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Model
1000AR
Regenerative
Brushless DC Motor Control
INSTALLATION AND
OPERATION
INSTRUCTION MANUAL
JUNE, 2001
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Model 1000AR Installation and Operation Manual PAGE 1 INTRODUCTION 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 l
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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 SOURC
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Model 1000AR Installation and Operation Manual PAGE 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
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Page 4 Model 1000AR Installation and Operation Manual MODEL 1000AR STANDARD CONNECTIONS Power Input L1 L2 L3 Output Terminals Warning: Input Do Not Connect Input Power Leads fuses to Output Terminals REGEN SPEED CONTROLLER CURRENT CONTROLLER BOARD 147-101 STAB POWERTEC GAIN MCL RCL JP1 MAX SPD JOG DIR/RL DIR JP3 POWER SEL GREEN DECEL STALL HS3 ACCEL RED RED BUS HS2 RAMP STOP RED/GREEN RED 2Q/4Q ENABLE HS1 YELLOW ESTOP COAST RED STOP RUN JOG PL REGEN RED TAC OV/UV RED/GREEN RED
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Model 1000AR Installation and Operation Manual PAGE 5 QUICK START 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). 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. Con
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Page 6 Model 1000AR Installation and Operation Manual REFERENCE PAGES Specifications..........................................................................................................................................2 Model 1000AR Standard Connections....................................................................................................4 Model 1000AR Dimensions Chart .................................................................................................
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Model 1000AR Installation and Operation Manual PAGE 7 TABLE OF CONTENTS INTRODUCTION..................................................................................................................................................... 1 REGENERATIVE … OPERATION ................................................................................................................... 3 QUICK START....................................................................................................
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Page 8 Model 1000AR Installation and Operation Manual 6/4/2001 © copyright 1997 by Powertec
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Model 1000AR Installation and Operation Manual PAGE 9 INSTALLATION ® ® Underwriter’s Laboratories requires this notice for UL listed equipment. This Notice applies to POWERTEC Brushless DC Drive Model Number 1000AR. 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 GENESIS Series Brushless DC (BLDC) drive and motor. You must consider how the motor will
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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 9.85" 9.13" 250mm 232mm Ø 0.28" DIA 7.1mm TYP 4 places 2.00" 51mm TYP 14.00" 18.00" 356mm 457mm R+ R- 8.35" 212mm 9.25" 235mm ENCLOSED UNITS Note: Units with separately mounted bus loaders come in a 34”H x 24”W x 18”D Nema1 Enclosure. 9.85" 7.05" 250mm 179mm Ø 0
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Model 1000AR Installation and Operation Manual PAGE 11 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
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Page 12 Model 1000AR Installation and Operation Manual NOMINAL MAXIMUM MAXIMUM AC LINE HORSE- KILO- CONTINUOUS INPUT HEAT VOLTAGE POWER WATTS AC LINE KVA OUTPUT IN CURRENT 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 5
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Model 1000AR Installation and Operation Manual PAGE 13 HOW DO I … 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 . a KVA rating at least equal to the HorsePower rating of the drive. Power 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 rati
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Page 14 Model 1000AR Installation and Operation Manual MODEL 1000AR FUSE BOARD Model 1000AR Output Electrical Ratings NOMINAL MAXIMUM MAXIMUM NOMINAL AC LINE HORSE- KILO- CONTINUOUS MOMENTARY HP VOLTAGE POWER WATTS MOTOR MOTOR CALIBRATE CURRENT CURRENT RESISTOR 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.
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Model 1000AR Installation and Operation Manual PAGE 15 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. Ful
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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 e
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Model 1000AR Installation and Operation Manual PAGE 17 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.
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Page 18 Model 1000AR Installation and Operation Manual CONTACTOR SPECIFICATIONS If you want to operate an Output or DB Contactor directly from the Model 1000AR, you must choose a coil that draws 1.77" less than 50 milliamps DC. The Output Contactor drawing on page 11 shows the A1 13 21 31 41 connections for direct operation of the contactor (use the same connections for Dynamic Braking). The coil must be 48VDC and draw less than 50 ma DC (2.4 Watts). This is the most power
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Model 1000AR Installation and Operation Manual PAGE 19 HOW DO I … CONNECT AN OUTPUT CONTACTOR? You may use an output contactor with the Model 1000AR. T3 T2 You MUST interlock the contactor with the Emergency Stop. You T1 GND WILL damage the drive if you do not interlock the contactor. M Requirements for the Model 1000 series are: 1. The contactor must close its main power contacts T1 T3 BEFORE it enables the drive; T2 G BLDC 2. The contactor may only open its contacts AFTER
