PowerTec Automobile 1000AR User Manual

Model

1000AR

Regenerative

Brushless DC Motor Control

INSTALLATION AND

OPERATION

INSTRUCTION MANUAL

JUNE, 2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

SPECIFICATIONS

Environmental

ALTITUDE :

Use above 3300 feet (1000 meters) requires de-rating.

De-rate at 3% of full rating for each additional 1100 feet (330 meters).

STORAGE TEMPERATURE :

-40 °C to +65 °C (-40 °F to + 150 °F)

AMBIENT TEMPERATURE :

Chassis :

Maximum air temperature of 55 °C (131 °F).

Maximum air temperature of 40 °C (104 °F).

Nema1 :

RELATIVE HUMIDITY :

Less than 95%, non-condensing.

POWER SOURCE :

Voltage :

Nominal 230 VAC, 380 VAC, or 460 VAC per nameplate rating.

-10%, +10% of nominal rated voltage.

Three (Drive will not operate on single phase).

48 to 62 Hertz

Voltage Tolerance :

Phases :

Frequency :

KVA Required :

Max KVA Rating :

KVA rating of source must be at least equal to Horsepower rating.

100 KVA (limited by input fuse AIC rating).

Dimensions

Physical Dimensions :

Approximate Weights :

1000AR chassis :

See page 8.

75 pounds ( 34 kg ).

110 pounds ( 50 kg )

1000AR Nema1 :

Performance

Maximum Load :

Speed Regulation :

Speed Accuracy :

Analog Mode :

Linearity :

Digital Mode :

Displacement power factor :

150% for 1 minute out of 10 minutes.

0.0% (on load change from no load to full load)

+/- 1.0% typical with speed pot supplied by internal reference.

+/- 0.5% typical with external reference source.

0.0 % typical ( +/- ¾ revolution of the motor shaft ).

0.96 typical

Adjustments

ACCELERATION TIME :

DECELERATION TIME :

2 to 90 seconds with JP2 installed; 0.05 to 2 seconds with JP2 removed..

Acceleration and deceleration times settable in analog mode only.

600 to 5000 RPM ( motor dependent ), analog mode only.

0 to 15% of MAXIMUM SPEED with 5K speed potentiometer, analog mode only.

0 to 30% of MAXIMUM SPEED, analog mode only.

MAXIMUM SPEED :

MINIMUM SPEED :

JOG SPEED :

CURRENT LIMIT :

GAIN :

Adjustable from 0% to 150% of rated current, calibrated by Horsepower Resistor.

10 to 1 stiffness ratio

STABILITY :

20 to 1 dynamic response.

Jumpers

See Page 32

See Page 36

See Page 22

LED Indicators

Terminal Assignments

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

REGENERATIVE VERSUS NON-REGENERATIVE OPERATION

Traditional AC induction motors and brush-type DC motors have windings on the rotor. They also have

stationary windings on the frame that produce magnetic fields if we energize them. When the motor rotates,

the windings move through the magnetic field.

If we externally force the shaft to turn, this movement through magnetic fields produces a potential at the

motor’s power terminals. We call this potential “Electro-Motive-Force” (or EMF, for short). The motor is now a

generator, and it is capable of supplying power if we keep the stationary windings energized.

In the case of the Brushless DC motor, a field produced by the permanent magnets on the rotor moves

around the stationary windings on the frame. We do not have to keep the windings energized to produce

power. You will see the importance of this in dynamic braking (below).

A motor is running in the MOTORING mode when it is drawing current from the power supply. The motor

is changing electrical energy into mechanical work at the motor shaft. This is the most common mode of motor

operation. The motor still produces the same potential at its terminals, but we call it “Counter-EMF” (CEMF)

when the motor is in the motoring mode. CEMF opposes the flow of current from the supply to the motor.

From the generator action, we derive the term REGENERATING. This indicates that the motor is no

longer drawing current from the supply. It is now returning current to the supply.

The motor can not draw current from the supply if the voltage produced by the rotation of the motor shaft

(the CEMF) exceeds the supply voltage. We see this condition when motor speed is greater than the speed

commanded by the speed reference. The load inertia may be greater than the amount of inertia that the motor

can slow down in the time allotted. External forces can drive the load faster than desired.

A load in motion will “coast” to a free-wheeling stop. Speed, inertia, and friction of the load determine how

long the stopping will take. The faster a load is moving, the longer

the load requires to stop. Larger inertias (more mass) take longer to

stop, but a higher friction load slows it down faster. A moving load

stops in a coasting situation by dissipating the energy of motion as

frictional heat, which acts as a brake. If inertia is high and friction is

low, the load will take a longer time to stop. We can use mechanical

brakes to increase the amount of friction.

A non-regenerative drive can not slow down a load in less time

than the load would slow down by itself. It cannot act as a brake. We

can supply braking force by making the motor act as a generator.

We can dissipate the energy of the inertia into passive resistors, but

we cannot connect the resistors until after we shut off the drive

(dynamic braking). With AC motors and brush-type DC drives, we

must keep the stationary fields energized, but not with BLDC. Even if

we lose drive power or plant power, dynamic braking still works.

Regenerative drives can supply braking force while the motor

control is active. A motor that operates on a regenerative drive

becomes a generator when it rotates at a speed faster than set

speed. The amount of power generated relates to the speed, inertia,

and friction of the load and motor. The regenerative drive accepts

the current from the motor, and dissipates the energy. The dissipative load presented by the controller must

be adequate.

When the motor generates energy, and the drive receives it, then the motor is REGENERATING. A

motor in the regenerating mode develops torque in the opposite direction of its rotation. It is not drawing power

from the supply, as it is in the motoring mode.

Regenerative power capability gives motors and controls the ability to change from higher

speeds to lower speeds quickly. This includes zero speed and the reversal of motor direction. This

happens much more quickly than with non-regenerative types of controls. The result is more rapid

stops and reversals of loads that would otherwise be a lot more sluggish in these actions.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

MODEL 1000AR STANDARD CONNECTIONS

Power Input

L1 L2 L3

Output Terminals

Warning:

Input

fuses

Do Not Connect

Input Power Leads

to Output Terminals

REGEN SPEED CONTROLLER

147-101

CURRENT CONTROLLER

BOARD

STAB

GAIN

POWERTEC

MCL

RCL

JP1

MAX SPD

JOG

DIR/RL

DIR

JP3

POWER

SEL

GREEN

DECEL

ACCEL

STALL

HS3

RED

BUS

RAMP STOP

2Q/4Q

HS2

RED/GREEN

RED

ENABLE

HS1

YELLOW

ESTOP

COAST

STOP

RED

RUN

JOG

REGEN

ENABLED

RED

TAC

OV/UV

RED/GREEN

RED

HOLD

TB1

IOC

10 11 12 13 14 15 16

RED

TB1

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

QUICK START

Follow these steps to quickly set up and operate the Model 1000AR Brushless DC drive. If you are not

sure of the procedure for any of the steps, consult the installation section (beginning on page 9).

CONNECTIONS

1. Connect the proper three-phase AC power from a suitably rated switching device to the input terminals L1, L2,

and L3. Check the nameplate. The sequence of the phases is not important to the drive.

2. Connect the power system ground to the GND terminal. Make sure the system ground is earth ground.

3. Connect T1 of the motor to T1 of the drive. Connect T2 to T2, and T3 to T3. The order of connection is

important. The motor will not run with improper motor connections..

4. Connect a ground wire from the motor’s ground lug to the GND terminal on the drive.

5. Connect the resistor to R+ and R- terminals on the chassis. If you have a separate bus loader, see page 21.

6. Connect the encoder cable to the motor. Consult the drawing on page 4. The cable used should be a nine-

conductor shielded cable. The colors do not matter, but they aid in tracing wires. Connect the shield at both

ends of the cable (the shield continues inside the motor, but is not connected there).

7. Connect a 10 Kilo-ohm Speed Potentiometer to TB2 terminals 4 (CW), 5 (Wiper), and 16 (CCW). Connect the

shield of the speed pot cable to TB2 terminal 16. To reverse rotation connect CW to TB2 terminal 6.

8. TB2 terminal 10 should be connected to the motor thermal (cable). The other side of the motor thermal should

be connected to TB5 terminal 3 (bus loader). Connect an Emergency Stop (ESTOP) button between TB3

terminal 1 and TB2 terminal 11. Use a normally-closed, maintained-open contact type pushbutton.

9. Connect a normally closed, momentary type, STOP pushbutton between TB2 terminals 11 and 12.

10. Connect a normally open, momentary type, RUN pushbutton between TB2 terminals 12 and 13.

11. If desired, connect a normally open, momentary type, JOG pushbutton between TB2 terminals 9 and 14.

12. If desired, connect a normally open, momentary type, HOLD pushbutton between TB2 terminals 9 and 15.

START UP

1. Before applying power, turn the speed pot fully counter-clockwise (CCW) and turn the MCL and RCL

potentiometers fully counter-clockwise. Do not connect the motor to a load for its initial run..

2. When you apply power, the PWR LED should light up GREEN immediately.

3. When you apply power, the BUS LED should light up RED immediately.

4. When power is on, the HS1, HS2, and HS3 LED’s may or may not be on RED, depending on the position of

the motor. Only one or two should light; never all three and never none.

5. When power is on, the TAC LED may be OFF, RED, GREEN, or ORANGE.

6. Within 30 seconds, the BUS LED should turn GREEN and the you should hear the charging contactor click as

it energizes. If this does not happen within 30 seconds, shut power off and consult the troubleshooting section.

7. The ESTOP LED should be ON GREEN on the Speed Controller board.

8. Press and release the START button. The RUN LED should light GREEN. The CURRENT LIMIT LED may

come on GREEN at this time because the MCL pot is all the way counter-clockwise.

9. Immediately after the RUN LED comes on, the ENABLE LED should light on both boards.

10. Increase the speed pot reference to about 10% of its rotation from the CCW position.

11. Turn the MCL pot slowly clockwise. If the motor does not turn (HS1, HS2, HS3, and TAC will start blinking)

before MCL is at 50%, turn the MCL pot back down fully CCW. Consult the troubleshooting section.

12. Leave the MCL pot at 50 % and increase the speed pot to 50% of its rotation. Check the motor speed with a

hand-held tachometer. Adjust the MAX speed pot, if necessary to attain 50% speed.

13. Turn the speed pot to 100% and measure the motor speed. Adjust MAX speed if necessary.

14. Press the Normal Stop button and start again. Time the acceleration to full speed and set ACCEL time.

15. Turn the RCL pot to 50%. Turn speed pot to 0% (CCW) and time decel ramp. Adjust DECEL for correct time.

16. Set STAB and GAIN to 50%. Press the Normal Stop button. Both ENABLE LED’s should go OFF.

17. Run the motor at high speed and push the HOLD button. The HOLD LED should light RED. The motor should

stop. Release the button and the motor should return to the previous speed.

18. Press Stop. Press the JOG button. The JOG LED should light GREEN. Set the JOG speed, if desired.

19. The motor is ready for service.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

REFERENCE PAGES

Specifications..........................................................................................................................................2

Model 1000AR Standard Connections....................................................................................................4

Model 1000AR Dimensions Chart ........................................................................................................10

Model 1000AR AC Input Electrical Ratings Table ..............................................................................12

Model 1000AR Output Electrical Ratings Table .................................................................................14

Regenerative Resistors .......................................................................................................................16

Contactor Specifications .....................................................................................................................18

Dynamic Braking Resistors .................................................................................................................18

Model 1000AR Control Connections Table .........................................................................................20

Terminal Descriptions List ...................................................................................................................22

PLC Interface Suggestions .................................................................................................................24

Digital Mode Notes ..............................................................................................................................26

Analog Versus Digital Operation Comparison .....................................................................................28

Standard Basic Connection Diagram ...................................................................................................30

Capacitor Board Location and Layout ..................................................................................................32

Current Controller Board Layout ..........................................................................................................34

Speed Controller Board Layout ............................................................................................................34

Jumpers List .......................................................................................................................................34

LED Indicators - Current Controller Board ...........................................................................................36

LED Indicators - Speed Controller Board..............................................................................................38

Adjustments .........................................................................................................................................40

Simplified Power Schematic ................................................................................................................42

Semiconductor Diagrams......................................................................................................................42

Transistor Module Static Test ...............................................................................................................44

Diode Bridge Test ................................................................................................................................46

Transistor Leakage Test .......................................................................................................................46

Encoder Waveforms and Connections .................................................................................................48

IOC Tests..............................................................................................................................................50

OV/UV Tests.........................................................................................................................................50

Block Diagram - Speed and Current Controller boards .......................................................................52

Base Driver board- Layout and Connections........................................................................................54

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

TABLE OF CONTENTS

INTRODUCTION..................................................................................................................................................... 1

REGENERATIVE … OPERATION ................................................................................................................... 3

QUICK START......................................................................................................................................................... 5

REFERENCE PAGES INDEX............................................................................................................................. 6

MOTOR PROTECTION........................................................................................................................................ 9

WARRANTY............................................................................................................................................................. 9

INSTALLATION

How Do I …

Physically Install the Model 1000AR Drive ?.....................................................................................11

Connect AC Power to the 1000AR Drive ? .......................................................................................13

Connect the Motor to the 1000AR Drive ? ........................................................................................15

Connect the Regenerative Resistors to the Model 1000AR? .........................................................17

Install an Output Contactor ? ............................................................................................................19

Install Dynamic Braking ? ..................................................................................................................19

Connect Standard Control Circuits ? ...............................................................................................21

Get RUN, Zero Speed, FAULT, and ENABLE Information ? .............................................................23

Connect an ANALOG Speed Reference ?.........................................................................................25

Connect a DIGITAL Speed Reference ?............................................................................................27

Connect a DIGIMAX^? ......................................................................................................................29

Installation Checklist .......................................................................................................................31

START UP

What Happens When I …

Apply Power to the Model 1000AR Drive ?........................................................................................33

Give the Start Command to the Model 1000AR Drive.......................................................................35

Give the Speed Command to the Model 1000AR Drive....................................................................37

Slow down or Overhaul the Model 1000AR.........................................................................................39

Make an Adjustment on the Model 1000AR Drive.............................................................................41

TROUBLESHOOTING

Troubleshooting Chart

Troubleshooting the Model 1000AR Drive...........................................................................................43

Troubleshooting Chart - POWER LED ................................................................................................45

Troubleshooting Chart - BUS LED.......................................................................................................47

Troubleshooting Chart - HS1, HS2, HS3, and TAC LED’s ..................................................................49

Troubleshooting Chart - RUN and ENBL LED’s ..................................................................................51

Troubleshooting Chart - TAC and ZERO SPEED LED’s.....................................................................53

Troubleshooting Chart - CURRENT LIMIT and PHAD LED’s .............................................................55

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

INSTALLATION

Underwriter’s Laboratories^®requires this notice for UL^®listed equipment.

This Notice applies to POWERTEC Brushless DC Drive Model Number 1000AR.

Do not use this device on a circuit capable of delivering more than

5000 RMS symmetrical Amperes at 500 VAC maximum voltage.

MOTOR PROTECTION CONSIDERATIONS

You are installing a GENESIS Series Brushless DC (BLDC) drive and motor. You must consider how

the motor will be protected while it is in service. These protections built into your system:

1. “F” Series motors have a thermal switch that opens at high winding temperatures. You must

connect this switch to the drive. Look up the method of connection in the drive manual. When the thermal

switch opens, the drive must shut off before high temperatures cause damage.

2. The Model 1000AR drive provides current limiting. This protection is adjustable from 0% to 150%

of the drive’s rated output current.

3. The Model 1000AR drive provides an over-current trip. The drive shuts off the drive if peak

currents greater than 300% of the RMS rating occur.

4. The Model 1000AR drive provides fast clearing fuses in the AC input. It does not provide an input

circuit breaker unless you chose that option at the time of purchase. If you did not purchase a circuit

breaker with the drive, you must supply a means to disconnect main power.. You must do this in order to

meet the requirements of the National Electrical Code.

5. GENESIS series drives do not provide running overload protection as described in Underwriters

Laboratories Industrial Control Equipment Specification 508. The user is responsible for complying with

local codes and practices. If you decide that you need more protection, that protection must shut off the

drive.

SUMMARY OF WARRANTY AND DISCLAIMER

Powertec manufactures Model 1000 Series Brushless DC (BLDC) motor controls. We warrant

these units against defects in materials and workmanship for a period of two years. This period begins on

the date of original shipment from the factory.

You must notify us in writing of a defect in materials or workmanship in a warranted unit. We will,

at our sole option, repair or replace such defective parts as we deem necessary to restore the unit to

service. We will make these repairs, or replacement of parts, at the factory. Shipping charges to and from

the factory and on-site service charges are the responsibility of the user.

There is no other warranty. We do not warrant the fitness of purpose for the application intended.

This warranty does not cover accidental or intentional damage or accidental or intentional abuse. This

warranty does not cover results from defective or incorrect installation, interference with other equipment,

or any other situation over which Powertec has no control.

This warranty does not cover any other claims, including, but not limited to, special, incidental, or

consequential damages.

Powertec supplies this manual as a guide to the use of our products. We have used our best

efforts to compile this information. If you find mistakes of fact in this manual, please notify your distributor

or Powertec at once.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

MODEL 1000AR DIMENSIONS

CHASSIS UNITS

Note: 10HP @ 230VAC, 10HP @ 380VAC, and 15HP @ 460VAC have the

same dimensions, but they have separately mounted bus loaders

9.85"

9.13"

250mm

232mm

Ø 0.28" DIA

7.1mm

TYP

4 places

2.00"

51mm

TYP

14.00"

18.00"

356mm

457mm

R+ R-

8.35"

212mm

9.25"

235mm

ENCLOSED UNITS

Note: Units with separately mounted bus loaders come in a 34”H x 24”W x 18”D Nema1 Enclosure.

9.85"

250mm

7.05"

179mm

Ø 0.28" DIA

7.1mm

TYP

4 places

22.38"

18.00"

14.00"

568mm

457mm

356mm

1000

2.00"

REGEN

51mm

TYP

8.90"

226mm

9.25"

235mm

2.20"

56mm

9.25"

235mm

ALL DIMENSIONS ARE APPROXIMATE. Consult factory for certified dimensions.

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

HOW DO I …

PHYSICALLY INSTALL THE MODEL 1000AR DRIVE?

Use of the Model 1000AR drive above 3300 ft (1000 meters) requires de-rating.

If the drive is to be stored, store it in its original packaging in a dry environment.

Storage temperature should be between -40°C and +65°C.

WARNING:

DANGEROUS HIGH VOLTAGES ARE NORMAL IN THIS EQUIPMENT! WHEN THE AC INPUT POWER IS

REMOVED, THE CAPACITORS ARE NOT DISCHARGED AT ONCE! BE SURE INPUT POWER IS OFF

AND CAPACITORS ARE DISCHARGED BEFORE WORKING ON THE MOTOR OR THE DRIVE.

WARNING! : IF YOU TESTED THE DRIVE BEFORE INSTALLATION MAKE SURE THAT THE BUS HAS DISCHARGED.

Mount with 1/4-20 bolts

and nuts in 4 places

Mount a Model 1000AR drive of the NEMA 1 style with the fuses at the top.

Free air must flow up through the fins on the back of the drive.

The temperature of the air around the drive (the ambient) must not exceed

40°C (104°F) with a relative humidity of 95% or less.

Leave at least 6 inches (150 mm) open space on all sides of a NEMA1

box. Do not mount it directly above a heat source, such as another drive. There

must be at least 18 inches (450 mm) open space between the units.

When you move a drive chassis, DO NOT handle the chassis by parts that

may bend or come loose. This applies to the front cover of the drive.

R+ R-

Mount the chassis style Model 1000AR drive in an upright position (fuses

at top) inside an enclosure to promote air flow through the heatsink.

The temperature of the air around the chassis unit may not exceed 55 °C

(131 °F). Relative humidity must be 95% or less, and non-condensing.

Avoid mounting one chassis directly above another. This will result in hot air

from the lower chassis flowing up into the upper chassis. Leave at least 12

inches (300 mm) of open space between them.

There must be free panel space of at least 3 inches (75 mm) above and

below the chassis.. This allows air flow through the heatsink fins.

The total heat dissipation within the electrical enclosure determines its size.

A list of heat outputs of the Model 1000AR is in the table on page 6.

NEMA1 and NEMA12 ventilated boxes depend on air flowing through the

enclosure for cooling. They must have an air flow of 1 CFM (cubic feet per

minute) per 10 watts of dissipation (1 cu meter / min per 350 watts).

The allowance for totally enclosed units is 1 square foot of enclosure surface

per 7 watts of dissipation (75 watts per square meter). Surface area includes

front, sides, top and bottom surfaces. Enclosure surfaces not exposed to cooling

air do not count.

R-

For further information, consult the publication THERMAL MANAGEMENT,

available from your distributor.

If a separate bus loader has been supplied, mount it on the panel near the drive. Mount it with the fins

vertically oriented, and make sure that air can flow through its heatsink.

Bus Loader Resistors become VERY HOT in the performance of their duty. Bus loader resistors

must be mounted OUTSIDE THE ENCLOSURE in a dry, well ventilated area, where there are no

flammable materials. Bus loader resistors are supplied in an expanded metal cage for wall mounting.

MODEL 1000AR AC INPUT ELECTRICAL RATINGS

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

NOMINAL

AC LINE

VOLTAGE

MAXIMUM

CONTINUOUS

AC LINE

CURRENT

1.4

MAXIMUM

HEAT

OUTPUT IN

WATTS

HORSE-

POWER

KILO-

WATTS

INPUT

KVA

230

1.5

7.5

0.37

0.56

0.75

1.1

1.5

2.2

3.7

5.6

7.5

0.550

0.725

0.950

1.450

1.950

2.900

4.825

7.200

9.525

1.8

2.4

3.6

4.9

122

165

232

281

385

7.3

12.1

18.1

23.9

‡

380

1.5

0.75

1.1

1.5

2.2

3.7

5.6

7.5

1.5

2.2

2.9

4.4

7.3

0.975

1.450

1.925

2.875

4.810

7.150

9.250

105

142

178

222

7.5

10.9

14.1

‡

460

7.5

1.5

2.2

3.7

5.6

7.5

2.4

3.5

5.9

8.9

11.4

17.8

1.910

2.800

4.750

7.100

9.050

14.150

113

144

200

258

355

475

‡ Indicates drives supplied with separate bus loader.

Notes

The Model 1000AR drives will operate on power line frequencies from 48 to 62 hertz.

The tolerance of the input voltage is +10% to -10% of the voltage listed on the nameplate. A service must be

capable of supporting the starting current of AC motors without dropping more than 10%. Brief power line disturbances

may trip a drive supplied with less than 95% of the nominal line voltage.

Do not measure the input voltage while the drive is not running. This neglects the effects of load on the power

source. Measure the actual input line voltage while the control is operating the motor in a loaded condition.

Brief power line disturbances will not normally disturb the Model 1000AR drives. The Model 1000AR drives do not

generate significant noise back onto the power service. Events that distort the AC waveform may lower the bus voltage.

These may trigger an under-voltage or power loss condition.

One of the most frequent problems encountered with digital type equipment is electrical noise. Noise is a

treacherous problem that is capable of causing destructive results. It can also cause intermittent and annoying problems.

The methods used in the installation of the equipment plays a large part in prevention of electrical noise problems in

operation. Any digital type control requires that extra care be taken in installation. Pay attention to the grounding of the

equipment, the shielding of wires and cables, and the placement of wires in the conduit runs. Pay attention to the

sections of this manual that address the precautions against noise. This also applies to peripheral equipment.

When you use other manufacturer’s equipment in a system, follow their directions regarding noise suppression and

protection. Pay particular attention to power and grounding requirements.

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

HOW DO I …

CONNECT AC POWER TO THE 1000AR DRIVE?

Standard Model 1000AR Brushless DC drives will not operate on

single phase AC power.

Model 1000AR drives require a three-phase main power source with

a KVA rating at least equal to the HorsePower rating of the drive. Power

is NOT returned to the power line during regeneration.

The branch service rating (in KVA) supplying the drive must not be

more than 10 times the HP rating of the drive. If it is, you may need

special disconnecting means with a higher AC short-circuit current

interrupting capacity.

Model 1000AR drives do not include a disconnecting switch for input

power. The user must supply a switch that meets the applicable code

requirements.

The maximum Interrupting Capacity (AIC) of the fuses is 5,000

amperes. You will need a switch with a rating greater than 5,000 amperes

if the short circuit current on the service is greater.

You do not necessarily need an ISOLATION TRANSFORMER for

operation of the drive. You may want to use one, or you might need to

meet local code requirements. You need to change the voltage level.

In those cases, you will need a transformer with a KVA rating at least

as large as the HP rating of the drive. If you use a transformer, we

recommend a delta/wye winding configuration. We also recommend that

the transformer have taps to raise or lower voltage.

TRANSFORMER

The user protection supplied before the wires determines the sizes of

the power wires to the drive input. The table on the opposite page lists the

full load AC line currents of Model 1000AR drives.

The order of connection of the input phases is not important.

We size the main fuses to protect the semiconductor elements of the

unit. THEY MAY OR MAY NOT MEET THE REQUIREMENTS OF

NATIONAL, STATE AND/OR LOCAL ELECTRICAL CODES. The

responsibility for meeting the branch service protection and other code

requirements and safety codes belongs to the user.

NOTICE:

AC LINE CURRENT OF THE BLDC DRIVE IS NOT

REPRESENTATIVE OF MOTOR LOAD CURRENT!

The AC input current is directly proportional to the POWER output of

the motor. The only time the AC line current reaches its full value is when

the motor is operating at full speed with full load.

R+ R-

DO NOT ATTEMPT TO MEASURE MOTOR LOAD

BY MEASURING AC INPUT LINE CURRENT TO THE BLDC MOTOR

CONTROL.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

MODEL 1000AR FUSE BOARD

Model 1000AR Output Electrical Ratings

NOMINAL

MAXIMUM

CONTINUOUS

MOTOR

MAXIMUM

MOMENTARY

MOTOR

NOMINAL

CALIBRATE

RESISTOR

AC LINE

HORSE-

POWER

KILO-

VOLTAGE

WATTS

CURRENT

230

1.5

7.5

0.37

0.56

0.75

1.1

1.5

2.2

3.7

5.6

7.5

2.2

3.4

4.7

7.0

8.5

12.8

22.8

31.1

41.5

3.3

5.1

7.0

10.5

12.7

19.2

34.2

46.6

61.1

68.1 K

45.3 K

33.2 K

22.1 K

18.2 K

12.1 K

6.81 K

4.99 K

3.74 K

‡

380

1.5

0.75

1.1

1.5

2.2

3.7

5.6

7.5

2.7

3.9

4.7

4.0

5.8

7.0

11.7

21.1

28.2

37.5

56.2 K

39.2 K

33.2 K

20.0 K

11.0 K

8.25 K

6.19 K

7.8

14.1

18.8

25.0

7.5

‡

460

7.5

1.5

2.2

3.7

5.6

7.5

4.0

6.9

11.6

17.1

20.7

31.1

6.0

39.2 K

22.1 K

13.3 K

9.09 K

7.50 K

4.99 K

10.3

17.4

25.6

31.0

46.6

‡ Indicates 1000A models.

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

HOW DO I …

CONNECT THE MOTOR TO THE 1000AR DRIVE?

We ship every drive from the factory with A STANDARD CONNECTIONS card.

Connect the motor lead marked T1 to the

T1 terminal on the drive. Connect the T2 lead

to T2 on the drive, and connect T3 to T3. Other

connections to T1, T2, and T3 at the motor will

vary with the motor. The motor will not operate

if the power wires from motor to drive are not in

the proper order.

Full load motor current determines the wire

size to the motor. The table on the opposite

page lists these currents.

Any high voltage, high frequency

equipment generates EMI and RFI. YOU

MUST USE METALLIC CONDUIT TO

ENCLOSE MOTOR WIRES BETWEEN THE

MOTOR AND THE DRIVE. This will minimize

interference.

R+ R-

TB1

TB2

GND

BLDC

MOTOR

You must install a ground wire between the

motor frame and the drive chassis. There is a

ground lug in most motors. If there is no

ground lug, make a connection at any bolt in

the motor junction box.

Orange

Brown

Red

Blue

Yellow

Black

Green

Purple

White

THIS GROUND WIRE MUST BE RUN IN

ADDITION TO GROUNDING THE MOTOR FRAME TO ITS MOUNTING, WHICH IS REQUIRED BY

CODE.

The purpose of this separate ground is to equalize the potential between the motor's frame and the

drive chassis. There may be enough impedance to broadcast EMI and RFI even with the motor grounded

to its mounting frame. A direct wire connection between the motor frame and the drive chassis minimizes

interference in other equipment.

The encoder feedback cable must be a shielded cable. Connect the shield to TB1 terminal 1 on the

control end. Standard installation requires a nine-conductor shielded cable (Belden^™part #9539 or

equivalent). The colors of this cable correspond to the colors of the wires in the motor and on the

connection diagram. You may interchange the Purple and White wires without ill effect.

The shield must be continuous from the motor to the control. Do NOT ground the shield at

intermediate points. This applies to all junction boxes installed between motor and control.

DO NOT USE THE SHIELD OF THE ENCODER CABLE AS AN ACTIVE CONDUCTOR!

If you want to use the motor thermal protector in a 120 VAC circuit, run it in wiring separate from the

cable. Use seven-conductor shielded cable. In this case, if the cable wire colors are different from the

diagram, you need to check them carefully for proper connections.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

REGENERATIVE RESISTORS

Regenerative motor controllers require a method of handling energy that is generated by the motor

and returned to the drive. Traditionally, this has been handled by two methods: (1) using the power lines

as a power sink by dumping excess energy back into the power source, and (2) dissipation as heat.

The first method was popular with DC drives, but it is becoming very unpopular because of the

disruptive effect of the electrical noise in the power system.

The first method has been used by Brushless DC drives, inverters, and vector-type controls. In motor

systems at larger horsepowers, the dissipation means can get bulky and expensive. At horsepowers in the

range of the 1000AR series of drives, they are not a big problem.

Regenerative resistors are rated in terms of resistance and power.

The resistance of the bus loader resistors must allow enough current to flow from the bus through the

resistor(s) to remove the energy at a rate faster than the motor can generate it. The bus voltage times the

bus loader current must be greater than 150% of the motor’s full power rating.

The power rating of the resistors depends on the duty cycle of the regeneration. Powertec uses four

ratings for the GENESIS series of drives:

1. STOPPING DUTY = used to stop the motor once per minute = approximately 10% duty cycle.

2. EXTENDED DUTY = used to stop high inertia loads = approximately 25% duty cycle.

3. LIFTING DUTY = used on cranes and hoists and inclined conveyors = 50% duty cycle.

4. CONTINUOUS DUTY = 100% duty cycle.

The standard supplied with standard GENESIS drives is STOPPING DUTY.

Any duty cycle other than stopping duty MUST BE EVALUATED BY A MECHANICAL ENGINEER.

The amount of regenerative power needed is a MECHANICAL, not an ELECTRICAL, calculation.

To avoid using many different resistors, standard resistor values have been adopted.

The standard resistor for 230 VAC drives is 25 ohms @ 420 W.

The standard resistor for 460 VAC drives is 70 ohms @ 420 W.

The standard resistor for 380 VAC drives is also 70 ohms @ 420 W.

One resistor is used in parallel for each 5 HP or portion thereof.

BUS LOADER RESISTOR TABLE - Standard Duty Resistors

Line Voltage

VAC

Motor HP

Resistors

# @ ohms

Equivalent R

ohms

Dissipation

watts

Peak Amps

ADC

Ave. Amps

ADC

230

up to 5

7.5

1 @ 25

2 @ 25

25.00

12.50

375

750

15.00

30.00

1.00

1.50

2.00

380

up to 5

7.5

1 @ 70

2 @ 70

70.00

35.00

375

750

8.86

17.72

0.60

0.90

1.20

460

up to 5

7.5

1 @ 70

2 @ 70

3 @ 70

70.00

35.00

23.33

375

750

10.72

21.45

32.16

0.50

0.75

1.00

1.50

1125

All resistors are connected in parallel.

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

HOW DO I …

CONNECT THE REGENERATIVE RESISTORS TO THE MODEL

1000AR?

All but the largest Model 1000AR drives have the bus

loader (149-201)built into the chassis. The bus loader mounts

on the lower left-hand side panel and it plugs directly to the

driver board. The power components for the bus loader are on

the lower third of the chassis.

You must include the interlock between terminals TB5-1

and TB5-3 in the control circuits. You must locate the drive’s

regenerative resistors outside the enclosure in a clean, dry,

well-ventilated area.

You MUST connect the regenerative resistors. The

horsepower of the drive, the inertia of the load, and the duty

cycle for regeneration determines the number of resistors

We use a standard 10% duty cycle for stopping duty and

for light regenerative loads. The standard resistor package is

NOT guaranteed to handle all situations. IT IS THE

RESPONSIBILITY OF THE USER TO SPECIFY THE SIZE OF

THE REGENERATIVE RESISTOR PACKAGE. If necessary,

an engineering evaluation should be made.

R+ R-

The interlock is built into the Bus Loader board. The

interlock will open if the bus loader fuse opens up or if the

board fails to function. If the drive tries to regenerate without

the bus loader operating, the drive will trip.

CONTROL

CIRCUIT

INTERLOCK

BUS LOADER

RESISTOR(S)

The separately mounted bus loader (149-

101) should be mounted close to the drive. The

resistors must be mounted in their own cage

outside any enclosure. Mount the resistors in a

clean, dry and well ventilated area away from

personnel.

TB5 terminals 3 and 5 must be connected

to the AC drive power. The drawing shows L1

and L2 connected, but any two of the three

phases can be connected.

The resistors must be connected to the R1

and R2 terminals. All standard resistors are

connected in parallel (see page 10 for resistor

values).

Connect the interlock at TB5 terminals 1

and 2 into the control circuit (see page 15).

Connect the fuse input to the POS BUS

connection on the Capacitor Board. Connect

the NEG terminal to the NEG BUS connection

on the Capacitor Board.

Operating the 1000AR drive without the Bus Loader attached, or with the Bus Loader disabled, will

result in the drive tripping. OverVoltage will occur as soon as regenerative operation is attempted. This

could also result in damage to the drive.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

CONTACTOR SPECIFICATIONS

If you want to operate an Output or DB Contactor directly

from the Model 1000AR, you must choose a coil that draws

less than 50 milliamps DC.

1.77"

The Output Contactor drawing on page 11 shows the

connections for direct operation of the contactor (use the

same connections for Dynamic Braking). The coil must be

48VDC and draw less than 50 ma DC (2.4 Watts). This is the

most power available from the Model 1000AR drive’s supplies.

To use a 115VAC or 230 VAC coil, you need a 156-012

Contactor Control board, as shown in the drawing on page 11.

Use the same drawing for the Output Contactor. Maximum

current for the Contactor Control board is 1 Amp at 230 VAC.

1.66"

You need three normally open power poles and a normally

open auxiliary for an Output Contactor. The contactor does

not make or break with current in the power contacts. Choose

the contact ratings only on the basis of carrying the current.

For Dynamic Braking, you need three normally closed

power poles and a normally open auxiliary. The contacts make

with current present, but they do not break current in the

dynamic braking operation. Choose contacts accordingly.

TOP VIEW

0.19"

1.25"

1.54"

The contactor outline sketched at left is from the SH-04

series by AEG Industries. The model used for the Output

Contactor is part number SH-04.40 and the Dynamic Braking

is SH-04.13. Contact ratings are 16 Amps.

BOTTOM VIEW

DYNAMIC BRAKING RESISTORS

We choose DB resistors for their ability to absorb high inrush currents and to accept large amounts of

power for short periods of time. Typical DB resistors can absorb ten times their power rating for up to five

seconds. The resistors must then cool down to ambient temperature before they can dissipate their full

rating again (usually a few minutes). It is possible to extend the ratings by about three times with power

resistors by forced-air cooling.

You can derive an approximate value of dynamic braking resistor from the bus voltage and the full

load current on the nameplate of the motor:

Bus Voltage X 0.47

Each Resistor Value ~ -----------------------------------

Motor FLA

Three resistors (or groups of resistors) are necessary. The power rating of each should be:

Power > 0.02 X (Buss Voltage)²/ (Resistor Value)

These formulas are very general, and results will vary from motor to motor. For dynamic braking

tailored to your application, consult POWERTEC Engineering.

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

HOW DO I …

CONNECT AN OUTPUT CONTACTOR?

You may use an output contactor with the Model 1000AR.

You MUST interlock the contactor with the Emergency Stop. You

WILL damage the drive if you do not interlock the contactor.

GND

Requirements for the Model 1000 series are:

1. The contactor must close its main power contacts

BEFORE it enables the drive;

2. The contactor may only open its contacts AFTER

disabling the drive.

BLDC

MOTOR

The contactor does not make or break current.

R+ R-

MOTOR

THERMAL

The figure at left shows the connections for a 48VDC output

contactor (such as AEG part number SH-04.40-ODC, which is

available from POWERTEC).

In this configuration, the contactor pulls in on a run

command and drops out ONLY on an emergency stop. The

contactor stays energized during normal stops.

TB2

10 11 12 13 14 15 16

CONTACTOR

POLE N.O.

N.O. aux

48VDC COIL

2.4

M (aux)

EMER

POWERTEC makes an optional track mount PC board (Part

STOP

RUN

JOG

# 156-012) for sequencing of contactors with AC coils.

Bus Loader

Interlock

DO NOT BREAK THE GROUND CONNECTION OR THE CABLE

CONNECTIONS WITH THE OUTPUT CONTACTOR.

HOW DO I …

CONNECT DYNAMIC BRAKING?

TO MOTOR

THERMAL

You MUST interlock the contactor with the

Emergency Stop when using Dynamic Braking. You will

damage the drive and/or the resistor banks if you do not

properly interlock the contactor.

Bus

Loader

Interlock

The requirements are:

The contactor must open the main power

contacts BEFORE the drive is enabled; AND

2. The contactor may only close its contacts

AFTER disabling the drive.

CONTACTOR

3 POLE n.c.

1 N.O. Aux

COIL < 230VAC

The AEG SH-04.13-ODC contactor is suitable to

the circuitry above. The figure on the left shows how to

use a POWERTEC 156-012 Contactor Control board to

control a larger contactor or a contactor with an AC coil.

In this configuration, the contactor energizes on a

run command and drops out ONLY on an emergency

stop. The contactor stays energized on a normal stop.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

MODEL 1000AR CONTROL CONNECTIONS

Normal l y cl osed thermal swi tch i n the motor. T HE MOT OR

MOTOR

THERMAL

T HERMAL SWICH MUST BE USED T O PROPERLY PROT ECT

T HE MOT OR! When the swi tch opens, the dri ve must be shut

off to prevent damage to the motor from overheati ng.

STD: CONNECT

FROM

TB2-10 TO TB5-1**

Vol tage must be present to RUN or JOG. When removed,

ENABLE REQUEST i s bl ocked i mmedi atel y (see page 29) and

al l control functi ons are di sabl ed. Do not connect vol tage to

termi nal wi th permanent j umper. In RAMP ST OP mode, thi s i s

the onl y way to stop the dri ve.

+24VDC ON TB2-11

EMERGENCY

STOP

STD: N/C PB FROM

TB2-11 TO TB5-3**

Vol tage must be present to mai ntai n RUN mode after a

momentary ST ART i s removed. When vol tage i s removed, the

dri ve decel erates to zero speed at the DECEL rate and shuts

off i f RAMP ST OP j umper JP2 i s i nstal l ed. Otherwi se dri ve

shuts off i mmedi atel y and the motor coasts to a stop.

Vol tage must be appl i ed to i ni ti ate RUN mode. When i t i s

removed, dri ve shuts off unl ess +24VDC i s present at T B2-5.

RUN LED turns on when +24VDC i s appl i ed to T B2-4. RUN

LED turns off and RUN rel ay drops out when vol tage i s

removed from both T B2-4 and T B2-5.

+24VDC ON TB2-12

RAMP STOP

STD: N/C PB FROM

TB2-11 TO TB2-12

+24VDC ON TB2-13

START /

RUN

STD: N/O PB FROM

TB2-12 TO TB2-13

Normal l y open dry contact cl oses when ST ART i s energi zed

and opens when RUN rel ay drops out. T he RUN contact does

not open on a F AULT . T he RUN contact does not cl ose on

JOG and opens i n RAMP ST OP mode.

RUN

CONTACT

TB2-7 AND TB2-8

Open col l ector transi stor output referenced to T B2-12. Rated

at 50 mADC @ 50 VDC max. T hi s output operates onl y i n RUN,

JOG, or RAMP ST OP modes. T he Z ERO SPEED output turns

on at about 10 RPM and off at about 5 RPM. T he Z ERO

SPEED output shuts off i f the ENABLE LED shuts off.

Voltage must be applied to initiate JOG mode. JOG mode will

be mai ntai ned onl y as l ong as the vol tage i s present. When

the voltage is removed, the drive will go to RAMP STOP mode

i f COAST T O ST OP j umper JP2 i s i nstal l ed. Otherwi se the

dri ve shuts off and the motor coasts to a stop.

ZERO

SPEED

OUTPUT: TB2-1

COMMON: TB2-16

-24VDC ON TB2-14

JOG

STD: N/O PB FROM

TB2-9 TO TB2-14

When the vol tage i s appl i ed, the output of the Vol tage

Controlled Oscillator is reduced to zero PPR. This causes the

dri ve to decel erate to zero speed i n current l i mi t and hol d

there. When the vol tage i s removed, the dri ve accel erates

back to set speed i n current l i mi t.

-24VDC ON TB2-15

HOLD

STD: N/O PB FROM

TB2-9 TO TB2-15

NOTICE: The drive is NOT OFF in the HOLD function.

Opti cal l y coupl ed transi stor output (i sol ated). Rated at 50

mADC @ 50 VDC. T urns on when bus has achi eved proper

l evel . Output i s off when any tri p occurs.

OUTPUT

FAULT

OUTPUT

COLLECTOR: TB1-12

EMITTER: TB1-13

+24VDC ON TB1-10

REFERENCE TB1-9

Appl y vol tage to swi tch to DIGIT AL mode. T B1-10 and T B1-9

are el ectri cal l y i sol ated from the board power suppl i es. T he

negati ve si de of the +24VDC used for the i nput must be

connected to T B1-9. External frequency must be appl i ed to

termi nal 11. T ermi nal 9 i s al so common for thi s frequency.

ANALOG/

DIGITAL

SWITCH

TB1-9 IS NOT DRIVE

COMMON

** Note: TB5 is on the Bus Loader. The Small Bus Loader interlock is TB5-1 and TB5-3.

The large Bus Loader interlock is TB5-1 and TB5-2.

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

HOW DO I …

CONNECT STANDARD CONTROL CIRCUITS?

If you are using an output contactor or dynamic

braking, go to page 19.

The table on the opposite page lists the functions of

the Model 1000AR. The table lists the connections and

descriptions of the control circuits. Read the descriptions of

the operations of these circuits very carefully. There are

differences between analog and digital modes.

The control circuits of Model 1000AR motor control

operate on 48 VDC. This results from using the positive and

negative 24 VDC supplies. Using 48VDC helps balance the

load of relays and other devices on the power supplies.

The maximum current from each of the raw supplies is

50 milliamps. Due to this limitation, you must use an

external supply when you use several external relays.

R+ R-

TB2

Bus Loader

Interlock

THE POWER SUPPLIES OF THE MODEL 1000AR

SHOULD NOT BE USED FOR EXTERNAL EQUIPMENT!

Powertec has an optional power supply (part # 127-101)

available for 24VDC to power external circuits.

TB5

10 11 12 13 14 15 16

MOTOR

THERMAL

EMER

STOP

It is possible to operate control circuits with a variety of

devices. Standard operator devices are O.K.., but the

current flow to these devices is very small. When locating

pushbuttons more than 30 feet away from the motor control,

consider using 120 VAC control circuits.

START

JOG

RAMP

STOP

RUN HOLD

Install ESTOP buttons Do NOT place a jumper across the Emergency Stop terminals. Because the

drive has a ramp to stop capability, this could set up an UNSAFE situation. IT IS STRONGLY

RECOMMENDED THAT AN EMERGENCY STOP BUTTON (or an ESTOP relay) BE CONNECTED TO

THE DRIVE! This should be of the MAINTAINED CONTACT TYPE.

The motor thermal must be used to PROPERLY protect the motor!

You can use a "two-wire" control by connecting a contact or switch between terminals 11 and 13 on

TB2. Leave off the RAMP STOP and START buttons. This DOES NOT disable the RAMP STOP function.

The only way to disable the RAMP STOP function is removing the RAMP STOP jumper.

The RAMP STOP function in the analog mode shorts the analog reference input to zero. This causes

the motor to decelerate to zero speed before shut-down.

Note that the JOG function is disabled by the RUN function. If you activate the JOG input while the

RUN mode is in operation, there will be no effect.

The HOLD function zeroes the speed reference to bring the motor to a stop and holds the drive at

zero speed. THE DRIVE IS NOT OFF IN THE HOLD MODE! There is a potential for the motor to run, so

the appropriate safety precautions should be taken.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

TERMINAL DESCRIPTIONS - MODEL 1000AR

TB1

Current Controller Board (141-108)

Dedicated Shields and Ground connection

HS1 position encoder

HS3 position encoder

HS2 position encoder

HS4 speed encoder

HS5 speed encoder

Encoder Common

for encoder ONLY

Encoder +5 VDC

for encoder ONLY

Isolated Common

for terminals 10 and 11

+24 VDC for Digital Mode

+24 VDC Square Wave

Auto/Manual Selection

External Frequency Input

Collector of FAULT transistor

Emitter of FAULT transistor

Drive Load output

-2VDC = 150%

+15VDC for extra encoder

Auxiliary Supply output

Power Supplies Common

TB2

Speed Controller Board (147-101)

ON at zero speed (open collector)

ON when enabled (open collector)

Speed Output (open collector)

-10VDC Reference Source

Speed Reference Input

+10VDC Reference Source

RUN output contact

30VDC 50 mA maximums

5 mA maximum

-10VDC to +10VDC

5 mA maximum

N/O 125VAC

RUN output contact

-24VDC supply

N/O 1A Resistive

50 mA maximum

+24VDC supply

EMERGENCY STOP Input

RAMP STOP Input

RUN/START Input

JOG Input

50 mA maximum

+24VDC to activate

-24VDC to activate

HOLD Input

Signal Common

TB3

TB5

Capacitor Board (141-106)

Horsepower calibration resistor

No connection

Horsepower calibration resistor

Bus Loader (Integral unit connected to Driver board)

Bus loader Interlock

No connection

Bus loader Interlock

N/O 125VAC

N/O 1A Resistive

HOW DO I …

GET RUN, ZERO SPEED, FAULT AND ENABLE INFORMATION?

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

The RUN relay contact at TB2 terminals 7 and 8 is a dry contact

rated at 1 Amp (Resistive load) at 125VAC. You may use it in an

external circuit as long as the voltage does not exceed 125 VAC

(limitation of the terminal strip).

You may use an auxiliary relay if you need more power, or if you

need more contacts, as shown in the drawing at the left. You should

use a 48VDC coil (highly recommended) since this reduces the burden

on one supply. The diode is a general purpose type rated for at least 1

Amp at 100VDC PIV (1N4002 or equivalent).

The ZERO SPEED output at TB2 terminal 1 is an open collector

NPN transistor, rated at 50 ma at 50 VDC. The ZERO SPEED

transistor turns on at about 10 RPM and turns off at about 5.RPM

The transistor emitter is at drive common and it may interface

directly with a PLC as a sinking input.

R+

R-

The output can operate a relay as shown in the top drawing on

the left. The transistor returns to drive common, so it is not possible to

use a 48VDC relay with the drive’s supplies. If you use a 24VDC relay,

the current must be as low as possible. The diode is a general

purpose type.

TB2

10 11 12 13 14 15 16

The ZERO SPEED relay will chatter at very low speeds. You can

overcome this with a latching circuit that releases at the first dropout of

the zero speed relay.

ZERO

RUN

RELAY

48VDC Coil

SPEED

RELAY

24VDC Coil

The FAULT output at TB1 terminals 12 and 13 is the output

transistor of an optical coupler. The coupler’s rating is 100VDC @ 50

ma.

Connect a FAULT relay with a 48VDC coil as shown in the

bottom figure at left. The external FAULT relay energizes when the

drive completes power-up and de-energizes when a fault occurs.

The diode is a general purpose diode.

The Model 1000AR has an ENABLE output terminal at TB2

terminal 2. The ENABLE output is an open collector transistor that

turns on when the drive is ready to accept a reference for speed

input, whether in RUN or in JOG. You must use a 24VDC coil on the

ENABLE output.

R+

R-

The ENABLE output shuts off if there is a trip or when the drive

shuts off either on Emergency Stop or a non-ramp stop, or when the

JOG input is released.

FAULT

OUTPUT

ISOLATOR

TB2

TB1

10 11 12 13 14 15 16

10 11

ENABLE

24V

The internal RUN relay drops out on RAMP STOP. The

ENABLE output remains energized throughout the RAMP STOP

sequence. Use ENABLE for functions which must continue when the

motor is running.

FAULT

48V

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

PLC INTERFACE

The interface of the Models 1000 and 1000A with a

process controller is dependent upon the ability of the PC

to handle the required signals.

SINKING CONNECTION

PLC

INPUT

MODULE

TB2

Most of the signals are +24 VDC or 48 VDC (positive

and negative 24 VDC supplies for control), or +10 VDC for

speed. You may also use computer generated frequency

signals for speed in the DIGITAL mode.

DRIVE

+24VDC

ZERO

SPEED

INPUT

There are two types of input modules.

A "sinking" connection uses the Programmable

Controller’s own power, or an external source, and

connects it (sinks it) to common level by the connected

input device. The drawing on the left illustrates the method

for using an open collector output to "sink" the input of a

+24 VDC PC input module using an external supply from

the drive.. When the transistor turns on, it turns on the

input module.

COM

SOURCING CONNECTION

PLC

INPUT

MODULE

TB2

DRIVE

+24VDC

A “sourcing” connection turns on the PLC module by

supplying power to it. The second figure shows a sourcing

connection. Notice, however, the inverted sense, that is,

when the transistor turns on, the input is not.

2Kohm

MIN

ZERO

SPEED

INPUT

You can use the fault output with connections similar

to those in the above figures. You can use a PLC input

module, with the FAULT output of the control at TB1

terminals 12 and 13, to sense a FAULT in the drive. The

bottom figure illustrates this.

COM

You need to keep in mind that the FAULT isolated

output transistor is "ON" when there is no fault present.

FAULT MONITOR

PLC

INPUT

MODULE

You should accomplish all of the programmable

controller operations of the standard control circuits of the

Models 1000 series controls with relays. These circuits

see 24VDC to ground, but they operate at 48VDC. RUN,

JOG, STOP, and EMERGENCY STOP inputs operate on

+24 VDC supplies. The circuitry, however, actually

operates between positive and negative supplies, and it is

difficult to make connections that do not involve both

power supplies.

TB1

FAULT

INPUT

COM

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

HOW DO I …

CONNECT AN ANALOG SPEED REFERENCE?

The analog speed reference for the Model 1000AR is -

10 VDC to +10 VDC with the positive connection on TB2

terminal 5 and the common connection on TB2 terminal 16.

Voltages less than -10 VDC become non-linear and

voltages greater than 10 VDC become non-linear.

The input impedance is about 100K. Using a speed

potentiometer with a resistance greater than 10 Kohms

may result in non-linear operation of the speed pot.

There is a 10VDC source at TB2 terminal 4 and a

+10VDC source at TB2 terminal 6. The supplies have a 10

ma limit.

R+ R-

There is no minimum speed pot on the 1000AR.

The input at TB2 terminal 5 is bi-polar. The direction of

the motor is dependent on the polarity of the input

reference. Connections are shown in the figure on the left

for bi-directional operation (-10 VDC for full speed forward

to +10VDC for full speed reverse. Zero VDC is zero speed.

BI-DIRECTIONAL

OPERATION

TB2

10 11 12 13 14 15 16

SPEED POT

10K

Enclose the wires to a speed pot in a shielded cable,

for noise reduction. Connect the shield only at the drive

end, on TB2 terminal 16.

UNI-DIRECTIONAL

OPERATION

TB2

The reference voltage for the input does not have to

come from the reference sources at TB2 terminals 4 and 6.

You can introduce an external reference voltage between

TB2 terminals 5 (+) and 16 (common). The speed of the

motor varies as the external voltage varies. The direction of

the motor changes when the polarity of the signal changes.

10 11 12 13 14 15 16

CCW

SPEED POT

10K

If you use an external “current source” speed control

(such as a 4 to 20 ma signal), you must convert it to a

voltage. Then you may introduce this voltage as a speed

reference command to TB2 terminal 5 (+) and TB2 terminal

16 (-), as shown in the diagram.

EXTERNAL SOURCE

10 11 12 13 14 15 16

TB2

0 TO 10VDC

REFERENCE

When using a speed pot or an external voltage, it is

not necessary to reduce the speed signal to zero before

starting the drive. Starting the drive with a speed input already present will not damage the drive, even at

very high accel rates.

The Brushless DC drive operates over very wide speed ranges, so when you want the motor to stop

with the drive in RUN mode, there must be ZERO VDC at the input. Voltages as low as 70 millivolts (0.070

VDC) will cause the motor to turn. Noise levels on the reference line can reach these values. You must be

very careful about shielding and common mode voltages if you expect to operate with references of less

than 0.5 VDC.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

DIGITAL MODE NOTES

Since the Brushless DC motor control system is inherently digital, the

performance in the digital mode of operation far exceeds the performance in the

analog mode. In the digital mode the control and motor respond to a frequency

signal fed to the control from an external source.

In the digital mode, we use the same digital control circuitry for the speed

control as we do in the analog mode. The analog output of the accel/decel

circuits drives a voltage-controlled-oscillator (VCO), which in turn feeds the digital

circuitry. We bypass the VCO in digital mode and use an external reference

frequency to control speed.

Activate the digital mode by applying a nominal +24 VDC voltage to TB1

terminal 10, positive with respect to TB1 terminal 9. There is also a jumper next

to P2 on the Current Controller board (141-108) which, when placed in the AF

position, switches the control into the digital mode without energizing terminal 10.

Either of these actions disconnects the control's internal VCO and looks for a

frequency at TB1 terminal 11, which must be positive with respect to TB1 terminal

9. This frequency signal must meet certain specifications:

"ON" VOLTAGE: 18 VDC min, 30 VDC max

"OFF" VOLTAGE: less than 1.5 VDC

FREQUENCY:

DUTY CYCLE:

2X desired RPM (250 frames or smaller)

25% min, 75% max

MAXIMUM FREQ: 50 Kilohertz

You can obtain the best tracking by "ramping" the frequency, that is,

changing the frequency gradually. The motor accelerates in current limit if a

frequency is present when the control starts.

The nature of the Brushless DC motor control is that the motor must return

a pulse for each reference pulse supplied, except in current limit! You will lose

pulses if the control goes into current limit, even for a brief time. So it is best to

not change the external frequency so rapidly that the motor cannot respond

without going into current limit.

In Digital Mode, you may select the direction of the motor rotation by the

polarity of a voltage at TB2 terminal 5 (2Q/4Q jumper in the 4Q position), or with

the FWD/REV jumper (2Q/4Q jumper in the 2Q position).

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

HOW DO I …

CONNECT A DIGITAL SPEED REFERENCE?

Apply +24VDC to TB1 terminal 10 (TB1-10)

with respect to TB1-9 to operate the Model 1000

with a digital reference. Terminal 9 on TB1 is NOT

the same as drive common. A jumper from TB2-10

will NOT switch to digital mode unless you connect

TB1-9 to a drive common terminal (TB1-16).

With +24VDC on TB1-10, a pulse train at TB1-

11 (with respect to TB1-9) commands the motor

movement. On page 20, there is a list of

recommended parameters for the pulse train.

R+ R-

You can also turn on digital mode by moving

the “AF-N” jumper (JP1) on the Current Controller

board to the AF position (the two left pins). After

placing the jumper in the AF position, you do not

have to energize terminal 10.

TB1

TB2

10 11

10 11 12 13 14 15 16

MAN AUTO

While in digital mode, Speed Controller board

adjustments related to speed do not function, that is,

SPEED POT, MIN SPD, MAX SPEED, ACCEL,

DECEL, and JOG. The pulse train input governs the

movement of the motor.

SPEED

POT

10K

VDC

24VDC

0VDC

Almost all motors used with the Model

1000AR standard drives have 30 pulse per

revolution quadrature encoders. This produces a

120 pulse per revolution (PPR) feedback. Each

pulse put into the drive is a command to turn 3°

in its mechanical rotation.

The pulse train input for a GENESIS drive

may come from another GENESIS drive, since

there is an output on TB2 (the figure below

shows Model 1000 connections). Terminal 3

(TB2-3) is the collector of a transistor (TB2-16 is

common) which switches at twice the motor RPM. If you connect a resistor (at least 1 Kohm minimum)

from TB2-10 (+24 VDC) to TB2-3, you generate a signal that can drive the input of another drive. Connect

TB2-3 on the first control to TB1-11 on the second control, and connect TB2-16 on the first control to TB1-

9 on the second. To switch to digital mode, connect TB2-10 on the first control to TB1-10 on the second.

With this setup, the second motor will

operate at exactly the same speed as the first,

as long as you avoid current limit on the

second control. If the first control encounters

current limit, or changes speed for any other

reason, the second one (the follower) will

follow it in speed, even to zero speed.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

ANALOG VERSUS DIGITAL OPERATION

The choice between ANALOG and DIGITAL operation comes down to performance.

In ANALOG mode, a voltage sets the speed of the motor. Due to analog component tolerances, the

best accuracy you can expect is on the order of +/- 1%. It is typically 0.1% or better. The biggest problem

with Brushless DC is not the following of an analog source. It is the obtaining of a clean and stable analog

source to follow. Electrical noise can

be a nasty problem, and you must

use good shielding methods.

ANALOG

Value

In single motor operation, the

motor does not have to follow a

precise speed or a profile generated

by another motor or other source.

The ANALOG speed reference is

Speed Regulation

Speed Accuracy

Speed Drift

0% from No Load to Full Load

+/- 1% of Speed Reference

adequate in almost all cases. Changing load does not change the speed of the motor.

Coordinating the speed of two or more motors with analog methods requires some type of trimming

device, such as a dancer or load cell. Analog tolerances and noise make exact coordination very hard.

In DIGITAL mode, the speed of the motor is proportional to the frequency of the pulse train presented

at the TB1 terminals 11 and 9. Each pulse to the drive at these terminals will require a pulse from the

motor. The EEPROM multiplier used

in the Current Controller board

DIGITAL

Value

determines the effect of the pulse

from the motor. Analog tolerances do

not disturb the system, nor will there

be any temperature drift.

For single motor operation, use

DIGITAL methods where precise

speeds are important, that is, if you

Speed Regulation

Speed Accuracy

0% from No Load to Full Load

1 Motor Feedback Pulse for each Pulse

of Speed Reference

Speed Drift

+/- 1 Speed Reference Pulse

really want to be able to set 1749 RPM and get that speed precisely. Motor load does not change the

speed and the speed set by DIGITAL means has a drift of 1 Speed Reference pulse (less than 3° of motor

shaft rotation).

Speed coordination of two or more motors requires DIGITAL means for systems that do not have a

trimming device. Two motors connected by DIGITAL signals will track pulse for pulse.

Even though the motors may be made to operate together or in an exact ratio, there is a possibility

that the mechanical system or the speed setting devices may not be identical. If this is the case, some

type of trimming device may be necessary in a digital system. If the material does not stretch, this will

become apparent in short order.

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

HOW DO I …

CONNECT A DIGIMAX®?

The DIGIMAX^®is a

crystal-based Speed or

Ratio controller. It creates a

train of pulses to command

the movement of a motor

when the drive is operating

in digital speed mode.

suitable train of

pulses applied at TB1

terminal 11 (with respect to

TB1-9) of the Model 1000

commands the drive to turn

the motor 3° for each pulse.

However, the drive’s routine

adjustments such as MIN

SPEED,

MAX

SPEED,

ACCEL, DECEL, and JOG

SPEED are not functional.

The DIGIMAX^supplies

these functions.

The wiring diagram at

left shows all the basic

connections

the

DIGIMAX. Not all of them

are necessary for all

installations. For instance,

external frequency is only

needed for slave mode.

The power, ground,

and shield connections on DIGIMAX TB1 are necessary. The jumper from TB1-4 goes to a screw in the

back plate.

The pulse train comes from DIGIMAX TB1 terminals 11(+) and 10(-). It is applied to the Model

1000AR TB1 terminals 11(+) and 9(-).

The MAN/AUTO switch may be left out. You can make a straight connection from DIGIMAX TB1-7 to

Model 1000AR TB1-10. Even this connection may be left off if the Current Controller board jumper JP1 is

in the AF position (see page 27).

The DIGIMAX control inputs are on TB2 terminals 5 through 10. These inputs require +24VDC. TB2

terminal 4 is the common connection for these isolated inputs. RUN (terminal 5) and ESTOP (terminal 7)

are required for DIGIMAX operation. PRESET (terminal 6) is an optional second speed. The REVERSE

input (terminal 8) must operate in conjunction with the drive’s reverse, if it is used.

The EXTERNAL FREQUENCY input (TB2 terminals 13 and 14) is only used in the SLAVE mode. It is

used when the DIGIMAX is to follow another pulse train from another DIGIMAX or drive.

The input at DIGIMAX TB2 terminals 15, 16, and 17 in an optional motor load reading signal.

For further information, refer to the DIGIMAX Installation and Operation Manual.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

Power Input

L1 L2 L3

Output Terminals

Warning:

Input

fuses

Do Not Connect

Input Power Leads

to Output Terminals

Model 1000AR Standard Connections

NOTICE:

ANY POWER EQUIPMENT SWITCHING HIGH VOLTAGES AT HIGH FREQUENCIES EMITS RADIO

FREQUENCY INTERFERENCE ( RFI ) AND ELECTROMAGNETIC INTERFERENCE ( EMI ). THE

MOTOR LEADS MUST BE RUN IN METALLIC CONDUIT TO PREVENT INTERFERENCE WITH

OTHER EQUIPMENT. THIS CONDUIT MUST BE ALL IN ONE PIECE, IF POSSIBLE, AND THIS

CONDUIT MUST BE SOLIDLY GROUNDED. ONLY THE MOTOR LEADS AND THE GROUND WIRE

FROM THE CONTROL TO THE MOTOR SHOULD BE IN THIS CONDUIT.

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

INSTALLATION CHECKLIST

Is the Model 1000AR securely mounted in a vertical position (fuses up) [page 5]?

Is there a clear path for airflow through the base heatsink and through the chassis [page 5]?

Is the temperature of the air surrounding the drive within specifications [page 5]?

Is the AC power source for the drive of the proper voltage, frequency, and capacity [page 7]?

Is the motor securely mounted and aligned [motor manual]?

Is the drive and motor system properly grounded [pages 7 and 9] ?

Are the motor leads connected in the proper order [page 9]?

Is the cable from the motor to the drive properly connected [page 9]?

Is the bus loader installed and properly connected [page 11]?

Are the regen resistors properly installed and connected [page 11]?

If an Output or Dynamic Braking Contactor is used, is it properly interlocked [page13]?

If Dynamic Braking is used, are the resistors properly installed and wired [page13]?

Is the motor thermal properly wired to the drive [pages 14 and 15]?

Is the Emergency Stop button properly installed [pages 14 and 15]?

Are other drive controls properly wired [pages 14 and 15]?

Is the Speed Reference source properly wired in [page 19 or 21]?

Is the motor mechanically safe to run (an unloaded motor is recommended) ?

Is the machine safe to run and are all personnel clear ?

Proceed to the Start Up section.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

BUS CONNECTIONS ARE ON

THE CAPACITOR BOARD ON

THE RIGHT SIDEWALL.

BEHIND FRONT PANELS.

R+ R-

CURRENT

CONTROLLER

BOARD

SPEED

CONTROLLER

BOARD

BUS LOADER

BOARD

Capacitor Board Layout and Connections

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

CURRENT CONTROLLER

BOARD

WHAT HAPPENS WHEN I …

APPLY POWER TO THE MODEL 1000AR ?

When you apply the power to the Model 1000AR, the graph

below demonstrates what happens to the drive’s bus voltage.

JP1

POWER ON

CONTACTOR

PULLS IN

640

VDC

563

JP3

VDC

540

POWER

GREEN

BUS

VDC

STALL

BUS

HS3

VOLTAGE IF

CONTACTOR

DOES NOT

PULL IN

RED

VOLTAGE

RED

BUS

HS2

RED/GREEN

OUTPUT

OF DIODE

BRIDGE

RED

ENABLE

HS1

YELLOW

RED

UNDERVOLTAGE

RED

TAC

OV/UV

RED/GREEN

VDC

RED

TIME

IOC

RED

PWR BUS

LED LED

ON RED

BUS

LED

TB1

GREEN

You can observe the bus voltage with a voltmeter connected to the POSITIVE BUS and NEGATIVE

BUS terminals on the Capacitor Board. This board is located on the right sidewall of the drive behind the

front panels (see page 26). The Bus terminals are near the top of the drive. BE CAREFUL. THESE

TERMINALS MAY HAVE POTENTIALS UP TO 800VDC!!

There are LED indicators on the Current Controller board (see the layout on page 28). The action of

some of these LED’s is indicated in the graph above and on subsequent pages.

The POWER LED (it is GREEN in color) comes on as soon as the main power is turned on. This

LED operates from the +24VDC raw power supply. If this LED does not come on, you should check the

incoming power, main fuses and power transformer fuse.

While the bus is charging, the BUS LED lights up RED in color. When the bus reaches a level of

approximately 35VDC below the nominal bus level, a contactor energizes to bypass the charging resistor.

The BUS light then changes to GREEN in color. If the light does not change to GREEN within 30 seconds,

turn off the input power and attach a meter to the bus terminals to monitor the bus voltage. See the

troubleshooting section for assistance.

On the Current Controller board, there are three LED’s labeled HS1, HS2, and HS3. These are the

encoder position indicators. One or two of these indicators should be on. If none are on or if all three are

on, there is a problem. Refer to the troubleshooting section. The TAC LED may be off or RED or GREEN.

It is not important at this time.

The ENABLE LED should be off.

Once the bus has charged up and the BUS LED is GREEN, you may proceed to the next section.

A GREEN LED on the Bus Loader should be ON, but the RED LED on the bus loader must be OFF.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

JUMPERS

SPEED CONTROLLER

BOARD

CURRENT CONTROLLER BOARD 141-108

JP1 - “AF-N” Jumper - Used to decide whether

or not the drive is permanently in the “DIGITAL”

mode. This selection overrides the input at TB1

terminal 10. If JP1 is in the “AF” position, the drive is

in the DIGITAL mode and TB1 terminal 10 has no

effect. If JP1 is in the “N” position, you must apply

+24VDC to TB1-terminal 10 to switch to DIGITAL

mode.

STAB

GAIN

MCL

RCL

JP1

MAX SPD

JOG SPD

DIR/RL

JUMPER

2QOP - “RESET” Jumper - Used to trap faults

when troubleshooting. Faults are normally reset by

pressing the STOP button when the RESET jumper

is in the INTERNAL (INT) position. When the RESET

jumper is moved to the MAN (Manual) position, the

faults do not reset by pushing the STOP button. The

fault must be reset by moving the RESET jumper to

the middle (RESET) position and then the jumper

must be moved to either INT or MAN. The drive will

not run with the jumper in the middle position.

DECEL

ACCEL

CURRENT

LIMIT

2Q/4Q

JUMPER

RAMP STOP

JUMPER

ESTO

RUN

FWD/REV

JUMPER

RAMP STOP

REGEN

JOG

ENABLED

HOLD

SPEED CONTROLLER BOARD 147-101

JP1 - “10% REGEN” Jumper - When installed,

allows Regen Current Limit up to 150%, when

removed, limits to 10% of full load current.

TB1

10 11 12 13 14 15 16 17 18

2QOP - “2Q Operation” Jumper - Leave this jumper installed. Removing it disables the Current loop.

DIR/RL - “ACCEL/DECEL Range” Jumper - Installing this jumper sets the ACCEL and DECEL rates to 2 to 90

seconds (approximately). With this jumper removed, ACCEL/DECEL rates are set for 50 ms to 2 seconds.

RAMP STOP - “RAMP STOP” Jumper - When this jumper is installed, the drive will decelerate at the DECEL rate to

zero speed and then shut off. If this jumper is removed, the drive shuts off as soon as the stop button is pressed.

2Q/4Q - “DIRECTION MODE” Jumper - The jumper marked 2Q/4Q actually controls the direction jumper’s mode. In

the 4Q position, the jumper sets the direction in Jog mode. This can be used to jog in the direction opposite the running

direction. In the 2Q position, the motor rotation direction is determined by the position of the FWD/REV jumper. In

Analog mode, the reference polarity must agree with the direction jumper or the drive will clamp the input reference to

zero. In Digital mode, the FWD/REV jumper can be used to set the motor direction.

FWD/REV

- “DIRECTION” Jumper - The direction jumper works with the 2Q/4Q jumper. See above.

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

WHAT HAPPENS WHEN I …

GIVE THE START COMMAND TO THE MODEL 1000 ?

Before starting the Model 1000AR drive, turn the Current Limit pots fully counter-clockwise, and the

speed reference command input, analog or digital, should be set to zero.

E.STOP

You must have +24VDC (all voltages relative to TB1 terminal

TB2

RUN

JOG

+24VDC

16) applied to TB2-11 (EStop input) before attempting to RUN or

JOG. You must maintain +24VDC on TB2 -11 for as long as you want

to run or jog.. Removing +24V from the Emergency Stop input will

stop the drive regardless of whatever other inputs may be energized.

CLOSED

E.STOP

o^TB2

AND

OPEN

You must apply +24VDC to TB2 terminal 13 to start

the drive. When you energize TB2-13, even if Emergency

Stop circuit is NOT energized, the RUN LED will lights and

START

E.STOP

TB2

STOP

RUN

+24V

CLOSED

START

ENABLE

ESTOP

the normally open RUN contact between TB2-1 and TB2-2

closes. If Emergency Stop is closed, the drive stays in RUN

mode as long as +24VDC is maintained on TB2 - 13.

If you use a momentary contact to energize the RUN

input at TB2-13, then you must have +24VDC applied to

TB2- 12 to continue running. If you do not have +24VDC

applied to TB2-12, then the RUN LED goes off and the

contact opens when you release the START button.

If you press the STOP button, or otherwise remove

+24VDC from TB2-12, the drive will go to the ramp stop

mode if the RAMP STOP jumper is installed. The motor will

START

OPEN

E.STOP

CLOSED

0 ^TB2

STOP

RUN

CLOSED

RUN

MODE

ENABLE

ESTOP

START

OPEN

E.STOP

CLOSED

STOP

OPEN

TB2

RUN

+24V

RAMP

STOP

ENABLE

decelerate to a stop and the drive shuts off.

ESTOP

To shut off immediately, open the Emergency Stop

button or otherwise remove +24VDC from TB2-11.

START

OPEN

E.STOP

STOP

0 ^TB2

RUN

+24V

EMERGENCY

CLOSED

OPEN

ENABLE

STOP

You start the drive in the JOG mode by applying -24

VDC (from TB2 terminal 9) to TB2 terminal 14. The JOG

E.STOP

ESTOP

TB2

+24V

-24V

JOG

LED will light. The RUN LED will NOT light. The RUN

JOG

CLOSED

JOG

contact will NOT close at TB2 terminals 7 and 8.

The JOG mode should be initiated from the STOPPED

condition. The JOG mode is locked out in RUN mode.

CLOSED

ENABLE

Place the drive in HOLD mode by applying -24VDC (from

TB2-9) to TB2 - 15. If the drive is stopped, HOLD will turn it

on. HOLD clamps the VCO to zero speed. If the drive is

running, it will decelerate to zero speed in current limit. As long

as HOLD is on, the motor resists turning in either direction.

E.STOP

START

OPEN

ESTOP

STOP

CLOSED

TB2

+24V

-24V

RUN/HOLD

RUN

CLOSED

HOLD

ENABLE

HOLD

CLOSED

In JOG, HOLD, or RUN mode, an ENABLE REQUEST is generated, and the ENABLE LED’s should

light on the Current Controller and Speed Controller boards. Reasons why the LED’s may not light:

1. The ENABLE LED will not light if the BUS LED is not GREEN;

2. The ENABLE LED will not light if the EMERGENCY STOP input is not energized;

3. The ENABLE LED will not light if any trip LED on the Current Controller board is lighted:

4. The ENABLE LED will not light if any of the ribbon cables is loose;

5. The ENABLE LED will not light if the RESET JUMPER is in the middle position.

Once the ENABLE LED is lit, turning the motor only requires the insertion of a speed reference.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

LED INDICATORS

CURRENT CONTROLLER BOARD 141-108

PWR

BUS

Power

Turns ON GREEN as soon as power is applied to the drive.

Turns OFF when power is removed from the drive.

Turns ON RED as soon as power is applied to the drive

Changes to GREEN when voltage across charging resistor drops below 35VDC.

Changes back to RED if there is an OV/UV fault AND the drive is not enabled.

Changes back to GREEN when OV/UV fault is cleared.

Turns off when power is removed from the drive.

Bus Status

HS1

HS2

HS3

TAC

Hall Sensor 1

Hall Sensor 2

Hall Sensor 3

Turns on RED when SOUTH magnetic pole is over HS1 in encoder.

Turns off when NORTH magnetic pole is over HS1 in encoder.

Turns on RED when SOUTH magnetic pole is over HS2 in encoder.

Turns off when NORTH magnetic pole is over HS2 in encoder.

Turns on RED when SOUTH magnetic pole is over HS3 in encoder.

Turns off when NORTH magnetic pole is over HS3 in encoder.

Turns on GREEN when SOUTH magnetic pole is over HS4 in encoder.

Turns off RED when SOUTH magnetic pole is over HS5 in encoder.

Turns on BOTH when SOUTH magnetic pole is over both HS4 and HS5.

Turns off when NORTH magnetic poles are over both HS4 and HS5.

Turns ON YELLOW when:

Hall Sensor 4

Hall Sensor 5

ENBL

Enable

1. Drive is in RUN mode with no faults.

2. Drive is in JOG mode with no faults.

3. During RAMP STOP with no faults.

Turns off when:

1. The UnderVoltage Timer times out.

2. There is an Undervoltage (UV) fault.

3. There is an OverVoltage (OV) fault.

4. There is an IOC fault.

5. There is a STALL fault.

6. RUN, JOG, HOLD, and RAMP STOP modes are all off.

Turns ON RED if motor does not move 30° within specified time.

Time is inversely proportional to motor current.

STALL

Stall Fault

Times out in 1.6 seconds at Current Limit (150% of full load).

Will not time out if current is less than 40% of full load.

Turns off when trips are reset.

Power Loss

Turns ON RED if the +24 VDC raw supply drops below 18VDC.

Turns ON RED if the +15VDC supply rises to within 3VDC of +24VDC.

Turns off when trips are reset if the condition no longer exists.

Turns ON RED in the following cases:

OV/UV

Overvoltage

UnderVoltage

1. Bus Voltage is greater than 120% of nominal at any time.

2. Bus Voltage is less than 75% of nominal at any time.

3. Bus Voltage is below 85% of nominal for 80 mS or more.

4. The charging contactor is not energized.

Turns off when trips are reset if the condition no longer exists.

Turns ON RED if bus current to output transistors exceeds 300%.

Turns off when trips are reset.

IOC

Instantaneous

OverCurrent

PHAD

Phase Advance Indicates electronic shifting of encoder signals to achieve Constant Horsepower.

GREEN indicates no phase advance.

ORANGE indicates 18° of phase advance timing.

RED indicates 30° of phase advance timing.

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

WHAT HAPPENS WHEN I …

GIVE THE SPEED COMMAND TO THE MODEL 1000AR ?

Once the drive is in RUN mode, the application of the speed reference should cause the motor to

turn. At this point:

• the PWR and BUS LED’s on the Current Controller board should be GREEN;

• one or two of the HS1, HS2, and HS3 LED’s should be on,

• the ENABLE LED should be ON on both Speed Controller and Current Controller.

• the ESTOP and RUN LED’s on the Speed Controller board should be ON,

• the TAC LED on the Current Controller may be OFF, RED or GREEN, depending on the

position of the motor.

• the ILIMIT LED may be on if the Motoring Current Limit (MCL) pot is fully counter-

clockwise.

If the above conditions do not exist, see the Troubleshooting section.

There are several ways to apply a reference:

1. For an analog speed reference, a speed pot or an external voltage, see page 25;

2. For a digital speed reference, see page 27 (Read the notes on page 26).

When the speed reference is increased from zero, the motor should turn. If the current limit LED

turns on, check for the following:

1. If the motor is not turning, turn the Motoring Current Limit pot (MCL) clockwise to see if the

motor will turn and the Current Limit LED turns OFF. If the pot is already more clockwise than

its mid-point, turn it all the way counter-clockwise to protect the motor and drive.

2. If the Current Limit pot is fully counterclockwise, and the motor is not turning, turn the pot

slowly clockwise to see if the motor will turn. If the motor turns, leave the Current Limit pot

where it is when the motor begins to turn.

3. If the motor does not turn when the Current Limit pot is increased, do not turn the Current

Limit pot higher than 50% of its rotation. Shut the drive off and check the connections

between the drive and the motor. It is quite common that these connections are mixed up.

When the speed reference is increased, if the motor does not turn, but the Current Limit LED does

NOT turn ON, check the following:

1. Make sure the RUN and both ENABLE LED’s are ON;

2. Make sure a reference is being properly applied:

•

For an analog reference, a voltage between 0 VDC and +10V must be present at

TB2-4 with respect to TB2-16(common). The AF/N jumper (JP1) on the Current

Controller board must be in the “N” position and there must be 0 VDC between

terminals 9 and 10 on TB1.

•

For a digital reference, there must be a suitable pulse train between terminals 11 and

9 on TB1 (see page 26). There must be 24VDC between TB1-10 (+) and TB1-9(-)

OR the “AF/N” jumper (JP1) on the Current Controller must be in the “AF” position.

When the motor begins to turn, the HS1, HS2, and HS3 LED’s on the Current Controller board will

begin to flash on and off. These indicate rotation of the motor by turning on when the encoder magnets

pass over the sensors. When the motor is turning rapidly, it will appear as though all three of the HS1,

HS2, and HS3 LED’s are on at the same time.

When the motor begins to turn, the TAC LED will begin to flash alternately RED and GREEN, then

appear to be ORANGE as the motor turns faster.

Check the speed of the motor at the 10%, 25%, 50% and 100% points of the speed reference.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

LED INDICATORS

SPEED CONTROLLER BOARD 141-107

RUN RUN mode

Turns ON GREEN when +24VDC is applied to TB2 terminal 13.

Stays ON GREEN as long as +24VDC is applied to TB2-12 or TB2-13.

Turns off when + 24VDC is removed from BOTH TB2-12 and TB2-13.

Turns on GREEN when speed demand cannot be satisfied.

One cause is current limit, which is adjustable from 0% to 150% of full load motor current.

Another cause is when the speed required is too great for that load and bus voltage.

Turns on RED when drive is in regenerative current limit, adjustable from 0% to 150% of

full load.

CURRENT LIMIT Current Limit

Turns off when above conditions cease to exist.

ENABLED

Enable

Turns ON YELLOW when:

1. Drive is in RUN mode with no faults.

2. Drive is in JOG mode with no faults.

3. During RAMP STOP with no faults.

Turns off when:

1. The UnderVoltage Timer times out.

2. There is an Undervoltage (UV) fault.

3. There is an OverVoltage (OV) fault.

4. There is an IOC fault.

5. There is a STALL fault.

6. RUN, JOG, HOLD, and RAMP STOP modes are all off.

Turns ON RED when motor speed exceeds reference speed at any time.

This may occur during stopping if the decel ramp time is less than the natural coasting

time of the motor/load, or during running if the motor is “overhauled”.

Turns OFF when motor is at or below the reference speed.

Turns ON GREEN when +24VDC is applied to TB2 terminal 11.

Stays ON GREEN as long as +24VDC is applied to TB2-11.

Turns off when + 24VDC is removed from TB2-11.

Turns ON GREEN when -24VDC is applied to TB2 terminal 14.

Stays ON GREEN as long as -24VDC is applied to TB2-14.

Turns off when +-24VDC is removed from TB2-14.

Turns ON GREEN when -24VDC is applied to TB2 terminal 15.

Stays ON GREEN as long as -24VDC is applied to TB2-15.

Turns off when +-24VDC is removed from TB2-15.

REGEN

Regen Mode

ESTP

JOG

EStop Input

Jog Input

HOLD

Hold Input

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

WHAT HAPPENS WHEN I …

SLOW DOWN OR OVERHAUL THE MODEL 1000AR ?

Since the Model 1000AR is a regenerative drive (see page 3), the motor does not coast when the

speed reference is reduced. The deceleration ramp is enforced by removing energy from the motor. This

is accomplished by treating the motor as a generator and applying a load to it.

RUNNING SPEED

A non-regenerative drive coasts when the

NON-REGEN DRIVE

motor speed exceeds the commanded

speed. The drive cannot force the motor to

REGEN DRIVE

slow down. The non-regenerative drive will

enforce the deceleration ramp time ONLY if

the decel ramp time is greater than the

natural coast time of the motor and load.

REGEN

NEW SPEED

(may be zero)

DECEL TIME

The regenerative drive (Model 1000AR) can enforce the decel ramp time at any regenerative load up

to its Regenerative Current Limit (RCL) setting. If the inertia of the load is greater than can be slowed by

the motor at regen current limit, or if the motor is being overhauled by another motor, the drive will

continue to apply the current limited value of torque, but the drive will lose speed control. The motor and

load will then slow down according to a modified coast time curve.

When you started up, you probably turned the RCL pot on the Speed Controller board down to the

fully counter-clockwise position. The first time you turn down the speed pot, you should see a RED

REGEN LED and a RED CURRENT LIMIT LED, but the motor may appear to be coasting. Turn the RCL

pot clockwise to about 50% and bring the motor up to a high speed again.

Now, when you turn the speed pot down (it does not need to be zero; it can be any new, lower

speed), the REGEN LED should light, but the CURRENT LIMIT LED may or may not come on. If the coast

time is much greater than the decel time, the drive may reach current limit. Whether or not current limit will

be reached can be predicted, but you need to know all the drive and motor data and all of the inertias

involved in the system to do so. The maximum (CW) setting of the RCL is equivalent to 150% of full load.

You should also see a RED LED on the bus loader flicker to show it is operating and the regenerative

resistors will get warm (for small or quick changes in speed) or hot (for longer regenerative intervals.

Since the regenerative mode is active only when the motor speed exceeds the commanded speed,

the REGEN LED will be on only during the deceleration period. Once the motor gets to the new speed,

regen shuts off and the drive returns to normal operation. If you are reversing the direction of the motor,

the REGEN LED will only stay on until the motor stops.

If the motor speed is being increased by an outside force pulling on it (overhauling load), the REGEN

LED will come on and stay on. The drive will attempt to hold the commanded speed by regenerating, up to

a maximum of its RCL setting. In any case of an overhauling load, you must be careful not to exceed the

rated capacity of the regenerative resistors.

If continuous regeneration is expected, and the overhauling load is caused by another motor, you

may want to consider using a “common bus” configuration. A common bus configuration requires another

BLDC drive which is ALWAYS in motoring mode while the regenerative unit is regenerating. This is the

case if the common bus motoring motor is doing the overhauling which is causing the regeneration of the

common bus regenerating motor.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

ADJUSTMENTS

CCW = Counter-ClockWise position

CW = ClockWise position

MAX SPD Maximum Speed

ANALOG MODE only.

Not an absolute speed limit. Calibration to reference.

At CCW, with 10VDC input, generates a VCO frequency of 1200 Hertz.

At CW, with 10VDC input, generates VCO frequency of 10 Kilohertz.

JOG SPD Jog Speed

ANALOG MODE only.

Sets speed during JOG mode.

CCW is zero Jog Speed.

CW is a jog speed of about 30% of full speed.

Direction is set by jumper (see page 34).

ACCEL

DECEL

GAIN

Acceleration time

Gain adjust

ANALOG MODE only.

Sets amount of time to change from zero speed to full speed.

With JP2in the R/L position, CCW is about 20 seconds.

With JP2in the DIR position, CCW is about 0.05 seconds.

With JP2in the R/L position, CW is about 0.5 seconds.

With JP2in the DIR position, CCW is about 0.05 seconds.

ANALOG MODE only.

Sets amount of time to change from full speed to zero speed.

With JP2in the R/L position, CCW is about 20 seconds.

With JP2in the DIR position, CCW is about 0.05 seconds.

With JP2in the R/L position, CW is about 0.5 seconds.

With JP2in the DIR position, CCW is about 0.05 seconds.

ANALOG and DIGITAL modes.

Sets the stiffness of the motor shaft.

Zero position is where the shaft should be at any point in time.

Motor amps is proportional to offset of the shaft from the zero position.

Stiffness is motor amps per degree of shaft offset from zero position.

CCW is about 0.56% of full load current per degree of offset.

CW is about 5.6% of full load current per degree of offset.

Normal Gain setting is between CCW and 50% of rotation.

STAB

MCL

Stability adjust

ANALOG and DIGITAL modes.

Sets the stability of the motor under load.

CCW makes the drive more sluggish.

CW makes the drive more sensitive.

Normal setting is at about mid-range (50%) of pot rotation.

Current Limit

Motoring

ANALOG and DIGITAL modes.

Sets the maximum motoring current to the motor in percent of full load.

This adjustment depends on the HP calibration resistor on TB3-1 and TB3-3.

CCW is zero percent, or zero current.

CW is maximum current limit, or about 150% of full load.

In normal operation, CLIM is set to 150% (CW).

RCL

Current Limit

Regeneration

ANALOG and DIGITAL modes.

Sets the maximum regenerative current to the motor in percent of full load.

This adjustment depends on the HP calibration resistor on TB3-1 and TB3-3.

CCW is zero percent, or zero current.

CW is maximum current limit, or about 150% of full load.

In normal operation, CLIM is set to 150% (CW).

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

WHAT HAPPENS WHEN I …

MAKE AN ADJUSTMENT ON THE MODEL 1000AR ?

Once the motor is running, it may be necessary to make adjustments to produce the desired results.

ACCEL time

MAX speed

Speed

Pot to

DECEL time

JOG speed

CCW

ZERO

speed

Speed

Pot to

Center

JOG JOG

ON OFF

Speed

Pot to CW

START

Speed

Pot at

STOP

RAMP

STOP

ACCEL time

CCW

The speed pot may be connected for bi-polar reference input. The CW end of the pot should be

connected to +10VDC (TB2-6), the CCW end to -10VDC (TB2-4), and the wiper to TB2-5.

If the speed pot is turned to 100% clockwise (CW), or the speed reference is otherwise increased to

+10VDC at TB2 terminal 5, the motor will accelerate to the maximum speed at the ACCEL rate.. You may

use the MAX on the Speed Controller to adjust maximum speed of the motor. Actually, MAX will affect the

speed at any reference. The MAX adjustment is not an absolute limit. It is a calibration to the reference.

If you then turn the speed pot to the center (0.0 VDC), the motor decelerates to a stop at the DECEL

rate. If the input is not exactly 0.0 VDC, the motor may turn slowly in one direction or the other.

Turning the speed pot to the CCW end causes the motor to accelerate to the MAX speed in the other

direction at the ACCEL rate.

The amount of time it takes the motor to change from zero speed to maximum speed is adjustable

with the ACCEL pot on the Speed Controller. The range of time depends on how JP2 is installed. With

JP2 in the R/L position, the time for acceleration is adjustable from about 0.5 seconds (ACCEL pot fully

CCW) to about 20 seconds (ACCEL POT fully CW). With JP2 in the DIR position, the time is not

adjustable.

The ACCEL time is the time it takes the ramp circuit to change the speed reference from zero to full

speed. The motor may not accelerate in the same amount of time if it is limited by inertia or load, in which

case the motor will accelerate in current limit.

When the STOP button is pressed at full speed, if the COAST TO STOP jumper is removed, the

drive will shut off and the motor will coast to a stop. The time it takes the motor to stop is called the “coast

time”. This time is not controlled unless Dynamic Braking is installed.

If the STOP button is pressed and the COAST TO STOP jumper is installed, RAMP STOP mode is

initiated. The speed reference input is clamped to zero after the input at TB2 terminal 10 and the drive

ramps the speed to zero. The drive then shuts off.

The amount of time allowed for the deceleration is adjustable with the DECEL pot on the Speed

Controller board. This time has the same ranges as the ACCEL pot.

The Models 1000AR is a regenerative drive. When the RAMP STOP mode is in operation, or if the

speed pot is turned to 0% while running at full speed, the DECEL time will be effective. When the motor

gets to zero speed, the drive shuts off.

JOG speed is adjustable with the JOG pot on the Speed Controller board. JOG speed is affected by

the MAX speed adjustment, but JOG speed is not affected by the MAX pot, the ACCEL pot, or the DECEL

pot. JOG accelerates in current limit.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

CONNECTIONS FOR 6 TRANSISTOR MODULE

Rcharge

INDUCTOR 1

CR1

BuP

BvP

BwP

BUSS FUSE

+BUSS

R+

R-

EvP

EwP

EuP

REGEN

RESI-

STORS

INPUT

CURRENT

SENSOR

FUSES

BUSS

LOADER

BOARD

OVER/

UNDER

VOLTAGE

TB3

TYPE FLQ

149-201

TB2

-BUSS

FU4

BUSS

LOADER

TRANSISTOR

CAPACITOR BOARD

141-106

P1-1

HORSEPOWER

CALIBRATE

RESISTOR

B1 E1 B4 E4

B2 E2 B5 E5

B3 E3 B6 E6

TO P3

CURRENT

CONTROLLER

TO P2

CURRENT

CONTROLLER

BASE DRIVER BOARD

141-105

460VAC

380VAC

BLK

BK/WH

POWER

TRANSFORMER

PRIMARY

POWER

TRANSFORMER

PRIMARY

BRN

230 VAC

POWER TRANSFORMER SECONDARIES

380 OR

460 VAC

VIO

SIMPLIFIED DRAWING

MODEL 1000AR POWER CIRCUITS

HIGH VOLTAGE

CONNECTIONS

LOW VOLTAGE

CONNECTIONS

L1, L2, AND L3 MAY BE SWITCHED AROUND

AMONG THEMSELVES WITHOUT ILL EFFECT

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

TROUBLESHOOTING THE MODEL 1000AR DRIVE

Troubleshooting of the Model 1000AR drive should only be attempted by

personnel experienced in working on high-voltage, high power equipment.

Equipment Necessary for Troubleshooting :

1. Safety Glasses

2. A Volt-Ohm-Milliammeter, preferably digital, with:

•

A DC Voltage scale of 1000VDC minimum

An AC True-RMS Voltage scale of 1000VAC minimum

A fuse-protected ohmmeter with as low a scale as possible

A frequency reading capability, if possible

A plug-in attachment to read AC and DC current, if possible

Meter leads insulated for 1500 VDC

3. A True RMS clamp on ammeter for AC current, or DC current, or both

4. An oscilloscope is handy if the person using it knows how to use it well.

5. Other equipment may be required for some configurations.

6. A Megger is useful for checking motor integrity and wiring insulation.

Spare Parts are Necessary to do On-Site Repairs Quickly and Efficiently.

Some or all of the following parts may be required for fast on-site repair.

Listed in approximate order of importance.

Item

Part

Spares

Description

Designation

Number

Quantity

Input Fuses

Transformer Fuse

Capacitor Board

Output Transistor Module

Driver Board

Current Controller Board

Input Diode Module

Power Transformer

Speed Controller Board

Input Choke

Bus Loader

Bus Loader Resistor(s)

Bus Loader Fuse

FU1, FU2, and FU3

FU4

* HP *

FLQ-8/10

141-206

* HP *

141-105

141-108

* HP *

141-004

147-101

141-005

149-201

50 ohm

* HP *

RECT1

* HP * means horsepower and/or voltage dependent.

Consult your Distributor for spare parts pricing and delivery.

A Word About The Troubleshooting Charts

Troubleshooting charts cannot solve every problem!

Troubleshooting charts are a useful tool in tracing simple problems down to the board or major component level.

Follow the troubleshooting chart as far as you can until the problem is resolved or you reach a dead end.

If you find yourself coming back to the same point in the troubleshooting chart several times, call the factory and

obtain the help of a trained technician. Let him know what point you keep coming to in the chart. This will help us to

improve the troubleshooting chart in the future.

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

TRANSISTOR MODULE STATIC TEST

Equipment needed:

Preparation:

A Digital Multi-Meter (DMM)with a diode scale is preferred. You should have a RED lead

in the positive (+) input and a BLACK lead in the negative (-) input.

Different meters give different readings on diode tests. KNOW YOUR METER !! Some

meters read backwards due to battery polarity. Test YOUR meter on a known good diode

bridge before performing tests so that you know how your meter will act.

Refer to page 32 for the drive power schematic and semi-conductor diagrams.

Precautions:

Procedure:

If the transistor module is to be tested in circuit, make sure power has been off long

enough for the capacitor banks to completely discharge.

The procedure is the same for in circuit or out of circuit testing. If a component tests bad

circuit, it must be tested again after it is removed because of the possibility of alternate

paths when the component is in circuit.

SIX TRANSISTOR MODULE

RED LEAD

BLACK LEAD

GOOD

open

BAD

short

0.3 to 2.0

0.3 to 0.7

open

short or open

short

open

short

0.3 to 500

short or open

TWO TRANSISTOR MODULE

RED LEAD

E1C2

BLACK LEAD

GOOD

open

0.3 to 2.0

0.3 to 0.7

open

BAD

short

short or open

short

E1C2

open

0.3 to 500

short

short or open

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart

NOTE: This chart assumes standard control connections

and no options installed which affect speed control.

Page 1

START

CC = Current Controller board.

SC = Speed Controller board.

Check for grounds,

then turn on power

This step assumes that you know for a

fact that the proper power is applied.

Yes

Page 2

Turn Power Off.

Remove fuses.

Check for shorts.

Install new fuses.

Re-apply power.

PWR

LED ON

Turn Power Off

Remove Fuse.

Unplug P2 on CC.

Replace Fuse

Start Over.

Yes

1st

time

fuses have

blown

Are

FU1, FU2,

and FU3

OK?

Fuse FU4

Do the following in

order, checking FU4

after each change.

P2 on CC

unplugged

Yes

1st Replace

PowerTransformer

Yes

Before disconnecting

any wires, make sure

you know where to re-

connect them.

Turn Power Off

Disconnect motor.

Turn Power Off

On CC: Plug in P2.

Unplug P3 and P4.

Unplug TB1 and TB2.

Re-apply Power.

After turning off power, make

sure that capacitors are

discharged before touching

live parts.

2nd Replace

Driver Board

Remove, separate, and tape up

wires on + (or P) terminal of

transistor bridge.Replace fuses.

Re-apply Power.

3rd Replace

P2 Ribbon Cable

Are

FU1, FU2,

and FU3

OK?

PWR

LED ON

Replace

Diode Bridge

Replace Current

Controller board.

Tolerance:

Yes

+ / - 4 VDC

Yes

Replace Speed

Controller board.

Turn Power Off

Re-connect + of diode bridge to

Capacitor Board tab. Leave + of

transistor module disconnected.

Re-apply Power.

Turn Power Off

Plug in P4 on CC.

Re-apply Power.

+24VDC

TB2-10(+) to

TB1-16(-)

Replace P4 Cable

Yes

Are

FU1, FU2,

and FU3

OK?

+24VDC

TB2-10(+) to

TB1-16(-)

Replace

Capacitor Board

Turn Power Off

Plug in TB2 on SC.

Re-apply Power.

Check external

controls on TB2.

Yes

Turn Power Off

Re-connect + (or P)

terminal of transistor

bridge.

+24VDC

TB2-10(+) to

TB1-16(-)

Turn Power Off

Plug in TB1 on CC.

Re-apply Power.

Replace

Capacitor Board

Yes

Re-apply Power.

Are

FU1, FU2,

and FU3

OK?

Replace Transistor

Block

Have motor

checked.

Check external

controls on TB1.

Yes

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

DIODE BRIDGE TEST

Equipment :

A Digital Multi-Meter (DMM)with a diode scale is preferred. You should have a RED lead in the

positive (+) input and a BLACK lead in the negative (-) input.

Preparation:

Different meters give different readings on diode tests. KNOW YOUR METER !! Some meters read

backwards due to battery polarity. Test YOUR meter on a known good diode bridge before

performing tests so that you know how your meter will act.

Precautions: If the diode bridge is to be tested in circuit, make sure power has been off long enough for the

capacitor banks to completely discharge.

Procedure:

The procedure is the same for in circuit or out of circuit testing. If a component tests bad in circuit, it

must be tested again after it is removed because of the possibility of alternate paths when the

component is in circuit.

1. Set the DMM on the diode scale.

2. Place the RED (positive) lead on the “-“ or “N” terminal of the diode bridge. Place the BLACK

(negative) lead on each of the AC terminals in turn. In each case you should read about 0.300

to 0.700 on a digital meter. If you see a short or an open circuit, disconnect the wires from the

diode bridge terminals and re-test.

3. Repeat the above step with the BLACK lead on the “+” or “P” terminal of the diode bridge,

placing the RED lead on each of the AC terminals.

4. Place the RED lead on the “+” or “P” terminal and the BLACK lead on the “-“ or “N” terminal. It

should read an open circuit.

TRANSISTOR LEAKAGE TEST

Equipment:

A Digital Multi-Meter (DMM) is preferred. You should have a RED lead in the positive (+) input and a

BLACK lead in the negative (-) input.

Preparation:

Set the meter on the 1000VDC scale. Be sure the leads are insulated for this voltage.

Refer to page 28 for the drive power schematic and semi-conductor diagrams.

Precautions: This test is an in-circuit test with power on. It should be performed by personnel who have been

trained to work around high voltage.

Procedure:

Turn the drive power off and disconnect motor leads T1, T2, and T3.

Turn the power on and wait for the bus to charge (a green BUS LED). If the bus will not charge, turn

power off and go to TRANSISTOR MODULE STATIC TEST.

Measure the BUS voltage (POSITIVE BUS to NEGATIVE BUS) before beginning.

1. Place the Red lead of the meter on the POSITIVE BUS. Place the BLACK lead, in turn, on T1,

then T2, then T3. In each case, notice the voltage reading.

•

If any voltage reading is 0 VDC, there may be a bad transistor. Turn off power, disconnect

the transistor module connected to the T lead with the bad reading, and perform the

TRANSISTOR MODULE STATIC TEST.

•

If any voltage reading is the same as the BUS VOLTAGE, it may indicate a problem in

the opposing transistor in that T lead leg or an unexpected alternate path in the circuit.

2. Repeat the above test with the BLACK lead on the NEGATIVE BUS and touching the RED

lead, in turn, to T1, T2, and T3. Check the transistor block connected to any T lead reading 0

VDC or BUS voltage.

•

If any voltage reading is 0 VDC, there may be a bad transistor. Turn off power, disconnect

the transistor module connected to the T lead with the bad reading, and perform the

TRANSISTOR MODULE STATIC TEST.

If any voltage reading is the same as the BUS VOLTAGE, it may indicate a problem in

the opposing transistor in that T lead leg or an unexpected alternate path in the circuit.

•

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart

NOTE: This chart assumes standard control connections

and no options installed which affect speed control.

Page 2

Wait up to 30 seconds for

BUS LED to change from

CC = Current Controller board.

RED to GREEN

From

Page 1

Page 3

BUS LED

GREEN

Yes

BUS LED

RED

Nominal Line Voltage = 230VAC

Too Low 208 VAC

Replace Current

Controller board

Nominal Line Voltage = 380VAC

Too Low 342VAC

Nominal Line Voltage = 460VAC

Too Low

415VAC

Yes

Disconnect Motor

Measure the Bus

Voltage between

POSITIVE BUS Tab

and the NEGATIVE

BUS Tab on the

Line

Voltage

Too Low

Fix Line Voltage

Problem

Yes

Capacitor Board.

Bus

VDC

< 10%

Bus

Loader

Connected

Charge

Fuse OK

Turn Power Off

Remove FU1 on

Capacitor Board

Replace

Charge Fuse

Yes

Line VAC = 230

Bus VDC = 320

Line VAC = 380

Bus VDC = 530

Yes

Disconnect

Bus Loader and

Start Over.

Yes

Line VAC = 460

Bus VDC = 640

Turn Power Off

Perform Diode

Bridge Test

Bus

VDC

> 90%

Perform

Transistor Module

Leakage Test

Diode

Bridge OK

Yes

Replace Diode

Bridge

Replace

Transistor

Module

Replace

Capacitor Board

Transistor

Module

OK?

Yes

Replace

Capacitor Board

Turn Power Off

Check Choke L1

for continuity

Yes

Choke

Replace

Capacitor Board

Replace

Choke

Yes

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

MOTOR ENCODER CONNECTIONS

IN MOTOR TERMINAL BOX

MOTOR ENCODER LAYOUT

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart

NOTE: This chart assumes standard control connections

and no options installed which affect speed control.

CC = Current Controller board.

Page 3

Yes

HS1 LED

HS2 LED

TAC LED

From

Page 2

Page 4

You can see the

rotation of these

three LED's by

Yes

turning the motor by

hand. There should

always be one or

two on at a time -

never all three on

and never all three

off.

Turn Motor by hand to

see the TAC LED

sequence, which is:

RED, ORANGE,

GREEN, OFF or the

reverse order.

HS2 LED

HS3 LED

TAC LED

operation

Yes

Turn off Power

Disconnect wires

on TB1-2, TB1-

3, and TB1-4.

HS3 LED

HSX LED's

means HS1,

HS2, and

HS3

Turn off Power

Disconnect wires

on TB1-5 and

TB1-6. Reapply

power.

Yes

Reapply power.

Turn off Power

Re-connect

wires on TB1-2,

TB1-3, and TB1-

4. Disconnect

Cable at motor

end. Reapply

power.

Are

Any of the

HSX LED's

TAC LED

Cable

Connected to

motor

Yes

Connect Encoder

Cable

Yes

Replace Current

Controller Board

Yes

Are

Any of the

HSX LED's

Turn off Power

Replace

Encoder

+5VDC

TB1-8(+)

TB1-7(-)

Disconnect Encoder

Cable at Motor End

Re-apply power.

Replace Encoder

Yes

Replace

Cable

Yes

Wiring

Turn off Power

Check Encoder Wiring

to Motor

+5VDC

TB1-8(+)

TB1-7(-)

Turn off Power

Disconnect TB1

Yes

Replace Current

Controll board

+5VDC

TB1-8(+)

TB1-7(-)

Replace Current

Controller board

Check TB1 Connections

Check for short in cable.

Fix Wiring

Yes

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

IOC TESTS:

An Instantaneous Over Current (IOC) fault is a serious matter. An IOC fault is indicated when the drive has

detected a potentially damaging amount of current going into the output transistor stage. Whenever possible, avoid

trying to restart the drive after an IOC fault until the following tests have been performed:

1. Turn off power and wait for the main power capacitors to discharge.

2. Turn the ILIMIT potentiometer fully Counter-ClockWise (CCW).

3. Disconnect the motor power leads and check the motor for grounds.

4. With power still off, perform the Transistor Module Static Test (page 32).

5. Re-apply power and perform the Transistor Leakage Test (page 34).

6. If any of the Driver board LED’s are on now, change the driver board.

7. Press the START button and rotate the motor slowly by hand. Watch the driver board LED’s to see

which ones are turning on and off. If the IOC LED comes on at some point in the rotation, change the

transistor block connected to that driver.

8. Turn off the power and, after the main capacitors have discharged, re-connect the motor and test the

entire motor power circuit for grounds again.

9. Turn power on and begin the start-up procedure again, turning up the ILIMIT potentiometer slowly to

catch a possible overcurrent event.

OV/UV TESTS:

An OverVoltage/UnderVoltage (OV/UV) indication may come on for many reasons. The important point to

remember is that the OV/UV indicator applies to the BUS voltage.

Make sure there are no common buss connections or bus loaders causing problems with the proper charging

and maintenance of the bus voltage.

1. Before turning off the main power, measure the AC line voltage at the input to the drive. It should be

the nameplate voltage +/- 10%. If it is not, correct it.

2. Assess when the OV/UV indication occurred. The OV/UV trip occurs:

•

If the BUS voltage exceeds 121% of nominal bus (see troubleshooting chart, page 35 for

voltages) for any period of time. This may occur if the line voltage exceeds 121% of nominal,

•

If the BUS voltage drops to less than 85% of nominal bus voltage for a period of time

exceeding 80 milliseconds (0.08 seconds), or

•

If the BUS voltage drops below 75% of nominal bus voltage for any length of time, or

If the charging contactor drops out.

3. In the case of 380VAC and 460VAC drives, check the balance of the voltage across the capacitor bank

halves. (Measure across R1 and R2). The voltages should not differ by more than 10%. If the voltages

are unbalanced, change the Capacitor board.

4. Do not assume that the AC line voltage which is measured while the drive is off will be the same while

the drive is running the motor under load. Measure the AC line voltage under both circumstances.

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart

NOTE: This chart assumes standard control connections

and no options installed which affect speed control.

CC = Current Controller board.

Page 4

Press START

RUN LED

Button and

Release

(See note

above)

From

Page 3

ENBL LED

Page 5

Yes

Release

START

Button

Yes

+24V

TB2-11(+)

TB2-16(-)

Check "EMERG

STOP Button"

connections

RUN LED

+24V

Press and

HOLD START

Button

TB2-12(+)

TB2-16(-)

Yes

PJ1

on CC

in RESET

position

Check

"START Button"

connections

Set PJ1 jumper on

Current Controller

board to either INT

or MAN position

Check

"STOP Button"

connections

Yes

+24V

TB2-13(+)

TB2-16(-)

This sequence

assumes that standard

control connections

are being used.

See page 21.

The voltages given

must be at the

indicated terminals

unless otherwise

indicated.

Yes

Replace Speed

Controller Board

+24V

TB2-12(+)

TB2-16(-)

PL LED

on CC

Release

START

Button

+24V

TB2-10(+)

TB2-16(-)

Yes

TRIP

+24V

TB2-11(+)

TB2-16(-)

>21VDC

Check

"STOP Button"

connections

Yes

<21VDC

Replace Current

Controller Board

IOC LED

on CC

Shut off power

Unplug P3 and TB2

Reapply power

Perform IOC

tests (page 50)

Yes

Replace Speed

Controller Board

+24V

TB5-3(+)

TB2-16(-)

Check "EMERG

STOP Button"

connections

<21VDC

+24V

TB2-10(+)

TB2-16(-)

Check Motor

Thermal and

wires

OVUV

LED on CC

Yes

Perform OV/UV

tests (page 50)

Yes

>21VDC

+24V

TB5-1(+)

TB2-16(-)

+24V

TB2-10(+)

TB2-16(-)

Check Bus

Loader for

Green LED

Shut off power

Plug In P3

Reapply power

Yes

Replace Cable

on P3 Connector

Replace Speed

Controller Board

+24V

TB2-10(+)

TB2-16(-)

Replace

Capacitor Board

<21VDC

+24V

TB2-10(+)

TB2-16(-)

Check

disconnected

wires

Disconnect all

wires connected

to TB2-10

Yes

Check TB2

Connections

>21VDC

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

BLOCK DIAGRAM - - SPEED CONTROLLER AND CURRENT CONTROLLER

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart

NOTE: This chart assumes standard control connections

and no options installed which affect speed control.

CC = Current Controller board.

Page 5

Increase SPEED

Are

HS1, HS2,

HS3

Changing

reference from

0% to 10%. If

ILIMIT is at full

CCW, turn it

25% CW.

From

Page 4

Page 6

TAC LED

changing

Yes

STOP.

motor

turning

motor

turning

Turn off power.

Disconnect

TB1-7 and

TB1-8

+5VDC

TB1-8(+)

TB1-7(-)

Change Current

Controller board

Yes

Measure voltages at

TB1-5 and TB1-6.

TB1-7 is common.

They switch between

0VDC and 8VDC as

the motor turns.

ILIMIT

LED

Speed

Controller

ENBL LED

ON?

Check Motor

Connections and

motor load

+5VDC

TB1-8(+)

TB1-7(-)

Yes

Replace Current

Controller board

Yes

STALL

LED

Are

TB1-5 and

TB1-6 OK

Are

T1, T2, T3

connected

TRIP

To Page 4

Yes

Check cable and/or

Change encoder

Connect Motor

Power Leads

Yes

motor

connected

to load

Check motor load

and connections

Disconnect motor

from load and

start over

Can you

turn the shaft

by hand

Yes

Check connections

of T1, T2, T3 and cable

connections

Yes

+5VDC

Replace Current

Controller board

HS1, HS2,

HS3 change

TB1-8(+)

TB1-7(-)

STOP.

Yes

Turn off power.

Turn motor shaft

by hand.

Do NOT

re-apply power

Re-Apply

Power and

Re-start

Can

you

turn the shaft

by hand

Check cable and/or

Change encoder

Yes

CURR LMT

LED ON

Yes

Can

you

turn the shaft

by hand

speed

reference

at 10%

Dynamic

Disconnect

Dynamic

Braking

Replace Speed

Controller board

Braking

Installed

Yes

Check motor

connections

Check motor

connections

Check motor

connections

Fix speed reference

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

DRIVER BOARD LAYOUT AND CONNECTIONS

DRIVER BOARD LED’S

The base driver board LED’s turn on when current is being supplied to the bases of

the output power transistors.

For output transistor numbering, see the Simplified Power Schematic drawing on

page 32.

On the Model 1000 series non-regenerative drives, transistors #1, #2, and #3 (

referred to as the “top” transistors because they are connected to the positive side of the

bus) are “block fired”, i.e., they are on continuously while the motor is in a position where

they should be on. On a four-pole motor (standard motors with frame sizes from 42T

through 259T), each of the output transistors 1, 2, and 3 are on for 60 degrees of shaft

rotation. This makes the LED’s for transistors 1, 2, and 3 easy to see while the motor is

running.

Transistors #4, #5, and #6 are each enabled for 60 degrees of shaft rotation while

the motor is in the corresponding position, but the output transistor is controlled by a

“pulse-width modulation” (PWM) which is determined by the motor current required.

Under light loads, this means that the transistor may only be on 1 percent of the time. The

LED’s for #4, #5, and #6 (referred to as the “bottom” transistors because they are

connected to the negative side of the bus) therefore, may be difficult to see. As the load

increases on the motor, observation becomes easier.

The best way to check the LED’s on the Base Driver Board is to disconnect the

motor power leads T1, T2, and T3, start the drive, and rotate the motor shaft by hand.

Then all of the LED’s will come on at full brightness.

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Model 1000AR Installation and Operation Manual

PAGE

POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart

NOTE: This chart assumes standard control connections

Page 6

Increase

SPEED

and no options installed which affect speed control.

CC = Current Controller board.

50% speed refers to 1/2 of

the max speed of the motor.

reference

from 10%

to 50%. If

CURREN

T LIMIT is

turned

motor at

50% speed

From

Page 5

Put Motor

In Service

Yes

down, turn

it up to

50% CW.

Yes

Adjust

MAX pot

on Speed

Controller

board

motor at

50% speed

Correct

Speed

Reference

+5VDC

TB2-5(+)

TB2-16(-)

CURRENT

LIMIT LED

On ?

Yes

the load

connected to

the motor

motor

running faster

than 50%

speed at

base speed

or more

Disconnect

load from the

motor and

Yes

start over

Turn off power,

disconnect T1, T2,

T3. Turn on power

and rotate motor

by hand.

Replace

Speed

Controller

board

PHAD

LED

On ?

1st

Yes

Are

all of the

Driver board

LED's OK

Remove

Phase

Advance

Chip U8 on

CCB

Replace

Base Driver

Board

motor an

F2 motor

Yes

2nd

Yes

Turn off power,

reconnect T1, T2,

and T3. Replace

Speed Controller

board. Restart.

Replace

Current

Controller

board

Replace

Capacitor

Board

Speed

at 50%

Replace

Motor

Return to

Start

Yes

OFFICIAL

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Page

Model 1000AR Installation and Operation Manual

6/4/2001

Download from Www.Somanuals.com. All Manuals Search And Download.

Patton electronic Switch 2156 2157 User Manual
Philips DVD Player SACD1000 User Manual
Philips Indoor Fireplace DVP5990 User Manual
Pioneer DVD Player DV 2750 User Manual
Pioneer Portable Speaker S IC651 LR User Manual
Plantronics Headphones CS361N User Manual
Polaris Lawn Mower S2188 8070PL8C User Manual
Polaroid Digital Camera i737 User Manual
Porter Cable Home Safety Product 90546223 User Manual
Procom Air Conditioner MD100TBA User Manual