PowerTec Automobile 1000AR User Manual

Model  
1000AR  
Regenerative  
Brushless DC Motor Control  
INSTALLATION AND  
OPERATION  
INSTRUCTION MANUAL  
JUNE, 2001  
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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..  
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  
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Model 1000AR Installation and Operation Manual  
PAGE  
3
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.  
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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  
RED  
BUS  
RAMP STOP  
2Q/4Q  
HS2  
RED/GREEN  
RED  
ENABLE  
HS1  
YELLOW  
ESTOP  
COAST  
STOP  
RED  
RUN  
JOG  
PL  
REGEN  
ENABLED  
RED  
TAC  
OV/UV  
RED/GREEN  
RED  
HOLD  
TB1  
IOC  
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16  
RED  
TB1  
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Model 1000AR Installation and Operation Manual  
PAGE  
5
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.  
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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  
© copyright 1997 by Powertec  
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Model 1000AR Installation and Operation Manual  
PAGE  
7
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  
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Model 1000AR Installation and Operation Manual  
6/4/2001  
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Model 1000AR Installation and Operation Manual  
PAGE  
9
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.  
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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  
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Model 1000AR Installation and Operation Manual  
PAGE  
11  
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
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  
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Model 1000AR Installation and Operation Manual  
NOMINAL  
AC LINE  
VOLTAGE  
MAXIMUM  
CONTINUOUS  
AC LINE  
CURRENT  
1.4  
MAXIMUM  
HEAT  
OUTPUT IN  
WATTS  
35  
HORSE-  
POWER  
KILO-  
WATTS  
INPUT  
KVA  
230  
230  
230  
230  
230  
230  
230  
230  
230  
½
¾
1
1.5  
2
3
5
7.5  
10  
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  
42  
60  
85  
122  
165  
232  
281  
385  
7.3  
12.1  
18.1  
23.9  
380  
380  
380  
380  
380  
380  
380  
1
1.5  
2
3
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  
36  
55  
70  
105  
142  
178  
222  
7.5  
10  
10.9  
14.1  
460  
460  
460  
460  
460  
460  
2
3
5
7.5  
10  
15  
1.5  
2.2  
3.7  
5.6  
7.5  
11  
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  
© copyright 1997 by Powertec  
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Model 1000AR Installation and Operation Manual  
PAGE  
13  
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.  
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14  
Model 1000AR Installation and Operation Manual  
MODEL 1000AR FUSE BOARD  
Model 1000AR Output Electrical Ratings  
NOMINAL  
MAXIMUM  
CONTINUOUS  
MOTOR  
MAXIMUM  
MOMENTARY  
MOTOR  
NOMINAL  
HP  
CALIBRATE  
RESISTOR  
AC LINE  
HORSE-  
POWER  
KILO-  
VOLTAGE  
WATTS  
CURRENT  
CURRENT  
230  
230  
230  
230  
230  
230  
230  
230  
230  
½
¾
1
1.5  
2
3
5
7.5  
10  
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  
380  
380  
380  
380  
380  
380  
1
1.5  
2
3
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  
10  
460  
460  
460  
460  
460  
460  
2
3
5
7.5  
10  
15  
1.5  
2.2  
3.7  
5.6  
7.5  
11  
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  
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Model 1000AR Installation and Operation Manual  
PAGE  
15  
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-  
T1  
T2  
T3  
TB1  
TB2  
GND  
BLDC  
MOTOR  
1
2
3
4
5
6
7
8
9
16  
1
2
3
4
5
6
7
8
9
18  
1
2
3
4
5
6
7
8
9
S
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 (Beldenpart #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.  
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16  
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  
HP  
Resistors  
# @ ohms  
Equivalent R  
ohms  
Dissipation  
watts  
Peak Amps  
ADC  
Ave. Amps  
ADC  
230  
230  
230  
up to 5  
7.5  
10  
1 @ 25  
2 @ 25  
2 @ 25  
25.00  
12.50  
12.50  
375  
750  
750  
15.00  
30.00  
30.00  
1.00  
1.50  
2.00  
380  
380  
380  
up to 5  
7.5  
10  
1 @ 70  
2 @ 70  
2 @ 70  
70.00  
35.00  
35.00  
375  
750  
750  
8.86  
17.72  
17.72  
0.60  
0.90  
1.20  
460  
460  
460  
460  
up to 5  
7.5  
10  
1 @ 70  
2 @ 70  
2 @ 70  
3 @ 70  
70.00  
35.00  
35.00  
23.33  
375  
750  
750  
10.72  
21.45  
21.45  
32.16  
0.50  
0.75  
1.00  
1.50  
15  
1125  
All resistors are connected in parallel.  
6/4/2001  
© copyright 1997 by Powertec  
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Model 1000AR Installation and Operation Manual  
PAGE  
17  
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.  
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18  
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.  
A1  
13  
21  
31  
41  
1.66"  
14  
22  
32  
42  
A2  
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  
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Model 1000AR Installation and Operation Manual  
PAGE  
19  
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.  
T3  
T2  
T1  
GND  
M
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.  
T1  
T3  
T2  
G
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  
9
8
10 11 12 13 14 15 16  
7
J
CONTACTOR  
POLE N.O.  
N.O. aux  
48VDC COIL  
2.4  
3
1
M
@
W
M (aux)  
J
EMER  
POWERTEC makes an optional track mount PC board (Part  
STOP  
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:  
1.  
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.  
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20  
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  
© copyright 1997 by Powertec  
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Model 1000AR Installation and Operation Manual  
PAGE  
21  
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  
7
8
9
10 11 12 13 14 15 16  
1
2
3
TO  
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.  
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Model 1000AR Installation and Operation Manual  
TERMINAL DESCRIPTIONS - MODEL 1000AR  
TB1  
Current Controller Board (141-108)  
1
2
Dedicated Shields and Ground connection  
HS1 position encoder  
3
HS3 position encoder  
4
HS2 position encoder  
5
HS4 speed encoder  
6
HS5 speed encoder  
7
Encoder Common  
for encoder ONLY  
8
Encoder +5 VDC  
for encoder ONLY  
9
Isolated Common  
for terminals 10 and 11  
+24 VDC for Digital Mode  
+24 VDC Square Wave  
10  
11  
12  
13  
14  
15  
16  
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)  
1
2
3
4
5
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  
30VDC 50 mA maximums  
30VDC 50 mA maximums  
5 mA maximum  
-10VDC to +10VDC  
5 mA maximum  
6
7
N/O 125VAC  
8
9
RUN output contact  
-24VDC supply  
N/O 1A Resistive  
50 mA maximum  
10  
11  
12  
13  
14  
15  
16  
+24VDC supply  
EMERGENCY STOP Input  
RAMP STOP Input  
RUN/START Input  
JOG Input  
50 mA maximum  
+24VDC to activate  
+24VDC to activate  
+24VDC to activate  
-24VDC to activate  
-24VDC to activate  
HOLD Input  
Signal Common  
TB3  
TB5  
Capacitor Board (141-106)  
1
2
3
Horsepower calibration resistor  
No connection  
Horsepower calibration resistor  
Bus Loader (Integral unit connected to Driver board)  
1
2
3
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?  
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PAGE  
23  
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  
1
2
3
4
5
6
7
8
9
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  
6
7
8
9
10 11 12 13 14 15 16  
1
2
3
4
5
6
7
8
9
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.  
DC  
FAULT  
48V  
DC  
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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  
10  
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  
+V  
ZERO  
SPEED  
1
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  
16  
SOURCING CONNECTION  
PLC  
INPUT  
MODULE  
TB2  
10  
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.  
+V  
2Kohm  
MIN  
ZERO  
SPEED  
1
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  
16  
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.  
+V  
TB1  
12  
FAULT  
INPUT  
COM  
13  
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Model 1000AR Installation and Operation Manual  
PAGE  
25  
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  
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16  
SPEED POT  
10K  
CW  
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.  
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16  
CCW  
SPEED POT  
10K  
CW  
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  
1
2
3
4
5
+
6
7
8
9
-
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.  
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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  
10  
3
16  
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).  
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Model 1000AR Installation and Operation Manual  
PAGE  
27  
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  
3
4
5
6
7
8
9
10 11  
12  
8
9
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  
24  
VDC  
CW  
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  
10  
second control. If the first control encounters  
current limit, or changes speed for any other  
3
reason, the second one (the follower) will  
follow it in speed, even to zero speed.  
16  
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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  
+/- 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.  
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Model 1000AR Installation and Operation Manual  
PAGE  
29  
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.  
A
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 DIGIMAXsupplies  
these functions.  
The wiring diagram at  
left shows all the basic  
connections  
to  
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.  
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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.  
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Model 1000AR Installation and Operation Manual  
PAGE  
31  
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.  
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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  
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Model 1000AR Installation and Operation Manual  
PAGE  
33  
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  
PL  
RED  
TAC  
0
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.  
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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  
2Q  
OP  
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  
P
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  
1
2
3
4
5
6
7
8
9
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  
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Model 1000AR Installation and Operation Manual  
PAGE  
35  
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  
11  
+
OR  
RUN  
RUN  
JOG  
JOG  
+24VDC  
+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  
oTB2  
AND  
11  
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  
+
+
+
13  
12  
11  
+24V  
+24V  
CLOSED  
CLOSED  
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  
13  
CLOSED  
RUN  
MODE  
+
12  
ENABLE  
ESTOP  
+
11  
START  
OPEN  
E.STOP  
CLOSED  
STOP  
OPEN  
TB2  
RUN  
0
+24V  
13  
RAMP  
STOP  
0
ENABLE  
12  
+
11  
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  
13  
EMERGENCY  
CLOSED  
0
OPEN  
ENABLE  
STOP  
12  
You start the drive in the JOG mode by applying -24  
VDC (from TB2 terminal 9) to TB2 terminal 14. The JOG  
0
E.STOP  
11  
ESTOP  
ESTOP  
TB2  
+
11  
+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.  
-
14  
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  
13  
0
0
0
+24V  
-24V  
RUN/HOLD  
RUN  
CLOSED  
HOLD  
12  
11  
14  
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.  
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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.  
PL  
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  
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Model 1000AR Installation and Operation Manual  
PAGE  
37  
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.  
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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  
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Model 1000AR Installation and Operation Manual  
PAGE  
39  
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.  
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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  
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  
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Model 1000AR Installation and Operation Manual  
PAGE  
41  
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  
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Page  
42  
Model 1000AR Installation and Operation Manual  
CONNECTIONS FOR 6 TRANSISTOR MODULE  
L1  
Rcharge  
INDUCTOR 1  
HS  
P
CR1  
CR1  
D2  
1
2
3
R3  
BuP  
BvP  
BwP  
BUSS FUSE  
+BUSS  
C9  
R+  
R-  
EvP  
EwP  
EuP  
U
V
W
REGEN  
RESI-  
STORS  
INPUT  
T1  
T2  
T3  
C2  
C8  
CURRENT  
SENSOR  
L1  
+
+
+
+
R2  
R1  
FUSES  
BUSS  
LOADER  
BOARD  
OVER/  
UNDER  
VOLTAGE  
L2  
L3  
TB3  
D
B
C
A
4
5
6
TYPE FLQ  
1
2
3
149-201  
TB2  
-BUSS  
FU4  
C1  
C7  
N
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  
P3  
BASE DRIVER BOARD  
141-105  
L3  
L2  
P1  
460VAC  
380VAC  
T2  
BLK  
BLK  
BK/WH  
POWER  
TRANSFORMER  
PRIMARY  
POWER  
TRANSFORMER  
PRIMARY  
WH  
WH  
BRN  
BRN  
230 VAC  
POWER TRANSFORMER SECONDARIES  
380 OR  
460 VAC  
VIO  
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  
© copyright 1997 by Powertec  
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Model 1000AR Installation and Operation Manual  
PAGE  
43  
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  
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 *  
10  
5
1
1
1
1
1
1
1
1
1
1
1
RECT1  
T1  
L1  
* 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.  
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44  
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  
in  
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  
P
N
N
N
N
U
V
W
P
P
P
U
V
W
B1  
B2  
B3  
B4  
B5  
B6  
N
P
U
V
W
P
0.3 to 2.0  
0.3 to 0.7  
0.3 to 0.7  
0.3 to 0.7  
0.3 to 0.7  
0.3 to 0.7  
0.3 to 0.7  
open  
open  
open  
open  
open  
short or open  
short or open  
short or open  
short or open  
short or open  
short or open  
short or open  
short  
P
P
B1  
B2  
B3  
B4  
B5  
B6  
U
V
W
N
short  
short  
short  
short  
open  
short  
0.3 to 500  
0.3 to 500  
0.3 to 500  
0.3 to 500  
0.3 to 500  
0.3 to 500  
short or open  
short or open  
short or open  
short or open  
short or open  
short or open  
N
N
TWO TRANSISTOR MODULE  
RED LEAD  
C1  
E2  
E2  
E1C2  
C1  
BLACK LEAD  
GOOD  
open  
0.3 to 2.0  
0.3 to 0.7  
0.3 to 0.7  
open  
BAD  
short  
short or open  
short or open  
short or open  
short  
E2  
C1  
E1C2  
C1  
B1  
E1C2  
B1  
B2  
B2  
E1C2  
C2  
open  
0.3 to 500  
0.3 to 500  
short  
short or open  
short or open  
6/4/2001  
© copyright 1997 by Powertec  
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Model 1000AR Installation and Operation Manual  
PAGE  
45  
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.  
Is  
PWR  
LED ON  
?
Turn Power Off  
Remove Fuse.  
Unplug P2 on CC.  
Replace Fuse  
Start Over.  
No  
Yes  
No  
1st  
time  
fuses have  
blown  
?
Are  
FU1, FU2,  
and FU3  
OK?  
Is  
Fuse FU4  
OK  
Is  
Do the following in  
order, checking FU4  
after each change.  
P2 on CC  
unplugged  
?
No  
Yes  
No  
Yes  
?
1st Replace  
PowerTransformer  
No  
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?  
Is  
PWR  
LED ON  
?
Replace  
Diode Bridge  
Replace Current  
Controller board.  
No  
No  
Tolerance:  
Yes  
+ / - 4 VDC  
Yes  
Replace Speed  
Controller board.  
Turn Power Off  
Is  
No  
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  
Yes  
Are  
FU1, FU2,  
and FU3  
OK?  
Is  
+24VDC  
TB2-10(+) to  
TB1-16(-)  
?
Replace  
Capacitor Board  
Turn Power Off  
Plug in TB2 on SC.  
Re-apply Power.  
No  
Check external  
controls on TB2.  
No  
Yes  
Turn Power Off  
Re-connect + (or P)  
terminal of transistor  
bridge.  
Is  
+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.  
No  
Yes  
No  
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46  
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  
© copyright 1997 by Powertec  
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Model 1000AR Installation and Operation Manual  
PAGE  
47  
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  
Is  
From  
Page 1  
To  
Page 3  
BUS LED  
GREEN  
?
Yes  
No  
Is  
BUS LED  
RED  
Nominal Line Voltage = 230VAC  
Too Low 208 VAC  
Replace Current  
Controller board  
<
No  
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  
Is  
Line  
Voltage  
Too Low  
?
Fix Line Voltage  
Problem  
No  
Yes  
Capacitor Board.  
Is  
Bus  
VDC  
< 10%  
?
Bus  
Loader  
Connected  
?
Is  
Charge  
Fuse OK  
?
Turn Power Off  
Remove FU1 on  
Capacitor Board  
Replace  
Charge Fuse  
Yes  
No  
No  
No  
No  
Line VAC = 230  
Bus VDC = 320  
Line VAC = 380  
Bus VDC = 530  
Yes  
Disconnect  
Bus Loader and  
Start Over.  
No  
Yes  
Line VAC = 460  
Bus VDC = 640  
Turn Power Off  
Perform Diode  
Bridge Test  
Is  
Bus  
VDC  
> 90%  
?
Perform  
Transistor Module  
Leakage Test  
No  
Is  
Diode  
Bridge OK  
?
Yes  
Replace Diode  
Bridge  
Is  
Replace  
Transistor  
Module  
Replace  
Capacitor Board  
Transistor  
Module  
OK?  
No  
Yes  
Replace  
Capacitor Board  
Turn Power Off  
Check Choke L1  
for continuity  
Yes  
Is  
Choke  
OK  
Replace  
Capacitor Board  
Replace  
Choke  
Yes  
?
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Page  
48  
Model 1000AR Installation and Operation Manual  
MOTOR ENCODER CONNECTIONS  
IN MOTOR TERMINAL BOX  
MOTOR ENCODER LAYOUT  
6/4/2001  
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Model 1000AR Installation and Operation Manual  
PAGE  
49  
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  
Is  
HS1 LED  
ON  
Is  
HS2 LED  
ON  
Is  
TAC LED  
ON  
From  
Page 2  
To  
Page 4  
No  
No  
?
?
?
You can see the  
rotation of these  
three LED's by  
Yes  
No  
No  
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.  
Is  
HS2 LED  
ON  
Is  
HS3 LED  
ON  
Is  
TAC LED  
operation  
OK  
Yes  
No  
?
?
?
Yes  
No  
No  
Turn off Power  
Disconnect wires  
on TB1-2, TB1-  
3, and TB1-4.  
Is  
HS3 LED  
ON  
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.  
No  
Are  
Any of the  
HSX LED's  
ON  
Is  
TAC LED  
ON  
Is  
Cable  
Connected to  
motor  
No  
Yes  
Connect Encoder  
Cable  
No  
?
?
Yes  
?
Replace Current  
Controller Board  
No  
Yes  
Are  
Any of the  
HSX LED's  
ON  
Turn off Power  
Replace  
Encoder  
+5VDC  
TB1-8(+)  
TB1-7(-)  
?
No  
Disconnect Encoder  
Cable at Motor End  
Re-apply power.  
Replace Encoder  
No  
?
Yes  
Replace  
Cable  
Yes  
Yes  
Is  
Wiring  
OK  
Turn off Power  
Check Encoder Wiring  
to Motor  
+5VDC  
TB1-8(+)  
TB1-7(-)  
?
Turn off Power  
Disconnect TB1  
Yes  
No  
Replace Current  
Controll board  
?
No  
+5VDC  
TB1-8(+)  
TB1-7(-)  
?
Replace Current  
Controller board  
Check TB1 Connections  
Check for short in cable.  
Fix Wiring  
No  
Yes  
OFFICIAL  
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Page  
50  
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,  
or  
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  
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Model 1000AR Installation and Operation Manual  
PAGE  
51  
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  
Is  
RUN LED  
ON  
Is  
Button and  
Release  
(See note  
above)  
From  
Page 3  
ENBL LED  
ON  
?
To  
Page 5  
Yes  
Yes  
?
Release  
START  
Button  
No  
No  
Yes  
+24V  
TB2-11(+)  
TB2-16(-)  
?
Check "EMERG  
STOP Button"  
connections  
Is  
RUN LED  
ON  
+24V  
Press and  
HOLD START  
Button  
No  
TB2-12(+)  
TB2-16(-)  
?
Yes  
?
Yes  
No  
No  
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  
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  
No  
TB2-12(+)  
TB2-16(-)  
?
No  
Is  
PL LED  
on CC  
ON  
Release  
START  
Button  
+24V  
TB2-10(+)  
TB2-16(-)  
?
Yes  
TRIP  
No  
?
+24V  
TB2-11(+)  
TB2-16(-)  
?
>21VDC  
Check  
"STOP Button"  
connections  
Yes  
Yes  
<21VDC  
No  
Replace Current  
Controller Board  
Is  
IOC LED  
on CC  
ON  
Shut off power  
Unplug P3 and TB2  
Reapply power  
Perform IOC  
tests (page 50)  
No  
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  
No  
Is  
OVUV  
LED on CC  
ON  
No  
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  
No  
Replace Cable  
on P3 Connector  
No  
Replace Speed  
Controller Board  
No  
No  
+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  
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Page  
52  
Model 1000AR Installation and Operation Manual  
BLOCK DIAGRAM - - SPEED CONTROLLER AND CURRENT CONTROLLER  
6/4/2001  
© copyright 1997 by Powertec  
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Model 1000AR Installation and Operation Manual  
PAGE  
53  
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.  
Is  
From  
Page 4  
To  
Page 6  
TAC LED  
changing  
?
Yes  
Yes  
No  
No  
STOP.  
Is  
motor  
turning  
?
Is  
motor  
turning  
?
Turn off power.  
Disconnect  
TB1-7 and  
TB1-8  
+5VDC  
TB1-8(+)  
TB1-7(-)  
?
Change Current  
Controller board  
No  
Yes  
Yes  
Yes  
Yes  
No  
No  
Measure voltages at  
TB1-5 and TB1-6.  
TB1-7 is common.  
They switch between  
0VDC and 8VDC as  
the motor turns.  
Is  
ILIMIT  
LED  
ON  
Is  
Speed  
Controller  
ENBL LED  
ON?  
Check Motor  
Connections and  
motor load  
+5VDC  
TB1-8(+)  
TB1-7(-)  
?
No  
No  
?
Yes  
No  
Yes  
Replace Current  
Controller board  
Yes  
Is  
STALL  
LED  
ON  
Are  
TB1-5 and  
TB1-6 OK  
?
Are  
T1, T2, T3  
connected  
?
TRIP  
To Page 4  
Yes  
No  
Yes  
?
Check cable and/or  
Change encoder  
No  
Connect Motor  
Power Leads  
Yes  
No  
Is  
motor  
connected  
to load  
?
Check motor load  
and connections  
Disconnect motor  
from load and  
start over  
Can you  
turn the shaft  
by hand  
?
Yes  
No  
Check connections  
of T1, T2, T3 and cable  
connections  
No  
Yes  
Do  
+5VDC  
Replace Current  
Controller board  
HS1, HS2,  
HS3 change  
?
No  
TB1-8(+)  
TB1-7(-)  
?
No  
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  
Yes  
Is  
CURR LMT  
LED ON  
?
Yes  
No  
No  
Is  
Can  
you  
turn the shaft  
by hand  
?
Is  
speed  
reference  
at 10%  
?
Dynamic  
Disconnect  
Dynamic  
Braking  
Replace Speed  
Controller board  
Braking  
Installed  
?
Yes  
Yes  
Yes  
No  
No  
No  
Check motor  
connections  
Check motor  
connections  
Check motor  
connections  
Fix speed reference  
OFFICIAL  
6/4/2001  
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Page  
54  
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  
© copyright 1997 by Powertec  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Model 1000AR Installation and Operation Manual  
PAGE  
55  
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  
Is  
motor at  
50% speed  
?
From  
Page 5  
Put Motor  
In Service  
Yes  
down, turn  
it up to  
50% CW.  
Yes  
No  
Adjust  
MAX pot  
on Speed  
Controller  
board  
Is  
Is  
motor at  
50% speed  
?
Correct  
Speed  
Reference  
+5VDC  
TB2-5(+)  
TB2-16(-)  
?
CURRENT  
LIMIT LED  
On ?  
No  
No  
Yes  
Yes  
Yes  
No  
Is  
the load  
connected to  
the motor  
?
Is  
motor  
running faster  
than 50%  
?
Is  
speed at  
base speed  
or more  
?
Disconnect  
load from the  
motor and  
Yes  
No  
Yes  
start over  
No  
No  
Turn off power,  
disconnect T1, T2,  
T3. Turn on power  
and rotate motor  
by hand.  
Replace  
Speed  
Controller  
board  
Is  
PHAD  
LED  
No  
On ?  
1st  
Yes  
Are  
all of the  
Driver board  
LED's OK  
?
Remove  
Phase  
Advance  
Chip U8 on  
CCB  
Is  
Replace  
Base Driver  
Board  
motor an  
F2 motor  
?
No  
Yes  
2nd  
Yes  
No  
Turn off power,  
reconnect T1, T2,  
and T3. Replace  
Speed Controller  
board. Restart.  
Replace  
Current  
Controller  
board  
Replace  
Capacitor  
Board  
Is  
Speed  
at 50%  
?
Replace  
Motor  
Return to  
Start  
No  
Yes  
OFFICIAL  
6/4/2001  
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Page  
56  
Model 1000AR Installation and Operation Manual  
6/4/2001  
© copyright 1997 by Powertec  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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