Power Tec 1000 Bedienungsanleitung

Repair Center for Powertec Drives and Motors

460 Milford Parkway

Milford, OH . 45150

www.motorsystems.com

513-576-1725

Model

1000

Brushless DC Motor Control

INSTALLATION AND

OPERATION

INSTRUCTION MANUAL

JUNE, 2001

Model 1000 Installation and Operation Manual Page 1

OFFICIAL 6/1/2001

INTRODUCTION

NTRODUCTIONNTRODUCTION

NTRODUCTION

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

Page 2 Model 1000 Installation and Operation Manual

RUN

123456789101112131415161718

TB2

REMOVE

FOR

COAST

STOP

JP1

CURRENT

LIMIT

LED

ZERO

SPEED

RUN

LED

MIN SPD

MAX SPD

JOG SPD

DECEL

ACCEL

CLIM

STAB

GAIN

POWERTEC

JP2

SPEED CONTROLLER

BOARD

LED

POWER

GREEN

HS3

RED

HS2

RED

HS1

RED

TAC

RED/GREEN

BUS

RED/GREEN

ENABLE

YELLOW

CURRENT CONTROLLER

BOARD

STALL

RED

OV/UV

RED

IOC

RED

TB1

JP1

JP3

Model 1000 Installation and Operation Manual Page 3

OFFICIAL 6/1/2001

QUICK

UICKUICK

UICK S

START

TARTTART

TART

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

1. 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.

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

3. 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..

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

5. 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).

6. 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.

7. Connect an Emergency Stop (ESTOP) button between TB2 terminals 6 and 7. Use a normally closed,

maintained open contact type pushbutton.

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

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

10.

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

11.

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

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

START UP

1. 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.

2. When you apply power, the PWR LED should light up GREEN immediately.

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

4. 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.

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

6. 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.

7. 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.

8. Immediately after the RUN LED comes on, the ENABLE LED should light.

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

10.

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

before CLIM is at 50%, turn the CLIM pot back down fully CCW. Consult the troubleshooting section.

11.

When the motor begins turning more than 10 RPM, the ZERO SPD LED should light up YELLOW.

12.

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

hand-held tachometer. Adjust the MAX speed pot, if necessary to attain 50% speed.

13.

Turn the speed pot to 100% and measure the motor speed. Adjust MAX speed if necessary.

14.

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

15.

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

16.

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

17.

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

18.

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

19.

The motor is ready for service.

Page 4 Model 1000 Installation and Operation Manual

REFERENCE PAGES

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 ................................................................................................................. 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

Model 1000 Installation and Operation Manual Page 5

OFFICIAL 6/1/2001

TABLE OF CONTENTS

INTRODUCTION..................................................................................................................................................... 1

QUICK START......................................................................................................................................................... 3

REFERENCE PAGES .......................................................................................................................................... 4

TABLE OF CONTENTS ...................................................................................................................................... 5

SPECIFICATIONS ................................................................................................................................................. 6

MOTOR PROTECTION ........................................................................................................................................ 7

WARRANTY ............................................................................................................................................................. 7

INSTALLATION

HOW DO I …

Physically Install the Model 1000 Drive ? ........................................................................................................... 9

Connect AC Power to the 1000 Drive ? ........................................................................................................... 11

Connect the Motor to the 1000 Drive ? ............................................................................................................ 13

Install an Output Contactor ? ........................................................................................................................... 15

Install Dynamic Braking ? ................................................................................................................................. 15

Connect Standard Control Circuits ? .............................................................................................................. 17

Get RUN, Zero Speed, FAULT, and ENABLE Information ? ............................................................................ 19

Connect an ANALOG Speed Reference ? ........................................................................................................ 21

Connect a DIGITAL Speed Reference ? ........................................................................................................... 23

Connect a DIGIMAX



? ..................................................................................................................................... 25

Installation Checklist ...................................................................................................................................... 27

START UP

WHAT HAPPENS WHEN 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................................................................................................. 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

Page 6 Model 1000 Installation and Operation Manual

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 SEE PAGE 30

LED INDICATORS SEE PAGE 32

TERMINAL ASSIGNMENTS SEE PAGE 18

Model 1000 Installation and Operation Manual Page 7

OFFICIAL 6/1/2001

INSTALLATION

NSTALLATIONNSTALLATION

NSTALLATION

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

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

MOTOR PROTECTION CONSIDERATIONS

You are about to install a GENESIS Series Brushless DC (BLDC) drive. You need to consider how the motor will be

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

1. “F” Series motors have an internal switch that opens at high winding temperatures. You must connect this

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.

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

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.

SUMMARY OF WARRANTY AND DISCLAIMER

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

defects in materials and workmanship for a period of two years. This period begins on the date of original shipment

from the factory.

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

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.

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

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 has no control.

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.

Do not use this device on a circuit capable of delivering more than

5000 RMS symmetrical Amperes at 500 VAC maximum voltage.

Page 8 Model 1000 Installation and Operation Manual

MODEL 1000 DIMENSIONS

CHASSIS UNITS

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