Baldor BSC 2000, BSC 3000 installation Guide

BSC Series 2000/ 3000

Servo Control

7/92

Installation & Operating Manual

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 Control- and 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

L

1.0 Specification

1.1 Usage 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-I nput

{

MR - Multiresolvercard

15
25

Nomin al C urrent (Amps)

35

{

45

1.3 Features

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

It provides the following features:

POWER SECTION:

• 3 respectively 4 output current versions (15/25/35/45A)
available.

• Ratio peak : nominal current = 2:1.
Both values independently adjustable.

• All BSC amplifiers are short circuit proof and require
no minimum load.

CONTROL I/O Section:

• 5 opto isolated control inputs for dedicated amplifier
functions

• Diagnostic display on front panel

GENERAL:

• Protection class IP20 (acc. to DIN40 050 / IEC144)

• Cooling: self-ventilation

20 : Series 2000

{

30 : Series 3000

BALDOR-SERVO-CONTRO

• Output power up to 30kVA

• Brushless-servomotors (2 to 8 poles) can be connected.

(Feedback: 2-pole resolver)

• Power wiring via terminal screws (max. wiring diameter
10mm²/AWG7)

• Wiring of control inputs and outputs via plug type
screw connection (max. wiring diameter 1,5mm²/
AWG15) or SUB-D connector

• Isolation classification according to DIN 0110 with
overvoltage category II

• 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 .

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.

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)

1)

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 an d 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:

Type

FN 351 - 8 - 29
FN 351 - 16
FN 351 - 25
FN 351 - 36
FN 351 - 50 - 29
FN 351 - 80 - 29
FN 351 - 110 - 29

Rated Voltage

[V]

3x 440 8 16 8.0 1.8 24667
3x 440 16 16 9.0 1.8 24668
3x 440 25 170 9.0 3.0 24669
3x 440 36 170 10.5 3.0 24670
3x 440 50 190 12.5 3.1 24671
3x 440 80 210 26.0 9.5 24672
3x 440 110 210 28.0 9.5 24673

Rated Current

(at 40°C)

[A]

Leakage

Current

[mA]

Power
Losses

[W]

Weight

[kg]

BALDOR

-

ID-No

1.5.2.2 Connection Cables

All cables have to be screened.

Motorcable and Signalcable

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

4

BALDOR

ID - No.

5mm Rail Wiring Diameter

10mm Rail
for T- and double T-profile

1.5.2.4 Connectors

Connection Designation BALDOR - ID -No.

for Motorcable
Plug
Socket

for Resolvercable
Plug
Socket

Connector
Housing

Siemens Clamp Siemens -No.

2

1.5 - 16 mm

1.5 - 35 mm
16 - 70 mm
16 - 120 mm
Wiring Diameter
95 - 300 mm

CONN SET FEM
CONN SET MALE

CONN SET FEM
CONN SET MALE

for BSC with EMC-Regulation

connector X2 with housing

2

2

2

2

8US19 21 -2AA00

8US19 41 -2AA00

2 x 4 pole
2 x 4 pole

12/6 pole
12/6 pole

25043A
25049A

-2AB00

-2AD00

-2AC00

24654A
24656A

24655A
24657A

1.5.2.5 PG - Cable Glands

PG Cable Gland Cable Dimensions Designation BALDOR

PG 9

PG 13.5

PG 21

4 - 8 mm
Resolvercable
BALDOR ID-No.19413
6 - 12 mm
Motorcable
BALDOR ID-No. 21599
13 - 18 mm
Motorcable
BALDOR ID-No. 21364

1.6 Technical Data

All values at T

= 40 °C, if not otherwise specified.

amb

1.6.1 Power Section

5

ID - No.

SCREWING 24658

SCREWING 24659

SCREWING 24660

General Unit BSC

2015

Nominal DC-Bus-Voltage
Uin (BPS) = 230V
Nominal DC-Bus-Voltage
Uin (BPS) = 400V
Nominal DC-Bus-Voltage
Uin (BPS) = 460V

DC-Bus-Voltage
absolute min./max.
Output Voltage Line/Line
fundamental wave; @V
Nominal Phase Current (±10%) A
Peak Phase Current (±10%)

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

DC-Bus (nom.)

VDC 320 -

VDC - 560

VDC - 650

VDC 0 ... 350 0 ... 740

V

0 ... 250 0 ... 500

RMS

15 25 35 45 15 25 35

RMS

A

30 50 70 90 30 50 70

RMS

BSC
2025

BSC
2035

BSC

2045

BSC
3015

BSC
3025

BSC
3035

Output Frequency Hz 0 ... 500
Nominal Switching Frequency kHz 8.5

6

1.6.2 24V

24V-Input Unit BSC2000 BSC3000

DC

Input

Input Voltage Range
absolute min./max.
max. V
Input Current; @ 28VDC A
Surge Current at Power On
@ 28VDC; @ 100ms

Ripple

= ±10%

VDC

1.6

RMS

A

2.5

RMS

20 ... 29

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.

2.0 Installation Recommendations

2.1 Mechanical 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.