Page 1
BLuAC5-S
BLuAC5-SE
BLuAC5-Q
BLuAC5-QE
920-0049 Rev. C
12/8/2014
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920-0049 Rev. C
12/8/2014
BLuAC5 S/Q Hardware manual
Contents
Introduction ............................................................................................................................... 4
Block Diagram .......................................................................................................................... 5
Getting Started ......................................................................................................................... 6
Status & Error Display LEDs .................................................................................................... 7
Serial Comm Tx & Rx LED .......................................................................................... 7
Bus voltage indication LED .......................................................................................... 7
Seven Segment Display Error codes ........................................................................... 8
Seven Segment Display Status codes ......................................................................... 9
Connecting to the PC using RS-232 ....................................................................................... 10
Regeneration LED ..................................................................................................... 10
Connecting to a host using RS-485 ........................................................................................ 11
A Short tutorial on RS-485 & RS-422 ........................................................................ 11
Getting and Connecting a RS485 4-wire adaptor to your PC .................................... 12
Getting and Connecting a RS485 2-wire adaptor to your PC .................................... 13
Before you connect the servo drive to your system ......................................................... 13
Connecting the AC Power Input.............................................................................................. 14
24 Volt Controller Input (Keep Alive) .......................................................................... 14
Connecting Single Phase AC input (90-260VAC) ...................................................... 15
Connecting 3-Phase AC input (90-260VAC) .............................................................. 15
Connecting the Motor ............................................................................................................. 16
Recommended Ferrite Core Instructions ................................................................................ 17
Fuses - External and Internal ................................................................................................. 17
Line Filters .............................................................................................................................. 17
Connecting the Encoder & Hall Sensors ................................................................................ 18
Encoder Pinout .......................................................................................................... 18
Connecting a Single-Ended Encoder ........................................................................ 19
Connecting Single-Ended Hall Sensors .................................................................... 19
IN/OUT 1 Connector ............................................................................................................... 20
Summary of Input Signals ......................................................................................... 20
IN/OUT 1 Connector Pin Diagram ............................................................................. 20
High Speed Digital Inputs .......................................................................................... 21
Using High Speed Inputs with 12-24 Volt Signals ...................................................... 22
Connecting to PLC with Sourcing (PNP) Outputs ..................................................... 23
Connecting to PLC with Sinking (NPN) Outputs ........................................................ 23
Using Mechanical Switches at 24 Volts. ..................................................................... 23
Standard Digital Inputs .............................................................................................. 24
What is COM? ......................................................................................................... 24
User Out 24V supply ................................................................................................. 24
Digital Input Connection Examples ............................................................................ 25
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BLuAC5 S/Q Hardware manual
Connecting Limit Switches to the BLUAC5 Drives..................................................... 26
BLuAC5 Limit Input diagram ..................................................................................... 26
Wiring a Mechanical Limit Switch .............................................................................. 27
Wiring a Limit Sensor ................................................................................................ 27
Analog Inputs ............................................................................................................. 28
Three dedicated purposes: ........................................................................................ 28
Basic Specifications: .................................................................................................. 28
Wiring a controller with differential output as a singled ended input .......................... 29
Wiring a controller with differential output to differential input .................................. 29
Wiring a potentiometer to a singled ended input ...................................................... 29
Programmable Outputs .............................................................................................. 30
Encoder Outputs ........................................................................................................ 31
IN/OUT2 Connector (-SE and -QE only) ................................................................................ 32
Single Ended Inputs .................................................................................................. 32
Differential Inputs ....................................................................................................... 32
Connecting to the Analog Input on the IN/OUT 2 Connector .................................... 33
Programmable Outputs on the IN/OUT 2 Connector ................................................. 34
Recommended AMP Motors .................................................................................................. 36
Alpha A Series ........................................................................................................... 36
M Series .................................................................................................................... 36
N Series ..................................................................................................................... 36
J Series ...................................................................................................................... 36
Other Supplier’s Motors ............................................................................................. 37
Setting Drive Current Limits .................................................................................................... 38
What is “Peak Current Limit”? .................................................................................... 38
Using DC Brushed Motors ...................................................................................................... 39
Servo Drive Regeneration ...................................................................................................... 40
Wiring Integral Holding Brakes ............................................................................................... 41
Mounting the Drive ................................................................................................................. 43
Mechanical Outline ................................................................................................................. 43
Technical Specifications ......................................................................................................... 44
Mating Connectors and Accessories ...................................................................................... 44
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920-0049 Rev. C
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BLuAC5 S/Q Hardware manual
Introduction
Thank you for selecting an Applied Motion Products motor control. We hope our dedication to
performance, quality and economy will make your motion control project successful.
If there’s anything we can do to improve our products or help you use them better, please call
or fax. We’d like to hear from you. Our phone number is (800) 525-1609 or you can reach us
by fax at (831) 761-6544. You can also email support@applied-motion.com.
Features
• Digital servo motor driver in complete fully featured package
• Operates directly from a 90 to 260Volt AC input
• Operates in torque, velocity or position mode
• Accepts analog signals, digital signals and RS-232/485 serial commands
• Motor current to 15 amps peak, 5 amps continuous
• Seven optically isolated digital inputs (15 inputs with expanded I/O board)
• Three optically isolated digital outputs (7 outputs with expanded I/O board)
• One differential or two single ended ±10 volt analog inputs for position, speed and torque
control. In the SCL and Q languages the analog inputs can be read and used to set other
parameters.
• 0-5V aux analog input
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BLuAC5 S/Q Hardware manual
motor
encoder
to RS-485 host
User Out 24 VDC
X1/STEP
X2/DIR
X3
X4
X5
X6/CCWLMT
X7/CWLMT
IN1
IN2
IN3
IN4
IN5/CWJOG
IN6/CCWJOG
IN7
IN8
to PC or MMI
ANALOG+
ANALOG–
Y1/BRAKE
Y2/INPOSN
Y3/ALARM
OUT1
OUT2
OUT3
OUT4
ENCODER OUT
Optical
Isolation
Optical
Isolation
Optical
Isolation
Optical
Isolation
-SE, -QE
ONLY
Internal
Logic
Supply
AC Input
Power
Converter
100 - 260 VAC
DC Bus LED
Internal
Regen
Clamp
External Regen Resistor
External Brake Resistor
Input 24 VDC
Regen LED
Seven Segment
Status Display
Rx Status LED
Tx Status LED
-SE, -QE
ONLY
IGBT
PWM
Power
Amplifier
RS-232
RS-485
Line
Drivers
DSP
Block Diagram
920-0049 Rev. C
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BLuAC5 S/Q Hardware manual
Getting Started
To use your BLuAC5 servo drive you must have the following:
• a compatible servo motor
• cables to connect the motor to the drive. If you are using an Applied Motion
A, N or M motor, use BLUENC and BLUMTR-FA cables (one of each).
You must use an “FA” (filtered) motor cable for proper operation of the BLUAC.
J motor, use 3004-301-3M and 3004-307-3M cables (one of each).
• a small at blade screwdriver for tightening the connectors (included).
• a personal computer running Microsoft Windows 98, NT, Me, 2000, XP or Vista.
• The Applied Motion CD that came with your drive.
• An Applied Motion programming cable (included)
If you’ve never used a BLU servo before, you’ll need to get familiar with the drive and the
set up software before you try to deploy the system in your application. We strongly recommend the following:
1. Install the Quick Tuner software from the CD.
2. Launch the software by clicking Start...Programs...Applied Motion Products...Quick
Tuner.
3. Connect the drive to your PC using the programming cable supplied.
4. Connect the drive to the AC power source (may be switched).
5. Connect the drive to the motor.
6. Apply power to the drive.
7. Follow the instructions in the Quick Tuner manual.
The connectors and other points of interest are illustrated on the next page. Depending on
your drive model and application, you’ll need to make connections to various parts of the
drive. These are detailed later in the manual.
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DC Bus
Motor Encoder IN / OUT 1
IN / OUT 2
PC/MMI
RS-485/422
C B A
GND
TX-
TX+
RX-
RX+
COMM
Status
Regen
GND
+24VDC
Input
320V pk
User Out
+24VDC
GND
CLAMP RES
EXT
BUS
BRAKING
L1
L2/N
L3
AC POWER
G
Error Codes
Position Limit
CCW Limit
CW Limit
Over Temp
Over Voltage
Under Voltage
Over Current
Current Limit
Hall Bad
Encoder Bad
Memory Failed
Regen Failed
Comm Error
Position Mode
Velocity Mode
Torque Mode
Step Mode
Operating Modes
Front View
X COMMON
X7 / CW Limit
X3 / Servo Enable
X5
X4 / Alarm Reset
Analog IN-
Analog IN+
X2 / DIR-
X2 / DIR+
X1 / STEP / PWM+
X1 / STEP / PWM-
GND
GND
A+
A-
B+
B-
Z+
Z-
+5V OUT
Y COMMON
Y3 / ALARM
Y2 / INPOSN
Y1 / BRAKE
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
2
3
1
19
20
21
22
23
24
25
Encoder
Outputs
X6 / CCW Limit
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
2
3
1
19
20
21
22
23
24
25
+5V
Out 1-
Out 2+
Out 1+
Ain Com
N/C
Ain 1
IN 8-
COM
IN 5
IN 6
IN 7+
IN 8+
IN 7-
IN 4
IN 1
COM
IN 2
COM
IN 3
Out 2-
Out 3+
Out 3-
Out 4+
Out 4-
enabled when
flashing
Drive Disabled
Si Mode
INT
rotating segment indicates Q
program running.
IN/OUT 2
IN/OUT 1
IN/OUT 1 Connector (DB25F)
•
digital inputs
•
digital outputs
•
analog inputs
•
encoder output
HD-15 connector
•
motor feedback
screw terminal
plugable connector
•
motor
plugable screw
terminal connector
•
RS-485 port
comm status LEDs
•
Rx (Green)
•
Tx (Amber)
RJ11 connector
•
RS-232 port
Always use the blue & white Applied Motion
screwdriver to tighten the screw terminal connectors.
Larger screwdrivers may remove the plastic dimples
that prevent the screws from falling out.
plugable screw
terminal connector
•
AC input 100-260VAC
plugable screw
terminal connector
•
Dynamic Braking Resistor
plugable screw
terminal connector
•
External Regen Resistor
IN/OUT 2 Connector (DB-25M)
-SE and -QE only
•
digital inputs
•
digital outputs
•
analog input
Status LED
•
Regen
Seven Segment
LED
•
status codes
•
error Codes
Status LED
•
DC Bus Voltage
present
plugable screw
terminal connector
•
User 24 volt output
plugable screw
terminal connector
•
24 volt (Keep Alive)
input
Standard on BLuAC5-Si
Option on -S, -Q
BLuAC5 S/Q Hardware manual
Status & Error Display LEDs
Serial Comm Tx & Rx LED
Indicates that data is being recieved or transmitted through the RS-232 or RS-485 serial
ports. Green indicates “Receiving”. Red indicates “Transmitting”
Bus voltage indication LED
Indicates when there is DC Bus voltage present on the drive. Servo drive cover should not be
removed when this LED is illuminated.
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BLuAC5 S/Q Hardware manual
Seven Segment Display Error codes
Note: codes with a ”*” indicate drive has faulted and flash at a 0.5 second rate.
*Position Limit Error: Indicates the Servomotor has exceeded the “Position Limit”
value.
CCW Limit: The Counter Clockwise limit has been triggered. This will depend on the
CCW/CW Input settings. Use “DL” command to enable usage
CW Limit: The Clockwise limit has been triggered. This will depend on the CCW/CW
Input settings. Use “DL” command to enable usage
*Over Temperature: The Drive PCB temperature has exceeded 75° C. This will
cause the drive to fault and cannot be cleared until the temperature drops below the
*Regeneration Error: While attempting to “dump” power into the regeneration shunt
resistor the device limits were reached or, there is no regeneration shunt resistor
*Over Voltage: The DC Bus voltage exceeded 400 Volts. The drive will be faulted
after this error.
Under Voltage: The DC Bus voltage has gone below 100 Volts. This does NOT fault
the drive.
*Over Current: The Motor phase current has exceeded the 20 amps (RMS). The
drive will be faulted.
Current Limit: The Motor phase current has exceeded the “Peak” current time limit
(As set by the CP command).
*Hall Pattern Bad: Indicates that the Hall sensor (commutation track) inputs are
incorrect. Drive only accepts 120° Hall sensor patterns. Could also indicate a failed
Cannot execute move: the most common cause of this alarm is when a move is
commanded while the motor is disabled.
*Encoder Failure: Indicates that the Encoder inputs are not providing the correct
states. This feature can be enabled or disabled using the QuickTuner® Setup utility.
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BLuAC5 S/Q Hardware manual
Memory Fault: When reading or writing to “Flash” memory an error occurred. This is
an indicator of memory problems that are typically induced with too many write cycles
(>100,000).
Memory Fault: Q segment could not be executed because it was blank.
Serial Comm Error: Indicates a Serial Communication error. This error is also indi-
cated by the Comm Tx and Rx LEDs ashing an alternating pattern.
Serial Comm Timeout: A complete command packet was not recevied in the normal
amount of time. This can happen if you try to type SCL or Q commands into Hyper-
terminal instead of using the SCL Utility. It will also occur if your host application
does not end each command with a carriage return (ASCII 13)
Seven Segment Display Status codes
Positioning Mode: The drive is in Positioning Mode. This is the mode used when
performing “point to point” moves.
Velocity Mode: The drive is in Velocity Mode. This is the mode used when “Jogging”
or Analog commanded Velocity.
Torque Mode: The drive is in Torque Control Mode. This is the mode used for Analog
commanded Torque operation.
920-0049 Rev. C
12/8/2014
Step & Direction Mode: The drive is in Step and Direction Control Mode. This is the
mode used for “Encoder Following” or Positioning using Step and Direction input.
Si Positioning: You should not see this code on a -S or -Q drive.
Drive Disabled: The drive output is disabled.
Q Program Running: An outside segment will be rotating around the display. The
rotate rate is about 0.2 seconds per segment.
Drive Start-up test pattern: This pattern is displayed for a short period of time at
drive start-up.
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920-0049 Rev. C
(5) GND
(4) Drive TX
(3) +5 Volt output for MMI & HUB
(2) Drive RX
2
35
6
DB9 to RJ11 Adaptor Pin assignments
DB9 female Signal Name RJ11 Signal Name
2RX4TX
3TX2RX
5 GND 5 GND
Servo Drive RJ11
1
(2) PC TX
(3) No Connection
(4) PC Rx
(5) PC Ground
1
Adaptor RJ11
6
Adaptor DB9
Front View
Front View
Front View
PC DB9 to
Servo Drive RJ11 Adaptor
NOTE: Pins 1 & 6 are not connected
BLuAC5 S/Q Hardware manual
12/8/2014
Regeneration LED
This LED indicates when the drive is actively applying the regeneration clamp. The clamp is
the internal circuitry that shunts the DC bus to a power resistor. The power resistor can be
either internal or external. (See “Servo Drive Regeneration” in this manual for more details)
Connecting to the PC using RS-232
• Locate your computer within 6 feet of the BLU servo drive.
• Your drive was shipped with a communication cable. Plug the large end into the serial port
of your PC and the small end into the RS-232 jack on your drive. Secure the adapter to the
PC with the screws on the sides.
Never connect a BLU servo drive to a telephone circuit. It uses the same connectors and cords as
telephones and modems, but the voltages are not compatible.
If your PC does not have a serial port, you should purchase a “USB Serial Converter”. We
have had good results with the Port Authority “USB Serial DB9” Adapter from CablesToGo.
com and with the SW1301 from SewellDirect.com.
For laptops, a PCMCIA converter card is a good choice. Our applications engineers use the
SSP-100 from Sewell Direct.
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BLuAC5 S/Q Hardware manual
920-0049 Rev. C
12/8/2014
Connecting to a host using RS-485
RS-485/422 allows you to connect more than one drive to a single host PC, PLC or other
computer. It also allows the communication cable to be long (more than 1000 feet). But the
device to which you connect must have an RS-485/422 port.
A Short tutorial on RS-485 & RS-422
There is a bit of confusion on the implementation of the these two serial interface specifications. RS-485 in the strictest definition is a “2-wire” interface that allows multi-node connections limited to “Half-duplex” serial communications. Up to 32 nodes that both transmit and
receive can be connected to the network. RS-422 also in the strictest definition is a “4-wire”
point to point connection that allows “Full-duplex” serial communications when connected to a
single node. RS-422 has one node that is the driver or transmitter and up to 10 nodes that are
receivers. RS-422 was not designed for a true multi-node network.
2- wire interfaces require one more significant feature. A network node, master or slave, must
be able to tristate its transmitter to allow other node to use the network when required. For
high speed baud rates this must be done very quickly to avoid communications collisions
4-wire interfaces can go beyond the simple point to point and do multi-node networks if the
slave nodes are capable of tri-stating their transmitters as required in the 2-wire networks.
Some RS-485 devices are setup to do this and can be used in a 4-wire configuration
On the AMP Servo drives the RS-485 can be implemented with either “2-wire” or “4-wire”. In
both cases communications is still limited to “Half-duplex” because of the nature of the serial
communications protocols used. 4-wire implementations can sometimes be easier due to the
greater number of Host RS-232 to RS-485 adaptors that support the 4-wire interface. 2-wire
implementations may require special Host adaptors that support “Auto enable” of the adaptor
transmitter. This is because PC software typically doesn’t support tri-stating the output of the
serial adaptors.
In both 2-wire and 4-wire systems one extra wire is always required to connect the “Grounds”
of all the nodes on the network. Even though in both cases the signals are sent differentially,
a command ground connection is absolutely required.
One more consideration must not be neglected. Proper cable shielding is a must. High voltage, high frequency, high current signals that are present on the servo motor cables can
emit a significant amount of electrical interference. Without proper shielding these signal can
disrupt even “noise tolerant” differential line drivers.
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Our RS-485 implementation is a 4-wire multi-drop network with separate transmit and receive
wires. One pair of wires connects from the host computer’s TX+ and TX- signals to each
drive’s RX+ and RX- terminals. Another pair connects the TX+ and TX- drive terminals to the
host computer’s RX+ and RX- signals. A common ground terminal is provided on each drive
and should be used to keep all drives at the same ground potential. Connect one drive’s GND
terminal to the host computer ground.
Before wiring the entire system, you’ll need to connect each drive individually to the host
computer so that a unique address can be assigned to each drive. Proceed as follows: (Also
see figure #1 below)
1. Connect the drive TX+ to the PC’s RX+ terminal.
2. Connect the drive TX- to PC RX-.
3. Connect RX+ to TX+.
4. Connect RX- to TX-.
5. Connect GND to GND.
BLuAC5 S/Q Hardware manual
Getting and Connecting a RS485 4-wire adaptor to your PC
Model 117701 from Jameco Electronics (800-831-4242) works well. This adaptor is for a 25
pin serial port. If you are like most people and have a 9 pin serial port on your PC, you will
also need to purchase Jameco cable 31721. Connect as follows:
adaptor drive
1 RX+
2 RX 3 TX 4 TX+
Set the switches for DCE and TxON,RxON. Don’t forget to plug in the DC power adaptor that
comes with the unit.
to PC GND
to PC RX-
to PC RX+
to PC TX-
to PC TX+
+RX- +TX- GND +RX- +TX- GND +RX- +TX- GND
Drive #1 Drive #2 Drive #3
4-Wire RS-485 Figure #1
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BLuAC5 S/Q Hardware manual
You can also connect the drive to the Host computer using only a 2-wire interface. In this case
you must rst connect the TX+ to the RX+ and the TX- to the RX- on the servo drives before
connecting to the Host adaptor. Usually RS-485 2-wire interfaces are labeled “A” & “B”.
920-0049 Rev. C
12/8/2014
Getting and Connecting a RS485 2-wire adaptor to your PC
Model 485-25E from Integrity Instruments (800-450-2001) works well. It comes with everything you need. Connect as follows:
adaptor drive
B TX+/RX+
A TX-/RX-
to PC GND
to PC TX-/RX- or B
to PC TX+/RX+ or A
+RX- +TX- GND
Drive #1 Drive #2
+RX- +TX- GND
+RX- +TX- GND
Drive #3
Before you connect the servo drive to your system
With the RS-232 cable connected between your PC and the Servo drive, on your PC, start
the SCL Setup Utility software. Select the proper comm port (1,2,3 or 4) then apply power to
the drive. Press the Caps Lock key. The drives only accept commands in uppercase. Type
RV then press ENTER. If the drive has power and is properly wired, it will respond with
“RV=x”. Where x is the firmware version of your drive. If the drive responds, you’re home
free: the RS485 network is functioning.
Next, you must choose an address for this drive. Any of the “low ASCII” characters (many of
which appear above the number keys on a PC keyboard) is acceptable: ! “ # $ % & ‘ ( ) * + , -
. / 0 1 2 3 4 5 6 7 8 9 : ; < > ? @
To find out what address is in the drive now, type DA then press enter. The drive will respond
with DA=x, where x is the address that was last stored. (For example, the response might
be DA=@ or DA=!). To change the address, type DAy, where y is the new address character,
then press ENTER.
To test the new address, type yRV, then press ENTER. For example, if you set the address to
% and want to test that, type %RV. The drive should respond just as it does to RV, the global
revision level request.
Once all the drives have been assigned unique addresses, you can proceed to wire the whole
system together.
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920-0049 Rev. C
Status
Regen
GND
+24VDC
Input
User Out
+24VDC
GND
12/8/2014
BLuAC5 S/Q Hardware manual
Connecting the AC Power Input
The AC supply to the drive can range for 90VAC RMS to 260VAC RMS, 50 to 60 Hz, single or
three phase.
The AC input voltage is the most significant attribute of the AC input to affect the power that is
available from the drive. At lower AC inputs the DC bus voltage is reduced and therefore will
limit performance of higher voltage AC servo motors. As a general rule AC inputs of 120VAC
will permit continuous operation of 500 Watt servo motors wile AC inputs of 240VAC will operated 1K Watt servo motors. It is wise to match as closely as possible the AC input and the
Servo Motor voltage rating.
AMP has a number of servo motors designed to operate at both 120 and 240VAC input (See
Recommended Motors later in this manual.)
When available three phase input is recommended for it’s lower ripple on the DC bus voltage.
This saves wear and tear on the DC bus capacitors and spreads out the current on the AC
input rectifiers.
WARNING: Exceeding the DC Bus voltage of 367VDC may cause the internal regeneration circuitry to activate. This may result in a drive fault or some cases can result in
drive failure.
24 Volt Controller Input (Keep Alive)
The BLUAC5 servo drives offer a 24 volt
input that will supply “Keep Alive” power to
the controller section of the drive. AC power
can be removed without shutting down the
servo controller. This function can be used to
maintain motor position information. When AC
power is restored to the drive the servo motor
can be re-enable and the original position
reestablished.
When 24 volt input is present and the AC
input is removed the drive will display a “U”
error code.
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BLuAC5 S/Q Hardware manual
DC Bus
320V pk
CLAMP RES
EXT
BUS
BRAKING
L1
L2/N
L3
AC POWER
G
Front View
X2 / DIR-
X2 / DIR+
GND
GND
A+
A-
B+
B-
Z+
Z-
+5V OUT
Y COMMON
Y3 / ALARM
Y2 / INPOSN
Y1 / BRAKE
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
19
20
21
22
23
24
25
Encoder
Outputs
18
17
16
15
14
11
10
9
8
7
6
5
4
2
3
1
+5V
Ain 1
IN 8-
COM
IN 5
IN 6
IN 7+
IN 8+
IN 7-
IN 4
IN 1
COM
IN 2
COM
IN 3
INT
DC Bus
Motor
C B A
320V pk
User Out
+24VDC
GND
CLAMP RES
EXT
BUS
BRAKING
L1
L2/N
L3
AC POWER
G
Front View
X COMMON
X5
X2 / DIR-
X2 / DIR+
X1 / STEP / PWM+
X1 / STEP / PWM-
GND
GND
A+
A-
B+
B-
Z+
Z-
+5V OUT
Y COMMON
Y3 / ALARM
Y2 / INPOSN
Y1 / BRAKE
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
2
3
1
19
20
21
22
23
24
25
Encoder
Outputs
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
2
3
1
19
20
21
22
23
+5V
Out 1-
Out 1+
Ain Com
N/C
Ain 1
IN 8-
COM
IN 5
IN 6
IN 7+
IN 8+
IN 7-
IN 4
IN 1
COM
IN 2
COM
IN 3
INT
Connecting Single Phase AC input (90-260VAC)
Connect Earth (Green) to “G”
“Hot” (Black) to “L1”
“Neutral” (White) to “L2/N”
920-0049 Rev. C
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Connecting 3-Phase AC input (90-260VAC)
Connect Earth (Green) to “G”
“Phase 1” (Black) to “L1”
“Phase 2” (White) to “L2”
“Phase 3” (Red) to “L3”
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BLuAC5 S/Q Hardware manual
Connecting the Motor
WARNING: Never connect or disconnect the motor while the power is on.
Applied Motion Products motor:
To connect an Applied Motion servo motor to your BLU Servo, you’ll need a set of mating
cables called the BLUENC and the BLUMTR-FA.
You must use the “FA” (filtered) motor cable for proper operation of the drive. The
green wire of the cable must be connected to the chassis ground screw of the BLUAC5.
Connect the small motor connector to one end of the motor cable. The other end of the
BLUMTR-FA has lead wires that connect to the drive’s screw terminal connector as follows:
A = red wire
B = white wire
C = black wire
Connect the green wire and the bare “drain” wire to the chassis ground screw.
Connect the large motor connector to one end of the BLUENC cable. The other end of the
BLUENC plugs into the BLU servo.
For J-Series motors, use 3004-301-3M and 3004-307-3M cables (one of each).
Non-Applied Motion motor:
Connect the motor leads to the screw terminal connector as follows:
A = motor phase A, R or U
B = motor phase B, S or V
C = motor phase C, T or W
Connect the ground wire to the chassis
ground screw.
For proper drive operation, you must use
a well shielded, properly grounded cable.
Ferrite filtering is highly recommended
and is essential if your application is
intended to comply with EMC directives
such as the CE Mark. Please contact
Applied Motion Products for technical
advice before connecting a non-Applied
Motion motor.
16
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BLuAC5 S/Q Hardware manual
920-0049 Rev. C
12/8/2014
Recommended Ferrite Core Instructions
At the drive end of the leads, you must twist the power wires, and wrap those wires through
ferrite cores. 4 foot cables require one ferrite with the twisted power wires running through the
core 5 wraps. Longer cables require less turns through the cores, but more cores stacked together as one. In the case of a 10 foot cable, use two ferrite cores stacked as one, and three
wraps. For a 20 foot cable - 3 ferrite cores stacked as one, with three turns through the cores.
You may contact Applied Motion Products for technical advice if needed.
Fuses - External and Internal
External Recommended Fuses:
- recommend Time Lag 6.3A
- Littelfuse 21506.3P (cartridge type, RoHS)
- Littelfuse 21506.3XEP (axial lead type)
Internal Fuses:
Our internal fuses are 6.3 Amp, slo-blow, use same or smaller for installation ahead of the
drive.
If you choose to use a circuit breaker ahead of the drive instead of using slo-blow fuses, we
recommend a surge rated 7.5 to 8.0 Amp circuit breaker.
Line Filters
We recommend Leviton 51000 series surge protection modules, which provide maximum
protection under all conditions. The Leviton modules are required for CE compliance. Corcom
10VR1 filters may be considered for non-CE compliant applications.
Surge Protector with Line Filter:
For 120VAC: Leviton 51010-WM
For 220VAC: Leviton 51240-WM
17
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920-0049 Rev. C
encoder Z+ (5)
Hall 1-(10)
encoder B- (4)
Hall 1+ (9)
encoder B+ (3)
Hall 3+ (13)
Hall 3- (14)
Shield (15)
(12) Hall 2-
(11) Hall 2+
(6) encod er Z-
(1) encod er A+
(7) +5VDC 200mA
(2) encod er A-
(8) GND
Connect shield
to Metal Frame
12/8/2014
BLuAC5 S/Q Hardware manual
Connecting the Encoder & Hall Sensors
Encoder Pinout
The encoder connections use an HD-15 connector. For an Applied Motion A, N or M series
motor, you’ll want to use one of our BLUENC cables. For J-Series motors, use 3004-301-3M
and 3004-307-3M cables (one of each).
If you are using another supplier’s motor, you’ll have to make your own cable according to
the pinout below. See the Mating Connectors section for mating connector information. When
connecting the Encoder and Hall sensors use high quality shielded cables. Connect cable
shield to HD-15 connector housing.
The BLuAC5 servo drive is designed for “Differential” inputs on both the encoder signals and
hall sensors. It is highly recommended that encoders with “Differential Line Drivers” be used
to provide maximum noise immunity. Using the BLUENC cable with AMP servo motors provides the best opportunity for minimizing connection problems.
18
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BLuAC5 S/Q Hardware manual
Single Ended Encoder
encoder A (3)
GND (1)
+5VDC (4)
encoder B (5)
index (2)
Encoder Connector
(8) GND
(5) Z+
(3) B+
(1) A+
(7) +5V
(4) B-
(6) Z-
(2) A-
NC
NC
NC
3.3k
Vcc
330
Vcc
220
Typical Input
Circuit
Single Ended Hall Sensors
V or B
U or A
GND
W or C
Encoder Connector
(7) +5V
NC
NC
NC
220
Vcc
220
Typical
Input
Circuit
+5V
(8) GND
Open Collector
Outputs
Vcc
(10) Hall 1-
(9) Hall 1+
(13) Hall 3+
(14) Hall 3-
(12) Hall 2-
(11) Hall 2+
920-0049 Rev. C
12/8/2014
Connecting a Single-Ended Encoder
Single-ended encoders may be connected to the servo drive as shown below. It some cases
this may cause loss of encoder data. Typically single ended encoders source impedance is
high and cannot drive a terminated transmission line. Because of this single-ended signals
may be more susceptible to “Ground” and induced noise.
NOTE: Not recommend in “High Noise” environ-
Connecting Single-Ended Hall Sensors
Single-ended Hall sensors may be connected to the servo drive as shown below. The output of the Hall sensors must be able to “sink” 10ma of current in order to properly drive the
hall sensor inputs. Typically “Open Collector outputs are best suited to driving the hall sensor
inputs.
NOTE: Not recommend in “High Noise” environments
19
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920-0049 Rev. C
X COMMON
X7 / CW Limit
X3 / Servo Enable
X5
X4 / Alarm Reset
Analog IN-
Analog IN+
X2 / DIR /CCW Jog-
X2 / DIR /CCWJog+
X1 / STEP / CW Jog+
X1 / STEP / CW Jog-
GND
GND
A+
A-
B+
B-
Z+
Z-
+5V OUT
Y COMMON
Y3 / FAULT
Y2 / INPOSN
Y1 / BRAKE
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
2
3
1
19
20
21
22
23
24
25
Encoder
Outputs
X6 / CCW Limit
12/8/2014
BLuAC5 S/Q Hardware manual
IN/OUT 1 Connector
The BLuAC5-S and BLuAC5-Q servo drives have seven digital inputs, one analog input and
three digital outputs located on the IN/OUT 1 connector. All inputs and outputs are programmable using the Quick Tuner software. They can also be congured “on the y” using SCL or
Q commands.
Summary of Input Signals
X1/STEP & X2/DIR: digital 5V differential inputs for commanding position or encoder following.
X3 - X7 are 12-24V single ended inputs:
X3/Servo Enable: Enables and disables the motor and servo system. Can be programmed
for active closed or active open. Note: When connected to Quick Tuner this input can be
overridden by the software.
X4/Alarm Reset: Close this signal momentarily to reset a drive fault (alarm).
X5: general purpose programmable input
X6/CCWLIM & X7/CWLIM: can be used to inhibit motion in a given direction, forcing the
motor and load to travel within mechanical limits.
Analog In: ±10V analog torque, velocity or position command signal. Can also be congured
for +10V, +5V or ±5V signals.
BLuAC5-SE and -QE drives provide an additional 8 digital inputs and one analog input on the
IN/OUT 2 connector.
IN/OUT 1 Connector Pin Diagram
20
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BLuAC5 S/Q Hardware manual
BLU
Servo
Drive
IN/OUT 1
COM
DIR-
DIR DIR+
STEP-
STEP STEP+
Indexer
with
Sourcing
Outputs
BLU
Servo
Drive
IN/OUT 1
+5V OUT
DIR+
DIR DIR-
STEP+
STEP STEP-
Indexer
with
Sinking
Outputs
inside IN/OUT 1
DB-25 PIN
330
X2+
X2-
10
9
330
220
pF
220
pF
X1+
X1-
12
11
920-0049 Rev. C
12/8/2014
High Speed Digital Inputs
The BLUAC5 drives include two high speed inputs called STEP and DIR. They accept 5 volt
single-ended or differential signals, up to 2 MHz. Normally these inputs connect to an external controller that provides step & direction (or step cw and step ccw) command signals. You
can also connect a master encoder to the high speed inputs for following applications.
Connecting to Indexer with Sourcing Outputs
Connecting to Indexer with Sinking Outputs
(includes many PLCs)
(includes Applied Motion Si-1 Indexer)
21
Page 22
920-0049 Rev. C
BLU
Servo
Drive
IN/OUT 1
DIR+
DIR+
DIR- DIR-
STEP+
STEP-
STEP+
STEP-
Indexer
with
Differential
Outputs
BLU Servo
Master
Encoder
GND
DIR-
DIR+
STEP-
STEP+
GND
B-
B+
A-
A+
12/8/2014
BLuAC5 S/Q Hardware manual
Connecting to Indexer with Differential Outputs
(includes Applied Motion Si-100 Indexer)
Using High Speed Inputs with 12-24 Volt Signals
Most PLCs don’t use 5 volt logic. You can connect signal levels as high as 24 volts to the
STEP and DIR inputs if you add external dropping resistors, as shown below.
• For 12 volt logic, add 820 ohm, 1/4 watt resistors
• For 24 volt logic, use 2200 ohm, 1/4 watt resistors
WARNING: The maximum voltage that can be applied directly to a high speed input
terminal is 5 volts. Never apply high voltage AC to an input terminal.
Connecting to a Master Encoder
(for following applications)
22
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BLuAC5 S/Q Hardware manual
BLU
Servo
Drive
+12-24V
X2+
OUT X2-
X1+
OUT X1-
PLC
with
Sinking
Outputs
R
R
BLU
Servo
Drive
+24V OUT
X2+
X2-
X1+
X1-
2200
2200
24V GND
BLUAC
Servo
Drive
+12-24V
GND
X2-
OUT1 X2+
X1-
OUT2 X1+
PLC
with
Sourcing
Outputs
R
R
Connecting to PLC with Sourcing (PNP) Outputs
(Most PLC’s use 24 volt logic)
920-0049 Rev. C
12/8/2014
Connecting to PLC with Sinking (NPN) Outputs
Using Mechanical Switches at 24 Volts.
(Most PLC’s use 24 volt logic)
23
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920-0049 Rev. C
2200
2200
2200
2200
2200
inside IN/OUT 1
XCOM
X3/SRVOEN
X4/ALMRST
X5
X7/CWLIM
X6/CCWLIM
8
7
6
5
3
4
Status
Regen
GND
+24VDC
Input
User Out
+24VDC
GND
12/8/2014
BLuAC5 S/Q Hardware manual
Standard Digital Inputs
As we mentioned in the previous section, the high
speed STEP/PWM and DIR inputs are configured for
five volt logic. All other five digital inputs are designed
for operation between 12 and 24 volts DC. They are
single ended, optically isolated input circuits that can
be used with sourcing or sinking signals, 12 to 24
volts. This allows connection to PLCs, sensors, relays
and mechanical switches. Because the input circuits
are isolated, they require a source of power. If you are
connecting to a PLC, you should be able to get power
from the PLC power supply. If you are using relays or
mechanical switches, you will need a 12-24 V power
supply. This also applies if you are connecting the
inputs to the programmable outputs of another Si product from Applied Motion.
What is COM?
“Common” is an electronics term for an electrical connection to a common voltage. Sometimes “common” means the same thing as “ground”, but not always. In the case of the BLU
Servo, if you are using sourcing (PNP) input signals, then you will want to connect COM to
ground (power supply -). If you are using sinking (NPN) signals, then COM must connect to
power supply +.
User Out 24V supply
The BLUAC5 has a 24 Volt 100ma isolated output
that can be used for powering Digital Inputs or outputs. This convenient power supply can be used in
place of an external supply.
Note: If current is flowing into or out of an input, the logic state of that input is low or closed.
If no current is flowing, or the input is not connected, the logic state is high or open.
The diagrams on the following pages show how to connect the inputs to various commonly
used devices.
24
Page 25
BLuAC5 S/Q Hardware manual
BLU Servo
switch or relay
(closed=logic low)
X3..X7
COM
User Out
+24 VDC
Supply
BLU Servo
+24VDC
GND
BLu Servo
X3..X7
XCOM
Si-1 indexer
MOTION+
MOTION–
12-24
VDC
Power
Supply
-
+
BLU Servo
X3..X7
XCOM
Si drive
OUT+
OUT–
12-24
VDC
Power
Supply
-
+
BLU Servo
NPN
Proximity
Sensor
X3..X7
XCOM
output
+
–
12-24
VDC
Power
Supply
-
+
Digital Input Connection Examples
920-0049 Rev. C
12/8/2014
25
Page 26
920-0049 Rev. C
2200
2200
inside IN/OUT 1
XCOM
CWLIM
CCWLIM
8
3
4
BLU Servo
PNP
Proximity
Sensor
X3..X7
output
+
–
XCOM
12-24
VDC
Power
Supply
-
+
12/8/2014
BLuAC5 S/Q Hardware manual
Connecting Limit Switches to the BLUAC5 Drives
The CWLIMIT and CCWLIMIT inputs are used for connecting end of travel sensors. By connecting switches or sensors that are triggered by the motion of the motor or load, you can
force the motor to operate within certain limits. This is useful if a program or operator error
could cause damage to your system by traveling too far.
The limit inputs are optically isolated. This allows you to choose a voltage for your limit circuits of 12 to 24 volts DC. This also allows you to have long wires on limit sensors that may
be far from the drive with less risk of introducing noise to the drive electronics. The schematic
diagram of the limit switch input circuit is shown below.
BLuAC5 Limit Input diagram
26
Page 27
BLuAC5 S/Q Hardware manual
BLU Servo
+
DC
Power
Supply
–
Limit
Sensor
output
+
–
COM
CW LIMIT
BLU Servo
+
DC
Power
Supply
–
Proximity
Sensor
output
+
–
CW LIMIT
COM
BLU
Servo
+
12-24
VDC
SUPPLY
-
CW LIMIT
XCOM
CCW LIMIT
920-0049 Rev. C
12/8/2014
Wiring a Mechanical Limit Switch
You can use normally open or normally closed limit switches. Either way, wire them as shown
here.
Wiring a Limit Sensor
Some systems use active limit sensors that produce a voltage output rather than a switch or
relay closure. These devices must be wired differently than switches.
If your sensor has an open collector output or a sinking output, wire it like this:
If the sensor output goes low at the limit, select the option “closed” (in the software). If the
output is open, or high voltage, choose “open”.
Other sensors have sourcing outputs. That means that current can ow out of the sensor
output, but not into it. In that case, wire the sensor this way:
27
Page 28
920-0049 Rev. C
IN/OUT 1
GND
20k ohms
A_CH1
A_CH2
+5
AIN+
AIN-
20k ohms
18
1
2
19
+10V to -10V
signal
signal return
IN/OUT 1
GND
AIN+
Single Ended Input
1
19
IN/OUT 1
GND/Shield
GND
±10V
AIN+
Differential Input
±10V
AIN-
1
2
19
12/8/2014
BLuAC5 S/Q Hardware manual
Analog Inputs
The BLuAC5 has two ±10 Volt analog inputs that can be used individually as single ended
inputs or differentially as one input. Analog inputs are used by the servo drive for a number of
dedicated purposes for controlling the servo or they can be used as general purpose analog
signals.
Three dedicated purposes:
• Analog Torque Mode
• Analog Velocity Mode
• Analog Positioning Mode.
Each of these three modes uses the analog input(s) for “commanding” the servo drive.
An analog signal can be also used to stop a “Feed to Sensor” move or to trigger a “Wait on Input”. The analog inputs can be read as variables in the SCL and Q languages and then used
to set nearly any drive parameter.
Basic Specifications:
• Each input can accept ±10 volts.
• The inputs have an impedance of 20K ohms.
• Because of the nature of the design, will
exhibit a 1.4V offset when not driven by an
analog source.
• Low source impedance is important for mini-
mizing analog errors, 100 ohms or lower is
recommended.
WARNING - Analog inputs must be used with care, they are not optically isolated and may not operate properly or could be damaged when system grounds are not compatible.
28
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BLuAC5 S/Q Hardware manual
920-0049 Rev. C
12/8/2014
Wiring a controller with differential output as a singled ended input
If both inputs are to be used for different purposes differential outputs can be connected to a
single input:
Wiring a controller with differential output to differential input
Care must be taken here to establish a good ground connection. The system ground in this
case can be used for the cable shield.
Wiring a potentiometer to a singled ended input
The +5Volt power supply from the servo drive should be used to minimize ground and voltage
difference effect.
29
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920-0049 Rev. C
BLu Servo
YCOM
OUT+
5-24 VDC
Power Supply
+–
Load
inside IN/OUT 1
Y1/BRAKE
YCOM
Y2/INPOSN
Y3/FAULT
14
17
16
15
12/8/2014
BLuAC5 S/Q Hardware manual
Programmable Outputs
The BLUAC5 drives feature three digital outputs:
Y1/Brake: controls an electric brake relay, automatically releasing and engaging as the drive requires
Y3/Fault: closes when a drive fault condition occurs.
The red and green LEDs will ash an error code.
Y2/In Position: indicates that the drive has achieved
a desired goal, such as a target position.
The BLUAC5-SE and -QE have four additional programmable outputs, located on the IN/OUT 2 con-
nector.
The outputs can be used to drive LEDs, relays and the inputs of other electronic devices like
PLCs and counters. The Y1/BRAKE, Y3/FAULT and Y2/INPOSN outputs can only sink current. The YCOM terminal must be tied to power supply (-).
Diagrams for various connections follow.
Do not connect the outputs to more than 30VDC.
The current through each output terminal must not exceed 100 mA.
Sinking (High Side) Load
30
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BLuAC5 S/Q Hardware manual
GND
A+
A-
B+
B-
Z+
Z-
Front View
18
17
16
15
14 13
12
11
10
9
8
7
6
5
4
2
3
1
19
20
21
22
23
24
25
Encoder
Outputs
BLu Servo
YCOM
OUT+
1N4935 suppression diode
5-24 VDC
Power Supply
+–
relay
920-0049 Rev. C
12/8/2014
Driving a Relay (Protective Diode Required)
Encoder Outputs
In some applications you may wish to read the encoder signals being generated by the motor, may be to feed to another drive set in following mode. The DB-25 I/O connector includes
encoder output signals for this purpose. The outputs are “Differential Line Driven” signals that
provides buffering from the source encoder signals.
Encoder Outputs (IN/OUT 1 Connector)
31
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920-0049 Rev. C
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
2
3
1
19
20
21
22
23
24
25
+5V
Out 1-
Out 2+
Out 1+
Ain Com
N/C
Ain 1
IN 8-
COM
IN 5
IN 6
IN 7+
IN 8+
IN 7-
IN 4
IN 1
COM
IN 2
COM
IN 3
Out 2-
Out 3+
Out 3-
Out 4+
Out 4-
IN/OUT 2
-SE and -QE only
2200
2200
2200
2200
2200
2200
inside IN/OUT 2
COM
COM
IN1
IN2
IN3
IN4
IN5
IN6
2200
IN7+
IN7-
2200
IN8+
IN8-
COM
1
DB-25 PIN
2
3
4
5
6
7
8
9
10
11
12
13
BLuAC5 S/Q Hardware manual
12/8/2014
IN/OUT2 Connector (-SE and -QE only)
The BLUAC5-SE and the BLUAC5-QE have a second DB-25
I/O connector labeled IN/OUT 2. This provides:
8 optically isolated digital inputs IN1 - IN8
4 optically isolated digital outputs OUT1 - OUT4
one 0 - 5 volt analog input, 10 bit ADC resolution
Single Ended Inputs
IN1 - IN6 are single ended, 12 - 24V inputs. They can, as a
group, be configured to accept current sourcing (PNP) signals
by tying one of the COM terminals to the return of the I/O
power supply. If the COM terminals are connected to the + I/O power supply then the inputs
1 - 6 will accept sinking (NPN) signals. Because the input circuits are isolated, they require
a source of power. If you are connecting to a PLC, you should be able to get power from the
PLC power supply. If you are using relays or mechanical switches, you will need a 12-24 V power
supply. This also applies if you are connecting the
inputs to the programmable outputs of another Si
product from Applied Motion.
Differential Inputs
IN7 and IN8 are differential, 12 - 24V inputs. They
can individually be configured to accept current
sourcing (PNP) or current sinking (NPN) signals.
Note: If current is flowing into or out of an input, the
logic state of that input is low or closed. If no current
is flowing, or the input is not connected, the logic
state is high or open.
The diagrams on the following pages show how
to connect the inputs to various commonly used
devices.
32
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BLuAC5 S/Q Hardware manual
1-10kW
pot
cw
ccw
BLU-QE/SE
GND
AIN
+5
920-0049 Rev. C
12/8/2014
Connecting to the Analog Input on the IN/OUT 2 Connector
The analog input on the IN/OUT 2 connector can be used by “Feed to Sensor” commands
and other input functions when operating the drive in “Host” mode. The analog input can also
be read back to the “Host” using the “IA3” immediate command. Readings are in Volts. See
“BLu Servo Host Command Reference” for more information.
+5 volt DC is provided for powering potentiometers. A 1000 to 10000 ohm potentiometer is
recommended and should be connected as shown below.
A 0 to 5 volt analog signal may also be used. Usually this signal comes from a PLC, a PC
with data acquisition card or a motion controller. Connections are shown below.
The +5V terminal is an output. Do not connect it to a power supply.
Connecting the Analog Input to a Potentiometer
Connecting the Analog Input to an Active Signal
0 - 5V
speed signal
signal return
BLU-QE/SE
AIN
GND
33
Page 34
920-0049 Rev. C
PLC
BLu-QE/SE
12-24 VDC
Power Supply
+ –
OUT-
OUT+
IN
COM
BLu Servo
YCOM
OUT+
5-24 VDC
Power Supply
+–
Load
inside IN/OUT 2
OUT1+
OUT1-
OUT2+
OUT2-
OUT3+
OUT3-
OUT4+
OUT4-
20
19
18
22
21
24
25
23
12/8/2014
BLuAC5 S/Q Hardware manual
Programmable Outputs on the IN/OUT 2 Connector
The IN/OUT 2 connector provides four additional
programmable outputs, OUT1 - OUT4.
The outputs can be used to drive LEDs, relays and
the inputs of other electronic devices like PLCs and
counters. The “+” (collector) and “-” (emitter) terminals of each phototransistor are available at the connector. This allows you to configure each output for
current sourcing or sinking.
Diagrams for various connections follow.
Do not connect the outputs to more than 30VDC.
The current through each output terminal must not
exceed 100 mA.
Connecting an IN/OUT 2 output to a PLC
Sinking (High Side) Load
34
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BLuAC5 S/Q Hardware manual
BLu Servo
YCOM
OUT+
1N4935 suppression diode
5-24 VDC
Power Supply
+–
relay
Driving a Relay (Requires Protective Diode)
920-0049 Rev. C
12/8/2014
35
Page 36
920-0049 Rev. C
12/8/2014
BLuAC5 S/Q Hardware manual
Recommended AMP Motors
Alpha A Series
Part Current Power Size
Number amps Watts Volts mm
A0400-101-4 5.2A 400 100 60
A0400-102-4 3.2A 400 200 60
A0600-102-5 4.2A 600 200 80
A0800-102-5 4.6A 800 200 80
A0950-103-5 4.5A 950 200 80
M Series
Part Current Power Size
Number amps Watts Volts mm
M0400-101-4 5.6A 400 100 60
M0400-102-5 2.7A 400 200 80
M0600-102-5 4.5A 600 200 80
M0750-102-5 4.9A 750 200 80
N Series
Part Current Power Size
Number amps Watts Volts NEMA
N0400-101-B 5.6A 400 100 23
N0400-102-C 2.7A 400 200 34
N0600-102-C 4.5A 600 200 34
N0750-102-C 4.9A 750 200 34
J Series
Part Current Power Size
Number amps Watts Volts mm
J0100-301-3 1.65A 100 120/220 VAC 40
J0200-301-4 2.8A 200 120 VAC 60
J0200-302-4 1.4A 200 220 VAC 60
J0400-301-4 5.5A 400 120 VAC 60
J0400-302-4 2.7A 400 220 VAC 60
J0750-302-5 4.5A 750 220 VAC 80
Note: to connect AMP motors to a BLU servo drive, an extension cable is required. They are
available in lengths of 4, 10 and 20 feet. Please contact your distributor or call the factory to
order.
36
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BLuAC5 S/Q Hardware manual
920-0049 Rev. C
12/8/2014
Other Supplier’s Motors
If you want to use a motor other than those recommended here, it must be a three phase motor with 120° commutation timing. The motor must also have an incremental encoder (index
signal is not required) with no fewer than 50 lines and no greater than 32,000 lines. The halls
and encoder must operate from +5VDC, 200 mA max (supplied by the BLU drive). The hall
signals may be single-ended or differential. We strongly recommend that the encoder have
differential line driver outputs, but single-ended may be acceptable if you use a shielded
cable.
If using other motors than AMP’s you will need a ferrite bead on each motor lead, with the
wire wrapped several turns - please refer to the section on wiring ferrites, page 17, or call an
Applied Motion Products service representitive.
The BLU servo drives feature sine commutation, which makes motors run more smoothly
than trapezoidal drives. If you choose a low cost motor with internal hall effect devices in-
stead of a quality motor with precision commutation tracks on the encoder disk, your performance may suffer.
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Setting Drive Current Limits
The BLUAC5 allows the user to set both the Motor Continuous and Peak current limits. Current settings are an RMS value. Using the QuickTuner™ the current settings can be uploaded
and downloaded.
Setting the current limits requires the user to know the limitations of the motor. In most cases
referring to the motor manufacturers specification will give the proper information. For AMP
motors, motor settings are available in parameter files that are located on the PC where
QuickTuner™ was installed.
What is “Peak Current Limit”?
The BLUAC5 uses this current value to establish the maximum possible RMS current that
will be driven to the motor. The peak current time is set to one second. That is, if the drive
attempts to run at peak current for more then one second it will fold back the current to the
continuous current setting.
The peak current time is actually calculated on a curve using an I²/T method. For current
values that are less than the peak but greater than the continuous, the current foldback time
is calculated from the peak and continuous settings. As shown in the diagram below, current
values below the peak value can be used for longer periods of time.
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DC Bus
Motor Encoder
C B A
320V pk
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Using DC Brushed Motors
DC Brushed motors can be used with the servo drive simply by connecting the motor and
encoder to the drive as show below and configuring the drive using the AMP Quick Tuner™
configuration tool.
Before connecting the Brushed motor to the servo drive you need to determine the motors
polarity. That is, we need to know which wire is positive and which is negative. When applying
DC power to the motor it needs to spin clockwise. After determining this, the wire connected
to the positive of the DC power should be labeled at such.
Connecting the wires as shown. Positive to “A” phase and negative to “B” phase.
If an Encoder is being used Connect the Motor’s Encoder as explained earlier in this manual.
Using QuickTuner™, select “Brush Motor” on the “Motor - Encoder” tab. Remember to set the
counts per turn in the “Encoder” setting. If the encoder is “Single Ended” be sure and check
the box.
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Servo Drive Regeneration
The BLuAC5 servo drive comes with a regeneration clamp circuit and power dump resistor
built in. The circuit is designed to handle any power level that the drive is able to put out but
the internal power dump resistor is not.
The internal power resistor is rated at a continuous 50 watts. This may not be adequate in
cases where the load has a high inertia content and very little frictional content. For these
cases, an external power resistor may be connected to the drive. The minimum size should
be 40 ohms, 50 Watts. A typical value is 50 ohms, 100 Watts. When using an external power
resistor the regeneration parameters must be changed using the QuickTuner™ configuration
tool. See example below.
We offer an external regeneration resistor assembly specifically designed for the BLUAC5.
The part number is RA-100, See page 44 for details.
Now comes the first question. How do I know if an external power resistor is needed?
There are two methods:
1. Calculation - Based on your load and operating conditions you can calculate the
power in watts that will be regenerated. (I know everybody will choose this method)
2. Trial & Error - After operating the system the drive faults and displays a “Regen” error (small “r”). Keep sizing up the resistor until it can withstand the regeneration.
And the second question is - How do I hook it up? See the diagram below.
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Y COMMON (pin 17)
Y1 / Brake (pin 14)
24 VDC
power
supply
BLUE brake lead
YELLOW brake lead
24 VDC relay
clamp diode
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Wiring Integral Holding Brakes
The integral holding brakes of AMP servo motors require between 200 and 400 mA at 24
VDC to operate properly. To wire and operate a holding brake from the Y1/Brake output of an
Applied Motion servo drive requires the following items:
• A 24 VDC power supply with minimum output of 450 mA
• A 24 VDC relay*
• A clamp diode such as 1N4935*
• An AMP servo motor with integral holding brake, designated by a “5” in the 7th position of
the motor part number. Example: M0400-151-4-000
• A “BK” type motor power cable or separate brake cable. Example: BLUMTR-BK-FA-10
* Relays with an integral clamp diode, like IDEC part number RU2S-D-D24, greatly simplify
the wiring effort by including the relay and a clamp diode in one unit.
Following the diagram below, connect the power supply, relay, and diode to the brake leads of
the servo motor, as well as the Y1/Brake output connections of the servo drive.
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Motor Power (W) 30 50 100 100 200 400 200 400 600 750
Motor Frame Size
NEMA 17
40 mm
NEMA 17
40 mm
NEMA 17
40 mm
NEMA 23
60 mm
NEMA 23
60mm
NEMA 23
60 mm
NEMA 34
80 mm
NEMA 34
80 mm
NEMA 34
80 mm
NEMA 34
80 mm
Rate d Voltage
Static Friction (in-lb)
Input Power (W) 9
Input Curr ent (A) 0.375
Arm ature Releas e
Tim e (mse c Max)
20
Arm ature Pull-In
Tim e (mse c Max)
40
9.5
0.39
50
80
20
50
9.5
0.39
50
80
20
40
24 VDC
2.83 11.24 22.5
5
0.2
9
0.375
BLuAC5 S/Q Hardware manual
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The holding brakes of M Series servo motors are fail-safe brakes, which means they are engaged when no power is applied to the brake. When setting up a servo drive in Quick Tuner,
be sure to set the Brake output options in the “Inputs-Outputs” tab as shown in the diagram
below. Make sure to select the check box for “Automatically release brake when moving by”
and selecting the radio button “closing the Brake output”.
The engaging and disengaging of the brake is done automatically by the servo drive. When
the drive is enabled and not faulted the brake will be disengaged. When the drive is disabled
and/or faulted the brake will be engaged.
There are two time delays associated with the Brake output function which are also set in
Quick Tuner (see diagram above). The first time delay controls how long the drive will delay
a move command if the move command immediately follows the disengagement of the brake.
The second time delay controls how long the drive will delay disabling the motor after engaging the brake when a motor disable command is issued.
Reference Information
Below is a summary of specifications for the integral holding brakes available with M Series
servo motors.
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4.848
7.800
2X 3.50
7.400
2.70
5.050
1.32
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Mounting the Drive
These drives can be mounted on the narrow side or the wide side. Either way, you’ll need
two #6 screws to secure the drive using the 0.2” mounting slots. The hole pattern and drive
outline are shown below.
•Never use your drive in a space where there is no air flow or where other devices cause the sur-
rounding air to be more than 40 °C.
•Never put the drive where it can get wet or where metal particles can get on it.
•Always provide air flow around the drive.
Mechanical Outline
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Technical Specifications
Amplifier
Digital Inputs
Analog Inputs
Outputs
24V Output
Encoder Output
Sine commutation IGBT. 16 kHz PWM.
90 - 260 VAC input
5A continuous, 15A peak
Step & Direction: differential, optically isolated, 5V logic. 330
ohms internal resistance.
0.5 µsec minimum pulse width. 2 µsec minimum set up time for direction
signal.
All other digital inputs: optically isolated, 12 - 24V logic. 2200 ohms.
Maximum current: 10 mA
±10VDC, 12 bit ADC
With Expanded I/O board: 0 to 5 VDC, 1K - 10K recommended impedance. 10 bit ADC
Photodarlington, 100 mA, 30 VDC max. Voltage drop: 1.2V max at 100
mA.
24VDC @ 100ma
26C31 line driver
Physical
2.70 x 4.848 x 7.80 inches overall. 2 lb 3.1 oz
Ambient temperature range: 0 to 40° C.
Mating Connectors and Accessories
Mating Connectors
Motor/Regen: Mating connector included. Phoenix P/N 1767012.
AC Input: Mating connector included. Phoenix P/N 1767025.
Brake: Mating connector included. Phoenix P/N 1766990.
RS-485: Mating connector included. PCD P/N ELVP05100.
I/O: DB-25 male. Mating connector included. AMP P/N 747912-2.
Shell Kit AMP P/N748678-3.
Motor feedback: HD-15 male. Norcomp P/N 180-015-102-001. Shell Kit AMP P/N 748678-1.
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Accessories
Motor Cables for Applied Motion “A”, “N” and “M” series servo motors:
BLUMTR-FA-04, four foot shielded and filtered cable
BLUMTR-FA-10, ten foot shielded and filtered cable
BLUMTR-FA-20, twenty foot shielded and filtered cable
Motor Cables for Applied Motion “J” series servo motors:
3004-307-3M, nine foot shielded and filtered cable
Encoder Cables for Applied Motion “A”, “N” and “M” series servo motors:
BLUENC-CA-04, four foot shielded cable
BLUENC-CA-10, ten foot shielded cable
BLUENC-CA-20, twenty foot shielded cable
Encoder Cables for Applied Motion “J” series servo motors:
3004-301-3M, nine foot shielded cable
Breakout Box for IN/OUT Connectors:
BOB-1, for IN/OUT 1, includes cable
BOB-2, for IN/OUT 2, includes cable (sometimes known as “BABS” because it’s a female
version of the BOB-1)
Screw Terminal Connectors that mate directly to the IN/OUT connectors on the front panel of
the drive:
Phoenix Contact P/N 2761619 (for IN/OUT 2) and 2761622 (for IN/OUT 1)
This connector is not available from Applied Motion.
You must purchase it from a Phoenix distributor.
Mating Cable for IN/OUT connectors with “ying leads”
Black Box P/N: BC00702
This cable is not available from Applied Motion. You must purchase it from Black Box.
Useful for custom wired applications. This shielded cable has a DB-25 connector on each
end. If you cut it in half it will provide 3 foot “DB-25 to ying lead cables” for both IN/OUT1
and IN/OUT 2.
It’ll be easier to wire if you get the cable color chart from Black Box’s website.
Surge Protector with Line Filter:
For 120VAC: Leviton 51010-WM
For 220VAC: Leviton 51240-WM
External Regen. Resistor Assembly
Specifically designed for the BLuAC5: RA-100 available from Applied Motion Products.
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Applied Motion Products, Inc.
404 Westridge Drive Watsonville, CA 95076
Tel (831) 761-6555 (800) 525-1609 Fax (831) 761-6544
www.appliedmotionproducts.com
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