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PowerTec 1000 User Manual

PowerTec 1000
52 pages
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Repair Center for Powertec Drives and Motors
460 Milford Parkway
Milford, OH . 45150
www.motorsystems.com
513-576-1725
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PowerTec 1000 Specifications

General IconGeneral
BrandPowerTec
Model1000
CategoryController
LanguageEnglish

Summary

INTRODUCTION

WHAT IS A GENESIS SERIES BRUSHLESS DC DRIVE?

Explains the GENESIS series of drives and their benefits to the user.

SPECIFICATIONS

ENVIRONMENTAL AND POWER SOURCE

Details operating environment, altitude, temperature, humidity, and power requirements for the drive.

PERFORMANCE AND ADJUSTMENTS

Covers speed regulation, accuracy, adjustments like acceleration, deceleration, speed limits, gain, stability, and current limit.

DIMENSIONS

Physical dimensions for chassis and enclosed units of the Model 1000 and 1000A drives.

TERMINAL DESCRIPTIONS

Lists and describes the function of each terminal on the Current Controller, Speed Controller, and Capacitor Boards.

JUMPERS AND INDICATORS

Explains the function of jumpers and the meaning of various LED indicators on the control boards.

INSTALLATION

MOTOR PROTECTION CONSIDERATIONS

Discusses how the drive protects the motor, including thermal switches and current limiting.

WARRANTY AND DISCLAIMER

Outlines the terms of the warranty and disclaims liability for improper use or installation.

PROCEDURES

PHYSICALLY INSTALL THE MODEL 1000 DRIVE

Provides guidelines for mounting the drive unit, ensuring proper airflow and clearances for cooling.

CONNECT AC POWER TO THE 1000 DRIVE

Explains how to connect the three-phase AC power source to the drive, including safety and code requirements.

CONNECT THE MOTOR TO THE 1000 DRIVE

Details the wiring process for connecting the BLDC motor to the drive, emphasizing cable and grounding.

CONNECT AN OUTPUT CONTACTOR

Guides on wiring an output contactor, including interlocking with the emergency stop.

CONNECT DYNAMIC BRAKING

Details how to connect dynamic braking, including safety interlocks and component selection.

CONNECT STANDARD CONTROL CIRCUITS

Explains how to connect external control devices like pushbuttons and switches to the drive.

GET RUN, ZERO SPEED, FAULT AND ENABLE INFORMATION

Describes how to obtain status information from drive outputs like RUN, FAULT, and ZERO SPEED LEDs.

CONNECT AN ANALOG SPEED REFERENCE

Guides on connecting an analog speed reference, such as a speed pot or external voltage, to the drive.

CONNECT A DIGITAL SPEED REFERENCE

Details connecting a digital speed reference, typically a pulse train, for precise speed control.

CONNECT A DIGIMAX®

Explains how to connect a DIGIMAX controller to command motor movement in digital speed mode.

ELECTRICAL INFORMATION

MODEL 1000 AC INPUT ELECTRICAL RATINGS

Provides a table detailing AC input voltage, horsepower, power, and current ratings for the drive.

EXTERNAL COMPONENTS

CONTACTOR SPECIFICATIONS

Provides specifications for output and dynamic braking contactors, including coil requirements.

DYNAMIC BRAKING RESISTORS

Explains the use and calculation of dynamic braking resistors for absorbing power.

CONTROL CONNECTIONS

CONNECT AN OUTPUT CONTACTOR

Guides on wiring an output contactor, including interlocking with the emergency stop.

CONNECT DYNAMIC BRAKING

Details how to connect dynamic braking, including safety interlocks and component selection.

MODEL 1000 CONTROL CONNECTIONS

Details the functions and connections for various control inputs like RUN, STOP, JOG, and thermal protection.

TERMINAL DESCRIPTIONS

TERMINAL DESCRIPTIONS MODEL 1000 AND 1000A

Lists and describes the function of each terminal on the Current Controller, Speed Controller, and Capacitor Boards.

PLC INTERFACE

PLC INTERFACE

Explains how to interface the drive with a programmable controller using sinking and sourcing connections.

DIGITAL MODE OPERATION

DIGITAL MODE NOTES

Provides information on operating the drive in digital mode using a frequency signal for speed control.

OPERATION MODES COMPARISON

ANALOG VERSUS DIGITAL OPERATION

Compares the performance, accuracy, and coordination capabilities of analog and digital speed control modes.

INSTALLATION CHECKLIST

INSTALLATION CHECKLIST

A checklist to ensure all installation steps have been completed correctly before operation.

CAPACITOR BOARD

CAPACITOR BOARD LAYOUT AND CONNECTIONS

Illustrates the layout and provides connection details for the capacitor board.

START UP BEHAVIOR

APPLY POWER TO THE MODEL 1000

Describes the sequence of events and LED indications when power is first applied to the drive.

START COMMAND

GIVE THE START COMMAND TO THE MODEL 1000

Details the steps and conditions required to initiate motor operation using start commands.

ADJUSTMENTS

MINIMUM AND MAXIMUM SPEED ADJUSTMENTS

Guides on adjusting minimum and maximum speed settings using potentiometers on the Speed Controller board.

ACCELERATION, DECELERATION, AND JOG SPEED

Explains how to set acceleration time, deceleration time, and jog speed using control pots.

GAIN, STABILITY, AND CURRENT LIMIT ADJUSTMENTS

Covers adjustments for motor shaft stiffness, drive stability, and motor current limit.

MAKING ADJUSTMENTS

ADJUSTING MOTOR SPEED AND RESPONSE

Guides on making adjustments to motor speed, acceleration, deceleration, and jog speed for desired performance.

TROUBLESHOOTING

TROUBLESHOOTING THE MODEL 1000 DRIVE

Introduces troubleshooting steps and required equipment for diagnosing drive issues.

EQUIPMENT NECESSARY FOR TROUBLESHOOTING

Lists essential tools and equipment required for performing troubleshooting tests on the drive.

SPARE PARTS

Lists commonly required spare parts for fast on-site repair of the drive.

TROUBLESHOOTING CHARTS

Explains how to use troubleshooting charts and provides guidance for resolving issues.

COMPONENT TESTING

TRANSISTOR MODULE STATIC TEST

Provides a procedure for testing transistor modules using a digital multimeter for continuity and resistance.

START UP TROUBLESHOOTING FLOWCHARTS

START UP TROUBLESHOOTING CHART - PAGE 1

A flowchart to diagnose issues encountered during the initial power-up and start-up sequence of the drive.

DIODE BRIDGE TEST

Details the procedure for testing the diode bridge rectifier using a multimeter for proper functionality.

TRANSISTOR LEAKAGE TEST

Guides on testing transistor leakage with the drive powered on, requiring careful handling of high voltages.

START UP TROUBLESHOOTING CHART - PAGE 2

Continues the troubleshooting flowchart, focusing on bus voltage and component checks after initial power application.

START UP TROUBLESHOOTING CHART - PAGE 3

The third part of the troubleshooting flowchart, focusing on encoder signals and related component checks.

START UP TROUBLESHOOTING CHART - PAGE 4

The fourth part of the troubleshooting flowchart, addressing issues with RUN, ENBL, and fault LEDs.

START UP TROUBLESHOOTING CHART - PAGE 5

The fifth part of the troubleshooting flowchart, covering motor turning, speed, and connection checks.

MOTOR ENCODER

ENCODER WAVEFORMS AND CONNECTIONS

Shows encoder waveforms and details motor encoder connection methods and layouts for proper feedback.

SPECIFIC FAULT TESTS

IOC AND OV/UV FAULT TESTS

Provides specific test procedures for diagnosing Instantaneous Over Current (IOC) and Over/Under Voltage (OV/UV) faults.

DRIVER BOARD

DRIVER BOARD LAYOUT AND CONNECTIONS

Illustrates the layout and connections of the driver board, detailing its components and wiring.

DRIVER BOARD LED'S

Explains the function and observation of LED indicators on the driver board for transistor status during operation.