Applied Motion Products BLuAC5 User manual

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ContentsContents
ContentsContents
Contents
Safety Instructions ................................................................................................. 5
Introduction ......................................................................................................... 6
Block Diagram...................................................................................................................6
Getting Started ..................................................................................................... 7
Status & Error Display LEDs ....................................................................................... 9
Serial Comm Tx & Rx LED ......................................................................................... 9
Bus voltage indication LED ......................................................................................... 9
Seven Segment Display Error codes .......................................................................... 9
Seven Segment Display Status codes ...................................................................... 10
Regeneration LED .................................................................................................... 10
Connecting to the PC using RS-232 ............................................................................ 11
Connecting to a host using RS-485 ............................................................................. 12
A Short tutorial on RS-485 & RS-422 .............................................................................. 12
4-wire RS-485/422 Network...................................................................................... 13
Getting and Connecting a RS-485 4-wire adaptor to your PC................................... 13
2-wire RS-485 Network............................................................................................. 14
Getting and Connecting a RS-485 2-wire adaptor to your PC................................... 14
BeforeYou connect the servo drive to your system -................................................. 14
Connecting the AC Power Input ................................................................................. 15
24Volt Controller Input (Keep Alive).......................................................................... 15
Connecting Single Phase AC input (90-260VAC) ............................................................ 16
Connecting 3-Phase AC input (90-260VAC).................................................................... 16
Connecting DC input (100-367VDC) .............................................................................. 16
Connecting the Motor ............................................................................................ 17
Connecting the Encoder & Hall Sensors ....................................................................... 18
Encoder Pinout ......................................................................................................... 18
Connecting a Single-Ended Encoder ........................................................................ 18
Connecting Single-Ended Hall Sensors .................................................................... 18
Connecting Input Signals ........................................................................................ 19
IN/OUT 1 I/O Connector ........................................................................................... 19
With Expanded I/O (IN/OUT 2) ................................................................................. 19
IN/OUT1 & IN/OUT 2 Connector Pinout Diagrams .................................................. 19
High Speed Digital Inputs................................................................................................ 20
Using High Speed Inputs with 12-24Volt Signals...................................................... 20
Using Mechanical Switches at 24Volts. .................................................................... 21
Connecting to PLC with Sourcing (PNP) Outputs ..................................................... 21
Connecting to PLC with Sinking (NPN) Outputs ....................................................... 21
Standard Digital Inputs ........................................................................................... 22
Single Ended Inputs ........................................................................................................ 22
What is COM? .......................................................................................................... 22
User Out 24V supply................................................................................................. 22
Digital Input Connection Examples ........................................................................... 23
Connecting Limit Switches to the BLuAC5 Drives ........................................................... 24
BLuAC5Limit Input diagram ..................................................................................... 24
Wiring a Mechanical Limit Switch.............................................................................. 24
Wiring a Limit Sensor................................................................................................ 24
Analog Inputs ...................................................................................................... 25
Three dedicated purposes: ....................................................................................... 25
Basic Specifications:................................................................................................. 25
Wiring a controller with differential output as a single ended input ........................... 26
Wiring a controller with differential output to differential input................................... 26
Wiring a potentiometer to a single ended input ........................................................ 26
Programmable Outputs ........................................................................................... 27
Encoder Outputs ............................................................................................................. 28

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BLuAC5 Expanded I/O board (IN/OUT 2) ......................................................................... 29
Single Ended Inputs ........................................................................................................ 29
What is COM? .......................................................................................................... 29
Connecting to the Aux Analog Input ................................................................................ 31
ProgrammableOutputs ................................................................................................... 32
Recommended AMP Motors ..................................................................................... 33
Alpha A Series.......................................................................................................... 33
Alpha M Series ......................................................................................................... 33
Alpha N Series.......................................................................................................... 33
Other Supplier's Motors................................................................................................... 33
Setting Drive Current Limits ..................................................................................... 34
What is “Peak Current Limit”? ................................................................................... 34
Using DC Brushed Motors ........................................................................................ 35
Servo Drive Regeneration ........................................................................................ 36
Mounting the Drive ................................................................................................ 37
BLuAC5 (all models) ................................................................................................ 37
Mechanical Outlines .............................................................................................. 38
Technical Specifications ......................................................................................... 39

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Safety InstructionsSafety Instructions
Safety InstructionsSafety Instructions
Safety Instructions
Only qualified personnel are permitted to transport, assembly, commission, and maintenance this equip-
ment.Properly qualified personnel are persons who are familiar with the transport, assembly, installation,
commissioning and operation of motors, and who have the appropriate qualifications for their jobs.The
qualified personnel must know and observe the following standards and regulations:
IEC 364 resp.CENELEC HD 384 or DIN VDE 0100
IEC report 664 or DINVDE 0110
National regulations for safety and accident prevention orVBG 4
To minimize the risk of potential safety problems, you should follow all applicable local and national codes
that regulate the installation and operation of your equipment. These codes vary from area to area and it
is your responsibility to determine which codes should be followed, and to verify that the equipment,
installation, and operation are in compliance with the latest revision of these codes.
Equipment damage or serious injury to personnel can result from the failure to follow all appli-
cable codes and standards. We do not guarantee the products described in this publication are
suitable for your particular application, not do we assume any responsibility for your product
design, installation, or operation.
• Read all available documentation before assembly and commissioning.Incorrect handling of products in
this manual can result in injury and damage to persons and machinery.Strictly adhere to the technical
information on the installation requirements.
• It is vital to ensure that all system components are connected to earth ground.Electrical safety is
impossible without a low-resistance earth connection.
•The BLUAC5 contains electrostatically sensitive components that can be damaged by incorrect han-
dling.Discharge yourself before touching the product.Avoid contact with high insulating materials (artifi-
cial fabrics, plastic film, etc.).Place the product on a conductive surface.
• During operation keep all covers and cabinet doors shut.Otherwise, there are deadly hazards that could
possibility cause severe damage to health or the product.
• In operation, depending on the degree of enclosure protection, the product can have bare components
that are live or have hot surfaces.Control and power cables can carry a high voltage even when the
motor is not rotating.
• Never pull out or plug in the product while the system is live.There is a danger of electric arcing and
danger to persons and contacts.
• After powering down the product, wait at least ten minutes before touching live sections of the equip-
ment or undoing connections (e.g., contacts, screwed connections).Capacitors can store dangerous
voltages for long periods of time after power has been switched off.To be safe, measure the contact
points with a meter before touching.
Be alert to the potential for personal injury.Follow the recommended precautions and safe operating
practices included with the alert symbols.Safety notices in this manual provide important information.
Read and be familiar with these instructions before attempting installation, operation, or maintenance.
The purpose of this section is to alert users to possible safety hazards associated with this equipment
and the precautions that need to be taken to reduce the risk of personal injury and damage to the equip-
ment.Failure to observe these precautions could result in serious bodily injury, damage to the equipment,
or operational difficulty.

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IntroductionIntroduction
IntroductionIntroduction
Introduction
Thank you for selecting an Applied Motion Products motor control. We hope our dedication
to performance, quality and economy will make your motion control project successful.
If there's anything we can do to improve our products or help you use them better, please
call or fax. We'd like to hear from you. Our phone number is [phone] or you can
reach us by fax at [phone].You can also email suppor[email protected].
BLuAC5 Features
• Digital servo motor driver in complete fully featured package
• Operates directly from a 100 to 260 Volt AC input, single phase or three phase
• Operates in torque, velocity or position mode
• Accepts analog signals, digital signals and RS-232/485 serial commands
• Motor current to 15.0 amps peak, 5.0 amps continuous
• Seven optically isolated digital inputs (15 inputs with expanded I/O board)
• Three optically isolated digital outputs (7 outputs with expanded I/O board)
• ±10 volt analog input for position, speed and torque control
• 0-5V aux analog input
Block Diagram
motor
encoder
to RS-485 host
RS-485
IGBT
PWM
Power
Amplifier
User Out 24 VDC
X1/STEP/PWM
X2/DIR
X3/SVEN
X4/ALMRST
X5
X6/CCWLMT
X7/CWLMT
to PC
ANALOG+
ANALOG–
Y1/BRAKE
Y2/INPOSN
Y3/ALARM
RS-232 Optical
Isolation
ENCODER OUT
Line
Drivers
DSP
Optical
Isolation
Internal
Logic
Supply
AC Input
Power
Converter
100 - 260 VAC
DC Bus LED
Internal
Regen
Clamp
External Regen Resistor
External Brake Resistor
Input 24 VDC
Regen LED
Seven Segment
Status Display
Rx Status LED
Tx Status LED

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Getting StartedGetting Started
Getting StartedGetting Started
Getting Started
This manual describes the use of three different drive models. What you need to know and
what you must have depends on the drive model. For all models, you must have the follow-
ing:
• a compatible servo motor
• cables to connect the motor to the drive. If you are using an Applied Motion
“Alpha” motor, use BLUENC and BLMTR cables (one of each).
• a small flat blade screwdriver for tightening the connectors (included).
• a personal computer running Microsoft Windows 95, 98, NT, Me, 2000 or XP.
• The Applied Motion CD that was included with your BLu servo drive
• An Applied Motion programming cable (included)
If you’ve never used a BLu servo before , you’ll need to get familiar with the drive and the
set up software before you try to deploy the system in your application. We strongly recom-
mend the following:
1. Install the QuickTuner ™ software from the CD.
2. Launch the software by clicking Start...Programs...Applied Motion
Products...QuickTuner.
3. Connect the drive to your PC using the programming cable supplied.
4. Connect the drive to the AC power source (may be switched).
5. Connect the drive to the motor.
6. Apply power to the drive.
7. Follow the instructions in the QuickTuner ™ manual. (On the CD)
The connectors and other points of interest are illustrated on the next page. Depending on
your drive model and application, you’ll need to make connections to various parts of the
drive. These are detailed later in the manual.

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DC Bus
Motor Encoder IN / OUT 1
IN / OUT 2
PC/MMI
RS-485/422
C B A
GND
TX-
TX+
RX-
RX+
COMM
Status
Regen
GND
+24VDC
Input
320V pk
User Out
+24VDC
GND
CLAMP RES
EXT
BUS
BRAKING
L1
L2/N
L3
AC POWER
G
Error Codes
Position Limit
CCW Limit
CW Limit
Over Temp
Over Voltage
Under Voltage
Over Current
Current Limit
Hall Bad
Encoder Bad
Memory Failed
Regen Failed
Comm Error
Position Mode
Velocity Mode
Torque Mode
Step Mode
Operating Modes
Front View
X COMMON
X7/ CWLimit
X3 / Servo Enable
X5
X4 / Alarm Reset
Analog IN-
Analog IN+
X2 / DIR-
X2 / DIR+
X1 / STEP / PWM+
X1 / STEP / PWM-
GND
GND
A+
A-
B+
B-
Z+
Z-
+5V OUT
Y COMMON
Y3 / ALARM
Y2 / INPOSN
Y1 / BRAKE
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17
16
15
14
13
12
11
10
9
8
7
6
5
4
2
3
1
19
20
21
22
23
24
25
Encoder
Outputs
X6/ CCWLimit
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17
16
15
14
13
12
11
10
9
8
7
6
5
4
2
3
1
19
20
21
22
23
24
25
+5V
Out 1-
Out 2+
Out 1+
Ain Com
N/C
Ain 1
IN 8-
COM
IN 5
IN 6
IN 7+
IN 8+
IN 7-
IN 4
IN 1
COM
IN 2
COM
IN 3
Out 2-
Out 3+
Out 3-
Out 4+
Out 4-
enabled when
flashing
Drive Disabled
Si Mode
INT
rotating segment indicates Q
program running.
IN/OUT 2
IN/OUT 1
DB-25 connector #1
• digital inputs
• digital outputs
• analog inputs
• encoder output
HD-15 connector
• motor feedback
screw terminal
plugable connector
• motor
plugable screw
terminal connector
• RS-485 port
comm status LEDs
• Rx (Green)
• Tx (Amber)
RJ11 connector
• RS-232 port
Always use the blue & white Applied Motion
screwdriver to tighten the screw terminal connectors.
Larger screwdrivers may remove the plastic dimples
that prevent the screws from falling out.
plugable screw
terminal connector
• AC input 100-260VAC
• DC input 90-367VDC
plugable screw
terminal connector
• Dynamic Braking Resistor
plugable screw
terminal connector
• External Regen Resistor
DB-25 connector #2
Expansion I/O
• digital inputs
• digital outputs
• analog input
Status LED
• Regen
Seven Segment
LED
• status codes
• error Codes
Status LED
• DC Bus Voltage
present
plugable screw
terminal connector
• User 24 volt output
plugable screw
terminal connector
• 24 volt (Keep Alive)
input
Standard on BLuAC5-Si
Option on -S, -Q

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Status & Error Display LEDsStatus & Error Display LEDs
Status & Error Display LEDsStatus & Error Display LEDs
Status & Error Display LEDs
Serial Comm Tx & Rx LED
Indicates that data is being received or transmitted through the RS-232 or RS-485 serial
ports. Green indicates “Receiving”. Amber indicates “Transmitting”
Bus voltage indication LED
Indicates when there is DC Bus voltage present on the drive.The servo drive cover should
not be removed when this LED is illuminated. (See “WARNINGS” at end of manual)
Seven Segment Display Error codes
Note: codes with a ”*” indicate drive has faulted and flash at a 0.5 second rate.
*Over Current: The Motor phase current has exceeded the 20 amps (RMS).The drive will be faulted.
*UnderVoltage: The DC Bus voltage has gone below 100Volts.
*OverVoltage: The DC Bus voltage exceeded 400Volts.The drive will be faulted after this error.
*Regeneration Error: While attempting to “dump”power into the regeneration shunt resistor the device
limits were reached (based on settings) or, there is no regeneration shunt resistor attached.
*OverTemperature: The Drive PCB temperature has exceeded 75° C.This will cause the drive to fault
and cannot be cleared until the temperature drops below the limit.
CW Limit: The Clockwise limit has been triggered.This will depend on the CCW/CW Input settings.Use
“DL” Host command or QuickTuner™ “I/O” panel to enable usage.
CCW Limit: The Counter Clockwise limit has been triggered.This will depend on the CCW/CW Input
settings.Use “DL” Host command or QuickTuner™ “I/O” panel to enable usage.
*Position Limit Error: Indicates the Servomotor has exceeded the“Position Limit”value, set by
QuickTuner™ “Drive” panel or the “PF”Host command.
Current Limit: The Motor phase current has exceeded the “Peak” current time limit (As set by the CP
Host command or QuickTuner™).
*Hall Pattern Bad: Indicates that the Hall sensor (commutation track) inputs are incorrect.Drive only
accepts 120° Hall sensor patterns.Could also indicate a failed sensor.
*Encoder Failure: Indicates that the Encoder inputs are not providing the correct states.This feature
can be enabled or disabled using the QuickTuner™ Setup utility, “Single Ended”checkbox.
Memory Fault: When reading or writing to “Flash”memory an error occurred.This is an indicator of
memory problems that are typically induced with too many write cycles (>100,000).
Serial Comm Error: Indicates a Serial Communication error.This error is also indicated by the Comm
Tx and Rx LEDs flashing an alternating pattern.This could result from a number of different conditions
such as incorrect Baud Rate, electrical noise or faulty wiring.

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Seven Segment Display Status codes
Regeneration LED
This LED indicates when the drive is actively applying the regeneration clamp.The clamp is
the internal circuitry that shunts the DC bus to a power resistor.The power resistor can be
either internal or external. (See “Servo Drive Regeneration” in this manual for more details)
Positioning Mode: The drive is in Positioning Mode.This is the mode used when performing “point to
point”moves.
Velocity Mode: The drive is inVelocity Mode.This is the mode used when “Jogging”or Analog com-
mandedVelocity.
Torque Mode: The drive is inTorque Control Mode.This is the mode used for Analog commanded
Torqueoperation.
Step & Direction Mode: The drive is in Step and Direction Control Mode.This is the mode used for
“Encoder Following” or Positioning using Step and Direction input.
Si Positioning: When in Si Programmer mode or running an Si program this code typically appears.
Drive Disabled: The drive output is disabled.
Q Program Running: An outside segment will be rotating around the display.The rotate rate is about
0.2 seconds per segment.
Drive Start-up test pattern: This pattern is displayed for a short period of time at drive start-up.