Baldor BSC 2000, BSC 3000 installation Guide

BSC Series 2000/ 3000

Servo Control

Installation & Operating Manual

7/92

C O N T E N T S

1.0	Specifications ...............................	1
1.1	Usage Definitions .......................	1
1.2	Identification ..............................	1
1.3	Features .....................................	1
1.4	Declaration of Conformity ..........	2
1.5	EMC Conformity and CE Marking	2
1.5.1	EMC Installation Instructions .....	2
1.5.2	Specifications add components ..	3
1.5.2.1	Mains Filters ..............................	3
1.5.2.2	Connection Cables .....................	4
1.5.2.3	Screen Connections ....................	4
1.5.2.4	Connectors ................................	4
1.5.2.5	PG-Cable Glands .......................	5
1.6	Technical Data ...........................	5
1.6.1	Power Section ............................	5
1.6.2	24VDC Input .............................	6
1.6.3	Velocity Controller ....................	6
1.6.4	Mechanical Section ....................	6
1.6.5	Environmental Section ...............	7
2.0	Installation Recommendations ....	7
2.1	Mechanical Installation ...............	7
2.2	Electrical Installation ..................	8
3.0	Interconnection Diagram .............	9
4.0	BSC Wiring ..............................	10
4.1	Power Wiring .............................	10
4.1.1	Power Supply .............................	10
4.1.2	24VDC Connection ....................	10
4.1.3	Motor Wiring .............................	10
4.2	Controland Signal Wiring .........	11
4.2.1	Control Inputs ............................	11
4.2.2	Control Outputs .........................	12
4.2.3	Command Input .........................	13
4.2.4	Encoder Output .........................	13
4.2.5	Resolver .....................................	13
4.3	Minimum Wiring Diagram ..........	14

5.0	Dimensions ...................................	16
6.0	System Set Up Procedure ............	18
6.1	Presets .......................................	18
6.1.1	Potentiometer Preset ..................	18
6.1.2	DIP-Switches Settings ................	18
6.2	System Set Up Step by Step .......	19
6.3	System Tuning ...........................	20
7.0	Status Monitor .............................	22
8.0	Testsignals ....................................	23
9.0	Identity Modul .............................	23
9.1	Component Functions ................	23
9.2	Component Layout ....................	24
10.0	I/O Hardware Description ...........	24
10.1	Input Signals ..............................	25
10.2	Output Signals ...........................	26
10.3	Encoder Output .........................	27
10.3.1	Encoder Signals .........................	27
10.4	Resolver .....................................	28

1

1.0Specification

1.1Usage Definitions

The amplifiers of the series BSC2000/3000 are electrical equipment for industrial power installations. They are designed for machine applications, which need variable speed controlled three-phase A.C. motors.

This product is only for use in industrial applications as described in norms EN 60204 and VDE 0160. This means use BSC2000/3000 in stationary groundbased applications only. It is not meant for use in home appliances, medical technics, cars, ships or airplanes.

Before the BSC is put into operation, please contact your Electric-Supply-Company for special operating conditions.

1.2 Identification

BSC x x xx - xx

{24 - External 24VDC-Input MR - Multiresolvercard

{	45
	15

	25	Nominal Current (Amps)
	35

{20 : Series 2000

30 : Series 3000

BALDOR-SERVO-CONTROL

1.3 Features

A BSC is an analog 1 axis amplifier with integrated power stage.

It provides the following features:

POWER SECTION:	• Output power up to 30kVA
• 3 respectively 4 output current versions (15/25/35/45A)
available.	• Brushless-servomotors (2 to 8 poles) can be connected.
• Ratio peak : nominal current = 2:1.	(Feedback: 2-pole resolver)
Both values independently adjustable.	• Power wiring via terminal screws (max. wiring diameter
• All BSC amplifiers are short circuit proof and require	10mm²/AWG7)
no minimum load.
CONTROL I/O Section:	• Wiring of control inputs and outputs via plug type
• 5 opto isolated control inputs for dedicated amplifier
functions	screw connection (max. wiring diameter 1,5mm²/
• Diagnostic display on front panel	AWG15) or SUB-D connector
GENERAL:	• Isolation classification according to DIN 0110 with
• Protection class IP20 (acc. to DIN40 050 / IEC144)	overvoltage category II
• Cooling: self-ventilation	• Contamination level 2

2

1.4 Declaration of Conformity

Herewith we declare, that our products are components only and not ready for immediate or instant use within the meaning of "Safety law of appliance", "EMC Law" or "Machine directive".

The final mode of operation is defined only by the insertion into the user´s construction.

It is the responsibility of the user to verify that his construction is in accordance with existing regulations.

It is prohibited by law to put the machine into operation before verifying that the machine is in accordance with EC directive 89/392 and 921/368.

The supplier declares product conformity with the following standards:

DIN VDE 0160	/ 05.88		Electronic equipment for use in electrical power installations
DIN VDE 0100			Erection of power installations with nominal voltages up to 1000V
DIN IEC 326 Part 1 / 10.90			Design and use of printed boards
DIN VDE 0110	Part 1-2 / 01.89 Dimensioning of clearance and creepage distances
DIN VDE 0110 Part 20 / 08.90
EN 60529 / 10.91		Degrees of protection provided by enclosures

1.5 EMC - Conformity and CE - Marking

The application of EMC conformal component and partly systems relieves the observance of EMC Guidelines and the guaranty of conformity for the manufacturer of machines. Therefore all standard components and partly systems will be tested according to the requirements of EMC regulation. Those tests will be executed by a competent and indepen-dent institution. The conformity of the products will be confirmed by a declaration of conformity from the European Community. The installation instructions refer to elimination of radio interference as well as to immunity from noise for BALDOR Drive Systems.

Thereby the user is informed about the EMC critical parts. The examples don´t show the complete possibilities of cabinet components or constructions.

Guidelines for EMC Conformity

	Machine Guideline (89/392/EWG)	- Machine Safety Law
	Application since 01.01.95
	EMV Guideline (89/336/EWG)	- EMC Law
	Applicade 01.01.96 on
	Low Voltage Guideline (73/23/EWG)	- Machine Safety Law
	Applicade 01.01.97 on

1.5.1 EMC Installation Instructions

To ensure electromagnetical compatibility (EMC) at hostile environment inside the cabinet following instructions are to be observed for construction. Only the implementation of following provisions enables the reduction of interference down to required values.

For the Drives Technology following key points are to be considered:

-Grounding

-Screening

-Filtering

3

Furthermore the relevant chapters of the Installation manual for the controllers have to be observed. For installation of the drives system the starting point is the installation into a cabinet.

For construction of a cabinet the following installation instructions have to be considered:

A)All metal conducting parts of a cabinet are to be connected arealy and conductable.Eventually the connections should be placed with an earthing strap at a central grounding point .1)

B)Signal lines and Power Cables are to be connected separately. (Avoid interaction space)

C)The screen connection of the signal lines and the power cables has to be ensued on a screen linequaranteeing enough space. This screen line also has to be conductable and connected to

the remaining housing parts.

D)The cable to the regeneration resistor has to be screened. The screen connection should be on both sides.

E)The mounting of the mains filter has to be situated at the input of the cabinet or behind the transformer. The filter is to connect on ground (cabinet housing, mounting plate etc.).

F)Wiring has to be conducted bundled and close to the cabinet housing or at the mounting line. The unused leads of a cable have to be connected on one side with ground. 1)

G)In case of worse potential balance between the screen connections a compensating leak with at least 10mm2 (AWG) has to be provided parallely in addition to reduction of the screen current.

1)Grounding in general describes all metal parts which can be connected to a protective conductor, e.g. housing of switch cabinet, motor housing, fundament grounder.

1.5.2 Specifications and Additional Components

1.5.2.1 Mains Filter

Following results are desired through the application of mains filters:

The electronic system should be protected from high frequency interferences which could enter via the mains cable (immunity from noise) and vice versa the mains cable may not transmit interferences from the electro-nic systems to the adjoining components (elimination of radio interference).

In the main line a mains input filter has to be provided between transformer and controller (In case of direct connecton this has to be in front of the controller).

To choose the fitting mains filter types following points have to be considered:

1.The need of power of the connected controller. Thereby the capacity and the ability of peak phase current has to be considered.

2.The required or prevailing mains impedance.

This table shows the corresponding mains filter types for 3 phase input:

		Rated Voltage	Rated Current	Leakage	Power	Weight	BALDOR
Type			(at 40°C)	Current	Losses		-
		[V]	[A]	[mA]	[W]	[kg]	ID-No
FN 351 - 8 - 29		3x 440	8	16	8.0	1.8	24667
FN 351 - 16		3x 440	16	16	9.0	1.8	24668
FN 351 - 25		3x 440	25	170	9.0	3.0	24669
FN 351	- 36	3x 440	36	170	10.5	3.0	24670
FN 351	- 50 - 29	3x 440	50	190	12.5	3.1	24671
FN 351	- 80 - 29	3x 440	80	210	26.0	9.5	24672
FN 351	- 110 - 29	3x 440	110	210	28.0	9.5	24673

1.5.2.2		Connection Cables	4
All cables have to be screened.
		Motorcable and Signalcable		BALDOR
				ID - No.
		Motorcable	4 x 1.0 mm2	21599
		Motorcable	4 x 2.5 mm2	21364
		Motorcable	4 x 6.0 mm2	21597
		Resolvercable	3 x [2 x 0.14 mm2]	19413
		Regen Resistorcable	3 x 2.5 mm2	11302
1.5.2.3		Screen Connection

Siemens Clamp			Siemens -No.
5mm Rail	Wiring Diameter		8US19 21	-2AA00
	1.5 - 16 mm2
	1.5 - 35 mm2			-2AB00
	16	- 70 mm2		-2AD00
	16	- 120 mm2		-2AC00
10mm Rail	Wiring Diameter		8US19 41	-2AA00
for T- and double T-profile	95	- 300 mm2

1.5.2.4 Connectors

Connection	Designation	BALDOR - ID -No.
for Motorcable
Plug	CONN SET FEM	2 x 4 pole		24654A
Socket	CONN SET MALE	2 x 4 pole		24656A
for Resolvercable
Plug	CONN SET FEM	12/6 pole		24655A
Socket	CONN SET MALE	12/6 pole		24657A
	for BSC with EMC-Regulation
	connector X2 with housing
Connector			25043A
Housing			25049A

5

1.5.2.5 PG - Cable Glands

PG Cable Gland	Cable Dimensions	Designation	BALDOR
			ID - No.
	4 - 8 mm	SCREWING	24658
PG 9	Resolvercable
	BALDOR ID-No.19413
	6 - 12 mm	SCREWING	24659
PG 13.5	Motorcable
	BALDOR ID-No. 21599
	13 - 18 mm	SCREWING	24660
PG 21	Motorcable
	BALDOR ID-No. 21364

1.6 Technical Data

All values at Tamb = 40 °C, if not otherwise specified.

1.6.1 Power Section

General	Unit	BSC	BSC		BSC	BSC	BSC	BSC	BSC
		2015	2025		2035	2045	3015	3025	3035
Nominal DC-Bus-Voltage	VDC			320				-
Uin (BPS) = 230V
Nominal DC-Bus-Voltage	VDC			-				560
Uin (BPS) = 400V
Nominal DC-Bus-Voltage	VDC			-				650
Uin (BPS) = 460V
DC-Bus-Voltage	VDC		0 ... 350					0 ... 740
absolute min./max.
Output Voltage Line/Line	VRMS		0 ... 250					0 ... 500
fundamental wave; @VDC-Bus (nom.)
Nominal Phase Current (±10%)	ARMS	15	25		35	45	15	25	35
Peak Phase Current (±10%)	ARMS	30	50		70	90	30	50	70
1.5s ±0.5s
Nominal Output Power	kVA	6.5	10.8		15.1	19.5	13.0	21.6	30.3
Efficiency	%					> 95
Min. Load Inductance	μH					200
Output Frequency	Hz					0 ... 500
Nominal Switching Frequency	kHz					8.5

6

1.6.2 24VDC Input

	24V-Input	Unit	BSC2000		BSC3000
	Input Voltage Range
	absolute min./max.	VDC		20 ... 29
	max. VRipple = ±10%
	Input Current; @ 28VDC	ARMS		1.6
	Surge Current at Power On	ARMS		2.5
	@ 28VDC; @ 100ms
1.6.3 Velocity Controller

Preamplifier	Unit	BSC2000		BSC3000
Command Input	VDC		0 .. ±10
Drift (velocity controller)	rpm/K		0.4
Balance (velocity controller)	rpm		typ. 8; adjustable to 0

	Resolverfeedback		Unit	BSC2000			BSC3000
	Resolution		bit		12
	Encoder-Simulation		ppr	250 / 500 / 1000 / 1024
	Signal			5V TTL ; A;A/; B;B/; C;C/
	Reference Pulse			available; non adjustable
1.6.4 Mechanical		Section
	Mechanical		Unit	BSC2000			BSC3000
	Mounting		-	Bookstyle or Thru the Wall
	Dimensions		mm	105 x 357 x 328	/ 140 x 357 x 328 1)
	Weight		kg	8.5	/		9.5 1)
1)	: BSC2045/3035

7

1.6.5 Environmental Section

Environmental	Unit	BSC2000		BSC3000
Operating Temperature Range	°C		+5 ... +45
Storage Temperature Range	°C		-25 ... +70
Humidity	%	10 ... 90; not condensating; according to DIN40 040, Class F
Class of Protection (Enclosure)	-	IP20; according to DIN40 050 / IEC 144
Max. Installation Altitude / M.S.L.	m		1000
Shock	-	10G; according to DIN IEC 68-2-6/29
Vibration	-	1G; 10 ... 150 Hz; according to DIN IEC 68-2-6/29

Legend:

This is an INFORMATION sign.

If this information is read, installation and / or amplifier operating problems can be avoided in advance.

This sign means ATTENTION.

In all cases it must be read and taken into account.

Non-observance can cause dangerous situations for equipment and personnel.

2.0Installation Recommendations

2.1Mechanical Installation

-For installation of your system use a cabinet with a protection class that suits your environmental conditions.

-As cooling air freely enters the unit, the environment must be free from corrosive chemical substances, oil, vapour, steam, metal particles and dust.

-Make sure that cooling is provided.

-Make sure that the top of the unit is covered during installation to prevent particles from falling into the unit.

-Keep DC-bus links as short as possible. Therefore always mount BSC2000/3000-combinations side by side.

-Mount all BSC vertical (Terminal blocks to the top).

-Use BSC2000/3000 in stationary groundbased applications only.