Aerotech BM User manual

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BM/BMS Brushless Motor
Hardware Manual
P/N: EDA135 (Revision 2.06.00)
Dedicated to the Science of
Motion
Aerotech, Inc.
101 Zeta Drive,
Pittsburgh, PA, 15238
Phone:412-963-7470
Fax:412-963-7459
www.aerotech.com
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Technical Support
Go to www.aerotech.com/service-and-support.aspx for information and support about your Aerotech prod-
ucts. The website provides downloadable resources (such as up-to-date software, product manuals, and
Help files), training schedules, and PC-to-PC remote technical support. You can also complete Product
Return (RMA) forms and get information about repairs and spare or replacement parts.
For immediate help, contact a service office or your sales representative. Have your customer order number
available before you call or include it in your email.
United States
(World Headquarters)
Phone: [phone]
Fax: [phone]
Email: [e-mail]
101 Zeta Drive
Pittsburgh, PA 15238
www.aerotech.com
United Kingdom
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Japan
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Germany
Phone: [phone]
Fax: [phone]
Email: [e-mail]
China
Phone: [phone]
Email: [e-mail]
France
Phone: [phone]
Email: [e-mail]
Taiwan
Phone: [phone]
Email: [e-mail]
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any
time. Refer to the most recent edition of the Aerotech Motion Control Product Guide for the most current
product information at www.aerotech.com.
N O T E : All drawings and illustrations are for reference only and were complete and accurate as of this
manual’s release. The most recent system drawings and schematics can be found on your software CD
ROM or on www.aerotech.com.
N O T E : This manual and any additional instructions included with the BM/BMS should be read in their
entirety before operating the BM/BMS .
N O T E : This product is intended for light industrial manufacturing or laboratory use.
This manual contains proprietary information and may not be reproduced, disclosed, or used in
whole or in part without the express written permission of Aerotech, Inc. Product names mentioned
herein are used for identification purposes only and may be trademarks of their respective com-
panies.
Copyright © 1996 - 2012 Aerotech, Inc. All Rights Reserved.
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BM/BMS Brushless Motor Hardware Manual Table of Contents
Table of Contents
Chapter 1: BM/BMS Brushless Motor Hardware Manual 1
1.1. EC Declaration of Conformity 2
1.2. Safety Procedures and Warnings 3
1.3. Motor Installation 5
1.3.1. Connector Pin Assignment 5
1.4. External Motor Wiring 8
1.4.1. Motor Power Conductors 8
1.4.2. Protective Ground 8
1.4.3. Over Current Protection 8
1.4.4. Hall-Effect Device and Thermistor Wiring 9
1.4.5. Wiring Guidelines 9
1.4.6. Thermal Protective Device 10
1.5. Hall-Effect Operation and Motor Phasing 12
1.6. Resolver Commutation 16
1.7. Motor Heating 17
1.8. Maintenance 18
1.9. Environmental Specifications 19
1.10. Motor Specifications 20
1.11. Brushless Motor Dimensions 26
1.12. Part Number and Ordering Information 31
Appendix A: Warranty and Field Service 33
Appendix B: Revision History 35
Index 37
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Table of Contents BM/BMS Brushless Motor Hardware Manual
List of Figures
Figure 1-1: BM/BMS Series Brushless Motors 1
Figure 1-2: Typical Thermal Sensor Resistance as a Function of Temperature 10
Figure 1-3: Typical Thermistor Interface Circuit 11
Figure 1-4: Hall Effect and Motor Phasing 12
Figure 1-5: Test Setup Configuration 13
Figure 1-6: Motor Lead Phasing with Oscilloscope 14
Figure 1-7: Hall Phasing with Oscilloscope 15
Figure 1-8: Resolver and Motor Phasing 16
Figure 1-9: Example Torque Speed Curve 17
Figure 1-10: BM22 Model Dimensions (NEMA 17) 26
Figure 1-11: BM75, BM130, BM200 Model Dimensions (NEMA 23) 27
Figure 1-12: BM250, BM500 Model Dimensions (NEMA 34) 27
Figure 1-13: BM800, BM1400 Model Dimensions (NEMA 42) 28
Figure 1-14: BM2000, BM3400, BM4500 Model Dimensions (IEC 142) 28
Figure 1-15: BMS35 Model Dimensions (NEMA 17) 29
Figure 1-16: BMS60 and BMS100 Model Dimensions (NEMA 23) 29
Figure 1-17: BMS280 and BMS465 Model Dimensions (NEMA 34) 30
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BM/BMS Brushless Motor Hardware Manual Table of Contents
List of Tables
Table 1-1: Motor Power Connector Pin Assignment (MS3101A-18-10P) 5
Table 1-2: Feedback Connector Pin Assignment (MS3101A-20-29P) 5
Table 1-3: Resolver Connector Pin Assignment (MS3101A-20-29P) 6
Table 1-4: 9-Pin D-Connector Pin Assignment 6
Table 1-5: 25-Pin D-Connector Pin Assignment 7
Table 1-6: BM22, BM75, BM130, BM200 Motor Specifications 20
Table 1-7: BM250 and BM500 Motor Specifications 21
Table 1-8: BM800, BM1400 Motor Specifications 22
Table 1-9: BM2000, BM3400, BM4500 Motor Specifications 23
Table 1-10: BMS35, BMS60, BMS100 Motor Specifications 24
Table 1-11: BMS280, BMS465 Motor Specifications 25
Table 1-12: BM Motor Options 31
Table 1-13: BMS Motor Options 32
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Table of Contents BM/BMS Brushless Motor Hardware Manual
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BM/BMS Brushless Motor Hardware Manual BM/BMS Brushless Motors
Chapter 1: BM/BMS Brushless Motor Hardware Man-
ual
The BM/BMS series comprise Aerotech's high-performance, brushless, permanent magnet rotary ser-
vomotors. The motors feature rare earth magnets for maximum torque and acceleration in a small package.
BM Series
The BM series motors can reach speeds up to 10,000 rpm and accelerations to 270,000 rad/sec2for
improved machine cycle times. Unlike DC brush-type servomotors, the BM series are brushless and main-
tenance free. This makes them ideal for critical applications where downtime cannot be tolerated. In addi-
tion, the BM series motors have very high power density resulting in high torque in a compact package.
Optional IP65 sealing make these motors ideal for harsh environments such as machine tool and even in
wash down applications such as food processing.
BMS Series
Aerotech’s BMS series brushless, slotless, servo motors represent the ultimate in high-performance rotary
motors. Available in standard NEMA frame sizes, these motors are unlike conventional brushless ser-
vomotors because they incorporate a totally slotless stator design that provides the ultimate in smooth veloc-
ity control. These motors are designed for applications requiring superior torque and stability performance.
Figure 1-1: BM/BMS Series Brushless Motors
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BM/BMS Brushless Motors BM/BMS Brushless Motor Hardware Manual
1.1. EC Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238
USA
Product BMS (excluding VAC6 versions)
Model/Types All
This is to certify that the aforementioned product is in accordance with the applicable requirements of the fol-
lowing Directive(s):
2006/95/EC Low Voltage Directive
and is in conformity with the applicable requirements of the following documents when installed and used in
accordance with the manufacturer’s supplied installation instructions.
IEC 60034-1:2004 Rotating Electrical Machines
IEC 61010-1:2001 Safety requirements for Electrical Equipment for meas-
urement, control, and laboratory use
NOTE: Safe operation of the motor requires over speed and
over current protection. This may be done by the con-
nected controller / amplifier combination.
Name / Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
Date September 2010
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BM/BMS Brushless Motor Hardware Manual BM/BMS Brushless Motors
1.2. Safety Procedures and Warnings
Read this manual in its entirety before installing, operating, or servicing this product. If you do not understand
the information contained here, contact an Aerotech representative before proceeding. Strictly adhere to the
statements given in this section and other handling, use, and operational information given throughout the
manual to avoid injury to you and damage to the equipment.
N O T E :
.
MODEL: BMXXX-XXXXXXXXX-
XX-XXX-XX
630XXXXX REV XX
XXX VAC
XXXXXX-A-1-1-X
DWG:
V:
LOT:
DW
This symbol on the motor label means
that the manual must be read in its
entirety to understand any potential
hazards and what actions will be
necessary to avoid them. Rear View
N O T E : BM/BMS motors (all Aerotech equipment) are not to be used in a manner not specified by Aero-
tech, Inc.
W A R N I N G :The BM/BMS Servo Motors are not intended to be directly connected to an
electrical power distribution system. They are meant to be part of a drive package consisting of
an amplifier and controller. The motor relies on the drive package for all manners of fault pro-
tection. Aerotech, Inc. does not approve their motors for use in any other manner.
W A R N I N G :Only trained personnel should operate, inspect, and maintain the BM/BMS .
W A R N I N G :To prevent electrical shock hazards only allow qualified persons to install and
service this equipment. Equipment grounds must be in place and maintained to reduce the risk
of potentially fatal or serious injury from electrical shock.
W A R N I N G :Never install or operate equipment that appears to be damaged.
W A R N I N G :Disconnect electrical power to the motor before performing maintenance pro-
cedures. In addition, uncouple or otherwise prevent motor-coupled machinery from moving the
motor during servicing.
DANGER:The motor temperature can pose a burn hazard. Do not touch the motor until it
has cooled sufficiently.
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BM/BMS Brushless Motors BM/BMS Brushless Motor Hardware Manual
DANGER:These motors are not rated for use in explosive atmospheres. They are not to be
operated in the presence of potentially explosive mixtures of air-borne dust or combustible
vapors.
DANGER:Motors and their associated drives, cabling, etc. are sources of electromagnetic
fields. Persons with external or implanted medical devices need to evaluate the risks asso-
ciated with these devices before entering an area where they are in use.
N O T E : All drawings and illustrations are for reference only and were complete and accurate as of this
manual’s release. The most recent system drawings and schematics can be found on your software CD
ROM or on www.aerotech.com.
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any
time. Refer to the most recent edition of the Aerotech Motion Control Product Guide for the most current
product information at www.aerotech.com.
4 Chapter 1 www.aerotech.com
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BM/BMS Brushless Motor Hardware Manual BM/BMS Brushless Motors
1.3. Motor Installation
Motors are installed by bolting the motor flange to a mounting surface using four holes on the motor flange.
The load is connected to the motor shaft using keyways and/or flats.
1.3.1. Connector Pin Assignment
The pin assignment for the MS motor power connector is displayed in Table 1-1, the MS feedback connector
is shown in Table 1-2, the optional resolver MS connector is shown in Table 1-3, and the D-sub motor and
feedback connector pin assignments are shown in Table 1-4 and Table 1-5.
W A R N I N G :During operation,do not allow motor connection cables to contact the motor
frame.
Table 1-1: Motor Power Connector Pin Assignment (MS3101A-18-10P)
Pin Function Connector
A Motor Phase A
MS3101A-10P
A
B
D
C
B Motor Phase B
C Motor Phase C
D Motor Frame Ground
Backshell Motor Cable Shield
Table 1-2: Feedback Connector Pin Assignment (MS3101A-20-29P)
Pin Function Connector
A Cosine
MS3101A-20-29P
A
N
B
C
D
E
F
RS
PT
G
H
J
K
L
M
B Cosine-N
C Sine
D Sine-N
E Marker
F Marker-N
G Common
H +5V
J Shield (no connection to frame)
K Hall Effect A
L Over-Temperature Thermistor Sensor (1)
M Hall Effect B
N Reserved
P Hall Effect C
R Reserved
S Brake +(2)
T Brake - (2)
(1) BMS motors only. Reserved on all other motors.
(2) 24 VDC @ 1 A max
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BM/BMS Brushless Motors BM/BMS Brushless Motor Hardware Manual
Table 1-3: Resolver Connector Pin Assignment (MS3101A-20-29P)
Pin Function
A Sine +
MS3101A-20-29P
A
N
B
C
D
E
F
RS
PT
G
H
J
K
L
M
B Sine -
C Cosine +
D Cosine -
E Ref +
F Ref -
N Sine Shield (no connection to frame)
P Cosine Shield (no connection to frame)
R Reference Shield (no connection to frame)
S Brake +(1)
T Brake - (1)
(1) 24 VDC @ 1 A max
Table 1-4: 9-Pin D-Connector Pin Assignment
Pin Description Connector
A1 MTR ØA (Motor Phase A)
1 2
543
A4A3A2A1
A2 MTR ØB (Motor Phase B)
A3 MTR ØC (Motor Phase C)
1 Shield for motor wiring connector
2 Reserved:Not Used
3 Reserved:Not Used
4 Reserved:Not Used
5 Reserved:Not Used
A4 Ground to motor frame
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BM/BMS Brushless Motor Hardware Manual BM/BMS Brushless Motors
Table 1-5: 25-Pin D-Connector Pin Assignment
Pin Label Description Connector
1 SIGSHLD Signal shield connection
1
13
14
25
2 Thermistor (1) Over-temperature Thermistor Sensor
3 Encoder +5V +5 V supply input for optical encoders (the typical require-
ment is 250 mA).
5 HALLB Hall Effect sensor, phase B
6 MKR-N Marker-N
7 MKR Marker
10 HALLA Hall Effect sensor, phase A
11 HALL C Hall Effect sensor, phase C
13 Brake -(2) Brake -
14 COS Cosine
15 COS-N Cosine-N
16 Limit +5V +5V supply input for optical limit switch boards (the typical
requirement is 50 mA).
17 SIN Sine
18 SIN-N Sine-N
20 Limit Common Common ground to limit switch.
21 Encoder Common Common ground to encoder power
25 Brake +(2) Brake +
(1) BMS motors only. Reserved on all other motors.
(2) With Brake option only (-BK or -BKH)
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BM/BMS Brushless Motors BM/BMS Brushless Motor Hardware Manual
1.4. External Motor Wiring
All external wiring to the motor must meet certain requirements to provide for safe and reliable operation. The
wiring must be able to supply the rated current without overheating. The wire insulation must be rated for the
voltage and temperature at which the motor is operating. And, efforts must also be made to reduce EMI emis-
sions and to increase EMI immunity through proper cable selection and installation. In addition to supplying
the external wiring the customer is also responsible for providing over current protection for the motor.
Guidelines are given below to help with the selection and installation of the wiring.
1.4.1. Motor Power Conductors
The motor power conductors must be sized to handle the electrical current requirements of the motor. The
motor data sheets list the required values for the various motors. The wire insulation voltage rating is chosen
based on the maximum voltage that will be applied to the motor.
1.4.2. Protective Ground
The protective ground is a safety conductor used to ground the motor case. The protective ground conductor
must have a current carrying capacity at least equal to that of the motor wires. The insulation is standard
Green/Yellow and must be rated for the maximum voltage applied to the motor winding. The protective
ground wire is usually bundled along with the motor wires, but system requirements may be that a separate
protective ground wire is needed.
1.4.3. Over Current Protection
Motors need to be provided with over current protection to prevent motor overheating. Over current protection
can be accomplished using programmable current limits, traps, over current protection circuitry, or fusing.
Fuse values should be selected according to the RMS current rating of the motor. For most applications
slow-blow type fuses should be used.
When the motor is part of an Aerotech system utilizing an Aerotech controller and drive, the “Apk” continuous
current rating of the motor must be used to set the motor over-current protection fault. If the motor is being
installed in a system not configured by Aerotech the customer is responsible for providing the necessary
over current protection.
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BM/BMS Brushless Motor Hardware Manual BM/BMS Brushless Motors
1.4.4. Hall-Effect Device and Thermistor Wiring
The insulation of these wires should have a rating for at least the maximum voltage applied to the motor wind-
ing. The temperature rating of the wire insulation must also be sufficiently high to withstand the operating
temperatures specific to the application.
1.4.5. Wiring Guidelines
The wiring guidelines given below can help to reduce EMI related problems which can result in poor overall
system performance.
lKeep cable lengths as short as possible. Long cable runs are more susceptible to EMI pickup than short
runs.
lUse grounded shielded cables for both the motor power and signal wiring
lThe use of twisted pair shielded cabling can help reduce magnetically induced currents.
lBraided shield has a slightly better low frequency shielding capability than a foil shield. Foil is often used
where RF shielding is necessary.
lDo not bundle signal, motor power cables, or AC power lines within the same protective shield or con-
duit. Instead, use separate protective shields or conduits.
lDo not introduce multiple paths to ground from a grounding point. Multiple paths to ground can create
ground loops within the system.
lThe use of EMI suppression devices may be necessary where the EMI environment warrants their use.
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BM/BMS Brushless Motors BM/BMS Brushless Motor Hardware Manual
1.4.6. Thermal Protective Device
BMS motors incorporate a positive-temperature coefficient (PTC) thermistor as a thermal protection device.
The nominal resistance of the thermistor is 100 ohms at 25°C. The thermistor exhibits a rapid increase in
resistance to 1,000 ohms as the motor temperature approaches the thermistor’s transition temperature of
100°C (refer to Figure 1-2).
W A R N I N G :The thermal protective device used in the BMS style motor must be incor-
porated in an external shutdown circuit to provide protection to the motor.
RT=f(T)
RT
10
10
1K
100
10K
100K
Ω
2
4
6
2
4
6
2
4
6
2
0 20 30 ... 80 90 100 11025-10-20 °C
Figure 1-2: Typical Thermal Sensor Resistance as a Function of Temperature
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BM/BMS Brushless Motor Hardware Manual BM/BMS Brushless Motors
This thermistor can be used in a variety of different electronic interfaces. A precaution when using this type
of device in an interface circuit is to avoid self-heating effects. An excessive amount of current through the
thermistor will cause its temperature to rise. False triggering will then occur. See Figure 1-3 for a typical inter-
face circuit.
0.1µF
5V Logic Interface
1kΩ
+5V
Thermal Sensor
Figure 1-3: Typical Thermistor Interface Circuit
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BM/BMS Brushless Motors BM/BMS Brushless Motor Hardware Manual
1.5. Hall-Effect Operation and Motor Phasing
Aerotech brushless motors are shipped from the factory with the correct motor phase to Hall effect rela-
tionship. Figure 1-4 shows the proper Hall effect to motor phasing for both clockwise (CW) and counter-
clockwise (CCW) motor rotation viewed as shown.
During CCW motor rotation, each
Hall effect signal is at a logic low
state when its corresponding
motor phase is at a negative voltage.
During CW rotation, each Hall
effect signal is at a logic high state
when its corresponding motor phase
is at a negative voltage.
Hall A
Hall B
Motor
Back
EMF
Hall C
240° 300° 360°120° 180°60°0° 5 63 421
ØCØAØB ØAØB
+V
+5V
0V
0V
-V
CW Motor Rotation
240° 300° 360°120° 180°60°0° 5 63 421
ØBØAØC ØAØC
+V
+5V
0V
0V
-V
Hall A
Hall B
Motor
Back
EMF
Hall C
CCW Motor Rotation
Figure 1-4: Hall Effect and Motor Phasing
The waveforms of the motor BEMF can be observed using an oscilloscope, a 5V power supply, and six 10,
000 ohm resistors, see Figure 1-5. To view the waveforms remove all electrical connections to the motor,
and configure the setup as shown in the figure. Motor leads 1, 2, and 3 are connected to the ends of the three
resistors wired as shown. The Hall device power connections are as shown. The three Hall signal wires are
connected via the remaining three resistors to the 5V lead of the power supply.
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BM/BMS Brushless Motor Hardware Manual BM/BMS Brushless Motors
Probe Common
Channel 1 Probe Channel 2 Probe
(Connect to TP4)
Probe Common
(Connect to TP4)
TP5
TP4
COM
+5V
COM
+5V
10K OHM
TYP
"Wye"
Configuration
10K OHM
TYP
Brushless Motor
Motor Lead 3
Motor Lead 1
Motor Lead 2
Power Supply
TP3
TP2
TP1
Test Setup
Configuation
Oscilloscope
TP6
TP7
Hall 1
Hall 2
Hall 3
Figure 1-5: Test Setup Configuration
W A R N I N G :The motor BEMF is monitored without power applied to the motor. Before per-
forming these steps, remove all connections to the motor that are not part of the test setup
shown in the figures. Remove all mechanical connections to the motor shaft also.
To determine the relative phasing/order of the three motor windings 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 of channel 1 in comparison to the peak of the sine wave of channel 2.
Next, disconnect channel 2 from TP2 and reconnect it to TP3 and again move the motor in the positive direc-
tion. Note the peak of the sine wave of channel 3 in comparison to the peak of the sine wave of channel 1.
Aerotech phasing expects ØC to be the lead signal in time, ØB to follow it, and ØA to follow ØB. This means
that whichever signal has been determined to lead the others in time is designated as the ØC winding.
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