BLD10 Service Manual
Contents
1. POWER SUPPLY YSS m MOTOR FE Has pr V UHM CABLE l y MOTOR B R U S H L E S Ss MOTOR CNC DRIVE MOTOR enD 00 oo G Sbarra di massa Start point for earthing CL Terra di sistama System earth In the figure above is shown a typical connection The encoder with line driver output is connected directly to the control Depart from the control wires A B GND to the converter signals in common mode In the example the encoder is supplied by the CNC while the hall sensors are supplied by Drive V terminal 12 It s also possible to supply the encoder with the voltage present on the 5V of the drive V terminal 12 verifying that the absorption of the encoder does not exceed 100mA The converter is ble to provide 130mA max 100mA for encoder and 30mA for Hall sensors Hall sensors must be supplied using the internal 5V of the Drive M1 connector 12 If an external supply is used open solder bridge S11 Service Manual for brushless DC motor drive BLD10 Version 02 15 Setting for Brushless motor with encoder BLD10 in this configuration must have following set up SOLDER BRIDGES ADJUSTMENT ZONE 7 ess A v Y 22ee2reeeere Solder Bridges set for Brushless motor Encoder feedback Ramp time disabled Standard Dynamic constant For the correct value of RENC resistor speed adjustment range see chapter 3 1 Not2. peak current lasts 2sec Main technical data FEATURE VALUE Supply voltage output 0 9 Vdc input PWM frequency 20Khz Operating temperature 0 40 C Storage temperature 10 70 C Drift analog input 0 5uV C Analog inputs VEL 10Vdc max impedance 20Kohm each Current monitor output CURR 7Vdc peak current Velocity monitor output TP1 8Vdc max speed Power supply output 5V 5Vdc max 130 mA Power supply output 9 8V 10Vdc max AMA Encoder max frequency 300Khz with level gt 2 8 24Vdc min max Fault drive output NPN max 50mA Start input 9V 30Vdc min max Band width current 2KHz Band width velocity 150Hz Minimum Inductance motor 400uH Weight 0 35 kg 10 6 OZ Altitude Up to 1000m without restrictions from 1000 to 2000m power derating 1 5 100m Service Manual for brushless DC motor drive BLD10 Version 02 15 1 4 Product view 1 Product Label 2 Fixing screws 3 Cover 4 Solder bridges 5 Adjustment zone 6 N 4calibration trimmers 7 LEDs 8 TEST point Encoder Armature velocity 9 M1 Signal terminal 16 pins MC1 5 16 ST 3 81 pitch 3 81 10 POWER Terminal 5 pins GMST 2 5 5 G 5 08 pitch 5 08 This image does not faithfully reproduce the product has purpose just for showing the parts Service Manual for
3. we increase the readiness and response of the motor With a GAIN clockwise turn CW we increase the gain of the PI internal speed loop Derivative potentiometer Acting in a clockwise CW can dampen any DERIV oscillations of the motor due to a high moment of inertia of the load In Chapter 3 3 explains how to dynamically tune the motor by acting on the 2 trimmer GAIN and DERIV All potentiometers are disabled in Torque mode Service Manual for brushless DC motor drive BLD10 Version 02 15 3 3 Dynamic adjustments The multi turn GAIN and DERIV trimmer allow to dynamically tune of the motor and its mechanics linked to it These trimmers have full excursion from minimum to maximum with 15 turns of rotation of the same The charts shown the track 1 yellow is the speed signal available in the point TEST Track 2 blue highlights instead the current signal taken at terminal 1 M1 signals connector pitch 3 81 Signals are reported with a step voltage of the reference signal speed of about 2V These signals can be displayed by connecting the two probes of an oscilloscope at those points The zero signal 0S zero probes can be connected by a wire to pin 4 M1 signals connector pitch 3 81 Speed signal ype Current signal Print Key S E Behavior of the motor with both GAIN and DERIVATIVES trimmer to a minimum of function trimmer totally rotated counterclockwise CCW The speed signal is unstabl
4. Connect the ground bar to the zinced panel of the drive by using a screw then connect that screw to earth 3 Connect earth to the motor s It suggests a conductive connection as much as possible to the chassis or the heatsink or the mounting panel of the electrical box D It refers to the earth connection Motor and Power cable as norm EN60204 in case of needing to have longer cable than standard ones WIRES SECTIN MOTOR TYPE BL012 240 BL018 240 BLS022 240 BL025 24E BL032 240 1 5mm 15AWG BL043 240 BLS043 240 2 5mm2 13 14AWG BL070 480 BL070 48E Control signals cable as norm EN60204 WIRES SECTION 0 5mm 20AWG Feedback signals cable as norm EN60204 WIRES SECTION 0 25 0 35mm2 22 24AWG Service Manual for brushless DC motor drive BLD10 Version 02 15 1 10 Dimensions 157 Service Manual for brushless DC motor drive BLD10 Version 02 15 1 11 Pin out overview Pin out view The figure below shows the view of the converter terminals M1 Signal terminal 16 pins type MC 1 5 16 ST 3 81 POWER Terminals 5 pins type GMST 2 5 5 G 5 08 On the test point TEST you can see the signal of speed The output from 0 to 8V is from zero to maximum speed At this point you can analyze the signal when you enable one of the following velocity feedback e Encoder e Armature NOTE Depending on the type of motor to drive follow the links re
5. chapters related settings read chapters 2 10 11 SOLDER BRIDGES Normally open OFF Normally closed ON Don t touch Normally open OFF See Chapter Ramp time adjustment If closed insert RACC resistor Normally closed ON Open install components in the adjustment zone for the dynamic velocity value CKV and RKV Standard value RKV 100Kohm CKV 47nF Normally closed ON If Open you must insert the GAIN resistor Static Gain Standard value 27 ohm Normally open OFF If closed when the IxT protection operates the green led OK and the output FAULT goes off Normally open OFF If closed the drive is set is for the armature feedback Insert also the resistance RA and RCA Normally closed ON In this position the drive is set for the encoder feedback If Open OFF other types of feedback are enabled Normally open OFF If closed setting the drive for PWM DIR command optional Normally closed ON Open S10 OFF for tachogenerator feedback Normally closed ON If open OFF the alarm protection for missing Hall Effect Signals will not disable the drive Service Manual for brushless DC motor drive BLD10 Version 02 15 2 1 Brushless motor with hallsignals Quadro elettrico Control cabinet 24VDG 24VDC 1 CURR 2 FAULT aut 2 REQ 4 END 5 16 iaut 6 1 V eur 7 START B VEL 9 VEL 1 ENC A CDT 11 ENG E 12 5 ut 12 GND DT 14 HALL 1 15 HALL 2 16 HALL 3 tHV GNDSe LI MM
6. feedback In order to set up the drive to other motors pls change the resistors as the table below BLD10 basic 10 20 A Motor type apd al voltage Rin ohm Rip Ohm RA Ohm RCA Ohm BLO12 240 3 5 7 24 820R 27K 4K7 68K BLO18 240 5 10 24 1K5 47K 4K7 120K BL022 240 714 24 3K9 120K 4K7 120K BL025 24E 714 24 3K9 120K 4K7 180K BL032 240 5 10 24 36 1K5 47K 8K2 150K BL043 240 714 24 36 3K9 120K 8K2 220K BLS043 240 714 24 36 3K9 120K 8K2 220K BLO70 480 48E 7 5 15 48 m 18K 470K Supply the drive with 5 6 Vdc more than the rated motor voltage Keys Rin rated current limit resistor Rip peak current limit resistor RCA voltage drop calibration resistor RA max speed calibration resistor See Appendix A page 37 the decoding of the values of resistances by the method of colored rings Service Manual for brushless DC motor drive BLD10 Version 02 15 2 3 Ramp time adjustements The product is standard set with this feature not enabled Section S3 open To enable the ramp acceleration close the solder bridge S3 and insert the RACC resistance NOTE The product issupplied by default with mounted 470ohm resistance value 0 8 sec ramp Ramp disabled standard setting VEL i 3 3V MOTOR 500 RPM 300 RPM Ramp disabled Ramp enabled VEL 3 3V 2V MOTOR 4 4500 RPM Tacc Tdec 300 RPM Ramp en
7. speed RPM Capacitor filter C In regards to the capacitor filter we suggest a working voltage of 100VDC Tipical value is from 4700uF to 10 000uF depending on the motor size and kind of application Capacity above the filter effect helps to recover energy during braking of the motor If the converter during braking has the green LED that flashes you must increase the value of the capacitor eg 10 000uF from a 20 000uF Fuses F1 e F2 A Fuses are required on both the primary and secondary of the transformer to protect against harm to the system and the transformer itself They need to be of the slow blow type to handle current in rush at power up Locate the primary fuse F1 on the hot leg of the AC input power and the secondary fuse F2 on the side of the secondary output before the rectifier Primary of the transformer use the formula below to calculate the correct values F1 A P VA trasfo V1 Secondary of the transformer Use the table below FUSE F2 A MOTOR TYPE 12 BL0120 240 BL180 240 BLS022 240 BL025 24E BL032 240 BL043 240 BLS043 240 16 BL070 480 BL070 48E Service Manual for brushless DC motor drive BLD10 Version 02 15 1 8 Note about connections Multiple connection In the case of multiple servodrives on the same power supply make connections type stars see drawing back Connect also feed converters using the shortest cable possible If the cable length exceeds 2m twist the and lead
8. wires between one of these wires and ground or short circuit inside the motor or the motor cables LED lights red ixt Excessive mechanical load LED lights red PTC Ambient temperature too high or the converter does not have a minimum circulation of air cooling ventilation or missing where expected from the size of the converter At Startup or Enabling the H ALL Led comes on One or more missing Hall Signals Missing power supply to Hall Cells With the green LED the motor will not start when you enable the drive with START Check for the enable signal START Also verify the presence of the speed signal between the terminals VEL Motor goes out of control when enabled Encoder signals incorrectly connected ENC A and ENC B signals swapped or encoder power supply missing or signals swapped Service Manual for brushless DC motor drive BLD10 Version 02 15 The resistances taken for calibration are 4 rings type as photos For the decoding of the ohmic value use the following table First ring tens digit Second ring unit digit Third ring multiplier Fourth ring tolerance APPENDIX A RESISTANCE VALUES DECODING BY THE MEANS OF COLOR S RINGS COLOR 1 RING 2 RING 3 RING 4 RING Black 0 x1 Brown 1 1 x10 Red 2 2 x 100 Orange 3 3 x 1 000 Yellow 4 4 x 10 000 Green
9. 5 5 x 100 000 Blu 6 6 x 1 000 000 Violet 7 7 x 10 000 000 Grey 8 8 White 9 9 GOLD 10 5 SILVER 100 10 NOTHING 25 For example the resistance in the picture Brown 1 tens digit Black O units digit Red Multiplier x 100 Gold 5 tolerance 10 x 100 1K 5 tolerance
10. N HM w SUPPLY Wfuse mo MOTOR i CABLE La La T 00000 00002202002020000000 MOTOR BRU S H LESS MOTOR CNC DRIVE Z MOTOR A oD 00 00 On Sbarra di massa Start point for earthing PE amp Terra di sistama System earth The following diagram shows a tipical application utilizing a Drive with Brushless motor only Hall signals These signals are used in the converter for the control of current and to regulate motor speed The adjustment range is lower than the use of Encoder Hall but good enough for many applications Service Manual for brushless DC motor drive BLD10 Version 02 15 Setting for Brushless motor with hall signals In this configuration BLD10 must set with the following Solder bridges and below internal setting SOLDER BRIDGES ADJUSTMENT ZONE 7 700505 P288GLELER2 Standard solder Bridges set for Hall feedback Armature Ramp time disabled Standard Dynamic constant Brushless motor For the correct value of RA and RCA resistor speed adjustment range see chapter 2 2 Note On the adjustement zone the othercomponents are not considered here the ones used to determine other calibrations for example Calibration current rating etc Service Manual for brushless DC motor drive BLD10 Version 02 15 2 2 Set up data for Intecno s motors BLD10 is set up by default on the motor BL043240 Hall sensor
11. Service Manual for brushless DC motor drive BLD10 INTECNO BLD10 Service Manual INTECNO s r l via Caduti di Sabbiuno n 9 E 40011 Anzola Emilia BO Italy tel 051 19985350 fax 051 19985360 Service Manual for brushless DC motor drive BLD10 Version 02 15 Agency approvals CE COMPLIANCE 89 336 EEC Electromagnetic EN 55011 Compatibility EN 550082 1 98 37 EC Safety of Machinery EN 60204 1 The EC mark that is applied to the drives references to the Low Voltage Directive 2006 95 EC and EC Directive on EMC 89 336 EC The standard EN 61800 5 1 is applied to ensure conformance with the Low Voltage Directive The standard EN 61800 3 is applied to ensure conformance with the EMC Directive In reference to noise immunity and noise emission the converters fulfi the requirement to the category second environment industrial environment If the installation of the drive is carried out differently than described in this manual the user must carry out new measures to satisfy the requisites of law CONDITIONS OF ACCEPTABILITY The devices shall be installed in compliance with the enclosure moun ting spacing and segregation requirements of the ultimate application These devices are intended as open type equipment The need to repeat a temperature test shal be considered in final end use application These devices are suitable for field wiring WARNING Risk of damage and or personal injury This drive doesn t contai
12. abled Table The time shown on the right are Resistance ohm TIME seconds related to a change to step on the 27 Ohm 15 reference signal input VEL of 10V 68 Ohm 5 Example from 0 to 10V or 10 to OV 100 Ohm 3 16 470 Ohm 0 8 1K Ohm 0 32 1 5K Ohm 0 26 3 3K Ohm 0 16 10K Ohm 0 086 Service Manual for brushless DC motor drive BLD10 Version 02 15 2 4 Intecno s motors connection Pls follow the drawing Power wires bigger section Yellow big or blue phase motor U pin U Red big or brown phase motor V pin V Black big phase motor W pin W Signal wires smaller section Red small Vdc pin 12 Black small GND pin 13 Blue hall U pin 14 Green hall V pin 15 White hall W pin 16 Small wires Hall sensor Red pin 12 Black pin 13 gt Blue pin 14 m Green pin 15 gt White pin 16 gt Big wires power wires Yellow pin U Red pinV e A Black pin W Just for motor BLO70480 BL07048E power wires colors can be different but the signal wires colors are the same as the other motors MOTOR only BLO70480 48E i Big wires power Blue pin U Brown pinV Black pin W Service Manual for brushless DC motor drive BLD10 Version 02 15 Connection picture as per example Use shielded wires in case you need longer wires 2 5 HW direction selection In ord
13. brushless DC motor drive BLD10 Version 02 15 1 5 Ambient conditions Cable duct Ensure air circulation inside the box ae Cable duct Dimensions are Expressed in mm Conductive mounting panel zinc coated Positioning in the electrical box Follow the instructions in the positioning of the servodrive into the electrical box The drive is naturally convection air flowcooled To ensure the drive cooling and make the installation easier for the operator it must be installed vertically leaving a free space of at least 20 mm 0 78 inch on each side of the device The converter must be mounted vertically on the electrical box In case you want to mount it horizontally remove the cover The electrical box must have suitably filtered air vents Leave the necessary space both above and below the converters Keep the drive from excessive mechanical vibration Notesduringtheassembly Caution during the wiring of the servodrive in the electrical box make sure that do not enter leading wires of copper or iron chips through the slits Before performing the work cover the holes with a piece of paper tape Of course after work it must be removed Service Manual for brushless DC motor drive BLD10 Version 02 15 1 6 Ventilation This servodrives are intended only for use in close locations Ambient chara
14. cteristics operating temperature from 0 to 40 C Humidity limit s between 5 to 95 non condensing Pollution degree 2 or better Mounting position NO In case of horizontal mounting take away the cover LLTI ELELLTELEFEFLTER In case you agree to put also the fan pls put it under the drive Standard heatsink fan under the drive operating temperature 0 40 C Service Manual for brushless DC motor drive BLD10 Version 02 15 1 7 Power supply construction Normally the power supply is built by a transformer a bridge rectifier and a filter capacity Alternatively the power supply can also be of switching type in this case refer factory by the appropriate sizing The converter have to be supplied from an isolating rectified transformer secondary or a DC isolated power supply Transformer T TRANSFORMER AC POWER i INPUT C Cri T VDC gt GND Voltage The primary voltage depends on what is available locally fora single phase The secondary voltage is calculated from the motor s voltage at the required operating speed The secondary voltage VDCis VDC V2 1 41 Example If the secondary transformer V2 is 45Vac the VDC output is 45 1 41 64Vdc PAY ATTENTION The drive has zero signal GND in conjunction with the zero power GND thereby preventing the following links Use a s
15. d pot 470K 1M Ohm The speed ring remains active and uses the input reference signal In this case the loop of internal velocity remains active Applying and eternal resistance tending to zero Ohm allocable current tends to zero Encreasing he resistance allocable current encreases too 47Kohm current is limited by 50 Speed loop is active Service Manual for brushless DC motor drive BLD10 Version 02 15 2 9 Start input The standard drive is supplied in this configuration Start enable input has logic range gt 9V to 30Vdc min max DRIVE Unconnected Enable input Drive Not Enabled Enable Input 24Vdc Drive Enabled Is possible to enable the drive connecting the START input to 10V output terminal 5 2 10 Current monitor output CURR analog output pin1 On this terminal is available analog output current monitor of motor with range OV 7V The value of 7V is the maximum current supplied by the drive For example if we have a size 10 20A 7V corresponds at 20A circulating on the motor The signal can be positive or negative depending on the direction of rotation of the motor Output Impedance is 10Kohm Consider the internal impedance in the case are linked external resistive divider Drive Multimeter Note Standard product is set to the signal CURR on terminal 1 reading of the current circulating on the motor and the REQ input at terminal 3 If these signals are not used you can use these termi
16. dled installed setted up and maintenanced only by competent personnel expert and trained in the installation of motion control electronic equipment Such technicians should be aware of potential electrical and mechanical hazards Shall never beliable or have any responsability if the products have been improperly stored installed used or maintened or if the costumer has permitted any unauthorized modifications adjustments and or repairs to the products Simbols security standard Warning of dangerous current present In case of doubt or in any case you don t know as to behave yourself before access to the AN drive power off the device and wait until all the LEDs are turned off May you have attention when you touch the drive because it may be hot Danger Sign All the circuits in the Drive are potential sources of severe electrical shock so follow these rules to avoiding possible personal injury Power off the drive and wait until all the leds are turned off before touching removing connecting or any other criticalaction Never disconnect any connectors before powering down the drive Service Manual for brushless DC motor drive BLD10 Version 02 15 1 2 Operation mode and feedback Description This is a drive capable of piloting DC brushless motors It s a High Performance full four quadrant drive The mosfet output power stage is controlled by a 20 Khz PWM Pulse Width Modulation signal that allows it to drive servo m
17. e On the adjustement zone are not considered here the other components used to determine other calibrations for example Calibration current rating etc The resistance RENC inserted determines the full scale of the motor speed To have a fine calibration turn the trimmer SPEED located on the front Moving the trimmer clockwise increases the speed and viceversa counterclockwise This calibration is to be performed with the motor running Service Manual for brushless DC motor drive BLD10 Version 02 15 3 5 Set up for encoder feedback This speed feedback allows the adjustment of the motor speed using the signal from an incremental encoder two channels A and B The signals from the encoder are read in a common way The logical value of these inputs must be in the range of gt 2 8 24V minimum and maximum To get good dynamic performance on the motor we recommend the use of encoders with at least 2000 2048PPR Acceptable performance is obtained however even with the use of the encoder 500 512PPR The settings and calibrations already shown in their respective sections enable the reaction encoder Even if the encoder is mounted Hall signals are always necessary to be connected a aa Fu 22 a SSsBBRSeeeRee RENC resistorcalculations The drive is set with solder bridge S8 closed and the resistance calibration speed RENC mounted on board 27Kohm Calibration for speed 3000rpm encoder with 10V refere
18. e the same for the current signal of M 10 6ms themotor See chart at right Turning clockwise CW the trimmer GAIN 4 5 o Save turns the dynamic behavior improves not exceed with this adjustement otherwise the motor will be vibrating See chart at right Save M 16 0ms M Posh Aus To improve the behavior of the motor and SAVEREC mechanics related to it and the over all lype damping of the speed signal oscillation act trimmer DERIV turning it clockwise CW 4 5 Print Key turns See chart at right NOTE The dynamic calibrations are performed using a reference speed in VEL of about 1 or 2V You can use the voltage output from the CNC control paying attention to rule out the correction of space Or use an external oscillator or a small battery 1 5 V M 16 0ms Service Manual for brushless DC motor drive BLD10 Version 02 15 3 4 Brushless motor with encoder Hall sensors CNC 24VDC 24VDC 10V GND Analog Relays Output Encoder GND VY GND CNC input IL i du xp START i DRIVE Ld Quadro elettrico Control cabinet DRIVE 1 CURR in2 2 FAULT leut 3 REQ INI 4 GND 5 9 BV eur 6 9 8V leurt 7 START 8 VEL 9 VEL 18 ENC A DT 11 END B 12 V eu 13 GND DT 14 HALL 1 15 HALL 2 16 HALL 3 HV GNDS CNC ENCODER HALL CABLE T ase ee 2 aee BSF eee a 00000 p020020000000009
19. er to get the change of direction of the motor without using the feature of inversion by the drive the user can procede as follows a Change each other the position of the motor phases U and V yellow with red And at the same time b Change each other the wires of the Hall signal pin 14 and pin 16 blue with white 2 6 Basic command diagram NOTE close pin 7 onto pin 5 or connect to pin 7 a voltage from 10 to 24 Vdc This enables the motor to run as per speed selected by the speed pot Start pin does not meet the ramp even if the ramp is enabled Opening pin 7 the motor stops by coast 5 9 8V 7 START Service Manual for brushless DC motor drive BLD10 Version 02 15 The simpliest basic connection is the following Speed pot 10 KOhm speed pot the central pin the one that changes connected to pin 8 VEL one of the external pins to the pin 4 GND and the other to a 3 ways selector that is connected itself as per the picture 0 stop 1 run forward 2 run reverse Speed is managed by the speed pot the direction by the polarity of the selector Service Manual for brushless DC motor drive BLD10 Version 02 15 2 7 Analog speed input Differential reference VEL This analog in differential mode has a 40Kohm of impedance input The following diagram shows an application utilizing a differential reference from a C N C DRIVE 8 VEL Common mode reference This analog in commo
20. justments 31 3 4 Brushless motor with encoder hall sensors 32 3 5 Set up for encoder feedback 33 Chapter 4 4 1 Indicator LEDs and protections 35 4 2 Troubleshooting 36 APPENDIX A Resistance values decoding by the means of color s 37 rings Service Manual for brushless DC motor drive BLD10 Version 02 15 1 1 Safety and note Caution Users must take care that this motion control equipment is capable of producing high forces and rapid movement so they must be used with attention especially during the application program s development This motion control equipments are sold as end users products to be installed only by practical staff in accordance with all local safety laws and regulations The device have to be enclosed such that any part is not be accessible while the system is powered on We strongly reccomend to follow these recommendations in order to avoid wrong uses of the equipment that may be impaired all the protections provided by the device Please read these notes carefully before powering up the drive It is very important to meet all applicable safety requirements during installation and operating of any motion control equipment Any installer has to assume the responsibility to ensure that he recognizes and complies all the relevant safety standards Any installation not meeting the safety requirements may damage the equipment or injury the user This motion control equipment shoul be han
21. lating to such applications Power terminals POWER CONNECTOR HV IN Positive Power supply input GND IN Negative Power Supply input GND U OUT Motor connection U phase V OUT Motor connection V phase W OUT Motor connection W phase NOTE pls read also the connection diagrams of the following chapters Service Manual for brushless DC motor drive BLD10 Version 02 15 Signal inputs and outputs M1 1 CURR IN2 This signal can be used in 2 distinct modes Current_motor monitor OUT 3 5Vdc Rated current 7Vdc Peak current output in Volts This output may be used to monitor the torque the motor is producing Standard setting IN2 setting IN Is possible setting this terminal for Limit sw input contact Intecno 2 FAULT OUT Fault drive open collector output max 50mA Normally closed opens when the drive in protection mode REQ can be used in 2 distinct modes 1 Motor Current limit mode by REQ setting A motor current limit mode connect an external resistor to GND reduces the maximun current Connect a 1 4W o 1 8W resistor between the TPRC pin 3 and GND pin 4 terminals A 47Kohm external resistor reduces the current by 50 Note The drive speed loop remains active 2 Torque request by REQ setting 3 REQ IN1 Range 10V which corresponds to the drives peak current output In this mode the speed loop is automatically disabled IN1 setting IN It s possible
22. n any user serviceable part Attempting to replace any internal component may result in damage to the unit and or personal injury This may also avoid the warranty All the informations and concepts included in this user guide are copyright and are supplied to the user with the understanding that it may not be copied disclosed or duplicated in whole or in part for any purpose not authorised by the factory All specifications are subject to change without prior notification Print in Italy 02 2015 Index Service Manual for brushless DC motor drive BLD10 Version 02 15 Chapter 1 1 1 Safety and note 4 1 2 Operation mode and feedback 5 1 3 Characteristics 6 1 4 Product view 7 1 5 Ambient conditions 8 1 6 Ventilation 9 1 7 Power supply construction 10 1 8 Notes about connection 12 1 9 Connections to earth and ground 13 1 10 Dimensions 14 1 11 Pin ount overview 15 1 12 Internal adjustments 17 Chapter 2 2 1 Brushless motor with Hall signals 19 2 2 Set up data for Intecno s motors 21 2 3 Ramp time adjustments 22 2 4 Intecno motors connections 23 2 5 HW direction selection 24 2 6 Basic command diagram 24 2 7 Analog speed input 26 2 8 REQ torque input 27 2 9 Start input 28 2 10 Current monitor output 28 Chapter 3 3 1 Speed offset adjustments 29 3 2 Trimmers adjustments 30 3 3 Dynamic ad
23. n mode has a 20Kohm of impedance input The following diagram shows an application using speed reference connections from C N C in the Common Mode DRIVE CNC Speed reference from external potentiometer The following figure shows an application with speed reference connections using an internal 10V power supply The speed potentiometer must have an included value between gt 5 and lt 10Kohm Speed pot Service Manual for brushless DC motor drive BLD10 Version 02 15 2 8 REQ torque input Current command mode With a voltage example from a CNC output you can command the drive in torque mode DRIVE CNC Applying a signal of 10V at TPRC the user enables the drive to supply positive or negative peak current The formula to determine the value of Voltage to apply in TPRC in order to obtain requested current is the following V TPRC 10 Request current PKcurrent Drive Example Drive size 10 20A request current 8A V TPRC 10 8 20 4V NOTE In current reference the loop of internal speed is automatically excluded In order to get a current 8A a voltage 4V in REQ pin must be applied in order to get a current 8A a voltage 4V must be applied Non apply voltage more than 10Vdc on REQ pin Current limit mode With an external potentiometer connected from GND and TPRC input you have a limitation of output current from zero to max size drive s Pot Or resistor Suggested spee
24. nals for two other control functions namedIN1 and IN2 Through the inputs IN1 and IN2 when set you can limit the motor torque in the two respective directions of rotation of the motor CW and CCW Can therefore be used as limits Overtravel left and right Ask how to set these inputs in the factory Service Manual for brushless DC motor drive BLD10 Version 02 15 3 1 Speed offset adjustments For this adjustment both Hall and Encoder signals are required The converter is supplied with zero adjustment already performed in encoder feedback If necessary turn the Offset trimmer to correct any offset error It makes up approximately 200mV on the reference input VEL With the reference input to zero turn the trimmer till to stop the motor This calibration works with any type of speed feedback adopted 3 2 Trimmer adjustments The converter is equipped with 4 trimmer with the following meanings Service Manual for brushless DC motor drive BLD10 Version 02 15 FEATURES Motor fine speed calibration With rotating clockwise CW or counterclockwise SHAso CCW is possible increase decrease the speed of the motor with range 25 Offset adjustment Allows the balance to zero motor speed Adjust this OE potentiometer to cancel any motor speed offset when the Velocity input is zero Gain potentiometer This adjustment improves the dynamic behavior of the motor With a clockwise CW
25. nce and 500PPR line count resolution encoder In order to change this resistance open the drive and calculate the following formula RENC 681 1000000 Fenc The resistor RENC determine what is the max speed of the motor at 10V of reference Where Fenc PPR RPM 60 Example N encoder pulses 1000 PPR Motor speed 3000 RPM RENC 681 1000000 50000 13 62 kohm The result of RENC resistance is 13 K Preferred resistance with 1 tolerance Once the resistor RENC is inserted proceed with final speed adjustment Operate using trimmer SPEED on the front of the drive With Clockwise Rotation the speed increases With Counter Clockwise Rotation the speed decreases The Range of regulation is about 20 Service Manual for brushless DC motor drive BLD10 Version 02 15 4 1 Indicator LEDs and protections The protections are all displayed by five LEDs on the front of the drive It also comes with a series of protections designed to safeguard the drive and the motor in case of malfunction FEATURES oK Normally ON Indicating the proper operation of all functions It turns OFF in case of GREEN any anomaly except protection intervention IxT The faults that affect this LED are Over Under input voltage Over temperature PTC Normally OFF This indicator is lit if the converter exceeding the limit calibration of IxT the rated current of the motor When the cur
26. otors where high dynamic performance and precise speed is required Operation mode SPEED CONTROL INPUT TORQUE CONTROL INPUT DESCRIPTION Itis speed piloting using an analogue reference differential or common mode It is torque piloting using an analogue reference This function allows you to control the current from the drive General characteristic START INPUT FAULT OUTPUT 2 ANALOG OUTPUT LED INDICATOR Velocity feedback DESCRIPTION Start input enable the drive with range from gt 9Vdc to 30Vdc min max Fault drive open collector output 50mA max Normally closed opens when in protection mode 1 motor velocity monitor TEST with range 8 Vdc output 1 current monitor CURR with range 7 Vdc output Five LEDs are located just in front of the potentiometers and show the current state of the drive STANDARD STANDARD STANDARD STANDARD STANDARD STANDARD Closing the velocity feedback loop to motor may be done in several different ways to accommodate most applications DC Brushless motor with Hall effect internal PWM Armature DC Brushless motor with Hall effect encoder Service Manual for brushless DC motor drive BLD10 Version 02 15 1 3 Characteristics Type Supply voltage Rated voltage Rated current Peak currentt Vdc Vdc A A BLD10 20 84 65 10 20 Minimum and maximum voltage
27. over Solder point standardconfiguration Solder bridges standard position are setting by factory for Brushless setting Hall sensor feedback Ramp time disabled Standard Dynamic constant a ap S1 S82 db 83 S4 qo 35 db 86 57 db S8 dp 59 810 si CDER CKV Service Manual for brushless DC motor drive BLD10 Version 02 15 Adjustement zone RDT RENC RA RCA RIN RIP RKV GAIN RACC CKV CDER FEATURES Non used Encoder resistor adjustement Armature resistor adjustement Drop compensation for internal motor resistance RI Drive rated current resistor Drive peak current resistor Resistor value that respectively form the proportional integral network of the velocity Loop gain Disabled by opening solder bridge S4 Standard value 100k and 47nF Changes static gain in the velocity loop Open solder bridge S5 and insert RGAIN if a change is required Consult factory for the correct value Resistor for setting acceleration time function See Chapter 2 3 Capacitor value that respectively form the proportional integral network of the velocity Loop gain Disabled by opening solder bridge S4 Standard value 100k and 47nF Derivative constant capacitor increases the velocity loop derivative constant Consult factory for the correct value Solder bridges Note For any feedback available are listed in the various
28. rent drawn back under the nominal pre RED set the alarm will auto resets and the LED turns off by itself PTC Normally OFF This indicator is lit when the internal temperature of the drive reaches 75 C Remove power and wait for the drive to cool before re applying power The RED operation causes the blocking of the drive and the storage of the alarm NOTE A fan heat sink or air conditioner may be needed to remedy the problem Normally OFF Indicates that between the motor terminals and or ground has been O C a short circuit The operation causes the blocking of the drive and the storage of the RED alarm Remove power supply and examine the motor connecting leads for shorts before re powering the converter to reset the alarm Normally OFF If lit it indicates that the Hall signal is missing or the power supply H ALL 5V is missing Check the Hall signals with a voltmeter or an oscilloscope RED In chapter 4 2 it explains the possible reasons for the alarms of the converter Service Manual for brushless DC motor drive BLD10 Version 02 15 4 2 Troubleshooting Possible causes for the alarms When power supply is on the green OK LED doesn t come on Check the voltage between HV and GND with a tester During deceleration of the motor the LED green blinks Increase the capacity filter example from 10 000uF to 20 000uF LED lights red O C Check the connections U V W a short circuit can be between two of these
29. s together as twisted pairs A NO Power supply Power supply The drives have to be supplied from an isolating rectified transformer secondary or a DC isolated power supply EMC note The conformity is assured only if it is installed following the precise assembly criteria expressed below The fundamental assembly characteristics are summarized below The correct ground connection of predisposed parts Using the division of cables technique Separate power cables from signal cables Use of shielded cables both for power connection to the transformer and the motor and for signal connection also to the controller Use of appropriate network to filter the line transformer input from disturbances conducted or produced by the drive series of filters released are available for this purpose Service Manual for brushless DC motor drive BLD10 Version 02 15 1 9 Connection to earth and ground Make sure that the servodrive and the motor are connected to earth in accordance with the current norms This connection must be done by using a copper bar mounted on insulating supports A Lbar PE amp Earth point connection Bar s section 30 x 5 mm 40x5mm then follow these indications 1 Connect to the ground bar the internal OV zero voltage of the CNC the earth terminals of the PLC CNC frames the OV of the auxiliary supply the CHASSIS of alldrives 2
30. tandard heavy duty power transformer without center taps on the secondary as shown in the schematic above DO NOT USE AN AUTOTRANSFORMER Power transformer T The transformer s nominal power is calculated based upon the sum of power from the single motors driven P VA Pn1 Pn2 Pn Motor N Cn 9 55 Where Pn Motor Power absorbed motor in W N Max speed of motor in RPM Cn Nominal torque of motor in Nm Note In multi axis applications the transformer s power can be downgraded by 30 If the max power transformer calculated is over 6KVA contact the factory Motor voltage If the secondary voltage of power supply is VDC the Vdc motor is calculated by the formula VDC Vdc motor 0 83 Where the Vdc motor is a sum of FCEM the drop R I for the winding resistance motor Vdc motor E Ri In Service Manual for brushless DC motor drive BLD10 Version 02 15 The FCEM of the motor E may be calculated by the formula E Ke N 1000 Example Brushless motor with the following data In 5 A Ri 1 Ohm E 48 V at nominal speed 3000 RPM Vdc motor 48 1 5 53V VDC 53 0 83 63 8V 63 8V is the VDC voltage request for the power supply You ll use a transformer with the secondary V2 64 1 41 45Vac When you use the transformer with V2 44 45Vac it is correct Misure unit E Ke n 1000 Vdc Im motor A Ri Winding resistance Ohm Ke Voltage constant V KRPM n MAX
31. to set this terminal for Limit sw input contact factory 4GND Signal Common Ground It corrisponds to power supply s negative GND input 5 10V OUT Power supply 10Vdc max 4mA 6 10V OUT Power supply 10Vdc max 4mA 7 START IN Positive drive enable with range gt 9Vdc min to 30Vdc max 8 VEL IN Reference Positive differential input Speed command 9 VEL IN Reference Negative differential input Speed command Encoder input Channel A High logic level from gt 2 8V to 24Vdc max Low logic 10 ENC A level lt 1 5V Encoder input Channel B High logic level from gt 2 8V to 24Vdc max Low logic level 11 ENC B IN lt 1 5V 12 V OUT Power supply 5V max 130mA 13 GND Signal Common Ground It corrisponds to power supply s negative GND input 14 HALL 1 IN 15 HALL 2 IN 16 HALL 3 IN Hall Sensor inputs from the motor Each input has a pull up resistor of 1 Kohm to internal 5V High logic level gt 3 2V Low logic level lt 1 5V Service Manual for brushless DC motor drive BLD10 Version 02 15 1 12 Internal adjustements If changes need to made to the internal drive setting powering please wait at least 30 seconds after the power has been removed and the OK LED is off All of the personalizations are located inside of the DRIVE See figure above To get the access to the adjustment pads and the Solder bridges unscrew and remove the c
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