Parker BD-E Series User manual

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IMPORTANT INFORMATION FOR USERS
Installation and Operation of Digiplan Equipment
It is important that Digiplan motion control equipment is installed and operated in such a way that all applicable
safety requirements are met. It is your responsibility as an installer to ensure that you identify the relevant safety
standards and comply with them; failure to do so may result in damage to equipment and personal injury. In
particular, you should study the contents of this user guide carefully before installing or operating the equipment.
Under no circumstances will the suppliers of the equipment be liable for any incidental, consequential or special
damages of any kind whatsoever, including but not limited to lost profits arising from or in any way connected with
the use of the equipment or this user guide.
!
SAFETY WARNING
High-performance motion control equipment is capable of producing rapid movement and very high forces.
Unexpected motion may occur especially during the development of controller programs. KEEP WELL CLEAR of
any machinery driven by stepper or servo motors. Never touch it while it is in operation.
This product is sold as a motion control component to be installed in a complete system using good engineering
practice. Care must be taken to ensure that the product is installed and used in a safe manner according to local
safety laws and regulations.
A permanent mains safety earth connection must be made to the earth terminal on the front of the drive
case before applying mains power.
If the equipment is used in any manner that does not conform to the instructions given in this manual , then the
protection provided by the equipment may be impaired.
EMC INFORMATION
EMC Information is presented in boxed paragraphs (such as this one). Digiplan cannot guarantee compliance
unless guidelines are strictly followed.
The information in this user guide, including any apparatus, methods, techniques, and concepts described herein,
are the proprietary property of Parker Digiplan or its licensors, and may not be copied, disclosed, or used for any
purpose not expressly authorised by the owner thereof.
Since Digiplan constantly strives to improve all of its products, we reserve the right to modify equipment and user
guides without prior notice. No part of this user guide may be reproduced in any form without the prior consent of
Digiplan.
© Digiplan Division of Parker Hannifin plc, 1996
– All Rights Reserved –

The following Warning and Caution labels are fitted to the drive:
WARNING
High voltages remain
after power removed.
Do not remove cover.
No user-serviceable
parts inside.
CAUTION
Hot surface
Do not touch
motor earth
Symbols used on the BD-E series of drives have the following meanings:
Refer to the
accompanying documentation
Risk of electric shock
Hot surface
Protective conductor terminal
Alternating current
Frame or chassis terminal

Product Type: BD150E/230V, BD75E/230V
The above product is in compliance with the requirements of directives
•89/336/EEC Electromagnetic Compatibility Directive
as amended by Directive 92/31/EEC
The product is intended for use in the Commercial, Light Industrial and Industrial
Environments as defined in the relevant EMC standards.
This product is compliant with the Low Voltage Directive.
•73/23/EEC Low Voltage Directive
•93/68/EEC CE Marking Directive

CONTENTS i
CONTENTS
Section 1. INTRODUCTION.......................................................................................1
Section 2. GETTING STARTED .................................................................................5
Section 3. INSTALLATION........................................................................................9
Section 4. HARDWARE REFERENCE........................................................................27
Section 5. MAINTENANCE & TROUBLESHOOTING ....................................................31
Appendix A. ENCODER SETUP................................................................................35
Index.....................................................................................................................41
User Guide Change Summary
The following is a summary of the primary changes to this user guide since the last version was
released.
When a user guide is updated, the new or changed text is differentiated with a change bar in
the outside margin (this paragraph is an example). If an entire chapter is changed, the change
bar is located on the outside margin of the chapter title.
Major changes introduced at revision 03 are:
LVD Compliance

ii BD SERVO DRIVES USER GUIDE

SECTION 1. INTRODUCTION 1
Section 1. INTRODUCTION
Product Description
The BD-E Series of EMC and LVD compliant brushless velocity/torque drives are capable of
operating direct-on-line from a 220-240V AC input, with no isolating transformer. A choice of two
current ratings are available:
BD150E/230V 6A RMS continuous (12A RMS peak)
BD75E/230V 3A RMS continuous (6A RMS peak)
Both drive types have high resolution sinusoidal commutation and have been designed to be
used with three phase brushless servo motors. Control of either velocity or torque is provided via
a ±10V analogue input.
The drives are equipped with multiple protection circuits which guard against output short circuits
and excessive current output over long time periods or at low speed operation. Further circuits
protect against overspeed operation, commutation loss, motor feedback loss, overvoltage,
undervoltage, supply failure and overtemperature faults.
Figure 1-1. BD-E Drive

2 BD SERVO DRIVES USER GUIDE
Product Features
Protection Circuits
Overcurrent Overspeed
Commutation loss Supply failure
Overvoltage Undervoltage
Overtemperature of motor and drive
Function Indicators Adjustments
It Clamp Tachometer gain
Current Limit Balance
Drive Fault Time constant
Overtemperature Damping
HV Present
Outputs and Inputs Other Features
Reset/Disable Power dump
Differential velocity/torque demand input
Fault output
Incremental encoder outputs
Monitor Circuits
Tachometer output
Current level output
Note: Three internally mounted indicators (visible through slots in top of case) are also provided
to allow motor setup. The LEDs are: Overcurrent
Index
Commutation
Controls and Indicators
LEDs
HV Present LED (Green)
This LED indicates that the DC bus voltage is present, but it does not necessarily mean that the
logic supplies are correct.
Warning - Risk of Electric Shock
When power is removed, the drive terminals should not be touched while the
green LED remains alight.

SECTION 1. INTRODUCTION 3
Current Limit LED (Yellow)
Illumination of this LED indicates that the current demand is exceeding the drives maximum
programmed current, and is therefore clamped. For adjustment of the current limit level, see the
current limit bit-switch setting sub-section.
IT Clamp LED (yellow)
The illumination of this LED indicates that the drive has been set to demand too much peak
current for too long a time, causing the current limit to be reduced to 6.8A RMS for the
BD150E/230V (3.4A RMS for the BD75E/230V) to protect the drive.
Overtemperature LED (Red)
Illumination of this LED indicates that either the drive or motor is operating outside its specified
continuous temperature rating, requiring extra cooling to be used or reduction of the operating
duty cycle.
Note: the over temperature LED will also be illuminated by faulty motor feedback connections.
For more information refer to the Maintenance and Troubleshooting Section.
Drive Fault LED (Red)
This LED indicates one of the following fault conditions:
• Overvoltage
• Undervoltage
• Supply failure
• Overcurrent
• Overspeed
For more information refer to the Maintenance and Troubleshooting Section.
HV Present
This LED indicates that a voltage is present on the High Voltage capacitors.
Internal Commutation LEDs
Three diagnostic/set-up LEDs are present within the drive, but can be observed through the
ventilation slots on top of the drive towards the front panel face. From the front panel face the
LEDs are:
Red Overcurrent
Yellow Index
Yellow Commutation

4 BD SERVO DRIVES USER GUIDE
The index LED is illuminated when the index pulse is high and the commutation LED lights when
the A channel of the commutation encoder (Com A+) is high. For more information refer to the
Commutation sub-section. The red overcurrent LED provides greater diagnostic information
under drive fault conditions.
Potentiometers
Balance
This 20 turn potentiometer is used to adjust the balance of the amplifier to give zero motor
current when there is no velocity input demand.
Tach Gain
The level of the velocity feedback is adjusted by this 20 turn potentiometer. For settings see the
Installation section.
Time Constant
The Time Constant single turn potentiometer and associated components determine the
bandwidth of the amplifier. For settings see the Installation section.
Damping
This single turn potentiometer adjusts the response characteristic of the amplifier so that the axis
achieves the demanded velocity without overshoot. For settings see the Installation section.
Bit Switch
All drive options are selected by the front panel bit switch, there are no internal links or
adjustments within the drive.
The bit switch selects the following functions:
Bit Switch Number Function
1, 2 Motor pole number
3 Commutation encoder pull-up selection
4 Encoder resolution
5 Velocity/Torque selection
6 Reset pull-up/pull-down
7, 8 Current limit
Table 1-1. Bit Switch Setting

SECTION 2. GETTING STARTED 5
Section 2. GETTING STARTED
What You Should Have
Upon receipt, you should inspect your BD-E Series Drive system for obvious damage to its
container. Report any damage as soon as possible. The items listed in Table 2-1 should be
present and in good condition. To verify that you have the proper drive model, check the model
number listed on the drive serial plate.
Ship Kit Table Part Description Part Number
BD-E Drive See drive identification below
BD User Guide 1600.208.XX
Cable Set BDCXXXX
Where XXXX specifies cable
length, for example BDC1500
specifies a 15 metre cable set.
Table 2-1. BD-E Drive Ship Kit
Systems may be shipped configured with drives and motors prewired or supplied as separate units.
Identification
Drive Identification
A typical part number may be given as:
E = EMC compliant
/230 = 230V AC input
150 = 1.5kW drive
75 = 0.75kW drive
BD = drive with ±10Vanalogue input
BD150E/230V
Figure 2-1. Drive Identification
Warning - risk of electric shock
If the drive mains earth becomes disconnected, the case and signal I/O lines will become
live at 120V AC (limited to 10mA), due to the filter required for EMC compliance.

6 BD SERVO DRIVES USER GUIDE
Pre-installation Test
This section provides procedures to help you to connect up your BD drive system for a pre-
installation test. Please note the pre-installation test allows you to become familiar with the
operation of the drive prior to permanent installation, it should only be set up and used by
competent personnel familiar with installation of motion control equipment. The safety earth
connection must be made as shown to minimise the risk of electric shock.
Figure 2-2 illustrates the pre-installation test configuration for systems operating from a 230V
mains supply. Please note the following points:
• The motor should be securely clamped to the test bench before any power is supplied.
MOTOR
FEEDBACK
MOTOR ENCODER
MAINS INPUT
EMERGENCY
STOP
SAFETY
EARTH
LIVE
NEUTRAL
EARTH
DRIVE
I/O
L
N
Figure 2-2. Pre-installation Test Configuration

SECTION 2. GETTING STARTED 7
1. Connect the Motor
WARNING - Electric Shock Hazard
Ensure that AC power is disconnected before attempting to connect or
disconnect the motor. Lethal voltages are present on the motor connectors.
Insert the plugs on the motor and encoder cables securely into the mating connectors on the
motor housing and ensure that the locking rings are tight. Fit the drive end connectors to the
corresponding sockets, ensuring that the motor cable screen is anchored under the P-clip (see
Fig 2-2). Connect the motor safety earth as shown using 2.5mm2wire.
2. Connecting to an AC Supply
The BD-E Series of drives operate direct-on-line from a 220-240V AC input, with no isolating
transformer. Please note that the safety earth connection is necessary to provide a return path
for the leakage current flowing through line-to-earth capacitors fitted on the internal filter board.
The AC input is connected directly to the front panel screw connectors, as shown in Figure 2-2.
Testing the BD System
1. Set the drive potentiometers as follows:
TIME CONSTANT Fully CCW
DAMPING Fully CCW
TACH GAIN Fully CW
2. The 8 bit switch is set to configure the drive for use with a particular motor/encoder
combination. Set the 8 bit switch as follows:
Motor pole numbers
Pole number Switch 1 Switch 2
6 OFF OFF
Commutation encoder pull-up voltage
Encoder pulled up to Switch 3
+5V ON
Encoder resolution setting
Encoder resolution Switch 4
1024 OFF
Note: Digiplan 3.4 inch motors have 1024 line encoders fitted.

8 BD SERVO DRIVES USER GUIDE
The velocity/torque bit switch 5 should be set to OFF (velocity amplifier).
Bit switch 6 should be set to OFF, to de-energise the drive. When a link or switch is fitted
between pins 5 and 6 of the Drive I/O Connector as shown in Figure 2-2, the drive will be
energised. This provides a failsafe solution.
Note: a connection must be made between pins 5 and 6 of the Drive I/O
connector to enable the drive.
Bit switches 7 and 8 should be both set to ON to minimise the motor current whilst setting up the
drive.
3. Make sure that the motor is held securely and that the shaft is free to rotate.
4. Turn on the main AC supply.
5. Rotate the Balance control until the motor shaft remains stationary. Rotating the Balance
control CW should cause the motor to rotate CW and therefore, rotating CCW should cause the
motor to rotate CCW.
6. Motor rotation confirms that the drive is operating correctly. If the motor fails to rotate, re-
check all connections and bit switch settings. If you do not discover the cause of the problem
refer to the
Maintenance & Troubleshooting section.

SECTION 3. INSTALLATION 9
Section 3. INSTALLATION
Precautions
During installation,take the normal precautions against damage caused by electrostatic
discharges. Earthed wrist straps should always be worn.
Environment
The drive system should be installed vertically in an area where there is at least a 50mm air gap
all around the package. The distance required is, however, application dependent, and may vary
according to the amount of heat generated by equipment mounted below the drive and by the
drive itself. An integral fan draws air into the base of the drive and expells it through vents in the
top panel. The ambient temperature must not be allowed to exceed 40°C if an operator has
access to the case, or 50°C if operator access is not allowed.
The drive requires a mains supply of Installation Category II and can be used in an atmosphere
of Pollution Degree 2. Humidity limits are 0-95% non-condensing.
Drive Dimensions
All BD drives are supplied as packaged units. Figure 3-1 shows the overall dimensions of the
drive and the distance required between mounting holes.
241
25
65
126
Fixing
centres
283
(for M6
screws)
298
252 Side view,
all models
Front
view,
BD75E,
BD150E
Figure 3-1. Drive Dimensions
Note: The dimensions given above do not allow for the room occupied by interface connectors.
CAUTION - Under certain operating conditions the top of the case may reach
temperatures in excess of 70°C.

10 BD SERVO DRIVES USER GUIDE
Drive Signal Connections
Pin 1
MOTOR
FEEDBACK
USER I/O
Pin 15
Pin 9
Pin 8
Pin 1
Pin 13
Pin 14
Pin 25
BIT
SWITCH 1
8
ON
HV present
Damping
Time constant
Tach gain
Balance
It Clamp
Current Limit
Drive Fault
Overtemperature
L
N
Figure 3-2. Connectors and Indicators

SECTION 3. INSTALLATION 11
User I/O Connector
User I/O Connector
Pin Functions Pin Signal Name Function
1V2 ±10V Analogue input
2V1 ±10V Analogue input
3 -15v Reference voltage
(current limited)
4 GND Ground
5RST *Reset
6 +15V Reference voltage
(current limited)
7 Tach Out Tachometer monitor
output
8 Curr. Level Out Current monitor
output
9FT Fault
10 **A+ A output from
incremental encoder
11 A- A output
12 B+ B output from
incremental encoder
13 B- B output
14 ***I+ Z output from
incremental encoder
15 I- Z output
* 0V holds drive in permanent reset condition. 15V allows drive to energise.
** A+ leads B+ for CW motor rotation
*** I+ is a once-per-rev high-going pulse, covering at least 1
4of a channel A+ cycle
and occuring when A+ and B+ are both high - see below:

12 BD SERVO DRIVES USER GUIDE
A+
B+
I+
Table 3-1. User I/O Connector Pin Functions
User I/O Pin Description
The User I/O connector provides access to the main drive control signals. The function of each
pin is described below.
Pin 1 (V2) & Pin 2 (V1)
Input pins 1 and 2 can act as differential analogue torque or velocity inputs, depending upon the
state of bit switch 5. The input impedance to ground of both of these inputs is 30K.
In torque mode (bit switch 5 ON), 10V between V1 and V2 will produce maximum current, but
you may restrict this by the setting of bit switches 7 and 8.
In velocity mode, ±10V between V1 and V2 will produce a speed of 2500 rpm (using an MD 34-
sized motor). These speeds assume the Tach Gain potentiometer is fully CW. You may
increase these speeds by turning the Tach Gain potentiometer CCW.
When V1 is positive with respect to V2, the motor will rotate CW in both torque and velocity
mode.
Pin 3 (-15V) & Pin 6 (+15V)
Pins 3 (-15V) & 6 (+15V) are current limited supplies (10mA max.) intended for use with Reset
and analogue demand inputs.
If bit switch 6 is OFF, the Reset input will need to be pulled up to pin 6 to energise the drive,
using a switch or PNP transistor. This will draw a current of 1mA from the +15V output.
If you require a manually adjustable velocity demand, a 50k ohm potentiometer can be
connected between pins 3 and 6, with the slider connected to pin 2 and pin 1 connected to pin 4.
This wiring configuration will also draw 1mA from the +15V and -15V outputs.
Pin 4 0V

SECTION 3. INSTALLATION 13
Pin 4 is drive ground and is linked to mains earth via a high frequency filter.
Pin 5 Reset
Pin 5 is the reset input, when the input is low, the drive is de-energised. Any latched faults
remain latched while the input is low and are reset on the high-going edge.
The reset input can be configured by bit switch 6. If bit switch 6 is OFF and the reset input is
open circuit, this input is pulled down to 0V via a 15k ohms resistor and the drive is de-energised.
To energised the drive, the reset input must be connected to +15V (pin 6 of the the user I/O
connector) via a switch or a PNP transistor.
Note: this is the 'fail safe' configuration.
Note: When bit switch 6 is OFF a connection must be made between pins 5 and 6 of the
Drive I/O connector to enable the drive.
If bit switch 6 is ON and the reset input is open circuit, the reset input is pulled up to +15V using
a 15k ohm resistor and the drive is energised. To de-energise the drive you will need to connect
this input to 0V (pin 4 of the user I/O connector).
Pin 7 Tach Output
Pin 7 is the internally buffered tachometer output. The output produces a signal of approximately
2V/krpm independent of line count. The output polarity is positive for CW motor rotation. This
output is not intended for accurate speed calibration, but for use when setting up the drive.
Pin 8 Current Monitor
Pin 8 is a unipolar current monitor signal used to indicate the total motor current with a sensitivity
of 2A/V for the BD150 (1A/V for the BD75). This output is not intended for accurate current
calibration, but for use when setting up the drive.
Note: the output represents a rectified summation of the 3 actual motor phase currents
thus, even when delivering a constant torque, the signal will contain approximately 13%
ripple at low shaft speeds.

14 BD SERVO DRIVES USER GUIDE
Pin 9 Fault Output
Pin 9 is an open collector fault output signal which goes low when a fault occurs. The output can
be pulled up to a maximum voltage of +28V, and the output transistor can pass a maximum
current of 25mA.
Pin 10 to 15 Encoder Outputs
Pins 10 to 15 are buffered encoder outputs using 26LS31 line drivers. Use twisted pair screened
cable and 26LS32 line receivers or optos.
Note: Particular care should be paid to these outputs to prevent EMC radiation problems. When
using line receivers - connect the screen to earth at both ends of the cable. In this configuration
the drive and controller should be mounted close together sharing the same ground plane.
For opto receivers - connect the screen to earth at the drive end only.
CAUTION - Avoid turning the Tach Gain potentiometer
fully CCW in velocity mode. This will result in the motor
running at maximum speed regardless of the input voltage.