PowerTec 1000AR User Manual
Model
1000AR
Regenerative
Brushless DC Motor Control
NSTALLATION AND
I
PERATION
O
NSTRUCTION MANUAL
I
J
UNE
, 2001
Model
1000AR
Installation and Operation Manual
NTRODUCTION
I
P
AGE
1
WHAT IS A GENESIS SERIES BRUSHLESS DC DRIVE ?
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.
Small BLDC motors have been in use for many years. The GENESIS series were the first drives
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:
Absolute Speed Control
High Efficiency
Low Maintenance.
ABSOLUTE SPEED CONTROL
The AC induction motor must slow down, or “slip”, in order to develop torque. The amount of slip varies
with the load on the motor. When the load changes from no load to full load, speed may change by 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” that causes the speed of the motor to vary as the
load changes. “IR Losses” cause 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 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 the motor. At the 100HP level, the total losses in the AC system approach 10%.
Brush-type DC motor systems at 100 HP are relatively efficient, but the losses total about 8%.
Brushless DC systems at the 100 HP level average less than 6%.
At 100 HP, each percentage of losses is 750 watts. That’s 18 KiloWatt-Hours (KWH) per day, or about
6,500 KWH per year. A 2% difference in efficiency results in over $1,000 a year in direct energy savings.
LOW MAINTENANCE
AC induction motors running on variable speed AC drives produce a lot of heat. The motors require more
frequent lubrication. They also need extra bearing changes. Heat also shortens the life of the motor.
Brush-type DC motors require frequent brush replacement. They also need commutator service and field
and armature rewinding. They also require frequent lubrication and bearing changes due to heat.
Brushless DC motors require lubrication. However, the oversize bearings and the low heat production in
the motor allow long bearing life. Maintenance on a Brushless DC motor is minimal.
POWER
POWER
1/10 to 300 HP.
QUICK START - Page 5 TABLE OF CONTENTS - Page 7
TEC offers the GENESIS series for general purpose industrial use
TEC also offers a complete line of servo-duty rated drives and motors covering the range from
.
OFFICIAL 6/4/2001
Page
2
Model
1000AR 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 :
1000AR chassis : 75 pounds ( 34 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 ( +/- 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
LED Indicators
See Page 32
See Page 36
Terminal Assignments See Page 22
6/4/2001 © copyright 1997 by Powertec
Model
1000AR
Installation and Operation Manual
P
AGE
3
REGENERATIVE VERSUS NON-REGENERATIVE OPERATION
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.
If we externally force the shaft to turn, this movement through magnetic fields produces a potential at the
motor’s power terminals. We call this potential “Electro-Motive-Force” (or EMF, for short). The motor is now a
generator, and it is capable of supplying power if we keep the stationary windings energized.
In the case of the Brushless DC motor, a field produced by the permanent magnets on the rotor moves
around the stationary windings on the frame. We do not have to keep the windings energized to produce
power. You will see the importance of this in dynamic braking (below).
A motor is running in the MOTORING mode when it is drawing current from the power supply. The motor
is changing electrical energy into mechanical work at the motor shaft. This is the most common mode of motor
operation. The motor still produces the same potential at its terminals, but we call it “Counter-EMF” (CEMF)
when the motor is in the motoring mode. CEMF opposes the flow of current from the supply to the motor.
From the generator action, we derive the term REGENERATING. This indicates that the motor is no
longer drawing current from the supply. It is now returning current to the supply.
The motor can not draw current from the supply if the voltage produced by the rotation of the motor shaft
(the CEMF) exceeds the supply voltage. We see this condition when motor speed is greater than the speed
commanded by the speed reference. The load inertia may be greater than the amount of inertia that the motor
can slow down in the time allotted. External forces can drive the load faster than desired.
A load 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 a brake. If inertia is high and friction is
low, the load will take a longer time to stop. We can use mechanical
brakes to increase the amount of friction.
A non-regenerative
than the load would slow down by itself. It cannot act as a brake. We
can supply braking force by making the motor act as a generator.
We can dissipate the energy of the inertia into passive resistors, but
we cannot connect the resistors until after we shut off the drive
(dynamic braking). With AC motors and brush-type DC drives, we
must keep the stationary fields energized, but not with BLDC. Even if
we lose drive power or plant power, dynamic braking still works.
Regenerative
control is active. A motor that operates on a regenerative drive
becomes a generator when it rotates at a speed faster than set
speed. The amount of power generated relates to the speed, inertia,
and friction of the load and motor. The regenerative drive accepts
the current from the motor, and dissipates the energy. The dissipative load presented by the controller must
be adequate.
When the motor generates energy, and the drive receives it, then the motor is REGENERATING. A
motor in the regenerating mode develops torque in the opposite direction of its rotation. It is not drawing power
from the supply, as it is in the motoring mode.
Regenerative power capability gives motors and controls the ability to change from higher
speeds to lower speeds quickly. This includes zero speed and the reversal of motor direction. This
happens much more quickly than with non-regenerative types of controls. The result is more rapid
stops and reversals of loads that would otherwise be a lot more sluggish in these actions.
drive can not slow down a load in less time
drives can supply braking force while the motor
OFFICIAL 6/4/2001
Page
4
Model
1000AR Installation and Operation Manual
MODEL 1000AR STANDARD CONNECTIONS
Power Input
L1 L2 L3
Output Terminals
Input
fuses
Warning:
Do Not Connect
Input Power Leads
to Output Terminals
CURRENT CONTROLLER
BOARD
REGEN SPEED CONTROLLER
147-101
POWERTEC
STAB
GAIN
MCL
RCL
JP1
MAX SPD
JOG
DIR/RL
REGEN
ENABLED
DIR
SEL
P4
RUN
TB1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
COAST
STOP
DECEL
ACCEL
RAMP STOP
2Q/4Q
ESTOP
RUN
JOG
HOLD
POWER
GREEN
HS3
RED
HS2
RED
HS1
RED
TAC
RED/GREEN
TB1
6/4/2001 © copyright 1997 by Powertec
JP3
STALL
RED
BUS
RED/GREEN
ENABLE
YELLOW
PL
RED
OV/UV
RED
IOC
RED
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).
1000AR
Installation and Operation Manual
UICK START
Q
CONNECTIONS
Connect the proper three-phase AC power from a suitably rated switching device to the input terminals L1, L2,
1.
and L3. Check the nameplate. The sequence of the phases is not important to the drive.
Connect the power system ground to the GND terminal. Make sure the system ground is earth ground.
2.
Connect T1 of the motor to T1 of the drive. Connect T2 to T2, and T3 to T3. The order of connection is
3.
important. The motor will not run with improper motor connections..
Connect a ground wire from the motor’s ground lug to the GND terminal on the drive.
4.
Connect the resistor to R+ and R- terminals on the chassis. If you have a separate bus loader, see page 21.
5.
Connect the encoder cable to the motor. Consult the drawing on page 4. The cable used should be a nine-
6.
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).
Connect a 10 Kilo-ohm Speed Potentiometer to TB2 terminals 4 (CW), 5 (Wiper), and 16 (CCW). Connect the
7.
shield of the speed pot cable to TB2 terminal 16. To reverse rotation connect CW to TB2 terminal 6.
TB2 terminal 10 should be connected to the motor thermal (cable). The other side of the motor thermal should
8.
be connected to TB5 terminal 3 (bus loader). Connect an Emergency Stop (ESTOP) button between TB3
terminal 1 and TB2 terminal 11. Use a normally-closed, maintained-open contact type pushbutton.
Connect a normally closed, momentary type, STOP pushbutton between TB2 terminals 11 and 12.
9.
Connect a normally open, momentary type, RUN pushbutton between TB2 terminals 12 and 13.
10.
If desired, connect a normally open, momentary type, JOG pushbutton between TB2 terminals 9 and 14.
11.
If desired, connect a normally open, momentary type, HOLD pushbutton between TB2 terminals 9 and 15.
12.
P
AGE
5
START UP
Before applying power, turn the speed pot fully counter-clockwise (CCW) and turn the MCL and RCL
1.
potentiometers fully counter-clockwise. Do not connect the motor to a load for its initial run..
When you apply power, the PWR LED should light up GREEN immediately.
2.
When you apply power, the BUS LED should light up RED immediately.
3.
When power is on, the HS1, HS2, and HS3 LED’s may or may not be on RED, depending on the position of
4.
the motor. Only one or two should light; never all three and never none.
When power is on, the TAC LED may be OFF, RED, GREEN, or ORANGE.
5.
Within 30 seconds, the BUS LED should turn GREEN and the you should hear the charging contactor click as
6.
it energizes. If this does not happen within 30 seconds, shut power off and consult the troubleshooting section.
The ESTOP LED should be ON GREEN on the Speed Controller board.
7.
Press and release the START button. The RUN LED should light GREEN. The CURRENT LIMIT LED may
8.
come on GREEN at this time because the MCL pot is all the way counter-clockwise.
Immediately after the RUN LED comes on, the ENABLE LED should light on both boards.
9.
Increase the speed pot reference to about 10% of its rotation from the CCW position.
10.
Turn the MCL pot slowly clockwise. If the motor does not turn (HS1, HS2, HS3, and TAC will start blinking)
11.
before MCL is at 50%, turn the MCL pot back down fully CCW. Consult the troubleshooting section.
Leave the MCL pot at 50 % and increase the speed pot to 50% of its rotation. Check the motor speed with a
12.
hand-held tachometer. Adjust the MAX speed pot, if necessary to attain 50% speed.
Turn the speed pot to 100% and measure the motor speed. Adjust MAX speed if necessary.
13.
Press the Normal Stop button and start again. Time the acceleration to full speed and set ACCEL time.
14.
Turn the RCL pot to 50%. Turn speed pot to 0% (CCW) and time decel ramp. Adjust DECEL for correct time.
15.
Set STAB and GAIN to 50%. Press the Normal Stop button. Both ENABLE LED’s should go OFF.
16.
Run the motor at high speed and push the HOLD button. The HOLD LED should light RED. The motor should
17.
stop. Release the button and the motor should return to the previous speed.
Press Stop. Press the JOG button. The JOG LED should light GREEN. Set the JOG speed, if desired.
18.
The motor is ready for service.
19.
OFFICIAL 6/4/2001
Page
6
Model
1000AR Installation and Operation Manual
REFERENCE PAGES
Specifications.......................................................................................................................................... 2
Model 1000AR Standard Connections.................................................................................................... 4
Model 1000AR Dimensions Chart ........................................................................................................10
Model 1000AR AC
Model 1000AR
Regenerative Resistors .......................................................................................................................16
Contactor Specifications .....................................................................................................................18
Dynamic Braking Resistors ................................................................................................................. 18
Model 1000AR Control Connections Table .........................................................................................20
Terminal Descriptions List ...................................................................................................................22
PLC 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 Diagrams......................................................................................................................42
Transistor Module Static Test ............................................................................................................... 44
Diode Bridge Test ................................................................................................................................ 46
Transistor Leakage Test ....................................................................................................................... 46
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
Input
Electrical Ratings Table .............................................................................. 12
Output
Electrical Ratings Table ................................................................................. 14
6/4/2001 © copyright 1997 by Powertec
Model
1000AR
Installation and Operation Manual
ABLE OF CONTENTS
T
P
AGE
7
INTRODUCTION
..................................................................................................................................................... 1
REGENERATIVE … OPERATION
QUICK START
REFERENCE PAGES INDEX
MOTOR PROTECTION
WARRANTY
......................................................................................................................................................... 5
............................................................................................................................. 6
........................................................................................................................................ 9
............................................................................................................................................................. 9
INSTALLATION
How Do I …
Physically Install
Connect AC Power
Connect the Motor
Connect the Regenerative Resistors
Install an
Install
Connect
Get
Connect an
Connect a
Connect a
Installation Checklist
Output Contactor
Dynamic Braking
Standard Control Circuits
RUN
, Zero Speed,
DIGITAL Speed Reference
DIGIMAX
the Model 1000AR Drive ?.....................................................................................11
to the 1000AR Drive ? .......................................................................................13
to the 1000AR Drive ? ........................................................................................15
? ............................................................................................................19
? ..................................................................................................................19
FAULT
ANALOG Speed Reference
? ......................................................................................................................29
.......................................................................................................................31
, and
START UP
................................................................................................................... 3
to the Model 1000AR? .........................................................17
? ...............................................................................................21
ENABLE
?............................................................................................27
Information ? ............................................................. 23
?.........................................................................................25
What Happens When I …
Apply Power
Give the Start Command
Give the Speed Command
Slow down or Overhaul the Model 1000AR .........................................................................................39
Make an Adjustment
to the Model 1000AR Drive ? ........................................................................................33
to the Model 1000AR Drive.......................................................................35
to the Model 1000AR Drive .................................................................... 37
on the Model 1000AR Drive............................................................................. 41
TROUBLESHOOTING
Troubleshooting Chart
Troubleshooting the Model 1000AR Drive ...........................................................................................43
Troubleshooting Chart - POWER LED ................................................................................................45
Troubleshooting Chart - BUS LED.......................................................................................................47
Troubleshooting Chart - HS1, HS2, HS3, and TAC LED’s ..................................................................49
Troubleshooting Chart - RUN and ENBL LED’s ..................................................................................51
Troubleshooting Chart - TAC and ZERO SPEED LED’s ..................................................................... 53
Troubleshooting Chart - CURRENT LIMIT and PHAD LED’s ............................................................. 55
OFFICIAL 6/4/2001
Page
8
Model
1000AR Installation and Operation Manual
6/4/2001 © copyright 1997 by Powertec
Model
1000AR
Underwriter’s Laboratories® requires this notice for UL® listed equipment.
This Notice applies to POWERTEC Brushless DC Drive Model Number 1000AR.
Installation and Operation Manual
NSTALLATION
I
Do not use this device on a circuit capable of delivering more than
5000 RMS symmetrical Amperes at 500 VAC maximum voltage.
MOTOR PROTECTION CONSIDERATIONS
You are installing a
the motor will be protected while it is in service. These protections built into your system:
“F” Series
1.
connect this switch to the drive. Look up the method of connection in the drive manual. When the thermal
switch opens, the drive must shut off before high temperatures cause damage.
2. The Model 1000AR drive provides current limiting. This protection is adjustable from 0% to 150%
of the drive’s rated output current.
3. The Model 1000AR drive provides an over-current trip. The drive shuts off the drive if peak
currents greater than 300% of the RMS rating occur.
4. The Model 1000AR 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 a circuit
breaker with the drive, you must supply a means to disconnect main power.. You must do this in order to
meet the requirements of the National Electrical Code.
GENESIS
5.
Laboratories Industrial Control 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.
GENESIS
motors have a thermal switch that opens at high winding temperatures. You must
series drives do not provide running overload protection as described in Underwriters
Series Brushless DC (BLDC) drive and motor. You must consider how
P
AGE
9
SUMMARY OF WARRANTY AND DISCLAIMER
Powertec
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
This warranty does not cover any other claims, including, but not limited to, special, incidental, or
consequential damages.
Powertec
efforts to compile this information. If you find mistakes of fact in this manual, please notify your distributor
Powertec
or
OFFICIAL 6/4/2001
manufactures Model 1000 Series Brushless DC (BLDC) motor controls. We warrant
Powertec
supplies this manual as a guide to the use of our products. We have used our best
at once.
has no control.
Page
10
Model
1000AR Installation and Operation Manual
MODEL 1000AR DIMENSIONS
CHASSIS UNITS
Note: 10HP @ 230VAC, 10HP @ 380VAC, and 15HP @ 460VAC have the
same dimensions, but they have separately mounted bus loaders
2.00"
51mm
TYP
9.85"
250mm
Ø 0.28" DIA
7.1mm
TYP
4 places
9.13"
232mm
14.00"
356mm
R+ R -
8.35"
212mm
9.25"
235mm
18.00"
457mm
ENCLOSED UNITS
Note: Units with separately mounted bus loaders come in a 34”H x 24”W x 18”D Nema1 Enclosure.
22.38"
568mm
9.85"
250mm
Ø 0.28" DIA
7.1mm
TYP
4 places
14.00"
356mm
7.05"
179mm
18.00"
457mm
1000
REGEN
8.90"
2.20"
56mm
226mm
9.25"
235mm
ALL DIMENSIONS ARE APPROXIMATE. Consult factory for certified dimensions.
6/4/2001 © copyright 1997 by Powertec
2.00"
51mm
TYP
9.25"
235mm
Model
1000AR
Installation and Operation Manual
P
AGE
HOW DO I …
PHYSICALLY INSTALL THE MODEL 1000AR DRIVE?
Use of the Model 1000AR drive above 3300 ft (1000 meters) requires de-rating.
If the drive is to be stored, store it in its original packaging in a dry environment.
Storage temperature should be between -40°C and +65°C.
WARNING: DANGEROUS HIGH VOLTAGES ARE NORMAL IN THIS EQUIPMENT! WHEN THE AC INPUT POWER IS
REMOVED, THE CAPACITORS ARE NOT DISCHARGED AT ONCE! BE SURE INPUT POWER IS OFF
AND CAPACITORS ARE DISCHARGED BEFORE WORKING ON THE MOTOR OR THE DRIVE.
11
WARNING! :
Mount with 1/4-20 bolts
and nuts in 4 places
IF YOU TESTED THE DRIVE BEFORE INSTALLATION MAKE SURE THAT THE BUS HAS DISCHARGED.
Mount a Model 1000AR drive of the NEMA 1 style with the fuses at the top.
Free air must flow up through the fins on the back of the drive.
The temperature of the air around the drive (the ambient) must not exceed
40°C (104°F) with a relative humidity of 95% or less.
Leave at least 6 inches (150 mm) open space on all sides of a NEMA1
box. Do not mount it directly above a heat source, such as another drive. There
must be at least 18 inches (450 mm) open space between the units.
R+ R-
When you move a drive chassis, DO NOT handle the chassis by parts that
may bend or come loose. This applies to the front cover of the drive.
Mount the chassis style Model 1000AR drive in an upright position (fuses
at top) inside an enclosure to promote air flow through the heatsink.
The temperature of the air around the chassis unit 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 heatsink fins.
The total heat dissipation within the electrical enclosure determines its size.
A list of heat outputs of the Model 1000AR is in the table on page 6.
NEMA1 and NEMA12 ventilated boxes depend on air flowing through the
enclosure for cooling. They must have an air flow of 1 CFM (cubic feet per
minute) per 10 watts of dissipation (1 cu meter / min per 350 watts).
R
R-
+
The allowance for totally enclosed units is 1 square foot of enclosure surface
per 7 watts of dissipation (75 watts per square meter). Surface area includes
front, sides, top and bottom surfaces. Enclosure surfaces not exposed to cooling
air do not count.
For further information, consult the publication
THERMAL MANAGEMENT
,
available from your distributor.
If a separate
bus loader has been supplied, mount it on the panel near the drive. Mount it with the fins
vertically oriented, and make sure that air can flow through its heatsink.
Bus Loader Resistors
become VERY HOT in the performance of their duty. Bus loader resistors
must be mounted OUTSIDE THE ENCLOSURE in a dry, well ventilated area, where there are no
flammable materials. Bus loader resistors are supplied in an expanded metal cage for wall mounting.
MODEL 1000AR AC INPUT ELECTRICAL RATINGS
OFFICIAL 6/4/2001
Page
12
NOMINAL
AC LINE
VOLTAGE
Model
1000AR Installation and Operation Manual
HORSEPOWER
KILO-
WATTS
MAXIMUM
CONTINUOUS
CURRENT
AC LINE
INPUT
KVA
MAXIMUM
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 1.950 122
230 3 2.2 7.3 2.900 165
230 5 3.7 12.1 4.825 232
230 7.5 5.6 18.1 7.200 281
‡
230 10 7.5 23.9 9.525 385
380 1 0.75 1.5 0.975 36
380 1.5 1.1 2.2 1.450 55
380 2 1.5 2.9 1.925 70
380 3 2.2 4.4 2.875 105
380 5 3.7 7.3 4.810 142
380 7.5 5.6 10.9 7.150 178
‡
380 10 7.5 14.1 9.250 222
460 2 1.5 2.4 1.910 113
460 3 2.2 3.5 2.800 144
460 5 3.7 5.9 4.750 200
460 7.5 5.6 8.9 7.100 258
460 10 7.5 11.4 9.050 355
‡
460 15 11 17.8 14.150 475
Indicates drives supplied with separate bus loader.
‡
Notes
The Model 1000AR drives will operate on power line frequencies from 48 to 62 hertz.
The
capable of supporting the starting current of AC motors without dropping more than 10%. Brief power line disturbances
may trip a drive supplied with less than 95% of the nominal line voltage.
source. Measure the actual input line voltage while the control is operating the motor in a loaded condition.
generate significant noise back onto the power service. Events that distort the AC waveform may lower the bus voltage.
These may trigger an under-voltage or power loss condition.
treacherous problem that is capable of causing destructive results. It can also cause intermittent and annoying problems.
The methods used in the installation of the equipment plays a large part in prevention of electrical noise problems in
operation. Any digital type control requires that extra care be taken in installation. Pay attention to the grounding of the
equipment, the shielding of wires and cables, and the placement of wires in the conduit runs. Pay attention to the
sections of this manual that address the precautions against noise. This also applies to peripheral equipment.
protection. Pay particular attention to power and grounding requirements.
tolerance
Do not measure the input voltage while the drive is not running. This neglects the effects of load on the power
Brief power line disturbances will not normally disturb the Model 1000AR drives. The Model 1000AR drives do not
One of the most frequent problems encountered with digital type equipment is electrical noise. Noise is a
When you use other manufacturer’s equipment in a system, follow their directions regarding noise suppression and
of the input voltage is +10% to -10% of the voltage listed on the nameplate. A service must be
6/4/2001 © copyright 1997 by Powertec
HOW DO I …
.
TRANSFORMER
R+ R-
Model
1000AR
Installation and Operation Manual
CONNECT AC POWER TO THE 1000AR DRIVE?
Standard Model 1000AR Brushless DC drives will not operate on
single phase AC power.
Model 1000AR drives require a three-phase main power source with
KVA rating
a
is NOT returned to the power line during regeneration.
The branch service rating (in KVA) supplying the drive must not be
more than 10 times the HP rating of the drive. If it is, you may need
special disconnecting means with a higher AC short-circuit current
interrupting capacity.
Model 1000AR drives do not include a disconnecting switch for input
power. The user must supply a switch that meets the applicable code
requirements.
The maximum Interrupting Capacity (AIC) of the fuses is 5,000
amperes. You will need a switch with a rating greater than 5,000 amperes
if the short circuit current on the service is greater.
You do not
operation of the drive. You may want to use one, or you might 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
the power wires to the drive input. The table on the opposite page lists the
full load AC line currents of Model 1000AR drives.
The order of connection of the input phases is not important.
We size the main fuses to protect the semiconductor elements of the
unit. THEY MAY OR MAY NOT MEET THE REQUIREMENTS OF
NATIONAL, STATE AND/OR LOCAL ELECTRICAL CODES. The
responsibility for meeting the branch service protection and other code
requirements and safety codes belongs to the user.
NOTICE: AC LINE CURRENT OF THE BLDC DRIVE IS NOT
The AC input current is directly proportional to the POWER output of
the motor. The only time the AC line current reaches its full value is when
the motor is operating at full speed with full load.
BY MEASURING AC INPUT LINE CURRENT TO THE BLDC MOTOR
at least equal to the
necessarily
REPRESENTATIVE OF MOTOR LOAD CURRENT!
DO NOT ATTEMPT TO MEASURE MOTOR LOAD
CONTROL.
HorsePower rating
need an ISOLATION TRANSFORMER for
of the drive. Power
P
AGE
13
OFFICIAL 6/4/2001
Page
14
Model
1000AR Installation and Operation Manual
MODEL 1000AR FUSE BOARD
Model 1000AR Output Electrical Ratings
NOMINAL
AC LINE
VOLTAGE
230 ½ 0.37 2.2 3.3 68.1 K
230 ¾ 0.56 3.4 5.1 45.3 K
230 1 0.75 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
‡
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
‡
460 2 1.5 4.0 6.0 39.2 K
460 3 2.2 6.9 10.3 22.1 K
460 5 3.7 11.6 17.4 13.3 K
460 7.5 5.6 17.1 25.6 9.09 K
460 10 7.5 20.7 31.0 7.50 K
‡
230 10 7.5 41.5 61.1 3.74 K
380 10 7.5 25.0 37.5 6.19 K
460 15 11 31.1 46.6 4.99 K
Indicates 1000A models.
‡
HORSEPOWER
KILO-
WATTS
MAXIMUM
CONTINUOUS
MOTOR
CURRENT
MAXIMUM
MOMENTARY
MOTOR
CURRENT
NOMINAL
HP
CALIBRATE
RESISTOR
6/4/2001 © copyright 1997 by Powertec
Model
1000AR
Installation and Operation Manual
P
AGE
HOW DO I …
CONNECT THE MOTOR TO THE 1000AR DRIVE?
We ship every drive from the factory with A STANDARD CONNECTIONS card.
Connect the motor lead marked T1 to the
T1 terminal on the drive. Connect the T2 lead
to T2 on the drive, and connect T3 to T3. Other
connections to T1, T2, and T3 at the motor will
vary with the motor. The motor will not operate
if the power wires from motor to drive are not in
the proper order.
Full load motor current determines the wire
size to the motor. The table on the opposite
page lists these currents.
R+ R-
T1 T2 T3
TB1
1 2 3 4 5 6 7 89
TB2
16
1 2 3 4 5 6 7 89
Orange
Brown
Blue
Yellow
Red
Black
Green
Purple
White
18
MOTOR
1 2 3 4 5 6 7 8 9 S
BLDC
GND
ADDITION TO GROUNDING THE MOTOR FRAME TO ITS MOUNTING, WHICH IS REQUIRED BY
CODE.
The purpose of this separate ground is to equalize 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. Standard installation requires a nine-conductor shielded cable (Belden
equivalent). The colors of this cable correspond to the colors of the wires in the motor and on the
connection diagram. You may interchange the Purple and White wires without ill effect.
The shield must be continuous from the motor to the control. Do NOT ground the shield at
intermediate points. This applies to all junction boxes installed between motor and control.
Any high voltage, high frequency
equipment generates EMI and RFI.
MUST USE METALLIC CONDUIT TO
ENCLOSE MOTOR WIRES BETWEEN THE
MOTOR AND THE DRIVE.
This will minimize
interference.
You must install a ground wire between the
motor frame and the drive chassis. There is a
ground lug in most motors. If there is no
ground lug, make a connection at any bolt in
the motor junction box.
THIS GROUND WIRE MUST BE RUN IN
™
part #9539 or
YOU
15
DO NOT USE THE SHIELD OF THE ENCODER CABLE AS AN ACTIVE CONDUCTOR!
If you want to use the motor thermal protector in a 120 VAC circuit, run it in wiring separate from the
cable. Use seven-conductor shielded cable. In this case, if the cable wire colors are different from the
diagram, you need to check them carefully for proper connections.
OFFICIAL 6/4/2001
Page
16
Model
1000AR Installation and Operation Manual
REGENERATIVE RESISTORS
Regenerative motor controllers require a method of handling energy that is generated by the motor
and returned to the drive. Traditionally, this has been handled by two methods: (1) using the power lines
as a power sink by dumping excess energy back into the power source, and (2) dissipation as heat.
The first method was popular with DC drives, but it is becoming very unpopular because of the
disruptive effect of the electrical noise in the power system.
The first method has been used by Brushless DC drives, inverters, and vector-type controls. In motor
systems at larger horsepowers, the dissipation means can get bulky and expensive. At horsepowers in the
range of the 1000AR series of drives, they are not a big problem.
Regenerative resistors are rated in terms of resistance and power.
The resistance of the bus loader resistors must allow enough current to flow from the bus through the
resistor(s) to remove the energy at a rate faster than the motor can generate it. 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.
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 STOPPING DUTY.
Any duty cycle other than stopping duty MUST BE EVALUATED BY A MECHANICAL ENGINEER.
The amount of regenerative power needed is a MECHANICAL, not an ELECTRICAL, calculation.
To avoid using many different resistors, standard resistor values have been adopted.
The standard resistor for 230 VAC drives is 25 ohms @ 420 W.
The standard resistor for 460 VAC drives is 70 ohms @ 420 W.
The standard resistor for 380 VAC drives is also 70 ohms @ 420 W.
One resistor is used in parallel for each 5 HP or portion thereof.
BUS LOADER RESISTOR TABLE - Standard Duty Resistors
Line Voltage Motor HP Resistors Equivalent R Dissipation Peak Amps Ave. Amps
HP # @ ohms ohms watts ADC ADC
VAC
230 up to 5 1 @ 25 25.00 375 15.00 1.00
230 7.5 2 @ 25 12.50 750 30.00 1.50
230 10 2 @ 25 12.50 750 30.00 2.00
380 up to 5 1 @ 70 70.00 375 8.86 0.60
380 7.5 2 @ 70 35.00 750 17.72 0.90
380 10 2 @ 70 35.00 750 17.72 1.20
460 up to 5 1 @ 70 70.00 375 10.72 0.50
460 7.5 2 @ 70 35.00 750 21.45 0.75
460 10 2 @ 70 35.00 750 21.45 1.00
460 15 3 @ 70 23.33 1125 32.16 1.50
All resistors are connected in parallel.
Powertec
uses four
6/4/2001 © copyright 1997 by Powertec
Model
1000AR
Installation and Operation Manual
P
AGE
HOW DO I …
CONNECT THE REGENERATIVE RESISTORS TO THE MODEL
1000AR?
All but the largest Model 1000AR drives have the bus
loader (149-201)built into the chassis. The bus loader mounts
on the lower left-hand side panel and it plugs directly to the
driver board. The power components for the bus loader are on
the lower third of the chassis.
You must include the interlock between terminals TB5-1
and TB5-3 in the control circuits. You must locate the drive’s
regenerative resistors outside the enclosure in a clean, dry,
well-ventilated area.
You MUST connect the regenerative resistors. The
horsepower of the drive, the inertia of the load, and the duty
cycle for regeneration determines the number of resistors
We use a standard 10% duty cycle for stopping duty and
for light regenerative loads. The standard resistor package is
NOT guaranteed to handle all situations. IT IS THE
R+ R-
CONTROL
CIRCUIT
INTERLOCK
Operating the 1000AR drive without the Bus Loader attached, or with the Bus Loader disabled, will
result in the drive tripping. OverVoltage will occur as soon as regenerative operation is attempted. This
could also result in damage to the drive.
BUS LOADER
RESISTOR(S)
RESPONSIBILITY OF THE USER TO SPECIFY THE SIZE OF
THE REGENERATIVE RESISTOR PACKAGE. If necessary,
an engineering evaluation should be 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 in a
clean, dry and well ventilated area away from
personnel.
TB5 terminals 3 and 5 must be connected
to the AC drive power. The drawing shows L1
and L2 connected, but any two of the three
phases can be connected.
The resistors must be connected to the R1
and R2 terminals. All standard resistors are
connected in parallel (see page 10 for resistor
values).
Connect the interlock at TB5 terminals 1
and 2 into the control circuit (see page 15).
Connect the fuse input to the POS BUS
connection on the Capacitor Board. Connect
the NEG terminal to the NEG BUS connection
on the Capacitor Board.
17
OFFICIAL 6/4/2001
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