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PowerTec 2000C 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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Summary of Contents for PowerTec 2000C

  • Page 1 Repair Center for Powertec Drives and Motors 460 Milford Parkway Milford, OH . 45150 www.motorsystems.com 513-576-1725...
  • Page 2 300% of the RMS rating occur. 4. POWERTEC provides sub-cycle time, fast clearing fuses in the three AC input legs to the drive. An input circuit breaker may or may not be provided, depending on the options selected at the time of purchase. If a breaker is not purchased with the drive, the user must supply a means of power disconnection in order to meet the requirements of the National Electric Code.
  • Page 3 Page Model 2000C / 3000C Manual...

  • Page 4: Table Of Contents

    MODELS 2000C AND 3000C INSTRUCTION MANUAL TABLE OF CONTENTS LIST OF ILLUSTRATIONS SUMMARY OF WARRANTY WARNING NOTICE POWERTEC SCHOOLS INTRODUCTION BRUSHLESS MOTOR TECHNOLOGY NON-REGEN VERSUS REGEN OPERATION A BRUSHLESS DC PRIMER BRUSHLESS MOTOR BENEFITS HOW TO USE THIS MANUAL APPLICATION DATA...

  • Page 5: List Of Illustrations

    Motor rotation result 26. Connecting FAULT output to PLC The encoder assembly 27. Connections for minimum speed 10. Front view of the Model 2000C 28. Simplified drawing of power circuits 11. 2000C Chassis dimensions 29. Parts layout of Current Sensor board 12.

  • Page 6: Summary Of Warranty

    This manual has been written as a guide to the use of POWERTEC products. It represents the best efforts to compile the information contained herein. Such mistakes as may appear in no way affect the above stated warranty. If mistakes of fact are found in this manual, please notify your distributor or POWERTEC at once.
  • Page 7 Figure 0: Mounting dimensions of the Models 2000C NEMA1 and 3000C NEMA1 enclosures.. Page Model 2000C / 3000C Manual...

  • Page 8: Introduction

    (known as IR losses), away from the output terminals of the motor control, where the motor’s CEMF (armature voltage) is often used to regulate speed. Since the © copyright 1995 by Page 1-1 Powertec Industrial Motors...
  • Page 9 1.2 NON-REGEN The POWERTEC Models 2000C and 3000C are non-regen- VERSUS REGEN erative Brushless DC motor controls. They will not accept energy coming from the motor due to overhauling loads and high inertias OPERATION during deceleration.
  • Page 10 It cannot act as a brake, so it shuts off and waits for speed to fall below that commanded by the reference at the time (if the control © copyright 1995 by Page 1-3 Powertec Industrial Motors...
  • Page 11 Regenerative power capability gives the motor and control the ability to change from higher speeds to lower speeds much more quickly than with non-regenerative types of controls, resulting in more rapid stops and quick reversals of loads. Page 1-4 Model 2000C/3000C Instruction Manual...
  • Page 12 The Brushless DC motor control is capable of running at very low speeds at very high torques while drawing very little current from the AC line. The result of this is © copyright 1995 by Page 1-5 Powertec Industrial Motors...
  • Page 13 If a heavy load is taken off the motor, the current will quickly drop to the new level, and an applied load will be quickly picked up. This accounts for the high efficiency of Brushless DC. Page 1-6 Model 2000C/3000C Instruction Manual...
  • Page 14 AC motor are followed in the assignment of Figure 7: Simplified drawing of the major parts of the Brushless DC motor. markings on the motor leads. For further information on motor connections see the POWERTEC Motor Manual. © copyright 1995 by Page 1-7...
  • Page 15 Shown in Figure 7 are the major parts of the POWERTEC Brushless DC motor in the off state. The stator windings are con- nected as in figure 6 and the motor is operated from the power bridge shown in Figure 5. This drawing is very simplified, showing only a two pole motor, for simplicity.
  • Page 16 There may be as many as 1440 electrical degrees per revolution in a motor. The next step will occur as the 5 transistor turns off, and the 6 transistor turns on (Figure 9). © copyright 1995 by Page 1-9 Powertec Industrial Motors...
  • Page 17 DC motor control can indicate position; outer magnets indicate speed operate its transistors and direction. during the entire commutation cycle. A 2 kilohertz PWM frequency allows the operation of a transistor every 500 microseconds (.0005 seconds). Page 1-10 Model 2000C/3000C Instruction Manual...
  • Page 18 There will always be two on and one off, or one on and two off. The speed of POWERTEC’s four pole Brushless DC motor is regulated by a two channel, 30 pulse (60 pole) digital tachometer on the motor shaft, which indicates both speed and direction of rotation.
  • Page 19 DC motors and controls for the industrial environment. Other manufacturers produce Brushless DC motors for some specialized applications, but only POWERTEC makes a full line of Brushless DC motors and controls from fractional to 600 horsepower for use on industrial power sources (230, 380, and 460VAC three phase) in...
  • Page 20 MOTOR BENEFITS ABSOLUTE SPEED CONTROL REGARDLESS OF LOAD — The speed regulation of the POWERTEC Brushless DC motor and control system is 0%! The speed of the motor does not change from no load to full load. Options include a speed accuracy of 50 PPM (parts per million) and absolute ratio control.
  • Page 21 Figure 11: Front view of the Model 2000C Brushless DC motor control (cover removed). Page 1-14 Model 2000C/3000C Instruction Manual...

  • Page 22: Brushless Motor Technology

    AC adjustable frequency operated motors, or the conventional DC brush-type motors. means must be used to employ AC motors in speed sensi- POWERTEC's Brushless DC motors have the high tive applications. reliability and low maintenance requirements which have Inverters do not help much with AC induction mo- always been associated with AC induction motors.

  • Page 23: Non-Regen Versus Regen Operation

    1.2 NON-REGEN VERSUS REGEN moving around the stationary windings of the stator. If the The POWERTEC Models 2000C and 3000C voltage produced by the rotation of the motor shaft (due to are non-regenerative Brushless DC motor controls. the CEMF) exceeds the supply voltage, the motor can not They will not accept energy coming from the motor draw current from the supply as long as this situation exists.

  • Page 24: A Brushless Dc Primer

    This accounts for the DC motor control is capable of running at very low speeds high efficiency of Brushless DC. at very high torques while drawing very little current from © copyright 1992, 1996 by Powertec Industrial Page Motors...
  • Page 25 Shown in Figure 6 are the major parts of the turned on to deliver maximum torque from the motor. POWERTEC Brushless DC motor in the off state. The While this is actually done in an EPROM (an Electrically stator windings are connected as in figure 5 and the motor Programmable Read Only Memory integrated circuit), the is operated from the power bridge shown in figure 4.
  • Page 26 AC motor windings goes through. If through the free-wheeling diodes which are in inverse winding switching were to stop, the motor would come to parallel connection with each output transistors. In this a halt. © copyright 1992, 1996 by Powertec Industrial Page Motors...
  • Page 27 There are Brushless DC motors. two speed feedback channels which are offset by 90 POWERTEC manuals contain a great deal of infor- electrical degrees, in quadrature. mation and further understanding will come also with use These 30 pulse per revolution signals from the motor of the motors and controls.

  • Page 28: Brushless Motor Benefits

    Model LESS OF LOAD -- The speed regulation of the 2000C and 3000C in this manual, there are plenty of block POWERTEC Brushless DC motor and control system diagrams and simplified diagrams which will help the...
  • Page 29 Figure 10: Front view of the Model 2000C Brushless DC motor control (cover removed). Page Model 2000C / 3000C Manual...

  • Page 30: Electrical Ratings

    +10%, -5% at all times INPUT POWER FREQUENCY: 48 to 62 Hertz RELATIVE HUMIDITY: 95% (non-condensing) SERVICE FACTOR: MAXIMUM SERVICE CAPACITY: 100 KVA (limited by input fuses AIC rating) STORAGE TEMPERATURE: -40°C to +65°C © copyright 1992, 1996 by Powertec Industrial Page Motors...

  • Page 31: Performance

    Motor Thermal input -24VDC raw supply 50mA max Motor Load output (-10VDC = 180%) RUN input +24VDC to RUN Common RUN hold (junction of RUN and STOP) -24VDC SPARE (tie point for motor thermal) Contactor control Page Model 2000C / 3000C Manual...

  • Page 32: Physical Installation

    It is the re- sponsibility of the user of this equip- Figure 12: The mounting dimensions of the chassis version of Model 2000C. © copyright 1992, 1996 by Powertec Industrial Page Motors...

  • Page 33: Installation

    3.4 THERMAL CONSIDERATIONS flow of 1 CFM (cubic feet per minute) for each 10 watts of The 2000C or 3000C chassis must be mounted in a dissipation (1 cubic meter /minute for each 350 watts). vertical position (fuses up) in a suitable enclosure. The...

  • Page 34: Electrical Installation

    (AIC) of the fuses on the care and concern in the installation than any other precise input of the Models 2000C and 3000C is 200,000 amperes. motor and control, although they do require more consid- If the maximum short circuit current available on the...
  • Page 35 Figure 13: Standard connections for the POWERTEC Models 2000C and 3000C. Page Model 2000C / 3000C Manual...

  • Page 36: Connecting The Motor

    Figure 14: Input fuses and transformer fuse holders for the Models 2000C. The motor leads marked T1, T2, and T3 will always causing the peak voltage to be significantly less than it connect to T1, T2, and T3 on the control, although the other should be.

  • Page 37: Output Contactor

    4.3.3 OUTPUT CONTACTOR 4.3.4 MOTOR FEEDBACK CABLE If an output contactor is used with the Model 2000C The encoder feedback cable must be a shielded or Model 3000C motor control, provisions MUST be made cable. See Figure 8 on page 1-10 for shield connections at in the control circuits to interlock the output contactor with the motor end.
  • Page 38 ** NOTE: TB2 terminal 6 is a "dead" terminal which has no connection on the board and is used as a tie point. Table 1: Control connections for the Models 2000C and 3000C. © copyright 1992, 1996 by Powertec Industrial...

  • Page 39: Reference Options

    Many of the control functions are changed slightly have positive 10VDC speed references built in. The when the 2000C or 3000C is changed from the analog to the reference source is accurate within 1%. digital mode. The analog mode uses the analog reference Analog control of speed consists of supplying a 0 input (TB2 terminal 10) to set speed.

  • Page 40: Digital Reference

    MAXIMUM FREQ: 50 KiloHertz It is not necessary to reduce the input reference to zero before starting or stopping the 2000C or 3000C. The The best tracking is gained by ramping the fre- reference input circuits and the accel/decel circuits are quency, changing the frequency gradually.

  • Page 41: Auxiliary Circuits

    Only those relays listed in this section are authorized to be operated from the Model 2000C supplies. If any other relays are operated from the supplies, it is at the user’s risk. DO NOT USE MORE...
  • Page 42 Figure 21 illustrates the wiring and connections to TEC Brushless DC motor control in the manner shown in connect an ENABLE relay to the Model 2000C. The Figure 20. Using an auxiliary relay makes fault contacts maximum current is 50mA. The diode around the coil must available to 120VAC control circuits (the fault output of be installed.

  • Page 43: Interface

    +24VDC PC input necessary to use an external Zero Speed circuit to shut off the Model 2000C. There is a built in RAMP STOP func- tion. However, it is sometimes necessary to detect Zero Speed in a system.

  • Page 44: Operation

    Base Driver board (part #4001-144002- the Models 2000C and 3000C are off. While the 2000C or XXX). The locations of all jumpers, adjustments, and test...

  • Page 45: Accel And Decel

    LIMIT (for increasing speeds) or by coasting (for decreas- NOTE: If the motor is cold, and is heavily loaded, the ing speeds). When the 2000C or 3000C is in current limit, motor may not come all the way up to rated speed. This will...

  • Page 46: Ramp Stop

    Remember that this Model 2000C and 3000C maxi- when the voltage at terminal 13 is removed (the +24VDC mum speed adjustment is in reality just a calibration to the should come from a point after the Emergency Stop input reference of 10VDC.

  • Page 47: Digital Mode

    MODE!! lates enough pulses to go into current limit. The only times that pulses will be lost is if the 2000C or 3000C goes into 5.3 CURRENT LIMIT current limit, or if a rapid decrease in the pulse rate cannot be responded to because of high inertia.

  • Page 48: Gain And Stability

    Voltage rating will vary somewhat with the RPM’s of the the load at any given speed. The POWERTEC Brushless motor. For this reason, the Horsepower Calibration Resis- DC motor control works on the basis of balancing the tors of units shipped from the factory may vary.
  • Page 49 Figure 28Simplified schematic diagram of the Model 2000C and 3000C power circuits. Page Model 2000C / 3000C Manual...

  • Page 50: Theory And Troubleshooting

    POWERTEC Model 380VAC or 460VAC, voltage divider resistors R3 and R4 2000C and the Model 3000C Brushless DC motor con- ensure that the voltage is equally divided across the 380VAC trols. The power sections of the two controls are electri- (530VDC) or 460VAC (640VDC) bus capacitor bank.

  • Page 51: Current Sensor Board

    6.3 CURRENT SENSOR BOARD The bus current sensor is calibrated by the Trip Calibrate resistor (located on TB3 terminals 1 and 2). This The Current Sensor Board (POWERTEC part resistor is installed by the factory using accurate instru- #4001-144009-XXX) contains circuits which moni-...

  • Page 52: Power Output Section

    FROM XFMR FROM XFMR FROM XFMR FROM XFMR B1 E1 B4 E4 B2 E2 E5 B5 B6 E6 B3 E3 Figure 30: Layout and connections of the base driver board 144-2.3. © copyright 1992, 1996 by Powertec Industrial Page Motors...
  • Page 53 Figure 31: Block diagram of the 2000C and 3000C Current Controller and Speed Controller Boards. Page Model 2000C / 3000C Manual...
  • Page 54 There are three lights on the Current Controller Board which monitor the position encoder channels (labelled HS1, HS2, and HS3). Figure 32: Layout of the Current Controller board © copyright 1992, 1996 by Powertec Industrial Page Motors...

  • Page 55: Speed Controller

    Models steady speed reference, the reference and feedback pulse 2000C and 3000C Brushless DC motor controls. rates must be the same or the counter would saturate and the drive would be in current limit.

  • Page 56: Troubleshooting

    (it may be necessary to use an oscilloscope). electrical wiring of the Model 2000C and the Model 3000C 4. Change the Current Controller Board. (follow the suggestions in the order given):...
  • Page 57 This LED is the latched version of THERMAL. step 1 is correct, thermal is open or wire is broken. 3. Check the wires for loose or broken connections. 4. Change the Current Sensor Board. 5. Change the heatsink thermal switch. Page Model 2000C / 3000C Manual...
  • Page 58 Figure 34: Some typical physical configurations of power semiconductors. © copyright 1992, 1996 by Powertec Industrial Page Motors...
  • Page 59 Figure 35: Connections of the Model 2000C or 3000C to the optional DIGIMAX IV. Page Model 2000C / 3000C Manual...
  • Page 60 ME601215 KD621K30 FWH-200 When ordering spare parts, have the serial number of your control(s) handy. Parts may be substituted by POWERTEC due to availability. Older drives may have to use cross-referenced parts. © copyright 1992, 1996 by Powertec Industrial Page...
  • Page 61 Page Model 2000C / 3000C Manual...

  • Page 62: Spare Parts

    ME601215 KD621K30 FWH-200 When ordering spare parts, have the serial number of your control(s) handy. Parts may be substituted by POWERTEC due to availability. Older drives may have to use cross-referenced parts. Page 7-1 © copyright 1995 by Powertec Industrial Motors...
  • Page 63 HIS PAGE WAS INTENTIONALLY LEFT BLANK Page 7-2 Model 2000C/3000C Instruction Manual...
  • Page 64 1 megohm, call the factory before proceeding. - Remove the isolating paper and replace the screw in the current regu- lator board once all terminals are verified to be isolated from ground. Page 8-1 © copyright 1995 by Powertec Industrial Motors...
  • Page 65 The motor will not actually run because the current limit is set at zero. The enable LED on the current regulator board should come on. Leave the current limit pot set to zero (full counter-clockwise.) Page 8-2 Model 2000C/3000C Instruction Manual...
  • Page 66 (after charge up) green enable tach loss phase advance (if installed) Speed Regulator Board current limit zero speed Current Sensor Board bus charged yellow temp OK green LED3 (current cal indicator) Page 8-3 © copyright 1995 by Powertec Industrial Motors...
  • Page 67 50%, then a possibility exists that there is a mechanical blockage of the motor, or that all three of the motor leads (not just two) are wired incorrectly. Damage may result to both motor and control if current limit is turned Page 8-4 Model 2000C/3000C Instruction Manual...
  • Page 68 If a controlled DECEL stop is needed then the jumper should be in place and a ramp stop pushbutton and an E-stop pushbutton should be wired. Page 8-5 © copyright 1995 by Powertec Industrial Motors...
  • Page 69 HIS PAGE WAS INTENTIONALLY LEFT BLANK Page 8-6 Model 2000C/3000C Instruction Manual...

This manual is also suitable for:

3000c

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