Kollmorgen BDS5 Installation And Setup Manual

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UPGRADE NOTICE for BDS5T / VSA

The following are features of the MC3 board that is incorporated into the BDS5T and the VSA.

NOTICE: Some changes may be required to existing wiring or probram in order to make the BDS5T

compatible to the BDS5 or the VSA, or the VSA compatible to the VFS5.

HARDWARE:

• On-board analog input

The analog input is on the connector T1 of the BDS5T and connector C10 on the VSA, Pin 5 is Diff. Hi and Pin 6 is Diff. Low.

• Tach output

Scaled for 1750 RPM/volts

• Communications

To convert from RS232 to RS485 install a jumper between pins 9 and 10 on connector J1

• Inputs

Built-in filters

SOFTWARE:

• Program Execution

Twice as fast as BDS5

• PL, PLIM, TRIP, and PDF

State is remembered through power-down

• A2D Switch

When using the on-board analog input set A2D to 1. When using the encoder input for master / slave application set A2D to 0. The gear ration when using the on-board analog input is GEARI / GEARO = 700 / 16384 for 10 volts = 10000 RPM.

• CAM function

Cam now has 1024 points, NORM ) ECAM starts the CAM function.

• PDF switch

Set to 1 for brushless motors. For induction motor control if PDF=1, the auto tune feature is available. If PDF=0, the control scheme is identical to the VFS5 and the auto tune feature is not available.

• Supports 10-bit resolver resolution for higher speed applications.

• User variables

2,000 user variables (x1 – x2000)

• Program memory is 27K

• “P”

May be omitted when printing one variable.

Diff Hi

Diff Lo

Front View of Connector C10 on VSA, T1 on BDS5T

BDS5

NSTALLATION AND SETUP MANUAL

Old Number M93101 - I

New Number MB5000H

SSUE 4

BDS5 T

ECHNICAL MANUAL CONFIGURATION

NSTALLATION AND SETUP MANUAL

( I

ECHNICAL MANUAL CONFIGURATION

M93101 )

PAGE NO.

-- ...............................Title P age..................................................................................................................... 0

-- ...............................Technical Manual Configuration................................................................................. 0

-- ...............................Configuration Table..................................................................................................... 0

-- ...............................Customer Response...................................................................................................... 0

-- ...............................Copyright Page ............................................................................................................ 0

-- ...............................Foreword...................................................................................................................... 0

-- ...............................How to Use This Manual............................................................................................. 0

i-ii................................T able of Contents......................................................................................................... 0

iii / (iv blank)..............List of Figures.............................................................................................................. 0

v / (vi blank)................List of Tables...............................................................................................................0

vii / (viii blank)...........List of Drawings .......................................................................................................... 0

1-1 -- 1-16...................Text Pages....................................................................................................................0

2-1 -- 2-26...................Text Pages....................................................................................................................0

3-1 -- 3-10...................Text Pages....................................................................................................................0

4-1 -- 4-4.....................Text Pages....................................................................................................................0

5-1 -- 5-6.....................Text Pages....................................................................................................................0

DESCRIPTION

ISSUE NO.*

A-1 / (A-2 blank)........Appendix A Warranty Information............................................................................. 0

B-1 -- B-22..................Appendix B Drawings.................................................................................................0

C-1 -- C-12..................Appendix C Error Codes............................................................................................. 0

D-1 -- D-2...................Appendix D Regional Sales Offices ........................................................................... 0

E-1 / (E-2 blank).........Appendix E On-line Reference Guide ........................................................................ 0

Glossary-i -- xiv..........Glossary....................................................................................................................... 0

Index-i -- iv.................Index............................................................................................................................ 0

* Zero in this column indicates an original page

ONFIGURATION TABLE

NSTALLATION AND SETUP MANUAL

( I

BDS5

M93101 )

RECORD

ISSUE NO.

(Revision) DATE CHANGED PAGES/BRIEF DESCRIPTION OF CHANGE CHANGE NO.

15 Mar 95

10 Nov 95

Replaces issue dated 15 Feb 95

Add Appendix E and include On-line Reference Guide Disk

OF REVISIONS

Original Release

- -

HANK YOU

Thank you and congratulations for choosing Industrial Drives' servo products for your motion control requirements. W e seek to provide our custom ers with quality products, excellent support and outs tanding value. In an effort to provide you with dependable and useful docum entation, we off er you an opportunity to critique this manual with your comments and suggestions. Your feedback on this reader comments form is very important to us. Please answer the questions below and return the form to:

INDUSTRIAL DRIVES -

Technical Manual Department

201 Rock Road Radford, VA 24141 U.S.A. FAX: 703/731/0847

Name: Title: Company: Street Address: City: State: Zip: Telephone: Fax: Product: Manual Part Number:

Please check the rating that best represents your opinion on each topic.

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4. Information accuracy.

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Printed in the United States of America.

NOTICE:

Not for use or disclosure outside of Industrial Drives except under written agreement.

All rights reserved. No part of this book shall be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise without the written permission from the publisher. While every precaution has been taken in the preparation of the book, the publisher assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information co ntained herein.

This document is proprietary information of Industrial Drives, A Kollmorgen Division, furnished for customer use ONLY. No other uses are authorized without written permission of Industrial Drives.

Information in this document is subject to change without notice and does not represent a commitment on the part of Industrial Drives or the Kollmorgen Corporation. Therefore, information contained in this manual may be updated from time-to-time due to product improvements, etc., and may not conform in every respect to former issues.

IBM-PC is a trademark of International Business Machines Corporation. OPTO-22 is a trademark of the OPTO-22 Company. U.L. is a trademark of Underwriters Laboratories. N.E.C. is a trademark of the National Electric Code. GOLDLINE, BDS4, BDS5, PSR4/5, Motion Link, PC-Scope, and Macro Moves are trademarks of the Kollmorgen Corporation.

WARNING

Dangerous voltages, currents, temperatures, and energy levels exist in this product and in the associated servo motor(s). Extreme caution should be exercised in the application of this equipment. Only qualified individuals should attempt to install, set-up, and operate this equipment. Ensure that the motor, drive, and the end-user assembly are all properly grounded per NEC requirements.

INDUSTRIAL DRIVES

201 Rock Road

Radford, VA 24141

Phone: 703/639/2495

Fax: 703/731/0847

BDS5 F

OREWORD

The commitment to quality at Industrial Drives is our first priority. In all aspects of our business: research, development, product design and customer service, we strive to guarantee total quality. This pledge is founded on a solid history of innovative technologi cal achievements dating back to 1948. One of the finest tributes to that achievement can now be seen at the Smithsonian which has on display the first stellar inertial navigation system developed by Dr. Charles Stark Draper. This system contains the first models of torque motors built by the founding organization of Industrial Drives. During the period of 1948 to 1960, our "firsts" in the industry numbered more than a dozen; they ranged from the simple but invaluable (such as the direct-drive DC torque motor and movie theater projection motors) to the exotic: submarine periscope drive motors for the U.S. Navy, electric drives, Curtis Wright electric brake coils, and numerous other innovations.

For more than a decade, Industrial Drives (known in the early days as part of Inland Motor Division of Kollmorgen) has c ontinued to enhance its sophisticated engineering solutions to pioneer new product development.

The results of these and other efforts has encouraged some of the most significant innovations in the servo industry. We developed the application of servo motors and drives in the Machine Tool market. We were the first with water-cooled servos, the integral brake, the flux forcing concept and the brushless motor. We developed the electronically commutated electric car motor. Industrial Drives pioneered rare

earth magnet development for the servo motor industry.

Between 1974 and 1980, Industrial Drives continued to lead the industry in servo application innovations. Our commitment to engineering excellence never waivered. In fact, that commitment grew stronger with the development of brushless submarine and submersible motors (visiting the Titanic graveyard), multi-axis electronic drives and antenna pedestal drives (delivering unprecedented accuracy and revolutionizing the entire industrial automation process).

The decade of the 1980's brought continued advancements in technology and penet ration of new markets requiring precise motion control. Already in the fifth generation of brushless products, Industrial Drives continues to lead the way with digital servo positioning capability and our newest motor offering, the GOLDLINE Series, incorporating the very latest high-energy, rare earth magnets (neodymium iron boron). Once again, we are setting the standards that others only hope to duplicate. Recently acknowledged by the Frost and Sullivan Foundation, a leading market specialist in the motion control industry, Industrial Drives and its parent, Kollmorgen Corporation, continue to rank first in servo technology.

Other achievements? Yes, too many in fact to mention. Each achievement stands as a testimony to the committed quality and excellence in design technology. This constancy of purpose is unyielding in an era of rapidly changing technology.

BDS5 H

OW TO USE THIS MANUAL

INTRODUCTION

This Installation and Setup Manual is designed to help you properly install a BDS5 Servo System. You do not have to be an expert in motion control to operate the system however this manual does assume you have the fundamental und erstanding of basi c electronics and motion control concepts. Many of these are explained in the glossary of this manual.

The BDS5 is a programmable motion control device. An understanding of c omputer programming techniques will be beneficial to all users. For applications that require complex programs, a professional programmer should be consulted.

RECOMMENDATIONS

It is recommended that you read this entire manual before you attempt to install the BDS5 so you can promptly find any information you need. This will also familiarize you with system components, and their relationship to one another.

After installation and before you apply your own application check all system functions and features to insure you have installed your BDS5 properly.

Proper installation can prevent potential difficulties before they cause harm to your system. Be sure to follow all instructions carefully and pay special attention to safety.

CONVENTIONS

To assist you in understanding the material in this manual, conventions have been estab l ished to enhance reader comprehension. Explanations of these conventions are as follows:

Safety warnings, cautions, and notes present

•

material that is important to user safety. Be sure to read any safety notices you see as they could prevent equipment damage, personal injury, or even death to you or a co-worker.

• Bold

•

text highlights other important information

that is critical to system operations.

CAPITALIZED text stresses attention to the details of the procedure.

Underlined text emphasizes crucial words in sentences that could be misunderstood if the word is not recognized.

DOUBLE BLOCKED

that are to be typed into the computer by the user to interface with the BDS5.

SINGLE BLOCKED

that are displayed by the BDS5 on the computer terminal to inform the user of system operations or problems.

text defines words

OW TO USE THIS MANUAL

BDS5

ABBREVIATIONS

CCW Counter Clockwise CW Clockwise D/L Direction Limit GC Goldline Cable GCS Goldline Cable Set LED Light Emitting Diode NEC National Electrical Code P/N Part Number R/D Resolver-to-Digital Regen Regeneration TL Test Limits UL Underwriters Laboratories

NOTICE:

This manual is the first of a two part manual structure. The the user on the normal operating procedures and practices to be used with the BDS5. Programming is explained as well as other software considerations.

User's Manual

is intended to instruct

BDS5 T

ABLE OF CONTENTS

CHAPTER 1. SYSTEM DESCRIPTION

1.1 Introduction..................................................... 1-1

1.2 Product Description ........................................ 1-1

1.3 Features........................................................... 1-1

1.4 Part Number Description................................ 1-3

1.4.1 BDS5 Model Number.................................. 1-4

1.4.2 Compensation Module Model Number........ 1-5

1.4.3 PSR4/5 Model Number................................ 1-6

1.4.4 ER-External Resistor Kit Model Number....1-7

1.4.5 Molex Assembly Tools................................ 1-7

1.5 Specifications and Ratings.............................. 1-8

1.6 Theory of Operation......................................1-12

1.7 Simplified Schematic Diagram

and System Diagram..................................... 1-13

CHAPTER 2. INSTALLATION

2.1 Introduction..................................................... 2-1

2.2 Safety Information .......................................... 2-1

2.3 Unpacking And Inspection.............................. 2-2

2.4 Installation Requirements................................ 2-2

2.4.1 Environmental Considerations..................... 2-2

2.4.2 Enclosures.................................................... 2-2

2.5 Mounting......................................................... 2-2

2.5.1 Mounting the BDS5..................................... 2-2

2.5.2 Mounting the PSR4/5................................... 2-3

2.5.3 Mounting the External Regen Resistor ........ 2-3

2.6 Wiring............................................................. 2-3

2.6.1 Wiring the Ground....................................... 2-4

2.6.2 Wiring the Power Connections .................... 2-4

2.6.2.1 Wiring the Motor......................................2-4

2.6.2.2 Motor Protection....................................... 2-5

2.6.2.3 Motor Thermostat.....................................2-5

2.6.2.4 Motor Brake.............................................. 2-5

2.6.2.5 Wiring the DC Bus....................................2-6

2.6.2.6 Wiring the AC Line................................... 2-6

2.6.2.7 Wiring the Regen Resistor........................2-6

2.6.3 Wiring the PSR4/5 Front Panel

Connectors...................................................... 2-6

2.6.3.1 Wiring the Control Power to C1 ............... 2-6

2.6.3.2 Wiring to the PSR4/5 Fault

Output on C1...................................................2-6

2.6.3.3 Wiring PSR4/5 Connector C2................... 2-6

2.6.4 Wiring the BDS5 Front Panel

Connectors...................................................... 2-7

2.6.4.1 Wiring C1, Encoder Equivalent................ 2-7

2.6.4.2 Encoder Equivalent Input.......................... 2-9

2.6.4.3 Pulse Input (OPT2 Card) .......................... 2-9

2.6.4.4 Encoder Equivalent Output....................... 2-9

2.6.4.5 Wiring C2, Customer I/O ........................ 2-10

2.6.4.6 Wiring C3, Resolver............................... 2-11

2.6.4.7 Wiring C4, Logic Power Supply............. 2-11

2.6.4.8 Wiring C5, Serial Communications........ 2-12

2.6.4.9 Wiring C6, Fan Power (20 Amp

Units Only)................................................... 2-14

2.6.4.10 Wiring C7, Standard I/O....................... 2-14

2.6.4.11 Wiring C8, Optional I/O.......................2-15

2.6.4.12 J1 Configuration Jumper....................... 2-16

2.6.5 Establishing Communications.................... 2-16

2.6.5.1 Required Data Format............................. 2-16

2.6.5.2 First Transmission................................... 2-16

2.6.5.3 Checking the Control Power...................2-17

2.6.5.4 If You Can't Communicate......................2-18

2.7 Initial Check-Out...........................................2-18

2.7.1 Checking Discrete Inputs...........................2-19

2.7.2 Checking General Purpose Outputs ........... 2-19

2.7.3 Cycle Ready............................................... 2-20

2.7.4 Checking STATUS.................................... 2-20

2.7.5 Checking Encoder Output.......................... 2-20

2.7.6 Checking Encoder Input............................. 2-20

2.7.7 Checking Pulse Input (Optional)................ 2-20

2.7.8 Checking Analog Input (Optional)............. 2-20

2.7.9 Checking the Resolver ............................... 2-21

2.7.10 Checking the Resolver Cable................... 2-21

2.7.11 Checking the AC Line Voltages............... 2-22

2.7.12 Checking the DC Bus Voltage................. 2-22

2.7.13 Checking the Motor................................. 2-23

CHAPTER 3. OPERATION

3.1 Introduction..................................................... 3-1

3.2 Start-Up and Checkout.................................... 3-1

3.2.1 If You Get ERROR 17, FEEDBACK

LOSS .............................................................. 3-2

3.2.2 If You Get ERROR 14, POWER BUS........ 3-2

3.2.3 If Your BDS5 System is Unstable................ 3-2

3.2.4 Jogging the Motor ........................................ 3-3

3.2.5 Low Speed Adjustment................................ 3-3

3.3 System Compensation..................................... 3-4

3.3.1 Critical Damping.......................................... 3-4

3.3.2 Underdamping..............................................3-4

3.3.3 Overdamping................................................3-5

3.3.4 Ringing.........................................................3-5

3.4 Tuning............................................................. 3-5

3.4.1 If Your System Is Completely Unstable.......3-6

3.4.2 Reducing ILIM.............................................3-6

3.5 Tune Command............................................... 3-6

ABLE OF CONTENTS

BDS5

3.6 Tuning The BDS5 Yourself............................3-7

3.6.1 Tuning the Velocity Loop ............................3-7

3.6.2 Tuning the Position Loop.............................3-7

3.7 RECORD and PLAY......................................3-8

3.8 Problems..........................................................3-9

3.8.1 Overloading the Motor.................................3-9

3.8.2 Compliance ..................................................3-9

3.8.3 Non-Linear Mechanics.................................3-9

3.8.4 Resonance..................................................3-10

3.8.5 Low-Pass Filters.........................................3-10

CHAPTER 4. MAINTENANCE

4.1 Introduction ..................................................... 4-1

4.2 Preventative Maintenance...............................4-1

4.2.1 Transient Voltages .......................................4-1

4.2.2 Surge Current...............................................4-2

4.2.3 Electrical Noise............................................4-2

4.2.4 Radio Frequency Energy..............................4-2

4.3 Periodic Maintenance......................................4-2

4.3.1 Ventilation....................................................4-3

4.3.2 Grounding Integrity......................................4-3

CHAPTER 5. TROUBLESHOOTING

APPENDIX A. WARRANTY INFORMATION

APPENDIX B. DRAWINGS

APPENDIX C. ERROR CODES

APPENDIX D. REGIONAL SALES OFFICES

APPENDIX E. ON-LINE REFERENCE GUIDE

5.1 Introduction ..................................................... 5-1

5.2 Spare Parts ......................................................5-1

5.2.1 BDS5 Spare Parts List..................................5-1

5.2.2 PSR4/5 Spare Parts List...............................5-1

5.2.3 Ordering Information...................................5-2

5.3 LED Status Indicators.....................................5-2

5.3.1 BDS5 LED's................................................. 5-2

5.3.2 PSR4/5 LED's ..............................................5-2

5.4 Error Log.........................................................5-3

5.4.1 Error Levels..................................................5-3

5.4.2 DEP..............................................................5-4

5.4.3 Error History................................................5-4

5.4.4 Displaying Error Messages ..........................5-4

5.4.5 Firmware Errors...........................................5-4

5.5 Enable and fault logic......................................5-5

5.5.1 Firmware Faults, Area 1...............................5-5

5.5.2 Fault Logic, Area 2.......................................5-5

5.5.3 Fault Latch, Area 3.......................................5-5

5.5.4 Ready Latch, Area 4.....................................5-5

5.5.5 ACTIVE, Area 5..........................................5-5

5.5.6 Relay and STATUS Control, Area 6............5-6

5.5.7 Motor Brake.................................................5-6

5.5.8 Output Relay................................................5-6

5.6 Factory Support and Repair Policies...............5-6

BDS5 L

IST OF FIGURES

FIGURE PAGE FIGURE PAGE

IST OF FIGURES

1.1 BDS5 Model Number Scheme........................ 1-4

1.2 Compensation Model Number Scheme........... 1-5

1.3 PSR4/5 Model Number Scheme..................... 1-6

1.4 External Regen Resistor Model

Number Scheme..............................................1-7

2.1 Safety-Alert Symbols...................................... 2-1

2.2 Master BDS5 and Slave BDS5....................... 2-8

2.3 Encoder Phasing For Clockwise Rotation....... 2-8

2.4 BDS5 (C1)...................................................... 2-9

3.1 Critical Damping............................................. 3-4

3.2 Underdamping.................................................3-5

3.3 Overdamping...................................................3-5

3.4 Ringing............................................................3-5

iii / (iv blank)

BDS5 L

IST OF TABLES

TABLE PAGE TABLE PAGE

IST OF TABLES

1.1 BDS5 Model Number Scheme........................ 1-4

1.2 PSR4/5 Model Number Scheme..................... 1-6

1.3 External Regen Resistor Model

Number Scheme..............................................1-7

1.4 Specifications.................................................. 1-8

1.5 Environmental Specifications ....................... 1-12

1.6 Mechanical Specifications............................ 1-12

2.1 Motor Cable Color Code.................................2-4

2.2 PSR4/5 Logic Power....................................... 2-7

2.3 Communications Requirements.....................2-12

2.4 Terminal Wiring............................................2-13

2.5 PC Wiring..................................................... 2-14

2.6 PSR4/5 C2 Wiring........................................2-17

2.7 Target of PRD vs. R/D Resolution................2-21

2.8 Target of PRD vs. R/D Resolution After

Clockwise /4 Revolution............................... 2-21

2.9 Goldline Resolver Cable Wiring................... 2-21

2.10 PRD Range for "Zero Position".................. 2-23

3.1 Tuning Criterion..............................................3-4

3.2 Allowed Tune Command Stability Settings.... 3-6

3.3 Velocity Loop Bandwidth vs. KVI ................. 3-7

3.4 Velocity Loop Bandwidth vs. KP

5.1 Error Severity Levels and Actions..................5-7

MAX

.......... 3-8

v / (vi blank)

BDS5 L

IST OF DRAWINGS

DRAWING PAGE

D-93030 BDS5 System Overview.........................................................1-14

A-84847 Typical BDS5 System Interconnect........................................ 1-16

A-96372M BDS5 Connectors................................................................2-25

A-84732 BDS5 Enable Fault Logic Diagram........................................B-3

A-93103 BDS5 Wiring Diagram .......................................................... B-4

A-93703 Mounting Hole Pattern BDS4A, BDS5, PSR4/5A.................B-11

A-62370 Outline B-102-X-12,14........................................................... B-13

A-62371 Outline B-104,6,-X-12,14.......................................................B-14

IST OF DRAWINGS

A-43268 Outline B-20X-X-21,31,23,33-(S)..........................................B-15

A-63093 Outline B-40X-X-A1,A3,B1,B3(-S).......................................B-16

A-63099 Outline B-602,4-X-A1,A3,B1,B3(-S)..................................... B-17

A-63100 Outline B-606-X-A1,A3,B1,B3(-S)........................................ B-18

A-63097 Outline B-802,4-X-A1,A3,B1,B3(-S)..................................... B-19

A-63096 Outline B-806-X-A1,A3,B1,B3(-S)........................................ B-20

A-93569 Outline & Dimension BDS5-3 & 6 Amp................................B-21

A-93571 Outline & Dimension BDS5-10 Amp.....................................B-22

A-93570 Outline & Dimension BDS5-20 Amp.....................................B-23

A-93880 Outline & Dimension BDS5-30/40 Amp................................B-24

A-96010 Outline & Dimension BDS5-55 Amp.....................................B-25

A-93581 Outline & Dimension PSR4/5A-12 & 20 Amp.......................B-26

A-93031 Outline & Dimension PSR4/5-50 & 75 Amp.......................... B-27

C-84723 PSR4/5 Simplified Schematic.................................................B-28

A-84888 Velocity Loop Tuning Flow Chart..........................................B-29

vii / (viii blank)

BDS5 C

HAPTER

YSTEM DESCRIPTION

HAPTER

YSTEM DESCRIPTION

1 - S

1.1 INTRODUCTION

The information in this chapter will enable you to understand the BDS5's basic functions and features. These concepts will allow you to apply them to your own unique applications.

1.2 PRODUCT DESCRIPTION

The BDS5 is a full-featured, high-performance, brushless positioning servo in one compact enclosure

it is the smallest, totally-integrated package



available to motion control users. The BDS5 combines a positioner, a servo amplifier, and an I/O interface into one unit. The BDS5 sets new standards for motion control with its simple BASIC-like command structure and sophisticated decision-making capability. The BDS5 provides the outstanding servo performance that you have come to expect from Industrial Drives. Using a high-performance microprocessor, the BDS5 does not have to compromise on either positioner software or servo performance. This single microprocessor closes all servo loops, resulting in a truly integrated positioning system. The BDS5 has the features and performance you need in your next positioning application.

1.3 FEATURES

The BDS5 offers a wide feature set to accommodate real world positioning requirements:

LOW COST

•

The BDS5 i s very affordable--even though it is full of advanced features. Use all or only a portion of these features to accomplish your application.

EASY TO INSTALL

•

The BDS5 is easy to install because the servo amplifier and the positioner are integrated into one package. Many interconnects, including the tachometer and encoder, are eliminated.

SIMPLE PROGRAMMING LANGUAGE

•

The BDS5 uses simple BASIC-like commands such as RUN, GOTO (for branching), and GOSUB / RETURN (for subroutines). In addition to a simple comparison statement, advanced IF / ELIF / ELSE / END IF statements result in more readable and less error-prone programs. You can comment every line in your program.

1-1

HAPTER

YSTEM DESCRIPTION

1 - S

BDS5

ADVANCED MOTION CONTROL MOVES

•

The simple language does not prevent you from solving complex proble ms. The BDS5 has separa te acceleration and deceleration rates, as well as linear, half S-curve, and full S-curve acceleration profiles. The BDS5 has Macro Moves for applications where simple indexes cannot do the job. A Macro Move is a combination of up to 30 accelerations, traverses, and decelerations, which are fully precalculated for faster execution. You can program teach modes where position end points can be changed by a factory operator

MASTER/SLAVE - ELECTRONIC GEARBOX

•

The electronic gearbox is used to link two motors together so that the velocity of the slave is proportional to the velocity of the master. The ratio can be from 32767:1 to 1:32767 and can be negative to allow the slave to move in the opposite direction. Also, the "index-on-gearing" feature permits phase adjustments.

MASTER/ SLAVE - PROFILE REGULATION

•

With profile regulation you can control the slave's motion profile according to an external master motor or frequency. Profile regulation modifies the velocity and acceleration of the slave axis without affecting the final position of the move. You can use profile regulation to implement "feed rate override."

MOTION GATING AND REGISTRATION

•

The BDS5 can precalculate moves to begin motion within one millisecond after a transition on the GATE input. This provides rapid and repeatable motion initiation. The BDS5 has the ability to capture the current position within 25 microseconds after a transition of the HOME input. This results in fast homing and accurate registration sequences.

MATHEMATICS Algebraic math is provided for

•

commands such as:

12 2 3

XXX

The BDS5 has 100 program labels, 50 user-definable variables, and 50 user-definable switches. It also has 15 mathematical/logical operations and over 150 system variables.

()

=× +

Quantities such as position, velocity, and acceleration are automatically scaled into user-defined units. This feature lets you program the BDS5 in convenient units, such as feet, inches, miles, RPM, and degrees.

SUPERIOR SERVO LOOP CONTROL

•

The BDS5 offers smooth, high-resolution control. Standard BDS5 position repeatability is better than one arc-minute, bidirectional. The BDS5 has a 32-bit position word. The BDS5 position loop completely eliminates the digital dither normally associated with positioning systems. Long-term speed stability is

0.01%. The standard system converter (12-bit) provides a resolution of 0.0005 RPM and a maximum speed of 8000 RPM.

SELF-TUNING

•

The BDS5 c an tune itself. You do not have to b e a servo expert to set up a system quickly. Just specify the desired bandwidth, and let the BDS5 do the rest.

POWERFUL MICROPROCESSOR

•

The heart of the BDS5 is the 16-bit processor that delivers high performance. The result: the BDS5 can control a motor and execute its motion program faster than a standard positioner can.

DIGITAL SERVO LOOPS

•

Both the position and velocity loops are totally digital. The digital loops give the BDS5 features not available in standard velocity drives, such as self-tuning, very low velocity offset, and digitally-adjustable servo tuning parameters. The optional analog input permits you to use the BDS5 as an analog velocity drive.

FEED-FORWARD GAIN

•

The digital feed-forward gain reduces following error and motion initiation delay, thereby increasing machine throughput.

DIAGNOSTICS

•

The BDS5 offers a complete set of error diagnostics. When an error occurs, the BDS5 displays an English

USER UNITS

•

1-2

BDS5 C

HAPTER

YSTEM DESCRIPTION

1 - S

language error message. The BDS5 remembers the last 20 errors even thr ough power loss. In addition, the BDS5 lets you write your own error handler. During a fault condition, you can use the error handler to set outputs, alert an operator, and shut down your process smoothly. The BDS5 offers trace and singlestep modes so that you can debug your program. The BDS5 has complete fault monitoring, including travel limit switches, feedback loss, and software position limits, as well as hardware safety circuits (watchdogs) and checksums for more reliable and safer operation.

I/O

•

The BDS5 has up to 32 I/O sections that you connect via ribbon cable to standard OPTO-22 compatible I/O boards or to INDUSTRIAL DRIVES I/O-32. The I/O-32 provides either fixed 24-volt or removable, industry standard, optically-isolated I/O in a GOLDLINE style package.

SERIAL COMMUNICATIONS

•

The BDS5's serial communications provide a powerful link to other popular factory automation devices such as PLC's, process control computers, and smart terminals. The BDS5 offers RS-232 for most terminals and RS-422/RS-485 for multidrop communications. With multidrop you can put up to 26 axes on one serial line. The BDS5 can autobaud from 300 baud to 19.2k baud, eliminating the need to set dip switches to start communicating.

MOTION LINK

•

Industrial Drives also offers MOTION LINK, a powerful, menu-driven communications package for

your IBM-PC (c) compatible computer. With this package, the BDS5's programs and variables can be retrieved from or saved to a disk drive. Also, on-line help and a full screen editor are built into MOTION LINK.

MENU-DRIVEN SOFTWARE

•

The BDS5's programming language allows you to write operator-friendly, menu-driven software. By incorporating an INDUSTRIAL DRIVES Data Entry Panel, or any other serial co mmunicati ons device, the operator can be prompted for specific process data.

MONITOR MODE

•

The BDS5 provides interactive communications and permits all system variables and parameters to be examined and modified at any time--even during actual program execution or while the motor is running.

1.4 PART NUMBER DESCRIPTION

A model number is printed on a gold and black tag on the front of your BDS5, PSR4/5, Compensation Card and External Regen Resistor modules. The model number identifies how the equipment is configured. Each component is described to explain what the model configurations are. You should verify that the model numbers represent the equipment desired for your application. Also verify the compatibility between components of the servo system. The model numbers are as follows:

1-3

HAPTER

YSTEM DESCRIPTION

1 - S

BDS5

1.4.1 BDS5 Model Number

B D S 5 A - 2 A B C D E F G H I

UL Designator Voltage and Current Ratings User Program Options Firmware Version Motor and Winding R/D Resolution

Figure 1.1. BDS5 Model Number Scheme

Table 1.1. BDS5 Model Number Scheme

LEGEND DEFINITION

A V

1 2

03 06 10 20 30 40 55

0 1

0 1 2 9

0 1

Motor and Wi nding

R/D Resolution

2 4

Firmware Version Firmware Version ( Assigned by Industri al Drives, not normally specified when ordering)

User Program User Program (This is reserved for systems that are programmed by Industrial Drives. This

UL Designator UL Listed (standar d) Non - UL Listed

Voltage Rating 115 VAC 230 VAC

Current Rating 3 Amps/Phase 6 Amps/Phase 10 Amps/Phase 20 Amps/Phase 30 Amps/Phase 40 Amps/Phase 55 Amps/Phase

Mechanical Options (0 indicates st andard feature) Standard Communication Options RS-232 (standard) RS-422/RS-485 Input Options Encoder Input (standard) Analog Input Pulse Input No Input I/O Options 8 I/O (standard) 32 I/O R/D Accuracy Options 8 ARC min (standard)

Motor and Wi nding Specifies Motor Model Type, Winding

R/D Resolution 12-Bit (4096 counts /rev) 14-Bit (16384 counts /rev)

Most current f irmware supplied -- unless otherwise s pecified.

is not normally s pecified when ordering.)

4 0 - 0 0 0 1 0 \ 6 0 5 C - 2 - / ______

1-4

BDS5 C

1.4.2 Compensation Module Model Number

/ 2 0 4 A

2 0 3 A B H

Voltage Rating Motor and Winding Current Rating

Figure 1.2. Compensation Model Number Scheme

A partial model number is printed on a gold and black tag on the front of the compensation module (the black plastic box secured to the front of your BDS5 by two screws). See Figure 1.2 for the descriptions of the model number (that is, what ABB and HHHH mean). The model number is as follows:

The compensation module depends on your motor and the voltage and current rating of your BDS5. It is important that the motor, the BDS5, and the compensation module model numbers all agree. For example, if your BDS5 model number is

CAUTION

HAPTER

YOU MUST HAVE THE PROPER COMPENSATION MODULE INSTALLED FOR YOUR MOTOR AND BDS5. THE COMPENSATION MODULE CHANGES IF THE AMPLIFIER RATINGS CHANGE, EVEN FOR THE SAME MOTOR.

YSTEM DESCRIPTION

1 - S

BDS5-203-00000\204A

then your compensation module model number must be:

203/204A

and your motor must be a 204A. An example of a 204A motor model number is:

B-204-A

-1-101/2021,

-21.

Failure to install the proper compensation module can cause damage to the BDS5, the motor, or both.

1-5

HAPTER

YSTEM DESCRIPTION

1 - S

1.4.3 PSR4/5 Model Number

BDS5

P S R 4 / 5A - 2 2 0 A B C D E

UL Designator Options Voltage Rating Current Rating

Figure 1.3. PSR4/5 Model Number Scheme

Table 1.2. PSR4/5 Model Number Scheme

- 0 0 0 3

LEGEND DEFINITIONS

A V

1 2

12 20 50 75

UL Designator UL Listed (standard) Non - UL Listed

Voltage Rating 115 VAC 230 VAC

Current Rating 12 Amps/Phase 20 Amps/Phase 50 Amps/Phase 75 Amps/Phase

1-6

00 01

02 03

Mechanical Options No Option (standard)

Electrical Regen Options for 12 and 20 Amp Models Only Standard Internal 40 W Regen (standard) External Regen (230 VAC Only) 8.8 Ohms, 400 W., Requires ER-01 Resistor Kit External Regen (115 VAC Only) 5.5 Ohms, 200 W., Requires ER-02 Resistor Kit External Regen (230 VAC Only) 5.8 Ohms, 700 W., Requires ER-03 Resistor Kit

Electrical Regen Options for 50 and 75 Amp Models Only No internal shunt regeneration (standard)

Requires external regeneration resistor kit ER-2X

BDS5 C

1.4.4 ER-External Resistor Kit Model Number

Contact Industrial Drives Application Engineering to size regeneration capability.

NOTE

E R - 0 1 / X X A B

Resistor Rating Options

Figure 1.4. External Regen Resistor Model Number Scheme

HAPTER

YSTEM DESCRIPTION

1 - S

Table 1.3. External Regen Resistor Model Number Scheme

LEGEND DEFINITIONS

01 02 03 20 21 22 23

1.4.5 Molex Assembly Tools

GOLDLINE series electronics (BDS4's, BDS5's, and PSR4/5's) use Molex MINI-FIT JR. series connectors. The necessary connectors and pins are included in your BDS5 and PSR4/5 connector kits.

Resistor Rating

8.8 Ohms, 400 W., 230V, 12 & 20 Amp Models Only

5.5 Ohms, 200 W., 115V, 12 & 20 Amp Models Only

5.8 Ohms, 700 W., 230V, 12 & 20 Amp Models Only

4.5 Ohms, 500 W., 230V, 50 & 75 Amp Models Only

4.4 Ohms, 1000 W., 230V, 50 & 75 Amp Models Only

2.2 Ohms, 1000 W., 230V, 75 Amp Models Only

2.2 Ohms, 2000 W., 230V, 75 Amp Models Only Options

None available at this printing.

You can obtain the crimping and extraction tools from your nearest Mo l ex distributor or by contacti ng Molex at (708) 969-4550.

Hand Crimping Tool Molex Order# 11-01-0122

Extractor Tool Molex Order# 11-03-0038

1-7

HAPTER

YSTEM DESCRIPTION

1 - S

BDS5

1.5 SPECIFICATIONS AND RATINGS

Table 1.4. Specifications

BDS5-1XX-(90-160 VAC L-L OUTPUT TO MOTOR)

DESCRIPTION BDS5-103 BDS5-106 BDS5-110 BDS5-120

Main DC Bus Minimum Maximum

130 VDC 225 VDC

15-20 VDC

@0.25 AMPS

Unregulated Logic Bus

+8-12 VDC @1.00 AMPS

Output Current (RMS/∅) Convection Cooled (45°C AMB) Continuous (RMS) Peak (2.0 sec) (RMS)

Output KVA (@ 160 VDC Bus) Continuous (45°C AMB) Peak (2.0 sec) (RMS)

Internal Heat Dissipation 30 WATTS 40 WATTS 60 WATTS 110 WATTS PWM Switching Frequency 10.0 kHz 10.0 kHz 10.0 kHz 10.0 kHz Motor Current Ripple

Frequency ±10% Resolver Excitation Frequency 8.5 kHz 8.5 kHz 8.5 kHz 8.5 kHz Form Factor RMS/AVG Fan (115 VAC) N/A N/A N/A 0.2 AMPS

3.0 AMPS

6.0 AMPS

0.6 KVA

1.2 KVA

20.0 kHz 20.0 kHz 20.0 kHz 20.0 kHz

≤

1.01

15-20 VDC

@0.25 AMPS +8-12 VDC

@1.00 AMPS

6.0 AMPS

12.0 AMPS

1.2 KVA

2.4 KVA

≤

1.01

15-20 VDC

@0.25 AMPS +8-12 VDC

@1.00 AMPS

10.0 AMPS

20.0 AMPS

2.0 KVA

4.0 KVA

≤

1.01

15-20 VDC

@0.25 AMPS +8-12 VDC

@1.00 AMPS

Fan Cooled

20.0 AMPS

40.0 AMPS

4.0 KVA

8.0 KVA

≤

1.01

1-8

BDS5 C

Table 1.4. Specifications (Cont.)

HAPTER

YSTEM DESCRIPTION

1 - S

BDS5-2XX-(160-253 VAC L-L OUTPUT TO MOTOR)

DESCRIPTION BDS5-203 BDS5-206 BDS5-210 BDS5-220

Main DC Bus Minimum Maximum

225 VDC 360 VDC

130 VDC 225 VDC

15-20 VDC

@0.25 AMPS

Unregulated Logic Bus

+8-12 VDC @1.00 AMPS

Output Current (RMS/∅) Convection Cooled (45°C AMB) Continuous (RMS) Peak (2.0 sec) (RMS)

Output KVA (@ 160 VDC Bus) Continuous (45°C AMB) Peak (2.0 sec) (RMS)

Internal Heat Dissipation 35 WATTS 50 WATTS 75 WATTS 150 WATTS PWM Switching Frequency 10.0 kHz 10.0 kHz 10.0 kHz 10.0 kHz Motor Current Ripple

Frequency ±10% Resolver Excitation Frequency 8.5 kHz 8.5 kHz 8.5 kHz 8.5 kHz Form Factor RMS/AVG Fan (115 VAC) N/A N/A N/A 0.2 AMPS

3.0 AMPS

6.0 AMPS

1.2 KVA

2.4 KVA

20.0 kHz 20.0 kHz 20.0 kHz 20.0 kHz

≤

1.01

15-20 VDC

@0.25 AMPS +8-12 VDC

@1.00 AMPS

6.0 AMPS

12.0 AMPS

2.0 KVA

4.0 KVA

≤

1.01

15-20 VDC

@0.25 AMPS +8-12 VDC

@1.00 AMPS

10.0 AMPS

20.0 AMPS

4.0 KVA

8.0 KVA

≤

1.01

15-20 VDC

@0.25 AMPS +8-12 VDC

@1.00 AMPS

20.0 AMPS

40.0 AMPS

8.0 KVA

16.0 KVA

≤

1.01

1-9

HAPTER

YSTEM DESCRIPTION

1 - S

Table 1.4. Specifications (Cont.)

PSR4/5-1XX-(90 - 160 VAC L-L INPUT)

DESCRIPTION PSR4/5-112- PSR4/5-120-

Main AC Line Input Voltage 90-160 VAC 90-160 VAC Phase 1-3 1-3 Frequency 47-63 Hz 47-63 Hz

BDS5

Current Cont. (RMS) 3-Phase Single-Phase

Peak (2.0 sec) 3-Phase Single-Phase

Peak (50.0 msec) 3-Phase Single-Phase

Control AC Line Input Voltage 90-132 VAC 90-132 VAC Phase 1 1 Frequency 47-63 Hz 47-63 Hz Main DC Bus Output Voltage

(Nominal 115 VAC Input)

Current 115 VAC Regeneration Shunt Resistor (Internal) 15 OHM 7.5 OHM Shunt Regulator Current (PK) 15.3 AMPS 30.6 AMPS Power Dissipation (Cont.) 40 WATTS 40 WATTS Power Dissipation (PK) 3.5 KW 7.0 KW Internal Heat Dissipation 120 WATTS 120 WATTS Regeneration Shunt Resistor (External Min) 5.5 OHM 5.5 OHM

12.0 AMPS

10.0 AMPS

24.0 AMPS

20.0 AMPS

50.0 AMPS

42.0 AMPS

160 VDC

1.1 AMPS RMS

20.0 AMPS

16.0 AMPS

40.0 AMPS

32.0 AMPS

80.0 AMPS

64.0 AMPS

160 VDC

1.1 AMPS RMS

Shunt Regulator Current (PK) 41.8 AMPS 41.8 AMPS Power Dissipation (Cont.) 200 WATTS 200 WATTS Power Dissipation (PK.) 9.6 KW 9.6 KW Soft-Start Surge Current (Max) 80 AMPS 80 AMPS Charge Time (Max) 25 MSEC 25 MSEC

1-10

BDS5 C

Table 1.4. Specifications (Cont.)

HAPTER

YSTEM DESCRIPTION

1 - S

PSR4/5-2XX-(160 - 253 VAC L-L INPUT)

DESCRIPTION PSR4/5-212- PSR4/5-220-

Main AC Line Input Voltage 160 - 253 VAC 160 - 253 VAC Phase 1-3 1-3 Frequency 47-63 Hz 47-63 Hz Current Cont. (RMS) 3 Phase

Single Phase Peak (2.0 sec) 3 Phase

Single Phase Peak (50.0 msec) 3 Phase

Single Phase Control AC Line Input Voltage 90-132 VAC 90-132 VAC Phase 1 1 Frequency 47-63 Hz 47-63 Hz Main DC Bus Output Voltage

(Nominal 115 VAC Input)

Current 115 VAC Regeneration Shunt Resistor (Internal) 25 OHM 12 OHM Shunt Regulator Current (PK) 15 AMPS 30 AMPS Power Dissipation (Cont.) 40 WATTS 40 WATTS Power Dissipation (PK) 5.6 KW 11.2 KW Internal Heat Dissipation 120 WATTS 150 WATTS Regeneration Shunt Resistor (External Min) 8.8 OHM 8.8 OHM

12.0 AMPS

10.0 AMPS

24.0 AMPS

20.0 AMPS

50.0 AMPS

42.0 AMPS

325 VDC

1.1 AMPS RMS

20.0 AMPS

16.0 AMPS

40.0 AMPS

32.0 AMPS

80.0 AMPS

64.0 AMPS

325 VDC

1.1 AMPS RMS

Shunt Regulator Current (PK) 44.3 AMPS 44.3 AMPS Power Dissipation (Cont.) 400 WATTS 400 WATTS Power Dissipation (PK) 17.3 KW 17.3 KW Soft Start Surge Current (Max) 150 AMPS 150 AMPS Charge Time (Max) 25 MSEC 25 MSEC

1-11

HAPTER

YSTEM DESCRIPTION

1 - S

BDS5

Table 1.5. Environmental Specifications

Operating Temperature*: 3, 6, & 10 AMP Units (Convection Cooled) 20 Amp Units (Internal Fan Cooled)

Storage Temperature -20o C to 70o C Humidity (Non-Condensing) 10% to 90%

* For operation ambients above 45°C, consult the Applications Group at Industrial Drives.

Table 1.6. Mechanical Specifications

C to 45o C

MODEL WIDTH HEIGHT DEPTH

NUMBER MM IN. MM IN. MM IN.

BDS5-X03- 56 2.20 340 13.49 280 11 BDS5-X06- 76 2.99 340 13.49 280 11 BDS5-X10- 98 3.86 340 13.49 280 11 BDS5-X20- 98 3.90 340 13.49 280 11

PSR4/5-

X12 & X20-

1.6 THEORY OF OPERATION

76 3.00 340 13.49 280 11

DISCRETE INPUTS

•

Drawing D-93030 shows a system overview.

MICROPROCESSOR SYSTEM

•

The BDS5 is a digital positioner and servo drive combined into one unit. The velocity loop is 100% digital. The BDS5 has battery backup RAM to remember your p rogram and most variables through power-down.

RESOLVER-TO-DIGITAL CONVERTER

•

The BDS5 is based on a Resolver-to-Digital (R/D) converter. The R/D generates a tachometer signal for your convenience. However, the BDS5 does not use the analog tach signal.

SERIAL PORT

•

The BDS5 has a serial port for communications. This port allows you to monitor the operation, issue commands, and transmit a program.

The BDS5 has 23 discrete inputs, including REMOTE ENABLE which is on Connector C2 only. Note that two signals, HOME and CYCLE, can be input to the BDS5 on two connectors, C2 and C7. Connector C2 provides these three signals with optical isolation. Connector C7 expects non-isolated TTL signals on a 26-pin ribbon cable connector. Optional Connector C8 expects non-isolated TTL signals on a 50-pin ribbon cable connector.

DISCRETE OUTPUTS

•

The BDS5 has 10 discrete outputs. Notice that O1 appears both on Connector C2 with optical isolation and on Connector C8.

ENCODER INPUT

•

The BDS5 accepts external inputs in encoder format. This can come from a master motor in a master/slave system. Note that you must use a resolver, even if you use a feedback encoder with the BDS5.

1-12

BDS5 C

HAPTER

YSTEM DESCRIPTION

1 - S

ENCODER EQUIVALENT OUTPUT

•

The BDS5 provides encoder format output derived from the R/D converter.

ANALOG INPUT (O PT1 CARD)

•

As an option, the BDS5 can accept a ±10 volt analog input. This input is converted to digital format by the BDS5. Gain and offset adjustments are made digitally inside the BDS5, not with potentiometers.

PULSE INPUT (OPT2 CARD)

•

The BDS5 can accept special pulse inputs. The standard BDS5 can accept signals directly from encoders or encoder-like devices. As an option, the BDS5 can accept other pulse formats, such as count/direction or up/down.

LED'S

•

The BDS5 provides LED's for diagnostics. These LED's are on the front panel of the BDS5. The LED's are listed below:

ACTIVE SYS OK CPU FAULT RELAY

CURRENT LOOP COMPENSATION

•

The BDS5 has analog current loops. The current loop compensation components are all contained in the compensation module located on the front of the BDS5. The current loop compensation changes when you change the motor model. You must install the correct compensation module when changing motor models.

YOU MUST HAVE THE PROPER COMPENSATION MODULE INSTALLED FOR YOUR MOTOR

CAUTION

Failure to install the proper compensation module can cause damage to the BDS5, the motor, or both.

1.7 SIMPLIFIED SCHEMATIC DIAGRAM AND SYSTEM DIAGRAM

Drawings D-93030 and A-84847 illustrate a BDS5 servo system with all of the major components.

1-13

HAPTER

24 VOLT DC CUSTOMER

SUPPLIED

IN COMMON

YSTEM DESCRIPTION

1 - S

I/O DC

COMMON

REMOTE

HOME

CYCLE

HOME

CYCLE

LIMIT

MOTION

GATE

MANUAL

I10

I11

I12

I13

I14

I15

I16

C2-PIN 5

C2-PIN 15

C2-PIN 9

C2-PIN 19

C2-PIN 8

C2-PIN 18

C7-PIN 9

C7-PIN 13

C7-PIN 11

C7-PIN 15

C7-PIN 17

C7 (EVEN PINS)

C7 STANDARD I/O

C8 (EVEN PINS)

C8-PIN 33

C8-PIN 31

C8-PIN 29

C8-PIN 27

C8-PIN 25

C8-PIN 23

C8-PIN 21

C8-PIN 19

C8-PIN 17

C8-PIN 15

C8-PIN 13

C8-PIN 11

C8-PIN 9

C8-PIN 7

C8-PIN 5

C8-PIN 3

C8-PIN 1

C8 OPTIONAL I/O

ALTERNATE POWER SOURCE FOR REMOTE, HOME, AND CYCLE ONLY !

OPTICAL ISOLATOR

INPUT BUFFERS

AND PULL-UP

74HC14

INPUT BUFFERS

AND PULL-UP

74LS540

RS-232

RS-485

TXD

RXD

TD+ TD-

RD+ RD-

C5-PIN 3

C5-PIN 2

120 OHM

C5-PIN 6

C5-PIN 7

120 OHM

C5-PIN 8

C5-PIN 9

MICROCOMPUTER SYSTEM

MICROPROCESSOR

BATTERY BACK-UP

RAM

452

ROM

BDS5

6 1K

1-14

DIFF CMD HI

DIFF CMD LO

IN A IN A

IN B IN B

C2-PIN 11

C2-PIN 1

C1-PIN 5

C1-PIN 10

C1-PIN 4

C1-PIN 9

ANALOG

TO PULSE

CONVERTER

OPTIONAL

SN75175

CH A

CH B

ENCODER

DIGITAL

BDS5 SYSTEM OVERVIEW

BDS5 C

75155

75156

RD TD

HARDWARE WATCHDOG

HAPTER

24 VOLT

OPTICAL

ISOLATOR

1 - S

"RELAY"

( N. O. )

YSTEM DESCRIPTION

"ACTIVE"

LED

"SYS OK"

LED

"CPU"

LED

"FAULT"

LED

"RELAY"

LED

C2-PIN 17 C2-PIN 16 C2-PIN 10

C2-PIN 20

RELAY

01 HI

01 LO

ISSUE

D-93030

SHULER

12-17-92

COPY CODEI

COMPENSATION

CARD

PIN 10 PIN 5

PIN 9 PIN 4

PIN 8 PIN 3

RESOLVER

DIGITAL

CONVERTER

A-PHASE

CURRENT

LOOP

B-PHASE

CURRENT

LOOP

C-PHASE

CURRENT

LOOP

C3-PIN 4

C3-PIN 10

C3-PIN 1

C3-PIN 9

C3-PIN 3

BUS +

REF HI

REF LO

SIN HIC3-PIN 7

SIN LO

COS HI

COS LO

PWM

POWER

STAGE

BUS -

ABSOLUTE

VALUE

CIRCUIT

CURRENT

SAMPLE

CURRENT

SAMPLE

CURRENT

SAMPLE

TACH SCALING = 1000 RPM/V

DIGITAL

ENCODER

OUTPUT BUFFERS

5 VOLTS = FULL SCALE

CH A

CH B

CH Z

WITH OPEN

COLLECTORS

ULN2803A

GND

1.0K

4700pf

75174

3.01K

C8 OPTIONAL I/O

C7 STANDARD I/O

MOTOR

RESOLVER

C2-PIN 2 C2-PIN 12

C1-PIN 1 C1-PIN 6

C1-PIN 2 C1-PIN 7

C1-PIN 3 C1-PIN 8

C8-PIN 35

C8-PIN 47

C8-PIN 45

C8-PIN 43 C8-PIN 41 C8-PIN 39 C8-PIN 37

C7-PIN 21

C7-PIN 19

C7-PIN 23

C2-PIN 4 C2-PIN 14

STATUS

01 02

03 04 05 06

CYCLE READY

I MONITOR COMMON

TACH MONITOR

COMMON

OUT A OUT A

OUT B

OUT Z

1-15

HAPTER

YSTEM DESCRIPTION

1 - S

BDS5

ISSUE

MASTER

ENCODER

A-84847

TERMINAL OR PC COMPATIBLE

ACTIVE SYS OK

FAULT

RELAY

MODEL No

SERIAL No

BUS+ BUS-

CPU

T 1

Ma Mb Mc

MODEL No.

REV No.

INDUSTRIAL DRIVES

GND

BDS5

EXTERNAL REGEN RESISTOR

D.C. BUS

REGEN

OVERLOAD

BLOWN FUSE

MODEL No

SERIAL No

INDUSTRIAL DRIVES

PSR

BUS+ BUS-

La Lb Lc

GND

CUSTOMER I/O (OPTO-22 COMPATIBLE)

CYCLE READY

O7 O8

GATE MOTION CYCLE LIMIT

HOME

STATUS MANUAL

115 VAC, 1 PHASE

O2 O3 O4

O5 O6

I1 I2 I3 I4 I5 I6 I7 I8 I9

I10

I1 I2 I3 I4 I5 I6

ISSUE

A-84847

R. FURR

1-14-91

1-16

230 VAC, 3 PHASE OR 115 VAC, 1 PHASE

GOLDLINE MOTOR

TYPICAL BDS5 SYSTEM INTERCONNECT

COPY CODE

BDS5 C

HAPTER

NSTALLATION

2.1 INTRODUCTION

HAPTER

NSTALLATION

2 - I

The information in this chapter will familiarize you with safety information, unpacking and inspection, installation requirements, mounting procedures and wiring for installing the BDS5, PSR4/5 and/or External Regen Resistors. Read the entire chapter carefully. The chapter contains an extensive checkout procedure because most installation problems are caused by incorrect wiring or poor wiring practices. Complete the entire checkout procedure before attempting to put your BDS5 system into operation.

2.2 SAFETY INFORMATION

The purpose of this section is to alert you to possible safety hazards associated with this equipment and the precautions you can take to reduce the risk of personal injury and damage to the equipment. Safety notices in this manual provide important information. Read and be familiar with these instructions before attempting installation, operation, or maintenance. Failure to observe these precautions could result in serious bodily injury, damage to the equipment, or operational difficulty.

WARNING

Figure 2.1. Safety-Alert Symbols

The safety-alert symbols are illustrated in Figure 2.1. When you see these symbols in this manual, be alert to the potential for personal injury. Follow the recommended precautions and safe operating practices included with the alert symbols.

Warning

to potential danger or harm. Failure to follow warning notices could result in personal injury or death.

Caution

which if not followed, could result in personal injury and/or equipment damage.

Note

understanding or use of these products.

" refers to personal safety. They alert you

" directs attention to general precautions,

" highlights information critical to your

CAUTION

NOTE

2-1

HAPTER

NSTALLATION

2 - I

BDS5

2.3 UNPACKING AND INSPECTION

Electronic components in this amplifier are static sensitive. Use proper

CAUTION

Upon receipt of the equipment, closely inspect components to ensure that no damage has occurred in shipment. If damage is detected, notify the carrier immediately.

Carefully remove packing material and remove the equipment from the shi pping container. Do not dispose of shipping materials until the packing list has been checked. Parts that are contained within the shipment, but not physically attached to the equipment, should be verified against the packing list. If any parts are missing, notify Industrial Drives at once.

procedures when handling component boards.

2.4 INSTALLATION REQUIREMENTS

from physical and environmental damage. Refer to specifications for complete system dimensions.

Allow sufficient clearance for the large "regenerative" heat producing resistor(s) mounted at the upper edge

CAUTION

of the PSR4/5 unit and the externally mounted regen (shunt regulator) power resistor(s).

2.5 MOUNTING

The BDS5 and PSR4/5 should be mounted in a cabinet or other suitable enclosure to protect them from physical and environmental damage.

The PSR4/5 and the BDS5 are provided with protective guards over the power terminal blocks. After wiring is complete, ALWAYS REPLACE THE PROTECTIVE GUARDS TO REDUCE SHOCK HAZARD.

Proper installation and field wiring are of prime importance when considering the application of servo amplifiers. Many problems may be avoided if installation of the equipment is done properly. Users should familiarize themselves with and follow installation and wiring instruction in addition to all applicable codes, laws, and standards. Pay special attention to the following topics when installing Industrial Drives' equipment.

2.4.1 Environmental Considerations

The environment that this equipment is placed in can have dramatic effects on its operation. Industrial Drives recommends that the BDS5 and PSR4/5 be operated and stored under the following conditions:

Operating Temperature: 0° C to 45° C

•

Storage Temperature: -20° C to 70° C

•

Humidity: 10% to 90% (Non Condensing)

•

2.4.2 Enclosures

It is suggested that the BDS5 and PSR4/ 5 be mounted in a cabinet or other suitable enclosure to protect them

REPLACE THE POWER TERMINAL GUARDS AFTER

WARNING

WIRING THE SYSTEM!

2.5.1 Mounting the BDS5

Refer to drawing A-93703 in Appendix B for mounting dimensions. The BDS5 and PSR4/5 should be mounted in the vertical position. Since these units are convection cooled, there should be a minimum of 25 millimeters (1 inch) of unobstructed space above and below the units. In addition, there should be a minimum of 20 millimeters (0.8 inch) between units to ensure proper airflow for these convection-cooled units.

2.5.2 Mounting the PSR4/5

The PSR4/5 Power Supply module may be mounted on either side of the BDS5. However, a 20 millimeter (0.8 inch) space is required between units.

Some PSR4/5's have resistors which dissipa te the energy returned to the PSR4/5 during regenerative braking. These are referred to as regen resistors. Some applications require externally mounted regen

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resistors, while others may require none at all. To determine if your PSR4/5 has internal regen resistors, check its model number.

REGEN RESISTORS GET HOT!

If your PSR4/5 has internal

CAUTION

NOTE

Refer to appropriate outline and dimension drawings in Appendix B for more information:

A-93569BDS5 3 and 6 Amp Unit A-93571BDS5 10 Amp Unit A-93570BDS5 20 Amp Unit A-93880BDS5 30 and 40 Amp Unit A-93010BDS5 55 Amp Unit A-93581PSR4/5 12 and 20 Amp Unit A-93031PSR4/5 50 and 75 Amp Unit

regen resistors, allow sufficient clearance above the PSR4/5.

Refer to Drawing A-93703 for more information concerning mounting.

2.5.3 Mounting the External Regen Resistor

External mounting of regen resistors is an option on PSR4/5's. To determine if your unit uses external regen resistors, check its model number. Also, the model number indicates the standard resistor value. These resistors should be enclosed to reduce shock hazard. Regen resistors get hot! They are a burn hazard and they are a fire hazard. They can produce enough heat to melt insulation. Enclos e these resistors! The enclosure must provide ventilation and withstand high temperatures. Do not mount the resistors underneath the BDS5 or PSR4/5.

EXTERNAL REGEN RESISTORS ARE A SHOCK HAZARD!

Mount these resistors

WARNING

CAUTION

properly! Enclose these resistors to protect personnel and equipment!

EXTERNAL REGEN RESISTORS GET HOT!

If you are using external regen resistors, allow sufficient clearance around the resistors. Enclosures must provide ventilation.

2.6 WIRING

The customer is responsible for providing proper circuit breaker or fuse protection. The customer is responsible for providing proper wire gauge and insulation rating for all wiring, including motor, AC line, DC bus, and External Regen Resistor connections. The customer is responsible for making sure that all system wiring and electrical protection comply with all applicable national and local electric codes.

Drawing A-93103 is the System Wiring Diagram. It is a seven-sheet drawing. Carefully read all of Drawing A-93103 before wiring your BDS5 system, including all of the notes on the last sheet. Refer to BDS5 Connectors Diagram A-96372M, provided at the end of this chapter, for connector locations.

Carefully read all seven sheets of Drawing A-93103 before wiring your BDS5

WARNING

system, including ALL of the notes on the last sheet.

When wiring your BDS5 system, obse rve the following guidelines:

1. Twist all AC leads to minimize electromagnetic emissions (noise).

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BDS5

2. Avoid running signal l eads in close proximity to power leads, motor stator leads, or other sources of electromagnetic noise. Run signal leads in separate conduit from power leads. Shields are recommended for signal leads.

3. Minimize lead lengths.

4. Connect the BDS5 system according to the System Wiring Diagram, A-93103; pay close attention to the grounding scheme and notes.

2.6.1 Wiring the Ground

Ground terminals are provided on the front of BDS4's, BDS5's, and PSR4/5's. These ground screws are directly below the Power Terminal Block of each unit.

To prevent shock hazard and to ensure proper operation of the system, the BDS5, PSR4/5, and the motor must be grounded. Each BDS5 and PSR4/5 has two ground screws on the front of its chassis.

GROUND YOUR BDS5, PSR4/5, and motor PROPERLY! Failure to

WARNING

One of the ground screws on the PSR4/5 should be connected to Earth Ground or Machine Ground. The other should be connected to the adjacent BDS5 ground screw, along with the ground wire fro m the motor. The ot her ground screw on the B DS5 chassis should then be connected to the next BDS5, etc. Use 10 AWG or larger wire for grounding between BDS5's and PSR4/5's and from PSR4/5 to Earth Ground or Machine Ground.

provide proper grounding can result in a shock hazard.

2.6.2 Wiring the Power Connections

This section discusses how to wire the PSR4/5 and BDS5 power connections.

To prevent equipment damage, the AC Line and the DC bus must be connected as

CAUTION

indicated by the System Wiring Diagram, A-93103.

for operation from either a 115 volt or a 230 volt AC Line. The PSR4/5 and the BDS5 must both have the same voltage rating. Operating a PSR4/5 or a BDS5 with incorrect voltage can damage the units.

Use the proper AC Line voltage. PSR4/5's and BDS5's are configured at the factory for 115 volt or 230 volt AC Line voltage. See the model

CAUTION

number description at the beginning of this chapter to determine the required voltage for your PSR4/5 and BDS5.

2.6.2.1 Wiring the Motor

Connect Pins A, B, and C of the motor connector through a motor cable to Ma, Mb, and Mc, respectively, on the Power Terminal Block located on the front of the BDS5 amplifier. Connect Pin D of the motor connector through the same motor cable to the BDS5 chassis ground screw located directly beneath the Power Terminal Block.

IT IS VERY IMPORTANT THAT YOU WIRE THE MOTOR PROPERLY. Brushless permanent magnet motors are not like induction motors. You cannot simply interchange two phases to reverse the direction of rotation.

Standard Industrial Drives motor cable has the color code as shown in Table 2.1.

Table 2.1. Motor Cable Color Code

Motor

Connector

Pin A M Pin B M Pin C M

WARNING

Incorrect motor wiring can cause erratic or runaway motor operation. Use of factory supplied cable sets is highly recommended.

Wire

Marker

a b c

BDS5 Power

Terminal Terminal M Terminal M Terminal M

a b c

The PSR4/5 and BDS5 are configured at the factory

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2.6.2.2 Motor Protection

Under normal conditions, you do not need to add protection for your motor; the BDS5 is normally configured to limit the continuous current below the rating of the motor. However, if the drive is oversized (that is, it can provide continuous current that greatly exceeds the motor's continuous current rating), you may want to add motor overload relays in series with the motor. Also, you can wire a contactor in series with the motor leads. ALWAYS BE CAREFUL TO WIRE THE MOTOR PROPERLY.

2.6.2.3 Motor Thermostat

Industrial Drives brushless motors have a thermostat. The thermostat contacts are closed during normal operation and open when the motor overheats. The BDS5 does not provide a direct input for the motor thermostat. You should connect the thermostat contacts to a BDS5 general purpose input, and program your BDS5 to bring about an orderly shutdown when the thermostat opens. The thermostat ratings are:

Rated Voltage: 277 VAC at 60 Hz

250 VAC at 50 Hz

WARNING

NOTE

LATCH THE MOTO R THERMOSTAT!

DO NOT CONNECT THE THERMOSTAT DIRECTLY TO THE BDS5 REMOTE ENABLE OR LIMIT INPUTS.

The motor thermostat resets (closes) when the motor cools. This can allow the motor to restart operation unexpectedly after a motor thermostat fault unless the thermostat is latched. Always latch the thermostat.

B series (GOLDLINE) motors have the thermostat wired to the resolver connector at the motor.

BR series motors have the thermostat wired to the power connector at the motor.

Rated Current: 2.5 Amps at power factor of 1.0

1.6 Amps at power factor of 0.6

Resistance: 50 m Ohms

The thermostat resets (closes) when the motor cools. The customer is responsible for making sure that the motor does no t begin moving unexpecte dly when the thermostat closes. Do not connect the thermostat directly in line with the BDS5 REMOTE ENABLE or LIMIT inputs, as this may allow the system to begin operatio n unexpectedly. Yo u must la tch the thermostat switch, either in hardware or software. IT CAN TAKE SEVERAL MINUTES FOR THE MOTOR TO COOL ENOUGH TO ALLOW THE THERMOSTAT TO CLOSE. UNEXPECTE D OPERATION SEVERAL MINUTES AFTER A FAULT IS A SAFETY HAZARD!

Some electrical noise from the motor leads will couple capacitively with the thermostat leads. This occasionally causes false thermostat trips. That is, your controller senses that the thermostat opened even though the thermostat contacts were closed . If this occurs you can use the thermostat contacts to energize a relay and then connect the relay contacts to your controller. The electrical noise does not normally cause relay contacts to open.

2.6.2.4 Motor Brake

Fail safe brakes are an option with INDUSTRIAL DRIVES motors. With GOLDLINE motors, the brake connections are available as blue flying leads on the resolver cable. They are available in more than one voltage rating, so check the model number of your motor carefully to determine the voltage and current required by the brake on your motor. Normally, you should control the brake with the STATUS input discussed in Chapter 4.

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BDS5

2.6.2.5 Wiring the DC Bus

Connect the DC Bus from the PSR4/5 Power Terminal Block (BUS+, BUS-) to the BDS5 Power Terminal Block (BUS+, BUS-). You must observe polarity of DC Bus connections: always connect BUS+ to BUS+ and connect BUS- to BUS-. For the PSR4/5-12 and 20, the DC Bus can be connected to any combination of 3 BDS4's or BDS5's (for example, 2 BDS5's and 1 BDS4). The PSR4/5-50 and -75 can be connected to any combination of 6 BD S4's or BDS5's, altho ugh no more than 3 units can be on one side of the PSR4/5. Refer to Note 8 on A-93103.

Failure to observe polarity of the DC Bus can result in

WARNING

CAUTION

personal injury.

Failure to observe the polarity of the DC Bus will result in damage to the PSR4/5 and BDS5.

2.6.2.6 Wiring the AC Line

Connect the three-phase AC Line to La, Lb, and Lc on the Power Terminal Block located on the front of the PSR4/5 unit.

2.6.3 Wiring the PSR4/5 Front Panel Connectors

This section will discuss wiring of the PSR4/5 front panel connectors, C1 and C2. The mating connectors for C1 and C2 are supplied with the PSR4/5.

2.6.3.1 Wiring the Control Power to C1

The Control Power for the PSR4/5 is 115 VAC. Connect the Control Power to Connector C1 of the PSR4/5. Connect one 115 VAC line to Pin 2 and the other to Pin 3. Other 115 VAC connections (such as fans on 20 Amp BDS4's and BDS5's) can be made from Connector C1 Pin 5 (one side of the 115 VAC line) and Pin 6 (the other side). See Drawing A-93103 for more information.

2.6.3.2 Wiring to the PSR4/5 Fault Output on C1

The PSR4/5 Fault Output Contact closes approximately 250 milliseconds after power is applied to the PSR4/5. This contact opens if a fault occurs in the PSR4/5. This is a relay contact from Pin 1 to Pin 4 of Connector C1. You can connect this contact to your controller or to a BDS4/5 remote inhibit. You should inhibit the entire system if a PSR4/5 fault occurs! See Note 2 of A-93103.

The PSR4/5 will work with a single-phase AC Line. Depending on the PSR4/5 model number, either 110 VAC or 220 VAC single-phase input lines may be connected to any two terminals, La, Lb, or Lc. Note that the PSR4/5 must be derated for single-phase AC Line operation. A 12-Amp PSR4/5 with a singlephase AC Line can only provide 10 Amps; a 20-Amp PSR4/5 with a single-phase AC line can only provide 16 Amps.

The PSR4/5 must be derated when operated from a single-

CAUTION

phase AC Line.

2.6.2.7 Wiring the Regen Resistor

If an external regen resistor is used, wire it to the External Regen Resistor Co nnector on the PSR4/5. Note that you must specify that you need an external regen resistor when ordering your PSR4 / 5 as this is an option. Refer to Notes 3 and 11 on System Wiring Diagram A-93103.

The ratings of this relay are:

2 amps at 28 Volts DC, resistive. 1 amp at 120 Volts AC, resistive.

INHIBIT YOUR SYSTEM IF A PSR4/5 FAULT OCCURS! YOU MUST WIRE YOUR

CAUTION

SYSTEM FOR THIS FUNCTION!

2.6.3.3 Wiring PSR4/5 Connector C2

Connector C2 is the Logic Power Supply for the BDS5. Wire the Logic Power Supply from Connector C2 on the PSR4/5 to Connector C4 of the BDS5. Each logic power supply voltage is connected to two pins so that you can wire from the PSR4/5 to the nearest BDS4 or BDS5. For example, +18 volts appears side by side on Pins 1 and 5. Note that the PSR4/5 12 and 20 amp models can have a maximum of three units (axis) connected, while the 50 and 75

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amp models made have six units connected. Table 2.2 lists the ratings of the PSR4/5 logic power supplies.

Table 2.2. PSR4/5 Logic Power

CURRENT

VOLTAGE

+ 18 VDC ±20%

- 18 VDC ±20% COMMON --- 3, 7 3, 7

+ 10 VDC ±20%

LOGIC POWER SUPPLY MAXIMUM RATINGS

(PER

AXIS)

0.25 AMP 1, 5 1, 5

0.25 AMP 2, 6 2, 6

1 AMP 4, 8 4, 8

BDS5

Connector

C4 PIN

PSR4/5

Connector

C2 PIN

Failure to observe the polarity of the logic power supply will result in damage to the

CAUTION

PSR4/5 and BDS5

Connecting more than a total of three units (either BDS4's or BDS5's) to one PSR4/5 (12

CAUTION

& 20 amp models) can damage the PSR4/5.

2.6.4 Wiring the BDS5 Front Panel Connectors

This section will discuss wiring of the BDS5 front panel connectors: C1, C2, C3, C4, C5, and C6 (C6 is on 20 Amp units only). Mating connectors for C1-C6 are supplied with the BDS5.

2.6.4.1 Wiring C1, Encoder Equivalent

The Encoder Equivalent Connector connects encoder inputs and encoder equivalent outputs. The BDS5 uses standard encoder format (A-B quadrature). This format has excellent noise immunity because only one

channel changes at a time. As an option, pulse inputs in different formats are also supported.

The Encod er Equivalent Connector is used for master/slave systems. If your BDS5 is the slave axis, then connect the output from the master to INA and INB. If your BDS5 is the master axis, connect OUTA, OUTB, and OUTZ to the inputs on the slave axies. See Figure 2.2 and/or Drawing A-93103 for connection diagrams.

All encoder signals are differential (as opposed to single-ended) to increase noise immunity. This means that each signal is transmitted with its logical inverse (for example, OUTA and OUTA'). Logical inverse means that if OUTA is 5 volts, then OUTA' is 0 volts and that if OUTA is 0 volts, then OUTA' is 5 volts. (Note that Drawing A-93103 shows the inverse of OUTA as OUTA with a bar drawn directly above it; here, the inverse of OUTA will be designated OUTA'.)

The encoder equivalent inputs and outputs conform to RS-485. One standard RS-485 output can drive up to 32 standard RS-485 inputs, provided that the interconnecting cable's capacitance is small enough. Capacitance increases with cable length, which implies that the transmitter (OUT's) and receivers (IN's) should be as close to each other as is practical.

You should use 120 ohm cable. For longer distances (over a 100 feet), consider using reduced capacitance cables such as those available from Black Box (Pittsburgh, PA). The cable should be run from point to point, as opposed to branching out from a single point. Branches could cause reflections (a transmission line effect) that can interfere with the signals. If the cable is very long, ringing (also a transmission line effect) may occur. If this happens, you should connect a 120 ohm resistor across each signal and its logical inverse at both ends of the cable.

The Encoder Equivalent Connector uses RS-485 compatible 75174 line drivers and 75175 line receivers, which are available from many IC manufacturers, including Texas Instruments.

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THE COMMONS OF MASTER/SLAVE BDS5's MUST BE CONNECTED. THIS IS ACCOMPLISHED THROUGH CONNECTOR C4 IF THE BDS5's SHARE ONE PSR4/5.

OUT A

OUT B

OUT Z

CONNECTOR C1

7 6 2

IN B (OPTIONAL)

IN A (OPTIONAL)

OUT A

OUT B

OUT Z

CONNECTOR C1

10 9 5

SLAVE BDS5

IN B (OPTIONAL)

(SEE NOTE 13, LAST SHEET)

IN A (OPTIONAL)

BDS5

MASTER BDS5

NOTE 13 - IF THE BDS5 USES THE OPTIONAL ANALOG INPUT CARD (BDS5 - OPT1), THE OPTIONAL ENCODER INPUTS IN CONNECTOR C1 ARE NOT USED.

REFERENCE TO NOTE 13 LAST SHEET STATES,

WIRE THROUGH AN OPTO-22 STYLE DC INPUT MODULE TO CONNECTOR C7 (PIN 9)

Figure 2.2. Master BDS5 and Slave BDS5 (Part of Drawing A-93103)

The BDS5 uses the same phasing for the encoder inputs and outputs; for clockwise rotation, Channel A leads Channel B. For standard systems, the inputs are Channel A (Pins 5, 10) and Channel B (Pins 4, 9). The outputs are Channel A (Pins 1, 6), Channel B (Pins 2, 7), and the marker channel, Channel Z (Pins 3,

CHANNEL A

8). There is no input Channel Z, though this signal often would be connected to HOME (see

Manual

). Refer to Figure 2.3 for a phasing diagram. The logic power supply common is not available on Connector C1. If you are wiring from one BDS5 to

User's

CHANNEL B

another BDS5 on the same PSR4/5, then you need not connect common, as the commons of the two drives will be connected through the logic power supply connector, C4. If you need to connect to common, you must obtain it from Connector C2 or C4. BE SURE THAT THE COMMON OF THE BDS5 AND OF THE ENCODER POWER SUPPLY ARE

CHANNEL Z

Figure 2.3. Encoder Phasing For Cloc kwise

Rotation

ELECTRICALLY CONNECTED TO EACH OTHER.

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6 1 OUT A

7 2 OUT B

8 3 OUT Z

9 4 IN B (Standard)

10 5 IN A (Standard)

IN B

IN A

OUT A

OUT B

OUT Z

(Standard)

Figure 2.4. BDS5 (C1)

2.6.4.2 Encoder Equivalent Input

The encoder and pulse inputs are for signals from a master encoder (for example, an encoder on another motor, or the encoder output of another BDS5). The BDS5 can also use an encoder for feedback in some cases. The encoder equivalent input is not available when the analog input (OPT1 Card) or pulse input (OPT2 Card) is installed.

If the encoder input is being used for a velocity command, as is the case for electronic gearbox applications, then you must be careful to connect the encoder input for the correct direction of rotation. If the BDS5 is being used as a velocity drive, and another controller is closing a position loop, reversing the encoder inputs can cause the BDS5 to run away or oscillate. BE CAREFUL TO CONNECT THE ENCODER/PULSE INPUT SO THAT THE DIRECTION IS CORRECT !

Phase the encoder/pulse input correctly. Incorrect phasing of the encoder input can

WARNING

cause excursions, oscillations, or runaways.

1. Control the BDS5 from a stepper-motor controller. For this function, configure the BDS5 as an electronic gearbox and select the format that is compatible with your controller.

2. Input a single-phase clock from your computer. There are occasions when you want to control the BDS5 with a unidirectional clock (for example, feedrate override). The Pulse Input option accepts a single-phase clock, such as would be generated from an electronic timer/counter chip.

The Pulse Input Option board (BDS5-OPT2) is mounted inside the BDS5 unit. This board accepts pulse inputs in three formats: count/direction, up/down, or single-phase. Use the toggle switch on the board to select the formats. See Drawing A-93146 for more information.

2.6.4.4 Encoder Equivalent Output

The Encoder Equivalent Output provides position information to another device in the system. The output is in standard encoder format. The Encoder Equivalent Output must be phased correctly. If the BDS5 is being used as a velocity drive, and another controller is closing a position loop, reversing the Encoder Equivalent Output can cause the BDS5 to run away or oscillate. BE CAREFUL TO CONNECT THE ENCODER EQUIVALENT OUTPUT SO THAT THE DIRECTION IS CORRECT!

Phase the Encoder Equivalent Output correctly. Incorrect phasing of the Encoder Equivalent Output can cause

WARNING

excursions, oscillations, or runaways.

Note that if your BDS5 is configured with the optional analog input, then encoder equivalent inputs are not available. The outputs are still available.

Systems with the optional analog inputs do not have

NOTE

encoder equivalent inputs.

2.6.4.3 Pulse Input (OPT2 Card)

As an option, you can also purchase your BDS5 with a Pulse Input option. This option allows you to:

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2.6.4.5 Wiring C2, Customer I/O

Connector C2 ha s a variety of signals:

Analog Input Pins 1, 11

•

The BDS5 accepts an analog input as an option. This option is specified when you order your system. If you use the analog input, then the encoder input is not available. If you use the analog input, refer to the User’s Manual paragraph 4.11 for a program that configures the BDS5 as a velocity drive.

The input is scaled for ±10 volts = full scale. Input impedance is > 20 k Ohm. The analog input is differential; that is, the input voltage is taken to be the voltage at Pin 11 minus the voltage a t Pin 1. Differential (two-wire) signals have highe r noise immunity than single-wire signals, since noise picked up by the wires is eliminated when the two voltages are subtracted.

BDS5

Tach Monitor Pin 2

•

Tach monitor indicates velocity. It is referenced to Common and scaled for 1000 RPM clockwise = +1 volt. This output has a 1k Ohm resistor in series and a 4700 pF filter capacitor connected to Common.

I Monitor Pin 4

•

I monitor is a Common-referenced signal scaled for full (peak) current = 5 volts. This output has a 3.01k Ohm resistor in series. I Monitor is always positive.

Common Pins 12, 14, 15

•

Logic Power Supply Common is provided on several pins since it is used in several places. Do not connect shields to Common.

Shield Pins 3, 13

•

Typically, one of the two wires will be at a voltage nominally the same as Common. Preferably, this wire should be connected to Pin 1. It is important to note that swapping Pins 1 and 11 reverses the polarity of this input.

When using the analog input you must be careful to shield it properly. You should use shielded, twistedpair cable. Connect the shield to Pin 13 or 3 on Connector C2 on the BDS5, or to the frame at the source of the signal, or at both ends. Determining the best shield connection is often a matter of trial-anderror. Begin by wiring the shield only at the BDS5.

If the BDS5 is being used as an analog velocity drive, then you must be careful to connect the analog input with the correct polarity, since the polarity determines the direction of rotation. If the BDS5 is being used as a velocity drive, and a different controller is closing a position loop, reversing the polarity of the analog input can cause the BDS5 to run away or oscillate. BE CAREFUL TO CONNECT THE ANALOG INPUT SO THAT ITS POLARITY IS CORRECT!

Phase the analog input correctly. Incorrect polarity of the analog input can cause

WARNING

excursions, oscillations, or runaways.

The shield pins are connected directly to the BDS5 frame. You should connect shields from cables to the shield pins.

Relay Pins 16, 17

•

These two pins are connected to a set of normally open relay contacts. The contacts are open on powerup, and close after the power-up self-tests and autobauding. The relay is controlled by the watchdog timer. If the contacts open once the BDS5 is running, then there is a serious fault and you cannot depend on the microprocessor to operate properly. Always wire all BDS5 relays to disconnect all power in the event of the relay contacts opening. These contacts are rated for a maximu m current of 1 Amp and a maximum voltage of 115 volts AC or DC. The maximum switched power is 30 Watts DC or 60 volt-amps AC.

CYCLE/CYCLE RETURN Pins 8, 7

•

CYCLE is on Pin 8; CYCLE RETURN is on Pin 7. CYCLE is normally used to start a cycle of a user program; it can also be used as a general purpose input. CYCLE is optically isolated. CYCLE should be pulled up to between 12 and 30 volts with reference to CYCLE RETURN (not Common) to turn on, or activate, the CYCLE input. Exceeding 30 volts could damage this input. Observe polarity when connecting CYCLE and CYCLE RETURN.

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Note that CYCLE is also available on Connector C7. The CYCLE signal on the Connector C7 is not optically isolated. If you use both CYCLE inputs, then the BDS5 will sense that CYCLE is on if the CYCLE signal from either Connector C2 or C7 is on.

REMOTE/REMOTE RETURN Pins 9, 6

•

REMOTE is on pin 9; REMOTE RETURN is on pin

6. REMOTE is an input that must be activated for the BDS5 to be enabled. REMOTE is optically isolated. It should be pulled up to between 12 and 30 volts with reference to REM O TE RETURN (not common) to activate the REMOTE input. Exceeding 30 volts could damage this input. Observe polarity when connecting REMOTE and REMOTE RE TURN.

HOME/HOME RETURN Pins 19, 18

•

HOME is on pin 19; HOME RETURN is on pin 18. HOME is intended to be connected to a home limit switch; it can also be used as a general purpose input. HOME is optically isolated. HOME should be pulled up to between 12 and 30 volts with reference to HOME RETURN (not Common) to activate the HOME input. Exceeding 30 volts could damage this input. Observe polarity when connecting HOME and HOME RETURN.

Note that HOME is also available on Connector C7. The HOME signal on Connector C7 is not optically isolated. If you use both HOME inputs, then the BDS5 will sense that HOME is on if the HOME signal from either Connector C2 or C7 is on.

I/O DC P in 5

•

Using BDS5 internal power supply (I/O DC) for any purpose except power for

CAUTION

•

O1 is an optically-isolated output. It is a solid state relay rated for 0.25 Amps and 30 VDC maximum. Only DC voltages, with the more positive voltage on Pin 10, may be applied to this output. You must observe polarity when connecting O1. You should install a 0.25 amp fuse in series with O1, as it is not fused internally.

Note that O1 is also available on Connector C8. The O1 signal on Connector C8 is not optically isolated. You can use both O1 signals at the same time.

HOME, CYCLE, and REMOTE ENABLE can da mage the PSR4/5.

O1 Pins 10, 20

2.6.4.6 Wiring C3, Resolver

Connect the resolver leads correctly. Incorrect motor resolver phasing can cause erratic operation, runaway, or

WARNING

Install the resolver cable between the motor and the BDS5. Make the connection at the motor resolver connector and Connector C3 on the BDS5.

damage to the system. Use of Industrial Drives resolver cable sets is highly recommended.

I/O DC is provided for occasions when you do not need optical isolation for HOME, CYCLE, and REMOTE ENABLE. An unregulated, low current power supply is provided on I/O DC to power those three inputs. Do NOT use I/O DC as a power supply for anything except these three isolated inputs!

If you want to use I/O DC, then connect the return lines (HOME RETURN, CYCLE RE TURN, and/or REMOTE RETURN) to Common. Then you can connect HOME, CYCLE, and/or REMOTE ENABLE to I/O DC (usual ly through a relay contact) to activat e those inputs.

If you are making your own resolver cables, you must obtain the procedure from INDUSTRIAL DRIVES to make cables.

2.6.4.7 Wiring C4, Logic Power

Supply

Wiring C4 is discussed above with "Wiring PSR4/5 Connector C2" since these two connectors are connected to each other.

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BDS5

2.6.4.8 Wiring C5, Serial Communications

Connector C5, the Serial Communications Connector, is on the front of the BDS5. It is a 9-pin, D-type, subminiature plug connector (DE-9P). The communications cabl e must have the mating DE-9S connector. See the System Wiring Diagram (A-93103, Sheet 3). Note that wiring for RS-232 and RS-485 is completely different. Refer to the model number to determine if your unit is RS-232 or RS-485. Be sure that the common of the BDS5 and the power supply common of your computer or terminal are electrically connected to each other, whether you are using RS-232 or RS-485. Use the COM pin on the serial connector (Connector C5) for the BDS5 common.

RS-232 VS RS-485

•

The BDS5 can communicate with a terminal or a computer over a serial data line with EIA RS-232-C, the most common electrical interface for terminals and personal computers. It can also communicate with EIA RS-485, a standard that supports multiple devices on one serial line. RS-485 is an upgrade of RS-422; RS-422 is restricted to one transmitter per serial line; otherwise, the devices will work with RS-485 devices. You should specify the communication standard that you want when you order your BDS5.

When choosing between RS-232 and RS-485, there are a number of factors to take into consideration. RS-232 is much more common than RS-485. Most terminals and computer serial ports are RS-232; however, RS-485 is becoming more available on personal computers. RS-485 is differential; RS-232 is single-ended. To illustrate this, RS-232 transmits one output, TxD. Alternatively, RS-485 simultaneously transmits TxD+ and TxD-, the logical inverse of TxD+. (Logical inverse means that if TxD+ = 1, then TxD- = 0). RS-232 transmitters typically have seriesterminated outputs, while RS-485 transmitters do not. All this makes RS-485 less susceptible to noise and able to transmit over much longer distances. On the other hand, RS-232 is easier to use and much less susceptible to transmission line effects. RS-232 is also less expensive. A major advantage of RS-485 is that it allows multidrop communication, where many axes can be connected on one serial line.

If you have an RS-232 terminal or computer, and you want to use RS-485, either for multidrop or for noise immunity, then you can purchase an RS-232-to-RS485 converter. For example, Anaheim Automation (Anaheim, CA) produces Model DC 2170 for this purpose.

The RS-232 serial input and outputs connect to 75155 line driver/receivers. The RS-485 serial input and outputs connect to 75176B line driver/receivers. These chips are available from many IC manufacturers, including Texas Instruments.

Table 2.3. Communication Requirements

To Communicate With Your BDS5, You Will Need:

RS-232 Terminal

IBM-PC Compatible with Communication

Software

RS-485 Terminal

and

Connector for Your Terminal

DE-9S Connector (Provided with BDS5)

3-Wire-with-Shield Cable (RS-232) 5-Wire-with-Shield Cable (RS-485)

Use one of the conductors to connect the power supply commons. The shield should not be used for this connection, but should connect to earth ground.

LINE TERMINATION

•

The BDS5 provides line termination for RS-485. An RS-485 line may need to be terminated to reduce ringing on long cables. (In this se ction, Line refers specifically to the RxD+/RxD- pair or the TxD+/TxDpair.)

A line is terminated by connecting a resistor from RxD+ to RxD- or TxD+ to TxD-. Terminating resistors are provided inside the BDS5. These resistors are connected by installing jumpers across Pins 3 and 4, and across Pins 7 and 8 on J1 on the front of the BDS5. The lines should only be terminated at the end of the communication cable. For example, if you are using several BDS5's in multidrop, then you should install the jumpers only on the units at the ends of the serial cable.

* *

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BDS5 C

CONNECTING TO A TERMINAL

•

Connect the pins on the DE-9S connector that came with your BDS5 as follows:

Table 2.4. Terminal Wiring

WIRING TO MOST RS-232 TERMINALS

BDS5 (DE-9) Female

1 SHIELD* 1

NOTE

For RS-485, you should install jumpers across Pins 3-4 and 7-8 on J1 on the front of the BDS5 at the end of the communication cable. If the device you are using to communicate with the BDS5 is at one end of the line, you should terminate the line at that end with a 120 ohm resistor.

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Terminal (DB-25) Male or Female

DISTANCE

•

RS-232 generally works well up to 50 feet using standard cable. Special low capacitance cable can extend this range up to 500 feet, although the baud rate may need to be reduced. These cables are available from many companies, including Black Box (Pittsburgh, PA).

RS-485 can be used up to 4000 feet. Be forewarned, however, that using very long cables may be more difficult than just making the connections. Special attention must be paid to AC loading, transmission line effects, noise pickup, and common-mode voltages. It would be wise to have a person who is knowledgeable in these matters to review the cable design beforehand. Again, baud rates may need to be reduced as the length increases, and low capacitance cables may be required.

You can obtain a copy of the specification for RS-232 or RS-485 by contacting:

Electronic Industries Association Engineering Department 2001 Eye Street, N.W. Washington, D.C. 20006

2RxD 3TxD 5COM7

* Usually, you will only connect the shield at one

end. Sometimes, the shield should be connected at both ends. This is system dependent and generally found by trial and error.

The table above assumes that your terminal has an RS-232 serial port which is configured as Data Terminal Equipment (DTE), the usual configura tion. If your terminal is configured as Data Communications Equipment ( DCE), then interc hange Pins 2 and 3 at one end of the cable.

Note that handshaking signals (CTS, DTR, etc.) are not supported.

← →

TxD 2 RxD 3

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BDS5

•

CONNECTING TO A COMPUTER

Connect the pins on the DE-9 connector that came with your BDS5 as follows:

Table 2.5. PC Wiring

WIRING TO AN IBM-PC COMPATIBLE COMPUTER

BDS5 IBM-PC (DE-9P) (DB-25S) Female Female

1 SHIELD* 1 1 SHIELD* FRAME 2 RxD <-- TxD 2 2 RxD <-- TxD 3 3 TxD --> RxD 3 3 TxD --> RxD 2 5COM75COM5

BDS5 IBM-AT (DE-9P) (DE-9S) Female Female

* Usually, you will only connect the shield at one

end. Sometimes, the shield should be connected at both ends. This is system dependent and generally found by trial and error.

+ The PC-AT doe s not have a pin for shield. If you

want to hook the shield to the PC-AT end of the cable, you must connect it directly to the frame of the computer.

If you use a computer, you will need communications software. The recommended communications software for use with the BDS5 is Motion Link, an Industrial Drives software package that is specially designed for t he BDS5. Other communications software packages include XTALK, QMODEM, PROCOM, KERMIT, and PC-TALK. See the

Manual

for more information about Motion Link.

User's

2.6.4.9 Wiring C6, Fan Power (20 Amp Units Only)

Connect the 115 VAC Control Power from the PSR4/5 (Connector C1) to the fan power connector on all 20 Amp BDS4's (Connector C4) and BDS5's (Connector C6). As the wiring diagram (A-93103, Sheet 1) shows, 115 VAC appears side by side on each connector, similar to the logic power supply connector. This allows you to "daisy-chain" the Control Power to each unit that requires it.

Connector C6 is only used on BDS5 and BDS4 amplifiers with continuous ratings of 20

NOTE

Amps and above.

The table above assumes your PC has an RS-232 serial port that is configured as Data Terminal Equipment (DTE), t he usual configuration. If your port is configured as D ata Communications Equipment (DCE), then interchange Pins 2 and 3 at one end of the cable.

Note that handshaking signals (CTS, DTR, etc.) are not supported.

If the PC-compatible computer is AC-line powered (that is, not battery powered), use extreme caution when interconnecting the PC to the BDS5 serial port. Both the PC and the BDS5 must share the same power supply common. If they do not, the voltage difference between the two commons could damage either or both machines.

Make sure that the Computer and BDS5 share the same power supply common. Either your computer or the

CAUTION

BDS5 or both can be damaged if the commons are not at the same potential.

2.6.4.10 Wiring C7, Standard I/O

C7 is a 26-pin ribbon cable connector. It provides non-isolated, 5-volt TTL-level inputs and outputs and directly interfaces to 8-line OPTO-22 compatible I/O boards. These boards are widely available and use industry standard optical isolation modules, available from several companies, including Potter and Brumfield, Grayhill, Gordos, OPTO-22, and Crydom. This connector is on top of the BDS5.

Note that you must provide a separate power supply when using standard OPTO-22 compatible I/O boards. This supply must provide 5 volts DC to power the I/O modules on the BDS5 side of the isolation. The common of this supply will normally be connected to the common of the BDS5 t hrough the even numbered pins on Connector C7. DO NOT USE THE BDS5 5 VDC POWER SUPPLY TO POWER I/O MODULES!

Additionally, a second power supply may be needed to provide power for those devices which are isolated from the BDS5 by the I/O modules. The common of this supply should not be connected to the BDS5 common.

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BDS5 C

If MOTION is off during power-up, the BDS5 will autobaud.

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You must provide an additional power supply for

NOTE

•

HOME is the input for the home limit switch. It is also the registration input. If your application has both a home limit switch and a registration input, use HOME for the registration input and connect the home limit switch to a general purpose input. This input can be used as a general purpose input if these primary functions are no t required.

HOME is available on two connectors. See the description of HOME on Connector C2 in section

2.6.4.5.

LIMIT Pin 11

•

This input must be turned on for normal operation. Connect the normally closed contacts of the overtravel limit switches in series with LIMIT.

If your application does not allow you to use hardware travel limit switches, then you must hardwire LIMIT on. If you are not using Connector C7 you can hardwire LIMIT on by installing a jumper directly on C7 between Pins 11 and 12. The BDS5 is shipped from the factory with this jumper installed.

CYCLE Pin 13

•

CYCLE is an input that is normally used to start a cycle of a user program. It can be used as a general purpose input if this primary function is not required. See the description of CYCLE on Connector C2 above.

MOTION Pin 15

•

MOTION is used to enable motion of any kind. If MOTION is off, then no motion will be allowed. MOTION is often connected to a stop button.

the I/O modules.

HOME Pin 9

If your application does not allow you to use MOTION, then you must hardwire it on. If you are not using Connector C7, you can hardwire MOTION, by installing a jumper directly on C7 between Pins 15 and 16. The BDS5 is shipped from the factory with this jumper installed.

GATE Pin 17

•

The GATE input starts precalculated motion profiles. It is used to synchronize motion with external events. This line may be used as a general purpose input if its primary function is not used .

O7, O8 Pins 19, 21

•

O7 and O8 are general purpose outputs.

CYCLE READY Pin 23

•

CYCLE READY is an output that indicates that the BDS5 is ready for the CYCLE line to be activated. CYCLE READY is often connected to PLC's or to a lamp on an operator panel.

2.6.4.11 Wiring C8, Optional I/O

C8 is a 50-pin ribbon cable connector as shown in drawing A-93103. It provides non-isolated, 5 volt TTL-level inputs and outputs and directly interfaces to 24-line, OPTO-22 compatible I/O boards. These boards are widely available and use industry standard optical isolation modules. This connector is optional. It is on top of the BDS5.

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BDS5

You must provide an additional power supply for

NOTE

O1-O6 Odd numbered Pins from 37 to 47

•

O1-O6 are general purpose outputs.

STATUS Pin 35

•

The STATUS output indicates the status of the BDS5. You can configure STATUS to indicate "active" or "ready to be activated" with the software switch STATMODE. See the Enable and Fault Logic Diagram, Drawing A-84732, for more information.

The state of the STATUS output is undefined for up to 25 milliseconds on power-up.

WARNING

MANUAL P in 33

•

MANUAL is used to change the BDS5 from AUTO mode to MANUAL mode. For more information, refer to User’s Manual Chapter 4. MANUAL may be used as a general purpose input if its primary function is not required.

I1-I16 Odd numbered Pins from 1 to 31

•

I1-I16 are general purpose inputs.

the I/O modules.

STATUS may turn on for up to 25 milliseconds after powerup.

2.6.4.12 J1 Configuration Jumper

Jumper J1 connects the RS-485 line terminators. Refer to the section on line termination for information.

Motion Link. For more information on Motion Link, refer to the

User's Manual

2.6.5.1 Required Data Format

The BDS5 and your terminal must use the same format for serial data. RS-232-C and RS-485 describe hardware only. There are other specifications left to up to the user: full- or half-duplex, the number of bits per character, whether or not parity is used, the number of stop bits, and the baud rate. Full-duplex means both the terminal and the BDS5 can send and receive at the same time. Half-duplex means only one system can talk at a time. Bits per character refers to the number of actual data bits sent at one time. The parity is a bit sent for error detection. The number of start and stop bits sets a minimum delay between characters. The baud rate is the rate at which bits are transmitted and received.

The BDS5 requirements are:

Full-duplex

8 bits per character

No parity

1 Start bit

1 Stop bit

Baud rates equal 300, 600, 1200, 2400, 4800,

9600, or 19200.

Most terminals and computers will allow you to set these options with little difficulty. Motion Link sets these requirements automatically.

2.6.5.2 First Transmission

Before you attempt to establish communications, you must:

1. Mount the BDS5 and PSR4/5 system as

described earlier in this chapter.

2. Make all connections as described in the earlier

sections of this chapter, especially connecting the BDS5 serial connector to your terminal or computer.

2.6.5 Establishing Communications

Industrial Drives supplies a communications package called, Motion Link, that is designed especially for communicating with the BDS5. Other terminal emulators can also be used as long as the required data format is followed. This manual is written for use with

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BDS5 C

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2.6.5.3 Checking the Control Power

SHOCK HAZARD!

115 VAC is present on the Control Power. Be very

WARNING

NOTE

Turn off control power. Remove PSR4/5 Connector C1. Turn on control power. Use an AC voltmeter to confirm that the voltage on PSR4/5 Connector C1, Pins 2 and 3 is 115 VAC +/- 15%.

Turn off control power. Re-install PSR4/5 Connector C1. Remove PSR4/5 Connector C2. Turn on control power. Use a DC voltmeter to confirm the logic supply (measure the pins in the PSR4/5 Connector C2).

careful when measuring these voltages.

Control Power is the 115 VAC connection at PSR4/5 Connector C1, pins 3 and 4.

If the CPU LED is not blinking...

Check the logic voltages from Table 2.6 above. If one or more of the voltages are missing, a fuse in the PSR4/5 opened because the logic supply was miswired. You may have miswired either Connector C2 on the PSR4/5, Connector C4 on any BDS5, or Connector C3 on any BDS4. Check your wiring carefully.

Make sure the MOTION input is off (contacts are open) when you power-up the BDS5. If the contacts are closed, open them and power-down the BDS5 and immediately power-up again. If the CPU LED is still not blinking, contact the factory.

1. If you are using Motion Link with an IBM-PC, type "ML" from DOS to start Motion Link. Motion Link will establish communications. Refer to User’s Manual for more information on installing and runni ng Motion Link.

2. Whether you are using a terminal or a PC, press the return key 5 to 10 times, pressing the key about twice per second.

Table 2.6. PSR4/5 C2 Voltages

+18 Volts ±20% Pins 1 and 5

-18 Volts ±20% Pins 2 and 6 Common Pins 3 and 7

+10 Volts ±20% Pins 4 and 8

If none of these voltages are present, check control power (115 VAC) on PSR4/5 Connector C1, Pins 2 and 3. If one or more of the voltages are missing, one or more fuse in the PSR4/5 may be open. Refer to the spare parts lists in Chapter 5 for descriptions of the fuses.

Turn off control power. Re-install PSR4/5 Connector C2.

Turn on control power. The green CPU LED on the front of the BDS5 should begin flashing, about 10 times per second. This indicates that the BDS5 is autobauding to establish communications.

These steps cause carriage return characters to be sent to the BDS5. When autobauding, the BDS5 looks for these characters and uses them to determine the

or speed at which your terminal is transmitting.

rate

Once the baud rate is determined, the BDS5 can establish communications with your terminal or computer.

Then the BDS5 should print this message (or one similar to it) on your terminal:

-->

The green SYS OK LED on the front of the BDS5 should turn on and remain on at all times after powerup (and auto bauding). T he "-->" means that your BDS5 is in the "interactive mode" and is ready to accept commands.

baud

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BDS5

2.6.5.4 If You Can't Communicate...

If the BDS5 does not respond, then check to be sure that Connector C5 is wired properly. A common mistake is that of having the transmit and receive lines swapped. Also, make sure that none of the wires in the cable are broken.

If the CPU LED has stopped blinking...

the BDS5 has established communications. However, the transmission from the BDS5 is not being displayed on your terminal. Check carefully for miswired cable, broken wires, or possibly a shorted transmit line from the BDS5 to your terminal.

If the CPU LED is still blinking...

the BDS5 has not established communications. You can determine that your terminal is working by disconnecting the serial cable at your terminal. Then, temporarily connect the transmit and receive pins to each other (usually Pins 2 and 3 on a 25-Pin DB-25 connector) and press a few keys. The characters that you type should appear on the terminal screen. If they do not, then your terminal is not functioning properly.

If your terminal is functioning prop erly...

3. If there is no response, then the terminal may not be properly connected.

If you do not have an oscilloscope...

you may be able to use a digital voltmeter. Many digital voltmeters are quite sensitive and can detect character transmissions. You should see some activity (change in voltage) on the meter display every time you press a key.

If you think the cable is correct, but you still cannot communicate...

your terminal may not be configured for the data format listed on page 16. Check the manual for your terminal or computer (virtually all IBM-PC compatible computers conform to this format). If you are using a terminal, be sure your terminal is set properly.

2.7 INITIAL CHECK-OUT

This section will discuss the procedure for checking most of the wiring on the system before enabling your BDS5. Communications must be established with your BDS5 before continuing.

the serial communications cable may have open circuits (br oken or missing wires) or may not be connected to the proper pins. You can determine if your serial cab le has open circuits by connecting your terminal on one end and disconnecting the cable on the BDS5 end. Again, temporarily connect the transmit and receive pins (this time on the far end of the cable), then type on the keyboard. The characters that you type should appear on the terminal screen. If they do not, then your cable is not functioning proper ly.

If your cable i s functioning properly...

the serial cable may still be the problem. You can determine if your cable is wired properly with an oscilloscope. For RS-232 systems, disconnect the cable from Connector C5. Connect ground on the scope probe to Pin 5 of the DE-9 connector on the cable. Use the oscilloscope to monitor Pin 2, with the time base between 1 and 20 milliseconds/division and the voltage sensitivity to 5 volts/division. While monitoring Pin 2, press several ke ys on t he keyboard. The oscilloscope display should show Pin 2 changing between ±9 volts every time you press a key. If not, check Pin 3. If Pin 3 is responding, then Pins 2 and 3 are reversed. Remove power and exchange Pins 2 and

In this section, the BDS5 will be used to check wiring to most of the BDS5 inputs and outputs. You will need to enter some BDS5 commands. This section will use a few commands that are described in more detail elsewhere in this manual. The first command is the print command. You can print the discrete inputs. For example, after the BDS5 has printed the prompt "-

->," you can type:

P LIMIT

and the BDS5 will print 1 or 0. 1 means that the input is on, indicating that the contacts are closed. 0 means that the input is off, indicating that the contacts are open.

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BDS5 C

__I1 __I2 __I3 __I4

NOTE

In this manual, instructions that you enter will be shown in italics and surrounded by a double line box. The response from the BDS5 will be in plain upper case letters.

__I5 __I6 __I7 __I8

__I9 __I10 __I11 __I12

__I13 __I14 __I15 __I16

__CYCLE __GATE __HOME __LIMIT

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2.7.1 Checking Discrete Inputs

You can check the state of all of the discrete inputs with the print command. This process will be demonstrated with the hardware travel limit switch, LIMIT. If you are not using the LI MIT switch, you can substitute another hardware switch, such as CYCLE or HOME which are available on Connector C2. In this case, substitute the words "CYCLE" or "HOME" for "LIMIT" in the following discussion.

1. Open the switch contacts.

2. Verify that the contacts are open. If you are using an Industrial Drives Input Module or an industry standard OPTO-22 compatible input module, there will be an LED on each input to indicate its state. The LED will be off if the contacts are open.

3. Use your terminal to enter:

P LIMIT

__MANUAL __MOTION __REMOTE

Note that if a fault condition exists, the state (on or off) of REMOTE may not be available. In this case, the value of REMOTE will print as -1.

2.7.2 Checking General Purpose Outputs

You can check all of the general purpose outputs by turning them on and then off. Be careful. The procedure in this section will activate all of the general purpose outputs. Be sure that activating an output will not cause a hazard to personnel or damage to equipment.

Commands in this section will turn on all general purpose outputs. Be certain that this

WARNING

is not a safety hazard. Make sure this will not damage equipment.

4. The BDS5 should respond with "0" indicating that the contacts are open.

5. Close the switch contacts.

6. Verify that the contacts are closed. (LED should be on.)

7. Use your terminal to enter:

P LIMIT

8. The BDS5 should respond with "1" indicating that the contacts are closed.

Repeat this process for each discrete input that you are using:

1. Turn on O1 by typing:

O1 ON

2. Verify that the output is on. If you are using an Industrial Drives Input Module, or an industry standard OPTO-22 compatible input module, there will be an LED on each output to indicate its state. The LED will be on if the output is on.

3. Turn off O1 by typing:

O1 OFF

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BDS5

4. Verify that the output is off.

Repeat this process for each discrete output that you are using:

__O1 __O2 __O3 __O4 __O5 __O6 __O7 __O8

2.7.3 Cycle Ready

CYCLE READY cannot be checked without a program. The Later, when you are familiar with programming, you can write a program that turns CYCLE READY on. Check this output at that time.

User's Manual

discusses this topic.

2.7.4 Checking STATUS

Check STATUS later in this chapter when the BDS5 is active. The STATUS output will turn on when you enable the BDS5.

If the results are not what you expected, use an oscilloscope to verify that all four signals are reaching Connector C1.

Note that encoder equivalent inputs are not available if your system has analog input.

2.7.7 Checking Pulse Input (Optional)

If you have a pulse input option, connect your pulse input to Connector C1. Stop the pulse train. Type:

P PEXT

Now inject a few pulses. Type:

P PEXT

PEXT should have changed by the number of pulses you injected. If the results are not what you expected, make sure that you have set the pulse format switch properly. Then, use an oscilloscope to verify that all four signals are reaching Connector C1.

2.7.5 Checking Encoder Output

Check the encoder output with a two-channel oscilloscope. Place Channel 1 on OUTA and Channel 2 on OUTA'. Rotate the motor by hand. You should see the encoder output on your scope. Repeat this process for OUTB and OUTB' and for OUTZ and OUTZ'. Note that OUTZ changes state only at one point during a full motor revolution.

2.7.6 Checking Encoder Input

If you have encoder input, connect your encoder to Connector C1. The encoder should not be moving. Type:

P PEXT

Now rotate the encoder. Type:

P PEXT

PEXT should have changed when you ro t ated the encoder shaft.

2.7.8 Checking Analog Input (Optional)

If you have analog input, connect your input voltage to Connector C2. Adjust the voltage to zero volts. Type:

P PEXT

Wait a few seconds and type:

P PEXT

PEXT shoul d not have changed or should have changed very little. Now raise the input voltage to a few volts. Type:

P PEXT

and PEXT should have changed much more than it did with the input zeroed.

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BDS5 C

2.7.10 Checking the Resolver Cable

2.7.9 Checking the Resolver

Follow this procedure if you are experiencing The BDS5 provides a feedback loss circuit which is designed to detect broken wires; it can detect relatively few wiring errors. You should use the following procedure to verify feedback circuit.

problems with the resolver. Disconnect the resolver

cable at both ends and use an ohm meter to verify this

resolver cable wiring table:

Table 2.9. Goldline Resolver Cable Wiring

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The feedback loss circuit is designed to detect broken wires. In general, it does not

WARNING

Turn the motor shaft by hand until the R/D converter output is within the ranges listed below. You can display the R/D output by repeatedly typing:

The standard R/D resolution is 12 bits. The resolution of your BDS5 is listed as part of the model number, which is shown on the front of the drive and described at the beginning o f t his chapter.

Rotate the motor shaft by hand until PRD is in the target range listed below:

Table 2.7. Target of PRD vs. R/D

R/D Resolution 12-Bit 14-Bit 16-Bit

Target Minimum

Target Maximum

Now rotate the motor shaft approximately 1/4 revolution CLOCKWISE. PRD should now fall in the range listed below:

Table 2.8. Target of PRD Versus R/D

Resolution After Clockwise 1/4 Revolution

R/D Resolution 12-Bit 14-Bit 16-Bit

Target Minimum

Target Maximum

If PRD does not fall into the range as listed above, then either the resolver is improperly wired or the feedback circuitry is not functioning correctly. The first step is to check the cable.

detect wiring errors.

P PRD

Resolution

250

800

1300

1000

3500 5500

4000

12500 22500

BDS5

1Sine LowB 2 Shield No Connect 3Cosine LowC 4 Reference High F 5 Shield No Connect 6 Not Used No Connect 7Sine HighA 8 Shield No Connect

9Cosine HighD 10 Reference Low E 11 Shield No Connect 12 Not Used No Connect

Flying Lead Thermostat (Black) T Flying Lead Thermostat (Black) U Flying Lead Optional Brake (Blue) N Flying Lead Optional Brake (Blue) P Flying Lead Optional Tach (Black) R Flying Lead Optional Tach (White) S

The following procedure uses an oscilloscope to measure the amplitude of signals with a frequency of 8 kHZ. Some digital voltmeters can

NOTE

measure the amplitude of signals at high frequencies (like 8 kHZ). However, many meters are designed to read 60 Hz and cannot be relied upon to read 8 kHZ signals.

Signal Resolver

Connector

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If the cable is correct, check the resolver reference signal. Install the resolver cable at both ends. Connect an oscilloscope probe to Connector C3, Pin 4 (extend the probe with a short length of wire to reach inside the connector housing if necessary) and connect the probe ground to common (Connector C3, Pin 10). Apply control power (115 VAC). The reference signal should be between 11.8 and 12.0 V peak-to-peak (4.17 and 4.24 V RMS) at a frequency of about 8 KHZ. If necessary, adjust the reference amplitude with potentiometer 219. This potentiometer is located between Connectors C2 and C3 and can be adjusted from the front of the unit without disassembly.

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BDS5

WAIT 5 MINUTES FOR THE DC BUS to DISCHARGE!

The DC Bus is connected to

WARNING

Remove the BUS+ and BUS- leads from the PSR4/5 Power Terminal Block. Disconnect Connector C2 from the PSR4/5.

large capacitors inside the PSR4/5. These capacitors can store a lot of energy.

If the reference signal is correct and the feedback circuitry is not working, your BDS5 may be malfunctioning. Conta ct the factory.

2.7.11 Checking the AC Line Voltages

SHOCK HAZARD!

Large voltages are present on the AC Line. Be very careful

WARNING

Open the circuit breaker or remove the fuses in the AC Line.

Turn on the AC Line. Use an AC voltmeter to check and record the 1- or 3-phase line-to-line voltage at the circuit breaker or fuse holders. Turn off the AC Line. Note the model number of the PSR4/5 and refer to the Model Number Tables, in Chapter 1, to confirm correct AC Li ne voltage.

when measuring these voltages.

Turn on Control Power to PSR4/5 Connector C1 and turn on the AC Line to the PSR4/5 Power Terminal Block (La, Lb, and Lc).

SHOCK HAZARD!

Large voltages are present on La, Lb, Lc, BUS+ and BUS-.

WARNING

Check and record the DC Bus output voltage at BUS+ with respect to BUS- on the PSR4/5 Power Terminal Block. It should be approximately 325 VDC for 230 VAC line voltage, or 162 VDC for 115 VAC line voltage.

REMOVE THE AC LINE VOLTAGE. WAIT 5 MINUTES FOR THE DC BUS TO DISCHARGE.

Reconnect the BUS+ and BUS- leads to the Power Terminal Block on the PSR4/5. Be careful to reconnect the leads with the correct polarity. Reinstall Connector C2 on the PSR4/5.

Be very careful when measuring these voltages.

2.7.12 Checking the DC Bus Voltage

Remove the AC Line. Wait 5 MINUTES for the DC BUS to discharge.

2-22

WARNING

OBSERVE POLARITY OF THE DC BUS!

When interconnecting Industrial Drives GOLDLINE Series Products, connect BUS+ to BUS+ and connect BUS- to BUS-.

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2.7.13 Checking the Motor

The MOTOR command is provided to ensure that your BDS5 is properly configured for your motor. Type:

MOTOR

The BDS5 should respond with something like:

MOTOR = B-204B

You can then verify that your motor is a 204B. Always check the motor nameplate to verify that you have wired the correct motor to your BDS5. This should agree with the part of your BDS5 model number as described in chapter 1.

Wiring the BDS5 to a motor for which it is not configured can cause the system to

WARNING

become unstable. Verify that you are connecting the correct motor.

To display PRD, type:

P PRD

Table 2.10. PRD Range for "Zero Position"

PRD

R/D Resolution

12-Bit 14-Bit 16-Bit

4. Turn on (close contacts of) LIMIT, MOTION, and REMOTE.

5. Turn on Control Power only.

6. Put the BDS5 into the zeroing mode. Type:

ZERO ON

7. Turn on AC Line.

8. Enable the BDS5. Type:

Less

Than

25 100 400

PRD

Greater

Than

4070 16300 65000

Verify that motor wiring is correct. IT IS VERY IMPORTANT THAT YOU WIRE T HE MOTOR PROPERLY. Brushless motors are not like induction motors. You cannot simply interchange two phases to reverse the direction of rotation. You MUST connect Pin A of the motor connector to Ma of the BDS5 power connector, Pin B of the motor connector to Mb, and Pin C of the motor connector to Mc.

Follow this procedure to check motor wiring:

1. Turn off the AC Line and the Control Power.

2. Remove all loads from the motor. The motor must be able to rotate freely for this test.

3. Rotate the motor by hand until PRD is in the zero position as shown in Table 2.10. Note that the position must be less than the small number

greater than

the large number.

The motor may move a small amount, but PRD should remain in the zero position. Type:

P PRD

If the motor rotates to the zero position, then type:

DIS ZERO OFF

and continue to the next section.

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If the motor rotated to the wrong position, then you must stop and correct this problem. Either the resolver is improperly wired, the motor is improperly wired, the motor is not functioning properly, or the resolver is not functioning properly. In most cases, the wiring is the problem. Check your motor and resolver wiring carefully. Follow the procedure in "Checking the Resolver Cable" in section 2.7.10. If you have wired the motor through motor-overload relays, verify that the relay is closed. Contact the factory if your motor does not rotate to the zero position and you can not correct the problem.

WARNING

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DO NOT PROCEED IF YOUR MOTOR IS NOT ZEROING PROPERLY.

BDS5

2-24

BDS5 C

MODEL No.

REV No.

C2 LOGIC POWER (to BDS5 C4)

ACTIVE SYS OK

CPU

FAULT

4 5

1 +18 VDC 2 -18 VDC 3 COMMON

5 +18 VDC 6 -18 VDC 7 COMMON 8 +10 VDC4 +10 VDC

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RELAY

T 1

MODEL No.

SERIAL No.

KOLLMORGEN

Industrial Drives

BUS+ BUS-

1 2

12 13

1 FAULT RLY 2 115 VAC HI

612

1 2

BDS5

3 115 VAC LO

MODEL No.

SERIAL No.

(SEE INSIDE BACK COVER FOR BDS5 CONNECTOR TABLES)

KOLLMORGEN

Industrial Drives

D.C. BUS

REGEN

OVERLOAD

BLOWN FUSE

C1 CONTROL INPUT POWER

4 FAULT RLY 5 115 VAC HI 6 115 VAC LO

1 5 6

5 6 7 8

PSR

BUS+ BUS-

Ma Mb Mc

GND

Lb Lc

GND

BDS5 CONNECTORS

RICK FURR

01-30-95

A-96372M

Issue

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BDS5

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3.1 INTRODUCTION

The information in this chapter will enable you to become familiar with system components and their dependence upon one another. Also, it will help you ensure each component is configured and functions properly. At this point, all safety stops and other precautions should be in place and working properly. Be prepared to stop the machine if necessary.

3.2 START-UP AND CHECKOUT

You should now be ready to supply power to test the servo systems functions and features. Work with only one axis section at a time. Confirm all other BDS5 amplifiers are inhibited, meaning the enable circuits are open ( high). Appropriate precautions should be taken to stop the machine if necessary. Limit switches and safety devices should be in place.

THE MOTOR MAY MOVE UNEXPECTEDLY!

BE PREPARED TO DISABLE THE BDS5!

Commands in this section will enable the BDS5. The system

WARNING

This section discusses how to enable the BDS5. Follow this procedure:

1. Turn on (close contacts of) LIMIT, MOTION, and REMOTE.

2. Turn on Control Power.

may be unstable. The motor may begin oscillating or run away. Be prepared to disable the BDS5 quickly. You can disable the BDS5 by turning off (opening the contacts) of LIMIT or REMOTE.

3. Turn on the AC Line.

4. Enable the BDS5. Type:

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BDS5

The motor should be still. If your motor is oscillating, disable the BDS5 by typing:

DIS

3.2.1 If You Get ERROR 17, FEEDBACK LOSS

If the BDS5 generates ERROR 17, FEEDBACK LOSS, then a lead in the resolver cable is probably broken. First, verify that the cable is wired correctly using the procedure in "Checking the Resolver Cable" in section 2.7.10.

If the cable appears to be wired correctly, use an oscilloscope to verify that the sine (Connector C3, Pin 7) and the cosine (Connector C3, Pin 9) are present. Note that the amplitudes of both these signals vary with motor position, so you will need to rotate the motor by hand to force sine and cosine to their maximum values. Expect a sine wave with a maximum peak-to-peak level of about 6.5 Volts at 8 kHZ.

If both sine and cosine are present on the connector and your BDS5 continues to generate ERROR 17, your unit may be malfunctioning; contact the factory.

3.2.2 If You Get ERROR 14, POWER BUS

ERROR 14, "POWER BUS," is generated when the BDS5 detects either an undervoltage or an overvoltage. If the BDS5 cannot be enabled because ERROR 14 continually reoccurs, it is probably because of undervoltage. Return to "Checking the AC Line Voltage" and "Checking the DC BUS Voltage" beginning in section 2 .7.11 to e nsure that the DC Bus is present.

If this error occurs only when the system is powered up, it is probably because your program attempts to enable the BDS5 before bus voltage is present. OK2EN is a switch that is ON when your BDS5 can be enabled without generating a fault. You can delay enabling the BDS5 until bus voltage is present by modifying your program to wait for OK2EN to be ON.

TIL OK2EN EQ ON EN

If the error occurs occasionally, it could be overvoltage or undervoltage. Overvolta ge is usually caused by regenerative energy from a deceleration which forces the DC BUS voltage to rise above the BDS5 overvoltage level--about 200 VDC for 115 VAC line voltage systems and about 400 VDC for 230 VAC. If the error occurs only during deceleration, it is probably an overvoltage error. This can be corrected by reducing the deceleration rate (although often, it must be reduced dramatically) or by adding increased regeneration capability. Contact Industrial Drives Application Engineering to add regeneration capability.

Undervoltage is caused by the loss of the AC Line. The undervoltage detection level is set well under 100 VDC (70 VAC) so that low line (from "brown out") almost never causes a n undervoltage fault. Your system may include protective circuits that remove power from the BDS5 when a problem is detected elsewhere in the system. This can cause the BDS5 to generate ERROR 14 and lead you to suspect the BDS5 of causing the original problem. If the problem occurs only rarely, you may have to purchase or rent a device to monitor the DC BUS voltage to determine the cause.

3.2.3 If Your BDS5 System is Unstable...

If the motor was oscillating, you need to retune your system. First, try to stabilize the system with the TUNE command. Type:

TUNE 10 2

Enable the drive. If your system is stable, you can skip ahead to the next section. If you want to improve the response, see Section 3.5 for details on the TUNE command.

If your system is not stable, disable the BDS5. You need to detune the system. First, disable the position loop. Type:

PL OFF

Disable the integrating velocity loop (in other words, enable the proportional velocity loop). Type:

PROP ON

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On power-up, the integrating velocity loop will be enabled (that is, PROP is turned off) and the position loop will be turned on. Be careful to turn PROP on and PL off every time you power-up until you stabilize the system for an integrating loop.

PROP is turned off and PL is turned on at power-up. If you are following this procedure to stop oscillations, be certain

WARNING

Now enable the drive by typing:

Reduce the proportional gain (KPROP) until oscillations stop. Type:

KPROP = KPROP/2

You may need to repeat this command a few times.

After oscillations stop, enable the position loop by typing:

to turn PROP on and PL off every time you power-up the drive.

PLIM OFF

Now type:

J 10

and the motor should rotate at 10 RPM. If PROP is on, the motion will be very unsteady. You need an integrating velocity loop for good low speed performance.

Disable the BDS5 and enable the software position limits. Type:

DIS PLIM ON

3.2.5 Low Speed Adjustment

SKIP THIS SECTION IF YOU HAD TO TURN PROP ON TO STABILIZE YOUR SYSTEM. The BDS5 has a low-speed adjustment. This adjustment helps smooth very low-speed motion. This adjustment is made with the variable KC which is normally set to 200. This value of KC produces sufficiently smooth low speed performance for almost all applications. However, if your application is very demanding, you may want to adjust KC somewhat. It is rare for this procedure to be required.

PL ON

Next, reduce the position loop gain (KP) until oscillations stop. Type:

KP = KP/2

You may need to repeat this command a few times.

If you need to tune your system for better performance, see Section 3.3.

3.2.4 Jogging the Motor

If you can enable the BDS5 without motor oscillations, then you can jog the motor. First, you should temporarily disable the BDS5 software position limits. Type:

1. Turn PL off by typing:

PL OFF

2. Twist the motor shaft back and forth lightly at

about 1 or 2 twists per second. You should feel very slight "graininess." This graininess is similar to the feel of anti-backlash gears. If you want to make the graininess more pronounced (so that you can feel it), set KC to zero. Type:

KC = 0

3. Adjust KC so that the graininess is minimized.

The best way to do this is by attaching a mirror to the motor shaft and shining a laser onto the mirror and observing the reflected dot about 10-20 feet from the motor. You can attempt to "feel" the graininess, but that measurement is so coarse that you should pr obably just set KC to 200 and skip this procedure. The normal

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BDS5

range for KC is between 175 and 225. This adjustment must be repeated when either the motor or the amplifier is changed out.

4. Restore PL. Type:

PL ON

This completes the initial check-out.

3.3 SYSTEM COMPENSATION

Feedback systems (like a motor controller) require tuning to attain high performance. Tuning is the process whereby the position and velocity loop gains are set, attempting to optimize the performance of a system (a BDS5 and a motor connected to a load) to a three-part criterion:

Table 3.1. Tuning Criterion

Noise Susceptibility

Response

Stability

Stability measures how controlled the system is. Stability can be measured with damping ratio or with overshoot in response to a step command. A discussion of different levels of stability follows.

3.3.1 Critical Damping

Generally, the most desirable amount of damping is Critical Damping. Critically damped systems respond as fast as possible with little or no overshoot. In Figure 3.1, the graph shows the response of a BDS5 TACH signal (on Connector C2, Pin 2) to a square wave input when the system is critically damped.

Tuning is normally a laborious procedure requiring an experienced person. However, the BDS5 provides many tools to aid tuning, making it a much simpler process than it has been in the past.

In a broad sense, the performance of a system is characterized by its noise susceptibility, response, and stability. These quantities tend to be mutually exclusive. The system designer must decide what noise susceptibility (in the form of a "busy" motor) is acceptable.

"Busyness" is random activity in the motor and can often be felt on the motor shaft. Busyness in a motor should not be confused with PWM noise. PWM noise is high pitched, relatively constant noise and cannot be felt on the motor shaft. Response is a measure of the system's quickness. Response can also be characterized by bandwidth and by rise time in response to a step command. Normally, designers want high bandwidth, though sometimes the response is purposely degraded to reduce stress on mechanical components. This is called

detuning

range from 20 to 60 Hz. Typical position loop bandwidths range from 0.1 to 0.2 times the velocity loop bandwidth.

. Typical velocity loop bandwidths

Figure 3.1. Critical Damping

3.3.2 Underdamping

Sometimes the system is tuned for critical damping and the system is still too slow. In these cases, you may be willing to accept less than critical damping. For applications that can work properly with a slightly underdamped system, you may reduce the stability to improve the response. The graph in Figure 3.2 shows a BDS5 slightly underdamped.

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Figure 3.2. Underdamping

3.3.3 Overdamping

An overdamped system is very stable but has a longer response time than critically damped or underdamped systems. Also, overdamped systems are noisier than less damped systems with the same response rate. The graph in Figure 3.3 shows an overdamped system.

Figure 3.4. Ringing

3.4 TUNING

The TUNE command shakes the motor vigorously. Secure

WARNING

The BDS5 is usually shipped with a tuning that will work reasonably well with the load inertia between 0 to 4 times the rotor inertia. Many applications have approximately matching inertia. If your system does, you may not have to adjust the tuning of your BDS5. The following section describes how you can re-tune your system.

NOTE

the motor before tuning.

When tuning a system, it may be desirable to disable the BDS5 quickly. You can use K, the KILL command, to disable with a one-letter command.

Figure 3.3. Overdamping

3.3.4 Ringing

When you are tuning the BDS5 you may tune it so that the response rings. Ringing is caused when you attempt to tune the BDS5 for either too rapid response (too high bandwidth) or too much stability (too much damping) or both. The only solution is to reduce the bandwidth or the stability or both. In Figure 3.4, the graph shows a system that rings.

The BDS5 provides self-tuning. This is a feature that senses the inertial load of your system and then attempts to set tuning parameters accordingly. Note that self-tuning is not fool-proof. You may need to adjust one or two of the tuning parameters to get exactly the response you need.

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BDS5

THE MOTOR MAY OSCILLATE!

Unloaded motors tuned for a large inertia load may become

WARNING

unstable when the system is activated. If the system becomes unstable, remove the power immediately.

3.4.1 If Your System Is Completely Unstable...

If your system is completely unstable when you enable it, remove power immediately. After restoring power, but before enabling the BDS5, turn off the switch PL, reduce KV to 100, and reduce KVI to 0. This should make the system stable.

;TYPE THESE LINES ONLY IF YOUR ;BDS5 IS UNSTABLE WHEN YOU ;ENABLE IT. DON'T FORGET TO ;RESTORE PL WHEN YOU HAVE ;FINISHED TUNING. PL OFF KVI = 0 KV = 100

does respo nd fast enough), then you a re done. Do not forget to restore ILIM to its original value.

The TUNE command shakes the motor vigorously. You may need to reduce ILIM before executing the TUNE

CAUTION

NOTE

command to protect your machine. Do not forget to restore ILIM when tuning is complete.

The TUNE command can cause the motor to overspeed. You may need to reduce ILIM to prevent overspeed errors. Do not forget to restore ILIM when tuning is complete.

3.5 TUNE COMMAND

When you enter a TUNE command, you specify the response time and the stability level. The response time is specified in the form of bandwidth. The higher the bandwidt h, the faster the re sponse. The level of stability is specified as follows:

If the BDS5 is still unstable, remove power and contact the factory. If it is stable, continue on with tuning. Do not forget to turn PL back on when you have finished tuning. Also, PL is always turned o n during the BDS5 power-up.

3.4.2 Reducing ILIM

You may need to reduce ILIM before executing the TUNE command since the TUNE command causes the motor to "shake" at about 15 Hz and at full torque. This may damage some machines. Also, lightly loaded motors can overspeed if ILIM is too high. You should r aise ILIM to the highest level that does not cause problems, because the tuning may not be acceptable if ILIM is too low. The effect can be that the torque the BDS5 produces is "swamped out" by friction. If you are not sure how much ILIM is necessary, reduce ILIM to a low value (say 5 or 10%) and gradually raise it. If the tuning is acceptable (that is, it does not ring or overshoot excessively, and it

Table 3.2. Allowed Tune Command

Stability Settings

1 2 3

WARNING

Enable the BDS5 and type this command:

TUNE 30 2

The BDS5 will shake the motor and set the tuning so that the velocity loop has a bandwidth of

Slightly overdamped Critically damped Slightly underdamped

The drive will be enabled and the motor will turn. Make sure the motor is secured. Even if the BDS5 is disabled, it will enable long enough to execute the TUNE command.

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approximately 30 Hz and is critically damped. The allowed bandwidths are 5, 10, 15, 20, 25, 30, 40, and 50 Hz.

The tune command does not always provide an acceptable tuning. If not, you can tune the BDS5 yourself.

3.6 TUNING THE BDS5 YOURSELF

If you use the TUNE command, and the resulting tuning variables cause the system to oscillate, there are generally two reasons:

1. The bandwidth in the TUNE command is set too high for the system to function properly.

2. The low-pass filter is set too low (this only applies if LPF is on).

In either case, first raise the low-pass filter frequency (LPFHZ) to as high a level as is acceptable. You may even decide to remove it by setting LPF to off.

and increase KVI to make the system more responsive.

You need to make several decisions: Is the unit underdamped? Is the system response too fast? Is the system ringing? Is there a resonance present? Then, take the action listed on Drawing A-84888.

There is a close relationship between the response of the system and the variable KVI. Response is often measured by the system frequency with which the system response falls to 70% of the nominal response. For example, if your velocity command was a sine wave with peaks of ±100 RPM, the bandwidth would be the frequency that the response fell to a sine wave with peaks of ±70 RPM. The relationship between velocity loop bandwidth and KVI is shown in Table 3.3.

Table 3.3. Velocity Loop Bandwith vs. KVI

KVI

1400 5 Hz

bandwidth

VELOCITY LOOP

. Bandwidth is the

BANDWIDTH

If the TUNE command does not provide a suitable set of tuning variables, then you have the op tion of tuning the BDS5 yourself. You will need an oscilloscope. Connect an oscilloscope channel to TACH MONITOR on Connector C2, Pin 2; atta c h the scope ground to COMMON on Connector C2, Pin

14. Use the TUNE command to get as close as

possible.

3.6.1 Tuning the Velocity Loop

The drive will be enabled and the motor will turn. Make sure

WARNING

Drawing A-84888 shows how to manually tune an integrating velocity loop. This procedure sets KV and KVI. First, you should use the TUNE command to set KV and KVI close to optimum values. Apply DC bus voltage to the BDS5. Follow the instructions shown on Drawing A-84888. The motor should start and stop every second. Press the escape key to enter the monitor mode where you can change tuning constants. The tach should be on the oscilloscope, showing the motor performance. As the drawing notes, you should increase KV for increased stability

the motor is secured.

2650 10 Hz 4000 15 Hz 5000 20 Hz 6250 25 Hz 7500 30 Hz 8750 40 Hz

10000 50 Hz

If you are using a proportional velocity loop (PROP is on), then adjust KPROP until the motor is performing appropriately.

3.6.2 Tuning the Position Loop

Once the velocity loop is tuned, you can tune the position loop. Break program execution and stop motion by typing S. Type in the following commands:

The drive will be enabled and the motor will turn. Make sure

WARNING

the motor is secured.

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PEMAX 30000 ZPE ;ZERO POSITION

PL ON KF=0 RUN 80

The motor shoul d again begin turning. Now adjust KP until the motor is performing appropriately. Table 3.4 shows the relationship between a properly tuned position loop (that is, the highest setting for KP) and velocity loop bandwidth. Note that the position loop bandwidth will be substantially lower than the velocity loop bandwidth (usually by a factor of 5 to 10).

Table 3.4. Velocity Loop Bandwidth vs.

MAX

500 5 Hz

1000 10 Hz

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;ERROR TO AVOID ;POSITION ERROR ;OVERFLOW WHEN ;ENABLING POSITION ;LOOP

MAX

VELOCITY LOOP

BANDWIDTH

BDS5

3.7 RECORD AND PLAY

The RECORD command allows you to record most BDS5 variables in real time for later playback. You can simultaneously record up to four variables. You can record any variable except PE, REMOTE, TMR1, TMR2, TMR3 , TMR4, VAVG, VXAVG, or any user switches. You can specify the time between points from one millisecond to one minute. You can record up to 1000 instances of 1 variable, 500 instances of 2 variables, 333 instances of 3, and 250 instances of 4 variables.

The format of the RECORD command is

RECORD <Number> <Time> <1 to 4 Variables>

Where number is the number of intervals over which the variables will be recorded, and time is the time in milliseconds of each interval.

Note: <Number> <= 1000 for 1 Variable

<Number> <= 500 for 2 Variables <Number> <= 333 for 3 Variables <Number> <= 250 for 4 Variables

For example, 1500 15 Hz 2000 20 Hz 2500 25 Hz 3000 30 Hz 4000 40 Hz 5000 50 Hz

If you want to eliminate some or all of the following error, you can raise KF as high as unity feedforward (Unity is defined as KF = 16384). However, the larger you make KF, the more you must reduce KP to eliminate overshoot and thus reduce the position loop performance. If you cannot get the desired performance from the position loop, then try reducing ACC and DEC to reduce overshoot. This can be a good way to limit overshoot in the position loop, and you may be able to raise KP slightly (about 20%) to improve performance.

405$ ;BEGINNING LABEL EN ;ENABLE BDS5 RECORD 500 1 VFB ;RECORD VFB FOR J 1000 ;1/2 SECOND JOG B ;1000 RPM

Records the velocity response of the BDS5 to a jog

command.

After data is recorded, you can use the PLAY

command to print each point on the screen. However,

Motion Link provides all the routines to retrieve, plot,

print, and store recorded data on your computer and

line printer.

The RECORD command is useful when tuning a

system because you can display the BDS5 response to

commands without an oscilloscope. However, it is

not limited to tuning. For example, you can record

VCMD to plot a motion profile, or you can plot

VEXT to watch the external encoder/analog input.

You can also plot user variables to watch the

performance of your program.

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Reducing ACC and DEC.

•

3.8 PROBLEMS

Reducing the load on the motor.

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Some times there are problems tuning. Usually the TUNE command will provide you with a tuning that is either acceptable or close to acceptable. If not, you can tune the system yourself. Sometimes there are physical factors that prevent you from attaining the performance you need. These problems fall into four categories:

1. Overloading the Motor

2. Compliance

3. Resonance

4. Changing Load Inertia or Reflected Inertia

3.8.1 Overloading the Motor

Overloading the motor is the most common problem for positioning systems (that is, systems with PL on). If you overload the system, the position error can grow to very large values. When the command stops, the motor "reels in" the following error and can overshoot excessively. It looks like a tuning problem, but it is actually caused by the motor being undersized, ACC or DEC being set to o high, or ILIM being set too low.

Increasing ILIM (if it is less than IMAX).

•

Using a BDS5 with a higher current rating.

•

Using a motor with more peak stall torque.

•

3.8.2 Compliance

In compliant systems, the load is not tightly coupled to the motor shaft. If you move the load by hand, you can feel springiness. Compliant systems often are very stable when you tune with lower target bandwidths. However, they oscillate vigorously at low frequencies when you try to tune them for higher bandwidths.

When a system is compliant, it has the following characteristics:

There is springiness between the motor and the

•

load or at the motor mounting plate.

The TUNE command calculates tuning

•

variables that cause the system to oscillate.

The frequency of oscillation is less than

•

100 Hz.

When a motor is overloaded, it has the following characteristics:

The system overshoots, sometimes excessively,

•

but does not ring or oscillate.

Reducing ACC and DEC eliminates the

•

problem.

Turning off PL eliminates the problem.

•

The motor current is near or at saturation

•

during a large part of the move. Use the BDS5 RECORD function to record ICMD.

If ICMD is equal to ILIM for more than a few

milliseconds, then your system is saturated.

Overloading the motor can be corrected by the following actions:

Compliance can be corrected by the following actions:

Reduce the bandwidth of the system.

•

Stiffen the machine so the load is not springy.

•

3.8.3 Non-Linear Mechanics

BDS5 tuning is based on linear control theory. The most important requirement of a linear motor controller is that the total reflected inertia should not

change substantially during operation. Load inertia includes all the inertia reflected to the motor, such as inertia through ge arboxes and le adscrews. Inertia can change in ways that are easy to understand, such as the inertia of a spool of cable decreasing when the cable is unrolled. It can also change in less intuitive

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ways, such as chain drives (which have load in one direction but are unloaded in the other) and systems with excessive backlash (where there is no load when gear teeth are not touching).

When the inertia changes, the system has the following characteristics:

System performance is excellent when the

•

motor is in some positions and unacceptable when the motor is in other positions.

Reducing the bandwidth eliminates the

•

problem.

If the system performance is poor because of changing inertia, you can make the follo wing corrections:

Correct the system mechanics so that inertia is

•

constant.

Detune (that is, reduce the b andwidth of) the

•

system. If the times when your system will have excessively changing inertia are predictable, you can write your program to detune your system in these regions.

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3.8.4 Resonance

BDS5

Enable the low-pass filter (LPF) and reduce

•

LPFHZ, if necessary.

Reduce the bandwidth of the system.

•

Shorten the length and increase the diameter of

•

shafts and lead screws.

3.8.5 Low-Pass Filters

The LPF switch enables the low-pass filter. It can be

turned on and off when the drive is operating. The

frequency of the low-pass filter is stored in LPFHZ in

Hz. It can also be changed when the drive is

operating. For example, if LPFHZ is 200 and LPF is

on, then a 200 Hz low-pass filter is run in the BDS5.

The filter can be modeled as two cascaded, low-pass,

single-pole filters, both with a 3 dB frequency of 200

Hz. LPFHZ should be set as high as possible, since it

degrades the system performance.

For example, the following sequence sets the low-

pass filter to 250 Hz and enables the drive.

LPF ON ;ENABLE LOW_PASS FILTER LPFHZ 250;SET BREAK FREQ. TO 250

;HZ

Resonance is a high frequency (> 500 Hz) where the system mechanics oscillate. Normally, systems with resonance will be very stable when you tune with lower target bandwidths. As you increase the target bandwidth, you will begin to hear a fairly pure, high pitch. If you want to decrease resonance, use shorter, larger diameter driving shafts. Often, the low-pass filter can help you raise the bandwidth 20% or 30%, but this can be a difficult trial-and-error process: you slowly lower the low-pass filter frequency (LPFHZ) and attempt to raise the target bandwidth for tuning.

When your system has a resonance, it will have the following characteristics:

The system will make a clear, high pitch

•

(>500 Hz). Do not confuse this problem with compliance, which has a low pitch.

If the system performance is poor because of changing inertia, you can make the follo wing corrections:

NOTE

If the low-pass filter is on, the TUNE command may not work well.

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BDS5 CHAPTER 4 - MAINTENANCE

CHAPTER 4 - MAINTENANCE BDS5

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4.1 INTRODUCTION

The information in this chapter will enable you to maintain the systems components ensuring smooth, efficient operation of the motor. Preventative maintenance of the equipment is also specified along with periodic maintenance. Follow these practices when operating your servo system.

4.2 PREVENTATIVE MAINTENANCE

Preventative maintenance can prevent situations that will damage your equipment. Four types of preventive maintenance are presented below. Following each of the procedures can reduce problems with and add life to your equipment .

Preventative maintenance to this equipment must be performed by qualified personnel familiar with the

CAUTION

construction, operation, and hazards involved with the application.

Preventative maintenance should be performed with the BDS5 system out of operation and disconnected from all sources of power.

4.2.1 Transient Voltages

All transient-producing devices must be properly suppressed.

NOTE

Solid state controls of the BDS5 may be affected by transient voltages. These voltages are in excess of the specified voltage for any given circuit. When these peak voltages occur, even for less than a second, permanent damage to the BDS5 can occur.

In order to help avoid transient voltages that may interfere with electronic circuit functions within the PSR4/5 and BDS5, all switched inductive devices or their wiring (solenoids, relay coils, starter coils, etc.) must be suppressed. A 220 ohm, 1/2 watt resistor in series with a 0.5 micro farad, 600 volt capacitor or equivalent is suggested.

4.2.2 Surge Current

CAUTION

Electronic components in this amplifier are static sensitive. Use proper procedures when handling component boards.

Excessive current greater than that of the specified limits of the PSR4/5 and BDS5 can cause permanent damage to the system. Current limiting means are recommended to protect from these currents.

4-1

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AINTENANCE

BDS5

If the short circuit inrush current generated by the power source is in excess of 5000 amps RMS symmetrical current, an isolation transformer or line inductor

CAUTION

Input transformers step up or step down input voltage and can be either autotransformers or isolation transformers. Isolation transformers help eliminate the following:

Damaging AC line voltage transients reaching

•

the PSR4/5 and BDS5.

Damaging currents which may develop if a

•

point inside the PSR4/5 or BDS5 becomes grounded.

must be utilized in the incoming power circuit. Failure to observe this precaution could result in damage to, or destruction of the PSR4/5 and BDS5.

Use twisted-pair wiring for control circuits of

•

the BDS5.

Follow good grounding practices when wiring

•

the PSR4/5 and BDS5. Be careful not to create a grounding loop with multiple ground paths. Follow the NEC's provisions on grounding.

4.2.4 Radio Frequency Energy

This equipment generates

NOTE

This equipment uses, and can radiate radio frequency

energy and must be installed and used in accordance

with this installation and service manual in order to

prevent possible interference with radio

communications or other electronic equipment.

radio frequency energy.

4.3 PERIODIC MAINTENANCE

4.2.3 Electrical Noise

The low levels of energy in the BDS5 control circuits may cause them to be vulnerable to electrical noise. Sources of electrical noise are those pieces of equipment that have l arge, fast changing vo ltages and currents when they switch on and off. These devices have the capability of inducing critical current and voltage transients on their respective power lines. These transients must be accommodated for with noise immunity provisions.

Electrical noise is prevented with the same methods as Surge Current and Transient Voltages. However, there are other methods of preventing electrical noise. Such as:

Maintain physical separation between electrical

•

noise sources and the BDS5 amplifier.

Maintain physical separation between electrical

•

noise sources and the BDS5 control wiring. This can be accomplished by using separate conduits or wiri ng trays for control wiring and power wiring.

Periodically you will need to inspect your equipment

for possible problems to insure ongoing safe and

efficient operation. Periodic maintenance should be

performed at scheduled intervals to insure proper

equipment performance. It must be performed by

qualified personnel familiar with the construction,

operation, and hazards involved with the BDS5 and

its application. Power should be disconnected during

all maintenance procedures.

4.3.1 Ventilation

The PSR4/5 and BDS5 should be mounted vertically

to allow maximum ventilation of the components.

This configuration allows the heat generated by the

components to vent through the top and draft in

cooler ai r through the bottom. The top and bottom of

the components are vented to allow this drafting to

occur. These ventilation passages should be kept

open. If the PSR4/5 requires auxiliary cooling with

fans, inspect the fans on a regular basis.

4-2

BDS5 C

4.3.2 Grounding Integrity

The method empl oyed for grounding or insulating the equipment from ground should be checked to assure its integrity on a regular basis. This check should be performed with the power off and the testing equipment grounded.

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4 - M

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BDS5

4-4

BDS5 C

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5.1 INTRODUCTION

The information in this chapter will enable you to order spare parts and isolate and resolve common system hardware problems. The BDS5 aids in diagnostic eva luation through its LED Status Indicators and the BDS5 Error Log. Both of these features are explained to assist you in finding solutions. As another part of Industrial Drives' obligation to it's customers, Factory Support and Repair is also defined.

5.2 SPARE PARTS

There are no user serviceable parts on the BDS5.

There are several fuses that are user serviceable on the PSR4/5. Remember, the PSR4/5 can be damaged by ESD (Electro-static discharge). Observe proper ESD protection practices.

The PSR4/5 can be damaged by ESD (electro-static discharge). Observe proper

CAUTION

ESD protection practices.

Connector Kit for 3, 6, and 10 Amp BDS5's (BDS5-x03, BDS5-x06 and BDS5-x10): BDS5C-100

5.2.2 PSR4/5 Spare Parts List

Connector Kit:

PSR4C-100

1.5 Amp Glass Fuse A-78896-008 Qty. 2

4.0 Amp Glass Fuse A-78896-012 Qty. 1

Regen Fuses:

Internal Regen, 12 Amp Units (PSR4/5-x12-xx00)

5 Amp Fuse: A-80552-007

Internal Regen, 20 Amp Units (PSR4/5-x20-xx00)

8 Amp Fuse: A-80552-009

8.8 Ohms External Regen, 230 Volt Units (PSR4/5-2xx-xx01) 12 Amp Fuse: A-80552-002

5.2.1 BDS5 Spare Parts List

Connector Kit for 20 Amp BDS5's (BDS5-x20):

BDS5C-101

5-1

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BDS5

5.5 Ohms External Regen, 115 Volt Units (PSR4/5-1xx-xx02) 10 Amp Fuse: A-80552-001

Soft-Start without Regen (PSR4/5-xxx-xx80)

6 Amp Fuse: A-80552-008

5.2.3 Ordering Information

If you need to order parts for the BDS5 and/or PSR4/5, you can order them through your local distributor. For a complete list of Industrial Drives' representatives contact us directly at:

INDUSTRIAL DRIVES 201 Rock Road Radford, VA 24141 U.S.A.

Telephone: 703/639-2495

FAX: 703/731-0847

TWX: 710/875-3743

This LED indicates the state of the software watchdog protection circuit. It is on during normal operation and blinks for the most serious errors. This LED also blinks during autobauding.

FAULT

•

This LED indicates that a fault has occurred. A fault is an error that is serious enough to disable the BDS5. You can turn the FAULT LED on or off from your program. The FAULT LED is turned off when you enable the BDS5.

RELAY

•

This LED indicates the status of the BDS5 relay. It is on when the relay contacts are closed and off otherwise.

5.3.2 PSR4/5 LED's

The PSR4/5-X12 and PSR4/5-X20 (12 and 20 Amp versions) have 4 indication LE D's:

5.3 LED STATUS INDICATORS

5.3.1 BDS5 LED's

The BDS5 provides LED's for diagnostics. These LED's are on the front panel of the BDS5. When the BDS5 is powered up, all LED's on the front panel turn on to verify they are operational. The states (on or off) of each LED are listed below.

ACTIVE

•

This LED shows whether the BDS5 is active. "Active" means that the BDS5 is enabled and the REMOTE input switch is on. This LED is on when the BDS5 is active and off when it is not active.

SYS OK

•

This LED indicates the state of the hardware watchdog protection circuit. It should be on during normal operation. However, it is off during autobauding. If SYS OK turns off, take the BDS5 out of service and contact the factory.

D.C. BUS

•

This green LED is on when AC Line Voltage is applied.

REGEN

•

This yellow LED turns on when the PSR4/5 regen circuit is active.

OVERLOAD

•

This red LED indicates a fault. It turns on when the PSR4/5 circuitry detects that the regen resistor has absorbed too much energy. It is turned off when power is removed and then reapplied. Normally, this is caused when the motor decelerates too rapidly or too often. If you get this fault, you may need to increase the power rating of your regen resistor and the PSR4/5 may need to be modified at the factory. If your system has an internal regen resistor, you will need a new PSR4/5 power supply designed for external regen. Contact the factory.

•

5-2

CPU

BLOWN FUSE

•

BDS5 C

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This red LED indicates a fault. It turns on when the fuse that protects the regen resistor has absorbed too much energy. You must remove power and replace the fuse. The spare parts list at the end of this chapter provides ordering information for this fuse. If the fuse blows during normal operation, see the section above on "OVERLOAD" because similar conditions cause both faults and similar actions must be taken to correct the conditions. If you replace the fuse and it blows within a few seconds of applying power, then the regen transistor is probably shorted. The PSR4/5 must be returned to the factory for repair.

The PSR4/5-X50 and PSR4/5-X75 (50 and 75 Amp versions) have 3 indication LE D's:

D.C. BUS

•

This green LED is on when AC Line Voltage is applied.

REGEN

•

This yellow LED turns on when the PSR4/5 regen circuit is active.

FAULT

•

5.4.1 Error Levels

The BDS5's response to an error depends on the error's severity. There are four levels of severity, listed below in increasing order:

Table 5.1. Error Severity Levels and

Actions

Errors which cause warnings.

Errors which cause a program break and stop motion, in addition to Level 1 Actions.

Errors which disable the system and set the FAULT LED, in addition to Level 2 Actions.

Errors which disable almost all BDS5

4. functions (includ ing communications) and flash the CPU LED to indicate the error number. These are called firmware errors.

When any error except a firmware error occurs, a message is displayed on the screen. The following items are printed: the error number, the offending entry, and an abbreviated error message. For example, disable the drive and type in a jog:

This red LED indicates an overtemperature fault. It turns on when the PSR4/5 thermostat opens. It turns off when the thermostat closes. If this fault occurs, it means that the regen resistor is on too often or for too long. If you get this fault, you may need to increase the power rating o f your regen resistor and the PSR4/5 may need to be modified at the factory. Contact the factory.

5.4 ERROR LOG

The BDS5 responds to a variety of conditions, both internal and external, hardware and software, which are grouped in a single broad category: errors. An error indicates that there is a problem somewhere. More serious errors are grouped as faults.

DIS J 100

The BDS5 will respond with:

ERR 50 'J 100' BDS5 INHIBITED

The error number (50), the offending entry (the whole line), and the error message (you cannot command a jog when the drive is inhibited) are given on one 80character line. The error message starts at character 40 so that if a 40-character display is used, the error message will not be printed. You can display the line directly, either with the Motion Link editor (GOTO A LINE NUMBER selection or ^Q^I), or with the BDS5 Editor (P command).

Sometimes only an entry is bad and not the whole line. In this case only the bad entry is printed. For example,

PROP 2

generates:

ERR 83 '2' ;BAD OR OUT OF RANGE

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BDS5

since PROP is a switch and cannot be set to 2. If the error comes from the program, the line number of the offending entry is also printed. Use the Editor to enter these lines at the top of the user program:

11$ PROP 2 B

Exit the Editor and type:

RUN 11

and the response should be:

ERR 83 LINE 2 '2' ;BAD OR OUT OF

;RANGE

This message shows that the error occurred on line 2. You can enter the Editor and type:

P 2

and the line:

PROP 2

will be displayed.

This causes the Error History to be sent to the terminal, with the most recent error sent first. When the BDS5 is powered up, a "DRIVE POWERED UP" message is inserted into Error History even though this is not an actual error.

To clear the Error History, type:

ERR CLR

Error History remains intact even through powerdown.

5.4.4 Displaying Error Messages

The ERR command can also be used to display an abbreviated description of the error. For example, type:

ERR 50

The BDS5 responds with:

ERR 50 BDS5 INHIBITED

You may display messages for errors from 1 through

999. If you type in an error number that the BDS5 does not recognize, it will respond with:

5.4.2 DEP

If your BDS5 prints to a Data Entry Panel (DEP-01) or any other 40 character wide display, the standard error messages will not print properly. The problem is that error messages are based on an 80 character wide display and the DEP-01 is only 40 characters wide. To correct this problem, the BDS5 provides the DEP switch, which, when turned on, cuts all error messages down to 40 characters. If your BDS5 prints to a DEP-01, type:

DEP ON

5.4.3 Error History

The BDS5 stores the twenty most recent errors in the Error History. To display the entire Error History, type:

ERR HIST

ERROR NOT FOUND.

A description of all errors is given in Appendix C.

5.4.5 Firmware Errors

Firmware errors are an indication of a serious problem with the BDS5. These errors stop

communications, disable the drive, and flash the CPU LED. The CPU LED flashes several times, then turns off and pauses. The number of flashes represents the error number. These error numbers range from 2 to

9. See Appendix C for information on these errors. Contact the factory should one of these errors occur.

5-4

BDS5 C

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5.5 ENABLE AND FAULT LOGIC

This section of this chapter discusses how the BDS5 is enabled and disabled. This discussion will center around Drawing A-84732 "BDS5--ENABLE and FAULT LOGIC DIAGRAM." This drawing has six areas, each of which is labeled with an encircled number, 1-6. Note that this drawing is a functional diagram; it does not directly represent the actual hardware and software used to implement these functions.

5.5.1 Firmware Faults, Area 1

Area 1 shows how firmware faults are combined. Firmware faults are the most serious errors. They include checksums (to help verify computer memory), watchdogs (to help verify that the computer is running prope rly), and the 5-volt logic power supply monitor.

These circuits are designed to watch the basic operation of the microprocessor. They do not generate error messages because the detected fault affects the microprocessor directly. Instead, they just blink the Central Processing Unit (CPU) LED.

As shown on Drawing A-84732, firmware faults set a latch to turn off communications and blink the CPU LED. The CPU LED blinks in cycles consisting of 2 to 8 blinks and a pause. The number of blinks corresponds to the error number, which you can look up in Appendix C. The only way to reset these faults is to power-down the BDS5. These faults are serious and you should consult the factory if they occur. Do not confuse these faults with autobauding on powerup. When auto bauding, the CPU LED blinks at a constant rate, about three times per second. The autobaud mode is described in the User’s Manual.

5.5.2 Fault Logic, Area 2

The large OR gate in Area 2 combines three types of faults: hardware, software, and firmware. The circuits that generate these faults are typical of motor controllers and are listed on the drawing. These faults are err ors that are ser i ous enough to disab l e the BDS5, as described in Appendix C.

5.5.3 Fault Latch, Area 3

The latch in Area 3 turns on the FAULT LED, the FAULT software switch, and the FAULT output on Connector C8. Any fault sets this latch; you can also write your program to turn it on if you detect a fault condition. The fault latch can be reset by:

1. Turning FAULT off,

2. Typing the enable command (EN), or

3. Powering down the BDS5.

5.5.4 Ready Latch, Area 4

Area 4 shows the logic required to make the drive ready. If there are no faults, the EN command sets the ready latch. This turns the READY software switch on. This latch is reset with the Kill (K) command, the Disable (DIS) command, or a fault. These turn READY off.

5.5.5 ACTIVE, Area 5

Area 5 shows that ACTIVE will be on if both READY and REMOTE are on. This turns on the ACTIVE LED. It also allows the BDS5 to actively control the motor.

REMOTE (Remote Enable) is an isolated input that is accessed from Connector C2 on the front of the drive. You can print REMOTE with the P command. It must be 1 to activate the BDS5. Note that some faults "hide" the value of the REMOTE input from the BDS5 microprocessor. This does not normally matter because all faults must be cleared before the drive will enable. If this condition exists, the BDS5 will print REMOTE as "-1".

5.5.6 Relay and STATUS Control, Area 6

Area 6 shows how software switch STATUS and the relay work. You can configure STATUS to indicate either drive READY (but not necessarily ACTIVE) or drive ACTIVE. The difference is in how you want to use STATUS. STATUS can be used for an interlock. In this case, you want STATUS to indicate drive ACTIVE. If the BDS5 becomes inactive for any reason (including the REMOTE input turning off), then STATUS will turn off. As an alternative,

5-5

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BDS5

you can use STATUS to indicate that the BDS5 is ready for the REMOTE input to turn on. That is, if REMOTE turns on, the BDS5 will be ACTIVE. In this case, you want STATUS to indicate drive READY.

The software switch STATMODE controls which state STATUS will indicate. If STATMODE is on, then STATUS will indicate drive READY. If STATMODE is off, then STATUS will indicate drive ACTIVE.

The operation of STATUS is shown by the and-gate and or-gate in area 6. If STATMODE is on, then READY will turn on STATUS through the and-gate. If STATMODE is off, then only ACTIVE (from area

5) will turn on STATUS through the o t he r leg of the or-gate. The STATUS output on optional Connector C8, Pin 35, is always the same as the STATUS software switch. Note, however, that the state of the STATUS output is undefined for 25 milliseconds after power-up.

STATUS may turn on for up to 25 milliseconds during power-

WARNING

up.

5.5.7 Motor Brake

Industrial Drives motors can be purchased with an optional brake. The brake is fail-safe in that if no current is applied the brake is active. If you set STATMODE to 0, you can use STATUS to control the brake. Then, when the BDS5 is disabled or powered down, the brake will be active.

5.5.8 Output Relay

One way to use the relay is to interconnect it with the main power contactor. In this case, a hardware watchdog fault will disconnect all power to the system.

The SYS OK LED indicates that there is not a hardware watchdog fault. If this LED goes out, you should remove the BDS5 from operation and contact the factory.

5.6 FACTORY SUPPORT AND REPAIR POLICIES

Industrial Drives is committed to helping you install, operate, maintain and troubleshoot your BDS5 servo system. If your BDS5 did not pass the "Initial Check Out" tests or is not operating properly, then contact the Field Service Department of Industrial Drives. Please see the software or programming questions. Be prepared to provide the full BDS5 and PSR4/5 model numbers listed on the front of your BDS5 and PSR4/5. Contact us at:

INDUSTRIAL DRIVES ATTN: Field Service Dept. 201 ROCK ROAD RADFORD, VA 24141

TELEPHONE: 703/639-2495

User's Manual

703/731-0847 (FAX) 710/875-3743 (TWX)

before calling about

The relay (Connector C2, pins 16 and 17) represents the state of the hardware watchdog. The hardware watchdog makes a system more reliable because the watchdog is independent of the microprocessor. If the processor is not working, the watchdog will usually detect it (though this is not guar anteed).

On power-up, the contacts are open until the BDS5 passes its power-up self tests. Then the contacts close and the BDS5 begins normal operation. Note that if the BDS5 is set to autobaud on power-up, the contacts will not close until after autobauding and establishing communications.

5-6

BDS5 A

PPENDIX

ARRANTY INFORMATION

PPENDIX

A - W

ARRANTY INFORMATION

Industrial Dri ves, a Kollmorgen Divi sion, warrants that equipment, delivered by it to the Purchaser, will be of the kind and quality described in the sales agreement and/or catalog and that the equipment will be free of defects in design, workmanship, and material.

The terms and conditions of this Warranty are provided with the product at the time of shipping or in advance upon request.

The items described in this manual are offered for sale at prices to be established by Industrial Drives and its authorized dealers.

A-1

APPENDIX

A - W

ARRANTY INFORMATION

BDS5

A-2

BDS5 A

PPENDIX

RAWINGS

PPENDIX

B - D

RAWINGS

PAGE

NUMBER

B-3

B-4 B-11 B-13 B-14 B-15 B-16 B-17 B-18 B-19 B-20 B-21 B-22

TITLE

BDS5 Enable Fault Logic Diagram BDS5 Wiring Diagram Mounting Hole Pattern BDS4A, BDS5, PSR4/5A Outline B-102-X-12,14 Outline B-104,6,-X-12,14 Outline B-20X-X-21,31,23,33-(S) Outline B-40X-X-A1,A3,B1,B3(-S) Outline B-602,4-X-A1,A3,B1,B3(-S) Outline B-606-X-A1,A3,B1,B3(-S) Outline B-802,4-X-A1,A3,B1,B3(-S) Outline B-806-X-A1,A3,B1,B3(-S) Outline & Dimension BDS5-3 & 6 Amp Outline & Dimension BDS5-10 Amp

DRAWING

NUMBER

A-84732 A-93103 A-93703 A-62370 A-62371 A-43268 A-63093 A-63099 A-63100 A-63097 A-63096 A-93569

A-93571 B-23 B-24 B-25 B-26 B-27 B-28 B-29

Outline & Dimension BDS5-20 Amp Outline & Dimension BDS5-30/40 Amp Outline & Dimension BDS5-55 Amp Outline & Dimension PSR4/5A-12 & 20 Amp Outline & Dimension PSR4/5-50 & 75 Amp PSR4/5 Simplified Schematic Velocity Loop Tuning Flow Chart

A-93570

A-93880

A-96010

A-93581

A-93031

C-84723

A-84888

B-1

PPENDIX

B - D

RAWINGS

BDS5

THIS PAGE INTENTIONALLY LEFT BLANK

B-2

ISSUE

A-84732

HARDWARE FAULTS

OVER TEMPERATURE BUS VOLTAGE +/-12 VOLT SUPPLY OVER CURRENT FEEDBACK LOSS

HARDWARE WATCHDOG

COMPENSATION BOARD

MICROPROCESSOR

ISSUE

A-84732

03-04-91

SCHULER

FIRMWARE FAULTS

UP FAIL ROM CHECKSUM

SOFTWARE WDOG 5 VOLT SUPPLY

" DIS " COMMAND

" K " COMMAND

" REMOTE " INPUT

C2-PIN 9 C2-PIN 6

SOFTWARE FAULTS

FOLLOWING ERROR

OVERTRAVEL GEARBOX OVERFLOW INTERNAL ERRORS MOTOR PARAMETERS OUT OF RANGE

POWER UP

" EN " COMMAND

OPTICAL

ISOLATION

SET

RESET

SET

LATCH

RESET

LATCH

SET

LATCH

RESET

" FAULT "

SOFTWARE SWITCH

" READY " SOFTWARE SWITCH

" STATUS " SOFTWARE SWITCH

" STATMODE " SOFTWARE SWITCH

TURN OFF COMMUNICATION

" ACTIVE " SOFTWARE SWITCH

HARDWARE WATCHDOG

COPY CODE I

BLINK

" CPU "

LED

" FAULT "

LED

ACTIVATE DRIVE

" ACTIVE "

LED

" SYS OK "

LED

HALT MICROPROCESSOR

RELAY

" RELAY "

LED

STATUS OUTPUT C8-PIN 35

C2-PIN 17 C2-PIN 16

(OPTIONAL)

BDS5-ENABLE/FAULT LOGIC DIAGRAM

A-84732 Sheet 1 of 1 B-3

B-4 A-93103 Sheet 1 of 7

(MOTOR SYSTEM RESOLVER AND THERMOSTAT CABLE) USE GOLDLINE CABLE ASSEMBLY GC-R-4/5-XX (SEE NOTES 1 & 10)

CONNECTOR PRESENT ON 20 AMP & LARGER UNITS ONLY

TO OTHER BDS4's AND/OR BDS5's (SEE NOTE 8)

(MOTOR POWER CABLE) USE INDUSTRIAL DRIVES CABLE ASSEMBLY. EXAMPLE: MODEL NO. FOR A B-20X MOTOR IS GC-M2-4/5-XX (SEE NOTE 10). THERMAL OVERLOAD PROTECTION IS NOT PROVIDED INTERNAL TO AMPLIFIER AND MUST BE PROVIDED EXTERNAL. REFER TO NATIONAL ELECTRICAL CODE FOR PROPER SIZING OF OVERLOAD PROTECTION. IT IS

RECOMMENDED THAT MOTOR WIRING BE A SHIELDED CABLE. USE PROPER SIZE WIRE. USE

COPPER WIRE AND 60°C OR 75°C TABLE FROM NEC FOR WIRE SIZE.

84451 TDG 4-30-92

7 8

84826 TDG

84924 TDG

COPY CODE

9-01-9284719 EWR 10-29-92 1-11-93

CONNECTOR C6

GND. SCREW

GRN/ YEL

APP'D.DATEECN NO.ISS.

CJF CJF RCF CJF

CONNECTOR C3

SHIELD SHIELD

CONNECTOR C4

POWER TERMINAL

BUS-

Ma Mb Mc

2 3 4

84051 V. ALLIE

84129 EWR 8-21-91 G.H.E.

BUS+

115 VAC HI 115 VAC LO

+18 VDC UNREGULATED

-18 VDC UNREGULATED

GND. SCREW

3-12-9183906 V. ALLIE 4-17-9183964 V. ALLIE 5-21-9184008 V. ALLIE 7-01-91 C.J.F.

COMMON

+10 VDC UNREGULATED

SEE NOTE 6

SEE NOTE 4

APP'D.DATEECN NO.ISS.

G.H.E. C.J.F. G.H.E.

Kollmorgen Industrial Drives

DWN. BY:VADATE

EXTERNAL REGEN RESISTOR CONNECTOR (ALWAYS PRESENT ON PSR4/5 50 AMP & LARGER. OPTIONAL ON PSR4/5 12 & 20 AMPS.)

GND. SCREW

RADFORD, VIRGINIA

CHK. BY:

1-09-91

PSR4/5BDS5

CONNECTOR C1

CONNECTOR C2

POWER TERMINAL MACHINE

BUS-

BUS+

LcLbLa

SEE NOTES 4 & 7

GND. SCREW

CIRCUIT BREAKERS OR FUSES (CUSTOMER SUPPLIED)

SEE NOTES ON LAST PAGE

SEE NOTE 3

CONTROL POWER 115 ±15% AC INPUT, 50-60 Hz (SEE NOTES 5, 7, & 12)

NORMALLY OPEN AUXILIARY CONTACT FROM MAIN POWER CONTACTOR (NOT REQUIRED FOR 12 AND 20 AMP PSR4/5)

OR EARTH GROUND

BDS5 WIRING DIAGRAM

(PSR4/5 & MOTOR CONNECTIONS)

DATE

APP'D. BY:

GHEFDO

DATE

1-11-91 1-10-91

SCALE

1:1

DWG. NO.

A-

LOGIC COMMON SHOULD BE TIED TO MACHINE OR EARTH GROUND EITHER EXTERNAL OR THROUGH CUSTOMER EQUIPMENT

DWG. NO.

SHEET 1 OF 7

93103

EMERGENCY STOP

OVERLOAD RELAY (ONLY FOR PSR 50 & 75 AMP UNITS) (SEE NOTE 11)

FAULT CONTACTS SEE NOTE 2

MOMENTARY PUSHBUTTON TO ENERGIZE MAIN POWER

MAIN POWER CONTACTOR

POWER CONTACTS OF MAIN POWER CONTACTOR

MAIN POWER 3 PHASE OR SINGLE PHASE

SHEET 1 OF 7

A-

ISSUE

CAD DWG.

ISSUE

1493103

DWG. NO.

A-

SHEET 2 OF 7

93103

ISSUE

+5 VOLT DC ENCODER AND I/O POWER SUPPLY

(CUSTOMER SUPPLIED)

COMMON OF ENCODER SUPPLY MUST BE TIED TO BDS5 COMMON

COMMON

MASTER

ENCODER

+5 V

OUT Z OUT Z OUT B OUT A OUT A OUT B

OUT A

OUT B

OUT Z

IN B (OPTIONAL)

IN A (OPTIONAL)

WIRE THROUGH AN OPTO-22 STYLE DC INPUT MODULE TO CONNECTOR C7 (PIN 9)

OCCASIONALLY THE ENCODER OUTPUTS MUST BE TERMINATED AT THE BDS5 WITH A 120 ohm, 1/2 WATT RESISTOR TO REDUCE RINGING.

CONNECTOR C1

10 5

OUT A

OUT B

OUT Z

IN B (OPTIONAL)

(SEE NOTE 13, LAST SHEET)

IN A (OPTIONAL)

SLAVE BDS5

THE COMMONS OF MASTER/SLAVE BDS5's MUST BE CONNECTED. THIS IS ACCOMPLISHED THROUGH CONNECTOR C4 IF THE BDS5's SHARE ONE PSR4/5.

IN B (OPTIONAL)

IN A (OPTIONAL)

OUT A

OUT B

OUT Z

CONNECTOR C1

7 6 2

OUT A

OUT B

OUT Z

MASTER BDS5

CONNECTOR C1

IN B (OPTIONAL)

10 9 5

(SEE NOTE 13, LAST SHEET)

IN A (OPTIONAL)

SLAVE BDS5

WIRE THROUGH AN OPTO-22 STYLE DC INPUT MODULE TO CONNECTOR C7 (PIN 9)

MASTER ENCODER AND SLAVE BDS5

ISS. ECN NO.

COPY CODE

APP'D.

DATE

ISS.

11 12 13 14

ECN NO.

85228 TDG 85244 LLS 85698 LLS 85972 MAW

DATE

5-7-93 5-18-93 3-16-94 6-14-94

APP'D. SCM

SCM SGD

Kollmorgen Industrial Drives

RADFORD, VIRGINIA

DWN. BY:VADATE

1-25-91

CHK. BY:

B-5 A-93103 Sheet 2 of 7

DATE

MASTER BDS5 AND SLAVE BDS5

BDS5 WIRING DIAGRAM

(C1 ENCODER EQUIVALENT)

APP'D. BY:

DATE

SCALE

1:1

DWG. NO.

A-

93103

SHEET 2 OF 7

ISSUE

B-6 A-93103 Sheet 3 of 7

BDS5 (DE-9S) FEMALE

COM

TXD RXD

SHIELD

COM RXD

TXD

CUSTOMER TERMINAL

C5 SERIAL RS-232 INTERCONNECT

IBM-PC (DB-25S) FEMALE

BDS5 (DE-9S) FEMALE

PIN 13

PIN 7

SHIELD

PIN 1

PIN 25

PIN 14

EXAMPLE: TO IBM-PC (RS-232 ONLY)

DEP01-00-1-0 (DE-9S) FEMALE

ALWAYS MAKE THE DEP01 CONNECTION LAST IN THE STRING FOR PROPER TERMINATION.

PIN 1 NORMALLY NOT CONNECTED

COPY CODE

ISS. ECN NO. DATE APP'D.

BDS5 (DE-9S) FEMALE AXIS 1

SHIELD

DEP01 SERIAL (RS-485 ONLY) TO C5

ISS. ECN NO. DATE APP'D.

SEE DETAIL J1 FOR JUMPER LOCATION

IMPEDANCE

TERMINATION

JUMPERS

120

INACTIVE

STATE

TERMINATION

JUMPERS

C5 SERIAL RS-485 INTERCONNECT

EXAMPLE: IBM-AT (RS-232 ONLY)

BDS5 (DE-9S) FEMALE AXIS 2

BDS5 (DE-9S) FEMALE

BDS5 (DE-9S) FEMALE AXIS 32

SHIELD

Kollmorgen Industrial Drives

DWN. BY:

1-25-91

DATE

COM RD-

RD+ TDTD+ SHIELD

IBM-AT (DE-9S) FEMALE

2 J1

RADFORD, VIRGINIA

CHK. BY:

COM TXD-

TXD+

RXDRXD+

CUSTOMER TERMINAL

EXAMPLE: DEP01-00-0-0 (RS-232 ONLY)

EXAMPLE: MOST RS-232 TERMINALS

IMPEDANCE & INACTIVE STATE

TERMINATION JUMPERS

ONLY INSTALL JUMPERS ON THE LAST BDS5 AXIS IN THE STRING

ON EACH BDS5 AXIS

J1J1120

DATE

APP'D. BY:

120

SEE DETAIL J1 FOR JUMPER LOCATION

DATE

DWG. NO. SHEET 3 OF 7

A-

DEP01-00-0-0 (DB-25P) MALE

BDS5 (DE-9S) FEMALE

SHIELD

BDS5 (DE-9S) FEMALE

SHIELD

FOR SHORT DISTANCES, LESS THAN 6 FEET, A RIBBON CABLE MAY BE USED.

BDS5 WIRING DIAGRAM

SCALE

1:1

PIN 13

PIN 7

PIN 1

DB-25P MALE

PIN 13

PIN 7

PIN 1

1 3

{

CONN. C5

DETAIL J1

(C5 SERIAL PORT)

DWG. NO. SHEET 3 OF 7

A-

93103

PIN 25

PIN 14

PIN 25

PIN 14

BDS5 MC2 CARD 2 4 6 8

ISSUE

1493103

DWG. NO. SHEET 4 OF 7

93103

A-

ISSUE

OPTIONAL ANALOG INPUT SEE NOTE 13, LAST SHEET

SCHEMATIC OF OPTIONAL ANALOG INPUT CARD (BDS5-OPT1). THE ANALOG INPUT IS SCALED FOR ±10 VOLTS = FULL SCALE. IF YOU USE THE ANALOG INPUT, SEE APPENDIX F OF THE BDS5 MANUAL FOR INSTRUCTIONS ON HOW TO CONFIGURE THE BDS5 AS A VELOCITY DRIVE.

THE HARDWARE WATCHDOG RELAY CONTACTS CAN DRIVE UP TO 1 AMP RESISTIVE, AND THE CONTACTS ARE RATED FOR 115 VAC. THE RELAY MUST BE DERATED FOR INDUCTIVE LOADS.

O1 IS AN OPTICALLY ISOLATED OUTPUT. IT IS A SOLID STATE RELAY RATED FOR 0.25 AMPS AND 30 VDC. YOU MUST OBSERVE POLARITY WHEN CONNECTING O1.

DIFF HI

±10V

DIFF LO

DIFF LO (OPTIONAL) DIFF HI (OPTIONAL)

O1 LO O1 HI

10k

.01UF

RELAY

10k

16.2k.01UF

SHIELD

CONNECTOR C2

CUSTOMER I/O

16.2k

19 9

1020

±8V

SHIELD

COMMON

TACH MONITOR

COMMON

I MONITOR

COMMON

I/O DC

TACH MONITOR IS A COMMON-REFERENCED SIGNAL SCALED FOR 1000 RPM CLOCKWISE = +1 VOLT. THIS SIGNAL HAS A 1k ohm RESISTOR IN LINE AND A 4700PF FILTER CAPACITOR CONNECTED TO COMMON.

I MONITOR IS A COMMON-REFERENCED SIGNAL SCALED FOR FULL CURRENT = 5 VOLTS. THIS SIGNAL HAS A 3.01k ohm RESISTOR IN LINE.

NON-ISOLATED POWER SUPPLY. SEE CHAPTER 2 "WIRING C2, CUSTOMERS I/O" BEFORE USING.

REMOTE RETURN HOME RETURN

CYCLE RETURN

CYCLE

HOME

REMOTE

24 VOLT DC ISOLATED POWER SUPPLY (CUSTOMER SUPPLIED)

COPY CODE

DATEISS. ECN NO.

APP'D.

ISS.

ECN NO.

DATE

APP'D.

Kollmorgen Industrial Drives

RADFORD, VIRGINIA

DWN. BY:

DATE

CHK. BY:

1-31-91

B-7 A-93103 Sheet 4 of 7

DATE

APP'D. BY:

DATE

BDS5 WIRING DIAGRAM

(CONNECTOR C2)

SCALE

DWG. NO. SHEET 4 OF 7

1:1

A-

93103

ISSUE

B-8 A-93103 Sheet 5 of 7

DWG. NO. SHEET 5 OF 7

93103

A-

ISSUE

SIGNALPIN

N/C

1 3

N/C N/C

5 7

N/C

HOME

9 11

LIMIT CYCLE

13 15

MOTION

GATE O8

21 23

CYCLE READY N/C25

EVEN

SIGNAL RETURN/

PINS

COMMON

A WIDE SELECTION OF ISOLATION MODULES, BOTH INPUT AND OUTPUT, ARE AVAILABLE FROM SEVERAL SOURCES. A TYPICAL I/O CONFIGURATION, USING DC ISOLATION MODULES, IS ILLUSTRATED. HOWEVER, YOUR I/O IS NOT LIMITED TO ONLY DC MODULES AS THE FOLLOWING LIST INDICATES.

MODULE TYPE INPUT MODULE LOAD VOLTAGE

INPUT AC OUTPUT AC INPUT DC OUTPUT DC

PIN 1

POLARIZING KEY

C7 (STANDARD)

PIN 25

90-280VAC N/A 3-32VDC N/A

PIN 2

TOP VIEW OF BDS5 (20-AMP UNIT SHOWN)

N/A 120-240VAC N/A 10-60VDC

PIN 2

PIN 26

PIN 1

POLARIZING KEY

PIN 25

PIN 1

ISOLATED OUTPUT

ISOLATED INPUT

OPTO-22 TYPE 8 POSITION I/O BOARD

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

NOTES:

1. VFS5 USES PIN 23 CYCLE READY AS METER DRIVE INPUT. (CONNECT TO PIN 1 OF C8 ON BDS5-EXT1-I/O CARD).

PIN 25

+5 VOLTS DC

ENCODER AND I/O POWER

SUPPLY

(CUSTOMER SUPPLIED)

-+ +

CYCLE READY

LOAD

GATE

MOTION

CYCLE

LIMIT

HOME

THE COMMON OF THIS SUPPLY IS CONNECTED TO THE BDS5 COMMON THROUGH THE RIBBON CABLE BY THE EVEN NUMBERED PINS.

THE COMMON OF THIS ISOLATED SUPPLY MUST NOT BE CONNECTED TO THE BDS5 COMMON

24 VOLT DC

ISOLATED POWER SUPPLY

(CUSTOMER SUPPLIED)

COPY CODE

ISS. ECN NO. DATE APP'D.

Kollmorgen Industrial Drives

BDS5 WIRING DIAGRAM

RADFORD, VIRGINIA

DWN. BY:

DATE

2-7-91

CHK. BY:

DATE

APP'D. BY:

DATE

SCALE

1:1

DWG. NO. SHEET 5 OF 7

(C7 STANDARD I/O)

93103 14

A-

ISSUE

NOTES:

1. VFS5 USES BDS5-EXT1-I/O WITH FILTERED INPUTS AND POWER METER DRIVER.

2. INPUT #16 (PIN 1) IS POWER METER INPUT. PIN 49 IS METER DRIVE OUT

SIGNAL

MET. OUT

47 45

O4 O5

39 37

STATUS

MANUAL I1

27 25

23 I5

19 17

I10 I11

I12

I13

I14

I15

I16 *

EVEN

SIGNAL

PINS

RETURN/ COMMON

* POWER METER INPUT ON VFS5 ONLY

ISS. ECN NO. DATE APP'D.

PIN 50

C8 (OPTIONAL)

PIN 2

POLARIZING KEY

PIN 1

TOP VIEW OF BDS5 (20-AMP UNIT SHOWN)

MODULE TYPE INPUT MODULE LOAD VOLTAGE

COPY CODE

INPUT AC OUTPUT AC INPUT DC OUTPUT DC

ISS. ECN NO. DATE APP'D.

90-280VAC N/A 3-32VDC N/A

PIN 49

POLARIZING KEY

PIN 1

LOGIC SUPPLY INPUT

+5 VOLTS DC ENCODER AND I/O POWER SUPPLY

(CUSTOMER SUPPLIED)

THE COMMON OF THIS SUPPLY IS CONNECTED TO THE BDS5 COMMON THROUGH THE RIBBON CABLE, BY THE EVEN NUMBERED PINS.

PIN 50

PIN 2

N/A 120-240VAC N/A 10-60VDC

Kollmorgen Industrial Drives

DATE

2-7-91

DWN. BY:

PIN 49

PIN 1

OPTO-22 TYPE 24 POSITION I/O BOARD

RADFORD, VIRGINIA

CHK. BY:

DATE

ISOLATED OUTPUT

ISOLATED INPUT

APP'D. BY:

DATE

DWG. NO. SHEET 6 OF 7

93103

A-

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

LOAD

STATUS

MANUAL

I10

I11

I12

I13

I14

I15

I16

TO METER (+) TO METER (-)

CYCLE READY POWER METER INPUT

THE COMMON OF THIS ISOLATED SUPPLY MUST NOT BE CONNECTED TO THE BDS5 COMMON

24 VOLT DC

ISOLATED POWER SUPPLY

(CUSTOMER SUPPLIED)

BDS5 WIRING DIAGRAM

(C8 OPTIONAL I/O)

SCALE

1:1

DWG. NO. SHEET 6 OF 7

93103

A-

ISSUE

B-9 A-93103 Sheet 6 of 7

B-10 A-93103 Sheet 7 of 7

NOTES:

WARNING: THE MOTOR THERMOSTAT AUTOMATICALLY RESETS WHEN THE MOTOR

COOLS. THE CUSTOMER IS RESPONSIBLE FOR LATCHING THIS SIGNAL TO INHIBIT OPERATION AFTER A MOTOR THERMOSTAT FAULT. CONNECT THERMOSTAT USING TWISTED PAIR WIRE.

CAUTION: THE PRS4/5 FAULT CONTACTS (RATED 115 VAC 1AMP) MUST BE WIRED

IN SERIES WITH THE OVERLOAD RELAY AS SHOWN ON SHEET 1. ON 12 & 20 AMP PSR4/5: THIS CONTACT IS NORMALLY OPEN AND WILL CLOSE WITHIN 250 MSEC. AFTER APPLICATION OF CONTROL AND MAIN POWER. THIS CONTACT OPENS IN FAULT CONDITIONS. ON 50 & 75 AMP PSR4/5 THIS CONTACT CLOSES ON APPLICATION OF CONTROL POWER AND WILL OPEN IN FAULT CONDITION.

CAUTION: RESISTOR IS CONNECTED TO HIGH VOLTAGE; ENSURE SUFFICIENT

ELECTRICAL CLEARANCE WHEN MOUNTING. RESISTOR MAY BECOME VERY HOT DURING OPERATION. DO NOT MOUNT NEAR MATERIALS THAT ARE FLAMMABLE OR DAMAGED BY HEAT. VENTILATION MAY BE REQUIRED. SEE WIRING DRAWING FOR SPECIFIC REGEN RESISTOR KIT. EACH KIT HAS DIFFERENT SERIES/PARALEL RESISTOR CONNECTIONS TO OBTAIN SPECIFIC RESISTANCE AND POWER RATING.

WIRE SIZES, BREAKERS AND FUSES FOR PSR4/5: PSR4/5-X12 HAS A MAXIMUM MAIN POWER INPUT CURRENT OF 12 AMPS RMS, PSR4/5-X20 HAS A MAXIMUM MAIN POWER INPUT CURRENT OF 20 AMPS RMS, PSR4/5-X50 HAS A MAXIMUM MAIN POWER INPUT CURRENT OF 50 AMPS RMS, PSR4/5-X75 HAS A MAXIMUM MAIN POWER INPUT CURRENT OF 75 AMPS RMS.

THE ACTUAL APPLICATION MAY REQUIRE LESS CURRENT. USE 600 VAC INSULATED WIRE AND REFER TO LOCAL ELECTRICAL CODES FOR PROPER WIRE SIZE FOR THE CURRENTS LISTED ABOVE. FUSES FOR MAIN POWER SHOULD BE A U.L. RATED TIME DELAY TYPE, SUCH AS, BUSS FRN-R SERIES.

THE POWER BUS BETWEEN A PSR4/5 AND BDS5 SHOULD USE THE FOLLOWING WIRE GAUGE WITH 600 VAC INSULATION: PSR4/5-X12, 14 AWG (OR LARGER) WIRE, PSR4/5-X20, 10 AWG WIRE, PSR4/5-X50, BUS BARS SUPPLIED WITH UNIT, OR 8 AWG (OR LARGER) WIRE, PSR4/5-X75, BUS BARS SUPPLIED WITH UNIT, OR 8 AWG (OR LARGER) WIRE.

ALL SIGNAL AND CONTROL WIRES TO BE 22-18 AWG WIRE. THE CRIMP TERMINALS FOR 22-18 AWG WIRE ARE SUPPLIED FOR USE WITH BDS5 CONNECTORS C1, C2, C3, C4, C6 AND PSR4/5 CONNECTORS C1 AND C2. FOR 16 AWG WIRE USE MOLEX #39-00-0078 TERMINALS.

IN THE BDS5 3 AMP THRU 20 AMP AND THE PSR4/5 12 AMP AND 20 AMP, THE SCREWS IN THE POWER TERMINAL BLOCKS ARE CAPTIVE. DO NOT ATTEMPT TO REMOVE THEM TO USE RING TERMINALS. USE LOCKING SPRING SPADE TERMINALS SUCH AS HOLLINGSWORTH #XSS20954S OR #SS20947SF FOR 16 AWG WIRE AND #XSS20836 OR #SS20832F FOR 12/10 AWG WIRE.

(ALL WIRES TO BE COPPER WITH MIN. TEMP RATING OF 60°C)

ALL AC LINES SHOULD BE TWISTED CABLES.

THE TOTAL NUMBER OF AXES ALLOWED, PER PSR4/5, DEPENDS ON THE PSR4/5 MODEL AND THE COMBINATION OF BDS4's AND/OR BDS5's: PSR4/5-X12: A MAXIMUM OF 4 BDS4s OR 3 BDS5s, PSR4/5-X20: A MAXIMUM OF 4 BDS4s OR 3 BDS5s, PSR4/5-X50: A MAXIMUM OF 6 BDS4s OR 6 BDS5s, PSR4/5-X75: A MAXIMUM OF 6 BDS4s OR 6 BDS5s. (IF THE BDS's ARE MIXED, THEN THE TOTAL NUMBER OF AXES THAT CAN BE USED WOULD BE THE MAXIMUM GIVEN FOR THE BDS5s.)

AXIS EXPANSION ON THE PSR4/5 50 AND 75 AMP UNITS ARE ALSO LIMITED TO A MAXIMUM OF 4 BDS4s OR 3 BDS5s ON EITHER SIDE OF THE PSR4/5.

THE BDS5 IS CONFIGURED AT THE FACTORY FOR EITHER RS-232 OR RS-485.

10.

XX IN THE CABLE NUMBER STANDS FOR CABLE LENGTH IN METERS. CABLE LENGTH IS AVAILABLE FROM 3 TO 75 METERS IN INCREMENTS OF 3 METERS.

11.

A THERMAL OVERLOAD RELAY IS SUPPLIED IN THE REGEN RESISTOR KIT FOR THE 50 AND 75 AMP PSR4/5's. THE THERMAL OVERLOAD RELAY, INCLUDED IN THE KIT, WAS SIZED FOR YOUR RESISTANCE AND POWER RATING. THE OUTPUT CONTACTS OF THE RELAY MUST BE WIRED TO DROP POWER TO THE MAIN POWER CONTACTOR IN A FAULT CONDITION, AS SHOWN ON SHEET 1.

12.

DO NOT WIRE CONTROL POWER (PSR4/5 CONNECTOR C1) THROUGH THE MAIN POWER CONTACTOR. THIS IS SO THAT CONTROL POWER WON'T BE REMOVED IF PSR4/5 FAULT CONTACTS OPEN (THIS WOULD TURN OFF ANY FAULT LEDS).

13.

IF THE BDS5 USES THE OPTIONAL ANOLOG INPUT CARD (BDS5-OPT1), THE OPTIONAL ENCODER INPUTS IN CONNECTOR C1 ARE NOT USED.

14.

RECOMMENDED TORQUES FOR CONNECTION TO TERMINAL BLOCKS AND GROUND.

BDS4/5-3 TO 20 AMP AND PSR4/5-12 AND 20 AMP

BDS4/5-30 TO 55 AMP

PSR4/5-50 TO 75 AMP

FOR GROUNDING TO MACHINE OR EARTH GROUND, A SCREW LUG SHOULD BE ATTACHED TO GROUND SCREW OR STUD. RECOMMENDED TORQUE OF 12 IN/LB FOR GROUND SCREWS AND 20 IN/LB FOR GROUND STUDS. MAY ALSO REFER TO NATIONAL ELECTRICAL CODE (NEC) OR UL STANDARD 486B FOR RECOMMENDED TORQUES

THERMAL OVERLOAD PROTECTION DOES NOT PROVIDE INTERNAL TO AMPLIFIER AND MUST BE PROVIDED EXTERNAL. REFER TO NATIONAL ELECTRICAL CODE FOR PROPER SIZING OF OVERLOAD PROTECTION.

DWG. NO. SHEET 7 OF 7

93103

A-

MAX TORQUE PER UL IS 12 IN/LB, EXTERNAL REGEN, MAIN POWER AND BUS CONNECTION. MAX TORQUE 12 IN/LB GROUND SCREW

MAX TORQUE 20 IN/LB MOTOR, BUS CONNECTION AND GROUND STUD

MAX TORQUE 20 IN/LB MAIN POWER, BUS CONNECTION AND GROUND STUD MAX TORQUE 12 IN/LB EXTERNAL REGEN CONNECTION

ISSUE

ISS.

ECN NO.

COPY CODE

DATE

APP'D.

ISS.

ECN NO. DATE APP'D.

Kollmorgen Industrial Drives

BDS5 WIRING DIAGRAM

RADFORD, VIRGINIA

SCALE

DATEDWN. BY:

2-13-91

CHK. BY:

DATE

APP'D. BY: DATE

1:1

DWG. NO. SHEET 7 OF 7

A-

(NOTES)

ISSUE

93103 14

THIRD ANGLE PROJECTION

UNLESS OTHERWISE SPECIFIED ANG. DIM. ±1 DEGREE

METRIC X DEC. PLACES ±.4 XX DEC. PLACES ±.13

[INCHES] XX DEC. PLACES ±.015 IN. XXX DEC. PLACES ±.005 IN.

DO NOT SCALE DWG. USE DIMENSIONS ONLY. ALL DIMENSIONS ARE MILLIMETERS. UNLESS OTHERWISE SPECIFIED.

DWG. NO.

A-

SHT 1 OF 2

93703

ISSUE

METRIC

356

328 MIN 340 MAX

BDS4 3 AMP 6 AMP

BDS5

3 AMP 6 AMP

20 20

23 23

20MM BETWEEN ALL UNITS FOR COOLING

BDS4

10 AMP

BDS5

10 AMP

107

BDS4

20 AMP

BDS5

20 AMP

PSR4/5 12 AMP 20 AMP

1-A 25mm MINIMUM FREE SPACE SHOULD BE MAINTAINED AROUND THE SYSTEM. 2-LOCATE THE HIGHEST CURRENT BDS4/5 AMPLIFIER NEXT TO THE PSR4/5 POWER SUPPLY AND REMAINING BDS4/5 AMPLIFIERS IN DESCENDING ORDER.

COPY CODE

ISS. ECN NO.

DATE APP'D.2ISS. ECN NO.

84949 TDG

DATE APP'D.

1-20-93

CJF

Kollmorgen Industrial Drives

RADFORD, VIRGINIA

DWN. BY:

TDG

DATE

1-6-93

B-11 A-93703 Sheet 1 of 2

DATECHK. BY:

APP'D. BY:

CJF

DATE

1-8-93

CAD DWG.

MOUNTING HOLE PATTERN

BDS4A, BDS5A, PSR4/5A

SCALE

1:4

DWG. NO.

A-

SHT 1 OF 2

93703

ISSUE

B-12 A-93703 Sheet 2 of 2

THIRD ANGLE PROJECTION

UNLESS OTHERWISE SPECIFIED ANG. DIM. ±1 DEGREE

METRIC X DEC. PLACES ±.4 XX DEC. PLACES ±.13

[INCHES] XX DEC. PLACES ±.015 IN. XXX DEC. PLACES ±.005 IN.

METRIC

20MM BETWEEN ALL UNITS FOR COOLING

138

28 80

158 100

DO NOT SCALE DWG. USE DIMENSIONS ONLY. ALL DIMENSIONS ARE MILLIMETERS. UNLESS OTHERWISE SPECIFIED.

140

DWG. NO.

SHT 2 OF 2

93703 2

A-

ISSUE

SEE NOTES ON SHEET 1.

COPY CODE

ISS. ECN NO. DATE APP'D.

343

BDS4 BDS4

40 AMP

BDS5

328

30 AMP 40 AMP

28 80 28

PSR4/5

55 AMP30 AMP

50 AMP 75 AMP

BDS5

55 AMP

100

30 80

CAD DWG.

APP'D.DATEECN NO.ISS.

Kollmorgen Industrial Drives

RADFORD, VIRGINIA

DATEDATE

TDG

1-6-93

CHK. BY:DWN. BY: DATE

APP'D. BY:

MOUNTING HOLE PATTERN BDS4A, BDS5A, PSR4/5A

SCALE

1/4

DWG. NO.

A-

SHT 2 OF 2

93703

ISSUE

THIRD ANGLE PROJECTION

METRIC

±3.0 [.12]

59.0

[2.32]

UNLESS OTHERWISE SPECIFIED ANG. DIM. ±1 DEGREE

RESOLVER LEADS 457 [18.0] MIN. LGTH.

MOTOR & THERMOSTAT LEADS 457 [18.0] MIN. LGTH.

70.0

METRIC X DEC. PLACES ±.4 XX DEC. PLACES ±.13

+1.5 [.06]

-0.0 [.00]

[2.76] SQUARE

60.00

XX DEC. PLACES ±.015 IN. XXX DEC. PLACES ±.005 IN.

±.5 [.02]

23.00 [.90]

18.0 [.71] MIN.

+.012

-.007

[2.362]

[INCHES]

DO NOT SCALE DWG.USE DIMENSIONS ONLY. ALL DIMENSIONS ARE MILLIMETERS WITH INCHES IN BRACKETS.UNLESS OTHERWISE SPECIFIED.

A 0.08 TIR

[.003]

183.2

[7.21]

2.36

[.093]

159.0

9.54

[.375]

MAX.

±1.0 [.04]

DWG. NO.

62370 2

A-

ISSUE

A 0.08 TIR

5.80 [.228] DIA. THRU (4) HOLES EQ. SPACED ON 75.00 [2.953] DIA. B.C.

NOTES:

1-PRESSURE ON SHAFT SEAL MUST NOT EXCEED 0.21 kg/cm2 [3 PSI] 2-MOTOR CAN BE MOUNTED IN ANY POSITION. 3--12 MODEL HAS BEEN DESIGNED WITH INTENT TO MEET IP-65 SEALING.

-14 MODEL HAS BEEN DESIGNED WITH INTENT TO MEET IP-65 SEALING, EXCEPT FOR MOUNTING FACE.

4-ELECTRICAL HOOK-UP PER HD-100.

ISS. ECN NO. DATE APP'D.

COPY CODE

[.003]

APP'D.DATEECN NO.ISS.

GLK84634

8-4-92

S.P.

11.00

[.433]

-A-

0.035

[.0014]

+.008

-.003

8.50

8.40

INDUSTRIAL DRIVES

CHK. BY:DWN. BY:

DATE

12-90

J.S.

B-13 A-62370 Sheet 1 of 1

[.335] [.331]

RADFORD, VIRGINIA A KOLLMORGEN DIVISION

APP'D. BY:

5-91

4.00

3.97

MKB

[.157] [.156]

KEYWAY DETAIL

DATEDATE

5-91

SCALE

HALF

STANDARD OPTIONS

MODEL NO.

OUTLINE

B-102-X-12,14

DWG. NO.

A-

-12

-14

CAD DWG

SHAFT SEAL

YES

ISSUE

262370

B-14 A-62371 Sheet 1 of 1

METRIC X DEC. PLACES ±.4 XX DEC. PLACES ±.13

THIRD ANGLE PROJECTION

UNLESS OTHERWISE SPECIFIED ANG. DIM. ±1 DEGREE

METRIC

RESOLVER LEADS 457 [18.0] MIN. LGTH.

MOTOR & THERMOSTAT LEADS 457 [18.0] MIN. LGTH.

±3.0 [.12]

59.0

[2.32]

+1.5 [.06]

-0.0 [.00]

70.0

(2.76)

SQUARE

A 0.08 TIR

[.003]

5.80 [.228] DIA. THRU (4) HOLES EQ. SPACED ON 75.00 [2.953] DIA. B.C.

NOTES:

1-PRESSURE ON SHAFT SEAL MUST NOT EXCEED 0.21 kg/cm2 [3 PSI] 2-MOTOR CAN BE MOUNTED IN ANY POSITION. 3--12 MODEL HAS BEEN DESIGNED WITH INTENT TO MEET IP-65 SEALING.

-14 MODEL HAS BEEN DESIGNED WITH INTENT TO MEET IP-65 SEALING, EXCEPT FOR MOUNTING FACE.

4-ELECTRICAL HOOK-UP PER HD-100.

ISS. ECN NO. DATE APP'D.

COPY CODE

8-4-92

GLK846342

60.00

APP'D.DATEECN NO.ISS.

XX DEC. PLACES ±.015 IN. XXX DEC. PLACES ±.005 IN.

±.5 [.02]

30.00 [1.18]

20.0 [.79] MIN.

+.012

-.007

[2.362]

14.00

[.551]

-A-

0.035

[.0014]

S.P.

[INCHES]

+.008

-.003

DATE

12-90

DO NOT SCALE DWG.USE DIMENSIONS ONLY. ALL DIMENSIONS ARE MILLIMETERS WITH INCHES IN BRACKETS.UNLESS OTHERWISE SPECIFIED.

A 0.08 TIR

[.003]

2.36

[.093]

9.54

[.375]

11.00

10.90

[.433] [.429]

KEYWAY DETAIL

INDUSTRIAL DRIVES

RADFORD, VIRGINIA A KOLLMORGEN DIVISION

CHK. BY:DWN. BY:

J.S.

5-91

APP'D. BY:

MKB

"A" MAX

±1.0 [.04]

"B"

DATEDATE

5-91

5.00

4.97

[.197] [.196]

244.2 (9.61)B-106

B-104

213.7 (8.41)

OUTLINE

B-104,6,-X-12-14

DWG. NO.

SCALE

HALF

A-

62371

DWG. NO.

62371 2

A-

STANDARD OPTIONS

MODEL NO.

-12

-14

220.0 (8.66)

189.5 (7.46)

ISSUE

CAD DWG

SHAFT SEAL

YES

"B""A" MAXMODEL

ISSUE

Kollmorgen BDS5 Installation And Setup Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ABBREVIATIONS

1.1 INTRODUCTION

1.2 PRODUCT DESCRIPTION

1.3 FEATURES

1.4 PART NUMBER DESCRIPTION

1.4.1 BDS5 Model Number

1.4.3 PSR4/5 Model Number

1.6 THEORY OF OPERATION

2.1 INTRODUCTION

2.2 SAFETY INFORMATION

2.3 UNPACKING AND INSPECTION

2.4 INSTALLATION REQUIREMENTS

2.5 MOUNTING

2.4.1 Environmental Considerations

2.4.2 Enclosures

2.5.1 Mounting the BDS5

2.5.2 Mounting the PSR4/5

2.5.3 Mounting the External Regen Resistor

2.6 WIRING

2.6.1 Wiring the Ground

2.6.2 Wiring the Power Connections

2.6.2.1 Wiring the Motor

2.6.2.2 Motor Protection

2.6.2.3 Motor Thermostat

2.6.2.4 Motor Brake

2.6.2.5 Wiring the DC Bus

2.6.2.6 Wiring the AC Line

2.6.3 Wiring the PSR4/5 Front Panel Connectors

2.6.3.1 Wiring the Control Power to C1

2.6.3.2 Wiring to the PSR4/5 Fault Output on C1

2.6.2.7 Wiring the Regen Resistor

2.6.3.3 Wiring PSR4/5 Connector C2

2.6.4 Wiring the BDS5 Front Panel Connectors

2.6.4.1 Wiring C1, Encoder Equivalent

2.6.4.2 Encoder Equivalent Input

2.6.4.4 Encoder Equivalent Output

2.6.4.3 Pulse Input (OPT2 Card)

2.6.4.5 Wiring C2, Customer I/O

2.6.4.6 Wiring C3, Resolver

2.6.4.8 Wiring C5, Serial Communications

2.6.4.9 Wiring C6, Fan Power (20 Amp Units Only)

2.6.4.10 Wiring C7, Standard I/O

2.6.4.11 Wiring C8, Optional I/O

2.6.4.12 J1 Configuration Jumper

2.6.5.1 Required Data Format

2.6.5.2 First Transmission

2.6.5 Establishing Communications

2.6.5.3 Checking the Control Power

2.6.5.4 If You Can't Communicate...

2.7 INITIAL CHECK-OUT

2.7.1 Checking Discrete Inputs

2.7.2 Checking General Purpose Outputs

2.7.3 Cycle Ready

2.7.4 Checking STATUS

2.7.7 Checking Pulse Input (Optional)

2.7.5 Checking Encoder Output

2.7.6 Checking Encoder Input

2.7.8 Checking Analog Input (Optional)

2.7.10 Checking the Resolver Cable

2.7.9 Checking the Resolver

2.7.11 Checking the AC Line Voltages

2.7.12 Checking the DC Bus Voltage

2.7.13 Checking the Motor

3.1 INTRODUCTION

3.2 START-UP AND CHECKOUT

3.2.1 If You Get ERROR 17, FEEDBACK LOSS

3.2.2 If You Get ERROR 14, POWER BUS

3.2.3 If Your BDS5 System is Unstable...

3.2.5 Low Speed Adjustment

3.2.4 Jogging the Motor

3.3 SYSTEM COMPENSATION

3.3.1 Critical Damping

3.3.2 Underdamping

3.3.3 Overdamping

3.4 TUNING

3.3.4 Ringing