PowerTec 1000 Instruction Manual

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Repair Center for Powertec Drives and Motors 460 Milford Parkway Milford, OH . 45150 www.motorsystems.com 513-576-1725

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Model

1000

Brushless DC Motor Control

NSTALLATION AND

PERATION

NSTRUCTION MANUAL

UNE

, 2001

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Model

Installation and Operation Manual

1000

Page

IIII

NTRODUCTION

NTRODUCTIONNTRODUCTION

WHAT IS A GENESIS SERIES BRUSHLESS DC DRIVE ?

The GENESIS series of drives were developed to operate very large Brushless DC motors. Large BLDC

motors were first made by POWERTEC Industrial Corporation in 1987.

Small BLDC motors have been in use for many years. The GENESIS series were the first drives that

were produced to operate really large BLDC motors. They range from fractional Horsepower (HP) to 300 HP.

Brushless DC motors and drives offer three significant benefits to the user:

1. Absolute Speed Control

2. High Efficiency

3. Low Maintenance.

ABSOLUTE SPEED CONTROL

The AC induction motor must “slip” in order to develop torque. “Slip” means that the rotor slows down when loaded. The amount of slip varies with the load on the motor. When the motor load changes from no load to full load, speed may change as much as 50 RPM. You must use extraordinary means to employ AC motors in speed sensitive applications.

Traditional brush-type DC motors have “IR Losses.” These cause the speed of the motor to vary as the load changes. “IR Losses” account for speed changes of as much as 2% of base speed. You can limit speed changes to about 0.5% with a very expensive tachometer. That is still 8 or 9 RPM from no load to full load. You must use extraordinary means to employ brush-type DC motors in speed sensitive applications.

Brushless DC drives and motors do not change speed when the load changes. This is true with the standard product, right out of the box! This is very good for speed sensitive applications.

HIGH EFFICIENCY

AC induction motors are fairly efficient when operated across the line on plant power. Using an AC variable speed inverter to control the speed of the AC motor adds power losses as heat in the drive. It also creates additional losses in the motor. Total losses in the AC system approach 10% at the 100HP level.

Brush-type DC motor systems at 100 HP are relatively efficient, but the losses total about 8%.

Losses average less than 6% in Brushless DC systems at the 100 HP level.

At 100 HP, each percentage of losses is 750 watts. That’s 18 Kilo-Watt-Hours (KWH) per day, or about 6,500 KWH per year. A 2% increase in efficiency results in over $1,000 a year in direct energy savings.

LOW MAINTENANCE

An AC motor running on a variable speed AC drive produces a lot of heat. The motor needs lubrication more often. It needs extra bearing changes. Heat also shortens the life of the motor.

Brush-type DC motors require frequent brush replacement. They need commutator service and field and armature rewinding. They also require frequent lubrication and bearing changes due to heat.

Brushless DC motors need greasing, but oversize bearings and low heat output allow long bearing life. Maintenance on a Brushless DC motor is minimal.

POWERTEC offers the GENESIS series for general purpose industrial use.

POWERTEC also offers a complete line of servo-duty rated drives and motors covering the range from

1/10 to 300 HP.

QUICK START - Page 3 TABLE OF CONTENTS - Page 5

OFFICIAL 6/1/2001

Page 4

Page

Model

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POWER

HS3

HS2

HS1

TAC

RED/GREEN

GREEN

RED

JP1

TB1

CURRENT CONTROLLER

BOARD

JP3

STALL

RED

BUS

RED/GREEN

ENABLE

YELLOW

RED

OV/UV

RED

IOC

RED

SPEED CONTROLLER

BOARD

POWERTEC

JP2

GAIN

STAB

CLIM

ACCEL

DECEL

JOG SPD

MAX SPD

MIN SPD

JP1

CURRENT

LIMIT

REMOVE

FOR

COAST

STOP

LED

RUN

LED

TB2

RUN

123456789101112131415161718

ZERO

SPEED

LED

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Page

QQQQ

UICK

UICK UICK

Follow these steps to quickly set up and operate the Model 1000 Brushless DC drive. If you are not sure of the procedure for any of the steps, consult the installation section (beginning on page 7).

CONNECTIONS

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

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

Connect the encoder cable to the motor. Consult the drawing on page 2. 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). Connect a 10 Kilo-ohm Speed Potentiometer to TB2 terminals 9 (CW), 10 (Wiper), and 11 (CCW). Connect the

shield of the speed pot cable to TB2 terminal 12. Connect an Emergency Stop (ESTOP) button between TB2 terminals 6 and 7. Use a normally closed,

maintained open contact type pushbutton. Connect a normally closed, momentary type, STOP pushbutton between TB2 terminals 7 and 5.

Connect a normally open, momentary type, RUN pushbutton between TB2 terminals 5 and 4.

If desired, connect a normally open, momentary type, JOG pushbutton between TB2 terminals 5 and 13.

10.

If desired, connect a Forward-Reverse (FWD-REV) selector switch to TB2 terminals 17 and 14. Use a single-

11.

pole, two-position switch. The switch should close a contact in the Reverse position.

START UP

Before applying power, turn the speed pot fully counter-clockwise (CCW) and turn the CLIM pot fully counter-

clockwise. Do not connect the motor to a load for its initial run. Set FWD-REV to FWD. When you apply power, the PWR LED should light up GREEN immediately.

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

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

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. Press and release the START button. The RUN LED should light. The CURRENT LIMIT LED may come on at

this time because the CLIM pot is all the way counter-clockwise. Immediately after the RUN LED comes on, the ENABLE LED should light.

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

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

10.

before CLIM is at 50%, turn the CLIM pot back down fully CCW. Consult the troubleshooting section. When the motor begins turning more than 10 RPM, the ZERO SPD LED should light up YELLOW.

11.

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

12.

hand-held tachometer. Adjust the MAX speed pot, if necessary to attain 50% speed. Turn the speed pot to 100% and measure the motor speed. Adjust MAX speed if necessary.

13.

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

14.

Turn speed pot to 0% (CCW) and set MIN SPD potentiometer, if desired.

15.

Set STAB and GAIN to 50% of their rotation. Press the Normal Stop button. ENABLE should go OFF.

16.

Press the JOG button and set the JOG speed, if desired.

17.

Start the drive at any speed and switch the Forward-Reverse switch to check reversing.

18.

The motor is ready for service.

19.

SSSS

TART

TARTTART

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REFERENCE PAGES

Model 1000 Dimensions Chart ...............................................................................................................8

Model 1000 AC Model 1000

Contactor Specifications .....................................................................................................................14

Dynamic Braking Resistors ................................................................................................................. 14

Model 1000 Control Connections Table ..............................................................................................16

Terminal Descriptions List ...................................................................................................................18

PLC Interface Suggestions .................................................................................................................20

Digital Mode Notes ..............................................................................................................................22

Analog Versus Digital Operation Comparison .....................................................................................24

Standard Basic Connection Diagram ................................................................................................... 26

Capacitor Board Location and Layout ..................................................................................................28

Current Controller Board Layout .......................................................................................................... 30

Speed Controller Board Layout ............................................................................................................30

Jumpers List .......................................................................................................................................30

LED Indicators .....................................................................................................................................32

Adjustments .........................................................................................................................................34

Simplified Power Schematic ................................................................................................................36

Semiconductor Diagrams......................................................................................................................36

Transistor Module Static Test ...............................................................................................................38

Diode Bridge Test ................................................................................................................................40

Transistor Leakage Test .......................................................................................................................40

Encoder Waveforms and Connections ................................................................................................. 42

IOC Tests.............................................................................................................................................. 44

OV/UV Tests ......................................................................................................................................... 44

Block Diagram Speed and Current Controller boards .......................................................................... 46

Base Driver board- Layout and Connections........................................................................................ 48

Output

Electrical Ratings Table ................................................................................... 10

Input

Electrical Ratings Table ...................................................................................... 12

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Page

TABLE OF CONTENTS

INTRODUCTION

QUICK START

REFERENCE PAGES TABLE OF CONTENTS SPECIFICATIONS MOTOR PROTECTION WARRANTY

INSTALLATION

HOW DO I …

Physically Install

Connect AC Power

Connect the Motor

Install an

Install

Dynamic Braking

Connect

Get

RUN

Connect an

Connect a

Installation Checklist

..................................................................................................................................................... 1

......................................................................................................................................................... 3

.......................................................................................................................................... 4

...................................................................................................................................... 5

................................................................................................................................................. 6

........................................................................................................................................ 7

............................................................................................................................................................. 7

the Model 1000 Drive ? ........................................................................................................... 9

to the 1000 Drive ? ........................................................................................................... 11

to the 1000 Drive ? ............................................................................................................ 13

Output Contactor

Standard Control Circuits

, Zero Speed,

ANALOG Speed Reference DIGITAL Speed Reference DIGIMAX



? ........................................................................................................................... 15

? ................................................................................................................................. 15

? .............................................................................................................. 17

, and

FAULT

? ..................................................................................................................................... 25

...................................................................................................................................... 27

ENABLE

Information ? ............................................................................ 19

?........................................................................................................ 21

? ........................................................................................................... 23

START UP

WHAT HAPPENS WHEN I …

Apply Power Give the Start Command Give the Speed Command Make an Adjustment

to the Model 1000 Drive ? ............................................................................................................ 29

to the Model 1000 Drive........................................................................................... 31

to the Model 1000 Drive ........................................................................................ 33

on the Model 1000 Drive................................................................................................. 35

TROUBLESHOOTING

Troubleshooting the Model 1000 Drive............................................................................................................... 37

Troubleshooting Chart - POWER LED ............................................................................................................... 39

Troubleshooting Chart - BUS LED...................................................................................................................... 41

Troubleshooting Chart - HS1, HS2, HS3, and TAC LED’s.................................................................................. 43

Troubleshooting Chart - RUN and ENBL LED’s ................................................................................................. 45

Troubleshooting Chart - TAC and ZERO SPEED LED’s .................................................................................... 47

Troubleshooting Chart - CURRENT LIMIT and PHAD LED’s............................................................................. 49

OFFICIAL 6/1/2001

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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). Nema1 : Maximum air temperature of 40 °C (104 °F).

RELATIVE HUMIDITY : Less than 95%, non-condensing.

POWER SOURCE : Voltage : Nominal 230 VAC, 380 VAC, or 460 VAC per nameplate rating. Voltage Tolerance : -10%, +10% of nominal rated voltage. Phases : Three (Drive will not operate on single phase). Frequency : 48 to 62 Hertz KVA Required : KVA rating of source must be at least equal to Horsepower rating. Max KVA Rating : 100 KVA (limited by input fuse AIC rating).

DIMENSIONS

Physical Dimensions : See page 8. Approximate Weights : 1000 chassis : 30 pounds ( 66 kg ). 1000A chassis : 44 pounds ( 97 kg ) 1000 Nema1 : 41 pounds ( 90 kg ) 1000A Nema1 : 56 pounds ( 123 kg )

PERFORMANCE

Maximum Load : 150% for 1 minute out of 10 minutes. Speed Regulation : 0.0% (on load change from no load to full load) Speed Accuracy : Analog Mode : +/- 1.0% typical with speed pot supplied by internal reference. Linearity : +/- 0.5% typical with external reference source. Digital Mode : 0.0 % typical ( +/- ¾ revolution of the motor shaft ). Displacement power factor : 0.96 typical

ADJUSTMENTS

ACCELERATION TIME : 2 to 90 seconds with JP2 installed; 0.05 to 2 seconds with JP2 removed.. DECELERATION TIME : 2 to 90 seconds with JP2 installed; 0.05 to 2 seconds with JP2 removed.. Acceleration and deceleration times settable in analog mode only. MAXIMUM SPEED : 600 to 5000 RPM ( motor dependent ), analog mode only. MINIMUM SPEED : 0 to 15% of MAXIMUM SPEED with 5K speed potentiometer, analog mode only. JOG SPEED : 0 to 30% of MAXIMUM SPEED, analog mode only. CURRENT LIMIT : Adjustable from 0% to 150% of rated current, calibrated by Horsepower Resistor. GAIN : 10 to 1 stiffness ratio STABILITY : 20 to 1 dynamic response.

JUMPERS

LED INDICATORS

TERMINAL ASSIGNMENTS

SEE PAGE 30

SEE PAGE 32

SEE PAGE 18

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IIII

NSTALLATION

NSTALLATIONNSTALLATION

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

This Notice applies to Brushless DC Drive Model Numbers 1000 and 1000A.

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 about to install a

protected while it is in service. This is what the Model 1000 series drive provides :

“F” Series

switch to the drive. Look up the method of connection in the drive manual. When the thermal switch opens, the drive has to be shut down before high temperatures can cause damage.

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

the drive’s rated output current.

3. The Model 1000 series drive provides an overcurrent trip. This shuts off the drive if peak currents greater than

300% of the RMS rating occur.

4. The Model 1000 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 an optional circuit breaker with the drive, you must supply a switch for input power. You must do this in order to meet the requirements of the National Electrical Code.

GENESIS

Industrial Control Equipment Specification 508. The user is responsible for complying with local codes and practices. If you decide you need more protection, that protection must shut off the drive.

motors have an internal switch that opens at high winding temperatures. You must connect this

series drives do not provide running overload protection as described in Underwriters Laboratories

GENESIS

Series Brushless DC (BLDC) drive. You need to consider how the motor will be

SUMMARY

Powertec

defects in materials and workmanship for a period of from the factory.

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.

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

damages.

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

OFFICIAL 6/1/2001

manufactures Model 1000 Series Brushless DC (BLDC) motor controls. We warrant these units against

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

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

has no control.

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

Powertec

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

OF WARRANTY AND DISCLAIMER

two years

. This period begins on the date of original shipment

Powertec

at once.

Page 10

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ODEL

1000 D

IMENSIONS

CHASSIS UNITS

ENCLOSED UNITS

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OW DO

WARNING:

I …

PHYSICALLY INSTALL THE MODEL 1000 DRIVE?

DANGEROUS HIGH VOLTAGES ARE NORMAL IN THIS EQUIPMENT! WHEN THE AC INPUT POWER IS REMOVED, THE CAPACITORS ARE NOT DISCHARGED AT ONCE! WAIT FIVE MINUTES AND THEN CHECK TO BE SURE THAT THE CAPACITORS ARE DISCHARGED BEFORE WORKING ON THE DRIVE.

WARNING! :

Mount with 1/4-20 bolts

and nuts in 4 places

IF YOU TESTED THE DRIVE BEFORE INSTALLATION, CHECK THE BUS VOLTAGE. YOU WANT TO MAKE SURE THAT THE BUS CAPACITORS HAVE DISCHARGED.

Mount a Model 1000 series drive of the NEMA 1 style with the fuses at the top. Do not block air flow around the unit. 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) of open space on all sides of the NEMA 1 box. Do not mount it directly above a heat source, such as another drive. If you mount two drive units in line vertically, there must be at least 18 inches (450 mm) of open space between the units.

When you move the Model 1000 series drive chassis to an enclosure, DO NOT handle the chassis by parts that may bend or come loose. This applies to the front cover of the drive. Support the chassis by the outside edges of the heatsink.

Mount the chassis style Model 1000 series drive in an upright position (fuses at top) inside an enclosure. Mount the chassis this way to promote cooling air flow through the heatsink fins.

The temperature of the air around the chassis (ambient) may not exceed 55 °C (131 °F). Relative humidity should be 95% or less, 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 a minimum free panel space of 3 inches (75 mm) above and below the chassis. This allows proper air flow through the heatsink fins.

The total heat dissipation within the electrical enclosure, for chassis units, determines the size. There is a list of the heat output of the Model 1000 series drives in the table on page 10.

NEMA 1, NEMA 1A, and NEMA 12 ventilated boxes depend upon 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 cubic meter/minute 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 surface areas. Enclosure surfaces not exposed to cooling air do not count.

For further information, consult the publication THERMAL MANAGEMENT, available from your distributor.

Use of the Model 1000 Series 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.

OFFICIAL 6/1/2001

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ODEL

1000 AC I

NPUT ELECTRICAL RATINGS

NOMINAL

AC LINE

VOLTAGE

230 ½ 0.37 1.4 0.550 35 230 ¾ 0.56 1.8 0.725 42 230 1 0.75 2.4 0.950 60 230 1.5 1.1 3.6 1.450 85 230 2 1.5 4.9 1.950 122 230 3 2.2 7.3 2.900 165 230 5 3.7 12.1 4.825 232 230 7.5 5.6 18.1 7.200 281

‡

230 10 7.5 23.9 9.525 385

380 1 0.75 1.5 0.975 36 380 1.5 1.1 2.2 1.450 55 380 2 1.5 2.9 1.925 70 380 3 2.2 4.4 2.875 105 380 5 3.7 7.3 4.810 142 380 7.5 5.6 10.9 7.150 178

‡

380 10 7.5 14.1 9.250 222

460 2 1.5 2.4 1.910 113 460 3 2.2 3.5 2.800 144 460 5 3.7 5.9 4.750 200 460 7.5 5.6 8.9 7.100 258 460 10 7.5 11.4 9.050 355

‡

460 15 11 17.8 14.150 475

HORSEPOWER

KILO-

WATTS

MAXIMUM

CONTINUOUS

AC LINE

CURRENT

INPUT

KVA

MAXIMUM

HEAT

OUTPUT IN

WATTS

Indicates 1000A models.

The Model 1000 Series drives are designed to operate on power line frequencies from 48 to 62 hertz.

The supplies AC motors, in addition to the drive, must be capable of supporting the starting current of the motors without dropping more than 10%. If the drive is operating at a line voltage of less than 95% of the nominal line voltage, brief power line disturbances may trip the drive.

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

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.

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 interference 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.

protection. Pay particular attention to power and grounding requirements.

tolerance

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

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

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

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

of the input voltage is +10% to -10% of the nominal voltage listed on the nameplate. A service that

OTES

Page 13

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Page

OW DO

TRANSFORMER

I …

CONNECT AC POWER TO THE 1000 DRIVE?

Standard Model 1000 series Brushless DC drives will not operate on

MAIN

POWER

GND

SEE FUSE

INPUT

BOARD

DRAWING

ON PAGE 8

single phase AC power.

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

KVA rating

However, the branch service rating (in KVA) supplying the drive must not

at least equal to the

HorsePower rating

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 1000 series drives do not include a disconnect for input power. The

user must supply a switch that meets 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 may need to change the voltage level.

If you use a transformer, you will need one 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.

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 1000 series 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: THE AC LINE CURRENT OF THE BRUSHLESS DC DRIVE IS NOT

REPRESENTATIVE OF THE OUTPUT LOAD CURRENT TO THE MOTOR!

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.

DO NOT ATTEMPT TO MEASURE MOTOR LOAD BY

MEASURING AC INPUT LINE CURRENT TO THE BLDC MOTOR

CONTROL.

of the drive.

OFFICIAL 6/1/2001

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MODEL 1000 FUSE BOARD

MODEL 1000 OUTPUT ELECTRICAL RATINGS

NOMINAL

AC LINE

VOLTAGE

230 ½ 0.37 2.2 3.3 68.1 K 230 ¾ 0.56 3.4 5.1 45.3 K 230 1 0.75 4.7 7.0 33.2 K 230 1.5 1.1 7.0 10.5 22.1 K 230 2 1.5 8.5 12.7 18.2 K 230 3 2.2 12.8 19.2 12.1 K 230 5 3.7 22.8 34.2 6.81 K 230 7.5 5.6 31.1 46.6 4.99 K

‡

380 1 0.75 2.7 4.0 56.2 K 380 1.5 1.1 3.9 5.8 39.2 K 380 2 1.5 4.7 7.0 33.2 K 380 3 2.2 7.8 11.7 20.0 K 380 5 3.7 14.1 21.1 11.0 K 380 7.5 5.6 18.8 28.2 8.25 K

‡

460 2 1.5 4.0 6.0 39.2 K 460 3 2.2 6.9 10.3 22.1 K 460 5 3.7 11.6 17.4 13.3 K 460 7.5 5.6 17.1 25.6 9.09 K 460 10 7.5 20.7 31.0 7.50 K

‡

230 10 7.5 41.5 61.1 3.74 K

380 10 7.5 25.0 37.5 6.19 K

460 15 11 31.1 46.6 4.99 K

Indicates 1000A models.

‡

HORSE-

POWER

KILO-

WATTS

MAXIMUM

CONTINUOUS

MOTOR

CURRENT

MAXIMUM

MOMENTARY

MOTOR

CURRENT

NOMINAL

CALIBRATE

RESISTOR

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Page

OW DO

I …

CONNECT THE MOTOR TO THE 1000 DRIVE?

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

GND

SEE FUSE

INPUT

BOARD

DRAWING

ON PAGE 8

SEE MOTOR

MANUAL FOR

CORRECT

MOTOR

CONNECTIONS

T1 T2 T3

TB1

1 2 3 4 5 6 7 89

TB2

1 2 3 4 5 6 7 89

Orange

Brown

Blue

Yellow

Red

Black

Green

Purple

White

BLDC

MOTOR

1 2 3 4 5 6 7 8 9 S

GND

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

CODE.

The purpose of this separate ground is to equalize the potential between the motor's frame and the drive chassis. There may be enough impedance to broadcast EMI and RFI even with the motor grounded to its mounting frame. A direct wire connection between the motor frame and the drive chassis minimizes interference in other equipment.

The encoder feedback cable must be a shielded cable. Connect the shield to TB1 terminal 1 on the control end. Standard installation requires a nine-conductor shielded cable (Belden 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.

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 correctly 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.

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.

THIS GROUND WIRE MUST BE RUN IN

™

part #9539 or equivalent).

OFFICIAL 6/1/2001

Page 16

Page

Model

Installation and Operation Manual

1000

CONTACTOR SPECIFICATIONS

If you want to operate an Output or Dynamic Braking Contactor directly from the Model 1000 or 1000A, you must choose a coil that draws less than 50 milliamps DC.

The Output Contactor drawing on page 15 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 1000 series 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 15. Use the same drawing for the Output Contactor. Maximum current for the Contactor Control board is 1 Amp at 230 VAC.

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.

1.25"

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.

1.66"

1.54"

1.77"

13 21 31 41

14 22 32 42 A2

TOP VIEW

BOTTOM VIEW

0.19"

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)

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

to your application, consult

Powertec

Engineering.

/ (Resistor Value)

Page 17

Model

Installation and Operation Manual

1000

Page

HOW DO

@ 2.4 W

TB2

CONTACTOR

3 POLE N.O.

1 N.O. aux

48VDC COIL

I …

M aux

RUN STOP

CONNECT AN OUTPUT CONTACTOR?

GND

BLDC

MOTOR

9 10 11 12 13

EMER STOP

181 2 3 4 5 6 7 814

MOTOR

THERMAL

JOG

DO NOT BREAK THE GROUND CONNECTION OR THE CABLE

CONNECTIONS WITH THE OUTPUT CONTACTOR.

When you use an output contactor with the Model 1000, you MUST interlock the output contactor with the Emergency Stop. You WILL damage the drive if you do not interlock it.

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.

It is important to note that the contactor does not make

or break current.

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 energizes on a run command and de-energizes ONLY on an emergency stop. The contactor stays energized during normal stops.

POWERTEC

makes an optional track mount PC board (Part

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

OW DO

I …

CONNECT DYNAMIC BRAKING?

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.

The requirements are:

1. The contactor must open the main power

contacts BEFORE the drive is enabled; AND

CONTACTOR

3 POLE N.C.

1 N.O. AUX

COIL < 230VAC

2. The contactor may only close its contacts AFTER disabling the drive.

The AEG SH-04.13-ODC contactor is suitable to the circuitry above. The figure on the left shows the connections for using 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 when there is a run command and de-energizes ONLY on an emergency stop. The contactor stays energized during normal stops.

OFFICIAL 6/1/2001

Page 18

Page

Model

ODEL

THERMAL

EMERGENCY

RAMP STOP

START / RUN

RUN CONTACT

ZERO SPEED

JOG

REVERSE

FAULT OUTPUT

ANALOG/ DIGITAL

SWITCH

1000 C

MOTOR

STOP

ONTROL CONNECTIONS

STD:

CONNECT FROM

TB2-8

+24VDC

TB2-6**

STD: N/C PB

TB2-7

+24VDC

TB2-6**

: N/C PB

TB2-7

+24VDC

TO TB

STD: N/O PB

TB2-5

TO TB

TB2-1

AND

OUTPUT

COMMON

+24VD

: TB2-16

: TB2-12

C ON

STD: N/O PB FROM

TB2-5

+24VDC

TB2-13

: N/O PB

STD

2-17

TO TB

OUTPUT

COLLECTOR

MITTER

+24VDC

REFERENCE TB

: TB1-12

: TB1-13

1-9

IS NOT DRIVE

COMMON

1000

TB2-7

FROM

TB2-5

FROM

2-5

TB2-4

FROM

2-4

TB2-2

TB2-13

TB2-14

FROM

2-14

TB1-10

1-9

Installation and Operation Manual

Normally closed bi-metallic thermal switch in the motor. THE MOTOR THERMAL SWICH MUST BE USED TO PROPERLY PROTECT THE MOTOR! When the motor thermal switch opens, the drive must be shut off to prevent damage to the motor from overheating. Voltage must be present to RUN or JOG. When removed, ENABLE REQUEST is blocked immediately (see page 31) and all control functions are disabled. Do not connect voltage to terminal with permanent jumper. In RAMP STOP mode, this is the only way to stop the drive. Voltage must be present to maintain RUN mode after a momentary START is removed. When voltage is removed, the drive decelerates to zero speed at the DECEL rate and shuts off if RAMP STOP jumper JP2 is installed. Otherwise drive shuts off immediately and the motor coasts to a stop. Voltage must be applied to initiate RUN mode. When it is removed, drive shuts off unless +24VDC is present at TB2-5. RUN LED turns on when +24VDC is applied to TB2-4. RUN LED turns off and RUN relay drops out when voltage is removed from both TB2-4 and TB2-5. Normally open dry contact which closes when START is energized and opens when RUN relay drops out (see above). The RUN contact does not open on a FAULT unless the fault removes the voltages from TB2-4 and TB2-5. The RUN contact does not close on JOG and opens in RAMP STOP mode. Open collector transistor output referenced to TB2-12. Rated at 50 mADC @ 50 VDC max. This output operates only in RUN, JOG, or RAMP STOP modes. The ZERO SPEED output turns on at about 10 RPM and off at about 5 RPM. The ZERO SPEED output shuts off if ENABLE LED shuts off. Voltage must be applied to initiate JOG mode. JOG mode will be maintained only as long as the voltage is present. When the voltage is removed, the drive will go to RAMP STOP mode if COAST TO STOP jumper JP2 is installed. Otherwise the drive shuts off and the motor coasts to a stop. Voltage must be applied to make motor go in reverse direction (forward direction is defined as clockwise rotation of shaft looking at output shaft end). In analog mode, applying or removing voltage causes drive to decelerate to zero speed and accelerate to set speed in opposite direction. In digital mode, input frequency must be reduced to zero until motor stops, then re-applied to go in opposite direction. Optically coupled transistor output (isolated). Rated at 50 mADC @ 50 VDC. Turns on when bus has achieved proper level. Output is off when any trip occurs.

Apply voltage to switch to DIGITAL mode. TB1-10 and TB1-9 are electrically isolated from the board power supplies. The negative side of the +24VDC used for the input must be connected to TB1-9. External frequency must be applied to terminal 11. Terminal 9 is also common for this frequency.

** NOTE: TB2-6 is a dead terminal. It is used as a tie point.

Page 19

Model

Installation and Operation Manual

1000

Page

OW DO

I …

CONNECT STANDARD CONTROL CIRCUITS?

If you are using an output contactor or dynamic

braking, see page 15

The table on the opposite page lists the functions, connections and descriptions of the control circuits of the Model 1000. Read the descriptions of the operations of these circuits carefully, since there are some differences between operation in analog and digital modes.

The control circuits of the POWERTEC Brushless DC Drive Models 1000 and 1000A motor controls operate on 48 VDC. This results from using the positive and negative 24 VDC unregulated power supplies. Using 48VDC helps to balance the load of relays and other devices on the supplies.

The maximum current from each of the raw supplies is 50 milliamps. Due to this supply limitation, you must use an external supply when you use several external relays.

TB2

16151413121110987654321 1817

MOTOR

THERMAL

THE POWER SUPPLIES OF THE MODELS 1000 AND 1000A SHOULD NOT BE USED FOR EXTERNAL EQUIPMENT! We make an optional power supply (part # 127-101) available for additional 24 VDC power.

EMER

STOP

JOG

FWD REV

It is possible to operate the control circuits with a variety of devices. Standard operator devices are O.K.. The current flowing through these devices is very small. When

START

RAMP

STOP

locating pushbuttons more than 30 feet away from the drive, you should consider using 120 VAC control circuits.

There is a desire in some cases to place a jumper

across the Emergency Stop terminals, rather than to install ESTOP buttons. 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.

HE MOTOR THERMAL MUST BE USED TO

PROPERLY

You can use the "two-wire" control method by connecting a contact or switch between terminals 7 and 4 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. In digital mode, you must reduce the external frequency to zero, or the RAMP STOP circuitry will not function.

Note that the JOG function OVERRIDES the RUN function. If you activate the JOG input while the RUN mode is in operation, it will change the motor speed to JOG speed.

PROTECT THE MOTOR

OFFICIAL 6/1/2001

Page 20

Page

Model

Installation and Operation Manual

1000

TERMINAL DESCRIPTIONS

- M

ODEL

1000

AND

1000A

TB1 CURRENT CONTROLLER BOARD (141-108)

1 Dedicated Shields and Ground connection 2 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 10 Auto/Manual Selection +24 VDC for Digital Mode 11 External Frequency Input +24 VDC Square Wave 12 Collector of FAULT transistor 13 Emitter of FAULT transistor 14 Drive Load output -2VDC = 150% 15 Auxiliary Supply output +15VDC for extra encoder 16 Power Supplies Common

TB2 SPEED CONTROLLER BOARD (141-107)

1 RUN contact closes on RUN 2 RUN contact 1 Amp 125 VAC 3 -24 VDC raw supply 50 ma max 4 RUN input +24VDC to RUN 5 RUN hold +24VDC to maintain RUN 6 SPARE tie point for motor thermal 7 Emergency STOP +24VDC to RUN 8 +24 VDC RUN Logic Supply 50 ma max 9 +10 VDC reference supply 10 Speed reference input 0 to +10VDC 11 Minimum speed connection for speed pot 12 Signal common 13 Jog input +24VDC to JOG 14 Forward/Reverse input +24VDC to reverse ** 15 Frequency output open collector to common 16 Zero speed output open collector to common 17 +24VDC raw supply 50 ma max 18 Current reference (velocity error) 0 to +10VDC

TB3 CAPACITOR BOARD (141-106)

1 Horsepower calibration resistor 2 No connection 3 Horsepower calibration resistor

*+24 VDC source for forward/reverse input must be must be from TB2 terminal 17 ONLY.

Page 21

Model

Installation and Operation Manual

1000

Page

OW DO

I …

GET RUN, ZERO SPEED, FAULT AND ENABLE INFORMATION?

The RUN relay contact at TB2 terminals 1 and 2 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 16 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

RUN

TB1

RUN RELAY

AUXILIARY 48VDC Coil

TB2

FAULT

OUTPUT

ISOLATOR

ZERO

SPEED

ZERO SPEED

RELAY

24VDC Coil

16151413121110987654321

ENABLE

48V

FAULT

48V

RUN

16151413121110987654321 1817

-24VDC

+24VDC

FROM TB2

TERM 17

interface directly with a PLC as a sinking input.

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.

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.

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 1000 does not have a READY output or an ENABLE output.

We can imitate an ENABLE relay by a combination of the FAULT output and the RUN output. The RUN relay does not

TB2

drop out on a fault. The combination of the FAULT and the RUN circuits shows that the drive is in the RUN mode and that

4321

there is no fault.

The internal RUN relay drops out on RAMP STOP. Therefore, do not use the ENABLE relay, as shown in the diagram, to control dynamic braking or contactor functions.

OFFICIAL 6/1/2001

Page 22

Page

Model

Installation and Operation Manual

1000

PLC INTERFACE

The interface of the Models 1000 and 1000A with a process controller is dependent upon SINKING CONNECTION

the ability of the PC to handle the required signals.

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

TB2

PLC

INPUT

MODULE

There are two types of input modules.

ZERO

SPEED

INPUT

A "sinking" connection uses the Programmable Controller’s own power, or an external source (such as the drive’s power as shown at left, and connects it (sinks

SOURCING CONNECTION

COM

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. When the transistor turns on, it turns on the input module.

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.

You can use the fault output with connections similar to those in the above figures. You can use a PLC input

DRIVE

ZERO

SPEED

+24VDC

TB2

2Kohm

MIN

PLC

INPUT

MODULE

INPUT

module, with the FAULT output of the control at TB1 terminals 12 and 13, to sense a FAULT in the drive. The

COM

bottom figure illustrates this.

You need to keep in mind that the FAULT isolated

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

FAULT MONITOR

the drive.

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, REVERSE, and EMERGENCY STOP inputs operate on +24 VDC supplies. The circuitry, however, actually operates between positive and negative supplies,

FAULT

TB1

PLC

INPUT

MODULE

INPUT

and it is difficult to make connections that do not involve both power supplies.

COM

Page 23

Model

Installation and Operation Manual

1000

Page

OW DO

I …

CONNECT AN ANALOG SPEED REFERENCE?

The analog speed reference for the Model 1000 and 1000A is 0 to +10 VDC with the positive connection on TB2 terminal 10 and the common connection on TB2 terminal 12. Voltages less than 0 VDC have no effect and voltages greater than 10 VDC become non-linear.

The input impedance is in excess of 100K when the drive is in RUN mode, and about 30 K when the drive is not in RUN mode. 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 9. The supply has a 10 ma limit.

There is a 1000 ohm potentiometer, connected as a rheostat, for MINIMUM SPEED between TB2-11 and common. With a 10K external speed pot, this allows a minimum speed adjustment of up to about 9% of full speed. You may connect the low end of the speed pot directly to TB2 terminal 12, bypassing the MIN SPD pot.

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 12.

The reference voltage for the input does not have to come from the reference source at TB2 terminal 9. You can introduce an external reference voltage between TB2 terminals 10 (+) and 12 (common). The speed of the motor varies as the external voltage varies.

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 command to TB2 terminal 10 (+) and TB2 terminal 12 (-).

When using a speed pot or an external voltage, it is not necessary to reduce the speed signal to zero

TB2

REF IN

+10VDC

REF IN

+10VDC

0 TO 10VDC

REFERENCE

SPEED

10 OHMS

POT 10K

10 OHMS

MIN

SPEED

16151413121110987654321 1817

before starting the drive. Starting the drive with a speed input already present will not damage the drive, even at very high accel rates.

The Brushless DC drive operates over very wide speed ranges, so when you want the motor to stop with the drive in RUN mode, there must be ZERO VDC at the input. Voltages as low as 70 millivolts (0.070 VDC) will cause the motor to turn. Noise levels on the reference line can reach these values. You must be very careful about shielding and common mode voltages if you expect to operate with references of less than 0.5 VDC.

OFFICIAL 6/1/2001

Page 24

Page

Model

Installation and Operation Manual

1000

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 (figure 16). 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: 2X desired RPM (250 frames or smaller) DUTY CYCLE: 25% min, 75% max MAXIMUM FREQ: 50 KiloHertz

You can obtain the best tracking by "ramping" the frequency, that is, changing the frequency gradually. The motor accelerates in current limit if a frequency is present when the control starts.

The nature of the Brushless DC motor control is that the motor must return a pulse for each reference pulse supplied, except in current limit! You will lose pulses if the control goes into current limit, even for a brief time. So it is best to not change the external frequency so rapidly that the motor cannot respond without going into current limit.

Page 25

Model

Installation and Operation Manual

1000

Page

OW 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, so a jumper from TB2-8 or TB2-17 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 22, there is a list of the parameters for the pulse train.

You can also activate digital mode by moving the “AF-N” jumper (JP1) on the Current

TB1

MAN AUTO

1615141312111098

VDC

24VDC

0VDC

TB2

1615141312111098 1817

SPEED

POT

10K

the collector of a transistor (TB2-12 is common) which switches at twice the motor RPM. If you connect a resistor (at least 1 Kohm minimum) from TB2-17 (+24 VDC) to TB2-15, you generate a signal that can drive the input of another drive. Connect TB2-15 on the first control to TB1-11 on the second control, and connect TB2-12 on the first control to TB1-9 on the second. To switch to digital mode, connect TB2-17 on the first control to TB1-10 on the second control.

Controller board to the AF position (the two left pins). Placing the jumper in the AF position makes it unnecessary to energize terminal 10.

While in digital mode, the 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.

Almost all motors used with the Model 1000 and 1000A standard drives have 30 pulse per revolution quadrature encoders. This produces a 120 pulse per revolution (PPR) feedback, so each pulse put into the drive is a command to turn 3° in its mechanical rotation.

The pulse train input for a may come from another

GENESIS

drive, since

drive

there is an output on TB2 (the figure below shows Model 1000 connections). Terminal 15 (TB2-15) is

With this arrangement, the second motor will operate at exactly the same speed as the first, as long as you avoid current limit on the second control. If the first control encounters current limit, or changes speed for any other reason, the second one (the follower) will follow it in speed, even to zero speed.

OFFICIAL 6/1/2001

Page 26

Page

Model

Installation and Operation Manual

1000

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

ANALOG

Value

Speed Regulation 0% from No Load to Full Load Speed Accuracy +/- 1% of Speed Reference Speed Drift +/- 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

DIGITAL Value

Speed Regulation 0% from No Load to Full Load Speed Accuracy 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.

source to follow. Electrical noise can be a nasty problem, and you must use good shielding methods.

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

motor. The EEPROM multiplier used in the Current Controller board 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

Page 27

Model

Installation and Operation Manual

1000

Page

OW 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 DIGIMAX supplies 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 1000

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 1000 TB1-10. Even this connection may be left off if the Current Controller board jumper JP1 is in the AF position (see page 23).

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 input, if it is used.

The EXTERNAL FREQUENCY input (TB2 terminals 13 and 14) is only used in the SLAVE mode. It is used when the DIGIMAX is to follow another pulse train from another DIGIMAX or drive.

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

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

OFFICIAL 6/1/2001

Page 28

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Model

Installation and Operation Manual

1000

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.

* NOTE:

THE POWER SUPPLY FOR THE FWD/REV SWITCH, WHEN USED, MUST COME FROM TB2

TERMINAL 17 ONLY. DO NOT CONNECT THE FWD/ REV SWITCH ANYWHERE IN THE CONTROL

PUSHBUTTONS CIRCUIT BETWEEN TB2 TERMINAL 4 AND TB2 TERMINAL 8.

Page 29

Model

Installation and Operation Manual

1000

Page

INSTALLATION CHECKLIST

Is the Model 1000 securely mounted in a vertical position (fuses up) [page 9]?

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

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

Is there a clear path for airflow through the base heatsink and through the chassis

Is the temperature of the air surrounding the drive within specifications

Is the AC power source for the drive of the proper voltage, frequency, and capacity

Is the motor securely mounted and aligned

Is the drive and motor system properly grounded

Are the motor leads connected in the proper order

Is the cable from the motor to the drive properly connected

If an Output Contactor is used, is it properly interlocked

If Dynamic Braking is used, are the resistors properly installed and wired

Is the motor thermal properly wired to the drive

Is the Emergency Stop button properly installed

Are other drive controls properly wired

Is the Speed Reference source properly wired in

Proceed to the Start Up section.

[motor manual]

[pages 11 and 13]

[page 13]

[pages 16 and 17]

[page 21 or 23]

[page 13]

[page15]

[page 9]

[page15]

[page 9]

[page 11]

OFFICIAL 6/1/2001

Page 30

Page

Model

Installation and Operation Manual

1000

BUS CONNECTIONS ARE ON

THE CAPACITOR BOARD ON

THE RIGHT SIDEWALL.

BEHIND FRONT PANELS.

CURRENT

CONTROLLER

BOARD

SPEED

CONTROLLER

BOARD

Capacitor Board Layout and Connections

Page 31

Model

Installation and Operation Manual

1000

Page

WHAT HAPPENS WHEN I …

APPLY POWER TO THE MODEL 1000 ?

When the power to the Model 1000 or 1000A is turned on, the graph below demonstrates what happens to the drive’s bus voltage.

640

VDC

563

VDC

540

VDC

VOLTAGE

POWER ON

CONTACTOR

PULLS IN

OUTPUT

OF DIODE

BRIDGE

BUS VOLTAGE

BUS VOLTAGE IF CONTACTOR DOES NOT PULL IN

UNDERVOLTAGE

START UP

VDC

PWR

LED

BUS LED RED

TIME

BUS LED

GREEN

The bus voltage can be observed 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 28). 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 30). 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 ENABLE LED should be off.

The TAC LED may be off or RED or GREEN. It is not important at this time.

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

OFFICIAL 6/1/2001

Page 32

Page

CURRENT CONTROLLER

BOARD

Model

Installation and Operation Manual

1000

SPEED CONTROLLER

BOARD

POWERTEC

JP2

JP1

GAIN

STAB

CLIM

ACCEL

POWER

GREEN

HS3

RED

HS2

RED

HS1

RED

JP3

STALL

RED

BUS

RED/GREEN

ENABLE

YELLOW

REMOVE

FOR

COAST

STOP

DECEL

JOG SPD

MAX SPD

MIN SPD

JP1

CURRENT

LIMIT

LED

TAC

RED/GREEN

TB1

RED

OV/UV

RED

IOC

RED

RUN

LED

TB2

RUN

123456789101112131415161718

ZERO

SPEED

LED

JUMPERS

CURRENT CONTROLLER BOARD 141-108

- “AF-N” Jumper - Used to decide whether or not the drive is permanently in the “DIGITAL”

JP1

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.

- “RESET” Jumper - Used to trap faults when troubleshooting. Faults are normally reset by

JP3

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.

SPEED CONTROLLER BOARD 141-107

- “COAST TO STOP” Jumper - Determines whether the drive has a RAMP STOP mode, i.e.

JP1

if the drive attempts to decelerate the motor to a stop or if the motor is allowed to coast to a stop. When the jumper is installed, the drive changes from RUN or JOG mode to RAMP STOP mode when the RUN or JOG mode is ended. If the jumper is removed, the drive has no RAMP STOP mode and the drive is disabled when the RUN or JOG mode ends.

- “RAMP RATE” Jumper - Sets the range of the ACCEL and DECEL pots. If the jumper is

JP2

installed, rates are adjustable from about 2 to about 90 seconds. If the jumper is removed, the rates are adjustable from about 50 milliseconds to about 2 seconds. Times given are the time to change speed from zero speed to maximum speed (ACCEL), or from maximum speed to zero speed (DECEL). Other speed change times are proportional.

Page 33

Model

Installation and Operation Manual

1000

Page

WHAT HAPPENS WHEN I …

GIVE THE START COMMAND TO THE MODEL 1000 ?

Before starting the Model 1000 drive, turn the Current Limit pot fully counter-clockwise, and the speed reference command input, analog or digital, should be set to zero.

You must have +24VDC (all voltages are relative to TB1 terminal 16) applied to TB2 terminal 7 (Emergency Stop input) before attempting to RUN or JOG. You must maintain +24V on TB2 - 7 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.

You must apply +24V to TB2 terminal 4 to start the

Model 1000 drive. When you energize TB2-4, even if the

START

Emergency Stop circuit is NOT energized, the RUN LED on the Speed Controller board will light up and the normally open RUN contact between TB2 terminals 1 and 2 will close. If the Emergency Stop is closed, the drive will be in the RUN mode as long as the +24V is maintained on TB2 -

RUN

MODE

4. If you use a momentary contact to energize the RUN

input at TB2-4, then you must have +24V applied to TB2 terminal 5 to continue running, as illustrated in the drawing at left. If you do not have +24V applied to TB2 - 5, then the

RUN

RAMP STOP

RUN LED will go off and the RUN contact will open as soon as you let go of the START button.

If you press the STOP button in the drawing at left, or

otherwise remove +24V from TB2-5, the drive will go to the ramp stop mode, i.e., the motor will coast or decelerate to

EMERGENCY

STOP

a stop and the drive shuts off.

To shut off immediately, open the Emergency Stop

button or otherwise remove +24V from TB2-7.

. The RUN contact will NOT close at TB2 terminals 1 and 2.

+24VDC

E.STOP

CLOSED

E.STOP

OPEN

E.STOP

+24V

E.STOP

+24V

E.STOP

+24V

E.STOP

+24V

OPEN

STOP

CLOSED

STOP

CLOSED

STOP

OPEN

STOP

TB2

RUN

AND

RUN JOG

START

TB2

CLOSEDCLOSED

START

TB2

OPENCLOSED

START

TB2

OPENCLOSED

START

TB2

OPENCLOSED

JOG

RUN

ENABLE

RUN

ENABLE

RUN

ENABLE

You may start the drive with the JOG input by applying +24 VDC to TB2 terminal 13. The JOG LED

will light. The RUN LED will NOT light up

The JOG mode should be initiated from the STOPPED condition. If the JOG input is energized while in RUN mode, the JOG overrides the RUN mode. When the JOG input is released, the drive returns to RUN mode (if it is still on) and accelerates to the speed commanded by the input speed reference.

In either JOG or RUN mode, an ENABLE REQUEST is generated, and the ENABLE LED should light on the Current Controller board. There are several reasons why the LED 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:

• The OV/UV LED, indicating an over-voltage or under-voltage bus condition;

• The PL LED, indicating a power supply deficiency;

• The IOC LED, indicating excessive current going to the output transistors.

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

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

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

OFFICIAL 6/1/2001

Page 34

Page

Model

Installation and Operation Manual

1000

LED INDICATORS

CURRENT CONTROLLER BOARD 141-108

PWR Power Turns ON GREEN as soon as power is applied to the drive. Turns OFF when power is removed from the drive. BUS Bus Status 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 revoved from the drive. HS1 Hall Sensor 1 Turns on RED when SOUTH magnetic pole is over HS1 in encoder. Turns off when NORTH magnetic pole is over HS1 in encoder. HS2 Hall Sensor 2 Turns on RED when SOUTH magnetic pole is over HS2 in encoder. Turns off when NORTH magnetic pole is over HS2 in encoder. HS3 Hall Sensor 3 Turns on RED when SOUTH magnetic pole is over HS3 in encoder. Turns off when NORTH magnetic pole is over HS3 in encoder. TAC Hall Sensor 4 Turns on GREEN when SOUTH magnetic pole is over HS4 in encoder. Hall Sensor 5 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. ENBL Enable Turns ON YELLOW when:

Drive is in RUN mode with no faults.

Drive is in JOG mode with no faults.

Turns off when:

STALL Stall Fault Turns ON RED if motor does not move 30° within specified time. Time is inversely proportional to motor current. 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. OV/UV Overvoltage Turns ON RED in the following cases: UnderVoltage 1. Bus Voltage is greater than 120% of nominal at any time.

Turns off when trips are reset if the condition no longer exists. IOC Instantaneous Turns ON RED if bus current to output transistors exceeds 300%. OverCurrent Turns off when trips are reset. 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.

SPEED CONTROLLER BOARD 141-107

RUN RUN mode Turns ON GREEN when +24VDC is applied to TB2 terminal 4. Stays ON GREEN as long as +24VDC is applied to TB2-4 or TB2-5. Turns off when + 24VDC is removed from BOTH TB2-4 and TB2-5. CURRENT LIMIT Current Limit Turns on RED 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 at that load and bus voltage. Turns off when above conditions cease to exist. ZERO SPEED Zero Speed Turns ON YELLOW when motor speed exceeds approximately 10 RPM with 120 PPR encoder. Turns OFF when RUN, JOG or RAMP STOP mode ends.

During RAMP STOP with no faults.

The UnderVoltage Timer times out.

There is an Undervoltage (UV) fault.

There is an OverVoltage (OV) fault.

There is an IOC fault.

There is a STALL fault.

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

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

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

The charging contactor is not energized.

Page 35

Model

Installation and Operation Manual

1000

Page

WHAT HAPPENS WHEN I …

GIVE THE SPEED COMMAND TO THE MODEL 1000 ?

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 (CCB) should be GREEN;

•

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

•

the ENABLE LED should be ON,

•

the RUN LED on the Speed Controller should be on,

•

the TAC LED on the CCB may be OFF, RED or GREEN, depending on the position of the motor.

•

the ILIMIT LED may be on if the Current Limit 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 21;

2. For a digital speed reference, see page 23 (Read the notes on page 22).

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 Current Limit pot 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 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 TB2-10 with respect to TB2-12(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 22). There must be +24V between terminals TB1-10 (+) and TB1-9(-) OR the “AF/N” jumper (JP1) on the Current Controller board 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.

When the motor begins to turn, the ZERO SPEED LED should turn on and remain lighted until the motor next comes to a stop.

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

OFFICIAL 6/1/2001

Page 36

Page

Model

Installation and Operation Manual

1000

ADJUSTMENTS

CCW = Counter-ClockWise position CW = ClockWise position

MIN Minimum Speed ANALOG MODE only.

No effect unless speed pot is connected to TB2-11. Effect equals 100 * 1000/(Speed Pot Value + 1000) percent of full speed CCW is 0% effect, or zero speed. CW is full effect. With a 5000 ohm speed pot, this is 16% of full speed.

MAX 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 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.

ACCEL Acceleration time ANALOG MODE only. Sets amount of time to change from zero speed to full speed. With JP2 installed, CCW is about 90 seconds. With JP2 not installed, CCW is about 2 seconds. With JP2 installed, CW is about 2 seconds. With JP2 not installed, CW is about 0.05 seconds.

DECEL Acceleration time ANALOG MODE only. Sets amount of time to change from full speed to zero speed. With JP2 installed, CCW is about 90 seconds. With JP2 not installed, CCW is about 2 seconds. With JP2 installed, CW is about 2 seconds. With JP2 not installed, CW is about 0.05 seconds.

GAIN Gain adjust 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 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.

CLIM Current Limit ANALOG and DIGITAL modes. Sets the maximum average 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. Initial startup should be made with CLIM fully CCW. Increase CLIM to full CW gradually as confidence in setup is gained. In normal operation, CLIM is set to 150% (CW).

Page 37

Model

Installation and Operation Manual

1000

Page

WHAT HAPPENS WHEN I …

MAKE AN ADJUSTMENT ON THE MODEL 1000 ?

Once the motor is running, it may be necessary to make adjustments to produce the desired results.

ACCEL time DECEL time

MAX speed

MIN speed

ZERO speed

START

Speed

Pot at

CCW

Speed

Pot to CW

STOP

RAMP STOP

JOGONJOG

OFF

JOG speed

With a standard speed pot connection (see page 21), the MIN pot on the Speed Controller board is actually a minimum reference level. When the drive is started in the RUN mode with the speed pot fully counter-clockwise (CCW, or 0%), the speed reference will be whatever is dialed in on the MIN speed pot.

If the low end of the speed pot is connected to TB2 terminal 12, or if an external reference is used, the MIN pot has no effect.

If the speed pot is turned to 100% clockwise (CW), or the speed reference is otherwise increased to +10VDC at TB2 terminal 10, the motor will accelerate to the maximum speed. You may use the MAX pot on the Speed Controller to adjust the maximum speed of the motor.

Actually, the MAX pot will affect the speed at any speed reference input. The MAX pot adjustment is not an absolute limit. It is a calibration to the reference.

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 board. The range of time depends on whether or not JP2 is installed. With JP2 installed, the time for acceleration is adjustable from about 2 seconds (ACCEL pot fully clockwise) to about 90 seconds (ACCEL POT fully CCW). With JP2 removed, the time is adjustable from about 0.05 seconds to about 2 seconds.

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 1000 and 1000A are non-regenerative drives, i.e., they have no braking effect. 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 only be effective if the coast time of the motor (see above) is shorter than the DECEL time. Otherwise, the motor will coast to a stop. When the motor gets to zero speed, the drive shuts off.

JOG speed is adjustable with the JOG pot on the Speed Controller board. JOG speed is affected by the MAX speed adjustment, but JOG speed is not affected by the MAX pot, the ACCEL pot, or the DECEL pot. JOG accelerates in current limit.

OFFICIAL 6/1/2001

Page 38

Page

Model

Installation and Operation Manual

1000

L1, L2, AND L3 MAY BE SWITCHED AROUND AMONG THEMSELVES WITHOUT ILL EFFECT

Page 39

Model

Installation and Operation Manual

1000

Page

TROUBLESHOOTING

TROUBLESHOOTINGTROUBLESHOOTING

ROUBLESHOOTING THE MODEL

1000 D

RIVE

Troubleshooting of the Model 1000 drive should only be attempted by personnel

experienced in working on high-voltage, high power equipment.

Equipment Necessary for Troubleshooting :

Safety Glasses

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

•

A True RMS clamp on ammeter for AC current, or DC current, or both

An oscilloscope is handy if the person using it knows how to use it well.

Other equipment may be required for some configurations.

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 FU1, FU2, and FU3 * HP * 10

Transformer Fuse FU4 FLQ-8/10 5

Capacitor Board 141-206 1

Output Transistor Module * HP * 1

Driver Board 141-105 1

Current Controller Board 141-108 1

Input Diode Module RECT1 * HP * 1

Power Transformer T1 141-004 1

Speed Controller Board 141-107 1

Input Choke L1 141-005 1

* HP * means horsepower and/or voltage dependent.

Consult your Distributor for spare parts pricing and delivery.

A Word About The Troubleshooting Charts

Troubleshooting charts cannot solve every problem

Troubleshooting charts are a useful tool in tracing simple problems down to the board or major component level. Follow the troubleshooting chart as far as you can until the problem is resolved or you reach a dead end. If you find yourself coming back to the same point in the troubleshooting chart several times, call the factory and obtain the help of a trained technician. Let him know what point you keep coming to in the chart. This will help us to improve the troubleshooting chart in the future.

OFFICIAL 6/1/2001

Page 40

Page

Model

Installation and Operation Manual

1000

TRANSISTOR MODULE STATIC TEST

Equipment needed: A Digital Multi-Meter (

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.

Refer to page 36 for the drive power schematic and semi-conductor diagrams.

Precautions: 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.

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.

SIX TRANSISTOR MODULE

RED LEAD BLACK LEAD GOOD BAD

P N open short N P 0.3 to 2.0 short or open N U 0.3 to 0.7 short or open N V 0.3 to 0.7 short or open N W 0.3 to 0.7 short or open U P 0.3 to 0.7 short or open V P 0.3 to 0.7 short or open

W P 0.3 to 0.7 short or open

P B1 open short P B2 open short P B3 open short U B4 open short V B5 open short

W B6 open short B1 U 0.3 to 500 short or open B2 V 0.3 to 500 short or open B3 W 0.3 to 500 short or open B4 N 0.3 to 500 short or open B5 N 0.3 to 500 short or open B6 N 0.3 to 500 short or open

TWO TRANSISTOR MODULE

RED LEAD BLACK LEAD GOOD BAD

C1 E2 open short E2 C1 0.3 to 2.0 short or open E2 E1C2 0.3 to 0.7 short or open

E1C2 C1 0.3 to 0.7 short or open

C1 B1 open short

E1C2 B2 open short

B1 E1C2 0.3 to 500 short or open B2 C2 0.3 to 500 short or open

)with a diode scale is preferred. You should have a RED lead

DMM

Page 41

Model

Installation and Operation Manual

1000

Page

POWERTEC Model 1000 Drive Start Up and Troubleshooting Chart

START

Turn Power Off.

Remove fuses. Check for shorts. Install new fuses.

Re-apply power.

Yes

1st

time

fuses have

blown

Page 1

Check for grounds,

then turn on power

PWR

LED ON

Are

No Yes

FU1, FU2,

and FU3

OK?

NOTE: This chart assumes standard control connections

and no options installed which affect speed control.

This step assumes that you know for a

fact that the proper power is applied.

CC = Current Controller board.

SC = Speed Controller board.

Yes

Fuse FU4

P2 on CC

unplugged

Yes

Page 2

Turn Power Off

Remove Fuse.

Unplug P2 on CC.

Replace Fuse

Start Over.

Do the following in

order, checking FU4

after each change.

Turn Power Off

Disconnect motor.

Remove, separate, and tape up

wires on + (or P) terminal of

transistor bridge.Replace fuses.

Re-apply Power.

Are

FU1, FU2,

and FU3

OK?

Yes

Turn Power Off

Re-connect + of diode bridge to Capacitor Board tab. Leave + of transistor module disconnected.

Re-apply Power.

Are

FU1, FU2,

and FU3

OK?

Yes

Turn Power Off

Re-connect + (or P) terminal of transistor

bridge.

Re-apply Power.

Before disconnecting any wires, make sure

you know where to re-

connect them.

Replace

Diode Bridge

Replace

Capacitor Board

Yes

Turn Power Off On CC: Plug in P2. Unplug P3 and P4.

Unplug TB1 and TB2.

Re-apply Power.

PWR

LED ON

Yes

Turn Power Off

Plug in P4 on CC.

Re-apply Power.

Turn Power Off

Plug in TB2 on SC.

Re-apply Power.

Turn Power Off

Plug in TB1 on CC.

Re-apply Power.

After turning off power, make

sure that capacitors are

discharged before touching

live parts.

Tolerance:

+ / - 4 VDC

+24VDC

TB2-17(+) to

TB1-16(-)

Yes

+24VDC

TB2-17(+) to

TB1-16(-)

Yes

+24VDC

TB2-17(+) to

TB1-16(-)

Yes

1st Replace

PowerTransformer

2nd Replace

Driver Board

3rd Replace

P2 Ribbon Cable

Replace Current Controller board.

Replace Speed

Controller board.

Replace P4 Cable

Check external

controls on TB2.

Replace

Capacitor Board

Replace Transistor

Block

OFFICIAL 6/1/2001

Are

FU1, FU2,

and FU3

OK?

Yes

Have motor

checked.

Check external

controls on TB1.

Page 42

Page

Model

IODE BRIDGE TEST

Equipment needed: A Digital Multi-Meter (

Preparation: Different meters give different readings on diode tests. KNOW YOUR METER !! Some

Precautions: If the diode bridge is to be tested in circuit, make sure power has been off long enough for

Procedure: The procedure is the same for in circuit or out of circuit testing. If a component tests bad

in the positive (+) input and a BLACK lead in the negative (-) input.

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.

the capacitor banks to completely discharge.

in circuit, it must be tested again after it is removed because of the possibility of alternate paths when the component is in circuit.

Set the DMM on the diode scale.

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. 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. Place the RED lead on the “+” or “P” terminal and the BLACK lead on the “-“ or “N”

terminal. It should read an open circuit.

Installation and Operation Manual

1000

)with a diode scale is preferred. You should have a RED lead

DMM

RANSISTOR LEAKAGE TEST

Equipment needed: A Digital Multi-Meter (

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 36 for the drive power schematic and semi-conductor diagrams.

Precautions:

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

Measure the BUS voltage (POSITIVE BUS to NEGATIVE BUS) before beginning. Place the Red lead of the meter on the POSITIVE BUS. Place the BLACK lead, in turn, on

This test is an in-circuit test with power on

have been trained to work around high voltage.

charge, turn power off and go to TRANSISTOR MODULE STATIC TEST.

T1, then T2, then T3. In each case, notice the voltage reading.

1. 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.

) is preferred. You should have a RED lead in the positive (+)

DMM

. It should be performed by personnel who

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.

If any voltage reading is 0 VDC, there may be a bad transistor. Turn off

•

problem in the opposing transistor in that T lead leg or an unexpected alternate path in the circuit.

Page 43

Model

Installation and Operation Manual

1000

Page

POWERTEC Model 1000 Drive Start Up and Troubleshooting Chart

Wait up to 30 seconds for

BUS LED to change from

RED to GREEN

From

Page 1

Page 2

BUS LED

GREEN

NOTE: This chart assumes standard control connections

and no options installed which affect speed control.

CC = Current Controller board.

Yes

Page 3

Replace Current Controller board

Disconnect Motor Measure the Bus

Voltage between POSITIVE BUS Tab and the NEGATIVE

BUS Tab on the

Capacitor Board.

Bus

VDC

< 10%

Bus

VDC

> 90%

Yes

Line VAC = 230 Bus VDC = 320

Line VAC = 380 Bus VDC = 530

Line VAC = 460 Bus VDC = 640

BUS LED

RED

Yes

Line

Voltage

Too Low

Bus

Loader

Connected

Yes

Perform

Transistor Module

Leakage Test

Yes

Bus Loader and

Nominal Line Voltage = 230VAC

Too Low < 208 VAC

Nominal Line Voltage = 380VAC

Too Low < 342VAC

Nominal Line Voltage = 460VAC

Too Low < 415VAC

Fix Line Voltage

Problem

Turn Power Off Remove FU1 on Capacitor Board

Disconnect

Start Over.

Charge

Fuse OK

Yes

Turn Power Off Perform Diode

Bridge Test

Replace

Charge Fuse

Yes

Replace

Capacitor Board

OFFICIAL 6/1/2001

Transistor

Module

OK?

Yes

Replace Transistor

Module

Replace

Capacitor Board

Replace

Capacitor Board

Diode

Bridge OK

Yes

Turn Power Off

Check Choke L1

for continuity

Yes No

Choke

Replace Diode

Bridge

Replace

Choke

Page 44

Page

Model

Installation and Operation Manual

1000

MOTOR ENCODER CONNECTIONS IN MOTOR TERMINAL BOX

MOTOR ENCODER LAYOUT

Page 45

Model

Installation and Operation Manual

1000

Page

POWERTEC Model 1000 Drive Start Up and Troubleshooting Chart

Page 3

Yes

NOTE: This chart assumes standard control connections

and no options installed which affect speed control.

CC = Current Controller board.

From

Page 2

You can see the rotation of these

three LED's by

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.

Connect Encoder

Cable

Replace Encoder

HS1 LED

HS2 LED

HS3 LED

Cable

Connected to

motor

Yes

+5VDC

TB1-8(+)

TB1-7(-)

Yes

Turn off Power

Disconnect Encoder

Cable at Motor End

Re-apply power.

HS2 LED

HS3 LED

Turn off Power

Disconnect wires

on TB1-2, TB1-

3, and TB1-4.

Reapply power.

Any of the

HSX LED's

Replace Current Controller Board

Yes

Are

TAC LED

Turn Motor by hand to

see the TAC LED

sequence, which is:

RED, ORANGE,

GREEN, OFF or the

reverse order.

HSX LED's

means HS1,

HS2, and

HS3

Turn off Power

Re-connect

wires on TB1-2,

TB1-3, and TB1-

4. Disconnect

Cable at motor

end. Reapply

power.

Are

Any of the

HSX LED's

Yes

Is TAC LED operation

Turn off Power

Disconnect wires

on TB1-5 and

TB1-6. Reapply

power.

Is TAC LED

Replace Encoder

Page 4

Yes

Wiring

Fix Wiring

Turn off Power

Check Encoder Wiring

to Motor

OFFICIAL 6/1/2001

Yes

+5VDC

TB1-8(+)

TB1-7(-)

Replace Current Controller board

Yes

Turn off Power

Disconnect TB1

+5VDC TB1-8(+) TB1-7(-)

Yes

NoYes

Replace

Cable

Replace Current

Controll board

Check TB1 Connections Check for short in cable.

Page 46

Page

Model

Installation and Operation Manual

1000

IOC T

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:

ESTS

Turn off power and wait for the main power capacitors to discharge.

Turn the ILIMIT potentiometer fully Counter-ClockWise (CCW).

Disconnect the motor power leads and check the motor for grounds.

With power still off, perform the Transistor Module Static Test (page 38).

Re-apply power and perform the Transistor Leakage Test (page 40).

If any of the Driver board LED’s are on now, change the driver board.

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. 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. Turn power on and begin the start-up procedure again, turning up the ILIMIT potentiometer slowly to

catch a possible overcurrent event.

OV/UV T

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.

ESTS

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.

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.

•

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.

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.

Page 47

Model

Installation and Operation Manual

1000

Page

POWERTEC Model 1000 Drive Start Up and Troubleshooting Chart

NOTE: This chart assumes standard control connections

Yes

Release

START

Yes

+24V

Check

+24V TB2-17(+) TB2-12(-)

<21VDC

Shut off power

Unplug P3 and TB2

Reapply power

+24V TB2-17(+) TB2-12(-)

>21VDC

Shut off power

Plug In P3

Reapply power

+24V TB2-17(+) TB2-12(-)

and no options installed which affect speed control.

Button

CC = Current Controller board.

ENBL LED

+24V TB2-7(+) TB2-12(-)

Yes

PJ1

on CC

in RESET

position

PL LED

Yes

<21VDC

>21VD

on CC

IOC LED

on CC

OVUV

LED on CC

Replace

Capacitor Board

Check TB2

Connections

From

Page 3

Check

"START Button"

connections

This sequence

assumes that standard

control connections

are being used.

See page 17.

The voltages given

must be at the

indicated terminals

unless otherwise

indicated.

Check

"STOP Button"

connections

In some cases TB2 terminal

6 may not be used. If so,

skip this block.

Check "EMERG

STOP Button"

connections

Check

"Motor Thermal"

connections

Replace Speed

Controller Board

Check

disconnected

wires

Yes

Press START

Button and

Release

(See note

above)

Press and

HOLD START

Button

Yes

+24V

TB2-5(+)

TB2-12(-)

+24V

TB2-7(+)

TB2-12(-)

+24V

TB2-6(+)

TB2-12(-)

+24V

TB2-8(+)

TB2-12(-)

+24V

TB2-8(+)

TB2-12(-)

RUN LED

TB2-4(+) TB2-12(-)

Replace Current Controller Board

Replace Speed

Controller Board

Disconnect all

wires connected

to TB2-8

and TB2-17

+24V

Release

START

Button

Yes

>21VD

<21VDC

Page 4

TB2-5(+)

TB2-12(-)

"STOP Button"

connections

Replace Speed

Controller Board

Yes

Page 5

Check "EMERG

STOP Button"

connections

Set PJ1 jumper on

Current Controller

board to either INT

or MAN position

TRIP

Perform IOC

tests (page 38)

Perform OV/UV tests (page 38)

Replace Cable

on P3 Connector

OFFICIAL 6/1/2001

Page 48

Page

Model

BLOCK DIAGRAM

BLOCK DIAGRAM ---- ---- SPEED CONTROLLER AND CURRENT CONTROLLER

BLOCK DIAGRAM BLOCK DIAGRAM

Installation and Operation Manual

1000

SPEED CONTROLLER AND CURRENT CONTROLLER

SPEED CONTROLLER AND CURRENT CONTROLLER SPEED CONTROLLER AND CURRENT CONTROLLER

Page 49

Model

Installation and Operation Manual

1000

Page

POWERTEC Model 1000 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.

Yes

ZERO SPD

LED ON

From

Page 4

Increase SPEED

reference from

0% to 10%. If

ILIMIT is at full

CCW, turn it up

to 25% CW.

Page 5

TAC LED

changing

No No

Yes

Page 6

STOP.

Turn off power.

Disconnect

TB1-7 and

TB1-8

+5VDC

TB1-8(+)

TB1-7(-)

Replace Current Controller board

Yes

Check cable and/or

Change encoder

Disconnect motor

from load and

start over

Check connections

of T1, T2, T3 and cable

connections

Yes

Can you

turn the shaft

by hand

Dynamic

Braking

Installed

Yes

Measure voltages at

TB1-5 and TB1-6. TB1-7 is common.

They switch between

0VDC and 8VDC as

the motor turns.

Yes

motor

connected

to load

STOP.

Turn off power.

Turn motor shaft

by hand. Do NOT

re-apply power

Disconnect

Dynamic

Braking

+5VDC TB1-8(+) TB1-7(-)

Yes

Are

TB1-5 and

TB1-6 OK

YesNo

Connect Motor

Power Leads

Re-Apply

Power and

Re-start

Yes

Can you

turn the shaft

by hand

motor

turning

ILIMIT

LED

Yes

Are T1, T2, T3 connected

Yes

Can you

turn the shaft

by hand

Yes

HS1, HS2,

HS3 change

Yes

VDC

at TB2-18(+) TB2-12(-)

>2.0VDC

motor

turning

ENBL

LED

STALL

LED

Yes

Check motor load

and connections

+5VDC

TB1-8(+)

TB1-7(-)

<2.0VDC

speed

reference

at 10%

Change Speed

Yes

Controller board

Check Motor

Connections and

Yes

motor load

Yes

TRIP

To Page 4

Replace Current

Controller board

Check cable and/or

Change encoder

Replace Speed

Controller board

Check motor

connections

OFFICIAL 6/1/2001

Check motor

connections

Check motor

connections

Fix speed reference

Page 50

Page

Model

Installation and Operation Manual

1000

DRIVER BOARD LAYOUT AND CONNECTIONS

DRIVER BOARD LAYOUT AND CONNECTIONSDRIVER 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 36.

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.

Page 51

Model

Installation and Operation Manual

1000

Page

POWERTEC Model 1000 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.

Yes

From

Page 5

Increase

SPEED reference from 10%

to 50%. If

CURRENT

LIMIT is

turned

down, turn

it up to

50% CW.

motor at

50% speed

Page 6

50% speed refers to 1/2 of

the max speed of the motor.

Put Motor In Service

Yes

Correct

Speed

Reference

Disconnect

load from the

motor and

start over

1st

Replace

Base Driver

Board

2nd

+5VDC

No Yes

Yes

TB2-10(+) TB2-12(-)

the load

connected to

the motor

Turn off power,

disconnect T1, T2,

T3. Turn on power

and rotate motor

by hand.

Are

all of the

Driver board

LED's OK

Yes

CURRENT

LIMIT LED

On ?

Yes

motor

running faster

No Yes

than 50%

Replace

Speed

Controller

board

Adjust

MAX pot on Speed Controller

board

Yes

speed at

base speed

or more

PHAD

LED On ?

Yes

motor an

F2 motor

Yes

motor at

50% speed

Remove

Phase

Advance Chip

U8 on CCB

Replace

Current

Controller

board

Replace

Motor

reconnect T1, T2,

and T3. Replace Speed Controller

OFFICIAL 6/1/2001

Turn off power,

board. Restart.

Is Speed at 50%

Replace

Capacitor

Board

Return to

YesNo

Start

Page 52

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Model

Installation and Operation Manual

1000