Instruction/ maintenance manual of the product 1000AR PowerTec
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Model 1000AR Regenerative Brushless DC Motor Control I NSTALLATION AND O PERATION I NSTRUCT ION M ANUA L J UNE , 2001.
Model 1000A R Inst allation and Operat ion Manual P AGE 1 OFFICIAL 6/4/ 2001 I NTRODUCTION WHA T IS A GENESIS SERIES BRUSHLESS DC DRIVE ? The GENESIS s eries of Brushless DC (BLDC) m otor c ontrols (dr ives) were developed to operate very large Brushles s DC m otors.
Page 2 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec SPECIFICAT IONS Environmental ALTITUDE : Use above 3300 feet (1000 m eters ) requires de-rat ing. De-rate at 3% of full rat ing for eac h additional 1100 f eet (330 m eters).
Model 1000A R Inst allation and Operat ion Manual P AGE 3 OFFICIAL 6/4/ 2001 REGENERATIVE VERSUS NON-REGENERA TIV E OPERAT ION Traditional AC induc tion m otors and brus h-type DC motors have windings on the rotor . They also have stationary windings on the fram e that produce m agnetic f ields if we energize them .
Page 4 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec MODEL 1000AR ST ANDA RD CONNECTIONS POWER GREEN HS3 RED HS2 RED HS1 RED TAC RED/GREEN BUS RED/GREEN EN.
Model 1000A R Inst allation and Operat ion Manual P AGE 5 OFFICIAL 6/4/ 2001 Q UICK S TART Follow these steps to quic kly set up and operate the Model 1000AR Brushles s DC drive. If you are not sure of the procedure f or any of the steps, cons ult the installation sec tion (beginning on page 9).
Page 6 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec REFERENCE PA G ES Specifications ................................................................................................................. ......
Model 1000A R Inst allation and Operat ion Manual P AGE 7 OFFICIAL 6/4/ 2001 T ABL E O F C ONTENTS INTRODUCTION ............................................................................................................................... ...........
Page 8 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec.
Model 1000A R Inst allation and Operat ion Manual P AGE 9 OFFICIAL 6/4/ 2001 I NSTA LLATION Underwriter’s Laboratories ® requires this notice for UL ® listed equipment.
Page 10 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec MODEL 1000AR DIMENSIONS CHA SSI S UNITS Note: 10HP @ 230VAC, 10HP @ 380VAC , and 15HP @ 460VAC have t.
Model 1000A R Inst allation and Operat ion Manual P AGE 11 OFFICIAL 6/4/ 2001 HOW DO I … PHYSICA LLY I NSTA LL THE MODEL 1000AR DRIVE? Use of the Model 1000AR drive abov e 3300 ft (1000 meters) requires de-rating. If the drive is to be stored, store it in its or iginal packaging in a dry environment.
Page 12 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec NOMINAL AC L IN E VOLTAG E HORSE- POWER KILO- WATTS MAX IMUM CONTINUOUS AC L IN E CURRENT INPUT KVA MAX IMUM HEAT OUTPUT IN WATTS 230 ½ 0.37 1.4 0.550 35 230 ¾ 0.
Model 1000A R Inst allation and Operat ion Manual P AGE 13 OFFICIAL 6/4/ 2001 HOW DO I … CONNECT A C POWER TO THE 1000A R DRIVE? Standard Model 1000AR Brushles s DC drives will not operate on single phase AC power.
Page 14 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec MODEL 1000AR FUSE BOA RD Mo del 1000A R O utput Electrical Rating s NOMINAL AC L IN E VOLTAG E HORSE- POWER KILO- WATTS MAX IMUM CONTINUOUS MOTOR CURRENT MAX IMUM MOMEN TAR Y MOTOR CURRENT NOMINAL HP CALIBRA TE RESISTOR 230 ½ 0.
Model 1000A R Inst allation and Operat ion Manual P AGE 15 OFFICIAL 6/4/ 2001 HOW DO I … CONNECT THE MOTOR TO THE 100 0A R DRIV E? We ship ev ery drive from the f actory with A ST A NDARD CONNECTIONS card. Connect the m otor lead m ark ed T1 to the T1 term inal on the dr ive.
Page 16 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec REGENERA TIVE RESISTORS Regenerative m otor controller s require a m ethod of handling energy that is generated by the m otor and returned to the drive.
Model 1000A R Inst allation and Operat ion Manual P AGE 17 OFFICIAL 6/4/ 2001 HOW DO I … CONNECT THE REGENERATIVE RESISTORS TO THE MODE L 1000A R? All but the lar gest Model 1000AR drives have the bus loader (149- 201)built into the chass is. T he bus loader m ounts on the lower left-hand s ide panel and it plugs directly to the driver board.
Page 18 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec CONTA CTOR SPECI FICAT I ONS If y ou want to oper ate an Output or DB Contactor dir ectly from the Model 1000AR, y ou m us t choose a c oil that draws less than 50 m illiam ps DC.
Model 1000A R Inst allation and Operat ion Manual P AGE 19 OFFICIAL 6/4/ 2001 HOW DO I … CONNECT A N OUTPUT CONTACTOR? You may use an output contac tor with the Model 1000AR. You MUST interlock the contac tor with the Emer gency Stop. Y ou W ILL damage the dr ive if you do not interlock the c ontactor.
Page 20 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec MODEL 1000AR CONTROL CONNECTIONS MOTO R THE RMA L STD: CONNECT FROM TB2-10 TO TB5-1** Normally cl osed thermal swit ch in the motor.
Model 1000A R Inst allation and Operat ion Manual P AGE 21 OFFICIAL 6/4/ 2001 HOW DO I … CONNECT STA NDA RD CONTROL CIRCUITS? If you are us ing an output contactor or dyna mic braking, go to page 19. The table on the oppos ite page lists the functions of the Model 1000AR.
Page 22 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec TERMINA L DESCRI PTIONS - M ODEL 1000A R TB1 Current Con troller Board ( 141-108) 1 Dedic ated Shield.
Model 1000A R Inst allation and Operat ion Manual P AGE 23 OFFICIAL 6/4/ 2001 The RUN relay contact at TB2 term inals 7 and 8 is a dry contact rated at 1 Am p (Resis tive load) at 125VAC. You may use it in an external cir cuit as long as the voltage does not exceed 125 VAC (lim itation of the term inal s trip).
Page 24 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec PLC INTERFA CE The int erf ace of t he Models 1000 and 1000A w it h a process cont roller is dependent upon the abilit y of the PC to handle the req uired sig nals.
Model 1000A R Inst allation and Operat ion Manual P AGE 25 OFFICIAL 6/4/ 2001 HOW DO I … CONNECT A N A NA LOG SPEED REFERENCE? The analog s peed refer ence for the Model 1000AR is - 10 VDC to +10 VDC with the positive connection on T B2 term inal 5 and the com m on connection on T B2 term inal 16.
Page 26 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec DIGIT AL MODE NOT ES Since the Brushles s DC m otor c ontrol system is inherently digital, the perfor manc e in the digital m ode of operation far exceeds the perform ance in the analog m ode.
Model 1000A R Inst allation and Operat ion Manual P AGE 27 OFFICIAL 6/4/ 2001 HOW DO I … CONNECT A DIGITA L SPEED REFERENCE? Apply +24VDC to T B1 term inal 10 (T B1-10) with respect to T B1-9 to operate the Model 1000 with a digital referenc e. Term inal 9 on T B1 is NOT the sam e as drive c om mon.
Page 28 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec A NA LOG VE RSU S DIGITA L OP ERA T ION The c hoice between ANALOG and DIGIT AL operation com es down to perform ance. In ANALOG mode, a voltage s ets the speed of the m otor.
Model 1000A R Inst allation and Operat ion Manual P AGE 29 OFFICIAL 6/4/ 2001 HOW DO I … CONN ECT A DIGIMA X®? The DIGIM A X ® is a crystal-based Speed or Ratio controller. It c reates a train of puls es to comm and the movem ent of a motor when the drive is operating in digital speed m ode.
Page 30 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec Output Terminals Warning: Do Not Connect Input Power Leads to Output Terminals Power Input L1 L2 L3 I.
Model 1000A R Inst allation and Operat ion Manual P AGE 31 OFFICIAL 6/4/ 2001 INST A LLA TION C HECKL IST Is the Model 1000AR sec urely mounted in a vertical pos ition (fus es up) [page 5]? Is there a.
Page 32 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec BUS CONNECTIONS ARE ON THE CAPACITOR BOARD ON THE RIGHT SIDEWALL.
Model 1000A R Inst allation and Operat ion Manual P AGE 33 OFFICIAL 6/4/ 2001 WHA T HA PPENS W HEN I … A PPLY POWER TO THE MODEL 1000A R ? W hen y ou apply the power to the Model 1000AR, the graph below demonstr ates what happens to the drive’s bus voltage.
Page 34 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec JUMPERS CURRENT CONT ROLLER BOARD 141-108 JP1 - “AF-N” Jumper - Used to decide whether or not the drive is permanently in the “DIGITAL” mode. This selection overrides the input at TB1 terminal 10.
Model 1000A R Inst allation and Operat ion Manual P AGE 35 OFFICIAL 6/4/ 2001 WHA T HA PPENS W HEN I … GIVE THE STA RT COMMAND TO T HE MODEL 1000 ? Before s tarting the Model 1000AR drive, turn the Cur rent Lim it pots fully counter-cloc kwise, and the speed ref erence com m and input, analog or digital, s hould be set to zero.
Page 36 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec LED INDICAT ORS CURRENT CONT ROLLER 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.
Model 1000A R Inst allation and Operat ion Manual P AGE 37 OFFICIAL 6/4/ 2001 WHA T HA PPENS W HEN I … GIVE THE SPEED COMM A ND TO THE MO DEL 1000A R ? Once the drive is in RUN m ode, the application of the speed ref erence should caus e the m otor to turn.
Page 38 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec LED INDICAT ORS SPEED CONTRO LLER BOARD 141-107 RUN RUN mode Turns ON GREEN when +24VDC is applied to TB2 terminal 13. Stays ON GREEN as long as +24V DC is applied to TB2-12 or TB2-13.
Model 1000A R Inst allation and Operat ion Manual P AGE 39 OFFICIAL 6/4/ 2001 WHA T HA PPENS W HEN I … SLOW DOWN O R OVERHA UL THE MODEL 1000A R ? Since the Model 1000AR is a regener ative drive (see page 3) , the m otor does not coas t when the speed ref erence is r educed.
Page 40 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec AD J U S T M E N T S CCW = Counter-Clock W ise pos ition CW = Clock W ise pos ition MAX SPD M aximum Speed ANALOG M ODE only. Not an absolute speed limit.
Model 1000A R Inst allation and Operat ion Manual P AGE 41 OFFICIAL 6/4/ 2001 WHA T HA PPENS W HEN I … MA KE AN A DJUSTMENT ON THE MODEL 1000A R ? Once the m otor is running, it m ay be necess ary to make adj ustm ents to produc e the desired res ults.
Page 42 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec BROWN BROWN RED BLACK ORANGE RED BLACK YELLOW RED BLACK ORANGE YELLOW B1 E1 B4 E4 B2 E2 B5 E5 B3 E3 B.
Model 1000A R Inst allation and Operat ion Manual P AGE 43 OFFICIAL 6/4/ 2001 TROUBLESHOOTIN G THE MODEL 1000A R DRIVE Troubleshooting of the Model 1000A R drive should only be attempted by personnel experienced in w orking on high-vo ltage, high pow er equipment.
Page 44 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec TRA NSISTOR MO DULE STA TIC TEST Equipment needed: A D igital M ulti- M eter ( DMM )with a diode scale is preferred. You should have a R ED lead in the positive (+) input and a BLACK lead in the negative (-) input.
Model 1000A R Inst allation and Operat ion Manual P AGE 45 OFFICIAL 6/4/ 2001 POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart NOTE: This chart assumes standard control connections and no options installed which affect speed control. CC = Current Controller board.
Page 46 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec DIODE BRI DGE TEST Equipment : A D igital M ulti- M eter ( DMM )with a diode scale is preferred. Y ou should have a RED lead in the positive (+) input and a BLACK lead in the negative (-) input.
Model 1000A R Inst allation and Operat ion Manual P AGE 47 OFFICIAL 6/4/ 2001 POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart NOTE: This chart assumes standard control connections and no options installed which affect speed control. CC = Current Controller board.
Page 48 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec MOTOR ENCODER CONNECTIONS IN MOTOR TERMINA L BOX MOTOR ENCODER LA YOUT.
Model 1000A R Inst allation and Operat ion Manual P AGE 49 OFFICIAL 6/4/ 2001 POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart NOTE: This chart assumes standard control connections and no options installed which affect speed control. CC = Current Controller board.
Page 50 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec IOC TESTS: An Instantaneous Over Current (IO C) fault is a serious matter. An IOC fault is indicated w hen the drive has detected a potentially damaging amount of current going into the output transistor stage.
Model 1000A R Inst allation and Operat ion Manual P AGE 51 OFFICIAL 6/4/ 2001 POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart NOTE: This chart assumes standard control connections and no options installed which affect speed control. CC = Current Controller board.
Page 52 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec BLOCK DIAGRA M - - SPEED CONTROLLER AND CURRENT CONTROLLER.
Model 1000A R Inst allation and Operat ion Manual P AGE 53 OFFICIAL 6/4/ 2001 POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart NOTE: This chart assumes standard control connections and no options installed which affect speed control. CC = Current Controller board.
Page 54 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec DRIVER BOA RD LAYOUT A ND CONNECTIONS DRIVER BOA RD LE D’S The bas e driver board LED’s turn on when current is being supplied to the bases of the output power transistors .
Model 1000A R Inst allation and Operat ion Manual P AGE 55 OFFICIAL 6/4/ 2001 POWERTEC Model 1000AR Drive Start Up and Troubleshooting Chart NOTE: This chart assumes standard control connections and no options installed which affect speed control. CC = Current Controller board.
Page 56 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec.
An important point after buying a device PowerTec 1000AR (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought PowerTec 1000AR yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data PowerTec 1000AR - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, PowerTec 1000AR you will learn all the available features of the product, as well as information on its operation. The information that you get PowerTec 1000AR will certainly help you make a decision on the purchase.
If you already are a holder of PowerTec 1000AR, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime PowerTec 1000AR.
However, one of the most important roles played by the user manual is to help in solving problems with PowerTec 1000AR. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device PowerTec 1000AR along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
