Page
8
Model
1000AR
Installation and Operation Manual
6/4/2001
© copyright 1997 by
Powertec
Страница 1: ...Model 1000AR Regenerative Brushless DC Motor Control INSTALLATION AND OPERATION INSTRUCTION MANUAL JUNE 2001 ...
Страница 2: ...t 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 relatively efficient when operated across the line on plant power Using an AC variable speed inverter to control the speed of the motor adds power losses as heat in the drive It also creates additional losses in ...
Страница 3: ... kg 1000AR Nema1 110 pounds 50 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 revolution of the motor shaft Displacement power factor 0 96 typical Adjustments ...
Страница 4: ...ad in motion will coast to a free wheeling stop Speed inertia and friction of the load determine how long the stopping will take The faster a load is moving the longer the load requires to stop Larger inertias more mass take longer to stop but a higher friction load slows it down faster A moving load stops in a coasting situation by dissipating the energy of motion as frictional heat which acts as...
Страница 5: ...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 Output Terminals Power Input L1 L2 L3 Input fuses P4 RUN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TB1 COAST STOP RAMP STOP JOG HOLD REGEN ACCEL DECEL MAX SPD JOG RCL MCL GAIN STAB POWERTEC DIR RL ENABLED RUN ESTOP 2Q 4Q DIR SEL REGEN SPEED CONTROLLER 147 101 ...
Страница 6: ...n TB2 terminals 9 and 15 START UP 1 Before applying power turn the speed pot fully counter clockwise CCW and turn the MCL and RCL potentiometers fully counter clockwise Do not connect the motor to a load for its initial run 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 L...
Страница 7: ...Interface Suggestions 24 Digital Mode Notes 26 Analog Versus Digital Operation Comparison 28 Standard Basic Connection Diagram 30 Capacitor Board Location and Layout 32 Current Controller Board Layout 34 Speed Controller Board Layout 34 Jumpers List 34 LED Indicators Current Controller Board 36 LED Indicators Speed Controller Board 38 Adjustments 40 Simplified Power Schematic 42 Semiconductor Diag...
Страница 8: ...mation 23 Connect an ANALOG Speed Reference 25 Connect a DIGITAL Speed Reference 27 Connect a DIGIMAX 29 Installation Checklist 31 START UP What Happens When I Apply Power to the Model 1000AR Drive 33 Give the Start Command to the Model 1000AR Drive 35 Give the Speed Command to the Model 1000AR Drive 37 Slow down or Overhaul the Model 1000AR 39 Make an Adjustment on the Model 1000AR Drive 41 TROUB...
Страница 9: ...Page 8 Model 1000AR Installation and Operation Manual 6 4 2001 copyright 1997 by Powertec ...
Страница 10: ...ontrol Equipment Specification 508 The user is responsible for complying with local codes and practices If you decide that 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 perio...
Страница 11: ...CLOSED UNITS Note Units with separately mounted bus loaders come in a 34 H x 24 W x 18 D Nema1 Enclosure ALL DIMENSIONS ARE APPROXIMATE Consult factory for certified dimensions R R 9 85 250mm 2 00 51mm TYP 18 00 457mm 14 00 356mm 9 25 235mm 8 35 212mm Ø 0 28 DIA 7 1mm TYP 4 places 9 13 232mm 1000 REGEN 22 38 568mm 8 90 226mm 9 25 235mm 9 85 250mm 2 00 51mm TYP 14 00 356mm 2 20 56mm Ø 0 28 DIA 7 1m...
Страница 12: ... may not exceed 55 C 131 F Relative humidity must be 95 or less and non condensing Avoid mounting one chassis directly above another This will result in hot air from the lower chassis flowing up into the upper chassis Leave at least 12 inches 300 mm of open space between them There must be free panel space of at least 3 inches 75 mm above and below the chassis This allows air flow through the heat...
Страница 13: ...tage Do not measure the input voltage while the drive is not running This neglects the effects of load on the power source Measure the actual input line voltage while the control is operating the motor in a loaded condition Brief power line disturbances will not normally disturb the Model 1000AR drives The Model 1000AR drives do not generate significant noise back onto the power service Events tha...
Страница 14: ...need to meet local code requirements You need to change the voltage level In those cases you will need a transformer with a KVA rating at least as large as the HP rating of the drive If you use a transformer we recommend a delta wye winding configuration We also recommend that the transformer have taps to raise or lower voltage The user protection supplied before the wires determines the sizes of ...
Страница 15: ...5 4 7 7 0 33 2 K 230 1 5 1 1 7 0 10 5 22 1 K 230 2 1 5 8 5 12 7 18 2 K 230 3 2 2 12 8 19 2 12 1 K 230 5 3 7 22 8 34 2 6 81 K 230 7 5 5 6 31 1 46 6 4 99 K 230 10 7 5 41 5 61 1 3 74 K 380 1 0 75 2 7 4 0 56 2 K 380 1 5 1 1 3 9 5 8 39 2 K 380 2 1 5 4 7 7 0 33 2 K 380 3 2 2 7 8 11 7 20 0 K 380 5 3 7 14 1 21 1 11 0 K 380 7 5 5 6 18 8 28 2 8 25 K 380 10 7 5 25 0 37 5 6 19 K 460 2 1 5 4 0 6 0 39 2 K 460 3...
Страница 16: ...qualize the potential between the motor s frame and the drive chassis There may be enough impedance to broadcast EMI and RFI even with the motor grounded to its mounting frame A direct wire connection between the motor frame and the drive chassis minimizes interference in other equipment The encoder feedback cable must be a shielded cable Connect the shield to TB1 terminal 1 on the control end Sta...
Страница 17: ...eneration Powertec uses four ratings for the GENESIS series of drives 1 STOPPING DUTY used to stop the motor once per minute approximately 10 duty cycle 2 EXTENDED DUTY used to stop high inertia loads approximately 25 duty cycle 3 LIFTING DUTY used on cranes and hoists and inclined conveyors 50 duty cycle 4 CONTINUOUS DUTY 100 duty cycle The standard supplied with standard GENESIS drives is STOPPI...
Страница 18: ...made The interlock is built into the Bus Loader board The interlock will open if the bus loader fuse opens up or if the board fails to function If the drive tries to regenerate without the bus loader operating the drive will trip The separately mounted bus loader 149 101 should be mounted close to the drive The resistors must be mounted in their own cage outside any enclosure Mount the resistors i...
Страница 19: ...t but they do not break current in the dynamic braking operation Choose contacts accordingly The contactor outline sketched at left is from the SH 04 series by AEG Industries The model used for the Output Contactor is part number SH 04 40 and the Dynamic Braking is SH 04 13 Contact ratings are 16 Amps DYNAMIC BRAKING RESISTORS We choose DB resistors for their ability to absorb high inrush currents...
Страница 20: ...coils DO NOT BREAK THE GROUND CONNECTION OR THE CABLE CONNECTIONS WITH THE OUTPUT CONTACTOR HOW DO I CONNECT DYNAMIC BRAKING You MUST interlock the contactor with the Emergency Stop when using Dynamic Braking You will damage the drive and or the resistor banks if you do not properly interlock the contactor The requirements are 1 The contactor must open the main power contacts BEFORE the drive is e...
Страница 21: ...enced to TB2 12 Rated at 50 mADC 50 VDC max This output operates only in RUN JOG or RAMP STOP modes The ZERO SPEED output turns on at about 10 RPM and off at about 5 RPM The ZERO SPEED output shuts off if the ENABLE LED shuts off JOG 24VDC ON TB2 14 STD N O PB FROM TB2 9 TO TB2 14 Voltage must be applied to initiate JOG mode JOG mode will be maintained only as long as the voltage is present When t...
Страница 22: ...ons more than 30 feet away from the motor control consider using 120 VAC control circuits Install ESTOP buttons Do NOT place a jumper across the Emergency Stop terminals Because the drive has a ramp to stop capability this could set up an UNSAFE situation IT IS STRONGLY RECOMMENDED THAT AN EMERGENCY STOP BUTTON or an ESTOP relay BE CONNECTED TO THE DRIVE This should be of the MAINTAINED CONTACT TY...
Страница 23: ...7 101 1 ON at zero speed open collector 30VDC 50 mA maximums 2 ON when enabled open collector 30VDC 50 mA maximums 3 Speed Output open collector 30VDC 50 mA maximums 4 10VDC Reference Source 5 mA maximum 5 Speed Reference Input 10VDC to 10VDC 6 10VDC Reference Source 5 mA maximum 7 RUN output contact N O 125VAC 8 RUN output contact N O 1A Resistive 9 24VDC supply 50 mA maximum 10 24VDC supply 50 m...
Страница 24: ...purpose type The ZERO SPEED relay will chatter at very low speeds You can overcome this with a latching circuit that releases at the first dropout of the zero speed relay The FAULT output at TB1 terminals 12 and 13 is the output transistor of an optical coupler The coupler s rating is 100VDC 50 ma Connect a FAULT relay with a 48VDC coil as shown in the bottom figure at left The external FAULT rela...
Страница 25: ...nd figure shows a sourcing connection Notice however the inverted sense that is when the transistor turns on the input is not You can use the fault output with connections similar to those in the above figures You can use a PLC input module with the FAULT output of the control at TB1 terminals 12 and 13 to sense a FAULT in the drive The bottom figure illustrates this You need to keep in mind that ...
Страница 26: ...introduce an external reference voltage between TB2 terminals 5 and 16 common The speed of the motor varies as the external voltage varies The direction of the motor changes when the polarity of the signal changes If you use an external current source speed control such as a 4 to 20 ma signal you must convert it to a voltage Then you may introduce this voltage as a speed reference command to TB2 t...
Страница 27: ...nto the digital mode without energizing terminal 10 Either of these actions disconnects the control s internal VCO and looks for a frequency at TB1 terminal 11 which must be positive with respect to TB1 terminal 9 This frequency signal must meet certain specifications ON VOLTAGE 18 VDC min 30 VDC max OFF VOLTAGE less than 1 5 VDC FREQUENCY 2X desired RPM 250 frames or smaller DUTY CYCLE 25 min 75 ...
Страница 28: ...andard drives have 30 pulse per revolution quadrature encoders This produces a 120 pulse per revolution PPR feedback Each pulse put into the drive is a command to turn 3 in its mechanical rotation The pulse train input for a GENESIS drive may come from another GENESIS drive since there is an output on TB2 the figure below shows Model 1000 connections Terminal 3 TB2 3 is the collector of a transist...
Страница 29: ... the drive at these terminals will require a pulse from the motor The EEPROM multiplier used in the Current Controller board determines the effect of the pulse from the motor 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 really want to be able to set 1749 RPM and g...
Страница 30: ... 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 The MAN AUTO switch may be left out You can make a straight connection from DIGIMAX TB1 7 to Model 1000AR TB1 10 Even this connection may be left off if the Current Controller board jumper JP1 is in the AF position see page 27 The DIGIMAX control inputs are on TB2 ter...
Страница 31: ...ions NOTICE ANY POWER EQUIPMENT SWITCHING HIGH VOLTAGES AT HIGH FREQUENCIES EMITS RADIO FREQUENCY INTERFERENCE RFI AND ELECTROMAGNETIC INTERFERENCE EMI THE MOTOR LEADS MUST BE RUN IN METALLIC CONDUIT TO PREVENT INTERFERENCE WITH 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 TH...
Страница 32: ...the proper order page 9 Is the cable from the motor to the drive properly connected page 9 Is the bus loader installed and properly connected page 11 Are the regen resistors properly installed and connected page 11 If an Output or Dynamic Braking Contactor is used is it properly interlocked page13 If Dynamic Braking is used are the resistors properly installed and wired page13 Is the motor thermal...
Страница 33: ...ration Manual 6 4 2001 copyright 1997 by Powertec 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 Layout and Connections ...
Страница 34: ...e 24VDC raw power supply If this LED does not come on you should check the incoming power main fuses and power transformer fuse While the bus is charging the BUS LED lights up RED in color When the bus reaches a level of approximately 35VDC below the nominal bus level a contactor energizes to bypass the charging resistor The BUS light then changes to GREEN in color If the light does not change to ...
Страница 35: ...mper installed Removing it disables the Current loop DIR RL ACCEL DECEL Range Jumper Installing this jumper sets the ACCEL and DECEL rates to 2 to 90 seconds approximately With this jumper removed ACCEL DECEL rates are set for 50 ms to 2 seconds RAMP STOP RAMP STOP Jumper When this jumper is installed the drive will decelerate at the DECEL rate to zero speed and then shut off If this jumper is rem...
Страница 36: ...minal 9 to TB2 terminal 14 The JOG LED will light The RUN LED will NOT light The RUN contact will NOT close at TB2 terminals 7 and 8 The JOG mode should be initiated from the STOPPED condition The JOG mode is locked out in RUN mode Place the drive in HOLD mode by applying 24VDC from TB2 9 to TB2 15 If the drive is stopped HOLD will turn it on HOLD clamps the VCO to zero speed If the drive is runni...
Страница 37: ...LOW when 1 Drive is in RUN mode with no faults 2 Drive is in JOG mode with no faults 3 During RAMP STOP with no faults Turns off when 1 The UnderVoltage Timer times out 2 There is an Undervoltage UV fault 3 There is an OverVoltage OV fault 4 There is an IOC fault 5 There is a STALL fault 6 RUN JOG HOLD and RAMP STOP modes are all off STALL Stall Fault Turns ON RED if motor does not move 30 within ...
Страница 38: ...slowly clockwise to see if the motor will turn If the motor turns leave the Current Limit pot where it is when the motor begins to turn 3 If the motor does not turn when the Current Limit pot is increased do not turn the Current Limit pot higher than 50 of its rotation Shut the drive off and check the connections between the drive and the motor It is quite common that these connections are mixed u...
Страница 39: ...g RAMP STOP with no faults Turns off when 1 The UnderVoltage Timer times out 2 There is an Undervoltage UV fault 3 There is an OverVoltage OV fault 4 There is an IOC fault 5 There is a STALL fault 6 RUN JOG HOLD and RAMP STOP modes are all off REGEN Regen Mode Turns ON RED when motor speed exceeds reference speed at any time This may occur during stopping if the decel ramp time is less than the na...
Страница 40: ...d the REGEN LED should light but the CURRENT LIMIT LED may or may not come on If the coast time is much greater than the decel time the drive may reach current limit Whether or not current limit will be reached can be predicted but you need to know all the drive and motor data and all of the inertias involved in the system to do so The maximum CW setting of the RCL is equivalent to 150 of full loa...
Страница 41: ...ut 0 05 seconds GAIN Gain adjust ANALOG and DIGITAL modes Sets the stiffness of the motor shaft Zero position is where the shaft should be at any point in time Motor amps is proportional to offset of the shaft from the zero position Stiffness is motor amps per degree of shaft offset from zero position CCW is about 0 56 of full load current per degree of offset CW is about 5 6 of full load current ...
Страница 42: ... of time depends on how JP2 is installed With JP2 in the R L position the time for acceleration is adjustable from about 0 5 seconds ACCEL pot fully CCW to about 20 seconds ACCEL POT fully CW With JP2 in the DIR position the time is not adjustable The ACCEL time is the time it takes the ramp circuit to change the speed reference from zero to full speed The motor may not accelerate in the same amou...
Страница 43: ...T CONTROLLER TO P3 CURRENT CONTROLLER BASE DRIVER BOARD 141 105 L1 INDUCTOR 1 R3 R2 R1 D2 P3 Rcharge CR1 T2 CR1 CURRENT SENSOR HS OVER UNDER VOLTAGE C9 BUSS FUSE REGEN RESI STORS R R C1 C7 C2 C8 A B C D HORSEPOWER CALIBRATE RESISTOR CAPACITOR BOARD 141 106 SIMPLIFIED DRAWING MODEL 1000AR POWER CIRCUITS 1 2 3 4 5 6 R W R R O W O O B B B W G W G G Y W Y Y HIGH VOLTAGE CONNECTIONS LOW VOLTAGE CONNECT...
Страница 44: ...parts may be required for fast on site repair Listed in approximate order of importance Item Part Part Spares Description Designation Number Quantity Input Fuses FU1 FU2 and FU3 HP 10 Transformer Fuse FU4 FLQ 8 10 5 Capacitor Board 141 206 1 Output Transistor Module HP 1 Driver Board 141 105 1 Current Controller Board 141 108 1 Input Diode Module RECT1 HP 1 Power Transformer T1 141 004 1 Speed Con...
Страница 45: ...circuit or out of circuit testing If a component tests bad in circuit it must be tested again after it is removed because of the possibility of alternate paths when the component is in circuit SIX TRANSISTOR MODULE RED LEAD BLACK LEAD GOOD BAD P N open short N P 0 3 to 2 0 short or open N U 0 3 to 0 7 short or open N V 0 3 to 0 7 short or open N W 0 3 to 0 7 short or open U P 0 3 to 0 7 short or o...
Страница 46: ...lowing in order checking FU4 after each change Is PWR LED ON Yes Turn Power Off Plug in P4 on CC Re apply Power Replace Speed Controller board Replace P4 Cable No Yes No Is 24VDC TB2 10 to TB1 16 Turn Power Off Plug in TB2 on SC Re apply Power No Check external controls on TB2 Turn Power Off Plug in TB1 on CC Re apply Power No Yes Is 24VDC TB2 10 to TB1 16 Yes Yes Replace Capacitor Board Tolerance...
Страница 47: ...ave a RED lead in the positive input and a BLACK lead in the negative input Preparation Set the meter on the 1000VDC scale Be sure the leads are insulated for this voltage Refer to page 28 for the drive power schematic and semi conductor diagrams Precautions This test is an in circuit test with power on It should be performed by personnel who have been trained to work around high voltage Procedure...
Страница 48: ...e OK Line VAC 230 Bus VDC 320 Line VAC 380 Bus VDC 530 Line VAC 460 Bus VDC 640 Yes Turn Power Off Remove FU1 on Capacitor Board No Replace Charge Fuse Replace Capacitor Board Yes Bus Loader Connected Disconnect Bus Loader and Start Over No Yes Is Bus VDC 90 Yes No Replace Transistor Module Turn Power Off Perform Diode Bridge Test Is Diode Bridge OK Yes No Replace Diode Bridge Turn Power Off Check...
Страница 49: ...Page 48 Model 1000AR Installation and Operation Manual 6 4 2001 copyright 1997 by Powertec MOTOR ENCODER CONNECTIONS IN MOTOR TERMINAL BOX MOTOR ENCODER LAYOUT ...
Страница 50: ...VDC TB1 8 TB1 7 Turn off Power Disconnect TB1 No Check TB1 Connections Check for short in cable Yes Turn off Power Disconnect wires on TB1 2 TB1 3 and TB1 4 Reapply power Are Any of the HSX LED s ON Replace Current Controller Board No Yes Turn off Power Re connect wires on TB1 2 TB1 3 and TB1 4 Disconnect Cable at motor end Reapply power Are Any of the HSX LED s ON No Replace Encoder Yes Replace C...
Страница 51: ... up the ILIMIT potentiometer slowly to catch a possible overcurrent event OV UV TESTS An OverVoltage UnderVoltage OV UV indication may come on for many reasons The important point to remember is that the OV UV indicator applies to the BUS voltage Make sure there are no common buss connections or bus loaders causing problems with the proper charging and maintenance of the bus voltage 1 Before turni...
Страница 52: ...eing used See page 21 The voltages given must be at the indicated terminals unless otherwise indicated No Yes Press and HOLD START Button Is RUN LED ON No Replace Speed Controller Board 24V TB2 11 TB2 16 Yes 24V TB2 12 TB2 16 No No Check STOP Button connections Yes No Check EMERG STOP Button connections Yes Release START Button Release START Button No PJ1 on CC in RESET position Yes Set PJ1 jumper...
Страница 53: ...Page 52 Model 1000AR Installation and Operation Manual 6 4 2001 copyright 1997 by Powertec BLOCK DIAGRAM SPEED CONTROLLER AND CURRENT CONTROLLER ...
Страница 54: ...Connect Motor Power Leads No Yes Is ILIMIT LED ON No Yes No Can you turn the shaft by hand Yes Disconnect motor from load and start over Yes Do HS1 HS2 HS3 change Is motor connected to load No No STOP Turn off power Turn motor shaft by hand Do NOT re apply power Can you turn the shaft by hand No Yes Check connections of T1 T2 T3 and cable connections Is Dynamic Braking Installed No Check motor con...
Страница 55: ...transistors 1 2 and 3 are on for 60 degrees of shaft rotation This makes the LED s for transistors 1 2 and 3 easy to see while the motor is running Transistors 4 5 and 6 are each enabled for 60 degrees of shaft rotation while the motor is in the corresponding position but the output transistor is controlled by a pulse width modulation PWM which is determined by the motor current required Under lig...
Страница 56: ...MAX pot on Speed Controller board Is motor at 50 speed Is motor running faster than 50 Disconnect load from the motor and start over No Yes 50 speed refers to 1 2 of the max speed of the motor Is the load connected to the motor Is speed at base speed or more Yes No Yes No Are all of the Driver board LED s OK Turn off power disconnect T1 T2 T3 Turn on power and rotate motor by hand Yes No Replace B...
Страница 57: ...Page 56 Model 1000AR Installation and Operation Manual 6 4 2001 copyright 1997 by Powertec ...
