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PowerTec 1000AR - page 1
Model 1000AR Regenerative Brushless DC Motor Control I NSTALLATION AND O PERATION I NSTRUCT ION M ANUA L J UNE , 2001 ...
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PowerTec 1000AR - page 2
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. Lar ge BLDC motor s were firs t m ade by PO W ERTEC Industr ial Corporation in the ...
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PowerTec 1000AR - page 3
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). STORAGE TEMPERATURE : -40 °C to +65 °C (-40 °F t o + 150 °F) AMBIENT TEM ...
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PowerTec 1000AR - page 4
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 . W hen the motor rotates, the win ...
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PowerTec 1000AR - page 5
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 ENABLE YELLOW CURRENT CONTROLLER BOARD STALL RED PL RED OV/UV RED IOC RED TB1 JP1 JP3 Output Terminals Warning: Do Not Connect Input Power Leads to Outp ...
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PowerTec 1000AR - page 6
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). CONNECTIONS 1. Connect the proper three-phase AC pow ...
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PowerTec 1000AR - page 7
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 ................................................................................................................. ......................... 2 Model 1000AR Standard C onnections .......................................... ...
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PowerTec 1000AR - page 8
Model 1000A R Inst allation and Operat ion Manual P AGE 7 OFFICIAL 6/4/ 2001 T ABL E O F C ONTENTS INTRODUCTION ............................................................................................................................... ...................... 1 REGE NER A TIVE … OPERA T ION ..................................................... ...
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PowerTec 1000AR - page 9
Page 8 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec ...
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PowerTec 1000AR - page 10
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. This Notice applies to POWERTEC B rushless DC Driv e Model Number 1000AR. MOTOR PROTE CT ION CONSID ERA TIONS You are installing a GENESIS Series Brushless DC (BLDC) drive and m ...
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PowerTec 1000AR - page 11
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 the same dimensions, but they have separately mounted bus loaders ENCLOSED UNITS Note: Units w i th separately mounted bus loaders come in a 34”H x 2 ...
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PowerTec 1000AR - page 12
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. Storage temperature should be between -40°C a ...
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PowerTec 1000AR - page 13
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 0.56 1.8 0.725 42 230 1 0.75 2.4 0.950 60 230 1.5 1.1 3.6 1.450 85 230 2 1.5 4.9 1.950 12 ...
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PowerTec 1000AR - page 14
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. Model 1000AR drives requir e a three-phase m ain power source with a KVA rating at least equal to the HorsePo wer rat ing of the dr i ...
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PowerTec 1000AR - page 15
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 0.37 2.2 3.3 68.1 K 230 ...
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PowerTec 1000AR - page 16
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. Connect the T2 lead to T2 on the drive, and c onnect T 3 to T3. O ther ...
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PowerTec 1000AR - page 17
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. T raditionally, this has been handled by tw o m ethods : (1) using the power lines as a power sink ...
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PowerTec 1000AR - page 18
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. T h ...
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PowerTec 1000AR - page 19
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. The Output Contac tor drawing on page 11 shows the connections for dire ...
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PowerTec 1000AR - page 20
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. Requirem ents for the Model 1000 series ar e ...
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PowerTec 1000AR - page 21
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. THE MOTO R THERMAL SWICH MUST BE USED TO PROPERLY PROT ECT THE MOTOR! When the swit ch opens, the drive must be s hut ...
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PowerTec 1000AR - page 22
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. The table lis ts the connections and descriptions of the contr ol circuits ...
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PowerTec 1000AR - page 23
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 Shields and Gr ound connection 2 HS1 pos ition encoder 3 HS3 pos ition encoder 4 HS2 pos ition encoder 5 HS4 s peed encoder 6 HS5 s peed encoder 7 Enc oder ...
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PowerTec 1000AR - page 24
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). You may use an auxiliar y relay if yo ...
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PowerTec 1000AR - page 25
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. Most of the sig nals are +24 VDC or 48 VDC (posit ive and negat ive 24 VDC supplies f ...
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PowerTec 1000AR - page 26
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. Voltages less than - 10 VDC becom e non-linear an ...
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PowerTec 1000AR - page 27
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. In the digital m ode the c ontrol and m otor respond to a ...
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PowerTec 1000AR - page 28
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. A j um per from TB2- 10 will NOT s witch to dig ...
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PowerTec 1000AR - page 29
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. Due to analog com ponent toleranc es, the best ac curacy you can expec t is ...
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PowerTec 1000AR - page 30
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. A suitable tr ain of pulses applied at T B1 term inal ...
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PowerTec 1000AR - page 31
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 Input fuses Model 1000AR Standard Connections NOTICE: A NY POWER EQ UIPMENT SWIT CHING HIG H VOLT A GES A T HIG H FREQUENCIES EM IT S RA DIO FREQUENCY ...
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PowerTec 1000AR - page 32
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 clear path for airflow through the base heatsink and through the chassis [page 5] ? Is the temperature of the air surrounding the drive w ithin speci ...
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PowerTec 1000AR - page 33
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. BEHIND FRONT PANELS. SPEED CONTROLLER BOARD CURRENT CONTROLLER BOARD R+ R- BUS LOADER BOARD Capacitor Board Lay out and Connections ...
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PowerTec 1000AR - page 34
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. POWER ON 640 VDC 563 VDC PWR LED ON BUS LED RED BUS LED GREEN VOLTAGE 0 VDC TIME CONTACT ...
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PowerTec 1000AR - page 35
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. If JP1 is in the “AF” position, the drive ...
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PowerTec 1000AR - page 36
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. You must have +24V ...
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PowerTec 1000AR - page 37
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. BUS Bus Status Turns ON RED as soon as power is applied to the drive Changes to GREEN ...
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PowerTec 1000AR - page 38
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. At this point: • the PW R and BUS LED’s on the Current Controller board should be GREE ...
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PowerTec 1000AR - page 39
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. Turns off when + 24VDC is removed from BOTH TB2-12 and TB 2-13. CU ...
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PowerTec 1000AR - page 40
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. T he deceleration ram p is enforc ed by removing energy from the m otor. ...
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PowerTec 1000AR - page 41
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. Calibration to reference. At CCW , with 10VDC input, generates a VCO frequency of 1200 Hertz. At ...
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PowerTec 1000AR - page 42
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. ZERO speed MAX speed JOG speed DECEL time START Speed Pot at CCW Speed Pot to CW STOP RAMP STOP ...
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PowerTec 1000AR - page 43
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 B6 E6 12 3 TB3 P1-1 460VAC 380VAC POWER TRANSFORMER PRIMARY 380 OR 460 VAC INPUT FUSES FU4 TYPE FLQ L1 L2 L3 230 VAC PRIMARY TRANSFORMER POWER L3 L2 BL ...
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PowerTec 1000AR - page 44
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. Equipment Necessary for Troubleshooting : 1. Safety Glasses 2. A Volt-Ohm-M illiammet ...
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PowerTec 1000AR - page 45
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. Preparation: D ifferent meters give ...
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PowerTec 1000AR - page 46
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. SC = Speed Controller board. START Check for grounds, then turn on powe ...
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PowerTec 1000AR - page 47
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. Preparation: Different meters give different readings on ...
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PowerTec 1000AR - page 48
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. Is BUS LED GREEN ? To Page 3 Wait up to 30 seconds for BUS LED to chang ...
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PowerTec 1000AR - page 49
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 ...
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PowerTec 1000AR - page 50
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. Is HS1 LED ON ? To Page 4 From Page 2 Page 3 No Is HS2 LED ON ? Is HS3 ...
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PowerTec 1000AR - page 51
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. W henever possible, avoid trying to rest ...
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PowerTec 1000AR - page 52
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. Is RUN LED ON ? To Page 5 From Page 3 Page 4 Is ENBL LED ON ? Press STA ...
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PowerTec 1000AR - page 53
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 ...
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PowerTec 1000AR - page 54
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. Is TAC LED changing ? To Page 6 From Page 4 Page 5 Are HS1, HS2, HS3 Ch ...
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PowerTec 1000AR - page 55
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 . For output trans istor num bering, s ee the Sim plified Power Schem atic ...
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PowerTec 1000AR - page 56
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. Is motor at 50% speed ? Put Motor In Service From Page 5 Page 6 Is PHAD ...
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PowerTec 1000AR - page 57
Page 56 Model 1000A R I nstall ation and Operation Manual 6/4/2001 © copy right 1997 by Powert ec ...
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