets of fuses 6 fuses and an SCR power cube 3 811 REMOTE STATION This NEMA 1 rated kit can operate the SCR drive from a remote location It includes start and stop momentary push buttons and a speed potentiometer with provision for adding a jog selector Switch 3 8 12 TEN TURN POTENTIOMETER KIT This kit may be used to replace the standard single turn potentiometer in the control to provide a much
81. s observed the rotational problem can be corrected in any of three 3 possible ways 1 Exchanging the A1 and A2 output leads to the motor 2 Exchanging the shunt field F1 and F2 leads on shunt wound motors only 3 Changing the position of the Forward Reverse switch if this option kit is being used NOTE EXCHANGING THE INCOMING POWER LEADS TO TERMINALS L1 AND L2 WILL NOT AFFECT THE DIRECTION OF MOTOR ROTATION 4 8 PANEL MOUNT AND LESS OPERATORS CONTROL LOGIC AND SIGNAL WIRING The Local On Off Run Jog and Start Stop controls required for these drives are customer supplied An uni directional speed potentiometer is supplied loosely with the drive Forward Reverse operation can be accomplished through the use of the optional Magnetic Reverse Kit The On Off switch is installed by the customer in the incoming L1 L2 line to the control On less operators controls this switch can be installed on the enclosure cover The control circuitry allows the customer to wire the Run Jog and Start Stop logic with the supplied uni directional potentiometer with or without a Forward Reverse switch The Run Jog Start Stop and potentiometer controls are wired into terminal block TB2 located along the left edge of the main PC board as shown in Figure 5 The basic Run Jog Start Stop and potentiometer connections are shown in Figure 12 and Figure 13 If Forward Reverse recommended that shielded wire be used for reference and
82. s switch to verify that the motor follows direction change commands SECTION 6 FUNCTIONAL DESCRIPTION This section describes in detail the following circuits included in the control 1 Power Bridge and Field Supply Run Jog and Start Stop Logic Accel Decel Circuit Regulating Circuitry Feedback Scaling Circuits Current Limit Circuit Firing Circuits Power Supplies 9 Indicators Throughout this section reference to the schematic diagrams in Figure 24 and Figure 25 is recommended 6 1 POWER BRIDGE AND FIELD SUPPLY Throughout this paragraph refer to Figure 7 L1 L2 D4 D5 F2 ARMATURE VOLTAGE FEEDBACK SIGNAL CURRENT FEEDBACK SIGNAL 522 ENCAPUSLATED SCR POWER CUBE Figure 7 Power Bridge Assembly The power bridge supplied in the control consists of an encapsulated SCR power cube containing two 2 SCRs and three 3 diodes The basic operation consists of the following sequence When L1 is more positive with respect to L2 SCR1 is gated on at a particular phase angle commanded by the drive regulator circuitry Current then flows from L1 through SCR1 the shunt resistor the drive motor diode D2 and back to L2 When L2 is more positive with respect to L1 SCR2 is gated on Current flows from L2 through 5 2 the shunt resistor diode D1 and back to L1 This results in a positive current flow through the mot
83. sed Low HP Control with M Contactor 2450 1002 Rev A Figure 20 6002 9 6 PSA ALVLOY I 600L 09V2 SI NOLLdO LY SIHL SAOW3N SNOILO3NNOO LV 3993 39 NOLLVLOH 3010 395993 39 OL YOLVLNWWOO 3HL ONIDV4 NOLLV LOH HOLOW TIM NMOHS SNOLLO3NNOO 07314 FUNLVNAV SON OL 031 9MM0 39 5 SHIM SNOILdO Y3MOTIOS IM3 JO BOVLIOA 3HL 3AVH LON 300 LINN 4 274 NO NOLLO3NNOO 15 S310N3Q ATIN 38 GNOHS IOH1NOO NO 104 IM3 IHL 5 SI NOILdO SIHL SIL LVH L 31ON NOLLISOd 8 NI LC Lnd SI Qu vOg NOILdO SIHL NO 104 LN3YUND JHL 3I NOLLISOd NI G39V1d 38 5 95908 IM3 3 LOW3U NO SI 104 LNIYYNO 3103 V dl GALNNOW SISSVHO NO TVNOILdO TVNOILdO H3H13901 39 LSNW 291 40 LON 5 VMIVI93L 319VIIM MV LON SI NOLO3NNOO TWWYSHL HOLON 4 2006 8 2 NOLOVINOO 3univwalv O10 V Wey 5206 09 2 Nd way 20 18101 181 OL YOLOW 500961 HM 2006 0802 Nd 2106 0692 Nd 1108 0892 Nd 10 S3MOTIO4 3OVLIOA Lb IN3HunO SLOWEY 10i Qaads OO
84. trols 2450 1010 NoRev 53 SECTION 1 SAFETY This section outlines procedures necessary to insure safe operation of any AC or DC drive For further information contact the Service Department at the location shown on the inside back cover of this manual 1 1 GENERAL SAFETY PRECAUTIONS WARNING THIS CONTROL AND ASSOCIATED MOTOR CONTAINS HAZARDOUS VOLTAGES AND ROTATING MECHANICAL PARTS EQUIPMENT DAMAGE OR PERSONAL INJURY CAN RESULT IF THE FOLLOWING GUIDELINES ARE NOT OBSERVED Only qualified personnel familiar with this equipment and the information supplied with it should be permitted to install operate troubleshoot or repair the apparatus A qualified person must be previously trained in the following procedures Energizing de energizing clearing grounding and tagging circuits and equipment accordance with established safety practices Caring and using protective equipment such as rubber gloves hardhat safety glasses or face shields flash clothing etc in accordance with established safety practices Rendering first aid Installation of the equipment must be done in accordance with the National Electrical Code and any other state or local codes Proper grounding conductor sizing and short circuit protection must be installed for safe operation During normal operation keep all covers in place and cabinet doors shut When performing visual inspections and maintenance be sure t
85. urnished with the control The panel mount controls are suitable for sub panel mounting inside a customer supplied control enclosure The operators for the panel mount control are customer supplied except for the speed potentiometer which is supplied loosely with the control 2 4 EQUIPMENT IDENTIFICATION It is important to identify the control completely and accurately whenever ordering spare parts or requesting assistance in service Figure 3 Panel Mount Control The enclosed controls include a product nameplate located on the bottom edge of the cover The less operators controls include a product nameplate located on the front cover The panel mount controls include a product nameplate located on the right edge of the chassis The product nameplate should appear similar to the sample nameplate shown in Figure 2 For any of these controls record the part number P N revision level REV and DATE for future reference in the front of this manual If the control is part of an engineered drive system the system cabinet will also include a product nameplate Record the part number and serial number S N of the engineered system and include this information with the information on the individual controls whenever contacting the factory AC INPUT 245 8010W FOCUS 2 DC DRIVE 9 2 MELLTRONICS COM V AC P N Figure 2 Typical Panel Mount Control Product Nameplate SECTION 3 CO
86. ut Connect jumper A to the C position and jumper B to the C position WARNING NEVER ATTEMPT TO CONVERT 1 4 2HP CONTROLS TO ANY OPERATING VOLTAGE OTHER THAN 120VAC INPUT 0 90VDC OUTPUT OR 240 VAC INPUT 0 180VDC OUTPUT NEVER ATTEMPT TO CONVERT 3 5HP CONTROLS TO ANY OPERATING VOLTAGE OTHER THAN 240VAC INPUT O 180VDC OUTPUT ANY SUCH ATTEMPTED CONVERSION CAN CAUSE EQUIPMENT DAMAGE AND POSSIBLE PERSONAL INJURY 4 32 MODE OF CONTROL SELECTION Next it must be determined if the unit is going to be used as a speed or torque control When used as a speed control the operation control potentiometer sets the motor RPM and the 121 n 0 4 motor produces only the torque necessary to drive the load at this RPM This is the type control used on most applications If however the unit is connected as a torque control used mainly on surface winders the operator control potentiometer sets the motor torque and the motor will run at an RPM determined by the torque speed characteristics of the driven load A If the unit is to control speed Place in the SPD position B unit is to control torque speed Place JP3 in the CURR position JA JB no F2 Fi L2 LY FE JP1 hu n AT Bs 8 Figure 5 Main PC Board Jumper Locations CAUTION WHEN USING THE UNIT AS A TORQUE CONTROL OBSERVE THE FOLLOWING PRECAUTIONS 1 IF LOAD TORQUE IS REMOVED OR REDUCED TO A LEVEL BELOW
87. v C SNOILO3NNOO SALVOICNI O Savd YACIOS SALVOICNI LL 0L0V 09V2 39018 OL LaL NIV OL Figure 25 Shunt Resistor Board for High HP Enclosed amp Less Operators Controls 2450 1010 NoRev REVISION UPDATES REV DATE DESCRIPTION REVISIONS NONE 08 20 03 157 RELEASE MELLTRONICS NONE A 05 16 05 277 RELEASE MELLTRONICS MISCELANEOUS SPELLING CHANGES B 11 09 09 37 RELEASE MELLTRONICS FIGS 12 25 REMOVE BASIC APPLICATION INFORMATION SECTION SPELLING ERRORS TABLE 2 JP2 01 05 2011 4 RELEASE MELLTRONICS RESIZE TO FIT LEGAL SECTION 10 WARRANTY MELLTRONICS warrants to the Buyer whom purchases for use and not for resale that the equipment described in this instruction manual is 5014 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 Return Material Authorization RMA prepare the goods for shipment and return the goods to SCR Melltronics for repair or replacement at Melltronics opt
88. ve or its associated equipment other than those shown on the diagrams supplied Connection of external devices to the tachometer or speed setting device can significantly affect drive performance CAUTION MEGGERING CIRCUITS CONNECTED TO THE DRIVE CAN CAUSE DAMAGE TO ELECTRONIC COMPONENTS DO NOT MEGGER OR HI POT THIS EQUIPMENT USE A BATTERY OPERATED VOLT OHM METER VOM TO CHECK FOR SHORTS OPENS OR MIS WIRING CONNECTION OF UNSUPPRESSED INDUCTIVE DEVICES TO THE DRIVE POWER FEED OR CONTROL CIRCUITS CAN CAUSE MIS OPERATION AND POSSIBLE COMPONENT DAMAGE TO THE EQUIPMENT DO NOT CONNECT POWER FACTOR CORRECTION CAPACITORS WITH THIS EQUIPMENT AS THIS MAY CAUSE HIGH VOLTAGES THAT CAN DAMAGE DRIVE 13 START UP SAFETY Detailed startup procedures are described in the Operation and Startup section of this manual Before and during startup it is imperative that all of the following safety procedures be observed WARNING AC POWER MUST BE DISCONNECTED FROM THE DRIVE CABINET TO ELIMINATE THE HAZARD OF SHOCK BEFORE IT IS SAFE TO TOUCH ANY OF THE INTERNAL PARTS OF CIRCUITS MAY BE AT LINE POTENTIAL THE DRIVE WHETHER THE ENCLOSED DRIVE IS OPEN OR CLOSED USE EXTREME CAUTION WARNING HAZARDOUS VOLTAGES ARE PRESENT ON THE MOTOR UNTIL ALL POWER TO THE CONTROL IS DISCONNECTED TURN OFF AND LOCKOUT ALL POWER TO THE CONTROL BEFORE TOUCHING ANY INTERNAL CIRCUITS ON THE MOTOR 1 of unauthorized parts in the repair of this

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