Summary of Contents for PowerTec Regenerative Brushless DC Motor Control 1000AR
- Page 1 Model 1000AR Regenerative Brushless DC Motor Control NSTALLATION AND PERATION NSTRUCTION ANUAL , 2001...
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Page 2: Introduction
The GENESIS series of Brushless DC (BLDC) motor controls (drives) were developed to operate very large Brushless DC motors. Large BLDC motors were first made by POWERTEC Industrial Corporation in the late 1980’s. POWERTEC was acquired by Powertec in 1993. -
Page 3: Specifications
10 to 1 stiffness ratio 20 to 1 dynamic response. S e e P a g e 3 2 S e e P a g e 3 6 S e e P a g e 2 2 6/4/2001 © copyright 1997 by Powertec... - Page 4 Model RE GE NE RATIV E V E RS US NON-RE GE NE RATIV E OP E RATION Traditional AC induction motors and brush-type DC motors have windings on the rotor. They also have stationary windings on the frame that produce magnetic fields if we energize them. When the motor rotates, the windings move through the magnetic field.
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Page 5: Model 1000Ar Standard Connections
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 6/4/2001 Output Terminals Warning: 147-101 STAB GAIN MAX SPD DIR/RL DECEL ACCEL RAMP STOP 2Q/4Q ESTOP COAST STOP HOLD © copyright 1997 by Powertec... -
Page 6: Quick Start
Model Follow these steps to quickly set up and operate the Model 1000AR Brushless DC drive. If you are not sure of the procedure for any of the steps, consult the installation section (beginning on page 9). C O N N E C TI O N S Connect the proper three-phase AC power from a suitably rated switching device to the input terminals L1, L2, and L3. -
Page 7: Table Of Contents
Encoder Waveforms and Connections ... 48 IOC Tests... 50 OV/UV Tests ... 50 Block Diagram - Speed and Current Controller boards ... 52 Base Driver board- Layout and Connections ... 54 1000AR Installation and Operation Manual 6/4/2001 © copyright 1997 by Powertec... - Page 8 Model INTRODUCTION ... 1 REGENERATIVE … OPERATION QUICK START ... 5 REFERENCE PAGES INDEX MOTOR PROTECTION ... 9 WARRANTY ... 9 I N S TAL L ATI O N H o w D o I … Physically Install the Model 1000AR Drive ?...11 Connect AC Power to the 1000AR Drive ? ...13 Connect the Motor to the 1000AR Drive ? ...15 Connect the Regenerative Resistors to the Model 1000AR? ...17...
- Page 9 1000AR Model Installation and Operation Manual Page 6/4/2001 © copyright 1997 by Powertec...
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Page 10: Motor Protection
This warranty does not cover any other claims, including, but not limited to, special, incidental, or consequential damages. Powertec supplies this manual as a guide to the use of our products. We have used our best efforts to compile this information. If you find mistakes of fact in this manual, please notify your distributor or Powertec at once. -
Page 11: Model 1000Ar Dimensions Chart
E N C L O S E D U N I TS Ø 0.28" DIA 7.1mm 4 places 14.00" 356mm 1000 2.00" REGEN 51mm 6/4/2001 9.13" 232mm 18.00" 457mm 7.05" 179mm 18.00" 457mm 9.25" 235mm © copyright 1997 by Powertec... -
Page 12: H O W D O I
Model H O W D O I … P H Y S I C AL L Y I N S TAL L TH E M O D E L 1 0 0 0 AR D R I V E ? Use of the Model 1000AR drive above 3300 ft (1000 meters) requires de-rating. -
Page 13: Model 1000Ar Ac Input Electrical Ratings Table
0.75 10.9 14.1 11.4 17.8 Notes 6/4/2001 MAXIMUM INPUT HEAT OUTPUT IN WATTS 0.550 0.725 0.950 1.450 1.950 2.900 4.825 7.200 9.525 0.975 1.450 1.925 2.875 4.810 7.150 9.250 1.910 2.800 4.750 7.100 9.050 14.150 © copyright 1997 by Powertec... -
Page 14: Connect Ac Power To The 1000Ar Drive
Model H O W D O I … CO NNE CT AC P O W E R T O T HE 1 0 0 0 AR DRI V E ? TRANSFORMER R+ R- OFFICIAL 1000AR Installation and Operation Manual Standard Model 1000AR Brushless DC drives will not operate on single phase AC power. -
Page 15: Model 1000Ar Output Electrical Ratings Table
56.2 K 39.2 K 33.2 K 11.7 20.0 K 21.1 11.0 K 28.2 8.25 K 37.5 6.19 K 39.2 K 10.3 22.1 K 17.4 13.3 K 25.6 9.09 K 31.0 7.50 K 46.6 4.99 K © copyright 1997 by Powertec... -
Page 16: Connect The Motor To The 1000Ar Drive
Model H O W D O I … CONNE CT THE MOTOR TO THE 1 0 0 0 AR DRIV E ? We ship every drive from the factory with A STANDARD CONNECTIONS card. R+ R- 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 Orange Brown... -
Page 17: Regenerative Resistors
The bus voltage times the bus loader current must be greater than 150% of the motor’s full power rating. The power rating of the resistors depends on the duty cycle of the regeneration. Powertec uses four ratings for the GENESIS series of drives: 1. -
Page 18: Connect The Regenerative Resistors To The Model 1000Ar
Model H O W D O I … CONNE CT THE RE GE NE RATIV E RE S I S TORS TO THE MODE L R+ R- CONTROL CIRCUIT INTERLOCK BUS LOADER RESISTOR(S) Operating the 1000AR drive without the Bus Loader attached, or with the Bus Loader disabled, will result in the drive tripping. -
Page 19: Contactor Specifications
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. 1000AR Installation and Operation Manual... -
Page 20: Install An Output Contactor
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. You MUST interlock the contactor with the... -
Page 21: Model 1000Ar Control Connections Table
1 1 . T e r m i n a l 9 i s a l s o c o m m o n f o r t h i s f r e q u e n c y . 6/4/2001 f u n c t i o n . f u n c t i o n . f u n c t i o n . © copyright 1997 by Powertec... -
Page 22: Connect Standard Control Circuits
THE POWER SUPPLIES OF THE MODEL 1000AR SHOULD NOT BE USED FOR EXTERNAL EQUIPMENT! Powertec has an optional power supply (part # 127-101) available for 24VDC to power external circuits. It is possible to operate control circuits with a variety of START devices. -
Page 23: Terminal Descriptions List
50 mA maximum 50 mA maximum +24VDC to activate +24VDC to activate +24VDC to activate -24VDC to activate -24VDC to activate ( 1 4 1 - 1 0 6 ) N/O 125VAC N/O 1A Resistive 6/4/2001 © copyright 1997 by Powertec... -
Page 24: Get Run, Zero Speed, Fault, And Enable Information
Model ZERO SPEED RELAY RELAY 48VDC Coil 24VDC Coil FAULT OUTPUT ISOLATOR ENABLE FAULT OFFICIAL 1000AR Installation and Operation Manual The RUN relay contact at TB2 terminals 7 and 8 is a dry contact rated at 1 Amp (Resistive load) at 125VAC. You may use it in an external circuit as long as the voltage does not exceed 125 VAC (limitation of the terminal strip). -
Page 25: Plc Interface Suggestions
JOG, STOP, and EMERGENCY STOP inputs operate on +24 VDC supplies. The circuitry, however, actually operates between positive and negative supplies, and it is difficult to make connections that do not involve both power supplies. 6/4/2001 © copyright 1997 by Powertec... -
Page 26: Connect An Analog Speed Reference
Model H O W D O I … CO NNE CT AN ANALO G S P E E D RE F E RE NCE ? R+ R- BI-DIRECTIONAL OPERATION SPEED POT UNI-DIRECTIONAL OPERATION SPEED POT EXTERNAL SOURCE 0 TO 10VDC REFERENCE starting the drive. -
Page 27: Digital Mode Notes
TB2 terminal 5 (2Q/4Q jumper in the 4Q position), or with the FWD/REV jumper (2Q/4Q jumper in the 2Q position). 1000AR Installation and Operation Manual 18 VDC min, 30 VDC max 2X desired RPM (250 frames or smaller) 25% min, 75% max 6/4/2001 © copyright 1997 by Powertec... -
Page 28: Connect A Digital Speed Reference
Model H O W D O I … 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 ? MAN AUTO 24VDC 0VDC common) which switches at twice the motor RPM. -
Page 29: Analog Versus Digital Operation Comparison
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 © copyright 1997 by Powertec board... -
Page 30: Connect A Digimax
Model H O W D O I … and shield connections on DIGIMAX TB1 are necessary. The jumper from TB1-4 goes to a screw in the back plate. The pulse train comes from DIGIMAX TB1 terminals 11(+) and 10(-). It is applied to the Model 1000AR TB1 terminals 11(+) and 9(-). -
Page 31: Standard Basic Connection Diagram
OTHER EQUIPMENT. THIS CONDUIT MUST BE ALL IN ONE PIECE, IF POSSIBLE, AND THIS CONDUIT MUST BE SOLIDLY GROUNDED. ONLY THE MOTOR LEADS AND THE GROUND WIRE FROM THE CONTROL TO THE MOTOR SHOULD BE IN THIS CONDUIT. 6/4/2001 © copyright 1997 by Powertec... -
Page 32: Installation Checklist
Model I N S TAL L ATI O N C H E C K L I S T Is the Model 1000AR securely mounted in a vertical position (fuses up) [page 5]? Is there a clear path for airflow through the base heatsink and through the chassis 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... -
Page 33: Capacitor Board Location And Layout
Model Installation and Operation Manual Page BUS CONNECTIONS ARE ON THE CAPACITOR BOARD ON THE RIGHT SIDEWALL. BEHIND FRONT PANELS. CURRENT SPEED CONTROLLER BUS LOADER CONTROLLER BOARD BOARD BOARD Capacitor Board Layout and Connections 6/4/2001 © copyright 1997 by Powertec... -
Page 34: W H At H Ap P E N S W H E N I
Model CURRENT CONTROLLER BOARD POWER GREEN STALL RED/GREEN ENABLE YELLOW OV/UV RED/GREEN You can observe the bus voltage with a voltmeter connected to the POSITIVE BUS and NEGATIVE BUS terminals on the Capacitor Board. This board is located on the right sidewall of the drive behind the front panels (see page 26). -
Page 35: Current Controller Board Layout
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 6/4/2001 SPEED CONTROLLER BOARD STAB GAIN MAX SPD JOG SPD DIR/RL JUMPER DECEL ACCEL 2Q/4Q JUMPER RAMP STOP JUMPER ESTO RAMP STOP HOLD © copyright 1997 by Powertec... -
Page 36: Give The Start Command To The Model 1000Ar Drive
Model W H AT H AP P E N S W H E N I … 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 1000AR drive, turn the Current Limit pots fully counter-clockwise, and the speed reference command input, analog or digital, should be set to zero. -
Page 37: Led Indicators - Current Controller Board
Turns off when trips are reset. Indicates electronic shifting of encoder signals to achieve Constant Horsepower. GREEN indicates no phase advance. ORANGE indicates 18° of phase advance timing. RED indicates 30° of phase advance timing. 6/4/2001 © copyright 1997 by Powertec... -
Page 38: Give The Speed Command To The Model 1000Ar Drive
Model 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 AR ? Once the drive is in RUN mode, the application of the speed reference should cause the motor to turn. -
Page 39: Led Indicators - Speed Controller Board
Turns off when +-24VDC is removed from TB2-14. Turns ON GREEN when -24VDC is applied to TB2 terminal 15. Stays ON GREEN as long as -24VDC is applied to TB2-15. Turns off when +-24VDC is removed from TB2-15. 6/4/2001 © copyright 1997 by Powertec... -
Page 40: Slow Down Or Overhaul The Model 1000Ar
Model W H AT H AP P E N S W H E N I … S L O W D O W N O R O V E R H AU L TH E M O D E L 1 0 0 0 AR ? Since the Model 1000AR is a regenerative drive (see page 3), the motor does not coast when the speed reference is reduced. -
Page 41: Adjustments
This adjustment depends on the HP calibration resistor on TB3-1 and TB3-3. CCW is zero percent, or zero current. CW is maximum current limit, or about 150% of full load. In normal operation, CLIM is set to 150% (CW). 6/4/2001 © copyright 1997 by Powertec... -
Page 42: Make An Adjustment On The Model 1000Ar Drive
Model W H AT H AP P E N S W H E N I … M AK E AN AD J U S TM E N T O N TH E M O D E L 1 0 0 0 AR ? Once the motor is running, it may be necessary to make adjustments to produce the desired results. -
Page 43: Simplified Power Schematic
230 VAC LOW VOLTAGE CONNECTIONS 6/4/2001 CONNECTIONS FOR 6 TRANSISTOR MODULE B1 E1 B4 E4 B2 E2 B5 E5 B3 E3 B6 E6 BASE DRIVER BOARD 141-105 POWER TRANSFORMER SECONDARIES SIMPLIFIED DRAWING MODEL 1000AR POWER CIRCUITS © copyright 1997 by Powertec... -
Page 44: Troubleshooting The Model 1000Ar Drive
Model T RO UBLE S HO O T I NG T HE MO DE L 1 0 0 0 AR DRI V E Troubleshooting of the Model 1000AR drive should only be attempted by personnel experienced in working on high-voltage, high power equipment. Equipment Necessary for Troubleshooting : Safety Glasses A Volt-Ohm-Milliammeter, preferably digital, with:... -
Page 45: Transistor Module Static Test
© copyright 1997 by Powertec... -
Page 46: Troubleshooting Chart - Power Led
Model POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart START Check for grounds, then turn on power Turn Power Off. Remove fuses. Check for shorts. LED ON Install new fuses. Re-apply power. time FU1, FU2, fuses have and FU3... -
Page 47: Diode Bridge 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. 1000AR Installation and Operation Manual 6/4/2001 © copyright 1997 by Powertec... -
Page 48: Troubleshooting Chart - Bus Led
Model POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart Wait up to 30 seconds for BUS LED to change from RED to GREEN From BUS LED Page 1 GREEN Replace Current BUS LED Controller board Disconnect Motor Measure the Bus... -
Page 49: Encoder Waveforms And Connections
1000AR Model Installation and Operation Manual Page MOTOR ENCODER CONNECTIONS IN MOTOR TERMINAL BOX MOTOR ENCODER LAYOUT 6/4/2001 © copyright 1997 by Powertec... -
Page 50: Troubleshooting Chart - Hs1, Hs2, Hs3, And Tac Led's
Model POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart From HS1 LED Page 2 You can see the rotation of these three LED's by turning the motor by hand. There should always be one or HS2 LED two on at a time -... -
Page 51: Ioc Tests
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. 1000AR Installation and Operation Manual 6/4/2001 © copyright 1997 by Powertec... -
Page 52: Troubleshooting Chart - Run And Enbl Led's
Model POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart Press START Button and From Release Page 3 (See note above) Press and HOLD START Button Check "START Button" connections This sequence assumes that standard control connections are being used. -
Page 53: Block Diagram - Speed And Current Controller Boards
B L O C K D I A G R A M - - S P E E D C O N T R O L L E R A N D C U R R E N T C O N T R O L L E R 6/4/2001 © copyright 1997 by Powertec... -
Page 54: Troubleshooting Chart - Tac And Zero Speed Led's
Model POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart Increase SPEED reference from From 0% to 10%. If ILIMIT is at full Page 4 CCW, turn it 25% CW. STOP. Turn off power. Disconnect TB1-8(+) TB1-7 and TB1-7(-) TB1-8 Measure voltages at TB1-5 and TB1-6. -
Page 55: Base Driver Board- Layout And Connections
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. 1000AR Installation and Operation Manual DRIV E R BOARD LE D’S 6/4/2001 © copyright 1997 by Powertec... -
Page 56: Troubleshooting Chart - Current Limit And Phad Led's
Model POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart Increase SPEED reference from 10% to 50%. If From motor at CURREN 50% speed Page 5 T LIMIT is turned down, turn it up to 50% CW. Correct +5VDC Speed... - Page 57 1000AR Model Installation and Operation Manual Page 6/4/2001 © copyright 1997 by Powertec...