Aerotech BM Series User manual

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Dedicated to the Science of Motion
Aerotech, Inc.
101 Zeta Drive, Pittsburgh, PA, 15238
Phone: [phone] Fax: [phone]
www.aerotech.com
BM/BMS Series Brushless
Motors
Hardware Manual
P/N: EDA135 (Revision: 1.04)

Product names mentioned herein are used for identification purposes only and may be trademarks of their respective
companies.
© Aerotech, Inc. 2006
Product Registration Register online at: http://www.aerotech.com/prodreg.cfm
United States Headquarters:
Phone: [phone]
Fax: [phone]
Email: [email protected]
United Kingdom:
Phone: [phone]
Fax: [phone]
Email: [email protected]
Technical Support
Germany:
Phone: [phone]
Fax: [phone]
Email: [email protected]
1.00 March 1996
1.01 February 2000
1.02 April 2, 2001
1.03 May 23, 2002
1.04 October 26, 2006
Revision History

BM/BMS Series Hardware Manual Table of Contents
www.aerotech.com iii
TABLE OF CONTENTS
DECLARATION OF CONFORMITY .............................................. ix
CHAPTER 1: INTRODUCTION ................................................1-1
1.1. Product Overview......................................................................1-1
1.1.1. BM Series.....................................................................1-1
1.1.2. BMS Series ..................................................................1-1
1.2. Warnings ...................................................................................1-2
1.3. Encoder Hall Effect Commutation.............................................1-3
1.4. Resolver Commutation .............................................................1-7
1.5. Part Number and Ordering Information ....................................1-9
1.6. Motor Specifications................................................................1-12
1.6.1. Feedback Device Specifications................................1-18
1.6.2. Connector Pin Assignments ......................................1-19
1.7. Installation ...............................................................................1-21
1.7.1. Wiring .........................................................................1-21
1.7.2. Overcurrent Protection...............................................1-22
1.7.3. Cooling .......................................................................1-22
1.8. Brushless Motor Dimensions ..................................................1-23
1.9. Environmental Specifications..................................................1-29
1.10. Preventative Maintenance ......................................................1-30
1.11. Cleaning ..................................................................................1-30
APPENDIX A: GLOSSARY OF TERMS ................................... A-1
APPENDIX B: WARRANTY AND FIELD SERVICE ................. B-1
APPENDIX C: TECHNICAL CHANGES ................................... C-1
C.1. Current Changes...................................................................... C-1
C.2. Archived Changes.................................................................... C-2
INDEX ...................................................................................Index-1
READER’S COMMENTS.............................................. Comment-1
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Table of Contents BM/BMS Series Hardware Manual
iv www.aerotech.com

BM/BMS Series Hardware Manual List of Figures
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LIST OF FIGURES
Figure 1-1: BM Series Brushless Motors.....................................................1-1
Figure 1-2: Hall Effect and Motor Phasing ..................................................1-3
Figure 1-3: Wye Resistor Test Setup Configuration....................................1-4
Figure 1-4: Motor Lead Phasing with Oscilloscope.....................................1-5
Figure 1-5: Hall Phasing with Oscilloscope.................................................1-6
Figure 1-6: Resolver and Motor Phasing.....................................................1-8
Figure 1-7: Phasing of Sine, Cosine, and Marker Channels for
Rotary Encoder .......................................................................1-18
Figure 1-8: BM75, BM130, BM200 Model Dimensions (NEMA 23) ..........1-23
Figure 1-9: BM250, BM500 Model Dimensions (NEMA 34) .....................1-24
Figure 1-10: BM800, BM1400 Model Dimensions (NEMA 42) ...................1-25
Figure 1-11: BM2000, BM3400, BM4500 Model Dimensions (IEC
142) .........................................................................................1-26
Figure 1-12: BMS60 and BMS100 Model Dimensions................................1-27
Figure 1-13: BMS280 and BMS465 Model Dimensions..............................1-28
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List of Figures BM/BMS Series Hardware Manual
vi www.aerotech.com

BM/BMS Series Hardware Manual List of Tables
www.aerotech.com vii
LIST OF TABLES
Table 1-1: BM Motor Part Number and Ordering Example........................1-9
Table 1-2: BM Motor Options .....................................................................1-9
Table 1-3: BMS Motor Part Number and Ordering Example (BMS60
– BMS100) ..............................................................................1-10
Table 1-4: BMS Motor Options (BMS60 – BMS100) ...............................1-10
Table 1-5: BMS Motor Part Number and Ordering Example
(BMS280 – BMS465) ..............................................................1-11
Table 1-6: BMS Motor Options (BMS280 – BMS465) .............................1-11
Table 1-7: BM75, BM130, BM200 Motor Specifications (NEMA 23
Frame).....................................................................................1-12
Table 1-8: BM250 and BM500 Motor Specifications (NEMA 34
Frame).....................................................................................1-13
Table 1-9: BM800, BM1400 Motor Specifications (NEMA 42 Frame) .....1-14
Table 1-10: BM2000, BM3400, BM4500 Motor Specifications (IEC
142 Frame)..............................................................................1-15
Table 1-11: BMS60, BMS100 Motor Specifications (NEMA 23
Frame).....................................................................................1-16
Table 1-12: BMS280, BMS465 Motor Specifications (NEMA 34
Frame).....................................................................................1-17
Table 1-13: Encoder Specifications ...........................................................1-18
Table 1-14: Resolver Specifications...........................................................1-18
Table 1-15: Motor Power Connector Pin Assignment (MS3101A-
10P).........................................................................................1-19
Table 1-16: Feedback Connector Pin Assignment (MS3101A-20-
29P).........................................................................................1-19
Table 1-17: Resolver Connector Pin Assignment (MS3101A-20-29P)......1-19
Table 1-18:D-sub Connector Pin Assignment..........................................1-20
Table 1-19: Preventative Maintenance ......................................................1-30
Table C-1: Current Changes...................................................................... C-1
Table C-2: Archived Changes.................................................................... C-2
∇∇∇

List of Tables BM/BMS Series Hardware Manual
viii www.aerotech.com

BM/BMS Series Hardware Manual Declaration of Conformity
www.aerotech.com ix
DECLARATION OF CONFORMITY
Manufacturer’s Name
and Address:
Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2897
Declares that the product: BMS Motor Series
Conforms to the following product specifications with the exception of the “VAC6”
versions and the exceptions listed below.
IEC 60034-1:2004 Rotating Electrical Machines
IEC 61010-1:2001 Safety requirements for Electrical Equipment for measurement,
control, and laboratory use.
Use: This product is intended for light industrial manufacturing or
laboratory use.
and complies with 73/23/EEC low voltage directive
Notes:
Safe operation of the motor requires over speed and over current protection. This may be
done by the connected controller / amplifier combination.
Pittsburgh, PA David F. Kincel_________________________
September 2006 Quality Assurance Manager
Alex Weibel ___________________________
Engineer Verifying Compliance

Declaration of Conformity BM/BMS Series Hardware Manual
x www.aerotech.com
∇∇∇

BM/BMS Series Hardware Manual Introduction
www.aerotech.com 1-1
CHAPTER 1: INTRODUCTION
1.1. Product Overview
The BM/BMS series motors can replace standard brushless or brush-type motors when
superior velocity smoothness and control, and higher acceleration are required. Higher
acceleration results in higher machine throughput and performance.
Features:
•50% more torque than brush DC servo motors
•15 times the acceleration than brush DC servo motors
•33% shorter length than brush DC servo motors
•Low to no maintenance
•top speeds up to 10,000 RPM
•a rated speed up to 4,000 RPM
•available with optional brake, front shaft seal, and gear reducers
•available in standard NEMA frame sizes
•choose encoder/HED or resolver feedback
1.1.1. BM Series
The BM series motors are available in ten different models with a rated power from 232
to 7,949 watts and torque ranging from 78 oz-in (0.55 N-m) to 4,480 oz-in (31.6 N-m).
The BM series are smaller and weigh less than brush or stepper motors of the same
power capacity. The motors feature standard NEMA frame sizes allowing easy
replacement of stepping motors. The motors have skewed stator laminations that provide
smooth velocity control. Signal and motor power connections are made through separate
MS-style or D sub connectors.
1.1.2. BMS Series
The BMS series motors are available in four different models with a rated power from
137 to 599 watts and torque ranging from 46 oz-in (0.33 N-m) to 405 oz-in (2.9 N-m).
The BMS series motors are manufactured with a slotless design and exhibit extremely
smooth velocity regulation.
Figure 1-1: BM Series Brushless Motors

Introduction BM/BMS Series Hardware Manual
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1.2. Warnings
The following warnings apply to the BM and BMS Series Motors. Failure to observe
these precautions could result in serious injury to personnel and/or damage to the
equipment.
Operators must be trained before allowing them to operate
equipment.
If the equipment is used in a manner not specified by the
manufacturer, protection of the equipment may be
impaired. The user should practice caution when following
the given procedures. Deviation from this may result in
damage to the equipment.
To minimize the possibility of electrical shock and bodily
injury when servicing the equipment, ensure that all
electrical power switches are in the off position and
disconnect main power.
Motors must be mounted securely before connecting
cables and applying power.
Allow all system components to adjust to room
temperature before installing. Do not apply power to
system components if moisture is present on them.
The motor case temperature may exceed 75°C in some
applications.
Do not disconnect motor connectors with power applied to
motor.

BM/BMS Series Hardware Manual Introduction
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1.3. Encoder Hall Effect Commutation
Aerotech brushless rotary motors are shipped from the factory with the correct motor
phase to Hall effect device relationship established. This is essential for proper motor
commutation.
Figure 1-2 shows the proper Hall effect to motor phasing for both clockwise (CW) and
counterclockwise (CCW) motor rotation (viewed looking into the mounting flange of the
motor).
Figure 1-2: Hall Effect and Motor Phasing
The waveforms created by the motor phasing can be observed using a two-channel
oscilloscope, a 5V power supply, and six (10,000 ohm, 1/4 watt) resistors (Figure 1-3).
Three resistors should be wired in a Wye configuration

Introduction BM/BMS Series Hardware Manual
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Disconnect the motor from the controller and connect it in the test configuration shown
in Figure 1-3. Motor leads 1, 2, and 3 should be connected to the ends of the three
resistors wired in a Wye configuration. The Hall common lead coming from the motor
should be connected to the power supply common. The 5V Hall power lead should be
connected to the 5V power line. The three Hall signal wires should be connected through
the remaining three resistors to the 5V lead of the power supply.
Figure 1-3: Wye Resistor Test Setup Configuration
Motor voltage is monitored without power applied to the
motor. Before performing these steps, remove all
connections to the motor except the wye resistor network.
Remove all mechanical connections to the motor shaft.

BM/BMS Series Hardware Manual Introduction
www.aerotech.com 1-5
All measurements should be made with the probe common of each channel of the
oscilloscope connected to a neutral reference test point (TP4, shown in Figure 1-4).
To determine the relative phasing/order of the three motor lead signals in relation to each
other, connect channel 1 of the oscilloscope to TP1. Connect channel 2 to TP2 and move
the motor in the positive direction (CW) by hand. Note the peak of the sine wave signal
of channel 1 in comparison to the peak of the sine wave signal of channel 2. Next,
disconnect channel 2 from TP2 and reconnect it to TP3 and again move the motor in the
positive direction. Note the peak of the sine wave signal of channel 3 in comparison to
the peak of the sine wave signal of channel 1.
Aerotech phasing configuration expects ØC to be the lead signal (in time), ØB to follow
it, and ØA to follow ØB. This means that whichever signal has its sine wave peak
farthest to the left should be designated as the ØC signal.
Figure 1-4: Motor Lead Phasing with Oscilloscope

Introduction BM/BMS Series Hardware Manual
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After the motor leads have been tested, the next step is to determine the phase of the Hall
signals. The expected (by an Aerotech system) relationship between motor and Hall leads
is that the peak of a motor lead signal should correspond to the low voltage phase of the
Hall signal (the relationship is shown in Figure 1-5).
With channel 1 still connected to one of the motor leads, connect channel 2 of the
oscilloscope to TP5, TP6, and then TP7, while advancing the motor in the positive
direction after each connection. Note which of the three Hall signals has the
complimentary phase relationship to the motor lead that channel 1 is connected to.
Move channel 1 of the oscilloscope to the second motor lead and repeat the steps from
above. Note which Hall signal corresponds to the currently selected motor lead and
repeat the process for the 3rd motor lead
Figure 1-5: Hall Phasing with Oscilloscope

BM/BMS Series Hardware Manual Introduction
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1.4. Resolver Commutation
An optional resolver can be used as the feedback device for a brushless rotary motor. The
resolver is aligned at the factory, so that the null position of the resolver corresponds to a
motor phase angle of zero degrees (refer to Figure 1-6). The null position of the resolver
is considered to be the point at which the sine feedback signal is resting at a zero level
and the cosine signal is resting at its positive peak.
The sine and cosine signals shown in Figure 1-6 represent
demodulated waveforms. In actual operation, these
signals are transmitted on a high frequency carrier (e. g., 5
KHz, 10 KHz).
The zero degree phase angle of the motor is defined as the position that the motor shaft
will align to if phase A is energized with a positive voltage with respect to phases B and
C. The 8 pole motors (4 pole pairs) have 4 zero degree points per revolution, and the 6
pole motors have 3 zero degree points per revolution.

Introduction BM/BMS Series Hardware Manual
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Figure 1-6: Resolver and Motor Phasing