StepperOnline BLD-550S User manual

User Manual
BLD-550S
Brushless DC Motor Driver
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Support: [e-mail]
Read the operating instructions carefully before putting the driver into operation with power

BLD-405S BLDC Brushless Driver
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Introduction
BLD-550S motor driver is a closed-loop speed controller and employs IGBT and MOS power devices. It utilizes the Hall
signals of the DC brushless motor after frequency multiplication to achieve closed-loop speed control. The control loop
has a PID speed regulator, making the system control stable and reliable. Especially at low speeds, it can always reach the
maximum torque. The speed control range is from 150 to 20,000 rpm.
1. Features
PID speed and current dual-loop regulator
High performance at a low price
20kHz PWM frequency
Electrical brake function to enable rapid motor response
Overload factor greater than 2, enabling maximum torque at low speed
Fault alarm functions for overvoltage, under-voltage, over-current, over-temperature, peak current, and Hall signals
Compatible with Hallless drive, it can be used as a brushless Hallless drive alone
2. Specifications
2.1 Electrical Specification
Input voltage 24VDC 36VDC 48VDC
Continuous Output Current 50A 40A 30A
Peak Output Current 75A/3S 75A/3S 75A/3S
2.2 Safety Precautions
* Do not measuring or touch any components without housing while operating
* Board inspection or fuse replacement can only be carried out after 1 minute of power off
* Operating without housing is forbidden
* Make sure to connect the ground well, otherwise the brushless motor will working unsteadily
* Should the driver be accidentally damaged during operation, our company is only responsible for the repair and
replacement of the driver within the warranty scope. Our company does not assume any liability for compensation for
motor damage, personal injury, property damage, or any other losses caused by the accidental failure of the driver

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3. Terminal and Signal
3.1 Control Interface
No. Terminal Name Description
8 COM COM terminal
7 F/R CW/CCW terminal
6 EN Stop/Start terminal
5 BK Brake terminal
4 SV Analogy signal input terminal
3 PG Speed output terminal
2 ALARM Alarm output terminal
1 +5V +5V power output terminal
3.2 Hall Signal Terminal
No. Name Description
1 GND Hall sensor Negative
2 HA Hall sensor A phase
3 HB Hall sensor B phase
4 HC Hall sensor C phase
5 +5V Hall sensor Positive
3.3 Motor Connection Terminal
No. Name Description
1 DC+ DC+
2 DC- DC-
3 FG For the Ground
4 U BLDC winding U phase(A)
5 V BLDC winding U phase(B)
6 W BLDC winding U phase(C)
3.4 Control Signal
No. Terminal Name Description
1 GND Signal ground
2 F/R CW/CCW terminal
3 EN Stop/Start terminal
4 BK Brake terminal
5 SV Analogy signal input terminal
6 PG Speed output terminal
7 ALM Alarm output terminal
8 +5V +5V power output terminal
GND: Signal ground
F/R: Forward/Reverse control. To reverse the motor, connect it to GND and do not connect it to switch it in the forward
direction. When switching between forward and reverse, the EN should be turned off first.
EN: When EN is connected to GND, the motor rotates (online state). When EN is not connected, the motor does not rotate
(offline state).

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SV: External speed attenuation: It can be attenuated from 0 to 100%. When the external speed command is connected to
5V, the speed can be adjusted through this potentiometer.
+5V: Speed control voltage output, which can be continuously adjusted by the potentiometer on SV and GND.
Wiring diagram of the driver and the brushless motor:
Dimension: 86x55x21mm

BLD-405S BLDC Brushless Driver
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4. Mechanical Specification
(Unit: mm [1inch=25.4mm])
5. Functions and Usage
5.1 Speed Adjustment Method
5.1.1 Internal potentiometer speed regulation: Rotate the potentiometer on the driver panel counterclockwise to reduce
the motor speed, and clockwise to increase the speed.
When the user uses external input to adjust the speed, the potentiometer must be set to the minimum state.
External input speed regulation Connect the two fixed terminals of the external potentiometer to the GND and +5v
terminals of the driver respectively, and connect the adjustable terminal
Connect to the SV terminal to use an external potentiometer (5K~100K) to adjust the speed, or use other control units
(such as PLC, single-chip microcomputer) to adjust the speed.
etc.) Input the analog voltage to the SV terminal to realize speed regulation (relative to GND), the acceptance range of the
SV port is DC OV~+5V, corresponding to
The motor speed is 0~rated speed.
5.1.2 External digital signal speed regulation: the amplitude of 5V can be applied between SV and GND, and the frequency
is 1KHz~2KHz
The pulse width digital signal (PWM) is used for speed regulation, and the motor speed is linearly adjusted by its duty cycle.
At this time, you can adjust the R-SV voltage

BLD-405S BLDC Brushless Driver
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The potentiometer performs 0~1.0 ratio attenuation processing on the amplitude of the SV digital signal. Generally, the
R-SV is adjusted to 1.0, and the SV input data
Word signals are not attenuated.
5.2 Motor Operate/Stop Control (EN)
By controlling the on/off state of the EN terminal relative to GND, the operation and stop of the motor can be controlled.
When the terminal is connected, the motor runs, and vice versa, the motor stops. When the motor is stopped by using the
run/stop terminal, it will come to a natural stop, and its motion characteristics are related to the load inertia.
5.3 Motor Rotation Direction Control (F/R)
The direction of the motor can be controlled by connecting or disconnecting terminal F/R and terminal GND. When F/R is
not connected to terminal GND, the motor runs clockwise (facing the motor shaft) and vice versa for counterclockwise
rotation.
Attention: To avoid damage to the driver when changing the motor direction, the motor should be stopped before the
direction changing to avoid performing direction operations while the motor is running.
5.4 Braking Stop (BK)
The braking stop of the motor can be controlled by the connection of control terminal BK to terminal GND. When control
terminal BK is disconnected from terminal GND, the motor runs, when it is switched on the motor quickly brakes to a stop,
braking stop is faster than natural stop, the specific stopping time is related to the load inertia of the user's system.
Attention: As the brake stop has a bad impact on both the electrical and the mechanical, a natural stop should be used if
there are no special stopping requirements.
5.5 Motor Speed Signal Output (PG)
The speed pulse output is a 5V pulse output, to obtain the signal a pull-up resistor of 3K ohm ~10K ohm should be
connected to the power supply. The number of output pulses per revolution of the motor is 3 x N, N being the number of
pairs of poles of the motor. For example: 2 pairs of poles, i.e. a four-pole motor, 6 pulses per revolution. When the motor
speed is 500 rpm, the output pulse of the terminal PG is 3000.
5.6 Alarm Output (ALM)
Alarm output of the driver: this terminal is low during an alarm. To obtain a signal, a pull-up resistor of 3K ohm to 10K ohm
should be connected to the power supply. When the alarm is on, this terminal is connected to GND (low level) and the
driver stops itself and is in alarm.
5.7 Driver Failure
When there is over-voltage or over-current inside the drive, the drive will enter a protection state, automatically stop
working, the motor will stop, and the blue light on the drive will go out. To clear the alarm, the enable terminal (that is,
disconnecting EN and GND) or power must be disconnected. If this fault occurs, please check the motor wiring or motor
load.

BLD-405S BLDC Brushless Driver
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6. Display and Keyboard Operation
Remark: "SET": Start/stop, (backspace)
"△": "+", Plus 1
"▽": "+", Minus 1
"ENT": "ENTER" （Recall setting parameter)
6.1 System Parameter Setting
Please ensure that the motor is under the stop situation when setting the parameter. That is, in the case of panel mode,
the motor is in the stop state or an external port mode, the motor is enabled to disconnect.
6.1.1 In standby mode, press the "ENTER" key to call up the system parameters, and then press ENTER again to call up the
setting value of the system parameters.
6.1.2 Use the "△" or "▽" keys to navigate to the parameter you want to modify. If you do not want to modify it, press the
"SET" key to exit the setting and return to standby mode.
6.1.3 Press "ENTER" to see the parameter content. If you do not want to modify it, press the "SET" key to exit the setting
and return to standby mode.
6.1.4 Use the "△" or "▽" keys to adjust the parameter value you want to modify.
6.1.5 Press the "ENTER" key to store the parameters and press the SET key to return to standby mode.
Note: In the setting state, if no key is pressed for one minute, it will automatically jump to the speed display interface.
6.2 Working Mode
There are two working modes for the driver, which can be set through the panel. One is the panel working mode, and the
other is the external port working mode. The motor operates according to the set mode, and the digital display shows the
motor's rotational speed. In panel working mode, press the SET key to start or stop the motor. Press and hold the △and
▽keys to increase or decrease the motor speed, and press the ENTER key to confirm the motor speed. The motor runs at
the set speed.
6.3 Protect Mode
While Motor operates abnormally, display will show Err×:

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Err-01 Stall
Err-02 Over Current
Err-04 Hall Fault
Err-05 Stall and Hall Fault
Err-08 Under-Voltage
Err-10 Over-Voltage
Err-20 Peak Current Alarm
Err-40 Temperature Alarm
6.4 Drives Parameter Setting
P00X:Operating Parameter
Code Name Setting Range Unit Default Value Change
P000 Control Mode 00 External port mode
18 Panel control mode
00
External Port
Mode
P001 Pair of Pole 1~255 Pair 2 o
P002 Rated Speed 1~65535
(external port mode effective) RPM 3000 o
P003 Display mode 00: Speed Display 00 o
P004 Starting torque 1~255 16 o
P005 Initial Speed w/o
Sensor Start 1~255 04 o
P006 Acceleration Time 1~255 0.1S 0 o
P007 Deceleration Time 1~255 0.1S 0 o
P008 Current Setting 1~255 44
P009 Temperature Alarm 1~255 34
P010 Panel Speed Setting 0~65535
Only external port mode effective RPM 2000
P011 Brake Force 0~1023 1023
P012 Site Address 0~250 1
P013 Reserved
P014 Current Adjusting
Parameter 0~FF Hexadec imal 3A

BLD-405S BLDC Brushless Driver
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P015 Reserved
P016 Reserved
7. System Usage
First, connect the motor and driver wires (motor winding wires, Hall signal wires, and power wires) strictly according to the
requirements. Brushless motors cannot achieve forward and reverse rotation by changing the wiring like asynchronous
motors. Incorrect wiring can cause abnormal motor operation or no operation at all. The main manifestations are that the
brushless motor vibrates or heats up quickly (within tens of seconds to two minutes, and the temperature rises to 80
degrees), and it can damage the motor and driver.
After connecting the motor winding wires, Hall wires, and driver power wires, you can try to run it. First, adjust the
potentiometer to the minimum, then press the start switch and slightly increase the motor potentiometer. The motor
should run. If the motor does not run or vibrates, it may be due to the wrong phase sequence of the motor wires. Please
recheck the order of the brushless motor leads until the motor can run normally. Then, stop the motor.
8. Communication Node
This communication model is used standard Mod bus protocol, implement national standards GB/T 19582.1
- 2008. It is using RS485 two-wire serial link communication, Physical interface uses two 3.81mm spacing 3
core Phoenix terminals, serial connection is very convenient. Transmission mode is RTU, testing mode is
CRC, CRC start word is FFFFH. Data mode is 8 bit asynchronous serial, 1 is stop bit, without invalid bit.
Currently there is only one communication speed 9600bps.
No. Address Parameter name Setting range Default unit Remark
00 $8000 First byte: control bit state
Second byte: Hall angle and
number of pole pairs of motors
First byte:
Bit0: EN
Bit1: FR
Bit2: BK
Bit3: NW1
Bit4: NW
Bit5: KHX
Bit6: HR60
Second byte:
Bit0-7: number of
pole pairs 1-255
00H
02H
01 $8001 The maximum rotational speed
of analogue speed regulation
0-65535 3000 Rpm
02 $8002 First byte: start torque
Second byte: sensorless start
speed
1-255
1-255
10H
04H
03 $8003 First byte: acceleration time
Second byte: deceleration time
1-255 10
10
0.1s
04 $8004 First byte: Maximum current 35H 144

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Addresses 8000H—8017H are read and write registers
Addresses 8018H-801FH are read-only registers
Other addresses are illegal
8000: first byte:
EN: when NW=0, 0: external EN low level effective 1: external EN high level effective
when NW=1, 0: EN ineffective 1: EN effective
FR: when NW=0, 0: FR low level effective 1: external FR high level effective
when NW=1, 0: FR ineffective 1: FR effective
The second byte: temperature
alarm point 30FH
corresponds to
13A
15 Have a
feeling
16 No feeling
05 $8005 External speed setting 0-65535 2000 RPM
06 $8006 Braking force 0-1023 1023
07 $8007 First byte: site address
Second byte: reserve
1-250 1
0
08-0F $8010-$8017 Reserved
10-17 $8010-$8017 Reserved
18 $8018 Actual motor speed
19 $8019 First byte: bus voltage
The second byte: bus current
Invalid
1A $801A First byte: control port status
Second byte: the analog port
value
Bit0: SW1
Bit1: SW2
Bit2: SW3
Bit3: SW4
Invalid
1B $801B First byte: the fault status
The second byte: Motor running
state
Bit0: stall
Bit1: over current
Bit2: hall
abnormality
Bit3: low bus
voltage
Bit4: over bus
voltage
Bit5: peak
current alarm
Bit6:
temperature
alarm
Bit7: Reserved
1C $801C-$801F Reserved
20 Over $8020 illegal

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BK: when NW=0, 0: external BK low level effective 1: external BK high level effective
when NW=1, 0: BK ineffective 1: BK effective
NW1: 0: Control terminal external effective(EN,FR,BK) 1: Internal effective
NW: 0: Speed external effective 1: Speed internal effective (under panel speed
adjusting mode, PWN speed adjusting mode and segmental speed adjusting mode, it must set to1)
KH: 0: Closed loop control 1: Open loop control
KHX: 0: Stall alarm 1: No alarm
Stall alarm under the open loop w/ sense mode.
HR60: 0: 120° hall control 1: 60° hall control (temporarily not supported)
For Example:
1. Write 1500 Speed:
01 06 80 05 DC 05 28 C8
2. Write 2 pair of poles EN start:
01 06 80 00 19 02 2A 5B
3. Write EN stop:
01 06 80 00 18 02 2B CB
4. Write brake:
01 06 80 00 1D 02 28 9B
5. Checking the fault state:
01 03 80 1b 00 01 DD CD
6. 01 06 80 00 19 02 2A 5B EN start 2 pair of poles
7. 01 06 80 05 D0 07 AC 09 Write 2000
8. 01 06 80 05 E8 03 BE 0A Write 1000
9. 01 06 80 00 18 02 2B CB EN stop
10. 01 06 80 00 19 01 6A 5A 1 pair of poles EN start
The write message is explained as follows:
Message Explain
01 Address
10 Function code
00 1B Start address register
00 05 The numbers of register
0A Total byte digits
02 58 Write the first register data
02 58 Write the second register data
00 F0 Write the third register data
00 03 Write the fourth register data
0D 40 Write the fifth register data
CD 83 CRC testing (from the address to the fifth register data)

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The successful feedback message is explained as follows:
Message 01 10 11 1B 00 05 70 0D
Explain Address Function Code The start register
address
The wrote
Register number CRC testing code
9. Communication Wires Connection
RS-485 communication can be carried out through a regular 3-pin 2.54 wiring port.
The pin definitions of a regular 3-pin 2.54 wiring port are as follows:
Pin Function
8 GND
6 A+
3 B-