Kollmorgen BDS5 Installation And Setup Manual
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
I
NSTALLATION AND SETUP MANUAL
Old Number M93101 - I
New Number MB5000H
SSUE 4
BDS5 T
ECHNICAL MANUAL CONFIGURATION
T
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
C
ONFIGURATION TABLE
C
NSTALLATION AND SETUP MANUAL
( I
BDS5
M93101 )
RECORD
ISSUE NO.
(Revision) DATE CHANGED PAGES/BRIEF DESCRIPTION OF CHANGE CHANGE NO.
3
4
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
- -
T
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:
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INDUSTRIAL DRIVES -
Technical Manual Department
201 Rock Road
Radford, VA 24141
U.S.A.
FAX: 703/731/0847
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Copyright 1993, Industrial Drives, A Kollmorgen Division. All rights reserved.
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
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
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
text defines words
OW TO USE THIS MANUAL
H
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
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
i
ABLE OF CONTENTS
T
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
ii
BDS5 L
IST OF FIGURES
L
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
L
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
L
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
C
YSTEM DESCRIPTION
S
1
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
C
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
C
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
A
V
B
1
2
C
03
06
10
20
30
40
55
D
0
E
0
1
F
0
1
2
9
G
0
1
H
0
I
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
C
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
A
V
B
1
2
C
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
D
E
E
1-6
00
00
01
02
03
00
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
A
01
02
03
20
21
22
23
B
00
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
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YSTEM DESCRIPTION
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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
130 VDC
225 VDC
130 VDC
225 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 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
225 VDC
360 VDC
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
C
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
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