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User Manual BL3416E2-A04-AC120

1. BL3416E2 A04 AC120 Plug n Play Servo System te dam with analog drive brushless motor and cables 5 com Continuous 16 Ib in 4500 rpm Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go www servo2go com ipeo Sold amp Serviced By Thank you for purchasing this QuickStart package QuickStart makes it easy to set up Advanced Motion Controls drives to get your system running quickly The drive and motor have been matched with each other the cables are custom made for this system and an interface board simplifies integration with your controller Remember if you need us we are here for you Our goal is to get you up and running as quickly as possible If at any point you have a question a team of applications engineers and our customer service staff are just a phone call away We are available weekdays from 8am to 5pm Pacific Time at 805 389 1935 We can also be contacted via email through our website www a m c com go to Contact Us 4 steps to success Getting Started 5 Minute I ntegrate Going into What s included with QuickStart QuickStart into Production QuickStart and what Lets spin the motor your System Transitioning from to expect Get your machine prototype to working production This manual has been laid out in four sections to guide you through the process of setting up and integrating your QuickStart system By following each step
2. 46 9 SPEED RATED VOLTAGE 4500 RATED VOLTAGE CONTINUOUS CURRENT VOLTAGE CONSTANT V KRPM RESISTANCE 0 204 PEAK CURRENT NERTIA kg cm Ib in s 2 034 0 0018 in in TORQUE CONSTANT Nm A Ib in A 0 159 1 40 H in s WEIGHT Kg Ib 3 54 7 8 NDUCTNACE 9 MOTOR CONNECTIONS MOTOR CONNECTOR SENSOR CONNECTOR MOLEX P N 43025 0600 AMP PIN 1 480702 0 CONTACTS AMP PIN CONTACTS MOLEX P N 350550 1 OR EQUIV 43030 0002 OR EQUIV AMP CONNECTOR P N 103650 7 OR EQUIVALENT 18 d 18 ENCODER LEADS VOABLE 16 ANG MIN 28 AWG 18 LONG SHIELDED CABLE 218 THRU 4 EQ 4 p AgSESBC a Vy SENSOR CONNECTIONS PIN COLOR FUNCTION 1 RED E 2 BLACK GROUND 4 ORANGE HALLB 5 YELLOW HALL C 6 BARE SHIELD 4 ENCODER CONNECTIONS REO voc BLACK COMMON GREEN OUTPUTB LORAIN WIRE CABLE SHIELD 0 4 Di 0751 010 IMENSION L 3 55 L 06 1251 03 Quick Start Motor ENCODER ELECTRICAL SPECIFICATIONS INPUT VOLTAGE INPUT CURRENT REQUIREMENTS INPUT RIPPLE OUTPUT CIRCUITS FREQUENCY RESPONSE INCREMENTAL OUTPUT FORMAT SYMMETRY MINIMUM EDGE SEPARATION COMMUTATION FORMAT COMMUTATION ACCURACY ENVIRONMENTAL SPECIFICATIONS STORAGE TEMPERATURE OPERATING TEMPERATURE HUMIDITY VIBRATION SHOCK MECHANICAL SPECIFICATIONS LINE COUNT 2500
3. Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 A ADVANCED MOTION CONTROLS 3805 Calle Tecate Camarillo CA 93012 Tel 805 389 1935 Fax 805 389 1165 BX25A20AC Series DESCRIPTION The BX25A20AC Series PWM servo amplifiers are designed to drive brushless DC motors at a high switching frequency The BX25A20AC is fully protected against over voltage over current over heating and short circuits This model interfaces with digital controllers or can be used as a stand alone drive and requires only a single unregulated AC power supply A single red green LED and a single digital output indicate operating status Loop gain current limit input gain and offset can be adjusted using 14 turn potentiometers The offset adjusting potentiometer can also be used as an on board input signal for testing purposes when SW1 DIP switch is ON SPECIFICATIONS All BX25A20AC specifications are identical to the BX25A20 specifications see BX30A series data sheets except for POWER STAGE SPECIFICATIONS BXSAMAC SINGLE PHASE AC SUPPLY VOLTAGE SHUNT SWITCH ON VOLTAGE SHUNT FUSE d 25 inches L 1 25 inches MECHANICAL SPECIFICATIONS POWER CONNECTOR Quick Disconnect 7 35 x 4 23 x 2 45 inches SIZE 186 7 x 107 4 x 62 2 mm WEIGHT If the shunt regulator is disabled the shut down voltage is 205 VDC These amplifiers contain a rectifier bridge and filter capacitors to generate the DC bus internally from the AC input power The
4. By ck Y 3b Configuration I ntegrate QuickStart into your System Configuration BX25A20AC Capabilities Mode Category Mode Name Torque Current Velocity Estimation Open Loop Encoder Velocity Hall Velocity Open Loop Mode does not use direct feedback to close the velocity loop therefore it can t be considered a true velocity mode Open Loop Mode produces velocity that is roughly proportional to the input command but is not as precise as using a Tachometer or Encoder Hall Velocity mode is not recommended with this system since Encoder Velocity mode is available with superior velocity control Velocity The correct mode is determined by the requirements of the controller Some controllers require that the drive be in torque mode Other controllers require that the drive be in velocity mode Check the documentation on your controller or contact the manufacturer of your controller to determine the correct mode for your drive Advanced Motion Controls Analog Servo Drives are configured using Switches and Potentiometers There is no software to download or configure The basic setup of these servo drives is straight forward and user friendly These instructions will walk you through the steps necessary to configure your drive to your system Configure the drive mode e Torque Mode page 14 e Velocity Mode page 16 o Encoder Velocity o Hall Velocity o Open Loop amy SERVOETEO com Toll
5. DC bus voltage is 1 4 times AC voltage RMS e g 170 VDC from 120 VAC During braking much of the stored mechanical energy is fed back into the power supply and charges the output capacitor to a higher voltage If the charge reaches the amplifier s over voltage shutdown point output current and braking will cease To ensure smooth braking of large inertial loads a built in shunt regulator is provided in this model The shunt regulator will switch on the internal power resistor when the bus voltage exceeds 195 VDC This resistor then dissipates the extra energy of the DC bus ORDERING INFORMATION Model BX25A20ACX Son eX atthe indicates the current revision letter SERVOP4GO com TYRICAL SYSTEM WIRING See section Toll Free Fax 877 378 0249 sales servo2go com MOUNTING DIMENSIONS See page F 11 BX30A SERIES BRUSHLESS SERVO AMPLIFIERS Model BX25A20 FEATURES e Surface mount technology e Small size low cost ease of use e DIP switch selectable modes current open loop tachometer Hall velocity and encoder velocity e Latching Non Latching fault active hi active low fault and inhibit enable are dip switch selectable e Four quadrant regenerative operation e Hall sensor commutation e Agency Approvals C BLOCK DIAGRAM 4 www a m c com MADE IN U S A BRUSHLESS PWM SERVO AMPLIFIER P1 CAUTION MOH VOLTAGE 4 oor aan 1 1 DVANCED MOTION CON TEST OPPS
6. Free Fax 877 378 0249 sales servo2go com www servo2go com BX30A Series PIN FUNCTIONS connector rm wwe eesmeowwoes Ds mmm 9 wesma y o REF IN 5 REF IN TACH IN Tachometer input max 60 VDC 60K input resistance VELOCITY MONITOR Velocity monitor 1 V 25 kHz encoder frequency OUT A Differential reference input Maximum 15 V 40K input resistance 1V 125 Hz Hall sensor frequency CURRENT MONITOR Proportional to motor current OUT 1 V 2 A when SW1 3 if off 1 V 4 when SW1 3 is on This TTL level input signal turns off all power devices of the H bridge when pulled to ground with SW2 3 ON If SW2 3 OFF pulling this INHIBIT IN pin to ground will enable the amplifier Inhibit will cause a fault condition and a red led if SW2 4 is on For customer use power for HALL sensors 5V 200 mA Note the 5V 200 mA total current on P1 10 and P3 1 combined should not exceed 200 mA SIGNAL GND Reference ground for the Hall sensors SGND HALL A HALLB HALL sensor inputs logic levels Internal 5 pull up Maximum low level input is 1 5 V minimum high level input is 3 5 V HALL C Monitors the input signal connected directly to the internal current CURRENT REFERENCE amplifier 7 25 V max peak current See current limit adjustment OUT information below 10 11 12 13 14 Transistor output Open collector Contact factory for higher pull up voltages This outp
7. Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Sold amp Serviced By m 3b Configuration Torque Mode Integrate QuickStart into your System Torque Mode Configuration The terms Torque Mode and Current Mode are synonymous They can be interchanged and you may see either of these terms throughout this document and other motion control documents The Switches and Potentiometers set the mode on the drive Use the Mode Selection Table for the correct configuration Mode Selection Table Torque Mode PotentiometersPot2 Current Limit Full CW Mid 7 turns Current Limit with these settings 12 5A continuous 25A peak Potentiometer Instructions CW is the clockwise direction CCW is the counterclockwise direction Full CW or Full CCW means the pot has been turned to the end of its travel where it begins to click on every turn These potentiometers have a 14 turn range before they start to click The number of potentiometer turns on the Mode Selection Table is referenced from the full counterclockwise position To maintain consistency in the number of turns the initial starting point is defined as follows 1 Turn the pot CCW until the pot begins to click on every turn 2 Continue to slowly turn the pot CCW until the next click is heard then stop 3 Now turn the pot in the CW direction the number of turns indicated in the Mode Selection Table SERVOET
8. Specifications B Drive C Motor D Cables E System Interface Board Sold amp Serviced By amy SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Z Sold amp Serviced By Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com System Specifications System Specifications Torque peak 35 16 3 975 Nm Torque continuous 15 63 16 1 77 Nm Velocity Maximum 4500 rpm Supply Voltage 120VAC Encoder Resolution 10000 counts rev Speed Torque Curve BL3416E2 A04 AC120 Torque Ib in 1000 2000 3000 4000 Speed rpm Sold amp Serviced By Py SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Sold amp Serviced By Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com BX25A20AC Series BX25A20AC SERIES BRUSHLESS SERVO AMPLIFIERS Model BX25A20AC 120VAC Single Supply Operation FEATURES Surface mount technology Small size low cost ease of use Built in shunt regulator DIP switch jumper selectable modes BRUSHLESS om current open loop tachometer HALL velocity and encoder velocity e Latching Non Latching fault active hi active low fault and inhibit enable are dip switch selectable e Four quadrant regenerative
9. cost of an encoder is prohibitive and the operating velocity is above 1000 rpm Open Loop This mode does not use any feedback to determine velocity Velocity is estimated by the duty cycle of the PWM Open Loop mode is the least accurate of these velocity modes The Switches and Potentiometers set the mode on the drive Use the Mode Selection Table for the correct configuration Continued amy SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com m 3b Configuration Velocity Mode Integrate QuickStart into your System The Switches and Potentiometers set the mode on the drive Use the Mode Selection Table for the correct configuration Mode Selection Table Velocity Mode swi 4 of otf On Switch Bank 1 Potentiometers 2 Current Limit Fullcw Full cw Full cw Current Limit with these settings 12 5A continuous 25A peak Potentiometer Instructions CW is the clockwise direction CCW is the counterclockwise direction Full CW or Full CCW means the pot has been turned to the end of its travel where it begins to click on every turn These potentiometers have a 14 turn range before they start to click The number of potentiometer turns on the Mode Selection Table is referenced from the full counterclockwise position To maintain consistency in the number of turns the initial starting point is defined as follows 1 Turn the pot C
10. lines revolution MAXIMUM SHAFT SPEED 8000 RPM THROUGH SHAFT DIAMETER 0 250 0 0000 0 0005 RADIAL SHAFT MOVEMENT 0 007 TIR AXIAL SHAFT MOVEMENT 0 030 MAX HOUSING Carbon Fiber Composite case ground via cable TERMINATION 15 conductor cable 28 AWG 18 long MOUNTING 1 812 Bolt Circle MOMENT OF INERTIAL 1 5 x 10 oz in s ACCELERATION 1 x 10 Radians s ACCURACY 1 0 Arc Minutes Mechanical Outline CW ROTATION FOR OUTPUT WAVEFORMS Sold 8 Servictd By OUTPUT amp 90 ELECTRICAL OUTPUT ouTPuT U CLOCKWISE SHAFT ROTATION Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 2 0 WWW Servo2go com100 ODER CABLE 928 A FOIL SHIELD 18 Quick Start Cable CBL D02 DRIVE CABLE WIRING SPECIFICATIONS CABLE CBL D02 aa 22 Wiring Scheme Wire Color Single Wire REF OUT yellow Single Wire SGND yellow black Single Wire REF OUT blue Single Wire TACH IN blue white Single Wire Velocity Monitor black A Single Wire Current Monitor black white 16 Pin Molex Single Wire Inhibit orange Connector Single Wire Hall A orange white C P N 22 01 3167 Single Wire Hall B red 26 Pin AMP D SUB Terminals Single Wire Hall C red white Plug P N 08 50 0114 Single Wire Current Ref brown P N 748365 1 Single Wire Fault brown white Housing REF IN P N 748677 2 green Terminals REF IN green white P N 748333 4 5V purple SGND purple white B Sing
11. 0 is the feedback cable Connect the black connectors and shield drain wire on this cable to the corresponding connectors on the motor Connect the 15pin D sub to the C1 connector on the System Interface Board SIB Motor Connect the white connector on the motor power cable CBL P02 10 to the corresponding connector on the motor Connect the green connector to the P2 connector on the drive Red Motor A P2 1 White Motor B P2 2 Black Motor C P2 3 CBL AC IEC supplies AC to the drive Do not apply power at this time An AC power strip or other switch can be used to make cycling power more convenient during testing Grounding Bring all ground wires to a central point ground such as a ground bus ground plane or a single ground bolt Also don t forget to ground the drive chassis Use the silver screw marked PE on the case Motor Ground The green wire coming from motor power cable is the motor chassis ground If the motor case is already grounded through direct contact with the machine housing then leave the green wire disconnected Grounding the motor at both the green wire and at the motor case causes a ground loop that has been shown to disrupt the feedback signals Choose one or the other 0 SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com 2 m 5 Minute QuickStart Inhibit Switch optional for this section An inhibit switch not included can
12. 0V 3mA d 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Ref In E Ref In Tach In Mel Mon Out Curr Mon Out Inhibit 5V SGND Hall 1 Hall 2 Hall 3 Curr Ref Fault Out m gt Hd Hd e m N m w N ji A Hd ul So wo co at a ar Hd m Hd E E z 2 o 7 c 3 p o n amp User Access Hd ISGND Encoder 5V Encoder Encoder Channel A Encoder Channel A Encoder Channel B Encoder Channel B ncoder Channel SER coder Channel l Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com N N H N N N 167 N Sold amp Serviced By N Un
13. ACH IM 50 Loge 1 3RIE pei Sk Sk Sok 50k 10k HALL 1 1 100 8 Shi S22 ii INTERNAL Lg d VELOCITY VELOCITY Pi 2 SIGNAL GND m FEEDBACK SENSE 1 10k U conv Ha 3 104 amp COMUERTER d A m Lees al 5 1 10 10k 7 CURRENT ENCODER 50 E 20008 SHE 1 SENSE GEE VELOCITY SW2 3 SWe 4 SWe 6 P3 5 SIGNAL GND E EA conv ik aj aj e af a 4 AND lt GROUNDS ARE NOT CONNECTED m 2 9 al d SEE TABLES BELOW CURRENT 2l a MONITOR a al E a Ll M 5 a 4 4 o ti n MODE SELECTION l j1 2 5 1 eui s sui amp sue i swe e ENC HALL TACH CURRENT MODE E ON OFF arp rc conn IMHIBIT LEUEL SELECT FAULT INHIBIT RELATION FAULT LEVEL FAULT CONDITION ENCODER UELDCITY on OFF ON OFF conn conn nc z E ER sue 3 Punu P1 9 to GND to Swe 4 INHIBIT FAULT SWe s our 1 16 SWe e LATCH LOOP Dh TON ar 1 r WE OFF ENABLE OFF HD OFF ACTIVE Lo DFF YES TACHOMETER MODE on OFF OFF OFF re ON INHIBIT ON YES ON ACTIVE Hi ON Ha CONNECTED COMN CONNECTED FAULT LATCH 1 LED GREEN NORMAL OPERATION LED RED FAULT KOT ER UNDER VOLTAGE SHORT CIRCUIT WER TEMPERATURE Sold amp
14. CW until the pot begins to click on every turn 2 Continue to slowly turn the pot CCW until the next click is heard then stop 3 Now turn the pot in the CW direction the number of turns indicated in the Mode Selection Table Continued Sold amp Serviced By amy SERVO Ocom Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Y 3b Configuration Velocity Mode I ntegrate QuickStart into your System Loop Gain Pot 1 In Velocity Mode the loop gain increases the responsiveness of the system The loop gain settings in the mode selection table are a good starting point However once the drive is in the system the loop gain will need to be adjusted to match the system dynamics To adjust the Loop Gain e Turn the Loop Gain pot to the full counterclockwise position e Enable the drive e Turn the Loop Gain pot clockwise e When the system begins to make a loud buzzing noise turn the pot in the counterclockwise direction until the buzzing stops e Turn the pot one more turn in the counter clockwise position Reference Gain Pot 3 The gain of the drive velocity out volts in can be adjusted using the Reference Gain Potentiometer Pot 3 Turning the pot clockwise increases the gain while turning the pot counter clockwise decreases the gain Sold amp Serviced By amy SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www s
15. DBACK SENSE X 1 0 1 I FAI conv 1 3 10U 8 3A COMJERTER X Sab sui 3 P1 10 L d 10k F ENCODER CURRENT 5U 8 200mA SENSE Pond x VELOCITY P3 5 SIGNAL GMD 5 E e He EN ELE 10k B a aj a4 rug or a aa xb enn XL GROUNDS CONNECTED i o 2 2 a z SEE TABLES BELOW CURRENT 5 z i MONITOR T EE EE m E m E EA ie X T p s o i i o MODE SELECTION swi 2 sm 4 5 1 5 sui e ewe i sue e ENC HALL TACH CURRENT MODE on on OFF OFF gt ne INHIBIT LEWEL SELECT FAULT INHIBIT RELATION FAULT LEVEL FAULT CONDITION ENCODER VELOCITY OM OFF OFF y on OFF J CONN CONN Ne Pull P1 9 to GND SWi2 4 INHIBIT FAULT 5 lt Pi ie gt LATCH HALL VELOCITY on arr oF ow ore cM nc comm MC OPEN LOOP MODE om nre cr nme OFF ENABLE OFF NG OFF ACTIVE Lo OFF YES TACHOMETER MODE on OFF OFF OFF n corn DH ON YES OH ACTIVE Hi oN Ho NC NOT CONNECTED COMN CONMECTED FAULT LATCH 1 Sold amp Servided LED GREEN NORMAL OPERATION LED RED FAULT T DPER MDETRDE RECI ED SETTING FOR CURRENT MODE FULLY CCW POTS FULLY CH UNGER RE SHIPPED IM CURRENT MODE WITH MAXIMUM CURRENT SETTINGS 3 SHORT CIRCUIT SEI FUNCTIONS SEE SWITCH DESCRIPTION 4 OUER TEMPERATURE x 0 AL USER INSTALLED THROUGH HOLE COMPONENTS
16. EO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com m 3b Configuration Torque Mode Integrate QuickStart into your System Gain Setting The gain of the drive amps out volts in can be adjusted using the Reference Gain Potentiometer Pot 3 Turning the pot to the full clockwise position results in a gain of roughly 2 5A V Turning the pot counter clockwise reduces the gain down to a minimum of zero Sold amp Serviced By Ey SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Sold amp Serviced By Z 3b Configuration Velocity Mode I ntegrate QuickStart into your System Velocity Mode Configuration Velocity mode outputs a velocity that is proportional to a given input command The gain can be expressed as output velocity input command Common units could be rpm V and counts per second V The three velocity modes available in this system offer varying degrees of performance Starting with the highest performance they are listed below Encoder Velocity Uses the encoder as the velocity feedback This mode is very accurate over the widest range of speeds Hall Velocity This mode uses the Hall sensors for velocity feedback This mode is not accurate at slow velocities but as the speed increases beyond 1000 rpm this mode becomes more usable This mode is popular in systems where the
17. ET swoim 1 TOMALOND 1 weimar 2 T m WLMONTORQUE CURA wOMTOR GUT BX30A Series BROKEN LINE REPRESENTS RECOMMENDED SETTING FOR CURRENT MODE FULLY CCH POTS FULLY AMPLIFIERS ARE SHIPPED IM CURRENT MODE WITH MAXIMUM CURRENT SETTINGS FOR OTHER SHITCH FUNCTIONS SEE SWITCH DESCRIPTION OPTIONAL USER INSTALLED THROUGH HOLE COMPONENTS B 3 4 1 9 1 16 FUNCTIONAL BLOCK DIAGRAM 1 15 1814U OPTICAL ISOLATION T 5U TRA 5U FAULT HM SHIT CURRENT REFERENCE wd J5 ik OFFSET 5006 ch OUTPUT Sue 5 TEST gl POTH jk ifik Pi 11 SIGNAL GND T MMBT2222 SW1 1 Sk B DNI SMES HIGH VOLTAGE P2 5 601 10 501 7 10k J 1 POWER GND P2 4 4REF IN 500k PEAK P 20k Sk CONT ora I gt REF IN GAIN CURRENT JS4 10k 607120 VEL 1 5 REF IM D gt nari E LIMIT MEN zl MOTOR C 2 3 CURRENT cot Em 20k CUTS DUTY CYCLE 153 NOTOR pena a NN 1 NDR 10k 801 5 CONTROL Pi 6 T
18. GRAM Connector C 4 Single Wires Twisted Pairs Connector A Twisted Pairs Connector B Shield Sold amp Serviced By SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Sold amp Serviced By Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Quick Start Cable CBL P02 10 POWER CABLE WIRING SPECIFICATIONS CABLE CBL P02 10 Pp Sidet Jj Common 0 Wiring Scheme Function Wire Color A 4 Pin AMP Single Wire Motor A Connector Terminals Single Wire Motor B P N 1 480703 0 Single Wire Motor C P N 350873 1 Shield B 3 Port Phoenix Connector P N 1757022 DIAGRAM Connector A Connector B ccce Single Wires Single Wires Sold amp Serviced By SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Sold amp Serviced By Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com System I nterface Board SI B 1 2 3 4 5 6 7 8 9 10111213 14 15 16 17 18 19 20 21 22 23 24 25 26 Dimensions 72mm x 72mm C1 Connector 15 pin to motor C2 Connector 26 pin to drive C3 Connector 26 pin user interface C3 Pin Functions Pin Function 1 3mA C1 15 Pin Dsub SGND 1 Shell NI HD Female 1
19. Serviced By 44 AD TABS Cale Tecate Camarillo CA 93012 CED MOTION CONTROLS sales servo2go com www servo2go com Tel 805 389 1935 Fax 805 389 1165 BX30A Series DESCRIPTION The BX30A Series PWM servo amplifiers are designed to drive brushless DC motors at a high switching frequency They are fully protected against over voltage over current over heating and short circuits All models interface with digital controllers or can be used as stand alone drives They require only a single unregulated DC power supply A single red green LED indicates operating status Loop gain current limit input gain and offset can be adjusted using 14 turn potentiometers The offset adjusting potentiometer can also be used as an on board input signal for testing purposes when SW1 DIP switch is ON These models can use quadrature encoder inputs or Hall sensors for velocity control SPECIFICATIONS POWER STAGE SPECIFICATIONS PEAK CURRENT 2 sec Max internally limited MAX CONTINUOUS CURRENT internally limited MINIMUM LOAD INDUCTANCE HEATSINK BASE TEMPERATURE RANGE POWER DISSIPATION AT CONTINUOUS CURRENT OVER VOLTAGE SHUT DOWN self reset BANDWIDTH load dependent 2 5 kHz MECHANICAL SPECIFICATIONS 7 35 x 4 40 x 1 45 inches SIZE 186 7 x 111 7 x 36 8 mm WEIGHT Low inductance motors require external inductors Sold amp Serviced By SERVOETEO com Toll Free Phone 877 378 0240 Toll
20. The current limit adjustment Pot 2 adjusts both peak and continuous current limit simultaneously It has 12 active turns plus 1 inactive turn at each end and is approximately linear Thus to adjust the current limit turn the potentiometer fully counter clockwise then turn clockwise to the appropriate value In many applications it is sufficient to use only the DIP switches for current limit adjustments SW3 reduces both peak and continuous current limit by 50 when OFF SW8 reduces only the continuous current limit by 50 when OFF CONTINUOUS PEAK CURRENT LIMIT RATIO 25 Sold amp Serviced By SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com BX30A Series P1 15 is the input to the internal current amplifier power stage Since the output current is proportional to P1 15 the adjusted current limit can easily be observed at this pin without connecting the motor Note that a command signal must be applied to the reference inputs to obtain a reading on P1 15 The maximum peak current value equals 7 25 V at this pin and the maximum continuous current value equals 3 63 V at this pin If SW3 ON peak rated amplifier current 7 25 V If SW3 OFF 7 peak rated amplifier current 7 25 V Example using the BX25A20 with SW3 ON 25A 7 25V and with SW3 OFF 12 5A 7 25V The actual current can be monitored at pin P1 8 VELOCITY DIRECTION SWITCH SW1 7 In either Hall or En
21. Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com ck W 3a Wiring I ntegrate QuickStart into your System Feedback The feedback on the motor is an incremental encoder with two Channels A and B and an Index I The signals are differential but are compatible with single ended circuitry simply leave the complimentary signals open A B and I The resolution is 10000 counts per revolution quadrature Power Requirements Encoder power is supplied by the drive 5VDC 125mA The screw terminals on the System Interface Board SIB provide easy access to the encoder signals Encoder Connection Signal SIB SGND C3 19 5VDC C3 20 Channel A C3 21 Channel A C3 22 Channel B C3 23 Channel B C3 24 Channel 1 C3 25 Channel l C3 26 Drive Mounting Mounting Dimensions can be found in the drive datasheet in the Appendix The drive can be mounted flat against the base plate or along the spine Mounting the drive flat on the base plate against a large thermally conductive surface for cooling will provide the most natural heat dissipation for the drive A metal back plane in a cabinet on the machine often makes a good surface Drives mounted on the spine can be mounted next to each other Maintain a minimum separation of 1 inch between drives to provide adequate convection cooling Note Additional cooling may be necessary t
22. be connected between pins 9 and 11 on the Interface Board This switch disables power to the motor until you are ready Opening the switch Enables the drive closing the switch Disables the drive Cautions Unexpected motion To avoid the motor from jumping unexpectedly and causing damage the motor should be secured either with clamps or bolted down using its mounting holes Sold amp Serviced By Ey SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com 2 m 5 Minute QuickStart User Power BL3416E2 A04 AC120 120VAC Cables and Connections BX25A20AC USER SUPPLIED CONTROLLER LE o PC Based Controller Stand Alone Controller USER INTERFACE A CBL D02 Pd Do not ground both this wire and the motor case Grounding both will cause a ground loop Choose one or the other NS CBL P02 10 XS AS IS UE mA ES MESA nn Ek System Interface Board Kom SIB N CBL F01 10 Caution The motor will move on initial power up See the manual to remove offset Ground Bring all ground connections to a central point or common plane that has solid contact with Earth ground Note Actual cables are longer than they appear in these images MBL3416E2 Sold amp Serviced By 0 J 880 ADVANCED Toll Free Phone 877 378 0240 MOTION CONTROLS Toll Free Fax 877 378 0249 sales se
23. coder Velocity Mode the velocity feedback direction switch SW1 7 allows the user to select the correct feedback polarity for proper operation In one switch position the motor will operate properly but the opposite switch position will cause the motor to run away due to positive feedback The correct switch position will not be the same for all applications It may be either ON or OFF depending on wiring combination NOTE If any of the BX25A20AC or BX30A series servo amplifiers are being used as a direct replacement for your B25A20AC BE25A20AC B30A or BE30A series in Hall or Encoder Velocity Mode SW1 7 MUST be set in the OPPOSITE position for proper operation Otherwise the motor will run away ORDERING INFORMATION Model BX25A20X X at the end indicates the current revision letter TYPICAL SYSTEM WIRING See section G MOUNTING DIMENSIONS See page F 35 Sold amp Serviced By amy SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Quick Start Motor MBL3416E2 BRUSHLESS SERVO MOTOR FEATURES 3 25 Inch NEMA 34 w Heavy Duty Shaft Continuous Torques up to 15 63 Ib in Speeds up to 4500 rpm Voltage Rating up to 170 Vdc Integrated Hall Effect Commutation 30 Lb Radial Load Capacity 1 2 from Front Face High Precision Optical Encoders 10000 count SPECIFICATIONS SPECIFICATIONS CONTINUOUS TORQUE Nm Ib in 1 77 15 63 PEAK TORQUE 3
24. e motor feedback wires even if they are shielded Although both of these cables originate at the amplifier and terminate at the motor try to find separate paths that maintain distance between the two A rule of thumb for the minimum distance between these wires is 1cm for every 1m of cable length Grounding Bring all ground wires to a central point ground such as a ground bus ground plane or a single ground bolt Also don t forget to ground the drive chassis Use the silver screw marked PE on the case Motor Ground The green wire coming from motor power cable is the motor chassis ground If the motor case is already grounded through direct contact with the machine housing then leave the green wire disconnected Grounding the motor at both the green wire and at the motor case causes a ground loop that has been shown to disrupt the feedback signals Choose one or the other Load Coupling A non rigid coupling must be used between the motor shaft and the load to minimize mechanical stress due to radial loads axial loads or misalignment If you feel that the radial load on the motor is excessive you may want to consider connecting the motor to an idler shaft that is supported by pillow block bearings or similar Then the load can be coupled to the idler shaft without risking damage to the motor bearings am SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Sold amp Serviced
25. e to turn the motor shaft at 30 20 rpm This is an indication that when put together it works out of the box No pots to tweak or software to configure Are the motors in the QuickStart program available for individual resale Quite simply not from Advanced Motion Controls The motors in these packages are meant to represent what is commonly available from many different manufacturers Your local Advanced Motion Controls representative can handle requests for motor model information for additional purchases How is QuickStart pricing important to me Careful selection of systems incorporate popular Advanced Motion Control s drives in order to maximize exposure and minimize costs What other considerations should you know about QuickStart Although it will be hard to find easy to configure systems like these at lower prices anywhere QuickStart isn t intended for multiple pre packaged system selling Initial exposure to Advanced Motion Controls drives is the key Each project will be followed up by our Sales department to determine overall progress and assist in determining the next step SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com 1 Getting Started Package Contents ckS oy d Li Brushless Servo Drive BX25A20AC Brushless NEMA 34 Motor w encoder MBL3416E2 Screw Terminal Board System Interface Board SIB Feedback Com
26. ervo2go com Sold amp Serviced By 4 m Going into Production Prototype to Production Once you have completed your proof of concept you will be ready to design for production If you decide that the QuickStart drive and motor are perfect for you then you re in luck Both are popular off the shelf items that are readily available Drives can be ordered directly from us and we can put you in touch with the appropriate motor supplier If your servo system requires a drive that better fits your application such as e Additional features e Different power range e Smaller size e Different form factor such as plug in style drives e Network connectivity Then our applications engineers can help optimize your system by selecting the best drive for your needs You will also be in contact with a local representative to help you with the selection of motors and other system components such as cables gear boxes slides bearings and more Feedback Your feedback is important to us Your comments can make QuickStart better and help us improve our processes technical support customer support and product offering Please go to www a m c com feedback html Ey SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Sold amp Serviced By Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com 5 Appendix Appendix A System
27. hat power has been applied to the drive Motor doesn t have holding torque Verify that the LED is Green Verify all cables are connected LED doesn t turn Green If an Inhibit Switch has been installed toggle the Inhibit switch Motor doesn t turn but has holding Turn Pot 4 Test Offset in either direction This will torque change the amount of offset in the drive Contact Factory f you can t get the motor turning within a few minutes please call and ask for technical support 805 389 1935 We want to get you up and running quickly Sold amp Serviced By SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com vickStan 3a Wiring oU N I ntegrate QuickStart into your System The following instructions are a continuation of the 5 Minute QuickStart This section explains controller wiring drive configuration drive mounting motor mounting SIB mounting and load coupling Signal Ground Almost all signals between the drive and the controller are referenced to signal ground Without this reference the drive and the controller would not be able to transmit signals to each other To ensure that the signals between the drive and the controller are referenced to the same potential the signal grounds on the controller and the drive must be connected together This is especially important for e Single ended command signals e Inhibit line e Ot
28. her inputs and outputs You will need to identify the signal ground on your controller and connect it to the signal ground on the drive For your convenience the Signal Ground is accessible at three locations on the SIB However to avoid ground loops there should only be one connection between the drive signal ground and the controller signal ground Don t add a connection if there is already continuity between the two grounds Available Signal Ground Locations on the SIB Controller SIB C3 2 SGND Signal Ground C3 11 SGND C3 19 SGND Command Signal Command signal and mode selection are dictated by the capabilities of your controller and the desired operation of your system Analog 10V command signals are suited for torque and velocity modes 10V Command Signal Single Ended Available Drive Modes SGND C3 2 SGND Torque Mode C3 4 Ref Velocity Mode Available Drive Modes C3 4 Ref Torque Mode Sold amp Serviced By 5 Velocity Mode 225 SERVOS GO com Toll Free Phone 877 378 0240 MO Friformation on Mode Selection PEermodes can be separated into three basic categories Torque Velocity and Position Tha namo nf tho manada docrrihoc wihat Inannc aro hainn clacad in tho Ariva Thaw 10V Command Signal Differential Sold amp Serviced By m 3a Wiring I ntegrate QuickStart into your System don t describe the end result of the operation For example a dri
29. in succession you will first be introduced to QuickStart then hook up the system for a simple bench test and then integrate QuickStart into your machine and finally transition into the production stage amy SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Sold amp Serviced By vickStan 1 o N Getting Started BL3416E2 A04 AC120 What to Expect What is QuickStart QuickStart is a system offering including a drive a motor all necessary cables and an interface board with screw terminal connections all in one box ready for fast delivery What purpose does QuickStart serve QuickStart is intended to introduce OEMs to Advanced Motion Controls servo drives and provide a positive first experience Why is Advanced Motion Controls offering a QuickStart package We realize that many OEMs today are faced with trying to get their machinery to market using the fastest possible methods Our solution is to provide a means by which motion control can be quickly proven How does QuickStart benefit potential customers QuickStart is designed to make system prototyping easier to include Advanced Motion Controls servo drives The attraction to OEM s is a savings of time money and the personnel needed to move from conception to production Upon receipt everything will plug in and operate within 5 minutes All systems are initially configured in velocity or voltage mod
30. le Wire Encoder A pink red 5 Pin Molex Single Wire Encoder B green black Connector 5V ray black P N 22 01 3057 Twisted Pair SGND 9 a Shield Shield NOTE For cables with only twisted pairs single wires can be paired with other single or unused wires Do NOT pair these two wires If pairing is required pair these wires with unused wires Twisted Pair Twisted Pair DIAGRAM Connector C o o c c o o Single Wires Twisted Pairs Twisted Pairs Connector B Grounding Shell Sold amp Servicdd By SERVOETEO com Free Phone 877 378 0240 l oll Free Fax 877 378 0249 sales servo2go com WWW Servo2go com Sold amp Serviced By Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Quick Start Cable CBL F01 10 FEEDBACK CABLE WIRING SPECIFICATIONS CABLE CBL F01 10 Sidet O Side2 Wiring Scheme Function Wire Color A Single Wire Hall A Brown 6 Pin Molex Single Wire Hall B Orange Connector Single Wire Hall C Yellow P N 43020 0601 5V Red Terminals SGND Black E 15 Pin AMP D SUB P N 43031 0002 Shield Shield Sheer Plug Twisted Pair rog P N 748364 1 B Housing 8 Pin Molex Twisted Pair Blue P N 748677 1 Connector m ds i P N 701 07 0007 Twisted Pair NOT Terminals P N 16 02 0077 T P SGND Black Flying Lead Shield Shield DIA
31. mutation Cable 10 foot CBL F01 10 L1 L1 L1 O Motor Power Cable 10 foot CBL P02 10 O Drive Power Cable CBL AC IEC O Drive Cable 1 5 foot CBL D02 Quick Connect Sheet O Documentation User Manual Brochure with CD ROM Additional Requirements Item Notes Requirements Power Source 120VAC 60 Hz Single Phase Acceptable Operating Range 30 125 VAC Controller 10V command signal Sold amp Serviced By amy SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Sold amp Serviced By vickStan 2 OU 5 Minute QuickStart Let s spin the motor This quick setup procedure will get the motor moving in a short amount of time without the need for a controller The drive has been pre configured in encoder velocity mode with a slight offset This will turn the motor at a slow steady speed on power up to demonstrate operation Once the system is shown to be operational the next section I ntegrating QuickStart into your System will guide you through the process of integrating the system into your application Wiring On page 7 you will find the cables and connections sheet Use this as a reference when following the steps in this section Drive Connect cable CBL D02 to the P1 and connectors on the drive Connect the other end to the C2 connector on the system interface board SIB Feedback CBL F01 1
32. nges the polarity of the velocity monitor signal Continuous current reduction Reduces continuous current Continuous peak current limit Continuous peak current limit by 5096 ratio is 50 limit ratio is 25 Integrator capacitor Adjusts the value of the integrator capacitor in velocity mode Increase Decrease 10 60 120 degree commutation phasing setting 120 degree phasing 60 degree phasing Shorts out the velocity voltage loop integrator capacitor 3 SWITCH FUNCTION DESCRIPTION Encoder Velocity feedback This connects the internally 2 11 generated velocity signal from Encoder velocity feedback Encoder velocity feedback the encoder For EVM SW6 must also be on enabled disabled Hall Velocity feedback This connects the internally 2 21 generated velocity signal from Hall sensor velocity feedback Hall sensor velocity feedback the Hall sensors For HVM SW6 must also be on enabled disabled INHIBIT ENABLE P1 9 pull to ground to INHIBIT P1 9 pull to ground to ENABLE Inhibit condition will cause a fault hibit condition will not cause INHIBIT FAULT a fault level on P1 16 or a red level on P1 16 and a red LED LED ACTIVE FAULT LEVEL OF P1 16 ACTIVE HIGH ACTIVE LOW Latching faults fault condition FAULT LATCH Non Latching faults once the fault Must e ad clears the unit will enable again y toggled to clear any fault condition T Important Note Amplifier will not operate properly with more than one switch ON due t
33. o dissipate the heat generated by the drive depending on ambient temperatures duty cycle and natural ventilation Motor Mounting Mounting Dimensions can be found in the motor datasheet in the Appendix The mounting surface must be stiff enough so it does not deflect when radial loads are applied to the motor shaft The mounting surface should also have good thermal SER ictivity especially if peak performance is demanded of the motor Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com Sold amp Serviced By ck W 3a Wiring I ntegrate QuickStart into your System SIB Mounting Mounting Dimensions can be found in the SIB datasheet in the Appendix The SIB can be mounted using the mounting holes or a DIN tray such as from Phoenix Contact If using the mounting holes standoffs must be used to keep the bottom of the SIB from shorting with the mounting surface Cable Routing Cable Datasheets can be found in the Appendix QuickStart cables come with excellent shielding and make proper grounding easy This makes proper cable routing less critical however proper routing practices should still be followed Route cables to minimize length and minimize exposure to noise sources The motor power wires are a major source of noise and the motor feedback wires are susceptible to receiving noise This is why it is never a good practice to route the motor power wires close to th
34. o multiple feedback signals See block diagram Sold amp Serviced By amy SERVOETEO com Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com 2 3 2 4 2 5 6 2 BX30A Series POTENTIOMETER FUNCTIONS POTENTIOMETER DESCRIPTION TURNING CW Pot 1 Loop gain adjustment in open loop amp velocity modes Turn this Increases loop gain pot fully ccw in current mode Current limit It adjusts both continuous and peak current limit Pot 2 RM h Increases current limit maintaining selected ratio 50 Reference gain It adjusts the ratio between input signal and Increases reference Pot 3 output variables voltage current velocity input gain Test Offset Used to adjust any imbalance in the input signal or in the amplifier When SW1 DIP switch is ON the sensitivity of Pot 4 N A this pot is greatly increased thus it can be used as an on board signal source for testing purposes See section G TEST POINTS FOR POTENTIOMETERS See section G OPERATING MODE SELECTION These modes can be selected by the DIP switches according to the chart in the functional block diagram Current mode Open loop mode Tachometer mode Encoder velocity mode Hall Velocity mode See section G for more information SET UP See section G for engineering and installation notes CURRENT LIMIT ADJUSTMENTS These amplifiers feature separate peak and continuous current limit adjustments
35. operation e Agency approvals Ns BLOCK DIAGRAM FROKEN LINE REPRESENTS 1 Pi 1 16 FUNCTIONSL BLOCK DIAGRAM P1 15 184HU OPTICAL ISOLATION 1 T 50 INA 5U FAULT 340 SLT CURRENT REF ERENCE IST 30 125VAC 10k J8 10k OFFSET 500k CH Seu PUTA 1 REGULATOR 5 5 TEST noi z ai aa POTH l ot S 1 11 SIGNAL GND rt NMB TEBE SHI 1 a CHS 34 i 5 8 SHEY 71 SH1 10 SHI Pi 4 REF IM Sook 4 PERK HUIM GND 20k go bk CONT l pe 5 Peg E REF IM GAIN 6 CURRENT CH tok 607120 VEL 1 5 REF IN cH pu cii LIMIT XM MA A E ur MOTOR P2 3 J L CURRENT E LIMIT T Sa REL Vo DUTY CYCLE J 53 1 s PHasp MOTOR wy contro bd 10k SHL 5 Hi DRIUE 1 6 TACH Th 50 LOGIC sk 25k 36 1 MOTOR A Pe 1 50k 10k HALL i ek e et a SMi amp sh2 2 PI 10 8 STERNAL Ua d VELOCITY VELOCITY us E m Fi a SIGNAL GND FEE
36. rvo2go com www servo2go com vickStan 2 5 Minute QuickStart I nhibit Line Test optional Follow this step only if you installed the inhibit switch described in the wiring section on page 6 This is to verify that the optional inhibit switch is functioning and the drive is initially powered up in a disabled state 1 Disconnect the motor power by unplugging the white connector on CBL P02 10 Unplugging this connection allows you to power up the system without the possibility of spinning the motor 2 Apply power to the drive Toggle the inhibit switch and verify that you can cause the LED color to change from Red to Green Set the switch so the LED is Red 3 Remove power from the drive and reconnect the white connector on CBL P02 10 mm Power Up Apply power to the drive If an inhibit switch has been installed enable the drive by toggling the inhibit switch so the LED turns Green 2 The motor should turn at a controlled speed 3 If the motor turns then the system has been hooked up correctly Remove power and continue to the next section If not then go to Troubleshooting 4 To stop the motor from turning turn the Test Offset switch SW1 1 to the OFF position Then use the offset pot Pot 4 to set the speed to zero The motor may continue to creep very slowly when in velocity mode True zero speed can be achieved once a controller is used to close the loop around the servo drive Troubleshooting LED not lit Verify t
37. ut can sink or source 20 mA max Active during FAULT OUT LED red output short circuit over voltage over temperature and power up reset Fault condition indicated by red LED Inhibit condition will indicate a fault if SW2 4 is on Active high or low fault selected by SW2 5 Latching faults non latching faults selectable with SW2 6 PGND For customer use power for the encoder 5V 200 mA Note the 200 total current on 1 10 and P3 1 combined should not exceed 200 mA EUN P3 ENC A 5V CMOS level quadrature encoder input ENCODER ENC B 5V CMOS level quadrature encoder input Se SRM SIGNAL GND Reference gnd for encoder SGND Toll Free Phone 877 378 0240 Toll Free Fax 877 378 0249 sales servo2go com www servo2go com BX30A Series SWITCH FUNCTIONS SETTING Test Offset Sensitivity of the offset pot Used as an on Test Offset board reference signal in test mode 2 Current loop gain Decrease Increase Current scaling When OFF increases sensitivity of current sense thus reducing both peak and continuous current limit by 50 Loop integrator This capacitor normally ensures error free operation in velocity mode by reducing the error signal Velocity voltage loop output of summing amplifier to zero integrator operating Velocity feedback Connects the internally generated velocity signal SW2 1 must also be on for encoder velocity mode and SW2 2 for Hall velocity mode Velocity direction Cha
38. ve in Torque mode can still be in a positioning application if the external controller closes the position loop In fact most high performance positioning systems use a drive in torque mode with the controller closing the velocity and position loops The correct mode is determined by the requirements of the controller Some controllers require that the drive be in torque mode Other controllers require that the drive be in velocity mode Check the documentation on your controller or contact the manufacturer of your controller to determine the correct mode for your drive Once the command signal and mode have been selected connect the controller to the signals as indicated in the above tables The proper gains and command settings must also be configured This will be explained later in the configuration section Drive I nhibit recommended The inhibit line is used to turn off power to the motor while the drive is still powered on Sometimes this is necessary if power to the motor needs to be removed quickly or if the user needs to manually move the load in a freewheeling condition If your controller has an inhibit function then we highly recommend that you use it Inhibit Connection Controller SIB Inhibit C3 9 Inhibit Note The inhibit input is configured to disable the drive when pulled low active low The control logic can be inverted by setting Switch 2 3 to the off position Continued amy SERVOETEO com

User Manual BL3416E2-A04-AC120

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