PowerTec 1000 Instruction Manual

Brushless dc motor control

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Repair Center for Powertec Drives and Motors

460 Milford Parkway

Milford, OH . 45150

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Page 1 Repair Center for Powertec Drives and Motors 460 Milford Parkway Milford, OH . 45150 www.motorsystems.com 513-576-1725...
Page 2 Model 1000 Brushless DC Motor Control NSTALLATION AND PERATION NSTRUCTION ANUAL , 2001...
Page 3: Introduction
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...
Page 5 TA R T TA R T 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).
Page 6: Table Of Contents
R E F E R E N C E P AG E S Model 1000 Dimensions Chart ....................... 8 Model 1000 AC Input Electrical Ratings Table ................... 10 Model 1000 Output Electrical Ratings Table ..................12 Contactor Specifications ........................14 Dynamic Braking Resistors .........................
Page 7: Table Of Contents
W H AT H AP P E N S W H E N I … Apply Power to the Model 1000 Drive ? ......................29 Give the Start Command to the Model 1000 Drive ................... 31 Give the Speed Command to the Model 1000 Drive ..................33 Make an Adjustment on the Model 1000 Drive....................
Page 8: Specifications
S P E C I F I C ATI O N S E N V I R O N M E N T AL 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)
Page 9: Motor Protection
Powertec supplies this manual as a guide to the use of our products. We have used our best efforts to compile this information. If you find mistakes of fact in this manual, please notify your distributor or Powertec at once.
Page 11: Physically Install The Model 1000 Drive
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.
Page 12 Measure the actual input line voltage while the control is operating the motor in a loaded condition. Brief power line disturbances will not normally disturb the Model 1000 series drives. The Model 1000 series drives do not generate significant noise back onto the power service. Events that distort the AC waveform may lower the bus voltage. These may trigger an under-voltage or power loss condition.
Page 13: Connect Ac Power To The 1000 Drive
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.
Page 15: Connect The Motor To The 1000 Drive
1000 Model Installation and Operation Manual Page I … CO NNE CT T HE MO T O R T O T HE 1 0 0 0 DRI V E ? We ship every drive from the factory with A STANDARD CONNECTIONS card.
Page 16: Contactor Specifications
C O N TAC TO R S P E C I F I C ATI O N S If you want to operate an Output or Dynamic Braking Contactor directly from the Model 1000 or 1000A, you must choose a coil that 1.77"...
Page 17: Install An Output Contactor
Page I … CONNE CT AN OUTP UT 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.
Page 19: Connect Standard Control Circuits
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.
Page 20 C AP AC I TO R B O AR D ( 1 4 1 - 1 0 6 ) Horsepower calibration resistor No connection Horsepower calibration resistor *+24 VDC source for forward/reverse input must be must be from TB2 terminal 17 ONLY. 6/1/2001 © copyright 1997 by Powertec...
Page 21: Get Run, Zero Speed, Fault, And Enable Information
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.
Page 22 Installation and Operation Manual Page P L C I N TE R F AC E The interface of the Models 1000 and 1000A with a process controller is dependent upon the ability of the PC to handle the required signals. SINKING CONNECTION...
Page 23: Connect An Analog Speed Reference
I … CO NNE CT AN ANALO G S P E E D RE F E RE NCE ? 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.
Page 24: Digital Mode Notes
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. 6/1/2001 © copyright 1997 by Powertec...
Page 25: Connect A Digital Speed Reference
C O N N E C T A D I G I T AL S P E E D R E F E R E N C E ? 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...
Page 26 If this is the case, some type of trimming device may be necessary in a digital system. If the material does not stretch, this will become apparent in short order. 6/1/2001 © copyright 1997 by Powertec...
Page 27: Connect A Digimax
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).
Page 28 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. 6/1/2001 © copyright 1997 by Powertec...
Page 29: Installation Checklist
Page I N S TAL L ATI O N C H E C K L I S T Is the Model 1000 securely mounted in a vertical position (fuses up) [page 9]? [page 9] Is there a clear path for airflow through the base heatsink and through the chassis...
Page 30: Current Controller Board Layout
1000 Model Installation and Operation Manual Page BUS CONNECTIONS ARE ON THE CAPACITOR BOARD ON THE RIGHT SIDEWALL. BEHIND FRONT PANELS. SPEED CURRENT CONTROLLER CONTROLLER BOARD BOARD Capacitor Board Layout and Connections 6/1/2001 © copyright 1997 by Powertec...
Page 31: Start Up
AP P L Y P O W E R T O T HE MO DE L 1 0 0 0 ? When the power to the Model 1000 or 1000A is turned on, the graph below demonstrates what happens to the drive’s bus voltage.
Page 32 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. 6/1/2001 © copyright 1997 by Powertec...
Page 33: Give The Start Command To The Model 1000 Drive
G I V E TH E S TAR T C O M M AN D TO TH E M O D E L 1 0 0 0 ? 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.
Page 34: Led Indicators
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. 6/1/2001 © copyright 1997 by Powertec...
Page 35: Give The Speed Command To The Model 1000 Drive
1000 Model Installation and Operation Manual Page W H AT H AP P E N S W H E N I … G I V E TH E S P E E D C O M M AN D TO TH E M O D E L 1 0 0 0 ? Once the drive is in RUN mode, the application of the speed reference should cause the motor to turn.
Page 36: Adjustments
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.
Page 37: Make An Adjustment On The Model 1000 Drive
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.
Page 39: Troubleshooting The Model 1000 Drive
R O U B L E S H O O T I N G T H E O D E L R I V E 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 :...
Page 40: Transistor Module Static Test
E1C2 0.3 to 0.7 short or open E1C2 0.3 to 0.7 short or open open short E1C2 open short E1C2 0.3 to 500 short or open 0.3 to 500 short or open 6/1/2001 © copyright 1997 by Powertec...
Page 41: Troubleshooting Chart - Power Led
1000 Model Installation and Operation Manual Page POWERTEC Model 1000 Drive Start Up and Troubleshooting Chart NOTE: This chart assumes standard control connections Page 1 START and no options installed which affect speed control. CC = Current Controller board. SC = Speed Controller board.
Page 42 • If any voltage reading is the same as the BUS VOLTAGE, it may indicate a problem in the opposing transistor in that T lead leg or an unexpected alternate path in the circuit. 6/1/2001 © copyright 1997 by Powertec...
Page 43: Diode Bridge Test
1000 Model Installation and Operation Manual Page POWERTEC Model 1000 Drive Start Up and Troubleshooting Chart Page 2 NOTE: This chart assumes standard control connections Wait up to 30 seconds for and no options installed which affect speed control. BUS LED to change from CC = Current Controller board.
Page 45: Troubleshooting Chart - Hs1, Hs2, Hs3, And Tac Led's
1000 Model Installation and Operation Manual Page POWERTEC Model 1000 Drive Start Up and Troubleshooting Chart Page 3 NOTE: This chart assumes standard control connections and no options installed which affect speed control. CC = Current Controller board. From HS1 LED...
Page 46: Transistor Leakage Test
Do not assume that the AC line voltage which is measured while the drive is off will be the same while the drive is running the motor under load. Measure the AC line voltage under both circumstances. 6/1/2001 © copyright 1997 by Powertec...
Page 47: Troubleshooting Chart - Run And Enbl Led's
1000 Model Installation and Operation Manual Page POWERTEC Model 1000 Drive Start Up and Troubleshooting Chart Page 4 NOTE: This chart assumes standard control connections and no options installed which affect speed control. CC = Current Controller board. Press START...
Page 49: Troubleshooting Chart - Tac And Zero Speed Led's
1000 Model Installation and Operation Manual Page POWERTEC Model 1000 Drive Start Up and Troubleshooting Chart Page 5 NOTE: This chart assumes standard control connections and no options installed which affect speed control. CC = Current Controller board. Increase SPEED...
Page 50 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...
Page 51: Troubleshooting Chart - Current Limit And Phad Led's
1000 Model Installation and Operation Manual Page POWERTEC Model 1000 Drive Start Up and Troubleshooting Chart Page 6 NOTE: This chart assumes standard control connections Increase and no options installed which affect speed control. SPEED CC = Current Controller board.

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