BSC Series 1000/1100 Servo Control for Brushless AC Motors Installation & Operating Manual 7/01 MN1202 Table of Contents
Section 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receiving & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dynamic Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24VDC Logic Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resolver Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simulated Encoder Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X2 Control I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 4 Switch Setting and Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Potentiometer Initial Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identity Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start­up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Off Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power On Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 1-2 1-2 2-1 3-1 3-1 3-1 3-1 3-2 3-2 3-3 3-3 3-4 3-6 3-7 3-7 3-7 3-7 3-8 3-8 3-9 4-1 4-1 4-1 4-1 4-2 4-3 4-3 4-3 4-4 MN1202 Table of Contents i Section 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BPS Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Noise Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6 Specifications and Product Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions & Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 7 CE Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CE Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMC ­ Conformity and CE ­ Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMC Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 5-1 5-2 6-1 6-1 6-2 6-4 7-1 7-1 7-1 7-3 ii Table of Contents MN1202 Section 1 General Information
Copyright Baldor 1997, 1999, 2000, 2001. All rights reserved. This manual is copyrighted and all rights are reserved. This document may not, in whole or in part, be copied or reproduced in any form without the prior written consent of Baldor. Baldor makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of fitness for any particular purpose. The information in this document is subject to change without notice. Baldor assumes no responsibility for any errors that may appear in this document. Microsoft and MS­DOS are registered trademarks, and Windows is a trademark of Microsoft Corporation. UL and cUL are registered trademarks of Underwriters Laboratories. CE Compliance
A custom unit may be required, contact Baldor. Compliance to Directive 89/336/EEC is the responsibility of the system integrator. A control, motor and all system components must have proper shielding, grounding, and filtering as described in MN1383. Please refer to MN1383 for installation techniques for CE compliance. For additional information, refer to Sections 3 and 7 of this manual. Limited Warranty
For a period of two (2) years from the date of original purchase, BALDOR will repair or replace without charge controls and accessories which our examination proves to be defective in material or workmanship. This warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused, or improperly installed and has been used in accordance with the instructions and/or ratings supplied. This warranty is in lieu of any other warranty or guarantee expressed or implied. BALDOR shall not be held responsible for any expense (including installation and removal), inconvenience, or consequential damage, including injury to any person or property caused by items of our manufacture or sale. (Some states do not allow exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply.) In any event, BALDOR's total liability, under all circumstances, shall not exceed the full purchase price of the control. Claims for purchase price refunds, repairs, or replacements must be referred to BALDOR with all pertinent data as to the defect, the date purchased, the task performed by the control, and the problem encountered. No liability is assumed for expendable items such as fuses. Goods may be returned only with written notification including a BALDOR Return Authorization Number and any return shipments must be prepaid. MN1202 General Information 1-1 Product Notice Intended use: These drives are intended for use in stationary ground based applications in industrial power installations according to the standards EN60204 and VDE0160. They are designed for machine applications that require variable speed controlled three phase brushless AC motors. These drives are not intended for use in applications such as: ­ ­ ­ ­ ­ Home appliances Medical instrumentation Mobile vehicles Ships Airplanes Unless otherwise specified, this drive is intended for installation in a suitable enclosure. The enclosure must protect the control from exposure to excessive or corrosive moisture, dust and dirt or abnormal ambient temperatures. The exact operating specifications are found in Section 6 of this manual. The installation, connection and control of drives is a skilled operation, disassembly or repair must not be attempted. In the event that a control fails to operate correctly, contact the place of purchase for return instructions. Safety Notice: This equipment contains high voltages. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the start­up procedure or troubleshoot this equipment. This equipment may be connected to other machines that have rotating parts or parts that are driven by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the start­up procedure or troubleshoot this equipment. ­ ­ ­ ­ System documentation must be available at all times. Keep non-qualified personnel at a safe distance from this equipment. Only qualified personnel familiar with the safe installation, operation and maintenance of this device should attempt start-up or operating procedures. Always remove power before making or removing any connections to this control. PRECAUTIONS: WARNING: Caution: Classifications of cautionary statements. Indicates a potentially hazardous situation which, if not avoided, could result in injury or death. Indicates a potentially hazardous situation which, if not avoided, could result in damage to property. Continued on next page. 1-2 General Information MN1202 WARNING: Do not touch any circuit board, power device or electrical connection before you first ensure that power has been disconnected and there is no high voltage present from this equipment or other equipment to which it is connected. Electrical shock can cause serious or fatal injury. Be sure that you are completely familiar with the safe operation of this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Be sure all wiring complies with the National Electrical Code and all regional and local codes or CE Compliance. Improper wiring may cause a hazardous condition. Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that grounds are connected. Electrical shock can cause serious or fatal injury. Do not remove cover for at least five (5) minutes after AC power is disconnected to allow capacitors to discharge. Electrical shock can cause serious or fatal injury. Improper operation of control may cause violent motion of the motor shaft and driven equipment. Be certain that unexpected motor shaft movement will not cause injury to personnel or damage to equipment. Peak torque of several times the rated motor torque can occur during control failure. Motor circuit may have high voltage present whenever AC power is applied, even when motor is not rotating. Electrical shock can cause serious or fatal injury. If a motor is driven mechanically, it may generate hazardous voltages that are conducted to its power input terminals. The enclosure must be grounded to prevent a possible shock hazard. When operating a motor with no load coupled to its shaft, remove the shaft key to prevent injury if it were to fly out when the shaft rotates. The motor shaft will rotate during the autotune procedure. Be certain that unexpected motor shaft movement will not cause injury to personnel or damage to equipment. A DB Resistor may generate enough heat to ignite combustible materials. To avoid fire hazard, keep all combustible materials and flammable vapors away from brake resistors. The user must provide an external hard-wired emergency stop circuit to disable the control in the event of an emergency. Suitable for use on a circuit capable of delivering not more than the RMS symmetrical short circuit amperes listed here at rated voltage. Horsepower RMS Symmetrical Amperes 1­50 5,000 To prevent equipment damage, be certain that the input power has correctly sized protective devices installed as well as a power disconnect. Continued on next page. WARNING: WARNING: WARNING: WARNING: WARNING: WARNING: WARNING: WARNING: WARNING: WARNING: WARNING: Caution: Caution: MN1202 General Information 1-3 Caution: Caution: Caution: Caution: Caution: Caution: Caution: Caution: Caution: Caution: Caution: Caution: Caution: Caution: Avoid locating control immediately above or beside heat generating equipment, or directly below water or steam pipes. Avoid locating control in the vicinity of corrosive substances or vapors, metal particles and dust. For UL installations, do not connect any resolver cable shields to the motor frame. At a minimum, resolver signal integrity will be compromised and damage to the control may result. For CE installations, refer to CE guidelines stated in Sections 3 and 7 of this manual. Do not connect AC power to the control terminals U, V and W. Connecting AC power to these terminals may result in damage to the control. Baldor recommends not using "Grounded Leg Delta" transformer power leads that may create ground loops and degrade system performance. Instead, we recommend using a four wire Wye. Logic signals are interruptible signals; these signals are removed when power is removed from the drive. Controls are intended to be connected to a permanent main power source, not a portable power source. Suitable fusing and circuit protection devices are required. The safe integration of the drive into a machine system is the responsibility of the machine designer. Be sure to comply with the local safety requirements at the place where the machine is to be used. In Europe this is the Machinery Directive, the ElectroMagnetic Compatibility Directive and the Low Voltage Directive. In the United States this is the National Electrical code and local codes. Controls must be installed inside an electrical cabinet that provides environmental control and protection. Installation information for the drive is provided in this manual. Motors and controlling devices that connect to the drive should have specifications compatible to the drive. Violent jamming (stopping) of the motor shaft during operation may damage the motor and control. Do not tin (solder) exposed wires. Solder contracts over time and may cause loose connections. Electrical components can be damaged by static electricity. Use ESD (electro-static discharge) procedures when handling this control. Ensure that resolver or encoder wires are properly connected. Incorrect installation may result in improper rotation or incorrect commutation. The holes in the top and bottom of the enclosure are for cable clamps. Be sure to use an M4 bolt 12mm in length. Longer bolts may short circuit the electrical components inside the control. 1-4 General Information MN1202 Section 2 Product Overview
Overview Motors The BSC product is designed to serve the needs of machine designers and manufacturers. Baldor products have both UL and CE approvals. Baldor servo controls are compatible with many motors from Baldor and other manufacturers. Motor parameters are provided with the PC software making the setup easy. Baldor compatible motors include: S S S
General Information BSM­4R / 63A / 80A / 80B Series motors BSM­6R Series motors BSM­4F / 6F / 8F / 90A / 90B Series motors The BSC1000/1100 is a resolver based servo control designed to be used with brushless servo motors. The control accepts a standard ±10 VDC to control brushless servo motors in either a velocity or current (torque) loop. The standard BSC 1100 series includes an internal power supply; the standard BSC 1000 series requires an external supply. Physically, the two units are identical. MN1202 Product Overview 2-1 2-2 Product Overview MN1202 Section 3 Installation
Receiving & Inspection
Baldor Controls are thoroughly tested at the factory and carefully packaged for shipment. When you receive your control, there are several things you should do immediately. 1. 2. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your control. Remove the control from the shipping container and remove all packing materials. The container and packing materials may be retained for future shipment. Verify that the part number of the control you received is the same as the part number listed on your purchase order. Inspect the control for external physical damage that may have been sustained during shipment and report any damage immediately to the commercial carrier that delivered your control. If the control is to be stored for several weeks before use, be sure that it is stored in a location that conforms to published storage humidity and temperature specifications stated in this manual. 3. 4. 5. Location Considerations The location of the control is important. Installation should be in an area that is protected from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and vibration. Exposure to these can reduce the operating life and degrade performance of the control. Several other factors should be carefully evaluated when selecting a location for installation: 1. 2. 3. For effective cooling and maintenance, the control should be mounted on a smooth, non-flammable vertical surface. At least 0.6 inches (15mm) top and bottom clearance must be provided for air flow. Refer to Section 6 for mounting dimensions. Altitude derating. Up to 3300 feet (1000 meters) no derating required. Derate the continuous and peak output current by 1.1% for each 330 feet (100 meters) above 3300 feet. Temperature derating. From 5°C to 45°C ambient no derating required. Above 45°C, derate the continuous and peak output current by 2.9% per °C above 45°C. Maximum ambient is 55°C. 4. Mechanical Installation Mount the control to the mounting surface. The control must be securely fastened to the mounting surface by the control mounting holes. The location of the mounting holes is shown in Section 6 of this manual. Power Loss Ratings
Control Type Power Loss (Watts) (For BSC11XX units, add 55Watts) 1002 19 1005 19 1010 54 1015 85 MN1202 Installation 3-1 Electrical Installation All interconnection wires between the control, AC power source, motor, host control and any
operator interface stations should be in metal conduits. Use listed closed loop connectors that are of appropriate size for wire gauge being used. Connectors are to be installed using crimp tool specified by the manufacturer of the connector. Only class 1 wiring should be used. System Grounding Baldor controls are designed to be powered from standard single and three phase lines that are electrically symmetrical with respect to ground. System grounding is an important step in the overall installation to prevent problems. The recommended grounding method is shown in Figure 3-1 for UL compliant systems (Figure 3-2 for CE compliant systems). Figure 3-1 Recommended System Grounding (3 phase) for UL
L1 AC Main Supply L2 L3 Safety Ground Driven Earth Ground Rod (Plant Ground) Earth Four Wire "Wye" Route all power wires L1, L2, L3 and Earth (Ground) together in conduit or cable. Control
L1 L2 L3 PE U V W Note: Wiring shown for clarity of grounding method only. Not representative of actual terminal block location. Note: Use shielded cable for control signal wires. Route control signal wires in conduit. These wires must be Ground per NEC and Local codes. kept separate from power and motor wires. Figure 3-2 Recommended System Grounding (3 phase) for CE
AC Main Supply Four Wire "Wye" Safety Ground PE Route all power wires L1, L2, L3 and Earth (Ground) together in conduit or cable. All shields Enclosure Backplane (see Section 6) Motor GND L1 L2 L3 Control
L1 L2 L3 PE U V W Note: Wiring shown for clarity of grounding method only. Not representative of actual terminal block location. Note: Use shielded cable for control signal wires. Route control signal wires in conduit. These wires must be kept separate from power and motor wires. 3-2 Installation MN1202 System Grounding Continued Ungrounded Distribution System With an ungrounded power distribution system it is possible to have a continuous current path to ground through the MOV devices. To avoid equipment damage, an isolation transformer with a grounded secondary is recommended. This provides three phase AC power that is symmetrical with respect to ground. Input Power Conditioning Baldor controls are designed for direct connection to standard single and three phase lines that are electrically symmetrical with respect to ground. Certain power line conditions must be avoided. An AC line reactor or an isolation transformer may be required for some power conditions. · If the feeder or branch circuit that provides power to the control has permanently connected power factor correction capacitors, an input AC line reactor or an isolation transformer must be connected between the power factor correction capacitors and the control. · If the feeder or branch circuit that provides power to the control has power factor correction capacitors that are switched on line and off line, the capacitors must not be switched while the control is connected to the AC power line. If the capacitors are switched on line while the control is still connected to the AC power line, additional protection is required. TVSS (Transient Voltage Surge Suppressor) of the proper rating must be installed between the AC line reactor or an isolation transformer and the AC input to the control. Power Disconnect A power disconnect should be installed between the input power service and the control for a
fail­safe method to disconnect power. The control will remain in a powered-up condition until all input power is removed from the control and the internal bus voltage is depleted. Protection Devices The control must have a suitable input power protection device installed. Input and output wire size is based on the use of copper conductor wire rated at 75 °C. Table 3-1 describes the wire size to be used for power connections and the ratings of the protection devices. Table 3-1 Wire Size and Protection Devices
Catalog Number Nominal Input Voltage BSC1002 BSC1102 BSC1105­1 BSC1005 BSC1105 BSC1110­1 BSC1010 BSC1110 BSC1115­1 BSC1015 BSC1115 ­ 115V (3f) 115V (1f) ­ 230V (3f) 115V (1f) ­ 230V (3f) 115V (1f) ­ 230V (3f) Continuous Output Amps (RMS) 2 2 5 5 5 10 10 10 15 15 15 Incoming Power Input Fuse (A) 6 6 10 10 10 20 20 20 30 30 30 AWG (USA) 14 14 14 14 14 12 12 12 10 10 10 Wire Gauge mm2 (Europe) 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 5.26 5.26 5.26 Note: All wire sizes are based on 75°C copper wire. Higher temperature smaller gauge wire may be used per NEC and local codes. Recommended fuses/breakers are based on 25°C ambient, maximum continuous control output current and no harmonic current. Requires separate DC Bus input voltage. No AC input or internal power supply available in this model. MN1202 Installation 3-3 AC Power Connections The location of the X7 connector is shown in Figure 3-6. Each BSC control must be fused separately. All interconnection wires between the control, AC power source, motor and any operator interface stations should be in metal conduits. Only class 1 wiring should be used. Wire and Fuses should be of the correct size specified in Table 3-1. Connect the AC power connections as shown in Figures 3-3 (three phase) or 3-4 (single phase). For single phase installations, do not connect any wires to L3. Figure 3-3 3 Phase Power Connections
L1 L2 L3 Earth
Note 1 Note 3 & 4 * Fuse Connections
Note 2 L1 L2 L3 PE Baldor Control * Components not provided with Control. Notes: 1. See Protection Device description in this section. 2. Metal conduit or shielded cable should be used. Connect conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding. 3. Use the same gauge wire for Earth as used for L1, L2, L3 connections. 3. Use same gauge wire for Earth ground as is used for L and N. (VDE (Germany) requires 10mm2 minimum). For CE compliance, connect "PE" to the backplane of the enclosure. 4. Reference EMC wiring in Section 7. Figure 3-4 Single Phase Power Connections (115V 1f only)
L N Earth
Note 1 Note 3 & 4 * Fuse Connections
Note 2 L1 L2 L3 PE Baldor Control * Components not provided with Control. Notes: 1. See Protection Device description in this section. 2. Metal conduit or shielded cable should be used. Connect conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding. 3. Use the same gauge wire for Earth as used for L1 and L2 connections. 3. Use same gauge wire for Earth ground as is used for L and N. (VDE (Germany) requires 10mm2 minimum). For CE compliance, connect "PE" to the backplane of the enclosure. 4. Reference EMC wiring in Section 7. 3-4 Installation MN1202 Figure 3-5 Single Phase Power Connections (230V 1f only)
L1 L2 Earth
Note 1 Note 3 & 4 * Fuse Connections
Note 2 L1 L2 L3 PE Baldor Control * Components not provided with Control. Notes: 1. See Protection Device description in this section. 2. Metal conduit or shielded cable should be used. Connect conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding. 3. Use the same gauge wire for Earth as used for L1 and L2 connections. 3. Use same gauge wire for Earth ground as is used for L and N. (VDE (Germany) requires 10mm2 minimum). For CE compliance, connect "PE" to the backplane of the enclosure. 4. Reference EMC wiring in Section 7. MN1202 Installation 3-5 Figure 3-6 Connector Locations
PE (Power Ground) X7
X1 - Power Connector PE L1 L2 L3 U V W VCC+ VCC­ R1 R2 +24V 0V Earth Ground Phase 1 Input Phase 2 Input Phase 3 Input Motor lead "U" Motor lead "V" Motor lead "W" Bus Power Bus Power Dynamic Brake Dynamic Brake Customer Provided AC Input Power Motor Connections Bus power for BSC1000 etc. Dynamic Brake (Regen Resistor) Logic Power input * L1 L2 L3 U V W vcc+ vccR1 R2 +24V 0V Reg. load * Only connect 24VDC to logic power input if option is installed. If option is not installed, connecting 24VDC to these terminals can cause damage to the control. Monitor Enable
ON ID
1 2 3 4 Current limit switches are accessed through a hole in the side panel in the approximate area shown. Off P 1 Ref Input gain X3 ­ Resolver 1 Ref+ 2 Ref­ 3 Cos+ 4 Cos­ X3
5 6 7 8 Sine+ Sine­ Not Used DGND
ON 1 3 Velocity gain 4 Velocity balance 5 Velocity loop gain 6 Peak current X2 ­ Control I/O 1 CMD+ 2 CMD­ 3 AGND 4 +15VDC 5 ­15VDC 6 Speed 7 DCurrent 8 Icmd 9 Enable 10 EMStop X2
11 12 13 14 15 16 17 18 19 20 CWLimit CCWLimit Current C CREF Fault+ Fault­ Warn_C Warn_E Reset DGND DIP Switches (Motor select)
X5 ­ Simulated Encoder Output 1 Not Used 6 CHB­ 2 Not Used 7 CHA+ 3 CHC­ 8 CHB+ 4 CHC+ 9 DGND 5 CHA­ Signal Ground (Shields) 2 3 4 5 6 X5 3-6 Installation MN1202 Motor Connections Motor connections are shown in Figure 3-7. (Connections U, V and W are shown in Figure 3-6). If connected wrong, erratic operation including moves at peak force may occur until the overcurrent limit trips. If erratic movement of the motor occurs, turn off power immediately and check the connections of the motor. Figure 3-7 Motor Connections for U.L.
Notes: Baldor Control 2.
U Note 1 V W PE 1. Note 2 V U W G 3. 4. Metal conduit or shielded cable should be used. Connect conduits so the use of Load Reactor* or RC Device* does not interrupt EMI/RFI shielding. Use same gauge wire for Earth ground as is used for the L1, L2 and L3. (VDE (Germany) requires 10mm2 minimum, 6AWG). For CE compliance, connect motor ground to the backplane of the enclosure. Reference EMC wiring in Section 7. Motor and resolver are phase sensitive. Connect only as instructed. This is the ground post on the top cover. * Optional components not provided with control.
* AC Servo Motor Figure 3-8 Motor Connections for CE
Notes: Baldor Control
This is the ground post on the top cover. 1. 2. U Note 1 V W PE 3. 4.
V U W G Metal conduit or shielded cable should be used. Connect conduits so the use of Load Reactor* or RC Device* does not interrupt EMI/RFI shielding. Use same gauge wire for Earth ground as is used for the L1, L2 and L3. (VDE (Germany) requires 10mm2 minimum, 6AWG). For CE compliance, connect motor ground to the backplane of the enclosure. Reference EMC wiring in Section 7. Motor and resolver are phase sensitive. Connect only as instructed. Note 2 Enclosure Backplane (see Section 7) * Optional components not provided with control.
* AC Servo Motor Note: For CE compliant installations, connect unused leads within the motor cable to "PE" on both ends of the cable. MN1202 Installation 3-7 M-Contactor If required by local codes or for safety reasons, an M-Contactor (motor circuit contactor) may be installed. However, incorrect installation or failure of the M-contactor or wiring may damage the control. If an M-Contactor is installed, the control must be disabled for at least 20msec before the M-Contactor is opened or the control may be damaged. M-Contactor connections are shown in Figure 3-9. Figure 3-9 Optional M-Contactor Connections
U V W To Power Source (Rated Coil Voltage) * M-Contactor * RC Device Electrocube RG1781-3 * M M M This is the ground post on the top cover. Note 1 and 2 * M Enable * Optional components not provided with control.
X2 9 Note: Close "Enable" after "M" contact closure. V U W G * Motor M=Contacts of optional M-Contactor Notes: 1. 2. Use same gauge wire for Earth ground as is used for the BPS L1, L2 and L3. (VDE (Germany) requires10mm2 minimum, 6AWG). For UL installations, connect motor ground to of the control as shown. For CE installations, connect motor ground to the enclosure backplane (see Figure 3-8). BUS Power For multi­axis applications, the second control may not have an internal supply. Bus power for the second control can be connected as shown in Figure 3-10. Figure 3-10
A control with an internal supply can provide bus power to a maximum of one control that requires an external power source. Simply connect the X7 VCC+ of the first control to the VCC+ of the second control. Then connect the X7 VCC­ of the first control to the VCC­ of the second control.
BSC1100 X7 vcc+ vccBSC1000 X7 vcc+ vcc- Internal Power Requires External Power Dynamic Brake Resistor An external DB (dynamic brake or regen resistor) resistor is required to dissipate excess power from the DC bus during motor deceleration operations. An external 320 watt resistor must be connected at the X7 terminals R1 and R2. Refer to Section 6 for selection information or contact Baldor. 24VDC Logic Power If the control is equipped with the internal 24VDC logic power circuit (BSC1XXX­24­X), 24VDC may be connected to this input to maintain voltage on the logic circuits at all times. An external 24VDC (20V to 60V source) supply must be used. This supply must remain on when AC power to the control is disconnected. Connect the power supply leads to X7 input terminals +24V and 0V. Note: All units are marked 24V and 0V. Do not connect an external 24VDC source to these terminals unless the control is equipped with the internal 24VDC logic power circuit (BSC1XXX­24­X). 3-8 Installation MN1202 Resolver Feedback The resolver connections are made at the X3 connector as shown in Figure 3-11 or 3-12. The resolver cable must be shielded twisted pair #22 AWG (0.34mm2) wire minimum. The cable must also have an overall shield. Maximum wire-to-wire or wire-to-shield capacitance is 50pf per foot. Resolver wiring must be separated from power wiring. Separate parallel runs of resolver and power cables by at least 3. Cross power wires at right angles only. Insulate or tape ungrounded end of shields to prevent contact with other conductors or ground. Note: Motor and resolver are phase sensitive. Connect only as instructed. Figure 3-11 Resolver Cable Connections for UL Installations
R2 S2 P
R1 S4 X3 5
P SIN+ SINCOS+ COSREF+ REF- (Common) Shell (Chassis) 6 3 4 1 2 S3 S1 P P = Twisted Pair Shields Figure 3-12 Resolver Cable Connections for CE Installations
R2 S2 P
R1 S4 X3 5
P SIN+ SINCOS+ COSREF+ REF- (Common) 6 3 4 1 2 S3 S1 P P = Twisted Pair PE PE Simulated Encoder Output The control provides a simulated encoder output at connector X5. This output may be used by external hardware to monitor the encoder signals. It is recommended that this output only drive one circuit load. Refer to Table 3-2. Table 3-2 Simulated Encoder Output at X5 Connector
X5 Pin 1 2 3 4 5 6 7 8 9 Shell Signal Name Not Used Not Used CHC­ CHC+ CHA­ CHB­ CHA+ CHB+ DGND * Chassis (Cable Shield) * For UL Installations ONLY. For CE Installations, connect the outer shield on each end of the cable to the signal ground (shields) at the bottom of the control. MN1202 Installation 3-9 X2 Control I/O Connections 18AWG wire is sufficient for all X2 connections. Analog I/O Command Input X3 pins 1, 2 and 3 allows connection of an external analog command input. This input can accept a 0-10VDC or ±10VDC signal and can be wired as a single ended or differential input, shown in Figure 3-13. Figure 3-13 Control Input Wiring
Single Ended Connection Differential Connection
X2
CMD+ CMDAGND Signal Source + Single Ended CW operation as shown
Signal Source X2 1 2 3 1 2 3 CMD+ CMDAGND 15VDC Output Speed Output Output Current Icmd X2 pins 4 and 5 provide 15VDC output @100mA maximum. (X2­3 is common). X2 pins 6 provides a motor velocity test point. (X2­3 is common). Motor RPM = VDC X 600 X2 pins 7 provides a test point to measure actual motor current. (X2­3 is common). Scaled 0 to 10VDC (where 10VDC = Ipeak) X2 pins 7 provides a test point to measure commanded motor current. (X2­3 is common). Scaled ±10VDC (where ±10VDC = Ipeak) Figure 3-14 Reset Wiring
X2 19 20 Reset DGND Close X2­19 to reset an over voltage, under voltage, over current, over temperature, resolver fault or electronic fusing (I2T) fault. 3-10 Installation MN1202 Digital I/O X2 Digital Inputs - (uses CREF, X2-14) Active High (Sourcing) - If pin X2-14 is grounded, an input is active when it is at +24VDC (+12VDC to +30VDC). Active Low (Sinking) - If pin X2-14 is at +24VDC (+12VDC to +30VDC), an input is active when it is grounded. Logic input connections are made at terminal strip X2. Input connections can be wired as active High or active Low as shown in Figure 3-15. X2 pin 14 is the Control Reference point (CREF) for the Isolated Input signals. Note: An internal 24VDC power supply connection is not available from the control to power the Input circuits. A customer provided external power source must be used as indicated in Figure 3-15. Figure 3-15 Active HIGH /LOW Relationship
Active Low (Sink) +24VDC GND Active High (Source) GND +24VDC Input A B
20mA 20mA Note: All inputs are referenced to CREF, X2-14.
X2 14
CREF ENABLE EMStop CW-ENABLE CCW-ENABLE Current C Input A 9 10 11 12 13 B +24VDC 9 - 17 7
Typical B GND 9 - 17 7
Typical B A GND A +24VDC Control Source Sink Control Table 3-1 Digital Input Signal Conditions
Pin Number X2-9 X2-10 X2-11 X2-12 X2-13 Signal Name Enable EMStop (Emergency Stop) CW-Enable CCW-Enable Current C (Torque/Velocity) Switch = Closed (active) Drive enabled. Motor enabled. Clockwise rotation enabled. Counter-clockwise rotation enabled. Current mode (Torque). Switch = Open (not active) Drive disabled. Motor disabled. Clockwise rotation disabled. Counter-clockwise rotation disabled. Velocity mode. Current C Use Current mode (X2­13 Closed) for positioning applications. Use Velocity mode (X2­13 Open) for speed control applications. Signal Name Digital Input Signal Definition
Enable EMStop CW-Enable CCW-Enable Current C CLOSED allows normal operation. OPEN disables the control and motor coasts to a stop. CLOSED allows normal operation. OPEN commands zero velocity and motor coasts to a stop. CLOSED allows normal operation in the CW direction. OPEN to disable CW rotation. The motor decels to a stop. CLOSED allows normal operation in the CCW direction. OPEN to disable CCW rotation. The motor decels to a stop. CLOSED current mode operation is enabled. OPEN velocity mode operation is enabled. MN1202 Installation 3-11 X2 Digital Outputs The control outputs are located on the X2 connector. A customer provided, external power supply must be used if digital outputs are to be used. The outputs provide status information and are not required for operation. Figure 3-16 Fault Relay Connections
15 Relay 16 Contact is closed when power is on and no faults are present. Control Customer provided interface circuit Customer provided external power source: and Non-Inductive Load 110VAC @ 0.3A maximum or 24VDC @ 0.8A maximum Note: After a fault, the output is reset by closing the reset switch (X2­19 to X2­20). Figure 3-17 Warning "C" and "E" Output Connections
+
RL VCC Source (+12VDC to +30VDC) Note: Customer must use a current limiting resistor (RL). The minimum value of RL can be calculated as follows: 17, 18 20 Control Output Signal CGND Customer Provided Interface Circuit OR
Relay R L minimum + VCC Source 0.04 Typical 35mA Maximum Table 3-2 Output Signal Conditions
Pin Number X2-15 X2-16 X2-17 X2-18 Signal Name Fault + Fault WarnC WarnE Switch = Closed (active) Drive OK - no faults detected. Drive OK - no faults detected. No Overcurrent fault detected. No Over temperature fault detected. Switch = Open (not active) Fault is detected. Fault is detected. I2T Overcurrent condition is detected. Over temperature condition is detected. Fault Relay WarnC WarnE A normally closed relay contact that opens if a fault occurs. The contact is rated: 24VDC @ 0.8A maximum or 110VAC @ 0.3A maximum. Over Current limit (I2T electronic fusing warning). Output can be connected to an external alarm circuit. Each output is rated 30VDC @ 35mA maximum. Overtemperature warning. Output can be connected to an external alarm circuit. This output is rated 30VDC @ 35mA maximum. 3-12 Installation MN1202 Section 4 Switch Setting and Start-Up
Introduction 26M These procedures are performed with the power off. Do not apply power until you are instructed to do so. This means AC power and 24VDC Logic power must both be disconnected. DIP Switch Settings (Refer to Section 3 for location) Motor Select (on front panel)
ON 1 2 3 4 5 6 Six DIP switches are located on the front panel. Refer to Table 4-1 to determine the correct setting of these switches. Note: All switches are shown in the "ON" position. Table 4-1 Control Address Setting
1 ON OFF ON 2 OFF ON ON Switch 3 4 OFF OFF OFF OFF ON OFF ON 5 6 Description For motors BSM 4R / 63A / 80A / 80B For motor BSM 6R For motors BSM 4F / 6F / 8F / 90A / 90B Encoder Simulation of 1024 Pulse per Revolution Encoder Simulation of 1000 Pulse per Revolution Encoder Simulation of 500 Pulse per Revolution Encoder Simulation of 250 Pulse per Revolution Off = Integral part of the velocity loop is active. On = Proportional loop only (no integral part). OFF OFF ON ON OFF ON Current Limit (on side panel)
ON 1 2 3 4 Current limit switches are accessed through a hole in the side panel. These switches reduce both the continuous and peak current by the same ratio. Off Table 4-2 Current Limit Setting
Switch 1 OFF ON OFF ON 2 OFF ON OFF ON 3 OFF OFF ON ON 4 OFF OFF ON ON Description 25% of full rated output current 50% of full rated output current 75% of full rated output current 100% of full rated output current Potentiometer Initial Settings
The potentiometers must be pre­set. Refer to Section 3 for location. Set the potentiometers to the pre­set positions indicated in Table 4-3. Table 4-3 Potentiometer Initial Preset Positions
Potentiometer P1 P3 P4 P5 P6 Function Reference Input Gain Velocity Feedback Gain Velocity Balance (Drift Adjustment) Velocity Loop Gain (Prop Gain) Peak Current Initial Setting (Factory settings) CW for maximum input gain CW for maximum gain Standstill at zero point command CCW for minimum gain CCW for reduced current MN1202 Switch Setting and Start-Up 4-1 Identity Module The Identity Module must be fully inserted into its socket to allow control operation. Several components are mounted on this module. Refer to Figure for their location and to Table 4-4 for their description. Note: If the Identity Module is not completely inserted, the unit will not operate. Figure 4-1 Identity Module Component Locations Table 4-4 Identity Module Component Descriptions
Component Description Factory Value R38 4.99 k Speed Scaling (4000 RPM) D401 Plug­in protection ­ R94 P­gain for velocity loop 100 k C19 I­gain for velocity loop 47 nF R22 ­ I2T­switching threshold (nom. current) R765 Special function 26.7 k R43 P­gain for current loop phase U 150 k C17 I­gain for current loop phase U 4.7 nF R44 P­gain for current loop phase V 150 k C11 I­gain for current loop phase V 4.7 nF D402 Plug­in protection ­ RES Reserved for special applications ­ R38 is used to set the maximum speed of the control/motor combination. The standard factory value is a 4.99 k resistor for 4000 RPM. If the motor's maximum speed for a given application is not 4000 RPM, this resistor should be replaced with one of the following resistor values below depending on the maximum required speed: 0 for 6000 RPM 4.99 k for 4000 RPM 10 k for 3000 RPM 20 k for 2000 RPM Contact Baldor for applications over 6000 RPM. R22 is used to limit the continuous current of the control (without affecting peak current). The standard factory arrangement is to not insert R22. If an I2T limit is desired, the value of R22 can be determined from Table 4-5. 4-2 Switch Setting and Start-Up MN1202 Table 4-5 Current Limit Value Determination
Value of R22 Ohms Open ( ) 20k 10k 5k BSC 1002/1102 Ipeak = 4A Icont = 2.0A Icont = 1.6A Icont = 1.3A Icont = 1.0A BSC 1005/1105 Ipeak = 10A Icont = 5.0A Icont = 4.0A Icont = 3.3A Icont = 2.5A BSC 1010/1110 Ipeak = 20A Icont = 10.0A Icont = 8.0A Icont = 6.7A Icont = 5.0A BSC 1015/1115 Ipeak = 30A Icont = 15.0A Icont = 12.0A Icont = 10.0A Icont = 7.5A Start­up Procedure
Power Off Checks Before you apply power, it is very important to verify the following: 1. 2. 3. 4. 5. 6. 7. Power On Checks Disconnect the load from the motor shaft until instructed to apply a load. If this cannot be done, disconnect the motor wires at X7-U, V and W. Verify that switches are set correctly. Verify the AC line voltage at the source matches the control rated voltage. Inspect all power connections for accuracy, workmanship and tightness. Verify that all wiring conforms to applicable codes. Verify that the control and motor are properly grounded to earth ground. Check all signal wiring for accuracy. If using a transformer, switch the primary side only, and check that the secondary voltage is 115 VAC for single phase units and between 115 VAC and 230 VAC for three phase units. 1. Temporarily disconnect the input speed command signal (±10 VDC) from the Control Signal Connector X2 inputs CMD + (pin 1) and CMD ­ (pin 2) and jumper the CMD + and CMD ­ inputs together. Switch on the main power. The motor may run away "out of control" if the resolver wires are connected incorrectly. Turn power off immediately and check resolver wires. If the motor shaft rotates in the wrong direction, check the wiring of the motor and the resolver. Turn power on. Verify that the "READY" LED is green, and the Status Monitor LED display on the front panel shows a decimal point on the bottom right. This verifies that power is applied, and the unit is enabled. If the motor is slowly rotating, adjust the Velocity Balance pot P4 for no rotation. Adjust P6 Peak Current CW (clockwise), and verify that the motor has holding torque. If the motor has no holding torque, make sure that the Identity Module is fully inserted, and check the wiring of the Control Signal Connector X2 pins: CW limit (pin 11), CCW limit (pin 12), ENABLE (pin 9), EMStop (pin 10). If the motor runs away or if Error 5 or 7 is displayed on the Status Monitor, switch off the main power immediately and check the resolver and motor wiring. Again, switch off the main power, and reconnect the input speed command signal (±10 VDC) to the CMD + and CMD ­ inputs. Switch on the main power and apply a small input speed command (5V or less is suggested). Positive command voltage will cause CW shaft rotation and negative command voltage will cause CCW (counterclockwise) shaft rotation. 2. 3. 4. 5. Note: When using single ended input, positive voltage input to CMD + causes CW shaft rotation, and positive voltage input to CMD ­ causes CCW shaft rotation. MN1202 Switch Setting and Start-Up 4-3 Adjustment Procedure The following procedure yields proper potentiometer adjustment for optimum servo control operation. For best results, read the entire procedure before making adjustments. 1. Apply a signal input command between 0 and 10 VDC at the Control Signal Connector X2 inputs CMD + (pin 1) and CMD ­ (pin 2). +5 VDC (for CW shaft rotation) or ­5 VDC (for CCW shaft rotation) is suggested. If the motor shaft rotates in the wrong direction for a given polarity of the signal input voltage, check the wiring of the motor and resolver. If the shaft still rotates in the wrong direction, reverse the CMD + and CMD ­ inputs. Note: When using single­ended input, positive voltage input to CMD + causes CW shaft rotation, and positive voltage input to CMD ­ causes CCW shaft rotation. 2. Slowly turn the Peak Current (P6) pot 1/4 turn CW, observing that the motor shaft speed may increase and stabilize. 3. If connected, verify that the CW and CCW limit switches properly inhibit the machine travel in the direction defined. 4. If the motor shaft drifts, or rotates when sent a zero velocity ("don't move") command, slowly adjust the Velocity Balance (P4) pot to eliminate any motor shaft rotation