Kollmorgen BDS4 Series User guide

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BDS4 SERIES
INSTALLATION AND SETUP MANUAL
M93100 - Issue 2
Old Number
New Number MB4001H
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© Copyright 1993, Danaher Motion Kollmorgen. All rights reserved
Printed in the United States of America
NOTICE
Not for use or disclosure outside of Danaher Motion Kollmorgen except under written
agreement.
All rights reserved. No part of this book shall be reproduced, stored in a retrieval system,
or transmitted by any means (electronic, mechanical, photocopying, recording, or
otherwise) without the written permission from the publisher. While every precaution has
been taken in the preparation of this book, the publisher assumes no responsibility for
errors or omissions. Neither is any liability assumed for damager resulting from the use
of the information contained herein.
This document is proprietary information of Danaher Motion Kollmorgen, furnished for
customer use ONLY. No other uses are authorized without written permission from
Danaher Motion Kollmorgen.
Information in this document is subject to change without notice and does not represent a
commitment on the part of Danaher Motion Kollmorgen. Therefore, information
contained in this manual may be updated without notice due to product improvements,
etc., and may not conform in every respect to former issues.
This product is covered by U. S. Patents:
4,447,771
4,479,078
4,490,661
Other (foreign patents pending)
U. L. is a trademark of Underwriter's Laboratories.
N. E. C. is a trademark of the National Electric Code.
Kollmorgen GOLDLine, BDS4, BDS5, and PSR4/5 are trademarks of Danaher Motion
Kollmorgen.
Dangerous voltages, currents, temperatures, and energy levels exist in this
product and in the associated servomotor(s). Extreme caution should be
exercised in the application of this equipment. Only qualified individuals
should attempt to install, setup, and operate this equipment. Ensure that the
motor, drive, and the end-user assembly are all properly grounded per NEC
requirements.
Danaher Motion Kollmorgen
Phone: [phone] or [phone]
Technical Support Fax: [phone]
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B
DS4 FOREWORD
FOREWORD
The commitment to quality at Industrial Drives is our
first priority. In all aspects of our business: research,
development, product design and customer service,
we strive to guarantee total quality. This pledge is
founded on a solid history of innovative technological
achievements dating back to 1948. One of the finest
tributes to that achievement can now be seen at the
Smithsonian which has on display the first stellar
inertial navigation system developed by Dr. Charles
Stark Draper. This system contains the first models
of torque motors built by the founding organization of
Industrial Drives. During the period of 1948 to 1960,
our "firsts" in the industry numbered more than a
dozen; they ranged from the simple but invaluable
(such as the direct-drive DC torque motor and movie
theater projection motors) to the exotic: submarine
periscope drive motors for the U.S. Navy, electric
drives, Curtis Wright electric brake coils, and
numerous other innovations.
For more than a decade, Industrial Drives (known in
the early days as part of Inland Motor Division of
Kollmorgen) has continued to enhance its
sophisticated engineering solutions to pioneer new
product development.
The results of these and other efforts has encouraged
some of the most significant innovations in the servo
industry. We developed the application of servo
motors and drives in the Machine Tool market. We
were the first with water-cooled servos, the integral
brake, the flux forcing concept and the brushless
motor. We developed the electronically commutated
electric car motor. Industrial Drives pioneered rare
earth magnet development for the servo motor
industry.
Between 1974 and 1980, Industrial Drives continued
to lead the industry in servo application innovations.
Our commitment to engineering excellence never
waivered. In fact, that commitment grew stronger
with the development of brushless submarine and
submersible motors (visiting the Titanic graveyard),
multi-axis electronic drives and antenna pedestal
drives (delivering unprecedented accuracy and
revolutionizing the entire industrial automation
process).
The decade of the 1980's brought continued
advancements in technology and penetration of new
markets requiring precise motion control. Already in
the fifth generation of brushless products, Industrial
Drives continues to lead the way with digital servo
positioning capability and our newest motor offering,
the GOLDLINE Series, incorporating the very latest
high-energy, rare earth magnets (neodymium iron
boron). Once again, we are setting the standards that
others only hope to duplicate. Recently
acknowledged by the Frost and Sullivan Foundation,
a leading market specialist in the motion control
industry, Industrial Drives and its parent, Kollmorgen
Corporation, continue to rank first in servo
technology.
Other achievements? Yes, too many in fact to
mention. Each achievement stands as a testimony to
the committed quality and excellence in design
technology. This constancy of purpose is unyielding
in an era of rapidly changing technology.
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A-63542………..Motor Connection
A-83908………..Purchase Spec. for Mini-Fit, Jr.Series Connector
A-83909………..Purchase Spec. for Mini-Fit, Jr.Series Terminals
A-84385………..Outline & Dimension PSR4/5 - 12 & 20 Amp
A-93031………..Outline & Dimension PSR4/5 - 50 & 75 Amp
A-93092………..PRS4/5 50A / 75A (with & without Soft Start) Simplified Schematic
A-93112………..Outline & Dimension BDS4 - 55 Amp
A-93141………..Wiring & Mounting DiagramER-20
A-93156………..Outline & Dimension BDS4 - 30 & 40 Amp
A-93231………..BDS4 Wiring Diagram
A-93314………..Wiring & Mounting Diagram ER-21
A-93315………..Wiring & Mounting Diagram ER-22
A-93316………..Wiring & Mounting Diagram ER-23
A-93369………..GOLDLINE Amplifier Assembly Guide for Resolver Cables
A-93408………..PRS4/5 12A / 20A Simplified Schematic
A-93409………..PSR4/5 Internal Schematic
A-93414………..GOLDLINE Amplifier Assembly Guide for Motor Cables (30, 40, & 55 Amp)
A-93421………..GOLDLINE Amplifier Assembly Guide for Motor Cables (3 thru 20 Amp)
A-93538………..GOLDLINE Amplifier Assembly Guide for Motor Cables (3 thru 20 Amp)
A-93539………..GOLDLINE Amplifier Assembly Guide for Motor Cables (30, 40, & 55 Amp)
A-93540………..GOLDLINE Amplifier Assembly Guide for Resolver Cables
A-93541………..BDS4 Direction Limit Wiring Diagram
A-93567………..Outline & Dimension BDS4 - 3 & 6 Amp
A-93568………..Outline & Dimension BDS4 - 20 Amp
A-93572………..Outline and Dimension BDS4 - 10 Amp
A-93656………..Mounting Hole Pattern BDS4, BDS5, PSR4/5
A-93700………..DC Bus Cable Assembly for BDS4/5 & PSR4/5
A-93703………..Mounting Hole Pattern BDS4
B-84929………..BDS4 & BDS5 Logic Cable Assembly
C-84113……….. BDS4 Simplified Schematic
C-84723……….. PSR4/5 Simplified Schematic
C-84724……….. PSR4/5 Internal Schematic
C-93185.……….BDS4 - OPT2/3A Pinout Options
D-93179………..BDS4 - OPT2/3A
List of Drawings BDS4
List of Drawings
v
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B
DS4 CHAPTER 1 - SYSTEM DESCRIPTION
1-1
CHAPTER 1
SYSTEM DESCRIPTION
1.1 INTRODUCTION
The information in this chapter will enable you to
understand the product's basic functions and features.
These concepts will allow you to apply them to your
own unique applications.
1.2 PRODUCT DESCRIPTION
Industrial Drives' BDS4 product lines are 3-phase
sine wave, brushless motor controllers. They are
fully regenerative four-quadrant, bi-directional
velocity loop amplifiers designed to be used with
Industrial Drives' high performance B series
permanent magnet brushless motors.
Although the BDS4 is basically an analog servo
amplifier, it contains a microprocessor to implement
Industrial Drives' patented Torque Angle Control
function for maximum system performance.
The BDS4 amplifier modules are available in sizes of
3, 6, 10, 20, 30, 40 and 55 amps RMS/phase
continuous. The modular design provides the
flexibility for multiple axes to share a common power
supply requiring no input isolation transformer.
The PSR4/5 Power Supply modules are available in
sizes of 12, 20, 50 and 75 amps RMS/phase
continuous (AC input line ratings).
Numerous Industrial Drives B Series motors with
various diameters, stack lengths, and windings are
also available.
1.3 FEATURES
Highlighted design features are:
•Modular construction maximizing serviceability.
•Two-part plug connectors interfacing between
the BDS4, PSR4/5, and other equipment.
•Routine adjustments accessible from the front of
the BDS4.
•High frequency (20 kHz) motor current ripple for
quality servo performance, higher efficiency, and
less audible noise.
•Differential velocity or current command input.
•Voltage programmable current limit input.
•A removable compensation board containing all
the components that make the BDS4 compatible
with a particular motor.
•Protection against thermal overload indicates any
overtemperature conditions. The BDS4 is
protected against peak current overloads by a
current foldback circuit. Also, it is protected
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HAPTER 1 - SYSTEM DESCRIPTION BDS4
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from logic bus out-of-tolerance conditions and
motor stator short circuit conditions, both line-to-
line and line-to-ground.
•Drive-Up contact closes indicating the amplifier
is ready for input command signal; opens on fault
conditions.
•Standard PSR4/5 Power Supply units contain a
Soft Start function and a dynamic bus discharge
function.
•The 12 and 20 amp PSR4/5 units have, as
standard, 40 watts of internal shunt regulation.
There are optional versions available having no
shunt regulator. Other options have externally
mounted power resistance allowing shunt
regulation of up to 700 watts. The shunt
regulator is protected from excessive peak
current by fuse. It is also protected from
excessive duty, if duty cycle exceeds a preset
limit, by shunt overload shutdown circuit.
•The 50 and 75 amp PSR4/5 shunt regulation is
accomplished with externally mounted power
resistor(s) with ratings from 500 to 2000 watts as
standard. Special units may be ordered for even
higher power. The shunt regulator is protected
from excessive peak current by a thermal
overload relay. It is also protected from
excessive duty, if duty cycle exceeds a preset
limit, by shunt overload shutdown circuit.
•Diagnostic LED indicators located on the front
panel on both the BDS4 and the PSR4/5
modules.
•Either a 12-Bit Parallel Position Information
Card or an Encoder Equivalent Output Card as
available options.
1.4 THEORY OF OPERATION
The BDS4 brushless servo system consists of three
main components:
1. PSR4/5 - Power Supply Module
2. BDS4 - Amplifier Module
3. B - Brushless Motor
All of the compensation components necessary to
match a BDS4 amplifier to a particular motor such as,
current loop compensation, velocity loop
compensation, and torque angle compensation, are
located on the removable BDS4 COMP
compensation board located inside the BDS4
amplifier.
The TL (Test Limits and Modification) Sheet
contains the compensation component values and
such information as maximum operating speed, peak
current limits, etc. that are assigned to each BDS4
system.
Only motors having the identical base model number
may be run on the BDS4 amplifiers. If a motor
having a different base motor model number is to be
run on a BDS4, the BDS4-COMP compensation
board must be altered or changed accordingly. The
BDS4 must remain the same current and voltage
rating.
1.4.1 PSR4/5 Power Supply Module
Refer to Figure 1.1 for a quick reference of the
PSR4/5 and drawings A-93409, A-93408 and A-
93092 for precise details.
The PSR4/5 Power Supply Module is divided into
four (4) main sections:
1. The Unregulated Logic Bus, supplied by the
Control AC line input voltage (normally
single-phase 115 VAC), is described in
Section 4.2.
2. The 310/140 Main DC Bus is supplied by
the main AC line input voltage (normally
three-phase 230 VAC or single-phase 115
VAC).
3. The Soft-Start Feature (standard) resistor
limits the inrush current (to charge-up the
Main Bus Capacitors) to a specific amount
as listed in Appendix D.
4. The Shunt Regulator (regeneration) section
includes circuitry which monitors the main
bus. During deceleration profiles, the motor
basically operates as a DC generator and
pumps energy back into the main bus
causing the bus to rise. The Shunt Regulator
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B
DS4 CHAPTER 1 - SYSTEM DESCRIPTION
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limits the voltage rise during the
deceleration periods.
•12 and 20 AMP Models:
The shunt regulator (regeneration) resistor
load is fuse protected. If the shunt regulator
is held on for too long, the shunt regulator
power transistor fails, or the shunt regulator
load resistor becomes shorted, the fuse will
blow and cause the Fault Contact on the
PSR4/5 to open and the BLOWN REGEN
FUSE LED to become illuminated.
Figure 1.1. BDS4 and PSR4/5 (Low Current Models shown)
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C
HAPTER 1 - SYSTEM DESCRIPTION BDS4
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The shunt regulator also includes a duty
cycle limit circuit to protect against
excessive load resistor heating. If the
average duty cycle limit is exceeded, the
regeneration circuitry will become disabled,
the Fault Contact will open, and the
OVERLOAD LED will become illuminated.
To reset this fault, remove and reapply all
input line power; bus capacitors must
completely discharge.
•50 and 75 AMP Models:
WARNING
The thermal overload output
contacts must be connected
into a shut down circuit (E
Stop string, etc.) to drop the
main power or a possible fire
hazard will exist. Refer to
Drawing A-93231.
The shunt regulator (regeneration) resistor is
protected by a thermal overload relay. If the
resistor rating is exceeded or if the shunt
regulator transistor fails, the thermal
overload output contacts will open
indicating an IMMEDIATE need to remove
the main power.
1.4.2 BDS4 Servo Amplifier Module
Refer to Figure 1.1 for a quick reference of the
BDS4's features.
The BDS4 Servo Amplifier is divided into four (4)
main sections:
1. Fault Diagnostics monitor various signal
leads. When a fault condition occurs the
fault circuit will become latched, the BDS4
will become internally inhibited, the
appropriate red LED will become
illuminated, and the Drive-Up contact will
open indicating that the BDS4 is in its
Inhibit mode.
2. The Input/Output interface circuitry is
divided into two functions:
(A) Signals to and from the motor and
BDS4.
These signals are associated with the
motor system resolver. A 7.0 kHz
excitation signal is generated in the
BDS4 and sent to the resolver. Two
resolver feedback signals (sine and
cosine) are received by the BDS4 and
processed by an R/D (resolver-to-
digital) converter. The R/D unit
generates a digital position word used in
electronically commutating the motor
and an analog velocity (internal tach)
signal to close the servo loop.
(B) Signals to and from the signal
source (PLC, CNC, etc.) and BDS4.
There are numerous signals that may
interface between the signal source
(PLC, CNC, etc.) and the BDS4. These
inputs and modes of operation differ
with each application.
3. The BDS4 consists of a single velocity loop
and three inner current loops. To give
precise velocity control, the velocity loop is
normally configured as a proportional, plus
an integral, plus a derivative gain servo loop.
The output of the velocity loop is the current
command for the three microprocessor-
based current loops.
The heart of the BDS4 is its microprocessor
which receives and processes the current
command (velocity error) signal from the
output of the velocity loop circuit, the
position information from the resolver-to-
digital converter, and several other signals.
After receiving the velocity error, the
microprocessor generates three sinusoidal
current commands. These current
commands are forwarded to the three
proportional plus integral current loops, one
for each of the three motor phases.
The microprocessor is the key element in the
Industrial Drives patented torque angle
technique. The microprocessor varies the
phase of the currents with respect to motor
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B
DS4 CHAPTER 1 - SYSTEM DESCRIPTION
1-5
flux and significantly improves the motor
speed-vs-torque profile.1
4. The outputs from the three current loop
circuits are converted into a 10 kHz pulse
width modulation scheme. The modulation
is such that the 10 kHz PWM results in 20
kHz current ripple in the motor, resulting in
very quiet motor operation.
The PWM switching signals are optically
coupled to the power stage gate drive
hardware for complete electrical isolation.
The BDS4 uses IGBT's (Isolated Gate
Bipolar Transistors) for the output power
stage; allowing high frequency operation.
1.4.3 Brushless DC Motor
The Industrial Drives' B Series brushless motors
feature the latest in permanent magnet technology,
utilizing high energy Neodymium-Iron-Boron alloys.
These brushless motors consist of permanent magnet
rotors and three-phase Y-stator windings. This places
the heat producing member on the outside where it
can best dissipate heat. These motors (depending on
size) are either four- or six-pole motors. Since they
are brushless motors, there are no commutators or
associated brushes. The motors run as synchronous
motors, meaning the rotor speed is the same as the
speed (frequency) of the stator's rotating magnetic
field. The feedback device is a brushless resolver,
mounted internally as part of the overall motor
construction. Another available option is the integral
brush tachometer. For more information, refer to the
Installation and Service Manual, B Series Brushless
Motors M-89031.
1.4.4 Power Up/Down Sequencing
First, apply the 115 VAC control voltage. Second,
apply the main AC voltage. Third, check for faults
and then enable the BDS4. The AC line input
voltages may be removed in any sequence.
1 The BDS4A/V sine-wave controller allows a wider range speed
because it has the ability to electronically change the angle
between the rotor flux and the stator flux—commonly referred to
as torque angle. Industrial Drives, A Kollmorgen Division,
Patented Numbers 4,447,771; 4,479,078; and 4,490,661.
1.4.5 With Soft-Start Circuit
(Standard)
1. Only the Control AC line input voltage is
applied.
a. The logic bus comes up.
b. A power-up reset pulse is generated in
the BDS4.
c. If no faults (other than main bus
undervolts) are present after the power-
up reset pulse is generated (a delay of
one second) then the drive is ready to be
enabled. However, there can be no
motor movement until the main AC line
input voltage is applied.
2. The Main AC line input voltage is applied.
a. The soft-start circuit charges the Main
DC bus capacitors in the PSR4/5
through a current limiting resistor.
b. The shunt regulator regeneration
circuitry is switched from dynamic bus
discharge to regular mode.
c. The undervoltage fault in the BDS4 is
now cleared (after approximately 3/4
sec. delay), and if jumper J21 is
installed on the BDS4-COMP Board,
the Drive Ready LED will become
illuminated and the Drive-Up contact in
the BDS4 (between Pins 10 and 20 of
Connector C1) will close. The BDS4 is
ready to be enabled and will enable
once the enable input is activated.
3. Only the Main AC line input voltage is
removed.
a. Approximately 30 msec. after the Main
AC line input voltage is removed, the
shunt regulator is switched from
regulate to the dynamic bus discharge
mode, and the main DC bus power is
discharged.
b. The shunt regulator circuit is
deactivated.
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HAPTER 1 - SYSTEM DESCRIPTION BDS4
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c. The Drive-Up contact within the BDS4
will open due to Bus undervolts.
4. Only the Control AC line input voltage is
removed.
a. The Drive-Up contact in the BDS4 will
open. The BDS4 is immediately
disabled.
b. Operation of the soft-start/dynamic bus
discharge and other circuits within the
PSR4/5 will not be affected.
c. The PSR4/5 fault contact will open.
1.4.6 Without Soft-Start Circuit or
Dynamic Bus Discharge (Optional)
1. Only the Control AC line input voltage is
applied.
a. The logic bus comes up.
b. A power-up reset pulse is generated in
the BDS4.
c. If no faults (other than main bus
undervolts) are present after the power-
up reset pulse is generated (a delay of
one second) then the drive is ready to be
enabled. However, there can be no
motor movement until the main AC line
input voltage is applied.
2. The Main AC line input voltage is applied.
a. The soft-start circuit charges the Main
DC bus capacitors in the PSR4/5
through a current limiting resistor.
b. The shunt regulator regeneration
circuitry is switched from dynamic bus
discharge to regular mode.
c. The undervoltage fault in the BDS4 is
now cleared (after approximately 3/4
sec. delay), and if jumper J21 is
installed on the BDS4-COMP Board,
the Drive Ready LED will become
illuminated and the Drive-Up contact in
the BDS4 (between Pins 10 and 20 of
Connector C1) will close. The BDS4 is
ready to be enabled and will enable
once the enable input is activated.
3. Only the Main AC line input voltage is removed.
a. The DC bus will bleed down slowly
after approximately five minutes.
b. The shunt regulator is deactivated.
c. The Drive-Up contact within the BDS4
will open.
4. Only the Control AC line input voltage is
removed.
a. The BDS4 will be immediately
disabled.
b. The BDS4 Drive-Up contact will open.
c. The PSR4/5 fault contact will open.
1.5 TYPICAL SYSTEM DIAGRAM
Figure 1.2 illustrates a typical system with all of the
major components.
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DS4 CHAPTER 1 - SYSTEM DESCRIPTION
1-7
Figure 1.2. Typical System Diagram
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B
DS4 CHAPTER 2 - INSTALLATION
2-1
CHAPTER 2
INSTALLATION
2.1 INTRODUCTION
The information in this chapter will familiarize you
with the safety information, unpacking and
inspection, installation requirements, assembly
procedures and electrical connections for installing
the BDS4. A checklist is provided at the end of this
chapter to insure proper installation.
2.2 SAFETY INFORMATION
The purpose of this section is to alert you to possible
safety hazards associated with this equipment and the
precautions you can take to reduce the risk of
personal injury and damage to the equipment.
Safety notices in this manual provide important
information. Read and be familiar with these
instructions before attempting installation, operation,
or maintenance. Failure to observe these precautions
could result in serious bodily injury, damage to the
equipment, or operational difficulty.
The safety-alert symbols are illustrated in Figure 2.1.
When you see these symbols in this manual, be alert
to the potential for personal injury. Follow the
recommended precautions and safe operating
practices included with the alert symbols.
"Warning" refers to personal safety. They alert you
to potential danger or harm. Failure to follow
warning notices could result in personal injury or
death.
"Caution" directs attention to general precautions,
which if not followed, could result in personal injury
and/or equipment damage.
"Note" highlights information critical to your
understanding or use of these products.
2.3 CONVENTIONS
To assist you in understanding the material in this
manual, conventions have been established to
enhance reader comprehension. Explanations of
these conventions are as follows:
•Safety warnings, cautions, and notes present
material that is important to user safety. Be sure
to read any safety notices you see as they could
prevent equipment damage, personal injury, or
even death to you or a co-worker.
•Bold text highlights other important information
that is critical to system operations.
WARNING CAUTION NOTE
Figure 2.1. Safety-Alert Symbols
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•CAPITALIZED text stresses attention to the
details of the procedure.
•Underlined text emphasizes crucial words in
sentences that could be misunderstood if the
word is not recognized.
2.3.1 BDS4 vs. BDS4V vs. BDS4A &
PSR4/5 vs. PSR4/5A
The BDS4, BDS4V and the BDS4A differ in
according to the following:
BDS4 Original Standard Configuration
BDS4V Industrial Standard Configuration
BDS4A U.L. 508 Approved Configuration
The BDS4 is the original amplifier developed by
Industrial Drives. It was followed by a value analysis
version, the BDS4V. The BDS4A was later
developed and submitted to UL for approval.
In a similar manner, the PSR4/5 and PSR4/5A follow
this scheme:
PSR4/5 Original Standard Configuration
PSR4/5A UL 508 Approved Configuration
This indicates that the BDS4A and PSR4/5A meet all
the safety standards set by the Underwriter
Laboratories. Where differences occur between
models, special instructions will be indicated in this
manual. For the purpose of referencing all amplifiers
and power supplies, the nomenclatures BDS4 and
PSR4/5 will be used. Check your model number to
verify your model.
2.3.2 Model Numbering Scheme
All Industrial Drives components contain a model and
serial number printed on a black and gold tag on the
front panel. The model number identifies how the
equipment is configured. Refer to Appendix C for
the model number scheme tables. These tables
explain what the model configurations are. You
should verify that the model numbers represent the
equipment desired for your application. Also verify
the compatibily between components of the servo
system.
2.3.3 Abbreviations
CCW Counter Clockwise
CW Clockwise
DIFF CMD Differential Command
D/L Direction Limit
GC Goldline Cable
GCS Goldline Cable Set
LED Light Emitting Diode
NEC National Electrical Code
P/N Part Number
R/D Resolver-to-Digital
Regen Regeneration
TL Test Limits
UL Underwriters Laboratories
2.4 UNPACKING AND INSPECTION
CAUTION
Electronic components in
this amplifier are static
sensitive. Use proper
procedures when handling
component boards.
Upon receipt of the equipment, closely inspect
components to ensure that no damage has occurred in
shipment. If damage is detected, notify the carrier
immediately.
Carefully remove packing material and remove the
equipment from the shipping container. Do not
dispose of shipping materials until the packing list has
been checked. Parts that are contained within the
shipment, but not physically attached to the
equipment, should be verified against the packing list.
If any parts are missing, notify Industrial Drives at
once.
2.5 INSTALLATION REQUIREMENTS
Proper installation and field wiring are of prime
importance when considering the application of servo
amplifiers. Many problems may be avoided if
installation of the equipment is done properly. Users
should familiarize themselves with and follow
installation and wiring instruction in addition to all
applicable codes, laws and standards. Pay special
attention to the following topics when installing
Industrial Drives' equipment.
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